Motorhispania MH7 Naked Workshop Manual Download Page 137 | Manualshive

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149

FAULTY LIGHTS OR TURN INDICATOR SYSTEM

THE HEADLIGHT DOES NOT COME ON

.

Incorrect headlight bulb.

.

Too many electrical accessories.

.

Excessive load

.

Incorrect connection.

.

Circuit incorrectly connected to earth.

.

Faulty contacts (main switch).

.

Blown headlight bulb.

BLOWN HEADLIGHT BULB

.

Incorrect headlight bulb

.

Battery faulty

.

Headlight bulb blown

THE REAR LIGHT / BRAKE LIGHT DOES NOT COME ON

.

Blown rear light bulb / Brake light bulb.

.

Too many electrical accessories.

.

Incorrect connection.

.

Blown rear light bulb / Brake light bulb.

BLOWN REAR LIGHT BULB / BRAKE LIGHT BULB

.

Incorrect rear light/brake light bulb.

.

Battery faulty.

.

Incorrectly adjusted rear brake light switch..

.

Rear light/brake light bulb reached end of life.

THE TURN INDICATORS DO NOT COME ON

.

Faulty turn indicator switch.

.

Blown turn indicator bulb.

.

Incorrect connection.

.

Damaged or faulty wiring loom.

.

Battery faulty.

.

Fuse blown, damaged or incorrect.

THE TURN INDICATORS BLINK SLOWLY

.

Faulty turn indicator switch.

.

Incorrect turn indicator bulb.

THE TURN INDICATORS BLINK RAPIDLY

.

Incorrect turn indicator bulb.

.

Blown turn indicator bulb.

THE HORN DOES NOT SOUND

.

Horn incorrectly adjusted.

.

Horn damaged or faulty.

.

Faulty horn switch.

.

Battery faulty.

.

Fault in wiring loom.

9

TROUBLESHOOTING

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Summary of Contents for MH7 Naked

Page 1: ......

Page 2: ...USED BY QUALIFIED TECHNICAL SERVICE DEPARTMENT MECHANICS INEXPERIENCED MECHANICS OR THOSE WITHOUT THE APPROPRIATE TOOLS AND EQUIPMENT CAN NOT CARRY OUT THE SERVICE WORK DESCRIBED IN THIS MANUAL CORRE...

Page 3: ...ly observed to ensure that the machine functions perfectly in accordance with the specification When changing parts or carrying out service work that involves dismantling it is recommended to use genu...

Page 4: ...5 7 6 5 4 3 2 1 8 9 SPECIFICATIONS COMMISSIONING CHASSIS ELECTRICAL SYSTEM ADJUSTMENT GENERAL CONTENTS GENERAL INFORMATION ENGINE MAINTENANCE TROUBLESHOOTING...

Page 5: ...7 GENERAL INFORMATION CONTENTS IDENTIFICATION Machine identification Engine identification 9 9 1...

Page 6: ...ront right hand side of the machine The chassis number is required when requesting any motorcycle part ENGINE IDENTIFICATION NUMBER The engine identification number is located at the top right hand si...

Page 7: ...11 2 CONTENTS GENERAL SPECIFICATIONS CHASSIS SPECIFICATIONS ENGINE SPECIFICATIONS TIGHTENING TORQUES 2 SPECIFICATIONS 13 14 15 16...

Page 8: ...IFICATIONS ELEMENT SPECIFICATIONS MODEL CODE MH7 NAKED 125cc DIMENSIONS Total length Total width Height without rear view mirrors Distance between axles WEIGHT 1980 mm 750 mm 795 mm 1310 mm 120 kg 2 S...

Page 9: ...FRONT SUSPENSION Type of suspension Type of front forks Forks capacity Travel REAR SUSPENSION Type of suspension Central hydraulic single shock absorber travel STEERING Tipo 2 75 x 17 Continental 100...

Page 10: ...at height Air screw position TRANSMISSION Type Primary transmission Secondary transmission Gearbox Gearbox capacity Clutch MAGNETO STARTER MOTOR Single cylinder 4 stroke YAMAHA 123 7 cc 54 mm X 54 mm...

