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Ducati SCRAMBLER 800, Workshop Manual

The Ducati Scrambler 800 is a versatile and dynamic motorcycle that is perfect for riders seeking adventure. Ensure you are always prepared with the Workshop Manual, available for free download from manualshive.com. This comprehensive manual will help you maintain and repair your bike with ease.

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DUCATI SCRAMBLER 800 Workshop

Manual 2015

S.01 - General

Symbols - Abbreviations - References

Product specifications

Dangerous products - warnings

General maintenance instructions

General safety rules

S.02 - Model-specific information

Model identification

Identification data

S.03 - Technical data

Technical specifications

Lights/instrument panel

Injection system

Fuel system

Injection-ignition system

Charging system/generator

Hydraulic brakes

Rear suspension

Rear wheel

Front suspension

Front wheel

Cooling system

Gearbox

Cylinder/piston

Crankshaft

Timing system/valves

Transmission

Colours

General

Overall dimensions

Overall dimensions

Fuel, lubricants and other fluids

Fuel, lubricants and other fluids

Tightening torque settings

Engine tightening torque values

Frame tightening torque values

Service tools

Diagnosis special tools

Frame special tools

Engine special tools

S.04 - Maintenance operations

Vehicle pre-delivery

Vehicle pre-delivery

Scheduled maintenance chart

Operations to be carried out by the customer

Operations to be carried out by the dealer

Maintenance operations

Adjusting the rear shock absorber

Adjusting the position of the gearchange pedal and rear brake pedal

Adjusting the front brake control lever

Adjusting the throttle cable

Checking rear brake pad wear and replacing brake pads

Checking front brake pad wear and replacing brake pads

Adjusting the chain tension

Adjusting the steering head bearing play

Summary of Contents for SCRAMBLER 800

Page 1: ...erall dimensions Fuel lubricants and other fluids Fuel lubricants and other fluids Tightening torque settings Engine tightening torque values Frame tightening torque values Service tools Diagnosis spe...

Page 2: ...ase mechanism Refitting the tail guard Removing the tail guard Refitting the rear side body panels Removing the rear side body panels Refitting the seat Removing the seat Mudguard Refitting the front...

Page 3: ...bling Setting menu DESMO SERVICE indication DESMO SERVICE countdown indication OIL SERVICE zero warning Service indication SERVICE High engine temperature Clock Displayed errors description Error warn...

Page 4: ...r brake control ABS system information ABS system deactivation ABS system operation information Operating principle ABS system components Routing wiring harnesses hoses Refitting the ABS control unit...

Page 5: ...otpegs Removing the front footpegs Stands Refitting the side stand Removing the side stand Inspecting the frame Checking the frame Refitting the structural parts and frame Removing structural componen...

Page 6: ...ulleys Refitting the timing layshaft pulley Removing the timing layshaft pulleys Disassembling the camshaft pulleys Removing the cylinder head pulley fixed tensioner Removing the mobile tensioner timi...

Page 7: ...erator assembly Removing the flywheel generator assembly Refitting the generator cover Reassembling the generator cover Disassembling the generator cover Removing the generator cover Crankcase externa...

Page 8: ...mbol indicates additional useful information for the current operation Product specifications Symbols in the diagram show the type of threadlocker sealant or lubricant to be used at the points indicat...

Page 9: ...high temperatures up to 200 C and pressures up to 350 bar fills gaps up to 0 4 mm Loctite 510 LOCK 5 Permanent adhesive for freely sliding cylindrical couplings or threaded couplings on mechanical par...

Page 10: ...ngth Loctite 454 gel DUCATI sealing compound THREE BOND 1215 Sealing compound THREE BOND 1207B Exhaust pipe sealing compound Self sealing paste hardens when heated and resists temperatures exceeding 1...

Page 11: ...to be repaired Note that the disassembly procedures in this manual describe the most efficient way to reach the part to be repaired General advice on repair work Always use top quality tools When lif...

Page 12: ...re handling these components or allow the engine and exhaust system to cool down before proceeding Warning The exhaust system might be hot even after engine is switched OFF pay particular attention no...

Page 13: ...table with the frame part numbers EC Plant Borgo Panigale VERSION 1 2 3 4 5 6 EC version frame ZDM K 100AA B JAPAN version frame ZDM K 101JA B EC 35 kW version frame ZDM K 102AA B EC 25 kW version fr...

Page 14: ...is the table with the engine part numbers EC Plant Borgo Panigale VERSION 1 2 3 Engine ZDM 800A2C Engine ML0 800A2C EC Plant THAI version Engine ML0 800A2D Engine ZDM 800A2D 1 Manufacturer 2 Engine t...

Page 15: ...ight LED No 1 LED 3 1W 13 5V Tail light Parking light LED No 2 LEDs 3 24W 12V Stop light LED No 6 LEDs 7 9W 12V Number plate light lamp No 3 LEDs 0 67W 13 5V Turn indicators Front lamp 12V RY10W Rear...

Page 16: ......

Page 17: ...thanol of 10 E10 Using fuel with ethanol content over 10 is forbidden Using it could result in severe damage to the engine and motorcycle components Using fuel with ethanol content over 10 will make t...

Page 18: ...gnition system Reference Technical specifications Starting Type Electric starter motor 12 V 0 7 kW Spark plugs Make and type NGK DCPR8E Electrode gap 0 7 0 8 mm Injection system Make Type Control unit...

Page 19: ...Charging system generator Reference Technical specifications Battery Voltage 12 V Charge 10 A h Type Sealed type maintenance free Generator Capacity 490 W 14 V 34 8 A...

Page 20: ...330 mm Brake calliper Make Brembo Type M 4 3 Calliper cylinder diameter 32 mm Pad friction material FERIT I D 450 FF Master cylinder Type PS 13 22 REAR Brake disc Type Fixed drilled disc Thickness 4m...

Page 21: ...Rear suspension Reference Technical specifications Type SACHS monoshock with adjustable preload Shock absorber Wheel travel 150 mm...

Page 22: ...mit Minimum tread depth In the most worn part 2 mm Tyre pressure Cold 2 50 bar rider only 2 90 bar full load Swinging arm shaft runout On 100 mm 0 2 mm Wheel rim runout Radial 1 mm Sideways 0 5 mm Dri...

Page 23: ...Front suspension Reference Technical specifications Type KAYABA non adjustable hydraulic upside down fork Leg 43 mm Wheel travel 150 mm Fork Oil level per leg 427 cc right leg 298 cc left leg...

Page 24: ...value Service limit Minimum tread depth In the most worn part 2 mm Tyre pressure Cold 2 50 bar rider only 2 50 bar full load Wheel shaft runout On 100 mm 0 05 mm Wheel rim runout Radial 1 mm Sideways...

Page 25: ......

Page 26: ...imit Gearbox shafts End float 0 05 0 020 mm Selector drum End float 0 10 0 040 mm Gear selector fork Fork slider thickness 3 90 4 00 mm n a Fork to gear clearance 0 1 0 3 mm n a Fork to gear clearance...

Page 27: ...on Nominal diameter 88 mm Diameter Section A Section B Section C 87 965 87 975 mm 87 975 87 985 mm 87 985 87 995 mm Connecting rod Connecting rod big end diameter 43 67 mm Gudgeon pin to piston cleara...

Page 28: ...Crankshaft Reference Standard value Service limit Crankshaft Oval n a Taper n a Main journals alignment n a Crank pin diameter 40 017 mm 0 016 mm...

Page 29: ...ter 38 5mm Valve lift With 0 mm valve clearance Intake 11 20 mm Exhaust 10 80 mm Opening rocker arm intake 0 10 0 15 mm 0 10 0 15 mm Opening rocker arm exhaust 0 10 0 15 mm 0 10 0 15 mm Closing rocker...

Page 30: ...l control Clutch control Cable type Gearbox 6 speed Primary drive 1 85 1 Final drive 15 46 Gearbox type With constant mesh spur gears operated by a lever on the left side of the motorcycle Transmissio...

Page 31: ...at Clear lacquer Charcoal Black Frame AKZO NOBEL Matt Black wheel rims PEHADUR EINBRENN LACK CLASSIC Orange Sunshine Primer Clear coat Clear lacquer Charcoal Black Frame AKZO NOBEL Matt Black wheel ri...

Page 32: ...Steering head angle 24 Steering angle 35 Trail 112 mm Front suspension Kayaba Non adjustable 41 mm hydraulic upside down fork Front wheel travel 150 mm Rear suspension Kayaba The rear suspension syste...

Page 33: ...cement 803 cu cm Compression ratio 11 0 5 1 Timing system Desmodromic type with two valves per cylinder operated by four rocker arms 2 opening rocker arms and 2 closing rocker arms and one overhead ca...

Page 34: ...20 mm 790 20 mm 1150 20 mm 855 20 mm CLASSIC 2140 20 mm 1450 20 mm 170 20 mm 790 20 mm 1150 20 mm 855 20 mm URBAN ENDURO 2100 20 mm 1450 20 mm 170 20 mm 790 20 mm 1150 20 mm 855 20 mm FULL THROTTLE 2...

Page 35: ...lectric systems Front fork SHELL Advance Fork 7 5 or Donax TA RH leg 427 cc LH leg 298 cc Important Do not use any additives in fuel or lubricants Using them could result in severe damage of the engin...

Page 36: ......

Page 37: ...0 11 Clutch Clutch drum nut M25x1 5 180 190 200 GREASE B Wet clutch spring screw 20 M6x1 9 10 11 Pistons Fixed tensioner assembly M8x1 18 20 22 LOCK 2 Vertical cylinder oil temperature sensor M8x1 25...

Page 38: ...que 30 rpm 20 4 Snug torque 10 rpm 35 5 Tightening 14 rpm 65 1 6 Check 70 to 103 Crankshaft dowel 8 M8x1 25 11 13 15 LOCK 5 Crankshaft drilled dowel 8 M8x1 25 11 13 15 LOCK 5 Covers Wet clutch fluid f...

Page 39: ...Clutch cover closing screw 30 80 90 M6x1 12 5 13 5 14 5 Special screw securing generator cover to stud bolt 30 35 M6x1 12 5 13 5 14 5 Screw securing pushrod plug on generator cover 12 M6x1 9 10 11...

Page 40: ...adlocker Headlight subframe puffer to steering plate fastener M6x1 8 Headlight support to bottom yoke retainer M6x1 8 Front turn indicators to headlight support fastener M6x1 8 Instrument panel Instru...

Page 41: ...x cover fastener M6x1 10 Tail light fastener M5x0 8 5 Braking system front Front brake master cylinder to handlebar fastener M6x1 10 Sequence 1 UP 2 1 Union on LH brake calliper fastener M10x1 23 Fron...

Page 42: ...readlocker AUSTRALIA version Gravel guard fastener M5x0 8 AUSTRALIA version Splash guard number plate holder plate to rear guard fastener M6x1 AUSTRALIA version Handlebar clutch control Handlebar U bo...

Page 43: ...Lower to upper mudguard fastener M5 5 Mudguard sub group to frame fastener M6x1 8 Front wheel Brake disc fastener M8x1 25 30 Pre applied threadlocker Front wheel nut fastener M25x1 25 63 GREASE B Rear...

Page 44: ...support bracket to frame fastener M6x1 10 LOCK 2 Tank to bracket on the frame rear fastener M6x1 10 Glove box under the seat fastener M5x0 8 5 Latch to frame fastener M5x0 8 5 Rear shock absorber fork...

Page 45: ...t fastener M5x0 8 5 Rear RH side body panel to frame fastener upper screw M6x1 8 Rear LH side body panels to frame fastener upper screw M5x0 8 5 Rear lower cover to frame fastener M6x1 8 Rear lower co...

Page 46: ...IMAGE 28620441A PC HASP DDS2 0 wrench 979000252 DDS 2 Ducati Diagnosis System 2 0 979000253 Belt tensioning 979000254 Diagnosis and power supply cable 979000255 Diagnosis and power supply cable CAN 97...

Page 47: ...heel shaft wrench 88713 2562 Chain installation tool 88713 0958 Rotation bar for fork overhaul 88713 1010 Exhaust gas suction fitting 88713 1058 Wrench to fit steering tube 88713 1062 Steering tube be...

Page 48: ...88713 3220 Engine repair work bench...

Page 49: ...sprocket retainer key 88713 0944 Oil cartridge wrench 88713 1749 Puller for driving pulley and cover 88713 1805 Driving pulley tightening tool 88713 1832 Engine repair work bench 88713 1994 Rocker arm...

Page 50: ...positioning tool 88713 2442 Tool to install seal ring on valve guide 88713 2556 Clutch housing reaction tool 88713 2676 Cylinder head nut tightening tool 88713 2834 Snap ring installation tool 88713...

Page 51: ...88713 2103 Bearing surface for head installation 88713 3334 Selector fork positioning plate 88713 3367 Flywheel wrench 88765 1000 88765 1005 88765 1006 Fork feeler gauges 88765 1298 Valve lower shim...

Page 52: ......

Page 53: ...nt and possible interference Check key and steering lock operation Check front and rear wheel shaft tightening front 63 Nm 5 Rear 145 Nm 10 Check the brake calliper retaining screws tightening front 4...

Page 54: ...mi or time interval km x1000 1 mi x1000 0 6 Months 6 Check engine oil level Check brake fluid level Check tyre pressure and wear Check final drive chain tension and lubrication Check brake pads Servic...

Page 55: ...calliper bolts and brake disc flange screws 12 Check front and rear wheel nuts tightening 12 Check frame to engine fasteners tightening Check wheel hub bearings Check and lubricate the rear wheel shaf...

Page 56: ...cators horn and controls 12 Reset the Service indication through the DDS Final test and road test of the motorcycle testing safety devices ex ABS and idling 12 Softly clean the motorcycle 12 Fill out...

Page 57: ...absorber The only possible adjustment on the rear shock absorber is spring preload Turn adjuster 1 using the suitable wrench to set Turn adjuster clockwise to decrease spring preload turn counter cloc...

Page 58: ...ls in relation to the footpegs can be adjusted to suit the preferred riding position To adjust the position of the gearchange pedal proceed as follows hold the linkage 1 and slacken the counter nuts 2...

Page 59: ...to pull the lever gently The brake lever has an adjuster 2 for adjusting the distance between lever and the handlebar To adjust it keep lever 1 fully extended and turn adjuster 2 turning it in corres...

Page 60: ...rvals The plastic covering should show no signs of pinching or cracking Lubricate the ends of Bowden cables with the specified grease periodically to ensure they run freely Operate the control to chec...

Page 61: ...Carefully close the control while engaging cable 4 into slide 5 on cover 2 Fasten cover and tighten two screws 3 to the torque of 1 8 Nm 10...

Page 62: ...t 1 mm of the friction material on pads is visible Important Change both pads even if just one of them is worn Change the brake pads as follows Remove the snap ring 7 from the pad retaining pin Force...

Page 63: ...have a shiny or vitrified appearance Operate the brake pedal repeatedly so that the pads firmly bed in against the disc thanks to the brake fluid pressure Check that the fluid level inside reservoir...

Page 64: ......

Page 65: ...with eyes and skin In case of accidental contact wash thoroughly with water Important On handing over the motorcycle after changing the brake pads inform the Customer that the front brake must be use...

Page 66: ...ke pads as follows Remove split pin 2 from the pad retaining pins Force the calliper pistons back into their seats by forcing the old brake pads apart Slide pad retaining pin 3 outwards Remove pad ret...

Page 67: ...ads that have a shiny or vitrified appearance Insert new pads and spring 4 Fit the centring pin 3 and fasten it with safety split pin 2 Pay utmost attention to spring 4 aiming arrow must be pointing t...

Page 68: ...hat the pads firmly bed in against the disc thanks to the brake fluid pressure Check that the level in the master cylinder tank is not below the MIN mark If necessary top up as follows Turn the handle...

Page 69: ...Remove the reservoir cover 5 by loosening the two screws 6 Remove reservoir inner membrane Top up with recommended fluid up to maximum level Refit the removed components...

Page 70: ...t the centre of the lower section with the motorcycle on the side stand lower the chain by pressing down on it only with your finger release it and measure the distance between the centre of the chain...

Page 71: ...chain tensioning Once adjustment is completed visually make sure that the number of reference notches 5 is the same on both left and right chain sliders taking edge 4 as a reference Once the adjustmen...

Page 72: ......

