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Cagiva Navigator, Workshop Manual

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D.33

ENGINE

• Insert a bar of suitable size into the holes of the primary driving

gears to align the teeth of the scissors gears.

• Remove no. 1 valve motion idler gear/sprocket 4 and timing chain

5.

• Remove key 6.

• Remove neutral switch contact 1 and the related spring 2.

• While holding the generator rotor with a 36-mm spanner, remove

no. 1 valve motion idler gear/sprocket nut 3 and the related washer.

5

4

6

2

1

Summary of Contents for Navigator

Page 1: ...1 Workshop Manual NAVIGATOR Copyright by MVAGUSTA MOTORCYCLES S p A Via G Macchi 144 Schiranna 21100 VARESE ITALY 1st Edition Printed in Italy Print no 8A0095860 ...

Page 2: ...arify the nature of the problem Clearly identify the causes of the malfunction This manual provides the fundamen tals of troubleshooting which the operator will complete with his personal experience and the participation in the periodic training courses organized by CAGIVA Make a rational plan of the repair so as to avoid wasting time in collecting spares preparing tools etc Only perform the opera...

Page 3: ... serial number 2 on the lower part of the right hand crankcase half Colour code on plate 3 inside the glove compartment under the saddle Homologation data on the plate applied to the frame lower tube next to the steering head tube When ordering spares always mention the motorcycle and engine serial numbers and the colour code 3 2 4 1 ...

Page 4: ...al information A 5 Maintenance B 9 Injection Air intake system C 45 Engine D 119 Suspensions and wheels E 299 Brakes F 324 Electrical equipment G 338 Engine cooling H 376 Specific tooling I 390 Tightening torques L 394 Index M 400 ...

Page 5: ...A 1 GENERAL INFORMATION A Section ...

Page 6: ...ION Dimensions and weight A 3 Engine unit A 3 Transmission unit A 3 Frame A 4 Front suspension A 4 Rear suspension A 4 Wheels and brakes A4 Electrical system A 4 Instrument panel A 4 Fuel oil coolant fork oil capacity A 4 ...

Page 7: ...m Displacement 996 cm3 Compression ratio 11 3 1 Fuel feed system Injection Air filter Non woven synthetic material Starter system Electric Lubrication system Wet sump TRANSMISSION UNIT Clutch Wet multi plate type Gearbox 6 speed constant mesh Gear change 1 down 5 up Primary reduction 1 838 57 31 Final reduction 2 562 41 16 Gear ratios 1a 2 666 32 12 2a 1 933 29 15 3a 1 500 27 18 4a 1 227 27 22 5a ...

Page 8: ...KES Front brake Twin disc Rear brake Single disc Front tyre Metzeler ME Z4 C 110 80 18 Rear tyre Metzeler ME Z4 150 70 17 ELECTRICAL SYSTEM Transistorised electronic ignition Ignition phase 3 before T D C at 1300 rpm Spark plugs NGK CR8EK or DENSO U24ETR Battery 12v 10Ah Generator Three phase AC generator Fuses 30 30 15 15 15 10 10A Headlight unit Main beam condenser halogen bulb H1 12v 55w Dipped...

Page 9: ...B 1 MAINTENANCE B Section ...

Page 10: ...B 2 MAINTENANCE Maintenance and tuning B 4 Compression check B 23 Oil pressure check B 24 Technical data B 25 ...

Page 11: ...ubstitute Air filter Check substitute Fuel feed system Check Brake fluid Check level Brake fluid Substitute Every 2 years Brake disc pads Check Brake discs Check Braking system Check Braking system Bleed air Every 20000 km every 2 years Accelerator control Check adjust Clutch control Check Steering Check bearing play Fork Substitute oil Every 2 years Secondary transmission chain Check tension lubr...

Page 12: ...e the seat Remove the complete fuel tap assembly by unscrewing the three screws 1 indicated in the figure Extract the flange 2 of the petrol covers Remove the six screws 3 using an 8mm spanner Extract the plate 4 paying attention to the two washers underneath Remove the tank cover 5 by unscrewing the two screws 6 Remove the windshield 7 by unscrewing the three screws 8 shown in the figure 2 1 4 3 ...

Page 13: ...ite side of the machine Disconnect the fuel tubes from the left fuel tank The fuel tubes are attached to the fuel tank by rapid attachments and their re moval automatically blocks the exit of fuel It is necessary to push the lever 3 and slide out the elbow union 4 to disassemble it Be fore effecting reassembly check that the small pin 4 is completely extended If it is not in position push on the l...

Page 14: ...ir The compressed air must be blown from the exterior of the filter element If compressed air is used internally the dust and dirt will be pushed into the pores of the filter thereby reducing the flow of air to the same element To assemble a clean or new filter element carry out the operation of disassembly in the reverse order Should the motorcycle be used frequently on dusty roads the filter ele...

Page 15: ...s indicated in the figure whilst the other screw is on the other side Disconnect the fuel tubes Remove the left side protection of the radiator Remove the lower radiator fixing and its spacer Unhook the radia tor from its mountings Push the radiator down so that there is access to the forward spark plug Remove the spark plug insulated cap Unscrew the spark plug as shown in the figure During this o...

Page 16: ...the radiator and the engine are cool enough to be touched before carrying out this operation REMOVAL OF SPARK PLUG N 2 REAR Remove the seat Remove the seat compartment by unscrewing the eight screws 1 Six of theses screws are shown in the figure Unhook the rubber mountings of the fuel filter Remove the spark plug insulated cap Remove the spark plug 1 ...

Page 17: ... 0 6 0 7 mm THE CONDITION OF THE ELECTRODES Controllare se gli elettrodi sono usurati o bruciati Se essi fossero estremamente usurati o bruciati sostituire la candela Sostituire la candela anche in caso di rottura dell isolante o dan neggiamento della filettatura When a spark plug substitution is made check the pitch size and the length of the thread If the threading is too short carbon residues w...

Page 18: ...ted 1 During periodical maintenance 2 When tappet maintenance is carried out 3 When the camshafts are removed for maintenance Valve tappet clearances cold Inlet 0 10 0 20 mm Exhaust 0 20 0 30 mm Valve tappet clearances must be checked when the piston is in the top dead centre T D C position of the compression cycle The inlet and exhaust cams of the front cylinder in position A indi cate that the f...

Page 19: ...ole line and bring the camshafts to the indicated posi tion in page B 10 To check the valve tappet clearances of the N 1 cylinder front insert a feeler gauge between the valve stem and the cam If the clearance is not correct adjust it within the specified range REAR CYLINDER Remove the seat the seat compartment and the spark plug as described in page B 8 Remove the left and right hand side panels ...

Page 20: ...ng care to not spill any fuel Place a cloth underneath the fuel filter Disassemble the expansion tank cover assembly Remove the rear cylinder head valve cover by unscrewing the four relative screws shown in the figure Rotate the crankshaft 270 3 4 of a turn to bring the piston of N 2 cylinder rear to T D C of the compression cycle Align the R T line on the rotor of the generator with the counter l...

Page 21: ... stem end with the numbers towards the cam Check the thickness of the pad with a micrometer to ascertain that it is the correct size See the selection table of the thickness of the pads for details Pages B 10 and B 11 Do not forget to apply some engine oil to the surfaces of the pad During the positioning of the pad check that the surface with the numbers points towards the tappets Reassemble the ...

Page 22: ...IED CLEARANCE NO ADJUSTMENT NECESSARY HOW TO USE THIS TABLE 1 Measure the clearance of the valve cold engine 2 Measure the thickness of the actual pad 3 Make the vertical column valve tappet clearance and horizontal column thickness match FOR EXAMPLE The valve tappet clearance is 0 23 mm The thickness of the actual pad is 0 70 mm The pad to use is 2 80 mm INTAKE SIDE ...

Page 23: ...t clearance and horizontal column thickness match FOR EXAMPLE The valve tappet clearance is 0 23 mm The thickness of the actual pad is 0 70 mm The pad to use is 2 80 mm EXHAUST SIDE EXHAUST VALVE PADS SELECTION TABLE NO 12892 41C00 XXX OPTIONAL ACTUAL PAD THICKNESS mm SUFFIX NO MEASURED CLEARANCE mm VALVE PAD SET 12800 41810 SPECIFIED CLEARANCE NO ADJUSTMENT NECESSARY ...

Page 24: ...the used oil into the container by unscrewing the sump plug 1 and the filling plug 2 Used oil contains dangerous substances that can damage the environment To change the oil it is recommended to use our service network that can dispose of the oil respect ing the environment and the norms in force Tighten the sump plug 1 to the specified torque and pour new oil into the filling hole 2 The engine ho...

Page 25: ...special wrench Never tighten the oil filter by hand Refill with new engine oil and check the level by following the same procedure used for the oil change OIL CAPACITY Oil change 3 1 litres Oil filter change 3 3 litres Engine overhaul 3 6 litres Utilise only ORIGINAL CAGIVA OIL FILTERS Filters and spare parts of other makes could differ with regards to the threading diameter and pitch filter perfo...

Page 26: ... locked in position Third phase Keeping the accelerator handgrip in the closed position slowly unscrew the screw adjuster 2 of the accelerator return cable B until a resistance is felt Tighten the locknut 1 whilst keeping the screw adjuster 2 locked in position Accelerator cable play 2 0 4 0 mm After making the adjustments check that the handlebar movement does not cause an increase in the tickove...

Page 27: ...m of play A at the end of the clutch lever Clutch lever play A 10 15 mm COOLING SYSTEM Check every 1000 km or 1 month Substitute the engine coolant every two years ENGINE COOLANT LEVEL CHECK The cooling of the engine is by forced circulation with a centrifugal pump situated on the left side of the engine a by pass valve ther mostat and a radiator The opening of the thermostat and the conse quent f...

Page 28: ...e 5 fill the radiator with the specified engine cool ant until it reaches the neck of the radiator Bleed air out of the system via the bleed nut 2 See chapter H for information regarding the engine coolant Tighten the air bleed nut to the specified torque Torque pressure Air bleed nut 4 13 N m 1 3 kg m Switch on the engine and completely bleed the air from the sys tem via the radiator neck Add eng...

Page 29: ...lock of wood Slowly rotate the rear wheel by hand with the engine in neutral Slack pins Excessive wear Damaged rollers Incorrect chain adjustment Dry or rusty links Missing O rings Bent or seized links The chain must be substituted if any one of these defects is found Substitute also the crown and pinion wheels when substituting the transmission chain CHECK Slacken the axle nut 1 Completely tighte...

Page 30: ...the chain slack after having tightened the axle nut 2 Torque pressure Rear axle nut 63 7 68 6 N m 6 5 7 kg m CLEANING AND LUBRICATION Wash the chain with kerosene If the chain tends to rust quickly shorten the maintenance intervals Do not use Trichloroethylene petrol or other similar liq uids These liquids possess an excessive solvent power and more importantly can damage the O rings that keep the...

Page 31: ...ed brake fluid Do not use or mix different types of fluids such as silicone or petrol based fluids Do not use brake fluid from old used or non sealed containers Do not use leftover fluids from previous maintenance or left for long periods of time Spillage or leaks of brake fluid are dangerous and imme diately discolour painted surfaces Check the brake tub ing and joints for cracks or leaks before ...

Page 32: ...g nuts 6 or 7 position the pedal in the desired position When the adjustment is completed tighten the nut 7 Torque pressure Rear brake pedal locknut 1 18 N m 1 8 kg m MAINTENANCE To change the rear brake disc pads proceed as follows Remove the 2 screws 1 of the rear mudguard 2 and rotate it as shown in the figure Remove the pincer assembly from the forks by unscrewing the 2 relative screws 3 Remov...

Page 33: ... Front brake bleed out the air via the bleed valve nipple Squeeze and release the brake lever several times in rapid suc cession and then squeeze it without releasing the lever Slacken the bleed valve nipple rotating it a 1 4 of a turn so that the fluid can pour out into the container This releases the tension on the brake lever and allows it to move towards the handgrip of the handlebar Close the...

Page 34: ...ounted on this machine are 110 80 18 for the front wheel and 150 70 17 for the rear wheel The use of different tyres to those specified could cause instability It is highly recommended to use tyres of the pre scribed size TYRE TYPE TUBELESS STEERING Check at 1000 km or 1 month Every 12000 km or 12 months The steering must be adjusted correctly to obtain a smooth rotating action of the handlebar an...

Page 35: ...ression of the two cylinders is more than 200 kPa All values of the compression are less than 1300 kPa 13 kg cm2 even if they are more than 1100 kPa 11 kg cm2 COMPRESSION TEST PROCEDURE Before verifying the engine compression check that the cylinder head bolts are tightened to the correct torque and that the valves are adjusted correctly Heat up the engine before proceeding with the test Check tha...

Page 36: ...ether OIL PRESSURE TEST PROCEDURE Switch on the engine and check that the oil pressure warning light is illuminated If it remains illuminated check the electrical circuit of the oil pressure warning light If the circuit is in good condition check the oil pressure as follows Remove the plug from the main oil way Insert the oil manometer along with its attachment in the position indicated Heat up th...

Page 37: ... Exhaust Valve seat width Intake and 0 9 1 1 Exhaust Valve head radial decentralising Intake and 0 03 Exhaust Valve spring floating width Internal 37 0 intake and exhaust External 40 7 Valve spring tension Internal 6 2 kg at 33 1 mm length intake and exhaust External 15 4 kg at 36 6 mm length Cam height Intake 37 770 37 838 37 47 Exhaust 36 380 36 448 36 08 Camshaft seat pin oil play Intake and 0 ...

Page 38: ...0 1700 kPa 1100 kPa automatic decompression activated 13 17 kg cm2 11 kg cm2 Compression pressure difference 200 kPa 2 kg cm2 Piston cylinder play 0 015 0 025 0 12 Cylinder diameter 98 000 98 015 Lines or scratches Piston diameter 97 980 97 995 97 880 Measured 10 mm from the base of the skirt Cylinder deformation 0 05 Piston ring floating end play 1st Approx 6 8 5 4 2nd Approx 9 9 7 9 Piston ring ...

Page 39: ...10 kPa 1 1 kg cm2 pressure Fan thermal switch OFF ON Approx 105 C activating temperature ON OFF Approx 100 C Coolant sensor 20 C Approx 2 45 kΩ resistance 50 C Approx 0 811 kΩ temperature 80 C Approx 0 318 kΩ 110 C Approx 0 142 kΩ 130 C Approx 0 088 kΩ GEARCHANGE TRANSMISSION CHAIN PART STANDARD LIMIT Primary reduction ratio 1 838 57 31 Secondary reduction ratio 2 235 58 17 Gear ratios 1st 2 666 3...

Page 40: ... IAP sensor outgoing voltage Approx 1 8 V at minimum TP sensor incoming voltage 4 5 5 5 V TP sensor resistance closed Approx 1 2 kΩ open Approx 4 4 kΩ TP sensor outgoing closed Approx 1 1 V voltage open Approx 4 2 V ECT sensor incoming voltage 4 5 5 5 V ECT sensor resistance 2 3 2 6 KΩ a 20 C IAT sensor incoming voltage 4 5 5 5 V IAT sensor resistance 2 2 2 7 kΩ a 20 C AP sensor incoming voltage 4...

Page 41: ...BI G resistance Ignition coil resistance Low 3 5 Ω terminal terminal High 20 28 kΩ terminal spark plug insulated cover Camshaft position sensor More than 4 0 V peak voltage Primary ignition coil peak voltage More than 280 V Generator winding resistance 0 1 1 0 Ω Y Y Max outgoing wattage generator Approx 380W at 5000 rpm Generator voltage without a More than 70V CA at 5000 rpm charge cold engine Ig...

Page 42: ...ight 2 Main beam warning light 2 Neutral warning light 2 Fuel level warning light 2 Number plate light 5 BRAKES WHEELS PART STANDARD LIMIT Rear brake pedal travel 5 Brake disc thickness Front 4 0 0 2 3 5 Rear 5 0 0 2 4 5 Brake disc deformation 0 30 front and rear Wheel deformation Axial 0 5 2 front and rear Radial 0 8 2 Wheel spindle axial deformation Front 0 1 0 2 Rear Unit W Unit mm ...

Page 43: ...r 150 70 17 Tread depth Front 2 0 Rear 2 0 SUSPENSION PART STANDARD LIMIT Fork travel 150 Fork spring floating length 280 Fork oil level 180 Rear spring assembly 180 installed length Rear wheel travel 160 Fork shaft pin deformation 0 30 TYRE PRESSURES COLD TYRE RIDER ONLY WITH PASSENGER PRESSURES kPa kg cm2 kPa kg cm2 FRONT 220 2 2 240 2 4 REAR 240 2 4 260 2 6 ...

Page 44: ...ngine oil type AGIP TEC 4T 10W 40 SINT 20005W 40 Engine oil capacity Oil change 3100 ml Filter change 3300 ml Overhaul 3600 ml Fork oil type SAE 7 5 Fork oil capacity 680 cc each leg Brake fluid type AGIP BRAKE 4 Coolant type Use antifreeze coolant that is compatible with aluminium radiators Mix with a ratio of 50 50 with distilled water only Coolant capacity 2000 ml FUEL COOLANT ...

Page 45: ...C 1 INJECTION AIR INTAKE SYSTEM C Section ...

Page 46: ... 9 Intake air system technical characteristics C 21 FI system position of parts C 26 FI system diagram C 27 FI system electrical diagram C 28 Auto diagnostic function C 29 Security function C 32 FI system diagnostics C 33 Fuel feed system C 51 Butterfly body C 55 Intake air system C 78 Sensors C 80 ...

Page 47: ...tact will not be made if the terminals are corroded and not perfectly clean If there are circuit problems check each lead by hand If there are cracks or breaks in the insulation repair or substitute the leads When carrying out measurements on electrical connectors with a tester insert the probe into the connector from the wiring system side of the connector coupling If it is not possible to insert...

