Husqvarna 2009 TE 250 Workshop Manual Download | Manualshive

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G.2

Part. N. 8000 H0368 (09-2008)

ENGINE OVERHAULING

Cleaning of components

All component must be cleaned with petrol and dried with compressed air.

During this operation inflammable vapours burst out and metal particles may be violently ejected. Consequently, it is
recommended to work in a room free from bare flames or sparks and that the operator wears goggles.

Assemblies

For a good and efficient engine operation, it is essential that all assemblies are within the tolerances prescribed. In fact, a “close” assembly
causes seizures as soon as the moving members heat up; while a “wide” assembly causes vibrations which in addition to being noisy
accelerate the wear of the moving components.

Cylinder head

Remove carbon deposits from the combustion chamber using a rounded
scraper.

Do not use a sharp tool to avoid valve seats and spark plug thread

damaging.

Check the machined surfaces of the cylinder head using a straight edge
and a feeler gauge taking readings at the points shown in the figure. If
the reading at any point is greater than the limit prescribed then regrind
the contact surface with the cylinder. Cylinder head distortion limit: 0.0019
in.

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Summary of Contents for 2009 TE 250

Page 1: ...Workshop Manual TE 250 310 450 510 2009 I E TC 250 450 510 2009 TXC 250 450 510 2009 only USA SMR 450 510 2009 I E Part N 8000 H0368 09 2008 ...

Page 2: ...tor S p a Varese Inc reserves the right to change specifications equipment or designs at any time without notice and without incurring obligation Illustrations in this manual are merely for demonstration purposes and could not exactly match the detail described No part of this manual can de reproduced without permission in writing of the copyright holder 1st Edition 09 2008 ...

Page 3: ...10 2009 I E TC 250 450 510 2009 TXC 250 450 510 2009 only USA SMR 450 510 2009 I E TE 250 ZKHA200AA9V000001 TE 310 ZKHA204AA9V000001 TE 450 ZKHA202AA9V000001 TE 510 ZKHA203AA9V000001 TE 250 USA ZKHKBECF 9V100001 TE 310 USA ZKHKBEDF 9V100001 TE 450 USA ZKHKBEFF 9V100000 TE 510 USA ZKHKBEHF 9V100000 TC 450 ZKHA202AA9V050001 TC 510 ZKHA203AA9V050001 TC 450 USA ZKHTC450 9V100000 TC 510 USA ZKHTC510 9V...

Page 4: ... the improper operation of the motorcycle and formulate proper clearing questions about the symptoms of the trouble detect clearly the cause of the trouble This manual gives the theoretical bases which however shall be integrated by the personal experience and by the attendance to training courses periodically organized by HUSQVARNA rationally plan the repair work in order to prevent dead time as ...

Page 5: ... F Engine overhauling G Engine re assembly H Front suspension I Rear suspension J Brakes L Electric system M Engine cooling system N KITS assembling instructions O Hydraulic control clutch P Optional Parts List Q Fuel injection system S Lubrication system T Specific tools W Torque wrench settings X Frame wheels Y Notes for USA CDN AUS models Z NOTES 1 Where not otherwise specified data and instruc...

Page 6: ...a 4 Part N 8000 H0368 09 2008 FOREWORD SUMMARY ...

Page 7: ...b 1 Part N 8000 H0368 09 2008 IMPORTANT NOTICES Section b ...

Page 8: ...covered with legal guarantee if the STANDARD CONFIGURATION is maintained and the suggested maintenance table shown on chapter B is observed If TE and SMR are transformed in COMPETITION MOTORCYCLES with FULL POWER ENGINE the suggested maintenance table for competition use is shown on chapter B IMPORTANT The reference for recognition of the guarantee will be the MOTORCYCLE CONFIGURATION as shown bel...

Page 9: ...esented on the road In order to maintain the vehicle s Guarantee of Functionality the client must follow the maintenance program indicated in the chapter B by carrying out maintenance checks at authorized HUSQVARNA dealers The cost for substituting parts and for the labour necessary in order to respect the maintenance plan is charged to the client The guarantee is EXTINGUISHED in the case where th...

Page 10: ...b 4 Part N 8000 H0368 09 2008 IMPORTANT NOTICES ...

Page 11: ...A 1 Part N 8000 H0368 09 2008 GENERAL Section A ...

Page 12: ...iming system A 3 Fuel feeding A 3 Lubrication A 3 Cooling A 3 Ignition A 3 Starting A 3 Transmission A 4 A 5 Frame A 6 Suspensions A 6 Brakes A 6 Wheels A 6 Tires A 6 Ignition system electric system A 7 Weights A 8 Overall dimensions A 8 Capacities A 9 ...

Page 13: ...throttle body MIKUNI D42 Type TC TXC 250 carburetor Keihin FCR MX 37 with acceleration pump and T P S Throttle Position Sensor Type TC TXC 450 510 carburetor Keihin FCR MX 41 with acceleration pump and T P S Throttle Position Sensor Dry type air filter LUBRICATION Type Dry sump with two oil pump rotors and cartridge filter COOLING By fluid with double cooler TC TXC By fluid with double cooler and ...

Page 14: ...z 22 27 Gearbox ratios TC 1st gear 1 866 z 28 15 2nd gear 250 1 529 z 26 17 2nd gear 450 510 1 444 z 26 18 3rd gear 1 263 z 24 19 4th gear 1 086 z 25 23 5 th gear 0 954 z 21 22 Final drive Drive between gearbox and rear wheel by 5 8 x 1 4 chain with OR for TE TXC and SMR models Transmission sprocket TE 250 310 450 510 TXC 250 450 510 z 13 Transmission sprocket TC 450 z 14 Transmission sprocket TC ...

Page 15: ...2 356 3rd gear TE TXC 250 TE 310 18 803 3rd gear TE TXC 450 510 13 204 3rd gear TC 250 17 631 3rd gear TC 450 12 357 3rd gear TC 510 11 616 3rd gear SMR 450 510 10 226 4th gear TE TXC 250 TE 310 15 329 4th gear TE TXC 450 510 10 764 4th gear TC 250 15 172 4th gear TC 450 10 633 4th gear TC 510 9 995 4th gear SMR 450 510 8 336 5th gear TE TXC 250 TE 310 12 974 5th gear TE TXC 450 510 9 111 5th gear...

Page 16: ...ependent hydraulic circuit controlled by pedal and pump on the motorcycle right side WHEELS Rims Front TE TC TXC TAKASAGO Excel in light alloy 1 6x21 Front SMR SANREMO in light alloy 3 50x17 Rear TE TXC TAKASAGO Excel in light alloy 2 15x18 Rear TC TAKASAGO Excel in light alloy 1 85x19 250 2 15x19 450 510 Rear SMR SANREMO in light alloy 4 25x17 TIRES Front TE TXC Michelin ENDURO COMP 3 Pirelli MT ...

Page 17: ... on the R H side of the frame Electric fan Two fuses 15A and one 20A on the right side of the rear mudguard Fall sensor SMR on the right side of the rear frame Coolant temperature sensor Lambda probe Headlamp with two filaments bulb of 12V 35 35W and parking light bulb of 12V 3W Rear tail light with stop bulbs of 12V 21W and parking light bulb of 12V 5W Turn signals bulb of 12V 10W Fuel pump insid...

Page 18: ...E 450 kg 112 lb 246 92 TE 510 kg 112 lb 246 92 TC 250 kg 100 lb 220 46 TC 450 kg 104 5 lb 230 38 TC 510 kg 105 lb 231 49 SMR 450 kg 120 5 lb 265 66 SMR 510 kg 120 5 lb 265 66 Dry weight overall width TXC 250 kg 104 7 lb 230 82 TXC 450 kg 110 lb 242 51 TXC 510 kg 111 lb 244 71 TE TC TXC SMR ...

Page 19: ...onditions TC 320 cm3 TE 725 cm3 SMR 740 cm3 Oil for rear shock absorber AGIP FORK 2 5 SAE 2 5 Fluid for cooling system AGIP COOL 2 0 2 4 Imp Pints 2 3 2 7 U S Pints Front brake fluid AGIP BRAKE 4 DOT 4 Rear brake fluid AGIP BRAKE 4 DOT 4 Clutch fluid OLIO MINERALE SAE 10 PER CIRCUITI IDRAULICI Drive chain lubrication AGIP CHAIN LUBE Grease lubrication AGIP BIKE GREASE Electric contact protection A...

Page 20: ...A 10 Part N 8000 H0368 09 2008 GENERAL ...

Page 21: ...B 1 Part N 8000 H0368 09 2008 MAINTENANCE Section B ...

Page 22: ...lines for leakage Throttle control Check operation Throttle control Check Adjust play Choke control Check operation Flexible controls and transmissions Check Adjust Drive chain Check Adjust Tyres Check pressure Side stand Check operation Interruttore cavalletto laterale Check operation Electrical equipment Check operation Instrument panel Check operation Lights Visual signals Check operation Horn ...

Page 23: ... DISENGAGEMENT ROD C DRIVE SPROCKET C S X STARTING GEARS C X PERIODIC MAINTENANCE SCHEDULE SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES AFTER FIRST 3 HOURS 4h MX 8h EN 8h MX 16h EN 16h MX 32h EN 32h MX 64h EN 40h MX 80h EN IF NECESSARY PAGE ITEM EVERY EVERY EVERY EVERY EVERY REPLACE SEE COUPON COUPON COUPON COUPON COUPON TC 450 510 TE TXC 250 450 510 2009 TE 310 2009 COMPETITION MOTORCYCLE RACING ...

Page 24: ... BUSHINGS C REAR CHAIN GUIDE REAR CHAIN GUARD C X REAR SWING ARM PIVOT NEEDLE BEARINGS L REAR SHOCK ABSORBER R REAR SUSPENSION LINKS NEEDLE BEARINGS AND GUDGEON PIN L THROTTLE CONTROL ASSY C L CLUTCH CONTROL ASSY C R PERIODIC MAINTENANCE SCHEDULE SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES AFTER FIRST 3 HOURS 4h MX 8h EN 8h MX 16h EN 16h MX 32h EN 32h MX 64h EN 40h MX 80h EN IF NECESSARY PAGE ITE...

Page 25: ...R HUSQVARNA DEALER FOR THESE SERVICES AFTER FIRST 3 HOURS 4h MX 8h EN 8h MX 16h EN 16h MX 32h EN 32h MX 64h EN 40h MX 80h EN IF NECESSARY PAGE ITEM KEY FOR MAINTENANCE SCHEDULE h HOURS S REPLACEMENT C CHECK C CLEARANCE CHECK P CLEANING R OVERHAUL L GREASING LUBRICATION MX MOTOCROSS EN ENDURO ROTATE 45 THE FASTENING BUSHES NOTE EVERY REMOVAL REPLACE ALL GASKETS REPLACE SCREWS AND NUTS IF WORN GENER...

Page 26: ... SPROCKET C S STARTING GEARS C X PERIODIC MAINTENANCE SCHEDULE SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES ITEM AFTER FIRST 3 HOURS EVERY 5 HOURS EVERY 15 HOURS REPLACE IF NECESSARY AFTER FIRST 1000 KM EVERY 5000 KM EVERY 10000 KM SEE PAGE COUPON COUPON COUPON SMR 450 510 TE 250 450 510 2009 TE 310 2009 STANDARD MOTORCYCLE STREET LEGAL with LIMITED POWER ENGINE SMR 450 510 2009 COMPETITION MOTORC...

Page 27: ... REAR SUSPENSION LINKS NEEDLE BEARINGS AND GUDGEON PIN L REAR SHOCK ABSORBER C THROTTLE CONTROL ASSY C L CLUTCH CONTROL ASSY C R THROTTLE AND STARTING DECOMPRESSOR CABLES C L X FRONT BRAKE DISC C X FRONT BRAKE SYSTEM FLUID C S PERIODIC MAINTENANCE SCHEDULE SEE YOUR HUSQVARNA DEALER FOR THESE SERVICES AFTER FIRST 1000 KM EVERY 5000 KM EVERY 10000 KM AFTER FIRST 3 HOURS EVERY 5 HOURS EVERY 15 HOURS ...

Page 28: ...T 3 HOURS COUPON COUPON COUPON EVERY 5000 KM EVERY 5 HOURS EVERY 10000 KM EVERY 15 HOURS REPLACE IF NECESSARY SEE PAGE KEY FOR MAINTENANCE SCHEDULE h HOURS S REPLACEMENT C CHECK C CLEARANCE CHECKP CLEANING R OVERHAUL L GREASING LUBRICATION MX MOTOCROSS EN ENDURO ROTATE 45 THE FASTENING BUSHES NOTE EVERY REMOVAL REPLACE ALL GASKETS REPLACE SCREWS AND NUTS IF WORN GENERAL CHECK AFTER RACING USE ON M...

Page 29: ...C 1 Part N 8000 H0368 09 2008 TROUBLES AND REMEDIES Section C ...

Page 30: ...locked Clean 2 Fuel cock blocked Clean 3 Fuel feed hose blocked Clean 4 Carburettor fuel filter dirty Clean 5 Worn out float valve or worn out floats Replace 6 Rocker blocking float valve Free Carburettor flooding TC TXC 1 High fuel level in float bowls Adjust 2 Worn out float valve or worn out floats in open position Replace or free Engine cuts out easily 1 Spark plug dirty Clean 2 Electronic con...

Page 31: ... or broken Replace 2 Gearshift forks worn Replace Slips out of gear 1 Sliding dogs worn Replace 2 Gear splines worn Replace 3 Sliding dog seats on gears worn Replace 4 Splines gearshift forks control shaft worn Replace 5 Gearshift forks control pins worn Replace Engine lacks power 1 Air filter dirty Clean 2 Carburettor main jet blocked or wrong size TC TXC Clean or replace 3 Poor quality fuel Repl...

Page 32: ...djust Suspension too soft 1 Insufficient oil in front fork stanchions Top up 2 Too low viscosity of front fork stanchion oil Replace 3 Weak front fork spring Replace 4 Weak rear shock absorber spring Replace 5 Rear shock absorber badly adjusted Adjust Wheel front and rear 1 Wheel rim bent Replace vibrates 2 Wheel hub bearings worn Replace 3 Wheel spokes loose Tighten 4 Wheel axle nut loose Tighten...

Page 33: ...ow 1 Wires to voltage regulator connected incorrectly or not at all or short circuiting Connect correctly or replace 2 Faulty voltage regulator Replace 3 Generator coil faulty Replace Generator charging too high 1 Voltage regulator faulty Replace The battery is discharged fast 1 Battery terminals dirty Clean Start motor won t start or slips 1 Battery flat Recharge TE SMR TXC 2 Control button on ri...

Page 34: ...C 6 Part N 8000 H0368 09 2008 TROUBLES AND REMEDIES ...

Page 35: ...SETTINGS AND ADJUSTMENTS Part N 8000 H0368 09 2008 D 1 Section D ...

Page 36: ...ge filter cleaning or replacement D 16 Coolant level check D 17 Replacement of coolant D 17 Air filter check TC TXC D 18 Air filter cleaning TC TXC D 18 Air filter check TE SMR D 19 Air filter cleaning TE SMR D 20 Secondary transmission chain adjustment D 21 Lubricating the transmission chain D 22 Adjusting the suspensions according to particular track conditions D 23 Adjusting the shock absorber ...

Page 37: ...SETTINGS AND ADJUSTMENTS Part N 8000 H0368 09 2008 D 3 TC TXC TE SMR ...

Page 38: ...NE First turn counterclockwise fastening rear pin 1 then remove the saddle HOW TO REMOVE THE TANK TC TXC Close the fuel tap 2 and loosen the strap 3 on the connecting pipe to the carburettor pull the pipe out of the carburettor Remove the screws 4 and the side panels Remove the locking screw A and pull out the tank with its conveyors 2 4 3 A ...

Page 39: ...s 1 and the side panels Remove the locking screw A of the tank Lift the tank then disconnect the connector of the fuel pump from the main cabling Disconnect the feeding pump B from the outlet coupling C on the fuel pump in the lower back section of the tank Pull out the tank with its conveyors 1 A C B ...

Page 40: ...e gear of the camshafts as illustrated in the figure Check by means of a feeler gauge that the valve clearance is 0 10 0 15 mm for INTAKE and 0 15 0 20 mm for EXHAUST Otherwise lift the retaining clip 7 using a hook let the rocker arm slide to one side extract the pad with a pair of pliers and check the thickness Depending on the result fit a new pad as spare parts pads are supplied rang ing from ...

Page 41: ... be incorrect unblock the counter ring nut and turn the adjusting screw by unscrewing it the clearance is reduced while by screwing screw it is increased the lever holder 5 is provided with the adjuster 6 the adjustment can be also effected with the tightener 7 on the R H side of the engine use this tightener if it is not possible to obtain the correct free play with the adjuster on the handlebar ...

Page 42: ...y screw ing screw 4 it is increased tighten the counter ring nut again 3 Operation with damaged throttle cable could result in an unsafe riding condition Exhaust gas contains poisonous carbon monoxide gas Never run the engine in a closed area or in a confined area In case of throttle control cables 1 and 2 replacement it is necessary to respect during reassembly the measure Á 10mm 0 4 in as shown ...

Page 43: ...ogressively loosen adjusting screw 1 to obtain the slow running required Idle adjustment TC TXC Adjust the carburetor with warm engine and with the throttle control in closed position Proceed as follows turn slow running adjusting screw 1 on the left side of the bike near the fuel cock turn the screw clockwise to increase the rpm and anticlockwise to descrease the rpm 3 TE SMR Idle adjustment TE S...

Page 44: ...brake control pedal Use a 5 mm allen wrench to loosen the six screws 2 that fasten clutch springs Remove springs pressure plate 3 complete with bearing and clutch control rod 4 Extract the discs 5 lubricate the new discs with engine oil then assemble the new discs first always mount a lined disc Reassemble pressure plate and springs Tighten the clutch springs bolts whilst following a cross over pa...

Page 45: ...KWISE To check the fluid level proceed as follows remove screws 1 cover 2 and rubber pump diaphragm on the handlebar clutch control by keeping the master cylinder 3 in horizontal position check the fluid level is NOT BELOW 4 mm 0 16 in from the upper surface D of the pump body if necessary add fluid until the correct level is reached see page A 9 TABLE FOR LUBRICATION and SUPPLIES for the fluid ty...

