Husqvarna TR 650 STRADA 2013 Page 283 Workshop Manual Download

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X.2

TR 650 TERRA 2013 - TR 650 STRADA 2013

TIGHTENING TORQUE FIGURES

Workshop Manual Ed. 09-2012

Description of tasks

Comment

Safety

torque

Fastening of tank assembly screw on LH side

8,0

Fastening of mesh oil filter on chassis

10,0

Fastening of oil pipe clamps

3,0

Fastening of plug on union for oil drainage from chassis

24,0

Insert bushing for adjustment of swinging arm clearance on chassis seat

GREASE

Fastening oil delivery/return pipes to engine

38,0

Fastening rigid oil pipes to engine cylinder head seat

12,0

Fastening rigid oil pipes to water pump cover

12,0

Fastening of oil refuelling cap on chassis

10,0

Fastening ABS ECU to support

8,0

Fastening ABS ECU support to chassis

8,0

Fastening of ignition/starter lock

19,0

PRECOAT

Fastening of handlebar clamps

19,0

Fastening of steering upper plate nut

80,0

Fastening of handlebar clamp screws

19,0

Fastening of fork plate side screws

19,0

Fastening of brake pipe screws to pumps/callipers/ABS ECU

24,0

Tightening of bushing for adjustment of swinging arm clearance

6,0

Insert the swinging arm pin from the LH SIDE

GREASE

Fastening of swinging arm pin to chassis

120,0

Fastening of engine lower screw on chassis

38,0

Fastening of engine LH screw to chassis

38,0

Fastening of engine RH screw to chassis with spacer

38,0

Fastening of engine front clamp nuts

24,0

Fastening of engine clamp plate - tighten

56,0

Retrieve the lower clamp upper screw - retighten

56,0

Retrieve the lower clamp lower screw - retighten

56,0

Fastening of clamp on throttle body coupling

0,6

Fit fuel pipe on union and then on throttle body

GREASE

Fastening of earth cable to engine cylinder RH side

8,0

Fastening of nut for starter motor cable

6,0

Fastening of neutral sensor cable to engine RH side

0,8

Fastening of turn indicator screws

2,0

Fastening of light support to upper plate

5,0

Fastening of front fairing support bracket screws to light support

2,0

Fastening of filter box air temperature sensor

2,0

Fastening of cover to filter box base

2,0

Fastening of central front locking to filter box base

2,0

Fastening filter box to base

1,5

Fastening of filter drawer to filter box

2,0

Summary of Contents for TR 650 STRADA 2013

Page 1: ...TR 650 TERRA 2013 TR 650 STRADA 2013 Workshop Manual Ed 09 2012 Rev 01 ...

Page 2: ...ed HUSQVARNA MOTORCYCLES S R L Varese disclaims all liabilities for any errors or omissions in this manual and reserves the right to make changes to reflect on going product development Illustrations in the manual may differ from actual components No reproduction in full or in part without written authorisation 1st edition 09 2012 Rev 01 ...

Page 3: ... 35 kW ABS ZKH0H11F DV000001 TR 650 TERRA 2013 TR 650 STRADA 2013 H11657 1 Workshop Manual Ed 09 2012 FOREWORD TABLE OF CONTENTS 1st edition 09 2012 Rev 01 Printed in Italy MODELS COVERED from serial number onwards Copyright by HUSQVARNA MOTORCYCLES S R L BMW Group Technical Service Via Nino Bixio 8 21024 Varese Italy tel 39 0332 75 61 11 tel 39 0332 756 558 www husqvarna motorcycles com Workshop ...

Page 4: ...photographs are provided next to the text Notes with special significance are identified as follows throughout the manual Accident prevention rules for operator and persons working nearby Damage to vehicle and or its components may result from incompliance with relevant instructions Additional information concerning the operation covered in the text Useful tips To prevent problems and ensure effec...

Page 5: ...ntents a Important notices b General information A Maintenance B Troubleshooting C Settings and adjustments D General procedures E Engine settings and adjustments F General engine procedures F1 Cylinder head removal disassembly F2 Crankcase disassembly F3 Engine torque figures F4 Engine parts wear limits F5 Front suspension I Rear suspension J Brakes L Electrical system M Engine cooling N Tighteni...

Page 6: ......

Page 7: ...b 1 TR 650 TERRA 2013 TR 650 STRADA 2013 b Workshop Manual Ed 09 2012 IMPORTANT NOTICES Section ...

Page 8: ... environment Keep out of reach of children Do not tilt the vehicle excessively since this may cause fuel to leak Engine In some cases coolant may become inflammable and if burnt produce invisible flames which cause burns Do not spill coolant onto hot components like the engine or exhaust pipe etc since it may ignite During maintenance work wear latex gloves Never leave the coolant in open containe...

Page 9: ... at the end of its service life take the battery to the special authorised recycling centres in accordance with the legal requirements in force in the country where the vehicle will be used Keep out of reach of children TR 650 TERRA and TR 650 STRADA models are STREET LEGAL motorcycles they are guaranteed exempt from functional defects and covered with legal guarantee as far as the STANDARD CON FI...

Page 10: ... the reassembly make sure that the bearings turn freely without obstruction or without getting stuck otherwise replace them Always replace the seals the sealing rings the split pins the screws with damaged thread and the self locking nuts with new parts Use genuine HUSQVARNA parts and the recommended lubricant brands At the end of a repair or periodic maintenance test the vehicle before delivering...

Page 11: ...A 1 TR 650 TERRA 2013 TR 650 STRADA 2013 A Workshop Manual Ed 09 2012 GENERAL INFORMATION Section ...

Page 12: ...3 Ignition A 3 Fuel system A 3 Primary drive A 3 Clutch A 3 Transmission A 3 Transmission ratio A 3 Secondary drive A 3 Final ratios A 4 Chassis A 4 Front suspension A 4 Rear suspension A 4 Front brake A 4 Rear brake A 4 Wheels A 4 Tyres A 4 Table for lubrication supplies A 5 Electrical components location A 5 Dimensions weight capacity A 6 ...

Page 13: ...sump with tank integrated in the chassis and cartridge oil filter Ignition Electronic with adjustable advance digital control Spark plug type NGK MAR9A J G06 Spark plug electrode gap 0 024 in 0 004 in 0 6 mm 0 1 mm Fuel system Electronic injection feed Primary drive Drive gear on crankshaft Z 37 Driven gear on clutch housing Z 72 Transmission ratio 1 946 Clutch Multidisc in oil bath with mechanica...

Page 14: ...wave disc with hydraulic control and floating calliper Wheels TR 650 STRADA Front in light alloy 2 5 x19 Rear in light alloy 3 x17 TR 650 TERRA Front with spokes and aluminium rim 1 85 x21 Rear with spokes and aluminium rim 3 x18 no ABS with spokes and aluminium rim 3 x17 ABS Tyres TR 650 STRADA Front 110 80 R19 M C 59 V Rear 140 80 R17 M C 59 V Cold tyre pressure Rider only Front 2 2 kg cm2 31 29...

Page 15: ...nic control unit on rear chassis under saddle Spark plug on cylinder head Starter motor in front of cylinder block Solenoid starter on rear chassis under saddle Potentiometer on throttle body Voltage regulator on right hand side of engine Neutral position sensor on right hand side of engine The electrical system includes the following elements 12V 10Ah battery in the central part Turning indicator...

Page 16: ...RRA 34 449 in 875 mm no ABS 18 34 055 in 865 mm ABS 17 Minimum height off ground STRADA 9 843 in 250 mm Minimum height off ground TERRA 10 472 in mm 266 no ABS 18 10 118 in 257 mm ABS 17 Weight without fuel STRADA 390 218 lb 177 kg Weight without fuel TERRA 383 604 174 kg Fuel tank capacity including reserve 3 08 Imp Gall 3 698 U S Gall l 14 Fuel reserve approx 0 55 Imp Gall 0 66 U S Gall 2 5 l Co...

Page 17: ...STRADA 2013 B Workshop Manual Ed 09 2012 MAINTENANCE Section All tightening indicated with the letter S Safety in section X Tightening Torques must be checked at each service or whenever other maintenance repair work is carried out ...

Page 18: ...THE FIRST 1 000 Km EVERY 10 000 Km EVERY 20 000 Km EVERY 30 000 Km EVERY 40 000 Km Check engine oil level C S S S S EVERY 1 000 Km Replace engine oil together with oil filter clean magnetic plug S S S S S EVERY 10 000 Km or ONCE A YEAR Check adjust valve play C R C R C R C R Replace spark plugs S S EVERY 20 000 Km Oil filter on oil return pipe from chassis P S P S Replace coolant EVERY 2 YEARS Che...

Page 19: ...C R C R C R C R Transmission cables and controls C R L C R L C R L C R L C R L Steering bearings and steering clearance C R C R C R C R Emptying the intake silencer hose C P C P C P C P Brake discs C S C S C S C S Brake pad wear C S C S C S C S Front fork oil change S S General vehicle operation C C C C C Braking systems check pipes C R C R C R C R C R Cooling system check level C S C S Lights war...

Page 20: ......

Page 21: ...C 1 TR 650 TERRA 2013 TR 650 STRADA 2013 C Manuale d officina Ed 09 2012 TROUBLESHOOTING Section ...

Page 22: ...plypipes fuelpump fuel pressure sensor and injectors Valve clearance below specification Adjust valve clearance according to speci fication Valve timing incorrect Adjust position of camshaft gears Ignition coil or ignition cable defective Check replace Ignition unit defective ignition timing incor rect Check replace crank position trigger and ECU Cylinder gasket defective Exchange cylinder head ga...

Page 23: ...aft gears Ignition coil supplies insufficient ignition voltage Check replace ignition coil Ignition unit defective ignition timing incor rect Check replace crank position trigger and ECU Valves leaking Exchange valves rework valve seats Clutch slipping See remedies clutch is slipping Fuel pressure too low Check fuel pressure sensor fuel pump and fuel supply Air filter dirty Exchange Exhaust system...

Page 24: ...ange cylinder head gasket Valve stem seals leaking Exchange valve stem seals Oil diluted with fuel Piston rings and or cylinder bore worn Exchange piston rings and or cylinder Oil diluted with fuel motocycle is only used in short distances cold engine Usemotorcycleatlongdistancesinbetween Engine vibrates Engine fixation into frame loose Tighten engine fixation Bearing or bearing seat worn Replace ...

Page 25: ...uale d officina Ed 09 2012 TROUBLESHOOTING Trouble Possible causes Remedy High engine oil pressure Pressureregulatingpistonblocked bypass valve stuck in closed position Check replace pressure regulating piston Oil circuit blocked Clean oil ducts ...

Page 26: ...piston pin worn Replace piston pin bore or piston pin Piston rings broken or ring grooves worn Replace piston rings broken or ring grooves The noise seems to come from the crankshaft countershaft or crankcase Bearings of crankshaft or conrods worn Replace the crankshaft Worn needle bushing and or balancer shaft bearings and or balancing connecting rod Replace the balancer shaft Noise seem to come ...

Page 27: ...ever Function of index lever or index spring imperfect Check index lever and index spring and exchange if necessary Adjustment of gearshift pawl incorrect Check and adjust pawl wich spring ex change if necessary Engagement teeth and or windows of gear box gears badly worn Exchange gears Gearshift forks are worn or bent Exchange gearshift forks Gearbox gears are worn or damaged Exchange gearshift g...

Page 28: ...n fork legs Remove excess oil Fork oil viscosity too high Change Overinflated tyres Deflate Improperly set rear shock absorber Adjust Damping is too soft Insufficient oil in fork legs Top up Fork oil viscosity too low Change Weak fork springs Replace Weak rear shock absorber spring Replace Improperly set rear shock absorber Adjust Front rear wheel shakes Bent wheel rim Replace Worn wheel hub beari...

Page 29: ...harge Cables running to voltage regulator im properly connected or shorted Connect correctly or replace Voltage regulator faulty Replace Faulty generator Replace Generator overcharges battery Voltage regulator faulty Replace Battery does not hold charge Battery terminals dirty Clean Faulty generator Replace Faulty battery Replace Starter motor does not start or slips Battery is flat Charge Control...

Page 30: ......

Page 31: ...D 1 TR 650 TERRA 2013 TR 650 STRADA 2013 D Workshop Manual Ed 09 2012 SETTINGS AND ADJUSTMENTS Section ...

