APRILIA 8140172 Service And Repair Manual Download

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ENGINE

RSV mille

- 116

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2%!33%-",9

Carefully read 0.2.1 (PRECAUTIONS AND GENERAL
INFORMATIONS).

3.8.1 BLEEDING THE ENGINE OIL CIRCUIT

◆

Refill the engine with motor oil, see 2.14 (CHANGING

THE ENGINE OIL AND THE OIL FILTER).

◆

Slip the two electric connectors off the two injectors (1-
2).

◆

Start the engine for a moment until the engine oil pres-
sure LED goes off.

◆

Insert the two electric connectors on the two injectors

(1-2).

◆

Top up with motor oil until the tank level reaches the

prescribed limit, see 2.13 (CHECKING THE ENGINE
OIL LEVEL AND TOPPING UP).

◆

Start the engine and let it idle for approx. 10 minutes.

◆

Check the oil level again and, where necessary, top up.

3.8.2 CHECKING THE ENGINE OIL PRESSURE

NOTE

Have the appropriate special tool

(3) to hand

cod. 8140181 (fuel-oil pressure gauge).

◆

Connect the oil pressure gauge (4) in place of the en-

gine oil pressure sensor (3).

Engine oil pressure: min. 50 kPa (0.5 bar).

NOTE

Check the oil pressure at a temperature of 80 °C

(176 °F) and at a speed of at least 1200 rpm.

CAUTION

If the oil pressure is below the minimum limit, check
the oil pump and relevant drive assembly.

◆

During reassembly, coat the thread of the engine oil

pressure sensor (3) with LOCTITE

243.

Driving torque of sensor (3): 15 Nm (1.5 kgm).

3.8.3 SYNCHRONIZING CYLINDERS

See 4.8.10 (CYLINDER SYNCHRONIZATION).

Summary of Contents for 8140172

Page 1: ...RSV mille MIN 956X Service and repair manual aprilia part 8140172 ...

Page 2: ...1 RSV mille INTRODUCTION 0 GENERAL INFORMATION 1 SERVICE AND SETTING UP 2 ENGINE 3 FUEL SUPPLY SYSTEM 4 COOLING SYSTEM 5 ELECTRICAL SYSTEM 6 CHASSIS PARTS 7 REPAIR INFORMATION 8 UPDATES 9 ANALYTICAL INDEX ...

Page 3: ...sponsibility as to the performance or use of said products First edition march 2000 Reprint Produced and printed by editing division Soave VERONA Italy Tel 39 045 76 11 911 Fax 39 045 76 12 241 E mail customer stp it www stp it On behalf of aprilia Consumer Service s p a via Noalese 156 30036 Santa Maria di Sala VE Italia Tel 39 041 57 86 101 Fax 39 041 57 86 100 www aprilia com 3 49 7 2 3 The fol...

Page 4: ...rings snap rings O rings split pins and screws whenever the thread appears damaged with new ones Before the assembly clean all the connection surfaces the oil seal edges and the gaskets Apply a thin layer of lithium based grease on the oil seal edges Put back the oil seals and the bearings with the mark or serial number facing towards the outside visible side When installing the bearings lubricate...

Page 5: ...0 4 RSV mille NOTE ...

Page 6: ...1 1 RSV mille GENERAL INFORMATION 1 ...

Page 7: ... 25 25 3 1 6 30 2 0 243 1 7 4 30 4 3 1 7 5 2 4 24 1 10 35 3 1 11 1 7 1 PRODUCT PROPERTIES 1 11 1 7 2 USE OF CONSUMABLES 1 12 30 4 3 1 15 1 8 1 MISCELLANEOUS TOOLS 1 15 1 8 2 ENGINE TOOLS 1 16 0 3 4 4 6 4 3500 24 34 1 17 1 9 1 ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND 1 17 1 9 2 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND 1 17 1 9 3 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND 1 17...

Page 8: ...area with the engine off Do not smoke while refuelling or near fuel vapours in any case avoid any contact with naked flames sparks and any other heat source to prevent the fuel from catching fire or from exploding Further prevent fuel from flowing out of the fuel filler as it could catch fire when getting in contact with the red hot surfaces of the engine In case some fuel has accidentally been sp...

Page 9: ...ed an oil with intermediate characteristics in com parison with the 0 F A 5W and 0 F A 20W or FORK 5W and FORK 20W these can be mixed as indicated below SAE 10W 0 F A 5W 67 of the volume 0 F A 20W 33 of the volume or FORK 5W 67 of the volume FORK 20W 33 of the volume SAE 15W 0 F A 5W 33 of the volume 0 F A 20W 67 of the volume or FORK 5W 33 of the volume FORK 20W 67 of the volume 1 2 4 BRAKE FLUID...

Page 10: ...mmended 0ECOBLU 40 C or COOL On the basis of the desired freezing temperature of the coolant mixture add to the water the percentage of cool ant indicated in the following table NOTE The characteristics of the various antifreeze liq uids are different Be sure to read the label on the product to learn the degree of protection it guarantees aCAUTION Use only antifreeze and anticorrosive without nitr...

Page 11: ...s are first loaded and then relieved and the engine parts can thus cool down Even if it is important to stress the engine components during running in take care not to exceed aCAUTION Only after the first 1500 km 937 mi of running in is it possible to obtain the best performance Keep in mind these important indications Do not open the throttle completely if the speed is low both during and after t...

Page 12: ...torque F 82 Nm 8 2 kgm at 7250 rpm Bore stroke 97 mm 67 5 mm Compression ratio 11 4 0 5 1 Average piston speed 22 5 m s at 10000 rpm Camshaft during intake stroke 262 valve lifting 10 6 mm Camshaft during exhaust stroke 259 valve lifting 10 6 mm Valve advance with valve clearance 1mm opening during intake stroke closing during intake stroke opening during exhaust stroke closing during exhaust stro...

Page 13: ...0 11 948 2nd 16 28 1 1 750 8 368 3rd 19 26 1 1 368 6 543 4th 22 24 1 1 090 5 216 5th 23 22 1 0 956 4 573 6th 27 23 1 0 851 4 073 sprocket teeth 17 Drive chain endless type with no connection link with sealed links model 525 dimensions 5 8 x 5 16 FUEL SUPPLY SYSTEM Type electronic injection Choke Ø 51 mm FUEL SUPPLY Type indirect injection MULTIPOINT Fuel premium grade unleaded petrol min O N 95 N ...

Page 14: ... MEZ3 120 65 17 4 Rear METZELER STELL RADIAL MEZ3 180 55 17 Rear METZELER STELL RADIAL MEZ3 180 55 17 4 Front MICHELIN HI SPORT TX15D 120 70 17 220 2 2 240 2 4 Rear MICHELIN HI SPORT TX25 190 50 17 250 2 5 270 2 7 Front MICHELIN PILOT RACE 120 70 ZR17 4 220 2 2 240 2 4 200 2 0 Rear MICHELIN PILOT RACE 180 55 ZR17 4 250 2 5 270 2 7 190 1 9 Front MICHELIN PILOT SPORT 120 65 ZR17 220 2 2 240 2 4 Rear...

Page 15: ... 20 W or FORK 5W and FORK 20W these can be mixed as indicated below SAE 10W 0F A 5W 67 of the volume 0F A 20W 33 of the volume or FORK 5W 67 of the volume FORK 20W 33 of the volume SAE 15W 0F A 5W 33 of the volume 0F A 20W 67 of the volume or FORK 5W 33 of the volume FORK 20W 67 of the volume Bearings and other lubrication points recommended 0AUTOGREASE MP or GREASE 30 As an alternative to the rec...

Page 16: ...eat the coupled parts to a temperature of 250 C 482 F LOCTITE 574 orange Solvent free seal in paste to be used instead of seals where there is a high friction factor and where a precise distance is required between the two components Applied in its liquid state it hardens after assembly on contact with the metal within a few hours A seal is created whose surface structure adapts to the surfaces to...

Page 17: ...e lever pin Fastening of cooling electrofan on support Fastening of fuel return pipe connection Fastening of fuel filler cap Throttle cable pullet fastening nut Throttle cable support bracket fastening screws Throttle valve pin fastening nut Throttle valve potentiometer fastening screws On coolant pump centre fastening screw On cylinder joining bracket fastening screws On engine half casing bearin...

Page 18: ...imol Grease 481 8116053 Assembly of front and rear wheel seals Assembly of fork pin bearings Assembly of clutch pump control rod On rear wheel pin thread On steering head bearings Assembly of rear brake pump control rod On rear brake lever pin On intermediate timing gear thrust washer Upper countershaft oil seal Starter motor gear LUBERING ST grease 8116038 Assembly of cold start control AP LUBE t...

Page 19: ...ide fairing rubber elements Cleaning of lower part of engine Assembly of start relay rubber element Assembly of flexible couplings on rear wheel sprocket Assembly of rubber elements on engine oil radiator Assembly of coupling on coolant filler Cleaning of engine oil tank prior to application of transfers Assembly of dashboard front fairing mount rubber elements Assembly of rubber element on rear b...

Page 20: ...s manual aCAUTION Before using the special tools consult any docu ments attached 1 8 1 MISCELLANEOUS TOOLS Pos Tool description and function Code 1 Complete tool kit for frame parts including semi shells for assembling oil seals front fork socket spanner for adjusting steering socket spanner for adjusting fork pin engine mounts 8140203 2 Chain disassembly reassembly tool 8140192 3 Centre stand 814...

Page 21: ...Driving shaft clutch cover bush inserter pad 0277727 15 Plug socket spanner 8140177 16 Tool for removal flywheel cover 0277252 17 Flywheel removal hexagonal bolt 0277780 18 Threaded pin for retaining the driving shaft at TDC 0240880 19 Gearshift secondary shaft guide bush 0277308 20 Vacuometer 8140256 21 Fuel oil pressure gauge 8140181 22 Rotor bolt removal bush 8140182 23 Clutch blocking tool 027...

Page 22: ...Loosen the knob 3 Move the fork support 4 positioning it so that the width corresponds to the distance between the two pins 1 on the rear fork Tighten the knob 3 At the same time introduce the two fork shaped seats 4 of the stand 5 under the two pins 1 provided on the vehicle Rest one foot on the rear part of the stand 5 Push the stand 5 downwards until it reaches the end of its stroke 1 9 3 POSIT...

Page 23: ...port pin 5 all the way onto the stud bolt 4 and tighten Hold the nut on the inside 6 still Unscrew and remove the engine lower rear fasten ing screw 7 Driving torque of nut 6 screw 7 50 Nm 5 0 kgm NOTE The screw 7 on the right hand side is longer Insert the lower right support pin 8 in the lower hole on the right hand side Insert the stud bolt 9 in the lower hole on the left hand side and screw it...

Page 24: ...ove the protective backing 4 completely NOTE It is advisable to use a sprayer 2 When using a sponge dab the surface with the sponge without pressing hard so as to avoid damaging the adhe sive Wet the surface of the adhesive with soapy water Apply the transfer 3 on the surface to be decorated and move it into the right position NOTE Always move the spatula in constant strokes from the centre of the...

Page 25: ...ication tape 5 from the surface of the transfer In order to assure good adhesion move the spatula over the transfer again concentrating in particular on the edges and corners NOTE With the wet method the final level of the trans fer is reached approx 48 hours after application Once the application tape has been removed make sure there are no air bubbles anywhere on the surface In the event air bub...

Page 26: ...tion and or imper fect coupling tighten the screws or bolts by proceeding as described below Manually screw all the fastening elements Applying half the prescribed driving torque tighten the elements that are diametrically opposite each other A and B C and D Repeat the previous operation by applying the pre scribed driving torque NOTE In this way the pressure exerted by the fastening elements will...

Page 27: ...m revolutions per minute HC unburnt hydrocarbons ISC idle speed control ISO International Standardization Organization kg kilograms kgm kilograms per metre 1 kgm 10 Nm km kilometres km h kilometres per hour kΩ kilo ohms kPa kiloPascal 1 kPa 0 01 bar kW kilowatt KS Clutch side L litres LAP lap race course LED light emitting diode m s metres second MAX maximum mi mile MIN minimum MPH miles per hour ...

Page 28: ...2 1 RSV mille 1 SERVICE AND SETTING UP 2 ...

Page 29: ...2 18 2 11 3 ADJUSTING THE ACCELERATOR CONTROL 2 19 34 24 2 19 4 6 4 00 50 2 19 4 4 4 2 2 20 4 00 50 4 2 22 4 4 2 22 4 00 50 4 2 4 2 3 5 2 24 4 00 50 4 2 2 2 5 2 25 4 00 50 4 54 5 2 26 4 2 3934 3 2 27 4 54 3934 3 2 28 4 2 4 2 5 2 29 4 2 2 2 5 2 30 4 54 5 2 31 534 4 2 2 2 42 6 2 4 2 6 2 2 31 534 4 2 2 2 42 6 2 2 2 32 4 2 0 7 2 2 32 34 2 2 33 2 28 1 CHECKING THE BEARING SLACK 2 33 2 28 2 ADJUSTING TH...

Page 30: ...nstructed of non edible parts Do not bite suck chew or low any part of the vehicle for any reason whatever If not expressly described otherwise reassembly of the units is carried out repeating the disassembly op erations in the reverse order 0 2 3 26 0 aprilia recommends respecting the intervals indicated for the periodic service on the various components in order to ensure the best operating cond...

Page 31: ...ke fluid every 2 years Coolant every 2 years Fork oil After the frist 7500 km 4687 mi and every 22500 km 14000 mi Engine oil Brake pads if worn Tyres every 1000 km 625 mi Tyre pressure every 15 days Engine idling rpm Nut bolt screw tightening Cylinders synchronization Suspensions and attitude Engine oil pressure warning light LED at every start Brake fluid bleeding Clutch fluid bleeding Drive chai...

Page 32: ...BRICANT CHART The points to be lubricated are indicated in the LU BRICATION CHART LUBRICATION CHART KEY 1 Steering bearings 2 Clutch lever pin 3 Lever cable for cold starting 4 Rider left footrest pin 5 Passenger left footrest pin 6 Passenger seat lock 7 Driving chain 8 Rear suspension leverage 9 Side stand pin 10 Passenger right footrest pin 11 Throttle grip 12 Accelerator cables 13 Front wheel p...