Page 48: ...ge the said components during the removal installation phases Take care to not touch the electrical terminals of the ECM The static electricity of the body can damage the component Before connecting or disconnecting an ECM coupling make sure that the ignition switch is in the OFF position This will prevent damage to the electronic parts Do not connect the battery with inverted polarities This will...

Page 49: ...age to the ECM and the sensors Use a good quality ohm meter voltmeter It will not be possible to obtain precise test results or possible personal injuries could re sult if bad quality equipment is used ELECTRICAL CIRCUIT TESTING PROCEDURE There are various methods of testing electrical circuits The one described here is the general method for testing open circuits or short circuits using an ohmmet...

Page 50: ...ring terminals Locate the defect and repair Continuity test Measure the resistance between the terminals of the coupling and both ends of the circuit being tested as indicated between posi tion A and C If no continuity is indicated complete resistance or over the limit of the scale signifies that the circuit between terminals A and C is open Disconnect the coupling in the circuit coupling B in the...

Page 51: ...s that there is an anomalous resistance of a level corresponding to the drop in voltage in the circuit between the terminals A and B Voltage between C and Earth approx 5 V B and Earth approx 5 V Drop of 2 V A and Earth approx 3 V SHORT CIRCUIT TESTS wiring Earth Disconnect the negative polarity cable of the battery Disconnect the connectors couplings and both ends of the circuit being tested Disco...

Page 52: ...tart with the tester at 0 ohms before testing each resistance or after having changed the range of the resistance When the resistance is measured with a multi tester also meas ure the resistance the charge is missing Subtract this resistance from that measured under charge to obtain the effective resist ance Resistance Resistance in ab measured sence of charge effective resistance When resistance ...

Page 53: ...ng of the throttle and various other adjustments that are determined according to signals received from various sensors that reveal the engine and riding conditions Intake air pressure sensor Intake air pressure IAP sensor signal Basic volume Crankshaft position sensor Engine rpm of injected CKP sensor signal fuel Throttle position sensor Throttle opening TP sensor signal Various sensors Various s...

Page 54: ...w voltage determines a longer injection time for the injection volume adjustment At high engine rpm the injection time volume is increased in the 5th and 6th gears The SRAD system makes this adjustment When the engine is being switched on a larger volume of fuel is injected into the system During acceleration the injection time of the fuel volume is increased in relation to the speed with which th...

Page 55: ...EL PUMP CONTROL SYSTEM section FUEL FEED SYSTEM The fuel feed system consists of the fuel tank fuel pump fuel filter feed tube feed tubing including the fuel injectors pressure regulator and the return feed tube The fuel is pumped from the tank to the fuel pump and the pressurised fuel flows into the injector installed in the fuel feed tubing As the fuel pressure applied at the fuel injector the p...

Page 56: ...dle valve and filter The injector is an electro magnetic injection jet that injects the fuel into the carburettor according to the signals received from the ECM When the ECM agitates the solenoid it becomes an electro magnet that attracts the piston At the same time the needle valve incorporated in the piston opens and the injector under pressure from the fuel injects the fuel in a conical dispers...

Page 57: ... current flows to the fuel pump motor via the side stand relay and the same pump relay thereby making the pump work on a continuous basis In the control circuit of the fuel pump there is a crash sensor If the machine should be dropped the crash sensor sends a signal to the ECM to deactivate the feed to the pump relay thereby interrupting the function of the fuel pump motor At the same time the cur...

Page 58: ...ed action have been memorised in the ROM They have been designed to compensate for differences in the intake air exhaust systems and the performance of cooling caused by the different leaning angles of the front cylinder and the rear cylinder LIGHT LOAD When the engine turns under a light load the volume of fuel injected time is based on the air pressure at the intake air and on the rpm of the eng...

Page 59: ...fuel at the right moment according to the operating conditions of the engine When the crankshaft starts to turn at the moment of ignition the ECM sends a signal to both front and rear injectors for the contemporaneous injection of fuel At the second revolution of the engine the injection of fuel is sequential and independent for both cylinders Crankshaft position sensor signal Front cylinder Timin...

Page 60: ...SENSOR The throttle position sensor is situated on the N 2 carburettor To get access to this component it is necessary to remove the left hand fuel tank as described in Chapter B This sensor is a variable resistance sensor and senses the angle of opening of the throttle In the sensor the battery voltage is changed to the relative voltage of the position of the throttle and is then sent to the ECM ...

Page 61: ...the timing synchronisation The volume of fuel injected increases when the engine rpm in creases The signal is related to the functioning of the fuel pump CAMSHAFT POSITION SENSOR CMP SENSOR The signal generating rotor is mounted on the N 2 intake valve camshaft and the camshaft position sensor explorer coil is situ ated on the cylinder head cover of the N 2 cylinder The sensor generates the signal...

Page 62: ...ature is low and diminishes when the temperature is high ENGINE COOLANT TEMPERATURE SENSOR ECT SENSOR The engine coolant temperature sensor is installed on the body of the thermostat assembly The sensor senses the engine coolant temperature that is obtained and the sensor then converts the resistance of the Thermistor into voltage which is transmitted to the ECM The volume of the injec tion increa...

Page 63: ...ain access to this component it is necessary to remove the left hand cover and right hand cover by unscrewing the two relative screws 1 Remove the parcel carrier by unscrewing the three screws 2 Dis connect the regulator connection The sensor senses the leaning angle of the machine When the machine is inclined more than 43 the mechanical switch closes ON and a signal is transmitted to the ECM At t...

Page 64: ...CHARACTERISTICS Whilst the machine is in motion the frontal air pressure flows into the air filter compartment in such a way that it pressurises the intake air This improves the intake air efficiency that subsequently permits a greater power output of the engine ...

Page 65: ...e sensor ECTS C Ignition coils IG COILS D Crankshaft position sensor CKPS E Rpm sensor F Atmospheric pressure sensor APS GFuel pump FP H Camshaft position sensor CMPS I Intake air pressure sensor IAPS J Throttle position sensor TPS L Intake air temperature MAir filter N Fuel injectors FI OFuel pump relay RELE FP ...

Page 66: ...C 22 INJECTION AIR INTAKE SYSTEM FI SYSTEM DIAGRAM SWITCH CLP FP TOS RELAY FP ECM BATTERY IATS TPS FI 1 FI 2 CMPS CKPS ECTS VD IAPS APS FI 1 FI 2 FPR JET 2nd AIR ...

Page 67: ...ROTTLE POSITION SENSOR IATS INTAKE AIR TEMPERATURE SENSOR CMPS CAMSHAFT POSITION SENSOR CKPS CRANKSHAFT POSITION SENSOR CMPS IATS FI 1 STARTER RELAY STARTER BUTTON FUEL PUMP FUEL PUMP RELAY ENGINE KILL SWITCH SIDE STAND RELAY 15 A CRASH SENSOR 15 A 15 A 10 A IGNITION COILS MAIN SWITCH FUEL TANK TPS FI 2 CKPS CLUTCH LEVER POSITION SWITCH ATMOSPHERIC PRESSURE SENSOR NEUTRAL WARNING LIGHT BATTERY ENG...

Page 68: ...ant temperature and the machine continue to function 2 When the ECM does not receive the sensor signals of the camshaft position or the crankshaft position the injection signal is interrupted The LCD display panel indicates FI and the engine coolant temperature The machine stops functioning 3 When the crash signal the ignition signals 1 and 2 the injector signals 1 and 2 the fuel pump relay signal...

Page 69: ...d these devices are indicated by codes The coupling of the special tool is connected to the coupling of the dealer mode Special tool 800096687 mode selector Do not disconnect the couplings of the ECM leads before checking the malfunction code If the leads are disconnected the code is cancelled and therefore cannot be further checked MALFUNCTION LCD INDICATION LED INDICATION MODE INDICATION NO c00 ...

Page 70: ...ay panel from the smallest to the biggest code 3 To obtain the appropriate signal from the throttle position sensor the basic sensor position is indicated on the LCD display panel The malfunction code is indicated in three columns In front of the three columns is an additional column that indicates the position with an upper middle or lower line If the indication is the upper line or lower line wh...

Page 71: ...ins fixed Engine coolant The engine coolant temperature YES YES temperature value remains fixed at 80 C Intake air temperature The intake air temperature YES YES sensor value remains fixed at 40 C Atmospheric pressure The atmospheric pressure YES YES sensor value remains fixed at 760 mmHg Ignition 1 Ignition 1 disactivated YES YES signal Cylinder 2 functions only 2 Ignition 2 disactivated YES YES ...

Page 72: ...e engine stalls Poor choke setting Immediately after switching on Abnormal tickover When the throttle is opened High Low Rpm When the throttle is closed Unstable When under load Uneven tickover from Rpm Other__________ to Rpm Other__________ OTHER PROBLEMS AMBIENT MOTORCYCLE CONDITIONS WHEN THE PROBLEM BECAME APPARENT Ambient conditions Weather Clear Cloudy Raining Snow Always Other_________ Tempe...

Page 73: ...fully understand the available functions and their correct use Read the precautions regarding the maintenance of the elec trical system see Chapter G before the inspection and carry out the instructions as indicated Remove the passenger seat Connect the special tool A to the dealer mode coupling on the wiring and turn over the engine for more than 4 seconds Switch on the special tool and check the...

Page 74: ...d Throttle position sensor wiring coupling connections The sensor produces the following voltage 0 15 V sensor voltage 4 85 V Outside this voltage range the code c15 is indicated Engine coolant temperature sensor wiring coupling connections The sensor produces the following voltage 0 15 V sensor voltage 4 85 V Outside this voltage range the code c21 is indicated Intake air temperature sensor wirin...

Page 75: ...tions battery feed The signal voltage of the gearchange position must be higher than 0 60V for more than 2 seconds Gearchange position sensor voltage 0 60V Gearchange position sensor wiring coupling connections Gearchange pre selector etc The fuel injection signal is interrupted Codes c32 or c33 are indi cated Injector wiring coupling connections injector feed When no signal is received from the f...

Page 76: ...sor continuity Ω infinite Terminal Earth Tester dial indication Resistance Ω Substitute the CMP sensor YES 2 Disconnect the CMP sensor connector Turn the engine over for several seconds with the starter motor and measure the peak voltage at the CMP sensor CMP sensor peak voltage More than 0 8V Red black Grey brown Repeat the described test procedure several times and measure the peak voltage If OK...

Page 77: ...r peak voltage More than 4V Violet blue Green blue Repeat the described test procedure several times and measure the peak voltage If OK measure the peak voltage of the CKP sensor at the terminals of the ECM N N or 4 or 13 Tester dial indication Voltage The connector contacts of the CKP NO sensor or the ECM are loose or ruined YES Substitute the CKP sensor The violet blue lead or the green blue lea...

Page 78: ...he IAP sensor are loose or ruined If OK measure the incoming voltage of the IAP sensor Disconnect the connector of the IAP sensor Turn the ignition switch to the ON position Measure the voltage between the red orange lead and Earth If OK measure the voltage between the red orange lead and the black brown lead IAP sensor incoming voltage 4 5 5 5V Red orange Earth Red orange black brown Tester dial ...

Page 79: ...ar substitute the IAP sensor YES Red orange lead yellow grey lead or black brown lead circuits open or in short circuit to Earth Or connections 9 1 or 24 are ruined If the leads and the connections are OK the problem is intermit tent or the ECM is defective Recheck each terminal and the wiring for open circuits or ruined connections see page C 6 Substitute the ECM and recheck Outgoing voltage Vcc ...

Page 80: ... OK measure the voltage between the red lead and the black brown lead TP sensor incoming voltage 4 5V 5 5V Red orange Earth red orange grey orange Tester dial indication Voltage NO The ECM connector contacts are loose or ruined Open circuit or YES short circuit of the red orange lead or the grey orange lead 2 Ensure that the ignition switch is in the OFF position Disconnect the TP sensor connector...

Page 81: ...V Throttle open Approx 4 2V Tester dial indication Voltage NO If the results of the check do not prove satisfactory substitute YES the TP sensor The red orange lead grey orange lead or black brown lead circuits are open or in short circuit to Earth or the 9 2 or 24 contacts are ruined If the leads and the connections are OK the problem is intermittent or the ECM is defective Recheck each terminal ...

Page 82: ...incoming voltage 4 5 5 5V brown violet Earth Brown violet black brown Tester dial indication Voltage NO ECM coupling contacts loose or ruined Green yellow lead or black YES brown lead circuit open or in short circuit 2 Turn the ignition switch to the OFF position Measure the resistance of the ECT sensor Check the continuity between the grey lead terminal and Earth ECT sensor resistance 2 3 2 6 kΩ ...

Page 83: ...n Tester dial indication Voltage NO ECM connector contacts loose or ruined Yellow brown lead circuit or black YES brown lead circuit open or in short circuit 2 Turn the ignition switch to the OFF position Measure the resistance of the IAT sensor IAT sensor resistance 2 2 2 7 kΩ at 20 C Terminal Terminal Tester dial indication Resistance Ω NO Substitute the IAT sensor YES Yellow brown lead circuit ...

Page 84: ... the ignition switch to the ON position Disconnect the AP sensor connectors Measure the voltage between the terminal of the red orange lead and Earth If OK measure the voltage between the terminal of the red orange lead and the terminal of the black brown lead AP sensor incoming voltage 4 5 5 5V red orange Earth red orange black brown Tester dial indication Voltage NO ECM coupling contacts loose o...

Page 85: ...nsor YES Red orange lead circuit violet yellow lead circuit black brown lead circuit open or in short circuit To Earth Or connections 9 10 or 24 ruined If the leads and the connections are OK the problem is intermittent or the ECM is defective Recheck each terminal and wiring for open circuits or ruined con nections see page C 6 Substitute the ECM and recheck Outgoing voltage Vcc voltage 4 5 5 0V ...

Page 86: ...the TO sensor connector Turn the ignition switch to the ON position Measure the voltage at the wiring connector between the black lead and the black white lead TO sensor voltage Approx 2 5V minimum Black black white Also measure the voltage whilst leaning the machine over Disassemble the TO sensor from its support and measure the voltage inclining it left and right more than 43 from the horizontal...

Page 87: ...he GP switch Lift up the machine on a suitable support Lift up the side stand Turn the engine kill switch to the ON position Turn the ignition switch to the ON position Measure the voltage at the wiring connector between the red lead and Earth changing from 1st to 6th gear GP switch resistance More than 0 6V Orange yellow Earth Tester dial indication Voltage NO Red lead circuit open or in short ci...

Page 88: ...the resistance is OK check the continuity between each terminal and Earth Continuity INJ 1 o 2 Ω infinite Terminal Terminal Tester dial indication Resistance Ω NO Substitute the injector YES 2 Turn the ignition switch to the ON position Measure the voltage of the injector between the orange lead and Earth Voltage INJ 1 or 2 Battery voltage Orange Earth Tester dial indication Voltage NO Orange lead...

Page 89: ...g contacts of the FP relay are loose or ruined If OK check the isolation and the continuity by referring to page C 6 for details NO Substitute the FP relay YES Blue violet lead circuit or brown lead circuit open or in short circuit to Earth Or the contacts 1 or 7 are ruined see page C 28 If the leads and the connections are OK the problem is intermit tent or the ECM is defective Recheck each termi...

Page 90: ...res sure Fuel pressure 2 9 kg cm2 290 kPa If the fuel pressure is less than specified check the following Fuel tube leak Blocked fuel filter Pressure regulator Fuel pump If the fuel pressure is more then specified check the following Blocked or pinched fuel return tube Fuel pump control valve Pressure regulator Before removing the special tools turn the ignition switch to the OFF position and slow...

Page 91: ...mp at the pump terminals Check the fuel pump relay as follows Check that the crash sensor functions Check that the fuses of the system are OK If the pump still does not emit a sound substitute the pump assembly FUEL FLOW QUANTITY CONTROL Remove the seat Remove the right hand fuel tank as described in Chapter B Disconnect the fuel tube from the incoming union as indicated in the fig Insert the tube...

Page 92: ... removed the seat compartment place a cloth under neath the filter as shown in the figure Remove the filter from the elastic supports after having removed the bands from the frame tubes When reassembling pay attention to the arrow on the filter This arrow indicates the direction of the fuel flow Check the condition of all fuel tubing FUEL RESERVE PROBE The probe is mounted on the right hand fuel t...

Page 93: ...e temperature sensor connector Remove the Blow by labyrinth 3 on the left hand side of the ma chine by unscrewing the two relative screws Slacken the fasten ing of the sleeve and remove the labyrinth 3 from the filter This mechanism stops oil spray from the engine from entering di rectly into the air filter compartment Remove the filter compartment by loosening the two fasteners on the butterfly b...

Page 94: ...fuel tube union 5 Fuel pressure adjuster 6 Fuel feed tubing 7 Throttle lever connection rod 15 Injector 16 Dust protector 17 O ring 18 Seal 19 Throttle stop screw 20 TP sensor 8 Fuel feed tubing support 9 Fuel connecting plate 10 Throttle lever N 2 11 Throttle lever N 1 12 Choke cam 13 Throttle balance lever 14 Butterfly valve shaft support ...

Page 95: ...left hand and right hand plastic protective covers of the fuel pump and the expansion tank Disconnect the incoming fuel tube by unscrewing the union fasten ers as shown in the figure Place a cloth underneath the union Disconnect the connectors 1 and 2 of the injectors Disconnect the connector of the TP sensor 3 Disconnect the tubing from the cylinders 4 and the suction tubing 5 on the secondary ai...

Page 96: ...ts underneath After having disassembled the anti vibration support 7 remove the screws 8 Remove the engine support frame 3 Pay attention to the spacer and the cable support that are freed during the removal procedure of the left hand engine support frame After having removed the sump guard as described in page B 7 drain the engine coolant into an appropriate container via the plug 9 To assist the ...