Page 46: ...ear side of the pump body TE TC and TXC For SMR model check the level on the fluid reservoir A decrease of the fuel level will let air into the sustem hence an extension of the level stroke If the brake lever feels mushy when it is applied there may be air in the brake lines or the brake may be defective CHECK THE BRAKING SYSTEM page L 2 If the lever free play is excessive the brake action can dec...

Page 47: ...e pedal as to the footrest may be adjusted according to the individual needs For the adjusting proceed as follows loosen the screw 1 turn the cam 2 in order to adjust the brake pedal idle stroke A the operation done tighten the screw 1 The adjusting operation carried out adjust the idle stroke of the pedal as shown on page D 19 ...

Page 48: ... idle stroke before starting the true braking action Should this not happen proceed as follows loosen nut 3 operate the pump rod 4 to increase or decrease the idle stroke tighten nut 3 at the end of the operation When the idle stroke figures are not met the brake pads will be subjected to a fast wear that may bring to the TOTAL BRAKE INEFFICIENCY If the brake pedal feels mushy when it is applied t...

Page 49: ...ping the motorcycle on a flat surface in vertical position remove the control screw 1 and check the oil should just barely escape from the hole on the R H cover To fill up remove the filler cap 2 Have this operation made with warmed up engine Be careful not to touch hot engine oil MAX MIN 1 2 ...

Page 50: ...he cap remove the three filters 5 6 and 7 on the L H side of the engine check O Rings for wear then clean filters with fuel Reassemble using the reverse procedure In order to replace the filter cartridge 4 unscrew the three fastening screws then the filter cartridge cover after filters replacement reassemble the drain cap 3 the engine guard A then pour the recommended oil quantity Reassemble on en...

Page 51: ...F position always keep a safe distance from the fane vanes Difficulties may arise in eliminating coolant from varnished surfaces If this occurs wash off with water Replacement of coolant Place a vessel on the R H side of the cylinder under the coolant drain screw 3 FIRST remove the screw 3 then SLOWLY open the R H radiator cap 4 slope the motorcycle on the right side to drain the coolant easily in...

Page 52: ...lter 5 from frame 6 AIR FILTER AND CLEANING Wash filter with a specific detergent AGIP Filter clean foam air detergent fluid or similar then dry it fully wash filter with gasoline only in case of necessity Plunge filter in special oil for filters AGIP Foam air filter protection oil or simi lar then wring it to drain superfluous oil Do not use gasoline or a low flash point solvent to clean the elem...

Page 53: ... 3 and the filter 4 Separate filter 5 from the exhaust silencer 6 ASSEMBLY To ensure tight fit slightly C grease filter edge on side facing filter housing While re inserting the filter into its housing make surs that piece A is turned upwards and edge B is on the left lower side of the filter case Reassemble the parts previously removed battery connect the positive cable first If the element assem...

Page 54: ...o clean the element A fire or explosion could result Clean the element in a well ventilated area and do not allow sparks or flames anywhere near the working area ASSEMBLY To ensure tight fit slightly C grease filter edge on side facing filter housing While re inserting the filter into its housing make surs that piece A is turned upwards and edge B is on the left lower side of the filter case Reass...

Page 55: ...ee times the rear wheel Now the chain should not be tight Fig A Fast adjustment Fig B Insert a bushing a with a 35 mm diameter or with the same thickness as shown in the image and make sure the lower section C of the chain is slightly taut If this is not the case proceed as follows loosen the nut 1 of the wheel axle on the right side with a 27 mm Allen wrench loosen the check nuts 2 on both chain ...

Page 56: ...ean and lubricate the chain to prevent oxidation Washing the chain with OR TXC TE SMR Wash using oil diesel oil or paraffin oil Never use gasoline tricloroetilene or solvents as the OR may suffer damages Use instead special sprays for chains with OR Lubricating the chain without OR TC First dry then plunge the chain in a bisulphide molybdenum lubricant or in high viscosity engine oil Warm up the o...

Page 57: ...same time Shock absorber have a harder compression and expecially a harder extension adjustment Work on the spring preload to lower the motorcycle rear side MUDDY GROUND Fork have a harder compression adjustment or replace the standard spring with a harder one Shockabsorber haveahardercompressionandextensionadjustments orreplace the standard spring with a harder one Work on the spring preload to l...

Page 58: ...1 With motorcycle on the stand measure distance A 2 Take the normal riding position on the motorcycle with all your riding apparel 3 With somebody s help take the new distance A 4 The difference between these two measurements constitutes the SAG of the motorcycle s rear end Suggested SAG 4 in with cold shock absorber 3 7 in with warmed up shock absorber 5 To get the right SAG according to your wei...

Page 59: ...loosen the screws 2 and remove the right side panel 3 2 TC TE TXC SMR Clean the ring nut 4 and the adjusting ring nut 5 of the spring 6 3 TC TE TXC SMR Loosen the check ring nut with a hook wrench or with an aluminium punch 4 Turn the adjusting ring nut as required 5 TC TE TXC SMR after adjusting according to the weight or riding style of the rider tighten the check ring nut tightening torque 5 Kg...

Page 60: ...er 3 To reset the standard calibration turn upper adjusters 1 and 3 clockwise until reaching fully closed position Return then back for the mentioned clicks In order to obtain a smooth braking action turn the adjusters anticlockwise Reverse the operation in order to obtain a harder braking action B EXTENSION Standard calibration 18 clicks 2 clicks To reset the standard calibration turn lower adjus...

Page 61: ...ibration turn register C clockwise to reach the position of fully closed then turn back by the mentioned clicks To obtain a smoother brak ing action turn the register anticlockwise Reverse the operation in order to obtain a harder action c AIR VENT to carry out after each competition or monthly TE SMR Set the motorcycle on its central stand fully extend the fork and loosen the valve D Tighten the ...

Page 62: ...TMENTS Front fork springs STANDARD K 4 5 N mm TE A spring spacer code 8000 B1713 K 4 8 N mm TXC 250 A spring spacer code 8000 B1690 K 5 0 N mm TC TXC 450 510 A spring spacer code 8000 B1716 K 5 0 N mm SMR A spring spacer code 8000 A7608 TC TXC TE SMR ...

Page 63: ...m in the perpendicu lar direction to their axis If play is noticed proceed with adjustment as follows loosen steering sleeve nut 1 loosen four screws that fix steering head to fork rods 3 turn the steering ring nut 2 clockwise of the steering sleeve using a proper tool to adjust play properly tighten steering sleeve nut 1 to a torque setting of 57 9 65 1 Lb ft 78 4 88 3 Nm tighten four screws on t...

Page 64: ...clamp 1 lower screw 4 then lower clamp 2 a Handlebar position change Turn the lower clamp 2 180 to move forward or backward 10 mm 0 04in the handlebar position with respect to the original setup b Handlebar height change Remove the lower spacer A then replace the screw 4 with a new one of L 65 mm 2 56 in height Once these operations are completed tighten the screws 3 to 2 75 3 05 kgm 27 30Nm 19 9 ...

Page 65: ...SETTINGS AND ADJUSTMENTS Part N 8000 H0368 09 2008 D 31 Checking the fuel hose Check the hose 1 for leaks and replace it if necessary Remove the fuel hose as shown on page E 23 1 ...

Page 66: ...de and a 10 mm T shaped spanner on the inside remove the locking screw 4 of the muffler Remove the spring 5 and with an 8 mm T shaped spanner remove the screw 8 then pull out the muffler Remove the six rear rivets 6 clamp and the exhaust terminal 7 Remove innner pipe and replace the deadening material Reassemble L H side panel and saddle When diffuculties are found in removing the muffler lightly ...

Page 67: ...panel 3 do the same on the right side Using an 8 mm T shaped spanner on the outside and a 10 mm T shaped spanner on the inside remove the locking screw 4 of the muffler Remove the spring 5 and pull out the muffler A o B Remove the four rear rivets 6 clamp and the exhaust terminal 7 Remove innner pipe and replace the deadening material Reassemble L H side panel and saddle When diffuculties are foun...

Page 68: ...2008 SETTINGS AND ADJUSTMENTS 1 2 3 4 5 Checking the exhaust system Remove the exhaust system components as shown on page E 20 Check the exhaust pipe 1 2 3 4 and silencer 5 for wear or damages Replace the component if necessary ...

Page 69: ...E 1 Part N 8000 H0364 09 2008 GENERAL OPERATIONS Section E ...

Page 70: ... E 16 Removal of rear frame with fender TE SMR with tail light and air filter box assy E 17 Removal of exhaust system E 20 Removal of fuel tank conveyors and spoiler E 23 Removal of cooling fan TE SMR radiators and coolant expansion tank TE SMR E 25 Removal of electronic power unit C D I electronic coil voltage regulator and clutch hose E 26 Removal of secondary drive chain E 26 ...

Page 71: ...rom the motorcycle Nevertheless in the case is had to effect operations on some parts of the motorcycle as the access to the rear shock absorber to the electric parts to the wiring harness etc it can be necessary to effect some partial dismantlements The descriptions that refer to these operations are listed beginning from the page E 15 LATO SINISTRO TE ...

Page 72: ...then the RED positive cable when reassembling first connect the RED positive cable then the BLACK negative cable release the elastic 5 and remove the battery 6 from its hous ing TXC After battery removal push ONCE THE ENGINE START BUTTON in or der to discharge the condenser 7 fastened near the H T coil 8 After battery disassembly DO NOT remove the condenser from the frame in case of engine startin...

Page 73: ...e to stop fuel flowing and loosen the clamp 3 on the carburettor fuel pipe remove this pipe from the carburettor and pour the remain ing fuel into a container Remove the fuel tank fastening screw 4 and pushing upward slightly in the front zone of the conveyors release them from the spoilers on the radiators Remove the fuel tank assy with conveyors 1 2 3 4 ...

Page 74: ...rom the fuel tank by slightly pressing upward in the front area of conveyors and release the conveyors from spoilers on radiators Disconnect the fuel pump connector from the main cable Disconnect the feed line B from the outlet fit ting C on the fuel pump on the lower rear part of the tank Extract the tank with the conveyors 1 2 C B ...

Page 75: ...TE TC TXC using an 8 mm T shaped spanner on the outside and a 10 mm T shaped spanner on the inside remove the locking screw 1 of the muffler 4 Remove the spring 2 and with an 8 mm T shaped spanner remove the screw 3 then pull out the muffler 4 1 4 2 3 4 ...

Page 76: ... pipes 6 and 7 from the cylinder head by gently hitting outward A 5 5 8 9 6 7 8 5 9 7 5 6 3 SMR use an 8 mm T wrench outside and a 10 mm T wrench inside to remove the fastening screw 1 of silencers 3 and 4 Remove the spring 2 and extract silencers 3 and 4 Remove the springs 5 that retain front pipes 6 and 7 to intermediate pipe 8 1 3 1 4 3 2 4 2 ...

Page 77: ...torcy cle Remove the carburetor floater chamber lower screw 5 the floater cham ber then eliminate the remaining gasoline 4 Remove the fastening pin 8 and the rear brake pedal 4 TE SMR loosen the left clamp 1 of the sleeve on the throttle body and the front clamp 2 on the cylinder head Disconnect the connector from the M A Q S 6 on the throttle body of the main cable Remove the throttle body 7 when...

Page 78: ... 1 Using a 8 mm wrench FIRST remove the screw 1 then SLOWLY open the R H radiator cap 2 slope the motorcycle on the right side to drain the coolant easily in the vessel Loosen lower clamps 3 of the hoses that connect the radiators to the engine Loosen the clamp 4 of the upper hose that con nects the L H radiator to the water pump 1 3 4 ...

Page 79: ... plug 2 and eliminate the used oil on the L H side of the engine using a 8 mm wrench remove the rear filter cover screws 3 and extract the steel filter 4 and the net filter 5 Still operating on the L H side of the engine using a 6 mm Allen wrench un screw the plug 6 then remove the net filter 7 and the O Ring on the R H side of the engine unscrew the three fastening screws 8 and remove the cover a...

Page 80: ... fasten guide chain plate Using a 8 mm wrench remove the three screws 6 that fasten the clutch control on the engine and eliminate the remaining fluid from the hose TE SMR TXC detach the electrical connections from the starting motor use a 8 mm wrench to remove the ground cable 8 and a 10 mm wrench to remove the nut under the rubber cap 9 Remove the clutch hose alternator cable connecting clamps 1...

Page 81: ...0364 09 2008 GENERAL OPERATIONS 8 TE SMR disconnect the cooling fan 1 from the main wiring harness Detach the thermoswitch 2 from the main wiring harness Remove the two screws 3 and the coolant expansion tank 4 1 1 3 4 2 ...

Page 82: ...n unscrew the fastening bolts 3 engine frame Remove the upper clamp 5 of the shock absorber Remove the guards 4 by removing the clamp to the frame use a 22 mm wrench on the left side unscrew the nut from the fork pin extract the axle from the R H side then pull back the rear swing arm in order to facilitate the engine disassem bly from the frame Lift the engine slope it on the L H side and remove ...

Page 83: ...cable when reassembling first connect the RED positive cable and then the BLACK negative cable remove the battery 3 from its housing TXC After battery removal push ONCE THE ENGINE START BUTTON in or der to discharge the condenser 4 fastened near the H T coil 5 After battery disassembly DO NOT remove the condenser from the fra me in case of engine starting in this condition the voltage regulator wi...

Page 84: ... 8000 H0364 09 2008 GENERAL OPERATIONS Removal of side panels Turn rear pin A counterclockwise and remove the saddle from the front fasten ing screw Loosen the screws 2 and remove the side panels 3 and 4 1 2 2 3 4 ...

Page 85: ...he battery A from the electric system as shown on page E 14 Remove the side panels as shown on page E 15 Remove the fuel tank as shown on page E 23 TE TC TXC SMR use an 8 mm T wrench and a 10 mm T wrench inside to remove the fastening screw 1 of silencers 4 Remove the spring 2 and use an 8 mm T wrench to remove also the screw 3 then extract the silencer 4 1 4 2 3 4 ...

Page 86: ...m wrench to remove the earth cable 5 and a 10 mm wrench for the nut under the rubber cap 6 remove the clamps A that hold the clutch pipe and the alternator cable 5 A 6 SMR use an 8 mm T wrench and a 10 mm T wrench inside to remove the fastening screw 1 of silencers 3 and 4 Remove the spring 2 and extract silencers 3 and 4 1 3 1 4 3 2 4 2 ...

Page 87: ... Without disconnecting them from the cabling system remove the voltage regu lator 9 the electronic CDI central unit 8 with the elastic support of the frame Loosen the clamp 10 that holds the rubber fitting from the filter box on the carburettor or on the throttle body 9 8 B C 7 10 10 Use a 12 mm box wrench to remove the upper 11 and lower 12 fasteners from the rear frame Pull the rear frame back a...

Page 88: ...rt N 8000 H0364 09 2008 GENERAL OPERATIONS Removal of exhaust system Remove the saddle as shown on page E 15 Remove the R H side panel TE TC TXC or both the side panels SMR as shown on page E 16 TE TC TXC SMR ...

Page 89: ...RAL OPERATIONS TE TC TXC use an 8 mm T wrench outside and a 10 mm T wrench inside to remove the fastening screw 1 of silencer 4 Remove the spring 2 and use an 8 mm T wrench to remove also the screw 3 then extract the silencer 4 1 4 2 3 4 ...

Page 90: ...ipes 6 and 7 from the cylinder head by gently hitting outward A 5 5 8 9 6 7 8 5 9 7 5 6 3 SMR use an 8 mm T wrench outside and a 10 mm T wrench inside to remove the fastening screw 1 of silencers 3 and 4 Remove the spring 2 and extract silencers 3 and 4 Remove the clamps A that the hold front pipes 6 and 7 to the intermediate pipe 8 1 3 1 4 3 2 4 2 ...

Page 91: ... the fuel tap 2 anticlockwise to stop fuel flowing and loosen the clamp 3 on the carburettor fuel pipe remove this pipe from the carburettor and pour the remaining fuel into a container Loosen the fastening screws 6 of the fuel tank Remove the screws 4 holding conveyors to the tank remove the conveyors 7 the screws 5 holding spoilers 8 to radiators Remove the spoilers and extract the tank 2 3 1 6 ...

Page 92: ...ank Remove the screws 4 holding the conveyors to the tank remove the conveyors 7 the screws 5 holding spoilers 8 to radiators Re move the spoilers Disconnect the connector of the fuel pump from the main cable Disconnect the feed line B from the outlet fitting C on the fuel pump on the lower rear part of the tank the feed line Extract the tank C B ...

Page 93: ...wiring harness remove the fan from its holding plate Detach the thermoswitch 2 from the main wiring harness Remove the grid 3 detach the breather hose 4 the other hoses A from the radiators remove the three screws 5 and the R H radiator Repeat the same operations to remove the L H radiator TE SMR remove the two screws 6 and the coolant expansion tank 7 2 1 5 4 A 7 A 6 A 3 A ...

Page 94: ... the spark plug Detach the voltage regulator electrical 3 connection from the main wiring harness the screw and voltage regulator Remove the fastening screw and the ignition coil 4 Unscrew the clutch hose union 5 on the L H side of the engine Drain the fluid from the hose When reassembling bleed the clutch system as shown on page P 7 2 1 3 4 Removal of secondary drive chain To remove the transmiss...

Page 95: ...F 1 Part N 8000 H0368 09 2008 ENGINE DISASSEMBLY Section F ...

Page 96: ...art pedal disassembly TC TE TXC F 12 Transmission cover disassembly F 13 Clutch disassembly TC TE TXC SMR 450 510 F 13 Kick start components disassembly TC TE TXC F 15 Electric starting system disassembly TE TXC SMR 450 510 F 16 Oil pump disassembly F 17 Gear control pedal and gear shifter disassembly F 18 Primary transmission driving gear disassembly F 20 Crankcase disassembly F 21 Gearbox disass...

Page 97: ...F 3 Part N 8000 H0368 09 2008 ENGINE DISASSEMBLY ...

