Cagiva Navigator Workshop Manual
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Cagiva Navigator Workshop Manual

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Table of Contents

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Workshop Manual

NAVIGATOR
Copyright by
MVAGUSTA MOTORCYCLES S.p.A.
Via G. Macchi , 144 (Schiranna)
21100 VARESE - ITALY
1st Edition
Printed in Italy
Print no. - 8A0095860
1

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  • Page 1: Workshop Manual

    Workshop Manual NAVIGATOR Copyright by MVAGUSTA MOTORCYCLES S.p.A. Via G. Macchi , 144 (Schiranna) 21100 VARESE - ITALY 1st Edition Printed in Italy Print no. - 8A0095860...
  • Page 2 Introduction This publication is intended for CAGIVA Workshops and is designed to help authorized personnel in service and repair operations. Familiarity with the specifications provided herein is a key factor in ensuring effective training of operators. To make the manual easy to understand, the different paragraphs are identified by icons that point out the subjects being dealt with.
  • Page 3 IDENTIFICATION DATA The vehicle is identified by the following: - Motorcycle serial number (1) on the right side of the head tube. - Engine serial number (2) on the lower part of the right-hand crankcase half. - Colour code on plate (3) inside the glove compartment under the saddle. - Homologation data on the plate applied to the frame lower tube, next to the steering head tube.

  • Page 4: Table Of Contents

    Contents Section Page General information ..............A Maintenance .................... Injection - Air intake system ............C Engine ..................D Suspensions and wheels ............E Brakes ...................... Electrical equipment ..............G Engine cooling ................H Specific tooling ................I Tightening torques............... L Index ......................
  • Page 5 GENERAL INFORMATION Section...

  • Page 6: Table Of Contents

    GENERAL INFORMATION Dimensions and weight ............A-3 Engine unit ................A-3 Transmission unit ..............A-3 Frame ..................A-4 Front suspension ..............A-4 Rear suspension ..............A-4 Wheels and brakes ..............A4 Electrical system ..............A-4 Instrument panel ..............A-4 Fuel/oil/coolant/fork oil capacity ..........A-4...

  • Page 7: General Information

    GENERAL INFORMATION NAVIGATOR DIMENSIONS AND WEIGHTS Overall length ................2168 mm Overall width ................790 mm Overall height ................1290 mm Wheelbase ................1530 mm Ground clearance ..............180 mm Seat height ................850 mm Dry weight ................222 kg...
  • Page 8 GENERAL INFORMATION FRAME Type ................... Rectangular and square box section tubular framework in highly resistant steel with box-type strengthening supports at the fork fulcrum attachment. FRONT SUSPENSION Type ................... Conventional advanced pivot hydraulic telescopic fork with 45 mm diameter tubes. Telescopic movement 150 mm. Steering angle ................
  • Page 9 MAINTENANCE Section...
  • Page 10 MAINTENANCE Maintenance and tuning ............B-4 Compression check ..............B-23 Oil pressure check ..............B-24 Technical data ................ B-25...

  • Page 11: Maintenance

    MAINTENANCE...

  • Page 12: Fuel Tank Removal

    MAINTENANCE MAINTENANCE AND TUNING This section describes the servicing procedures for each part of pe- riodical maintenance. FUEL TANK REMOVAL To complete this operation it is necessary to previously remove the seat. • Remove the complete fuel tap assembly by unscrewing the three screws 1 indicated in the figure.
  • Page 13 MAINTENANCE • Remove the fairing by unscrewing the five screws 1. There is one front screw and four screws highlighted in the figure. • Remove the front protection by unscrewing the two lower screws 2, as shown in the figure. •...

  • Page 14: Air Filter

    MAINTENANCE • Slacken and remove the two tank union clamps 1. One is situated at the front of the vehicle and the other at the back of the tank. • Finally, remove the two fixing screws 2. Disconnect the overflow tube from the left fuel tank.

  • Page 15: Spark Plugs

    MAINTENANCE SPARK PLUGS Check every 6000 km (or 6 months) Substitute every 12000 km (or 12 months) After the first 1000 km it is necessary to remove the spark plugs, clean them and check the distance between the electrodes (0.6÷0.7 mm).
  • Page 16 MAINTENANCE Be careful to not damage the finning of the radiator. The radiator and engine can provocate serious burns when they are hot. Wait until the radiator and the engine are cool enough to be touched before carrying out this operation. REMOVAL OF SPARK PLUG N°...
  • Page 17 MAINTENANCE HEAT GRADE CODE • Check the heat grade code of the spark plug. CR8EK DENSO U24ETR The type “R” spark plug has a resistor on the central electrode to avoid radio disturbance. CARBON DEPOSITS • Check the spark plugs for carbon deposits. If there are deposits, use the appropriate machine or a pointed tool to eliminate them.
  • Page 18 MAINTENANCE When the front and rear spark plug insulated caps are pushed on, turn the triangular signs on the insulated caps A towards the ex- haust side of the cylinders. VALVE TAPPET CLEARANCE ADJUSTMENT Check every 24000 km (or every two years) •...
  • Page 19 MAINTENANCE • Remove the plug of the generator cover 1 and the timing cover inspection plug 2. • Turn the engine camshaft to bring the piston of the N° 1 cylinder (front) to the top dead centre (T.D.C.) position of the compression cycle.
  • Page 20 MAINTENANCE • Unhook the rear brake fluid chamber by unscrewing the screw shown in the figure. • Disconnect the electrical connector of the camshaft position sen- sor. • Remove the sensor by unscrewing the two relative screws. • Disassemble the fuel filter from its supports and disconnect it from the fuel tubes, taking care to not spill any fuel.
  • Page 21 MAINTENANCE • Check the valve tappet clearance of the N° 2 cylinder (rear) using the same procedure used for the N° 1 cylinder (front) and adjust as necessary. VALVE TAPPET CLEARANCE ADJUSTMENT The valve tappet clearance adjustment is regulated by the substitu- tion of the valve stem pad with another that is thicker or thinner.
  • Page 22 MAINTENANCE (INTAKE SIDE) B.14...
  • Page 23 MAINTENANCE (EXHAUST SIDE) B.15...

  • Page 24: Engine Oil And Oil Filter

    MAINTENANCE FUEL TUBING Check every 6000 km (or 6 months). Substitute every 4 years. After removing the fuel tank, check to see if the feed tube 1 and return tubes 2 and 3 are damaged or show signs of leaking. Substi- tute the tubes if any defects are found.
  • Page 25 Oil change: 3.1 litres Oil filter change: 3.3 litres Engine overhaul: 3.6 litres Utilise only ORIGINAL CAGIVA OIL FILTERS. Filters and spare parts of other makes could differ with regards to the threading (diameter and pitch), filter performance and du- ration.
  • Page 26 MAINTENANCE ACCELERATOR CABLE PLAY Check at 1000 km (or 1 month) Every 6000 km (or 6 months). Adjust the accelerator cable play following these three phases. First phase: • Slacken the locknut 1 of the accelerator return cable B and com- pletely screw in the screw adjuster 2.
  • Page 27 MAINTENANCE CLUTCH Check every 6000 km (or 6 months). • Remove the speed sensor 1. • Remove the left hand footrest from the frame by unscrewing the two relative screws. • Remove the engine pinion cover 2 by unscrewing the three rela- tive screws.
  • Page 28 MAINTENANCE ENGINE COOLANT CHANGE • After having removed the tank, remove the radiator cap 1, the expansion tank cap and the drain plugs 2 end 3. Drain the engine coolant. * Do not remove the radiator cap when the engine is hot. Boiling liquid or steam can cause serious burns.
  • Page 29 MAINTENANCE RADIATOR TUBES • Remove the sump guard protection 5 by unscrewing the two screws 6 indicated in the figure. Push it aside in the direction of the arrow. Check to see if the radiator tubes are damaged, cracked or leak. If any defect is found, substitute the tubes immediately.
  • Page 30 MAINTENANCE CHAIN ADJUSTMENT • Slacken or tighten both chain screw adjusters 1 until the chain reaches a slack of 25-35 mm in the central position of the chain between the crown and pinion. The marks A on both screw adjust- ers must be in the same position of the scale to ensure the correct alignment of the wheel.
  • Page 31 MAINTENANCE BRAKES (BRAKES) Check at 1000 km (or 1 month) Every 6000 km (or 6 months) (BRAKE AND BRAKE FLUID TUBING) Check every 6000 km (or 6 months). Substitute the tubes every four years. Substitute the brake fluid every two years. BRAKE FLUID LEVEL CHECK •...
  • Page 32 MAINTENANCE • To change the rear brake pads, proceed as follows: • Remove the two screws of the rear spray guard 3 rotate it as shown in the figure. Substitute the pads in pairs to guarantee maximum brak- ing performance.. BRAKE PEDAL HEIGHT The rear brake pedal must have a travel of 10-15 mm before the braking action takes place.
  • Page 33 MAINTENANCE BLEEDING THE AIR FROM THE BRAKING SYSTEM The air that is trapped in the braking system acts as a cushion, ab- sorbing the greater part of the pressure exerted by the brake pump. The performance of the brake pincer is therefore compromised. The presence of air in the system is indicated by a “sponginess”...
  • Page 34 MAINTENANCE TYRES Check every 6000 km (or 6 months) CONDITION OF THE TREAD Badly worn tyres decrease the road holding and are therefore danger- ous. It is recommended that tyres be changed when the tread reaches the minimum level. Operating limit Tread depth (front): 2.0 mm (rear): 2.0 mm...
  • Page 35 MAINTENANCE COMPRESSION TEST The compression of a cylinder is an optimum indicator of the internal condition of the engine. The decision to overhaul the engine is often the result of a compression test. Amongst the periodical maintenance data to be found at the dealer are also the compression measurements for each maintenance operation. COMPRESSION SPECIFICATION (automatic decompression activated) Standard Limit...

  • Page 36: Oil Pressure Test

    MAINTENANCE OIL PRESSURE TEST Periodically check the oil pressure for an approximate evaluation of the condition of the moving parts of the engine. OIL PRESSURE SPECIFICATION More than 300 kPa (3.0 kg/cm ) at 3000 rpm, oil temperature 60°C. Less than 600 kPa (6.0 kg/cm If the pressure of the oil is more or less than those specified, consider the following causes: LOW OIL PRESSURE * Oil filter blocked...

  • Page 37: Technical Data

    MAINTENANCE TECHNICAL DATA Unit: mm VALVE + GUIDE PART STANDARD LIMIT Valve diameter Intake ––––– Exhaust ––––– Valve tappet clearance (cold) Intake 0.10-0.20 ––––– Exhaust 0.20-0.30 ––––– Valve stem/guide play Intake 0.010-0.037 ––––– Exhaust 0.030-0.057 ––––– Valve stem distortion Intake and ––––––...
  • Page 38 MAINTENANCE Unit: mm CYLINDER + PISTON + PISTON RINGS PART STANDARD LIMIT Compression pressure 1300-1700 kPa 1100 kPa (automatic decompression activated) (13-17 kg/cm (11 kg/cm Compression pressure difference 200 kPa –––––– (2 kg/cm Piston/cylinder play 0.015-0.025 0,12 Cylinder diameter 98.000-98.015 Lines or scratches Piston diameter 97.980-97.995...
  • Page 39 MAINTENANCE OIL PUMP PART STANDARD LIMIT Oil pump reduction ratio 1.301 (57/31 x 29/41) ––––– Oil pressure (at 60°C.) More than 300 kPa (3.0 kg/cm ) at 3000 rpm ––––– CLUTCH PART STANDARD LIMIT Clutch lever play 10-15 ––––– Clutch main plate thickness 2.92-3.08 –––––...
  • Page 40 MAINTENANCE PART STANDARD LIMIT Transmission chain slack 25-35 ––––– Gearlever travel ––––– Rear brake lever travel 10÷15 ––––– INJECTOR + FUEL PUMP + FUEL PRESSURE ADJUSTER PART TECHNICAL CHARACTERISTICS NOTES Injector resistance 11-16 ohms at 20°C. Fuel pump flow Approx. 1 litre per minute at 290 kPa (2.9 kg/cm Fuel pressure adjuster Approx.
  • Page 41 MAINTENANCE CARBURATORE PART TECHNICAL CHARACTERISTICS Minimum rpm - choke 2000 rpm at 20°-30° 3500-4000 at 90° Minimum rpm – tickover 1300-1350 rpm Accelerator cable play 2.0-4.0 mm Unit: mm excluding ratios ELECTRICAL SYSTEM PART TECHNICAL CHARACTERISTICS NOTES Timing synchronisation 3° BTDC at 1200 rpm Firing order1·2 Spark plugs Type...
  • Page 42 MAINTENANCE WATTAGE Unit: W PART TECHNICAL CHARACTERISTICS Headlight Sidelight Stop/tail light 21/5 Direction indicators Revcounter light Direction indicator warning light Main beam warning light Neutral warning light Fuel level warning light Number plate light Unit: mm BRAKES + WHEELS PART STANDARD LIMIT Rear brake pedal travel...

  • Page 43: Tyre Pressures

    MAINTENANCE PART STANDARD LIMIT Axial deformation – wheel Front –––––– Rear ––––– Wheel dimensions Front 3.00“X18” ––––– Rear 4.25 “X17” Tyre dimensions Front 110/80 -18” ––––– Rear 150/70 -17” ––––– Tread depth Front ––––– Rear ––––– SUSPENSION PART STANDARD LIMIT Fork travel –––––...
  • Page 44 MAINTENANCE FUEL + COOLANT PART TECHNICAL CHARACTERISTICS NOTES Fuel type The fuel must be 95 octane petrol or higher. It is recommended that lead free petrol be used. Fuel tank capacity 20 L Engine oil type AGIP TEC 4T 10W/40 SINT 20005W/40 Engine oil capacity Oil change...
  • Page 45 INJECTION - AIR INTAKE SYSTEM Section...
  • Page 46 INJECTION - AIR INTAKE SYSTEM Maintenance precautions ............C-3 FI system technical characteristics ........C-9 Intake air system technical characteristics ......C-21 FI system - position of parts ........... C-26 FI system diagram ..............C-27 FI system - electrical diagram ..........C-28 Auto-diagnostic function ............

