TR 650 TERRA 2013 TR 650 STRADA 2013: Workshop Manual

TR 650 TERRA 2013
TR 650 STRADA 2013
Workshop Manual Ed. 09-2012

Rev 00
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Revision Record
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HUSQVARNA MOTORCYCLES S.R.L. - Varese disclaims all liabilities for any errors or omissions in this manual and
reserves the right to make changes to reflect on-going product development. Illustrations in the manual may differ from
actual components. No reproduction in full or in part without written authorisation.
1st edition (09-2012) - Rev. 00

FOREWORD, TABLE OF CONTENTS
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TR 650 TERRA 2013 - TR 650 STRADA 2013
Workshop Manual
TR 650 TERRA 2013

TR 650 STRADA 2013
Copyright by
HUSQVARNA MOTORCYCLES S.R.L.
BMW Group
Technical Service
Via Nino Bixio, 8
21024
(Varese) - Italy
tel. ++39 0332 75.61.11
tel. ++39 0332 756 558
www.husqvarna-motorcycles.com
1st edition (09-2012) - Rev. 00

Printed in Italy
MODELS COVERED (from serial number onwards)
TR 650 TERRA (43 kW): ZKH0H11A#DV000001

TR 650 TERRA (43 kW - ABS): ZKH0H11C#DV000001
TR 650 TERRA (35 kW - ABS): ZKH0H11D#DV000001
TR 650 STRADA (43 kW - ABS): ZKH0H11E#DV000001
TR 650 STRADA (35 kW - ABS): ZKH0H11F#DV000001
H11657
1. Chassis serial number
a.1

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Foreword
This publication is designed for use by HUSQVARNA Service Centres to assist authorised personnel in the maintenance
and repair of the models covered in this manual. The technical information provided in this manual is a critical comple-
ment to operator training and operators should become thoroughly familiar with it.
This publication is for the exclusive use of those HUSQVARNA technicians who have an adequate basic mechanical
preparation and a good knowledge of the vehicles repair procedures. Thus much information has been intentionally
omitted as it was considered superfluous. The technicians must adopt special safety procedures that they will deem
necessary in order to prevent damages to the motorbike, to its components, and to people.
For ease of understanding, diagrams and photographs are provided next to the text.
Notes with special significance are identified as follows throughout the manual:
Accident-prevention rules for operator and persons working nearby.
Damage to vehicle and/or its components may result from incompliance with relevant instructions.
Additional information concerning the operation covered in the text.
Useful tips
To prevent problems and ensure effective service work, observe the following HUSQVARNA recommendations:
– before repair, evaluate the customer's description of the problem and ask the appropriate questions to clearly identify
problem symptoms;
– diagnose the problem and identify the causes clearly. This manual provides basic background information that must
be supplemented with the operator's expertise and specific training available through HUSQVARNA held at regular
periods;
– plan ahead before starting work: gather any spare parts and tools to avoid unnecessary delays;
– avoid unnecessary disassembly work to get to the part that needs repairing.
Always read the relevant instructions and follow the disassembly sequence outlined in this manual.
a.2

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Table of Contents
Title Section
Foreword, table of contents.................................................................................. a
Important notices.................................................................................................. b
General information..............................................................................................A
Maintenance.........................................................................................................B
Troubleshooting................................................................................................... C
Settings and adjustments.................................................................................... D
General procedures..............................................................................................E
Engine settings and adjustments.........................................................................F
General engine procedures................................................................................F1
Cylinder head removal/disassembly...................................................................F2
Crankcase disassembly.....................................................................................F3
Engine torque figures.........................................................................................F4
Engine parts wear limits.....................................................................................F5
Front suspension................................................................................................... I
Rear suspension.................................................................................................. J
Brakes.................................................................................................................. L
Electrical system................................................................................................. M
Engine cooling..................................................................................................... N
Tightening torque figures......................................................................................X
Chassis and wheels.............................................................................................Y
NOTES
Unless otherwise specified, data and specifications apply to all models.
a.3

IMPORTANT NOTICES
Section
b
b.1

IMPORTANT NOTICES
GENERAL SAFETY WARNINGS

Read these general recommendations carefully before using the vehicle.
Carbon monoxide
Only run the engine in an open or very well ventilated area. If you do work in an enclosed area, make sure you use a fume extraction
system.
Exhaust emissions contain carbon monoxide, a poisonous gas which can cause loss of consciousness and even
death if inhaled.
Parts of the vehicle that become hot

Before working on the engine and the exhaust unit, wait for them to cool down; while the vehicle is running, these parts become very
hot and remain hot for some time after turning off the engine.
Risk of burns - work with caution and wear suitable PPE if necessary.
Fuel
The fuel used to power internal combustion engines is highly flammable and explosive.
Do all fuelling and maintenance operations with the engine switched off and in ventilated areas; do not
smoke and avoid contact between the fuel and naked flames, sparks, etc. that may cause an explosion.
Do not dispose of fuel in the environment.
Keep out of reach of children.
Do not tilt the vehicle excessively since this may cause fuel to leak.
Engine
In some cases, coolant may become inflammable and if burnt, produce invisible flames which cause burns.
Do not spill coolant onto hot components like the engine or exhaust pipe, etc. since it may ignite.
During maintenance work, wear latex gloves.
Never leave the coolant in open containers in areas accessible to children and animals since it is toxic.
DO NOT remove the radiator cap when the engine is hot; the coolant is pressurised and may cause scalding.
Engine oil
Do not dispose of oil in the environment since it is highly polluting.
Wear latex gloves since prolonged contact with the skin can cause serious damage.
Send used oil to special authorised recyclers in accordance with the legal requirements in force in the country where
the vehicle will be used.
Brake fluid
Brake fluid is highly corrosive and may damage the rubber and painted parts of the vehicle.
While performing maintenance work, protect your eyes by wearing special goggles and wear protective gloves.
In the event of accidental contact with the eyes, rinse them with plenty of clean, running water and seek medical advice
immediately.
b.2

IMPORTANT NOTICES
Battery
Recharge the battery in well ventilated areas since the battery produces toxic, highly inflammable gases when being
recharged; do not smoke or use naked flames or sparks.
The liquid in the battery is highly corrosive. If it comes into contact with the skin, rinse thoroughly with running water.
It is extremely important to protect your eyes because even a small amount of liquid can cause irreversible damage
to the eyes.

