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Husqvarna 2011 SMR449, Workshop Manual, Page: 191 / 385

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Husqvarna 2011 SMR449 Workshop Manual Download Page 191

F1.85

H01883

H01809

H01808

ENGINE DISASSEMBLY/REASSEMBLY

1

st

 edition (08-2010) _Rev. 11-2010

Gearbox unit - disassembly / assembly

Preliminary operations

Engine oil drainage
Head disassembly
Gear lever disassembly
Engine left crankcase cover disassembly
Engine right crankcase cover disassembly
Securing crankshaft at TDC
Starter motor idle gear disengagement
Flywheel disassembly
Clutch unit disassembly

Crankcase left half disassembly

•  Remove screws (1, 2, 3).

•  Disassemble crankcase left half (4).

 

  Warning

Due to sealant high adhesion, some engine parts could prove hard to disas

-

semble. Disengage these parts by gently tapping them with a rubber hammer, 

taking care not to damage cooling fins or other crankcase parts.

•  Remove gasket (5), and guide sleeves (6).

Gearbox disassembly

•  Disassemble the following parts:

-  Gearbox output shaft (1)

-  Gearbox input shaft (2)

-  Gearbox input shaft fork (3)

-  Gearbox input shaft guide (4)

-  Selector drum (5)

-  Gearbox output shaft guide (6)

-  Gearbox output shaft fork (7)

Gearbox check

•  Transmission shaft check

Check

•  Check gearbox bearings (1).

Summary of Contents for 2011 SMR449

Page 1: ...www husqvarna motorcycles com Technical DVD Technical DVD Workshop Manual My 2011 Ed 11 2010 ...

Page 2: ...rors or omissions in this manual and reserves the right to make changes to reflect on going product development Illustrations in the ma nual may differ from actual components No reproduction in full or in part without written authorisation 1st edition 08 2010 _Rev 11 2010 ...

Page 3: ...MR 511 ZKHA601ABBV000001 SMR 511 USA ZKHLEEGM BV000001 1st edition 08 2010 _Rev 11 2010 FOREWORD TABLE OF CONTENTS 1st edition 08 2010 Rev 11 2010 Printed in Italy MODELS COVERED from serial number onwards Copyright by HUSQVARNA MOTORCYCLES S R L BMW Group Technical Service Via Nino Bixio 8 21024 Varese Italy tel 39 0332 75 61 11 tel 39 0332 756 558 www husqvarna motorcycles com Workshop Manual 1 ...

Page 4: ...iption of the problem and ask the appropriate questions to clearly identify problem symptoms diagnose the problem and identify the causes clearly This manual provides basic background information that must be supplemented with the operator s expertise and specific training available through HUSQVARNA held at regular periods plan ahead before starting work gather any spare parts and tools to avoid ...

Page 5: ...nts a Important Notices b General Information A Maintenance B Troubleshooting C Settings and Adjustments D General Procedures E Adjustments Engine F Engine Disassembly Reassembly F1 Front Suspension I Rear Suspension J Brakes L Electrical system M Engine Cooling N Hydraulically Controlled Clutch P Fuel injection system S Tightening Torque Figures X Chassis and Wheels Y Notes for USA CDN Models Z ...

Page 6: ......

Page 7: ...b 1 b 1st edition 08 2010 _Rev 11 2010 IMPORTANT NOTICES Section ...

Page 8: ...YS remember that these motorcycles are specifically designed for racing i e for usage conditions significantly different from those experienced in regular road use In order to maintain the vehicle s Guarantee of Functionality the client must follow the maintenance programme indicated in Section B by having the required maintenance inspections carried out at authorised HUSQVARNA dealers The cost fo...

Page 9: ...A 1 A 1st edition 08 2010 _Rev 11 2010 GENERAL INFORMATION Section ...

Page 10: ...e A 3 Timing system A 3 Fuel system A 3 Lubrication A 3 Cooling A 3 Ignition system A 3 Starter A 3 Drive and Transmission A 3 Chassis A 4 Suspension A 4 Brakes A 4 Wheels A 4 Tyres A 4 Electrical components location A 5 Supplies A 6 Overall dimensions Weight A 7 ...

Page 11: ...0 011 0 014 in 0 28 0 35 mm Fuel system Type Electronic injection feed Air filtering through lubricated filter Lubrication Type wet sump with two lobe pumps and cartridge filter Cooling Liquid with double radiator and electric fan Ignition system Electronic capacitive discharge with adjustable advance digital control Spark plug type NGK CR 9EKB Spark plug electrode gap 0 03 in 0 7 mm Starting elec...

Page 12: ... 20 348 2nd gear 16 689 3rd gear 13 645 4th gear 11 126 5th gear 9 283 6th gear 8 162 Total transmission ratios SMR 1st gear 17 116 2nd gear 14 038 3rd gear 11 477 4th gear 9 358 5th gear 7 808 6th gear 6 865 Chassis Twin beam and twin cradle steel chassis with round and elliptic cross section rear chassis in aluminium alloy Suspension Front TC TE TXC Fork type Upside down hydraulic fork and advan...

Page 13: ...er cylinder on right side of vehicle Wheels Rims Front TC TE TXC in light alloy 1 6x21 Front SMR in light alloy 3 5x17 Rear TC in light alloy 2 15x19 Rear TE TXC in light alloy 2 15x18 Rear SMR in light alloy 4 25x17 Tyres TC Front 80 100x21 Rear 110 90x19 TXC Front 80 100x21 Rear 110 100x18 TE Front 90 90x21 Rear 140 80x18 SMR Front 120 70x17 Rear 150 60x17 Cold tyre pressure Front TC 12 8 14 22 ...

Page 14: ...f the steering tube The electrical system includes the following elements 12V 6Ah battery under the saddle A 30A fuse positioned on the starter contactor Fuel pump relay positioned on the front left side under the air box Electric fan relay on chassis right hand side Electric fan Coolant temperature sensor Fuel pump inside the tank Condenser Electrical components location TE SMR The ignition syste...

Page 15: ...u in 556 cu cm Cartridge 11 35 cu in 186 cu cm Fork sleeve 22 58 cu in 370 cu cm TE 40 28 cu in 660 cu cm SMR 45 16 cu in 740 cu cm Rear shock absorber oil CASTROL SYNTHETIC FORK OIL 5W Cooling system fluid CASTROL MOTORCYCLE COOLANT 0 24 gal 0 9 litres Front brake fluid CASTROL RESPONSE SUPER DOT 4 Rear brake fluid CASTROL RESPONSE SUPER DOT 4 Clutch fluid CASTROL RESPONSE SUPER DOT 4 Drive chain...

Page 16: ...GENERAL INFORMATION Overall dimensions Weight Kerb weight without fuel TC 108 Kg 238 1 lb Kerb weight without fuel TE 113 Kg 249 12 lb Kerb weight without fuel TXC 110 Kg 242 51 lb Kerb weight without fuel SMR 123 5 Kg 272 27 Ib max width ...

Page 17: ...A 9 1st edition 08 2010 _Rev 11 2010 GENERAL INFORMATION ...

Page 18: ...A 10 820 mm 32 28 inch 1210 mm 47 64 inch 280 mm 11 02 inch 2170 mm 85 43 inch 1460 mm 57 48 inch H06375 SMR 1st edition 08 2010 _Rev 11 2010 GENERAL INFORMATION ...

Page 19: ...B 1 B MAINTENANCE 1st edition 08 2010 _Rev 11 2010 Section ...

Page 20: ...ylinder head C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X Cylinder C X CYLINDER HEAD GASKET S SPARK PLUG P S Piston S Crankshaft S crankcase bearings S OIL PUMP C Primary torque limiter C X Gearbox C X CLUTCH HUB C X CLUTCH PLATES C X CLUTCH PRESSURE PLATE C X CLUTCH HOUSING C X CLUTCH PUSHROD C X ST...

Page 21: ...head C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X Cylinder C X CYLINDER HEAD GASKET S SPARK PLUG P S Piston S Crankshaft S crankcase bearings S OIL PUMP C Primary torque limiter C X Gearbox C X CLUTCH HUB C X CLUTCH PLATES C X CLUTCH PRESSURE PLATE C X CLUTCH HOUSING C X CLUTCH PUSHROD C X STARTER GE...

Page 22: ...ERS VALVE COLLETS C X VALVE BUCKETS ROCKER ARM C X Cylinder head C CAMSHAFT C TIMING CHAIN SLIDER C X TIMING CHAIN S TIMING DRIVEN GEAR C X TIMING DRIVE GEAR C X TIMING CHAIN TENSIONER C X INTAKE COUPLING C X Cylinder C X CYLINDER HEAD GASKET S SPARK PLUG S Piston S Crankshaft S crankcase bearings S OIL PUMP C Primary torque limiter C X Gearbox C X CLUTCH HUB C X CLUTCH PLATES C X CLUTCH PRESSURE ...

Page 23: ...GS C STEERING HEAD STEERING CROWN WITH PIN L C LIGHTS INDICATIONS HORN TE C C BATTERY C WHEEL SPOKES TENSION C C HANDLEBAR HOLDERS AND FASTENINGS SET C C C SECOND DRIVE CHAIN C L S REAR CHAINGUIDE REAR CHAIN GUARD C X CHAIN SLIDER C X GEARB OUTPUT SPROCKET REAR SPROCKET C C X Roulements ancrage bras oscillant sur châssis L Embiellage suspension arrière roulements amortisseur L THROTTLE CONTROL ASS...

Page 24: ...ES TENSION C C HANDLEBAR HOLDERS AND FASTENINGS SET C C SECOND DRIVE CHAIN L C L C X REAR CHAINGUIDE REAR CHAIN GUARD C X CHAIN SLIDER C X GEARB OUTPUT SPROCKET REAR SPROCKET C C X Roulements ancrage bras oscillant sur châssis L Embiellage suspension arrière roulements amortisseur L REAR SHOCK ABSORBER SMR C X THROTTLE CONTROL ASSY C L OVERALL TIGHTENING OF NUTS AND BOLTS C C CLUTCH CONTROL ASSY C...

Page 25: ...C 1 C 1st edition 08 2010 _Rev 11 2010 TROUBLESHOOTING Section ...

Page 26: ...tle body is not receiving fuel 1 Faulty fuel pump relay Change 2 Faulty fuel pump Check change 3 Clogged fuel inlet hose Clean Engine stalls 1 Fouled spark plug Clean easily 2 Electronic control unit faulty Replace 3 Dirty injector Clean 4 Low idle Adjust Engine is noisy Noise seems to come from piston 1 Too much piston to cylinder clearance Replace 2 Worn piston rings or piston grooves Replace 3 ...

Page 27: ...turn spring Replace 2 Worn shifter forks Replace Transmission jumps out of gear 1 Worn sliding gear dogs Replace 2 Worn gear grooves Replace 3 Worn dog slots in gears Replace 4 Worn selector shaft splines Replace 5 Damaged shifter fork shafts Replace Engine has low power 1 Dirty air filter Clean 2 Poor fuel quality Replace 3 Intake coupling loose Tighten 4 Spark plug electrode gap too wide Adjust ...

Page 28: ...g is 1 Insufficient oil in fork legs Top up too soft 2 Fork oil viscosity too low Change 3 Weak fork springs Replace 4 Weak rear shock absorber spring Replace 5 Improperly set rear shock absorber Adjust Front rear wheel 1 Bent wheel rim Replace shakes 2 Worn wheel hub bearings Replace 3 Incorrect spoke tension Adjust 4 Wheel axle nut loose Tighten 5 Worn rear swinging arm bearings Replace 6 Improp...

Page 29: ...g to voltage regulator improperly connected or Connect correctly or is not providing enough charge shorted replace 2 Voltage regulator faulty Replace 3 Generator coil faulty Replace Generator overcharges battery 1 Voltage regulator faulty Replace Battery does not hold charge 1 Battery terminals dirty Clean Starter motor 1 Battery is flat Charge does not start or slips 2 Control on R H switch fault...

Page 30: ......

Page 31: ...D 1 D SETTINGS AND ADJUSTMENTS 1st edition 08 2010 _Rev 11 2010 Section ...

Page 32: ...ge cleaning or replacement D 13 Coolant level check D 14 Coolant replacement D 15 Air filter check D 16 Air filter cleaning D 16 Chain adjustment D 17 Chain lubrication D 18 Disassembling and cleaning D 18 Washing chain without O rings TC D 18 Lubricating chain without O rings TC D 18 Lubricating chain with O rings TE TXC SMR D 18 Suspension setup according to track condition D 19 Shock absorber a...

Page 33: ...D 3 H006104 TC H006105 TE H006106 TXC H06374 SMR SETTINGS AND ADJUSTMENTS 1st edition 08 2010 _Rev 11 2010 ...

Page 34: ...NGS AND ADJUSTMENTS Saddle removal Turn pin 1 counter clockwise and remove saddle 2 from central retaining screw Side panel removal Remove the saddle as described in the relevant paragraph Left hand side panel Loosen the four screws 1 using an 8 mm wrench and remove the side panel 2 ...

Page 35: ...4 4 6 5 H006113 3 3 SETTINGS AND ADJUSTMENTS 1st edition 08 2010 _Rev 11 2010 Right hand side panel Loosen the five screws 3 using an 8 mm wrench release side panel 4 from scoop 5 by disengaging retaining tabs 6 ...

Page 36: ...ddle and side panels as described in the relevant para graphs Left hand side scoop Loosen the three screws 1 using an 8 mm wrench and remove the scoop 2 Right hand side scoop Loosen the two screws 3 using an 8 mm wrench and remove horn 4 and scoop 5 Engine guard removal Loosen the screws 1 using an 8 mm wrench and remove the engine guard 2 ...

Page 37: ...08 in should this not be the case loosen check nuts 4 and 5 turn and keep twistgrip 3 in the fully closed position loosen upper return cable 6 using adjuster screw 7 keeping twistgrip 3 fully closed reset cable 6 clearance by turning ad juster screw 7 tighten check nut 4 turn adjuster screw 8 until reaching an opening clearance of approx 2 mm 0 08 in tighten check nut 5 reassemble all parts in the...

Page 38: ...ticlockwise through 33 clicks until obtaining an idle speed of 1 850 1 950 rpm which can be read using the suitable diagnosis instrument Idle adjustment TE TXC SMR Adjust the carburettor with warm engine and with the throttle control in closed position Proceed as follows Turn adjuster screw 1 with a screwdriver until reaching an idle speed of 1 850 1 950 rpm to be detected by the special diagnosis...

Page 39: ...tment and fluid level check TC TE TXC The adjuster 1 located on the control lever allows adjusting of the free play a Free play a shall be of at least 3 mm 0 12 in The level of the fluid in master cylinder reservoir must never be below the mini mum value 2 which can be checked from the inspection window on the rear of the master cylinder body A decrease of the fluid level will let air into the sys...

Page 40: ...let air into the system hence an extension of the lever stroke If the brake lever feels mushy when pulled there may be air in the brake line or the brake may be defective CHECK THE BRAKING SYSTEM see Section L Too much brake lever free play may reduce braking action CHECK BRAKE PAD THICKNESS see Section L Do not spill brake fluid onto any painted surface or lens for example lights lens Do not mix ...

Page 41: ...paragraph Rear brake pedal free play adjustment Rear brake pedal free play adjustment Before staring the braking action rear brake pedal shall have a free play B of 5 mm 0 2 in Should this not happen operate as follows Loosen the nut 3 Operate the master cylinder linkage 4 to increase or decrease free play Tighten the nut 3 at the end of the operation When the free play requirement is not met the ...

