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Head unit: checks and adjustments

Reset the degree wheel of tool part no.

88713.0123:

the horizontal piston is at TDC in the combustion stroke and

therefore you can proceed with checking valve clearance on this cylinder head.

To measure valve clearance in the vertical cylinder, rotate the crankshaft counterclockwise through 270°. This will

bring the vertical piston at TDC during the combustion stroke that is the correct position for checking valve clearance

on this cylinder head.

Checking opening clearance (Sa) at intake/exhaust

To check opening clearance (Sa), slide a feeler gauge between opening rocker arm (B) and shim (3). Measured

clearance must be within the specified limits (Sect C1.1,

Timing/valves

If the clearance measured is outside the specified limits, remove the opening shim (3) as described under paragraph

Removing the valves

in Section N 4.4, and replace it with a suitable one to reach the recommended assembly

clearance.

Note

When performing this check and inserting the feeler gauge, pay attention to overcome rocker arm closing spring force

to take up rocker arm operating play: for this purpose, ensure that shim can rotate freely.

Note

Spare opening shims are available in 1.8 - 3.45 size: the size is punched on the shim.

file:///C|/Documents%20and%20Settings/F4i/My%...manual/wsm/usa/Mon695_MY07_N_4A9_00.62.1.html (3 of 8) [10/7/2008 8:45:21 PM]

Содержание MONSTER 695

Страница 1: ...ed in the spare parts catalogue Caution This manual also describes pre delivery checks Ducati Motor Holding S p A declines all responsibility for any technical errors or omissions in this manual and r...

Страница 2: ...back to the original condition Caution Some of the sections of this manual are not present being the relevant parts not installed on the vehicle Caution The manual structure has been designed to be ap...

Страница 3: ...the motorcycle and its components Note This symbol indicates additional useful information for the current operation Text references X The bold reference indicates a part that is not illustrated in t...

Страница 4: ...Low strength threadlocker Loctite 222 LOCK 2 Medium strength threadlocker compatible with oil Loctite 243 LOCK 3 High strength sealant for threaded parts Loctite 270 LOCK 4 Flange sealant Resistant to...

Страница 5: ...stress and high temperature solvent proof and chemical proof Loctite 128443 LOCK 11 Instantaneous jelly sealant featuring tensile cut strength Loctite 454 gel DUCATI liquid gasket 942470014 Exhaust pi...

Страница 6: ...ammable and becomes explosive under particular conditions Keep away from children Hot component parts Warning The engine and exhaust component parts become hot when the engine is running and will stay...

Страница 7: ...nt any unnecessary downtime for example picking up of required spare parts or arrangement of required tools etc Time and money can be saved by limiting the number of operations needed to reach the par...

Страница 8: ...2 Symbols abbreviations references 5 Product specifications 6 3 Dangerous products warnings 8 General safety rules 8 General maintenance indications 9 file C Documents 20and 20Settings F4i My 20D i 2...

Страница 9: ...Monster 695 i e Each Ducati motorcycle has two identification numbers frame number and engine number and an EC nameplate A not used in the USA version file C Documents 20and 20Settings F4i My 0manual...

Страница 10: ...e parts Data punched on frame European version 1 Manufacturer s name Ducati Motor Holding 2 Type same on all Monsters 3 Variant 4 Version 5 Year of manufacture 7 2007 6 Plant of manufacture 7 Progress...

Страница 11: ...digit X 4 Model year 7 2007 5 Plant of manufacture 6 Progressive serial No Data punched on engine European version 1 Manufacturer s name Ducati Motor Holding 2 Engine type 3 Progressive production No...

Страница 12: ...on data Data punched on engine USA version 1 Engine type 2 Model year 3 Progressive production No file C Documents 20and 20Settings F4i My 0manual wsm usa Mon695_MY07_B_1_1_00 7 1 html 4 of 4 10 7 200...

Страница 13: ...ormation 0Model specific information 1 Identification data 3 Identification data for Monster 695 i e 3 file C Documents 20and 20Settings F4i My 20D i 20manual wsm usa Mon695_MY07_B_IND_00 6 1 html 10...

Страница 14: ...size 120 60 ZR 17 Rear rim Light alloy three spokes with cush drive damper pads Rear rim size MT 4 50x17 Rear tyre size 160 60 ZR 17 Type of tyre Radial tubeless tyre Front brake Hydraulic with 2 cal...

Страница 15: ...echnical specifications Clutch Multi plate wet clutch Clutch control Hydraulic Gearbox Six gears Primary drive 33 61 Transmission ratio 1 85 Final drive 15 48 Gearbox type Constant mesh spur gears con...

Страница 16: ...87 970 mm 87 980 mm 87 990 mm 0 005 mm 0 005 mm 0 005 mm Gudgeon pin piston clearance 0 004 0 012 mm 0 025 mm Piston cylinder coupling clearance 0 025 0 045 mm 0 12 mm Gudgeon pin connecting rod clear...

Страница 17: ...n position 2 mm Tyre pressure Cold 2 2 bar 2 4 bar Swingarm shaft eccentricity On 100 mm 0 2 mm Wheel rim eccentricity Radial 0 8 mm 2 mm Axial 0 5 mm 2 mm Chain Make Type D I D 520 V L 4 Dimensions 5...

Страница 18: ...linder diameter 32 mm Pads friction material FERIT I D 450 FF Brake master cylinder Type PS11 Master cylinder diameter 11 mm Charging system generator Reference Technical specifications Battery Voltag...

Страница 19: ...ndicator light 12V 10W Instrument panel light 12V 2W Turn indicator warning light 12V 1 2W High beam warning light 12V 1 2W Neutral light 12V 1 2W Oil pressure warning light 12V 1 2W Injection system...

Страница 20: ...Dimensions 1 2 Dimensions file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_C_1B4_00 10 1 html 1 of 2 10 7 2008 8 41 59 PM...

Страница 21: ...Dimensions file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_C_1B4_00 10 1 html 2 of 2 10 7 2008 8 41 59 PM...

Страница 22: ...ct Cleaner Front fork SHELL Advance Fork 7 5 or DONAX TA 0 400 each leg Caution Do not use fuel or lubricant additives Engine oil A good engine oil has special properties Use only a highly detergent e...

Страница 23: ...ure air pressure sensor retaining screw M 5x0 8 3 Front fork Steering head retaining screw center position M 8x1 25 23 GREASE B Steering head retaining screws M 8x1 25 24 GREASE B Bottom yoke screw M...

Страница 24: ...ake lever pin M 8x1 25 24 LOCK 2 Rear brake Rear brake caliper retaining screw M 8x1 25 24 GREASE B Brake bleeding fitting M 10x1 23 Rear brake master cylinder retaining screw M 6x1 10 Screw retaining...

Страница 25: ...screws M 8x1 25 24 Heat guard to footpeg holder retaining screw M 6x1 3 Front and Rear wheel Front wheel nut M 25x1 25 63 GREASE B Rear wheel shaft nut M 25x1 25 83 GREASE B Brake disc mounting screw...

Страница 26: ...ew M 6x1 8 Side stand Side stand plate retaining screw M 10x1 5 36 LOCK 5 Side stand sensor wire retainer screw M 6x1 10 Side stand pivot nut M 8x1 25 24 Side stand sensor retaining screw M 6x1 10 Fra...

Страница 27: ...M 12x1 15 13 17 LOCK 2 or THREE BOND 1324 Oil temperature sensor M 12x1 5 18 16 19 LOCK 4 Spark plugs M 12x1 25 20 18 22 Head nuts 1st snug torque 2nd snug torque final torque M 10x1 5 15 25 40 23 38...

Страница 28: ...REE BOND 1324 Head service screws aluminium M 6x1 3 2 3 LOCK 5 or THREE BOND 1375B Intake manifold fuel pump fitting M 6x1 2 5 2 3 LOCK 2 or THREE BOND 1324 Bosch pick up retaining screws M 6x1 10 9 1...

Страница 29: ...6x1 10 9 11 Screws M 5x1 5 5 7 Note For product specifications and symbols refer to Product specifications A 2 file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_C_3_4_00 12 1 html 7...

Страница 30: ...iption 88700 5644 Tool to set belt roller ring nut for camshaft 88713 2107 Reaction tool to tighten timing belt rollers 88713 2676 Head nuts tightening tool 88713 2103 Support for head assembly file C...

Страница 31: ...eck tool 97900 0215 DDS Ducati Diagnosis System kit for measuring cylinder vacuum 88713 0137 Crankshaft sprocket stop tool 88765 1058 Valve lift gauge file C Documents 20and 20Settings F4i My manual w...

Страница 32: ...mm fork feeler gauge 88713 2362 Tool to fit spring and closing rocker arm 88713 2009 Tool to lock belt rollers 88713 0262 Pin to fit the rocker arms 88713 0844 Drift to fit split rings file C Documen...

Страница 33: ...closing the crankcases 88713 1091 Plate for gear selector fork positioning 88713 1749 Puller for drive belt roller and cover 88765 1297 TDC check gauge file C Documents 20and 20Settings F4i My manual...

Страница 34: ...2556 ATPC system clutch housing locking tool 88713 2591 Clutch screw 88713 1010 Exhaust gas pick up point 88713 1215 Timing belt tensioner file C Documents 20and 20Settings F4i My manual wsm usa Mon6...

Страница 35: ...ing 88713 2092 Primary gears puller 88713 0879 Valve guide extraction tool 88713 0874 Exhaust valve guide drift 88713 0875 Intake valve guide drift file C Documents 20and 20Settings F4i My manual wsm...

Страница 36: ...2 Wrench for tightening the primary sprocket ring nut Spare parts catalogue Workshop special tools Frame special tools Part No Description 677 4 003 1A Chain joint 88713 1072 Bottom yoke bearing drift...

Страница 37: ...wheel shaft tool 88713 1096 Fork overhaul tool for fitting the seal 88713 1515 Frame engine support 88713 1058 Tool to fit steering tube top bolt file C Documents 20and 20Settings F4i My manual wsm u...

Страница 38: ...Service Tools 88713 1062 Tool to fit steering tube bearings file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_C_4_4_00 13 1 html 9 of 9 10 7 2008 8 42 23 PM...

Страница 39: ...sion 6 Hydraulic brakes 7 Charging system generator 7 Ignition system 7 Fuel system 8 Injection system 8 Lights instrument panel 8 1 2 Dimensions 9 2 Fuels and lubricants 10 3 Torque settings 11 Frame...

Страница 40: ...apt to one another and above all not to adversely affect the life of basic engine parts it is advisable to avoid harsh accelerations and not to run the engine at high rpm for too long especially uphil...

Страница 41: ...vant reservoirs Tyre condition Check tyre pressure and condition Sect C 1 1 Front wheel Rear wheel Controls Work the brake clutch throttle and gear change controls levers pedals and twistgrips and che...

Страница 42: ...choke lever to B Let the engine start without using the throttle Move the choke lever to vertical position A Caution The oil pressure light should go out a few seconds after the engine has started If...

Страница 43: ...least 2 seconds before pressing the button 3 again Caution Do not rev up the engine when it is cold Allow some time for oil to warm up and reach all points that need lubricating Warning The motorcycl...

Страница 44: ...Starting engine warm up file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_D_2_5_00 16 1 html 3 of 3 10 7 2008 8 42 28 PM...

Страница 45: ...utch and brake fluid Checking and adjusting brake and clutch controls Checking lubricating throttle choke control Checking tyres wear and pressure Checking brake pads Change them if necessary Checking...

Страница 46: ...ention set mileage km mi or time interval Km x1000 1 mi x1000 0 6 Months 6 Checking the engine oil level Checking brake and clutch fluid level Checking tyres wear and pressure Checking chain tension a...

Страница 47: ...d filter cartridge Note Change the oil when the engine is hot but off In these conditions the oil is more fluid and will drain more rapidly and completely Remove the drain plug 3 on the oil sump and a...

Страница 48: ...ghten to the specified torque Sect C 3 Engine torque settings Clean the oil mesh filter every second oil change Unscrew the outer plug 5 Release and withdraw the mesh filter 7 Clean the mesh filter wi...

Страница 49: ...h off the engine and allow several minutes for the oil to settle Check the oil level and top up to MAX mark if necessary Refit any parts you have removed Checking valve clearances Proceed as described...

Страница 50: ...losing rocker arm Intake A Nominal 0 0 05 mm In operation 0 0 20 mm Exhaust A Nominal 0 0 05 mm In operation 0 0 20 mm If the clearances measured are outside the specified limits measure clearance and...

Страница 51: ...s indicated in the Routine maintenance table Sect D 3 Raise the fuel tank Sect L 2 Removing the fuel tank Release the cover clips 1 on either side of the airbox Remove the cover 2 Remove the filter ca...

Страница 52: ...onditions the air filter cartridge must be changed more frequently Changing the brake fluid Warning Brake fluid will damage painted surfaces if spilled on them In addition it will cause severe injury...

Страница 53: ...t oil flows off Warning When filling up keep oil level above MIN mark to avoid air bubbles into the circuit Let oil flow off from the bleed valve 2 until of different color Tighten the bleed valve to...

Страница 54: ...ve 4 put one end of the hose into a container on the floor Suck the oil up from the reservoir B Fill reservoir B with fresh oil up to MAX level Pump up two or three times with the pedal to pressurize...

Страница 55: ...aining the braking circuit Warning Brake fluid will damage painted surfaces if spilled on them In addition it will cause severe injury if spilled on the skin or into your eyes In the event of accident...

Страница 56: ...eeder available attach a length of transparent plastic tubing to the caliper bleed valve 2 front or 4 rear and put the other end of the hose into a container holding spent brake fluid you will have pl...

Страница 57: ...t remain immersed in the discharged brake fluid at all times Operate the brake lever or pedal several times to let the fluid reach all points of the circuit and expel any air Connect the brake bleeder...

Страница 58: ...one fourth one fourth of a turn Allow several seconds and then release the lever or pedal gradually and close the bleed valve 2 or 4 Caution Do not release the brake lever or pedal until the bleed va...

Страница 59: ...s if spilled on them In addition it will cause severe injury if spilled on the skin or into your eyes In the event of accidental contact with skin or eyes wash the affected area with abundant running...

Страница 60: ...ve 3 put one end of the hose into a container on the floor Suck the oil up from the reservoir A Fill reservoir A with fresh oil up to MAX level file C Documents 20and 20Settings F4i My anual wsm usa M...

Страница 61: ...circuit Let oil flow off from the bleed valve 3 until of different color Tighten the bleed valve 3 to the specified torque Sect C 3 Frame torque settings and top up oil to correct level Draining the...

Страница 62: ...pump the bleeder until all the fluid has fully drained off the circuit If you do not have a bleeder available connect a piece of transparent plastic tubing to the bleed valve 3 Place the other end in...

Страница 63: ...Tighten the bleed valve to the specified torque Sect C 3 Frame torque settings Filling the clutch circuit Warning Clutch fluid will damage painted surfaces if spilled on them In addition it will cause...

Страница 64: ...e If you are using a commercial bleeder follow the manufacturer s instructions Pump with the bleeder and slacken the bleed valve 3 Ensure the fluid level never drops below the MIN level Repeat the ble...

Страница 65: ...tion Do not release the clutch lever until the bleed valve has been fully tightened Repeat the bleeding operation until air bubbles no longer come out of the plastic tube Tighten the bleed valve 3 to...

Страница 66: ...ve both clamps 2 and remove the handlebar Loosen the screws 3 on the steering head at the fork leg clamps Loosen the clamp screw 4 securing the steering tube to the steering head Tighten the ring nut...

Страница 67: ...is tightest Place the motorcycle on the side stand Push the chain upwards with one finger at swingarm mid length see label The lower section of the chain should move by approx 25 27 mm When required a...

Страница 68: ...nd tighten them to the specified torque Sect C 3 Frame torque settings Checking brake pad wear Changing brake pads Warning Brake fluid will damage painted surfaces if spilled on them In addition it wi...