If it comes into contact with the eyes, rinse thoroughly with clean, running water and if swallowed accidentally, drink
plenty of water or milk.
In all cases, seek medical advice immediately.
The battery liquid is corrosive and should not be poured onto the painted or rubber parts.
The battery liquid is highly polluting. DO NOT dispose in the environment; at the end of its service life, take the battery
to the special authorised recycling centres in accordance with the legal requirements in force in the country where
the vehicle will be used.
TR 650 TERRA and TR 650 STRADA models are

STREET LEGAL motorcycles; they are guaranteed
exempt from functional defects and covered with
legal guarantee, as far as the STANDARD CON-
FIGURATION IS MAINTAINED and the suggested
maintenance table shown in Section "B" is observed.
* In order to maintain the vehicle’s “Guarantee of

Functionality”, the client must follow the mainte-
nance programme indicated in Section B by having
the required maintenance inspections carried out
at authorised HUSQVARNA dealers. The cost for
changing parts and for the labour necessary in order
to comply with the maintenance plan is charged to
the Client. The warranty becomes NULL AND VOID
if the motorcycle is rented.
Notes
Left and right side is determined when seated on
motorcycle.
Z: number of teeth
H11658
Unless otherwise specified, data and instructions
apply to all market variants.
b.3

IMPORTANT NOTICES
RECOMMENDED SHOP PRACTICES

Before disassembling components or before performing repair operations, clean the motorbike removing possible mud, dust, or
foreign bodies.
- Put the vehicle in a well lit area;

- Fasten the vehicle in a steady position so that it cannot overturn; use suitable stands and belts.
- Use suitable equipment for lifting/removing heavy parts.
- Use appropriate keys (not pliers) to loosen/tighten nuts and screws.
- When loosening or tightening nuts or bolts, always begin with the bigger ones or from the centre. Tighten to the specified torque
and follow a cross pattern or a dedicated pattern as outlined in the relevant section.
- Always mark any parts or positions that might be confused upon assembly.
- Use special tools where specified.
- Clean thoroughly the removed components before refitting them
- During the reassembly, make sure that the bearings turn freely without obstruction or without getting stuck, otherwise replace
them
- Always replace the seals, the sealing rings, the split pins, the screws with damaged thread, and the self-locking nuts with new
parts.
- Use genuine HUSQVARNA parts and the recommended lubricant brands.
- At the end of a repair or periodic maintenance, test the vehicle before delivering it to the customer.
Electrical parts
- Disconnect the electrical component connectors by pressing the special safety hooks.
- Make sure that inside the connector there is no dirt or rust; if need be, clean them with an air jet or suitable products.
- Make sure that the cables are correctly seamed to the connector terminals.
- When you reconnect the connectors, ensure the correct coupling.
Do not disconnect the connectors by pulling the electrical cables.
- Technical Bulletins might contain more up-to-date setting data and procedures than this manual. Be sure to read them.
Where not specified, refit the previously removed components following the procedures in the reverse order with
respect to the removal.
b.4

GENERAL INFORMATION
Section
A
A.1

GENERAL INFORMATION
Sommario
Engine...........................................................................................................A.3
Timing system...............................................................................................A.3
Lubrication.....................................................................................................A.3
Ignition...........................................................................................................A.3
Fuel system...................................................................................................A.3
Primary drive.................................................................................................A.3
Clutch............................................................................................................A.3
Transmission.................................................................................................A.3
Transmission ratio.........................................................................................A.3
Secondary drive............................................................................................A.3
Final ratios.....................................................................................................A.4
Chassis..........................................................................................................A.4
Front suspension...........................................................................................A.4
Rear suspension...........................................................................................A.4
Front brake....................................................................................................A.4
Rear brake.....................................................................................................A.4
Wheels..........................................................................................................A.4
Tyres..............................................................................................................A.4
Table for lubrication, supplies........................................................................A.5
Electrical components location......................................................................A.5
Dimensions, weight, capacity........................................................................A.6
A.2

GENERAL INFORMATION
Engine
Single cylinder, 4 stroke engine with four valves
Cooling..............................................................................liquid and electric fan
Bore....................................................................................... 3,937 in (100 mm)

Stroke...................................................................................... 3,268 in (83 mm)
Displacement...................................................................... 39,787 in3 (652 cm3)
Compression ratio ...................................................................................12,3:1
Starting ................................................................................................... electric

Type of fuel.............................................................. unleaded fuel 95ROZ/RON
Timing system
Double overhead camshaft chain operated; 4 valves
Valve clearance (with engine cold)

Intake.............................................................0,009 ÷ 0,011 in (0,23 ÷ 0,28 mm)
Exhaust........................................................ 0,015 ÷ 0,017 in (0,38 ÷ 0,43 mm)
Lubrication
Dry sump with tank integrated in the chassis and cartridge oil filter.
Ignition
Electronic with adjustable advance (digital control)
Spark plug type................................................................ “NGK” MAR9A-J-G06