Page 42: ...th con sequent wrong topping up Start vehicle as described in the relevant section let it run for approx 3 to 5 minutes so as to warm engine up Turn engine off With the vehicle in a flat ground and in vertical position check oil level through the inspection sight glass 1 positioned on engine right casing Make sure the level is in between the MIN and MAX notches To top up remove filler cap 2 To ens...

Page 43: ...move the engine guard as described under the relevant paragraph Remove the oil filler cap 1 put a drip pan under engine remove oil drainage plug 2 evacuate the exhausted oil and clean magnet on plug 2 on reassembly tighten plug 2 to a torque of 15 Nm 1 5 Kgm 11 6 ft lb loosen the two caps 3 and remove the two mesh filters 4 and 5 on reassembly tighten the two plugs 3 to a torque of 10 Nm 1 0 Kgm 7...

Page 44: ... that oil quantity does not exceed MAX level set the vehicle on the side stand TE TXC SMR or on triangle stand left side TC and check through the sight glass 1 that in this position the level drops below the MAX reference notch Coolant level check Check level 1 inside left radiator with the engine cold and the vehicle in vertical position The coolant should be approximately 10 mm 0 4 in above the ...

Page 45: ...e vessel Reassemble the screw 1 To fill in the system set motorcycle on a central stand or in any case keep the bike in a vertical position not on the side stand Pour the necessary quantity of coolant in the radiator then warm up the en gine in order to eliminate any possible air bubbles Allow the coolant to cool down then remove cap 2 and check the level as explained under Coolant level check Per...

Page 46: ...rts in reverse order making sure to position filter sponge 5 with the TOP wording facing up Refit filter 2 inside guides push it all the way down and lock it using the clip on fasteners 1 Air filter cleaning Wash the filter with a specific detergent CASTROL FOAM AIR FILTER CLEAN ER or similar then dry it fully wash filter with gasoline only in case of need Plunge the filter in special oil for filt...

Page 47: ...tension involves excessive and early wear of the chain slider lower part periodically check for wear and replace it if worn out If it is not proceed as follows on the right side with a 27 mm Allen wrench loosen the locking nut 2 of the wheel axle loosen the check nuts 3 on both chain tensioners with a 12 mm wrench and work on the screws 4 with a 10 mm wrench to achieve the right tension when the a...

Page 48: ...thylene or solvents as the O rings may get damaged Use instead special sprays for chains with O rings Lubricating chain without O rings TC After drying dip the chain in Molybdenum Disulphide chain lubricant if possible or in warm high viscosity engine oil if warmed up oil will be more fluid As an alternative you can use suitable spray lubricants Lubricating chain with O rings TE TXC SMR Lubricate ...

Page 49: ...ecially harder rebound settings Work on the spring preload to lower the motorcycle riding height rear end MUDDY GROUND Front fork set compression harder or replace the standard spring with a harder spring Shock absorber harder compression and rebound settings or replace the standard spring with a harder spring Work on the spring preload to lift the motorcycle riding height rear end Changing the sp...

Page 50: ...rider Measure dimension A The difference between dimension A with the wheel raised off the ground and dimension A with the wheel on the ground shall be 40 45 mm 1 57 1 77 in 3 Have bike resting on the ground with rider sitting on it Measure dimension A The difference between dimension A with the wheel raised off the ground and dimension A with the wheel on the ground and rider sitting on it shall ...

Page 51: ...f the spring 3 3 Either with a hook wrench or an aluminium punch loosen the lock ring nut 4 Turn the adjuster ring nut as required 5 Adjust preload to suit your weight or riding style and tighten the lock ring nut firmly tightening torque 10 Nm 1 Kgm 7 38 ft lb 6 Refit the right hand side panel and the saddle Be careful not to touch hot exhaust pipe while adjusting the shock absorber A Spring stan...

Page 52: ...and adjuster ring nut 2 of the spring 3 3 Either with a hook wrench or an aluminium punch loosen the lock ring nut 4 Turn the adjuster ring nut as required 5 Adjust preload to suit your weight or riding style and tighten the lock ring nut firmly tightening torque 10 Nm 1 Kgm 7 38 ft lb 6 Refit the right hand side panel and the saddle Be careful not to touch hot exhaust pipe while adjusting the sho...

Page 53: ... standard setting turn upper adjusters 1 and 2 clockwise until reach ing fully closed position Then turn them back to the above mentioned positions In order to obtain a smooth braking action turn the adjusters counter clockwise Vice versa to obtain a harder braking action B REBOUND Standard setting TE 18 turns TC TXC 17 turns SMR 11 click 2 click To reset the standard setting turn lower adjuster 3...

Page 54: ...er braking action REBOUND Fig b TC TXC LOWER ADJUSTER TE TOP ADJUSTER TC TXC 10 clicks TE 14 clicks To reset standard calibration turn adjuster C clockwise to reach the fully closed position then turn it back by the mentioned clicks In order to obtain a smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action BLEEDING Fig a b to carry out after each co...

Page 55: ... In order to obtain a smooth braking action turn the adjuster counter clockwise Vice versa to obtain a harder braking action c BLEEDING to carry out after each competition or monthly Set the motorcycle on a central stand release the fork fully extended and loosen the air vent valve D Once this operation is over tighten the valve Never force the adjusting screws beyond the maximum open and closed p...

Page 56: ...l in a front to rear motion to feel for play If any play is detected adjust as follows Remove the saddle Loosen the steering head tube nut 1 Loosen the two bolts 3 that secure the fork legs to the steering head turn ring nut 2 on steering tube clockwise using the suitable special wrench until obtaining correct clearance tighten the steering head tube nut 1 to 8 9 Kgm 78 4 88 3 Nm Tighten the four ...

Page 57: ...l as described in the relevant paragraphs Release the control unit 1 off its mounts and remove it from its housing Using a Phillips screwdriver loosen the clamp 2 connecting the tube 3 to throttle body 4 Remove the front tank tank with pump as described in the corresponding paragraph Slide the tank 5 with tube 3 connected off the bike Using the suitable pliers open clamp 6 and remove tube 3 from t...

Page 58: ...08 2010 _Rev 11 2010 SETTINGS AND ADJUSTMENTS Exhaust system check Remove exhaust system components as described in Section E Ensure that pipe 1 and silencer 2 do not show any sign of failure or damage replace if cracked or damaged ...

Page 59: ...E 1 E 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Section ...

Page 60: ...val SMR E 15 Exhaust System Removal TE TXC E 16 Exhaust system removal TC E 19 Rear chassis removal E 21 Rear tank removal E 23 Solenoid starter removal E 23 CDI electronic control unit removal E 24 Voltage regulator removal E 24 Coil removal and spark plug check E 25 Clutch hose removal E 27 Horn removal TE SMR E 28 Electric cooling fan removal TE TXC SMR E 28 Air filter box removal E 29 Engine g...

Page 61: ... GENERAL PROCEDURES Saddle removal Turn pin 1 counter clockwise and remove saddle 2 from chassis fastening Side panel removal Remove the saddle as described in the relevant paragraph Left hand side panel Loosen the four screws 1 using an 8 mm wrench and remove the side panel 2 ...

Page 62: ...6114 4 6 5 H006113 3 3 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Right hand side panel Loosen the five screws 3 using an 8 mm wrench release side panel 4 from scoop 5 by disengaging retaining tabs 6 ...

Page 63: ...ber plate holder and mudguard Loosen the four screws 2 with a 8 mm wrench and remove front mudguard 3 Number Plate Holder Removal TE SMR Remove rear turning indicators as described in the relevant section Using a 8 mm wrench loosen the two screws 1 disconnect number plate bulb 3 and remove number plate holder 2 On reassembly check the correct positioning of the two bushings 4 ...

Page 64: ...ddle the two side panels and the number plate holder TE SMR as described in the relevant paragraphs Using a 8 mm wrench loosen the two screws 1 positioned under rear mudguard disconnect connector 2 TE SMR and remove tail light Using a 8 mm wrench loosen the two front retaining screws 3 and remove the complete mudguard 4 ...

Page 65: ...tive cable 1 then the RED positive cable 2 when reassembling first connect the RED positive cable then the BLACK negative cable release retaining elastic strap 3 and remove battery 4 from its compartment Tank Removal Close both fuel cocks 1 Remove the saddle and the two side panels as described in the relevant paragraphs Release the electronic control unit 2 off its mounts and move it aside ...

Page 66: ...5 6 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Undo the upper clamp 3 connecting fuel pump to throttle body Disconnect pump supply connector 4 Slacken clamp 5 with long nose pliers and disconnect breather hose 6 from tank ...

Page 67: ...per screw 8 using a 14 mm wrench undo and remove lower bolt 9 with two 14 mm wrenches then remove engine left connecting rod 10 as for TC model remove exhaust manifold as described in the relevant paragraph to undo bolt 9 On reassembly position connecting rod 10 with the written side facing the inner part of the bike to a tightening torque of 50 Nm 5 0 Kgm 36 88 ft lb loctite 243 ...

Page 68: ...DURES With a 8 mm socket wrench undo screw 11 and remove the screw with rubbers and spacers On reassembly tighten screw 11 to 10 Nm 1 0 Kgm 7 38 ft lb Remove tank 12 and drain any residual fuel through cock For upper tank removal refer to the rear chassis removal paragraph ...

Page 69: ...ce throttle body supply hose 3 open metal clamp 4 and then after hose replacement close clamp again using the special pliers On reassembly tighten screws 1 to a torque of 7 Nm 0 7 Kgm 5 16 ft lb checking that the O ring 8 is correctly positioned in its seat and it is not damaged Cock Removal Remove lower fuel tank as described in the relevant paragraph Using a Phillips screwdriver loosen screws 1 ...

Page 70: ...graph Use a 4 mm Allen wrench to loosen the screw 1 and remove the cover 2 of the throttle body Using a 10 mm Allen wrench loosen nuts 3 and 4 and remove cables 5 and 6 On reassembly cable 6 with the RED ring shall be fitted onto throttle body lower side Loosen clamp 7 of intake coupling 8 squeeze hose coupling on the inner side filter box side until it comes out of its seat Using a screwdriver pr...

Page 71: ... 13 12 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Disconnect injector connector 9 Detach the pressure sensor 10 From the right side TE TXC SMR remove second throttle connector 11 second throttle TPS connector 12 and TPS connector 13 ...

Page 72: ...t edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES TC disconnect TPS connector 14 Loosen intake manifold 16 upper screw 15 Working on bike right side slightly lift throttle body and turn it clockwise by 90 then remove it from bike left side ...

Page 73: ...E 15 SMR H06518 1 2 3 4 5 6 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Exhaust System Removal SMR Key SMR Silencer 1 Clamp 2 Seal 3 Lambda sensor 4 Manifold 5 Seal 6 ...

Page 74: ...XC H06517 1a 1 2 3 4 5 6 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Exhaust System Removal TE TXC Key TE TXC 1 Silencer Lanfranconi 1a Silencer Krapovic 2 Clamp 3 Seal 4 Lambda sensor 5 Manifold 6 Seal ...

Page 75: ... _Rev 11 2010 GENERAL PROCEDURES Working on the right side loosen upper screw 1 using a 12 mm T wrench Working on the left side loosen screw 2 using a 12 mm T wrench Loosen clamp 4 screw 3 with a 13 mm wrench and move it onto the exhaust manifold Remove silencer 5 ...

Page 76: ... 8 7 H02449 9 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Cut Lambda sensor cable clamps and remove connector 6 Loosen the two screws 7 using a 12 mmAllen wrench then remove manifold 8 On reassembly replace seal 9 ...

Page 77: ...E 19 TC H02450 4 6 5 7 3 2 1 8 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Exhaust system removal TC Key Silencer 1 Spring 2 Manifold 3 Spring 4 Flange 5 Bushing 6 Seal 7 Nut 8 ...

Page 78: ...edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Working on the right side loosen support clamp upper screw 1 using a 12 mm T wrench Working on the left side loosen screw 2 using a 12 mm T wrench Release spring 3 Remove silencer 4 4 H02520 ...

Page 79: ...en remove flange 8 bushing 9 and gasket 10 On reassembly screw nuts 7 to a torque of 26 Nm 2 65 Kgm 19 18 ft lb Rear chassis removal Remove saddle side panels number plate holder rear mudguard exhaust silencer and battery as described in the relevant paragraphs Disconnect control unit 1 and solenoid starter 2 from their mounts Detach tank breather hoses 3 from tank 4 H02523 6 3 10 8 9 7 5 ...

Page 80: ...tion 08 2010 _Rev 11 2010 GENERAL PROCEDURES Cut clamps 5 of the rear wiring harness Make sure that fuel tank cocks are closed then disconnect hose 6 from rear tank cock 7 Using a 10 mm wrench loosen the four screws 8 and remove the chassis 9 with tank 10 ...

Page 81: ...ing tank 2 to rear chassis 3 and remove tank on reassembly check the correct positioning of the bushings Solenoid starter removal Remove the saddle as described in the relevant paragraph Disconnect the negative and positive cables of the battery Disconnect the starter motor positive cable 1 from the solenoid starter 2 Disconnect the connector 3 and remove the solenoid starter 2 from its mount ...

Page 82: ...cribed in the relevant paragraph Remove the connector 1 from the CDI electronic control unit 2 and take the control unit together with its anti vibration mount out of the chassis Voltage regulator removal Remove the saddle as described in the relevant paragraph Loosen the screws 1 using a 8 mm wrench Disconnect the connector 2 and remove voltage regulator 3 ...

Page 83: ...ine the state of the spark plug just after it has been removed from the engine since the scale deposits on the plug and the colour of the insulator provide useful indications Correct heat rating The tip of the insulator should be dry and the colour should be light brown or grey High heat rating In this case the insulator tip is dry and covered with dark deposits Low heat rating In this case the sp...

Page 84: ...y using one having the same rating Before refitting the plug thoroughly clean the electrodes and the insula tor using a metal brush Apply graphitised grease on spark plug thread screw it by hand all the way down then tighten it to the torque of 10 12 Nm 7 38 8 85 ft Ib Loosen spark plug and tighten it again to 10 12 Nm 7 38 8 85 ft Ib Spark plugs which have cracked insulators or corroded electrode...

Page 85: ...rew 1 with a 8 mm wrench and move number plate holder or headlamp fairing Loosen screw 2 with a 8 mm wrench and remove the cover 3 Loosen screw 4 with a 8 mm wrench and disconnect clamp 5 from engine Loosen clutch hose 7 union 6 and drain all oil out of hose On reassembly bleed the clutch system as described in Section P ...

Page 86: ...S Horn removal TE SMR Loosen the two screws 1 using a 8 mm wrench Disconnect connector 2 and remove horn 3 Electric cooling fan removal TE TXC SMR Remove saddle first and then the left side panel Disconnect the connector 1 Loosen the four screws 2 with a 7 mm wrench and remove electric fan 3 ...

Page 87: ... box removal Remove saddle left and right side panels filter and voltage regulator as indicated in the relevant paragraphs Loosen screw 1 with a 8 mm wrench securing left scoop Loosen intake coupling 3 clamp 2 and slide coupling out from the front side Disconnect air temperature sensor connector 4 ...

Page 88: ...02475 5 H02476 7 6 H02478 6 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Disconnect Blow by hose 5 Loosen the three screws 6 with a 8 mm wrench Lower filter box 7 and remove it from the bike right side ...

