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Refitting the rear footpegs
Fit spring (17) into rear footpeg (15).
Apply generic grease on the spring end and insert the ball (16).
Position plate (18) so that the two chamfers are facing the rear side.
Press on the plates and insert the plate/footpeg assembly in the footpeg holder.
Smear the recommended grease on pin (13) and insert as shown.
Lock shaft using circlip (12).
Содержание SCRAMBLER 800
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Страница 48: ...88713 3220 Engine repair work bench...
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Страница 94: ...Loosen screws 11 of pulley 12 vertical and horizontal cylinder Turn pulley counter clockwise...
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Страница 113: ...Fix the number plate light 16 by means of screws 17 Position the wiring with ties as shown in the figure...
Страница 114: ...Fit mudguard 3 and fix it with screw 6 Position the rear subframe mudguard assembly on the vehicle Start screws 4...
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Страница 119: ...Fit nipple 3 into its seat 4 Position the underseat cover 1 and fix it by means of screws 2...
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Страница 127: ...Removing the tail guard Remove the two lower screws 7 of tail guard 8 Remove the two lateral screws 9 and 10...
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Страница 144: ...Tighten the four screws 2 to a torque of 8 Nm 10...
Страница 145: ...Removing the front mudguard Loosen the two screws 2 from both sides of the front mudguard 1 Remove the front mudguard 1...
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Страница 149: ...Fix heat guard 2 by tightening screws 1...
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Страница 151: ...Removing the belly pan Undo screws 1 that retain the belly pan 2 Remove the belly pan 2...
Страница 152: ...Table Z For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 153: ...TABLE AA...
Страница 154: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame TABLE BB...
Страница 155: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame TABLE CC...
Страница 156: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame TABLE DD...
Страница 157: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 158: ...Table Y For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 159: ...Table X For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 160: ...Table W...
Страница 161: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 162: ...Table V For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 163: ...Table U For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 164: ...Table T For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 165: ...Table S For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 166: ...Table R For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 167: ...Table Q...
Страница 168: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 169: ...Table P...
Страница 170: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 171: ...Table O For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 172: ...Table N...
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Страница 174: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 175: ...Table M For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 176: ...Table L For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 177: ...Table K...
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Страница 179: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 180: ...Table J...
Страница 181: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 182: ...Table H For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 183: ...Table G...
Страница 184: ...For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 185: ...Table F For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 186: ...Table E For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 187: ...Table D For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 188: ...Table C For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 189: ...Table A For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
Страница 190: ...TABLE A For the complete index of the wirings divided by tables refer to chapter Routing of wiring on frame...
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Страница 199: ...A blown fuse can be identified by breakage of the inner filament B...
Страница 204: ...Fit cover 4 and fix it with screw 3 Fasten the battery cover by means of belt 1...
Страница 213: ...Refit the seat Refitting the seat...
Страница 215: ...Electric starting system The electric starting system consists of a solenoid starter 1 and a starter motor...
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Страница 219: ...Remove headlight 5 and disconnect connector 6...
Страница 221: ...Fix the U bolts 4 by tightening screws 3 to a torque of 5 Nm 10...
Страница 223: ...Remove bulb 3 by releasing spring 4...
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Страница 262: ...1000 rpm 5000 rpm 11000 rpm...
Страница 275: ...Electric diagram CONTROLS ON RIGHT HAND SWITCH...
Страница 279: ...Electric diagram Clutch switch The clutch switch 1 is located on the clutch lever lower side...
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Страница 282: ...Main relay and injection To remove and refit the main relay refer to chapter Starting system...
Страница 284: ...Check for rpm timing sensor pick up correct operation with the diagnosis instrument DDS 2 Electric diagram...
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Страница 288: ...Disconnect connectors 7 and 8 of the horizontal and vertical cylinder coils...
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Страница 291: ...Ignition spark plug To check the spark plug refer to chapter Replacing the spark plugs...
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Страница 321: ...Insert shaft 6...
Страница 322: ...Fit nut 3 without tightening it to torque...
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Страница 330: ...If the values measured are not within the tolerance limits replace the wheel...
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Страница 333: ...Working from the left hand side use a plastic mallet to drive the wheel shaft 6 out from the opposite side and remove it...
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Страница 335: ...Remove the wheel and recover spacer 7...
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Страница 337: ...Overhauling the rear wheel To overhaul the rear rim proceed as described for the front one in Overhauling the front rim...
Страница 338: ...Overhauling the rear wheel To overhaul the rear rim proceed as described for the front one in Overhauling the front rim...
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Страница 344: ...Remove the chain and the rear wheel and collect the spacer 3 Properly support the vehicle while removing the wheel...
Страница 347: ...Secure the hose with the relevant guide 6 Tighten the two screws 5...
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Страница 353: ...Undo special screw 7 and collect seals 8 Remove the brake hose Loosen the screws 9 and remove the brake calliper 10...
