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Scorpa 2008 SY-250FR 15thA, Manual Manual

The Scorpa 2008 SY-250FR 15thA is a high-performance off-road motorcycle, and its user manual is essential for unleashing its full potential. Easily access the comprehensive manual for free download at manualshive.com, empowering riders with detailed instructions and maintenance guidelines to optimize their riding experience.

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2 

7.2.4

 

Friction plate ..................................................................................................................................................... 45

 

7.2.5

 

Clutch plate ....................................................................................................................................................... 45

 

7.2.6

 

Push lever shaft ................................................................................................................................................. 45

 

7.2.7

 

Push rod ............................................................................................................................................................ 46

 

7.3

 

A

SSEMBLY AND INSTALLATION

 .............................................................................................................................. 46

 

7.3.1

 

Push lever shaft ................................................................................................................................................. 46

 

7.3.2

 

Clutch ................................................................................................................................................................ 47

 

8

 

OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ............................................. 50

 

8.1

 

R

EMOVAL POINTS

 ................................................................................................................................................... 52

 

8.1.1

 

Impeller shaft..................................................................................................................................................... 52

 

8.1.2

 

Oil seal .............................................................................................................................................................. 52

 

8.2

 

I

NSPECTION

 ............................................................................................................................................................ 53

 

8.2.1

 

Oil delivery pipe ................................................................................................................................................ 53

 

8.2.2

 

Impeller shaft..................................................................................................................................................... 53

 

8.2.3

 

Impeller shaft gear ............................................................................................................................................ 53

 

8.2.4

 

Bearing .............................................................................................................................................................. 53

 

8.2.5

 

Oil seal .............................................................................................................................................................. 54

 

8.3

 

A

SSEMBLY AND INSTALLATION

 .............................................................................................................................. 54

 

8.3.1

 

Oil seal .............................................................................................................................................................. 54

 

8.3.2

 

Impeller shaft..................................................................................................................................................... 54

 

8.3.3

 

Right crankcase cover ....................................................................................................................................... 55

 

8.3.4

 

Kickstarter crank ............................................................................................................................................... 56

 

8.3.5

 

Water pump housing .......................................................................................................................................... 57

 

8.3.6

 

Oil filter element ................................................................................................................................................ 57

 

9

 

BALANCER ................................................................................................................................................................. 58

 

9.1

 

R

EMOVAL POINTS

 ................................................................................................................................................... 59

 

9.1.1

 

Balancer shaft drive gear and balancer shaft driven gear ................................................................................ 59

 

9.1.2

 

Balancer ............................................................................................................................................................ 59

 

9.2

 

I

NSPECTION

 ............................................................................................................................................................ 59

 

9.2.1

 

Primary drive gear, balancer shaft drive gear and balancer shaft driven gear ................................................ 59

 

9.2.2

 

Balancer ............................................................................................................................................................ 60

 

9.3

 

A

SSEMBLAGE ET INSTALLATION

 ............................................................................................................................. 61

 

9.3.1

 

Balancer shaft drive gear and balancer shaft drive gear .................................................................................. 61

 

10

 

OIL PUMP .................................................................................................................................................................... 62

 

10.1

 

I

NSPECTION

 ............................................................................................................................................................ 64

 

10.1.1

 

Oil pump ....................................................................................................................................................... 64

 

10.2

 

A

SSEMBLY AND INSTALLATION

 .............................................................................................................................. 65

 

10.2.1

 

oil pump ........................................................................................................................................................ 65

 

11

 

KICK SHAFT AND SHIFT SHAFT .......................................................................................................................... 67

 

11.1

 

R

EMOVAL POINTS

 ................................................................................................................................................... 69

 

11.1.1

 

Kick shaft assembly ....................................................................................................................................... 69

 

11.1.2

 

Shift guide and shift lever assembly .............................................................................................................. 69

 

11.1.3

 

Segment ......................................................................................................................................................... 69

 

11.2

 

I

NSPECTION

 ............................................................................................................................................................ 69

 

11.2.1

 

Kick shaft and ratchet wheel ......................................................................................................................... 69

 

11.2.2

 

Kick gear, kick idle gear and ratchet wheel .................................................................................................. 70

 

11.2.3

 

Shift shaft ...................................................................................................................................................... 70

 

11.2.4

 

Shift guide and shift lever assembly .............................................................................................................. 70

 

11.2.5

 

Stopper lever ................................................................................................................................................. 70

 

11.3

 

A

SSEMBLY AND INSTALLATION

 .............................................................................................................................. 71

 

11.3.1

 

Segment ......................................................................................................................................................... 71

 

11.3.2

 

Stopper lever ................................................................................................................................................. 71

 

11.3.3

 

Shift guide and shift lever assembly .............................................................................................................. 72

 

11.3.4

 

Shift shaft ...................................................................................................................................................... 73

 

11.3.5

 

Kick shaft assembly ....................................................................................................................................... 73

 

11.3.6

 

Kick idle gear ................................................................................................................................................ 74

 

Summary of Contents for 2008 SY-250FR 15thA

Page 1: ......