Page 98: ... disassembly Remove the six fastening screws 8 mm wrench and the alternator cover Using a17mmwrench positionthepistonatT D C attheendofthecompressionstroke in this condition the mark on the cylinder head is aligned with the two marks on the idle gear of the camshafts as shown in the figure on page F 7 Remove the spark plug 16 mm wrench and the lubrication hose from the cylinder head 13 mm wrench ...

Page 99: ...nsioner 10 mm wrench then remove the two fastening screws 8 mm wrench and the cam chain tensioner assembly Remove the eight fastening screws of the camshaft clamps 5 mm wrench and the clamps themselves using these same screws Remove the lubricating tube Remove the camshafts ...

Page 100: ...er pump body disassembly Loosen the hose water pump cylinder head clamp and remove the hose from cylinder head Remove the two fastening screws 8 mm wrench and the water pump body from the cylinder head Remove the timing driven gear Water pump rotor fastening nut 4 9 Nm 0 5 Kgm 3 6 ft lb LOCTITE 243 ...

Page 101: ...oolant fluid temperature sensor with its O ring Remove the two screws on the L H S 8 mm wrench then the front nut under the cylinder head 13 mm wrench Remove the four inner screws on the cylinder head 10 mm wrench whilst following a cross over pattern Remove the cylinder head and relative gasket ...

Page 102: ...NE DISASSEMBLY Valve disassembly Using a hook remove the rocker arm spacer clip Remove the fastening screw 5 mm wrench and the chain slider Remove the fastening screws 6 mm wrench then the rocker arm axles and the rocker arms themselves ...

Page 103: ...ure that the valve spring compressor is always straight otherwise the valve stem can bend To prevent loss of tension do not compress the valve springs more than necessary Mark all parts so that they can be reassembled correctly If the valve cotters have made a burr on the valve stem remove it before removing the valve Remove the sealing gaskets from the valve guides Remember to replace the gaskets...

Page 104: ...68 09 2008 ENGINE DISASSEMBLY Cylinder disassembly Afterhavingremovedthecylinderheadgasket removethetwodowelbushingsand the cylinder itself Piston disassembly Remove the piston pin clips then the piston pin and the piston ...

Page 105: ...7 mm wrench Remove the rotor using the puller code no 8000 A1559 for TC TXC and 8000 B0144 for TE SMR Remove the valve timing pinion using a puller If the chain slider is worn remove the fastening screw then the chain slider in order to replace it Chain slider fastening screw 3 Nm 0 3 Kgm 2 1 ft lb Remove the timing system chain ...

Page 106: ...F 12 Part N 8000 H0368 09 2008 ENGINE DISASSEMBLY Kick start pedal disassembly TC TE TXC Remove kick start pedal fastening screw 4 mm wrench washer and kick start pedal ...

Page 107: ...wrench then the transmission cover Remove gasket dowel bushings and O Rings Clutch disassembly TE TXC TC SMR 450 510 Remove the six screws 12 that fasten the springs 11 5 mm wrench whilst following a cross over pattern and in steps Remove the pressure plate 10 with the bearing and the clutch control cap 9 Remove clutch discs 8 ...

Page 108: ...trol rod 13 Bend back tabs of the hub washer 6 and holding the clutch hub nut 27 mm wrench remove the nut 7 using the clutch disassembly tool A code no 8000 79015 Remove the washer 6 the clutch hub 5 the grooved washer 4 the clutch housing 3 the bushing 2 and the washer 1 ...

Page 109: ... 8000 H0368 09 2008 ENGINE DISASSEMBLY Kick start components disassembly TC TE TXC Release spring 1 from seat on crankcase A and remove kick starter shaft assy 2 Remove circlip 3 washer 4 and starting idle gear 5 ...

Page 110: ... H0368 09 2008 ENGINE DISASSEMBLY Electric starting system disassembly TE TXC SMR 450 510 Remove the four fastening screws 8 mm wrench and starting gears retaining plate Extract the starting gear and starting idle gear ...

Page 111: ...ning screws 8 mm wrench and extract the starting motor Oil pump disassembly Using pointed pliers remove the oil pump idle gear circlip then the idle gear Remove the three fastening screws 8 mm wrench and extract the oil pump body the gasket the two bushes and the oil pump ...

Page 112: ...he position of the gear control pedal to make the reassembly easier Remove the fastening screw 8 mm wrench and the gear control pedal from the gear shifter shaft Extract from the R H S the gear shifter shaft and the bushing from the ratchet wheel Remove the two fastening screws the gear shifter retaining plate and the ratchet wheel ...

Page 113: ...t N 8000 H0368 09 2008 ENGINE DISASSEMBLY Remove the gear shifter drum fastening bolt 5 mm wrench Remove the fastening screw and the gears pawl together with its spring Pay attention for not to lose the roller ...

Page 114: ...lace an aluminium shim between the teeth of the free wheel gear in order to prevent its rotation and loosen the fastening nut 27 mm wrench left side thread nut Remove the driving gear and the free wheel mark the reassembly direction the free wheel gear the needle bearing the washer and the spacer ...

Page 115: ...Crankcase disassembly Remove the circlip from the secondary shaft R H S Remove the drive sprocket circlip and the drive sprocket from the secondary shaft Extract the drive sprocket spacer Remove the twelve screws from the L H crankcase side 8 mm wrench ...

Page 116: ...her the following pictures show the correct disassembling sequence Secondary shaft fork pin Secondary shaft forks Fix the crankcase puller code no 1517 94702 in the holes of the flywheel cover and pull off the L H crankcase side During this operation lightly strike the secondary shaft at intervals using a rubber hammer to avoid the crankcase from getting stuck ...

Page 117: ...F 23 Part N 8000 H0368 09 2008 ENGINE DISASSEMBLY Primary shaft fork pin Selector drum Primary shaft fork Extract the primary and secondary shaft assemblies ...

Page 118: ... and counter balancing shaft disassembly SMR 450 510 Place the puller bushing on the R H S of the crankshaft Fix the puller on the crankcase half and push out th crankshaft strike lightly the layshaft with a rubber hammer in order to avoid it from getting stuck ...

Page 119: ...r disassembly tool and extract the idle gear Place the crankshaft in a suitable position and press the crankpin out of one of the crankshaft flywheels Remove the connecting rod with the needle bearing from the flywheel then turn the flywheel over half and press out the crankpin ...

Page 120: ...F 26 Part N 8000 H0368 09 2008 ENGINE DISASSEMBLY ...

Page 121: ...Cylinder piston fitting G 12 Gudgeon pin G 13 Piston rings G 14 Piston rings cylinder clearance G 14 Piston ring Piston rings groove clearance G 15 Gudgeon pin connecting rod small end clearance G 15 Connecting rod big end radial clearance G 15 Connecting rod big end side clearance G 16 Crankshaft G 16 Connecting rod small end bush replacement G 17 Clutch unit G 18 Clutch housing friction disc cle...

Page 122: ...ribed Infact a close assembly causes seizures as soon as the moving members heat up while a wide assembly causes vibrations which in addition to being noisy accelerate the wear of the moving components Cylinder head Remove carbon deposits from the combustion chamber using a rounded scraper Do not use a sharp tool to avoid valve seats and spark plug thread damaging Check the machined surfaces of th...

Page 123: ...83 in Recutting the valve seats Clean carbon and deposits from the valves Apply some Prussian blue to the valve face and lap it against the seat with a suitable lapping tool Remove the valve and measure the width X of the contact surface If the width exceeds 0 06 in the seat should be recut Standard width of the contact surface is A 0 0354 0 0433 in for the INTAKE A 0 0354 0 0394 in for the EXHAUS...

Page 124: ...valve is in the right place on the valve Use marking colour to determine where is the contact surface The contact surface should be 0 02 in from the edge of the valve If the contact surface is too low recut the seat with the 73 and the 45 cutters If the contact surface is too high recut the seat with the 20 and the 45 cutters Make sure that the width of the contact surface is correct ...

Page 125: ...alve 250 310 450 510 nominal clearance 0 000315 0 00138 in Wear limit 0 002 in Exhaust valve 250 310 450 510 nominal clearance 0 0007 0 00177 in Wear limit 0 003 in Replacement of valve guides Use a suitable drift and drive out the guide from the cylinder head Make sure that the cylinder head isn t damaged Heat the cylinder in an oven to 170 C 338 F Use a suitable drift and install a new valve gui...

Page 126: ...by resting it on a Vee block and measuring the distortion with a comparator Wear limit 0 0019 in Check the concetricity of the valve head by resting an angle comparator against the head and then rotate the valve in a Vee block Wear limit 0 0012 in Valve spring Check the free length L If this does not correspond to the prescribed limits then substitute the springs 250 310 cc spring L 1 38 in Wear l...

Page 127: ...Lubricate the valve guides and valve stem with oil when the valve is installed Install the seal ring the springs and the cup Use tool code 8000 39521 to compress the valve springs and can install halves cones Do not compress the valve springs more than necessary Do not damage the cylinder head ...

Page 128: ...he clearance between the rockerarm and the rocker arm shaft Measure the inner diameter of the rocker arm and the outer diameter of the rocker arm shaft and accurately determine the clearance Maximum clearance 0 04 in If greater replace the two rocker arms When reassembling tighten rocker arm axles to 25 Nm 2 55 Kgm18 4 ft lb LOCTITE 243 Starter decompressor Check that starter decompressor rotate f...

Page 129: ...haft between two references and then check deviation using two comparators Wear limit 0 0039 in Check that the cams are in good conditions without wear or deformation Cam height H INTAKE new 36 57 mm 1 440 in 450 510 36 69mm 1 444 in 250 310 EXHAUST new 35 94 mm 1 415 in 450 510 and 250 310 A INTAKE B EXHAUST A B INTAKE EXHAUST ...

Page 130: ...nd metal is visible in the bottom of the wear marks Camshaft chain and gearing At every engine overhaul the wear of the camshaft gear teeth and the chain rollers should be checked If the teeth are badly worn then replace the three components Hold the chain taut and check the length of 20 links 21 pins If any one of three cam drive components is found to be worn then all three components should be ...

Page 131: ... taper wear limit 0 0019 in Max ovality wear limit 0 0019 in If the wear limits are greater than those prescribed then replace the cylinder with the piston reboring the cylinder liner is not possible since the cylinder liner has been given a special hardening treatment Piston Thoroughly clean the piston crown and piston ring grooves of any carbon de posits Carry out a visual check and a measuremen...

Page 132: ...in 450 510 cc Piston diameter Take the piston diameter Dp at B distance of 6 mm 0 24 in TE TC TXC 250 8mm 0 31in TE SMR450 510 9mm 0 35in TE310 TC TXC450 510 from the top The clearance is Dc Dp MODEL CLEARANCE Dc Dp WEAR LIMIT 250 0 020 0 046 mm 0 10 mm 0 00079 0 00181 in 0 004 in 310 0 037 0 063 mm 0 15 mm 0 00146 0 00248 in 0 006 in 450 510 0 025 0 055 mm 0 12 mm 0 0010 0 0022 in 0 0047 in ...

Page 133: ...G 13 Part N 8000 H0368 09 2008 ENGINE OVERHAULING Gudgeon pin The gudgeon pin should be perfectly smooth without scoring grooving or bluish discoloration caused by overheating ...

Page 134: ...n rings cylinder clearance PISTON RING NOMINAL CLEARANCE H WEAR LIMIT A TE TXC 250 TE 310 0 20 0 35 mm 0 5 mm 0 00787 0 0138 in 0 0197 in A TE SMR 450 TC TXC 510 0 25 0 40 mm 0 7 mm 0 0094 0 00157 in 0 027 in A TE SMR 510 0 20 0 45 mm 0 7 mm 0 00787 0 0177 in 0 027 in B TE SMR 450 0 40 0 55 mm 1 mm 0 00157 0 0216 in 0 0394 in B TE SMR 510 0 20 0 45 mm 0 7 mm 0 00787 0 0177 in 0 027 in C TE TXC 250...

Page 135: ... 011 0 033 mm 0 07 mm 0 00043 0 00130 in 0 0027 in A TE 310 0 020 0 060 mm 0 11 mm 0 000787 0 00236 in 0 0043 in A TC TXC 450 510 0 070 0 110 mm 0 22 mm 0 00027 0 0043 in 0 0087 in A TE SMR 450 0 065 0 100 mm 0 24 mm 0 00256 0 00394 in 0 009 in A TE SMR 510 0 030 0 065 mm 0 13 mm 0 00012 0 0025 in 0 0051 in B TE SMR 450 0 035 0 070 mm 0 15 mm 0 00138 0 00027 in 0 0059 in B TE SMR 510 0 020 0 055 m...

Page 136: ...clearance Crankshaft Main joiurnals must not present any scores or grooves their threads key seats and slots have to be in good conditions STANDARD LIMITE DI SERVIZIO 0 300 0 677 mm 0 75 mm 0 012 0 027 in 0 03 in Crankshaft run out STANDARD WEAR LIMIT 0 05 mm 0 0019 in 0 05 mm 0 05 mm 0 05 mm Al di sotto di 0 02 mm ...

Page 137: ...lfide grease Insert the bush from the side marked with the elephant and check that the bush holes coincide with the ones of the rod The clearance between the bush and its seat is 0 00138 0 00366 in for 250 310 cc models and 0 00193 0 00374 for 450 510 cc models Ream the bush to an internal diameter C as indicated on table MODEL INNER DIAMETER C 250 310 16 012 16 022 mm 0 6304 0 6308 in 450 510 20 ...

Page 138: ...ck the thickness of the clutch lining discs Thickness of new plate 0 118 in Wear limit 0 114 in Check the distortion of each plate both lined and unlined by resting on a flat surface use a feeler gauge Wear limit 0 2 mm 0 00078 in Clutch housing friction disc clearance Clutch spring Check the free lenght L of each spring with a gauge New spring L 1 61 in Wear limit 1 53 in Replace any spring which...

Page 139: ...part 5 Clutch disc hub check the housing grooves of discs without friction material for wear or failure If worn or breaked replace the part 6 Clutch disc housing Check the housing grooves of discs with friction material for wear or failure Check the needle bearings seats for wear If worn or breaked replace the clutch disc housing 7 Set of matched primary Check the teeth gear for wear and failure I...

Page 140: ...l inspection of the gear selector forks any bent forks should be replaced A bent fork will make gear changing difficult and can cause the gear to disengage without notice under power Use a feeler gauge to check the clearance between each selector fork and the groove on its gear If the prescribed wear limit is exceeded for any one of the three gears then it is necessary to establish whether the gea...

Page 141: ...s of metal wires Check that the gate valve is in good condition and runs freely in its housing but without excessive clearance Check that the pin and spray nozzle are in good conditions Check that the pin valve has a good seal CARBURETTOR SETTING KEIHIN TC TXC 1 Main jet 175 250 180 450 510 2 Idle jet 42 250 45 450 510 3 Starting jet 72 250 85 450 510 4 Main air jet 200 5 Throttle valve 15 M 6 Tap...

Page 142: ...ns 450 510 progressively loosen adjusting screw 1 to obtain the slow running required NOTE An incorrect idle jet size could cause troubles of starting of the engine In this case if turning the screw 2 no engine speed change is obtained a smaller idle jet has to be installed if the engine stops when the screw 2 is not yet completely turned a larger idle jet has to be installled After the idle jet r...

Page 143: ... solvent for cleaning Blow out all passages and jets with compressed air Never use a wire 2 Inspect Main jet 1 Pilot jet 2 Needle jet 9 Pilot screw 7 Starter jet 3 Main air jet 4 Pilot air jet 8 Damage Replace Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with compressed air Never use a wire ...

Page 144: ... 9 and valve seat c Grooved wear a Replace Dust b Clean THROTTLE VALVE Check for free movement Stick Repair or replace Insert the throttle valve 5 into the carburetor body and check for free movement JET NEEDLE Inspect jet needle 6 Bends Wear Replace Standard clip position 4th Groove ...

Page 145: ...in the needle valve resulting in an incorrect measurement Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE Thefloatarmshouldberestingontheneedlevalve butnotcompressingtheneedle valve Ifthefloatheightisnotwithinspecification inspectthevalveseatandneedlevalve If either is worn replace them both If both are fine adjust the float h...

Page 146: ...ed from the float chamber close the fuel tap by tightening the ring nut A Place the hose 3 in a vessel loosen the drain screw 4 on the float chamber lower side then tighten the screw again after the fuel drain WARNING Never litter the environment with fuel and let the engine running in open air never in closed rooms A ...

Page 147: ...H 1 Part N H0368 09 2008 ENGINE REASSEMBLY Section H ...

Page 148: ...XC H 26 Reassembly of clutch TE TXC TC SMR 450 510 H 27 Reassembly of timing system drive gear and chain H 29 Reassembly of flywheel H 30 Reassembly of transmission cover H 31 Reassembly of piston and cylinder H 32 Reassembly of cylinder head H 33 Reassembly of cam chain tensioner TE TC TXC SMR H 36 Reassembly of valve lifter H 37 Reassembly of cylinder head cover spark plug lubrication hose H 39 ...

Page 149: ...iedanddrawnforawelldeterminednumberofworking hours Itisadvisabletoreplacethosebearingswhichundergothegreatestwearandtearespeciallyinviewofthefactthatgenerallyspeaking they are difficult to check for wear What above is suggested in addition to the size verification of the single components as foreseen in the properchapter seechapterG ENGINEOVERHAULING Weemphasizetheimportanceofthoroughlycleaningall...

Page 150: ...H 4 Part N 8000 H0368 09 2008 ENGINE REASSEMBLY CRANKSHAFT COUNTER BALANCING SHAFT ALTERNATOR LUBRICATION L H CRANKCASE Instructions for assembly and lubrication ...

Page 151: ...8 ft lb M5x0 8 LOCTITE 272 TE SMR 6 Nm 0 6 Kgm 4 3 ft lb 19 M5x0 8 LOCTITE 272 6 Nm 0 6 Kgm 4 3 ft lb LUBRICATING POINTS NOTES LUBRICANT INSTRUCTIONS FOR ASSEMBLY A Degrease B Mount with Engine oil C Glue the two half casings by Loctite 510 Pianermetic E Align the stator notch to the notch on the stator cover G Grease WATER RESISTANT O Engine oil O G Engine oil or grease WATER RESISTANT STANDARD M...

