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The descriptions and illustrations given in this publication are not binding. While the basic specifications as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all countries. The availability of each model should be checked at the official Piaggio sales network. " Copyright 2010 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited." PIAGGIO & C. S.p.A. - Q.C.S./After sales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) www.piaggio.com
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS TOOLING MAINTENANCE TROUBLESHOOTING ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE SUSPENSIONS BRAKING SYSTEM CHASSIS PRE-DELIVERY TIME
CHAR TOOL MAIN TROUBL ELE SYS ENG VE ENG SUSP BRAK SYS CHAS PRE DE TIME
INDEX OF TOPICS
CHARACTERISTICS
CHAR
Characteristics
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust fumes are toxic. - The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water and seek immediate medical attention. - The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks or flames near the battery, especially when charging it. - Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working area, and avoid naked flames or sparks. - Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that you do not breathe in the dust produced by the wear of the friction material. Even though the latter contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spares may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and split pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Characteristics
Vehicle identification
Chassis prefix LBMM701 Engine prefix M701M
Engine
ENGINE
Specification Engine Desc./Quantity Single cylinder 4-stroke
CHAR - 8
Characteristics
Specification Timing system Valve clearance Bore x stroke Engine capacity Compression ratio carburettor Engine idle speed Starter Max power to the shaft Cooling
Desc./Quantity Single overhead camshaft (SOHC) with 2 valves intake 0.10 exhaust 0.15 57 x 48.6 mm 124 cm (10.6+/-0.5):1 KEIHIN CVEK26 approx. 1.600 1.800 rpm starter 10.5 CV at 8000 rpm Forced-circulation air cooling.
Transmission
TRANSMISSION
Specification Transmission
Desc./Quantity With continuously variable expandable pulley transmission with torque server, V belt, automatic clutch, gear reduction unit and transmission housing with forced air circulation cooling.
Capacities
CAPACITY
Specification Engine oil Rear hub oil Fuel tank capacity Fork stem (oil level height without spring, compressed fork) Desc./Quantity 1.10 l approx. 250 cc ~ 7.0 litres (2.0 l of which is reserve) 85 mm
Electrical system
ELECTRICAL SYSTEM
Specification Starter Spark plug Ignition advance Battery Fuses Ignition type Alternator Desc./Quantity starter Champion NGK CR7EB - RG6YC 15 1 at 2,000 rpm 12 V / 10 Ah No. 1 20A, No. 1 15A, No. 1 7.5A Electronic capacitive discharge ignition (CDI) and variable advance, with separate HV coil. alternating current
CHAR - 9
Characteristics
Brakes
BRAKES
Specification Front brake Rear brake Desc./Quantity Disc brake ( 220 mm) with hydraulic control (lever on the far right of the handlebar) and floating calliper. 110mm drum brake
Secondary air
In order to reduce polluting emissions, the vehicle is furnished with a catalytic converter in the silencer. To favour the catalytic process, an extra amount of oxygen is added via a secondary air system (SAS). This system allows more oxygen to be added to the unburned gases before they reach the converter, thus improving the action of the catalytic converter. The air enters the exhaust duct from the head, and is purified by a black filter. The system is fitted with a control valve that disables operation while decelerating to avoid unwanted noise. To ensure the best functioning of the SAS system, every 12,000 km the vehicle should be taken to an Authorised Piaggio Service Centre to have the filter cleaned (Scheduled maintenance operations section).
CHAR - 10
Characteristics
The filter sponge should be cleaned with water and mild soap, then it should be dried with a cloth and slight blows of compressed air.
CAUTION
Tightening Torques
HEAD AND CYLINDER
Name Ignition spark plug Head cover screws Nuts fixing head to cylinder (*) Head fixing screws (external) Starter ground screw Flywheel air duct screw Pressure reducer counterweight retainer Camshaft pulley screw Timing chain tensioner slider screw Starter counterweight support screw Tightener screw: Timing chain tensioner central screw Camshaft retention plate screw Nut fixing silencer to cylinder head Head intake manifold screw Torque in Nm 18 Nm 11 to 13 28 to 30 11 to 13 7 to 8.5 3 to 4 7 to 8.5 12 to 14 10 to 14 11 to 15 5 to 6 5 to 6 5 to 6 16 to 18 11 to 13
(*) Lubricate the retainer threads before fitting and lock in a crossed sequence and repeat tightening 2 or 3 times.
CHAR - 11
Characteristics
TRANSMISSION
Name Drive pulley nut () Transmission cover screw Driven pulley shaft nut Rear hub cap screws Clutch unit nut on driven pulley () Apply LOCTITE 243 threadlock Torque in Nm 75 - 83 11 to 13 54 to 60 24 to 27 55 to 60
FLYWHEEL
Name Flywheel fan screws Stator assembly screws () Flywheel nut Pick-up screw () Apply LOCTITE 243 threadlock Torque in Nm 3 to 4 3 to 4 52 to 58 3 to 4
STEERING ASSEMBLY
Name Upper steering ring nut Lower steering ring nut Handlebar fixing screw Mirror fastening spacer Torque in Nm 30 to 36 10 - 13 (loosen by 90) 45 to 50 25
CHASSIS ASSEMBLY
Name Engine arm pin - chassis arm Centre stand pivot on engine Silent block-swinging arm retaining bolts Torque in Nm 45.5 42.5 42.5
FRONT SUSPENSION
Name Piston tightening fork lower screw Front wheel axle nut Fork clamp screw Fork stanchion upper cap Safety screw on fork leg Torque in Nm 25 - 35 45 - 50 20 to 25 15 30 6-7
FRONT BRAKE
Name Brake fluid hose-pump fitting Brake fluid pipe-calliper fitting Calliper to fork tightening screw Disc tightening screw Oil bleed screw Torque in Nm 20 to 25 20 to 25 20 to 25 8 to 12 8 to 12
CHAR - 12
Characteristics
Torque in Nm 8 15 to 20
REAR SUSPENSION
Name Rear wheel axle Shock absorber nut Torque in Nm 115 22.5
SADDLE UNIT
Name Saddle plate fixing nut Torque in Nm 10
BODYWORK UNIT
Name Helmet compartment fixing screw Rear grab handle fixing screw Battery cover fixing screw Front wheel housing to chassis fixing screw Front wheel housing to leg shield back plate fixing screw Front mudguard fixing screw Footrest fixing screw Screw fixing leg shield back plate to chassis Leg shield back plate to leg shield fixing screw Footrest spoiler fixing screw Passenger footrest protection fixing screw Passenger footrest to side body panel fixing screw Rear mudguard fixing screw Rear brake adjustment nut Torque in Nm 3 20.5 6 6 3 6 6 6 3 6 3 6 6 5
CHAR - 13
Characteristics
Name Coupling 3rd oversize Coupling 3rd oversize Coupling 3rd oversize
Initials N3 O3 P3
Piston rings
SEALING RINGS (125)
Name Compression ring Oil scraper ring Oil scraper ring Compression ring 1st oversize Oil scraper ring 1st oversize Oil scraper ring 1st oversize Compression ring 2nd oversize Oil scraper ring 2nd oversize Oil scraper ring 2nd oversize Compression ring 3rd oversize Oil scraper ring 3rd oversize Oil scraper ring 3rd oversize Description Dimensions 57 x 1 57x1 57x2.5 57.2 x 1 57.2x1 57.2x2.5 57.4x1 57.4x1 57.4x2.5 57.6x1 57.6x1 57.6x2.5 Initials A A A A A A A A A A A A Quantity 0.15 to 0.30 0.10 to 0.30 0.10 to 0.35 0.15 to 0.30 0.10 to 0.30 0.10 to 0.35 0.15 to 0.30 0.10 to 0.30 0.10 to 0.35 0.15 to 0.30 0.10 to 0.30 0.10 to 0.35
CHAR - 14
Characteristics
Name Crankcase Crankcase Crankshaft half-bearing Crankshaft half-bearing Crankshaft half-bearing Crankshaft category 1 Crankcase category 1 Crankshaft category 1 Crankcase category 2 Crankshaft category 2 Crankcase category 1 Crankshaft category 2 Crankcase category 2
Description
Dimensions
Initials Category 1 Category 2 Category B - blue Category C - yellow Category E - green E-E C-C C-C B-B
Quantity 32.953 to 32.959 32.959 to 32.965 1.973 to 1.976 1.976 to 1.979 1.979 to 1.982
Characteristic
Compression ratio 10.6: 1
CHAR - 15
Characteristics
SHIMMING SYSTEM
Specification Value measured Thickness Value measured Thickness Value measured Thickness Desc./Quantity 0 to 0.1 0.8 0.05 0.1 to 0.3 0.6 0.05 0.3 - 0.4 0.4 0.05
Products
RECOMMENDED PRODUCTS TABLE
Product AGIP ROTRA 80W-90 AGIP CITY HI TEC 4T AGIP FILTER OIL AGIP CITY HI TEC 4T AGIP GREASE MU3 AGIP BRAKE 4 AGIP GREASE PV2 Description rear hub oil Oil to lubricate flexible transmissions (brakes, throttle control and odometer) Oil for air filter sponge Specifications SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications Oil for 4-stroke engines
Mineral oil with specific additives for increased adhesiveness Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil Grease for odometer transmission gear Soap-based lithium grease with NLGI 3; case ISO-L-XBCHA3, DIN K3K-20 Brake fluid FMVSS DOT 4 Synthetic fluid Grease for steering bearings, bolt seatSoap-based lithium and zinc oxide ings for swinging arms and faying surface grease containing NLGI 2; ISO-Lof driven pulley spring (only pulley side) XBCIB2 Grease for brake lever, gas White calcium complex soap-based spray grease with NLGI 2; ISO-L-XBCIB2 Fork oil Grade 7.5 W
CHAR - 16
INDEX OF TOPICS
TOOLING
TOOL
Tooling
SPECIFIC TOOLS
Stores code 001330Y Description Tool for fitting steering seats
001467Y009
001467Y013
002465Y
005095Y
Engine support
006029Y
008564Y
Flywheel extractor
TOOL - 18
Tooling
020055Y
020074Y
020150Y
020151Y
Air heater
020193Y
020201Y
TOOL - 19
Tooling
020263Y
020271Y
020306Y
020329Y
020330Y
TOOL - 20
Tooling
020332Y
020334Y
020335Y
020357Y 020359Y
TOOL - 21
Tooling
020363Y
20-mm guide
020364Y
25-mm guide
020368Y
020375Y
28 x 30 mm adaptor
020376Y
Adaptor handle
TOOL - 22
Tooling
020382Y011
020409Y
020412Y
15-mm guide
020423Y
TOOL - 23
Tooling
020425Y
020426Y
020427Y
020428Y
020430Y
TOOL - 24
Tooling
020434Y
020439Y
17-mm guide
020444Y
020456Y 020565Y
020622Y
TOOL - 25
Tooling
TOOL - 26
INDEX OF TOPICS
MAINTENANCE
MAIN
Maintenance
Maintenance chart
Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been suggested, which are included in the summary table on the following page. Any minor faults should be reported without delay to an Authorised Service Centre or Dealer without waiting until the next scheduled service to solve it. It is indispensable to have your vehicle serviced to the prescribed intervals of time, even if you have not reached the predicted mileage. Punctual vehicle servicing is necessary for the correct use of the guarantee. For all further information regarding the Guarantee application modes and the execution of the "Programmed Maintenance" refer to the "Guarantee Booklet".
I I I I R R R R A I I I A I I
I C I I I I I R R I R L A I I I
I C I I I I I R R I R L I I I
I C I I I I I R R I R L I I I
I C I I I I I R R I R L A I I I
I I
I I
I I
I I
I I
Maintenance
- Connect the induction pincers being careful to respect the proper polarity (the arrow stamped on the pincers must be pointing at the spark plug). - Place the light selector in central position (1 spark = 1 crankshaft turn as in 2-T engines). - Start the engine and check that the light works properly and the rpm indicator can read also the high rpm (e.g. 8000 rpm). - If flash unsteadiness or revolution reading error is detected (e.g. half values), increase the resistive load on the spark plug power line (10 15 K in series to HV wire). - Operating on the flash bulb phase difference calibrator, make the reference on the flywheel cover coincide with the fan reference as shown in the photograph. Read the advance degrees indicated by the stroboscopic light and compare them with those specified.
Characteristic
Ignition advance check 15 1 at 2000 rpm - 28 1 at 6000 rpm
MAIN - 29
Maintenance
Spark plug
Place the vehicle on its central stand - Remove the central cover; - Detach the coil from the chassis, leaving it connected to the system, and disconnect the spark plug H.V. cable cap - Unscrew the spark plug using the socket wrench supplied. -Examine the condition of the spark plug, check that the insulating material is whole and measure the distance between the electrodes using a feeler gauge. -Adjust the distance if necessary by bending the side electrode very carefully. In the case of defects, replace the spark plug with one of the specified type. MAIN - 30
Maintenance
- Engage the spark plug with the due inclination and screw it right down by hand, then do it up with the wrench at the prescribed torque. - Fit the cap on the spark plug as far as it will go. - Refit the coil and the central cover.
CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 5,000 KM. USE OF STARTERS NOT CONFORMING OR SPARK PLUGS NOT THOSE DESCRIBED CAN SERIOUSLY DAMAGE THE ENGINE.
Electric characteristic
Recommended spark plug NGK CR7EB Alternative spark plug CHAMPION RG6YC Electrode gap 0.6 to 0.7 mm.
See also
Chassis
Hub oil
MAIN - 31
Maintenance
Check
Do the following to check the correct level: - Ride a few kilometres until the regular working temperature is reached, then stop the engine. - Park the vehicle on level ground and rest it on the centre stand. - Unscrew the oil filler dipstick, dry it with a clean cloth and reinsert it. - Remove the dipstick and make sure that the oil level reaches the indicated reference notch. - Screw up the oil dipstick back in and make sure it is locked properly in place.
Recommended products
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications
Replacement
- Ride a few kilometres until the regular working temperature is reached, then stop the engine. - Park the vehicle on level ground and rest it on the centre stand. - Remove the oil filler dipstick and drain out the oil completely. - Screw in the drainage cap again and fill the hub with the prescribed oil. - Check the level. - Screw the oil filler dipstick back into place, being sure it is completely blocked.
Characteristic
Rear hub oil Quantity: approx. 250 cc
MAIN - 32
Maintenance
Air filter
- Remove the cap of the air cleaner, unscrewing the five screws and the fixing knob. - Take out the filtering element. Cleaning: - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of compressed air. -Saturate with a 50% mixture of gasoline and oil. - Drip dry the filtering element and then squeeze it with your hands without wringing. -Let it dry and refit it again.
CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER, THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.
Recommended products
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for increased adhesiveness
- Loosen the indicated clamps and slide off the filter box.
MAIN - 33
Maintenance
Recommended products
AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
See also
Engine oil filter
Check
In four stroke engines, the engine oil is used to lubricate the timing elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all four stroke engines, the deterioration of the oil characteristics, or a certain consumption should be considered normal, especially if during the run-in period. Consumption can particularly reflect the conditions of use (i.e. when driving at 'full acceleration' all the time, oil consumption increases). MAIN - 34
Maintenance
This operation must be carried out with the engine cold and following the procedure below: 1) Rest the vehicle on the central stand and on a flat ground. 2) Undo cap/dipstick, dry it off with a clean cloth and reinsert it, screwing down completely. 3) Remove the cap/dipstick again and check that the level is between the max. and min levels; topup, if required. The MAX level reference mark indicates the amount of oil in the engine. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level will be lower; in order to carry out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct level.
Characteristic
Engine oil 1.10 l The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoring the level between the MIN and MAX reference marks requires ~ 400 cm of oil.
Recommended products
AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications
MAIN - 35
Maintenance
If the light turns on during braking, at idling speed or while turning a corner, it is necessary to check the oil level and the lubrication system.
transmissions
Put the vehicle in gear and regulate the idling by turning the adjustment screw on the left-hand side of the carburettor. Adjust the control cables as follows. Handlebar control: - remove the front handlebar cover leaving it connected to the system; - remove the rubber hoods and regulate the cable adjustments in such a way that they cause a minimum clearance on the throttle. Carburettor control: - remove the inspection cover of the helmet compartment; - remove the rubber hoods and regulate the cable adjustments in such a way that the sheaths have a minimum clearance.
MAIN - 36
Maintenance
Braking system
MAIN - 37
Maintenance
Level check
Proceed as follows: - Rest the vehicle on its centre stand with the handlebars perfectly horizontal; - Check the fluid level through the corresponding sight glass. A certain lowering of the level is caused by wear on the brake pads.
Top-up
Proceed as follows: - Undo the two screws and remove the cover with the seal. - Top-up using only the fluid specified, without exceeding the maximum level.
CAUTION ONLY USE DOT 4-CLASSIFIED BRAKE FLUID. CAUTION
AVOID CONTACT OF THE BRAKE FLUID WITH YOUR EYES, SKIN, AND CLOTHING. IN CASE OF ACCIDENTAL CONTACT, WASH WITH WATER. CAUTION BRAKING CIRCUIT FLUID IS HIGHLY CORROSIVE; MAKE SURE THAT IT DOES NOT COME INTO CONTACT WITH THE PAINTWORK. CAUTION BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUNDING AIR. IF THE CONTENT OF MOISTURE IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, BRAKING WILL BE INEFFICIENT. NEVER USE BRAKE FLUID FROM OPEN OR PARTIALLY USED CONTAINERS. UNDER NORMAL CLIMATIC CONDITIONS, THE FLUID MUST BE CHANGED EVERY 20,000 KM OR ANYWAY EVERY TWO YEARS. N.B. SEE THE BRAKING SYSTEM CHAPTER WITH REGARD TO THE CHANGING OF BRAKE FLUID AND THE BLEEDING OF AIR FROM THE CIRCUITS.
Recommended products
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
MAIN - 38
Maintenance
Headlight adjustment
Proceed as follows: 1. Place the vehicle in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10 m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the vehicle is perpendicular to the screen; 2. Turn on the headlight and check that the borderline of the projected light beam on the screen is no higher than 9/10 or lower than 7/10 of the distance from the ground to the centre of the vehicle's headlamp; 3. Otherwise, adjust the headlight by turning the knobs of the body inside the wheel housing. - Tighten the screw (clockwise) to raise the light beam; - undo the screw (anticlockwise) to lower the light beam.
N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EUROPEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.
CO check
- Remove the inspection cover of the SAS valve, by undoing the three indicated screws. - Remove the clamp and the secondary air valve as shown in the photograph. - Connect the exhaust fumes outlet tube with the secondary air tube rubber sleeve. This connection should guarantee the system tightness to avoid distorting the CO value reading
N.B. IN CASE OF 1000 PPM UNBURNED HYDROCARBONS (HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYSTEM, THE VALVE CLEARANCE AND THE EXHAUST VALVE TIGHTNESS. N.B.
MAIN - 39
Maintenance
IN CASE OF UNSTABLE CO, CHECK THAT THE CARBURETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYSTEM AND THE DEPRESSION SEALS WORK ADEQUATELY N.B. OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN THE TANK AND THE FUEL CIRCUIT. N.B. ALSO CHECK THE CARBURETION ADJUSTMENT IS OBTAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS. N.B. CHECK THAT THE RESULT IS OBTAINED WITH THE VALVE GAS IN CLOSED POSITION.
Specific tooling
020332Y Digital rpm indicator
Characteristic
CO Check 3.80.7 to 165050 RPM
- Remove the 4 flywheel cover screws indicated in the photograph and remove the flywheel cover.
MAIN - 40
Maintenance
- Remove the filter indicated in the photograph. - Check the condition of the fan cover gasket and its correct positioning. - Check the SAS filter housing for dents or deformations - Clean the SAS filter carefully. Replace the filter if it is damaged or deformed. To refit, carry out the removal operations but in reverse order.
CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE CHART. CAUTION NEVER RUN THE ENGINE WITHOUT THE SECONDARY AIR FILTER
MAIN - 41
INDEX OF TOPICS
TROUBLESHOOTING
TROUBL
Troubleshooting
Fuel nozzles or cock clogged or dirty Dirty or faulty vacuum-operated cock Failing automatic starter on the carburettor Excessive drive belt wear Lack of compression: parts, cylinder and valves worn Oil level exceeds maximum Excess of scales in the combustion chamber Incorrect timing or worn timing system elements Silencer obstructed Inefficient automatic transmission
Wrong valve adjustment Overheated valves Valve seat distorted Worn cylinder, Worn or broken piston rings
Starting difficulties
START-UP PROBLEMS
Possible Cause Flat battery Operation Check the state of the battery. If it shows signs of sulphation replace it and bring the new battery into service charging it for eight hours at a current of 1/10 of the capacity of the battery itself Replace the spark plug or check the ignition circuit components Try starting-up with the throttle fully open. If the engine fails to start, remove the spark plug, dry it and before refitting, make the motor turn so as to expel the fuel excess taking care to connect the cap to the spark plug, and this in turn to the ground. If the fuel tank is empty, refuel and start up. Inspect the head and/or restore the correct clearance Check starter motor Drain off the fuel no longer up to standard; then, refill Check that fuel is adequately supplied through the pipe by applying a vacuum to the vacuum pipe
Incorrect valve sealing or valve adjustment Rpm too low at start-up or engine and start-up system damaged Altered fuel characteristics Vacuum operated cock failure
TROUBL - 43
Troubleshooting
Possible Cause Failing automatic starter on the carburettor Start-up enabling buttons failure Carburettor nozzles clogged or dirty Air filter blocked or dirty.
Operation Check the electrical wiring and mechanical movement, replace if necessary. Check continuity using an Ohm meter, with the switch pressed; replace if necessary Dismantle, wash with solvent and dry with compressed air Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (AGIP Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.
TROUBL - 44
Troubleshooting
Insufficient braking
INEFFICIENT OR NOISY BRAKING
Possible Cause Worn brake pads or shoes Front brake disk loose or deformed Operation Replace the brake pads or shoes and check for brake disk or drum wear conditions. Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Carefully bleed the hydraulic braking system, (there must be no flexible movement of the brake lever). Failing elastic fittings, plunger or brake pump seals, replace Adjust the clearance with the appropriate adjuster located on the back part of the crankcase.
Air bubbles inside the hydraulic braking system Fluid leakage in hydraulic braking system Excessive clearance in the rear brake control cable
Brakes overheating
BRAKE OVERHEAT
Possible Cause Rubber gaskets swollen or stuck Compensation holes on the pump clogged Brake disc slack or distorted Operation Replace gaskets. Clean carefully and blast with compressed air Check the brake disc screws are locked; use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc. Check calliper and replace any damaged part.
TROUBL - 45
Troubleshooting
TROUBL - 46
Troubleshooting
Noisy suspension
NOISY SUSPENSION
Possible Cause NOISY SUSPENSION Operation If the front suspension is noisy, check: that the front shock absorber works properly and the ball bearings are good condition. Finally, check the locking torque of the wheel axle nut, the brake calliper and the disc. Check that the swinging arm connecting the engine to the chassis and the rear shock absorber work properly.
TROUBL - 47
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
Key: 1. Multiple connectors 2. Horn 3. Horn button 4. Fuel level transmitter 5. Diagnostic socket 6. Oil level warning light 7. Instrument panel lighting bulbs 8. High beam warning light 9. Turn indicator warning light 10. Fuel level instrument 11. Instrument panel 12. NTC temperature sensor 13. Low fuel warning light 14. Light switch 15. Key switch 16. Turn indicator switch 17. Starter button 18. Front stop switch 19. Rear stop switch ELE SYS - 49
Electrical system
20. Rear left turn indicator 21. Rear light 22. License plate light 23. Rear right turn indicator 24. Start-up relay 25. Starter motor 26. Battery 27. Main fuse 28. Auxiliary fuses 29. Coil 30. Spark plug 31. Throttle sensor 32. CDI control unit 33. Automatic starter 34. Carburettor PTC heater 35. Regulator 36. Oil pressure sensor 37. Pick-up 38. Generator 39. Front right turn indicator 40. High beam light 41. Front position light 42. Low beam light 43. Front left turn indicator 44. Front headlamp 45. Ground point on chassis Colours of the electrical cables: B = White Bl = Blue G = Yellow Mr = Brown N = Black BV = White-Green GN = Yellow-Black Gr = Grey Rs = Pink R = Red Vi = Violet ELE SYS - 50
Electrical system
V = Green VN = Green-Black BN = Black-White BBl = White-Blue GV = Yellow-Green Ar = Orange Az = Sky blue GrBl = Grey-Blue GrN = Grey-Black RBl = Red-Blue GR =Yellow-Red BlN = Blue-Black
ELE SYS - 51
Electrical system
Components arrangement
ELE SYS - 52
Electrical system
1. Air temperature sensor - Remove the leg shield, as described in the BODYWORK chapter to reach it.
2. Voltage regulator - 3. Coil - Remove the rear central cover to reach it.
4. Battery - 5. Main fuse - Lift the saddle and remove the cover to reach it.
ELE SYS - 53
Electrical system
9. Ignition switch - Remove the leg shield back plate to reach it.
10. Fuel level transmitter - 11. Diagnosis connector - Remove the battery inspection cover to reach them.
ELE SYS - 54
Electrical system
12. Oil pressure sensor - 13. Engine speed sensor - Remove the fan cover cap to reach them, as described in the ENGINE chapter.
