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APRILIA ETV mille, Workshop Manual, Page: 109 / 352

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APRILIA ETV mille Workshop Manual Download Page 109

ETV mille

ENGINE

3

  

- 4 -

 

00

Release 00/2004 - 04

3.2 ENGINE COMPONENTS THAT CAN BE 

REMOVED WITH THE ENGINE INSTALLED 
IN THE FRAME

Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR-
MATION) carefully.

The parts listed below can be removed leaving the
engine in the frame.

WARNING

Necessary removal procedures are listed in the
proper sequence in this section.

Certain procedures include cross-references to rele-
vant sections of the manual. Some of the operations
described there may not be strictly required for the
job at hand. Proceed sensibly to avoid redundant
work, that is, always make sure you really need to
remove a particular component before proceeding.

Perform the minimum operations required to give
access to the component to be serviced.

TOP END

- Valve cover (1), see 0.4.1 (ENGINE WORKSHOP

MANUALS).

- Valve cover (2), cylinder head, rear cylinder and piston,

see 0.4.1 (ENGINE WORKSHOP MANUALS).

- Front (3) and rear (4) cylinder intake flanges.
- Camshaft position sensor and camshafts, see 0.4.1

(ENGINE WORKSHOP MANUALS).

- Timing chain, chain tensioner and front and rear

cylinder timing drive assembly, see 0.4.1 (ENGINE
WORKSHOP MANUALS).

- Valves, see 0.4.1 (ENGINE WORKSHOP MANUALS)..

FRONT END

- Front cylinder exhaust pipe, see 7.1.42 (REMOVING

THE EXHAUST PIPES).

- Starter motor (5), see 0.4.1 (ENGINE WORKSHOP

MANUALS).

REAR END

- Exhaust removal, see 7.1.41 (EXHAUST SILENCER

REMOVAL).

RIGHT SIDE

LEFT SIDE

22

4

15

4

16 17

7

6

9

3

1

12

8

11

10

13

14

19

20

5

18

19

Summary of Contents for ETV mille

Page 1: ...www serviceaprilia com workshopmanual ETV mille 1188 3 00 2004 04 8140776 UK ...

Page 2: ...INTRODUCTION 0 1 00 Release 00 2004 04 0 INTRODUCTION 1 GENERAL INFORMATION 2 PERIODIC MAINTENANCE AND ADJUSTMENTS 3 ENGINE 4 FUEL SYSTEM 5 COOLING SYSTEM 6 ELECTRICAL SYSTEM 7 CHASSIS 8 REPAIR INFORMATION ABS 9 ...

Page 3: ...ALS 0 7 00 0 4 1 ENGINE WORKSHOP MANUALS 0 7 00 0 4 2 PARTS CATALOGUES 0 7 00 0 4 3 SPECIAL TOOLS CATALOGUES 0 7 00 0 4 4 OWNER S MANUALS 0 7 00 0 5 SAFETY INFORMATION 0 8 00 0 5 1 GENERAL PRECAUTIONS AND INFORMATION 0 8 00 0 5 2 BEFORE DISASSEMBLING ANY COMPONENTS 0 8 00 0 5 3 DISASSEMBLING THE COMPONENTS 0 8 00 0 5 4 REASSEMBLING THE COMPONENTS 0 8 00 0 6 SAFETY INFORMATION 0 9 00 0 6 1 CONVENTI...

Page 4: ...00 00 1 6 00 00 1 7 00 00 1 8 00 00 1 9 00 00 1 10 00 00 1 11 00 00 1 12 00 00 1 13 00 00 1 14 00 00 1 15 00 00 1 16 00 00 1 17 00 00 1 18 00 00 1 19 00 00 1 20 00 00 1 21 00 00 1 22 00 00 2 1 00 00 2 2 00 00 2 3 00 00 2 4 00 00 2 5 00 00 2 6 00 00 pag Release 2 7 00 00 2 8 00 00 2 9 00 00 2 10 00 00 2 11 00 00 2 12 00 00 2 13 00 00 2 14 00 00 2 15 00 00 2 16 00 00 2 17 00 00 2 18 00 00 2 19 00 00...

Page 5: ... 6 40 00 00 6 41 00 00 6 42 00 00 6 43 00 00 6 44 00 00 6 45 00 00 6 46 00 00 6 47 00 00 6 48 00 00 pag Release CONTINUED 6 49 00 00 6 50 00 00 6 51 00 00 6 52 00 00 6 53 00 00 6 54 00 00 6 55 00 00 6 56 00 00 6 57 00 00 6 58 00 00 7 1 00 00 7 2 00 00 7 3 00 00 7 4 00 00 7 5 00 00 7 6 00 00 7 7 00 00 7 8 00 00 7 9 00 00 7 10 00 00 7 11 00 00 7 12 00 00 7 13 00 00 7 14 00 00 7 15 00 00 7 16 00 00 7...

Page 6: ...0 7 95 00 00 7 96 00 00 7 97 00 00 7 98 00 00 8 1 00 00 8 2 00 00 8 3 00 00 8 4 00 00 8 5 00 00 8 6 00 00 8 7 00 00 8 8 00 00 8 9 00 00 8 10 00 00 8 11 00 00 8 12 00 00 pag Release 8 13 00 00 8 14 00 00 8 15 00 00 8 16 00 00 8 17 00 00 8 18 00 00 8 19 00 00 8 20 00 00 8 21 00 00 8 22 00 00 8 23 00 00 8 24 00 00 8 25 00 00 8 26 00 00 9 1 00 00 9 2 00 00 9 3 00 00 9 4 00 00 9 5 00 00 9 6 00 00 9 7 0...

Page 7: ...he front wheel stand see 1 9 1 PLACING THE MOTORCYCLE ON THE FRONT WHEEL STAND Slide both pins 1 of the front wheel stand into the holes 2 at front fork bottom end of the same time Press down on stand 3 until it rests fully on the ground PLACING THE MOTORCYCLE ON THE CENTRE STAND 1 9 2 Read paragraph 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Part no 8140176 complete stand Remove the lowe...

Page 8: ...pection or repair procedure please contact the aprilia Consumer Service A C S Department who will be glad to provide full information on the procedure in question as well as on any updates or engineering changes affecting the motorcycle under consideration Aprilia s p a reserves the right to make changes to its products at any time barring any such changes as may alter the essential features of a ...

Page 9: ...d personal injury Read 1 2 WARNINGS CONCERNING FUEL LUBRICANTS COOLANT AND OTHER COMPONENT PARTS carefully 0 5 2 BEFORE DISASSEMBLING ANY COMPONENTS Clean off all dirt mud and dust and clear any foreign objects from the vehicle before disassembling any components Use the model specific special tools where specified 0 5 3 DISASSEMBLING THE COMPONENTS Never use pliers or similar tools to slacken and...

Page 10: ...left and right are referred to the motorcycle when viewed from the riding position Motorcycle operation and basic maintenance are covered in the OWNER S MANUAL Any operations preceded by the star symbol must be repeated on the opposite side of the motorcycle In this manual any variants are identified with these symbols Frame ZD4DW STARTING FROM MODEL YEAR 2001 AUTOMATIC SWITCH ON DEVICE Option Cat...

Page 11: ...dle Speed Control ISO International Standardization Organization kg kilograms kgm kilograms per metre 1 kgm 10 Nm km kilometres km h kilometres per hour kPa kiloPascal 1 kPa 0 01 bar KS clutch side from the German Kupplung seite kW kiloWatt kΩ kiloOhm l litres LAP racetrack lap LED Light Emitting Diode m s metres per second max maximum mbar millibar 1 mbar 0 1 kPa mi miles MIN minimum MPH miles pe...

Page 12: ...ETV mille INTRODUCTION 0 11 00 Release 00 2004 04 NOTES ...

Page 13: ...ETV mille INTRODUCTION 0 12 00 Release 00 2004 04 NOTES ...

Page 14: ...ETV mille GENERAL INFORMATION 1 1 00 Release 00 2004 04 1 GENERAL INFORMATION ...

Page 15: ...LUTCH FLUID 1 5 00 1 2 7 CARBON OXIDE 1 6 00 1 2 8 HOT COMPONENT PARTS 1 6 00 1 3 RUNNING IN RECOMMENDATIONS 1 6 00 1 4 SPARE PARTS 1 7 00 1 5 SPECIFICATIONS 1 7 00 1 6 LUBRICANT CHART 1 10 00 1 7 CONSUMABLES 1 11 00 1 7 1 PRODUCT FEATURES 1 11 00 1 7 2 PRODUCT APPLICATIONS 1 12 00 1 8 SPECIAL TOOLS 1 15 00 1 8 1 SUNDRY TOOLS 1 15 00 1 8 2 ENGINE TOOLS 1 16 00 1 9 PLACING THE MOTORCYCLE ON THE SER...

Page 16: ... conditions Refuelling and engine service should take place in a well ventilated area with the engine stopped Do not smoke when refuelling or in the proximity of sources of fuel vapours Avoid contact with bare flames sources of sparks or any other source which may ignite the fuel or lead to explosion Take care not to spill fuel out of the filler or it may ignite when in contact with hot engine par...

Page 17: ...nded front fork oil see 1 6 LUBRICANT CHART 1 2 4 BRAKE FLUID NOTEThis vehicle is fitted with front and rear disc brakes Each braking system is operated by an independent hydraulic circuit The information provided below applies to both braking systems CAUTION Brake fluid is an irritant Avoid contact with eyes or skin In the event of accidental contact wash affected body parts thoroughly In the eve...

Page 18: ...LUBRICANT CHART Refer to the chart given below and add water with the quantity of anti freeze to obtain a solution with the desired freezing point NOTE The different brands of anti freeze available on the market have varying specifications Always read product label to determine the degree of protection afforded WARNING Use only nitrite free anti freeze and corrosion inhibitors with a freezing poin...

Page 19: ...o engine components during the running in period it is equally important to spare the engine at this stage in vehicle s life WARNING Top acceleration performance is only obtained after covering the first 1500 km 937 mi Observe the following instructions Avoid harsh accelerations and do not flip the throttle open abruptly when the engine is running at low speed both during and after the running in ...

Page 20: ... 77 kW 104 HP at 9250 rpm Max torque 96 5 Nm 9 78 kgm at 7250 rpm Max torque 90 Nm 9 17 kgm at 7000 rpm Bore stroke 97 mm 67 5 mm Compression ratio 10 4 Ø 0 5 1 Average piston speed 22 5 m s at 10000 rpm Camshaft during intake stroke 242 valve lift 9 50 mm Camshaft during exhaust stroke 242 valve lift 9 50 mm Timing advance with 1 mm valve clearance intake valve opens intake valve closes exhaust v...

Page 21: ...nt 2 5 l 50 water 50 ethylene glycol anti freeze Seat 2 Max carrying load rider pillion rider luggage 182 kg DRIVE DRIVE RATIOS Gear 1st 2nd 3rd 4th 5th 6th Primary drive ratio 31 60 1 1 935 Secondary drive ratio 14 35 1 2 50 16 28 1 1 750 19 26 1 1 368 22 24 1 1 090 23 22 1 1 956 27 23 1 0 851 Final drive ratio 17 45 1 2 647 Total drive ratio 12 804 9 041 7 006 5 582 4 896 4 358 Sprocket 17 teeth...

Page 22: ...E TRIAL WING 101 RADIAL F SPEC 12MBY 110 80R19 220 2 2 250 2 5 Rear alternative BRIDGESTONE TRIAL WING 152 RADIAL F SPEC P1NBJ 150 70R17 250 2 5 290 2 9 Front alternative MICHELIN ANAKEE B 59V M C TL TT 110 80R19 220 2 2 250 2 5 Rear alternative MICHELIN ANAKEE B 69V M C TL TT 150 70R17 250 2 5 290 2 9 SPARK PLUGS Standard NGK R DCPR9E Electrode gap 0 6 0 7 mm Resistance 5 KΩ ELECTRIC SYSTEM Batte...

Page 23: ...y F A 5W and F A 20W oils or FORK 5W and FORK 20W oils you may mix the different products as follows SAE 10W F A 5W 67 of volume F A 20W 33 of volume or FORK 5W 67 del volume FORK 20W 33 of volume SAE 15W F A 5W 33 of volume F A 20W 67 of volume or FORK 5W 33 of volume FORK 20W 67 of volume Bearings and other lubrication points GREASE MP or GREASE 30 As an alternative to recommended grease use top...

Page 24: ...m Withstands temperatures in the 55 to 175 C range 99 to 347 F Mated parts must be heated up to 250 C 482 F before they can be disassembled Orange LOCTITE 574 Solvent free sealant Eliminates the need for gaskets in joints exposed to high friction and where a specified gap needs to be maintained between parts Liquid sealant cures within a few hours after assembly when in contact with metal to form ...

Page 25: ...lutch LOCTITE 243 0897651 Steering retaining bush Rear brake caliper detent Front sprocket Rear brake pedal spindle Cooling fans to support Fuel return line fitting Fuel filler cap Throttle cable pulley nut Throttle cable bracket screws Throttle valve spindle nut Throttle position sensor screws Coolant pump central screw Cylinder connecting bracket screws Engine casing bearing screws Cylinder stud...

Page 26: ...racket on flywheel cover Camshaft sensor cable Bimol Grease 481 8116053 Front and rear wheel seals on assembly Swinging arm shaft bearings on assembly Clutch master cylinder actuating rod on assembly Rear wheel shaft thread Steering head bearings Rear brake master cylinder actuating rod on assembly Rear brake pedal spindle Thrust washer of timing idler gear Upper balancing shaft seal Starter motor...

Page 27: ...n assembly For cleaning bottom part of engine Starter relay rubber on assembly Cush drive to rear wheel sprocket on assembly Engine oil cooler rubbers on assembly Hose coupling to coolant filler cap on assembly For cleaning engine oil tank before decal application Instrument panel front fairing rubbers on assembly Rear brake pedal rubber on assembly Hoses to fuel filter inside fuel tank on assembl...

Page 28: ...ded order the brand specific special tools see Special Tools Catalogue WARNING Always read the instructions supplied with the special tools before use 1 8 1 SUNDRY TOOLS Ref Tool designation and application Part number 1A Tool for seal fitment Æ 50 mm 8140580 1B Split sleeve for fork oil seal fitment Æ 50 mm 8140146 2 Tool for chain removal fitment 8140192 3 Centre stand 8140176 4 Axone 2000 81405...

Page 29: ...extractor 0277720 12 14 Drifts to fit crankshaft bearing sleeves 0277725 13 Drift to fit clutch cover crankshaft bearing sleeves 0277727 15 Spark plug tool 8140177 16 Flywheel cover puller 0277252 17 Hexagon nut for flywheel removal 0277780 18 Threaded rod to hold crankshaft in TDC position 0240880 19 Transmission secondary shaft guide sleeve 0277308 20 Vacuum gauge 8140256 21 Fuel oil pressure ga...

Page 30: ... 1 9 1 PLACING THE MOTORCYCLE ON THE FRONT WHEEL STAND Place the motorcycle on the centre stand Slide both pins 1 of the front wheel stand 3 into the holes 2 at front fork bottom end at the same time Put one foot on the front end of the stand 3 Press down on stand 3 until it rests fully on the ground 1 2 3 ...

Page 31: ...s 5 fully onto stud bolt 4 and tighten Hold the nut 6 on the inside steady Release and remove the rear lower engine mounting bolt 7 Torque wrench setting for nut 6 bolt 7 50 Nm 5 0 kgm NOTE The bolt 7 on the right hand side is longer Slide the lower right hand mounting boss 8 into the lower hole on the right hand side Fit the stud bolt 9 into the lower hole on the left hand side and screw it fully...

Page 32: ...d on the bench and remove the protective film 4 NOTE A spray dispenser 2 will work best If you are using a sponge dab the decal surface lightly or the adhesive will deteriorate Wet the adhesive face with soap water Place the decal 3 in the proper position on the part you wish to decorate NOTE Always apply the spatula to the decal centre and move it towards the edges with regular movements Rub the ...

Page 33: ...ecals applied using water will take about 48 hours to stick to part permanently Once you have removed the application tape check for any air trapped underneath the decal If there are any air bubbles Prick a hole on the edge 7 of the air bubble using a pin or a cutter 6 Apply the spatula 1 at the opposite end and move it across the bubble to squeeze air out 1 Application tape is used to facilitate ...

Page 34: ...n to clean dry threads at room temperature NOTE Follow the instructions below to avoid distortion and or improper fit Screw all fasteners finger tight Tighten fasteners in a cross pattern A and B C and D to half the specified torque Repeat sequence tightening to specified torque NOTE This way the load generated by the fasteners is applied evenly across joint surface Screw or bolt thread Spanner Ti...

Page 35: ...ETV mille GENERAL INFORMATION 1 22 00 Release 00 2004 04 NOTE ...

Page 36: ...ETV mille PERIODIC MAINTENANCE AND ADJUSTMENTS 2 1 00 Release 00 2004 04 2 PERIODIC MAINTENANCE AND ADJUSTMENTS ...

Page 37: ...00 2 16 CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL 2 31 00 2 17 CHECKING AND TOPPING UP CLUTCH FLUID LEVEL 2 33 00 2 18 BLEEDING THE BRAKE CIRCUITS 2 35 00 2 19 BLEEDING THE CLUTCH 2 40 00 2 20 CHANGING THE FRONT BRAKE FLUID 2 41 00 2 21 CHANGING THE REAR BRAKE FLUID 2 42 00 2 22 CHANGING THE CLUTCH FLUID 2 43 00 2 23 ADJUSTING THE FRONT BRAKE LEVER AND CLUTCH LEVER 2 43 00 2 24 ADJUSTING REAR...

