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TM RACING 250Fi EN Workshop Manual Download Page 1

www.tmracing.it

Ed.02 - 03/2019

  Workshop Manual

250 - 300

EN

450

Summary of Contents for 250Fi EN

Page 1: ...www tmracing it Ed 02 03 2019 Workshop Manual 250 300 EN 450 ...

Page 2: ...d reserves the right to make any modifications required for the development of its products Illustrations shown are approximate and in some cases may not precisely correspond with the part referred to Reproduction of this publication even partial without written authorisation is prohibited ...

Page 3: ...n order to clarify the symptoms of the problem clearly diagnose the cause of the anomaly From this manual it is possible to assimilate the essential theoretical bases which moreover must be integrated by personal experience and the participation of courses which are periodically organised by TM Racing plan the repair rationally in order to prevent downtimes receiving spare parts preparation of too...

Page 4: ......

Page 5: ... 34 4 16 Chain Tension EN MX SMR SMX 34 4 17 Chain Maintenance 35 4 18 Chain Wear 35 4 19 CHECKING SHOCK ABSORBER STATIC SAG 36 4 20 CHECKING SHOCK ABSORBER RIDER SAG 36 4 21 SHOCK ABSORBER COMPRESSION ADJUSTMENT 37 4 22 SHOCK ABSORBER REBOUND ADJUSTMENT 38 4 23 Varying Pre Load And Replacing Shock Absorber Spring 38 4 24 Fork Compression Adjustment 39 4 25 Fork Rebound Adjustment 40 4 26 Varying ...

Page 6: ...E ROD REMOVAL 75 6 15 LINKAGES 77 6 16 REAR SWING ARM REMOVAL 78 6 17 FRONT SWING ARM REMOVAL 83 6 18 FRONT SWING ARM DISMANTLING 86 6 19 STEERING PLATE STEERING BEARINGS REMOVAL 97 6 20 ACOUSTIC SIGNAL REPLACEMENT 100 6 21 MAP CHANGE SELECTOR SWITCH REPLACEMENT 100 6 22 COMBINATION SWITCH REPLACEMENT 101 6 23 START COMMAND REPLACEMENT 102 6 24 INSTRUMENT REPLACEMENT 102 6 25 TENSION ADJUSTER REPL...

Page 7: ...3 1 IDENTIFICATION OF THE VEHICLE ...

Page 8: ...4 1 IDENTIFICATION OF THE VEHICLE ...

Page 9: ...word ALL it means that the information relates to all motorcycles with standard engine regardless of the type of use Code 2 Type of Use used alone means that the information refers to all motorcycles with that type of use regardless of displacement and power source All EN SMR SMM models are equipped as standard with electric start E S as well as kick start K S MX SMX models have K S as standard an...

Page 10: ...er Make a note of this number in the relevant space at the beginning of the manual KAYABA FORK CODE The fork code 2 is a capital letter printed on the inside of each foot TM SHOCK ABSORBER CODE The shock absorber code 3 is printed on an adhesive label applied near to the compression braking valve 1 IDENTIFICATION OF THE VEHICLE ...

Page 11: ...7 2 TECHNICAL SPECIFICATIONS ...

Page 12: ...8 2 TECHNICAL SPECIFICATIONS ...

Page 13: ...pt 140 80 18 Off road air pressure 1 0 bar off road 1 5 bar on road Tank capacity 6 75 litres Chain O Ring 5 8 x 1 4 Optional sprockets 48 49 50 51 52 53 Bulbs High low beam EU4 Led 13 2V 7 3W 14 7W Front position light EU4 Led 13 5V 0 8W High low beam headlight HS1 12V 35 35W Front position light W5W 12V 5W Rear pos stop number plate lights LED 12V 0 9W 0 06W Turn indicator signal R10W 12V 10W Ba...

Page 14: ...nuts and screws swing arm pin shock absorber Check wear on chain junction mesh pinion sprocket and guides chain tension Lubricate chain Check fluid level in hydraulic clutch control tank Replace hydraulic clutch fluid Check brake fluid level pad thickness front and rear brake discs Replace front and rear brake fluid Check condition and sealing of brake pipes Check operation adjustment smoothness a...

Page 15: ... if installed Replace silencer soundproofing material Check exhaust system sealing and fixing Clean air filter and filter housing Check condition and sealing of throttle body coupler and filter housing Check fuel pressure Check accelerator cables play and idle speed adjustment Check conditions smoothness and arrangement without bends adjustment and lubrication of control cables WARNING Components ...

Page 16: ...d check their movement Check tightness of chassis screws fork plates fork feet wheel pin nuts and screws swing arm pin shock absorber Check wear on chain junction mesh pinion sprocket and guides chain tension Lubricate chain Check fluid level in hydraulic clutch control tank Replace hydraulic clutch fluid Check brake fluid level pad thickness front and rear brake discs Replace front and rear brake...

