SERVICE MANUAL 1 A EDITION w w w. m o t o r h i s p a n i a. e s

Transcription

1 SERVICE MANUAL REF. OF PUBLICATION: A EDITION USE THIS SERVICE MANUAL WITH THE RELATED MANUALS INDICATED IN THE FOREWORD TO THIS MANUAL w w w. m o t o r h i s p a n i a. e s

2 IMPORTANT Read this manual and follow the instructions carefully. Especially important information is indicated with the words WARNING, CAUTION and N.B., which have quite precise meanings. Pay special attention to the instructions that follow these titles. WARNING: Contains a potential danger that may cause injury or even death. CAUTION: Contains a potential danger that may damage the machine. N.B.: Contains special information to aid maintenance or clarify some point in the instructions. WARNING: This service manual has been prepared for authorised G.H.E. ENGINEHISPA NIA, S.L. dealers, and should only be used by qualified Technical Service department mechanics. Mechanics without experience or without the proper tools and equipment cannot carry out the service work described in this manual properly. A bad repair may cause injury to the mechanic, and the machine may not be in a condition to ensure the safety of rider and passengers.

3 FOREWORD This manual describes the procedures for the diagnosis, maintenance, adjustments, basic service work, changing of parts and the dismantling and assembling of the main parts. Model applicable: RYZ 50 CROSS (C) and RYZ 50 SUPERMOTARD (SM) with the following VIN numbers and later ones: VTVDV0C00 ~ VTVDV0CE2 ~ VTVDV1CE2 ~ This text is classifi ed into sections, each of which has a section number, as can be seen in the Contents on the following page, and on the fi rst page of every individual section there is a contents list for that section. Keep this manual to hand so that it can be consulted quickly when carrying out service work. The specifi ed points must be carefully observed to ensure that the machine functions perfectly in accordance with the specifi cation. When changing parts or carrying out service work that involves dismantling, it is recommended to use genuine G.H.E. ENGINEHIS- PANIA, S.L. spare parts, tools and service materials, as specifi ed in the corresponding descriptions. All the information, fi gures and specifi cations in this manual are based on the latest approved product information available at the time of publication. The main model used for the description throughout this manual is the model with basic specifi cations. Therefore the fi gures may appear slightly different from the model in the workshop. G.H.E. ENGINEHISPANIA, S.L. reserves the right to make changes without prior warning. RELATED MANUALS TITLE OF THE MANUAL MANUAL NO. APPLICABILITY RYZ50 SPARE PARTS CATALOGUE Manual with all the spare parts for the RYZ50 model. G.H.E. ENGINEHISPANIA, S.L. DEPARTAMENTO DE SERVICIO COPYRIGHT G.H.E. ENGINEHISPANIA, S.L. 2006

4 NOTES:

5 CONTENTS OF SECTION GENERAL INFORMATION SPECIFICATIONS MAINTENANCE CHASSIS ENGINE ELECTRICAL SYSTEM TROUBLESHOOTING SECTION

6 NOTES:

7 GENERAL INFORMATION 1-1 SECTION 1 GENERAL INFORMATION CONTENTS USING THIS MANUAL IDENTIFICATION Machine identifi cation Engine identifi cation

8 1-1 GENERAL INFORMATION USING THIS MANUAL At the beginning of this manual there is a GENERAL CON- TENTS LIST, enabling the SECTION containing the information needed for the service to be found quickly. In addition, each section has its own contents list on its fi rst page with a description of its main points. In each section of this manual the page numbers start from the beginning. The numbers appear at the top of the page together with the name of the section. This manual includes units of measurement in the international system (SI). The use of the SPECIAL TOOLS and of the TIGHTNESS TOR- QUE SPECIFICATIONS are indicated in bold type, as in the following example: 5) Immobilise the clutch dog with the special tool. Special tool (C) Tighten the nut. Tightness torque: 7.5 dan m (75 N m) Fold back the clutch nut tab washer. Fit the clutch control lever with its spring and its washer.

9 GENERAL INFORMATION 1-1 IDENTIFICATION IDENTIFICATION OF THE MACHINE The machine is marked with a plate (, situated on the righthand side of the chassis. This plate has the VIN (VEHICLE IDENTIFICATION NUMBER) engraved on it. 1 The VIN (VEHICLE IDENTIFICATION NUMBER) is engraved on the right-hand chassis beam (. ENGINE IDENTIFICATION The Engine Identifi cation Number ( is marked on the engine, on the left-hand side of the machine.

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11 SPECIFICATIONS 2-2 SECCION 2 SPECIFICATIONS CONTENTS 2 GENERAL SPECIFICATIONS ENGINE SPECIFICATIONS CHASSIS SPECIFICATIONS TIGHTENING TORQUES

12 2-2 SPECIFICATIONS GENERAL SPECIFICATIONS ELEMENT SPECIFICATION 2 Model code DIMENSIONS RYZ TL RYZ SM RYZ UB Total length Total width Height without rear-view mirror Distance between axles RYZ TL: mm RYZ SM y UB: mm 820 mm RYZ TL: mm RYZ SM: mm RYZ UB: mm 820 mm WEIGHT Weight empty Weight running Maximum permittable weight RYZ TL: 97 kg RYZ SM: 98 kg RYZ UB: 101 kg RYZ TL: 97 kg RYZ SM: 98 kg RYZ UB: 101 kg 255 kg Top speed 45 km/h ENGINE SPECIFICATIONS ELEMENT SPECIFICATION ENGINE Engine type Make Cubic capacity Stroke x diameter Maximum power Maximum torque Volumetric compression ratio AM6.(EU.-liquid cooled 2-stroke Minarelli 50 cc 49,7 cm³ 40,3 x 39 mm 1,4 Kw a rev/min 2.89 Nm a rev/min 12.0 ± 0.1 : 1 FUEL Recommended fuel Total capacity of fuel tank (including reserve) Only 95 octane lead-free petrol 6 litres ± 0.5

13 SPECIFICATIONS 2-2 ELEMENT ESPECIFICACIÓN LUBRICATION Type Recommended oil Oil tank capacity Separate lubrication by a variable rate piston pump, synchronised with the throttle and driven by geared take-off from the crankshaft. The oil is injected directly into the carburettor. Semi-synthetic Motul 510 2St special anti-smoke two-stroke oil 1.1 Litres 2 COOLING Type Cooling circuit capacity Circulation of water coolant by a pump driven by geared take-off from the crankshaft. 0,7 Litres IGNITION Type Spark plug CDI NGK BR 9ES CARBURETTOR Make / Type Idle rate Initial position of air screw Needle Main jet Idle jet DELL ORTO / PHBN ±50 rev/min 1.5 turns A8 3rd notch TRANSMISSION Type Primary transmission Secondary transmission Gearbox Gearbox capacity Clutch By sprocket and crown gear, with the gearbox and rear wheel joined by a 126 link roller chain. (12.7 pitch) 20x71 11x52 6 speed 0.75 litres Motul TRANSOIL (SAE 10W30) Multi-disk with oil bath and cable control Magneto Ducati 85 W Starter motor Ducati

14 2-2 SPECIFICATIONS CHASSIS SPECIFICATIONS ELEMENT SPECIFICATION 2 WHEELS Front wheel Front tyre Front pressure Rear wheel Rear tyre Rear pressure FRONT BRAKES Type Ø brake pistons Disk Ø Disk thickness Ø main piston (cylinder) RYZ TL: 1,85 21 RYZ SM: 2,5 17 RYZ UB: 1,85 16 RYZ TL: 90/9021 RYZ SM: 100/8017 RYZ UB: 90/9016 RYZ TL: 1,9 ± 1 bar RYZ SM: 2.0 ± 1bar RYZ UB: 2.3 ± 1 bar RYZ TL: 2,5 18 RYZ SM: 3,5 17 RYZ UB: 2,5 16 RYZ TL: 120/8018 RYZ SM: 130/7017 RYZ UB: 120/8016 RYZ TL: 2.1 ± 1 bar RYZ SM: 2.3 ± 1 bar RYZ UB: 2.7 ± 1 bar Disk with hydraulic calliper 25 mm ( RYZ TL: 200 mm; RYZ TOP TL: 220 mm RYZ SM: 200 mm; RYZ TOP SM: 220 mm RYZ UB: 220 mm; RYZ TOP UB: 220 mm 4 mm 12 mm REAR BARKES Type Ø brake pistons Disk Ø Disk thickness Ø main piston (cylinder) Disk with hydraulic calliper 32 mm ( RYZ TL: 240 mm; RYZ TOP TL: 260 mm RYZ SM: 260 mm; RYZ TOP SM: 280 mm RYZ UB: 260 mm; RYZ TOP UB: 280 mm 4 mm 12 mm FRONT SUSPENSION Type of suspension Type of front forks Forks capacity Travel Telescopic forks Hydraulic fl uid shock absorber 0.3 litres per tube 230 mm

15 SPECIFICATIONS 2-2 ELEMENT SPECIFICATION REAR SUSPENSION Type of suspension Travel of central single hydraulic shock absorber Variable fl exibility swinging arm, combined with a 44 mm central single hydraulic shock absorber 44 mm 2 STEERING Type Steering column mounted on ball bearings

16 2-2 SPECIFICATIONS TIGHTENING TORQUES ELEMENT TIGHTENING TORQUE 2 BODY Side covers Front mudguard Rear mudguard Skirting 0,1 dan m (1 N m) 0,1 dan m (1 N m) 0,8/0,1 dan m (8/1 N m) 0,8/0,1 dan m (8/1 N m) CHASSIS Front wheel shaft Rear wheel shaft Rear wheel shaft nut Suspension arm nut Chassis engine mounting Shock absorber top mounting Shock absorber top mounting Forks T-sections Front brake calliper Rear brake calliper Front brake disk Rear brake disk Support on chassis Steering lock 4,5 dan m (45 N m) 1,2 dan m (12 N m) 6,5 dan m (65 N m) 6,5 dan m (65 N m) 2,8 dan m (28 N m) 4,3 dan m (43 N m) 4,3 dan m (43 N m) 1,5 dan m (15 N m) 2,5 dan m (25 N m) 2,5 dan m (25 N m) 1 dan m (10 N m) 1 dan m (10 N m) 1,9 dan m (19 N m) 0,6 dan m (6 N m) ESTÁNDAR 5.mm diameter nut and bolt 6 mm diameter nut and bolt 8 mm diameter nut and bolt 10 mm diameter nut and bolt 12 mm diameter nut and bolt 0,5 dan m (5 N m) 1 dan m (10 N m) 2,2 dan m (22 N m) 3,5 dan m (35 N m) 5,5 dan m (55 N m)