Page 152: ...H 6 Part N 8000 H0368 09 2008 ENGINE REASSEMBLY TRANSMISSION GEARSHIFT MECHANISM Instructions for assembly and lubrication ...

Page 153: ...243 8 Nm 0 8 Kgm 5 8 ft lb 24 M5x0 8 6 Nm 0 6 Kgm 4 3 ft lb LUBRICATING POINTS NOTES LUBRICANT INSTRUCTIONS FOR ASSEMBLY D Fit it with the opening towards the engine center O Engine oil O G Engine oil or grease WATER RESISTANT STANDARD M5x0 8 6 Nm 0 6 Kgm 4 3 ft lb M6x1 8 Nm 0 8 Kgm 5 8 ft l M8x1 25 21 Nm 2 1 Kgm 15 5 ft lb ...

Page 154: ...H 8 Part N 8000 H0368 09 2008 ENGINE REASSEMBLY CLUTCH STARTING SYSTEM LUBRICATION R H CRANKCASE Instructions for assembly and lubrication ...

Page 155: ...5 Nm 7 6 Kgm 55 ft lb 21 M6x1 LOCTITE 243 11 Nm 1 1 Kgm 7 9 ft lb 22 M10x1 25 LOCTITE 601 15 Nm 1 5 Kgm 10 8 ft lb STANDARD M5x0 8 6 Nm 0 6 Kgm 4 3 ft lb M6x1 8 Nm 0 8 Kgm 5 8 ft lb M8x1 25 21 Nm 2 1 Kgm 15 5 ft lb LUBRICATING POINTS NOTES LUBRICANT INSTRUCTIONS FOR ASSEMBLY C Glue the two half casings by Loctite 510 Pianermetic O Engine oil O G Engine oil or grease WATER RESISTANT ...

Page 156: ...H 10 Part N 8000 H0368 09 2008 ENGINE REASSEMBLY CLUTCH STARTING SYSTEM LUBRICATION R H CRANKCASE Instructions for assembly and lubrication ...

Page 157: ... Kgm 5 8 ft lb 20 M18x1 75 Nm 7 6 Kgm 55 ft lb 21 M6x1 LOCTITE 243 8 Nm 0 8 Kgm 5 8 ft lb STANDARD M5x0 8 6 Nm 0 6 Kgm 4 3 ft lb M6x1 8 Nm 0 8 Kgm 5 8 ft lb M8x1 25 21 Nm 2 1 Kgm 15 5 ft lb LUBRICATING POINTS NOTES LUBRICANT INSTRUCTIONS FOR ASSEMBLY C Glue the two half casings by Loctite 510 Pianermetic O Engine oil O G Engine oil or grease WATER RESISTANT ...

Page 158: ...H 12 Part N 8000 H0368 09 2008 ENGINE REASSEMBLY CYLINDER HEAD CYLINDER PISTON TIMING SYSTEM WATER PUMP SPARK PLUG Instructions for assembly and lubrication ...

Page 159: ...Kgm 2 2 ft lb 18 M10x1 12 Nm 1 23 Kgm 8 9 ft lb 25 M5x0 8 LOCTITE 243 4 9 Nm 0 5 Kgm 3 6 ft lb 26 M6x1 LOCTITE 542 8 Nm 0 8 Kgm 5 8 ft lb 27 M14x1 5 LOCTITE 542 25 Nm 0 25 Kgm 18 4 ft lb 29 M10x1 25 TE SMR 5 Nm 0 5 Kgm 3 6 ft lb 29 M10x1 25 TC TXC 8 Nm 0 8 Kgm 5 8 ft lb 43 M5x0 8 LOCTITE 243 Excluded USA model 5 Nm 0 5 Kgm 3 6 ft lb STANDARD M5x0 8 6 Nm 0 6 Kgm 4 3 ft lb M6x1 8 Nm 0 8 Kgm 5 8 ft l...

Page 160: ... in the flywheel Fit the roller bearing and lubricate with engine oil Fit the connecting rod and the second half flywheel See that the half flywheels are aligned using a triangle Join all the elements using a press Press the crank discs together to the same distance as the length of the crankpin Respect measure B shown on page H 15 when fitting the coupling pin ...

Page 161: ...ed with half flywheel Check the connecting rod side float into the flywheels It must be 0 4 0 5 mm 0 0157 0 0197 in Check the alignment of the crankshaft between centers Runout may not exceed 0 02 mm 0 0008 in at the bearing positions Make an initial alignment of the flywheel using a copper hammer ...

Page 162: ...ure Remove pin after assembly Using a depth slide gauge measure height B between the bearing and joint face on the two crankcase halves Measure width A of the crankshaft Taking into account that the play between crankshaft and base has to be 0 4 mm 0 0157 in shim washer C thickness to be used is given by difference C B on both sides A 0 4 mm Shim washers are available in the following thicknesses ...

Page 163: ... SMR A 5th gear engaged B 6th gear engaged C 6th gear aligned with shaft broaching D lubricate at the assembly with MOLYKOTE G n plus Main shaft Mount the bushing the 5th gear on the bushing and after that the washer and the circlip The washer should be between the gear and the circlip Mount the 3rd 4th gear and after that the washer Mount 6th gear and the steel spacer Mount 2nd gear and the circl...

Page 164: ...ear the washer and the circlip Mount the 6th gear and the circlip Mount the washer Fit the washer into the 3rd gear Mount the 3rd gear the washer and the circlip Apply MOLYKOTE G n plus under 3rd gear Mount the washer Fit the bush into the 4th speed gear Mount the 4th speed gear the washer and the circlip Apply MOLYKOTE G n plus under 4th gear Mount 5th gear and the washer Mount the needle bearing...

Page 165: ...e 4th gear Mount the spacer only for 400 450 510 cc Mount 2nd gear Main shaft complete Auxiliary shaft complete A 1st gear engaged B 3rd gear engaged C 2nd gear engaged D 1st gear aligned with shaft broaching E lubricate at the assembly with MOLYKOTE G n plus Auxiliary shaft Mount the plug and the bush Mount 2nd gear the washer and the circlip Mount the 4th gear and the circlip Mount the washer Fi...

Page 166: ... then support the half case using a suitable tool code no 8A00 90662 Install the two gearbox shafts as one unit Warm up at approx 125 C 257 F and fit the ball bearings into the two half cases with a suitable tool crankcase bearings plates screws 11Nm 1 1 Kgm 7 9 ft lb LOCTITE 272 Install the three gear strikers ...

Page 167: ... H0368 09 2008 ENGINE REASSEMBLY Make sure that the mounting of the bushes is correct apply grease on the bushes Lubricate with motor oil the surfaces that fit in the gear wheels Put the selector drum in its place ...

Page 168: ...s Make sure that the gear strikers move easily on the shafts Check gearbox operation by turning the gear selector drum Warm the crankshaft ball bearings of the crankcase Lubricate with motor oil the crankshaft journal with grease and assemble the shaft in the right half crankcase ...

Page 169: ...bling of the crankshaft and the counter balancing shaft is obligatory on 400 450 510models Mount the distance washer on the crankshaft Smear the union surface of the left half case with LOCTITE 510 warmthecrankshaftbearingseatandfitthehalfcase Inordertojointhecrankcase by striking with a plastic hammer join the two halves Tighten the allen bolts 8 Nm 0 8 Kgm 5 8 ft lb ...

Page 170: ...E 243 Mount the starting driven gear NOTE reassemble the free wheel in accordance with the mark previously done during disassembly Check the gears teeth for wear and failure If worn or breaked replace it Mout the second starting driven gear Mount the retaining plate 11 Nm 1 1 Kgm 7 9 ft lb LOCTITE 243 Tightenthegearselectorfixingpin 20Nm 2Kgm 14 5ft lb LOCTITE270 mount the gear fixing click and th...

Page 171: ...ump driven gear and the circlip Mount the circlip on the auxiliary shaft Reassembly of gear shaft Check the shaft for wear in the gear shift mechanism groove Mount the spring and lubricate the shaft with motor oil Insert the shaft in the crankcase in order to align the spring to the spring selector pin ...

Page 172: ...008 ENGINE REASSEMBLY Reassembly of kick start components TE TC TXC Assemble the shaft assy 2 in the seat B on crankcase A then place the hook return spring 1 in the crankcase hole D Assemble idling gear 5 washer 4 and circlip 3 ...

Page 173: ...b place an aluminium shim between the teeth of the primary drive gears in order to prevent its rotation Reassemble clutch discs 8 mount the clutch plates starting with one of the lined driving discs followed by one of the driven discs the last of the driving discs goes on last clutch control cap 9 pressure plate 10 and springs 11 Tight the clutch springs screws 12 whilst following a cross over pat...

Page 174: ...H 28 Part N 8000 H0368 09 2008 ENGINE REASSEMBLY Reassemble the pinion spacer with the O ring housing turned inwards Be careful not to damage O Ring on the spline shaft Mount the pinion and the circlip ...

Page 175: ... gear and chain The key for the cam chain sprocket must be installed with the cut end out towards the drive gear Lubricate the cam chain sprocket and install it on the crankshaft using a drift Reassemble the cam drive chain Reassemble the flywheel key the spring and the flywheel ...

Page 176: ...centrifugated oil and attracted to the magnets Reassembly the Woodruff key and the rotor on the crankshaft Holding the rotor on the R H side place an aluminium shim between the teeth of the primary drive gears in order to prevent its rotation mount the nut and tighten it to 75 Nm 7 65 Kgm 55 3 ft lb Mount the two centering bushes ...

Page 177: ... transmission cover If the centering bushes have been removed reassemble them in the crankcase Mount the gasket and the O rings Check that the engine oil hole is not obstructed Mount the transmission cover and tighten the twelve screws 8 Nm 0 8 Kgm 5 8 ft lb ...

Page 178: ...turned upwards Assembly of piston and cylinder Install a new base gasket Install the piston lubricate the piston with motor oil and install the piston pin circlips Make sure that the arrow on the piston is pointing forward Lubricate the cylinder liner with engine oil and push it down over the piston rings PISTON RING CUT SETTING PISTON RING CUT SETTING PISTON RING CUT SETTING ...

Page 179: ... screws to 25 Nm 2 55 Kgm 18 4 ft lb LOCTITE 243 when reassembling Always use a new gasket head when assembling see Cylinder head gasket selection chart on page H 45 Assemble chain slider on cylinder head 12 Nm 1 23 Kgm 8 9 ft lb then the cylinder head Tighten the cylinder head nuts whilst following a cross over pattern and in steps to 37 Nm 90 3 8 Kgm 90 27 5 ft lb 90 MOLIKOTE HSC ...

Page 180: ...er nuts 15 Nm 1 5 Kgm 10 8 ft lb Reassemble the lubrication hose on the transmission cover 15 Nm 1 5 Kgm 10 8 ft lb If the intake manifold A of the cylinder head has been dismantled tighten the two screws to 3 Nm 0 3 Kgm 2 2 ft lb LOCTITE 272 Reassemble the coolant drain screw on cylinder R H side 8 Nm 0 8 Kgm 5 8 ft lb ...

Page 181: ...ting the crankshaft and mount the chain Mount the water pump 8 Nm 0 8 Kgm 5 8 ft lb LOCTITE 542 without rotating the crankshaft in order to obtain the perfect alignement of the twin chasing on the gear to the spline on head face see picture tighten water pump fastening screws to 8 Nm 0 8 Kgm 5 8 ft lb LOCTITE 542 Mount cylinder head water pump hose ...

Page 182: ...er with its two screws 8 Nm 0 8 Kgm 5 8 ft lb Insert the spring the washer and the rear bolt 5 Nm 0 5 Kgm 3 6 ft lb Mount the intake camshaft aligning the reference on the gear with the left reference on the timing gear Mount the exhaust camshaft aligning the reference on the gear with the right reference on the timing gear TE TC TXC SMR TE TC TXC SMR TE TC TXC SMR ...

Page 183: ...lifter Mountthevalvelifterintheheadand turningitinliftposition inserttheretainingpin Reassemble the lubrication tube Lubricate the cammes abundantly with motor oil Reassemble the four U bolts for fixing the camshaft and tight the screws to 12 Nm 1 2 Kgm 8 7 ft lb ...

Page 184: ...0 006 in for INTAKE and 0 15 0 20 mm 0 006 0 008 in for EXHAUST Otherwise lift the retaining clip A using a hook let the rocker arm slide to one side extract the pad with a pair of pliers and check the thickness Depending on the result fit a new pad as spare parts pads are supplied ranging from 1 60 mm 0 063 in to 2 60 mm 0 102 in in steps of 0 05 mm 0 002 in The new pad thickness S will be S G1 G...

Page 185: ... the positive shaft Reassembly of cylinder head cover spark plug lubrication hose Mount the cylinder head cover and its gasket on the cylinder head Tight the screws whilst following a cross over pattern and in steps 8 Nm 0 8 Kgm 5 8 ft lb Assemble the spark plug 10 12 Nm 1 1 23 Kgm 7 2 8 9 ft lb and the lubrication hose 15 Nm 1 5 Kgm 10 8 ft lb ...

Page 186: ...ark and stator cover mark are aligned and tighten the two stator fastening screws 8 Nm 0 8 Kgm 5 8 ft lb LOCTITE 272 for TC TXC and 6 Nm 0 6 Kgm 4 3 ft lb LOCTITE 272 for TE SMR Fit the fly wheel grommet on the crankcase Tighten the two pick up fastening screws 6 Nm 0 6 Kgm 4 3 ft lb LOCTITE 272 Mount the flywheel cover and tightenthe six screws to 8 Nm 0 8 Kgm 5 8 ft lb Mount the electric startin...

Page 187: ...rify that the start pedal does not touch the crankcase cover Reassembly of the engine oil filters and drain plug Reassemble on engine L H side filter 1 6 Nm 0 6 Kgm 4 3 ft lb LOCTITE 243 e 2 25 Nm 2 55 Kgm 18 4 ft lb ed inferiormente il tappo 3 scarico olio 25 Nm 2 55 Kgm 18 4 ft lb TE SMR reassemble the coolant fluid temperature sensor with its O ring on the cylinder head NOTE If the throttle bod...

Page 188: ...ne lower guard if previously removed 14 7 Nm 1 5 Kgm 10 8 ft lb Assemble the cooling system hoses using the respective fastening clamps Using a 8 mm wrench assemble the coolant draining screw on the cylinder Reassemble the rear brake pedal with the relevant bolt 41 6 Nm 4 2 Kgm 30 7 ft lb LOCTITE 243 Reassemble the side guards of the frame Reassemble the carburetor TC TXC or the throttle body TE S...

Page 189: ...H 43 Part N H0368 09 2008 ENGINE REASSEMBLY ...

Page 190: ... lower than cylinder head face 0 1 0 05 mm 0 7 mm 8A00 A5462 250 8A00 H0504 310 2 piston aligned with cylinder head face 0 0 05 mm 0 8 mm 8000 A5462 STD 250 8000 H0504 STD 310 3 piston projecting from cylinder head face 0 1 0 05 mm 0 9 mm 8B00 A5462 250 8B00 H0504 310 450 510 CONDITION see picture A gasket thickness gasket code 1 piston lower than cylinder head face 0 6 0 05 mm 1 0 mm 8E00 A4195 1...

Page 191: ...I 1 Part N 8000 H0368 09 2008 FRONT SUSPENSION Section I ...

Page 192: ...on adjustment I 23 Removing the front fork I 24 Front suspension TC TXC I 26 INSTRUCTIONS FOR USE OF Ø50USD FORK models TC TXC I 27 Components of the fork I 28 General rules for a proper overhauling I 29 Instructions for Clamping in the Vice I 29 Problems Possible causes Solutions I 30 General maintenance operations I 30 Cleaning The Fork Legs I 31 Bleeding the air I 32 Draining the oil I 33 Braki...

Page 193: ...I 3 Part N 8000 H0368 09 2008 FRONT SUSPENSION TE SMR TC TXC ...

Page 194: ...escopic hydraulic fork with advanced axle the diameter of the stem is 50 mm The thermal excursion of the wheel on the legs axis is 300 mm TE e 250 mm SMR 37 31 7 30 29 22 55 28 27 54 53 32 33 34 38 35 36 58 8 9 10 11 12 13 25 21 20 19 34 45 44 49 4 42 33 46 41 39 5 39 6 2 1 2 26 15 16 17 40 40 18 3 48 14 61 8 8 40 TE SMR ...

Page 195: ... alloy anodised and polished inside Sliding bushings With Teflon facing free from static friction Seals Computer designed seal rings guarantee the beast seal under compression and the minimum friction during rebound Springs Madeofsteel theyareavailableindifferentstiffness K Formoredetailed information please refer to Table 4 Springs Oil MARZOCCHI with special formula It eliminates the formation of...

Page 196: ... Compression adjustment screw 21 Spri ng 24 Spri ng gui de 25 Pre load tube 28 Foot buffer 30 Cartridge body 31 Inner rod 32 Pumping element rod 33 Washers recall spring 34 Rebound piston washer 36 Pumping element piston 37 Rebound damping piston washers stack 39 Upper sliding bushing 41 Bottom valve 43 Compression valve washer 45 Bottom valve piston 46 Compression damping piston washers stack 48 ...

Page 197: ...rewdriver tip Only proceed to maintenance overhaul operations if you are sure you are able to do it and you have got the right tools to do so If this is not the case or if you are unsure please contact an authorized service center where specialized technicians with the right tools and original spare parts will service and overhaul your fork putting it back into its original working conditions Only...

Page 198: ...e rod adjustment variations 2 The adjustment screw is stuck 2 Take off and clean adjustment screw 3 Impurities in the oil 3 Change the oil making sure the forks inside components are properly cleaned 4 Valves are blocked with impurities 4 Change the oil making sure the forks inside components are properly cleaned Fork is too smooth with any 1 Oil level too low 1 Re establish correct oil level adju...

Page 199: ...d the visible surface of the oil seal with silicon grease Re assembly Re assemble the dust seal 12 in its seat pressing it home with your hands Bleeding the air This operation must be carried out with the fork assembled on the motorcycle and with the fork s legs fully extended front wheel off the ground The pressure generated by the air that can get into the fork legs while the motorcycle is being...