Page 17: ...ed if a defect is detected or wear limit values are exceeded at the check The afore mentioned operations must be performed by an authorised tm workshop or by specialised personnel The hour meter is integrated inside the dashboard FRAME COUPLING TORQUES Front wheel pin flanged nut M20x1 5 40 Nm Front brake calliper fix screw EN MX M8 25 Nm Front brake calliper fix screw SMR SMM SMX M10 40 Nm Rear b...

Page 18: ...14 ...

Page 19: ...15 3 DIAGNOSIS ...

Page 20: ...16 3 DIAGNOSIS ...

Page 21: ... a TM dealer if you have any questions For anything not covered in this paragraph consult the PDA section PROBLEM CAUSE SOLUTION ENGINE DOES NOT TURN OVER MODELS WITH E S Incorrect command EN SMR SMM Correctly repeat the procedure to activate the starter motor according to the motorcycle model Ignition key not inserted or not turned SMR SMM Insert the ignition key and turn it clockwise Incorrect c...

Page 22: ...ion system PDA Faulty injection system Check the injection system PDA Damaged wiring Check the wiring earth connections connectors cables and sheaths integrity Damaged spark plug cap Check the spark plug cap and replace it if required Faulty stop switch EN SMR SMM Check the start and stop command Faulty engine stop button MX SMX Check the engine stop button Engine Does Not Keep Running At Idle Inc...

Page 23: ...ol Faulty injection system Check the injection system Diagnostic Tool Faulty ECU Replace the ECU Engine Overheats Excessively Insufficient fluid in the cooling system Check and top up the coolant level Check the sealing of the cooling system Insufficient ventilation Ride for a while on a flat road at moderate speed without stressing the engine an optional electric fan can be fitted Air in cooling ...

Page 24: ...nge the maps in the control unit only Racing models Display the engine operating hours Upload new maps provided by TM Racing Racing models only Acquire data in real time in 2D and numerical format The instrument receives continuous software and firmware updates allowed by the specific hardware configuration without additional costs and is available for sale to all TM Racing Clients WARNING In orde...

Page 25: ...21 4 REGISTRATIONS ADJUSTMENTS ...

Page 26: ...22 4 REGISTRATIONS ADJUSTMENTS ...

Page 27: ...o discharge the overpressure Caution danger of burns In case of burns immediately place the area affected under cold running water and seek medical advice Coolant is toxic Keep it out of the reach of children If coolant is swallowed seek medical advice immediately If coolant gets in your eyes rinse them immediately with cold water and seek medical advice NOTE The coolant is a mixture of 40 antifre...

Page 28: ... radiator cap being careful to cover it with a cloth to discharge overpressure Caution danger of burns In case of burns immediately place the area affected under cold running water and seek medical advice Coolant is toxic Keep it out of the reach of children If coolant is swallowed seek medical advice immediately If coolant gets in your eyes rinse them immediately with cold water and seek medical ...

Page 29: ...ydraulic control Never use dot5 or other fluids Keep the brake hydraulic fluid from coming into contact with painted parts brake fluid corrodes paint Only use clean brake fluid coming from hermetically sealed containers 4 4 BLEEDING HYDRAULIC CLUTCH To bleed the air disassemble the cover of the clutch pump on the handlebar Connect the suction device to bleeder screw 1 of the clutch cylinder on the...

Page 30: ... handlebar and has an inspection indicator 4 With the tank in horizontal position the fluid level must never drop below the indicator centreline DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED Topping up brake fluid Remove screws 5 cover 6 and membrane 7 Place the tank horizontally and t...

Page 31: ...h the tank in horizontal position the fluid level must never drop below the indicator centreline DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED Topping up brake fluid Remove screws 3 cover 4 and membrane 5 Place the tank horizontally and top up with DOT4 brake fluid up to the upper limi...

Page 32: ... tank in an upright position the fluid level must always be within the MAX and MIN indexes DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED Topping up brake fluid Loosen and remove the cover 3 and membrane 4 Place the tank vertically and top up with DOT4 brake fluid to the tank s MAX inde...

Page 33: ...he tank in an upright position the fluid level must always be within the MAX and MIN indexes DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE BEYOND THE LIMITS ALLOWED Topping up brake fluid Loosen and remove the cover 3 and membrane 4 Place the tank vertically and top up with DOT4 brake fluid to the tank s MAX in...

Page 34: ...ed on the pump body DANGER IF THE BRAKE FLUID LEVEL DROPS BELOW THE MINIMUM VALUE IT MEANS THERE IS A LEAK IN THE BRAKE SYSTEM OR THAT THE BRAKE PADS ARE COMPLETELY WORN Topping up rear brake fluid Top up as soon as the rear brake fluid level reaches the centreline of the indicator located on the pump body To do this loosen the two screws 1 and remove the cover 2 Top up with DOT4 brake fluid to th...