Страница 69: ...it new pads and their springs 5 and 6 Insert the centering pin 3 and lock it using the split pins 2 Operate the brake lever repeatedly so that the pads bed in under the action of the brake pistons Che...

Страница 70: ...ads To change the pads proceed as follows Remove the split pin 1 from the caliper retaining pin The split pin is on caliper inner side Force the brake pads apart to force the caliper pistons into thei...

Страница 71: ...the calipers Sect G 3 Removing the front brake system and G 6 Removing the rear brake system Warning The brake calipers are critical safety components Observe the instructions given in Section G Wheel...

Страница 72: ...2000 rpm Turn screw 7 to adjust the rpm Likewise loosen the lock nut 5 and work the adjuster 4 to adjust the throttle control cable Check for proper conditions of the outer sheaths of the throttle and...

Страница 73: ...ar brake pedals in relation to the footpegs can be adjusted to suit rider preferred riding position To adjust the position of the gear change pedal proceed as follows Clamp the rod 1 and loosen the lo...

Страница 74: ...rake cylinder control rod To increase the amount of pedal free travel screw the rod further into the fork 6 Unscrew the rod to decrease Tighten the lock nut 7 and check the amount of pedal free travel...

Страница 75: ...rench pin does not slip out suddenly from the slots in the ring nut This could cause minor injuries to your hands Do not use wrenches which are too small or have short handles Standard spring length 1...

Страница 76: ...97900 0228 Battery adapter 9 814 1 114 1A Oil pressure connection 10 514 1 032 1A Auxiliary test cable 11 552 1 037 1A Cylinder compression cable M12 fitting 12 875 1 065 1A Oil pressure tube 13 97900...

Страница 77: ...se any faults in the injection ignition system via a serial port This system provides a full range of features to test a number of motorcycle devices measure the current and voltage outputs from any e...

Страница 78: ...the DUCATI control units resides in the BBAD memory card D located in the BBAD module B The base unit features two connection areas one at the top and one at the bottom The top one has 6 connectors on...

Страница 79: ...ware installation PC version USB cable Belt tension sensor Instrument power supply The DDS 1 can be powered as follows from the mains connect mains power supply 14 to power connector N from the vehicl...

Страница 80: ...ster detects a power supply voltage below 9 Volts it will abort any procedures underway at that time Once voltage is again within specified limits you will have to repeat procedure set up The DDS 1 ca...

Страница 81: ...t diagnosis connector P connecting battery adapter 8 to power and diagnosis cable connector R and then connecting the adapter to the vehicle battery file C Documents 20and 20Settings F4i My anual wsm...

Страница 82: ...ected to special feelers the DDS can read voltage current and temperature values as well as timing belt tension values and pressure values into oil and fuel circuits Checking and adjusting timing belt...

Страница 83: ...power and diagnosis cable Measurement Module 3 connector V Secure the belt tension sensor bracket 15 using belt cover screw 21 Aim the middle green led of the sensor 15 at the centre of the belt sect...

Страница 84: ...ss on Belt tension icon and then Start to enter the Belt mechanical tension page The page shows you which socket of the cable Measurement Module 3 is to be used with a capital A B or C file C Document...

Страница 85: ...es as the DDS needs at least 1 second to read the value Warning Check tension reading on the belt sections 22 and 23 indicated in the figure Belt tension values are indicated in Sect C 1 1 Timing valv...

Страница 86: ...nsioner 26 by hand to stretch the timing belt or lower down to slacken Note If the crankcase has been removed from the frame turn screw 24 using the suitable tool 27 and position tool pusher U on the...

Страница 87: ...When the throttle body throttle position sensor electronic control unit or wiring have been replaced perform this procedure first before starting the engine Ensure that the throttle is fully home on i...

Страница 88: ...Press the Vehicle selection icon and press Vehicle selection icon in the following page choose the model and confirm then select the version and confirm file C Documents 20and 20Settings F4i My anual...

Страница 89: ...tems that can be diagnosed Select Engine electronic system and press Confirm D to confirm Then press Self diagnosis icon to enter self diagnosis function file C Documents 20and 20Settings F4i My anual...

Страница 90: ...their relevant values Note Perform the necessary connections with the ignition key set to OFF Press Settings icon to display the special parameters Select TPS reset and press Execute file C Documents...

Страница 91: ...ting procedure establishes a connection between electronic control unit and throttle body For this reason the zero setting procedure must be repeated each time the throttle body throttle position sens...

Страница 92: ...When oil temperature is above 75 C you can start the following adjustment procedure always bear in mind that at the end of the adjustment oil temperature should not exceed 100 C Idling should be betw...

Страница 93: ...k the choke control adjuster 22 to adjust choke lever 23 so that the lever 24 can travel smoothly all its stroke Checking engine oil pressure Note A table at the end of this section explains the icons...

Страница 94: ...rew the connector all the way in Refit the pressure switch 21 complete with seal to the connector 9 and reconnect it to the electric system connector A Connect the pressure sensor 5 to the hose 12 in...

Страница 95: ...the power and diagnosis cable Measurement Module 3 to measurement module connector B of the DDS 1 Connect the pressure sensor 5 to port A or C of cable 3 file C Documents 20and 20Settings F4i My anual...

Страница 96: ...tion then press on Pressure Measurement icon D and then Start E The page shows you which socket of the cable Measurement Module 3 is to be used with a capital A B or C file C Documents 20and 20Setting...

Страница 97: ...y mode F to select the display mode Measured value is indicated next to letter A or C depending on the cable used if socket A of cable 3 is used measured value will correspond to letter A on the scree...

Страница 98: ...e relief valve is jammed in the open position that the spring is too weak or that the oil pump is faulty Other causes of incorrect pressure readings include badly worn seals and gaskets badly worn eng...

Страница 99: ...high low or a large compression difference between the two cylinders will cause a drop in engine performance and can cause engine breakdowns Start the engine and let it warm up until the fan switches...

Страница 100: ...osis cable Measurement Module 3 to measurement module connector B of the DDS 1 Connect the pressure sensor 5 to port A or C of cable 3 Note Take the reading in one cylinder at a time Press Measurement...

Страница 101: ...between cylinders 2 bar Excessively high compression readings indicate the following deposits in the combustion chamber Low compression readings indicate gas leakage between head and cylinder worn va...

Страница 102: ...g fuel pressure tube 17 connect one end D to union of delivery hose to tank and the other end E to delivery hose 20 in this way you create a pressure pick up point F Connect the pressure sensor 5 to t...

Страница 103: ...le connector E of the DDS 1 Connect the pressure sensor 5 to port A or C of cable 3 Press Measurement module icon on DDS 1 to select the Measurement module function then press on Pressure Measurement...

Страница 104: ...ndicated next to letter A or C depending on the cable used if socket A of cable 3 is used measured value will correspond to letter A on the screen Maximum pressure must be 3 bar nominal pressure When...

Страница 105: ...ion P 8 Immobilizer and Transponder that consists in entering the emergency code also using the DDS Switch on the DDS 1 refer to Instrument power supply Connect the diagnosis connector H the power and...

Страница 106: ...on and confirm Press System selection icon displayed to show the vehicle systems that can be diagnosed Select Engine electronic system and press Confirm B to confirm Then press Self diagnosis icon to...

Страница 107: ...values Note Perform the necessary connections with the ignition key set to OFF Press Actuators C to display actuators and components connected to ECU Select Immobilizer override and press Execute D f...

Страница 108: ...ss Confirm B If the operation is performed the message Was the operation successful is displayed press Confirm If there are problems in performing the operation the relevant error messages are display...

Страница 109: ...the different vehicle components such as wiring diagrams for the electronic systems and details on the system layout and parts location Switch on the DDS 1 refer to Instrument power supply Connect the...

Страница 110: ...nd confirm then select the version and confirm Press System selection icon displayed to show the vehicle systems that can be diagnosed Select Engine electronic system and press Confirm B to confirm fi...

Страница 111: ...agnosis function pressing Self diagnosis icon to see if the system is faulty If errors are present the symbol D is displayed Press Errors E to display the errors Once errors are detected it is possibl...

Страница 112: ...njection ignition system and all electric items fitted to motorcycle When applied to a cable the amperemeter clamp 18 detects the magnetic field generated by the current passing through that cable Rem...

Страница 113: ...the amperemeter clamp to the battery positive terminal lead with the arrow on the clamp pointing towards the battery positive terminal Press Measurement module icon on DDS 1 to select the Measurement...

Страница 114: ...t means that generator is feeding all electric items and charging battery at the same time A negative value means that charging system is not feeding the loads and a significant amount of current is s...

Страница 115: ...reversed This will lead to wrong diagnosis Icons table Symbol Description Confirm Exit Measurement module Belt tension Start stop Menu key 1 Vehicle selection Vehicle selection Self diagnosis file C D...

Страница 116: ...Display mode Reset Pressure measurement Cylinder compression Actuators Guided diagnosis System selection Errors Clamp type amperemeter file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY0...

Страница 117: ...filters 14 Changing the brake fluid 15 Draining the braking circuit 18 Filling the brake circuit 20 Changing the clutch fluid 23 Draining the clutch circuit 25 Filling the clutch circuit 27 Adjusting...

Страница 118: ...6 Checking cylinder compression 61 Checking fuel pressure 64 Procedure to override the immobilizer system 67 Guided diagnosis 71 Checking the charging system 74 Icons table 77 file C Documents 20and 2...

Страница 119: ...s in this section identify parts shown in this exploded view diagram These parts do not appear in the figures near the text Disassembling the rear view mirrors Use a hexagonal wrench to loosen mirror...

Страница 120: ...s Position the rear view mirror 1 to the U bolt 3 Screw the mirror fully in Position and tighten the mirror 1 with a hexagonal wrench Refit the clamps 3 if removed and fix them with screws 2 file C Do...

Страница 121: ...sher 6 Cover 7 Screw 8 Special screw 9 Screw 10 Washer 11 Side body panel 12 Washer 13 Nut 14 Insert 15 Seat lock 16 Splashguard Spare parts catalogue file C Documents 20and 20Settings F4i My manual w...

Страница 122: ...in the figures near the text Removing the seat Release the lock 15 and lift the seat Remove the complete seat 1 Disassembling the seat Unscrew the screw 8 placed under the seat and remove the cover 6...

Страница 123: ...ighten the screw 8 to the specified torque Sect C 3 Frame torque settings Refitting the seat Insert the seat 1 and press until the lock 15 becomes engaged file C Documents 20and 20Settings F4i My manu...

Страница 124: ...crews 3 Collect the washers 4 Undo the nuts 13 and collect the washers 5 The screw 7 remains on oil breather tank A Remove the screw 7 from oil breather tank A Withdraw the splashguard 16 in a rearwar...

Страница 125: ...3 to the specified torque Set C 3 Frame torque settings Refit the seat as described under Refitting the seat in this section Removing the side body panels Remove the seat as described under Removing t...

Страница 126: ...ers 10 and start the screws 9 in their threads Tighten the screws 9 to the specified torque Sect C 3 Frame torque settings Refit the seat as described under Refitting the seat in this section file C D...

Страница 127: ...Seat file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_E_3_4_00 22 1 html 7 of 7 10 7 2008 8 43 13 PM...

Страница 128: ...Spare parts catalogue Frame Swingarm and chain Caution Bold reference numbers in this section identify parts shown in this exploded view diagram These parts do not appear in the figures near the text...

Страница 129: ...uard 1 Note The USA versions fit a cat s eye on front mudguard 1 Refitting the front mudguard Warning Do not ride the motorcycle without the front mudguard or the brake hoses might touch the wheel und...

Страница 130: ...3 to the specified torque Sect C 3 Frame torque settings Removing the rear mudguard Unscrew the four screws 5 and detach the mudguard 4 from the swingarm Refitting the rear mudguard Fit the rear mudgu...

Страница 131: ...Front and rear mudguard file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_E_4_4_00 23 1 html 4 of 4 10 7 2008 8 43 15 PM...

Страница 132: ...lash guard 9 Refitting the splash guard 10 Removing the side body panels 11 Refitting the side body panels 12 4 Front and rear mudguard 13 Removing the front mudguard 14 Refitting the front mudguard 1...

Страница 133: ...l adjuster on handlebar 9 Blanking plug 10 Throttle control adjuster on throttle body 11 choke control adjuster on throttle body 12 Choke control adjuster on handlebar 13 Cover 14 Left hand switch wit...

Страница 134: ...e the throttle control pulley until releasing the cable nipple D from the pulley Slip off the rubber gaiter A slacken the lock nut and turn out the adjuster 10 until it slides off the throttle control...

Страница 135: ...ar Warning Disturbing the throttle cable may affect the throttle body adjustments Before refitting throttle control cable read Sect D 5 Zero setting the throttle position sensor TPS Reassembling the t...

Страница 136: ...ken the check nut and turn out the adjuster 11 until it comes off the bracket Withdraw the choke control 2 and collect the spring 7 Loosen screws V and remove the left hand switch 14 together with cho...

Страница 137: ...ote The spare choke cable is supplied together with adjusters and drive cable Grease the choke cable 2 Fit the choke cable 2 in the left hand switch and fit the stop pin G into its seat Fix the left h...

Страница 138: ...in the sheath Rotate the lever fully down and make sure that the small lever H of the throttle body contacts the end stop L If not so slacken the screw F and release the core cable 2 Repeat the proces...

Страница 139: ...Throttle control choke file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_F_1_6_00 25 1 html 7 of 8 10 7 2008 8 43 19 PM...

Страница 140: ...Throttle control choke file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_F_1_6_00 25 1 html 8 of 8 10 7 2008 8 43 19 PM...

Страница 141: ...er with dowel 5 Spare cap 6 Clutch hose 7 Spare clamp 8 Gasket 9 Special screw 10 Filler 11 Bleed unit 12 Dust seal 13 O ring 14 Clutch transmission unit 15 Screw 16 Clutch pushrod 17 O ring 18 Micros...

Страница 142: ...laced that is control lever reservoir assembly and cylinder fasteners Operations Reference See Section Drain the clutch circuit D 4 Draining the clutch circuit Undo the special screw 9 keep the seals...

Страница 143: ...Incorrectly positioned hoses can cause faults and interfere with moving parts Refer to the figures at the end of these section for the correct routing of the clutch hose 6 and hose ties Position the...

Страница 144: ...unit seal and complete piston Operations Reference See Section Drain the clutch circuit D 4 Draining the clutch circuit Unscrew the 3 screws 15 fixing the clutch transmission unit 14 to the engine Wit...

Страница 145: ...with the transmission unit 14 onto the casing Tighten the screws 15 to the specified torque Sect C 3 Frame torque settings Position the hose 6 onto the clutch transmission unit 14 Ensure the hose fit...

Страница 146: ...efit the drain 11 and the dust seal 12 Please refer to the table on next page for proper positioning of clamps for hose 6 Operations Reference See Section Fill the clutch circuit D 4 Filling the clutc...

Страница 147: ...Clutch hydraulic control file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_F_2_6_00 26 1 html 7 of 8 10 7 2008 8 43 23 PM...

Страница 148: ...Clutch hydraulic control file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_F_2_6_00 26 1 html 8 of 8 10 7 2008 8 43 23 PM...

Страница 149: ...er with dowel 3 Rubber pad 4 Nut 5 Microswitch 6 Spare lever pin 7 Screw 8 Spare cap 9 Spare sight glass 10 Spare clamp Spare parts catalogue Front brake Caution file C Documents 20and 20Settings F4i...

Страница 150: ...lever reservoir unit and reservoir and cylinder fasteners Operations Reference See Section Draining the braking system D 4 Filling the brake circuit Disconnect the brake line from master cylinder G 3...

Страница 151: ...s starting from the top one indicated with an arrow and then proceeding in a 1 2 1 sequence If hose C has been disturbed follow indications as specified under Sect G 3 Refitting the front brake system...

