beverly by emmanouil karpadakis

SERVICE STATION MANUAL

•BEVERLY 125-200 cc

Piaggio & C. S. p. A. Pontedera After Sales Service Dis. 594845 - 08/01 Grafica e Stampa: C.L.D. - Pontedera (PI) "© Copyright 2001 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. No part of this publication may be reproduced." Data are subject to modification without notice. We decline all liability for the use of non-original spare parts or accessories that have not been tested and/or approved.

BEVERLY 125-200 CC

SERVICE STATION MANUAL This manual has been prepared by Piaggio & C. S.p.A. for use in the workshops of authorised Piaggio dealers and sub-agents. It is assumed that the person utilising this manual for servicing or repairing Piaggio vehicles has a knowledge of the principles of mechanics and standard procedures for vehicle repair. Any important changes in vehicle characteristics or specific repair operations will be divulged by means of updates to this manual. Satisfactory repair or service cannot be achieved without the necessary equipment and tools. Refer to the pages of this manual concerning specific tools and equipment and the special tools catalogue. Critical information in the manual is indicated as follows:

N.B.: Important information for facilitating and explaining a procedure.

Warning - Procedures that must be followed to avoid damage to the vehicle. Caution

- Procedures that must be followed to eliminate the risk of injury to repair / service personnel.

NOTE - For all operations relating to the engine, please refer to the "Service Station Manual" for 4S 4V 125-180200 cc engines.

VEHICLE SPECIFICATIONS AND OVERHAUL DATA

SPECIFIC TOOLS

MAINTENANCE AND TROUBLESHOOTING

ELECTRICAL EQUIPMENT

ENGINE

FRONT AND REAR SUSPENSIONS

BRAKING SYSTEM

BODYWORK

PRE-DELIVERY OPERATIONS

JOB TIME SHEET

General guidelines Safety prescriptions

Maintenance regulations

- If the work to be carried out requires the vehicle engine to be running, make sure the workshop is well ventilated and use proper exhausters. Do not run the engine in closed places. Exhaust fumes are toxic.

- Use only genuine PIAGGIO spare parts and recommended lubricants. The use of non-original or nonconforming spare parts can cause damage to the vehicle.

Battery electrolyte contains sulphuric acid. Protect the eyes, clothes and skin. Sulphuric acid is highly corrosive, if it comes into contact with eyes or skin, wash the affected area abundantly with water and seek immediate medical assistance.

The battery produces hydrogen gas which is potentially explosive. Do not smoke near the battery and keep naked flames and sparks well clear, especially when the battery is on charge.

Petrol is highly flammable and can be explosive in certain conditions. Do not smoke in the work area and do not introduce naked flames or sparks.

Clean the brake discs and pads in a ventilated area. Direct the compressed air jet so as not to inhale the dust produced by pad wear. Although the brake linings contain no asbestos, the dust is harmful if inhaled.

- The only specific t o o l s that can be used are those expressly designed for this vehicle. - Always fit new gaskets, seal rings and split pins when reassembling parts. - After disassembly, clean parts with non-flammable solvent or a solvent with a high flash point. Lubricate all surfaces before reassembly with the exception of conical couplings. - After reassembling, check that all the components are correctly installed and that they work perfectly. - Use only metric tools for disassembly, assembly and maintenance work. Metric screws, nuts and bolts are not interchangeable with British-measure fasteners. The vehicle may be damaged if unsuitable tools or nuts, bolts or screws are used. - When working on the electrical system, ensure electrical components are correctly installed, paying particular attention to ground and battery connections.

Vehicle identification

01 001

1 -2

01 002

Specifications WEIGHT AND DIMENSIONS Total dry kerb weight Width (at handgrips) Length Wheelbase Saddle height

Rear hub 149 Kg 758 mm 2120 mm 1475 mm 975 mm

ENGINE Type

Single-cylinder, four-stroke, four-valve, liquid-cooled. Timing system Single overhead camshaft driven by chain on left side, three-arm rockers with threaded adjuster. Bore 57 mm (125 cc) 72 mm (200 cc) Stroke 48, 6 mm Displacement 124. 015 cm3 (125 cc) 197. 775 cm3 (200 cc) Compression ratio 12 - 1 3 : 1 (125 cc) 1 1 - 1 2 : 1 (200 cc) Walbro Carburettor WVF-7G (125 cc) WVF-7H (200 cc) Idle speed 1650 + 50 rpm CO adjustment 3. 8 + 0. 7 % Air filter sponge soaked in 50 percent petrol-oil mixture. Starter system electric starter motor (200 cc engine with torque limiter). Lubrication lubrication with chain driven lobe pump in crankcase, mesh strainer and cartridge filter. Fuel system Petrol supplied by carburettor with vacuum pump. Max. power (crankshaft): 125 cc 11 kW (15 HP) at 9700 rpm 200 cc 15. 4 kW (21 HP) at 8500 rpm Top speed 104 Km/h (125 cc) 125 Km/h (200 cc) TRANSMISSIONS Transmission

By automatic variator, with expanding pulleys, torque converter, V belt, automatic clutch, reduction gearing and transmission compartment cooled by forced air circulation.

Coolant

~ 250 cc. (recommended oil: TUTELA ZC 90). PARAFLU 11FE (diluted)

FRAME AND SUSPENSION Type Welded steel tubing with pressed steel reinforcements. Front suspension Hydraulic telescopic fork with forward-shifted pin and 0 35 mm rods. Front wheel max. travel 104 mm Rear suspension Engine functioning as swing arm pivoting on frame through arm with two degrees of freedom. Pair of double-acting hydraulic shock absorbers and coaxial springs with four-position preload adjustment. Max. rear shock absorber travel: 95. 5 mm BRAKES Front

Rear

0 260 mm disc with hydraulically operated dual piston floating caliper (lever at right end of handlebar). 0 260 mm disc with hydraulically operated dual opposed piston caliper (lever at left hand of handlebar).

WHEELS AND TYRES Lightweight alloy wheels: front 3. 00x16" rear 3. 50x16" Tyres: front: 110/70-16" M/C 52P Tubeless rear: 140/70-16" M/C 65P Tubeless Tyre pressure (cold): front: 2 bar rear: 2. 2 bar (2. 5 bar with pillion) Note: Check and adjust tyre pressure with tyres at ambient temperature. Adjust pressure according to the weight of the rider and accessories.

ELECTRICAL COMPONENTS Ignition type Capacitive-discharge electronic ignition with variable advance and separate HV coil. Ignition advance variable (before T. D. C. ): (125 cc) from 10°+ 1° at 2000 rpm to 34° ± 1 ° at 6000 rpm (200 cc) from 10° + 1° at 2000 rpm to 32° ± 1 ° at 6500 rpm Spark plug NGK CR 8EB Battery 12V-10Ah Fuses N° 2 15A, N° 1 10A, N° 1 7. 5A, N° 4 4A Generator AC current CAPACITIES Engine oil ~ 1100 cc (recommended oil: Selenia HI Scooter 4 Tech) Fuel tank (including ~ 2. 5 I reserve) ~ 10 L 01_003

1 -3

Tightening torques

Q. ty

Tightening torque N-m

Steering assembly Steering upper ring nut Steering lower ring nut Handlebar clamping screw (*) Handlebar control clevis fixing screws

1 1 1 4

30-36 10-13 then loosen by 90째 45-50 7- 10

Frame assembly Swing arm pivot - engine Frame-swingarm pivot nut Spacer clamping threaded bushing Spacer clamping threaded bushing counternut Frame arm-engine arm link nut Silent bloc support plate bolt Centre stand bolt Side stand clamping bolt Side stand switch screw

1 1 1 1 1 1 2 1 1

64-72 64-72 13-17 90-110 33-41 64-72 25-30 35-40 5-7

Front suspension Screw fixing plungers to fork lower plate Front wheel spindle Fork leg screw Screw fixing front mudguard to plate Screw fixing mudguard plate to fork

4 1 2 4 3

20-25 45-50 6-7 4. 5 - 7 9-11

Front brake Pump-tube oil connection Tube-caliper oil connection Screw clamping calliper to fork Disc clamping screw (째) Oil bleeder screw Pad clamping pin

1 1 2 5 1 2

16-20 16-20 20-25 5-6, 5 12- 16 19. 6-24. 5

Rear suspension Left-hand lower shock absorber support bolt Shock absorber upper fastening Shock absorber lower fastening Rear wheel spindle Screws clamping wheel rim to hub Silencer support arm screws on engine (*)

2 2 2 1 5 2

20-25 33-41 33-41 104-126 34-38 20-25

Rear brake Pump-tube oil connection Tube-caliper oil connection Hose/rigid tube oil connection Rear disc clamping bolt Oil bleeder screw Screw clamping brake caliper to support Screw clamping rear brake caliper support to engine Pad clamping pin

1 2 1 5 1 2 2 2

16-20 16-20 9-11 11 - 13 12- 16 20-25 20-25 20-25

Silencer Screw clamping manifold to silencer Screw clamping heat shield to silencer Exhaust gas intake screw Screw fixing silencer support arm to crankcase Screw fixing silencer to support arm

1 4 1 2 3

15. 5- 18. 5 5-6 22-26 33-41 20-25

PART

(째) Apply thread locking LOCTITE medium, type 242. (*) Tighten the two screws after tightening the rear wheel spindle nut with the prescribed torque. Safety tightenings: refer to page 9-2 "Predelivery Operations".

1 -4

Tightening torques

PART

Q. ty

Tightening torque N m

Lubrication Hub oil drain plug Oil filter connection on crankcase Engine oil drain plug/gauze strainer Oil filter Oil pump cover screw Oil pump to crankcase fixing screw Oil pump drive gear screw Oil pump cover plate screw Oil sump screw Minimum oil pressure sensor

1 1 1 1 2 2 1 2 7 1

15- 17 27-33 24-30

Cylinder head Spark plug Cylinder head cover screw Cylinder head cover screw (*) (•) Nuts fastening cylinder head to cylinder Starter weight screw (200 cc) M5 side screw fastening washers on cam shaft (125 cc) Tappet adjuster counternut Intake manifold screw Timing chain tightener shoe screw Starting weight bell screw (200 cc) M6 central screw fastening washers on cam shaft (125 cc) Timing chain tightener support screw Timing chain tightener central screw Camshaft retaining plate screw

1 5 4 2 1 1 2 2 1 1 1 2 1 2

Transmission Belt support roller screw Clutch assembly nut on driven pulley Driving pulley nut Transmission cover screw Driven pulley shaft nut Rear hub cover screw

1 1 1 13 1 7

11 - 13 45-50 75-83 11 - 13 54-60 24-27

Flywheel Flywheel cover fixing screw Stator assembly screw (°) Flywheel nut Pick-up fixing screw

4 2 1 2

5-6 3-4

Crankcase and crankshaft Crankcase inside partition screw (transmission-side shaft) Crankcase joining screw Starter motor screw Crankcase valve gear cover screw (°)

2 11 2 3

11 - 13 11 - 13 3. 5-4. 5

Cooling system Water pump impeller cover Water pump impeller drive joint screw Thermostat cover screw

3 3 2

3-4 3-4 3-4

Power plant

4-6

0. 7-0. 9 5-6

10- 14 4-6

10- 14 12- 14 12- 14 7-9

9- 11 + 180° 11 - 13 7-8. 5 7-8. 5 6-8

11 - 13 10- 14 11 - 15 11 -15 11 -13 5-6 4-6

52-58 3-4

4-6

(•) Tighten the nuts in two phases, following a crosswise pattern. (°) Apply threadlocking LOCTITE medium, type 242. (*) Lubricate nuts with engine oil before fitting.