Page 200: ...spanner to unscrew the fork cap 48 completely Remove the fork cap 48 the guide spring cap 20 the spring 21 and the preload tube 25 Remove from the rod s edge 32 the adjustment return inner rod 31 Free the fork leg 5 from the vice and tip it into a container of a suitable size to drain the oil pump the fork to help the oil flow out The R5051AC is available as spare part if you tighten it on the rod...

Page 201: ...o the slot obtained at the tooling lower edge must be perfectly inserted into the body hexagon WARNING In the tooling upper part there are two opposite holes where you can insert an axle to make the blocking easier However the tooling must not be rotated in any case but only used to hold the fork leg inner parts Using the 21 mm tube wrench unscrew the bottom valve 41 Remove the bottom valve set 41...

Page 202: ...t buffer 28 Using a small screwdriver prize the stop ring 27 off the rod Remove the stop ring 27 and the push rod 29 off the rod Push the rod 32 towards the inside area of the body 30 to be able to slide the complete pumping element out starting from the bottom Thepumpingelementcanbecompletelyoverhauledandadjusted Paragraph 4 8 shows how to overhaul and modify the pumping element setting Verify th...

Page 203: ...n the oil seal 10 the spring cup 9 and the bottom guide bushing 8 will be removed from the slider Remove the top guide bushing 39 by hand If this operation is difficult by hand use a flat tip screwdriver in the bushing groove Remove the bottom guide bushing 8 the spring cup 9 the oil seal 10 the stop ring 11 and the dust seal 12 from the stanchion tube WARNING The old oil seals and dust seals must...

Page 204: ...4 and the spring 33 following this order Assembling The washers 37 and the piston 36 are the ones causing the rebound braking It is possible if needed to modify the fork s behaviour during the rebound phase by replacing the washers 37 and the piston 36 with other components having different characteristics WARNING Utilizzare solamente lamelle e pistoni originali Marzocchi non modificare i componen...

Page 205: ...or 13 mm according to the installed nut tighten the nut 38 up to the required torque see Table 1 Tightening torques BOTTOM VALVE OVERHAULING COMPRESSION BRAKING Dismantling Clamp in the vice the bottom screw through the spanner seizing 47 Using a 13 mm spanner unscrew the nut 42 Remove the nut 42 the spring 33 the washer 43 the piston 45 complete with the o ring 44 the washer or the washers stack ...

Page 206: ... the washer 43 and the spring 33 following this order WARNING The piston must be oriented in a way that the holes having smaller diameter are placed towards the setting washers 46 Tighten the nut 42 by hand Lock the bottom screw in the vice through the spanner seizing 47 Using a 13 mm spanner tighten the nut 42 up to the required torque see Table 1 Tightening torques RE ASSEMBLING THE FORK LEG SLI...

Page 207: ...estanchiontube cleaninganytraces of adhesive left on the fork Insert the top guide bushing 39 by hand If this operation is difficult by hand use a flat tip screwdriver in the bushing groove Delicately introduce the stanchion tube into the slider being very careful not to damage the top guide bushing Guidethebottomguidebushinguntilitcomesintocontactwiththeslider thespring cup and the oil seal Mount...

Page 208: ...its seat pressing it home with your hands RE ASSEMBLINGTHEPUMPINGELEMENTUNITANDTHEBOTTOMVALVE Insert the pumping element rod 32 into the body 30 In both pumping elements there is a sealing segment before the assembling make sure that it is not worn or damaged Replace if necessary Take great care and if necessary use a small flat tip screwdriver to help the pumping element piston into the sleeve In...

Page 209: ...tact with the stop ring Insert the foot buffer 28 this must be inserted keeping the oil flow slots towards the push rod Insert the upper nut 26 and tighten it on the push rod 29 Hold the nut 26 with a 18 mm spanner and tighten the push rod 29 up to the required torque see Table 1 Tightening Torques using a 17 mm spanner Insert the guide spring 24 in the pumping element rod 32 the guide spring must...

Page 210: ...ou can block the body rotation to do so the slot obtained at the tooling bottom edge must be perfectly inserted into the body hexagon WARNING In the tooling upper part there are two opposite holes where you can insert an axle to make blocking easier However the tooling must not be rotated in any case but only used to hold the fork leg inner parts Usinga21mmtubewrenchtightenthebottomvalve 41 uptoth...

Page 211: ...le 2 Oil and quantity and if necessary refill to the right level A lower or higher volume of air or a type of oil other than the recommended type can change the behaviour of the fork in every phase Lift the slider 13 on the stanchion tube 5 Insert the adjustment return inner rod 31 Insert the preload tube 21 the spring 25 and the guide spring cup 20 Screw the fork cap 48 down Fully unscrew the adj...

Page 212: ...akes and wheel The incorrect assembly of these elements can be dangerous for the rider For the fork to work correctly the wheel must be installed on the fork as follows Inserttheaxlethroughtherightwheelaxleclamp thewheelandtheleftwheelaxle clamp Screw down the nut on the left side of the axle and tighten fully Fully compress the fork a few times Tighten the two bolts on the right wheel axle clamp ...

Page 213: ... phase WARNING Do not force the adjustment screw R past its limits COMPRESSION ADJUSTMENT The compression damping adjustment can be made by acting on the adjustment screw C you can see at the bottom of both fork legs To modify the compression braking adjustment always start from the fully closed position thescrewisfullyturnedclockwise Eachscrewpositioncan be recognized by a click Remove the plasti...

Page 214: ...s follows remove on the L H side the screws 1 the brake hose and the instrument cable clamp TE SMR on the fork tube guard remove the six screws 2 and the fork tube guards remove the brake caliper from the L H fork tube by unscrewing the two fastening screws 3 remove the front wheel following the instructions on page Y 6 unloose the screws 4 fastening each fork slider to the steering head and steer...

Page 215: ...USPENSION B 2 4 mm 0 08 0 16in remove the fork legs Assemble the front wheel following the instructions on page Y 8 and check the distance B between magnet 6 on the brake disc and sensor 7 on the brake caliper Restore the starting measure A ...

Page 216: ...8 FRONT SUSPENSION Front suspension TC TXC The front suspension unit is a MARZOCCHI U S D telescopic hydraulic fork with advanced axle the diameter of the stem is 50 mm The thermal excursion of the wheel on the legs axis is 300 mm ...

Page 217: ... of aluminium alloy turned on a CNC anodized and polished inside Sliding bushes With Teflon facing free from static friction Seals Computer designed seal rings guarantee the best seal under compression and the minimum friction during rebound Springs Made of steel they are available in different stiffness K Oil MARZOCCHI oil with special formula It eliminates the formation of foam and keeps the vis...

Page 218: ...Spring 24 Inner rod 25 Rod 26 37 Washers recall spring 33 Rebound damping piston washers stack 35 Body in the cartridge 39 Compression piston 41 Compression damping valve washers stack 43 Compression valve 44 Stanchion tube 46 Upper sliding bushing 48 Foot nut 53 Spring preload adjustment set 70 Wheel axle clamp 71 Rebound adjustment screw 72 Rebound adjustment conic pin In the following gure the ...

Page 219: ...nents with the tip of the screwdriver Only use original Marzocchi spare parts Beforeservicingoroverhaulingyourforks makesureyouhavetheMarzocchiOverhaulKitthatcorrespondsyou reyourforks ifapplicable along with all the spare parts necessary for the complete service or overhaul of both legs Work in a clean ordered well lit place if possible avoid working outdoors Carefully check that your work area i...

Page 220: ...n or replace rod to adjustment variations 2 The adjustment screw is stuck 2 Take off and clean adjustment screw 3 Impurities in the oil 3 Change the oil making sure the forks inside components are properly cleaned 4 Valves are blocked with impurities 4 Change the oil making sure the forks inside components are properly cleaned Fork is too smooth 1 Oil level too low 1 Re establish correct oil level...

Page 221: ...fully clean the stanchion tube 44 before carrying out this operation Using a small screwdriver prize the dust seal 16 off the slider 11 without scratching or damaging the stanchion tube and the slider Slide the dust seal along the stanchion tube Clean inside the dust seal and its seat on the slider with a jet of compressed air Lubricatethedustsealandthevisiblesurfaceofthesealingringwithsilicongrea...

Page 222: ... necessary to discharge the air in both fork legs monthly or after every race Bleed the air when the fork leg SAG is less than that set otherwise the suspension tends to become hard following the increase in pre load due to air pressure To carry out this operation you will need a small pin punch The air bleed valve is on the top caps of both legs If the fork is not operating at optimum levels or i...

Page 223: ...Clamp the fork leg 11 in the vice Remove the lock cap 1 from the fork leg using a 4mm open ended spanner Slowly lower the slider 11 on the stanchion tube Free the fork leg 11 from the vice and tip it into a container of a suitable size to drain the oil pump the fork to help the oil ﬂow out Check appearance density and quality of the old oil to get an idea of the condition of the sealing and guidin...

Page 224: ...der 11 OVERHAULINGANDMODIFYINGTHECARTRIDGEUNITANDCOMPRESSION VALVE SETTING Breaking down the cartridge Rotate the rebound adjuster in fully closed position rotate it fully clockwise Fixthecartridgeset 21 inthevicebymeansofthespecialprotectionjaws R5155 as shown in the ﬁgure Use a 21mm spanner to unscrew the compression valve unit 43 Remove the complete compression valve unit 43 Free the cartridge ...

Page 225: ...tched adhesive tape onto the end of the rod 25 in order to cover the rod threading Do not apply thick adhesive tape Push the rod 25 towards the cartridge up to removal The pumping element and the compression valve can be completely overhauled and re used Section 4 7 2 4 7 3 explains the overhauling and setting procedure for the pumping unit and the compression valve Check the piston segment for we...

Page 226: ...rkbehaviourduringreboundifneeded The by pass washers 30 are responsible for rebound braking Whenever necessary fork behaviour can be modiﬁ ed during compression by replacing the washers 30 with others having different features WARNING Use only Marzocchi original washers and pistons Do notmodify the components Replace the piston segment 31 if needed In the end part of the rod ﬁt the spring 26 and t...

Page 227: ...urcanbemodiﬁedduringcompressionby replacing the washers 38 with others having different features WARNING Use only Marzocchi original washers and pistons Do not modify the components Replace the piston O ring 40 if necessary Install the washer or washers stack which regulate compression 41 and the piston 39 with O ring 40 onto the bottom valve Insert the spring 36 and the by pass washer 37 into nut...

Page 228: ... of the pumping element into the pumping element tube sleeve Insert the piston without any interference Remove the adhesive tape from the rod s upper edge 25 Rotate the rebound adjuster in fully closed position rotate it fully clockwise Tighten by hand the locknut 27 and the rebound adjustment set 24 into the rod threaded area 25 Fix the rebound adjuster set 24 with a 17 mm spanner and screw the l...

Page 229: ...r completing this operation when the rod is completely extended you will see that the bladder tends to compress next to the 4 radial holes in the tube sleeve Insert the rod 25 slowly by about 50mm until the bladder is no longer compressed next to the 4 holes Free the cartridge from the vice Fixthecartridgeinthevicebymeansofthespecialprotectionjaws R5198AC sothat the 4 holes on the bladder are seal...

Page 230: ... the vice Fixthecartridgeset 21 inthevicebymeansofthespecialprotectionjaws R5155 as shown in the ﬁgure Screw the compression valve unit and tighten it to the required torque Tightening torques with a 21 mm open ended wrench Check the correct oil ﬁlling To check make the rod perform a few full strokes and make sure that the smoothness is uniform and that the rubber bladder with the cartridge rod in...

Page 231: ...he sealing ring 14 the spring cup 13 and the bottom guide bushing 12 will be removed from the slider Remove the top guide bushing 46 by hand If this operation is difﬁcult by hand use a ﬂat tip screwdriver in the bushing groove Remove the bottom guide bushing 12 the spring cup 13 the sealing ring 14 the stop ring 15 and the dust seal 16 from the stanchion tube WARNING The old sealing rings and dust...

Page 232: ... ring 14 spring cup 13 and bottom guide bushing 12 WARNING Make sure the sealing ring 14 is correctly oriented in a way that the hollow side is turned towards the spring Remove the adhesive tape from the end of the stanchion tube cleaning any traces of adhesive left on the fork Insert the top guide bushing 12 by hand If this operation is difﬁcult by hand use a ﬂat tip screwdriver in the bushing gr...

Page 233: ... pre load spacer 17 and the spring 19 inside the stanchion tube It is possible to modify the spring preload value by following the instructions given in paragraph 5 2 Insert the complete pumping unit 21 into the slider 11 Clamp the fork leg in the vice by the wheel axle clamp 70 Push the top cap so that the lower part of the cartridge comes out of the wheel axle clamp Tighten the bottom nut 48 and...

Page 234: ...hion tube Use the 4mm open ended spanner to tighten the cap 1 onto the slider at the recommended torque see Table 5 Tightening torques Re adjust see p I 45 FITTING THE FORK BACK ON THE MOTORCYCLE WARNING Fit the fork back onto the frame following the instructions inthe motorcycle manufacturer s manual as for the steering elements brakes and wheel The incorrect assembly ofthese elements can be dang...

Page 235: ...e adjusteratatime takingnoteofthemodiﬁcationsyoucarryoutandtheimprovements you obtain WARNING During the setting operations never force the adjusterspast their limits INITIAL SUSPENSION BOTTOMING ADJUSTMENT OptimalspringhardnessisthatwhichreachestherequiredSAG inotherwords the suspension is lowered solely due to the rider s weight How to measure SAG In order to measure the SAG you only need to car...

Page 236: ...l ring REBOUND ADJUSTMENT Adjust extension or rebound braking by turning the adjuster R Withthereboundadjusteryoucancontrolsuspensionreturnspeedaftercompression The regulating adjuster is on the lower part of the wheel axle clamp in both legs The right rebound speed setting makes the vehiclestable letting it follow the variations in the terrain and any obstacles Una corretta taratura della velocit...

Page 237: ... soft setting means less stability but also a less nervous ride To modify the compression braking adjustment always start from the fully closed position thescrewisfullyturnedclockwise Eachscrewpositioncan be recognized by a click Carry out regulation by turning the adjuster with a ﬂat tipped screwdriver Turning the adjuster C clockwise increases the compression hydraulic damping and proportionally...

Page 238: ...he front wheel from the ground working as follows remove on the L H side the screws 1 the brake hose and the instrument cable clamp TE SMR on the fork tube guard remove the six screws 2 and the fork tube guards remove the brake caliper from the L H fork tube by unscrewing the two fastening screws 3 remove the front wheel following the instructions on page Y 6 TC TCX ...

Page 239: ...stening each fork slider to the steering head and steering base remove the fork legs Assemble the front wheel following the instructions on page Y 8 and check the distance B between magnet 6 on the brake disc and sensor 7 on the brake caliper Restore the starting measure A ...

Page 240: ...I 50 Part N 8000 H0368 09 2008 FRONT SUSPENSION ...

Page 241: ...J 6 Checks on the piston unit J 8 Replacing the gasket J 8 Checking the adjustment J 9 Reservoir replacement J 10 Disassembling the air oil diaphragm of the reservoir J 11 Reassembling the shock absorber J 11 Shock absorber damping adjustment J 14 Disassembly and overhauling the rear swing arm J 15 Overhauling the rear swing arm axle J 16 Overhauling the rocking lever and the rear suspension tie r...

Page 242: ...J 2 Part N 8000 H0368 09 2008 REAR SUSPENSION TIGHTENING TORQUES 1 2 52 4 Nm 5 35 Kgm 38 6 ft lb Rear shock absorber LUBRICATION POINTS GREASE 1 2 ...

Page 243: ...of the progressive type and consists of a shock absorber a series of linkages and a swing arm The pre load of the shock absorber spring can be adjusted according to the driving and ground conditions Even the hydraulic damping can be adjusted from outside Periodically check the wear of the components ...

Page 244: ...throttle body TE SMR 2 4 7 3 8 5 1 9 Loosen the upper fastening screw 2 of the rear frame 4 remove the lower fastening screw 3 and turn the rear frame forward making sure not to damage electric cables Remove the front fixing pin 5 of the suspension tie rod on the frame the lower fastening screw 6 of the shock absorber the upper fastening screw 7 and then remove the shock absorber 8 IMPORTANT when ...

Page 245: ...the shock absorber in the vice take care that it gets not warped Loosen the counter ring nut the ring nut the spring cap and the spring Measure the free lenght of the spring USEFUL LIMIT 9 59 9 70 in SMR 9 98 10 1 in TE TXC 250 9 98 10 1 in TE TC TXC 450 510 When the spring lenght is lower than the useful limit replace the spring CHECKING THE SHOCK ABSORBER Visuale check of the shock absorber to d...

Page 246: ...re and exert the pressure by your hands when carrying out this operation Use two small screwdrivers to remove the snap ring and take care not to damage the inner surface To remove the snap ring place first one ring end outside the groove Remove the other ring end insert one screwdriver between the snap ring and the reservoir and lever by the other screwdriver Remove the whole snap ring and check t...

Page 247: ... Lay the shock absorber on the working table Loosen or dig ot the cover according to the model Once the plug is removed push and drive the forkrod guide inside the body so as to free snap ring housing Remove then the snap ring using a screwdriver ...

Page 248: ...r the oil in a clean and leave it to clear Checks on the piston unit 1 Check whether the piston right is worn out or damaged in this case replace it 2 Check the OR on the forkrod replace the OF if scored 3 Checkwhetherthechromiumplatedforkrodsurfaceisdamagedorscored Inthis case replace the replace the damaged forkrod guide the gasket and the DU bush The forkrod and forkrod guide connection unit is...

Page 249: ...adjustment for operating defect it is necessary to unscrew the knob stopping dowel before unscrewing heat with warm air Proceed as follows unscrew the ring nut with a suitable wrench extract the parts paying attention to the dismantling sequence in order to correctly effect then the reassembly ...

Page 250: ... at a torque of 30 Nm 3 kgm 29 2 ft lbs It is strictly forbidden to replace the compression blades with other types of blades as blades different from the original ones can cause the explosion of the shock absorber during use Reservoir replacement In case of reservoir replacement it is necessary to heat with warm air near the screwed side and unscrew it with a suitable tool Replace the O Ring of t...