Page 32: ...Clutch free play adjustment D 7 Rear brake pedal free play adjustment D 8 Rear brake fluid level check D 8 Oil level check D 9 Engine oil replacement and cartridge filter replacement D 9 Replacement of cartridge filter D 10 Filling D 11 Coolant level check D 11 Coolant replacement D 12 Air filter check D 13 Chain tension adjustment D 14 Lubricating the chain D 14 Suspension D 15 Shock absorber spr...

Page 33: ... saddle proceed as follows Insert the key in the lock 1 positioned in the rear part of the motorcycle turn the key clockwise to release the saddle 2 and then lift it and pull it out towards the rear releasing it from the front fastener To fit the saddle back on fasten it at the front and then press the rear until the fastening Click is heard ...

Page 34: ...w the four screws 1 that fasten the cover 2 and remove it Side panel removal Remove the saddle as described in the relevant paragraph Remove the upper cover as described in the relevant paragraph Unscrew the five screws 1 and remove the left hand side panel 2 from its fittings Repeat to remove the right hand side panel When refitting first insert the rear and then the front fittings ...

Page 35: ...t in an unsafe riding condition When throttle control cables 4 are replaced adjust new cables as previously explained Throttle control The throttle twistgrip 1 is located on the right hand side of the handlebar Throttle position adjustment The position of the control on the handlebar can be adjusted by loosening the two retaining screws 2 Do not forget to tighten the screws 2 after adjusting Front...

Page 36: ...e fluid onto any painted surface or lens for example lights lens Do not mix two brands of fluid Completely change the brake fluid in the brake system if you wish to switch to another fluid brand Brake fluid may cause irritation Avoid contact with skin or eyes In case of contact flush thoroughly with water and call a doctor if your eyes were exposed Clutch control The clutch control lever 1 is loca...

Page 37: ...regulate the position of the lever 1 push it outwards and then select the required position by means of the adjuster screw 2 Clutch free play adjustment Free play A must be 5 10 mm 0 196 0 39 in Move the rubber gaiter 1 regulate the adjuster screws 2 and the counter adjuster screw 3 to obtain the indicated free play after completing the operation make sure the counter adjuster screw 3 is properly ...

Page 38: ...may be air in the brake line or the brake may be defective CHECK THE BRAKING SYSTEM see Section L C to increase clearance D to decrease clearance Rear brake fluid level check The fluid level in the master cylinder tank shall never be below the minimum level 1 shown on the transparent reservoir 2 A decrease in the fluid level will let air into the system and increase the lever stroke If the brake p...

Page 39: ...il see the section Technical data Never exceed max level Engine oil replacement and cartridge filter replacement Be careful not to touch hot engine oil Drain the oil with WARM ENGINE proceed as follows Place the motorcycle on its side stand Remove the cap 1 with the dipstick Oil change must be performed in two stages Draining oil from tank Draining oil from engine Draining oil from tank Place a 2 ...

Page 40: ...ove the sprocket casing 6 Unscrew the screws 7 and remove the oil filter cover 8 Replace the filter 9 with a new one then refit the cover 8 making sure that the O ring 10 is not damaged and positioned correctly on the cover Refit the sprocket casing 6 making sure that the cable 11 of the rear stop switch is positioned correctly as in the figure and that the cable guide 12 is fastened externally on...

Page 41: ...maged replace it For the type of oil to use refer to the Technical data paragraph Coolant level check When the engine is cold check that the level of the coolant is between the MIN and MAX marks on the expansion tank 1 on the left hand side of the motorcycle If topping up is necessary do the following Do not remove the radiator cap 2 since all the liquid in the expan sion tank 1 will flow out Remo...

Page 42: ... all the coolant to flow out of the water pump drain age hole Filling Re tighten screw 2 on the water pump Remove the radiator cap 4 Pour the coolant into the radiator 5 until it is full and gradually top up as the level drops until it stays at maximum level Put the radiator cap on again and pour the coolant into the expansion tank 2 until it reaches maximum level Put the cap 1 of the expansion ta...

Page 43: ...before removing the cover Unscrew the screws 1 and remove the cover 2 together with the filter 3 remove the filter 3 and check that it is not clogged dirty replace if neces sary when refitting check that the filter 3 is correctly placed in its housing 4 Before refitting the filter check that the contact surfaces between the filter the filter box and the cover are completely clean ...

Page 44: ...ight side loosen the locking nut 3 of the wheel axle loosen the check nuts 4 on both chain tensioners turn the adjuster screws 5 to obtain the correct tension and check on both sides that the wheel centring sliders 6 are in the same position as the mark ings in the chain tensioner slider seats on the swinging arms once adjusted tighten the check nuts 4 and the wheel axle nut 3 After adjusting alwa...

Page 45: ... most requirements Before making any change and afterwards if the adjustment is not satisfactory always start from the standard suspension setting and increase or decrease the adjusting clicks one at a time Shock absorber spring preload adjustment This is easier to do if you lift the motorcycle at the centre so that the rear wheel is released Adjust the ring nut 1 using the spanner provided by tur...

Page 46: ...n the adjuster counter clockwise Vice versa to obtain a harder braking action Fork adjustment On the fork installed on this motorbike version it is not possible to perform any type of adjustment Fuel supply hose inspection and replacement Remove the saddle as described in the relevant paragraph Check fuel supply hose 1 conditions if cracked swollen kinked etc it is necessary to change it as follow...

Page 47: ...leaks from the sealing elements gaskets and to ensure that the Silent Blocks are not damaged Subsequently inspect the single components by disassembling the exhaust system Also check the tightening of the flange nuts 1 fastening the manifold to the cylinder head and the clamps 2 fastening the silencers to the manifolds as well as the tightening of the screw 3 fastening the silencer to its support ...

Page 48: ...para graphs Drain the oil from the tank on the chassis as described in the relevant paragraph Disconnect the connectors 1 and 2 from the coils tubes 3 and 4 Remove the coils tubes 3 and 4 Remove the spark plugs When refitting do not invert the coils tubes the coil with the white ring nut should be fitted on the outer part of the cylinder head and the connector with the white clamp connected to the...

Page 49: ... you place the prong A on the slot B of the intake manifold Disconnect the cylinder head from the electrical system Move the two pipes 11 of the ABS to unscrew the screw 12 then un screw the screws 13 and remove them Remove the head cover 14 at the back of the motorcycle if this is difficult remove the intake manifold 15 by unscrewing the corresponding screws without losing the corresponding gaske...

Page 50: ......

Page 51: ...E 1 TR 650 TERRA 2013 TR 650 STRADA 2013 E Workshop Manual Ed 09 2012 GENERAL PROCEDURES Section ...

Page 52: ...r turning indicators E 12 Removal of radiator guards E 13 Removal of lower tail cover E 14 Removal of tail chassis E 16 Front fairing removal E 17 Front turning indicator removal E 18 Combined dashboard removal E 19 Removal of front mudguard E 20 Removal of fuel tank E 21 Fuel pump removal E 24 Fuel pump inspection E 26 Removal of filter box E 27 Dismantling of filter box E 29 Throttle body remova...

Page 53: ...ement Loosen the nut 1 and remove the rotary type switch 2 Release the spring 3 Loosen the screw 4 and remove the stand 5 When reassembling grease the screw 4 and the stand fork and refit the bushing 6 correctly with its bearing 7 The screw 4 must be replaced at every disassembly NOTE For the correct installation of the rotatory type switch 2 refer to chapter M ...

Page 54: ...n the lock 1 positioned in the rear part of the motorcycle turn the key clockwise to release the saddle 2 and then lift it and pull it out towards the rear releasing it from the front fastener To fit the saddle back on fasten it at the front and then press the rear until the fastening Click is heard Removal of central upper cover Unscrew the four screws 1 that fasten the cover 2 and remove it ...

Page 55: ... Unscrew the five screws 1 and remove the left side panel 2 by releasing the fixing tabs Repeat to remove the right side panel When reassembling first insert the rear fixing tabs and then the front ones Removal of luggage rack Remove the saddle as described in the relevant paragraph Unscrew the screws 1 and remove the luggage rack 2 When reassembling tighten the screws to torque by placing the lon...

Page 56: ...ggage rack as described in the relevant paragraphs Unscrew the screws 1 and remove the tail 2 Removal of rear panels Remove the saddle luggage rack rear tail cover and the side panels as described in the relevant paragraphs Unscrew the upper screws 1 Unscrew the three lower screws 2 and remove the left rear panel 3 Repeat the above steps to remove the right rear panel 4 ...

Page 57: ...Workshop Manual Ed 09 2012 GENERAL PROCEDURES Removal of antitheft device compartment cover Remove the saddle the luggage rack and the rear tail cover as described in the relevant paragraphs Unscrew the two lower screws 1 and the two upper screws 2 and remove the cover 3 ...

Page 58: ...t device compartment cover as described in the relevant paragraphs Push up the end of the cable 1 and remove it from the support plate 2 Unscrew the screw 3 and remove the plate 2 from the plastic Remove the key block 4 and detach it from the cable 5 When refitting the new key block follow the same steps for removal in reverse order and make sure that the reference guide 6 in the block is correctl...

Page 59: ... lock Remove the saddle the luggage rack and the rear tail cover as described in the relevant paragraphs Removal of number plate holder Remove the saddle the luggage rack the rear tail cover and the antitheft device compartment cover as described in the relevant paragraphs Unscrew the upper screws 1 and the lower screws 2 of the rear panels 3 ...

Page 60: ...9 5 H11810 6 H11811 9 7 7 8 GENERAL PROCEDURES Workshop Manual Ed 09 2012 Disconnect the tail light connector 4 and the turning indicator connectors 5 Remove the licence plate light bulb holder 6 Unscrew the two screws 7 of the lock 8 and remove the cable 9 ...

Page 61: ...Manual Ed 09 2012 GENERAL PROCEDURES Pull the two rear panels 3 apart so that you can access the screws 10 Unscrew the screws 10 of the number plate holder 11 and remove it along with the key block tail light and turning indicators Remove the various parts by unscrewing the relevant screws ...

Page 62: ...ector 2 and remove the tail light 3 Removal of rear turning indicators Remove the saddle the luggage rack the rear tail cover and the antitheft device compartment cover as described in the relevant paragraphs Disconnect the two connectors 1 Unscrew the screws 2 and remove the turning indicators 3 During the reassembly of the turning indicators make sure that the water discharge hole 4 faces downwa...

Page 63: ...anels as described in the relevant paragraph Unscrew the screws 1 Put the guard 2 out and release it from the fittings top fitting with clip 3 bottom fitting with rubber ring 4 Use spray grease to make removal and reassembly easier Retrieve the upper clip When reassembling first insert the bottom pin 5 in the rubber ring 4 then the upper clip 3 and finally the screws 1 ...

Page 64: ...artment cover the side panels and the rear panels as described in the relevant paragraphs Remove the battery 1 as described in the relevant paragraph Disconnect the tail light connector 2 and the turning indicator connectors 3 Unscrew the screws 4 that secure the ECU 5 Remove the starter relay 6 the relays 7 the fuse box 8 and the diagnosis socket 9 from their supports Free the lower cover from th...

Page 65: ...2013 TR 650 STRADA 2013 H11827 10 H11828 11 H11829 12 Workshop Manual Ed 09 2012 GENERAL PROCEDURES Unscrew the two front screws 10 in the battery compartment and the two rear screws 11 and then remove the lower cover 12 ...

Page 66: ...in the relevant paragraphs Unfasten the two clips 1 of the shock absorber protection 2 Unscrew the screw 3 fastening the rear brake fluid tank 4 Move the cable harness with the electrical components in the inner part of the chassis and place them on the rear wheel Unscrew the four screws 5 and slide the chassis out from the rear 6 When reassembling make sure that you put the cable harness back in ...

Page 67: ...E 17 TR 650 TERRA 2013 TR 650 STRADA 2013 H11835 1 1 1 1 H11836 2 Workshop Manual Ed 09 2012 GENERAL PROCEDURES Front fairing removal Unscrew the screws 1 and remove the front fairing 2 ...

Page 68: ...Disconnect the left turning indicator connector 3 Unscrew the screw 4 and remove the entire left turning indicator 5 Retrieve the nut after unscrewing the screw 4 Repeat the above steps to remove the right turning indicator During the reassembly of the turning indicators make sure that the water discharge hole 6 faces downwards and that the connector of the right hand turning indicator is connecte...

Page 69: ...scribed in the relevant paragraph Remove the clips 1 and raise the dashboard 2 Disconnect the connector 3 and remove the dashboard 2 During the reassembly insert the pins in the special rubbers and lock the dashboard with the special retaining clips After the replacement of the dashboard it is necessary to connect the diagnostic tool to the vehicle and follow the wizard ...