Page 11: ...chassis Steering lock STANDARD 5 mm diameter bolt and nut 6 mm diameter bolt and nut 8 mm diameter bolt and nut 10 mm diameter bolt and nut 12 mm diameter bolt and nut 0 1 daN m 1 N m 0 1 daN m 1 N m...

Page 12: ...17 CONTENTS COMMISSIONING Battery preparation except maintenance free batteries Checking levels Commissioning the fuel and oil circuits Checks before delivery to customer 19 20 20 20 3 COMMISSIONING...

Page 13: ...are places where no bubbles are emerging the liquid can be encouraged to enter by tapping this part with the finger without removing the electrolyte container REMOVING THE ELECTROLYTE CONTAINER Check...

Page 14: ...12 N m Rear wheel shaft nut tightening torque 6 5 daN m 65 N m 2 Check tightness of nuts and bolts see Tightening torques 3 Check the adjustment and effectiveness of the brakes 4 Check the inflation p...

Page 15: ...FRONT BRAKE DISK REAR WHEEL REAR BRAKE CALLIPER REAR BRAKE DISK REAR BRAKE FLUID RESERVOIR REAR BRAKE LEVER REAR SPROCKET PROP STAND FRONT BRAKE LEVER FRONT BRAKE FLUID RESERVOIR THROTTLE CONTROL CLUT...

Page 16: ...ns in reverse or der CENTRAL COVERS REMOVAL Remove the seat see section Unscrew the 3 Allen bolts A on each end of the cover Remove the central cover ASSEMBLY To assemble carry out the operations in r...

Page 17: ...e seat upwards and backwards ASSEMBLY Fit the central tab A under the flange B At the same time fit the two anchorages C located on both sides of the seat onto the chassis securing flanges Lower the b...

Page 18: ...erations in reverse order A A A PILLION PASSENGER SEAT REMOVAL Remove the seat see section Unscrew the 4 Allen bolts A Remove the pillion passenger seat ASSEMBLY Fit the pillion passenger seat in its...

Page 19: ...ER PLATE REMOVAL Remove the seat see section Remove the pillion passenger seat see section Remove the right and left hand rear cowling see section Remove the turn indicators see section Remove the rea...

Page 20: ...fice C Unscrew the 3 screws D from the cover Remove the top tank cover E Remove the joining seal F Unscrew the 6 Allen bolts G Remove the tank filler hole Remove the tank filler hole rubber seal ASSEM...

Page 21: ...support orifice C Unscrew the 3 bolts D from the central cover Remove the cover E Unscrew the 4 bolts F from the side cover Remove the covers ASSEMBLY To assemble carry out the operations in reverse...

Page 22: ...ve the tank covers see section Disconnect the tap from the general wiring A Remove the pipe B from the tap Remove the tank C Unscrew the clamp D and remove the tap ASSEMBLY To assemble carry out the o...

Page 23: ...the battery see section Unscrew the 7 bolts A Remove the support ASSEMBLY To assemble carry out the operations in reverse order A A A FRONT MUDGUARD REMOVAL Unscrew the 4 bolts A Remove the front mudg...

Page 24: ...tions in reverse order REAR FOOTRESTS REMOVAL Remove the clip and the washer A Remove the key B and the washer Remove the spring C Remove the footrest ASSEMBLY To assemble carry out the operations in...

Page 25: ...t the chain onto the front sprocket and the rear sprocket Fit the securing clip Adjust the tensioners Fit the 2 wheel shaft nuts N B THE CHAIN SHOULD HAVE A LOOSE PLAY OF 30mm 30mm C B A CHAIN REMOVAL...

Page 26: ...ts A Remove the protector ASSEMBLY To assemble carry out the operations in reverse order A Allen key GEAR CHANGE PEDAL REMOVAL Unscrew the 2 bolts A Remove the gear change pedal ASSEMBLY To assemble c...

Page 27: ...ork arm securing the shaft B Extract the wheel B until the separator E the wheel and the separator F are freed D F B A C E WARNING PLACE THE MACHINE ON A FLAT SURFACE STAND THE MACHINE ON A SUITABLE S...