Page 33: ...he LAP push button 6 and then the push button R and keep them pressed for about five seconds With the ignition key 1 in position n the standard set tings on the dashboard are the following Right display Clock 7 coolant temperature in C 8 Left display Instantaneous speed in km h 9 trip 1 trip odometer 10 total kilometres miles odometer 11 Upon installation of the battery or of the 30A main fuses th...

Page 34: ...tton R for about two seconds NOTE The measurement of the maximum speed is rele vant to the distance covered from the last setting to zero of the maximum speed itself The distance trip 1 2 shown on the display indicates the number of kilometres miles covered from the last setting to zero to the distance trip 1 To display the average speed 5 and the distance trip 2 6 press the push button B again fo...

Page 35: ... the maximum value it starts again from the beginning NOTE It is not possible to set the red line at values low er than 2000 rpm or higher than 12000 rpm aCAUTION Never exceed the recommended rpm see table To confirm release the push button C After three seconds the red line threshold setting is stored NOTE The setting is confirmed by the coming on of the red line warning light LED max 2 2 3 5 MUL...

Page 36: ...ssed in volt 3 appears in the lower part of the right display while the coolant temperature 1 is displayed in the upper part The writing V BATT 4 is displayed The recharge circuit functions correctly if at 4000 rpm the battery voltage with low beam on is included be tween 13 and 15 V 2 3 8 SETTING THE HOUR When the push button D is pressed for the second time the hour segments 5 start blinking in ...

Page 37: ... 4 press the push but ton B To be able to see the stored times in sequence press the LAP push button 1 The writings etc 5 are displayed To start timing again press the push button B NOTE It is possible to store max forty times after which the LAP push button 1 is not effective any long er To set the memory to zero press the push button A and the LAP push button 1 at the same time for two seconds T...

Page 38: ...ve cable and then the neg ative cable Disconnect following the reverse order NOTE Check battery voltage with a portable tester If voltage is less than 12V the battery must be recharged If the voltage drops below 8V the electronic unit is not working and is preventing engine operation 2 4 1 CHECKING AND CLEANING THE TERMINALS Carefully read 2 4 BATTERY Turn the ignition switch to position m Remove ...

Page 39: ... COMPUTER If the vehicle remains unused for more than fifteen days it is necessary to recharge the battery in order to prevent its sulphation see 2 4 2 RECHARGING THE BAT TERY Remove the battery see 7 1 8 REMOVING THE BAT TERY and put it in a cool and dry place It is important to check the charge periodically about once a month during the winter or when the vehicle re mains unused in order to prev...

Page 40: ...ot be disconnected aCAUTION Take care never to let the clamps of one cable touch those of another Remove the red protection element 1 Connect one end of jump lead to the positive pole of the battery on the vehicle providing assistance A and the other end on the positive pole of the battery on the vehicle to be started B Connect one end of the other jump lead to the negative pole of the battery on ...

Page 41: ...spark plug 2 Remove any trace of dirt from the spark plug base Introduce the special spanner provided in the tool kit on the spark plug Insert the 13 mm fork spanner provided in the tool kit in the hexagonal seat of the spark plug spanner Unscrew the spark plug and extract it from its seat tak ing care to prevent dust or other substances from get ting inside the cylinder aCAUTION This vehicle is f...

Page 42: ...he threads Tighten the spark plug by means of the spanner you will find in the tool kit giving it half a turn to compress the washer Spark plug driving torque 20 Nm 2 0 kgm aCAUTION The spark plug must be well tightened otherwise the engine may overheat and be seriously damaged Position the spark plug cap 1 properly so that it does not come off due to the vibrations of the engine Put back the fuel...

Page 43: ...ick release cou pling 1 to catch any fuel spills Disconnect the male quick release coupling 1 from the receptacle 2 by pressing the relevant button NOTE Procure a screwdriver type pipe clamp 3 to re place the original one of a special type Loosen the clamp 4 and disconnect the pipe 5 Place the free end of the pipe 5 inside the container prepared beforehand Insert the male quick release coupling 1 ...

Page 44: ...he metal net of the air cleaner 3 Do not use screwdrivers or alike Seize the air cleaner 3 vertically and strike it more than once on a clean surface If necessary clean the air cleaner 3 with a com pressed air jet directing it from the inside towards the outside of the filter Clean the outer part of the air cleaner 3 with a clean cloth CHANGING Replace the air cleaner 3 with a new one of the same ...

Page 45: ...adjuster 2 throttle body pin 3 cable couplings ends accelerator control Check the idle speed 2 11 2 IDLING ADJUSTMENT Check the accelerator control adjustment 2 11 3 AD JUSTING THE ACCELERATOR CONTROL 2 11 2 IDLING ADJUSTMENT Adjust the idling every time it is irregular To carry out this operation proceed as follows Ride for a few miles until reaching the normal running temperature Position the ge...

Page 46: ...ary proceed as follows Position the vehicle on the stand Lift the fuel tank see 2 8 LIFTING THE FUEL TANK Loosen the lock nut 10 Rotate the adjuster 11 in order to restore the pre scribed value After this adjustment tighten the lock nut 10 and check the freeplay once again aCAUTION Once the adjustment has been made check that the rotation of the handlebar does not influence the en gine rpm 4 6 4 0...

Page 47: ...1 6 LUBRICANT CHART 4 4 4 2 Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS and 1 2 2 ENGINE OIL Periodically check the engine oil level see 2 13 CHECK ING THE ENGINE OIL LEVEL AND TOPPING UP change the oil after the first 1000 km 625 mi and suc cessively every 7500 km 4687 mi or 8 month aCAUTION If the vehicle is used in dusty areas change the oil more frequently In case of use on racet...

Page 48: ...ilter 8 aCAUTION Do not use filters that have already been used Spread an oil film on the sealing ring 9 of the new en gine oil filter Fit the new engine oil filter Put back the cover 7 screw and tighten the two screws 6 CLEANING THE ENGINE OIL FILTER ON THE TANK Clean the engine oil filter 10 on the tank every 15000 km 9375 mi or every two engine oil changes NOTE Prepare a pipe clamp 11 to replac...

Page 49: ...ances into the fluid If you use a funnel or other similar items make sure that they are perfectly clean Top up the expansion tank by adding coolant see 1 6 LUBRICANT CHART until this almost reaches the FULL level Do not exceed this level otherwise the coolant will flow out while the engine is running Put back the filling cap 2 aCAUTION In case of excessive consumption of coolant and in case the ta...

Page 50: ...drain plugs 6 7 with two new aluminium washers Driving torque of drain plugs 6 7 10 Nm 1 0 kgm Top up through the filler neck 8 until full Squeeze and release the couplings 9 10 a few times with your hands so as to create a slight pressure and enable the coolant to flow into the pipes Top up again until full NOTE The level is correct when the coolant stabilizes immediately below the filler neck 8 ...

Page 51: ...the MIN mark pro vide for topping up TOPPING UP aCAUTION The brake fluid may flow out of the tank Do not operate the front brake lever if the screws 1 are loose or most important if the brake fluid tank cover has been removed Unscrew the two screws 1 of the brake reservoir 2 by means of a short cross headed screwdriver aWARNING Avoid any prolonged exposure of the brake fluid to the air The brake f...

Page 52: ...If the fluid does not reach at least the MIN mark pro vide for topping up TOPPING UP Remove the right fairing see 7 1 26 REMOVING THE SIDE FAIRINGS aCAUTION The brake fluid may flow out of the tank Do not operate the rear brake lever if the brake fluid tank plug is loose or has been removed Unscrew the screw 3 completely Slightly move the whole reservoir 1 outwards aWARNING Avoid any prolonged exp...

Page 53: ...id contained in the tank 1 is parallel to the plug 2 Make sure that the fluid level exceeds the MIN mark MIN minimum level MAX maximum level If the fluid does not reach the MIN mark provide for topping up TOPPING UP aCAUTION The fluid may flow out Do not operate the clutch control lever if the reservoir plug is loose or has been removed aWARNING Avoid any prolonged exposure of the clutch fluid to ...

Page 54: ...id tank see 2 17 CHECKING AND TOPPING UP THE FRONT BRAKES FLUID and 2 18 CHECKING AND TOPPING UP THE REAR BRAKE FLUID Remove the plastic protection cap Insert a transparent plastic tube on the bleeder 1 on the pump and then on the bleeder 2 or 3 on the cal iper and put the other end of the tube in a container Rapidly pull and release the brake lever several times then keep it completely pulled Loo...

Page 55: ...ND TOPPING UP THE CLUTCH FLUID Remove the left side fairing see 7 1 26 REMOVING THE SIDE FAIRINGS Remove the plastic protection cap Insert a transparent plastic tube on the bleeder 1 and put the other end of the tube in a container Rapidly pull and release the clutch lever several times then keep it completely pulled Loosen the bleeder a quarter turn so that the clutch flu id flows into the contai...

Page 56: ...sure that there is always fluid in the tank during the operation otherwise once finished the brak ing system will need bleeding see 2 20 BLEEDING THE BRAKING SYSTEMS Keep an eye on the tank 2 as the fluid flows out and tighten the bleeder 1 before it empties entirely Top up the tank 2 see 2 17 CHECKING AND TOP PING UP THE FRONT BRAKES FLUID Loosen the bleeder 1 again approx half a turn Watch as th...

Page 57: ... sure that there is always fluid in the tank during the operation otherwise once finished the brak ing system will need bleeding see 2 20 BLEEDING THE BRAKING SYSTEMS Keep an eye on the tank 2 as the fluid flows out and tighten the bleeder 1 before it empties entirely Top up the tank 2 see 2 18 CHECKING AND TOP PING UP THE REAR BRAKE FLUID Loosen the bleeder 1 again approx half a turn Watch as the...

Page 58: ... tighten the bleeder 1 before it empties entirely Top up the tank 2 see 2 19 CHECKING AND TOP PING UP THE CLUTCH FLUID Loosen the bleeder 1 again approx half a turn Watch as the liquid flows out through the tube and as soon as the colour of the fluid starts to change from dark to light tighten the bleeder 1 again and remove the tube Driving torque of bleeder 1 15 Nm 1 5 kgm Refit the rubber protec...

Page 59: ... 0 7 2 The wear of the disc brake pads depends on the use on the kind of drive and on the road NOTE The following information refer to a single brak ing system but are valid for both To carry out a rapid checking of the wear of the pads pro ceed as follows Position the vehicle on the side stand on firm and level ground Carry out a visual check between the disc and the pads proceeding from below on...

Page 60: ...k is encountered adjust the steer ing 2 28 2 ADJUSTING THE BEARING SLACK Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS NOTE The following procedure does not necessarily have to be performed with the front fairing removed though it is advisable to remove it in order to gain more room for manoeuvre see 7 1 20 REMOVING THE FRONT PART OF THE FAIRING Unscrew and remove the screw 1 securing ...

Page 61: ...e lock ring 10 Tightening of lock ring 10 manual until contact 1 4 turn NOTE Bend the tabs of the tab washer 9 upwards Bend the four tabs of the tab washer 9 upwards onto the grooved sectors of the lock ring 10 Refit the upper plate 3 making sure it is correctly housed Lubricate the thread and base on which the bush 8 rests using motor oil see1 6 LUBRICANT CHART Screw on and tighten the upper bush...

Page 62: ...INFORMATIONS Change the front fork oil after the first 7500 km 4687 mi and successively every 22500 km 14000 mi Every 7500 km 4687 mi carry out the following check ing operations With pulled front brake lever press the handlebar re peatedly thrusting the fork downwards The stroke must be gentle and there must be no trace of oil on the rods If the fork tends to bottom out carry out a adjusting see ...

Page 63: ...he adjusting nut 3 one notch at a time Test the vehicle repeatedly on the road until obtaining the optimal adjustment Set the same spring preload and hydraulic braking for both rods a different setting of the rods decreases the stability of the vehicle while riding When the spring preload is increased it is necessary to increase also the hydraulic braking in order to avoid sudden jerks while ridin...

Page 64: ...ht of the forecarriage the following operations require the assistance of another opera tor Agree on the operating procedures in advance The removal must be carried out with the greatest care Grip the forecarriage firmly and lift it slightly in the direc tion in which the sliders 4 are inserted on the two fas tening plates 3 6 Place one or more of the shims between the tyre and the support 1 depen...

Page 65: ...JUSTING THE REAR FORK Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS Position the vehicle on the relevant centre support stand see 1 9 4 SETTING THE VEHICLE ON THE CENTRE SUPPORT STAND Loosen the nut 1 completely NOTE Have the special tool to hand cod 8140203 socket spanner for adjusting fork pin engine mounts Use the special setscrew spanner to loosen the lock ring 2 completely Working...

Page 66: ...nded use of the vehicle aCAUTION For the adjustment always start from the most rigid setting screw adjuster 1 and knob adjuster 2 com pletely rotated clockwise Do not rotate the screw adjuster 1 beyond its limit position to avoid damaging the thread Make sure that the screw adjuster 1 always snaps and is not in any intermediate position Slightly unscrew the locking ring nut 4 by means of the appro...

Page 67: ...void affecting the operation of the shock absorb er neither remove the plug 7 nor adjust the under lying valve since this may cause nitrogen to flow out with consequent risk of accidents clockwise anticlockwise Rear suspension Standard adjustment Adjustment for racetrack use Possible adjustments Shock absorber distance between centers A 322 1 mm 322 1 mm from 320 to 327 mm Spring length preloaded ...

Page 68: ...ns to its original position very slowly check if the rear sus pension is adjusted correctly see 2 31 2 ADJUSTING THE REAR SHOCK ABSORBER If after the adjustment the defect persists this means that the shock absorber bumps through and must therefore be reloaded 2 4 7 Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS Check every 7500 km 4687 mi Position the vehicle on the special front suppo...

Page 69: ...ECK ING THE COMPONENTS If after various spins the wheel continues to stop in the same place the wheel needs balancing 8 534 543 Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS Tighten the exhaust manifold nuts after the first 1000 km 625 mi and then every 7500 km 4687 mi or 8 months aWARNING Allow the engine to cool to room temperature Remove the side fairings see 7 1 26 REMOVING THE SID...

