Benelli Tornado Tre Novicento 903 Workshop Manual Download Page 6

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MF9_UK

5.1.5

MOUNT CAMSHAFT

121

5.2

CYLINDER HEAD

125

5.2.1

REMOVE CYLINDER HEAD

125

5.2.2

CHECK CYLINDERHEAD

126

5.2.3

MOUNT CYLINDER HEAD

126

5.3

VALVES AND VALVE SPRINGS

127

5.3.1

REMOVE VALVES

127

5.3.2

CHECK VALVES AND VALVE GUIDES

128

5.3.3

CHECK VALVE HOUSING

130

5.3.4

CHECK VALVE SPRINGS

131

5.3.5

CHECK BUCKET-TYPE TAPPET

132

5.3.6

MOUNT VALVES

133

5.4

CYLINDER

135

5.4.1

DISMANTLE CYLINDER CASING

135

5.4.2

CHECK CYLINDER

136

5.4.3

DISMANTLE WATER COLLECTOR

136

5.4.4

CHECK WATER COLLECTOR

137

5.4.5

MOUNT WATER COLLECTOR

137

5.4.6

MOUNT CYLINDERS

137

5.5

PISTONS

138

5.5.1

DISMANTLE PISTONS

138

5.5.2

CHECK PISTONS

139

5.5.3

CHECK SEGMENTS

139

5.5.4

CHECK PISTON PIN

140

5.5.5

MOUNT PISTONS

140

5.6

GENERATOR

141

5.6.1

REMOVE GENERATOR

141

5.6.2

MOUNT GENERATOR

142

5.7

DISTRIBUTION SENSOR AND PHONIC WHEEL

142

5.7.1

REMOVE DISTRIBUTION SENSOR

142

5.7.2

MOUNT DISTRIBUTION SENSOR

143

5.7.3

REMOVE PHONIC WHEEL

143

5.7.4

MOUNT PHONIC WHEEL

143

5.8

CLUTCH

144

5.8.1

DISMANTLE CLUTCH COMMAND

144

5.8.2

REMOVE CLUTCH

144

5.8.3

REMOVE CLUTCH COVER

146

5.8.4

REMOVE PRIMARY TRANSMISSION

147

5.8.5

DISMANTLE CLUTCH GROUP

147

5.8.6

CHECK EXTERNAL EQUIPPED DISK

149

5.8.7

CHECK INTERNAL DISK

149

5.8.8

CHECK CLUTCH SPRINGS

149

5.8.9

CHECK CLUTCU COVER

150

5.8.10 CHECK PRIMARY ASSEMBLY

151

5.8.11 MOUNT CLUTCH GROUP

151

5.8.12 MOUNT PRIMARY ASSEMBLY

153

5.8.13 MOUNT CLUTCH COVER

153

5.8.14 MOUNT CLUTCH

154

Summary of Contents for Tornado Tre Novicento 903

Page 1: ...UK 1 MF9_UK T T T T L I M I T E D E D I T I O N COPERTINA ...

Page 2: ...UK 2 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 3: ...special attention WARNING indicates a grave danger for the safety of people and or the integrity of the vehicle OILING Indicates the type of oil to use TIGHTENING Indicates the correct tightness value to carry out SPECIFIC VALUE indicates the specific value using precision instruments SPECIFIC INSTRUMENTS indicates the specific instruments to use I I I I Introduction ...

Page 4: ...DJUSTMENT CO 56 3 6 ADJUSTMENT THROTTLE HOUSING 58 3 7 CHECK STEPPER 61 3 8 ADJUSTMENT CLUTCH LEVER PLAY 61 3 9 ADJUSTMENT VALVE PLAY 62 3 10 ENGINE DISTRIBUTION 63 3 11 CHECK ENGINE OIL LEVEL 69 3 12 CHANGE ENGINE OIL AND FILTER 70 3 13 CHECK COOLING LIQUID LEVEL 73 3 14 CHANGE REFRIGERANT LIQUID 74 3 15 FILL COOLING PLANT 76 3 16 CHECK FUEL TUBES 78 3 17 CHECK EXHAUST PLANT 78 3 18 ADJUSTMENT FR...

Page 5: ...RROWS 103 3 39 3 2 CHANGE BACK ARROWS 104 4 COWLING 105 4 1 DISMANTLE COWLING 105 4 2 DISMANTLE LOWER SEMI COWLING 105 4 3 DISMANTLE UPPER SEMI COWLING 106 4 3 1 DISMANTLE LEFT AND RIGHT INSTRUMENT BOARD INTERNAL FASTENINGS 106 4 4 DISMANTLE LEFT AND RIGHT REAR VIEW MIRRORS 107 4 5 DISMANTLE TAIL PIECE 108 4 6 DISMANTLE LEFT AND RIGHT UPPER COWLING 110 4 7 DISMANTLE WHEEL HOUSING 111 4 8 DISMANTLE...

Page 6: ... DISMANTLE PISTONS 138 5 5 2 CHECK PISTONS 139 5 5 3 CHECK SEGMENTS 139 5 5 4 CHECK PISTON PIN 140 5 5 5 MOUNT PISTONS 140 5 6 GENERATOR 141 5 6 1 REMOVE GENERATOR 141 5 6 2 MOUNT GENERATOR 142 5 7 DISTRIBUTION SENSOR AND PHONIC WHEEL 142 5 7 1 REMOVE DISTRIBUTION SENSOR 142 5 7 2 MOUNT DISTRIBUTION SENSOR 143 5 7 3 REMOVE PHONIC WHEEL 143 5 7 4 MOUNT PHONIC WHEEL 143 5 8 CLUTCH 144 5 8 1 DISMANTL...

Page 7: ... 172 5 10 8 MOUNT OIL PUMP 173 5 10 9 MOUNT OVERPRESSURE VALVE 174 5 10 10MOUNT OIL SUMP 174 5 11 CASING 175 5 11 1 DISMANTLE CASING 175 5 11 2 DISMANTLE FREE WHEEL 182 5 11 3 DISMANTLE BALANCING COUNTER SHAFT 184 5 11 4 DISMANTLE ENGINE SHAFT 185 5 11 5 CHECK CASING 185 5 11 6 CHECK ENGINE SHAFT AND CONNECTING ROD 186 5 11 7 CHECK BALANCING COUNTER SHAFT 187 5 11 8 CHECK FREE WHEEL 188 5 11 9 ASS...

Page 8: ...8 INSTALL REAR WHEEL 236 7 3 FRONT AND REAR BRAKES 237 7 3 1 REMOVE FRONT BRAKE PUMP 237 7 3 2 REMOVE REAR BRAKE PUMP 238 7 3 3 CHECK FRONT AND REAR BRAKE PUMPS 239 7 3 4 INSTALL FRONT BRAKE PUMP 240 7 3 5 INSTALL REAR BRAKE PUMP 240 7 3 6 DISMANTLE FRONT PLANT BRAKE TUBES 241 7 3 7 DISMANTLE REAR PLANT BRAKE TUBES 242 7 3 8 CHECK FRONT AND REAR BRAKE TUBING 243 7 3 9 MOUNT FRONT BRAKE TUBES PLANT...

Page 9: ...R 264 7 9 REAR FORK 266 7 9 1 REMOVE REAR FORK 266 7 9 2 DISMANTLE REAR FORK COMPONENTS 268 7 9 3 CHECK REAR FORK 269 7 9 4 MOUNT REAR FORK 270 7 9 5 INSTALL REAR FORK 271 7 10 FRONT FRAME 272 7 10 1 REMOVE FRONT FRAME 272 7 10 2 CHECK FRONT FRAME 272 7 10 3 INSTALL FRONT FRAME 273 7 11 REAR FRAME 273 7 11 1 DISMANTLE REAR FRAME 273 7 11 2 CHECK REAR FRAME 274 7 11 3 INSTALL REAR FRAME 274 7 12 TR...

Page 10: ...D 313 9 14 CLUTCH SWITCH 313 9 15 SPEED SENSOR 314 9 16 OIL PRESSURE SENSOR 314 9 17 FRONT LIGHTS 315 9 18 REAR LIGHTS 315 9 18 1 REAR HEADLIGHT 315 9 18 2 LICENCE PLATE LIGHT SUPPORT 316 9 18 3 FRONT AND REAR ARROWS 316 9 18 3 1FRONT ARROWS 316 9 18 3 2REAR ARROWS 317 10 DIAGNOSTICS 319 10 1 ELECTRICAL PART 319 10 2 FRAME 323 10 3 PRELIMINARY OPERATIONS 326 10 4 SELF DIAGNOSIS 326 10 5 RESET THRO...

Page 11: ...ECIAL INSTRUMENTS paragraph 3 During dismantling avoid separating the coupled components including cylinders pistons gears and other parts that have become coupled during normal wear The coupled components must always be re used or changed without separating them 4 During dismantling clean all the components and place them in a bowl following the order of dismantling This will make the re mounting...

Page 12: ...y washers plates and the ends of the safety pins on a flat surface of bolts or nuts BALL BEARINGS AND OIL SEALS WARNING Do not rotate the compressed air ball bearings as this might damage their surfaces 1 Install the ball bearings and the oil seals so that the Producer brand or data are visible At the moment of installing the oil seal oil the lip with a slight layer of grease The ball bearings rot...

Page 13: ...G FOR DISTRIBUTION 2 R180197017000 INSTRUMENT FOR MOUNTING CLUTCH OIL SEAL CASING 3 R180197018000 CYLINDER MOUNTING SPACERS 4 R180197019000 SMALL CYLINDER COLUMN FIXING SPAN 5 R180197020000 FALSE SPARKING PLUG 6 R180197021000 PISTON THREAD MEASURER 1 3 1 SPECIAL ENGINE INSTRUMENTS ...

Page 14: ...T I O N 7 R180197022000 P M S MEASURER 8 R180197023000 CLUTCH COVER OIL SEAL PAD 9 R180197024000 OIL SEAL PINION PAD 10 R180197025000 OIL SEAL VALVE PAD 11 R180197026000 INSTRUMENT FOR CHECKING VALVE LIFT 12 R180197027000 GONIOMETER INDICATOR ...

Page 15: ... 13 R180197028000 CLUTCH OIL SEAL PAD ON FLANGE 14 R180197029000 ENGINE SUPPORT 15 R180197030000 INSTRUUMENT FOR CHECKING ENGINE SHAFT AXIAL PLAY 16 R180197036000 ENGINE MANAGEMENT DIAGNOSTIC INSTRUMENT 17 R180100143000 RAPID RELEASE PETROL TUBE KIT ...

Page 16: ...E D I T I O N 1 R180197033000 20 ALLEN WRENCH 2 R180197031000 STEERING RING NUT CLAMPS 3 R180197034000 EMGINE DISMANTLING INSTRUMENT 4 R180197032000 ENGINE SHOULDER ADJUSTMENT CLAMPS Compulsory instruments 1 3 1 SPECIAL FRAME INSTRUMENTS ...

Page 17: ... stroke cylinders in line Bore 88 mm Stroke 49 2 mm Total displacement 898 cm Compression ratio 11 05 1 Max power at shaft 95 1 EC 100 kw 136 cv at 11500 rpm reduced for foreign countries 72 kw 98 cv Minimum rotation at full speed 1350 rpm Maximum at full speed 11800 rpm Distribution At 4 valves per 00HC cylinder Valves Suction valve diameter 33 mm Exhaust valve 29 mm Distribution diagram Suction ...

Page 18: ...lated lever commands the rotation of the drum 6 gear gearbox Primary ratio 44 79 1 1 795 Ratio pinion crown 15 41 1 2 563 Total ratios First gear 14 39 Second gear 18 35 Third gear 21 32 Fourth gear 223 30 Fifth gear 24 28 Sixth gear 25 27 OILING COOLING Oiling Humid housing with trochoidal circulation pump opening pressure of the oil circuit valve 6 5 bar Engine oil quantity With filter 3 5 l Wit...

Page 19: ...STANDARD LIMITS Type Cast Rim Dimensions 17 x MT3 50 Material aluminium Wheel span 120 mm FRONT TIRE STANDARD LIMITS Type Tubeless Dimensions 120 70 ZR17 58W Model D207F RR DUNLOP Tire pressure cold 250 kPa 2 5 kg cm 2 5 bar Maximum pneumatic pressure 250 kPa 2 5 kg cm2 2 5 bar Minimum depth tread 1 6 mm REAR WHEEL STANDARD LIMITS Type Cast Rim Dimensions 17 x MT3 50 Material aluminium Wheel span ...

Page 20: ...Brake liquid advised DOT 4 Brake disks Diameter x thickness 320 x 4 5 mm Min thickness 4 0 mm Max deformation 0 1 mm Thickness brake pads 4 5 mm 0 5 mm Internal cylinder pump diameter 15 mm Internal cylinder clamps diameter 34 mm REAR BRAKES STANDARD LIMITS Type Single disk Brake liquid advised DOT 4 Brake disks Diameter x thickness 240 x 5 mm Min thickness 4 5 mm Max deformation 0 1 mm Thickness ...

Page 21: ...Adjustment positions in compression Road 25 kicks Track 10 kicks BAC K SUSPENSION STANDARD LIMITS Type Oscillating fork Type of rear fork Helical spring damper gas oil Rear fork stroke 62 mm Spring Spring rate K1 7 5 N mm 0 75 kgf mm Spring stroke K1 62 mm Optional spring available no Gas air pressure preload spring 1200 kPat 12 kgf cm2 Adjustment preload spring positions 14 mm Adjustment position...

Page 22: ...esistance 2500 Ù at 20 C 322 5 Ù at 80 C Engine control system SAGEM MC 1000 Relay group Safety relay CM1 NAIS 12V h o Dazzle anti dazzle light Ignition relay 01RA001 SAGEM h o Injector U9122 357 SAGEM type Pick up type O1VR001 SAGEM Engine stepper model 028M001 SAGEM Type bi phase Ignition coils Model 02IG001 SAGEM Primary coil resistance 0 6 Ù Secondary coil resistance 10 KÙ Primary coil inducta...

Page 23: ...e 100A Coil resistance 4 4 Ù at 20 C Horn Model AB1242 262 O S C Max amperage 1 5A Direction indicator relay Model 70 016 70 001 4 Type Full transistor Flashing frequency 60 120 rpm Wattage 10W 10W 2W x2 Oil level switch model 285520 10 BITRON Fuel pump Model BITRON Max amperage 5A max at 13 5V Level sensor in the fuel pump Min resistance 285 Ù tank empty Max resistance 21 Ù tank full Stand switch...

Page 24: ...chapters of the manual together with the relative special instructions if necessary If not otherwise specified the bolts are considered with greased thread created at environmental temperature A B BOLT TORQUES Nm kgf m 10 mm 6 mm 10 1 0 12 mm 8 mm 22 2 2 14 mm 10 mm 45 4 5 17 mm 12 mm 80 8 0 19 mm 14 mm 130 13 0 22 mm 16 mm 200 20 0 ...

Page 25: ...K WITH NUT M12x1 25 40 GREASE RIGHTHAND ENGINE FIXING SCREW HEAD TORQUE ON M6 10 FRAMEWORK RIGHTHAND ENGINE HEAD ON LEFTHAND FRAMEWORK M12x1 25 40 GREASE WITH NUT FRAME GROUP STEERING FERRULES TORQUE ON LOWER AND UPPER SADDLE M8 25 POSTS ENGINE FRONT SUPPORT ROD ON STEERING SADDLE POST M10 1 25 GREASE WITH NUT FORK DAMPER SUPPORT ON CROSSBAR M16x1 5 50 GREASE REAR FORK FERRULES TORQUE ON THE SADDL...