Spark plug electrode gap....................................................0,024 in (± 0,004 in)
0,6 mm (± 0,1 mm)
Fuel system
Electronic injection feed
Primary drive
Drive gear on crankshaft............................................................................. Z 37
Driven gear on clutch housing..................................................................... Z 72
Transmission ratio .....................................................................................1.946
Clutch
Multidisc in oil bath with mechanical control
Transmission
With front couplings always engaged
Transmission ratio
1st gear......................................................................................... 2.750 (33/12)
2nd gear........................................................................................ 1.750 (28/16)
3rd gear......................................................................................... 1.313 (21/16)
4th gear......................................................................................... 1.045 (23/22)
5th gear......................................................................................... 0.875 (21/24)
Secondary drive
Transmission sprocket ................................................................................ Z 16
Rear wheel sprocket.................................................................................... Z 47
Transmission ratio .....................................................................................2.938
Drive chain dimensions...........................................................520KR0 112 links
A.3

GENERAL INFORMATION
Final ratios
1st gear....................................................................................................15.722
2nd gear...................................................................................................10.005
3rd gear .....................................................................................................7.506
4th gear......................................................................................................5.974
5th gear......................................................................................................2.898
Chassis
Single frame, in round, rectangular and ellipsoidal steel pipes; rear steel chassis
Front suspension
Upside down type hydraulic fork..............................ø 1.81 in (46 mm) fork legs
Wheel travel ........................................................................... 7.48 in (190 mm)
Rear suspension
Hydraulic monoshock (adjustment of spring preload and rebound hydraulic
damping)
Wheel travel ........................................................................... 7.48 in (190 mm)
Front brake
Ø 11,811 in (300 mm) fixed disc with hydraulic control and floating calliper
Rear brake
Ø 9,449 in (240 mm) floating wave disc with hydraulic control and floating calliper
Wheels
TR 650 STRADA
Front..................................................................................in light alloy: 2.5”x19”
Rear......................................................................................in light alloy: 3”x17”
TR 650 TERRA
Front................................................. with spokes and aluminium rim: 1.85”x21”
Rear........................................with spokes and aluminium rim: 3”x18” (no ABS)
with spokes and aluminium rim: 3”x17” ( ABS)
Tyres
TR 650 STRADA
Front................................................................................ 110/80 R19” M/C 59 V
Rear.................................................................................140/80 R17” M/C 59 V
Cold tyre pressure (Rider only)
Front.................................................................................2.2 kg/cm2 (31.29 psi)
Rear..................................................................................2.0 kg/cm2 (28.45 psi)
Cold tyre pressure (Rider and passenger)
Front.................................................................................2.2 kg/cm2 (31.29 psi)
Rear..................................................................................2,5 kg/cm2 (35.56 psi)
TR 650 TERRA
Front.....................................................................90/90 21” M/C 54 H TL (ABS)
90/90 21” M/C 54 S (no ABS)
Rear.........................................................................140/80 17” M/C 59 H (ABS)
140/80 18” M/C 70 S (no ABS)
Cold tyre pressure (Rider only)
Front.................................................................................2.0 kg/cm2 (28.45 psi)
Rear..................................................................................2.5 kg/cm2 (35.56 psi)
Cold tyre pressure (Rider and passenger)
Front.................................................................................2,0 kg/cm2 (28.45 psi)
Rear..................................................................................2,8 kg/cm2 (39.82 psi)
A.4

GENERAL INFORMATION
Table for lubrication, supplies
Engine, gearbox and primary drive
lubricating oil................................ CASTROL POWER1 RACING SAE 10W-50
Engine coolant ...................................... CASTROL MOTORCYCLE COOLANT
Brake fluid ...........................................CASTROL RESPONSE SUPER DOT 4
Grease lubrication.....................................................CASTROL LM GREASE 2
Secondary drive chain lubrication................ CASTROL CHAIN LUBE RACING
Electric contact protection.......................CASTROL METAL PARTS CLEANER
Electrical components location

The ignition system includes the following elements:
- Generator on the inner side of R.H. crankcase half cover;
- Electronic ignition coil with integrated spark plug cap positioned on cylinder head;
- Electronic control unit on rear chassis under saddle;
- Spark plug on cylinder head;
- Starter motor in front of cylinder block;
- Solenoid starter on rear chassis under saddle;
- Potentiometer on throttle body;
- Voltage regulator on right-hand side of engine;
- Neutral position sensor on right-hand side of engine.
The electrical system includes the following elements:

- 12V - 10Ah battery in the central part;
- Turning indicator flasher integrated in the digital instrument;
- Fuel pump relay, main relay and fan on rear chassis under saddle;
- Electric fan;
- Auxiliary fuses on rear chassis under saddle; two 30A main fuses on solenoid starter;
- Coolant temperature sensor on cylinder head;
- Lambda sensor;
- Headlamp with H4-12V-55/60W HD halogen bulb and 12V-5W parking light bulb;
- LED tail light with stop light bulb;
- 12V-RY10W turning indicator bulbs;
- Fuel pump inside the tank.
- Multifunction digital instrument.
A.5