Page 73: ...adjustment as follows Undo the four screws 1 remove U bolt 2 and handlebar 3 from steering head setting it so as not to hinder the following operations Slacken the clamp screws 4 securing the steering...

Page 74: ...screws 4 and 5 previously loosened to a torque of 24 Nm 5 Reposition handlebar 3 install U bolt 2 smear screws 1 with specified grease and tighten the four screws 1 to 25 Nm 5 following a 1 2 3 4 3 s...

Page 75: ...clutch lever 1 you must clearly feel the passage from a very low resistance to a very high resistance operating force The free play corresponds to the lever travel where the clutch resistance force i...

Page 76: ...ncrease distance A increase the free play by tightening adjuster 10 and then working adjuster 3 To decrease distance A decrease the free play by loosening adjuster 10 and then working adjuster 3 Tight...

Page 77: ......

Page 78: ...ircuit Changing the fluid in the rear brake circuit Unscrew the cover 6 of the rear brake fluid reservoir 7 Attach a transparent plastic tubing to the bleed valve 8 and insert the other end of the tub...

Page 79: ...e times until the circuit is pressurised Hold pedal depressed Open the bleed valve 8 to allow fluid to flow out The pedal is at the end of travel when it is in the lower position Now screw bleed valve...

Page 80: ...n In case of accidental contact wash thoroughly with water Remove the cover with membrane 1 from the front brake fluid reservoir 2 by undoing the screws 3 Siphon the fluid from the reservoir 2 using s...

Page 81: ...y out this operation undo the fixing screws 4 of the calliper on the fork bottom end and push pads taking them apart during this operation be careful with the fluid level which must always be sucked o...

Page 82: ...nce that all pistons are fully moved back and that all the fluid in the tank has been sucked out connect to the bleed valve 5 a transparent tube by immersing the end in a container placed on the floor...

Page 83: ...Fill the reservoir 2 with new oil up to the MAX mark Pull the lever to make a 20 30 mm stroke and keep the lever in this position using a non elastic clamp...

Page 84: ...Loosen the bleed valve of the calliper 5 and then take the lever through the whole stroke to allow fluid to flow out The lever is resting against the handgrip...

Page 85: ...t completely Then with the bleed valve definitely closed to the specified torque actuate repeatedly the lever until a pressure is detected in the brake system Warning After draining the old fluid from...

Page 86: ...anging and cleaning the air filters Remove the side fairings and disconnect voltage regulator Removing the airbox Loosen screws 1 on airbox cover 2 Remove the airbox cover 2 Remove filter 4 from cover...

Page 87: ...spark plugs Do not use the motorcycle without a filter as impurities in the air could get into the engine and cause damage Properly reinstall cartridge on airbox cover and refit all removed parts in p...

Page 88: ...central electrode for wear Warning Do not use spark plugs with inadequate heat rating or incorrect thread length The spark plug must be securely installed If a spark plug is loose it can overheat and...

Page 89: ......

Page 90: ...tem Remove the belt covers Removing the timing belt external covers Working from vehicle left hand side loosen the two screws 3 and remove plug 1 from generator cover 2 Fit tool A part no 88713 2011 s...

Page 91: ...Working on the opposite side align the reference mark on belt roller 7 with the reference mark on crankcase 8 turning tool A...

Page 92: ...e combustion stage with the horizontal cylinder Check it by inserting tool B in the spark plug hole Now tool A pin 6 should be aligned with one of the two holes 5 on generator casing Tighten pin 6 so...

Page 93: ...Work on the vertical head and remove spark plug cap and plug 9 Fit tool C part no 88713 2288 fully home If that is not possible turn belt roller 7 until tool C can be inserted fully home...

Page 94: ...Loosen screws 11 of pulley 12 vertical and horizontal cylinder Turn pulley counter clockwise...

Page 95: ...Loosen the two screws 13 from belt tensioner 14 on vertical cylinder and belt tensioner 15 on horizontal cylinder Remove both belts...

Page 96: ...ile belt tensioner 16 Check proper tensioning using the suitable tool D part no 97900 0253 frequency reading for proper tensioning is 140 Hz with a new belt If this value is not reached work the mobil...

Page 97: ...Tighten screws 11 of pulley 12 Remove tool C tighten the plug and put back spark plug cap Apply the same procedure to the horizontal head...

Page 98: ......

Page 99: ...Refit the belt covers Refitting the timing belt external covers Refit the exhaust system Refitting the exhaust system...

Page 100: ...e seat Removing the seat Remove the fuel tank Removing the fuel tank Remove the blow by Removing the airbox Remove the following parts from the electrical component box Battery Starter relay Fuse box...

Page 101: ...nkshaft so that the valve to be inspected is in rest position With the valve in the rest position slide a feeler gauge between opening rocker arm and shim to measure the clearance The clearance must b...

Page 102: ...losing rocker arm and shim to measure the clearance Closing rocker arm INTAKE Assembly 0 0 05 mm Inspection 0 0 05 mm EXHAUST Assembly 0 0 05 mm Inspection 0 0 05 mm If detected values exceed the spec...

Page 103: ...ate thickness to obtain the specified clearance Note Opening rocker arm shims measuring from 1 8 to 3 45 and closing rocker arm shims from 2 2 to 4 5 are available as spare parts the size is punched o...

Page 104: ...ster and completely Remove the drain plug 1 with gasket 2 from the oil sump and allow the oil to drain off Warning Dispose of oil and or filter cartridges in compliance with environmental protection r...

Page 105: ...Fit a new cartridge 3 using tool part no 88713 2906 Use engine oil to lubricate seal Note As an alternative it is advisable to refill the filter cartridge with engine oil before fitting it this enable...

Page 106: ...with fuel and compressed air Take care not to damage the mesh Refit mesh filter 6 seal 5 on plug 4 and tighten it to a torque of 42 Nm Min 38 Nm Max 46 Nm Restore proper engine oil level Remove the f...

Page 107: ...ing light on the instrument panel switches off a few seconds after starting up the engine If not stop the engine and trace the fault After a few minutes check that the oil level is the specified one i...

Page 108: ...he engine and allow a few minutes for the oil to settle to a steady level Oil level must be checked with the vehicle perfectly upright and the engine hot but off Oil level must be between the MIN and...

Page 109: ...rror 2 with nut 1 on the U bolt Screw the RH rear view mirror 2 in the indicated direction until reaching the required position Then keeping the rear view mirror in its position tighten nut 2 always i...

Page 110: ...Removing the rear view mirrors Loosen nut 1 in the direction shown in the figure Loosen the rear view mirror 2 Follow the same procedure with the LH mirror...

Page 111: ...Refitting the tail guard Check that clips 7 are fitted on mudguard support frame 5 Fix the two turn indicators 8 with screws 9 Position splash guard 10 on frame 5 and fix it with screws 11...

Page 112: ...Fit cat s eye 12 and fix it with two nuts 14 with washer 13 Position number plate light 16 by inserting cable 15 in frame 5 as shown in the figure...

Page 113: ...Fix the number plate light 16 by means of screws 17 Position the wiring with ties as shown in the figure...

Page 114: ...Fit mudguard 3 and fix it with screw 6 Position the rear subframe mudguard assembly on the vehicle Start screws 4...

Page 115: ...Working on the lower side start screws 1 and 2 Tighten screws 4 1 and 2 Connect the turn indicator and number plate light connectors...

Page 116: ...ber plate connectors Remove screws 1 and 2 located on the lower side of the rear mudguard 3 Remove screws 4 that retain the rear mudguard 3 on both sides of the vehicle Remove the frame mudguard assem...

Page 117: ......

Page 118: ...underseat cover Fit tabs 8 and 9 into the relevant recesses on the cover Insert plate 10 on inner side of the underseat cover aiming it as shown in the figure There is just one possible position becau...

Page 119: ...Fit nipple 3 into its seat 4 Position the underseat cover 1 and fix it by means of screws 2...

Page 120: ......

Page 121: ...ng the seat release mechanism Remove the underseat cover 1 loosening screws 2 Remove nipple 3 from its seat on the lock lever 4 Release lock lever cable 5 Unscrew nut 6 and remove the seat opening dev...

Page 122: ......

Page 123: ...he vehicle the presence of the two retaining clips 16 Fasten the two turn indicators by tightening screws 17 to the torque of 5 Nm 10 If previously removed join the tail guard upper part 13 with the l...

Page 124: ...Connect the two turn indicator connectors 11 and 12 Position tail guard 8 on the frame and start the two screws 9 and 10 Make sure that washers 18 are present on the screws...

Page 125: ......

Page 126: ...Start the two screws 7 in the tail guard lower side Tighten the screws 9 and 10 to a torque of 5 Nm 10 and the screws 7 to a torque of 8 Nm 10...

Page 127: ...Removing the tail guard Remove the two lower screws 7 of tail guard 8 Remove the two lateral screws 9 and 10...

Page 128: ...frame and disconnect the connectors of RH 11 and LH 12 turn indicators Remove tail guard 8 To disassemble the tail guard proceed as follows Loosen the two screws 15 and separate the tail guard upper...

Page 129: ......

Page 130: ...o side body panels If not already present on the side body panels fit trims 20 fully home by inserting the three pins 21 in the relevant holes with retainers A on the side body panels RH side body pan...

Page 131: ...2 on RH rear side body panel 3 Start lower screws 2 Tighten screw 1 with washer 22 and the two screws 2 to a torque of 8 Nm 10 LH side body panel Position the LH side body panel 6 inserting pin 23 ful...

Page 132: ...Start screw 4 with washer 25 on LH side body panel 6 Start lower screws 5 Tighten screw 4 and the two screws 5 to a torque of 8 Nm 10...

Page 133: ...Removing the rear side body panels Remove the seat Removing the seat RH side body panel Loosen the upper screw 1 and the two rear screws 2 of the underseat side body panel 3...

Page 134: ...Remove the side body panel by pulling it outwards LH side body panel Loosen the upper screw 4 and the two rear screws 5 of the underseat side body panel 6...

Page 135: ...Release the side body panel front side Slide out the side body panel by sliding it first downwards and then towards the rear side so as to release it from the shock absorber...

Page 136: ......

Page 137: ...Refitting the seat Position the rider seat 2 by inserting the front catch A under the tank fastener B as shown in the figure Push the seat rear end until pin clicks in place inside latch...

Page 138: ......

Page 139: ...Removing the seat Insert the key into the catch 1 and turn it clockwise until the latch disengages with an audible click Slide out seat 2 from the front side by lifting it...

Page 140: ...mudguard Position support 4 in the suitable seats 3 of front mudguard 1 Fix the mudguard support to the steering plate 5 by tightening screws 2 Upon assembly check the presence of rubber elements 6 a...

Page 141: ...Removing the front mudguard Loosen the four screws 2 from the lower side of the front mudguard 1 Remove the front mudguard 1...

Page 142: ...Refitting the front mudguard Position the front mudguard by centring it on the forks Start four screws 2 with spacer 3 on front mudguard 1...

Page 143: ......

Page 144: ...Tighten the four screws 2 to a torque of 8 Nm 10...

Page 145: ...Removing the front mudguard Loosen the two screws 2 from both sides of the front mudguard 1 Remove the front mudguard 1...

Page 146: ......

Page 147: ...crew 5 with spacer 4 Make sure clip 6 is in place If previously removed install bracket 7 and fix it by means of screws 8 with spacers 9 USA version Besides the support 7 fix also the Canister support...

Page 148: ...ehicle right side if previously removed install mounting bracket 19 by means of screw 16 with spacer 17 Make sure clip 18 is in place Check that rubber elements 20 and spacers 21 are fitted on the sum...

Page 149: ...Fix heat guard 2 by tightening screws 1...

Page 150: ......

Page 151: ...Removing the belly pan Undo screws 1 that retain the belly pan 2 Remove the belly pan 2...

Page 152: ...Table Z For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 153: ...TABLE AA...

Page 154: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame TABLE BB...

Page 155: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame TABLE CC...

Page 156: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame TABLE DD...

Page 157: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 158: ...Table Y For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 159: ...Table X For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 160: ...Table W...

Page 161: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 162: ...Table V For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 163: ...Table U For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 164: ...Table T For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 165: ...Table S For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 166: ...Table R For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 167: ...Table Q...

Page 168: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 169: ...Table P...

Page 170: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 171: ...Table O For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 172: ...Table N...

Page 173: ......

Page 174: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 175: ...Table M For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 176: ...Table L For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 177: ...Table K...

Page 178: ......

Page 179: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 180: ...Table J...

Page 181: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 182: ...Table H For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 183: ...Table G...

Page 184: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 185: ...Table F For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 186: ...Table E For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 187: ...Table D For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 188: ...Table C For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 189: ...Table A For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 190: ...TABLE A For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...

Page 191: ...ch 11 Clutch switch 12 Key switch 13 Left turn indicator 14 TABLE K Right hand switch 15 Front brake switch 16 Right turn indicator 17 TABLE L Headlight 18 TABLE M Key switch 19 Immobiliser 20 TABLE N...

Page 192: ...l speed sensor 30 TABLE X Tail light cable 31 TABLE Y Rear turn indicator 32 Left turn indicator 33 TABLE Z Engine temperature 34 TABLE AA Front speed sensor 35 TABLE BB Instrument panel 36 TABLE CC N...

Page 193: ...Fuse box key Fuse box key Pos El item Rat 1 Key on 10 A 2 El loads 15 A 3 Instrument panel 10 A 4 Control unit 5 A 5 Injection 20 A 6 ABS motor 25 A 7 ABS 10 A...

Page 194: ...Wire colour coding B Blue W White V Violet Bk Black Y Yellow R Red Lb Light blue Gr Grey G Green Bn Brown O Orange P Pink...

Page 195: ...23 Fuel pump relay 24 Vertical lambda sensor 25 Horizontal lambda sensor 26 Horizontal spark plug 27 Horizontal coil 28 Vertical spark plug 29 Vertical coil 30 Horizontal injector 31 Vertical injector...

Page 196: ...the generator in accordance with battery voltage If the battery is drained the current has the value necessary to restore optimum operating conditions of the battery itself While if the battery is fu...

Page 197: ......

Page 198: ...portant Do not disconnect the battery cables when engine is running because this would cause irreparable damage to the regulator Regulator fuse The 30 A fuse positioned inside electromagnetic switch 5...

Page 199: ...A blown fuse can be identified by breakage of the inner filament B...

Page 200: ...ition key to OFF before replacing the fuse to avoid possible short circuits Warning Never use a fuse with a rating other than the specified value Failure to observe this rule may damage the electric s...

Page 201: ...re testing disconnect the generator wiring from the electrical system when the ignition key is set to OFF Rpm Active voltage Minimum voltage Maximum voltage 1500 rpm 20 8 V 18 9 V 24 5 V 2500 rpm 34 3...

Page 202: ...emove the valve cover located on top of the cover If the block cover or terminals are broken or if the valve cover has been tampered with IT IS ABSOLUTELY NECESSARY TO REPLACE THE BATTERY Important If...

Page 203: ...e battery 2 Warning Insulate the ground cable ends you just removed to prevent them from touching the motorcycle Refitting the battery Position the battery 2 Connect the positive pole by means of scre...

Page 204: ...Fit cover 4 and fix it with screw 3 Fasten the battery cover by means of belt 1...

Page 205: ...minutes and consult an ophthalmologist In the event of accidental ingestion drink large quantities of water or milk and continue with milk of magnesia a beaten egg or vegetable oil Do not allow sparks...

Page 206: ...ttery cells Warning Do not peel or perforate the sealed areas Place the electrolyte container 2 upside down Align the six sealed elements with the six filler holes on the battery Push the container 2...

Page 207: ...utes If no bubbles emerge from one of the holes tap gently on the bottom of the respective container Important Never move the container away from the battery Do not cut or puncture the container Make...

Page 208: ...g it Recharge the battery as described in the paragraph Recharging the battery Note When using an automatic battery charger ensure that the charger current ampere is equal to or higher than the value...

Page 209: ...y if the battery becomes too hot to the touch Leave to cool before resuming charging Use only constant voltage battery chargers Check that battery terminals are properly connected to the battery charg...

Page 210: ...Checking the battery charging system Perform checks on the system as indicated in the following paragraphs Recharging the battery Topping up the electrolyte Battery Alternator Rectifier regulator...

Page 211: ...ng the seat Disconnect the battery Battery Removal procedure Disconnect solenoid starter connector 2 from the wiring Slide the solenoid starter out of its seat Remove protection 3 Undo the screws 4 ta...