Page 97: ... chine This creates space in which the butterfly body can be re moved more easily Loosen the two fasteners on the collectors Unscrew the screws 3 and free the choke adjuster support plate Unscrew the screws 2 and remove the coil assembly from the frame Extract the butterfly body assembly 2 1 1 2 ...

Page 98: ...the carburettor assembly Remove the TP sensor 1 Remove the choke adjuster assembly 2 Remove the throttle cable guide 3 Remove the fuel feed tubing 1 by removing the nuts Remove the fuel pressure adjuster 2 and the incoming fuel tube union 3 from the fuel feed tubing Remove the fuel injectors 4 and 5 1 3 2 ...

Page 99: ...rews Remove the N 1 throttle lever 1 and the N 2 throttle lever 2 Re move the connection rod 3 by unscrewing the nuts Remove the spring stop 4 the spring 5 and the ferrule 6 Remove the washer 7 and the ferrule 8 Remove the connecting plate 9 the choke cable guide 10 and the choke cam 11 6 7 3 2 1 6 4 5 8 7 9 10 11 10 ...

Page 100: ...wly rotate the air screw in a clockwise direction and count the number of turns necessary to gently screw in the air screw into its seat Note the number of turns so that the screw can be replaced correctly after cleaning Remove the air screw with the spring washer and O ring ...

Page 101: ... Do not use wire to clean the passageways It could cause damage If the components cannot be cleaned satisfacto rily with a spray product it may be necessary to use an immersion liquid Always follow the manufacturer s instruc tion for use of the product and clean the components in the correct way Do not clean rubber or plastic parts of the carburettor with cleaning products CHECK Check the followin...

Page 102: ...ard adjustment Approx 1 1 2 turns backwards Replace the air screw cap Substitute the O ring Replace the choke cable 1 Replace the washer 2 the spring 3 the spring stop 4 and the choke cam 5 Insert the clamp A of the suction tube in the correct way Model E 33 At the same time replace the connecting plate 6 Lightly tighten plate screws Replace the ferrule 7 and the washer 8 Replace the ferrule 9 the...

Page 103: ...N 2 throttle lever check the insertion of the ferrule 3 the washer 4 and the spring 5 Replace the N 2 throttle lever 6 and hook the spring A to the N 2 lever Replace the elastic washer 7 Tighten the nut 8 Replace the N 1 throttle lever 9 on the N 1 butterfly valve spindle and then replace the ferrule 10 and the elastic washer 11 Tighten the nut 12 1 5 4 3 8 7 A 6 9 10 12 11 ...

Page 104: ...s 3 and the O rings 4 on the injectors Apply a thin layer of engine oil to the new O rings 4 Replace the injectors inserting them squarely into the carburettor Substitute the seals and the O rings with new ones Never rotate the injector when inserting it Apply a thin layer of engine oil to the new O ring 5 and insert it into the fuel pressure adjuster Substitute the O ring with a new one Replace t...

Page 105: ...o avoid fuel leakage Replace the fuel feed tubing 2 and tighten the nuts to the specified torque Torque pressure Fuel feed tubing assembly nut 13 Nm 1 3 kg m Replace the fuel return tube Apply a thin layer of A grease to the seal 3 and replace it on the N 2 butterfly valve spindle Replace the TP sensor on the N 2 butterfly valve spindle aligning the tongue of the spindle with the groove B of the T...

Page 106: ...he side of the air intake collectors During reassembly pay attention to the correct position ing of the tubes and the cables Connect the traction cable 1 and the return cable 2 of the throttle to the butterfly valve cam Adjust the throttle cable play with the lock adjusters 3 and 4 See page C 73 for details Connect the choke cable and adjust the choke cam play by the lock adjuster 5 See page C 73 ...

Page 107: ...e mounting screw Torque pressure Mounting nut 23 Nm 2 3 kg m Replace the complete T shaped coil support Connect the injector couplings 2 and 3 Connect the connector of the TP sensor 4 Connect the suction tube from the rear butterfly body to the sec ondary air valve and the relative sleeves 4 2 3 ...

Page 108: ...so that the screws and their seats are correctly aligned To assemble the left hand engine support frames correctly replace the spacers and the cable support During this phase take care in inserting the tube onto the secondary air compartment Replace the Blow by labyrinth AIR FILTER ASSEMBLY Reassemble the air filter in the reverse order of removal Tighten the two bands on the butterfly bodies Asse...

Page 109: ...in layer of engine oil to the new seals and O rings of the injectors Insert the injectors squarely into the carburettor Never rotate the injector during insertion see page C 62 AIR SCREW ADJUSTMENT If it is necessary adjust the butterfly valve synchronisation and the air screws according to the specification Remove the right hand fuel tank as described in page B 4 Remove engine coolant cap union a...

Page 110: ...check the rpm of the choke system If the speed of the engine is not as specified adjust to 2000 rpm as follows Remove the left hand fuel tank as described in page B 4 Completely pull the choke cable and check that the cam A touches the stop B If not adjust with the cable lock adjuster 2 Switch on the engine and completely rotate the choke lever 1 Adjust the choke speed to 2000 rpm by rotating the ...

Page 111: ...terfly body to the balancing accessory Install the appropriate plug into the suction tube 3 of the secondary air compartment Special tool 800097957 Suction balancing accessory The dimensions of each nipple are different and it is therefore neces sary to have a nipple adaptor for each nipple To adapt to the dimen sions use the two tubes utilised for the carburettors of the NAVIGA TOR 1000 on the th...

Page 112: ...teel sphere 3 in the tube onto the central line 4 The balancing accessory must be positioned at approximately 30 from horizontal After confirming that the sphere remains steady on the central line disconnect the tube from the nipple of the front carburettor and connect the following tube to the same nipple Rotate the air screw to bring the sphere 5 onto the central line The balancing accessory is ...

Page 113: ...ce is small less than 20 mmHg approxi mately the diameter of a sphere use the air screw to balance the suction The standard adjustment of the air screw is 1 1 2 a turn backwards from the fully screwed in position After having balanced the butterfly valves adjust the engine tickover to 1300 rpm using the throttle stop screw This must be done after replacing the air filter compartment When the diffe...

Page 114: ...as follows Slacken the locknut 3 and tighten or loosen the screw 2 to obtain a play A of 0 25 mm This screw regulates an excessive butterfly valve movement Throttle lever play 0 25 mm THROTTLE POSITION SENSOR ADJUSTMENT TPS After making all necessary adjustments check and adjust if necessary the TPS sensor setting TPS Air screw Rear Front Suction nipple N 2 Suction nipple N 1 Jet Ø 1 0 Tube Thrott...

Page 115: ... unscrew the traction cable screw adjuster 6 until 2 0 4 00 mm of play is obtained at the throttle handgrip Tighten the locknut 4 whilst keeping the adjuster 6 still Keep the throttle handgrip in the closed position and slowly turn the return cable screw adjuster 3 to obtain a slack of 1 0 mm Tighten the locknut 1 CHOKE CABLE ADJUSTMENT Remove the fuel tank as described in Chapter B Remove the air...

Page 116: ... the coupling 4 Reassemble the TP sensor on the N 2 butterfly valve rod aligning the tongue A with the groove B of the TP sensor See page C 17 for the adjustment procedure of the TP sensor setting CKP SENSOR CHECK The signal generating rotor is mounted on the extreme left of the crankshaft and the crankshaft position sensor explorer coil is situ ated inside the generator cover CKP SENSOR REMOVAL R...

Page 117: ...ibed in page B 4 Disconnect the electrical connection Remove the ECT sensor AP SENSOR CHECK The atmospheric pressure sensor is situated in the compartment underneath the seat AP SENSOR REMOVAL REASSEMBLY Remove the seat Remove the bottom panel as described in Chapter B Remove the ECM control unit support Disconnect the coupling 1 and remove theAP sensor from the frame Reassembly is in the reverse ...

Page 118: ...C 74 INJECTION AIR INTAKE SYSTEM ...

Page 119: ...D 1 ENGINE D Section ...

Page 120: ...D 114 Water pump Clutch cover D 123 Primary driving gear Valve motion idler gear shaft sprocket no 1 D 129 Starting system Generator Crankshaft position sensor D 134 Gear preselector D 143 Crankcase Gearbox Crankshaft Connecting rod D 151 Engine lubrication system D 169 ...

Page 121: ...lator Oil pressure switch D 115 D 116 D 32 D 124 D 130 D 130 D 32 D 172 D 172 D 175 D 119 D 119 D 51 D 127 D 133 D 133 D 50 D 174 D 174 D 176 Carburettors Cylinder head covers Camshafts Cylinder heads Cylinders Pistons Timing chain tension adjusters Timing chain stretchers Timing chain guide Thermostat Oil filter Oil cooler Starter motor C 59 D 21 D 88 D 88 107 D 106 107 D 106 107 D 25 D 22 26 D 2...

Page 122: ...ingestion cause vomiting and immediately seek medical attention REMOVING AND INSTALLING THE EN GINE REMOVING THE ENGINE Before removing the engine from the frame wash it with a steam cleaner or other suitable equipment The engine removing proce dure is described below and installation is obtained by following the same steps in reverse order Remove saddle 1 Remove the right hand side cover as descr...

Page 123: ... connector from the temperature sensor that is situ ated on the cooling system thermostat housing Remove the connector of the camshaft position sensor Remove the radiator by unscrewing the three screws 3 as shown in the figure and lift it up to remove it from its supports During this operation it is advisable to remove the two radiator side protections by unscrewing the two relative fixings for ea...

Page 124: ... wiring exactly as it was before disassembly Remove the band on the engine coolant thermostat housing as indicated in the figure Remove the radiator complete with manicotti and cooling fan Remove the butterfly bodies as described in page C 53 C 55 EXHAUST SILENCER REMOVAL Remove the right and left hand silencers from the frame by unscrew ing the two fixing screws Remove the two screws as indicated...

Page 125: ...t hand footrest assembly 1 together with the gearchange lever 2 Remove the two screws 3 on the footrest and also the screw 4 on the gearchange lever mark with a black marker the position of the lever on the gearchange lever shaft Disconnect the connector 5 of the speed sensor lead 6 and re move the rubber band Unscrew the three screws 7 and remove the cover 8 of the engine pinion together with the...

Page 126: ...ch disengagement mechanism assembly 2 To ease the reinstallation of the assembly slacken off the locking nut and the adjuster screw before removing the mounting bolts of the clutch disengagement mechanism Remove the clutch disengagement lever 3 from the clutch cable only in case of substitution At the moment of reinstallation bend the stop plate A of the clutch disengagement lever 3 to lock them t...

Page 127: ... nut 1 and the engine pinion washer Remove the engine pinion 2 Remove the oil radiator 3 by unscrewing the mounting bolts 4 and the junction bolts of the oil tubes Remove the transmission chain from the crown wheel 2 1 3 4 ...

Page 128: ...leasing the rubber bands Take care when reassembling the electrical wiring and the rubber bands It is important to replace the wiring exactly as it was before disassembly Disconnect the connector of the neutral sensor lead Remove the rubber bands Take care when reassembling the electrical wiring and the rubber bands It is important to replace the wiring exactly as it was before disassembly Disconn...

Page 129: ...move the rear brake pedal by unscrewing the fixings indicated in the figure Be careful to not lose the washers and the compo nents on the threaded spindle Support the engine with a suitable support To facilitate the removal of the engine lift up the frame by utilising a jack for safety Unscrew the pin 1 as indicated in the figure and extract it Unscrew the nut 2 and extract the fixing pin that fix...

Page 130: ...D 12 ENGINE Gradually lower the power plant When removing the engine from the frame take care not to damage either ...

Page 131: ...se of the frame Before tightening the various fixings of the engine to the specified torque make sure that the fixings are all properly inserted into their holes Torque pressure 39 2 44 1 N m 4 4 5 kg m Insert the stud 2 and tighten it to the specified torque Torque pressure 39 2 44 1 N m 4 4 5 kg m Assemble the rear brake pedal by tightening the fixing pivot to the specified torque Torque pressur...

Page 132: ...rque Torque pressure Secondary air tube fixing 8 6 9 8 N m 0 9 1 0 kg m Utilise new washers when refitting the tubes onto the cylinders When inserting the insulated covers onto the spark plugs make sure that the triangular countersigns on the insulated covers point towards the exhaust side of the cylinder ...

Page 133: ...45 50 4 5 5 0 front fix screw right hand side of the eng frame C 45 50 4 5 5 0 central fixing screw engine 2 support frames D 45 50 4 5 5 0 upper rear fix screw engine frame bracket E 45 50 4 5 5 0 lower rear fix screw engine frame bracket Tightening torques LENGTH ITEM mm A 60 B 35 Bolt C 216 D 125 E 156 ...

Page 134: ...fied torque Tightening torque Engine sprocket nut 115 N m 11 5 kg m 83 95 lb ft Tighten speed sensor rotor bolt 3 with the prescribed torque Tightening torque Speed sensor rotor bolt 13 N m 1 3 kg m 9 49 lb ft After adjusting the drive chain slack by means of adjusters 4 tighten wheel spindle nut 5 with the specified torque Tightening torque Rear axle nut 100 N m 10 0 kg m 73 lb ft For information...

Page 135: ...3 Fully screw in throw out 4 onto the throw out lever and place both parts on the push rod Grease the seal lip and the throw out balls Specific product AGIP GREASE 30 Position the throw out as shown in the figure at the right Fully tighten the throw out fastening bolts with the related spacer Apply a small quantity of threadlocking product to the throw out fas tening bolts Specific product LOC TIT...

Page 136: ...line with each other Tighten to the specified torque Torque pressure Gearchange lever gear shaft fixing bolt Replace the pedal in the position as described in the Suspension chapter Tighten the bolts of the exhaust tubes and the fixing bolts of the silencers to the specified torque When refitting the exhaust tubes to the cylinders renew the gaskets 9 8 11 7 N m 1 1 2 kg m 9 8 11 7 N m 1 1 2 kg m 2...

Page 137: ...ecified torque Torque pressures Engine support frame fixing engine 44 1 49 05 N m 4 5 5 0 kg m Engine support frame fixing 44 1 49 05 N m 4 5 5 0 kg m Reassemble on top of the engine support frames the anti vibra tion mountings for the tank Check and adjust the following Page Engine coolant B 19 Engine oil B 16 Synchronisation of the butterfly valves C 69 Tickover adjustment B 17 Transmission chai...

Page 138: ...camshaft cylinder head piston connecting rod etc and sort the parts into groups so that each component can be reinstalled in its original position Remove the front and rear spark plugs Remove crankcase breather pipe 2 6 Remove thermostat casing 3 with pipes 4 3 4 4 5 5 Remove water joints 5 and O rings 6 from the head of each cylin der 4 2 ...

Page 139: ...he mark on the valve gear timing inspection hole and bring the camshafts to the position shown in the figure In the above condition the no 1 front cylinder is at the top dead centre TDC of the compression stroke and lines A on the cam shafts are parallel with the mating surface of the cylinder head cover see pages D 86 87 Remove valve gear timing inspection plug 1 and generator cover plug 2 NO 1 F...

Page 140: ...nsion adjuster 5 and the related gas ket To facilitate reinstallation slightly loosen front timing chain tension adjuster bolt 6 before removing the adjuster Remove no 2 valve motion idler gear sprocket 7 after removing shaft 8 with copper washer 9 and thrust washer 10 Take care not to drop thrust washer 10 into the crankcase Remove cylinder head bolts M6 11 and timing chain stretcher fastening bo...

Page 141: ... rear cylinder heads To identify each cylinder head mark the positions of the front and rear cylinders Refer to pages D 81 104 for instructions on cylinder head serv icing Remove cylinder head gasket 3 dowel pins 4 timing chain guide 5 cylinder nuts 6 and clamp 7 Remove the cylinder Firmly grip the cylinder at both ends and lift it up squarely If the cylinder does not come out loosen the gasket by...

Page 142: ...camshaft position sensor 1 and the related gasket Remove the cylinder head cover bolts and the related gaskets Remove cylinder head cover 2 and the related gaskets Remove the dowel pins Turn the crankshaft until the R T line on the generator rotor is aligned with the mark on the valve gear timing inspection hole and bring the camshafts to the position shown in the figure In the above condition the...

Page 143: ... crankcase Remove the two camshafts intake 1 and exhaust 2 Remove C rings 3 Remove dowel pins 4 Take care not to drop C rings 3 and dowel pins 4 into the crankcase Remove rear timing chain tension adjuster 5 and the related gas ket To facilitate reinstallation slightly loosen rear timing chain tension adjuster bolt 6 before removing the adjuster 3 1 4 3 6 2 4 5 8 7 9 10 ...

Page 144: ... Loosen the cylinder head bolts gradually by following a crosswise pattern CAUTION Take care not to damage the cylinder while removing or handling it To identify each cylinder head mark the positions of the front and rear cylinders Refer to the section CAMSHAFT CYLINDER HEAD for instruc tions on cylinder head servicing Remove cylinder head nuts M6 4 Remove cylinder head nut M8 5 Loosen cylinder nu...

Page 145: ... Write the cylinder numbers on the crowns of their respective pis tons Refer to page D 108 for information on how to inspect the cylinder and the piston Remove starter motor 8 Remove cylinder head gasket 1 dowel pins 2 timing chain guide 3 and cylinder nuts 4 Remove the cylinder Firmly grip the cylinder at both ends and lift it up squarely If the cylinder does not come out loosen the gasket by gen...

Page 146: ...shings 9 from the crankcase and the generator cover Remove generator cover 1 Remove dowel pin 2 and gasket 3 Remove starting torque limiter 4 and washers 5 Remove starting idler gear 6 spacer 7 and shaft 8 1 2 3 5 4 6 8 9 7 ...

Page 147: ...n Remove water pump casing 1 with the O ring Remove dowel pin 2 Remove impeller 3 Remove clutch bell housing cover 4 Remove clutch cover 5 and the clamps Extract the clutch cover squarely to avoid damaging the water pump oil seal Refer to page D 125 for instructions on how to remove and fit the oil seal and the mechanical seal Remove gasket 6 and dowel pins 7 1 2 7 6 7 3 ...

