APRILIA RST FUTURA - 2001 Service Manual Download

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RST mille

USA

INTRODUCTION

- 1 -

Release 00/2002 - 03

INTRODUCTION

GENERAL INFORMATION

SERVICE AND SETTING UP

ENGINE

FUEL SYSTEM

COOLING SYSTEM

ELECTRICAL SYSTEM

CHASSIS

TROUBLESHOOTING

ANALYTICAL INDEX

Summary of Contents for RST FUTURA - 2001

Page 1: ...USA INTRODUCTION 0 1 00 Release 00 2002 03 0 INTRODUCTION 1 GENERAL INFORMATION 2 SERVICE AND SETTING UP 3 ENGINE 4 FUEL SYSTEM 5 COOLING SYSTEM 6 ELECTRICAL SYSTEM 7 CHASSIS 8 TROUBLESHOOTING i ANALYTICAL INDEX ...

Page 2: ...N UPDATING THE MANUAL 0 3 00 0 1 2 UPDATED MANUAL GENERAL LIST 0 3 00 0 2 HOW TO CONSULT THE MANUAL 0 6 00 0 3 FOREWORD 0 7 00 0 4 REFERENCE SERVICE LITERATURE 0 7 00 0 4 1 ENGINE SERVICE MANUAL 0 7 00 0 4 2 SPARE PARTS CATALOGUES 0 7 00 0 4 3 SPECIAL TOOLS MANUALS 0 7 00 0 4 4 OPERATING AND MAINTENANCE MANUALS 0 7 00 0 5 ABBREVIATIONS SYMBOLS ACRONYMS 0 8 00 ...

Page 3: ...0 00 2 6 00 00 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 2 20 00 00 2 21 00 00 2 22 00 00 2 23 00 00 2 24 00 00 2 25 00 00 2 26 00 00 2 27 00 00 2 28 00 00 2 29 00 00 2 30 00 00 2 31 00 00 2 32 00 00 2 33 00 00 2 34 00 00 2 35 00 00 page Release 2 36 00 00 2 37 00 00 2 38 00 00 2 39 00 00 2 40 00 00 2...

Page 4: ... 30 00 00 6 31 00 00 6 32 00 00 6 33 00 00 6 34 00 00 6 35 00 00 6 36 00 00 6 37 00 00 6 38 00 00 page Release CONT D CONT D 6 39 00 00 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 6 49 00 00 6 50 00 00 6 51 00 00 6 52 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 0...

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Page 6: ... THE VEHICLE ON THE FRONT SUPPORT STAND At the same time insert the two pins 1 of the stand 3 into the two holes 2 at the bottom of the front fork PLACING THE VEHICLE ON THE CENTER SUPPORT STAND 3 1 2 1 9 2 Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATION Code 8140176 complete stand Remove the lower fairing see 7 1 33 REMOVING THE LOWER FAIRING Hold the internal nut 1 steady in place Unscr...

Page 7: ...ore it is necessary that the latest aprilia information be kept available to the servicing mechanics If you have questions regarding repair and servicing procedures contact the aprilia Consumer Service A C S A C S Technical counselors will be able to assist you with any problems that you might face aprilia s p a reserves the right to modify any of its models in any manner at any time This manual i...

Page 8: ...ead screw HS hex socket head screw in inch ISC Idle Speed Control ISO International Standardization Organization kg kilograms 1 kg 2 2046224 lb kgm kilograms per meter 1 kgm 10 Nm km kilometers 1km 0 62137119 mi km h kilometers per hour kΩ kiloohms kPa kiloPascal 1 kPa 0 145 psi 0 01 bar KS clutch side Kupplungseite kW kilowatts liters 1 0 2641721 US gal LAP lap for competitive riding LED Light Em...

Page 9: ...RST mille USA INTRODUCTION 0 9 00 Release 00 2002 03 NOTES ...

Page 10: ...RST mille USA INTRODUCTION 0 10 00 Release 00 2002 03 NOTE ...

Page 11: ...RST mille USA GENERAL INFORMATION 1 1 00 Release 00 2002 03 1 GENERAL INFORMATION ...

Page 12: ... RULES 1 14 00 1 6 HOW TO USE YOUR SERVICE AND REPAIR MANUAL 1 15 00 1 6 1 HOW TO USE THIS MANUAL 1 15 00 1 6 2 REQUESTING SPARE PARTS 1 15 00 1 7 IDENTIFICATION DATA 1 16 00 1 7 1 VEHICLE IDENTIFICATION NUMBER V I N FRAME NUMBER 1 16 00 1 7 2 INFORMATION CONTAINED IN THE VEHICLE IDENTIFICATION NUMBER 1 16 00 1 8 POSITION OF SERIAL NUMBERS 1 17 00 1 8 1 FRAME NUMBER 1 17 00 1 8 2 ENGINE NUMBER 1 1...

Page 13: ...S Throughout this manual you will encounter the following symbols DANGER When you find this symbol on the vehicle or in the manual this indicates that a potential for serious personal injury or death exists Failure to follow this warning may result in serious risk of personal injury or death of the mechanic working on the vehicle the operator of the vehicle or the general public It also indicates ...

Page 14: ...r parts When performing mainatenace operations on the clutch control system place a clean shop towel on these parts Always wear goggles when servicing the clutch control system with clutch control fluid Clutch control fluid is extremely destructive to your eyes If you should accidentally get clutch control fluid in your eyes flush immediately with a large quantity of cool clear water and seek prof...

Page 15: ...lure to heed this warning can lead to serious personal injury such as when an ill fitting wrench slips and you slam your hand into the workbench or a part of the vehicle DISMANTLING THE COMPONENTS Do not loosen and or tighten the screws and nuts using pliers or other tools always use the appropriate wrench Before disconnecting any line cable etc mark each part with a number or distinguishing mark ...

Page 16: ...or is properly aligned before attempting to assemble it Press the connectors firmly together listening for the typical click sound for those connectors provided with a click tab Ensure that both halves of the connectors are firmly pressed together 1 3 11 FASTENERS TIGHTENING TORQUES DANGER Remember that the tightening torque of all fasteners on the wheels brakes axles and other components of the s...

Page 17: ... and change clothes Should you accidentally spill gasoline in your eyes flush with a large quantity of water and immediately contact a health professional Should you accidentally get gasoline into your mouth do not induce vomiting Drink a large quantity of milk or clear water and immediately contact a health professional Never try to siphon gasoline by sucking it with your mouth Use a manual pump ...

Page 18: ...vel see 2 12 CHECKING AND TOPPING UP THE ENGINE OIL LEVEL Renew the engine oil after the first 600 mi 1 000 Km and thereafter every 4 600 mi 7 500 km see 2 13 CHANGING THE ENGINE OIL AND OIL FILTER For competition use renew every 2 300 mi 3 750 km NOTE Use high quality 15W 50 oil see 1 12 LUBRICANT CHART As an alternative to the recommended oil it is possible to use high quality oils with characte...

Page 19: ...r fluid on a disc will contaminate the brake pads Dirty pads must be discarded and replaced a dirty or oily disc must be cleaned with a high quality degreaser DANGER Perform these maintenance operations at one half of the specified intervals if the vehicle is often used in rainy or very dusty conditions on unpaved roads or in any kind of competition Check the levels of the brake fluid in the reser...

Page 20: ... the vehicle is often used in rainy or very dusty conditions on unpaved roads or in any kind of competition Check the levels of the clutch fluid in the reservoir after the first 600 mi 1 000 km and thereafter every 4 650 mi 7 500 km for competition use thereafter every 2 300 mi 3 750 km see 2 18 CHECKING AND TOPPING UP THE CLUTCH FLUID Renew the fluid every two years see 2 23 CHANGING THE CLUTCH F...

Page 21: ... system It is advisable to maintain 50 water 50 antifreeze year round This way losses due to evaporation are reduced and topping up the radiator need not be done very frequently Thus the mineral salt deposits left in the radiator by evaporation are reduced and the cooling efficiency of the system uncompromised If the outdoor temperature is below 0ºC 32ºF check the antifreeze concentration in the c...

Page 22: ... consequent loss of control Again road holding and handling characteristics will be degraded and brake performance will be reduced Insure that all tires are equipped with properly installed valve caps Changing repairing maintenance and balancing operations are very important and should be carried out by qualified technicians with appropriate tools If the tires are new they may still be covered wit...

Page 23: ...if used is a metal platinum rhodium bivalent type This device provides for the oxidation of the CO carbonmonoxide and of the HC unburned hydrocarbons contained in the exhaust gases changing them into carbon dioxide and steam respectively WARNING Do not use leaded gasoline since it causes the destruction of the catalytic converter 1 4 11 EXHAUST SILECER DANGER Tampering with the exhaust system is p...

Page 24: ...first 60 mi 100 km apply the brakes with caution avoid sudden and prolonged braking This ensure correct bedding in of the pads on the discs During the first 600 mi 1 000 km never exceed 6 000 rpm DANGER After the vehicle has been operated for 600 mi 1 000 km perform the checking operations shown in column After running in of the 2 1 SCHEDULED MAINTENANCE PLAN Rectify any faults found Failure to he...

Page 25: ...G SPARE PARTS NOTE When asking your Dealer for spare parts specify the spare parts code indicated on the SPARE PARTS IDENTIFICATION LABEL Write down the identification code in the space here below in order to remember it in also case of loss or deterioration of the label The label is placed under the saddle see to be able to read it remove the saddle see 7 1 1 on the right part of the frame In thi...

Page 26: ...on the identification plate B which is located on the front portion near the steering head of the frame 1 7 2 INFORMATION CONTAINED IN THE VEHICLE IDENTIFICATION NUMBER Description of the vehicle identification number V I N stamped on the steering head of the frame A and on the identification plate B FOR STATE OF CALIFORNIA ONLY DIGIT MEANING 1 Manufacturer s identification alphanumeric code 2 Veh...

Page 27: ...rial numbers is subject to serious sanctions under criminal and civil law Altering the frame number will void the warranty effective immediately 1 8 1 FRAME NUMBER The frame number is stamped on the right side of the steering column This is also the Vehicle Identification Number 1 8 2 ENGINE NUMBER The engine number is engraved on the rear near the countershaft sprocket ...

Page 28: ...RST mille USA GENERAL INFORMATION 1 18 00 Release 00 2002 03 1 8 3 POSITION OF THE WARNING ADHESIVE LABELS 1 2 3 3a 4 5 9 10 11 12 13 14 15 16 9 6 6a 7 8 5a ...

Page 29: ...on 1 1a FOR STATE OF CALIFORNIA ONLY 2 NOT PROVIDED FOR 49 STATES 2a FOR STATE OF CALIFORNIA ONLY 3 4 4a FOR STATE OF CALIFORNIA ONLY 5 6 7 00 00 00 00 8 9 10 11 12 13 14 FOR STATE OF CALIFORNIA ONLY 14a 15 FOR STATE OF CALIFORNIA ONLY 15a 16 MUFFLER STAMPING Ref Description ...

Page 30: ... 12 Drain line from restrictor 13 Tee 14 Vacuum line from purge valve 15 Drain line 16 Tee 17 Cylinder synchronization line 18 Drain line to manifold vacuum port 19 Ported vacuum port left part of throttle body 20 Air box 21 Warm air inlet fitting from air box 22 Tee 23 Sensor line to fuel pressure regulator Electronic Contrl Unit 24 Warm air inlet from air box 25 Tee 26 Warm air inlet to carbon c...

Page 31: ...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 11 8 0 5 1 Average piston speed 22 5 m s at 10000 rpm Camshaft during intake stroke 262 valve lifting 0 42 in 10 6 mm Camshaft during exhaust stroke 259 valve lifting 0 42 in 10 6 mm Valve advance with valve clearance 1 mm opening during intake stroke clos...

Page 32: ...0 cm3 oil and filter change 4 1 qt 3900 cm3 Fork oil for each leg 18 70 0 08 fl oz 553 2 5 cm Coolant 0 66 gal 2 5 l 50 water 50 nitrite free anti corrosion antifreeze ethylene glycol Seats 2 Max vehicle load rider passenger luggage 401 24 lb 182 kg DRIVE GEAR RATIOS Ratio 1ª 2ª 3ª 4ª 5ª 6ª Primary 31 60 1 1 935 Secondary 14 35 1 2 500 16 28 1 1 750 19 26 1 1 368 22 24 1 1 091 23 22 1 1 957 27 23 ...

Page 33: ...el Brand Type Size Recommended Pressure PSI kPa Bar solo rider Front standard METZELER ME Z4 B 120 70ZR17 36 2 250 2 5 Rear standard METZELER ME Z4 180 55ZR17 40 6 280 2 8 Front standard MICHELIN PILOT SPORT 120 70ZR17 36 2 250 2 5 Rear standard MICHELIN PILOT SPORT 180 55ZR17 40 6 280 2 8 Front alternatively METZELER ME Z3 120 70ZR17 36 2 250 2 5 Rear alternatively METZELER ME Z3 180 55ZR17 40 6 ...

Page 34: ... rolling bearings working temperature range 30 C 140 C 22 F 248 F dripping point 150 C 230 C 302 F 446 F high protection against corrosion good resistance to water and oxidation Protection of battery poles Neutral grease or Vaseline Spray grease for chains recommended CHAIN SPRAY or CHAIN LUBE DANGER Use only fresh brake fluid Brake fluid recommended F F DOT 5 DOT 4 compatible or BRAKE 5 1 DOT 5 D...

Page 35: ...d with Loctite 648 it may be necessary to heat the assembled parts to a temperature of 250 C 482 F LOCTITE 574 orange Solvent free joint cement to be used instead of gaskets where components are held firmly together and where a precise distance is required between the two components Applied in its liquid state it hardens after assembly on contact with the metal within a few hours A seal is created...

Page 36: ...rews Throttle valve pin fastening nut Throttle valve potentiometer fastening screws On coolant pump center fastening screw On cylinder joining bracket fastening screws On engine half case bearing lock screws On cylinder fastening studs On crankshaft position sensor fastening screws On index lever and plate fastening screws On crankshaft fastening nut On timing gear fastening screws On upper balanc...

Page 37: ...ake lever pivot On intermediate timing gear thrust washer Lower balanceshaft oil seal Starter motor gear LUBERING ST Grease 8116038 Assembly of cold start control Temporary lubricant AP LUBE Assembly of handlebar balanceweights grommet Assembly of throttle cable adjuster grommets Assembly of grommet on gearshift pedal Insertion of radiator lower pins on supporting grommets Assembly of breather tub...

Page 38: ...Assembly of start relay grommet Assembly of flexible couplings on rear wheel sprocket Assembly of grommets on engine oil radiator Assembly of coupling on coolant filler Cleaning of engine oil tank prior to application of transfers Assembly of dashboard front fairing mount grommets Assembly of grommet on rear brake lever Assembly of lines on fuel filter inside tank Assembly of coolant radiator unio...

Page 39: ... work on this vehicle To do so will not only ensure that you damage the vehicle sometimes irreparably but you will also hurt yourself Failure to use special tools will certainly lead to injury to the mechanic 1 14 1 MISCELLANEOUS TOOLS Pos Tool name and function Code 1 Complete tool kit for chassis including half cylinders for installing oil seals front fork steering adjustment socket wrench socke...

Page 40: ...rankshaft bushing inserter drift 0277725 13 Crankshaft clutch cover bushing inserter drift 0277727 15 Cap socket wrench 8140177 16 Flywheel cover removal tool 0277252 17 Flywheel removal hexagonal bolt 0277780 18 Threaded bolt to lock the crankshaft at TDC 0240880 19 Countershaft guide bushing 0277308 20 Vacuum gauge 8140256 21 Fuel oil pressure gauge 8140181 22 Alternator rotor bolt removal bushi...

Page 41: ...SUPPORT STANDS 1 15 1 PLACING THE VEHICLE ON THE FRONT SUPPORT STAND Place the vehicle on the center stand At the same time insert the two pins 1 of the stand 3 into the two holes 2 at the bottom of the front fork Rest one foot at the front of the stand 3 Push the stand 3 all the way down 3 1 2 ...

Page 42: ...e upper left support pin 5 all the way onto the threaded shaft 4 and tighten Hold the nut 6 in place Loosen and remove the upper right rear engine bolt 7 Tightening torque nut 6 bolt 7 36 ftlb 50 Nm NOTE The bolt 7 on the right side is longer Insert the lower right support pin 8 in the lower hole on the right hand side Insert the threaded shaft 9 in the lower hole on the left hand side and bolt it...

Page 43: ...he transfer spread flat on the work surface remove the backing paper 4 completely NOTE We recommend using a spray bottle 2 If using a sponge sponge the surface without pressing to keep from ruining the glue Wet the surface of the adhesive with soapy water Apply the transfer 3 to the surface to be decorated and move it to the desired position NOTE Always move the spatula in even strokes from the ce...

Page 44: ...he glue is not fully set for about 48 hours Once you have removed the application tape make sure there are no air bubbles on the surface If you do find surface air bubbles Use a pin or hobby knife 6 to puncture the edge 7 of the air bubble With the spatula 1 start from the side opposite the hole and scrape the bubble to allow any remaining air to escape Application tape is used to facilitate the a...

Page 45: ... upon removal so new ones must be used upon reinstallation NOTE Have the appropriate special tool available aprilia part 0277295 click clamp installation pliers WARNING Upon installation replace the click clamp that has been removed with a new click clamp having the same dimensions see 0 4 2 SPARE PARTS CATALOGUES Do not attempt to reinstall the removed click clamp since it is unusable Do not repl...