Page 70: ...VE UNIT 2 35 1 CHECKING THE SLACK To check the slack proceed as follows Position the vehicle on the appropriate rear support stand Position the shifting lever in neutral Make sure that the vertical oscillation in an intermedi ate point between pinion and crown in the lower part of the chain is about 25 mm Move the vehicle forwards or turn the wheel in order to be able to check the vertical oscilla...

Page 71: ... 120 Nm 12 0 kgm Check the chain slack see 2 35 1 CHECKING THE SLACK 2 35 4 CLEANING AND LUBRICATION Never wash the chain with water jets steam jets high pressure water jets and highly inflammable solvents Wash the chain with naphtha or kerosene If it tends to rust quickly intensify the maintenance in tervals aCAUTION Do not use trichloroethylene petrol or other similar liquids their dissolving po...

Page 72: ...ylinder see 3 2 3 REMOV ING THE CLUTCH CONTROL CYLINDER Unscrew and remove the three screws 1 Driving torque of screws 1 12 Nm 1 2 kgm NOTE Release the cable of the side stand switch from the clip Remove the pinion protection case 2 Remove the guide plate 3 Make sure the guide plate 3 is not worn or damaged if so replace with a new one 2 35 6 INSPECTING THE DRIVING CHAIN SHOE Position the vehicle ...

Page 73: ... INFLATION PRESSURE aCAUTION Periodically check the tyre inflation pressure at room temperature If the tyres are hot the measurement is not correct Carry out the measurement especially before and af ter long rides If the inflation pressure is too high the ground une venness cannot be dampened and is therefore trans mitted to the handlebar thus compromising the driv ing comfort and reducing the roa...

Page 74: ... release coupling 3 is properly inserted in the receptacle 4 For further details see section 4 FUEL SYSTEM 2 54 0 0 3 Carefully read 1 2 4 BRAKE FLUID and 1 2 6 CLUTCH FLUID Check the pipes every 7500 km 4687 mi or 8 months Replace every four years If you should encounter signs of wear cracking etc replace the pipes 3934 0 0 3 Carefully read 1 2 5 COOLANT Check the cooling system pipes every 7500 ...

Page 75: ...safety i e right left handlebar front brake lever clutch lever fuel delivery pipe front fork to plates front fork wheel pin clamps front wheel front brake pipe fittings front brake discs front brake calipers engine pinion rear brake lever rear fork rear fork leverage rear shock absorber rear wheel rear brake disc rear brake caliper rear brake pipe fittings aCAUTION The fastening elements must be t...

Page 76: ...ion fastening 1 M10 50 5 0 L243 Clutch control cylinder fastening 3 M6 12 1 2 Pinion case fastening 3 M6 6 0 6 Fastening of fuel delivery pipe to throttle body 1 M12x1 5 22 2 2 Coolant drain screw 1 M6 10 1 0 Coolant thermistors 2 M14 30 3 0 Carter Description Q ty Screw nut Nm kgm Note Grooved ball bearings for selector roller MS casing 1 Screw T P M6 x 13 11 1 1 L243 Grooved ball bearings for se...

Page 77: ...ion Q ty Screw nut Nm kgm Note Camshaft support head 1 front 8 Screw T C E I M6 x 30 11 1 1 Head 1 front 2 Exhaust pipe M18 x 1 5 Manual tightening L243 Head 2 rear 1 Exhaust pipe M18 x 1 5 Manual tightening L243 Camshaft support head 2 rear 4 Screw T C E I M6 x 30 11 1 1 Camshaft support head 2 rear 2 Screw T C E I M6 x 45 11 1 1 Camshaft support head 2 rear 2 Screw T C E I M6 x 55 11 1 1 Head 2 ...

Page 78: ...netic gear unidirectional case L648 Free wheel flange 3 Screw T C E I M8 x 16 30 3 0 L648 Magnetic gear cone L648 Ignition driving shaft 1 Screw T C E I M16 x 30 130 13 0 L648 Ignition device cover MS casing 12 Screw T C E I M6 x 35 11 1 1 Ignition device cover 1 Plug screw M24 x 1 5 3 0 3 Camshaft position sensor head 1 front 2 Taptite screw M5 x 12 4 0 4 L243 Starter motor 2 Screw T C E I M6 x 3...

Page 79: ...sorber Description Q ty Screw nut Nm kgm Note Fastening of shock absorber to frame 1 M10 50 5 0 Linkage Description Q ty Screw nut Nm kgm Note Fastening of single connecting rod to frame 1 M10 50 5 0 Fastening of single double connecting rod to frame 1 M10 50 5 0 Fastening of double connecting rod fork 1 M10 50 5 0 Fastening of double connecting rod shock absorber 1 M10 50 5 0 ELECTRICAL SYSTEM De...

Page 80: ...lectrofan motor to mount 3 3 M4 2 0 2 L243 Radiator coolant drain screws 1 1 M6 10 1 0 L572 Fastening of expansion tank to coils mount 2 M6 10 1 0 Fastening of expansion tank cap 1 M28x3 man Fastening of coolant filler neck 1 M6 10 1 0 BRAKING SYSTEMS Front system Description Q ty Screw nut Nm kgm Note Fastening of right and left brake caliper 2 2 M10x1 25 50 5 0 Fastening of brake fluid tank 1 M6...

Page 81: ...Fastening of electric terminals on flange 2 M5 5 0 5 Closing of fuel return 1 M6 10 1 0 L243 Fastening of fuel delivery pipe on flange 1 M12x1 5 22 2 2 Petrol level sensor on pump mount 2 SWP 2 9x12 1 5 0 15 Fastening of fuel pump cables on flange 2 M6 10 1 0 Tank Description Q ty Screw nut Nm kgm Note Fastening of cap on tank 3 M5 5 0 5 Fastening of fuel pump flange on tank 8 M5 7 0 7 Fastening o...

Page 82: ...ng of silencer protection to lower fairing 2 M6 5 0 5 Fastening of sides 4 M6 5 0 5 Fastening of saddle support bush and lower moulded cover 2 M6 5 0 5 Fastening of saddle support lower moulded cover 4 M6 4 0 4 Fastening of rear fairing to saddle support lower moulded cover 6 M5 2 0 2 Fastening of rear fairing end to rear fairing 2 2 M5 upper 5 lower 3 0 5 0 3 Fastening of rear fairing passenger g...

Page 83: ...TROLS Description Q ty Screw nut Nm kgm Note Fastening of anti vibration weights 2 M6 12 1 2 Anti vibration weights metal ring 2 M18x1 35 3 5 Fastening of right left handlebars to the fork 2 M8 25 2 5 Handlebars lock screw 2 M6 12 1 2 Fastening of left dimmer switch 1 M5 1 5 0 15 Fastening of right dimmer switch 1 M4 1 0 1 Fastening of front brake lever 2 M5 8 0 8 Fastening of clutch lever 2 M5 8 ...

Page 84: ...3 1 RSV mille 1 3 ENGINE 3 ...

Page 85: ... 6 13 REPLACING AND INSTALLING THE CONNECTING RODS 3 51 3 6 14 COUNTERSHAFT AND COUNTERSHAFT MECHANISM 3 52 3 6 15 GEARSHIFT 3 53 3 6 16 GEAR SELECTION 3 58 3 6 17 CLUTCH AND PRIMARY TRANSMISSION ASSEMBLY 3 59 3 6 18 DISASSEMBLING THE COMPLETE CLUTCH HOUSING 3 61 3 6 19 CLUTCH COVER 3 62 3 6 20 SUPPORT BUSHES 3 62 3 6 21 COOLANT PUMP 3 64 3 6 22 TIMING DRIVE ASSEMBLY 3 66 3 6 23 HEAD AND CAMSHAFT ...

Page 86: ...CE AND REPAIR WORK aWARNING During the assembly phase bear in mind the engines weight approx 65 kg and centre of gravity support accordingly Take care around any potentially hazardous points where you might be squashed or cut aCAUTION The maintenance of engines and systems calls for specific experience and the use of special tools Any maintenance and repair work must be performed by suitably train...

Page 87: ...3 DISASSEMBLING CYL INDER 1 FRONT HEAD AND PISTON Tappet cover 2 head cylinder and rear piston see 3 5 4 DISASSEMBLING CYLINDER 2 REAR HEAD AND PISTON Front 3 and rear 4 cylinder intake flange Camshaft position sensor and camshafts see 3 6 23 HEAD AND CAMSHAFTS DISASSEMBLY Chain chain tightener and front and rear cylinder tim ing drive assembly see 3 5 6 DISASSEMBLING CYLINDER 1 FRONT TIMING DRIVE...

Page 88: ...LTER Neutral gear switch 11 Clutch control cylinder 12 see 3 2 3 REMOVING THE CLUTCH CONTROL CYLINDER Flywheel cover 13 and ignition system see 3 5 5 REMOVING THE FLYWHEEL COVER AND IGNI TION SYSTEM Engine oil tank 14 see 7 1 49 REMOVING THE EN GINE OIL TANK RIGHT SIDE Front cylinder coolant thermistor 15 see 5 5 RE MOVING THE COOLANT THERMISTORS Front cylinder spark plugs 16 17 see 2 7 SPARK PLUG...

Page 89: ...o the rear cylinder Driving torque of nuts 6 25 Nm 2 5 kgm aCAUTION When slipping the exhaust pipes 5 7 off the rele vant cylinders take care not to damage the thread of the fastening stud bolts Move the exhaust manifold 3 together with the ex haust pipe 7 back and slightly downwards until the exhaust pipes flange is released from the stud bolts on the rear cylinder Twisting gradually one way and ...

Page 90: ...ONS and 1 2 6 CLUTCH FLUID Remove the left side fairing see 7 1 26 REMOVING THE SIDE FAIRINGS Unscrew and remove the screws 3 Driving torque of screws 3 12 Nm 1 2 kgm Slide off the cylinder 4 aCAUTION Perform the operations with the utmost care the cyl inder 4 remains connected to the pipe Once the cylinder 4 has been removed do not pull the clutch lever as the piston is liable to come out of its ...

Page 91: ...he job must therefore be gathered and set in place before hand Dry weight of the engine 65 kg Turn the ignition switch to position m Position the vehicle on the relevant rear support stands Disconnect the negative cable and positive cable from the battery in that order aCAUTION When refitting first connect the positive cable and then the negative one Remove the fuel tank see 7 1 5 COMPLETE REMOV A...

Page 92: ...n place taking ex treme care as it remains connected to the electric ca ble by means of the brake light switch 12 Remove the rear brake pump 13 see 7 6 4 REMOV ING THE BRAKE PUMP aCAUTION Move the rear brake pump 13 and secure it in place taking extreme care as it remains connected to the brake fluid pipes The brake fluid tank 14 must be held vertically to prevent the fluid spilling out Remove the...

Page 93: ... compo nents Clean the outside of the engine thoroughly Remove the exhaust pipes see 3 2 1 REMOVING THE EXHAUST PIPES Disconnect the electric connector 20 from the elec trofan Disconnect the electric cables from the horn aCAUTION When refitting make sure the electric connectors are plugged in properly aCAUTION Mark the coupling and pipes so as to prevent them being swapped over by mistake during r...

Page 94: ...al expansion valve 28 see 5 6 REMOVING THE THERMAL EXPANSION VALVE together with the three couplings Slip the coupling 29 off the coolant pump aCAUTION Free all the cables and pipes from the respective clamps located at intervals along their routes Procure an equal number of clamps to be used for re fitting Plug all openings on the engine pipes and couplings to prevent foreign bodies getting in Ga...

Page 95: ...safely bearing the weight of the engine The engine weight approx 65 kg Fasten the special engine lifting hook on and secure it in place with the screws 30 Hook the bands 34 onto the hoist 33 and the hook 32 as illustrated aWARNING The entire engine and hoist setup must be stable en suring that the subsequent operations can be per formed safety Lift the hoist arm 33 until the bands 34 are taught aC...

Page 96: ...ENGINE 3 13 RSV mille NOTE The elements fastening the engine to the frame must be removed in the order given RIGHT SIDE A B C D LEFT SIDE E F G H ...

Page 97: ...inside nut 39 still loosen the screw 40 Driving torque of nut 39 and screw 40 50 Nm 5 0 kgm Unscrew and remove the two screws 43 and recover the relevant washers 44 Driving torque of screws 43 40 Nm 4 0 kgm Recover the two spacers 45 Unscrew and remove the two screws 46 and recover the washers 47 Driving torque of screws 46 40 Nm 4 0 kgm ...

Page 98: ...ssembling screw the adjusting bushes 38 42 on by hand all the way until they touch the engine before torquing them to specification Holding the inside nut 35 still loosen and remove the screw 36 Holding the inside nut 39 still loosen and remove the screw 40 Holding the inside nut 51 still loosen and remove the screw 52 Driving torque of nut 51 and screw 52 50 Nm 5 0 kgm Holding the inside nut 48 s...

Page 99: ...over if poorly balanced Unhook the bands 34 from the hoist Slide the bands 34 out from the frame Move the engine from under the frame Hook the bands 34 back up to the engine NOTE If the engine is to be worked on set it on the rel evant stand 54 cod 8140187 8140188 aCAUTION If no work is to be performed on the engine leave it rested on the floor and attached to the bands 34 and hoist for extra safe...

Page 100: ...the coolant see 2 15 CHECKING AND TOP PING UP COOLANT Top up the motor oil see 2 13 CHECKING THE EN GINE OIL LEVEL AND TOPPING UP If the engine has been overhauled bleed the engine oil circuit see 3 8 1 BLEEDING THE ENGINE OIL CIR CUIT and check the engine oil pressure 3 8 2 CHECKING THE ENGINE OIL PRESSURE Check the driving chain is taught and where neces sary adjust see 2 35 1 CHECKING THE SLACK...

Page 101: ...n the right place NOTE Before going ahead with the disassembly of the engine gather the appropriate special tools see 1 8 2 ENGINE TOOLS 3 5 1 ENGINE DISASSEMBLY SEQUENCE NOTE This diagram shows the operations to be per formed and the sequence to be followed when disassem bling the engine parts In order to remove the parts outlined with short dashes the engine must be removed from the frame ...