Page 38: ...TV mille PERIODIC MAINTENANCE AND ADJUSTMENTS 2 3 00 Release 00 2004 04 2 40 MAINTAINING FASTENERS AT THE CORRECT TIGHTENING TORQUE 2 61 00 2 41 FASTENERS 2 62 00 2 41 1 CLEANING AND LUBRICATION 2 68 00 ...

Page 39: ...ay cause severe burns All component parts of the vehicle are inedible Do not bite suck chew or swallow any vehicle parts Unless expressly specified otherwise reassembly is carried out by reversing the disassembly procedure 2 1 PERIODIC MAINTENANCE CHART In order to preserve the motorcycle in sleek running order aprilia recommends that you strictly observe the periodic maintenance intervals recomme...

Page 40: ...Engine oil filter Engine oil filter on oil tank Front fork Vehicle operation Beam operation setting Brakes Cooling system Light system Safety switches Clutch fluid every 2 years Brake fluid every 2 years Coolant every 2 years Front fork oil After the first 7 500 km 4 687 mi and every 22 500 km 14 000 mi Engine oil Front fork oil seals After the first 30 000 km 18 750 mi and then every 22 500 km 14...

Page 41: ...Clutch wear Brake pads wear before each ride and every 2000 km 1250 mi inspect and clean set or adjust lubricate or replace as required clean replace set or adjust Service the motorcycle more frequently when you ride in the rain on dusty or bumpy roads or in competition trials THESE OPERATIONS CAN BE CARRIED OUT BY THE OWNER Check every 15 days or at scheduled intervals Component Post running in c...

Page 42: ...ed with engine oil or grease see 1 6 LUBRICANT CHART Lubrication points are shown in the LAYOUT OF LUBRICATION POINTS KEY TO THE LAYOUT OF LUBRICATION POINTS 1 Steering bearings 2 Clutch lever spindle 3 Rider right hand footpeg 4 Rider left hand footpeg 5 Passenger left hand footpeg 6 Rear wheel spindle and hub bearings 7 Drive chain 8 Rear suspension levers 9 Side stand spindle 10 Passenger right...

Page 43: ...tion switch key 1 to position The following instrument panel lights will come on within the next three seconds all warning LED lights all backlighting LEDs all segments of the left hand display all segments and messages of the right hand multifunction display This is part of an auto test routine of LED message segment and instrument operation After three seconds all lights except the oil pressure ...

Page 44: ...les or the distance covered since the trip meter was last reset NOTE Whenever the ignition switch is set to the display will revert to odometer mode total mileage The trip meter is reset to zero as follows Set display to trip meter mode see above Hold down the SET button 1 for over three seconds and all segments 2 will be reset to zero NOTE The trip meter will reset automatically each time the bat...

Page 45: ...m Gives engine speed in rpm Never exceed maximum engine rpm Fuel reserve LED light Comes on when fuel level in the tank drops to 4 Ø 1 l Refuel as soon as possible when this light comes on Side stand LED light Comes on when the side stand is down Oil pressure LED light Comes on whenever the ignition switch is set to and the engine is stopped to test LED operation If the oil pressure LED stays on a...

Page 46: ...selected see 2 3 2 PROGRAM MING BUT TONS for instructions on how to toggle between indications Multifunction digital display right hand side Air temperature indication T AIR Air temperature indication Temperature is displayed in the numeric sector indication in figures When temperature drops below 20 C 4 F characters are displayed as long as temperature is between 20 C 4 F and 50 C 122 F the exact...

Page 47: ...g stop the engine Wait for the cooling fans to switch off and check coolant level see 2 14 COOLANT CHANGE When temperature reading is 126 135 C 259 275 F and the last two segments of the indicator scale are flashing stop the motorcycle and let the engine idle for a couple of minutes This will allow coolant to circulate throughout the cooling system Set the engine kill switch to and check coolant l...

Page 48: ...ee battery which seldom needs inspecting and may need charging from time to time If necessary replace with a battery of the same type See 6 14 BATTERY for more details WARNING Be sure to connect each battery lead to the matching terminal Set the ignition switch to before connecting or disconnecting the battery Connect the positive lead first and then the negative lead Disconnect in the reverse ord...

Page 49: ...rotective cap 1 aside Check that battery lead connections 2 and battery terminals 3 are in good condition free from corrosion or any deposits coated with neutral grease or vaseline If needed Disconnect the negative and positive leads in the order Clean off corrosion deposits using a wire brush Reconnect the positive and negative leads in the order Coat battery lead connections and terminals with n...

Page 50: ...See 2 3 MULTIFUNCTION COMPUTER for instructions on how to set these functions again When the vehicle is left unused for over a fortnight charge the battery to avoid sulphation see 2 4 2 CHARGING THE BATTERY Remove the battery see 7 1 7 BATTERY REMOVAL and store it in a cool dry place To avoid degradation in the wintertime or while the motorcycle is stored away check battery charge at regular inter...

Page 51: ...bles together Slide the red protective cap 1 aside Attach one jumper cable to the positive terminal of the battery in the starting vehicle A Attach the other end of the jumper cable to the positive terminal of the dead vehicle battery B Attach the other jumper cable to the negative terminal of the battery in the starting vehicle A Attach the other end of the jumper cable to the frame of the vehicl...

Page 52: ...zard the ignition system produces high voltages Pull the spark plug cap 1 off the spark plug 2 Remove any traces of dirt from the spark plug base Fit the suitable spark plug tool supplied with the tool kit to the spark plug Fit the 13 mm fork key supplied with the tool kit to the hexagon of the spark plug tool Unscrew and extract the spark plug Ensure that no dust or foreign matter fall into the c...

Page 53: ...ould be 0 6 0 7 mm If it needs adjusting bend the earth electrode carefully Make sure the washer is in good condition Fit the washer and screw the spark plug finger tight to avoid damaging the thread Tighten using the supplied tool Screw in each spark plug by one half turn to compress the washer Torque wrench setting for spark plugs 20 Nm 2 0 kgm WARNING It is essential to tighten the spark plugs ...

Page 54: ...of more than adequate capacity to contain the amount of fuel in the tank Place the container on the floor on the rihgt hand side of the motorcycle NOTE Before proceeding be sure to have a hose equipped with a female quick disconnect fitting ready at hand Place the free end of the hose into the container you have prepared previously Fit the female quick disconnect fitting to the male quick disconne...

Page 55: ...wing the procedure described below WARNING Cleaning the filter does not eliminate the need to change the filter at the specified intervals Do not start the engine when the air cleaner is not in place Do not clean the filter element with petrol or solvents These products may cause the fuel to ignite in the fuel system leading to personal injury and vehicle damage NOTE To give access to the cap 1 re...

Page 56: ...ed from inside the air cleaner housing 8 before installing the air box cover 3 Make sure the air cleaner is correctly positioned or it will let unfiltered air into the system Note that early wear of piston rings and cylinder is frequently due to a defective or badly positioned air cleaner CLEANING THE FILTER ELEMENT WARNING Do not use a screwdriver or any other tools on the air cleaner Hold the ai...

Page 57: ...and ensure that the twistgrip snaps closed smoothly when released If needed Make sure the components listed below are in the proper position and well lubricated cable housing twistgrip adjuster 1 throttle body adjusters 2 throttle body axle 3 cable end caps throttle control Check throttle cable play adjustment see 2 10 3 THROTTLE CABLE PLAY ADJUSTMENT 2 10 2 IDLING ADJUSTMENT Manual adjustment for...

Page 58: ...ay in the throttle twistgrip cable measured at twistgrip edge If not so Place the motorcycle on the stand Take off the rubber gaiter 1 Loosen the locknut 2 Rotate the adjuster 3 until setting the specified free play After adjusting tighten the locknut 2 and check free play again Refit the rubber gaiter 1 WARNING Turn the handlebars and ensure that idling speed is unaffected by handlebar movement O...

Page 59: ...ne and heat up oil to operating temperature Perform this check after a trip or take a short ride outside town Normally covering 15 km 9 5 mi will be enough to warm up engine oil to operating temperature Stop the engine Keep the motorcycle upright with both wheels on the ground Check oil level in the oil clear hose 1 MAX maximum level MIN minimum level The difference between the MIN and MAX levels ...

Page 60: ...level ground Remove the radiator spoiler see 7 1 24 REMOVING THE LOWER SUMP GUARD Place a container 1 under the drain plug 2 located on the tank 3 Container capacity should be greater than 4000 cu cm Release and remove the drain plug 2 located on the tank 3 Release and remove the filler cap 4 Drain the oil into the container 1 Let the last of the oil drip out for several minutes Inspect the sealin...

Page 61: ... Change all clips when reassembling use clips of the same type as the original Slacken the clip 12 and disconnect the hose 11 Release and remove the engine oil filter 10 located on the tank and clean with an air line Inspect the seal of the engine oil filter 10 located on the tank Screw in the oil filter and tighten Torque wrench setting for engine oil filter 10 located on the tank 30 Nm 3 0 kgm C...

Page 62: ...LL and LOW marks FULL maximum level LOW minimum level If not so Release and remove the filler cap 2 CAUTION Coolant is toxic when ingested contact with eyes or skin may cause irritation Do not put your fingers or any tools into the filler opening to check coolant level WARNING Do not add any additives or other products If you are using a funnel or other tool ensure that it is perfectly clean Add c...

Page 63: ...s under pressure when hot Do not remove the filler cap 3 while the engine is hot Remove the filler cap 3 to facilitate drainage DO NOT RELEASE COOLANT INTO THE ENVIRONMENT NOTE When refitting smear some LOCTITE 572 on the threads of the drain plug 1 Refit the drain plug 1 and renew the aluminium washer Torque wrench setting for drain plug 1 10 Nm 1 kgm Refit the expansion reservoir Top up coolant ...

Page 64: ... Never top up with or mix different types of silicone or petroleum based fluids Never use brake fluid from containers which have been open or kept in storage for long periods Take care to avoid accidental ingress of water or dust into the circuit INSPECTION NOTE Place the motorcycle on firm and level ground Hold the motorcycle upright with both wheels on the ground Rotate the handlebars to right f...

Page 65: ... in place Collect the guide cover 4 Remove the seal 5 WARNING Do not rock the motorcycle from side to side when topping up or brake fluid will spill out Do not add any additives or other products If you are using a funnel or other tool ensure it is perfectly clean NOTE To achieve the MAX level top up to the mark 6 etched inside the brake fluid reservoir 1 Top up the reservoir 1 with brake fluid se...

Page 66: ...nt finished parts will damage if brake fluid is spilt on them Before each ride ensure that the brake lines are not twisted or cracked and check the fittings for leaks Never top up with or mix different types of silicone or petroleum based fluids Never use brake fluid from containers which have been open or kept in storage for long periods Take care to avoid accidental ingress of water or dust into...

Page 67: ... for nut 3 3 Nm 0 3 kgm Remove the safety clip 4 NOTE Ensure that the fluid level is parallel with reservoir edge in a horizontal position to avoid spillage Untighten and remove the plug 2 with seal WARNING Do not add any additives or other products If you are using a funnel or other tool ensure it is perfectly clean Top up the reservoir 1 with brake fluid see 1 6 LUBRICANT CHART until bringing le...

Page 68: ...ill damage if clutch fluid is spilt on them Before each ride ensure that the clutch lines are not twisted or cracked and check the fittings for leaks Never top up with or mix different types of silicone or petroleum based fluids Never use clutch fluid from containers which have been kept open or in storage for long periods Take care to avoid accidental ingress of water or dust into the circuit INS...

Page 69: ...hillips screwdriver WARNING Do not rock the motorcycle from side to side when topping up or clutch fluid will spill out Do not add any additives or other products If you are using a funnel or other tool ensure it is perfectly clean Lift and remove the cover 3 complete with screws 2 Remove the seal 4 NOTE The MAX level is achieved when the sight glass 5 is full Note that actual level is indicated w...

Page 70: ...r skin In the event of accidental contact wash the affected area thoroughly In the event of contact with eyes contact an eye specialist or seek medical advice DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT KEEP AWAY FROM CHILDREN WARNING Handle with care contact with brake fluid will alter the chemical properties of paintwork plastic and rubber parts etc Wear latex gloves during servicing Do not ...

Page 71: ...tem you will first have to remove the rear brake caliper see 7 8 1 REMOVING THE REAR SWINGING ARM Top up brake fluid level in the reservoir see 2 15 CHECKING AND TOPPING UP FRONT BRAKE FLUID LEVEL and see 2 16 CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL Remove the rubber cap Attach a clear plastic hose to the caliper bleed nipples 1 2 Insert the other end of the hose into a container Pump the b...

Page 72: ...ted NOTE Do not close the brake fluid reservoir after topping up since for the bleeding operations it is necessary to top up the brake fluid reservoir more than once Top up the brake fluid tank see 2 15 CHECKING AND TOPPING UP FRONT BRAKE FLUID LEVEL or 2 16 CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL WARNING Always wear goggles or a protective screen for the eyes when the brake lever or the br...

Page 73: ...e clutch lever allowing it to touch the handgrip Tighten the bleeder 1 2 Release the brake lever for the front brake or the brake pump rod for the rear brake and pull it three or four times Repeat the operations marked with until no air bubbles can be seen in the brake fluid that flows out of the bleeder valve NOTEDuring the performance of these operations more and more resistance will be met when...

Page 74: ...d brake fluid CHECKS TO BE CARRIED OUT AFTER BLEEDING THE BRAKING SYSTEMS After bleeding the braking systems keep to the following indications Make sure that the brake discs and the brake pads are completely free of grease or oil CAUTION Pull the brake lever for the front brake or the brake pump rod for the rear brake repeatedly and verify the correct operation of the braking system CAUTION Have a...

Page 75: ... Bleed the clutch as follows Top up clutch fluid level in the reservoir see 2 17 CHECKING AND TOPPING UP CLUTCH FLUID LEVEL Remove the rubber cap Attach a clear plastic hose to the bleed nipple 1 Insert the other end of the hose into a container Pump the clutch lever quickly Repeat several times then keep the lever pulled in Slacken the bleed nipple by one quarter of a turn to let the clutch fluid...

Page 76: ...E Ensure that there is fluid in the reservoir at all times during the operation or you will have to bleed the system when finished see 2 18 BLEEDING THE BRAKE CIRCUITS Keep an eye on the reservoir 2 while fluid drains off Tighten the bleed nipple 1 before fluid has drained off completely Top up the reservoir 2 see 2 15 CHECKING AND TOPPING UP FRONT BRAKE FLUID LEVEL Loosen the bleed nipple 1 again...

Page 77: ... Ensure that there is fluid in the reservoir 2 at all times during the operation or you will have to bleed the system when finished see 2 18 BLEEDING THE BRAKE CIRCUITS Keep an eye on the reservoir 2 while fluid drains off Tighten the bleed nipple 1 before fluid has drained off completely Top up the reservoir 2 see 2 16 CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL Loosen the bleed nipple 1 again...

Page 78: ...ighten the bleed nipple 1 before fluid has drained off completely Top up the reservoir 2 see 2 17 CHECKING AND TOPPING UP CLUTCH FLUID LEVEL Loosen the bleed nipple 1 again by about half turn Look at the fluid draining from the hose When fluid colour changes from dark to a lighter shade tighten the bleed nipple 1 and disconnect the bleed hose Torque wrench setting for bleed nipple 1 20 Nm 2 0 kgm ...

Page 79: ...t by the locknut 1 Loosen the linkage 4 until it touches the master cylinder piston Tighten the linkage allowing 0 5 1 mm play between master cylinder linkage 4 and master cylinder piston WARNING Ensure that the brake lever 5 has some free play otherwise the brake will stay applied even when the lever is released leading to early wear of brake pads and discs Free play of lever 5 4 mm measured at l...

Page 80: ...front end to check the front brake calipers 1 from the bottom up at the rear end to check the rear brake caliper 2 WARNING If brake pads were allowed to wear down until uncovering the metal substrate metal to metal contact with the brake disc would lead to rattle and the brake caliper sparking This will result in loss of braking and brake disc damage causing a dangerous riding condition When the l...

Page 81: ... Rock the forks back and forth in the direction of travel If you feel any play adjust the bearings see 2 27 2 ADJUSTING PLAY IN THE BEARINGS 2 27 2 ADJUSTING PLAY IN THE BEARINGS Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Slacken but do not remove the two screws 1 securing the top yoke 2 Slacken but do not remove the four screws 3 Turn the handlebars 4 in the direction of travel Scre...

Page 82: ...tighten by one quarter of a turn NOTE The tabs of the safety washer 6 should be bent upwards Bend the four tabs of the safety washer 6 upwards over the recesses of the locknut 7 Replace the top yoke 2 Ensure that it becomes properly seated in place Apply oil part no 8116050 to the thread and underside of the bush 5 Tighten the top bush 5 Take care to refit the shim in the proper position Undo the ...

Page 83: ...4687 mi and every 22500 km 14000 mi afterwards The following inspections should be performed every 7500 km 4687 mi Keep the brake lever squeezed in and press down repeatedly on the handlebars to compress the front fork The front fork should compress in a smooth motion Inspect the fork legs for any traces of oil If the front fork has a tendency to bottom out oil should be changed see 7 7 1 CHANGING...

Page 84: ...e the bearings see 7 8 2 DISMANTLING THE SWINGING ARM 2 29 1 SWINGING ARM ADJUSTMENT Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Place the vehicle on the centre stand Undo the nut 1 fully NOTE Make sure to have the special tool no 8140203 socket for swinging arm spindle engine mount adjustment Slacken the lockring 2 fully using the special socket Working from the right hand side of th...

