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Derbi Rambla 250, Manual, Page: 110 / 259

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Derbi Rambla 250 Manual Download Page 110

Removing the cylinder - piston assy.

Cylinder and piston removal
- Remove the chain guide pad.
- Remove the 4 sealing O-rings on the stud bolts
- Slide off the cylinder.
- Remove the gasket on the cylinder base.
- Remove the 2 seeger rings, the pin and the pis-
ton.
- Remove the piston sealing rings.

CAUTION

TO AVOID DAMAGING THE PISTON, KEEP IT FIRM WHILE
REMOVING THE CYLINDER.

NOTE

BE CAREFUL NOT TO DAMAGE THE SEALING RINGS
DURING REMOVAL.

Inspecting the small end

- Measure the inside diameter of the small end us-
ing a specific micrometer.

NOTE

Replace the crankshaft if the rod small end diameter exceeds

the standard diameter, shows signs of wear or overheating

Characteristic

Checking the rod small end: Max. diameter

15.030 mm

Checking the rod small end: Standard diame-
ter

15+0.015 +0.025 mm

Engine

ENG - 110

Summary of Contents for Rambla 250

Page 1: ...WORKSHOP MANUAL RAMBLA 250 ...

Page 2: ......

Page 3: ...sections of this manual rela ting to specific tools along with the specific tool c atalogue N B Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to completely observe ...

Page 4: ......

Page 5: ...HAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG INJECTION INJEC SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...ed to keep the engine running in order to carry out any procedure please ensure that you do so in an open or very well ventilated area Never let the engine run in an enclosed area If you do work in an enclosed area make sure to use a smoke extraction system CAUTION EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH FUEL CAUTION FUEL USED ...

Page 8: ... REACH OF CHILDREN BRAKE FLUID CAUTION THE BRAKE FLUID MAY DAMAGE PAINTED PVC OR RUBBER SURFACES WHEN SERVICING THE BRAKE SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKE SYSTEM THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES RINSE THEM IMMEDIATELY WITH ABUNDANT COLD CLEAN WATER AND SEEK M...

Page 9: ... ORDER THE POSSIBLE OVERLAPPING OF OPERATIONS REFERRED TO IN THE OTHER CHAPTERS MUST BE CARRIED OUT LOGICALLY AVOIDING ANY UNNECESSARY RE MOVAL OF COMPONENTS DO NOT POLISH MATT PAINTWORK WITH ABRASIVE PASTES NEVER USE FUEL AS SOLVENT FOR CLEANING THE SCOOTER DO NOT USE ALCOHOL PETROL OR SOLVENTS TO CLEAN RUBBER AND PLASTIC PARTS AND THE SADDLE USE ONLY WATER AND NEUTRAL SOAP INSTEAD DISCONNECT THE...

Page 10: ...ghten nuts and screws in successive steps before ap plying the tightening torque Always replace self locking nuts washers sealing rings circlips O rings split pins and screws with new ones if their tread is damaged When fitting bearings make sure to lubricate them well Check that each component is fitted correctly After a repair or routine maintenance procedure carry out pre ride checks and test t...

Page 11: ...NOT MIX DIFFERENT LIQ UIDS WHEN TOPPING UP IN ORDER NOT TO DAMAGE THE BRAKE SYSTEM DO NOT USE BRAKE FLUID TAKEN FROM OLD CONTAINERS OR FROM CONTAINERS THAT HAVE BEEN OPEN FOR A PROLONGED TIME SUDDEN CHANGES IN THE PLAY OR ELASTIC RESISTANCE IN THE BRAKE LEVERS ARE DUE TO FAULTS IN THE HYDRAULIC CIRCUIT MAKE ESPECIALLY SURE THAT BRAKE DISCS AND THE FRICTION MATERIAL ARE NOT SMEARED OR GREASY PARTIC...

Page 12: ... THE PRODUCT CAUTION USE ONLY ANTIFREEZE AND CORROSION INHIBITORS WITHOUT NITRITE THAT ENSURE A PROTECTION OF AT LEAST 35 C 31 F TYRES CAUTION CHANGING REPAIR MAINTENANCE AND BALANCING ARE IMPORTANT OPERATIONS THAT ARE CARRIED OUT BY QUALIFIED PERSONNEL USING SUITABLE TOOLS THE NEW TYRES MAY BE COVERED WITH A THIN LAYER OF PROTECTIVE COATING THAT IS SLIPPERY DRIVE CAREFULLY FOR THE FIRST FEW KILOM...

Page 13: ...et sump forced lubrication system overhead camshaft Overall engine capacity 244 29 cm Bore stroke 72 mm 60 mm Compression ratio 11 0 0 5 1 Start up Electric Engine revs at idle speed 1600 100 rpm Clutch Automatic centrifugal dry clutch Transmission Automatic Cooling forced circulation air cooling driven by a centrifugal pump Valve clearance Inlet 0 10 Outlet 0 15 Throttle body diffuser throttle bo...

Page 14: ...hts 12V 10W 7 Rear tail light stop light 12V 5W 21W 8 License plate light 12V 5W 9 Instrument panel lighting LED 10 Turn indicator warning light LED 11 High beam warning light LED 12 Low fuel warning light LED 13 Spark plug CHAMPION RG4 PHP 14 Spark plug electrode gap 0 7 0 8 mm 0 027 in 0 031 in 15 Ignition type Capacitive discharge ignition variable advance 16 Ignition advance Variable managed b...

Page 15: ...screws 7 9 5 2 6 6 ftlb Screws fixing oil pump to crankcase 5 6 3 7 4 4 ftlb oil pump driving crown gear screw 10 14 7 4 10 3 ftlb Oil pump cover plate screws 4 6 3 4 4 ftlb Oil sump screws 10 14 7 4 10 3 ftlb Minimum oil pressure sensor 12 14 8 9 10 3 ftlb CYLINDER HEAD Name Torque in Nm Spark plug 12 14 8 9 10 3 ftlb Cylinder head cover screws 6 7 4 4 5 2 ftlb Head to cylinder retaining nuts 7 1...

Page 16: ...s fixing lock nut 110 20 81 4 ftlb CHASSIS Name Torque in Nm License plate holder support to chassis retainer 25 20 18 5 ftlb Passenger grab handle to chassis retainer 25 20 18 5 ftlb Horn to chassis retainer 10 20 7 4 ftlb Regulator to chassis retainer 10 20 7 4 ftlb Switch to chassis retainer 10 20 7 4 ftlb Control unit to chassis retainer 10 20 7 4 ftlb Fuel tank to chassis retainer 10 20 7 4 f...

Page 17: ...b Left side inspection cover retainer 3 20 2 22 ftlb Right side inspection cover retainer 3 20 2 22 ftlb Battery cover retainer 3 20 2 22 ftlb Footrest retainer 3 20 2 22 ftlb Right and left lower shield retainer 3 20 2 22 ftlb Glove box lid on front internal shield retainer 1 20 0 74 ftlb Front internal shield to front external shield retainer 1 20 0 74 ftlb Glove box net on front internal shield...

Page 18: ...ftlb Silent block on chassis retainer 50 20 37 ftlb EXHAUST Name Torque in Nm Manifold to engine retainer 15 20 11 1 ftlb Muffler to manifold retainer 16 20 11 84 ftlb Muffler on plate retainer 25 20 18 5 ftlb Protection on muffler retainer 7 20 5 18 ftlb REAR WHEEL Name Torque in Nm Rear wheel retainer 110 20 81 4 ftlb Speed sensor screw retainer 10 20 7 4 ftlb Speed sensor on muffler plate retai...

Page 19: ...N COUPLING CATEGORY Name Initials Cylinder Piston Play on fitting Cylinder Piston M 1 72 01 72 017 71 953 71 960 0 050 0 064 Cylinder Piston N 2 72 017 72 024 71 960 71 967 0 050 0 064 Cylinder Piston O 3 72 024 72 031 71 967 71 974 0 050 0 064 Cylinder Piston P 4 72 031 72 038 71 974 71 981 0 050 0 064 If only the piston is replaced check the cylinder category taking into account the CYLINDER PIS...

Page 20: ...sions Initials Quantity Half shaft transmission side 16 6 0 0 05 A D 0 20 0 50 Half shaft flywheel side 16 6 0 0 05 B D 0 20 0 50 Connecting rod 18 0 10 0 15 C D 0 20 0 50 Spacer tool 51 4 0 05 E D 0 20 0 50 Slot packing system Characteristic Compression ratio 10 5 11 5 1 Characteristics CHAR 20 ...

Page 21: ... ratio and vice versa NOTE DISTANCE A SHOULD BE MEASURED WITH NO GASKET FITTED BETWEEN THE CRANK CASE AND THE CYLINDER AND AFTER RESETTING THE DIAL GAUGE WITH SUPPORT ON A GROUND PLANE SHIMMING FOR 250 ENGINES Name Measure A Thickness Shimming 3 70 3 60 0 4 0 05 Shimming 3 60 3 40 0 6 0 05 Shimming 3 40 3 30 0 8 0 05 Products RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP CITY ...

Page 22: ...um grease with molybdenum for bearings and other points needing lubri cation NLGI 2 AGIP BRAKE 4 Brake fluid FMVSS DOT4 SPECIAL AGIP PERMANENT fluid Coolant Biodegradable coolant ready for use with long life technology and character istics pink Freezing protection up to 40 According to CUNA 956 16 stand ard Characteristics CHAR 22 ...

Page 23: ...INDEX OF TOPICS TOOLING TOOL ...

Page 24: ...140259 Universal tool for clutch assemblies AP8140665 Adapter for clutch assembly removal AP8140535 Front pulley fitting removal AP8140181 Fuel pressure check tool AP8140266 Comparator door AP8140729 Chain cover fitting removal Tooling TOOL 24 ...

Page 25: ...wheel extractor AP8140659 Valve oil seal punch AP8140662 Punch for roller casing 020425Y Shaft oil seal punch 020376Y Adapter handle 020455Y 10 mm guide for oil seal on water pump shaft 020412Y Clutch oil seal punch D 15 mm Tooling TOOL 25 ...

Page 26: ...scription 020439Y Shaft 2 oil seal punch 17 mm 020359Y 42 x 47 mm punch 020363Y Crankshaft oil seal punch D 20 mm 020456Y Ø 24 mm punch 020364Y 25 mm Adaptor 020414Y 28 mm punch 020357Y 32x35 mm punch Tooling TOOL 26 ...

