Gilera SATURNO BIALBERO 350 Workshop Manual Download

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WORKSHOP MANUAL

SATURNO BIALBERO

350-500

Summary of Contents for SATURNO BIALBERO 350

Page 1: ...WORKSHOP MANUAL SATURNO BIALBERO 350 500 ...

Page 2: ...section on the various known faults with which the Saturno is prone to suffer Whilst these faults were obviously not included in the original official manuals we believed they should be a part of any publication dealing with Saturno maintenance There have also been a couple of obvious errors within the original manuals and these have been copied as is into this manual but a note has been added wit...

Page 3: ...Cylinder Piston Clutch Primary drive Oil pump Crankcase Gearbox Crankshaft components FRAMES Working procedures Front Wheel Front suspension Steering Rear Suspension Rear wheel Brakes ELECTRICAL SYSTEM Battery Charging circuit Ignition system Electric starter Switches Horn Lights Rear mudguard Exhaust Trouble shooting Circuit diagram Section 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ...

Page 4: ...ON 1 SUB INDEX Known faults Safety procedures Maintenance procedures Model Identification Technical data Torque wrench settings Engine overhaul data Cables and wire passage Section Page 1 1 1 2 1 2 1 2 1 3 1 4 1 5 1 6 1 ...

Page 5: ...ngs will make a big difference Starter bolts work loose Loctite on the bolt threads and check occasionally Rear suspension linkage gets all the bad weather Put axle stands under footrests to support bike with rear wheel off the ground Take weight of wheel swinging arm and remove bolts from rising rate link 3 point bracket attached to bottom of rear suspension unit Grease thoroughly and replace Thi...

Page 6: ...Always use new gaskets O rings split pins and safety plates when reassembling Always tighten nuts or bolts starting with those of greater diameter or found internally tighten in a diagonal sequence in 2 or 3 passes and to the recommended torque unless otherwise noted Clean components with non flammable solvents or at least solvents having a high flash point Lubricate working surfaces prior to reas...

Page 7: ...MODEL IDENTIFICATION 1 2 1 2 2 ...

Page 8: ...essive Stroke Wheels Front Tyre size Pressure Above believed to be incorrect we recommend Rear Tyre size Pressure Above believed to be incorrect we recommend Brakes Front floating disc with hydraulic double piston Disc diameter Rear floating disc with hydraulic single piston Disc diameter Fuel tank capacity Fuel tank reserve 350cc 500cc 2030 mm 730 mm 1170 mm 1410 mm 790 mm 360 mm 145 kg 24 30 30 ...

Page 9: ... Silkolene Pro cool etc Air filter sponge type Intake valve diameter Exhaust valve diameter Valve clearance cold clearance between camshaft and rocker arm Intake cold Exhaust cold TRANSMISSION Clutch wet multiplate Primary drive Gearbox with straight tooth gears and claw couplings Gear ratio 1st gear 2nd gear 3rd gear 4th gear 5th gear Final drive 350cc 500cc 80 X 69 4 92 X 74 348 8 cc 491 9 cc 9 ...

Page 10: ...starting Electrical starting Standard spark plug Champion Electrode gap Fuses Starter motor Headlamp Driving lamp Tail stop lamp Turn signal lamp Instrument lamp Warning indicator lamp 350cc 500cc Dell Orto PHF36PS PHM40VS K54 K4 3a tacca 3rd notch 2a tacca 2nd notch AB262 AB265 128 138 58 53 40 40 Ø 1 1 5C55 3 5 AB262 AB265 5 5 14g 10g 1 giro rev 1300 1400 1 5 giro rev 1300 1400 1300 1400 both 7 ...

Page 11: ...ort on head Lower plate mounting bolts Top plate mounting bolts Damper mount Rear fork mount Suspension connecting rod support to frame Suspension connecting rod lever mount Suspension damper lever mount Suspension rear fork lever mount Front calliper Front brake disk Rear calliper Rear brake disc on flange Rear wheel flange Rear sprocket mounting bolts Front wheel spindle Spindle fastening bolts ...

Page 12: ...earance 1st and 2nd ring scraper ring Oil pressure Water thermostat opens at Water thermostat fully opens at Cooling fan enable temperature Valve clearance between camshaft and rocker arm Intake cold Exhaust cold 350cc 500cc 0 030 0 042 mm 0 030 0 059 mm 0 017 0 060 mm 0 05 0 25 mm 0 15 0 25 mm 0 000 0 008 mm 0 015 0 030 mm 0 049 0 087 mm 0 084 0 140 mm 0 030 0 066 mm 0 012 0 042 mm 0 025 0 055 mm...