17 MAINTENANCE AND COMMISSIONING 3-1 SECTION 3 MAINTENANCE AND COMMISSIONING CONTENTS INTRODUCTION MAINTENANCE PLAN Checking Renewing Checking and decarbonising Checking and greasing Checking and adjusting Cleaning and adjusting COMMISSIONING Battery preparation (except maintenance-free batteries) Checking levels Commissioning the fuel and oil circuits Checks before delivery to customer TIGHTENING TORQUE SPECIFICATIONS SERVICE MATERIALS REQUIRED

18 3-2 MAINTENANCE AND COMMISSIONING INTRODUCTION This section includes all the information needed to perform the recommended maintenance and commissioning operations. Observing these procedures will ensure the machine functions more reliably and has a longer useful life, while reducing the need for costly repair work. All maintenance technicians must be familiar with the whole of this section. 3 MAINTENANCE PLAN Reinforced maintenance is designed for machines used in severe conditions: driver temperament, short journeys with a cold engine, dusty regions or environments with a temperature higher than 30ºC. CHECKING MAINTENANCE OPERATIONS 500 KM OR 3 MONTHS EVERY 3,000 KM EVERY 6,000 KM REINFORCED MAINTENANCE Every km Every km Adjusting idle speed Throttle cable and oil pump Front and rear brake cable Functioning of the electrical equipment Fuel circuit Oil circuit Front and rear brake fl uid piping Coolant circuit Carburettor heating circuit Tyre pressures Condition, pressure and wear of tyres Front and rear brake fl uid level Coolant level Battery electrolyte level Tightening nuts and bolts Charging the battery RENEWING MAINTENANCE OPERATIONS 500 KM OR 3 MONTHS EVERY KM EVERY KM REINFORCED MAINTENANCE Every km Every km Intake fi lter element Front and rear brake pads (where appropriate) Gearbox oil Chain sprocket- crown gear (where appropriate) Clutch disks (where appropriate)

19 MAINTENANCE AND COMMISSIONING 3-3 CHECKING AND DECARBONISING MAINTENANCE OPERATIONS 500 KM OR MONTHS EVERY KM EVERY KM REINFORCED MAINTENANCE Every km Every km Piston ( Cylinder head ( Exhaust port ( ( The need to decarbonise can be estimated by checking the quantity of carbonisation present in the cylinder exhaust outlet. CHECKING AND GREASING Every km Every km Every km 3 MAINTENANCE OPERATIONS 500 KM OR MONTHS EVERY KM EVERY KM REINFORCED MAINTENANCE Every km Every km Chain tension and condition CHECKING AND ADJUSTING MAINTENANCE OPERATIONS 500 KM OR MONTHS EVERY KM EVERY KM REINFORCED MAINTENANCE Every km Every km Clutch cable Oil pump control Spark plug Tension of the wheel spokes CHECKING AND ADJUSTING MAINTENANCE OPERATIONS 500 KM OR MONTHS EVERY KM EVERY KM REINFORCED MAINTENANCE Every km Every km Carburettor

20 3-4 MAINTENANCE AND COMMISSIONING COMMISSIONING BATTERY PREPARATION (ECEPT MAIN- TENANCE-FREE BATTERIES) 3 5) 6) 7) Remove the battery Remove the six fi ller plugs and the air vent plug. Replenish with electrolyte up to the UPPER LEVEL mark. Electrolyte: (35% sulphuric acid = 1.28 g/cm) Allow the battery to stand for approximately half an hour. Top up if necessary. Charge the battery for at least 2 hours at an intensity of 400 ma (0.4 A). Refi t the battery and connect the vapour vent pipe. 8) Connect the red cable to the positive battery terminal and the black cable to the negative battery terminal. WARNING: A continuación, eventualmente se deberá restablecer el nivel de la batería después de una carga completa, utilizando exclusivamente agua destilada. CHECKING LEVELS Check the gearbox oil level. Check the coolant level. Check the brake fl uid level. COMMISSIONING THE FUEL AND OIL CIRCUITS Put 1 litre of unleaded petrol in the fuel tank. This should be 95 or 98 octane mixed with 3% Motul 510 semi-synthetic 2-stroke oil. Put Motul 510 semi-synthetic 2-stroke oil in the oil tank. Engine oil: Motul 510 semi-synthetic 2-stroke oil Start up the engine and disconnect the special tube entering the carburettor to check that the oil is fl owing drop by drop (the speed of the drops increases with the engine revs). Complete the fi lling of the fuel tank with unleaded 95 or 98 octane petrol without oil mixture.

21 MAINTENANCE AND COMMISSIONING 3-5 CHECKS BEFORE DELIVERY TO CUSTOMER Check the tightness of the wheel nuts. Front wheel tightness torque: 4.5 dan m (5 N m) Rear wheel tightness torque: 6.5 dan m (75 N m) Check the tightness of all nuts and bolts. Check the adjustment and effectiveness of the brakes. Check the infl ation pressure of the tyres when cold. Front tyre inflation pressure: RYZ SM: 2 bars (200 kpa) RYZ C: 1.5 bars (150 kpa) Rear tyre inflation pressure: RYZ SM: 2.3 bars (230 kpa) RYZ C: 1.7 bars (170 kpa) 3 5) 6) 7) Check the functioning of the lights, the turn indicators, the horn and the brake light. Check the functioning of the different indicator lights. Carry out a road test.

22 3-6 MAINTENANCE AND COMMISSIONING TIGHTENING TORQUE SPECIFICATIONS SECURING DEVICES Front wheel shaft bolt Rear wheel shaft nut dan m 4,5 6,5 N m MATERIALS SERVICING MATERIALS REQUIRED RECOMMENDED MH PRODUCT USE Engine oil Electrolyte Motul 510 semi-synthetic 2-stroke oil 35% sulphuric acid = 1.28 g/cm³ Filling the engine oil tank Topping up the battery during maintenance

23 CHASSIS 4-1 SECTION 4 CHASSIS CONTENTS SERVICING THE MACHINE FRONT WHEEL Removal Assembly Operations that can be performed with the front wheel removed FRONT BRAKES Dismantling the front brake calliper and brake pads FORKS Removal Dismantling the fork tubes Sealing rings Removal Assembly REAR WHEELS Dismantling the rear brake calliper and brake pads Operations that can be performed with the rear wheel removed TRANSMISSION CHAIN Adjusting the chain tension SEAT Removal FUEL TANK Removing the fuel tank or fuel tap SHOCK ABSORBER Removal AIR FILTER Removing the air fi lter sponge Removing the air fi lter box EHAUST Removal CARBURETTOR Removal Adjustment Dismantling the valves CHASSIS Removal Removing the frame Assembly TIGHTENING TORQUE SPECIFICATIONS SERVICING MATERIALS REQUIRED SPECIAL TOOLS

24 4-2 CHASSIS SERVICING THE MACHINE FRONT WHEEL CAUTION: Place the machine on a flat surface. Stand the machine on a suitable support, in such a way that the front wheel is off the ground. Do not activate the brake lever during the removal and refitting process. REMOVAL 4 Unscrew the speedometer cable. Unlock the two bolts on the wheel shaft clamp ( ( at the front of the fork arm. Remove the wheel shaft, the washer and the spacer. Remove the wheel. CAUTION: Do not activate the brake lever, or as an alternative precaution place a wedge between the brake pads. ASSEMBLY Refi t in the reverse order to removal, bearing the following points in mind: Grease the wheel shaft, together with the speedometer takeoff, before refi tting the wheel. Position the speedometer take-off in such a way that it does not interfere with the cable (. Wheel shaft tightness torque: 4.5 dan m (5 N m) Wheel shaft clamp tightness torque: 1.2 dan m (12 N m) OPERATIONS THAT CAN BE PERFORMED WITH THE FRONT WHEEL REMOVED Changing the tyre or the inner tube. N.B.: Identify the roll direction of the tyre before removing it, and refit in the same direction (Supermotard only).

25 CHASSIS 4-3 Changing the brake disk. N.B.: In refitting, respect the order of assembly: mark the outer side and fit the six self-locking bolts. Changing the wheel bearings. Changing the speedometer take-off. FRONT BRAKE N.B.: The brake pads are identical; on dismantling without renewing, identify the fitting direction and refit in the same direction. WARNING: As a result of removing the wheel, the calliper or the brake pads, and before performing a road test, check the good functioning of the brake by applying the brake lever various times. 4 DISMANTLING THE FRONT BRAKE CALLIPER AND BRAKE PADS Remove the two bolts ( from the calliper on the fork arm. Remove the pins (. Remove the brake pads ( and the anti-vibration plates (. FORKS CAUTION: Place the machine on a flat surface. Stand the machine on a suitable support, in such a way that the front wheel is off the ground. Do not activate the brake lever during the dismantling and refitting process.

26 4-4 CHASSIS REMOVAL 5) 6) 7) 8) 9) Remove the headlight housing assembly. Remove the front mudguard. Disconnect the headlight and the turn indicators. Remove the two bolts from the brake calliper, and remove it without disconnecting it. Unscrew the speedometer cable from the speedometer takeoff. Remove the guides from the fl exible hydraulic fl uid pipe and the speedometer cable. Remove the handlebars. Remove the steering locknut (. Remove the two bolts ( from the top T section. 4 10) Remove the forks top T section ( with the instrument panel and contact key switch. 1 Remove the front wheel. 1 Remove the steering bolt ( with its washer (5). 1 Extract the forks bottom T section (6) and the two steering column arms (7) (the forks are fi tted a little tightly onto the steering arm bearings). 1 Remove the washer (8) on the bottom T section. DISMANTLING THE FORK ARMS 5) 6) 7) 8) N.B.: If the arms are being dismantled to change the seals, loosen in order the securing bolts on the top T section and the fork tube plugs. Remove the headlight housing assembly. Disconnect the headlight and the turn indicators. Remove the brake calliper without disconnecting it. Unscrew the speedometer cable from its drive. Remove the guides from the fl exible hydraulic fl uid pipe and the speedometer cable. Remove the front wheel. Remove the six bolts ( on the top and bottom T sections. Remove the fork arms.