Page 35: ...and increases fuel consumption In some cases dust may enter the engine causing serious damage Maintenance must therefore be performed on the air filter on a regular basis Rotate the screw 1 by 1 4 of a turn Lift the filter cover 2 and remove it Loosen the butterfly screw 3 and remove it Carefully remove the filter 4 from its housing 4 REGISTRATIONS ADJUSTMENTS ...

Page 36: ...t the filter cover 2 WARNING Do not clean the sponge element with petrol or petroleum which may corrode it For correct maintenance use specific products available on the market for cleaning and lubrication Never start the motorcycle without the air filter The infiltration of dust and dirt may cause damage and serious wear Make sure that the seal between the rubber sleeve and filter case is perfect...

Page 37: ...tective caps WARNING With the engine running make sure that the minimum idle speed is correct and that it does not increase when you steer to the right or left up to stopping 4 14 ADJUSTING IDLE SPEED Adjusting the idle speed greatly affects engine start up i e an engine with correctly adjusted idle speed will be easier to start than an engine with incorrect idle speed adjustment Every TM Racing m...

Page 38: ...6 CHAIN TENSIONING EN MX SMR SMX Loosen nut 1 of the wheel pin loosen the counter nuts 2 from both sides and operate on the adjustment screws 3 from both sides by the same amount To increase the chain tension loosen the adjustment screws To decrease the chain tension tighten the adjustment screws Obtain correct chain tension To align the rear wheel correctly the marks 4 on the right and left chain...

Page 39: ...ARNING On mounting the chain joint 1 the closed part must always be in the direction of travel Always check wear of the pinion sprocket and guide runners Replace these parts if necessary 4 18 CHAIN WEAR Carefully follow the instructions below to check the state of wear of the chain Shift into neutral gear pull the upper part of the chain upwards applying a force of 10 15 Kg At this point measure t...

Page 40: ... pre load and replacing shock absorber spring chapter 4 20 CHECKING SHOCK ABSORBER RIDER SAG Correct shock absorber rider sag should correspond to a lowering of the motorcycle of approx 90 105 mm Procedure Ask for help to hold the motorcycle Sit on the motorcycle wearing full protective gear in normal position feet on the footrests and bounce up and down several times to normalise the rear suspens...

Page 41: ... all closed High speeds The adjuster is a hex ring nut 2 and is concentric to the low speed adjustment screw Use a 14 mm hex wrench By rotating clockwise braking increases or anticlockwise it decreases A total number of 28 clicks are available STANDARD ADJUSTMENT 250 300 MX 12 clicks from all closed 450 MX 14 clicks from all closed 250 300 EN 12 clicks from all closed 450 EN 16 clicks from all clo...

Page 42: ... 250 300 SMX 15 clicks from all closed 450 SMX 22 clicks from all closed 450 SMR 19 clicks from all closed 450 SMM 12 clicks from all closed 4 23 VARYING PRE LOAD AND REPLACING SHOCK ABSORBER SPRING The spring pre load can be varied by rotating the adjustment ring nut At every turn of the regulation ring nut the pre load varies by 1 5 mm To facilitate the operation it is recommended to disassemble...

Page 43: ... number of clicks in order to be able to restore standard adjustment It is normal to count the clicks starting from the all closed position Both rods must be adjusted the same way Standard Adjustment 16 clicks from all closed KAYABA USD FORK The adjustment screw 1 is positioned on the upper part of the fork cap Use a screwdriver By rotating clockwise braking increases or anticlockwise it decreases...

Page 44: ... adjustment It is normal to count the clicks starting from the all closed position Both rods must be adjusted the same way Standard Adjustment 16 clicks from all closed KAYABA USD FORK The adjustment screw 1 is positioned on the lower part of the fork foot Use a screwdriver By rotating clockwise braking increases or anticlockwise it decreases A total number of 21 clicks are available WARNING Do no...

Page 45: ...em Before using the valve put the motorcycle up on its stand so that the front wheel does not touch the ground If the motorcycle is used mostly on road it is sufficient to carry out this operation only during periodical maintenance WARNING Excessive pressure inside the fork may cause oil to leak from the fork If oil should leak from the fork try bleeding the air before replacing the sealing elemen...

Page 46: ...and nut 2 of the fork head and tighten or loosen the ring nut 3 as necessary Do not tighten the ring nut 3 beyond the play elimination point this prevents damage to the bearings Tighten the fork head nut and then the four x M8 17 Nm screws Make sure steering is smooth without jamming or play DANGER IF THE STEERING BEARINGS ARE TOO TIGHT OR HAVE PLAY PERFORMANCE ON THE ROAD MAY BE IRREGULAR AND CON...

Page 47: ...the motorcycle with the tyres inflated to the right pressure and with a person sitting on the seat perfectly perpendicular with the longitudinal axis Facing a wall or screen at a distance of 10 metres trace a horizontal line corresponding to the height of the centre of the headlight and a vertical in line with the longitudinal axis of the vehicle Perform the check possibly in the penumbra When swi...