Page 27: ...5Y 28x30 mm punch 020360Y 52x55 mm punch AP8140917 Tool for valve pressure plate AP8140661 Lock wrench for clutch bell AP8140300 55 mm wrench 020627Y Flywheel lock wrench AP8140179 Support for valve fitting removal Tooling TOOL 27 ...

Page 28: ...de Description AP8140660 Piston fitting ring AP8140664 Guide to mount the movable driven pulley 020483Y 30 mm guide 020477Y 37 mm Adaptor 002095Y Engine support AP8140919 Valve oil seal extractor Tooling TOOL 28 ...

Page 29: ... Description AP8140920 Tool for pin rings AP8140922 Crankcase splitting strip AP8140921 Oil seal punch 001467Y035 Bell for OD 47 mm bearings 020481Y Adaptor cable harness AP8140915 Crankcase check Tooling TOOL 29 ...

Page 30: ...Stores code Description AP8140916 Hub cover support AP8140252 Multipurpose wrench AP8140595 Axone battery charger 230V 50Hz AP8202311 Axone battery charger 110V 60Hz Tooling TOOL 30 ...

Page 31: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 32: ... locks check Throttle lever adjustment Air filter cleaning Air filter in belt compartment Check Engine oil filter Replace Electrical system and battery Check Coolant level check Brake fluid level check Engine oil Change Brake pad wear check Tyre pressure and wear check Vehicle and brake test test drive Hub oil Check Suspensions Check Steering check up Sliding block variable speed rollers Replaceme...

Page 33: ...evel check Engine oil Change Brake pad wear check Sliding block variable speed rollers Replacement Tyre pressure and wear check Vehicle and brake test test drive Hub oil Check Suspensions Check Steering check up 60 000 KM Action Spark plug Replace Driving belt replacement Throttle lever adjustment Air filter cleaning Air filter in belt compartment Check Engine oil filter Replace Valve clearance ch...

Page 34: ...g and remove it from its seat being careful not to let dust or any other substance into the cylinder Check that the spark plug electrode and centre porcelain are free of carbon deposits or signs of corrosion If nec essary clean using suitable spark plug cleaners and or a metal brush Replace the spark plug if its insulator is cracked the electrodes show signs of corrosion or excessive deposits or t...

Page 35: ...CING A SPARK PLUG CHECK THE PITCH AND LENGTH OF THE THREAD IF THE THREADED SEC TION IS TOO SHORT CARBON DEPOSITS WILL BUILD UP ON THE THREAD SEAT AND THUS THE ENGINE MAY GET DAMAGED WHEN THE SUITABLE SPARK PLUG IS REFIT TED USE SPARK PLUGS OF THE RECOMMENDED TYPE ONLY OTHERWISE ENGINE LIFE AND PERFORMANCE COULD BE COMPROMISED CHECK THE GAP BETWEEN THE ELECTRODES WITH A THICKNESS FEELER GAUGE TO AV...

Page 36: ...ng and wait about one minute so that the oil flows evenly into the crankcase Check the oil level and top up if required Top up with small quantities of oil until the recommended level is reached At the end of the operation screw and tighten the cap dipstick NOTE RIDING THE VEHICLE WITH INSUFFICIENT LUBRICATION OR CONTAMINATED OR NOT REC OMMENDED LUBRICANTS ACCELERATES THE WEAR AND TEAR OF MOVING P...

Page 37: ... CORDING TO THE REGULATIONS IN FORCE Air filter Clean the air filter and check its condition following the indications specified in the scheduled mainte nance table Carry out the maintenance procedures more fre quently if the vehicle is used in wet or dusty areas or off road In this case the air filter can be partially cleaned after travelling along this kind of roads CAUTION PARTIAL AIR FILTER CL...

Page 38: ...ipe 1 for dirt CAUTION REMOVE ANY DEPOSIT THAT MAY HAVE FORMED IN THE BLEED PIPE COMING FROM THE FILTER HOUSING PRO CEED AS FOLLOWS Remove the cover 2 Drain the content in a container then send it to a recycling bank NOTE NEVER REUSE A FILTER Replace the air filter with a new one of the same type Engine oil Replacement Rest the vehicle on its centre stand Shut off the engine and let it cool down s...

Page 39: ...ne and let it run for sev eral minutes Stop the engine and let it cool down Check the engine oil level CAUTION USED OIL CONTAINS SUBSTANCES THAT ARE HARM FUL TO THE ENVIRONMENT DISPOSE OF USED OIL AC CORDING TO THE REGULATIONS IN FORCE Check ENGINE OIL CHECK Park the vehicle on firm and level ground Rest the vehicle on its centre stand CAUTION WAIT SOME MINUTES UNTIL THE ENGINE AND THE EXHAUST SYS...

Page 40: ...NOT GO BEYOND THE MAX OR BELOW THE MIN LEVEL MARKS TO AVOID SEVERE ENGINE DAMAGE ENGINE OIL TOP UP Pour a small quantity of oil through the fill opening 2 and wait about one mi nute so that the oil flows evenly into the crankcase Check the oil leveland top up if re quired Top up with small quantities of oil until the recommended level is reached At the end of the operation screw and tighten the ca...

Page 41: ...engine oil Recommended products AGIP CITY HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that exceeds the requirements of API SL ACEA A3 JASO MA specifications Oil pressure warning light The vehicle has an icon on the display and a gen eral alarm warning light on the instrument panel that light up when the key is turned to ON This light should however go off once the engine is started In case the ic...

Page 42: ...hecking the ignition timing Remove the plastic cap on the flywheel cover Turn the flywheel until the reference mark T on the rotor matches the reference mark on the fly wheel cover as shown in the figure TDC Make sure that the reference 4V on the camshaft control pulley is aligned with the reference point on the head as shown in the second figure If the refer Maintenance MAIN 42 ...

Page 43: ... TO REMOVE THE RADIATOR Level check Stop the engine and wait until it cools down Remove the front case Make sure that the coolant level in the expansion tank 1 is between the MIN and MAX reference marks MIN minimum level MAX maximum level CAUTION WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING UP THE COOLANT LEVEL NOTE PARK THE VEHICLE ON SAFE AND LEVEL GROUND Otherwise Loosen but do n...

Page 44: ...l Refit the filler cap 2 Refit the front case CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN CAUTION IF THERE IS AN EXCESSIVE CONSUMPTION OF COOLANT OR WHEN THE EXPANSION TANK REMAINS EMPTY CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT FOR REPAIRS TAKE YOUR VEHICLE TO AN OFFICIAL DERBI DEALER Recommended product...

Page 45: ... LEVEL GROUND Park the vehicle on its centre stand on safe and level ground Make sure that the fluid level in the reservoir is above the MIN mark If the fluid does not reach at least the MIN reference mark CAUTION BRAKE FLUID LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN Check the brake pads for wear Top up fluid level if the break pads and or disc are not to be replaced Top up Undo and remove...

Page 46: ...HE TANK TO THE MAXIMUM BUT JUST OVER THE MIN LEVEL TOP UP TO MAXIMUM LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW BRAKE LEV EL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN IT IS ADVISABLE NOT TO TOP UP TO THE MAX LEVEL MARK WHEN THE BRAKE PADS ARE WORN BE CAUSE YOUR RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS System check Rear brake calliper To carry out a quick pad wear check Rest the vehicle on i...

Page 47: ...LIPERS To check brake pad wear Rest the scooter on its centre stand Remove the front brake calliper Carry out a visual inspection Replace both brake pads when the friction material even if in one brake pad only is worn to about 1 5 mm 0 05 in Maintenance MAIN 47 ...

Page 48: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 49: ...N PRESSURE Possible Cause Operation By Pass remains open Check the By Pass and replace it if required Carefully clean the By Pass area Oil pump with excessive clearance Check the sizes of the oil pump components Oil filter too dirty Replace the cartridge filter Oil level too low Fill up to the correct level with recommended oil type Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFO...

Page 50: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 51: ...KEY Electrical system ELE SYS 51 ...

Page 52: ... 15 Complete rear light 16 License plate light 17 Stop lights start up enabling switch relay 18 19 Start up relay 20 Starter motor 21 Main fuses 22 Auxiliary fuses 23 Plug socket 24 Battery 25 HV coil 26 Spark plug 27 Automatic starter 28 CDI control unit 29 Connector for oil sensor only 30 Oil pressure sensor 31 Pick up 32 Generator 33 Voltage regulator 34 Thermoswitch 35 Fan 36 Glove box light 3...

Page 53: ...Front left turn indicator 43 Complete front headlamp 44 Det Blinker only 45 Kit for det blinker only CABLE COLOUR Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black R red V green Vi purple Ro pink Components arrangement Electrical system ELE SYS 53 ...

Page 54: ... Battery 5 Coil 6 Rear light unit 7 Fuses 8 Spark plug 9 Fuel level sensor 10 Automatic starter 11 Voltage regulator 12 Control unit 13 Start up relay 14 Horn 15 Front headlamp 16 Pick up sensor 17 Water temperature sensor 18 Generator Electrical system ELE SYS 54 ...

Page 55: ...1 Front turn indicators Turn indicator light 12V 10W 2 Electric fan 3 Instrument panel 4 Battery 12V 10 Ah Electrical system ELE SYS 55 ...

Page 56: ...to ignition switch voltage regu lator electric fan 15A fuse 2 From the ignition switch to all light loads and horn Auxiliary fuses 15A fuse 3 From the ignition switch to all light loads and horn 15A fuse 4 From the ignition switch to ignition 8 Spark plug NGK CR7EB alternatively NGK CR8EB NGK CR9EB CHAMPION RG6YC CHAMPION RG4HC Spark plug electrode gap 0 7 0 8mm Spark plug cap resistance 5 K Elect...

Page 57: ... 100 10 Ohm Full tank 1200 10 Ohm 10 Automatic starter Approximately 30 Ohm at 20 C 68 F 11 Voltage regulator SH640D Recharging voltage to terminals off load 13 15 V at 5000 RPM 12 Control unit MARELLI Electrical system ELE SYS 57 ...

Page 58: ...dlamp Low high beam lights 12 V 55 W H7 Front position light 12V 5W 16 Pick up sensor Winding resistance 105 10 Ohm at 20 C 68 F 17 Water temperature sensor 100 C 212 F 144 Ohm 80 C 176 F 262 Ohm 60 C 140 F 512 Ohm 40 C 104 F 1090 Ohm Electrical system ELE SYS 58 ...