Страница 152: ...ose 4 Clamp 5 Pin 6 Spring 7 Special screw 8 Rubber block 9 Brake lever 10 Nut 11 Clip 12 Washer 13 Switch 14 Bush 15 Clevis pin 16 Hose 17 Rear brake cylinder 18 Screw file C Documents 20and 20Settin...

Страница 153: ...nufacturer recommends that you do not attempt to service the internal components of the brake master cylinder Incorrect overhaul of these critical safety components can endanger rider safety Maintenan...

Страница 154: ...pplied as a complete assembly The inner components may not be replaced individually Please refer to the exploded view at the beginning of this section for indications on disassembly of master cylinder...

Страница 155: ...Refitting the rear brake master cylinder Lubricate the O ring B and fit it to the pin 5 Lubricate the other O ring B Refit the pin 5 to the brake pedal lever 9 insert the spring 6 the other O ring B...

Страница 156: ...cting brake master cylinder to caliper is correctly positioned as shown on next page Operations Reference See Section Fill the braking system D 4 Filling the brake circuit Rear brake hose routing file...

Страница 157: ...Rear brake control file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_F_4_6_00 28 1 html 6 of 6 10 7 2008 8 43 29 PM...

Страница 158: ...l 3 Screw 4 Rubber block 5 Bush 6 Washer 7 Nut 8 Ball joint 9 Nut 10 Actuating rod 11 Nut 12 Nut 13 Ball joint 14 Gear small lever 15 Screw 16 Screw 17 O ring file C Documents 20and 20Settings F4i My...

Страница 159: ...14 together with the gear change control assembly Note Mark small lever 14 position relative to the gear selector shaft To remove the small lever 14 from the gear change control assembly unscrew the s...

Страница 160: ...the gear change and rear brake pedals Refitting the gear change control To refit reverse the removal procedure Note On refitting always renew O rings 17 Apply threadlocker to the screw 16 the pin 1 a...

Страница 161: ...echanisms 1 Screw 2 Latch 3 Rubber block 4 Screw 5 Lever 6 Ring nut 7 Plate 8 Seat lock 9 Spring washer 10 Screw Spare parts catalogue Seat Caution file C Documents 20and 20Settings F4i My manual wsm...

Страница 162: ...ws 4 and remove the seat lock lever 5 Release the nipple A of the Bowden cable of the lever 5 Unscrew the retaining screws 10 and remove the seat lock assembly Note Make sure to collect the two spring...

Страница 163: ...al of the removal procedure Smear threadlocker on ring nut 6 and screws 4 If you have removed the seat refit it Sect E 3 Refitting the seat and then lower the seat and check that the latch 2 is lockin...

Страница 164: ...y 14 3 Front brake control 17 Removing the front brake master cylinder 18 Refitting the front brake master cylinder 19 4 Rear brake control 20 Removing the rear brake master cylinder 21 Disassembling...

Страница 165: ...eal 5 Bearing 6 Inner spacer 7 Valve 8 Front wheel shaft 9 Front wheel rim Spare parts catalogue Front fork Front and rear wheels Caution file C Documents 20and 20Settings F4i My manual wsm usa Mon695...

Страница 166: ...B Repeat the process for the other caliper Do not disconnect the hoses Warning Do not operate the brake lever when the calipers are disassembled or fluid will leak out from the actuating pistons Note...

Страница 167: ...gs Check for wear by hand with the bearing in its seat Clean and degrease bearing first Turn the inner ring Check the amount of radial and axial play Excessive play will cause vibration and make the b...

Страница 168: ...with grease as this will reduce braking efficiency Using a tubular drift B which only exerts pressure on the bearing outer ring drive the bearing fully into its seat Ensure that the spacer 6 is in pla...

Страница 169: ...gauge measure rim run out and out of round relative to wheel shaft axis see Sect C 1 1 Front wheel If the values measured are not within the limits change the rim Refitting the front wheel When throug...

Страница 170: ...ool in the special notches at the bottom end of the fork Grease the thread and underhead of shaft lock nut 1 Fit and tighten the lock nut on the end of the wheel shaft Tighten the nut 1 to the specifi...

Страница 171: ...n on the handlebars to load the suspension so the fork legs will become properly seated onto the wheel shaft Grease the pinch bolts 2 Tighten the pinch bolts 2 to the specified torque Sect C 3 Frame t...

Страница 172: ...ly 6 Right fork leg assembly 7 Blanking plug 8 Washer 9 Spring 10 Hose 11 Outer sleeve 12 Complete damper cartridge 13 Adjusting screw 14 Gasket 15 Bush 16 Dust seal 17 Circlip file C Documents 20and...

Страница 173: ...ts listed below Operations Reference See Section Remove the front brake calipers G 3 Removing the front brake system Removing the front mudguard E 4 Removing the front mudguard Removing the front whee...

Страница 174: ...Loosen the plug 7 on the fork leg when still fitted onto the vehicle Note The special tools required for front fork overhaul are listed in Section C 4 Frame special tools Unscrew the cap nut 7 file C...

Страница 175: ...loosen plug 7 from cartridge 26 collect gasket 22 Loosen the lock nut 23 until all thread on cartridge 26 is exposed Hold the spring 9 with a hand collect washer 8 from one side and slowly release spr...

Страница 176: ...spring 9 Remove the preload tube 10 Pump the outer sleeve 11 and the cartridge 26 to let oil off the leg file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_G_2_8_00 33 1 html 5 of 14...

Страница 177: ...tact with fork oil Clamp the slider 18 in a vice equipped with protection jaws Unscrew the compression adjuster 13 Remove the adjuster screw 13 and collect the seal 14 Pull out the complete damper car...

Страница 178: ...he outer sleeve 11 from the slider 18 Quickly tap to counteract the pilot bush 19 Remove the bush 15 from the slider by inserting a screwdriver into the bush opening Remove the following parts from th...

Страница 179: ...uld show no signs of scores scratches or distortions Check that stanchion tubes are straight Maximum straightness error allowed is 0 10 mm Each time the slider is separated from the sleeve it is a goo...

Страница 180: ...r seal grease before fitting the oil seal 21 When fitting the oil seal 21 its marked surface should point the dust seal 16 Fit the following parts into the slider 18 dust seal 16 snap ring 17 oil seal...

Страница 181: ...tool Fit the snap ring 17 and the dust seal 16 Caution The outer sleeve must slide freely along the slider Only support the sliders and the outer sleeve with your hands so not to damage the oil seals...

Страница 182: ...in both fork legs Recommended oil SHELL Advance Fork 7 5 or DONAX TA Standard capacity 0 480 cu dm each leg Standard oil level 104 mm Oil quantity affects fork behaviour when at the end of the compres...

Страница 183: ...lock nut and tighten the upper plug 7 with O ring onto the cartridge 26 Tighten the cap nut 7 to the specified torque Sect C 3 Frame torque settings Refitting the front fork Refit the fork legs Fork l...

Страница 184: ...and 1 to the specified torque Sect C 3 Frame torque settings in a 1 2 1 sequence to clamp the fork legs securely in the bottom yoke 4 and steering head 3 file C Documents 20and 20Settings F4i My anual...

Страница 185: ...tact the wheel under braking Refit any components you have removed from the frame Operations Reference See Section Refitting the front wheel G 1 Refitting the front wheel Refitting the front mudguard...

Страница 186: ...alve 6 Special screw 7 Dust seal 8 Cylinder to calipers hose 9 Set of brake pads 10 Left brake caliper 11 Springs 12 Cable guide 13 Brake disc 14 Screw 15 Headlight bracket 16 Screw Spare parts catalo...

Страница 187: ...er and seek medical advice if necessary Please refer to Sect D 4 Draining the braking circuit for maintenance instructions brake pads wear check and replacement brake fluid change and so on Removing t...

Страница 188: ...and detach the calipers from the hose 8 Removing the brake discs The front brake discs are made up of an inner rotor which is fixed to the wheel rim and an outer friction rotor Both parts must be chan...

Страница 189: ...r brake disc wear inspection please see the service limits indicated in Hydraulic brakes Sect C 1 1 Refitting the front brake system Refitting the brake discs Before refitting the brake disc to the wh...

Страница 190: ...e Sect C 3 Frame torque settings Refit the hose connectors 8 to the front brake calipers position the seals 4 and tighten the special screws 6 to secure them in place Locate the caliper 10 to the disc...

Страница 191: ...through the hose guide 12 The particular bent shape of the hose guide is designed to restrict hose 8 movement under braking and avoid damage Correct position is shown in the diagram Tighten the screws...

Страница 192: ...ake Operations Reference See Section Fill the braking system D 4 Draining the braking circuit file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_G_3_8_00 34 1 html 7 of 7 10 7 2008 8...

Страница 193: ...nner spacer 7 Valve 8 Wheel rim 9 Vibration damping pad 10 Bearing 11 Brake disc 12 Screw 13 Screw 14 Washer 15 Cover 16 Slider Spare parts catalogue file C Documents 20and 20Settings F4i My manual ws...

Страница 194: ...m the left side Collect the plates 3 at either side of the swingarm Caution During this operation properly support the wheel so that it will not fall while wheel shaft 2 is being removed Push the whee...

Страница 195: ...sc 11 to the wheel shaft 2 Remove the rear brake disc 11 The brake disc must be perfectly clean with no rust oil grease or other dirt and no deep scoring For brake disc service limit please see Sect C...

Страница 196: ...d of swingarm Make sure to match the hole in the left chain slider Hold the caliper plate in position onto swingarm clip fit the clip into plate slot Slide the wheel in the swingarm Insert the wheel s...

Страница 197: ...ed torque Sect C 3 Frame torque settings Tighten the chain tensioner screws 4 to the specified torque Sect C 3 Frame torque settings Refit the brake caliper A tighten the screws B to the specified tor...

Страница 198: ...anking plug 5 Circlip 6 Swingarm shaft 7 Screw 8 Rear swingarm 9 Shim 10 Upper chain sliding shoe 11 Shim Spare parts catalogue Half crankcases Swingarm and chain file C Documents 20and 20Settings F4i...

Страница 199: ...rake system Remove the vertical cylinder exhaust pipe L 8 Removing the exhaust system Remove the shock absorber and the linkage from the rear swingarm G 7 Removing the monoshock absorber The component...

Страница 200: ...the shaft and move the gauge horizontally Measure distortion Service limit 0 3 mm Sect C 1 1 Rear wheel Replace shaft when distortion exceeds the specified limit Replace any cracked or distorted shaf...

Страница 201: ...ims on left side Shims on right side 0 10 One 0 10 mm shim 0 20 One 0 10 mm shim One 0 10 mm shim 0 30 One 0 10 mm shim One 0 20 mm shim Caution Always put the largest amount of shimming on the right...

Страница 202: ...9 Fit the other circlip 5 Tighten the screws 7 to the specified torque Sect C 3 Frame torque settings Fit the plugs 4 on either side of the swingarm Operations Reference See Section Refit the shock ab...

Страница 203: ...bly G 8 Final drive Refit the rear mudguard E 4 Refitting the rear mudguard Refit the rear wheel G 4 Refitting the rear wheel file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_G_5_8_...

Страница 204: ...crew 6 Spring washer 7 Washer 8 Spare pin and clip 9 Dust seal 10 Spare bleed valve 11 Set of brake pads 12 Hose retainer 13 Speed sensor 14 Screw 15 Spacer 16 Screw Spare parts catalogue file C Docum...

Страница 205: ...er safety Maintenance operations on these units are limited to replacing brake pads fasteners and bleed unit Release and remove the special screw 1 retaining the hose A to the rear brake caliper and t...

Страница 206: ...or 13 position it to the caliper holder plate with the spacer 15 and tighten the screw 14 to the specified torque Sect C 3 Frame torque settings Fit the special copper gaskets 2 to the connector when...

Страница 207: ...7 and the spring washers 6 on the screws 5 Tighten the screws 5 to the specified torque Sect C 3 Frame torque settings Note The air gap between sensor 13 and brake disc retaining screw 14 must be 0 6...

Страница 208: ...r bearing 4 Bush 5 Screw 6 Shock absorber 7 Screw 8 Spacer 9 Washer 10 Screw 11 Screw 12 Bush 13 Ball joint 14 Spacer 15 Linkage 16 Nut Spare parts catalogue file C Documents 20and 20Settings F4i My m...

Страница 209: ...ers for chain tension adjustment at the rear end For monoshock absorber adjustment please refer to Sect D 4 Adjusting the rear shock absorber Removing the monoshock absorber Remove the seat Sect E 3 R...

Страница 210: ...ed length must be restored on refitting Disassembling the rear shock absorber Loosen the ring nut A and the adjusting ring nut B of the spring with a pin wrench or special tools Remove the retainer C...

Страница 211: ...at the bottom end connection Install the retainer C Tighten the adjusting ring nut B of the spring until obtaining the length L measured previously Note One full turn of the adjusting ring nut will i...

Страница 212: ...from the frame Loosen and remove retaining screw 10 Remove the complete rocker arm 1 from the frame Overhauling the rear suspension rocker arm Disassembling the rear suspension rocker arm Rocker moti...

Страница 213: ...in the hole use a press in case of jams Fit a new seal 2 on the drift as shown in the cross section view Drive it onto the needle roller bearing previously fitted Repeat the above procedure for the o...

Страница 214: ...er arm between the frame supports as shown in the figure Fit the washer 9 to the screw 10 with the concave side facing the screw Insert the screw fully home into the frame Install the nut 16 with the...

Страница 215: ...rocker arm and tighten the screw 5 to the specified torque Sect C 3 Frame torque settings Position the bottom end of shock absorber and linkage to the swingarm Grease threaded bush 12 sliding surface...

Страница 216: ...sprocket Z 48 6 Nut 7 Circlip 8 Spacer 9 Chain 10 Screw 11 Front sprocket retaining plate 12 Front chain sprocket 13 Front sprocket cover 14 Screw Spare parts catalogue file C Documents 20and 20Setti...

Страница 217: ...ive inspection Check the wear of the final drive Visually inspect the front 12 and rear 5 sprockets If the tooth profile is as shown by the broken line in the figure change the sprockets To check chai...

Страница 218: ...the plate 11 from the gearbox secondary shaft Slide the front chain sprocket 12 with the chain 9 off gearbox secondary shaft and take the chain off the sprocket Refitting the chain sprocket Check that...

Страница 219: ...to the thread of the screws 10 Engage first gear Tighten the screws 10 to the specified torque Sect C 3 Frame torque settings Adjust chain tension Sect D 4 Adjusting chain tension Position the front s...

Страница 220: ...e to the specified torque Sect C 3 Frame torque settings Apply threadlocker to end threads of the pins 1 Fit the new sprocket 5 hold the pins and tighten the nuts 6 to the specified torque Sect C 3 Fr...

Страница 221: ...nce See Section Refit the rear wheel G 4 Refitting the rear wheel Adjust chain tension D 4 Adjusting chain tension file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_G_8_8_00 39 1 htm...

Страница 222: ...onents 25 Refitting the front brake system 26 4 Rear wheel 29 Removing the rear wheel 30 Overhauling the rear wheel 31 Refitting the rear wheel 32 5 Rear swingarm 33 Removing the swingarm 34 Swingarm...

Страница 223: ...Refitting the rear suspension 52 8 Final drive 53 Final drive inspection 54 Removing the chain sprocket 55 Refitting the chain sprocket 56 Removing the rear sprocket 57 Refitting the rear sprocket 58...

Страница 224: ...bar and controls Caution Bold reference numbers in this section identify parts shown in this exploded view diagram These parts do not appear in the figures near the text Removing the handlebar file C...

Страница 225: ...ve the front brake control F 3 Removing the front brake master cylinder Remove the clutch hydraulic control F 2 Removing the clutch master cylinder assembly Release and remove the screws 3 of the clam...

Страница 226: ...in the steering head Position the clamps 1 to the handlebar Caution The arrow B on the back of the clamps must be facing the tank When fitting the handlebars make sure the dots A lie in the same line...

Страница 227: ...ront brake control F 3 Refitting the front brake master cylinder Install the right and left switches P 5 Checking the indicators and lighting system components Install the throttle control F 1 Reassem...