Page 28: ...e the calliper ASSEMBLY Fit the calliper Secure with the 2 bolts B and washers Fit the banjo bolt A Refill the fluid reservoir see section B FRONT BRAKE DISK REMOVAL Remove the front wheel see section...

Page 29: ...the separator the wheel and the other separator C A B E N B PAY MAXIMUM ATTENTION TO THE POSITION OF THESEPARATING BUSHES DO NOT APPLY THE BRAKE PEDAL DURING THIS OPERATION IF YOU DO SO YOU WILL NEED...

Page 30: ...wheel Insert the shaft through to the other side of the wheel Fit the chain B on the sprocket Fit the other separator Insert the shaft through to the other side of the swin ging arm Fit the tensioner...

Page 31: ...t the banjo bolt A Fit the calliper on the support Fit the calliper support on the swinging arm using the bolts B Fit the rear wheel see section Refill the fluid reservoir see section REAR BRAKE DISK...

Page 32: ...LEVER REMOVAL Remove the 2 bolts A securing the fluid reservoir to the support Remove the bolt and the nut B Remove the spring C Unscrew the bolt D and the nut E securing the lever to the support and...

Page 33: ...Remove the rear sprocket ASSEMBLY To assemble carry out the operations in reverse order PROP STAND REMOVAL Remove the spring A Unscrew the bolt B securing the nut C on the inside Remove the prop stand...

Page 34: ...mirror A Unscrew the brake cable B Remove the rear brake switch C Remove the lever see section Unscrew the banjo bolt D Drain the brake fluid Unscrew the 2 Allen bolts E from the clamp Remove the bra...

Page 35: ...ottle control ASSEMBLY Fit the cable terminal F Fit the cable through the cover guide G Fit the cable through the tensioner cut out H A C E CLUTCH LEVER REMOVAL Remove the rubber A Loosen the cable te...

Page 36: ...assemble carry out the operations in reverse order B A 4 CHASSIS C HANDLEBARS REMOVAL Remove the front brake reservoir see section Remove the commutator see section Remove the electric start button A...

Page 37: ...ations in reverse order B IGNITION SWITCH REMOVAL Disconnect from the general wiring A Unscrew the 2 headlight housing bolts B Remove the headlight housing Unscrew the 2 bolts C Remove the switch ASSE...

Page 38: ...lts A Remove the central nut B located at the bottom of the engine Remove the pipe and the gasket ASSEMBLY To assemble carry out the operations in reverse order B WARNING CHECK THAT THE EXHAUST PIPE I...

Page 39: ...il ASSEMBLY To assemble carry out the operations in reverse order SHOCK ABSORBER REMOVAL Remove the seat see section Remove the tank see section Remove the 2 bolts and the 2 securing nuts A Remove the...

Page 40: ...cable clamp located at the bottom of the swinging arm Remove the trim B Remove chain roller Unscrew the nut A on both sides Remove the swinging arm shaft Remove the swinging arm ASSEMBLY To assemble c...

Page 41: ...move the front mudguards see section Remove the mudguard brackets A Remove the nut and washer B Loosen the 2 bolts C from the top plate Remove the fork tubes from the bottom Remove the top plate ASSEM...

Page 42: ...O ring B the spacer C and the spring D Drain the hydraulic fluid into a container Unscrew the bolt E and the seal F Remove the dust guard G the locking ring H the airtight seal I and the ring J Hydra...

Page 43: ...burettor air intake A Disconnect the throttle cable B Disconnect the fuel intake C Disconnect the choke cable D Disconnect the gas outlet pipe E Disconnect the inlet manifold F Disconnect the cables G...

Page 44: ...MAIN BEAM DIPPED BEAM BULB FRONT HEADLIGHT SIDELIGHT REAR LIGHT FRONT AND REAR TURN INDICATORS NUMBER PLATE LIGHT RELAY E C U COIL REGULATOR FUSE BATTERY INSTRUMENT PANEL 53 54 55 56 57 58 58 59 59 59...