Page 70: ...TRADA version Unscrew the two screws 1 and release the front brake hose 2 from the cable ring Unscrew the screws 3 on both sides and remove the mudguard 4 TERRA version Unscrew screws 8 and screws 9 and then remove the front mudguard 10 To disassemble the mudguard 10 unscrew the screws 11 Removal of upper pushrod ON STRADA VERSION Unscrew screws 5 and screws 6 and then remove the pushrod 7 ...

Page 71: ...saddle side panels and rear panels the battery silencers and the central exhaust manifold While disassembling the tank do not bend force or pull the cable harness too hard Unscrew the screw 1 and remove the rear brake oil tank Unscrew the screw 2 on the right side of the tank Unscrew the two screws 3 on the battery compartment Disconnect the breather hose 4 ...

Page 72: ...e connector 7 from the fuel pump Unscrew the two screws 8 on both sides that secure the upper part of the rear chassis and loosen the lower screws 9 Lower the rear chassis with the tank and place it with a support on the rear wheel and then unscrew the lower screws 9 When lowering the chassis the tank interferes with the filter box and the fuel delivery pipe make sure you do not break the pipe fit...

Page 73: ... 2012 GENERAL PROCEDURES Remove the central part of the cable harness 10 from the chassis Turn the chassis to the right and remove the tank 11 Follow the same steps in reverse order to reassemble the tank and make sure you put the cable harness back in the same position it was before ...

Page 74: ...because the fuel will leak out we recommend emptying the tank by drawing the fuel through suction using a special tool Fuel vapours are extremely harmful Make sure you do not inhale them and work in ventilated areas Disassemble the saddle as described in the relevant paragraph Disconnect the connector 1 Disconnect the fuel pipe 2 by pressing the ring nut 3 and lifting the union 4 Undo screws 5 and...

Page 75: ...e the pump 7 from the tank Check the seal 8 for wear change it if dry or damaged When reassembling the pump align the tab 9 located under the connec tor with the seat 10 of the ring nut and the seat 11 of the ring nut with the bump 12 on the tank Tighten the screws 5 to torque and reconnect the union 4 and the con nector 1 ...

Page 76: ...onnect the positive pole 12V of the power supply to the pin of the red cable in the pump connector Connect the negative pole of the power supply to the negative pin in the pump connector Never keep the pump connected to the power supply unit for more than 3 seconds in a row HYDRAULIC DIAGRAM OUT REGULATOR FINE FILTER PUMP FUEL PRE FILTER ELECTRIC DIAGRAM GROUND SIGNAL GROUND FUEL SYSTEM ...

Page 77: ...ve the front panels the radiator guards the rear panels the exhaust silenc ers and the central exhaust manifold as described in the relevant paragraphs Unscrew the side screw 1 and the front screw 2 then remove the tank 3 at the rear of the motorcycle and pour the coolant in a container Disconnect the fuel pipe by pressing the ring nut 4 and lifting the union 5 ...

Page 78: ...e two upper screws 7 of the chassis and loosen the two lower screws 8 Rock the rear chassis with the fuel tank towards the rear of the motorcycle by placing a suitable support on the rear wheel so that the cable harness is not too tight Unscrew the screw 9 on the lower right hand part of the filter box Lift the filter box 10 by releasing it form the special fittings and from the throttle body ...

Page 79: ...maged re place if necessary When reassembling fit the filter box onto the throttle body until the seal element 11 is pushed all the way down To make it easier to insert use special lubricants and slightly rock the filter box Dismantling of filter box Unscrew the three screws 1 and remove the air filter 2 with its support Unscrew the screws 3 to remove the front cover 4 of the filter box ...

Page 80: ...ibed in the relevant paragraph Disconnect the injector connector 1 the throttle position sensor connector 2 and the idle speed adjustment actuator connector 3 Disconnect the throttle cable 4 Loosen the clamp 5 Remove the throttle body 6 with the fuel supply pipe NOTE The electromechanical parts have a set position If replaced they must be reassembled in exactly the same position ...

Page 81: ...TR 650 STRADA 2013 H11943 1 2 3 4 5 6 7 8 3 4 Workshop Manual Ed 09 2012 GENERAL PROCEDURES Exhaust system removal Key 1 Left silencer 2 Right silencer 3 Clamps 4 Gaskets 5 Central manifold 6 Manifold 7 Lambda sensor 8 Gasket ...

Page 82: ...URES Workshop Manual Ed 09 2012 Exhaust system removal Remove the saddle as described in the relevant paragraph Unscrew the rear support 1 on both sides Loosen the clamps 2 on both sides and remove both silencers 3 by sliding them out of the support 4 Loosen the clamp 5 and remove the central manifold 6 ...

Page 83: ...9 2012 GENERAL PROCEDURES Disconnect the Lambda sensor connector 7 Undo the nuts 8 fastening the exhaust manifold 9 to the cylinder head remove the manifold and retrieve the steel gasket 10 When reassembling fit the steel gasket 10 onto the manifold making sure that the support tabs are inserted on the pipe ...

Page 84: ...speed Clean off any dirt around spark plug base before removing the spark plug Unscrew the spark plugs using the special spanner to remove them from the cylinder head It is very useful to examine the state of the spark plug just after it has been removed from the engine since the scale deposits on the plug and the colour of the insulator provide useful indications Correct heat rating the tip of th...

Page 85: ...orn 3 Radiator removal Remove the saddle and the radiator guards as described in the relevant paragraphs Drain the coolant as indicated in the relevant paragraph Use suitable pliers to open the clamps 1 that fasten the pipes 2 and 3 that connect the radiator engine Remove the two pipes 2 and 3 from the radiator Open the clamp 4 and remove the pipe 5 that connects the expansion tank to the radiator...

Page 86: ...650 STRADA 2013 H11960 6 H11961 6 H11962 7 H11963 8 GENERAL PROCEDURES Workshop Manual Ed 09 2012 Unscrew the two upper screws 6 Cut the clamp 7 that secures the electric fan cable harness Disconnect the electric fan connector 8 ...

Page 87: ...remove it from its special support 10 When reassembling make sure that the support 10 is correctly inserted in the retaining pin 11 Removal of electric fan Remove the left radiator guard as described in the relevant paragraph Cut the clamp 1 and remove the cable harness Disconnect the connector 2 Unscrew the three screws 3 by locking the nut 4 on the other side Remove the electric fan ...

Page 88: ...E 38 TR 650 TERRA 2013 TR 650 STRADA 2013 H11969 1 2 GENERAL PROCEDURES Workshop Manual Ed 09 2012 Gearbox lever removal Loosen the screw 1 and remove the lever 2 ...

Page 89: ... following components in order as described in the relevant para graphs sections exhaust fuel tank filter box throttle body sprocket casing voltage regulator Remove the voltage regulator support plate 1 by unscrewing the screws 2 Disconnect the connectors 3 and remove the plate 1 with the horn Disconnect the coolant temperature sensor connector 4 ...

Page 90: ...H11976 10 12 11 GENERAL PROCEDURES Workshop Manual Ed 09 2012 Unscrew the screw 5 and disconnect the ground cable 6 Remove clutch cable 7 Unfasten the nut 8 of the starter motor power supply cable 9 Remove the clip 10 and remove the master cylinder 11 from the brake lever 12 ...

Page 91: ...GENERAL PROCEDURES Unfasten the nut 13 and remove the chain tensioner slider 14 Slightly ease the pin 15 in order to release the left slider 16 Move the wheel towards the engine to remove the chain 17 from the sprocket Remove the screw 26 Remove the connection cable 27 Place a hoister under the engine and raise slightly ...

Page 92: ... lower screws 21 that fasten the engine to the chassis Remove the swinging arm pin 22 Unscrew the two upper screws 23 that fasten the engine to the chassis When reassembling align the spacer 24 with the right upper screw Lower the hoister keeping the engine 25 balanced and then remove the engine from the front Reassembly of engine Reassemble by following the steps in reverse order and make sure yo...

Page 93: ...F 1 TR 650 TERRA 2013 TR 650 STRADA 2013 Workshop Manual Ed 09 2012 ENGINE SETTINGS AND ADJUSTMENTS F Section Refer to chapter F4 for all engine tightening torques ...

Page 94: ...ance check F 3 Valve clearance measurement F 3 PAD REPLACEMENT F 4 Locking the crankshaft F 4 Chain tensioner disassembly F 5 Chain guide disassembly F 5 Camshaft removal F 6 Pad replacement F 6 Camshaft assembly F 6 Chain tensioner installation F 7 Chain guide installation F 7 Removal of engine block screw F 7 TIMING CHECK F 8 ENGINE PHASING F 9 ...

Page 95: ...face upwards In this position both cams of the intake and exhaust camshafts must face upwards and be at the same angle relative to the upper face of the head Valve clearance measurement Measure valve clearance using a feeler between the cam and valve bucket both for the intake 4 and exhaust 5 cams Note down the measurements on a measurement sheet Technical specifications Intake valve clearance wit...

Page 96: ...NT Bring the to the top dead centre as described in the previous paragraph and lock the crankshaft Locking the crankshaft Remove the screw 1 with the sealing ring Check that the notch on the crankshaft is visible through the hole Fully screw down the retaining screw 2 manually the screw must perfectly engage in the notch of the crankshaft ...

Page 97: ...11490 H11491 1 2 3 H11492 1 2 Workshop Manual Ed 09 2012 ENGINE SETTINGS AND ADJUSTMENTS Chain tensioner disassembly Remove the screw 1 with the sealing ring 2 and chain tensioner 3 Chain guide disassembly Remove the screws 1 and chain guide 2 ...

Page 98: ... the valve bucket 1 According to the measurement of the valve clearance replace the pads with those of a size appropriate to restore the correct valve clearance Replace adjustment pad 2 with one having a thickness adequate to restore the correct value making sure it is firmly seated in the seat Install the corresponding valve buckets as marked Camshaft assembly Install the chain slider 1 making su...

Page 99: ...ADJUSTMENTS Chain tensioner installation Insert the chain tensioner 1 and tighten the screw 2 replacing the gaskets 3 Chain guide installation Clean the threading and screws Install the chain guide 1 and tighten the screws 2 Removal of engine block screw Remove the locking screw 1 and re tighten the screw 2 to torque replac ing the gasket ...

Page 100: ...3 located on the camshaft gears must be coplanar with the sealing surface Make sure the notch on the crankshaft is visible through the hole marks 3 coplanar to the surface and notch 4 visible indicate a correct timing If the notch cannot be seen through the hole carefully turn the engine until it can be seen through the hole then fully tighten down the retaining screw 5 manually blocking the engin...

Page 101: ...usly described Remove the chain tensioner and guide as previously described Remove the screws 1 with the washers 2 Remove the top part of the support 3 Lift the camshaft 4 from the opposite side of the distribution gears to facilitate the removal of the chain then position the camshafts 4 so that the marks dashes 5 are coplanar with the sealing surface Reassemble all parts in the reverse order com...

Page 102: ......

Page 103: ...F1 1 TR 650 TERRA 2013 TR 650 STRADA 2013 F1 Workshop Manual Ed 09 2012 GENERAL ENGINE PROCEDURES Section Refer to chapter F4 for all engine tightening torques ...

Page 104: ...ngine crankcase cover assembly F1 7 IGNITION COVER REMOVAL REFITTING F1 7 Crankshaft sensor and stator removal F1 8 Crankshaft sensor and stator installation F1 8 Mounting the ignition cover F1 9 Replacement of the gearbox output shaft oil seal F1 9 Flywheel and starter motor idle gear removal F1 10 Removal installation of the freewheel from on the flywheel F1 10 Starter motor idle gear removal in...

Page 105: ...ws 3 and cover 4 with relative sealing ring When refitting mount the screws 1 on the top part of the cover 4 and screws 3 on the bottom part Check the sealing ring condition and replace as necessary Tighten the screws at recommended torque in a crosswise sense and refit the lever 1 Remove the left engine crankcase cover Remove the lever 1 as described in the relevant paragraph Remove the water pum...

Page 106: ...r removal Remove the water pump cover the clutch cover and the left casing as de scribed in the relative chapters Remove the water pump 1 and oil seal 2 of the gearbox selector shaft as described in the relative section Replace the casing 3 and reassemble everything following steps in inverse order Gearbox selector shaft oil seal removal installation Usinganappropriatetoolcarefullyremovetheoilseal...