Page 48: ...44 ...

Page 49: ...45 5 GENERAL OPERATIONS ...

Page 50: ...46 5 GENERAL OPERATIONS ...

Page 51: ... seat 2 out towards the rear of the motorcycle 5 2 LATERAL PANELS DETACHMENT Remove the seat as described in the relative paragraph Unscrew the screw 1 and remove the panel 2 Proceed in the same manner for the left panel NOTE On re mounting position the bushes correctly under the screws 5 GENERAL OPERATIONS ...

Page 52: ...veyor 4 Proceed in the same way for the left conveyor NOTE On re mounting position the bushes correctly under the screws 5 4 RADIATOR FINS REMOVAL Remove the radiator conveyors as described in the relative paragraph Use a screwdriver to press on the clamps 1 until the fins 2 are released Remove the fins 2 releasing the pegs 3 NOTE On re mounting insert the pegs 3 correctly into the relative holes ...

Page 53: ...ert it into the fork inserting the disc between the brake pads without damaging them Position the wheel correctly and mount the wheel pin 4 positioning the spacer 5 on the left part of the wheel Temporarily screw and tighten the flanged screw 1 until the wheel spacer is blocked Tighten the locking screws 2 onto the right fork foot to prevent the wheel pin from turning and tighten the flanged screw...

Page 54: ...m 8 5 mm MX EN FT 13 7 mm 13 7 mm To re mount the rear wheel insert the spacer sprocket side in the hub insert the wheel into the swing arm and supporting the wheel mount the chain on the sprocket and position the calliper 4 with its support Insert the wheel pin 2 from the sprocket side halfway into the wheel to allow the spacer to be positioned brake side Insert the pin completely insert the chai...

Page 55: ...51 6 PARTS REMOVAL ...

Page 56: ...52 6 PARTS REMOVAL ...

Page 57: ...crews and thinner spacers 4 onto the front screws REAR MUD GUARD REMOVAL Remove theseat theright and left side podsand thelicence plateholder as described in the relevant paragraphs Loosen the silencer fixing screws 1 and 2 10 mm internal wrench and 8 mm external Loosen the screws 3 4 mm internal Allen wrench and 10 mm external that fix the mud guard support subframe and remove the latter 4 6 PART...

Page 58: ...ix the mud guard to the tank Remove the mud guard 6 NOTE Re mount everything in reverse order to disassembly paying attention to position the wide spacer 7 on the lower support and the narrow one 8 on the rear support when mounting the silencer 6 PARTS REMOVAL ...

Page 59: ...ators Remove the seat the right and left side pods as described in the relevant paragraphs Cut the straps 1 Disconnect the tail light wires 2 Disconnect the wires 3 of the rear direction indicators Loosen the silencer fixing screws 4 and 5 10 mm internal wrench and 8 mm external 6 PARTS REMOVAL ...

Page 60: ...cycle rear subframe 8 Loosen the screws 9 with relative washer which fix the mud guard to the tank Remove the complete mud guard 10 NOTE Re mount everything in reverse order to disassembly paying attention to position the wide spacer 11 on the lower support and the narrow one 12 on the rear support when mounting the silencer 6 PARTS REMOVAL ...

Page 61: ...ps 3 Slide the cables 4 of the direction indicators out from the hole in the mud guard Loosen the screw 5 with the relative nut and remove the rear direction indicator 6 NOTE On re mounting fix the cabling with plastic straps positioning them as originally and connect the direction indicators colour with colour Right indicator red black wire black wire Left indicator red yellow wire black wire 6 P...

Page 62: ...L LIGHT REPLACEMENT Remove the seat and left lateral panel as described in the relevant paragraphs Cut the straps 1 Disconnect the wires 2 Cut the straps 3 Unscrew the screws 4 with nut 5 in the lower part 6 PARTS REMOVAL ...

Page 63: ...ght 8 Slide the licence plate holder 9 from the support subframe Cut the strap 10 and remove the tail light NOTE Re mount everything proceeding in reverse order to disassembly fix the cabling with plastic straps positioning them as originally and connect the tail light colour with colour 6 PARTS REMOVAL ...

Page 64: ...OLDER REMOVAL Remove the seat and left lateral panel as described in the relevant paragraphs Cut the straps 1 Disconnect the tail light wires 2 Disconnect the wires 3 of the rear direction indicators Cut the straps 4 6 PARTS REMOVAL ...

Page 65: ... with tail light and direction indicators Cut the strap 9 Remove the direction indicators and tail light by unscrewing the relative screws NOTE Re mounteverythingproceedinginreverseordertodisassembly fix the cabling with plastic straps positioning them as originally and connect the tail light and the direction indicators colour with colour 6 PARTS REMOVAL ...

Page 66: ...e headlight 2 onto the fork rods Disconnect the connector 3 from the headlight Disconnect the connectors 4 of the front direction indicators Unscrew the two screws 5 that fix the headlight 6 to the mask Unscrew the headlight adjustment screw 7 completely and remove the headlight 6 6 PARTS REMOVAL ...