Page 148: ...Remove pressure plate 1 Remove push rod 2 bearing 3 and thrust washer 4 Remove clutch push rod 5 Should push rod 5 be difficult to extract use a magnet or an iron wire Remove the clutch driving and driven plates Remove spring washer 6 and its seat 7 Specific tool 800096675 Clutch hub sleeve support 5 1 3 4 2 7 6 8 ...

Page 149: ...emove primary driving gear assembly 6 Remove washer 1 Remove clutch drum 2 together with driving cam 3 and driven cam 4 Remove driving cam 3 and driven cam 4 from clutch drum 2 These three parts must be replaced as a set 3 4 2 1 4 3 2 6 5 ...

Page 150: ... Remove needle roller bearing 1 collar 2 and thrust washer 3 Remove oil pump driven gear 4 after removing the circlip Remove pin 5 and washer 6 Take care not to drop the circlip pin 5 or washer 6 into the crank case Remove oil pressure regulator 7 and oil sump filter 8 8 1 2 3 3 5 6 7 9 10 ...

Page 151: ...eeth of the scissors gears Remove no 1 valve motion idler gear sprocket 4 and timing chain 5 Remove key 6 Remove neutral switch contact 1 and the related spring 2 While holding the generator rotor with a 36 mm spanner remove no 1 valve motion idler gear sprocket nut 3 and the related washer 5 4 6 2 1 ...

Page 152: ...r rotor with a 36 mm 1 417 in span ner remove primary driving gear nut 1 This nut has a left hand thread Turning it anticlockwise may cause damage Remove washer 2 Remove primary driving gear assembly 3 Refer to page D 130 for instructions on how to remove and fit the primary driving gear Remove key 4 and thrust washer 5 1 3 2 4 5 ...

Page 153: ...tor rotor assembly 1 by rotating the spe cial tool while holding the rotor with a 36 mm 1 417 in spanner Specific tool 800096684 Rotor extractor Remove key 2 and starting driven gear 3 Remove no 1 valve motion idler gear sprocket 4 and timing chain 5 Remove the gearbox cover bolts and clamp 6 Remove gearbox cover 7 8 9 3 2 6 7 8 1 4 5 ...

Page 154: ...6659 Oil filter spanner Pull out gear shaft arm 1 with washers 2 Remove gear preselector plate 3 Remove gear preselector stop 4 with the related spring and washer Remove gear arm stop bolt 5 Remove oil seal retainer 6 and engine sprocket spacer 7 with the O ring 2 2 1 4 3 5 6 7 1 2 9 8 ...

Page 155: ...he crankcase separator so that the tool arms are parallel with the crankcase sides The crankshaft and the transmission components must remain in the left crankcase half When separating the crankcase tap the countershaft end with a plastic mallet Remove dowel pins 1 Remove crankshaft 2 along with thrust shim 3 Refer to page D 153 for instructions on how to service the crank shaft and the connecting...

Page 156: ...r to page D 170 for details of how to inspect the oil pump Remove reed valve 4 Remove piston cooling oil nozzles 5 from the left and right crank case halves Remove the oil seals using the specially designed tool Specific tool 800096653 Gasket separator Replace the removed oil seal with a new one 3 5 2 1 ...

Page 157: ...ctions on how to remove and install the crankshaft bearings Remove the bearing setscrews Remove bearings 1 2 3 4 5 and 6 using the special tools Specific tools 800096676 Bearing extractor for 1 800096683 Sliding shaft for 1 800096655 Bearing separator for 2 4 5 800096656 Bearing separator for 3 6 2 1 3 6 7 5 4 ...

Page 158: ...ed by following the disassembling proce dure in reverse order However a number of operations require spe cial instructions or precautions Apply engine oil over all movable and sliding parts before reassembly Fit bearings 1 2 4 5 6 and 7 in the crankcase using the specially designed tools Specific tools 800096873 Bearing installer for 1 6 7 800096657 Bearing installer for 2 4 5 Fit bearing 3 in the...

Page 159: ...GREASE 30 Install the oil jet in the left crankcase half Tighten the oil gallery plug with the specified torque Specific product Oil gallery plug M8 10 N m 1 0 kg m 7 3 lb ft Fit new O rings to the oil jet To prevent oil leakage always use new O rings Apply engine oil to the O ring when installing the oil jet Apply a small quantity of specific product to the bolts and then tighten with the prescri...

Page 160: ...case half Apply a film of molybdenum bisulphide to the crankshaft bearings and to the shim Specific product MOLIKOTE Never strike the crankshaft with a plastic mallet when in stalling it in the crankcase Installation of the crankcase in the left crankcase half should be an easy operation Fit countershaft assembly 2 and driving shaft assembly 3 Fit washer 4 to the driving shaft Insert dowel pins 11...

Page 161: ...the RHODORSEAL 5552 seal ant to the oil hole the oil groove and the bearing Apply the product to distorted surfaces as it forms a relatively thick film Fit plate 1 and oil pump 2 to the right hand crankcase half Apply a small quantity of specific product to the oil pump fastening bolts and to the plate bolts and then tighten with the prescribed torques Specific product LOC TITE 243 Tightening torq...

Page 162: ...alize the pressure Tighten all fastening bolts with the specified torques Tightening torques Crankcase bolts M8 22 N m 2 2 kg m 16 06 lb ft M6 11 N m 1 1 kg m 8 03 lb ft When assembling the left and right crankcase halves take care not to drop the O rings into the crankcase Left hand crankcase half ...

Page 163: ...BOND TB 1215 Tightening torque Oil pressure switch 14 N m 1 4 kg m 10 22 lb ft After tightening the crankcase bolts ensure that the crankshaft the driving shaft and the countershaft can rotate freely Apply a film of engine oil to the oil filter gasket before installation Install the oil filter by rotating it manually until the filter gasket comes into contact with the mounting surface Specific too...

Page 164: ...ar preselector stop bolt 3 and then tighten with the specified torque Specific product LOC TITE 243 Tightening torque Gear preselector stop bolt 10 N m 1 0 kg m 7 3 lb ft Ensure that the gear preselector stop moves properly Check the neutral position Fit the gear preselector stop plate after aligning preselector pins A with plate holes B Apply a small quantity of specific product to gear preselect...

Page 165: ... Use a new gasket to prevent oil leakage Fit the gearbox cover Fit the new sealing washer on bolt 3 and the clamp on bolt 4 as shown in the figure Fit a new sealing washer to prevent oil leakage Grease the oil seal lip before fitting the gearbox cover Specific product AGIP GREASE 30 Install oil seal retainer 5 Install no 1 valve motion idler gear sprocket 6 and timing chain 7 5 6 7 1 2 1 4 3 Degre...

Page 166: ...ator rotor assembly 2 and driven starting gear 3 to the crankshaft Apply specific product to rotor bolt 4 and then fit it Specific product LOC TITE 270 While holding the generator rotor with a 36 mm spanner tighten its bolt 4 with the specified torque Tightening torque Rotor bolt 160 N m 16 0 kg m 116 8 lb ft Fully insert key 6 into its slot on the crankshaft 1 4 A 5 6 2 3 ...

Page 167: ... the subsequent installation of the no 2 valve motion idler gear sprocket see pages D 83 to D 88 Install primary driving gear assembly 1 and washer 2 The convex side of washer 2 must face outwards Fit the primary driving gear nut This nut has a left hand thread Mark L A on the nut must face outwards While holding the generator rotor with a 36 mm spanner tighten the primary driving gear nut with th...

Page 168: ...on idler gear sprocket nut 2 with the related washer While holding the crankshaft on the generator rotor tighten no 1 valve motion idler gear sprocket nut 2 with the specified torque Tightening torque No 1 valve motion idler gear sprocket nut 70 N m 7 0 kg m 51 1 lb ft Before tightening the no 1 valve motion idler gear sprocket nut be sure to engage the front and rear timing chains with their resp...

Page 169: ...Fit the thrust washer on the countershaft Bevelled side C of the thrust washer must face the crankcase side Install oil sump filter 1 and oil pressure regulator 2 Oil sump filter projection A must face downwards Tighten oil pressure regulator 2 with the specified torque Tightening torque Oil pressure regulator 28 N m 2 8 kg m 20 44 lb ft 2 1 A 4 3 B 5 5 6 C ...

Page 170: ...untershaft When installing primary driven gear assembly 3 align the teeth of the primary gears by inserting a bar of suitable size into their holes Be sure to engage the oil pump driving and driven gears with the primary driving and driven gears When installing the oil pump driving gear align pin A with slot B and turn oil pump driving gear convex side C to the primary driv ing gear Fit thrust rin...

Page 171: ...utch hub sleeve support Fit clutch driving cam 1 on clutch drum 2 Align I mark A on the clutch driving cam with I mark A on driven cam 3 Fit clutch drum 2 with driving cam 1 and driven cam 3 to the countershaft These three parts must be replaced as a set Fit washer 4 to the countershaft The convex side of the washer must face outwards Lock clutch drum nut 5 with a punch 3 2 1 4 5 1 2 3 ...

Page 172: ... thickness 1 6 mm 0 063 in 7 pcs b No 2 driven plate thickness 2 0 mm 0 079 in 2 pcs Correctly fit spring washer seat 1 and spring washer 2 to the clutch drum Insert the clutch driving and driven plates one by one into the clutch drum in the order shown in the figure Insert no 2 driving plate B first There are two types of driving plates no 1 and no 2 differ ing in inside diameter Insert the outer...

Page 173: ...to the countershaft Place pressure plate 5 on the clutch drum While holding the generator rotor with a 36 mm spanner tighten the clutch spring fastening bolts with the specified torque following a crisscross pattern see figure Tightening torque Clutch spring fastening bolts 10 N m 1 0 kg m 7 3 lb ft Install gasket 6 and dowel pins 7 Use a new gasket to prevent oil leakage 1 4 2 3 5 7 6 7 ...

Page 174: ...washer to prevent oil leakage Fit a new O ring on clutch bell housing cover 1 Use a new O ring to prevent oil leakage After degreasing groove D of clutch bell housing cover 1 correctly position the O ring in the groove Apply specific product to the O ring tab and to clutch bell housing groove D Specific product RHODORSEAL 5552 Grease the O ring Specific product AGIP GREASE 30 Fit clutch bell housi...

Page 175: ...r 2 and its fastening bolt 1 to the shaft Tighten impeller fastening bolt 1 with the specified torque Tightening torque Impeller fastening bolt 8 Nm 0 8 kg m 5 84 lb ft Fit dowel pin 3 Fit a new O ring on water pump casing 4 Use a new O ring to prevent oil leakage Grease the O ring Specific product AGIP GREASE 30 Fit water pump casing 4 Temporarily tighten the water pump casing bolts 1 3 2 4 E F 1...

Page 176: ...t 3 Apply engine oil and specific product to shaft 3 Specific product MOLIKOTE Fit bushings 4 into the crankcase and the generator cover Apply engine oil and specific product inside the bushings Specific product MOLIKOTE Install starting torque limiter 5 and fit washers 6 Fit dowel pin 7 and gasket 8 Use a new gasket to prevent oil leakage 1 2 3 4 5 6 8 7 6 5 6 ...

Page 177: ... the O ring Specific product AGIP GREASE 30 Install the starter motor Firmly tighten the starter motor fastening bolts together with clamp 1 Fit the piston rings in the following order scraper ring 2nd ring 1st ring The 1st and 2nd rings differ in profile When fitting the 1st ring on the piston be sure to turn its convex side upwards The 2nd middle ring bears the lettering RN stamped on one side T...

Page 178: ...n pin Specific product MOLIKOTE When installing the front and rear pistons triangular marks A must be positioned on the exhaust side Place a clean rag over the cylinder base to prevent the piston pin circlip from falling into the crankcase Install the front and rear pistons Pull up the timing chains or they may get caught between the crankcase and the valve gear driving sprocket when the crankshaf...

Page 179: ...lves as shown in the figure When replacing stud bolt A apply THREEBOND TB 1215 to the thread on the crankcase side Specific product THREEBOND TB 1215 Fit dowel pins 2 and new gaskets 3 to the crankcase To prevent oil leakage use new gaskets Apply engine oil to the sliding surfaces of the pistons and cylin ders The cylinders are identified by the stamped letters F and R F Front no 1 cylinder R Rear...

Page 180: ...n cylinder M6 nuts 1 Apply clamp A with the front cylinder nut as shown in the figure Pull the timing chains out of the cylinders and fit chain guides 2 There are slideways cast in the crankcase for the lower ends of each timing chain guide 2 Take care to properly insert timing chain guides 2 into the slideways Fit dowel pins 3 and the new cylinder head gaskets 4 on the front and rear cylinders To...

Page 181: ... m 4 2 kg m 30 66 lb ft Fit the washers on the cylinder head bolts M10 as shown in the figure Apply engine oil to the washers before fitting the cylinder head bolts After screwing the cylinder head bolts M10 tight fit cylinder head nuts M8 1 M6 2 and bolts M6 3 Tighten cylinder head nuts 1 and 2 and bolts 3 and cylinder nuts 4 Tightening torques Cylinder head nut M8 1 25 N m 2 5 kg m 18 25 lb ft C...

Page 182: ...6 lb ft Fit the washers on the cylinder head bolts M10 as shown in the figure Apply engine oil to the washers before fitting the cylinder head bolts After screwing the cylinder head bolts M10 tight fit cylinder head nuts M8 1 M6 2 bolts M6 3 and oil cooler mounting bracket 4 Tighten cylinder head nuts 1 and 2 and bolts 3 and cylinder nuts 5 Tightening torques Cylinder head nut M8 1 25 N m 2 5 kg m...

Page 183: ...sert the end of its support A into the guide cast in the cylinder When fitting the no 1 front timing chain stretcher pass it behind rib B Tighten the timing chain stretcher fastening bolts with the speci fied torque Tightening torque Timing chain stretcher fastening bolt 10 Nm 1 0 kg m 7 3 lb ft No 1 front cylinder No 2 rear cylinder No 1 front cylinder No 2 rear cylinder 1 2 FRONT FRONT ...

Page 184: ...er gears sprock ets Apply molybdenum bisulphide grease to the no 2 valve motion idler gear sprocket to its shaft 1 and to thrust washer 2 Specific product MOLIKOTE Thrust washer 2 must be selected for each cylinder head Refer to page D 84 for information on thrust washer specifications To facilitate proper installation use paint to mark line C on the no 2 valve motion idler gear sprocket Fit the n...

Page 185: ...nder head refer to pages D 83 87 If line A does not align with line B rotate the generator rotor 360 degrees one full turn to bring the F T line on the generator rotor at the valve gear timing inspection hole mark and correctly reinstall the no 2 valve motion idler gear sprocket see figure Pull up the timing chains or they may get caught between the crankcase and the valve gear driving sprocket wh...

Page 186: ...dler gear sprocket shaft 40 Nm 4 0 kg m 29 2 lb ft NO 1 FRONT TIMING CHAIN TENSION ADJUSTER Fit the front timing chain tension adjuster by following the proce dure described below The timing chain tension adjusters differ in shape 1 For no 1 front cylinder 2 For no 2 rear cylinder Fully screw in timing chain tension adjuster bolt 3 3 1 2 ...

Page 187: ...asing ratchet 2 From this position unscrew adjuster bolt 1 until adjuster rod 2 locks The timing chain tension adjuster is now ready for installation Unscrew adjuster bolt 3 while compressing the adjuster rod Fit a new gasket 4 To prevent oil leakage use a new gasket 1 3 1 4 ...

Page 188: ...ng the timing chain tension adjuster ensure that it works properly by checking the timing chain slack REAR NO 2 VALVE MOTION IDLER GEAR SPROCKET To install the rear no 2 valve motion idler gear sprocket the crank shaft must be in the position top dead centre of the compression stroke used for the installation of the front idler gear sprocket The other procedures are the same as those used for the ...

Page 189: ...ghten the fastening bolts with the specified torque Tightening torque Timing chain tension adjuster fastening bolt 10 N m 1 0 kg m 7 3 lb ft Fit O ring 2 spring 3 and front adjuster bolt 4 and then tighten with the specified torque Grease O ring 2 before installation Specific product AGIP GREASE 30 Tightening torque Timing chain tension adjuster bolt rear 4 7 N m 0 7 kg m 5 11 lb ft A click may be...

Page 190: ...k of the valve gear timing inspection hole Check the positions of lines A on the front and rear no 2 valve motion idler gears sprockets No 1 front cylinder top dead centre TDC of compression stroke NO 1 FRONT CAMSHAFTS In the above conditions install the no 1 front intake and exhaust camshafts by following these steps FRONT ...

Page 191: ...afts in the cylinder head ap ply specific product to their journals Apply engine oil to the camshaft journal bearings Specific product MOLIKOTE Position the no 1 front intake and exhaust camshafts Align lines A on the camshafts so that they are parallel with the mating surface of the cylinder head cover Position the cam faces as shown in the figure Insert C rings 5 into the groove of each camshaft...

Page 192: ... head or the camshafts Each camshaft is identified by a die cast letter A Tighten the camshaft bearing bolts with the prescribed torque Tightening torque Camshaft bearing bolt 10 N m 1 0 kg m 7 3 lb ft The camshaft bearing bolts are made of a special material having a much higher strength than other high strength bolts Never use bolts other than those specified These bolts are identified by a 9 st...

Page 193: ...he mark of the tappet inspection hole In this position engraved line A of the no 2 valve motion idler gear sprocket is not visible Position the no 2 rear intake 1 and exhaust 2 camshafts Align lines B on the camshafts so that so that they are parallel with the mating surface of the cylinder head cover Position the cam faces as shown in the figure Insert C rings 3 into the groove of each camshaft F...