Page 45: ...ss the headlight Loosen the two bolts C one on each side securing the headlight to the chassis Tilt the headlight D forwards to make working easier Remove the bulb connector E Then remove the dust gua...

Page 46: ...ull down the headlight housing C to extract the hea dlight Then pull out the bulb D while holding the headlight housing with the other hand ASSEMBLY To assemble carry out the operations in reverse ord...

Page 47: ...t be ca rried out by way of the step for the rear wheel Disconnect the light from the wiring A Hold the light with one hand Remove the two nuts B securing the light to the num ber plate bracket ASSEMB...

Page 48: ...bolt A holding the screen Remove the screen B Turn the bulb C to the left and remove it ASSEMBLY To assemble carry out the operations in reverse order WARNING KEEP THE SWITCH DISCONNECTED DURING THIS...

Page 49: ...REMOVAL Remove the bolt A holding the screen Then pull out the bulb B while holding the bulb holder C with the other hand ASSEMBLY To assemble carry out the operations in reverse order A B C 5 ELECTR...

Page 50: ...uel tank see section Disconnect the ECU A ASSEMBLY To assemble carry out the operations in reverse order RELAY A REMOVAL Remove the seat see section Disconnect the relay A ASSEMBLY To assemble carry o...

Page 51: ...fuel tank see section Remove the 2 bolts A Remove the regulator B ASSEMBLY To assemble carry out the operations in reverse order FUSE REMOVAL Remove the seat see section Remove the pillion passenger...

Page 52: ...LY To assemble carry out the operations in reverse order WARNING TAKE THE BATTERY TO YOUR DEALER SO THAT THEY CAN RECYCLE IT CAUTION IF YOU RENEW THE BATTERY ENSURE THAT THE NEW ONE DOES NOT EXCEED 12...

Page 53: ...n to the following one with the vehicle stopped or not To update the instrumentation with the new function it s enough briefly pushing the bu tton tmin 1 sec when it will be left the display will show...

Page 54: ...PERA TION OF THE SPEEDOMETER 1 AIM This document constitutes the technical manual with functional specifications for MHRN speedometer 2 REFERENCES M A E electronic devices general contract 3 SYSTEM GE...

Page 55: ...2 Totalizer function TOTAL The information is visualized on digit 8 12 and accompa nied by TOTAL logo as shown in pic 5 3 The data is permanently memorized in a non volatile me mory E2prom refresh ev...

Page 56: ...both when the vehicle is stopped and when it is running this causes also the setting to zero of LAP and AVE functions If the data gets over 999 9 the system automatically sets to zero TD LAP and AVE f...

Page 57: ...s and to exit from regulation phase Time parameter will be shown in 0 24 format if unit of measurement chosen is km h while it will be shown in 0 12 format if unit of measurement is mph In this case o...

Page 58: ...o set to zero the counter of this parame ter by pushing the Set button for about 2 seconds in correspondence of the function LAP till when the value 00 00 appears The setting to zero of LAP which is p...

Page 59: ...ess lost 5 7 Max speed function MAX This function describes the correct working visualization of maximum speed function The information is visualized by using digit 14 16 and logo MAX pic 5 11 The par...

Page 60: ...e to signal the possibility that after switching ON of the vehicle the speedometer can loose its settled data The signal is the graphic bar visualization regardless the current function by blinking th...

Page 61: ...tors lights function The system has to switch on the led when the inputs No 2 or No 13 of the connector are high at the same time of Indicators lights ignition 7 3 Neutral light function The system ha...

Page 62: ...parameters To save the modifications in the memory it is necessary that the set up procedure is completed using the Mode button by keeping pressed the Mode button in corres pondence of the measuremen...

Page 63: ...speed 0 or If the key is turned OFF The system will be automatically taken to the sta dard operating mode and the modifications possibly produced will be lost 8 3 Modifications allowed to the factory...

Page 64: ...passage to the following screen The information concerning the number of im pulses which the instrumentation receives from the speed sensor is saved in memory Obs 8 5 Impulses can also NOT have the sa...

Page 65: ...cle is turned on speed 0 or if the key is turned OFF The system will be automatically taken to the standard operating mode and the modifications possibly produced will be lost 8 3 4 Distance unit meas...