15. CDI control unit - Remove the leg shield to reach it.
16. Right brake switch - 17. Left brake switch Remove the front handlebar cover to reach them.
ELE SYS - 55
Electrical system
18. Automatic starter - 19. PTC heater - 20. Throttle position sensor - Remove the helmet compartment to reach them.
21. Horn button - 22. Light switch - 23. Turn indicator switch - They are fixed inside the rear handlebar cover, on the left-hand side.
24. Engine starter button - It is fixed inside the rear handlebar cover, on the right-hand side.
ELE SYS - 56
Electrical system
Ground points
- On the vehicle there is a chassis ground point, beneath the rear central cover.
ELE SYS - 57
Electrical system
1. Upper branch of the main cable harness 2. Front brake stop switch cable 3. Engine starter button cable 4. Front left turn indicator cable 5. Front right turn indicator cable 6. Rear brake stop switch cable 7. Instrument panel connectors 8. Light switch connector
9. Central branch of the main cable harness 10. Air temperature sensor connector 11. Ignition switch connector 12. Front light cable 13. Secondary fuse cable 14. CDI control unit cable
ELE SYS - 58
Electrical system
15. Horn cable 16. Transverse branch of the main cable harness
Back side
Electrical system
18. Regulator cable - chassis ground 19. Coil cable 20. Spark plug cable 21. Branch of devices on engine 22. Rear branch of the main cable harness
23. Start-up solenoid cable 24. Rear lights and fuel level transmitter connecting branch 25. Battery positive and main fuse connecting cable 26. Battery negative connecting cable 27. Diagnosis connector cable 28. Fuel level transmitter cable
ELE SYS - 60
Electrical system
29. Battery positive lead 30. Main fuse connecting cable 31. Battery negative lead 32. Diagnosis connector 33. Rear right turn indicator cable 34. Rear left turn indicator cable 35. Rear light cable 36. License plate lamp cable
37. Ground cable on engine 38. Starter motor positive wire 39. Connector for stator, pick-up and oil pressure sensor 40. Branch connecting devices on carburettor 41. Automatic starter connector ELE SYS - 61
Electrical system
42. PTC resistor connector 43. Throttle position potentiometer connecting cable
Key: 1. Multiple connectors 5. Diagnostic socket 15. Key switch 26. Battery 27. Main fuse 28. Auxiliary fuses 29. Coil 30. Spark plug 31. Throttle sensor 32. CDI control unit 37. Pick-up
ELE SYS - 62
Electrical system
Key: 1. Multiple connectors 15. Key switch 17. Starter button 18. Front stop switch 19. Rear stop switch 21. Rear light 24. Start-up relay 25. Starter motor 26. Battery 27. Main fuse 28. Auxiliary fuses 35. Regulator 38. Generator 45. Ground point on chassis
ELE SYS - 63
Electrical system
Key: 1. Multiple connectors 4. Fuel level transmitter 6. Oil level warning light 10. Fuel level instrument 11. Instrument panel 12. NTC temperature sensor 13. Low fuel warning light 15. Key switch 26. Battery 27. Main fuse 28. Auxiliary fuses 32. CDI control unit 36. Oil pressure sensor 45. Ground point on chassis
ELE SYS - 64
Electrical system
Instrument panel bulb, indicator warning lights, oil pressure and high beams Front turn indicator light bulb
ELE SYS - 65
Electrical system
Key: 1. Multiple connectors 2. Horn 3. Horn button 15. Key switch 26. Battery 27. Main fuse 28. Auxiliary fuses 32. CDI control unit 33. Automatic starter 34. Carburettor PTC heater 45. Ground point on chassis
ELE SYS - 66
Electrical system
Key: 1. Multiple connectors 7. Instrument panel lighting bulbs 8. High beam warning light 9. Turn indicator warning light 11. Instrument panel 14. Light switch 15. Key switch 16. Turn indicator switch 18. Front stop switch 19. Rear stop switch 20. Rear left turn indicator 21. Rear light 22. License plate light 23. Rear right turn indicator 26. Battery 27. Main fuse 28. Auxiliary fuses
ELE SYS - 67
Electrical system
32. CDI control unit 39. Front right turn indicator 40. High beam light 41. Front position light 42. Low beam light 43. Front left turn indicator 44. Front headlamp
No spark plug
Once the lack of power to the spark plug has been detected and the LED indicates it can be ignited, follow this procedure: - Check the Pick-Up. The check includes the Pick-Up and its power line. Disconnect the control unit connector and measure the resistance between terminal No. 10 (Blue/ Yellow) and terminal No. 12 (Blue). If the value measured is incorrect, repeat the check directly on the component. Disconnect the pick-up connector on the engine and measure the resistance between the pin corresponding to the
ELE SYS - 68
Electrical system
Blue-Yellow cable of the wiring and the ground connection on the engine. If correct values are detected, check that the cable is not interrupted.
Electric characteristic
Pick-up resistance value ~ 130 Ohm - HV primary coil check Disconnect the control unit connector and check that the cable between terminal No. 4 (White/Violet) and terminal No. 12 (Blue) is not interrupted (see figure). If non-conforming values are measured, check again the HV coil primary directly on the positive and negative terminals. If the values are correct, repair the cable harness or reset the connections; otherwise, replace the HV coil
Electric characteristic
High voltage coil primary resistance value High voltage coil primary resistance value: ~ 0.5 Ohm - HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.
Specific tooling
020409Y Multimeter adaptor - Peak voltage detection
Electric characteristic
High voltage coil secondary resistance value High voltage coil secondary resistance value: ~ 3000 300 Ohm
ELE SYS - 69
Electrical system
- H.V. coil With the control unit and HV coil connected to the circuit, measure the voltage of the coil primary during the start-up test with the voltage peak adaptor and connect the positive terminal to the ground one and the negative to the coil positive connector. If non-conforming values are measured, replace the control unit.
THE POSITIVE TERMINAL OF THE HV COIL PRIMARY IS BLACK.
Electric characteristic
High voltage coil voltage value High voltage coil voltage value: > 100 Volt
Specific tooling
020334Y Multiple battery charger
Switches check
To check buttons and switches, check that, according to their position, the continuity of contacts is correct as indicated in the following charts. KEY Or: Orange SB: Sky Blue Wh: White Bl: Blue Y: Yellow Gr: Grey Br: Brown B: Black Pi: Pink R: Red Gre: Green Pr: Purple
ELE SYS - 70
Electrical system
STARTER BUTTON
LIGHT SWITCH
HORN BUTTON
ELE SYS - 71
Electrical system
Stator check
Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.
Electric characteristic
Ohm value: 1 1 Ohm
Also check that all yellow cables are insulated from the ground connection. If non-conforming values are detected, repeat the checks directly to the stator. In case of further repetitions of incorrect values replace the stator or repair the wiring.
ELE SYS - 72
Electrical system
Characteristic
Distributed current 13A at 6000 rpm
Starter motor
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If it does not work: - Check the continuity of the Green/Red cable between the 7.5A fuse (B) and stop buttons. - Check the continuity between the starter button Green/Red cable and the stop button Green/Yellow cables. - Check continuity between the Yellow/Red cable between the starter button and the start-up solenoid. - Check that the Red cable between the battery and the start-up solenoid, and the latter and the starter motor are not interrupted. - Check the start-up solenoid. - Check the contacts of the ignition switch, the starter button and the stop buttons. - Check the efficiency of the fuses. - Check that the starter motor is grounded. - If all the tests are positive, replace the starter motor.
ELE SYS - 73
Electrical system
Horn control
KEY 1. Battery 2. Main fuse (A) 20A 3. Ignition switch contacts 4. Secondary fuse (C) 15A 5. Horn button 6. Horn
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. If the horn does not work: - Check the efficiency of the fuses. - Check the ignition switch and the horn button contacts. - If the components are not damaged, check wiring for continuity. - Check the continuity of the Green cable which connects the horn button to 15A fuse (C). - Check the continuity of the Grey cable which connects the switch to the horn. - If all the tests are positive, replace the horn.
ELE SYS - 74
Electrical system
Choke Inspection
Refer to the engine section to check the resistance and operating conditions of the component. As regards voltage supply, keep the connector connected to the system and check that the two terminals receive battery voltage when the engine is on (see figure). If no voltage is detected, connect the multimeter negative probe to the ground lead and the positive probe to the automatic starter Yellow cable; with the ignition switch set to "ON" check whether there is battery voltage; if there is no voltage, check the wiring connections to the ignition switch. If there is voltage, check again the ignition control unit connector. After disconnecting the starter, start up the engine and keep it at idle speed and check there is voltage when the multimeter positive terminal is connected to terminal No. 9 (Green/Red) and the negative one to terminal No. 11 (Green/Black). Replace the control unit if there is no voltage; otherwise, check the wiring connections between the starter and the control unit.
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED. Check that bulb operates properly. Check continuity of the Blue-Black cable between the CDI control unit and the turn indicators switch. Check that the turn indicator switch works properly. Check continuity of the Red and Blue cables which connect the switch to the bulbs.
level indicators
WARNING
ALL CONTINUITY TESTS MUST BE CARRIED OUT WITH THE CORRESPONDING CONNECTORS DISCONNECTED.
ELE SYS - 75
Electrical system
If faults are detected: - With a multimeter, check resistance values between the Grey-Green cable and the Blue cable of the fuel level transmitter by moving the arm with the float. - If the transmitter operates correctly but the indication on the instrument panel is not exact, check that the cable harnesses between them are not interrupted. - Check continuity of the Green cable which connects the instrument panel to the 15A secondary fuse (C). - Check continuity of the Grey/Green cable which connects the instrument panel to the probe checking fuel level.
Electric characteristic
Resistance value when the tank is full ~ 7.4 Resistance value when the tank is empty ~ 101
Fuses
The electrical system is protected by a main fuse (A) connected on the left-hand side of the helmet compartment next to the battery. For access it is necessary to remove the battery cover and the transparent protection over the fuse block. Starter circuit, light circuit, horn and instrument panel are protected by two secondary fuses (B) and (C) located inside the glove-box.
CAUTION BEFORE REPLACING THE BLOWN FUSE, SEARCH AND SOLVE THE PROBLEM THAT CAUSED IT TO BLOW. NEVER TRY TO REPLACE A BLOWN FUSE WITH A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED OR USING OTHER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE).
ELE SYS - 76
Electrical system
FUSE CHART
1 Specification FUSE A Desc./Quantity Capacity:20A Protected circuits: Recharge circuit, oil pressure sensor, oil pressure warning light. Capacity:7.5 A Protected circuits: Start-up circuit, starter motor, stop light bulb, ECU power supply. Capacity:15A Protected circuits: Rear light bulb, license plate light bulb, turn indicator bulb, turn indicator warning light, fuel gauge, instrument panel lighting bulb, horn, low beam bulb, high beam bulb, high beam warning light.
Fuse B
Fuse C
Sealed battery
Commissioning sealed batteries INSTRUCTIONS FOR REFRESHING THE STOCK CHARGE OF AN OPEN CIRCUIT 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a standard tester. - If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge. - If voltage is below 12.60 V, a renewal recharge is required as explained in 2). 2) Constant voltage battery charge mode -Constant voltage equal to 14.4014.70V -Initial charge voltage equal to 0.30.5 for nominal capacity -Duration of the charge: 10 to 12 h recommended Minimum 6 h ELE SYS - 77
Electrical system
Maximum 24 h 3) Constant current battery charge mode -Charge current equal to 1/10 of the nominal capacity of the battery -Duration of the charge: 5 h
WARNING
-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Battery installation
VRLA battery (valve-regulated lead-acid battery) Maintenance Free (MF)
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN 1) Battery preparation Position the battery on a flat surface. Remove the adhesive sheet closing cells and proceed as quickly as possible to run the subsequent activation phases.
2) Electrolyte preparation. Remove the container of the electrolyte from the pack. Remove and preserve cover strips from the container, in fact, the strip will later be used as a closing cover. Note: Do not pierce the sealing of the container or the container itself because inside there is sulfuric acid.