Page 67: ...he headlight as described in the relative paragraph 6 7 FRONT DIRECTION INDICATOR LIGHT REPLACEMENT Release the four elastics 1 that block the headlight 2 onto the fork rods Disconnect the connector 3 from the headlight Disconnect the connectors 4 of the front direction indicators Loosen the screw 5 with the relative nut and remove the rear direction indicator NOTE Re mount the headlight proceedin...

Page 68: ...64 1 5 8 8 7 9 5 6 2 3 4 2 Key 1 Silencer 2 Silencer support straps 3 Spacer 4 Spacer 5 Springs 6 Extension 7 Manifold 8 Springs 9 Manifold on cylinder 6 PARTS REMOVAL 6 8 EXHAUST UNIT ...

Page 69: ...e relevant paragraphs Loosen the silencer fixing screws 1 and 2 10 mm internal wrench and 8 mm external Release the spring 3 that blocks the silencer 4 and extension 5 in position Remove the silencer 4 Release the spring 3 that blocks the extension 5 and exhaust manifold 6 in position 6 PARTS REMOVAL ...

Page 70: ...8 8 9 Slide out the extension 5 Release the two springs 7 that connect the exhaust manifold 6 to the manifold on the cylinder Remove the manifold 6 Loosen the manifold 9 fixing nuts 8 on the cylinder 6 PARTS REMOVAL ...

Page 71: ...ing the manifold 9 to clean the contact surfaces 10 of the manifold and cylinder from residues of Threebond 1215 sealant and tighten the nuts 8 with a torque of 12 Nm 1 2 kgm 8 85 ft lb Loxeal 82 33 To position the wide spacer 11 on the lower support and the narrowone 12 ontherearsupport whenmountingthesilencer 6 PARTS REMOVAL ...

Page 72: ...h guard as described in the relevant paragraphs Loosen the two screws 1 that fix the control unit 2 to the tank 3 Lift the contactor 4 releasing it from the support bracket 5 Loosen the screws 6 from both sides and remove the rear subframe 7 while supporting the tank 3 6 PARTS REMOVAL ...

Page 73: ...ctor 9 Push the quick coupling ring nut 10 towards the fitting 11 and disconnect the hose 12 from the tank NOTE Re mounteverythingproceedinginreverseordertodisassembly paying attention to wrap the sheath 8 around the fuel hose 12 and the pump electric connection cable 6 PARTS REMOVAL ...

Page 74: ... the tank as described in the relative paragraph Unscrew the screw 1 and remove the contactor support plate 2 Loosen the screws 3 and remove the fins 4 Stretch the strap 5 and remove the bleeder hose 6 Unscrew and remove the cap 7 6 PARTS REMOVAL ...

Page 75: ...8 gradually cross wise until they are fully home on the plastic of the pump 9 compressing the gasket 11 At this point tighten them by 1 2 turn 1 turn max NOTE Do not tighten the screws too much so as not to damage the tank or pump 6 12 Injector Replacement Remove the Airbox as described in the relevant paragraph Loosen the strap 1 between the throttle body and the coupling Disconnect the hose 2 fr...

Page 76: ...le body 5 detaching it from the coupling and disconnect the injector connector 6 Loosen the screw 7 of the injector supply fitting 8 Extract the injector 9 from the throttle body Slide the injector 9 out and replace it NOTE When re mounting the injector pay attention not to invert it 6 PARTS REMOVAL ...

Page 77: ... REMOVAL Remove the rear subframe complete with tank and mud guard as described in the relevant paragraph Unscrew the nut 1 of the shock absorber lower pin 2 Slide the pin 2 out Loosen the nut 3 pin 4 fixing the tie rod 5 to the rocker 6 Slide the pin 4 out 6 PARTS REMOVAL ...

Page 78: ...upper attachment Remove the shock absorber 10 from the frame NOTE Re mount everything in reverse order paying attention to re mountthepins 2 4 and 8 fromtheleftsideofthemotorcycle and the relative nuts from the right side Tighten the nut 1 with a torque of 35 Nm 3 5 kgm 25 81 ft lb Tighten the nut 3 with a torque of 60 Nm 6 kgm 44 25 ft lb Tighten the nut 7 with a torque of 40 Nm 4 0 kgm 29 5 ft l...

Page 79: ... 4 6 14 REAR SHOCK ABSORBER ROCKERS AND TIE ROD REMOVAL Unscrew the nut 1 of the shock absorber lower pin Slide the pin 2 out Loosen the nut 3 pin 4 fixing the tie rod 5 to the rocker 6 Remove the pin 4 6 PARTS REMOVAL ...