  • Page 47: Injection - Air Intake System

    INJECTION - AIR INTAKE SYSTEM MAINTENANCE PRECAUTIONS Observe the following when handling components of the FI system or when carrying out maintenance on the system. Click CONNECTORS/COUPLINGS • When putting connectors together, make sure that the connectors are pushed fully home until a click is heard. •...
  • Page 48 INJECTION - AIR INTAKE SYSTEM FUSES • Always search for the cause of a blown fuse. Eliminate the cause and then substitute the fuse. • Use only fuses of the correct amperage. • Do not use wire or another substitute for a fuse. ECM/VARIOUS SENSORS •...
  • Page 49 INJECTION - AIR INTAKE SYSTEM • Do not remove the terminals of the battery whilst the engine is running. If a terminal is removed, this would cause an inverted electrical force that would seriously damage the ECM. • Before measuring the voltage on any terminal of the electrical sys- tem, check that the voltage of the battery is 11V higher.
  • Page 50 INJECTION - AIR INTAKE SYSTEM • Disconnect the negative polarity cable from the battery. • Check to see if the connectors/couplings and both ends of the circuit are not loose. Also check the snap-fit couplings for correct insertion. Sensor Check to see if the connection is loose •...
  • Page 51 INJECTION - AIR INTAKE SYSTEM Voltage test If the circuit tested has fewer volts than normal, the voltage test can also be used as a continuity test. • With all connectors/couplings connected and with voltage running through the circuit being tested, measure the voltage between each terminal and Earth.
  • Page 52 INJECTION - AIR INTAKE SYSTEM • Disconnect the coupling in the circuit (coupling B) and measure the resistance between the terminals A and Earth. Left side If continuity is indicated signifies that there is a short circuit to Earth between the terminals A and B of the circuit. USE OF THE TESTER •...
  • Page 53 INJECTION - AIR INTAKE SYSTEM FI SYSTEM TECHNICAL CHARACTERISTICS INJECTION TIME (INJECTION VOLUME) The factor that determines the timing of the injection is the time of the basic injection. This is calculated on the basis of intake air pressure, the rpm of the engine, the opening of the throttle and various other adjustments that are determined according to signals received from various sensors that reveal the engine and riding conditions.
  • Page 54 INJECTION - AIR INTAKE SYSTEM INJECTION TIME ADJUSTMENT (VOLUME) Various sensors allow injection time adjustments (volume) to be carried out on the basis of the following signals. SIGNAL DESCRIPTION ATMOSPHERIC PRESSURE SENSOR SIGNAL When the atmospheric pressure is low, the sensor sends a signal to the ECM to reduce the injection time (volume).
  • Page 55 INJECTION - AIR INTAKE SYSTEM FUEL FEED SYSTEM The fuel feed system consists of the fuel tank, fuel pump, fuel filter, feed tube, feed tubing (including the fuel injectors), pressure regulator and the return feed tube. The fuel is pumped from the tank to the fuel pump and the pressurised fuel flows into the injector installed in the fuel feed tubing.

  • Page 56: Fuel Pressure Regulator

    INJECTION - AIR INTAKE SYSTEM FUEL PRESSURE REGULATOR The fuel pressure regulator is a diaphragm release valve that consists of a diaphragm, spring and a valve. It always maintains the pressure of the fuel to the injector at 2.9 kg/cm (290 kPa) higher than the pressure in the carburettor.

  • Page 57: Fuel Pump Control System

    INJECTION - AIR INTAKE SYSTEM FUEL PUMP CONTROL SYSTEM When the ignition switch is switched to ON, the battery current reaches the fuel pump motor via the relay of the side stand and the also pump relay, that turns the motor. As the ECM possesses a timing function, the pump motor stops turning three seconds after the ignition switch is switched ON.
  • Page 58 INJECTION - AIR INTAKE SYSTEM ECM (FI CONTROL UNIT) The ECM unit is situated underneath the seat and the seat compartment towards the rear of the machine. The ECM consists of a CPU (Central Control Unit), a memory (ROM) and incoming/outgoing sections (I/O). Signals sent by each sensor are received at the incoming section and then to the CPU.
  • Page 59 INJECTION - AIR INTAKE SYSTEM INJECTION SYNCHRONISATION Fuel injection is effected by a sequential injection type system that is independent for each cylinder. The system uses the crankshaft position sensor (signal generator) to determine the position of the pistons (injection synchroni- sation and timing synchronisation).
  • Page 60 INJECTION - AIR INTAKE SYSTEM SENSORS INTAKE AIR SUCTION SENSOR (IAP SENSOR) The intake air pressure sensor is situated on the right hand side of the air filter compartment. The sensor senses the suction of air in the intake air tube (spring type) of the butterfly body and this pressure is converted into volt- age and sent to the ECM.
  • Page 61 INJECTION - AIR INTAKE SYSTEM INJECTION - AIR INTAKE SYSTEM CRANKSHAFT POSITION SENSOR (CKP SENSOR) The signal generating rotor is mounted on the extreme left of the engine crankshaft and the crankshaft position sensor (explorer coil) is situated inside the generator cover. The sensor generates the signal that is transmitted to the ECM.
  • Page 62 INJECTION - AIR INTAKE SYSTEM INTAKE AIR TEMPERATURE SENSOR (IAT SENSOR) The sensor of the intake air temperature is situated on the front part of the air filter compartment. The sensor reads the intake air temperature that is obtained and the sensor then converts the resistance of the Thermistor into voltage, which is transmitted to the ECM.
  • Page 63 INJECTION - AIR INTAKE SYSTEM INJECTION - AIR INTAKE SYSTEM ATMOSPHERIC PRESSURE SENSOR (AP SENSOR) The sensor of the atmospheric pressure is situated underneath the ECM support. Remove the tool kit compartment as described in Chapter B. Remove the ECM central processing unit and its support by unscrew- ing the four screws shown in the figure.
  • Page 64 INJECTION - AIR INTAKE SYSTEM INTAKE AIR SYSTEM TECHNICAL CHARACTERISTICS Whilst the machine is in motion, the frontal air pressure flows into the air filter compartment in such a way that it pressurises the intake air. This improves the intake air efficiency that subsequently permits a greater power output of the engine.
  • Page 65 INJECTION - AIR INTAKE SYSTEM POSITION OF THE FI SYSTEM COMPONENTS C.21...
  • Page 66 INJECTION - AIR INTAKE SYSTEM FI SYSTEM DIAGRAM SWITCH CLP RELAY FP BATTERY IATS (#2) (#1) FI (#2) FI (#1) IAPS CMPS CKPS ECTS C.22...
  • Page 67 INJECTION - AIR INTAKE SYSTEM FI ELECTRICAL SYSTEM DIAGRAM C.23...

  • Page 68: User Mode

    INJECTION - AIR INTAKE SYSTEM AUTO-DIAGNOSTIC FUNCTION An auto-diagnostic function is incorporated in the ECM. This function has two modes: the user mode and the dealer mode. The user can only utilise the LCD display and the LED indicator. To check the functions of the FI system devices, it is necessary to prepare the dealer mode and utilise the special tool for the reading of the malfunction codes.

  • Page 69: Dealer Mode

    INJECTION - AIR INTAKE SYSTEM DEALER MODE The malfunction is memorised in the computer and it is possible to find it by connecting the coupling of the special tool to the coupling of the dealer mode. The malfunction code is visualised on the LCD display panel. Malfunction signifies that the ECM has not received signals from the related devices and these devices are indicated by codes.
  • Page 70 INJECTION - AIR INTAKE SYSTEM CODE MALFUNCTIONING COMPONENT NOTES None No component defective Camshaft position sensor (CMP sensor) Crankshaft position sensor (CKP sensor) Explorer coil signal, generator signal Intake air pressure sensor (IAP sensor) Throttle position sensor (TP sensor) Engine coolant temperature sensor (ECT sensor) Intake air temperature sensor (IAT sensor) Atmospheric pressure sensor (AP sensor) Crash sensor (TO sensor)
  • Page 71 INJECTION - AIR INTAKE SYSTEM SECURITY FUNCTION The FI system is supplied with a security system that allows the switching on of the engine and the riding of the machine even when the ECM notes malfunctions. ITEM SECURITY INTERVENTION STARTING RIDING Camshaft position When the signal of the camshaft...
  • Page 72 INJECTION - AIR INTAKE SYSTEM FI DIAGNOSTIC SYSTEM CLIENT’S CLAIM ANALYSES CLIENT’S NOTE: Note the details of the problem (defect, claim) and the description of the same. The use of this inspection form helps in the collection of information to carry out analyses and the appropriate diagnosis. EXAMPLE: CLIENT PROBLEM INSPECTION FORM User name: Model:...

  • Page 73: Auto-Diagnostic Procedure

    INJECTION - AIR INTAKE SYSTEM AUTO-DIAGNOSTIC PROCEDURE • Do not disconnect the ECM couplings, the battery cables, the ECM Earth wiring from the engine or from the fuse before hav- ing checked that the malfunction code (auto-diagnostic code) has been memorised. The disconnection of these parts cancel the information memo- rised in the ECM.
  • Page 74 INJECTION - AIR INTAKE SYSTEM MALFUNCTION CODES AND MALFUNCTIONS MALFUNCTION RELATED ITEM RELATED MALFUNCTION CONDITION CODE CHECK NO PROBLEM ––––––––––––––––––––––––– Camshaft position The signal does not reach the ECM for more than 2 seconds sensor after having received the starting signal. The wiring of the camshaft position sensor and the mechanical parts (camshaft position sensor, rear intake camshaft pin, wiring connections/couplings).
  • Page 75 INJECTION - AIR INTAKE SYSTEM Ignition signal Code c25 is indicated for the rear cylinder. The ignition coil, wiring/ (#2 rear) coupling connections, battery feed. Gearchange position signal The signal voltage of the gearchange position must be higher than 0.60V for more than 2 seconds. (Gearchange position sensor voltage >...
  • Page 76 INJECTION - AIR INTAKE SYSTEM “C11” CMP SENSOR CIRCUIT MALFUNCTION PROBLEM POSSIBLE CAUSE CMP sensor signal is missing for 2 seconds when • Metal particles or foreign bodies on the CMP sensor or the engine is turned. on the end of the rotor. •...
  • Page 77 INJECTION - AIR INTAKE SYSTEM “C12” CKP SENSOR CIRCUIT MALFUNCTION PROBLEM POSSIBLE CAUSE CKP sensor signal missing for 2 seconds when • Metal particles or foreign bodies on the CKP sensor or the engine is turned over. on the end of the rotor. •...
  • Page 78 INJECTION - AIR INTAKE SYSTEM “C13” SENSOR CIRCUIT MALFUNCTION PROBLEM POSSIBLE CAUSE Low voltage and pressure. • Suction passageway between the carburettor and the High voltage and pressure. IAP sensor blocked. (0,5V Sensor voltage < 4,5V) • Air taken in from the suction passageway between the Outside the indicated range.
  • Page 79 INJECTION - AIR INTAKE SYSTEM Remove the IAP sensor. Connect a suction pump with a dial to the suction V on the outgoing passageway of the IAP sensor. Earth Connect three batteries of 1.5V in series (check that the total voltage is 4.5-5.0V) and connect the –...
  • Page 80 INJECTION - AIR INTAKE SYSTEM TP “C14” SENSOR CIRCUIT MALFUNCTION PROBLEM POSSIBLE CAUSE High or low voltage signal • TP sensor maladjusted. Difference between the actual opening of the throttle • TP sensor circuit open or short-circuited. and the opening calculated by the ECM that is more •...
  • Page 81 INJECTION - AIR INTAKE SYSTEM Connect the TP sensor connector. Grey/Orange Turn the ignition switch to the ON position. Measure the outgoing voltage of the TP sensor on the connector (between the grey/orange lead and the black/ brown lead) whilst turning the handgrip of the throttle. TP sensor outgoing voltage: Throttle closed: Approx.
  • Page 82 INJECTION - AIR INTAKE SYSTEM ECT “C15” SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE PROBLEMS • Brown/violet lead circuit in short-circuit to Earth. High temperature of the engine coolant (low voltage – low resistance) • Black/brown lead circuit open. Low temperature of the engine coolant •...
  • Page 83 INJECTION - AIR INTAKE SYSTEM “C21” IAT SENSOR CIRCUIT MALFUNCTION POSSIBLE CAUSE PROBLEM • Yellow/brown lead circuit in short-circuit to Earth. High temperature – air intake (low voltage – low resist- ance) • Black/brown lead circuit open. Low temperature – air intake (high voltage – high re- •...
  • Page 84 INJECTION - AIR INTAKE SYSTEM “C22” AP SENSOR CIRCUIT MALFUNCTION PROBLEM POSSIBLE CAUSE Low pressure and high voltage. • Passage of air blocked by dust. High pressure and high voltage. • Red/orange lead circuit open or in short-circuit to Earth. (0,25V ≤...
  • Page 85 INJECTION - AIR INTAKE SYSTEM Remove the AP sensor. Outgoing voltage Connect a suction pump with a dial to the suction passageway of the AP sensor. Earth Connect three 1.5V batteries in series (check that the total volts is 4.5-5.0V). Connect the – terminal to the earth terminal and + terminal to the Vcc terminal.
  • Page 86 INJECTION - AIR INTAKE SYSTEM “C23” TO SENSOR CIRCUIT MALFUNCTION PROBLEM POSSIBLE CAUSE Missing TO sensor signal for several seconds after the • TO sensor circuit open or in short-circuit. ignition switch has been turned ON. • TO sensor malfunction. Voltage signal or high.
  • Page 87 INJECTION - AIR INTAKE SYSTEM “C24” OR “C25” IGNITION SYSTEM MALFUNCTION (see page G24) “C31” GEARCHANGE SENSOR CIRCUIT MALFUNCTION PROBLEM POSSIBLE CAUSE Gearchange position switch voltage not present • Gearchange position switch circuit open or in short- Low switch voltage circuit.
  • Page 88 INJECTION - AIR INTAKE SYSTEM “C32” OR “C33” FUEL INJECTION MALFUNCTION PROBLEM POSSIBLE CAUSE Injector current not present. • Injector circuit open or in short-circuit. • Injector malfunction. • ECM malfunction. CHECK • Remove the seat. • Remove the fuel tank as described in Chapter B. •...
  • Page 89 INJECTION - AIR INTAKE SYSTEM “C41” FP RELAY CIRCUIT MALFUNCTION PROBLEM POSSIBLE CAUSE Relay signal at the fuel pump not present. • Fuel pump relay circuit open or in short-circuit. • Fuel pump relay malfunction. • ECM malfunction. CHECK • Remove the seat. Turn the ignition switch to the OFF position.
  • Page 90 INJECTION - AIR INTAKE SYSTEM FUEL PRESSURE CHECK • Remove the seat. • Remove the fuel tank as described in Chapter B. • Place a cloth underneath the fuel pressure control plug 1. Slacken it slowly and collect the remaining fuel by utilising a suitable con- tainer.
  • Page 91 INJECTION - AIR INTAKE SYSTEM FUEL PUMP CONTROL Turn the ignition switch to the ON position and check that the fuel pump operates for several seconds. If the pump motor makes no sound to indicate that it is operating, carry out the following checks: - Check the electrical output of the pump at the pump terminals.
  • Page 92 INJECTION - AIR INTAKE SYSTEM INTAKE FILTER After having removed the left hand fuel tank, remove the central union indicated in the figure as follows: • Slacken the locking ring nut 1. • Unscrew the union 2 complete with filter. •...

  • Page 93: Air Filter Removal

    INJECTION - AIR INTAKE SYSTEM INJECTION - AIR INTAKE SYSTEM AIR FILTER REMOVAL • Remove the seat. • Remove the fuel tank as described in Chapter B. • Remove the IAP sensor 1 from the filter and the suction extin- guisher 2 from the left hand side of the machine.
  • Page 94 INJECTION - AIR INTAKE SYSTEM BUTTERFLY BODY CONSTRUCTION 8 Fuel feed tubing support 15 Injector 1 Fuel pressure control plug 9 Fuel connecting plate 16 Dust protector 2 Fuel tube union nut 10 Throttle lever N° 2 17 O-ring 3 Sealing washer 18 Seal 11 Throttle lever N°...
  • Page 95 INJECTION - AIR INTAKE SYSTEM INJECTION - AIR INTAKE SYSTEM BUTTERFLY BODY REMOVAL • Remove the air filter and other relative parts as described in Page C-49. • Disconnect the suction tube from the three way union. • Remove the left hand and right hand plastic protective covers of the fuel pump and the expansion tank.
  • Page 96 INJECTION - AIR INTAKE SYSTEM • Disconnect the throttle cables 1 and the choke cables 2 by loosen- ing the relative locknuts. After having disconnected the throttle cables, do not com- pletely open and completely close the butterfly valve. This could damage the valve and the body of the carburettor.
  • Page 97 INJECTION - AIR INTAKE SYSTEM • Extract the expansion tank from the right hand side of the ma- chine. This creates space in which the butterfly body can be re- moved more easily. • Loosen the two fasteners on the collectors. •...
  • Page 98 INJECTION - AIR INTAKE SYSTEM DISASSEMBLING THE CARBURETTOR • Disconnect the suction tubes of the carburettor assembly. • Remove the TP sensor 1. • Remove the choke adjuster assembly 2. Remove the throttle cable guide 3. • Remove the fuel feed tubing 1 by removing the nuts. •...
  • Page 99 INJECTION - AIR INTAKE SYSTEM • Remove the injector seals 6. • Remove the fuel feed tubing support 7 by removing the screws. • Remove the N° 1 throttle lever 1 and the N° 2 throttle lever 2. Re- move the connection rod 3 by unscrewing the nuts. •...
  • Page 100 INJECTION - AIR INTAKE SYSTEM • Remove the carburettor air screw cap. • Slowly rotate the air screw in a clockwise direction and count the number of turns necessary to gently screw in the air screw into its seat. Note the number of turns so that the screw can be replaced correctly after cleaning.

