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Refitting the external components
Check the condition of O-rings (3) and replace them if necessary.
Install the blow-by valve (2) in the crankcase along with O-rings (3), previously lubricated.
Tighten screw (1) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).
Fit nuts (5) on nipples (4).
Apply recommended threadlocker to the plug thread (4). Tighten nipples (4) to a torque of 32 Nm (Min. 29
Nm - Max. 35 Nm).
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...
Страница 592: ......
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...
Страница 718: ......
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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