Page 85: ...dest possible range or riding conditions meaning low and high speed whether riding solo or carrying a full load However rear suspension setting may be modified to suit specific needs in accordance with vehicle usage CAUTION Before setting adjusters let the engine and the silencer to cool down completely WARNING Before adjusting set both adjusters to the stiffest settings This means that both adjus...

Page 86: ...ions for instance rider passenger and luggage REAR SHOCK ABSORBER SETTING CHART clockwise anti clockwise 2 30 3 INSPECTING THE REAR SUSPENSION LINKAGE SYSTEM Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Check bearings every 30000 km 18641 mi NOTE An assistant will be required to keep the vehicle upright during the procedure Hold the tail of the motorcycle firmly with your hand Press do...

Page 87: ...ctions The wheel should be spinning smoothly with no hardness or unusual noise If not so change the bearings see 7 2 2 WHEEL REMOVAL If you detect any wobble inspect wheel and tyre see 7 2 4 WHEEL COMPONENT INSPECTION A spinning wheel that always stops in exactly the same position needs balancing 2 32 REAR WHEEL Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Check every 7500 km 4687 mi P...

Page 88: ...pples may still have worked them selves loose Determine which wheel spokes 3 need tensioning up NOTE The procedure described below is referred to one spoke Loosen the grub screw 2 Work the nipple 1 so as to set the spoke 3 to the correct tension tighten to tension up the spoke 3 loosen to slacken the spoke 3 NOTE If nipple adjustment 1 is ineffective loosen the grub screw 2 again Tighten the grub ...

Page 89: ...d torque Torque wrench setting for nuts 1 2 25 Nm 2 5 kgm 2 35 DRIVE CHAIN Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Inspect and lubricate as required every 1000 km 625 mi The vehicle is fitted with an endless chain that has no master link Chain type 525 WARNING The drive chain links are fitted with O rings that retain the grease inside Use the utmost care when adjusting lubricating...

Page 90: ...hain Slack should be the same throughout one full turn of the wheel WARNING If slack is greater at particular positions of the chain it means that some links are warped or have seized To prevent seizure lubricate the chain frequently see 2 41 1 CLEANING AND LUBRICATION Chain slack must be adjusted whenever it differs from the specified 15 mm regardless of whether it is greater or less than the 15 ...

Page 91: ...ter the inspection proceed as follows Place the motorcycle on the rcentre stand Slacken the nut 1 NOTE The fixed reference marks 2 and 3 inside the seats of the chain tensioner sliders on the swinging arm sides before the wheel spindle facilitate correct wheel centring Slacken the two locknuts 4 Work the adjusters 5 until obtaining the correct chain slack Make sure the adjusters are set at the sam...

Page 92: ...e of chain or more important they may damage the O rings that retain the grease in the gaps between rollers and pins Lubricate the chain every 1000 km 625 mi and whenever it seems appropriate Leave the chain to dry then spray with aerosol lubricant for O ring chains see 1 6 LUBRICANT CHART NOTE Do not ride when you have only just lubricated the chain Centrifugal force would cause the newly applied...

Page 93: ...h slave cylinder see 3 2 1 CLUTCH SLAVE CYLINDER REMOVAL Undo and remove the three screws 1 Torque wrench setting for screws 1 10 Nm 1 0 kgm NOTE Release the wire of the side stand switch from its retainer Remove the sprocket cover 2 Remove the guide plate 3 Check the guide plate 3 for damage or wear Replace as required 2 35 6 CHAIN SLIDER INSPECTION Place the vehicle on the stand Check the chain ...

Page 94: ...est left to experienced mechanics MINIMUM RECOMMENDED TREAD DEPTH A front and rear tyre ºººººººº2 mm 3 mm INFLATION PRESSURES Check the tyre inflation pressures at regular intervals when the tyres are cold Checking pressure on hot tyres will result in inaccurate measurement Take care to check tyres pressures before and after a long journey An overinflated tyre will provide a harsh ride reduce ridi...

Page 95: ...le quick disconnect fittings 3 5 are properly seated in the female quick disconnect fittings 4 6 See Section 4 FUEL SYSTEM for more details 2 38 BRAKE AND CLUTCH LINES Read 1 2 4 BRAKE FLUID and 1 2 6 CLUTCH FLUID carefully Check the brake and clutch lines every 7500 km 4687 mi or 8 months Renew every four years Always change a worn cracked or damaged line 2 39 COOLANT PIPES Read 1 2 5 COOLANT car...

Page 96: ... handlebars secured to top yoke front brake lever clutch lever fuel delivery pipe front fork to yoke front fork to front wheel spindle clamps front wheel front brake line fittings front brake discs front brake calipers engine sprocket rear brake lever swinging arm swinging arm linkage system rear shock absorber rear wheel rear brake disc rear brake caliper rear brake line fittings WARNING All fast...

Page 97: ... cat Only for models with catalytic converter nocat Only for models w o catalytic converter Ing1 Lubricate with antiseize grease Ing2 Lubricate with grease part no 8116053 ENGINE Engine to frame Description Qty Screw nut Nm kgm Notes Front mounting bolts 2 2 M10 50 5 0 Upper and lower rear mounting bolts on left hand side 2 M10 50 5 0 Upper and lower rear mounting bolts on right hand side of adjus...

Page 98: ...L243 Chain slider to swinging arm 2 M5 5 0 5 Chain guard to swinging arm 4 M5 5 0 5 Brake hose bracket fixing 1 M5 5 0 5 Locknut screw chain tensioner fixing 2 M8 10 1 0 Oil FOOTPEGS AND STAND Description Qty Screw nut Nm kgm Notes Rider footpeg brackets to frame 5 M10 50 5 0 Oil Passenger footpeg brackets to frame 4 M8 25 2 5 Sliding pin 2 M8 25 2 5 L243 Side stand pivot bolt 1 M10 10 1 0 Side st...

Page 99: ...xing 1 M4 2 0 2 Fuse box and relay to dashboard front fairing bracket 4 M6 5 0 5 Relay cable to starter motor 1 M6 5 0 5 Ground connection to engine 2 M6 10 1 0 Cables to relay 2 M6 4 0 4 AIRBOX Description Qty Screw nut Nm kgm Notes Airbox cover fixings 8 M5 3 0 3 Airbox to throttle body 6 M6 7 0 7 Oil Intake funnels to airbox 4 SWP3 9 1 5 0 15 Idling control stepper motor 2 M5 2 5 0 25 L243 Air ...

Page 100: ...ng2 Rear brake rod locknut 1 M6 man Locknut for rear brake lever height adjustment 1 M6 man Rear brake caliper 2 M8 25 2 5 Brake disc fixings 6 M8 25 2 5 L243 Brake master cylinder and guard fixings 2 M6 10 1 0 Brake fluid reservoir fixing 1 M6 3 0 3 Rear brake hose fixings 2 M10x1 20 2 0 Clutch hose fixings 2 M10x1 20 2 0 EXHAUST SYSTEM Description Qty Screw nut Nm kgm Notes Exhaust pipes to engi...

Page 101: ...side mount fixings 4 SWP 3 9 1 0 1 Front mudguard to fork 2 M5 5 0 5 Front mudguard to clips 2 M5 4 0 4 Radiator spoiler and sump guard to radiator bottom bracket 2 M5 5 0 5 Sump guard bottom fixings 2 M5 5 0 5 Side fairing to fuel tank 4 M5 5 0 5 Side fairing to frame plate 2 M5 5 0 5 Radiator conveyors to fairing side element 8 SWP3 9 1 0 1 Fairing side elements to radiator spoiler 2 M5 5 0 5 Cl...

Page 102: ...3 0 3 Cat s eye fixing 2 M4 3 0 3 IGNITION SWITCH AND LOCK Description Qty Screw nut Nm kgm Notes Ignition switch unit fixing 1 M8 25 2 5 Vs Ignition switch unit fixing 1 M8 25 2 5 Lock fixing 2 M6 7 0 7 HANDLEBARS AND CONTROLS Description Qty Screw nut Nm kgm Notes Vibration damping weights 2 M6 10 1 0 Handlebars bridge 4 M8 25 2 5 Oil Left hand light dip switch 2 M6 10 1 0 Right hand light dip s...

Page 103: ...zzles or highly flammable solvents Wash the drive chain with fuel oil or kerosene If the chain tends to become rusty quickly service more frequently WARNING Do not use trichlorethylene petrol or similar prod ucts these products may be too aggressive for this type of chain or more important they may damage the O rings that retain the grease in the gaps between rollers and pins ...

Page 104: ...ETV mille PERIODIC MAINTENANCE AND ADJUSTMENTS 2 69 00 Release 00 2004 04 NOTE ...

Page 105: ...ETV mille PERIODIC MAINTENANCE AND ADJUSTMENTS 2 70 00 Release 00 2004 04 NOTE ...

Page 106: ...ETV mille ENGINE 3 1 00 Release 00 2004 04 ENGINE 3 ...

Page 107: ...SEALANTS 3 3 00 3 1 5 LUBRICANTS 3 3 00 3 1 6 SPECIAL TOOLS 3 3 00 3 1 7 TORQUE FIGURES 3 3 00 3 1 8 PRECONDITIONS FOR MAINTENANCE AND REPAIR WORK 3 3 00 3 1 9 GENERAL MAINTENANCE AND REPAIR INSTRUCTIONS 3 3 00 3 2 ENGINE COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED IN THE FRAME 3 4 00 3 2 1 CLUTCH SLAVE CYLINDER REMOVAL 3 6 00 3 3 TAKING THE ENGINE OUT OF THE FRAME 3 7 00 3 4 FITTING ...

Page 108: ...roximately and must be supported adequately upon installation Handle using lifting equipment of adequate weight capacity and consider the centre of gravity of the engine Be careful of any projecting parts or sharp edges to avoid injury from squeezing or cutting WARNING In order to maintain the motorcycle engine and systems a thorough knowledge of the motorcycle is required In addition always use t...

Page 109: ...articular component before proceeding Perform the minimum operations required to give access to the component to be serviced TOP END Valve cover 1 see 0 4 1 ENGINE WORKSHOP MANUALS Valve cover 2 cylinder head rear cylinder and piston see 0 4 1 ENGINE WORKSHOP MANUALS Front 3 and rear 4 cylinder intake flanges Camshaft position sensor and camshafts see 0 4 1 ENGINE WORKSHOP MANUALS Timing chain cha...

Page 110: ...ral switch 11 Clutch slave cylinder 12 see 3 2 1 CLUTCH SLAVE CYLINDER REMOVAL Flywheel cover 13 and ignition system see 0 4 1 ENGINE WORKSHOP MANUALS Engine oil tank 14 see 7 1 44 REMOVING THE ENGINE OIL TANK RIGHT HAND SIDE Front cylinder coolant thermistor 15 see 5 4 REMOVING THE COOLANT THERMISTORS Front cylinder spark plugs 16 17 see 2 7 SPARK PLUGS Coolant pump 18 see 0 4 1 ENGINE WORKSHOP M...

Page 111: ... screws 1 Torque wrench setting for screws 1 10 Nm 1 0 kgm Withdraw the slave cylinder assembly 2 WARNING Pull gently as the slave cylinder 2 is still connected to the clutch line Never operate the clutch lever with the slave cylinder 2 removed or the piston may fall out leading to loss of clutch fluid To be on the safe side secure the piston with a plastic clip see picture 1 1 2 2 ...

Page 112: ... from the frame Make sure to have all necessary equipment ready at hand and in place before proceeding Dry engine weight approximately 67 Kg Set the ignition switch to Place the motorcycle on the centre stand Disconnect the battery negative lead first then the positive lead WARNING Reverse the order when reconnecting the leads positive lead first then negative lead Remove the fuel tank see 7 1 4 R...

Page 113: ...der see 3 2 1 CLUTCH SLAVE CYLINDER REMOVAL Remove the drive sprocket see 7 8 1 REMOVING THE REAR SWINGING ARM Remove the gear shift lever see 7 1 40 REMOVING THE REAR BRAKE LEVER Pull the spark plug caps off the plugs 13 WARNING Clean the outer surface of engine with a degreasing detergent brushes and rags Ensure that no rubber or plastic parts come in contact with detergents and corrosive or pen...

Page 114: ...ing connector on assembly WARNING Mark hose and pipes with their relative positions to avoid confusing them when refitting Remove the engine oil tank 16 see 7 1 44 REMOV ING THE ENGINE OIL TANK together with the engine oil cooler 17 see 7 1 45 OIL COOLER REMOVAL by disconnecting the pipe 18 at engine end Remove the radiator 19 together with cooling fan 20 see 5 2 REMOVING THE RADIATOR Remove the t...

Page 115: ...ws 25 Collect the plate 26 Torque wrench setting for screws 25 40 Nm 4 0 kgm NOTE Make sure to have the special tool 27 part no 8140183 engine lifting eyebolt a hoist 24 and suitable slings 23 ready at hand CAUTION Hoist 24 and slings 23 must have adequate weight capacity in order to lift and handle the engine safely The engine weighs approximately 67 kg Install the engine lifting eyebolt 27 part ...

Page 116: ... 11 00 Release 00 2004 04 NOTE Engine to frame fixings must be removed in this order LEFT HAND SIDE A B C D RIGHT HAND SIDE E F G H 31 A B 30 D 36 35 C 32 34 33 G H 11 45 46 E 39 37 40 38 F 42 43 44 41 B A B C D H G E F ...

Page 117: ...or check nut 35 and screw 36 50 Nm 5 0 kgm Hold the check nut 38 steady Release and remove the screw 37 Torque wrench setting for check nut 38 and screw 37 50 Nm 5 0 kgm NOTE On assembly lubricate the screw 37 with oil part no 8116050 Hold the check nut 41 steady Release and remove the screw 42 Torque wrench setting for check nut 41 and screw 42 50 Nm 5 0 kgm NOTE On assembly lubricate the screw 4...

Page 118: ...shes 40 44 manually until bringing them fully home in the engine and then tighten to the specified torque Hold the check nut 38 steady Release and remove the screw 37 Hold the check nut 41 steady Release and remove the screw 42 Ensure that the slings 23 are taut Release and remove the two screws 45 and collect the washers 46 Torque wrench setting for screws 45 50 Nm 5 0 kgm Collect the two shims 1...

Page 119: ...ine to prevent it falling over Release the hoist slings 23 Remove the slings 23 from the frame Move the engine aside from under the frame Fasten the slings 23 to the engine again NOTE If the engine needs servicing place it in the spe cial stand 29 part no 8140187 8140188 WARNING Unless you need to service the engine it will be safer when left on the floor still fastened to slings 23 and hoist Clea...

Page 120: ...ant level see 2 13 CHECKING AND TOP PING UP COOLANT LEVEL Top up engine oil level see 2 11 CHECKING AND TOPPING UP ENGINE OIL LEVEL If you have overhauled the engine bleed the engine oil circuit and check oil pressure see 0 4 1 ENGINE WORKSHOP MANUALS Check chain slack and adjust as required see 2 35 1 CHAIN SLACK INSPECTION and 2 35 3 CHAIN SLACK ADJUSTMENT WARNING Inspect any parts you have remo...

Page 121: ...ETV mille ENGINE 3 16 00 Release 00 2004 04 NOTES ...

Page 122: ...ETV mille FUEL SYSTEM 4 1 00 Release 00 2004 04 FUEL SYSTEM 4 ...

Page 123: ... SENSORS 4 9 00 4 7 3 FUEL INJECTION LAYOUT 4 11 00 4 7 4 ENGINE CONTROL UNIT C ONNECTORS 4 12 00 4 7 5 AUTOMATIC OPERATION TEST 4 13 00 4 7 6 ELECTRONIC SYSTEM TROUBLESHOOTING BASED ON DISPLAY INFORMATION 4 13 00 4 8 THROTTLE BODY 4 14 00 4 8 1 THROTTLE BODY REMOVAL 4 14 00 4 8 2 REMOVING THE INJECTORS 4 15 00 4 9 DISMANTLING THE THROTTLE BODY 4 16 00 4 10 THROTTLE BODY INSPECTION 4 17 00 4 10 1 ...

Page 124: ...owing components the fuel pump assembly a drain hose to drain water from the filler cap when it rains or after washing a drain hose to drain fuel from the tank for the event it is overfilled Key 1 Fuel tank 2 Filler cap 3 Fuel pump assembly 4 Drain hoses 5 Fuel return hose 6 Fuel sensor 7 Fuel delivery filter 8 Fuel pump 9 Fuel delivery hose 2 1 6 3 7 6 8 5 9 4 ...

Page 125: ... 7 2 FUEL PUMP TEST for proper operation Change the fuel delivery filter 5 NOTE It is recommended that you also wash the fuel tank thoroughly 4 1 2 INSPECTING THE FUEL LINES Check the fuel lines every 7500 km 4687 mi or 8 months renew every 4 years CAUTION Pay special attention to the delivery 1 and return 2 hoses and fittings The operating pressure of the delivery hose 1 is approximately 450 Kpa ...

Page 126: ... and remove the six screws 1 Release the screw 2 Rotate the fuel pipe fitting 3 Release and remove the screw 4 NOTE On assembly turn in all screws until finger tight and then tighten to the specified torque in a cross pattern Torque wrench setting for screws 1 4 6 Nm 0 6 kgm Torque wrench setting for screws 2 10 Nm 1 0 kgm WARNING On assembly apply LOCTITE 518 to the thread of screws 1 4 On assemb...