Page 26: ...PPORT ROD ON FRONT M5 10 BRAKE PUMP FRONT OIL BRAKE TANK ON SUPPORT ROD M5 5 CLUTCH LEVER ON LEFT SEMI HANDLEBAR M6 5 PEDAL GROUP COMMANDS PILOT FOOTBOARD ON FRAME SUPPORTS M8 22 LOCTITE 243 GEAR TORQUE COMMAND ON SHAFT M6 10 DRIVING GEAR ROD ON GEAR COMMAND WITH NUT M6 10 DRIVING GEAR ROD ON GEAR PEDAL WITH NUT M6 10 FORK LEVER ON LEFT AND RIGHT FOOTREST SUPPORTS M8 22 LOCTITE 243 LOWER SPRING CR...

Page 27: ...GREASE FRONT MUDGUARD SUPPORTS ON FORKS M5 6 BRAKE CLAMP SUPPORTS ON FORKS M10X1 25 50 LOCTITE 243 STRAP TORQUE STEERING DAMPER ON DAMPER M6 10 BODY STEERING DAMPER ON STEERING HEAD M6 10 STEERING DAMPER ON FRAME M6 10 REAR SUSPENSION GROUP DAMPER ON FORK WITH NUT M10x1 25 35 GREASE UPPER MOUNT DAMPER ON ROCKER ARM WITH NUT M10x1 5 35 GREASE LOWER MOUNT REAR SUPSENSION RODS ON REAR FORK WITH M10x1...

Page 28: ...25 35 SPRING HOOK ON HANGER M6 10 COOLING PLANT GROUP LATERAL RADIATOR BOX ON SADDLE PILLAR M6 3 UPPER FRONT RADIATOR BOX RADIATOR ON SADDLE PILLAR M6 10 RADIATOR BOX COVER ON BASE Autofil 4 1 Autofil 4 8 1 RADIATOR BOX FASTENINGS THREADS M6 4 LOCTITE 243 UPPER COVER RADIATOR BOX FASTENINGS Autofil 4 1 LOWER COVER RADIATOR BOX FASTENNGS Autofil 4 1 EXPANSION TANK ON FRAME M6 3 FANS ON SUPPORT M6 3...

Page 29: ...SUPPORT M8 22 GREASE HYDRAULIC CONNECTION ON REAR BRAKE CLIP M10X1 15 RESTORE BOLT TORQUE TWICE AFTER HAVING LOOSENED HYDROSTOP ON REAR BRAKE PUMP M10X1 15 RESTORE BOLT TORQUE TWICE AFTER HAVING LOOSENED REAR BRAKE OIL TANK ON RADIATOR BOX WITH WELL NUT M5 4 EXHAUST PLANT GROUP EXHAUST COLLECTORS ON ENGINE HEAD M8 13 METAFLUX SILENCER SUPPORT ON SADDLE PILLAR M8 25 LOCTITE 243 SILENCER ON SUPPORT ...

Page 30: ... T I O N PETROL PUMP ON TANK M5 3 PETROL TUBE ON THROTTLE BODY M12X1 5 25 DISTRIBUTOR ON PLATE M5 4 GAS CABLES FIXING PLATE ON THROTTLE BODY M6 10 FRONT AND BACK BODYWORK GROUP USE STANDARD TIGHTENING TORQUE WITH M6 THREAD FOR BODYWORK 8Nm 20 ...

Page 31: ...8 LOCTITE 243 SMALL PLATES AND TUBE TSP FIXING SCREW M6x1x16 9 8 CYLINDRICAL TEI DIN908 CAP M16x1 5 24 5 LOCTITE 243 CYLINDRICAL TEI DIN906 CAP M10x1 BY HAND LOCTITE 243 OIL DIAPHRAGM M8x1 25x10 24 5 LOCTITE 243 NEUTRAL POSITION SENSOR M8x1 9 8 LOCTITE 243 MIN OIL PRESSURE SENSOR M10x1 24 5 LOCTITE 243 OIL LOAD CLUTCH SUMP CAP M24x1 5 BY HAND CLUTCH SUMP PHASE CAP M40x1 BY STRIKING TEF CLUTCH SUMP...

Page 32: ...5 LOCTITE 270 ROD SCREW M9x1 14 7 24 5 MOLYCOTE 73 GREASE ENGINE GROUP CYLINDER PISTON HEAD PRISONNER SCREW M8x25 24 5 LOCTITE 270 CONICAL TEI DOWEL DIN906 M6x1x6 BY HAND LOCTITE 243 CONICAL CAP DIN906 M14x1 5 BY HAND LOCTITE 243 TCB CAP FIXING SCREW M6x1x35 13 TCB CAP FIXING SCREW M6x1x45 13 HEAD FIXING NUT M10x1 44 1 49 MOLYCOTE GREASE TCEI TIGHTENER FIXING SCREW M6x1x25 9 8 TEF CYLINDER CAP SCR...

Page 33: ...OCTITE 243 TEF GEAR COMMAND SUMP FIXING SCREW M6x1x14 9 8 TEF GEAR COMMAND SUMP FIXING SCREW M6x1x25 9 8 TEF CHAIN COVER SUMP FIXING SCREW M6x1x25 9 8 TCEI B GEAR FLANGE FIXING SCREW M8x1 25x60 19 6 TCEI B GEAR FLANGE FIXING SCREW M8x1 25x25 19 6 ENGINE GROUP COOLING PUMP ROTOR BLIND FIXING NUT M6x1 8 3 LOCTITE 243 TCEI B PUMP COVER FIXING SCREW M6x1x20 9 8 TEF PURGE SCREW M6x1x10 9 8 LOCTITE 243 ...

Page 34: ...IL ENGINE OIL Ball bearings Piston surface Piston segments Piston pin Shafts nuts and screws Oil pump rotors Distribution bowl surfaces LOCTITE sustitute the element Clean and degrease the surfaces MOLYBDENUM BISULFIDE OIL Suction and discharge valve stems LITHIUM SOAP GREASE Sealing ring lips TEFLON SYNTOFLON PASTE Engine shaft pins Eccentric shaft pins Eccentric shaft u bolts MOLYCOTE COPPER GRE...

Page 35: ...UK 35 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 36: ...UK 36 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 37: ...UK 37 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 38: ...UK 38 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 39: ...UK 39 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 40: ...UK 40 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 41: ...UK 41 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 42: ...UK 42 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 43: ...UK 43 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 44: ...UK 44 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 45: ...UK 45 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 46: ...UK 46 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 47: ...UK 47 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 48: ...UK 48 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 49: ...ore delivery running in 1st 2nd 3rd Service Service Service Engine oil Engine oil filter Cooling liquid Cooling plant Electrofans Valves Distribution chain Distribution mobile pad Distribution chain stretcher Sparking plugs Before every use of the vehicle R R R Every year in any case R R R At every change of engine oil in any case i i i Every2 years i i i i i i i i i i Every25000 km 15000 mi i i O...

Page 50: ...ulating tubes Brake liquid Gear command Brakes Clutch Brake pads Accelerator command R i i i i i i i i i At every change of the transmission chain in any case i i i Clean and oil every 1000 km 625 mi i i i At every change of the transmission chain in any case i i i i i i i i i Every 3 years in any case i i i Every 25000 km 15000 mi Every 2 years in any case i i i i i i i i i i i i i i i i i Check ...

Page 51: ... bearings Rear damper Front fork oil Battery connections Electrical plant Instrumentation Vision Lights Signals Horn Front headlight Ignition switch i i i i i i i i i i Every 20000 km 12000 mi i i i i i i i i Every 50000 km 30000 mi i i i i i i i i Every35000 km 21000 mi i i i i i i Ogni 20000 km 12000 mi i i i i i i i i i i i i i i i i i i i i i i i At every variation in the state of the vehicle ...

Page 52: ...ange T tighten MAINTENANCE FREQUENCY 0 km 1000 km 6000 km 11000 km 0 mi 625 mi 3750 mi 6875 mi COMPONENTS OPERATION before delivery running in 1st 2nd 3rd Service Service Service Locks Screws and nuts Tube clamp straps General oiling General test i i i i i T T T i i i i i i i i i i i i Check Functioning Check Tighten Check Tighten ...

Page 53: ...t and right upper cowling see DISMANTLE LEFT AND RIGHT UPPER COWLING Remove the tank see DISMANTLE TANK Remove the air box conduits see DISMANTLE AIR BOX Remove the air box see DISMANTLE AIR BOX WARNING Clean the dirt around the sparking plugs before removing them Loosen and remove the nut 1 Remove the coil support rod 2 and the coil 3 Remove the sparking plugs beneath Sight check the state of the...

Page 54: ... Use the reverse procedure to dismantling 3 3 CLEAN AIR BOX WARNING To avoid the risk of fire or explosion do not use petrol or inflammable solvents in cleaning the filtering element inside the filter box Remove the tank see DISMANTLE TANK Loosen and remove the eight screws 1 around the air box and the central screw Remove the air box cover 2 ...

Page 55: ...tion the filtering element Position the air box cover 2 and fix it with the nine screws Mount the tank see MOUNT TANK 3 4 GAS COMMAND PLAY Remove the internal instrumentation fastenings see DISMANTLE INTERNAL INSTRUMENTATION FASTENINGS Remove the small cap see DISMANTLE SMALL CAP Remove the lower cowling see DISMANTLE LOWER COWLING Remove the left and right upper cowling see DISMANTLE LEFT AND RIG...

Page 56: ... GAS COMMAND PLAY 0 5 mm 3 5 ADJUSTMENT CO SPECIFIC INSTRUMENTS Engine management diagnostic instruments R180197036000 WARNING The Axone connection must be carried out with the key on OFF Remove the saddle connect the Axone to the diagnostic socket 1 under the saddle Turn the key to ON Check that the arrest bike switch on the right command is on RUN Check that the vehicle is not in any gear Select...

Page 57: ...The position of the Stepper must maintain a value between 30 and 40 pitches If this value does not correspond select the Adatt icon with Axone Bring the Stepper to within the mentioned values with the Adjustment icon Hammer and Screwdriver on the Stepper Manual and bring the Stepper to within the previously mentioned values Varying these two parameters using Axone Carb Adjustment at minimum try to...

Page 58: ...EEL HOUSING Remove gearbox see DISMANTLE GEARBOX Unscrew the gearbox fixing screw without disconnecting it to allow being able to remove the petrol tank Remove the petrol tank see DISMANTLE TANK Remove the petrol tank in such a way as not to prevent access to the throttle body but such as to guarantee supply to the engine Dismantle airr box conduits see DISMANTLE CONDUITS Remove the rear tail piec...

Page 59: ...Disconnect the three tubes that connect the throttle body to the Stepper 1 Disconnect the three lips 2 that connect the throttle body Connect using the three T switches 3 the minimum air conduits of the throttle body to a mercury columned Vacuum meter ...

Page 60: ...rt the engine check that the mercury columns 4 with the engine at minimum are alligned and then proceed to balancing Tighten the upper by pass screws 5 closing the passages completely Work on the by pass screws loosening them until the columns are equal ...

Page 61: ...Use the specified Axone instruments for adjusting Remove the stepper from the lower part of the air box 1 Sight check that the stepper is not broken otherwise change it Sight check that there are no obstructions inside the stepper If necessary clean the stepper Insert the stepper as in the figure Mount the air box see MOUNT AIR BOX 3 8 ADJUSTMENT CLUTCH LEVER PLAY Move the adjustment cover cap Uns...

Page 62: ...Remove the wheel housing see DISMANTLE WHEEL HOUSING Remove the coils Remove the sparking plugs Remove the head cover see DISMANTLE HEAD COVER Remove the phonic wheel inspection cap 1 Make the engine turn over with the phonic wheel retaining screw and in the meantime measure the valve play between the cams and the small bowls with the feeler If adjustment is necessary operate as follows SPECIFIC V...

Page 63: ...ck the distribution with the reference signs 3 10 ENGINE DISTRIBUTION WARNING Specific instruments are needed to set up the distribution goniometer drive upper dead centre Measurer and equipment for checking valve lifter Remove the head cover see DISMANTLE HEAD COVER Remove the goniometer indicator fixing screw 1 Remove the phonic wheel cover 2 ...

Page 64: ... as indicated on it and align the two reference signs A WARNING When mounting the goniometer indicator check the presence of about 5 mm of space to avoid contact between the indicator and the goniometer Position the goniometer drive 4 in the place of the phonic wheel screw 3 SPECIFIC EQUIPMENT Goniometer drive 4 R180197015000 ...

Page 65: ...27000 Position the upper dead centre measurer 7 in the place of the first piston sparking plug SPECIFIC EQUIPMENT U p c Measurer 7 R180197022000 Position the equipment for checking the valve lifter 8 on the two suction and exhaust bridges at the height of the first piston tightening it with the two screws 9 SPECIFIC EQUIPMENT Equipment for checking lifter valves R180197026000 ...

Page 66: ...goniomenter drive clockwise until finding the upper dead centre The olives of the two eccentric shafts on the first piston should be turned towards each other Once the u d c upper dead centre is found position the crown 12 at zero on the central test indicator ...

Page 67: ...cides with zero and tighten the screws again Turn the test indicator crown 12 until it coincides with zero Turn the goniometer drive from the upper dead centre clockwise until it reaches 1 mm on the test indicator 12 Check that the specific value is indicated on the goniometer SPECIFIC VALUE Suction opening 21 before the UDC ...

Page 68: ... indicator 12 Lock the two worm screws with Loctite after having degreased them one at a time 13 N m 1 3 Kg m Position the olive of the exhaust shaft on the first piston as in the figure Turn the test indicator crown 14 to zero Load 1 mm refering to the test indicators 15 Check that the value expressed by the indicator corresponds to the specific value SPECIFIC VALUE Exhaust opening 36 before the ...

Page 69: ...sing during filling WARNING New or used engine oil can be dangerous Swallowing new or used engine oil can be harmful to people and domestic animals In the case of swallowing engine oil call a doctor immediately and in order to avoid sucking the product into the lungs do not provoke vomiting It has been noted that continuous contact with engine oil provokes skin cancer in cavies Brief contacts with...

Page 70: ... level must be between the MAX and MIN references on the casing In the case where the level of the oil is below the MIN reference refill To restore the level undo the oil cap 1 with the engine off and pour a quantity of oil of the type advised until reaching half way up the spyhole between the MAX and MIN references Screw on the cap 1 again 3 12 CHANGE ENGINE OIL AND FILTER Remove the lower semi c...

Page 71: ... I T I O N WARNING Used oils are harmful to the environment Dispose of the used oils according to the regulations in vigour Remove the oil loading cap 1 Remove the oil discharge cap 2 Let all the used oil empty away Change the oil filter 3 ...

Page 72: ...p 2 and tighten it 22 N m 2 2 Kg m Engine oil quantity without substitution of oil filter about 3 1 litres with substitution of oil filter about 3 5 litres Always check that the level in the spyhole is midway between the Max and Min references Restore the level of the engine oil and close the oil loading cap 1 again Re mount the lower semi cowling see MOUNT THE LOWER SEMI COWLING Re check the leve...

