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Husqvarna 2011 SMS 125, Workshop Manual

The Husqvarna 2011 SMS 125 Workshop Manual is the ultimate resource for those looking to service and maintain their motorcycle. This comprehensive manual provides detailed instructions and diagrams, enabling users to confidently perform repairs. Download this invaluable resource for free from manualshive.com, and ensure your bike performs at its best.

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M.2

ELECTRICAL SYSTEM

Ed. 05-2011

Wiring diagram ........................................................................................... M.5

Key to wiring diagram ................................................................................. M.5

Colour coding key ....................................................................................... M.5

Electrical components location ................................................................... M.6

Electrical components location ................................................................... M.8

Checking generator stator windings resistance .......................................... M.9

Generator performance .............................................................................. M.9

Alternator inspection ................................................................................. M.10

Electronic ignition system ......................................................................... M.10

CHARGING SYSTEM  ..............................................................................M.11

CHARGING SYSTEM WIRING DIAGRAM ...............................................M.11

CHARGING SYSTEM INSPECTIONS ..................................................... M.12

Current loss at the battery ........................................................................ M.12

Regulated voltage..................................................................................... M.12

Voltage regulator/rectifier inspection

 ........................................................ M.12

Voltage regulator ...................................................................................... M.12

Checking coil windings resistance ............................................................ M.13

Electronic control unit (ECU) .................................................................... M.14

Spark plug  ............................................................................................... M.14

BATTERY ................................................................................................. M.15

Battery charger ......................................................................................... M.15

Charging system check ............................................................................ M.15

Carburettor throttle position sensor (TPS) inspection............................... M.16

Carburettor throttle valve sensor (TPS) calibration  ................................. M.16

Checking air temperature sensor ............................................................. M.17

Checking  coolant temperature sensor ..................................................... M.18

Checking lubricating oil pump operation................................................... M.18

Checking the supply system ..................................................................... M.18

Checking the pump................................................................................... M.18

Headlight unit with front fairing removal ................................................... M.19

Removing headlight from front fairing....................................................... M.20

Front turning indicator removal ................................................................. M.21

HEADLAMP, TAIL LIGHT.......................................................................... M.22

Headlamp adjustment .............................................................................. M.22

Headlamp bulbs replacement ................................................................... M.22

Tail light replacement ................................................................................ M.23

Number plate bulb replacement ............................................................... M.24

Rear turning indicator removal ................................................................. M.25

Rear wiring harness replacement ............................................................. M.26

Type "A" wiring harness  ........................................................................... M.26

Type "B" wiring harness  ........................................................................... M.27

Handlebar switches .................................................................................. M.28

Right-hand switch ..................................................................................... M.28

Left-hand switch ....................................................................................... M.28

Colour coding key ..................................................................................... M.29

FUSES...................................................................................................... M.30

SEMICONDUCTOR PARTS ..................................................................... M.30

DIGITAL DASHBOARD, WARNING LIGHTS ........................................... M.31

1- SPEED (Kmh or mph) / ODO ............................................................... M.31

2 - SPEED / CLOCK ................................................................................. M.32

3 - SPEED / TRIP 1 .................................................................................. M.32

4 - SPEED / LAP TIMER (STP) ................................................................ M.32

5- SPEED / HOUR COUNTER ................................................................. M.33

6- DASHBOARD DIAGNOSTIC ............................................................... M.33

Dashboard replacement ........................................................................... M.34

Instructions for the instrument setting....................................................... M.34

Ignition switch removal ............................................................................. M.35

Summary of Contents for 2011 SMS 125

Page 1: ...Workshop Manual WRE 125 2011 SMS 125 2011 Ed 05 2011 ...

Page 2: ... any errors or omissions in this manual and reserves the right to make changes to reflect on going product development Illustrations in the manual may differ from actual components No reproduction in full or in part without written authorisation 1st edition 05 2011 ...

Page 3: ... 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 Chassis serial number TE 250 310 2011 I E WRE 125 2011 SMS 125 2011 WRE 125 ZKHH200AABV000000 SMS 125 ZKHH200ABBV000000 ...

Page 4: ...he 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 unnecessary...

Page 5: ...ance B Troubleshooting C Settings and Adjustments D General Procedures E Engine Disassembly F Engine Overhaul G Engine Assembly H Front Suspension I Rear Suspension J Brakes L Electrical System M Engine Cooling N Special Tools W Tightening Torque Figures X Chassis and Wheels Y NOTES Unless otherwise specified data and specifications apply to all models ...

Page 6: ......

Page 7: ...b 1 b IMPORTANT NOTICES Ed 05 2011 Section ...

Page 8: ...esult in severe engine damage IMPORTANT VEHICLE CONFIGURATION as outlined below is a prerequisite for the war ranty to remain valid A STANDARD MOTORCYCLE FOR ROAD USE DERATED 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 ...

Page 9: ...A 1 A GENERAL INFORMATION Ed 05 2011 Section ...

Page 10: ...TCH A 3 TRANSMISSION A 3 Transmission ratio A 3 SECONDARY DRIVE WRE A 4 SECONDARY DRIVE SMS A 4 FINAL RATIOS WRE A 4 FINAL RATIOS SMS A 4 FRAME A 4 FRONT SUSPENSION A 4 REAR SUSPENSION A 4 FRONT BRAKE A 4 REAR BRAKE A 4 RIMS A 4 TIRES A 4 Cold tire pressure A 5 Electrical components location A 5 Overall dimensions A 6 Weight A 6 Capacities A 7 ...

Page 11: ...ON QN 84 NGK BR9EG Spark plug gap 0 6 mm 0 0236 in FUEL SYSTEM Type Carburettor DELL ORTO VHST 28 Venturi diameter mm 28 1 10 in High speed jet 142 Low speed jet 38 Starting jet 60 Main nozzle HN 268 Floater g 6 5 Throttle valve 55 Metering pin D 48 Metering pin slot 2nd Idle mixture adjusting screw 1 1 2 turns PRIMARY DRIVE Drive pinion gear Z 22 Clutch ring gear Z 72 Transmission ratio 3 272 CLU...

Page 12: ...in circular sectioned tubes in steel rear steel chassis FRONT SUSPENSION Type Upside down telescopic hydraulic front fork with advanced axle stanchions tubes Ø 1 57 in ø 40 mm Legs axis stroke 260 mm 10 24 in REAR SUSPENSION Type progressive with hydraulic single shock absorber spring preload adjustment Wheel stroke 272 mm 10 71 in FRONT BRAKE Type fixed disc Ø 260 mm 10 24 in with hydraulic contr...

Page 13: ...saddle Voltage regulator on the left side of the chassis near the steering tube Spark plug on cylinder head The electrical system includes the following elements 12V 4Ah Battery under the saddle Turning indicator flasher on left side of rear chassis Fuses located on services bracket on left hand side of subframe Oil pump located on right hand side of rear subframe Air temperature sensor located in...

Page 14: ...2208 86 93 in SMS mm 2145 84 49 in Overall width C mm 825 32 48 in Overall height D WRE mm 1245 49 01 in SMS mm 1175 46 26 in Saddle height E WRE mm 944 37 16 in SMS mm 929 36 57 in Minimum ground clearance F WRE mm 330 13 00 in SMS mm 265 10 43 in Weight Kerb weight without fuel WRE 108 Kg 238 01ß lb Kerb weight without fuel SMS 111 Kg 244 71 lb ...

Page 15: ...all 0 172 U S Gall Engine lubricating oil CASTROL POWER 1 RACING 2T Gearbox and primary drive lubricating oil CASTROL POWER 1 RACING 5W 40 Engine coolant CASTROL MOTORCYCLE COOLANT Brake system fluid CASTROL RESPONSE SUPER DOT 4 Grease lubrication CASTROL LM GREASE 2 Final drive chain lubrication CASTROL CHAIN LUBE RACING Front fork oil Castrol syntHetic fork OIL 5W 520 cm3 Electric contact protec...

Page 16: ......

Page 17: ...B 1 B MAINTENANCE Ed 05 2011 Section ...

Page 18: ...mi 10000 Km 6213 mi 15000 Km 9320 mi 20000 Km 12427 mi AS REQUIRED TRANSMISSION OIL C S S S S ENGINE OIL C COOLANT C C S C S X SPARK PLUG C S S S S PISTON CYLINDER C C C C X EXHAUST VALVE DECARBONIZING P P P P X CLUTCH DISC C C C C X AIR FILTER P P S P S CARBURETOR IDLE CO C C CARBURETOR C P C P C P C P C P EXHAUST VALVE CLEANING OIL DRAINAGE P WRE SMS 125 LEGENDA C CHECK P CLEAN C P CHECK CLEAN S...

Page 19: ... TANKS P P FUEL HOSES AND FILTERS P P S P S HEADLAMP BEAM HEIGHT C C C C C LIGHTS INDICATIONS HORN C C C C C BATTERY C C C C C WHEEL SPOKES TENSION C C C C C STEERING BEARINGS PLAY C C C SECOND DRIVE CHAIN CHAIN TENS ROLLERS C C C C C C GEARB OUTPUT SPROCKET REAR SPROCKET C S C S SIDE STAND SCREWS C C C C C WHEEL HUB BEARINGS C C X FRONT FORK FLUID S S OVERALL TIGHTENING OF NUTS AND BOLTS C C C C ...