ELE SYS - 78
Electrical system
3) Procedure for filling the battery with acid. Position the electrolyte container upside down with the six areas sealed in line with the six battery filler holes. Push the container down with enough force to break the seals. The electrolyte should start to flow inside the battery. Note: Do not tilt the container to prevent the flow of electrolyte from pausing or stopping. 4) Control the flow of electrolyte Make sure air bubbles are rising from all six filling holes. Leave the container in this position for 20 minutes or more. Note:If there are no air bubbles coming out of the filling holes, lightly tap the bottom of the container two or three times. Do not remove the container from the battery. 5) Take out the container. Make sure all the electrolyte in the battery is drained. Gently tap the bottom of the container if electrolyte remains in the container. Now, gently pull the container out from the battery, only do this when the container is completely empty, and proceed immediately to the next point. 6) Battery closing. Insert the airtight cover strips into the filling holes. Press horizontally with both hands and make sure that the strip is levelled with the top part of the battery. Note:To do this, do not use sharp objects that could damage the closing strip, use gloves to protect your hands and do not bring your face close to the battery. The filling process is now complete. Do not remove the strip of caps under any circumstances, do not add water or electrolyte. Place the battery down for 1 to 2 hours prior to the charging from the battery. 7) Recharging the new battery With the above-mentioned procedure, the battery will have gained around 70% - 75% of its total electrical capacity. Before installing the battery on the vehicle, it must be fully charged and then must be recharged. If the battery is to be installed on the vehicle prior to this pre-charged one, the battery will not be able to exceed 75% charge without jeopardising its useful life on vehicle. The dry charge battery MF like the completely loaded YTX, must have a no-load voltage between
ELE SYS - 79
Electrical system
12.8 - 13.15 V Bring the battery to full charge, using the 020648Y battery charger: a - select the type of battery with the red switch on the left of the panel battery charger panel b - select NEW on the yellow timer c - connect the clamps of the battery charger to the battery poles (black clamp to negative pole (-) and red clamp to positive pole (+)).
e - Press the "MF" black button to activate the battery recharge Maintenance Free as shown in figure.
f - Check the ignition of the green LED indicated with a red arrow in figure.
ELE SYS - 80
Electrical system
g - The activation cycle of the new battery lasts for 30 minutes after the ignition of the recharge LED has taken place
h - Disconnect the clamps from the battery and check the voltage, if voltages are detected of less than 12.8 V, proceed with a new recharge of the battery starting from point c of the recharge procedure of the new battery, otherwise go to point i
i - The battery is now completely activated, disconnect the battery charger from the fuel supply grid, disconnect the clamps from the battery and proceed to fitting the battery on the vehicle.
ELE SYS - 81
INDEX OF TOPICS
ENG VE
- Undo the 2 screws fixing the silencer to the housing; then remove the whole muffler paying attention to the interference between its supporting bracket and the cooling cover.
ENG VE - 83
- Loosen the throttle control cables by acting on the carburettor set screws and slide them off the pulley.
See also
Exhaust assy. Removal - Remove the fuel supply pipe from the carburettor
- Remove the fuel valve low-pressure pipe from the manifold as shown in the photograph
- Remove the flywheel wiring connector, the ground terminal and the starter motor positive cable indicated in the figure
ENG VE - 84
- Remove the clamp retaining the starter wiring and the heater indicated in the figure
- Keep the engine-swinging arm pin nut blocked on the left-hand side of the vehicle and undo the pin from the opposite side.
ENG VE - 85
- Adequately support the vehicle (i.e. with a jack) and remove the engine-swinging arm pin and the shock absorber lower mount. The engine is now free.
ENG VE - 86
INDEX OF TOPICS
ENGINE
ENG
Engine
This section describes the operations to be carried out on the engine and the tools to be used.
Specific tooling
020423Y Driven pulley lock wrench
Air duct
- Unscrew the Torx screws fixing the air duct bulkhead and remove the bulkhead. - Remove the 3 screws, then take out the duct as well as the filter.
ENG - 88
Engine
Specific tooling
020376Y Adaptor handle 020375Y 28 x 30 mm adaptor
ENG - 89
Engine
Specific tooling
020151Y Air heater 020376Y Adaptor handle 020357Y 32x35-mm Adaptor 020412Y 15-mm guide
Characteristic
Max. value clutch bell Max. value: 134.5 mm Clutch bell standard value Standard value: 134 - 134.2 mm
ENG - 90
Engine
Checking the bell working surface eccentricity - Install the bell on a driven pulley shaft using 2 bearings (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft unit on the support to check the crankshaft alignment.
- Using a feeler dial gauge and the magnetic base, measure the bell eccentricity. - Repeat the measurement in 3 positions (Central, internal, external). - If faults are found, replace the bell.
Specific tooling
020074Y Support base for checking crankshaft alignment 020335Y Magnetic mounting for dial gauge
Characteristic
clutch bell inspection: Limit eccentricity. Admissible limit eccentricity: 0.15 mm
ENG - 91
Engine
- Fit the driven pulley unit in the tool so as the bolt get into the masses clutch support holes. Afterwards make the support screw make contact with a minimum force. - Using the specific wrench, inserted 46 mm from the side, remove the clutch central locking nut.
- Separate the driven pulley into its components (clutch with fan and contrast spring with plastic fittings).
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE VICE AND THE CENTRAL SCREW MUST NOT BE TIGHTENED WITH EXCESSIVE TORQUE AS THIS MAY DAMAGE THE PULLEY OR DEFORM THE SPECIFIC TOOL.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55
Characteristic
Check minimum thickness 1 mm
ENG - 92
Engine
Specific tooling
020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020439Y 17-mm guide
ENG - 93
Engine
Characteristic
Minimum diameter permitted 40.96 mm Standard diameter 40.965 mm
Characteristic
Minimum admissible diameter: 41.08 mm Standard diameter 41.035 mm
Specific tooling
020424Y Driven pulley roller casing fitting punch
ENG - 94
Engine
- To assemble the new ball bearing insert it completely down in its housing with the specific punch and finally assemble the Seeger ring.
Specific tooling
020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020439Y 17-mm guide
Specific tooling
020263Y Driven pulley assembly sheath
Recommended products
MONTBLANC MOLYBDENUM GREASE Grease with molybdenum disulphide
ENG - 95
Engine
Characteristic
Standard length: 106 mm Acceptable limit after use 102.5 mm (4.035 in)
Characteristic
Minimum thickness permitted: 1 mm - Support the driven pulley spring compressor specific tool with the control screw in vertical axis. - Arrange the tool with the medium length pins screwed in position "C" on the inside. - Introduce the adapter ring No. 11 with the chamfering facing upwards. - Insert the clutch on the adapter ring. - Lubricate the end of the spring that abuts against the torque server closing collar. - Insert the spring with its plastic holder in contact with the clutch. - Insert the drive belt into the pulley unit according to their direction of rotation.
ENG - 96
Engine
- Insert the pulley unit with the belt into the tool. - Slightly preload the spring. - Make sure that the clutch is perfectly inserted into the adapter ring before proceeding to tighten the clutch nut. - Place the tool in the clamp with the control screw on the horizontal axis. - Fully preload the spring. - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt according to its direction of rotation. - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool.
N.B. DURING THE SPRING PRELOADING PHASE, BE CAREFUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING. N.B. FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYMMETRIC; THE FLATTEST SURFACE SHOULD BE MOUNTED IN CONTACT WITH THE CLUTCH.
Specific tooling
020444Y Tool for fitting/ removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 wrench 46 x 55
ENG - 97
Engine
Drive-belt
- Make sure the drive belt is not damaged and does not show abnormal wear. - Replace as indicated in the scheduled maintenance table.
Specific tooling
020368Y driving pulley lock wrench - Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling free assembled rollers. - Remove the return rollers plate with the relative guide sliders.
Engine
CVT ROLLERS
Specification Minimum diameter permitted Standard diameter Desc./Quantity 18.5 mm 260.1 mm
- Check the guide shoes for the variator back-plate are not worn. - Check there is no wear in the roller housing, and the surfaces in contact with the belt on either of the pulley halves.
- Pre-assemble the movable half-pulley with the roller contrast plate by placing the rollers as shown in the figure, that is, during insertion, the closed side should be on the left side of the pulley thrust. - Mount the complete bushing unit on the crankshaft.
ENG - 99
Engine
Specific tooling
020368Y driving pulley lock wrench
Recommended products
Loctite 243 Medium strength threadlock Medium Loctite 243 threadlock
ENG - 100
Engine
Specific tooling
020423Y Driven pulley lock wrench
ENG - 101
Engine
Specific tooling
001467Y009 Driver for OD 42-mm bearings 001467Y013 Calliper to extract 15-mm bearings
Specific tooling
020376Y Adaptor handle 020364Y 25-mm guide With the appropriate tools, remove the oil seal as shown in the figure.
Specific tooling
020376Y Adaptor handle 020359Y 42x47-mm Adaptor
Engine
With the sectional punch, remove the driven pulley shaft bearing.
Specific tooling
020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20-mm guide
See also
Removing the driven pulley
Specific tooling
020150Y Air heater mounting 020151Y Air heater - Reassemble the driven pulley axle bearing positioning it with ball bearing in view from the inside of the hub cover using the adequate tools
Specific tooling
020376Y Adaptor handle
ENG - 103
Engine
- Refit the Seeger ring with the opening facing the bearing as shown in the figure and fit a new oil seal flush with the crankcase.
Specific tooling
020151Y Air heater 020150Y Air heater mounting -The wheel axle bearing on the cover, should be assembled with the specific tools
Specific tooling
020364Y 25-mm guide 020360Y 52x55-mm Adaptor 020376Y Adaptor handle Assemble the Seeger ring. Assemble the oil seal flush with the internal surface as shown in the figure to the hub using the adequate tools and with the seal lip towards the inside of the hub.
Specific tooling
020376Y Adaptor handle 020360Y 52x55-mm Adaptor
Specific tooling
020150Y Air heater mounting 020151Y Air heater ENG - 104
Engine
ENG - 105
Engine
- Loosen the clamp and remove the carburettor from the manifold. -Remove the complete manifold acting on the 2 retainers as shown in the figure.
- Slide the access flap to the spark plug. - Remove the two self threading screws, left and right and the lateral left fixing screw on the crankcase base. - Take off the two caps from the thermal group. - Remove the gasket seal of the housing on the head.
ENG - 106
Engine
Cooling fan
- Remove the fan cover cap. - Remove the cooling fan by acting on the three fixings indicated in the figure.
ENG - 107
Engine
Specific tooling
020565Y Flywheel lock calliper spanner
Specific tooling
008564Y Flywheel extractor
ENG - 108
Engine
ENG - 109
Engine
- Remove the central screw fastener and the automatic valve lifter retaining cover, as shown in the figure. - Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer.
- Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket.
- Remove the inner hexagonal screw and the counterweight - Remove the camshaft control pulley with its washer. ENG - 110
Engine
- Remove the command sprocket wheel and the timing chain. - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. The tensioner pad must be removed from the transmission side. As regards the lower chain guide slider, it may only be removed after the head has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
See also
Transmission cover Removing the driving pulley Removal
- Remove the pin of the rocking levers from the flywheel side holes. - Remove the rocking levers and the elastic washer.
N.B. MARK THE ROCKERS ASSEMBLE POSITION, SO AS TO AVOID THE INVERSION OF INTAKE WITH THE EXHAUST.
ENG - 111
Engine
Specific tooling
020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool
- Remove the oil seals with the appropriate tool. - Remove the lower spring supports.
Specific tooling
020431Y Valve oil seal extractor
ENG - 112
Engine
- Remove the two retainer rings, the wrist pin and the piston. - Remove the 3 piston rings from the piston.
N.B. BE CAREFUL NOT TO DAMAGE THE PISTON RINGS DURING REMOVAL.
Characteristic
Connecting rod small end check-up: Maximum diameter 15.030 mm Connecting rod small end check-up: Standard diameter 15+0.015+0.025 mm
ENG - 113
Engine
Characteristic
Standard pin diameter 14.996 to 15 mm Minimum diameter permitted 14.994 mm
Characteristic
Piston pin bore - standard diameter 15+0.001 +0.006
- Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis. - Measure 36.5 mm from the piston crown's shown in the figure.
N.B. THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS. FOR THIS REASON MEASUREMENT OF THE DIAMETER MUST BE CARRIED OUT ACCORDING TO THE AXIS OF THE PISTON.
- Using a bore meter, measure the inner cylinder diameter at three different points according to the directions shown in the figure. - Check that the coupling surface with the head is not worn or misshapen. - Pistons and cylinders are classified into categories based on their diameter. The coupling is carried out in pairs (A-A, B-B, C-C, D-D).
Characteristic
Maximum allowable run-out: 0.05 mm
ENG - 114
Engine
- The cylinder rectifying operation should be carried out with a surfacing that respects the original angle. - The cylinder surface roughness should be 0.9 micron. - This is indispensable for a good seating of the sealing rings, which in turn minimises oil consumption and guarantees optimum performance. - The pistons are oversized due to cylinder rectification and are subdivided into three categories 1st, 2nd, 3rd with 0.2-0.4-0.6 mm oversize. They are also classified into 4 categories A-A, B-B, CC, D-D.
ENG - 115
Engine
Specific tooling
020430Y Pin lock fitting tool
- With the opening in position indicated on the tool, take retainer ring in the closed position using the punch. - Fit the wrist pin retainer ring using the plug as shown in the figure
N.B. THE TOOL FOR INSTALLING THE RETAINER RINGS MUST BE USED MANUALLY. CAUTION USING A HAMMER TO POSITION THE RINGS CAN DAMAGE THE LOCKING HOUSING.