Page 89: ...t wrench loosen the three screws 1 and remove engine guard 2 Gear shift pedal removal Remove chain and engine guard as indicated in the relevant paragraph Engage the 2nd gear with the gear shift pedal 1 Using a 8 mm socket wrench loosen screw 2 and remove gear shift pedal 1 on reassembly tighten screw 2 to 10 Nm 1 02 Kgm 7 38 ft lb ...

Page 90: ...Remove chain and gear shift pedal as indicated in the relevant para graphs Loosen screw 2 and remove chain guard 1 Fit a support under the engine so that the rear wheel is raised off the ground Loosen lower screw 3 using two 14 mm wrenches Loosen the three screws 4 with a 8 mm wrench securing chain slider 5 to swinging arm 6 ...

Page 91: ...0 _Rev 11 2010 GENERAL PROCEDURES Loosen screw 7 with a Phillips screwdriver Loosen screw 9 with a 8 mm wrench and remove chain roller 8 Loosen screws 11 with a 8 mm wrench and remove sprocket guard 10 Raise rear wheel 12 and keep it raised off the ground with a belt ...

Page 92: ...E 34 H02489 5 A H02490 5 B 1st edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Slide out the chain slider 5 as shown in figures A and B ...

Page 93: ...oosen screw 1 positioned onto pump body and drain off cooling sys tem Loosen clamps 2 and remove engine cooling hoses 3 4 and 5 Loosen screw 6 with an 8 mm wrench and detach ground cable 8 To loosen the nut 7 retaining the Motor positive cable 9 it is neces sary to use two 8 mm wrenches one to hold the lock nut 7a and the other to loose the nut 7 retaining the cable This operation is required to p...

Page 94: ...oosen screw 10 with a 8 mm wrench and remove cover 11 Loosen screw 12 with a 8 mm wrench and disconnect clamp 13 from engine Loosen the three screws 14 with a 8 mm wrench and disconnect clutch actuator 14a Disconnect spark plug cap coil 16 connector 15 loosen screw 18 with a 8 mm wrench and disconnect ground cable 19 ...

Page 95: ...OCEDURES Turn coil 16 by 90 so that connector is pointing to bike rear end then remove it Disconnect Blow by hose 20 Loosen screw 21 and screw 22 with a 14 mm wrench and remove right connecting rod 23 Disconnect all engine wiring harnesses Loosen screw 24 and remove neutral sensor wiring harness 25 ...

Page 96: ...L PROCEDURES Remove rear brake pedal 26 by loosening screw 27 with a 6 mm Allen wrench and releasing spring 28 Loosen rear engine mounting bolt 29 with two 14 mm wrenches and the two front screws 30 with a 12 mm wrench engine will rest on chassis cradle Remove engine from chassis right side ...

Page 97: ... edition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Radiator Removal Remove saddle side panels scoops and radiator grids as described in the relevant paragraphs Drain off all coolant as indicated in the relevant paragraph Loosen clamps 1 and remove hoses 2 ...

Page 98: ...ition 08 2010 _Rev 11 2010 GENERAL PROCEDURES Disconnect temperature sensor connector 3 Disconnect electric fan connector 4 TE TXC SMR Loosen the four screws 5 with a 8 mm wrench and remove left hand ra diator 6 complete with fan TE TXC SMR and right hand radiator 7 ...

Page 99: ...F 1 F ADJUSTMENTS ENGINE 1st edition 08 2010 _Rev 11 2010 Section ...

Page 100: ...F 2 ADJUSTMENTS ENGINE 1st edition 08 2010 _Rev 11 2010 Valve clearance check F 3 Set valve clearance cylinder head cover removed F 4 ...

Page 101: ...mm TE TXC SMR Intake valve clearance with cold engine Max 35 C 2 84 3 56 in 0 20 0 25 mm TC Exhaust valve clearan ce with cold engine Max 35 C 3 56 4 27 in 0 25 0 30 mm TE TXC SMR Exhaust valve clearan ce with cold engine Max 35 C 4 27 4 98 in 0 30 0 35 mm TC Result Valve clearance outside tolerance values Action When assembling use adjuster plates and the correct half balls Take note of readings ...

Page 102: ... 2010 Engine positioning at ignition TDC Turn engine until reaching TDC Reference marks arrows parallel with cylinder head Securing crankshaft at TDC Remove screw 1 with sealing ring Lock crankshaft at TDC using special tool 8000H5009 Set valve clearance cylinder head cover removed ...

Page 103: ...hen from exhaust shaft 3 and lay it in a safe position to prevent it from falling to the ground Remove intake camshaft 2 Remove exhaust camshaft 3 Mark bucket type tappet Take out bucket type tappets overturn rocker arms Before fitting shims and new half balls measure the thickness using a mi crometer calliper Replace shims and half balls making sure they are correctly positioned Take rocker arms ...

Page 104: ...ing mount assembly Assemble guide sleeves 4 Lubricate mount 3 at camshaft sliding surfaces then assemble it Consumables Molykote D Paste Consumables Clear solid lubricant for metal part assembling and settling Fit long 1 and short 2 screws tightening them by hand Bearing mount securing Tighten screws according to the indicated sequence Tightening torque figures Camshaft mount on cylinder head M8 x...

Page 105: ...rance with cold engine Max 35 C 2 84 3 56 in 0 20 0 25 mm TC Exhaust valve clea rance with cold engine Max 35 C 3 56 4 27 in 0 25 0 30 mm TE TXC SMR Exhaust valve clea rance with cold engine Max 35 C 4 27 4 98 in 0 30 0 35 mm TC Result Valve clearance outside tolerance values Action Valve clearance adjustment Crankshaft disconnection Remove special tool N 8000H5009 Fit screw 1 with new sealing rin...

Page 106: ......

Page 107: ...F1 1 F1 ENGINE DISASSEMBLY REASSEMBLY 1st edition 08 2010 _Rev 11 2010 Section ...

Page 108: ...ioning at ignition TDC 15 Securing crankshaft at TDC 15 Camshaft disassembly 16 Camshaft assembly 16 Bearing mount disassembly 16 Camshaft check 16 Bearing mount assembly 17 Bearing mount fitting 17 Engine left crankcase 18 Engine left crankcase cover disassembly 18 Engine left crankcase cover assembly 18 Alternator replacement 19 Flywheel disassembly 19 Stator disassembly 20 Freewheel disassembly...

Page 109: ...kcase oil seal replacement crankcase cover removed 39 Coolant pump control rear oil seal disassembly 39 Coolant pump control shaft check 39 Coolant pump control rear oil seal assembly 39 Coolant pump drive replacement crankcase cover removed 40 Slider loosening at the lower area 40 Coolant pump shaft disassembly 40 Coolant pump shaft assembly 41 Slider assembly at the lower area 41 Chain front spr...

Page 110: ...il intake pump replacement crankcase cover removed 64 Removing oil intake pump 64 Fitting oil intake pump 64 Removing and assembling or replacing pressure oil pump 65 Oil force pump disassembly 65 Oil force pump assembly 65 Oil pump shaft 66 Oil pump shaft disassembly 66 Oil pump shaft assembly 66 Replacing gearbox control shaft radial sealing ring 67 Removing oil seal from gearbox shaft 67 Fittin...

Page 111: ...sassembly assembly 85 Crankcase left half disassembly 85 Gearbox disassembly 85 Gearbox check 85 Disassembly Reassembly of the gearbox 5 Speed TC 86 Disassembly Reassembly of the gearbox 6 Speed TE TXC SMS 88 Gearbox oil pipe disassembly 90 Gearbox oil pipe assembly 90 Gearbox input shaft right bearing disassembly 90 Gearbox input shaft left bearing disassembly 90 Gearbox output shaft right bearin...

Page 112: ...F1 6 ENGINE DISASSEMBLY REASSEMBLY 1st edition 08 2010 _Rev 11 2010 Gear selector lock replacement 103 Gear selector disassembly 103 Gear selector assembly 103 ...

Page 113: ...embly Remove plug 1 with O Ring 2 Disassemble oil filter 3 Oil filter assembly Assemble oil filter 3 Assemble screw 1 with the O Ring 2 slightly greased Tightening torque figures Oil filter cover on crankcase M45 x 1 5 with O Ring Grease thread 15 Nm 1 5 Kgm 11 06 ft lb Oil filter replacement ...

Page 114: ...t edition 08 2010 _Rev 11 2010 Disassemble front oil mesh filter Disassemble the following parts screw 1 Filter 3 O Rings 2 4 5 Disassemble rear oil mesh filter Disassemble the following parts screw 1 Filter 3 O Rings 2 4 5 Engine oil filter disassembly ...

Page 115: ... 1 Tightening torque figures Oil mesh filter screw plug on crankcase M20 x 1 5 with O Ring Grease thread 10 Nm 1 Kgm 7 38 ft lb Assemble front oil mesh filter Assemble the following parts O Rings 5 4 2 Filter 3 Fit screw 1 Tightening torque figures Oil mesh filter screw plug on crankcase M20 x 1 5 with O Ring Grease thread 10 Nm 1 Kgm 7 38 ft lb Engine oil filter assembly ...

Page 116: ...ion coil disassembly Disassemble the following parts Screw 1 Spark plug recess ignition coil 2 Spark plug recess ignition coil assembly Fit spark plug recess ignition coil 2 Fit screw 1 Tightening torque figures Ignition coil inside engine M5 x 16 10 9 6 Nm 0 6 Kgm 4 43 ft lb Spark plug recess ignition coil ...

Page 117: ...BLY 1st edition 08 2010 _Rev 11 2010 Spark plug recess disassembly Remove seal 1 and spark plug recess 2 Spark plug recess assembly Check lower O Ring inside cylinder head recess for damages Assemble spark plug recess 2 and seal 1 Spark plug recess ...

Page 118: ...11 2010 Spark plug disassembly Disassemble spark plug using a wrench suitable tool Spark plug assembly Fit spark plug 1 using the 16 mm spark plug bushing Tightening torque figures Spark plug inside cylinder head M10 Lubrication Copper paste 12 Nm 1 2 Kgm 8 85 ft lb Spark plug ...

Page 119: ...ter piston 1 Oil pressure adjustment valve assembly Grease adjuster piston and spring Consumables Castrol GPS SAE 10W 40 Engine oil Assemble the following parts Adjuster piston 4 Spring 3 Seal 2 Fit screw 1 Tightening torque figures Oil adjustment valve screw plug onto crankcase M14 x 1 with sealing ring Grease thread 15 Nm 1 5 Kgm 11 06 ft lb Oil pressure adjustment valve replacement ...

Page 120: ... 2 with gasket 3 Fitting cylinder head cover Clean gasket 3 and cylinder head and cylinder head cover 2 sealing sur face Apply sealant onto gasket Consumables 3 Bond 1209 Surface sealer Assemble cylinder head cover 2 with gasket 3 Fit screws with seal 1 Tightening torque figures Cylinder head cover on cylinder head M6 Grease thread 7 Nm 0 7 Kgm 5 16 ft lb Cylinder head cover ...

Page 121: ...BLY 1st edition 08 2010 _Rev 11 2010 Engine positioning at ignition TDC Turn engine until reaching TDC Reference marks arrows parallel with cylinder head Securing crankshaft at TDC Remove screw 1 with sealing ring Lock crankshaft at TDC using special tool 8000H5009 ...

Page 122: ...ound Remove intake camshaft 2 Remove exhaust camshaft 3 Camshaft check Check Check camshafts and bearings for wear and damages Result Camshaft with worn or damaged bearing Action Replace camshaft Camshaft removal Camshaft assembly Make sure that crankshaft is well secured at TDC Lubricate all bearing surfaces Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling...

Page 123: ...g and settling Fit long 1 and short 2 screws tightening them by hand Bearing mount securing Tighten screws according to the indicated sequence Tightening torque figures Camshaft mount on cylinder head M8 x 30 Grease thread Pre tightening torque 10 Nm 1 Kgm 7 38 ft lb Final tightening torque 20 Nm 2 Kgm 14 75 ft lb M8 x 40 Grease thread Pre tightening torque 10 Nm 1 Kgm 7 38 ft lb Final tightening ...

Page 124: ...assembly Clean sealing surface Assemble the following parts Oil spraying nozzle 7 Guide sleeves 6 Gasket 5 Cover 4 Fit screws 2 with new washers 3 Tightening torque figures Engine and crankcase fairing screw connections M6 x 25 11 Nm 1 1 Kgm 8 11 ft lb Fit screws 1 with new sealing rings 3 Tightening torque figures Engine and crankcase fairing screw connections M6 x 30 11 Nm 1 1 Kgm 8 11 ft lb Tig...

Page 125: ...nt Preliminary operations Engine oil drainage Engine positioning at ignition TDC Securing crankshaft at TDC Engine left crankcase cover disassembly Flywheel disassembly Remove nut 1 Heat flywheel 1 Technical specifications Release connection temperature 80 C Remove flywheel 1 using puller N 8000H5011 and presser N 8000H5013 ...

Page 126: ...ubber sheath 4 Stator 5 Freewheel disassembly Disassemble the following parts Screws 1 Flywheel 2 Freewheel 3 Freewheel assembly Clean freewheel 3 threaded holes Position flywheel 2 onto freewheel 3 Fit screws 1 Tightening torque figures Freewheel body onto flywheel M6 x 12 10 9 Cross head microincapsulated screw replacement Pre tightening torque 3 Nm Final tightening torque 25 Nm ...

Page 127: ...209 Surface sealer Position retaining plate 4 and pulse transducer 3 Insert rubber sleeve 2 Tighten screws 1 Tightening torque figures Pulse transducer onto engine left crankcase cover M5 x 12 10 9 Microincapsulated screw replacement 6 Nm Flywheel assembly Clean flywheel and crankshaft cone as well as thread Apply a thin layer of sealant onto flywheel cone Consumables Loctite 638 Sealant Fit flywh...

Page 128: ...ing 2 Bearing 3 Washer 4 Lay crankcase cover 1 onto a suitable base and protect it against scratch es Insert washer 4 inside crankcase cover 1 Heat crankcase cover 1 at the bearing 3 Technical specifications Release connection temperature 80 C Fit bearing 3 and centring ring 2 all the way down using a suitable tool Crankcase left cover replacement Stator assembly Clean screw 1 and 5 threaded holes...

Page 129: ...onto rubber sheath 2 sealing surfaces Consumables 3 Bond 1209 Surface sealer Position retaining plate 4 and pulse transducer 3 Insert rubber sleeve 2 Tighten screws 1 Tightening torque figures Pulse transducer onto engine left crankcase cover M5 x 12 10 9 Microincapsulated screw replacement 6 Nm ...

Page 130: ...s Engine oil drainage Engine left crankcase cover disassembly Crankshaft sensor disassembly Remove screws 1 Remove crankcase sensor 2 Crankshaft sensor assembly Assemble crankcase sensor 2 Fit new screws 1 Tightening torque figures Pulse transducer onto engine left crankcase cover M5 x 12 10 9 Microincapsulated screw replacement 6 Nm ...

Page 131: ...Needle roller bearing 4 Freewheel gear replacement Freewheel gear assembly Lubricate needle roller bearing 4 and gear 3 then fit them Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit guide 2 with screws 1 Tightening torque figures Starter motor freewheel retainer onto crankcase M5 Microincapsulated screw replacement 6 Nm ...