Page 20: ......

Page 21: ...C 1 C TROUBLESHOOTING Ed 05 2011 Section ...

Page 22: ...wide Adjust 4 Ignition coil faulty Replace 5 High tension cables open circuit or shorted Check 6 Key operated switch faulty Replace The carburettor is not receiving fuel 1 Tank cap breather clogged Clean 2 Fuel cock clogged Clean 3 Clogged fuel inlet hose Clean 4 Floater valve faulty Replace 5 Linkage is blocking floater valve Release Carburettor floods 1 High fuel level in bowl Adjust 2 Floater v...

Page 23: ... clutch 1 Worn plates Replace 2 Too much clearance between clutch housing and friction plates Replace Noise seems to come from gearbox 1 Worn gears Replace 2 Worn gear grooves Replace Noise seems to come from the secondary drive chain 1 Chain stretched worn or improperly adjusted Replace or adjust 2 Worn transmission sprockets Replace The clutch slips 1 Clutch adjuster screw with insufficient clea...

Page 24: ... Insufficient compression Check for the cause 6 Carburettor main jet clogged or of the wrong size Clean or replace 7 Too much ignition advance Adjust 8 Deposits on the exhaust valve Clean 9 Exhaust valve wrongly installed Adjust The engine overheats 1 Dirty combustion chamber and or piston crown with carbon deposits Clean 2 Insufficient oil in engine or wrong oil Top up or change 3 Obstructions bl...

Page 25: ...il in fork legs Top up 2 Fork oil viscosity too low Replace 3 Damping cartridge inside fork legs is not working properly Replace 4 Weak rear shock absorber spring Replace 5 Improperly set rear shock absorber Adjust Front and rear wheel vibrates 1 Bent wheel rim Replace 2 Worn wheel hub bearings Replace 3 Incorrect spoke tension Adjust 4 Wheel axle nut loose Tighten 5 Worn rear swinging arm bearing...

Page 26: ...h recommend ed spark plug 3 Mixture too lean Adjust carburettor Generator does not charge or is not provid ing enough charge 1 Cables running to voltage regulator improperly connected or shorted Connect correctly or 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 termi...

Page 27: ...D 1 D SETTINGS AND ADJUSTMENTS Ed 05 2011 Section ...

Page 28: ...Engine lubrication oil level D 14 Exhaust valve cleaning oil drainage D 14 Lubricating oil pump drainage D 15 Coolant level check D 16 Coolant replacement D 17 Air filter check D 18 Air filter cleaning D 18 Assembly D 19 Chain adjustment D 20 Chain lubrication D 21 Disassembling and cleaning D 21 Washing a chain without O rings D 21 Lubricating a chain without O rings D 21 Shock absorber adjustmen...

Page 29: ...D 3 H02628 WRE 125 H02629 SMS 125 SMS 125 H02630 H02631 SMS 125 SETTINGS AND ADJUSTMENTS Ed 05 2011 ...

Page 30: ...fixing 1 counter clockwise remove it and extract the saddle Tank removal Remove the saddle as described in the relevant paragraph Remove the screws 1 and the side panels 8 mm Allen wrench Remove the tank retaining screw 2 8 mm Allen wrench Release the clamp 5 close the cock 3 and disconnect the hose 4 ...

Page 31: ...D 5 H02638 6 SETTINGS AND ADJUSTMENTS Ed 05 2011 Lift the front part of the tank 6 and remove it from the bike with the scoops ...

Page 32: ... mm 0 04 in then tighten lock nut and regis ter if register 3 should not provide sufficient movement to allow for correct adjustment then adjust register placed on carburetor There should be approx 1 mm 0 04 in play on latter register otherwise move the rubber cap 4 aside and after loosening the check nut 6 loosen or tighten the adjuster screw 5 to reduce or increase free play Operation with damag...

Page 33: ...e engine is hot and throttle is closed as follows turn the idle speed adjuster screw 1 until setting 1500 RPM 100 turn clock wise to increase the speed and counter clockwise to reduce the speed Exhaust gas contains poisonous carbon monoxide gas Never run the engine in a closed area or in a confined area ...

Page 34: ...s 4 securing the clutch springs Remove springs pressure plate 5 with bearing 6 and clutch actuator plate 7 Remove the plates 8 lubricate the new plates with engine oil and install them always start with a friction plate Refit clutch actuator plate bearing and pressure plate Tighten the spring screws gradually in a cross pattern When refitting the clutch cover check gasket for wear and replace as r...

Page 35: ... you will need to adjust cable tension using the adjuster on the lever Remove the rubber protection 1 Loosen the lock ring nut 3 and turn the tensioner 2 There should be at least 10 mm 0 39 in free play A before the clutch begins to disengage When through with the adjustment tighten the lock ring nut 3 and refit the rubber protection 1 ...

Page 36: ...ever stroke If the brake lever feels mushy when pulled there may be air in the brake lines or the brake may be defective Check the system or proceed to drainage as outlined in the relevant paragraph Do not spill brake fluid onto any painted surface or light lens Do not mix two brands of fluid Completely change the brake fluid in the brake system if you wish to switch to another fluid brand Brake f...

Page 37: ...dal following the instructions provided in paragraph Rear brake pedal free play adjustment Rear brake pedal free play adjustment The rear brake pedal 3 should have 5 mm free play B before the brake begins to bite Should this not happen operate as follows Loosen the nut 4 Operate the master cylinder linkage 5 to increase or decrease free play Tighten the nut 4 at the end of the operation When the f...

Page 38: ...elevant paragraph Do not spill brake fluid onto any painted surface or light lens Do not mix two brands of fluid Completely change the brake fluid in the brake system if you wish to switch to another fluid brand Brake fluid may cause irritation Avoid contact with skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed Checking the oil level Keeping t...

Page 39: ...ne guard 1 by undoing the screws 2 To completely replace the oil unscrew the plug 3 under the oil sump and let oil come out then screw the plug again with its gasket and pour fresh oil from the hole of the loading plug Use only the prescribed quantity and type of oil Have this operation made with warmed up engine ...

Page 40: ... rear pin 1 counterclockwise Remove the cap 2 Visually check that the oil level in the tank is sufficient if necessary top up with the oil type indicated in the lubricant table Exhaust valve cleaning oil drainage Open the clamp 1 and remove the cap 2 draining all the residual oil from the secondary air circuit inside a container ...

Page 41: ...ettor pipe 4 and disconnect pipe place a container under it and check that the ignition key 1 is in OFF disconnect oil pump connector 2 rotate the ignition key 1 to ON and reconnect the connector 2 A five minute pump cycle will be carried out during which the warning light 3 will flash every 0 5 sec After this operation connect the hose to the carburettor again Lubricating oil pump does not requir...

Page 42: ...cular to the ground The coolant should be approximately 0 39 in above the cells The radiator cap features two locking positions the first one is for prior discharge of pressure from the cooling system Avoid removing radiator cap when engine is hot as coolant may spout out and cause scalding Difficulties may arise in eliminating coolant from painted surfaces If this occurs wash off with water ...

Page 43: ...minium sealing washer Avoid removing radiator cap when engine is hot as coolant may spout out and cause scalding Difficulties may arise in eliminating coolant from painted surfaces If this occurs wash off with water Pour the necessary quantity of coolant in the radiator then warm up the engine in order to eliminate any possible air bubbles Periodically check the connecting hoses see Scheduled Main...

Page 44: ...e subframe 7 Air filter cleaning Wash the filter with a specific detergent CASTROL FOAM AIR FILTER CLEANER or similar then dry it fully wash filter with gasoline only in case of necessity Plunge the filter in special oil for filters CASTROL FOAM AIR FILTER OIL or similar then wring it to drain superfluous oil Do not use gasoline or a low flash point solvent to clean the element A fire or explosion...

Page 45: ...rs that piece A is turned up wards and edge B is on the left lower side of the filter case Reassemble the parts previously removed When positioning the engine oil bowl take care to correctly reposi tion pump intake hose 1 making also sure that it is not kinked If the element assembly is not installed correctly dirt and dust may enter and the engine resulting in rapid wear of the piston rings and c...

Page 46: ... in as shown in the nameplate 1 on chain cover Incorrect chain 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 25 mm Allen wrench loosen the locking nut 2 of the wheel axle adjust the linkages 3 on both sides of the swinging arm using a 6 mm Allen wrench make sur...

Page 47: ...or naphtha If you use fuel or especially trichloroethylene dry and lubricate the chain to avoid oxidisation Lubricating a chain without O rings 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 Assemble the master link clip 3 by setting the ...

Page 48: ...again 4 The difference between these two measurements is the distance the rear end settles when the rider sits on the motorcycle RIDER SAG Recommended rider sag is 100 mm with a cold shock absorber and 95 mm with a warm shock absorber 5 To achieve correct rider sag for your weight adjust the spring preload of the shock absorber see relevant paragraph The shock absorber adjustment affects both the ...

