Husqvarna 2011 SMS 630 Page 354 Workshop Manual Download

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M.3

Part. N. 8000 H2051 (02-2010)

ELECTRICAL SYSTEM

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

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

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

LOCATION OF ELECTRICAL COMPONENTS ........................................... M.6

WIRING DIAGRAM .................................................................................. M.10

CHARGING SYSTEM ............................................................................... M.10

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

Current loss at the battery ......................................................................... M.11

Regulated voltage...................................................................................... M.11

Generator inspection ................................................................................. M.12

Generator no-load performance ............................................................... M.13

Voltage regulator/rectifier inspection

......................................................... M.13

Wiring diagram ......................................................................................... M.13

Colour coding key ...................................................................................... M.13

STARTING SYSTEM ................................................................................. M.14

Wiring diagram ......................................................................................... M.14

STARTING SYSTEM INSPECTION .......................................................... M.15

Starter motor test curves ........................................................................... M.16

Starter motor maintenance ........................................................................ M.16

Solenoid starter inspection ........................................................................ M.17

Solenoid starter wiring diagram ................................................................ M.17

Electronic ignition system .......................................................................... M.18

Checking ignition coil windings resistance ................................................ M.20

Electronic control unit (ECU) ..................................................................... M.21

Spark plug ................................................................................................ M.22

Gear position sensor inspection (GPS: Gear Position Sensor) ................. M.23

Battery ....................................................................................................... M.24

Battery charger .......................................................................................... M.24

HEADLIGHT ADJUSTMENT ..................................................................... M.26

Headlamp bulbs replacement .................................................................... M.27

Tail light replacement ................................................................................. M.29

Number plate bulb replacement ................................................................ M.29

Turning indicator bulb replacement. .......................................................... M.30

Rear turning indicator removal .................................................................. M.30

Front turning indicator removal .................................................................. M.31

Number plate light removal........................................................................ M.32

Number plate holder removal .................................................................... M.33

Rear mudguard removal ............................................................................ M.33

Left-hand switch ........................................................................................ M.34

Colour coding key ...................................................................................... M.34

Right-hand switch ...................................................................................... M.35

Colour coding key ...................................................................................... M.35

FUSES....................................................................................................... M.36

SEMICONDUCTOR PARTS ...................................................................... M.36

CONNECTORS ......................................................................................... M.37

COUPLERS ............................................................................................... M.37

DIGITAL DASHBOARD, WARNING LIGHTS ............................................ M.38

1- SPEED (kmh or mph) / ODO / RPM ..................................................... M.39

2- SPEED / H / RPM.................................................................................. M.39

3- SPEED / CLOCK / RPM ........................................................................ M.39

4- SPEED / TRIP 1 / RPM ......................................................................... M.40

5- SPEED / STP 1 / RPM .......................................................................... M.40

6- SPEED / AVS 1 / RPM .......................................................................... M.40

7- SPEED / MAX SPEED / RPM ............................................................... M.41

8- SPEED / TRIP 2 / RPM ......................................................................... M.41

9- TRP 2 / CLOCK / RPM .......................................................................... M.41

10- SPEED /RPM (engine r.p.m. numerical value) .................................... M.41

Summary of Contents for 2011 SMS 630

Page 1: ...TE 630 2011 I E SMS 630 2011 I E Part N 8000 H2051 02 2010 Workshop Manual ...

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 ma nual may differ from actual components No reproduction in full or in part without written authorisation 1st edition 02 2010 ...

Page 3: ...ght 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 TE 630 ZKHA4 01AA B V 000001 TE 630 USA ZKHKD EKP B V 000001 SMS 630 ZKHA4 01AB B V 000001 SMS 630 USA ZKHLD EKP B V 000001 1 Chassis serial number TE 630 2011 I E SMS 630 2011 I E ...

Page 4: ...y 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 delays avoid unnecessary disassembly work to get to the part t...

Page 5: ...and Adjustments D General Procedures E Engine Disassembly F Engine Overhaul G Engine Reassembly H Front Suspension I Rear Suspension J Brakes L Electrical System M Engine Cooling N Hydraulically Controlled Clutch P Optional Components Q Fuel Injection System S Special Tools W Tightening Torque Figures X Chassis and Wheels Y NOTES Unless otherwise specified data and specifications apply to all mode...

Page 6: ......

Page 7: ...b 1 Part N 8000 H2051 02 2010 b IMPORTANT NOTICES Section ...

Page 8: ...ality 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 for changing parts and for the labour necessary in order to comply with the maintenance plan is charged to the Client The warranty becomes NULL AND VOID if the motorcycle is rented Notes Left and right side is determined w...

Page 9: ...A 1 Part N 8000 H2051 02 2010 A GENERAL INFORMATION Section ...

Page 10: ...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 5 Electrical components location A 5 Overall dimensions Weight A 6 Capacities A 7 ...

Page 11: ...apacity 1 2 Litres Ignition system Type Electronic inductive with adjustable advance digital control Spark plug type NGK CR8EB Spark plug gap 0 7 0 8 mm Drive and transmission Clutch oil bath multiple disc clutch hydraulic control Transmission constant mesh gear type Motion is transmitted from engine to gearbox primary shaft through spur gears Primary drive Drive pinion gear Z 32 Clutch ring gear ...

Page 12: ...s in steel rear chassis in squared sectioned tubes in light alloy Suspension Front Type Upside down telescopic hydraulic front fork with advanced axle adjustable in rebound stroke tubes ø 45 mm Leg axis stroke TE 270 mm Leg axis stroke SMS 250 mm Rear Type progressive with hydraulic single shock absorber preload regulation of spring and hydraulic brake in compression and extension Wheel stroke TE ...

Page 13: ...n air temperature on throttle body The electrical system includes the following elements 12V 14Ah battery under the saddle Turning indicators flasher located on the utilities holder plate under the saddle Relays located on the utilities holder plate under the saddle Electric fan relay Injector Lambda sensor fuel pump coil relay Horn turning indicators stop lights low and high beam lights relay Ele...

Page 14: ...A 6 Part N 8000 H2051 02 2010 GENERAL INFORMATION Overall dimensions Weight Kerb weight without fuel TE 150 Kg 330 69 lb SMS 158 Kg 348 33 lb max width ...

Page 15: ...A 7 Part N 8000 H2051 02 2010 GENERAL INFORMATION ...

Page 16: ...ork oil CASTROL SYNTHETIC FORK OIL 5W 610 cc 37 22 CU IN Rear shock absorber oil CASTROL SYNTHETIC FORK OIL 5W Coolant CASTROL MOTORCYCLE COOLANT 1 2 litres 0 27 GAL Brake system fluid CASTROL RESPONSE SUPER DOT 4 Clutch fluid CASTROL FORK OIL 10W Secondary drive chain lubrication CASTROL CHAIN LUBE RACING Grease lubrication CASTROL LM GREASE 2 Electric contact protection CASTROL METAL PARTS CLEAN...

Page 17: ...B 1 Part N 8000 H2051 02 2010 B MAINTENANCE Section ...

Page 18: ...R S SPARK PLUG P S P S SPARK PLUG CAP C C C C ENGINE OIL S S S S S ENGINE OIL INTAKE FILTER P P P CLUTCH CUSH DRIVE DAMPER C C ENGINE OIL FILTER CARTRIDGE S S S AIR FILTER P P S S P S S CLUTCH AND BRAKE FLUIDS C C S C S BRAKE HYDRAULIC CONTROLS C C C C C BRAKE PADS WEAR C C S BOWDEN CABLES C P P P P THROTTLE CONTROL C C C C C TYRE PRESSURE AND WEAR C C C C C ELECTRIC FAN C C C C HEADLAMP BEAM HEIG...

Page 19: ...OUPON SERVICE COUPON SERVICE COUPON SERVICE COUPON SERVICE COUPON WHEEL HUB BEARINGS C C FRONT FORK OIL S R S R OVERALL TIGHTENING OF NUTS AND BOLTS C C C C C LUBRICATION GREASING L L L L L LEGEND C CHECK C CHECK CLEARANCE P CLEAN P S CLEAN OR CHANGE depending on the conditions of use of the motorcycle S REPLACE L LUBRICATION R FORK OVERHAUL NOTES REPLACE GASKETS AND SEALS AFTER EACH REMOVAL REPLA...

Page 20: ......

Page 21: ...C 1 Part N 8000 H2051 02 2010 C TROUBLESHOOTING Section ...

Page 22: ...5 High tension cables open circuit or shorted Check 6 Electronic control unit faulty Replace 7 Right hand switchfaulty Replace The engine stops 1 Dirty spark plug Clean easily 2 Electronic control unit faulty Replace 3 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 Too much carbon build...

Page 23: ...ar ratchets Replace 3 Damaged shifter fork shafts Replace Gear shift pedal does not return in position 1 Weak or broken selector return spring Replace 2 Worn shifter forks Replace The gears are disengaged 1 Worn sliding gear engagements 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 power lack...

Page 24: ...1 Insufficient oil quantity 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 Wheel front and 1 Bent wheel rim Replace rear vibrates 2 Worn wheel hub bearings Replace 3 Incorrect spoke tension Adjust 4 Wheel axle nut loose Tighten 5 Worn rear swinging arm bearings Replac...

Page 25: ...g Generator does not provide charge 1 Cable arriving to the voltage regulator badly connected Connect correctly or or is not providing enough charge shorted replace 2 Voltage regulator faulty Replace 3 Generator coil faulty Replace Overload generator 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...

Page 26: ......

Page 27: ...D 1 Part N 8000 H2051 02 2010 D SETTINGS AND ADJUSTMENTS Section ...

Page 28: ...ever adjustment and fluid level check D 20 Rear brake pedal adjustment D 21 Rear brake pedal free play adjustment D 21 Rear brake fluid level check D 22 Air filter check D 22 Air filter cleaning D 23 Chain adjustment D 24 Chain lubrication D 25 Removal and cleaning D 25 Washing a chain without O rings D 25 Chain guide roller chain guide eye chain slider D 25 Lubricating an O ring chain D 25 Suspen...

Page 29: ...D 3 Part N 8000 H2051 02 2010 SETTINGS AND ADJUSTMENTS ...

Page 30: ...saddle as described in the relevant paragraph Close both fuel cocks 1 Use a 6 mm Allen wrench to loosen the screw 2 and remove the screw with its spacer Place a vessel under the R H cock to collect fuel Loosen clamp 3 and disconnect tube 4 from the fuel cock Let the fuel drain out ...

Page 31: ...02 2010 SETTINGS AND ADJUSTMENTS Remove the covers 5 located on the R H and L H side of the tank Loosen the screws 6 using an 8 mm wrench Move to the left side of the tank slacken clamp 9 and disconnect the breather hose 10 ...

Page 32: ...pump 12 connector 11 Disconnect the hose 13 connecting tank to throttle body press down the ring 14 and disconnect hose 13 from pump 12 Raise the tank 15 and remove it together with the scoops Reassemble all parts in the reverse order compared to disassembly and tighten screws to the specified torque see Section X ...

Page 33: ...a feeler gauge to make sure clearance is 0 10 0 15 mm on the INTAKE side and 0 15 0 20 mm on the EXHAUST side If not so raise the retaining clip 3 using a spring tool push rocker arm aside extract shim with a pair of tweezers and check shim thickness Depending on what you find fit a new shim with the required thickness repla cement shims are available in a 1 60 mm to 2 60 mm thickness range in 0 0...

Page 34: ...uitably turn the adjuster screws 5 loosen to decrease play or tighten to increase it tighten back the lock nuts 4 reassemble all parts in the reverse order compared to disassembly Operation with damaged throttle cable could result in an unsafe riding condition Exhaust gas contains poisonous carbon monoxide Never run the engine indoors Enrichener lever play adjustment The lever 1 holder features an...

Page 35: ...lockwise to increase the speed and anticlockwise to reduce the spe ed To do this you need to reach the adjuster screw from airbox front end using the supplied 8 10 wrench and work lengthwise with respect to the motorcycle Engine oil level check Keeping the motorcycle level and upright check the oil level through the inspec tion window 1 on the right crankcase Make sure the level is in between the ...

Page 36: ...18 1 ft lb M22 plug 2 60 Nm 6 1 Kgm 44 ft lb and gaskets be sure to clean off any debris collected by the magnet core of plug 2 Fill the specified quantity of oil see capacities table in Section A through the filler hole Let the engine idle for a few minutes stop it and wait a few minutes to let oil settle inside the crankcase With the motorcycle upright make sure the level is in between the MIN a...

Page 37: ...the rear brake lever 1 as follows disengage the return spring and use a 6 mm wrench to loosen the Allen screw 2 Loosen the eleven M6 L30 screws 3 and the two M6 L40 screws 4 using an 8 mm ring wrench and then remove the clutch cover 5 comple te with filter and oil pump Remove the filter 6 wash it with petrol and blow it with compressed air and then refit it exactly in the original position Reassem...

Page 38: ... 8 mm wrench and remove the cover 8 Remove filters 9 10 and their gaskets Wash filters with petrol and blow them with compressed air refit filters exactly in their original positions using new gaskets 11 which you will have greased properly Refit cover 8 and tighten the screws 7 to the specified torque see Section X ...

Page 39: ... tank 2 located in front of the rear shock absorber The radiator cap 3 features two locking positions the first one is for prior di scharge of pressure from the cooling system Avoid removing radiator cap 3 when engine is hot as coolant may spout out and cause scalding Because the cooling fan 4 can be activated even when the start switch is in OFF position always keep at a safe distance from the fa...

Page 40: ... engine SLOWLY open the R H radiator cap 2 slope the motorcycle on the right side to drain the coolant easily in the vessel Reassemble the tube 3 and tighten the clamp 4 See Section X or Section F for tightening torque Standard procedure Pour the necessary quantity of coolant in the radiator then warm up the engine in order to eliminate any possible air bubbles Allow the coolant to cool down then ...

Page 41: ...ly Using an 8 mm wrench unscrew the six screws 6 securing the clutch springs Remove washer springs pressure plate 7 washer axial bearing 8 and clutch plate pack 10 Collect actuator plate 9 and rod 5 from gearbox input shaft 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 gr...

Page 42: ...djuster B COUNTER CLOCKWISE Fluid level is checked as follows remove screws 1 cover 2 and rubber diaphragm from the control keep the control cylinder 3 in a horizontal position and make sure that fluid level has not dropped lower than 4 mm 0 16 in below the upper edge D of master cylinder body if needed top up with the fluid specified in the CAPACITIES TABLE SEC TION A NEVER use brake fluid Refit ...

Page 43: ...e master cylinder body TE For SMS model check the level on the clear reservoir A decrease of the fluid level will 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 THI...

Page 44: ...ollowing the instructions provided in paragraph Rear brake pedal free play adjustment Rear brake pedal free play adjustment The rear brake pedal 3 should have a free play B 5 mm before the brakes begin to bite Should this not happen operate as follows loosen nut 4 operate the pump rod 5 to increase or decrease the free play tighten nut 4 at the end of the operation When the free play requirement i...

Page 45: ...rcycle under such conditions have the brake system immediately checked see Section L 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 ...

Page 46: ...7 Air filter cleaning Wash the filter with a specific detergent CASTROL FOAM AIR FILTER CLEA NER or similar then dry it fully wash filter with gasoline only in case of need 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 fuel or a low flash point solvent to clean the filtering element A fire or explosion could re...

Page 47: ...the chain features a slack A measuring approximately 12 mm as shown in the nameplate 1 on swingarm 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 adjustment is completed tighte...

Page 48: ...ichloroethylene or solvents as the O rings may get damaged Use instead special sprays for chains with O rings Lubricating an O ring chain Lubricate all metallic and rubber O ring elements using a brush and engine oil with SAE 80 90 viscosity inside and outside parts If the chain has been cut reassemble it using the master link Assemble the master link clip 3 by setting the closed side facing the c...

Page 49: ...ression setting Shock absorber harder compression and especially harder rebound settings Work on the spring preload to lower the motorcycle riding height rear end MUDDY GROUND Front fork harder compression setting Shock absorber harder compression and rebound settings Work on the spring preload to lift the motorcycle riding height rear end ALWAYS remember that all the motorcycles and their parts u...

Page 50: ...wo measurements is the distance the rear end settles when the rider sits on the motorcycle RIDER SAG Recommended rider sag is 90 mm with a cold shock absorber and 85 87 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 stability and the handling of the mo...

Page 51: ...de it toward vehicle front 3 Clean lock ring nut 3 and adjuster ring nut 4 of the spring 5 4 Either with a hook wrench or an aluminium punch loosen the lock ring nut 5 Turn the adjuster ring nut as required 6 Adjust preload to suit your weight or riding style and tighten the lock ring nut firmly tightening torque 50 Nm 5 Kgm 67 8 ft lb 7 Reassemble the L H side panel and the saddle Be careful not ...

Page 52: ...il reaching fully closed position Then turn them back the number of clicks specified above In order to obtain a smooth braking action turn the adjuster screws counter clockwise Vice versa to obtain a harder braking action B REBOUND Standard setting TE 20 clicks 2 clicks SMS 26 clicks 2 clicks To reset the standard setting turn lower adjuster 3 clockwise until reaching fully closed position Then tu...

Page 53: ... mentioned clicks In order to obtain a smooth braking action turn the adjuster screw counter clockwise Vice versa to obtain a harder braking action b air vent 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 loosen the screw F NOTE Never force the ...

Page 54: ...ove the damper rod caps remove springs from the legs letting the oil drain into the legs bring fork to stroke end check that the level is at distance A below the upper limit of damper rod Oil quantity in each fork leg TE 630 cm3 SMS 600 cm3 A 80mm 3 15 in TE A 90mm 3 54 in SMS NOTE Flexibility index of the standard springs K 5 N mm TE K 5 4 N mm SMS NOTE Always replace both the spring and the spac...

Page 55: ...D 29 Part N 8000 H2051 02 2010 H006002 SETTINGS AND ADJUSTMENTS MARZOCCHI front fork springs STANDARD K 4 8 N mm spring spacer part no 8000 H1994 ...

Page 56: ...nd 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 clockwise using the ...

Page 57: ...ETTINGS AND ADJUSTMENTS Supply hose check Remove saddle and tank as outlined in the relevant paragraphs Check the hose 1 running from pump to throttle body 2 To replace the hose squeeze the two retainer tabs 3 on throttle body fitting ...