Page 102: ...chain 30 Cylinder 2 timing drive gears 31 Complete support plate and disengagement rod 32 Cylinder 1 head 33 Cylinder 1 head with cylinder 34 Cylinder 2 top side countershaft 35 Cylinder 2 timing chain 36 Clutch discs 37 Cylinder 1 camshafts 38 Cylinder 1 piston 39 Cylinder 2 camshafts 40 Cylinder 2 head with cylinder 41 Cylinder 2 head 42 Primary transmission 43 Cylinder 1 valves 44 Cylinder 2 pi...

Page 103: ...STON Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS aCAUTION The head must be disassembled together with the cylinder This is the only way in which the head can be de tached from the actual cylinder Remove the two spark plugs 3 from the head see 2 7 SPARK PLUGS Unscrew and remove the five complete M6 spacer screws 4 and remove the head cover 5 together with the respective gasket Unscrew...

Page 104: ...stening slot NOTE Turn the driving shaft both ways to make sure that the threaded bolt is engaged perfectly The bolt should not be overtightened max 5 Nm 0 5 kgm Unscrew and remove the closing screw 15 complete with seal 16 and remove the complete chain tightener 17 Unscrew and remove the two M6 spacer screws 18 and remove the chain guide bracket 19 Unscrew and remove the three M6x10 T C E I screw...

Page 105: ... slot and pull out the two locating dowels 29 aCAUTION Do not apply any mechanical markings Use a felt pen to mark the piston crown on the exhaust side 30 to remind you which direction it should be re assembled in In the same way mark both the piston and the cylinder with a 1 so that the two components can be recon nected in the same point aCAUTION In order to prevent unbalanced forces the axis of...

Page 106: ... driving shaft guide the connecting rod and timing chain of cylinder 1 so as to prevent them from getting stuck inside the housing Use a size 14 bent hexagon head driver 5 to turn the driving shaft anticlockwise approx 300 so that piston 2 is at TDC ignition NOTE At the TDC ignition the reference marks IN 6 and EX 7 of the two gears prove parallel to the head uncoupling surface and face each other...

Page 107: ... remove the three M6 x 14 T C E I screws 16A Unscrew and remove the closing screw 17 complete with seal 18 and remove the complete chain tightener 19 Pull the chain guide shoe 20 out from above Unscrew and remove the two M6 T C E I screws 21 with the relevant washers and remove the chain guide 22 Remove both the driving gear 14 and the two gears 23 Unscrew and remove the two M6 T C E I screws 23A ...

Page 108: ...g in the base with a clean cloth Remove the cylinder base gasket from its slot and pull out the two locating dowels 30 aCAUTION Do not apply any mechanical markings Use a felt pen to mark the piston crown on the exhaust side 31 to remind you which direction it should be as sembled in In the same way mark both the piston and the cylinder with a 1 so that the two components can be recon nected in th...

Page 109: ... cod 0277252 tool for disassembling the flywheel cover Screw the special tool 2 onto the flywheel cover 3 Lift the flywheel cover 3 Remove the gasket 4 NOTE The driving shaft must be retained at the TDC of piston 1 or piston 2 Unscrew and remove the M14 T C E I screw 5 and remove the washer 6 NOTE Have the appropriate special tool 7 to hand cod 0277780 flywheel removal bolt Screw the special tool ...

Page 110: ... still fitted on the engine In order to remove the timing chain 14 the chain tightener and camshaft gears must be removed see 3 5 3 DISASSEMBLING CYLINDER 1 FRONT HEAD AND PISTON NOTE During disassembly of the roller bearing flange 9 there is no need to remove the components 10 11 12 from the actual flange Pull out the spacer bush 10 the two locating dowels 11 and two roller bearings 12 NOTE As of...

Page 111: ...ving the engine from the frame Unscrew and remove the M10 T E screw 1 Remove the washer 2 the spring washer 3 and the pinion 4 NOTE Where necessary use the universal sleeve pull er to remove the pinion taking care not to damage the secondary shaft Unscrew and remove the two M6 T C E I screws 5 Remove the cover of the oil filter 6 and the O ring 7 Remove the oil filter cartridge 8 from the filter h...

Page 112: ...clutch disengaging shaft must be held still with a bent hexagon head driver Unscrew and remove the four M6 T C E I screws 10 and remove the coolant pump casing 11 complete with shaped seal NOTE The lower T C E I screw 12 coolant drain plug also features a seal See 3 6 21 COOLANT PUMP for instructions on disas sembling the coolant pump NOTE If the M8 T C E I screw 15 has not been previ ously remove...

Page 113: ... Remove the lined discs 6 and steel discs 7 from the clutch housing 8 NOTE Have the appropriate special tool 10 to hand cod 0277881 clutch blocking tool Insert the clutch blocking tool 10 in the clutch housing 8 and on the clutch hub 11 aCAUTION Insert the clutch blocking tool all the way into the clutch drum so as not to damage the basket when loosening the T E nut Unscrew and remove the M24x1 5 ...

Page 114: ...w and remove the M22x1 5 T E nut 1 remove the spring washer 2 and countershaft counterweight 3 Unscrew and remove the M33x1 5 T E nut 4 and re move the spring washer 5 Remove the drive gear 6 from the driving shaft Remove the differential gears 7 from the driving shaft and countershaft together Detach the key 8 the upper washer 9 and coolant pump gear 10 from the countershaft Remove the coolant pu...

Page 115: ...g chain 10 the chain tightener and camshaft gears must be removed see 3 5 4 DISASSEMBLING CYLINDER 2 REAR HEAD AND PISTON Remove the complete roller bearing flange 4 together with the two calibrated bushes 5 and spacer bush 6 Remove the chain tightener shoe 7 pulling it out from above Remove the two roller bearings 8 Remove the intermediate drive gear 9 and timing chain 10 pulling both out togethe...

Page 116: ...id out through the slot on the pump cover 5 Slide the pin 3 out of the oil pump shaft 4 Unscrew and remove the four M6 T C E I screws 6 and remove the complete oil pump 7 from the engine casing aWARNING When removing the whole oil pump 7 it is advisable to leave the inside rotor 8 and pin 9 fitted since there is a danger of the pin 9 falling into the oil sump Remove the suction pumps external roto...

Page 117: ...ng shafts by hand to enable the gear to engage Engage 6th gear Remove the complete selector shaft 2 Unscrew and remove the M6 T C E I screw 3 and re move the index plate 4 NOTE Use a screwdriver to push the complete posi tioning lever 5 down to make it easier to remove the in dex plate Unscrew and remove the M6 T C E I screw 6 and re move the washer 7 positioning lever 5 graduated ring 8 and posit...

Page 118: ...use a screwdriver inserted in the appropriate points 4 to help prise them apart Take your time and work with extreme care Never strike the gasket surface Do not use excessive force Should it prove impossible to separate the two halves of the casing check for any screws which have not been loosened NOTE When lifting the engine half casing the wash ers of the secondary shaft may be attached on the i...

Page 119: ...tor cylinder Push the 3rd and 4th gear selector gear 7 upwards and remove the fork 5 from the primary shaft Set the engine half casing upright on the assembly bench NOTE Keep both the secondary shaft and primary shaft still with one hand whilst tapping the secondary shaft 3 with a plastic hammer working from the outside This forces the two shafts out of their relevant housings complete with the ge...

Page 120: ...ing housings thoroughly with a gentle solvent Clean all the gasket surfaces and check for damage NOTE Place the two halves of the engine half casing on a flat surface to prevent damage Make sure the two halves of the engine half casing do not feature cracks or signs of damage Make sure all the threads are in a perfect state of repair Make sure all the oil seals remaining in their slots are not wor...

Page 121: ...r in all the lubrication holes 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 in the two halves of the casing and where necessary clean them by blowing a jet of compressed air inside 3 6 2 ENGINE HALF CASING CLUTCH SIDE 3 6 3 ENGINE HALF CASING FLYWHEEL SIDE ...

Page 122: ... As a rule the disassembled oil seals should be replaced Unscrew and remove the M6 FH screws 4 securing the ball bearings Remove the M6 x 13 flanged head screw 5 NOTE In order to avoid damaging the gasket surface an old engine casing gasket should be placed under neath the puller plate Remove the primary shaft ball bearings 6 with the aid of a universal sleeve puller 7 Remove the ball bearings usi...

Page 123: ...way in on the inner ring using a suitable as sembly punch Apply LOCTITE 243 on the screws 4 5 securing the ball bearings and screw them into the engine casing Driving torque of M6 T P screw 4 11 Nm 1 1 kgm Driving torque of M5x10 flanged head screw 5 11 Nm 1 1 kgm NOTE Have the appropriate special tools below to hand 13 cod 8140070 handle for pads 14 cod 0277680 gearshift secondary shaft oil seal ...

Page 124: ...ON Take a number of measurements especially in the di rection of the axis of both cylinders None of the val ues must exceed the limit value aCAUTION Measure the radial play of the driving shaft and coun tershaft see 3 6 11 DRIVING SHAFT and 3 6 14 COUNTERSHAFT AND COUNTERSHAFT MECHA NISM Check for signs of wear or slipping on the axial thrust bearing surfaces 3 4 for the driving shaft in both halv...

Page 125: ...iving shaft sleeve puller pad 9 cod 2777530 countershaft sleeve puller pad Heat the engine casing to approx 150 C 302 F for approx fifteen minutes Remove the main bushes from the inside out setting them on a press and using the assembly pads 8 9 aCAUTION In order to insert and remove the main bushes the engine casing must be supported by applying a spac er tube around the main bush housing on the ...

Page 126: ...lied on the engine casing is no longer clearly legible calculate the diameter based on the average of a number of different measurements aCAUTION Take a number of measurements especially in the di rection of the axis of both cylinders M MOLYKOTE G N Driving shaft Hole in the engine casing Main bushes marking Engine casing marking Ø49 899 Ø49 908 mm red red Ø49 908 Ø49 918 mm blue blue Ø49 918 Ø49 ...

Page 127: ...uch es Remove the O ring 14 before the installer punch makes contact aCAUTION In order to insert and remove the main bushes the engine casing must be supported by applying a spac er tube around the main bush housing The lower main bush of the driving shaft flywheel side features a lubrication hole 11 Once assembled make sure the lubrication hole 11 on the main bush is lined up with the engine casi...

Page 128: ...lindrical pin prove worn during disassem bly heat the peripheral range of the cylindrical pin slot on the outer wall of the engine half casing with a jet of hot air 4 approx 100 C 212 F next pull the cylin drical pin out with a pair of pliers rotating it upwards ASSEMBLY With due care insert the cylindrical pins all the way in using a plastic hammer Coat the cylindrical pin 3 of the coolant pump i...

Page 129: ...all the way Driving torque of stud bolt 3 10 Nm 1 0 kgm Screw on the nozzle 4 Fasten the M6 T C E I screw 5 together with the seal 6 Driving torque of screw 5 6 Nm 0 6 kgm Insert the oil gauze 7 3 6 9 COMPLETE OIL SPRAY PIPE Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS DISASSEMBLY Heat the peripheral range of the oil spray pipe 8 on the engine casing using a jet of hot air approx 100 ...

Page 130: ... gear 1 is attached to the support plate of the complete clutch housing TAKING THE OIL PUMP APART Remove the suction pumps internal rotor 3 from the oil pump shaft Remove the pin 4 Slip off the oil pump lid 5 and pin 6 Remove the pressure pumps external rotor 7 Remove the oil pump shaft 8 from the pressure pump casing 9 Remove the pressure pumps internal rotor 10 and pin 11 Unscrew the plug 12 and...

Page 131: ...ve component must be replaced Make sure the adjusting piston 14 slides smoothly in the oil pump lid Check the adjusting piston and oil pump lid for any signs of wear adjusting piston 14 wear limit 18 min Ø 9 975 mm oil pump lid 5 wear limit 19 max Ø 10 035 mm compression spring 13 minimum lenght of the spring 20 when not com pressed 56 0 mm Engage the adjusting piston 14 with the cone end fac ing ...

Page 132: ...is exceeded the worn part must be replaced The radial play is determined based on the following values maximum value of the main bushes diameter in the en gine casing minus the driving shaft diameter at the main bush housing Measure the main bush diameter see 3 6 5 ENGINE HALF CASING MAIN BUSHES DRIVING SHAFT AND COUNTERSHAFT Measure the radial play of the support bushes 2 Permissible radial play ...

Page 133: ...ear limit max Ø 42 050 mm aCAUTION Measure the diameter of the connecting rod big end Fasten the cover 2 with the connecting rod M10x1 screws 3 Driving torque screws 3 see 3 6 13 REPLACING AND INSTALLING THE CONNECTING RODS aCAUTION The fastening of the connecting rod M10x1 screws 3 will require the use of a setting dial 7 and a fitting for a size 12 socket spanner NOTE None of the values may exce...

Page 134: ...0 Nm 3 0 kgm 3rd final tightening phase tighten the two screws by 70 aCAUTION The fastening of the M10x1 screws 7 will require the use of a goniometer 8 and a ring socket spanner Measure the radial play 9 of the connecting rod end with a comparator Radial play 0 020 0 045 mm If the radial play is greater than 0 045 mm the bushes of the size corresponding to the colours blue or yellow must be chose...

Page 135: ... 6 5 ENGINE HALF CASING MAIN BUSHES DRIVING SHAFT AND COUNTERSHAFT and 3 5 8 REMOVING THE CLUTCH COVER NOTE If the max permissible radial play is exceeded the worn part must be replaced Permissible radial play of the countershaft max 0 30 mm NOTE Once the two halves of the engine casing have been coupled check the end play of the countershaft with a comparator The following components must also be...

Page 136: ...RMATIONS aCAUTION When taking the gearshift apart set the disassem bled components down according to the assembly position assigning them to the corresponding shaft so as to be sure they are reassembled and installed correctly Following disassembly the seeger rings must always be replaced ...

Page 137: ...tarting with the idle gear of 1st gear 1 and then mov ing on to the shim washers 2 roller cages 3 seeger rings 4 and shim rings 5 Primary shaft Use crimpers to remove the seeger rings 7 Remove the gears from the primary shaft starting with the fixed gear of 2nd gear 6 and then moving on to the seeger rings 7 shim rings 8 the roller bearing 9 and shim washer 10 ...