Page 73: ...ul if swaIlowed and enters into contact with the eyes or the skin Keep the cooling liquid far from children and domestic animals In the case of swallowing cooling liquid call a doctor immediately and in order to avoid sucking the product into the lungs do not provoke vomiting In the case of contact of the engine cooling liquid with the eyes or the skin immediately rinse with water WARNING Do not u...

Page 74: ... the cap and fill using the cooling fluid advised in the oils and liquids table After restoring the level re mount the cap and the saddle accurately 3 14 CHANGE REFRIGERANT LIQUID NOTE Carry out the following operations with the engine cold and the bike on the lateral assembly stand Remove the saddle see REMOVE SADDLE Remove the lower left semi cowling see DISMANTLE LOWER SEMI COWLING Remove the r...

Page 75: ...e complete emptying of the cooling liquid contained in the cylinder blocks lean the bike on both sides and press contemporaneously on the entry and exit rubber tubes of the radiator Wait for the cooling liquid to empty itself completely WARNING In re mountng always substitute the copper washers of the discharge screws with new washers and tighten TIGHTEN LIQUID DISCHARGE SCREWS 8 N m 0 8 Kg m ...

Page 76: ...bout 3 litres of refrigerant liquid through the radiator cap 1 NOTE Help by pressing on the rubber tubes of the radiator to eliminate eventual air locks Fill with about 100 cc of refrigerant liquid through the expansion tank cap 2 Remount the radiator cap 2 Remount the expansion tank cap 2 Start the engine and bring it to working temperature until the fans start Let it cool and check the level of ...

Page 77: ...TANK CONTINUOUS PURGE LINE COLLECTOR WATER RADIATOR RADIATOR CAP Opening 1 2 bar Radiator cap open WATER PUMP WATER DISCHARGE SCREW CYLINDER BLOCKS WATER DISCHARGE SCREW on discharge side ENGINE WATER LINE Thermostat open HEAD BLOCK HEAT EXCHANGER SHUTTER JET THERMOSTAT Opening 75 C ...

Page 78: ...DISMANTLE LOWER SEMI COWLING Remove the exhaust plant see DISMANTLE EXHAUST PLANT Check the state of the components of the exhaust plant If some element is excessively worn or damaged change it Mount the exhaust plant see MOUNT EXHAUST PLANT 3 18 ADJUSTMENT FRONT BRAKE LEVER WARNING Danger never carry out adjustment with the engine running Push lever 1 forward to neutralize the thrust of the sprin...

Page 79: ...y diminishes by loosening 3 20 CHECK BRAKE LIQUID WARNING An insufficient quantity of brake liquid may allow the penetration of air into the brake plant reducing the efficiency of braking with a consequent increase in the risk of accidents The presence of air in the hydraulic plant can be felt in the case in which pressing the brake pedal there is a sensation of excessive pliability In the case of...

Page 80: ...mediately with water Wear on the brake pads causes a normal fall in the level of the fluid In any case the level must be between the MAX and MIN references If this level falls below the MIN reference a check must be made of the braking plant 3 21 CHECK FRONT AND REAR BRAKE PADS The front brake pads have to be changed when the pad disk contact surfaces are coplanar with the thickness A present on t...

Page 81: ...T BRAKE PADS WARNING After changing the brake pads work on the brake command with long but not intense braking for about a hundred Km WARNING Always change the two pairs of pads together Undo the two pins 1 and remove the two springs 2 Change the two pairs of pads 3 Re position the springs 2 and the pins 1 Do the same for the other front clamp 3 21 2 CHANGE REAR BRAKE PADS Remove the safety ring 4...

Page 82: ...ferent type might cause a dangerous chemical reaction and a diminishing of braking efficiency with a consequent increase in the risk of accidents WARNING Work with maximum care on dismantling the clamps at the km counter cable 2 WARNING To carry out the purge of the rear plant the brake clamps of the relative support have to be dismantled and the plant tubing kept as vertical as possible Bring the...

Page 83: ... the tap of the rear plant oil tank Operate and release the lever 3 repeatedly and in rapid succession Press fully and open the purge screw 2 Repeat the procedure until all the air bubbles have been completely removed Check the oil level in the tank during the operation Restore if necessary Close the purge screw 2 Close the rear tank plant after having checked the oil level Mount the brake clamp a...

Page 84: ...the right as well as the left clamp Procede in the same way as for the brake purge clamps also on the front brake pump 3 24 ADJUSTMENT GEAR COMMAND PEDAL Remove the fixing screws 3 of the gear pedal rod Loosen the two nuts 1 Adjust the angle of the gear command pedal by working on the rod 2 Rotating it clockwise the pedal will bend lower and vice versa if rotated anti clockwise ...

Page 85: ...ge them Every time the chain is changed the relative sprocket wheels must also be changed Loosen the nut 1 and the locknut 2 Adjust the chain loosening the screw 3 to measure and fixing it with the counternut 2 Check the correctness of the adjustment with a caliper and repeat the operation on the other side Keeping the chain in tension upwards the axis of its lower section must be at a distance of...

Page 86: ...harmful to children and domestic animals Keep open flames and objects at high temperature far from the kerosene Keep children and domestic animals far from the kerosene Correctly dispose of the used kerosene WARNING Only use the advised oil or an equivalent one The chain must be correctly oiled to guarantee maximum efficiency Preliminary cleaning before oiling is necessary to dissolve deposits of ...

Page 87: ...ecessary procede as follows Remove the upper steering plate 1 see DISMANTLE FRONT FORK WARNING Never exceed the bolt torque to avoid steering malfunction Loosen the counter ring nut 2 and tighten the ring nut 3 using the specific instrument SPECIFIC EQUIPMENT Steering ring nut clamp R180197031000 16 N m 1 6 Kg m Tighten the counter ring nut 2 MANUAL 90 ...

Page 88: ...y If necesary repeat the previous operations Mount the upper steering plate 1 see MOUNT FRONT FORK Check the free rotation of the steering 3 28 CHECK FORK Keeping the front brake on check the state of the fork as shown in the figure Sight check the state of the splashguards ...

Page 89: ...raking in extension adjustment 2 Braking in compression adjustment 3 REAR SUSPENSION Standard Set up Preload spring 4 spins 4 mm Braking in extension 14 kicks Braking in compression 22 kicks NOTE Adjusting the preload is carried out starting from all open in direction Adjusting in compression and extenstions starts instead from all closed in drection Track Preload spring 4 spins 4 mm Braking in ex...

Page 90: ... adjuster 4 The preload will be rigid clockwise The preload will be slack anti clockwise Adjusting the hydraulic braking device in extension is carried out in sudden steps Rotate the regulator 5 clockwise to increase the braking action or anti clockwise to diminish it Adjusting the hydraulic braking device in compression is carried out in sudden steps Rotate the adjuster 6 clockwise to increase th...

Page 91: ... DAMPER Three adjustments are possible on the rear damper Preload spring adjustment 1 Braking in extension adjustment 2 Braking in compression adjustment 3 REAR SUSPENSION NOTE The adjustment of the preload is carried out starting from the length of the damper equal to 146 mm Adjustment in compression and extension starts from all closed in direction Standard set up Spring length 146 mm Brake in e...

Page 92: ...he hydraulic braking device in compensation is carried out in sudden steps Rotate the adjuster 3 clockwise to increase the braking action or anti clockwise to diminish it If you want to lengthen or shorten the wheelbase remove the damper from the small connecting rod loosen the two locknuts 4 rotate the anchorage support clockwise to shorten anti clockwise to lengthen Adjusting the hydraulic brake...

Page 93: ...to slip on the rim or its detachment with consequent deflation of the tire and loss of control of the vehicle Check the pressure of the tires with a manometer NOTE In the case of long continuous driving increase the value of nominal pressure by 0 2 bar Check the wear on the tires When the tread is at the same level as in A change the tire Pressure Front tire 250 kPa 2 5 bar Rear tire 250 kPa 2 5 b...

Page 94: ...ure The value must enter within the specific value SPECIFIC VALUE Axial veer 0 3 mm Work on the front wheel as on the back wheel SPECIFIC VALUE Axial veer 0 05 mm Excessive veering and eccentricity are generally caused by wear of the ball bearings Change the ball bearings If the problem persists change the rim of the wheel ...

Page 95: ...T AID as follows EXTERNAL CONTACT Rinse with a lot of water INTERNAL CONTACT Drink great quantities of water or milk and immediately call a doctor EYES Rinse with water for 15 minutes and immediately see a doctor Moreover leakage of sulphuric acid leads to the formation of hydrogen that can provoke an explosion in the presence of a spark or a flame 3 35 ELECTRICAL PLANT 3 35 1 CHECK BATTERY This m...

Page 96: ...inal Negative tester probe negative battery terminal NOTE It is possible to check the state of the MF battery recharging by measuring the tension at empty i e the tension present with the positive terminal dfisconnected It is not necessary to recharge when the tension at empty is equal to or superior to 12 8V Check the recharging of the battery as illustrated in the diagram and the follwing exampl...

Page 97: ...er is off Make sure that the clips are well connected to the battery terminals and are not short circuited A corroded clip can provoke overheating at the contact point and a clip left behind can cause sparking If the battery heats up during recharging disconnect the battery charger and let the battery cool down before continuing This is necessary to avoid the battery exploding As illustrated in th...

Page 98: ...e battery Connect the battery charger and an ampere meter to the battery Begin the recharging operation Is the amperage higher than the standard charge indicated on the battery Wait more than 30 minutes before measuring the tension at empty of the battery 12 8 V recharge completed 12 0 12 7 V recharging needs to be carried out less than 12 0 V change the battery NOTE Set the recharge tension to 16...

Page 99: ...ated on the battery Wait more than 30 minutes before measuring the tension at empty of the battery 12 8 V recharge completed 12 0 12 7 V recharging needs to be carried out less than 12 0 V change the battery NOTE Set the recharge tension to 16 17V if the tension is lower the recharge will be insufficient If the tension is higher the battery will overload This kind of battery charger is not suitabl...

Page 100: ...trical plant of the motorcycle with a consequent danger of fire The service fuses 3 are under the saddle remove it to reach them Open the cover change the burned out fuses and remount the cover NOTE Consult the information in the key to identify the function of the fuses Eight fuses are in the fuse box Reserve fuse 10A 4 Reserve fuse 15A 5 Reserve fuse 25A 6 Oil spyhole reserve fuse 10A 7 Cooling ...

Page 101: ...r lamp holder and change the lamp For the anti dazzle lamp 4 remove the rubber dust cover disconnect the cabling and change the lamp 4 freeing it from the spring 5 Repeat the operation for the anti dazzle lamp 6 freeing the lamp 6 from the spring 7 3 38 ADUSTMENT FRONT HEADLIGHT To carry out the correct adjustment of the luminous beam projected by the front headlight position the vehicle at about ...

Page 102: ...e light adjustment 5 Vertical headlight adjustment 6 Positioning the lever 7 low the light is set for driving to the right vice versa if positioned high it is set for driving to the left 3 39 CHANGING REAR LIGHTS 3 39 1 CHANGING REAR HEADLIGHT Loosen and remove the screw 1 Remove the glass cover 2 Turn the lens upwards avoiding breaking the fixing tab Change the bulb 3 Position the glass cover 2 u...

Page 103: ...n lamp Position the rubber lamp holder and tighten the screw 1 3 39 3 CHANGE FRONT AND REAR ARROWS 3 39 3 1 CHANGE FRONT ARROWS Loosen and remove screw 1 Remove the glass cover 2 Remove the arrow body 3 Change the damaged lamp 4 turning it anti clockwise Position the arrow body 3 and glass cover and fix with screw 1 Operate in the same way with the opposite arrow ...

Page 104: ... M I T E D E D I T I O N 3 39 3 2 CHANGE REAR ARROWS Loosen and remove the screw 1 Remove the glass cover 2 and change the bulb Position the glass cover 2 and tighten the screw 1 Operate in the same way with the opposite arrow ...

Page 105: ...o not damage the cowling while removing WARNING Take note of the position of the screws for correct remounting Position the engine on the rear assembly stand Unscrew and remove the six screws 1 on the right side of the vehicle WARNING During the following operation support the lower semi cowlings Lower the lateral assembly stand Unscrew and remove the six screws 1 on the left side of the vehicle R...

Page 106: ...2 from the left 3 as indicated in the figure 4 3 DISMANTLE UPPER SEMI COWLING 4 3 1 DISMANTLE LEFT AND RIGHT INTERNAL INSTRUMENT BOARD FASTENINGS Unscrew and remove the screw 1 Remove the left instrument board fastenings 2 Procede in the same way with the right instrument board fastenings Unscrew and remove the screw 3 ...

Page 107: ...ning 4 and remove it Proceed in the same way with the right internal instrument board fastening 5 4 4 DISMANTLE LEFT AND RIGHT REARVIEW MIRRORS Extract the internal rubber cap fastening Support the left rearview mirror Unscrew the screw 1 and remove the left mirror Proceed in the same way with the opposite right mirror ...

Page 108: ...ews 1 There are two high speed nails in the area indicated by the arrows Remove the two high speed nails 2 under the front headlight to separte the cowlings from the wheel housing Loosen and remove the two screws 3 and screw 4 Remove the upper right side panel 5 Remove the small cap working on the remaining two screws 1 Proceed in the same way as this with the upper left side panel ...

Page 109: ...ng Remove the saddle 1 using the supplied wrench Unscrew and remove the centre fixing screw 2 of the license plate holder support Unscrew and remove the two lower license plate holder support fixing screws 3 Remove the license plate holder Unscrew and remove the rwo lower tail piece fixing screws 4 Disconnect the tail piece connector 5 ...

Page 110: ...T E D E D I T I O N Loosen and remove screw 6 remove the glass cover of the tail piece 7 Loosen screw 8 and extract the parabola 9 Detach the contacts to the tail piece and remove the parabola 9 Loosen and remove the four screws 10 ...

Page 111: ...an is necessary Remove the rear tail piece 11 enlarging its front part slightly and passing it towards the rear of the bike as indicated in the figure 4 7 DISMANTLE WHEEL HOUSING Remove the lower cowlings see DISMANTLE LEFT AND RIGHT COWLINGS Loosen and remove the two high speed nails 1 Loosen and remove the two screws 2 Remove the wheel housing 3 ...

Page 112: ... UPPER LEFT AND RIGHT COWLINGS Loosen and remove the two screws 1 and screw 2 on both sides Loosen and remove the two screws 3 Disconnect the cabling of the direction indicators Remove the cowling beneath the headlight 4 4 9 DISMANTLE FRONT MUDGUARD Loosen and remove the two screws 1 on each side and remove the front mudguard 2 4 10 DISMANTLE REAR MUDGUARD Loosen and remove the three fixing screws...

Page 113: ...ove the cable grommet cover 2 4 12 DISMANTLE RIGHT AND LEFT FOOTRESTS Loosen and remove the two screws 1 and remove the right footrest 2 Proceed in the same way with the left footrest 3 4 13 DISMANTLE HOOD Remove the lower semi cowlings see DISMANTLE LOWER SEMI COWLINGS Loosen and remove the four screws 1 and remove the hood 2 ...