Page 46: ...re NOTE To avoid damage to the threads tighten screws and bolts as follows Run up the fasteners finger tight Applying half the prescribed tightening torque tighten the fasteners that are diametrically opposite each other A and B C and D Repeat applying the prescribed tightening torque NOTE In this way the pressure exerted by the fasteners will be uniformly distributed across the joint surface Stee...

Page 47: ...RST mille USA GENERAL INFORMATION 1 37 00 Release 00 2002 03 NOTE ...

Page 48: ...RST mille USA GENERAL INFORMATION 1 38 00 Release 00 2002 03 NOTE ...

Page 49: ...RST mille USA SCHEDULED MAINTENANCE AND TUNING OPERATIONS 2 1 00 Release 00 2002 03 SCHEDULED MAINTENANCE AND TUNING OPERATIONS 2 ...

Page 50: ...27 00 2 15 CHANGING THE COOLANT 2 28 00 2 16 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID 2 29 00 2 17 CHECKING AND TOPPING UP THE REAR BRAKE FLUID 2 30 00 2 18 CHECKING AND TOPPING UP THE CLUTCH FLUID 2 32 00 2 19 BLEEDING THE BRAKE SYSTEMS 2 34 00 2 20 CLUTCH CONTROL SYSTEM BLEEDING 2 38 00 2 21 CHANGING THE FRONT BRAKE FLUID 2 39 00 2 22 CHANGING THE REAR BRAKE FLUID 2 40 00 2 23 CHANGING THE ...

Page 51: ... USA SCHEDULED MAINTENANCE AND TUNING OPERATIONS 2 3 00 Release 00 2002 03 2 39 COOLING SYSTEM PIPES 2 59 00 2 40 TIGHTENING NUTS AND BOLTS 2 60 00 2 41 FASTENERS 2 61 00 2 41 1 CLEANING AND LUBRICATION 2 67 00 ...

Page 52: ... safe for human consumption therefore avoid the temptation of holding parts in your mouth while you are working on the vehicle Some of the parts and coatings used in the manufacture of this vehicle are noxious some are downright toxic Keep all parts of the vehicle out of your mouth at all times 2 1 SCHEDULED MAINTENANCE PLAN To keep the vehicle in top running condition aprilia recommends that you ...

Page 53: ...ght operation direction c Hardware clearance R f Grease on throttle body pin c c Brake systems c c Cooling system c Light system c c Safety switches c c Clutch fluid c every 2 years e Brake fluid c every 2 years e Coolant c every 2 years e Fork oil After the first 4687 mi 7500 km and every 14000 mi 22500 km thereafter e Engine oil e e Brake pads If worn e Pistons every 3125 ml 5000 Km c Tires c c ...

Page 54: ... wear before every trip and every 1250 mi 2000 km c c check and clean adjust lubricate or replace if necessary d clean e replace f adjust Perform these maintenance operations more frequently if your vehicle is often used in rainy or very dusty conditions on unpaved roads or in any kind of competition OPERATIONS THAT MAY BE CARRIED OUT BY THE OWNER For competitive use replace every 3750 km 2343 mi ...

Page 55: ...t might rust must be protected using motor oil or grease see 1 12 LUBRICANT CHART The LUBRICATION DIAGRAM shows the lubrication points LUBRICATION DIAGRAM LEGEND 1 Steering bearings 2 Clutch lever pivot 3 Right rider foot rest pin 4 Left rider foot rest pivot 5 Left passenger foot rest pivot 6 Rear wheel axle and bearings 7 Drive chain 8 Rear suspension linkage 9 Side stand pivot 10 Right passenge...

Page 56: ...turning the ignition key 1 to position the following dashboard lights will come on all LED warning lights all backlit LEDs all segments of the left display all segments and messages on the right multifunction display This sequence of displays tests the proper operation of all LEDs messages sections and instruments After about three seconds have passed on the dashboard only the engine oil pressure ...

Page 57: ...ometer mileage counter Display the trip mileage Press the SET key 1 for longer than three seconds the segments 2 will be reset NOTE The trip kilometers are reset to zero if the battery is removed 2 3 5 SWITCHING BETWEEN KM MI L GAL C F NOTE The km mi l gal C F settings are set and locked by aprilia while manufacturing the vehicle based on the country for which it is intended They cannot be changed...

Page 58: ...when the fuel tank contains 1 05 0 26 gal 4 1 l of fuel When this occurs refuel as soon as possible Side stand down LED Lights when the side stand is lowered Engine oil pressure LED Lights whenever the ignition switch is set to and the engine is not running to perform a lamp test If the engine oil pressure LED remains on after starting the engine or comes on while the engine is running at engine s...

Page 59: ... the fuel level in your motorcycle to become so low that you will run out of fuel NOTE Alternatively the digital sector may be used to display the air temperature T AIR while the analogue indicator is left inactive To alternate displays see 2 3 2 PROGRAM MING KEYS Multifunction digital display right side Air temperature indicator T AIR When the digital display flashes a temperature of less than or...

Page 60: ...egment flashes stop the engine wait for the cooling valves to shut off and check the coolant level see 2 15 CHANGING THE COOLANT If a temperature of 259 275 F is displayed and the last two segments of the scale flash stop the vehicle and let the engine idle for approximately two minutes to allow coolant to circulate regularly within the system then set the engine stop switch to and check the coola...

Page 61: ...tenance free battery It requires no maintenance beyond occasional inspections and recharging if needed Always replace the battery with one of the same type For more information see 6 14 BATTERY WARNING Never reverse the battery cable connections Connect and disconnect the battery with the ignition switch set to First connect the cable positive then the negative cable Disconnect in reverse order NO...

Page 62: ...er boot 1 Make sure that the battery cable terminals 2 3 are in good condition not corroded or encrusted with deposits covered with neutral grease or Vaseline If necessary Disconnect the negative cable and positive cable in that order Clean with a wire brush to remove any traces of corrosion Connect the positive cable and negative cable in that order Coat the terminals with neutral grease or Vasel...

Page 63: ...2 3 MULTIFUNCTION COMPUTER If your vehicle remains unused for more than a couple of weeks it will be necessary to recharge the battery to avoid sulfur damage see 2 4 2 RECHARGING THE BATTERY Remove the battery see 7 1 9 REMOVING THE BATTERY and store it in a cool dry place Over the winter or whenever the vehicle remains unused periodically check the battery charge once a month or so to prevent it ...

Page 64: ...disconnected WARNING The terminals of one cable must never come into contact with those of the other Pull back the red rubber boot 1 Connect the end of one jumper cable to the positive pole of the battery on the on the vehicle providing assistance A the other end to the positive pole of the battery on the vehicle to be started B Connect the end of the other jumper cable to the negative pole of the...

Page 65: ...em Remove the spark plug cap 1 Remove all traces of dirt from the base of the spark plug Place the special wrench supplied with the tool kit over the spark plug Place the 13 mm open end wrench supplied in the tool kit over the hexagonal seat of the special spark plug wrench Unscrew the spark plug and remove it from its seat being careful not to allow dust or other matter into the cylinder WARNING ...

Page 66: ... round wire feeler gauge The gap should measure 0 02 0 03 in 0 6 0 7 mm Adjust if needed by carefully bending the earth electrode Make sure that the gasket is in good condition With the gasket in place screw in the spark plug by hand to avoid damaging the thread Tighten using the wrench provided in the tool kit turning each spark plug 1 2 turn to compress the gasket Tightening torque for spark plu...

Page 67: ...emove the grille 2 Remove the saddle see 7 1 1 REMOVING THE SADDLE Unscrew and remove the two bolts 3 that fasten the front part of the fuel tank 4 Recover the bushings and washers Tightening torque for bolts 3 5 90 ftlb 8 Nm Remove the fuel tank support rod 5 from the seats provided under the saddle NOTE The rubber covered end of the rod 5 must be placed in the center hole of the steering head Li...

Page 68: ...loor on the left hand side of the vehicle NOTE Place a cloth under the male quick release coupling 1 to catch any spilled fuel Disconnect the male quick release coupling 1 from the container 2 by pressing the button NOTE Procure a hose complete with male quick release coupling Place the free end of the hose inside the container prepared beforehand Insert the male quick release coupling of the hose...

Page 69: ...vent any foreign matter from entering the intake tubes Make sure the gasket 5 is intact replace if damaged PARTIAL CLEANING WARNING Do not press down or beat on the metal screen of the air filter 3 Do not use screwdrivers or similar tools on the filter itself Hold the air filter 3 upright and strike it repeatedly against a clean surface If necessary clean the air filter 3 with a blast of compresse...

Page 70: ...its original position DANGER If turning the handlebar alters the engine speed do not ride the vehicle until you have rectified the problem Failure to observe this warning can lead to a runaway engine loss of control and subsequent serious accident injury and even death If necessary Check the correct position and the lubrication of the following components sheath throttle grip adjuster 1 throttle b...

Page 71: ... vehicle on the stand Pull back the rubber boot 1 Loosen the lock nut 2 Rotate the adjuster 3 so as to restore the proper play After the adjustment tighten the lock nut 2 and check the play again Replace the rubber boot 1 WARNING After completing the adjustment make sure that turning the handlebar does not alter the engine idle speed and that when the throttle is released it returns gently and aut...

Page 72: ...l pressure LED does not light Start the engine Ride the vehicle for approximately 10 miles or 15 20 minutes Shut off the engine Place the vehicle on the center stand Keep the vehicle upright with both wheels resting on the ground Through the slot on the left fairing check the engine oil level on the transparent tube 1 MAX maximum level MIN minimum level The difference between MAX and MIN is approx...

Page 73: ...g see 7 1 28 REMOVING THE SIDE FAIRINGS Remove the lower fairing see 7 1 33 REMOVING THE LOWER FAIRING Place a container 1 with a capacity greater than 1 gallon 4000 cm under the drain plug 2 on the reservoir 3 Unscrew and remove the drain plug 2 from the reservoir 3 Unscrew and remove the filler cap 4 Drain the oil and let it drip for a few minutes into the container 1 Check the gasket of the dra...

Page 74: ...ially remove the engine oil tank 3 in order to slide out the engine oil filter Unscrew and remove the two screws 14 Move the engine oil tank 3 outwards Remove the engine oil filter 10 on the tank and clean with a blast of compressed air WARNING When reassembling make sure that the fitting 15 of the filter oil 10 is facing outwards The pipe 13 must not be in contact with the expansion tank Carefull...

Page 75: ...ion tank 1 is between the FULL and LOW marks FULL maximum level LOW minimum level If not Unscrew and remove the screw 2 Remove the cover 3 Unscrew and remove the filler cap 4 DANGER Coolant is harmful if swallowed contact with skin or eyes may cause irritation Do not insert your finger or any foreign objects to check for coolant See Safety Warnings Section 1 2 SAFETY WARNINGS WARNING Do not add ad...

Page 76: ... has drained out empty the left radiator DISPOSE OF THE FLUID IN COMPLIANCE WITH ENVIRONMENTAL REGULATIONS NOTE When reassembling apply LOCTITE 572 to the thread of the two radiator drain plugs Reassemble the drain plug 1 with a new aluminum washer Tightening torque for drain plug 1 7 3 ftlb 10 Nm Reassemble the expansion tank Top up from the filler neck 4 until full Squeeze and release the radiat...

Page 77: ... system CHECK NOTE Place the vehicle on the center stand on a flat hard surface Turn the handlebar all the way to the right Make sure the fluid contained in the reservoir exceeds the MIN mark MIN minimum level MAX maximum level If the fluid does not at least reach the MIN mark top up the reservoir TOPPING UP WARNING Danger of brake fluid leaking Do not operate the front brake lever with the screw ...

Page 78: ...ew pads are installed The level of fluid gradually decreases as the pads become worn To reassemble the components follow the procedure in reverse order 2 17 CHECKING AND TOPPING UP THE REAR BRAKE FLUID Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION and 1 3 5 BRAKE FLUID Check the brake fluid every 4687 mi 7500 km or 8 months and change it every two years WARNING If you notice that the br...

Page 79: ...rake fluid reservoir open ONLY as long as necessary for topping up Use a short Philips screwdriver to unscrew the two screws 1 of the brake fluid reservoir 2 Raise and remove the cover 3 complete with screws 1 and gasket 4 NOTE To keep from spilling brake fluid while topping up keep the fluid in the reservoir parallel to the reservoir rim horizontal WARNING Do not add additives or other substances...

Page 80: ...fluid will damage the painted and plastic surfaces Before riding inspect the lines to make sure they are not twisted or cracked and that the fittings do not leak Do not use or mix together different types of fluids with a silicone or petroleum base Do not use clutch fluid taken from old containers or those that have been left standing open Take care to prevent water and dust from accidentally ente...

Page 81: ...servoir to catch any spills Turn the handlebar all the way to the left Use a short Philips screwdriver to unscrew the screw 1 WARNING Do not unscrew the screw 2 with the handlebar wheel turned to the left as fluid will leak out Turn the handlebar all the way to the right Unscrew the screw 2 WARNING Avoid shaking the vehicle to keep from spilling fluid while topping up Do not add additives or other...

Page 82: ...Then try your vehicle in a parking lot or other safe area with little traffic to ensure that the brakes are working properly Failure to observe this warning can lead to a serious accident with subsequent serious injury or death DISPOSE OF THE FLUID IN COMPLIANCE WITH ENVIRONMENTAL REGULATIONS KEEP OUT OF REACH OF CHILDREN WARNING Handle brake fluid with care Especially do not spill it on painted o...

Page 83: ...e has no bends in the shape of an overturned U NOTE To bleed the rear brake system you must first remove the rear brake caliper see 7 6 2 REMOVING THE REAR BRAKE CALIPER Top up the brake fluid in the reservoir see 2 16 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID and 2 17 CHECKING AND TOPPING UP THE REAR BRAKE FLUID Remove the dust cover Fit a piece of transparent plastic tubing over the clamp bl...

Page 84: ...aliper itself For the rear brake system only the rear brake caliper has already been removed during the system bleeding procedure unscrew and remove the screw 3 retrieving the nut you will need the help of a second mechanic to keep the brake fluid reservoir 4 higher than the master cylinder NOTE Have an approximately 3 mm thick shim to place between the brake pads Place the shim between the pads a...

Page 85: ...ever a few times to pressurize the system Use the spacer or other tool to widen the caliper pistons WARNING Never adjust the caliper pistons directly always on the pads Work gently to avoid damaging the pads Check whether any air bubbles escape into the reservoir along with the fluid If there are still air bubbles repeat the procedure until there are no more bubbles in the fluid NOTE Fill the rese...

Page 86: ...e clutch fluid in the reservoir see 2 18 CHECKING AND TOPPING UP THE CLUTCH FLUID Remove the left fairing see 7 1 28 REMOVING THE SIDE FAIRINGS Remove dust cover Fit a piece of transparent plastic tubing over the bleeder nipple 1 and insert the other end into a container Squeeze and release the lever several times and then hold it fully squeezed Loosen the bleeder nipple by 1 4 turn so that the fl...

Page 87: ...oughout this operation make sure there is always fluid present in the reservoir otherwise after the operation you will need to bleed the system see 2 19 BLEEDING THE BRAKE SYSTEMS Watch the reservoir 2 as the fluid flows out and tighten the bleeder nipple 1 before it empties entirely Top up the reservoir 2 see 2 16 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID Loosen the bleeder nipple 1 again by ...

Page 88: ...n NOTE Throughout this operation make sure there is always fluid present in the reservoir 2 otherwise after the operation you will need to bleed the system see 2 19 BLEEDING THE BRAKE SYSTEMS Watch the reservoir 2 as the fluid flows out and tighten the bleeder nipple 1 before it empties entirely Top up the reservoir 2 see 2 19 BLEEDING THE BRAKE SYSTEMS Loosen the bleeder nipple 1 by approximately...

Page 89: ...out and tighten the bleeder nipple 1 before it empties entirely Top up the reservoir 2 see 2 18 CHECKING AND TOPPING UP THE CLUTCH FLUID Loosen the bleeder nipple 1 again by approximately half a turn Watch as the fluid flows out through the tube As soon as you observe that the fluid flowing through the tube is clear and no longer dark tighten the bleeder nipple 1 again and remove the tube Tighteni...

Page 90: ...er cylinder piston Screw in the push rod to ensure a minimum clearance of 0 02 0 04 in 0 5 1 mm between the master cylinder push rod 4 and the master cylinder piston NOTE Make sure there is enough play on the lever 5 If not the brake will remain slightly applied causing the brake components to wear out prematurely Lever 5 clearance 0 16 in 4 mm measured at the end of the lever Lock the master cyli...

Page 91: ...support to come into direct contact with the disc creating a metallic grinding noise and producing sparks from the clamp the braking effectiveness safety and integrity of the disc would thus be compromised Never ride a motorcycle with worn out brake pads Failure to observe this warning can lead to loss of braking effectiveness with a collision upset and serious injury or even death If the thicknes...

Page 92: ...erior handling the steering is equipped with rolling bearings The steering must be adjusted correctly to provide smooth rotation of the handlebar and safe driving Tight steering hinders the smooth rotation of the handlebar whereas play steering reduces stability 2 28 1 CHECKING THE BEARING PLAY Place the vehicle on the center stand Shake the fork fore and aft There should be no play If you detect ...