Page 49: ...de panel 3 2 Clean lock ring nut 4 and adjuster ring nut 5 of the spring 6 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 40 Nm 4 Kgm 29 50 ft lb 6 Reassemble the R H side panel and the saddle Be careful not to touch hot ex...

Page 50: ...cause the front end to rotate the handlebar should turn smoothly Sit on the ground in front of the front wheel and hold the lower ends of the fork legs Push and pull in a front to rear motion to feel for play If any play is detected adjust as follows Loosen the steering head tube nut 1 Loosen the four bolts 3 that secure the fork legs to the steering head Turn the steering head tube ring nut 2 clo...

Page 51: ...relevant paragraph Check that the pump intake hose 1 and the delivery hose 2 slide freely and are not kinked Check that hose 2 is correctly fitted into its supporting clips 3 and that it does not rest on the engine If the hoses have cracks or are too stiff bleed al oil inside them into the bowl then replace them To replace hose release clamps 4 On reassembly check that the plastic spiral allowing ...

Page 52: ...Ensure that pipe 1 and silencer 2 do not show any sign of failure or damage replace if cracked or damaged Remove the right hand side panel 3 and check the conditions of the silent blocks 4 If damaged replace them by loosening screws 5 7 mm wrench Check the conditions of the springs 6 securing manifold 7 to the head replace them if they have lost elasticity ...

Page 53: ...oting on such shaft of a connection lever D and another control lever E pivoting on the valve control shaft With the valves fully closed the min distance from the piston must be equal to or over 0 4 0 5 mm 0 0157 0 0197 in To perform this adjustment proceed as follows Remove the cover 1 by loosening the screws 2 using an 8 mm wrench Loosen the screws 3 and 4 locking plate 5 in place using a 13 mm ...

Page 54: ......

Page 55: ...E 1 E GENERAL PROCEDURES Ed 05 2011 Section ...

Page 56: ...removal E 8 Exhaust system removal E 10 Fuel tank and scoop removal E 12 Scoop removal E 14 Spoiler removal E 14 Voltage regulator removal E 15 Ignition coil removal E 15 Horn removal E 16 Number plate holder removal E 16 Air box removal E 17 Front mudguard removal E 19 Rear brake pedal removal E 20 Carburettor removal E 20 Secondary drive chain removal E 23 Engine removal E 23 Engine removal E 24...

Page 57: ...s section describes the operations preliminary to engine removal Please note that in order to gain access to certain motorcycle components rear shock absorber electrical parts wiring etc it may be necessary to partially remove some parts RIGHT HAND SIDE LEFT HAND SIDE ...

Page 58: ...E 4 H02705 2 1 1 H02706 2 2 H02707 GENERAL PROCEDURES Ed 05 2011 Engine guard removal Using an 8 mm wrench loosen screws 1 Remove engine guard 2 releasing it from the rear support ...

Page 59: ... described in the relevant paragraph Using an 8 mm wrench loosen retaining screws 1 and remove side panels 2 and 3 Battery removal Remove the saddle as outlined in the relevant paragraph Using an 8 mm Allen wrench first remove the BLACK negative cable then the RED positive cable when reassembling first connect the RED positive cable then the BLACK negative cable remove the battery 1 from its hous ...

Page 60: ...elivery pipe 4 to carburettor releasing the relevant clamp 5 Plug pipe 4 and slide it out of the special supporting clips Lift oil reservoir 6 and disconnect level sensor connector 7 On reassembly take care to correctly position oil pump intake pipe checking that it is not kinked and that the plastic spiral allowing its correct sliding and preventing it from kinking has been correctly positioned i...

Page 61: ...16 1 3 GENERAL PROCEDURES Ed 05 2011 Electronic control unit removal Remove the saddle as outlined in the relevant paragraph Remove control unit 1 from the special vibration mount 2 Release connector 3 from control unit 1 ...

Page 62: ...levant paragraphs Shear the plastic clips securing wiring to rear chassis Disconnect air temperature sensor connector 1 positioned inside filter box widen tabs and pull Disconnect the connector 2 between main wiring harness and rear wiring harness Using an 8 mm wrench loosen screw 3 and remove bracket 4 from fuse and flasher support Loosen clamp 5 securing filter box to carburettor Using a 10 mm w...

Page 63: ...E 9 H02717 9 8 H02722 7 GENERAL PROCEDURES Ed 05 2011 To remove upper pin 7 loosen nut with a 12 mm wrench and pin with a 13 mm wrench Lift chassis 8 complete with filter box 9 ...

Page 64: ...2011 Exhaust system removal Remove the saddle as described in the relevant paragraph Remove the right hand side panel as described in the relevant paragraph Using an 8 mm T wrench remove silencer 2 retaining screws 1 and remove silencer from vehicle ...

Page 65: ...5 GENERAL PROCEDURES Ed 05 2011 Remove clamp 3 and disconnect secondary air circuit pipe 4 from exhaust manifold 5 Release the two springs 6 To remove manifold 5 loosen screw 7 with an 8 mm wrench Check seal 8 and metal gasket 9 for wear Change if damaged ...

Page 66: ...10 12 6 12 8 7 H02731 1 GENERAL PROCEDURES Ed 05 2011 Fuel tank and scoop removal Remove the saddle as described in the relevant paragraph Remove the side panels as described in the relevant paragraph Remove the breather hose 1 ...

Page 67: ...733 6 7 GENERAL PROCEDURES Ed 05 2011 Loosen tank retaining screw 2 with an 8 mm Allen wrench Close fuel cock 3 release clamp 5 and disconnect pipe 4 Raise the tank 6 from the front end and remove it from bike complete with scoops 7 ...

Page 68: ...ench loosen front screw 8 between scoop 7 and tank Using an 8 mm wrench loosen side screw 9 and upper screws 10 with a Phillips screwdriver then remove scoop 7 Spoiler removal Remove the fuel tank as outlined in the relevant paragraph Using an 8 mm socket wrench loosen the two screws 11 and remove spoiler 12 On reassembly check that horn 13 is correctly positioned and secured in place ...

Page 69: ...removal Disconnect the connector 1 Loosen the two retaining screws 2 and remove the regulator 3 8 mm wrench Ignition coil removal Remove saddle and fuel tank as described in the relevant paragraphs Remove the spark plug cap 1 Remove the retaining screws 2 and then the coil 3 8 mm wrench ...

Page 70: ... the horn 3 with its brack et Number plate holder removal Remove tail light as outlined in section M Disconnect rear turning indicator connectors 1 and 2 Slide turning indicator cables out of rubber gaiter 3 Using an 8 mm wrench loosen screws 4 and remove number plate holder complete with turning indicators On reassembly make sure that number plate holder light cable 5 is positioned as shown in th...

Page 71: ...ervoir and silencer in this order as outlined in the relevant paragraphs Disconnect air temperature sensor connector 1 positioned inside filter box widen tabs and pull Loosen clamp 2 securing filter box to carburettor Loosen the screws 3 using a 10 mm wrench Loosen upper pin 4 using a 12 mm wrench on nut and a 13 mm wrench on pin ...

Page 72: ...011 Overturn chassis 5 with filter box 6 without removing control unit and fuse and flasher holder bracket Using an 8 mm wrench loosen the four screws 7 and remove filter box 6 from chassis Using a 2 5 mm Allen wrench loosen the two screws 8 and remove tem perature sensor 9 ...

Page 73: ...d 05 2011 Using an 8 mm wrench loosen the two screws 10 and remove shock absorber protection 11 Remove rivets 13 and remove upper rubber protection 12 Remove the air filter Front mudguard removal Using an 8 mm wrench loosen the four screws 1 and remove mudguard 2 ...

Page 74: ...6 mmAllen wrench loosen screw 1 and remove lever 2 complete with pump pushrod 3 Carburettor removal Close fuel cock 1 release clamp 3 and disconnect pipe 2 Disconnect TPS sensor connector 4 Important Do not remove TPS from carburettor in order not to lose calibration Disconnect secondary air circuit hose 7 ...

Page 75: ...1 H02764 5 H02749 6 H02761 10 H02762 9 8 GENERAL PROCEDURES Ed 05 2011 Loosen clamps 6 and disconnect mixture oil hose 5 Slightly turn carburettor 8 to the left loosen screw 9 and remove starter control 10 ...

Page 76: ... PROCEDURES Ed 05 2011 Loosen the two screws 11 and remove carburettor valve cover 12 Detach carburettor 8 and remove it On reassembly take care that carburettor breather hoses 13 are correctly positioned inside their seats and that they are not kinked ...

Page 77: ...n 5 Engine removal Remove the saddle as described in the relevant paragraph Remove the fuel tank as described in the relevant paragraph Remove the exhaust system as described in the relevant paragraph Drain all coolant as described in the relevant paragraph Remove secondary drive chain as described in the relevant paragraph Remove rear brake pedal as described in the relevant paragraph ...

Page 78: ...H02770 4 H02771 5 GENERAL PROCEDURES Ed 05 2011 Engine removal Lift retaining tab and disconnect clutch cable 1 Disconnect ignition connector 2 PICKUP connector 3 and coolant tem perature sensor 4 Take off the spark plug cap 5 ...