Page 66: ...zero of TD of the chronometer of the average and max speed can be done both with the vehi cle stopped or in movement as described in the previous paragraphs Clock regulation is possible only when veh...

Page 67: ...e ON for about 2 seconds picture 10 2 Third page visualization of the wheel circumference of the measurement unit selected for the distance of the impulses number for every turn of the wheel and of th...

Page 68: ...and will return to the standard operation mode Obs 10 2 If during the Start up phase the key will be turned off the instrumentation will interrupt the check and will return to sleep mode Graphic bar...

Page 69: ...ening follo wing activities happen Check of the display and of lights for about 2 seconds Visualization of selected wheel circumference of wheel turns impulses of unit of measurement and of graphic ba...

Page 70: ...evision camera COLL_AUTO Erasing of the E2prom E2PROM Calibrating pointer position on the dial IND To well operate inside the Test Menu some inputs of the speedometer are set up again as follows 13 1...

Page 71: ...Md button must be pressed inside the corres pondent screen in Test menu by using Up and Down buttons the selection will occur pic 13 2 Now the system will show the standard screen except for the batte...

Page 72: ...be possible by using whate ver of the three buttons Up Md or Down 13 4 Pointer s procedure of calibration IND The calibration is useful to correct eventual mis takes of position made during the phase...

Page 73: ...No PM1 PM2 PM3 PM4 PM5 MIn 20 Simb VMAX TSto IHall IInMax IoutMax Units V C mA mA mA Max 17 85 20 20 20 Feature Supply voltage Operative Temperature Current absorption during On with all the light sw...

Page 74: ...Left Indicator Not connected Not connected Not connected Settings if connetcetd to gnd Neutral Vcc Sensor RPM Positive battery 1 2 3 4 5 6 7 8 9 Producer Part Number MOLEX 43045 1818 Male figure Fema...

Page 75: ...ER PISTON CHECKING THE CYLINDER CHECKING THE PISTON CHECKING THE PISTON RINGS INSTALLING THE PISTON RINGS ON THE PISTON SETTING THE TIMING CLUTCH CHECKING THE CLUTCH CHECKING AND CLEANING THE OIL FILT...

Page 76: ...bath multi disc clutch with manual control 4 smooth discs 5 lining discs 5 speed Carburettor Mikuni VM20 Trochoidal pump CR7HSA Electric 400 W Non catalytic Type Cooling Bore x stroke Cubic capacity...

Page 77: ...absolutely be changed if there are any wear marks cracks etc If they have to be changed install genuine pi pes Petrol is highly inflammable do not smoke in the working area and avoid proximity to flam...

Page 78: ...m daN 1 m daN 2 m daN 1 2 m daN Cylinder head Cylinder casings Transmission cover Inlet manifold Camshaft gear Camshaft gear cover Chain tensioner Chain tensioner Conrod and crankshaft assembly gear...

Page 79: ...4 2541002000221 Engine mount Engine mount adapter Flywheel clamp Externa1 circlips pliers Protective end piece large model 2541002000214 2541002000221 MH Code Designation Used with 2541002000222 25410...

Page 80: ...adapter P N 758464 Put the assembly on stand P N 64765 clamped in the jaws of a vice Remove the bolt 1 in order to drain off the gearbox Tightening torque 2 m daN REMOVAL OF THE CYLINDER HEAD Removal...

Page 81: ...ylin der head mark A Immobilize the conrod and crankshaft assembly by means of the flywheel magneto nut Remove the camshaft gear bolt Removal of the chain tensioner 5 plug 4 Removal of the chain tensi...

Page 82: ...der head REMOVAL OF THE CYLINDER PISTON Removal of the metal gasket 6 and the 2 centring pillars 7 Remove the chain guide pad 8 Removal of the cylinder and its O ring Remove the base gasket 9 and the...

Page 83: ...re The rings must be free in their grooves Measure the piston diameter at 4 5 mm from the piston skirt Piston diameter 53 977 to 53 996 mm Cylinder piston set 0 020 to 0 028 mm Utilisation limit 0 15...