Page 93: ...h to keep from damaging the dashboard Use a small blade screwdriver straighten the tabs the ones folded upward of the lock plate 9 NOTE Have on hand the special tool code 8140203 steering adjustment socket wrench Use the special socket wrench to loosen and remove the ring nut 10 Remove the lock plate 9 DANGER During reassembly the lock plate 9 must be replaced Never reuse a lock plate Always repla...

Page 94: ...upper bushing 6 88 50 ftlb 120 Nm Insert and tighten the screw 5 Tightening torque for screw 5 18 44 ftlb 25 Nm NOTE When reassembling lubricate the thread and under the head of the screw 4 Insert and tighten the screw 4 Tightening torque for screw 4 18 44 ftlb 25 Nm WARNING After everything has been tightened make sure the handlebars rotate smoothly in both directions If not they may damage the s...

Page 95: ...oil after the first 4687 mi 7500 km and every 14 000 mi 22 500 km thereafter Every 4687 mi 7500 km carry out the following checks Applying the front brake lever press on the handlebar repeatedly to push the fork down The fork must slide smoothly and evenly and there must be no traces of oil on the fork tubes If the fork tends to bottom out adjust as needed see 2 29 2 ADJUSTING THE FRONT FORK and c...

Page 96: ...able if there are different settings on the two sides When the spring preload is increased it is necessary to also increase the hydraulic damping to avoid harshness while riding WARNING When adjusting always start from the most rigid setting screw 1 turned fully clockwise Use the notches provided on the adjuster screw 1 as reference marks for adjusting of hydraulic damping on extension Gradually r...

Page 97: ...SWINGING ARM Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Place the vehicle on the center stand Completely loosen the nut 1 NOTE Have on hand the special tool code 8140203 socket wrench for adjusting swinging arm pivot engine mounts Use the special socket wrench to completely loosen the locking ring nut 2 Working from the right hand side of the vehicle rotate the swinging arm pivot 3 c...

Page 98: ...igh speeds with light or heavy vehicle loads It is however possible to customize the setting to best suit the way in which the vehicle is to be used WARNING When adjusting always start from the most rigid setting in this case with the adjuster screw 1 and adjuster knob 2 turned all the way clockwise Do not turn the adjuster screw 1 beyond its maximum position to avoid damaging the thread Make sure...

Page 99: ... of the vehicle press downward and release several times If the movement is not smooth and is accompanied by creaking and or if you notice any play replace the bearings of the rear suspension linkage see 7 10 2 DISASSEMBLING THE REAR SUSPENSION LINKAGE If after you pressed the vehicle downwards it returns to its original position very slowly check whether the rear suspension is adjusted correctly ...

Page 100: ...le as the wheel spins check the components in question see 7 2 3 CHECKING THE COMPONENTS If after repeated spinning the wheel comes to a stop in the same position it must be balanced 2 33 REAR WHEEL Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATION Check every 4687 mi 7500 km Place the vehicle on the center stand Spin the wheel in both directions by hand Make sure the wheel turns smoothly a...

Page 101: ...very 4687 mi 7500 km or 8 months thereafter DANGER Let the engine cool down to ambient temperature Remove the side fairings see 7 1 28 REMOVING THE SIDE FAIRINGS Remove the front grille see 7 1 35 REMOVING THE RADIATOR SPOILER Torque the three nuts 1 of the front cylinder exhaust manifold to specification Torque the three nuts 2 of the rear cylinder exhaust manifold to specification Tightening tor...

Page 102: ...chain making sure that the chain and sprockets show none of the defects listed below damaged rollers loose pins dry rusted crushed or seized links excess wear missing O rings sprocket teeth excessively worn or damaged A quick check to determine the condition of the chain and sprockets may be made by grasping the chain and attempting to pull it away from the rear sprocket If you can pull the chain ...

Page 103: ...G If the clearance is greater in certain positions this means that some of the links are crushed or seized up To prevent the risk of seizing lubricate the chain frequently see 2 41 1 CLEANING AND LUBRICATION If the clearance is even but more or less than 0 98 in 25 mm adjust as needed see 2 35 3 ADJUSTING THE DRIVE CHAIN WARNING An excessively loose chain may cause noise or make the chain rattle w...

Page 104: ...wn in figure A To tighten the chain Insert the pin wrench 2 as shown in figure B With the pin wrench 2 correctly inserted hook the pin wrench 2 to the ring nut 3 Insert the extension 4 in the pin wrench Use the pin wrench 2 to adjust the chain clearance Check the chain play see 2 35 1 CHECKING THE PLAY Tighten the two screws 1 Tightening torque for bolts 1 25 81 ftlb 35 Nm Lubricate the chain ever...

Page 105: ...gulator mount 5 Tightening torque for screws 4 8 85 ftlbv 12 Nm Retrieve the three bushings 6 and three shock mount grommets 7 Remove the housing 5 to retrieve the bushings Loosen the screw 8 and extract the gearshift lever 9 Remove the clutch cylinder see 3 2 1 REMOVING THE CLUTCH CYLINDER NOTE Release the side stand switch cable Remove the countershaft sprocket cover 10 Remove the guide plate 11...

Page 106: ...t the tires from deflating suddenly Changing repairing maintaining and balancing the tires are all very important tasks they must therefore be carried out using the appropriate tools and expertise MINIMUM TREAD DEPTH LIMIT A front e rear 0 12 in 3 mm INFLATION PRESSURE Periodically check the inflation pressure of the tires at ambient temperature If the tires are warm the measurement will not be co...

Page 107: ... Replace every four years Replace the fuel lines if you find any signs of wear cracks etc High pressure delivery line 1 4 7 PSI 450 kpa 4 5 bar Return line 2 NOTE Make sure that the male quick release coupling 3 has been correctly inserted into the container 4 For more information see sect 4 FUEL SYSTEM 2 38 BRAKE AND CLUTCH CONTROL LINES Carefully read 1 4 3 BRAKE and 1 4 5 CLUTCH CONTROL FLUID C...

Page 108: ...cifically right left handlebars front brake lever clutch lever fuel delivery line front fork to plates front fork wheel axle clamps front wheel front brake line fittings front brake discs front brake calipers engine countershaft sprocket rear brake lever swinging arm swinging arm leverage rear shock absorber rear wheel rear brake disc rear brake caliper rear brake line fittings WARNING The fastene...

Page 109: ... Description Qty Screw nut ftlb Nm Notes Engine oil inlet flange 2 M6 8 12 Engine oil drain cap 2 M6 8 12 Countershaft sprocket on gearbox shaft fastener 1 M10 36 50 L243 Clutch cylinder fastener 3 M6 8 12 Countershaft sprocket case fastener 3 M6 8 12 Guard plate on clutch cover 2 M5 3 6 5 SWINGING ARM Description Qty Screw nut ftlb Nm Notes Bushing for adjusting swinging arm pivot 1 M30x1 5 8 12 ...

Page 110: ...lb Nm Notes Damper absorber frame fastener 1 M10 33 2 45 lub Linkage Single connecting rod to frame fastener 1 M10 33 2 45 lub Single double connecting rod to frame fastener 1 M10 33 2 45 lub Double connecting rod fork fastener 1 M10 33 2 45 lub Double connecting rod shock absorber fastener 1 M10 33 2 45 lub ELECTRICAL SYSTEM Description Qty Screw nut ftlb Nm Notes Battery clamping bracket fastene...

Page 111: ...ngr Flexible coupling safety screw 3 M3 0 8 1 2 Wheel screw cover 1 M10 7 3 10 lub O ring COOLING SYSTEM Description Qty Screw nut ftlb Nm Notes 3 way manifold closing screw 1 M14x1 5 21 7 30 L572 Electric fan mount fastener 2 2 M6 4 4 6 Electric fan motor to mount fastener 3 3 SWP3 9 0 7 1 L243 Radiator coolant drain plugs 1 1 M6 7 3 10 L572 Expansion tank to coils mount fastener 2 M6 5 9 8 Expan...

Page 112: ... on lt pipe 2 M6 4 4 6 Click clamp on muffler engagement 2 M6 10 8 15 sil FUEL TANK Description Qty Screw nut ftlb Nm Notes Pump mount to fuel delivery line fastener 1 M12x1 5 16 2 22 Cap to tank fastener 7 M5 3 6 5 Fuel pump flange fastener to tank 8 M5 4 4 6 L518 Front tank to frame fastener 2 M6 5 9 8 lub Tank cover 2 M5 2 2 3 Fuel rail on fuel line 2 M5 3 6 5 ENGINE OIL RADIATOR AND TANK Descr...

Page 113: ...es Rider footrest mount to frame 4 M8 18 25 Passenger footrest mount to saddle support 4 M8 18 25 Saddle support to frame 4 M10 33 2 45 Tank drift to saddle support 2 M8 man Mount to frame 2 M6 7 3 10 Center stand spring pin 1 M6 7 3 10 Oil tank mount to frame 2 M6 7 3 10 Throttle balance line fastener 1 M6 7 3 10 REAR BODY Description Qty Screw nut ftlb Nm Notes License plate holder to mount 2 M5...

Page 114: ...vibration weights fastener 2 M6 7 3 10 Anti vibration weights ring nut 2 M18x1 5 28 8 35 Right left handlebars fastener to fork 2 M8 21 7 30 Ingr Right left handlebars lock screw 2 M6 8 8 12 Left dimmer switch fastener 2 M5 1 4 2 Right dimmer switch Fastening 2 M5 1 4 2 Front brake control fastener 2 M6 7 3 10 Clutch cylinder fastener 2 M6 7 3 10 Clutch line fitting to pump and cylinder 2 M10x1 14...

Page 115: ...ammable solvents to wash the chain Wash the chain with diesel fuel or kerosene If the chain tends to rust quickly perform maintenance operations more often WARNING Never use trichloroethylene gasoline or similar fluids they may be too powerful as solvents for this chain and more importantly they may damage the O rings that retain grease in the gaps between rollers and pins ...

Page 116: ...RST mille USA SCHEDULED MAINTENANCE AND TUNING OPERATIONS 2 68 00 Release 00 2002 03 NOTES ...

Page 117: ...RST mille USA ENGINE 3 1 00 Release 00 2002 03 ENGINE 3 ...

Page 118: ... 00 3 1 6 SPECIAL TOOLS 3 3 00 3 1 7 TIGHTENING TORQUES 3 3 00 3 1 8 PRECAUTIONS TO OBSERVE WHEN CARRYING OUT MAINTENANCE OPERATIONS AND REPAIRS 3 3 00 3 1 9 GENERAL INFORMATION ABOUT MAINTENANCE AND REPAIRS 3 4 00 3 2 ENGINE COMPONENTS THAT MAY BE DISASSEMBLED WITHOUT REMOVING THE ENGINE FROM THE FRAME 3 4 00 3 2 1 REMOVING THE CLUTCH CYLINDER 3 6 00 3 3 REMOVING THE COMPLETE ENGINE FROM THE FRAM...

Page 119: ...and the center of gravity of the engine support it appropriately Be careful around any points that present a hazard for crushing or cutting body parts WARNING Engine and system maintenance demands technical training and knowledge both general mechanical knowledge and knowledge specific to this engine as well as familiarity with certain common and special tools used in disassembly repair reassembly...

Page 120: ...in cross referenced instructions to avoid unnecessarily removing components Perform only those operations needed to remove the component in question TOP Tappet cover 1 see 0 4 1 ENGINE SERVICE MANUAL Tappet cover 2 head cylinder and rear piston see 0 4 1 ENGINE SERVICE MANUAL Front 3 and rear 4 intake cylinder manifolds Camshaft position sensor and camshafts see 0 4 1 ENGINE SERVICE MANUAL Chain c...

Page 121: ... OIL FILTER Neutral gear switch 11 Clutch cylinder 12 see 3 2 1 REMOVING THE CLUTCH CYLINDER Flywheel cover 13 and ignition system see 0 4 1 ENGINE SERVICE MANUAL Engine oil tank 14 see 7 1 55 REMOVING THE ENGINE OIL TANK RIGHT 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 SERVICE ...

Page 122: ...THE DRIVE CHAIN GUIDE PLATE Unscrew and remove the screws 3 Tightening torque for screws 3 8 8 ftlb 12 Nm Remove the cylinder 2 WARNING Take great care when removing the clutch cylinder the line remains attached Do not touch the clutch lever after the cylinder 2 has been removed This could cause the piston to fall from its bore and clutch fluid would be spilled out To prevent this from happening u...

Page 123: ...from underneath the equipment for the job must therefore be gathered and set in place beforehand Engine dry weight 147 7 lb 67 kg Set the ignition switch to Place the vehicle on the stand Disconnect the negative cable and positive cable of the battery in that order WARNING When reassembling first connect the positive cable then the negative cable Remove the fuel tank see 7 1 6 REMOVING THE FUEL TA...

Page 124: ...E Remove the expansion tank see 5 8 REMOVING THE EXPANSION TANK Disconnect the spark plug caps 10 WARNING Use a non flammable solvent brushes and rags to clean the exterior of the engine Avoid damaging rubber and plastic parts with corrosive or flammable cleansers and solvents Should it be necessary to use a steam cleaner do not aim the high pressure jets of water steam or air at the following par...

Page 125: ...ling make sure electrical connectors are properly fitted WARNING Mark both the coupling and lines to avoid mix ups when reassembling Remove the engine oil tank 12 see 7 1 55 REMOVING THE ENGINE OIL TANK along with the engine oil radiator 13 see 7 1 56 REMOVING THE ENGINE OIL RADIATOR disconnecting the lines joining it to the engine 14 15 Remove both radiators 16 17 while still connected see 5 2 RE...

Page 126: ...complete thermostat 23 see 5 5 REMOVING THE THERMOSTAT along with the three couplings Slip the coupling 24 off the coolant pump WARNING Release all cables and lines from the clamps holding them in place along their path Have the same number of clamps ready to use when reassembling Plug all the engine openings hoses and hose couplings to prevent any foreign matter from accidentally entering the eng...

Page 127: ...fall with potential serious personal injury to the mechanic Use only appropriately rated lifting equipment in perfect condition If the lifting equipment is unstable the motorcycle could fall over causing serious personal injury Use only equipment that is completely stable Install the special eye hook 27 code 8140183 to lift the engine and fasten it in place with the screws 25 Hook the slings 29 to...

Page 128: ... Release 00 2002 03 NOTE The fasteners holding the engine to the frame must be removed in the order given LEFT SIDE A B C D RIGHT SIDE E F G H 31 A B 30 D 36 35 C 32 34 33 G H 47 45 46 E 39 37 38 40 F 42 43 44 41 B A B C D H G E F ...

Page 129: ...ut 35 in place while you unscrew and remove the bolt 36 Tightening torque for nut 35 and bolt 36 36 ftlb 50 Nm Hold the nut 38 in place while you unscrew and remove the bolt 37 Tightening torque for nut 38 and bolt 37 36 ftlb 50 Nm Hold the nut 41 in place while you unscrew and remove the bolt 42 Tightening torque for nut 41 and bolt 42 36 ftlb 50 Nm Use the special socket wrench 48 code 8140203 t...

Page 130: ... bushings 40 44 in by hand and slide them up against the engine torque them to specifications Hold the nut 38 in place while you unscrew and remove the bolt 37 Hold the nut 41 in place while you unscrew and remove the bolt 42 Make sure the slings 29 are stretched taut Unscrew and remove the two bolts 45 saving the washers 46 Tightening torque for bolts 45 29 ftlb 40 Nm Recover the two spacers 47 4...

Page 131: ...und Secure the engine so that it will not tip over even if poorly balanced Unhook the slings 29 from the hoist Slide the slings 29 off the frame Move the engine out from underneath the frame Connect the slings 29 back to the engine NOTE If you will be working on the engine set it on the stand 8 code 8140187 8140188 WARNING If you do not need to work on the engine leave it resting on the floor and ...

Page 132: ...d as described below Make sure that all nuts bolts securing the engine are properly torqued Top up coolant see 2 14 CHECKING AND TOPPING UP THE COOLANT Top up engine oil see 2 12 CHECKING AND TOPPING UP THE ENGINE OIL LEVEL If the engine has been overhauled bleed the engine oil circuit and check the engine oil pressure Check the drive chain tension and adjust if necessary see 2 35 1 CHECKING THE P...

Page 133: ...RST mille USA ENGINE 3 17 00 Release 00 2002 03 NOTES ...

Page 134: ...RST mille USA ENGINE 3 18 00 Release 00 2002 03 NOTES ...

Page 135: ...RST mille USA FUEL SYSTEM 4 1 00 Release 00 2002 03 FUEL SYSTEM 4 ...

Page 136: ...ATION 4 8 00 4 7 2 SENSORS 4 9 00 4 7 3 INJECTION SYSTEM DIAGRAM 4 11 00 4 7 4 ELECTRONIC CONTROL UNIT 4 12 00 4 7 5 AUTOMATIC TESTING 4 13 00 4 7 6 ROUBLESHOOTING IN THE ELECTRONIC SYSTEM USING DISPLAYED INFORMATION 4 13 00 4 8 THROTTLE BODY 4 14 00 4 8 1 REMOVING THE THROTTLE BODY 4 14 00 4 8 2 REMOVING THE INJECTORS 4 15 00 4 9 DISASSEMBLING THE THROTTLE BODY 4 16 00 4 10 INSPECTING THE THROTTL...