1 -5

Vehicle overhaul data

BEVERLY 125cc

Assembly clearances

01 004

Piston and cylinder mating 125 cc

1 -6

(Values in mm)

Vehicle overhaul data

BEVERLY 125cc O Rings

01_005

NAME Compression ring Scraper ring Scraper ring

DIMENSIONS 57 x 1 57x1 57x2.5

CLEARANCE NAME A A A

ASSEMBLY CLEARANCE 0. 1 5 - 0 . 30 0. 1 0 - 0 . 30 0. 1 5 - 0 . 35

Compression ring 1st Oversize Scraper ring 1 st Oversize Scraper ring 1 st Oversize

57. 2 x 1 57. 2 x 1 57. 2 x 2. 5

A A A

0. 1 5 - 0 . 30 0. 1 0 - 0 . 30 0. 1 5 - 0 . 35

Compression ring 2nd Oversize Scraper ring 2nd Oversize Scraper ring 2nd Oversize

57. 4 x 1 57. 4 x 1 57. 4 x 2 . 5

A A A

0. 1 5 - 0 . 30 0. 1 0 - 0 . 30 0. 1 5 - 0 . 35

Compression ring 3rd Oversize Scraper ring 3rd Oversize Scraper ring 3rd Oversize

57. 6 x 1 57. 6 x 1 57. 6 x 2. 5

A A A

0. 1 5 - 0 . 30 0. 1 0 - 0 . 30 0. 1 5 - 0 . 35

SHIMMING METHOD FOR LIMITING THE COMPRESSION RATIO: CR = 12 * 1 3 : 1 Note: The "A" measurement refers to the piston projection, i. e. it indicates how much the piston top surface projects above the cylinder upper surface. The more the piston sticks out of the cylinder, the thicker the base gasket to be fitted will be (to recover the correct compression ratio) and vice versa.

FIT THE GASKETS SHOWN IN THE TABLE ACCORDING TO SIZE "A"

01 006 N. B. MEASUREMENT "A" IS TO BE TAKEN WITHOUT ANY GASKET BETWEEN THE CRANKCASE AND THE CYLINDER.

MEASUREMENT "A"

GASKET THICKNESS

2. 2 - 2. 4

0. 4 ± 0. 05

2. 4 - 2. 6

0. 6± 0. 05

1 -7

BEVERLY 200 cc

Vehicle overhaul data Assembly clearances

01_007

Piston and cylinder mating 200 cc PART

DIMENSIONS

Cylinder

72 +0. 018 72 -0. 010

71. 9 6 7 ±0. 014

Piston

ASSEMBLY

MATING CLAS SES CLASS

CYLINDER

PISTON

71. 990-71. 997

71. 997-72. 004

C D

72. 004 - 72. 011

71. 953-71. 960 71. 960 - 71. 967 71. 967-71. 974

72. 011 -72. 018

71. 974-71. 981

0. 030 0. 044

O Rings

NAME

DIMENSIONS

CLEARANCE NAME

ASSEMBLY CLEARANCE

Compression ring

72 x 1. 5 72 x 1

0. 1 5 - 0 . 30

A A

0. 20 - 0. 40

Scraper ring Scraper ring

1 -8

72 x 2. 5

0. 20 - 0. 40

BEVERLY 200 cc

Vehicle overhaul data

SHIMMING METHOD FOR LIMITING THE COMPRESSION RATIO: CR = 11 + 1 2 : 1

Note: The "A" value to be measured is referred to the piston recess. It indicates the amount by which the surface formed by the piston crown lowers compared to the surface formed by the cylinder upper part. The more the piston descends into the cylinder, the less the base gasket to be applied (to recover the compression ratio) will be, and vice versa.

FIT THE GASKETS SHOWN IN THE TABLE ACCORDING TO SIZE "A"

N. B. THE "A" VALUE MUST BE MEASURED WITHOUT ANY GASKET ASSEMBLED BETWEEN THE CRANKCASE AND THE CYLINDER, AND AFTER HAVING SET TO ZERO THE COMPARATOR COMPLETE WITH STAND ON A GROUND SURFACE.

01 008

End play between driving shaft and connecting rod - Engine 125 - 200 cc 4T 4V LEADER

01_009

1 -9

Vehicle overhaul data Checking the crankshaft alignment

Measure the diameters on both axes X and Y Standard Diameter (125-200 cc) Class 1

28. 998 - 29. 004

Class 2

29. 004-29. 010

01 010

Maximum allowable misalignment: A = 0. 15 mm B = 0. 01 mm C = 0. 01 mm D = 0. 10 mm

Specific tools: Stand and comparator Crankshaft aligning tool

020335Y 020074Y

Crankcase - Crankshaft - Half crankshaft bearings

1 -10

Special tools Specific tools for BEVERLY 125-200 cc

RECOMMENDED TOOLS NAME Engine support - to be fitted with the following parts:

PART NO. 002095Y

15-Tube, 22-Cross member, 23-Nut, 44-Plate, 46-Clamp Snap ring pliers

002465Y

Drift for removing thrust rings from steering head tube

020004Y

Crankshaft aligning tool

020074Y

Support for air heater "METABO HG 1500/2"

020150Y

Air heater "METABO HG 1500/2"

020151Y

Crankcase separation plate

020262Y

Mitivac-type vacuum pump

020329Y

Stroboscopic gun for two- and four-stroke engines

020330Y

Digital multimeter

020331Y

Digital rev counter

020332Y

Single battery charger

020333Y

Multiple battery charger

020334Y

Magnetic stand and comparator

020335Y

Multimeter adaptor (for peak voltage measuring)

020409Y

Steering tube lower bearing extractor

020458Y

Drift for fitting bearing on steering tube

020459Y

Exhaust gas analyser

2-2

494929

Special tools

NECESSARY TOOLS NAME Steering seat installer, to be fitted with parts:

PART NO. 001330Y

001330Y009-For lower seat, 001330Y010-For upper seat Bell 15 mm pliers

001467Y Part. 9 001467Y014

Flywheel extractor

008564Y

Steering tube ring nut spanner

020055Y

Oil pressure gauge

020193Y

Half pulley fitting sheath

020263Y

Piston fitting band (125 cc engine)

020287Y

Valve sealing ring drift

020306Y

32 x 35 mm driven pulley shaft bearing fitting adaptor

020357Y

42 x 47 mm hub bearing fitting adaptor

020359Y

52 x 55 mm hub bearing fitting adaptor

020360Y

20 mm hub bearing fitting guide

020363Y

25 mm driven pulley ball bearing fitting guide

020364Y

Drive pulley stop spanner (125 cc engine)

020368Y

28 x 30 mm Driven pulley ball bearing fitting adaptor

020375Y

Adaptor sleeve

020376Y

Tool for removing valve lock cones

020382Y

Bushing (valve remover)

020382Y011

Piston fitting band (200 cc engine)

020393Y

15 mm hub bearing fitting guide

020412Y

Clutch bell housing stop spanner

020423Y

Driven pulley roller casing drift

020424Y

Flywheel-side oil seal drift

020425Y

Piston fitting fork

020426Y

Piston projection support

020428Y

Piston pin retainer fitting tool (125 cc engine)

020430Y

Valve oil seal extractor

020431Y

Oil pressure gauge connection

020434Y

17 mm shock absorber support bearing fitting guide

020439Y

Water pump overhauling tool

020440Y

Drive pulley stop spanner (200 cc engine)

020442Y

Driven half pulley spring compressor tool

020444Y

24 mm adaptor

020456Y

37 mm adaptor - For axle and driven pulley bearing

020477Y

30 mm guide - For fitting hub bearings

020483Y

Fork oil seal removing tool

020487Y

Piston pin retainer fitting tool (200 cc engine)

020488Y

Hub cover support pillar kit

020489Y

Compass flywheel stop spanner

020565Y

2-3

TABLE OF CONTENTS

MAINTENANCE AND TROUBLESHOOTING

Maintenance

Safety tightenings: refer to the chapter "Predelivery Operations". (â&#x20AC;˘) Refer to rules on page 3-11

3-2

Maintenance Carburettor - Disassemble all carburettor components, accurately wash them in solvent, then dry them with compressed air. To ensure thorough cleaning, pay special attention to the passages in the carburettor body. - Carefully check the condition of all components. - The throttle must slide freely in the chamber, if the play is excessive because or wear, replace the throttle. - Replace the carburettor if the chamber shows signs of wear as to prejudice the valve's regular seal or free sliding (though it is new). - When reassembling the carburettor, it is a good rule to replace the gaskets.

Characteristics:

* Identification letter may be changed every time carburettor is updated.

Caution | - Petrol is highly explosive. Always fit new seals and gaskets to prevent leakage.

1. Diaphragm cover - 2. Throttle valve spring - 3. Conical needle support - 4. Conical needle spring - 5. Conical needle - 6. Throttle valve diaphragm - 7. Automatic starting device - 8. Idle speed adjusting screw - 9. Accelerating pump rocker - 10. Idle mixture adjusting screw - 1 1 . Float pin -12. Accelerating pump assembly 13. Float-14. Float chamber-15. Idling jet-16. Main jet -17. Diffuser -18. Float chamber drain screw. 03 001

3-3

Maintenance Spark plug Check and replacement Warning - Remove the spark plug when the engine is cold. Replace the spark plug every 12, 000 km. The use of unsuitable ignition control units and spark plugs other than those specified can seriously damage the engine. Recommended spark plug: NGK CR 8 EB - Put the vehicle on the central stand. - Open the door on the left side of the vehicle by levering in the recess in the lower part of the door after removing the screw. - Disconnect the spark plug HV cable cap. - Unscrew the spark plug with the spanner provided. - Check the spark plug to see if the insulator is cracked, the electrodes are worn out or excessively sooty. Also check the condition of the seal washer and measure the spark gap with a suitable thickness gauge. Spark gap: 0. 7 - 0. 8 mm - If necessary adjust the spark gap by carefully bending the side electrode. If the spark plug has any of the defects mentioned above, replace it with a plug of the recommended type. - Insert the plug into the hole with the proper inclination, screw it in fully by hand and then tighten it with the specially designed spanner. Tightening torque: Sparkplug: 1 2 - 1 4 N m - Push the spark plug cap all the way down onto the spark plug and then proceed to the reassembly.

03 002

03 003

Air filter - Remove the left footboard and the left side panel as described in Chapter 8 - Bodywork. - Remove the cleaner cap after loosening the 9 fixing screws. - Pull out the filter element. - Replace the air filter with a new one.

Note: Check and if necessary blow the air filter every 6, 000 km. Direct the air jet from the inside to the outside of the filter (i. e. in the opposite direction to the air flow during normal engine operation). Every 6, 000 km, during the scheduled service, remove the retainer, take off the rubber cap from under the filter box as shown in the figure and drain any oil residues.

Cleaning (Every 12, 000 Km): - Wash with water and shampoo. - Dry with light jets of compressed air and wipe with a clean cloth. - Soak with a 50% fuel-oil mixture with SELENIA AIR FILTER OIL - Let the filter cartridge drip and then squeeze it between the hands without wringing. - Refit the filter element.

3-4

03 004

Warning - if the vehicle is mostly used on dusty roads, the air filter needs to be cleaned at shorter intervals than indicated in the Maintenance Schedule.

Warning - Do not run the engine if the air filter is not in place as this would result in excessive wear of the cylinder and piston as well as in damage to the carburettor.

Maintenance Engine oil level In four-stroke engines oil is used to lubricate the valve gear components, the crankshaft bearings and the power plant. A lack of engine oil can cause serious damage to the engine. In all four-stroke engines, oil deterioration and consumption are, to some extent, normal, especially during running-in. Consumption partly depends on the riding style (for example, constantly riding at full throttle increases oil consumption).