Page 194: ...or the camshafts Each camshaft is identified by a die cast letter A Tighten the camshaft bearing bolts with the prescribed torque Tightening torque Camshaft bearing bolt 10 N m 1 0 kg m 7 3 lb ft The camshaft bearing bolts are made of a special material having a much higher strength than other high strength bolts Never use bolts other than those specified These bolts are identified by a 9 stamped ...

Page 195: ...0 degrees 1 full turn and check their positions again Be sure to check the position of F T line A on the genera tor rotor of line B on no 2 valve motion idler gears sprock ets C and of the line on the camshafts No 1 front cylinder top dead centre TDC of compres sion stroke FRONT ...

Page 196: ...ied torque Tightening torque Camshaft position sensor fastening bolt 8 N m 0 8 kg m 5 84 lb ft To prevent oil leakage fit a new gasket Fit new gaskets 2 and 3 on each cylinder head cover Apply specific product to the gasket end caps as shown in the figure Specific product RHODORSEAL 5552 To prevent oil leakage use new gaskets Fit dowel pins 4 on the front and rear cylinder heads 1 3 2 3 No 1 front...

Page 197: ...ad cover bolts with the specified torque Tightening torque Cylinder head cover bolt 14 N m 1 4 kg m 10 22 lb ft Tighten tappet inspection hole plug 2 and generator cover plug 3 with the specified torques Tightening torques Tappet inspection hole plug 23 N m 2 3 kg m 16 79 lb ft Generator cover plug 15 N m 1 5 kg m 10 95 lb ft Fit new O rings to the cooling system joint and grease them Specific pro...

Page 198: ...ing screws Turn the heads of the fastening screws to the left Fit crankcase breather pipe 1 Fit the spark plugs on each cylinder head and tighten them with the specified torque Tightening torque Spark plug 11 N m 1 1 kg m 8 03 lb ft Before using an ignition spanner screw in the spark plugs manually to avoid damaging the aluminium threads 1 ...

Page 199: ...D 81 ENGINE CAMSHAFT CYLINDER HEAD ...

Page 200: ...D 82 ENGINE CONTENTS DESCRIPTION OF THE VALVE GEAR SYSTEM D 83 REMOVING THE CAMSHAFTS D 88 CHECKING AND SERVICING THE CAMSHAFTS AND THE CYLINDER HEAD D 90 INSTALLING THE CAMSHAFTS D 102 ...

Page 201: ...gure below shows the positions of the primary driving gear and of the no 1 valve motion idler gear sprocket when the piston in the front cylinder is at each of the two top dead centres The difference between the compres sion and the exhaust top dead centres as seen on the gear is in the position of the no 1 valve motion sprocket While the meshing teeth of the no 1 valve motion idler gear continuou...

Page 202: ...pression stroke If on the other hand the engraved line points in the opposite direction the front cylinder is at the top dead centre of the exhaust stroke The no 1 valve motion idler gear sprocket has in fact only one punched mark This mark should be located in either of the two positions illustrated as is appropriate for their respective top dead centres NO 1 CAM DRIVE IDLE GEAR SPROCKET FRONT NO...

Page 203: ...s sprockets the cylinder should be at the top dead centre of the compression stroke If the relative positions of the primary drive gear and the no 1 valve motion idler gear sprocket cannot be checked because the clutch cover remains installed on the engine fit the no 2 valve motion idler gear sprocket temporar ily so that the engraved line is perpendicular to the cylinder head cover mating surface...

Page 204: ...D 86 ENGINE VALVE TIMING DIAGRAM FRONT FRONT CYLINDER TDC OF COMPRESSION STROKE ...

Page 205: ...EX IN COM IN EX POW COM IN POSITION POSITION POSITION Front cylinder Front cylinder head Rear cylinder Rear cylinder head Valve timing inspection hole Primary driving gear and no 1 valve motion idler gear sprocket Refer to figure on page 3A 2 ...

Page 206: ...ch step The intake camshaft The exhaust camshaft see page D 22 Remove The radiator see page D 5 The spark plug see page B 7 To facilitate the removal disconnect the engine coolant recovery tube the small tube on the radiator by slackening the clamp band The cylinder head cover see page D 21 The tappet inspection hole plug The generator cover plug see page D 21 The camshaft journal bearings see pag...

Page 207: ... Refer to the pages indicated for details on how to perform each step The intake camshaft The exhaust camshaft see page D 25 Remove The saddle The spark plug page B 8 The cylinder head cover see page D 24 The tappet inspection hole plug The generator cover plug see page D 21 The camshaft journal bearings see page D 24 ...

Page 208: ...cation of each removed component Sort the parts into groups designated as No 1 No 2 Ex haust Intake etc so that each part can be restored to its original position during reassembly CHECKING AND SERVICING THE CAMSHAFTS AND THE CYLINDER HEAD CAM WEAR Worn out cams are often the cause of mistimed tappet operation and reduced power output The limit of cam wear is specified for the intake and exhaust c...

Page 209: ... tern Tightening torque Camshaft journal bearing bolt 10 N m 1 0 kg m 7 3 lb ft Do not turn the camshaft while the plastigauge is in place Remove the camshaft journal bearings and measure the length of the compressed plastigauge with the scale The measurement should be taken at the widest portion If the measured camshaft journal oil clearance exceeds the speci fied limit measure the inside diamete...

Page 210: ... the gears and the automatic decompressor unit They are unserviceable TIMING CHAIN TENSION ADJUSTER The timing chain tension adjusters are maintained at the proper ten sion automatically Release ratchet A and move push rod B into position to see if it slides freely If the push rod is difficult to move or if the ratchet mechanism is faulty replace the timing chain tension adjuster assembly with a n...

Page 211: ...trezzi speciali comprimere le molle della valvola e rimuovere i due semiconi 2 dallo stelo della valvola Specific tools 800096664 Valve spring compression tool 800096665 Valve spring compression attachment Tweezers Remove valve spring retainer 3 and valve springs 4 1 1 Pull out the valve from the opposite side ...

Page 212: ...the specified limit Specific tools Comparator 1 100 mm 10 mm 0 039 3 937 in 0 3937 in Magnetic stand 800096650 V blocks Service limit Valve stem runout 0 05 mm 0 00197 in VALVE HEAD RADIAL RUNOUT Place the comparator at right angles to the valve head face and measure the radial runout If it exceeds the specified limit replace the valve Specific tools Comparator 1 100 mm 10 mm 0 039 3 937 in 0 3937...

Page 213: ...f the stem is within the limit replace the guide Check the clearance again after replacing the valve or the guide Specific tool Micrometer 0 25 mm 0 0 984 in Standard Valve stem O D IN 5 475 5 490 mm 0 2155 0 2161 in EX 5 455 5 470 mm 0 2148 0 2153 in If the valve guides need to be removed in order to be replaced after checking the related parts follow the procedure described in the VALVE GUIDE SE...

Page 214: ...lve seat with an even layer of Prussian blue Fit the valve and rotate it to obtain a clear impression of the seating area In this operation use the valve lapper to hold the valve head The circular impression left on the valve seating area must be con tinuous without any breaks In addition the width of the coloured ring representing the width of the seating area must be in the range specified below...

Page 215: ... as possible If the seating area is positioned too high on the valve or if it is too wide lower or narrow it by using 15 60 cutters on the exhaust side and 30 60 cutters on the intake side If the seating area is too low or too narrow raise or widen it using the 45 cutter After obtaining the desired valve seat position and width use the 45 cutter lightly to remove any burrs caused by the previous c...

Page 216: ...sh of the spiral spring ensures the valve seal A weakened spring results in reduced power output and often accounts for ab normal noise from the valve gear mechanisms Check the strength of the springs by measuring their free length and the force required to compress them If the free length is less than specified or if the force required for compression is not in the specified range replace both th...

Page 217: ...rance 0 15 0 29 mm 0 0059 0 0114 in If the thrust clearance exceeds the specified range adjust it by fol lowing these steps Remove the thrust ring and measure its thickness with a microm eter If the clearance is not as specified change the thrust washer with a different one Measure the thrust clearance again as described above Specific tool Micrometer 0 25 mm 0 0 984 in Standard check Unit mm in C...

Page 218: ...oduct MOLIKOTE Fit the valve springs with small pitch portion A facing the cylinder head B large pitch portion Fit the spring valve retainer and using the valve lifter compress the springs fit the cotter halves to the stem end and then release the tool to allow cotters 1 to wedge between the retainer and the stem Ensure that rounded lip C of the cotter halves fits snugly into groove D in the stem ...

Page 219: ...rew threads Specific product LOC TITE 243 Ensure that UP mark A faces upwards Use a new O ring to prevent air from being sucked in through the joint EXHAUST PIPE When installing the rear exhaust pipe tighten the bolts with the specified torque Tightening torque Exhaust pipe bolt 23 N M 2 3 kg m 16 79 lb ft To prevent leakages of exhaust gas be sure to use a new gasket CAMSHAFT POSITION SENSOR When...

Page 220: ...rocedure in reverse order Refer to the pages indicated for details on how to perform each step Fit The camshafts The dowel pins The C rings see pages D 72 73 The camshaft journal bearings see page D 74 The generator cover plug The tappet timing inspection plug see page D 79 The cylinder head cover see pages D 78 79 ...

Page 221: ...R CAMSHAFT Install the components listed below in the order indicated When fitting the components follow the fitting procedures described in the pages indicated Fit The camshafts The dowel pins The C rings see page D 75 The camshaft journal bearings see page D 76 ...

Page 222: ...D 104 ENGINE The generator cover plug The tappet timing inspection plug see page D 79 The cylinder head cover see pages D 78 79 The spark plug ...

Page 223: ...ENTS REMOVING THE CYLINDER AND THE PISTON D 106 CHECKING THE CYLINDER AND THE PISTON D 108 INSTALLING THE CYLINDER AND THE PISTON D 111 POSITIONING OF PISTON RINGS EXHAUST 2nd ring Lower side ring Upper side ring 1st ring Spacer INTAKE ...

Page 224: ... the no 1 front cylinder and piston Refer to the pages indicated for details on how to perform each step Remove The cylinder head see pages D 21 23 The timing chain guide The cylinder head gasket The dowel pins see page D 23 The cylinder see page D 23 The piston pin The piston see page D 24 CREMOVING THE CYLINDER AND THE PISTON ...

Page 225: ...cated before removing the no 2 rear cylinder and piston Refer to the pages indicated for details on how to perform each step Remove The cylinder head see page D 26 The timing chain guide The cylinder head gasket The dowel pins see page D 27 The cylinder see page D 27 The piston pin The piston see page D 27 ...

Page 226: ...auge Service limit Cylinder distortion 0 05 mm 0 00197 in CYLINDER BARREL Check if the barrel wall is scratched pitted or damaged Measure the barrel diameter at six different points Standard Cylinder barrel 98 000 98 015 mm 3 85826 3 85885 in Specific tool Comparator PISTON DIAMETER Using a micrometer measure the outside diameter of the piston in the position shown in the figure If the measurement...

Page 227: ...the 1st and 2nd piston rings If either of the two clearances exceeds the speci fied limit replace both the piston and the piston rings Specific tools Thickness gauge Micrometer 0 25 mm 0 0 984 in Service limit Piston ring groove clearance 1st 0 18 mm 0 0071 in 2nd 0 15 mm 0 0059 in Standard Groove width 1st 0 93 0 95 mm 0 0367 0 0374 in 1 55 1 57 mm 0 0610 0 0618 in 2nd 1 01 1 03 mm 0 0398 0 0405 ...

Page 228: ...n Specific tool Thickness gauge PISTON PIN AND PISTON PIN BORE Using a bore gauge measure the inside diameter of the piston pin bore and then using a micrometer measure the outside diameter of the piston pin at three different points If the difference between the two measurements exceeds the specified limit replace the piston and the piston pin Service Limit Piston pin bore I D 22 030 mm 0 8672 in...

Page 229: ...st element to be inserted into the scraper ring groove is spacer 1 After positioning the spacer fit the two side rings 2 The spacer and the side rings do not have an upper or lower side and can be fitted either way Position the end gaps of the three piston rings as shown in the figure Before inserting the pistons into the cylinders ensure that the ring end gaps are positioned as indicated When ins...

Page 230: ...ollowing the removing procedure in re verse order Refer to the pages indicated for details on how to perform each step Fit The piston pin The piston The oil jet The dowel pins The gasket see pages D 61 D 62 and D 63 The cylinder see page D 62 The cylinder head see page D 64 ...

Page 231: ...y following the removing procedure in re verse order Refer to the pages indicated for details on how to perform each step Fit The piston pin The piston The oil jet The dowel pins The gasket see page D 59 The cylinder see page D 62 and D 63 The cylinder head see page D 63 ...

Page 232: ...REMOVING THE CLUTCH THROW OUT D 116 CHECKING THE CLUTCH AND THE THROW OUT D 117 INSTALLING THE CLUTCH D 119 INSTALLING THE CLUTCH THROW OUT D 122 CLUTCH No 1 driving plate 9 pcs No 1 driven plate 7 pcs No 2 driving plate 1 pcs No 2 driven plate 2 pcs ...

Page 233: ...pages indicated for details on how to perform each step Drain The engine oil Remove The clutch bell housing cover see page D 29 The clutch springs The pressure plate see pages D 29 and D 30 The push rod The bearing The washer see page D 30 The clutch push rod The clutch plates The spring washer The spring washer seat see page D 30 ...

Page 234: ...assembly see page D 37 The needle roller bearing The collar The thrust washer see page D 32 REMOVING THE CLUTCH THROW OUT Remove the throw out components as described below Refer to the pages indicated for details on how to perform each step Remove The gearchange lever and the left hand footrest The engine pinion cover see pages D 7 and D 8 ...

Page 235: ...iper If any plate is out of specification replace it with a new one Standard Driving plate thickness no 1 and no 2 2 92 3 08 mm 0 1159 0 1212 in Specific tool Vernier caliper Measure the width of the driven plate teeth with a vernier caliper If the teeth on a plate have worn down beyond the service limit re place the plate Service limit Driving plate tooth width no 1 and no 2 12 9 mm 0 5070 in Spe...

Page 236: ...ed limit Replace all the springs if any one of them is out of specification Service limit Clutch spring free length 29 6 mm 1 1653 in Specific tool Vernier caliper CLUTCH BEARING Inspect the bearing of the clutch throw out for any defects and in particular cracks to decide whether it can be reused or needs to be replaced Smooth engagement and disengagement of the clutch largely de pend on the cond...

Page 237: ...es indicated for details on how to perform each step Fit The thrust washer The collar The needle roller bearing see page D 52 The primary driven gear assembly The thrust washer see page D 52 The clutch driven cam The clutch driving cam The clutch drum see pages D 51 and D 53 Washer seat 1 Spring washer 2 see page D 54 ...

Page 238: ...s D 54 and D 55 The clutch push rod The bearing The washer see page D 55 The pressure plate The clutch springs see page D 55 The clutch bell housing cover see page D 56 Adjust the following according to specifications Page Engine oil B 13 Clutch lever play B 15 ...

Page 239: ...D 121 ENGINE Location of thicker 2 0 mm driven plate ...

Page 240: ...e in reverse order Refer to the pages indicated for details on how to perform each step Fit The clutch push rod see page D 18 The throw out assembly The engine sprocket cover The gearchange lever and the left hand footrest Adjust the following according to specifications Page Clutch lever play B 15 ...

Page 241: ...ONTENTS REMOVING THE WATER PUMP AND THE CLUTCH COVER D 124 CHECKING AND SERVICING THE WATER PUMP AND THE CLUTCH COVER D 125 INSTALLING THE WATER PUMP AND THE CLUTCH COVER D 127 Position of sealing washer Position of clamp Position of clamp ...

Page 242: ...ages indicated for details on how to perform each step Drain The engine oil see page B 16 The engine coolant see pages B 19 and B 20 Remove the sump guard see page B 7 Remove The hose mounted directly on the pump housing cover The water pump casing see page D 29 The dowel pin The impeller see page D 29 Clutch cover 4 see page D 29 The dowel pin The gasket REMOVING THE WATER PUMP AND THE CLUTCH COV...

Page 243: ...ver and visually inspect the mechanical seal and the oil seal for damage CHECKING THE OIL SEAL Before removing the clutch cover and draining the engine oil check for leakages of engine oil from the clutch cover drain hole If there is an oil leak remove the clutch cover and visually check the oil seal lip for damage REMOVING THE OIL SEAL AND THE MECHANICAL SEAL Remove oil seal 1 from the clutch cov...

Page 244: ...emove the mechanical seal and the oil seal INSTALLING THE OIL SEAL AND THE MECHANICAL SEAL Using a suitable tool fit a new mechanical seal in the clutch cover When installing the mechanical seal apply LOCTITE to its outer surface Specific product RHODORSEAL 5552 Fit a new oil seal into the clutch cover using a suitable tool Outer side A of the oil seal must face the clutch cover side A Oil seal Me...

Page 245: ...by following the removing procedure in re verse order Refer to the pages indicated for details on how to perform each step Fit The gasket The dowel pin see page D 55 Clutch cover 4 see pages D 55 and D 56 The impeller see page D 56 The impeller fastening bolt see page D 57 The dowel pin ...

Page 246: ...128 ENGINE The water pump casing see pages D 57 and D 58 The water hose Adjust the following according to specifications Page Engine coolant B 19 Engine oil B 16 MECHANICAL SEALING RING DEGREASE IMPELLER ...

Page 247: ... MOTION IDLER GEAR SPROCKET SHAFT D 130 CHECKING THE PRIMARY DRIVING GEAR NO 1 VALVE MOTION SPROCKET AND THE PRIMARY DRIVING GEAR NO 1 VALVE MOTION IDLER GEAR SPROCKET SHAFT D 132 CHECKING AND SERVICING THE PRIMARY DRIVING GEAR D 132 FITTING THE PRIMARY DRIVING GEAR AND THE NO 1 VALVE MOTION IDLER GEAR SPROCKET SHAFT D 133 Left hand thread ...