Страница 228: ...eal 5 Bearing 6 Bearing 7 Seal 8 Washer 9 Bottom yoke 10 Screw 11 Grub screw 12 Nut 13 Splashguard Spare parts catalogue Handlebar and controls file C Documents 20and 20Settings F4i My manual wsm usa...

Страница 229: ...bearing play adjustment If the problem persists inspect the steering bearings 5 and 6 for wear and replace as required The replacement procedure is detailed in paragraph Disassembling the steering tub...

Страница 230: ...y threadlocker to the nut thread 12 Hold the grub screw 11 steady and lock the nut 12 Rotate the front fork assembly to the left repeat the procedure for the other dowel and tighten the nut Disassembl...

Страница 231: ...ndo from the steering shaft Remove seal 4 bearing inner ring A and ball ring B of the top bearing 5 from steering shaft Slide bottom yoke 9 and steering shaft out of frame tube Withdraw the ball ring...

Страница 232: ...s C of bearings 5 and 6 onto the headstock Proceed as follows heat steering tube up to 150 C place the outer rings C of the bearings into the seats in the steering tube insert the fixed bush E with th...

Страница 233: ...t no 88713 1072 into the steering shaft Keep the inner ring A pressed onto seal 7 manually for at least 10 15 seconds Grease the inner bearing ring A with the specified grease Fit the ball ring B into...

Страница 234: ...ts larger side should be face up Fit the oil seal 4 with the flat face facing upwards Grease the ring nut 3 Screw the ring nut 3 finger tight until it contacts the oil seal 4 Position the special bush...

Страница 235: ...ead to the specified torque Sect C 3 Frame torque settings If removed fit the splashguard 13 apply threadlocker to the screws 10 and tighten them to the specified torque Sect C 3 Frame torque settings...

Страница 236: ...5 Circlip 6 Spring 7 Complete RH footpeg 8 RH footpeg plate 9 Ball 10 Plate 11 Washer 12 Spring 13 Screw 14 LH guard 15 Screw 16 Washer 17 RH guard 18 LH footpeg plate file C Documents 20and 20Setting...

Страница 237: ...linder connected to the system Before removing the left footpeg plate loosen the screw D securing the gearchange control C to the engine and leave the gearbox unit connected to the plate Unscrew the t...

Страница 238: ...withdraw the pin 4 to release footpeg 7 and spring 6 Repeat procedure for the left footpeg Note It is also possible to remove the footpeg even with footpeg plate fitted to the vehicle Refitting the fo...

Страница 239: ...on of the vibration damping pads 1 on the footpeg plate Locate footpeg plate to the threaded holes in the frame and engine casing Caution On refitting position the washers 2 at the frame mounting poin...

Страница 240: ...trol A to the right footpeg tighten the screws B to the specified torque Sect C 3 Frame torque settings Mount the gear change control C to the engine Apply threadlocker to the screw D and tighten to t...

Страница 241: ...crew 3 Stand plate 4 Screw 5 Switch 6 Spring 7 Plate 8 Pivot 9 Nut 10 Plate pin Spare parts catalogue Stands Caution file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_H_5_7_00 44 1 h...

Страница 242: ...the retaining screw 4 and remove the stand switch 5 Unhook the stand return springs 6 from the pin located on the stand plate 3 and remove the springs Unscrew the pivot 8 retaining the stand to the p...

Страница 243: ...the retaining screw 4 and tighten to the specified torque Sect C 3 Frame torque settings Refitting the side stand Position the side stand plate 3 to the frame Apply the specified threadlocker to the t...

Страница 244: ...components Before performing the frame dimensional checks you will need to remove a number of components to give all round access to the frame See the specific instructions in the relevant sections T...

Страница 245: ...Frame inspection file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_H_6_7_00 45 1 html 2 of 4 10 7 2008 8 44 22 PM...

Страница 246: ...2 mm A2 205 3 205 8 mm A3 100 mm B 692 5 mm B1 239 5 mm C 34 0 5 mm C1 149 2 0 5 mm C2 100 100 3 mm C3 26 0 5 mm D 54 961 54 991 mm D1 15 mm 24 24 18 file C Documents 20and 20Settings F4i My manual ws...

Страница 247: ...ght cause danger Changes can also break E E C directives on Manufacturer s liability and general product safety Refitting frame and related components Once the frame has been checked reassemble the mo...

Страница 248: ...mp 3 Tail light 4 Tail guard 5 Tail light 6 Screw 7 Vibration damping pad 8 Spacer 9 Nut 10 Turn indicator 11 Wiring 12 Nut 13 Plate 14 Turn indicator 15 Screw 16 Nut 17 Nut 18 Washer file C Documents...

Страница 249: ...r wiring at the main wiring harness end Sect P 1 Arrangement of wiring on frame Loosen the nuts 21 securing the number plate holder 1 to the frame and to the tail guard 4 Collect the rubber blocks 22...

Страница 250: ...Tail light and number plate holder file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_H_7_7_00 46 1 html 3 of 3 10 7 2008 8 44 25 PM...

Страница 251: ...gs 16 Refitting the footpegs 18 5 Stands 20 Removing the side stand 21 Refitting the side stand 23 6 Frame inspection 24 Removing the frame and related components 25 Checking the frame 28 Refitting fr...

Страница 252: ...Electric system 0GENERAL SUMMARY Section A 0Description 1 How to use the manual 3 Manual layout 4 2 Symbols abbreviations references 5 Product specifications 6 3 Dangerous products warnings 8 General...

Страница 253: ...Rear wheel 6 Rear suspension 6 Hydraulic brakes 7 Charging system generator 7 Ignition system 7 Fuel system 8 Injection system 8 Lights instrument panel 8 1 2 Dimensions 9 2 Fuels and lubricants 10 3...

Страница 254: ...and cleaning the air filters 14 Changing the brake fluid 15 Draining the braking circuit 18 Filling the brake circuit 20 Changing the clutch fluid 23 Draining the clutch circuit 25 Filling the clutch...

Страница 255: ...e rear view mirrors 4 Refitting the rear view mirrors 4 3 Seat 5 Removing the seat 6 Refitting the seat 8 Removing the splash guard 9 Refitting the splash guard 10 Removing the side body panels 11 Ref...

Страница 256: ...rake master cylinder 19 4 Rear brake control 20 Removing the rear brake master cylinder 21 Disassembling the rear brake control 23 Refitting the rear brake master cylinder 24 5 Gear change control 26...

Страница 257: ...oving the swingarm 34 Swingarm shaft inspection 36 Checking swingarm end float 37 Refitting the rear swingarm 38 6 Rear brake 40 Removing the rear brake system 41 Refitting the rear brake system 43 7...

Страница 258: ...nts 12 4 Footpeg supports 15 Removing the footpegs 16 Refitting the footpegs 18 5 Stands 20 Removing the side stand 21 Refitting the side stand 23 6 Frame inspection 24 Removing the frame and related...

Страница 259: ...box 19 Refitting the airbox 21 8 Exhaust system 24 Catalytic converter operating principle 25 Removing the exhaust system 26 Refitting the exhaust system 29 10 Canister Filter 32 Canister Filter Syste...

Страница 260: ...e 5 Removing the engine 6 Reassembling the engine 9 2 1 Lubrication system oil pump 10 Lubrication system 11 Removing the oil pump 13 Disassembling the oil pump gear 14 Reassembling the oil pump gear...

Страница 261: ...shafts 52 Checking the oil seals 52 Checking the circlips 53 Checking the bearings 53 Refitting the camshaft 54 Refitting the cam covers 56 4 4 Head unit valves rocker arms 58 Disassembling the engine...

Страница 262: ...x shafts 128 Removing the gearbox 129 Disassembling the gearbox shafts 131 Overhauling the gearbox 136 Inspecting the gear selector forks 137 Inspecting the fork selector drum 138 Reassembling the gea...

Страница 263: ...the connecting rods 195 Disassembling the connecting rods 195 Overhauling the connecting rods 196 Reassembling the connecting rods 202 Refitting the connecting rod unit 203 Section P 0Electric system...

Страница 264: ...tor 36 4 Lighting devices 38 Changing light bulbs 38 High beam relay 43 Beam setting 44 5 Indicators and lighting system 45 Checking the indicators and lighting system components 45 Changing light bul...

Страница 265: ...Description How to use the multimeter to check electric systems 66 file C Documents 20and 20Settings F4i My ti 20manual wsm usa Mon695_MY07_IND 1 1 html 14 of 14 10 7 2008 8 44 33 PM...

Страница 266: ...stic tank 12 Removing the throttle body 13 Refitting the throttle body 15 7 Airbox 18 Removing the airbox 19 Refitting the airbox 21 8 Exhaust system 24 Catalytic converter operating principle 25 Remo...

Страница 267: ...an be replaced Inside the flange is a thermistor 5 outputting fuel level and a pressure regulator The regulator is required to keep the pressure head constant on the injectors To quick release fitting...

Страница 268: ...fuel reaches a Tee through an outer line from which two lines branch off one line to the electric injectors which are fed in parallel and one line to the tank return fitting The pressure regulator rec...

Страница 269: ...de 5 Hose 6 Plate 7 Spacer 8 Nut 9 CANISTER Filter 10 Hose guide 11 Hose guide 12 Filter to tank outlet hose 13 Hose guide 14 Hose 15 Hose guide 16 Hose 17 Spring 18 Hose guide file C Documents 20and...

Страница 270: ...versions only USA versions are fitted with an additional system featuring a Canister filter to prevent fuel vapour release into the atmosphere The hose 12 is connected to the Canister filter 9 after...

Страница 271: ...he hose 12 Loosen clamps 18 securing the Canister Filter 9 connection hoses to horizontal and vertical cylinder manifolds Disconnect hose 21 connecting the Canister Filter 9 to the vertical cylinder D...

Страница 272: ...the screws A to the specified torque Sect C3 Frame torque settings Operations Reference See Section Refit the fuel tank L 2 Refitting the plastic fuel tank Refit the seat E 3 Refitting the seat Routin...

Страница 273: ...Canister Filter file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L10_10_00 53 1 html 5 of 11 10 7 2008 8 44 39 PM...

Страница 274: ...Canister Filter Routing of hoses clamps and Canister filter position file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L10_10_00 53 1 html 6 of 11 10 7 2008 8 44 39 PM...

Страница 275: ...Canister Filter file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L10_10_00 53 1 html 7 of 11 10 7 2008 8 44 40 PM...

Страница 276: ...Canister Filter Routing of hoses clamps and Canister filter position file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L10_10_00 53 1 html 8 of 11 10 7 2008 8 44 40 PM...

Страница 277: ...Canister Filter file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L10_10_00 53 1 html 9 of 11 10 7 2008 8 44 40 PM...

Страница 278: ...Canister Filter Routing of hoses clamps and Canister filter position file C Documents 20and 20Settings F4i My nual wsm usa Mon695_MY07_L10_10_00 53 1 html 10 of 11 10 7 2008 8 44 40 PM...

Страница 279: ...Canister Filter file C Documents 20and 20Settings F4i My nual wsm usa Mon695_MY07_L10_10_00 53 1 html 11 of 11 10 7 2008 8 44 40 PM...

Страница 280: ...ook 5 Bush 6 Shim 7 Pin 8 Split pin 9 Screw 10 Cable guide 11 Screw 12 Screw 13 Screw 14 Filler plug 15 Washer 16 Panel BLACK 17 Sticker 18 Gasket file C Documents 20and 20Settings F4i My anual wsm us...

Страница 281: ...Bold reference numbers in this section identify parts shown in this exploded view diagram These parts do not appear in the figures near the text Removing the fuel tank Remove or lift the seat Sect E 3...

Страница 282: ...lide out pin 7 keep bushings 5 and washers 6 then remove the tank from the frame Removing the filler plug unit plastic tank Remove the filler plug unit from the fuel tank as follows open the filler pl...

Страница 283: ...Refit the complete plug 14 in the tank housing and tighten the screws 13 and 12 to the specified torque Sect C 3 Frame torque settings Replacing fuel tank flange Release the six retaining screws 27 o...

Страница 284: ...he arrow stamped on the outer casing pointing towards the flange Change the flange O ring 30 Grease the new O ring and reverse the removal procedure to refit Caution Make sure to fit the flange in the...

Страница 285: ...Return hose D quick release fitting 35 breather hose 20 and drain hose 21 Position the tank to the bracket 10 Position the pin 7 to the bracket 10 with bushes 5 and washers 6 Lock with the split pin 8...

Страница 286: ...Plastic fuel tank Plastic tank drain breather hoses routing file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L2_10_00 49 1 html 7 of 10 10 7 2008 8 44 44 PM...

Страница 287: ...Plastic fuel tank Fuel hoses routing from plastic fuel tank to throttle body file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L2_10_00 49 1 html 8 of 10 10 7 2008 8 44 44 PM...

Страница 288: ...Plastic fuel tank file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L2_10_00 49 1 html 9 of 10 10 7 2008 8 44 44 PM...

Страница 289: ...Plastic fuel tank file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_L2_10_00 49 1 html 10 of 10 10 7 2008 8 44 44 PM...

Страница 290: ...hrottle position sensor 3 Clamp 4 Hose coupling 5 Clip R 6 Hose 7 Clamp 8 Injector 9 Hose 10 Clip M 11 Complete throttle body 12 Screw 13 Hose 14 Screw 15 Washer Spare parts catalogue file C Documents...

Страница 291: ...ble F 1 Disassembling the throttle control Disconnect the choke control cable F 1 Removing the choke control Loosen the clamps 3 securing throttle body to intake manifolds A Disconnect the main wiring...

Страница 292: ...ctor connection hose 6 to the injectors Unscrew the screws 14 to release the injectors from the throttle body Collect the washers 15 Refitting the injectors Grease the O rings of the injectors Positio...

Страница 293: ...dy Line up the mould parting lines D visible on the hoses with those F of the throttle body Tighten the clips to the specified torque Sect C 3 Frame torque settings Position them as shown in the figur...

Страница 294: ...ion sensor be replaced reset the throttle body as specified under Zero setting the throttle position sensor TPS Sect D5 Operations Reference See Section Connect the choke control cable F 1 Refitting t...

Страница 295: ...plastic tank Refit the fuel tank L 2 Refitting the plastic fuel tank Injector connection hose routing file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_L6_10_00 50 1 html 6 of 6 10...

Страница 296: ...3 Airbox cover 4 Stud bolt 5 Filter housing 6 Hose 7 Peg 8 Rubber block 9 Hook 10 Pin 11 Clamp 12 Spacer 13 Screw Spare parts catalogue Inlet dict file C Documents 20and 20Settings F4i My manual wsm u...

Страница 297: ...emove the fuel tank L 2 Removing the fuel tank Disconnect the coil connector at the main wiring harness end Sect P 1 Arrangement of wiring on frame Release the clips 9 Remove the cover 3 If necessary...

Страница 298: ...the hose clips 11 and withdraw the hoses from the housing Loosen the screw 13 collect the spacer 12 file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_L7_10_00 51 1 html 3 of 7 10 7 2...

Страница 299: ...he pins 10 to refit the cover 5 hooks 9 Start the stud bolts 4 in their holes on the air box 5 and tighten them to the specified torque Sect C 3 Frame torque settings Start the two pegs 7 on the box 5...

Страница 300: ...block 8 on the frame Tighten the hose clips 11 to the specified torque Sect C 3 Frame torque settings to secure the hoses to the filter housing 5 Insert the oil breather hose 1 into the housing 5 fil...

Страница 301: ...the clips 9 Connect the coil connector to the wiring harness Refit the fuel tank Sect L 2 Refitting the plastic fuel tank Oil breather tank to air box hose routing file C Documents 20and 20Settings F...

Страница 302: ...Airbox file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_L7_10_00 51 1 html 7 of 7 10 7 2008 8 44 50 PM...