Page 137: ...e water drain tube which drains away any water accidentally introduced into the fuel line from rain or while washing The overflow drain which accommodates overflow gasoline in the event of overfilling Legend 1 Fuel tank 2 Filling cap 3 Fuel intake pump unit 4 Drainage lines 5 Fuel return line 6 Fuel sensor 7 Fuel delivery filter 8 Fuel pump 9 Fuel delivery line 2 1 6 3 7 8 5 9 4 ...

Page 138: ...ee 6 10 3 ENGINE OIL PRESSURE SENSOR fuel intake pump 5 see 6 7 2 CHECKING THE FUEL PUMP Replace the delivery filter 6 NOTE During this procedure it is also advisable to wash the tank thoroughly 4 1 2 CHECK THE FUEL INTAKE Check the fuel lines every 4687 mi 7500 km or every 8 months replace every 4 years DANGER Be especially thorough in checking the delivery line 1 return line 2 and their fittings...

Page 139: ...he paint NOTE Place the tank on a clean surface with the pump assembly facing upwards Unscrew and remove the bolts 1 NOTE When reassembling insert all bolts by hand and cross tighten Tightening torque for bolts 1 4 4 ftlb 6 Nm WARNING When removing the pump assembly 2 be careful not to damage the fuel level sensor 3 and lines Remove the complete pump assembly 2 WARNING When reassembling make sure ...

Page 140: ...el sensor 2 from the support 3 4 5 REMOVING THE FUEL DELIVERY FILTER Remove the complete fuel intake pump unit see 4 3 COMPLETELY REMOVING THE FUEL INTAKE PUMP UNIT Unscrew and remove the screw 6 to free the grounding cable NOTE Use the special click clamp installation pliers code 0277295 during reassembly replace each clamp with a new one of the same kind Release the click clamp 1 2 Slide the hos...

Page 141: ...ach clamp with a new one of the same kind Release the click clamp 2 Slide the fuel hose 4 from the pump 3 Unscrew and remove the three bolts 5 WARNING When performing the operations listed below take care not to stretch or twist the electrical wires Remove the snap ring 6 from the filter element 7 WARNING When reassembling replace the snap ring 6 with a new one of the same kind Remove the filter e...

Page 142: ...factors provided by the various sensors Every time the engine is switched on the electronic control unit checks the sensors and ignition coils making sure that they are functioning properly If any errors are detected the message EFI flashes on the display The safety devices inside the electronic control unit shut down both ignition and fuel injection if the engine speed exceeds the maximum allowab...

Page 143: ...age To obtain this information it is necessary to obtain further details about the position by applying a strategy of varying the engine speed The information about the engine position is used to determine the engine speed and for any activities that must be synchronized with the wheel rotation such as fuel injection Atmospheric pressure sensor Location inside the electronic control unit 3 This se...

Page 144: ...gine temperature sensor 6 The engine temperature sensor is a thermistor with a negative temperature coefficient This means that its resistance decreases as the temperature increases This sensor is positioned to provide a precise indication of the engine running temperature The EMS compensates for the various engine operating properties within different engine temperature ranges For example a cold ...

Page 145: ...JECTOR REAR CYLINDER INJECTOR INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 Injection switch 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 weight P1 D4 P2C1 ignitionswitch Supplyvia Engine...

Page 146: ...TE 50 GREEN LIGHT BLUE 49 ORANGE LIGHT BLUE 48 YELLOW BLUE 20 BLUE GREEN 21 BLUE GREEN 36 RED BLACK 30 BLUE GREEN WELDED TO THE SHIELDING OF THE 2 CABLES AND PROTECTED WITH HEAT SHRINK FILM 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 ...

Page 147: ...nts should be taken with components at a temperature of 68 F 20 C General troubleshooting instructions as soon as you have identified the fault remove the defective component If the EFI LED comes on while the vehicle is running it means the control unite has detected a fault FAULT CODE TABLE Code Description of fault 12 crankshaft pick up position sensor malfunction 15 throttle position sensor TPS...

Page 148: ... THE FUEL TANK Remove the air filter case see 7 1 8 REMOVING THE AIR FILTER CASE Disconnect the electrical connectors right injector 1 left injector 2 throttle valve potentiometer 3 WARNING When reassembling make sure the electrical connectors are properly inserted NOTE Use the special click clamp installation pliers code 0277295 during reassembly replace each clamp with a new one of the same kind...

Page 149: ... on a clean surface Plug the inlet manifolds to prevent foreign matter from entering the cylinders WARNING During reassembly the fuel delivery line 12 must not be twisted or placed where it is likely to be pinched by other components it must be replaced if found to be damaged or deteriorated the fuel delivery line 12 must be placed so that it arrives on the right hand side of the throttle body 6 p...

Page 150: ...ith O ring 3 left injector 4 and O ring 5 Unscrew and remove the two screws 6 Tightening torque for screws 6 26 ftlb 3 5 Nm Remove the fuel line 7 complete with O ring 8 right injector 9 and O ring 10 Unscrew and remove the two screws 11 Tightening torque for screws 11 0 8 ftlb 1 2 Nm Remove the potentiometer 12 NOTE Replace all seals during reassembly These components are supplied in the repair k...

Page 151: ...ers Use only proprietary gasket removers degreasers or cleansers that do not require heating Clean all openings and passages in the throttle body with compressed air 4 10 3 THROTTLE VALVE POTENTIOMETER WARNING The two HS bolts fastening the throttle valve potentiometer 1 are painted over during the manufacturing process and cannot be loosened The throttle valve potentiometer may be adjusted only w...

Page 152: ...n contact with the gasoline Do not smoke or use open flames Always dispose of fuel in compliance with environmental regulations Raise the fuel tank see 2 8 LIFTING THE FUEL TANK Pull out the two free tubes 2 on the left side of the motorcycle under the side panel Unplug the two free transparent lines 2 and connect them to those of the vacuum gauge 1 using two 6 mm fittings Completely close the two...

Page 153: ...nnect the two rigid tubes to the appropriate exhaust tube outlets connect the other tube to the exhaust gas analyzer 1 Make sure that the idle speed is 1250 100 rpm If not adjust as needed see 2 11 2 ADJUSTING THE IDLE SPEED Check the tester 1 for the CO values which should match those indicated and be the same for both cylinders CO values for both cylinders 1 5 2 at 1250 100 rpm CO values for bot...

Page 154: ...richer blend and thus increasing the value of CO vice versa if the parameter is reduced the CO value falls WARNING Slowly change the parameter on the instrument no more than 2 or 3 pulses at a time and wait for the CO value to stabilize on the exhaust gas analyzer 1 Use the vehicle exhaust tester 2 connection lines of suitable length 2 3 Check the CO on both exhausts and make sure that the maximum...

Page 155: ... press the enter key The next screen shows a series of data regarding the various control unit parameters Press the or key then use the UP and DOWN arrows to select the item Closed Throttle Position and press enter A throttle valve alignment reference parameter appears at the top of the display use the UP arrow to increase the value of the parameter until it stabilizes at which point the control u...

Page 156: ...RST mille USA FUEL SYSTEM 4 22 00 Release 00 2002 03 NOTES ...

Page 157: ...RST mille USA COOLING SYSTEM 5 1 00 Release 00 2002 03 COOLING SYSTEM 5 ...

Page 158: ...STEM 5 1 DESCRIPTION 5 3 00 5 2 REMOVING THE RADIATORS 5 5 00 5 3 REMOVING THE ELECTRIC COOLING FANS 5 6 00 5 4 REMOVING THE COOLANT THERMISTORS 5 7 00 5 5 REMOVING THE THERMOSTAT 5 8 00 5 6 REMOVING THE FILLER NECK 5 8 00 5 7 REMOVING THE THREE WAY MANIFOLD 5 9 00 5 8 REMOVING THE EXPANSION TANK 5 9 00 ...

Page 159: ...ee 2 14 CHECKING AND TOPPING UP THE COOLANT For more information about coolant see 1 3 7 COOLANT Legend 1 Front cylinder thermistor 2 Rear cylinder thermistor 3 Breather tube 4 Compensation tubes 5 Filler hose 6 Filler neck 7 Engine hose right side thermostat 8 Rear cylinder hose three way manifold 9 Front cylinder hose three way manifold 10 Expansion tank 11 Three way manifold 12 Three way manifo...

Page 160: ...e right hand side and flows directly to the thermostat to the left radiator three way manifold and to the right radiator thermostat gradually opening then back to the pump Path with coolant temperature greater than 176 F 80 C From the pump coolant enters engine temperature taken by thermistors and shown on the right hand dashboard display Coolant leaves the engine to three way manifold temperature...

Page 161: ...de 0277295 during reassembly replace each clamp with a new one of the same kind Release the click clamp 7 Slide the hose 8 off the radiator 4 Unscrew and remove the screw 9 and recover the bushing and grommet 10 if necessary NOTE Replace the grommet 10 if you find it to be damaged WARNING Proceed with care Do not damage the radiator fins Tilt the radiator 4 slightly forward while lifting extractin...

Page 162: ...crew and remove the two screws 2 Tightening torque for screws 2 4 4 ftlb 6 Nm Recover the two nuts 3 Tilt the complete electric fan 4 slightly back and at the same time move it outwards pulling the internal holding pin from its seat on the radiator 5 Remove the electric fan 4 NOTE Replace the grommet 6 if you find it to be damaged If necessary Unscrew and remove the four screws 7 saving the washer...

Page 163: ...ter case and gradually lift and slide it off the intake flanges Move away and set the group on the left hand side of the vehicle Disconnect the electrical connector 4 WARNING When reassembling make sure the electrical connector 4 is fitted properly Unscrew and remove the thermistor 5 Prepare a new thermistor and apply LOCTITE 574 on its thread Screw on the new thermistor 5 by hand and tighten If a...

Page 164: ...RNING Plug all the coupling openings to prevent any foreign matter from accidentally entering 5 6 REMOVING THE FILLER NECK Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION and 1 3 7 COOLANT Completely discharge the cooling circuit see 2 15 CHANGING THE COOLANT NOTE Use the special click clamp installation pliers code 0277295 during reassembly replace each clamp with a new one of the same k...

Page 165: ...g openings to prevent any foreign matter from accidentally entering 5 8 REMOVING THE EXPANSION TANK Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION and 1 3 7 COOLANT Remove the right fairing see 7 1 28 REMOVING THE SIDE FAIRINGS NOTE Use the special click clamp installation pliers code 0277295 during reassembly replace each clamp with a new one of the same kind LLoosen and remove the clic...

Page 166: ...RST mille USA COOLING SYSTEM 5 10 00 Release 00 2002 03 NOTES ...

Page 167: ...RST mille USA ELECTRICAL SYSTEM 6 1 00 Release 00 2002 03 ELECTRICAL SYSTEM 6 ...

Page 168: ... 7 3 CHECKING THE FUEL PUMP RELAY 6 22 00 6 8 IGNITION SAFETY SYSTEM 6 23 00 6 8 1 WIRING DIAGRAM 6 23 00 6 8 2 STARTING SAFETY OPERATING LOGIC 6 24 00 6 8 3 CHECKING THE START RELAY 6 24 00 6 8 4 CHECKING THE DIODE 6 25 00 6 8 5 CHECKING THE SIDE STAND SWITCH 6 26 00 6 8 6 CHECKING THE DIODE MODULE 6 26 00 6 8 7 CHECKING THE SAFETY SYSTEM SWITCHES 6 27 00 6 9 ELECTRIC COOLING FANS 6 28 00 6 9 1 W...

Page 169: ...A ELECTRICAL SYSTEM 6 3 00 Release 00 2002 03 6 1 LOCATIONS OF ELECTRICAL COMPONENTS 24 25 26 28 27 26 21 7 22 21 20 19 18 1 23 3 17 16 15 14 13 12 11 10 9 8 6 5 4 42 43 41 39 38 37 44 2 35 36 30 31 32 33 34 29 40 ...

Page 170: ...ture sensor 23 Throttle sensor 24 Low beam relay 25 High beam relay 26 High beam bulbs 27 Low beam bulb 28 Front parking light bulb 29 Right fan 30 Front right direction indicator 31 Secondary fuses 15A 32 Flasher 33 Overturn sensor 34 Ignition switch 35 Right dimmer switch 36 Front stop switch 37 Fuel pump sensor group 38 Test and diagnostics connector 39 Main fuses 30 A 40 Rear stop switch 41 Ri...

Page 171: ... two electrical connectors as follows Press the safety latches if provided WARNING Do not pull on the wires to disconnect the two connectors Grasp the two connectors and disconnect them by pulling in opposite directions If you see any dirt rust moisture etc carefully clean the inside of the connector using compressed air Make sure that the cables are correctly crimped to the terminals placed insid...

Page 172: ... 3 5 CHECKING THE VOLTAGE REGULATOR Wiring diagram legend NOTE For the positions of the components see 6 1 LOCATIONS OF ELECTRICAL COMPONENTS 1 Battery 2 Main fuses 30 A 3 Alternator 4 Voltage regulator 5 Ignition switch Standard charge voltage 13 15 V DC at 4000 rpm 6 3 2 CHECKING THE OPEN CIRCUIT ALTERNATOR OPERATION Remove the left lower fairing see 7 1 33 REMOVING THE LOWER FAIRING Disconnect ...

Page 173: ... regulator cables WARNING When reassembling make sure the electrical connector 1 is properly connected Use a tester scale Ω to check the continuity between the cables of the stator on the internal female terminals yellow cables G Also check the isolation of the stator mount Standard resistance value 0 1 1Ω Standard resistance value between cables and stator mount A B 30 A Main Fuse Regulator Flywh...

Page 174: ... regulator side internal male terminals NOTE There are two green V and two red white Bi R wires The two green wires are connected together and the two red white wires are connected together Measurements may be made using either of the two green and either of the two red white wires WARNING This measurement method is only approximate if possible make sure the charger is in good working order by usi...

Page 175: ...e that the 30 A main fuse and the 15 A fuse D are intact Make sure the kill switch device is working properly see 6 8 IGNITION SAFETY SYSTEM as well as the key see 6 5 IGNITION INJECTION SYSTEM Make sure the engine stop relay is in good working order see 6 7 3 CHECKING THE FUEL PUMP RELAY Check the injection relay see 6 4 3 CHECKING THE INJECTION RELAY Check the overturn sensor see 6 4 4 CHECKING ...

Page 176: ...on WARNING Observe the polarity connecting the pole to terminal 86 and the pole to terminal 85 there is a diode inside 6 4 4 CHECKING THE OVERTURN SENSOR Remove the front fairing see 7 1 20 REMOVING THE FRONT FAIRING WARNING Have ready a bulb max 12 V 2W Prepare a circuit like the one shown in the figure Close the switch A with the sensor set to horizontal the bulb B will light Tilt the sensor by ...

Page 177: ... Front cylinder injector 11 Dashboard 12 Rear cylinder coil center spark plug 13 Rear cylinder coil side spark plug 14 Front cylinder coil side spark plug 15 Front cylinder coil center 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 D1 N 7 12WAY...

Page 178: ...bly low if the message remains lit even after carrying out the operations described in paragraph 6 5 1 TROUBLESHOOTING the engine may be switched on but will not start if the message continues to flash even after you have carried out the operations described in 6 5 1 TROUBLESHOOTING proceed with checking the sensors 6 5 3 VERIFYING FAULT CODES Raise the saddle see 7 1 1 REMOVING THE SADDLE Connect...

Page 179: ...listed whether the fuel pump is working properly see 6 7 2 CHECKING THE FUEL PUMP the injectors are working properly see 6 6 1 CHECKING THE INJECTORS the antitheft setup connector located under the passenger saddle white is connected properly the ignition switch is working properly see 6 13 2 SWITCHES the engine stop switch is working properly see 6 13 2 SWITCHES the 30 A main fuses and 15 A secon...

Page 180: ...in the diagram mark corresponding terminals on both connectors Y Electronic control unit connector 26 way Z Electronic control unit connector 16 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 43 40 39 45 54 63 42 25 46 47 48 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 P1E4 P2...

Page 181: ...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 Electric fans P1 H4 M R P2 G2 G N P2 G1 G N 45 Gasoline 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 valve potentiometer P1 E4 2 8 3 4 kΩ variable depending on the angle B R P1 E3 M Bi P1 B3 M G 49 Rear cylind...

Page 182: ...2 CHOKE MOTOR Raise the air filter case see 7 1 8 REMOVING THE AIR FILTER CASE NOTE The stepper motor opens and closes the air passages to alter the air gasoline mixture as needed Make sure the stepper motor 2 is working properly Unscrew and remove the two screws 1 and detach it from the filter case Set the key to and then immediately to After you have set the key to the white cylinder comes all t...

Page 183: ...ASUREMENT A Resistance between the two terminals A and B regardless of the position of the throttle valves Standard value 1 2 kΩ 10 MEASUREMENT B Resistance between the terminals A and C With throttle valves completely closed accelerating gradually until they are fully open the resistance will change as follows Standard value from 1 2 kΩ to 2 4 kΩ 10 NOTE To make it easier to unscrew the two screw...

Page 184: ...istor 2 Immerse the thermistor 4 in a container 3 of water In the same container immerse a thermometer 5 with a range of 0 150 C 32 302 F Place the container on a burner 6 and slowly heat the fluid Check the temperature shown on the thermometer 5 and the thermistor value shown on the tester Make sure that the value changes based on temperature as indicated If the values do not change or differ too...