Page 138: ...es surface area engagement teeth 3 and mating slots of gearshift gears profile for spline shafts 4 of the secondary shaft and primary shaft check all the gear selection gears 5 both on the sec ondary shaft and primary shaft slide smoothly housings of the idle gear bearings 6 triangular tooth profile 7 of the chain pinion the grooves for seeger rings 8 on the secondary shaft and on the primary shaf...

Page 139: ...replaced Should the engagement teeth or mating slots prove worn the relevant gears must be replaced mating with each other Check the internal diameter of the idle gears of 3rd 4th and 6th gear Wear limit 16 max Ø 29 022 mm Check for any signs of rolling or grooves on the bushes of the idle gears of 2nd 17 and 5th gear and measure the in ternal diameter of the gears Check for any signs of rolling o...

Page 140: ...N Do not reuse the seeger rings The seeger rings must be replaced every time the gearshift is taken apart Pull the ends of the seeger rings apart just enough to be able to slide the ring onto the shaft If the seeger ring is pulled apart two much its locking effect is irreparably reduced Make sure the seeger rings are properly installed in the corresponding groove Once the two gearshift shafts have...

Page 141: ...ring surfac es of the gearshift forks Wear limit max 3 950 mm NOTE If the chromium finish is missing in some points replace the fork in question Check the diameters 4 of the gearshift fork guide pins Wear limit min Ø 5 850 mm Check the eccentricity of the two fork shafts 5 Max permissible eccentricity 0 02 mm Check the wear of the ratchet gear in the area in which it comes into contact with the in...

Page 142: ...ature grooves or temper colours Measure the width 4 of the driving element and the thickness of the lined discs 1 Measure the set of the nine lined discs Wear limit min 30 9 mm Measure the set of discs with all the discs together 5 made up of 10 steel discs and 9 lined discs Wear limit 5 min 46 3 mm Measure the length of the individual clutch springs 6 in the released position Wear limit 6 min 44 ...

Page 143: ...Check the eccentricity of the disengaging shaft 11 also checking for signs of rolling on the oil seal sliding surface Check the diaphragm 12 for cracks and where nec essary replace it Check the guide grooves on the clutch housing 13 and the external toothing of the clutch hub 14 for any dents 15 Max dent depth 15 0 3 mm Check the bush of the clutch gear 16 for grooves and damage measure the intern...

Page 144: ...E You are strongly recommended to replace all the compression springs 5 and spring pins 6 together Measure the length of the spring housing in the clutch housing 9 Wear limit 10 max 32 65 mm ASSEMBLY Insert the washer 8 and the spring washer 7 on the clutch housing 9 aCAUTION Make sure the spring washer is positioned correctly Fit it with the concavity facing the clutch gear 4 Place the clutch gea...

Page 145: ...aCAUTION Take a number of measurements especially in the di rection of the axis of both cylinders None of the values must exceed the limit value Measure the radial play of the driving shaft and coun tershaft see 3 6 5 ENGINE HALF CASING MAIN BUSHES DRIVING SHAFT AND COUNTERSHAFT 3 6 20 SUPPORT BUSHES Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS DISASSEMBLY Mark the contact surface 3 o...

Page 146: ...727 clutch cover driving shaft bush in serter pad 7 cod 0277729 main countershaft bush inserter pad Place the driving shaft and countershaft main bushes on the inserter pads 6 7 using a suitable O ring 8 to hold them in place Line up the contact surface of the main bushes with the previously applied coloured marking 3 With due care insert the main bushes on a press until the installer punch touche...

Page 147: ... clutch cover for the purpose of disassembly Remove the oil seal 7 together with the sliding seal ing ring 8 with a hole punch 9 INSPECTION Check the impeller 3 for signs of damage or distortion and where necessary replace it Check the coolant pump shaft 6 for signs of rolling around the oil seal sliding area and where necessary replace it Measure the coolant pump shaft housing slot 10 on the clut...

Page 148: ...itted so that it faces the impeller 3 Insert the sliding sealing ring 8 all the way in using the assembly pad aCAUTION Take care not to damage the impeller 3 Screw the impeller 3 firmly onto the coolant pump shaft 6 Coat the coolant pump shaft 6 with MOLYKOTE G N and insert it from the outside all the way onto the oil seal assembly Install the washer 5 on the coolant pump shaft Install the pin 4 i...

Page 149: ...ck the slots of the idler gears 3 for wear Wear limit 4 max 20 015 mm Check the roller bearings 5 for wear Check the two bearing flanges 6 for wear around the sliding area of the roller bearings 5 Wear limit 7 max 15 98 mm Check the chain guide shoe 8 chain tightener shoe 9 chain guide 10 and chain guide bracket 11 for any traces of rolling Max depth of the rolling traces 1 2 mm Check the teeth of...

Page 150: ...ve washers 3 from head 2 and remove the chain guide 4 and the bush plate 5 Remove the upper countershaft 6 from head 2 nscrew and remove the eight M6 T C E I screws 7 together with the respective washers 8 and remove the camshaft U bolt 9 from head 1 and 2 Remove the intake camshaft 10 and exhaust cam shaft 11 from head 1 and 2 NOTE Set the disassembled components aside in groups according to the ...

Page 151: ...e valve springs 3 4 using the clamping bow 5 and a valve spring compressor fitting 6 and remove the valve cotters 7 Release the valve springs 3 4 Remove the valve spring housings 8 of the two valve springs 3 4 and remove the valves 9 Clean the combustion chamber removing the residual combustion products and the deposits from the cooling cavity Check the thread of the spark plugs and the fastening ...

Page 152: ...gauge with the corresponding graduated scale 3 Wear limit max 0 060 mm If the wear limit is exceeded the bush housings on the camshafts and on the head must be measured and the worn part replaced Camshaft bush housings wear limit 4 min Ø 23 950 mm Head bush housings wear limit max Ø 24 040 mm Insert the intake and exhaust camshafts in the respec tive housings in the head and measure the end play w...

Page 153: ...70 mm If the maximum permissible radial play is exceeded the worn part must be replaced NOTE Should the bushes be worn the whole bush plate must be replaced Install the countershaft in the head 2 rear and meas ure the end play with a comparator Wear limit max 0 040 mm NOTE If the end play wear limit is exceeded replace the bush plate Install the countershaft in head 2 see 3 7 12 AS SEMBLING HEAD 2...

Page 154: ... and with the expansion sleeve suitable for the bearing NOTE As a rule the ball bearings and the oil seals should be replaced Lift the oil seal 5 NOTE Before assembling oil the external diameter of the oil seal slightly The closed side of the oil seal must face outwards Grease the sealing lips aCAUTION In order to avoid damaging the ball bearing under no circumstances should the oil seal touch the...

Page 155: ...seal 3 To eliminate the valve guide with a reamer 5 as far as the start of the notch 6 NOTE The sharp edge of the valve guide must be elim inated as otherwise the head slot is in danger of being to slide when the valve guide is removed Have the appropriate special tool 7 to hand cod 0277510 valve guide disassembly pad NOTE Do not heat the head Use the pad 7 to remove the rest of the guide valve in...

Page 156: ...hat the intake valve guide has a longer smoothed surface 9 Check how much the head 10 of the valve guide pro trudes on the camshaft side 10 Protrusion 13 3 0 2 mm Bore the valve guide with a 6 F7 reamer Hole of the valve guide Ø 6 006 6 018 mm NOTE Use cutting fluid only to lubricate the reamer The reamer should only be turned in the cutting direction never in the opposite direction and cleaned of...

Page 157: ...ere necessary replace it Check the diameter of the stem with a micrometer intake valve wear limit 2 min Ø 5 950 mm exhaust valve wear limit 2 min Ø 5 935 mm Check the eccentricity of the valve valve stem permissible eccentricity 3 max 0 05 mm valve head permissible eccentricity 4 max 0 05 mm Check whether the fastening grooves 5 of the valve cotters are in a perfect state of repair VALVE SPRINGS M...

Page 158: ...ntinuous the valve seat can be ground GRINDING THE VALVE SEATS A intake B exhaust NOTE The valve seats can be ground with a valve seat grinding device centred in the valve guide Perform grinding at 45 with the valve seat grinding de vice until the whole valve seat is covered in tailing During this operation make sure no more material than necessary is removed Lastly grind at 35 until the given dia...

Page 159: ...Bosch or Sun tester NOTE If the pressure loss is less than 7 this means valve tightness is correct Fit the valve springs 5 6 and valve spring caps 7 NOTE The intake and exhaust valve springs are identi cal but must always be fitted so that the coloured mark ing is at the top since the winding of the springs is pro gressive Preload the valve springs with the spring compressor 8 and special clamping...

Page 160: ... any lime scale Measure the bore of the cylinder in 3 places at a dis tance of 45 mm from the upper edge 1 consider the highest value for the wear limit Cylinder A dimension when new bore Ø 97 000 97 012 mm wear limit max Ø 97 027 mm Cylinder B dimension when new bore Ø 97 012 97 025 mm wear limit max Ø 97 040 mm NOTE The size group A or B is punched onto the lower side of the cylinder 2 NOTE In o...

Page 161: ...on play measurement piston play cylinder diameter minus piston diam eter wear limit max 0 090 mm NOTE If the wear limit is exceeded a new piston must be used or the cylinder replaced complete with piston If the piston is replaced the two seeger rings securing the gudgeon pins must always be replaced along with the actual gudgeon pins Take special care when matching the cylinder pis ton Red piston ...

Page 162: ...tapered protruding ring 12 and the L section ring 13 to make sure the sliding surface is cleaned Measure the piston ring gap 14 with a feeler gauge wear limit max 1 00 mm NOTE In order to measure the gap required insert the piston ring in the cylinder and push it inside so that it is lined up with the piston The cylinder bore must not feature any signs of wear Measure the thickness of the rings wi...

Page 163: ...ameter Double starter gear wear limit 4 max Ø 10 10 mm Idler gear wear limit 5 max Ø 10 08 mm Freewheel gear 6 wear limit max Ø 35 07 mm NOTE The bush inside the freewheel gear 3 must be inserted so that it is fixed and unable to move freely Should signs of distortion be encountered on the sliding surface or materials found to be broken the freewheel gear must be replaced Check the sliding surface...

Page 164: ...ooves the freewheel housing must be replaced FREEWHEEL HOUSING DISASSEMBLY Unscrew and remove the three M8x16 T C E I screws 12 and detach the freewheel housing 11 from the magnetic wheel 13 FREEWHEEL HOUSING ASSEMBLY aCAUTION Use LOCTITE 648 on the flat surface of the housing 11 Apply a coat of LOCTITE 648 on the flat surface of the freewheel housing 11 and place it in the centre of the magnetic ...

Page 165: ...alternating cur rent which is then transformed into direct current by the regulator rectifier which then charges the battery aWARNING Before performing any repair work on the ignition generator take out the ignition key and disconnect the battery disconnecting the negative pole first Take care around the high voltage in the ignition gen erator ...

Page 166: ...e cable bracket 6 Check the flywheel cover 7 is flat and make sure it features no signs of damage on the gasket surfaces Assembling the stator Insert the stator in the flywheel cover and fasten it with the three M6 T C E I screws 2 coating the screws with LOCTITE 243 Driving torque 11 Nm 1 1 kgm Coat the cable rubber 8 with SILASTIC 732 RTV and place it in the ignition cover Coat the two screws 3 ...

Page 167: ...r motor is not normally subject to any particular wear and tear In the event the carbon brushes are worn they can be re placed using the available repair kit if not replace the complete starter motor Check the starter motors toothing 4 for broken materi als wear and distortion NOTE Where necessary replace the starter motor Check the starter motor mount O ring 5 for wear and any signs of damage and...

Page 168: ...the guide bush 1 on top of the gear of the sec ondary shaft 2 Grease the secondary shaft seal between the two lips Apply a coat of LOCTITE Anti Seize on the housings of the secondary shaft 2 and primary shaft 3 Insert the primary shaft 3 in the housing in the fly wheel side half of the engine casing Insert the secondary shaft 2 in the housing in the fly wheel side half of the engine casing Insert ...

Page 169: ...t of MOLYKOTE G N on the housings of the bushes for the driving shaft and countershaft Insert the driving shaft 10 in the housing in the fly wheel side half of the engine casing NOTE Position the lower connecting rod 11 towards cylinder 2 rear and the upper connecting rod 12 to wards cylinder 1 front aCAUTION Do not tilt the driving shaft during insertion so as to avoid damaging the main bushes in...

Page 170: ... the clutch side half of the engine casing 8 on the flywheel side half NOTE Where necessary use a plastic hammer to tap on the casing rib near of the shaft Take care not to damage the gasket surface of the clutch cover 9 Rotate the engine casing towards the clutch side aCAUTION Screw on the screws in a crisscross pattern tighten ing them gradually Screw the twenty M6 T C E I screws onto the engine...

Page 171: ...RAL INFORMATIONS NOTE Lock the M6 T C E I screw 24 in place with a LOCTITE 243 product Fit the index spring 20 shim 21 index lever 22 and washer 23 and secure them with the M6 T C E I screw 24 Driving torque of screw 24 11 Nm 1 1 kgm NOTE Lock the M6 T C E I screw 27 in place with a LOCTITE 243 product Press the index lever 22 down and insert the index plate 25 in the shift cam slot 26 fastening i...

Page 172: ...gears and make sure the drive pins 4 of the index plate 5 are in the central position NOTE If this is not the case one of the needle springs 1 end must be bent Check the preloading of the positioning spring 6 It must be quite hard to lift the positioning lever 7 of the shift cam index plate 5 NOTE Rotating the shift cam must cause the position ing spring 6 to push the positioning lever 7 into the ...

Page 173: ... rotor aCAUTION Make sure the LOCTITE product does not get inside the pressure pump hole Apply a thin film of LOCTITE 574 on the external gas ket surface of the oil pump casing 6 and install it on the oil pump shaft 4 Fasten the oil pump casing 6 complete with pin 7 inside the casing Insert the pin 8 in the central hole of the oil pump shaft Insert the duly oiled internal rotor 9 of the pressure p...