  • Page 101: Cleaning The Carburettor

    INJECTION - AIR INTAKE SYSTEM INJECTION - AIR INTAKE SYSTEM CLEANING THE CARBURETTOR When cleaning carburettors, certain chemical products (es- pecially liquids for immersing and cleaning carburettors) are extremely corrosive and therefore must be handled with great care. Always follow the manufacturer’s instructions for use.
  • Page 102 INJECTION - AIR INTAKE SYSTEM CARBURETTOR REASSEMBLY • After cleaning the carburettor, replace the air screw in its original position by screwing in until it lightly rests on its seat. Then un- screw the number of turns noted during the removal. Air screw standard adjustment: Approx.
  • Page 103 INJECTION - AIR INTAKE SYSTEM INJECTION - AIR INTAKE SYSTEM • Completely close the butterfly valve 1 on the rear carburettor and on the front carburettor. • Before replacing the N° 2 throttle lever, check the insertion of the ferrule 3, the washer 4 and the spring 5. •...
  • Page 104 INJECTION - AIR INTAKE SYSTEM • Correctly replace the suction tube clamp A. • Replace the fuel feed tubing support 1. • Tighten the connecting plate screws and the screws of the fuel feed tubing support. • Apply a thin layer of engine oil to the new injector seals 2 and replace them.
  • Page 105 INJECTION - AIR INTAKE SYSTEM • Replace the incoming fuel tube joint 1 at the correct angle on the feed tubing. • Tighten the joint nut of the incoming fuel tube to the specified torque. 30° Torque pressure Tube joint nut: 23 Nm (2.3 kg-m) Replace and renew the sealing washers on both sides of the tube joint.
  • Page 106 INJECTION - AIR INTAKE SYSTEM • Connect the suction tubes 1 of the three-way sensor 2 and the fuel pressure adjuster 3 as shown in the figure. CARBURETTOR INSTALLATION • Install the carburettor assembly and tighten the screws of the bands on the side of the air intake collectors.
  • Page 107 INJECTION - AIR INTAKE SYSTEM • Replace the support plate of the tickover adjustment using the mounting screw. Torque pressure Mounting nut: 23 Nm (2.3 kg-m) • Replace the complete T-shaped coil support. • Connect the injector couplings 2 and 3. •...
  • Page 108 INJECTION - AIR INTAKE SYSTEM • Replace the expansion tank in the reverse order of removal. Carry out the bleeding of air of the cooling system as described in Chapter B. • Assemble the engine support frames 3 and the relative screws, 4, 5, 6 and 7.

  • Page 109: Fuel Injector Removal

    INJECTION - AIR INTAKE SYSTEM FUEL INJECTOR CHECK The fuel injector must be checked without removing it from the car- burettor. See page C-49 for details. FUEL INJECTOR REMOVAL • Lift up and sustain the fuel tank with a suitable support. •...

  • Page 110: Choke Adjustment

    INJECTION - AIR INTAKE SYSTEM CHOKE ADJUSTMENT The choke is a cold start system that mechanically opens the butter- fly valve by utilising a cam. The cam is made to rotate by the cable and it pushes the butterfly valve rod attachment. The butterfly valve therefore opens allowing the engine to turnover from cold at a maxi- mum of 2000 rpm (20°÷30°).
  • Page 111 INJECTION - AIR INTAKE SYSTEM CARBURETTOR SYNCHRONISATION Check and adjust the butterfly valve synchronisation of the front and rear cylinders. CALIBRATION ACCESSORY • Remove the right hand fuel tank. • Switch on the engine and let it run for several minutes to warm up. •...
  • Page 112 INJECTION - AIR INTAKE SYSTEM • Connect a revcounter. • Switch on the engine and let it tickover at 1300 rpm by utilising the throttle stop screw 1. When the carburettor is without the air filter compartment, make sure that no foreign bodies enter the engine. Such material could damage the internal parts of the engine.
  • Page 113 INJECTION - AIR INTAKE SYSTEM • Connect a revcounter and switch on the engine. • Utilising the throttle stop screw, turn the engine over at 1300 rpm. • Check the suction of the two cylinders and balance the two butter- fly valves.
  • Page 114 INJECTION - AIR INTAKE SYSTEM THROTTLE LEVER PLAY After synchronising the butterfly valves and adjusting the tickover, check that the play A between the throttle lever 1 and the stop screw 2 is 0.25 mm. If not, adjust the play A as follows. •...

  • Page 115: Throttle Cable Adjustment

    INJECTION - AIR INTAKE SYSTEM THROTTLE CABLE ADJUSTMENT Fine adjustments can be carried out by using the screw adjuster on the throttle handgrip (see Chapter B). MAJOR ADJUSTMENTS • Remove the fuel tank as described in pages B-4 and B-6. •...
  • Page 116 INJECTION - AIR INTAKE SYSTEM SENSORS IAP SENSOR CHECK The air intake air pressure sensor is situated on the right hand side of the air filter compartment. IAP SENSOR REMOVAL/REASSEMBLY • Remove the right hand fuel tank. • Remove the fixing screws of the IAP sensor 1 and disconnect the coupling 2.
  • Page 117 INJECTION - AIR INTAKE SYSTEM IAT SENSOR CHECK The air intake air temperature sensor is situated on the front part of the air filter compartment. IAT SENSOR REMOVAL/REASSEMBLY • Remove the fuel tank. • Disconnect the IAT sensor coupling 1 and remove the IAT sensor from the air filter compartment.
  • Page 118 INJECTION - AIR INTAKE SYSTEM C.74...
  • Page 119 ENGINE Section...
  • Page 120 ENGINE Camshaft/Cylinder head ..........D-81 Cylinder/Piston ..............D-105 Clutch ................D-114 Water pump/Clutch cover ..........D-123 Primary driving gear/Valve motion idler gear shaft/sprocket no. 1 ............D-129 Starting system/Generator/Crankshaft position sensor ..............D-134 Gear preselector ............D-143 Crankcase/Gearbox/Crankshaft/Connecting rod ..D-151 Engine lubrication system ..........D-169...

  • Page 121: Engine

    ENGINE ENGINE COMPONENTS THAT CAN BE REMOVED WITHOUT REMOV- ING THE ENGINE The parts listed below can be removed and reinstalled without removing the engine from the chassis. Refer to the pages shown next to each item for information on the removing and installing procedures. ENGINE LEFT SIDE PARTS REMOVAL...

  • Page 122: Removing The Engine

    ENGINE REMOVING AND INSTALLING THE EN- GINE REMOVING THE ENGINE Before removing the engine from the frame, wash it with a steam cleaner or other suitable equipment. The engine removing proce- dure is described below and installation is obtained by following the same steps in reverse order.
  • Page 123 ENGINE • Remove the air filter and its various components (see page C.51) • Remove the engine support frames 1 and 2 as described in page C.54. • Remove the engine coolant expansion tank as described in page C.55. • Remove the connector from the temperature sensor that is situ- ated on the cooling system thermostat housing.
  • Page 124 ENGINE • Disconnect the connectors of the engine coolant temperature hous- ing 1 and the cooling fan connector 2 and the hoses 6. They are all found on the right hand side of the machine. Take care when reassembling the electrical wiring and the rubber bands.
  • Page 125 ENGINE • Remove the two fixing screws, the front cylinder exhaust tube as indicated in the figure. • Remove the exhaust tube. • After removing the screws as indicated in the figure, remove the rear cylinder exhaust tube. • Remove the left hand footrest assembly 1 together with the gearchange lever 2.
  • Page 126 ENGINE • Remove the two mounting bolts 1 and the washer of the clutch disengagement mechanism of the clutch. • Remove the clutch disengagement mechanism assembly 2. To ease the reinstallation of the assembly, slacken off the locking nut and the adjuster screw before removing the mounting bolts of the clutch disengagement mechanism.
  • Page 127 ENGINE • Remove the transmission chain from the crown wheel. • Remove the nut 1 and the engine pinion washer. • Remove the engine pinion 2. • Remove the oil radiator 3 by unscrewing the mounting bolts 4 and the junction bolts of the oil tubes.
  • Page 128 ENGINE • Disconnect the electrical leads of the starter motor 1 and the oil pressure sensor 2. • Remove the insulated covers from the spark plugs. Take care when reassembling the electrical wiring and the rubber bands. It is important to replace the wiring exactly as it was before disassembly.
  • Page 129 ENGINE • Remove the right hand footrest by unscrewing the two fixings as shown in the figure. Removing the right hand footrest assists the removal of the engine from the frame. • Remove the return spring of the rear brake pedal. •...
  • Page 130 ENGINE • Gradually lower the power plant. When removing the engine from the frame, take care not to damage either. D.12...
  • Page 131 ENGINE INSTALLATION OF THE ENGINE INTO THE FRAME Install the engine in the reverse order of removal. Proceed carefully taking care to correctly position the tubing and wiring. • Before proceeding with the installation of the engine into the frame, support the frame with a jack or an adequate support.
  • Page 132 ENGINE • Reinstall the secondary air tubes on the cylinders tightening the screws to the specified torque. Torque pressure Secondary air tube fixing 8.6/9.8 N.m (0.9/1.0 kg-m) Utilise new washers when refitting the tubes onto the cylinders. • When inserting the insulated covers onto the spark plugs, make sure that the triangular countersigns on the insulated covers point towards the exhaust side of the cylinder.
  • Page 133 ENGINE Tightening torques: LENGTH ITEM N·m kg-m Description ITEM 45÷50 4,5÷5,0 front fix. screw-left hand side of the eng./frame 45÷50 4,5÷5,0 front fix. screw-right hand side of the eng./frame 45÷50 4,5÷5,0 central fixing screw engine/2 support frames Bolt 45÷50 4,5÷5,0 upper rear fix. screw engine/frame bracket 45÷50 4,5÷5,0 lower rear fix.
  • Page 134 ENGINE • Install the oil-cooler and tighten oil line union bolts 1 with the pre- scribed torque. Tightening torque: Oil line union bolt 23 N.m (2,3 kg-m) (16.79 lb·ft) • Tighten engine sprocket nut 2 with the specified torque. Tightening torque: Engine sprocket nut 115 N.m (11,5 kg-m) (83.95 lb·ft)
  • Page 135 ENGINE • Fit the cable on the generator cover and momentarily place throw- out lever 1 on the push rod. • Pull the cable and adjust the angle of the throw-out lever end within 5-10 degrees by rotating adjuster 2. •...
  • Page 136 ENGINE • Reassemble the left hand footrest tightening the two bolts to the specified torque. Torque pressure Footrest fixing bolts 23.5/25.4 N.m (2.4/2.6 kg-m) • Reassemble the gearchange lever onto the gear lever shaft mak- ing sure that the previously marked countersigns are in line with each other.
  • Page 137 ENGINE • Reassemble the various components following the reverse order of removal of the engine from the frame. Reassemble the left and right hand engine support frames, supporting the engine so that the various fixing holes can be aligned correctly. Tighten the various fixings to the specified torque.

  • Page 138: Disassembling The Engine

    ENGINE DISASSEMBLING AND REASSEMBLING THE ENGINE DISASSEMBLING THE ENGINE Identify the position of each removed component (intake pipe, camshaft, cylinder head, piston, connecting rod, etc.) and sort the parts into groups so that each component can be reinstalled in its original position. •...
  • Page 139 ENGINE ENGINE • Remove valve gear timing inspection plug 1 and generator cover plug 2. NO. 1 (FRONT) CYLINDER • Remove the cylinder head cover bolts and the related gaskets. • Remove cylinder head cover 3 and the gaskets. • Remove the dowel pins. •...
  • Page 140 ENGINE • Remove the two camshafts, intake 1 and exhaust 2. • Remove C-rings 3. • Remove dowel pins 4. Take care not to drop C-rings 3 and dowel pins 4 into the crankcase. • Remove front timing chain tension adjuster 5 and the related gas- ket.
  • Page 141 ENGINE • Remove cylinder head nut (M8) 1, and loosen cylinder nuts 2. • Remove the cylinder head bolts (M10) with the related washers. • Remove the cylinder head assembly. Loosen the cylinder head bolts gradually by following a crosswise pattern.
  • Page 142 ENGINE • Place a clean rag over the cylinder base to prevent the piston pin circlip from falling into the crankcase. • Remove the piston pin circlip. • Extract the piston pin and remove the piston. * Write the cylinder numbers on the crowns of their respective pis- tons.
  • Page 143 ENGINE • Remove the two camshafts, intake 1 and exhaust 2. • Remove C-rings 3. • Remove dowel pins 4. Take care not to drop C-rings 3 and dowel pins 4 into the crankcase. • Remove rear timing chain tension adjuster 5 and the related gas- ket.
  • Page 144 ENGINE • Remove cylinder head bolts (M6) 1 and timing chain stretcher fas- tening bolt 2. • Remove timing chain stretcher 3. • Remove cylinder head nuts (M6) 4. • Remove cylinder head nut (M8) 5. • Loosen cylinder nuts 6. •...
  • Page 145 ENGINE • Remove cylinder head gasket 1, dowel pins 2, timing chain guide 3, and cylinder nuts 4. • Remove the cylinder. Firmly grip the cylinder at both ends and lift it up squarely. If the cylinder does not come out, loosen the gasket by gently tapping the finless part with a plastic mallet.
  • Page 146 ENGINE • Remove generator cover 1. • Remove dowel pin 2 and gasket 3. • Remove starting torque limiter 4 and washers 5. • Remove starting idler gear 6, spacer 7, and shaft 8. • Remove bushings 9 from the crankcase and the generator cover. D.28...
  • Page 147 ENGINE • Remove water pump casing 1 with the O-ring. • Remove dowel pin 2. • Remove impeller 3. • Remove clutch bell housing cover 4. • Remove clutch cover 5 and the clamps. * Extract the clutch cover squarely to avoid damaging the water pump oil seal.
  • Page 148 ENGINE • Remove pressure plate 1. • Remove push rod 2, bearing 3 and thrust washer 4. • Remove clutch push rod 5. Should push rod 5 be difficult to extract, use a magnet or an iron wire. • Remove the clutch driving and driven plates. •...
  • Page 149 ENGINE • Remove washer 1. • Remove clutch drum 2 together with driving cam 3 and driven cam • Remove driving cam 3 and driven cam 4 from clutch drum 2. These three parts must be replaced as a set. •...
  • Page 150 ENGINE • Remove needle roller bearing 1, collar 2, and thrust washer 3. • Remove oil pump driven gear 4 after removing the circlip. • Remove pin 5 and washer 6. Take care not to drop the circlip, pin 5 or washer 6 into the crank- case.
  • Page 151 ENGINE • Remove neutral switch contact 1 and the related spring 2. • While holding the generator rotor with a 36-mm spanner, remove no. 1 valve motion idler gear/sprocket nut 3 and the related washer. • Insert a bar of suitable size into the holes of the primary driving gears to align the teeth of the scissors gears.
  • Page 152 ENGINE • While holding the generator rotor with a 36 mm (1.417 in) span- ner, remove primary driving gear nut 1. This nut has a left-hand thread. Turning it anticlockwise may cause damage. • Remove washer 2. • Remove primary driving gear assembly 3. Refer to page D-130 for instructions on how to remove and fit the primary driving gear.
  • Page 153 ENGINE • After removing the generator rotor bolt, fit the special tool in the hub and remove generator rotor assembly 1 by rotating the spe- cial tool while holding the rotor with a 36 mm (1.417 in) spanner. Specific tool: 800096684 Rotor extractor •...
  • Page 154 ENGINE • Pull out gear shaft/arm 1 with washers 2. • Remove gear preselector plate 3. • Remove gear preselector stop 4 with the related spring and washer. • Remove gear arm stop bolt 5. • Remove oil seal retainer 6 and engine sprocket spacer 7 with the O-ring.
  • Page 155 ENGINE • Remove the crankcase bolts. • Separate the crankcase into two parts, left and right, using the specially designed tool. Specific tool: 800096674 Crankcase separator * Fit the crankcase separator so that the tool arms are parallel with the crankcase sides. * The crankshaft and the transmission components must remain in the left crankcase half.
  • Page 156 ENGINE • Remove O-ring 1, oil pump 2 and plate 3. Refer to page D-170 for details of how to inspect the oil pump. • Remove reed valve 4. • Remove piston cooling oil nozzles 5 from the left and right crank- case halves.
  • Page 157 ENGINE • Remove the bearing setscrews. • Remove bearings 1, 2, 3, 4, 5 and 6 using the special tools. Specific tools: 800096676: Bearing extractor (for 1) 800096683: Sliding shaft (for 1) 800096655: Bearing separator (for 2,4,5) 800096656: Bearing separator (for 3,6) Replace the removed bearings with new ones.