Page 114: ...E D I T I O N 4 14 DISMANTLE TANK Loosen and remove the two screws 1 and remove the steering block cover 2 Loosen and remove the two screws 3 Loosen and remove screw 4 and move the trigger box and the trigger box support as in the figure ...

Page 115: ...UK 115 MF9_UK T T T T L I M I T E D E D I T I O N Loosen and remove the screw 5 Raise the fuel tank 6 Disconnect the petrol pump cabling 7 ...

Page 116: ... closure cap 10 to avoid oil spilling out 4 15 DISMANTLE TANK FUEL PUMP Remove the tank from the vehicle see DISMANTLE TANK Empty the tank conserving the fuel in a dry place and far from the rays of the sun and open flames Loosen and remove the six screws 1 and remove the pump 2 For remounting proceed in the reverse way to dismantling NOTE Position the sealing O ring correctly in the apposite seat...

Page 117: ...CIFIC EQUIPMENT Engine dismantling instrument R180197034000 To support the engine use the specific equipment SPECIFIC EQUIPMENT Engine support R180197029000 Remove the access cover 1 to the phonic wheel Position the phonic wheel as shown in the figure The two signs A and B must coincide PMS Remove the three aluminium rods 2 that fix the relative coils using the fixing nuts 3 ...

Page 118: ... N Remove the coils 4 and the sparking plugs beneath WARNING Take note of the position of the screws for correct remounting Unscrew the eight head cover fixing screws 5 Remove the head cover Remove the chain pad 6 unscrewing the two fixing screws 7 ...

Page 119: ...ixing screws Remove the camshafts and the chain 5 1 2 CHECK CAMSHAFT Check the olives of the camshaft with a micrometer as indicated in the figure If the value does not enter within the specific measure change the element SUCTION SHAFT VALUE LIMIT A 37 mm B 27 85 mm EXHAUST SHAFT A 36 6 mm B 27 85 mm Check the concentricity of the camshaft with a comparator as shown in the figure If the value does...

Page 120: ...IC EQUIPMENT Instrument for checking engine shaft axle R180197030000 5 1 3 CHECK CHAIN SPROCKET WHEELS AND CAMSHAFT CHAIN GUIDE Check the state of wear of the camshaft distribution chain 1 If the element has blocked links is excessively worn or has exceeded 25000 Km change it Sight check the distribution chain guides 1 Fixed guide FRONT PART 2 Mobile guide REAR PART 3 Upper guide FIXED ON HEAD If ...

Page 121: ...hain position the fixed pad and then the mobile pad Position the exhaust shaft and transmission chain position the end shields in the original position with the writing towards the outside and with the number on the inside of the head and tighten the fixing screws according to the diagram in the figu re 1st phase 6 N m 2nd phase 13 N m Position the suction shaft and the transmission chain position...

Page 122: ...n the fixed pad Position the body of the chain stretcher 1 complete with O ring 2 and tighten the two screws 6 as specified in the diagram 10 N m 1 Kg m Position the rod pushing spring 3 and the washer 4 and tighten everything with a drive screw 5 as in the diagram 7 8 N m 0 7 0 8 Kg m WARNING Always check that the chain stretcher is always in position 0 in exhaust before mounting it Align the sig...

Page 123: ...at the position of the phonic wheel is as indicated in the figure A and B aligned Check the valve play with a feeler If the valve play is not within the specific value adjust the valve play see ADJUST VALVE PLAY Screw the phonic wheel cover onto the right side of the engine SUCTION SHAFT FUNCTIONING PLAY 0 25 0 30 EXHAUST SHAFT FUNCTIONING PLAY 0 30 0 35 ...

Page 124: ... gaskets of the head cover 1 and 2 WARNING Make sure during mounting that the gaskets 2 do not fall into the head Apply THREEBOND paste as in the drawing Position the head cover and tighten screws 3 and 4 where indicated in the figure Insert the 8 head fixing screws with suitable rubber washers ...

Page 125: ...tion not to cut or damage the gaskets 10 N m 1 Kg m 5 2 CYLINDER HEAD 5 2 1 REMOVE CYLINDER Remove the canshaft see REMOVE CAMSHAFT Loosen and remove the eight nuts 1 indicated in the figure and the two screws on the right side of the engine distribution side NOTE Loosen for a moment the fixing screws and nuts according to the sequence indicated in the figure Then remove the head ...

Page 126: ...is is outside the specific value rectify the head VALUE LIMIT HEAD DISTORTION max distortion 0 1 mm 5 2 3 MOUNT CYLINDER HEAD NOTE Always use new gaskets Clean and degrease the head surface and the cylinders Position the cylinder head Position the fixing screws and nuts Tighten to the specified worm drive following the order in the figure in the following phases 1st phase 2 5 Kg m 2nd phase 3 5 Kg...

Page 127: ...MOVE CYLINDER HEAD Position the head on a support 1 slightly inclined so that the valve to be removed is perpendicular to the surface To remove the valve use the apposite instrument 3 with the correct mount 3 compressing the valve and undo the two lock cones Loosen the clamp and remove the valve and its components as in the photo ...

Page 128: ...h valve and coupling them to their pads Free the pusher spring plate using the specified instrument to remove the two lock cones Remove the external spring 5 the internal spring 6 valve 4 the valve seal ring and the lower cup 5 3 2 CHECK VALVES AND VALVE GUIDES The following procedure must be carried out on all valves and relative valve guides Check that values A and B are within the tollerance of...

Page 129: ... carbon deposits If the surface is excessively ruined change the element Check thickness A indicated in the figure VALVE THICKNESS VALUE LIMIT A 0 9 1 1 mm Check the concentricity of the valve stem If the concentricity value does not enter within the margin change the element VALVE CONCENTRICITY VALUE LIMIT 0 01 mm ...

Page 130: ...e necessary to remove the bluing at the point at which the seat and the face of the valve touch NOTE If the trace is not partial or not uniform carry out a smoothing operation on the face and the seat of the valve Smooth the face of the valve the seat of the valve NOTE After having changed the cylinder head or the valve and the relative guide it will be necessary to smooth the seat and face of the...

Page 131: ...tions Completely eliminate the smoothing paste from the face and the seat of the valve at the end of each operation Apply the Dykem Workshop b tincture of bluing to the face of the valve Install the valve in the cylinder head Press the valve through the valve guide and on the valve seat to leave a clear trace 5 3 4 CHECK THE VALVE SPRING The following procedure is valid for all the valve springs M...

Page 132: ...m Load value limit 298 N Check the inclination a of the valve spring as illustrated in the figure If a does not enter within the specific value change it VALUE LIMIT INCLINATION SUCTION SPRING A 2 mm VALUE LIMIT INCLINATION EXHAUST SPRING A 2 mm 5 3 5 CHECK BUCKET TYPE TAPPET The follwing procedure must be applied to all the bucket type tappets Check that the buckets are not broken or scratched if...

Page 133: ...the valve stem with the recommended oil RECOMMENED OIL Disulfide of molybdenum oil Mount the lower small cup 1 Check the thickness of the small cup If the thickness is 1 5 mm add a clearance adjustment of 0 6 mm WARNING Always use new gaskets and oil seals Mount the valve holder hood 2 with the apposite pad 3 SPECIFIC EQUIPMENT INSTRUMENT 3 R180197025000 ...

Page 134: ... I T E D E D I T I O N WARNING The suction valves are larger than the exhaust valves Insert the valves 4 Position the internal 5 and external 6 springs as shown in the figure Insert the two lock cones 7 into the upper small cup 8 ...

Page 135: ... the bucket type tappets 10 NOTE Check that the buckets turn easily by rotating them with a finger Make sure that the individual valve lifters and the valve guide are re mounted in the original position 5 4 CYLINDER 5 4 1 DISMANTLE CYLINDER BODY Remove the cylinder head see REMOVE CYLINDER HEAD Remove the gasket of the head 2 the cylinder body 2 and the base of the cylinders gasket beneath ...

Page 136: ...ge the pistons and the elastic straps if necessary The cylinder is distinguished by a letter that indicates the class it belongs to The cylinder piston coupling must be carried out among the same classes that they belong to The letters are on the external front part exhaust side of the cylinder 5 4 3 DISMANTLE WATER COLLECTOR Unscrew and remove the three screws 1 and remove the collector 2 CLASS D...

Page 137: ...ys use new gaskets Position the gasket 1 and the collector 2 and tighten the screws 3 10 N m 1 Kg m 5 4 6 MOUNT CYLINDERS WARNING Always use new gaskets Position the gasket 1 and the liners 2 and 4 as shown in the figure and check the correct position of the centering dowels Position the cylinder pistons 5 6 and 7 enter them in order SPECIFIC EQUIPMENT CYLINDER MOUNTING LINERS R180197018000 ...

Page 138: ...N 5 5 PISTON 5 5 1 DISMANTLE PISTON Remove the cylinder see DISMANTLE CYLINDER BODY The following procedure must be applied to all the pistons Remove the elastic ring 1 WARNING Do not use a hammer to remove the pins 2 Remove pin 2 and remove piston 3 ...

Page 139: ... a letter that indicates the class it belongs to The cylinder piston coupling must be carried out among the same classes that they belong to NOTE The maximum play of the piston is of 0 1 mm Change the piston if necessary 5 5 3 CHECK SEGMENTS The following procedure must be applied to all the segments Check the absence of scuffing and traces of shrinkage on every segment Check that the edge of the ...

Page 140: ...e a enters within the specific value NOMINAL VALUE a 18 995 19 000 mm Check the value of b NOMINAL VALUE b 19 002 19 008 mm NOTE If the play between the piston pin and the piston is greater than 0 03 mm change the piston 5 5 5 MOUNT PISTON Position the two segments 1 and the scrapper ring 2 on the piston positioning the opening at 120 from each other ...

Page 141: ... pointing towards the exhaust Insert the pin 4 WARINING Always use new elastic rings for mounting the pistons Position the two elastic rings 5 one for each side 5 6 GENERATOR 5 6 1 REMOVAL GENERATOR WARNING Support the generator during the mounting phase Remove the electrical connections Loosen and remove the three screws 1 ...

Page 142: ...R To mount the generator grease the O ring and work in the reverse way to dismantling tightening screws 1 to the specific worm drive after having applied LOCTITE NOTE To ease mounting the generator position the engine if possible horizontally 27 N m 2 7 Kg m LOCTITE 243 5 7 PHASE SENSOR AND PHONIC WHEEL 5 7 1 REMOVE PHASE SENSOR Remove the phase sensor 1 by unscrewing the fixing screw 2 ...

Page 143: ... REMOVE CLUTCH COVER Unscrew and remove screw 3 and remove the phonic wheel 4 5 7 4 MOUNT PHONIC WHEEL WARNING During the phonic wheel mounting phase position it with the writing towards the outside of the engine Position the phonic wheel 4 and tighten the fixing screw to the specified worm drive Check the liner a between the phonic wheel and the phase sensor VALUE LIMIT a from 0 8 to 1 0 mm 24 5 ...

Page 144: ...DISMANTLE CLUTCH COMMAND Remove the clutch command cable and unscrew the three screws 1 Remove the clutch body command and the cable support plate 3 Remove the ferrule 4 and the clutch command rod 5 5 8 2 REMOVE THE CLUTCH Remove the four screws 1 and the clutch hood 2 ...

Page 145: ... D I T I O N Remove the circlip 3 WARNING Do not allow the ball to come out during the following dismantling operation Remove the ball bearing group the pin and the nut 4 Unscrew and remove the clutch fixing nut 5 Remove the clutch group 6 ...

Page 146: ...CH COVER Place a container under the oil sump to allow the oil to empty Remove the discharge screw cap NOTE Be careful not to lose the sealing washer beneath WARNING Note the position of the screws for correct re mounting Remove the clutch see DISMANTLE CLUTCH GROUP First remove the centering screws 2 then screws 3 4 and 5 ...

Page 147: ... group 1 the two roller cages and the spacer beneath 5 8 5 DISMANTLE CLUTCH GROUP WARNING Take note while dismantling the clutch of the position of the elements for correct re mounting Remove the clutch see DISMANTLE CLUTCH GROUP Remove the screws 1 then the small cups 2 and the springs 3 Remove the disk pusher plate 4 Remove the Belleville spring 5 ...

Page 148: ..._UK T T T T L I M I T E D E D I T I O N Remove the eight external disks 6 the nine internal disks 7 and the load modulation spring beneath Remove the drag hub 8 Separate the coupling 9 from the sliding flange 10 ...

Page 149: ...RNAL DISK The following operations must be carried out on all the internal disks Check the distortion of the disk as shown in the figure If the disk is broken or does not enter within the specific value change the entire set of disks VALUE LIMIT MAX DISTORTION 0 1 mm 5 8 8 CHECK CLUTCH SPRINGS The following operations must be carried out on all the clutch springs Measure the lengths a of the free ...

Page 150: ...enter within the specific value change the entire set of springs VALUE LIMIT CLUTCH SPRING INCLINE d 2 mm 5 8 9 CHECK CLUTCH COVER Check that the cover 1 is not broken otherwise change it Check the free movment of the ball bearing 2 otherwise change it Check the state of the oil seal 3 and if necessary change it Check the wear on the small tires and flexible couplings To change the oil seal 3 use ...

Page 151: ...e components of the primary assembly are not excessivly worn rough or broken If necessary change the component or components or the entire primary assembly 5 8 11 MOUNT CLUTCH GROUP Position the coupling 1 in the sliding flange 2 as indicated in the figure Insert the drag hub 3 as in the figure ...

Page 152: ...ave face turned upwards WARNNG During the following phase make sure to insert the internal disk with the bigger liner 2 mm first with respect to the others 1 6 mm Position the Belleville spring 5 and alternate an internal disk 6 and an external disk WARNING During the following phase make sure to position the disk pusher 7 so as to make it coincide with the two points A and B Position the disk pus...

Page 153: ...d outwards Position the two roller cages 2 and the spacer 3 Position the primary assembly 4 5 8 13 MOUNT CLUTCH COVER WARNING Aways use new gaskets Put THREEBOND 1215 sealing paste onto the casing surface and onto the clutch cover 1 Then position the gasket and the clutch cover 1 and tighten with the centering screws 2 and then with screws 3 4 and 5 ...

Page 154: ...he figu re 10 N m 1 Kg m 5 8 14 MOUNT CLUTCH WARNING The spacer should be inserted with its smaller diameter facing outwards Position the clutch cover 1 the O ring 2 and the spacer 3 on the primary shaft 4 Position the clutch plate 5 in the cover 1 and fix with nut 6 and tighten 50 N m 5 0 Kg m LOCTITE 243 ...

Page 155: ...n 7 complete with ball bearing 8 Fix with elastic ring 9 5 8 15 MOUNT CLUTCH COMMAND Insert the clutch command rod 1 Insert the ferrule 2 Position the cable support rod 3 and the clutch command body 4 Fix the clutch command with the three screws 5 and tighten Insert the clutch command cable 10 N m 1 Kg m LOCTITE 243 ...

Page 156: ...y remains between the elastic ring and the ball bearing Use the same procedure for subsituting the clutch with a new one unscrewing the disk pusher pin in this case however 1 2 a turn 15 N m 1 5 Kg m 5 9 GEARS 5 9 1 REMOVE GEARS Remove the primary assembly see REMOVE PRIMARY TRANSMISION WARNING Before removing the gears remove the neutral sensor at the back of the engine Loosen and remove the nine...