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Страница 369: ...Fit washer 15 on the footpeg holder plate 8...
Страница 373: ...Fill the rear braking system Changing the rear brake system fluid...
Страница 377: ...Separate bracket 6 and lever 7...
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Страница 383: ...TABLE C TABLE D...
Страница 384: ...TABLE E...
Страница 385: ...TABLE F TABLE G...
Страница 386: ...TABLE H...
Страница 387: ...TABLE I...
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Страница 391: ...Disconnect the connector 11 Remove the ABS control unit 7 loosening the two screws 8...
Страница 392: ...Release the two hoses 3 and 4 from cable ring 9...
Страница 393: ...Release the brake hose 6 from the clip 10...
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Страница 407: ...Adjusting the throttle cable For the throttle control cable adjustment refer to chapter Adjusting the throttle cable...
Страница 409: ...Insert the steering head on the two screws 19 and take it fully home against lower U bolt 17...
Страница 413: ...Tighten the screws 4 to a torque of 1 5 Nm 10...
Страница 414: ...Fit right hand switch 2 on the handlebar Position the switch 2 so that pin D engages in hole on the handlebar E...
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Страница 419: ...Undo and remove the screws 11 from the steering head Tighten screw 12 and ring nut 13 and remove the steering head 14...
Страница 420: ...Loosen two nuts 15 and separate the steering head 16 of the lower U bolt 17...
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Страница 440: ...Remove dust seal 5 from outer sleeve 1...
Страница 445: ...Activate the damper rod a few times Fit spring 4...
Страница 447: ...Bring plug 1 fully home on lock nut 12 Tighten plug 2 on lock nut 12 Tighten plug 1 on the fork sleeve...
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Страница 450: ...Loosen screw 2 securing the fork sleeve to the bottom yoke 4 Slide the fork downwards...
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Страница 458: ...Steering angle adjustment In this vehicle it is not possible to adjust the steering...
Страница 462: ...Overhauling the rear shock absorber This shock absorber can not be overhauled...
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Страница 468: ...Fit circlip 3 in wheel shaft 4 Insert screw 5 applying the specified product and tighten it to a torque of 18 Nm 5...
Страница 469: ...Lock shaft using circlip 8 Refit chain guard 1 by tightening the two screws 2 to a torque of 5 Nm 10...
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Страница 480: ...Insert spacer 4 fully home Lubricate the pins with the recommended product...
Страница 482: ...Refit the rear wheel Refitting the rear wheel...
Страница 484: ...Loosen the nuts retaining the rear sprocket to the rear sprocket flange previously loosened...
Страница 487: ...Tension the belt Fit the sprocket cover 1 and tighten the screws 2 to a torque of 6 Nm 10...
Страница 490: ...Remove the front sprocket 6 from the gearbox secondary shaft 5...
Страница 502: ...Tighten the screw 4 to a torque of 36 Nm 10...
Страница 505: ...Loosen nut 9 of pin 10 retaining stand to plate...
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Страница 508: ...L 331 7 mm...
Страница 510: ...Make sure clips 4 are in place...
Страница 511: ...Make sure clips 5 are in place...
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Страница 515: ...Refit the tail guard Refitting the tail guard Refit the seat Refitting the seat...
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Страница 526: ...Remove the three screws 14 securing the number plate holder plate 15 Remove the number plate holder from its support...
Страница 527: ...Remove the number plate light 17 by loosening the two screws 16...
Страница 531: ...Tighten nuts 2 and 3 to a torque of 5 Nm 10...
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Страница 536: ...Tighten the two screws 13 to the silent blocks to a torque of 5 Nm 10...
Страница 538: ...Tighten screw 2 retaining side body panel 1 to tank 3 to a torque of 5 Nm 10...
Страница 540: ...Fit the tank cover 6 by pulling it inwards to engage pins 4 in fixing points 5...
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Страница 544: ...Use the indicated product to lubricate the contact areas of tabs 10 with the seal...
Страница 545: ...Removing the fuel tank flange Loosen the screws 2 and remove fuel pump flange 3...
Страница 547: ...Removing the tank filler plug Open the fuel plug and loosen the four retaining screws 1 Remove the tank plug...
Страница 549: ...Disconnect hoses 14 and connector 15...
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Страница 557: ...Connect the Map Sensor hose 3 and fix it with clip 4...
Страница 558: ...Reconnect the horizontal cylinder connector 1 and the vertical cylinder connector 2...
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Страница 566: ...Fit seal 22 in its seat on the airbox Fit two spacers 23 as shown in the figure...
Страница 574: ...Ensure that gasket 41 is present on the airbox...
Страница 578: ...Connect the regulator connectors...
Страница 579: ...Connect air connector Connect the secondary air system connector 6 connect the secondary air hose 8 and tighten clip 7...
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Страница 585: ...Disconnect air connector Disconnect the regulator connectors...
Страница 586: ...Undo screws 11 and remove the airbox cover 10...
Страница 587: ...Disconnect throttle cable 12...