Page 185: ...istor 1 Immerse the thermistor 1 in a container 3 containing coolant In the same container immerse a thermometer 4 with a range of 0 150 C 32 302 F Place the container on a burner 5 and slowly heat the fluid Check the temperature shown on the thermometer 4 and the thermistor 1 value shown on the tester Make sure that the value changes based on temperature as indicated If the values do not change o...

Page 186: ... intact the resistance values must approximately match those indicated Standard values measurement A 0 6 Ω 10 measurement B 10 kΩ 10 WARNING This measurement method is only approximate if possible make sure the coil is in good working order by using another one you know functions properly Repeat the operations for the other coils 6 6 7 CHECKING THE CRANKSHAFT POSITION SENSOR With the engine off Re...

Page 187: ...STEM 6 7 1 WIRING DIAGRAM NOTE For the positions of the components see 6 1 LOCATIONS OF ELECTRICAL COMPONENTS Legend 1 Battery 2 Fuel pump relay 3 Pump 4 Overturn sensor 5 Engine stop relay 6 Electronic control unit ECU 7 Fuse Ar V E1 Grey H1 Black Ro Bi V N B Bi 1 2 7 3 4 6 5 ...

Page 188: ...re that the pump works properly and emits its usual hum Check the pressure gauge to make sure the intake pressure is at least 50 76 PSI 350 kPa 3 5 bar 6 7 3 CHECKING THE FUEL PUMP RELAY To check the relay Disconnect the four way connector 1 white from the relay 2 WARNING When reassembling make sure the electrical connector 1 is properly connected Connect the two internal male terminals A B to a 1...

Page 189: ...S Wiring diagram legend 8 Diode module 9 Switch on clutch lever 10 Neutral gear switch 12 Starter button 16 Start relay 17 Starter motor 18 Battery 29 Secondary fuses 15A 58 Stand down LED 59 Gear in neutral LED 70 Side stand switch A To battery ignition switch B To the secondary 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 Diodo Engine Kill 10 16 ...

Page 190: ...ct the cables from the terminals on the relay 2 Apply 12 V to the two internal male prongs of the connector 1 on the relay side Use a tester in ohm meter mode to check the relay operation by measuring the resistance between the two contact screws on the relay 2 Correct value with relay energized 0 Ω Correct value with relay not energized Ω If the values do not match those indicated replace the rel...

Page 191: ...tor 1 is properly connected Use a tester in diode test mode to check the values between the two internal male prongs of the diode as shown in the figure Correct value measurement A 0 Ω Correct value measurement B If the tester does not have a diode test function connect to a 12 V battery inserting a 12 V 2 W bulb on the positive cable connecting the diode as shown in the figure WARNING Never use b...

Page 192: ...ottle grip released and the engine idling fully squeeze the clutch lever Engage the first gear by pushing the gearshift lever down Lower the side stand 1 which will activate the safety switch 3 At this point the engine must stop the side stand down LED must light on the dashboard If this does not occur replace the switch 3 6 8 6 CHECKING THE DIODE MODULE Remove the left fairing see 7 1 28 REMOVING...

Page 193: ...check the continuity of the switches referring to the specific diagram Should you detect anything out of order replace the corresponding group of switches 1 NEUTRAL GEAR SWITCH 2 SIDE STAND SWITCH 3 CLUTCH LEVER SWITCH Pos Cables Screw Neutral Side stand pos Cables M V N Lowered Raised Pos Cables Gr M Activated 1 2 3 ...

Page 194: ...TE The following steps refer to a single fan but are applicable to both Carry out the first three steps described in paragraph 5 3 REMOVING THE ELECTRIC COOLING FANS NOTE Have a 12 V battery ready Connect the connector black 1 to the battery Make sure that the fan turns freely If the fans are working properly check coolant thermistor see 6 6 5 CHECKING THE COOLANT THERMISTORS OPERATION injection s...

Page 195: ...he locations of the components see 6 1 LOCATIONS OF ELECTRICAL COMPONENTS Legend 1 Dashboard 2 External temperature sensor 3 Oil pressure sensor 4 Fuel level 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 CONNETTORE 16VIE CONNETTORE 12VIE 1 2 3 6 4 5 ...

Page 196: ...ironment with a temperature of 20 C 68 F Measure the electrical resistance using an ohm meter scale 0 2kΩ between the terminals of the connector 1 Correct value 12 200 kΩ 12 700 kΩ If the air temperature sensor is working properly check the dashboard Disconnect the 16 way connector 2 see 7 1 24 REMOVING THE DASHBOARD Apply a resistance of 12 4 k Ω between terminals 2 and 9 If the dashboard is work...

Page 197: ... With the ignition switch set to the red engine oil pressure LED should light If the LED does not light as described check the sensor Use a tester scale x 100 Ω to check the continuity between the terminal tab 3 and the sensor 2 housing see figure Correct value with engine off 0 Ω Correct value with engine running Ω If the resulting values do not match those listed make sure the engine oil level i...

Page 198: ... the speed sensor 1 located on the right side of the motorcycle Measure the electrical resistance between the two terminals of the connector 1 on the sensor side Correct value 3 83 M Ω 5 REVERSING THE POLARITY Correct value NOTE Replace the speed sensor if the values are incorrect If the values are correct Replace the dashboard see 7 1 24 REMOVING THE DASHBOARD Make sure the dashboard wires are pr...

Page 199: ...ensor side Correct value with the fuel tank full less than 14 Ω Correct value without fuel between 240 and 400 Ω NOTE Replace the fuel level sensor if the values are incorrect If the values are correct test the dashboard operation by connecting a resistance between the orange black and white yellow wires of the 4 way connector 1 on the main system side With resistance 10 Ω the dashboard shows 9 we...

Page 200: ...OOLANT THERMISTORS OPERATION Test the dashboard operation by connecting a resistance between the white black and white red wires of the two way connector 1 With resistance 90 Ω dashboard indicator 9 wedges lit the last two flashing degree indicator from 126 C to 135 C from 258 8 F to 275 F With resistance 1600 Ω dashboard indicator 1 wedge lit degree indicator 1 ...

Page 201: ...r switch 3 Right dimmer switch version 4 Key 5 Low beam relay 6 High beam relay 7 Fuses 15 A 8 Fuses 30 A 9 Battery 10 License plate lamp 11 Low beam 12 High beam 13 Front parking light 14 Rear parking light 15 Dashboard light LED 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 Ar G Gr G 1 2 3 6 4 ...

Page 202: ...ONT FAIRING Remove the relay in question Power the two male terminals 85 86 with a voltage of 12 V Use a tester in ohm meter mode to check the continuity between the other two terminals 87 30 Correct value with relay energized 0 Ω Correct value with relay not energized Ω If the values do not match those indicated replace the relay in question 1 85 86 12V 30 87 1 ...

Page 203: ...L COMPONENTS Legend 1 Left dimmer switch 2 Horn 3 Fuse 15 A 4 Fuse 30 A 5 Key 6 Battery 7 Flasher 8 Rear right direction indicator bulb 9 Rear left direction indicator bulb 10 Front right direction indicator bulb 11 Front left direction indicator bulb 12 Dashboard 13 Direction indicators 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 204: ...orking there is probably a problem with the flasher To test the flasher operation Remove the front fairing see 7 1 20 REMOVING THE FRONT FAIRING Disconnect the two connectors 1 of the flasher 2 Jumper the two connectors 1 Activate the direction indicator controls 3 If the lights remain steadily lit replace the flasher 2 If necessary check the main fuses 30 A and the electrical system If one of the...

Page 205: ...BUZZERS 6 13 1 WIRING DIAGRAM NOTE For the positions of the components see 6 1 LOCATIONS OF ELECTRICAL COMPONENTS Legend 1 Front stop switch 2 Rear stop switch 3 Fuse 15 A 4 Fuse 30 A 5 Key 6 Battery 7 Taillight 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 206: ...ter to check the continuity of the switches referring to the specific diagram Should you detect anything out of order replace the corresponding group of switches 1 BRAKE LIGHT SWITCH ON FRONT BRAKE 2 BRAKE LIGHT SWITCH ON REAR BRAKE Pos Cables V V G Activated Pos Cables Gr M Activated ...

Page 207: ...professional medical attention If someone should accidentally swallow battery electrolyte drink large amounts of milk or water then continue with milk of magnesia or vegetable oil See a physician immediately Since the battery gives off explosive hydrogen gas keep away from open flames sparks or cigarettes or any other source of heat When you are charging or using a battery make sure that the room ...

Page 208: ...rains out smoothly WARNING Do not remove the reservoirs 2 from the battery until all of the liquid has drained Should any liquid still be left in the reservoirs 2 once the twenty minutes are up tap your fingers on the top of the reservoirs to help the remaining liquid out Lift the reservoirs 2 with care disengaging them from the battery Place the row of stoppers 3 over the battery cell openings Pr...

Page 209: ...ng a charge first check the recharging circuit to make sure it is functioning correctly see 6 3 CHECKING THE RECHARGING SYSTEM Also make sure that There are no signs of damage external case cracked and no electrolyte leak The cables are firmly connected to the terminals Apply a normal charge for at least 10 hours WARNING After recharging check the open circuit voltage again if it is below 12V the ...

Page 210: ...3 lower NOTE It is necessary to remove the right and left dashboard panels when replacing the low beam and high beam bulbs The lower saddle panel must be removed to replace the parking light bulb To replace HIGH BEAM BULBS NOTE Work on the same side as the bulb to be replaced NOTE Remove one connector at a time to avoid returning them to the incorrect position during reassembly If the bulb sockets...

Page 211: ...incorrect position during reassembly If the bulb sockets must all be removed at the same time take great care to reassemble them in the proper position Remove the right dashboard panel see 7 1 20 REMOVING THE FRONT FAIRING WARNING Do not pull the electrical cables to extract the bulb socket Grasp the bulb socket 8 pull it and disconnect it from the bulb 3 Pull back the boot 10 with your fingers Re...

Page 212: ...ce the rear direction indicator lamps see 6 15 3 REPLACING THE TAILLIGHT BULBS 6 15 3 REPLACING THE TAILLIGHT BULBS The taillight houses two parking light brake light bulbs 1 two rear direction indicator lamps 2 To replace Before replacing a bulb check the operation of the brake light switches see 6 13 2 SWITCHES DANGER The exhaust silencer becomes extremely hot during operation You could be burne...

Page 213: ... the bulb sockets must all be removed at the same time take great care to reassemble them in the proper position Turn the bulb seat 5 counter clockwise Push the bulb 2 in slightly and rotate it counter clockwise Remove the bulb 2 from its seat WARNING Insert the bulb in the socket lining up the two bulb pins with the corresponding guides on the socket Correctly install a new bulb of the same type ...

Page 214: ...er the filament 2 is blown Before replacing the fuse if possible try to determine the cause of the problem Replace any blown fuse with a new fuse with the same amperage rating NOTE If you use the spare fuse replace it as soon as convenient Remove the saddle see 7 1 1 REMOVING THE SADDLE Follow the same procedure described above for secondary fuses to check and replace the main fuses NOTE Removing ...

Page 215: ...at establishes the maximum height of the headlight beam For vehicles used in other countries you must observe local regulations Before adjusting the headlight beam horizontally you must first adjust it vertically see 6 17 ADJUSTING THE HEADLIGHT BEAM VERTICALLY To adjust the headlight beam Remove the left dashboard panel see 7 1 20 REMOVING THE FRONT FAIRING Sit on the vehicle as though you were r...

Page 216: ...RST mille USA ELECTRICAL SYSTEM 6 50 00 Release 00 2002 03 6 19 WIRING DIAGRAM RST MILLE FUTURA ...

Page 217: ...dlight dashboard B fuel pump C parking lights rear brake lights horn direction indicators D starting safety logic E available 35 36 Pick up 37 Alternator 38 Voltage regulator 39 Injection relay 40 41 Rear cylinder injector 42 Front cylinder injector 43 Cooling fans 44 Fuel reserve sensor 45 Fuel pump 46 Air thermistor electronic control unit 47 Coolant temperature thermistor electronic control uni...

Page 218: ...RST mille USA ELECTRICAL SYSTEM 6 52 00 Release 00 2002 03 NOTES ...

Page 219: ...RST mille USA CHASSIS 7 1 00 Release 00 2002 03 7 CHASSIS ...

Page 220: ...1 39 COMPLETELY REMOVING THE SADDLE RELEASE 7 33 00 7 1 40 REMOVING THE LOWER SADDLE PANEL 7 33 00 7 1 41 REMOVING THE SADDLE SUPPORT LOWER MOLDED COVER 7 34 00 7 1 42 REMOVING THE LICENSE PLATE HOLDER 7 36 00 7 1 43 REMOVING THE PASSENGER FOOTREST SUPPORTS 7 36 00 7 1 44 REMOVING THE PASSENGER FOOTREST 7 37 00 7 1 45 REMOVING THE LEFT RIDER FOOTREST SUPPORT 7 37 00 7 1 46 REMOVING THE RIGHT RIDER...

Page 221: ...90 00 7 9 SWINGING ARM 7 91 00 7 9 1 REMOVING THE SWINGING ARM 7 91 00 7 9 2 DISASSEMBLING THE SWINGING ARM 7 92 00 7 9 3 CHECKING THE COMPONENTS 7 93 00 7 9 4 RE INSTALLING THE SWINGING ARM 7 94 00 7 10 REAR SUSPENSION 7 96 00 7 10 1 REMOVING THE SHOCK ABSORBER 7 96 00 7 10 2 DISASSEMBLING THE REAR SUSPENSION LINKAGE 7 97 00 7 10 3 DISASSEMBLING THE SUSPENSION LINKAGE 7 98 00 7 10 4 CHECKING THE ...

Page 222: ...r 7 Engine oil reservoir cap 8 Left rider footrest 9 Battery 10 Main fuse holder 30A 11 Saddle 12 Left passenger footrest locking closed open 13 Drive chain 14 Swinging arm 15 Center stand 16 Side stand 17 Gearshift lever 18 Electronic control unit 19 Engine oil filter 20 Engine oil reservoir 21 Lower left fairing 22 Engine oil level 23 Left fairing 3 1 2 4 5 8 9 10 11 12 13 14 15 17 16 18 19 20 2...

Page 223: ... shock absorber 5 Fuel tank 6 Fuel tank cap 7 Air filter 8 Front brake fluid reservoir 9 Secondary fuse holder 15A 10 Right rearview mirror 11 Horn 12 Coolant expansion tank 13 Coolant expansion tank plug 14 Rear brake lever 15 Right rider footrest 16 Rear brake master cylinder 17 Rear brake fluid reservoir 1 5 6 3 2 4 7 8 10 9 12 11 13 14 15 16 17 ...

Page 224: ...ove tool kit compartment When reassembling the saddle 1 make sure that the lock clicks into place If necessary Remove the front side panels see 7 1 3 REMOVING THE FRONT SIDE PANELS 7 1 2 REMOVING THE REAR SIDE PANELS NOTE The following steps refer to removing a single side panel but are applicable to both Remove the saddle see 7 1 1 REMOVING THE SADDLE Place the saddle on a flat surface Unscrew an...

Page 225: ...plates 2 7 1 4 REMOVING THE BAG RACKS NOTE The following steps refer to removing a single rack but are applicable to both Remove the saddle see 7 1 1 REMOVING THE SADDLE Unscrew and remove the screw 1 retrieving the washer and bushing from inside Tightening torque for screws 1 0 7 ftlb 1 Nm Unscrew and remove the screw 2 retrieving the bushing Tightening torque for screw 2 7 3 ftlb 10 Nm Unscrew a...

Page 226: ...3 Nm Remove the grille 3 Unscrew and remove the two screws 4 holding the front of the tank 5 retrieve the two bushings and replace the two grommets if they are damaged Tightening torque for screws 4 5 9 ftlb 8 Nm NOTE Place a cloth under the male quick release coupling 6 to catch any spilled fuel Press the push button 8 to disconnect the male quick release coupling 6 from the female 7 NOTE When re...

Page 227: ...roximately half a turn then wait a few seconds to allow the system to depressurize Unscrew and remove the banjo screw 1 and retrieve the two gaskets 2 Tightening torque for banjo screw 1 16 2 ftlb 22 Nm DANGER When reassembling use two new gaskets 2 and torque the banjo screw 1 as specified so that the tank will not leak This is essential as the injection pressure is approximately 450 kPa 4 5 bar ...

Page 228: ...que for screws 1 3 6 ftlb 5 Nm NOTE You may leave the other three screws mounted since they are purely decorative Open the cap 2 WARNING When removing the screw 3 be careful not to drop it into the tank Unscrew and remove the screw 3 Tightening torque for screws 3 3 6 ftlb 5 Nm Remove the plug 2 complete with ring nut 4 WARNING Plug the tank opening to prevent any foreign matter from accidentally ...

Page 229: ...ke sure the electrical connector is fitted properly Remove the filter case 9 complete with intake manifold 10 NOTE Plug the openings with a clean rag to prevent any foreign matter from entering the air passages The intake manifold 10 must be positioned correctly and aligned perfectly with the air intake holes in the frame Make sure that the air filter case 9 rests snugly against the throttle body ...