Page 59: ...the two electrical connectors strictly observing the following procedure Press the relevant safety hooks if any CAUTION DO NOT PULL THE CABLES TO DISCONNECT THE TWO CONNECTORS Grip the two connectors and disconnect them by pulling them in opposite directions If there are signs of dirt rust humidity etc clean the connector internal parts carefully by using a pressurised air jet Make sure that the c...

Page 60: ...are provided you will hear them click into place Conceptual diagrams 1 Magneto flywheel Pick up 2 Voltage regulator 3 Injection electronic control unit 4 ECU Diag 5 Engine stop switch 6 Main fuse 7 Key switch 8 Injection load remote control 9 Auxiliary fuses 10 Battery Electrical system ELE SYS 60 ...

Page 61: ...dlight bulb 22 Light switch 23 Turn indicator control device 24 Turn indicator bulbs 25 Turn indicator switch 26 Instrument panel diag 27 Fuel level transmitter 28 Scroll switch 29 Instrument panel 30 Oil pressure sensor 31 Electric fan remote control 32 Electric fan 33 Speed sensor 34 Engine temperature sensor 35 Fuel pump 36 Fuel injector 37 Lambda probe 38 Spark plug 39 HV coil 40 Fall sensor K...

Page 62: ...5 Engine stop switch 6 Main fuse 7 Key switch 8 Injection load remote control 9 Auxiliary fuses 10 Battery 38 Spark plug 39 HV coil Key Ar Orange Az Sky blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Electrical system ELE SYS 62 ...

Page 63: ...11 Starter motor 12 Start up remote control switch 13 Starter button 14 Front stop switch 15 Rear stop switch 19 Stop light remote control 20 Rear light unit A Tail light stop light twin bulb Key Ar Orange Az Sky blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Electrical system ELE SYS 63 ...

Page 64: ...in fuse 7 Key switch 8 Injection load remote control 9 Auxiliary fuses 10 Battery 27 Fuel level transmitter 28 Scroll switch 29 Instrument panel 30 Oil pressure sensor 33 Speed sensor 34 Engine temperature sensor 35 Fuel pump 36 Fuel injector 37 Lambda probe 40 Fall sensor Key Electrical system ELE SYS 64 ...

Page 65: ... Magneto flywheel Pick up 3 Injection electronic control unit 5 Engine stop switch 6 Main fuse 7 Key switch 8 Injection load remote control 9 Auxiliary fuses 10 Battery 38 Spark plug 39 HV coil Key Ar Orange Az Sky blue Bi White Bl Blue Gi Yellow Gr Grey Ma Brown Ne Black Ro Pink Rs Red Ve Green Vi Purple Electrical system ELE SYS 65 ...

Page 66: ...tery 20 Rear light unit A Tail light stop light twin bulb B License plate light bulb 21 Front headlight assembly A Tail light B Low beam headlight bulb C High beam headlight bulb 22 Light switch 23 Turn indicator control device 24 Turn indicator bulbs 25 Turn indicator switch 29 Instrument panel Electrical system ELE SYS 66 ...

Page 67: ... least 10 hours for instance during the long winter break Electric characteristic Battery 12V 12 Ah CHECK In case of malfunction first check that the recharge system works properly To check the battery remove the battery from the vehicle as follows Visually check that the container outer casing does not leak Charge the battery slowly for at least 10 hours If the off load voltage is lower than 12V ...

Page 68: ... voltage read ings and trip odometer reset Total odometer ODO function When the instrument panel lights on the multifunction display 1 shows the odometer ODO function Trip odometer TRIP function When the odometer ODO function is displayed press the MODE 2 button once to view the TRIP function Press the MODE 2 button longer than three seconds to reset the counter of the trip times stored Battery vo...

Page 69: ...S STOPPED Data check function SERVICE When the vehicle is started and right after the ignition check if there are less than 300 km 200 mi left to the next Service the specific icon flashes for 5 seconds Once the service mileage has been reached the icon remains steadily until the Service is reset The warning light can be zero set even if the mileage is lower up to 300 km 200 mi compared with the S...

Page 70: ...surements de tected Oil pressure sensor This is a normally open contact it signals an alarm in the oil pressure In case of malfunction a ground signal is indicated the general alarm warning light and the corresponding icon on the display turn on Battery failure If the battery voltage is below approx 10 0 V or exceeds approx 16 V the battery icon flashes at a 1Hz frequency The general alarm warning...

Page 71: ...general alarm warn ing light turns on and the corresponding icon on the display flashes If the instrument panel detects a null resistance short circuit all the segments light up the gen eral alarm warning light turns on and the corre sponding icon on the display flashes 1 Each time the battery is attached the fuel gauge indicates full tank regardless of the quantity of fuel in the tank it takes ap...

Page 72: ...onnectors Dashboard PINOUT The connector diagram seen on the instrument panel and the relevant pinout are shown in the fig ure The numbers are also stamped on the plastic part of the connectors and also on the connector body KEY A Black B Grey CONNECTOR PINOUT Specification Desc Quantity 1 Key Positive 2 Right indicator input 3 Speed sensor power supply 4 RPM 5 Speed sensor ground lead 6 General g...

Page 73: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 74: ...ust silencer to the manifold Undo and remove the three fixing screws 2 Remove exhaust silencer CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF COMPLETELY Remove the rear central cover Unscrew and remove the two fixing nuts of the exhaust manifold CAUTION ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF Disconnect the lambda probe connec tor Engine from vehicle ENG VE 74 ...

Page 75: ...silencer Rear brake calliper Throttle body Remove the footrest lower protection by sliding it upwards and turning it Get a container of adequate capacity to collect the fluid and place it under the cooling system pump Remove the expansion tank cap Loosen the clamp and remove the ra diator pump pipe and allow the cool ant to drain into the collecting contain er Undo the screw and remove the cable g...

Page 76: ...spark plug tube and re lease its cable from any retainer Disconnect the lambda probe connec tor Remove the injector connector Remove the fast release fittings from the injector support Engine from vehicle ENG VE 76 ...

Page 77: ...move the starter motor supply and ground nuts Disconnect the starter motor supply and ground cables and leads Working from the vehicle left side re move the generator connectors Cut any retaining straps Remove the fuel bleeding pipe Engine from vehicle ENG VE 77 ...

Page 78: ...in of the shock absorber Working from the left side unscrew and remove the nut and slide off the fixing pin of the shock absorber Working on the right side unscrew and remove the nut From the left side slide off the pin and collect the washer and the spacer Remove the engine by pulling it back wards Engine from vehicle ENG VE 78 ...

Page 79: ...INDEX OF TOPICS ENGINE ENG ...

Page 80: ... holes Using the clutch bell lock wrench shown in the figure remove the driven pulley shaft lock nut and washer Specific tooling AP8140661 Lock wrench for clutch bell Pull out the cap dipstick from the engine oil filling tube Remove the 10 screws Now remove the transmission cover NOTE WHEN REMOVING THE TRANSMISSION COVER BE CAREFUL NOT TO DROP THE CLUTCH BELL Air duct Remove the transmission compa...

Page 81: ... 020412Y Clutch oil seal punch D 15 mm Refitting the driven pulley shaft bearing Slightly heat the crankcase internal side so as not to damage the coated surface Insert the bearing in its housing Refit the seeger ring CAUTION REST THE COVER ON A SUITABLE SURFACE TO AVOID DAMAGING THE COVER COAT NOTE ALWAYS REPLACE THE BEARING WITH A NEW ONE AT EVERY REFIT Specific tooling 020376Y Adapter handle 02...

Page 82: ...efects that could jeopardise belt functioning For refitting place the roller with the belt contain ment edge on the engine crankcase side Tighten the screw to the prescribed torque Locking torques N m Belt support roller screw 11 13 8 1 9 6 ftlb Removing the driven pulley Remove the clutch bell and the entire driven pul ley assembly NOTE THE ASSEMBLY CAN ALSO BE REMOVED EVEN IF THE DRIVING PULLEY ...

Page 83: ...ven pulley shaft with 2 bearings inside diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft assembly on the support to check the crankshaft alignment Using a feeler pin gauge and the magnetic base measure the bell eccentricity Repeat the measurement at 3 positions Central internal external In case of anomalies replace the bell Characteristic clutch bell check Limit ecc...

Page 84: ...en pulley spring compressor tool Fit the driven pulley assembly on the tool by inserting the 3 pins in the ventilation holes on the mass holder support Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut Use the special multipurpose wrench to remove the nut fixing the clutch Disassemble the driven pulley into its components Clutch and s...

Page 85: ...erver pins and pull the half pulleys apart Removing the driven half pulley bearing Check there are no signs of wear and or noise otherwise replace it Remove the snap ring using two flat blade screw drivers Place pulley bushing on the threaded side ade quately on a wood support Using a hammer and pin knock the ball bearing out as shown in the figure Support the pulley properly Specific tooling 0014...

Page 86: ... the outside diameter of the pulley bushing Check the surface in contact with the belt to make sure there are no signs of abnormal wear Check the riveted joints work properly Check the evenness of the surface in contact with the belt Characteristic Half pulley minimum diameter Minimum diameter allowed Ø 40 96 mm Half pulley standard diameter Standard diameter Ø 40 985 mm wear limit 0 3 mm Engine E...

Page 87: ...surface MOVABLE DRIVEN HALF PULLEY DIMENSIONS Specification Desc Quantity wear limit 0 3 mm standard diameter Ø 41 000 41 035 Maximum diameter admitted Ø 41 08 mm Refitting the driven half pulley bearing Place pulley bushing on the threaded side ade quately on a wood support Assemble a new roller casing as shown in the figure To fit the new ball bearing follow the example in the picture using a sp...

Page 88: ... collar Using a curved spout grease gun lubricate the driven pulley assembly with approximately 6 grams of grease Apply the grease through one of the holes in the bushing until grease comes out through the hole on the opposite side This proce dure is necessary to prevent the presence of grease beyond the O rings NOTE THE TORQUE SERVER CAN BE GREASED WITH BEAR INGS FITTED OR WHEN THEY ARE BEING REP...

Page 89: ...or Insert the lever pin in the hole of the adaptor ring Tighten the fixing nut to the prescribed torque NOTE WHEN PRELOADING THE SPRING BE CAREFUL NOT TO DAMAGE THE PLASTIC STOP OF THE SPRING AND THE BUSHING THREADING NOTE FOR DESIGN REASONS THE NUT IS SLIGHTLY ASYMMETRIC THE FLATTEST SURFACE SHOULD BE MOUNTED CONTACTING THE CLUTCH Specific tooling AP8140259 Universal tool for clutch assemblies AP...