Page 58: ... 8000 H2051 02 2010 SETTINGS AND ADJUSTMENTS Exhaust system check Remove exhaust system components as described in Section E Check pipes 1 2 and 3 and silencers 4 for cracks or damage replace if cracked or damaged ...

Page 59: ...E 1 Part N 8000 H2051 02 2010 E GENERAL PROCEDURES Section ...

Page 60: ...p E 20 Expansion tank removal E 22 Removing utilities solenoid starter relays fuses flasher E 23 Electronic control unit removal E 24 Voltage regulator removal E 24 Ignition coil removal E 24 Electric cooling fan removal E 25 Front mudguard removal E 25 Horn removal E 25 Headlamp removal and bulb replacement E 26 Digital dashboard removal E 28 Headlamp fairing removal E 29 Ignition switch removal ...

Page 61: ...is 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 62: ...addle removal Insert the key in latch 1 then turn clockwise to release the saddle lock remove the saddle Side panel removal Remove the saddle as described in the relevant paragraph Disengage rear side panels 2 and 3 then slide them toward vehicle front ...

Page 63: ...escribed in the relevant paragraph Release the elastic strap 3 holding the battery First remove the BLACK negative cable 8 mm Allen wrench then the RED positive cable when reassembling first connect the RED positive cable then the BLACK negative cable remove the battery 1 from its housing ...

Page 64: ...E 6 Part N 8000 H2051 02 2010 10 9 8 8 3 3 5 5 3 4 4 4 4 3 3 3 10 2 11 7 1 6 2 2 H006005 GENERAL PROCEDURES Exhaust system removal ...

Page 65: ... guard 1 and L H guards 2 loosening the screws 3 with a 4 mm Allen wrench Remove saddle and side panels as described in the relevant paragraph Loosen the screws 4 securing silencers to rear chassis using an 8 mm ring wrench on the outside and a 10 mm ring wrench on the inside ...

Page 66: ...E 8 Part N 8000 H2051 02 2010 H006007 6 H006008 GENERAL PROCEDURES Loosen metal clip 5 using a 13 mm wrench and remove the silencers 6 Disconnect the Lambda sensor connector 7 ...

Page 67: ... H006009 11 GENERAL PROCEDURES Loosen the two clamps 8 using a 13 mm ring wrench and remove the central pipe 9 Loosen the four screws 10 of the exhaust manifolds 11 using a 4 mmAllen wrench and remove the manifolds with their rings ...

Page 68: ...in the relevant paragraphs Loosen the upper locking nut 1 using a 12 mm ring wrench Loosen the lower screw 2 securing air box to chassis using an 8 mm ring wrench Remove the hose 3 connecting filter to head Move to the left side of the motorcycle and loosen clamp 4 that secures filter to throttle body use a 7 mm ring wrench ...

Page 69: ...E 11 Part N 8000 H2051 02 2010 GENERAL PROCEDURES Remove the complete air box 5 easing it off in rear to front motion ...

Page 70: ...hand side panel as outlined in the relevant paragraphs Loosen the clamps 1 securing throttle body 2 to air box hose coupling and head Disconnect the M A Q S sensor connector 3 from the throttle body Disconnect the wiring harness connector 4 from the throttle body Loosen screw 5 and remove the cover 6 ...

Page 71: ... 8000 H2051 02 2010 GENERAL PROCEDURES Slacken adjusters 7 and disconnect the throttle cables 8 Remove the starter cable 9 Remove the throttle body 2 on assembly adjust the throttle cable as outlined in Section D ...

Page 72: ...tlined in the relevant paragraphs Shear the plastic clips securing main wiring harness Use a 3 mm Allen wrench to loosen the screw 1 and remove the cover 2 of the utilities holder plate 3 Loosen the two screws 4 of the utilities holder plate 3 Disconnect the connector 5 of the rear wiring harness Disconnect the electronic control unit 6 complete with flexible mounting from the rear chassis ...

Page 73: ... 8 using an 8 mm Allen wrench Push down the internal mudguard 8 and then slide the utilities holder plate 3 toward vehicle front to remove it Loosen the two screws 9 and remove the rear brake master cylinder cover 10 Loosen the screws 11 securing footpegs and rear chassis to chassis 6 mm Allen wrench ...

Page 74: ... 2010 H006010 15 14 GENERAL PROCEDURES Loosen the two nuts 12 of the voltage regulator 13 and remove it Unscrew the top locking nut 14 extract the pin 15 and remove the rear chassis sliding it toward the rear end of the vehicle ...

Page 75: ...saddle as described in the relevant paragraph Close both fuel cocks 1 Use a 6 mm Allen wrench to loosen the screw 2 and remove the screw with its spacer Place a vessel under the R H cock to collect fuel Loosen clamp 3 and disconnect tube 4 from the fuel cock Let the fuel drain out ...

Page 76: ...51 02 2010 GENERAL PROCEDURES Remove the covers 5 located on the R H and L H side of the tank Loosen the screws 6 using an 8 mm wrench Move to the left side of the tank slacken clamp 9 and disconnect the bre ather hose 10 ...

Page 77: ...p 12 connector 11 Disconnect the hose 13 connecting tank to throttle body press down the ring 14 and disconnect hose 13 from pump 12 Raise the tank 15 and remove it together with the scoops Reassemble all parts in the reverse order compared to disassembly and tighten screws to the specified torque see Section X ...

Page 78: ...move the fuel cap flange Loosen the screws 7 using an 8 mm ring wrench and remove right 5 and left scoops 6 On assembly make sure the bushings 8 are correctly positio ned in the scoops before tightening the screws 7 Loosen the screws 9 using an 8 mm ring wrench and remove the fuel pump 10 IMPORTANT Make sure to position gasket 11 correctly on assembly Use a screwdriver to loosen the screws 12 and ...

Page 79: ...E 21 Part N 8000 H2051 02 2010 H01162 7 8 5 9 7 8 7 8 7 8 7 8 6 7 8 14 12 14 12 7 8 10 11 13 14 13 GENERAL PROCEDURES ...

Page 80: ...s outlined in the relevant paragraphs Loosen the two upper retaining screws 1 of the expansion tank 2 on the left side of the motorcycle Disconnect breather hose from radiator cap Remove the expansion tank 2 from the right side of the motorcycle Remove the cap 3 and drain all fluid Loosen the clamp 4 and disconnect the breather hose ...

Page 81: ...plate 3 holds 4 Solenoid starter disconnect connector 5 and remove solenoid starter from plate with its flexible mount 6 Flasher release it from its seat and disconnect the connector 7 8 Fuses take off the protection cap 9 and remove the blade fuses 10 Relays release the fuses from their seat and remove them with the flexible mount then remove the connector 11 Rollover sensor SMS only loosen the t...

Page 82: ...tach it from the rear chassis Disconnect the connector 2 Voltage regulator removal Remove saddle right hand side panel and air box cover as outlined in the relevant paragraphs Loosen the two screws 1 disconnect the connector 2 and remove the voltage regulator 3 Ignition coil removal Remove saddle and fuel tank as described in the relevant paragraphs Remove the spark plug cap 1 Disconnect the conne...

Page 83: ...tor 2 Remove the electric fan 3 together with its bracket 4 Loosen the three screws 5 using a 7 mm wrench and take the electric fan 3 off the bracket 4 Front mudguard removal Loosen the four screws 1 using an 8 mm ring wrench and remove the mudguard 2 Horn removal Remove the front mudguard as described in the relevant paragraph Loosen the retaining screw 1 of the horn 2 with an 8 mm ring wrench Di...

Page 84: ...6 Part N 8000 H2051 02 2010 GENERAL PROCEDURES Headlamp removal Proceed as follows to reach the headlamp bulbs pull out the front fairing 1 to remove it loosen the three screws 2 and remove the headlamp 3 ...

Page 85: ...E 27 Part N 8000 H2051 02 2010 H01177 2 2 GENERAL PROCEDURES On assembly make sure the midline of side screw heads 2 lines up with the notch C on the support ...

Page 86: ...ERAL PROCEDURES Digital dashboard removal Remove the headlamp as described in the relevant paragraph Loosen the three screws 1 using an 8 mm ring wrench be sure to collect the spacers Raise the dashboard 2 and disconnect the connector 3 ...

Page 87: ...nt mudguard and digital dashboard as outlined in the relevant paragraphs Disconnect the diagnostic connector 1 Loosen the three screws 2 using an 8 mm ring wrench open the clamp 3 slip off brake and trip meter cables and remove headlamp fairing 4 On assembly make sure to position bushing 5 and rubbers 6 correctly ...

Page 88: ...L PROCEDURES Ignition switch removal Remove headlamp fairing saddle and tank as outlined in the relevant para graphs Loosen the two screws 1 using a 6 mm Allen wrench Release the clamp 2 and slip off the cable 3 Disconnect the connector 4 ...

Page 89: ...ve saddle and tank as outlined in the relevant paragraphs Drain coolant from the radiators as described in Section D Disconnect the three clamps 1 disconnect the hoses 2 from the thermal expansion valve 3 and remove the valve Note After refitting the thermal expansion valve fill with coolant as outlined in Section D ...

Page 90: ...move the saddle as described in the relevant paragraph Remove the side panels 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 Remove the chain as described in the relevant paragraph Drain coolant from the radiators as described in Section D Remove the air filter as described in the r...

Page 91: ...efit screw 1a in the original position on assem bly Make sure no one pulls the clutch lever with the actuator remo ved Disconnect the two ignition connectors 3 and the gear sensor connector 4 Loosen the screw 5 of the starter motor electric connection using a 10 mm ring wrench and loosen the ground cable screw 6 with an 8 mm ring wrench Disconnect the connector 7 from the temperature sensor 8 ...

Page 92: ...EDURES Take off the spark plug cap 9 Loosen the clamp 10 using a 7 mm ring wrench and disconnect the hose 11 from the left hand radiator to make room for the ignition connectors 3 Loosen the clamps 12 using a 7 mm ring wrench and detach the hoses 13 from the engine ...

Page 93: ... PROCEDURES Loosen the two screws 14 using an 8 mm ring wrench and remove the rear brake master cylinder guard 15 Disengage the rear brake pedal return spring 16 Loosen the nut 17 of the rear engine mounting bolt using a 22 mm socket wrench ...

Page 94: ...two 12 mm ring wrenches Loosen the nut 20 of the front bolts using a 10 mm ring wrench on the left hand side and a 12 mm wrench on the right hand side Make sure the gear sensor and ignition cables have been released Keep the engine raised and remove the two front bolts 18 on the left side and the lower 20 and rear bolts 17 on the right side of the engine then remove the engine from one side Place ...

Page 95: ...cooling fan and its bracket as described in the relevant paragraph Drain all coolant as described in the relevant paragraph see Section D Release the grids 1 and remove them Loosen the clamps 2 and disconnect the hoses 3 from the left hand radiator 4 Open the clamp 6 and disconnect the hose 7 Disconnect the breather hose 8 Loosen the clamps 9 and disconnect the hoses 10 from the right hand radiato...

Page 96: ...L PROCEDURES Use a 7 mm ring wrench to loosen the two screws 11 and a 5 mm Allen wrench to loosen the central screw 12 Remove the left hand radiator 13 Loosen the two screws 14 using a 7 mm ring wrench and remove the right hand radiator 15 ...

Page 97: ...F 1 Part N 8000 H2051 02 2010 F ENGINE DISASSEMBLY Section ...

Page 98: ...8 Oil filters removal F 19 Clutch disassembly F 20 Clutch actuator removal F 23 Starter motor flange removal F 24 Starter motor removal F 24 Gearbox drive shaft removal F 25 Gear sensor removal F 27 Crankcase crankshaft and countershaft disassembly F 28 Left crankcase seal replacement F 31 Countershaft removal F 32 Gearbox disassembly F 32 Crankshaft removal F 33 Crankshaft components removal F 34...

Page 99: ...022 6 1 2 8 4 H006023 10 3 ENGINE DISASSEMBLY Layout of engine components 1 Cylinder head cover 2 Cylinder head 3 Chain tensioner 4 Cylinder 5 Starter motor 6 Head lubrication pipe 7 Oil pump 8 Clutch cover 9 Oil filter 10 Water pump 11 Ignition cover ...

Page 100: ... Camshaft removal Remove the head cover as described in the relevant paragraph Remove the eight screws 1 securing the ignition cover 2 8 mm wrench and remove the cover together with stator 3 timing drive gears 4 and gasket The two longer screws 1a and 1b L 65mm must be refitted in their original positions Make sure to collect the starter drive bushing 5 remove it from the flange 6 and fit it on th...

Page 101: ...010 H006028 H006029 8 9 10 ENGINE DISASSEMBLY Using a 24 mm wrench bring the piston to T D C at the end of the compres sion stroke In this condition the mark 8 on the head will be lined with the mark 9 on camshaft drive gear 10 ...

Page 102: ...GINE DISASSEMBLY Remove the chain tensioner 11 as follows Loosen the screw 12 with an 8 mm wrench Use a flat head screwdriver to release spring tension turning screw 13 fully clockwise Loosen the two screws 14 using an 8 mm wrench and remove the chain tensioner 11 ...

Page 103: ...034 17 H006033 H006035 18 ENGINE DISASSEMBLY Remove the eight screws 15 securing the camshaft 17 caps 16 5 mm Allen wrench and remove the camshafts tightening one of the screws you have removed into the threaded holes 18 Remove the oil pipe 19 and the camshafts 17 ...

Page 104: ...e two screws 3 securing pump body 4 to head 8 mm wrench and remove pump body and timing drive gear 5 Check the seal 8 for wear on assembly replace if damaged Water pump disassembly Loosen the screw 9 with an 8 mm wrench to take pump body apart Loosen the nut 10 to remove the impeller 11 Remove shaft 12 to replace bearing 13 and seal 14 Check the seal 15 for wear on assembly replace if damaged Reas...

Page 105: ...INE DISASSEMBLY Cylinder head removal Remove head cover camshafts chain tensioner and water pump as described in the relevant paragraph Remove the two screws 1 on the left side 8 mm wrench and the nuts 2 located up front and at the rear under the head 13 mm wrench ...

Page 106: ...F 10 Part N 8000 H2051 02 2010 H006044 3 H006045 4 ENGINE DISASSEMBLY Use a 5 mm Allen wrench to loosen the screw 3 and remove the chain slider 4 ...

Page 107: ...rt N 8000 H2051 02 2010 H006042 6 H006043 7 H006041 5 5 6 ENGINE DISASSEMBLY Remove the four stud bolts 5 inside cylinder head 6 10 mm Allen wrench in a cross pattern Remove the cylinder head and its gasket 7 ...

Page 108: ... head as described in the relevant paragraph Remove the rocker arm spring spacers 1 using a hook Remove the rocker arm shaft screws 2 6 mmAllen wrench and then remove rocker arm shafts 3 and rocker arms 4 Mark the valves and their components so as to refit in their original posi tions on assembly Remove the shims 5 using a small magnet ...

Page 109: ...mber Make sure the valve spring compressor is aligned straight on the spring or you might bend the valve stem Do not compress the springs too much or they will weaken Mark all parts to ensure that they are refitted in their original positions on assembly If the valve collets 7 have caused burrs on the valve stems remove them before removing the valves Remove the seals 8 from the valve guides Remem...

Page 110: ...009 H006055 2 H006056 3 4 ENGINE DISASSEMBLY Cylinder removal Remove the head as described in the relevant paragraph Remove the centring bushings 1 Loosen the cylinder retaining screw 2 using an 8 mm wrench Remove the cylinder 3 with its gasket 4 ...

Page 111: ...ASSEMBLY Piston removal Remove the piston pin retaining rings 1 slide out the piston pin 2 and remove the piston 3 Flywheel removal Remove the ignition cover as described in the relevant paragraph Loosen the nut 1 and washer 2 securing the rotor 3 24 mm wrench Fit guard 4 to the crankshaft ...

Page 112: ... 02 2010 H006061 5 3 H01703 6 3 H01704 8 7 ENGINE DISASSEMBLY Remove the rotor 3 using the puller 5 part no 8000 39523 Remove the flywheel 3 together with freewheel and idler gear 6 Remove the roller cage 7 and the washer 8 ...

Page 113: ...000 H2051 02 2010 H006065 H01705 9 9 ENGINE DISASSEMBLY Remove the screws 9 5 mmAllen wrench and inspect the freewheel roller races should show no signs of wear or damage Ensure that all gears are in good condition ...

Page 114: ...emoval Before removing the clutch cover drain engine oil as described in the relevant Section Remove the thirteen screws 1 securing the cover 2 8 mm wrench and remove cover 2 and gasket 3 The screws are not all the same length mark them with their positions to ensure correct reassembly Remove the bushings 5 ...

Page 115: ... its seat using long nose pliers Wash filter with petrol and blow with compressed air refit filter with the short pin facing outside Reassemble all parts in the reverse order compared to disassembly Cartridge filter Loosen the screws 2 8 mm wrench and remove cover 3 spring 4 and filter 5 Replace the filter 5 and make sure to fit it with the rubber end 6 facing into the engine Check the O ring 7 an...

Page 116: ...the two mesh filters 10 wash them with petrol and blow with com pressed air Reassemble all parts in the reverse order compared to disassembly Check cover seal for damage Clutch disassembly Remove the clutch cover as described in the relevant paragraph Using an 8 mm wrench unscrew the six screws 1 securing the clutch springs Remove springs pressure plate 2 with actuator 3 bearing 4 and shim ...

Page 117: ... H006078 5 H006079 6 H006080 8 7 ENGINE DISASSEMBLY Extract the plates 5 Straighten the tab of the lock washer 6 Remove the nut 7 with its lock washer 27 mm wrench using the clutch removal tool A part no 8000 39524 Remove the hub 8 ...

Page 118: ...081 9 H006082 12 10 11 H006083 13 14 ENGINE DISASSEMBLY Remove the splined spacer 9 Remove clutch housing 10 and clutch pushrod 11 Clutch housing and drive gear 12 must always be replaced as a set Remove the bushing 13 and its washer 14 ...