Page 107: ...ing the shaft 3 in place slide the lever 2 onto the shaft are release Check the lever 2 when at fill stroke to make sure that there is no interference with the cover 4 of the clutch see arrow Clutch disengagement shaft removal Remove the clutch cover as described in the relevant paragraph Remove the retaining ring 1 Extract the clutch disengagement shaft 2 by pulling it out upwards Clutch disengag...

Page 108: ...ppropriate tool The top bearing 2 must be aligned with the sealing ring seat Clutch disengagement shaft oil seal installation Lubricate the oil seal lip 1 with engine oil If the clutch disengagement shaft is installed cover the notches with adhesive tape and use an appropriate tool so that the oil seal is not damaged Install the shaft oil seal 1 using a suitable tool The open side of the sealing r...

Page 109: ...nsmission sprocket mates correctly Tighten the screws 1 replacing the sealing ring 2 Check that the broaching of the clutch disengagement shaft mates properly with the clutch centre pin Mount the screws 3 with the washers Screw in screws 1 and 3 to torque in two steps and in a cross pattern IGNITION COVER REMOVAL REFITTING Remove the screws 1 Remove the cover 2 with its gasket and be careful of th...

Page 110: ...Crankshaft sensor and stator installation Spread sealant on the cable ring 1 and insert into the cover Clean the threads of the screws 2 with oil Tighten the screws 2 to torque Clean and spread sealant on the cable ring 3 and insert into the cover Install the crankshaft sensor 4 with its support 5 and the screws 6 by tightening these last to torque The new cover has no threading as it is created b...

Page 111: ... the engine casing cover right side tightening to torque in a cross pattern Replacement of the gearbox output shaft oil seal Remove the sprocket chain as described in the relevant paragraph Use an appropriate tool to remove the oil seal 1 paying attention to avoid damaging the seat Lubricate the new oil seal lip Cover the shaft toothing 2 with an appropriate tool or adhesive tape suc cessively mou...

Page 112: ...e of approx 100 C Unscrew the nut 2 and washer 3 Remove the flywheel together with the freewheel 4 using a suitable puller Removal installation of the freewheel from on the flywheel Heat the freewheel to about 120 C Undo the screws 1 remove the flange 2 and freewheel 3 Installation Check the condition of the freewheel 3 and replace it if it is ruined Install the freewheel 3 onto the flywheel with ...

Page 113: ...an the collar and internal bearing of the freewheel gear and lubricate with engine oil Clean the cone of the crankshaft and of the flywheel Apply a thin layer of Loctite 648 on the crankshaft cone Pay attention that the freewheel bearing does not come into contact with the Loctite Fit the flywheel 1 onto the crankshaft making sure that the groove and the key are aligned and that the freewheel is s...

Page 114: ...acing outwards Insert the tapered washer 3 so that the larger diameter rests on the sprocket and that the taper side of the bushing 2 faces the washer Apply a thin layer of Loctite 243 on the retaining screw 1 Tighten the screw 1 on the shaft to torque being careful to insert the taper side of the bushing in the hole of the tapered washer STARTER MOTOR REMOVAL INSTALLATION Removal Remove the screw...

Page 115: ...OMPLETE CLUTCH Removal Remove the gearbox lever the clutch cover and secure the engine at the top dead centre as described in the relevant paragraphs Loosen the screws 1 proceeding with diametrically opposite operations then remove them with the washers 2 and the springs 3 Remove the pressure plate 4 Remove the lined plates 5 and the steel plates 6 Remove the Belleville washer 7 and coupling washe...

Page 116: ...housing 14 making sure that the bearing 15a is positioned towards the engine Fit the clutch housing 14 all the way down paying attention to the oil pump gears Fit the OR gasket 13 onto the gearbox shaft Mount the broached washer 12 onto the shaft and push into its seat Clean the tapered teeth on the primary shaft and on the clutch hub 9 and lubricate them The clutch shaft oil nozzle shall not be d...

Page 117: ...ates 6 with engine oil Insert first a lined plate 5 then a steel disc 6 and alternate layers until ending with a lined plate The plate pack contains seven lined plates and six made of steel Fit the pressure plate 4 Insert the flanged bushings 2 on the springs 3 and fit the springs on the pressure plate 4 Tighten the screws 1 to torque in a diametrically opposite order Refit the other parts that we...

Page 118: ...te with the upper side facing downwards Heat the pressure plate to approx 80 C Remove the disengagement bearing 6 using a suitable puller Clean the housing of the support Lubricate the clutch disengagement bearing with engine oil Heat the pressure plate to approx 80 C Fit the clutch disengagement bearing 6 using a suitable tool The writing on the bearing must face towards the engine visible during...

Page 119: ...to check the clearance between the rotor 10 and casing maximum allowed clearance is 0 25 mm 0 01 in Replace the pump if the clearance is greater Installation Check pin integrity 11 and 4 and replace if ruined Refit pin 11 onto pivot 8 and insert into the casing Clean the parts and lubricate the engine 10 and the piston 9 with motor oil and fit into the pin 8 making sure that the reference dot on t...

Page 120: ...o collect the oil in the filter seat and oil filter Loosen the two screws 1 and remove the oil pump cover 2 Remove the oil filter 3 Clean the filter box of residual oil Loosen the pressure control valve 4 and the unidirectional valve 5 Replace the valves and screw down all the way with Loctite 243 Refit the oil filter 3 Check the condition of the OR gasket 6 replace if ruined lubricate with motor ...

Page 121: ...ar on the shaft 6 Check the seal rings replace if necessary If replacing the sealing rings or shaft be sure to replace both in tandem Insert the sealing ring 7 into the seat of the left cover use a suitable tool Fill the gaps between the sealing rings with lubricant grease use Molycote 111 Insert the sealing ring 8 using a suitable tool until the outer lip touches the edge of the left cover Check ...

Page 122: ... the chain tensioner towards the rear of the engine 3 Remove the dual gearbox 4 from the shaft and remove the timing chain 5 Check the chain tensioner slide 3 for wear replace if worn by undoing screw 6 Insertthetimingchain 5 intotherecessandpositionitaroundthecrankshaft push towards the chain tensioner slider 3 rear of the engine Mount the dual gearbox 4 onto the crankshaft Fit the chain 5 onto t...

Page 123: ...F2 1 TR 650 TERRA 2013 TR 650 STRADA 2013 Workshop Manual Ed 09 2012 CYLINDER HEAD REMOVAL DISASSEMBLY F2 Section Refer to chapter F4 for all engine tightening torques ...

Page 124: ...sioner removal installation F2 4 Locking the crankshaft F2 4 Crankshaft locking screw removal F2 5 Camshaft removal replacement F2 5 Checking the decompression lever F2 6 Removing the decompression lever F2 6 Installing the decompression lever F2 6 Camshaft assembly F2 7 Timing chain slider replacement F2 7 Cylinder head removal installation replacement of cylinder head gasket F2 8 Valve removal F...

Page 125: ...g Do not mount coils in inverse positions The coil with the with gasket covering must be placed towards the outside that having the black gasket covering towards the inside Cylinder head cover removal installation Removal Remove the screws 1 Remove the head cover 2 with the gasket 3 Installation Clean the gasket 3 and the sealing surfaces on the cover 2 and head 3 Lubricate the gasket and the seal...

Page 126: ...r 3 into the hole Replace the sealing ring 2 and tighten the screw 1 to torque Locking the crankshaft Rotate the motor in the normal direction of rotation as indicated in the previous paragraph until the markings dashes on the gears of the camshafts are in position coplanar with the sealing surface Remove the screw 1 with the sealing ring Check that the notch on the crankshaft is visible through t...

Page 127: ...ghten the screw 2 to torque replac ing the gasket Camshaft removal replacement Remove the head cover and lock the engine at the top dead centre as de scribed in the relevant paragraphs Removal Remove the screws 1 with the washers 2 Remove the top part of the support 3 Remove the chain 4 from the gears and fix to a point safe to avoid it from falling into the engine Remove the camshafts 5 with the ...

Page 128: ... is equal to A 0 7 mm 0 03 in When activated the projection of the centrifugal weight on the base circum ference of the cam must not be less than the measurement A Replace the decompression lever if the distance is lower Removing the decompression lever Use a punch to extract the pin 1 from the weight 2 Remove the spring 3 Installing the decompression lever Insert the new spring 1 into the camshaf...

Page 129: ...hain slider replacement Remove the head cover the chain tensioner the intake camshaft and the clutch as described in the relative paragraphs Unscrew the screw 1 Remove the mobile chain tensioner slider 2 towards the top Remove the fixed slider 3 of the timing chain towards the top Check the chain sliders for wear and replace them if worn Insert the slider 2 Clean the threading Tighten the screw 1 ...

Page 130: ... DISASSEMBLY Workshop Manual Ed 09 2012 Cylinder head removal installation replacement of cylinder head gasket Remove the camshafts timing chain sliders as described in the relevant paragraphs Removal Undo screws 1 and 2 Undo screws 3 and 4 Unscrew the screw 5 Unscrew the nuts 6 Remove the cylinder head 7 ...

Page 131: ...ing chain 9 through the well Mount the cylinder head 7 while paying attention not to damage the timing chain 9 and the chain tensioner slider 10 Tighten the screws 6 in a cross pattern with a first pre tightening torque then tighten with a final specified torque Tighten the screws 1 2 3 4 and 5 without securing them Tighten the screws 1 2 3 4 and 5 at the torque specified according to sequence A t...

Page 132: ...er 8 from the cylinder head and position near their respective valve buckets Disassemble the valves 9 and place near their respective components springs valve buckets etc Refit after all necessary checks and or repairs have been made Insert the valve Fit the cylinder head to the jig No 3 Insert the bottom retainer 8 into the cylinder head Make sure that the inner lip of the oil seal 7 is not damag...

Page 133: ...F3 1 TR 650 TERRA 2013 TR 650 STRADA 2013 F3 Workshop Manual Ed 09 2012 CRANKCASE DISASSEMBLY Section Refer to chapter F4 for all engine tightening torques ...

Page 134: ...r F3 12 Gear installation F3 12 Crankshaft gear removal F3 13 Gear installation F3 13 Replacement of the countershaft bearings F3 13 GEARBOX SHAFTS REMOVAL INSTALLATION F3 14 Removal of the gear engage forks F3 14 Gearbox shafts removal F3 14 Gearbox shafts installation F3 15 Fork installation F3 15 Engagement system check F3 15 Disassembly assembly of the gearbox input shaft shaft removed F3 16 D...

Page 135: ...Press the chain tensioner forward and extract the cylinder with care making sure that the piston does not strike the engine casing Installation Insert a new gasket 1 into the stud bolts 2 Lubricate the piston rings Install the timing chain 3 through the slot on the cylinder 4 Fit the cylinder 4 onto the stud bolts 2 while paying attention to the chain tensioner slider 5 Place the piston 6 into the...

Page 136: ...tallation Visually inspect the piston rings and grooves of the piston Pay attention that the gaps between the sealing rings do not coincide with the piston pin axis Turn both the piston ring gaps 3 approx 30 with respect to each other Offset the gaps of the other piston rings 2 1 respectively 120 with respect to the upper gap of the scraper ring Lubricate the piston pin with motor oil Install the ...

Page 137: ...cking piston diameter Measure the piston diameter dimensionA transversely relative to the axis of the pin at a distance of 16mm 0 63 in above the lower edge of the piston Measurement when new Wear limit Piston diameter 99 985 0 015 mm 3 9364 0 0006 in 99 95 mm 3 935 in Replace the piston if its diameter falls out of tolerance Technical speci fications Measurement when new Wear limit 1 groove 0 03 ...

Page 138: ...rations Disassembly Remove the screws 1 Disassemble the oil filter cover 2 and the filter Disassemble the switch 3 of the neutral position Undo screws 4 and 5 When refitting correctly position the relevant housing in the screws 4 and 5 as they are of two different lengths Screws 4 45 mm 1 77 in Screws 5 75 mm 2 95 in Position the engine with left crankcase side clutch side facing upwards Tighten t...

Page 139: ...earbox forks the drum 7 the ratchet 8 the lever 9 and the spring 10 are installed properly The bearings may be damaged if the crankcase is not disassembled and assembled vertically Donotrocktheenginecrankcaseduringdisassemblyandassembly Mount the left side crankcase onto the left side casing Tighten the screws 11 and 12 to torque Screws 11 45 mm 1 77 in length Screws 12 75 mm 2 95 in length Clean ...