Page 79: ...ipes 9 from engine 10 Using a 27 mm wrench loosen nut 11 on swinging arm shaft then work ing on the right side remove swinging arm shaft until releasing engine but without removing swinging arm Using a 12 mm wrench on the left side and a 10 mm wrench on the right side loosen nuts 12 then remove engine retaining screws Slightly raise engine and remove it from bike right side ...

Page 80: ... together with scoops and spoilers as outlined in the relevant paragraphs Drain all coolant as outlined in the relevant paragraph Using an 8 mm wrench loosen screws 2 and remove radiator protections 1 Remove the plastic grids 3 from the radiators 4 Open clamps 5 and disconnect hoses 6 from right hand radiator 7 ...

Page 81: ... 12 H02782 10 13 GENERAL PROCEDURES Ed 05 2011 Open clamps 8 and disconnect hoses 9 from left hand radiator 10 Open clamp 11 and disconnect the radiator connecting hose 12 Using an 8 mm wrench loosen screws 13 and remove left hand radiator 10 ...

Page 82: ...5 2011 Using an 8 mm wrench loosen screws 14 and remove right hand radiator 7 Thermostat removal Remove fuel tank and drain all coolant as outlined in the relevant para graph Open the three clamps 1 securing the thermostat 2 Disconnect the hoses 3 and remove the thermostat 2 ...

Page 83: ...F 1 F ENGINE DISASSEMBLY Ed 05 2011 Section ...

Page 84: ...mponents F 4 Clutch side crankcase half component disassembly F 5 Sprocket side component and cover disassembly F 9 Intake valve disassembly F 12 Exhaust valve disassembly F 13 Piston cylinder and head assy disassembly F 14 Splitting the crankcase F 16 Gearbox removal F 16 Crankshaft removal F 17 ...

Page 85: ...ening the retaining screws 9 10 and 11 Remove water pump impeller 12 by turning it by hand counter clockwise On reassembly take care that pump cover centring bushings 13 are positioned close to the two longer screws and replace gasket 14 Loosen the eight retaining screws 15 and 16 two and six pieces respectively on crankcase half right hand side cover Remove cover by levering onto starter shaft en...

Page 86: ...11 1 Screw 2 Washer 3 Spring 4 Pressure plate 5 Clutch assembly 6 Thrust washer 7 Needle roller bearing 8 Retainer 9 Ball 10 Pushrod 11 Clutch control shaft 12 Lock washer 13 Nut 14 Clutch hub 15 Washer 17 Clutch housing 18 Needle roller bearing 19 Spacer 20 Spacer 21 Washer Clutch components ...

Page 87: ...2 and springs 3 Remove pressure plate 4 and clutch plates pack 5 from hub Slide thrust washer 6 axial roller bearing 7 and retainer 8 out of pri mary shaft end Tilt engine block on the right side and slide out ball 9 and pushrod 10 Working on the opposite side slide out clutch control lever 11 together with return spring and bushing Using a chisel and a hammer straighten the bent sections of lock ...

Page 88: ...special tool part no 8000 79015 with the ends inserted inside the two opposite grooves on clutch hub Lock clutch hub in place with tool and loosen locking nut 13 with a 22 mm socket wrench Slide nut 13 lock washer 12 and clutch hub 14 out of primary shaft end Slide washer 15 out of primary shaft ...

Page 89: ...tershaft nut 16 placing a 1 2 gear or an aluminium shim be tween clutch housing gear 17 and countershaft gear 18 Slide clutch housing 17 the two needle roller cages 18 with spacer 19 the inner spacer 20 and three tab washer 21 out of primary shaft Slide water pump control gear 22 and primary drive gear 23 out of crank shaft ...

Page 90: ...25 H06538 26 ENGINE DISASSEMBLY Ed 05 2011 Remove the Woodruff key from crankshaft Slide countershaft idle gear 24 with the relevant shims 25 out of right crankcase half Slide selector shaft 26 out of right crankcase half rear side ...

Page 91: ...ankcase half Working on the inner side slide out starter shaft 28 assembly complete with control gear and collect washer 29 Sprocket side component and cover disassembly Loosen the three retaining screws 1 and remove cover 2 Collect gas ket Loosen the two retaining screws 3 on sprocket cover 4 and remove it together with the protective plate and spacers ...

Page 92: ...screw Lock sprocket 6 in place using tool part no 00YA2273 and then with a 13 mm socket wrench loosen sprocket sealing screw on output shaft Slide out this screw lock washer large washer and sprocket On reassembly take care to correctly position the large washer the two caulked ends shall be pointing the sprocket Remove also spacer with the O ring ...

Page 93: ... mm socket wrench loosen rotor sealing nut Remove lock washer Use tool 7 part no 8000 51614 and secure it onto rotor with three screws having a suitable length Holding the tool in place with a 19 mm Allen wrench and working clockwise on the central screw remove rotor from crankshaft with a 17 mm Allen wrench ...

Page 94: ...tator Slide rubber block and plate 9 out of left crankcase half and remove the complete stator 10 Remove the Woodruff key from crankshaft Intake valve disassembly Using the special wrench part no 8000 98431 loosen the four sealing screws 1 on intake valve unit 2 Slide out the carburettor to valve fitting ...

Page 95: ...case and collect gasket 3 Exhaust valve disassembly Remove exhaust valve control unit 1 ad described in the relevant paragraph Loosen screw 2 and remove parts 3 4 5 and 6 Remove screws 7 and cover 8 Loosen grub screw 9 duly turn shaft 10 and remove if from its seat on cylinder Remove screws 11 and exhaust valves 12 ...

Page 96: ... operations carried out so far The piston cylinder and head assy removal proves now necessary in order to separate the crankcase halves Loosen the five head sealing screws 1 on cylinder and collect the washer underneath Remove head 2 and collect the two outer 3 and inner 4 O rings NOTE The O rings between head and cylinder shall be changed upon each reassembly Loosen the four retaining nuts 5 betw...

Page 97: ...as piston ring end could enter gaps thus preventing piston removal and causing damage to the piston ring itself To eliminate this risk removal operations shall be carried out with the piston at BDC Remove one of piston pin 7 retainers duly support piston and partially slide out piston pin using a cylindrical pin 8 until piston is free Remove piston 9 with piston pin Slide roller cage out of connec...

Page 98: ...tral pin and separate crankcase halves To make this operation easier tap output shaft end with a mallet while working with tool pin Remove shims from crankshaft primary shaft selector shaft and counter shaft Gearbox removal Slide counter roller out of balance shaft Remove the two pins 1 with shifter forks Remove the two gearbox shafts 2 and 3 complete with gears at the same time To make this opera...

Page 99: ...h those on right crankcase half outer side and secure tool with three screws of a suitable length Duly support crankshaft and work on central pin to remove it When removing crankshaft never tap on its end even with a plastic hammer To remove bearing that will remain integral to the crankshaft on the left side use tool part no 8000 89030 On reassembly take special care to position shim between shaf...

Page 100: ......

Page 101: ...G 1 G ENGINE OVERHAUL Ed 05 2011 Section ...

Page 102: ...ting rod big end axial clearance G 11 Connecting rod twist warping G 11 Head G 12 Crankshaft G 12 Crankshaft straightness G 12 Various crankshaft straightness check G 13 Bearings G 13 Needle roller bearing replacement G 14 Replace oil seal G 14 Clutch unit G 15 Friction plate thickness G 15 Friction plate to clutch housing clearance G 16 Clutch plate distortion G 16 Clutch spring G 16 Gear change ...

Page 103: ...cleaned with gasoline and dried with compressed air During this procedure flammable vapours develop and metal particles may be blown at high speed it is therefore recommended to perform this procedure away from open flames or sources of ignition and to wear goggles ...

Page 104: ...d remove the piston and reassemble it on the connecting rod e reassemble the cylinder together with the head inserting the 0 5 mm seal on the crankcase f take the piston to the T D C and check that the reading on the dial gauge is equal to 1 2 mm 0 05 in figure B g should the reading be different restore the correct condition using a cylinder foot gasket of suitable thickness Alternatively a Remov...

Page 105: ...s 0 015 mm 0 0006 in In case of damages or excessive wear the cylinder shall be replaced Cylinders are marked by a letter or a colour referring to the class they belong to Cylinder measuring Check that the internal surface is perfectly smooth and free from scuffing Take the reading of the liner diameter DN 10 mm from the upper surface as indicated in the diagram towards the exhaust axis ...

Page 106: ...iston diameter D shall be measured 13 5 mm 0 53 in from the skirt bottom perpendicularly to the piston pin axis Standard Max size limit 1 02 1 04 mm 0 0401 0 0409 in 1 1 mm 0 043 in Clearances To ensure the best operating conditions and maximum performance all clearances must be within the specified tolerance A tight fit will lead to seizure as moving parts heat up whereas a loose fit will cause a...

Page 107: ...iston pin to piston clearance it shall be 0 002 0 009 mm 0 000079 0 000354 in Wear limit 0 012 mm 0 0005 in When replac ing the piston pin it is also necessary to replace the needle roller bearing cage in compliance with what specified in the paragraph piston pin piston connect ing rod small end clearance H06566 3 Cylinder Piston Abbreviation Size Abbreviation Size Clearance A B or BLACK BLUE 53 9...