27 CHASSIS 4-5 SEALING RINGS REMOVAL Remove the forks. See Dismantling the forks in this section. Remove the fork tube plug (. Remove the spacer ( and the spring (. Upturn the fork tube to empty the hydraulic fluid into a container. N.B.: Slide the tube in and out of the fork arm several times to empty out the fluid. 4 5) 6) Remove bolt ( and its seal (5). Withdraw the fork tube from the fork arm with the piston, the end of compression cone and its washer. 7) Remove the dust guard (6), the circlip (7) and the seal (8) from the forks arm.

28 4-6 CHASSIS ASSEMBLY WARNING: Check the condition of the fork tube: there should not be any signs of corrosion or impacts, and should be perfectly straight and clean. Fit a new seal (, lightly lubricated, using a seal pusher. Refi t the seal circlip (. 4 Insert the fork tube into the fork arm with the end of compression cone ( and its washer (, taking care not to bend over the seal lip. Fit a new seal and tighten the drain screw. Drain screw tightness torque: 2.3 dan m (23 N m) 5) 6) Fit a new dust guard, lightly lubricated. Pour in 0.3 litres of SAE 15 (Esso Univis N46) type hydraulic fl uid into the fork tube. Hydraulic fluid for forks: SAE 15 (Esso Univis N 6) type 7) 8) 9) Refi t the spring (5) with the tighter coils upwards. Refi t the spacer (6). Refi t the fork tube plug (7). Tube tightness torque: 2 dan m (20 N m)

29 CHASSIS 4-7 REAR WHEEL CAUTION: Place the machine on a flat surface. Stand the machine on a suitable support, in such a way that the rear wheel is off the ground. Do not activate the brake pedal during the dismantling and refitting process. N.B.: If the brake calliper is being renewed, the circuit will have to be bled. DISMANTLING THE REAR BRAKE CALLIPER AND BRAKE PADS Dismantle the rear wheel shaft, the chain tensioners ( and the spacers (. Remove the wheel without unhooking the chain. 4 N.B.: The wheel needs to be removed to allow the brake calliper to be extracted from its housing in the suspension arm. Remove the pins (. Remove the brake pads. N.B.: The brake pads are identical; on removing without renewing, identify the fitting direction and refit in the same direction. CAUTION: As a result of removing the wheel, the calliper or the brake pads, and before performing a road test, check the good functioning of the brake by applying the brake pedal various times.

30 4-8 CHASSIS OPERATIONS THAT CAN BE PERFORMED WITH THE REAR WHEEL REMOVED Changing the tyre, the inner tube or valve. N.B.: Identify the roll direction of the tyre before removing it, and refit in the same direction (Supermotard only) Changing the brake disk. N.B.: Ensure the correct fitting direction for the disk, with the marked part outwards. Fit the six self-locking bolts. 4 Changing the wheel bearings. Changing the crown gear. N.B.: Fit the six normal self-locking bolts. If the crown gear is to be reused, its turn direction must be noted before removing. TRANSMISSION CHAIN CAUTION: The machine must be on its support, with the gearbox in neutral. ADJUSTING THE CHAIN TENSION Unscrew the nuts ( from the wheel shaft and the locknuts ( on the tensioner bolts. Turn both tensioning bolts ( the same amount to achieve a movement of 25 mm in the chain. Chain movement: 25 mm Check the correct alignment of the chain between the gearbox output sprocket and the rear crown wheel. Retighten the nuts on the wheel shaft and the locknuts on the tensioner bolts.

31 CHASSIS 4-9 5) Check the chain tension. CAUTION: A chain that is too tight causes rapid wear of the gearbox output shaft, the rear wheel bearings, the chain and the sprockets. SEAT REMOVAL Remove the plug ( on the inside of the rear skirting. Remove the seat nut through the hole in the rear skirting, and pull the seat ( backwards to separate it from the chassis. 4 Remove the seat. FUEL TANK REMOVING THE FUEL TANK OR FUEL TAP Remove the seat see Removing the seat in this section. Remove the bolts ( from the radiator fairings. Remove the bolts ( from the fuel tank. 5) Lift up the tank to disconnect the fuel level indicator connector (, the fuel supply pipe ( and the fuel tap vacuum outlet (. Remove the tank.

32 4-10 CHASSIS SHOCK ABSORBER REMOVAL CAUTION: Stand the machine on blocks under the chassis to ensure that the rear wheel is off the ground. Remove the seat see Removing the seat in this section. Remove the nut, the washer and the bottom securing shaft from the shock absorber (. Remove the nut, the washer and the top securing shaft from the shock absorber (. 4 Remove the shock absorber from the right-hand side of the machine by pulling it downwards. AIR FILTER REMOVING THE AIR FILTER SPONGE Remove the left-hand side cover. Remove the air fi lter cover (four screws) and its seal. CAUTION: The grilles are of a different size. Be sure to reposition them correctly on refitting. Remove the sponge ( and the two grilles (.

33 CHASSIS 4-11 REMOVING THE AIR FILTER BO 5) 6) 7) 8) Remove the seat see Removing the seat in this section. Remove the side fairings. Remove the shock absorber see Removing the shock absorber in this section. Remove the two bottom securing bolts ( on the skirting. Remove the air intake connector ( from the air fi lter box. Remove the three securing bolts ( from the air fi lter box. Loosen the clamp on the hose from the air fi lter to the carburettor. Remove the air fi lter box from the left-hand side of the machine. 4 EHAUST REMOVAL N.B.: The rear silencer can be removed on its own. Remove the left-hand side fairing. Unhook the two springs ( from the exhaust pipe at the cylinder point. Remove the securing bolt ( on the fl exible support to the chassis.

34 4-12 CHASSIS 5) Remove the bottom securing bolt ( on the rear silencer. Unscrew the top securing bolt ( on the rear silencer. 6) 7) Separate the silencer from the exhaust pipe. Remove the exhaust pipe. 4 CARBURETTOR REMOVAL Remove the seat see Removing the seat in this section. Remove the fuel tank see Removing the fuel tank in this section. Disconnect the carburettor heating pipes (. CAUTION: Plug the pipes to prevent coolant from spilling. 5) 6) 7) Remove the throttle cable (. Remove the bolt from the starter motor connector (. Remove the oil pipe (. Loosen the clamp on the inlet connection (5) with a 3 mm male safety spanner. Special tool 3 mm safety spanner Ref ) Loosen the clamp on the air fi lter connection (6). 9) Free the carburettor from the inlet connection. 10) Remove the carburettor.

35 CHASSIS 4-13 ADJUSTMENT Idle: screw (7). Mixture: screw (8). DISMANTLING THE VALVES Remove the carburettor see Removing the carburettor in this section. Remove the four bolts on the inlet connector, two of them ( using the 4mm male safety spanner. 4 Special tool 4 mm safety spanner Ref Remove the connector and the inlet valve. CHASSIS REMOVAL N.B.: This method is only valid when changing the chassis. In the event of a chassis change as a result of an accident, it will be necessary to complete the repair method or change the damaged elements. 5) 6) 7) 8) 9) 10) 1 1 Remove the seat see Removing the seat in this section. Remove the fuel tank see Removing the fuel tank in this section. Remove the side covers. Disconnect and remove the battery. Disconnect the rear wiring and the rear brake light switch. Remove the exhaust assembly. Remove the rear brake fl uid reservoir and the master cylinder without disconnecting it. Loosen the clamp on the air fi lter hose. Remove the top securing bolt on the shock absorber. Remove the two rear chassis securing bolts on the main chassis. Remove the rear chassis assembly. Remove the chain.

36 4-14 CHASSIS 1 Disconnect: a) The neutral switch. b) The yellow magneto output cable. c) The starter connector. d) The temperature sensor. e) The ignition unit. f) The earth cables on the ignition module. g) The supply pipe on the oil pump. h) The petrol and choke valves. i) The oil pump cable. j) The clutch cable ) 16) 17) 18) 19) 20) Remove the bottom securing bolt on the radiator. Loosen the top rear engine securing bolt. Remove the bottom rear securing bolt. Remove the three bolts on the two engine supports under the engine. Loosen the two side securing bolts on the front engine support (without removing the nuts). Loosen and remove the two front engine support securing bolts on the chassis front box section. Push the support forwards. Remove the engine assembly and radiator. Remove the oil tank. Remove the headlight housing assembly. 2 Disconnect: a) the front headlight. b) the instrument panel connection. c) the steering lock connection. d) the control unit connection. e) the starter switch connection. f) the brake light switch. g) the throttle, starter, clutch and speedometer cables. 25) Remove the master cylinder from the front brake without disconnecting it. 26) Remove the handlebars. 27) Remove the top forks T section. 28) Remove the forks assembly and front wheel. 29) Remove the suspension arm assembly, the shock absorber, brake calliper, brake cylinder and rear wheel. 30) Remove the chassis. REMOVING THE FRAME Remove: a) the controls and cables. b) the prop stand. c) the rear brake pedal. d) the main wiring. e) the electrical components. f) the steering bearings. g) the locknuts.