Страница 303: ...ead exhaust pipe 6 Vertical head exhaust pipe 7 Blanking plug 8 Clamp 9 Rubber block 10 Spacer 11 Screw 12 RH silencer 13 RH bracket 14 Washer 15 Nut 16 LH silencer 17 Screw 18 Washer file C Documents...

Страница 304: ...fuel ratio is maintained close to ideal value within a certain tolerance thus obtaining minimum emissions of hydrocarbons HC carbon monoxide CO and nitrogen oxide NOX 3 way catalytic converters then...

Страница 305: ...from the horizontal head exhaust pipe 5 Loosen the clamp 8 of horizontal head exhaust pipe 5 and vertical head exhaust pipe 6 file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_L8_10_...

Страница 306: ...tain the exhaust pipe flanges to the heads Remove the flanges from the heads Unscrew the two retaining screws 24 of the exhaust pipes file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY0...

Страница 307: ...any further detail on lambda sensor Detach the vertical head exhaust pipe 6 from the vertical head and collect the seal 1 Caution Block off the head exhaust ports to prevent the ingress of dirt into t...

Страница 308: ...torque Sect C 3 Frame torque settings Tighten screws 24 with spacer 22 to the specified torque Sect C 3 Frame torque settings Connect the lambda sensor 27 to main wiring harness Sect P1 Arrangement o...

Страница 309: ...he silencer brackets against footpeg plates A and insert the bushes 10 fully home Insert the screws 11 Fit the washers 14 at the opposite end and snug the nuts 15 finger tight Hold nuts and tighten th...

Страница 310: ...axis of the exhaust pipe slots B The clamps 8 should be flush with the exhaust pipes and the slots B should be partially covered Tighten the clamps 8 to the specified torque Sect C 3 Frame torque sett...

Страница 311: ...Exhaust system file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_L8_10_00 52 1 html 9 of 9 10 7 2008 8 44 55 PM...

Страница 312: ...amental for optimal engine operation The air fuel mixture is given by the ratio in weight of air and fuel taken in by the engine the ideal or stoichiometric ratio is that which establishes complete co...

Страница 313: ...Description of the fuel injection ignition system file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_M_1_3_00 55 1 html 2 of 8 10 7 2008 8 44 59 PM...

Страница 314: ...etric efficiency Volumetric efficiency is experimentally taken onto the engine in the whole operating range rotation speed and engine load conditions Taken values are then used for the generation of a...

Страница 315: ...end to sensor position diagram 1 Coil horizontal cylinder 2 Electronic control unit 3 Coil vertical cylinder 4 Spark plug 5 Throttle position sensor 6 Injectors 7 Air pressure temperature sensor 8 Oil...

Страница 316: ...he flange also fits the pressure regulator controlling fuel feed and keeping it constant at a value higher than engine generated vacuum Fuel which is not injected into intake manifolds goes back to th...

Страница 317: ...ntake air circuit The air circuit consists of two intake manifolds 1 a throttle body 2 and an airbox 3 installed over the throttle body file C Documents 20and 20Settings F4i My manual wsm usa Mon695_M...

Страница 318: ...injected fuel if riding on variable sea level roads It also allows the ECU to correct mixture strength according to air density Assuming that air volume is unchanging if temperature is higher oxygen c...

Страница 319: ...e unit receives the engine RPM and timing signals that allow it to proceed with injection and ignition To facilitate start up the basic mixture is made richer in accordance with the engine temperature...

Страница 320: ...gnosis outlet 18 Vertical cylinder coil 19 Horizontal cylinder coil 20 Horizontal cylinder spark plug 21 Vertical cylinder spark plug 22 Horizontal cylinder injector 23 Vertical cylinder injector 24 T...

Страница 321: ...mines the following values Fuel amount delivered to each cylinder according to a timed sequence Closing time of injectors and therefore injection timing referred to the end of intake stage for each cy...

Страница 322: ...ontrol unit Position the control unit to the battery mount 5 on the right side of the motorcycle and start the two screws 3 in their holes Place the ground cable 4 under the rear screw as shown in the...

Страница 323: ...wing the motorcycle from rider position Tighten the screws to the specified torque Sect C 3 Engine torque settings The connector 1 has a grey pinout frame end Body whereas the connector 2 has a black...

Страница 324: ...Push the connector axially fully home into the control unit Rotate the clip B until locking the connector clip is in the locked position Repeat procedure for the other connector 2 Make sure the conne...

Страница 325: ...n Assuming that fuel properties such as viscosity and density as well as injector delivery and pressure head which is controlled by fuel pressure regulator do not change over time the amount of inject...

Страница 326: ...is Sect D 5 The outfeed of the fuel must be steady and the jet must be atomised without drops Do not leave the fuel system filled with fuel if you are leaving the motorcycle unused for long periods Th...

Страница 327: ...t of fuel known as Lambda 1 This is considered as the ideal ratio for complete combustion hence the name Lambda Sensor therefore lambda 1 means stoichiometric mixture ratio lambda 1 means lean mixture...

Страница 328: ...n under Guided diagnosis Sect D 5 Removing the air temperature pressure sensor To gain access to the air temperature pressure sensor 1 remove the headlight Sect P 4 Changing the headlight disconnect t...

Страница 329: ...h compressed air to remove any dirt Take out spark plug caps 1 on both heads and remove spark plugs Take care not to let any foreign body enter the combustion chambers file C Documents 20and 20Setting...

Страница 330: ...settings Refit spark plug caps 1 Caution Do not use spark plugs with an unsuitable heat rating or incorrect thread length Spark plugs must be properly tightened Spark plugs that are not correctly tigh...

Страница 331: ...located next to the wheel in the rear left side of the vehicle Disconnect spark plug cable 3 to remove the coil 1 Undo the nuts 4 and collect the washers Remove the coil 1 from the plate 5 Disconnect...

Страница 332: ...e unit as a key parameter for calculating the quantity of fuel and the ignition advance Note To check operation of this item use the DDS please refer to Guided diagnosis Sect D 5 The throttle position...

Страница 333: ...e timing layshaft gear is used by the control unit for calculating engine rotation speed and timing reference values Note To check operation of these items use the DDS please refer to Guided diagnosis...

Страница 334: ...e relay from the electric system and power contacts 86 and 85 small contacts with 12 V battery The electric magnet must click Connect the multimeter to contacts 30 and 87 large contacts to check for e...

Страница 335: ...ystem components close to zero and if available a continuity beep should be heard If not replace checked part file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_M_3_3_00 57 1 html 15 o...

Страница 336: ...ating stages 9 2 Injection ignition system 10 3 Fuel injection ignition system components 11 Electronic control unit 11 Electric injector 15 Lambda sensor 16 Air temperature pressure sensor 18 Spark p...

Страница 337: ...bolt 5 Engine Spare parts catalogue Half crankcases Frame Swingarm and chain Caution Bold reference numbers in this section identify parts shown in this exploded view diagram These parts do not appea...

Страница 338: ...ical disassembly sequence of the parts to be removed and makes reference to the relevant sections describing the specific disassembly procedures This section describes only the operations to be carrie...

Страница 339: ...engine front mounting bolt 2 and rear bolt 4 Remove the front mounting screw 2 from engine right side Loosen swingarm clamp screws A Slide out the swingarm shaft B of half of its length from the right...

Страница 340: ...upport on the right side and secure it with the other screw B The supports hold frame and swingarm in the correct position for refitting the engine later on Remove the engine 5 Reassembling the engine...

Страница 341: ...bling the complete engine Tighten the nuts 3 to the specified torque Sect C 3 Engine torque settings file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_N_1_9_00 59 1 html 5 of 5 10 7...

Страница 342: ...body 6 Circlip 7 Reduction bush 8 Spring washer 9 Screw 10 Screw 11 Spring washer 12 Pump control gear 13 Bush 14 By pass valve cap 15 Centring bush 16 By pass spring 17 Pressure relief by pass valve...

Страница 343: ...Bold reference numbers in this section identify parts shown in this exploded view diagram These parts do not appear in the figures near the text Lubrication system file C Documents 20and 20Settings F4...

Страница 344: ...before oil reaches pump After flowing out of the pump the oil flows into the cooler before reaching the cartridge filter P which is fitted with an inner anti clogging valve ensuring proper oil circul...

Страница 345: ...the clutch cover N 6 2 Removing the clutch cover Undo and remove the screws 9 and 10 fixing the complete pump Remove the complete oil pump 1 and slide the two O rings 2 and 4 and the two centring bus...

Страница 346: ...d slide out spring 16 and by pass valve 17 Check for proper operating conditions Remove the circlip 6 withdraw the bush 13 and remove the snap ring 3 Remove the pump control gear 12 file C Documents 2...

Страница 347: ...nd spring 16 into pump then tighten plug 14 to the specified torque Sect C 3 Engine torque settings applying a medium strength threadlocker Fit pump cover 2 to pump body 5 complete with gears Refittin...

Страница 348: ...haft sprocket Bring dial gauge pointer in contact with one of the oil pump gear teeth and set the instrument to zero on this position Slightly move the gear to measure the clearance Take four readings...

Страница 349: ...amp 6 Oil breather valve 7 Clamp 8 O ring 9 Clamp Spare parts catalogue Air inductio and oil vent Caution Bold reference numbers in this section identify parts shown in this exploded view diagram Thes...

Страница 350: ...on hose 4 to the oil breather valve 6 and disconnect hose from the oil filter valve Loosen the clip 5 of the connection hose to the oil breather valve and disconnect hose 4 Unscrew the retaining screw...

Страница 351: ...he specified torque Sect C 3 Frame torque settings and then to secure it to breather valve 6 tightening clamp 5 to the specified torque Sect C 3 Frame torque settings Installation is a reversal of the...

Страница 352: ...e hose clips orientated as originally fitted Operations Reference See Section Refit the fuel tank L 2 Refitting the plastic fuel tank Refit the seat E 3 Refitting the seat file C Documents 20and 20Set...

Страница 353: ...parts catalogue Head timing Vertical head Horizontal head Caution Bold reference numbers in this section identify parts shown in this exploded view diagram These parts do not appear in the figures nea...

Страница 354: ...w an engine block removed from the frame Take off the inspection cover on generator side and install tool part no 88713 0123 Turn the crankshaft until lining up the transmission pulley mark with the c...

Страница 355: ...r gauge between opening rocker arm B and shim 3 Measured clearance must be within the specified limits Sect C1 1 Timing valves If the clearance measured is outside the specified limits remove the open...

Страница 356: ...him to freely turn with no remarkable play Clearance must be within the specified limits Sect C 1 1 Timing valves If not so remove the closing shim 1 as described in paragraph Removing the valves Sect...

Страница 357: ...e hole of the head cover as shown With the camshaft at rest position take up valve opening clearance fitting a suitably sized feeler gauge between upper rocker arm and opening shim file C Documents 20...

Страница 358: ...e for the exhaust valve positioning the dial gauge mount to the opposite side of the head Refit all parts according to the procedure described under previous paragraph Checking and adjusting valve cle...

Страница 359: ...degree wheel G part no 98112 0002 With the camshaft at rest position take up valve opening clearance fitting a suitably sized feeler gauge D between opening rocker arm and opening shim Check that cam...

Страница 360: ...i e turn clockwise of degree wheel G until gauge C points 1 mm lift of intake valve Check degrees again Rotate clockwise again until obtaining 1 mm lift of the exhaust valve Check degrees again Repeat...

Страница 361: ...Screw 6 Elastic stop ring nut 7 Washer 8 Outer timing belt roller 9 Horizontal cylinder toothed belt 10 Middle washer 11 Fixed tensioner assembly 12 Screw 13 Elastic stop ring nut 14 Washer 15 Special...

Страница 362: ...parts do not appear in the figures near the text Removing the timing side covers Operations Reference See Section Lift the tank L 2 Removing the fuel tank Note For reasons of clarity the figures show...

Страница 363: ...1 of the horizontal cylinder timing belt Loosen screw 22 securing the horizontal cylinder tensioner collect washer 23 and move tensioner 21 to its rest position Remove the horizontal cylinder timing b...

Страница 364: ...no 88713 2107 to the belt roller to lock rotation as shown Fit the bush of tool part no 88700 5644 to a torque wrench and slacken the belt roller ring nut 13 Remove ring nut 13 washer 14 and belt rol...

Страница 365: ...ioners may also be removed leaving the belts in place Unscrew and remove the fixed tensioners 11 Use the spanner of tool part no 88700 5644 to lock rotation of the drive belt roller installed to the c...

Страница 366: ...key 27 on the timing layshaft Remove middle washer 10 and inner belt roller 29 After having removed the inner belt roller 29 remove the second key 26 on the timing layshaft Remove the circlip 25 file...

Страница 367: ...without exceeding play Install bearings 20 into plate 21 take them fully home Install the snap ring 19 in its seat A on pin 21 Disassembling the belt rollers Loosen and remove the three screws 12 Sli...

Страница 368: ...elt roller B and washer 15 on flange 17 as shown use reference marks to ensure correct positioning Caution On refitting make sure to line up the mark D of spacer flange and mark A on belt roller and w...

Страница 369: ...read and underside then fit washer 14 and ring nut Caution At reassembly always use new ring nuts Fit the bush of tool part no 88700 5644 to a torque wrench and tighten ring nuts 13 to the specified t...

Страница 370: ...ting hub pointing outwards and the guide washer 10 on the timing layshaft Fit the second key 27 the outer belt roller 8 with hub projecting inward the outer spacer 7 and locking ring nut 6 Caution To...

Страница 371: ...settings Reassembling the timing belt tensioners If removed smear a film of recommended threadlocker onto fixed tensioner 11 and tighten to the specified torque Sect C 3 Engine torque settings Set te...

Страница 372: ...the combustion stroke This is indicated by the mark A on the timing layshaft belt roller 8 aligning with the mark B on the clutch cover Unscrew the two screws D and remove the small cover C from the g...

Страница 373: ...es 17 of the horizontal and vertical belt rollers 16 Tool ends must locate into the flange slots Install the horizontal 9 and vertical 28 timing belts manually Do not use any tools and do not disturb...

Страница 374: ...nsion Sect D 5 Warning Check tension reading on the belt sections H and G indicated in the figure Set desired tension and ensure that screws 22 24 and 12 are tightened to the specified torque Sect C 3...

Страница 375: ...Remove the two locking tools 88713 2009 from belt roller flange Remove the tool part no 88713 2011 you used to lock the crankshaft Unscrew the tool bolt E Refit the small cover C to the generator cove...

Страница 376: ...ontal timing belt 2 to the engine Start the screws 5 and the screws 3 in their holes in the cover and tighten to the specified torque Sect C 3 Engine torque settings Position the vertical timing belt...

Страница 377: ...ers timing system Operations Reference See Section Refit the fuel tank L 2 Refitting the plastic fuel tank file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_N_4B9_00 63 1 html 17 of 1...

Страница 378: ...Horizontal rubber cap 7 Screw 8 Valve cover 9 Valve cover gasket 10 Vertical head 11 Horizontal head 12 Stud bolt 13 Stud bolt 14 Circlip 15 Key 16 Vertical head camshaft 17 Gasket 18 Circlip file C...

Страница 379: ...parts do not appear in the figures near the text Removing the engine oil temperature sensor Operations Reference See Section Disconnect oil temperature sensor from main wiring harness P 1 Arrangement...

Страница 380: ...ring nut and withdraw the sensor mount 31 Refitting the engine oil temperature sensor Check seal 28 and spacer 27 Replace as required Note Change the O rings 30 before refitting file C Documents 20and...

Страница 381: ...emoving the throttle body Note This operation can be carried out even if engine is on the frame For precision purposes the figures show the head removed from the engine Undo and remove the lock nuts 3...

Страница 382: ...10 and 11 and tighten to the specified torque Sect C 3 Engine torque settings Check the O ring 35 and replace it if worn Smear O rings 35 with engine oil position the intake manifolds 34 and secure t...