Page 108: ...oned perfectly parallel to the groove surfaces in the piston Otherwise the piston shall be replaced Piston ring height The table shows the values of the axial clearance between lower upper piston ring and piston seat Piston ring to groove clearance Piston ring to cylinder clearance Insert the piston ring at the bottom of the bore where minimum wear occurs taking care to position it squarely and me...

Page 109: ...diameter A of the connecting rod small end and based on this value the proper needle roller bearing cage will have to be assembled NOTE When asking for the needle roller bearing cage specify the selection A connecting rod small end hole diameter colour selection mm in D piston pin diameter colour selection mm in B needle roller bearing cage diameter se lection White 18 998 19 000 0 7479 0 7480 Whi...

Page 110: ...l pin Based on these values assemble the suitable needle roller bearing cage NOTE When asking for the needle roller bearing cage specify the selection E connecting rod small end hole diameter colour selection mm in D pin flywheel connecting rod big end hole diameter colour selection mm in Needle roller bearing cage diameter selec tion White 30 014 30 016 1 1816 1 1817 Black 23 998 23 996 0 9448 0 ...

Page 111: ...nt to check its wholeness Should readings not comply with the max allowed wear limits it will be neces sary to replace it These tests can be carried out even with connecting rod assembled to crank shaft Big end axial clearance Connecting rod twist warping Standard Max wear limit 0 45 0 84 mm 0 0177 0 0331 in 1 1 mm 0 043 in Standard Max wear limit max 0 025 100 mm max 0 00098 in 4 in 0 05 100 mm 0...

Page 112: ...in journals should show no scoring or scuffing Threads keyways and splines must be in good condition Crankshaft straightness Standard Max wear limit less than 0 02 mm 0 00078 in 0 05 mm 0 0019 in To disassemble crankshaft use a support and suitable punches On reassembly comply with the specified tolerances Assemble the coupling pin into the flywheel halves with an oil having a C 3 ENGLER viscosity...

Page 113: ...l The main bearings shall always be removed in pairs and installed with the writing pointing out wards to replace them it is necessary to heat up the crankcase halves in a fur nace at 90 100 C and remove the bearing using a driver tool and a hammer Install the new bearing while the crankcase is still hot perfectly squarely with respect to the housing axis using the special installer that only appl...

Page 114: ...pump shaft use special tool part no 8000 43824 Oil seal replacement Replace the oil seals at each engine overhaul To install the new oil seals in sert them squarely into their housings and use suitable driver tools After the assembly lubricate with engine oil the oil seal lip Carry out this operation with utmost care and attention ...

Page 115: ...e they are in the best conditions Clutch plates should show no signs of bluing scoring or distortion the plates fitted with friction material shall have a thickness complying with the values indicated in the table Friction plate thickness Standard Max size limit 3 05 2 95 mm 0 120 0 116 in 2 8 mm 0 11 in ...

Page 116: ...lar features but are different in length When checking them the free length shall not be lower than the value specified below Standard Max wear limit Friction plate within 0 05 mm 0 0019 in 0 2 mm 0 0078 in Steel plate within 0 01 mm 0 0004 in 0 25 mm 0 0098 in Standard Max size limit 0 25 0 35 mm 0 0098 0 0138 in 0 8 mm 0 031 in Free check length Standard Max wear limit 45 mm 1 77 in 42 5 mm 1 67...

Page 117: ...re that the idle gears rotate freely on their shafts and that their clearance is not higher than 0 10 mm 0 004 in The shaft threading and grooves must be in perfect conditions Moreover make sure that the gear selector components are in good conditions Check that the selector groove width complies with the specified tolerance ...

Page 118: ...ears hard to engage and let the transmission jump out of gear unex pectedly under loading Fork slider thickness Fork guide pin diameter Gear groove length Standard Max size limit 3 35 3 43 mm 0 132 0 135 in 3 31 mm 0 130 in Standard Max size limit 5 8 5 9 mm 0 228 0 232 in 5 75 mm 0 226 in Standard Max size limit 3 65 3 72 mm 0 143 0 146 in 3 8 mm 0 150 in ...

Page 119: ...G 19 H06592 3 ENGINE OVERHAUL Ed 05 2011 Control shaft groove width Standard Max size limit 6 05 6 15 mm 0 238 0 242 in 6 20 mm 0 244 in ...

Page 120: ...he motorcycle Description Ref Dell Orto PHBH 28 1 Throttle valve 2 Taper needle 3 Idle diffuser 4 Floater 5 Jet at maximum 6 Main nozzle 7 Start jet 8 Air screw turned out Venturi diameter mm 55 D 48 2nd groove U 38 N 2 6 5 gr 142 HN 268 60 1 and 1 2 28 with washer between retainer and throttle valve Carburettor ...

Page 121: ...ne warmed up Loosen the air adjuster screw b of 1 1 2 turns from the fully closed position then gradually act on the idle speed adjuster screw a until reaching the idle speed of 1 500 1 700 rpm b Throttle intermediate position Should it be necessary to modify mixture ratio from the idle position at about 1 5 of throttle valve opening fit a valve with a smaller front drain side to enrich it and wit...

Page 122: ...itude greatly affect the behaviour of the air fuel mixture within the carburettor It is thus necessary to modify the original jet size inferring the correction factor on the graph below EXAMPLE With a temperature of 25 C and an altitude of 1000 m a correction factor of 0 94 is obtained Therefore the main jet to be used to replace the original one 142 will be 142x0 94 133 5 134 jet available H06627...

Page 123: ...late stops When refitting the removed parts apply Loctite on the screws Exhaust valve Clean the valves with a spark plug cleaner brush or with thin sand paper Clean and replace them following the intervals indicated in section B Do not use scrapers or tool bits which may damage the external surfaces of the valve affecting its sealing capacity against the cyl inder ...

Page 124: ......

Page 125: ...H 1 H ENGINE ASSEMBLY Ed 05 2011 Section ...

Page 126: ...ummary and general assembly notes H 4 Crankshaft reassembly H 4 Gear shift part reassembly H 5 Piston cylinder and head reassembly H 9 Primary drive and countershaft gears line up H 12 Clutch reassembly H 13 Right cover reassembly H 15 Exhaust valve reassembly H 17 ...

Page 127: ... have been calculated for a certain operating life We recommend replacing the bearings especially those exposed to heavy loading also considering that checking them for wear is not an easy procedure These recommendations are in addition to the dimensional checks of individual components specified in the relevant section see Section ENGINE OVERHAUL Cleaning all components thoroughly is critical to ...

Page 128: ...k oil seal wear Countershaft Check roller bearing clearance on ignition side LUBRICATION POINTS LUBRICANT Pin Connecting rod small end Oil Roller bearing Pin Connecting rod big end Oil Piston Cylinder liner Spray oil Clutch housing roller bearing Oil Shaft gears Oil O rings Oil and grease Starter and gearbox drive shaft sleeves Molicote Mating parts Gearbox Molicote Engine sealing rings Grease Clu...

Page 129: ...rts Office can supply shims having different thickness so as to achieve correct axial clearance Fit the original shims if removed parts are to be reassembled Fit the primary and output shaft at the same time inside the right crankcase half with the 1st 4th gear fork of the output shaft already inside its seat For correct gearbox operation check control dimensions shown in the fig ures A Primary sh...

Page 130: ...on primary shaft end Check the position of the centring bushings and place a new gasket on the right crankcase half Close the crankcase halves with the suitable retaining screws see relevant diagram 1 M6X35 screw No 5 pieces 2 M6X45 screw No 3 pieces 3 M6X50 screw No 2 pieces 4 M6X65 screw No 2 pieces Fit the selector shaft with its bearing and sector gear well lubricated with engine oil in the ri...

Page 131: ...re When closing the crankcase halves check that they are perfectly aligned and correctly positioned Make sure that the crankshaft and the gear shafts can rotate freely in neutral Should these shafts not rotate correctly tap them with a rubber hammer to allow their correct settling Should this problem still occur open the crankcase halves again After closing the crankcase halves block off the cylin...

Page 132: ...ar end of the crankcase half and the protruding tooth D Pre charge the lever return spring by turning its end clockwise until it is fitted inside the special crankcase half hole Fit the selector shaft with spacer spring inside the crankcase half Position it so that the pin on the crankcase half can be inserted between the ends of the selector shaft spring and that the two pins of the selector shaf...

Page 133: ... position of the crankshaft gear must correspond to that of the piston at TDC Therefore it is necessary to proceed to piston cylinder and head reassembly to determine this condition Piston cylinder and head reassembly Fit the roller cage on connecting rod small end and position cylinder bottom seal 1 Install the piston with its rings inside the connecting rod taking care that the arrow on the crow...

Page 134: ...o be assembled with engine oil and fit the cylinder into the piston by compressing the ends of the piston rings with your fingers or us ing a universal piston installation tool During installation avoid rotating the cylinder since piston ring ends could enter ducts ...

Page 135: ...e cylin der Tighten the nuts 2 between cylinder and crankcase to the recommended torque working crossways Fit the duly greased external 3 and internal 4 O rings in the cylinder seats and insert the head inside cylinder stud bolts Working crossways lock head retaining screws 5 tightening them to the rec ommended torque ...