Page 80: ...rything in reverse order paying attention to re mountthepins 2 4 and 8 fromtheleftsideofthemotorcycle and the relative nuts from the right side Tighten the nut 1 with a torque of 35 Nm 3 5 kgm 25 81ft lb Tighten the nut 3 with a torque of 60 Nm 6 kgm 44 25 ft lb Tighten the nut 7 with a torque of 60 Nm 6 kgm 44 25 ft lb Tighten the nut 9 with a torque of 40 Nm 4 kgm 29 50 ft lb medium threadlocker...

Page 81: ...6 4 9 3 2 2 9 3 7 7 6 3 2 8 2 3 9 10 5 2 1 3 9 2 2 3 6 3 4 7 Key 1 Rocker 2 Roller cage 3 Oil seal 4 Bush cover 5 Chain wheel 6 Nut 7 Screw 8 Front suspension rod 9 Spacer 10 Pin 6 15 LINKAGES 6 PARTS REMOVAL ...

Page 82: ...the wheel 2 If the chain has a connecting link remove it and remove the chain If the chain does not have a connecting link the chain runner must be removed to release the chain itself Unscrew the screw 3 Loosen the two screws 4 blocking from the part opposite the nuts 5 and remove the chain guide 6 6 PARTS REMOVAL ...

Page 83: ...nd release the chain 8 NOTE On re mounting the chain runner make sure the two spacers are re positioned correctly 9 Slide the calliper support 10 out from the attachment on the swing arm Releases the hoses 11 from the supports 12 6 PARTS REMOVAL ...

Page 84: ...strap 13 fixed to the silencer Loosen the nut 14 fixing the swing arm to the rocker 15 Slide the rocker pin 16 out NOTE On re mounting insert the pin 16 from the left part and the nut from the right part Lower the rocker 15 in a way to release the spring arm 17 6 PARTS REMOVAL ...

Page 85: ...9 Release the spring 20 releasing the lever 19 in a way to access the swing arm pin From one side loosen the nut 21 of the swing arm pin Slide the pin 22 out from the opposite side Loosen the shock absorber upper fixing pin in a way that the frame widens 6 PARTS REMOVAL ...

Page 86: ...rectly re mount the swing arm pin 22 grease before inserting and then check that the nut 23 is tightened flush to the pin Now tighten the nut positioned from the opposite side with a torque of 40 Nm 4 0 kgm 29 5 ft lb Tighten the nut 14 of the rocker pin with a torque of 60 Nm 6 kgm 44 25 ft lb Grease and tighten the nut 1 of the wheel pin with a torque of 80 Nm 8 0 kgm 59 ft lb Grease the roll ca...

Page 87: ...and the steering plate in a way to position the rod correctly on re mounting NOTE Normally the distance is approx 13 mm on the first reference notch of the rod Release the four elastics 1 that block the headlight 2 onto the fork rods Disconnect the connector 3 from the headlight 6 PARTS REMOVAL ...

Page 88: ... 4 4 6 5 8 7 8 Disconnect the connectors 4 of the front direction indicators On the left rod loosen the screws 5 and move the brake calliper 6 then loosen the screws 7 and strip the hose 8 6 PARTS REMOVAL ...

Page 89: ... then tighten the screws 9 with a torque of 20 Nm 2 0 kgm 14 75 ft lb and the screws 10 with a torque of 15 Nm 1 5 kgm 11 06 ft lb Re mountthebrakecalliperontheleftfork tighteningthescrews 5 to a torque value of 25 Nm 2 5 Kgm 18 44 ft lb Re mounteverything proceedinginreverseorderandre connect the direction indicator connectors 4 colour with colour 6 PARTS REMOVAL ...

Page 90: ... HOLDERS Made in aluminium alloy machined with cnc anodised and polished internally RUNNING BUSHES with Teflon coating no first detachment friction GASKETS Sealing rings designed by computer ensure maximum sealing in compression and minimum friction in extension SPRINGS Madeinsteelandavailablewithdifferentstiffnessconstants K For more detailed information refer to the Table OIL KAYABA with special...

Page 91: ...Compression valve 2 Right rod 3 Left rod 4 Lh leg 5 Rh leg 6 Rod holder 7 Extension adjuster 8 Lock ring 9 Bush 10 Bush 11 Washer 12 Sealing ring 13 Lock ring 14 Dust scraper 15 Bush 16 Bush 17 Spring 18 Complete pumping unit 19 Steering wheel 6 PARTS REMOVAL ...

Page 92: ...nate the oil from the shock absorber unit Block the wheel pin support and loosen the adjustment screw Push the internal pipe downwards Position the tool in the figure between the wheel pin support and the cartridge unit nut Hold the nut in its housing with a wrench and remove the adjustment screw Pay attention not to injure fingers 6 PARTS REMOVAL ...

Page 93: ...ve unit from the cartridge assy Use an appropriate tool to block the orthogonal external area of the cartridge assy Use the same tool in the orthogonal internal area of the foot valve assy Loosen the foot valve unit using a wrench Check that the OR rings on the foot valve unit are not damaged Replace them if necessary 6 PARTS REMOVAL ...