Page 2: ... to read this user manual before starting the bike In this you could find the pieces of information about the maintenance and the controls of your SCORPA SY 250FR 15thA First and foremost you will find all security instructions to avoid the risks and the danger of motorbike riding Moreover the advice given in this manual will help you to keep your motorbike in perfect working order If necessary do...

Page 3: ......

Page 4: ......

Page 5: ...ho work on the bike This symbol concerns the indications the precautions and the instructions which must be followed to avoid the deterioration of your vehicle NB This symbol introduces pieces of information which will allow you to maintain your bike NB The user manual takes part in the bike and must be given to the new owner in case the bike is sold SCORPA is always working to develop and to impr...

Page 6: ... 3 3 2 Fuel 12 3 3 3 Fuel tap 13 3 4 SIDE STAND 13 4 CHECK BEFORE USE 14 4 1 CHECK POINTS BEFORE USE 14 5 INSTRUCTIONS AND ADVICE BEFORE STARTING THE BIKE 16 5 1 STARTING COLD ENGINE 16 5 2 START WHEN THE ENGINE IS ALREADY WARM 17 5 3 GEAR CHANGE 17 5 4 FUEL CONSUMPTION REDUCTION 17 5 5 ENGINE LAPPING 18 5 6 PARKING 18 6 MAINTENANCE AND LITTLE FIXING 19 6 1 TOOLS 19 6 2 REGULAR LUBRICATIONS AND MA...

Page 7: ...ift levers 36 6 16 SIDE STAND 37 6 17 FRONT SUSPENSION 38 6 17 1 Inspection 38 6 17 2 Adjustment 38 6 18 REAR SUSPENSION 38 6 18 1 Inspection 38 6 18 2 Adjustment 38 6 19 FRONT FORK AND STEERING 39 6 19 1 Front fork check 39 6 19 2 Check of the functioning of the fork 39 6 19 3 Check of the steering 40 6 19 4 Check of the wheel bearings 40 6 20 REPLACEMENT OF ELECTRIC ELEMENTS 40 6 20 1 Replacemen...

Page 8: ...a safe driving and quick reflexes Riding motorbike implies that you wear sturdy bike clothes The helmet the clothes of leather or of reinforced synthetic materials solid shoes preferably bike boots and gloves are essential for the rider Wearing such equipments must not lead to change of the way of riding and the security instructions must be respected 2 Description of the vehicle 2 1 Identificatio...

Page 9: ...5 2 2 Right side 2 3 Left side Handle bar Rear suspension Fork Brake Steering locker Fuel tank tag Rear light Fuel tap Air cleaner case Side stand Rear brake ...

Page 10: ...ctric switches 3 1 1 Engine circuit breaker Engine circuit breaker Press this button in emergency like a fall The effect is to cut the motor 3 1 2 Speedometer Clutch lever Choke Speedometer Brake lever Throttle Tank cap Switchers Left handgrip Digital screen Indicator light ...

Page 11: ...rder to indicate a turn to the left push the control to the left towards the symbol In order to indicate a turn to the right push the control to the right towards the symbol NB when the indicators control is released it goes back to the middle In order to turn the indicators off press the control when it is back in central position Horn control the horn rings when you push this control Horn Sideli...

Page 12: ...ht look at the previous paragraph 4 The high beam light look at the previous paragraph 3 2 2 Clutch lever The clutch lever is located on the left side of the handlebar It is fixed near the left handgrip To decltch pull the lever towards the handgrip To engage just release the lever If you would like to obtain smoothly driving the solution is to pull the lever very quickly and to release it very pr...

Page 13: ...oosing one of the 5 gears of the gearbox 3 2 4 Front brake lever The front brake lever is situated on the right side of the handlebar To operate the front brake pull the lever towards the handgrip Precautions in the handling of the brake levers The brake levers handling must be accompanied by high precautions In fact a wheel lock often means the fall of the rider and its bike That is one of the ma...

Page 14: ...g As told for the front brake lever be careful not to operate too strongly the rear brake pedal Otherwise it can lead to the lock of the rear wheel and the fall of the rider 3 2 6 Choke handling As the engine is cold it may need to have recourse to the choke in order to make the air fuel mixture richer Pull the control to open the choke and enrich the mixture Push the control towards the ground to...

Page 15: ...ight Withdraw the key the direction is locked Unlocking the direction insert the key in the lock and turn it a quarter of turn towards left the lock goes up Turn the key a quarter of turn towards right to withdraw the key and put it in your pocket WARNING Do not let the key in the key while riding Always withdraw it before starting using your bike 3 3 Fuel tank 3 3 1 Fuel tank cap B A Lock ...

Page 16: ...can cause serious deteriorations on the engine and on the exhaust system SCORPA will not be responsible for any problem in that case Before each use check that the quantity of fuel is sufficient In case it is not complete in the tank The filling up must absolutely not exceed the maximum level Otherwise the fuel contained in the tank could easily flow along it WARNING The fuel tank must not be too ...

Page 17: ...OFF The tap is off and the fuel is not able to flow to the carburettor The tap must be on off when the engine does not run ON the tap is running and the fuel can flow to the carburettor The tap must be on on before trying to start the engine and during the use of the bike RES Reserve when the fuel tank is almost empty and the fuel does not flow anymore put the tap on the position res This system i...