Page 119: ...lutch actuator removal Loosen the two screws 1 and screw 1a of the clutch actuator 2 using an 8 mm ring wrench remove the actuator Make sure to refit screw 1a in the original position on assembly Loosen screw 3 and remove the actuator flange 4 Check seal 5 and replace it if damaged ...

Page 120: ...ith its drive gear Remove the flange 1 tapping gently on the projections with a rubber ham mer with its gasket 2 the second drive gear 3 and the centring bushings 4 To remove the drive unit 3 remove snap ring 5 washer 6 and seal 7 and then slide off the drive unit 3 from the opposite end Starter motor removal Remove the starter motor flange as described in the relevant paragraph Loosen the two scr...

Page 121: ... H006091 2 H006092 3 4 ENGINE DISASSEMBLY Gearbox drive shaft removal Pull out the selector shaft 1 Loosen the two 4 mm socket head screws 2 and remove plate 3 and selector sector gear 4 Be careful not to lose sector gear assembly components ...

Page 122: ...006093 6 5 H006094 5 H006095 7 8 9 ENGINE DISASSEMBLY Remove the drum 5 loosening the central shaft 6 with a 12 mm Allen wrench Use a 13 mm socket wrench to loosen the retaining screw 7 of the ratchet 8 and remove ratchet and spring 9 ...

Page 123: ...F 27 Part N 8000 H2051 02 2010 H006096 2 1 H006097 3 4 ENGINE DISASSEMBLY Gear sensor removal Loosen the screws 1 using an 8 mm Allen wrench and remove the sensor 2 Remove pushrod 3 and spring 4 ...

Page 124: ...r motor flange with starter motor filters on flywheel side and gear sensor as described in the relevant paragraphs Remove bushing 1 on the sprocket shaft and extract the O ring 2 using a small screwdriver Lift the tab of the lock washer 3 using a chisel Loosen the countershaft nut 4 using an impact screwdriver 27 mm key and remove counterweight 5 and washer 3 ...

Page 125: ... lock washer 6 using a chisel Loosen the countershaft nut 7 using an impact screwdriver 24 mm key and remove gear 8 and washer 6 Lift the tab of the lock washer 9 using a chisel Hold the connecting rod with one hand and loosen the crankshaft gear nut 10 using an impact screwdriver 38 mm key ...

Page 126: ... screws 12 using an 8 mm socket wrench WARNING The screws are not all the same length mark them so as to refit them in their original positions on assembly the central screws has a copper washer Secure the puller no 8000 89743 to the left crankcase and separate the two crankcase halves 12a M6 x 55 mm 12b M6 x 55 mm copper washer 12c M6 x 55 mm 12d M6 x 65 mm ...

Page 127: ...ase seal replacement Remove the sprocket seal 1 with a screwdriver WARNING On assembly position the seal flush with the crankcase Loosen the screws 2 using an 8 mm wrench and remove the plate 3 re taining the crankshaft seal 4 Remove the seal 4 with a screwdriver ...

Page 128: ...al Tap the countershaft 1 with a rubber hammer and remove it from the cran kcase Gearbox disassembly Remove the shaft 1 of the output shaft shifter forks Release the forks 2 and 3 from the drum 4 and remove them Remove the input shaft fork shaft 5 and remove the drum 4 ...

Page 129: ...rk 6 Remove input shaft 7 and output shaft 8 being careful not to lose any shims if fitted Crankshaft removal Slide the puller 1 part no 8000 89743 over the right end of the cran kshaft Secure the puller to the crankcase half and remove the crankshaft 2 from the opposite side ...

Page 130: ...nents removal Insert a plate 1 between the two flywheel halves Remove the crank pin from one of the flywheel halves using a press Remove connecting rod and needle roller bearing Turn the shaft and remove the crank pin 2 Remove the threaded cap and clean the crank pin ...

Page 131: ...en the screw 1 with an 8 mm wrench and remove the plate 2 Remove the seal 3 with a screwdriver Crankcase bearings removal Remove the retaining plates 1 and 2 from the crankcase halves Heat up the crankcase halves to around 125 C in a furnace and extract the bearings using a suitable driver tool ...

Page 132: ...remove the four screws 1 8 mm wrench securing the small cover remove all compo nents until getting to the oil pump drive shaft 2 Stator removal Take the ignition cover which you have removed previously and remove the five Allen screws three 6 mm screws 1 and two 4 mm screws 2 remove stator 3 and pick up sensor 4 from the left cover ...

Page 133: ...ston G 11 Cylinder to piston clearance G 12 Piston pin G 13 Piston rings G 14 Piston ring to cylinder clearance G 14 Piston ring to groove clearance G 15 Big end radial clearance G 16 Big end radial clearance G 16 Balancing countershaft G 16 Crankshaft G 17 Crankshaft straightness G 17 Small end bushing replacement G 17 Clutch G 18 Friction plate to clutch housing clearance G 19 Clutch spring G 19...

Page 134: ...arances must be within the specified tolerance A tight fit will lead to seizure as moving parts heat up whereas a loose fit will cause annoying vibration resulting in early wear of moving parts Cylinder head Remove fouling deposits from the combustion chamber using a rounded scra per Do not use sharp tools or you might damage valve seats and spark plug thread Check the machined surface of the cyli...

Page 135: ...ply Prussian Blue to the valve and rotate it in its seat using a rubber hose or other similar tool Remove the valve and measure the width X of the seating face If width is greater than 1 5 mm the seat needs to be refaced The standard width measured as shown of the seating face of the valve is A 0 9 1 1 mm for INTAKE A 0 9 1 0 mm for EXHAUST Valves cannot be ground and must be replaced if damaged I...

Page 136: ...ition is very important Use a dye to check seat contact surface po sition it should be 0 5 mm from valve edge If seat contact surface is too low on valve face reface the seat with 73 and 45 cutters If the contact surface is too high on valve face reface the seat with 20 and 45 cutters Ensure that seat contact surface is the correct width ...

Page 137: ... gauge Intake valve normal clearance 0 008 0 035 mm Service limit 0 05 mm Exhaust valve normal clearance 0 018 0 045 mm Service limit 0 08 mm Valve guide replacement Remove the valve guide from the cylinder head using a suitable punch Make sure that the cylinder head is not damaged Heat up the head in a furnace up to 170 C Install the new guide from the top of the head using a suitable punch Smear...

Page 138: ...ortion or wear Check for the following Valve stem runout place valve on a V block and measure runout with a dial gauge Service limit 0 05 mm Valve head out of round place valve on a V block and check with a dial gauge at right angles to the head while turning the valve Service limit 0 03 mm Valve spring Check free length L If outside the specified service limit replace the springs Spring L 43 4 mm...

Page 139: ...e guides and stems with oil before installation Fit sealing ring 1 springs 2 and valve spring retainer 3 Use tool no 8000 39521 to compress the valve springs and install the valve collets 4 Do not compress the springs too much and avoid damage to the cylinder head a Head side ...

Page 140: ... the valve stem tip to avoid pushing the valve off centre Rocker arm inspection Check rocker arm to shaft clearance Measure rocker arm inside diameter and shaft diameter and calculate clearance Maximum clearance 0 1 mm If the limit is exceeded replace both rocker arms On assembly tighten shaft bolts to 25 Nm 2 55 Kgm 18 4 ft lb LOCTITE 243 ...

Page 141: ...for streaks scoring dents and waviness Clamp the camshaft between centres and check deviation using two dial gauges Service limit 0 1 mm Check that the lobes are in pristine conditions without signs of scoring or distortion Height H of lobes when new INTAKE 36 57 mm EXHAUST 35 94 mm EXHAUST INTAKE ...

Page 142: ...VERHAUL Timing chain and gears Check the chain for wear at each engine overhaul Replace chain is too noisy or worn Timing chain tensioners Chain tensioners must be replaced when the lower area of the wear indicators is worn down to the metal ...

Page 143: ...per and out of round Max taper wear limit 0 05 mm Max out of round wear limit 0 05 mm If cylinder is worn beyond these limits replace both cylinder and piston The liner undergoes a special hardening treatment and cannot be ground Piston Clean off any carbon deposits from piston crown and grooves Perform a careful visual inspection of the piston and check its dimensions There should be no signs of ...

Page 144: ...er Measure inside diameter Dc with an internal bore micrometer 10 mm below the edge distance A Piston diameter Measure piston diameter Dp 8 9 mm above skirt edge distance B Clearance is calculated as follows Dc Dp CLEARANCE Dc Dp SERVICE LIMIT 0 025 0 055 mm 0 0010 0 0022 in 0 12 mm 0 0047 in ...

Page 145: ...G 13 Part N 8000 H2051 02 2010 ENGINE OVERHAUL Piston pin The piston pin must be perfectly smooth with no signs of scoring dents or bluing due to overheating ...

Page 146: ...n pin 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 measure end gap PISTON MOUNTING CLEARANCE H SERVICE LIMIT A 0 20 0 45 mm 0 00787 0 0177 in 0 7 mm 0 027 in B 0 20 0 45 mm 0 00787 0 0177 in 0 7 mm 0 027 in C 0 10 0 20 mm 0 00394 0 00787 in 0 35 mm 0 014 in ...

Page 147: ...rked on one side that side must be facing up PISTON MOUNTING CLEARANCE H SERVICE LIMIT A 0 030 0 065 mm 0 00012 0 0025 in 0 13 mm 0 0051 in B 0 020 0 055 mm 0 0008 0 0022 in 0 11 mm 0 0043 in C 0 010 0 180 mm 0 0004 0 0071 in 0 35 mm 0 0138 in Piston pin to small end clearance A 0 012 0 027 mm SERVICE LIMIT 0 055 mm Big end side clearance B 0 026 0 036 mm SERVICE LIMIT 0 080 mm position of end gap...

Page 148: ...es and check that journals run concentric using a dial gauge maximum runout allowed 0 02 mm Measure diameters A B C and D ØA wear limit 16 945 mm ØB wear limit 19 965 mm ØC wear limit 19 965 mm ØD wear limit 19 960 mm STANDARD WEAR LIMIT 0 02 0 028 mm 0 0008 0 00112 in 0 04 mm 0 0016 in STANDARD WEAR LIMIT 0 50 0 70 mm 0 0197 0 0275 in 0 080 mm 0 00315 in ...

Page 149: ...s Small end bushing replacement You will need an appropriate punch and a press to change the bushing Smear the outer face of the bushings with moly grease before installation The bushing should be mounted with an interference fit of 0 049 0 095 mm 0 00196 0 0038 in Match the oil holes of the new bushing with those in the connecting rod ream the bushing bore to 20 mm 0 022 0 012 0 79 in 0 00088 0 0...

Page 150: ...plates should show no signs of bluing scoring or distortion Measure the thickness of friction plates Plate thickness when new 2 92 3 08 mm 0 1149 0 1212 in Service limit 2 65 mm 0 106 in Place each friction and steel plate on a surface plate and check for distortion using a feeler gauge Use a feeler gauge Service limit 0 15 mm 0 006 in ...

Page 151: ...ured clearance exceeds the service limit replace clutch plates or housing and repeat measurement If measurement is still outside the service limit replace the complete clutch assembly Clutch spring Measure the free length L of each spring with a calliper New spring L 41 mm 1 61 in Service limit 39 mm 1 38 in Change any spring that is outside the service limit STANDARD SERVICE LIMIT 0 30 0 50 mm 0 ...

Page 152: ...e the part 5 Clutch hub Check the steel plate slots for signs of wear or failure If any are found replace the part 6 Clutch housing Check the friction plate slots for signs of wear or failure Check the needle roller bearing seats for signs of wear If any are found replace the part 7 Primary drive gear pair Check gear teeth for signs of wear or failure If any are found replace the part ...

Page 153: ...learance of the each shifter fork in its gear groove using a feeler gauge If any one of the three gears is outside the service limit measure the width of gear groove and fork thickness to determine which component needs to be replaced Shifter fork to groove clearance new fork and gear 0 070 0 225 mm 0 0028 0 0088 in Service limit 0 26 mm 0 010 in Selector drum Check drum grooves for wear or dents ...

Page 154: ...nce between shifter fork pin and drum groove taking the ne cessary measurements with a calliper If service limit is exceeded compare the components with new parts to determine which one needs to be removed Shifter fork to drum groove clearance from new 0 15 0 35 mm 0 006 0 014 in Service limit 0 5 mm 0 02 in ...

Page 155: ...ds replacing use a feeler gauge and a straight edge If pump rotors 1 and 2 have been separated from pump body make sure to line up the dots on inner and outer rotors on assembly Check pump body mating face for scoring dents or scuffing On assembly inspect the seals 3 and make sure the pins 4 are located correctly for tightening torque figures see Sections H and X Side clearance 0 10 mm 0 0039 in ...

Page 156: ......

Page 157: ...H 1 Part N 8000 H2051 02 2010 H ENGINE REASSEMBLY Section ...

Page 158: ...res H 11 Crankshaft installation H 12 Input shaft H 15 Output shaft H 16 Crankcase assembly H 17 Gear sensor installation H 23 Gear shift control assembly H 24 Crankshaft gears installation H 27 Countershaft weight gear installation H 27 Clutch assembly H 30 Piston ring installation H 33 Piston and cylinder installation H 33 Cylinder head gasket selection table H 35 Cylinder head installation H 36...

Page 159: ... calculated for a certain 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 G ENGINE OVERHAUL Cleaning all components thoroughly is critical to reliability bearin...

Page 160: ...H 4 Part N 8000 H2051 02 2010 ENGINE REASSEMBLY Assembly and lubrication instructions CRANK ALTERNATOR LUBRICATION LEFT CRANKCASE HALF ...

Page 161: ...Kgm 5 90 ft lb 5 M5 x 0 8 Loctite 243 8 Nm 0 8 Kgm 5 90 ft lb 6 M16 x 1 25 130 Nm 13 2 Kgm 95 88 ft lb 7 M6 x 1 Loctite 270 8 Nm 0 8 Kgm 5 90 ft lb 8 M4 x 0 7 Loctite 272 3 Nm 0 3 Kgm 2 21 ft lb 9 M6 x 1 Loctite 270 20 Nm 2 Kgm 14 75 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS A Degrease B Apply engine oil on installation E Line up stator mark with cover mark G WATER RESISTA...

Page 162: ...H 6 Part N 8000 H2051 02 2010 ENGINE REASSEMBLY Assembly and lubrication instructions GEARBOX GEAR SHIFT CONTROL ...

Page 163: ...2 M8 x 1 25 LOCTITE 243 28 Nm 2 85 Kgm 20 65 ft lb 3 M6 x 1 LOCTITE 243 9 Nm 0 92 Kgm 6 64 ft lb 4 M5 x 0 8 LOCTITE 243 8 Nm 0 8 Kgm 5 90 ft lb LUBRICATION POINTS NOTES LUBRICANT INSTALLATION INSTRUCTIONS D Install with open end pointing to engine centre O Engine oil O G Engine oil or WATER RESISTANT grease ...

Page 164: ...H 8 Part N 8000 H2051 02 2010 ENGINE REASSEMBLY Assembly and lubrication instructions CLUTCH KICK START LUBRICATION RIGHT CRANKCASE HALF ...

Page 165: ...ne oil C Join crankcase halves using Loctite 5205 1 M24 x 1 25 LOCTITE 243 100 Nm 10 2 Kgm 73 76 ft lb 2 M18 x 1 61 7 Nm 6 3 Kgm 45 73 ft lb 3 M6 x 1 LOCTITE 243 9 Nm 0 92 Kgm 6 64 ft lb 4 M6 x 1 LOCTITE 243 9 Nm 0 92 Kgm 6 64 ft lb 5 M10 x 1 15 Nm 1 5 Kgm 3 69 ft lb 6 M14 x 1 5 24 Nm 2 45 Kgm 17 70 ft lb 7 M22 x 1 5 30 Nm 3 Kgm 22 13 ft lb ...

Page 166: ...H 10 Part N 8000 H2051 02 2010 ENGINE REASSEMBLY Assembly and lubrication instructions HEAD CYLINDER PISTON TIMING SYSTEM WATER PUMP SPARK PLUG ...

Page 167: ...lb 3 M8 x 1 25 15 Nm 1 5 Kgm 11 6 ft lb 4 M10 x 1 5 MOLIKOTE HSC COPPER GREASE 37 Nm 90 3 8 Kgm 90 27 29 ft lb 90 5 M6 x 1 12 Nm 1 2 Kgm 8 85 ft lb 6 M14 x 1 5 LOCTITE 243 25 Nm 2 55 Kgm 18 44 ft lb 7 M6 x 1 8 Nm 0 8 Kgm 5 9 ft lb 8 M10 x 1 25 ENGINES WITH ELECTRO NIC INJECTION 15 1 Nm 1 5 1 Kgm 11 06 ft lb 9 M6 x 1 LOCTITE 243 8 Nm 0 8 Kgm 5 90 ft lb 10 M8 x 1 25 12 Nm 1 23 Kgm 8 85 ft lb 11 M5 x...

Page 168: ...ghly Lubricate the crank pin 1 with engine oil and insert it into the flywheel half 2 WARNING Match the oil passage holes Fig A Fit the needle roller bearing 3 and lubricate it the engine oil Install the connec ting rod 4 and the second flywheel half 5 and align the two flywheel halves using a square ...

Page 169: ...mounting dimension A and set crank pin 1 at distance B on the right flywheel half A 6 35 64 45 mm 2 574 2 578 in B 0 9 1 1 mm 0 036 0 044 in Measure axial clearance D of connecting rod to flywheels it should be 0 45 0 7 mm 0 018 0 03 in Measure crankshaft runout at the bearing locations C Runout must not exceed 0 03 mm 0 0012 in Straighten the crankshaft using a copper hammer ...

Page 170: ...H 14 Part N 8000 H2051 02 2010 ENGINE REASSEMBLY Input shaft Output shaft ...

Page 171: ...rounded edges of washer and retaining ring facing the gear Fit 5th 6th sliding gear 6 Fit washer 7 with the rounded edge facing the gear Fit plain bearing 8 Lubricate inner and outer face with Molikote G n plus grease before installation Fit 3rd gear 9 Fit spacer 10 and 2nd gear 11 B Control dimension with 4th gear engaged C Control dimension with 3rd gear engaged TE SMS 1st 13 13 2nd 16 16 3rd 20...