  • Page 158: Assembling The Engine

    ENGINE ASSEMBLING THE ENGINE The engine is reassembled by following the disassembling proce- dure in reverse order. However, a number of operations require spe- cial instructions or precautions. Apply engine oil over all movable and sliding parts before reassembly. • Fit bearings 1, 2, 4, 5, 6 and 7 in the crankcase using the specially designed tools.
  • Page 159 ENGINE • Fit oil seals 1 and 2 in the crankcase using the specially designed tools. • Grease the oil seal lips. Specific tools: 800096873: Bearing installer (for1) 800096657: Bearing installer (for2) Specific product: AGIP GREASE 30 • Fit new O-rings to the cooling oil nozzle of each piston. To prevent oil leakage, always use new O-rings.
  • Page 160 ENGINE • Fit thrust shim 1 to the crankshaft. * Grooved side A of thrust shim 1 must face the crankshaft web side. * The thrust shim is selected according to the crankshaft thrust clear- ance (refer to pages D-167 -169). •...
  • Page 161 ENGINE • Fit plate 1 and oil pump 2 to the right-hand crankcase half. Apply a small quantity of specific product to the oil pump fastening bolts and to the plate bolts, and then tighten with the prescribed torques. Specific product: LOC-TITE 243 Tightening torques: Oil pump fastening bolt 10 N.m (1,0 kg-m) (7.3 lb·ft)
  • Page 162 ENGINE Left-hand crankcase half • When fastening the left and right crankcase halves, tighten each bolt gradually to equalize the pressure. Tighten all fastening bolts with the specified torques. Tightening torques: Crankcase bolts (M8) 22 N.m (2,2 kg-m) (16.06 lb·ft) (M6) 11 N.m (1,1 kg-m) (8.03 lb·ft) When assembling the left and right crankcase halves, take care not to drop the O-rings into the crankcase.
  • Page 163 ENGINE ENGINE After tightening the crankcase bolts, ensure that the crankshaft, the driving shaft and the countershaft can rotate freely. • Fit a new O-ring in engine sprocket spacer 1. Use a new O-ring to prevent oil leakage. • Fit engine sprocket spacer 1 to the driving shaft. * Grooved side A of the engine sprocket spacer must face the crank- case side.
  • Page 164 ENGINE • Apply a small quantity of specific product to gear arm stop bolt 1 and then tighten with the specified torque. Specific product: LOC-TITE 270 Tightening torque: Gear arm stop bolt 23 N.m (2,3 kg-m) (16.79 lb·ft) • Fit gear preselector stop 2, the related bolt 3, washer 4 and return spring 5.
  • Page 165 ENGINE • Fit dowel pins 1 and gasket 2. Use a new gasket to prevent oil leakage. • Fit the gearbox cover. Fit the new sealing washer on bolt 3 and the clamp on bolt 4 as shown in the figure. Fit a new sealing washer to prevent oil leakage.
  • Page 166 ENGINE • Fully insert key 1 into its slot on the crankshaft. • Fit generator rotor assembly 2 and driven starting gear 3 to the crankshaft. • Apply specific product to rotor bolt 4 and then fit it. Specific product: LOC-TITE 270 •...
  • Page 167 ENGINE • Install primary driving gear assembly 1 and washer 2. The convex side of washer 2 must face outwards. • Fit the primary driving gear nut. * This nut has a left-hand thread. * Mark “L” A on the nut must face outwards. •...
  • Page 168 ENGINE • Insert key 1 as shown in the figure. • Fit no. 1 valve motion idler gear/sprocket nut 2 with the related washer. • While holding the crankshaft on the generator rotor, tighten no. 1 valve motion idler gear/sprocket nut 2 with the specified torque. Tightening torque: No.
  • Page 169 ENGINE • Install oil sump filter 1 and oil pressure regulator 2. Oil sump filter projection A must face downwards. • Tighten oil pressure regulator 2 with the specified torque. Tightening torque: Oil pressure regulator 28 N.m (2,8 kg-m) (20.44 lb·ft) •...
  • Page 170 ENGINE • Fit needle roller bearing 1 and collar 2 to the countershaft and lubricate them with engine oil. • Fit primary driven gear assembly 3 to the countershaft. * When installing primary driven gear assembly 3, align the teeth of the primary gears by inserting a bar of suitable size into their holes.
  • Page 171 ENGINE • Fit clutch driving cam 1 on clutch drum 2. Align “I” mark A on the clutch driving cam with “I” mark A on driven cam 3. • Fit clutch drum 2 with driving cam 1 and driven cam 3 to the countershaft.
  • Page 172 ENGINE • Correctly fit spring washer seat 1 and spring washer 2 to the clutch drum. • Insert the clutch driving and driven plates one by one into the clutch drum in the order shown in the figure. Insert no.2 driving plate B first.
  • Page 173 ENGINE ENGINE • Fit clutch push rod 1 in the countershaft. • Fit clutch push rod 2, bearing 3 and thrust washer 4 to the countershaft. • Place pressure plate 5 on the clutch drum. • While holding the generator rotor with a 36-mm spanner, tighten the clutch spring fastening bolts with the specified torque following a crisscross pattern (see figure).
  • Page 174 ENGINE • Fit the clutch cover. • To avoid damaging the oil seal lip, cover the edge of the no. 1 valve motion idler gear shaft with a vinyl film or tape A before fitting the clutch cover. • To prevent damage to the oil seal lip, fit the clutch cover squarely.
  • Page 175 ENGINE ENGINE • Fit the sealing washer and the washer on impeller fastening bolt 1. Sealing washer metal side E and washer convex side F must face the head of the impeller fastening bolt. • Fit impeller 2 and its fastening bolt 1 to the shaft. •...
  • Page 176 ENGINE • Firmly tighten the clutch bell housing cover bolts, the water pump casing bolts, and the clutch cover bolts. • Fit starting idler gear 1, spacer 2 and shaft 3. Apply engine oil and specific product to shaft 3. Specific product: MOLIKOTE •...
  • Page 177 ENGINE • Fit the generator cover and firmly tighten its bolts. Fit the sealing washer on generator cover bolt A as shown in the figure. To prevent oil leakage, use a new sealing washer. • Fit a new O-ring to the starter motor. To prevent oil leakage, use a new O-ring.
  • Page 178 ENGINE • The first element of the scraper ring to be inserted into the groove is spacer 1. After fitting the spacer, insert the two side rings 2. The spacer and the side rings do not have an upper or lower side and can be fitted either way.
  • Page 179 ENGINE • Apply engine oil to the new O-rings. • Install front and rear oil jets 1 as shown in the figure. To prevent oil leakage, use new oil rings. • Apply a film of specific product to the mating surfaces of the left and right crankcase halves as shown in the figure.
  • Page 180 ENGINE • Hold the piston rings in position and insert the pistons into the front and rear cylinders. When installing the cylinders, keep the timing chains taut. Make sure the timing chains are not caught between the driving sprocket and the crankcase when the crankcase is turned.
  • Page 181 ENGINE • Place the rear cylinder head on the cylinder. When installing the cylinder head, keep the timing chain taut. • Using a torque spanner, tighten the cylinder head bolts (M10) to the specified torque in two steps and following a sequential cross- wise pattern.
  • Page 182 ENGINE • Place the front cylinder head on the cylinder. When installing the cylinder head, keep the timing chain taut. • Using a torque spanner, tighten the cylinder head bolts (M10) to the specified torque in two steps and following a sequential cross- wise pattern.
  • Page 183 ENGINE • Pull up the timing chains and fit the timing chain stretchers in each cylinder head. 1 No. 1 (front) cylinder head 2 No. 2 (rear) cylinder head * When fitting a timing chain stretcher, insert the end of its support A into the guide cast in the cylinder.
  • Page 184 ENGINE FRONT NO. 2 VALVE MOTION IDLER GEAR/SPROCKET • Turn the crankshaft anticlockwise with a tubular spanner and align “F|T” line A on the generator rotor with valve gear timing inspec- tion hole mark B while pulling up the timing chain. Pull up the timing chain, or it may get caught between the crankcase and the valve gear driving sprocket.
  • Page 185 ENGINE • Check and correct the positions of the “F|T” line on the generator rotor and on no. 2 valve motion idler gear/sprocket 1. When checking the above positions, take up the timing chain slack on the side of chain guide 2 by holding the no. 2 valve motion idler gear/sprocket with one hand.
  • Page 186 ENGINE • Tighten the shaft of the no. 2 valve motion idler gear/sprocket with the specified torque. Tightening torque: No. 2 valve motion idler gear/sprocket shaft 40 Nm (4,0 kg-m) (29.2 lb·ft) NO. 1 (FRONT) TIMING CHAIN TENSION ADJUSTER • Fit the front timing chain tension adjuster by following the proce- dure described below.
  • Page 187 ENGINE • Fully compress timing chain tension adjuster rod 1 after releasing ratchet 2. • From this position, unscrew adjuster bolt 1 until adjuster rod 2 locks. The timing chain tension adjuster is now ready for installation. Unscrew adjuster bolt 3 while compressing the adjuster rod. •...
  • Page 188 ENGINE • Install the timing chain tension adjuster as shown in the figure and tighten the fastening bolts with the specified torque. Tightening torque: Timing chain tension adjuster fastening bolt 10 N·m (1,0 kg-m) (7.3 lb·ft) • Release the adjuster by screwing in bolt 1. A click may be heard when the timing chain tension adjuster rod is released.
  • Page 189 ENGINE NO. 2 (REAR) TIMING CHAIN TENSION ADJUSTER • Fit the rear timing chain tension adjuster by following these steps: • Remove the no. 2 (rear) timing chain tension adjuster. • Fit a new gasket 1. To prevent oil leakage, use a new gasket. •...
  • Page 190 ENGINE • Rotate the generator rotor 720 degrees (two full turns) and align the “F|T” line on the generator rotor with the mark of the valve gear timing inspection hole. • Check the positions of lines A on the front and rear no. 2 valve motion idler gears/sprockets.
  • Page 191 ENGINE The camshafts are identified by letters and differ in shape. 1 For the no. 1 (front) exhaust camshaft 2 For the no. 1 (front) intake camshaft 3 For the no. 2 (rear) intake camshaft 4 For the no. 2 (rear) exhaust camshaft Immediately before placing the camshafts in the cylinder head, ap- ply specific product to their journals.
  • Page 192 ENGINE • Install the intake and exhaust camshaft journal bearings. • Fix the camshaft bearings evenly by tightening the bolts according to a sequential crosswise pattern. (Equalize the pressure by shift- ing the spanner diagonally so as to fasten the shafts evenly.) * Failure to tighten the camshaft journal bearings evenly may result in damage to the cylinder head or the camshafts.
  • Page 193 ENGINE NO. 2 (REAR) CAMSHAFTS • Install the no. 2 (rear) intake and exhaust camshafts by following these steps: • From the installing position of the no. 1 (front) camshafts, rotate the crankshaft 360 degrees (1 full turn) and align the “F|T” line on the generator rotor with the mark of the tappet inspection hole.
  • Page 194 ENGINE • Install the intake and exhaust camshaft journal bearings. • Fix the camshaft bearings evenly by tightening the bolts according to a sequential crosswise pattern. (Equalize the pressure by shift- ing the spanner diagonally so as to fasten the shafts evenly.) * Failure to tighten the camshaft journal bearings evenly may result in damage to the cylinder head or the camshafts.
  • Page 195 ENGINE • After installing the no. 2 (rear) camshafts, rotate the crankshaft 360 degrees (1 full turn) and check their positions again. Be sure to check the position of “F|T” line A on the genera- tor rotor, of line B on no. 2 valve motion idler gears/sprock- ets C, and of the line on the camshafts.
  • Page 196 ENGINE • Pour engine oil into each of the front and rear cylinder head pock- ets. Be sure to check the tappet clearance (refer to pages B-7 to B-11.) • Install camshaft position sensor 1 and tighten the fastening bolts with the specified torque.
  • Page 197 ENGINE ENGINE • Place the cylinder head covers on the cylinder heads. • Fit a gasket to each cylinder head cover bolt. To prevent oil leakage, use new gaskets. • After applying engine oil to the gaskets, tighten the cylinder head cover bolts with the specified torque.
  • Page 198 ENGINE • Firmly tighten the cooling system union bolts. • Install the thermostat casing with the coolant lines and firmly tighten the fastening screws. Turn the heads of the fastening screws to the left. • Fit crankcase breather pipe 1. •...
  • Page 199 ENGINE CAMSHAFT/CYLINDER HEAD D.81...
  • Page 200 ENGINE CONTENTS DESCRIPTION OF THE VALVE GEAR SYSTEM ..................D-83 REMOVING THE CAMSHAFTS ....................... D-88 CHECKING AND SERVICING THE CAMSHAFTS AND THE CYLINDER HEAD ........D-90 INSTALLING THE CAMSHAFTS ......................D-102 D.82...
  • Page 201 DESCRIPTION OF THE VALVE GEAR SYSTEM The Navigator 1000 valve gear system consists of the crankshaft, the primary driving gear, the no. 1 valve motion idler gear/sprocket, the no. 1 valve motion idler gear/sprocket shaft, the timing chains, the no. 2 valve motion idler gears/sprockets and the camshafts.
  • Page 202 ENGINE FRONT NO. 2 CAM DRIVE IDLE FRONT NO. 2 CAM DRIVE IDLE GEAR/SPROCKET GEAR/SPROCKET 18 TEETH 31 TEETH NO. 1 CAM DRIVE IDLE 36 TEETH GEAR/SPROCKET ENGRAVED LINE ENGRAVED LINE 31 TEETH FRONT CYLINDER TDC OF EXHAUST FRONT CYLINDER TDC OF STROKE COMPRESSION STROKE The two top dead centres, one on the compression stroke and the other on the exhaust stroke, can be identified by...
  • Page 203 ENGINE When reassembling the engine, position the no. 1 and no. 2 valve motion idler gears/sprockets at their top dead centres. Improper assembly - such as the positioning of the no. 2 valve motion idler gear/sprocket at the top dead centre of the compression stroke and the no.
  • Page 204 ENGINE D.86...
  • Page 205 ENGINE D.87...