Page 90: ...ing belt 250 4T minimum width 19 5 mm Driving belt 250 4T standard width 21 3 0 2 mm During the wear checks foreseen in the scheduled maintenance services check that the rim bottom of the toothing does not show signs of incisions or cracking see figure the rim bottom of the tooth must not have incisions or cracking if it does change the belt Engine ENG 90 ...

Page 91: ...iameter Measure the outside diameter of the pulley sliding bushing shown in the figure Check that the rollers are not damaged or worn Check the guide shoes for the variator roller con trast plate are not worn Check that there is no wear in the roller housings or the surfaces in contact with the belt on both half pulleys Check that stationary driving pulley does not show signs of abnormal wear on t...

Page 92: ... Ø 20 mm Refitting the driving pulley Preassemble the movable half pulley with the roller contrast plate by placing the rollers in their housings with the larger support surface touching the pulley according to the direction of rotation Check that the roller contact plate does not show flaws or is damaged on the grooved edge Fit the entire bushing assembly on the crank shaft Fit the driven pulley ...

Page 93: ...tring dowels and that the sealing gasket for the oil sump has been ade quately fitted on the transmission cover Replace the cover by tightening the 10 screws to the prescribed torque Refit the oil filling cap dipstick Refit the steel washer and the driven pulley nut Tighten the nut to the specified torque using the lock wrench and the torque wrench tools Refit the plastic cover Specific tooling AP...

Page 94: ... 7 flanged screws indicated in the figure Remove the hub cover and the relevant gasket Removing the wheel axle Remove the wheel axle with gear Remove the intermediate gear Removing the hub bearings Check the status of the bearings being examined wear clearance and noise Engine ENG 94 ...

Page 95: ...P8140916 Hub cover support Removing the driven pulley shaft bearing Should the driven pulley shaft its bearing and oil guard be removed take out the transmission cover and the clutch assembly as described above Extract the driven pulley shaft from its bearing Remove the oil guard using a screwdriver work ing from inside the bearing and being careful not to damage the housing make it come out on th...

Page 96: ...heck the three shafts for wear or distortions on the toothed surfaces on the bearing housings and the oil seal positions In faults are found replace the damaged parts Inspecting the hub cover Check that the coupling surfaces are not dented or distorted Check the capacity of both the bearings and the wheel oil seal In case of faults replace the damaged parts Engine ENG 96 ...

Page 97: ...lar punch as shown in the figure Fit the seeger ring Fit the oil guard with its sealing lip facing the hub internal side and place it flush with the internal surface using the specific tool used on the 52 mm side The 52 mm side of the adaptor should face the bearing Specific tooling 020376Y Adapter handle 020360Y 52 x 55 mm adaptor 020483Y 30 mm guide Engine ENG 97 ...

Page 98: ...ngs must be fitted using the appropriate tools The 42 mm side of the adaptor should face the bearing Specific tooling 020150Y Air heater support 020151Y Air heater 020376Y Adapter handle 020359Y 42 x 47 mm adaptor 020412Y Clutch oil seal punch D 15 mm NOTE Use the stud bolt kit to support the cover adequately when fitting the bearing on the cover Engine ENG 98 ...

Page 99: ...7 mm adaptor 020363Y Crankshaft oil seal punch D 20 mm NOTE WHEN FITTING THE BEARINGS ON THE ENGINE CRANKCASE THE CRANKCASE SHOULD AS FAR AS POSSIBLE BE SUPPORTED ON A SURFACE TO ALLOW THE BEARINGS TO BE DRIV EN VERTICALLY Refit the seeger ring with the opening facing the bearing opposite and fit the new oil guard levelled with the crankcase on the pulley side Refitting the hub bearings Assemble t...

Page 100: ...horter screw easily recognisable by its different colour as shown in the figure Fasten the bleeding pipe support bracket with the lower screw Fit the remaining screws and tighten the 7 screws to the prescribed torque Locking torques N m Rear hub cover screws 24 27 17 7 19 9 ftlb Flywheel cover Removing the hub cover Remove the clamp fixing the hose to the cylinder Remove the 10 clamps Remove the f...

Page 101: ...its cable harness Locking torques N m Screws fixing freewheel to flywheel 13 15 9 6 11 1 ftlb Refitting the stator Refit the stator and the flywheel carrying out the removal steps but in reverse order tightening the retainers to the prescribed torque Locking torques N m Stator unit screws 3 4 2 2 3 ftlb Apply LOCTITE 242 medium strength threadlock Engine ENG 101 ...

Page 102: ...r over the engine and tighten the screws to the prescribed torque Follow the removal procedure but in reverse order CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR MAKE SURE THE CEN TRING DOWELS ARE FITTED Locking torques N m Flywheel cover screw 11 13 8 1 9 6 ftlb Flywheel and starting Removing the starter motor Remove the two screws indicated in the figure Take out the starter mot...

Page 103: ...spacer Do up the flywheel fixing nut by 3 or 4 threads so that the flywheel does not fall accidentally upon extraction Screw the extractor onto the flywheel and extract it as shown in the photograph Remove the tongue on the crankshaft Remove the starter motor gear Undo the screw and remove the crown gear bracket Remove the flywheel crown gear Specific tooling AP8140252 Multipurpose wrench AP814030...

Page 104: ...the freewheel holes and the fixing screws Apply the recommended product to the end of the screws Recommended products Loctite 243 Medium strength threadlock Fit the freewheel on the magneto flywheel mak ing sure that the ground side is in contact with the flywheel that is the wheel seeger ring should be visible Tighten the 6 fixing screws in a criss cross se quence to the prescribed torque Locking...

Page 105: ...mission gear Tighten the flywheel fixing nut to the prescribed torque with a multipurpose wrench Refit the retention plate Specific tooling AP8140252 Multipurpose wrench Locking torques N m Flywheel nut 94 102 69 4 75 3 ftlb Refitting the starter motor Fit and lubricate a new O ring on the starter mo tor Fit the starter motor on the crankcase and lock the 2 screws to the prescribed torque Locking ...

Page 106: ...5 screws indicated in the figure Removing the timing system drive First remove the parts listed below transmission cover driving pulley with belt oil sump with spring and by pass piston oil pump pulley cover O ring on the crankshaft and the sprocket wheel separa tion washer Remove the tappet cover Remove the central screw fastener and the au tomatic valve lifter retaining cover indicated in the fi...

Page 107: ...bly and its end of stroke washer Loosen the central screw on the tensioner first Remove the 2 clamps indicated in the figure Remove the tensioner and its gasket Remove the internal hex screw and the counter weight shown in the figure Remove the camshaft control pulley and its washer Engine ENG 107 ...

Page 108: ... MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED Removing the cam shaft Remove the 2 screws and the camshaft mounting bracket indicated in the figure Remove the camshaft Remove the pins and the rocking levers from the flywheel side holes NOTE IF NECESSARY THE HEAD MAY BE REMOVED TOGETH ER WITH THE CAMSHAFT ROCKING LEVER PINS AND MOUNTING BRACKET THE HEAD CAN...

Page 109: ...UNTING BRACKET THE HEAD CAN ALSO BE RE MOVED WITHOUT TAKING OUT THE CHAIN AND THE CHAIN TIGHTENER OF THE CRANKSHAFT Removing the valves Using the appropriate tool fitted with an adapter remove the cotter pins plates springs and valves Remove the oil seals with the specific tool Remove the spring lower supports CAUTION Arrange the valves so as to recognise their original position on the head Specif...

Page 110: ...VOID DAMAGING THE PISTON KEEP IT FIRM WHILE REMOVING THE CYLINDER NOTE BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL Inspecting the small end Measure the inside diameter of the small end us ing a specific micrometer NOTE Replace the crankshaft if the rod small end diameter exceeds the standard diameter shows signs of wear or overheating Characteristic Checking the rod small end Max dia...

Page 111: ...tion shown in the figure Carefully clean the sealing rings housings Measure the sealing rings grooves coupling clearance using suitable sensors as shown in the diagram If clearances measured exceed the limits speci fied in the table below the piston should be re placed by a new one NOTE MEASURE CLEARANCE BY INSERTING THE BLADE OF THE THICKNESS GAUGE FROM THE 2nd SEALING RING SIDE NOTE THE PIN HOUS...

Page 112: ...ling surface with the head is not worn or misshapen Pistons and cylinders are classified according to their diameter The coupling is carried out in pairs M M N N O O P P Characteristic cylinder standard diameter 71 990 72 018 mm to 33 mm Maximum run out allowed 0 05 mm Inspecting the piston rings SEALING RINGS Alternately insert the 3 sealing rings in the cylin der in the area where it keeps its o...

Page 113: ...he appropriate tool With the opening in the position indicated on the tool S left D right Set the snap ring into its position with the punch Fit the pin stop ring using the plug as shown in the figure piston fitting Install piston and pin onto the connecting rod with the piston arrow aligned facing the exhaust Fit the pin snap ring onto the appropriate tool With the opening in the position indicat...

Page 114: ...ES BY HOW DEEP THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE CYLINDER CROWN THE FURTHER THE PISTON ENTERS INTO THE CYLINDER THE THINNER THE BASE GASKET TO BE USED SHOULD BE TO COMPENSATE THE COMPRESSION RATIO AND VICE VERSA SHIMMING FOR 250 ENGINES Name Measure A Thickness Shimming 3 70 3 60 0 4 0 05 Shimming 3 60 3 40 0 6 0 05 Shimming 3 40 3 30 0 8 0 05 Engine ENG 114 ...

Page 115: ...iston ring with the word top or the reference mark facing the piston crown Offset the piston ring gaps on the three rings by 120º as shown in the figure Lubricate the components with engine oil 250 engines are fitted with top ring with an L sec tion NOTE THE 2 PISTON RINGS ARE MADE WITH A TAPERED CY LINDRICAL CONTACT SECTION THIS IS TO OBTAIN A BETTER BEDDING Refitting the cylinder Fit the cylinde...

Page 116: ... A Ø 12 000 12 018 bearing B Ø 20 000 20 021 bearing C Ø 37 000 37 025 Inspecting the timing system components Check that the guide slider and the tensioner pad are not excessively worn Check that the chain assembly the camshaft driving pulley and the sprocket wheel are not worn If sings of wear are found replace the parts if the chain pinion or pulley are worn replace the whole assembly Remove th...