Page 157: ...NING Take note of the position of the forks before removing them for correct re mounting Remove the pin 6 Loosen and remove the two screws 8 Remove the stop plate 9 Free and remove the two fork pins 10 from the washers 11 working on the screws 12 Remove the forks Remove the nut 13 holding the pinion firm with the instrument 15 Remove the safety washer the pinion and the spacer ...

Page 158: ...xing pin support the positive valve gear 17 see previous figure to avoid it falling Rotate the gear flange external side above Unscrew and remove the drum fixing pin 18 Remove the posiive valve gear 17 see previous figure and the gear selector drum 19 WARNING Make sure that the peg 20 is well inserted into its seat Unscrew and remove the threaded pin 21 and the the gear fixing assembly 22 the wash...

Page 159: ...ary change them NOTE It is necessary to remove plate 3 working on screws 4 to change the ball bearings 1 and 2 5 9 4 CHECK FORK GEAR AND SLIDE RODS The following procedure must be carried out on all the fork gears Check the state of elements 1 and 2 shown in the figure and if necessary change them Check the free movement of the fork on the slide rod ...

Page 160: ...essary change the element 5 9 5 CHECK POSITIVE GEAR SHAFT VALVE Check the state of the positive gear shaft valve guide If necessary change it 5 9 6 CHECK PRIMARY AND SECONDARY SHAFT Check wear and eventual breaks on the primary shaft 1 and the secondary shaft 2 and their components If necessary change the component the components or the entire shaft ...

Page 161: ...r flange on the apposite support external side above Position the gear fixing spring i in the appropriate hole Position the washer 2 and the gear fixing spring 3 and fix with the threaded pin 4 Tighten 10 N m 1 Kg m Position pin 5 onto the positive valve gear shaft with the appropriate instrument and the two liners 6 of 0 2 mm each ...

Page 162: ...g it with a suitable support NOTE Check while mounting the gear selector drum that the two elements shown coincide Fix the drum 7 with the threaded pin 8 and tighten NOTE Once pin 8 is tightened it is possible to remove the support previously positioned under the positi ve valve gear shaft 10 N m 1 Kg m LOCTITE 243 ...

Page 163: ...9_UK T T T T L I M I T E D E D I T I O N Mount springs 10 and push rods 11 onto the flange 9 Position the pawls 12 Position the stop plate 13 Position the pre mounted pin complete with sprocket wheel and pawl 15 ...

Page 164: ...ITE 243 Position the pre mounted pin 15 10 N m 1 Kg m LOCTITE 243 Rotate the flange on the support internal side above Couple the primary and secondary shafts Position them as shown in the figure Rotate the flange external side above WARNING Support the primary and secondary shafts because they are loose ...

Page 165: ... L I M I T E D E D I T I O N Position the O Ring 16 on the secondary shaft Position the spacer 17 with its minor dimension outwards Position the pinion 18 the safety washer 19 and the nut 20 Tighten the nut 140 N m 14 Kg m ...

Page 166: ...t selector 22 as indicated in the figure Position the two forks 23 on the secondary shaft and fork 24 on the primary shaft NOTE Forks 23 are greater in diameter than fork 24 Insert the two slide rods 25 Insert the two washers 26 into the hole of the rod and fix them with screws 27 and tighten Position the ferrule onto the sprocket wheel pin 28 10 N m 1 Kg m LOCTITE 243 ...

Page 167: ...already pre mounted as shown in the figure Insert the oil seal 31 onto the gear command cover with the appropriate instrument Insert the two centering dowels and the specific instrument 32 Mount the gasket 33 Mount the cover 30 and push it down until the instrument 32 has completed emerged ...

Page 168: ... 9 8 MOUNT GEARS WARNING While mounting the gears make sure that they are in fourth gear to avoid breaking the neutral sensor Otherwise remove the neutral sensor before re mounting the gears Insert the sealing O Ring and the gears 1 and tighten the screws 2 according to the order indicated 20 N m 2 0 Kg m ...

Page 169: ...10 1 DISMANTLE OIL SUMP Unscrew and remove the oil discharge cap 1 and the copper gasket beneath Unscrew and remove the twelve screws 2 and remove the oil sump 3 5 10 2 DISMANTLE OVERPRESSURE OIL VALVE Remove the oil sump see DISMANTLE OIL SUMP Remove the overpressure oil valve 1 ...

Page 170: ...ove the primary asembly see REMOVE PRIMARY ASSEMBLY Remove the safety ring 1 and the toothed wheel 2 Unscrew and remove the three screws 3 and extract the oil pump 4 5 10 4 DISMANTLE OIL PUMP Remove the oil pump shaft 1 complete with internal rotor 2 Remove the external rotor ...

Page 171: ...breaks on the oil sump eventually changing it Check the presence of foreign bodies on the suction filter 2 eventually cleaning it Check the state of the filter 2 If damaged substitute the piece working on screws 3 5 10 6 CHECK OIL PUMP Check that the pump body 1 and the toothed wheel 2 are not damaged or excessively worn If necessary change the element or elements ...

Page 172: ...thin the specific value otherwise change the oil pump 1 Internal rotor 2 External rotor 3 Pump body VALUE LIMIT a 0 25 mm max b 0 2 mm max 5 10 7 ASSEMBLE OIL PUMP Position the pin 2 in the shaft 1 Insert the internal rotor 3 and the 1 mm liner clearance and block with the safety ring 4 Position the shaft inside the body 5 as indicated in the figure ...

Page 173: ...the two rotors abundantly 5 10 8 MOUNT OIL PUMP Insert the oil pump from the right with the specific instrument until it touches as in the figure Insert the centering dowel Fix with the three screws 7 and tighten 8 5 N m 0 85 Kg m LOCTITE 243 Insert the toothed wheel 8 and fix with the elastic ring 9 ...

Page 174: ...LOCTITE 243 5 10 10 MOUNT OIL SUMP WARNING Aways use new gaskets Apply THREEBOND 1215 sealing paste to the casing surface and oil sump Position the O Ring 1 on the casing Position the two centering dowels on the base Position the sump 2 and tighten the discharge cap 3 22 N m 2 2 Kg m Tighten according to the order indicated in the figure 10 N m 1 Kg m ...

Page 175: ...p see DISMANTLE OIL PUMP Remove the water pump see DISMANTLE WATER PUMP Remove the gears see ADJUSTMENT PHASE Remove the exchanger see WATER OIL EXCHANGER Remove the counter shaft cover 1 unscrewing the four screws 2 Remove the stop plate 3 unscrewing the two screws 4 WARNING Note the position of the screws for correct re mounting Remove the five screws 5 indicated in the figure upper part of the ...

Page 176: ...UK 176 MF9_UK T T T T L I M I T E D E D I T I O N Remove the five screws 6 Remove screw 7 Remove the two screws 8 ...

Page 177: ...UK 177 MF9_UK T T T T L I M I T E D E D I T I O N Remove screw 9 Remove the two screws 10 Loosen and remove screw 11 ...

Page 178: ...I T E D E D I T I O N WARNING Take note of the position of the screws for correct re mounting Remove the nine screws 12 indicated in the figure lower part of the engine Remove the lower base 13 Remove the large plastic lock nut 14 ...

Page 179: ...M I T E D E D I T I O N Remove the ring 15 Remove the balancing counter shaft 16 Remove the engine shaft 17 WARNING Take note of the position of the bronze bearings for correct re mounting Remove the four semi bronze bearings 18 ...

Page 180: ...UK 180 MF9_UK T T T T L I M I T E D E D I T I O N Remove the drainage tube stop plate 19 Remove the drainage tube 20 Remove the ball bearings 21 and 22 Remove screw 23 and plate 24 freeing the pin 25 ...

Page 181: ... D I T I O N Support the satellite gear 27 and take off the pin 26 as shown in the figure Unscrew and remove screw 28 washer 29 and the female flexible coupling 30 Support the toothed wheel 31 and remove pin 32 Remove the toothed wheel 31 ...

Page 182: ...UK 182 MF9_UK T T T T L I M I T E D E D I T I O N Remove the spacer 33 Remove the free wheel 34 5 11 2 DISMANTLE FREE WHEEL Remove the elastic safety ring Remove the washer 1 ...

Page 183: ...UK 183 MF9_UK T T T T L I M I T E D E D I T I O N Remove the toothed wheel 2 Remove the roller cage 3 Remove the screws 4 ...

Page 184: ...4 MF9_UK T T T T L I M I T E D E D I T I O N Dismantle the free wheel 5 11 3 DISMANTLE BALANCING COUNTER SHAFT Remove the circlip 1 Remove the ball bearing 2 and the toothed wheel 3 Remove the ball bearing 4 ...

Page 185: ...ing procedure must be applied to all the connecting rods mounted on the engine shaft Unscrew and remove screws 1 Remove the connecting rod 2 from the engine shaft 3 5 11 5 CHECK CASING Check the presence of any breaks on the upper and lower casing eventually changing the casings always coupled Check the free rotation of the ball bearings changing them if necessary ...

Page 186: ...ry 5 11 6 CHECK ENGINE SHAFT AND CONNECTING ROD Check eventual breaks or excessive wear on the whole engine shaft 1 Change the piece if necessary Check the eccentricity of the engine shaft at the points indicated in the figure If the eccentricity does not enter within the specific value change the piece VALUE LIMIT ECCENTRICITY 0 030 mm ...

Page 187: ...nd on the two semi bronze bearings 5 11 7 CHECK BALANCING COUNTER SHAFT Check the eventual presence of breaks on the balancing counter shaft Check the free rotation of the ball bearings Check eventual breaks or excessive wear on the toothed wheel If necessary change the elements or the entire balancing counter shaft ...

Page 188: ... T I O N 5 11 8 CHECK FREE WHEEL Check eventual breaks wear and slippage on the free wheel Change the element if necessary 5 11 9 ASSEMBLE FREE WHEEL Assemble the two elements as shown in the figure Tighten screws 1 17 N m 1 7 Kg m LOCTITE 270 ...

Page 189: ...UK 189 MF9_UK T T T T L I M I T E D E D I T I O N Position the roller cages 2 Positon the toothed wheel 3 Position the washer 4 and fix with the circlip ...

Page 190: ...g for the coupling is turned towards the front of the engine WARNING Always change the connecting rod screws after each dismantling Oil the thread and the diameter under the flanging of the fixing screws 3 with the recommended oil Tighten the fixing screws 3 slightly RECOMMENDED OIL MOLIKOTE CU7439 PLUS copper grease CONNECTING ROD BRONZE BEARINGS SELECTION TABLE TYPE COLOUR Ø CONNECTING ROD HEAD ...

Page 191: ...e shaft on the upper semi casing Tighten screws 3 in three phases 1st 15 N m 1 5 Kg m 2nd 25 N m 2 5 Kg m 3 rd 50 5 11 11 MOUNTAGGIO BALANCING COUNTER SHAFT Position the ball bearing 1 and fix with the circlip 2 Position the roller ball bearing 3 on the counter shaft 4 ...

Page 192: ... 5 11 12 MOUNT CASING Position the roller cage 1 block it with washer 2 and fix with screw 3 tightly 10 N m 1 Kg m LOCTITE 243 Position the ball bearing 4 with the apposite pad and fix with the circlip 5 Position the liner 6 as indicated in the figure ...

Page 193: ...ion the free wheel 7 as shown in the figure Position the toothed wheel 8 and insert pin 9 until touching in the direction in the figure Position the washer 11 in the female flexible coupling housing and fix with screw 12 tightly 25 N m 2 5 Kg m LOCTITE 270 ...

Page 194: ...T T T L I M I T E D E D I T I O N Position the toothed wheel 13 as shown in the figure Position pin 14 until touching as indicated in the figure Position plate 15 and fix with screw 16 tightly 10 N m 1 Kg m LOCTITE 243 ...

Page 195: ... the two elements shown as in the figure Position ball bearings 17 and 18 WARNING Position element 19 as shown in the figure Position the drainage tube until touching 19 Position the tube retaining plate and ball bearing 20 and fix with screws 21 tightly 10 N m 1 Kg m ...

Page 196: ... BEARING STD COLOUR SELECTION A Red 1 918 1 922 B Blue 1 922 1 926 C Yellow 1 926 1 930 Ø seat std A red 41 830 41 836 Ø seat std B blue 41 836 41 843 Ø seat std C yellow 41 843 41 849 Ø single std shaft 37 960 37 970 CONNECTING ROD SEMI BALL BEARING STD COLOUR SELECTION A Red 1 660 1 684 B Blue 1 684 1 688 C Yellow 1 688 1 692 Ø seat std A red 40 395 40 401 Ø seat std B blue 40 401 40 407 Ø seat ...

Page 197: ...ransmission chain side Position the four semi bronze bearings 25 each slotted with the correct colour associated with its letter stamped on the outside of the casing 24 centering them with the tooth in the cable LETTER COLOUR A Red B Blue C Yellow Position the engine shaft 26 as in the figure Position the balancing counter shaft 27 ...

Page 198: ...Make sure that the toothed wheels of the balancing counter shaft and the engine shaft are as shown in the figure Position ring 28 Position the large cap 29 one per side in the apposite seats Put THREEBOND 1215 on the contact surfaces of the two casings ...

Page 199: ...30 on the upper WARNING Follow the mounting phases correctly Position screws 31 and tighten in three phases according to the order stamped on the casing 1st 10 N m 1 Kg m 2nd 20 N m 2 Kg m 3rd 37 N m 3 7 Kg m Tighten screws 32 in two phases 1st 10 N m 1 Kg m 2nd 25 N m 2 5 Kg m ...

Page 200: ...UK 200 MF9_UK T T T T L I M I T E D E D I T I O N Tighten screws 33 according to the order in the figure 10 N m 1 Kg m Tighten screw 34 10 N m 1 Kg m Tighten the two screws 35 10 N m 1 Kg m ...

Page 201: ...UK T T T T L I M I T E D E D I T I O N Tighten screw 36 10 N m 1 Kg m Tighten the two screws 37 in two phases 1st 10 N m 1 Kg m 2nd 25 N m 2 5 Kg m Tighten screw 38 in two phases 1 10 N m 1 Kg m 2 25 N m 2 5 Kg m ...

Page 202: ...n balancing counter shaft ball bearing stop plate 40 and fix with the two screws 41 tightly 10 N m 1 Kg m WARNING Always use new gaskets Apply THREEBOND 1215 sealing paste on the surfaces of the casing and the cover Position the gasket and the counter shaft cover 42 Tighten the screws 43 10 N m 1 Kg m ...

Page 203: ...NT BOARD FASTENINGS Remove the lower semi cowling see DISMANTLE LOWER COWLING Remove the upper semi cowling see DISMANTLE UPPER COWLING Remove the tailpiece see DISMANTLE TAILPIECE Remove the air box conduits see DISMANTLE AIR BOX Remove the radiator conduits see DISMANTLE RADIATOR Unscrew the screw on the water pump 1 to purge the radiator liquid 2 positioning a recipient to collect the liquid Di...

Page 204: ...D I T I O N Unscrew the two small bands 8 and 9 of the send and return radiator tubes 10 and 11 Remove the expansion tank unscrewing the two fixing screws 13 and 14 Remove the relay support rod 15 unscrewing the two fixing screws 16 and 17 ...