Checking the oil level Perform this operation when the engine cold, as described below: 1) Put the vehicle on its central stand on a flat surface. 2) Unscrew dipstick «A», dry it with a clean cloth and refit by screwing it completely. 3) Remove the dipstick again and check that the oil level is between the MAX and MIN marks on the dipstick; top up if necessary. The MAX level mark indicates an amount of about 1100 cc of engine oil. The level will be lower if checked after using the vehicle (i. e. when the engine is hot). To obtain a correct indication of the oil level, wait for at least 10 minutes after switching off the engine.

Check that the gauze strainer and drain plug O-rings are in good condition. Lubricate the O-rings and refit the gauze strainer and the oil drain plug. Tighten the drain plug with the prescribed torque. Fit the new filter cartridge taking care to lubricate the Oring before refitting. Fill with fresh engine oil. Since a certain amount of oil remains in the circuit, the replenishment must be made by adding approximately 600 - 650 cc of fresh oil through cap « A». Subsequently start the engine, let it idle for a few minutes and then switch it off. After about 5 minutes, check the level and if necessary top up without exceeding the MAX level. The filter cartridge must be replaced every time the oil is changed. For top-ups and renewals use fresh oil of the Selenia HI Scooter 4 Tech type. Note: Renew the oil when the engine is hot.

Tightening torque: Engine oil drain plug: 24-30 N m Recommended oil: Selenia HI Scooter 4 Tech

Topping up If the oil level is too low, top up by adding fresh oil without exceeding the MAX level. Approximately 400 cc of oil are needed to restore the level between the MIN and MAX marks.

Oil pressure warning light A warning light on the instrument panel comes on when the ignition key is turned to the "ON" position. The light must go out after the engine has started. Should the warning light come on while braking, idling or cornering, check the oil level and the lubrication system as soon as possible.

03 006

Renewing the oil and the filter The oil and the filter must be renewed every 6, 000 km. Drain all the oil from the engine through gauze strainer drain plug «B», on the flywheel side. To facilitate the outflow, loosen cap/dipstick «A». Once the oil has drained completely through the drain hole, unscrew oil filter cartridge «C» and remove. 03 007

3-5

Maintenance Checking the hub oil level - Put the vehicle on the central stand on level ground. - Unscrew oil dipstick «A», wipe it with a clean cloth, reinsert it and then screw it in fully. - Pull out the dipstick and check that the oil reaches the lower notch (see figure). If the oil level is below the MAX mark, pour fresh oil into the hub until the correct level is restored. - Reinsert the dipstick and screw it tight. The notches on the hub oil dipstick, with the exception of the MAX mark, are meant for other models and fulfil no specific function on this vehicle. 03 008

Renewing the hub oil - Remove oil filler plug «A». - Unscrew oil drain plug «B» and drain all the oil. - Re-tighten the oil drain plug and then fill the hub with fresh oil.

Recommended oil: TUTELA ZC 90 Hub oil capacity: ~ 250 cc Tightening torques: Hub oil drain screw: 15-17 N m 03 009

3-6

Maintenance Engine cooling Filling with engine coolant The level of the fluid must be checked every 6, 000 km when the engine is cold. Follow these steps: - Put the vehicle on the central stand on level ground. - Turn out the screw shown in the figure and remove the expansion tank cap on the right side of the vehicle. - Remove the expansion tank cap and top up if the coolant is below or near the MIN level in the expansion tank. The level of the fluid should always be between the MIN and MAX marks. - To check the level, look into the expansion tank: a mark in the filler wall shows the MIN and MAX levels. - The coolant consists of a 50 percent mixture of de-mineralized water and antifreeze solution with a base of ethylene glycol and corrosion inhibitors.

W a r n i n g . to prevent the coolant from leaking out of the expansion tank during use, be sure to never exceed the MAX level when refilling.

03 011

Checking the brake fluid level The front and rear brake fluid reservoirs are located on the pumps installed on the handlebar cover. Follow these steps: - Put the vehicle on the central stand and turn the handlebar to the central position; - Check the level of the fluid through the sight, shown in the figure. A certain decrease in the level of the fluid occurs as a result of pad wear. 03 012

Restoring the brake fluid level Warning

- Only use brake fluid classified as DOT 4.

Use the following procedure: Loosen the two screws, remove the reservoir cap, remove the gasket and top up only with the prescribed fluid without exceeding the maximum level.

Brake fluid type: TUTELA TOP 4

03 013

3-7

Maintenance Warning - Keep the brake fluid away from the skin, the eyes and clothing. In case of contact, rinse generously with water. Warning - The brake fluid is highly corrosive. Take care not to spill it on the paintwork. Warning - The brake fluid is hygroscopic, i. e. it absorbs humidity from the air. If the humidity contained in the fluid exceeds a given concentration, the braking action becomes insufficient. Never draw the fluid from open or partly empty containers. 03 014

Under normal climatic conditions the fluid should be renewed every 20, 000 km, or in any case every two years.

N. B.: Change the brake fluid and bleed the system as described in Chapter 7-Braking system.

Steering lock Disassembly with lock turned to "OFF" - Remove the rear shield as described in Chapter 8Bodywork. - Remove the immobilizer aerial shown in the figure.

03 015

- Disconnect the wiring. - Pull out the retaining spring shown in the figure and remove the ignition switch.

03 016

3-8

Maintenance - Push the bolt lightly and extract the retainer from the milled part shown in the figure. - Extract the bolt assembly from the lock body. - To refit, follow the reverse procedure.

03 017

Removal with lock in LOCK position The bolt retaining spring is not accessible in the LOCK position. It is then necessary to drill the bolt as show in the figure to eject it. Note: To refit the bolt from this position, first disengage the steering lock by putting the lock body (inner and outer part) in the OFF position. Proceed as described in the previous paragraph.

03 018

Adjusting the headlight - Place the unloaded vehicle on a level surface, 10 metres from a half-lit white screen, with the tyres inflated to the prescribed pressure. Ensure that the axis of the vehicle is perpendicular to the screen. - Draw a horizontal line on the screen 69-72 cm above the ground. - Switch on the headlight, turn on the low beam and check that the horizontal line that divides the dark area from the lighted area is not above the line previously drawn on the screen. To shift the headlight, turn the adjusting screw in the glove compartment (see figure).

03 020

3-9

Maintenance Checking the spark advance - To check the spark advance, use the stroboscopic lamp with the induction clamp connected to the spark plug feeder cable. - Connect the induction clamp paying attention to the polarity (the arrow stamped on the clamp must face the spark plug). - Place the lamp selector in the central position (1 spark = 1 crankshaft revolution as in 2-stroke engines). - Start the engine and check that the lamp works properly, and that the revolution counter can also read high engine speeds (e. g. 8, 000 rpm). - If flashing or rpm reading instabilities are noted (e. g. halved values), increase the resistive load on the spark plug feeder cable (10-15 kQ in series at HV cable). - Remove the plastic cover from the slotted hole on the flywheel cover. - Using the lamp flash phase shift corrector, align the reference mark on the flywheel cover with the level on the water pump drive. Read the degrees of advance on the stroboscopic lamp. - Check the revolving speed corresponding to the degrees of advance in the tables below. - If any discrepancy is found, check the pick-up and the control unit feeders (positive-negative). If necessary, replace the control unit.

- An unprogrammed control unit prevents the engine from exceeding 2, 000 rpm. - A programmed control unit allows the engine to revolve within prescribed limits. 125cc engine: 200 cc engine:

from 10°± 1° at 2, 000 rpm to 34° ± 1 ° at 6, 000 rpm from 10°± 1° at 2, 000 rpm to 32°± 1° at 6, 500 rpm

Specific tool: 2-stroke and 4-stroke stroboscopic gun 020330Y

03 021

Spark advance variation curve 125 cc engine

RPM LIMITER First level Trip level

10700

Second level

±50

11000±50

±50

Restore level Spark

10600 1 spark

10900 ±50

suppression

out of 7

out of 3

2 sparks X 1000 rpm 03 022

Spark advance variation curve 200 cc engine

RPM LIMITER First level

Second level

Trip level

9900

±50

10100150

Restore level Spark

9800 ±50 1 spark

10000+-50

suppression

out of 7

out of 3

2 sparks X 1000 rpm 03 023

3-10

Maintenance Checking the CO concentration - This check can be required when engine operation is irregular or while adjusting the slow running. - The test must be carried out after carefully washing all carburettor components and making sure that the air filter is clean and the spark plug is in good condition. 1) Warm up the engine by riding at a speed of approximately 50 km/h for about 5 minutes. This will allow the automatic starting device to cut out its circuit. 2) Switch off the engine for the minimum time required to perform steps 3) and 4). 3) Fit an extension tube approximately 50 cm in length to the exhaust gas outlet on the silencer. 4) Take special care in ensuring the seal between the silencer and the tube. Insert the exhaust gas analyser probe into the tube. 5) Connect the multimeter thermometer to the sump using an oil filler plug specially prepared for the insertion of the probe. 6) Start the engine and, before proceeding to tune up the idle speed, ensure that the oil temperature is 7080Â° C. 7) Allow the idle speed to stabilize for about a minute. 8) Without opening the throttle and using the specially designed flow screw, adjust the speed of the engine to 1, 650 Âą 50 rpm. 9) Adjust the flow screw until the CO percentage is 3. 8 Âą 0. 7 percent. 10) Slowly rotate the throttle twist grip until the engine reaches a speed of 4, 000 rpm, then close the throttle again. Check that the idle speed is the same as specified above. If not, repeat the procedure from step 3).

03 024

Specific tool: Digital revolution counter: 020332Y Exhaust gas analyser: 494929 Digital multimeter: 020331Y 03 025

3 - 11

Troubleshooting

SYNTOM Poor performance

Rear wheel turns when engine is idling Starting problems

3-12

POSSIBLE CAUSE

INTERVENTION

Carburettor dirty. Fuel pump or one-way valve faulty.

Remove, wash with solvent and dry with cornDressed air, or replace

Timing failure or timing system parts worn

Reset timing phase or replace any worn parts.

Silencer blocked

Renew.

Air filter clogged or dirty

Remove the sponge, wash it in water and shampoo, and then soak it in a 50 percent mixture of petrol and a specific oil (Selenia Air Filter Oil). Squeeze the sponge between the hands without twisting, allow it to drip and then replace it.

Automatic choke faulty

Check the mechanical sliding and the electrical connection and ensure that power is supplied. If necessary replace.

Clutch slippage

Check and if necessary replace the clutch assembly and/or the clutch bell housing

Automatic transmission faulty

Check the rollers and the sliding of the pulleys. Replace any faulty parts and lubricate the movable driven pulley guide with Montblanc Molybdenum Grease.

Drive belt worn

Renew.

Poor compression: piston rings, cylinder, valves and valve seats worn

Replace worn parts.

Engine oil level exceeds MAX mark

Find out the cause and adjust the oil level.

Idle speed set too high

Adjust the slow running and, if necessary, the CO concentration.

Faulty clutch

Check the clutch springs/weights

Battery is down

Check the battery charge. If the battery shows any signs of sulphation, replace it with a new one (refer to page 4-13 for installing instructions).

Carburettor dirty or fuel pump faulty

Remove, wash with solvent and dry with compressed air, or replace

Spark plug faulty or spark advance incorrect

Replace the spark plug or check the ignition circuit components.

Air filter clogged or dirty

Automatic choke faulty

Check the mechanical sliding and the electrical connection and ensure that power is supplied. If necessary replace.

Engine flooded

Open the throttle wide and try to start the engine. If it does not start, remove the spark plug, dry it and, before replacing it, crank the engine to expel the excess fuel, taking care to keep the spark plug cap connected to the spark plug and the spark plug to earth. If the fuel has run out, refuel and then start the engine.