Page 172: ...ear Fit 6th gear 9 Fit 5th gear 10 Fit washer 11 and retaining ring 12 with the rounded edges of washer and retaining ring facing the gear NOTE 5th and 6th gears should turn freely against each another Fit 4th gear 13 with the flange facing 5th gear Fit bushing 14 to the input shaft 1 Lubricate inner and outer face with Molikote G n plus grease before installation Fit 1st gear 15 with the bevelled...

Page 173: ...ankcase half mating faces and place crankcase half on tool no 8000 90662 Heat up to around 125 C and drive the ball bearings into each crankcase half using a suitable driver tool Fit the retaining plates 1 and 2 to the crankcase bearings See Section x for tightening torque figures ...

Page 174: ...NGINE REASSEMBLY Install the input and output shaft assembly pushing them fully home into the right crankcase half and make sure input 3 and output shaft 4 gears are flush Lubricate the shifter forks 5 with engine oil and install them ...

Page 175: ...INE REASSEMBLY Insert the selector drum 6 into its seat Install the fork shafts 7 and 8 and make sure the forks move freely Make sure the fork pins 9 are correctly located in the drum grooves 6 Rotate the selector drum to test operation ...

Page 176: ...SSEMBLY Heat up the crankshaft bearing 10 and install the crankshaft 11 Fit the countershaft 12 onto its bearing Make sure both crankcase locating bushings 13 are in place Apply a layer of LOCTITE 5205 on the right crankcase mating surface 14 ...

Page 177: ...e bearing locations and install the crankcase Grease the sprocket bearing bushing 15 and fit it into the bearing fit the left crankcase half onto the right crankcase half To join the crankcase halves tap with a plastic hammer Tighten the screws 16 using an 8 mm wrench Make sure to fit the screws in the correct positions according the pattern shown ...

Page 178: ...e screws 19 with an 8 mm wrench see Section X for tightening torque figures Insert bushing 20 with its O ring 21 the O ring groove must be facing into the engine Cover the upper section of the engine with a cloth a sponge or the like to prevent screws or other parts from accidentally falling into the engine ...

Page 179: ... N 8000 H2051 02 2010 ENGINE REASSEMBLY Gear sensor installation Insert spring 1 and pushrod 2 into the their seat 3 Fit the sensor 4 make sure to install the gasket Tighten the screws 5 8 N m 0 8 Kgm 5 8 ft lb ...

Page 180: ...het 1 and tighten the screw 2 13 mm wrench 28 N m 2 8 Kgm 20 65 ft lb Engage the spring 3 with the suitable pin Install the selector drum 4 making sure the tab 5 locates in the recess 6 and secure drum with its screw 7 Apply Loctite 243 tighten to 28 Nm 2 8 Kgm 20 65 ft lb using a 12 mm wrench ...

Page 181: ... transmission shaft to test gearbox for proper operation Refit the ratchet assembly 8 together with the plate making sure ratchets and springs are in the correct positions Tighten the screws 9 of plate 10 using a 4 mm Allen wrench Loctite 243 9 3 Nm 0 93 Kgm 6 85 ft lb ...

Page 182: ...aft is positioned correctly Lubricate the shaft with engine oil and insert the shaft 12 into the crankcase so that the teeth 13 mesh with sector gear 8 teeth and spring 14 locates to its abutment pin Install the gear shift lever 15 and operate the gearbox manually 10 mm wrench 9 Nm 0 9 Kgm 6 64 ft lb ...

Page 183: ... crankshaft with the timing dot facing out Fit the input shaft driving gear 2 with the bevelled side facing out Countershaft weight gear installation Fit the countershaft gear 1 line up its dot with that of the crankshaft gear 2 to set timing Fit the lock washer 3 onto the gear making sure the tab locates into the key way ...

Page 184: ... an aluminium shim 5 between countershaft gear 1 and crankshaft gear 2 Bend the lock washer 3 Fit the lock washer 6 onto the crankshaft gear making sure the tab locates into the keyway Tighten the nut 7 with a 38 mm wrench to 100 N m 10 Kgm 73 69 ft lb placing a half gear 8 between countershaft gear 1 and crankshaft gear 2 ...

Page 185: ...o the countershaft Fit the lock washer 10 onto the shaft making sure the tab locates into the keyway Tighten the nut 11 with a 27 mm wrench to 70 N m 7 Kgm 51 58 ft lb placing a half gear at the opposite side of the engine between countershaft gear 1 and crankshaft gear 2 Bend the lock washer 10 ...

Page 186: ... 8000 H2051 02 2010 ENGINE REASSEMBLY Clutch assembly Slide washer 1 and bushing 2 over the shaft lubricate with engine oil Lubricate the shaft with engine oil and fit the clutch housing 3 Fit the splined spacer 4 ...

Page 187: ...0 H2051 02 2010 ENGINE REASSEMBLY Fit the clutch hub 5 and its lock washer 6 Use the suitable tool 7 to prevent rotation and tighten the nut 8 with a 27 mm wrench to 61 7 Nm 6 17 Kgm 45 47 ft lb Bend the lock washer 6 ...

Page 188: ...irst and then a steel plate and keep alternating between friction and steel plates the last to go in should be a steel plate Fit actuator plate 10 thrust bearing 11 thrust washer 12 pressure plate 13 and springs 14 Tighten the spring screws 15 gradually in a cross pattern 5 Nm 0 5 Kgm 3 6 ft lb ...

Page 189: ...ing up Piston and cylinder installation Remove the cylinder protection 1 Install a new cylinder foot gasket 2 Assemble piston 3 to connecting rod 4 lubricate with engine oil and fit the piston pin retaining rings 5 Make sure the arrow mark on the piston is pointing to the front end Make sure that the locating pins 6 are in place PISTON RING END GAP ALIGNMENT position of end gap d ...

Page 190: ...r the piston rings Fit the two locating bushings 8 Secure the cylinder 7 to the crankcase tightening screw 9 with an 8 mm wrench see Section X for tightening torque figures Install the timing chain 10 Position the slider 11 and tighten screw 12 using a 5 mm Allen wrench see Section X for tightening torque figures ...

Page 191: ...ove spacers and screws 13 and fit the appropriate head gasket Cylinder head gasket selection table Bring piston to T D C at the end of the compression stroke measure distance A between piston crown and head gasket mating face and select the appropriate gasket according to the table below CONDITION see diagram A Gasket thickness Gasket part no 1 piston lower than cylinder mating face 0 5 0 05 mm 1 ...

Page 192: ...ming chain 2 with a tool Tighten the head bolts 3 gradually in a cross pattern to 38 Nm 90 3 8 Kgm 90 28 03 90 ft lb using a 10 mm Allen wrench Tighten the two head to cylinder nuts 4 at the sides with a 13 mm wrench see Section X for tightening torque figures Refit the cooling water temperature sensor 4A using a 17 mm ring wrench 15 Nm 1 5 Kgm 11 6 ft lb Tighten the two head to cylinder bolts 5 w...

Page 193: ...h a 5 mm Allen wrench see Section X for tightening torque figures Refit the four shims 8 on the valves as marked on removal Fit the shafts 9 of the rocker arms 10 as marked on removal with the slotted end facing outwards Tighten the screws 11 with a 6 Allen wrench see Section X for tightening torque figures Fit the two spring spacers 12 ...

Page 194: ...to Top Dead Centre Insert the timing drive gear 2 into the head lining up the notch on the camshaft drive gear 3 with the notch on the head mating face Install the chain on the gear 4 Fit the water pump 5 to the head check the O ring 6 for damage Tighten the screws 7 with an 8 mm wrench to 8 Nm 0 8 Kgm 5 8 ft lb Loctite 542 Connect the rubber hose 8 and tighten the clamp 9 ...

Page 195: ...ain tensioner installation Refit the chain tensioner 1 and its gasket Tighten the two screws 2 using an 8 mm wrench 10 Nm 1 0 Kgm 7 25 ft lb Release the chain tensioner 1 using a screwdriver turn counter clockwise Refit the screw 3 with its washer 8 mm wrench ...

Page 196: ... gear 3 with the head mating face Make sure the dot on the inboard side of gear 3 is lined up with the dot on the left of the timing gear 4 Install the exhaust camshaft 5 lining up the dot on gear 6 with the head mating face Make sure the dot on the inboard side of gear 6 is lined up with the dot on the right of the timing gear 4 Refit the oil pipe 7 with the curved end 7a at the intake camshaft e...

Page 197: ...it back to Top Dead Centre position Use a feeler gauge 10 to check clearance between rocker arm and shim Correct values are as follows intake 15 hundredths exhaust 20 hundredths If clearance is not as specified release the spring spacer using a hook push aside rocker arm 11 and change the shim 12 Replacement shims are available in a 1 60 mm to 2 60 mm thickness range in 0 05 mm increments Thicknes...

Page 198: ...ons 5552 compound on the half round cutouts 1 Refit head cover 2 and tighten the screws 3 in a cross pattern 8 mm wrench 8 Nm 0 8 Kgm 5 8 ft lb Refit the lubrication pipe to the head 4 and tighten the drilled bolt 5 8 mm wrench 8 Nm 0 8 Kgm 5 90 ft lb Refit the Spark plug 6 10 12 Nm 1 0 1 2 Kgm 7 2 8 9 ft lb ...

Page 199: ...2 Insert the cable guide 3 into its seat in the cover and tighten the two retaining screws 4 of the pick up sensor 5 with its plate using a 3 mm Allen wrench 3 Nm 0 3 Kgm 2 21 ft lb Loctite 272 Make sure the two centring bushings 6 are in place Fit the gasket to the crankcase locate the starter motor 7 to its flange 8 and install on the crankcase Make sure the two locating bushings 9 are positione...

Page 200: ... see Section X for tightening torque figures Degrease crankshaft taper end and flywheel bore and smear crankshaft taper end with Loctite 270 Install flywheel 13 together with drive gear 14 Fit washer 15 and nut 16 and tighten with a 24 mm wrench 130 Nm 13 0 Kgm 95 89 ft lb fitting a dummy gear to the crankshaft gears at the opposite end ...

Page 201: ... and cover 19 and tighten the screws 20 in a cross pattern with an 8 mm wrench see Section X for tightening torque figures Screws 20 are not all the same length make sure to refit them in their original positions Secure starter motor 7 tightening screw 21 8 mm wrench see Section X for tightening torque figures ...

Page 202: ...rtridge assembly Assemble oil pump components in the order shown Secure the cover using the four screws 1 9 Nm 0 9 Kgm 6 5 ft lb Refit the filter cartridge 2 and secure the cover using the two screws 9 Nm 0 9 Kgm 6 5 ft lb Fit a new gasket and install the complete cover 3 using the thirteen retaining screws 9 Nm 0 9 Kgm 6 5 ft lb ...

Page 203: ...to the crankcase Refit the gasket 3 Refit the cover 4 making sure to mate pump shaft 5 with the slotted end 6 of the output shaft gently rock the sprocket to facilitate installation Tighten the screws 7 in a cross pattern with an 8 wrench see Section X for tightening torque figures Screws 7 are not all the same length make sure to refit them in their original positions ...

Page 204: ...8000 H2051 02 2010 ENGINE REASSEMBLY Clutch actuator installation Refit the flange 1 and tighten the screw 2 8 mm wrench see Section X for tightening torque figures Insert the clutch pushrod 3 thinner end 3a first ...

Page 205: ...I 1 Part N 8000 H2051 02 2010 I FRONT SUSPENSION Section ...

Page 206: ...I 2 Part N 8000 H2051 02 2010 FRONT SUSPENSION Front fork removal I 4 Marzocchi manual I 5 ...

Page 207: ...the left hand side remove the six screws 3 and the fork leg guards 4 remove the brake calliper from the L H fork leg loosening the two retaining screws 5 remove the front wheel as described in Section Y loosen the bolts 6 that secure the fork legs to steering head and bottom yoke remove the fork legs Refit the front wheel as described in Section Y Set height A back to original value Refit the brak...

Page 208: ...I 4 Part N 8000 H2051 02 2010 FRONT SUSPENSION ...

Page 209: ...I 5 Part N 8000 H2051 02 2010 FRONT SUSPENSION MARZOCCHI MANUAL ...

Page 210: ...Factory Works ISTRUZIONI PER L USO E LA MANUTENZIONE USE AND MAINTENANCE INSTRUCTION MANUAL MODE D EMPLOI ET ENTRETIEN BETRIEBS UND WARTUNGSANLEITUNG INSTRUCCIONES PARA EL USO Y MANTENIMIENTO SHIVER SHIVER ...

Page 211: ... suspension system NORME DI SICUREZZA PER L UTILIZZATORE DEL MANUALE ATTENZIONE La non corretta osservazione delle procedure indicate nel presente manuale può provocare danni al prodotto incidenti infortuni o addirittura la morte del motociclista 1 USO DEL MANUALE Leggere attentamente comprendere e seguire scrupolosamente le istruzioni presenti in questo manuale E una parte essenziale del prodotto...

Page 212: ...encial del producto y debe mantenerlo siempre a mano para su consulta El seguimiento incorrecto de las instrucciones de uso y mantenimiento o cualquier otra indicación puede causar accidentes lesiones graves o la muerte Tenga en cuenta que la instalación y reparación de cualquier sistema de suspensión requiere conocimiento específico herramientas y experiencia Las nociones generales de mecánica pu...

Page 213: ... tratti conviene immediatamente rivolgersi ad centro autorizzato Marzocchi prima di utilizzarla di nuovo A GENERAL SAFETY RECOMMENDATIONS Be sure to use the correct suspension system for the terrain on which you ride Check with your motorcycle retailer or Marzocchi for assistance in selecting the correct suspension system Please note that there are inherent risks associated with off road motorcycl...

Page 214: ...cuado y que está todo en perfecto estado La durabilidad de los productos Marzocchi depende de muchos factores como el estilo de pedaleo y las condiciones Los golpes caídas uso inadecuado o extremo en general pueden comprometer la seguridad de la estructura Por favor revise su horquilla regularmente y que un mecánico cualificado compruebe si tiene pérdidas de aceite golpes deformaciones o cualquier...

Page 215: ...i quali non è stata progettata Anche l atterrare impropriamente dopo un salto sottopone la forcella a stress che non è in grado di assorbire Salti o balzi sono consentiti solo nel Always wear a properly fitted and fastened helmet that has been approved by the Department of Transportation DOT SNELL or CE and any other safety equipment necessary for your riding style B BEFORE EVERY RIDE Check that n...

Page 216: ...e uso o abuso No someta su horquilla a una falta de uso o abuso innecesario Aprenda como utilizarla y siempre dentro de sus posibilidades Utilizarla sin control sólo unas pocas veces supondrá el equivalente a años de mal uso Debe aprender como evitar los obstáculos que surjan durante el recorrido Chocar directamente con rocas árboles o agujeros puede someter la horquilla a una presión cuyo diseño ...

Page 217: ...dubbi contattare il distributore Marzocchi locale not designed to absorb You should only perform jumps or drops when a transition is available to help absorb the impact forces generated during the landing and both wheels should smoothly make contact with the transition at the same time Any other type of landing is dangerous as it could result in a component part failure and an accident The steepne...

Page 218: ...erán de la altura desde la que salte o descienda Cada situación es diferente para cada corredor Consulte con un corredor experto antes de realizar cualquier salto o descenso PRECAUCION No evitar los obstáculos que surjan durante el recorrido o realizar un aterrizaje incorrecto después de un salto o descenso puede dañar cualquier pieza de la motocycleta causando pérdida de control fuertes lesiones ...

Page 219: ...posizione stelo portastelo e montaggio anelli di tenuta 68 4 11 Riempimento olio 80 4 12 Rimontaggio forcella sul motociclo 84 CONTENTS 1 Introduction 14 1 1 Conventions 18 1 1 1 Orientation of the fork 18 1 1 2 Editorial pictograms 18 1 1 3 Equipment 20 2 General information 22 2 1 Characteristics 22 2 2 Components of the fork 26 3 General safety regulations 30 3 1 Instructions for clamping in th...

Page 220: ...hen Abhilfe 37 4 2 Tabelle für Turnusmäßige Wartung 41 4 3 Reinigung Staubabstreifer 43 4 4 Entlüftung 45 4 5 Ölablass 47 4 6 Zerlegung Pumpengruppe und Bodenventil 51 4 7 Zerlegung Holm Gleitrohr und Entfernung der Dichtringe 57 4 8 Überholung und Änderung der Kartusche und Bodenventileinstellung 61 4 8 1 Überholung der Kartusche Zugstufendämpfung 61 4 8 2 Überholung des Bodenventils Druckstufend...

Page 221: ...ion adjustment 88 6 Tables 90 6 1 Table 1 Tightening torques 90 6 2 Table 2 Oil and quantity 90 6 3 Table 3 Standard setting 91 6 4 Table 4 Springs 91 Notes 93 7 Warranty 94 5 Tarature 86 5 1 Registro estensione 86 5 2 Registro compressione 88 6 Tabelle 90 6 1 Tabella 1 Coppie di serraggio 90 6 2 Tabella 2 Olio e quantità 90 6 3 Tabella 3 Taratura standard 91 6 4 Tabella 4 Molle 91 Note 93 7 Garan...

Page 222: ...o de aceite 81 4 12 Reensemblaje de la horquilla en la motocicleta 85 5 Ajustes 87 5 1 Ajuste rebote 87 5 2 Ajuste compresión 89 6 Tablas 90 6 1 Tabla 1 Pares de torsión 90 6 2 Tabla 2 Aceite y cantidad 90 6 3 Tabla 3 Ajuste estándard 91 6 4 Tabla 4 Muelles 91 Notas 93 7 Garantía 95 4 11 Remplissage de l huile 81 4 12 Remontage de la fourche sur le motocycle 85 5 Réglages 87 5 1 Réglage détente 87...

Page 223: ...1 PREMESSE Il presente manuale contiene informazioni importanti relative al montaggio all utilizzo e alla manutenzione del sistema di sospensione da voi scelto e deve quindi essere letto con estrema attenzione Prima di iniziare la lettura occorre leggere attentamente e apprendere quanto contenuto nella sezione Norme di sicurezza per l utilizzatore del manuale Quanto contenuto nella sezione Norme d...