Page 174: ...g shaft so that the connecting rod of cyl inder 2 rear is at TDC NOTE Have the appropriate special tool 17 to hand cod 0240880 threaded bolt for retaining the driving shaft at TDC Lock the driving shaft in place with the threaded bolt 17 NOTE When cylinder 2 is at TDC the fastening slot 18 of cylinder 1 is visible through the gap under the countershaft The threaded bolt 17 must never be overtighte...

Page 175: ...ously have been fastened in the casing Insert the bearing flange 25 and fasten it using the three M8 T C E I screws 26 27 and the spring wash ers 28 i e two M8x45 screws 26 one M8x20 screw 27 Driving torque of screws 26 27 25 Nm 2 5 kgm O Motor oil Check the rotation of the intermediate drive gear Insert the key 30 in the driving shaft The reference mark 31 on the intermediate drive gear must coin...

Page 176: ...n the driving shaft NOTE The reference point must be visible Insert the gear 8 on the countershaft NOTE The reference point must be visible and must coincide with the reference mark on the driving gear Lift the countershaft all the way in the axial direction and insert the counterweight 9 onto the countershaft NOTE The counterweight notch 10 must be engaged by the end of the key 2 Insert the sprin...

Page 177: ...g it with LOCTITE 243 Driving torque of nut 2 230 Nm 23 0 kgm Insert the washer 3 on the primary shaft Coat the housing and toothing of the primary shaft 4 with LOCTITE Anti Seize aCAUTION Once disassembled always replace the oil pump gear Place a new oil pump gear 5 on the preassembled clutch drum 6 and engage it Insert the preassembled clutch drum 6 on the primary shaft 4 NOTE Turn the oil pump ...

Page 178: ... steel one 13 Insert a steel disc 13 followed by a lined disc 14 and continuing alternately NOTE The first lined disc at the top 15 must be insert ed in the staggered groove The top lined disc 15 is recognizable as it has a dot punched onto it Make sure this disc does not feature any slack though it must not be locked in place Oil the friction disengaging shaft 16 and insert it in the primary shaf...

Page 179: ...e piston with MOLYKOTE G N Install the piston 3 on the connecting rod and push the gudgeon pin 4 in using a punch suitable for the job aCAUTION Observe the assembly direction indicated by the pre viously applied reference mark If a new piston is used the red or green reference point 5 on the piston crown must face in the direc tion of the exhaust 6 only for 2 cylinder Take special care when matchi...

Page 180: ...n the piston pushing down hard NOTE Support the piston 3 Make sure the two gudgeon pin seeger rings are inserted perfectly in the groove of the piston and that the hook 8 is inserted in the slot of the actual piston Where necessary fit the second gudgeon pin seeger ring 7 repeating the same procedure as described above ...

Page 181: ... over the piston to preload the piston rings Place the chain tightener shoe 13 in the chain com partment of the cylinder 14 and push the cylinder over the piston so that the ring compressor is pushed down Remove the ring compressor 12 Insert the timing chain 15 through the cylinders chain compartment NOTE The timing chain can be guided inside using an O ring or similar device to aid assembly Place...

Page 182: ...fter buckets 3 and insert them in the head Oil the four camshaft bushes 4 inside the head Fit the exhaust camshaft 5 and intake camshaft 6 with the cam lobe facing up NOTE Difference on exhaust and intake camshafts up to engine 524 388 the exhaust camshaft features a double shoulder 7 as of engine 524 389 the intake camshaft features a distinguishing groove R Insert the camshaft by hand and measur...

Page 183: ...ve R NOTE Tighten the camshaft U bolt gradually starting from the inside and working in a crisscross pattern Fasten the main U bolt of the camshaft 4 with the four washers 5 and the eight M6 T C E I screws 6 7 8 four M6x30 T C E I screws 6 two M6x45 T C E I screws 7 two M6x55 T C E I screws 8 Driving torque of screws 6 7 8 11 Nm 1 1 kgm Insert the countershaft 9 Coat both countershaft bushes 10 wi...

Page 184: ...6 NOTE The timing chain must be taught on the traction side 7 Engage the second timing gear 8 in the timing chain so that the IN reference mark 9 faces the EX refer ence mark 4 of the exhaust camshaft timing gear In this position push the timing gear 8 onto the intake camshaft and line up the holes of the timing gear with those on the camshaft aWARNING The three T C E I M6 x 14 11 screws must only...

Page 185: ...ly Insert the key 17 in the slot on the countershaft Push the differential gear 18 onto the countershaft so that the two reference marks 19 are lined up with each other NOTE Make sure the sharp edged side of the counter weight faces the countershaft Push the counterweight 20 onto the countershaft Fasten the M14x1 T E nut 21 with a coat of LOC TITE 243 and tighten it Driving torque of nut 21 50 Nm ...

Page 186: ...nt of grease place the thrust washer 5 on the intermediate timing gear 6 Place the timing chain 7 around the intermediate tim ing gear 6 guiding both through the chain compart ment and seating them NOTE Attach the timing chain 7 based on the refer ence mark applied during disassembly Guide the chain tightener shoe 8 though the chain compartment and fasten it in the housing by means of the spacer s...

Page 187: ...ion 19 and counterweight 20 NOTE The half moon shaped key 18 must be insert ed in the upper counterweight slot Make sure the reference mark on the intermediate drive gear coincides with the reference mark 16 on the bear ing flange Fasten the M10 T C E I screw 21 with a coat of LOCTITE 648 and screw it on to the countershaft Driving torque of screw 21 50 Nm 5 0 kgm C LOCTITE 648 NOTE The countersha...

Page 188: ...ng 9 Coat the cone of the rotor 7 with LOCTITE 648 Push the complete rotor 7 onto the driving shaft so that the driving shaft key coincides with the slot on the flywheel hub NOTE The double starter gear 3 must be rotated clockwise so that the freewheel can slide over the free wheel gear 5 During assembly be careful not to let any LOCTITE product get inside the sleeve of the freewheel gear 5 NOTE C...

Page 189: ...side the piston with MOLYKOTE G N Install the piston 3 on the connecting rod and push the gudgeon pin 4 in using a punch suitable for the job aCAUTION Observe the assembly direction indicated by the pre viously applied reference mark If a new piston is used the red or green reference point 5 on the piston crown must face in the direc tion of the intake 6 Take special care when matching the cylinde...

Page 190: ...n the piston pushing down hard NOTE Support the piston 3 Make sure the two gudgeon pin seeger rings are inserted perfectly in the groove of the piston and that the hook 8 is inserted in the slot of the actual piston Where necessary fit the second gudgeon pin seeger ring 7 repeating the same procedure as described above ...

Page 191: ...er the piston to preload the piston rings Place the chain tightener shoe 13 in the chain com partment of the cylinder 14 and push the cylinder over the piston so that the ring compressor is pushed down Remove the ring compressor 12 Insert the timing chain 15 through the cylinders chain compartment NOTE The timing chain can be guided inside using an O ring or similar device to aid assembly Place th...

Page 192: ...524 389 the intake camshaft features a distinguishing groove R NOTE Tighten the camshaft U bolt gradually starting from the inside and working in a crisscross pattern Fasten the U bolt of the camshaft 4 with the seven washers 5 and seven M6x30 T C E I screws 6 Driving torque of screws 6 11 Nm 1 1 kgm Fit the camshaft sensor 7 and secure it in place with two M5 Taptite screws 8 fastening them with ...

Page 193: ...re the timing gear with the three M6 T C E I screws 8 coating them with LOCTITE 243 Driving torque of screws 8 11 Nm 1 1 kgm Engage the second timing gear 9 in the timing chain so that the IN reference mark 10 faces the EX ref erence mark 5 on the timing gear of the exhaust cam shaft In this position push the timing gear 9 onto the intake camshaft and line up the holes of the timing gear with thos...

Page 194: ...he head cover 4 Place the head cover on head 1 front and on head 2 rear securing it with the five M6 spacer screws 5 Driving torque of screws 5 9 Nm 0 9 kgm Secure the intake flange 6 with the two M8 T C E I screws 7 and respective washers Driving torque of screws 7 19 Nm 1 9 kgm Secure the support bracket 8 with the two M10 T C E I screws 9 fasten the two M10 nuts and apply LOCTITE 243 Driving to...

Page 195: ...0277252 flywheel cover removal tool Screw the tool 3 onto the ignition cover Fit the ignition cover on the casing and screw it on with the twelve M6 T C E I screws 5 Driving torque of screws 5 11 Nm 1 1 kgm Remove the tool 3 and tighten the plastic closing screw 6 complete with O ring Screw on the four spark plugs inside the two heads us ing the special spanner Driving torque of spark plugs 18 Nm ...

Page 196: ... gear 9 Screw on the clutch cover 6 using the eleven M6 T C E I screws 10 and four M8 T C E I screws 11 12 eleven M6 x 35 screws 10 three M8 x 55 screws 11 one M8 x 65 screw 12 Driving torque M6 T C E I screws 10 11 Nm 1 1 kgm M8 T C E I screws 11 12 19 Nm 1 9 kgm NOTE Fit the seal 13 on the M8x65 T C E I screw 12 NOTE Fit the seal 18 on the M6x25 T C E I screw 17 coolant drain plug Insert the sha...

Page 197: ... not be fixed in the clutch cover retainers 26 NOTE Fit the support cup 20 and cup 22 on the clutch disengaging shaft with the rounded edge 27 fac ing out NOTE Hold the diaphragm 21 still on the clutch disen gaging shaft 24 using a bent hexagon head driver Rotate the complete clutch disengaging shaft 24 and fasten the diaphragm 21 in the clutch cover retainers 26 Insert the preassembled diaphragm ...

Page 198: ... THE DRIVING CHAIN PINION Coat the toothing of the secondary shaft with LOC TITE Anti Seize Push in the chain pinion 3 with the collar facing in and secure it with the spring washer 4 washer 5 and M10 T E screw 6 Driving torque of screw 6 50 Nm 5 0 kgm Fit a new oil filter 7 in the engine compartment Fasten the oil filter cover 8 and O ring 9 with two M6 T C E I screws 10 Driving torque of screws ...

Page 199: ...P Start the engine and let it idle for approx 10 minutes Check the oil level again and where necessary top up 3 8 2 CHECKING THE ENGINE OIL PRESSURE NOTE Have the appropriate special tool 3 to hand cod 8140181 fuel oil pressure gauge Connect the oil pressure gauge 4 in place of the en gine oil pressure sensor 3 Engine oil pressure min 50 kPa 0 5 bar NOTE Check the oil pressure at a temperature of ...

Page 200: ...4 1 RSV mille 1 2 3 FUEL SUPPLY SYSTEM 4 ...

Page 201: ...ON SENSOR 4 11 4 7 8 DRIVING SHAFT POSITION SENSOR 4 11 4 7 9 INTAKE PRESSURE SENSOR 4 11 4 7 10 INTAKE PRESSURE SENSOR 4 11 4 7 11 THROTTLE VALVE POTENTIOMETER 4 11 4 7 12 COOLANT THERMISTORS 4 11 4 7 13 AIR THERMISTORS 4 11 4 7 14 IGNITION COILS 4 11 4 2 44 9 4 12 4 8 1 REMOVING THE INJECTORS 4 12 4 8 2 REMOVING THE THROTTLE BODY 4 12 4 8 3 DISASSEMBLING THE THROTTLE BODY 4 14 4 8 4 INSPECTING T...

Page 202: ...draining water from the filler cap in the event of rain or during washing a pipe for draining off petrol in the event the tank is overfilled Key 1 Fuel tank 2 Filler cap 3 Fuel supply pump unit 4 Filler cap water drainage pipe 5 Fuel overflow drainage pipe 6 Fuel level sensor 7 Fuel delivery filter 8 Fuel supply pump 9 Fuel delivery pipe 10 Fuel return pipe ...

Page 203: ...2 CHECKING THE FUEL PUMP Change the delivery filter 7 NOTE During this procedure it is also advisable to wash the tank completely 4 1 2 CHECKING THE FUEL SUPPLY Check the fuel pipes every 7500 km 4687 mi or 8 months replace every 4 years aWARNING Check the delivery pipe 8 return pipe 9 and rele vant connections extremely carefully the operating pressure of the delivery pipe 8 is approx 450 kPa 4 5...

Page 204: ...NOTE Obtain appropriate pliers to attach the clamps or screwdriver type pipe clamps to replace the original ones special type without screw Lift the pump unit 2 just enough to be able to get at the pipe clamps 3 4 Release the head off the pipe clamps 3 4 aCAUTION When removing the pump unit 2 take care not to damage the pipes and the fuel level sensor 5 Remove the whole pump unit 2 2 6 4 5 6 3 3 2...

Page 205: ...ways and keep it held down Lift the pump mount 7 just enough to be able to slide out the fuel pump 2 Slide the fuel pump 2 off the mount 7 and recover the O ring 8 aCAUTION If the rubber element 9 supporting the pump proves damaged replace it If the filtering mesh 10 features traces of sediments clean it using a compressed air jet directed so that the impurities do not get inside 2 6 4 6 29 4 2 Re...

Page 206: ...e vehicle falls over When the vehicle is set on the side stand and a gear is engaged ignition is stopped preventing the vehicle from starting aCAUTION Any modifications or variations made to the exhaust system intake system or the engine control unit may result in serious damage to the engine The assembly modification or use of non original parts shall cause any warranty to become void and shall e...

Page 207: ... and ignition angle Coolant thermistor 15 Location on head 2 16 rear cylinder The temperature sensor detects the coolant tempera ture and is required to correct the injection time The injection time is increased if the coolant has not yet reached the working temperature Atmospheric pressure sensor Location inside the engine control unit 5 The intake pressure measured by the sensor is con verted in...

Page 208: ...sensor 8 Fuel pressure regulator 9 Injectors 10 Throttle valve potentiometer 11 Camshaft position sensor 12 Thermistors 13 To multifunction display right hand side 14 Driving shaft position sensor and generator 15 Driving shaft position sensor and generator connector 16 HV ignition coil cylinder 1 front 17 HV ignition coil cylinder 2 rear 18 Spark plug cylinder 1 front 19 Spark plug cylinder 2 rea...