Page 140: ... in the relevant paragraph Removal Match the marking 1 of the countershaft and marking 2 of the crankshaft with the crankcase marking 3 First remove the crankshaft 4 followed by the countershaft 5 paying at tention to the spacer rings of the crankshaft Check piston ring wear by measuring inside diameter wear limit ø 46 8 mm 1 81 in Replace the rings if this value is exceeded ...

Page 141: ...ight side casings heat the two semi casings if needed Bearings installation If bearings are installed incorrectly lubrication may be insufficient with consequential seizure Donotinvert thebearings thebearingswiththeinnergrooveshould be mounted on the right half the smooth bearings are mounted on the left crankcase half Place the bearings 6a and 7a in the lower part taking care to align the hole in...

Page 142: ...distance from the crank arm to the outer surface of the crankcase B On the left crankcase half of the engine with an appropriate tool measure the distance from the outer surface of the casing to the contact surface of the crankshaft washer Calculate the axial clearance of the engine according to the following formula paying attention to the thickness of the crankcase gasket Crankcase gasket thickn...

Page 143: ...kcase marking 3 First remove the crankshaft 4 followed by the countershaft 5 paying at tention to the spacer rings of the crankshaft Installation Place the right crankcase half with the flywheel side facing down Oil the crankcase bearing seats Position the crankshaft washer on the right casing Insert the countershaft 5 and the crankshaft 4 in the crankcase placing them aligned with the marking 1 o...

Page 144: ...de surface of the crankcase to the internal ring of the ball bearing B distance from the bearing seat to the outside surface of the crankcase G Crankcase gasket thickness X Countershaft axial clearance A G B X Axial clearance of the countershaft must be equal to 0 1 0 3 mm 0 0039 0 0118 in If this condition is not satisfied use a spacer washer of appropriate thickness to obtain the correct clearan...

Page 145: ... crankshaft until it stops by using a suitable tool centring the pin 1 with the hole in the crankshaft When installed check that the pin 1 does not protrude from the gear Replacement of the countershaft bearings Remove the countershaft as described in the relevant paragraph Removal Remove the oil seal by extracting it from the outside section of the crankcase Heat the left crankcase half to 100 C ...

Page 146: ...hen the crankcase has cooled insert a new oil seal using an appropriate tool Repeat on the right side of the crankcase GEARBOX SHAFTS REMOVAL INSTALLATION Disassemble the crankcase as described in the relevant paragraph Removal of the gear engage forks Extract the pins 1 from the forks 2 Tip the forks 2 outwards and extract them Gearbox shafts removal Remove the input shaft assembly 3 and the outp...

Page 147: ...y attention to the proper fork and shaft coupling Install the engagement fork 5 onto the input shaft 3 Install the engagement forks 6 and 7 onto the output shafts Insert the engagement forks 5 6 and 7 into the corresponding sliding gears of the gearbox shaft Rotate the forks inwards and insert the ratchet guides into the selector drum 8 Insert the pins 1 into their seats Engagement system check Te...

Page 148: ...he cogwheel 6 Remove the retaining ring 7 Extract the washer 8 and gear 9 Re assembly During operation the gear pairs slide towards each other If just one coupling gear is replaced the load bearing capacity on gears may become significantly worse Replace the paired gears but one at a time All components must be checked before installation and replaced if neces sary Secure the gearbox input shaft 1...

Page 149: ...g 17 Re assembly During operation the gear pairs slide towards each other If just one coupling gear is replaced the load bearing ca pacity on gears may become significantly worse Replace the paired gears but one at a time All components must be checked before installation and replaced if necessary Secure the gearbox output shaft 1 in a vice with protective clamps Install the lubricated needle roll...

Page 150: ...se the ratchet 2 with the spring 1 in correspondence with the star of the selector drum Latch the spring 3 to the lever 4 Insert the spring 5 with the bushing 6 and the thrust washer 7 onto the gearbox shaft 8 Insert into the crankcase the gearbox shaft 8 placing it into the ratchet 2 Make sure that the spring 5 is properly inserted into the retainer 9 Engagement system check Test proper gearbox o...

Page 151: ...nstallation Move the ratchet 1 so that the drum 2 can be easily fit Check that the ratchet 1 is properly positioned on the drum star 2 Turn the selector drum 2 to the neutral position arrow The ratchet 1 is in the position shown in figure arrow Rotate the pins 3 towards the drum 2 with the relative forks inserting the ratchets 4 into the relative drum slots Use a plastic mallet to tap the pins 3 i...

Page 152: ...kcase half Installation Heat the engine crankcase to about 80 100 C Install the bearings 1 and 2 on the crankcase with appropriate tools mak ing sure that the closed side of the bearings faces outwards Mesh oil filter During engine overhaul we recommend cleaning the mesh oil filter A using compressed air Remove the screws 1 and the plate 2 Extract the mesh oil filter A and clean with compressed ai...

Page 153: ...ecified torque using a torque wrench An insufficiently tightened screw or nut could get damaged or come completely loose damaging the motorcycle and or injuring the rider A screw or nut tightened beyond the permitted max torque value might get damaged or break and therefore come completely loose The specified values refer to clean threads ...

Page 154: ...F4 2 TR 650 TERRA 2013 TR 650 STRADA 2013 ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 KEY A Lubricate with engine oil B Grease C Tighten manually CONVERSION TABLE 1 Nm 0 1 Kgm 1 Nm 0 73756 ft lb ...

Page 155: ...F4 3 TR 650 TERRA 2013 TR 650 STRADA 2013 H11772 A A 20 Nm 38 Nm Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 156: ...F4 4 TR 650 TERRA 2013 TR 650 STRADA 2013 H11773 A A A A A A 12 Nm 12 Nm 193 1mm 17 Nm 12 Nm Loctite 243 12 Nm Loctite 243 3 Nm Loctite 243 ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 157: ...F4 5 TR 650 TERRA 2013 TR 650 STRADA 2013 H11774 10 Nm 13 2 Nm Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 158: ...F4 6 TR 650 TERRA 2013 TR 650 STRADA 2013 H11775 10 Nm 30 Nm 16 Nm 1 20 Nm 2 60 Nm 25 Nm 30 Nm 30 Nm 22 1 mm ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 159: ...F4 7 TR 650 TERRA 2013 TR 650 STRADA 2013 H11776 10 Nm 10 Nm Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 160: ...F4 8 TR 650 TERRA 2013 TR 650 STRADA 2013 H11777 A A 12 Nm 12 Nm 12 Nm 11 Nm ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 161: ...F4 9 TR 650 TERRA 2013 TR 650 STRADA 2013 H11778 AIR BOX 4 Nm 4 Nm 10 Nm 11 Nm Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 162: ...F4 10 TR 650 TERRA 2013 TR 650 STRADA 2013 H11779 A A ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 163: ...F4 11 TR 650 TERRA 2013 TR 650 STRADA 2013 H11780 60 Nm 10 Nm 40 Nm 60 Nm 10 Nm Loctite 243 180 Nm Loctite 243 A A Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 164: ...F4 12 TR 650 TERRA 2013 TR 650 STRADA 2013 H11781 PRESSURE PUMP SCAVENGE PUMP 10 Nm 40 Nm A A 6 Nm Loctite 243 6 Nm Loctite 243 ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 165: ...F4 13 TR 650 TERRA 2013 TR 650 STRADA 2013 H11782 10 Nm A A Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 166: ...F4 14 TR 650 TERRA 2013 TR 650 STRADA 2013 H11783 A 10 Nm ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 167: ...F4 15 TR 650 TERRA 2013 TR 650 STRADA 2013 H11784 8 Nm 6 Nm 10 Nm B Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 168: ...F4 16 TR 650 TERRA 2013 TR 650 STRADA 2013 H11785 7 Nm Loctite 243 35 Nm Loctite 648 10 Nm Loctite 243 180 Nm Loctite 243 ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 169: ...F4 17 TR 650 TERRA 2013 TR 650 STRADA 2013 H11786 6 Nm Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 170: ...F4 18 TR 650 TERRA 2013 TR 650 STRADA 2013 H11787 13 Nm ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 171: ...F4 19 TR 650 TERRA 2013 TR 650 STRADA 2013 H11788 140 Nm Loctite 243 10 Nm Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

Page 172: ...F4 20 TR 650 TERRA 2013 TR 650 STRADA 2013 H11789 II I IV V III IV V III II I 40 Nm ENGINE TORQUE FIGURES Workshop Manual Ed 09 2012 ...

Page 173: ...F4 21 TR 650 TERRA 2013 TR 650 STRADA 2013 H12096 5 Nm Loctite 243 5 Nm 4 5 Nm Workshop Manual Ed 09 2012 ENGINE TORQUE FIGURES ...

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Page 175: ...F5 1 TR 650 TERRA 2013 TR 650 STRADA 2013 F5 ENGINE PARTS WEAR LIMITS Workshop Manual Ed 09 2012 Section ...

Page 176: ...EAR LIMITS Workshop Manual Ed 09 2012 Table of Contents Engine block F5 3 Cylinder head and cover F5 3 Crankshaft and bearings F5 3 Connecting rods and bearings F5 3 Piston with rings and bearings F5 3 Countershaft F5 4 Camshaft F5 4 Valve with springs F5 4 ...

Page 177: ...n Wear limit 0 10 mm 0 0039 in Crankshaft axial clearance 0 10 0 30 mm 0 0039 0 0118 in Connecting rod and bearings Connecting rod axial clearance New 0 30 0 65 mm 0 0118 0 0256 in Wear limit max 0 8 mm max 0 0315 in Radial clearance of large connecting rod eye Wear limit max 0 08 mm max 0 0031 in Diameter of small connecting rod eye New 22 015 22 025 mm 0 8667 0 8671 in Wear limit max 22 04 mm ma...

Page 178: ... 0079 0 0157 in Wear limit max 1 00 mm max 0 0394 in Gap between piston segments 2 groove New 0 20 0 40 mm 0 0079 0 0157 in Wear limit max 1 00 mm max 0 0394 in Gap between piston segments 3 groove New 0 20 0 40 mm 0 0079 0 0157 in Wear limit max 1 00 mm max 0 0394 in Countershaft Axial clearance of the countershaft 0 10 0 30 mm 0 0039 0 0118 in Camshaft Centrifugal force decompressor Centrifugal ...

Page 179: ...I 1 TR 650 TERRA 2013 TR 650 STRADA 2013 I Workshop Manual Ed 09 2012 FRONT SUSPENSION Section ...

Page 180: ...I 2 TR 650 TERRA 2013 TR 650 STRADA 2013 FRONT SUSPENSION Workshop Manual Ed 09 2012 Sommario Front end I 3 Disassembly I 4 Assembly I 6 ...

Page 181: ...R 650 STRADA 2013 H11985 1 2 2 3 2 2 4 5 6 7 8 6 7 Workshop Manual Ed 09 2012 FRONT SUSPENSION Front end Key 1 Steering nut 2 Fork leg retaining screws 3 Steering head 4 Ring nut 5 Bottom yoke 6 Bearings 7 Dust seal 8 Washer ...

Page 182: ...ng the headlamp the front mudguard as described in the relevant paragraphs Loosen the four screws 1 and move the handlebar without removing it Protect carefully the fairings and the painted parts to prevent scratches and or damages When reassembling reposition the spacers 2 with the higher part facing forward Loosen the screws 3 from both sides and remove the fork leg stems 4 ...

Page 183: ...1991 3 7 H11992 9 8 Workshop Manual Ed 09 2012 FRONT SUSPENSION Loosen the nut 5 and remove the steering head 6 Completely loosen the screws 3 and remove the cable ring 7 Loosen the ring nut 8 and remove the bottom yoke 9 with the related bearings and the dust seal ...

Page 184: ...efore fitting them on the chassis Fit the bottom yoke 1 complete with the dust seal 2 and the washer 3 Fit the upper dust seal 6 and tighten the ring nut 7 by hand Initially tighten the ring nut to 15 Nm and then loosen it Retighten the ring nut in order to annul any clearance but in a manner that permits the steering to turn freely to the right and to the left Fit the steering head 8 and tighten ...

Page 185: ...t the fork legs 10 and adjust their withdrawal in the following manner first notch GROUND version second notch ROAD version Lock them in position by tightening the lower screws 11 to torque Tighten the nut 9 to torque Tighten the upper screws 12 of the fork legs to torque Reassembleinreverseordertheothercomponentsthatwerepreviouslyremoved ...

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Page 187: ...J 1 TR 650 TERRA 2013 TR 650 STRADA 2013 J Workshop Manual Ed 09 2012 REAR SUSPENSION Section ...