Page 224: ...ado y mantenimiento de su suspensión por favor contacte con el centro autorizado más cercano que puede encontrar en la página de Internet www marzocchi com PRECAUCION El presente manual no sirve para explicar el montaje desmontaje de la horquilla de la motocicleta de la rueda del grupo de freno de las piezas de la dirección o de cualquier otro componente directa o indirectamente relacionado con la...

Page 225: ...grade kits and overhauling kits visit our website www marzocchi com in the section Products aftermarket moto ATTENZIONE L utilizzatore e il manutentore sono gli unici responsabili della corretta applicazione delle istruzioni di assemblaggio contenute nel presente libretto Guidate sempre nel pieno rispetto delle norme di sicurezza e prestando sempre la massima attenzione NOTA Per ulteriori informaz...

Page 226: ... aplicación de las instrucciones de ensamblaje contenidas en el presente manual Conduzca siempre respetando las normas de seguridad y prestando siempre la máxima atención NOTA Fuer weitere Informationen über Dampfung Kit upgrade Kit überholung bitte besuchen unseren Website www marzocchi com in der Produkte Aftermarket Motorrad Abteilung ATTENTION L utilisateur et le réparateur sont les seuls resp...

Page 227: ...la forcella 1 1 2 Editorial pictograms WARNING Descriptions preceded by this symbol contain information instructions or procedures which if not respected can cause damage or bad function to the fork accidents to the user even fatal ones or damage to the environment REMEMBER Descriptions preceded by this symbol contain information prescriptions or procedures recommended by MARZOCCHI for the best fo...

Page 228: ...nen WICHTIG Die Beschreibungen die von diesem Symbol vorgegangen sind enthalten Informationen Vorschriften oder Prozeduren die von MARZOCCHI zur besseren Benutzung der Gabel empfohlen werden S U P É R I E U R I N F É R I E U R A R R I È R E A V A N T G A U C H E D R O I T E 1 1 Konventionen 1 1 1 Richtungsangaben Gabel O B E N U N T E N H I N T E N V O R N L I N K S R E C H T S 1 1 Convenciones 1 ...

Page 229: ...anasce in materiale tenero Millimetre ruler Righello millimetrato Graduated container Misurino graduato Container with wide mouth Contenitore con imboccatura larga Adhesive tape Nastro adesivo Grease Grasso Silicone grease spray Grasso siliconato spray Marzocchi Introducer Cod R5080AC Introduttore Marzocchi Cod R5080AC 12 mm spanner Chiave fissa da 12 mm 18 mm spanner Chiave fissa da 18 mm 19 mm s...

Page 230: ...lave fija de 12 mm 12 mm Maulschlüssel Clé de 12 mm Llave fija de 18 mm 18 mm Maulschlüssel Clé de 18 mm Llave fija de 19 mm 19 mm Maulschlüssel Clé de 19 mm Destornillador pequeño Kleiner Schraubendreher Tournevis plat de petite dimension Destornillador de estrella tipo PH Kreuzschlitzschraubendreher Typ PH Tournevis cruciforme de type PH Herramienta bloqueo protección Marzocchi Cód R5081AA Marzo...

Page 231: ...orrimento Con riporto in teflon esenti da attrito di primo distacco Guarnizioni Anelli di tenuta progettati al computer assicurano massima tenuta in compressione e minimo attrito in estensione 2 GENERAL INFORMATION Shiver 45 Factory Works is a telehydraulic upside down fork with advanced axle The Shiver 45 Factory Works is based on a multivalve damping system and spring for static load The compres...

Page 232: ... para la regulación de las fases de compresión y de rebote En el tapón superior de las dos barras está colocado un tornillo para la purga del aire contenido al interior de la botella 2 1 Características Barras De acero especial con alta resistencia con tratamientos superficiales de galvanización y de endurecimiento TIN Botellas En aleación de aluminio trabajadas con CNC anodizadas y bruñidas al in...

Page 233: ...e di lavoro esente da attrito di primo distacco Per informazioni più dettagliate fare riferimento alla Tabella 2 Olio e quantità Springs Made of steel they are available in different stiffness K For more detailed information please refer to Table 4 Springs Oil MARZOCCHI with special formula It eliminates the formation of foam and keeps the viscosity characteristics unchanged in any working conditi...

Page 234: ...uelles Aceite MARZOCCHI de especial fórmula elimina la formación de espuma y mantiene inalteradas las características de viscosidad en cualquier condición de trabajo sin roce estático Para informaciones más detalladas consulte la Tabla 2 Aceite y cantidad Ressorts En acier disponibles en plusieurs duretés K Pour des informations plus détaillés se reporter au Tableau 4 Ressorts Huile Marzocchi à fo...

Page 235: ...otorcycle frame light background 2 2 Componenti della forcella La forcella Shiver 45 Factory Works utilizza un sistema di smorzamento multivalvola che si contraddistingue per la uguale configurazione dei due steli Ogni stelo costituisce pertanto un sistema completo di sospensione a cui fare riferimento quando si opera una registrazione 5 Tubo portante 8 Boccola di scorrimento Inferiore 9 Scodellin...

Page 236: ...SHIVER 27 9 12 33 48 39 24 30 31 72 5 13 33 70 41 71 34 36 10 37 19 21 25 73 8 32 28 43 45 46 MZ015002 ...

Page 237: ...28 MZ015002 9 12 33 48 39 24 30 31 72 5 13 33 70 41 71 34 36 10 37 19 21 25 73 8 32 28 43 45 46 ...

Page 238: ... pie 30 Protección del cartucho 31 Vástago interior 32 Vástago elemento de bomba 33 Muelle retorno laminillas 34 Laminilla pistón rebote 36 Pistón elemento de bomba 37 Paquete laminillas pistón freno rebote 39 Casquillo guía superior 41 Válvula de pie 43 Laminilla válvula compresión 45 Pistón válvula de pie 46 Paquete laminillas pistón freno compresión 48 Tapón 70 Portarueda 71 Tornillo ajuste amo...

Page 239: ...chiavi metriche e non in pollici Le chiavi con misure in pollici possono avere dimensioni simili a quelle in millimetri ma possono danneggiare le viti e rendere poi impossibile la svitatura Per svitare le viti con impronta a taglio o a 3 GENERAL SAFETY REGULATIONS After a complete breakdown always use new original Marzocchi seals when reassembling To tighten two bolts or nuts that are near each ot...

Page 240: ...egradables Antes del montaje lubrique siempre con aceite para horquillas todas las partes en contacto Si no va a utilizar la horquilla durante un tiempo lubrique siempre los componentes de la horquilla que estén en contacto con aceite No esparcir en el ambiente lubricantes solventes o detergentes no completamente biodegradables estos deben ser recogidos y conservados en recipientes especiales para...

Page 241: ...a la moto e in particolare della forcella Verificare rigorosamente che nella zona di lavoro non vi sia presenza di trucioli metallici o polvere È consigliabile procedere alla revisione di uno stelo alla volta Non modificare i componenti della forcella Use the correct size and sort of screwdriver to unscrew slotted or crosshead screws When using a screwdriver to assemble or disassemble metal stop r...

Page 242: ... hacer el mantenimiento y revisar la horquilla restableciéndola a las condiciones originales de un producto nuevo Utilice solamente partes de recambio originales Antes de efectuar operaciones de mantenimiento revisión asegúrese de poseer los recambios necesarios para la revisión completa de ambas barras n 2 retenes n 2 guardapolvos n 2 segmentos pistón Trabaje en ambientes limpios ordenados y bien...

Page 243: ...stelo nella zona di fissaggio della base di sterzo C Asta del pompante nella parte superiore alla sede dell anello di battuta del guidamolla D Presa di chiave della valvola di fondo 3 1 Instructions for clamping in the vice For some maintenance procedures you may have to use the vice to clamp some components of the fork WARNING The incorrect use of the vice can cause irreparable damage to the fork...

Page 244: ...pannstocks auf die Arbeiten beschränken bei denen sie unerlässlich ist den Spannstock mit Spannbacken aus weichem Material bestücken beim Anziehen des Spannstocks nicht übertreiben keine Gabelteile im Spannstock befestigen bei denen auch eine minimale Unrundheit das Teil unbrauchbar machen würde In der Abbildung sind die empfohlenen Bereiche für die Befestigung der Gabel im Spannstock markiert A R...

Page 245: ...i scorrimento usurate Worn sliding bushings Sostituire le boccole di scorrimento Replace the sliding bushings Olio esausto Old oil Sostituire l olio Change the oil Scarsa scorrevolezza degli steli Fork legs not sliding properly Steli non correttamente allineati Fork legs not aligned correctly Allentare il perno ruota ed eseguire il corretto allineamento vedi par 4 12 Loosen the wheel axle and alig...

Page 246: ...os Remplacer les bagues de glissement Gleitbuchsen auswechseln Sustituya los casquillos guía L huile est usée Öl verbraucht Aceite consumido Vidanger l huile Öl wechseln Sustituya el aceite Glissement insuffisant des fourreaux Schlechtes Gleiten der Holme Poco deslizamiento de las barras Les fourreaux ne sont pas alignés correctement Holme nicht vorschriftsmäßig ausgerichtet Barras no alineadas co...

Page 247: ...her viscosity one Molla troppo tenera o fuori servizio Too soft or damaged spring Sostituire la molla Replace the spring La forcella si dimostra troppo dura in ogni configurazione dei registri Fork is too stiff with any adjustment Livello dell olio superiore a quello consigliato Oil level too high Ripristinare il corretto livello dell olio Re establish correct oil level Viscosità dell olio troppo ...

Page 248: ...aciones Niveau de l huile trop bas Ölvolumen zu niedrig Nivel de aceite demasiado bajo Rétablir le niveau d huile correct Das richtige Ölvolumen ergänzen Reestablezca el nivel de aceite correcto Viscosité de l huile trop basse Ölviskosität zu niedrig Viscosidad del aceite demasiado baja Remplacer l huile par un autre ayant plus de viscosité Das Öl mit einem höheren Viskosität wechseln Sustituya el...

Page 249: ... gara After every race Dopo ogni uso After every use Dopo ogni uso After every use Sostituzione olio Change the oil 6 ore Every 6 hours 20 ore Every 20 hours 30 ore Every 30 hours 60 ore Every 60 hours Sostituzione anelli di tenuta Replace the sealing rings 6 ore Every 6 hours 20 ore Every 20 hours 30 ore Every 30 hours 60 ore Every 60 hours Quando la sospensione viene utilizzata su terreni fangos...

Page 250: ...isation Vor jedem Einsatz Antes de cada salida Nettoyage du cache poussière Reinigung Staubabstreifer Limpieza guardapolvo Après chaque compétition Nach jedem Rennen Después de cada competición Après chaque compétition Nach jedem Rennen Después de cada competición Après chaque utilisation Nach jedem Einsatz Después de cada utilización Après chaque utilisation Nach jedem Einsatz Después de cada uti...

Page 251: ...la superficie visibile dell anello di tenuta Rimontaggio Rimontare in sede il raschiapolvere 12 facendo pressione con le mani 4 3 Cleaning the dust seal REMEMBER This operation can be carried out with the fork installed on the motorcycle Dismantling Carefully clean the stanchion tube 6 before carrying out this operation With a small screwdriver prize the dust seal 12 off the slider 13 without scra...

Page 252: ...icht verkratzt wird Den Staubabstreifer entlang dem Tauchrohr nach unten führen und mit einem Druckluftstrahl den Innenbereich des Staubabstreifers und seinen Sitz am Gleitrohr säubern ACHTUNG Die Verwendung von Metallwerkzeugen für das Abtragen von Schmutzteilchen ist unbedingt zu vermeiden Die Holme einen kurzen Hub ausführen lassen dann die eventuell an den Tauchrohren vorhandenen Verunreinigun...

Page 253: ... 14 alla coppia prescritta vedi Tabella 1 Coppie di serraggio prestando attenzione a non danneggiare l anello di tenuta 50 PH 4 4 Bleeding the air REMEMBER This operation must be carried out with the fork assembled on the motorcycle and with the fork s legs fully extended front wheel off the ground The pressure generated by the air that can get into the fork legs while the motorcycle is being used...

Page 254: ...d einen Druck erzeugen der Funktionsstörungen der Gabel verursachen kann Ausbau Jeden Monat oder nach jedem Rennen muss an beiden Holmen die Entlüftungsschraube 14 im oberen Teil des Gleitrohrs mit einem Kreuzschlitzschraubendreher aufgedreht werden um den eventuell im Inneren entstandenen Druck abzulassen Den Zustand des Dichtrings 50 überprüfen falls nötig auswechseln Wiedereinbau Die Entlüftung...

Page 255: ...rodado 23 con chiave da 19 mm e servendosi di una seconda chiave sempre da 19 mm svitare completamente il tappo di chiusura 48 19 mm R5051AC 4 5 Draining the oil WARNING This operation cannot be carried out with the fork installed on the motorcycle REMEMBER We recommend loosening the fork cap a little before removing the fork leg from the fork yokes Remove the fork leg from the fork yokes accordin...

Page 256: ... der vom Hersteller des Motorrads vorgesehenen Prozedur von den Gabelbrücken abnehmen Den Holm im Spannstock einspannen Den Verschluss 48 mit dem 19 mm Schlüssel vollständig aufschrauben Das Gleitrohr langsam auf das Tauchrohr nach unten ziehen Den Federhülseteller 20 und die Feder 21 so weit nach unten drücken dass ein 19 mm Schlüssel auf die Kontermutter 23 gesetzt werden kann Die Kontermutter 2...

Page 257: ... alla sostituzione delle boccole guida e degli elementi di tenuta NOTA Nel paragrafo 4 11 è illustrata la procedura per il montaggio e il riempimento olio 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 o...

Page 258: ...HTIG Das Werkzeug R5051AC ist als Ersatzteil verfügbar wenn es am Stabsende eingeschraubt wird ist es einfacher den Stab selbst vom Gleitrohresinnere abzunehmen WICHTIG Wenn man das Aussehen die Dichte und die Qualität des verbrauchten Öls betrachtet kann man Rückschlüsse auf den Zustand der Dicht und Führungselemente ziehen Wenn das Öl dickflüssig und dunkel ist und Festkörperchen aufweist ist ei...

Page 259: ...e fermi i componenti interni allo stelo Con la chiave a bussola da 21 mm svitare la valvola di fondo 41 Rimuovere il gruppo valvola di fondo 41 Sfilare il gruppo ammortizzatore 21 dal tubo portante 5 17 mm 18 mm 21 mm R5081AA 4 6 Braking down the pumping element and the bottom valve WARNING This operation must be done only after having drained all of the oil out of the fork leg Clamp the wheel axl...

Page 260: ...extremität liegende Langloch sich perfekt in den Hülsesechskant einsitzt ACHTUNG Im oberen Gerätsgebiet sind zwei diametral entgegengesetzte Löcher zu sehen wo eine Achse eingesetzt werden kann um die Blockierung einfacher zu machen Das Gerät kann jedoch auf keinen Fall rotiert werden sondern nur zur Blockierung der innenliegenden Komponenten des Holmes benutzt werden Mit einer 21 mm Steckschlüsse...

Page 261: ...scalzare l anello di fermo 27 dall asta Rimuovere dall asta l anello di fermo 27 e il puntale 29 Unscrew and remove the locknut 23 and take off the guide spring 24 In order to be able to act on the pumping element you will need to remove the foot buffer components hold the foot buffer nut 26 using a 18 mm spanner and unscrew the push rod 29 with a 17 mm hexagonal spanner Remove the upper nut 26 an...

Page 262: ... zu entfernen die Mutter des Bodenpuffers 26 mit einer 18 mm Schlüssel blockiert halten und die Spitze 29 mit einer 17 mm Sechskantschlüssel ausschrauben Die obere Mutter 26 und den Bodenpuffer 28 herausziehen Mit einem kleinen Schraubendreher den Haltering 27 vom Stab aufheben Den Haltering 27 und die Spitze 29 vom Stab abnehmen Desatornille la contratuerca 23 y saque la guía del muelle 24 Para h...

Page 263: ...afo 4 10 è illustrata la procedura per la ricomposizione del gruppo pompante e della valvola di fondo 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 REMEMBER The pumping element can be completely overhauled and adjusted Paragraph 4 8 shows how to overhaul and modify the pumping element setting Verify the segment ...

Page 264: ...nn WICHTIG Das Pumpenelement ist vollständig überholbar und kalibrierbar Im Paragraph 4 8 wird die Prozedur zur Überholung und Änderung des Pumpenelementseinstellung erklärt Den Segmentverschleiß 35 überprüfen WICHTIG Im Paragraph 4 10 wird die Prozedur zum Zusammenbau des Pumpenelementseinstellung erklärt Empuje el vástago 32 hacia el interior de la protección 30 para poder sacar el elemento de b...

Page 265: ...zzando un piccolo cacciavite a taglio Con il medesimo cacciavite rimuovere l anello metallico di fermo 11 4 7 Braking down the fork leg slider and removing the oil seals Remove the dust seal 12 from its seat using a small flat tip screwdriver With the same screwdriver remove the metal stop ring 11 MZ012016 12 MZ012017 11 ...

Page 266: ...t métallique 11 4 7 Zerlegung Holm Gleitrohr und Entfernung der Dichtringe Den Staubabstreifer 12 mit einem kleinen Schraubendreher abnehmen Mit demselben Schraubendreher den metallenen Haltering 11 abnehmen 4 7 Decomposición barra de horquilla botella y eliminación de los retenes Saque el guardapolvo 12 de su sede utilizando un destornillador pequeño Con el mismo destornillador elimine el anillo ...

Page 267: ...essere riutilizzati NOTA Nel paragrafo 4 9 è illustrata la procedura per il montaggio degli elementi di tenuta e la ricomposizione stelo portastelo Pull the stanchion tube 6 out of the slider 13 to separate these two elements 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...

Page 268: ...lt Die obere Führungsbuchse 39 von Hand abnehmen Falls dies von Hand schwer ausführbar ist kann man sich durch Einsetzen eines Schraubendrehers in den Schlitz der Buchse behelfen Die untere Führungsbuchse 8 den Teller 9 den Dichtring 10 den Haltering 11 und den Staubabstreifer 12 aus dem Tauchrohr entnehmen ACHTUNG Die abgenommenen Dichtringe und Staubabstreifer dürfen nicht wiederverwendet werden...