Page 136: ...e top dead centre Insert on the primary shaft the three tab washer 1 the inner spacer and the two roller cages 2 with spacer 3 Then with piston at top dead centre fit the clutch housing so that the punched references on gears are positioned as shown in the figure A primary drive gear on crankshaft B primary drive gear on clutch housing C Countershaft idle gear D Countershaft gear ...

Page 137: ... spring and clutch control lever shaft inside L H crankcase half seat Fit the washer 1 and the disengagement group into the primary shaft in the following order the fist rod and the ball All these parts must be greased before reassembly Insert the clutch hub 2 in the primary shaft ...

Page 138: ... the nut with a 22 mm socket wrench to the specified tightening torque Rivet washer onto nut Fit the friction plates starting by one of the seven line steel plates 3 and alternate it with one of the six friction plates 4 the last friction plate 3 will complete the pack Insert the spring retainer 5 and the axial needle roller bearing 6 on primary shaft end ...

Page 139: ...thrust washer 7 and assemble the pressure plate 8 Fit the clutch springs 9 and lock them onto hub with the suitable washers and screws Right cover reassembly Install the original shim at the ends of water pump control shaft A and intro duce it inside its seat on RH crankcase half ...

Page 140: ...side its special cover seat Insert the eight retaining screws taking care that the one at the rear centring bushing white arrow is longer than the other ones Moreover the oil pump pipe retaining bracket must be installed under the screw placed on top of the kick start lever H06640 1 2 2 2 2 2 2 2 5 3 4 Screw assembly diagram 1 M6X20 screw No 1 piece 2 M6X25 screw No 7 pieces 3 M6X35 screw No 1 pie...

Page 141: ...r than 0 4 0 5 mm 0 0157 0 0197 in On bushings A check the wear of the seats holes for pin B if worn replace the parts Once engine reassembly is over fit it back on the chassis resetting the origi nal and previously removed assemblies and cooling circuit connections Per form the necessary adjustments as described in section Settings and adjust ments Exhaust valve position check Check the exhaust v...

Page 142: ......

Page 143: ...I 1 I FRONT SUSPENSION Ed 05 2011 Section ...

Page 144: ...I 2 FRONT SUSPENSION Ed 05 2011 Front fork removal I 4 Front fork overhaul I 6 Key I 6 Disassembly I 7 Assembly I 9 Oil replacement I 10 ...

Page 145: ...I 3 H02628 WRE 125 H02629 SMS 125 H02630 SMS 125 H02631 SMS 125 FRONT SUSPENSION Ed 05 2011 ...

Page 146: ...ight 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 remove the six screws 2 and the fork leg guards ...

Page 147: ... 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 Set height A back to original value ...

Page 148: ...9 2 1 3 5 8 11 4 6 FRONT SUSPENSION Ed 05 2011 Front fork overhaul Key 1 Bottom yoke with pin 2 Steering head 3 Nut 4 Tube spacer 5 Cap 6 Outer tube 7 LH damper unit 8 RH damper unit 9 Ring nut 10 Clamp 11 Leg protection ...

Page 149: ...wards onto inner tube Screw a threaded bar A onto inner shock absorber rod Pull absorber rod upwards using the bar and at the same time push upper retainer 3 downwards with your hand so as to slide out the two split rings 4 Remove bar Slide out upper retainer Drain all exhausted oil out of inner tube pumping the rod to full travel several times Take slider 2 out of inner tube ...

Page 150: ...ake care not to dam age inner seal lip Using a thin screwdriver remove slider inner retaining ring 6 When removing the sealing ring 7 it is advisable to protect its lip with a special bush B Using a large tip screwdriver press under sealing ring and at the same time turn slider to make its removal easier Slide out lower retainer 8 ...

Page 151: ... lower retainer 8 with the discharged side pointing outwards Slide sealing ring 7 inside the special bumper C and drive it fully home inside slider Lock it inside slider with the retaining ring 6 Install it on the duly lubricated dust seal tube 5 and move it downwards along tube ...

Page 152: ...ing rod to full travel several times to allow oil distribution inside shock absorber Check that with the leg fully closed between slider top and oil level an air volume of 80 mm is present After emptying some oil can still be present inside damping car tridge inner galleries If the recommended quantity of oil is introduced the level will be too high Whenever replacing oil always refer to the air v...

Page 153: ...ull rod outwards and at the same time push retainer 3 downwards so as to allow split rings 4 correct insertion Leave bar and retainer and check that split rings are correctly installed onto rod Grease the O ring 9 positioned onto cap 1 Screw cap 1 onto slider 2 ...

Page 154: ......

Page 155: ...J 1 J REAR SUSPENSION Ed 05 2011 Section ...

Page 156: ...points grease J 3 Rear suspension J 4 Type of suspension J 4 Rear shock absorber removal J 5 Disassembling and servicing the swinging arm J 6 Servicing the swinging arm shaft J 7 Servicing the rear suspension drop drag link J 7 Chain roller chain guide chain slider J 8 ...

Page 157: ...J 3 H02807 1 H02808 2 H02809 H02810 REAR SUSPENSION Ed 05 2011 Rear shock absorber TIGHTENING TORQUE FIGURES 44 49 Nm 4 4 4 5 Kgm 32 5 36 2 H Lb Lubrication points grease ...

Page 158: ...rrain conditions Periodically check all components for wear Type of suspension Steel swinging arm suspension with hydraulic single shock absorber Swing ing arm shaft is fitted on chassis side and swinging arm pivots onto shaft this system ensures bike greater stability The shock absorber driven by a series of progressive link rods SOFT DAMP features a spring preload adjuster based on the weight an...

Page 159: ...ear chassis as described in paragraph E General Procedures Using a 14 mm wrench loosen nut 1 on bike left side Slightly raise rear swinging arm and remove lower pin 2 from the right side Using a 14 mm wrench loosen upper nut 3 then remove upper pin 4 and shock absorber 5 from the left side On reassembly position nut 3 and nut 1 on the left side of shock absorber retaining pins ...

Page 160: ...n guard 4 as outlined in the relevant paragraphs see section E Remove rear wheel 4a as outlined in the relevant paragraph see section Y Using a 17 mm Allen wrench on the left side and a 15 mm Allen wrench on the right side loosen and remove pin 5 Using two 14 mm wrenches loosen and remove shock absorber bottom retaining pin 6 On reassembly make sure that pin 5 and 6 heads are positioned on bike ri...

Page 161: ...p and drag link With drop link 1 and drag link 2 still in place connected to swinging arm and chassis respectively rock them both back and forth in all directions to check for radial and axial clearance Some axial clearance in the drop drag link is required for the swinging arm to achieve the ideal position for proper operation If any radial clearance is detected remove the part from swinging arm ...

Page 162: ... Check the wear of the above mentioned elements and replace them when necessary Check the chain guide alignment and remember that a bent element can cause chain early wear In this case chain might unwrap from the sprocket 1 Chain roller 2 Chain guide 3 Chain slider A Master link clip ...

Page 163: ...L 1 L BRAKES Ed 05 2011 Section ...

Page 164: ...rake disc L 4 Checking brake pads for wear replacing the pads L 5 Bleeding the front braking system L 6 Bleeding the rear braking system L 7 Changing the fluid L 8 Removal of the rear braking system L 11 Removal of the front braking system L 12 ...

Page 165: ...ipped 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 3 Front brake line 4 Front brake calliper 5 Front brake disc 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 166: ...0 mm Front brake disc thickness when new 3 0 mm Wear limit 2 5 mm Rear brake disc diameter 240 mm Rear brake disc thickness when new 4 0 mm Wear limit 3 5 mm Disc warpage must not exceed 0 15 mm check disc mounted on the rim with a dial gauge To remove the disc from the wheel rim you need to loosen the four retaining screws Onassembly cleanallmatingsurfacesthoroughlyandtightenthescrews to the spec...

Page 167: ...s 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 braking system after replacing the pads Simply operate the control lever several times until bringing t...

Page 168: ...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 bleeding procedure This will keep the master cylinder res...

Page 169: ... 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 procedure Fluid...

Page 170: ...ontaminants 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 procedure is as follows ...

Page 171: ...ed 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 and reservoir cover After changing the...

Page 172: ...L 10 H02836 C H02837 D BRAKES Ed 05 2011 Periodicallychecktheconnectinghoses C and D seeScheduledMaintenance Chart Section B replace worn or cracked hoses ...

Page 173: ...al of the rear braking system Remove the rear wheel as outlined in the paragraph see chapter Y Remove the hose 2 supports 1 by loosening the screws 3 using an 8 mm wrench Loosen the two screws 4 and remove the pump 5 by disconnecting the STOP micro switch connector 6 ...

Page 174: ...el 1 as outlined in the relevant paragraph see sec tion Y Loosen the screws 3 and remove the block 2 Loosen the two screws 5 and disconnect the brake calliper 6 Release the hose 7 from the support 8 Disconnect the STOP microswitch connector 9 Loosen the two screws 10 6 mm wrench and remove the brake lever 11 complete with pump and tank ...

Page 175: ...M 1 M ELECTRICAL SYSTEM Ed 05 2011 Section ...