Page 84: ...of each ring no special direction Install the compression ring 3 by placing the TOP mark upwards Install the compression ring 4 by placing the TOP mark upwards FITTING THE PISTON Install the piston w...

Page 85: ...ring gap 4 Lower oil control ring gap FITTING THE CYLINDER Install the cylinder base gasket and the 2 guiding pillars on the crankcase Fit a new O ring 1 on the cylinder skirt Fit the cylinder over th...

Page 86: ...Fit the 6 screws Tighten in 2 or 3 sequences the 6 screws that secure the cylinder head in the indicated direction Tightening torque 6 mm diameter screw 1 m daN 8 mm diameter screw 2 2 m daN FITTING...

Page 87: ...amshaft Make sure the mark I of the camshaft gear isaligned with the mark B of the cylinder head If necessary dislodge the gear from the camshaft without removing it and move the chain around the gear...

Page 88: ...sioner and the 2 attachment screws Tightening torque 1 m daN Install the tensioner cap Tightening torque 0 8 m daN Check the alignment of the timing marks of the flywheel magneto with the mark A of th...

Page 89: ...98 6 ENGINE Install the timing gear 1 cover Tightening torque 1 m daN Install the timing mark cap 2 Fit the central cap 3...

Page 90: ...ansmission cover 9 fixing bolts Remove the transmission cover Tightening torque 1 m daN Remove the paper gasket 1 and the 2 locating pins 2 Remove the 4 bolts and spring 3 from the pressure plate 4 Re...

Page 91: ...53731 Remove the nut and the washer Immobilize the gears by fitting a copper washer A bet ween the gears Loosen and remove the nut 8 from the conrod and crankshaft assembly and the washer Remove The c...

Page 92: ...14 from the crank Remove the centrifugal filter 15 Remove the drive gear from the oil pump 16 Remove washer 17 Remove the circlip Remove the pinion 18 Remove the tapered washer Remove the oil pump 2 f...

Page 93: ...Disc thickness 3 mm Utilisation limit 2 8 mm Measure the length of the springs Spring length 33 mm Utilisation limit 31 mm Check the condition of the notches of the clutch housing and the condition o...

Page 94: ...ENGINE CHECKING AND CLEANING THE OIL FILTERS Clean the centrifugal filter by dipping it into a cleanser Blow through the holes A of the centrifugal filter with compressed air Check and clean the strai...

Page 95: ...FITTING THE CLUTCH Install the conrod and crankshaft assembly The washer 1 The pinion 2 The centrifugal filter 3 the F mark outwards The key 4 The pinion 5 the C mark outwards The washer 6 and the nu...

Page 96: ...15 Tightening torque 7 m daN Lock the clutch main shaft 16 with tool P N 753731 Tighten the nut 17 Tightening torque 6 m daN Fold over the clutch nut washer locking tab Fit the ball into the input sha...

Page 97: ...on the smooth discs are offset by 90 from the others Fit the pressure plate 20 lining up the arrow C on the plate with the round imprint D on the clutch main shaft Tightening torque 0 6 m daN Fit the...

Page 98: ...re plate locknut 1 Bring the lever into contact with the control rod Check that the mark A of the lever is lined up with the notch B of the crankcase It is isn t adjust with the screw 2 Tighten the lo...

Page 99: ...pins Tightening torque 1 m daN Immobilize the rotor 1 using the flywheel clamp P N 68570 Remove the nut 2 Tightening torque 7 m daN By means of the 3 screws secure the flywheel extrac tor P N 758465...

Page 100: ...109 6 ENGINE CHECKING THE OVERRUNNING CLUTCH Rotate the overrunning clutch by hand It must rotate in direction A It must be block in direction B If it doesn t replace the overrunning clutch...

Page 101: ...ve the cylinder head Remove the cylinder and the piston Remove the primary drive Remove the flywheel magneto rotor Remove the gear shift shaft 1 Remove the screw that secures the star locking lever 2...

Page 102: ...e kick starter pinion is on the engine but it is not used Remove the screw which secures 9 the chain tensio ner slipper 10 Remove the chain tensioner slipper Remove the timing chain and notice its dir...