GENERAL INFORMATION
Dimensions, weight, capacity

Wheelbase ............................................................................................................................55,055 in (1500 mm)
Total length (STRADA) ......................................................................................................... 88,504 in (2248 mm)
Total length (TERRA)............................................................................................................ 89,252 in (2267 mm)
Overall width ............................................................................................................................34,843 in (885 mm)
Max. height (STRADA).......................................................................................................... 47,441 in (1205 mm)
Max. height (TERRA).............................................................................................................. 48,15 in (1223 mm)
Saddle height (STRADA).........................................................................................................33,858 in (860 mm)
Saddle height (TERRA)...............................34,449 in (875 mm) (no ABS - 18”) / 34,055 in (865 mm) (ABS - 17”)
Minimum height off ground (STRADA) ......................................................................................9,843 in (250 mm)
Minimum height off ground (TERRA).............. 10,472 in (mm 266) (no ABS 18”) / 10,118 in (257 mm) (ABS 17”)
Weight, without fuel (STRADA)................................................................................................390,218 lb (177 kg)
Weight without fuel. (TERRA).......................................................................................................383,604 (174 kg)
Fuel tank capacity including reserve.......................................................... 3,08 Imp. Gall. / 3,698 U.S. Gall. / l 14
Fuel reserve................................................................................... approx. 0,55 Imp. Gall. / 0,66 U.S. Gall. / 2.5 l
Coolant tank capacity............................................................................ 0,255 Imp. Gall. / 0,306 U.S. Gall. / 1.16 l
Oil and oil filter replacement..................................................................... 0,44 Imp. Gall. / 0,528 U.S. Gall. / 2.0 l
Topping up oil between minimum and max. level.................................. 0,055 Imp. Gall. / 0,066 U.S. Gall. / l 0.25
C
D
1500 mm
A
B
885 mm
H11659
A.6

MAINTENANCE
Section
B
B.1

MAINTENANCE
TR 650 STRADA SCHEDULED MAINTENANCE CHART

TR 650 TERRA (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
ENGINE
SERVICE SERVICE SERVICE SERVICE SERVICE
COUPON COUPON COUPON COUPON COUPON
AFTER EVERY EVERY EVERY EVERY
THE FIRST 10.000 Km 20.000 Km 30.000 Km 40.000 Km
1.000 Km
Check engine oil level EVERY
C S S S S
1.000 Km
Replace engine oil together with oil filter, EVERY
clean magnetic plug 10.000 Km
S S S S S or
ONCE A
YEAR
Check / adjust valve play C/R C/R C/R C/R
Replace spark plugs EVERY
S S
20.000 Km
Oil filter (on oil return pipe from chassis) P/S P/S
Replace coolant EVERY 2 YEARS
Check / adjust clutch play C/R C/R C/R C/R C/R
C: Check
S: Change
R: Reset
B.2

MAINTENANCE
TR 650 STRADA SCHEDULED MAINTENANCE CHART

TR 650 TERRA (TO BE CARRIED OUT AT THE HUSQVARNA DEALER)
CHASSIS
SERVICE SERVICE SERVICE SERVICE SERVICE
COUPON COUPON COUPON COUPON COUPON
AFTER THE EVERY EVERY EVERY EVERY
FIRST 10.000 Km 20.000 Km 30.000 Km 40.000 Km
1.000 Km
Check and lubricate secondary chain Lubricate the secondary drive chain at least once every 1,000 km.
If used on dusty or wet roads, do this more frequently
Second.Drive chain: check tension and
wear C/L/S C/L/S C/L/S C/L/S
Check front/rear sprockets for wear: if nec-

essary, replace along with the secondary C/L/S C/L/S C/L/S C/L/S
drive chain
Air filter S S
If the vehicle is used in very dusty conditions/on very dusty roads, reduce this service
to 10,000 km
Transmission cables and controls C/R/L C/R/L C/R/L C/R/L C/R/L
Steering bearings and steering clearance C/R C/R C/R C/R
Emptying the intake silencer hose C/P C/P C/P C/P
Brake discs C/S C/S C/S C/S
Brake pad wear C/S C/S C/S C/S
Front fork (oil change) S S
General vehicle operation C C C C C
Braking systems (check pipes) C/R C/R C/R C/R C/R
Cooling system (check level) C/S C/S
Lights / warnings C/R C/R C/R C/R C/R
Safety switches C/R C/R C/R C/R
Brake fluid (3)
C/R C/R C/R C/R C/R
Coolant (1) C/R C/R C/R C/R C/R
Checking battery charge level C/R C/R C/R C/R
Tyres: Pressure / Wear C/R C/R C/R C/R
Wheels (checking spoke tension - terra
C/R C/R C/R C/R
version)
Control unit diagnosis C/R C/R C/R C/R C/R
Side stand C/R/L C/R/L C/R/L C/R/L
Checking function and clearance of ac-
C/R C/R C/R C/R
celerator cable
Fuel hoses (2) C/S
Check cooling-water tubes and water
pump for condition and leakage / replace C C C C
if necessary
S: Change (1):
Replace every 2 years
L: Lubricate (2):
Replace every 4 years
P: Clean (3):
Replace every year
R: Reset
C: Check
B.3