Page 188: ...ion J 3 Rear shock absorber removal J 3 Lubrication points grease J 6 Servicing the rear suspension drop and drag link J 7 Removal of the chain guard J 8 Removal of the sprocket guard casing J 8 Removal of the rear swinging arm J 9 Servicing the swinging arm shaft J 11 Replacement of the chain slider J 11 ...

Page 189: ...g and terrain conditions Hydraulic damping is also adjustable using outer adjuster screws Periodically check all components for wear Fasten the vehicle in a steady position so that it cannot overturn use suitable stands and belts Rear shock absorber removal Position a lift under the lower central beam 1 of the chassis and lift the motorcycle until the rear wheel has been lifted up off the ground L...

Page 190: ...09 2012 Loosen the upper screw 5 fixing the shock absorber 4 Lift the rear wheel as much as possible in order to remove the shock absorber 4 from the lower part of the motorcycle Upon reassembly the retaining screws must be inserted from the left side and the nuts must be fixed from the right side ...

Page 191: ...A D E F Workshop Manual Ed 09 2012 REAR SUSPENSION A Wheelbase 341 1 5 mm 13 42 0 05 in B Spring in its seat 201 1 5 mm 7 91 0 05 in C Met Met travel 74 mm 2 91 in D Wheelbase 341 1 5 mm 13 42 0 05 in E Spring in its seat 198 1 5 mm 7 79 0 05 in F Met Met travel 74 mm 2 91 in ...

Page 192: ...J 6 TR 650 TERRA 2013 TR 650 STRADA 2013 H111004 H111005 REAR SUSPENSION Workshop Manual Ed 09 2012 Lubrication points grease ...

Page 193: ...check the wear of the spacer for the various components Position a lift under the lower central beam 1 of the chassis and lift the motorcycle until the rear wheel has been lifted up off the ground Loosen the nut and remove the screw 2 Fasten the vehicle in a steady position so that it cannot overturn use suitable stands and belts Loosen and remove the lower screw 4 fixing the shock absorber 5 Loos...

Page 194: ...remove the chain guard 2 withdrawing it towards the rear part Removal of the sprocket guard casing Loosen the screws 1 and remove the sprocket guard casing 2 Refit the sprocket casing 2 making sure that the cable 3 of the rear stop switch is positioned correctly as in the figure and that the cable guide 4 is fastened externally onto the bottom screw Tighten the screws 1 to torque ...

Page 195: ...round Remove the wheel and the chain guard as described in the relative para graphs Remove the clips 1 that fix the protection 2 to the swinging arm Fasten the vehicle in a steady position so that it cannot overturn use suitable stands and belts Remove the clamp 3 of the rear brake tube by loosening the relative screw 4 Remove the rear brake calliper 5 and place it to the side being careful not to...

Page 196: ...10 Manually check the wear status of the roller cages and the relative bushings turn the bushing inside the roller cage if you feel any tightness or hear noise replace them Upon reassembly carefully grease the needle cages and the piston pins using the type of grease indicated in the technical data para graph Before reassembling the swinging arm turn the clearance recovery ring nut 11 and bring it...

Page 197: ...seat for housing the swinging arm pin head position the swinging arm pin with the milled parts of the head in a vertical position so they are correctly inserted in the seat Reassembly everything proceeding in reverse order Servicing the swinging arm shaft Check shaft taper using a dial gauge Place the shaft on two identical reference blocks Turn the shaft and move the dial gauge horizontally to de...

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Page 199: ...L 1 TR 650 TERRA 2013 TR 650 STRADA 2013 L Workshop Manual Ed 09 2012 BRAKES Section ...

Page 200: ... with ABS L 10 Front braking system removal Versions with ABS L 10 Removing the front brake calliper L 10 Removing the front master cylinder L 11 Removing the rear braking system Versions with ABS L 11 Removing the rear master cylinder L 12 Removing the rear brake calliper L 13 Checking brake pads for wear replacing the pads L 14 Brake fluid replacement L 16 Fluid replacement and system bleeding L...

Page 201: ...s two independent circuits Each circuit is equipped with a brake calliper connected to a master cylinder with a fluid reservoir 1 Front brake lever 2 Front master cylinder 3 Front oil reservoir 4 Front line 5 Hand front brake calliper 6 Hand front brake disc 7 Rear brake fluid reservoir 8 Rear line 9 Rear brake calliper 10 Rear brake disc 11 Rear master cylinder 12 Rear brake control pedal ...

Page 202: ...ted to a control unit which modulates the pressure in each of the two circuits to prevent the wheels from locking up under braking ABS circuit diagram X Front master cylinder Z Front calliper Y Rear master cylinder W Rear calliper 1 Line connecting front master cylinder to ABS unit 2 Line connecting ABS unit to front brake calliper 3 Line connecting rear master cylinder to ABS unit 4 Line connecti...

Page 203: ...aster cylinder 8 Front oil reservoir 9 Front line connecting brake calliper to ABS unit 10 Hand front brake calliper 11 Hand front brake disc 12 Rear brake fluid reservoir 13 Rear line connecting master cylinder to ABS unit 14 Rear master cylinder 15 Rear brake control pedal 16 Rear brake calliper 17 Rear brake disc 18 Rear line connecting brake calliper to ABS unit ...

Page 204: ...ess wear limit mm 4 5 0 177 in Thedistortionofthediscsmustnotexceed0 15mm 0 006in themeasurement should be made with a feeler gauge and a disc installed on the rim To remove the disc from the wheel rim you need to loosen the five retaining screws Onassembly cleanallmatingsurfacesthoroughlyandtightenthescrews to the specified torque During the removal replacement of the discs replace the retaining ...

Page 205: ... components If it is necessary to replace the master cylinder 2 open the clamp 12 and detach the line 13 collecting all the fluid draining from the reservoir then undo the union 14 and disconnect the delivery line 15 When reassembling fit the rear brake line in exactly the same posi tion as before fastening with the relative clamps and the relative hose guide If the braking system has been disasse...

Page 206: ...epeat this procedure a few times until all the fluid has drained Undo the drilled bolt 8 and detach the line 9 Undo the screws 10 and remove the brake calliper 11 collecting any fluid remaining in the line Do not spill brake fluid onto any painted surface or lens for example lights lens Do not mix two brands of fluid Completely change the brake fluid in the brake system if you wish to switch to an...

Page 207: ...o absorb any spilled fluid Drain the fluid from the front braking and rear braking systems as described in the relative paragraphs Disconnect the connector 1 from the ABS unit press the tab 2 to release the connector Undo the drilled bolts 3 and disconnect the lines 4 Undo the screws 5 and remove the ABS unit 6 Fit the new ABS unit tightening the screws 5 remove the protective caps and reconnect t...

Page 208: ...unit to rear brake calliper Front braking system removal Versions with ABS To remove the front braking system the individual components of the system must be separated After separation drain the components of brake fluid as described in the paragraph Changing brake fluid Do not spill brake fluid onto any painted surface or lens for example lights lens Do not mix two brands of fluid Completely chan...

Page 209: ...e paragraph Replace all the seal washers Removing the rear braking system Versions with ABS Remove the rear chassis complete with fuel tank and the rear wheel as de scribed in the relative paragraphs To remove the rear braking system the individual components of the system must be separated After separation drain the components of brake fluid as described in the paragraph Changing brake fluid Dono...

Page 210: ...e the safety clip 1 and disconnect the master cylinder 2 from the lever 3 Loosen the screw 4 and remove the oil reservoir 5 Undo the screws 6 and detach the master cylinder 2 If it is necessary to replace the master cylinder 2 open the clamp 7 and detach the line 8 collecting all the fluid draining from the reservoir then undo the union 9 and disconnect the delivery line 10 ...

Page 211: ...speed sensor 4 Undo the threaded bolt 5 and remove the brake calliper 6 collecting any fluid remaining in the line During reassembly refit the rear brake lines in exactly the same positions as before replacing all the seal washers and fastening with the relative clamps as indicated in the paragraph Replacing a brake line and with the relative hose guide then fill the reservoir with brake fluid and...

Page 212: ...ts 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 DISASSEMBLY OF THE REAR PADS Remove the safety clip 1 Slide out pin 2 Remove the pads 3 making sure not to damage the pre load clip inside the calliper Do not use the brake pedal while removing the pads ASSEMBLY OF THE...

Page 213: ...in 2 completely Remove the brake pad 5 retrieving the clip 6 Install the new brake pads Insert the pin 2 to hold the pads in place Refit the calliper 4 tightening the screws 3 to the correct torque Insert the pin 2 completely and refit the split pin 1 Do not use the brake lever while removing the pads Acting as described above after replacing the pads it is not necessary to bleed the system just a...

Page 214: ...s or water Do not change brake fluid in the rain or with a strong wind Only use brake fluid of the specified type taken from a sealed new container Never reuse brake fluid Avoid the ingress of contaminants such as dirt water etc into the reservoir Do not keep the reservoir open without its cover longer than neces sary this would increase the risk of contamination Handle the fluid with care to avoi...

Page 215: ...n the valve 2 and release the lever 7 Repeat this procedure a few times until all the fluid has drained Fill the reservoir 6 with the new fluid Pull the lever 7 of the brake and keep it pulled so that the system remains under pressure loosen the valve 2 tighten the valve 2 always with the lever pulled then release the lever 7 Top up the fluid level 6 and repeat a few times the procedure described ...

Page 216: ... tighten the valve 2 and release the pedal 5 Repeat this procedure a few times until the oil is completely drained Fill the reservoir 4 with new liquid Press on the brake pedal 5 and hold it pressed so that the system is under pressure loosen the valve 2 tighten the valve 2 always with the pedal pressed then release the pedal Top up the fluid level 4 and repeat a few times the procedure described ...

Page 217: ...ing the bleeding procedure This will keep the master cylinder reservoir higher mak ing bleeding easier Proceed as follows Remove the master cylinder cover 1 and the relative bellow 2 Loosen the bleed screw 3 slightly Fluid level inside the reservoir shall never drop below the minimum notch during the bleeding procedure Pull the brake lever 4 slowly and check that the fluid draining from the bleed ...

Page 218: ...nuing to hold the lever then release the lever Repeat the previous step a few times until the fluid flowing through the trans parent tube contains no air bubbles Top up the fluid level in the reservoir 5 correctly If the bleeding procedure was performed correctly the lever will no longer feel spongy If not so repeat the procedure Fluid level inside the reservoir shall never drop below the minimum ...

Page 219: ... bleed valve 4 so that the fluid comes out of the hose at the beginning only air will come out then close the valve 4 Release the pedal and wait a few seconds Repeat the process until you see only fluid without bubbles coming out of the hose Tighten the bleed valve to the specified torque and check fluid level 2 in the reservoir before refitting the cap 1 If the bleeding procedure was performed co...

Page 220: ...A 2013 TR 650 STRADA 2013 H11896 D H11897 C BRAKES Workshop Manual Ed 09 2012 Periodically check the connecting hoses C and D see Scheduled Mainte nance Chart Section B if they show signs of wear or damage replace them ...

Page 221: ...M 1 TR 650 TERRA 2013 TR 650 STRADA 2013 M Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Section ...

Page 222: ...Battery charger M 19 Headlight tail light M 20 Headlight adjustment M 20 Front headlamp bulb replacement M 21 Headlight removal M 23 Turning indicator bulb replacement M 25 Tail light replacement M 25 Number plate bulb replacement M 26 Left hand switch M 27 Right hand handlebar switch M 29 Right hand switch removal M 30 Left hand switch removal M 31 Fuses M 32 General fuse 30A M 32 Auxiliary fuses...

Page 223: ...M 3 TR 650 TERRA 2013 TR 650 STRADA 2013 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Starting system M 48 Electronic ignition system M 48 Electrical connectors positioning M 49 Important M 53 ...

Page 224: ...M 4 TR 650 TERRA 2013 TR 650 STRADA 2013 ELECTRICAL SYSTEM Workshop Manual Ed 09 2012 ...

Page 225: ...9562 X9133 X9134 X9130 X9231 X9230 X9260 X9700 X9590S X9500 X9341 X9045 X9023 X9035 X9690 X9349B X9080B X9080 X9051 X9001 X9040 X9010 X9018 X9030 X9091 X9070 2 X9070 1 X9570 X9601 X9517 X9506 X9572 X9092 X9092B X9326 X9100 X9052 X9093 X9220B X9194 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Wiring diagram NON ABS Version ...