37 CHASSIS 4-15 ASSEMBLY Carry out the assembly of the new chassis proceeding in the reverse order. N.B.: Before assembling the new chassis, ensure that the VIN number is engraved and the chassis plate affixed. TIGHTENING TORQUE SPECIFICATIONS SECURING DEVICES Front wheel shaft bolt dan m 4,5 N m 45 4 Front wheel shaft tightness torque: 1,2 12 Fork tube drain bolt 2,3 23 Fork tube plug 2,0 20 SERVICING MATERIALS REQUIRED MATERIALS RECOMMENDED MH PRODUCT USE Air fi lter oil Forks hydraulic fl uid Motul Air Filter Oil SAE 15 (Esso Univis N N46) type Adhesive oil for the air fi lter sponge Filling the front fork tubes SPECIAL TOOLS Safety spanner (3 mm) Safety spanner (4 mm)

38 NOTES:

39 ENGINE 5-1 SECTION 5 ENGINE CONTENTS OPERATIONS THAT CAN BE CARRIED OUT ON THE ENGINE WITHOUT REMOVING IT Removing the cylinder head Dismantling the cylinder-piston assembly ENGINE ASSEMBLY Removal Installation DISMANTLING THE ENGINE Mounting the engine on its support Removing the magneto Removing the armature Removing the starter motor (where fi tted) Removing the gearbox output sprocket Removing the clutch cover Removing the clutch Removing the crankshaft-connecting rod gears and balance shaft Removing the connector and the inlet valve Removing the cylinder head/cylinder assembly Removing the piston Removing the thermostat valve Removing the temperature sensor Separating the engine crankcases Dismantling the gearbox and the selecting system Removing a primary or secondary drive shaft gear Removing the balance shaft Removing the crankshaft-connecting rod Checking the crankshaft-connecting rod FITTING SPECIFIC ELEMENTS IN THE ENGINE Fitting the crankshaft-connecting rod bearings Fitting the output seal Fitting the selector shaft output seal Fitting the clutch lever output seal Fitting the balance shaft Fitting the crankshaft-connecting rod Fitting the gearbox Fitting the left-hand half-crankcase Checking the piston Checking the piston rings Fefi ting the piston Fitting the cylinder Fitting the cylinder head Fitting the right-hand seal Fitting the crankshaft-connecting rod gears and the balance shaft Fitting the clutch Adjusting the clutch control lever Fitting the kick-start system (where fi tted) and the clutch cover Fitting the magneto VARIOUS OPERATIONS Removing the water pump Fitting the water pump Dismantling the oil pump and its drive gears Fitting the oil pump

40 5-2 ENGINE TIGHTENING TORQUE SPECIFICATIONS SERVICING MATERIALS REQUIRED SPECIAL TOOLS

41 ENGINE 5-3 OPERATIONS THAT CAN BE CARRIED OUT ON THE ENGINE N.B.: The following operations do not require the engine to be removed. REMOVING THE CYLINDER HEAD 5) 6) 7) 8) Remove the seat see Removing the seat in Section 4 CHASSIS. Remove the fuel tank see Removing the fuel tank in Section 4 CHASSIS. Drain the cooling circuit (drain screw on the water pump). Remove the radiator/cylinder head pipe (. Disconnect the carburettor heating pipes (. Disconnect the temperature sensor. Remove the suppressor. Remove the spark plug. 5 N.B.: To remove the cylinder head, see corresponding chapter in this section. DISMANTLING THE CYLINDER-PISTON ASSEMBLY Remove the seat see Removing the seat in Section 4 CHASSIS. Remove the fuel tank see Removing the fuel tank in Section 4 CHASSIS. Remove the exhaust see Removing the exhaust in Section 4 CHASSIS. Drain the cooling circuit (drain screw on the water pump). 5) 6) 7) Remove the radiator/cylinder head pipe. Disconnect the carburettor heating pipes. Remove the securing bolts from the front support on the chassis cradle.

42 5-4 ENGINE 8) 9) Unscrew the side securing bolts on the engine support. Remove the engine securing bolt ( and push the support forwards. N.B.: To remove the cylinder head, the cylinder and the piston, see corresponding chapter in this section. 5 ENGINE ASSEMBLY REMOVAL 5) 6) 7) 8) Remove the seat see Removing the seat in Section 4 CHASSIS. Remove the fuel tank see Removing the fuel tank in Section 4 CHASSIS. Remove the left-hand side fairing. Disconnect the battery. Drain the cooling circuit (drain screw [1] on the water pump). Remove the chain guard (two bolts). Remove the chain. Remove the exhaust see Removing the exhaust in Section 4 CHASSIS. Disconnect the oil supply and the oil pump control cable. 9) 10) Remove the clutch cable. 1 Disconnect the starter motor, the neutral switch, the magneto output wiring (the yellow cable and high-tension coil supply cables), the suppressor and the temperature sensor. 1 Disconnect the carburettor heating pipes. 1 Separate the carburettor from the air fi lter box and inlet connectors. 1 Disconnect the coolant pipes on the water pump and cylinder head.

43 ENGINE ) Loosen the three engine securing points (, without removing the top rear securing nut. 16) Loosen the two securing points ( on the chassis strengtheners (. 17) Remove the front support securing shaft. 18) Lower the two chassis strengtheners. 19) 20) 2 Loosen the two side securing bolts (5) on the front engine support (without removing the nuts). Loosen and remove the two front engine support securing bolts (6) on the chassis front box section. Push the support forwards. 5 2 Remove the rear bottom securing shaft. 2 Unhook the engine from the top rear chassis pins (7) to remove it. N.B.: With the engine removed, see Section 5 ENGINE for details of operations to be performed on the engine. INSTALLATION Fit the shaft, the washers and the nut ( on the engine top rear mounting.

44 5-6 ENGINE Hang the engine on the top rear securing shaft (. Insert the engine securing shaft into the front support ( and the two chassis strengtheners (. Insert the rear bottom securing shaft (5). 5 DISMANTLING THE ENGINE MOUNTING THE ENGINE ON ITS SUPPORT Mount the engine on the engine support mounting. Special tool (A) Immobilise the motor on the mounting with two rubber pegs. Mount the assembly onto the engine support while held in a workbench clamp. Special tool (B) REMOVING THE MAGNETO Remove the magneto cover. Remove the paper gasket. Immobilise the rotor ( with a front pivot spanner (. Remove the nut. N.B.: Depending on the model, the rotor acts as a crown gear for the starter motor.

45 ENGINE 5-7 5) Screw the magneto extractor onto the rotor. Special tool: Ref ) Immobilise the magneto extractor and turn the pushing bolt until the rotor comes free. REMOVING THE ARMATURE Remove the three securing bolts ( from the stator plate and armature assembly (. Remove the stator plate and armature assembly. N.B.: Tap the bolts with a mallet and punch to help to free the assembly. 5 WARNING: The three bolts should be renewed with every removal. REMOVING THE STARTER MOTOR (WHERE FITTED) Remove the three securing bolts ( from the starter motor. Remove the two rubber pegs that immobilise the motor on its mounting. Move the engine on the mounting guides to allow the starter motor to be removed. Refi t the two rubber pegs. REMOVING THE GEARBO OUTPUT SPROCKET Remove the rubber ring ( with a pair of pliers. Remove the sprocket (. Remove the second rubber ring.

46 5-8 ENGINE REMOVING THE CLUTCH COVER Remove the kick-start lever securing bolt (where fi tted). Apply the kick-start lever slightly and hold it in position. Loosen the stop ( on the starter shaft and release the kickstart lever to slacken the spring. Remove the kick-start lever. N.B.: Prepare a container to hold the oil from the gearbox. 5 5) Remove the bolt ( to drain the gearbox. 6) 7) 8) Remove the eight cover securing bolts. Remove the cover. Remove the two centring pivots and the paper gasket. REMOVING THE CLUTCH Remove the four bolts and springs ( from the pressure plate (. Remove the pressure plate.

47 ENGINE 5-9 Remove the assembly ( consisting of four friction disks and three smooth disks. Remove the primary shaft: the pusher (, the ball (5) and the push rod (6). 5) Remove the clutch control lever (7) with its spring (8) and its washer (9). 5 6) 7) Fold back the clutch nut (10) tab washer (1. Immobilise the clutch dog (1 with the clutch immobilisation tool. Special tool (C) 8) Remove the nut and the washer. 9) Remove the clutch dog (1, the grooved spacer (1, the hood (1, the fl at washer (15) and the tapered washer (16).

48 5-10 ENGINE REMOVING THE CRANKSHAFT-CONNECTING ROD GEARS AND BALANCE SHAFT Immobilise the balance shaft with a bolt (a) inserted in the threaded perforations. Turn the gear ( on the balance shaft so that the bolt rests against a crankcase rib. Remove the crankshaft-connecting rod nut (. Remove the balance shaft nut (. 5) 6) Remove the two gears (20 and 30 tooth) and the key. ( from the crankshaft-connecting rod. Remove the 34 tooth gear and the key (5) from the balance shaft. 5 REMOVING THE INLET CONNECTOR AND VALVE Remove the four bolts on the inlet connector, two of them ( using the safety spanner. Special tool: Ref Remove the connector and the inlet valve. Check the perfect condition of the valve assembly blades and support. WARNING: The position of the stop must be 7 mm from the valve stop.

49 ENGINE 5-11 REMOVING THE CYLINDER HEAD/CYLINDER ASSEMBLY 5) Remove the spark plug. In the order indicated, loosen the four securing nuts on the cylinder head/cylinder assembly in two or three steps Remove the four nuts and washers. Remove the cylinder head and the two O-rings. Remove the cylinder and the cylinder gasket. REMOVING THE PISTON Remove one of the two circlips ( with a pair of circlip pliers (. Remove the gudgeon pin. Remove the piston. Remove the needle bearing assembly from the end of the connecting rod. 5 REMOVING THE THERMOSTAT VALVE Remove the two bolts ( from the thermostat valve (. Remove the thermostat valve. WARNING: In refitting, take care to position the breather hole (a) at the highest point. REMOVING THE TEMPERATURE SENSOR WARNING: There is a metal gasket to ensure the temperature sensor ( remains watertight.

50 5-12 ENGINE SEPARATING THE ENGINE CRANKCASES Remove the three securing bolts on the left-hand crankcase. Fit the protective bush onto the crankshaft-connecting rod. 5 Special tool (D) Fit the crankcase opening tool supplied with the plate onto the left-hand crankcase. Special tool (E) Special tool (F) 5) 6) Fit the assembly onto the crankcase with the four bolts. (. Remove the two rubber engine support mounting pegs. Turn the tool s central bolt until the crankcases separate. N.B.: On opening, tap the ends of the secondary and selection shafts alternately with a plastic mallet to ensure that the two crankcase separate in parallel. 7) Remove the left-hand crankcase. 8) 9) N.B.: Recover the friction washers that may be stuck to the lefthand crankcase with oil. Remove the centring rods (. Remove the two rubber engine support mounting pegs.