Page 248: ...g gear the no 1 valve motion idler gear sprocket and the no 1 valve motion idler gear sprocket shaft remove the items listed below in the order indicated Refer to the pages indicated for details on how to perform each step Remove The camshafts The timing chain tension adjusters The no 2 valve motion idler gears sprockets see page D 88 The following parts can be removed without removing the cylinde...

Page 249: ...e D 28 The no 1 valve motion idler gear sprocket The timing chain see page D 33 The primary driving gear see page D 34 The generator rotor see pages D 34 and D 35 The no 1 valve motion idler gear sprocket shaft The timing chain see page D 35 ...

Page 250: ...et with new parts CHECKING AND SERVICING THE PRIMARY DRIVING GEAR CHECKING THE PRIMARY DRIVING GEAR Visually check the wear of the gear teeth If the teeth are worn re place the gear DISASSEMBLING THE PRIMARY DRIVING GEAR Remove the circlip and disassemble the primary driving gear Specific tool 800096765 Snap ring pliers 1 ASSEMBLING THE PRIMARY DRIVING GEAR Fit the springs between the gears as sho...

Page 251: ...ING THE PRIMARY DRIVING GEAR AND THE NO 1 VALVE MOTION IDLER GEAR SPROCKET SHAFT Refer to the sections on engine assembly and installation for infor mation on how to fit the primary driving gear the no 1 valve motion idler gear sprocket and the no 1 valve motion idler gear sprocket shaft ENGINE ASSEMBLY Refer to pages D 40 80 ENGINE INSTALLATION Refer to pages D 13 19 After installing the power pl...

Page 252: ...HAFT POSITION SENSOR D 135 CHECKING AND SERVICING THE STARTING TORQUE LIMITER THE GENERATOR AND THE CRANKSHAFT POSITION SENSOR D 137 INSTALLING THE STARTING TORQUE LIMITER THE GENERATOR AND THE CRANKSHAFT POSITION SENSOR D 140 REMOVING THE STARTER MOTOR D 142 CHECKING AND SERVICING THE STARTER MOTOR D 142 INSTALLING THE STARTER MOTOR D 142 ...

Page 253: ...he pages indicated for details on how to perform each step After draining the engine oil Remove the sump guard see page B 7 Remove the left hand footrest complete with the gearchange lever assembly see page D 7 Unscrew the two screws as shown in the figure and remove the silencer protection Remove the pinion cover by unscrewing the three fixing screws Be careful of the centring pins The clutch thr...

Page 254: ...he gasket see page D 28 The starting torque limiter see page D 28 The starting idler gear The shaft The spacer The bushings see page D 28 The generator rotor assembly see pages D 34 and D 35 The starting driven gear see page D 35 ...

Page 255: ... 2 6 4 kg m 30 66 lb ft Place the torque limiter in a vice and attach the special tools as shown in the figure If the slipping torque is not as specified replace the starting torque limiter with a new one CHECKING THE STARTING TORQUE LIMITER SHAFT BUSH INGS Check the bushings for wear and damage If any defects are found replace the bushings with new ones CHECKING THE STARTER MOTOR SHAFT BEARING Ch...

Page 256: ... 3 96 lb ft Crankshaft position sensor fastening bolt 3 5 5 N m 0 55 kg m 3 96 lb ft CHECKING THE STARTER COUPLING Fit the starting driven gear on the starter coupling and turn the driven gear manually to ensure that the coupling moves freely The gear turns in one direction only If strong resistance opposes rotation check the starter coupling and the contact area between the cou pling and the driv...

Page 257: ... 3 When fitting starter coupling housing 3 on the generator rotor align hole B in the starter coupling housing with projection C on the generator rotor Apply specific product to the bolts and tighten them with the pre scribed torque Specific product LOC TITE 270 Tightening torque Starter coupling bolt 10 N m 1 0 kg m 7 3 lb ft 2 A 3 B 3 C 1 ...

Page 258: ... following the removing procedure in re verse order Refer to the pages indicated for details on how to perform each step Fit The starting driven gear The generator rotor assembly see pages D 47 and D 48 The starting idler gear The shaft The spacer see page D 58 The bushings see page D 58 The starting torque limiter see page D 58 ...

Page 259: ...w out assembly see pages D 16 and D 17 The engine sprocket cover The silencer protection by tightening the two fixings Reassemble the left hand footrest and gearchange lever assem bly as described in page D 18 Adjust the following according to specifications Page Engine oil B 16 Clutch lever play B 19 ...

Page 260: ...l cooler from its supports and push it downwards CHECKING AND SERVICING THE STARTER MOTOR Refer to section G INSTALLING THE STARTER MOTOR Reinstall the starter motor and its two relative mounting bolts and tighten them to the specified torque NOTA Fit clamp 1 to the bolt as shown in the figure Apply specific product to the starter motor O ring Specific product AGIP GREASE 30 To prevent oil leakage...

Page 261: ...GEAR PRESELECTOR CONTENTS REMOVING THE GEAR PRESELECTOR ASSEMBLY D 144 CHECKING AND SERVICING THE GEAR PRESELECTOR ASSEMBLY D 146 INSTALLING THE GEAR PRESELECTOR ASSEMBLY D 148 FOOTREST TOP GEAR CHANGE LEVER HEIGHT ...

Page 262: ...cated for details on how to perform each step Remove The engine pinion cover and the silencer protection see page D 7 and D 8 The left hand footrest and gearchange lever assembly The speed sensor rotor see page D 16 The clutch disengagement assembly see page D 16 The engine pinion see page D 17 REMOVING THE GEAR PRESELECTOR ASSEMBLY ...

Page 263: ...ar covering by unscrewing the five relative fixings see page D 35 The dowel pins The gasket see page D 35 The gear shaft arm see page D 36 The gear preselector plate The gear preselector stop The gear arm stop bolt see page D 36 ...

Page 264: ...ck if gear shaft arm assembly 1 is worn or bent CHECKING THE RETURN SPRINGS Check if return springs 4 and 6 show any signs of damage or fatigue FITTING THE GEAR SHAFT ARM Fit the following parts on gear shaft arm assembly 1 as shown in the figure at the right 2 Washer 6 Plate return spring 3 Circlip 7 Washer 4 Gear shaft return spring 8 Circlip 5 Gear preselector plate 9 Washer Specific tool 80009...

Page 265: ...h a new one REPLACING THE OIL SEAL Remove the gear shaft oil seal from the gearbox cover Fit a new oil seal Always replace removed oil seals with new ones Grease the oil seal lip to avoid damaging the oil seal when fitting the gearbox cover Specific product AGIP GREASE 30 CHECKING THE GEAR SHAFT HOLE Check if the gear shaft holes are worn or damaged ...

Page 266: ...everse order Refer to the pages indicated for details on how to perform each step Fit The gear arm stop bolt The gear preselector stop The gear preselector plate see page D 46 The gear shaft arm see page D 46 The gasket The dowel pins see page D 47 Replace the old gasket with a new gasket The gearbox cover see page D 47 ...

Page 267: ...INE The engine sprocket see page D 16 The speed sensor rotor see page D 16 The clutch throw out assembly see page D 17 The engine sprocket cover The left hand footrest and gearchange lever assembly see page D 18 ...

Page 268: ...D 150 ENGINE Adjust the following according to specifications Page Engine oil B 13 Clutch lever play B 15 Drive chain slack B 17 ...

Page 269: ...D 151 ENGINE CRANKCASE GEARBOX CRANKSHAFT CONNECTING ROD ...

Page 270: ...SMISSION D 153 CHECKING THE CONNECTING ROD AND THE CRANKSHAFT D 160 CHECKING AND SERVICING THE CONNECTING ROD BEARINGS CRANKPINS D 160 CHECKING AND SERVICING THE CRANKSHAFT BEARINGS D 163 ADJUSTING THE CRANKSHAFT THRUST CLEARANCE D 167 INSTALLING THE TRANSMISSION THE CRANKSHAFT AND THE CONNECTING ROD D 168 CONTENTS ...

Page 271: ...NSMIS SION Identify the position of each removed component and sort the parts into groups e g driving driven etc so that each component can be reinstalled in its original position FORK GROOVE PLAY Using a thickness gauge measure the play of the gear change fork in its groove in the gear The play of each gear change fork plays an important role in ensur ing smooth and reliable gear operation Servic...

Page 272: ...iving gear 2 and 6th driving gear 3 Replace the removed O ring with a new one Remove 6th driving gear bushing 4 washer 5 and 3rd 4th driving gears 6 Remove the circlip using the specially designed tool Specific tool 800096765 Snap ring pliers Remove 5th driving gear 7 and its bushing 8 Checking thickness 8 7 6 4 5 2 1 3 ...

Page 273: ...er 2 Remove 1st driven gear bushing 3 washer 4 and 5th driven shaft 5 Remove the circlip using the specially designed tool Specific tool 800096765 Snap ring pliers Remove 4th driven gear 6 and its bushing 7 Remove washer 8 and 3rd driven gear 9 9 7 6 3 5 4 2 1 8 ...

Page 274: ...rive gear 3 its bushing 4 and washer 5 ASSEMBLY Assemble the countershaft and the driving shaft by following the reverse procedure to disassembly Pay attention to the following Turn the bushings manually to ensure that they rotate smoothly Before fitting the gears apply a film of molybdenum bisulphide or engine oil to the driving shaft and the countershaft Grease the O ring before fitting it Speci...

Page 275: ...groove When reassembling the transmission pay attention to the positions of the washers and the circlips The sectional view shown here will serve as a reference for correctly fitting gears washers and circlips see pages D 158 and D 159 When fitting a new circlip pay attention to its direction Fit it so that the thrust side is as shown in the figure After fitting the bushings of the 3rd and 4th dri...

Page 276: ...iven gear 6th driven gear 2nd driven gear Driving shaft 1st driven gear 5th driven gear 4th driven gear 3rd driven gear 6th driven gear 2nd driven gear Driving shaft Countershaft 1st driving gear 5th driving gear 3rd 4th driving gears 6th driving gear 2nd driving gear ...

Page 277: ...D 159 ENGINE ...

Page 278: ...nce with a thickness gauge Service limit Big end side clearance 0 5 mm 0 0197 in Standard Big end width 21 95 22 00 mm 0 8642 0 8661 in Crankpin width 44 17 44 22 mm 1 7389 1 7410 in Specific tool Micrometer 0 25 mm 0 0 9842 in CHECKINGAND SERVICING THE CONNECTING ROD BEARINGS CRANKPINS CHECKING THE CONNECTING ROD BEARINGS CRANKPINS Loosen the bearing cap bolts and tap them with a plastic mallet t...

Page 279: ...Specific tool 800096872 Thickness gauge Never turn the crankshaft or the connecting rod after inserting a piece of plastigauge Remove the bearing cap and measure the length of the compressed plastigauge with the scale Take the measurement at the widest portion Service limit Connecting rod big end oil clearance 0 080 mm 0 00315 in If the oil clearance exceeds the specified limit select the neces sa...

Page 280: ...7 1 8891 in Specific tool Micrometer 25 50 mm 0 984 1 968 in Bearing thickness Colore No parte Spessore Green 1 480 1 484 mm 12164 02F00 0A0 0 0583 0 0584 in Black 1 484 1 488 12164 02F00 0B0 0 0584 0 0585 in Brown 1 488 1 492 mm 12164 02F00 0C0 0 0585 0 0587 in Yellow 1 492 1 496 mm 12164 02F00 0D0 0 0587 0 0589 in Replace the bearing as a set ASSEMBLING THE BEARINGS When fitting the bearings in ...

Page 281: ...rod bearing cap bolt initial 40 N m 4 0 kg m 29 2 lb ft final 80 N m 8 0 kg m 58 4 lb ft Check that the connecting rod rotates freely CHECKING AND SERVICING THE CRANK SHAFT BEARINGS CHECKING THE CRANKSHAFT BEARINGS Check the crankshaft bearings for damage If the bearings are damaged replace them with a specified set of bearings Check the crankshaft journals for damage Using the specially designed ...

Page 282: ...0 0C0 Green 1 994 1 997 mm 12229 02F00 0C0 Black 0 0785 0 0786 in Replace the bearing as a set REPLACING THE CRANKSHAFT BEARINGS Replace the crankshaft bearings using the specially designed tool and following the procedure described below Specific tool 800096654 Crankshaft bearing remover installer Apply the special tool as shown in the figure to remove the crank shaft bearings Remove the cranksha...

Page 283: ...g installer set 800096677 Final drive bearing separating assembling tool Fit the specified crankcase bearings to the special tool Before fitting the bearings apply engine oil to the bearings and the special tool When inserting the bearing align the bearing side with en graved line A and the bearing rim with the contact surface of the special tool Tighten the bolts of the special tool with the spec...

Page 284: ...nkcase hole Be sure to position the grooved bearing on the upper side and the ungrooved bearing on the lower side Align the bearing rims and the surface of the special tool with line B on the crankcase Apply enough engine oil to the special tool and the bearing and then carefully position the special tool Using a hand press gradually insert the bearing into the crank shaft bearing hole until speci...

Page 285: ...n the left hand crankcase half and fit the thrust shim to the crankshaft Fit the right hand crankcase half and temporarily tighten the crank case bolts There is no need to apply specific product to the mating surface The face with oil groove A of thrust shim 1 must face the crank Install the generator rotor with the key and tighten its bolt tempo rarily Fit the thrust washer and the primary drivin...

Page 286: ...Checking that the shim thickness is in the standard range INSTALLING THE TRANSMISSION THE CRANKSHAFT AND THE CONNECTING ROD Refer to the sections on engine assembly and installation for instructions on how to install these engine parts ENGINE ASSEMBLY Refer to pages D 40 D 80 ENGINE INSTALLATION Refer to pages D 13 D 19 Unit mm in Part no Thrust shim thickness 800097666 1 925 1 950 0 07579 0 07677...

Page 287: ...TENTS OIL PUMP D 170 OIL SUMP FILTER OIL PRESSURE REGULATOR D 172 OIL PRESSURE SWITCH OIL COOLER D 175 OIL FILTER D 177 OIL PRESSURE D 177 PISTON COOLING OIL JET OIL NOZZLE D 177 ENGINE LUBRICATION DIAGRAM D 178 ENGINE LUBRICATION SYSTEM D 119 ...

Page 288: ... REMOVAL Remove the oil pump fastening screw Remove oil pump cover 1 Remove rotor shaft 2 driving pin 3 inner rotor 4 and outer rotor 5 from oil pump body 6 CHECK Using a thickness gauge check the clearance of the rotor tip and that of the outer rotor If the clearance exceeds the service limit replace the oil pump with a new one Specific tool Thickness gauge Service limit Rotor tip clearance 0 20 ...

Page 289: ...il pump body Punched mark B on the outer rotor must face the pump body and punched mark C on the inner rotor must face the pump cover Apply a small quantity of specific product to the screw and then tighten it Specific product LOC TITE 243 Refer to the sections on engine assembly and installation for in structions on how to install the oil pump ENGINE ASSEMBLY Refer to pages D 40 80 ENGINE INSTALL...

Page 290: ... in the order indicated Refer to the pages indicated for details on how to perform each step Drain The engine oil see page B 16 The engine coolant see page B 19 Remove the sump guard see page B 7 Remove The water hose The water pump see page D 29 The dowel pin The impeller see page D 29 The clutch cover see page D 29 The dowel pin The gasket ...

Page 291: ...THE OIL PRESSURE REGULATOR Check the operation of the oil pressure regulator by pushing the piston with a suitable bar If the piston does not work replace the oil pressure regulator with a new one CLEANING THE OIL SUMP FILTER Clean the oil sump filter with compressed air ...

Page 292: ...ollowing the removing procedure in re verse order Refer to the pages indicated for details on how to perform each step Fit The oil pressure regulator see page D 51 The oil sump filter see page D 51 The gasket The dowel pin see page D 55 Clutch cover 4 see pages D 55 and D 56 ...

Page 293: ...st the following according to specifications Page Engine coolant B 19 Engine oil B 16 OIL PRESSURE SWITCH OIL COOLER REMOVAL After draining the engine oil remove the oil pressure switch and the oil cooler Refer to the page indicated below for details on how to drain the engine oil Drain The engine oil see page D 16 Remove The oil pressure switch The oil cooler ...

Page 294: ... between the oil cooler fins Check if the cooler shows any signs of oil leakage If any defects are found replace the oil cooler with a new one If the cooler fins are bent or dented straighten them with a small screwdriver INSTALLATION Installation is obtained by following the removing procedure in re verse order Refer to the pages indicated for details on how to perform each step Fit The oil coole...

Page 295: ...age B 16 Remove The oil jet The cylinder The oil jets for each cylinder head see pages D 23 and D 27 The piston cooling oil nozzles see page D 38 INSTALLATION Installation is obtained by following the removing procedure in re verse order Refer to the pages indicated for details on how to perform each step Fit The piston cooling oil nozzles see page D 41 The oil jets for each cylinder head see page...

Page 296: ... TIMING CHAINAND SPROCKETS OIL JET OIL JET NO 1 PISTON C O O L I N G NOZZLE NO 2 PISTON C O O L I N G NOZZLE NO 1 NO 2 CYLINDER WALLS LEFT HAND CRANK SHAFT BEARING NO 1 NO 2 CRANKSHAFT JOURNAL BEARINGS RIGHT HAND CRANK SHAFT BEARING S TA R T E R COUPLING GENERATOR DRIVING SHAFT L E F T H A N D BEARING COUNTERSHAFT LEFT HAND BEAR ING OIL JET OIL GALLERY OIL PRESSURE SWITCH DRIVING SHAFT GEARS AND B...

Page 297: ...D 179 ENGINE ENGINE LUBRICATION SYSTEM ...

Page 298: ...D 180 ENGINE ...

Page 299: ...E 1 SUSPENSIONS AND WHEELS E Section ...

Page 300: ...E 2 SUSPENSIONS AND WHEELS Front wheel E 3 Front suspension E 6 Rear wheel E 17 Rear suspension E 20 Frame E 24 ...