Page 212: ...ity If there is no electric continuity ensure that the terminals are not oxidised and apply water repellent spray Change the solenoid starter if the malfunction persists Refitting procedure Lay down t...

Page 213: ...Refit the seat Refitting the seat...

Page 214: ...oad applied to the shaft Warning Secure the starter motor to a test bench making sure not to damage the casing Warning Use a fully charged 12 V battery for the test Use battery motor connection cables...

Page 215: ...Electric starting system The electric starting system consists of a solenoid starter 1 and a starter motor...

Page 216: ...d with the longitudinal axis of the motorcycle Note If possible perform this check in dim light Switch on the low beam The height of the upper limit between the dark area and the lit area must not be...

Page 217: ......

Page 218: ...acing the light bulbs Headlight Removing the light assembly Remove retainer 1 and the headlight regulation screw 2 Loosen screw 2 on the opposite side Remove screws 3 that retain U bolts 4 of headligh...

Page 219: ...Remove headlight 5 and disconnect connector 6...

Page 220: ...Refitting the light assembly Connect connector 6 to headlight 5 Fit headlight 5 by matching seats A with the two pins 6 on the headlight support subframe 7...

Page 221: ...Fix the U bolts 4 by tightening screws 3 to a torque of 5 Nm 10...

Page 222: ...tion screw 2 until reaching the correct orientation Then insert the safety retainer 1 CHANGING BULBS To remove the bulb remove the headlight from the frame Replacing the headlight Remove retaining scr...

Page 223: ...Remove bulb 3 by releasing spring 4...

Page 224: ...procedures until you confirm all the digits of the PIN CODE When you press button 4 to confirm the fourth and last digit if the PIN code A is correct the instrument panel shows the message OK for 2 s...

Page 225: ......

Page 226: ...rvice centre will program all new and old keys The Ducati authorised service centre may ask to the customer to prove to be the motorcycle owner The codes of the keys missing during the programming pro...

Page 227: ...in this case you are not able to start the engine contact an authorised Ducati service centre Warning Strong impacts could damage the electronic components inside the key During the procedure always...

Page 228: ...ith 2 keys They contain the Immobilizer system code Keys B are those for the standard use i e to start the engine open the fuel tank plug open the seat lock Warning Separate the keys and use only one...

Page 229: ...11 0 V Immobilizer keys reset This activation allows erasing the keys to reprogramme the Immobilizer System Upon receiving this request the instrument panel resets the previously stored keys Upon nex...

Page 230: ...Fig 1 3 on the left switch If the turn indicator is not reset manually the instrument panel will automatically switch it off after the motorcycle has travelled 500 m 0 3 miles from when the turn indi...

Page 231: ...d press button 4 Select SPEED option by pressing button 1 or 2 Once SPEED function is highlighted press CONFIRM MENU button 4 When entering the function units of measurement mph km h are indicated cur...

Page 232: ...ighlight the previous item Select the required unit of measurement and then press the CONFIRM MENU button 4 to confirm the selected unit then the selected unit of measurement is saved in the instrumen...

Page 233: ...After 3 seconds the instrument panel shows WAIT for 2 seconds then the DF OK message indicates that the units of measurement have been restored...

Page 234: ...reases by one 1 up to 9 and then starts back from 0 3 Each time you press the button 1 the displayed number decreases by one 1 up to 1 and then starts back from 0 4 To confirm the number press the but...

Page 235: ...will be shown the EXIT option will be highlighted and its box will be flashing To quit press button 4 If settings have not been saved the instrument panel will highlight again the string of four dash...

Page 236: ...Note The activations must be performed only with key turned to ON engine off and battery voltage 11 0 V PIN CODE reset This activation allows erasing the previously stored PIN CODE to enter a new one...

Page 237: ...sing button 1 or 2 Once function is highlighted press CONFIRM MENU button 4 Note If upon accessing this function the O Old indication is displayed together with four flashing dashes a PIN code is alre...

Page 238: ...nctions Note The activations must be performed only with key turned to ON engine off and battery voltage 11 0 V PIN CODE reset This activation allows erasing the previously stored PIN CODE to enter a...

Page 239: ...If you hold button 2 down the number increases cyclically in steps of one hour every second when the button is held depressed the hours do not flash pressing button 4 gives access to the minute setti...

Page 240: ...ay backlighting maximum brightness recommended in conditions of strong ambient light Select MED to set the display backlighting medium brightness 70 recommended in conditions of medium low ambient lig...

Page 241: ...f battery voltage is between 11 8 V and 14 9 V the reading will be displayed steady if battery voltage is between 0 0 and 11 7 Volt the reading will be displayed with LOW message flashing if battery v...

Page 242: ...box is flashing press button 4 To select a different status than the one set press button 1 alternative option RQ starts flashing in the Menu Press button 4 for 3 seconds to confirm WAIT is displayed...

Page 243: ......

Page 244: ...unit enabling disabling EXIT to quit the Setting Menu For safety reasons the setting menu can be accessed only when vehicle speed is below or equal to 20 Km h if this menu is accessed and vehicle spe...

Page 245: ...entre performs a reset Activations through diagnosis instrument The DUCATI diagnosis instrument allows performing a series of activations to check some instrument panel functions and resetting paramet...

Page 246: ...ymbol are displayed together with the indication of the kilometres left before the following service operation Activations through diagnosis instrument The DUCATI diagnosis instrument allows performin...

Page 247: ...ed Ducati Service Centre performs a reset Activations through diagnosis instrument The DUCATI diagnosis instrument allows performing a series of activations to check some instrument panel functions an...

Page 248: ...is indication shows the user that the motorcycle is due for service and must be taken to a Ducati Authorised Service Centre The service warning indication can be reset only by the Authorised Ducati Se...

Page 249: ...flashing HI message steady temperature icon and set unit of measurement C or F Note When this warning is triggered the instrument panel will not display the clock until value gets equal to or below 2...

Page 250: ...hows the time in the following format hh hours mm minutes with the message AM for values ranging between 0 00 and 11 59 or PM for values ranging between 12 00 and 12 59 and between 1 00 and 11 59 In c...

Page 251: ...y malfunction Ignition coil malfunction Injector malfunction Engine rpm sensor malfunction Lambda sensor or Lambda sensor heater malfunction Motorcycle starting relay malfunction Secondary air system...

Page 252: ...ation operation SD STND Side stand sensor not working Error icons table WARNING LIGHT ERROR MESSAGE ERROR ENGINE Engine control unit AIR T Air temperature sensor BATT Battery voltage SPEED Speed senso...

Page 253: ...tton 2 If several errors are active the corresponding indications will be displayed one after the other each remaining on display for 3 seconds When an error is triggered the EOBD light turns on as we...

Page 254: ...ider to identify any abnormal motorcycle behaviour in real time Upon Key ON if there are active errors or during normal operation of the vehicle whenever an error is triggered the instrument panel tur...

Page 255: ...C or 38 F 255 F For any different temperature below 39 C 38 F or above 124 C 255 F a string of three dashes is steadily displayed followed by the unit of measurement If the air temperature sensor is i...

Page 256: ...using button 2 Trip fuel reading remains stored even after Key Off until the motorcycle is refuelled Count is interrupted automatically as soon as fuel is topped up to above minimum level When the rea...

Page 257: ...9 mi distance travelled is reset and the meter automatically starts counting from 0 again While the trip meter is displayed press button 1 for 3 seconds to reset TRIP 2 The TRIP 2 counter is automati...

Page 258: ...9 mi distance travelled is reset and the meter automatically starts counting from 0 again While the trip meter is displayed press button 1 for 3 seconds to reset TRIP 1 The TRIP 1 counter is automati...

Page 259: ...The DUCATI diagnosis instrument allows performing a series of activations to check some instrument panel functions and resetting parameters or warning lights After each activation the instrument pane...

Page 260: ...ns MENU 1 functions are Odometer TOT Trip meter 1 TRIP 1 Trip meter 2 TRIP 2 Partial fuel reserve counter TRIP FUEL Ambient air temperature T AIR By pressing button 2 it is possible to view the functi...

Page 261: ...tions through diagnosis instrument The DUCATI diagnosis instrument allows performing a series of activations to check some instrument panel functions and resetting parameters or warning lights After e...

Page 262: ...1000 rpm 5000 rpm 11000 rpm...

Page 263: ...receiving the speed value steady ON the rear speed sensor is in fault flashing Activations through diagnosis instrument The DUCATI diagnosis instrument allows performing a series of activations to che...

Page 264: ...rve counter TRIP FUEL e Ambient air temperature AIR f Clock Additional information Service indication SERVICE ERROR indication The functions within the Setting Menu that can be modified by the user ar...

Page 265: ...essary During this first check stage if the motorcycle speed exceeds 20 km h 12 mph actual speed the instrument panel will stop the display check routine and display the standard screen containing upd...

Page 266: ...display layout instrument panel shows for 10 seconds in Menu 1 the Odometer page and then shows the page saved upon previous KEY OFF Hold the button 2 for 3 seconds when actual motorcycle speed is lo...

Page 267: ...set instrument panel parameters with the position 3 HIGH BEAM FLASH BUTTON FLASH This button is the high beam flasher 4 TURN INDICATORS CANCEL BUTTON The turn indicators cancel button may also be used...

Page 268: ...ystem ABS 9M ABS 9M system is a two channel latest generation system that actuates combined braking with anti lift up function for the rear wheel so as to guarantee not only a reduced stopping distanc...

Page 269: ...Acronyms and abbreviations used in the Manual ABS Antilock Braking System CAN Controller Area Network DDA DUCATI Data Acquisition DSB Dashboard ECU Engine Control Unit...

Page 270: ...EEN A warning light turns on and blinks when the relevant turn indicator is active when the warning lights blink at the same time the HAZARD function is active 8 ENGINE VEHICLE DIAGNOSIS EOBD LIGHT AM...

Page 271: ...ol Unit may have a different setting for the thresholds that precede the rev limiter and the rev limiter itself Immobilizer Key ON status Light OFF Key OFF status Light ON flashing Key OFF status for...

Page 272: ...nnect the main wiring switch connector and perform the check using an analogue or digital multimeter Note The same test may be done using the DDS 2 diagnosis instrument LEFT HAND SWITCH CONTROL Remove...

Page 273: ...re open and no continuity beep should be heard if provided If these conditions are not met the device must be replaced Turn indicator switch TURN 3 The turn indicators cancel button may also be used i...

Page 274: ...d Orange wires Unlike the Hi Beam switch 6 should be pressed For the refitting procedure refer to chapter Refitting the handlebar Right hand switch In the event of a fault the internal connections of...

Page 275: ...Electric diagram CONTROLS ON RIGHT HAND SWITCH...

Page 276: ...and must be replaced Starter button Proceed as described for the engine stop button and check for continuity between the Blue White and Black wires when the starter button 2 is pressed If there is no...

Page 277: ...y between the terminals of the corresponding switch No electric continuity should be available when brakes are not operated Electric diagram If these tests fail to produce positive results the part in...

Page 278: ...tery to the two fastons With a multimeter connected between the two poles threaded pins of the solenoid starter check for electric continuity If there is no electric continuity ensure that the termina...

Page 279: ...Electric diagram Clutch switch The clutch switch 1 is located on the clutch lever lower side...

Page 280: ...he front brake lever is operated there must be electric continuity between the terminals of the corresponding switch No electric continuity should be available when brakes are not operated If these te...

Page 281: ......

Page 282: ...Main relay and injection To remove and refit the main relay refer to chapter Starting system...

Page 283: ...peed The toothed pulley usually features Xn teeth with a gap of two teeth as reference for the first cylinder TDC Position 1 the pick up sensor detects the full area i e the tooth Position 2 the pick...

Page 284: ...Check for rpm timing sensor pick up correct operation with the diagnosis instrument DDS 2 Electric diagram...

Page 285: ......

Page 286: ...tle body The TPS sends information to the control unit about the exact position of the throttle To remove and refit the TPS refer to chapters Removing the airbox and throttle body and Refitting the ai...

Page 287: ...oltage to a value that allows the spark creation in the spark plug The vehicle features two coils one for the horizontal cylinder 1 and another for the vertical cylinder 2 located under the covers 3 a...

Page 288: ...Disconnect connectors 7 and 8 of the horizontal and vertical cylinder coils...

Page 289: ...CONTROLS Check the correct operation with the DDS 2 diagnosis instrument connected to control unit diagnostic socket Electric diagram...

Page 290: ......

Page 291: ...Ignition spark plug To check the spark plug refer to chapter Replacing the spark plugs...

Page 292: ...sensor 1 using the DDS 2 After selecting the proper items on the DDS 2 menu read the external air temperature value among the different displayed parameters and compare it with the actual value Change...

Page 293: ...d based on the preset stoichiometric ratio determines the correct quantity of fuel to be delivered to the injectors The air fuel ratio is therefore always excellent Check the correct operation of MAP...

Page 294: ...pressure value is outside the specified range check the lubrication circuit components and service as necessary Switch on the instrument panel ignition key turned to ON without starting the engine dis...

Page 295: ...ency range for the catalytic converter The vehicle is provided with two lambda sensors one per cylinder lambda sensor 1 for horizontal cylinder exhaust lambda sensor 2 for vertical cylinder exhaust If...

Page 296: ...Check lambda sensors correct operation with the DDS 2 diagnosis instrument connected to control unit diagnostic socket Electric diagram...

Page 297: ......

Page 298: ...perature The stepper motor works on the throttle valve opening closing To remove and refit the stepper motor refer to chapters Removing the airbox and throttle body and Refitting the airbox and thrott...

Page 299: ...Electric injector To remove refit the injector refer to chapters Removing the throttle body and Refitting the throttle body...

Page 300: ...battery voltage so that it can adjust injector opening time and ignition coil charging time accordingly The ECU determines the following values quantity of fuel delivered to each cylinder injector cl...

Page 301: ...Refit control unit 1 by engaging it on pins 3 ensuring it is properly in seat Connect connector 2 Refit the seat Refitting the seat...

Page 302: ...like those indicated in values A and B An excessive wear can cause vibrations and instability of the vehicle and therefore it is necessary to replace them To remove the bearings and the sealing rings...

Page 303: ...ve the latter fully into its seat Use the same method to install the sealing rings 9 Ensure that spacer 8 is fitted between the two wheel hub bearings Note Wheels must be rebalanced after repair maint...

Page 304: ...ectly Check for not spokes emitting a hollow sound when hit with a metallic object this could mean that there are loosen spokes that have been used for a long time without preload in this case check t...

Page 305: ...hit with a metallic object this to avoid that seizure or oxidation of spoke and nipple coupling cancels the action of the applied torque if necessary restore the correct coupling ensuring not to use...

Page 306: ...at right angle to the surface to check for the axial runout use the outer side of rim D and for the radial runout use the internal surfaced of the rim without nipples E While the wheel is rotating me...

Page 307: ...5 Note To perform these operations easily it may be necessary to remove the brake disc and loosen the other spokes Unscrew nipple 11 and remove the damaged spoke 10 by sliding it off the seat in the h...

Page 308: ...he wheel on the centring tool B no 88713 2775 using suitable spacers F Block the wheel pack checking for no end float Check the rim axial and radial runout as described before Rotate the rim if the de...

Page 309: ...the opposite side Check the axial runout again as described above Loosen the wheel pack invert its installation sense and tighten it to check the axial and radial runout and camber on the other side...

Page 310: ......

Page 311: ...like those indicated in values A and B An excessive wear can cause vibrations and instability of the vehicle and therefore it is necessary to replace them To remove the bearings and the sealing rings...

Page 312: ...ve the latter fully into its seat Use the same method to install the sealing rings 9 Ensure that spacer 8 is fitted between the two wheel hub bearings Note Wheels must be rebalanced after repair maint...

Page 313: ...ectly Check for not spokes emitting a hollow sound when hit with a metallic object this could mean that there are loosen spokes that have been used for a long time without preload in this case check t...

Page 314: ...hit with a metallic object this to avoid that seizure or oxidation of spoke and nipple coupling cancels the action of the applied torque if necessary restore the correct coupling ensuring not to use...

Page 315: ...at right angle to the surface to check for the axial runout use the outer side of rim D and for the radial runout use the internal surfaced of the rim without nipples E While the wheel is rotating me...

Page 316: ...5 Note To perform these operations easily it may be necessary to remove the brake disc and loosen the other spokes Unscrew nipple 11 and remove the damaged spoke 10 by sliding it off the seat in the h...