Incorrect valves seal or wrong valves adjustment

Check head and/or adjust clearance.

Starting speed too low or starting motor anc system faulty

Check starter motor, starting system and torque limiter

Modified fuel characteristics

Drain worn fuel and refuel

Troubleshooting

INTERVENTION

SYNTOM

POSSIBLE CAUSE

Rich mixture

Calibrated air holes on carburettor obstructed Remove, wash in solvent and dry with compressed air Float valve faulty Check float and valve operation

Weak mixture

Level in float bowl too high

Restore the level in the float chamber by bending the fuel inlet needle thrust blade on the float so that the float is parallel with the chamber surface when the carburettor is in an upside-down position.

Automatic choke stays activated

Check the mechanical sliding and the electrical connection and ensure that power is supplied. If necessary replace.

Air filter dirty

Carburettor jets clogged

Remove, wash in solvent and dry with compressed air.

Float valve faulty

Check the sliding of the float and the operation of the valve. Restore the level in the float chamber by bending the fuel inlet needle thrust blade on the float so that the float is parallel with the chamber surface when the carburettor is in an upside-down position.

Level in float bowl too low

Low compression

Excessive oil consumption / excessive smoke from exhaust pipe

Tank breather clogged

Restore proper tank aeration.

Feed pipes choked or throttled

Restore proper fuel flow.

Intake manifold cracked or clamps poorly Replace the intake connection and check for tightened any abnormal air inleakage. Incorrect valve adjustment Adjust valve clearance. Valves overheated Remove the cylinder head and the valves, then grind or replace the valves. Valve seats distorted/worn Replace head assembly. Cylinder worn. Piston rings worn or broken. Replace cylinder-piston assembly or piston rings. Piston rings worn or broken or improperly Replace cylinder-piston assembly or piston fitted rings only. Oil leaks from joints or gaskets Check and replace the gaskets or restore the seal of the joints Worn oil retainer Replace valve oil retainer. Valve guides worn

Insufficient lubrication pressure

Oil level too low

Check and if necessary replace head assembly. Top up with recommended oil type (Selenia HI Scooter 4 Tech).

Oil filter excessively dirty

Replace the cartridge filter.

Oil pump play excessive

Carry out the dimensional checks on the oil pump components. Check the by-pass and if necessary replace it. Carefully clean the by-pass area.

By-pass stays open

3-13

Troubleshooting

SYNTOM

POSSIBLE CAUSE

Engine tends to cut out at full throttle

Main jet dirty. Carburetion lean

Wash the jet with solvent and then dry it with compressed air

Water in carburettor

Empty the float chamber using the specially designed drain screw

Float level incorrect

Fuel supply circuit faulty

Check and if necessary replace the fuel Dump. Check the vacuum intake and the duct seal.

Idling jet dirty

Wash in solvent and dry with compressed air.

Starting device stays activated

Check: electrical connections, circuit continuity, mechanical sliding and power supply; replace as necessary

Spark plug faulty or spark advance incorrect

Replace the spark plug or check the ignition circuit components.

Compression end pressure too low

Check thermal unit seals and replacy any worn parts.

Idle speed wrongly tuned

Tune up using a rev counter

Cut-off device broken

Check the operation of the valve, membrane and spring; check if the air adjusters and the sponge filter are clean

Incorrect timing

Restore correct timing and check timing system parts.

Air filter clogged or dirty

Starting device faulty

Check electrical connections, circuit continuity, mechanical sliding, and power supply

Fuel pump faulty

Check the seal of the vacuum duct.

Jets loose

Check that the main and idling jets are securely seated

Float level incorrect

Clutch faulty

Check for the presence of grease on the clutch weights Check that the area of contact of the clutch weights with the bell housing is chiefly at the centre and equivalent for the three weights Check that the bell housing is not scored or abnormally wor

Engine tends to stop when idling

Fuel consumption excessive

Clutch irregular operation or grapping

3-14

INTERVENTION

Troubleshooting

SYNTOM

POSSIBLE CAUSE

INTERVENTION

Braking system

Poor braking

Check the wear of the brake pads (MIN. 1. 5 mm). Ensure that the brake discs are not worn, scored or distorted. Check the brake fluid level in the pumps and if necessary renew the brake fluid. Check for air in the circuits and bleed it as necessary. Ensure that the front brake caliper moves along the disc axis.

Brake disc loose or distorted

Check the tightening of the brake disc screws. Using a comparator and with the wheel fitted on the vehicle, measure the axial runout of the brake disc.

Coolant leaking from the hydraulic brake circuit

Flexible connections, piston or brake pump gaskets faulty. Replace

Pistons defective sliding

Check caliper, renew any damaged part.

Brake disc loose or distorted

Check the tightening of the brake disc screws. Using a comparator, measure the axial shift of the disc with the wheel fitted on the vehicle.

Pump compensation holes clogged.

Clean thoroughly and blow with compressed air.

Rubber gaskets swollen or stuck.

Replace the gaskets.

Brakes overheating

Battery

The battery requires regular maintenance. If the vehicle is to remain idle for a month or more, the battery must be charged from time to time. Over a period of 3 months disuse, the battery will discharge completely. When installing the battery, make sure you connect t)lack ground lead to the negative terminal and the red lead to the positive terminal.

Steering controls and suspensions

Steering stiff

Check the tightening of the upper and lower ring nuts. If steering rotation is still uneven, check the bearing ball rolling races. Replace if the races appear to be embedded, or if the balls are flattened.

Steering play excessive

Ditto

Suspension noisy

If the front suspension is noisy, check the operation of the front shock absorber, the condition of the ball bearings and of the related locknuts, the rubber stops and the sliding bushes. Also check the tightening torques of the wheel hub, the brake caliper, the brake disc and the shock absorber on the hub and steering tube connections.

Oil leaking from suspension

Replace the shock absorber. Check the wear of the steering caps and adjusters.

Electronic ignition device faulty

With the ignition switch in the ON position, jumper contacts 1 (Blue-Black) and 5 (RedBlue) on the electronic control unit connector. If the turn indicators do not light up and stay lit when the related switch is operated, replace the regulator, otherwise check the wiring and the switch.

Turn indicators do not work

3-15

ELECTRICAL EQUIPMENT

20 34

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

4-2

VOLTAGE REGULATOR SIDESTAND SWITCH FRONT FUSE BOX STARTER RELAY SWITCH FLYWHEEL MAGNETO STARTER MOTOR HELMET COMPARTMENT LAMP BUTTON HELMET COMPARTMENT LAMP 12V SOCKET REAR FUSE BOX ANALOGUE INSTRUMENT PANEL DIGITAL DISPLAY LIGHTS SELECTOR SWITCH WITH HIGH BEAM FLASH REAR BRAKE LIGHT BUTTON FRONT BRAKE LIGHT BUTTON HEADLIGHT WITH TURN INDICATORS TURN INDICATOR SWITCH HORN BUTTON HORN

20 21 22 23 24

REAR LIGHT WITH TURN INDICATORS NUMBER-PLATE LIGHT BATTERY ENGINE STOP SWITCH WHEEL REVOLUTION SENSOR

25 26 27 28 29

LIGHTS SWITCH START BUTTON STAND BUTTON PREWIRING IGNITION SWITCH SADDLE OPENING BUTTON OUTSIDE TEMPERATURE SENSOR ENGINE STOP RELAY SWITCH LIGHTS RELAY SWITCH IMMOBILIZER AERIAL

30 31 32 33 34 ELECTRONIC IGNITION DEVICE 35 AUTOMATIC CHOKE 36 SPARK PLUG 37 HVCOIL

Electrical equipment diagram Electrical system components 1. Horn. 2. Headlight (two 12V-5W side light bulbs, two 12V55W dipped/full beam bulbs, two 12V-1OW left and right turn indicator bulbs). 3. Outside temperature sensor. 4. Front brake light button. 5. Rear brake light button. 6. Electric stand button prewiring. 7. Wheel turns sensor. 8. Analogue instrument panel (three 12V-2W instrument panel light bulbs, seven 12V-1. 2W bulbs for: left turn indicator warning light, right turn indicator warning light, full beam warning light, engine stop warning light, sidestand down warning light, oil pressure warning light, reserve fuel warning light, coolant temperature warning light). 9. Digital instrument panel assembly. 10. Saddle opening button. 11. Horn button. 12. Turn indicators switch. 13. Lights selector switch with full-beam flash. 14. Engine stop relay switch. 15. Headlight relay switch. 16. Engine stop switch. 17. Lights switch. 18. Start button. 19. Radio-interphone prewiring. 20. Front fuse carrier (1-2-4: 4A fuses, 3: 7. 5 fuse). 21. Ignition switch.

22. Immobilizer antenna. 23. Electronic ignition device. 24. Diode. 25. Thermal switch. 26. Electric fan. 27. Side stand switch. 28. Electric stand prewiring. 29. Helmet compartment lighting button. 30. Actuator for saddle opening mechanism. 31. Thermistor. 32. Automatic choke. 33. Spark plug. 34. HV coil. 35. Helmet compartment lamp. 36. Regulator. 37. Starting relay switch. 38. Rear fuse carrier (5: 4A fuse, 6: 10A fuse, 7-8: 15A fuses). 39. Starter motor. 40. Engine oil pressure sensor. 41. 12V-10Ah battery. 42. 12V electrical socket. 43. Flywheel magneto. 44. Pick-up. 45. Number plate light, bulbs 12V-5W. 46. Rear light (two 12V-3W side light bulbs, three 12V10W left and right turn indicator and brake light bulbs). 47. Fuel level transmitter.

WIRE COLOUR CODING: B=White - BUBlue - G=Yellow - Mr=Brown - N=Black - BV=White-Green - GN=YellowBlack - Gr=Grey - Rs=Pink - R=Red - Vi=Purple - V=Green - VN=Green-Black - BN=White-Black - BBI=White-Blue - GV=Yellow-Green - Ar=Orange - A=Light blue - GrBI=Grey-Blue - GrN=Grey-Black.

Warning - When working on the electrical system, pay special attention to the correct connection of wires leading to the electronic ignition unit and observe the polarity and connector colour coding.

4-5

Electrical diagrams

Ignition section

04 002

4-6

Electrical diagrams

Lights and automatic choke section

04 003

4-7

Electrical diagrams

Battery recharge and starting section

04 004

4-8

Electrical diagrams

Start permissive buttons and level indicators

04 005

4-9

Electrical diagrams

Digital instrument panel

04 007

4-11

Electrical equipment Electronic ignition (immobilizer system) The electronic ignition system is d. c. -fed and comes complete with an immobilizer anti-theft system built into the electronic control unit. The ignition system consists of: - Electronic control unit - Immobilizer aerial - Master and service key with built-in transponder - HVcoil - Diagnostic LED

The diagnostic LED also works as a deterring blinker. This function is activated every time the ignition switch is turned to the "OFF" position, when the sidestand is lowered, or the emergency stop switch is set to the "OFF" position. It remains activated for 48 hours in order not to affect the battery charge. When the ignition switch is turned to the "ON" position, the deterring blinker function is deactivated. Subsequently, a flash confirms the switching to the "ON" status. The duration of the flash depends on the programming of the electronic control unit (see figure).

If the LED is out and stays out when the ignition switch is turned to "ON", check if:

- Battery voltage is present - The fuses are in working order, main fuse 15A (N째 7). If the deterring LED stays out, follow these steps to check that power is supplied to the control unit: Disconnect the control unit connector and check the following: - Battery voltage is present between terminal no. 4 (Red/Black) and earth. - Battery voltage is present between terminals n o . 4 (Red/Black) and 8 (Negative) as shown in the figure.