51 ENGINE 5-13 DISMANTLING THE GEARBO AND THE SELECTION SYSTEM Position the selector drum to guide the Mecanindus pin against the secondary drive shaft selector fork shaft.. Remove the selection shaft ( fi tted with its two friction washers. 5 Remove the secondary drive shaft selector forks shaft (. Remove the top selector fork ( from the secondary drive shaft. 5) 6) 7) Turn the selector drum ( to lower the selector fork (5) on the primary drive shaft in the bottom slot of the drum. Remove the selector drum. Remove the second selector fork (6) from the secondary drive shaft.

52 5-14 ENGINE 8) Remove together the secondary drive shaft assembly and the primary drive shaft fitted with its selector fork. 9) Remove the friction washer (7) from the secondary drive shaft, in the event of it being stuck with oil onto the right-hand crankcase. 10) Remove the locking ball (8) and its push spring. 5 REMOVING A GEAR FROM A PRIMARY OR SECON- DARY DRIVE SHAFT Remove the rubber rings and the gears with pliers. On refitting, take note of the position and the direction of fitting for every part: 1. Primary drive shaft with 1st speed gear. 2. 3rd speed and 4th speed gear. 3. 5th speed gear. 4. 2nd speed gear. 5. 6th speed gear. 6. Rubber ring. 7. Secondary drive shaft. 8. 1st speed gear. 9. 3rd speed gear th speed gear th speed gear nd speed gear th speed gear. 14. Rubber ring. 15. Friction washer.

53 ENGINE 5-15 WARNING: When renewing a gear, renew the corresponding gear on the other drive shaft. The rubber rings must be renewed after every dismantling. REMOVING THE BALANCE SHAFT Remove the balance shaft ( using a plastic mallet if necessary. 5 REMOVING THE CRANKSHAFT-CONNECTING ROD Remove the crankshaft-connecting rod ( with its spacer ( and its O-ring ( by lightly tapping its end with a plastic mallet, if necessary. N.B.: The crankshaft-connecting rod is fitted freely onto the right-hand crankcase bearing. CHECKING THE CRANKSHAFT-CONNECTING ROD Using a set of feeler gauges, check the side clearance of the connecting rod big end. The connecting rod big end side clearance must not exceed: 4/10 mm. Maximum side clearance: 4/10 mm (0.4 mm).

54 5-16 ENGINE The eccentricity values measured at the ends of the crankshaft-connecting rod must not exceed 4/100 mm, and must be measure at: - 50 mm from the transmission side - 50 mm from the magneto side Maximum eccentricity: 4/100 mm (0.4 mm). 5

55 ENGINE 5-17 FITTING SPECIFIC ELEMENTS IN THE ENGINE FITTING THE CRANKSHAFT-CONNECTING ROD BEARINGS CAUTION: The crankshaft-connecting rod bearings and seals must be renewed after each opening of the engine crankcase. N.B.: On opening the crankcases, if the bearings remain fitted to the crankshaft-connecting rod, use a bearing remover (. N.B.: If the bearing remains in the left-hand crankcase, the crankcase must be heated up using a heat stripper to release it. This operation should be performed quickly, to ensure that the bearing is removed and refitted in the crankcase. 5 Turn one of the crankcases over onto its flat joint, heat it up (to 80 to 90ºC) until the bearing falls out by itself. Remove the seal. While the crankcase is still hot and expanded, fit the new bearing fully into its housing. Fit a new seal into the left-hand crankcase using the tool. Special tool (G) CAUTION: The right-hand side seal must be fitted after closing the crankcases, fitting the O-ring and the spacer, to prevent it from turning over or damaging the seal rims.

56 5-18 ENGINE FITTING THE OUTPUT SEAL Using the pusher tool, fi t the gearbox output seal. Special tool (G) FITTING THE SELECTOR SHAFT SEAL Using the pusher tool, fi t the selector shaft seal. 5 Special tool (H) FITTING THE CLUTCH LEVER SEAL Using the pusher tool, fi t the clutch shaft seal. Special tool (I) FITTING THE BALANCE SHAFT Fit the balance shaft ( into the right-hand half of the crankcase, using a plastic mallet where necessary. FITTING THE CRANKSHAFT-CONNECTING ROD Fit the crankshaft-connecting rod ( to the right-hand half of the crankcase. N.B.: The crankshaft-connecting rod is fitted freely onto the right-hand crankcase bearing.

57 ENGINE 5-19 FITTING THE GEARBO Lightly grease and fi t the friction washer ( onto the right-hand crankcase secondary drive shaft needle bearing assembly. Fit the push spring and fi t the locking ball ( lightly greased into its housing. Fit together the secondary drive shaft assembly and the primary drive shaft fi tted with its selector fork ( into the right-hand half of the crankcase. 5 Fit the curved fork ( on the 5th speed gear onto the secondary drive shaft. 5) 6) Fitting the selector drum with its two washers. Position the selector fork guide ( in the intermediate slot of the selector drum.

58 5-20 ENGINE 7) 8) 9) Fit the selector fork (5) on the 6th speed gear. Position the selector fork guide ( in the lower slot of the selector drum. Position the selector fork guide (5) in the upper slot of the selector drum. 10) Fit the selector forks shaft (6). 1 Position the selector drum in 4th speed; the Mecanindus pin is aligned with the selector fork shaft. 5 1 Fit the selector shaft (7), fitted with its two 5 friction washers. FITTING THE LEFT-HAND HALF-CRANKCASE Check that the friction washers are present on: a) the secondary drive shaft (. b) the selector drum (. c) the selector shaft 5) 6) 7) Fit the centring rods (. Check that the right-hand crankcase joining surface is perfectly clean. Apply sealing paste to the right-hand crankcase joining surface. Grease the ends of the shafts lightly. Check that the left-hand crankcase joining surface is perfectly clean. Fit the left-hand half of the crankcase. 8) Screw the stud on the end of the crankshaft-connecting rod. Special tool (J)

59 ENGINE ) Insert the support tool supplied with the plate on the stud Special tool (E) Special tool (F) 10) Centre the assembly on the crankcase with the four bolts. (5). 1 Fit the centring tool on the support tool. 1 Special tool (K) Screw the stud nut down until the crankcases close completely with the screw-plate (. 1 Fit and tighten the thirteen securing bolts. Securing tightness torque: 1,1 dan m (11 N m) 1 N.B.: Check that the crankshaft-connecting rod turns freely inside the crankcases. Fit the gear lever without tightening it. Turn the primary drive shaft manually and check that the gears turn smoothly. 5 15) Lubricate the crankshaft-connecting rod and the bearings lightly with 2-stroke oil. CHECKING THE PISTON The pistol should not show signs of scratching or seizing. The piston rings must move freely in their grooves. CHECKING THE PISTON RINGS Remove the piston rings carefully. Fit one ring inside the cylinder bore parallel to the bore, and with a feeler gauge, measure the ring gap clearance Piston ring gap clearance: from 0.15 mm to 0.30 mm Limit of use: 1 mm

60 5-22 ENGINE REFITTING THE PISTON Fit the needle bearing assembly ( in the connecting rod small end, after lubricating it with 2-stroke oil. Fit the piston on the connecting rod, with the front positioning cams of the piston rings towards the intake side. Fit the gudgeon pin. Fit the circlips with a pair of circlip pliers. CAUTION: The circlips should be renewed with every removal. CAUTION: The circlip openings should face upwards or downwards (, but never sideways. 5 FITTING THE CYLINDER Fit a new cylinder gasket ( without oil or grease. Ensure that the openings of the rings are facing the piston positioning dogs. Fit the cylinder ( and insert it, while at the same time compressing the piston rings by hand. Instert the cylinder into the piston compressing the piston rings by hand.

61 ENGINE 5-23 FITTING THE CYLINDER HEAD Check that the O-ring housings are perfectly clean. Fit new O-rings ( on the cylinder head. Fit the cylinder head onto the cylinder. Tighten the 4 cylinder head securing nuts diagonally in 2 or 3 stages. Cylinder head nuts tightness torque: 1.8 dan m (18 N m) 5) Fit the spark plug. Spark plug tightness torque: 2.5 dan m (25 N m) 5 FITTING THE RIGHT HAND SEAL Fit a new O-ring ( and spacer ( on the crankshaft-connecting rod. Fit a new seal (, with the lip facing outwards. Use the special tool Special tool (G)

62 5-24 ENGINE FITTING THE CRANKSHAFT-CONNECTING ROD GEARS AND THE BALANCE SHAFT Fit the key ( into its housing on the crankshaft-connecting rod. Fit the key ( into its housing on the balance shaft. 5 5) 6) 7) 8) 9) Fit the crankshaft-connecting rod (, with the marked tooth facing outwards. Fit the balance shaft gear (, ensuring that the space between the marked tooth with two points (a) coincides with the tooth marked with one point (a) on the crankshaft-connecting rod gear. Fit the nut without tightening it. Immobilise the balance shaft with a bolt (b) inserted in the threaded perforations. Turn the gear on the balance shaft so that the bolt rests against a crankcase rib. Tighten the nut (5) on the balance shaft. Nut tightness torque: 6 dan m (60 N m) Fit the gear (6) with the spot-facing outwards and the nut (7). 10) Tighten the crankshaft-connecting rod gear. Nut tightness torque: 7.5 dan m (75 N m) FITTING THE CLUTCH Fit the primary drive shaft. a) the tapered washer ( with the dished side towards the bearing. b) the flat washer (. c) the clutch bell housing (. d) the ribbed spacer (, e) the clutch dog (5), f) the nut tab washer (6) and the nut (7).