Page 13: ...CABLES AND WIRE PASSAGE 1 6 Point out the passage of each cable and wire figs 5 6 7 8 9 1 6 ...

Page 14: ...ng extraction punch 19 1 20506 2 1 Flywheel puller 19 1 20501 Con rod small end bushing installation punch 19 1 20505 Puller for steering bearing lower race 19 1 20109 Camshaft pulley blocking tool 19 1 20504 Sprocket locking wrench 19 1 20086 Camshaft oil ring installation punch 19 1 20503 ...

Page 15: ...2 Pad for crankshaft and flywheel puller 19 1 20513 Piston support 19 1 20512 Main journal bushing extraction punch 19 1 20507 Main journal bearing extraction ring ignition side 19 1 20511 Main journal bearing installation punch clutch side 19 1 20508 Main journal bearing installation punch ignition side 19 1 20509 ...

Page 16: ...llation sleeve 19 1 20525 2 3 Oil filter removal spanner 19 1 20520 Compression check tool 19 1 20524 Valve spring compression tool 19 1 20519 Valve guide extraction installation punch 19 1 20523 Drive gear blocking tool 19 1 20515 Valve clearance adjustment tool 19 1 20522 ...

Page 17: ...ve seats 19 1 20529 Punch 19 1 20566 2 4 Complete roller cage extractor 19 1 20528 Chain slack tool 19 1 20565 Engine support base 19 1 20527 Battery charge density meter 19 1 20564 Engine support 19 1 20526 Pin sliding punch 19 1 20530 ...

Page 18: ...SPECIAL TOOLS 2 2 5 Exhaust manifold spring removal tool 19 1 20551 Clutch collets tool 19 1 20540 Complete tool kit 19 1 20563 ...

Page 19: ...ngine oil and filter replacement Spark plug Throttle control Clutch Drive chain Chain replacement Rear brake pedal height adjustment Gearshift lever height adjustment Foot pedals damper bushings replacement Trouble shooting Engine oil replacement Clutch transmission cylinder on the engine Section Page 3 1 3 2 3 2 3 2 3 3 3 3 3 3 3 3 3 4 3 4 3 4 3 5 3 5 3 5 3 6 3 6 3 6 3 6 3 6 3 7 3 8 ...

Page 20: ...ck and adjustment Sprocket brake calliper and disc wheel spindle chain pinion mounting bolts Chain check adjustment lubrication if necessary replace the whole drive Brake pads and blocks check replace if req d Fork oil replacement Fork pivot joint tightening check Steering bearing play check and lubrication Battery charge electrical system efficiency Tyre pressure check X X X X X X X X X X X X X X...

Page 21: ...INTENTIONALLY BLANK ...

Page 22: ...n the two mounting screws remove the carburettor top and pull off the throttle valve complete with needle jet fig 4 Loosen the lower bowl plug and remove bowl fig 5 Remove the jets nozzle float needle valve and disassemble the accelerator pump Inspect the carburettor body and fuel channels wash with kerosene or appropriate solvent if dirty Blow into the channels with compressed air Examine the con...

Page 23: ...MAINTENANCE 3 2 3 2 2 ...

Page 24: ...hen wring it or let dry NEVER use petrol or low flash point solvents to wash the element Immerse element in lubricating oil then squeeze it to remove excess oil If filter element is worn replace with new element Remount element in its filter box Replace filter box lid VALVE CLEARANCE Check valve clearance with engine cold Remove fuel tank It is recommended to remove the 2 control units and ignitio...

Page 25: ...MAINTENANCE 3 3 3 3 2 ...

Page 26: ...es of oil into the filler cap Check oil level Start the engine then stop it after an idle period of approx 1 minute If necessary add some oil and check for leaks Every two oil changes it is necessary to replace the filter cartridge Remove filter cartridge using appropriate tool 19 1 20520 fig 11 Install new filter after lubrication of its gasket with engine oil The correct oil level is reached wit...

Page 27: ...MAINTENANCE 3 4 3 4 2 ...