Страница 591: ...LH cover Loosen the upper screw 4 of the LH airbox cover 7 the lateral and lower screws 8 Remove the LH airbox cover 7...
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Страница 594: ...Position the spark arrestor plate 13 and pay attention to the insertion direction Fit the reed valve 12 on cover 11...
Страница 598: ...Fit the lateral cover so that pins 17 engage in their seat 18 Tighten the screw 2 to a torque of 5 Nm 10...
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Страница 604: ...Connect the regulator connectors...
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Страница 606: ...Removing the air filters Disconnect the regulator connectors Undo screws 4 and remove the airbox cover 3...
Страница 607: ...Remove the airbox cover Loosen the three screws 5 of the support to remove the air filter Remove the airbox 6...
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Страница 612: ...Fix the two exhaust pipes 4 with screws 5...
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Страница 625: ...Loosen the lambda sensor 11 and remove the exhaust manifold 2 by loosening the two screws 12...
Страница 627: ...Fix heat guard 4 by tightening screws 5 to a torque of 5 Nm 10...
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Страница 630: ...Remove the silencer external side 6 by loosening screw 7...
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Страница 650: ...Inspecting the oil cooler Visually inspect the cooler Replace it at any sign of damage or leaks...
Страница 652: ...To remove the oil hoses 6 and 7 loosen the two nuts 8 Loosen the two nipples 9 by recovering the relevant two gaskets 10...
Страница 656: ...Exhaust Opening 61 B T D C Closing 7 A B D C Intake valve diameter 44 mm Exhaust valve diameter 38 5 mm...
Страница 662: ...Refitting the timing belts To refit the timing belts refer to paragraph Replacing the timing belts...
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Страница 675: ...Important Upon reassembly always use new ring nuts Loosen and remove the fixed tensioners 11...
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Страница 684: ...Fit the camshaft 11 from the head LH side...
Страница 685: ...While fitting the camshaft pay attention not to damage the seal Rotate camshaft to evenly lubricate contact areas...
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Страница 692: ...Removing the rocker arm shaft cap Loosen screws 5 securing cap 6 and remove it Remove keyway 7 of camshaft 8...
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Страница 700: ...Temporarily fit the camshaft...
Страница 705: ...Refit the caps the camshafts and the valve covers Refitting the camshafts...
Страница 715: ...Slide out valve closing shim 11 from the valve 12 Withdraw valve 12 from the lower side of the cylinder head...
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Страница 738: ...Lock clutch housing with tool T no 88713 2556 and loosen retaining nut 7...
Страница 740: ...Remove the spacer 11 from the clutch housing 10...
Страница 744: ...Fill the engine with oil Changing the engine oil and filter cartridge...
Страница 746: ...Bring shaft 9 fully against clutch cover 2 Rotate shaft 9 counter clockwise until part 14 touches mating surface 15...
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Страница 753: ...Working on clutch cover lever slowly remove cover to release it from clutch control pin...
Страница 762: ...Insert shaft 12 in plate 9 position washer 7 and block with the snap ring 6...
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Страница 781: ...Remove the fifth speed driven gear 16...
Страница 783: ...Remove the fourth speed driven gear 19 with its roller bearing cage 20 and splined washer 21...
Страница 784: ...Remove the third speed driven gear 22 with its roller bearing cage 20 and splined washer 18...
Страница 785: ...Remove snap ring 17 and slide out the sixth speed driven gear 23...
Страница 786: ...Remove the snap ring 17 and withdraw the splined washer 18 and the second speed driven gear 24...
Страница 788: ...Disassembling the gearbox primary shaft Remove washer 26 from the primary shaft...
Страница 789: ...Remove the second speed driving gear 28 Use two screwdrivers to prise out the snap ring 17 and the splined washer 18...
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Страница 792: ...Withdraw the third and fourth speed driving gear 30 Remove the snap ring 17 and the splined washer 18...
Страница 793: ...Remove the fifth speed driving gear 31 with its roller cage 20...
Страница 794: ...Slide out washer 25 from the primary shaft 9...
Страница 795: ......
Страница 797: ...Remove them from the shaft ends and fit them in the relevant bearings on the crankcase half...
Страница 803: ...Remove the inner ring 19 the needle roller bearing cage 20 and the washer 21...
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Страница 810: ...Refit the gear shift Refitting the gearbox unit Fill the engine with oil Changing the engine oil and filter cartridge...
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Страница 816: ...Use tool A no 88713 1749 to the holes of the just removed screws 1 and remove the cover...
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Страница 833: ...Loosen plug 10 taking care not to damage seal 11 Remove the drain plug 12 with its seal 13...
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Страница 852: ...Orient the seal ring 26 as shown The arrow refers to the insertion direction...
Страница 854: ...Orient the seal ring 32 as shown The arrow refers to the insertion direction...
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Страница 869: ...Apply specified threadlocker to the threads of plugs 5 6 and 7 then refit them...
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