Page 209: ...itch CLT Clutch control lever switch STA Starter motor relay E 02 Earth IG 12 HV ignition coil cylinder 1 front IG 11 HV ignition coil cylinder 1 front 4 7 4 ENGINE CONTROL UNIT CONNECTORS For further details see 6 17 CONNECTIONS TO THE ENGINE CONTROL UNIT 16 pin connector 2 Terminal labelling Connections N Driving shaft position sensor G Camshaft position sensor VCC Intake pressure sensor and thr...

Page 210: ...the defective component 4 7 7 CAMSHAFT POSITION SENSOR Fault code 11 See 6 4 6 CHECKING THE CAMSHAFT POSITION SENSOR 4 7 8 DRIVING SHAFT POSITION SENSOR Fault code 12 See 6 4 5 CHECKING THE PICK UP 4 7 9 INTAKE PRESSURE SENSOR Fault code 13 See 6 4 11 CHECKING THE INTAKE PRESSURE SENSOR 4 7 10 INTAKE PRESSURE SENSOR Fault code 14 Check for pressure loss in the connection pipes 1 2 3 and make sure ...

Page 211: ...actual sensor is replaced 4 8 1 REMOVING THE INJECTORS See 4 8 2 REMOVING THE THROTTLE BODY See 6 4 12 CHECKING THE INJECTORS for the checking procedure 4 8 2 REMOVING THE THROTTLE BODY Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS Partially remove the fuel tank see 7 1 4 PARTIAL RE MOVAL OF THE FUEL TANK Remove the air filter casing see 7 1 7 REMOVING THE AIR CLEANER CASE Disconnect t...

Page 212: ...necessary restore the correct freeplay see 2 12 COLD START CABLE Loosen the two clamps 17 18 aCAUTION When removing the throttle body 11 be careful to make sure it remains connected to the fuel tank 20 by means of the fuel pipe 19 Grip the throttle body 11 firmly and hitch it one way and the other to lift it and slide it off the intake flanges Place the whole throttle body 11 and fuel tank 20 stil...

Page 213: ...the whole support bracket 4 securing the throttle cables with the two bushes 5 and the torsion spring 6 off the throttle body Unscrew and remove the two M 6x16 screws 7 and remove the fuel pressure regulator 8 complete with O ring Unscrew and remove the three M6x25 screws 9 and remove the left injector support 10 together with the relevant gasket 11 injector 12 and sealing ring 13 from the throttl...

Page 214: ...s sealing ring 18 may be kept in serted in the slot on the throttle body Unscrew and remove the M8x1 nut 19 and remove the spring washer 20 the pulley 21 the two bushes 22 and torsion spring 23 Slide the fulcrum pin 24 together with the lock washer 25 out of the hole on the throttle cable support brack et and remove the two shaft sealing rings 26 with the torsion spring 27 and cold start lever 28 ...

Page 215: ...n all the openings and pipes of the throttle body 1 using compressed air aCAUTION Once the intake pressure sensor 9 its installed not utilice the compressed air for the pipes cleaning danger for damages Check the pipes of the intake pressure sensor 2 watching out for any clogging Check the throttle valves unit and the cable fastening mechanism 3 watching out for any signs of mechani cal damage NOT...

Page 216: ...ue of screws 9 10 9 Nm 0 9 kgm If the synchronizing screws 11 and respective O rings 12 have been replaced screw on the screws 11 fair ly tight until they touch the stop and then unscrew them a single turn Presetting of synchronizing screws 11 1 turn aCAUTION The precise adjustment of the screws 11 must be performed using a vacuum gauge see 4 8 10 CYLIN DER SYNCHRONIZATION Fasten the fuel pressure...

Page 217: ... NOTE Spray a temporary lubricant AP LUBE on the spring 20 see 1 7 2 USE OF CONSUMABLES Fit the spring washer 22 NOTE Apply LOCTITE 243 on the thread of the nut 23 Screw on nut M8x1 23 and tighten it Driving torque of nut 23 3 Nm 0 3 kgm NOTE Apply LOCTITE 243 on the thread of the screws 25 Fasten the throttle cable support bracket 24 using the three M5x12 hex head screws 25 Driving torque of scre...

Page 218: ...emove the air filter casing see 7 1 7 REMOVING THE AIR CLEANER CASE Unscrew and remove the M8x1 nut 1 and remove the spring washer Slide out the control lever 2 and retrieve the two bush es 3 and torsion spring 4 Remove the control lever 2 from the tie rod of the ball joint 5 ASSEMBLY aCAUTION For the vehicles with the following engine numbers the throttle valve control lever 2 must be replaced wi...

Page 219: ...rottle body and throttle valve con trol lever 2 Fit the spring washer NOTE Apply LOCTITE 243 on the thread of the nut 1 Screw on the M8x1 nut 1 and tighten it Driving torque 1 3 Nm 0 3 kgm NOTE Once assembly is complete make sure the le vers rotate freely The throttle valve control lever 2 must be returned to its original position by the torsion spring Check for end play on the throttle valve cont...

Page 220: ...m scale With throttle valves closed Use the thickness gauge 1 to measure the minimum play between the lever 2 and the contact surface 3 on the throttle body in a number of points End play min 0 1 mm aCAUTION If the minimum value measured is less than 0 1 mm the whole throttle body cod 295690 must be re placed With throttle valves open Repeat the above procedure End play min 0 15 mm aCAUTION If the...

Page 221: ... adjusting screw 1 until it touches the stop onto the throttle valve control lever 5 and turn it an other 1 2 3 4 turn before tightening the M5x0 5 nut 2 Idling setting 1 2 3 4 turn SETTING THE COLD START DEVICE aCAUTION Whenever the whole throttle cable support bracket is replaced the cold start control adjusting screw 6 must be adjusted again once the idling adjusting screw 1 has been set NOTE H...

Page 222: ...ew on the two M4x12 T C E I sunk hexagon cheese head screws 2 and tighten the throttle valve potentiometer quite firmly but so that the screws can still be turned further Turn the ignition switch to position n To connect the TEST connectors 3 Turn the throttle valve potentiometer until the display longer reads aCAUTION Any adjustment of the position sensor must be per formed with the valves closed...

Page 223: ... Lift the petrol tank see 2 8 LIFTING THE FUEL TANK Loosen and remove the two front and rear exhaust pipe plugs 6 7 NOTE Upon reassembly apply LOCTITE 8150 on the threaded of the plugs 6 7 Connect the exhaust gas tester pipes 5 connect the two rigid pipes to the appropriate exhaust pipe outlets connect the other pipe to the exhaust gas tester 4 Start the engine and make sure the idling rpm is 1250...

Page 224: ...de of the vehicle Unscrew and remove the two screws 14 fastening the intake flange 15 to the front cylinder and recover the washers Remove the intake flange 15 of cylinder 1 front Fit the vacuometer intake flange 1 in place and posi tion it so that the connector 16 is on the right hand side of the vehicle Fit the two screws 14 back in place with their respec tive washers and tighten them Torque se...

Page 225: ...justed remove the vacuometer at tachment 1 and fit the intake flange 15 aWARNING It is vital that the vacuometer intake flange 1 be re placed with the original intake flange 15 aWARNING Slight differences in the vacuum values between the two cylinders are acceptable only if the CO values fall within the range of the preset parameters from 0 8 to 1 3 If the CO values and or the vacuum values do not...

Page 226: ...5 1 RSV mille 1 2 3 4 COOLING SYSTEM 5 ...

Page 227: ...OLING SYSTEM 4 4 43 3 2 04 5 3 2 6 4 2 4 23 5 5 2 6 4 42 3 5 6 2 6 4 4 4 2 37 4 5 7 2 6 4 4 4 2 34 23 5 7 2 6 4 4 2 80 3 6 6 5 8 5 6 1 CHECKING THE THERMAL EXPANSION VALVE 5 8 2 6 4 2 5 9 2 6 4 4 2 7 9 5 9 2 6 4 80 3 4 5 10 4 05 0 5 10 ...

Page 228: ...regarding the coolant see 1 2 5 COOLANT Key 1 Front cylinder thermistor 2 Rear cylinder thermistor 3 Breather pipe 4 Coolant compensation pipes 5 Filler hose 6 Filler neck 7 Engine hose right side thermal expansion valve 8 Rear cylinder hose three way manifold 9 Front cylinder hose three way manifold 10 Thermal switch 11 Three way manifold 12 Three way manifold hose left radiator 13 Radiator link ...

Page 229: ...s conveyed directly to the thermal expansion valve three way mani fold left radiator right radiator ther mal expansion valve gradually opening pump Path with coolant temperature over 80 C 176 F Pump coolant enters the galleries temperature taken by thermistors and sent up on the right hand dis play on the dashboard coolant leaves the galler ies three way manifold temperature taken by thermal switc...

Page 230: ... Unscrew and remove the screw 9 retrieving the bush and the rubber element 10 if necessary NOTE If the rubber element 10 is damaged replace it aCAUTION Proceed with care Do not damage the radiator fins Tilt the radiator 4 slightly forwards and at the same time lift it sliding the two lower anchorage pins 12 13 from their slot on the radiator mount 11 Remove the radiator 4 complete with the electro...

Page 231: ...Unscrew and remove the two screws 2 Driving torque of screws 2 6 Nm 0 6 kgm Retrieve the two nuts 3 Tilt the whole electrofan 4 slightly forwards at the same time moving it outwards pulling the internal an chorage pin out of its slot on the radiator 5 Remove the electrofan 4 NOTE If the rubber element 6 is damaged replace it Where necessary Unscrew and remove the three screws 7 and retrieve the wa...

Page 232: ...HECKING THE THERMAL SWITCH OPERATION for further details on the thermal switch aCAUTION Plug the hole on the three way manifold so as to pre vent any foreign bodies from falling in 2 6 4 4 4 2 34 23 Carefully read 0 2 1 PRECAUTIONS AND GENERAL INFORMATIONS and 1 2 5 COOLANT NOTE The following procedure refers to a single ther mistor though it is applicable to both Lift the fuel tank see 2 8 LIFTIN...

Page 233: ...SION VALVE Check the heat sensitive wax for signs of cracking or excessive wear in this case replace the whole valve 3 Check the valve 3 is working properly as follows Tie a piece of string around the valve 3 Place a container 8 holding coolant on a burner 9 Immerse the valve 3 in the container NOTE The valve 3 must be fully submersed without allowing it to touch the walls or bottom of the contain...

Page 234: ...FUEL TANK Remove the engine oil tank see 7 1 49 REMOVING THE ENGINE OIL TANK Drain the cooling circuit completely see 2 16 CHANG ING THE COOLANT Disconnect the electric connectors 9 10 from the ther mal switch 11 aCAUTION When reassembling make sure the electric connec tors 9 10 are plugged in properly NOTE Obtain appropriate pliers to attach the clamps or screwdriver type pipe clamps to replace t...

Page 235: ... tape Unscrew and remove the fastening screw 4 keeping the rear brake fluid tank 5 in place Move the rear brake fluid tank 5 and secure it in place with adhesive tape Unscrew and remove the two fastening screws 6 7 and retrieve the two bushes Remove the expansion tank 8 keeping it the right way up If the inner and outer foam edging is damaged replace it aWARNING The coolant is noxious Put the expa...

Page 236: ...6 1 RSV mille 6 6 6 6 6 ELECTRICAL SYSTEM 6 ...

Page 237: ...F RELAY 6 17 4 3 49 3934 6 18 6 6 1 WIRING DIAGRAM 6 18 6 6 2 STARTING SAFETY OPERATING LOGIC 6 19 6 6 3 CHECKING THE STARTING RELAY 6 19 6 6 4 CHECKING THE SIDE STAND AND THE SAFETY SWITCH 6 20 6 6 5 CHECKING THE DIODE MODULE 6 20 37 4 3 6 21 43 3934 6 23 6 8 1 WIRING DIAGRAM 6 23 6 8 2 CHECKING THE LIGHTS RELAY 6 24 6 8 3 CHECKING THE LIGHTS LAP DIODE multifunction 6 24 42 6 25 6 9 1 WIRING DIAG...

Page 238: ...safety couplings if provided aCAUTION Do not pull the cables to disconnect the two connec tors Grasp the two connectors and disconnect them by pull ing in opposite directions If dirt rust dampness etc can be noticed carefully clean the inside of the connector by means of a pressu rized air jet Make sure that the cables are correctly crimped to the terminals positioned inside the connectors NOTE Th...

Page 239: ...6 4 ELECTRICAL SYSTEM RSV mille 42 0 43 9 54 ...

Page 240: ...ear cylinder coil 2 25 Front cylinder coil 1 26 Front cylinder coil 2 27 Spark plugs 29 Secondary fuses 15A 30 Ignition switch 31 Low beam relay 32 High beam relay 33 Cooling fan relay 34 Front parking light bulb 35 High beam bulbs 36 Low beam bulb 37 Front right direction indicator 38 Front left direction indicator 39 Thermal switch 40 Cooling fans 41 Rear light 42 Dashboard 43 Rear left directio...

Page 241: ...E VOLTAGE REG ULATOR Wiring diagram key NOTE See 6 2 ELECTRIC COMPONENTS LAYOUT for the positioning of the components 18 Battery 19 Main fuse 30A 20 Generator 22 Voltage regulator 30 Ignition switch n m s Standard charging voltage 13 to 15 V d c at 4000 rpm 6 3 2 CHECKING THE ALTERNATOR LOADLESS OPERATION Remove the rear fairing see 7 1 36 REMOVING THE REAR FAIRING Disconnect the voltage regulator...

Page 242: ...airing see 7 1 36 REMOVING THE REAR FAIRING Disconnect the three way connector 1 coloured brown Disconnect the six way connector 2 coloured white aCAUTION When reassembling make sure the electric connec tors 1 2 are plugged in properly Using a pocket tester scale x 1MΩ measure the re sistance between the cables indicated in the table be low from the regulator side internal male terminals NOTE The ...

Page 243: ...ition sensor 3 Throttle valve potentiometer 4 Suction pressure sensor 5 Coolant thermistor 6 Air thermistor 7 Fall sensor 9 Clutch control lever switch 10 Neutral switch 15 Fuel pump relay 18 Battery 21 Pick up 23 Rear cylinder coil 1 24 Rear cylinder coil 2 25 Front cylinder coil 1 26 Front cylinder coil 2 30 Ignition switch 44 Front cylinder injector 45 Rear cylinder injector 52 Fuel pump 68 TES...