TROUBLESHOOTING
Section
C
Manuale d'officina Ed. 09-2012
C.1

TROUBLESHOOTING
ENGINE
Trouble Possible causes Remedy

Ignition switch not in ON position Switch ignition switch to position ON
Engine-stop-switch on OFF position Switch to position ON
Starter motor does not operate or does not Check/replace battery and check connec-
Flat battery, loose or rusty connections
turn engine over tions, check charging system
Ignition circuit in short-circuit Check ignition circuit
Starter motor defect Replace starter motor
Spark plugs loose Tighten spark plugs
Spark plugs not according to specifications
Replace spark plug
or defective
Spark plugs fouled or wet Clean or exchange
Check/replace battery and check con-
Battery nearly discharged, starting rpm
nections, check if battery is charged by
too low
generator
Check fuel tank if empty
Fuel supply inadequate Check / replace fuel supply pipes, fuel pump,
fuel pressure sensor and injectors
Engine turns over but does not start engine Adjust valve clearance according to speci-
or starts hard Valve clearance below specification
fication
Valve timing incorrect Adjust position of camshaft gears
Ignition coil or ignition cable defective Check / replace
Ignition unit defective, ignition timing incor- Check / replace crank position trigger and
rect ECU
Cylinder gasket defective Exchange cylinder head gasket
Valves and valve guides worn or imperfect Exchange valves, rework valve seats or
valve seat exchange cylinder head
Piston rings and/or cylinder bore worn Exchange piston rings and/or cylinder
Engine oil too heavy (winter operation) Exchange engine oil
Excessive spark plug electrode gap Exchange spark plug
Adjust valve clearance according to speci-
Valve clearance below specification
fication
Tighten intake socket or exchange if nec-
Intake coupling not tightened or damaged
essary
Engine runs irregularly at idle Ignition unit defective, ignition timing incor- Check / replace crank position trigger and
rect ECU
Valves leaking Rework valve seats
For other possible causes see also "Engine
starts over but does not start engine or
starts hard"
C.2

TROUBLESHOOTING

Check fuel pressure sensor, fuel pump and
Fuel pressure too low
fuel supply
Leak air Check / replace intake socket
Engine runs irregularly at higher speed Camshafts worn Check and replace if necessary
For other possible causes see also "Engine
starts over but does not start engine or
starts hard"
Leak air, intake system leaking Check / replace intake socket
Replace spark plug
or defective
Valve clearance not according specification
fication
Valve timing incorrect Adjust position of camshaft gears
Ignition coil supplies insufficient ignition
Check / replace ignition coil
voltage
Engine has no or insufficient performance rect ECU
Valves leaking Exchange valves, rework valve seats
Clutch slipping See remedies "clutch is slipping".
Check fuel pressure sensor, fuel pump and
Fuel pressure too low
fuel supply
Air filter dirty Exchange
Exhaust system defective Exchange
Excessive Blow-by gases, Piston rings and/
Exchange piston rings and/or cylinder
or cylinder bore worn
Engine oil not according to specifications Exchange engine oil
Use fuel of specified octane number (min.
Fuel of too low octane number
ROZ 95)
Replace spark plug
or defective
Engine knocks or pings
Check / replace intake socket and intake
Leak air, intake system leaking
system
rect ECU
C.3

TROUBLESHOOTING

Not enough coolant in cooling system, cool-
Refill coolant, check system under pressure
ing system leaking, air in cooling system
Cooling fan motor defective Replace cooling fan motor
Not enough engine oil in the engine Refill oil
Radiator dirty Clean radiator
Faulty thermostatic valve Replace
Engine overheats Ignition unit defective, ignition timing incor- Check / replace crank position trigger, ECU
rect and sensors
Repair water pump, check and renew water
Water pump, water pump drive defective
pump drive
Oil pump or oil pump drive defective, oil Exchange oil pump or oil pump gears,
circuit blocked clean oil circuit
Cylinder head gasket defective Exchange cylinder head gasket
Leak air Check / replace intake socket
Engine temperature is too low Faulty thermostatic valve Replace
Too much oil in the engine (oil in the airbox) Drain engine oil
Cylinder head gasket leaking Exchange cylinder head gasket
Valve stem seals leaking Exchange valve stem seals
Engine produces excessive blue smoke or
engine uses too much oil Oil diluted with fuel / Piston rings and/or
cylinder bore worn
Oil diluted with fuel / motocycle is only used
Use motorcycle at long distances in between
in short distances (cold engine)
Engine fixation into frame loose Tighten engine fixation
Engine vibrates
Bearing or bearing seat worn Replace bearing or worn component
in short distances
Engine oil quantity increases
Oil diluted with fuel / Piston rings and/or
cylinder bore worn
Not enough engine oil in the engine Refill oil
Pressure regulating piston blocked (bypass
Check/replace pressure regulating piston
valve stuck in opened position)
Check / replace oil pump and/or oil pump
Oil pump and/or oil pump drive defective
drive
Low or no engine oil pressure Oil pump worn Replace oil pump
Oil diluted with fuel / Piston rings and/or
cylinder bore worn
in short distances
Oil sieve / oil filter dirty/blocked Clean / replace oil sieve and replace oil filter
C.4

TROUBLESHOOTING

Pressure regulating piston blocked (bypass
Check/replace pressure regulating piston
High engine oil pressure valve stuck in closed position)
Oil circuit blocked Clean oil ducts
C.5

TROUBLESHOOTING

Noise is heard when the engine is started:
Sprag clutch, sprag clutch housing or free- Replace Sprag clutch, sprag clutch housing
wheel gear worn or freewheel gear
Teeth of starter motor and/or starter drive Replace starter motor and/or starter drive
gears worn gears
Noise disappears after the engine is started
Chain tensioner does not work
when oil pressure is available
Noise seems to come from the valve train:
Excessive valve clearance
fication
Chain tensioner does not work Replace chain tensioner
Camshaft or brackets of camshaft worn Replace camshafts and/or cylinder head
Camshaft drive worn or loose Tighten or replace camshaft gears
Camshaft chain, chain guide or chain ten- Replace camshaft chain, chain guide or
sion guide worn chain tension guide
Noise seems to come from the piston:
Piston or cylinder worn Replace piston or cylinder
Piston pin bore or piston pin worn Replace piston pin bore or piston pin
Piston rings broken or ring grooves worn Replace piston rings broken or ring grooves
The noise seems to come from the
Engine excessively noisy crankshaft, countershaft or crankcase:
Bearings of crankshaft or conrods worn Replace the crankshaft
Worn needle bushing and/or balancer shaft
Replace the balancer shaft
bearings and/or balancing connecting rod
Noise seem to come from the clutch or
clutch side:
Friction plates (hammer heads) and/or
Replace friction plates and /or clutch drum
clutch drum worn
Excessive or insufficient backlash of the
Replace primary drive assy.
teeth of the primary drive gears
Clutch drum, clutch hub or pressure plate Replace clutch drum, clutch hub or pres-
worn sure plate
Bearing of clutch gear worn Replace primary drive assy.
Disk springs of primary drive assy. worn Replace primary drive assy.
Springs and spring retainers of primary
Replace springs and spring retainers
drive assy. Worn
Noise with clutch engaged - ball bearing of
Replace ball bearing
the pressure plate worn
Noise seem to come from the gearbox:
Check gears and gear shafts, replace if
Tooth flanks of the gearbox gears worn
necessary
Ball bearing of gearbox shafts and/or needle
Replace bearings
bearings of gears worn
C.6