Page 18: ...Check points Fuel Fuel level check Filling up if necessary Fuel hose check to detect a possible leak Engine oil Engine oil level check If necessary filling up to the recommended level with the indicated oil Motul 300V Sport 100 synthesis ester SAE 10w40 Visual check to detect a possible leak Front brake Check of the functioning In case the brakes are soft or spongy ask your dealer to bleed the cir...

Page 19: ...he rotating parts if necessary Motul EZ Lub Brake levers and clutch lever Make sure of the functioning progressiveness and regularity Lubrication of the rotating parts if necessary Motul EZ Lub Frame fastenings Check of the nuts and screws tightening Tighten if necessary Lights signalling and electric contacts Check the functioning Adjustment and correct if necessary NB It is strongly recommended ...

Page 20: ...utral position for security reasons The gearbox is placed on neutral If the bike is in gear the clutch lever must be pulled and the side stand folded up 1 Turn the tap towards to ON 2 Pull the choke lever and release the accelerator handling 3 Spread the kick starter 4 Place you right foot on it and step very violently on it towards to the ground 5 If the engine does not start operate the two last...

Page 21: ...n the engine runs The problem is that a lack of lubrication will damage seriously the gearbox even the engine of your bike It is essential always to operate the clutch lever when you change the gears Otherwise you will damage the gearbox the engine and the transmission Those parts are not conceived for such shocks and stresses caused by the change in force of the gears 5 4 Fuel consumption reducti...

Page 22: ...a long period At 12 hours Replace the engine oil and clean the oil filter element After 12 hours The running it is complete You also can use the bike in the normal conditions which are given in this manual WARNING If a problem appears during the lapping SCORPA recommends submitting the matter to your dealer as soon as possible 5 6 Parking When the bike is parked the control of the fuel tank tap ha...

Page 23: ...tened WARNING If you do not master the techniques enough or if you do not have the required tools it is preferable for you to leave the work to your dealer 6 1 Tools In most operations are only used usual tools So they often can be bought in simple equipment or do it yourself stores If you do have not the necessary tools for one of the task you can leave the work to your dealer 6 2 Regular lubrica...

Page 24: ...nspect score marks and wear clean Replace Air filter element Clean with Motul air filter clean Lubricate with Motul air filter oil Replace Clutch Inspect housing friction plate clutch plate and spring Adjust Replace Transmission Inspect Replace the bearing Shift fork shift cam guide bar Inspect wear Rotor nut Retighten Exhaust pipe silencer Inspect and retighten Clean Replace Crank Inspect and cle...

Page 25: ...k the excessive play in the arm Transmission chain Check the chain tension Check the alignment of the rear wheel Clean with Motul chaine clean and lube with Motul chaine lub off road Dismount and lube the chain puller Replace the chain Steering head Inspect free play and retighten Inspect bearings Frame screws Check the screws and the nuts Check if the guard is tightened Side stand Check the funct...

Page 26: ...e increase of the maintenance frequency All the parts which have to be lubricated or greased are concerned as far as the air filter which needs to be more frequently and after all off road ride Those conditions are the rain the humidity the sand or the dust The SY 250FR 15thA is equipped with two hydraulic disk brakes which require a special maintenance o Replacement of the brake master cylinders ...

Page 27: ...rence system 2 Unscrew the spark plug in the direction B thanks to a spark plug spanner The spark plug state check consists in two stages too 1 Make sure the porcelain colour around the electrodes is dark or light coffee coloured because that colour shows the spark plug works in good conditions 2 Check the weakening level and that the carbon deposits thickness are not excessive If one of those sit...

Page 28: ...he engine oil level before every use The lack of engine oil can cause an insufficient lubrication of the moving parts as far as a superheating The list of regular maintenance and lubrications gives you the recommended frequency for each task For a greater longevity of the engine use the Motul 300 V 100 synthesis ester SAE 10w40 four strokes high performances 6 4 1 Engine oil level check 1 The bike...

Page 29: ...5 Air filter cleaning In order to keep the high level of performances of the bike and its reliability it is essential to clean regularly the air filter following the indications given by the list of regular checks and maintenance As it has already been advised the cleaning must be more frequent if the atmospheric and use conditions are humid or dusty Follow the 8 stages 1 Unscrew the tightening ri...

Page 30: ...carburettor is a part of the fuel line Therefore be sure to install it in a well ventilated area away from flammable objects and any sources of fire Never look into the carburettor intake Flames may shoot out from the pipe if the engine back fires while it is being started Gasoline may be discharged from the accelerator pump nozzle when the carburettor has been removed The carburettor is extremely...

Page 31: ...ixture is too rich or too lean the engine power will drop resulting in poor acceleration Main screw adjustment The richness of the air fuel mixture with the throttle fully closed to open can be set by turning the main screw Turning in the main screw will make the mixture lean at low speeds and turning it out will enrich it NOTE If the engine idling speed fluctuates turn the main screw only of a tu...

Page 32: ...or pump adjustment The carburettor pump actuator must begin to turn when the valve begin to go up You can verify this while actuating gas handle If not adjust the cable tension in order to valve upping and pump turning begin in the same time 6 7 Play of the valves As the time goes along the play of the valves changes and it may alter the ratio of air to fuel of the inlet air fuel mixture The solut...