Page 176: ...ing air temperature sensor M 17 Checking coolant temperature sensor M 18 Checking lubricating oil pump operation M 18 Checking the supply system M 18 Checking the pump M 18 Headlight unit with front fairing removal M 19 Removing headlight from front fairing M 20 Front turning indicator removal M 21 HEADLAMP TAIL LIGHT M 22 Headlamp adjustment M 22 Headlamp bulbs replacement M 22 Tail light replace...

Page 177: ...CHARGING SYSTEM M 35 ELECTRONIC IGNITION SYSTEM M 35 Connector positioning M 36 Bike left hand side M 36 Bike right hand side M 37 Front side under headlamp fairing M 38 Under the saddle M 38 Rear side under tail light M 39 Securing the wiring harness M 40 ...

Page 178: ...M 4 ELECTRICAL SYSTEM Ed 05 2011 ...

Page 179: ... Black O G Orange Green P Purple Pk Pink R Red R Bk Red Black Sb Sky blue V Violet W White W Bk White Black W G White Green W R White Red W V White Violet W Y White Yellow Y Yellow Y B Yellow Blue Y Bk Yellow Black Y Br Yellow Brown Y G Yellow Green Y Sb Yellow Sky blue Y R Yellow Red Key to wiring diagram 1 Battery 2 Electronic control unit 3 Fuse 4 Control unit interface connector 5 Coil 6 Ignit...

Page 180: ...ctrical component location The ignition system includes the following elements Generator 1 on the inner side of L H crankcase half cover Electronic ignition coil 2 under the fuel tank Electronic control unit 3 under the saddle Voltage regulator 4 on steering tube left side ...

Page 181: ...nder head Spark plug cap 5a TPS sensor 6 on carburettor Oil pump 7 positioned on right hand rear chassis Air temperature sensor 8 positioned inside filter box close to oil pump Coolant temperature sensor 9 Carburettor additional air solenoid valve 10 positioned on left hand side close to thermostat ...

Page 182: ...he following elements 12V 4Ah Battery 11 under the saddle Turning indicator flasher 12 on left side of rear chassis Fuses 13 on utilities holder plate on left side of rear chassis Headlamp 14 with 12V 35 35W twin halogen bulb and 12V 3W parking light bulb LED tail light 15 Turning indicators 16 12V 10W bulbs Horn 17 up front on right side near the radiator ...

Page 183: ...er of 160 at 6 000 rpm positioned inside engine left side cover Ignition current start spark approx 350 rpm Measure across the terminals of the connector 1 correct value is about 0 6 If resistance is outside the specified limits replace the complete generator Generator performance RPM A D C typical 1500 5 6 2000 8 4 3000 10 8 4000 11 5 5000 11 9 6000 12 0 ...

Page 184: ...0V Tester will show a certain voltage value 20V 50V If no value is shown or in case a great voltage unbalance is present across yel low cables then stator is faulty It will thus be necessary make a further check using an Ohmmeter measuring the insulation between the tested cable and ground This insulation shall be total i e with infinite resistance Electronic ignition system The electronic ignitio...

Page 185: ...nt 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 against overloading CHARGING SYSTEM WIRING DIAGRAM ...

Page 186: ...he lights off keep engine running at 6 000 rpm Battery voltage shall progressively increase until reaching regulator 1 calibrated value approx 14 14 5 V while charging current shall progressively decrease until reaching a value of 0 5 A If current does not decrease and voltage increases above the 15 V limit regulator 1 is faulty and must be replaced If on the other hand voltage stays below approx ...

Page 187: ...ion coil Primary winding resistance 4 5 15 at 20 C Secondary winding resistance 19 5 K 20 at 20 C without spark plug cap cable If resistance is outside the specified limits replace the coil Also check the resistance of the terminal cap contacting the spark plug Terminal cap resistance 4 5 5 5 K 5 at 20 C If resistance is outside the specified limits replace the cap The area where the coil is secur...

Page 188: ...the coil A gap that is too narrow may cause difficulties when accelerating when idling or poor performance at low speed Clean off any dirt around spark plug base before removing the spark plug It is good practice to closely inspect the spark plug after removal as any deposits on it and the colour of the insulator provide useful indications on spark plug heat rating carburetion ignition and the gen...

Page 189: ... the battery 1 from its housing Check using a voltmeter that battery voltage is not less than 12 5 V If it is not so the battery needs to be charged Using a battery charger with a constant voltage first connect the RED positive cable to the battery positive terminal then the BLACK negative cable to the battery negative terminal At a constant voltage level of 14 4 V apply x Amps according the batte...

Page 190: ... one specified in the table Carburettor throttle valve sensor TPS calibration Throttle valve sensor shall be calibrated in case it is replaced or if any operation is carried out on throttle control Remove saddle as indicated in the relevant paragraph see section E Using a tester check that battery voltage is above 11 V Fully loosen idle screw 5 Remove cap 1 from connector 2 Connect control unit pr...

Page 191: ...e Engine Stop key 6 and release throttle control Turn ignition key 3 back to OFF Disconnect control unit programming connector from connector 2 and refit cap 1 Adjust idle speed as indicated in the relevant paragraph see section D Checking air temperature sensor Remove right rear panel as described in the relevant paragraph see section E Disconnect connector 1 and with the tester in OHM mode check...

Page 192: ...f Checking the supply system Turn ignition key 1 to ON disconnect connector 2 from oil pump warning light 3 will stay on Using a tester check that the voltage between chassis ground and connector yellow black wire is above 11 V Checking the pump Using the special pliers loosen clamp onto pump 5 to carburettor pipe 4 and disconnect pipe Position a container under carburettor and make sure that the ...

Page 193: ...ench loosen screw 1 Move headlamp fairing 2 forward and lift it to release damping pads 3 from their mounts 4 Open pipe support 5 and slide out front brake pipe 6 and speed sensor cable 7 Disconnect headlight connector 8 and turning indicator connectors 9 On reassembly make sure that damping pads 3 are correctly installed inside supports 4 ...

Page 194: ... Removing headlight from front fairing Remove the headlight unit complete with front fairing as outlined in the relevant paragraph Loosen beam adjuster screw 1 Disconnect headlight connector 2 Widen the supporting tabs 3 and remove headlight 4 from the inside ...

Page 195: ...val Remove the headlight unit complete with front fairing as outlined in the relevant paragraph Disconnect connectors 1 and 2 of right and left turn indicators respec tively Using a 10 mm wrench on the inside and an 8 mm wrench on the outside loosen screws 3 and remove turning indicators 4 ...

Page 196: ... 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 raised or lowered turning the screw 1 Headlamp bulbs replace...

Page 197: ...ed with bare hands To replace the parking light bulb 5 extract it from the inside cover Once the bulb has been replaced reverse the above procedure to reassem ble Tail light replacement 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...

Page 198: ...replacement Loosen screw 1 and remove the number plate bulb 2 from the 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 ...

Page 199: ...e the tail light as outlined in the relevant paragraph Disconnect connectors 1 and 2 of right and left turn indicators respec tively Slide turning indicator cables out of rubber gaiter 3 Using a 10 mm wrench on the inside and an 8 mm wrench on the outside loosen screws 4 and remove turning indicators 5 ...

Page 200: ...ss to chas sis Disconnect rear turning indicator connectors and remove wiring harness Two types of equivalent fully interchangeable wir ing harnesses but with a different shape are avail able Type A wiring harness 1 Main wiring harness connector 2 Tail light connector 3 LH turning indicator signal 3a SKY BLUE cable signal 3b BLUE cable ground 4 RH turning indicator signal 4a RED BLACK cable signal...

Page 201: ...ICAL SYSTEM Ed 05 2011 Type B wiring harness 1 Main wiring harness connector 2 Main wiring harness connector 3 LH turning indicator signal RED BLACK 4 RH turning indicator signal YELLOW 5 Number plate light signal SKY BLUE 6 Ground cables ...

Page 202: ...ne stop button Left hand switch 1 High beam flasher self cancelling 2 High beam switch Low beam 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 5 Light main switch On Off switch for low beam and high beam On Off switch for position lights Off PO...

Page 203: ... Gr G G Bk H01039 ELECTRICAL SYSTEM Ed 05 2011 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 204: ...ther fuse with a different rating Never use a wire or other makeshift repair techniques instead of installing a new fuse SEMICONDUCTOR PARTS Be careful to never drop parts that incorporate a semiconductor such as the ECU or the voltage regulator rectifier Closely follow the relevant instructions when inspecting these parts An improper procedure may lead to severe damage ...

Page 205: ...oes not show any functions To select dashboard functions and reset functions use the SCROLL button A The functions which can be selected in this sequence are as follows 1 SPEED ODO 2 SPEED CLOCK 3 SPEED TRIP 4 SPEED LAP TIMER 5 SPEED HOUR COUNTER 1 SPEED ODO IMPORTANT in the event of a MALFUNCTION the FAIL wording followed by a number will be shown on the tester DISPLAY For alarm list see point 6 ...