ENG - 116
Engine
Specific tooling
020426Y Piston fitting fork ENG - 117
Engine
Characteristic
Maximum admitted unevenness: Cylinder head check 0.05 mm
STANDARD DIAMETER
Specification Standard diameter Standard diameter Standard diameter Desc./Quantity A 32.5 to 32.525 B 20 to 20.021 C 12 to 12.018
ENG - 118
Engine
- Remove the central screw and the tensioner spring. Check that the one-way mechanism is not worn. - Check the condition of the tensioner spring. - If examples of wear are found, replace the whole unit.
Characteristic
Standard drainage guide diameter 5.012 mm Standard intake guide diameter 5.012 mm
ENG - 119
Engine
- If the width of the impression on the valve seat or the diameter of the valve guide exceed the specified limits, replace the cylinder head. - Check width of the impression on the valve seat V
Characteristic
Wear limits: Max. 1.6 mm.
Characteristic
Minimum diameter admitted - Intake: 4.96 mm Minimum diameter admitted - Exhaust: 4.95 mm Standard clearance - Intake: 0.013 to 0.040 mm Standard clearance - Exhaust: 0.025 to 0.052 mm Maximum clearance admitted- Intake: 0.062 mm Maximum clearance admitted - Exhaust: 0.072 mm - Check that there are no signs of wear on the contact surface with the articulated register terminal. - If the sealing surface on the valves is wider than the specified limit, damaged in one or more points or curved, replace the valve with a new one.
Characteristic
Standard valve length - Intake: 80.6 mm Valve standard length: Exhaust ENG - 120
Engine
79.6 mm - If no faults are found during the above checks, you can use the same valves. For best sealing results, it is advisable to grind the valves. Grind the valves gently with a fine-grained lapping compound. During grinding, keep the cylinder head in a horizontal position. This will prevent the lapping compound residues from penetrating between the valve stem/guide coupling.
CAUTION TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
- Insert the valves into the cylinder head. - Test the 2 valves alternatively. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
Characteristic
Valve spring length 33.9 to 34.4 mm
ENG - 121
Engine
Specific tooling
020306Y Punch for assembling valve seal rings - Fit the valves, the springs and the spring retaining caps. Using the appropriate tool with adapter 11, compress the springs and insert the cotters in their seats.
Specific tooling
020382Y Valve cotters equipped with part 012 removal tool 020382Y011 adapter for valve removal tool
Characteristic
Standard diameter Bearing A : 32.5 mm -0.025 -0.050 mm Standard diameter Bearing B 20 -0.020 -0.041 mm Minimum admitted diameter bearing A : 32.440 mm Minimum admitted diameter bearing B : 19.950 mm Intake cam height 27.512 mm Exhaust cam height 27.212 mm
ENG - 122
Engine
- Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft. - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
Characteristic
Maximum axial clearance admitted 0.42 mm - Check there are no signs of wear on the automatic valve lifter cam, or the end-of stroke roller, or the rubber buffer on the automatic valve-lifter retaining cover. - Check that the valve lifter spring has not yielded. - Replace any defective or worn components.
- Check there are no signs of scoring or wear on the rocking lever bolt. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. - Measure the internal diameter of each rocking lever. -Check that the elastic washer dedicated to the axle clearance of the rocking levers is not worn. In case of failure, replace the damaged components.
Characteristic
Minimum diameter permitted 11.970 mm Maximum diameter allowed 12.030 mm
Engine
-Screw the nuts and lock them in a crossed sequence and in 2 or 3 stages to the specific torque.
- Fit the timing chain sprocket wheel on the crankshaft, with the chamfer facing the insertion side. - Loop the timing chain around the sprocket on the crankshaft. - Fit the tensioner pad by the cylinder head. - Fit the spacer and the screw fastener. - Fit the pin, the exhaust rocking lever, the spring washer and the intake rocking lever. - Lubricate the 2 rocking levers through the holes at the top. - Lubricate the 2 bearings and insert the camshaft in the cylinder head with the cams opposing the rocking levers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed torque.
ENG - 124
Engine
- Refit the spacer on the cam shaft. - Rotate the engine so that the piston is at top dead centre, using the reference marks on the flywheel and the crankcase. - While doing so, fit the chain onto the control camshaft pulley and keep the reference 2V in correspondence with the reference mark on the head. - Fit the pulley onto the camshaft. - Assemble the counterweight with the corresponding fixing screw and tighten to the specified torque.
-Fit the end-stop ring on the automatic valve lifter cam and fit the automatic valve lifter cam to the cam shaft. - Fit the automatic valve lifter return spring. - During this operation the spring must be loaded approximately 180.
N.B. GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE ENGINE.
- Fit the automatic valve-lifter retaining dish, using the counterweight screw fastener as a reference. - Tighten the clamping screw to the prescribed torque.
- Set the tensioner cursor in the rest position. - Fit the chain tensioner on the cylinder, using a new gasket, and tight the two screws to the prescribed torque. ENG - 125
Engine
Electric characteristic
Recommended spark plug NGK CR7EB Electrode gap 0.6 0.7 mm
ENG - 126
Engine
- Refit the cylinder head cover, tightening the 4 clamping screws to the prescribed torque. - Refit the fan and the housing. - Reassemble the oil pump control, the chain compartment cover, the by-pass and the oil sump as described in the lubrication chapter. - Reassemble the driving pulley, the belt and the transmission cover as described in the transmission chapter.
Crankcase - crankshaft
- Precautionary remove the following units: transmission cover, driving pulley, driven pulley and belt, rear hub cover, gears, bearings and oil seals as described in the transmission chapter. - Remove the oil sump, the by-pass, the chain compartment cover and the oil pump as in the lubrication chapter. - Remove the flywheel cover, the fan, the flywheel and the stator as described in the magneto flywheel chapter. - Remove the oil filter and the oil pressure bulb. - Remove the cylinder-piston-head unit as described in the cylinder head timing system chapter. - Remove the 2 retainers indicated in the figure and the starter motor. - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with specific tool dial gauge.
Specific tooling
020262Y Crankcase splitting plate 020335Y Magnetic mounting for dial gauge
Characteristic
Standard clearance ENG - 127
Engine
0.15 to 0.40 mm
- Remove the coupling gasket of the crankcase halves. - Remove the two screws and the internal shield shown in the diagram.
CAUTION WHILE OPENING THE CRANKCASES AND REMOVING THE CRANKSHAFT, CHECK THAT THE THREADED SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSHINGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS.
- Remove the oil seal on the flywheel side. - Remove the oil filter fitting shown in the diagram
Characteristic
Standard clearance 0.20 to 0.50 mm
ENG - 128
Engine
- Check the radial clearance on the connecting rod. -Check the surfaces that limit the axial clearance are not scored and measure the width of the crankshaft between these surfaces, as shown in the diagram.
CAUTION BE CAREFUL NOT TO LET THE MEASUREMENT BE AFFECTED BY THE UNIONS WITH THE CRANKSHAFT ENDS.
Characteristic
Standard clearance 0.036 to 0.054 mm - If the axial clearance between crankshaft and crankcase is exceeding and the crankshaft does not have any defect, the problem must be due to either excessive wear or wrong machining on the crankcase.
CAUTION THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH IS WITHIN THE STANDARD VALUES AND THE SURFACES SHOW NO SIGNS OF SCORING.
Characteristic
Distance between the shoulders 55.67 to 55.85 mm - Check the diameters of both the bearings of the crankshaft in accordance with the axes and surfaces shown in the figure. The half-shafts are classified in two categories Cat. 1 and Cat. 2 as shown the chart below.
STANDARD DIAMETER
Specification Category 1 Category 2 Desc./Quantity 28.998 to 29.004 28.004 to 29.010
ENG - 129
Engine
Specific tooling
020074Y Support base for checking crankshaft alignment
Characteristic
Off-line maximum admitted A = 0.15 mm
B = 0.01 mm C = 0.01 mm D = 0.10 mm
ENG - 130
Engine
- On the flywheel side crankcase half, take particular care cleaning the oil ducts for the main bushings, the oil duct for the jet that lubricates the cylinder head and the oil drainage duct at the flywheel side oil seal.
N.B. THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. THE JET CLOGGING IMPAIRS THE HEAD LUBRICATION AND THE TIMING MECHANISMS. A JET FAILURE CAUSES A DECREASE OF THE MAIN BUSHING AND CONNECTING ROD LUBRICATION PRESSURE.
- Inspect the mating surfaces on the crankcase halves for scratches or deformation, taking particular with the surfaces that mate with the cylinder and the mating surfaces between the crankcase halves. - Defects in the crankcase coupling gasket or the surfaces indicated in the figure can cause a drop in the oil pressure and affect the lubricating pressure for the main bushings and the connecting rod.
ENG - 131
Engine
- Check the main bearing seats that limit axial clearance in the crankshaft show no signs of wear. The dimension between these seats is measured by way of the procedure described previously for measuring the crankshaft axial clearance and dimensions.
Characteristic
Standard driving depth 1.35 to 1.6 - Check the inside diameter of the main bushings in the three directions indicated in the diagram. - Repeat the measurements for the other bushing half. see diagram. - The standard bushing diameter after driving is variable on the basis of a coupling selection. ENG - 132
Engine
- The bushing housings in the crankcase are classified into 2 categories - Cat. 1 and Cat. 2 - just like those for the crankshaft. - The main bushings are subdivided into 3 thickness categories; see the table below:
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-SHELL COUPLING SURFACE SINCE THE ENDS ARE RELIEVED TO ALLOW BENDING DURING THE DRIVING OPERATION.
MAIN BEARINGS
Specification B C E Desc./Quantity Blue Yellow Green
- Fit the oil filter joint and tighten it to the prescribed torque. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, together with the alignment dowels.
ENG - 133
Engine
- Lubricate the main bushings and insert the crankshaft in the transmission side crankcase half. - Reassemble both crankcase halves. - Fit the 11 screws and tighten them to the prescribed torque.
N.B. WHEN FITTING THE HALF CASING AND THE CRANKSHAFT, TAKE CARE NO TO DAMAGE THE SHAFT THREADED TANGS.
Specific tooling
020425Y Punch for flywheel-side oil seal
Lubrication
ENG - 134
Engine
Conceptual diagrams
ENG - 135
Engine
Characteristic
Minimum pressure admitted 3.2 atm.
ENG - 136
Engine
Removal
- Remove the transmission cover and the complete drive pulley beforehand
- Install the base of the appropriate tool on the oil seal using the screws provided.
- Screw the threaded bar onto the base of the tool and extract the oil seal.
Specific tooling
020622Y Transmission-side oil seal punch
Refitting
- Prepare the new oil seal, lubricating the sealing lip. Warning: do not lubricate the surface for keying onto the engine crankcase.
CAUTION DO NOT LUBRICATE THE KEYING SURFACE ONTO THE ENGINE CRANKCASE.
ENG - 137
Engine
- Preassemble the oil seal with the appropriate tool, positioning the screws - Place the sheath over the crankshaft
- Insert the tool with the oil seal on the crankshaft until it comes into contact with the crankcase
CAUTION ORIENT THE OIL SEAL BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS. WHEN THE POSITION IS REACHED, DO NOT RETRACT THE OIL SEAL. FAILURE TO COMPLY WITH THIS RULE CAN CAUSE A WRONG POSITIONING OF THE OIL SEAL SHEATH.
- Orientate the oil seal by inserting the bracket which is part of the specific tool.
- Tighten the threaded bar onto the crankshaft as far as it will go.
ENG - 138
Engine
- Use the nut to move the base of the tool until you can see end of the oil seal driving stroke
- Remove all of the tool components following the procedure in reverse order
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCEDURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO THE WRONG TENSIONING OF THE OIL PUMP CONTROL CHAIN. Assemble a new oil seal on the flywheel side using the specific tool as shown in the photograph
N.B. FAILURE TO USE THE SPECIFIC TOOL CAN RESULT IN AN INCORRECT DEPTH POSITION AND AS A CONSEQUENCE IN INADEQUATE OIL SEAL.
Specific tooling
020425Y Punch for flywheel-side oil seal
ENG - 139
Engine
- Remove the cover of the pump control pulley using the two retainers, as shown in the figure. - Block the rotation of the oil pump control pulley using a screwdriver inserted through one of its two holes.
- Remove the central screw with cup washer, as shown in the diagram. - Remove the chain with the pulley. - Remove the crankshaft control pinion.
- Remove the oil pump acting on the 2 retainers as shown in the figure. - Remove the oil pump seal.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover. - Remove the circlip retaining the innermost rotor. - Remove and wash the rotors thoroughly with petrol and compressed air. - Reassemble the rotors in the pump body, keeping the two reference marks visible Replace the retainer ring.
ENG - 140
Engine
- Using a feeler gauge, check the distance between the rotors in the position shown in the figure.
Characteristic
Maximum clearance admitted 0.12 mm
Measure the distance between the outer rotor and the pump body; see figure.