Page 251: ...bstances Dry the body using compressend air Hold the shock absorber eye in a vice using aluminium or bronze jaws or wrapping it in a cloth Pour inside the shock absorber body 70 80 cm3 4 3 4 9 cu in of oil Insert the forkrod inside the shock absorber body and take care that the sliding track is undamaged Push the forkrod the piston and the connection inside and leave room for topping up Tighten th...

Page 252: ...hese operations Proceed by topping up until reachin approx 2 cms 0 8 in from the body edge Then execute 4 or 5 alternating strokes of 5 6 cms 2 2 4 in to bleed the air left under the piston unit These movements should be slow to prevent the reservoir diaphragm from moving through cavitation or compression Top up with oil the smap ring throat is reached then slowly fit the forkrod and the inside en...

Page 253: ...leaks are not present Set the plug on the body Reassembling the end of stroke pad and its washer When the end of stroke pads needs to be replaced block the forkrod in a vice using aluminium or bronze jaws then tighten the connection again using Loctite and a 50 Nm torque Reassemblethespringandtakeittotheinitialpreloadusingtheringnutandthe counter ring nut Themanufacturerdeclinesanyandallresponsabi...

Page 254: ...ndard calibration rotate upper adjusters 1 and 3 clockwise to the fully closed position then move back for the clicks specified above For smoother braking turn the adjusters anticlockwise turn them clockwise for harder braking B EXTENSION standard calibration 18 clicks 2 clicks To reset the standard calibration rotate upper adjuster 2 clockwise to the fully closed position then move back for the c...

Page 255: ...no need to loosen the chain adjusters 6 on the fork the chain tension level will stay the same after reassembling Remove the entire wheel C by taking care of the spacers located at the hub sides Remove the shock absorber 7 as described on page J 3 Remove the nut 8 of the fork pin and then the fork Make sure the fork pin is parallel page J 16 and manually check the wear of the roller bearing D and ...

Page 256: ...ill mounted on the rear swing arm and on the frame respectively manually check their radial and axial play pulling thesepartsinanydirection Therockingleverandtierodhavebeendesignedwith a certain amount of axial play in order to allow the shock absorber to always find the ideal operating position If however there is any axial play it will be necessary to remove the component from the the swing arm ...

Page 257: ...t spring Chain tension rollers chain driving roller chain guide chain runner Check the wear of the above mentioned elements and replace them when necessary Check the chain guide alignement and remember that a bent element can cause a rapid wear of the chain In this case a chain fleeting from the sprocket may ensue TE TC TXC SMR ...

Page 258: ...J 18 Part N 8000 H0368 09 2008 REAR SUSPENSION ...

Page 259: ...L 1 Part N 8000 H0368 09 2008 BRAKES Section L ...

Page 260: ... 2008 BRAKES Braking system L 2 Brake disc L 4 Wear check and brake pads replacement L 5 Front braking system bleeding TE TC TXC L 6 Front braking system bleeding SMR L 7 Rear braking system bleeding L 8 Fluid replacement L 9 ...

Page 261: ...ke hose 4 Front brake caliper 5 Front brake disc 6 Rear brake oil tank 7 Rear brake hose 8 Rear brake caliper 9 Rear brake disc 10 Rear brake pump 11 Rear brake control pedal BRAKING SYSTEM The braking systems is divided into two completely independent circuits Each system is provided with a caliper connected to a hydraulic control pump with tank for the fluid SMR ...

Page 262: ...E TC TXC 0 197 in SMR Brake disc thickness at wear limit 0 098 in TE TC TXC 0 177 in SMR Rear brake disc diameter 9 45 in Rear brake disc thickness when new 0 157 in Brake disc thickness at wear limit 0 138 in The disc distortion must not exceed 0 15 mm 0 006 in this measure is to be taken with a comparator and with the disc mounted on the rim Loosenthefourfixingscrewstoremovethedisquefromtherim W...

Page 263: ...n off any fluid or oil that inadverently gets on the pads or disc with alcohol Replace the pads with new ones if they cannot be cleaned satisfactorily PADS REMOVAL Remove springs 1 Remove pins 2 Remove pads PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the springs 1 If the above procedure is followed it will not be necessary to bleed the brake system after new pads have be...

Page 264: ...luid reservoir cap 2 Duringthebleedoperationthefluidlevelinsidethereservoirmustnever be lower than the minimum level As the braking fluid is a very corrosive substance in the case it comes in contact with your eyes wash them abundantly with water During the bleeding of the braking circuit keep the handlebar turned leftwards This is the way to lift pump tank and to make easier the bleeding of the b...

Page 265: ...ve Restore the brake fluid level A then reassemble the rubber and the fluid reservoir cap 2 During the bleed operation the fluid level inside the reservoir must never be lower than the minimum level As the braking fluid is a very corrosive substance in the case it comes in contact with your eyes wash them abundantly with water During the bleeding of the braking circuit keep the handlebar turned le...

Page 266: ...y Release the pedal and wait for a few seconds before repeating the operation until only fluid come out of the tube Close the bleed union to the prescribed torque and check the fluid level B inside the reservoir before reassemblle the cap 1 If the bleeding operation has be done correctly the pedal will have no mushy feel If not repeat the operation Duringthebleedoperationthefluidlevelinsidetherese...

Page 267: ...the fluid proceed as follows Remove the rubber cap on the bleeding valve 1 or 1A Attach a clear plastic hose to the bleeding valve on the brake caliper and turn the other end of the hose into a container Remove fluid reservoir cap 2 or 2A 21 mm wrench and the rubber Loosen bleeding valve on the brake caliper Pump with brake lever 3 or brake pedal 3A in order to push brake fluid out of line Close t...

Page 268: ...L 10 Part N 8000 H0368 09 2008 BRAKES SMR TE TC TXC ...

Page 269: ...L 11 Part N 8000 H0368 09 2008 BRAKES Periodically check the connecting hoses C and D see Periodical maintenance card page B 9 if the hoses are worned or cracked their replacement is advised ...

Page 270: ...L 12 Part N 8000 H0368 09 2008 BRAKES ...

Page 271: ...art remote control switch check TE SMR TXC M 18 ELECTRONIC IGNITION SYSTEM TC TXC M 19 ELECTRONIC IGNITION SYSTEM TE SMR M 20 Electronic coil resistance check M 22 Electronic power unit ECU M 23 ELECTRONIC POWER UNIT WIRING DIAGRAM ECU TE SMR M 24 Voltage regulator TE SMR TXC M 25 VOLTAGE REGULATOR RECTIFIER WIRING DIAGRAM M 25 Spark plug M 26 Gear shift position sensor check GPS M 27 Carburetor t...

Page 272: ... 18 Starting motor 19 Spark plug 20 R H rear turn indicator 21 L H rear turn indicator 22 Gear shift position sensor 23 H T Coil 24 Position throttle control sensor 40 25 R H switch 26 Ignition switch 27 Clutch microswitch 28 Speed sensor 29 Relay for electric fan 30 DC relay 31 Lambda probe 32 Air temperature sensor 40 33 Coolant temperature sensor 34 Pressure sensor 40 35 Fuel pump 36 Fall senso...

Page 273: ...ite G Green G Bk Green Black G R Green Red G Y Green Yellow Gr Grey Gr Bk Grey Black Gr G Grey Green O Orange O Bk Orange Black Pk Pink R Red R Bk Red Black Sb Sky blue V Violet W White W B White Blue W Bk White Black W G White Green W R White Red W V White Violet W Y White Yellow Y Yellow Y Bk Yellow Black Y Br Yellow Brown Y Gr Yellow Grey Y O Yellow Orange Y Sb Yellow Sky blue Y R Yellow Red ...

Page 274: ... start remote control switch 7 Starting motor 8 Spark plug 9 Gear shift position sensor 10 Electronic coil 11 Carburetor throttle position sensor 12 Engine stop 13 Engine start 14 Clutch microswitch Cable colour coding B Blue Br Brown Bk Black G Green Gr Grey Gr R Grey Red O Orange P Pink R Red Sb Sky blue V Violet W White Y Yellow 1 2 3 4 5 6 7 8 10 9 11 12 13 14 ELECTRIC STARTER KIT ...

Page 275: ...emote control switch TXC 7 Starting motor TXC 8 Spark plug 9 Gear shift position sensor 10 Electronic coil 11 Carburetor throttle position sensor 12 Engine stop 13 Engine start TXC 14 Clutch microswitch TXC ELECTRIC STARTER KIT NOT AVAILABLE ON TC Cable colour coding B Blue Br Brown Bk Black G Green Gr Grey Gr R Grey Red O Orange P Pink R Red Sb Sky blue V Violet W White Y Yellow 1 2 3 4 5 6 7 8 1...

Page 276: ...ture 10 on the throttle body The electric system includes the following elements Battery 12V 6Ah 7 or in alternative 12V 7Ah under the saddle Flashing indicator device 17 on the left side of the rear frame Relay 14 for light and injection system on the L H side of the frame Relay 14 for the electric fan on the R H side of the frame Electric fan 16 Two fuses 9 15A and one 13 20A on the right side o...

Page 277: ...M 7 Part N 8000 H0368 09 2008 ELECTRIC SYSTEM DIGITAL INSTRUMENT 5 19 22 21 13 11 9 20 ...

Page 278: ...k Electronic power unit C D I 3 under the fuel tank Voltage regulator 4 TXC under the fuel tank Spark plug 5 on the R H side of cylinder head Starting motor 12V 450W 6 TXC behind the cylinder TE TXC SMR Electric start remote control switch 7 TXC on the left side of the rear frame Potentiometer 10 on the carburettor The electric system includes the following elements TXC Battery 12V 6Ah 7 under the...

Page 279: ...M 9 Part N 8000 H0368 09 2008 ELECTRIC SYSTEM DIGITAL INSTRUMENT 6 5 10 11 7 9 9 8 ...

Page 280: ...ttery and changes the AC current to the DC current All these components maintain a constant voltage and prevent the battery from overcharging CHARGING SYSTEM TXC The charging system consists of Alternator 2 Voltage regulator rectifier 3 Condenser 4 Battery 5 The AC current produced by the alternator is converted by the regulator rectifier into DC current The regulator rectifier prevents overchargi...

Page 281: ...M 11 Part N 8000 H0368 09 2008 ELECTRIC SYSTEM DIGITAL INSTRUMENT For the key to electrical cables see pages M 4 M 5 ...

Page 282: ...re than one month and a half it is recommended to remove battery from electrical system and store it in a dry place Regulated voltage To gain access to the battery remove the saddle see page E 15 When the engine is warm and working at slightly more than 3000 rpm measure the tension between the two battery terminals positive and negative with a tester in order to make this check the battery must be...

Page 283: ...GER Resistance between WHITE and GREEN cables 100 15 TE SMR 2 CHARGE Resistance between YELLOW and WHITE cables 0 16 15 TC TXC 2 CHARGE Resistance between then YELLOW cables 0 65 15 TE SMR 3 LAMP Resistance between YELLOW and GROUND cables on the engine 0 65 15 TC TXC If the resistance is not between the specified values replace the generator assy ...

Page 284: ...ENT EVERY ENGINE OVERHAUL CLEAN THE FLYWHEL ROTOR REMOVING ANY DEBRIS GATHERED IN CENTRIFUGATED OIL AND ATTRACTED TO THE MAGNETS Generator no load voltage performances 1 Secondary no load voltage 2 Charging current 3 Lighting voltage 4 Rotational frequency TC TXC ...

Page 285: ...nctional whilst the battery is charged 12 5V 13V start the engine if the battery tension does not increase 14 V after about two minutes substitute the regulator To access the regulator remove the seat and fuel tank pages E 15 E 23 Remove the fixing screw 1 and the regulator 1 1 1 For the key to electrical cables and components see pages M 4 M 5 ...

Page 286: ...STEM TXC The starter system consists of Battery 5 Electric start remote control switch 6 Starting motor 7 Engine stop switch 12 Engine start switch 13 Clutch switch 14 Pull the clutch lever until the engine starts Pressing the starting switch the button energizes the electric start remote control switch causing the contact points to close and completing the starter system circuit from the strating...

Page 287: ...h to remove the nut 1 under the rubber cap and a 8 mm wrench to remove the starting motor and ground cable screws 2 Remove the starting motor Starter motor check If a fault has been diagnosed in the starter motor it is necessary to proceed as follows with the check Connect a tester between earth and the starter motor terminal Check that there is continuity between the positive pole and the engine ...

Page 288: ...negative poles of the battery to avoid short circuits during assembly Disconnect the cables of the starter motor and the positive cable of the battery from the relay Apply 12 volts to the terminals 1 and 2 of the relay and check the continuity between terminals B M Do not apply the battery voltage to the starter relay for more than five seconds to avoid overheating and therefore damaging the windi...

Page 289: ...p The digital electronic ignition allows to change the timing curve according with the following items ENGINE r p m CARBURETOR THROTTLE VALVE POSITION SENSOR ENGAGED GEAR This system allows to optimize the engine performances in every condition of employment In case of throttle valve or transmission gear failure the ignition is able to allow the use of the motorcycle however The electronic ignitio...

Page 290: ...attery with a power relay and is controlled by the ECU The synchronization of the ignition is checked with precision with regard to the engine r p m and the position of the throttle control Besides this basic condition also the temperature and air pressure sensors and the coolant temperature influence the synchronization of the ignition Electronic power unit 1 ECU W T S 33 Water Temperature Sensor...

Page 291: ...M 21 Part N 8000 H0368 09 2008 ELECTRIC SYSTEM DIGITAL INSTRUMENT 31 26 27 35 23 33 1 25 36 37 38 40 6 SMR 22 17 2 3 18 16 ELECTRONIC IGNITION SYSTEM TE SMR ...

Page 292: ...sistance 4 5 Ω 15 a 20 C Secondary winding resistance 5 KΩ 20 a 20 C without spark plug cap cable If the resistance is not between the specified values replace the electronic coil Also check the resistance of the terminal cap contact with the spark plug Terminal cap resistance 4 5 5 5 KΩ 5 a 20 C If the resistance is not between the specified values replace the electronic coil NOTE The ignition co...

Page 293: ...ages E 15 E 23 This unit consists of a condensor a pick up signal rectifier circuit and ignition advance circuit synchronised with the pick up signal and a switching circuit for discharging the condensor ELECTRONIC UNIT C D I WIRING DIAGRAM ECU TC TXC 1 1 1 Electronic unit 2 Alternator 3 Voltage regulator 5 Battery 10 Electronic coil 12 Engine stop 10 12 1 2 3 5 ...

Page 294: ...1 ECU W T S 33 Water Temperature Sensor Ignition coil 23 Fuel pump 35 Clutch switch 27 Ignition switch 26 O2 sensor heater 31 Battery 16 Electric start remote control switch 17 Starting motor 18 Voltage regulator rectifier 3 Alternator 2 Gear shift position sensor 22 M A Q S 40 pressure sensor TPS sensor air temperature sensor Power relay 38 Fuse 37 R H switch 25 Injector 6 Fall sensor 36 SMR ...

Page 295: ...e diodes to rectify the current produced by the generator It contains also an electronic device operating in relation to the battery tension if battery has a low charge recharge current will be high on the contary if battery will be charged the current will be lower Do not disconnect the battery cables when engine is on since the regulator should be irreparably damaged 1 TXC ...

Page 296: ...mine the state of the spark plug just after it has been removed from the engine since che deposits on the plug and the colour of the insulator provide useful indications concerning the heat rating of the plug carburation ignition and general engine condition Before refitting the plug thoroughly clean the insulator using a brass metal brush Apply a little graphite grease to the spark plug thread fi...

Page 297: ... hole where is the gear sensor BLACK cable 2 The lever 3 is placed on the left hand side of the engine After every shift the lever automatically returns to horizontal position First gear is engaged by pushing the lever downwards all the other gears are engaged by pushing the lever upwards See the table below for the data to be checked A NEUTRAL open circuit 312 319 B 1st gear 556 568 725 739 C 2nd...

Page 298: ...position then detach the throttle position sensor cable 1 from the main wiring harness Set the two tester terminals in corrispondence of YELLOW A and BLACK B cables and check for the correct values see table A Yellow B Black a throttle control grip in CLOSED position 890 990 b throttle control grip in COMPLETELY OPEN position KEIHIN MX 37 MX 41 3 4 4 4 K 5 1 ...

Page 299: ...gain access to the battery 1 remove the saddle see page E 15 first remove the BLACK negative cable then the RED positive cable when reassembling first connect the RED positive cable then the BLACK negative cable remove the battery 1 from its housing Check using a voltmeter that battery voltage is not less than 12 5 V If not the battery needs to be charged Using a battery charter with a constant vo...

Page 300: ...itch on to dipped beam the upper limit of the beam should be at a height which is so greater than 9 10 of the height from the ground of the centre of the headlamp Adjust the headlamp aiming by turning screw A to lower or lift the high beam Headlamp bulbs replacement To gain access to the healamp bulbs proceede as follows remove the upper fastening screw of the the headlamp carrier to the instrumen...

Page 301: ... gain access to the tail light bulb 12V 5 21W proceed as follows remove the two fastening screws 1 and the rear lens 2 pull the lamp 3 inside turn it counterclockwise then remove it from the lamp holder After replacement reverse operations for reassembly Make sure not to tighten the screws excessively ...

Page 302: ...e plate light lamp Remove the licence plate light support 4 by extracting it from the tail of the motorbike Extract the lamp holder with the lamp from the support Turn the lamp 5 to remove it from the lamp holder After replacing the lamp reassemble all the parts in the inverse order 4 5 ...

Page 303: ...UTATORS Measure the commutators continuity using a tester In case of anomalies replace the defective part 1 Engine start and stop switches TC TXC 1 Engine ignition button TXC 2 Engine stop button TC TXC TE SMR 1 2 1 Engine ignition button 3 Engine start stop button 2 R H Commutator ...

Page 304: ...trol low beam 3 Left turm signals automatic return Right turm signals automatic return To deactivate the turn signals press the control lever after its returning to center 4 Warning horn Cable colour coding B Blue Bk Black B Bk Blue Black B W Blue White G Green G Bk Green Black G W Green White Gr Grey Y Yellow R Red Sb Sky blue W White W B White Blue W Bk White Black ...