Page 132: ...r replacement Preliminary operations Engine oil drainage Securing crankshaft at TDC Brake pedal release Clutch actuator disassembly Clutch cover disassembly Remove screws 1 Remove clutch cover 2 with gasket 3 Removing clutch pressure plate Disassemble the following parts Presser 1 O Ring 2 Bearing 3 Screws 4 Pressure plate 5 ...

Page 133: ...1 2010 Removing clutch plates Remove clutch plates pack 1 Technical specifications Clutch plates number 6 steel plates 6 lined plates Clutch hub disassembly Remove nut 1 Remove hub 2 Clutch housing disassembly Disassemble the following parts Thrust washer 1 Clutch housing 2 Bearing 3 ...

Page 134: ...ble clearance Action Replace clutch housing seat crankcase cover removed Clutch housing clearance reading Fit needle roller bearing cage 1 clutch housing 2 thrust washer 3 and hub 4 Fit nut 5 Tightening torque figures Clutch hub on crankshaft Collar nut M20 x 1 5 10 9 Replace microincapsulated screw nut 120 Nm Check using a feeler gauge 2 read the axial clearance between clutch housing 1 and axial...

Page 135: ...t washer If needed repeat the procedure Technical specifications Space washers thickness for clutch cage distance adjustment 2 200 mm 2 250 mm 2 300 mm 2 350 mm 2 400 mm 2 450 mm 2 500 mm 2 550 mm 2 600 mm Disassemble the following parts Hub 4 Thrust washer 3 Clutch housing 2 Needle roller bearing cage 1 ...

Page 136: ...mble clutch housing 2 Fit thrust washer 1 Clutch hub assembly Lubricate hub 2 inner toothing and fit it Consumables MP 3 paste High performance lubricating grease Clean crankshaft thread and nut 1 Fit nut 1 Tightening torque figures Clutch hub on crankshaft Collar nut M20 x 1 5 10 9 Replace microincapsulated screw nut 120 Nm Fit clutch plates Take special care that inner line plate cavities arrows...

Page 137: ...rol GPS SAE 10W 40 Engine oil Pressure plate assembly Fit pressure plate 5 Fit screws 4 working crossways Tightening torque figures Pressure plate on clutch case M5 x 12 10 9 Microincapsulated screw replacement 6 Nm Fit bearing 3 Fit presser 1 with O Ring 2 Clutch cover assembly Clean gasket groove and bearing surface check gasket and if needed re place it Fit clutch cover 2 with gasket 3 Fit scre...

Page 138: ...lement disassembly Clutch disengagement bearing disassembly Remove disengagement bearing 1 Clutch disengagement bearing assembly Lubricate disengagement bearing 1 and assemble it Consumables Castrol GPS SAE 10W 40 Engine oil Checking the clutch pack thickness Clutch plates pack thickness must be L 31 0 4 0 if this size is reduced due to wear and tear it is possible to restore it using the shims in...

Page 139: ...tch housing disassembly Coolant pump cover disassembly Coolant pump rotor disassembly Engine right crankcase cover disassembly Disassemble the following parts Screws 1 2 3 Washer 4 Engine right crankcase Disassemble the following parts Cover 1 with idler gear 2 Guide sleeves 3 Gasket 4 Engine right crankcase assembly Clean sealing surface Assemble the following parts Gasket 4 Guide sleeves 3 Cover...

Page 140: ...nnections M6 x 30 11 Nm Fit screws 1 working crossways Tightening torque figures Engine and crankcase fairing screw connections M6 x 25 11 Nm Fit a new screw 3 with washer 4 but do not tighten them Tightening torque figures Cooling channel gasket inside right engine fairing on crankcase M6 x 16 Replace screw with microincapsulated sealing washer 11 Nm ...

Page 141: ...F1 35 H01742 H01869 ENGINE DISASSEMBLY REASSEMBLY 1st edition 08 2010 _Rev 11 2010 Clutch thrust washer disassembly Remove washer 1 Clutch thrust washer Clutch thrust washer assembly Fit washer 1 ...

Page 142: ...010 _Rev 11 2010 Clutch housing axial bearing disassembly Remove bearing 1 Clutch housing axial bearing Clutch housing axial bearing assembly Lubricate bearing 1 and assemble it Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling ...

Page 143: ...ASSEMBLY 1st edition 08 2010 _Rev 11 2010 Coolant pump disassembly and assembly Coolant pump cover disassembly Disassemble the following parts Screws 1 2 3 Cover 5 Seal 6 Coolant pump rotor disassembly Disassemble the following parts screw 1 Rotor 2 ...

Page 144: ...ent 6 Nm Coolant pump cover assembly Clean seal groove and bearing surface check seal 6 and if needed re place it Fit pump cover 5 with seal 6 Fit screw 3 Tightening torque figures Engine and crankcase fairing screw connections M6 x 45 11 Nm Fit screw 2 Tightening torque figures Engine and crankcase fairing screw connections M6 x 25 11 Nm Fit screws 1 Tightening torque figures Engine and crankcase...

Page 145: ...l replacement crankcase cover removed Coolant pump control rear oil seal disassembly Remove oil seal 1 Coolant pump control shaft check Check Result Damaged or worn shaft Action Replace coolant pump drive crankcase cover removed Coolant pump control rear oil seal assembly Clean oil seal seat Fit oil seal 1 using a suitable tool ...

Page 146: ...moved Slider loosening in the lower area Remove screw with O Ring 1 Coolant pump shaft disassembly Disassemble the following parts Oil seal 1 Stop ring 2 Take special care not to let timing chain touch coolant pump gear Remove shaft 3 and front bearing 5 using a suitable sliding hammer pull er Remove stop ring 4 and bearing 5 from shaft 3 ...

Page 147: ... solid lubricant for metal part assembling and settling Assemble bearing 5 and stop ring 4 onto shaft 3 When fitting the shaft take special care to the timing chain Fit shaft 3 with front bearing 5 Assemble the following parts Stop ring 2 Oil seal 1 Slider assembly in the lower area Fit screw with O Ring 1 Tightening torque figures Front slider at crankcase lower part M8 15 Nm ...

Page 148: ...hain sprocket removal Remove screws 1 and stop washer 2 Remove chain sprocket 3 Chain sprocket Sprocket assembly Assemble chain sprocket 3 Fit stop washer 2 and new screws 1 Tightening torque figures Sprocket on gearbox output shaft M5 x 8 10 9 Microincapsulated screw replacement 6 Nm ...

Page 149: ... Disassemble the following parts screw 1 Chain tensioner 2 O Rings 3 4 Chain tensioner assembly Assemble the following parts O Rings 4 3 Chain tensioner 2 Fit screw 1 Tightening torque figures Chain tensioner screw cap M24 x 1 5 with O Ring Grease thread 20 Nm Chain tensioner disassembly and reassembly or replacement ...

Page 150: ...t 5 Guide sleeves 6 Cylinder head disassembly and reassembly head gasket replacement Cylinder head assembly Clean sealing surfaces Apply reference pins 6 and a new head gasket 5 Pull timing chain through the recess Fit nuts 3 1 and cylinder head screws 2 without tightening them Secure nuts 3 working crossways then secure nuts 1 Tightening torque figures Cylinder head with cylinder on engine Nut M1...

Page 151: ...ck tappet 1 for wear Replace it if necessary Remove valve bearing plate and lay it onto the relevant bucket type tappet 1 Caution Half balls can fall inside cylinder head oil ducts Plug ducts with a cloth Overturn rocker arms 2 and disassemble half balls 3 Note half balls 3 position Screw flat insert N 8000H5042 onto bearing plate N 8000H5015 Cylinder head replacement cylinder head removed ...

Page 152: ...and compression plate N 8000H5019 Precharge springs using the compression plate N 8000H5019 Remove valve collets 1 Remove supporting bracket N 8000H5017 spindle with handle N 8000H5016 connector N 80005018 and compression plate N 80005019 Remove support plate N 80005015 Take out valves downward Removing valve spring Take upper retainer 1 and valve spring 2 out of cylinder head Removing valve stem ...

Page 153: ...tion 08 2010 _Rev 11 2010 Rocker arm disassembly Remove stop rings 1 and rocker arms 2 Rocker arm shaft disassembly Remove the screw 1 with the O ring 2 Remove left rocker arm shaft 1 with a suitable tool 2 Remove right rocker arm shaft 1 using a suitable sliding hammer puller ...

Page 154: ...pply a dial gauge at right angles with valve stem preferably close to cylinder head bearing point Measure valve clearance by moving it Repeat this procedure by moving dial gauge by 90 A B Technical specifications Intake valve clearance inside corresponding guide New with 15 mm valve lift 0 01 mm Wear limit with 15 mm valve lift Max 0 25 mm Exhaust valve clearance inside corresponding guide New wit...

Page 155: ...onsumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble right rocker arm shaft 1 with a suitable tool 2 Assemble left rocker arm shaft 1 with a suitable tool Fit screw 1 and screw with the O Ring 2 Tightening torque figures Rocker arm shafts onto cylinder head M6 Microincapsulated screw replacement 11 Nm ...

Page 156: ...icant for metal part assembling and settling Fit tappet roller 2 Caution Rocker arm correct operation will be impaired if clips are reused Always change safety clips Fit safety fasteners 1 Fitting valve stem seal Install valve Fit spring 2 lower retainer Install valve stem seal 1 Valve spring assembly Fit valve spring 2 with the thicker side pointing down Fit upper spring retainer 1 ...

Page 157: ... the compression plate N 8000H5019 Lubricate and assemble valve collets 1 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Removesupportingplate N 8000H5015 supportingbracket N 8000H5017 spindle with handle N 8000H5016 connector N 8000H5018 and com pression plate N 8000H5019 Caution Half balls can fall inside cylinder head oil ducts Plug ducts with a cloth ...

Page 158: ...ve screw 1 Remove chain tensioning slider 2 Slider disassembly Disassemble the following parts screw 1 Washer 2 Screw with O Ring 3 Slider 4 Chain slider Chain sliding and tensioning sliders check Check Check chain tensioning 1 and sliding 2 sliders sliding surfaces Result Sliding surfaces are damaged or worn Action Change sliders ...

Page 159: ...2 Fit screw 1 Tightening torque figures Slider onto cylinder head Calibrated screw M8 15 Nm Fit screw with O Ring 3 Tightening torque figures Front slider at crankcase lower part M8 15 Nm Chain tensioner assembly Fit chain tensioner 2 Fit screw 1 Tightening torque figures Chain tensioner on crankcase M8 Microincapsulated screw replacement 15 Nm ...

Page 160: ...bly Spark plug disassembly Removing cylinder head cover Spark plug recess disassembly Bearing mount disassembly Camshaft removal Slider disassembly Cylinder head disassembly Cylinder disassembly Remove cylinder 1 taking special care not to let screws fall down Remove gasket 2 and centring pins 3 Cylinder disassembly and reassembly or replacement ...

Page 161: ...check Check Check cylinder liner and sealing surface for damages Measure bore using an inside micrometer gauge in three points A B C Technical specifications Cylinder bore diameter Tolerance group 1 New 40 mm from upper edge 450 cc 98 000 0 012 mm 0 480 cc 101 000 0 012 mm 0 Cylinder bore diameter Tolerance group 2 New 40 mm from upper edge 450 cc 98 012 0 012 mm 0 480 cc 101 012 0 012 mm 0 Result...

Page 162: ...New transverse to piston pin axis above piston lower edge by 4 mm 450 97 935 0 005 mm 0 005 480 100 935 0 005 mm Result Piston diameter is outside tolerance values Action Replace piston Piston stroke clearance definition Check Piston diameter B less cylinder diameter A piston clearance Technical specifications Piston installation clearance 0 06 0 08 mm Result Piston stroke clearance is outside tol...

Page 163: ... scraper ring 2 with the EK wording pointing up Upper piston ring 1 with the TOP wording pointing up Piston with cylinder assembly Position piston ring and scraper ring inside annular grooves offset by 180 Warning Offset garter spring port by approx 180 compared to scraper ring port The TOP wording shall be pointing up Technical specifications Piston ring assembly direction Top mark pointing up Gr...

Page 164: ... recess fit cylinders 1 with piston until connecting rod small end Keep cylinder 1 with piston 2 at the height of connecting rod small end Lubricate piston pin 3 and assemble it Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit the new stop rings 4 Make sure to respect correct assembly position Fit the screws at cylinder 5 bottom Fit cylinder Subsequent ...

Page 165: ...ositioning at ignition TDC Securing crankshaft at TDC Chain tensioner disassembly Bearing mount disassembly Camshaft removal Clutch disassembly Coolant pump disassembly Engine right crankcase cover disassembly Chain tensioning slider disassembly Slider disassembly Coolant pump shaft disassembly Timing chain disassembly Slide timing chain 1 out of countershaft gear 2 and remove it upward Timing cha...

Page 166: ... Result Worn or damaged timing chain Action Replace timing chain Check Check gear and chain sprocket for damages and wear Result Figure 1 no distortion or min teeth distortion Action Wheel chain and sprocket are in good conditions Result Figure 2 teeth distortion Action Change chain and gear Result Figure 3 heavily worn teeth Action Change chain and gear Check Check camshaft for damages and wear R...

Page 167: ...y Clutch housing axial bearing disassembly Clutch thrust washer disassembly Oil pump idler gear disassembly Disassemble the following parts Stop ring 1 Washer 2 Gear 3 Bearing 4 Oil pump control gear disassembly Disassemble the following parts Stop ring 1 Washer 2 Gear 3 Needle roller 4 Replacing oil pump gears crankcase cover removed ...

Page 168: ...ller N 8000H5011 and jaws N 8000H5012 Assembly of crankshaft gear pointing oil pump idler gear Heat gear 1 Technical specifications Release connection temperature 180 C Fit gear 1 with the dowel protruding towards crankcase Oil pump control gear assembly Lubricate needle roller 4 and gear 3 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble the follo...

Page 169: ...t edition 08 2010 _Rev 11 2010 Oil pump idler gear assembly Lubricate bearing 4 and gear 3 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble the following parts Bearing 4 Gear 3 Washer 2 Stop ring 1 ...

Page 170: ...take pump disassembly Disassemble the following parts Screws 1 Cover 2 Inner rotor 3 Outer rotor 4 Needle roller 5 Fit oil intake pump Lubricate needle roller 5 outer rotor 4 and inner rotor 3 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble the following parts Needle roller 5 Outer rotor 4 and inner rotor 3 with reference mark pointing out Cover 2...

Page 171: ...il force pump disassembly Disassemble the following parts Stop ring 1 Cover 3 with seal 2 Inner rotor 4 Outer rotor 5 Needle roller 6 Oil force pump assembly Lubricate needle roller 6 outer rotor 5 and inner rotor 4 Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Assemble the following parts Needle roller 6 Outer rotor 5 and inner rotor 4 with reference ma...

Page 172: ... disassembly Remove shaft 1 from crankcase Oil pumps shaft assembly Lubricate shaft 1 and assemble it inside crankcase Shaft side with two holes shall be positioned on engine right side Consumables Molykote D Paste Clear solid lubricant for metal parts assembling and settling Oil pumps shaft ...

Page 173: ...Rev 11 2010 Replace gearbox control shaft radial sealing ring Preliminary operations Gear lever disassembly Removing oil seal from gearbox shaft Using a suitable tool remove oil seal 1 with the utmost care Fitting gearbox shaft oil seal Fit oil seal 1 using a suitable tool ...