Page 94: ... oil completely Remove the dust scraper using a flat tip screwdriver Remove the lock ring using a flat tip screwdriver Extract the internal pipe from the external one NOTE To facilitate the operation make the pipes run quickly but carefully forwards and backwards several times until they are separated 6 PARTS REMOVAL ...

Page 95: ...on register Replace the damaged OR rings Replace the complete unit do not re use it Check the spring Replace it if The external diameter is damaged or excessively worn The free length is equal to or less than 475 mm 18 7 in Check the internal pipe Replace it if distortions are detected Do not repair or re use a pipe with distortions If the pipe has surface defects clean the surface with sand paper...

Page 96: ...atter with a plastic casing as shown in the figure This will protect the lip of the ring thus preventing damage Mount the metal bush and the washer on the external pipe inserting them into the housing with the aid of a guide Mount the oil seal on the external pipe and insert it into the housing with a guide Make sure that the grooves of the lock ring in the internal surface of the external pipe is...

Page 97: ...e mounting the cartridge assy Tighten the nut until it is locked on the internal rod Make sure that the length of the threading on the internal rod is minimum 15 mm 0 6 in Fill the cartridge with specific oil 200 cm3 12 2 in3 Eliminate the air from the cylinder by moving the piston rod up and down several times 6 PARTS REMOVAL ...

Page 98: ...tridge assy with the end part of the piston rod facing downwards as shown in the figure Pump the piston rod up and down approx 10 times to distribute the oil evenly in all the assy Drain the excess oil from the cartridge by moving the shock absorber unit along its entire travel Pay attention not to deform or damage the piston rod or the other parts Remember that the excess oil can escape from the ...

Page 99: ...internal pipe downwards Position the tool in the figure between the wheel pin support and the cartridge unit nut Insert the internal rod into the piston rod and tighten the adjustment screw Pay attention not to injure fingers Tighten the adjustment screw to the stop position Make sure that there is play between the lower part of the adjustment screw and the upper limit of the nut 6 PARTS REMOVAL ...

Page 100: ...o 28 Nm 20 6 ft lb Block the wheel pin support and tighten the adjustment screw to it at 50 Nm 36 8 ft lb Pour the envisioned amount of oil into theexternal pipe 350cm3 21 36 in3 Tighten the cylinder onto the external pipe at 29 Nm 21 4 ft lb 6 PARTS REMOVAL ...

Page 101: ...3 3 6 19 STEERING PLATE STEERING BEARINGS REMOVAL Remove the fork rods 1 as described in the relative paragraph Unscrew the central nut 2 Move the upper steering plate 3 complete with handlebar 6 PARTS REMOVAL ...

Page 102: ...r loosen the ring nut 4 of the steering pin 5 Slide the lower plate 6 out complete with bearing Heat the pin 5 and the plate 6 and use relevant tools to remove the bearing 7 Remove the oil seal 8 and the upper bearing 9 6 PARTS REMOVAL ...

Page 103: ...10 and 11 using a punch NOTE On re mounting clean the inside of the steering head and the steering pin well Insert the bearing housing using a punch Re mount the bearings greasing both the housing and the bearings 6 PARTS REMOVAL ...

Page 104: ...gnal device and re mount everything in reverse order to disassembly 6 21 M A P C H A N G E S E L E C T O R S W I T C H REPLACEMENT Remove the left radiator conveyor as described in the relevant paragraph Unscrew the two screws 1 that fix the selector switch 2 to the handlebar Release the connector 3 cut the straps that block cabling and replace NOTE Onre mounting fixthecablingaspreviously usingpla...

Page 105: ...out removing it Disconnect the cable 1 of the starter auxiliary lever 2 Loosen the two screws 3 to detach the switch from the handlebar Disconnect connectors 4 and 5 cut the straps and remove the switch Replace the switch re mount everything in reverse order and fix the cabling with plastic straps as described previously 6 PARTS REMOVAL ...

Page 106: ...stic straps that fix the cabling Disconnect the connector 3 and replace the start command NOTE On re mounting fix the cabling as previously using plastic straps 6 24 INSTRUMENT REPLACEMENT Release the four elastics that block the headlight onto the fork rods and move it without removing it Disconnect the fuel reserve connector 1 Disconnect the odometer sensor connector 2 6 PARTS REMOVAL ...

Page 107: ...103 3 4 3 4 6 PARTS REMOVAL Disconnect the instrument lighting connector 3 Disconnect the direction indicators connector 4 Unscrew the two screws 3 and replace the instrument 4 ...

Page 108: ...ive cable 3 and the starter motor cable 4 Remove the contactor 5 NOTE Replace the contactor and re mount the cables 3 and 4 in the same position DO NOT INVERT 6 27 INDICATOR LIGHT REPLACEMENT Remove the seat as described in the relative section Disconnect the connector 1 Slide the indicator light 2 from the support bracket 3 6 28 CONTROL UNIT REPLACEMENT Remove the seat and Indicator light as desc...