Page 33: ...or by putting a jack under the engine protection Take care the bike is stalled enough to prevent it from overturning 4 Remove successively the axle nut and the axle 5 Make the wheel move to the front of the bike and remove the chain from the rear sprocket 6 Remove the rear wheel from the swinging arm 6 8 4 Fitting of the rear wheel 1 Place the wheel within the arms and put back the chain on the re...

Page 34: ...hey are well shared out among the left and the right Adapt the air in the tires to the transported load The air in the tires their condition and the depth of their treads must be checked before each use 6 9 1 Check of the conditions and of the treads depth of the tires Some conditions must imply the replacement of the concerned tire If the depth of the treads has reached the minimum legal value If...

Page 35: ...is advised not to ride to fast until the tire is well run WARNING Never try to repair an old and cracked or a buckled rim It must imperatively be replaced by a new one 6 11 Transmission chain The tension of the transmission chain has to be check before each use and adjusted if it needs to be 6 11 1Check of the tension 1 Place the bike on a horizontal area and set it upright Careful There must not ...

Page 36: ...tresses on the transmission parts chain sprockets and on the engine 6 11 3Lubrication It is essential to clean and lubrication the chain as often as said in the List of the regular maintenance and lubrication Otherwise the chain will deteriorate quickly particularly if you ride in humid and dusty areas After the first cleaning of the bike brush out the mud and the grime thanks to an old piece of r...

Page 37: ...ple clamp To the holder handlebar dismantle and fixing see Steering part to chassis user manual 6 13 Adjustment of the clutch lever loose The clutch lever play must be bounded by 10 and 15 mm as shown on the following diagram It has to be checked and adjusted before each use Here is the process Loosen the lock nut of the clutch lever To increase the loose turn the screw clockwise To reduce it turn...

Page 38: ...t manage to adjust it ask your dealer to adjust it 6 14 2Adjustment of the rear brake pedal loose The loose of the brake pedal must be bounded by 20 and 30 mm as shown on the diagram It must be checked regularly and adjusted to the recommended value if necessary Loosen the lock nut of the brake pedal Tighten the setting screw to increase the loose and loosen it to reduce the loose As soon as the g...

Page 39: ...u 6 14 4 Brake fluid level control If the level of brake fluid is not sufficient that may create air bubbles in the hydraulic circuit so that the brakes could work badly The consequences could be very serious for the rider The regular check before each use of the bike and the filling up are essential The fall of the brake fluid level may be caused by an excessive pads wear or by bubbles in the hyd...

Page 40: ...ar joint of the master cylinder and of the caliper as far as the brake fluid hose following the recommended frequency and in case of leak of fluid collar joint replace every two years brake hose replace every four years 6 15 Lubrications 6 15 1Cable The accelerator cable the choke and clutch cables have to be checked before each use So a good functioning of the controls is obtained and it is easie...

Page 41: ... does not totally fold up it can make the driving very dangerous If needs be lubricate the articulation of the stand as far as all contact surfaces which take part in the rotation with EZ Lub multi protect WARNING If the side stand does not work properly despite the lubrication it is strongly recommended to make it check by your dealer If it needs to be replace the defective part Side stand ...

Page 42: ...Modify one adjustment a time in one click increments in order not to get confused If no just return to the standard position and start over 6 18 Rear suspension 6 18 1Inspection Check for a broken or collapsed spring Check the suspension action by bouncing the rear of the machine Check the rear shock absorber for a bent shaft or oil leaks If there is a problem make it inspect by your dealer and re...

Page 43: ...eck the condition of the front fork pipes lack of scratch of claw mark or of damage and the lack of fork oil leak If there is one it must be minor Otherwise the fork has to be inspected by your dealer then repaired or replaced WARNING This operation requires putting well the bike on blocks to prevent it from overturning 6 19 2Check of the functioning of the fork 1 Place the bike the most verticall...

Page 44: ...brications In case the buckles have loose or in case the wheels do not revolve well it has to be inspected and maybe repaired or replaced by an occupational mechanistic 6 20 Replacement of electric elements 6 20 1Replacement of a light bulb If one of the bulbs is dud you can replace it by following the instructions Undo the two screws of the head light Remove the light of the headlight Separate th...

Page 45: ...uality controls led by SCORPA during the development and the manufacturing of its bikes a breakdown could happen A problem could cause difficulty for the start out a loss of performance or an abnormal functioning The following diagram gives some pieces of information about the checks you could operate in order to set better the probable reasons for the breakdown If any important operation has to o...

Page 46: ...ike inspect by your dealer Loss of compression Kick start the bike The engine does not start Make it inspect by your dealer Turn an half of the throttle Then kick start Wipe with a dry duster Adjust the electrodes distance damp Make it check by your dealer Dry Remove the spark plug Check the electrodes ...

Page 47: ...haust pipe fixing nut and bolt Install the carburetor see carburetor installation Screw the exhaust pipe fixing nut 13 N m and bolt 24 N m Install the air cleaner case see air cleaner case installation 7 2 Install the speedometer Install the speedometer bracket Fixed the speedometer bracket with two bolts like picture Install the speedometer on its bracket with two bolts like a picture Connect the...