Page 127: ...VING THE FUEL DELIVERY FILTER Remove the fuel pump assembly see 4 3 REMOVING THE FUEL PUMP ASSEMBLY Release and remove the screw 6 to release the ground cable NOTE Make sure to have the special clip pliers part no 0277295 ready at hand Renew all clips on assembly Use clips of the same type fitted originally Release the head of the hose securing clip 1 2 Pull the hose 3 off the filter 4 Detach the ...

Page 128: ... Use clips of the same type fitted originally Release the clip head 2 Detach the fuel hose 4 from the pump 3 Release and remove the three screws 5 WARNING Take care not to pull or twist any electrical wires when performing the operations described below Remove the circlip 6 from the mesh filter 7 WARNING Install a new circlip 6 of the same type on assembly Remove the mesh filter 7 WARNING Remove a...

Page 129: ...ECU tests sensors and ignition coils for proper operation Any fault detected at this time will turn on a flashing EFI message on the display Safety devices built into the ECU shut down the ignition and fuel injection systems whenever engine speed rises beyond the maximum rpm allowed that is 10 500 rpm or when the motorcycle falls over When the motorcycle is on the side stand and a gear is engaged ...

Page 130: ... exhaust stroke Such accuracy requires more details of the position which are obtained through a particular engine speed variation strategy Engine position information is used to determine engine speed and to control those operations that need to be synchronised with engine rotation such as fuel injection Atmospheric pressure sensor Location built into Engine Control Unit 3 This is a piezoelectric...

Page 131: ...lerate or slow down Engine temperature sensor 6 The engine temperature sensor is a negative resistance thermistor This means that sensor resistance decreases as temperature increases The sensor is conveniently located to provide an accurate indication of engine operating temperature The EMS compensates for the varying engine characteristic in the different engine temperature ranges This is because...

Page 132: ...CTOR REAR CYLINDER INJECTOR INJECTOR NO 1 INJECTOR NO 2 INJECTOR NO 3 INJECTOR NO 4 Kill Switch ECM MC 1000 Power ground pins P1 Vign P2 E1 Vbat P1H4 P2 F3 P2 G1 P2 G2 P1 H1 G1 P1H3 P1H2 P2H1 P2H4 P2 H2 P1 F1 P1 F2 P1 E2 P1 E1 P2 A2 P2 B2 P1G4 P2G3 P2G4 P2 D2 P2 C2 P2 A1 P2 D3 P1 B3 P1E3 P1 E4 P1D1 P1 B2 P1A1 P1B1 P2 C4 Engine rotation Frame ground P1 D4 P2C1 ignitionswitch Supplyvia Engine positi...

Page 133: ... WHITE 50 GREEN LIGHT BLUE 49 ORANGE LIGHT BLUE 48 YELLOW BLUE 20 BLUE GREEN 21 BLUE GREEN 36 RED BLACK 30 BLUE GREEN SOLDERED TO SHIELDING OF THE TWO WIRES HEAT SHRINK PROTECTION 1 RED 35 PINK BLACK 25 BLUE BLACK 39 WHITE PURPLE 37 BROWN YELLOW 2 BLUE 40 PINK 43 LIGHT BLUE 41 PURPLE 26 PURPLE BROWN 31 BLUE RED 42 YELLOW 44 BLUE WHITE 19 BLUE GREEN 46 GREEN GREY 45 GREY RED 17 RED BROWN 38 BROWN W...

Page 134: ...ttery disconnect the battery negative lead first WARNING All measurements must be taken with the components at 20 C 68 F General troubleshooting advice locate fault and remove defective component When the EFI light comes on while riding it means that the engine control unit has detected a fault FAULT CODE TABLE Fault code Description of fault 12 Crankshaft position sensor pick up fault 15 Throttle...

Page 135: ...MOVING THE FUEL TANK Remove the airbox see 7 1 6 AIRBOX REMOVAL Disconnect the connectors of right hand injector 1 left hand injector 2 throttle position sensor 3 WARNING Make sure to refit the connectors to the matching connectors on assembly NOTE Make sure to have the special clip pliers part no 0277295 ready at hand Renew all clips on assembly Use clips of the same type fitted originally Releas...

Page 136: ...ers WARNING On assembly Ensure the fuel delivery hose 12 is not twisted and is routed clear of any components that might trap it underneath Renew the hose if damaged or deteriorated Route the fuel delivery hose 12 between the two intake flanges then under the throttle body and up to the opposite right hand side of the throttle body 6 The throttle body 6 must be properly seated on the intake flange...

Page 137: ...ng 3 left hand injector 4 and O ring 5 Release and remove the two screws 6 Torque wrench setting for screws 6 3 5 Nm 0 35 kgm Remove the fuel duct 7 together with O ring 8 right hand injector 9 and O ring 10 Release and remove the two screws 11 Torque wrench setting for screws 11 1 2 Nm 0 12 kgm Remove the potentiometer 12 NOTE Renew all seals on assembly Spare seals are included in the repair kit...

Page 138: ...reaser or a detergent for cold cleaning Blow all openings and ducts of the throttle body with compressed air 4 10 3 THROTTLE POSITION SENSOR WARNING The two socket head screws securing the throttle position sensor potentiometer 1 are coated with paint at the factory and must not be disturbed The throttle position sensor can only be set when installed from new that is when it is replaced Position t...

Page 139: ... have a vacuum gauge 1 ready at hand CAUTION Fuel vapours are harmful to human health Ensure the room is well ventilated before proceeding Do not inhale fuel vapours Avoid contact with skin Do not smoke or use bare flames Do not release fuel into the environment Remove the left hand lower panel see 7 1 3 REMOVING THE SIDE BODY PANELS Extract the two service hoses 2 located under the side panel on ...

Page 140: ...n the exhaust pipes connect the other tube to the exhaust emission analyser 1 Ensure that idling speed is 1250 Ø 100 rpm Adjust if needed see 2 10 2 IDLING ADJUSTMENT The analyser 1 should give the same CO reading for both cylinders In addition the CO reading should comply with the specified value Specified CO rate for both cylinders 1 5 2 at 1250 Ø 100 rpm Specified CO rate for both cylinders 1 1...

Page 141: ...rich the fuel mixture and the CO rate will increase accordingly Conversely decrease the parameter to decrease the CO rate WARNING Adjust gradually Press the key a couple of times two or three maximum and then wait for the CO reading on the analyser display 1 to stabilise Ensure that the tubing 2 used to connect motorcycle exhaust to analyser is the adequate length 1 5 m to 3 m Check the CO rate on...

Page 142: ...and press the Enter key The screen that appears next holds a set of ECU parameters Press the key or the key and select the option Closed Throttle Position using the UP and DOWN arrow keys Press Enter to confirm A reference parameter for throttle alignment appears in the top portion of the display Use the UP arrow key to increase the parameter until it stabilises When this occurs the Engine Control...

Page 143: ...ETV mille FUEL SYSTEM 4 22 00 Release 00 2004 04 NOTES ...

Page 144: ...ETV mille COOLING SYSTEM 5 1 00 Release 00 2004 04 COOLING SYSTEM 5 ...

Page 145: ... Release 00 2004 04 COOLING SYSTEM 5 1 DESCRIPTION 5 3 00 5 2 REMOVING THE RADIATOR 5 5 00 5 3 REMOVING THE COOLING FAN 5 6 00 5 4 REMOVING THE COOLANT THERMISTORS 5 7 00 5 5 REMOVING THE THERMAL EXPANSION VALVE 5 8 00 5 6 REMOVING THE EXPANSION RESERVOIR 5 9 00 ...

Page 146: ...evel inspection and top up see 2 13 CHECKING AND TOP PING UP COOLANT LEVEL See 1 2 5 COOLANT for more details on coolant Key 1 Front cylinder thermistor 2 Rear cylinder thermistor 3 Breather tube 4 Balance tubing 5 Cooling fan 6 Filler cap 7 Engine to thermal expansion valve pipe on right hand side of engine 8 Cylinder pipe three way manifold 9 Centrifugal pump 10 Expansion reservoir 11 Three way ...

Page 147: ...uct on right hand side of engine and direct to thermal expansion valve to three way manifold of left radiator through right radiator to thermal expansion valve valve is opening gradually and back to the pump Coolant circulation when coolant temperature exceeds 80 C 176 F The pump circulates coolant to the ducts thermistors detect temperature temperature reading appears on right hand display of ins...

Page 148: ...7 and slide it out of the way Detach the hose 8 from the radiator 3 Remove the fuel tank see 7 1 4 REMOVING THE FUEL TANK Disconnect the connector 9 WARNING Make sure to refit the connector 9 to the matching connector on assembly Release and remove the two screws 11 Collect the bushes and seals 10 where fitted Torque wrench setting for screws 11 10 Nm 1 kgm NOTE On assembly lubricate the screws 11...

Page 149: ... connector 1 WARNING Make sure to refit the connector 1 to the matching connector on assembly Release and remove the three screws 2 Torque wrench setting for screws 2 1 Nm 0 1 kgm NOTE On assembly apply LOCTITE 243 to the thread of the three screws 2 Collect the three vibration damping rubbers 3 NOTE Change the rubbers 3 if damaged Tilt the cooling fan assembly 4 slightly backwards while pulling i...

Page 150: ...l alternating motions and lift until releasing the throttle body from the intake flanges Slide the assembly aside placing it on the left hand side of the motorcycle Disconnect the connector 4 WARNING Make sure to refit the connector 4 to the matching connector on assembly Release and remove the thermistor 5 Collect a new thermistor and apply LOCTITE 574 to the thread Screw in the new thermistor 5 ...

Page 151: ...sure to have the special clip pliers part no 0277295 ready at hand On refitting renew all clips using the same type fitted originally Loosen the clip 1 Slide out the hose 2 at the radiator 8 Loosen the clip 4 Loosen the head of the hose clip 5 Grasp the thermal expansion valve 3 and pull it clear of the two hoses 6 7 in small motions WARNING Block off the openings of the hoses to prevent the ingre...

Page 152: ... radiator 3 Bend the hose 2 over and secure it to the top of the expansion reservoir using adhesive tape Release and remove the screw 5 Torque wrench setting for screw 5 3 Nm 0 3 kgm Release and remove the screw 4 securing the expansion reservoir Torque wrench setting for screw 4 10 Nm 1 4 kgm Lift the expansion reservoir 7 Release the hose 2 from the hose fastner WARNING When refitting place the ...

Page 153: ...ETV mille COOLING SYSTEM 5 10 00 Release 00 2004 04 NOTE ...

Page 154: ...ETV mille ELECTRICAL SYSTEM 6 1 00 Release 00 2004 04 ELECTRICAL SYSTEM 6 ...

Page 155: ...SAFETY LOCKOUT SYSTEM 6 24 00 6 8 1 WIRING DIAGRAM 6 24 00 6 8 2 SAFETY LOCKOUT SYSTEM OPERATION 6 25 00 6 8 3 STARTER RELAY TEST 6 26 00 6 8 4 DIODE TEST 6 27 00 6 8 5 SIDE STAND SWITCH TEST 6 28 00 6 8 6 DIODE MODULE TEST 6 29 00 6 8 7 TESTING THE SAFETY LOCKOUT SYSTEM SWITCHES 6 30 00 6 9 COOLING FAN 6 31 00 6 9 1 WIRING DIAGRAM 6 31 00 6 9 2 COOLING FAN TEST 6 31 00 6 10 SAFETY LOCKOUT SYSTEM ...

Page 156: ...TV mille ELECTRICAL SYSTEM 6 3 00 Release 00 2004 04 6 1 LAYOUT OF ELECTRICAL COMPONENTS 24 25 28 21 20 19 18 44 37 17 16 1 4 39 36 22 40 26 2 43 42 38 23 13 3 33 32 9 11 8 10 15 41 14 12 5 7 30 31 34 35 ...

Page 157: ...ndicator 22 Air temperature sensor 23 Throttle position sensor 24 Low beam relay 25 High beam relay 26 High beam low beam bulbs 27 Spark plugs 28 Front parking light bulb 29 Neutral switch 30 Front right indicator 31 Auxiliary fuses 15 A 32 Flasher 33 Bank angle sensor 34 Ignition switch 35 Right hand light dip switch 36 Front brake light switch 37 Fuel sensor pump assembly 38 Test and diagnostics...

Page 158: ...s as follows Press down on the locking tab where fitted WARNING Never separate two connectors by pulling on the wiring Grasp both connectors and pull them in opposite directions until they become separated Remove any dirt rust moisture etc from inside the connector blowing with compressed air Ensure that the wires are securely crimped to the terminals inside each connector NOTE A connector will on...

Page 159: ...ECTIFIER TEST Key to the diagram NOTE See 6 1 LAYOUT OF ELECTRICAL COMPONENTS for the location of the different components 1 Battery 2 Main fuses 30 A 3 Generator 4 Rectifier 5 Ignition switch Correct charge voltage 13 15 V DC at 4000 rpm 6 3 2 ALTERNATOR LOADLESS OPERATION TEST Remove the right hand lower fairing see 7 1 3 REMOVING THE SIDE BODY PANELS Disconnect the three way connector 1 coloure...

Page 160: ...ed brown of the rectifier wiring WARNING Make sure to refit the connector 1 to the matching connector on assembly Set the multimeter to the Ω range and check for continuity across stator wires that is across the inner female terminals yellow G wires Check stator mount insulation Correct resistance reading 0 1 1Ω Correct resistance reading between wires and stator mount A B 30 A Main fuse Rectifier...

Page 161: ... across the wires listed in the table below Measure at rectifier end inner male terminals NOTE The green V and white red Bi R leads are connected together Measure across either one of them when testing WARNING This test method provides an approximate measure of resistance Where possible fit a substitute rectifier known to be in good working order to test the charge system If the reading found devi...

Page 162: ... 4 2 TROUBLESHOOTING Check that the 30 A main fuse and the 15 A fuse D are in good condition Test kill switch device operation see 6 8 SAFETY LOCKOUT SYSTEM Test key operated switch operation see 6 5 IGNITION INJECTION SYSTEM Test the engine cutout relay for proper operation see 6 7 3 TEST OF FUEL PUMP RELAY AND ENGINE CUTOUT RELAY Test the injection relay see 6 4 3 INJECTION RELAY TEST Test the b...

Page 163: ...7 1 20 HEADLIGHT REMOVAL Ensure that the sensor 1 is installed correctly The arrow printed on the rubber should be faced upward Disconnect the white grey two way connector 2 and measure resistance across the terminals at sensor end WARNING Make sure to refit the connector 2 to the matching connector on assembly Use a multimeter set to the 100 kΩ range to measure resistance across the terminals of ...

Page 164: ...r 10 Front cylinder injector 11 Instrument panel 12 Rear cylinder coil centre spark plug 13 Rear cylinder coil side spark plug 14 Front cylinder coil side spark plug 15 Front cylinder coil centre spark plug M G Ar Bi V Az Ar Az Gr R V Gr G B R M M Bi B R Ro N R N B G Az G Vi Gr Bi Vi M Ro Ro D3 Gr A1 Gr H2 N H3 N H4 Gr H1 Gr H2 Gr H3 Gr H4 N D4 N E1 N E2 N F2 N F1 N B1 N B2 N B3 N E3 N E4 N A1 N D...

Page 165: ...Off appears in the clock field the battery is likely to be flat You have performed the operations described in subsection 6 5 1 TROUBLESHOOTING the wording stays on the starter motor operates but the engine will not start up You have performed the operations described in subsection 6 5 1 TROUBLESHOOTING the wording is flashing check the sensors 6 5 3 FAULT CODES Lift the seat see 7 1 2 REMOVING TH...

Page 166: ...he injectors for proper operation see 6 6 1 INJECTOR TEST ensure that the anti theft system connector is properly connected this will be the white connector under the passenger seat check the ignition switch for proper operation see 6 13 2 SWITCHES check the engine kill switch for proper operation see 6 13 2 SWITCHES check the condition of the 30 A main FUSES AND 15 A AUXILIARY FUSES see 6 16 REPL...

Page 167: ... and z used in the diagram identify the terminals of the two connectors Y Ecu connector 32 way Z Ecu connector 32 way H G F E D C B A 1 2 3 4 G H F D E B C A 4 3 2 1 H G F E D C B A 1 2 3 4 G H F D E B C A 4 3 2 1 41 43 40 39 45 54 63 42 25 46 47 48 15 36 30 27 26 28 52 51 50 49 16 2 33 9 9 P1H2 P1G4 P2G3 P2C3 P1A1 P1E3 P2C4 P2G4 P2D2 P2C2 P1B1 P1D1 P1B2 P1B3 P2B3 P1E4 P2G2 P2G1 P1G1 P2F3 P1H1 P1F...

Page 168: ... Vi P1 H4 M R 41 Rear cylinder injector P1 H4 11 17 Ω M R P1 H2 V Gr 42 Front cylinder injector P1 H4 11 17 Ω M R P1 H3 Gr R 43 Cooling fan P1 H4 M R P2 G2 G N P2 G1 G N 45 Fuel pump P1 H1 B Bi 46 Air thermistor P1 E4 B R P1 D1 R N 47 Coolant thermistor P1 E4 1 9 2 9 kΩ B R P1 B2 Ro N 48 Throttle position sensor P1 E4 2 8 3 4 kΩ varies with angle B R P1 E3 M Bi P1 B3 M G 49 Rear cylinder coil P1 H...

Page 169: ...C AIR ADJUSTMENT MOTOR Lift the airbox see 7 1 6 AIRBOX REMOVAL NOTE This is a stepper motor that opens and closes some particular air passages to make the air fuel mixture richer or leaner To test the stepper motor 2 for proper operation Release and remove the two screws 1 and remove the motor from the airbox Set the ignition switch key to and then right away to When the key is set to an automati...