  • Page 206: Removing The Camshafts

    ENGINE REMOVING THE CAMSHAFTS NO. 1 (FRONT) CAMSHAFTS To remove the no. 1 (front) camshafts, remove the following parts in the order given below. Refer to the pages indicated for details on how to perform each step. Remove: • The radiator (see page D-5). •...
  • Page 207 ENGINE NO. 2 (REAR) CAMSHAFTS To remove the no. 2 (rear) camshafts, remove the following parts in the order given below. Refer to the pages indicated for details on how to perform each step. Remove: • The saddle. • The spark plug (page B-8). •...
  • Page 208 ENGINE CHECKING AND SERVICING THE CAMSHAFTS AND THE CYLINDER HEAD Identify the exact location of each removed component. Sort the parts into groups designated as “No. 1”, “No. 2”, “Ex- haust”, “Intake”, etc., so that each part can be restored to its original position during reassembly.
  • Page 209 ENGINE CAMSHAFT JOURNAL WEAR To determine whether a camshaft journal is worn beyond the service limit, measure the oil clearance with the camshaft in place. Measure plastigauge 1 in its widest portion to determine the oil clearance, which should be as follows: Service limit Camshaft journal oil clearance (IN.
  • Page 210 ENGINE CAMSHAFT RUNOUT Measure the runout with a comparator. Replace the camshaft if the runout exceeds the specified limit. Service limit Camshaft runout (IN. & EX.): 0,1 mm (0.0039 in) Specific tools: Comparator (1/100 mm, 10 mm) (0.039/3.937 in, 0.3937 in) Magnetic stand 800096650: V-blocks CAMSHAFT GEARS AND AUTOMATIC DECOMPRESSOR...
  • Page 211 ENGINE CYLINDER HEAD • Remove the tappets and shims 1 either manually or using a mag- net. • Utilizzando gli attrezzi speciali, comprimere le molle della valvola e rimuovere i due semiconi 2 dallo stelo della valvola. Specific tools: 800096664: Valve spring compression tool 800096665: Valve spring compression attachment Tweezers...
  • Page 212 ENGINE • Remove oil seals 1 and spring seats 2 Do not reuse the oil seals. CYLINDER HEAD DISTORTION Decoke the combustion chambers. Check the gasketed surface of the cylinder head for distortion using a straightedge and a thickness gauge. Take measurements at the positions shown in the figure.
  • Page 213 ENGINE VALVE STEM DEFLECTION Lift the valve about 10 mm (0.3937 in) over the valve seat. Position the comparator as shown in the figure and measure the valve stem deflection in the two directions, perpendicular to each other, X and Y.
  • Page 214 ENGINE • Lubricate the hole in the cylinder head and the stem hole of each valve guide and then insert the guide into the hole using the valve guide installer and its attachment. Valve Specific tools: 800096671 - Valve guide remover/installer guide Cylinder 800096672 - Valve guide installer attachment...
  • Page 215 ENGINE The valve seating area must be inspected after each cut. Specific tools: 96768 - Valve seat cutter (N-626) 800096667 - Valve seat working guide (N-140-5.5) 800096666 - Valve seat working set • Insert the guide with a slight rotation. Seat the guide snugly. Fit the 45°...
  • Page 216 ENGINE • Clean and fit the cylinder head and valve components. Fill the intake and exhaust ports with petrol and check that there are no leaks. If any leaks are found, check for burrs or other factors that prevent the valve seat and the seating surface from sealing prop- erly.
  • Page 217 ENGINE NO. 2 VALVE MOTION IDLER GEAR/SPROCKET THRUST CLEARANCE Install no. 2 valve motion idler gear/sprocket 1, its shaft 2, copper washer 3 and thrust washer 4 on each cylinder head as shown in the figure. Tighten shaft 2 with the specified torque. Using a thick- ness gauge, measure the thrust clearance between the cylinder head and thrust washer 4.
  • Page 218 ENGINE CYLINDER HEAD ASSEMBLY • Fit the valve spring seats. • Oil all the oil seals and fit them using the valve guide installer. Specific tool: 800096671 - Valve guide remover/installer Never reuse used oil seals. • Insert the valves after lubricating their stems completely and evenly with good-quality molybdenum bisulphide.
  • Page 219 ENGINE • Fit the tappet biscuit and pad in their original positions. * Apply engine oil to the tappet biscuit and pad before fitting them. * Be sure to insert the tappet pad so that the surface stamped with a figure faces the tappet.

  • Page 220: Installing The Camshafts

    ENGINE INSTALLING THE CAMSHAFTS NO. 1 (FRONT) CAMSHAFT Installation is obtained by following the disassembling procedure in reverse order. Refer to the pages indicated for details on how to perform each step. Fit: • The camshafts. • The dowel pins •...
  • Page 221 ENGINE • The spark plug. • The radiator (see page H-8). NO. 2 (REAR) CAMSHAFT Install the components listed below in the order indicated. When fitting the components, follow the fitting procedures described in the pages indicated. Fit: • The camshafts. •...
  • Page 222 ENGINE • The generator cover plug. • The tappet timing inspection plug (see page D-79). • The cylinder head cover (see pages D-78 -79). • The spark plug. D.104...
  • Page 223 ENGINE CYLINDER/PISTON EXHAUST • 2nd ring • Lower side ring • Upper side ring • 1st ring • Spacer INTAKE POSITIONING OF PISTON RINGS CONTENTS REMOVING THE CYLINDER AND THE PISTON .................. D-106 CHECKING THE CYLINDER AND THE PISTON .................. D-108 INSTALLING THE CYLINDER AND THE PISTON .................
  • Page 224 ENGINE CREMOVING THE CYLINDER AND THE PISTON NO. 1 (FRONT) CYLINDER AND PISTON The components listed below must be removed in the order indi- cated before removing the no. 1 (front) cylinder and piston. Refer to the pages indicated for details on how to perform each step. Remove: •...
  • Page 225 ENGINE NO. 2 (REAR) CYLINDER AND PISTON The components listed below must be removed in the order indi- cated before removing the no. 2 (rear) cylinder and piston. Refer to the pages indicated for details on how to perform each step.
  • Page 226 ENGINE CHECKING THE CYLINDER AND THE PISTON CYLINDER BLOCK DISTORTION Check the gasketed surface of the cylinder block for distortion using a straightedge and a thickness gauge. Take measurements at the positions shown in the figure. If the maximum reading at any posi- tion exceeds the specified limit, replace the cylinder block.
  • Page 227 ENGINE PISTON/CYLINDER CLEARANCE After completing the previously described measurement, if the clear- ance between the piston and the cylinder exceeds the specified limit, replace both the cylinder and the piston. Service limit Piston/cylinder clearance: 0,12 mm (0.0047 in) PISTON RING/PISTON GROOVE CLEARANCE Using a thickness gauge, measure the side clearance of the 1st and 2nd piston rings.
  • Page 228 ENGINE PISTON RING FREE END GAP AND PISTON RING END GAP Before fitting the piston rings, measure the free end gap of each ring using a vernier caliper. Then fit the ring in the cylinder and measure the end gap of the ring using a thickness gauge. If the end gap is excessive, replace the ring.
  • Page 229 ENGINE INSTALLING THE PISTON AND THE CYLINDER Install the piston rings in the following order: scraper, 2nd ring, 1st 1st ring ring. The sections of the 1st and 2nd rings differ in shape. 2nd ring • Be sure to fit the 1st ring so that its convex side faces upwards. •...
  • Page 230 ENGINE NO. 1 (FRONT) PISTON AND CYLINDER Installation is obtained by following the removing procedure in re- verse order. Refer to the pages indicated for details on how to perform each step. Fit: • The piston pin. • The piston. •...
  • Page 231 ENGINE NO. 2 (REAR) PISTON AND CYLINDER Installation is obtained by following the removing procedure in re- verse order. Refer to the pages indicated for details on how to perform each step. Fit: • The piston pin. • The piston. •...
  • Page 232 ENGINE CLUTCH No.1 driving plate (9 pcs) No.2 driven No.1 driven plate (2 pcs) plate (7 pcs) No.2 driving plate (1 pcs) CONTENTS REMOVING THE CLUTCH ........................D-115 REMOVING THE CLUTCH THROW-OUT ..................... D-116 CHECKING THE CLUTCH AND THE THROW-OUT ................D-117 INSTALLING THE CLUTCH ........................