Page 48: ... disc Put the washer against the disk then put the magnet Screw the fixing bolt of the rear brake disc 7 3 Install the electrical wiring Remove the fuel tank see fuel tank removal Connect the homologated electrical wiring to the principal electrical wiring Sensor magnet ...

Page 49: ...a picture Put the head light homologated Connect the front direction light with the homologated electrical wiring black with black White blue with white Blue red with white Connect the front brake indicator The Homologated Electrical Wiring passage ...

Page 50: ...ense plate bracket long 150 millimeters between the wheel axle and the left higher fixing bolt Install the fixing plate of the bracket Screw the 5 bolts Connect the two electrical lugs of the rear light with homologated electrical wiring Connect the direction lights generator unit 150mm ...

Page 51: ...ermits the parts not only to keep their original appearance and their level of performance but to assure the length of their use life too Moreover the regular maintenance of the bike is the necessary condition to be sure the recourse to the guarantee will be possible 8 1 1 Before cleaning Make sure the electric terminal spad tags the spark plug cap and all caps are well protected and positioned Wa...

Page 52: ...is not the case dry it with a soft piece of rag As soon as the bike is dried lubrificate the chain with Motul Chaine lub Off Road and all parts which could corrode Scrub the chromium plated or anodized metallic surfaces with a clean piece of rag and an anticorrosion chemical Do not cover and store the bike before it is totally dry 8 2 Putting away Here are explained two different ways to put away ...

Page 53: ...k plug and its cap Lubrificate all cables levers pedals gearshift lever side stand and articulations with Motul EZ Lub Multi Protect If possible it is preferable to heighten the bike so that the humidity is not concentrated in the same place of the tyres Put a cap on the end of the exhaust pipe Store the bike in a fresh and dry place If this place is dusty and if animals could damage the bike cove...

Page 54: ......

Page 55: ...le de type API Service de classe SE SF Sgmin Air filter cotton filter Fuel Type Unleaded gasoline Capacité 2 0 L Carburator Fabricant Dell Orto Modèle VHST26 with pump Spark NGK R CR8E Gap 0 7 0 8 mm Transmission Primary reduction Gear system Secondary reduction Chain drive System Secondary reduction 48 9 5 33 ratio Transmission type Constant mesh 5 speeds Operation left foot operation Chassis Fra...

Page 56: ...n Right foot Liquide Huile Motul Brake Fluid DOT 4 Suspension Front Type Telescopic fork Rear Type Swingarm Shock absorber Front Coil spring Oil damper Rear Coil spring Oil damper Wheel travel Front 180 mm Rear 170 mm Electrical Ignition system CDI Identification number Type Adhesive plate Position Steering column of the frame ...

Page 57: ......

Page 58: ...r head 19 5 VALVES AND VALVES SPRINGS 20 5 1 REMOVAL POINTS 21 5 1 1 Valve lifter and valve cotter 21 5 2 INSPECTION 22 5 2 1 Valves 22 5 2 2 Valve spring 26 5 2 3 Valve lifter 26 5 3 VALVE CLEARANCE INSPECTION AND ADJUSTMENT 27 5 4 ASSEMBLY AND INSTALLATION 32 5 4 1 Valve and valve spring 32 6 CYLINDER AND PISTON 34 6 1 REMOVAL POINTS 35 6 1 1 Piston and piston ring 35 6 2 INSPECTION 36 6 2 1 Cyl...

Page 59: ...n gear 59 9 1 2 Balancer 59 9 2 INSPECTION 59 9 2 1 Primary drive gear balancer shaft drive gear and balancer shaft driven gear 59 9 2 2 Balancer 60 9 3 ASSEMBLAGE ET INSTALLATION 61 9 3 1 Balancer shaft drive gear and balancer shaft drive gear 61 10 OIL PUMP 62 10 1 INSPECTION 64 10 1 1 Oil pump 64 10 2 ASSEMBLY AND INSTALLATION 65 10 2 1 oil pump 65 11 KICK SHAFT AND SHIFT SHAFT 67 11 1 REMOVAL ...

Page 60: ...INSPECTION 83 13 3 1 Timing chain and timing chain guide 83 13 3 2 Crankcase 84 13 3 3 Crankshaft 84 13 3 4 Oil strainer 85 13 3 5 Oil delivery pipe 2 85 13 4 ASSEMBLY AND INSTALLATION 85 13 4 1 crankcase bearing 85 13 4 2 Cranshaft 86 14 TRANSMISSION 89 14 1 REMOVAL POINTS 90 14 1 1 Transmission 90 14 2 INSPECTION 90 14 2 1 Gears 90 14 2 2 Bearing 91 14 2 3 Shift fork shift cam and segment 91 14 ...

Page 61: ...4 1 Glossary ...

Page 62: ... t throw out the liquid in the nature Unscrew the radiator fixing bolt Unscrew the engine hose collar and take out the hose Unplug the temperature sensor Remove carefully the radiator from the frame Unscrew the radiator hose collars and take out the radiator hoses 2 2 Radiator installation Install the hose on the radiator and screw the collars Plug the temperature sensor Install the radiator in th...