Page 269: ...tensione 37 il pistone 36 completo di segmento 35 la lamella 34 e la molla 33 12 mm 13 mm 4 8 Overhauling and modifying the cartridge and bottom valve setting 4 8 1 Cartridge overhauling rebound braking Dismantling Clamp in the vice the rod 32 milled area Unscrew the nut 38 using a 12 or 13 mm spanner according to the mounted nut Remove the nut 38 the washer or the washers stack regulating the reb...

Page 270: ... Desmontaje Bloquee en la prensa la parte fresada del vástago 32 Desatornille la tuerca 38 con una llave de 12 o 13 mm según el tipo de turca utilizada Quite la tuerca 38 la laminilla o el paquete de laminillas 37 que ajustan el rebote el pistón 36 con su segmento 35 la laminilla 34 y el muelle 33 siguiendo este orden 12 mm 13 mm 4 8 Révision et modification réglage cartouche et clapet de pied 4 8...

Page 271: ...to the required torque see Table 1 Tightening torques Montaggio NOTA Le lamelle 37 e il pistone 36 determinano il freno in estensione Qualora fosse necessario è possibile modificare il comportamento della forcella in fase di estensione sostituendo le lamelle 37 ed il pistone 36 con elementi aventi differenti caratteristiche ATTENZIONE Utilizzare solamente lamelle e pistoni originali Marzocchi non ...

Page 272: ...r el segmento del pistón 35 Inserte en la parte terminal del vástago el muelle 33 la laminilla 34 el pistón 36 con su segmento 35 la laminilla o las laminillas 37 que ajustan el rebote siguiendo este orden PRECAUCION El pistón tiene que orientarse con los agujeros que tienen el diámetro menor hacia las laminillas de regulación 37 Atornille la tuerca 38 a mano Bloquee en la prensa la parte fresada ...

Page 273: ...or the washers stack regulating the compression 46 following this order 13 mm 4 8 2 Revisione valvola di fondo freno in compressione Smontaggio Bloccare in morsa la vite di fondo attraverso la presa di chiave 47 Servendosi di una chiave da 13 mm svitare il dado 42 Rimuovere nell ordine il dado 42 la molla 33 la lamella 43 il pistone 45 completo anello o ring 44 la lamella o il pacco di lamelle che...

Page 274: ...je Bloquee el tornillo de pie a través del agarre 47 Con una llave de 13 mm desatornille la tuerca 42 Quite la tuerca 42 el muelle 33 la laminilla 43 el pistón 45 con su anillo O ring 44 la laminilla o el paquete de laminillas 46 que ajustan la compresión siguiendo este orden 13 mm 4 8 2 Révision clapet de pied freinage en compression Démontage Bloquer dans l étau la vis de fond par la prise de cl...

Page 275: ... nut 42 up to the required torque see Table 1 Tightening torques Montaggio NOTA Le lamelle 46 e il pistone 45 determinano il freno in compressione Qualora fosse necessario è possibile modificare il comportamento della forcella in fase di compressione sostituendo le lamelle 46 ed il pistone 45 con elementi aventi differenti caratteristiche ATTENZIONE Utilizzare solamente lamelle e pistoni originali...

Page 276: ... particulares Si necesario reemplazar el anillo O ring del pistón 44 Inserte en la válvula de pie la laminilla o el paquete de laminillas 46 que ajustan la compresión el pistón 45 con su anillo O ring 44 la laminilla 43 y el muelle 33 siguiendo este orden PRECAUCION El pistón tiene que orientarse con los agujeros que tienen el diámetro menor hacia las laminillas de regulación 46 Atornille la tuerc...

Page 277: ...ttenzione all orientamento dell anello di tenuta 10 esso deve essere inserito in maniera tale che la parte cava sia rivolta verso lo scodellino 9 G R EAS E R5080AC 4 9 Re assembling the fork leg slider and oil seals REMEMBER The old oil seals and dust seals must not be used again Before re assembling check the conditions of the guide bushings replace them if they are scratched or grooved Check the...

Page 278: ...t sind auswechseln Die Teflonbeschichtung der Führungsbuchsen überprüfen sie muss unversehrt sein Das Ende des Tauchrohrs so mit einem Klebeband umwickeln dass der Sitz der oberen Buchse abgedeckt ist Den Staubabstreifer und den Dichtring leicht einfetten In dieser Reihenfolge in das Tauchrohr einsetzen Staubabstreifer 12 Haltering 11 Dichtring 10 Teller 9 und untere Führungsbuchse 8 ACHTUNG Seien...

Page 279: ...ortante 5 l apposito introduttore e con questo spingendo sull anello di tenuta 10 introdurre in sede la boccola guida inferiore lo scodellino e l anello di tenuta Remove the adhesive tape from the end of the stanchion tube cleaning any traces of adhesive left on the fork Insert the top guide bushing 39 by hand REMEMBER If this operation is difficult by hand use a flat tip screwdriver in the bushin...

Page 280: ...wer ausführbar ist kann man sich durch Einsetzen eines Schraubendrehers in den Schlitz der Buchse behelfen Das Tauchrohr vorsichtig in das Gleitrohr einschieben dabei sorgfältig darauf achten dass die obere Führungsbuchse nicht beschädigt wird Die untere Führungsbuchse bis zur Berührung mit dem Gleitrohr dem Teller und dem Dichtring einführen Den zugehörigen Einschubzylinder am Tauchrohr 5 anbring...

Page 281: ...a attenzione a non rigare il tubo portante Inserire in sede il raschiapolvere 12 facendo pressione con le mani Mount the stop ring 11 using a small flat tip screwdriver checking it fits perfectly into its groove and being very careful not to scratch the stanchion tube Re assemble the dust seal 12 in its seat pressing it home with your hands MZ012017 11 MZ012008 12 ...

Page 282: ...gen dazu einen kleinen Schraubendreher zu Hilfe nehmen der perfekt in die entsprechende Rille passt und sorgfältig dabei darauf achten dass das Tauchrohr nicht verkratzt wird Den Staubabstreifer 12 durch Drücken mit den Händen wieder einsetzen Monte el anillo de seguridad 11 ayudándose con un destornillador pequeño comprobando que se introduzca perfectamente en su ranura y prestando mucha atención...

Page 283: ...do va inserito con le asole per il passaggio dell olio rivolte verso il puntale Introdurre il dado superiore 26 ed avvitarlo sul puntale 29 G R EAS E 17 mm 18 mm 21 mm R5081AA 4 10 Re assembling the pumping element unit and the bottom valve Insert the pumping element rod 32 into the body 30 REMEMBER In both pumping elements there is a sealing segment before the assembling make sure that it is not ...

Page 284: ...n Das Einsetzen des Kolbens muss ohne Anstoßen erfolgen Die Spitze 29 des Bodenpuffers in den Stab 32 einsetzen das muss so durchgeführt werden dass die Seite mit dem Schlüsseleingriff nach der Hülse 30 gerichtet ist und dass der Sitz F für den Metalldraht 27 übersteigt wird Den Metalldraht 27 in seinen Sitz F einsetzen Die Spitze 29 bis zur Berührung mit dem Haltering anbringen Den Bodenpuffer so...

Page 285: ...iametro minore rivolta verso il tampone di fondo Avvitare a fondo il controdado 23 senza serrare Hold the nut 26 with a 18 mm spanner and tighten the push rod 29 up to the required torque see Table 1 Tightening Torques using a 17 mm spanner Insert the guide spring 24 in the pumping element rod 32 the guide spring must have the smaller diameter side towards the foot buffer Screw the locknut 23 till...

Page 286: ...pitze 29 mit einer 17 mm Schlüssel mit dem vorgeschriebenen Anzugsmoment anziehen siehe Tabelle 1 Anzugsmomente Die Federhülse 24 in den Pumpenelementstab 32 so einsetzen dass die Seite mit kleinerem Durchmesser nach dem Bodenpuffer gerichtet ist Die Gegenmutter 23 einschrauben ohne festmachen Tenga fija la tuerca 26 con una llave de 18 mm y con una llave de 17 mm apriete la varilla de empuje 29 h...

Page 287: ...er tenere fermi i componenti interni allo stelo Con chiave a bussola da 21 mm avvitare la valvola di fondo 41 alla coppia prescritta vedi Tabella 1 Coppie di serraggio Push the pre assembled pumping element 23 until it is in contact with the stanchion tube 5 Tighten the bottom valve by hand Insert the R5081AA tooling inside the fork leg in a way that you can block the body rotation to do so the sl...

Page 288: ...Langloch sich perfekt in den Hülsesechskant einsitzt ACHTUNG Im oberen Gerätsgebiet sind zwei diametral entgegengesetzte Löcher zu sehen wo eine Achse eingesetzt werden kann um die Blockierung einfacher zu machen Das Gerät kann jedoch auf keinen Fall rotiert werden sondern nur zur Blockierung der innenliegenden Komponenten des Holmes benutzt werden Mit einer 21 mm Steckschlüssel das Bodenventil 41...

Page 289: ...istro 31 Inserire il tubetto di precarica 21 la molla 25 e lo scodellino guidamolla 20 Avvitare a fondo il tappo di chiusura 48 19 mm R5051AC 4 11 Filling with oil REMEMBER The R5051AC is available as spare part if you tighten it on the rod s edge you can make the rod extraction from the inner part of the slider easier Lift the slider completely on the stanchion tube Prepare the quantity of oil to...

Page 290: ...n dann einige Pumpbewegungen ausführen um die Luft auszutreiben Die restliche Ölmenge einfüllen Das Gleitrohr vom Tauchrohr nach unten ziehen bis der Staubabstreifer am Radaufnahmefuß anstößt Einige Minuten warten dann das Luftvolumen kontrollieren siehe Tabelle 2 Öl und Füllmengen und gegebenenfalls Öl nachfüllen WICHTIG Ein geringeres oder höheres Luftvolumen oder ein anderes als das vorgeschrie...

Page 291: ...hiusura 48 sul portastelo Ripristinare la corretta taratura agendo sulla vite di registro R vedi paragrafo 5 Fully unscrew the adjustment screw R which corresponds to the open adjuster Using two 19 mm spanners tighten locknut 23 on the cap 48 up to the required torque see Table 1 Tightening torques Lift the slider on the stanchion tube Tighten fork cap 48 on the slider with the 19 mm spanner to th...

Page 292: ...em Verschluss 48 mit dem vorgeschriebenen Anzugsmoment siehe Tabelle 1 Anzugsmomente anziehen Das Gleitrohr über das Tauchrohr hochschieben Mit der 19 mm Schlüssel den Verschluss 48 mit dem vorgeschriebenen Anzugsmoment siehe Tabelle 1 Anzugsmomente anziehen Die richtige Einstellung durch die Einstellschraube R siehe Paragraph 5 rückstellen Desatornille competamente el tornillo de regulación R que...

Page 293: ...1 ATTENZIONE Nel caso in cui la forcella sia corredata da testa e crocera fa fede la procedura di installazione contenuta nel manuale del costruttore della moto 4 12 Fitting the fork back on the motorcycle WARNING Fit the fork back onto the frame following the instructions in the motorcycle manufacturer s manual as for the steering elements brakes and wheel The incorrect assembly of these elements...

Page 294: ...to Para un funcionamiento correcto de la horquilla la rueda debe ser instalada en la horquilla de la siguiente manera Introduzca el perno a través del portarueda derecho la rueda y el portarueda izquierdo Atornille la tuerca del perno en el lado izquierdo y apriete hasta el fondo Realice algunas compresiones completas de las barras de horquilla Apriete los dos tornillos del portarueda derecho con ...

Page 295: ...the adjustment screw R past its limits 5 TARATURE 5 1 Registro estensione La taratura del freno in estensione o freno di ritorno può essere eseguita agendo sulla vite di registro R presente sui tappi superiori di entrambi gli steli NOTA Per modificare la taratura del freno in estensione partire sempre dalla posizione di tutto chiuso registro completamente girato in senso orario Ogni posizione del ...

Page 296: ...o gira el regulador R por medio de un destornillador de tamaño adecuado en el sentido de las agujas del reloj aumenta la amortiguación hidráulica del rebote haciendo que la horquilla vuelva lentamente durante la fase del rebote Cuando gira el regulador R por medio de un destornillador de tamaño adecuado en el sentido contrario de las agujas del reloj disminuye la amortiguación hidráulica del rebot...

Page 297: ...he plastic cap back to its seat 5 2 Registro compressione La taratura del freno in compressione può essere eseguita agendo sulla vite di registro C presente nella parte inferiore di ogni stelo NOTA Per modificare la taratura del freno in compressione partire sempre dalla posizione di tutto chiuso registro completamente girato in senso orario Ogni posizione del registro è identificata da un click R...

Page 298: ... el regulador C por medio de un destornillador de tamaño adecuado en el sentido de las agujas del reloj aumenta la compresión hidráulica reduciendo el recorrido que hace la horquilla bajo la misma presión Cuando gira el regulador C por medio de un destornillador de tamaño adecuado en el sentido contrario a las agujas del reloj disminuye la compresión hidráulica haciendo que la horquilla se hunda f...

Page 299: ...ss auf Stab Tapón en el vástago 10 Tappo su portastelo Cap on slider Bouchon sur porte fourreau Verschluss auf Gleitrohr Tapón en la botella 25 Vite spurgo aria Air bleed screw Vis de purge de l air Luftauslassschraube Tornillo de purga aire 7 Tampone di fondo Foot buffer Tampon de fond Bodenpuffer Almohadilla de pie 15 Tipo Type Type Typ Tipo Clima Climate Climat Klima Clima Quantità Quantity Qua...

Page 300: ...stensione Rebound Détente Zugstufe Rebote 10 click dalla posizione tutto chiuso 10 clicks form fully closed position 10 clicks de la position complètement serré 10 clicks von der völlig geschlossene Position 10 clicks de la posición completamente cerrado Costante molla K Spring rate K Dureté du ressort K Federhärte K Dureza del muelle K Codice Code Référence Artikel Código Lunghezza Length Longueu...

Page 301: ...92 MARZOCCHI Dis n Forc Shiver 45 Factory Works 47 49 45 44 43 33 42 39 37 46 41 23 14 15 16 17 24 26 28 29 30 31 32 33 34 38 35 36 25 21 8 9 10 11 12 22 39 5 13 6 40 18 20 19 48 27 8 8 ...

Page 302: ...SHIVER 93 NOTE NOTES NOTES ANMERKUNGEN NOTAS ...

Page 303: ...anty also does not include any expenses related to the transportation of the 7 GARANZIA Nel caso in cui vengano riscontrati difetti attinenti a materiali o lavorazione su uno qualsiasi dei componenti del sistema di sospensione Marzocchi entro i termini stabiliti dalla presente garanzia 2 anni il medesimo componente difettoso dovrà essere riparato o sostituito a facoltà della Marzocchi S p A gratui...

Page 304: ...aje anómalo reparaciones ejecutadas de manera incorrecta o instalación impropia de los repuestos uso de repuestos o acesorios que no correspondan à las características establecidas por Marzocchi S p A ejecución de modificaciones no recomendadas o aprobadas por escrito por Marzocchi S p A desarrollo de actividades como virtuosidades acrobáticas saltos acrobáticos subidas y o normal desgaste y deter...

Page 305: ...tuire i suddetti componenti La presente garanzia inoltre non copre le eventuali spese sostenute per il trasporto del sistema di sospensione Marzocchi a o da un rivenditore autorizzato Marzocchi i costi della manodopera richiesta per rimuovere dal veicolo il suddetto sistema di sospensione Marzocchi oppure l indennizzo richiesto per porre riparo al disagio dovuto al mancato utilizzo del sistema di ...

Page 306: ... el número de serie del sistema de suspensión Marzocchi sea alterado borrado no se pueda leer o haya sido dañado de alguna manera 2 COMPRADOR esta garantía se concede únicamente al comprador original del sistema de suspensión Marzocchi y no se entiende extendida a terceros Los derechos que pertenecen al comprador según los términos de esta garantía no se pueden ceder 3 DURACIÓN esta garantía empez...

Page 307: ...sed on alleged negligence or other tortious implicite od esplicite dichiarazione od impegni stipulati precedentemente e rappresenta il contratto indivisibile tra le parti con riferimento alla garanzia di questo sistema di sospensione Marzocchi Tutte le garanzie implicite od esplicite non contenute nel presente documento sono espressamente escluse 6 DANNI Salvo espressamente prescritto dalla presen...

Page 308: ...TES ASOCIADOS A UNA RECLAMACIÓN SEGÚN LOS TÉRMINOS DE ESTE ACUERDO DONDE LA RECLAMACIÓN SE BASE SOBRE EL CONTRATO ILÍCITO U OTRO Las declaraciones de garantía sobredichas son exclusivas y en lugar de todos los otros remedios Hay estados donde no se permite la exclusión o la limitación de daños indirectos o emergentes por lo tanto esta limitación o exclusión no se puede aplicar 7 RENUNCIA LAS EVENT...

Page 309: ...chi S p A il solo ed esclusivo rimedio per l acquirente sarà costituito dalla riparazione o sostituzione dei materiali risultati difettosi sulla base di quanto precedentemente stabilito Nessun rivenditore e nessun altro agente o dipendente della Marzocchi S p A è autorizzato ad apportare variazioni estendere od ampliare la presente garanzia 8 AVVERTENZA Installare riparare ed usare sempre il siste...

Page 310: ...viamente Ningun revendedor y ningun otro agente o dependiente de Marzocchi S p A es autorizado a hacer variaciones a prolongar o extender esta garantía 8 ADVERTENCIA instalar reparar y utilizar siempre el sistema de suspensión Marzocchi en conformidad a las instrucciones contenidas en el respectivo Manual de instrucción provisto por Marzocchi S p A 9 OTROS DERECHOS esta garantía les asegura especí...

Page 311: ...under licence by Marzocchi S p A fattura o scontrino fiscale In tal caso Vi preghiamo di aver cura di riportare nome cognome indirizzo data di acquisto specificando il tipo di problema o difetto rilevato La filosofia di Marzocchi S p A è quella di offrire un servizio all insegna della cortesia ed efficienza in riferimento ai reclami sottoposti nel corso della garanzia Trattate con cura il sistema ...