Page 28: ...drive sprockets measure play by moving the chain up and down Max play allowed 30 mm Chain slack adjustment Loosen the two rear wheel eccentrics locking bolts fig 15 Use the appropriate tool 19 1 20565 to rotate the eccentric to get the correct slack on the chain Make sure both eccentrics have turned the same amount by checking the alignment notches fig 16 Verify that the chain drive and driven spr...

Page 29: ...MAINTENANCE 3 5 3 5 2 ...

Page 30: ... then rotate the rod in the desired position fig 20 GEARSHIFT LEVER HEIGHT ADJUSTMENT Loosen the gearshift rod Remove the joint and rotate it to the desired position fig 21 FOOT PEDALS DAMPER BUSHINGS REPLACEMENT Remove the socket head screw at the end of the pedal remove the bushing and aluminium coupler replace bushings if worn fig 22 Remove the pedal bolt Check bolt diameter should be 16 mm fig...

Page 31: ...MAINTENANCE 3 6 3 6 2 ...

Page 32: ...d let it run at idle speed for about a minute Stop the engine and check the oil level through the transparent oil window on the left side of the engine fig 29 If necessary remove the oil cap on the clutch guard fig 30 and add the recommended oil to the engine until the maximum level is reached as shown in the oil window 3 7 ...

Page 33: ...Check that the piston and cylinder do not show signs of scratches or other damage fig 41 If there are signs of damage replace the whole unit Push the piston grommet inside the cylinder to extract the piston in case of replacement Reassembly The piston grommet must be replaced by another each time it is removed Reassemble the piston in the clutch transmission cylinder Mount the clutch transmission ...

Page 34: ...MAINTENANCE 3 8 3 8 2 ...

Page 35: ...SECTION 4 INTENTIONALLY BLANK ...

Page 36: ...ENGINE REMOVAL INSTALLATION 5 1 5 1 Working procedures Engine removal installation Section Page 5 1 5 1 ...

Page 37: ...ean hands only Avoid bending or twisting the belt Gudgeon pin snap rings gaskets oil seals and rubber ring seals must be substituted at every disassembly Lubricate all moving components prior to assembly Spring washers must always be installed with the convex side out When removing or installing the engine always have the motorcycle supported so that it will be steady Drain the motor oil Remove se...

Page 38: ...cting the throttle cable Disconnect the oil pressure and neutral indicator wires Remove ignition cover Disconnect starter motor wires Disconnect oil breather hose Remove rear brake fluid reservoir Remove brake hose to frame clamp Do not disconnect brake hose from reservoir Remove engine to frame top support Remove the 2 lower engine mounting bolts only Loosen rear damper plate to frame mounting nu...

Page 39: ...ENGINE REMOVAL INSTALLATION 5 1 5 1 3 ...

Page 40: ...GENERATOR TIMING BELT GEARBOX SELECTOR 6 INDEX 6 Disassembly Inspection Reassembly Valve timing Torque wrench settings Section Page 6 1 6 1 6 2 6 2 6 3 ...

Page 41: ... remove cover fig 9 Slide out the gearshift pedal shaft together with selector drum assembly fig 10 Remove selector drum cam central bolt fig 11 Remove crankshaft pinion using extractor 19 1 20514 figs 12 13 Remove the electric starter s freewheel driven gear complete with bushing and caged needle bearing from the balanced auxiliary shaft after having removed its fastening bolt and spring washer L...

Page 42: ...GENERATOR TIMING BELT GEARBOX SELECTOR 6 1 6 1 2 ...

Page 43: ...GENERATOR TIMING BELT GEARBOX SELECTOR 6 1 6 1 3 ...

Page 44: ...osened the lock nut VALVE TIMING Put piston at TDC indicated by aligning the reference mark on the generator rotor with the fixed mark as shown in fig 18 Place the camshafts with their reference marks facing as shown in fig 19 This operation must be carried out without actuating the valves rotate it clockwise or counter clockwise as necessary Install the timing belt and take up the slack with the ...

Page 45: ...GENERATOR TIMING BELT GEARBOX SELECTOR 6 2 6 2 2 ...

Page 46: ...TORQUE WRENCH SETTINGS 6 3 Freewheel fastening bolt Generator rotor fastening bolt Chain sprocket fastening bolt Selector cam fastening bolt Tensioner pulley fastening nut Lubricate threads with oil Use Loctite 270 40 Nm 40 Nm 40 Nm 40 Nm 40 Nm ...

