Chapter 2
–
Frame / Panels / Exhaust
Service manual AJP PR3/PR4 2 - 11
21.5mm) and remove the screw together with
the two spacer bushings;
Remove the screw fixing the bottom of the
right beam to the frame (with a Allen key of
8mm);
Remove the swing arm shaft nut (with 22mm
box key) and enter a came up the left side to
extract the engine shaft / swing arm;
Release the rear brake pump on the beam;
Release the kneecap, and remove the brake
pedal;
Separate the right beam of the frame;
Remove the right skate holder.
INSTALLATION:
Install the new right beam on the frame,
properly aligning the various holes of the
fixing points, and temporarily tighten all the
screws until you get full seating of the beam in
the frame;
NOTE:
If necessary, use only the rubber
hammer, or nylon, to adjust the fit of the
aluminum beam on the frame.
Enter the swing arm / motor shaft with the
washer through the hole of the right beam.
Tighten the motor shaft / swing arm and all
the beam fixing screws to the frame with the
specified torque, as for the left beam.
Proceed with the installation by following the
procedures in reverse order of removal.
FRAME
Replacement
If it’s necessary to replace the steel frame,
remove the crankcase protection and put the
motorcycle resting on a bench / appropriate
support stand so that the two motorcycle
wheels rest against the ground.
NOTE:
Before disassembling the components, can be
beneficial to take note or photos of the
position of the various components, especially
electric cables and wires, electric wiring, as
well as the routing of fuel piping, for later
reference in a manner that ensures the
assembly of all the pieces in the correct
position to ensure the a safely functioning of
the motorcycle.
REMOVAL:
Perform the steps described above for the
replacement of the beams.
Release the rubber clamps on front forks,
disconnect the terminals of the headlight and
turn signals connections and remove the
headlight.
Cut the plastic clamps on the right side of the
handlebar and release the switch cable /
connecting wires in front of the brake pump;
Loosen the 3P and 6P connectors of the lights
switch, the 5P connector of the ignition switch,
the 4P start button and kill switch connector,
2P front stop switch connector (on models
equipped with new brake pump);
Disconnect the connectors of the various
electrical components, and remove the
electrical wiring;