  • Page 233: Removing The Clutch

    ENGINE REMOVING THE CLUTCH After draining the engine oil, remove the following components in the order indicated. Refer to the pages indicated for details on how to perform each step. Drain: • The engine oil. Remove: • The clutch bell housing cover (see page D-29). •...
  • Page 234 ENGINE • The clutch drum. • The clutch driving cam. • The clutch driven cam (see pages D-30 and D-31). • The thrust washer. • The primary driven gear assembly (see page D-37). • The needle roller bearing. • The collar. •...
  • Page 235 ENGINE • The throw-out assembly (see page D-8.) • The clutch push rod (see page D-8.) CHECKING THE CLUTCH AND THE THROW- CLUTCH DRIVING PLATES Wipe the oil from the driving plates with a clean rag. Measure the thickness of the clutch driving plates using a vernier caliper.
  • Page 236 ENGINE CLUTCH DRIVEN PLATES Wipe the oil from the driven plates with a clean rag. Measure the distortion of the driven plates using a thickness gauge and a surface plate. Replace any driven plates that are distorted beyond the specified limit.
  • Page 237 ENGINE INSTALLING THE CLUTCH To install the clutch, use the removing procedure in reverse order. Refer to the pages indicated for details on how to perform each step. Fit: • The thrust washer. • The collar. • The needle roller bearing (see page D-52). •...
  • Page 238 ENGINE • The clutch plates. • The clutch push rod (see pages D-54 and D-55). • The clutch push rod. • The bearing. • The washer (see page D-55). • The pressure plate. • The clutch springs (see page D-55). •...
  • Page 239 ENGINE Location of thicker (2.0 mm) driven plate D.121...
  • Page 240 ENGINE INSTALLING THE CLUTCH THROW-OUT To fit the clutch throw-out, use the removing procedure in reverse order. Refer to the pages indicated for details on how to perform each step. Fit: • The clutch push rod (see page D-18). • The throw-out assembly. •...
  • Page 241 ENGINE WATER PUMP/CLUTCH COVER Position of clamp Position of sealing washer Position of clamp CONTENTS REMOVING THE WATER PUMP AND THE CLUTCH COVER ............. D-124 CHECKING AND SERVICING THE WATER PUMP AND THE CLUTCH COVER ........ D-125 INSTALLING THE WATER PUMP AND THE CLUTCH COVER ............D-127 D.123...
  • Page 242 ENGINE REMOVING THE WATER PUMP AND THE CLUTCH COVER After draining the engine oil and the coolant, remove the parts listed below in the order indicated. • This operation must be carried out with the engine installed in the frame. Refer to the pages indicated for details on how to perform each step.
  • Page 243 ENGINE CHECKING AND SERVICING THE WATER PUMP AND THE CLUTCH COVER CHECKING THE MECHANICAL SEAL AND THE SEALING WASHER Before removing the water pump and draining the coolant, check for coolant leakages from the clutch cover drain hole. If coolant is leak- ing, remove the clutch cover and visually inspect the mechanical seal and the oil seal for damage.
  • Page 244 ENGINE • Remove the mechanical seal using a tubular spanner or a similar tool. Replace the removed mechanical seal with a new one. If no coolant or oil leakage from the drain hole is found, there is no need to remove the mechanical seal and the oil seal. INSTALLING THE OIL SEAL AND THE MECHANICAL SEAL •...
  • Page 245 ENGINE INSTALLING THE WATER PUMP AND THE CLUTCH COVER Installation is obtained by following the removing procedure in re- verse order. Refer to the pages indicated for details on how to perform each step. Fit: • The gasket. • The dowel pin (see page D-55). •...
  • Page 246 ENGINE • The water pump casing (see pages D-57 and D-58). • The water hose. Adjust the following according to specifications: Page * Engine coolant ..........B-19 * Engine oil ............B-16 IMPELLER MECHANICAL SEALING RING (DEGREASE) D.128...
  • Page 247 ENGINE PRIMARY DRIVING GEAR/NO. 1 VALVE MOTION IDLER GEAR/ SPROCKET SHAFT * Left-hand thread CONTENTS REMOVING THE PRIMARY DRIVING GEAR AND THE NO. 1 VALVE MOTION IDLER GEAR/SPROCKET SHAFT ..............D-130 CHECKING THE PRIMARY DRIVING GEAR/NO. 1 VALVE MOTION SPROCKET AND THE PRIMARY DRIVING GEAR/NO. 1 VALVE MOTION IDLER GEAR/SPROCKET SHAFT ..................
  • Page 248 ENGINE REMOVING THE PRIMARY DRIVING GEAR AND THE NO. 1 VALVE MOTION IDLER GEAR/ SPROCKET SHAFT The above items can be removed while supporting the engine as- sembly with a suitable jack. For further details, refer to the section on engine removal. ENGINE REMOVAL ......
  • Page 249 ENGINE • The generator cover (see page D-28). • The no. 1 valve motion idler gear/sprocket. • The timing chain (see page D-33). • The primary driving gear (see page D-34). • The generator rotor (see pages D-34 and D-35). •...
  • Page 250 ENGINE CHECKING THE PRIMARY DRIVING GEAR/NO. 1 VALVE MOTION SPROCKET AND THE PRI- MARY DRIVING GEAR/NO. 1 VALVE MOTION IDLER GEAR/SPROCKET SHAFT CHECK Visually check the wear of the gear and sprocket teeth. If the teeth are worn, replace the gear and the sprocket with new parts. CHECKING AND SERVICING THE PRIMARY DRIVING GEAR CHECKING THE PRIMARY DRIVING GEAR...
  • Page 251 ENGINE • Carefully fit the circlip with the specially designed pliers. Specific tool: 800096765 - Snap ring pliers * Never reuse a removed circlip. After removing the circlip from the gear, discard it and fit a new circlip. * When fitting a new circlip, take care not to part its ends more than is required to fit it on the gear.
  • Page 252 ENGINE STARTING SYSTEM/GENERATOR/CRANKSHAFT POSITION SENSOR CONTENTS REMOVING THE STARTING TORQUE LIMITER, THE GENERATOR AND THE CRANKSHAFT POSITION SENSOR ................... D-135 CHECKING AND SERVICING THE STARTING TORQUE LIMITER, THE GENERATOR AND THE CRANKSHAFT POSITION SENSOR ........... D-137 INSTALLING THE STARTING TORQUE LIMITER, THE GENERATOR AND THE CRANKSHAFT POSITION SENSOR ...................
  • Page 253 ENGINE REMOVING THE STARTING TORQUE LIMITER, THE GENERATOR AND THE CRANKSHAFT POSITION SENSOR The following components must be removed in the order indicated so that the starter torque limiter, the generator and the crankshaft position sensor can be removed. • This operation can be carried out without removing the engine. Refer to the pages indicated for details on how to perform each step.
  • Page 254 ENGINE • The dowel pin. • The gasket (see page D-28). • The starting torque limiter (see page D-28). • The starting idler gear. • The shaft. • The spacer. • The bushings (see page D-28). • The generator rotor assembly (see pages D-34 and D-35). •...
  • Page 255 ENGINE CHECKING AND SERVICING THE STARTING TORQUE LIMITER, THE GENERATOR AND THE CRANKSHAFT POSITION SENSOR CHECKING THE STARTING TORQUE LIMITER Do not attempt to disassemble the starting torque limiter. The starting torque limiter is only available as an assembly. • Check the slipping torque with the specially designed tools. Specific tools: 800096685 - Starting torque limiter holder 1 800096686 - Starting torque limiter connection 2...
  • Page 256 ENGINE CHECKING THE GENERATOR STATOR AND THE CRANK- SHAFT POSITION SENSOR Refer to section G. SERVICING THE GENERATOR STATOR AND THE CRANK- SHAFT POSITION SENSOR When replacing the generator stator or the crankshaft position sen- sor, apply specific product to generator stator fastening bolts 1, clamp bolt 2 and crankshaft position sensor fastening bolt 3, and then tighten with the specified torque.
  • Page 257 ENGINE • When fitting one-way coupling 2 into guide 1, position one-way coupling flanged side A so that it faces starter coupling housing 3. • When fitting starter coupling housing 3 on the generator rotor, align hole B in the starter coupling housing with projection C on the generator rotor.
  • Page 258 ENGINE INSTALLING THE STARTING TORQUE LIMITER, THE GENERATOR AND THE CRANKSHAFT POSITION SENSOR Installation is obtained by following the removing procedure in re- verse order. Refer to the pages indicated for details on how to perform each step. Fit: • The starting driven gear. •...
  • Page 259 ENGINE • The gasket. • The dowel pin (see page D-58). • The generator cover (see page D-59). • The clutch throw-out assembly (see pages D-16 and D-17). • The engine sprocket cover. • The silencer protection by tightening the two fixings. •...
  • Page 260 ENGINE REMOVING THE STARTER MOTOR After previously removing the sump guard as described in page xx, disconnect the starter motor lead and remove the starter motor by unscrewing the two mounting bolts. • Detach the oil cooler from its supports and push it downwards. CHECKING AND SERVICING THE STARTER MOTOR Refer to section G.
  • Page 261 ENGINE GEAR PRESELECTOR FOOTREST TOP GEAR CHANGE LEVER HEIGHT CONTENTS REMOVING THE GEAR PRESELECTOR ASSEMBLY ................. D-144 CHECKING AND SERVICING THE GEAR PRESELECTOR ASSEMBLY ..........D-146 INSTALLING THE GEAR PRESELECTOR ASSEMBLY ............... D-148 D.143...
  • Page 262 ENGINE REMOVING THE GEAR PRESELECTOR ASSEMBLY After draining the oil from the engine, remove the components listed below in the order indicated. Refer to the pages indicated for details on how to perform each step. Remove: • The engine pinion cover and the silencer protection (see page D- 7 and D-8).
  • Page 263 ENGINE • Remove the gear covering by unscrewing the five relative fixings (see page D-35.) • The dowel pins. • The gasket (see page D-35). • The gear shaft/arm (see page D-36). • The gear preselector plate. • The gear preselector stop. •...
  • Page 264 ENGINE CHECKING AND SERVICING THE GEAR PRESELECTOR ASSEMBLY REMOVING THE GEAR SHAFT/ARM • Remove the following parts from gear shaft/arm assembly 1: 2 Washer 6 Plate return spring 3 Circlip 7 Washer 4 Gear shaft return spring 8 Circlip 5 Gear preselector plate 9 Washer Specific tool: 800096765 - Snap ring pliers CHECKING THE GEAR SHAFT/ARM...
  • Page 265 ENGINE CHECKING THE OIL SEAL Check if the gear shaft oil seal is damaged or if its lip is worn. If any defects are found, replace the oil seal with a new one. REPLACING THE OIL SEAL • Remove the gear shaft oil seal from the gearbox cover. •...
  • Page 266 ENGINE INSTALLING THE GEAR PRESELECTOR ASSEMBLY Installation is obtained by following the removing procedure in reverse order. Refer to the pages indicated for details on how to perform each step. Fit: • The gear arm stop bolt. • The gear preselector stop. •...
  • Page 267 ENGINE • The engine sprocket (see page D-16.) • The speed sensor rotor (see page D-16) • The clutch throw-out assembly (see page D-17). • The engine sprocket cover. • The left hand footrest and gearchange lever assembly (see page D-18) D.149...
  • Page 268 ENGINE Adjust the following according to specifications: Page * Engine oil .............. B-13 * Clutch lever play ............ B-15 * Drive chain slack ........... B-17 D.150...
  • Page 269 ENGINE CRANKCASE/GEARBOX/CRANKSHAFT/CONNECTING ROD D.151...
  • Page 270 ENGINE CONTENTS REMOVING THE TRANSMISSION, THE CRANKSHAFT AND THE CONNECTING ROD ....D-153 CHECKING AND SERVICING THE TRANSMISSION ................D-153 CHECKING THE CONNECTING ROD AND THE CRANKSHAFT ............D-160 CHECKING AND SERVICING THE CONNECTING ROD BEARINGS/CRANKPINS ......D-160 CHECKING AND SERVICING THE CRANKSHAFT BEARINGS ............D-163 ADJUSTING THE CRANKSHAFT THRUST CLEARANCE ..............
  • Page 271 ENGINE REMOVING THE TRANSMISSION, THE CRANK- SHAFT AND THE CONNECTING ROD The crankcase must be separated to allow the transmission, the crankshaft and the connecting rod to be serviced. Access to these engine parts is obtained by removing and disassembling the en- gine.
  • Page 272 ENGINE Standard Gear change fork thickness: 4,8-4,9 mm (0.1906-0.1929 in) Checking thickness REMOVAL Countershaft • Remove O-ring 1, 2nd driving gear 2, and 6th driving gear 3. Replace the removed O-ring with a new one. • Remove 6th driving gear bushing 4, washer 5, and 3rd/4th driving gears 6.
  • Page 273 ENGINE Driving shaft • Remove 1st driven gear 1 and washer 2. • Remove 1st driven gear bushing 3, washer 4, and 5th driven shaft • Remove the circlip using the specially designed tool. Specific tool: 800096765 - Snap ring pliers •...
  • Page 274 ENGINE • Remove 3rd driven gear bushing 1. • Remove 6th driven gear 2 after removing the circlip. Specific tool: 800096765 - Snap ring pliers • Remove the circlip using the specially designed tool. Specific tool: 800096765 - Snap ring pliers •...
  • Page 275 ENGINE * Never reuse a removed circlip. After removing the circlip from the shaft, discard it and fit a new circlip. * When fitting a new circlip, take care not to part its ends more than is required to fit it on the shaft. * After fitting a circlip, always check that it is fully and se- curely seated in its groove.
  • Page 276 ENGINE Countershaft/1st 1st driven gear 1st driven gear driving gear 5th driven gear 5th driven gear 5th driving gear 4th driven gear 4th driven gear 3rd/4th driving gears 3rd driven gear 3rd driven gear 6th driving gear 6th driven gear 6th driven gear 2nd driving gear 2nd driven gear...
  • Page 277 ENGINE D.159...
  • Page 278 ENGINE CHECKING THE CONNECTING ROD AND THE CRANKSHAFT CONNECTING ROD SMALL END I.D. Measure the small end inside diameter with a bore gauge. Specific tools: Comparator (1/1000 mm, 1 mm, 0.00004-0.03937 in) Bore gauge (18-35 mm, 0.708-1.389 in) Service limit Small end I.D.: 22,040 mm (0.8677 in) If the small end inside diameter exceeds the specified limit, replace the connecting rod.
  • Page 279 ENGINE SELECTING THE CONNECTING ROD-CRANKPIN BEARINGS • Position some plastigauge axially on the crankpin, avoiding the oil hole, in the top dead centre or low dead centre position as shown in the figure. • Tighten the bearing cap bolts in two steps to the prescribed torque. When fitting the bearing cap to the crankpin, be sure to distinguish the side with inside diameter code B from the other side.
  • Page 280 ENGINE Connecting rod I.D. specification Code B I.D. Specification 48.000-48.008 mm (1.8897-1.8904 in) 48.008-48.016 mm (1.8901-1.8904 in) Connecting rod O.D. specification Code C O.D. Specification 44.992-45.000 mm (1.7713-1.7716 in) 44.984-44.992 mm (1.7710-1.7713 in) 44.976-47.984 mm (1.7707-1.8891 in) Specific tool: Micrometer (25-50 mm, 0.984-1.968 in) Bearing thickness Colore (No.
  • Page 281 ENGINE • Apply engine oil and specific product to the crankpin and bearing surface. Specific product: MOLIKOTE • When fitting the connecting rods to the crankshaft, ensure that connecting rod inside diameter codes A face the cylinder intake valves and that oil holes B face inwards. •...
  • Page 282 ENGINE SELECTING THE CRANKSHAFT BEARINGS Select the specified bearings by referring to crankcase hole I.D. code. The crankcase hole i.d. codes A, “A”, “B” or “C”, are stamped on the inside of each crankcase half. Bearing selection table I.D. Code A I.D.
  • Page 283 ENGINE • Gradually remove the bearing using the special tool and a hand press. Hand press Removed bearings must be replaced with new ones. Bearing Carter Bearing We recommend using a hand press to remove the crankshaft bear- ings. However, the crankshaft bearings can also be removed with the following special tools.
  • Page 284 ENGINE Before fitting the bearing, slightly shave the sharp edge in- side the bevel with an oilstone and then wash the crank- case hole with engine oil. Sharp edge • Insert the bearings installed in the special tool into the crankcase half as shown in the figure.
  • Page 285 ENGINE We recommend using a hand press to remove the crankshaft bear- ings. However, the crankshaft bearings can also be removed with the following special tools. Special tools: 800096678 - Bearing installer set 800096677 - Final drive bearing separating/assembling tool •...
  • Page 286 ENGINE • Using a thickness meter, measure the thrust clearance at some points between the crankcase and the thrust washer. Standard Crankshaft thrust clearance: 0,050-0,100 mm (0.00197-0.00394 in) Specific tool: Thickness gauge If the thrust clearance exceeds the specified range, adjust it by fol- lowing these steps: •...

  • Page 287: Engine Lubrication System

    ENGINE ENGINE LUBRICATION SYSTEM CONTENTS OIL PUMP ............................... D-170 OIL SUMP FILTER/OIL PRESSURE REGULATOR ................D-172 OIL PRESSURE SWITCH/OIL COOLER ....................D-175 OIL FILTER ............................. D-177 OIL PRESSURE............................D-177 PISTON COOLING OIL JET/OIL NOZZLE .................... D-177 ENGINE LUBRICATION DIAGRAM ....................... D-178 ENGINE LUBRICATION SYSTEM ......................
  • Page 288 ENGINE OIL PUMP REMOVAL To service the oil pump one must first separate the crankcase. It is also necessary to remove and disassemble the engine. For fur- ther information, refer to the sections on engine removal and disas- sembly. * ENGINE REMOVAL ....Refer to page D-4. * ENGINE DISASSEMBLY ...
  • Page 289 ENGINE ASSEMBLY AND INSTALLATION Wash the oil pump with clean engine oil before reassembly. • Insert the rotor shaft into the inner rotor. Align driving pin 1 with slot A in the inner rotor. • Install the outer and inner rotors in the oil pump body. Punched mark B on the outer rotor must face the pump body and punched mark C on the inner rotor must face the pump cover.
  • Page 290 ENGINE OIL SUMP FILTER/OIL PRESSURE REGULATOR REMOVAL After draining the engine oil and the coolant, remove the compo- nents listed below in the order indicated Refer to the pages indicated for details on how to perform each step. Drain: • The engine oil (see page B-16.) •...
  • Page 291 ENGINE • The oil sump filter. • The oil pressure regulator. CHECKING THE OIL PRESSURE REGULATOR Check the operation of the oil pressure regulator by pushing the piston with a suitable bar. If the piston does not work, replace the oil pressure regulator with a new one.
  • Page 292 ENGINE INSTALLING THE OIL SUMP FILTER Installation is obtained by following the removing procedure in re- verse order. Refer to the pages indicated for details on how to perform each step. Fit: • The oil pressure regulator (see page D-51). •...
  • Page 293 ENGINE • The impeller (see page D-56). • The impeller fastening bolt (see page D-57). • The dowel pin. • The water pump casing (see pages D-57 and D-58). • The water hose. Adjust the following according to specifications: Page * Engine coolant ..............
  • Page 294 ENGINE CHECKING THE OIL PRESSURE SWITCH Refer to section G. CHECKING THE OIL COOLER PIPES Check if the oil cooler pipes show any signs of damage or leakage. If any defects are found, replace the oil cooler pipes with new ones. CHECKING AND CLEANING THE OIL COOLER Using a compressed air jet, remove the dirt and dust from between the oil cooler fins.

  • Page 295: Oil Filter

    ENGINE OIL FILTER Refer to page B-17. OIL PRESSURE Refer to page B-28. PISTON COOLING OIL JET/OIL NOZZLE REMOVAL The oil jet (for the transmission) can be removed after draining the oil from the engine. The piston cooling oil nozzles and the oil jets (for each cylinder head) can be removed after removing each cylinder.

  • Page 296: Oil Sump

    ENGINE ENGINE LUBRICATION CHART NO. 1 (FRONT) CYLINDER NO. 2 (REAR) CYLINDER EX. CAMSHAFT IN. CAMSHAFT IN. CAMSHAFT EX. CAMSHAFT JOURNALS AND JOURNALS AND JOURNALS AND JOURNALS AND CAMS CAMS CAMS CAMS TAPPETS TAPPETS TIMING IDLER GEAR TIMING IDLER GEAR BUSHING BUSHING NO.
  • Page 297 ENGINE ENGINE LUBRICATION SYSTEM D.179...
  • Page 298 ENGINE D.180...
  • Page 299 SUSPENSIONS AND WHEELS Section...
  • Page 300 SUSPENSIONS AND WHEELS Front wheel ................E-3 Front suspension ..............E-6 Rear wheel ................E-17 Rear suspension ..............E-20 Frame ..................E-24...

  • Page 301: Suspensions And Wheels

    SUSPENSIONS AND WHEELS FRONT WHEEL Light alloy wheel rim with traditional spokes ............3.00” x 18” Six spoke alloy wheel rim ..................3.00” x 18” Tubeless tyre dimensions ..................110/80-18” Cold pressure (only rider) ................ Kg/cm 2.2-Psi 31.2 Cold pressure (+ passenger) ..............Kg/cm 2.4-Psi 34.1 FRONT WHEEL REMOVAL Remove the sump guard and place a support underneath the engine...
  • Page 302 SUSPENSIONS AND WHEELS FRONT WHEEL OVERHAUL Carry out the radial and axial check on the wheel as shown in the figure. The maximum movement values for this check fall into the following categories: Axial movement ............. 0.5 [mm] Eccentricity ..............0.8 [mm] Bearing wear generally causes an excessive axial movement or eccentricity.
  • Page 303 SUSPENSIONS AND WHEELS BENT WHEEL SPINDLE Check the distortion of the axis of the wheel spindle using “V” supports and a comparator. Maximum axis distortion ..........≤ 0,25 [mm] WHEEL ASSEMBLY Replace the wheel, the wheel spindle and spacer on the right hand side of the machine in reverse order of removal.