Characteristic
Admissible limit clearance: 0.20 mm
Check the axial clearance of the rotors with a trued bar as reference, as shown in the figure.
Characteristic
Limit values admitted: 0.09 mm
Refitting
- Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the assembly. - Fit the pulley to the pump, the central screw to the specified torque and the cup washer. -Fit the oil pump cover, by tightening the two screws to the prescribed torque. ENG - 141
Engine
N.B. FIT THE CUP WASHER SO THAT ITS OUTER (CURVED) RIM TOUCHES THE PULLEY.
Characteristic
By-pass check up: Standard length 54.2 mm
ENG - 142
Engine
ENG - 143
Engine
- Operate the pump slowly and check if there is an increase of pressure. A small leakage is considered to be normal. If anomalies are detected, replace the pump.
N.B. A MALFUNCTIONING ONE-WAY VALVE CAN RESULT IN RUBBER SLEEVE AND FILTER OVERHEATING N.B. ABSENCE OF VIBRATION INDICATES INEFFICIENT SEALING
Specific tooling
020329Y Mity-Vac vacuum-operated pump
ENG - 144
Engine
Lack of tightness or the fact that the valve opens at different vacuum values should be regarded as anomalies. In this case, replace it.
N.B. LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS IN EXHAUST NOISE (EXPLOSIONS IN THE SILENCER). INCORRECT CUT-OFF VALVE CALIBRATION CAN RESULT IN CATALYTIC CONVERTER MALFUNCTIONING N.B. A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES JEOPARDISING THE CORRECT OPERATION OF THE CUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Fuel supply
- Disconnect the fuel supply and the suction taking pipe from the carburettor. - Check that there are no fuel leaks between the two tubes. - Close the fuel outlet pipe. - By means of the MITYVAC pump apply 0.1 bar of suction to the tap. - Make sure that the suction is kept stable and that and that there are no fuel leaks. - Reconnect the vacuum pipe to the manifold. - Position the fuel pipe with the outlet at the point of the tap. - Turn the engine by using the starter motor for five seconds with the carburettor at minimum. - Take up the fuel by means of a graded burette.
N.B. THE MEASUREMENT MAY BE FALSIFIED BY THE INCORRECT NUMBER OF REVS OR BY THE WRONG POSITION OF THE TUBE. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW RATE. THE SUCTION OUT-
ENG - 145
Engine
LET ON THE MANIFOLD HAS A SECTION INTENTIONALLY REDUCED FOR THE PURPOSE OF ENHANCING THE SUCTION PULSATION AND THEREBY GUARANTEE A CONSTANT TAP FLOW RATE.
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Characteristic
Minimum flow rate 20 cc - Completely empty the fuel tank. - Remove the petrol delivery pipe and the lowpressure pipe. - Loosen the clip and remove the cock. - Clean the tank and the filter of the cock with a specific solvent. - Refit the cock making sure that there is an ORing. - Turn the cock to the direction it had before it was removed and block the clip.
N.B. THE FILTER CAN BE UNSCREWED FROM THE COCK TO FACILITATE CLEANING.
ENG - 146
Engine
With the multimeter, check if the potentiometer is working correctly by placing the probes on both contacts indicated in the photograph. With throttle valve completely closed, the resistance value should be approx. 1.3 kOhm. With throttle valve completely open, the resistance value should be approx. 4.05 kOhm.
- Remove the protection, the bracket and the starter acting on the screw shown in the figure.
- Remove the 2 screws and the starter support with the gasket.
ENG - 147
Engine
- Remove the clamp and cover with the airing filter of the diaphragm chamber.
- Remove the 4 fixing screws shown in the figure and the vacuum chamber cover.
WARNING DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
ENG - 148
Engine
- Unscrew the bayonet joint 1/8 of a turn and remove, take out the spring and vacuum valve needle
- Remove the chamber with the accelerating pump, its control and gasket.
- Remove the oil pump seal. - Remove the intake and exhaust valves of the intake pump from the tank
N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL. N.B. AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL.
ENG - 149
Engine
Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side. - Remove the float and the plunger. - Remove the maximum nozzle
ENG - 150
Engine
-Remove diffuser.
ENG - 151
Engine
- For maximum circuit, check the air adjustment is correct as shown in the figure.
ENG - 152
Engine
- For the minimum circuit, make sure the following points are properly cleaned: air gauging, exhaust section controlled by flow screw, progression holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible internal calibrations. - Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE EXHAUST IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAYING. - Check that there are 5 closing ball joints for the operating pipes on the carburettor body. - Check that the coupling surfaces, the chamber and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear. - Check that the plunger seat does not show abnormal wear. - Replace the carburettor in case of irregularities. - Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS. - Wash and blow the minimum nozzle properly and reassemble it.
ENG - 153
Engine
- Properly wash and blow the components of the sprayer maximum circuit, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser. - Assemble the diffuser making sure the sprayer is being adequately inserted and lock it. -Assemble the maximum nozzle.
- Check that the tapered pin does not show signs of wear on the sealing surfaces of the shock absorber pin and the return clamp. - Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that there are no fuel infiltration. - Replace it in case of failures. - Introduce the float with the rod on the fuel feeding tube side.
N.B.
ENG - 154
Engine
- Remove the drainage screw from the tank, wash and blow it properly and make sure the acceleration pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air. - Reassemble the acceleration pump valves following this order: INTAKE VALVE (A) Spring Ball Nozzle
IN VALVE (M)
N.B. THE IN VALVE NOZZLE, CORRESPONDING TO THE ACCELERATION PUMP, IS MILLED.
-Check the screw tightness introducing a small amount of fuel in the tank. - Assemble a new gasket on the tank. - Assemble the tank on the carburettor body fastening the 4 screws. - Check that the control roller is free to rotate in its own seat.
N.B. MAKE SURE THE TANK GASKET IS CORRECTLY INTRODUCED N.B. AVOID DEFORMING THE ACCELERATION PUMP CONTROL ROCKER.
- Wash and blow the flow screw properly. - Check that screw is not deformed and/or rusty. - Assemble the spring on the screw. - Screw the flow screw on the carburettor body.
- The screw final position should be determined by an exhaust fume analysis. - Adjust the carburettor by turning the screw twice from the close position.
ENG - 155
Engine
Level check
- Place the carburettor inclined as shown in the figure.
- Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
ENG - 156
Engine
Insert a transparent rubber pipe to the bleeding intake of the fuel tank. Keep the pipe up so that the ends are higher than the venturi pipe. Unscrew the bleed screw and stabilise the petrol level, then measure as shown in the diagram.
ENG - 157
Engine
- Reassemble the spring with the pin lock. - Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover. - Tighten the screws.
ENG - 158
Engine
- Wash and blow dry the filter sponge of the ambient pressure intake.
- Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws.
ENG - 159
Engine
Characteristic
Check the Kehin automatic starter: Protrusion value
ENG - 160
Engine
XX XX mm at approx. 20C Check max. protrusion of Kehin aut. starter XXX XXX mm Check aut. Kehin max. time starter 5 min
ENG - 161
Engine
ENG - 162
INDEX OF TOPICS
SUSPENSIONS
SUSP
Suspensions
- Loosen the two wheel axle safety screws on the fork leg, on the odometer gear side.
SUSP - 164
Suspensions
- Remove the front wheel. - Slide off the odometer gear from the wheel hub.
CAUTION DO NOT ACT ON THE FRONT BRAKE LEVER ONCE THE FRONT WHEEL IS REMOVED. BY DOING SO, THE CALLIPER PISTONS COULD COME OUT FROM THEIR HOUSING AND ALSO THE BRAKE FLUID MIGHT SPILL OUT.
Specific tooling
001467Y013 Calliper to extract 15-mm bearings 001467Y009 Driver for OD 42-mm bearings
SUSP - 165
Suspensions
- Support the front wheel with two wooden shims that make it possible to avoid scratching in the case of contact with the rim. - Insert the punch (consisting of adaptor handle, 24 mm adaptor and 15 mm guide) from the odometer drive side to permit the removal of the brake disc side bearing and the spacer bushing.
Specific tooling
020376Y Adaptor handle 020456Y 24 mm adaptor 020412Y 15-mm guide
SUSP - 166
Suspensions
- Heat the bearing seat on the side the brake disc with the heat gun.
- Grease one side of the new bearing to make it stay together with the adaptor.
- Insert the bearing using the punch consisting of adaptor handle, 42x47 mm adaptor and 15 mm guide, and drive it up to the stop.
- Reinsert the spacer bushing on the brake disc side using the appropriate tool and take it to the stop.
Specific tooling
020376Y Adaptor handle 020359Y 42x47-mm Adaptor 020412Y 15-mm guide 020201Y Spacer bushing driving tube
SUSP - 167
Suspensions
- Heat the bearing seat on the odometer drive side with the heat gun. - Grease one side of the new bearing to make it stay together with the adaptor.
- Insert the new bearing on the odometer drive side by using a punch consisting of adaptor handle, 32x35 adaptor and 15 mm guide and drive it fully home.
Specific tooling
020376Y Adaptor handle 020357Y 32x35-mm Adaptor 020412Y 15-mm guide
SUSP - 168
Suspensions
WHEEL RIM INSPECTION - Make sure that the rim is not deformed or cracked. Replace it if necessary. - Check wheel eccentricity. If tolerance limits are exceeded, check the wheel rim and the bearings. If necessary, replace the wheel.
Characteristic
Eccentricity limits: Vertical: 2 mm
Horizontal: 2 mm
- Check the wheel balance. - Check wheel on the wheel balancer and turn it several times, paying attention to its position when it stops. If the wheel is steadily balanced, it will not always stop at the same point. If it always stops at the same point, the wheel is not balanced and must be balanced. Place weights on the lightest part of the wheel so that it does not stop any more at a particular point after being turned several times.
SUSP - 169
Suspensions
- Insert the wheel axle after greasing it from the brake disc opposite side, centring the retainer on the fork leg onto the projecting parts of the odometer drive. - Holding the wheel axle, lock the nut on the opposite side to the specified torque.
SUSP - 170
Suspensions
- Make the fork travel to adjust the fork legs on the wheel axle. - Lock the two safety screws located on the fork leg to the specified torque, according to the sequence 1-2-1.
Handlebar Removal
- Remove the front and rear handlebar cover. - Detach the front brake pump from the handlebar. - Disconnect the rear brake, throttle control and odometer control cables. - Remove the screw fixing the handlebar to the steering tube. - Remove the handlebar.
See also
Front handlebar cover Rear handlebar cover Front brake pump
Refitting
- Install the handlebars on the steering tube, paying attention to the centring, aligning the recess on the handlebar with that on the steering tube as shown in the figure. - Tighten the handlebar fixing screw on the steering tube to the prescribed torque.
SUSP - 171
Suspensions
REMOVING THE STANCHIONS - Remove the legshield. - Remove the brake calliper. - Remove the front wheel. - Remove circlip 7, the two screws 8 and slide off the stanchion. - Unscrew the upper cap 6. - Remove the components including the spring. - Drain the oil into a collecting container.
SUSP - 172
Suspensions
See also
Legshield Removal Removing the front wheel
Overhaul
STANCHION INSPECTION - Check the sliding surface for scorings and/or scratches. - If the scorings are deep, replace the stanchion. SLEEVE INSPECTION - Check that it is not damaged and/or cracked. - If there are signs of excessive wear or damage, replace the affected component. - Replace the oil seal 4 and the dust gaiter 5 and fit it once you have lubricated their seat. - Replace the O-ring on the inner cap 1 - Replace sealing washer 2.
Refitting
- Refit the stanchion and the piston and tighten screw 3 with its washer 2 to the specified torque. - Pour the recommended quantity of specific oil into the stanchion unit. - Insert the spring and the components. - Tighten the upper cap 6 to the specified torque. - Introduce the stanchion in the bottom yoke and install the circlip 7.
SUSP - 173
Suspensions
- Push on the upper cap 6 until the circlip touches the bottom yoke. - Tighten the screws 8 to the prescribed torque.
Characteristic
Fork stem (oil level height without spring, compressed fork) 85 mm
SUSP - 174
Suspensions
- Position the vehicle on centre stand. - Set a support under the vehicle in such a way that the wheel is able to move freely and the vehicle does not fall. - Remove the handlebar. - Remove the legshield. - Remove the front brake calliper. - Release the fork from the odometer cable and from the front brake calliper pipe. - Loosen the upper ring nut 1 and collect the shim washer 2.
Specific tooling
020055Y Wrench for steering tube ring nut
When the specified torque of the lower ring nut is reached, loosen by 90.
See also
Removal Legshield Removal - Remove the balls retainer 7 of the lower bearing B from the steering tube.