Page 117: ... of valve V Max wear 1 6 mm Remove any carbon deposits from the valve guides Measure the inside diameter of each valve guide Measure according to the rocker thrust direction at three different heights If the width of the mark on the valve seat or the diameter of the valve guide exceed the specified limits replace the cylinder head Characteristic Valve seat wear Intake guide admissible limit 5 022 ...

Page 118: ...alves themselves Sealing surface width After use Intake and outlet 1 6 mm If the sealing surface on the valve is wider than the specified limit damaged in one or more points or curved replace the valve with a new one CAUTION DO NOT CHANGE THE VALVE FITTING POSITION RH LH Characteristic Valve wear check Standard intake and outlet 0 99 1 27 mm Engine ENG 118 ...

Page 119: ...e valve stem and the guide see figure CAUTION TO AVOID SCORING THE FAYING SURFACE DO NOT RO TATE THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED NOTE DO NOT CHANGE THE VALVE FITTING POSITION Characteristic Valve check standard length Outlet 94 4 mm Valve check standard length Inlet 94 6 m...

Page 120: ...the specified punch fit the 4 sealing rings Fit the valves the springs and the plates Using the specified tool with the appropriate adaptor compress the springs and insert the cotters in their seats NOTE DO NOT CHANGE THE VALVE FITTING POSITION FIT THE VALVE SPRINGS WITH THE REFERENCE COLOUR ON THE COTTERS SIDE TURNS WITH GREATER PITCH Specific tooling AP8140179 Support for valve fitting removal A...

Page 121: ...tomatic valve lifter return spring is not deformed by over stretching Replace any defective or worn component Check there are no signs of wear or scoring on the rocker pins Check the internal diameter of each rocker arm Check there are no signs of wear on the contact pads with the cam and on the jointed adjustment plate Characteristic Rocking levers inside diameter Standard di ameter Ø 12 000 12 0...

Page 122: ...he spacer and the fixing screw Tighten the screw to the prescribed torque Fit the pins and rocker levers Lubricate the 2 rocking levers through the holes at the top Lubricate the 2 bearings and insert the camshaft in the cylinder head with the cams opposed to the rocking levers Insert the retention plate and tighten the two screws shown in the picture to the prescribed tor que Refit the spacer on ...

Page 123: ...h using the counterweight fixing screw as reference Tighten the central fixing screw to the prescribed torque Set the tensioner slider to its home position Fit the chain tensioner on the cylinder using a new gasket and tighten the 2 screws to the pre scribed torque Insert the chain tensioning spring together with the central screw and washer and tighten the cap to the prescribed torque Adjust valv...

Page 124: ... the cylinder head and the cylinder fit the cylinder head gasket and the cylinder head Lubricate the stud bolt threading Tighten up the nuts to an initial pre torque of 7 1 Nm Tighten up the nuts to a second pre torque of 10 1 Nm Rotate by an angle of 270 To carry out the operations described above fol low the tightening sequence indicated in the figure Fit the two screws on the timing chain side ...

Page 125: ... cover by tightening the 5 screws to the prescribed torque Take care to correctly position the gasket Locking torques N m Cylinder head cover screws 6 7 4 4 5 2 ftlb Refitting the intake manifold Assemble the inlet manifold and tighten the 3 screws Locking torques N m Inlet manifold screws 11 13 8 1 9 6 ftlb Engine ENG 125 ...

Page 126: ...oil seal Remove the oil filter fitting shown in the figure Check the connecting rod axial clearance Check the connecting rod radial clearance Check that the surfaces that limit the axial clear ance are not scored and with the aid of a gauge measure the crankshaft width as shown in the fig ure If the crankshaft crankcase axial clearance ex ceeds what specified and the crankshaft does not show any d...

Page 127: ...SERVED NOTE WHEN MEASURING THE CRANKSHAFT WIDTH MAKE SURE THAT THE MEASUREMENTS ARE NOT MODIFIED BY THE COUPLING SPOKES WITH THE CRANKSHAFT BEARINGS Characteristic Crankshaft crankcase axial clearance Stand ard clearance 0 15 0 40 mm when cold Crankshaft connecting rod axial clearance Standard clearance 0 20 0 50 mm Crankshaft connecting rod radial clearance Standard clearance 0 036 0 054 mm Crank...

Page 128: ... replaced ei ther and when cleaning the crankshaft be very careful that no impurities get in through the shaft lubrication holes In order to prevent damaging the connecting rod bushings do not attempt cleaning the lubrication duct with compressed air Make sure that the 2 buffers on the crankpin are properly fitted A wrong installation of a buffer can seriously af fect the bushing lubrication press...

Page 129: ...scratches or de formation paying special attention to the cylinder crankcase surfaces and the crankcase halves coupling surfaces Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in oil pressure and thus affect the lubricating pres sure for the main bushings and the connecting rod Check that the surfaces limiting the crankshaft axial clearance show n...

Page 130: ... the coupling surface of the two half bearings must be perpendicular to the cylinder axis as shown in the figure The oil supplying channel section is also influ enced by the depth to which the bushings are driven compared with the crankshaft axial clear ance of the limiting surface Measure the bushings diameter at the 3 positions indicated in the figure Repeat the measurements for the other half o...

Page 131: ...scri bed torque Position the oil pre filter element as shown in the photograph Place a new gasket on one of the crankcase half preferably on the transmission side together with the centring dowels Lubricate the main bushings and insert the crank shaft in the transmission side crankcase half Couple the 2 crankcase halves Fit the 10 screws and tighten them to the pre scribed torque Fit and lubricate...

Page 132: ...gauge as indicated in the photograph If it driving depth varies significantly from that indicated it means that the stud bolt has yielded Should this occur replace it By working on two cylinder head fixing nuts fitted nut and lock nut remove the stud bolt from its seat as shown in the photograph Thoroughly clean the threaded seat on the crank case Refit a new stud bolt and apply the special produc...

Page 133: ...Lubrication Conceptual diagrams LUBRICATION CIRCUIT Engine ENG 133 ...

Page 134: ...Engine ENG 134 ...

Page 135: ... the specific tools on the engine once the measurement is complete Refit the oil pressure switch and washer tightening it to the prescribed torque and fit the flywheel cover If oil pressure reading are not within the specified limits check in the following order the oil filter the oil by pass valve the oil pump and the crankshaft seals NOTE THIS CHECK MUST BE CARRIED OUT WITH OIL AT THE CORRECT LE...

Page 136: ...tall the base of the appropriate tool on the oil guard using the screws supplied Specific tooling AP8140729 Chain cover fitting removal Screw the threaded bar onto the base of the tool and extract the oil guard Specific tooling AP8140729 Chain cover fitting removal Engine ENG 136 ...

Page 137: ...ar onto the crankshaft up to the end of travel Use the nut to move the base of the tool until you can feel the end of the stroke of the oil seal driving Remove all of the tool components following the procedure in reverse order CAUTION DO NOT LUBRICATE THE KEYING SURFACE ON THE EN GINE CRANKCASE CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS ONCE THE POSITIO...

Page 138: ...erting a screwdriver through one of its holes Remove the central screw with Belleville washer indicated in the figure Remove the chain and the crown gear Remove the control sprocket wheel and its O ring Remove the oil pump by unscrewing the 2 screws indicated in the figure Remove the sealing gasket NOTE IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION IS...

Page 139: ...ring Measure distance between rotors with a thick ness gauge at the position shown in the picture Measure the distance between the outer rotor and the pump body see figure Check the axial clearance of the rotors using a trued bar as shown in the figure Characteristic Rotor axial clearance Limit value allowed 0 09 mm Distance between outer rotor and pump body limit clearance allowed 0 20 mm Distanc...

Page 140: ...the holes for the crankcase fixing screws are aligned Make sure the gasket is the correct position and refit the pump on the engine crankcase The pump can only be fitted in one position Tighten the screws to the prescribed torque Fit a new O ring on the pinion Assemble the chain Fit the pulley the central screw and the belleville washer Tighten to the specified torque Assemble the oil pump cover b...

Page 141: ...cket wheel as described in the Transmission chapter Drain the oil from the sump as described above Remove the 7 screws shown in the figure and the 2 brackets fixing the rear brake fluid pipe Remove the spring the by pass piston the gas ket and the centring dowels shown in the figure Inspecting the by pass valve Check the free length of the spring Check that the plunger is not scored Make sure that...

Page 142: ...nd supporting brackets of the rear brake pipes in the reverse order followed for removal Tighten the screws to the prescribed torque Refit the driving pulley assembly the belt the pinion and the transmission cover as described in the Transmissions chapter When testing the lubrication system refer to the Crankcase and Crankshaft chapter re garding lubrication of the crankshaft and con necting rod L...

Page 143: ...INDEX OF TOPICS INJECTION INJEC ...

Page 144: ...constant based on the ambient pressure The fuel supply circuit consists of Fuel pump Fuel filter Injector Pressure regulator Pump filter and regulator are placed into the fuel tank using a single support The injector is connected by two pipes provided with fast release fittings This results in a continuous circulation thereby avoiding the risk of fuel boiling The pressure regulator is at the end o...

Page 145: ...6 cycles of use cold start running at regular engine temperature stop The diagnostic tester is also required for adjusting idle speed carburetion Specific tooling AP8140595 Axone battery charger 230V 50Hz AP8202311 Axone battery charger 110V 60Hz The MIU injection ignition system carries out checks on the rpm indicator and the radiator cool ing electric fan The MIU control unit power supply is fur...

Page 146: ...y 1 Instrument panel 2 Throttle body and injection electronic control unit MIU 3 Connector for diagnosis 4 Fuel pump 5 Water Temperature Sensor 6 Fuel injector 7 HV coil 8 Flywheel revolution timing sensor 9 Lambda Probe Injection INJEC 146 ...

Page 147: ...a If the air filter is dirty b If the by pass circuit is clogged c If the Stepper motor is failing F Others a If the timing system is not correctly adjusted b If the idle carburetion is not correct c If the throttle valve position sensor is not correctly reset 2 MIU system failure may be caused by loose connectors Make sure that all connections are properly implemented Check the connectors as foll...

Page 148: ... the tank up to a little over half its capacity This ensures that the pump will be covered by fuel 7 When washing the vehicle do not press the electric components and wirings 8 When an ignition fault is detected proceed to check the battery and the injection system connections first 9 Before disconnecting the MIU control unit connector follow these steps respecting the order shown Set the switch t...