Page 226: ...93 X9052 X9100 X9326 X9092B X9092 X9572 X9506 X9517 X9601 X9570 X9070 1 X9070 2 X9091 X9030 X9018 X9010 X9040 X9001 X9051 X9080 X9080B X9349B X9553 X9060 X9141 X9910 X9800 X9900 X9552 X9550 X9201 X9157 X9238 X9131 X9562 X9133 X9134 X9130 X9231 X9230 X9260 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Wiring diagram ABS Version ...

Page 227: ... X9070 2 Left hand switch X9080 Right hand switch X9080B Clamp starter button X9091 Clutch microswitch X9092 Neutral switch X9092B Pull up gearbox in neutral X9093 Side stand switch X9100 Fuel pump X9130 Solenoid starter X9131 Starter motor X9133 Solenoid starter X9134 Solenoid starter X9141 Radiator fan X9157 Horn X9159 Exhaust valve X9190 ABS X9193 Front speed sensor X9194 Rear speed sensor X920...

Page 228: ...nsor X9572 Canister cleaning valve USA X9590S Diagnostic connector X9601 Cylinder fuel injector X9690 Lambda probe X9700 Anti theft device X9800 Radiator fan relay X9900 Main relay X9910 Fuel pump Colour key Bk Black Bl Blue Br Brown Gr Green Gy Grey R Red V Violet W White Y Yellow Bk Bl Black Blue Bk Br Black Brown Bk R Black Red Bk V Black Violet Bk W Black White Bl Bk Blue Black Bl Bk W Blue Bl...

Page 229: ...ide the right hand cover Electronic ignition coils 2 integrated with spark plug cap positioned on the cylinder head Spark plugs on the cylinder head Components on rear chassis under saddle ECU 3 Starter relay 4 with 30A fuse Diagnostics socket 5 Relay 6 Fuse box 7 Battery 8 Fuel pump 9 Voltage regulator 10 on a support on the battery Starter motor 11 on the front part of the engine Horn 12 ...

Page 230: ...ual Ed 09 2012 Throttle open position sensor 13 on throttle body Idle actuator 14 on throttle body Coolant temperature sensor 15 on RH side of cylinder head Electric fan 16 on the rear part of the radiator Headlamp 17 with H4 12V 55 60W HD twin halogen lamp and 12V 5W LL parking light bulb LED tail light 18 Turning indicators 19 12V 10W bulbs ...

Page 231: ...onnect the stator coil connector from the wiring and measure resistance with a meter 1 Measure across the terminals of the connector 2 correct value is about 0 1 1 0 If resistance is outside the specified limits replace the complete generator Generator performance 14V 400W AT EACH ENGINE OVERHAUL CLEAN FLYWHEEL ROTOR TO REMOVE ANY DEBRIS SUSPENDED IN SWIRLING OIL AND CAP TURED BY THE MAGNETS ...

Page 232: ...M 12 TR 650 TERRA 2013 TR 650 STRADA 2013 H111045 ELECTRICAL SYSTEM Workshop Manual Ed 09 2012 Neutral position sensor Positioned in the left hand side of the engine under the sprocket casing ...

Page 233: ...TR 650 TERRA 2013 TR 650 STRADA 2013 M 7 M 12a H12062 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Ignition and injection system ...

Page 234: ...re sensor a throttle position sensor and a pressure sensor on the throttle body The ignition system is composed of ECU 1 Battery 2 Starter relay 3 Fuse box 4 EFI general relay 5 Ignition 6 Transponder antenna 7 R H switch 8 Clutch lever microswitch 9 Spark plug coils 10 Engine ground terminal 11 Neutral position sensor 12 Side stand microswitch 13 Alternator 14 Voltage regulator 15 Coolant tempera...

Page 235: ...stem is composed of Battery 1 Voltage regulator 2 Alternator 3 Starter relay 4 The alternated current generated by the alternator is converted into direct cur rent by the voltage regulator The voltage regulator serves a dual purpose it provides overvoltage protection for the battery and converts alternated current into direct current ...

Page 236: ...3 000 rpm measure voltage across the positive and negative terminal of the battery using a meter the battery must be charged when performing this test If reading is outside a 14 0 14 5 V check generator and voltage regulator as described in the relevant paragraph Voltage regulator inspection With the ignition on and the battery charged 12 5 13 V start the engine if the battery voltage does not inc...

Page 237: ...TRICAL SYSTEM Workshop Manual Ed 09 2012 Electric starting system The starting system is composed of ECU 1 Battery 2 Starter relay 3 Starter motor 4 Fuse box 5 Ignition 6 Transponder antenna 7 R H switch 8 Clutch lever microswitch 9 Neutral position sensor 10 Side stand sensor 11 ...

Page 238: ...circuits during disassembly Disconnect the starter relay connector A Disconnect the starter motor and battery positive cable wires at relay end Ap ply 12 Volts to the terminals 1 and 2 on the relay and check the continuity between the terminals B M Do not apply such voltage to the relay for more than 5 seconds as it could overheat and suffer damage Use a multimeter to establish whether the winding...

Page 239: ...e primary and secondary winding with a me ter Primary winding resistance 0 87 at 20 C between terminals 1 and 3 WIRING DIAGRAM 1 PIN 1 Ground 2 PIN 2 Ground 3 PIN 3 Vbatt 12V Electronic control unit ECU Remove the saddle as described in Section E to gain access to the ECU 1 The control unit consist of a microprocessor system that controls the ignition advance according to the signals coming from t...

Page 240: ...le to carry out a standard slow charging cycle 0 5A for 8 hours for 12V 10Ah battery Quick charging is advised only in situations of extreme necessity since the life of lead elements is drastically reduced by such cycle 5A for 0 5 hours for 12V 10Ah battery Battery charger To gain access to the battery 1 remove the elastic band first remove the BLACK negative cable then the RED positive cable when...

Page 241: ...e the motorcycle and set the motorcycle perpendicular to its longitudinal axis In front of a wall or a screen positioned at a distance of 10 metres 32 8 ft draw a horizontal line corresponding to headlight centre height and a vertical line aligned 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 sho...

Page 242: ... H111061 4 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Front headlamp bulb replacement Proceed as follows to reach the headlamp bulbs Loosen the screws 1 and remove the front fairing 2 completely loosen the top headlight adjustment screw 3 loosen the two side headlight retention screws 4 ...

Page 243: ...e the light bulb 9 Headlamp bulb 9 is of the halogen type be careful when replacing it since the glass part shall not be touched with bare hands Make sure that the new bulb is of the HD type Heavy Duty To replace the parking light bulb Detach the bulb holder 10 and remove the light bulb 11 Make sure that the new bulb is of the LL type Long Life After making replacement proceed to fit back on in th...

Page 244: ... 2 H111058 3 H111059 3 H111060 H111061 4 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Headlight removal Loosen the screws 1 and remove the front fairing 2 completely loosen the top headlight adjustment screw 3 loosen the two side headlight retention screws 4 ...

Page 245: ...M 24 TR 650 TERRA 2013 TR 650 STRADA 2013 H111062 5 H12014 6 ELECTRICAL SYSTEM Workshop Manual Ed 09 2012 remove the headlight 5 by turning it downwards see illustration disconnect the connector 6 ...

Page 246: ...ment Loosen the screw 1 remove lens 2 and replace bulb 3 pushing it inside and turning it to remove it Once the bulb has been replaced reverse the above procedure to reassemble 12V 10W bulb Tail light replacement The tail light 1 is a LED light if it does not work properly it must be replaced The removal of the tail light is described in Chapter E ...

Page 247: ...b 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 reassemble 12V 5W bulb Make sure that the new bulb is of the LL type Long Life ...

Page 248: ...ch 1 High beam flashing light 2 High beam switch control Low beam switch 3 Left hand turning indicators self cancelling Right hand turning indicators self cancelling To deactivate the turning indicators press the control lever after it is returned to the centre 4 ABS switch where fitted By pressing the button for over 3 seconds the ABS antilock braking system is engaged or disengaged 5 Horn Turn S...

Page 249: ... TR 650 TERRA 2013 TR 650 STRADA 2013 H12092 MY13 H12093 MY12 ELECTRICAL SYSTEM Workshop Manual Ed 09 2012 Key AZ Light blue Gr Grey N Black Bl Blue B White G Yellow V Green A Orange R Red M Brown VI Violet ...

Page 250: ... H111072 2 1 H10947 V V BL V BL N G Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Right hand handlebar switch The right hand switch features the following controls 1 Engine start button 2 Engine KILL SWITCH Key V Green Bl Blue N Black G Yellow ...

Page 251: ...ing as described in the relevant paragraph Unscrew the screws 1 and move the support 2 to gain access to the con nectors Remove the headlight as described in the relevant paragraph Loosen the screws 3 and move the lever master cylinder Disconnect the connector 4 Unscrew the screws 5 and remove the switch 6 When reassembling put the cable harness back in the same posi tion it was before ...

Page 252: ...he front fairing as described in the relevant paragraph Unscrew the screws 1 and move the support 2 to gain access to the con nectors Remove the headlight as described in the relevant paragraph Disconnect the two connectors 3 Loosen the two screws 4 and remove the light switch 5 When reassembling put the cable harness back in the same posi tion it was before ...

Page 253: ...a spare 1 General fuse 2 Spare fuse Auxiliary fuses 3 Located at the rear of the motorcycle under the saddle Fuse 1 7 5 A Instrument panel Turning indicators Engine control Solenoid starter Diagnosis socket Fuse 2 15 A Horn Number plate light Headlight high beam and low beam Stop light Accessories socket Fuse 3 15 A Ignition Injectors Fuel pump Fuse 4 7 5 A Lambda sensor Canister washing valve Fus...

Page 254: ... that incorporate a semiconductor such as the ECU or the voltage regulator rectifier Closely follow the relevant instructions when inspecting these parts An improper procedure may lead to severe damage Relay removal Remove the saddle as described in the relevant paragraph Lift the relays 1 off their supports and disconnect them by removing the connectors ...

Page 255: ...aragraph then remove them 1 Main relay 2 Electric fan relay 3 Fuel pump relay 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 256: ...ts 2 Multifunction display see Description of multifunction display 3 Rev meter Indicates the engine rpm 4 Alarm system warning light optional RED 5 MODE button 6 SET button This displays the various functions of the multifunction display see De scription of multifunction display 7 HAZARD button When this is pressed the turning indicators warning light and warning light flash at the same time Pres...

Page 257: ...ntly when the high beam is on Neutral warning light GREEN This lights up permanently when the motorcycle is in neutral Engine diagnosis warning light ORANGE This lights up permanently when the engine ECU has diagnosed mal functioning There are two types of fault Critical fault the engine switches off and you must contact your HUSQ VARNA dealer Fault with emergency operating the engine operates wit...

Page 258: ...splays the parameter set in 5 7 This lights up in sequence from left to right as the coolant temperature increases In case of overheating the indicator lights up steady and the bar 7 flashes Clock adjustment The clock must be set when the motorcycle is stationary and the key is set to ON The clock is set to 24 hours Press the S button 1 until the word CLOCK appears on the display Press the S butto...

Page 259: ...rrently in use Press the S button once to change the unit of measurement Once you have selected the unit of measurement press the S button for more than 4 seconds to confirm the set data and go onto the next scale The following units of measurement can be set Km mp the display will show the speed in km h or mp h the total distance covered in km or mp the partial TRIP distance covered in km or mp T...

Page 260: ...or more than 4 seconds to reset and start a new partial count of the kilometres miles subsequently travelled When this function is set after the fuel reserve light has come on press the S button S 1 for more than 4 seconds to display fuel consumption in litres or gallons depending on the unit of measurement you have selected from when you go onto fuel reserve CON function When this function is act...

Page 261: ...ECU disconnect the battery cables Remove the saddle as described in the relevant paragraph Unscrew the two screws 1 and remove the ECU 2 Disconnect the connector 3 pressing with a screwdriver the tooth 4 and turning the locking element 5 Refit a new control unit proceeding in the reverse order To replace the part use the diagnostic tool and follow the guided procedure ...

Page 262: ...STRADA H111097 3 TERRA H111099 4 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Ignition removal Remove the front fairing as described in the relevant paragraph Unscrew the screw 1 to remove the connector bracket 2 Unscrew the screws 3 under the mudguard and the upper screw 4 ...

Page 263: ...tor 8 and the alarm system antenna cable as before using the two ties 6 and the rubber clamp 7 Remove the ignition switch connector 9 and remove it from the headlight support Unscrew the two screws 10 and remove the ignition switch 11 Reverse the removal procedure to reassemble making sure you put the cables back in the same position they were before Reassemble a new ignition switch by following t...