Страница 383: ...tery mount P 2 Battery mount Remove the timing covers and the timing belts N 4 2 Removing the timing side covers Remove the timing belt rollers from the heads N 4 2 Disassembling the timing system Not...

Страница 384: ...s 16 and 22 when removing the belt rollers Unscrew the retaining screws 21 of the cover 20 supporting camshaft 16 and 22 Take off the cam cover 20 and its gasket 17 file C Documents 20and 20Settings F...

Страница 385: ...earings after removal Reassembling the cam cover Install the bearing 19 with the shielded side A outward Lubricate all components with engine oil before refitting Insert the circlip 18 into the cam co...

Страница 386: ...cover on the intake side 8 of vertical head 10 loosen pegs 37 and collect the gasket 9 To remove the cover on the exhaust side 8 of horizontal head 11 and the cover on intake side 25 of horizontal he...

Страница 387: ...pecified torque Sect C 3 Engine torque settings Removing the camshafts Operations Reference See Section Remove the timing belt rollers N 4 2 Disassembling the timing system Note This operation is also...

Страница 388: ...rocker arms This will avoid damage to the components during removal Extract the vertical head camshaft 16 from its seat Remove the spacer 4 from the seal 3 Remove the seal 3 from the head file C Docum...

Страница 389: ...moved it shall be renewed Checking the camshafts Check that the contact surfaces of the cams are free from scratches grooves steps and waving Worn cams prevent correct timing and lead to loss of perfo...

Страница 390: ...uitable tools Lubricate oil seal lip after installation This operation requires the utmost care Checking the circlips Note Replace any snap rings which are distorted or have lost their spring All circ...

Страница 391: ...inner ring outwards at different positions to check for play Remove any bearings which run hard or are noisy or have play Note Change the bearings at each cylinder head overhaul Refitting the camshaf...

Страница 392: ...f you have left the rocker arms in place in the head Sect N 4 4 Head unit valves rocker arms rotate the camshaft 16 until finding the position at which the cams will not contact the rocker arms Before...

Страница 393: ...il it becomes seated into the bearing 5 Check key 15 and keyway for wear and then fit it Refitting the cam covers Note Check gasket 17 and replace if worn Position the complete cam cover 20 with the g...

Страница 394: ...Note Pay attention to the key 15 in the camshaft 16 Position the horizontal head cover 2 to the left side of head and insert the retaining screws 1 Tighten the screws 1 to the specified torque Sect C...

Страница 395: ...eads N 4 2 Reassembling the timing system Refit the timing belts and timing belt covers N 4 2 Refitting the timing side covers Refit the battery mount P 2 Battery mount Refit the airbox L 7 Refitting...

Страница 396: ...7 Split rings 8 Valve closing shim 9 Spring 10 Exhaust valve seal 11 Exhaust valve guide 12 Intake valve seal 13 Intake valve guide 14 Intake valve seat 15 Exhaust valve seat 16 Exhaust valve 17 Intak...

Страница 397: ...sor from main wiring harness P 1 Arrangement of wiring on frame Remove timing side covers and timing belts N 4 2 Disassembling the timing system Note For reasons of clarity the figures show an engine...

Страница 398: ...valve covers N 4 3 Removing the valve covers Slip off the clip 1 of the opening rocker arm 3 Fit tool part no 88713 2107 to the head belt roller or use the bush of tool part no 88700 5644 and rotate t...

Страница 399: ...wo screwdrivers lock the closing rocker arm 18 with valve open for position A set screwdriver under closing rocker arm while for position B push onto closing rocker arm along valve axis file C Documen...

Страница 400: ...he split rings 7 from valve stem using tweezers Remove the valve closing shim 8 from the valve 17 Withdraw the valve 17 from the bottom end of head Remove the valve seal 12 from the head Repeat proced...

Страница 401: ...rs Remove the clip 1 from the rocker arm shaft 4 Screw the tool part no 88713 1994 featuring M5 pin on the thread of the opening rocker arm shaft 4 Withdraw the rocker arm shaft 4 Remove the opening r...

Страница 402: ...tool part no 88713 2362 Remove the closing rocker arm shaft 4 using tool part no 88713 1994 Collect the two shims 5 Remove rocker arm 18 spring 9 and tool part no 88713 2362 file C Documents 20and 20...

Страница 403: ...ombustion chamber and relevant ducts Check that there are no cracks and that there are no grooves steps or damage of any kind on the sealing surfaces Mating surface to cylinder must be perfectly flat...

Страница 404: ...k the following measure the diameter of the stem B at various positions along the portion that runs in the valve guide Check the valve stem for buckling Place valve on a V block set a dial gauge perpe...

Страница 405: ...vely damaged replace it choosing an adequately oversized valve seat Spare valve seats are available with 0 03 and 0 06 mm outer diameter oversize Caution If seats are replaced change the valve guides...

Страница 406: ...contact surface W between valve and seat Correct size is 1 0 1 5 mm Maximum limit 2 0 mm Grind seat if outside the above limit Fill the intake and exhaust ducts with fuel to check for leaks In the eve...

Страница 407: ...valves Changing valve guides Change valve guides as follows Heat head gradually and evenly in an oven up to 200 C Remove original valve guides using a suitable tool see diagram Let them cool down and...

Страница 408: ...eck condition of rocker arm bore and shaft Nominal rocker arm bore diameter 10 040 10 062 mm Nominal rocker arm shaft diameter 10 001 10 010 mm Check that the contact surfaces of opening and closing s...

Страница 409: ...ght fit in the head If it is loose install the 0 02 mm oversized shaft available from the Spare Parts Department Checking the rocker arm springs Check condition of closing rocker arm return springs Ch...

Страница 410: ...ry important to carefully clean all components Fit the oil seal 12 and 10 to the valve guide Oil seals are colour coded as follows green seal for the exhaust valve black seal for the intake valve Lubr...

Страница 411: ...assembled tool rocker arm and spring into the head and install the pin part no 88713 0262 to hold assembly in place Install the valve 17 temporarily Fit as many shims 5 as required to centre the rock...

Страница 412: ...th the threaded hole end B pointing outwards Release the spring 9 and remove the tool part no 88713 2362 Using again pin part no 88713 0262 set opening rocker arm 3 and fit side shims 2 position rocke...

Страница 413: ...m After shimming remove tool part no 88713 0262 and position the shaft 4 with the threaded hole end B pointing outwards Insert side clip 1 onto pin 4 of opening rocker arm 3 in between the two spacers...

Страница 414: ...rewdrivers lock the closing rocker arm 18 with valve open for position A set screwdriver under closing rocker arm while for position B push onto closing rocker arm along valve axis Locate the closing...

Страница 415: ...act return spring action and check clearance between rocker arm sliding shoe and closing shim Sect N 4 1 Checking closing clearance Sc at exhaust intake If clearance is outside the specified limit adj...

Страница 416: ...e Repeat procedure for the exhaust valve 16 Operations Reference See Section Refit the valve covers N 4 3 Refitting the valve covers Reassembling the heads Make sure the O rings A and the locating pin...

Страница 417: ...pecial washers 20 on the stud bolts with the sharp edge facing the head and the flat side pointing inwards Grease the underhead of the nuts 19 and the thread of the stud bolts with the specified greas...

Страница 418: ...tretch abnormally leading to severe engine damage Operations Reference See Section Refit the side covers and the timing belts N 4 2 Refitting the timing side covers Connect oil temperature sensor to m...

Страница 419: ...cylinder 5 Piston rings 6 Cylinder base gasket 7 Pin 8 Horizontal cylinder 9 Piston 10 Circlip 11 Locating dowel Spare parts catalogue Cylinders pistons Alternator cover file C Documents 20and 20Sett...

Страница 420: ...If needed aid removal rocking the cylinder gently with both hands or tap cylinder base lightly with a plastic mallet Lift cylinder just enough to give access to gudgeon pin 3 Cylinder and piston are...

Страница 421: ...e side withdraw gudgeon pin 3 just enough to release the connecting rod Lift the piston cylinder assembly clear of the stud bolts file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_N_5...

Страница 422: ...8700 5644 Repeat operations performed on the horizontal cylinder to remove vertical cylinder piston assembly Overhauling the cylinder piston assy Overhauling the cylinder Check that the inner surface...

Страница 423: ...s excellent friction and wear resistance but prevents grinding The cylinders are marked with their class a letter punched on the side of the cylinder Always match cylinder and piston from the same cla...

Страница 424: ...meter P 10 mm above skirt base at right angles to the axis of the gudgeon pin Pistons must always be changed in pairs Piston cylinder clearance Pistons are marked with their class a letter printed on...

Страница 425: ...mbly clearance must be 0 002 0 008 mm Max allowed wear limit 0 035 mm If you change the gudgeon pin you must also change the connecting rod small end bush Overhauling the piston rings The piston rings...

Страница 426: ...ring max wear limit 0 15 mm Other rings 2nd ring and scraper ring wear limit 0 10 mm Note The mark punched on piston rings must always be facing up file C Documents 20and 20Settings F4i My anual wsm...

Страница 427: ...on hole that accommodates the gudgeon pin Measure gudgeon pin diameter Wear limit 0 025 mm Note If you change the gudgeon pin you must also change the connecting rod small end bush file C Documents 20...

Страница 428: ...mm Refitting cylinder piston assy If you are using new cylinders and pistons match cylinders and pistons from the same class Cylinder class is identified by a letter punched on cylinder top face in t...

Страница 429: ...gs and cylinders Ensure that the engine block includes the cylinder centring pins 11 Apply liquid gasket to the gasket 6 as shown in the figure Position the gasket 6 on the cylinder 8 Be sure to match...

Страница 430: ...n 9 Block off casing opening with a cloth then fit circlip 10 Caution At reassembly always use new circlips 10 Press cylinder 8 down until it contacts the casing Perform same operations to the other c...

Страница 431: ...iston assy Caution Place the locating pins 7 with the smaller hole pointing away from cylinder file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_N_5_9_00 66 1 html 13 of 13 10 7 2008...

Страница 432: ...ch control pin 4 Clutch spring 5 Pressure plate 6 Bearing 7 Clutch plates 8 Nut 9 Safety washer 10 Clutch drum 11 Shim 12 Spring 13 Hub Spare parts catalogue Clutch file C Documents 20and 20Settings F...

Страница 433: ...plines It is this special design that provides the follow up torque and anti hop features using the axial component of driving torque under acceleration and braking torque under braking respectively W...

Страница 434: ...ings on the gear teeth Disassembling the APTC system Operations Reference See Section Drain engine oil D 4 Changing the engine oil and filter cartridge Remove the clutch cover N 6 2 Removing the clutc...

Страница 435: ...rt no 88713 2556 and loosen the nut 8 Remove the safety washer 9 Slide the hub plates drum assembly out of the housing A use tools part no 88713 2591 file C Documents 20and 20Settings F4i My anual wsm...

Страница 436: ...tes drum assembly Remove the three tools part no 88713 2591 Remove the hub 13 and the plates 7 from the drum 10 Collect the three springs 12 Remove the plates 7 from the hub 13 file C Documents 20and...

Страница 437: ...in the clutch housing B and measure clearance S with a feeler gauge The clearance S must not exceed 0 6 mm If it does change the plates and if necessary the clutch housing Overhauling the clutch plat...

Страница 438: ...find too much play Check contact surface of last driven plate If extremely scored apply a lapping compound 6 12 micron thick onto a working surface and move the plate until it is perfectly flat Check...

Страница 439: ...nto drum 10 Fit the clutch plates 7 on hub 13 start with one of the 11 driving plates B alternated with the 10 driven plates C Fit all clutch plates 7 with hub 13 on the drum 10 Warning While refittin...

Страница 440: ...plate pack and hub 13 to overcome the springs 12 load Note Screw in the three tools part no 88713 2532 until the clutch plates are slightly loaded Reassembling the APTC unit Position the spacer 11 on...

Страница 441: ...t the last clutch plate A so that is it offset with respect to the others Fit the safety washer 9 to the primary shaft file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_N_6A9_00 67 1...

Страница 442: ...haft Lock clutch housing with tool part no 88713 2556 so to hold it while tightening nut 8 Tighten the nut 8 to the specified torque Sect C 3 Remove the three tools part no 88713 2591 Fit the pusher p...

Страница 443: ...3 in a cross sequence Remove tool part no 88713 2556 Operations Reference See Section Refit the clutch cover N 6 1 Refitting the clutch cover Fill oil into the engine D 4 Changing the engine oil and f...

Страница 444: ...Screw 4 Oil sight glass 5 Screw 6 Panel BLACK 7 Screw 8 Bush 9 Seal 10 Shim 11 Circlip 12 O ring 13 Centring bush 14 O ring 15 Blanking plug 16 Washer 17 Cover 18 Spacer file C Documents 20and 20Setti...

Страница 445: ...ng the engine oil and filter cartridge Disconnect oil pressure sensor P 5 Checking front and rear STOP switches neutral switch oil pressure switch and clutch switch Unscrew the screw 7 placed at the b...

Страница 446: ...cating bush 13 Replace if distorted Disassembling the clutch cover Unscrew the six retaining screws 19 of the inner cover 17 Remove inner cover 17 and sound deadening panel 6 file C Documents 20and 20...

Страница 447: ...ence fit in the cover Remove with a suitable puller Visually inspect the seal 9 and replace as required Remove the plug 15 and its O ring 14 the engine oil pressure switch 21 and its seal 20 from the...

Страница 448: ...the seal 20 When fitting a new bush 8 drive it fully home into the clutch cover seat using a press and a suitable drift Position the sound deadening panel 6 inside the clutch cover 1 as shown in the...

Страница 449: ...h cover Clean and degrease mating surfaces on cover and casing and ensure that the centring bush 13 and the O ring 12 at the lubrication drill are fitted in the casing Apply an even regular bead of DU...

Страница 450: ...t C 3 Engine torque settings in a cross sequence Note Refit the cable guide 22 bush 18 and washer 16 Operations Reference See Section Connect oil pressure sensor P 5 Checking front and rear STOP switc...

Страница 451: ...h unit clutch cover Fill engine with oil D 4 Changing the engine oil and filter cartridge file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_N_6B9_00 68 1 html 8 of 8 10 7 2008 8 45 5...

Страница 452: ...r 5 Threaded ring nut 6 Safety washer Spare parts catalogue Clutch Clutch cover Crankshaft Caution Bold reference numbers in this section identify parts shown in this exploded view diagram These parts...

Страница 453: ...tch cover N 6 2 Removing the clutch cover Remove the clutch N 6 1 Disassembling the APTC system Remove the oil pump N 2 1 Removing the oil pump Remove the clutch housing 1 together with needle roller...

Страница 454: ...uring the driving gear of primary transmission B Hold the primary drive gear B using wrench part no 88713 2423 and release the sprocket ring nut 5 using bush file C Documents 20and 20Settings F4i My m...

Страница 455: ...y washer 6 Remove the driving gear of primary transmission B using the puller part no 88713 2092 fit an aluminium or brass plate between puller screw and crankshaft file C Documents 20and 20Settings F...

Страница 456: ...s and checking meshing play Degrease the taper end of the crankshaft and the mating surface on the primary drive gear accurately Check that the key C and inner spacer D are correctly fitted to the cra...

Страница 457: ...ace pointer tip in contact with a gear tooth Turn the driven gear A to match teething and check with the dial gauge that play ranges between 0 05 and 0 07 mm Repeat measurement at 16 positions of the...

Страница 458: ...etween oil pump gear and primary drive gear on crankshaft Sect N 2 1 Refitting the oil pump Carefully degrease the mating surfaces of clutch housing 1 inner bearing 3 and bush 2 Slide the inner spacer...

Страница 459: ...6 1 Reassembling the APTC unit Refit the clutch cover N 6 2 Refitting the clutch cover Fill oil into the engine D 4 Changing the engine oil and filter cartridge file C Documents 20and 20Settings F4i...