Page 305: ...dirt or a broken cover COUPLINGS Block couplings ensure that the block is released before disconnecting it to push it completely home when connecting it When disconnecting a coupling ensure that the body of the coupling is gripped and do not pull it apart by the leads Check that the terminals of the couplings are not slack or bent Check that the terminals are not corroded or dirty ...

Page 306: ...or any other substitute for the fuse SEMICONDUCTOR PARTS Do not drop semiconductor parts such as those incorporated in the ECU or in the voltage regulator rectifier When checking these parts carry out the instructions to the letter The lack of using the correct procedurecan cause grave damage BATTERY TE SMR TXC when assembling first remove the BLACK negative cable then the RED posi tive cable when...

Page 307: ...ro the functions use the SCROLL knob A The instrument functions are the following as shown below 1 SPEED ODO figure 1 page 15 2 SPEED CLOCK figure 2 page 15 3 SPEED TRIP figure 3 page 16 4 SPEED CHRONO figure 4 page 16 5 SPEED RPM engine r p m numerical value figure 5 page 16 1 SPEED ODO figure 1 page 15 IMPORTANT in case of FUEL INJECTION SYSTEM malfunction on the right side of the instrument dis...

Page 308: ...ta will be lost after battery detachment To setup the TRIP push the SCROLL A button holding down more than 3 seconds 4 SPEED CHRONO STP figure 4 SPEED motorcycle speedmaximum value 299 Km h o 299 mph STP 1 miles kilometers covered time Reading from 0 00 to 99 59 59 the data will be lost after battery detachment To activate the function STP 1 push the knob SCROLL A for more than 3 seconds 1st step ...

Page 309: ...MALFUNCTION in case of FUEL INJECTION SYSTEM malfunction on the right side of the instrument display will be displayed the warning message FAIL TE SMR A A Instructions for the instrument setting Upon turning on the instrument if the operation DID NOT already take place it is necessary to set the instrument associating it with the relative motorcycle by selection of the codes illustrated in the fig...

Page 310: ...see page M 12 2 incorrect voltage see page M 12 3 generator no continuity see page M 12 4 incorrect generator no load voltage performances see page M 14 5 faulty voltage regulator see page M 15 Battery overloading 1 faulty voltage regulator see page M 15 2 faulty battery see page M 12 STARTER SYSTEM Starting motor don t start 1 faulty electric start remote control switch see page M 18 2 loosened s...

Page 311: ...M 41 Part N 8000 H0368 09 2008 ELECTRIC SYSTEM DIGITAL INSTRUMENT WIRE HARNESS TC TXC SMR 450R WIRE HARNESS TE SMR ...

Page 312: ...RUMENT CABLE RUNWAY AND ASSEMBLING INSTRUCTIONS FOR THE TE SMR ELECTRIC PARTS H T coil positioning Connect the H T colil as shown in the picture Relay positioning 3 parts R S relay Turn indicators flash device positioning Turn indicators flash device L S relay ...

Page 313: ...with flat side downward Remote control switch positioning Install the remote control switch as shown Positioning the voltage rectifier Voltage regulator with dissipation plate covered in thermal grease Fastening the starter motor remote control switch cable Connect the starter motor remote control switch cable as shown in the picture ...

Page 314: ...the starter motor Threading of negative battery cable Threading of earth cable between motor and negative cable of battery Securing of earth cable to regulator cable Secure the earth cable of the regulator to the right screw of the injection coil Securing of earth cables between motor and frame Electric earthing Secure the earth cable between the motor and the frame and the cabling earthing slot a...

Page 315: ... Be careful with the routes of the radiator vent pipe and the gas pipes Connecting relay Connect the DC cable to the relay on the right side of the motorbike Connecting relay Connect indistinctively the POW and FAN cables to the relays on the left side of the motorbike Connecting the electric fan Connect the electric fan connector as shown ...

Page 316: ...ng the injector Connect the injector connector as shown Connecting the central unit Connect the central unit connector as shown Ignition coil connection Connect the ignition coil connector as shown Positioning of the fuel pump connector Place the fuel pump connector as shown ...

Page 317: ...tor Connect the MAQS connector as shown Connecting the engine water temperature connector Connect the engine water temperature connector as shown Posiotioning the lambda sensor Screw the lambda sensor as shown Connecting the lambda sensor connector Connect the lambda sensor connector as shown ...

Page 318: ...or cables Threading of frame cables and back light connector Thread the back of the cables as shown in the figure Connect the back light connector Connection of remote control switch Connect the connector to the remote control switch as shown Connection of intermittent turn indicator Connect the connector to the intermittent turn indicator as shown ...

Page 319: ...Thread the cables as shown fasten with the clip provided Fastening of clip to fuse box Fit the clips provided to the three fuse boxes Fastening of clip to fuse box Fit the three fuses in the pierced wall on the back fender Connection of tilt sensor plug TE only Connect the plug as shown in the figure ...

Page 320: ...n the figure Connection of back stop Connect the stop sensor as shown in the figure Threading of steering sleeve cables Secure the cables with the clip provided Fastening of instrument holder plate connectors Fasten the instrument and diagnostics connector using the fastening clips provided Fit the plug into the diagnostics connector ...

Page 321: ...plug into the double map connector Clutch and left handle block connectors Connect the left block and clutch sensor connectors Front stop speed sensor and right handle block connectors Connect the right block front stop and speed sensor connectors Horn connector Connect the horn as shown in the figure ...

Page 322: ...me with a clamp as shown in the picture Fastening wiring Fasten the back stop cable to the frame with a strap as shown in the figure Fastening wiring Fasten the back stop cable to the frame with a strap as shown in the figure Fastening wiring Fasten the wire harness to the frame with two clamps as shown in the picture ...

Page 323: ...g Make sure the cable node is secured outside the frame Fastening wiring Place the GPS and Pick Up connectors as shown Fastening wiring Secure the generator connector as shown Fastening wiring Connect the start speed sensor and lambda sensor cable bundle to the hydraulic clutch pipe ...

Page 324: ...TAL INSTRUMENT Fastening wiring Connect the start and speed sensor cable bundle to the hydraulic clutch pipe Fastening wiring Fasten the front wire harness with two clamps as shown Fastening wiring Fasten the front wire harness with two clamps as shown ...

Page 325: ...llowing parts a Rear opening of the muffler b Clutch and brake levers hand grips handlebar commutators c Air cleaner intake d Fork head wheel bearings e Rear suspension links it is necessary ABSOLUTELY TO AVOID THAT HIGH PRESSURE JETS OF WATER OR AIR come to contact with THE ELECTRICAL PARTS pages M 6 M 7 and any parts of the INJECTION SYSTEM especially the electronic central unit 1 and the M A Q ...

Page 326: ...M 56 Part N 8000 H0368 09 2008 ELECTRIC SYSTEM DIGITAL INSTRUMENT ...

Page 327: ...N 1 Part N 8000 H0368 09 2008 ENGINE COOLING SYSTEM Section N ...

Page 328: ...N 2 Part N 8000 H0368 09 2008 ENGINE COOLING SYSTEM Checking the cooling fluid level N 3 Cooling system N 4 Engine cooling system overhauling N 5 ...

Page 329: ...ges to the crankshaft assembly However if engine overheating is noticed check that radiator is completely filled up Check of radiator level must be performed with cold engine see page D 32 If for any reason you have to operate on a hot engine take care to slowly discharge pressure The radiator cap 1 is provided of two unlocking positions the first being for the previous pressure discharge Opening ...

Page 330: ... and two cooolers with vertical flow 1 Radiator cap 2 R H Radiator 3 L H Radiator 4 Union 5 Water pump 6 Water pump cover 7 Breather hose 8 Radiators hose 9 R H lower hose 10 L H lower hose 11 Water pump Union hose 12 Union L H Radiator hose 13 Union R H Radiator hose 14 Water pump Cylinder head hose 15 Expansion tank TE SMR 16 Electric fan TE SMR 7 2 1 9 10 15 8 3 12 4 16 11 6 13 5 14 ...

Page 331: ...straighten them so restoring the air passage The radiant mass has not to be clogged or damaged for more than 20 of its surface If the damaged surface is over this limit it shall be advisable to replace radiator Periodically check the connecting hoses see Periodical maintenance card page B 8 this will avoid coolant leakages and consequent engine seizure If hoses show cracks swelling or hardenings d...

Page 332: ...N 6 Part N 8000 H0368 09 2008 ENGINE COOLING SYSTEM ...

Page 333: ... guard O 3 Passenger footrest Kit SMR O 4 Carburetor KEIHIN 37 kit TXC 250 and KEIHIN 41 kit TC TXC 450 510 O 7 Hand guards kit TE O 8 Blinkers Kit SMR O 9 Blinkers Kit TE O 11 Hook Kit for race starting phase TC TXC O 14 Kick starter kit SMR O 16 Assembling instructions for full power version on TE SMR models O 22 ...

Page 334: ...t page O 7 4 8000 A4296 TC TXC 450 510 Carburetor KEIHIN 37 kit page O 7 5 80A0 A6211 TE Hand guards kit page O 8 6 8000 B0150 SMR Blinkers Kit page O 9 6 8000 H0804 TE Blinkers Kit page O 11 7 8000 B1530 TC TXC 250 450 510 SMR 450 R Hook Kit for race starting phase page O 14 8 8000 B0591 SMR Kick starter kit page O 16 9 TE SMR Assembling instructions for full power version on TE SMR models page O...

Page 335: ...guards SMR excluded and central engine guard 1 2 Side engine guards SMR excluded 3 Central engine guard A Screw M6x25 mm no 4 pieces B Bushing Ø6 2xØ8xØ12x9 mm no 4 pieces C Nut M6 no 4 pieces D Screw M6x15 mm no 4 pieces E Nut M6 no 4 pieces Assemble as shown in the figure ...

Page 336: ...ther one The description refers to the assembly of the left footrest 7 the assembly of the right footrest 8 is symmetrical 3 Passenger footrest SMR C 7 a 2 5 6 A D B 1 Proceed as follow Preliminarily mount the foot rests A and B on the relevant supports C and D Remove the saddle and side panel as shown on page E 15 E 16 From both sides remove the fastening screws of the air filter box 1 ...

Page 337: ...ame Remove the frame lower screw 7 Provisionally fasten the foot rest support in the front side by means of the M8x25 mm 4 screw supplied with the Kit do not tighten fully Insert the spacer 5 into the plate and fasten the rear by means of the M8x40 mm 6 screw also supplied with the Kit 2 7 6 ...

Page 338: ... 6 Part N 8000 H0368 09 2008 KIT ASSEMBLING INSTRUCTIONS Fully tighten also the front screw 4 Assemble back the rear fastening screws 1 of the air filter box Assemble back the saddle and side panels 6 1 ...

Page 339: ...1 TXC 450 510 Remove the carburetor page E 9 The kit consists of TXC 250 1 Idle jet 40 45 3 Main jet 170 180 TXC 450 510 1 Idle jet 42 48 3 Main jet 185 Remove the floater chamber A Replace the parts 1 and 3 with the KIT parts Reassemble the carburettor in the reverse order that was shown for disassembling ...

Page 340: ...e the rubber guards and the fastening screws of the front brake a and clutch b control levers Place the right hand guard A then fasten it with screw 1 washer 2 and nut 3 Place the left hand guard B then fasten it with screw 4 washer 5 and nut 6 Fasten the hand guards with the straps 7 ...

Page 341: ...and assemble the plate complete with turn signal using the same screws 4 and the corresponding spacer 5 R H side remember to assemble the horn C too between the turn signal plate and the steering head Connect the turn signals to the main wiring harness Regarding the correct connection to the main wiring harness see the wiring diagram page O 13 The description refers to the assembly of the left tur...

Page 342: ...ghtening the nut 6 Remove the screws 9 the rear tail light then connect the turn signals and the flasher to the main wiring harness Regarding the correct connection to the main wiringharness seethewiringdiagram pageO 11 Reassemblethereartaillight and the grommet 10 The description refers to the assembly of the left turn signal 2 the assembly of the right turn signal is symmetrical After completing...

Page 343: ...rews D and the spacer 7 R H side remember to assemble the horn E between the turn signal plate and the spacer on the front fork steering head Connect the turn signals to the main wiring harness see the wiring diagram on page O 13 The description refers to the assembly of the left turn signal 1 the assembly of the right turn signal is symmetrical 1 L H front turn signal no 1 piece 2 R H front turn ...

Page 344: ...ignal 3 or 4 on the hole of the frame and tighten the nut 10 Remove the screws a the rear tail light then connect the turn signals to the main wiring harness see the wiring diagram on page O 13 Reassemble the rear tail light and the grommet b The description refers to the assembly of the left turn signal 3 the assembly of the right turn signal is symmetrical After completing the assembly operation...

Page 345: ...O 9 11 L H front turn indicator nr 1 page O 9 11 Turn indicators flasher nr 8 page O 10 20 R H rear turn indicator nr 1 page O 9 21 L H rear turn indicator nr 2 page O 9 B Blue R Bk Red Black Sb Sky Blue 13 7 30 28 10 31 26 29 27 35 23 33 19 20 15 21 16 17 18 3 2 22 32 24 34 38 37 36 25 6 12 14 5 4 8 9 11 40 1 39 TE SMR ...

Page 346: ...09 2008 KIT ASSEMBLING INSTRUCTIONS 7 The Kit Hook for race starting phase TC TXC Code 8000 B1530 consists of B C A D Part No Description Code Q ty A Ring 8000A6135 1 B Hook 8000B1529 1 C Screw 80B047053 4 D Screw 60N407330 1 ...

Page 347: ...the hook B on slider guard as indicated in fig 6 and holding the hook in place mark the positions of the four screw holes using a point Remove the hook and make the four holes with a drill Ø 4 5 mm perpendicularly to the surface of the slider guard Fix the hook on the slider protection with the four screws C Loosen the four screws 5 fastening the R H front fork leg and withdraw this from the steer...

Page 348: ...ntrol pedal bolt 9 Kick starter kit 34 for SMR To effect the above mentioned operations it is not necessary to remove the engine from the motorcycle 6 Plate 1 10 Washer 2 14 Spring 1 15 Sliding gear 1 35 Gear Z 32 37 Spring 1 38 Screw M6x14 mm 2 39 Spacer 1 40 Idling gear Z 30 1 41 Thrust washer 0 5 mm 1 42 Kick start pedal 1 43 Pedal hub 1 44 Spring 1 45 O Ring 1 46 Screw M6x28 mm 1 47 Ball 7 32 ...

Page 349: ... Remove the six screws 12 that fasten the springs 11 5 mm wrench whilst following a cross over pattern and in steps Remove the pressure plate 10 with the bearing and the clutch control cap 9 Remove clutch discs 8 Bend back tabs of the hub washer 6 and holding the clutch hub nut 27 mm wrench remove the nut 7 using the clutch disassembly tool A code no 8000 79015 Remove the washer 6 the clutch hub 5...

Page 350: ...clip 13 the spacer 12 then fasten the plate 6 in the holes A on the R H crankcase C using the two screws 38 M6x14 LOCTITE 243 Assemble the shaft assy E in the seat B then place the hook return spring 37 in the crankcase hole D Assemble idling gear 40 washer 41 and circlip 13 ...

Page 351: ...astening nut 7 27 mm socket and tool A code no 8000 79015 tighten at 75 Nm 7 5 kgm 55 ft lb Remember to bend locking tab over nut when tight Reassemble clutch discs 8 clutch control cap 9 pressure plate 10 and springs 11 Tighttheclutchspringsscrews 12 whilstfollowingacross overpatternandinsteps 5 mm allen wrench 8 Nm 0 8 Kgm 5 8 ft lb ...

Page 352: ...6 ft lb 8 mm wrench Reassemble oil line bolt on crankcase cover 13 mm wrench tighten at 15 Nm 1 5 kgm 11 ft lb Assemble kick start pedal 42 tightening the screw 48 with 4 mm allen wrench tighten at 8 Nm 0 8 kgm 6 ft lb verify that the start pedal in rest position does not touch the crankcase cover Check that the pedal 42 works and returns freely 48 42 42 ...

Page 353: ... Quarts 1 6 U S Quarts of AGIP RACING 4T 10W 60 Reassemble the rear brake control pedal 6 mm allen wrench tighten fastening bolt at 42 Nm 4 2 kgm 31ft lb LOCTITE 243 Check that O Rings are in place Check the brake fluid level A in the tank Connect the battery to electric system E 15 and test kick start pedal 42 A 42 ...

Page 354: ...d to both the models Illustrations are merely for demonstration purposes and could not exactly match the detail described TE SMR All modifications reported below cause THE REGISTERED VEHICLE TO BE NON COMPLIANT and unsuitable for circulating on public roads consequently it may be used only in CLOSED CIRCUITS by authorised subjects holding the relevant driving licence ...

Page 355: ...wer The vehicle cannot be used without battery under any circumstances do not remove the battery If the battery is removed disconnected while the engine is running the injection system is damaged seriously do not attempt to disconnect the battery 1 Lambda sensor plug 8000A7724 2 Lambda sensora plug gasket 8000A7749 3 Lambda sensor connector 8000A6750 Full power version components 4 Air filter cage...

Page 356: ...rottle cable pulley of the throttle body located on the right side of the vehicle Move away the pedal starting lever from the pulley cover Loosen the hexagonal socket screw holding the plastic cover Remove the screw Remove the cover of the throttle cable pulley Throttle body plate removal ...

Page 357: ... 8000 H0368 09 2008 KIT ASSEMBLING INSTRUCTIONS Loosen the nuts of the throttle cables Remove the throttle cables from their housings Loosen both screws fastening the pulley locking plate Remove the locking plate ...

Page 358: ...iously removed plate holding screws Tighten both screws Place the throttle cables into their housings Tighten the throttle cables by means of the relevant nuts Make sure that the cable has a certain clearance Make sure that the cables are not tight or locked in any way Position the pulley cover back into its housing ...

Page 359: ...O 27 Part N 8000 H0368 09 2008 KIT ASSEMBLING INSTRUCTIONS Position the pulley cover into its housing Anchor the pulley cover by means of the previously removed suitable screw ...

Page 360: ...d spanner on the outside and a 10 mm T shaped spanner on the inside remove the locking screw of the muffler Remove the spring between muffler and the central pipe then with an 8 mm T shaped spanner remove the front fastening screw of the central pipe to the frame Pull out the muffler Pull out the catalyst 1 from the exhaust central pipe ...