Page 170: ...multimeter set to the kΩ range MEASUREMENT A Resistance between terminals A and B regardless of throttle position Correct reading 1 2 kΩ 10 MEASUREMENT B Resistance between terminals A and C Begin with the throttles fully closed and open gradually until the throttles are fully open resistance should increase as follows Correct reading from 1 2 kΩ to 2 4 kΩ 10 NOTE The two screws 3 are retained wit...

Page 171: ... filled with water Suspend a thermometer 5 with a 0 150 C 32 302 F range in the container Place the container on a gas burner 6 and heat up the water gradually Check the temperature reading of the thermometer 5 and the thermistor output indicated by the multimeter Thermistor output should vary with temperature as indicated in the table below NOTE If standard values do not change or are too differe...

Page 172: ...thermistor 1 in a container 3 filled with coolant Suspend a thermometer 4 with a 0 150 C 32 302 F range in the container Place the container on a gas burner 5 and heat up the coolant gradually Check the temperature reading of the thermometer 4 and the thermistor 1 output indicated by the multimeter Thermistor output should vary with temperature as indicated in the table below NOTE If standard valu...

Page 173: ...ssembly Disconnect the wiring from the coil 2 Check resistance using a multimeter Observe the layout A and B in the diagram for meter connection Check for continuity of the primary and secondary windings The resistance readings found need not match standard values exactly If the windings are in good working order resistance readings should approximate the standard values Standard values layout A 0...

Page 174: ...way connector 1 and attach the multimeter leads direct to the sensor 2 Set the multimeter to the x 1000 Ω range and measure resistance across sensor terminals Observe terminal polarity see diagram Correct reading 560 Ω 10 Replace sensor when infinite resistance is detected or when the reading found is below the specified range 1 2 Ω ...

Page 175: ...04 04 6 7 FUEL PUMP SYSTEM 6 7 1 WIRING DIAGRAM NOTE See 6 1 LAYOUT OF ELECTRICAL COMPONENTS for the location of the components Key 1 Battery 2 Fuel pump relay 3 Pump 4 Fuse 5 Engine cutout relay 6 Ecu Ar V E1 Grey H1 Black Ro Bi V N B Bi 1 2 4 3 6 5 ...

Page 176: ...sure should be at least 350 kPa 3 5 bar 6 7 3 TEST OF FUEL PUMP RELAY AND ENGINE CUTOUT RELAY To test relay operation Remove the rider seat see 7 1 2 REMOVING THE RIDER SEAT Disconnect the four way connector 1 coloured white from the relay 2 WARNING Make sure to refit the connector 1 to the matching connector on assembly Feed 12 Volts to the two inner male terminals A B Check for continuity betwee...

Page 177: ...s Key to diagram 8 Diode module 9 Clutch lever switch 10 Neutral light switch 12 Start button 16 Starter relay 17 Starter motor 18 Battery 29 Auxiliary fuses 15 A 58 Side stand light LED 59 Neutral light LED 70 Side stand switch A To battery ignition switch B To auxiliary fuses 15 A Gr G R G R M N Vi N Gr B M Vi M V B V M V V Gr 29 59 58 18 12 17 9 10 70 8 Diode Engine Kill 10 16 ...

Page 178: ...engine kill switch is set to the starter motor will not run TRANSMISSION SIDE STAND CLUTCH LEVER STAND LIGHT IGNITION ENGINE STARTER MOTOR NEUTRAL ENGAGED UP PULLED IN OFF OPERATES RUNS RELEASED DOWN PULLED IN ON RELEASED GEAR ENGAGED UP PULLED IN OFF RELEASED LOCKED OUT DOWN PULLED IN ON LOCKED OUT RELEASED ...

Page 179: ...connector 1 to the matching connector on assembly Lift the relay 2 until it is clear of its retainers Slide off the two rubber boots 3 4 Disconnect the wiring from the terminals of the relay 2 Feed 12 Volts to the two inner terminals in the connector 1 at the relay end Check for continuity between the two contact screws of the relay 2 using a multimeter set to the Ohm range Correct reading when re...

Page 180: ...nector on assembly Place a multimeter in the diode test mode and measure across the two male terminals accommodated inside the diode as shown in the diagrams Correct reading layout A 0 1 Ω Correct reading layout B When there is no multimeter including a diode test feature available feed 12 Volts to the diode fit a 12 V 2 W bulb to the positive lead and connect the leads to the diode as shown in th...

Page 181: ...ts ignition or shuts down the engine whenever a gear is engaged while the side stand 1 is down To test safety switch 3 operation Sit astride the motorcycle Raise the side stand 1 Start the engine With the throttle twistgrip released and the engine idling pull the clutch lever all the way in Push down on gear shift lever to engage the first gear Lower the side stand 1 This should cause the safety s...

Page 182: ... from the module 2 WARNING Make sure to refit the connector 1 to the matching connector on assembly Apply 12 Volts to the various terminals with a 12 V 2 W bulb fitted to the positive lead as shown WARNING Do not use a bulb rated higher than 2 W or the module will damage WARNING The bulb should illuminate as indicated in the chart If not so replace the module 2 1 2 3 4 5 1 2 3 4 5 1 2 ...

Page 183: ...eck for switch continuity using a multimeter Please refer to the relevant diagram Replace any switch found to deviate from the specified mode of operation 1 NEUTRAL SWITCH 2 SIDE STAND SWITCH 3 CLUTCH LEVER SWITCH Position Leads Screw Neutral Position Leads M V N Down Up Position Leads Gr M Activated 1 2 3 ...

Page 184: ...tor 6 9 2 COOLING FAN TEST Perform the first three steps of the procedure described in subsection 5 3 REMOVING THE COOLING FAN NOTE Make sure to have a 12 V battery ready at hand Attach the black connector 1 to the battery Ensure that the fan turns freely If the fan is working properly check the following coolant thermistor see 6 6 5 COOLANT THERMISTOR TEST ignition system power supply proper conn...

Page 185: ... 6 1 LAYOUT OF ELECTRICAL COMPONENTS for the location of the components Key 1 Instrument panel 2 Ambient temperature sensor 3 Oil pressure sensor 4 Fuel sensor 5 Speed sensor 6 Coolant temperature sensor 2 M Ro N Bi Gr Az N Bi G B Ar Bi N Bi R Gr B 9 1 2 5 4 3 6 11 16 16 WAY CONNECTOR 12 WAY CONNECTOR 1 2 3 6 4 5 ...

Page 186: ... an ambient temperature of 20 C 68 F Measure resistance across the terminals of connector 1 using an ohmmeter set to a 0 20kΩ range Correct reading 12 200 kΩ 12 700 kΩ If the air temperature sensor is operating properly check the instrument panel as follows Disconnect the sixteen way connector 2 see 7 1 19 REMOVING THE INSTRUMENT PANEL Apply 12 4 kΩ across terminals 2 and 9 A properly working inst...

Page 187: ...nition switch set to the red engine oil LED should light up If the LED does not light up check sensor for proper operation Check for continuity between the terminal tab 3 and sensor housing 2 using a multimeter set to a x 100Ω range see diagram Correct reading with the engine off 0Ω Correct reading with the engine running Ω If the readings found deviate from those specified ensure that engine oil ...

Page 188: ...Gr Bi and blue orange B Ar leads Correct reading 6VDC 3rd test Place the motorcycle on the centre stand Place the transmission in neutral Perform the 2nd test Rotate the rear wheel manually until one of the six screws 4 is before the sensor 3 The multimeter will read zero V for about two seconds and then the reading will rise back to 6V If the 1st test turns out a wrong reading disconnect the sens...

Page 189: ...ading with a full tank less than 14 Ω Correct reading with empty tank between 240 and 400 Ω NOTE Replace the fuel sensor if the readings obtained deviate from the specified limits If detected readings are correct test instrument panel operation by connecting a resistor across the orange black and white yellow leads of the four way connector 1 at the main wiring harness With 10 Ω resistor 9 sectors...

Page 190: ...anel operation by connecting a resistor across the white black and white red leads of the two way connector 1 With 90 Ω resistor Panel indication 9 sectors light up the last two sectors will be flashing Temperature indication in degrees from 126 C to 135 C from 258 8 F to 275 F With 1600 Ω resistor Panel indication 1 sector on Temperature indication in degrees 1 ...

Page 191: ...nd light dip switch on version 4 Key operated switch 5 Low beam relay 6 High beam relay 7 15 A fuses 8 30 A fuses 9 Battery 10 Number plate light 11 Low beam 12 High beam 13 Front parking light 14 Rear parking light 15 Instrument panel lighting Leds C A G V G N R B Bi R V V R G R G V G V G V G N N Bi V R Gr V R Az B N G N Bi V G N PASSING N R Bi V N G G Gr G N V R G R G V G V G V V R B Bi R Ar V A...

Page 192: ...e the two screws 1 Remove the relay box cover 2 Remove the relay to be tested Feed 12 Volts to the two male terminals 85 86 Check for continuity between the other two terminals 87 30 using a multimeter set to the Ohm range Correct reading when relay is fed 0Ω Correct reading when relay is not fed Ω Change the relay when detected readings deviate from those specified 1 1 2 Ω 85 86 12V 30 87 ...

Page 193: ...the components Key 1 Left hand light dip switch 2 Warning horn 3 15 A fuse 4 30 A fuse 5 Key operated switch 6 Battery 7 Flasher 8 Rear right indicator bulb 9 Rear left indicator bulb 10 Front right indicator bulb 11 Front left indicator bulb 12 Instrument panel 13 Indicator repeater light LED C N Bi V R Gr V R B V R Az B N R Gr V R Az B N G N PASSING L B 1 2 3 6 4 5 7 8 9 13 12 10 11 ...

Page 194: ...ng there might be a problem with the flasher To test flasher operation Remove the front fairing see 7 1 20 HEADLIGHT REMOVAL Disconnect the connector 1 of the flasher 2 Fit a jumper to the connector 1 Operate the direction indicator control 3 If the indicator lights come on but do not flash replace the flasher 2 It may also be necessary to check the 30 A main fuses and the electrical system When t...

Page 195: ... 13 1 WIRING DIAGRAM NOTE See 6 1 LAYOUT OF ELECTRICAL COMPONENTS for the location of the components Key 1 Front brake light switch 2 Rear brake light switch 3 15 A fuse 4 30 A fuse 5 Key operated switch 6 Battery 7 Tail light 8 Brake lights R B Bi R V V R G R G V G V G V G V V G N C 1 2 3 6 4 5 7 8 ...

Page 196: ... Check switches for continuity using a multimeter Please refer to the relevant diagram Replace any switch found to deviate from the specified mode of operation 1 FRONT BRAKE LIGHT SWITCH 2 REAR BRAKE LIGHT SWITCH Position Wires Gr M Activated Position Wires Gr M Activated ...

Page 197: ...mmediately If battery fluid is swallowed accidentally drink abundant water or milk Seek medical attention immediately and keep drinking magnesia milk or vegetable oil in the meantime The battery gives off explosive gases Keep the battery well away from any sources of ignition such as flames sparks or any heat sources Do not smoke near the battery Provide adequate ventilation when charging or using...

Page 198: ...ry WARNING Do not remove the container 2 unless all fluid has drained out If there is still some fluid left in the container 2 after twenty minutes tap the uppermost end of the container with your fingers to obtain complete drainage Lift the container 2 carefully to release it from the battery Place the caps 3 over the battery cell openings Press down firmly until the underside 3 of the cap strip ...

Page 199: ...SYSTEM INSPECTION In addition check for the following Inspect the battery for any sign of damage such as a cracked housing and check for fluid leaks Ensure that the battery leads are securely fixed to the terminals Charge at normal charge rate for at least 10 hours WARNING After charging check loadless voltage Replace the battery when loadless voltage is less than 12 V 6 14 4 RETURN UNDER WARRANTY...

Page 200: ... high beam low beam bulbs 1 one on each side one parking light bulb 2 at the bottom Replacement HIGH BEAM LOW BEAM BULBS NOTE Work on the side where the burnt out bulb is located NOTE Disconnect one connector at a time to avoid confusing the various connectors when refitting When two connectors must be removed at the same time mark them with their positions and make sure to refit them in the corre...

Page 201: ...TEM 6 48 00 Release 00 2004 04 PARKING LIGHT BULB WARNING Do not pull on the wiring to extract the bulb holder Grasp the parking light bulb holder 7 and pull to extract Remove the bulb 2 and fit a new bulb of equal rating 2 7 ...

Page 202: ...ve the lens 2 WARNING Ensure that the lens locates properly to the housing when refitting Tighten the screw 1 carefully Do not overtighten or the lens will damage Push down the bulb 3 gently and twist anti clockwise Extract the bulb 3 from the bulb holder WARNING When fitting the bulb ensure that the two locating pegs locate properly into the slots in the bulb holder Install a new bulb of equal ra...

Page 203: ...lens locates properly to the housing when refitting Tighten the screw 1 carefully Do not overtighten or the lens will damage Push down the bulb 3 gently and twist anti clockwise Extract the bulb 3 from the bulb holder WARNING When fitting the bulb ensure that the two locating pegs locate properly into the slots in the bulb holder Install a new bulb of equal rating WARNING If the bulb holder 4 slip...

Page 204: ... protective shield correctly into its seat Tighten the screws 2 gradually Do not overtighten or the protective shield will damage Push down on the bulb 1 lightly and twist anti clockwise Extract the bulb 1 from the bulb holder WARNING When fitting the bulb ensure that the two locating pegs locate properly into the slots in the bulb holder Install a new bulb of equal rating 6 15 5 TAIL LIGHT BULB R...

Page 205: ...ses A blown fuse is identified by the link bar 2 in the centre being divided When you find a blown fuse determine and rectify the cause if possible before fitting a new fuse Replace any failed fuses with a fuse of equal current rating NOTE When you use one of the spare fuses remember to add a new fuse of equal rating to the fuse box Remove the seat see 7 1 2 REMOVING THE RIDER SEAT Repeat the proc...

Page 206: ...ve the law in force in the country of the user To set beam height NOTE The instructions below apply to both light units Remove the front fairing panel see 7 1 18 REMOVING THE FRONT FAIRING Sit astride the motorcycle Right hand headlight unit 1 Working on the rear right hand side of the front fairing rotate the adjuster wheel 3 ROTATE CLOCKWISE to lower the beam ROTATE ANTI CLOCKWISE to raise the b...

Page 207: ... beam Remove the front fairing panel see 7 1 18 REMOVING THE FRONT FAIRING Sit astride the motorcycle Right hand headlight unit 1 Working on the rear right hand side of the front fairing turn the adjuster 3 using a screwdriver TIGHTEN turn clockwise to move the beam to the right SLACKEN turn anti clockwise to move the beam to the left Left hand headlight unit 2 Working on the rear left hand side o...

Page 208: ... 1000 1 0 1 2 3 4 5 6 7 8 9 10 11 12 0 20 40 60 80 90 100 140 160 180 200 220 240 260 280 T AIR SERVICE TIME EFI MODE SET F C L gal iagnosis D C ontrol ngine E EFI ABS km h km C1 B3 B2 B1 A4 A3 A2 A1 B4 E2 E C U H2 E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 D1 C4 C3 C2 D2 D3 D4 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 A1 H4 H3 G1 G2 G3 H1 F3 F4 G4 H2 H3 H4 E3 E4 F1 F2 1 54 Az G Ro Vi R M R Bi N...

Page 209: ... parking lights rear brake lights warning horn direction indicators and instrument panel D starter safety lockout system E spare 35 36 Pick up 37 Generator 38 Rectifier 39 Injection relay 40 41 Rear cylinder injector 42 Front cylinder injector 43 Cooling fan 44 Low fuel sensor 45 Fuel pump 46 Air thermistor Engine Control Unit 47 Coolant temperature thermistor Engine Control Unit 48 Throttle posit...

Page 210: ...ETV mille ELECTRICAL SYSTEM 6 57 00 Release 00 2004 04 NOTES ...

Page 211: ...ETV mille ELECTRICAL SYSTEM 6 58 00 Release 00 2004 04 NOTES ...

Page 212: ...ETV mille CHASSIS 7 1 00 Release 00 2004 04 7 CHASSIS ...

Page 213: ...T HAND RIDER FOOTPEG BRACKET 7 37 00 7 1 37 REMOVING THE RIGHT HAND RIDER FOOTPEG BRACKET 7 37 00 7 1 38 REMOVING THE RIDER FOOTPEG 7 38 00 7 1 39 REMOVING THE GEAR SHIFT LEVER ASSEMBLY 7 38 00 7 1 40 REMOVING THE REAR BRAKE LEVER 7 39 00 7 1 41 EXHAUST SILENCER REMOVAL 7 40 00 7 1 42 REMOVING THE EXHAUST PIPES 7 41 00 7 1 43 SIDE STAND REMOVAL 7 42 00 7 1 44 REMOVING THE ENGINE OIL TANK 7 43 00 7...

Page 214: ...OMPONENT INSPECTION 7 87 00 7 8 4 INSTALLING THE SWINGING ARM 7 88 00 7 9 REAR SUSPENSION 7 90 00 7 9 1 REAR SHOCK ABSORBER REMOVAL 7 90 00 7 9 2 REMOVING THE REAR SUSPENSION LINKAGES 7 92 00 7 9 3 DISMANTLING THE REAR SUSPENSION LINKAGE SYSTEM 7 93 00 7 9 4 COMPONENT INSPECTION 7 93 00 7 10 DISMANTLING THE DRIVE CHAIN 7 94 00 7 10 1 CHAIN TOOL 7 94 00 7 10 2 BREAKING THE CHAIN 7 95 00 7 10 3 FITT...