Page 301: ...eath the engine so that the front wheel is raised from the ground Proceed as follows Remove the fixings of the brake pincers and remove the complete assembly as indicated in page F 8 Remove the nut 1 indicated in the figure and also the spacer Slacken the four screws 2 that fix the wheel spindle to the fork legs Slide out the spindle 3 and remove the wheel Do not activate the front brake lever dur...

Page 302: ...heel as shown in the figure The maximum movement values for this check fall into the following categories Axial movement 0 5 mm Eccentricity 0 8 mm Bearing wear generally causes an excessive axial movement or eccentricity Substitute the bearings in this case and if the problem persists substitute the wheel FRONT WHEEL BEARING SUBSTITUTION The substitution of the bearings must be carried out in the...

Page 303: ... direction of the rotation of the wheel Tighten the wheel spindle nut countering the rotation of the spindle by the key as shown in the figure Tighten the wheel spindle fixing screws to the correct torque pressure Front wheel spindle nut 49 53 9 N m Front wheel spindle fixing screws 8 8 8 9 N m Assemble the brake pincers tightening the screws to a torque pressure of 23 25 N m Assemble the brake di...

Page 304: ...wheel travel 150 mm Fork leg oil capacity 680 cc Fork tube oil level 150 mm FRONT FORK REMOVAL Raise the machine sufficiently enough to facilitate the removal of the fork assembly Remove the front wheel as previously described Page E 3 Unscrew the three screws 1 that hold the mudguard attachment 2 in place Remove the front brake tubing from the fork assembly 1 2 1 ...

Page 305: ...carry out this operation after having removed the fuel tank as described in page B 4 FORK ASSEMBLY OVERHAUL Using a 30 mm spanner unscrew the upper plug 4 If necessary hold the stem tight with a vice Take care to not ruin the chromed part of the stem Push the spring down to allow enough space to insert a 19 mm spanner onto the locknut 5 Unscrew the upper plug 4 with the 30 mm spanner as shown in t...

Page 306: ...operation protect the parts that are clamped in a vice with adequate protection Move the cartridge around so that the oil is emptied from it Check that the rod inside the cartridge slides up and down smoothly SUPPORT TUBE SLIDING ASSEMBLY REMOVAL Remove the dust protector 1 and the stop ring 2 underneath Disassemble the sliding assembly from the support tube as shown in the figure For normal clean...

Page 307: ...e sealing ring Remove the bush 2 from the stem Check that the internal surface of the sheath and external surface of the stem are in good condition The sliding bushes must not show signs of excessive wear or lines Check that the oil seals and the dust seals do not show signs of cuts or cracking SUPPORT TUBE SLIDING ASSEMBLY REASSEMBLY It is advisable to use anti wear bushes and new oil seals when ...

Page 308: ...rew complete with washer Tighten it to the correct torque Lower fork screw 50 N m Keep the fork in the vertical position without the spring and the spacer Compress them together completely Pour in 680 cc of specified fork oil Slowly pump several times the internal rod of the assembly until there are no bubbles in the oil There should be a continuous braking action in the fork movement Move the ste...

Page 309: ...e nut on the pumping rod Assemble the spring spacer Lift up the pumping rod and maintain the fork at an angle Assemble the spring Make sure that the nylon bushes on the ends of the spring are in place Compress the spring pull out the pumping rod and insert the 19 mm spanner onto the nut as shown in the figure Check the condition of the O ring on the fork plug If it is damaged substitute it Assembl...

Page 310: ...e order of removal Position the fork tubes to 33 5 mm as indicated in the figure Tighten the four screws at the base of the steering and the two screws at the steering head to a torque of 22 5 24 5 N m Assemble the mudguard and the mudguard attachment Proceed with the reassembly of the wheel as described in page E 5 ...

Page 311: ...bed HANDLEBAR REMOVAL To remove the handlebars from the steering and to substitute the handlebars it is necessary to remove the rear view mirrors the right hand 1 and left hand 2 electrical components assembly the clutch 3 lever assembly and the front brake lever assembly 4 For the electrical components assembly unscrew the lower screws 5 For the clutch lever assembly and the front brake lever ass...

Page 312: ...nstructions for removal in reverse order If the handlebars must be removed from the steering only for the removal of the steering then the above operation does not need to be carried out Remove the four steering fixing screws 8 remove the cables 9 and push the complete assembly to the front part of the machine To substitute the handlebar supports after having removed the handlebars remove the two ...

Page 313: ... dust cap 4 if it is not integrated with the ring nut and the bearing underneath Pull out the steering base from the steering head housing Check the condition of the various parts removed If necessary substitute the steering bearings Remove the bearing seats using a mallet and a drift as shown in the figure When removing the bearing seats work around the external ring of the bearings so that a str...

Page 314: ...indle on an adequate surface STEERING REASSEMBLY After checking that the various steering components are not damaged or worn reassemble every part in the reverse order of removal Tighten the steering tube fixing ring nut 1 Turn the base of the steering several times so that the roller bearings settle into their seats Slacken by a 1 4 1 2 of a turn the ring nut 1 Insert the fork tubes lightly tight...

Page 315: ...ewing the four screws 1 Place a support underneath the engine so that the rear wheel is raised up from the ground Proceed as follows Slacken the wheel spindle nut 2 Slacken the screws 3 of the chain tensioner Remove the nut 2 and slide out the wheel spindle 4 from the opposite side Push the wheel forward and remove the chain from the crown wheel Slide the wheel out from the fork paying attention t...

Page 316: ...ates the teeth profile of the crown wheel and the pinion wheel under normal conditions and under conditions of excessive wear If excessive wear is noted substitute the various components CROWN WHEEL SUBSTITUTION After having removed the rear wheel remove the crown wheel support flange As indicated in the figure keep the screws 2 steady Slacken the relative flange nuts When reassembling apply a lit...

Page 317: ...figure To reassemble carry out the phases of assembly in reverse order Check the chain as described in the maintenance chapter PINION WHEEL SUBSTITUTION Remove the pinion wheel cover as described in the maintenance chapter Remove the screw 1 and the speed sensor rotor 2 Remove the pinion wheel nut and the pinion wheel To reassemble proceed in the reverse order to removal Tighten the pinion wheel n...

Page 318: ...igure Slide out the bolt from the opposite side 1 REAR SUSPENSION Remove the two nut and bolt fixings 2 and 3 as indicated in the figure Remove the shock absorber GENERAL CHECK OF THE SHOCK ABSORBER Carry out the following checks Check the condition of the shock absorber stem It must not be damaged or distorted If so substitute the shock absorber Check for oil leaks If leakage is considerable subs...

Page 319: ...tandard position softer suspension unscrew the adjuster 1 maximum of 14 clicks To obtain greater braking in respect of the standard position harder suspension screw in the adjuster 1 maximum of 20 clicks To restore the standard calibration completely screw in the adjuster 1 and unscrew 20 clicks The standard calibration is optimum for use with rider and passenger and under normal road conditions D...

Page 320: ...mbly of the oil seals They must be inserted into their relative seats by using a drift on the external diameter Check the play of the spacers 7 inside the bearings If excessive play is found substitute the bearings on the balancer To remove the connection rod of the rear suspension it is necessary to remove the following components Remove the chain roller 1 Unscrew the two chain guide fixing screw...

Page 321: ...kg m Torque pressure compensator frame 39 2 44 1 N m 4 0 4 5 kg m REAR FORK REMOVAL Remove the rubber cap shock absorber protection by unscrewing the four screws 1 Remove the two tube channels 2 of the rear brake tubing Remove the rear brake pincer complete with attachment from the fork Remove the two rubber caps 3 with Cagiva printed on the top Slacken the spindle 4 indicated in the figure Remove...

Page 322: ...tilising a tube of adequate diameter for the extraction When reassembling work on the external ring of the bear ings Pay particular attention to the oil seals Grease the various parts After having positioned the fork in its seat insert the spindle of the fork in the correct hole Screw on the special bolt and tighten to the torque pressure specified of 58 8 63 7 N m 6 6 5 kg m Check the condition o...

Page 323: ... substitute or realign the frame all components must be removed Follow the procedures for removal of the various components as described in the various sections of this manual For a brief check consult the figure The dimensions quoted above can establish if the frame needs to be re aligned or substituted A badly damaged frame must be substituted ...

Page 324: ...F 1 BRAKES F Section ...

Page 325: ...rake fluid substitution F 5 Bleeding air from the braking system F 6 Front brake pincer removal and disassembly F 7 Rear brake pincer removal and disassembly F 9 Front brake pump system removal and disassembly F 11 Rear brake pump system removal and disassembly F 14 ...

Page 326: ...F 3 BRAKES FRONT BRAKE Type Fixed twin discs Ø 296 mm Double piston pincers REAR BRAKE Type Fixed single disc Ø 240 mm ...

Page 327: ...e to stay within the wear limits New front disc thickness 4 0 mm New rear disc thickness 5 0 mm Front disc thickness at the wear limit 3 5 mm Rear disc thickness at the wear limit 4 5 mm Carry out the distortion check of the disc utilising a comparator with the disc mounted on the hub Max distortion allowed 0 3 mm Remove the wheel as described in the Suspension chapter To remove the discs from the...

Page 328: ...ng screws to the fork to a torque of 34 3 39 2 N m Reassemble in the reverse order of removal Pay attention to the leaf spring inside the rear brake pincer It is not necessary to carry out the bleeding of the air from the sys tem after having substituted the brake pads It is sufficient just to activate the brake lever or pedal repeatedly to bring the pistons back to the normal position Check the b...

Page 329: ...to the bleed valve nipple 3 of the pincer and insert the other end of the tube in a container Slacken the bleed valve nipple and pump the brake lever or pedal until the system is completely empty of brake fluid Close the bleed valve nipple and disconnect the tube Fill the cham ber with new brake fluid until it reaches the upper level mark The same procedure is used for the front brake Specific pro...

Page 330: ... m 0 75 kg m Front brake bleed the air via the bleed valve nipple Squeeze and release the brake lever several times in rapid succession and then squeeze it without releasing the lever Slacken the bleed valve nipple rotating it a _ of a turn so that the fluid can pour out into the container This releases the ten sion on the brake lever and allows it to move towards the handgrip of the handlebar Clo...

Page 331: ...er assembly by unscrewing the two pincer mounting screws 2 Never use brake fluid left over from a previous change of fluid or brake fluid that has been stored for a long period of time If the brake system leaks fluid riding safety is compromised Leaking fluid can also damage painted surfaces Check for cracks or leaks on the tubes and at the joint bolts of the brakes To reassemble completely push i...

Page 332: ...k for cracks or leaks on the tubes and at the joint bolts of the brakes Remove the bolt 1 Remove the two pincer 2 mounting screws If there are signs of leakage or traces of oil on the pincer body it must be substituted To reassemble completely push in the pistons and proceed in the reverse order of removal Tighten the joint bolt and the two pincer screws to the torque specified Brake tube bolt 23 ...

Page 333: ... that it does not come into contact with any painted surface of the machine Brake fluid reacts chemically with paint plastic rubber etc caus ing severe damage Remove the right hand rear view mirror Remove the two screws of the pump support clamp paying atten tion to the spacer underneath the lower screw Remove the brake pump together with the brake fluid chamber Remove the fluid chamber along with...

Page 334: ... pump onto the handlebars tighten the upper fixing bolt first Torque pressure Front brake pump fixing bolt 10 N m 1 0 kg m Bleed the air from the braking system after reassembling the brake pump If the support is substituted make sure that when reassembling the brake fluid chamber align the projection of the chamber with the hole of the support Play Punched mark Brake pump Handlebar Upper blocking...

Page 335: ...two screws 1 as shown in the figure Remove the screws 3 and the relative nut Remove the two screws 5 indicated in the figure Extract the rear brake pump 1 3 Disassemble the rear brake fluid chamber by removing the support screw 4 Remove the elastic bands Place a cloth underneath the joint 2 Disconnect the electrical connections Remove the rear brake tube joint 2 2 4 5 ...

Page 336: ...ntion to the following points Specified product AGIP BRAKE 4 brake fluid Tighten each bolt to the specified torque Torque pressure Brake tube joint bolt 23 N m 2 3 kg m Brake pump mounting bolt to the frame 10 N m 1 0 kg m Bleed the air from the braking system after reassembling the brake pump see page F 7 ...

Page 337: ...F 14 BRAKES ...

Page 338: ...G 1 ELECTRICAL EQUIPMENT G Section ...

Page 339: ...TRICAL EQUIPMENT Precautionary maintenance advice G 5 Battery G 6 Charging system G 7 Starter system and side stand ignition security system G 12 Ignition system G 21 Instruments G 28 Lights G 34 Switches G 37 ...

Page 340: ...G 3 ELECTRICAL EQUIPMENT ...

Page 341: ...23 Cam sensor 24 Speed sensor 25 Injector 1 26 Injector 2 27 Side stand switch 28 Engine coolant temperature sensor 29 Engine pick up 30 Rectifier 31 Warning hazard 32 Fuel pump relay 33 Injection relay 34 Remote switch 35 Battery 36 Rear light left and right rear indicators 37 Heat switch 38 Fan 39 Fuse box 40 Diagnostics 41 General relay 42 Resistance 43 Rectifier fuse 44 Generator COLOUR LEGEND...

Page 342: ...TERMINALS Place the fixing bands in the original position Bend the terminal so that the wiring is fixed solidly When systemising the wiring make sure that leads do not hang down They must be fixed correctly Do not utilise wire or other substitutes for fixing bands FUSES When a fuse burns out always investigate the cause repair and then substitute the fuse Do not utilise a fuse of a different capac...

Page 343: ...eakage substitute the battery with a new one immediately If the terminals of the battery are corroded or covered with white powder clean with emery paper CHARGING THE BATTERY Check the charge condition of the battery using a voltmeter If the open circuit output is less than 12 6V charge the battery in the fol lowing way Utilise a constant output battery charger Connect the cables of the battery ch...

Page 344: ...ntinuous current by the rectifier and is then utilised for charging the battery FUNCTION OF THE RECTIFIER When the rpm of the engine are low and the voltage generated by the AC generator is less than the regulated nominal voltage supplied by the rectifier the rectifier does not operate In this case the current generated charges the battery directly AC generator Rectifier Ignition switch Charge Bat...

Page 345: ...in the direction of A to B At this point the generated current from the AC generator passes through the SCR without charging the battery and returns to the AC generator At the end of this phase seeing that the AC current generated by the AC generator returns to point B The inverted current tends to flow towards the SCR The circuit of the SCR therefore passes from the OFF condition and starts to ch...

Page 346: ...f charge see page G 11 Correct Check the rectifier see page G 11 Correct Check the wiring system Correct Installed There are leakages Correct Missing continuity Incorrect Incorrect Incorrect Remove the accessories Wiring in short circuit Leads loose or disconnected Defective battery Defective battery Abnormal riding conditions Defective generator winding or leads disconnected Defective AC generato...

Page 347: ...sition when measuring the current If a leakage is found look for the part where the circuit tester meas ures less than 1 mA by removing the couplings and connectors one at a time CHARGE OUTPUT TEST Remove the seat and the battery support plate Switch on the engine and let it run at 5000 rpm with the headlight switch in the ON position and the selector at the HI main beam position Measure the CC vo...

Page 348: ...eads If the measurement of the circuit tester is less than the speci fied value substitute the AC generator with a new one Generator performance in the absence of a charge More than 70V at 5000 rpm cold engine Circuit tester dial indication Voltage RECTIFIER TEST Remove the right hand support cover Disconnect the connectors of the rectifier Utilising a multi tester measure the voltage between the ...

Page 349: ...ion switch IG and the battery Pressing the starter button situated on the right hand switch assembly of the handlebars agitates the relay that causes the contact points to close that connect the starter motor to the battery The starter motor absorbs approximately 80 amperes when starting the engine BR Brown R Red BK Black Y R Yellow red G R Green Red BK W Black White R W Red White R BR Red Brown Y...

Page 350: ...owing two conditions 1 Gearchange NEUTRAL ON Side stand LOWERED OFF The flow of current A agitates the injection relay and the ECM CPU and the coils are activated even if the side stand is lowered This condition is exclusively to heat up the engine 2 Gearchange GEAR INSERTED OFF Side stand raised ON The flow of current B agitates the injection relay and the coils are activated The engine can be sw...

Page 351: ...efective diode Defective injection relay Defective starter switch Defective clutch lever position switch Connector contacts poor or defective Wiring circuit open Defective starter relay The engine does not turn even if the starter motor turns Defective starter gear Check the to see that the starter motor turns by connecting the terminal of the starter motor directly to the terminal of the bat tery...

Page 352: ...emble the starter motor as indicated in the figure STARTER MOTOR CHECK BRUSHES Check the brushes for signs of abnormal wear cracks or if the brush attachment is smooth If the brushes are defective substitute the brush assembly 1 O ring 2 Cover internal 3 Starter motor housing 4 Rotor 5 Spring and brush attachment 6 Cover external ...

Page 353: ... segment and the rotor shaft If there is no continuity between the segments or between the seg ments and the rotor substitute the rotor Circuit tester dial indication Continuity test OIL SEAL CHECK Check to see if the oil seal edges are damaged or if there are leak ages If damage is found substitute the cover of the housing STARTER MOTOR REASSEMBLY Reassemble the starter motor in the reverse order...

Page 354: ...test Do not apply the voltage of the battery to the starter relay for more than five seconds This could overheat the relay and damage the wiring Starter motor Battery 1 Remove the cover of the starter relay 2 Remove the complete rear protection complete with rectifier by unscrewing the three relative fixings Disconnect the starter motor lead and the battery cable fixed to the starter relay Remove ...

Page 355: ... anomaly is found substitute the compo nent DIODE The diode 1 is situated under the ECM CPU Remove the ECM CPU as described in Chapter C by unscrewing the four relative fixings Disconnect the diode Utilising a multi tester measure the voltage between the terminals as indicated in the following table Unit V Circuit tester probe on Circuit tester probe on 1 3 2 0 4 0 6 2 0 4 0 6 Circuit tester dial ...