Page 264: ...H12004 1 H12005 2 2 2 H12006 3 4 5 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Rear stop microswitch replacement Unscrew the screw 1 Unscrew the three screws 2 and remove the plastic cover 3 Disconnect connector 4 and remove the microswitch 5 ...

Page 265: ...orkshop Manual Ed 09 2012 Clutch microswitch replacement Remove the headlight as described in the relevant paragraph Open the rubber clamps 1 Disconnect the connector 2 Unscrew the microswitch 3 and replace it When reassembling put the cable harness back in the same posi tion it was before ...

Page 266: ...the nut 1 Disconnect the microswitch 2 Disconnect the connector 3 Fit a new microswitch and tighten the nut to torque 1 When reassembling put the cable harness back in the same posi tion it was before Speed sensor replacement Rear wheel ABS Remove the fuel tank as described in the relevant paragraph Loosen the screw 1 Remove the fastening from the harness 2 Disconnect the connector 3 Replace the s...

Page 267: ...stand Disconnect the connector 3 Replace the switch 2 during the reassembly insert the switch tab 4 in the hole 5 of the stand and the upper part of the switch in the centring pin 6 Water temperature sensor replacement Remove the expansion tank and drain the cooling system as described in the relevant paragraph Disconnect the connector 1 and remove it Loosen the sensor 2 replace and tighten it to ...

Page 268: ...DA 2 2 H12074 3 4 Workshop Manual Ed 09 2012 ELECTRICAL SYSTEM Replacement of front wheel ABS sensor Disconnect the connector 1 Free the cable harness from its fasteners 2 Unscrew the screw 3 and remove the sensor 4 Reassemble the hose as it was before and make sure it is laid correctly ...

Page 269: ...ulty voltage regulator see paragraph Voltage regulator inspection 2 defective battery see paragraph Battery Starting system If the starter motor does not start this might be a symptom of 1 faulty starter relay see paragraph Starter relay inspection 2 loose starter motor cable 3 faulty starter motor see paragraph Starter motor inspection 4 flat battery see paragraph Battery charger Electronic ignit...

Page 270: ...itioning The following connectors are located in the front underneath the headlight 1 Dashboard connector 2 R H turning indicator connector 3 Front stop microswitch connector 4 Right hand switch connector 5 Ignition switch connector 6 Left hand switch connectors 7 L H turning indicator connector 8 Clutch microswitch connector 9 Alarm system antenna connector ...

Page 271: ...he right hand side of the bike the following connectors are to be found 10 Speed sensor rear wheel ABS connector 11 Crankshaft position sensor connector 12 Voltage regulator connector 13 Engine ground screw 14 Coolant temperature sensor connector The following connectors are located to the left of the motorcycle 15 Electric fan connector ...

Page 272: ... 16 Lambda sensor connector 16A Front wheel ABS sensor connector The following connectors are located underneath the saddle 17 Fuel pump connector 18 Diagnosis connector 19 Fuses 20 Relay connectors 21 ECU connector 22 Starter relay connector The following connectors are located on the engine cylinder head 23 Coil 1 connector 24 Coil 2 connector ...

Page 273: ...Ed 09 2012 The following connectors are located on the throttle body 25 Throttle open sensor connector 26 Idle actuator connector The following connectors are located on the rear chassis 27 Tail light connector 28 Right hand turning indicator connector 29 Left hand turning indicator connector 30 Anti theft device connector ...

Page 274: ...ollowing parts from water a Rear opening of the muffler b Clutch and front brake levers handgrips handlebar switches c Air filter intake d Steering head wheel bearings 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 and the digital dashboard 2 ...

Page 275: ......

Page 276: ...N 1 TR 650 TERRA 2013 TR 650 STRADA 2013 N Workshop Manual Ed 09 2012 ENGINE COOLING Section ...

Page 277: ...N 2 TR 650 TERRA 2013 TR 650 STRADA 2013 ENGINE COOLING Workshop Manual Ed 09 2012 Sommario Coolant level check N 3 Coolant replacement N 4 Cooling circuit N 5 Servicing the engine cooling system N 6 ...

Page 278: ...n the left hand side of the motorcycle If topping up is necessary do the following Do not remove the radiator cap 2 since all the liquid in the expan sion tank 1 will flow out Remove the cap 3 and add the fluid needed to restore the level to the ex pansion tank 1 for the type of liquid to use see the section Technical data Difficulties may arise in eliminating coolant from painted surfaces If this...

Page 279: ...the coolant to flow out of the water pump drain age hole Filling Re tighten screw 3 on the water pump Remove the radiator cap 4 Pour the coolant into the radiator 5 until it is full and gradually top up as the level drops until it stays at maximum level Put the radiator cap on again and pour the coolant into the expansion tank 2 until it reaches maximum level Put the cap 1 of the expansion tank on...

Page 280: ...ling circuit The forced circulation cooling system uses a centrifugal pump located to the left of the engine crankcase and a downdraft radiator 1 Radiator cap 2 Radiator 3 Expansion tank 4 Expansion tank cap 5 Water pump 6 Intake coupling 7 Delivery coupling 8 Cooling fan 9 Expansion tank radiator connection pipe ...

Page 281: ...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 there are cracks swelling or hardening in the couplings they should be r...

Page 282: ...come damaged its thread might strip or the nut screw might fail and work itself loose Listed in the table are the tightening torque figures for the most important nuts and screws which have determined in accordance with thread diameter pitch and specific application These figures are obtained after cleaning the threads with solvent All tightening indicated with the letter S Safety must be checked ...

Page 283: ...S Tightening of bushing for adjustment of swinging arm clearance 6 0 Insert the swinging arm pin from the LH SIDE GREASE Fastening of swinging arm pin to chassis 120 0 S Fastening of engine lower screw on chassis 38 0 S Fastening of engine LH screw to chassis 38 0 S Fastening of engine RH screw to chassis with spacer 38 0 S Fastening of engine front clamp nuts 24 0 S Fastening of engine clamp plat...

Page 284: ...0 Fastening of ECU to support plate 6 0 Damping pads for fastening of ECU support plate to rear mudguard GREASE Fastening of ECU support plate to rear mudguard 2 0 Fastening of sprocket 19 0 S Screw for fastening footrest fixing plate onto support 8 0 Fastening of rear brake master cylinder 8 0 Fastening of rear stop switch cover 1 0 Fastening of stop switch support 3 0 Bushing in rear brake lever...

Page 285: ...seat 7 0 Fastening of rear wheel speed sensor 8 0 Fastening of chain casing 8 0 PRECOAT Terra Fastening of pushrod to front mudguard tail 1 5 Fastening of front fairing front mudguard lower clamp to plate 8 0 Front fastening of front fairing lower clamp to light support 2 0 Rear fastening of front fairing lower clamp to light support 2 0 Fastening of front headlight to support 5 0 Fastening of vol...

Page 286: ...ce plate light to number plate holder seat 3 0 Fastening of tail light to number plate holder seat 3 0 Fastening of radiator guards 2 0 Fastening of sides to chassis 2 0 Fastening of side connecting cover 2 0 Fastening of scoops 2 0 Fastening of tank cover 2 0 Fastening of heat protecting covers onto silencers 5 0 PRECOAT Fastening of front fairing 2 0 Fastening of luggage rack 19 0 PRECOAT S ...

Page 287: ......

Page 288: ...Y 1 TR 650 TERRA 2013 TR 650 STRADA 2013 Y Workshop Manual Ed 09 2012 CHASSIS AND WHEELS Section ...

Page 289: ...nt wheel Y 6 Front wheel Y 7 Removing the front wheel Y 8 Reassembling the front wheel Y 9 Rear wheel Y 10 Rear wheel Y 11 Removing the rear wheel procedure valid for all models Y 12 Wheel axle warpage Y 13 Axle runout over 100 mm Y 13 Wheel rim warpage Y 13 Rear chain sprocket secondary drive sprocket and chain Y 14 Checking sprocket wear Y 14 ...

Page 290: ...he chassis is a tubular steel trellis type with stainless steel removable rear small chassis In case of violent shocks or accidents if you think that the chassis might be bent or damaged proceed with an im mediate inspection and if necessary replace it Lubrication points lubricant 1 Steering bearings grease ...

Page 291: ...Y 4 TR 650 TERRA 2013 TR 650 STRADA 2013 H11723 1 C 1 C 1 B 1 B 1 B 1 B 1 B 1 C 1 C H11746 A A A CHASSIS AND WHEELS Workshop Manual Ed 09 2012 ...

Page 292: ...TRADA 2013 Workshop Manual Ed 09 2012 CHASSIS AND WHEELS Check the assemblies shown in the figure for cracks or damage If any are found replace the part A ENGINE MOUNTING SCREWS B REAR CHASSIS MOUNTING SCREWS C FOOTREST PINS SPRINGS ...

Page 293: ...Workshop Manual Ed 09 2012 Front wheel 1 Tyre 2 Rim 3 Ball beraing 4 Sealing ring 5 Internal spacer 6 Spacer 7 Wheel axle 8 Brake disc 9 Tone wheel 10 Washer 11 Tone wheel and disc retaining screw 12 Washer 13 Axle fixing nut 14 Valve For technical characteristics regarding the front wheel see section A Gen eral Information of this manual ...

Page 294: ...end 1 Tyre 2 Inner tube 3 Front wheel assy 4 Spoke 5 Nipple 6 Wheel axle 7 Sealing ring 8 Ball bearing 9 Hub 10 Bushing 11 Brake disc 12 Tone wheel and disc retaining screw ABS version 13 Tone wheel ABS version 14 Spacer 15 Washer 16 Nut 17 Washer 18 Gasket For technical characteristics regarding the front wheel see section A Gen eral Information of this manual ...

Page 295: ... the front wheel is lifted from the ground Loosen the bolts 1 holding the wheel axle 2 to the front fork mounts Hold the wheel axle head in place and simultaneously unscrew the nut 3 on the opposite side then remove the wheel axle 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 ...

Page 296: ...fully home against the L H fork leg during this operation the wheel should be turned Tighten the nut 3 on the left hand side of the fork WITHOUT locking it Now pump for a while pushing the handlebar downwards until you are sure that the fork legs are perfectly aligned Lock the screws 4 on the right hand fork leg 8 Nm 0 8 kgm 5 9 ft lb the nut 3 on the left hand side 80 Nm 8 kgm 59 005 ft lb and th...

Page 297: ...SIS AND WHEELS Workshop Manual Ed 09 2012 Rear wheel 1 Tyre 2 Rim 3 Internal spacer 4 Ball bearing 5 Retaining circlip 6 Sealing ring 7 Spacer 8 Tone wheel 9 Spacer 10 Anti vibration buffer rubber ring 11 Sprocket carrier 12 Spacer 13 Chain sprocket 14 Brake disc 15 Wheel axle 16 Valve 17 Screw 18 Screw 19 Washer 20 Nut 21 Spacer ...

Page 298: ...HASSIS AND WHEELS Rear wheel 1 Tyre 2 Air chamber 3 Rim 4 Spacer 5 Ball bearing 6 Retaining circlip 7 Sealing ring 8 Spacer 9 Spacer 10 Tone wheel 11 Anti vibration buffer rubber ring 12 Sprocket carrier 13 Spacer 14 Chain sprocket 15 Brake disc 16 Spoke 17 Nipple 18 Wheel axle 19 Sealing ring 20 Spacer 21 Screw 22 Screw 23 Screw 24 Washer 25 Nut 26 Gasket 27 Hub ...

Page 299: ...ides of the hub For reassembly follow the removal procedure in the reverse order by inserting the brake disc in the calliper Refit the chain tensioner sliders 5 correctly so that the head of the axle 3 and the washer 6 slot into the corresponding slider housings The flat part A of the chain tensioner sliders must face the chain tensioner screw Check the cush drive dampers for wear 7 if only one of...

Page 300: ...xle Standard Max limit Wheel axle less than 0 1 mm 0 2 mm 0 079 in less than 0 039 in PIN FRONT Wheel rim warpage The table below reports the allowed limits for wheel rim warpage An excessive side runout and out of round are generally caused by worn out bearings In these cases replace the bearings and the sealing rings If this does not solve the problem change the wheel rim or the wheel Standard M...

Page 301: ...ingly worn sprocket 1 Normal wear 2 Exceeding wear If the sprocket is exceedingly worn replace it after loosening the six nuts 1 that retain it to the cush drive damper Chain and sprockets must always be replaced as a set Checking sprocket wear Check the transmission sprocket for damage or wear When worn down like the sprocket shown in the figure it must be replaced Wheelmisalignmentcausesabnormal...

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