63 ENGINE 5-25 Immobilise the clutch dog with the special tool. Special tool (C) Tighten the nut. 5) Nut tightness torque: 7.5 dan m (75 N m) Fold over the clutch nut tab washer. Fit the clutch control lever with its spring and its washer. 6) 7) Fit the pusher (8), the ball (9) and the push rod (10) onto the primary drive shaft. Fit the clutch disks beginning with a friction disk (1 and alternating smooth and friction disks (1. 5 8) While fi tting, ensure that the marks (a) on the smooth disks are turned 120º one from the other. 9) Fit the pressure plate (1, ensuring that the arrow (b) on the plate coincides with the round mark (c) on the clutch dog. 10) Fit the springs (1 on the pressure plate and the 4 bolts and washers (5). Bolts tightness torque: 0.5 dan m (5 N m)

64 5-26 ENGINE ADJUSTING THE CLUTCH CONTROL LEVER Loosen the pressure plate locknut (. Position the lever resting on the control rod. Turn the central pressure plate bolt ( to position the control lever at 30 with respect to the sealing joint of the magneto cover. Tighten the locknut without altering the adjustment. Nut tightness torque: 2.7 dan m (27 N m) FITTING THE KICK-START SYSTEM (WHERE FIT- TED) AND THE CLUTCH COVER 5 5) Fit the spring ( onto the kick-start shaft. Fit the kick-start attack gear (, and the take-off ramp (a)in alignment with the arm of the return spring (b). Fit the kick-start shaft (. Fit the two centring rods and a new paper gasket. Fit the clutch cover, turning the crankshaft-connecting rod manually if necessary, so that the water pump gear meshes with the crankshaft-connecting rod gear. 6) Fit the eight cover securing bolts. 7) 8) Bolts tightness torque: 1.1 dan m (11 N m) Fit and apply the kick-start lever slightly and hold it in position. Fit the starter shaft stop. Nut tightness torque: 3 dan m (30 N m) 9) Release the kick-start lever. FITTING THE MAGNETO Fit the armature assembly. Fit and tighten the three securing bolts ( on the armature assembly. Bolts tightness torque: 0.3 dan m (3 N m)

65 ENGINE ) Fit the rotor ( onto the crankshaft connecting rod, ensuring that it is seated on the key. Immobilise the rotor with a front pivot adjustable spanner (. Fit and tighten the rotor nut. Nut tightness torque: 5.2 dan m (52 N m) 6) Fit the gasket and the magneto cover. Bolts tightness torque: 0,4 dan m (4 N m) VARIOUS OPERATIONS REMOVING THE WATER PUMP 5) 6) Remove the eight clutch cover securing bolts. Remove the clutch cover. Remove the eight water pump cover securing bolts (. Remove the cover. Remove the two centring pivots and the paper gasket. (. On the inside of the clutch cover, remove: a) the rubber ring (. b) the washer (. c) the 30 tooth nylon gear (5). d) the driving cotter pin (6). e) the washer (7). f) the turbine with its shaft (8). g) the seal (9). 5 7) Check the condition of the turbine shaft. If there is evidence of wear, renew the turbine. FITTING THE WATER PUMP Fit a new lightly greased seal (9), using the special tool. Special tool (L) Proceed in the reverse order to dismantling. CAUTION: The rubber ring and the paper gasket must be renewed every time the unit is dismantled.

66 5-28 ENGINE DISMANTLING THE OIL PUMP AND ITS DRIVE GEARS 5) Remove the eight clutch cover securing bolts. Remove the clutch cover. Remove the oil pump cover. Remove the two oil pump securing bolts. Remove the pump ( with its O-ring. 6) On the inside of the clutch cover, remove: a) the two rubber rings (. b) the gear (. 5 c) the driving cotter pin (. d) the washer (5). e) the pump shaft and its washer (6). f) the gear with its two washers (7). 7) Check the condition of the oil pump shaft. If there is evidence of wear, renew the shaft. FITTING THE OIL PUMP Lubricate the two shafts. Proceed in the reverse order to dismantling. CAUTION: The rubber rings and the O-ring must be renewed every time the unit is dismantled.

67 ENGINE 5-29 TIGHTENING TORQUE SPECIFICATIONS PARTS SECURED Cylinder head Crankcases Transmission cover Water pump Inlet connector dan m 1,8 1,1 1,1 1,1 1,1 N m Crankshaft-connecting rod gear 7,5 75 Balance shaft gear 6 6,60 Clutch bell housing 7,5 75 Clutch pressure plate Clutch stop locknut Starter motor 0,5 2,7 1, Rotor 5,2 52 Stator 0,3 3 Magneto cover 0,4 4 Gearbox drain plug 1,18 18 Spark plug 2,5 25 SERVICING MATERIALS REQUIRED MATERIALS RECOMMENDED MH PRODUCT USE Engine oil Gearbox oil Motul 510 semi-synthetic 2-stroke oil Motul TRANSOIL (SAE 10W30) Filling the engine oil tank Filling the gearbox

68 5-30 ENGINE SPECIAL TOOLS Magneto extractor Valve assembly male safety key (4 mm) A Engine support adaptation B Engine support 5 C Clutch immobilisation tool D Large model protection bush E Crankcase opening and extraction tool F Crankcase opening plate G Primary transmission side crankshaft seal pusher H Selector shaft seal pusher. I Clutch lever lip seal pusher J Pin (Ø10. length125) K Centring device with fl ange L Water pump lip seal pusher N.B.: All these tools are included in the engine maintenance kit (reference:

69 ELECTRICAL SYSTEM 6-1 SECTION 6 ELECTRICAL SYSTEM CONTENTS SERVICING THE MACHINE REMOVING THE BATTERY REMOVING THE STARTER MOTOR RELAY REMOVING THE VOLTAGE REGULATOR/TURN INDICATOR CONTROLLER REMOVING THE IGNITION CONTROLLER REMOVING THE MAGNETO ROTOR AND ARMATURE REMOVING THE NEUTRAL POSITION SWITCH REMOVING THE STARTER MOTOR REMOVING THE DIODES DIGITAL INSTRUMENT PANEL (WHERE FITTED) USE Button functions Succession of the functions FUNCTIONS OF THE MAIN MENU Current speed Trip (TD) Automatic chronometer (LAP) Average speed (AVE) Totaliser (TOD) Rev-counter (RPM) Battery voltage alarm Sleep mode CONFIGURATION Altering the wheel circumference Altering the unit of measurement Altering the pulses per wheel turn Altering the pulses for every engine revolution STARTING THE SYSTEM UP FIRST INSTRUMENT PANEL INSTALLATION ELECTRICAL CHARACTERISTICS Maximum functioning characteristics Functioning operating characteristics Connector confi guration

70 6-2 ELECTRICAL SYSTEM SERVICING THE MACHINE REMOVING THE BATTERY Remove the seat see Removing the seat in Section 4 (CHASSIS) Disconnect and remove the battery. WARNING: First disconnect the negative cable and then the positive cable. REMOVING THE STARTER MOTOR RELAY Remove the seat see Removing the seat in Section 4 (CHASSIS) Disconnect the battery. WARNING: First disconnect the negative cable and then the positive cable. 6 Remove the fuel tank see Removing the fuel tank in Section 4 CHASSIS. Disconnect and remove the starter motor relay (. REMOVING THE VOLTAGE REGULA- TOR/TURN INDICATOR CONTROLLER Remove the seat see Removing the seat in Section 4 (CHASSIS) Disconnect the battery. WARNING: First disconnect the negative cable and then the positive cable. 5) Remove the fuel tank see Removing the fuel tank in Section 4 CHASSIS. Remove the two securing bolts. Disconnect and remove the regulator (. N.B.: The same device has two functions: voltage regulator and turn indicator controller.

71 ELECTRICAL SYSTEM 6-3 REMOVING THE IGNITION CONTROLLER Remove the right-hand radiator fairing. Disconnect and remove the ignition block (. N.B.: The ignition block has two functions, an ignition box and a high tension coil. REMOVING THE MAGNETO ROTOR AND ARMATURE Remove the fi ve cover securing bolts. Remove the rotor (. N.B.: For other operations on the magneto, see Section 5 (EN- GINE). Depending on the model, the rotor also acts as a starter crown gear. REMOVING THE NEUTRAL POSITION SWITCH 6 Remove the chain guard (two bolts). Disconnect the switch cable (. Remove the switch (. WARNING: Tilt the machine over to prevent the oil from spilling from the box. REMOVING THE STARTER MOTOR Remove the left-hand cover securing (fi ve bolts). Remove the three securing bolts from the starter motor. (two inside and one outside). Disconnect the supply cable ( from the starter motor (. Remove the starter motor.

72 6-4 ELECTRICAL SYSTEM REMOVING THE DIODES Remove the seat see Removing the seat in Section 4 (CHASSIS) Disconnect the battery. WARNING: First disconnect the negative cable and then the positive cable. Remove the fuel tank see Removing the fuel tank in Section 4 (CHASSIS). N.B.: To access the diodes, the taping needs to be cut and an incision made in the main wiring protection conduit. The diodes are protected by a plastic coating. 6 The function of the diodes is the following: Polarity anti-inversion diode (. Turn indicator circuit anti-reverse diodes (.

73 ELECTRICAL SYSTEM 6-5 DIGITAL INSTRUMENT PANEL (WHERE FITTED) USE BUTTON FUNCTIONS The button can be used to: Move from one function to another. Set the trip meter, chronometer and average velocity display to zero. Alter the wheel circumference value, the unit of measurement and the number of pulses per wheel turn or engine revolution. It is always possible to pass from one function to another, regardless of the status of the machine in movement or halted. The only thing required is to press the button briefly (1 second),and on releasing it, the new screen appears with the new function. Zeroing of the trip meter, as well as adjusting the chronometer and average speed display can be carried out with the machine either halted or in motion, in accordance with the procedures described in the following paragraphs. The CONFIGURATION menu can only be accessed with the machine halted, by positioning in TOD function and holding the button down for 5 seconds. Data will only be memorised by leaving the confi guration menu by means of the mode button. KEY BUTTON SPEED ASSOCIATED FUNCTIONS 6 OFF - - Button inactive ON ON >0 The confi guration menu cannot be accessed ON ON 0 All the button functions are enabled SUCCESSION OF THE FUNCTIONS It is always possible to pass from one function to another, either with the machine halted or in motion, by using the button and in the following sequence: TD LAP AVE TOD RPM See the functions in the procedures described in the following paragraphs.