Page 174: ...shaft oil seal Gearbox output shaft left oil seal disassembly Remove oil seal 1 Gearbox output shaft right oil seal disassembly Remove oil seal 1 Gearbox output shaft right oil seal assembly Fit the new oil seal 1 using a suitable tool Gearbox output shaft left oil seal assembly Fit oil seal 1 using a suitable tool ...

Page 175: ...k sealing ring 1 for damages Replace it if necessary Lubricate contact surface arrow Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit starter motor taking special care to sealing ring 3 Fit screws 2 with the ground cable pointing up Tightening torque figures Starter motor onto crankcase M6 x 25 Grease thread 11 Nm Fit positive cable 1 Tightening torque ...

Page 176: ...ar lever disassembly Engine left crankcase cover disassembly Securing crankshaft at TDC Starter motor idle gear disengagement Flywheel disassembly Gear disassembly with starter motor protected against overload Remove gear 1 with shaft 2 Starter motor idle gear disassembly Disassemble the following parts Nut 1 Washer 2 Gear 3 Needle roller bearing 4 Bushing 5 ...

Page 177: ...uide 2 Gear 3 Needle roller bearing 4 Freewheel gear assembly Lubricate needle roller bearing 4 and gear 3 then fit them Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit guide 2 with screws 1 Tightening torque figures Starter motor freewheel retainer onto crankcase M5 Microincapsulated screw replacement 6 Nm ...

Page 178: ... part assembling and settling Lubricate gear 3 and assemble it with the dowel pointing towards counter shaft Consumables Molykote D Paste Clear solid lubricant for metal part assembling and settling Fit washer 2 with nut 1 but do not tighten them Gear assembly with starter motor protected against overload Lubricate shaft 2 with gear 1 and assemble them Consumables Molykote D Paste Clear solid lubr...

Page 179: ... 11 2010 Starter motor idle gear disengagement Loosen nut 1 Starter motor idle gear fitting Tighten nut 1 all the way down Tightening torque figures Engine and crankcase fairing screw connections M12 x 1 Replace microincapsulated screw nut 50 Nm Starter motor idle gear ...

Page 180: ...shaft axial clearance check Crankshaft countershaft and relevant bearings Preliminary operations Engine oil drainage Head disassembly Gear lever disassembly Engine left crankcase cover disassembly Securing crankshaft at TDC Starter motor idle gear disengagement Flywheel disassembly Crankcase left half disassembly Remove screws 1 2 3 Disassemble crankcase left half 4 Warning Due to sealant high adh...

Page 181: ...isassembly Lock control gear 1 using tool N 8000H5010 to prevent it from moving Remove screw Caution LH thread 2 Remove control gear 1 Remove crankshaft and countershaft Move crankshaft 1 and countershaft 2 reference marks arrows so as to make them match Remove countershaft and countershaft at the same time ...

Page 182: ...hot parts wear protective gloves Remove bushing 1 using a suitable pre heated puller Technical specifications Pre heating tempera ture of puller for main bearing inner rings 300 C Apply puller around the bushing 1 After a reduced heating phase remove bushing Crankshaft for countershaft gear disassembly Remove space washer 1 if any Mark assembly position on gear 2 and on crankshaft Remove gear 2 wi...

Page 183: ...ed puller Technical specifications Pre heating temperature of puller for main bearing inner rings 300 C Apply puller around the bushing 1 After a reduced heating phase remove bushing Crankshaft axial clearance adjustment Measure crankshaft at the bearing seats arrows and divide the read value A by 2 A1 Technical specifications Crankshaft reference block Dimension at 34 55 0 05 mm 0 Add to A1 the v...

Page 184: ...connecting rod for damages and wear Measure connecting rod bearing clearance Lock crankshaft in vertical posi tion and using a dial gauge read the max possible bearing clearance A Technical specifications Connecting rod axial clearance 0 80 0 90 mm Result Damaged connecting rod or bearing clearance outside tolerance val ues Action Replace crankshaft with connecting rod Crankshaft replacement Alway...

Page 185: ...st washer Technical specifications Crankcase gasket thickness 0 5 mm Crankshaft space washer thickness 0 1 mm 0 15 mm 0 2 mm 0 25 mm 0 3 mm Crankshaft axial clearance adjustment right side Measure right bearing D seat depth using a depth gauge Add to this value half of crankcase gasket value The value measured on right crankshaft A1 B is deducted from the meas ured right bearing seat depth C half ...

Page 186: ...t bearing disassembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 1 Remove ring 2 Crankshaft left bearing assembly Caution Temperature differences as well...

Page 187: ...sembly Remove oil seal 1 Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 2 Countershaft left bearing disassembly Remove screws 1 Remove stop striker 2 Caution...

Page 188: ...rature 180 C Fit bearing 3 using a suitable tool Fit stop striker 2 with new screws 1 Tightening torque figures Countershaft retainer onto crankcase M5 x 12 Microincapsulated screw replacement 6 Nm Countershaft right bearing assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not ...

Page 189: ...eat bearing bushing 1 Technical specifications Pre heating temperature of puller for main bearing inner rings 300 C Spray crankshaft with cooling fluid Fit bearing bushing 1 using a suitable tool Oil pump gear assembly onto crankshaft Fit reference pins 3 Heat gear 2 Technical specifications Release connection temperature 80 C For installation refer to the reference marks Spray crankshaft with coo...

Page 190: ...nkshaft with cooling fluid Fit bearing bushing 2 using a suitable tool Fit roller cage 1 Control gear assembly Fit control gear 1 holding it in place with a tool N 8000H5010 to prevent it from turning Fit screw 2 Tightening torque figures Engine and crankcase fairing screw connections Left hand thread M16 x1 Microincapsulated screw repla cement 140 Nm Assemble crankshaft and countershaft Lubricate...

Page 191: ...lf disassembly Remove screws 1 2 3 Disassemble crankcase left half 4 Warning Due to sealant high adhesion some engine parts could prove hard to disas semble Disengage these parts by gently tapping them with a rubber hammer taking care not to damage cooling fins or other crankcase parts Remove gasket 5 and guide sleeves 6 Gearbox disassembly Disassemble the following parts Gearbox output shaft 1 Ge...

Page 192: ... pitting or wear signs Result Teeth sides worn or pitted Action Replace gear Disassembly Reassembly of the gearbox 5 Speed TC Caution During operation gear wheel sets slide one towards the other If just one cou pling gear is replaced the load bearing capacity on gears may become signifi cantly worse Replace gear wheels together with the coupled wheels only Caution Reinstall the input shaft and out...

Page 193: ... 4th 3rd 5th 2nd H06429 Z 30 Z 24 Z 32 Z 29 Z 23 1st 4th 3rd 5th 2nd H06428 TC Z 14 Z 23 Z 15 Z 23 Z 16 ENGINE DISASSEMBLY REASSEMBLY 1st edition 08 2010 _Rev 11 2010 Input shaft 6 speed TC Output shaft 6 speed TC ...

Page 194: ...oad bearing capacity on gears may become signifi cantly worse Replace gear wheels together with the coupled wheels only Caution Reinstall the input shaft and output shaft as indicated in the figure paying atten tion not to damage the roller cages the washers and snap rings Upon reassembly always use new snap rings Lubricate bearing shaft and gears Consumables Molykote D Paste Clear solid lubricant...

Page 195: ... 4th H06430 Z 14 Z 23 Z 15 20 Z 24 Z 16 6th 2nd 1st 5th 3rd 4th H06431 Z 30 Z 22 Z 32 Z 24 Z 23 Z 25 TE TXC SMR ENGINE DISASSEMBLY REASSEMBLY 1st edition 08 2010 _Rev 11 2010 Input shaft 6 speed TE TXC SMS Output shaft 6 speed TE TXC SMS ...

Page 196: ...acks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 1 Gearbox input shaft left bearing disassembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure no...

Page 197: ... making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 2 Gearbox output shaft left bearing disassembly Remove oil seal 1 Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended v...

Page 198: ...mbly Remove oil seal 1 Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Remove bearing 2 Gearbox input shaft idler gear bearing disassembly Caution Temperature differences as...

Page 199: ...ecommended value Heat crankcase Technical specifications Release connection temperature 180 C Fit bearing 1 using a suitable tool Gearbox shaft left bearing assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specificati...

Page 200: ...as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperature 180 C Fit bearing 2 using a suitable tool Fit the new oil seal 1 using a suitable tool Gearbox output shaft right bearing assembly Caution Temperature differences ...

Page 201: ...nection temperature 180 C Fit bearing 1 open side facing the crankcase with a suitable tool Gearbox input shaft right bearing assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat crankcase Technical specifications Release connection temperat...

Page 202: ...ed clearance Action Replace bearings Check Check bearing points 2 Result Damaged or widened bearing points Action Replace crankcase cover Replace crankcase Insert idler gear 1 inside locking tool N 8000H5020 Apply an insert for socket wrench N 8000H5767 onto clutch Check Check starting torque Technical specifications Clutch check torque inside primary drive unit New 190 250 Nm Wear limit Min 140 N...

Page 203: ...re not to exceed the recommended value Heat gear 1 and remove it using a suitable tool Technical specifications Release connection temperature 80 C Idler gear assembly Caution Temperature differences as well as casing overheating may lead to structure changes and to cracks due to internal stresses Evenly heat casing making sure not to exceed the recommended value Heat idler gear 1 and assemble it ...

Page 204: ...plete selector shaft disassembly Remove gearbox shaft 1 with spring 2 and washer 3 Gearbox shaft check Check Check gearbox shaft for damages Result Damaged gearbox shaft Action Replace gearbox shaft crankcase cover removed Gearbox shaft complete assembly Fit gearbox shaft 1 with spring 2 and washer 3 Take special care to correct spring 2 positioning ...

Page 205: ...isassembly Remove gearbox guides 1 Turn forks 2 from selector cylinder 3 Remove selector drum 3 Selector drum check Check Check drum grooves for wear at curved sections in particular arrow Result Worn grooves Action Replace selector drum Selector drum assembly Fit selector drum 3 Turn forks 2 inside selector drum 3 Fit gearbox guides 1 ...

Page 206: ...al specifications Gear selector fork rib width on contact surfaces New 4 9 0 05 mm 0 05 Wear limit Min 4 6 Nm Result Dimension A outside tolerance values Action Replace forks Check Measure clearance between fork and engagement gear using a feeler gauge Technical specifications Gear selector fork axial clearance inside engagement gear groove Wear limit Max 0 5 mm Result Dimension exceeding max limi...

Page 207: ...st gear 6 Space washer 7 Gearbox output shaft guide 8 Gearbox input shaft guide 9 Clean sealing surfaces and apply a new gasket 5 Fit guide sleeves 6 Fit crankcase left half 4 Fit screws 1 2 3 but do not tighten them Fit screws 1 Tightening torque figures Engine and crankcase fairing screw connections M6 x 70 11 Nm Fit screw 2 Tightening torque figures Engine and crankcase fairing screw connection...

Page 208: ...assembly Coolant pump cover disassembly Coolant pump rotor disassembly Engine right crankcase cover disassembly Gear selector lock disassembly Disassemble the following parts screw 1 Bushing 2 Stop element 3 Washer 4 Spring 5 Gear selector lock assembly Assemble the following parts Spring 5 Washer 4 Stop element 3 Bushing 2 Fit new screw 1 Tightening torque figures Stop lever on crankcase lower si...

Page 209: ...bly Engine right crankcase cover disassembly Gear selector disassembly Remove gear selector lock and secure it using a suitable auxiliary tool Remove screw 1 Remove gear selector 2 with reference pin 3 Remove gear selector lock retainer Gear selector assembly Remove gear selector lock and secure it using a suitable auxiliary tool Fit gear selector 2 with reference pin 3 Fit screw 1 Tightening torq...

Page 210: ......

Page 211: ...I 1 I 1st edition 08 2010 _Rev 11 2010 FRONT SUSPENSION Section ...

Page 212: ...G I 30 Instructions for clamping in the vice I 31 Problems Possible causes Solutions I 32 Cleaning the dust seal I 33 Bleeding the air I 33 Draining the oil I 34 Braking down the pumping element and the bottom valve I 35 Braking down the fork leg slider and removing the oil seals I 37 Overhauling and modifying the cartridge and bottom valve setting I 38 Cartridge overhauling rebound braking I 38 B...

Page 213: ...NSION Front fork removal Measure height A it will need to be restored to original value on assembly Set a block under the engine and see that the front wheel is lifted from the ground and then proceed as follows remove the screws 1 and the brake line clamp on the left hand side ...

Page 214: ...rews 2 and the fork leg guards remove the brake calliper from the L H fork leg loosening the two retaining screws 3 remove the front wheel as described in Section Y loosen the bolts 4 that secure the fork legs to steering head and bottom yoke remove the fork legs Refit fork legs and front wheel as described in Section Y ...

Page 215: ...o drain cartridge oil INNER TUBES Special high strength steel chrome plated and TIN coated OUTER TUBES CNC machined aluminium alloy anodised and polished in side SLIDING BUSHES Teflon coated stiction free SEALS Computer designed sealing rings ensure maximum sealing on compression and minimal friction on rebound SPRINGS Steel springs different spring rates K available See Table for more detailed in...

Page 216: ...st edition 08 2010 _Rev 11 2010 FRONT SUSPENSION Front suspension TC TXC Front suspension is handled by a KAYABA upside down telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travel is 300 mm ...

Page 217: ...ly slacken the cap nuts before removing the fork legs from the motorcycle Drain oil from the damper unit Clamp the wheel axle carrier in a vice and loosen the adjuster screw Push down the inner tube Slip the tool shown in the figure between wheel axle carrier and cartridge nut Hold the nut with a wrench and remove the adjuster screw Be careful not to hurt your fingers ...

Page 218: ... the cartridge Remove the bottom valve assembly from the cartridge Hold the cartridge octagonal nut with the suitable tool to prevent rotation Use a similar tool in the octagonal recess of the bottom valve assembly Use a key to slacken the bottom valve assembly Check the O rings on the bottom valve assembly for damage Replace as required ...

Page 219: ...eg upside down and allow at least 20 minutes for oil to drain Remove the dust seal using a flat head screwdriver Remove the retaining ring using a flat head screwdriver Pull the inner tube until separating it from the outer tube Note to facilitate removal quickly but carefully pump the tubes back and forth until separating them ...

Page 220: ...the rebound adjuster Replace damaged O rings Replace the complete assembly do not reuse it Check the spring Replace it if outside diameter is damaged or exceedingly worn Free length is 449 mm 17 7 in or less Check the inner tube Replace if distorted Never attempt to repair or reuse a distorted fork tube If the tube shows surface defects sand the surface If repair is not possible replace the tube N...

Page 221: ...ner tube cover tube edge with plastic as shown in the figure This will avoid damage to the oil seal lip Fit metal bushing and washer to outer tube using an appropriate installer Fit the oil seal to the outer tube and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully visible Install the retaining ring Make sure that the retaining ri...

Page 222: ...is not play between dust seal and outer tube Refit the cartridge Tighten the nut all the way onto the rebound adjuster rod Make sure rebound adjuster rod thread length is at least 15 mm 0 6 in Fill the cartridge with the specified oil Pump the piston rod up and down repeatedly to remove any air from the cyl inder ...