Page 215: ...g lock parking lights 5 Engine oil tank cap 6 Saddle lock 7 Rider left footrest 8 Rider saddle 9 Battery 10 Passenger seat 11 Electronic unit 12 Rear fork 13 Drive chain 14 Passenger left footrest snapping closed open 15 Centre stand 16 Side stand 17 Shifting lever 18 Engine oil filter 19 Engine oil tank 20 Engine oil level 21 Horn 22 Left fairing ...

Page 216: ...e carrier 15A 11 Air temperature sensor 12 Front phonic wheel 13 Coolant expansion tank cap 14 Coolant expansion 15 Rear brake control lever 16 Rider right footrest 17 Rear brake pump 18 Rear brake fluid tank 19 Passenger right footrest snapping closed open 20 Rear phonic wheel 21 ABS control unit 22 ABS fuses I I I I I I I I I I I II I I I I I IIIIIIIIIIIIII I I IIIIIIIIIIII I I I I I I I I I I I...

Page 217: ...ed in the glove tool kit compartment Slide the two front lugs 4 into their seats 5 Lower the seat 2 and press down The seat lock should click audibly into the locked position CAUTION Ensure that the seat 2 is locked securely in place before riding 7 1 2 REMOVING THE RIDER SEAT Remove the passenger seat see 7 1 1 RELEASING LOCKING THE PASSENGER SEAT Release and remove the two screws 1 and collect t...

Page 218: ...rew 4 Torque wrench setting for screw 4 6 Nm 0 6 kgm NOTE The next three steps are only necessary when removing the left side body panel Move aside the left side body panel 5 Disconnect the connector 6 from the power socket WARNING Ensure that the connector 6 is fitted to the matching connector on assembly Release the seat anchoring cable 7 WARNING Ensure that the seat anchoring cable 7 is fastene...

Page 219: ...p components Always make sure the fuel tank filler cap is closed securely Remove the seat see 7 1 2 REMOVING THE RIDER SEAT Release and remove the two front mounting bolts 1 of the fuel tank 2 and collect bushes and washers Torque wrench setting for bolts 1 10 Nm 1 0 kgm Release and remove the screw 3 Torque wrench setting for screw 3 5 Nm 0 5 kgm Release and remove the screw 4 Torque wrench setti...

Page 220: ...quick disconnect fittings 7 8 CAUTION On refitting ensure that the quick disconnect fittings 7 8 are re connected properly NOTE Make a note of the routing of the pipes 9 and 10 to position them correctly when refitting the fuel tank WARNING Do not disconnect the pipes 9 10 from the fuel tank Release the pipes 9 10 from the retainer 11 on the sprocket cover WARNING Do not exert exceeding force on t...

Page 221: ...D OR EXPLOSION HAZARD Place the motorcycle on the stand Release and remove the three screws 1 Torque wrench setting for screws 1 6 Nm 0 6 kgm NOTE The other three screws are there for aesthetic purposes only and can be left in place Open the filler cap 2 WARNING Be careful when removing the screw 3 Take care not to drop it into the fuel tank Release and remove the screw 3 Torque wrench setting for...

Page 222: ... wrench setting for screws 10 2 Nm 0 2 kgm Release the six screws 8 NOTE Lubricate the six screws 8 with oil part no 8116050 on assembly Torque wrench setting for screws 8 2 Nm 0 2 kgm Lift the airbox 9 and disconnect the connector 11 WARNING Make sure the connector 11 is properly fitted to the matching connector on assembly Remove the airbox 9 WARNING Block off the openings with a clean cloth to ...

Page 223: ...ive terminal screw 1 Slide the negative lead 2 aside Lift the red protective cap 3 Release and remove the positive terminal screw 4 Slide the positive lead 5 aside WARNING Do not pull on the wiring Release and remove the screw 6 Keep the nut 9 and the bush 10 Torque wrench setting for screw 6 5 Nm 0 5 kgm Raise the battery retaining bracket 7 Grasp the battery 8 firmly and lift it out of its mount...

Page 224: ...SSENGER SEAT Disconnect the two connectors 1 from the Ecu 2 WARNING Make sure the two connectors 1 are properly fitted to the matching connectors on assembly Release and remove the two screws 3 Torque wrench setting for screws 3 5 Nm 0 5 kgm Lift and remove the Ecu 2 from the rider seat WARNING Each time the Engine Control Unit 2 is replaced the throttle position sensor has to be set see 4 10 3 TH...

Page 225: ...nscrew and remove the screw 2 Tightening torque of the screws 2 10 Nm 1 0 kgm Collect the cup 3 Remove the hand guard Remove the counterweight 4 Slide the nozzle of an air gun between grip 5 and handlebar 6 Operate the gun while rotating the nozzle Grasp the grip 5 with the other hand and pull to extract 6 5 4 1 3 2 ...

Page 226: ... section Refit the clamp with the arrow pointing upwards When the clutch control 2 has to be taken off the handlebar Perform the first three steps of the procedure described in subsection 2 20 CHANGING THE FRONT BRAKE FLUID When all fluid has drained out release and remove the screw 4 and collect the two sealing washers Torque wrench setting for screw 4 20 Nm 2 0 kgm WARNING Renew the two sealing ...

Page 227: ... Separate the housing halves 2 3 WARNING Refit the bottom housing half 2 first on assembly Ensure that the locating peg locates into the hole in the left hand handlebar Remove the headlight see 7 1 20 HEADLIGHT REMOVAL Release the wiring harness from the clips 4 NOTE Make sure to have enough spare clips ready at hand to secure the harness properly on refitting Disconnect the connector 5 of the lef...

Page 228: ...x see 7 1 6 AIRBOX REMOVAL Slacken the locknut 3 Release the throttle cable adjuster 4 from the throttle cable anchor point Disconnect the throttle cable Repeat the last three steps for the other throttle cable WARNING On refitting ensure that both throttle cable adjusters are fastened securely to their anchor points Check free play and adjust if needed See 2 10 3 THROTTLE CABLE PLAY ADJUSTMENT Sl...

Page 229: ...ned by the hose NOTE The clamp 1 has an arrow etched in the top section Refit the clamp with the arrow pointing upwards When the front brake control 3 has to be taken off the handlebar Perform the first three steps of the procedure described in subsection 2 20 CHANGING THE FRONT BRAKE FLUID When all fluid has drained out release and remove the screw 4 and collect the two sealing washers Torque wre...

Page 230: ...rs 2 WARNING Make sure to refit the connectors 2 to the matching connectors on assembly Release the wiring from the clips 7 NOTE You will have to renew all clips on assembly Make sure to have enough spare clips ready at hand Release and remove the two bolts 3 4 that secure the two housing halves 5 6 at the bottom end Torque wrench setting for bolts 3 4 2 Nm 0 2 kgm NOTE The shorter screw 3 is fitt...

Page 231: ...1 of the ignition switch assembly at the main wiring harness WARNING Make sure to refit the connector 1 to the matching connector on assembly Release and remove the two screws 2 Withdraw the switch 3 from the bottom In the event you need to remove the ignition switch steering lock 4 completely Perform the first four steps outlined above Release and remove the two screws 5 6 Torque wrench setting f...

Page 232: ...ove the throttle control see 7 1 12 REMOVING THE THROTTLE CONTROL Release and remove the four screws 2 Torque wrench setting for screw 2 25 Nm 2 5 kgm NOTE Lubricate the four screws 2 with oil part no 8116050 on assembly Remove the plate 3 Remove the handlebar 4 together with left grip and counterweight 7 1 17 REMOVING THE REARVIEW MIRRORS Place the motorcycle on the stand Slip off the protective ...

Page 233: ...our bolts that secure the windshield front fairing Remove the windshield front fairing Unscrew and remove the four bolts that secure the upper dashboard bracket Remove the upper dashboard bracket Unscrew and remove the four bolts that secure the lower dashboard bracket Remove the lower dashboard bracket ...

Page 234: ...ETV mille CHASSIS 7 23 00 Release 00 2004 04 Work on both sides and remove the two lower fixing bolts Remove both side covers ...

Page 235: ...0 8 kgm Ease out the instrument panel 4 Slide back the protection sleeve 2 and disconnect the two connectors 3 WARNING Make sure to refit the connectors 3 to the matching connectors on assembly Remove the instrument panel 4 7 1 20 HEADLIGHT REMOVAL Remove the front fairing panel see 7 1 18 REMOVING THE FRONT FAIRING Disconnect the light connector 1 from the main wiring harness Unscrew and remove t...

Page 236: ...rew 3 Torque wrench setting for screw 3 4 Nm 0 4 kgm WARNING Handle all plastic and paint finished parts with care to avoid scratching or damage Withdraw the mudguard 2 from the front 7 1 22 REMOVING THE FRONT INDICATORS Remove the side fairing complete with the indicator see 7 1 18 REMOVING THE FRONT FAIRING Disconnect the electrical connector for the relevant indicator Unscrew the indicator fixi...

Page 237: ...HE LOWER SUMP GUARD Unscrew and remove the four fixing screws Remove the lower sump guard 7 1 25 WARNING HORN REMOVAL Remove the radiator spoiler see 7 1 24 REMOVING THE LOWER SUMP GUARD Disconnect the two connectors 1 WARNING Ensure that both connectors 1 are fitted to the matching connectors on assembly Release and remove the screw 2 Torque wrench setting for screw 2 25 Nm 2 5 kgm Remove the hor...

Page 238: ...REMOVING THE INSTRUMENT PANEL Disconnect the five connectors 1 WARNING Ensure that the connectors 1 are fitted to the matching connectors on assembly Extract the bank angle sensor 2 and the flasher 3 from their mounts but leave them connected to the wiring Release and remove the two screws 4 Torque wrench setting for screws 4 5 Nm 0 5 kgm Remove the relay box 5 Release and remove the two screws 6 ...

Page 239: ... 1 0 kgm Withdraw the two screws 12 from the opposite side Remove the instrument panel front fairing subframe 8 7 1 27 REMOVING THE FRONT FAIRING LOWER LOCKUP Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Place the motorcycle on the stand Release and remove the four screws 1 Torque wrench setting for screws 1 10 Nm 1 0 kgm WARNING Take care not to damage the brake hoses Handle plastic a...

Page 240: ...lips on assembly Make sure to have enough spare clips ready at hand Undo and remove the three nuts 2 Remove the tail light 7 1 29 GRAB RAIL REMOVAL Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Remove the passenger seat see 7 1 1 RELEASING LOCKING THE PASSENGER SEAT Release and remove the four screws 1 Torque wrench setting for screws 1 25 Nm 2 5 kgm Remove the grab rail 2 Collect the t...

Page 241: ...EMOVING THE SEAT LOWER MOULDED COVER Prise the clip 2 open with a screwdriver to release the seat releasing cable 1 WARNING Ensure that the cable 1 is routed correctly and is not twisted on assembly Release and remove the two nuts 3 that retain the lock 4 and collect the two screws on the opposite side Torque wrench setting for nuts 3 7 Nm 0 7 kgm Remove the passenger seat lock 4 2 1 3 4 ...

Page 242: ...ail see 7 1 29 GRAB RAIL REMOVAL Release and remove the two front retaining screws 1 Torque wrench setting for screws 1 25 Nm 2 5 kgm Release and remove the screw 2 Torque wrench setting for screw 2 5 Nm 0 5 kgm Lift the seat lower moulded cover 3 Release the passenger seat releasing cable 4 WARNING Ensure that the cable 4 is routed correctly and is not twisted on assembly Remove the seat lower mo...

Page 243: ...e described in subsection 7 1 28 TAIL LIGHT REMOVAL Release and remove the screw 1 and collect the nut 2 Release the cable from its mounting point WARNING On refitting make sure the cable locates correctly into its mounting point Remove the direction indicator 3 NOTE Repeat the process for the other direction indicator if needed 3 1 2 ...

Page 244: ...ROL UNIT Remove the number plate bracket see 7 1 34 REMOVING THE NUMBER PLATE BRACKET Take the tool kit and any personal belongings out of the glove compartment Release the fuse carrier 1 from its mount Release diode module 2 engine cutout relay 3 fuel pump relay 4 and fuel injection relay 5 from their mounts Release the two rear coils 6 from their mounts Undo and remove the two nuts 7 Torque wren...

Page 245: ...2004 04 Release and remove the two screws 9 Torque wrench setting for screws 9 6 Nm 0 6 kgm Release and remove the two screws 10 Torque wrench setting for screws 10 6 Nm 0 6 kgm Remove the seat end cover pulling in a rearward motion 9 9 10 ...

Page 246: ...e four connectors 1 WARNING Make sure to refit the connectors 1 to the matching connectors on assembly Release and remove the screw 2 Torque wrench setting for screw 2 5 Nm 0 5 kgm Release and remove the screw 3 Torque wrench setting for screw 3 25 Nm 2 5 kgm Remove the number plate bracket 4 together with tail light 5 number plate light 6 and rear direction indicators 7 NOTE If needed the individ...

Page 247: ...stand CAUTION Allow the engine and exhaust silencer to cool down completely Release and remove the two screws 1 Torque wrench setting for screws 1 25 Nm 2 5 kgm Remove the heat guard 2 complete with footpeg 3 If needed Remove the retaining ring 4 Withdraw the spindle 5 Remove the footpeg 3 NOTE Repeat process to remove the other passenger footpeg if needed 1 3 1 2 4 5 ...

Page 248: ...the left hand rider footpeg bracket 2 complete with left hand rider footpeg 3 and side stand 4 7 1 37 REMOVING THE RIGHT HAND RIDER FOOTPEG BRACKET Remove the rear brake lever see subsection 7 1 40 REMOVING THE REAR BRAKE LEVER Undo and remove the nut 1 Remove the rear brake light switch 2 Release and remove the two screws 3 NOTE Lubricate the screws 3 with oil part no 8116050 on assembly Torque w...

Page 249: ...ining ring 1 Withdraw the spindle 2 Collect footpeg 3 and spring 4 NOTE Repeat the process to remove the other rider footpeg if needed 7 1 39 REMOVING THE GEAR SHIFT LEVER ASSEMBLY WARNING Mark lever and spindle before removal to ensure they are refitted in the correct position on assembly Place the motorcycle on the centre stand Slacken the screw 1 and slide the gear shift lever 2 off the spindle...

Page 250: ...safety ring 1 aside Rotate the pin 2 of the clevis pin fork downwards Withdraw the pin 2 of the clevis pin fork Unhook the spring 3 from the lever 4 and collect the seal 5 Release and remove the pivot bolt 6 and collect the O ring Remove the lever 4 NOTE Apply LOCTITE 243 to the thread of the pivot bolt 6 on assembly Torque wrench setting for pivot bolt 6 20 Nm 2 0 kgm 2 6 1 3 4 5 ...

Page 251: ...ns to eliminate any resistance due to scale accumulation Withdraw the exhaust silencer 3 until removing it completely WARNING Block off the exhaust pipe opening to prevent the ingress of dirt If needed remove the guards as follows Release and remove the four screws 8 and collect the washers 9 NOTE Apply LOCTITE 243 to the four screws 8 on assembly Torque wrench setting for screws 8 for models not ...

Page 252: ...ylinder Torque wrench setting for nuts 3 25 Nm 2 5 kgm Undo and remove the three nuts 6 that secure the exhaust pipe flange 2 to the rear cylinder Torque wrench setting for nuts 6 25 Nm 2 5 kgm WARNING Pull gently when separating the exhaust pipes 4 2 from the cylinders or the stud bolt threads will damage Twist the exhaust pipe 2 slightly in both direction and pull until lifting it off the exhaus...

Page 253: ...he connector 3 is fitted to the matching connector on assembly Release the wire from the hook WARNING Make sure to route the wire correctly when refitting Release the two springs 4 Undo and remove the nut 2 and collect the washers 5 Torque wrench setting for nut 2 30 Nm 3 0 kgm Release and remove the pivot bolt 7 complete with stand switch 1 Remove the stand 6 If you need to remove the side stand ...

Page 254: ...same type fitted originally on assembly Release the clip 2 Detach the hose 3 from the engine oil filter 4 Tilt the oil tank 9 Release the two clips 5 6 Withdraw the hoses 7 8 Remove the oil tank 9 Release and remove the engine oil filter 4 fitted to the tank and blow it with compressed air Check the seal of the engine oil filter 4 fitted to the tank 9 Refit and tighten the filter Torque wrench set...

Page 255: ...ally on assembly Release the clips 2 3 Withdraw the hoses 4 5 Release and remove the three retaining screws 6 Torque wrench setting for screws 6 10 Nm 1 0 kgm NOTE Replace the seals if damaged Remove the oil cooler 1 7 1 46 UPPER CHAIN GUARD REMOVAL Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Place the motorcycle on the stand Release and remove the screw 1 Torque wrench setting for sc...

Page 256: ...ETV mille CHASSIS 7 45 00 Release 00 2004 04 7 1 47 REMOVING THE CHAIN GUARD Unscrew and remove the front fixing screw Unscrew and remove the lower fixing screw Remove the guard ...

Page 257: ...E Slacken the drive chain a bit to facilitate removal of the drive sprocket 4 See 2 35 3 CHAIN SLACK ADJUSTMENT Withdraw the drive sprocket 4 together with the chain from the shaft Remove the drive sprocket 4 NOTE Apply LOCTITE Anti Seize to the inner toothing of the drive sprocket 4 on assembly Remove the upper chain guard see 7 1 46 UPPER CHAIN GUARD REMOVAL Release and remove the screws 5 6 Tor...