TROUBLESHOOTING

Fatigue of clutch springs Replace clutch springs
Clutch slips Clutch plates worn or warped Replace clutch plates
Clutch disengages unsatisfactorily Clutch plates warped Exchange clutch plates
Clutch plates stuck together Clean or exchange
Clutch plates worn or warped Replace clutch plates
Guide slots for friction plates in clutch drum
The clutch drags Replace clutch drum
are worn
Guide slots for steel plates in clutch hub
Replace clutch hub
are worn
Gearshifting action incomplete Always actuate gearshift lever till stop
Gearshift lever incorrectly adjusted Correct position of gearshift lever
Fastener of gearshift lever loose Tighten fastener
Gearshift lever bent Replace gearshift lever
Function of index lever or index spring Check index lever and index spring and
imperfect exchange if necessary
Gears do not engage or gears jump out at
start or at abrupt acceleration Check and adjust pawl wich spring, ex-
Adjustment of gearshift pawl incorrect
change if necessary
Engagement teeth and/or windows of gear-
Exchange gears
box gears badly worn
Gearshift forks are worn or bent Exchange gearshift forks
Gearbox gears are worn or damaged Exchange gearshift gearbox gears
The clutch does not disengage See "Clutch disengages unsatisfactorily"
Gears can be shifted only noisily Clutch does not disengage See "Clutch disengages unsatisfactorily"
Spark plugs not according to specifications Replace spark plug
Spark plugs loose Tighten spark plugs
Spark plugs overheated, burnt or dirty Tighten intake socket or exchange if nec-
Intake socket not tight or leaking
essary
Fuel supply system defective Check and replace if necessary
Check/replace battery and check connec-
Battery faulty, loose or corroded connections
tions
Rectifier regluator defective Replace rectifier regluator
The generator does not charge the battery Break in current, short circuit or earthing of
Replace stator
stator windings
Break in cables or short circuit, connec-
Check and replace if necessary
tions loose
C.7

TROUBLESHOOTING
CHASSIS
Trouble Cause Remedy

Insufficient tyre pressure Inflate
Bearing adjuster ring nut or steering stem
Adjust
Handlebar turns hard nut overtightened
Bent steering stem Replace bottom yoke
Worn or seized steering bearings Replace
Bent fork legs Replace
Bent front wheel axle Replace
Warped chassis Replace
Handlebar vibration
Bent front wheel rim Replace
Worn front wheel bearings Replace
Improperly balanced wheel Balance
Too much oil in fork legs Remove excess oil
Fork oil viscosity too high Change
Damping is too hard
Overinflated tyres Deflate
Improperly set rear shock absorber Adjust
Insufficient oil in fork legs Top up
Fork oil viscosity too low Change
Damping is too soft Weak fork springs Replace
Weak rear shock absorber spring Replace
Improperly set rear shock absorber Adjust
Bent wheel rim Replace
Worn wheel hub bearings Replace
(Front / rear) wheel shakes Wheel axle nut loose Tighten
Worn rear swinging arm bearings Replace
Improperly balanced wheel Balance
Worn shock absorber joints Replace
Rear suspension is noisy
Shock absorber faulty Replace
Air in brake system Bleed
Insufficient fluid in tank Top up
Poor braking (front and rear)
Worn brake pad and/or disc Replace
Damaged disc Replace
C.8

TROUBLESHOOTING
ELECTRICAL SYSTEM (see also Section M)
Trouble Cause Remedy

Dirty air filter Clean
Spark plug fouls easily Worn piston rings Replace
Worn piston or cylinder liner Replace
Spark plug electrode gap too close Adjust
Spark plug electrodes overheat
Wrong heat rating Replace with recommended spark plug
Cables running to voltage regulator im-
Connect correctly or replace
Generator does not charge or is not properly connected or shorted
providing enough charge Voltage regulator faulty Replace
Faulty generator Replace
Generator overcharges battery Voltage regulator faulty Replace
Battery terminals dirty Clean
Battery does not hold charge Faulty generator Replace
Faulty battery Replace
Battery is flat Charge
Control on R.H. switch faulty Replace
Starter relay faulty Replace
Starter motor does not start or slips Starter motor faulty Repair or replace
Worn starter gears Replace
Worn or damaged freewheel rollers Replace freewheel
Ignition key not recognised Check control unit key immobiliser
C.9