4-12

Electrical equipment - Battery voltage is present between terminals nos. 5 and 8 with the ignition switch in the "ON" position, the sidestand is up and the emergency stop switch is in the "RUN" position. If no malfunction is found, replace the control unit, otherwise check the wiring and the following components: -

Engine stop relay switch Emergency stop switch Sidestand contacts Ignition switch contacts

Uncoded ignition system When the ignition system has not been coded yet, the engine can be run at a maximum of 2, 000 rpm. Any attempt to rev up causes the engine to misfire. To code the system, pull up the sidestand, set the emergency stop switch to the "RUN" position and use the MASTER (brown) and SERVICE (black) keys as follows: - Insert the MASTER key, turn the ignition switch to "ON" and maintain this position for 2 seconds (minimum 1 second, maximum to 3 seconds). - Insert all the blue keys available in succession, each time turning the ignition switch to "ON" for 2 seconds. - Insert the MASTER key again and turn it to "ON" for 2 seconds. The time needed to change keys should not exceed 10 seconds. A maximum of 3 service (black) keys can be coded in the same coding session. It is essential to observe the sequence and time limits as described above, otherwise the procedure will have to be restarted from the beginning. Once the control unit has been coded, an unbreakable relation is created between the control unit and the MASTER key transponder.

This relation allows new service keys to be coded in case of loss, replacement, etc. Each new storing operation cancels the previous one. Should the service keys lose the data stored in them, it is essential to carefully check the shielding of the highvoltage system: Shielded cap resistance: ~ 5000 Q. The use of resistive spark plugs is recommended (see figure).

Diagnostic codes After the flash that denotes the switching to the "ON" status, the system may display a series of malfunction codes. The LED stays initially out for 2 seconds, then the diagnostic codes are displayed in 0. 5-second flashes. Once the malfunction code has been displayed, the LED stays lit to denote that ignition is impossible (see chart below).

4-13

Electrical equipment 2-FLASH CODE Example - Electronic control unit programmed, transponder absent and/or aerial malfunctioning Ignition inhibited - Vehicle immobilized

3-FLASH CODE Example - Electronic control unit programmed, aerial in working condition and transponder code unknown Ignition inhibited - Vehicle immobilized

04 013

2-flash diagnostic code If the 2-flash diagnostic code is displayed, check the following: - Check if the malfunction persists when the key (including the MASTER key) is changed. If the anomaly persists with any key, detach the control unit aerial connector and check the continuity of the aerial by means of multimeter 020331Y. Resistive value: ~ 7 - 9 Ohm If the value is not as specified, replace the aerial. If no anomaly is found, replace the control unit. Warning - Before performing the storing procedure on the new control unit, check that no malfunction code is signalled. This precaution is needed to avoid wasting a new control unit.

3-flash diagnostic code If the 3-flash diagnostic code is displayed, check if the anomaly persists after inserting the MASTER key into the ignition switch. - If the malfunction disappears when the MASTER key is used, proceed to code the service (blue) keys again. - If the anomaly persists, then the MASTER key and the control unit are not matched. In that case, replace the control unit and proceed to code the keys. The immobilizer system is in working order when, after turning the ignition switch to "ON", one 0. 7-second flash is emitted (see chart). In that case, ignition is possible.

Example - Electronic control unit programmed, transponder present, key programmed and aerial in working order Ignition enabled (normal operating conditions)

04 014

4-14

Electrical equipment Ignition system Once the immobilizer system has been enabled, it will be possible to obtain the spark at the plug through the HV coil and the signals coming from the pick-up. The basic power supply comes from the battery. The system is so tuned that any battery voltage reduction is immediately detected by the starting system and is virtually inconsequential to the ignition system. The pick-up is connected to the control unit by a single wire. As a result, the pick-up earth is connected to the control unit through the frame and the earth wire from the engine. To avoid hampering the ignition system during the starting process, it is essential that the engine-frame earth connection is as efficient as possible.

No power supplied to the spark plug If no power is supplied to the spark plug and the LED signals that ignition is possible, follow these steps:

- Check the pick-up Detach the control unit connector and check continuity between terminals nos. 2 (green) and 8 (black). The check involves the pick-up and its supply line:

Resistance: 105-124 Q

If the circuit is interrupted, repeat the check between the flywheel connector and the and the engine earth (see engine manual). If the measured values are not as specified, replace the pick-up, otherwise repair the wiring. If, on the other hand, the values are as specified, try replacing the control unit (without programming it) and ensure that the problem has been solved by checking that a spark is produced at the plug. Then proceed to program the control unit.

- Checking the HV coil primary circuit Detach the control unit connector and check continuity between terminals nos. 3 and 8 (see figure). Resistance: 0. 4-0. 5 Q If the resistance is not as specified, repeat the check directly on the positive and negative terminals of the HV coil primary circuit. If the resistance is as specified, proceed to repair the wiring or restore the connections, otherwise replace the HVcoil. 04 016

4-15

Electrical equipment - Checking the HV coil secondary circuit Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable end and the negative terminal of the HV coil (see figure). Resistance: ~ 3, 000 Âą 300 Q If the measured values are not as specified, replace the HV coil. To obtain a more accurate diagnosis, proceed to verify the peak voltage using multimeter adaptor. Specific tool: Multimeter adaptor 020409Y

- Pick-up Detach the control unit connector and connect the positive terminal to connector no. 2 and the negative terminal to connector no. 8 (see figure).

04 017

1 2 3 4 5 6 7 8

Crank the engine turn by operating the starter motor and measure the voltage produced by the pick-up. Pick-up voltage: > 2V If the voltage is not as specified, replace the pick-up. Note: The multimeter must be set to measure direct voltage. 04 018

- HVcoil With the control unit and the HVcoil normally connected, measure the voltage of the coil primary circuit during the starting test using the peak voltage adaptor and connecting the positive terminal to earth and the negative terminal to the coil positive connector. Voltage: > 100V If the voltage is not as specified, replace the control unit. Note: The positive terminal of the HV coil primary circuit is black in colour, whereas the negative terminal is coded in green. 04 019

Battery recharge system The battery recharge system consists of a three-phase generator and a permanent-magnet flywheel. The generator is directly connected to the voltage regulator. The latter is in turn directly connected to earth and to the battery positive terminal via the 15A (NÂ° 7) protection fuse. The system is therefore not connected to the ignition switch. The three-phase generator allows considerable recharging power, and at low rpm offers a good compromise between supplied power and idle speed stability. For this reason, it is essential that the slow running is adjusted as specified.

4-16

Electrical equipment Checking the voltage regulator With a fully charged battery and all lights out, measure the voltage at the battery terminals with the engine running at high speed. The voltage must not exceed 15. 2V. If a higher voltage is detected, replace the regulator.

If the voltage is less than 14V, proceed with the checks on the stator and its wiring. 04 020

Checking the stator Disconnect the voltage regulator connector and check for continuity between each yellow wire and the other two. Ohmic value: 0. 7-0. 9 Q

04 021

Also check that each yellow wire is insulated from earth. If any values are not as specified, repeat the checks directly on the stator. If incorrect values are still found, replace the stator, otherwise repair the wiring.

Checking the recharge system power output Connect the induction nippers of an ammeter to the positive cable of the voltage regulator. Measure the battery voltage and, after turning the lights on without starting the engine, wait for the voltage to steady at approximately 12V. Start the engine and measure the current supplied by the system with the lights on and the engine running at high speed. If the supplied current is less than 8A, repeat the test using a new regulator and/or stator.

4-17

Electrical equipment Checking the automatic starting device section For information on how to carry out the functional and resistive check of the component, refer to the engine section. Regarding the starting device power supply, keep the system connector attached and check that battery voltage is present on the two terminals when the engine is running (see figure). If no voltage is detected, connect the multimeter negative terminal to earth and the multimeter positive terminal to the orange wire on the automatic starting device. With the ignition switch in the "ON" position, check for the presence of battery voltage. If no voltage is detected, check the wiring connecting with the ignition switch and the two protecting fuses 15A (N째 8). If, on the other hand, battery voltage is present, repeat the check from the ignition control unit connector. After disconnecting the starting device, start the engine and keep it idling. Check for the presence of electrical power by connecting the multimeter positive terminal to terminal no. 5 (White-Green) and the negative terminal to terminal no. 7 (White/Black) (see figure). If no voltage is detected, replace the control unit after ensuring that the fuses are intact, otherwise check the wiring between the choke and the control unit, and if necessary replace the choke.

Turn indicators fail to operate If the turn indicators fail to operate, follow these steps: - Detach the control unit connector and check that there is battery voltage between terminal no. 4 (Red/ Black) and earth. - Carry out the same check between terminals nos. 4 and no. 8 (Black). - Repeat the check between terminals nos. 5 (White/ Green) and 8 (Black) with the ignition switch in the "ON" position, the sidestand up and the emergency switch in the "RUN" position.

If no voltage is detected, check the wiring, the connections and the condition of the main 15A fuse, otherwise follow this procedure: - Jumper terminals nos. 1 (Black/Blue) and 4 (Red/ Black) as shown in the figure. Operate the turn indicator switch alternately left and right and check that the lights come on. If so, the control unit is broken and will have to be replaced. Otherwise check the wiring between the control unit and the turn indicator switch and then repeat the test. If the wiring is intact and the turn indicators still fail to operate, replace the turn indicator switch as it is certainly faulty.

4-18

04 024

Electrical equipment Fuses The electrical equipment is protected by: 1. Four fuses «A» protecting the outside electrical socket, located under the right-hand side panel. 2. Four fuses «B» protecting the different circuits, located in the upper left portion of the glove compartment. The tables show the positions and specifications of the fuses installed on the vehicle.

Warning - Before replacing a blown fuse, trace and eliminate the fault that caused the blowing. Never attempt to replace a fuse using a different material (e. g. a length of wire) or a fuse having a greater amperage than prescribed.

04 028

04 029

N°

FUSE

N. 1 4A

Electric stand prewiring, starter relay switch coil, engine stop relay coil, engine disabled warning light, oil pressure warning light, reserve fuel warning light, coolant temperature warning light

N. 1 4A

Brake light bulb, starter relay switch inhibitor

N. 1 7, 5A

N. 1 4A

N°

FUSE

N. 1 4A

Digital instrument panel, diagnostic LED, radio/interphone prewiring

N. 1 10A

Headlight (high/low beam bulb)

N. 1 15A

General

N. 1 15A

Helmet compartment lamp, 12V socket, saddle electrical opening actuator

PROTECTED CIRCUITS

Horn, passing function, electric stand and radio/interphone prewiring Analogue instrument panel light bulbs, number-plate light bulb, front and rear parking light bulbs

PROTECTED CIRCUITS

4-19

Electrical equipment Instrument panel The instrument panel is divided into two parts, an analogue section fixed to the handlebar cover and a digital section integral with the handlebar cover. The analogue section includes: - Speedometer (mph-Km/h) - Fuel gauge - Coolant temperature warning light (red) - Reserve fuel warning light (amber) - Left-hand turn indicator warning light (green) - Right-hand turn indicator warning light (green) - High beam warning light (blue) - Emergency stop switch / sidestand down warning light (red) - Oil pressure warning light (red).