- Wash carefully all the parts removed. - To refit, carry out the removal operations but in reverse order. SUSP - 175
Suspensions
- Appropriately lubricate the bearings with recommended products. BEARING SEAT REPLACEMENT ON CHASSIS - Only remove the seats if it is strictly necessary. - Using the special tool remove the upper bearing A seat 5 by putting the special tool into the lower part of the headstock as indicated in the figure. - Remove the lower bearing B seat 6 on the headstock by inserting the punch from the top on the headstock.
Specific tooling
020004Y Punch for removing steering bearings from headstock - Using the special tool, refit the upper A and lower B bearing seats on the headstock.
Specific tooling
001330Y Tool for fitting steering seats
LOWER BEARING SEAT REPLACEMENT ON FORK Check the condition of the lower bearing B seat 8 on the fork (steering tube). Replace if there are faults. - Support the fork properly. - Using the special tool, remove the seat 8 on the steering tube as shown in the photograph by applying small mallet blows.
Specific tooling
020004Y Punch for removing steering bearings from headstock
SUSP - 176
Suspensions
Always use a new seat on refitting. - Using the special tool, refit the seat 8 with the aid of a few mallet blows and bring it as far as the stop shown in the photo.
Specific tooling
006029Y Punch for fitting fifth steering bearing on steering tube
Steering bearing
CHECKING THE BEARINGS CLEARANCE To check the steering, it is necessary to: - Position the vehicle on centre stand. - Place a support under the motorcycle in such a way that the front wheel is able to move freely and the vehicle does not fall. When carrying out this operation, pay attention not to mistake the centre stand clearance with that of the steering. Repeat this test many times before deciding if the steering clearance must be adjusted. - Hold the fork sleeves and pull the fork forwards and backwards, with the steering in forward position. - There should be no clearance forward or backward If there is clearance, the steering must be adjusted. ADJUSTING THE BEARING CLEARANCE - Remove the legshield. - Loosen the upper ring nut 1 using the specific wrench. - Screw in the lower ring nut 3 until the bearing clearance is totally eliminated.
CAUTION DO NOT EXCESSIVELY TIGHTEN THE LOWER RING NUT 3 BECAUSE THE STEERING BEARINGS COULD GET DAMAGED.
- Check clearance as described above. Make sure the front fork can move all long its stroke, from left to right or vice versa, rotating freely and smoothly. SUSP - 177
Suspensions
- Keep the lower ring nut 3 in position, by using a specific wrench and tighten the upper ring nut 1 to the specified torque. Check again the bearings clearance.
Specific tooling
020055Y Wrench for steering tube ring nut
See also
Legshield
SUSP - 178
Suspensions
See also
Exhaust assy. Removal - Pull the rear brake and keep it pulled with a clamp. - Unscrew the wheel fixing nut and collect the washer. - Take out the wheel from its housing.
- To refit, carry out the removal operations but in reverse order, be careful to use a new cotter pin.
Swing-arm Removal
- Rest the vehicle on its centre stand. - Support the engine adequately. - Unscrew the nut on the left-hand side of the engine and slide off the bolt from the opposite side.
SUSP - 179
Suspensions
- Loosen the nut on the inside of the frame from the left-hand side and remove the relevant pin.
- Remove the Seeger ring shown in the picture. - Remove the helmet compartment. - Slide off the support spring by using a normal spring puller.
SUSP - 180
Suspensions
- Lower the front end of the engine to free the swinging arm. - Slide off the swinging arm from the right-hand side of the vehicle. - To replace the silent block it is necessary to remove the support bracket, after removing the swinging arm and the side fairings. - Unscrew the two indicated retainers and remove the bracket with silent block from chassis. - To remove the silent block from the bracket, please use the specific tool.
Specific tooling
020271Y Tool for removing-fitting silent bloc
Overhaul
Regularly check the clearance of the swinging arm retainer pins. To carry out these operations, proceed as follows: - Position the vehicle on centre stand. - Hold the rear wheel firmly and try to move it perpendicularly to the travel direction. - If there is any clearance, check all the fastening elements that connect the swinging arm to the engine and chassis as well as the condition of the silent block.
Shock absorbers
SUSP - 181
Suspensions
Removal
- Remove the side fairings. - Support the vehicle adequately. - Undo the inner nut and slide off the shock-absorber to chassis upper fixing screw.
- Undo the inner nut and slide off the shock-absorber to engine lower fixing screw. - Remove the shock absorber. - To refit tighten the screws to the prescribed tightening torque.
See also
Side fairings
Centre-stand
- Support the vehicle adequately. - Undo the nut on the left-hand side of the engine.
SUSP - 182
Suspensions
- When refitting lubricate the pin and the springs with the specified grease and tighten the nut to the specified tightening torque.
SUSP - 183
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
Braking system
Refitting
- Refit the calliper on the support and tighten the screws to the specified torque. - Refit the tube complete with fitting with new copper gaskets. - Place the tube joint in the original position and tighten it to the specified torque. - Bleed the air from the system.
See also
Front
Braking system
Removal
Proceed as follows: - remove the front wheel. - Undo the five screws fixing the disc. - Remove the brake disc.
Refitting
When refitting, position the disc correctly, following the direction indicated on the same disc.
Disc Inspection
- Check the disc thickness.
Characteristic
Disc minimum thickness: 3.5 mm
Braking system
Using the appropriate tool, measure how much the disc protrudes when the wheel is fitted properly. The protrusion, measured near the external edge of the disc, must be less than 0.1 mm.
If a value other than that prescribed is detected, remove the front wheel and check how much the disc protrudes. Maximum permissible out of true is 0.1 mm. If the value measured is greater, fit a new disc and repeat the check.
If the problem persists, check and replace the wheel rim if necessary.
Specific tooling
020335Y Magnetic mounting for dial gauge
See also
Removing the front wheel
Braking system
See also
Front brake calliper - Check the thickness of the friction material. If thinner than the minimum value, replace it.
Characteristic
Minimum friction material thickness 1.5 mm
- In case of uneven wear, replace the brake pads when the friction material thickness difference is 0.5 mm.
CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
Braking system
Refitting
- To refit, carry out the disassembly operations in the inverse order, fitting the inner spring correctly and tightening the fixing screws to the specified torque.
Fill Front
N.B.
IF THERE IS AIR IN THE HYDRAULIC SYSTEM, THE WATER WILL ABSORB MOST OF THE POWER OF THE BRAKE MAIN CYLINDER AND THEREFORE, IT WILL REDUCE THE CALLIPER PERFORMANCE WHEN BRAKING. THE PRESENCE OF AIR IS SIGNALLED BY THE 'SPONGINESS' OF THE BRAKE CONTROL AND POOR BRAKING EFFICIENCY.
CAUTION
CONSIDERING THE DANGER POSED FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY TO BLEED THE HYDRAULIC SYSTEM AFTER REFITTING BRAKES AND CARRYING OUT REGULAR MAINTENANCE OPERATIONS. - Once the bleed valve is closed, fill the system with brake fluid to the maximum level. -Undo the bleed screw. -Apply the tube of the special tool to the bleed screws. When bleeding it is necessary to fill the oil tank in continuation while working with a MITYVAC pump on the bleed screws until no more air comes out of the system. The operation is finished when just oil comes out of the bleed screws. -Do up the bleed screw. -When the operation is over, tighten up the oil bleed screw to the prescribed torque.
N.B. IF AIR CONTINUES TO COME OUT DURING PURGING, EXAMINE ALL THE FITTINGS:
Braking system
IF SAID FITTINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS. CAUTION - DURING THE OPERATIONS, THE VEHICLE MUST BE ON THE STAND AND LEVEL. N.B. DURING PURGING FREQUENTLY CHECK THE LEVEL TO PREVENT AIR GETTING INTO THE SYSTEM THROUGH THE PUMP. WARNING - BRAKING CIRCUIT FLUID IS HYGROSCOPIC. IT ABSORBS HUMIDITY FROM THE SURROUNDING AIR. IF THE LEVEL OF HUMIDITY IN THE BRAKING FLUID EXCEEDS A GIVEN VALUE, BRAKING EFFICIENCY WILL BE REDUCED. THEREFORE, ALWAYS USE FLUID FROM SEALED CONTAINERS. UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THIS LIQUID EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS, CHANGE THE FLUID MORE FREQUENTLY. CAUTION WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE OIL ON IT.
Specific tooling
020329Y Mity-Vac vacuum-operated pump
Recommended products
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
Braking system
- Operate on the two U bolt clamps (see figure). - On refitting, perform the operation in reverse. - Tighten the hydraulic line to the prescribed torque and then fill and purge the system.
See also
Front handlebar cover Rear handlebar cover
Drum brake removal - Remove the rear wheel. - Hold the lower shoe and slide it out with the upper one. For fitting: - First assembly two shoes and the springs then place them on the pin and on the cam.
See also
Removing the rear wheel
Braking system
Transmission replacement - Remove the front handlebar cover. - Remove the leg shield and the footrest. - Loosen the brake set screw - Release the transmission from its retainers to the engine.
See also
Front handlebar cover Legshield Footrest - Release the transmission from the retainers on chassis and from the control lever. - Fit the new transmission, fixing and positioning it like the one replaced. - Adjust the drum brake activation point.
Braking system
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
Seat
- Undo the four nuts indicated in the figure and collect the washers.
Driving mirrors
- Lift the rubber cover. - Loosen the indicated nut, keeping the lower spacer blocked. - Undo the mirror from the lower spacer. - Remove the lower spacer, if necessary.
N.B. THE RIGHT MIRROR SHOULD BE UNSCREWED CLOCKWISE.
CHAS - 195
Chassis
- Disconnect the connectors of the instrument panel and the odometer cable. - Remove the handlebar cover together with the instrument panel and controls.
See also
Front handlebar cover
Instrument panel
- Remove the rear handlebar cover. - Undo the four screws indicated.
See also
Rear handlebar cover
CHAS - 196
Chassis
- Undo the front screw. - Lift the upper edge to release and separate it from the rear handlebar cover. - Disconnect the turn indicators connections and remove the front handlebar cover.
See also
Driving mirrors
CHAS - 197
Chassis
Headlight assy.
- Remove the legshield. - Undo the four screws indicated.
FRONT TURN INDICATORS - Remove the front handlebar cover. - Undo the three screws indicated.
See also
Legshield Front handlebar cover
Legshield
- Remove the leg shield back plate. - Working from the front wheel housing internal side, undo the two screws from both sides of the vehicle.
CHAS - 198
Chassis
- Move the leg shield forward, opening the lower ends and detach the headlight bulb connections.
Knee-guard
- Remove the front handlebar cover. - Undo the five side screws on the sides of the leg shield back plate as shown.
CHAS - 199
Chassis
- Undo the screw in the glove-box and the one under the chassis number lid. - Before refitting the leg shield back plate, loosen the footrest fixing screws, so as to fit the two components in the best conditions.
N.B. WHILE REFITTING, PLEASE REMEMBER TO ATTACH THE GLOVE-BOX OPENING LEVER TO THE KEY-OPERATED DEVICE.
See also
Front handlebar cover
- Undo the upper screw. - Slide the housing off the fork stanchions.
See also
Legshield Front mudguard Removing the front wheel
CHAS - 200
Chassis
Footrest
- Remove the leg shield back plate. - Remove the side fairings. - Undo the indicated screws and remove the protections.
See also
Knee-guard Side fairings
Side fairings
- Remove the rear handles. - Remove the rear central cover. - Undo the two screws indicated.
CHAS - 201
Chassis
- Undo from both sides of the vehicle the screw placed under the footrest.
CHAS - 202
Chassis
- Open the front ends of the side fairings to slide off the indicated upper inserts.
- Disconnect the connections of the turn indicators and of the rear light unit.
See also
Handles and top side fairings Rear central cover
CHAS - 203
Chassis
- Undo the two screws indicated. - Remove the license plate support together with the turn indicators.
See also
Side fairings
Rear mudguard
- Undo the right-hand side screw.
- Undo the rear screw that fixes also the air filter box.
CHAS - 204
Chassis
Helmet bay
- Remove the side fairings. - Remove the battery cover and the battery. - Undo the two screws inside the helmet compartment.
- Disconnect the fuse box and free the helmet compartment from the cables.
See also
Side fairings Battery
spoiler
- Remove the footrest. - Undo the three screws indicated.
CHAS - 205
Chassis
- Undo from both sides of the vehicle the screw placed under the footrest.
See also
Footrest
Fuel tank
Remove the side fairings and the helmet compartment. - Detach the pipes from the vacuum-operated cock.
CHAS - 206
Chassis
- Undo the central screw and loosen the two side screws on the license plate support frame.
- Disconnect the fuel probe connector and detach the breather pipe from the filler.
See also
Side fairings Helmet bay
See also
CHAS - 207
Chassis
Seat
Front mudguard
- Operating from both sides of the vehicle, undo the three indicated screws.
Battery
- Undo the three indicated screws and remove the battery cover.