Page 205: ...E D E D I T I O N Remove the fixing screw of the expansion tank support plate 19 and the radiator box Remove the rear brake oil tank 20 unscrewing screw 21 taking care not to upset it Remove the radiator box fixing screw 22 right side ...

Page 206: ...he central radiator box fixing screw 23 Press lightly on the radiator box in the engine forward direction to unhook it Take the radiator box off 6 1 2 DISMANTLE RADIATOR BOX Position the radiator box on a surface with the cap upwards Unscrew the seven screws 1 ...

Page 207: ...UK 207 MF9_UK T T T T L I M I T E D E D I T I O N Rotate the radiator box and unscrew the screws 2 Unscrew the last four screws 2 Unhook the fan body 3 and extract the radiator 4 ...

Page 208: ...ator if necessary Check the state of the radiator entry and exit tubes Change the elements if necessary Check the radiator tap seal 1 checking that it is not damaged 6 1 4 MOUNT RADIATOR Reverse the operations described in the dismantling procedu re Pour the refrigerant liquid into the the cooling plant see CHANGE REFRIGERANT LIQUID ...

Page 209: ...iquid refrigerant circuit see CHANGE LIQUID REFRIGERANT Remove the engine oil filter 1 see REMOVE OIL FILTER Disconnect the entry and exit connectors A and B NOTE Take care not to lose the clearance Loosen and remove screw 2 and remove the exchanger 3 Check that the exchanger is not damaged otherwise change the element Check that there are no breaks in the entry and exit tubes Change the damaged e...

Page 210: ...l the O Ring on the exchanger 1 Position the exchanger 1 as in the figure WARNING Always re mount the clearance element Insert the clearance element 2 before the connector to screw 3 Tighten screw 3 in two phases 1st phase 30 N m 3 Kg m 2nd phase 60 N m 6 Kg m Use LOCTITE 243 ...

Page 211: ...e the lacking oil into the engine Remount the exhaust plant Remount the wheel housing Remount the semi cowling 6 3 THERMOSTAT 6 3 1 DISMANTLE THERMOSTAT WARNING Always use new gaskets and oil seals Remove the refrigerant liquid from the cooling circuit see CHANGE REFRIGENRANT LIQUID Remove the tubes 1 loosening the bands 2 Loosen and remove the two screws 3 and remove the thermostat cover 4 ...

Page 212: ... maximum opening of 7 mm at 90 C as shown in the diagram in the figure Check the above conditions by immersing the thermostat 1 in a container with water Slowly heat the water and check the temperature with a thermometer 2 Change the thermostat if necessary Check that the thermostat cover and the tubes connected to it are not broken otherwise change the damaged element ...

Page 213: ...ards as in the figure Position ithe thermostat 1 as indicated in the figure Position the thermostat cover 3 and tighten with the two screws 4 il coperchio termostato 3 e fissare con le due viti 4 10 N m 1 Kg m Position thei tubes 5 and tighten with the bands 6 Reinsert the refrigerant liquid into the cooling circuit see CHANGE REFRIGERANT LIQUID ...

Page 214: ...erant liquid from the cooling circuIt CHANGE RERIGERANT LIQUID Remove the two entry and exit tubes 1 in the pump 2 6 4 2 DISMANTLE WATER PUMP Loosen and remove the two screws 4 and the small plates 5 Remove the entry elbow 6 Loosen and remove the two screws 3 and remove the water pump Remove the l O Ring 7 ...

Page 215: ...UK 215 MF9_UK T T T T L I M I T E D E D I T I O N Loosen and remove the two screws 8 Remove the cover 9 Loosen and remove the nut 10 and remove the rotor 11 ...

Page 216: ...T L I M I T E D E D I T I O N Remove the external circlip 12 the internal circlip 13 and the ball bearing beneath Remove the liner 14 the shaft 15 the ball bearing 16 and the oil seal beneath Remove the mechanical seal 17 ...

Page 217: ... the various components of the pump Check that the various elements are not broken Change worn or damaged elements if necessary 6 4 4 ASSEMBLE WATER PUMP Position the pump body 1 on a support WARNING The oil seal must be inserted downwards with the lip closed Position the oil seal until it touches 2 ...

Page 218: ...MF9_UK T T T T L I M I T E D E D I T I O N Grease the shaft 4 at the points indicated in the figure Position the shaft 4 inside the pump body 1 Position the first ball bearing 5 using a press to make it touch ...

Page 219: ...UK 219 MF9_UK T T T T L I M I T E D E D I T I O N Position the liner 6 Position the second ball bearing 7 using a press to make it touch Fix the ball bearings with the external 8 and internal 9 circlips ...

Page 220: ...nting the counterface and the mechanical seal make sure that they are clean and bear no traces of grease Position the counterface as in the figure 10 Position the mechanical seal 11 until it touches as shown in the figure Position the rotor 12 making it meets clutch A ...

Page 221: ...ling washer 13 and fix it tight with the nut 14 8 N m 0 8 Kg m Always use LOCTITE 243 Position the cover and lock it tight with the two screws 15 10 N m 1 Kg m Position the sealing washer 16 and tightly screw the purge screw 17 up 10 N m 1 Kg m Always use LOCTITE 243 ...

Page 222: ...ing 18 on the pump body Position the entry elbow 19 and fix with the two small plates 20 and the two screws 21 tightly 10 N m 1 Kg m 6 4 5 MOUNT WATER PUMP Position the pump 1 as in the figure and screw the two screws 2 up tightly 10 N m 1 Kg m Always use LOCTITE 243 ...

Page 223: ...UK 223 MF9_UK T T T T L I M I T E D E D I T I O N Reposition the entry and exit tubes 3 of the pump tightening the two bands 4 Restore the level of the liquid in the circuit see CHANGE COOLING LIQUID ...

Page 224: ...UK 224 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 225: ...pport suitable to sustain the bike without the front wheel Loosen the four fork clamp screws 1 Loosen and remove the brake clamp fixing screws 2 on both sides Loosen and remove the wheel pin screw 3 WARNING Note the position of the elements for correct re mounting WARNING During the following operation prevent the left spacer falling Remove the pin 4 Remove the front wheel ...

Page 226: ...lacement 0 3 mm Check the state of wear of the disk with a gauge If the value of the liner A does not enter within the specific value change the piece SPECIFIC VALUE A 4 5 mm 7 1 3 DISMANTLE FRONT WHEEL WARNING During the following procedure prevent the internal spacer falling if dismantling the ball bearings is envisaged Remove the six disk 2 fixing screws 1 Remove the disk 2 end the ball bearing...

Page 227: ...displacement of the two cylindrical zones A and B with respect to one another with a comparator The lateral displacement cylindricity error must enter within the specific value If the lateral displacement value does not enter within the specific value change the piece SPECIFIC VALUE 0 05 mm 7 1 5 MOUNT FRONT WHEEL WARNING Before mounting the ball bearings identify correctly the right and left side...

Page 228: ...isk 22 N m 2 2 Kg m Grease thread 7 1 6 INSTALL FRONT WHEEL WARNING After each operation on the bike it is advisable to balance it WARNING While installing the wheel pay attention to the direction of mounting Position the front wheel and the left co axial spacer 1 in their respective housing holes on the fork and insert the wheel pin from the right ...

Page 229: ... thread Tighten the four screws 3 of the fork clamps Mount the brake clamps 30 N m 3 Kg m Grease the thread Clamp screws 50 N m 5 Kg m Grease the thread Brake clamp screws 7 2 REAR WHEEL BRAKE DISK AND CROWN 7 2 1 REMOVE REAR WHEEL Position the bike on the supplied rear assembly stand 1 ...

Page 230: ...5 Remove the wheel 7 2 2 CHECK REAR BRAKE DISK WARNING The following procedure must be carried out with the disk mounted on the wheel Check the lateral displacement of the brake disk with a comparator The lateral displacement must enter within the specific value If the value of the displacement does not enter within the specific value change the piece SPECIFIC VALUE Lateral displacement 0 3 mm ...

Page 231: ...ce SPECIFIC VALUE A 4 5 mm 7 2 3 DISMANTLE REAR WHEEL Loosen and remove the five brake disk fixing screws 1 Remove the brake disk 2 Change the brake disk fixing screws Remove the right spacer 3 extracting it from the wheel Loosen and remove the five disk holder flange fixing screws 4 Remove the disk holder flange 5 Change the disk holder flange fixing screws 4 at every dismantling ...

Page 232: ...ring the following operation prevent the internal spacer falling if dismantling the ball bearings is envisaged Remove the five flexible couplings 7 Remove the circlip 9 Extract the ball bearings 8 on both sides This operation is to be carried out exclusively if required by the maintenance plan or if the ball bearing could be the source of malfunctioning Once dismantled the ball bearings must be ch...

Page 233: ...enter within the specific value change the piece Check the cylindricity of the rear wheel pin SPECIFIC VALUE A 0 05 mm WARNING Do not try to straighten a bent pin Check the lateral displacement of the cylinder zone A with a comparator This lateral displacement cylindricity error must enter within the specific value If the value of the displacement does not enter within the specific value change th...

Page 234: ...hange them 7 2 6 CHECK CROWN Sight check that the crown 1 is not broken and that the teeth are not excessively worn Change the crown the pinion and the chain if necessary 7 2 7 MOUNT REAR WHEEL WARNING Identify correctly the left and right of the wheel based on the sense of rotation before mounting the ball bearings ...

Page 235: ...sert the internal spacer from the right side and push the right side ball bearing in until it touches Position the five flexible couplings in the correct seats 3 Position the crown 4 on the flange 5 and fix it with the nuts 6 tightening then according to the order indicated 45 N m 4 5 Kg m Grease thread Position the flange 5 on the wheel 7 ...

Page 236: ...all bearing 22 N m 2 2 Kg m with LOCTITE 243 Positiona the disk 11 and tighten the five screws 10 according to the order in the figure 22 N m 2 2 Kg m Grease thread 7 2 8 INSTALL REAR WHEEL WARNING It is advisable to balance the wheel after every operation on the wheel Position the wheel 1 Position the right chain stretcher plate 2 and insert the pin 3 from the right with the head on the right sid...

Page 237: ...ed before proceeding to remove the pump Position the end of a tube of suitable diameter at the purge screw 1 of a front brake clamp and the other end in a suitable recipient Open the purge screw 1 and empty the braking liquid Do the same thing with the opposite clamp NOTE To help empty the liquid open the liquid tank cap and work on the front brake lever repeatedly WARNING Place a rag under the co...

Page 238: ...le diameter at the purge screw 1 and the other end in a suitable recipient Open the purge screw 1 and empty the braking liquid Do the same thing with the opposite clamp NOTE To help empty the liquid open the liquid tank cap and work on the rear brake lever repeatedly Dismantle the footrest see DISMANTLE FOOTREST First loosen the idrostop 2 making sure not to twist the wires of the relative cabling...

Page 239: ...il the latter is completely unscrewed Remove the idrostop Remove the entire tank pump 7 3 3 CHECK FRONT AND REAR BRAKE PUMP Check that the front and rear brake pumps are not damaged If necessary change the damaged pump Check that the front and rear brake pumps are not obstructed If necessary eliminate the obstruction with a jet of compressed air ...

Page 240: ...tly with screw 5 on the connector 15 N m 1 5 Kg m 7 3 5 INSTALL REAR BRAKE PUMP Connect the cap 1 of the brake pedal pump and tighten the screw 3 10 N m 1 Kg m WARNING Always change the braking plant sealing gaskets Fix the eye of 5 of the brake tube to the pump using the idrostop and the two gaskets 6 Rotate the pump to tighten the idrostop 4 Tighten the idrostop keeping the brake tube in the cor...

Page 241: ...ule 9 with screw 10 Mount the footrest see MOUNT FOOTREST 4 N m 0 4 Kg m 7 3 6 DISMANTLE FRONT BRAKE PLANT TUBES Position the end of a tube of suitable diameter at the purge screw 1 of a brake clamp and the other end in a suitable recipient Open the purge screw 1 and empty the braking liquid NOTE To help empty the liquid open the liquid tank cap and work on the rear brake lever repeatedly ...

Page 242: ...amp support and position it under the brake pump Position the end of a tube of suitable diameter at the purge screw 1 of a brake clamp and the other end in a suitable recipient Open the purge screw 1 and empty the braking liquid Remove the brake tube 2 from the clamp 3 unscrewing screw 4 NOTE To help empty the liquid open the liquid tank cap and work on the rear brake lever repeatedly Dismantle th...

Page 243: ...9 MOUNT FRONT BRAKE TUBES PLANT WARNING Always change the sealing gaskets at every dismantling Position the brake plant tubes with the T 1 connector on the right side of the vehicle Fix the tubes with the connector screws and the sealing gaskets tightly two on the clamp and one on the pump 15 N m 1 5 Kg m Restore the level of the braking liquid and purge the plant see PURGE BRAKING PLANT ...

Page 244: ...king liquid and purge the plant see PURGE BRAKING PLANT 7 3 11 DISMANTLE FRONT BRAKE CLAMPS WARNING Always change the sealing gaskets at every dismantling Remove the front brake clamp from the clamp support and position it under the brake pump Position the end of a tube of suitable diameter at the purge screw 1 of a brake clamp and the other end in a suitable recipient Open the purge screw 1 and e...

Page 245: ...ove the rear brake clamp from the clamp support unscrewing the two screws and position it under the brake pump Position the end of a tube of suitable diameter at the purge screw 1 of a brake clamp and the other end in a suitable recipient Open the purge screw 1 and empty the braking liquid NOTE To help empty the liquid open the liquid tank cap and work on the rear brake lever repeatedly Loosen and...

Page 246: ...ow losses If necessary change the damaged element 7 3 14 MOUNT FRONT BRAKE CLAMP Position the right 1 and left 2 brake clamps Tighten screws 3 Position the brake tubing on the two clamps and on the pump 50 N m 5 Kg m Tighten screws 4 15 N m 1 5 Kg m Restore the level of the braking liquid and purge the front plant see PURGE BRAKING PLANT ...

Page 247: ... MOUNT REAR BRAKE CLAMP Tighten the connector screw 1 on the clamp 2 15 N m 1 5 Kg m Restore the level of the braking liquid and purge the rear plant see PURGE BRAKING PLANT Position the clamp 2 on the clamp support 3 Tighten the two screws 4 22 N m 2 2 Kg m ...

Page 248: ...left lower cowlings see REMOVE LOWER COWLINGS Remove the front wheel 3 see REMOVE FRONT WHEEL Loosen and remove the two screws 4 and free the clamp 5 Repeat the operation on the opposite clamp as well Remove the upper steering plate see DISMANTLE STEERING PLATE SPECIFIC INSTRUMENTS Alan wrench 20 R180197033000 Remove the right semi handlebar see REMOVE RIGHT SEMI HANDLEBAR Remove the left semi han...

Page 249: ...FICATIONS chapter with regard to checking the stems and linings 7 4 3 INSTALL FORK LININGS WARNING Do not damage the surfaces of the linings WARNING The stem must be mounted with the brake clamp holder support towards the inside of the vehicle Insert from under the lining right 1 and left 2 without tightening the screws 3 ...

Page 250: ...MOUNT LEFT SEMI HANDLEBAR Position the upper steering plate 4 and adjust the stems according to specific value A SPECIFIC VALUE A 1 mm Tighten the screws 5 one for each stem 25 N m 2 5 Kg m Tighten the steering plate central screw 6 60 N m 6 Kg m Tighten the six screws 3 three for each stem Position the front wheel see MOUNT FRONT WHEEL 12 N m 1 2 Kg m ...