  • Page 304: Front Fork Removal

    SUSPENSIONS AND WHEELS FRONT SUSPENSION The front suspension consists of conventional advanced pivot telescopic hydraulic forks. Fork leg diameter ....................Ø 43 [mm] Front wheel travel ..................... 150 [mm] Fork leg oil capacity ..................... 680 cc Fork tube oil level ..................... 150 [mm] FRONT FORK REMOVAL •...
  • Page 305 SUSPENSIONS AND WHEELS SUSPENSIONS AND WHEELS • Unscrew the four mudguard fixing screws 1. Remove the mudguard. • Slacken the two fixing clamp screws 2 that fix the fork tubes to the steering head. • Slacken the four fixing clamp screws 3 at the base of the steering. As a preventive measure, it is advisable to carry out this operation after having removed the fuel tank as described in page B-4.
  • Page 306 SUSPENSIONS AND WHEELS • Empty the used oil from the tube. Slide out the support spacer, moving the tube around so that it is removed more easily. Dispose of the oil in the correct way. • Remove the screw 1 placed at the base of each stem and slide out the cartridge 2.
  • Page 307 SUSPENSIONS AND WHEELS • To substitute fork oil seals, proceed as follows: It is advisable to protect the edge of the sliding section with a special ring cap 1, when extracting the sealing ring. Using a wide screwdriver, exert pressure under the sealing ring and at the same time, rotate the sliding section to allow the sealing ring to slide out.
  • Page 308 SUSPENSIONS AND WHEELS • Assemble the bush onto the stem. • Insert the stem inside the sheath. • Using the special tool, assemble in the following sequence, the bush, spacer and the oil seal as shown in the figure. • Assemble the stop ring and the dust seal. •...
  • Page 309 SUSPENSIONS AND WHEELS * Always keep the oil level above the upper extremity of the cartridge to avoid the possibility of air entering into the cartridge during this operation. * Make sure that all air is bled from the system. •...
  • Page 310 SUSPENSIONS AND WHEELS FORK ASSEMBLY – REASSEMBLY • Proceed with the reassembly of the fork assembly in the reverse order of removal. • Position the fork tubes to 33.5 mm, as indicated in the figure. • Tighten the four screws at the base of the steering and the two screws at the steering head to a torque of 22.5 ÷...
  • Page 311 SUSPENSIONS AND WHEELS STEERING REMOVAL Carry out the following procedure to remove the steering assembly from the frame: • Remove the fuel tank as described in page B-4. • Remove the front wheel, the mudguard and the fork legs as previously described.
  • Page 312 SUSPENSIONS AND WHEELS • If the handlebars have to be substituted, it will be necessary to remove the left hand and right hand counterweights by unscrewing the two screws 7. • To reassemble the handlebar assembly, follow the instructions for removal in reverse order.
  • Page 313 SUSPENSIONS AND WHEELS • Remove the screw from the steering spindle 1. • Slacken the screws 2 on the steering head fixing to the fork tubes. • Remove the connector of the ignition switch assembly. Lift up the steering head and remove it. •...
  • Page 314 SUSPENSIONS AND WHEELS • Accurately clean the various seats, the external part of the steering tube and the internal part of the steering head housing. • Assemble the new bearing on the steering tube by using a tube of the correct diameter placed against the external ring of the bearing. See the figure.

  • Page 315: Rear Wheel

    SUSPENSIONS AND WHEELS REAR WHEEL Light alloy wheel rim with traditional spokes (with flexible joints) ......4.25”x17” Six spoke alloy wheel rim (with flexible joints) ............4.25”x17” Tubeless tyre dimensions ..................150/70-17” Cold pressure (only rider) ................ Kg/cm 2.4-Psi 34.1 Cold pressure (+ passenger) ..............Kg/cm 2.6-Psi 36.9 REAR WHEEL REMOVAL •...
  • Page 316 SUSPENSIONS AND WHEELS REAR WHEEL OVERHAUL Proceed as follows for the wheel bearing and flange substitution, the wheel rim check and the wheel spindle for deformation check. • Check the bearings and the flexible joints for wear. If necessary, substitute them. When reassembling the rear wheel, it is necessary to check the chain tension and the wheel alignment by adjusting the index adjusters 1 on both sides of the fork.
  • Page 317 SUSPENSIONS AND WHEELS SUBSTITUTION OF THE CHAIN • Open the chain using the appropriate tool on the chain removal link that can be seen from the inside of the fork. It has two rollers closed in a different way from the other links. See figure. To reassemble, carry out the phases of assembly in reverse order.

  • Page 318: Rear Shock Absorber Removal

    SUSPENSIONS AND WHEELS REAR SUSPENSION REAR SHOCK ABSORBER REMOVAL If the rear shock absorber is leaking liquid or damaged, substitute it as follows: • Remove the under seat compartment, the right and left hand side covers situated under the seat as described in the maintenance chapter.
  • Page 319 SUSPENSIONS AND WHEELS The shock absorber contains pressurised gas and must not be opened for any reason. When reassembling, follow the removal procedure in reverse order. Tighten the three nuts 1, 2 and 3 to the torque pressure of 39,2÷44,1 N·m.
  • Page 320 SUSPENSIONS AND WHEELS To remove the connection rod of the rear suspension, it is necessary to remove the following components: • Remove the chain roller 1. • Unscrew the two chain guide fixing screws 2 indicated in the figu- • Push down the chain guide 3. The spindle 4 relative to the fixing nut of the connection rod to the frame is therefore left free.
  • Page 321 • Remove the two tube channels 2 of the rear brake tubing. • Remove the rear brake pincer complete with attachment from the fork. • Remove the two rubber caps 3 with Cagiva printed on the top. • Slacken the spindle 4 indicated in the figure. • Remove the spindle.
  • Page 322 SUSPENSIONS AND WHEELS • Check the various components on the fork (bearings, oil seals, chain guide and the fork itself). If excessive play is found between the bush 1 and the relative bearings 2 or the fork axis 3 and the relative bushes, substitute them. First, remove the oil seals and then the bearings utilising a tube of adequate diameter for the extraction.
  • Page 323 SUSPENSIONS AND WHEELS FRAME Rectangular and square section tube framework in highly resistant steel. FRAME SUBSTITUTION If it is necessary to substitute or realign the frame, all components must be removed. Follow the procedures for removal of the various components as described in the various sections of this manual. For a brief check, consult the figure.
  • Page 324 BRAKES Section...
  • Page 325 BRAKES Brakes ..................F-3 Brake discs ................F-4 Brake pad wear check ............F-4 Brake fluid substitution ............F-5 Bleeding air from the braking system ........F-6 Front brake pincer removal and disassembly ......F-7 Rear brake pincer removal and disassembly ......F-9 Front brake pump system removal and disassembly .....

  • Page 326: Brakes

    BRAKES FRONT BRAKE Type ............Fixed twin discs Ø 296 mm. Double piston pincers. REAR BRAKE Type ..................Fixed single disc Ø 240 mm.

  • Page 327: Brake Pad Wear Check

    BRAKES DISC BRAKE Checking the disc is important. It must be perfectly clean without rust, oil, grease or other dirt and must not have deep lines scored on it. Scoring of a certain depth can be eliminated by reaming the disc, taking care to stay within the wear limits.
  • Page 328 BRAKES To check the pads, the following components must be removed: Front brake: • Remove the blocking screw 1; • Unscrew the plug underneath; • Extract the pad. Rear brake: • Remove the two screws of the spray guard 2 and remove it; •...
  • Page 329 BRAKES BRAKE FLUID SUBSTITUTION • Place the machine on a level surface and straighten the handle- bars. • Remove the cap of the brake fluid chamber and the diaphragm by removing the cap stop 1. • Suck out as much of the old liquid as possible. •...
  • Page 330 BRAKES BLEEDING THE AIR FROM THE BRAK- ING SYSTEM The air that is trapped in the braking system acts as a cushion, absorbing the greater part of the pressure exerted by the brake pump. The performance of the brake pincer is therefore compro- mised.
  • Page 331 BRAKES FRONT BRAKE PINCER ASSEMBLY REMOVAL If there are signs of leakage or traces of oil on the pincer body, it must be substituted. • Drain the brake fluid as previously described and illustrated. • Remove the brake tube from the pincer by unscrewing the joint bolt 1.
  • Page 332 BRAKES REAR BRAKE PINCER REMOVAL • Remove the spray guard fixing screws. Never use brake fluid left over from a previous change of fluid or brake fluid that has been stored for a long period of time. If the brake system leaks fluid, riding security is compro- mised.
  • Page 333 BRAKES FRONT BRAKE PUMP ASSEMBLY RE- MOVAL • Drain the brake fluid as described in page F-6. • Disconnect the front brake switch leads. • Place a cloth underneath the brake pump joint bolt to collect the last drops of fluid left in the system. Remove the joint bolt 1 and disconnect the brake tube.
  • Page 334 BRAKES BRAKE PUMP REASSEMBLY Reassemble the brake pump in the reverse order of removal. • When reassembling the brake switch, align the projection of the switch with the hole of the pump. • When reassembling the brake pump onto the handlebars, tighten Brake pump the upper fixing bolt first.
  • Page 335 BRAKES REAR BRAKE PUMP REMOVAL • Drain the brake fluid from the rear brake system as described in page B-7. • Remove the right hand passenger footrest by unscrewing the two screws 1 as shown in the figure. • Place a cloth underneath the joint 2. •...
  • Page 336 BRAKES BRAKE PUMP REASSEMBLY Install the brake pump assembly in the reverse order of removal. Pay attention to the following points: Specified product: AGIP BRAKE 4 brake fluid. • Tighten each bolt to the specified torque. Torque pressure: Brake tube joint bolt: 23 N.m (2.3 kg-m) Brake pump mounting bolt to the frame: 10 N.m (1.0 kg-m)
  • Page 337 BRAKES F.14...
  • Page 338 ELECTRICAL EQUIPMENT Section...
  • Page 339 ELECTRICAL EQUIPMENT Precautionary maintenance advice ........G-5 Battery ..................G-6 Charging system ..............G-7 Starter system and side stand/ignition security system ..G-12 Ignition system ............... G-21 Instruments ................G-28 Lights ..................G-34 Switches ................. G-37...

  • Page 340: Electrical Equipment

    ELECTRICAL EQUIPMENT...
  • Page 341 ELECTRICAL EQUIPMENT ELECTRICAL WIRING SYSTEM DIAGRAM: COLOUR LEGENDS: Injection CPU Atmospheric pressure sensor Yellow Air intake air pressure sensor Blue Oil pressure Green Leaning angle sensor White Air intake air temperature sensor Black Fuel probe Pink Butterfly sensor Vehicle security Violet 10.
  • Page 342 ELECTRICAL EQUIPMENT PRECAUTIONARY MAINTENANCE ADVICE CONNECTORS • When connecting a connector, make sure that a click is heard. Click • Check to see if the connector is dirty, corroded or if its cover is broken. CONNECTORS Click • Block connectors – release the block before disconnecting it and push it right in when making the connection.

  • Page 343: Charging The Battery

    ELECTRICAL EQUIPMENT BATTERY - The battery is sealed and does not need any maintenance whatsoever. Bear in mind that the battery electro- lyte contains sulphuric acid. Should there be a leakage of acid from the battery, avoid contact with the eyes, skin and clothing.

  • Page 344: Charging System

    ELECTRICAL EQUIPMENT CHARGING SYSTEM DESCRIPTION The charging circuit of the system is illustrated in the figure and is composed of an AC generator, a rectifier and a battery. The AC alternating current generated by the generator is transformed into CC continuous current by the rectifier and is then utilised for charging the battery.
  • Page 345 ELECTRICAL EQUIPMENT When the engine rpm increase, the voltage generated by the AC generator also increases. The voltage between the battery terminals also increases in proportion. When it reaches the regulated voltage of the CI (integrated circuit) and the CI is then in an “ON” position, a signal is sent to the SCR port (Tiristore) and the SCR is also brought to an “ON”...
  • Page 346 ELECTRICAL EQUIPMENT DIAGNOSTICS The battery discharges rapidly Check the accessories that consume Installed • Remove the accessories. too much energy. Not installed Check the battery current leakage. There are leakages • Wiring in short-circuit. (See page G-10) • Leads loose or disconnected. •...
  • Page 347 ELECTRICAL EQUIPMENT CHECK BATTERY CURRENT LEAKAGE TEST • Remove the seat and the under seat compartment. • Turn the ignition switch to the “OFF” position. • Disconnect the negative cable - of the battery. • Connect a multi-tester between the - negative terminal and the – negative cable of the battery.
  • Page 348 ELECTRICAL EQUIPMENT GENERATOR WINDING RESISTANCE TEST • Remove the left side support cover. • Disconnect the coupling from the generator. Measure the resistance between the three leads of connector 1. Check that the stator nucleus is isolated. If the resistance does not conform to the specified values, substitute the stator.

  • Page 349: Starter System Description

    ELECTRICAL EQUIPMENT STARTER SYSTEM AND SIDE STAND/IGNITION SECURITY SYSTEM STARTER SYSTEM DESCRIPTION The starter system is represented by the diagram below. It is comprised of a starter motor, clutch lever position switch, starter relay, starter button, engine kill button, right hand command, side stand relay, side stand switch, gearchange position switch, ignition switch (IG) and the battery.
  • Page 350 ELECTRICAL EQUIPMENT SIDE STAND/IGNITION SECURITY SYSTEM DESCRIPTION The side stand/ignition security system avoids the switching on of the engine whilst the side stand is in the lowered position. The circuit consists of a relay, warning light, diode and switches. It controls the activation of the ignition coil on the basis of the position of the gearchange and the side stand using the interconnected gearchange and side stand position switches.
  • Page 351 ELECTRICAL EQUIPMENT DIAGNOSTICS The starter motor does not turn. Check the to see that the starter motor turns by connecting the terminal of the starter The click With the gears in neutral, turn the ig- motor directly to the + terminal of the bat- is heard nition switch to the “ON”...
  • Page 352 ELECTRICAL EQUIPMENT STARTER MOTOR REMOVAL AND DISASSEM- • Disconnect the starter motor lead. • Remove the starter motor. • Disassemble the starter motor as indicated in the figure. 1. O-ring 2. Cover (internal) 3. Starter motor housing 4. Rotor 5. Spring and brush attachment 6.

  • Page 353: Starter Motor Reassembly

    ELECTRICAL EQUIPMENT COMMUTATOR Check to see if the connector is discoloured, abnormally worn or if the height A is insufficient. Segment Substitute the rotor if the commutator is abnormally worn. If the sur- face is discoloured, brighten it with emery paper and clean it with a dry cloth.
  • Page 354 ELECTRICAL EQUIPMENT • Apply a small quantity of LOCTITE 243 to the bolts of the starter motor housing. STARTER RELAY CHECK • Disconnect the – negative cable of the battery 1. • Remove the cover of the starter relay 2. •...
  • Page 355 ELECTRICAL EQUIPMENT • Check to see if the winding of the relay is open or to Earth. Check the resistance. The winding is in good condition if the resistance is as indicated. Starter relay resistance Standard: 3-6 Ω TESTING THE PARTS OF THE SIDE STAND/IG- NITION SECURITY SYSTEM If the security system does not function in the correct way, check each component.
  • Page 356 ELECTRICAL EQUIPMENT GEARCHANGE POSITION SWITCH The lead connector of the gearchange position switch is situated underneath the right hand cover of the machine. • Disconnect the lead of the gearchange position switch and check the continuity between the blue lead and Earth with gears in neu- tral.
  • Page 357 ELECTRICAL EQUIPMENT INJECTION RELAY AND FUEL PUMP RELAY The injection relay and the fuel pump relay are situated in the com- partment underneath the ECM CPU. • Remove the injection relay or the fuel pump relay. The injection relay and the fuel pump relay are the same but can be distinguished by the colours of the leads.