Page 361: ...UCTIONS Intake silencer replacement Remove the battery then place it on the side of the bike Remove the wing nut bolt and the air filter Remove the intake silencer from the air filter then replace it with the filter cage 800069549 supplied with the KIT ...

Page 362: ...O 30 Part N 8000 H0368 09 2008 KIT ASSEMBLING INSTRUCTIONS Reassemble the new air filter assy according with the pictures Reassemble the battery ...

Page 363: ...bling Loosen the lambda probe from the exhaust pipe DO NOT EXPOSE THE PROBE TO OIL OR SOLVENTS Assemble the 8000A7724 probe plug with the 8000A7749 gasket Tighten the lambda probe plug Detach the lambda probe connector from the main wiring harness then mount in its place the connector 8000 A6750 ...

Page 364: ...ton 8000H0590 The dual mode button allows to select the correct map according with the ground conditions knob in rest position to select dry ground map SEL 1 on instrument display push knob to select wet ground map SEL 2 on instrument display DUAL MODE BUTTON ASSEMBLING TE ...

Page 365: ...rward the headlamp carrier and pull it towards the high in order to uncouple from the two lower supports Remove the headlamp carrier Remove the plug on the cable located behind the headlamp carrier Assemble the dual mode button connector on the above mentioned cable Assemble the dual mode button next to the L H commutator and fasten it with the supplied clamp ...

Page 366: ...LWAYS the map SEL 1 The switching to SEL 2 is possible with ENGINE ON pushing the dual mode button for 1 second with a water temperature of approx 40 C 104 F and approx 10 seconds after the engine start In the absence of these conditions the switching will not be made From SEL 2 pushing the dual mode button for 1 second SEL 1 is selected again and so on SEL 2 MAP FOR WET GROUND SEL 1 MAP FOR DRY G...

Page 367: ...hole on the rear mudguard as shown in the picture then two additional holes with the same diameter matching the holes of the Racing light Use the available screws to anchor Remove the rear turn indicators RACING LICENSE PLATE HOLDER ASSEMBLING Licence plate holder kit 8000B1641 ...

Page 368: ...O 36 Part N 8000 H0368 09 2008 KIT ASSEMBLING INSTRUCTIONS Pass the licence plate holder cables along the rear frame Connect the rear light connector Reassemble the previous removed parts ...

Page 369: ... 8000 H0368 09 2008 HYDRAULIC CONTROL CLUTCH Section P Hydraulic clutch system P 2 Discharge of hydraulic system fluid P 4 Overhaul of the control pump for clutch release P 4 Bleeding of the hydraulic system P 5 ...

Page 370: ...P 2 Part N 8000 H0368 09 2008 HYDRAULIC CONTROL CLUTCH ...

Page 371: ...fected by the gear on the clutch housing 8 The clutch housing contains both the driving discs 9 and driven discs 10 the driven discs move the clutch hub 11 fastened on the gearbox main shaft 1 Clutch master cylinder 2 Clutch control lever 3 Master cylinder slave cylinder hose 4 Push rod 5 Clutch slave cylinder 6 Pressure disc 7 Bleeder valve 8 Clutch housing with clutch ring gear 9 Clutch driving ...

Page 372: ...over and the diaphragm and act release control lever until all fluid is discharged Overhaul of the control pump for clutch release Drain the system detach the pump from the L H side of the handlebar and disassemble the pump completely Replace all gaskets re assemble the pump and assemble it again on the handlebar Connect the hose and pour new fluid from the tank bleed the system as shown on page P...

Page 373: ...ber cap 3 and the bleeding nipple 5 mount a syringe in the bleeding nipple hole then refill with fresh fluid see LUBRICATION TABLE on page A 9 NEVER use brake fluid refill until fluid is discharged from the lower hole B on the pump body WITHOUT BUBBLES The fluid level MUST NEVER BE below 4 mm from the top A of the clutch pump body see picture Reassemble the removed parts ...

Page 374: ...P 6 Part N 8000 H0368 09 2008 HYDRAULIC CONTROL CLUTCH ...

Page 375: ...Q 1 Part N 8000 H0368 09 2008 OPTIONAL PARTS LIST Section Q ...

Page 376: ...Z 48 1 450 510 8C0096837 REAR SPROCKET Z 49 1 450 510 2 800063827 DRIVE SPROCKET Z 12 1 450 510 800063828 DRIVE SPROCKET Z 13 1 450 510 800063830 DRIVE SPROCKET Z 15 1 450 510 4 8000A5982 ENGINE GASKET KIT 1 450 510 5 8000A5736 ENGINE SEALS KIT 1 450 510 6 800098504 REAR SHOCK ABSORBER SPRING K 5 4 Kg mm 1 450 510 OPTIONAL PARTS TXC Pos Code Nr NAME MODELS 1 8A0096837 REAR SPROCKET Z 47 1 250 8B00...

Page 377: ...59 REAR SPROCKET Z 43 450 510 8B00A4859 REAR SPROCKET Z 44 450 510 8G00A4859 REAR SPROCKET Z 45 450 510 2 800063829 DRIVE SPROCKET Z 14 450 510 3 8000H0772 LICENCE PLATE HOLDER KIT RACING 1 450 510 4 8000A5982 ENGINE GASKET KIT 450 510 5 8000B0364 ENGINE SEALS KIT 450 510 10 8000B0591 KICKSTARTER KIT 450 510 ...

Page 378: ...Q 4 Part N 8000 H0368 09 2008 OPTIONAL PARTS LIST ...

Page 379: ... 1 Part N 8000 H0368 09 2008 FUEL INJECTION SYSTEM Fuel injection system S 2 Operating instructions for the DIAGNOSIS SOFTWARE KIT on the fuel injection S 3 Fuel pump check S 5 Relay check S 6 Section S ...

Page 380: ...s Air temperature in the intake manifold Engine coolant temperature Atmosphericpressureintheintakemanifold inthecurrentpositionandaltitude Throttle opening percentage SMR Vehicle rollover Rich or lean combustion mixture O2 sensor Battery voltage Sensors source Current gear position Pulse width of fuel injector Ignition coil O2 heater The diagnostic software DIAGNOSIS SOFTWARE KIT see on pages S 3 ...

Page 381: ...E on PC turn the ignition key F in ON position then place the R H commutator in RUN position start the Diagnostic Tool Software previously installed then carry out the controls If the throttle body H will be removed and or replaced it is necessary to adjust the T P S again selecting the options T P S Idle Adjust ment Command page 32 on Operation Manual and Feedback Adjustment Command page 29 on Op...

Page 382: ...pment the identification numbers of the frame VIN and of the engine Engine No of the motorcycle In case of replacement the new ECU will only show the number of engine running hours NOTES The NEUTRAL green warning light comes on ONLY when the ignition key is in ON position and the R H commutator is in RUN position The front rear lights and the instrument display will come on when the ignition key i...

Page 383: ...or has not remained any gasoline therefore set the meter on Impedance position and effect the reading on the cables BLUE and WHITE The value will have to be 1 3 KOhms 10 to 20 C B pump working Connect the RED and BLACK cables to a 12V stabilized feeler then check that the fuel pump runs Don t continuously effect this last check for more than 3 seconds ...

Page 384: ... located on the frame R H side no 1 and L H side no 2 A set the meter on Impedance position and check that the exciter coil func tions properly the value will have to be 80 Ohm 10 at 20 C B set then the meter on Continuity position and check that the circuit is open C using a 12V stabilized feeler for the coil and check that the circuit is closed 1 1 1 ...

Page 385: ...T 1 Part N 8000 H0368 09 2008 LUBRICATION SYSTEM Section T ...

Page 386: ...lter 2 Main oil pump 3 Easy change filter 4 Piston D C roller bearing Conn rod Starter driver wheel 5 Camshaft Intake 6 Camshaft Exhaust 7 Spark and timing chamber 8 Cranking mechanism chamber 9 Net filter 10 Oil pump for secondary circuit 11 Mainshaft 12 Counter shaft 13 Primary drive driven gear ...

Page 387: ...T 3 Part N 8000 H0368 09 2008 LUBRICATION SYSTEM LUBRICATION SYSTEM DIAGRAM ...

Page 388: ...T 4 Part N 8000 H0368 09 2008 LUBRICATION SYSTEM ...

Page 389: ...W 1 Part N 8000 H0368 09 2008 SPECIFIC TOOLS Section W ...

Page 390: ... Valves assembling and removing tool 5 8A00 90662 Support for assy 6 8000 A9634 Diagnosys kit TE SMR 6A 8000 H0237 Control unit Reprogramming kit TE SMR 8 8000 A1625 Dial gauge holding tool 11 8000 79015 Clutch hub retaining wrench 13 1519 84701 Spring hook Put the vehicle to RACING CONFIG as described in section O non type approved vehicle and use the kit to map the control unit SPECIAL TOOLS ...

Page 391: ... nuts or bolts can cause them to become damaged or loose leading to vehicle damage or injury to the rider Overtightening a nut or bolt can strip its thread or cause breakage The table shows the torque settings for the main nuts and bolts in relation to thread diameter pitch and use The above torque settings refer to threads which have been cleaned with solvent ...

Page 392: ...l filter plug M14x1 5 25Nm 2 55 Kgm 18 4 ft lb Engine oil filter cartridge cover fastening screw M5x0 8 LOCTITE 243 6 Nm 0 6 Kgm 4 3 ft lb Oil filling cap M18x1 5 3 Nm 0 3 Kgm 2 1 ft lb Carburetor union fastening screw TC TXC M4x0 7 LOCTITE 272 3 Nm 0 3 Kgm 2 2 ft lb Alternator fastening nut M12x1 75Nm 7 65 Kgm 55 3 ft lb Stator plate fastening screw TC TXC M6x1 LOCTITE 272 8 Nm 0 8 Kgm 5 8 ft lb ...

Page 393: ...Nm 0 25 Kgm 1 8 ft lb Rear stop control switch TE SMR M10x1 19 Nm 1 95 Kgm 14 ft lb Front control switch connector fastening screw SMR M2x0 4 0 8 Nm 0 1 Kgm 0 6 ft lb Rear brake pedal adjusting cam fastening screw M6x1 14 7 Nm 1 4 Kgm 10 8 ft lb Front brake hose guide plate fastening screw M6x1 6 Nm 0 6 Kgm 4 4 ft lb Front brake tank cap fastening screw SMR M6x1 4 9 Nm 0 5 Kgm 3 6 ft lb Front fork...

Page 394: ...lb Spoiler to fuel tank fastening screw M6x1 6 Nm 0 6 Kgm 4 4 ft lb Front number holder upper fastening screw TC TXC M6x1 6 Nm 0 6 Kgm 4 4 ft lb Front number holder lower fastening screw TC TXC M6x1 10 4 Nm 1 05 Kgm 7 7 ft lb Rear shock absorber guard fastening screw M6x1 6 Nm 0 6 Kgm 4 4 ft lb Rear fender front fastening screw M6x1 10 4 Nm 1 05 Kgm 7 7 ft lb Rear fender rear fastening screw M6x1 ...

Page 395: ...Front brake disc fastening screw TE TC TXC M6x1 LOCTITE 243 14 7 Nm 1 5 Kgm 1 0 8 ft lb Front brake disc fastening screw SMR M8x1 25 34 7 Nm 3 54 Kgm 25 6 ft lb Rear brake disc fastening screw M6x1 LOCTITE 243 14 7 Nm 1 5 Kgm 10 8 ft lb Front wheel nipple M4 07x0 75 4 4 Nm 0 45 Kgm 3 2 ft lb Rear wheel nipple M4 5x0 75 4 4 Nm 0 45 Kgm 3 2 ft lb Rear wheel sprocket fastening nut M8x1 25 LOCTITE 243...

Page 396: ...eel screws on brass copper aluminium M5 4 Nm 0 4 Kgm 3 ft lb steel screws on iron steel M5 6 Nm 0 6 Kgm 4 4 ft lb steel screws on plastic with metal spacer M6 6 5 Nm 0 65 Kgm 4 8 ft lbb steel screws on brass copper aluminium M6 6 5 Nm 0 65 Kgm 4 8 ft lb steel screws on iron steel M6 10 5 Nm 1 Kgm 7 7 ft lb steel screws on brass copper aluminium M8 16 Nm 1 6 Kgm 11 8 ft lb steel screws on iron stee...

Page 397: ...e Y 2 Front wheel Y 5 Removing the front wheel Y 6 Reassembling the front wheel Y 8 Rear wheel Y 10 Removing rear wheel Y 11 Wheels overhauling Y 12 Bending the wheel pin Y 12 Wheel spokes Y 13 Rims warpage Y 13 Rear sprocket transmission sprocket rear chain Y 14 ...

Page 398: ...tsapproximatelyattheexhaustleveland includesround rectangularandellipticsectionsteelpipes lightalloy rear frame For a rough check please see the picture The size indicated enable to see if the frame should be realigned or replaced The frames seriously damaged should be replaced ...

Page 399: ...76 7 440 5 22 7 17 34 B 460 423 18 11 16 65 C 442 259 17 40 10 19 D 394 2 337 2 15 52 13 27 E 311 23 2 12 24 0 91 F 302 4 1 8 11 9 0 07 G 262 5 81 5 10 33 3 2 H 240 8 95 9 9 48 3 77 I 65 5 170 2 57 6 69 L 20 335 4 0 78 13 20 M 84 8 374 3 33 14 72 N 430 1 576 1 16 93 22 68 width P 215 4 8 48 width Q 90 2 3 55 steering axis angle α 26 5 ...

Page 400: ... AND WHEELS Check the assemblies shown on the picture for wear or failure If worn or breaked replace them A ENGINE FASTENING BOLTS B REAR FRAME FASTENING BOLTS C CHAIN GUIDE ROLLER BEARING D FOOTRESTS PIVOTS SPRINGS E SIDE STAND SPRINGS ...

Page 401: ...1 SMR SANREMO in light alloy 3 50x17 Tire make type and dimension TE TXC Michelin ENDUROCOMP 3 Pirelli MT83Scorpion Dunlop 54R D907 TC Pirelli 51R MT 32A 80 100 x 21 SMR Pirelli MTR 21 DRAGON EVO 120 70 17 Cold tire pressure TE Racing use TC TXC 0 9 1 0 Kg cm2 TE Road use 1 1 Kg cm2 SMR 1 4 kg cm2 Racing use 1 8 kg cm2 Road use driver only 2 0 kg cm2 Road use driver and passenger TE TC TXC ...

Page 402: ... the engine and see that the front wheel is lifted from the ground SMR remove the two screws A and the brake caliper Loosen the screws 1 fastening the wheel axle 2 to the fork rod supports Lock the wheel pin head and at the same time loosen the screw 3 on the opposite side remove the wheel axle TE TC TXC TE TC TXC ...

Page 403: ...N 8000 H0368 09 2008 FRAME AND WHEELS Do not operate the front brake lever when the wheel has been removed this causes the caliper piston to move outwards After removal lay down the wheel with brake disc on top ...

Page 404: ...l hub TE TC TXC Fit the wheel between the front fork legs so that the brake disc is fitted into the caliper SMR Fit the wheel between the front fork legs Fit the wheel axle 2 from the R H side after greasing it and push it to the stop on the L H leg during this operation the wheel should be turned TE TC TXC TE TC TXC 2 1 ...

Page 405: ...de 51 45 Nm 5 25 Kgm 38 ft lb the screws 1 on the L H leg 10 4 Nm 1 05 Kgm 7 7 ft lb SMR fit the brake caliper on the disc assemble the caliper on its holding plate and tighten the screws A at 25 5 Nm 2 6 Kgm 18 8 ft lb Check that the brake disc slides between the caliper pads without any friction Check the distance between magnet on the brake disc and sensor on the brake caliper page I 61 After r...

Page 406: ... 450 510 SMR SANREMO in light alloy 4 25x17 Rim make type and dimension TE TXC Michelin ENDURO COMP 3 Pirelli MT 83 Scorpion Dunlop 70R D907 120 90x18 250 140 80x18 450 510 TC Pirelli NHS 62 MT 32 100 90x19 250 110 90x19 450 510 SMR Pirelli MTR 22 DRAGON EVO 150 60x17 Cold tire pressure TE Racing use TC TXC 0 8 0 9 Kg cm2 TE Road use 1 0 Kg cm2 SMR 1 6 kg cm2 Racing use 2 0 kg cm2 Road use rider o...

Page 407: ...anged after the reassembly Extract the complete rear wheel by taking care of the spacers located at the hub sides To reassemble reverse the above procedure remembering to insert the disc into the caliper Do not operate the rear brake pedal when the wheel has been removed this causes the caliper piston to move outwards After removal lay down the wheel with brake disc on top After reassembly pump th...

Page 408: ...must not be reassembled When reassembling new bearings checl the seat It must be clean and without groovesorscatches Greasetheseatbeforefittingthebearing thenputitintheseat using a proper tubolar pad exercising pressure only on the bearing outer ring uo to complete inserting Place the spacer and the proceed with the placing of the other bearing Check their alignement by placing the wheel pin After...

Page 409: ...t the spokes with A live sound accounts for an accurate tightening while a dull sound means that a new tightening is necessary Rims warpage The table below shows the control value that the wheel rim must be checked Too much skid and eccentricity are generally caused by any worn bearings In this case replace teh bearings If this operation does not get round this trouble replace the rim or the wheel...

Page 410: ...f teeth in normal and excessive wear Should the sprocket be badly worn out replace it by loosening the six fastening screws to the hub After every rear sprocket replacement also replace the drive sprocket and transmission chain 1 Normal consumption 2 Excessive consumption TIGHTENING TORQUES 3 34 3 Nm 3 5 Kgm 25 3 ft lb LOCTITE 243 ...

Page 411: ...1st pin center and 21 st pin center Check the pinion damages or wear and replace it should the wear degree be as the one shown in figure Misalignment of the wheel will result in abnormal wear and may result in an unsafe riding condition Inmuddyandwetconditions mudstickstothechainandsprocketsresulting in an overtight chain The pinion the chain and the rear sprocket wheel wear increases when running...

Page 412: ...Y 16 Part N 8000 H0368 09 2008 FRAME AND WHEELS ...

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