SETTINGS AND ADJUSTMENTS
Section
D
D.1

Sommario
Saddle removal.............................................................................................D.3
Removal of central upper cover....................................................................D.4
Side panel removal........................................................................................D.4
Throttle cable adjustment..............................................................................D.5
Throttle control..............................................................................................D.5
Throttle position adjustment..........................................................................D.5
Front brake control........................................................................................D.5
Position adjustment.......................................................................................D.5
Front brake lever adjustment and fluid level check.......................................D.6
Clutch control................................................................................................D.6
Position adjustment.......................................................................................D.6
Clutch control lever distance adjustment.......................................................D.7
Clutch free play adjustment...........................................................................D.7
Rear brake pedal free play adjustment.........................................................D.8
Rear brake fluid level check..........................................................................D.8
Oil level check...............................................................................................D.9
Engine oil replacement and cartridge filter replacement...............................D.9
Replacement of cartridge filter....................................................................D.10
Filling...........................................................................................................D.11
Coolant level check.....................................................................................D.11
Coolant replacement...................................................................................D.12
Air filter check..............................................................................................D.13
Chain tension adjustment............................................................................D.14
Lubricating the chain...................................................................................D.14
Suspension .................................................................................................D.15
Shock absorber spring preload adjustment.................................................D.15
Rebound shock absorber hydraulic damping adjustment...........................D.16
Fork adjustment ..........................................................................................D.16
Fuel supply hose inspection and replacement............................................D.16
Exhaust system check.................................................................................D.17
Idle speed adjustment.................................................................................D.18
Checking and adjustment of valve clearance..............................................D.18
D.2

Saddle removal
To remove the saddle proceed as follows:
2 - Insert the key in the lock (1) positioned in the rear part of the motorcycle;
- turn the key clockwise to release the saddle (2), and then lift it and pull it out
towards the rear, releasing it from the front fastener.
To fit the saddle back on, fasten it at the front and then press the rear until the
1 fastening "Click" is heard.
H11660
H11661
D.3

Removal of central upper cover

- Unscrew the four screws (1) that fasten the cover (2) and remove it.
1
2
H11662
Side panel removal

- Remove the saddle as described in the relevant paragraph.
- Remove the upper cover as described in the relevant paragraph.
1 - Unscrew the five screws (1) and remove the left-hand side panel (2) from
its fittings.
- Repeat to remove the right-hand side panel.
When refitting, first insert the rear and then the front fittings.
H11664
H11663
H11665 H11666
D.4

Throttle cable adjustment

4 To check the correct adjustment of the throttle control cable, operate as follows:
- remove the reservoir and the filter box as outlined in the relevant sections;
- turn throttle twistgrip (1) and make sure that there is a clearance of approx.
2 mm 2 mm (0.08 in);
(0,8 in.) - if this does not work, unlock the check nut (2);
- work on the nut (3) until you have about 2 mm clearance (0.08 in.);
- tighten check nut (2).
- reassemble all parts, in the reverse order compared to disassembly.
1
Operation with damaged throttle cable could result in an unsafe
2 mm riding condition.
(0,8 in.) H11667 When throttle control cables (4) are replaced, adjust new cables as previously
explained.
2
4 3
H11668
Throttle control
2 1 The throttle twistgrip (1) is located on the right-hand side of the handlebar:
Throttle position adjustment

The position of the control on the handlebar can be adjusted by loosening the
two retaining screws (2).
Do not forget to tighten the screws (2) after adjusting.

2
H11669
Front brake control

The brake control lever (1) is located on the right-hand side of the handlebar.
Position adjustment
1 The position of the control on the handlebar can be adjusted by loosening the
two retaining screws (2).
After adjustment, turn the handlebar as far as possible to the right

and make sure that the lever does not touch the bodywork
A stop switch, during the braking action, causes the stop light on the tail light
to come on.
2
H11670
D.5

Front brake lever adjustment and fluid level check

The level of the fluid in the master cylinder reservoir must never be below the
minimum level visible through the inspection sight glass (1) on the side of the
2 master cylinder (2) body.
A decrease of the fuel level will let air into the sustem, hence an extension of
the level stroke.
If the brake lever feels mushy when pulled, there may be air in the
MIN brake line or the brake may be defective: CHECK THE BRAKING
SYSTEM (see Section "L").
1
Too much brake lever free play may reduce braking action: CHECK
H11671 BRAKE PAD THICKNESS (see Section "L").
Do not spill brake fluid onto any painted surface or lens (for example
lights lens).
Do not mix two brands of fluid. Completely change the brake fluid
in the brake system if you wish to switch to another fluid brand.
Brake fluid may cause irritation. Avoid contact with skin or eyes. In
case of contact, flush thoroughly with water and call a doctor if your
eyes were exposed.
Clutch control
The clutch control lever (1) is located on the left-hand side of the handlebar.
1
Position adjustment
The position of the clutch control on the handlebar can be adjusted by loosening
the retaining screws (2).
After adjustment, turn the handlebar as far as possible to the left

and make sure that the lever does not touch the bodywork.
2
H11672
A "STOP" switch on the clutch lever support allows you to start the engine when
the motorcycle is in gear or the clutch lever is pulled (the stand must be off the
ground).
D.6

Clutch control lever distance adjustment

The lever (1) can be adjusted (3 settings available) to suit the rider's hand size
To regulate the position of the lever (1) push it outwards and then select the
required position by means of the adjuster screw (2).
2
H11673
Clutch free play adjustment

Free play (A) must be 5 -10 mm (0.196 - 0.39 in).
- Move the rubber gaiter (1);

- regulate the adjuster screws (2) and the counter adjuster screw (3) to obtain
A the indicated free play.
- after completing the operation, make sure the counter adjuster screw (3) is
properly tightened and then replace the rubber gaiter (1).
3
2
1 H11674
D.7