Page 223: ...m valve assembly installed check that the piston rod is fully extended Hold the cartridge octagonal nut to prevent rotation Use a similar tool in the octagonal recess of the bottom valve assembly Tighten the bottom valve assembly to 29 Nm 21 4 ft lb using a wrench Hold the cartridge with the piston rod end pointing downwards as shown in the figure Pump the piston rod up and down a dozen times to h...

Page 224: ...her parts Please note that excess oil may flow out from the hole located before the res ervoir If you see no oil flowing out it means that there isn t enough oil in the car tridge Add oil to the cartridge before refitting it Drain excess oil from the reservoir Clean off any excess oil from the cartridge Install spring guide and spring on the cartridge Insert the cartridge into the inner tube ...

Page 225: ... cartridge nut Insert the rebound adjuster rod into the piston rod and tighten the adjuster screw Be careful not to hurt your fingers Tighten the adjuster screw all the way in Make sure that there is some play between the bottom edge of the adjuster screw and the upper edge of the nut Tighten nut and adjuster to 28 Nm 20 6 ft lb using a wrench ...

Page 226: ...FRONT SUSPENSION Clamp the wheel axle carrier in a vice and tighten the adjuster screw onto the carrier to 55 Nm 40 5 ft lb Fill the outer tube with the specified quantity of oil Tighten the cylinder onto the outer tube to 29 Nm 21 4 ft lb ...

Page 227: ...8 2010 _Rev 11 2010 FRONT SUSPENSION Front suspension TE Front suspension is handled by a KAYABA upside down telescopic hydraulic fork with advanced axle and 48 mm legs Wheel travelis 300 mm Front suspension Mod TE 2010 ...

Page 228: ...ch outer tube Note it is good practice to moderately slacken the cap nuts before removing the fork legs from the motorcycle Loosen the fork cap nut and the nut with a wrench Remove top cap nut spring retainer spring and rebound adjuster rod Drain the oil Pump the piston rod up and down to drain oil from the cylinder ...

Page 229: ...I 19 1st edition 08 2010 _Rev 11 2010 FRONT SUSPENSION Remove nut spring guide O ring and collar bushing Hold the cartridge top end steady Loosen and remove the bottom valve assembly ...

Page 230: ...I 20 1st edition 08 2010 _Rev 11 2010 FRONT SUSPENSION Take the cartridge out of the outer tube Remove the dust seal using a flat head screwdriver ...

Page 231: ...until separating them Remove the sealing rings and the metal rings mounted on the inner tube Do not reuse any metal parts after removal Replace them with new components Replace damaged sealing rings Washer and retaining ring may be reused if they are not damaged Check the rebound adjuster rod for distortion or damage Replace as required Loosen and remove the bottom valve assembly Replace damaged O...

Page 232: ...repair is not possible replace the tube Never reuse an inner tube if scored or showing bulges on the outer surface Check the outer tube Replace the tube is any distortion is detected or if the sliding surface is dam aged Mount sealing rings and metal parts on the inner tube See the figure below for the installation sequence Note 1 Grease the edge of the sealing ring Note 2 Before sliding the seali...

Page 233: ...outer tube and push it home using an appropriate in staller Make sure that the retaining ring groove inside the outer tube is fully visible Install the retaining ring Make sure that the retaining ring is fully seated in the groove inside the outer tube Fit the dust seal to the outer tube Make sure that there is not play between dust seal and outer tube ...

Page 234: ...I 24 1st edition 08 2010 _Rev 11 2010 FRONT SUSPENSION Insert the cartridge into the outer tube Hold the cartridge top end into place Tighten the bottom valve assembly to 55 Nm 40 5 ft lb ...

Page 235: ... 71 in portion of the rebound adjuster rod protrudes from the piston rod Oil filling Fill with the specified quantity of oil Fill the damper unit with the specified quantity of oil Slowly pump the piston rod up and down to help oil reach all points of the car tridge Note if you haven t drained all oil from the damper unit on disassembly follow the procedure outlined below Filling oil to specified ...

Page 236: ...d up and down to help oil reach all points of the cartridge Note add oil if level in the damper unit is too low Finally top up to the upper edge of the outer tube Allow the fork leg to rest until no more air bubbles can be seen then top up oil to specified level Insert the rebound adjuster rod into the piston rod Insert spring and spring guide retainer and tighten the cap nut Tighten fork cap nut ...

Page 237: ...st edition 08 2010 _Rev 11 2010 FRONT SUSPENSION Front suspension SMR Front suspension is handled by a MARZOCCHI U S D upside down telescopic hydraulic fork with advanced axle and 50 mm legs Wheel travelis 258 mm ...

Page 238: ...k s legs upper cap you can find a screw for the slider inner air bleed Stanchion tubes Made of special chromed high resistance steel with a special hardening surface treatment TIN Sliders Made of CNC aluminium alloy anodised and polished inside Sliding bushings With Teflon facing free from static friction Seals Computer designed seal rings guarantee the beast seal under compres sion and the minimu...

Page 239: ...re 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 Cap 70 Wheel axle clamp 71 Rebound adjustment screw 72 Conic pi...

Page 240: ...nners not imperial spanners which may have similar sizes but can damage the bolts and make it impossible to unscrew them Use the correct size and sort of screwdriver to unscrew slotted or crosshead screws When using a screwdriver to assemble or disassemble metal stop rings o rings sliding bushings or seal segments avoid scratching or cutting the components with the screwdriver tip Only proceed to ...

Page 241: ...tions below Limit the use of the vice to those operations where the use of the same is absolutely necessary Use a vice with padded jaws Avoid over tightening the vice Avoid clamping parts of the fork where even slight ovalization could damage the part The figure shows the zones recommended for fixing the fork in the vice A Wheel axle clamp B Slider in the steering crown fixing zone C Top part of p...

Page 242: ...ushings 2 Old oil 2 Change the oil Fork legs not sliding properly 1 Fork legs not aligned correctly 1 Loosen the wheel axle and align the fork correctly see Par 4 2 The fork does not react to adjustment variations 1 The pin inside the rod is stuck 1 Clean or replace rod 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 fo...

Page 243: ...traces of dirt from the stanchion tubes Lubricate the dust seal and 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 motor cycle and with the fork s legs fully extended front wheel off the ground The pressure generated by th...

Page 244: ...locknut 23 with A 19 mm spanner use another 19 mm 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 av...

Page 245: ... body rotation to do so the slot obtained at the tooling lower edge must be perfectly inserted into the body hexagon 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 botto...

Page 246: ...26 and the foot 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 The pumping element can be completely overhauled and adjusted Par agraph 4 8 shows how to overhaul and modify the pumping el...

Page 247: ... you will have to pull hard With this operation 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...

Page 248: ...lete with the segment 35 the washer 34 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 Only use original Marzocchi washers and pistons do not ...

Page 249: ...lled area Using a proper spanner 12 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...

Page 250: ... washer 43 and the spring 33 following this order 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 slider and oil ...

Page 251: ...f the stanchion tube cleaning any traces 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 bush ing groove Delicately introduce the stanchion tube into the slider being very careful not to damage the top guide bushing Guide the bottom guide bushing until it comes into contact with the slider the spring cup ...

Page 252: ... 12 in its seat pressing it home with your hands Re assembling the pumping element unit and the bottom valve Insert the pumping element rod 32 into the body 30 In both pumping elements there is a sealing segment before the as sembling 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 in...

Page 253: ...h rod 29 into contact 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 span ner Insert the guide spring 24 in the pumping element rod 32 the...

Page 254: ...you can block the body rotation to do so the slot obtained at the tooling bottom edge must be perfectly inserted into the body hexagon 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 Using a 21 mm tube wrench tighten the bottom valve 41 up t...

Page 255: ... axle clamp Wait a few minutes and check the air volume see Table 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 recom mended 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 guid...

Page 256: ......

Page 257: ...J 1 J 1st edition 08 2010 _Rev 11 2010 REAR SUSPENSION Section ...

Page 258: ...ION Rear shock absorber J 3 Lubrication points grease J 3 Rear suspension J 4 Rear shock absorber removal J 5 Disassembling and servicing the swinging arm J 6 Linkage disassembly J 8 Chain roller chain guide chain slider J 9 Chain sprocket removal J 9 ...

Page 259: ...J 3 1 H006175 2 H006176 H006244 H006178 1st edition 08 2010 _Rev 11 2010 REAR SUSPENSION Rear shock absorber TIGHTENING TORQUE FIGURES 1 2 50 Nm 5 0 Kgm 36 88 ft lb Lubrication points grease ...

Page 260: ... rear suspension is made up of a shock absorber a linkage system and a swinging arm The spring preload of the shock absorber can be adjusted to suit riding and terrain conditions Hydraulic damping is also adjustable using outer adjuster screws Periodically check all components for wear ...

Page 261: ...nd control unit as described in the cor responding chapters Remove wiring from the top mounting point Loosen lower screw 1 using two 14 mm wrenches Loosen upper screw 2 using two 14 mm wrenches Shift the rear cover 3 and take out the rear shock absorber 4 from the rear right hand side of the bike Upon reassembly remove rear brake hose support 5 to insert the torque wrench Tightening torque of shoc...

Page 262: ...Disassembling and servicing the swinging arm Remove the chain and rear wheel as described in the relevant chapters Remove the two side protections A from the chassis Disconnect the rear stop connector 1 Loosen the two screws 2 and remove the brake master cylinder 3 complete with tube and calliper 4 ...

Page 263: ... 2010 _Rev 11 2010 REAR SUSPENSION Loosen the two screws 5 using an 8 mm wrench and remove rear brake hose support 6 to slide out the pin 7 Using a 17 mm wrench loosen nut 8 and remove pin 7 on the other side Using a 10 mm Allen wrench loosen pins 9 and remove swinging arm 10 ...

Page 264: ...ng them Linkage disassembly To remove drag link 1 and drop link 2 proceed as follows Using a 14 mm wrench remove the screw 3 retaining shock absorber drop link 2 Using a 17 mm wrench remove nut 4 and remove pin 5 on the other side Using a 14 mm wrench remove nut 6 and screw 7 on the other side Ensure that needle roller bearings 8 and bushes 9 are not worn and replace them if necessary Upon reassem...

Page 265: ...a Master link clip Chain sprocket removal Fit a support under the engine so that the rear wheel is raised off the ground Remove chain chassis side protections rear shock absorber lower screw as indicated in the relevant paragraphs chapters Using a 10 mm Allen wrench loosen pins 1 fastening swinging arm to chassis Shift swinging arm 2 toward the bike rear end Manually engage the first gear Using an...

Page 266: ......

Page 267: ...L 1 L 1st edition 08 2010 _Rev 11 2010 BRAKES Section ...

Page 268: ...5 Checking brake pads for wear replacing the pads TC TE TXC L 6 Checking brake pads for wear replacing the pads TC TE TXC L 7 Bleeding the front braking system TC TE TXC L 8 Bleeding the front braking system SMS L 9 Bleeding the rear braking system L 10 Changing the fluid L 11 ...

Page 269: ...ystem The braking system uses two independent circuits Each system is equipped with a brake calliper connected to a master cylinder with a fluid reservoir 1 Front brake lever 2 Front brake master cylinder with fluid reservoir 2a Brake master cylinder 2b Brake fluid reservoir 3 Front brake line 4 Front brake calliper 5 Front brake disc ...

Page 270: ...H006214 11 10 6 7 8 9 1st edition 08 2010 _Rev 11 2010 BRAKES 6 Rear brake fluid reservoir 7 Rear brake line 8 Rear brake calliper 9 Rear brake disc 10 Rear brake master cylinder 11 Rear brake control pedal ...

Page 271: ...rake disc thickness when new 3 0 mm 0 12 in TC TE TXC 5 0 mm 0 2 in SMR Wear limit 2 5 mm 0 1 in TC TE TXC 4 5 mm 0 18 in SMR Rear brake disc diameter 240 mm 9 45 in Rear brake disc thickness when new 4 0 mm 0 16 in Wear limit 3 5 mm 0 14 in Disc warpage must not exceed 0 15 mm 0 015 in check disc mounted on the rim with a dial gauge To remove the disc from the wheel rim you need to loosen the fou...

Page 272: ...lcohol any fluid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily PADS REMOVAL Remove clips 1 Slide out pins 2 Remove pads Do not work the brake lever or pedal while removing the pads PADS INSTALLATION Install new brake pads Reassemble the two pins 2 and the clips 1 The above procedure eliminates the need to bleed the brakin...

Page 273: ...fluid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily PADS REMOVAL REAR Remove clips 1 Slide out pin 2 Remove pads FRONT Press on clips 3 Slide out pins 4 Remove clips 3 Remove pads Do not work the brake lever or pedal while removing the pads PADS INSTALLATION REAR Install new brake pads Reassemble the two pins 2 and the cl...

Page 274: ...d free of air bubbles now tighten the bleed valve Top up fluid level A and refit rubber gaiter and reservoir cover 2 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake fluid is corrosive In the event of contact with eyes rinse with abundant water Motorcycle handlebar must be turned to the left during the bleed ing procedure This will keep ...

Page 275: ...perate the lever repeatedly until the fluid flowing out of the hose looks clear and free of air bubbles now tighten the bleed valve Top up fluid level A and refit rubber gaiter and reservoir cover 2 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Brake fluid is corrosive In the event of contact with eyes rinse with abundant water Motorcycle h...

Page 276: ...e fluid only air at first then slightly close the valve Release the pedal and wait a few seconds Repeat the process until you see only fluid coming out of the hose Tighten the bleed valve to the specified torque and check fluid level B in the reservoir before refitting the cap A If the bleeding procedure was performed correctly the pedal will no longer have that mushy feel If not so repeat the pro...

Page 277: ... Avoid the ingress of contaminants such as dirt water etc into the reservoir Do not keep the reservoir open without its cover longer than neces sary this would increase the risk of contamination Handle the fluid with care to avoid damage to painted parts Do not mix two brands of fluid This would reduce boil over point leading to loss of braking efficiency or degrading of rubber parts Replacement p...

Page 278: ...ntil draining all fluid Tighten the bleed valve and fill the reservoir with fresh fluid Loosen the bleed valve operate lever or pedal tighten the valve keeping lever or pedal pressed and then release quickly Repeat the process until the circuit is full and you can see clear fluid coming out of the plastic hose now tighten the bleed valve Top up with fluid up to level A or B and refit rubber gaiter...

Page 279: ...L 13 H06407 C TC TE TXC H006230 D SMR H06408 C 1st edition 08 2010 _Rev 11 2010 BRAKES Periodicallychecktheconnectinghoses C and D seeScheduledMaintenance Chart Section B replace worn or cracked hoses ...

Page 280: ......

Page 281: ...M 1 M ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Section ...

Page 282: ...e regulator M 29 VOLTAGE REGULATOR RECTIFIER WIRING DIAGRAM M 29 ELECTRICAL STARTING SYSTEM M 30 STARTING SYSTEM INSPECTION M 31 Starter motor inspection M 31 Solenoid starter inspection M 31 Solenoid starter wiring diagram M 31 Coil windings resistance inspection M 32 Electronic control unit ECU M 32 Spark plug M 33 BATTERY M 33 Battery charger M 33 HEADLAMP TAIL LIGHT TE SMR M 34 Headlamp adjust...

Page 283: ...t edition 08 2010 _Rev 11 2010 TROUBLESHOOTING M 48 CHARGING SYSTEM M 48 STARTING SYSTEM M 48 ELECTRONIC IGNITION SYSTEM M 48 Connector position TE SMR M 49 Connector position TC M 53 Connector position TXC M 55 IMPORTANT M 58 ...