Page 103: ...tering pins Fit the 2 nuts that secure the engine to the fixture Remove the balance shaft 12 Remove the 2 pins 13 of the shift forks Remove the selector cylinder 14 Remove the shift forks Remove at th...

Page 104: ...N 64706 fitted with plate P N 758466 Fix the assembly to the casing using 4 bolts 1 Tighten the tool centre screw holding the crank with one hand on the other side until it is fully extracted Removing...

Page 105: ...mm The out of round values measured on the ends of the crank should not exceed 0 03 mm and must be measu red 30 mm from the transmission side end 60 mm from the flywheel magneto end Check the conditi...

Page 106: ...k the condition of the grooves C of the selector cylinder Check the condition of every gear Check that every gear slides and rotates on the corre ponding shaft Check the condition of the sliding gear...

Page 107: ...H BEARING The bearing is positioned into the casing by means of a press FITTING THE SEALS AND GASKETS Using tool P N 753729 fit the clutch lever seal The gearbox output and gear shift shaft seals are...

Page 108: ...58466 Centre the assembly to the casing with 4 bolts 1 Fit centring tool P N 64710 to tool P N 64706 Tighten pin nut P N 69104 on pin P N 64712 in order to bring the crankshat assembly into contact wi...

Page 109: ...upwards Install the selector cylinder 2 Fit the shift fork guides into the grooves of the cylinder Install the shift fork pins 3 Install the balance shaft 4 by lining up the mark of the balance shaft...

Page 110: ...n Fit the 2 centring pins 5 Put gasket seal paste on the LH crankcase gasket seat Place the RH casing over the LH casing assembly No tools are necessary for assembling the casings which shall be carri...

Page 111: ...te 8 Tightening torque 0 8 m daN Install the timing chain Install the the chain tensioner slipper Tightening torque 1 m daN Fit The circlip 9 The washer 10 The starter drive pinion 11 The kick starter...

Page 112: ...tar locking lever 10 and its spring 11 Tightening torque 1 m daN Install the star 12 and its 2 centering pins Tightening torque 0 8 m daN Install the shift shaft 13 NOTE WHEN RE INSTALLING FIT A SCREW...

Page 113: ...per plate 2 Remove the camshaft 1 Using the intertia extractor Remove the cam follower shafts Remove the inlet 3 and exhaust 4 rockers REMOVAL OF THE VALVES OR VALVE STEM SEALS Compress the spring of...

Page 114: ...alve stem 5 replace it with a new seal after removing all the carbon residues which could remain inside the cylinder head NOTE WHEN RE INSTALLING LUBRICATE THE 2 HALF CONES 4 SO AS TO HOLD THEM IN THE...

Page 115: ...a wrench turn the crankshaft counterclockwise so as to align the crankshaft gear mark I with the cylin der head mark A Using the set of feeler gauges measure the clearance of each valve Clearances 10...

Page 116: ...chamber cap 1 Dismantle the valve equipped with its needle spring and carburettor chamber cap Dismantle the needle 2 by pushing it out in order to remove the clips 3 REMOVAL OF THE FLOAT NEEDLE VALVE...

Page 117: ...he paper gasket Remove the float 3 pin 2 Remove the float and the needle valve Remove the idle jet 4 Remove the main jet 5 Remove the jet spray nozzle 6 Check the condition of the needle valve and the...

Page 118: ...hen re fitting this operation allows you to put them back to their initial adjutment position Remove the idle screw and the mixture control screw with their spring Clean the body of the carburettor an...

Page 119: ...of the float 5 Install the float on the carburettor body while fitting the needle valve into its recess Fit the pin 6 into the float Fit the paper gasket Fit teh float chamber Fit and tighten the 4 sc...

Page 120: ...129 CONTENTS TRANSMISSION CHAIN TENSION LUTCH TENSION THROTTLE CONTROL TENSIONING THE FRONT BRAKE TENSIONING THE REAR BRAKE PEDAL CHANGING CARBURETTOR 131 132 132 133 133 134 134 7 7 ADJUSTMENT...