Page 63: ...Install the fuel tank the air cleaner case cover refer to side covers installation 2 3 Level of cooling liquid WARNING this operation must be done when the engine is cold Don t throw out the liquid in the nature Open the radiator cap The liquid must be at the level of the radiator fins like the schema Close the radiator cap ...

Page 64: ...7 3 Camshafts 3 1 Cylinder head cover ...

Page 65: ...8 3 2 Camshafts ...

Page 66: ...9 3 3 Removal points 3 3 1 Camshafts ...

Page 67: ...10 ...

Page 68: ...11 3 4 Inspection 3 4 1 Camshafts ...

Page 69: ...12 ...

Page 70: ...13 3 4 2 Camshaft sprocket 3 4 3 Decompression system 3 4 4 Timing chain tensioner ...

Page 71: ...14 3 5 Assembly and installation 3 5 1 Camshaft ...

Page 72: ...15 ...

Page 73: ...16 ...

Page 74: ...17 4 Cylinder head 4 1 Removal points ...

Page 75: ...18 4 2 Inspection ...

Page 76: ...19 4 3 Assembly and installation 4 3 1 Cylinder head ...

Page 77: ...20 5 Valves and valves springs ...

Page 78: ...21 5 1 Removal points 5 1 1 Valve lifter and valve cotter ...

Page 79: ...22 5 2 Inspection 5 2 1 Valves ...

Page 80: ...23 ...

Page 81: ...24 ...

Page 82: ...25 ...

Page 83: ...26 5 2 2 Valve spring 5 2 3 Valve lifter ...

Page 84: ...27 5 3 Valve clearance inspection and adjustment ...

Page 85: ...28 ...

Page 86: ...29 ...

Page 87: ...30 ...

Page 88: ...31 ...

Page 89: ...32 5 4 Assembly and installation 5 4 1 Valve and valve spring ...

Page 90: ...33 ...

Page 91: ...34 6 Cylinder and piston ...

Page 92: ...35 6 1 Removal points 6 1 1 Piston and piston ring ...

Page 93: ...36 6 2 Inspection 6 2 1 Cylinder and piston ...

Page 94: ...37 ...

Page 95: ...38 6 2 2 Piston ring ...

Page 96: ...39 6 3 Piston pin ...

Page 97: ...40 6 4 Assembly and installation 6 4 1 Piston ring and piston ...

Page 98: ...41 6 5 Cylinder ...

Page 99: ...42 7 Clutch ...

Page 100: ...43 ...

Page 101: ...44 7 1 Removal points 7 1 1 Clutch boss 7 2 Inspection 7 2 1 Clutch housing and boss 7 2 2 Primary driven gear ...

Page 102: ...45 7 2 3 Clutch spring 7 2 4 Friction plate 7 2 5 Clutch plate 7 2 6 Push lever shaft ...

Page 103: ...46 7 2 7 Push rod 7 3 Assembly and installation 7 3 1 Push lever shaft ...

Page 104: ...47 7 3 2 Clutch ...

Page 105: ...48 ...

Page 106: ...49 ...

Page 107: ...50 8 Oil filter element water pump and right crankcase cover ...

Page 108: ...51 ...

Page 109: ...52 8 1 Removal points 8 1 1 Impeller shaft 8 1 2 Oil seal ...

Page 110: ...53 8 2 Inspection 8 2 1 Oil delivery pipe 8 2 2 Impeller shaft 8 2 3 Impeller shaft gear 8 2 4 Bearing ...

Page 111: ...54 8 2 5 Oil seal 8 3 Assembly and installation 8 3 1 Oil seal 8 3 2 Impeller shaft ...

Page 112: ...55 8 3 3 Right crankcase cover ...

Page 113: ...56 8 3 4 Kickstarter crank ...

Page 114: ...57 8 3 5 Water pump housing 8 3 6 Oil filter element ...

Page 115: ...58 9 Balancer ...

Page 116: ...59 9 1 Removal points 9 1 1 Balancer shaft drive gear and balancer shaft driven gear 9 1 2 Balancer 9 2 Inspection 9 2 1 Primary drive gear balancer shaft drive gear and balancer shaft driven gear ...

Page 117: ...60 9 2 2 Balancer ...

Page 118: ...61 9 3 Assemblage et installation 9 3 1 Balancer shaft drive gear and balancer shaft drive gear ...

Page 119: ...62 10 Oil pump ...

Page 120: ...63 ...

Page 121: ...64 10 1 Inspection 10 1 1Oil pump ...

Page 122: ...65 10 2 Assembly and installation 10 2 1oil pump ...

Page 123: ...66 ...

Page 124: ...67 11 Kick shaft and shift shaft ...

Page 125: ...68 ...

Page 126: ...69 11 1 Removal points 11 1 1Kick shaft assembly 11 1 2Shift guide and shift lever assembly 11 1 3Segment 11 2 Inspection 11 2 1Kick shaft and ratchet wheel ...

Page 127: ...70 11 2 2Kick gear kick idle gear and ratchet wheel 11 2 3Shift shaft 11 2 4Shift guide and shift lever assembly 11 2 5Stopper lever ...

Page 128: ...71 11 3 Assembly and installation 11 3 1Segment 11 3 2Stopper lever ...