74 6-6 ELECTRICAL SYSTEM FUNCTIONS OF THE MAIN MENU CURRENT SPEED The information is always displayed in large electronic digits (see fi gure), regardless of the function selected or the alarm active. The information is displayed on screen every 0.5 seconds. Representation of the current speed data: Representation in kph (original confi guration): in this case, the km/h logo will be displayed. Representation in Mph (See Altering the unit of measurement in CONFIGURATION): in this case no logo will be displayed. TRIP (TD) 6 This is an automatic onboard partial totaliser. This function is always displayed in small digits accompanied by TD. The data displayed indicates the distance travelled by the machine expressed either in km or in miles (depending on the measurement unit selected), with a resolution of 0.1 (km or miles). It is an automatic meter which is activated autonomously by the fi rst pulse coming from the speed sensor. The data is not memorised permanently. The meter associated with this parameter can be zeroed by holding the button down (in relation totod function) for approx. 3 seconds, until the value appears. Zeroing this meter also zeroes the lap and AVE functions. If the data exceeds the fi gure, the system returns the TD, LAP and Ave to zero and begins to count again. CAUTION: When there is no current present, the TD value will be irremediably lost. AUTOMATIC CHRONOMETER (LAP) This is the chronometer related to the TD and AVE. The information is displayed in small digits and accompanied with LAP. The data represents the real time of the distance covered by the machine associated with the TD parameter (in the mm:ss format if the hour=0, and in the hh:mm format if the hour>0). It is an automatic meter: It is activated autonomously by the fi rst pulse coming from the speed sensor. When LAP is operative, the digit separating the hours from minutes or minutes from seconds is displayed fl ashing, whereas it is unfl ashing when LAP is not operative.

75 ELECTRICAL SYSTEM 6-7 It stops 3 seconds after the reception of the last pulse from the speed sensor. The data is not memorised permanently. The meter can be zeroed by holding down the button (in relation to the LAP function) for approximately 3 seconds, until the 0.0 value appears. Zeroing this meter, either with the machine halted or in motion, also causes the zeroing of the TD and AVE functions. If the data exceeds the value, the system returns the TD, LAP and Ave to zero and begins to count again. CAUTION: When there is no current present, the LAP value will be irremediably lost. AVERAGE SPEED (AVE) The information is displayed in small electronic digits, accompanied by AVE, which indicates the function selected. The data represents the average speed maintained by the machine (expressed in km/h or in Mph, depending on the unit of measurement selected), calculated as the proportion between the distance travelled (represented by TD) and the time needed to travel the distance (represented by LAP); the average speed is calculated every 0.1 km (or 0.1 miles depending on the unit of measurement selected) travelled by the machine. The data is not memorised permanently. The counter associated with this function can be zeroed by holding the button down (in relation to the AVE function) for approx. 3 seconds, until the 0.0 value appears. Zeroing this meter, either with the machine halted or in motion, also causes the zeroing of the TD and LAP functions. The AVE meter is also zeroed when LAP reaches the 23:59:59 value, or when TD reaches the value. If the data to be displayed exceeds the 409 value, the character ---- will be displayed. 6 CAUTION: When there is no current present, the LAP value will be irremediably lost.

76 6-8 ELECTRICAL SYSTEM TOTALISER (TOD) The information is displayed in small electronic digits, accompanied by TOD, as can be seen in the fi gure. The data is memorised permanently in a non-volatile memory (updated with every kilometre travelled). If no data appears registered in the memory, the number will be displayed. The information is always calculated in km. However, it can be expressed either in km or in miles. The conversion is possible by accessing the confi guration menu. In normal use instrumentation conditions, it is not possible to zero this information. REV-COUNTER (RPM) 6 The information is displayed in small digits and accompanied by an indication along the graphical bar and the inscription RPM next to this. The data is displayed in revolutions per minute. The value is updated every 0.5 seconds. The resolution is a constant 100 rpm over the whole scale. Scale background value: 12,000 rpm. The number of pulses for each engine revolution can be selected by accessing the confi guration menu. The graphical bar, updated every 0.5 seconds, is interpreted in accordance with the following table: Rpmx100 (turns/min) Sec. illuminated Rpmx100 (turns/min) Sec. illuminated Rpmx100 (turns/min) Sec. illuminated 0 0 From 36 to 41 7 From 80 to Up to 14 1 From 42 to 47 8 From 86 to From 15 to 17 2 From 48 to 53 9 From 92 to From 18 to 20 3 From 54 to From 94 to From 21 to 23 4 From 62 to From 96 to From 24 to 29 5 From 68 to Over and above - excessive From 30 to 35 6 From 74 to BATTERY VOLTAGE ALARM When the voltage value is lower than or equal to 12.0v, the system activates the alarm. The indication consists of fl ashing the battery symbol and displaying the inscription MIN (regardless of the function being displayed). This alarm does not affect the normal functioning of the instrument panel. The state of alarm ceases when the voltage returns to 12.5v.Thus, the entire sequence is repeated every time the voltage is lower than or equal to 12.0v, and is interrupted every time the voltage is greater than 12.5v.

77 ELECTRICAL SYSTEM 6-9 SLEEP MODE Every time the key switch is turned to the OFF position, the following operations take place: The screen and its lighting are switched off. All the indicator lights that were on are turned off. Entry into sleep phase, characterised by a low current consumption, in which the system interrupts every activity. CONFIGURATION The confi guration menu can only be accessed with the machine halted. Holding the mode button down for approximately 5 seconds accesses the TOD function, and the confi guration menu is displayed. This menu allows the user to alter the following parameters: the circumference of the wheel (minimum 1,000 mm, maximum 2,500 mm). Unit of measurement (Km/h or Mph). Number of pulses coming from the speed sensor for each turn of the wheel (minimum 1, maximum 1. Number of pulses for each engine revolution (minimum 1, maximum 6). To ensure that the alterations made in the confi guration menu are consolidated, the user needs to run through the entire sequence of screens envisaged in this menu, making sure to exit the confi guration menu (and re-establishing the standard operating mode). To re-establish the standard operating mode, keep the mode button held down in the last screen, regarding the number of pulses per engine revolution (which is the last menu confi guration screen), until the apparatus returns to the standard operating mode. 6 If the confi guration menu is exited by: putting the machine in motion, turning the ignition key, or not holding the button down for 20 seconds, the alterations made will not be registered and the system will return to the preceding values. CAUTION: The system will only permanently save the changes made when the configuration procedure is carried out correctly.

78 6-10 ELECTRICAL SYSTEM ALTERING THE WHEEL CIRCUMFERENCE Once inside the confi guration menu, the fi rst parameter that can be altered is the wheel circumference. The screen displays the only information seen, which is the circumference of the wheel, whereas all the other segments are off. The different fi gures that make up the wheel circumference value can be altered, starting with the most signifi cant fi gure and moving successively to the least signifi cant. Depending on the detail selected (which will be displayed fl ashing), a brief press of the button will cause the fi gure to rise by one unit, while a longer press will enable changing to another fi gure. The information regarding the wheel circumference selected is stored in memory. 6 CAUTION: Regulating interval: from 1,000 mm to 2,500 mm with intervals of 1 mm. Once the regulating menu has been accessed: - if 20 seconds go past without the button being pressed, or - if the machine is started up, or - if the key switch is turned to the OFF position, the system will automatically return to standard operating mode, and the changes made will be lost. ALTERING THE UNIT OF MEASUREMENT Once the wheel circumference regulating has been completed, it is possible to alter the unit of measurement by pressing the button for approximately 3 seconds. Once the least signifi cant fi gure has been altered: at this point the two inscriptions km/h and Mph will appear on the screen, and at the outset the selected value will fl ash. The procedure for changing the unit is identical to that described in the previous section. The information regarding the unit of measurement is stored in memory. CAUTION: Regulating interval: from 1,000 mm to 2,500 mm with intervals of 1 mm. Once the regulating menu has been accessed: - if 20 seconds go past without the button being pressed, or - if the machine is started up, or - if the key switch is turned to the OFF position, the system will automatically return to standard operating mode, and the changes made will be lost.

79 ELECTRICAL SYSTEM 6-11 ALTERING THE PULSES PER WHEEL TURN Once the unit of measurement has been selected ( it appears fl ashing), press the mode button for 3 seconds. It will then be possible to alter the number of pulses for the wheel. This parameter expresses the number of pulses which the electronic sensor sends to the instrument panel for every turn of the wheel. This information is stored in memory. CAUTION: Regulating interval: from 1,000 mm to 2,500 mm with intervals of 1 mm. Once the regulating menu has been accessed: - if 20 seconds go past without the button being pressed, or - if the machine is started up, or - if the key switch is turned to the OFF position, the system will automatically return to standard operating mode, and the changes made will be lost. ALTERING THE IMPULSES FOR EVERY ENGINE REVOLUTION Once the alteration made in the previous screen is completed, the button must be held down for 3 seconds, and then it will be possible to alter the number of pulses for every engine revolution. This parameter expresses the number of pulses for each revolution of the engine s primary drive shaft that the machine is able to send to the instrument panel. This screen can be distinguished from the previous one by having the logo RPM. This information is stored in memory. 6 CAUTION: Regulating interval: from 1,000 mm to 2,500 mm with intervals of 1 mm. Once the regulating menu has been accessed: - if 20 seconds go past without the button being pressed, or - if the machine is started up, or - if the key switch is turned to the OFF position, the system will automatically return to standard operating mode, and the changes made will be lost.

80 6-12 ELECTRICAL SYSTEM STARTING THE SYSTEM On switching on (key from OFF to ON), the system provides the user with a series of data, which, in order to simplify things, are shown on different screens in the form of pages: First page: software version and date. This information only appears during the fi rst instrument panel installation. 5) Second page: glass check; all the glass segments remain lit up for 3 seconds. Third page: wheel circumference, measurement unit (only in the case of km/h), number of pulses for each turn of the wheel and number of pulses for each engine revolution (see fi gure). At the same time as displaying the aforementioned screens, the system also checks the indicator lights and the glass backlighting: all the indicator lights come on and then go off at the end of the screen check. Once all of this has been completed, the system displays normal view. 6 FIRST INSTRUMENT PANEL INSTALLATION The values that the instrument panel has registered by default are: Wheel circumference: 2,205 mm. Unit of measurement: km/h for speed and km for distance. Pulses per turn of the wheel: 1. Pulses per engine revolution: 1. To alter any of these parameters it is necessary to follow the steps described in the CONFIGURATION part of this section. N.B.: During the first instrument panel installation, the version and date of the software incorporated always appear on the screen.