Page 149: ...emperature Sensor 10 11 lambda probe 12 Engine stop switch 13 Engine revolution sensor 14 Fuel injector 15 Engine revolution sensor 16 Diagnosis output 17 18 Ground connection Connected to water temperature sensor engine stop 19 20 Injection load remote control 21 Lambda probe heater 22 HV coil 23 24 Start up enabling 25 Rollover protection switch 26 Ground connection Injection INJEC 149 ...

Page 150: ...e 15 A 9 Key switch contacts 10 Fuel pump 11 Injection load remote control 12 Starter button 13 Start up remote control 14 Electric fan remote control 15 Injection electronic control unit 16 Starter motor 17 Electric fan 18 Engine stop switch 19 Engine revolution sensor 20 Connector for diagnosis 21 Water Temperature Sensor 22 Water temperature gauge Injection INJEC 150 ...

Page 151: ...ure is read by a different sensor Engine revs rpm Measured by the crankshaft rpm detection sensor Target idle revs 1600 rpm Target revs saved to the electronic control unit memory they vary according to engine temperature Ignition advance Ignition advance in relation to TDC TPS Trimmer Idle motor 50 steps Idle motor position example value measured with warm engine Battery voltage V Voltage measure...

Page 152: ...device is activated if it is not correctly activated this will be immediately shown in the Axone screen page Injectors The device is activated if it is not correctly activated this will be immediately shown in the Axone screen page Electric fan The device is activated if it is not correctly activated this will be immediately shown in the Axone screen page Idle motor The device is activated if it i...

Page 153: ...ector Revolution timing sensor Fuel supply Fuel present in the tank Fuel pump activation Fuel pressure low Injector flow low Power to the spark plug Spark plug Shielded cap HV Coil secondary insulation Parameter reliability Coolant temperature Distribution timing injection start Intake air temperature Starting difficulties ENGINE START UP PROBLEMS Possible Cause Operation Faults detected by self d...

Page 154: ...leaning Air filter Diffuser and throttle valve Supplementary air pipe and Stepper Intake system seal seepage Intake manifold head Throttle body manifold Intake manifold Filter housing Fuel supply low pressure Fuel pump Pressure regulator Fuel filter Injector flow Engine does not rev down ENGINE DOES NOT RETURN TO IDLING IDLING TOO HIGH Possible Cause Operation Faults detected by self diagnosis Pum...

Page 155: ...GULAR ENGINE PROGRESS WITH VALVE SLIGHTLY OPEN Possible Cause Operation Intake system cleaning Air filter Diffuser and throttle valve Supplementary air pipe and Stepper Intake system seal Intake manifold Filter housing Ignition system Spark plug wear check Parameter reliability Throttle valve position signal Coolant temperature signal Intake air temperature signal Ignition advance TPS reset succes...

Page 156: ...iency Spark plug Parameter reliability Throttle valve position signal Coolant temperature signal Intake air temperature signal Ignition advance Intake system seal Intake manifold Filter housing TPS reset successful TPS reset successful Fuel supply Fuel pressure Fuel filter Injector flow Fuel quality Selecting the thickness for the cylinder base gasket Selecting the thickness for the cylinder base ...

Page 157: ...emoving the injector Preventively remove Helmet compartment Rear central cover Remove the footrest lower protection by sliding it upwards and turning it Remove the injector connector Injection INJEC 157 ...

Page 158: ...support Undo and remove the screw Refitting the injector For refitting follow the operations in reverse order observing the tightening torque Removing the butterfly valve Remove the screws fixing the control unit cable harness support Injection INJEC 158 ...

Page 159: ... Remove the MIU control unit connector Unscrew the throttle body sleeve fas tening clamp Remove the sleeve Remove throttle control retainer Injection INJEC 159 ...

Page 160: ...he butterfly valve To refit follow the removal steps but in reverse or der being careful to position the clip fixing the throttle body to the air filter bellows at 45 as shown in the photograph Injection INJEC 160 ...

Page 161: ...cuit COMPONENTS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 20 A 3 Key switch contacts 4 Fuse 15 A 5 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda Probe Injection INJEC 161 ...

Page 162: ...en pins 30 and 87 of the remote control Check the power supply line of the injection load remote control energising coil after switching the line ON make sure there is battery voltage for two seconds between the Green Brown cable and the Blue Red cable of the remote control base If there is none check the continuity of the Green Red cable between the fuse box in the battery compartment and the rem...

Page 163: ...20 on the interface wiring is insulated from the earth connection Specific tooling Digital multimeter Circuit leak test Fit the specific tool for fuel pressure control with the pipe fitted with the pressure gauge on the de livery pipe Checking under regular functioning by placing the specific tool between the pump and the injector With 12V battery voltage check that the fuel pressure is 2 5 BAR an...

Page 164: ...rox 110 cm Specific tooling AP8140181 Fuel pressure check tool Fuel filter check Disconnect the terminals of the electrical pump Remove the screw indicated in the photograph Remove the clip fixing the piping to the filter shown in the photograph Injection INJEC 164 ...

Page 165: ...Separate the lower part of the pump support as shown in the photograph Remove the filter from the pump support Injection INJEC 165 ...

Page 166: ...or circuit COMPONENTS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 20 A 3 Key switch contacts 4 Fuse 15 A 5 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda Probe Injection INJEC 166 ...

Page 167: ...te control Check the power supply line of the injection load remote control energising coil after switching the line ON make sure there is battery voltage for two seconds between the Green Red cable and the Black Purple cable of the remote control base If there is none check the continuity of the Green Red cable between the fuse box in the battery compartment and the remote control base and of the...

Page 168: ...and the earth connection If there is none check the continuity of the Green Red cable between the fuse box No 4 15A and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED BATTERY REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection INJEC 168 ...

Page 169: ...witch to ON and check there is voltage with in jector disconnected and control unit connected between the Red Brown cable of the injector con nector and the earth connection With injector disconnected and the injector load remote control disconnected check the continuity of the Red Brown cable between the injector con nector and remote control base Injection INJEC 169 ...

Page 170: ...ments supplied for the injection tester Connect the cable terminals to an auxiliary battery Activate the fuel pump with the active diagnosis Check that within 15 seconds approximately 40 cm of fuel is delivered with a regulation pressure of about 2 5 BAR Specific tooling AP8140181 Fuel pressure check tool Carry out the injector sealing test Dry the injector outlet with a blast of compressed air Ac...

Page 171: ...Components location Injection INJEC 171 ...

Page 172: ...or 7 HV coil 8 Flywheel revolution timing sensor 9 Lambda Probe 10 Injection load remote control 11 Battery 12V 12 Ah 12 Electric fan remote control 13 fall sensor Tachometer With interface wiring disconnected from the control unit and connected to the system check that the sensor resistance between pins 13 15 is between 100 and 150 Ohm at an engine temperature of about 20 Injection INJEC 172 ...

Page 173: ... the control unit check the continuity of the rpm sensor connector red cable between pin 13 and pin 1 and the rpm sensor connector white cable between pin 15 and pin 2 With the interface wiring disconnected from the control unit and the rpm sensor connector also disconnected check that the red and brown cables pin 13 15 are insulated from each other and in sulated from the earth connection Specifi...

Page 174: ...OMPONENTS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 20 A 3 Key switch contacts 4 Fuse 15 A 5 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda Probe Injection INJEC 174 ...

Page 175: ...nit The power of the ignition is increased during the engine start up phase The injection system recognises the 4 stroke cycle so ignition is only commanded in the compression phase Specific tooling Digital multimeter Check that the 20A main fuse No 2 and the injection load 15A No 4 fuse are in good conditions Check there is voltage between pins 22 and 26 of the interface wiring for around two sec...

Page 176: ...oil after switching the line ON make sure there is battery voltage for two seconds between the Green Red cable and the Black Purple cable of the remote control base If there is none check the continuity of the Green Red cable between the fuse box in the battery compartment and the remote control base and of the Black Purple cable between pin 8 of the control unit and the remote control base NOTE C...

Page 177: ...and the earth connection If there is none check the continuity of the Green Red cable between the fuse box No 4 15A and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED BATTERY REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection INJEC 177 ...

Page 178: ...Coolant temperature sensor TEMPERATURE SENSOR 1 Specification Desc Quantity 1 Water Temperature Sensor 2 Engine stop switch Injection INJEC 178 ...

Page 179: ...the interface wiring and the pin 3 of sensor connector and the continuity be tween pin 26 of the interface wiring and pin 1 of sensor connector Specific tooling AP8181059 Control unit interface wiring Zeroing the throttle Throttle valve position signal reset TPS reset The MIU control unit is supplied with throttle valve position sensor and is pre calibrated Pre calibration entails regulating the m...

Page 180: ...ng to the pre calibrated position To reset proceed as follows Connect the Axone following the specific instructions Shift to ON Press the and keys go to the adjustable parameters screen and select TPS RESET parameter Specific tooling AP8140595 Axone battery charger 230V 50Hz AP8202311 Axone battery charger 110V 60Hz Make sure that the throttle valve control is in con tact with the stop screw Guara...

Page 181: ...Given that the TPS reset is also carried out when the control unit is replaced place the control unit filter box bellows fixing clip at 45 upon refitting as shown in the photograph Injection INJEC 181 ...

Page 182: ... COMPONENTS Specification Desc Quantity 1 Battery 12V 12 Ah 2 Fuse 20 A 3 Key switch contacts 4 Fuse 15 A 5 6 Injection load remote control 7 Fuel pump 8 HV coil 9 Fuel injector 10 Lambda Probe Injection INJEC 182 ...

Page 183: ...h value to a low one with a mixture with lambda 1 Since the probe only works at high temperatures it has an electric preheating element inside controlled by the control unit to make it start operating quickly Specific tooling AP8181059 Control unit interface wiring Check that the 20A main fuse No 2 and the injection load 15A No 4 fuse are in good conditions Check there is voltage between pins 21 a...

Page 184: ...oil after switching the line ON make sure there is battery voltage for two seconds between the Green Red cable and the Black Purple cable of the remote control base If there is none check the continuity of the Green Red cable between the fuse box in the battery compartment and the remote control base and of the Black Purple cable between pin 8 of the control unit and the remote control base NOTE C...

Page 185: ...and the earth connection If there is none check the continuity of the Green Red cable between the fuse box No 4 15A and the remote control base NOTE CONTINUITY TESTS MUST BE CARRIED OUT WITH THE COMPONENTS DISCONNECTED BATTERY REMOTE CONTROLS CONTROL UNIT FUSES ETC Injection INJEC 185 ...