04 030

The digital section includes: - Five-digit display showing total kilometres/miles covered, trip kilometres/miles covered, kilometres/miles covered on the reserve, four-digit clock function. - Symbol indicating the kilometres/miles covered on the reserve. - Two-digit display showing the outside temperature. - Symbol indicating the total kilometres/miles covered. - Symbol indicating the trip kilometres/miles covered. - Clock display symbol. - Symbol denoting that temperature is nearing 0째 C. 04 031

Description of the functions controlled through the buttons Selecting the function to be displayed (total mileage counter, trip mileage counter, clock, distance covered on the reserve): Press the "MODE" button for less than 1 second. Resetting the trip mileage counter: Press the "SET" button for longer than 3 seconds while the trip counter is displayed. Setting the clock: Press the "CLOCK" button for longer than 3 seconds. Only the minute digits stay lit. Pressing the "SET" button causes the minutes to increase every 0. 5 seconds. Pressing the "SET" button for longer than 4 seconds causes the minutes to increase every 0. 1 seconds. Pressing the "CLOCK" button again lights up the hour digits and turns off the minute digits. The hour digits increase every 0. 5 seconds. Pressing the "SET" button for longer than 2 seconds causes the hours to increase every 0. 2 seconds. The time setting procedure ends if no button is depressed for 4 seconds and is enabled only if the vehicle is stationary. Selecting the unit: Pressing the "MODE" and "CLOCK" buttons simultaneously for longer than 3 seconds and turning the ignition key to the "ON" position displays the "SET" caption along with the selected unit. Description of the other functions Distance covered on the reserve: - The count is started when the reserve fuel contact has been closed for longer than 13. 5 seconds. The count is reset when the ignition key is turned to the "ON" position and the reserve fuel contact is open and stays open after the vehicle has travelled for 20 seconds. "ICE" logo: - Constantly lit when the temperature ranges between -20째 C and 3째 C. - The logo blinks (f = 2 Hz) for 40 seconds every time a temperature in the above range decreases by one degree.

4-20

Electrical equipment Temperature warning light Initial check at the same time as the LCD bar check. The warning light stays lit if the resistance of the thermistor is greater than 109 ± 3 Q. The warning light flashes with a frequency of 1 Hz if the resistance of the thermistor is greater than 500 kQ. At temperatures ranging from 70° C to 130° C the current in the thermistor must be less than 10 mA.

LCD characteristics 5 digits for the total mileage counter: maximum reading = 99999, minimum reading = 00000 4 digits for trip mileage counter: maximum reading = 999. 9, minimum reading = 0. 0 4 digits for the clock: maximum reading = 23: 59, minimum reading = 0: 00 4 digits for the distance covered on the reserve: maximum reading = 999. 9, minima reading = 0. 0 3 digits for the temperature: maximum reading = 50 (then "HI" is displayed), minimum reading = -20 (then "LO" is displayed) The "-" sign is always displayed next to the related figure. The digits are shared for the total and trip mileage counters, the clock, and the distance covered on the reserve. Non-significant digits should be out (with the exception of the minutes and the total). When the ignition key is turned to the "ON" position, all the bars light up at the same time for less than 2 seconds. When the ignition key is turned to the "OFF" position, all the bars go out.

Specifications Supply voltage 11-16V. Minimum supply voltage needed to avoid clock and trip counter reset 4. 5 V. Maximum working current with ignition key in ON position < 200 mA Maximum working current with ignition key in OFF position < 0. 5 mA Operating temperature range -20° C / +85° C Damage temperature > 90° C Rolling circumference 1708 mm Pulses per turn 16 Speedometer tolerance range (throughout scale) +8% / +12% Blue light km e mi units (factory setting km) Total distance covered stored in non-volatile and unalterable memory. Ambient temperature unit: degrees centigrade

4-21

Electrical equipment Sealed battery Putting a sealed battery into service If the vehicle is equipped with a sealed battery, servicing is limited to checking the charge level and, if necessary, recharging the battery. These operations must be performed during predelivery, and every six months of open-circuit storage. Therefore, in addition to checking and, if necessary, charging the battery before delivery, it is necessary to carry out these operations before storing the vehicle, and subsequently every six months.

Cleaning the battery Keep the battery clean, especially the top; coat the terminals with Vaseline. Warning - Never use fuses having a greater capacity than the one recommended. The use of a fuse of unsuitable capacity may result in serious damage to the whole vehicle or even cause a fire. Warning - To ensure maximum performance the battery must be charged before using the vehicle. Insufficient battery charge or low electrolyte level when first used will result in premature failure of the battery.

RECHARGING THE BATTERY FOLLOWING OPENCIRCUIT STORAGE 1) Checking the voltage Before installing the battery on the vehicle, measure the open-circuit voltage with an ordinary multimeter. - If the voltage exceeds 12. 60 V, the battery can be installed without recharging. - If the voltage is less than 12. 60 V, recharge the battery as described at item 2). 2) Constant-voltage charging method - Constant voltage: 14. 40-14. 70 V - Initial charging current: 0. 3-0. 5 x rating - Charging time: Recommended 10-12 hrs Minimum 6 hrs Maximum 24 hrs 3) Constant-current charging method - Initial charging current: 1/10 of rating - Charging time: Maximum 5 hrs Caution - When the battery is deeply discharged (far below 12. 6V), 5 hours' recharging may not be enough to obtain optimum performance. In these conditions, however, to avoid damaging the battery beyond repair, it is essential not to recharge it for more than 8 consecutive hours. Battery recharge Routine battery charging with the battery off the vehicle must be performed with battery charger 020333Y (single) or 020334Y (multiple), positioning the battery charge selector in relation to the type of battery (i. e. with a current equivalent to 1/10 of the battery rated capacity). Ensure you connect up to the battery with the correct polarity (+ to + and - to -).

4-22

If the vehicle is not used for some time (1 month or more) the battery must be periodically recharged. In three months the battery runs down completely. When refitting the battery take care not to invert the connections: the ground lead (black) is to be connected to the negative (-) terminal and the other lead (red) must be connected to the positive (+) terminal.

ENGINE

Engine Engine disassembly from frame Caution Caution gine cold.

- Take care when handling the petrol.

- Perform these operation with the en-

- Disconnect the battery. - Remove the saddle, and the upper and lower body sides (Chapter 8 - Bodywork) - Drain the coolant. - Disassemble the muffler assembly and relevant support, as described below. - Remove the rear wheel (Chapter 6 - Front/Rear Suspension) - Remove the accelerator control transmissions. - Disconnect the air filter sleeve and the manifold shown in the figure. - Disconnect the earth cable from the engine. - Disconnect the electrical devices on the carburettor and the starter motor feeder. - Detach the fuel delivery and return pipes to the injector and the coolant system pipes (head outlet and thermostat input). - Detach the H. V. cable from the spark plug. - Detach the generator harness from the vehicle electrical system.

Warning - When installing the battery, first fix the positive cable and then the negative cable.

05 001

Muffler assembly disassembly - Unloose the two fixings of the exhaust manifold on the head.

05 002

Unloose the 3 screws fixing the muffler to the supporting arm. Remove the muffler assembly.

05 003

5-2

Engine Supporting arm disassembly - Unscrew and remove the r. h. shock absorber to supporting arm lower fixing bolt - Unloose the arm to engine 2 fixing screws. - Remove the cotter pin and the safety plug; unloose the wheel spindle nut; to prevent the wheel from turning, apply the rear brake. - Remove the supporting arm.

05 004

Disassembly of l. h. shock absorber lower pin - Remove the bolt shown in the figure.

N. B.: To remove the shock absorber support, unscrew the two nuts on the left side and remove the screws.

05 005

Engine pin/swing arm disassembly -

Adequately support the engine. Remove the nut shown in the figure. Pull out the pin on the left side. Now the engine is free.

Engine assembly to vehicle - Perform the assembly in the reverse order observing the tightening torques indicated in Chapter 1. Warning take care not invert the position of the two accelerator control transmissions. Check that both show a slight play with the valve in contact with the register.

- Check the engine oil level, top up if necessary with oil of the recommended type. - Fill the cooling system. - Check the accelerator and electrical devices function.

FRONT AND REAR SUSPENSIONS

6-2

Front and Rear Suspensions Removing the front wheel - Remove the front brake caliper after loosening the brake disc fixing screws. - Remove the speed sensor.

06 001

- Loosen the axle locknut.

06 002

Loosen the two axle safety screws on the leg, on the brake caliper side. Pull out the axle.

06 003

6-3

Front and Rear Suspensions Overhauling the front wheel Check that the wheel bearings show no signs of wear. If the bearings need to be replaced, follow these steps: - To avoid damage, remove the plastic cap on the speed sensor side after unscrewing the five fixing screws. - Remove the two bearings on the speedometer gear side using pliers 14 or 34 and bell 9. - Remove the inner spacer.

06 004

Specific tools: Bell: 001467Y009 Pliers: 001467Y014* Pliers: 001467Y034*

Use either of these tools.

06 005

- Support the front wheel with two wood shims so as to avoid scratching the wheel rim. - Insert the drift consisting of the adaptor handle, the adaptor and the 15 mm guide on the speedometer gear side to allow the removal of the bearing on the brake disc side and of the spacer bushing.

Specific tools Adaptor handle: 020376Y 0 24 mm adaptor: 020456Y 15 mm guide: 020412Y 06 006

- Using the heat gun, heat the housing of the bearing on the brake disc side.

06 007

6-4

Front and Rear Suspensions - Fit the bearing and drive it fully home using a drift consisting of the adaptor handle, the 42x47 mm adaptor and the 15 mm guide.

06 008

Reinsert the spacer bushing on the brake disc side and drive it fully home using the specific tool.

Specific tools Adaptor handle: 020376Y 42x47 adaptor: 020359Y 15 mm guide: 020412Y Spacer bushing driving tube: 020201Y 06 009

- Turn the wheel upside down and fit the inner spacer so that the spacer side with the seeger ring faces the bearing on the brake disc side fitted previously.

06 010

- Using the heat gun, heat the housing of the bearing on the speedometer gear side.

06 011

6-5

Front and Rear Suspensions - Fit the two bearings and drive them fully home using a drift consisting of the adaptor handle, the 32x35 adaptor and the 15 mm guide.

Specific tools Adaptor handle: 020376Y 32x35 mm adaptor: 020357Y 15mmguide: 020412Y 06 012

- Refit the cap and tighten the five fixing screws.

06 013

Fitting the front wheel - Check the condition of the speed sensor seal ring and of the related groove on the wheel rim. - Grease the axle and insert it on the speed sensor side, and insert the speed sensor itself. N. B.: Take care not to damage the speed sensor. Before fitting the speed sensor, de-phase the speed sensor inner stop by 90째 with reference to the wheel stop. - Tighten the axle nut with the prescribed torque. 06 002

- Tighten the two safety screws on the leg with the prescribed torque.

Tightening torques: Axle nut: 45-50 N m Safety screw on leg: 6-7 N m 06 003

6-6

Front and Rear Suspensions Removing the fork - Remove the brake caliper from its support. - Remove the speed sensor.

- Remove the axle locknut.

06 002

Loosen the two safety screws on the leg. Remove the axle. Remove the wheel together with the brake disc.

06 003

Remove the front and rear covers as described in Chapter 8 - Bodywork. Remove the pin fastening the handlebar to the steering tube. Remove the handlebar and rest it on the front shield rear cover.

06 014

6-7

Front and Rear Suspensions - Using the specific tool, loosen and remove the upper ring, the spacer washer, the counter-ring and the spacer ring. - Remove the fork.

N. B.: Take care to support the fork so as to prevent it from coming off abruptly.

Specific tool Steering tube ring removing spanner: 020055Y 06 015

Overhauling the bearing and the thrust ring seat on the steering head tube - Check that the upper ball bearing and the housing of the lower roller bearing are not worn or pitted. N. B.: Remove the upper ball bearing only if strictly necessary. To replace the bearing, follow these steps: - Insert a bearing removing drift from below and remove the upper ball bearing on the steering head tube. Then insert the drift from the top of the steering head tube and remove the lower housing of the roller bearing. Specific tool: Thrust ring seat removing drift: 020004Y 06 016

Refitting the bearing and the thrust ring seat on the steering head tube Using the specific tool, follow these steps to fit the upper ball bearing and the seat of the lower roller bearing on the steering head tube: - Place a new upper ball bearing on the head tube and a roller bearing housing on the lower part. - Insert the pull screw of the specific tool fitted with the bearing and housing driving adaptors into the steering head tube (see figure). - Using two 24 mm spanners, turn in the screw until the housing and the bearing reach their stops.