Page 258: ...remove the two screws 9 Remove the rectifier 10 Release the wire from the clips 3 NOTE You will have to renew all the clips on refitting Make sure to have enough spare clips ready at hand Release the starter relay housing 1 from its mount Release and remove the two screws 4 from the shock absorber adjuster knob 5 Move aside the shock absorber adjuster knob 5 WARNING Take care not to damage the sho...

Page 259: ...ETV mille CHASSIS 7 48 00 Release 00 2004 04 7 1 50 REMOVING THE SIDE GUARDS Unscrew and remove the rear screw and bush Unscrew and remove the front fixing screw Remove the side guard ...

Page 260: ...ETV mille CHASSIS 7 49 00 Release 00 2004 04 7 1 51 REMOVING THE INNER GUARD Unscrew and remove the two rear screws Unscrew and remove the two front screws Remove the inner guard ...

Page 261: ...ove the two side fairings Remove the upper sump guard see 7 1 23 REMOVING THE UPPER SUMP GUARD Remove the lower sump guard see 7 1 24 REMOVING THE LOWER SUMP GUARD Remove the hose clamp that holds the breather pipes on the left Unscrew and remove the two rear fixing bolts Unscrew and remove the two front fixing bolts Remove the sump guard protection ...

Page 262: ... sure to perform just the operations strictly required to give access to the component to be removed Remove the engine see 3 3 TAKING THE ENGINE OUT OF THE FRAME Place the motorcycle on the special centre stand see 1 9 2 PLACING THE MOTORCYCLE ON THE CENTRE STAND Remove the front end complete with front wheel assembly see 7 6 1 HEADSTOCK REMOVAL Remove the instrument panel subframe 2 see 7 1 26 RE...

Page 263: ...emoving the side stand bracket 13 or you might damage the switch Release and remove the three screws 12 Remove the left hand rider footpeg bracket 13 complete with side stand 14 and switch Torque wrench setting for screws 12 50 Nm 5 0 kgm NOTE Lubricate the screws 12 with oil part no 8116050 on assembly Place the frame 1 in a sling and hook the slings to a hoist to support the frame WARNING Slings...

Page 264: ...e CHASSIS 7 53 00 Release 00 2004 04 7 2 FRONT WHEEL Key 1 Wheel spindle 2 Spacer 3 Washer 4 Nut GREASE see 1 6 LUBRICANT CHART 7 2 1 ADJUSTING WHEEL SPOKE TENSION See 2 33 ADJUSTING WHEEL SPOKE TENSION 4 3 2 1 ...

Page 265: ... remove the two mounting bolts 1 of the front brake caliper 2 Torque wrench setting for caliper mounting bolts 1 50 Nm 5 0 kgm Remove the brake caliper 2 from the brake disc but leave the caliper 3 attached to the brake line WARNING Do not operate the front brake lever when the calipers are not in place or the pistons might fall out leading to brake fluid spillage Undo and remove the nut 4 and col...

Page 266: ...bearing 4 using a suitable bearing extractor WARNING Inspect the bearings after each removal and replace as required See 7 2 4 WHEEL COMPONENT INSPECTION Collect the inner spacer 5 Clean the hub bore thoroughly NOTE Wash all components using clean detergent WARNING Refit the bearings using a drift with the same diameter as the bearing outer ring Do not tap the balls or the inner ring Ensure that t...

Page 267: ...ls for damage or wear and replace as required WHEEL SPINDLE Check spindle 2 run out using a dial gauge Replace the spindle 2 when run out exceeds the maximum limit allowed Wheel spindle run out limit 0 25 mm WHEEL RIM Use a dial gauge to ensure that wheel rim radial and axial run out does not exceed the maximum limit allowed Exceeding run out is normally due to worn or damaged bearings Replace the...

Page 268: ...aligns with the holes in the forks Slide the wheel spindle 1 fully home Fit the washer and screw the nut 2 hand tight Tighten the two wheel spindle clamp bolts 3 to prevent wheel spindle 1 rotation Torque wrench setting for wheel spindle clamp bolts 3 10 Nm 1 0 kgm Tighten the nut 2 to the specified torque Torque wrench setting for wheel hub nut 2 80 Nm 8 0 kgm Tighten the two wheel spindle clamp ...

Page 269: ... down This will allow the fork legs to seat themselves properly Tighten the two wheel spindle clamp bolts 3 Torque wrench setting for wheel spindle clamp bolts 3 10 Nm 1 0 kgm WARNING After refitting the wheel work the front brake lever repeatedly and check for proper operation of the brake Ensure that the wheel is properly centred and balanced 4 3 ...

Page 270: ...SSIS 7 59 00 Release 00 2004 04 7 3 REAR WHEEL Key 1 Wheel spindle 2 Spacer 3 Wheel 4 Washer 5 Nut GREASE see 1 6 LUBRICANT CHART 7 3 1 ADJUSTING WHEEL SPOKE TENSION See 2 33 ADJUSTING WHEEL SPOKE TENSION 1 4 5 3 2 ...

Page 271: ...spindle 2 from the right hand side Push the wheel forward and take the drive chain 3 off the rear sprocket 4 WARNING Note the positions of the chain tensioner sliders 5 6 to ensure they are refitted at the correct locations on assembly Remove the right hand 5 and left hand 6 chain tensioner sliders Remove the wheel pulling in a rearward motion WARNING Do not operate the rear brake lever with the w...

Page 272: ...NG Inspect the bearings after each removal and replace as required Clean the hub bore thoroughly NOTE Wash all components using clean detergent WARNING Refit the bearings using a drift with the same diameter as the bearing outer ring Do not tap the balls or the inner ring Ensure that the inboard bearing 5 is fully home in the hub If needed Release and remove the six bolts 6 Collect the nuts 7 and ...

Page 273: ...ve the left hand bearing 3 first and then the right hand bearing 4 using a suitable bearing extractor WARNING Inspect the bearings after each removal and replace as required Collect the inner spacer 5 Clean the hub bore thoroughly NOTE Wash all components using clean detergent WARNING Refit the bearings using a drift with the same diameter as the bearing outer ring Do not tap the balls or the inne...

Page 274: ... rear chain sprocket 3 by hand in both directions Check the play between cush drive rubbers 1 and wheel hub In the event excess play is found replace all cush drive rubbers 1 REAR CHAIN SPROCKET Check the toothing of front and rear 3 chain sprockets for wear In the event excess wear is found replace front and rear chain sprockets and drive chain as a set see 7 3 3 DISMANTLING THE FINAL DRIVE ASSEM...

Page 275: ...o the swinging arm Push the wheel forward and wrap the drive chain 7 around the rear chain sprocket 8 CAUTION Do not attempt to align the holes by putting your fingers into the holes This could result in severe personal injury Move the wheel backward until the wheel hub bore aligns with the holes in the swinging arm Rotate the brake caliper carrier 1 complete with brake caliper 2 The carrier will ...

Page 276: ...Brake calipers The front brake is discussed in further detail in the following sections see 1 2 4 BRAKE FLUID see 2 15 CHECKING AND TOPPING UP FRONT BRAKE FLUID LEVEL see 2 18 BLEEDING THE BRAKE CIRCUITS see 2 26 CHECKING BRAKE PADS FOR WEAR see 8 4 5 FRONT BRAKING SYSTEM WARNING The two caliper mounting bolts must be replaced with new bolts of the same type each time the caliper is removed 1 6 7 ...

Page 277: ...Extract both brake pads 4 WARNING Do not operate the brake lever with the brake pads removed or the brake caliper pistons might fall out leading to loss of brake fluid Fit new brake pads taking care to align the holes with the caliper holes WARNING The brake pads must always be replaced in pairs Ensure they become properly seated in the brake caliper Refit the spindle 3 Insert the elastic stop 5 R...

Page 278: ...AKE DISC REMOVAL Disc run out limit 0 3 mm 7 4 3 BRAKE DISC REMOVAL Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Remove the front wheel see 7 2 2 WHEEL REMOVAL NOTE The operations described below apply to both brake discs The screws 1 are retained with LOCTITE 243 Use of an air gun is recommended to release the screws Release and remove the six brake disc screws 1 Torque wrench setting...

Page 279: ...al 10 Brake master cylinder The rear brake is discussed in further detail in the following sections see 1 2 4 BRAKE FLUID see 2 16 CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL see 2 18 BLEEDING THE BRAKE CIRCUITS see 2 24 ADJUSTING REAR BRAKE LEVER PLAY see 2 26 CHECKING BRAKE PADS FOR WEAR see 8 4 6 REAR BRAKING SYSTEM WARNING The two caliper mounting bolts must be replaced with new bolts of th...

Page 280: ...e the position of the retaining clip 9 before removing the caliper half 8 The clip must be refitted in the original position and direction on assembly Take apart the two caliper halves 7 8 Collect the retaining clip 9 Extract the two brake pads 2 WARNING Do not operate the brake lever after removing the brake pads 2 or the pistons might fall out leading to brake fluid spillage Fit two new pads Mak...

Page 281: ...out measured exceeds the disc run out limit see 7 5 3 BRAKE DISC REMOVAL Disc run out limit 0 3 mm 7 5 3 BRAKE DISC REMOVAL Read 0 5 1 GENERAL PRECAUTIONS AND INFORMATION carefully Remove the rear wheel see 7 3 2 WHEEL REMOVAL NOTE The screws 1 are retained with LOCTITE 243 Use of an air gun is recommended to release the screws Release and remove the six screws 1 WARNING Apply LOCTITE 243 to the t...

Page 282: ...d collect the two sealing washers Torque wrench setting for screw 1 20 Nm 2 0 kgm Perform the first four steps of the procedure described in subsection 7 1 40 REMOVING THE REAR BRAKE LEVER Slacken the hose clip 2 and slide it aside Detach the hose 3 from the fitting at master cylinder end Remove the rear brake fluid reservoir 7 together with master cylinder guard 6 and hose 3 Remove the master cyl...

Page 283: ...4 Lockring 5 Locking washer 6 Adjusting ring 7 Protection cap 8 Dust seal 9 Bearings 10 Bottom yoke 11 Washer GREASE see 1 6 LUBRICANT CHART The steering is discussed in further detail in the following sections see 2 27 STEERING see 2 28 INSPECTING THE FRONT SUSPENSION 1 2 3 4 5 6 8 7 9 11 8 10 ...

Page 284: ...USTING PLAY IN THE BEARINGS Use the special socket to slacken and remove the adjusting ring 4 WARNING The front end is heavy An assistant will be required to support it When working with an assistant plan the whole procedure carefully together Proceed with the utmost care when removing the headstock Make sure the brake hose does not snag on any parts during the process While the assistant holds th...

Page 285: ... procedure to assemble Smear a light coat of grease over the total length of the stem 1 see 1 6 LUBRICANT CHART Before finally tightening the adjusting ring 2 turn the steering in both directions repeatedly This will allow the bearings to seat themselves properly Adjust play in the bearings see 2 27 2 ADJUSTING PLAY IN THE BEARINGS Turn the handlebars to ensure that cables and hoses do not bind En...

Page 286: ...op cap 2 O ring 3 Slider 4 Spacer tube 5 Spring 6 Capscrew 7 Washer 8 Stanchion tube 9 Damping cylinder assembly 10 Oil seal 11 Bush 12 Spring 13 Dust seal 14 Retaining ring 15 Guide ring 16 Oil seal 17 Washer 18 Guide bush 1 2 4 5 10 12 9 11 13 14 16 17 18 8 7 6 15 3 ...

Page 287: ...rvice the fork legs one at a time Always refit a fork leg in the correct position before removing the other Place the motorcycle on a lift with the front wheel protruding over the runway edge Put the motorcycle on the centre stand Secure the tail section to the runway with suitable belts so to raise the front wheel Remove the front wheel see 7 2 2 WHEEL REMOVAL It is not necessary to use a front w...

Page 288: ...n and slider thoroughly NOTE Make sure to have a container having a capacity greater than 750 cu cm ready at hand before proceeding WARNING Use utmost care during the disassembly procedure Place the slider 3 in a vice with soft jaws Slacken the top cap 1 using an Allen socket Take care not to damage the O ring 2 during removal Push the stanchion into the slider WARNING The stanchion and slider ass...

Page 289: ... collect the copper washer 7 Extract the damping cylinder 9 complete with oil seal 10 bush 11 and spring 12 from the slider 3 NOTE Replace the whole damping cylinder assembly 9 if damaged The only component that can be replaced individually is the oil seal 10 Prise off the dust seal 13 using a flat blade screwdriver 8 6 7 10 9 12 11 13 8 3 ...

Page 290: ...ider 3 and pull firmly to separate it from the stanchion 8 The guide ring 15 acts as a stopper and will draw oil seal 16 washer 17 and guide bush 18 out of the stanchion 8 when it is extracted Use a small screwdriver to take guide ring 15 and guide bush 18 apart This will release the washer 17 and oil seal 16 from the slider 3 3 14 8 18 15 17 16 ...

Page 291: ...all structure leading to a dangerous riding condition SLIDER Inspect for damage and or cracking Replace if damaged SPRING Check spring condition 2 and length Replace the spring 2 if stretched beyond the service limit Minimum length of the uncompressed spring 400 mm Check the condition of the following components guide ring 3 guide bush 4 damping cylinder 5 oil seal 6 Replace any component which sh...

Page 292: ... INSPECTION Use utmost care during the re assembly procedure NOTE Make sure to have the special tool A ready at hand before proceeding Apply a light film of fork oil to the bushes and seals before assembly See 1 6 LUBRICANT CHART Install the components to the slider 1 in the order dust seal 2 retaining ring 3 oil seal 4 lubricate before fitment washer 5 guide bush 6 guide ring 7 Place the stanchio...

Page 293: ...for specifications Measure level fitting a graduated rod 16 into the slider 1 Oil quantity 750 2 5 cu cm Oil level 120 2 mm from slider edge NOTE The slider 1 must be perfectly vertical to ensure accurate measurement Oil level must be the same in both fork legs Insert the spacer tube 17 into the slider 1 Make sure the O ring 19 is fitted to the slider top cap 18 Start the slider top cap 18 in the ...

Page 294: ...operly seated in the top 4 and bottom yokes 3 Tighten the two bolts 6 securing the bottom yoke 3 to the slider 1 Torque wrench setting for bolts 6 25 Nm 2 5 kgm Tighten the bolt 7 securing the top yoke 4 to the slider 1 Torque wrench setting for bolt 7 25 Nm 2 5 kgm Withdraw the wheel spindle 5 Refit the wheel see 7 2 2 WHEEL REMOVAL WARNING When finished operate the front brake and press down on ...

Page 295: ...the rear brake caliper 3 WARNING On refitting replace the two caliper 3 mounting bolts 2 with new bolts of the same type fitted originally Torque wrench setting for bolts 2 25 Nm 2 5 kgm WARNING Take care not to damage the brake hose brake disc and brake pads during removal Slide the brake caliper 3 off the brake disc 4 WARNING Do not operate the rear brake lever when the caliper is not in place o...

Page 296: ...ht hand side of the motorcycle rotate the swinging arm spindle 17 anti clockwise The spindle will draw the adjusting ring 9 until it works itself loose WARNING The tail section is heavy An assistant will be required to perform the following operations When working with an assistant plan the whole procedure carefully together Use utmost care when removing the swinging arm Support the swinging arm a...

Page 297: ...ng a suitable extractor WARNING Inspect the bearings after each removal Replace as required Remove the inner spacer 7 and collect the two O rings 8 Remove the inner spacer 9 Remove the seals 10 Remove the two roller bearings 11 using a suitable extractor WARNING Inspect the bearings after each removal Replace as required Clean the inside of the bearing housings thoroughly NOTE Wash all components ...

Page 298: ...t rotate smoothly with no hardness or noise There should be no end float Replace any bearings that do not meet these requirements WARNING Apply grease to the bearing balls on the sides of each bearing and needle rollers see 1 6 LUBRICANT CHART SEALS Check the condition of the seals Replace any damaged or worn seals SWINGING ARM SPINDLE Check spindle 2 run out using a dial gauge Replace spindle 2 w...

Page 299: ...the spindle 1 fully home NOTE Ensure that the hexagon of the spindle head 1 locates correctly into the adjusting bush 2 Fit the lockring 4 and turn in manually by a few turns Fit the nut 5 to the spindle 1 Screw the nut hand tight Adjust the swinging arm see 2 29 1 SWINGING ARM ADJUSTMENT Remove the adhesive tape to release the drive chain 3 Wrap the chain 3 around the drive sprocket 6 NOTE Apply ...

Page 300: ...bolts of the same type fitted originally Tighten the two bolts 15 Torque wrench setting for bolts 15 25 Nm 2 5 kgm Place the speed sensor 16 in its seat Tighten the screw 17 Torque wrench setting for screw 17 12 Nm 1 2 kgm Place the brake hose and the speed sensor cable in their seats on the swingarm Secure the speed sensor cable to the brake hose using a plastic clip 18 Position the hose retainer...

Page 301: ...t the bolt 2 but not quite all the way Torque wrench setting for nut 1 45 Nm 4 5 kgm Withdraw the bolt 2 from the opposite side Release and remove the nut 4 Torque wrench setting for nut 4 45 Nm 4 5 kgm Withdraw the pivot bolt 3 that secures the link to the swinging arm from the opposite Working on the right hand side of the motorcycle release and remove the bolt 5 and collect the washer Torque wr...

Page 302: ... reservoir aside Grasp the shock absorber 8 and remove in a downward motion Withdraw the spacer 12 on the shock absorber upper fork Withdraw the silentbloc 13 on the shock absorber upper connection NOTE Wash all components with clean detergents Inspect all components see 7 9 4 COMPONENT INSPECTION 11 10 10 11 12 8 13 ...