Page 47: ...CYLINDER HEAD VALVETRAIN COMPONENTS 7 SUB INDEX Diagram Disassembly Inspection Reassembly Torque wrench settings Section Page 7 1 7 2 7 3 7 4 7 4 7 ...

Page 48: ...CYLINDER HEAD VALVETRAIN COMPONENTS 7 1 7 1 ...

Page 49: ...cker arm shaft retainer bushing fig 6 Remove the cylinder head cover and remove the camshafts with their oil seals figs 7 8 Remove the valve lifter device found on the left hand side of head near the exhaust valve by extracting the retainer pin fig 9 The little shaft together with the lifter may now be dismantled by hand Extract the retainer bushing and intake rocker arm shaft use an 8mm bolt with...

Page 50: ...CYLINDER HEAD VALVETRAIN COMPONENTS 7 2 7 2 2 ...

Page 51: ...CYLINDER HEAD VALVETRAIN COMPONENTS 7 2 7 2 3 ...

Page 52: ...esn t show signs of excessive wear In the event of valve seat wear resurface by grinding Check that the valve stem is straight Max straightness error allowed 0 01 mm fig 15 The face must be radial with respect to the stem fig 16 Valve seat must be in good shape with no sign of pitting cracking or corrosion Springs After visual inspection of the springs and valves measure the length of each spring ...

Page 53: ...CYLINDER HEAD VALVETRAIN COMPONENTS 7 3 7 3 2 ...

Page 54: ...Always use new oil seals for both valve guides and camshafts for the latter use special tool 19 1 20502 for the former use special tool 19 1 20503 Oil the lip seal before mounting Install the head gasket make sure the correct side is facing up All contact surfaces must be clean and in good condition fig 19 Between head and cylinder there are four rubber anti vibration devises that are Installed af...

Page 55: ...INTENTIONALLY BLANK ...

Page 56: ...CYLINDER PISTON 8 SUB INDEX Diagram Disassembly Inspection Reassembly Section Page 8 1 8 2 8 2 8 2 8 ...

Page 57: ...CYLINDER PISTON 8 1 8 1 ...

Page 58: ...rubber O ring found around the oil feed line fig 6 INSPECTION After a thorough cleaning of all parts all components must go through a careful visual inspection Replace all parts that show sign of damage and or wear Careful attention goes to cylinder wall piston surfaces rings and gudgeon pin with no signs of scoring deep grooves shrinkage or any other damage Cylinder Measure bore diameter with a m...

Page 59: ...CYLINDER PISTON 8 2 8 2 2 ...

Page 60: ...t damaged or scaled Verify that it starts to open at 75 C and that it is fully opened at 85 C Check condition of the thermostat s O ring REASSEMBLY Assemble in reverse order of disassembly Pay close attention to the following points Piston rings are installed in a specific order and direction The first two rings are marked with the letters TOP 2 and TOP for the first and second ring respectively t...

Page 61: ...CYLINDER PISTON 8 2 8 2 4 ...

Page 62: ...CLUTCH PRIMARY DRIVE OIL PUMP 9 SUB INDEX Diagram Disassembly Inspection Reassembly Torque wrench setting Section Page 9 1 9 2 9 2 9 3 9 3 9 ...

Page 63: ...CLUTCH PRIMARY DRIVE OIL PUMP 9 1 9 1 ...

Page 64: ...ver and slide out the washer of the mainshaft Slide out both drive and driven gears from the balance shaft fig 11 Remove the spacer washer near the right main bearing fig 9 INSPECTION After a thorough cleaning of all parts inspect all components carefully All those parts that show sign of wear and or damage must be replaced All gears must be in good condition with no sign of wear deep scratches or...

Page 65: ...CLUTCH PRIMARY DRIVE OIL PUMP 9 2 9 2 2 ...

Page 66: ...CLUTCH PRIMARY DRIVE OIL PUMP 9 2 9 2 3 ...

Page 67: ...lance shaft mark In this case the teeth inner surface present a triangular groove Operate in way that the groove is aligned with the balance shaft mark fig 14 Mount the clutch drum by inserting the oil pump pawl guide into its seat The clutch drive plates are installed with the arrow imprinted on the friction material facing out Install the spring washers with the convex side facing out Oil all wa...