Page 230: ...emove the screw 4 on the positive terminal Move the positive cable 5 to one side WARNING Do not force electrical cables Remove the start relay 6 Unscrew and remove the screw 7 Tightening torque for screw 7 3 6 ftlb 5 Nm Lift the bracket 8 holding the battery in place Firmly grasp the battery 9 and lift it out of its compartment DANGER Once it has been removed store the battery in a safe place and ...

Page 231: ...ng torque for screws 3 7 3 ftlb 10 Nm Remove the control unit 2 WARNING When replacing the control unit 2 you must also align the throttle valve position sensor see 4 10 3 THROTTLE VALVE POTENTIOMETER 7 1 11 REMOVING THE HANDGRIP FROM THE LEFT HANDLEBAR Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Place the vehicle on the stand Set the ignition switch to Hold the balance weight in plac...

Page 232: ...for terminal 5 25 8 ftlb 35 Nm Remove the pin 6 and the rubber bushing 7 Insert the tip of a compressed air gun between the handlegrip 8 and the handlebar 9 Moving the gun tip with a circular motion blow air into the space At the same time use your other hand to grasp and pull off the grip 8 5 7 6 8 9 ...

Page 233: ...ow engraved on the top facing upward Should you need to completely remove the clutch control 2 Follow the first three steps described in chapter 2 21 CHANGING THE FRONT BRAKE FLUID When all the fluid has drained out unscrew and remove the screw 4 and retrieve the two seals Tightening torque for screw 4 14 5 ftlb 20 Nm WARNING When reassembling replace the two seals with two new washers of the same...

Page 234: ...front fairing see 7 1 20 REMOVING THE FRONT FAIRING Free the wiring from the two holding clamps 4 NOTE Have the same number of clamps ready to use when reassembling Disconnect the electrical connector 5 of the left dimmer switch WARNING When reassembling make sure the connector 5 is fitted properly Remove the two halves of the electrical controls 2 3 7 1 14 REMOVING THE THROTTLE CONTROL Carefully ...

Page 235: ...ROL Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Place the vehicle on the stand Set the ignition switch to Unscrew and remove the two screws 2 fastening the front brake control 3 Tightening torque for screw 2 7 3 ftlb 10 Nm Remove the front brake lever clamp 1 and move the front brake control 3 which remains attached via the brake line NOTE When reassembling the brake lever clamp 1 mus...

Page 236: ...he front fairing see 7 1 20 REMOVING THE FRONT FAIRING Disconnect the electrical connector 1 of the right dimmer switch WARNING When reassembling make sure the connector 1 is fitted properly Disconnect the connector 2 WARNING When reassembling make sure the connector 2 is fitted properly Unscrew and remove the two screws 3 4 fastening the two halves of the controls 5 6 from the bottom NOTE When re...

Page 237: ...in wiring WARNING When reassembling make sure the connector 1 is fitted properly Unscrew and remove the screw 2 retrieving the bushing 3 NOTE When reassembling place the cable guide 4 correctly Use a small hammer and chisel to notch the head of the special screw 5 and turn it until it s loose Unscrew by hand and remove the screw 5 NOTE When reassembling use a new screw of the same type Torque the ...

Page 238: ...screw and remove the screw 1 Tightening torque for screw 1 8 8 ftlb 12 Nm Loosen the screw 2 Tightening torque for screw 2 18 ftlb 25 Nm NOTE When reassembling apply a little grease under the head of the screw 2 Slide the handlebar 3 from the fork 7 1 19 REMOVING THE RIGHT HANDLEBAR Remove the throttle control see 7 1 14 REMOVING THE THROTTLE CONTROL Remove the brake control see 7 1 15 REMOVING TH...

Page 239: ...1 24 REMOVING THE DASHBOARD Unscrew and remove the three screws 8 retrieving the three nuts Slide the front fairing glass 9 out Remove the upper dashboard molding see 7 1 23 REMOVING THE UPPER DASHBOARD MOLDING WARNING Handle all plastic and painted components with care to avoid scraping or scratching them Disconnect from the main wiring 10 the connectors for the headlight 11 front direction indic...

Page 240: ...oid scraping or scratching them Unscrew and remove the two nuts 3 Remove the mirror pulling the wiring through the slot 4 Retrieve the gasket 5 NOTE If necessary repeat the above steps to remove the other rearview mirror WARNING After reassembly adjust the rearview mirrors as needed and tighten the nuts 3 to ensure their stability 7 1 22 REMOVING THE HEADLIGHT Carefully read 1 3 9 PRECAUTIONS AND ...

Page 241: ...ly read 0 5 1 PRECAUTIONS AND GENERAL INFORMATION Remove the dashboard panels see 7 1 20 REMOVING THE FRONT FAIRING Unscrew and remove the two screws 2 retrieving the two bushings and the anti vibration grommets Tightening torque for screws 2 2 9 ftlb 4 Nm WARNING Replace the grommets if damaged Move the dashboard 3 out of the way Slip the boot off the connectors 1 and disconnect the latter from t...

Page 242: ...EMOVING THE FRONT FAIRING Unscrew and remove the two screws 1 saving the two nuts Tightening torque for screws 1 1 4 ftlb 2 Nm Remove the fuse box 2 Uncouple the two light relays 3 flasher 4 and the overturn sensor 5 leaving them connected to the wiring WARNING Replace the grommets if damaged Unscrew and remove the two nuts 7 Tightening torque for nuts 7 7 3 ftlb 10 Nm Remove the two screws 8 Remo...

Page 243: ...nd painted components with care to avoid scraping or scratching them Pull the mudguard 2 out from the front 7 1 27 REMOVING THE HORN Place the vehicle on the stand Remove the radiator spoiler see 7 1 35 REMOVING THE RADIATOR SPOILER Disconnect the two horn connectors 1 WARNING When reassembling make sure the two connectors 1 are fitted together properly To remove the horn 3 complete with bracket u...

Page 244: ...ARNING Handle all plastic and painted components with care to avoid scraping or scratching them Remove the side fairing 4 WARNING Replace the internal soundproofing panel if damaged NOTE If necessary repeat the above steps to remove the other side fairing 7 1 29 REMOVING THE FRONT DIRECTION INDICATORS If you need to replace the front direction indicator proceed by removing the mirror see 7 1 21 RE...

Page 245: ... half housings see 7 1 22 REMOVING THE HEADLIGHT Disconnect the electrical connector 1 from the air thermistor WARNING When reassembling make sure the connector 1 is fitted properly Unscrew and remove the ten screws 2 Tightening torque for screws 2 1 4 ftlb 2 Nm Unscrew and remove the screw 3 saving the washer Tightening torque for screws 3 7 3 ftlb 10 Nm Partially remove the control unit case 4 a...

Page 246: ...ng torque for screws 2 3 6 ftlb 5 Nm Remove the right air duct 3 7 1 32 REMOVING THE FRONT FAIRING LOWER LOCKUP Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Place the vehicle on the center stand Unscrew and remove the three screws 1 Tightening torque for screws 1 3 6 ftlb 5 Nm WARNING Be very careful to avoid damaging the brake lines Nudge the front fairing lower lockup 1 until you fin...

Page 247: ... screws 1 2 9 ftlb 4 Nm Unscrew and remove the screw 5 Unscrew and remove the rear screw 2 saving the bushing WARNING When reassembling make sure the bushing is fitted properly Tightening torque for screws 2 2 9 ftlb 4 Nm Unscrew and remove the screw 3 Tightening torque for screws 3 1 4 ftlb 2 Nm Unscrew and remove the screw 6 Tightening torque for screw 6 2 9 ftlb 4 Nm WARNING Handle all plastic ...

Page 248: ...above steps to remove the other air inlet duct case 7 1 35 REMOVING THE RADIATOR SPOILER Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Place the vehicle on the center stand DANGER Wait until the engine and exhaust silencer have completely cooled down Unscrew and remove the two upper fastening screws 1 Tightening torque for screws 1 3 6 ftlb 5 Nm Unscrew and remove the side fastening scr...

Page 249: ...cal 1 from the taillight WARNING When reassembling make sure the electrical connector 1 is fitted properly Release the wiring from the two line fasteners 2 and the clamp located under the grab handle Unscrew and remove the three fastening screws 3 retrieving the anti vibration grommets and bushings Tightening torque for screws 3 5 2 ftlb 7 Nm WARNING Handle all plastic and painted components with ...

Page 250: ...e 2 complete with taillight WARNING When reassembling make sure the taillight wiring is positioned correctly Place the complete rear grab handle on a flat surface NOTE If necessary disassemble the taillight by unscrewing the three screws 3 7 1 38 REMOVING THE SADDLE LOCK Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Remove the saddle see 7 1 1 REMOVING THE SADDLE Free the saddle release...

Page 251: ...terminal from the switch Remove the hasp 5 and retrieve the plate 6 Remove the saddle release switch 7 from the left plate 2 WARNING When reassembling make sure the reference element 8 is correctly positioned in its seat on the plate 6 and on the switch hasp 5 7 1 40 REMOVING THE LOWER SADDLE PANEL Place the vehicle on the center stand Remove the saddle see 7 1 1 REMOVING THE SADDLE Remove the sad...

Page 252: ... REAR GRAB HANDLE Remove the fuel tank see 7 1 5 PARTIALLY REMOVING THE FUEL TANK Remove the tools provided and any other items from the compartment Remove the battery see 7 1 9 REMOVING THE BATTERY Remove the muffler see 7 1 50 REMOVAL EXHAUST SILENCER Remove the lower saddle panel see 7 1 40 REMOVING THE LOWER SADDLE PANEL Pull the water drain tube 1 downward WARNING When reassembling make sure ...

Page 253: ...etrieving the three clips 6 Tightening torque for screws 5 2 9 ftlb 4 Nm Unscrew and remove the screw 7 Tightening torque for screw 7 2 9 ftlb 4 Nm Lower the front part and raise the back of the saddle support lower molded cover 8 Remove the saddle support lower molded cover 8 by sliding it out from the back WARNING Replace the adhesive gasket 9 if worn or deteriorated 4 6 5 9 5 6 8 7 ...

Page 254: ... complete license plate holder 2 NOTE Remove the individual components if necessary 7 1 43 REMOVING THE PASSENGER FOOTREST SUPPORTS Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Remove the saddle see 7 1 1 REMOVING THE SADDLE Unscrew and remove the two screws 1 Tightening torque for screws 1 18 ftlb 25 Nm Remove the footrest support 2 complete with footrest Also remove the footrest 3 if...

Page 255: ...careful not to reverse the position of the two shims 4 7 during reassembly NOTE If necessary repeat the above steps to remove the other footrest 7 1 45 REMOVING THE LEFT RIDER FOOTREST SUPPORT Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Place the vehicle on the stand Remove the lower fairing see 7 1 33 REMOVING THE LOWER FAIRING Unscrew and remove the screw 1 holding the gearshift lev...

Page 256: ...ove the rear brake master cylinder 2 and rear brake fluid reservoir 5 still fastened together making sure the latter remains upright to prevent spills Unscrew and remove the two screws 6 Tightening torque for screws 6 18 ftlb 25 Nm Remove the footrest support 7 complete with brake lever 8 NOTE Also remove the brake lever 8 if necessary 7 1 47 REMOVING THE RIDER FOOTREST Carefully read 1 3 9 PRECAU...

Page 257: ...ssembling Place the vehicle on the center stand Remove the left lower fairing see 7 1 33 REMOVING THE LOWER FAIRING Loosen the screw 1 and slide out the jaw 2 from the gearbox pivot Tightening torque for screws 1 7 3 ftlb 10 Nm Unscrew and remove the pin 3 retrieving the washer 4 Slide the gearshift pedal 5 out from the side complete with rods NOTE Also replace the individual elements if necessary...

Page 258: ...fork axle 2 downward Slide out the fork axle 2 Release the spring 3 from the lever 4 Remove the rear stop switch 5 Tightening torque for rear stop switch 5 7 3 ftlb 10 Nm Unscrew and remove the pin 6 and retrieve the washer 7 Remove the lever 4 Remove the bushing 8 if necessary NOTE When reassembling apply LOCTITE 243 to the thread of the pin 6 Tightening torque for pin 6 10 8 ftlb 15 Nm 2 6 1 3 4...

Page 259: ...2 to the exhaust pipes 3 WARNING When reassembling the muffler must rest against the clamp 1 fastened to the exhaust pipe 3 When reassembling apply black silicone between the muffler 2 and the exhaust pipes see 2 41 FASTENERS Unscrew and remove the screw 4 retrieving the nut 5 Tightening torque for screw 4 7 3 ftlb 10 Nm Remove the exhaust silencer 2 complete with license plate holder 8 Retrieve t...

Page 260: ...e expansion tank to keep out any foreign matter 7 1 52 REMOVING THE EXPANSION TANK Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Remove both lower fairings see 7 1 33 REMOVING THE LOWER FAIRING Remove the exhaust pipes see 7 1 51 REMOVING THE EXHAUST PIPES Loosen the three nuts 3 so that the rear cylinder exhaust manifold 2 can be moved slightly Tightening torque for nuts 3 18 ftlb 25 N...

Page 261: ...ng the exhaust manifold flange 4 to the rear cylinder Tightening torque for nuts 3 18 ftlb 25 Nm WARNING When sliding the exhaust manifolds 4 2 out of their cylinders be very careful to avoid damaging the threads of the studs Rotate the exhaust manifold 4 and remove as shown in the figure Move the exhaust pipe 2 forward until the flange is out of the stud bolts on the front cylinder Turn the exhau...

Page 262: ...crew and remove the screw 4 and retrieve the washer 5 Tightening torque for screw 4 7 3 ftlb 10 Nm Slide out the switch 1 WARNING When reassembling place the switch 1 correctly with the seat inserted in the special rotation proof pin Upon reassembly apply Loctite 243 to the switch 1 Perform this procedure with the side stand retracted Loosen and remove the nut 2 Tightening torque for nut 2 18 ftlb...

Page 263: ...fastening screw 6 Tightening torque for screw 6 7 3 ftlb 10 Nm NOTE Replace the grommet if damaged Loosen and remove the two nuts 7 8 Tightening torque for nuts 7 8 3 6 ftlb 5 Nm NOTE If the two silent blocks are damaged replace them Slide the tank 9 out of the two silent blocks Release the clamp 10 Pull the oil hose 11 out Remove the complete tank 9 Unscrew and remove the engine oil filter 12 on ...

Page 264: ... CHANGING THE ENGINE OIL AND OIL FILTER NOTE Use the special click clamp installation pliers code 0277295 during reassembly replace each clamp with a new one of the same kind Release the clamps 2 3 Remove the couplings 4 5 Unscrew and remove the three fastening screws 6 7 8 Tightening torque for screws 6 7 8 7 3 ftlb 10 Nm NOTE Replace the grommets if damaged Remove the radiator 1 6 2 7 9 4 3 8 1 ...

Page 265: ...to remove the countershaft sprocket 4 slightly loosen the chain tension see 2 35 3 ADJUSTING THE DRIVE CHAIN Slide the drive countershaft sprocket 4 from the shaft complete with chain Remove the drive countershaft sprocket 4 NOTE When reassembling apply LOCTITE Anti Seize on the internal spline of the countershaft sprocket 4 Remove the upper chain housing see 7 1 58 REMOVING THE UPPER CHAIN HOUSIN...

Page 266: ...Remove the line fastener 5 by lifting it out Remove the outer guard 7 Move the odometer cable and rear brake line from the upper chain housing 6 Remove the upper chain housing 6 by sliding it out from behind 7 1 59 REMOVING THE REAR HOUSING Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Place the vehicle on the center stand Remove the saddle support lower molded cover see 7 1 41 REMOVING...

Page 267: ...ing components Perform only those operations needed to remove the component in question Remove the engine see 3 3 REMOVING THE COMPLETE ENGINE FROM THE FRAME Place the vehicle on the appropriate central support stand see 1 15 2 PLACING THE VEHICLE ON THE CENTER SUPPORT STAND Remove the front fork complete with front wheel see 7 1 1 REMOVING THE SADDLE Remove the dashboard mount see 7 1 25 REMOVING...

Page 268: ...g the frame 1 appropriately and hook the slings to a hoist for support NOTE The slings and hoist must be sufficient to safely support the entire frame 1 Frame weight 21 8 lb 9 9 Kg Raise the frame 1 just enough to be able to remove the center support stand Remove the center stand When you have finished re installing the frame proceed as follows Make sure that all components are correctly fastened ...

Page 269: ...Release 00 2002 03 7 2 FRONT WHEEL Legend 1 Wheel axle nut 2 Seal 3 Seal 4 Bearing 5 Internal spacer 6 Complete wheel 7 Circlip 8 Right spacer 9 Washer 10 Nut 11 Left spacer GREASE see 1 12 LUBRICANT CHART 9 6 5 3 2 1 10 8 2 7 4 11 ...

Page 270: ...attached to the brake line WARNING Do not work the front brake lever after removing the caliper pistons otherwise the clamp pins could come out of their housings causing brake fluid to leak out Loosen and remove the nut 4 and retrieve the washer Tightening torque for wheel axle nut 4 59 ftlb 80 Nm Partially loosen the two axle clamp screws 5 Tightening torque for the axle clamp screws 5 16 2 ftlb ...

Page 271: ...g 4 Remove the flex ring 3 Use a special extractor to extract the right bearing 5 WARNING Check the bearings after every disassembly and replace if needed see 7 2 3 CHECKING THE COMPONENTS Retrieve the internal spacer 6 Thoroughly clean the inside of the hub NOTE Wash all components with clean solvent WARNING When reassembling insert the bearings using a drift with the same diameter as the outer r...