Page 244: ...play Remove the right side panel see 7 1 3 REMOVING THE SIDE COVERS Connect the two one way TEST connectors 1 Turn the ignition switch to position n Start the engine or attempt to start it The message DIAG comes up on the left display along with a number corresponding to the reference code relat ing to the fault see table the fault detected may be caused by breaks in the cables and or connections ...

Page 245: ...roken Wiring faulty Engine running or engine shut off Connector sensor cable and sensor Yes Coolant thermistor 21 Yes cold starting difficult Air thermistor 22 Yes Yes altimetrical compensation lack Atmospheric pressure sensor ECU inside 23 Sensor faulty Cannot be checked replace the ECU Ignition coil 1 of front cylinder 33 Ignition coil faulty or wiring not connected Engine running Connector igni...

Page 246: ...in perfect condition Repeat the procedure for the other coils 6 4 5 CHECKING THE PICK UP With the engine switched off Lift the fuel tank see 2 8 LIFTING THE FUEL TANK Disconnect the two way connector 5 coloured white and take the measurements on the engine side termi nals aCAUTION When reassembling make sure the electric connec tor 5 is plugged in properly Using a pocket tester scale x 100 Ω measu...

Page 247: ...g the sensor in the opposite direction 6 4 8 CHECKING THE COOLANT THERMISTOR OPERATION NOTE The value of the temperature measured by the front cylinder thermistor right hand side is sent up on the right hand display that measured by the rear cylinder thermistor left hand side is sent to the electronic unit Remove the thermistor 3 see 5 5 REMOVING THE COOLANT THERMISTORS Connect a tester 4 set as a...

Page 248: ...rse the thermistor in a container 4 holding water Immerse a thermometer 5 with a 0 to 150 C 32 to 302 F range in the same container Place the container on a burner 6 and slowly warm up the liquid Check the temperature indicated on the thermometer 5 and the thermistor value indicated by the tester Make sure that the value varies according to the temper ature as indicated If values do not vary or if...

Page 249: ...llows standard value with throttle valves closed 0 34 5 69 kΩ with throttle valves open 2 87 8 41 kΩ NOTE In order to make it easier to unscrew the screws 3 secured using LOCTITE 243 heat them first with a hot air blower Unscrew and remove the screws 3 Remove the potentiometer 2 Using a tester kΩ scale measure the resistance be tween the potentiometer terminals 2 measurement B Standard value with ...

Page 250: ...vidually not at the same time Measurements A B and C must produce the follow ing values Standard values measurement A 12 kΩ measurement B 11 50 kΩ measurement C 4 kΩ If the resistance proves to be any value other than that prescribed the sensor 2 must be changed 6 4 12 CHECKING THE INJECTORS With the engine switched off Lift the fuel tank see 2 8 LIFTING THE FUEL TANK NOTE The following procedure ...

Page 251: ...sitioning of the components Wiring diagram key 11 Arrangement for the installation of the anti theft device 12 Right dimmer switch 14 Engine stop relay 15 Fuel pump relay 29 Secondary fuses 15 A 52 Fuel pump A To the battery ignition switch B To the HV coil C To the injectors electronic unit D To the electronic unit ...

Page 252: ...ppropriate special tool cod 8140181 fuel oil pressure gauge to hand Fit the appropriate special tool Insert the free end of the pipe inside a container Power the positive green V and negative Ò blue B cables with a voltage of 12 V d c from the pump unit side Make sure the pump is working and produces the char acteristic humming sound and check the pressure gauge gives a supply pressure reading of ...

Page 253: ...onents Wiring diagram key 8 Diode module 9 Clutch control lever switch 10 Neutral switch 12 Right dimmer switch 16 Start relay 17 Starter 18 Battery 29 Secondary fuses 15 A 58 Side stand down warning light 59 Neutral warning light 70 Side stand switch A To the battery ignition switch B To the secondary fuses 15 A C To the electronic unit ...

Page 254: ...ubber protections 3 4 Disconnect the cables 5 6 from the relevant terminals on the relay 2 From the relay side power the two internal terminals of connector 1 at 12V Using a tester acting as ohmmeter check the for breaks between the two screw contacts on the relay 2 Correct value with relay powered 0Ω Correct value with relay not powered Ω If the values do not correspond to those indicated change ...

Page 255: ...and engine idling pull the clutch lever completely Engage the first gear pushing the shifting lever down wards Lower the side stand 1 thus operating the safety switch 3 At this point the engine must stop the side stand down warning light must come on Should this fail to happen replace the switch 3 6 6 5 CHECKING THE DIODE MODULE Remove the passenger seat see 7 1 2 UNLOCKING LOCKING THE PASSENGER S...

Page 256: ...DE SWITCH SET 3 Horn push button 4 Direction indicator switch 5 Dimmer switch 6 High beam signaller push button LAP push button multifunction 7 Light switch not provided for _ LEFT SIDE SWITCH SET _ 3 Horn push button 4 Direction indicator switch 5 Dimmer switchi 6 High beam signaller push button LAP push button multifunction Pos Cables Ar Gr V R G R V R r n RUN OFF Pos Cables Gr V G N Bi Bi B R A...

Page 257: ...HT SWITCH 10 REAR BRAKE STOPLIGHT SWITCH 11 NEUTRAL GEAR SWITCH 12 STAND SWITCH 13 CLUTCH LEVER SWITCH Pos Cables R V Gr V Bi R n m s Pos Cables R V Gr V Bi R n m s Pos Cables Gr M Operating Pos Cables G G Operating Pos Cables Screw Neutral Stand Cables M V N Down Up Pos Cables Gr M Operating ...

Page 258: ...iagram key 13 Left dimmer switch 29 Secondary fuses 15 A 31 Low beam relay 32 High beam relay 34 Front parking light bulb 35 High beam bulbs 36 Low beam bulb 41 Rear light 63 Dashboard bulbs 67 Dimmer switch diode LAP multifunction 69 Headlight 72 Rear parking light stoplight bulbs A To the battery ignition switch B To the right display chronometer ...

Page 259: ...E LIGHTS LAP DIODE multifunction To check operation of diode Disconnect the three way connector 3 coloured white under the rubber protection cap to the left of the handlebar aCAUTION When reassembling make sure the electric connec tor 3 is plugged in properly Using a tester in diode test mode check the values between the two male terminals in the diode as illus trated in the figure Correct value m...

Page 260: ...an 1 Remove the left hand side fairing see 7 1 26 REMOV ING THE SIDE FAIRINGS Disconnect the two electric terminals 2 3 from the thermal switch 4 and connect them together Turn the ignition switch to position n aCAUTION Then reassembling make sure the electric terminals 2 3 are connected properly If the electrofan does not work Turn the ignition switch to position m Make sure the connector 5 is co...

Page 261: ...ld ing coolant Immerse a thermometer 4 with a 0 150 C 32 302 F range in the same container Place the container on a burner 5 and slowly warm up the coolant Check that the temperature reading on the thermome ter 4 and the value indicated by the tester 2 corre spond to the data in the table If the values depart excessively from those indicated in the table change the thermal switch 1 6 9 4 CHECKING ...

Page 262: ...ANK Disconnect the three way electric connector 1 col oured white of the fuel pump unit aCAUTION When reassembling make sure the electric connec tor 1 is plugged in properly Connect together the orange black Ar N and blue B cables from the system side With the ignition switch 2 set to n the g low fuel warning light should come on after a second If the g light does not come on as expected make sure...

Page 263: ... engine see 6 4 8 CHECKING THE COOLANT THERMISTOR OPERA TION 6 10 4 CHECKING THE ENGINE OIL LOW PRESSURE SENSOR Remove the lower fairing see 7 1 32 REMOVING THE LOWER FAIRING Slip off the rubber protection 3 Disconnect the electric terminal 4 from the sensor 5 and earth it aCAUTION When reassembling make sure the electric terminal 4 is connected properly With the ignition switch set to n the red l...

Page 264: ... tester should read zero V for approx two seconds before returning to 6 V If test 1st gives an incorrect result disconnect the sen sor 3 and repeat test 1 st If the wrong value persists the dashboard is faulty and must be replaced with one in perfect condition If test 1 st gives a correct result and test 2 nd an incor rect value the sensor 3 is faulty and must be re placed If both tests 1 st and 2...

Page 265: ...he liquid is accidentally swallowed drink large amounts of water or milk then continue drinking milk of magnesia or vegetable oil and promptly call a doc tor The battery gives off explosive gases particularly during the phase of starting and or recharging keep it away from flames sparks cigarettes and any other source of heat During recharging or using make sure the room is properly ventilated and...

Page 266: ...battery aCAUTION The row of stoppers 3 must NEVER be removed Connect the battery to a battery charger Subject the battery to a normal charge cycle see ta ble Refit the battery on the vehicle on being returned to the customer 6 11 2 MAINTENANCE If the vehicle remains unused for more than fifteen days the battery must be recharged to prevent sulpha tion recharge the battery using a normal charge see...

Page 267: ...ARKING LIGHT BULB Remove the front part of the fairing see 7 1 20 RE MOVING THE FRONT PART OF THE FAIRING aCAUTION To extract the bulb socket do not pull the electric wires Grasp the parking light bulb socket 4 pull it and re move it from its seat Withdraw the bulb 5 and replace it with one of the same type HIGH BEAM BULBS Remove the front part of the fairing see 7 1 20 RE MOVING THE FRONT PART OF...

Page 268: ...he bulb socket 4 goes out of its seat insert it correctly making the bulb socket opening coincide with the screw seat 6 12 3 CHANGING THE REAR LIGHT BULB NOTE The rear light houses two parking light stoplight bulbs 5 The following operations refer to a single bulb but are valid for both Position the vehicle on the stand NOTE Before changing a bulb check the fuses see 6 15 CHANGING THE FUSES and th...

Page 269: ...ON If the defect persists even after the bulb light has been changed check the relevant sensor switch see 6 6 4 CHECKING THE SIDE STAND AND THE SAFE TY SWITCH 6 10 2 LOW FUEL WARNING LIGHT 6 10 4 CHECKING THE ENGINE OIL LOW PRES SURE SENSOR NOTE The two LEDs 11 and 12 cannot be removed Pos Description 3 Bulbs for right hand display lighting 4 Bulbs for left hand display lighting 5 Bulbs for rev co...

Page 270: ...the fair ing adjust the apposite screw 1 by means of a short cross tip screwdriver By SCREWING IT clockwise you set the beam up wards By UNSCREWING IT anticlockwise you set the beam downwards 534 4 2 4 4 NOTE To check the direction of the headlight beam specific procedures must be adopted in accordance with the regulations in force in the country where the vehicle is used NOTE Before proceeding wi...

Page 271: ...e and check if the filament 4 is broken Before replacing a fuse try to find out the cause of the trouble if possible Replace the damaged fuse with a new one having the same amperage NOTE If you use one of the spare fuses put a new fuse in the proper seat Remove the rider saddle see 7 1 1 REMOVING THE RIDER SADDLE Carry out the operations previously described for the secondary fuses also for the ma...

Page 272: ... 2 Stoplight switch on the front brake control lever 3 Safety switch on the side stand 4 Switch on the clutch control lever Make sure that there are no dirt or mud deposits on the switch the pin must be able to move without interfer ences returning automatically to its initial position Make sure that the cables are connected correctly Check the spring 5 it must not be damaged worn or weakened ...

Page 273: ...the positioning of the components See 4 7 4 ENGINE CONTROL UNIT CONNECTORS for further details NOTE The initials y and z appearing in the diagram next to the relevant numbers mark the respective termi nals on both connectors Y Electronic unit connector 26 way Z Electronic unit connector 16 way ...

Page 274: ...l sensor Z 7 10 kΩ Earth Z 14 Ro Bi 9 Clutch control lever switch y 20 M V y 21 M Vi 11 Starting relay y 22 G R 15 Fuel pump relay y 16 Ar G 21 Pick up Z 9 150 300 Ω Bi G Z 1 B G Earth y 2 10 11 23 B V Z 7 16 42 Diagnostics y 17 B Vi 42 Rev counter y 14 Gr Vi 23 Rear cylinder coil y 1 4 5 Ω V Gr y 12 Az G 24 Rear cylinder coil y 1 4 5 Ω V Gr y 13 Ro G 25 Front cylinder coil y 1 4 5 Ω V Gr y 25 Ro ...

Page 275: ...6 40 ELECTRICAL SYSTEM RSV mille 7 2 2 236 MILLE DASHBOARD CONNECTOR 20 WAY ELECTRONIC UNIT CONNECTOR 26 WAY ELECTRONIC UNIT CONNECTOR 16 WAY ...

Page 276: ...relay 33 Cooling fan relay 34 Front parking light bulb 35 High beam bulbs 36 Low beam bulb 37 Front right direction indicator 38 Front left direction indicator 39 Thermal switch 40 Cooling fans 41 Rear light 42 Dashboard 43 Rear left direction indicator 44 Front cylinder injector 45 Rear cylinder injector 46 Front stoplight switch 47 Rear stoplight switch 48 Rear right direction indicator 49 Horn ...

Page 277: ...6 42 ELECTRICAL SYSTEM RSV mille 7 2 2 236 MILLE _ DASHBOARD CONNECTOR 20 WAY ELECTRONIC UNIT CONNECTOR 26 WAY ELECTRONIC UNIT CONNECTOR 16 WAY ...

Page 278: ... relay 33 Cooling fan relay 34 Front parking light bulb 35 High beam bulbs 36 Low beam bulb 37 Front right direction indicator 38 Front left direction indicator 39 Thermal switch 40 Cooling fans 41 Rear light 42 Dashboard 43 Rear left direction indicator 44 Front cylinder injector 45 Rear cylinder injector 46 Front stoplight switch 47 Rear stoplight switch 48 Rear right direction indicator 49 Horn...

Page 279: ...6 44 ELECTRICAL SYSTEM RSV mille NOTE ...

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APRILIA 8140172, Service And Repair Manual

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