Page 68: ...CRANKCASE GEARBOX CRANKSHAFT COMPONENTS 10 SUB INDEX Diagram Disassembly Inspection Reassembly Torque wrench settings Section Page 10 1 10 2 10 3 10 3 10 3 10 ...

Page 69: ...CRANKCASE GEARBOX CRANKSHAFT COMPONENTS 10 10 1 ...

Page 70: ... of the cases and or at the end of the gearbox shafts When separating the cases fig 1 check to see if a spacer washer from one of the shafts has fallen out reinstall if necessary Slide out the gear selector fork shaft and remove the forks fig 2 Remove the selector drum balance shaft and the two gear train shafts figs 3 4 5 Remove crankshaft with connecting rod fig 6 Loosen the nuts of the connecti...

Page 71: ...CRANKCASE GEARBOX CRANKSHAFT COMPONENTS 10 10 2 2 ...

Page 72: ...f it is necessary to replace the wrist pin use special tool 19 1 20506 for removal to install use special tool 19 1 20505 Be careful to align the pin lubrication hole with the one in the small end Connecting rod cap radial gap must be between 0 15 0 25 mm It is recommended to replace connecting rod bolts at every overhaul Note the fitting of the connecting rod cap mount the connecting rod in the s...

Page 73: ...ssemble in reverse order of disassembly Pay close attention to the following points Crankshaft balance shaft and gears are all mounted in the left crankcase Use Loctite 574 on the contact surface of the two cases The crankshaft thrust ring is installed in the right case with the antifriction surface side facing the shaft and so is the selector drum spacer washer Hold these components in with a lit...

Page 74: ...FRAMES INDEX Working procedures Front wheel Front suspension Steering Rear suspension Rear wheel Brakes Section 11 12 13 14 15 ...

Page 75: ... must be carried out in a precise order mark all components to be removed one at a time or place them in separate containers so as to mount them in the same position as prior to disassembly Pay attention to the position of the component prior to removal so as to mount it correctly upon reassembly Lubricate all moving components prior to assembly Spring washers must always be installed with the con...

Page 76: ...FRONT WHEEL 12 SUB INDEX Diagram Disassembly Reassembly Technical data Trouble shooting Section Page 12 1 12 2 12 3 12 3 12 4 12 ...

Page 77: ...FRONT WHEEL 12 12 1 ...

Page 78: ...ty with a comparator fig 2 Allowed limit 0 20 mm Rim Check rim centering on a centering bench Spin wheel manually and measure the centering error with a comparator fig 3 Allowed limits Radial oscillation 2 00 mm Axial oscillation 2 00 mm Bearing inspection Rotate each bearing s inner ring with a finger The bearings must turn smoothly and without noise make sure the outer part of the bearing is per...

Page 79: ...FRONT WHEEL 12 12 2 2 ...

Page 80: ...unt the spacer insert the left bearing fig 7 Place some grease on the inside of the dust cover and mount it fig 8 Install the speedometer drive gear ring in the wheel hub aligning the tabs with the slot Grease the speedometer drive and mount it in the wheel hub aligning the tabs with the slot fig 9 REASSEMBLY Place calliper on brake disc being careful not to damage the pads Clean wheel spindle and...

Page 81: ...FRONT WHEEL 12 12 2 4 ...

Page 82: ...l spindle and mount it There are no spindle thrust or spacer washers Tighten the spindle to the recommended torque then connect cable to the speedometer drive TECHNICAL DATA Standard values Wheel rim centering error 0 5 mm Fork spring free length 420 mm Front forks oil capacity 310 cc for each side 12 3 ...

Page 83: ...illation Bent rim Worn front wheel bearings Damaged tyre Incorrectly torqued wheel spindle Suspension too soft Insufficient fork oil Fork oil too thin Weakened fork springs Suspension too hard Too much fork oil Fork oil too dense Damaged leg or stanchion Noisy front suspension Fork stanchion sticky Insufficient oil in forks Loose front fork bolts Poor braking performance Missing or insufficient br...

Page 84: ...SUSPENSION STEERING 13 Diagram Removal Inspection Reassembly Section Page 13 1 13 2 13 3 13 3 13 ...

Page 85: ...SUSPENSION STEERING 13 13 1 ...

Page 86: ...th both stanchions and legs Remove the outer steering sleeve rings check that the bearings ring races are in good shape if worn replace both rings and bearings If the motorcycle has been in an accident check for cracks around the steering head Steering sleeve lower bearing replacement Remove bearing with the appropriate tool fig 4 Steering sleeve assembly Grease the bearings Install the sleeve in ...