Page 317: ...he wheel on the centring tool B no 88713 2775 using suitable spacers F Block the wheel pack checking for no end float Check the rim axial and radial runout as described before Rotate the rim if the de...

Page 318: ...the opposite side Check the axial runout again as described above Loosen the wheel pack invert its installation sense and tighten it to check the axial and radial runout and camber on the other side...

Page 319: ......

Page 320: ...wheel When all the necessary inspections have been completed refit the front wheel as follows Lubricate the wheel shaft 6 Insert front wheel between the fork legs fitting spacer 7 between wheel hub a...

Page 321: ...Insert shaft 6...

Page 322: ...Fit nut 3 without tightening it to torque...

Page 323: ...side of calliper retaining screws 2 Pre tighten the two screws 2 to a torque of 2 Nm 10 Work several times on the brake lever to allow the calliper to settle Hold the brake lever pulled and simultaneo...

Page 324: ...Tighten the screws 5 on the motorcycle s left side to a torque of 10 Nm 5 following a 1 2 1 sequence Tighten nut 3 to a torque of 63 Nm 5...

Page 325: ......

Page 326: ...ly tightened Lower the bike to the ground by removing the support Push on the handlebar to load the suspensions and to allow the fork legs to settle on the wheel shaft Tighten the screws 5 to a torque...

Page 327: ...like those indicated in values A and B An excessive wear can cause vibrations and instability of the vehicle and therefore it is necessary to replace them To remove the bearings and the sealing rings...

Page 328: ...ve the latter fully into its seat Use the same method to install the sealing rings 9 Ensure that spacer 8 is fitted between the two wheel hub bearings Note Wheels must be rebalanced after repair maint...

Page 329: ...the rim as follows Visually inspect the rim for cracks scoring and deformation change the rim if damaged Insert the shaft in the wheel and position it on two fixed reference blocks Using a dial gauge...

Page 330: ...If the values measured are not within the tolerance limits replace the wheel...

Page 331: ...1 by loosening the two screws 2 securing the calliper to the fork leg without disconnecting them from the hoses Warning Do not operate the brake lever when the callipers are removed This can cause the...

Page 332: ......

Page 333: ...Working from the left hand side use a plastic mallet to drive the wheel shaft 6 out from the opposite side and remove it...

Page 334: ......

Page 335: ...Remove the wheel and recover spacer 7...

Page 336: ......

Page 337: ...Overhauling the rear wheel To overhaul the rear rim proceed as described for the front one in Overhauling the front rim...

Page 338: ...Overhauling the rear wheel To overhaul the rear rim proceed as described for the front one in Overhauling the front rim...

Page 339: ...in ends 4 of the rear sprocket flange Place rear sprocket flange 5 with spacer 6 inside vibration damping pads 7 Fit spacer 3 in the relevant seat Insert the retaining pin 2 after having lubricated it...

Page 340: ......

Page 341: ...Before tightening nut 1 keep the chain tensioned Adjusting the chain tension Tighten nut 1 to a torque of 145 Nm 5 Refit the number plate holder Refitting the number plate holder...

Page 342: ...m as follows Visually inspect the rim for cracks scoring and deformation change the rim if damaged Using a dial gauge duly supported measure rim runout and out of round relative to the shaft axle If t...

Page 343: ...e number plate holder Removing the number plate holder Properly support the motorcycle with the service stand and engage the first gear Loosen and remove retaining nut 1 of the rear wheel shaft Remove...

Page 344: ...Remove the chain and the rear wheel and collect the spacer 3 Properly support the vehicle while removing the wheel...

Page 345: ...orrectly positioned hoses can affect brake operation and foul moving parts Position the component as shown in the figure Values to be respected X 35 Y 60 When reconnecting the brake line to the callip...

Page 346: ...X 98 Lubricate the two screws 9 with the recommended product Fasten calliper 10 by tightening the two screws 9 to a torque of 45 Nm 5 Tighten screw 7 with seals 8 to a torque of 23 Nm 10...

Page 347: ...Secure the hose with the relevant guide 6 Tighten the two screws 5...

Page 348: ......

Page 349: ...ll contact surfaces thoroughly and apply the specified threadlocker on the threads of screws 1 Tighten the screws 1 retaining the brake disc 2 to the wheel following the indicated sequence Tighten the...

Page 350: ...ure of this component Incorrect overhaul of this component could endanger rider safety Operations should be limited to replacement of the pads fasteners and the bleed valve assembly The brake disc mus...

Page 351: ...n inner carrier which is mounted to the wheel and an outer rotor Both parts must be replaced together as a pair Remove the front wheel Removing the front wheel Undo the screws 1 securing the brake dis...

Page 352: ...em Changing the front brake system fluid Remove the rear view mirrors Removing the rear view mirrors Undo the special screw 1 collecting the sealing washers 2 to release the front brake master cylinde...

Page 353: ...Undo special screw 7 and collect seals 8 Remove the brake hose Loosen the screws 9 and remove the brake calliper 10...

Page 354: ......

Page 355: ...rrosive and will damage paint Avoid contact with eyes and skin In case of accidental contact wash thoroughly with water For all maintenance operations wear check and replacement of brake pads and brak...

Page 356: ...rnal edge matches with the mark A Position clamp 6 on the handlebar and start the screws 5 Tighten the fastening screws 5 to the specified torque of 10 Nm 10 following the sequence 1 2 1 starting from...

Page 357: ...ncorrectly positioned hose can cause system faults and interfere with moving parts Aim hose 4 as shown in the figure by respecting values X 35 and Y 60 and then tighten the special screw 1 to a torque...

Page 358: ...positioning of the hose 4 and retaining ties see Section Routing wiring hoses Refit the rear view mirrors Refitting the rear view mirrors Fill the front braking system Changing the front brake system...

Page 359: ...ly and relative fasteners and master cylinder fasteners Drain the front braking system Changing the front brake system fluid Remove the rear view mirror Removing the rear view mirrors For the front AB...

Page 360: ......

Page 361: ...Refitting the rear brake disc Position brake disc 2 on wheel 3 and the phonic wheel 4 on the disc Tighten the screws 1 with pre applied threadlocker to a torque of 25 Nm 5 in a cross pattern...

Page 362: ...Removing the rear brake disc Remove the rear wheel Removing the rear wheel Loosen and remove screws 1 retaining the brake disc 2 to wheel 3 Remove the phonic wheel 4...

Page 363: ...arning If incorrectly positioned hoses can affect brake operation and foul moving parts Position the component as shown in the figure X 90 Y 13 Lubricate the two pins with the recommended product Inse...

Page 364: ...ar wheel Tighten special screw 1 with the two seals 3 to a torque of 23 Nm 10 If previously removed fit speed sensor 6 with spacer 8 and tighten screw 7 to a torque of 7 Nm 10 Check the Air Gap Adjust...

Page 365: ......

Page 366: ...its are limited to replacement of the following parts control lever fluid reservoir assembly and relative fasteners and master cylinder fasteners Drain the rear braking system Changing the rear brake...

Page 367: ...e brake pads follow instructions in the paragraph Checking brake pad wear and replacing rear brake pads To remove the speed sensor 6 undo the fastening screw 7 paying attention to the spacer defining...

Page 368: ...ock shaft using retainer 14 Reconnect hose 11 locating seals 12 on both sides of the hose union and secure it with the special screw 10 Tighten the special screw 10 to a torque of 23 Nm 10 Note Pay pa...

Page 369: ...Fit washer 15 on the footpeg holder plate 8...

Page 370: ...Fit spring 9 by inserting its end in the seat on the footpeg holder plate 8 Fit footpeg 6 into lever 7 Grease O ring 16 with indicated product...

Page 371: ...Insert the footpeg brake lever assembly in footpeg holder plate 8 Engage spring end 9 in the recess on the brake lever 7 Apply the specified threadlocker and tighten nut 5 to a torque of 22 Nm 5...

Page 372: ...ition the rear brake master cylinder 3 on the vehicle inserting the retaining screws 2 Insert the rod 4 inside the master cylinder 3 after applying the recommended grease Tighten screws 2 to a torque...

Page 373: ...Fill the rear braking system Changing the rear brake system fluid...

Page 374: ...inside the brake pedal 6 needs to be replaced grease the external surface and fit the new bush using a press to insert it The bush must be placed at 2 mm from the pedal external face To disassemble th...

Page 375: ...y Maintenance operations on these units are limited to replacement of the following parts control lever fluid reservoir assembly and relative fasteners and master cylinder fasteners Drain the rear bra...

Page 376: ...Loosen nut 5 securing the RH footpeg 6 Slide out brake control lever 7 and footpeg 6 of the footpeg holder plate 8 Collect washer 9...

Page 377: ...Separate bracket 6 and lever 7...

Page 378: ...Undo special screw 12 from master cylinder 3 and slide out hose 11 collecting seals 12 Remove rear brake master cylinder 3 from vehicle...

Page 379: ......

Page 380: ......

Page 381: ......

Page 382: ...rake master cylinder TABLE A TABLE B TABLE C TABLE D TABLE E TABLE F 3 Front brake calliper hose TABLE A TABLE B TABLE G TABLE I 4 Rear brake master cylinder TABLE A TABLE B TABLE G TABLE H TABLE I 5...

Page 383: ...TABLE C TABLE D...

Page 384: ...TABLE E...

Page 385: ...TABLE F TABLE G...

Page 386: ...TABLE H...

Page 387: ...TABLE I...

Page 388: ...t as shown in the figure X 77 Y 90 Z 5 Hoses 3 4 5 and 6 must be secured in place using new sealing washers 2 on unions Fasten the ABS control unit 8 by tightening the screws to the torque of 6 8 Nm 1...

Page 389: ......

Page 390: ...e battery Remove the front brake system Removing the front brake system Remove the rear brake system Removing the complete rear brake control Loosen special screws 1 collect seals 2 and remove the fol...

Page 391: ...Disconnect the connector 11 Remove the ABS control unit 7 loosening the two screws 8...

Page 392: ...Release the two hoses 3 and 4 from cable ring 9...

Page 393: ...Release the brake hose 6 from the clip 10...

Page 394: ......

Page 395: ...liper holder plate 3 by loosening retaining screw 4 and collecting calibrated sealing washer 5 Check air gap between new rear ABS sensor 2 and rear phonic wheel as explained under Adjusting the AIR GA...

Page 396: ...front ABS sensor 2 with calibrated gasket 4 sliding cable out from cable grommet REFITTING PROCEDURE Before refitting make sure that contact parts between front ABS sensor 2 and its seat are free of d...

Page 397: ...Connect connector 1 to main wiring Fasten all clips retaining front ABS sensor cable 1 refer to tables under section Routing wiring harnesses hoses...

Page 398: ...S control unit flow into the master cylinder Purge must be carried out by means of the corresponding unions 1 placed on the callipers and the brake master cylinders Important Do not undo the special s...

Page 399: ......

Page 400: ...placing or refitting of the calliper holder plate It is necessary to check the air gap between the speed sensor and the phonic wheel once the components are refitted Note Perform the test in three poi...

Page 401: ......

Page 402: ......

Page 403: ...time you add or remove a shim Measure the AIR GAP Put the required shims Important The sum of the feeler gauge must never exceed 3 mm Once the shimming is completed tighten the sensor retaining screw...

Page 404: ...rol Fit throttle control on handlebar Fasten the handlebar as described in chapter Refitting the handlebar Match the throttle control pin 6 with the handlebar seat 7 Tighten screws 1 of throttle contr...

Page 405: ......

Page 406: ...Removing the throttle control Loosen screws 1 of throttle control 2 Release handlebar 3 from U bolt 4 loosening screws 5 Slide out throttle control 2...

Page 407: ...Adjusting the throttle cable For the throttle control cable adjustment refer to chapter Adjusting the throttle cable...

Page 408: ...he relevant seats in the steering head 16 Aim the silent block 18 as shown in the figure Drive the silent block 18 fully home in line with its seat Note Drive the silent block by working on the outer...

Page 409: ...Insert the steering head on the two screws 19 and take it fully home against lower U bolt 17...

Page 410: ...Fit two washers 20 on screws 19 and start two nuts 15 Screw two nuts 15 If previously removed fit rubber blocks 21 in the relevant seats on the lower U bolt 17...

Page 411: ...handlebar 9 in its seat on the lower U bolt 17 with the arrows facing the rear side of the vehicle Reference points A on handlebar must be at the same distance from U bolt 8 and flush with the U bolt...

Page 412: ...Apply recommended product to screws 7 and tighten to 22 Nm 5 in the 1 2 3 4 3 sequence Fit left hand switch on the handlebar Position the switch 5 so that pin B engages in hole C on the handlebar...

Page 413: ...Tighten the screws 4 to a torque of 1 5 Nm 10...

Page 414: ...Fit right hand switch 2 on the handlebar Position the switch 2 so that pin D engages in hole on the handlebar E...

Page 415: ...Tighten the screws 1 to a torque of 1 5 Nm 10 Insert counterweight B in the handlebar and fix it with screw B Tighten the screw B to a torque of 3 5 Nm 10...

Page 416: ......

Page 417: ...ntrol Remove the complete front brake control Removing the front brake system Remove the clutch control Removing the clutch assembly Handlebar counterweight Loosen the retaining screw A and remove cou...

Page 418: ...e left hand switch 5 by disconnecting connector 6 and loosening screws 4 Undo and remove the screws 7 Remove U bolt 8 securing the handlebar Remove the handlebar 9 Disconnect instrument panel connecto...

Page 419: ...Undo and remove the screws 11 from the steering head Tighten screw 12 and ring nut 13 and remove the steering head 14...

Page 420: ...Loosen two nuts 15 and separate the steering head 16 of the lower U bolt 17...

Page 421: ......

Page 422: ...ing the clutch assembly Start the two screws 5 of the clutch control 6 Tighten the screws 5 to a torque of 10 Nm 10 Insert nipple 3 in the clutch layshaft 4 Tighten screw 1 of the clutch mounting brac...

Page 423: ......

Page 424: ...Removing the clutch assembly Undo the fixing screw 1 of the clutch bracket 2 Release nipple 3 from the clutch layshaft 4 Loosen the two screws 5 of the clutch control 6...

Page 425: ......

Page 426: ...Refitting the ignition switch Tighten the two retaining screws 2 of the key switch 3 Connect the connector 1 Refit the headlight Refit the tank Refitting the fuel tank...

Page 427: ...Removing the ignition switch Remove the fuel tank Removing the fuel tank Remove the headlight Disconnect the connector 1 Loosen the two retaining screws 2 of the key switch...

Page 428: ...me in gearchange lever Fit the second O ring 10 on the shaft Start the gearchange lever pin 8 the two O rings 10 in the LH footpeg holder plate Fit plate 4 fully home in its seat on the footpeg holder...

Page 429: ......

Page 430: ...needs to be replaced grease the external surface and drive the bush into place using a press The bush must be seated 2 mm below the outer face of the pedal After performing an operation on the gear s...

Page 431: ...Removing the gear change control Undo the retaining screw 1 of the gearbox rod 2 Remove the LH footpeg holder Loosen nut 3 and collect plate 4...

Page 432: ...Separate the footpeg gearchange lever assembly 6 from the footpeg holder 5 Loosen screw 7 and separate the gearbox rod 2 from the gearbox pedal 8...

Page 433: ......

Page 434: ...rk 5 on bottom yoke 4 by respecting the indicated value Lubricate screws 1 and 2 with specified product Block the leg by tightening screw 1 to a torque of 24 Nm 5 Tighten the screws 2 to a torque of 2...

Page 435: ...ont wheel Front mudguard Refitting the front mudguard NOT VALID FOR URBAN ENDURO Headlight Phonic wheel sensor Replacing the front phonic wheel Fit spacers C of screws B Fit leg cover A by fixing it w...

Page 436: ......

Page 437: ...fork The two legs are different the LH one does not have a spring nor the pre load tube To remove it follow the removal procedure of the RH leg REMOVING THE RH LEG Vice the fork 1 and pay attention t...

Page 438: ...Take the outer sleeve 1 down Drain all fluid from the sleeve To help draining move damper rod a few times then leave sleeve upside down until fluid has completely drained...

Page 439: ...s not possible to measure the air volume from fluid surface to fork edge when filling the fork with fluid Set the fork in the vice and clamp the bottom end Use the suitable protection plates to avoid...

Page 440: ...Remove dust seal 5 from outer sleeve 1...