Page 312: ... un revendedor autorizado o bien un centro de asistencia Marzocchi adjuntando copia de la factura o del talón fiscal En este caso les rogamos indicar nombre apellido dirección fecha de compra y especificar el tipo de problema o defecto observado La filosofía de Marzocchi S p A es la de ofrecer un servicio de cortesía y eficiencia con referencia a las reclamaciones sometidas en el curso de la garan...

Page 313: ...84 Cod 900890 MARZOCCHI S p A Via Grazia 2 40069 Lavino di Zola Predosa Bologna ITALY Ph 39 0 51 61 68 711 Fx 39 0 51 75 88 57 Giugno 2003 Edizione 00 ...

Page 314: ...J 1 Part N 8000 H2051 02 2010 J REAR SUSPENSION Section ...

Page 315: ...bsorber inspection J 7 Reservoir cap with its valve removal J 7 Piston assembly inspections J 10 Seal replacement J 10 Checking the setting J 11 Reservoir replacement J 14 Floating piston removal J 14 Shock absorber assembly J 15 Shock absorber damping adjustment J 19 Disassembling and servicing the swinging arm J 20 Servicing the swinging arm shaft J 22 Servicing the rear suspension drop drag lin...

Page 316: ...J 3 Part N 8000 H2051 02 2010 REAR SUSPENSION Rear shock absorber TIGHTENING TORQUE FIGURES 1 2 52 4 Nm 5 35 Kgm 38 6 ft lb Lubrication points grease ...

Page 317: ...r 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 318: ...dle side panels silencer and rear chassis see Section E General Procedures Loosen the front clamp 1 of the intake coupling Remove the front bolt 2 securing the suspension linkage to the chassis the bottom 3 and top 4 shock absorber mounting bolts and remove the shock absorber 5 IMPORTANT On assembly fit the bottom locking nut 3 of the shock absorber on the LEFT SIDE ...

Page 319: ...bling the rear shock absorber Clean the shock absorber before disassembly SPRING SERVICING Measure the spring in place before removal Spring removal clamp the shock absorber in a vice taking care to avoid distorting it Slacken lock ring nut and ring nut spring retainer and spring ...

Page 320: ... the shock absorber and look for oil leaks or other issues Replace the shock absorber if needed Push on the reservoir valve to discharge the gas Aim valve away from you to prevent any debris from getting into your eyes Reservoir cap and valve removal Locate a suitable tool to reservoir cap and push down on cap until gaining access to the retaining ring Push down with your hand and use great care ...

Page 321: ...nd of the ring out of its groove Then slide out the other end slip the tip of a screwdriver between ring and reservoir and prise off with the other screwdriver Take out the retaining ring Check the grooves in reservoir body for burrs If any burrs are detected they must be removed and the grooves must be reconditioned Screw a pipe with inner thread onto the cap and extract the cap using pliers ...

Page 322: ...ENSION Place the shock absorber on a bench Unscrew or knock out the cover depen ding on the model Once the tank cap is removed push the rod guide down into the body so as to expose the circlip groove and remove the circlip with a screwdriver ...

Page 323: ...need to replace the reservoir floating piston Pour the oil into a clean pan and leave it to settle Piston assembly inspections 1 Check the seal for wear or damage replace if worn or damaged 2 Check the O ring on the rod guide Replace if scored 3 Check the surface of the chrome plated rod for dents or scoring If any damage isfound sealandDUbushwillbedamagedaswellandyouwillneedtoreplace the rod guid...

Page 324: ...he suspension is not operating properly and you need to adjust compression damping loosen the knob dowel heat with an air gun before loosening Proceed as follows loosen the ring nut with the suitable key slide off all parts noting their positions to ensure correct assembly ...

Page 325: ...J 12 Part N 8000 H2051 02 2010 REAR SUSPENSION ...

Page 326: ...g and slotted ring Slide the needle shaft off the cap tighten the ring insert into slot pressing lightly and secure in place tightening the cap to 30 Nm 3 kgm 29 2 ft lb It is strictly forbidden to change the compression washers This could cause the shock absorber to explode while in service ...

Page 327: ... smear the thread in the mount Apply Loctite and screw on the reservoir being careful not to damage the O ring Tighten to 40 Nm 4 Kgm 39 2 ft lb NOTE Perform these procedures in a clean environment and clean any com ponents to be reused Floating piston removal If you have drained the shock oil you will need to remove the floating piston Extract the floating piston using pliers and be careful not t...

Page 328: ...compressed air if needed Clamp the shock absorber eye in a vice with aluminium or bronze jaws or use a shop rag to protect the eye Fill 70 80 cu cm 4 3 4 9 cu in of oil into the shock absorber body Insert the complete piston rod into the shock absorber body taking care not to damage the sliding surface push rod with piston and mount but leave a gap to top up with oil later ...

Page 329: ...ting piston into the reservoir see picture Push the floating piston quickly down to reservoir bottom while holding the rod steady in the appropriate position for top up The oil inside the reservoir will flow into the shock absorber body and fill it up to a certain level as it seeps through the piston washers These operations need to be performed quickly to avoid the ingress of air ...

Page 330: ...e floating piston might become displaced due to cavita tion or compression Top up with oil up to the circlip groove while slowly setting the rod so the inner bumper is level with the groove Hold the rod steady and slide the rod guide into the shock absorber cylinder Push the rod guide down into the body past the circlip groove Insert the circlip making sure it is securely in place Pull the rod upw...

Page 331: ...ar Refit the cap to the valve and check for oil or air leaks Drive the cap onto the body Refitting bumper and washer If you have replaced the bumper clamp the rod in a vice with bronze or aluminium jaws apply Loctite to the mount and tighten to about 50 Nm Refit the spring and set to initial preload using ring nut and lock ring nut All liability is disclaimed for any damage resulting from procedur...

Page 332: ...on Then turn them back the number of clicks specified above In order to obtain a smooth braking action turn the adjuster screws counter clockwise Vice versa to obtain a harder braking action B REBOUND TE Standard setting 20 clicks 2 clicks B REBOUND SMS Standard setting 26 clicks 2 clicks Standard setting turn lower adjuster screw clockwise to fully closed position and then turn it back the number...

Page 333: ...rom the ground Remove the rear wheel as described in Section Y Remove the final drive chain 1 as described in Section E Detach the rear brake line 3 from the swinging arm 2 Loosen the screws 4 using a 7 mm ring wrench and remove the guard 5 Remove the caps 7 at both ends and use a mm socket wrench to loosen the nut 8 of the bolt 9 securing the drop link 10 at the top end ...

Page 334: ...from the right hand side Remove the swinging arm 2 pulling towards the rear end of the motorcycle Check swinging arm shaft straightness and manually check the roller cages 13 and their bushings 14 for wear turn the bushing 14 inside the roller cage 13 if you feel any tightness or hear noise replace them TIGHTENING TORQUE FIGURES 8 80 Nm 8 2 Kgm 59 ft lb 11 122 5 Nm 12 5 Kgm 90 3 ft lb LOCTITE 243 ...

Page 335: ...ink 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 play is detected remove the part from swinging arm or chassis and check inner spacer A and bearings...

Page 336: ...er 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 337: ......

Page 338: ...L 1 Part N 8000 H2051 02 2010 L BRAKES Section ...

Page 339: ...ng system L 3 Brake disc L 4 Checking brake pads for wear replacing the pads L 5 Pads cleaning L 5 Bleeding the front braking system TE L 7 Bleeding the front braking system SMS L 8 Bleeding the rear braking system L 10 Changing the fluid L 11 ...

Page 340: ... cylinder with a fluid reservoir 1 Front brake lever 2 Front brake master cylinder with fluid reservoir TE 2 Front brake master cylinder SMS 2A Fluid reservoir SMS 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 341: ... 320 mm SMS Front brake disc thickness when new 3 0 mm TE 5 0 mm SMS Wear limit 2 5 mm TE 4 5 mm SMS Rear brake disc diameter 220 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 cleanallmatingsurfacesthorou...

Page 342: ... or any oil gets on brake pads or discs Clean off with alcohol any fluid or oil that inadvertently gets on the pads or disc Replace the pads with new ones if they cannot be cleaned satisfactorily BRAKE PADS REMOVAL TE front TE SMS rear Remove clips 1 Slide out pin 2 Remove pads SMS front Press on clips 3 Slide out pins 4 Remove clips 3 Remove pads Do not work the brake lever or pedal while removin...

Page 343: ...ins 4 Pull clips 3 out to make sure they are engaged on pins 4 The above procedure eliminates the need to bleed the braking system after replacing the pads Simply operate the control lever several times until bringing the pistons back to their normal position Drain some fluid from the reservoir when replacing the pads or the pistons backing up into the cylinders might cause fluid to spill out of t...

Page 344: ...leed valve 1 Attach a clear plastic hose to the calliper bleed valve and place the other end of the hose in a vessel make sure the hose end stays dipped in the fluid throughout the procedure Remove the reservoir cover 2 and the rubber gaiter and fill the reservoir with fresh fluid Slacken the bleed valve and operate the lever 3 repeatedly until the fluid flowing out of the hose looks clear and fre...

Page 345: ...same Proceed as follows Take the rubber cover off the bleed valve 1 or 1A Attach a clear plastic hose to the calliper bleed valve and place the other end of the hose in a vessel make sure the hose end stays dipped in the fluid throughout the procedure Remove the reservoir cover 2 and the rubber gaiter and fill the reservoir with fresh fluid Slacken the bleed valve and operate the lever repeatedly ...

Page 346: ... will keep the master cylinder reservoir higher making bleeding easier The bleeding procedure does not remove all air from the circuit any small amounts of air left in the circuit will disappear after a short period of usage this will eliminate the mushy feel of the lever and restore its travel to proper length If brake lever or brake pedal feel mush after a fall or a repair resulting in loss of b...

Page 347: ...ightly 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 cover A and the rubber gaiter If the bleeding procedure was performed correctly the pedal will no longer have that mushy feel If not so repeat the procedure Fl...

Page 348: ...ntaminants 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 T...

Page 349: ...d 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 350: ... traces of spills immediately 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 Periodically check the connecting hoses C and D see Scheduled Maintenance Chart Section B replace worn or cracked hoses ...

Page 351: ......

Page 352: ...M 1 M Part N 8000 H2051 02 2010 ELECTRICAL SYSTEM Section ...

Page 353: ......

Page 354: ...onic control unit ECU M 21 Spark plug M 22 Gear position sensor inspection GPS Gear Position Sensor M 23 Battery M 24 Battery charger M 24 HEADLIGHT ADJUSTMENT M 26 Headlamp bulbs replacement M 27 Tail light replacement M 29 Number plate bulb replacement M 29 Turning indicator bulb replacement M 30 Rear turning indicator removal M 30 Front turning indicator removal M 31 Number plate light removal ...

Page 355: ...n M 46 Injector connection M 46 MAQS connector connection M 46 Engine water temperature connector M 46 Lambda sensor position and connector M 47 Ignition switch and left hand switch connection M 47 Right hand switch connection M 47 Ignition and gear sensor cable connection M 48 Rear stop connection M 48 Securing the handlebar wiring harness M 48 Securing the dashboard bracket connectors M 49 Headl...

Page 356: ...r 29 Front stop switch 30 Rear stop switch 31 Rear R H turning indicator 32 Tail light 33 Rear L H turning indicator 34 Front R H turning indicator 35 Headlamp 36 Front L H turning indicator 37 Air temperature sensor 21 38 Throttle position sensor 21 39 Pressure sensor 21 Colour coding key B Blue B Bk Blue Black Bk Black Br Brown Br Bk Brown Black Br R Brown Red Br W Brown White G Green G Bk Green...

Page 357: ...NTS 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 the R H side of the rear chassis ...

Page 358: ...AL SYSTEM Spark plug 5 on the R H side of the cylinder head 12V 700W Starter motor 6 behind the cylinder Solenoid starter 8 located on the fuse holder plate under the saddle M A Q S sensor air temperature pressure throttle position 10 on throt tle body ...

Page 359: ...dicators stop lights low and high beam lights relay 14B Electric fan 16 Fuses located on the utilities holder plate under the saddle Fuse 23 FP 15A cable sheath marked P fuel pump HT coil lam bda sensor heater injector Fuse 23A FM 15A cable sheath marked M 12V depending on igni tion switch system voltage parking lights Fuse 23B FDC 20A cable sheath marked DC electric fan rear stop light high beam ...

Page 360: ...2 2010 ELECTRICAL SYSTEM Lambda sensor 18 Headlamp 20 with twin halogen bulb of 12V 60 55W and parking light bulb of 12V 5W The tail light 21 is a LED light Turning indicators 22 12V 10W bulb Fuel pump 19 inside the fuel tank ...

Page 361: ...ed into direct current 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 Battery 15 Solenoid starter 16 Voltage regulator rectifier 18 Generator 19 ...

Page 362: ... If the vehicle is to remain unused for long periods it is recommended to disconnect the battery from the electrical system and store it in a dry place Regulated voltage Remove the saddle as described in the relevant section to gain access to the battery With the engine warmed up and running at slightly above 3000 rpm measure voltage across the positive and negative terminal of the battery using a...

Page 363: ... should be 100 Ohm 20 at 20 C B Set the meter to the Impedance scale and check battery charging Any and all combinations of the three wires should give the following reading 0 21 Ohm 15 at 20 C C Check that NONE of the three wires has continuity to ground At each engine overhaul clean flywheel rotor to remove any debris suspended in swirling oil and captured by the magnets ...

Page 364: ... device that adjusts charging voltage to battery charge if battery charge is low charging voltage will be lower Do not disconnect the battery cables while the engine is running or the regulator will suffer irreparable damage Withtheignitiononandthebatterycharged 12 5 13V starttheengine ifbattery voltage fails to rise 14 5 V within the next two minutes change the regulator as outlined in the releva...

Page 365: ...in the clutch lever and hold it squeezed until the engine starts When the starter button is pressed the starter relay is energised and closes the circuit that connects starter motor and battery Clutch microswitch 6 Ignition switch 8 Battery 15 Solenoid starter 16 Starter motor 17 Fuses 23 R H switch 25 Wiring diagram ...

Page 366: ...t is detected check the starter motor as follows connect a meter across ground and starter motor contact check for continuity between the positive pole and motor ground If no continuity is found replace the starter motor Starter motor Rated voltage 12V Current draw 700 W No load test Voltage 11 5 V Current 22 A Speed 7000 rpm Cranking test Voltage 8 5 V Current 165 A Torque 1 86 Nm 0 19 Kgm 1 33 f...

Page 367: ... RPM 4 Light voltage 5 Charging current Starter motor test curves Starter motor maintenance Starter motor maintenance consists in inspecting brushes for wear and checking the electrical and mechanical insulation between stator and rotor Accurately grease starter motor moving parts with CASTROL LM GREASE 2 ...

Page 368: ...ter motor and battery positive cable wires at relay end Apply 12 Volts to relay terminals 5 and 6 and check for continuity betwe en terminals B M Do not feed battery voltage to the relay longer than 5 seconds or the relay might overheat leading to winding damage Use a multimeter to establish whether the winding is open circuit or resistance exists A winding in good condition will give the followin...

Page 369: ...n This ignition system is composed of a crankshaft position pick up sensor an ECU an ignition coil and an inta ke manifold pressure sensor The ignition coil is fed by the battery through a power relay and is controlled by the ECU Ignition timing is accurately determi ned based on engine RPM and accelerator position In addition to these key parameters inputs from the intake air temperature and pres...

Page 370: ... Clutch microswitch 6 Ignition switch 8 Lambda sensor 9 Battery 15 Solenoid starter 16 Starter motor 17 Voltage regulator rectifier 18 Alternator 19 Gear sensor 20 M A Q S sensor 21 pressure sensor TPS air temperature sensor Power relay 22 Fuse 23 R H switch 25 Injector 26 For a description of wires please see page M 5 Wiring diagram ...

Page 371: ...or 2 from the wiring remove retaining screws 3 and coil 1 and measure resistance in the primary and secondary windings with a meter A primary winding resistance 4 5 Ohm 15 at 20 C B secondary winding resistance 19 5 KOhm 20 at 20 C without spark plug cap cable If resistance is outside the specified limits replace the coil Also check the resi stance of the terminal cap contacting the spark plug ...

Page 372: ...is outside the specified limits replace the cap NOTE Theareawherethecoilissecuredmustbetotallyfreefromoxideandpaint A faulty ground contact will damage the coil and cause ignition problems Electronic control unit ECU Remove the saddle as described in Section E to gain access to the electronic control unit 1 ...

Page 373: ... 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 general condition of the engine Before refitting the spark plug accurately clean the insulator with a wire brush Smear some graphite grease on spark plug thread do it fully home finger tight then...

Page 374: ...nsert the other probe into the connector hole for the WHITE BLACK gear sensor wire 2 The lever 3 is placed on the left hand side of the engine After each gear shift it automatically returns to the horizontal position First gear is engaged by pushing the lever downwards for other gears push it upwards Check the readings provided in the relevant table A NEUTRAL 312 319 B 1st 725 739 C 2nd 1 31 1 34 ...

Page 375: ... to release the saddle lock remove the saddle Release the elastic strap 3 holding the battery first remove the BLACK or BLUE negative cable then the RED positive cable when reassembling first connect the RED positive cable then the BLACK or BLUE negative cable remove the battery 2 from its housing Check using a voltmeter that battery voltage is not less than 12 5 V If it is not so the battery need...

Page 376: ...a doctor Eyes Flush with water for no less than 15 minutes and get prompt medi cal attention If the battery is left unused it has to be in any case recharged with slow cycle 12V 14Ah battery 1 4A for 10 hours at least eve ry 3 weeks Batteries produce explosive gas ventilate when charging or using indoors When using a battery charger always connect the battery before turning on the charger This pro...

Page 377: ... horizontal line at the height of headlight centre and a vertical one in line with vehicle longitudinal axis If possible execute this operation in a shaded place When the low beam is on the upper edge between dark and lit zone should be at 9 10th of headlight centre from ground Beam height can be adjusted as follows pull out the front fairing 1 to remove it loosen the two screws 2 work adjuster sc...