Page 87: ...SUSPENSION STEERING 13 13 2 2 ...

Page 88: ...eg don t show signs of abrasions scratches and excessive or abnormal wear Replace any worn or damaged components Oil seal replacement Remove the oil seal retainer ring and remove the oil seal Avoid damage to the leg s internal and external surfaces The oil seals may be replaced without pulling the stanchions from the fork yokes Mount the oil seals then retainer ring REASSEMBLY Clean all components...

Page 89: ...SUSPENSION STEERING 13 13 3 4 ...

Page 90: ...bly figs 11 12 Left fork component reassembly figs 13 14 Install the spacer spring and tighten to the correct torque Install the stanchion in the steering column and yoke by rotating it by hand Make sure the end of each stanchion is aligned with the end of the yoke Tighten the yoke and steering column bolts of one side Tighten the bolts of the other side Install the front mudguard and brake callip...

Page 91: ...INTENTIONALLY BLANK ...

Page 92: ...REAR SUSPENSION AND WHEEL 14 SUB INDEX Diagram Technical data Troubleshooting Wheel Suspension Final Drive Section Page 14 1 14 2 14 2 14 2 14 3 14 4 14 ...

Page 93: ...REAR SUSPENSION AND WHEEL 14 14 1 ...

Page 94: ...iper bracket and wheel spacer hang down Pull out the wheel spindle fully Remove chain from sprocket and pull out the wheel Don t actuate the brake pedal once the wheel is removed otherwise it ll be difficult to insert the brake disc between the brake pads on reassembly Wheel spindle inspection Place spindle on two V shaped supports and measure eccentricity with a comparator fig 2 Allowed limit 0 2...

Page 95: ...REAR SUSPENSION AND WHEEL 14 14 2 2 ...

Page 96: ... sprocket from the flange fig 6 Replace the rubber flexible couplings if damaged or worn The flexible couplings are made up by two components one inner metal ring and one outer rubber ring fig 7 If the wheel bearings need to be replaced remove the bearings and spacer once removed the bearings must always be replaced with new ones Use a hydraulic press and the correct tool to mount the bearings fig...

Page 97: ...REAR SUSPENSION AND WHEEL 14 14 2 4 ...

Page 98: ...ect the damper and make sure there are no signs of dents oil leaks or other damage make sure the damper rod isn t bent Replace damper if necessary Reassembly Place some grease on the upper and lower damper mounting bolts prior to installation Mount damper and tighten the upper and lower bolts to the correct torque Damper pivot joint and swing fork Remove rear wheel Remove silencer Remove lower dam...

Page 99: ...REAR SUSPENSION AND WHEEL 14 14 3 2 ...

Page 100: ...the damper fork pivot fig 23 Grease and then mount the dust cover Pivot bolts inspection Measure the bolts with a micrometer fig 24 Wear limit dia 15 95 mm Replace both bolts and rods if worn Measure the pivot bolt with a micrometer fig 25 Wear limit dia 17 92 mm Replace both bolt and bushings if worn Check for surface markings produced by the rods caged rollers Swing fork reassembly Mount fork on...

Page 101: ...REAR SUSPENSION AND WHEEL 14 14 3 4 ...

Page 102: ...the drive driven sprockets must give a chain deflection of 35 40 mm If the chain loosens this means that some links may be damaged or frozen Wear condition of the links rollers and driven sprocket teeth must be frequently inspected These components must be replaced when wear limit goes beyond the indicated values fig 5 on page 14 2 4 Chain status inspection If a part of the chain or the drive driv...

Page 103: ...BRAKES 15 Brake pad replacement Servicing information Technical data Troubleshooting Section Page 15 1 15 2 15 2 15 2 15 ...

Page 104: ...o the master cylinder in the event of fluid depletion BRAKE PAD REPLACEMENT Front brake Always replace brake pads in pairs this will allow a uniform pressure on the disc Loosen the front pad s bolt lock nut fig 1 Remove the pads bolt and remove the pads fig 2 Install new pads and mount the pads bolt mount the lock nut and tighten to the correct torque Rear brake Remove the calliper mounting bolts ...

Page 105: ...BRAKES 15 15 1 2 ...