Page 441: ...Using suitable tools remove snap ring 6 Slide out outer sleeve 1 from fork leg 7 by hitting several times to counter hold the sliding bushing resistance...

Page 442: ...Remove oil seal 8 washer 9 and bushes 10 and 11 Important Protect the sleeve with rubber before vicing it to avoid any damage REFITTING THE FRONT FORK Protect bushing seat with some adhesive tape...

Page 443: ...5 Snap ring 6 Oil seal 8 Shim 9 Bushing 10 Note Pay attention to the direction of installation of oil seal spring must face outward Fit leg 7 into sleeve 1 Install bushing 10 in its housing Fit shim 9...

Page 444: ...l 8 Fit snap ring 6 and dust seal 5 Remove the adhesive tape previously applied Fit the sliding bushing 11 in its housing Fit tool X part no 88713 0950 Fill in Quantity of fluid for the RH leg 427 cc...

Page 445: ...Activate the damper rod a few times Fit spring 4...

Page 446: ...Important The spring must be oriented and positioned with the side featuring the smaller diameter against the pre load tube Insert the preload tube 3...

Page 447: ...Bring plug 1 fully home on lock nut 12 Tighten plug 2 on lock nut 12 Tighten plug 1 on the fork sleeve...

Page 448: ......

Page 449: ...g the front mudguard NOT VALID FOR URBAN ENDURO Front wheel Removing the front wheel Headlight Phonic wheel sensor Removing the brake disc The procedure below refers to one fork but it applies to both...

Page 450: ...Loosen screw 2 securing the fork sleeve to the bottom yoke 4 Slide the fork downwards...

Page 451: ...fit the outer rings C upper and lower in their seats on the steering tube fit the fixed bush G with threaded hole of the tool into the lower ring fit the other movable bush H into the upper end of th...

Page 452: ...8 manually pushing for at least 10 15 seconds Lubricate the inner ring 7 with the recommended grease Fit the ball race 6 on the steering shaft with the smaller diameter of the cage facing upwards and...

Page 453: ...tion ring nut 1 and tighten it to the specified torque Refit the following components on the vehicle Forks Refitting the front fork Handlebar Refitting the handlebar Front wheel Refitting the front wh...

Page 454: ...Removing the forks Handlebar Removing the handlebar Warning All parts fitted to the steering head and bottom yoke including wiring and hoses can remain on the motorcycle provided they do not hinder t...

Page 455: ...Remove the bottom yoke 5 complete with the steering shaft from the frame Remove the ball race 6 Use a universal puller to remove the internal ring C having care not to damage the seat...

Page 456: ...Important The removed seals and bearings shall not be reused and must be replaced with similar new components Remove dust seal 8 and spacer 9...

Page 457: ......

Page 458: ...Steering angle adjustment In this vehicle it is not possible to adjust the steering...

Page 459: ...Adjusting the steering head bearing clearance Adjust steering bearing clearance as explained in paragraph Adjusting the steering head bearing clearance...

Page 460: ...ing the rear suspension Ensure that bushings 5 and 6 and spacer 7 are fitted on the frame Insert the shock absorber upper part in the frame and insert screw 3 Tighten nut 2 on screw 3 to a torque of 4...

Page 461: ...Apply specified grease to the thread and underhead of the lower screw 4 insert the shock absorber lower part in the swinging arm and tighten screw 4 to a torque of 42 Nm 5...

Page 462: ...Overhauling the rear shock absorber This shock absorber can not be overhauled...

Page 463: ...ock absorber Support the rear side of the vehicle in a suitable way To remove the rear shock absorber 1 from the vehicle loosen nut 2 of the upper retaining screw 3 Loosen the lower screw 4 Remove the...

Page 464: ......

Page 465: ...ck absorber pivots onto a swinging arm at the bottom and frame at the top The whole system gives the motorcycle excellent stability The only possible adjustment on the rear shock absorber is spring pr...

Page 466: ...Refitting the rear swinging arm Use grease to lubricate the bearings on the crankcase Position the shims as described in chapter Overhauling the rear swinging arm Install circlip 7 onto shaft 4...

Page 467: ...Bring the swinging arm seat close to the seat on the crankcase Insert pin 4 fully home Lubricate with specified product the swingarm shaft in the indicated product...

Page 468: ...Fit circlip 3 in wheel shaft 4 Insert screw 5 applying the specified product and tighten it to a torque of 18 Nm 5...

Page 469: ...Lock shaft using circlip 8 Refit chain guard 1 by tightening the two screws 2 to a torque of 5 Nm 10...

Page 470: ...e silencer Refit the rear calliper Refitting the rear brake calliper Refit the rear shock absorber Refitting the rear shock absorber Refit the rear wheel Refitting the rear wheel Refit the footpeg hol...

Page 471: ...ging arm left section against the engine insert a 1 8 mm shim from the other section and check with a feeler gauge or calibrated shims the clearance on the engine side The maximum side play allowed is...

Page 472: ...The shims with greater size have to be fitted on the swinging arm right hand side The thinner shim must always be in contact with the swinging arm Do NOT fit shims with size equal to 0 1 on the left...

Page 473: ...Inspecting the swinging arm shaft Before refitting the swinging arm shaft 4 check it carefully for distortion Turn the shaft on a reference surface and measure distortion using a feeler gauge...

Page 474: ...move the rear calliper Removing the rear brake calliper Remove the shock absorber Removing the rear shock absorber Remove the footpeg holder plates Removing the front footpeg support Remove the chain...

Page 475: ...Loosen screw 5 and remove it from the swinging arm Slide out swingarm shaft 4 from the vehicle LH side Remove the swinging arm...

Page 476: ......

Page 477: ...ricated at regular intervals to protect metal parts of the chain and the O rings Lubrication also serves to keep the O rings soft and pliable to ensure the maximum sealing efficiency Using a brush app...

Page 478: ...O rings must be washed in oil diesel fuel or paraffin Do not use fuel trichloroethylene or other solvents which will damage the rubber O rings For the same reason use only sprays specifically formulat...

Page 479: ...ket If removed screw pins 5 to the rear sprocket flange 3 with specified threadlocker applied in the indicated point Tighten the pins to a torque of 46 Nm 5 Position rear sprocket 1 on rear sprocket f...

Page 480: ...Insert spacer 4 fully home Lubricate the pins with the recommended product...

Page 481: ...Position the rear sprocket flange rear sprocket assembly in the rear wheel Fit spacer 6 and tighten nuts 2 to a torque of 46 Nm 5...

Page 482: ...Refit the rear wheel Refitting the rear wheel...

Page 483: ...ving the rear sprocket Remove the rear wheel Removing the rear wheel Loosen nuts 2 retaining rear sprocket 1 to rear sprocket flange 3 Remove the rear sprocket flange 3 from the rear wheel Remove spac...

Page 484: ...Loosen the nuts retaining the rear sprocket to the rear sprocket flange previously loosened...

Page 485: ...rbox secondary shaft and push it over the groove 7 Respect the positioning shown in figure Insert stop plate 4 on the gearbox secondary shaft 5 and rotate it inside groove 7 until the plate holes matc...

Page 486: ...it using the tool X no 88713 1344 which was used to open the chain The tool consists of a holder A a punch B body C and two wrenches D and E and a plate holder F Connect the two ends of the chain with...

Page 487: ...Tension the belt Fit the sprocket cover 1 and tighten the screws 2 to a torque of 6 Nm 10...

Page 488: ...E Fit the link to be opened into the holder A Fit the punch B into the body C and manually undo the screw until the punch no longer protrudes Fit the holder A and the link into the body C Manually tu...

Page 489: ...Remove the chain Engage a low gear and loosen the two screws 3 on the sprocket stop plate 4 Remove plate 4 of the gearbox secondary shaft 5...

Page 490: ...Remove the front sprocket 6 from the gearbox secondary shaft 5...

Page 491: ...ear visually check the front sprocket 1 and the rear sprocket 2 If the teeth are worn as shown in the figure dotted line the final drive must be replaced Important Make sure that the rear sprocket fro...

Page 492: ...ase on the spring end and insert the ball 16 Position plate 18 so that the two chamfers are facing the rear side Press on the plates and insert the plate footpeg assembly in the footpeg holder Smear t...

Page 493: ...ing the rear footpegs The following procedure applies to both rear footpegs Remove the snap ring 12 releasing pins 13 and 15 and recovering ball 16 spring 17 and the two plates 18 Slide off the footpe...

Page 494: ...n them as shown in the figure Use a suitable press to fit the silent block 20 LH footpeg holder Position the footpeg holder on the frame Start the screws 2 and 3 retaining footpeg holder to the frame...

Page 495: ...the footpeg holder on the frame Start the screws 6 and 5 retaining footpeg holder to the frame Tighten the screws 6 to a torque of 36 Nm 10 Tighten the screw 5 to a torque of 55 Nm 5 Refit the silenc...

Page 496: ...ing the front footpeg support LH footpeg holder Release the gearbox rod by loosening screw 1 Loosen the screws 2 and 3 retaining footpeg holder to the frame Undo screw 4 securing footpeg holder to exh...

Page 497: ...footpeg holder from the frame RH footpeg holder Remove the silencer Removing the silencer Loosen the screws 5 and 6 retaining footpeg holder to the frame Remove footpeg holder 7 by releasing the rear...

Page 498: ...nt footpegs Position spring 11 so that it engages in the footpeg holder bracket as shown in the figure Fit front footpeg 10 in place Apply the recommended grease to pin 9 Fit pin 9 as shown Lock shaft...

Page 499: ...tpegs Remove the footpeg holders Removing the front footpeg support Remove the circlip 8 thereby releasing the pin 9 Slide out pin 9 while supporting the footpeg 10 Slide out footpeg 10 from its seat...

Page 500: ...pecified product Fix with pin 10 Tighten nut 9 to a torque of 20 Nm 10 Position springs 7 and 8 fixing them in retainers A and B Place sensor 2 on the side stand inserting the sensor pin C into the st...

Page 501: ...Start and tighten the screw 6 with pre applied threadlocker to a torque of 5 Nm 10 Place the side stand on the frame fit screw 3 and tighten it to a torque of 36 Nm 10...

Page 502: ...Tighten the screw 4 to a torque of 36 Nm 10...

Page 503: ...Properly support the vehicle Disconnect connector 1 of the side stand switch 2 from the main wiring Undo screw 3 securing stand to engine block Undo the retaining screw 4 of the footpeg holder plate...

Page 504: ...Disassembling the side stand Loosen screw 6 and remove the switch from the stand Release stand return springs 7 and 8 disengaging them from retainers A and B...

Page 505: ...Loosen nut 9 of pin 10 retaining stand to plate...

Page 506: ......

Page 507: ...r replaced Important Damaged frames must be changed not repaired Any work carried out on the frame can give rise to potential danger infringing the requirements of EC directives concerning manufacture...

Page 508: ...L 331 7 mm...

Page 509: ...Refitting the structural parts on frame Make sure that the two outer rings 1 in the steering tube 2 are fitted Make sure that the vibration damping pads 3 are fitted...

Page 510: ...Make sure clips 4 are in place...

Page 511: ...Make sure clips 5 are in place...

Page 512: ......

Page 513: ...hrottle body the blow by and the oil breather pipe Removing the throttle body Remove the secondary air system pipes and valve Removing the secondary air system Remove the supply system and the injecto...

Page 514: ...il light Position tail light 3 so that stud bolts A are in their seats B on the frame Tighten the two screws 3 to a torque of 5 Nm 10 Connect connector 2 and position it by means of two ties 1 as show...

Page 515: ...Refit the tail guard Refitting the tail guard Refit the seat Refitting the seat...

Page 516: ...move the seat Removing the seat Remove the tail guard Removing the tail guard Release the cables from the ties 1 Disconnect tail light connector 2 from main wiring Loosen the two retaining screws 3 an...

Page 517: ......

Page 518: ...previously removed proceed as follows Apply the indicated threadlocker on the two screws 8 Fit support 9 on swinging arm 10 by starting it by hand without tightening to torque Fix number plate holder...

Page 519: ...bframe number plate holder mating surfaces Apply the specified threadlocker to screws 11 and 18 11 TCEIF M8X35 screw 18 TCEIF M8X35 screw Insert screw 18 with elastic washer E and short washer D from...

Page 520: ...nging arm by starting the screw by hand without tightening to torque Tighten the screws in the indicated sequence below Tighten the two screws 8 to a torque of 25 Nm 10 Tighten the screw 12 to a torqu...

Page 521: ...Connect the connector 4 Position the chain guard Insert screw 3 Fit bushing 2 with the relevant screw 1 and tighten screws 1 and 3 to a torque of 5 Nm 10...

Page 522: ......

Page 523: ...s procedure is valid for all customisations except the CLASSIC one To make the number plate holder removal easier we recommend removing also the chain guard Remove screw 1 and the relevant bushing 2 R...

Page 524: ...Loosen screws 5 of cable rings 6 Remove clamp 7 Remove the two screws 8 that retain the number plate holder subframe support 9 to swinging arm 10...

Page 525: ...number plate holder subframe to the swinging arm Remove the number plate holder subframe In the picture the chain guard has not been removed yet Disassembling the number plate holder Remove screws 13...

Page 526: ...Remove the three screws 14 securing the number plate holder plate 15 Remove the number plate holder from its support...

Page 527: ...Remove the number plate light 17 by loosening the two screws 16...

Page 528: ...fit heat guard 4 on case 5 on the rear side with heat reflective material as shown in the figure Important Pay attention to avoid any air bubbles between the heat reflective material and the electrica...

Page 529: ...Position the solenoid starter support 8 on the suitable stud bolts Start screws 9 and tighten them to a torque of 1 5 Nm 10...

Page 530: ...Position electrical components compartment in the frame Start screws 1 and tighten them to a torque of 5 Nm 10 Position screws 10 from the internal side of the electrical components compartment...

Page 531: ...Tighten nuts 2 and 3 to a torque of 5 Nm 10...

Page 532: ......

Page 533: ...oving the tail guard Remove the battery Remove the fuse box Remove the ABS control unit Removing the ABS control unit Loosen and remove the two rear screws 1 Loosen nut 2 and remove the screw from the...

Page 534: ......

Page 535: ...at two silent blocks 16 are present on both sides of the frame Position the tank on the frame so as to connect connector 15 and hoses 14 For the connection grip the flange and push it down A Insert ho...

Page 536: ...Tighten the two screws 13 to the silent blocks to a torque of 5 Nm 10...

Page 537: ...Tighten the two screws 11 of tank 12 Refit the seat Refitting the seat Refitting the tank side body panels Position side body panel 1 engaging tab 6 in bracket 7 on tank 3...

Page 538: ...Tighten screw 2 retaining side body panel 1 to tank 3 to a torque of 5 Nm 10...

Page 539: ...Reposition adhesive logo A The image below shows the ICON customisation The procedure is the same for all customisations Check that on the tank there are rubber elements 7...

Page 540: ...Fit the tank cover 6 by pulling it inwards to engage pins 4 in fixing points 5...

Page 541: ......

Page 542: ...Refitting the fuel tank flange If removed or damaged fit seal 4 on pump 5 and lubricate it with the specified product Insert the pump unit 5 in the tank seat 6 as shown in the picture...

Page 543: ...ing flange 7 on pump 5 centring notch 8 on rib 9 Turn flange 7 and pump 5 assembly by centring flange hole with the holes on the tank Start screws 2 and tighten them to a torque of 5 Nm 10 respecting...

Page 544: ...Use the indicated product to lubricate the contact areas of tabs 10 with the seal...

Page 545: ...Removing the fuel tank flange Loosen the screws 2 and remove fuel pump flange 3...

Page 546: ...Refitting the tank filler plug Insert the fuel plug and start the four retaining screws 1 Tighten the screws 1 to a torque of 5 Nm 10...

Page 547: ...Removing the tank filler plug Open the fuel plug and loosen the four retaining screws 1 Remove the tank plug...

Page 548: ...ring tank 12 to the frame Working on both sides remove screws 13 Lift the tank as required to reach the fuel flange located under the tank Grip the flange and push it down A Slide out hose 14 Disconne...

Page 549: ...Disconnect hoses 14 and connector 15...

Page 550: ...the fuel pipes There may be fuel leakages Removing the tank fairings Remove adhesive logo A The image below shows the ICON customisation The procedure is the same for all customisations Remove screw 2...