Page 303: ...washer Torque wrench setting for nut 3 40 Nm 4 0 kgm Working from the right hand side of the motorcycle release and remove the nut 5 Torque wrench setting for nut 5 45 Nm 4 5 kgm Withdraw the bolt 6 from the opposite side Remove the complete linkage system 4 of the rear suspension NOTE Grease all pivot points of the linkages when refitting see 1 6 LUBRICANT CHART Take care to refit all parts in th...

Page 304: ...row marks on the double connecting links arrowed in the diagram must be placed uppermost facing outside and pointing in the direction of travel 7 9 4 COMPONENT INSPECTION WARNING Visually inspect all components for distortion damage cracking and denting Replace any damaged components BEARINGS Rotate the bearing needle rollers manually They must rotate smoothly with no hardness or noise There shoul...

Page 305: ... only rivet type chains on this motorcycle Key to tool diagram 1 Tool main body 2 Hex nut width across flats 27 mm 3 Hexagon head screw width across flats 19 mm 4 Locating peg 5 Rivet tool 6 Reference marks A and B 7 Rivet holes 8 Rivet exit hole 9 Driving pin 10 Extractor end 11 Driving end 12 Supporting plate Key to chain diagram 13 Connecting link plate 14 O rings 15 Outer link plate 1 9 5 12 4...

Page 306: ...pin 2 to the tool body 3 with the larger diameter end facing into the tool body Fit the tool body 3 to the rivet tool 1 Move the tool body 3 until the locating peg 4 lines up with the mark A on the rivet tool 1 Turn in the screw 5 manually until the driving pin 2 contacts the rivet to be extracted NOTE Make sure that the driving pin 2 is perfectly centred to the rivet to be pushed out Fit a 27 mm ...

Page 307: ...ings at the end of the pins Fit the outer link plate to the pins Fit the supporting plate 6 to the outer link plate Fit the rivet tool 1 to the chain Move the rivet tool 1 until the tool side holes align with the heads of the connecting link pins Fit the driving pin 2 to the tool body 3 with the smaller diameter end facing into the body Fit the tool body 3 to the rivet tool 1 Move the tool body 3 ...

Page 308: ...ving pin 6 contacts the rivet NOTE Make sure that the driving pin 6 is perfectly aligned with the rivet WARNING Wear protective goggles or a face shield Fit a 27 mm spanner to the hex nut on the tool body 2 to hold the tool body steady Tighten the screw 1 using a 19 mm spanner until squeezing the rivet end WARNING Ensure that the rivet is fastened securely The closing head of the rivet must be eve...

Page 309: ...ETV mille CHASSIS 7 98 00 Release 00 2004 04 NOTE ...

Page 310: ...ETV mille REPAIR INFORMATION 8 1 00 Release 00 2004 04 8 REPAIR INFORMATION ...

Page 311: ... 00 8 2 9 BREATHER AND DRAIN HOSES 8 19 00 8 2 10 WIRING 8 20 00 8 3 ELECTRICAL SYSTEM INSPECTION 8 26 00 8 3 1 SPARK PLUGS NO SPARK 8 26 00 8 3 2 PROBLEMS WITH BATTERY CHARGING 8 26 00 8 3 3 PROBLEMS WITH IGNITION AND OR STARTING 8 26 00 8 3 4 PROBLEMS WITH THE AUXILIARY SYSTEMS 8 27 00 8 4 ELECTRICAL SYSTEM INSPECTION 8 28 00 8 4 1 ENGINE 8 28 00 8 4 2 THROTTLE BODY COMPONENTS 8 28 00 8 4 3 FUEL...

Page 312: ...4 1 ENGINE WORKSHOP MANU ALS 8 1 1 ENGINE TROUBLE SYMPTOM AND POSSIBLE CAUSE REMEDY Engine does not start or is difficult to start Set the engine kill switch to Set to and press Safety lockout system has cut in Check and rectify as required Bank angle sensor faulty Replace Breather hole in fuel filler cap obstructed Clean Battery low Charge the battery Battery damaged Replace Freewheeling clutch o...

Page 313: ...ce Camshafts worn Replace See also Engine does not start or is difficult to start for other possible causes Loss of power Foul spark plugs Clean or replace Spark plugs do not meet specification Replace Valve clearance too tight Adjust Exhaust system defective Replace Valve timing incorrectly adjusted Adjust Valve springs defective Replace Valve seats leaking Re cut valve seats Intake hose or intak...

Page 314: ...tem leaking Replace Faulty injector Replace Cylinder head gasket defective Replace Engine produces exceeding exhaust fumes blue smoke Clutch membrane leaking Replace Valve stem seals worn Replace Valve stems or valve guides worn Replace Cylinder barrel scratched or scored Replace Piston rings or cylinder worn Replace Cylinder head gasket leaking Replace Engine vibration Engine fixings loose Tighte...

Page 315: ...g plate faulty Replace Primary drive worn or broken Replace Noise seems to come from the flywheel casing Timing gears worn or broken Replace Noise seems to come from the crankpin con rod assembly Connecting rod bearings worn Replace Crankshaft bearing sleeves or balancing shaft bearings worn Replace Noise seems to come from the transmission Transmission gears or shafts worn or broken Replace Prima...

Page 316: ...e Selector forks worn or distorted Replace See also Clutch does not disengage for other possible causes Gears slip out upon starting or under harsh acceleration Selector gears worn Replace Selector forks worn or distorted Replace Guide springs worn or broken Replace Up downshift is rough or gear does not engage fully gear shift lever distorted or improperly adjusted Push down gear shift pedal all ...

Page 317: ...Repair or tighten Alternator stator coils discharging to ground or interrupted Replace Regulator rectifier faulty Replace Battery faulty Replace Alternator is overcharging the battery Short circuit inside battery Repair or replace Regulator rectifier damaged or faulty Replace Ground of regulator rectifier erratic Replace Erratic charge Terminal insulator worn due to vibration causes transient shor...

Page 318: ... Wheel hub bearing damaged Replace Front or rear wheel spindle loose Tighten to the specified torque Brake pads worn Replace Brake lever has exceeding travel Air in the hydraulic circuit Bleed the circuit Brake fluid level low Replace Brake fluid does not meet specification Replace Brake caliper pistons jammed Dismantle and clean Brake fluid leakage Fittings loose Tighten to the specified torque H...

Page 319: ... suspension mountings loose Tighten Rear wheel wobbles Wheel rim warped Replace Wheel hub bearings worn Replace Tyre defective or does not meet specification Replace Swinging arm bearings worn Replace Suspension bolts and nuts loose Replace Rear wheel nut loose Tighten Rear suspension too soft Shock absorber spring yielded Replace Adjusters incorrectly set Adjust Shock absorber is leaking oil Repl...

Page 320: ...ETV mille REPAIR INFORMATION 8 11 00 Release 00 2004 04 8 2 ROUTING AND CONNECTIONS OF WIRING CABLES AND HOSES 8 2 1 FRONT BRAKE HOSES 8 2 2 REAR BRAKE HOSES A C D B A B C D E F E F ...

Page 321: ...ETV mille REPAIR INFORMATION 8 12 00 Release 00 2004 04 8 2 3 FUEL SYSTEM HOSES B A A B A C D C D ...

Page 322: ...ETV mille REPAIR INFORMATION 8 13 00 Release 00 2004 04 8 2 4 CLUTCH HOSE 8 2 5 PRESSURE TUBES FOR PPC DEVICE A B A B C D E C D E ...

Page 323: ...ETV mille REPAIR INFORMATION 8 14 00 Release 00 2004 04 8 2 6 COOLING SYSTEM TUBES B A A B B C C D ...

Page 324: ...ETV mille REPAIR INFORMATION 8 15 00 Release 00 2004 04 8 2 7 THROTTLE CABLES E D D E G F F G ...

Page 325: ...ETV mille REPAIR INFORMATION 8 16 00 Release 00 2004 04 8 2 8 ENGINE OIL TUBES A B A B D C C D ...

Page 326: ...ETV mille REPAIR INFORMATION 8 17 00 Release 00 2004 04 8 2 9 BREATHER AND DRAIN HOSES B A C A B C ...

Page 327: ...ox 7 Right hand light dip switch connector 8 Instrument panel connectors 9 Throttle position sensor 10 Air temperature sensor 11 Left hand light dip switch connector 12 Light dip steering lock switch 13 Oil pressure sensor 14 Rear brake light 15 Engine ground 16 Fuel injection connectors 17 Speed sensor 18 Power outlet 15 16 5 17 18 14 13 11 2 7 9 8 10 12 4 6 1 3 ...

Page 328: ...TV mille REPAIR INFORMATION 8 19 00 Release 00 2004 04 Key 1 Battery positive terminal 2 Rear direction indicator 3 Rectifier 4 Tail light and number plate light 5 Main fuses 6 Starter relay 1 5 6 2 4 3 ...

Page 329: ...und 9 Pick up 10 Coolant temperature sensor 11 Diagnosis connector 12 Front cylinder coil no 1 13 Front cylinder coil no 2 14 Rear cylinder coil no 1 15 Rear cylinder coil no 2 16 Front cylinder injector 17 Rear cylinder injector 18 Throttle position sensor 19 Engine stop relay 20 Fuel injection relay 21 Diode module 22 Automatic air adjustment motor 1 8 12 6 13 18 8 16 7 10 4 11 5 2 14 15 20 3 19...

Page 330: ...ETV mille REPAIR INFORMATION 8 21 00 Release 00 2004 04 ...

Page 331: ...ETV mille REPAIR INFORMATION 8 22 00 Release 00 2004 04 ...

Page 332: ...ystem see 6 4 2 TROUBLESHOOTING IF THE ENGINE DOES NOT START In addition See 6 6 6 IGNITION COIL TEST See 6 6 7 CRANKSHAFT POSITION SENSOR TEST See 6 4 4 BANK ANGLE SENSOR TEST See 6 6 4 AIR THERMISTOR TEST See 6 6 5 COOLANT THERMISTOR TEST See 6 6 3 THROTTLE POSITION SENSOR TEST See 6 6 1 INJECTOR TEST See 6 7 2 FUEL PUMP TEST See 6 7 3 TEST OF FUEL PUMP RELAY AND ENGINE CUTOUT RELAY See 6 8 2 SA...

Page 333: ...KING SYSTEM Brake discs steel Disc thickness 5 mm service limit 4 5 mm Disc diameter 300 mm Number of caliper pistons 4 opposite pistons Diameter of caliper pistons 30 mm lower pistons 34 mm upper pistons Brake pads sintered Brake pad lining standard TOSHIBA TT 2802 Brake pad lining option FERIT FERODO ID 450 Brake pad surface 23 68 sq cm Rubber hose diameter standard OD 10 mm ID 3 2 mm Diameter o...

Page 334: ...NS 2 28 1 FRONT SUSPEN SION and 7 7 FRONT FORK 8 4 10 REAR SUSPENSION See 1 5 SPECIFICATIONS 2 28 1 FRONT SUSPEN SION 7 8 REAR SWINGING ARM and 7 9 REAR SUSPENSION 8 4 11 STEERING See 2 27 1 CHECKING PLAY IN THE BEARINGS and 7 6 STEERING 8 4 12 CAPACITIES FLUID SPECIFICATIONS See 1 5 SPECIFICATIONS and 1 6 LUBRICANT CHART 8 4 13 CHASSIS FRAME SEAT SUBFRAME INSTRUMENT PANEL MOUNT Frame Seat subfram...

Page 335: ...ETV mille REPAIR INFORMATION 8 26 00 Release 00 2004 04 NOTE ...

Page 336: ...ETV mille ABS 9 1 00 Release 00 2004 04 9 ABS ...

Page 337: ...9 1 1 DESCRIPTION 9 6 00 9 1 2 COMPONENT MAINTENANCE 9 7 00 9 1 3 REPLACING THE FRONT WHEEL SENSOR 9 7 00 9 1 4 REPLACING THE REAR WHEEL SENSOR 9 8 00 9 1 5 REMOVING THE ABS CONTROLLER 9 8 00 9 1 6 BLEEDING ABS EQUIPPED BRAKES 9 9 00 9 1 7 TROUBLESHOOTING 9 10 00 9 2 WIRING DIAGRAM 9 14 00 ...

Page 338: ...roller 3 Front phonic wheel 4 Front brake calliper 5 Front brake master cylinder 6 Rear brake master cylinder 7 Rear wheel sensor 8 Rear phonic wheel 9 Speed sensor 10 Rear brake master cylinder CAUTION See the following page for a diagram of the ABS controller 5 1 4 2 10 9 3 4 6 7 8 ...

Page 339: ...e white arrow shows brake fluid path when the ABS system is operating 2 ABS controller 4 Front brake callipers 5 Front brake master cylinder 6 Rear brake master cylinder 10 Rear brake calliper 11 ABS pump 12 Front reservoir 13 Rear reservoir 14 Front dump valve 15 Rear dump valve 16 Front isolator valve 17 Rear isolator valve 2 5 4 10 11 12 16 17 14 13 15 6 ...

Page 340: ...e as in conventional braking 2 ABS detects a dangerous condition wheel starting to skid The system closes the isolator valve 16 and opens the dump valve 14 at the same time At this stage the rider has no control over brake pressure and the ABS releases some of the pressure in the callipers 4 Excess fluid is diverted into the front reservoir 12 until the ABS pump 11 switches on automatically to pum...

Page 341: ...s the same speed as the other wheel During that instant the rider has no control over brake pressure If speed difference persists the system may see this as a fault and disable ABS The brake then operates like a conventional brake When the engine is started the light 6 comes on and should go out after about 3 seconds If the light stays on it means that a malfunction has been detected and the ABS i...

Page 342: ... three locations spaced 120 apart Correct rea dings must be within the following ranges Front 0 4 1 85 mm 0 016 0 073 in Rear 0 7 1 80 mm 0 028 0 071 in CAUTION If measured gap is outside the allowed range change the sensor 1 and or the phonic wheel 2 and check again making sure all measurements are within the specified range CLEANING THE PHONIC WHEELS 2 It is important to make sure the phonic whe...

Page 343: ...the two expanding inserts 2 Remove the bracket retaining the ABS controller 3 Loosen the two nuts 4 Remove the controller plastic guard Disconnect the electric connector and move aside the wiring Note the positions of the hoses to ensure correct reas sembly Unscrew and remove the four screws 5 securing the brake hoses to the ABS controller Extract the ABS controller from the side to remove CAUTION...

Page 344: ...urised brake bleeder to speed up the bleeding procedure In the event some air is trapped in the portion of hose connecting controller and front brake callipers move the calliper pistons apart to push air back into the reservoir WARNING Do not unscrew the four screws 1 on the ABS con troller unless you need to replace the controller CAUTION If the ABS controller needs replacing please note that spa...

Page 345: ...r fuse or wiring No ground at controller pins 16 and 19 ONI OFF Axone NON entra in comunicazione con la centralina Check ground connection to battery Connect wiring correctly Controller is misreading speed sensor electric sig nals ONI OFF Front rear speed sensor closed open circuit 33 31 Sensor discon nected Connect sensor Sensor wiring shorted Change sensor wiring Sensor wiring interrupted Change...

Page 346: ...tor and 30 A fuse for continuity or check corre sponding wiring brought from key block Repair connec tor fuse or wiring Valve relay failed Change ABS controller Controller anomaly ON OFF Controller 21 ECU failed Change ABS controller Abnormal power supply voltage ON OFF ON Power supply voltage fault is stored only when road speed exceeds 6 kph 58 Voltage too low Charge change battery Voltage too h...

Page 347: ...OFF ON when lever is operated Rear lever ON OFF ON when lever is operated ABS switch ON OFF OFF if system was not turned off before connection with Axone in the opposite case OFF DEVICE ACTUATION Delete faults ABS light Holding down the key with Axone con nected will display the opposite status as current status Example current status is ON holding down the key will give an OFF reading DISPLAY ERR...

Page 348: ...ve relay See Troubleshooting table Front isolator valve See Troubleshooting table Rear isolator valve See Troubleshooting table Front dump valve See Troubleshooting table Rear dump valve See Troubleshooting table Controller See Troubleshooting table ...

Page 349: ...1 H4 H3 G1 G2 G3 H1 F3 F4 G4 H2 H3 H4 E3 E4 F1 F2 Az G Ro Vi R M R Bi N R Bi 30 87 86 85 C B A V Ar V Ar Az V N R N D E Az Gr V N R N NERO GRIGIO Bi G N V G B G G M M V Gr B Vi N M Vi Ar Az B Ar Gr Bi B Ar Gr Bi V M Ro Bi Vi Gr B Ar Bi N Bi R Bi G Ar N Gr Bi M N N Ar Bi Ro G Az R Bi Gr B M B B 3 Ar V 2 B V 1 5 V Bi V N G R V R 1 4 3 2 5 B V CRUSCOTTO LUCI POSIZ STOP 1 B R M R M R M Ar Bi V Az Ar A...

Page 350: ...ors and instrument panel D starter starting interlock relay E free 35 Power outlet 36 Pick up 37 Flywheel 38 Voltage regulator 39 Injection relay 40 Purge valve California only 41 Rear cylinder injector 42 Front cylinder injector 43 Cooling fans 44 Fuel reserve sensor 45 Fuel pump 46 Air thermistor ECU 47 Coolant thermistor ECU 48 Throttle position sensor 49 Rear cylinder coil 50 Rear cylinder coi...

Page 351: ...ETV mille ABS 9 16 00 Release 00 2004 04 NOTE ...

Page 352: ...aprilia s p a via G Galilei 1 30033 Noale VE Italy tel 39 041 5829111 fax 39 041 5829190 www serviceaprilia com www aprilia com ...

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