Page 186: ...down to 2V Place the multimeter probes between pins 4 and 11 With the engine running at idle speed check that the voltage oscillates between 0V and 1V With the throttle valve fully open the voltage is 1V During the closing phase the voltage is 0V If the voltage remains constant the sensor may be damaged Remove the sensor and check that there are no oil or carbon deposits in it Injection INJEC 186 ...

Page 187: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 188: ...KEY 1 Grey front wheel rim 2 Bearing 3 Spacer 4 Front wheel left spacer 5 Front wheel right spacer 6 Front wheel pin 7 Tubeless valve 8 Front brake disc Qty 2 9 TE flanged screw 10 Front cover 11 Oil seal 12 Cap Suspensions SUSP 188 ...

Page 189: ...EEL OTHER WISE THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAKAGE Remove the front wheel Clean the two sides of the hub with a cloth Remove the right oil seal 1 Remove the right bearing 2 with a suitable extractor Remove the left oil seal 3 Remove the left bearing 4 with a suitable extractor Carry out a thorough check of the bear ings Collect the internal spacer 5 Clean...

Page 190: ...ONS SPECIALLY THE ONES BELOW GASKETS Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear WHEEL PIN Using a dial gauge check the wheel pin 2 ec centricity Replace the pin 2 if the eccentricity exceeds the limit value Characteristic Maximum eccentricity 0 25 mm RIM Using a dial gauge check that the radial eccen tricity A and the axial eccentricit...

Page 191: ...TO AVOID UNEX PECTED FLAT TYRES BALANCE THE WHEEL AFTER A TYRE IS MENDED Refitting the front wheel For refitting follow the operations in reverse order observing the tightening torque Handlebar Removal Remove the front handlebar cover SEE INSTRUMENT PANEL Remove the rear handlebar cover SEE INSTRUMENT PANEL Remove the internal front shield Remove the clamps NOTE USE NEW CLAMPS FOR REFITTING Undo a...

Page 192: ... Disconnect the handlebar electrical control connectors Undo and remove the two screws Lower the brake pump U bolt Remove the brake pump keep it con nected to the brake pipe Suspensions SUSP 192 ...

Page 193: ...the brake pump U bolt Remove the throttle grip Remove the safety screw 2 Loosen the main screw 1 Slide off the handlebar upwards Refitting For refitting follow the operations in reverse order observing the tightening torque Suspensions SUSP 193 ...

Page 194: ... 4 Rubber cap 5 Sealing cap 6 O ring 7 Spring 8 Pumping member 9 Counter spring 10 Bottom buffer 11 Left stem 12 Dust guard gasket 13 Safety circlip 14 Sealing gasket 15 Cap 16 Bushing 17 Left wheel holder 18 Sealing washer 19 Lower screw Suspensions SUSP 194 ...

Page 195: ... screws 1 NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE WHEEL HOLDER STEM SLEEVE BUT THEY APPLY TO BOTH Remove the shield back plate Remove the upper Seeger ring 2 Remove the wheel holder stem sleeve WHEEL HOLDER STEMS SLEEVES REMOVAL Drain off the oil Place the stem in a vice fitted with pro tection jaws aluminium Suspensions SUSP 195 ...

Page 196: ... stem and collect the cen tring bushing NOTE BE CAREFUL NOT TO DAMAGE THE SLEEVE INTERIOR WHEN REMOVING THE DIFFERENT COMPONENTS Remove the pumping member 2 and the spring 3 from the stem Remove the dust guard from the sleeve Suspensions SUSP 196 ...

Page 197: ... Remove the Seeger ring Remove the oil seal Remove the washer If necessary remove the spacer 4 Suspensions SUSP 197 ...

Page 198: ...ORE CARRYING OUT THESE OPERATIONS CAUTION THE WHEEL HOLDER STEM SLEEVE UNIT CONTAINS OIL DO NOT TURN IT OVER OR TILT IT TOO MUCH WHEN REMOVING IT Remove the upper closing cap Lower the pumping element until the Seeger ring 1 can be removed Remove the Seeger ring 1 Remove the cap and the O ring Suspensions SUSP 198 ...

Page 199: ...nd or scratches These scorings can be eliminated by rubbing them with wet sandpaper fine grain If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending ...

Page 200: ... excessive wear or damage replace the affected compo nent Replace the following components with new ones O ring gasket on the cap 1 oil seal 2 dust guard 3 OIL FILLING Place the wheel holder stem sleeve unit in a vice fitted with protection jaws aluminium Fit the spring Suspensions SUSP 200 ...

Page 201: ... the wheel holder stem sleeve unit CAUTION NEVER REUSE OIL Remove the cap with the O ring Fit the pumping member 1 Lower the pumping element until the Seeger ring 2 can be fitted Fit the Seeger ring 2 Suspensions SUSP 201 ...

Page 202: ...tection jaws aluminium Fit the spacer 1 CAUTION BE EXTREMELY CAREFUL SO THAT NO FOREIGN BOD IES GET INTO THE SLEEVE OR THE WHEEL HOLDER STEM Insert the washer NOTE SPREAD A THIN LAYER OF FORK OIL ON GASKETS AND BUSHINGS BEFORE REFITTING THEM Insert the oil seal Suspensions SUSP 202 ...

Page 203: ...the Seeger ring Fit the dust guard Insert the pumping member and the spring in the stem Fit the components below on the sleeve in the following order the cen tring bushing 2 and the stem Suspensions SUSP 203 ...

Page 204: ...Tighten the lower screw 3 Refill with oil Steering column KEY 1 Cap 2 Lock nut 3 Adjusting nut 4 Upper dust guard 5 Upper bearing 6 Separating ring 7 Lower bearing 8 Lower dust guard Suspensions SUSP 204 ...

Page 205: ...n Replace the whole bearing if neces sary CAUTION CHECK THAT THE COMPONENTS ARE IN GOOD CONDI TIONS CAUTION APPLY GREASE ON BALL CONTACT AREAS ON BOTH SEATS 2 AND 3 Rear Removing the rear wheel KEY 1 Grey rear wheel rim 2 Rear cover 3 Internal wheel spacer 4 External wheel spacer 5 Nut 6 Cap 7 Split pin Suspensions SUSP 205 ...

Page 206: ...er 4 Undo and remove the two screws and remove the muffler support plate Remove the spacer 5 placed on the wheel pin Remove the rear wheel by sliding it off from the right side CAUTION UPON REMOVING REFITTING PAY ATTENTION NOT TO DAMAGE THE BRAKE HOSES DISCS AND PADS CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OTHERWISE THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESUL...

Page 207: ...crew and remove the nut 2 and collect the washer Remove the screw 3 Slide off the left shock absorber Unscrew and remove the nut 1 Slide off the right shock absorber Refitting For refitting follow the operations in reverse order observing the tightening torque Suspensions SUSP 207 ...

Page 208: ... right side disconnect the spring 1 from the stand hook 2 Undo and remove the screw 3 and collect the self locking nut Remove the centre stand NOTE CARRY OUT THE FOLLOWING OPERATIONS FROM THE OPPOSITE SIDE OF THE STAND Suspensions SUSP 208 ...

Page 209: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 210: ...luid reservoir 3 Front brake control lever 4 Rear brake pump reservoir 5 Rear brake control lever 6 Rear brake calliper 7 Rear brake pads 8 Rear brake lever pipe rear brake calliper 9 Front brake calliper 10 Front brake pads Rear brake calliper Braking system BRAK SYS 210 ...

Page 211: ...de off the brake calliper from the disc Rear brake disc Removal Remove the rear wheel Undo and remove the five brake disc screws Remove the brake disc CAUTION UPON REFITTING APPLY THE RECOMMENDED PROD UCT ON THE THREADING OF THE BRAKE DISC SCREWS Recommended products LOCTITE 243 Loctite adhesive to assembly cylindrical pieces Loctite adhesive to assembly cylindrical pieces Braking system BRAK SYS ...

Page 212: ...D ON THE WHEEL Characteristic Minimum value for brake disc thickness 3 8 mm Using a dial gauge check that disc os cillation does not exceed the tolerance otherwise replace it Characteristic Brake disc oscillation tolerance 0 5 mm Front brake disc OPERATIONS VALID FOR BOTH FRONT BRAKE DISCS Removal Remove the front wheel Undo and remove the five brake disc screws Remove the brake disc Refitting For...

Page 213: ...he minimum thickness with a micrometer at different points Replace the disc if the minimum thickness even at a single point of the disc is less than the minimum value CAUTION OPERATIONS TO BE CARRIED OUT WITH BRAKE DISC FITTED ON THE WHEEL Characteristic Minimum value for brake disc thickness 3 8 mm Using a dial gauge check that disc os cillation does not exceed the tolerance otherwise replace it ...

Page 214: ... ITS SEAT RESULTING IN BRAKE FLUID LEAK AGE Refitting OPERATIONS VALID FOR BOTH FRONT CALLIPERS CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER UPON REFITTING DO NOT INVERT THE POSITION OF THE LOCK For refitting follow the operations in reverse order observing the tightening torque Rear brake pads Braking system BRAK SYS 214 ...

Page 215: ...OW STAMPED ON THE SPRING MUST ALWAYS BE TURNED IN THE RIDING DIRECTION Slide off the brake pads Refitting CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER UPON REFITTING DO NOT INVERT THE POSITION OF THE LOCK Braking system BRAK SYS 215 ...

Page 216: ...brake fluid reservoir cap Check the fluid flows out of the reser voir and before the reservoir is empty close the bleed valve 4 and 5 Top up the fluid in the reservoir Open the bleed valve 4 and 5 again approximately half a turn Check that the fluid drains off through the pipe and when the fluid changes colour from dark to light close the bleed valve 4 and 5 and remove the pipe Refit the rubber pr...

Page 217: ... FLUID WHILE TOPPING UP KEEP THE FLUID IN THE RESERVOIR PARALLEL TO THE RES ERVOIR EDGE IN HORIZONTAL POSITION Remove the gasket 2 Top up with oil if required Remove the rubber protection cover of the bleed valve 4 and 5 Connect a transparent pipe to the bleed valve 4 and 5 NOTE DO NOT SMEAR THE PADS OR THE DISC WITH BRAKE FLUID Place the free end of the transparent pipe into a container Operate t...