Page 551: ...Remove side body panel 1 by sliding it towards the vehicle front side Remove the tank cover 6 by pulling it outwards to remove pins 4 from fixing points 5...

Page 552: ......

Page 553: ......

Page 554: ...Nm 10 Refit the remaining part of the airbox as described in paragraph Refitting the airbox Refitting the intake manifold and injectors Position the intake manifold 15 with relevant clamps 13 and 14 o...

Page 555: ...Apply specified grease to the O ring 18 Insert injector 11 of the horizontal cylinder in injector 12 of the vertical cylinder in the suitable seat A on the intake manifold 15...

Page 556: ...the injectors into the unions fully home keeping them in line with their relevant seat Fit union 10 on the vertical cylinder injector as shown in the figure Tighten the screw 9 Fit union 8 on the hor...

Page 557: ...Connect the Map Sensor hose 3 and fix it with clip 4...

Page 558: ...Reconnect the horizontal cylinder connector 1 and the vertical cylinder connector 2...

Page 559: ......

Page 560: ...in paragraph Removing the airbox After releasing the throttle body from the wiring and the throttle cable loosen clip 16 to remove it Removing the intake manifold and injectors After removing the airb...

Page 561: ...ap Sensor hose 3 removing clamp 4 Disconnect hose 5 removing clamp 6 Undo the screw 7 and remove the horizontal cylinder head injector union 8 Undo the screw 9 and remove the vertical cylinder head in...

Page 562: ...Remove the horizontal cylinder injector 11 and the vertical cylinder injector 12 Unscrew the two clips 13 and 14 and remove the intake manifold 15...

Page 563: ......

Page 564: ...ting the airbox If previously disassembled reassemble the airbox as explained below Fit two vibration damping pads 19 in the relevant brackets and fit spacers 20 as shown in the figure Fit the two cli...

Page 565: ......

Page 566: ...Fit seal 22 in its seat on the airbox Fit two spacers 23 as shown in the figure...

Page 567: ...Fit blow by box 24 fully home on airbox by inserting union in the relevant seat Start screws 25 and tighten them to a torque of 3 Nm 10...

Page 568: ...Use the indicated product to lubricate tabs 26 of the blow by box Engage the MAP_SENSOR support fully home on the just lubricated tabs Apply the specified lubricant in the hole and on pin 28...

Page 569: ...Lubricate MAP SENSOR seal 29 using the specified product Fit MAP SENSOR 29 on the support by introducing the pin with O ring in the support recess and at the same time pin in the MAP SENSOR hole...

Page 570: ...To ensure a correct assembly pin must be pulled letting the poppet 30 get completely out on the side opposite to insertion Fit the pipe 31 with clip 32 in the relevant union of the blow by box...

Page 571: ...Aim hose 31 and the clip as shown in the figure Tighten the clip to a torque of 1 5 Nm 10 Fit seal 33 onto air temperature sensor 34...

Page 572: ...Fasten sensor 34 to the airbox and tighten the two screws 35 to a torque of 1 Nm 10 Fit hose 36 fully home on the Airbox by inserting edge 37 fully inside the recess...

Page 573: ...Insert the throttle body in the airbox and tighten clip 16 to a torque of 1 5 Nm 10 Position the airbox in the frame and fix it by tightening screws 17 to a torque of 10 Nm 10...

Page 574: ...Ensure that gasket 41 is present on the airbox...

Page 575: ...If removed fit the voltage regulator 40 and tighten screws 29 to a torque of 10 Nm 10 Connect the MAP SENSOR connector 17...

Page 576: ...Connect STEPPER motor 13 and potentiometer 14 Route the cables through the hose guide 15 Secure the throttle body with clamp 16...

Page 577: ...Connect throttle cable 12 Check that air sensor 43 fits the support 42 Install the air filter as described in paragraph Refitting the air filter...

Page 578: ...Connect the regulator connectors...

Page 579: ...Connect air connector Connect the secondary air system connector 6 connect the secondary air hose 8 and tighten clip 7...

Page 580: ...Connect connector 5 of stepper motor and potentiometer Position the side body panel so that the two pins 17 of the internal side 15 engage in seats 18...

Page 581: ...l tank Refitting the fuel tank Remove the seat Refitting the seat Airbox cover assembly RH airbox cover Position the RH airbox cover 5 so that the upper end is under the tank cover B Start the upper r...

Page 582: ...ox cover Position the LH airbox cover 7 Start the upper retaining screw 4 of the LH airbox cover 7 and the lateral screws 8 Tighten the screws 4 to a torque of 5 Nm 10 and the screws 8 to a torque of...

Page 583: ......

Page 584: ...fuel tank Remove the side body panels Removing the airbox cover Remove side body panels 1 and 3 loosening screws 2 and 4 Disconnect connector 5 of stepper motor and potentiometer Disconnect the second...

Page 585: ...Disconnect air connector Disconnect the regulator connectors...

Page 586: ...Undo screws 11 and remove the airbox cover 10...

Page 587: ...Disconnect throttle cable 12...

Page 588: ...Loosen clip 16 Disconnect STEPPER motor 13 and potentiometer 14 Release the cables from the airbox by sliding out hose guide 15...

Page 589: ...Disconnect the MAP SENSOR connector 17 Remove the ties that can obstacle the airbox removal Remove the airbox with the throttle body by loosening the screws 18...

Page 590: ...Removing the airbox cover RH cover Loosen the upper retaining screw 4 of the RH airbox cover 5 and the lower screws 6 Remove the RH airbox cover 5...

Page 591: ...LH cover Loosen the upper screw 4 of the LH airbox cover 7 the lateral and lower screws 8 Remove the LH airbox cover 7...

Page 592: ......

Page 593: ...the secondary air system valve cover and on head cover If disassembled refit the secondary air system valves following the procedure described below Fit the retaining screw 15 in the secondary air sys...

Page 594: ...Position the spark arrestor plate 13 and pay attention to the insertion direction Fit the reed valve 12 on cover 11...

Page 595: ...Position the secondary air system cover 11 on the vertical and horizontal cylinder head cover as shown in the figure Tighten the screws 17 to a torque of 6 Nm Min 5 Max 7...

Page 596: ...ng on the vertical head position hose 5 as shown in the figure and fix it with clip 8 Repeat the operation on the horizontal cylinder head orienting hose 6 as shown in the figure and fixing it with cl...

Page 597: ...ith the suitable clip Connect the secondary air system sensor to the vertical head through hose 5 repeat the operation with the horizontal cylinder head hose 6 and hose 7 coming from the airbox Fix th...

Page 598: ...Fit the lateral cover so that pins 17 engage in their seat 18 Tighten the screw 2 to a torque of 5 Nm 10...

Page 599: ......

Page 600: ...the fuel tank Remove the lateral cover 1 loosening screw 2 Disconnect connector 3 of the secondary air system Remove clips 4 and disconnect vertical cylinder pipe 5 horizontal cylinder pipe 6 and air...

Page 601: ...Work on the vertical head and remove clip 8 and disconnect pipe 5 Repeat the operation on the horizontal head removing clamp 9 and hose 6...

Page 602: ...en the two screws 10 and slide out in this sequence cover 11 reed valve 12 spark arrestor plate 13 secondary air plate base 14 the relevant retaining screw 15 and O ring 16 Note block off the secondar...

Page 603: ...ber support 7 on filter 6 Fit air filter unit fully home on the relevant cover 3 by inserting the support edge 7 in the cover internal wall Fit the filter base 8 fully against the air filter 6 Fix it...

Page 604: ...Connect the regulator connectors...

Page 605: ......

Page 606: ...Removing the air filters Disconnect the regulator connectors Undo screws 4 and remove the airbox cover 3...

Page 607: ...Remove the airbox cover Loosen the three screws 5 of the support to remove the air filter Remove the airbox 6...

Page 608: ......

Page 609: ...cer Start and tighten screw 2 in the footpeg holder plate to a torque of 10 Nm 10 Working on vehicle left side tighten screw 1 to a torque of 10 Nm 10 Fix the silencer to the central part of the exhau...

Page 610: ...REASSEMBLING THE SILENCER Insert the two exhaust pipes 8 fully inside the central body 9 by aligning their edge with plate 11 as shown in the figure Tighten clamps 19...

Page 611: ...Make sure clip 12 is in place Fit the heat guard 6 with spacer 13 and washer 14 Fix it by tightening screw 7 to a torque of 4 Nm 10 Make sure clips 16 are in place...

Page 612: ...Fix the two exhaust pipes 4 with screws 5...

Page 613: ......

Page 614: ...Removing the silencer Loosen the silencer retaining screw 1 to the frame on the vehicle left side Working on the vehicle right side loosen retaining screw 2 Remove spring 3 Slide out the silencer...

Page 615: ...If it is necessary to disassemble the silencer remove heat guard 4 by loosening the retaining screws 5 Remove heat guards 4...

Page 616: ...Remove heat guard 6 by loosening screw 7 It is possible to separate the two exhaust pipes 8 from the central body 9 by loosening the two clamps 19...

Page 617: ......

Page 618: ...th relevant seal to a torque of 25 Nm 10 Start the lambda sensor and tighten it to a torque of 45 Nm 10 Fit the heat reflective material 15 in heat guard 16 Position the two washers 17 on heat guard 1...

Page 619: ...rews 12 and tightening them starting from one of the two following the procedure below The first one to 6 Nm 10 The second one to 24 10 Nm Then again the first one to 24 10 Nm Insert the primary exhau...

Page 620: ...crews 10 and tightening them starting from one of the two following the procedure below The first one to 6 Nm 10 The second one to 24 10 Nm Then again the first one to 24 10 Nm Fit the two clips 19 on...

Page 621: ...Position head guard 20 and tighten the two screws 21 to the torque of 5 Nm 10 Fit cover 22 on heat guard 20 tightening two screws 23 to a torque of 5 Nm 10...

Page 622: ...Fix the exhaust manifold 1 and the exhaust pipe 3 to the central body 4 through the two springs 6 and 7 Refit the silencer Refitting the silencer...

Page 623: ...l body 5 Silencer Remove the silencer Removing the silencer Remove the spring 6 retaining the horizontal head exhaust manifold 1 to central body 4 and 7 primary exhaust pipe of vertical head 3 to cent...

Page 624: ...Loosen lambda sensor 9 of the horizontal cylinder head exhaust manifold 1 Remove the exhaust manifold 1 from the horizontal head by loosening the two retaining screws 10...

Page 625: ...Loosen the lambda sensor 11 and remove the exhaust manifold 2 by loosening the two screws 12...

Page 626: ...the exhaust through spring 3 Start and tighten screw 2 in the footpeg holder plate to a torque of 10 Nm 10 Working on vehicle left side tighten screw 1 to a torque of 10 Nm 10 Fit the silencer externa...

Page 627: ...Fix heat guard 4 by tightening screws 5 to a torque of 5 Nm 10...

Page 628: ......

Page 629: ...ning screw 1 to the frame on the vehicle left side On the vehicle right side loosen retaining screw 2 and remove spring 3 Slide out the silencer If it is necessary to disassemble the silencer remove h...

Page 630: ...Remove the silencer external side 6 by loosening screw 7...

Page 631: ......

Page 632: ...ting the Canister filter Position the canister filter 8 and fix it to the bracket through nuts 7 Tighten nuts 7 to a torque of 8 Nm 10 Position hoses 4 5 and 6 on the filter and fix it with clips 1 2...

Page 633: ...Removing the canister filter Remove clips 1 2 and 3 and release hoses 4 5 and 6 respectively Unscrew the two nuts 7 and remove the canister filter 8...

Page 634: ...featuring a Canister filter that prevents fuel fumes from being discharged into the atmosphere The breather hose 4 is connected to the Canister filter 1 when the fuel has been filtered it is returned...

Page 635: ...ngine Fit the engine in the frame Lubricate screws 1 with the indicated grease and tighten to a torque of 60 Nm 5 Refit the swinging arm Refitting the rear swinging arm Refit the rear wheel Refitting...

Page 636: ...fitting the clutch assembly Refit the electric connections Refit the airbox Refitting the airbox Refit the oil cooler Refitting the lubrication system Refit the rear brake assembly Refitting the rear...

Page 637: ......

Page 638: ...mplete rear brake control Remove the oil cooler Removing the lubrication system Remove the airbox Removing the airbox Remove the exhaust system Removing the exhaust system Remove the electric connecti...

Page 639: ...Remove the swinging arm Removing the rear swinging arm Position a support under the engine Remove the two pins 1 that retain the engine to the frame Remove the engine from the frame...

Page 640: ......

Page 641: ...rence bushes 5 and O rings 4 according to the casing lubrication channels Place oil pump 3 on the casing Start screws 1 and 2 retaining the complete pump Tighten screws 1 to 26 Nm Min 23 Nm Max 29 Nm...

Page 642: ...htly to measure the backlash take four readings in opposed positions The backlash must be 0 10 mm To take the measurement use a dial gauge Refit the clutch cover Refitting the clutch cover Fill the lu...

Page 643: ...pump control gear 10 on oil pump checking the presence of key 11 Lock the gear using circlip 9 Insert by pass valve 8 spring 7 and plug 6 Tighten plug 6 to a torque of 17 Nm Min 15 Nm Max 19 Nm after...

Page 644: ......

Page 645: ...Disassembling the oil pump gear Remove the plug 6 and extract the spring 7 and by pass valve 8 Check their wear conditions Remove circlip 9 and withdraw the pump drive gear 10...

Page 646: ...ng the engine oil and filter cartridge Remove the clutch cover Removing the clutch cover Loosen and remove screws 1 and 2 retaining the complete pump Remove the complete oil pump 3 Extract the two O r...

Page 647: ......

Page 648: ...r with gasket 10 and tighten them to 23 Nm 10 Tighten nuts 8 to a torque of 25 Nm 5 to fasten pipes 6 and 7 Position the oil cooler 5 and fix it by means of the two screws 4 Tighten the two screws 4 t...

Page 649: ......

Page 650: ...Inspecting the oil cooler Visually inspect the cooler Replace it at any sign of damage or leaks...

Page 651: ...oil Changing the engine oil and filter cartridge Note Pay attention that during the lubrication system removal procedure oil can spill from the couplings Loosen and remove the two oil couplings 1 and...

Page 652: ...To remove the oil hoses 6 and 7 loosen the two nuts 8 Loosen the two nipples 9 by recovering the relevant two gaskets 10...

Page 653: ...in this condition the camshaft can rotate If it moves stiffly use a thinner feeler gauge In this condition with the piston of the horizontal cylinder at TDC with the valves fully closed as confirmed b...

Page 654: ...ate until you obtain an intake valve lift of 1 mm on the gauge B during closure of the valve for the compression stroke Check the angular displacement value with the specified one Continue to rotate t...

Page 655: ...e dial gauge to zero when the valve is fully closed Rotate the intake camshaft so as to allow the intake valves to lift fully Check on the dial gauge that the measured value corresponds to the prescri...

Page 656: ...Exhaust Opening 61 B T D C Closing 7 A B D C Intake valve diameter 44 mm Exhaust valve diameter 38 5 mm...

Page 657: ...Remove the seat Removing the seat Remove the fuel tank Removing the fuel tank Remove the blow by Removing the airbox Remove the following parts from the electrical component box Battery Starter relay...

Page 658: ...nkshaft so that the valve to be inspected is in rest position With the valve in the rest position slide a feeler gauge between opening rocker arm and shim to measure the clearance The clearance must b...

Page 659: ...losing rocker arm and shim to measure the clearance Closing rocker arm INTAKE Assembly 0 0 05 mm Inspection 0 0 05 mm EXHAUST Assembly 0 0 05 mm Inspection 0 0 05 mm If detected values exceed the spec...

Page 660: ...ate thickness to obtain the specified clearance Note Opening rocker arm shims measuring from 1 8 to 3 45 and closing rocker arm shims from 2 2 to 4 5 are available as spare parts the size is punched o...

Page 661: ...e vertical timing belt cover 3 on the engine Start screw 1 on the cover Position the horizontal timing belt cover 2 on the engine Tighten the screws 1 to a torque of 10 Nm Min 9 Nm Max 11 Nm Refit the...

Page 662: ...Refitting the timing belts To refit the timing belts refer to paragraph Replacing the timing belts...

Page 663: ...layshaft on the pulley side To guide it in its position use protection cap no 88700 5749 and the supplied drift Fit spacer 19 with the recess facing the casing Position the first keyway 18 the intern...