Page 284: ...M 4 TC 2 5 1 10 7 6 3 9 8 4 11 13 14 15 12 17 18 19 16 21 20 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Engine wiring diagram TC ...

Page 285: ... Engine ground 20 Condenser 21 Diode connector Colour coding key blge Blue Yellow blgn Blue Green blrt Blue Red blsw Blue Black br Brown brbl Brown Blue brge Brown Yellow brgr Brown Grey brsw Brown Black brvi Brown Violet brws Brown White gebl Yellow Blue gebr Yellow Brown gegn Yellow Green gert Yellow Red gnbl Green Blue gnge Green Yellow gngews Green Yellow White gnsw Green Black grvi Grey Viole...

Page 286: ...M 6 TE TXC SMR 2 5 1 10 7 6 3 9 8 4 11 12 14 15 13 17 18 19 16 21 22 20 24 23 25 26 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Engine wiring diagram TE TXC SMR ...

Page 287: ...21 Solenoid starter 22 Engine ground 23 Condenser 24 Diode connector 25 Fan relay 26 Fan Colour coding key blge Blue Yellow blgn Blue Green blrt Blue Red blsw Blue Black br Brown brbl Brown Blue brge Brown Yellow brgr Brown Grey brsw Brown Black brvi Brown Violet brws Brown White gebl Yellow Blue gebr Yellow Brown gegn Yellow Green gert Yellow Red gnbl Green Blue gnge Green Yellow gngews Green Yel...

Page 288: ...M 8 TCX 1 2 3 4 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Adapter TXC ...

Page 289: ...M 9 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Key to wiring diagram 1 Adapter to engine wiring connector 2 Clutch connector 3 RH switch connector 4 Speed sensor connector ...

Page 290: ...The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 with integrated spark plug cap positioned on cylinder head Spark plug on cylinder head Electronic control unit 3 under the saddle Voltage regulator 4 located at the back of the steering tube ...

Page 291: ...t edition 08 2010 _Rev 11 2010 Starter motor 5 in front of engine cylinder Solenoid starter 6 positioned under saddle on rear chassis MAP SENSOR 7 sensor on throttle body The electrical system includes the following elements Fuel pump 8 positioned inside the tank 9 ...

Page 292: ...8 2010 _Rev 11 2010 12V 4Ah Battery 10 under the saddle A 30A fuse 11 positioned on the solenoid starter Fuel pump relay 12 positioned on the front left side under the air box Main starting relay 13 positioned on the front left side under the air box Coolant temperature sensor 14 ...

Page 293: ...engine rear side Electrical components location TE SMR The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 with integrated spark plug cap positioned on cylinder head Spark plug on cylinder head Electronic control unit 3 under the saddle ...

Page 294: ...t edition 08 2010 _Rev 11 2010 Voltage regulator 4 located at the back of the steering tube Starter motor 5 in front of engine cylinder Solenoid starter 6 positioned under saddle on rear chassis Potentiometers 7 and 8 on throttle body 7 2nd throttle 8 1st throttle ...

Page 295: ...em includes the following elements 12V 6Ah Battery 9 under the saddle Turning indicator flasher 10 at the front end below the headlamp fairing Light relay 11 Fuel pump relay 12 and main relay 13 positioned on the front left side under the air box Electric fan relay 14 on the right side under the air box 9 H06287 ...

Page 296: ...H06293 15 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Electric fan 15 A 10A lights fuse 16 positioned below the headlamp fairing and a 30A main fuse 17 positioned on the solenoid starter Coolant temperature sensor 18 Lambda sensor 19 ...

Page 297: ...CTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Headlamp 20 with 12V 35W twin halogen bulb and 12V 5W parking light bulb LED tail light 21 with stop light bulb Turning indicators 22 12V 6W bulbs Fuel pump 23 inside the tank 24 Odometer 25 H06291 24 23 ...

Page 298: ...n engine rear side Electrical components location TXC The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 with integrated spark plug cap positioned on cylinder head Spark plug on cylinder head Electronic control unit 3 under the saddle ...

Page 299: ...t edition 08 2010 _Rev 11 2010 Voltage regulator 4 located at the back of the steering tube Starter motor 5 in front of engine cylinder Solenoid starter 6 positioned under saddle on rear chassis Potentiometers 7 and 7A on throttle body 7 2nd throttle 7A 1st throttle ...

Page 300: ...al system includes the following elements Fuel pump 8 positioned inside the tank 9 12V 6Ah Battery 10 under the saddle A 30A fuse 11 positioned on the solenoid starter Fuel pump relay 12 positioned on the front left side under the air box Main starting relay 13 positioned on the front left side under the air box ...

Page 301: ...5 H06378 17 H06300 18 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Electric fan relay 14 on the chassis right side Lambda sensor 15 Coolant temperature sensor 16 Electric fan 17 Condenser 18 positioned on engine rear side ...

Page 302: ...nd measure resistance with a meter 1 Check that across the terminals of the connector 2 the value is about 0 8 If resistance is outside the specified limits replace the complete generator Generator no load performance MAX 13A at 14V RPM A D C typical 1900 11A AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS SUSPENDED IN SWIRLING OIL AND CAPTURED BY THE MAGNETS ...

Page 303: ...r inspection The condenser 1 keeps the bike running in case of accidental disconnection of battery loosening of cable fastening device Disconnect the condenser and check that its capacitance is 2 200 Micro farad In case the reading is different it is necessary to replace it ...

Page 304: ...M 24 TC 2 5 1 6 3 4 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Ignition system TC ...

Page 305: ...ion coil 3 and an intake manifold pressure sensor 5 The ignition coil is fed by the battery through a power relay and is controlled by the ECU Ignition timing is accurately determined based on engine RPM and accelerator position In addition to these key parameters inputs from the intake air temperature 4 and pressure 5 sensors and from the coolant temperature sensor 6 are also used to control igni...

Page 306: ...M 26 TE TXC SMR 2 5 1 6 3 4 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Ignition system TE TXC SMR ...

Page 307: ... ignition coil 3 and an intake manifold pressure sensor 5 The ignition coil is fed by the battery through a power relay and is controlled by the ECU Ignition timing is accurately determined based on engine RPM and accelerator position In ad dition to these key parameters inputs from the intake air temperature 4 and pressure 5 sensors and from the coolant temperature sensor are also used to control...

Page 308: ...id starter 3 Battery 4 Starter motor 5 The alternated current generated by the alternator is converted into direct cur rent by the voltage regulator rectifier The voltage regulator rectifier serves a dual purpose it provides overvoltage protection for the battery and converts alternated current into direct current All components listed above help keep voltage constant and protect the battery again...

Page 309: ...t slightly above 3000 rpm measure voltage across the positive and negative terminal of the battery using a meter the battery must be charged when performing this test If reading is outside a 14 0 14 5 V range check generator and voltage regulator rectifier as described in the relevant paragraph Voltage regulator rectifier inspection With the ignition on and the battery charged 12 5 13 V start the ...

Page 310: ...posed of Battery 1 Solenoid starter 2 Starter motor 3 R H switch 4 Clutch microswitch 5 TC TXC Ignition switch 6 TE SMR For a description of wires and components please see the key to the wiring diagram H06525 TC TXC 4 5 3 2 1 M 30A 12V 2 1 3 4 BATTERY START RELAY OFF 1 2 RH SWITCH Red Brown Red White blue Red blue STARTER MOTOR OFF RUN Clutch switch START Red white Red Brown Colour coding key TE ...

Page 311: ...ltage 11 25 V Current 30 A Speed 12 000 rpm Solenoid starter inspection Disconnect the cables at the battery negative terminal to avoid possible short circuits during disassembly Disconnect the starter relay connector A Disconnect the starter motor and battery positive cable wires at relay end Apply 12 Volts to relay terminals 1 and 2 and check for continuity between terminals B M Do not feed batt...

Page 312: ... 15 at 20 C Secondary winding resistance Open circuit If resistance is outside the specified limits replace the coil Terminal cap resistance 4 5 5 5 K 5 at 20 C If resistance is outside the specified limits replace the cap Electronic control unit ECU Remove the saddle see Section E to gain access to the electronic control unit 1 It is composed of a capacitor a rectifier circuit that handles input ...

Page 313: ...charging cycle 12V 6Ah battery 0 6A for 8 hours Quick charging is advised only in situations of extreme necessity since the life of lead elements is drastically reduced by such cycle 12V 6Ah battery 6A for 0 5 hours Battery charger To gain access to the battery 1 remove the saddle as outlined in the relevant paragraph first remove the BLACK negative cable then the RED positive cable when reassembl...

Page 314: ...The motorcycle must be on level ground and the optical axis of the headlamp must be perpendicular to the wall The motorcycle must be upright Measure the height from the ground to the centre of the lamp and draw a cross on the wall at the same height When the low beam is on the upper edge between dark and lit zone should be at 9 10th of the height of headlamp centre from ground Beam height can be r...

Page 315: ...2 H06314 3 H06315 4 H06316 5 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 loosen the two lower screws 2 using a Phillips screwdriver move headlight unit 3 aside release connector 4 slide off the rubber gaiter 5 ...

Page 316: ...ake out bulb 7 Note Headlamp bulb 7 is of the halogen type be careful when replacing it since the glass part shall not be touched with bare hands 12V 35 35 W bulb HS1 To replace the parking light bulb 8 extract it from the inside cover Once the bulb has been replaced reverse the above procedure to reassem ble 12V 6W bulb ...

Page 317: ... pushing it inside and turning it to remove it Once the bulb has been replaced reverse the above procedure to reassem ble 12V 6W bulb Tail light replacement TE SMR Remove the tail light as follows Loosen the two screws 1 under the rear mudguard Extract the tail light 2 and disconnect the connector 3 Once the bulb has been replaced reverse the above procedure to reassem ble Be careful not to overti...

Page 318: ...e mud guard Extract the bulb holder 3 with the bulb 4 from the housing Pull the bulb 4 to detach it from bulb holder Once the bulb has been replaced reverse the above procedure to reassem ble 12V 5W bulb Handlebar switches Measure continuity on the different switches using a meter Replace any part found to be faulty Left hand switch TC 1 Engine stop switch TC POSITION COLOUR ...

Page 319: ...switch 3 Left hand turning indicators self cancelling Right hand turning indicators self cancelling To deactivate the turning indicators press the control lever after it is returned to the centre 4 Horn Colour coding key 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 320: ...H06453 B Bk B Br G ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Right hand switch TE TXC SMR 1 Engine start button 2 Engine start stop switch Colour coding key B Blue Br Brown G Green Br Bk Brown Black ...

Page 321: ... Bk Bk G ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Right hand switch TC 1 Engine start button 2 Double map push button Colour coding key Bk Black R Red B Blue G Green Br Bk Brown Black Bk G Black Green B Bk Blue Black ...

Page 322: ...fuel pump TE SMR TXC Injector lambda sensor heater coil fuel pump electric fan Auxiliary fuse 2 10A TE SMR Positioned in the bike front side below the headlamp fairing and close to the dashboard Protection TE SMR Lights horn dashboard power supply turning indicators In order to avoid short circuits on models TE SMR before working on fuses turn the ignition switch to OFF SEMICONDUCTOR PARTS Be care...

Page 323: ...ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 Relay test Gain access to the relays as indicated in the relevant paragraph then remove them 1 Main starting relay 2 Fuel pump relay 3 Electric fan relay TE TXC SMR 4 Light relay TE SMR ...

Page 324: ...o the Impedance scale and check the energiser coil for proper operation Reading should be 80 Ohm 10 at 20 C B Set the meter to Continuity mode and check the circuit is open C Feed the coil from a power supply unit with stable 12V output and make sure that the circuit closes ...

Page 325: ... follows 1 SPEED ODO 2 SPEED CLOCK 3 SPEED TRIP 4 SPEED LAP TIMER 5 SPEED 1 SPEED ODO IMPORTANT In the event of a FUEL INJECTION SYSTEM MALFUNCTION the word FAIL appears on the right side of the dashboard display When this is the case contact your HUSQVARNA dealer 1 SPEED km h or mph ODO SPEED vehicle speed maximum value 299 Km h or 299 mph ODO odometer maximum value 99999 Km To change unit from k...

Page 326: ...ime Reading from 0 00 to 99 59 59 data will be lost after disconnecting the bat tery To activate the function STP push the SCROLL button A and hold for more than 3 seconds 1st step activate function 2nd step stop counters 3rd step reset STP 4th step activate function 5th step stop counters and so on 5 SPEED SPEED speed maximum value 299 Km h or 299 mph The display also provides a fuel injection sy...

Page 327: ...board replacement TE SMR Remove the headlamp fairing as explained under Headlamp bulb replace ment Remove the two retaining screws 1 securing the dashboard to its bracket disconnect the connector 2 and remove the dashboard 3 To refit the dashboard reverse the disassembly procedure ...

Page 328: ...regulator see paragraph Voltage regulator rectifier inspec tion 2 faulty battery see paragraph Current loss at the battery STARTING SYSTEM If the starter motor does not start this might be a symptom of 1 faulty solenoid starter see paragraph Solenoid starter inspection 2 loose starter motor cable 3 faulty starter motor see paragraph Starter motor inspection 4 flat battery see paragraph Battery cha...

Page 329: ...on the front side below the headlamp fairing 1 Headlamp connector 2 Turning indicator flasher connector 3 Light relay connector 4 Dashboard connector 5 Wiring harnesses connector 6 Front brake stop switch connector 7 Speed sensor connector 8 Ignition switch connector 9 Left hand dip switch connector 10 Right hand switch connector 11 Front turning indicator connector ...

Page 330: ...0 _Rev 11 2010 The following connectors are positioned on the bike right side 12 Temperature sensor connector 13 Electric fan relay connector 14 Lambda sensor connector 15 Condenser connector 16 2nd throttle connector 17 1st throttle connector 18 Sensor connector 19 Current generator connector ...

Page 331: ...51 H06340 23 20 H06342 H06344 21 H06345 22 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 20 Voltage regulator connector 21 Injector connector 22 Pressure sensor connector 23 Rear stop brake connector ...

Page 332: ... turning indicator connector 26 Number plate light connector The following connectors are positioned on the bike left side 27 Main starting relay connector 28 Fuel pump relay connector 29 Air temperature sensor connector 30 Electric fan connector 31 Coil connector The following connectors are positioned under the saddle 32 Fuel pump connector 33 Electronic control unit connector 34 Solenoid starte...

Page 333: ...e following connectors are positioned on the front side below the number holder 1 RH switch connector 2 Clutch sensor connector 3 Engine stop connector The following connectors are positioned on the bike right side 4 Temperature sensor connector 5 TPS connector 6 Generator connector 7 Fuel pump connector 8 Injection connector 9 Pressure sensor connector ...

Page 334: ...nnector The following connectors are positioned on the bike left side 11 Main starting relay connector 12 Fuel pump relay connector 13 Air temperature sensor connector 14 Coil connector 15 Condenser connector The following connectors are positioned under the saddle 16 Electronic control unit connector 17 Solenoid starter connector ...

Page 335: ...ng connectors are positioned under the number holder 1 Speed sensor connector 2 Clutch connector 3 RH switch connector 4 Wiring harnesses connector The following connectors are positioned on the bike right side 5 Temperature sensor connector 6 Electric fan relay connector 7 Lambda sensor connector 8 2nd throttle connector 9 2nd throttle TPS connector 10 TPS connector ...