Страница 460: ...opper bolt 6 Gasket 7 Gear stopper spring 8 Ball 9 Circlip 10 Fork return spring 11 Shim thk 0 5 12 Shim thk 0 2 13 Circlip 14 Nut 15 Gearbox drum control fork 16 Gear lever pin 17 Shaft with gear lev...

Страница 461: ...or levers Operations Reference See Section Remove generator cover and flywheel generator assembly N 8 Flywheel generator Remove clutch housing N 6 3 Disassembling the primary drive gears Undo the comp...

Страница 462: ...ponents of the lever need replacing disassemble as shown in the picture Removing the gear stopper and ratchet Undo the gear stopper bolt 5 and remove seal 6 spring 7 and gear ball 8 file C Documents 2...

Страница 463: ...topper to clutch side casing The end of the spring 1 must locate behind the casing rib Tighten the bolt 3 to the specified torque Sect C 3 Engine torque settings Thoroughly grease and then fit ball 8...

Страница 464: ...ear selector lever has been taken apart insert the spring 17 on the shaft 16 as shown in the photograph Insert plate 23 and shim 24 and fit circlip 9 to secure in place file C Documents 20and 20Settin...

Страница 465: ...red to the shoulders of the plate loosen check nut 13 and turn eccentric pin 15 to set the position Tighten the lock nut 13 Place the spring 10 between shaft 16 and fork 14 Insert the circlip 12 file...

Страница 466: ...it gear change lever or a service lever and shift to third gear Fit plate part no 88713 1091 to the fork shaft pins see figure Align the notch A which marks the centreline of the fork shaft pawl with...

Страница 467: ...he same time to check that all the gears engage when shifting up and down Remove gear change lever Operations Reference See Section Refit clutch housing N 6 3 Refitting the primary drive gears and che...

Страница 468: ...fety washer thk 0 5 7 Circlip 8 Driving gear 3rd 4th speed 9 Driving gear 6th speed 10 Driving gear 2nd speed 11 Shim thk 1 8 12 Safety washer thk 0 5 13 Fork control drum 14 Special square roller 15...

Страница 469: ...k 1 32 Square roller stop ring Spare parts catalogue Gearchange Gear box Caution Bold reference numbers in this section identify parts shown in this exploded view diagram These parts do not appear in...

Страница 470: ...edle rollers 14 Remove the gear selector forks 29 and 28 Remove gearbox primary 2 and secondary 25 shafts complete with gears Do not damage or lose the shims at shaft ends If the bearing inner rings A...

Страница 471: ...r Caution Refit the shims in the original positions on assembly Failure to do so could lead to jamming and you will have to re open engine casing Disassembling the secondary shaft Remove the clutch si...

Страница 472: ...circlip 7 taking care not to damage the shaft surface Slide out circlip 7 and safety washer 6 Remove the driven gear for the 4th speed 21 its needle roller cage 4 and the safety washer 12 file C Docum...

Страница 473: ...age 4 and the safety washer 6 Remove the circlip 7 and remove the driven gear for the 6th speed 23 Remove the circlip 7 the safety washer 6 and the driven gear for the 2nd speed 24 file C Documents 20...

Страница 474: ...bare Disassembling the primary shaft Remove chain side shim 11 and clutch side shim 1 from primary shaft Slide out the 2nd drive gear 10 Using two screwdrivers remove circlip 7 and safety washer 6 fi...

Страница 475: ...ace Slide out sixth drive gear 9 with needle roller bearing 4 Then slide out safety washer 6 and circlip 7 Slide out third and fourth drive gear 8 Slide out circlip 7 and safety washer 6 file C Docume...

Страница 476: ...shafts Slide out fifth drive gear 5 with needle roller bearing 4 Remove the shim 3 from the primary shaft 2 file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_N_7B9_00 71 1 html 9 of...

Страница 477: ...esmodromic drum groove due to incorrect end float Correct clearances by shimming the gearbox shafts and drum with suitable shims For total end float of gearbox shafts and selector drums refer to Sect...

Страница 478: ...part must be changed by comparing the values with the values of new components Sect C 1 1 Gearbox Also check wear on drum support pins they must not show any signs of grooves burrs and deformation Tur...

Страница 479: ...Fig 1 shows all parts to be fitted onto the primary shaft 2 after calculating correct thickness for shims 1 and 11 Sect N 9 2 Shimming the shafts file C Documents 20and 20Settings F4i My anual wsm us...

Страница 480: ...arts to be fitted onto the secondary shaft 25 after calculating correct thickness for shims 15 and 26 Sect N 9 2 Shimming the shafts file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_...

Страница 481: ...xample Fit the circlip 7 Ensure it is fully seated into the shaft It is recommended a suitable sized tube drift be used to seat the ring Fit the safety washer 6 into the shaft it should rest against t...

Страница 482: ...12 onto the gear it is larger than the other safety washer 6 Fit another needle roller cage 4 as described Fit the gear for 4th speed 21 file C Documents 20and 20Settings F4i My anual wsm usa Mon695_...

Страница 483: ...bly When finished run a practical test Place gear in neutral and check that the front coupling dogs A of the sliding gears B are centred to the matching dogs of the fixed gears C i e that the distance...

Страница 484: ...rbox shafts sliding gear B Operations Reference See Section Close the casings N 9 2 Closing the casings file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_N_7B9_00 71 1 html 17 of 17 1...

Страница 485: ...O ring 5 Cover 6 Screw 7 Engine sensor 8 Thickness 9 O ring 10 Screw 11 Screw 12 Screw 13 Flange 14 Reference pin 15 Circlip 16 Ignition flywheel 17 Washer 18 Inner ring file C Documents 20and 20Setti...

Страница 486: ...not appear in the figures near the text Removing the generator cover Operations Reference See Section Drain engine oil D 4 Changing the engine oil and filter cartridge Remove gearchange control F 5 Re...

Страница 487: ...11 and 12 arrowed in the figure Collect the two washers 35 and hose guide 36 Fix tool part no 88713 1749 to the holes of the screws 6 you have just removed Turn the tool shaft slowly to remove the co...

Страница 488: ...kshaft there is a bearing 26 held in place by a circlip 27 Remove circlip 27 with suitable tweezers Remove bearing 26 using a universal puller Removing the flywheel generator assembly Fit tool part no...

Страница 489: ...le unscrewing the nut keep pressing box end axially onto nut to avoid damage or injury in the event wrench suddenly slips off the nut Remove nut 34 Belleville washer 33 and flywheel 22 Remove driven g...

Страница 490: ...signs of wear or damage of any kind In the event of defects dismantle the assembly Disassembling the flywheel generator assembly Undo the eight screws 25 and remove rotor 23 from flywheel Slide out re...

Страница 491: ...e facing the flange The flange should have the rounded side facing the starter clutch When refitting the starter clutch make sure the arrow etched on outer ring is pointing in the direction of rotatio...

Страница 492: ...l only Do not use grease as it could affect starter clutch operation Fit the flange 13 to the flywheel 16 with the tapered side facing the flywheel Install the flange with the aid of a pin or spanner...

Страница 493: ...r clutch Fit the thus assembled flywheel unit 22 on the starter clutch 21 Make sure the inner ring 18 is still centered in the washer 17 Flywheel reference mark must be aligned with the crankshaft spl...

Страница 494: ...ommended to allow three hours after tightening before starting the engine to ensure the sealant is completely dry Reassembling generator cover Position stator 32 into the cover with the hole for the o...

Страница 495: ...nge lever shaft This will facilitate cover installation and prevent damage to the oil seal 3 if it is already installed in the cover Tap at different positions with a rubber mallet to help locate cove...

Страница 496: ...the specified torque Sect C 3 Engine torque settings Dampen oil seal 3 with alcohol and fit it on the generator cover at the gear change lever shaft Sect F 5 Refitting the gear change control Fit the...

Страница 497: ...hanged check sensor air gap see procedure below Remove screw plug B from the inspection hole in the LH side casing Do not check the air gap at the teeth gap Fit a feeler gauge A into the hole and meas...

Страница 498: ...cover G 8 Refitting the chain sprocket Refit the clutch transmission unit F 2 Refitting the clutch transmission assembly Refit gearchange control F 5 Refitting the gear change control Fill engine with...

Страница 499: ...Key 6 Aluminium gasket 7 Screw 8 Aluminium gasket 9 Blanking plug 10 Breather valve 11 O ring 12 Head stud bolt 13 Locating dowel 14 Blanking plug 15 Blanking plug 16 Seal thk 2 17 Nipple 18 Mesh fil...

Страница 500: ...from the frame N 1 Removing the engine Remove the lubrication system N 2 1 Removing the oil pump Remove the complete head unit with timing system N 4 2 Cylinder heads side covers timing system Remove...

Страница 501: ...17 Undo and remove the screw 7 with gasket 6 to check engine timing sensor air gap Remove mesh filter 18 and seal from the clutch side casing as described under Sect D 4 Changing the engine oil and fi...

Страница 502: ...t outer components Remove drain plug 9 with seal 28 Remove neutral light switch 19 with seal 20 file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_N_9A9_00 73 1 html 4 of 10 10 7 2008...

Страница 503: ...e block and tighten to the specified torque Sect C 3 Engine torque settings Tighten both plugs 14 and seals 8 to the specified torque Sect C 3 Engine torque settings Tighten oil filter cartridge suppo...

Страница 504: ...er cartridge Refit the ratchet and gear stopper Sect N 7 1 Reassembling gear stopper and ratchet To refit stud bolts 12 on casing apply speed bond on threads and tighten to the specified torque Sect C...

Страница 505: ...tor side cover and the complete generator N 8 Flywheel generator Slide out the drive gear A of the timing gear pair 2 and the key 5 Unbend the safety washer 3 of the timing gear retaining nut 4 Hold t...

Страница 506: ...k timing gears 2 for wear Change if necessary Caution The two timing gears 2 must be always changed in pair To reassemble follow the disassembly procedure in reverse order Caution Once finished make s...

Страница 507: ...arter motor driven gear Operations Reference See Section Remove the generator flywheel unit N 8 Flywheel generator Remove circlip 25 and washer 24 Remove the starter lay gear 23 and the shim 22 Loosen...

Страница 508: ...te Apply recommended threadlocker to screw 26 then tighten it to the specified torque Sect C 3 Engine torque settings Operations Reference See Section Refit the generator flywheel unit N 8 Flywheel ge...

Страница 509: ...side casing 4 Bearing 5 O ring 6 Circlip 7 Bearing 8 Screw 9 Stop plate 10 Bearing 11 Seal 12 Bearing 13 Washer 14 Bearing 15 Bearing 16 Clutch side casing 17 Spacer 18 Screw file C Documents 20and 20...

Страница 510: ...oil pump Remove the complete head unit with timing system N 4 2 Removing the timing side covers Remove the complete cylinder piston unit N 5 Removing cylinder piston assy Remove the generator side cov...

Страница 511: ...nerator cover or a service cover with puller part no 88713 1749 fitted to it Secure cover to casing with some of the original screws and begin separation by turning the central pin of the tool Tap on...

Страница 512: ...or drum from the casing Sect N 7 2 Gearbox assembly gearbox shafts Slide out the crankshaft A using a plastic hammer Do not damage or lose the shims file C Documents 20and 20Settings F4i My anual wsm...

Страница 513: ...bearings next paragraph If you have to change the gearbox primary shaft bearing 12 remember that there is a seal 13 placed between bearing and chain side casing Note It is a good rule to change all c...

Страница 514: ...rings 24 Check that the oilways are not clogged or obstructed Check centring bushes 19 If apparently distorted or loose in their seats change them using proper tools When the locating bushes 19 are ha...

Страница 515: ...0 C Remove the bearing using a drift and a hammer Fit the new bearing while the casing is still hot perfectly square into its seat Use a tubular drift which only applies pressure on the bearing outer...

Страница 516: ...ons and clean Mating surfaces must be perfectly flat and free from burrs Reassembling the clutch side casing Check that the following parts are in place inside casing Secondary shaft end bearing 15 Pr...

Страница 517: ...r 13 Main bearing 4 The ball bearing 7 with circlip 6 at the position of the timing layshaft Note Except for the main bearings all other bearings do not have a mounting position Shimming the shafts Be...

Страница 518: ...of shimming required for each casing note that S S1 S2 where S1 and S2 represent the shimming for the casings 1 and 2 Considering shaft alignment this gives S1 P1 0 15 A 2 And finally the second shimm...

Страница 519: ...n a support plate fixed to crankcase Bring stylus in contact with crankshaft end and set dial gauge to zero with the stylus touching the crankshaft file C Documents 20and 20Settings F4i My anual wsm u...

Страница 520: ...l shimming for the primary shaft SA and the secondary shaft SB proceed as follows Measure A and B on the primary and secondary shafts for secondary shaft also add 2 3 mm for shim C Measure the depth c...

Страница 521: ...clutch side casing depth P2 chain side casing depth A gearbox drum shoulder Considering that end float should be 0 10 0 40 mm and taking the average optimal value of 0 25 mm This gives S P1 P2 A 0 25...

Страница 522: ...re the casing by fitting a few screws in the holes near the drum position Place a dial gauge T with magnetic base on a support plate fixed to crankcase Bring stylus in contact with selector drum end a...

Страница 523: ...ector drum Note Final end float should be closer to 0 40 rather than 0 10 mm Separate the casings and insert the necessary shims on each side of the selector drum To shim the gearbox primary shaft G b...

Страница 524: ...nt from the other clutch dogs change the primary shaft shim L Fit a 2 5 mm shim H to the secondary shaft Fit the secondary shaft to the clutch side right casing Install the two forks with their pins S...

Страница 525: ...gearbox shafts Measure end float of secondary and primary shafts with the dial gauge Final play must be between 0 05 and 0 20 mm for both shafts Note Play should be closer to 0 05 rather than 0 20 mm...

Страница 526: ...casings Insert the forks of the 1st 4th 3rd 2nd gears F and the fork of the 5th 6th gears G into the grooves of the sliding gears Fit the fork selector drum P with calculated shims file C Documents 20...

Страница 527: ...ever assembly M see Sect N 7 1 Reassembling the gear selector lever Place gearbox in NEUTRAL and look through the opening of the horizontal cylinder to check that the clutch dogs of the sliding gears...

Страница 528: ...ngs Fit the timing layshaft 2 into the clutch side casing roller bearing 21 To prevent damage to the oil seal on the timing layshaft insert a protection cap part no 88700 5749 on the shaft threaded en...

Страница 529: ...hen refitting used components make sure that the inner races D of the gearbox shaft end bearings are fitted into the correct bearing and are not on the shaft Then install gearbox unit into the casings...

Страница 530: ...ary shaft driven gears Note Both forks are alike Insert the fork of the 5th 6th gears G into the primary shaft driven gear Fit the fork selector drum P in the casings with calculated shims file C Docu...

Страница 531: ...O ring 5 and place it close to the oil duct connecting the two casings Caution Make sure that the connecting rods B are correctly positioned in the cylinders Incorrect positioning will inevitably lead...

Страница 532: ...them correctly Note Apply recommended grease when refitting drilled screw 28 Ref Qty Description 25 6 M8x75 mm screws 28 1 M8x75 mm drilled screw 26 5 M6x35 mm screws 27 1 M6x75 mm screw Progressivel...

Страница 533: ...oil and filter cartridge Refit the complete clutch unit N 6 1 Reassembling the APTC unit Refit the clutch side cover N 6 2 Refitting the clutch cover Refit engine ignition assembly P 3 Electric starti...

Страница 534: ...screw 3 Blanking plug 4 Threaded dowel 5 Complete connecting rod 6 Bush 7 Bearing 8 Special screw 9 Shim 10 Key 11 Key Spare parts catalogue Crankshaft Half crankcases file C Documents 20and 20Setting...

Страница 535: ...ling the APTC system Open the casings N 9 2 Opening the casings Open the casings and then remove the crankshaft 1 together with connecting rod 5 Disassembling the connecting rods To disassemble the co...

Страница 536: ...ig end bearings Change the bearings every time the engine is overhauled Spare bearings are supplied ready for installation They must not be reworked with scrapers or emery cloth Connecting rod big end...