Page 251: ...two screws 8 Do the same with the opposite brake clamp 50 N m 5 Kg m 7 5 SEMI HANDLEBARS 7 5 1 REMOVE RIGHT SEMI HANDLEBAR Remove the upper steering plate see DISMANTLE STEERING HEAD Loosen and remove the two screws 2 and free the front brake pump 3 Remove the gas command using the two screws beneath ...

Page 252: ...the right semi handlebar off upwards 7 5 2 REMOVE LEFT SEMI HANDLEBAR Disconnect the micro clutch connector 1 taking the rubber cap off first Loosen and remove the two screws 2 and free the clutch command 3 Disconnect the cabling of the left lights command Loosen and remove screw 4 and take the left semi handlebar off upwards ...

Page 253: ...ing plate 5 see MOUNT STEERING HEAD 7 5 3 DISMANTLE RIGHT SEMI HANDLEBAR Remove the right semi handlebar see REMOVE RIGHT SEMI HANDLEBAR Remove the start command block 1 using the two screws beneath it Separate the semi handlebar rod 2 from the support 3 unscrewing screw 4 ...

Page 254: ...BAR Remove the handle Remove the block 1 unscrewing the two fixing screws under it Separate the semi handlebar rod 2 from the support 3 unscrewing screw 4 7 5 5 CHECK RIGHT SEMI HANDLEBAR WARNING Do not try to straighten the semi handlebar rod Check that the rod 1 and the support 2 are not damaged or bent Change the damaged element if necessary ...

Page 255: ...AR WARNING Do not try to straighten the semi handlebar rod WARNING During the assembly of the semi handlebar make the two signs coincide as shown in figure A Assemble the semi handlebar rod 1 with the support 2 Fix with screw 3 without tightening it 7 5 8 MOUNT LEFT SEMI HANDLEBAR WARNING During the assembly of the semi handlebar make the two signs coincide as shown in figure A Assemble the semi h...

Page 256: ...I HANDLE Position the ignition block 1 and tighten the two fixing screws Position the gas command 2 and fix with the two fixing screws Position the right semi handlebar 3 Position the front pump brake 4 and fix it with the two screws 5 Connect the ignition command connector ...

Page 257: ...m 0 6 Kg m Tighten the plate lining assembly screw 8 30 N m 3 Kg m 7 5 10 INSTALL LEFT SEMI HANDLEBAR Position the lights block 1 on the semi handlebar 2 WARNING The longest screw must be positioned at the back of the block Position the semi handlebar on the stem Insert the steering plate see mount ...

Page 258: ...Connect the micro clutch connector 5 on the lever Tighten the semi handlebar screw 6 30 N m 3 Kg m Insert the handle 7 7 6 STEERING DAMPER 7 6 1 DISMANTLE STEERING DAMPER Loosen and remove the two fixing screws 1 and remove the steering damper 2 7 6 2 CHECK STEERING DAMPER Check that the damper does not show losses or damage Change the piece if necesary Do not try to straighten the slide rod ...

Page 259: ...see DISMANTLE STEERING Remove the two semi handlebar fixing screws 2 Remove the steering fixing screw 3 Loosen and remove the safety screw 4 of the two semi handlebars and remove the upper plate 5 Remove the fork stems see REMOVE FORK STEMS Warning Support the lower steering plate during the folllowing operation Loosen and remove the counter ring nut 6 Loosen and remove the ring nut 7 SPECIFIC EQU...

Page 260: ... T E D E D I T I O N Remove the dust cover 8 Remove the upper cowling pin 9 and the lower steering plate complete with pin 10 Remove the ball cage 11 and the upper and lower coupling pins inside the chassis Remove the ball cage 12 ...

Page 261: ...ERING PLATE Check that none of the components of the steering plate are broken Check that the steering roller cages are not excessively worn or broken Change the elements damaged or worn if necessary 7 7 3 MOUNT LOWER STEERING PLATE Carry out in reverse order to dismantling Tighten the ring nut 1 40 N m 4 Kg m Tighten the counter ring nut 2 Manual 90 ...

Page 262: ...fixing screw 3 60 N m 6 Kg m 7 8 REAR DAMPER 7 8 1 REMOVE REAR DAMPER Support the vehicle adequately Remove the rear wheel 1 see REMOVE REAR WHEEL Remove the lower semi cowling 2 see DISMANTLE SEMI COWLING Loosen and remove the right side rear fork fixing pin 3 of the bike ...

Page 263: ...the apposite instrument and loosen the adjustor 5 SPECIFIC EQUIPMENT Engine shoulder adjustment wrench R180197032000 Loosen and remove nuts 6 and relative screws Remove the rear fork pin 7 from the left side and lower the rear fork as far as possible extracting it from the damper and rotating it downwards ...

Page 264: ... and remove screw 9 Remove the rear damper 10 7 8 2 CHECK REAR DAMPER Apply to the direct supplier listed in the SPECIFICATIONS chapter with regard to checking the rear damper 7 8 3 MOUNT REAR DAMPER Operate in the reverse sense to dismantling Tighten the nut 1 50 N m 5 Kg m ...

Page 265: ...ster to touch 3 and tighten it 90 Tighten the ring nut inside the frame 40 N m 4 Kg m Insert the pin from the left side Tighten the rear fork fixing pin screw 4 Re mount the rear wheel see MOUNT REAR WHEEL Adjust the chain see ADJUST CHAIN Re mount the semi cowling see MOUNT SEMI COWLING 65 N m 65 Kg m ...

Page 266: ...owling 1 see DISMANTLE SEMI COWLING Remove the rear wheel 2 see REMOVE REAR WHEEL l Remove the chain 3 see DISMANTLE CHAIN Disconnect the mileage counter cabling connector Remove the brake clamp unscrewing the two fixing screws 4 Remove the oil guide tube unscrewing the two fixing screws 5 Loosen and remove the large fork pin fixing screw 6 ...

Page 267: ...267 MF9_UK T T T T L I M I T E D E D I T I O N Loosen the reaction ring nut 7 inside the chassis and loosen the adjustor 8 Loosen and remove nuts 9 and relative screws Undo pin 10 and remove the rear fork ...

Page 268: ...DISMANTLE REAR FORK COMPONENTS Loosen and remove the two screws Remove the chain casing 2 Loosen and remove the two screws 3 and remove the chain pad 4 Remove the ferrule 5 and the oil seal 6 Repeat the operation on the opposite part of the rear fork as well ...

Page 269: ...chain adjustment screw 10 and the locknut 11 Repeat the operation on the opposite part of the rear fork as well 7 9 3 CHECK REAR FORK Sight check the state of the rear fork change it if there are breaks Check the free rotation of the ball bearings 1 If necessary change them Check the state of wear of the chain pad If necessary change it Check the state of the chian adjustors If necessary change th...

Page 270: ... 7 9 4 MOUNT REAR FORK WARNING Always use new oil seals Proceed in the reverse manner to dismantling Tighten the assembly stand support screw 1 20 N m 2 Kg m Tighten the chain pad screws 2 10 N m 1 Kg m Tighten the chain casing screws 3 10 N m 1 Kg m ...

Page 271: ...RK Operate in the reverse manner to removal Bring the adjustor 1 to touch and tighten 90 Tighten the ring nut 2 inside the chassis 40 N m 4 Kg m Insert the pin from the left side Tighten the rear fork pin fixing screw 3 65 N m 6 5 Kg m Tighten the two nuts 4 50 N m 5 Kg m ...

Page 272: ...ee REMOVE UPPER COWLINGS Remove the lower cowlings see REMOVE LOWER COWLINGS Remove the instrument see REMOVE INSTRUMENT Remove the front headlight 1 see REMOVE FRONT HEADLIGHT Remove the band 2 and free the external temperature sensor 3 Loosen and remove the two nuts 3 and relative screws Remove the front frame 7 10 2 CHECK FRONT FRAME Sight check the state of the front frame Change the piece if ...

Page 273: ...ove right and left upper cowlings see REMOVE UPPER COWLINGS Remove right and left lower cowlings see REMOVE LOWER COWLINGS Remove the tailpiece see REMOVE TAILPIECE Remove the radiator box conduits see REMOVE RADIATOR BOX Loosen and remove the two screws 1 freeing the relay fixing plate 2 and disconnect the two radiator cap tubes 3 Loosen the five radiator box fixing screws without removing them l...

Page 274: ...m the electrical plant and the radiator cap tubes NOTE Always check the passage of the electrical plant and the radiator cap tubes before dismantling 7 11 2 CHECK REAR FRAME Sight check the state of the rear frame If necessary change the piece Do not attempt to straighten 7 11 3 INSTALL REAR FRAME Tighten the screws 1 25 N m 2 5 Kg m Tighten screw 2 25 N m 2 5 Kg m ...

Page 275: ... m Operate in the reverse manner to remove the remaining elements 7 12 TRANSMISSION CHAIN 7 12 1 REMOVE TRANSMISSION CHAIN Remove the transmission chain 1 with a link cutter 7 12 2 CHECK TRANSMISSION CHAIN Check that the chain is not excessively worn or excessively loose Change the chain if necesary Check that the chain does not have crushed or seized up links ...

Page 276: ...y disolve the dirt deposits on the chain using kerosene These deposits must be later removed with a clean rag or a jet of air Then oil the chain 7 12 3 INSTALL TRANSMISSION CHAIN Position the chain on the crown and on the pinion Unite the two ends of the chain 1 and 2 with the specific equipment Adjust the chain see ADJUST CHAIN ...

Page 277: ...re and therefore the density of the air are compensated by adjusting the quantity of fuel injected at a level conforming to clean combustion and low emissions Barometric pressure sensor the barometric pressure sensor is incorporated within the ECM and is connected to the air filter box by a flexible tube The barometric pressure sensor measures the pressure of the air in the air filter box The dens...

Page 278: ...the gears are in neutral or the clutch lever that has a switch is pulled up to the handle Clutch switch placed on the clutch lever The engine will not start until the lever is pulled up to the handle 8 1 3 POSITION OF THE SENSORS 1 Barometric pressure sensor Engine control module under the saddle 2 Clutch lever on the clutch lever 3 Suction air temperature sensor low in the air filter box 4 Coolin...

Page 279: ... ECM below the saddle of the vehicle When ignition takes place the main power relay is encouraged to supply a stable voltage to the ECM When turned off the ECM maintains the main power relay in such a way as to be able to accomplish the turning off procedure that includes Inserting the data in the ECM memory Supplying data about the position of the stepper engine of the air control valve Activatin...

Page 280: ...197036000 able to identify damage present or presenting itself on the bike This Software is supplied with a manual guide to the use of the programme in order to be able to carry out a check on every single component of the system The system can also be checked observing the operations desribed as follows 8 3 NUMBERING THE ECM CONNECTORS The diagram on the side shows the sequence of the two ECM con...

Page 281: ... diagram to the side shows the numbering of the pins as they appear on the connector The position of the ECM connectors is described in this manual through the identification of the connector 1 black or 2 grey followed by the row number and the column number in which it is situated In the example to the side pin 1 F2 is shown from the intersection of the lines ...

Page 282: ...gine Positions on connectors Battery Services injection connection sectioning Oil pressure sensor Engine shaft sensor Liquid thermistor Air thermistor Accelerator potentiometer Engine speed Water tempera ture Instrumentation 8 4 FUEL PUMP CHECKING SYSTEM Key OR Orange AZ Azure WH White BL Black BLU Blue YE Yellow RE Red PI Pnk GR Grey BR Brown GR Green VI Violet SK Sky blue ...

Page 283: ...pin 2 of the Pick up connector 8 5 SUPPLEMENTARY DIAGNOSIS The following tables if used correctly help to identify a fault in the system once the diagnostic code of the problem has been stored PHASE SENSOR ENGINE SHAFT MC 1000 ECM Instruction Check and note the data on the display of the diagnostic instrument see Axone instruction manual if available Make sure that the sensor is inserted correctly...

Page 284: ...cancel the fault code and start the engine to check that the fault has disappeared Instruction Check and note the data on the display of the diagnostic instrument see Axone instruction manual if available Check and note the data on the sensor of the diagnostic instrument see Axone instruction manual Make sure that the sensor is inserted correctly and the connector fixed well Disconnect the ECM and...

Page 285: ...lt OK Fault 2 Check the resistance value ECM pin 1 E1 at ECM pin 1 F1 ECM pin 1 E2 at ECM pin 1 F2 3 Check whether the cable is short circuited ECM Pin 1 E1 at the chassis ECM Pin 1 E2 at the chassis ECM Pin 1 F1 at the chassis ECM Pin 1 F2 at the chassis 4 Check the continuity of the cable ECM Pin 1 E1at pin A of the stepper connector ECMPin 1 E at pin B of the stepper connector ECM Pin 1 F2 at p...

Page 286: ...njector and proceed to test 3 Proceed to test 4 Disconnect the relative injector and proceed to test 5 Proceed to test 7 Locate and repair the cable fault proceed to test 7 Proceed to test 6 Locate and repair the cable fault and proceed to test 7 Result Ok Fault from15 5 a 16 3 Open circuit Short circuit Ok Short circuit Ok Open circuit Test 1 Check the integrity of the terminal and the cable ECM ...

Page 287: ... assistance Ok Short circuit from 15 5 to 16 3 Fault Ok The fault persists 5 Check the continuity of the cable for short circuiting ECM Pin 1 H4 at ECM pin 1 H3 injector 1 ECM Pin 1 H4 at ECM pin 1 H2 injector 2 ECM Pin 1 H4 atECM pin 1 G3 injector 3 6 Check the resistance of the relative injector injector pin 1 to injector pin 2 7 Reconnect the cabling cancel the fault code and activate the engin...

Page 288: ...test 3 Locate and repair the cable fault proceed to test 5 Proceed to test 4 Locate and repair the cable fault proceed to test 5 Change the position sensor of the throttle body group proceed to test 5 Locate and repair the cable fault proceed to test 5 Activity carried out terminate the test Contact the Benelli assistance Result OK Fault OK Short circuit OK Open circuit OK Short circuit OK The fau...

Page 289: ...test 3 Procedere al test 4 Disconnect the relative coil and proceed to test 5 Proceed to test 7 Locate and rectify the cable fault proceed to test 7 Proceed to test 6 Locate and rectify the cable fault proceed to test 7 Result OK Fault 0 8 Ù Open circuit Short circuit OK Short circuit OK Open circuit Test 1 Check the integrity of the terminal and the cable ECM pin 2 H1 ECM pin 2 H2 ECM pin 2 H4 2 ...

Page 290: ...f the ignition coil 7 Reconnect the cabling cancel the fault code and activate the engine to check the elimination of the fault Instruction Check and note the data on the display of the diagnostic instrument see Axone instruction manual if available Check and note the data on the sensor of the diagnostic instrument see Axone instruction manual Make sure that the connector is inserted correctly Dis...

Page 291: ...n circuit OK Short circuit OK Fault OK Short circuit OK Fault Test 1 Check the integrity of the terminal and the cable ECM pin 1 B2 ECM pin1 E4 2 Check the resistance value ECM pin 1 B2 to ECM pin 1 E4 depending on the temperature see below 3 Check the continuity of the cable ECM pin 1 B2 to sensor pin 2 ECM pin 1 E4 to sensor pin 1 4 Check the cabling for short circuiting pin 1 B2 al ECM pin 1 E4...