Page 336: ...11 2010 11 Current generator connector 12 Voltage regulator connector 13 Pressure sensor connector The following connectors are positioned on the bike left side 14 Main starting relay connector 15 Fuel pump relay connector 16 Air temperature sensor connector 17 Electric fan connector 18 Coil connector ...

Page 337: ...06366 22 ELECTRICAL SYSTEM 1st edition 08 2010 _Rev 11 2010 The following connectors are positioned under the saddle 19 Fuel pump connector 20 Electronic control unit connector 21 Solenoid starter connector 22 Diagnostics connector ...

Page 338: ...opening of the muffler b Clutch and front brake levers handgrips handlebar switches c Air filter intake d Steering head wheel bearings e Rear suspension drag drop link In addition to these precautions NEVER ALLOW HIGH PRESSURE AIR OR WATER to get in contact with any ELECTRICAL PARTS the FUEL INJECTION SYSTEM and especially the electronic control unit 1 and the digital dashboard 2 ...

Page 339: ...N 1 N 1st edition 08 2010 _Rev 11 2010 ENGINE COOLING Section ...

Page 340: ...N 2 1st edition 08 2010 _Rev 11 2010 ENGINE COOLING Coolant level check N 3 Cooling circuit N 4 Engine cooling system overhaul N 5 ...

Page 341: ...ad and radiator The cylinder and piston assembly will overheat and seize and in the worst scenario crankshaft damage may result If the event of engine overheating check that the radiator is full Level in the radiator must be checked from cold see Section D In the event you need to check level when the engine is hot be sure to discharge pressure gradually The radiator cap 1 has a pressure relief po...

Page 342: ...ation cooling system uses a centrifugal pump located to the left of the head and two down draft radiators 1 Radiator cap 2 Right hand radiator 3 Left hand radiator 4 Water temperature sensor 5 Water pump 6 Breather hose 7 Cylinder head radiator connection pipe 8 Water pump radiator lower pipe 9 Cooling fan TE TXC SMR ...

Page 343: ...age to radiator Straighten any bent fins to ensure free flow of air If the cooling mass is clogged or damaged no more than 20 of its surface must be affected If damage exceeds this limit the radiator must be replaced Periodically check the connecting hoses see Section B Scheduled Maintenance Chart this will avoid coolant leakage and consequent engine seizure If hoses show cracks swelling or harden...

Page 344: ......

Page 345: ...P 1 P 1st edition 08 2010 _Rev 11 2010 HYDRAULICALLY CONTROLLED CLUTCH Section ...

Page 346: ...P 2 1st edition 08 2010 _Rev 11 2010 HYDRAULICALLY CONTROLLED CLUTCH Hydraulic clutch system P 3 Draining clutch fluid P 4 Clutch master cylinder servicing P 5 Bleeding the clutch system P 6 ...

Page 347: ...ated on the left side of the handlebar and a piston installed on the right crankcase half Clutch is disengaged through piston 1 that works on clutch pushrod 1 Clutch master cylinder 2 Clutch lever 3 Master cylinder to piston hose 4 Piston assembly 5 Bleed fitting The fluid used in the hydraulic circuit will damage painted parts if spilt on them Handle it with care when servicing the system ...

Page 348: ... HYDRAULICALLY CONTROLLED CLUTCH Draining clutch fluid Connect a plastic hose to the bleed valve 1 and the loosen the valve turning it back 1 or 2 turns Remove reservoir cap 2 and gasket 3 and operate the control lever 4 until draining all fluid ...

Page 349: ...icing Drain the circuit detach the master cylinder from the left side of the handlebar and take it apart Replace all seals reassemble the master cylinder and refit it to the handlebar Reconnect the hose and fill fresh fluid into the reservoir bleed the system as described in the relevant paragraph ...

Page 350: ... and operate the lever 4 repeatedly until the fluid flowing out of the hose looks clear and free of air bubbles now tighten the bleed valve Top up fluid level A and refit rubber diaphragm 3 and reservoir cover 2 Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Hydraulic fluid is corrosive In the event of contact with eyes rinse with abundant w...

Page 351: ...S 1 S FUEL INJECTION SYSTEM 1st Edition 08 2010 _Rev 11 2010 Section ...

Page 352: ...S 2 FUEL INJECTION SYSTEM 1st edition 08 2010 _Rev 11 2010 FUEL INJECTION SYSTEM S 3 Instructions for using HUSQVARNA SERVICE TOOL for fuel injection system S 4 Fuel pump check S 6 ...

Page 353: ... fan shaped spray of fuel is injected into the combustion chamber The parameters that play a role in determining proper fuel delivery under all operating conditions are as follows Air temperature in the intake manifold Engine coolant temperature Atmospheric pressure in the intake manifold in current location and at cur rent altitude Throttle opening Battery voltage Fuel injection pulse width Ignit...

Page 354: ...ECU interface connector C connect the kit cable 3 to the connector C Connect the USB cable 4 to the PC start the Diagnostic Tool software you have installed and perform the required tests at the end of the analysis remove the cable 3 from the connector C If the cable remains connected the control unit and the users are pow ered Remove the cable 4 This diagnostic software can check the following in...

Page 355: ...addition to identifying any current malfunction the software stores past malfunctions that have been resolved store malfunc tions can be deleted following the instructions provided in the Operation Manual For fuel pump and relay inspections see relevant paragraphs ...

Page 356: ...the pump as described in Section E Connect the power supply unit positive pole 12V to the red lead pin in the pump connector Connect the power supply unit negative pole to the negative lead pin in the pump connector Never keep the pump connected to the power supply unit for more than 3 seconds in a row ...

Page 357: ... loose causing damage to motorcycle and injury to rider An overtightened nut or screw might become damaged its thread might strip or the nut screw might fail and work itself loose Listed in the table are the tightening torque figures for the most important nuts and screws which have determined in accordance with thread diameter pitch and specific application These figures are obtained after cleani...

Page 358: ...5 00 36 88 THROTTLE BODY CLAMP FASTENING 0 30 0 03 0 22 THROTTLE BODY COVER FASTENING 3 00 0 30 2 21 SHOCK ABSORBER TO DROP LINK FASTENING 50 00 5 00 36 88 SHOCK ABSORBER TO CHASSIS FASTENING 50 00 5 00 36 88 REAR BRAKE MASTER CYLINDER FASTENING 10 00 1 00 7 38 STARTER MOTOR FASTENING 10 00 1 00 7 38 POSITIVE CABLE TO STARTER MOTOR FASTENING 8 00 0 80 5 90 FILTER BOX BASE FASTENING 8 00 0 80 5 90 ...

Page 359: ...R SHOCK ABSORBER PROTECTION FASTENING 5 00 0 50 3 69 CLUTCH ACTUATOR COVER TO ENGINE FASTENING 5 00 0 50 3 69 REAR WHEEL AXLE FASTENING 142 00 14 20 104 73 CHASSIS PROTECTION TO CHAIN ROLLER FASTENING 10 00 1 00 7 38 HORN FASTENING 5 00 0 50 3 69 RIGHT SCOOP FASTENING 5 00 0 50 3 69 LEFT SCOOP FASTENING 5 00 0 50 3 69 LEFT SIDE PANEL FASTENING 5 00 0 50 3 69 RIGHT SIDE PANEL FASTENING 5 00 0 50 3 ...

Page 360: ...UNT PLATE FASTENING 4 00 0 40 2 95 COCK FASTENING 1 50 0 15 1 11 COCK FASTENING US TANK 9 00 0 90 6 64 TANK FASTENING 2 00 0 20 1 48 REAR CHASSIS TO TANK PAD FASTENING 8 00 0 80 5 90 RIGHT REAR CHASSIS TO SIDE PANEL PAD FASTENING 8 00 0 80 5 90 LEFT REAR CHASSIS TO SIDE PANEL PAD FASTENING 8 00 0 80 5 90 NUMBER PLATE LIGHT FASTENING 3 00 0 30 2 21 SADDLE SPACER FASTENING 10 00 1 00 7 38 SIDE PANEL...

Page 361: ...4 Nm 0 4 Kgm 3 ft lb Steel 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 spacers M6 6 5 Nm 0 65 Kgm 4 8 ft lb 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 St...

Page 362: ...X 6 1st edition 08 2010 _Rev 11 2010 TIGHTENING TORQUE FIGURES ...

Page 363: ...Y 1 Y 1st edition 08 2010 _Rev 11 2010 CHASSIS AND WHEELS Section ...

Page 364: ...he front wheel 7 Reassembling the front wheel 8 Rear wheel TC TE TXC 11 Rear wheel SMR 12 Removing the rear wheel 13 Wheel servicing 14 Wheel axle warpage 14 Axle runout over 100 mm 14 Wheel spokes 15 Wheel rim warpage 15 Rear chain sprocket secondary drive sprocket and chain 16 Tightening torque figures 16 Checking pinion and sprockets for wear 17 ...

Page 365: ...010 CHASSIS AND WHEELS Chassis The single frame branches off at the exhaust and is made of steel tubes with circular rectangular and ellipsoidal section the rear chassis is made from light alloy A badly damaged chassis must be replaced ...

Page 366: ...EELS Lubrication points lubricant 1 Steering bearings grease Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE RETAINING PINS SCREWS B ENGINE MOUNTING LINKS C REAR CHASSIS MOUNTING BOLTS D CHAIN GUIDE ROLLER BEARING E FOOTPEGS PINS SPRINGS ...

Page 367: ...TXC Light alloy wheel hub and rim with high strength steel spokes Type and size of wheel rims light alloy 1 6x21 TC TXC Type and size of tyre 80 100 x 21 TE Type and size of tyre 90 90 x 21 Cold tyre pressure TC 0 9 1 0 Kg sq cm TE TXC racing 0 9 1 0 Kg sq cm TE road use 1 1 Kg sq cm ...

Page 368: ...t wheel SMR Light alloy wheel hub and rim with high strength steel spokes Type and size of wheel rims light alloy 3 5x17 Type and size of tyre 120 70x17 Cold tyre pressure SMR 1 4 Kg cm2 SMR 1 8 Kg cm2 SMR 2 0 Kg cm2 In case of racing use Rider only Rider and passenger ...

Page 369: ...R 2 1st edition 08 2010 _Rev 11 2010 CHASSIS AND WHEELS Removing the front wheel Set a stand or a block under the engine and see that the front wheel is lifted from the ground Loosen the bolts 1 holding the wheel axle 2 to the front fork mounts ...

Page 370: ...l axle in place and unscrew the bolt 3 on the op posite side draw the wheel axle out Do not operate the front brake lever when the wheel has been removed this causes the calliper pistons to move outwards After removal lay down the wheel with brake disc on top Reassembling the front wheel Fit the L H spacer on the wheel hub ...

Page 371: ...H side after greasing it and push it fully home against the L H fork leg during this operation the wheel should be turned Tighten the screw 3 on the fork L H side but DO NOT lock it Lock the screws 1 on the R H leg 10 4 Nm 1 05 Kgm 7 7 ft lb the screw 3 on the L H side 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 After reassembly pull the brake control lever un...

Page 372: ...Y 10 TE TXC SMR H06389 1st edition 08 2010 _Rev 11 2010 CHASSIS AND WHEELS TE TXC SMR Check the gap B between magnet 6 on brake disc and sensor 7 on brake calliper Set height A back to original value ...

Page 373: ...trength steel spokes TC Type and size of wheel rims light alloy 2 15x19 TE TXC Type and size of wheel rims light alloy 2 15x18 TC Type and size of tyre 140 90x19 TXC Type and size of tyre 110x100x18 TE Type and size of tyre 110x100x18 Cold tyre pressure TC 0 8 0 9 Kg sq cm TE TXC racing 0 8 0 9 Kg sq cm TE road use 1 0 Kg sq cm ...

Page 374: ...r wheel SMR Light alloy wheel hub and rim with high strength steel spokes Type and size of wheel rims light alloy 4 25 x17 Type and size of tyre 150 60x17 Cold tyre pressure SMR 1 6 Kg cm2 SMR 2 Kg cm2 SMR 2 2 Kg cm2 In case of racing use Rider only Rider and passenger ...

Page 375: ...essary to loosen the chain tensioners 2 in this way the chain tension will remain un changed after reassembly Extract the complete rear wheel keeping the spacers located at the hub sides To reassemble reverse the above procedure remembering to insert the brake disc into the calliper Do not operate the rear brake pedal when the wheel has been re moved this causes the calliper pistons to move outwar...

Page 376: ...iscard the bearings after removal Never reuse them Before installing the new bearings check to ensure the seat is clean and shows no grooves or scratches Lubricate the seat before installing the bearing Drive the bearing into place using the special installer that only applies pressure to the outer race Fit the spacer and the other bearing Check for perfect alignment as you slide the axle into pla...

Page 377: ...l such as a screwdriver a clear crisp sound indicates proper tightening a dull sound means that the spokes need to be tightened Wheel rim warpage The table below reports the allowed limits for wheel rim warpage Exceeding runout or out of round are generally due to worn bearings When this is the case replace the bearings If this does not solve the problem change the wheel rim or the wheel Standard ...

Page 378: ...t the side shows the profiles of a normally worn and an exceedingly worn sprocket 1 Normal wear 2 Exceeding wear If the sprocket is exceedingly worn replace it after loosening the six screws that retain it to the hub Chain and sprockets must always be replaced as a set Tightening torque figures 3 34 3 Nm 3 5 Kgm 25 3 ft lb LOCTITE 243 ...

Page 379: ...he sprocket shown in the figure it must be replaced Wheelmisalignmentcausesabnormalwear makingthemotorcycle unsafe to ride Dirt caked on sprockets and chain collected while riding on muddy or wet terrain increases chain tension If you expect to ride on muddy or wet terrain slacken the chain a bit Riding on muddy terrain significantly increases chain and sprocket wear ...

Page 380: ......

Page 381: ...Z 19 NOTES FOR USA CDN 1st edition 08 2010 _Rev 11 2010 Z Section ...

Page 382: ... 2010 SPARK ARRESTER TE TXC SMR The models are equipped with a U S Forest Service approved spark arrester for maximum efficienty and performance SPARK ARRESTER MAINTENANCE AND CLEANOUT IN STRUCTIONS Proceed as follows Disassembly and Cleanout every 5000miles ...

Page 383: ... Cleanout the screen blowing air on the outside surface in order to remove any carbon particles b Shake the muffler handling it vertically with S A chamber toward the bottom in order to remove any carbon particles from the chamber if the screen is broken Replace the spark arrester unit as a whole screen end cap It is not allowed to replace the screen wire mesh alone ...

Page 384: ... 2010 _Rev 11 2010 Assembly Mount the screen matching the 3 holes Tighten the screw and washer with a torque of 3Nm For all screws check the proper torque every 500Km and tighten if necessary Final assembly Muffler side view SA Homologation stamp on the opposite face ...

Page 385: ...SITO MOTORE ENGINE MOTEUR MOTOR MOTOR ARIA AIR AIR LUFT AIRE 6 5 11 9 2 3 4 12 7 8 1 10 9 H06441 KIT Canister TE TXC SMR 1st edition 08 2010 _Rev 11 2010 1 Canister 2 Support 3 Clamp 4 Adhesive gum 5 Fitting 6 Seal washer 7 Clamp 8 Clamp 9 Clamp 10 Tube 11 Tube 12 Tube ...

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