Page 272: ...entricity of the axle 2 If the eccentricity exceeds the limit value replace the axle 2 Maximum eccentricity 0 009 in 0 25 mm WHEEL RIM Use a dial indicator to make sure that the radial A and axial B eccentricity of the wheel rim 3 does not exceed the limit value Excess eccentricity is usually caused by worn or damaged bearings If the value does not return to within the limit indicated after changi...

Page 273: ...e for the axle clamp screws 4 16 2 ftlb 22 Nm Fully torque the nut 3 Tightening torque for wheel axle nut 3 59 ftlb 80 Nm Tighten the two axle clamp screws 5 Tightening torque for the axle clamp screws 5 16 2 ftlb 22 Nm WARNING Be very careful to avoid damaging the brake pads Slip the brake caliper 6 onto the disc and position it so that the fastener holes are aligned with the holes on the support...

Page 274: ...03 Make sure the wheel is properly centered and balanced 7 3 REAR WHEEL Legend 1 Wheel screw cover 2 O ring 3 Snap ring 4 Wheel screw stop 5 Wheel screw 6 Wheel cable 7 Complete wheel 8 Wheel axle nut GREASE see 1 12 LUBRICANT CHART 2 7 8 1 3 6 4 5 ...

Page 275: ...nd remove the cap 1 Remove the snap ring 2 Slide out the screw locking nut 3 Engage first gear to keep the wheel from turning Insert the bushing 5 supplied with the tool kit into the screw hole 4 Insert the torque wrench into the hexagonal slot of the bushing 5 Tightening torque for wheel fastening screw 125 3 ftlb 170 Nm DANGER The drive shaft has a key 7 Do not allow the key 7 to fall out of its...

Page 276: ... the key 1 is present on the drive shaft seat Place the centering bushing 4 correctly mating the slot 5 with the key 1 Spread a light coating of grease lubricant on the thread of the wheel fastening screw 6 Screw in the wheel fastening screw 6 by hand Insert the bushing 8 in the screw hole 7 Insert the torque wrench into the hexagonal slot of the bushing 8 DANGER Make sure that the wheel fastening...

Page 277: ...p ring 10 correctly Return the plug 11 to its place using the spanner wrench 12 WARNING After reassembly operate the rear brake lever repeatedly and make sure the brake system is in good working order Make sure the wheel is properly centered and balanced 10 11 12 ...

Page 278: ...O ring 9 O ring 10 Roller cage 11 O ring 12 Sprocket hub 13 Sprocket 14 Screw 15 Spring washer 16 Self locking flanged nut 17 Flexible coupling grommet 18 Belleville washer 19 Roller cage 20 Center bearing 21 Ring 22 O ring 23 Flexible coupling holder 24 Belleville washer 25 Screw 26 Screw 27 Screw 7 9 8 4 3 1 2 5 6 18 11 14 12 15 13 16 17 21 22 23 24 25 26 27 19 20 10 ...

Page 279: ...move the three safety screws 1 2 Tightening torque for safety screws 1 2 110 6 ftlb 150 Nm WARNING When reassembling make sure that the safety screw 1 the longer one is all the way down in one of the three holes in the wheel fastening screw 3 Insert the bushing 5 supplied with the tool kit into the screw hole 4 Insert the torque wrench into the hexagonal slot of the bushing 5 Unscrew and remove th...

Page 280: ...ssembling insert all screws by hand and cross tighten Tightening torque for brake disc screws 10 22 1 ftlb 30 Nm Lower the brake disc 11 Slide the axle 12 complete with brake disc 10 out from the right side Remove the snap ring 13 Remove the snap ring 14 WARNING When reassembling the snap rings 13 14 make sure that you hear the typical click indicating that the ring is correctly fastened Remove th...

Page 281: ...flexible coupling grommets 1 are not damaged and or excessively worn Replace the grommets 1 if necessary sprocket Check the teeth of the sprocket 2 and countershaft sprocket If excessively worn replace sprocket countershaft sprocket and drive chain see 7 4 1 REMOVING THE FINAL DRIVE ASSEMBLY and 7 1 57 REMOVING THE DRIVE CHAIN SHOE WARNING Replace all three to avoid premature wear on new component...

Page 282: ...move the snap ring 2 Slide the eccentric cam out from the left side NOTE Remove the individual components if necessary 7 4 4 REMOVING THE SPROCKET Place the vehicle on the center stand Loosen the drive chain tension see 2 35 3 ADJUSTING THE DRIVE CHAIN Unscrew and remove the six nuts 1 NOTE When reassembling insert all nuts 1 by hand and cross tighten to torque Tightening torque for nuts 1 18 4 ft...

Page 283: ...s 7 Bleeder nipples 8 Brake calipers For more information see 1 3 5 BRAKE FLUID see 2 16 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID see 2 19 BLEEDING THE BRAKE SYSTEMS see 2 27 CHECKING THE BRAKE PAD WEAR see 8 4 5 FRONT BRAKE SYSTEM WARNING When disassembling reassembling the brake caliper replace the clamp fastening screws with two new screws of the same type 7 8 7 1 5 2 8 3 4 6 ...

Page 284: ...sing a pair of pliers take first one pad then the other and shake them gently back and forth to eliminate any pressure by the caliper pistons and make it easier to remove the pads Extract the two pads 4 WARNING Do not operate the brake lever after removing the pads otherwise the caliper pistons could come out of their seat causing brake fluid to leak out Insert two new pads placing them so that th...

Page 285: ... Disc wobble tolerance 0 01 in 0 3 mm 7 5 3 REMOVING THE BRAKE DISCS Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATION Remove the front wheel see 7 2 1 REMOVING THE COMPLETE WHEEL NOTE The following information refers to a single disc but is applicable to both To unscrew the screws 1 we recommend using an impact wrench which delivers the sharp blow needed to release the screws from the LOCT...

Page 286: ...ch 9 Brake pedal 10 Brake master cylinder For more information see 1 3 5 BRAKE FLUID see 2 17 CHECKING AND TOPPING UP THE REAR BRAKE FLUID see 2 19 BLEEDING THE BRAKE SYSTEMS see 2 25 ADJUSTING THE CLEARANCE OF THE REAR BRAKE LEVER see 2 27 CHECKING THE BRAKE PAD WEAR see 8 4 6 REAR BRAKE SYSTEM WARNING When disassembling reassembling the brake caliper replace the clamp fastening screws with two n...

Page 287: ...ide Remove the brake pads 3 Retrieve the safety springs 4 WARNING Do not operate the brake lever after removing the pads otherwise the caliper pistons could come out of their seat causing brake fluid to leak out Insert two new pads placing them so that their holes are aligned with those on the clamp WARNING Always replace both pads and make sure they are correctly positioned inside the clamp When ...

Page 288: ...MOVING THE COMPLETE WHEEL Slide out the safety spring 1 Unscrew and remove the screw 2 Tightening torque for screw 2 18 ftlb 25 Nm Turn the caliper 3 upwards Slide the caliper 3 out from the left The caliper 3 remains attached to the rear brake line 4 If necessary empty the rear brake system see 2 22 CHANGING THE REAR BRAKE FLUID Unscrew and remove the screw 5 and retrieve the two gaskets 6 Tighte...

Page 289: ...the minimum thickness at various points on the disc NOTE If the smallest thickness is below the minimum value even in a single part of the disc replace the disc see 7 6 4 REMOVING THE BRAKE DISC Minimum disc thickness 0 18 in 4 5 mm Use a dial indicator to make sure that the disc does not wobble beyond the stated tolerance otherwise replace it see 7 6 4 REMOVING THE BRAKE DISC Disc wobble toleranc...

Page 290: ...e with disc on the vice inserting a soft material aluminum between the jaws NOTE To unscrew the screws 2 we recommend using an impact wrench which delivers the sharp blow needed to release the screws from the LOCTITE 243 Unscrew and remove the six screws 2 WARNING When reassembling apply LOCTITE 243 to the thread of the screws 2 NOTE When reassembling insert all screws by hand and cross tighten in...

Page 291: ...d remove the screw 1 and retrieve the two seals Tightening torque for screw 1 14 5 ftlb 20 Nm Loosen and remove the click clamp 2 Pull the hose 3 from the fitting on the master cylinder Unscrew and remove the two screws 4 Tightening torque for screws 4 7 3 ftlb 10 Nm Retrieve the guard 5 Slide the master cylinder 6 out NOTE When reassembling top up brake fluid see 2 17 CHECKING AND TOPPING UP THE ...

Page 292: ...ng 2 Washer 3 Fork head 4 Locking ring nut 5 Locking washer 6 Adjustment ring nut 7 Protective cover 8 Dust seal 9 Bearings 10 Triple clamp GREASE see 1 12 LUBRICANT CHART For more information see 2 28 STEERING see 2 29 INSPECTING THE FRONT SUSPENSION 3 1 2 4 10 8 8 5 6 7 9 9 ...

Page 293: ...ch operations Proceed very carefully with removal operations While removing the front fork be careful that the brake fluid line does not catch on anything While one person holds the front fork in position slowly raise the lift platform until you are able to slide the steering head out of the front fork Retrieve the dust ring 4 Remove the upper dust ring 5 Extract the bearing 6 Use a special extrac...

Page 294: ...long the entire length of the pivot 1 see 1 12 LUBRICANT CHART Before fully tightening the adjusting ring nut 2 turn the steering several times in both directions to allow the bearings to settle Proceed with adjusting the bearing play see 2 28 2 ADJUSTING THE BEARING PLAY As you turn the handlebars make sure that the cables and tubes are not pulled taut twisted and or crossed Top up brake fluid se...

Page 295: ...Ring 4 Upper fork tube cap 5 Center screw 6 Copper washer 7 Complete damper 8 Bushing 9 Spring spacer tube 10 Spring 11 Lower spring seat 12 Lower collar 13 Upper fork tube 14 Sliding bushing 15 Lower fork tube 16 Ring 17 Bushing 18 Stop ring 19 Dust seal 15 4 7 13 2 3 1 13 11 10 9 14 8 17 18 19 16 6 5 ...

Page 296: ...nt wheel protruding beyond the edge of the platform Use belts to fasten the rear drive train to the platform so as to raise the front wheel Remove the front wheel see 7 2 1 REMOVING THE COMPLETE WHEEL It is not necessary to use the front support stand Remove the front fender see 7 1 26 REMOVING THE FRONT MUDGUARD Unscrew and remove the two screws 1 and slide off both brake calipers 2 leaving them ...

Page 297: ...m WARNING Proceed very carefully with disassembly operations zTurn the upper screw adjuster 1 all the way counter clockwise to reduce the hydraulic damping on extension zRemove the retainer ring 2 zUnscrew and remove the spring preload adjuster 3 zRemove the spring preload 4 thruster zPlace the lower fork tube upper fork tube unit in a vice using the two halves of the special tool C WARNING The up...

Page 298: ...oth hands on the tool A zPush downward at the same time inserting the tool B between the lock nut 7 and the washer 8 zWhile holding the damper rod 9 unscrew the upper fork tube cap 5 using the appropriate wrench zRest both hands on the tool A zPush downward at the same time removing the tool B zRemove the tools A zRemove the washer 8 zRemove the slider bushing 10 A B 7 8 5 9 A B 8 10 ...

Page 299: ...ogether with the upper fork tube and empty the oil into the container 12 NOTE z To make sure to get all of the oil out pump the damper rod 9 slowly up and down eight to ten times in the upper fork tube You will know when you are done because the lower tube will slide smoothly inside the upper tube If they have not already come out while emptying the oil remove the following in the order given lowe...

Page 300: ... resistance Remove the lower fork tube unit 21 from the upper fork tube 22 WARNING When removing the slider bushing 17 be extremely careful to avoid damaging it especially the sliding surface Use a blade screwdriver to slightly widen the bushing 17 and remove it from the lower fork tube 21 Remove the following components from the tube 21 in the given order guide bushing 20 ring 19 gasket 18 stop r...

Page 301: ...rial aluminum between the jaws Unscrew and remove the center screw 23 and retrieve the copper washer 24 Remove the complete damper 9 from the lower fork tube 21 WARNING The damper 9 must not be disassembled Remove the centering bushing 25 WARNING Wash all components with clean solvent 21 24 23 9 21 25 ...

Page 302: ... and inevitably followed by an upset and accident with serious injury or even death UPPER FORK TUBE Make sure it is not damaged and or cracked if so replace SPRING Make sure the spring 2 is intact and that its length is within the prescribed limit If the length does not match the prescribed limit replace the spring 2 Minimum free length of the spring 9 76 in 284 mm Check the status of the followin...

Page 303: ...he operations that follow make sure you have on hand the special tools A B C and D Before re mounting the gaskets and bushings lubricate them with a thin coating of fork oil see 1 12 LUBRICANT CHART Place the lower fork tube 1 in a vice with its opening facing upwards inserting a soft material aluminum between the jaws NOTE Apply grease inside the centering bushing 2 see 1 12 LUBRICANT CHART Inser...

Page 304: ...sket 8 with the labeled side facing the retainer ring 7 gasket 8 ring 9 guide bushing 10 Move the aforementioned five components down towards the lower fork tube Remove the tape from the end of the lower fork tube 1 Use electrician s tape to hold the guide bushing 10 in place Reassemble the slider bushing 11 on the lower fork tube 1 6 1 8 7 10 9 11 1 ...

Page 305: ...seal 15 into its appropriate seat on the upper fork tube 12 making sure that it is correctly placed zGrasp the lower fork tube 1 and slowly move it up and down a few times NOTE The lower fork tube 1 must slide freely and smoothly in the upper fork tube 12 without encountering any resistance if not this means that the guide bushing 10 slider bushing 11 or gasket 8 is damaged zKeeping the upper fork...

Page 306: ...ing components in the tube 1 in the given order lower collar 14 lower spring seat 15 spring 16 spring spacer tube 17 complete with spring seat and slider ring slider 18 washer 19 zUnscrew and remove the threaded pin A1 from the tool A zPlace the stationary part of the tool A so that the tooth engages the hole on the spring spacer tube 17 zPlace the threaded pin A1 in the hole on the stationary par...

Page 307: ... tool A zPush downward at the same time removing the tool B zRemove the tools A zPlace the lower fork tube upper fork tube unit in a vice using the two halves of the special tool C zScrew and tighten the upper fork tube cap 5 on the upper fork tube Tightening torque for the upper fork tube cap 5 upper fork tube 25 8 ftlb 35 Nm zInsert the spring preload thruster 22 zScrew on the spring preload adj...

Page 308: ...ork tube 1 Tightening torque for screws 6 18 ftlb 25 Nm Lubricate the thread of the screw 7 and tighten Tightening torque for screw 7 21 7 ftlb 30 Nm Tighten the screw 8 fastening the fork head 4 to the upper fork tube 1 Tightening torque for screw 8 18 ftlb 25 Nm Lower the lift platform Remove the axle 5 Reassemble the wheel see 7 2 1 REMOVING THE COMPLETE WHEEL Remove the belts fastening the rea...

Page 309: ...rieving the two washers 6 7 and remove the countershaft sprocket 4 Tightening torque for screw 5 36 ftlb 50 Nm Remove the expansion tank see 7 1 52 REMOVING THE EXPANSION TANK Remove rear shock absorber see 7 10 1 REMOVING THE SHOCK ABSORBER Remove both the rider footrest supports see 7 1 45 REMOVING THE LEFT RIDER FOOTREST SUPPORT and 7 1 46 REMOVING THE RIGHT RIDER FOOTREST SUPPORT Remove the re...

Page 310: ... NOTE Remove the rear wheel axle if necessary see 7 4 1 REMOVING THE FINAL DRIVE ASSEMBLY 7 9 2 DISASSEMBLING THE SWINGING ARM Carefully read 1 3 9 PRECAUTIONS AND GENERAL INFORMATION Remove the swinging arm see 7 9 1 REMOVING THE SWINGING ARM Use a rag to clean both sides of the bearing housings Slip off the bushing 1 Remove the seal 2 Remove the seal 3 Remove the snap ring 4 Use a special extrac...

Page 311: ...uld be no axial clearance Any bearings found to have these faults must be replaced WARNING Apply grease to the balls on the sides of each bearing and rollers see 1 12 LUBRICANT CHART GASKETS Make sure the gaskets are intact replaced if damaged or excessively worn SWINGING ARM PIVOT Use a dial indicator to make sure that the swinging arm pivot 2 eccentricity does not exceed the allowable limit If n...

Page 312: ...ex head on the pivot 1 is correctly inserted in the hexagonal recess on the adjuster bushing 2 Fit the lock ring 4 and screw it on by hand a few turns Place the washer 5 and nut 6 on the swinging arm pivot tightening them by hand Now adjust the swinging arm see 2 30 1 ADJUSTING THE SWINGING ARM Remove the tape to release the chain 3 Fit the chain 3 back over the countershaft sprocket 7 NOTE Apply ...

Page 313: ...et hub see 7 4 1 REMOVING THE FINAL DRIVE ASSEMBLY Replace the rear wheel see 7 3 1 REMOVING THE COMPLETE WHEEL Replace the double connecting rod 14 tightening the nut 15 on the pivot 16 Tightening torque for nut 16 36 ftlb 50 Nm Replace the shift lever 11 on the serrated gearbox pivot making sure that it is properly aligned Tighten the screw 12 Tightening torque for screw 12 7 2 ftlb 10 Nm Replac...