Page 121: ...ribed below must be carried out on both sides Loosen the two nuts A securing the rear wheel Loosen the securing nut B Using the bolt C adjust the tension of the chain The chain D should have a toleran...

Page 122: ...heel C to tighten or loosen the cable Use the locking wheel B to set the position THROTTLE CONTROL To increase or decrease the throttle twist grip tension Remove the protective rubber A Loosen the loc...

Page 123: ...B increase or decrease the action of the front brake Use the securing nut A to set the position B B A A 7 ADJUSTMENT TENSIONING THE REAR BRAKE To increase or decrease the tension of the rear brake Loo...

Page 124: ...t the position of the gear change pedal to adapt the position to your requirements Put the gear change pedal in neutral position Unscrew the bolt A Place in the desired position Loosen the nuts B Adju...

Page 125: ...135 CONTENTS FRONT BRAKE FLUID REAR BRAKE FLUID FLUID LEVEL SPARK PLUG AIR FILTER CLEANING BRAKE PADS TYRES STEERING MAINTENANCE PLAN 8 MAINTENANCE 137 137 138 138 139 139 139 140 141...

Page 126: ...essary Recommended fluid DOT 3 DOT 4 REAR BRAKE FLUID The brake fluid reservoir is located behind the lever There is an inspection window A in the reservoir to view the fluid level Check that the leve...

Page 127: ...fit the cap Remove the cap again and check the level marked on the dipstick A Recommended oil SAE 10W30 SPARK PLUG Standard spark plug CR6HSA Abnormal colour Renew The normal colour is light brown Ins...

Page 128: ...LTER CLEAN Rinse and dry the filter Impregnate with AGIP FILTE oil Eliminate the excess by pressure BRAKE PADS Measure the thickness A of the lining of the pads Service limit lining 1mm A 8 MAINTENANC...

Page 129: ...and the washer Remove the top plate handlebars assembly C The inside of the steering Remove the oil seal D Remove the spacer pipe E Remove the oil seal F ASSEMBLY To assemble carry out the operations...

Page 130: ...conditions driver mood short journeys with a cold engine dusty regions or an ambient temperature of above 30 C CHECK REINFORCED MAINTENANCE Every 1 500 km Every 3 000 km Adjust idling speed Throttle...

Page 131: ...km or 3 months Every 3 000 km CHECKING AND GREASING REINFORCED MAINTENANCE X Every 1 500 km Every 3 000 km Chain tension and condition MAINTENANCE OPERATIONS 500 km or 3 months Every 3 000 km Every 6...

Page 132: ...START INCORRECT IDLING SPEED FAULTY GEAR CHANGE FAULTY CLUTCH OVERHEATING POOR BRAKING FAULTY FRONT FORK ARMS UNSTABLE HANDLING FAULTY LIGHTS OR TURN INDICATOR SYSTEM 145 146 146 147 147 147 148 148 1...

Page 133: ...ton Air filter incorrectly fitted Air filter element obstructed Crankcase fitted incorrectly Seized crankshaft Cylinder head gasket damaged FUEL SYSTEM Fuel tank empty Fuel tank drain pipe blocked Alt...

Page 134: ...r damaged Faulty spark plug cap Primary or secondary coils broken or short circuited Faulty spark plug cable FAULTY GEAR CHANGE DIFFICULTY CHANGING GEAR See The clutch is dragging in this section THE...

Page 135: ...h lobe Marks not aligned Incorrect oil level Incorrect oil viscosity high Oil altered OVERHEATING ENGINE Coolant passages blocked Large accumulation of carbon deposits Incorrect oil level Incorrect oi...

Page 136: ...Top support incorrectly fitted Bottom support fitted incorrectly badly tightened lock nut Bent steering shaft Damaged ball bearings or bearing guide ring Uneven fluid levels in the two front fork arms...

Page 137: ...bulb BLOWN REAR LIGHT BULB BRAKE LIGHT BULB Incorrect rear light brake light bulb Battery faulty Incorrectly adjusted rear brake light switch Rear light brake light bulb reached end of life THE TURN...

Page 138: ...Created by www ciandisseny com...

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