Page 129: ...72 11 3 3Shift guide and shift lever assembly ...

Page 130: ...73 11 3 4Shift shaft 11 3 5Kick shaft assembly ...

Page 131: ...74 11 3 6Kick idle gear ...

Page 132: ...75 12 AC Magneto ...

Page 133: ...76 12 1 Removal points 12 1 1Rotor 12 2 Inspection 12 2 1AC Magneto 12 2 2Woodruff key ...

Page 134: ...77 12 3 Assembly and installation 12 3 1AC Magneto ...

Page 135: ...78 ...

Page 136: ...79 13 Crankcase and crankshatf ...

Page 137: ...80 ...

Page 138: ...81 13 1 Crankcase bearing ...

Page 139: ...82 13 2 Removal points 13 2 1Crankcase ...

Page 140: ...83 13 2 2Crankshaft 13 2 3Crankcase bearing 13 3 Inspection 13 3 1Timing chain and timing chain guide ...

Page 141: ...84 13 3 2Crankcase 13 3 3Crankshaft ...

Page 142: ...85 13 3 4Oil strainer 13 3 5Oil delivery pipe 2 13 4 Assembly and installation 13 4 1crankcase bearing ...

Page 143: ...86 13 4 2Cranshaft ...

Page 144: ...87 ...

Page 145: ...88 ...

Page 146: ...89 14 Transmission ...

Page 147: ...90 14 1 Removal points 14 1 1Transmission 14 2 Inspection 14 2 1Gears ...

Page 148: ...91 14 2 2Bearing 14 2 3Shift fork shift cam and segment ...

Page 149: ...92 14 3 Assembly and installation 14 3 1Transmission ...

Page 150: ...93 ...

Page 151: ...94 ...

Page 152: ... in the command Dismount the carburettor 15 2 Carburettor installation Joint the carburettor on the pipe Screw the carburettor fixing collar on the pipe Guide the cables to the handlebar Install the starter cable on the command Install the accelerator cable on the command Install the throttle cover Install the air cleaner case see air cleaner case installation Install the fuel tank cover the air c...

Page 153: ......

Page 154: ...WHEEL REMOVAL 11 7 2 FRONT WHEEL INSTALLATION 11 8 REAR WHEEL 12 8 1 REAR WHEEL REMOVAL 12 8 2 REAR WHEEL INSTALLATION 12 9 FRONT BRAKE 13 9 1 FRONT BRAKE CONTROL REMOVAL 14 9 2 FRONT BRAKE CONTROL INSTALLATION 14 10 REAR BRAKE 15 10 1 REAR BRAKE CONTROL REMOVAL 16 10 2 REAR BRAKE CONTROL INSTALLATION 16 11 STEERING 17 11 1 HANDLE CROWNS REMOVAL 18 11 2 HANDLE CROWNS INSTALLATION 18 12 FORK 19 12 ...

Page 155: ... CONTROL REMOVAL 23 15 2 CLUTCH CONTROL INSTALLATION 23 16 SIDE STAND AND FOOTREST 24 16 1 SIDE STAND AND FOOTRESTS REMOVAL 24 16 2 SIDE STAND AND FOOTRESTS INSTALLATION 24 17 FRAME 25 17 1 ENGINE REMOVAL 26 17 2 ENGINE INSTALLATION 26 ...

Page 156: ...4 1 Glossary Lubricate with grease Lubricate with copper grease Use hard locking agent Use soft locking agent 6 N m Tightening torque ...

Page 157: ...5 2 Plastics ...

Page 158: ...s side covers Unscrew the 4 license plate support bolts and remove it 2 2 Side covers installations Install the silencer side covers For each side screw the 2 silencer side covers bolts Install the rear fender Plug the electric cables Screw the 3 rear fender bolts putting the heat protecting washers Install the air cleaner case cover Screw the air cleaner case cover bolt Install the license plate ...

Page 159: ...e cock position must be on OFF Remove the side covers Drain the fuel tank on the position RES never throw out the fuel in the nature Unscrew the cover bolts 3 2 Fuel tank and side covers installation Install the cock with a new seal Screw the 2 cock bolts Install the side covers Install the fuel tank connecting the fuel hose with the clip Install the tank cover see side covers installation ...

Page 160: ...burettor sleeve collar front part carburettor Remove the air cleaner cap by pulling it Remove the air cleaner case Remove the air cleaner filter 4 2 Air cleaner case installation Install the air cleaner filter Install the air cleaner case Joint the air cleaner sleeve to the carburettor Install the air cleaner cap Screw the bolt fixing the air cleaner case to the silencer Screw collars Install the ...

Page 161: ...r see carburettor removal Unscrew the exhaust pipe fixing nut and bolt Remove the exhaust pipe 5 2 Exhaust pipe installation Place the exhaust pipe put a new seal Screw the exhaust pipe fixing nut and bolt Install the carburettor see carburettor installation Install the air cleaner case see air cleaner case installation ...