Page 314: ...e rear housing Working from the left side of the vehicle loosen and remove the nut 4 and push the screw 5 partially out NOTE Replace the nut 4 if you find it to be damaged Tightening torque for nut 4 36 ftlb 50 Nm Remove the screw 5 from the opposite side Working from the right side of the vehicle loosen and remove the nut 6 Tightening torque for nut 6 36 ftlb 50 Nm Remove the screw 7 from the opp...

Page 315: ...site side Loosen and remove the nut 3 Tightening torque for nut 3 36 ftlb 50 Nm Remove the screw 4 from the opposite side Loosen and remove the nut 5 Tightening torque for nut 5 36 ftlb 50 Nm Remove the screw 6 from the opposite side Remove the complete suspension linkage assembly 7 NOTE When reassembling grease the linkage pivot points see 1 12 LUBRICANT CHART Be extremely careful that all parts ...

Page 316: ...askets 5 Use a special extractor to remove the two roller bearings 6 Retrieve the internal spacer 7 Remove the two seals gaskets 8 Remove the internal spacer 9 Use a special extractor to remove the two roller bearings 10 NOTE Wash all components with clean solvent NOTE During reassembly couple the single connecting rod 11 to the double connecting rods 3 4 as shown in the figure the arrow on the to...

Page 317: ...s must be replaced WARNING Apply grease to the rollers see 1 6 LUBRICANT CHART GASKETS Make sure the gaskets are intact replaced if damaged or excessively worn SHOCK ABSORBER Make sure there are no oil leaks in the shock absorber and that its stroke is smooth and progressive If not replace DANGER The shock absorber contains pressurized nitrogen In order to avoid the risk of explosion keep it away ...

Page 318: ...ns with rivet type links should be installed on this vehicle Tool legend 1 Main body 2 Tied hexagonal boss for 27 mm wrench 3 Hex head screw for 19 mm wrench 4 Locating dowel 5 Rivet tool 6 A and B reference marking 7 Location holes for joining pins 8 Pin exit hole 9 Pusher 10 Breaking side 11 Joining side 12 Support plate Chain legend 13 Master plate 14 O rings 15 Rivet plate 1 9 5 12 4 2 3 11 10...

Page 319: ...ide the main body 3 Fit the main body 3 on the rivet tool 1 Move the main body 3 so that the locating dowel 4 is in line with mark A on the rivet tool 1 Turn the screw 5 by hand until the pusher 2 touches the pin to be pushed out NOTE Make sure that the pusher 2 is perfectly aligned with the pin to be pushed out Use a 27 mm wrench over the tied hexagonal boss on the central body 3 to hold the body...

Page 320: ...an O ring on the tip of each pin Slip the rivet plate over the pins Fit the support plate 6 on the rivet plate Fit the rivet tool 1 onto the chain Move the rivet tool 1 so that its side holes match the heads of the pins on the joining plate Insert the smallest diameter of the pusher 2 into the main body 3 Fit the main body 3 on the rivet tool 1 Move the main body 3 so that the locating dowel 4 is ...

Page 321: ... that the pusher 6 is perfectly aligned with the pin to be riveted WARNING Wear safety goggles or a shield to protect your eyes Hold the central body 2 stationary using a 1 06 in 27 mm wrench over the tied hexagonal boss Use a 0 74 in 19 mm wrench to turn the screw 1 until the edge of the pin has been riveted WARNING Make sure that the pin has been riveted correctly the riveted edge of the pin mus...

Page 322: ...RST mille USA 7 104 00 Release 00 2002 03 NOTES ...

Page 323: ...RST mille USA GENERAL INFORMATION 8 1 00 Release 00 2002 03 8 GENERAL INFORMATION ...

Page 324: ...VERFLOW DRAINAGE LINES 8 17 00 8 2 9 THROTTLE CONTROL CABLES 8 18 00 8 2 10 ELECTRICAL CABLES 8 19 00 8 3 CHECKING THE ELECTRICAL SYSTEM 8 24 00 8 3 1 SPARK PLUGS NO SPARK 8 24 00 8 3 2 BATTERY RECHARGING PROBLEMS 8 24 00 8 3 3 PROBLEMS WITH IGNITION AND OR STARTING 8 24 00 8 3 4 PROBLEMS WITH AUXILIARY SYSTEMS 8 24 00 8 4 CHECKING THE ELECTRICAL SYSTEM 8 25 00 8 4 1 ENGINE 8 25 00 8 4 2 THROTTLE ...

Page 325: ...CE MANUAL 8 1 1 ENGINE DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The engine is difficult or impossible to start Engine stop switch set to Set to position Starting safety logic faulty Check and restore the necessary conditions Overturn sensor faulty Replace Vent hole on tank cap clogged Clean Battery charge low Recharge Battery damaged Replace Sprag clutch sprag clutch gear worn or faulty Replace D...

Page 326: ... too low Clean the fuel system or replace the pump Faulty fuel pump Replace Camshafts worn Replace See the subsection entitled Engine difficult or impossible to start for other possible causes Engine lacks power Spark plugs dirty Clean or replace Spark plugs not to spec Replace Insufficient valve clearance Adjust Exhaust system faulty Replace Valve timing incorrect Adjust Valve springs faulty Repl...

Page 327: ...ications Intake coupling or intake system leaking Replace Faulty injector Replace Faulty head gasket Replace The engine produces excessive exhaust fumes blue smoke Clutch diaphragm leaking Replace Valve stem gaskets worn Replace Valve stems or valve guides worn Replace Scratches or grooves on the cylinder wall Replace Piston rings or cylinder worn Replace Head gasket leaking Replace The engine vib...

Page 328: ...e support plate faulty Replace Primary transmission worn or broken Replace The noise seems to come from the flywheel case Timing gears worn or broken Replace The noise seems to come from the crank gear Connecting rod bearings worn Replace Crankshaft bushings or balanceshaft bearings worn Replace The noise seems to come from the gearbox Gears or gearbox shafts worn or broken Replace Primary gear wo...

Page 329: ...rshift mechanism faulty Repair or replace The gearshift forks are worn or bent Replace For other possible causes see the subsection entitled The clutch does not disengage The gears disengage during start up or hard acceleration Gearbox gears worn Replace The gearshift forks are worn or bent Replace Detent springs worn out or broken Replace Gears do not change smoothly or completely the gearshift i...

Page 330: ...ator coils grounded or broken Replace Regulator rectifier faulty Replace Faulty battery Replace The alternator charges too much Short circuit in the battery Repair or replace Regulator rectifier damaged or faulty Replace Intermittent grounding of the regulator rectifier Replace Charge not constant Terminal insulation worn due to vibrations with consequent temporary short circuits Repair or replace...

Page 331: ...ing damaged Replace Loose front or rear wheel axle nut Torque to specifications Worn pads Replace Excessive brake lever stroke Air in the hydraulic circuit Bleed the circuit Not enough brake fluid Replace Unsuited brake fluid Replace Brake caliper pistons jammed or stuck Disassemble and clean Brake fluid leaking Connection fittings not tight enough Torque to specifications Cracked lines Replace Ma...

Page 332: ...heel wobbly Bent wheel rim Replace Worn wheel bearings Replace Tire faulty or wrong type Replace Worn fork bearings Replace Suspension screws and nuts loose Replace Rear wheel fastening nut loose Tighten Rear suspension too soft Shock absorber spring weakened Replace Incorrectly adjusted setting devices Adjust Oil leak from shock absorber Replace Nitrogen leaking from shock absorber Replace Rear s...

Page 333: ...RST mille USA GENERAL INFORMATION 8 11 00 Release 00 2002 03 8 2 LOCATION FASTENING AND ROUTING OF WIRING CABLES AND LINES 8 2 1 FRONT BRAKE LINES 8 2 2 REAR BRAKE LINES E F G G A A B E F C D A C D B ...

Page 334: ...RST mille USA GENERAL INFORMATION 8 12 00 Release 00 2002 03 8 2 3 FUEL SYSTEM LINES A C D C D B A A B ...

Page 335: ...RST mille USA GENERAL INFORMATION 8 13 00 Release 00 2002 03 8 2 4 CLUTCH CONTROL LINE 8 2 5 PPC DEVICE PRESSURE LINES A B C D E C A B D E ...

Page 336: ...RST mille USA GENERAL INFORMATION 8 14 00 Release 00 2002 03 8 2 6 COOLING SYSTEM LINES E D C B A C A B D ...

Page 337: ...RST mille USA GENERAL INFORMATION 8 15 00 Release 00 2002 03 F G H G E F H ...

Page 338: ...RST mille USA GENERAL INFORMATION 8 16 00 Release 00 2002 03 8 2 7 ENGINE OIL LINES D B C A C A B D ...

Page 339: ...RST mille USA GENERAL INFORMATION 8 17 00 Release 00 2002 03 8 2 8 BREATHER AND OVERFLOW DRAINAGE LINES B A C A C B ...

Page 340: ...RST mille USA GENERAL INFORMATION 8 18 00 Release 00 2002 03 8 2 9 THROTTLE CONTROL CABLES A B A B ...

Page 341: ... 1 Flasher 2 Headlight wiring 3 Fall sensor 4 Light relay 5 Front right direction indicator 6 Secondary fuse box 7 Right dimmer switch connector 8 Dashboard connectors 9 Front left direction indicator connector 10 Air temperature sensor 11 Left dimmer switch connector 1 2 3 4 5 6 4 8 9 10 11 7 ...

Page 342: ...3 Legend 1 Horn 2 Oil pressure sensor 3 Voltage regulator 4 Engine earth 5 Main fuses 6 Start relay 7 Taillight 8 Positive battery pole 9 Rear brake light 10 Speed sensor connector 11 Coolant temperature sensor 12 Injection connectors 1 3 11 10 5 2 8 7 6 9 12 4 ...

Page 343: ...or 7 Right fan connector 8 Diode 9 Pick up 10 Coolant thermistor 11 Clutch switch 12 Front cylinder coil 1 13 Front cylinder coil 2 14 Rear cylinder coil 1 15 Rear cylinder coil 2 16 Front cylinder injector 17 Rear cylinder injector 18 Throttle valve potentiometer 19 Relay 20 Injection relay 21 Diode module 22 Choke motor 11 6 4 9 5 7 14 15 1 12 13 2 17 3 10 21 20 19 16 18 8 22 ...

Page 344: ...RST mille USA GENERAL INFORMATION 8 22 00 Release 00 2002 03 ...

Page 345: ...RST mille USA GENERAL INFORMATION 8 23 00 Release 00 2002 03 ...

Page 346: ...OUBLESHOOTING IF THE ENGINE DOES NOT START In addition see 6 6 6 CHECKING THE IGNITION COILS see 6 6 7 CHECKING THE CRANKSHAFT POSITION SENSOR see 6 4 4 CHECKING THE OVERTURN SENSOR see 6 6 4 CHECKING THE AIR THERMISTOR OPERATION see 6 6 5 CHECKING THE COOLANT THERMISTORS OPERATION see 6 6 3 CHECKING THE THROTTLE VALVE POTENTIOMETER see 6 6 1 CHECKING THE INJECTORS see 6 7 2 CHECKING THE FUEL PUMP...

Page 347: ...EAR BRAKE SYSTEM Disc material steel Disc thickness 0 19 in minimum 0 17 in Disc diameter 10 0 in Number of clamp pins 2 facing each other Diameter of clamp pins 1 1 in Pad friction material standard FERIT FERODO ID 450 Pad friction material alternative TOSHIBA TTH38GF FERIT FERODO ID 450 452 459 Pad surface area 2 48 in Diameter rubber lines standard Øe 0 3 in Øi 0 12 in Diameter of metal plait l...

Page 348: ...RST mille USA GENERAL INFORMATION 8 26 00 Release 00 2002 03 NOTES ...

Page 349: ...RST mille USA ANALYTICAL INDEX 1 00 Release 00 2002 03 i i ANALYTICAL INDEX ...

Page 350: ...ge CABLES AUXILIARY STARTING 2 6 2 16 THROTTLE CONTROL 8 2 9 8 18 ELECTRICAL 8 2 10 8 19 CAPACITY FLUID PROPERTIES 8 4 12 8 26 CARBON MONOXIDE 1 2 6 1 6 CHAIN CHECKING THE WEAR 2 35 2 2 55 DRIVE 2 35 2 54 DRIVE ADJUSTING 2 35 3 2 55 DRIVE REMOVING 7 11 7 100 CHAIN BREAKER RIVET TOOL 7 11 1 7 100 CHANGING FUSES 6 16 6 48 BULBS 6 15 6 44 HEADLIGHT BULBS 6 15 1 6 44 TAILLIGHT BULBS 6 15 3 6 46 DIRECT...

Page 351: ... Ref Page DASHBOARD ADJUSTING THE LIGHTING 2 3 3 2 8 REMOVING 7 1 24 7 23 DASHBOARD INDICATORS 6 10 6 29 DESCRIPTION 5 1 5 3 DIAGRAM ELECTRICAL SYSTEMS INJECTION 6 4 1 6 9 WIRING RST MILLE FUTURA 6 19 6 50 WIRING LIGHT SYSTEM 6 11 1 6 35 WIRING PUMP SYSTEM FUEL 6 7 1 6 21 WIRING INDICATOR SYSTEM WARNING LIGHTS AND BUZZERS 6 13 1 6 39 WIRING INDICATOR SYSTEM WARNING LIGHTS AND BUZZERS 6 12 1 6 37 W...

Page 352: ...AM 4 7 3 4 11 INJECTORS CHECKING 6 6 1 6 16 REMOVING 4 8 2 4 15 INSPECTION THROTTLE BODY 4 10 4 17 DRIVE CHAIN SHOE 2 35 5 2 56 CHAIN GUIDE PLATE 2 35 4 2 56 FRONT SUSPENSION 2 29 2 47 REAR SUSPENSION 2 31 2 50 INSTALLATION COMPLETE ENGINE ON THE FRAME 3 4 3 16 LOWER UPPER FORK TUBES 7 8 6 7 90 INSTRUCTIONS FOR APPLYING TRANSFERS 1 10 1 19 INSTRUMENTS TABLE 2 3 8 2 10 INTRODUCTION 6 2 6 5 K Ref Pa...

Page 353: ... 5 7 73 R Ref Page RADIATORS REMOVING 5 2 5 5 RADIATOR SPOILER REMOVING 7 1 35 7 30 REAR BRAKE 7 6 7 68 REAR BRAKE CALIPER REMOVING 7 6 2 7 70 REAR HOUSING REMOVING 7 1 59 7 48 REAR GRAB HANDLE REMOVING 7 1 37 7 32 REASSEMBLY REAR WHEEL WHEEL REAR REASSEMBLY 7 3 2 7 58 UPPER LOWER FORK TUBE UNIT 7 8 5 7 85 STEERING 7 7 3 7 76 RECHARGING BATTERY 2 4 2 2 15 BATTERY PROBLEMS 8 3 2 8 25 RECHARGING VOL...

Page 354: ...TORS 5 4 5 7 EXHAUST PIPES 7 1 51 7 42 THERMOSTAT 5 5 5 8 EXPANSION TANK 5 8 5 9 RETURN UNDER WARRANTY 6 14 4 6 43 RIVETING THE PINS 7 11 4 7 103 RST MILLE FUTURA WIRING DIAGRAM 6 19 6 50 S Ref Page SADDLE REMOVING 7 1 1 7 6 SADDLE LOCK REMOVING 7 1 38 7 32 SAFETY OPERATING LOGIC STARTING 6 8 2 6 24 SCHEDULED MAINTENANCE CHART 2 1 1 2 5 SCHEDULED MAINTENANCE PLAN 2 1 2 4 SEALANTS 3 1 4 3 3 SENSOR ...

Page 355: ... 5 TECHNICAL SPECIFICATIONS 3 1 1 3 3 TERMINALS AND CLAMPS CHECKING AND CLEANING 2 4 1 2 14 TESTING HORN 6 12 2 6 38 FAULT CODES 6 5 3 6 12 THROTTLE CONTROL OPERATION 2 11 1 2 22 FLASHER 6 12 3 6 38 BRAKE PAD WEAR 2 27 2 43 THERMISTORS COOLANT CHECKING OPERATION 6 6 5 6 19 COOLANT REMOVING 5 4 5 7 THREE WAY MANIFOLD REMOVING 5 7 5 9 THROTTLE 2 11 2 22 ADJUSTING THE CONTROL 2 11 3 2 23 THROTTLE BOD...

Page 356: ...VOLTAGE REGULATOR CHECKING 6 3 5 6 8 W Ref Page WARNINGS FOR FUEL LUBRICANTS COOLANT AND OTHER COMPONENTS 1 2 1 3 WHEEL FRONT 2 32 2 52 FRONT 7 2 7 51 COMPLETE REMOVING 7 2 1 7 52 7 3 1 7 57 REAR 2 33 2 52 REAR 7 3 7 56 DISASSEMBLING 7 2 2 7 53 WHEELS 8 4 8 8 26 WIRE COLORS 6 2 1 6 5 ...

Page 357: ...RST mille USA ANALYTICAL INDEX 9 00 Release 00 2002 03 i NOTES ...

Page 358: ...RST mille USA ANALYTICAL INDEX 10 00 Release 00 2002 03 i NOTES ...

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