N. B.: Always use a new bearing and a new housing.

Specific tools Upper plate adaptor: 001330Y0010 Lower plate adaptor: 001330Y009

6-8

06 017

Front and Rear Suspensions Overhauling the roller bearing on the steering tube - Check that the roller bearing shows no signs of wear or pitting. N. B.: Remove the bearing only if strictly necessary. To replace the bearing, follow these steps: - Clamp the fork in a vice. - Insert the thrust cap into the upper end of the steering tube. 06 018

- Fit the specific tool as shown in the figure.

06 019

- Fit the retaining ring for the two half rings.

Using a 19 mm hexagonal spanner, extract the roller bearing.

Specific tool Roller bearing extractor: 020458Y

Front and Rear Suspensions Refitting the roller bearing to the steering tube - Insert a new cap and a new dust ring into the steering tube. - Insert a new roller bearing into the steering tube. - Using the specific tool and a mallet, drive the dust ring and the bearing fully home.

Specific tool Drift for fitting thrust ring seats on steering tube: 006029Y 06 022

Overhauling the fork rods - Using a 10 mm Allen key, loosen the upper rod plug.

06 023

- Loosen the rod support clamp and remove the leg and the rod.

06 024

Remove the first, 15-coil spring. Remove the spring rest cap. Remove the second, 21-coil spring. Drain the oil. Separate the rod from the leg after removing the screw with a copper washer shown in the figure. To prevent the rotation of the plunger, insert a 12 mm Allen key into the rod.

06 025

6-10

Front and Rear Suspensions Remove the dust ring with a screwdriver as shown in the figure.

06 026

Remove the oil seal safety retainer with a screwdriver. Pull out the oil seal with the specific tool. Insert the rod with the cable in the oil seal. Insert the two 0 35 mm rod half rings in sequence.

06 027

- While keeping the rod in an upright position, fit the 0 35 mm rod bell. - Fit the nut on the thread and extract the oil seal.

Specific tool Oil seal extractor: 020487Y 06 028

Checking the length of the springs

06 029

6-11

Front and Rear Suspensions Checking the rods and the legs Check that there are no signs of wear or seizing between the rods and the legs. Replace any damaged parts. Minimum rod diameter: 34. 90 mm Maximum leg diameter: 35. 10 mm

Checking the plunger Check that the oil holes on the plunger are not clogged. Ensure that the elastic seal ring is not damaged.

06 030

Refitting the rods to the legs - Fit a new oil seal and push it fully home with the specific adaptor and adaptor handle. - Fit the safety retainer. - Fit a new dust ring.

06 031

- Insert the counter spring into the plunger. - Insert the plunger into the rod. - Fit the plunger guide bushing at the lower end of the stem. - Insert the rod into the leg taking care not to push out the rod guide bushing.

06 032

6-12

Front and Rear Suspensions Fit and tighten the copper washer with the prescribed torque. To prevent the rotation of the plunger, insert a 12 mm Allen key into the rod. Pour 102 Âą 1 cc of SELENIA FORK 10 W oil into the rod.

06 025

Insert the 21 -coil spring, the rest cap with the chamfered side facing downwards, and then the 15-coil spring.

06 033

Place the rod in the fork clamp. Tighten the clamp a first time to allow the upper rod plug to be screwed in. Check the condition of the plug seal ring and then tighten the plug on the rod with the prescribed torque.

06 023

- Loosen the fork clamp screws and cause the rod plug to make contact with the clamp. - Tighten the clamp screws with the prescribed torque.

Tightening torques Lower leg screw with copper washer: 25-35 N m Rod upper cap: 15-30 N m Fork clamp screws: 20-25 N m Specific tools Adaptor handle: 020376Y 42x47 mm adaptor: 020359Y 06 024

6-13

Front and Rear Suspensions Refitting the fork to the vehicle - Lubricate the roller bearing with TUTELA Z2 lithium soap grease.

06 034

Fit the fork to the steering head tube. Fit the spacer ring. Using the specific tool, turn in the first ring in the steering tube (steering upper ball bearing). Tighten with a torque of 10-13 N-m and turn the spanner 90째 anticlockwise. Fit the spacer washer. Using the specific tool, turn in the second locking ring in the steering tube and tighten it with a torque of 3036 N m

06 015

Refit the handlebar on the steering tube taking care to centre it by aligning the groove on the handlebar with that on the steering tube (see figure). Tighten the screw fixing the handlebar to the steering tube with the prescribed torque.

06 014

6-14

Front and Rear Suspensions - Replace the front and rear handlebar covers as described in Chapter 8 - Bodywork. - Fit the front wheel as previously described. - Loosen the brake disc fixing screws and fit the brake caliper on the brake disc. - Tighten the brake disc fixing screws with the prescribed torque after applying threadlocking LOCTITE 242. - Tighten the screws that fasten the brake caliper to the support.

06 001

Tightening torques Screw clamping handlebar to steering tube: 45-50 N m Steering upper ring: 30-36 N m Steering lower ring: 10-13 N m, then loosen by 90 Brake caliper clamping screw: 20-25 N m Brake disc clamping screw: 11-13 N-m Plastic protection fixing screw: 5-6 N m

Specific tools Steering ring spanner: 0200055Y

Rear shock absorbers Removal Follow these steps: - Put the vehicle on the centre stand. - Remove the side panels following the procedure described in Chapter 8 - Bodywork. - Using a jack, slightly lift the engine so as to free both shock absorbers. - Remove the silencer. - Unscrew the shock absorber spring assembly fixing screw from the support fastened to the engine on one side, and from that fixed to the silencer support on the other side. - Unscrew the two upper nuts (one on each side) fixing the shock absorber spring assembly to the frame and then remove the shock absorbers.

06 035

Fitting Follow the reverse procedure to the removal and apply the prescribed tightening torques. Tightening torques Lower shock absorber fixing screw: 33-41 N m Upper shock absorber fixing screw: 33-41 N m 06 036

6-15

Front and Rear Suspensions Replacing the stand assembly -

Remove the two stand return springs. Unscrew the nut shown in the figure. Remove the pivot from the right-hand side. Remove the stand. After refitting the stand, tighten the nut with the prescribed torque.

Tightening torque Centre stand fastening bolt: 25-30 N m 06 037

Removing the side stand - Release the springs. - Unfasten the nut. - Remove the screw.

Refitting Perform the above operations in reverse order. Tightening torque Sidestand locknut: 40-45 N m 06 038

Swingarm - Put the vehicle on the centre stand. - Suitably support the engine. - Unscrew the nut shown in the figure and pull out the pivot on the left side.

06 039

- Unscrew the nut and the counternut on the left side of the vehicle (see figure) and remove the pivot on the opposite side. - Remove the rear brake line fixing screw (see figure).

06 040

6 - 16

Front and Rear Suspensions Unscrew the nut inside the frame on the left side (see figure) and remove the pivot. Remove the swingarm.

06 041

Check the entire swingarm assembly. Check all the components, centring bushes, rubber pads, Silentbloc. Check the play of the bearings fitted on the engine. Replace any worn components causing excessive play on the rear suspension. To reassemble, follow the removing procedure in reverse order, referring to the figure below. Grease the bearings and the rotary parts with TUTELA Z2 grease.

06 042

- Before tightening the nuts on the swingarm pivots, remove the swingarm axial play by means of the adjusting bush shown in the figure. - Do not tighten the bush. Tighten the counternut with the prescribed torque. - Complete the operation by tightening the nuts on the related pivots with the prescribed torques. Tightening torques Swingarm-engine pivot: 64-72 N m Frame-swingarm pivot: 64-72 N m Apply LOCTITE 242 over the pivots. 06 043

6-17

BRAKING SYSTEM

7-2

Braking System Checking pad wear and replacing the brake pads Removing the front brake pads: Follow these steps: - Free the brake caliper by loosening the two screws that fasten the caliper to its support (see figure). - Unscrew the two pad securing pins (see figure). - Remove the two pads paying attention to the pad retaining spring. - Measure the thickness of the pads. Minimum pad thickness: 1. 5 mm

07 001

To refit the pads, follow these steps: - Place the two pads inside the caliper. - Tighten the pad fastening pins with the prescribed torque after applying threadlocking LOCTITE 242. - Fit the caliper on its support and tighten the two screws with the prescribed torque. Tightening torques Screws clamping caliper to support: 20-25 N m Pad fastening pins: 19. 6-24. 5 N m N. B.: Should you find any difficulty positioning the caliper on the disc, gently part the brake pads. 07 002

Removing and replacing the rear brake pads Follow these steps: - Loosen the two screws that fasten the caliper to its support (see figure). - Loosen the two pad securing pins. - Remove the pads paying attention to the pad retaining spring. - Measure the thickness of the pads. Minimum pad thickness: 1. 5 mm If the pads are thinner than the prescribed limit, replace them with new ones. 07 003

To refit the pads, use the same procedure described for the front brake caliper. - Tighten the two caliper fastening screws with the prescribed torque.

Tightening torques Pad fastening pins: 19. 6-24. 5 N m Screws clamping caliper to support: 20-25 N m Screws clamping caliper support to engine: 20-25 N m

7-3

Braking System Brake discs Checking thickness The brake disc should always be clean, free from rust, oil, grease or dirt, and must show no signs of deep scoring. Thickness Thickness Thickness Thickness

of of of of

front disc (new) rear disc (new) front disc (wear limit) rear disc (wear limit)

4. 0 4. 0 3. 5 3. 5

mm mm mm mm 07 004

Checking distortion Take down the wheel and, using the specific equipment, check that the axial runout of the braking surface is as specified. Maximum radial runout: 0. 1 mm If that is not the case, replace the disc as described below and then repeat the measurement.

N. B.: Before refitting, thoroughly clean the disc and its seat on the hub. 07 005

Replacing the front brake disc Follow these steps: - Take down the front wheel as described in Chapter 6 - Front and Rear Suspensions. - Loosen the five disc fixing screws. - Thoroughly clean the seats on the front wheel hub and the disc. When fitting the new disc, take care to position it properly by referring to the arrow stamped on it. - Tighten the screws with the prescribed torque after applying threadlocking LOCTITE medium 242. N. B.: The disc side with the stamped arrow, which indicates the direction of motion, must face away from the vehicle. Tightening torques Brake disc clamping screws: 5. 0-6. 5 N m 07 006

Replacing the rear brake disc Follow these steps after taking down the rear wheel as described in Chapter 6 - Front and Rear Suspensions. - Remove the hub complete with the brake disc. - Proceed in a similar manner to the front brake disc. N. B.: The disc side with the stamped arrow, which indicates the direction of rotation, must face away from the vehicle. Tightening torques: Brake disc fixing screw: 11 + 13 N m 07 007

7-4

Braking System Bleeding the braking system Follow these steps: - Put the vehicle on its stand on level ground. - Loosen the two screws shown in the figure and open the front brake fluid reservoir. - Apply a tube of suitable diameter and drain the circuit using the bleeder screw on the brake caliper. - Collect the spent fluid in a container. - Pull the brake lever repeatedly until all the fluid has flown out. - Close the bleeder valve. - Fill the reservoir with the prescribed fluid to the maximum level. - Apply the tube of the specific tool to the bleed fitting. - While operating the bleeding tool, constantly pour fresh fluid into the reservoir so as to avoid sucking in air. Carry on with the operation until no air comes out of the bleeder. - Tighten the bleeder screw with the prescribed torque. - Close the brake pump reservoir.