Page 218: ...and 5 and release the brake lever Refit the cover 1 NOTE AFTER REFITTING PULL THE BRAKE LEVER REPEAT EDLY AND CHECK THE CORRECT OPERATION OF THE BRAKING SYSTEM NOTE REPEAT THE THREE LAST OPERATIONS UNTIL THERE ARE NO MORE AIR BUBBLES Braking system BRAK SYS 218 ...

Page 219: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 220: ...ator fitting pump pipe 4 Clamp 5 Breather pipe 6 White clic clamps 7 White clic clamp 8 Expansion tank cap 9 Clip 10 TBEI flanged screw 11 To the water pump 12 From the head 13 Fitting head sleeve 14 Fitting 15 Electric fan connector 16 Electric fan Cooling system COOL SYS 220 ...

Page 221: ...front central cover Disconnect the electric fan connector CAUTION OPERATE WITH CAUTION SO AS NOT TO DAMAGE THE RADIATOR FINS Connect the connector ends to the bat tery poles by means of two cables If the electric fan does not turn Rotate the fan manually and check that the blades do not touch the support If rotation is free of obstacles Check the cable harnesses between fan and relay If no malfunc...

Page 222: ... remove the three screws Remove the electric fan Coolant replacement Emptying NOTE USE A CONTAINER OF ADEQUATE CAPACITY TO COLLECT THE FLUID THAT MAY LEAK DUR ING OPERATION Remove the front shield Loosen the clamp Slide off the pipe Drain off the system NOTE REMOVE THE EXPANSION TANK CAP TO FACILITATE COOLANT DRAINAGE Cooling system COOL SYS 222 ...

Page 223: ...mark Run the vehicle until it warms up Shut off the engine bleed again and top up Refit the central inspection cover Locking torques N m Fixing the radiator pump hose clamps 3 2 2 ftlb System bleed Start the engine until the operating temperature is reached Remove the bleed valve rubber cap Use a rubber hose of suitable length to connect the valve to the expansion tank Place one end of the hose on...

Page 224: ...l inside the expansion tank Locking torques N m Bleed screw 3 Thermostat Removal Preventively remove Helmet compartment Rear central cover Remove the footrest lower protection by sliding it upwards and turning it Remove the thermostat cover Extract the thermostatic valve Cooling system COOL SYS 224 ...

Page 225: ... the container using the thermal gun Check the temperature when the thermostat starts to open Heat to obtain the thermostat full opening 3 Replace the thermostat if it is not working prop erly CAUTION MAKE SURE NEITHER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER FOR A COR RECT TEST PERFORMANCE Specific tooling 020331Y Digital multimeter 020151Y Heat gun Characteristic Thermostat check...

Page 226: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 227: ...he key anticlockwise Lift the saddle Undo and remove the four screws Remove the saddle Rear rack Insert the key in the saddle lock Turn the key anticlockwise Lift the saddle Undo and remove the four screws Slide off the screw cap Chassis CHAS 227 ...

Page 228: ...ove the luggage rack Driving mirrors Operating from both sides unscrew the mirror CAUTION THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCK WISE Rear handlebar cover Operating from both sides undo and remove the two screws Chassis CHAS 228 ...

Page 229: ... Undo and remove the screw Disconnect the connector Instrument panel Remove the rear handlebar cover Undo and remove the four screws Pull the instrument panel backwards Chassis CHAS 229 ...

Page 230: ... Undo the three screws Slide off the instrument panel forwards Front handlebar cover Remove the rear handlebar cover Remove the front handlebar cover Chassis CHAS 230 ...

Page 231: ...ides undo and remove the five screws CAUTION PLACE A SUPPORT UNDER THE CHASSIS SO THAT THE FRONT WHEEL DOES NOT TOUCH THE GROUND Operating from both sides undo and remove the three screws Undo and remove the two screws Move the external legshield forwards and disconnect front headlamp con nector Chassis CHAS 231 ...

Page 232: ...urn indicators from the back Slide the external front shield off the front fork Knee guard Remove the front central cover Operating from both sides undo and remove the screw Remove the handlebar cover Undo and remove the two screws Slide off the bag hook Chassis CHAS 232 ...

Page 233: ... and remove the four side screws Disconnect the auxiliary plug socket in the glove box By making the handlebar rotate pull forwards the internal legshield off the hooks being careful with the fitting slots Footrest Remove the central inspection cover Remove both side fairings Operating on both sides undo and re move the rear screw of the footrest Chassis CHAS 233 ...

Page 234: ...tment Operating from both sides undo and remove the lower screw fixing it to the internal legshield Remove the footrest being careful with the tongues and the related fitting slots Left and right fairings removal Remove the rear central cover Undo and remove the screw Undo the two screws and remove the passenger footrest rubber Chassis CHAS 234 ...

Page 235: ...rest removal In riding position rotate the passenger footrest 1 Lift the footrest upper rubber edge 3 Slide and remove the pin 4 Remove the passenger footrest 1 NOTE THESE OPERATIONS REFER TO ONLY ONE PASSENGER FOOTREST BUT THEY APPLY TO BOTH NOTE THIS OPERATION IS NECESSARY ONLY TO REMOVE THE METAL PART OF THE FOOTREST TO REMOVE FAIR INGS JUST REMOVE THE PASSENGER FOOTREST RUB BER Chassis CHAS 23...

Page 236: ...g cover Remove the filter Filter casing removal Remove the helmet compartment Remove the rear central cover Remove the left under sear fairing Loosen the intake manifold clamp Slide off the intake manifold Undo and remove the three screws keeping the related nuts locked Chassis CHAS 236 ...

Page 237: ...Chassis CHAS 237 ...

Page 238: ...ront locking Move the filter housing leftwards Release the clamp of the oil breather pipe Remove the oil breather pipe Remove the filter casing Tail guard Remove the rear central cover Operating on both sides undo and re move the four lower screws Chassis CHAS 238 ...

Page 239: ... Undo and remove the two screws in side the helmet compartment Operating on both sides undo and re move the screw Undo and remove the three fixing screws Chassis CHAS 239 ...

Page 240: ... the tail section from it fittings with the side fairings Move the tail section backwards and disconnect the rear light connector Undo the two fixing screws and remove the seat lock Remove the tail section by sliding it backwards Chassis CHAS 240 ...

Page 241: ...Rear mudguard Undo and remove the three screws Undo the three screws and remove li cense plate Undo and remove the screw Undo and remove the screw Chassis CHAS 241 ...

Page 242: ...bulb but keep it connected to the cables Remove the rear mudguard Should the rear mudguard holder frame be re moved before taking out the rear mudguard pro ceed as follows Undo and remove the two screws Helmet bay Remove the tail section Remove the luggage rack Chassis CHAS 242 ...

Page 243: ...ve the two screws Operating on both sides undo and re move the screw Remove the fuel tank cap 3 Remove the gasket 4 and release it by sliding it off from the breather pipe 5 Screw the fuel tank cap 3 Chassis CHAS 243 ...

Page 244: ...Removal Remove the helmet compartment Operating on both sides undo and re move the two screws and collect the washers Disconnect the connector Disconnect the connector 1 Disconnect the fuel pipe 2 Slide off the tank forwards Fuel Probe Removal Chassis CHAS 244 ...

Page 245: ...OTH IN ORDER TO AVOID FUEL SPLASHES CAUTION ONCE THE PROBE IS REMOVED FROM THE TANK CLOSE THE PROBE ENTRY OPENING WITH A CLOTH TO AVOID INHALING THE PETROL BEING EVAPORATED FROM THE TANK Front mudguard Operating from both sides undo and remove the two screws Slide off the front mudguard forwards Chassis CHAS 245 ...

Page 246: ...ing careful with the tongues and related fitting slots Lift the saddle Undo and remove the two screws Undo and remove the two screws Remove the central inspection cover by sliding it off its hooks Radiator fan Drain off the system Remove the shield back plate Remove the legshield Disconnect the electric fan connector Chassis CHAS 246 ...

Page 247: ... Loosen the clamps and remove the three pipes Undo and remove the screw Slide off the radiator upwards Chassis CHAS 247 ...

Page 248: ...n and remove the clamp Loosen and remove the clamp NOTE UPON REFITTING REPLACE THE REMOVED CLAMPS WITH NEW ONES Operating from both sides undo and remove the screw Remove the expansion tank Flyscreen Remove the front handlebar cover Operating from both sides undo and remove the two rear screws Chassis CHAS 248 ...

Page 249: ...indshield Fairing removal Operating from both sides undo and remove the screw Detach the front right handlebar cover from the left one Radiator cover Operating on both sides undo and re move the screw Chassis CHAS 249 ...

Page 250: ...careful with the tongues and related fitting slots Lower cover NOTE THE FOLLOWING OPERATIONS REFER TO ONE SIDE OF THE VEHICLE BUT APPLY TO BOTH Undo and remove the rear screw Undo and remove the two side screws Undo and remove the two screws Chassis CHAS 250 ...

Page 251: ...footrest and slide the lower shield off its hooks being careful with the tongues and related fitting slots The lower shield can be split into right and left sec tions To do this proceed as follows Undo and remove the two screws Slide off the lower shield to separate it into a right and a left section Chassis CHAS 251 ...

Page 252: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 253: ...mbly Plastic parts fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument p...

Page 254: ...OTHING IN CASE OF CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTIO...

Page 255: ...l inspection Hydraulic braking system Brake levers stroke Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESS...

Page 256: ...UNIT WATER TEMPERATUR SENSOR FAN RELE COIL 40 39 38 37 1 21 5 24 30 29 1 1 1 15 1 1 REV 0 8 BATTERY VOLTAGE REGOLATOR 19 1 7 44 14 12 13 1 17 17 9 18 16 36 37 20 26 31 32 33 34 35 38 39 40 FRONT LH TURN INDICATOR 46 1 1 REAR LIGHT OIL SENS INJECTION RELE 31 47 2 REAR LH TURN INDICATOR 16 LAMBDA PROBE 32 48 1 ON B G B G B Gr V Ar R Ar LOCK OFF V Ar M V G R R N R Ar R Ar 15 A R R B G R R B G Az N N ...

Page 257: ...lutch 49 83 84 89 Coolant 178 222 D Display E Engine oil 38 F Fork 194 Fuel 156 164 244 H Hub oil 35 I Identification 12 Instrument panel 229 M Maintenance 9 32 Mirrors 228 O Oil filter 41 R Recommended products S Saddle Shock absorbers 206 Spark plug 34 Stand Start up ...

Page 258: ...T Tank 244 248 Technical data Transmission 13 80 93 Turn indicators 66 Tyres 15 ...

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