Page 664: ...ring nuts from loosening and consequent serious engine damage always use new self locking ring nuts on all the timing pulleys Block with the key of tool A no 88700 5644 the pulley rotation and use the...

Page 665: ......

Page 666: ...t pulley 23 on hub 24 making the pulley reference point A coincide with the hub reference mark B Fit washer 22 fully home on the pulley aligning the reference notch C with pulley reference point A and...

Page 667: ...ten it to a torque of 20 Nm Min 18 Nm Max 22 Nm Check that the tab seat on the end of the camshaft is in good condition and without burrs Fit a key 1 in the keyway of the camshaft Fit the pulley assem...

Page 668: ...Insert tool 88713 3152 in the pulleys to block its rotation Apply a thin layer of specified grease on the thread and on the underhead of ring nut 8 fit washer 9 and the ring nut...

Page 669: ...Important Always fit new nuts on reassembly Use the bush of tool no 88700 5644 and a torque wrench to tighten ring nuts 8 to 71 Nm Min 64 Nm Max 78 Nm...

Page 670: ...g layshaft pulleys Block with the key of tool A no 88700 5644 the driving pulley rotation on the crankcase and use the tool bush to loosen the retaining ring nut 12 Remove ring nut 12 washer 13 and th...

Page 671: ...Remove the first key 15 located on the timing layshaft Remove the spacer 16 and the inner pulley 17 Remove the second key 18 located on the timing layshaft Remove spacer 19 and snap ring 20...

Page 672: ......

Page 673: ...Disassembling the camshaft pulleys To disassemble the pulley loosen and remove the three screws 21 slide out washer 22 and pulley 23 from flange 24...

Page 674: ...tensioner To remove the head pulleys fit tool part no 88713 3152 on the pulley to block its rotation and use the bush of tool part no 88700 5644 inserted in a torque wrench or a ratchet wrench to loo...

Page 675: ...Important Upon reassembly always use new ring nuts Loosen and remove the fixed tensioners 11...

Page 676: ...positioning screw 4 of the horizontal cylinder belt mobile tensioner 5 Loosen retaining screw 6 of tensioner 5 and bring it to its rest position Remove the timing belt 7 Perform the same operation seq...

Page 677: ......

Page 678: ...seat Removing the seat Remove the exhaust system Removing the exhaust system Loosen screws 1 and remove the external cover 2 of the horizontal timing belt Loosen screws 1 retaining the external cover...

Page 679: ...Refitting the intake manifold Position intake manifolds 3 and fix them using nuts 2 Tighten nuts 2 to a torque of 15Nm Min 13Nm Max 17Nm Refit the engine in the frame...

Page 680: ...Removing the intake manifold Remove the engine from the frame Loosen clap 1 of the vertical head intake manifold Repeat the same procedure on the horizontal head...

Page 681: ...Remove intake manifold Loosen and remove nuts 2 securing the vertical and horizontal head intake manifolds Remove manifolds 3...

Page 682: ......

Page 683: ...der head to insert the camshaft it is necessary to rotate the camshaft until the cams reach a position that does not interfere with the rocker arms Before fitting the camshaft check the punched letter...

Page 684: ...Fit the camshaft 11 from the head LH side...

Page 685: ...While fitting the camshaft pay attention not to damage the seal Rotate camshaft to evenly lubricate contact areas...

Page 686: ...If previously removed reposition spring 9 of the opening rocker arm 10 Check the key 7 and its seat conditions and then refit it...

Page 687: ...sten cap 6 with screws 5 after applying indicated threadlocker Tighten the screws 5 to a torque of 13 5 Nm Min 12 5 Nm Max 14 5 Nm following a 1 2 1 sequence Fitting the timing internal cover Position...

Page 688: ...itting the valve covers Fit O ring A in the suitable seat on the valve cover 2 Lubricate the O ring with the indicated product Position cover 2 and start screws 1 to a torque of 10 Nm Min 9 Nm Max 11...

Page 689: ...mshaft between two opposite centres and check the run out using a dial gauge service level 0 1 mm The camshaft has a punched letter O horizontal V vertical Oil seal check Replace the seal upon every e...

Page 690: ......

Page 691: ...fts Removing the valve covers Loosen the screws 1 securing valve covers 2 and remove the covers Removing the timing internal cover Remove the head pulley Removing the camshaft pulleys Loosen screws 3...

Page 692: ...Removing the rocker arm shaft cap Loosen screws 5 securing cap 6 and remove it Remove keyway 7 of camshaft 8...

Page 693: ...until the cams are in a position that does not interfere with the rocker arms To facilitate the operations with installed rocker arms remove spring 9 of the opening rocker arm 10 Slide cylinder head...

Page 694: ......

Page 695: ...there are the reference pins C and bushings D Fit the complete head on the casing stud bolts and bring it fully home on the cylinder Fit the special washers 2 in the stud bolts with the sharp edge fac...

Page 696: ...Important Failure to follow the described procedure may cause an abnormal stretch of the stud bolts and serious damages to the engine Refit the engine in the frame...

Page 697: ...n removed fit new ones after lubricating them with engine oil and fit them on the side with spring on tool no 88713 2442 Fit the end of the tool into the valve guide and use a hammer to tap the sealin...

Page 698: ......

Page 699: ...the rocker arm shafts make sure that the threaded hole is on the head outer side Release spring 15 and remove tool A no 88713 2783 Follow the same procedure on the exhaust side Lubricate valves 19 wit...

Page 700: ...Temporarily fit the camshaft...

Page 701: ...Use a suitable tool to block the closing rocker arm 10 in the position with valve open Fit the closing shim 11 with the bigger diameter side facing down in the valve stem 12...

Page 702: ...tion the closing rocker arm 10 in its rest position Use a suitable tool to compress the spring as much as possible while holding valve shim and split rings in the valve closed position Release the clo...

Page 703: ...ase adjust the valve clearance Once the specified clearance is reached remove the temporarily fitted camshaft lubricate it with oil and reposition it on the cylinder head Opening rocker arm Insert roc...

Page 704: ...pulleys Position the valve opening shim With the valve in rest position check that the clearance between rocker arm and the relevant adjuster is the specified one If this is not the case adjust the va...

Page 705: ...Refit the caps the camshafts and the valve covers Refitting the camshafts...

Page 706: ...the cylinder head with circular movements on the surface until a flat surface is obtained Checking the valves Check that the stem and the valve seat contact surface are in good condition There must be...

Page 707: ...0 03 and 0 06 mm oversized outside diameters Valve guide Check the internal surface of the valve guides there should be no signs of deformation or cracking Thoroughly check the dimensions of the valv...

Page 708: ...th the new seats and lap the valves Coupling valve seat and valve Use Prussian blue or a mixture of minium and oil to check that the contact surface A between valve and seat is 1 0 1 5 mm Maximum allo...

Page 709: ...check the seat conditions and dimensions Choose a suitable valve guide to obtain an interference fit in the cylinder head of 0 022 0 051 mm they are available as spare parts with outer diameter oversi...

Page 710: ...ions and the diameter of rocker arm bore and shaft rocker arm internal hole nominal diameter 10 040 10 062 mm shaft nominal diameter 10 0 005 mm Check that the work surfaces of the adjusters and the v...

Page 711: ...haft coupling The clearance upon fitting must be 0 03 0 06 mm Maximum allowed wear limit 0 08 mm The rocker arms must be slightly forced on the cylinder head If the clearance is excessive fit the shaf...

Page 712: ...Checking the rocker arm springs Thoroughly check the springs 15 of the closing rocker arms 10 No cracks deformations or failure must be present...

Page 713: ...t caps Removing the camshafts Slide out spring 4 of the opening rocker arm 5 Move rocker arm 5 to free the opening shim 6 Screw tool no 88713 2837 on the threaded end of the opening rocker arm shaft 7...

Page 714: ...in the position with valve open Slide the valve closing shim 11 on the intake valve stem 12 to allow the removal of the two split rings 13 that retain the valve Use small tip pliers or a magnet screwd...

Page 715: ...Slide out valve closing shim 11 from the valve 12 Withdraw valve 12 from the lower side of the cylinder head...

Page 716: ...Repeat the same operations for the exhaust side Slide out closing rocker arm shaft 14 using tool no 88713 2837 Slide out rocker arm 10 and spring 15...

Page 717: ...8713 2676 undo nuts 1 on the cylinder head stud bolts Remove nuts 1 and collect the special washers 2 located between nut and head Remove the complete head from the engine by sliding it out of the stu...

Page 718: ......

Page 719: ...wn between the two valve recesses If the pistons have been separated from their cylinders before reassembling these components position the piston ring gaps at 120 from one another the markings must a...

Page 720: ...and the horizontal cylinder O The sides touching gasket 6 are Side touching the vertical cylinder Side touching the casing near the vertical cylinder Side touching the horizontal cylinder Side touchi...

Page 721: ...e coupling tape and ovality value In the event of damage or excessive wear the cylinder must be replaced as it has a silicon carbide coating which provides the cylinder walls with excellent anti frict...

Page 722: ...n the piston crown and piston ring grooves removing any carbon deposits Visually inspect the piston and check its dimensions carefully there must be no signs of scuffing scoring cracks or other damage...

Page 723: ...from the same size class Overhauling the gudgeon pins Gudgeon pins must be perfectly smooth without signs of scoring steps or blueing due to overheating The well lubricated gudgeon pin must slide smo...

Page 724: ...Overhauling the piston rings The piston rings must not show any signs of scuffing or scoring Spare pistons are supplied complete with piston rings and gudgeon pin...

Page 725: ...0 10 mm for the others 2nd and oil scraper ring Note The piston rings must always be fitted with markings facing upwards Piston gudgeon pin coupling Measure the piston ring gap Upper and intermediate...

Page 726: ...e engine Remove the heads Removing the engine heads Slide out of the cylinder surface the pin 1 bushings 2 and head gasket 3 Use tool A no 88700 5644 to bring the piston 4 of the horizontal cylinder 5...

Page 727: ...the gudgeon pin 6 Since insertion of piston in the cylinder is a difficult operation to perform at the time of reassembly remove the cylinder together with the piston as described below Block the cran...

Page 728: ...out the gudgeon pin 6 sufficiently to release the connecting rod of the crankshaft Lift the cylinder piston assembly clear of the engine block stud bolts If work is to be carried out on the piston car...

Page 729: ...ylinder piston assembly follow the procedure performed on the horizontal cylinder Remove gaskets 8 between cylinder and casing Important Mark the pistons to show from which cylinder they were removed...

Page 730: ...the clutch plate pack on hub The plate pack 9 consists of 11 driving plates A with 2 8 mm thickness 6 driven plates B with 2 mm thickness 1 convex driven plate C with 1 5 mm thickness 3 driven plates...

Page 731: ...Fit the hub plates drum assy 9 to the clutch housing 10 Fit lock washer 8 on primary shaft driving it fully home inside clutch unit...

Page 732: ...primary shaft thread then insert nut driving it fully home by hand inside primary shaft Lock clutch housing with tool T no 88713 2556 so as to hold it when tightening nut 7 Tighten nut 7 to a torque o...

Page 733: ...Position pusher plate 5 with the clutch control pin 6 Fit springs 4 and ring 3 on pusher plate 5 Start screws 2 and tighten them to a torque of 5 Nm Min 4 5 Nm Max 5 5 Nm...

Page 734: ...Remove the two service pins 1 Refit the clutch cover Refitting the clutch cover Fill the engine with oil Changing the engine oil and filter cartridge...

Page 735: ...replace the plates and if necessary the clutch housing Overhauling the clutch plates The clutch plates must not show any signs of blackening grooves or deformation Measure the thickness of the fricti...

Page 736: ...f the last friction plate if extremely scored polish it in the same manner as described previously for the cylinder head surface Overhauling the cylinder head components Check the condition of the spr...

Page 737: ...filter cartridge Remove the clutch cover Removing the clutch cover Fit the two service pins 1 inside their seats on hub Undo the fixing screws 2 and remove the ring 3 and the springs 4 from the pushe...

Page 738: ...Lock clutch housing with tool T no 88713 2556 and loosen retaining nut 7...

Page 739: ...Remove the lock washer 8 Slide the hub plates drum assy 9 out of clutch housing 10 marking them so as to refit them in the same position in which they were removed...

Page 740: ...Remove the spacer 11 from the clutch housing 10...

Page 741: ...parts check that the clutch operates correctly Then deal with the problem in a systematic manner The following is a list of possible causes of clutch malfunction A clutch which does not disengage may...

Page 742: ...ad of DUCATI sealing compound A on the mating surface of the crankcase half and around all holes Bring cover near the crankcase half and operating on clutch cover lever make sure that clutch control p...

Page 743: ...ax 14 5 Refit the clutch cable on the clutch cover Turn adjuster 6 to tension clutch cable 5 on handlebar Screw adjuster 5 Adjuster 6 standard adjustment is 5 mm from the fully home position The maxim...

Page 744: ...Fill the engine with oil Changing the engine oil and filter cartridge...

Page 745: ...h layshaft 9 in the points indicated in the figure Lubricate seal 10 using the specified product Using a suitable tool drive ring 10 in the clutch cover seat Insert clutch layshaft 9 in seal ring 10 h...

Page 746: ...Bring shaft 9 fully against clutch cover 2 Rotate shaft 9 counter clockwise until part 14 touches mating surface 15...

Page 747: ...it snap ring 8 on pin 9 and perform a functional test Oil filler cap Make sure that the oil filler cap 6 has O ring 7 Position plug 6 on cover 2 and tighten it to a torque of 5 Nm Min 4 5 Nm Max 5 5 N...

Page 748: ...Fit spacer 17 and snap ring 16 Oil sight glass If previously removed refit the sight glass Lubricate sight glass 19 with specified product Using a suitable drift fit the sight glass to the value indi...

Page 749: ......

Page 750: ......

Page 751: ...Disassembling the clutch cover Oil filler cap Remove the plug 6 with its O ring 7 from cover 2 Clutch layshaft Remove snap ring 8 from clutch layshaft 9 Remove the clutch layshaft 9...

Page 752: ...ne oil Changing the engine oil and filter cartridge Loosen the fastening screws 2 3 and 4 on the clutch cover 1 Screw clutch cable 5 fully home on clutch lever on handlebar working adjuster 6 Remove t...

Page 753: ...Working on clutch cover lever slowly remove cover to release it from clutch control pin...

Page 754: ...lutch housing 1 complete with inner spacer 4 the driven gear 2 the roller bearing 3 and the inner race on the gearbox primary shaft Warning If fitting a new primary driving gear check the backlash Fix...

Page 755: ...rque of 190 Nm Min 171 Nm Max 209 Nm Bend the washer 6 over ring nut 7 Refit the oil pump and check the backlash between the oil pump gear and the primary drive gear on the crankshaft Thoroughly degre...

Page 756: ...Refit the clutch unit Refitting the clutch Refit the clutch cover Refitting the clutch cover Fill the engine with oil Changing the engine oil and filter cartridge...

Page 757: ...ch cover Removing the clutch cover Remove the clutch unit Removing the clutch Remove the oil pump Removing the oil pump Remove the clutch housing 1 complete with needle bearing 3 and primary driven ge...

Page 758: ...Lock the primary drive gear 8 with holding tool A no 88713 2423 and loosen sprocket threaded ring nut 7 Remove the nut 7 and the lockwasher 6...

Page 759: ...primary drive driving gear 8 using puller B no 88713 2092 and place between crankshaft and puller screw an aluminium or brass pad Pay attention to tab 9 positioned on the crankshaft and to the intern...

Page 760: ...rily fit gearchange lever or a service lever and sprocket and shift to neutral gear Set tool A part no 88713 3334 on the gearbox pawl Position the tool by inserting the engine pin 25 inside the tool h...

Page 761: ...he same time to check that all the gears engage when shifting up and down Remove the gearchange lever Reassembling the gearchange mechanism If during the removal procedure the gearchange mechanism has...

Page 762: ...Insert shaft 12 in plate 9 position washer 7 and block with the snap ring 6...

Page 763: ...ition lever 12 correctly according to the plate 9 position The lever pin must be equidistant from the plate edges to modify its position work on the suitable eccentric pin 11 after loosening lock nut...

Page 764: ...pring 16 between shaft 12 and fork 5 Fit ring 14 to block the coupled elements Check that the spring 16 is installed correctly as shown in the figure Then tighten nut 13 to a torque of 10 Nm Min 9 Nm...