Page 378: ...t the front fairing 1 to remove it loosen the three screws 2 and remove the headlamp 3 detach connector 4 from the bulb slide off the rubber gaiter 5 release the bulb holder clips 6 and take 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 ...

Page 379: ...00 H2051 02 2010 ELECTRICAL SYSTEM To replace the parking light bulb 8 extract it from the inside cover After replacement reassemble any removed parts making sure to set the centre of side screws 2 at the notch C on the support ...

Page 380: ...tor 3 Once the tail light has been replaced reverse the above procedure to reas semble Be careful not to overtighten the screws Number plate bulb replacement Loosen screw 1 and remove the number plate bulb 2 from the mudguard 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 reasse...

Page 381: ... been replaced reverse the removal procedure to reas semble Rear turning indicator removal Remove the tail light as described in the relevant paragraph Detach the rubber gaiter 1 and extract the right and left turning indicator cables with their connectors Disconnect the LH 2 and RH 3 connectors Loosen the screws 4 using an 8 mm Allen wrench on the outside and a 10 mm wrench on the inside and then...

Page 382: ...headlamp cover and headlamp as described in the relevant para graph Disconnect connector 1 left turning indicator connector 2 and right turning indicator Loosen the screws 3 using an 8 mm Allen wrench on the outside and a 10 mm wrench on the inside and then remove the turning indicators 4 ...

Page 383: ...ber gaiter 1 and extract the turning indicator and number plate cables Disconnect the two connectors 2 Use a 4 mm Allen wrench on the outside and an 8 mm ring wrench on the inside to loosen the screw 3 remove the tail light 4 and extract the bulb 5 together with its bulb holder Once the bulb has been replaced reverse the above procedure to reassem ble ...

Page 384: ...ht cables 2 and disconnect them Loosen the two screws 3 using an 8 mm Allen wrench and remove the number plate holder 4 together with the turning indicators Rear mudguard removal Remove the tail light as described in the relevant paragraph Detach the rubber gaiter 1 extract the turning indicator tail light and number plate light cables 2 and disconnect them Loosen the four screws 3 using an 8 mm A...

Page 385: ...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 386: ...040 H01041 B Bk Br Y Sb Br Part N 8000 H2051 02 2010 ELECTRICAL SYSTEM Right hand switch 1 Engine start button 2 Engine start stop switch Colour coding key B Blue Br Brown Br Bk Brown Black Y Sb Yellow Sky blue ...

Page 387: ...heath marked P fuel pump HT coil lambda sensor heater injector Fuse 23A FM 15A cable sheath marked M 12V depending on ignition switch system voltage parking lights Fuse 23B FDC 20A cable sheath marked DC electric fan rear stop light high beam low beam turning indicators horn instrument panel power supply instrument functions display SEMICONDUCTOR PARTS Be careful to never drop parts that incorpora...

Page 388: ...pect its cover for damage COUPLERS When working with lock type couplers make sure to release the lock befo re disconnecting and push coupler fully in when connecting it When disconnecting the connector make sure to grab connector body and do not pull on the wires Check coupler terminals to ensure they are not loose or bent Check terminals for signs of corrosion or dirt ...

Page 389: ...select instrument functions and reset functions use the SCROLL button A Available functions are listed below in the order they appear when selec ting them 1 SPEED ODO 2 SPEED H 3 SPEED CLOCK 4 SPEED TRIP 1 5 SPEED STP 1 6 SPEED AVS 1 7 SPEED MAX SPEED 8 SPEED TRIP 2 9 SPEED TRP 2 CLOCK 10 SPEED RPM numerical value Note The RPM function seen on the vertical bar indicator is ALWAYS active Functions ...

Page 390: ...y will then go back to the standard function shown in Fig 1 Note After the previously described operation the ODO setting will be converted and all other data reset the H Counter is unchanged 2 SPEED H RPM figure 2 SPEED speed maximum value 299 kmh or 299mph H shows the engine running hours data are saved to permanent memory every 10 minutes Maximum value 9999 59 RPM engine r p m shown on the vert...

Page 391: ...0 to 23 59 59 data will be lost after disconnecting the battery To activate the function STP 1 push the SCROLL button A and hold for more than 3 seconds 1st step activate function 2nd step stop counters 3rd step reset STP 1 TRIP 1 and AVS 1 data 4th step activate function 5th step stop counters and so on NOTE STP 1 data TRIP 1 data AVS 1 RPM engine r p m shown on the vertical bar indicator see fig...

Page 392: ...r more than 3 se conds RPM engine r p m shown on the vertical bar indicator 9 TRP 2 CLOCK RPM figure 9 TRIP 2 distance maximum value 999 9 km miles data will be lost after disconnecting the battery To reset TRIP 2 push the SCROLL button A and hold for more than 3 se conds CLOCK Clock reading from 0 00 to 23 59 59 data will be lost after di sconnecting the battery To reset the clock push the knob S...

Page 393: ...ulator 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 charge...

Page 394: ...YSTEM 1 Horn 2 Voltage regulator 3 Electronic control unit 4 Main wiring harness 5 Rear wiring harness Turning indicators Tail light Number plate light 6 Relay 7 Turning indicator flasher 8 Fuses 9 Solenoid starter 10 Rollover sensor SMS Wiring ...

Page 395: ...der plate under the saddle 1 Solenoid starter 2 Rollover sensor 3 Relay Injector Lambda Sensor Fuel Pump Coil 4 Electric fan relay 5 Horn turning indicators stop lights low and high beam lights relay 6 Turning indicator flasher 7 Fuse 23 FP 15A cable sheath marked P fuel pump HT coil lambda sensor heater injector 8 Fuse 23A FM 15A cable sheath marked M 12V depending on ignition switch system volta...

Page 396: ... position 11 Coat voltage regulator with heat grease Securing the starter motor solenoid starter cable Connect the starter motor solenoid starter cable 12 as shown in the figure Securing the engine chassis battery ground cables 13 The engine ground to chassis and engine ground to battery cables are secured to the screw found on the right engine crankcase ...

Page 397: ...e ground cable 15 to the regulator retaining screw Electric fan connection Connect the electric fan connector 16 Injector connection Connect the connector 17 to the throttle body MAQS connector connection Connect the connector 18 as shown Engine water temperature connector Connect the engine water temperature connectors 19 to the thermostat ...

Page 398: ...nector Tighten the Lambda sensor 20 into its seat Connect the Lambda sensor connector 21 as shown Ignition switch and left hand switch connection Connect the ignition switch 22 and left hand switch 23 connec tors as shown Right hand switch connection Connect connector 24 as shown ...

Page 399: ...sensor cable connection Connect the ignition 25 and gear sensor 26 connectors as shown Rear stop connection Connect the wiring connector 27 to the rear STOP sensor Securing the handlebar wiring harness Strap wiring to handlebar with rubber clips as shown in the figure ...

Page 400: ...ct the headlamp unit to the matching connector Connect the connectors 39 to the turning indicators Connect the connector 40 to the front brake lever Connect the connector 37 to the speed sensor Cable routing Routing of steering head tube wiring Route the main wiring harness cables 1 on the left of the steering head tube into clip 2 Route the main wiring harness cables 3 on the right of the steerin...

Page 401: ...h hose 8 with clips 9 Strap the Lambda sensor cable 10 to the wiring harness with clip 11 Strap the stop micro switch cable 12 to the battery negative cable 13 with clip 14 Securing the wiring harness to the rear chassis Strap main wiring harness and light turning indicator wiring harness to the rear chassis with clips 15 route it over the rear shock absorber Securing the wiring harness to the mud...

Page 402: ... a Rear 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 INJEC TION SYSTEM and especially the electronic control unit 1 ...

Page 403: ......

Page 404: ...N 1 Part N 8000 H2051 02 2010 N ENGINE COOLING Section ...

Page 405: ...N 2 Part N 8000 H2051 02 2010 ENGINE COOLING Coolant level check N 3 Cooling circuit N 4 Engine cooling system overhaul N 5 ...

Page 406: ...n 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 depressurize the system safely Failure to follow the above instructi...

Page 407: ...ing 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 Fitting 5 Water pump 6 Breather hose 7 Radiator connecting pipe 8 Radiators to cylinder head pipe 9 Water pump to fitting pipe 10 Fitting to left hand radiator pipe 11 Fitting to right hand radiator pipe ...

Page 408: ...hten 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 sheaths des...

Page 409: ......

Page 410: ...P 1 Part N 8000 H2051 02 2010 P HYDRAULICALLY CONTROLLED CLUTCH Section ...

Page 411: ...P 2 Part N 8000 H2051 02 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 412: ...haft a to the gearbox input shaft b via the gear on the clutch housing 8 The clutch housing accommodates friction plates 9 and steel plates 10 that operate the clutch hub 11 secured to the gearbox input shaft 1 Clutch master cylinder 2 Clutch lever 3 Master cylinder to piston hose 4 Pushrod 5 Piston assembly 6 Pressure plate 7 Bleed fitting 8 Clutch housing with clutch ring gear 9 Steel plate 10 F...

Page 413: ...LY CONTROLLED CLUTCH Draining clutch fluid Remove cap A Connect a plastic hose to the bleed valve 1 and 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 414: ...g 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 415: ...stem needs bleeding Bleeding procedure is as follows NEVER use brake fluid Remove screws 1 cover 2 and rubber diaphragm Remove the rubber gaiter 3 Loosen the nipple 4 Connect a hose to a syringe and fit the other end of the hose to the fitting 5 of nipple 4 Add the fluid specified in the LUBRICANT CHART Keep adding fluid until the fluid flowing out of the hole B on the pump body looks CLEAR of air...

Page 416: ...In the event of contact with eyes rinse with abundant water Motorcycle handlebar must be turned to the right during the blee ding procedure This will keep the master cylinder reservoir higher making bleeding easier The bleeding procedure does not remove all air from the circuit any small amounts of air left in the circuit will disappear after a short period of usage this will eliminate the mushy f...

Page 417: ......

Page 418: ...Q 1 Part N 8000 H2051 02 2010 Q OPTIONAL COMPONENTS Section ...

Page 419: ...HING 1 3 800060898 SCREW TTEI M6x1 CH5 L15 1 4 800030319 WASHER D20 D6 4 THK2 5 1 5 800098910 STAND RETURN SPRING 1 6 800048802 RUBBER BLOCK 2 7 8B0096837 CHAIN SPROCKET Z 48 1 7 8A0096837 CHAIN SPROCKET Z 47 1 7 800096837 CHAIN SPROCKET Z 46 1 Pos Part No Description 1 8000A8006 CENTRE STAND ASSEMBLY 1 2 8A0078466 ROTATION BUSHING 1 3 800060898 SCREW TTEI M6x1 CH5 L15 1 4 800030319 WASHER D20 D6 ...

Page 420: ...Q 3 Part N 8000 H2051 02 2010 OPTIONAL COMPONENTS ...

Page 421: ......

Page 422: ...S 1 Part N 8000 H2051 02 2010 S FUEL INJECTION SYSTEM Section ...

Page 423: ...S 2 Part N 8000 H2051 02 2010 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM S 3 Operation Manual for DIAGNOSTIC TOOL SOFTWARE KIT for fuel injection system S 4 Fuel pump test S 6 Relay test S 7 ...

Page 424: ...ld Engine coolant temperature Atmospheric pressure in the intake manifold in current location and at current altitude Throttle opening SMS 630 Rollover Lean or rich mixture LAMBDA sensor Battery voltage Sensor power supply unit Gear shift position Fuel injection pulse width Ignition coil Lambda sensor heater The DIAGNOSTIC TOOL SOFTWARE KIT see page S 3 S 4 lets you test the components listed abov...

Page 425: ...t to RUN The DIAGNOSTIC TOOL SOFTWARE KIT A is composed of Diagnostic Tool Software CD ROM including User Guide PDF Operation Manual PDF User Guide hard copy Operation Manual hard copy PC cable for connection to electronic control unit ECU connector After installing the Diagnostic Tool Software according to the instructions provided in the User Guide proceed as follows remove the front fairing 1 s...

Page 426: ...old 2 WATER TEMPERATURE engine coolant temperature 3 AIR PRESSURE atmospheric pressure in current location and at current altitude 4 THROTTLE POSITION throttle opening rate 5 TILT SENSOR SMS detects rollover 6 O2 SENSOR detects lean or rich mixture 7 BATTERY SENSOR battery voltage 8 SENSOR POWER SUPPLY power supply unit feeding the sensors 9 GEAR SHIFT POSITION currently selected gear shift positi...

Page 427: ...n number VIN and engine number engine no of the motorcycle If ECU is replaced the new ECU will only report engine service hours NOTES The green neutral light ONLY turns on when the ignition key is set to ON and the right switch to RUN When the ignition key is turned to the ON position the front and rear lights and the display light up Left switch functions and the stop light can ONLY be selected w...

Page 428: ...Correct value is as follows 1 3 KOhm 10 at 20 C pump operation Connect contacts T5 and T2 to a power supply unit with constant 12V output and make sure that the pump runs Never keep the pump connected to the power supply unit for more than 3 seconds in a row T1 Terminal 1 Not occupied T2 Terminal 2 Pump power supply Negative terminal T3 Terminal 3 Thermistor Ground Reserve T4 Terminal 4 Thermistor...

Page 429: ...relays 1 located on the utilities holder plate A Set the meter to 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 430: ...W 1 W SPECIAL TOOLS Part N 8000 H2051 02 2010 Section ...

Page 431: ...0662 Engine jig 7 8000 A8072 Flywheel removal tool 8 8000 A1625 Dial gauge mount 10 8A00 H1387 Diagnostic CD 12 8000 39521 Valve installation removal tool 13 1519 84701 Spring hook 14 8000 39524 Clutch hub tool 15 8000 90611 Crankcase bearing puller 21 8000 83254 Crankshaft guard for flywheel removal 23 8000 H1154 ECU programming kit ...

Page 432: ...se 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 cleaning t...

Page 433: ...N 8000 H2051 02 2010 Motore Basamento Motore Manovellismo Motore Trasmissione Motore Distribuzione 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 ENGINE 8000 H1759 Engine Cylinder Head ...

Page 434: ...X 3 Part N 8000 H2051 02 2010 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES Engine Lubrication System Engine Electrical System Engine Clutch Engine Gear shift control Engine Cooling System ...

Page 435: ...TIGHTENING TORQUE FIGURES 5 CHASSIS 93909 NOTE Unless otherwise specified standard torque values for the different thread sizes are as follows M5x0 8 5 6 6 2 Nm 0 57 0 63 Kgm 4 1 4 5 ft lb M6x1 7 6 8 4 Nm 0 80 0 85 Kgm 5 8 6 1 ft lb M8x1 25 24 26 Nm 2 4 2 6 Kgm 17 3 18 8 ft lb ...

Page 436: ...X 5 Part N 8000 H2051 02 2010 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 HANDLEBAR AND CONTROLS 99669 TIGHTENING TORQUE FIGURES 5 FRONT SUSPENSION 99669 ...

Page 437: ...X 6 Part N 8000 H2051 02 2010 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 REAR SUSPENSION 99669 ...

Page 438: ...X 7 Part N 8000 H2051 02 2010 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 FAIRINGS AND MUDGUARDS 99669 TIGHTENING TORQUE FIGURES 5 ELECTRICAL SYSTEM 99669 ...

Page 439: ...X 8 Part N 8000 H2051 02 2010 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 FUEL SYSTEM 99669 TIGHTENING TORQUE FIGURES 5 WHEELS AND BRAKES 99669 ...

Page 440: ... 2010 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb 1 Nm 0 73756 ft lb TIGHTENING TORQUE FIGURES TIGHTENING TORQUE FIGURES 5 EXHAUST 99669 TIGHTENING TORQUE FIGURES 5 INSTRUMENTS 99669 TIGHTENING TORQUE FIGURES 5 COOLING SYSTEM 99669 ...

Page 441: ... 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 Steel screws o...

Page 442: ...Y 1 Part N 8000 H2051 02 2010 Y CHASSIS AND WHEELS Section ...

Page 443: ...moval Y 6 Front wheel installation Y 7 Rear wheel Y 8 Rear wheel removal Y 9 Wheel servicing Y 10 Wheel axle warpage Y 10 Axle runout over 100 mm Y 10 Wheel spokes Y 11 Wheel rim warpage Y 11 Rear chain sprocket secondary drive sprocket and chain Y 12 Tightening torque figures Y 12 Checking chain and sprockets for wear Y 13 ...

Page 444: ...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 445: ...icant 1 Steering bearings grease Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE MOUNTING BOLTS AND BRACKETS B REAR CHASSIS MOUNTING BOLTS C CHAIN GUIDE ROLLER BEARING D FOOTPEGS PINS SPRINGS E PASSENGER GRAB HANDLES ...

Page 446: ...h steel spokes Front wheel RIMS Front TE in light alloy 1 6 x21 Front SMS in light alloy 3 50 x17 TYRES Front TE 90 90x21 SMS 120 70x17 Cold tyre pressure TE Front Rider only 1 2 Kg cm2 Rider and passenger 1 5 Kg cm2 Cold tyre pressure SMS Front Rider only 1 8 Kg cm2 Rider and passenger 2 0 Kg cm2 ...

Page 447: ...screws A and the brake calliper 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 448: ...rk 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 7 ft lb SMS Fit the brake calliper on the disc assemble the calliper on its mounting plate and...

Page 449: ...gth steel spokes RIMS Rear TE in light alloy 2 15 x18 Rear SMS in light alloy 4 25 x17 TYRES Rear TE 140 80x18 SMS 150 60x17 Cold tyre pressure TE Rear Rider only 1 5 Kg cm2 Rider and passenger 1 8 Kg cm2 Cold tyre pressure SMS Rear Rider only 2 0 Kg cm2 Rider and passenger 2 2 Kg cm2 Rear wheel ...

Page 450: ... 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 outwards After removal lay...

Page 451: ...ard 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 place ...

Page 452: ...ch 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 Max ...

Page 453: ...e 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 454: ...ink Check the transmission sprocket for damage or wear When worn down like the sprocket shown in the figure it must be replaced Wheelmisalignmentcausesabnormalwear makingthemotorcycle unsafe to ride Dirt caked on sprockets and chain collected while riding on mud dy 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 s...

Page 455: ......

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