  • Page 358: Ignition System

    ELECTRICAL EQUIPMENT IGNITION SYSTEM DESCRIPTION The ECM CPU controls the ignition system. It is a normal transistorised digital ignition system that determines precise ignition timing according to the rpm of the engine, the gearchange position and the throttle position. The system consists of a crankshaft position sensor (explorer coil), an ECM CPU, two ignition coils and two spark plugs.
  • Page 359 ELECTRICAL EQUIPMENT Injection relay Engine kill switch Fuse Transformer Oscillator Key commutator Ignition coil Outgoing circuit Feed source ignition switch Generator Spark plug rotor fuse Electrical (Central wave circuit Process- Unit) Battery Gearchange LEAD COLOURS p o s i t i o n G: Green switch B: Blue...
  • Page 360 ELECTRICAL EQUIPMENT DIAGNOSTICS * Check that the gearchange is in neutral and the engine kill switch is in the “RUN” position. Check to see if the Worn or non-firing spark plugs fuse is blown and the battery is completely charged be- fore carrying out diagnostic operations.
  • Page 361 ELECTRICAL EQUIPMENT TEST PEAK VOLTAGE OF THE PRIMARY WINDING OF THE IGNI- TION COIL • Remove the insulated covers of the two spark plugs as described in pages B-7 and B-8. • Connect two new spark plugs to the insulated covers and then connect them to Earth.
  • Page 362 ELECTRICAL EQUIPMENT Test the peak voltage of the N° 2 ignition coil primary winding follow- ing the same procedure used for the N° 1 ignition coil. N° 2 ignition coil: GR/BK terminal – Earth Select “IG.COIL” (probe +) (probe -) Do not disconnect the lead of the ignition coil primary winding.
  • Page 363 ELECTRICAL EQUIPMENT Ignition coil resistance Primary winding: 3-5 Ω (pole (+) -(pole (+) Secondary winding: 20-28 kΩ (spark plug cover – pole +) CRANKSHAFT POSITION SENSOR (Multi-tester check) • Remove the seat. • Remove the under seat compartment tray. • Disconnect the connector 1 from the ECM CPU. Check that all couplings are connected correctly and the battery is fully charged.
  • Page 364 ELECTRICAL EQUIPMENT • Remove the right hand frame cover • Disconnect the lead coupling of the crankshaft position sensor 1 and connect the multi-tester with the peak voltage adaptor. Green/blue (+ probe) – Violet/blue (- probe) • Measure the peak voltage of the crankshaft position sensor using the same procedure utilised for the measuring at the lead coupling of the ECM CPU.
  • Page 365 ELECTRICAL EQUIPMENT INSTRUMENTS REMOVAL • Remove the nose fairing and the instrument panel as described in Chapter B. • Raise up the instrument panel, freeing it from the anti-vibration mountings. • Disconnect the lead coupling. When connecting or disconnecting the instrument panel, make sure that the ignition switch is in the in the “OFF”...
  • Page 366 ELECTRICAL EQUIPMENT CHECK Using a circuit tester, check the continuity between the indicated terminals in the following diagram. If the measurement of the conti- nuity is not correct, remove and check the bulb. If the bulb is blown, replace with a new bulb and recheck the conti- nuity.
  • Page 367 ELECTRICAL EQUIPMENT ENGINE COOLANT TEMPERATURE SENSOR AND INDICA- TOR CHECK The LCD 1 (Liquid Crystal Display) and LED 2 (Light Emission Di- ode) in the revcounter dial supply the information about the engine coolant temperature. The checking procedure for this system is de- scribed as follows.
  • Page 368 ELECTRICAL EQUIPMENT The following table indicates the relation of resistance between the LED and the LCD. RESISTANCE “– – –” Approx. 0,811 kΩ “50”°C Approx. 0,088 kΩ “130”°C Flashes With jumper lead “HI” Flashes If one or all of the indications are abnormal, substitute the engine coolant temperature sensor.
  • Page 369 ELECTRICAL EQUIPMENT SPEEDOMETER CHECK If the speedometer, kilometre counter or the partial kilometre coun- ter do not function in the correct way, check the speedometer sen- sor and the coupling connections. If the sensor and the connections are OK, substitute the speedom- eter.
  • Page 370 ELECTRICAL EQUIPMENT LIGHTS HEADLIGHT H1 HALOGEN LAMP: 12v 55w H3 HALOGEN LAMP: 12v 55w N° 3 Side light bulb: 12V 5W Vertically and horizontally adjust the headlight after reassembly. HALOGEN LAMP SUBSTITUTION Remove the instrument assembly from its rubber supports. •...
  • Page 371 ELECTRICAL EQUIPMENT INSTRUMENT PANEL BULB SUBSTITUTION To gain access to the various warning light bulbs and the bulbs that illuminate the instruments, operate as follows: • Remove the windshield and the nose fairing by unscrewing the six fixing screws. • Extract the instrument panel from its anti-vibration housing and disconnect the electrical wiring.
  • Page 372 ELECTRICAL EQUIPMENT To substitute the rear light bulb, it is necessary to remove the two screws 1, by gaining access from the inside of the number plate holder. Remove the lens from the outside and remove the bulb from its holder.

  • Page 373: Fuel Pump Relay

    ELECTRICAL EQUIPMENT INJECTION RELAY The lateral injection relay is situated underneath the ECM CPU. FUEL PUMP RELAY The fuel pump relay is situated underneath the ECM CPU. STARTER RELAY The starter relay is situated underneath the rear cover of the parcel carrier.
  • Page 374 ELECTRICAL EQUIPMENT SWITCHES HORN BUTTON Check the continuity of each switch using a circuit tester. Colour B/BI If there is any irregularity, substitute the respective switch Position assembly with a new one. • IGNITION SWITCH PRESS (Per E-24) FRONT BRAKE SWITCH Colour Colour Position...
  • Page 375 ELECTRICAL EQUIPMENT G.38...
  • Page 376 ENGINE COOLING Section...
  • Page 377 ENGINE COOLING Cooling system ............... H-3 Engine coolant ............... H-5 Radiator and engine coolant tubes ........H-6 Cooling fan ................H-9 Fan thermal switch ..............H-10 Engine coolant temperature sensor ........H-12 Thermostat ................H-13 Water pump ................H-14...

  • Page 378: Engine Cooling

    ENGINE COOLING COOLING SYSTEM DESCRIPTION The engine is cooled by an engine coolant that is pumped by force around the cooling system. The engine coolant passes through the water jackets that are present in the cylinders, the cylinder heads and the radiator. The type of pump used to pump the engine coolant around the cooling system is a high-pressure centrifugal pump.
  • Page 379 ENGINE COOLING CONSTRUCTION Torque pressure PART N·m kg-m 1. Cooling fan 2. Thermostat housing 3. Radiator cap 4. Engine coolant tank 5. Thermostat 6. Radiator 7. Water pump A. Cooling fan mounting bolt B. Cooling fan thermal switch C. Radiator mounting bolt D.

  • Page 380: Engine Coolant

    ENGINE COOLING ENGINE COOLANT The cooling circuit is filled with a 50/50 mixture of distilled water and Antifreeze Freezing ethyl-glycol antifreeze in the factory. This 50/50 mixture supplies an %age point optimum protection against corrosion and the temperature. It also -31°C protects the system against freezing to –31°C.
  • Page 381 ENGINE COOLING ENGINE COOLANT - RADIATOR AND TUBES REMOVAL • Drain the engine coolant as described in Chapter B. * Do not open the cap of the radiator when the engine is hot. Boiling liquid or vapours can cause serious burns. * The engine coolant is dangerous if swallowed or if it comes into contact with the skin or eyes.
  • Page 382 ENGINE COOLING RADIATOR CAP CHECK Check the release pressure of the radiator cap utilising the appropri- ate tester as follows: • Apply the cap to the tester as indicated and slowly create a pres- sure by activating the tester. Make sure to interrupt the pressure at 110 ±15 kPa (1.1 ±0.15 kg/cm ) With the tester at stop, check that the pressure remains steady for 10 seconds.
  • Page 383 ENGINE COOLING RADIATOR CHECK AND CLEANING Dirt and foreign bodies embedded in the radiator must be removed. Compressed air is advisable for this type of cleaning. Bent or notched fins can be straightened with a little screwdriver. If it is necessary to substitute the radiator, release it from the two lateral protections, the anti-vibration supports, the cooling fan and the engine coolant temperature housing.

  • Page 384: Cooling Fan

    ENGINE COOLING COOLING FAN REMOVAL • Remove the radiator. • Remove the cooling fan by unscrewing the three screws indicated in the figure. CHECK • Remove the coupling of the cooling fan lead. Check the charging current of the fan motor with an ampmeter as shown in the figure.
  • Page 385 ENGINE COOLING COOLING FAN THERMAL SWITCH The cooling fan, positioned behind the radiator, is fixed to the radiator by three bolts. A thermal switch automatically controls the fan motor. This switch remains open when the temperature of the engine coolant is low. It closes when the temperature of the engine coolant reaches approximately 105°C.
  • Page 386 ENGINE COOLING TEST As shown in the figure, check that the thermal switch enters into the closing phase on reaching the specified temperature of 105°C. Connect the thermal switch to a tester and immerse it in a pan of oil. Place the pan onto the lighted gas and heat the oil to slowly in- crease the temperature and observe the temperature of the ther- mometer when the switch closes.
  • Page 387 ENGINE COOLING ENGINE COOLANT TEMPERATURE SEN- REMOVAL • Drain the engine coolant as described in page D-20. * Do not open the cap of the radiator when the engine is hot. Boiling liquid or vapours can cause serious burns. * The engine coolant is dangerous if swallowed or if it comes into contact with the skin or eyes.
  • Page 388 ENGINE COOLING ASSEMBLY • Tighten the engine coolant temperature sensor to the torque speci- fied. Torque pressure: Engine coolant temperature sensor 18 N.m (1.8 kg-m) Be careful when handling the engine coolant temperature sensor. It could be damaged if dropped. •...

  • Page 389: Water Pump

    ENGINE COOLING CHECK Check the pad of the thermostat for cracks. Check the functioning of the thermostat as follows: • Pass a piece of string through the flange as indicated in the figure. • Immerse the thermostat in a heat-resistant glass of water as indi- cated in the figure.
  • Page 390 SPECIFIC TOOLING Section...
  • Page 391 SPECIFIC TOOLING...

  • Page 392: Specific Tooling

    SPECIFIC TOOLING POS. N. CODE Q.TY DESCRIPTION 800096765 Pincers for elastic rings 800096766 Pincers for elastic rings 800096650 “V” blocks 800096651 Feeler gauges 800096872 Feeler gauges 800096767 Tester 800096653 Gasket separator 800096654 Load bearing separator/assembler 800096655 Bearing separator 800096656 Bearing separator 800096657 Bearing assembler 800006658...
  • Page 393 SPECIFIC TOOLING...
  • Page 394 TORQUE PRESSURES Section...
  • Page 395 TORQUE PRESSURES TORQUE PRESSURES ENGINE APPLICATION N·m Kg-m Cylinder head valve cover bolt Spark plug Camshaft seat support bolt Timing chain tension adjuster bolt Timing chain tension adjuster mounting bolt Intermediate gear shaft/N° 2 timing sprocket Timing chain tensioner mounting bolt Cylinder head nut (M8) (M6)
  • Page 396 TORQUE PRESSURES APPLICATION N·m Kg-m Exhaust tube bolt Cover bearing lock screw Silencer mounting nut Silencer joint nut Oil tube junction bolt (M12) (M14) Speed sensor rotor bolt/engine pinion sprocket nut Engine mounting blocking bolt 11.5 Engine mounting bolt Engine thrust bearing adjuster (M12) (M10) Engine thrust bearing adjuster locknut...
  • Page 397 TORQUE PRESSURES APPLICATION N·m Kg-m Latch bolt fixing 5.46/7.84 0.6/0.8 Carrier fixing 9.8/11.7 1/1.2 HANDLEBAR COMMANDS APPLICATION N·m Kg-m Counterweight fixing U bolt fixing 4.9/6.8 0.5/0.7 Clamp fixing 4.9/6.8 0.5/0.7 Oil tank fixing 8.8/9.8 0.9/1 Cable-feed fixing 8.8/9.8 0.9/1 Brake pump fixing 8.8/9.8 0.9/1 Tank fixing...
  • Page 398 TORQUE PRESSURES FAIRING AND MUDGUARDS APPLICATION N·m Kg-m Front mudguard fixing 0.5/0.7 Underneath seat side cover fixing 9/10 0.9/1.0 Front mudguard fixings central 9/10 0.9/1.0 Rear mudguard fixings 9/10 0.9/1.0 Atmospheric pressure sensor fixing 0.4/0.5 Fuse box fixing 0.4/0.5 Seat fixing 0.7/0.8 Number plate support fixing 0.7/0.8...

  • Page 399: Exhaust System

    TORQUE PRESSURES WHEELS AND BRAKES APPLICATION N·m Kg-m Front brake disc fixing 22/24 2.2/2.4 Front wheel spindle fixing 95/100 9.5/10 Rear brake disc fixing 33/35 3.3/3.5 Crown sprocket fixing 50/52 5.0/5.2 Rear wheel spindle fixing 95/100 9.5/10 EXHAUST SYSTEM APPLICATION N·m Kg-m Exhaust tube and silencer band fixings...
  • Page 400 INDEX Section...
  • Page 401 INDEX GENERAL DESCRIPTION ............ A-1 Instrument panel ..............A-4 Dimensions and weight ............A-3 Electrical system ..............A-4 Engine unit ................A-3 Fuel/oil/engine coolant/fork oil capacity ......... A-4 Wheels and brakes ..............A-4 Front suspension ..............A-4 Rear suspension ..............A-4 Frame ..................

  • Page 402: Index

    INDEX Auto-diagnostic function ............C-24 Security function ..............C-27 Fuses ..................C-4 Throttle lever play ..............C-72 Throttle position sensor adjustment (TPS) ......C-72 Fuel injector ................C-12 Carburettor system ..............C-64 Dealer mode ................C-25 Electric fuel pump ..............C-11 FI system –...
  • Page 403 INDEX Camshaft installation .............. D-102 Crankshaft/connecting rod/gearbox installation ..... D-168 Clutch disengagement device installation ......D-122 Clutch installation ..............D-119 Gearchange pre-selector group installation ......D-148 Engine/frame installation ............D-13 Piston/cylinder installation ............D-111 Water pump/clutch cover installation........D-127 Oil pressure switch/oil cooler ..........D-175 Water pump/clutch cover ............
  • Page 404 INDEX BRAKES ................. F-1 Brake pump check ..............F-11 Brake pump check ..............F-15 Brake pad wear check ............F-4 Brake discs ................F-4 Front brake ................F-3 Rear brake ................F-3 Brake pump assembly and installation ........F-11 Brake pump assembly and installation ........F-15 Front brake pincer removal and reassembly ......
  • Page 405 INDEX...
  • Page 406 INDEX...
  • Page 407 INDEX...

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