Page 765: ...ly and the generator cover Refitting the flywheel generator assembly Refit the gear shift Refitting the gear shift Refit the front sprocket Refitting the front sprocket Fill with engine oil Changing t...

Page 766: ...cing the gear ratchet Apply threadlocker on screw thread Start the screw in the crankcase half Position spring end against the crankcase half rib Tighten screw 21 to a torque of 18 Nm Min 16 Nm Max 20...

Page 767: ...Refit the clutch unit Refitting the clutch Reconnect the oil pressure sensor Fill the engine with oil Changing the engine oil and filter cartridge...

Page 768: ...Disconnect the oil pressure sensor Remove the clutch cover Removing the clutch cover Remove the clutch unit Removing the clutch Undo the interlock plunger screw 17 and remove the seal 18 the spring 1...

Page 769: ......

Page 770: ...ont sprocket Remove the generator cover Removing the generator cover Undo the fixing screws 1 and 2 of the complete gearchange mechanism 3 Remove screws 1 and 2 plate 4 and slide out the gearchange me...

Page 771: ...ical test ensure that with the gearbox in neutral the front coupling dogs A of sliding gears B are equidistant on both sides with respect to the corresponding coupling dogs on the fixed gears C Check...

Page 772: ...s an example Fit the snap ring 17 checking that it is fully inserted into its groove on the shaft Push the snap ring into position with a suitable size tubular drift Slide the three pointed washer 18...

Page 773: ...Fit the three pointed washer 21 which has a bigger outer diameter than the other one 18 in the gear Fit another roller bearing cage 20 using the method already described Fit the 4th speed gear 19...

Page 774: ...Fit another three pointed washer 18 and another snap ring 17 into the shaft Push it inside its seat using the previously used drift...

Page 775: ......

Page 776: ...as been exceeded determine which part must be replaced by comparing these dimensions with those of new components Also check the wear on the drum support pins these must not show any signs of scoring...

Page 777: ...y lead to difficulties in gear changing or may suddenly disengage when under load Use a feeler gauge to check the clearance of each fork in its gear groove If the service limit has been exceeded check...

Page 778: ......

Page 779: ...ositioned Check the needle roller bearings for wear The threads and splines of the shafts must be in perfect condition Also check that the component parts of the gear selector mechanism are in good co...

Page 780: ...entially lead to jamming when using the gear selector control making it necessary to reopen the crankcase Disassembling the gearbox secondary shaft Remove the chain side washer 11 and the clutch shim...

Page 781: ...Remove the fifth speed driven gear 16...

Page 782: ...Use two flat blade screwdrivers to remove the snap ring 17 from its seat taking care not to damage the shaft surface Remove the snap ring 17 and the splined washer 18...

Page 783: ...Remove the fourth speed driven gear 19 with its roller bearing cage 20 and splined washer 21...

Page 784: ...Remove the third speed driven gear 22 with its roller bearing cage 20 and splined washer 18...

Page 785: ...Remove snap ring 17 and slide out the sixth speed driven gear 23...

Page 786: ...Remove the snap ring 17 and withdraw the splined washer 18 and the second speed driven gear 24...

Page 787: ...Withdraw the roller bearing cage 20 and the shim 25 All the components have thus been removed from gearbox secondary shaft 10...

Page 788: ...Disassembling the gearbox primary shaft Remove washer 26 from the primary shaft...

Page 789: ...Remove the second speed driving gear 28 Use two screwdrivers to prise out the snap ring 17 and the splined washer 18...

Page 790: ...tant Take care to avoid damaging the surface of the shaft while removing the snap ring Remove the sixth speed driving gear 29 with its roller cage 20 Then remove the splined washer 18 and the snap rin...

Page 791: ......

Page 792: ...Withdraw the third and fourth speed driving gear 30 Remove the snap ring 17 and the splined washer 18...

Page 793: ...Remove the fifth speed driving gear 31 with its roller cage 20...

Page 794: ...Slide out washer 25 from the primary shaft 9...

Page 795: ......

Page 796: ...shims 5 and 6 fitted on the shaft Once removed it is possible to replace block ring 7 and special needles 8 Remove gear selector forks 2 and 3 Remove the gearbox primary 9 and secondary 10 shafts com...

Page 797: ...Remove them from the shaft ends and fit them in the relevant bearings on the crankcase half...

Page 798: ...arter clutch 27 on flywheel 23 Bring the starter clutch edge B fully home on the flywheel Position flange 28 on the flywheel and start screws 24 Tighten screws 24 Position rotor 26 on flywheel 23 Appl...

Page 799: ...rankshaft ensuring not to move the internal ring 19 in washer 21 The flywheel assembly must be positioned with the reference sign aligned with the crankshaft groove near the key seat Use engine oil to...

Page 800: ...Block the flywheel rotation with the suitable tool A no 88713 2036 Tighten nut 15 to a torque of 270 Nm Min 256 Nm Max 284 Nm...

Page 801: ...ly Inspect the inner part of generator rotor 8 for signs of damage Check that the starter clutch is working properly and that the roller races do not show signs of wear or damage of any kind Disassemb...

Page 802: ...he generator flywheel by heating it up with an industrial heating gun we recommend not to use naked flame heating methods that could damage the starting components Warning While unscrewing the nut app...

Page 803: ...Remove the inner ring 19 the needle roller bearing cage 20 and the washer 21...

Page 804: ...that the roller races do not show signs of wear or damage of any kind Disassemble the unit if you find faulty operation Disassembling the flywheel generator assembly Unscrew the eight screws 22 and re...

Page 805: ......

Page 806: ...ad a continuous uniform bead of DUCATI sealing compound on the cover mating surface and around the holes of the screws and bushes Tap the cover at different positions with a rubber mallet to facilitat...

Page 807: ...er and hose grommet 7 under screw 5 near the starter motor Tighten the screws in the indicated sequence Tighten to a torque of 13 5 Nm Min 12 5 Nm Max 14 5 Nm Use tool B part no 88713 3394 on the gear...

Page 808: ...bricate oil seal 27 with the recommended product Fit oil seal 27 on the tool orienting it with the spring facing the inner side Fit the oil seal fully home with tool C no 88713 3394 Remove tools B and...

Page 809: ...Make sure that the O ring 28 is installed on the cover 2 Apply grease to the screws 1 Tighten the two fixing screws 1 of the cover 2 matching the crankshaft to a torque of 5 Nm Min 4 5 Nm Max 5 5 Nm...

Page 810: ...Refit the gear shift Refitting the gearbox unit Fill the engine with oil Changing the engine oil and filter cartridge...

Page 811: ...the cover and pointing the cover recess Apply threadlocker on stator retaining screws 9 and tighten them to 10 Nm Min 9 Nm Max 11 Nm Install plate 11 above the cable Before the installation make sure...

Page 812: ......

Page 813: ...stator Remove the stator 10 and the cable guide bracket 11 The generator cover is fitted with a bearing 12 held in place by the circlip 13 which is located on the end of the crankshaft Remove the circ...

Page 814: ......

Page 815: ...tridge Remove the gear shift Removing the gear shift Remove the front sprocket cover Removing the front sprocket cover Undo the two retaining screws 1 of the centre cap 2 over the end of the crankshaf...

Page 816: ...Use tool A no 88713 1749 to the holes of the just removed screws 1 and remove the cover...

Page 817: ...Refitting the starter motor Start retaining screws 2 with specified threadlocker Tighten the screws 3 to a torque of 10 Nm min 9 Nm max 11 Nm Connect the connector 1...

Page 818: ...Removing the starter motor Remove the generator cover Removing the generator cover Remove starter motor connector 1 Loosen screw 3 and the two screws 2 Remove starter motor 4...

Page 819: ......

Page 820: ...Refitting the starter motor idler gear Refitting is the reverse of removal Apply indicated threadlocker to screw 5 of pin 6 and tighten it to a torque of 10 Nm Min 9 Nm Max 11 Nm...

Page 821: ...Removing the starter motor idler gear Remove the snap ring 1 and washer 2 Remove the starter motor idler gear 3 and washer 4 Loosen screw 5 securing pin 6 and remove the latter...

Page 822: ...of the timing layshaft key 4 and the crankshaft key 6 Refitting is the reverse of removal Align the two references of the timing layshaft gears with the camshaft reference On completion of the refitt...

Page 823: ......

Page 824: ...driving gear 1 of the timing gears Straighten out the lock washer 2 of timing gear lock nut 3 Restrain the timing gear by inserting a pin in one of the holes and unscrew the locking nut 3 Slide out n...

Page 825: ...ecessary Install the blow by valve 2 in the crankcase along with O rings 3 previously lubricated Tighten screw 1 to a torque of 10 Nm Min 9 Nm Max 11 Nm Fit nuts 5 on nipples 4 Apply recommended threa...

Page 826: ...readlocker on nipple 6 Tighten oil filter cartridge support nipple 6 to a torque of 42 Nm Min 38 Nm Max 46 Nm Screw the drain plug 12 with seal 13 to a torque of 20 Nm Min 18 Nm Max 22 Nm after applyi...

Page 827: ...switch 14 and the relevant seal 15 by tightening to a torque of 10 Nm Min 9 Nm Max 11 Nm Apply threadlocker to plug 10 start it with the relevant gasket 11 and tighten the plug to a torque of 25 Nm Mi...

Page 828: ...er 9 If previously removed refit the stud bolts 16 on the crankcase halves applying sealant on the thread and tightening to a torque of 30 Nm Min 28 Nm Max 32 Nm Make sure that the O rings 20 are fitt...

Page 829: ...ighten to a torque of 10 Nm Min 9 Nm Max 11 Nm Use a feeler gauge to check the clearance between the engine sensor 17 and the timing gear 23 The value must be between 0 6 and 0 8 mm Fit on the casing...

Page 830: ...n assembly Refit the cylinder heads Refitting the cylinder heads Refit the generator cover Refitting the generator cover Refit the oil pump Refitting the oil pump Refit the clutch cover Refitting the...

Page 831: ...the oil pump Remove the generator cover Removing the generator cover Remove the heads Removing the engine heads Remove the cylinder Removing the cylinder piston assembly Undo screw 1 and remove the b...

Page 832: ...Loosen and remove the oil filter cartridge Loosen and remove oil filter supporting nipple 6 Loosen plug 7 and remove seal 8 Remove the mesh filter 9 from the clutch side crankcase half...

Page 833: ...Loosen plug 10 taking care not to damage seal 11 Remove the drain plug 12 with its seal 13...

Page 834: ...Remove the neutral switch 14 and the relevant seal 15 Remove the cylinder head stud bolts 16 with the aid of the appropriate tool...

Page 835: ...To remove the engine sensor 17 undo the screw 18 and collect the washer 19 Check the condition of O rings 20 on the crankcase half and replace them if necessary...

Page 836: ......

Page 837: ...haft 2 in the roller bearing 29 on the clutch side crankcase half To avoid damaging the sealing ring 23 on the timing layshaft protect the threaded end of the shaft with the special protective cap par...

Page 838: ...x assembly in the crankcase half make sure that the inner races of the gearbox shaft end bearings are fitted into the correct bearings and have not been left on the shafts Match gearbox shafts fit the...

Page 839: ...Insert the forks of 1st 4th and 2nd 3rd speed 38 inside the sliding grooves of the secondary shaft driven gears Insert the fork of 5th 6th speed 39 inside the primary shaft driven gear...

Page 840: ...Fit the fork selector drum 40 with the calculated shims on crankcase half Install pins 41 in the previously installed forks...

Page 841: ...cylinders Check that the two centring bushes 43 are correctly fitted After having duly greased it to hold it in position install the O ring 8 on the oil channel between the two crankcase halves Apply...

Page 842: ...different lengths Start and progressively drive fully home the jointing screws starting with those with a larger diameter M8 Install two M8 screws 3 on the clutch side crankcase half Tighten all screw...

Page 843: ......

Page 844: ...der piston assembly Refit the complete cylinder head assembly Refitting the cylinder heads Refit the flywheel generator assembly Refitting the flywheel generator assembly Refit the oil pump Refitting...

Page 845: ...bearings proceed as follows to determine the total SA height of the shimming Measure value LA between the bearing supporting surfaces on the crankshaft Measure LA1 and LA2 corresponding to the distan...

Page 846: ......

Page 847: ...stalled at the timing layshaft Refitting the generator side crankcase half The following parts must be present on the internal side of the crankcase half the double race ball bearing 11 supporting the...

Page 848: ...Note Bearings do not have a specific mounting position except main bearings however it is good practice to install the bearings so that the written side is facing inwards...

Page 849: ...ring while the crankcase is still hot keeping it perfectly square in its seat using a tubular drift that only bears on the outer ring of the bearing allow the parts to cool and check that the bearing...

Page 850: ...nd 12 on the ends of the gearbox secondary shaft and timing layshaft bearings 15 and 16 When replacing bearings 13 and 14 supporting the gearbox primary shaft block them on the crankcase half with spa...

Page 851: ...aring replacement on the swingarm shaft proceed as follows Chain side crankcase half Fit snap ring 24 in hole 25 Smear specified grease inside hole Fit seal ring 26 and the two bearings 27 and 28 resp...

Page 852: ...Orient the seal ring 26 as shown The arrow refers to the insertion direction...

Page 853: ...Clutch side crankcase half Fit snap ring 31 in the hole Smear specified grease inside hole Fit seal ring 32 and the two bearings 33 and 34 respecting the indicated value...

Page 854: ...Orient the seal ring 32 as shown The arrow refers to the insertion direction...

Page 855: ...he oil pump Remove the generator cover Removing the generator cover Remove the heads Removing the engine heads Remove the cylinder Removing the cylinder piston assembly Remove the starter motor idler...

Page 856: ...generator cover or a service cover with puller A part no 88713 1749 fitted Secure cover to crankcase half with some of the original screws and begin separation by turning the central pin of the tool...

Page 857: ...he gearbox selector drum from the crankcase halves Drive out the crankshaft 6 using a plastic mallet paying attention not to damage washers 7 Remove the timing layshaft 2 Recover O ring 8 in the oil p...

Page 858: ......

Page 859: ...emery cloth and oil Check that the grooves are in perfect condition with no signs of forcing Check that each connecting rod is fitted with its centring pins 8 between cap and the relevant shank If the...

Page 860: ...A each time the engine is overhauled Spare bearings are supplied ready for fitting and they must not be reworked with scrapers or emery cloth Check that the progressive number punched on the two part...

Page 861: ...ting rod big end bearing colour Connecting rod cap big end bearing colour A A RED RED B B BLUE BLUE Insert bearing shells in the connecting rod head matching the tooth 4 with the corresponding marks o...

Page 862: ...e side Fill the recommended grease into the two ends of the hole to lubricate threads and underside of the new screws 3 and the thread of the shaft Warning The grease utilised is irritant in contact w...

Page 863: ...lowing sizes 0 1 mm 0 2 mm 0 3 mm Using a torque wrench as shown in the figure tighten screws 3 to the values specified here below tighten to 35 Nm pause of 2 seconds and 360 loosening pre tighten aga...

Page 864: ......

Page 865: ...measured at 100 mm from the connecting rod longitudinal axis it must be H h lower than 0 02 mm otherwise replace the con rod Connecting rod big end diameter must be within the specified limits It is p...

Page 866: ...scored or grooved The threads keyways and slots must be in good condition Check for fretting or burrs in the fillet between journal and shoulder Fillet radius 1 5 mm Use a micrometer to measure oval a...

Page 867: ...measure the alignment of the main journals by positioning the crankshaft between two centres Loosen all crankshaft plugs 5 6 and 7 heating the crankshaft if necessary to remove the sealant applied at...

Page 868: ...peration use a heat gun able to reach 150 C Clean all the oilways using suitable diameter metal brushes and then blow with compressed air to remove any residues that may have accumulated and are restr...

Page 869: ...Apply specified threadlocker to the threads of plugs 5 6 and 7 then refit them...

Page 870: ...arance between the bearing shells and crankshaft use a strip A of GREEN Plastigage PG 1 on the journal Fit the connecting rod with the original bearings 4 and tighten the screws 3 to a torque of 49 Nm...

Page 871: ......

Page 872: ...d assembly Important Take care not to mix up components of different connecting rods and maintain the original orientation To disassemble the connecting rod assembly loosen screws 3 and separate conne...

Page 873: ...g the clutch Remove the oil pump Removing the oil pump Remove the generator cover Removing the generator cover Remove the heads Removing the engine heads Remove the cylinder Removing the cylinder pist...

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