Page 292: ...E TEMPERATURE SENSOR MC 1000 ECM Instruction Proceed to test 2 Rectify the fault proceed to test 7 Disconnect the temperature sensor and proceed to test 6 Proceed to test 3 Disconnect the temperature sensor proceed to test 4 Proceed to test 5 Locate and rectify cable fault proceed to test 7 Proceed to test 5 Locate and rectify cable fault proceed to test 7 Result OK Fault OK Open circuit Short cir...

Page 293: ... Sensor pin 1 to sensor pin 2 depending on the temperature see below 6 Check the cabling for short circuiting EXM pin 1 D1 to the chassis 7 Reconnect the cabling cancel the fault code and activate the engine to check the elimination of the fault If the engine is hot remove the sensor and let it cool down beofre carrying out the test Resistance data Resistance value 1 6 a 1 8 KÙ 1 9 a 2 2 KÙ 2 3 a ...

Page 294: ...ify the cable fault proceed to test 5 Procedere al test 4 Locate and rectify the cable fault proceed to test 5 Procedere al test 5 Locate and rectify the cable fault proceed to test 5 Activity carried out terminate the test Contact the Benelli assistance Result OK Fault OK Short circuit OK Open circuit OK Short circuit OK Fault Test 1 Check the integrity of the terminal and the cable ECM pin 1 H1 ...

Page 295: ...ct the ECM proceed to test 3 Locate and rectify the cable fault proceed to test 4 Procee to test 4 Locate and rectify the cabling fault between the ECM and the sensors if the cabling is alright change the ECM Proceed to test 4 Activity carried terminate the test Contact the Benelli assistance Result OK Fault OK Short circuit from 4 5 to 5 5 v Fault OK Fault Test 1 Check the integrity of the termin...

Page 296: ...Alternator damaged high voltage Fault code P0560 P0562 P0563 VOLTAGE SUPPLY SENSOR MC 1000 ECM Instruction Proceed to test 2 Rectify the fault proceed to test 3 Proceed to test 3 Locate and repair the cable fault proceed to test 3 Activity carried out terminate the test Contact the Benelli assistance Result OK Fault The same through the battery voltage Less than through the battery voltage OK F au...

Page 297: ...test 3 Locate and rectify the cable fault proceed to test 5 Procedere al test 4 Locate and rectify the cable fault proceed to test 5 Proceed to test 5 Locate and rectify the cable fault proceed to test 5 Activity carried out terminate the test Contact the Benelli assistance Result Ok Fault Ok Short circuit Ok Open circuit Ok Short circuit Ok Fault persists Test 1 Check the integrity of the termina...

Page 298: ...repair the cable fault proceed to test 5 Proceed to test 4 Locate and rectify the cable fault proceed to test 5 Proceed to test 5 Locate and repair the cable fault proceed to test 5 Activity carried out terminate ithe test Contact the Benelli l assistance Result Ok Fault Ok Short circuit Ok Open circuit Ok Short circuit Ok Fault Test 1 Check the integrity of the terminal and the cable ECM pins 2 G...

Page 299: ...proceed to test 5 Proceed to test 3 Locate and repair the cable fault proceed to test 5 Proceed to test 4 Locate and rectify the cable fault proceed to test 5 Change the temperature indicator proceed to test 5 Locate and repair the cable fault proceed to test 5 Activity carried terminate the test Contact the Benelli assistance Result Ok Fault Ok Short circuit Ok Open circuit Ok Short circuit Ok Fa...

Page 300: ...4 Locate and rectify the cable fault proceed to test 6 Proceed to test 5 Locate and rectify the cable fault proceed to test 6 Change the rev counter proceed to test 6 Locate and rectify the cable fault proceed to test 6 Activity carried out terminate the test Contact the Benelli assistance Result Ok Fault Ok Short circuit 1 1 a 1 3 Ù Fault Ok Short circuit Ok Short circuit Ok Fault Test 1 Check th...

Page 301: ...UK 301 MF9_UK T T T T L I M I T E D E D I T I O N E E E E Electrical P P P P Plant 9 ELECTRICAL PLANT ...

Page 302: ... front arrow Licence plate light Dimmer stop Horn Fall sensor Diode modules Pink black Gi Pink Sectioning Intermittent light Idrostop Neutral Alternator Frame chassis Support Start relay Speed sensor Dimmer relay Injection relay Injection relay Pink Dazzle relay Safety relay KEY OR Orange AZ Azure WH White BL Black BLU Blue YE Yellow RE Red PI Pink GR Grey BR Brown VI Violet GR Green SK Sky blue ...

Page 303: ...k 6 GND speed sensor Blue Black 7 Supply speed sensor N C 8 Output speed sensor Blue 9 Tachymeter Grey Violet 10 Set Reset switch Violet Black A COLOURS 11 Level spyhole Brown Yellow 12 GND level spyhole Yellow Violet 13 Oil pressure sensor Violet 14 Water Temperature Brown Green 15 Injection alarm Pink Black 16 Right flashtlight Pink 17 Left flashlight Azure Blue 18 Neutral White Violet 19 Headli...

Page 304: ...block before disconnecting it and to press down completely when connecting On disconnecting the connector make sure to hold the body of the connector and not pull the wires Check whether the connector terminals are loose or bent Check whether the terminals are corroded or dirty 9 2 FUSES Always investigate the cause of a fuse burning out repair and then change the fuse Do not use a fuse with a cap...

Page 305: ...hecking instructions to the letter Failure to respect the correct procedure can cause grave damage 9 4 BATTERY WARNING Do not use batteries other that those specified The battery 1 mounted on this vehicle is the hermetic type There is no need therefore for maintenance The batteries advised are the following FIAMM F12 12B YUASA YT12B 4 Proceed to reload following the indications in the battery pack...

Page 306: ...h Check the voltage after 30 minutes from loading the voltage at the battery heads Voltage Ã 12 5 Volt 9 4 1 CHECK BATTERY EFFICIENCY Check battery current losses Bring the ignition switch to the OFF position Disconnect the cables of the negative pole of the battery Connect thel multitester between the negative pole and the negative cable of the battery in function of a continuous current ammeter ...

Page 307: ...e battery see electricity diagram NOTE In the case of eventually installing anti theft devices disconnect the latter before carrying out the checks Check load exit Dismantle the semi cowlings to get to the alterrnator zone Start the engine and make it spin at 2000 rev min with the lights switch ON and the selector on the dazzle position Hl Measure the DC voltage between the positive and negative t...

Page 308: ... under the saddle Open the fusebox cover to identify the position of the burned out fuse read the key placed under the cover and consult the electricity diagram 9 6 RELAYS 9 6 1 RELAY STARTER The relay starter 1 is on the left side of the engine inside the left semi cowliing Lights Red Orange White Petro pump Red White Orange Black Injection Red Orange Services Red Green Brown Electric fan Red Whi...

Page 309: ...Disconnect the supply cables on the battery Remove the starter relay see DISMANTLE RELAY Disconnect the suppy cables 1 on the engine starter 2 unscrew the engine starter fixing screws 3 and extract the component Check that the engine rotates freely without effort Otherwise change the piece Check the state of the O ring and if damaged change the piece NOTE Oil the O ring during mounting paying atte...

Page 310: ...ect the battery supply cables Disconnect the connector 2 lift the protective cap and unscrew the starter supply fixing nut 3 Unscrew the three fixing screws 4 and extract the alternator moving the water pump tube slightly and paying attention not to let the flexible rubber couplings fall To re mount it use the reverse procedure oiling the flexible couplings and the O rings Tighten the three screws...

Page 311: ...ry discharged Check the presence of the 12V on the connector relay between YE GR and black when the starter button is pressed Ignition switch defective Shut off engine switch defective Neutral switch defective Diode defective General relay defective Starter button defective Clutch lever position switch defective Contact connector defective Open circuit on the cabling Fuse damaged Voltage present C...

Page 312: ...heck what follows If the above conditions are satisfied the diode module is functioning 9 12 GEAR POSITION SWITCH The connector of the neutral switch wire is in the rear zone of the engine Disconnect the neutral switch wire and check the continuity between the NEUTRAL sensor wire and the chassis Tester prod Tester prod Resistance A B Ø Ù C B Ø Ù B A Ù B C Ù In the cae in which there is no continui...

Page 313: ...teral stand switch and measure the continuity as described below Check the continuity with a multitester as indicated in the table Stand PIN 1 PIN 2 Raised Lowered If the above conditions are satisfied the stand switch is functioning 9 14 CLUTCH SWITCH Disconnect the clutch switch cables Use a tester to check the following on the clutch switch pins Clutch PIN 1 PIN 2 Pulled Released ...

Page 314: ...sensor as described in the ENGINE chapter 2 Disconnect the connector 2 and check that the connector measures 10K betwen terminal A brown wire and B blue wire 9 16 OIL PRESSURE SENSOR To check the good functioning of this component the continuity between the contact on the sensor 1 and the chassis of the vehicle must be ascertained with the vehicle not running as shown in the figure On the contrary...

Page 315: ...SMANTLE LOWER COWLING Remove the upper left semi cowling see DISMANTLR LEFT AND RIGHT UPPER COWLING For the position lamp 3 remove the rubber lamp holder and change the lamp For the dimmer lamp 4 remove the rubber dust cover disconnect the cabling and change the lamp 4 freeing it from the spring 5 For the dazzle light 6 proceed in the same way as for the dimmer freeing the lamp 6 from the spring 7...

Page 316: ...g the dismantling proce dure Tighten screw 1 9 18 2 LICENCE PLATE LIGHT HOLDER Loosen and remove screw 1 Remove the rubber lamp holder Change the position lamp Position the lampholder and tighten screw 1 9 18 3 FRONT AND REAR ARROWS 9 18 3 1 FRONT ARROWS Loosen and remove screw 1 Remove the glass cover 2 ...

Page 317: ...i clockwise Position the arrow body 3 and the glass cover 2 and fix with screw 1 Operate in the same way with the opposite arrow 9 18 3 2 REAR ARROWS Loosen and remove screw 1 Remove the glass cover 2 and change the lamp Position the glass cover 2 and tighten screw 1 Operate in the same way for the opposite arrow ...

Page 318: ...UK 318 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 319: ...Starter damaged Change Starter button damaged Change Right electrical connection block Deoxidise Restore Relay starter damaged Change Power cable connections defective Deoxidise Restore COOLING PLANT Electric fan not functioning Electric fan fuse burnt Change Electric fan fuse connection defective Deoxidise Restore ECU defective Change H2 bulb Change H2 bulb connection defective Deoxidise Restore ...

Page 320: ...Repair Horn not functioning 10A engine fuse burnt Change 10A engine fuse connection defective Deoxidise Restore Horn damaged Change Switch damaged Change Horn connection defective Deoxidise Restore Switch connection defective Deoxidise Restore Direction indicators not functioning 10A engine fuse burnt Change 10A engine fuse connection defective Deoxidise Restore Intermittent light damaged Change I...

Page 321: ...Neutral sensor burnt Change Neutral sensor connection defective Deoxidise Restore Warning light burnt Change instrument board State of battery warning light does not light up Alternator connection defective Deoxidise Restore Instrument board damaged Change Instrument board connection defective Deoxidise Restore Warning light burnt Change instrument board Fuel reserve warning light does not light u...

Page 322: ...y relay connection defective Deoxidise Restore Injector damaged Change Injector connection defective Deoxidise Restore ECU injection damaged Change Lateral injection hanger damaged Change Pick up engine damaged Change Pick up light phonic wheel not exact Change Petrol pump damaged Change IGNITION PLANT Sparking plug spark absent Fuse burnt Change Fuse connection defective Deoxidise Restore Ignitio...

Page 323: ...nge Wheel not balanced Balance Tire defective Change Tire not suitable Change Wheel ball bearings damaged Tighten Pin fixing screws not tight Tighten Pin fixing ring nut not tight Tighten Front wheel rotates with difficulty Ball bearings damaged Change Wheel pin damaged Change Brake pads drag excessively on the disks see brakes Check Brake disks bent Change Wheel ring nut pin tightened excessively...

Page 324: ...sion insufficient Adjust Hydraulic brake in extension insufficient Adjust Tire pressure low Adjust Damper damaged Change Rear suspension too rigid Preload spring excessive Adjust Hydraulic brake in compression insufficient Adjust Hydraulic brake in extension insufficient Adjust Tire pressure high Adjust Rear wheel ball bearings damaged Change Suspension balancer ball bearings damaged Change Damper...

Page 325: ...d Change Fixing pipe loosened Tighten Poor engine performance Exhaust pipe damaged Change Fixing pipe loosened Tighten COOLING PLANT Engine temperature too high Cooling liquid level too low Refill Cooling fan defective Change Expansion tank cooling liquid cap defective Change Electric fan therrmo switch defective Change Sensor temperature instrument defective Change Thermostat blocked closed Chang...

Page 326: ... INJECTION 11 Press ENTER 12 The FRAME CODE menu is not defined press ENTER 13 From the PLANT TYPE menu select Sagem 14 Press ENTER 15 The VERSION Il menu is not defined press ENTER 16 Follow the instructions seen on the instrument and press ENTER 17 At this point the instrument is in communication with the console With the and keys it is possible to scroll the following menus identified by icons ...

Page 327: ... important in order to have a correct reading of the CO that the position of the stepper is at a value of about 30 40 steps as acting on the FUEL ADJUSTMENT AT MINIMUM value this parameter is modified automatically this parameter with the engine running is in continuous correction and it is very difficult to read a fixed value equal to 30 40 steps It is therefore sufficient that the fluctuations a...

Page 328: ...UK 328 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 329: ...ff gas vapours from the tank are directed into the EVAP cannister where they are absorbed and stored When the engine is running and the EVAP control valve is open the gas vapours contained in the Cannister are sent to the engine through the Stepper and burnt 11 2 CANNISTER POSITION It is severely forbidden to remove it maintenance is not envisaged In the case of loss of gas change the piece Check ...

Page 330: ... O N Disconnect the tube 3 connected to the gas tank Disconnect the tube 4 connected to the Stepper 11 4 CANNISTER CONNECTION Tube 1 connects the gas tank to the Cannister T connector 2 with connection tube 3 between the Cannister and the Stepper ...

Page 331: ...e European version 11 6 LIGHT COMMANDS The left light command is not equipped with an ON OFF switch To remove it use the same procedure as the European version 11 7 REAR CATADIOPTRICS Two catadioptrics 1 are positioned at the rear one to the left and one to the right To remove them dismantle the licence plate holder see DISMANTLE LICENCE PLATE HOLDER as in the European version ...

Page 332: ...on the left and one on the right In the case of removal change the element because it is fixed with double adhesive 11 9 REAR ARROWS The rear arrows 1 are not in carbon To remove them use the same procedure as in the European version The gas tank 2 is not in carbon To remove it use the same procedure as in the European version ...

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Page 334: ...UK 334 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 335: ...UK 335 MF9_UK T T T T L I M I T E D E D I T I O N ...

Page 336: ...UK 336 MF9_UK T T T T L I M I T E D E D I T I O N ...

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Benelli Tornado Tre Novicento 903, Workshop Manual

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