Page 106: ...aster cylinder inspection Drain the brake fluid Remove the master cylinder and its metal protection Remove the rubber protection Remove the retainer ring from the master cylinder fig 9 Remove the piston and measure the piston s outer diameter fig 10 Wear limit 12 94 mm Make sure the piston seals aren t damaged Lubricate all components with brake fluid prior to assembly Install all components in th...

Page 107: ...BRAKES 15 15 1 4 ...

Page 108: ...eter Rear calliper piston outer diameter Rear brake disc thickness Rear brake disc distortion TROUBLESHOOTING Brake pedal lever is soft or spongy Air in system Brake fluid level too low Leakage in the hydraulic system Brake pedal lever is too hard Frozen pistons Hydraulic system clogged Worn or glazed pads Brakes drag Blocked hydraulic system Frozen pistons Brake sticks or pulls to one side Dirty ...

Page 109: ...BATTERY CHARGING CIRCUIT 16 Battery voltage Battery charging Battery removal Battery reinstallation Charging circuit Troubleshooting Section Page 16 1 16 1 16 1 16 1 16 2 16 2 16 ...

Page 110: ...ater after charging Note The battery s electrolyte contains sulphuric acid Always protect the eyes skin and clothes If electrolyte gets on the skin or in the eyes wash thoroughly with water for eyes also seek qualified medical advice BATTERY REMOVAL Remove seat Remove the battery securing rubber band fig 1 Disconnect the negative and then the positive terminals Remove the battery Battery inspectio...

Page 111: ...nd cable Connect the ammeter between the ground cable and the negative post on the battery The ammeter must have a reading of 0 A with the ignition in the off position Charge circuit check Make sure the battery is in working order before proceeding with this operation Warm the engine up Remove seat Connect the voltmeter fig 2 above Keep engine running at idle Slowly increase engine speed Voltage s...

Page 112: ...hows a resistance of 1000 1500 Ω Alternator stator coil check Disconnect the alternator wires fig 5 Remove the alternator stator coil Check for continuity between the two wires of the alternator stator coil fig 6 Check for continuity between the wires of the alternator stator rectifier fig 7 Check if there is no continuity on the contrary between the above mentioned stator coil wires and ground fi...

Page 113: ...BATTERY CHARGING CIRCUIT 16 16 2 3 ...

Page 114: ...IGNITION SYSTEM 17 Description Inspection Spark Plug Troubleshooting Section Page 17 1 17 2 17 3 17 3 17 ...

Page 115: ...ark plug Magneto flywheel The magneto flywheel consists of a condenser charge windings and a pick up coil to generate the activation signal for the CDI control unit CDI control unit The CDI control unit consists of a condenser pulse generator connected to the flywheel s pick up windings ignition advance circuit operating from the signal coming from the pick up and condenser discharge circuit HT co...

Page 116: ...p coil test Place tester leads between the pick up s output wires White Green White Red to determine the resistance and insulation fig 2 a Resistance value 110 Ω 10 at 20 C b Insulation test make sure the needle doesn t move while placing one terminal to ground fig 3 HT coil test Remove fuel tank and seat Disconnect the electrical wires and spark plug cap Remove ignition coil Measure the resistanc...

Page 117: ...IGNITION SYSTEM 17 17 2 2 ...

Page 118: ... The electrical wires are loose broken or shorted Between excitation coil and ignition control unit Between ignition control unit and engine kill switch Between ignition coil and spark plug Between generator and ignition control unit Between ignition coil and ignition control unit Ignition coil is defective Ignition control unit is defective Excitation coil is defective Generator is defective Engi...

Page 119: ...ELECTRIC STARTER 18 Starter motor Casing insulation check Troubleshooting Section Page 18 1 18 1 18 1 18 ...

Page 120: ...re shaft there must not be continuity fig 3 CASING INSULATION CHECK Check for continuity between the cable terminal and starter casing and between the cable terminal and brushes lead fig 4 Replace starter if there is no continuity in the windings or if it s shorted to the casing Install the starter taking care in positioning the spacer washers Install the cover and fasten the two nuts Install the ...

Page 121: ...ELECTRIC STARTER 18 18 1 2 ...

Page 122: ...INTENTIONALLY BLANK ...