CHAS - 208
Chassis
- Disconnect the negative and positive cables. - Slide off the breather pipe.
CHAS - 209
INDEX OF TOPICS
PRE-DELIVERY
PRE DE
Pre-delivery
Aesthetic inspection
Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt
Electrical system
Electrical system: - Main switch - Headlamps: high beam lights, low beam lights, tail and parking lights and their warning lights - Adjusting the headlights according to the regulations currently in force - Rear light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel gauge - Instrument panel warning lights - Horn - Starter PRE DE - 211
Pre-delivery
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL. KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINAL FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING. IN CASE OF CONTACT WITH YOUR EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15 MINUTES AND SEEK IMMEDIATE MEDICAL ATTENTION. IF IT ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GASES; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO ENSURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES. KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.
Levels check
Level check: - Hydraulic braking system fluid level. - Rear hub oil level - Engine oil level
Road test
Test ride - Cold start - Instrument operations - Response to the throttle control - Stability on acceleration and braking - Rear and front brake efficiency - Rear and front suspension efficiency - Abnormal noise
PRE DE - 212
Pre-delivery
Static test
Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks
CAUTION
Functional inspection
Functional Checks: Braking system (hydraulic) - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Throttle travel check Others - Check documentation - Check the chassis and engine numbers - Tool kit - License plate fitting - Check locks - Check tyre pressures - Installation of mirrors and any accessories
PRE DE - 213
INDEX OF TOPICS
TIME
TIME
Time
Engine
ENGINE
1 Code 001001 Action Engine from chassis - Removal and refit. Duration
TIME - 215
Time
Crankcase
CRANKCASE
1 2 3 Code 001133 001153 002031 Action Engine crankcase - Replacement Crankcase halves gasket - Replacement Rear wheel hub bearings - Replacement Duration
TIME - 216
Time
Crankshaft
CRANKSHAFT
1 2 Code 001117 001099 Action Crankshaft - Replacement Flywheel-side oil seal - Replacement Duration
TIME - 217
Time
Cylinder assy.
CYLINDER ASSEMBLY
1 2 Code 001002 001107 Action Cylinder-Piston - Replacement Cylinder / piston - Inspection / cleaning Duration
TIME - 218
Time
HEAD ASSEMBLY
1 2 3 Code 001045 001056 001126 Action Valves - Replacement Head gasket - change Head - Replacement Duration
TIME - 219
Time
TIME - 220
Time
HEAD COVER
1 2 3 4 5 6 7 Code 001089 001088 001159 001093 001097 001091 001074 Action Head cover - Replacement Head cover gasket - Replacement Oil vapour recovery tank - Service Spark plug - Replacement Cooling hood - Replacement Head cover sealing ring Oil vapour recovery pipe - Replacement Duration
TIME - 221
Time
Chain tensioner
CHAIN TENSIONER
1 2 Code 001129 001124 Action Chain tensioner - Service and Replacement By pass lubrication - Replacement Duration
TIME - 222
Time
Oil filter
OIL FILTER
1 2 3 4 Code 001123 001160 003064 001102 Action Oil filter -Replacement Oil pressure sensor - change Engine oil - change Net oil filter - change / Cleaning Duration
TIME - 223
Time
Flywheel cover
FLYWHEEL COVER
1 2 3 4 5 Code 001087 001163 001161 001174 001164 Action Flywheel cover - Replacement Silencer secondary air connection Replacement Secondary air filter - Replacement / Cleaning SAS valve - Replacement Crankcase secondary air connection - Replacement Duration
TIME - 224
Time
Driven pulley
DRIVEN PULLEY
1 2 3 4 Code 001155 001022 001012 001110 Action clutch housing - Replacement Clutch - Replacement Driven pulley - overhaul Driven pulley- Replacement Duration
TIME - 225
Time
Oil pump
OIL PUMP
1 2 3 4 5 6 7 Code 001051 001125 001042 001112 001130 001100 001122 Action Belt/Timing chain - Change Chain guide pads - Replacement Oil pump - overhaul Oil pump - change Oil sump - change Clutch-side oil seal - Replacement Oil pump chain - Replacement Duration
TIME - 226
Time
TIME - 227
Time
Driving pulley
DRIVING PULLEY
1 2 3 4 Code 001066 001086 001177 001011 Action Driving pulley - Removal and refitting Driving half-pulley - Replacement CVT rollers / sliders - Replacement Drive belt - Replacement Duration
TIME - 228
Time
Transmission cover
TRANSMISSION COVER
1 2 3 Code 001096 001135 001065 Action Transmission crankcase cover - Replacement Transmission cover bearing - Replacement Transmission cover - Removal and Refit Duration
TIME - 229
Time
Starter motor
STARTER MOTOR
1 2 Code 001020 001017 Action Starter motor - Replacement Start-up pinion - Replacement Duration
TIME - 230
Time
Flywheel magneto
TIME - 231
Time
Carburettor
CARBURETTOR
1 2 3 4 5 6 Code 001082 001013 004122 001081 001008 001063 Action Carburettor heating resistor - Replacement Intake manifold - change Air cleaner carburettor fitting - Replacement Automatic choke - Replacement Carburettor - Inspection Carburettor - Replacement Duration
TIME - 232
Time
Exhaust pipe
SILENCER
1 2 3 Code 001009 001136 001095 Action Silencer - Replacement Exhaust emissions - Adjustment Silencer heatshield - Replacement Duration
TIME - 233
Time
Air cleaner
AIR CLEANER
1 2 Code 001014 001015 Action Air filter - Replacement/Cleaning Air filter box - Replacement Duration
TIME - 234
Time
Frame
CHASSIS
1 2 3 Code 004001 004004 001053 Action Chassis - Replacement Stand - Replacement Stand pin - Replacement Duration
TIME - 235
Time
Legshield spoiler
SPOILER LEGSHIELD
1 2 3 4 5 Code 004159 004149 004064 004015 004053 Action Plates / Stickers - Replacement Shield central cover - Replacement Leg shield, front part - Removal and refitting Footrest - Removal and Refitting Spoiler - Replacement Duration
TIME - 236
Time
Rear cover
REAR SHIELD
1 2 3 Code 004174 004065 004081 Action Trunk levers - Replacement Legshield, rear part - Removal and refitting Top box lid - Replacement Duration
TIME - 237
Time
Central cover
CENTRAL COVER
1 2 3 4 5 Code 004059 004106 004085 004105 004131 Action Spark plug inspection flap - Replacement Helmet compartment band - Replacement Fairing (1) - Replacement Right side clamp - Replacement Luggage rack mounting - Replacement Duration
TIME - 238
Time
Underseat compartment
HELMET COMPARTMENT
1 2 3 Code 005046 004016 001027 Action Battery cover - change Helmet compartment - Removal and Refitting Body / air cleaner union - Replacement Duration
TIME - 239
Time
Plate holder
1 2
Action License plate holder mounting - Replacement number plate holder - Replacement
Duration
TIME - 240
Time
Mudguard
MUDGUARDS
1 2 Code 004002 004009 Action Front mudguard - change Rear mudguard - Replacement Duration
TIME - 241
Time
Fuel tank
FUEL TANK
1 2 3 4 5 6 Code 004168 005010 004112 004005 004007 004109 Action Fuel tank cap - Replacement Tank float - Replacement Cock-carburettor hose - Replacement Fuel tank - Replacement Fuel valve - Replacement Fuel tank breather - change Duration
TIME - 242
Time
Rear shock-absorber
TIME - 243
Time
STEERING BEARING
1 2 Code 003002 003073 Action Steering bearing - Replacement Steering clearance - Adjustment Duration
TIME - 244
Time
Handlebar covers
HANDLEBAR COVERS
1 2 3 4 5 6 Code 004019 004018 005078 005076 005014 005038 Action Handlebar rear section - Replacement Handlebar front section - Replacement Odometer glass - Replacement Clock / Cell - Replacement Odometer - Replacement Instrument panel warning light bulbs - Replacement Duration
TIME - 245
Time
Handlebar components
HANDLEBAR COMPONENTS
1 2 3 4 5 6 7 8 9 10 11 Code 004066 002037 002071 003001 005017 002024 003061 002060 004162 002059 002063 Action Driving mirror - Replacement Brake or clutch lever - Replacement Left hand grip - Replacement Handlebar - Removal and refitting Stop switch - Replacement Front brake pump - Removal and Refitting Accelerator transmission - adjust Complete throttle control - Replacement Mirror mounting and/or brake pump fitting U-bolt - Replacement Right hand grip - Replacement Throttle control transmission - Replacement Duration
TIME - 246
Time
Swing-arm
SWINGING ARM
1 2 Code 001072 003080 Action Engine / frame swinging arm fitting Replacement Swinging arm on chassis - Replacement Duration
TIME - 247
Time
Brake hoses
BRAKE PIPING
1 2 3 4 Code 002007 002039 002021 002047 Action Front brake shoes/pads - Remov. and Refitt Front brake calliper - Removal and Refitting Front brake hose - Remov. and Refitt. Front brake fluid and system bleeding plug - Repl. Duration
TIME - 248
Time
Seat
SADDLE
1 2 Code 004003 004068 Action Saddle - Replacement Passenger handgrip - Replacement Duration
TIME - 249
Time
INDICATOR LIGHTS
1 2 3 4 5 6 7 8 9 10 11 Code 005002 005012 005067 005008 005005 005066 005022 005068 005131 005031 005032 Action Front headlamp - Replacement Front turn indicator - Replacement Front turn indicator bulb - Replacement Headlight bulbs - Replacement Taillight - change Rear light bulbs - Replacement Rear turning indicators - Replacement Rear turning indicator bulb - Replacement number plate light support - Replacement number plate light bulb - Replacement number plate light glass - Replacement Duration
TIME - 250
Time
Front wheel
FRONT WHEEL
1 2 3 4 5 6 7 Code 003038 002011 003040 003047 003037 004123 002041 Action Front wheel axle - Remov. and Refit. Odometer drive - Replacement Front wheel bearings - Replacement Front tyre - Replacement Front wheel rim - Removal and Refitting Front wheel - Replacement Brake disc - Replacement Duration
Tone wheel or drive greasing Please take note that the code has been introduced: 900001 - Tone wheel / drive greasing - 15'. Never mistake the codes 002011 (movement sensor replacement) and 005089 (tone wheel replacement) in the event of noise of the indicated components. The grease recommended is TUTELA MRM 2 (soap-based lithium grease with Molybdenum disulphide). In the following points, the area to be greased is indicated with an arrow (1 - Drive, 2 - Tone wheel)
TIME - 251
Time
Rear wheel
REAR WHEEL
1 2 3 4 Code 002002 004126 001016 001071 Action Rear brake pads/shoes - Repl. Rear wheel tyre - Replacement Rear wheel - Replacement Rear wheel rim - Removal and Refitting Duration
TIME - 252
Time
Electric devices
ELECTRICAL DEVICES
1 2 3 4 5 6 7 8 9 10 11
Code 001023 005035 005001 001094 001069 005052 005025 005009 005011 005007 005114
Action Control unit - Replacement Headlight solenoid - Replacement Electrical system - Replacement Spark plug cap - Replacement HV coil - Replacement Fuse - Replacement Battery fuse box - Replacement Voltage regulator - Replacement Start-up solenoid - Replacement Battery - change Electrical system - Service
Duration
Electronic controls
ELECTRIC CONTROLS
1 2 3 4 5 6 7 8 Code 005039 005006 005040 005003 005041 005016 004096 005072 Action Lights switch - Replacement Light or turning indicator switch - Replacement Horn button - Replacement Horn - Replacement Starter button - Replacement Key switch - Replacement Lock series - Replacement Immobilizer aerial - Replacement Duration
TIME - 253
Time
Front suspension
FRONT SUSPENSION
1 2 3 4 5 6 Code 003010 003048 003076 003079 003051 003069 Action Front suspension - Service Fork oil seal - Replacement Fork sleeve - Replacement Fork stem - Replacement Complete fork - Replacement Front fork oil - Replacing Duration
TIME - 254
A
Air filter: 33
B
Battery: 46, 63, 70, 77, 78, 205, 208 Brake: 171, 185, 187, 188, 190, 191, 248 Bulbs:
C
Carburettor: 11, 146, 152, 232 Checks: 68
E
Electric: 253 Engine oil: 34
F
Fuel: 45, 145, 206, 242 Fuses: 76
H
Headlight: 39, 198 Horn: 74 Hub oil: 31
I
Identification: 8 Instrument panel: 196
M
Maintenance: 7, 28 Mirrors: 195, 197
O
Oil filter: 34, 35, 223
R
Recommended products:
S
Saddle: Shock absorbers: 181 Spark plug: 30, 68 Start-up: Suspension: 47, 254
T
Tank: 206, 242 Transmission: 9, 45, 88, 100, 111, 229 Turn indicators: 67 Tyres: 10
V
Vehicle: 8, 83