Страница 537: ...ame time Locate the new bush to the small end of the connecting rod with the opening at right angles to the upper hole of the con rod small end Drill the new bush at the same positions of the oil hole...

Страница 538: ...d condition Check for fretting or burrs in the fillet between crank pin and shoulder Fillet radius 1 5 mm Use a micrometer to measure oval and taper of the crank pin Measure oval and taper in several...

Страница 539: ...ween two centres Sect C 1 1 Cylinder piston Undo all crankshaft plugs 4 3 and 2 If they are hard to remove heat plug to remove the threadlocker used at assembly Use an air gun capable of reaching 150...

Страница 540: ...s and blow with compressed air to remove any deposits preventing proper oil circulation Apply DUCATI liquid gasket to the threads of the plugs 3 4 and 2 and then refit them file C Documents 20and 20Se...

Страница 541: ...rence line B Replace the bearings or the crankshaft if the thickness measured the clearance is not within the specified limits see Section C 1 1 Cylinder piston for con rod bearings to crankpin cleara...

Страница 542: ...contact with skin and wear protective gloves Caution Failure to grease the con rod bolts will lead to incorrect clearance and breakage Fit the fork gauge part no 88765 1000 available shims are 0 1 mm...

Страница 543: ...6 1 Reassembling the APTC unit Refit the clutch side cover N 6 2 Refitting the clutch cover Refit engine ignition assembly P 3 Electric starting Refit the generator side cover and the complete genera...

Страница 544: ...gine timing 25 4 2 Cylinder heads side covers timing system 27 Removing the timing side covers 28 Disassembling the timing system 29 Reassembling the timing system 33 Refitting the timing side covers...

Страница 545: ...lutch cover 104 Removing the clutch cover 105 Disassembling the clutch cover 106 Reassembling the clutch cover 108 Refitting the clutch cover 109 6 3 Clutch unit primary gears 111 Disassembling the pr...

Страница 546: ...nents 159 Removing the outer components 160 Reassembling the outer components 163 Removing the timing lay gear 165 Reassembling the timing lay gear 167 Removing the starter motor driven gear 168 Refit...

Страница 547: ...Engine file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_N_IND_00 58 1 html 4 of 4 10 7 2008 8 46 43 PM...

Страница 548: ...Wiring diagram 1 Wiring diagram file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_P_1A9_00 77 1 html 1 of 5 10 7 2008 8 46 49 PM...

Страница 549: ...r spark plug 23 Horizontal cylinder injector 24 Vertical cylinder injector 25 Throttle position sensor 26 Rpm timing sensor 27 Side stand switch 28 Control unit 29 Injection relay 30 Neutral switch 31...

Страница 550: ...zed to ensure the minimum obstruction Each section is designed to prevent interference with parts that might damage wires or cause operating failures when riding The diagrams on the following pages sh...

Страница 551: ...Diagram F Solenoid starter Starter motor 23 Diagram F Fuse box 24 Diagram F Control unit ground 25 Diagram F Engine ground 27 Diagram G Regulator fuse for versions with plastic fuel tank 28 Diagram G...

Страница 552: ...tch connection 45 Diagram P Right switch connector 46 Diagram P Front right turn indicator connection 47 Diagram P Rear brake switch 48 Diagram Q Speed sensor connector 49 Diagram Q Speed sensor 50 Di...

Страница 553: ...Diagram A Diagram A file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 1 of 20 10 7 2008 8 46 52 PM...

Страница 554: ...Diagram A Diagram B file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 2 of 20 10 7 2008 8 46 52 PM...

Страница 555: ...Diagram A file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 3 of 20 10 7 2008 8 46 52 PM...

Страница 556: ...Diagram A Diagram C file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 4 of 20 10 7 2008 8 46 52 PM...

Страница 557: ...Diagram A Diagram D file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 5 of 20 10 7 2008 8 46 52 PM...

Страница 558: ...Diagram A file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 6 of 20 10 7 2008 8 46 52 PM...

Страница 559: ...Diagram A Diagram E file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 7 of 20 10 7 2008 8 46 52 PM...

Страница 560: ...Diagram A Diagram F file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 8 of 20 10 7 2008 8 46 52 PM...

Страница 561: ...Diagram A file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 9 of 20 10 7 2008 8 46 52 PM...

Страница 562: ...Diagram A Diagram G file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 10 of 20 10 7 2008 8 46 52 PM...

Страница 563: ...Diagram A Diagram H file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 11 of 20 10 7 2008 8 46 52 PM...

Страница 564: ...Diagram A Diagram J file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 12 of 20 10 7 2008 8 46 52 PM...

Страница 565: ...Diagram A file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 13 of 20 10 7 2008 8 46 52 PM...

Страница 566: ...Diagram A Diagram K file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 14 of 20 10 7 2008 8 46 52 PM...

Страница 567: ...Diagram A Diagram L file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 15 of 20 10 7 2008 8 46 52 PM...

Страница 568: ...Diagram A Diagram M file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 16 of 20 10 7 2008 8 46 52 PM...

Страница 569: ...Diagram A file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 17 of 20 10 7 2008 8 46 52 PM...

Страница 570: ...Diagram A Diagram N file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 18 of 20 10 7 2008 8 46 52 PM...

Страница 571: ...Diagram A Diagram P Diagram Q file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 19 of 20 10 7 2008 8 46 53 PM...

Страница 572: ...Diagram A file C Documents 20and 20Settings F4i My anual wsm usa Mon695_MY07_P_1B9_00 78 1 html 20 of 20 10 7 2008 8 46 53 PM...

Страница 573: ...supplied to the battery currently discharging Or it is possible to use a multimeter Sect P 9 Testers connect probes from multimeter to battery terminals select the direct current position on the mult...

Страница 574: ...case the ammeter shows a change take voltage back to 16 17 or change the battery Adding electrolyte Remove the battery from the vehicle Warning Carefully read the relevant safety rules before making...

Страница 575: ...is suitable for your battery Take the fluid container off the vinyl case Remove the cap bar 3 from the container 2 Caution Keep the cap bar 3 at hand because it will be used to plug the battery cells...

Страница 576: ...er in this position for more than twenty minutes Should no air bubbles show from one of the filler holes slightly tap on the bottom of the corresponding bottle Caution Never detach the container from...

Страница 577: ...g the battery Note When using an automatic reduction battery charger check that the charger current amperes is equal or higher than the value of standard charging system STD indicated on the battery i...

Страница 578: ...attery clean Smear grease on the battery terminals to prevent corrosion Warning Do not remove the sealing bar 1 on the top of the cover or top up fluid Replace battery if block cover and terminals are...

Страница 579: ...C 3 Frame torque settings and use a waterproof spray Battery mount Remove the battery as described under Battery in this section Remove the Regulator fuse as described in this section Remove the elec...

Страница 580: ...e specified torque Sect C 3 Frame torque settings Generator The generator is a 12V 520W alternator consisting of a fixed stator A located in the generator cover and a rotor B fixed to the crankshaft f...

Страница 581: ...ective V 27 10 78 10 Values notably lower than the mentioned values can be due to partially demagnetized rotor short circuited coil windings In the above cases the whole generator assembly rotor and s...

Страница 582: ...e DDS please refer to Checking the charging system Sect D 5 Removing the regulator Remove the seat Sect E 3 Removing the seat Remove the fuel tank Sect L 2 Removing the fuel tank Open the clamp and di...

Страница 583: ...the plastic fuel tank Install the seat Sect E 3 Refitting the seat Regulator fuse The 30A fuse placed at the side of the battery mount protects the electronic regulator Remove the protective cap A to...

Страница 584: ...FF position before changing a fuse Warning Use only fuses with the specified amperage Using fuses with the incorrect amperage may damage the electrical system and cause fires file C Documents 20and 20...

Страница 585: ...p on right switch 1 Engine Start on right switch 1 Neutral sensor 30 Side stand sensor 27 Clutch microswitch 43 If all above inputs send enabling signals the control unit 28 will enable engine ignitio...

Страница 586: ...no load applied to the shaft Secure the starter motor to a test bench Ensure not to damage motor case Use a 12V fully charged battery Take battery motor connection cables not longer than 70 cm and ha...

Страница 587: ...ove timing intermediate gears and starter motor intermediate gear Sect N 9 1 Removing the starter motor driven gear Disconnect starter motor starter contactor cable 3 see diagram in Arrangement of wir...

Страница 588: ...e torque settings Connect starter motor starter contactor cable 3 Caution Fill the protective cap with protective grease before fitting it on the starter motor If the starting gears assembly was repla...

Страница 589: ...the starter contactor from the wiring Starter contactor operational check Apply a 12V battery across the positive A and negative B terminals of the connector Connect a multimeter between the two poles...

Страница 590: ...re not oxidized and use waterproof spray Tighten the nuts 4 to the specified torque Sect C 3 Frame torque settings Reconnect connector 2 to wiring file C Documents 20and 20Settings F4i My manual wsm u...

Страница 591: ...el Warning Headlamp halogen bulbs become hot when turned on and stay hot for some time after they are switched off Allow bulbs to cool down before changing them To gain access to headlight bulbs loose...

Страница 592: ...cken resulting in reduced bulb brilliancy Insert the locating pins of the bulb base into their seats to obtain correct alignment Hook the clip 3 to the headlamp holders Connect the cables previously d...

Страница 593: ...the rim reflector assembly in place Replacing the number plate light bulbs Remove the bulb holder from the inside of the number plate holder to gain access to the number plate bulb 5 Remove the bulb...

Страница 594: ...ght loosen the screws 1 collect caps 2 Disconnect connector 3 from front wiring Loosen screws 4 to remove turn indicators file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_P_4_9_00 8...

Страница 595: ...vibration dampers 6 Vibration dampers 6 and screws 7 secure the instrument panel to the steering head Headlight support 5 is secured to the bottom yoke by means of screws 8 file C Documents 20and 20S...

Страница 596: ...e system in order to control the light automatic switch off strategy i e 1 If on after normal use lights go off 60 seconds after engine is stopped by means of Engine kill button 2 and with key ON they...

Страница 597: ...lated to the correct pressure and with a rider seated Position the motorcycle 10 meters from a wall or flat surface On the wall or surface draw a horizontal line at the same height from the ground as...

Страница 598: ...to check the maximum height of the light beam To adjust the height of the light beam turn the adjusting screws 1 that retain the headlamp to the side supports file C Documents 20and 20Settings F4i My...

Страница 599: ...heck for electric continuity which must be available when HORN is pressed see Sect P 9 Testers on multimeter operation When HORN button is pressed resistance value taken by the multimeter should be cl...

Страница 600: ...ow cables High beam HI Red Black and Blue Yellow cables Flasher PASSING Check for continuity across the Red Black and Grey cables Fit the left switch tighten the screws 1 to the specified torque Sect...

Страница 601: ...roceed as described for the engine stop button and check for continuity between Blue White and Black cables when starter button is pressed see Sect P 9 Testers on multimeter operation If the above doe...

Страница 602: ...inals of front STOP switch 1 and rear STOP switch 2 with a multimeter Sect P 9 Testerson multimeter operation when either front or rear brake is enabled No electric continuity should be available when...

Страница 603: ...the neutral switch should be changed If the light stays on turn the ignition key to OFF to switch off the instrument panel and use a multimeter to check whether the section between neutral switch and...

Страница 604: ...he instrument panel is grounded Check with ignition key positioned to OFF instrument panel off Clutch switch For the clutch switch 5 proceed as described for STOP switches see beginning of this sectio...

Страница 605: ...that fasten the lens 5 and remove The bulb has a bayonet fitting Press and twist clockwise to extract Fit a new bulb Press and twist clockwise until it becomes properly seated with an audible click R...

Страница 606: ...Indicators and lighting system file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_P_5_9_00 82 1 html 8 of 8 10 7 2008 8 47 09 PM...

Страница 607: ...should be heard Turn the ignition key to ON and connect a multimeter to contacts 3 and 6 and then to 2 and 5 to check for electric continuity Resistance value taken by the multimeter should be close...

Страница 608: ...5 Removing the side stand and disconnect it from the main wiring harness refer to Arrangement of wiring on frame under Sect P 1 Use an analog or digital multimeter Sect P 9 How to use the multimeter t...

Страница 609: ...ght hand side of the battery mount To access the fuses open the fuse box cover Fuse layout and amperage are shown on the cover Please refer to Arrangement of wiring on frame Sect P 1 for ampere rating...

Страница 610: ...fuses with the incorrect amperage may damage the electrical system and cause fires In addition to the fuses contained into the fuse box the bike is also equipped with a 30A fuse positioned under the b...

Страница 611: ...iagrams in Arrangement of wiring on frame in Sect P 1 Note The spare instrument panel comes as a complete assembly Inner components may not be replaced individually Caution When the instrument panel i...

Страница 612: ...ght doubles as a diagnostic light for the immobilizer system Note This light will keep flashing for 24 hours after immobilizer is activated The light then turns off but the immobilizer system is still...

Страница 613: ...p meter is displayed to reset Operation of LCD unit 11 Press the button 13 with the key turned to ON to display clock and coolant temperature LCD 11 clock setting Press button 13 for at least 2 second...

Страница 614: ...is turned to ON to indicate that the motorcycle is due for service inspection Note The MAInt warning may be cancelled as follows Hold down the button 13 and turn the key to ON Wait until the warning...

Страница 615: ...OWER SAVE mode lights can be reactivated only by turning the key from OFF to ON If the engine was started and then stopped by means of the RUN STOP switch lights are reactivated by simply starting the...

Страница 616: ...e red key be used only for programming the immobilizer system Use the black keys to start the engine Keep the red key in a safe place Two black keys they are used to start the engine the key head incl...

Страница 617: ...nd enables engine start if code is correct Immobilizer warning lights and indications Each time the key is turned from ON to OFF engine is disabled by the immobilizer When the ignition key is turned f...

Страница 618: ...re 1 and a countdown starting from 30 Important ensure that the ignition switch was to OFF for at least thirty seconds before performing the above ensure that countdown has started and turn the key to...

Страница 619: ...ed to ON for 5 to 15 seconds not less than 5 and not more than 15 seconds to allow data transfer from the decoder to the engine control unit and then turn the key to OFF allow 10 seconds before turnin...

Страница 620: ...or both three flashes indicate that the inserted key has not been acknowledged by the system four flashes indicate that the engine control unit is programmed but the decoder in the instrument panel is...

Страница 621: ...time the key is positioned to OFF after overriding the immobilizer as described above upon the following key ON the same error will show and engine is disabled again The above procedure should be rep...

Страница 622: ...slot A Apply threadlocker to the two special screws 6 Install the key operated switch with plate and antenna to the frame 7 and start the two special screws 6 in their holes Turn the screws fully in a...

Страница 623: ...the vice jaws are protected Use pliers to extract the key 2 the protections 3 and the transponder 4 Change any damaged components and reverse the dismantling procedure to reassemble file C Documents...

Страница 624: ...Immobilizer and Transponder file C Documents 20and 20Settings F4i My manual wsm usa Mon695_MY07_P_8_9_00 85 1 html 9 of 9 10 7 2008 8 47 22 PM...

Страница 625: ...se as possible to this value for example 15V or 20V A 10V full scale is not correct The same applies if amperes or ohm values should be taken Sometimes the instrument automatically sets the full scale...

Страница 626: ...ong electric system sections or in switches or relays To check a section of the electric system included between two connections disconnect those connections connect multimeter terminals to both ends...

Страница 627: ...Diagram K 17 Diagram L 18 Diagram M 19 Diagram N 20 Diagram P 21 Diagram Q 22 2 Charging system battery 23 Checking the charging system 23 Recharging the battery 24 Adding electrolyte 25 Battery 28 Ba...

Страница 628: ...bs 50 6 Protection and safety devices 52 Checking protection and safety devices components 52 Checking the fuses 54 7 Warning lights and indicators 55 Instrument panel 55 8 Immobilizer and Transponder...

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