Page 123: ...WITCHES HORN LIGHTS REAR MUDGUARD EXHAUST PIPE 19 Instruments Head tail lights turn indicators Switches Horn Rear mudguard Exhaust pipe Troubleshooting Section Page 19 1 19 1 19 2 19 2 19 2 19 2 19 3 19 ...

Page 124: ...s Remove the headlamp fairing optic group and disconnect the bulb wires Remove the bulb cover and replace if necessary fig 2 Remove the bulb holder with the TOP marking facing up Connect the wires to the bulbs Install the headlamp and fairing and fasten with its mounting bolts Adjust the position of the headlamp TAIL LAMP Remove the rear lens cover screws Replace the bulb if necessary fig 3 Instal...

Page 125: ...SWITCHES HORN LIGHTS REAR MUDGUARD EXHAUST PIPE 19 19 1 2 ...

Page 126: ... indicator should turn on If not check for a short or disconnected wire or that the warning light bulb is not burned replace bulb if necessary If the sensor with switch in ON position and engine at stop does not show any continuity between main wire and ground it should be replaced RESERVE FUEL INDICATOR Remove the reserve fuel sensor from the tank Move the float towards the threaded part of the s...

Page 127: ...EAR MUDGUARD Remove the seat mounting bolts Remove the seat by pulling it towards the rear about 2 or 3 cm then lift it up fig 5 Remove tail light Remove rear turn indicators Disconnect the rear turn signals and tail light wires Remove the four mounting screws fig 6 Remove the brake fluid reservoir without disconnecting the fluid tubing Pull out the electrical system Remove rear mudguard Assemble ...

Page 128: ...SWITCHES HORN LIGHTS REAR MUDGUARD EXHAUST PIPE 19 19 2 3 ...

Page 129: ...aulty or burned bulbs Defective switch Open or shorted circuits Burned fuse Loose broken or shorted wires Battery weak or not connected All lights are on but are weak Battery weak Excessive resistance in the harness or switches High beam doesn t come on with switch in the ON position High beam filament is burned Switch is defective 19 3 ...

Page 130: ...TROUBLESHOOTING 20 Engine doesn t start or starts with difficulty Poor performance Poor road handling Section Page 20 1 20 2 20 3 20 ...

Page 131: ...TROUBLESHOOTING 20 20 1 ...

Page 132: ...TROUBLESHOOTING 20 20 2 1 Continued on page 20 2 2 ...

Page 133: ...TROUBLESHOOTING 20 20 2 2 Continued from page 20 2 1 ...

Page 134: ...TROUBLESHOOTING 20 20 3 ...

Page 135: ...rs Handlebar light control left Horn Blinker buzzer Water temperature indicator instrument Water temperature light 12V 1 2W Odometer and rev counter 12V 2W Oil pressure indicator light 12V 1 2W Fuel reserve indicator light 12V 1 2W Neutral indicator light 12V 1 2W Blinker indicator light left 12V 1 2W Blinker indicator light right 12V 1 2W High beam indicator light 12V 1 2W Water temperature therm...

Page 136: ...CIRCUIT DIAGRAM 21 1 21 1 ...

Page 137: ...s the compression damping and the left does the rebound Both have 310cc of SAE10 fork oil as standard If you want to change the damping experiment with the left leg Try mixing oil grades to give an in between grade eg SAE15 Increasing the oil quantity will not affect the damping but will give the effect of stiffer springs Having said all this the forks work very well as they are but it is worth ch...

Page 138: ...e standard headlight bulb 40 45w tungsten with Bosch bayonet fitting is not satisfactory but now you can get a 35 35w halogen bulb with Bosch bayonet fitting and this is far better Torque your head studs You will need a torque wrench with a range up to 40 Nm and down to about 15 Nm with a socket and an extension bar that is long enough to get the wrench clear of the frame Slacken the four bolts by...

Page 139: ...re correctly adjusted when there is no free play It is very easy to over tighten them and then they will fail quite quickly Tighten them until the forks will not fall from side under their own weight when you turn them Now slacken off slightly until they will fall freely Now tighten the top nut You may find that now the races are too tight If they are slacken the top nut loosen the adjuster a bit ...

Page 140: ... tap the race out first one side then the other a little at a time Getting the bottom inner off is tricky Carefully tap a slim cold chisel or screwdriver under the race first one side then the other but go steady You will probably damage the dust cap which is under the race so be sure to replace it very cheap The important thing when refitting the races is to get them fully seated all the way roun...

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