07 008

Follow the same procedure for the rear brake circuit. N. B.: If air keeps coming out during the bleeding, inspect all connections. If they are in order, check for possible air leakage from the pump seals and the caliper pistons. During the operation, oil may trickle from the bleeder screw onto the brake caliper and disc. In that case, carefully wipe the caliper and de-grease the disc.

Tightening torque Bleeder screw: 12-16 N m Specific tool Mityvac-type vacuum pump: 020329Y

7-5

Braking System Removing the front/rear brake caliper - Check the condition of the brake lines, the seal and the connection. If any fluid is leaking onto the brake caliper, replace the caliper. - Disconnect the oil pipe from the caliper and collect the oil in a container. - Remove the fastenings shown in the figure. - When refitting, tighten the nuts with the prescribed torque. - Bleed the system as previously described. The replacement is obtained in much the same way for both calipers, the only difference being that the rear brake caliper must be removed from the vehicle together with its support. To do this, unscrew the two bolts shown in the figure.

07 009

N. B.: When refitting, replace the copper gaskets on the connections. Tightening torques Oil bleeder screw: 12-16 N m Screws clamping caliper to support: 20-25 N m Screws clamping rear brake caliper support to engine: 20-25 N m Oil connection: 16-20 N m 07 009 A

Refitting the brake caliper Insert in the front caliper body: - Fit the seal rings and pistons (1) on the front caliper body. - Refit plate (2). - Position pad retaining spring (3). - Refit the pads and carry out the bleeding. - Position the caliper on the disc and fasten it to the support, tightening the bolts with the prescribed torque. - Fasten the pipe connection on the caliper with the prescribed torque. - Follow the same steps for the rear brake caliper.

Tightening torques Screws fixing front/rear brake caliper to support: 20-25 N m Screw fixing oil connection to caliper: 16-20 N m

07 011

7-6

Braking System General rules for servicing the hydraulic brake system Caution - The brake fluid is corrosive. Always wear protective gloves. In case of contact with the eyes, rinse generously with water. Used brake fluid is harmful to the environment. Be sure to collect and dispose of it according to the regulations in force.

N. B.: Top up or renew the fluid exclusively with DOT4 -NHTSA 116 fluid. Always keep all parts scrupulously clean. The brake fluid is highly corrosive to painted surfaces. The brake fluid is hygroscopic, i. e. it absorbs humidity from the air. If the humidity contained in the fluid exceeds a certain level, the braking action will be reduced owing to a decrease in the boiling point of the fluid. N. B.: Always take the brake fluid from sealed containers.

Under normal riding and climatic conditions the brake fluid should be renewed every two years. If the brakes are subject to heavy strain, renew the fluid at shorter intervals. To ensure that the parts to be reused are perfectly clean and free from oil, diesel and grease, wash them carefully in denatured alcohol.

N. B.: Rubber parts must not be left in alcohol for longer than 20 seconds. The parts should then be dried with a compressed air jet and wiped with a clean cloth. The seal rings must be immersed in the liquid of use. The use of the PRF1 protective agent is tolerated.

Caution - The presence of brake fluid on the disc or pads reduces the braking action. In that case, replace the pads and clean the disc with a good-quality solvent.

Replacing the front and rear brake pumps - Drain the circuit as previously described. - Disconnect the pump oil pipe taking care to avoid the outflow of any oil residues. - Remove the front/rear brake light button from the lever. - Unscrew the two clevis clamping screws and remove the clevis together with the rearview mirror. - Remove the front brake pump together with the lever. - To refit the parts, perform the above operations in reverse order. - Fasten the hydraulic line with the prescribed torque and bleed the system as previously described. - Follow the same procedure to replace the rear brake pump.

- The brake fluid is hygroscopic, i. e. it absorbs humidity from the air. If the humidity contained in the fluid exceeds a certain level, the braking action will be reduced. It is therefore advisable to take the fluid from sealed containers. Under normal riding and climatic conditions the brake fluid should be renewed every two years. If the brakes are subject to heavy strain, renew the fluid at shorter intervals.

07 012

Warning - During the operation, oil may leak between the bleeder screw and the seat on the caliper. In that case, carefully dry the caliper and degrease the disc. At the end of the operation tighten the oil bleeder screw with the prescribed torque.

Tightening torques Oil bleeder screw: 12-16 N m Hydraulic line fixing screw: 16-20 N m 7-7

BODYWORK

8-2

Bodywork Rear handlebar cover - Loosen the four side screws, two on the rear handlebar cover (see figure) and two on the front handlebar cover. - Remove the rear handlebar cover and disconnect the liquid crystal display wiring.

08 001

Liquid crystal display - Remove the rear handlebar cover as previously described. - Loosen the three screws shown in the figure. - Remove the display.

08 002

Front handlebar cover - Remove the rear handlebar cover as previously described. - Loosen the two screws shown in the figure. - Remove the front handlebar cover.

08 003

Instrument panel - Remove the front and rear handlebar covers as previously described. - Loosen the two screws shown in the figure. - Loosen the two screws underneath the front section of the instrument panel. - Disconnect the wiring. - Remove the instrument panel.

08 004

8-3

Bodywork Frame central cover - Open the fuel tank access door. - Loosen the four screws shown in the figure. - Momentarily remove the fuel tank cap and the rubber mat below it. - Remove the frame central cover, disconnecting it from the door opening cable.

08 005

Headlight insert / Front shield - Remove the headlight insert after loosening the four fixing screws, two of which shown in the figure and two located lower down. - Detach the electrical connectors. - Pull out the headlight insert.

08 006

- Loosen screw fastening the expansion tank access cover. - Loosen the two fixing screws on the upper part of the countershield, one of which is shown in the figure. - Loosen the remaining two screws fastening the front shield to the wheel housing.

08 007

- Remove the frame central cover as previously described. - Loosen the two screws shown in the figure. - Remove the front shield.

08 008

8-4

Bodywork Rear shield / Glove compartment - Remove the front shield as described in the previous paragraph. - Loosen the two screws fixing the fuse box to the glove compartment. - Remove the electrical connectors. - Remove the expansion tank. - Loosen the fixing screw in the glove compartment and the two screws under the frame central cover. - Disconnect the saddle closing cable. - Remove the rear shield together with the glove compartment. 08 009

08 010

Carrier - Loosen the two fixing screws and remove the battery cover. - Remove the snap-on plastic cover from the carrier. - Loosen the three Allen screws shown in the figure and remove the carrier.

08 021

Rear lamp cluster - Remove the two side bumpers after loosening the fixing screws shown in the figure (one screw on each side). - Remove the snap-on carrier cover. - Loosen the three rear light fixing screws. - Remove the rear lamp cluster after disconnecting the wiring.

08 011

8-5

Bodywork Side panels - Remove the central cover as previously described. - Remove the rear lamp cluster as previously described. - Remove the three fixing screws shown in the figure and take off the saddle. - Remove the undersaddle cover after unscrewing the related fixing screw, located under the saddle securing plate. - Unscrew the six side panel fixing screws. - Remove the side panels. 08 012

Helmet compartment - Remove the side panels as previously described. - Detach the electrical connectors. - Unscrew the eight fixing screws, four of which located inside the helmet compartment. - Remove the number-plate holder tail after unscrewing the four fixing screws shown in the figure and disconnecting the wiring. - Remove the helmet compartment.

08 013

Left and right footboards - Remove the central cover as previously described. - Remove the right-hand footrest after loosening the screw shown in the figure. - Remove the right-hand mat. - Unscrew the seven footboard fixing screws. - Remove the right-hand footboard. - Follow the same steps to remove the left-hand footboard.

08 014

Front mudguard - Remove the screw fixing the cable guide support on the right side of the mudguard. - Loosen the three fixing screws shown in the figure and remove the mudguard.

08 015

8-6

Bodywork Front wheel housing - Remove the front shield. - Remove the countershield together with the glove compartment. - Remove the footboards. - Remove the front suspension as described in Chapter 6 - Front and Rear Suspensions. - Remove the remaining screws fixing the cover to the frame. - Disconnect the outside temperature sensor. - Remove the radiator cover. 08 016

Fuel tank N. B.: This operation should be performed when the tank is empty. -

Remove the frame central cover. Remove the front shield. Remove the glove compartment. Remove the radiator cover. Remove the footboard as previously described.

08 017

- Disconnect the fuel gauge electrical connector, the fuel feed pipe and the tank breather pipe. - Loosen the horn fixing screw shown in the figure at the top and then remove the horn after detaching the electrical connector. - Remove the cross members after loosening the four fixing screws. - Remove the bracket after loosening the two screws that fix it to the frame. - Remove the two screws fixing the tank to the frame. - Tip the tank and remove it from below.

08 018

Radiator and electric fan -

Remove the front wheel housing. Prepare a container for the coolant. Remove the expansion tank outlet and return pipes. Remove the coolant supply and return pipes from the radiator. - Loosen the screw fixing the radiator to the frame. - Disengage the radiator and the electric fan.

08 019

8-7

Bodywork Rear mudguard - Remove the four fixing screws, two of which shown in the figure and the other two located on the opposite side under the air filter. - Remove the rear mudguard.

08 020

PREDELIVERY OPERATIONS

Predelivery operations Predelivery checks: Appearance • Paintwork • Mating of plastics • Scratches •Dirt

Warning - To ensure maximum performance, the battery must be charged before use. Inadequate charging of the battery before it is first used with a low level of the electrolyte shortens the life of the battery. W a r n i n g . when installing the battery, first fix the positive cable and then the negative cable.

Fastenings • Safety tightening torques • Cover fixing screws Electrical equipment • Master switch • Lights: high beam, low beam, parking lights (front and rear) and related warning lights • Headlight adjustment according to regulations in force • Front and rear brake light buttons and related bulb. • Turn indicators and related warning lights • Instrument panel light • Instruments: fuel gauge and temperature indicator • Instrument panel warning lights • Horn • Electric start • Engine switched off with emergency stop switch and sidestand • Saddle electrical opening button Levels • Hydraulic braking system fluid level • Rear hub oil level • Engine coolant level • Engine oil level Road test • Cold starting • Operation of instruments • Operation of throttle control • Stability during acceleration and braking • Operation of front and rear brakes • Operation of front and rear suspensions • Abnormal noise from vehicle Static test after road test • Hot restarting • Operation of starting device • Idle speed stability (when turning handlebar) • Steering smooth rotation • Leakages • Operation of radiator electric fan Functional test • Hydraulic braking system • Clutch • Engine Other

9-2

lever travel check operation Verify general operation and check for abnormal noise check papers check frame and engine numbers check tool kit fit number plate check locks check tyre pressures fit mirrors and any accessories

Caution - The battery electrolyte is poisonous and causes severe burns as it contains sulphuric acid. Avoid contact with the eyes, the skin and clothing. In case of contact with the eyes or the skin, rinse generously with water for about 15 minutes and immediately seek medical attention. In case of ingestion, immediately drink large quantities of water or vegetable oil. Immediately seek medical attention. Batteries produce explosive gases. Keep them away from open flames, sparks and cigarettes. If the battery is charged in a closed place, take care to ensure adequate ventilation. Always protect the eyes when working close to batteries. KEEP OUT OF REACH OF CHILDREN Warning - Never use fuses having a higher rating than recommended. Using a fuse of unsuitable rating may seriously damage the vehicle or even cause a fire. Warning - Check the inflating pressures when the tyres are at ambient temperature. Warning - Do not exceed the recommended inflating pressures as the tyres may burst.

Safety tightening torques:

JOB TIME SHEET

10-2

10-

-4

10-5

I0-6

10-7

10-8

10-9

10-10

10- 11

10-12

10-13

10-14