Page 109: ...g plastic straps as previously described 6 30 REAR STOP SENSOR REPLACEMENT Disconnect the connector 1 Cut the plastic straps that fix the cabling Unscrew the sensor 2 from the rear brake pump and replace it with a new one NOTE DO NOT press the brake pedal with the sensor removed After having replaced the rear stop sensor the oil level in the tank must be checked If necessary add as described in th...

Page 110: ...or 2 from the front brake pump and replace it with a new one NOTE DO NOT press the brake lever with the sensor removed After replacing the front stop sensor it is necessary to perform the functionofthefrontbrakeand ifnecessary bleeditasdescribed in the relevant paragraph Fix the cabling using plastic straps as previously described 6 PARTS REMOVAL ...

Page 111: ...7 1 11 12 6 A C B D A C B 6 32 COOLING SYSTEM Key 1 Radiator cap 2 Strap 3 Radiators connection hose 4 Bleeder hose 5 Strap 6 Upper hose 7 Strap 8 Lower hose 9 Screw 10 Right radiator 11 Washer 12 Vibration damper 13 Left radiator 6 PARTS REMOVAL ...

Page 112: ...ll of the coolant contained in the radiators NOTE On re mounting the screw 1 replace the aluminium washer Right radiator On the right radiator loosen the strap 2 of the connection hose 3 of the two radiators Use a screwdriver to detach the bleeder hose 4 Loosen the strap 5 and disconnect the upper hose 6 Loosen the strap 7 and disconnect the lower hose 8 6 PARTS REMOVAL ...

Page 113: ...o screws 9 and remove the right radiator 10 Left radiator Loosen the strap 11 and strap 12 and detach the relevant hoses Loosen the strap 13 and disconnect the hose 14 Unscrew the two screws 15 and remove the right radiator 16 6 PARTS REMOVAL ...

Page 114: ...as described in the relevant paragraphs Drain the coolant from the radiators as described in the relevant paragraphs Loosen the straps 1 and disconnect the radiator hoses 2 from the head Cut the straps 3 which fix the bleeder hose 4 Loosen the strap 5 and disconnect the radiators connection hose 6 Unscrew the two screws 7 6 PARTS REMOVAL ...

Page 115: ...diator 8 complete with hoses Unscrew the two screws 9 and remove the left radiator 10 complete with hoses Remove the drain hose 11 as described in the relative paragraph Unscrew the screw 12 and remove the kick start lever 13 6 PARTS REMOVAL ...

Page 116: ...112 14 15 16 17 18 Unscrew the pin 14 of the brake pedal 15 Release the spring 16 and move the brake pedal Disconnect the starter motor electric connections 17 Unwind the sheath cover 18 6 PARTS REMOVAL ...

Page 117: ... Loosen the screws 19 and detach the clutch actuator 20 with the pinion cover casing 21 Unscrew the screw 22 and remove the pinion cover support 23 Remove the seeger ring 24 Slide out the pinion 25 with the chain 6 PARTS REMOVAL ...

Page 118: ...26 27 28 29 Detach the voltage adjuster connection connector 26 Disconnect the engine electric connection connectors 27 Detach the spark plug cap 28 Disconnect the fuel hose 29 from the pump 6 PARTS REMOVAL ...

Page 119: ...the strap between the throttle body and the coupling Unscrew the screw 30 that fixes the idle speed adjustment knob 31 Detach the throttle body 32 from the engine Disconnect the temperature sensor connector 33 6 PARTS REMOVAL ...

Page 120: ...The two brackets are the same mark them in order to re mount them correctly Loosen the engine lower fixing pin 38 block the pin using a 12 mm socket wrench 39 and loosen the nut 40 using a 14 mm closed end spanner Loosen the engine upper fixing pin 41 block the pin using a 12 mm socket wrench 42 and loosen the nut 43 using a 14 mm closed end spanner 6 PARTS REMOVAL ...

Page 121: ...117 41 43 43 38 Slide the upper pin 41 out and leave the lower pin 38 mounted Unscrew the swing arm pin 43 Slide out the swing arm pin 43 Slide out the lower pin 38 6 PARTS REMOVAL ...

Page 122: ...the engine 45 forward as much as possible in a way to detach it from the swing arm Loosen the strap 46 mark the manifold 47 in order to re mount it in the same direction and then remove it Rotate the engine 45 and remove it from the right side of the motorcycle 6 PARTS REMOVAL ...

Page 123: ...the engine support brackets 35 and 37 tightening the screws 34 and 36 with a torque of 22 Nm 2 2 kgm 16 22 ft lb Tighten the pins 38 and 41 with a torque of 45 Nm 4 5 kgm 33 19 ft lb Tighten the swing arm pin 43 with a torque of 70 Nm 7 0 kgm 51 6 ft lb following that indicated in the Swing Arm Removal paragraph 6 PARTS REMOVAL ...

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