Page 206: ...299 Km h or 299 mph TRIP 1 distance maximum value 999 9 km or 621 31 mi data will be lost after disconnecting the battery To reset TRIP push the SCROLL button A and hold for more than 3 sec onds 4 SPEED LAP TIMER STP SPEED speed maximum value 299 Km h or 299 mph STP 1 miles kilometres covered time Reading from 0 00 to 99 59 59 data will be lost after disconnecting the bat tery To activate the func...

Page 207: ... 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s 0 5s blinking until the power off off 3s 3s 3s 1s 1 5s 0 5s 0 5s 0 5s 3s 1s 1s 1 5s 1s 1 5s 1 5s 1 5s 1 5s 3s 1s 1s 1 5s 3s 1s 1s 1 5s 3s 1 5s 0 5s 3s 1s 1s 1 5s 3s 1 5s 0 5s 0 5s 0 5s oil pump code TPS code Air valve open or short circuit code Engine temperature sensor code Air temperature sensor code on on on on on ...

Page 208: ...d reverse the disassembly procedure Instructions for the instrument setting Upon turning on the instrument if the operation DID NOT already take place it is necessary to set the instrument associating it with the relative motorcycle by selection of the codes illustrated in the figures shown The identification codes appear on the display of the instrument at 2 second intervals when the required cod...

Page 209: ...resistance 4 incorrect no load performance of generator see paragraph Generator no load performance 5 voltage regulator malfunction see paragraph Voltage regulator rectifier inspection a battery overload indicates 1 faulty voltage regulator see paragraph Voltage regulator rectifier inspec tion 2 faulty battery see paragraph Current loss at the battery ELECTRONIC IGNITION SYSTEM A weak or missing s...

Page 210: ...sis upper left hand side close to coil Generator connector 2 positioned under tank on chassis upper left hand side close to coil Pick up connector 3 positioned under tank on chassis upper left hand side close to coil Secondary circuit valve connector 4 positioned on chassis central part above head close to thermostat TPS connector 5 positioned on carburettor left hand side ...

Page 211: ... on rear chassis left hand side Oil level sensor connector 9 positioned on rear chassis left hand side Voltage regulator connector 9a positioned on steering tube left hand side Coolant temperature sensor connector 10 positioned on head left hand side Bike right hand side Oil pump connector 11 positioned on rear chassis right hand side Air temperature sensor connector 12 positioned on rear chassis ...

Page 212: ... connector 14 Front stop sensor connector 15 Speed sensor connector 16 Dashboard connector 17 Left hand switch connector 18 Front left hand turning indicator connectors 19 Headlight connector 20 Front right hand turning indicator connector 21 Horn connector 21a Under the saddle Electronic control unit connector 22 Diagnostic connector 23 ...

Page 213: ...601 26 27 25 ELECTRICAL SYSTEM Ed 05 2011 Rear side under tail light Tail light connector 24 Number plate light connector 25 Rear right hand turning indicator connectors 26 Rear left hand turning indicator connectors 27 ...

Page 214: ...c sensors and of a rear branch connecting tail light number plate light and rear turning indicators Main wiring harness 1 starts on bike front side passes through clip 2 slides along chassis slanted tube and is hold in place by clamps 3 On chassis rear side wiring harness 1 passes above air filter fitting 4 to connect to fuses control unit and flasher to air temperature sensor and oil level sensor...

Page 215: ... harness reaching stop microswitch is secured to chassis through clamps 7 On the front side wiring harness 1 is secured to clips 8 and 9 to holder plate and with clamp 10 Onhandlebar left handswitch right handswitchandstopmicroswitchwiring harness is secured on handlebar through rubber straps 11 ...

Page 216: ......

Page 217: ...N 1 N ENGINE COOLING Ed 05 2011 Section ...

Page 218: ...N 2 ENGINE COOLING Ed 05 2011 Coolant level check N 3 Cooling circuit N 4 Engine cooling system overhaul N 5 ...

Page 219: ...r 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 position to depr...

Page 220: ...gal 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 Fitting 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Water pump radiator lower pipe 9 Thermostat to connection pipe 10 Thermostat 11 Thermostat to head pipe 12 Thermostat radiators upper pipe ...

Page 221: ...ator 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 hardening due to ...

Page 222: ......

Page 223: ...W 1 W SPECIAL TOOLS Ed 05 2011 Section ...

Page 224: ...ub tool 6 8000 79016 Crankcase half puller and crankshaft removal tool 7 8000 79017 Tool to install crankshaft inside crankcase 9 8000 43824 Valve drive gear needle roller bearing water pump bearing and valve control puller 10 8000 33054 Oil pump shaft needle roller bearing puller 11 8000 43720 Gearbox shaft bearing puller 14 8000 98431 Anti tampering screw wrench ...

Page 225: ...ing 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 cleaning the thre...

Page 226: ...ary shaft plate ret screw M5x0 8 5 1 5 7 0 52 0 58 3 8 4 2 Starter shaft ret screw LOCTITE 270 M6x1 9 3 10 3 0 95 1 05 6 9 7 6 Oil drain plug M14x1 25 23 5 25 5 2 4 2 6 17 3 18 8 Intake valve ret screw M6x1 7 8 8 8 0 8 0 9 5 8 6 5 Stator ret screw M5x0 8 3 9 4 4 0 40 0 45 2 9 3 2 Rotor lock nut M12x1 25 73 5 83 3 7 5 8 5 54 2 61 5 Spark plug M14x1 25 23 5 25 5 2 4 2 6 17 3 18 8 Clutch hub lock nut...

Page 227: ...ight switch M10x1 18 1 20 1 1 85 2 05 13 4 14 8 Front wheel axle ret screw M6x1 9 3 10 3 0 95 1 05 6 9 7 6 Fork leg retaining screw M8x1 25 23 5 25 5 2 4 2 6 17 3 18 8 Steering bearing adjuster ring nut 1st screwing M25x1 3 2 3 6 0 33 0 37 2 4 2 7 Steering stem nut M24x1 79 87 8 1 8 9 58 64 Brake pedal adjustment cam ret screw M6x1 12 1 13 3 1 24 1 36 9 9 8 Application Thread Nm Kgm ft lb Handleba...

Page 228: ... tank ret screw M6x1 10 3 11 3 1 05 1 15 7 6 8 3 Front brake disc ret screw M6x1 17 6 19 6 1 8 2 0 13 14 5 Front wheel axle ret screw M10x1 5 49 54 5 0 5 5 36 2 39 8 Brake calliper ret screw M8x1 25 23 3 26 5 2 4 2 7 17 3 19 5 Fuel cock ret screw ø 5 5 2 35 2 55 0 24 0 26 1 73 1 88 Saddle front ret screw M6x1 5 6 6 2 0 57 0 63 4 1 4 5 Air box ret screw M6x1 10 3 11 3 1 05 1 15 7 6 8 3 Brake line t...

Page 229: ...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 Steel screws on iron steel M8 26 Nm 2 6 Kgm 19 1 ft lb Steel screws on iro...

Page 230: ......

Page 231: ...Y 1 Y CHASSIS AND WHEELS Ed 05 2011 Section ...

Page 232: ... 6 Reassembling the front wheel Y 7 Speed sensor Y 8 Rear wheel Y 9 Removing the rear wheel Y 10 Wheel servicing Y 11 Wheel axle warpage Y 11 Axle runout over 100 mm Y 11 Wheel spokes Y 12 Wheel rim warpage Y 12 Rear chain sprocket secondary drive sprocket and chain Y 13 Tightening torque figures Y 13 Checking pinion and sprockets for wear Y 14 ...

Page 233: ... Ed 05 2011 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 234: ...g bearings grease Controllo componenti telaio Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE MOUNTING BOLTS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER BEARING D FOOTPEGS PINS SPRINGS E Passenger footrest chassis retaining screw Chassis parts check ...

Page 235: ... LEGEND 1 Tyre 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Seal 8 Bearings 9 Hub 10 Spacer 11 Brake Disc 12 Brake disc retaining screw 13 Circlip 14 Outer spacer 15 Pin retaining screw For technical characteristics regarding the front wheel see section A Gen eral Information of this manual ...

Page 236: ... from the ground Loosen the bolts 1 holding the wheel axle 2 to the front fork mounts Hold the head of the wheel axle in place and unscrew the bolt 3 on the opposite side draw the wheel axle out Do not operate the front brake lever when the wheel has been re moved this causes the calliper pistons to move outwards After removal lay down the wheel with brake disc on top ...

Page 237: ...he 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 Now pump for a while pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned 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 ...

Page 238: ...Y 8 H02632 CHASSIS AND WHEELS Ed 05 2011 Speed sensor Check the gap B between magnet 6 on brake disc and sensor 7 on brake calliper ...

Page 239: ...e 2 Inner tube 3 Rim 4 Spoke 5 Nipple 6 Wheel axle 7 Spacer 8 Brake Disc 9 Seal 10 Circlip 11 Bearings 12 Spacer holder 13 Inner spacer 14 Hub 15 Sprocket 16 Sprocket retaining screw 17 Wheel axle locking nut For technical characteristics regarding the rear wheel see section A Gen eral Information of this manual ...

Page 240: ...osen 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 removed this causes the calliper pistons to move outwards After remo...

Page 241: ... 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 place Wheels ...

Page 242: ... 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 Max limit S...

Page 243: ... 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 244: ... 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 ...

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