Page 162: ...crew the 4 bolts fixing the silencer to the frame Remove the silencer of the exhaust pipe 6 2 Muffler installation Lubricate the graphite seals Joint the silencer to the exhaust pipe Screw the 4 bolts fixing the silencer to the frame Screw the bolt fixing the air cleaner case to the muffler support Install the rear fender the air cleaner case cover the side covers and the fuel tank cover see side ...

Page 163: ...te the threading with copper grease Place the front wheel with the disc between the pad kit and install the axle with the spacer at the calliper side Put the wheel axle Screw the wheel axle bolt Unscrew the 2 bottom fork axle bolts opposite side of brake disc Screw the wheel axle bolt to the recommended torque Unscrew again the 2 bottom fork axle bolts opposite side of brake disc Unscrew partly th...

Page 164: ...rning don t operate the brake without the wheel put a key between the pads 8 2 Rear wheel installation Place the rear wheel and the chain Install the left eccentric on the axle Lubricate the axle Install the axle Install the right eccentric Lubricate the axle nut threading with copper grease Adjust the drive chain slack Screw the rear wheel nut ...

Page 165: ...13 9 Front brake ...

Page 166: ...er warning the liquid is corrosive for the painting and dangerous for the body 9 2 Front brake control installation To install the hose screw the pipe portion bolt to the master cylinder after changing the washer seals then screw the pipe portion bolt the slave cylinder after changing the washer seals To install the lever put the 2 spacers then screw the bold after positioning the lever and finall...

Page 167: ...15 10 Rear brake ...

Page 168: ... bolt Warning the liquid is corrosive for the painting and dangerous for the body 10 2 Rear brake control installation To install the hose screw the pipe portion bolt to the master cylinder after changing the washer seals then screw the pipe portion bolt the slave cylinder after changing the washer seals Install the rear master cylinder and the 2 fixing bolts Install the liquid container then scre...

Page 169: ...17 11 Steering ...

Page 170: ...owns installation Lubricate the lower steering bearing Install the upper handle crown in the steering Lubricate and install the upper steering bearing Install the o ring Install the washer then screw the upper bearing support nut with the steering nut wrench screw to eliminate the play make sure there are no hard points in the steering Install the upper handle crown and screw the front fork cap nu...

Page 171: ...r tube 12 2 Fork installation Install correctly the inner tube the upper line should be just visible at the top of the upper crown Screw temporarily the lower crown bolts Screw the upper crown bolts lubricated with copper grease Screw the lower crown bolts lubricated with copper grease Repeat the work for the other inner tube Install the front fender bracket and screw the 4 fixing bolts Install th...

Page 172: ...Pump several time to distribute oil fork 9 The oil quantity is good then the level of oil is 160 mm 6 29 in with inner tube and damper rod in lower position 10 Pump several time inner tube and damper rod and check the level If the level isn t constant supplement 11 Install the spring and the spacer metal ring in contact with spring 12 Remove Front fork cap bolt and tighten it 20Nm 15Ibf ft Open fo...

Page 173: ...ut remove the bolt then remove the chain cover 13 2 Swing arm installation Install the chain cover and the fixing bolts Screw the chain cover nut and bold use soft locking agent on the bolt Screw the rear brake calliper stop and the nut Install the protective plate with the fixing bolts Screw the chain cover nuts Screw the eccentric strop bolt use hard locking agent Install the chain puller and sc...

Page 174: ...er fixing bolt Hold the swing arm to avoid damages Unscrew and take out the absorber lower fixing bolt Take out the absorber 14 2 Rear shock absorber installation Place the absorber Screw the absorber lower fixing bolt Place and hold up the swing arm Screw the absorber upper fixing bolt Install the air cleaner case see air cleaner case installation ...

Page 175: ...en near the master cylinder warning the liquid is corrosive for the painting and dangerous for the body 15 2 Clutch control installation To install the hose screw the pipe portion bolt to the master cylinder after changing the washer seals then screw the pipe portion bolt the slave cylinder after changing the washer seals To install the lever put the 2 spacers then screw the bold after positioning...

Page 176: ...spacer be careful of the spring Unscrew the footrest bracket fixing nuts Take out the bolts and take out the bracket 16 2 Side stand and footrests installation Place the side stand on the bracket and put the bolt and the spacer Screw the side stand axle nut Screw the side stand bracket fixing bolt use hard locking agent Place the footrest bracket on the frame and put the bolts Screw the nuts Put t...

Page 177: ...25 17 Frame ...

Page 178: ... 2 frame fixing bolts and place the nuts Install the clutch control see clutch control installation Install the engine guard pad Install the left lower frame and place the 2 fixing bolts with hard locking agent Install the right lower frame and place the 3 fixing bolts with hard locking agent Install the swing arm see swing arm installation without installing the rear wheel Screw the lower frames ...

Page 179: ......

Page 180: ...1 CONTENTS 1 ELECTRICAL 2 1 1 WIRING DIAGRAM 2 1 2 SPARK GAP TEST 3 1 3 LEADS AND IGNITION COIL CONNECTION INSPECTION 3 1 4 IGNITION COIL INSPECTION 4 ...

Page 181: ...2 1 Electrical 1 1 Wiring diagram ...

Page 182: ...3 1 2 Spark gap test 1 3 Leads and ignition coil connection inspection ...

Page 183: ...4 1 4 Ignition coil inspection ...

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