Page 356: ... When connecting a multi tester to the system install copper adap tors external diameter less than 0 5 mm on the rear side of the lead coupling Connect the circuit tester probes to the copper adap tors Utilise copper adaptors of less than 0 5 mm diameter to avoid damaging the rubber of the impermeable coupling SIDE STAND SWITCH The side stand switch connector is situated underneath the seat compar...

Page 357: ...ame but can be distinguished by the colours of the leads Injection relay lead colours R W R W Y Bk R Br Fuel pump relay lead colours Gr R B V 0 Br GR R Grey red B V Blue violet O Orange BR Brown W R White red Y Bk Yellow black R BR Red brown Firstly check the isolation between terminals 2 and 4 with the circuit tester Apply 12 volts to terminals 1 and 3 and check the continuity be tween the termin...

Page 358: ... the engine This signal determines the ignition timing and the signal that is sent to the revcounter This signal determines the ignition timing without calculating the signals under 700 rpm because the rotation speed of the engine is constantly changing at low revolutions Above 700 rpm the signal is processed by the ECM CPU and calculates the ignition timing with regards to the choke setting and t...

Page 359: ...xceed 10 200 rpm without a load Transformer Feed source Oscillator CPU Central Process ing Unit Electrical wave circuit Generator rotor Gearchange p o s i t i o n switch ROM Throttle position sensor C r a n k shaft posi tion sensor Outgoing circuit ignition switch Engine kill switch Injection relay Fuse Ignition coil Spark plug fuse Battery LEAD COLOURS G Green B Blue R Red BK Black Y R Yellow red...

Page 360: ...efective ignition switch Wiring interrupted or poor or defective con nection of the appropriate circuit coupling Check the spark plugs Defective ignition coil Defective crankshaft position sen sor Defective ECM CPU Poor or defective connection of the ignition couplings Check that the gearchange is in neutral and the engine kill switch is in the RUN position Check to see if the fuse is blown and th...

Page 361: ... BK Earth probe probe Do not disconnect the lead of the ignition coil primary winding Follow the instruction manual when using the multi tester with the peak voltage adaptor Put the gearchange into neutral and turn the ignition switch to the ON position Turn the engine over for several seconds pressing the starter button and measure the peak voltage of the ignition coil primary winding Repeat this...

Page 362: ...tester is 8 mm Using the circuit tester test the spark performance of the ignition coil The connections for the test are as indicated in the figure If there are no sparks or the sparks are orange in the above men tioned conditions the ignition coil must be defective Spark More than 8 mm To avoid electric shocks do not touch the pincers during the test Follow the instruction manual when using the e...

Page 363: ...ruction manual when using the multi tester with the peak voltage adaptor Put the gearchange into neutral and turn the ignition switch to the ON position Turn the engine over for several seconds by pushing the starter button and measure the peak voltage of the crankshaft position sensor Repeat the abovementioned procedure several times and meas ure the highest peak voltage of the crankshaft positio...

Page 364: ...ut the peak voltage at the lead coupling of the ECM CPU is abnormal the wiring must be substituted If both peak voltages are abnormal substitute the crankshaft position sensor and carry out the test again CRANKSHAFT POSITION SENSOR RESISTANCE Remove the tail fairing and disconnect the lead coupling Measure the resistance between the leads and Earth If the resist ance is not as specified the cranks...

Page 365: ...ng it from the anti vibration mountings Disconnect the lead coupling When connecting or disconnecting the instrument panel make sure that the ignition switch is in the in the OFF position This is to avoid damaging electronic parts DISASSEMBLY Disassemble the instrument panel as follows 1 Instrument panel cover 2 Instrument assembly 3 Instrument assembly housing 3 2 1 ...

Page 366: ...new bulb and recheck the conti nuity If the bulb is OK substitute the instrument assembly PART probe of the circuit tester on probe of the circuit tester on MAIN BEAM 1 8 NEUTRAL 2 13 DIRECTION 10 8 INDICATORS R L 9 8 LIGHTS 3 8 1 Main beam 2 Neutral 3 Lights 4 Fuel A 5 Fuel B 6 Oil 7 FI 8 Earth 9 Left hand direction indicators 10 Right hand direction indicators 11 Revcounter 12 Ignition 13 Earth ...

Page 367: ... ignition switch to the OFF position Connect a resistance of approximately 0 811 kΩ between the BR BK lead and the BR V lead coming from the main wiring circuit at the engine coolant temperature sensor coupling Turn the ignition switch to the ON position The LCD should indi cate 50 C and the LED should not be illuminated Third phase Turn the ignition switch to the OFF position Change the resistanc...

Page 368: ...s are abnormal substitute the engine coolant temperature sensor To carry out the engine coolant temperature sensor check see page H 12 FUEL RESERVE PROBE The probe is mounted on the right hand fuel tank as shown in the figure To carry out an electrical test on the probe it must be dry which means that the tank is empty Measure the resistance value using a circuit tester on the terminals of the pro...

Page 369: ...n the figure B R Black with red line B W Black with white line Circuit tester dial indication Voltage In the abovementioned conditions if a screwdriver that touches the speed sensor surfaces is removed the indicated voltage of the circuit tester changes 0V 12V o 12V 0V If the indicated voltage does not change substitute the sensor The highest indicated voltage of the circuit tester is the battery ...

Page 370: ...lamp wiring left side Unhook the lamp retaining spring and remove the lamp from its housing Substitute the lamp and commence the reassembly in the reverse or der of removal To substitute the sidelight bulb it is necessary to pull out the bulb holder 2 from the headlight housing Extract the bulb change it and reassemble in the reverse order of removal NEVER touch the glass part of the halogen lamps...

Page 371: ...R BULB SUBSTITUTION To gain access to the direction indicator bulbs it is necessary to remove the fuel tanks as described in Chapter B Carry out the bulb changes as follows Disconnect the indicator lead from the main wiring circuit in the handlebar compartment Remove the screws 2 that fix the indicator body inside the fuel tank Slide out the indicator body Remove the two screws 3 that fix the lens...

Page 372: ...of the illuminated zone must be at a height not less than the cross marked on the wall previously 9 10ths of X Any adjustment necessary can be made by regulating the adjuster screw 2 on the back of the projector body This is done as follows Remove the windshield the nose fairing and the instrument panel as described in Chapter B Make the adjustment using a screwdriver Screwing in the adjuster the ...

Page 373: ... situated underneath the rear cover of the parcel carrier DIRECTION INDICATOR RELAY The direction indicator relay is situated underneath the rear cover of the parcel carrier If the direction indicator does not light up check the bulb switch and connections of the circuit If the bulb switch and circuit are OK the direction indicator relay could be defective Substitute it Check that the battery is f...

Page 374: ...Position ENGINE KILL SWITCH Position Colour Position STARTER BUTTON Colour Position HORN BUTTON FRONT BRAKE SWITCH Colour Position REAR BRAKE SWITCH Colour Position CLUTCH LEVER POSITION SWITCH Colour Position OIL PRESSURE SWITCH Colour Position Before carrying out the oil pressure switch check make sure that the level of oil is correct See page B 12 WIRING COLOURS B black R Red Lbl Light blue Y Y...

Page 375: ...G 38 ELECTRICAL EQUIPMENT ...

Page 376: ...H 1 ENGINE COOLING H Section ...

Page 377: ...2 ENGINE COOLING Cooling system H 3 Engine coolant H 5 Radiator and engine coolant tubes H 6 Cooling fan H 9 Fan thermal switch H 10 Engine coolant temperature sensor H 12 Thermostat H 13 Water pump H 14 ...

Page 378: ... a valve for the control of the flow of engine coolant on the basis of the temperature The thermo sensitive wax pearl activates the valve In the following figure the thermostat is in the closed position and therefore the engine coolant circulates in a controlled condition according to the pump the engine the by pass holes of the thermostat and the radiator When the temperature of the engine coolan...

Page 379: ... 18 1 8 1 Cooling fan 2 Thermostat housing 3 Radiator cap 4 Engine coolant tank 5 Thermostat 6 Radiator 7 Water pump A Cooling fan mounting bolt B Cooling fan thermal switch C Radiator mounting bolt D Engine coolant temperature sensor Torque pressure 3 7 4 2 5 A 1 C 6 B D ...

Page 380: ... unscrew completely The engine must be cold when maintenance is carried out on the cooling system The engine coolant is dangerous If it comes into contact with the skin or the eyes Repeatedly rinse with abundant water If it is swallowed provocate vomiting and immediately call a doctor Keep the engine coolant out of reach of children Antifreeze Freezing age point 50 31 C 55 40 C 60 55 C Fig 1 Freez...

Page 381: ...rocedure outlined in pages C 54 and C 55 Do not open the cap of the radiator when the engine is hot Boiling liquid or vapours can cause serious burns The engine coolant is dangerous if swallowed or if it comes into contact with the skin or eyes Rinse thoroughly with abundant water If it is swallowed provocate vomiting and immediately call a doctor ...

Page 382: ...ed and slowly create a pres sure by activating the tester Make sure to interrupt the pressure at 110 15 kPa 1 1 0 15 kg cm2 With the tester at stop check that the pressure remains steady for 10 seconds Substitute the cap if one or two of these requisites are not satisfied Radiator cap release pressure 110 15 kPa 1 1 0 15 kg cm2 1 Radiator cap tester 2 Radiator cap 2 1 ...

Page 383: ...aged it must be substituted Leaks where there are connections should be eliminated by tightening the relative ring clamps ASSEMBLY The assembly of the radiator is carried out in the reverse order of removal Take note of the following points RADIATOR MOUNTING BOLT Tighten the mounting bolt of the radiator to the specified torque Torque pressure Radiator mounting bolt 6 N m 0 6 kg m Make sure that t...

Page 384: ...the cooling fan from the motor to carry out the abovementioned test REASSEMBLY Reassemble the radiator and the cooling fan in the reverse order of removal Be careful of the following points FAN MOUNTING BOLTS Tighten the fan mounting bolts to the specified torque Torque pressure Cooling fan mounting bolts 6 N m 0 6 kg m RADIATOR MOUNTING BOLTS Tighten the fan mounting bolts to the specified torque...

Page 385: ...ses when the temperature of the engine coolant reaches approximately 105 C and it activates the fan Cooling fan fuse Cooling fan motor Thermal switch Battery WIRING COLOURS Bl Blue G BK Green black O BK Orange black G W Green white General relay To remove the thermal switch it is necessary to firstly drain the en gine coolant as described in page D 20 Disconnect the coupling of the thermal switch ...

Page 386: ...test Thermal switch specification OFF ON Approx 105 C ON OFF Approx 100 C ASSEMBLY Grease the O ring Specified product AGIP GREASE 30 Tighten the thermal switch of the cooling fan to the specified torque Torque pressure Cooling fan thermal switch 18 N m 1 8 kg m Be careful when handling the thermal switch It could be damaged if dropped After replacing the cooling fan thermal switch top up the syst...

Page 387: ...e sensor 1 CHECK Check that the resistance of the engine coolant temperature sensor changes with the temperature as specified The sensor is mounted on the side of the thermostat housing Carry out the test as follows Connect the engine coolant temperature sensor to an ohmmeter and immerse it in a pan of oil Place it onto the lighted gas and heat the oil to slowly increase the temperature and observ...

Page 388: ... 5 5 N m 0 55 kg m Air bleed bolt M8 13 N m 1 3 kg m THERMOSTAT REMOVAL Drain the engine coolant as described in page B 20 Do not open the cap of the radiator when the engine is hot Boiling liquid or vapours can cause serious burns The engine coolant is dangerous if swallowed or if it comes into contact with the skin or eyes Rinse thoroughly with abundant water If it is swallowed provocate vomitin...

Page 389: ... thermostat valve should lift up at least 7 mm Standard Lifting up of the thermostat valve more than 7 mm at 90 C If the thermostat does not operate correctly in either of the two cases opening temperature and lifting up of the valve it must be substituted ASSEMBLY Install the thermostat in the reverse order of removal Grease the rubber seal of the thermostat Specified product AGIP GREASE 30 The h...

Page 390: ...I 1 SPECIFIC TOOLING I Section ...

Page 391: ...I 2 SPECIFIC TOOLING ...

Page 392: ...sembly accessory 22 800096668 1 Reamer handle 23 800096669 1 Valve guide reamer 5 5 mm 24 800096670 1 Valve guide reamer 10 8 mm 25 800096671 1 Valve guide separator assembler 26 800096673 1 Suction meter 27 800096674 1 Basic separator tools 28 800096675 1 Clutch hub sleeve support 30 800096680 1 Steering bearing assembler 31 800096676 1 Bearing extractor 32 800096677 1 Final transmission bearing ...

Page 393: ...I 4 SPECIFIC TOOLING ...

Page 394: ...L 1 TORQUE PRESSURES L Section ...

Page 395: ...g nut 100 10 0 Clutch spring fixing bolt 10 1 0 Clutch spring support bolt 11 1 1 Oil pressure regulator 28 2 8 Intermediate gear shaft N 1 timing sprocket 70 7 0 Primary gear drive nut 95 9 5 Generator cover plug 15 1 5 Valve timing control plug 23 2 3 Generator rotor bolt 160 16 0 Starter engaging bolt 10 1 0 Generator stator fixing bolt 10 1 0 Generator stator clamp bolt 5 5 0 55 Camshaft posit...

Page 396: ...9 05 4 5 5 Central engine fixing 44 1 49 05 4 5 5 Left hand front support fixing 44 1 49 05 4 5 5 Right hand front support fixing 44 1 49 05 4 5 5 Spacer fixing 8 8 9 8 0 9 1 Seat frame fixing 21 5 23 5 2 2 2 4 Front frame fixing 21 5 23 5 2 2 2 4 Front footrest support fixing 23 5 25 4 2 4 2 6 Rear footrest support fixing 24 5 29 4 2 5 3 Roller fixing 21 5 23 5 2 2 2 4 Roller fixing 8 8 9 8 0 9 1...

Page 397: ...pin fixing ring 45 50 4 5 5 0 Fork cover fixing 22 24 2 2 2 4 Rocking balancer shackle stud shock absorber fixing 45 48 4 5 4 8 Shackle stud frame fixing 45 48 4 5 4 8 Shock absorber fixing to frame 45 48 4 5 4 8 Chain tension adjuster fixing 9 10 0 9 1 0 APPLICATION N m Kg m Counterweight fixing 2 9 0 9 U bolt fixing 4 9 6 8 0 5 0 7 Clamp fixing 4 9 6 8 0 5 0 7 Oil tank fixing 8 8 9 8 0 9 1 Cable...

Page 398: ...h cable fixing 9 10 0 9 1 0 Negative pole battery fixing 9 10 0 9 1 0 Side stand switch fixing 9 10 0 9 1 0 Coil fixing 5 7 0 5 0 7 ELECTRICAL SYSTEM FUEL FEED SYSTEM APPLICATION N m Kg m Fuel tank fuel exit insert fixing Torque controlled Tank cap fixing 5 7 0 5 0 7 Tank cap fixing and cap hole closure 5 7 0 5 0 7 Fuel pump fixing 5 7 0 5 0 7 Tank front fixing 9 10 0 9 1 0 Tank rear fixing 9 10 0...

Page 399: ...cover fixing to the engine 9 10 0 9 1 0 EXHAUST SYSTEM APPLICATION N m Kg m Passenger strap plate fixing on the seat 9 10 0 9 1 0 Tail side cover fixing 5 7 0 5 0 7 SEAT APPLICATION N m Kg m Electric fan fixing 9 10 0 9 1 0 Radiator cap 28 30 2 8 3 0 Radiator fixing 9 10 0 9 1 0 Expansion tank fixing 9 10 0 9 1 0 Radiator tube band fixing 4 5 0 4 0 5 Electric fan switch 16 18 1 6 1 8 COOLING SYSTE...

Page 400: ...M 1 INDEX M Section ...

Page 401: ... Valve clearance B 10 Engine oil and oil filter B 16 Maintenance and tuning B 4 Tyres B 26 Oil pressure test procedure B 28 Compression test procedure B 27 Tickover B 17 Balancing of the carburettors B 18 Fuel tank removal B 4 Steering B 26 Fuel tubing B 16 AIR INTAKE AIR INJECTION SYSTEM C 1 Air intake system technical characteristics C 20 FI system technical characteristics C 9 Malfunction codes...

Page 402: ...sation C 15 Fuel pump control system C 13 Incoming fuel feed system C 11 Carburettor disassembly C 56 Carburettor disassembly C 60 Air filter disassembly C 51 Use of testers C 8 ENGINE D 1 Camshaft cylinder head D 81 Cover gearchange crankshaft connecting rod D 151 Cylinder piston D 105 Engine components that can be removed without removing the engine D 3 Cylinder piston test D 108 Camshaft cylind...

Page 403: ...elector group removal D 144 Starter motor removal D 142 Water pump clutch cover removal D 124 Timing synchronisation diagram D 86 Engine lubrication system diagram D 178 Engine lubrication system D 169 Engine lubrication system D 179 Engine disassembly assembly D 20 Timing distribution table D 87 SUSPENSION AND WHEELS E 1 Removal check of the rear suspension compensator assembly E 21 Front fork as...

Page 404: ...ng circuit F 7 ELECTRICAL SYSTEM G 1 Maintenance precautions G 5 Initial charge G 38 Ignition side stand security system movement check G 18 Starter relay check G 17 Switches G 37 Lights G 33 Maintenance G 39 Starter motor assembly G 16 Charging operations G 40 Starter motor removal and disassembly G 15 Starter system and side stand security system disassembly G 12 Ignition system G 21 Charging sy...

Page 405: ...M 6 INDEX ...

Page 406: ...M 7 INDEX ...

Page 407: ...M 8 INDEX ...

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