81 ELECTRICAL SYSTEM 6-13 ELECTRICAL CHARACTERISTICS MAIMUM FUNCTIONING CHARACTERISTICS CHARACTERISTICS Min. Max. Unit Max. operating temperature - 17 V Storage temperature C Maximum current internal - 20 ma Maximum input current - 20 ma Maximum output current - 20 ma CARACTERISTICAS OPERATIVAS DE FUNCIONA- MIENTO CHARACTERISTICS Min. Typ. Max. Unit Supply voltage 6,0 ( 12 16,0 V Operating temperature C Abs. current will all the indicator lights on (Vbat=13.0V) - 259,1 280 ma 6 Abs. current will all the indicator lights off (Vbat=13.0V) Abs. current in sleep (Vbat=13.0V) - 105,1 110 ma - 0,36 1 ma ( Minimum value of the voltage applicable to the input that does not jeopardise the correct functioning of the instrument panel. In this value, the optoelectronic part (indicator lights and backlighting) are turned off. CONNECTOR CONFIGURATION POS. MEANING POS. MEANING 1 Turn indicators 10 Water sensor 2 Turn indicators 11 Sub-key/under key 3 Neutral 12 RPM 4 Main beam 13 GND 5 NC 14 Battery positive Terminal insertion side view. 6 7 Button NC GND sensor Vcc sensor 8 Oil 17 NC 9 Fuel 18 NC

82 NOTES:

83 TROUBLESHOOTING 7-1 SECTION 7 TROUBLESHOOTING CONTENTS INTRODUCTION FAILURE TO START Engine Fuel system Electrical systems INCORRECT IDLING Engine Fuel system Electrical systems FAULTY GEAR-CHANGE Diffi culty changing gear The gear pedal does not move The gears jump FAULTY CLUTCH The clutch slips The clutch drags OVERHEATING Engine Cooling system Chassis Electrical systems POOR BRAKING FAULTY FRONT FORK ARMS Leaking oil Incorrect functioning UNSTABLE HANDLING FAULTY LIGHTS OR TURN INDICATOR SYSTEM The headlight does not come on Blown headlight bulb The rear light / Brake light does not come on Blown rear light bulb / Brake light bulb The turn indicators do not come on The turn indicators fl ash slowly The turn indicators fl ash rapidly The horn does not sound

84 7-2 TROUBLESHOOTING INTRODUCTION N.B.: The following troubleshooting guide does not cover all the possible causes of faults. It may however prove useful as a guide for basic fault finding. Use this manual to consult the corresponding checking, adjusting and part renewal procedures. ENGINE Loose spark plug. Loose cylinder head or cylinder. Damaged cylinder head gasket. Damaged cylinder gasket. Cylinder worn or damaged. Incorrect valve clearance. Seized valve. Wrongly fitted piston ring. Damaged, worn or fatigued piston ring. Seized piston ring. Seized or damaged piston. Air filter incorrectly fitted. Air filter element obstructed. Crankcase fitted incorrectly. Seized crankshaft. FAILURE TO START 7 FUEL SYSTEM Fuel tank empty. Fuel tank drain pipe blocked. Altered or contaminated fuel. Carburettor air suction blocked. ELECTRICAL SYSTEMS Flat battery. Faulty battery. Fuse blown, damaged or incorrect. Fuse fitted incorrectly. Incorrect spark plug gap. Oiled-up spark plug. Electrode worn or damaged. Insulation worn or damaged. Faulty spark plug cap. Primary or secondary coils broken or short-circuited. Faulty spark plug cable. Faulty main switch. Faulty engine stop switch. Broken or short-circuited wiring. Faulty neutral light switch. Faulty starter switch. Loose connections. Faulty starter motor.

85 TROUBLESHOOTING 7-3 INCORRECT IDLING ENGINE Incorrect valve clearance. Air filter element obstructed. FUEL SYSTEM Incorrectly adjusted engine idling. Incorrect throttle cable clearance. Flooded throttle body. Faulty air intake system. ELECTRICAL SYSTEMS Flat battery. Faulty battery. Fuse blown, damaged or incorrect. Fuse fitted incorrectly. Incorrect spark plug gap. Oiled-up spark plug. Electrode worn or damaged. Insulation worn or damaged. Faulty spark plug cap. Primary or secondary coils broken or short-circuited. Faulty spark plug cable. 7 FAULTY GEAR-CHANGE DIFFICULTY CHANGING GEAR See The clutch is dragging in this section. THE GEAR PEDAL DOES NOT MOVE Bent gear-change shaft. Foreign object in the selection drum slot. Seized gear change fork. Bent gear-change fork guide bar. Seized gearbox gearing. Foreign object between the gearbox gears. Incorrectly fitted gearbox.

86 7-4 TROUBLESHOOTING THE GEARS JUMP Incorrect gear change pedal position. Incorrect stop lever return. Worn gear selector fork. Worn selection drum slot. Worn gear securing device. FAULTY CLUTCH THE CLUTCH SLIPS Clutch incorrectly fitted. Clutch cable incorrectly adjusted. Loose or fatigued clutch spring. Worn friction plate. Worn clutch plate. Incorrect oil level. Incorrect oil viscosity (low). Oil altered. THE CLUTCH DRAGS 7 Uneven clutch spring tension. Bent pressure plate. Bent clutch plate. Distorted friction plate. Bent clutch push bar. Broken clutch lobe. Marks not aligned. Incorrect oil level. Incorrect oil viscosity (high). Oil altered. OVERHEATING ENGINE Coolant passages blocked. Large accumulation of carbon deposits. Incorrect oil level Incorrect oil viscosity. Inferior oil quality. COOLING SYSTEM Low coolant level. Radiator damaged or leaking. Defective radiator cap.

87 TROUBLESHOOTING 7-5 Radiator fins bent or damaged. Water pump damaged or failed. Pipe connected incorrectly. Damaged piping. CHASSIS Brakes activated. ELECTRICAL SYSTEMS Incorrect spark plug electrode gap. Worn brake pad. Worn brake pad. Air in the hydraulic brake system. Leaking brake fluid. Damaged brake calliper seal. Damaged brake pipe. Oil or grease on the brake disk. Oil or grease on the brake pad. Incorrect brake fluid level. POOR BRAKING DAMAGED FRONT FORK ARMS 7 LEAKING HYDRAULIC FLUID Inner tube bent, damaged or rusted. Outer tube cracked or damaged. Oil seal fitted incorrectly Damaged oil seal lip. Incorrect fluid level (high). Loose shock absorber bar assembly bolt. Damaged shock absorber bar assembly copper washer. INCORRECT FUNCTIONING Inner tube bent or damaged. Outer tube bent or damaged. Damaged forks spring. Outer tube hose worn or damaged. Shock absorber bar bent or damaged. Incorrect fluid viscosity. Incorrect fluid level.

88 7-6 TROUBLESHOOTING UNSTABLE HANDLING Handlebars bent or incorrectly fitted. Top support incorrectly fitted. Bottom support fitted incorrectly (badly tightened lock nut). Bent steering shaft. Damaged ball bearings or bearing guide ring. Uneven fluid levels (in the two front fork arms). Uneven fork spring tension (in the two front fork arms). Broken fork spring. Inner tube bent or damaged. Outer tube bent or damaged. Worn bearing or hose. Swinging arm bent or damaged. Faulty rear shock absorber spring. Oil or petrol leak. Uneven tire pressures (front and rear). Incorrect tyre pressure. Uneven tyre wear. Incorrect wheel balancing. Broken or loose spokes. Damaged wheel bearing. Bent or loose wheel shaft. Excessive decentring of the wheel. Bent frame. Damaged steering column tube. Incorrectly fi tted bearing guide ring. 7 FAULTY LIGHTING SYSTEM OR TURN INDICATORS HEADLIGHT DOES NOT COME ON Incorrect headlight bulb. Too many electrical accessories. Excessive load. Incorrect connection. Circuit incorrectly connected to earth. Faulty contacts (main switch). Blown headlight bulb. BLOWN HEADLIGHT BULB Incorrect headlight bulb. Battery faulty. Headlight bulb has reached end of life. REAR LIGHT/BRAKE LIGHT DOES NOT COME ON Incorrect rear light/brake light bulb. Too many electrical accessories. Incorrect connection. Blown rear light/brake light bulb.

89 TROUBLESHOOTING 7-7 BLOWN REAR LIGHT/BRAKE LIGHT BULB Incorrect rear light/brake light bulb. Battery faulty. Incorrectly adjusted rear brake light switch. Rear light/brake light bulb reached end of life. TURN INDICATORS DO NOT COME ON Faulty turn indicator switch. Blown turn indicator bulb. Incorrect connection. Damaged or faulty wiring loom. Battery faulty. Fuse blown damaged or incorrect. TURN INDICATORS FLASH SLOWLY Faulty turn indicator switch. Incorrect turn indicator bulb. TURN INDICATORS FLASH QUICKLY Incorrect turn indicator bulb. Blown turn indicator bulb. HORN DOES NOT SOUND Horn incorrectly adjusted. Horn damaged or faulty. Faulty horn switch. Battery faulty. Faulty wiring loom. 7

90 NOTES:

91

92 G.H.E. ENGINEHISPANIA, S.L. RYZ 50 SERVICE MANUAL 1st Edition Published November, G.H.E. ENGINEHISPANIA, S.L. All rights reserved. No part of this publication may be reproduced or transmitted in any form, nor by any electronic or mechanical means for any use whatsoever, without the written authorisation of ENGINEHISPANIA, S.L. G.H.E. ENGINEHISPANIA, S.L. Service Department Parque Sevilla Industrial-Calle Seville, Spain Tel.: Fax: Traduction: Reproduction of this material is prohibited PUBLICATION REF: * * w w w. m o t o r h i s p a n i a. e s 1 st EDITION