Rear brake pedal free play adjustment

Before staring the braking action, rear brake pedal (1) shall have a free play
(B) of 5-10 mm (0,196 ÷ 0,39 in.). Should this not happen, operate as follows:
1 - Loosen the nut (2);
- Operate the master cylinder linkage (3) to increase or decrease free play;
- Tighten the nut (2) at the end of the operation.
B
When the free play requirement is not met, the brake pads will be
subjected to an early wear that may lead to TOTAL BRAKE INEF-
FECTIVENESS.
If the brake pedal feels mushy when pulled, there may be air in the
brake line or the brake may be defective. CHECK THE BRAKING
H11675 SYSTEM (see Section L).
C: to increase clearance
D: to decrease clearance
3
C
H11676
Rear brake fluid level check

MAX The fluid level in the master cylinder tank shall never be below the minimum
level (1) shown on the transparent reservoir (2).
A decrease in the fluid level will let air into the system and increase the lever
stroke.
If the brake pedal feels mushy when pulled, there may be air in the
2 brake lines or the brake may be defective.
MIN 1
Do not spill brake fluid onto any painted surface or light lens.
H11677
Do not mix two brands of fluid. Completely change the brake fluid
in the brake system if you wish to switch to another fluid brand.
Brake fluid may cause irritation. Avoid contact with skin or eyes.
In case of contact, flush thoroughly with water and call a doctor if
your eyes were exposed.
D.8

Oil level check

MAX The oil level must be checked with the vehicle in vertical position on a flat sur-
MAX
face.
1 - Start the motorcycle and heat the engine until the cooling fan starts; wait for
MIN another 3 minutes and switch off the engine.
MIN
- Check the level as follows:
- Undo the cap (1) with the dipstick (2) and remove it from the frame.
- Clean the dipstick (2) with a cloth.
- Place the dipstick (2) in the hole (3) without screwing the cap on.
- Remove the dipstick (2) from the hole (3) and check that the level is be-
3 tween the two MIN and MAX marks.
2 - To top up, pour oil into the hole (3); for the type of oil, see the section
“Technical data”.
H11678
Never exceed max. level.
Engine oil replacement and cartridge filter replacement

Be careful not to touch hot engine oil.
1

Drain the oil with WARM ENGINE; proceed as follows:
- Place the motorcycle on its side stand
- Remove the cap (1) with the dipstick
Oil change must be performed in two stages:

Draining oil from tank;
Draining oil from engine
H11679
2 Draining oil from tank:

- Place a 2 litre container under the coupling (2) and then unscrew the screw
(3) and let the oil in the tank drain out completely.
- Once it has drained out, tighten the screw (3) with its corresponding washer.
Draining oil from engine:

3 - Place a container to collect the oil under the engine.
- Unscrew the screw (4) and let all the oil in the engine drain out completely.
- Once it has drained out, clean the magnetic screw (4), replace the gasket
and refit it on the engine by tightening it to torque.
H11680 Fill with oil as described in the relevant paragraph.
H11681
D.9

Replacement of cartridge filter

- Unscrew the screws (5) and remove the sprocket casing (6).
6 - Unscrew the screws (7) and remove the oil filter cover (8).
- Replace the filter (9) with a new one, then refit the cover (8) making sure that
the O-ring (10) is not damaged and positioned correctly on the cover.
- Refit the sprocket casing (6) making sure that the cable (11) of the rear stop
switch is positioned correctly as in the figure and that the cable guide (12) is
fastened externally onto the bottom screw.
5
H11682
7
H11683
11
9
H11684 H11686
12
10
H11685 H11687
D.10

Filling
- Remove the cap (1) with the dipstick.
- Pour 1.5 litres of oil into the chassis tank.
1 - Run the engine for 30 seconds and then switch it off.
- Pour another 0.5 litres of oil into the chassis tank.
- Check the oil level as described in the relevant paragraph.
Check the condition of the gasket (2) of the cap (1) with the dipstick
and if it is damaged, replace it.
For the type of oil to use, refer to the “Technical data”paragraph.
2
H11743
Coolant level check

When the engine is cold, check that the level of the coolant is between the MIN
and MAX marks on the expansion tank (1) on the left-hand side of the motorcycle.
If topping up is necessary, do the following:
3 Do not remove the radiator cap (2) since all the liquid in the expan-
sion tank (1) will flow out.
- Remove the cap (3) and add the fluid needed to restore the level to the ex-
pansion tank (1).
1 (for the type of liquid to use, see the section “Technical data”).
MAX
MIN Difficulties may arise in eliminating coolant from painted surfaces.
If this occurs, wash off with water.
Never exceed max. level.
H11689
H11690
D.11

Coolant replacement
Drainage
- Place the motorcycle on its side stand.
- Remove the cap (1) of the expansion tank (2).
- Place a 2 litre container under the water pump and unscrew the screw (3).
- Let a small amount of coolant drain out and then turn the radiator cap (4) to
the first click and wait for all the coolant to flow out of the water pump drain-
age hole.
1
Filling
- Re-tighten screw (2) on the water pump.
- Remove the radiator cap (4).
2 - Pour the coolant into the radiator (5) until it is full and gradually top up as the
level drops until it stays at maximum level.
- Put the radiator cap on again and pour the coolant into the expansion tank
(2) until it reaches maximum level.
- Put the cap (1) of the expansion tank on again.
- Start the engine, wait for the radiator cooling fan to start up and then wait
another 3 minutes.
- Switch off the engine and wait for it to cool, then check the level as described
in the relevant paragraph.
H11691
3 H11692
5 H11693
D.12

Air filter check

Note: Clean the filter area before removing the cover.
- Unscrew the screws (1) and remove the cover (2) together with the filter (3);
- remove the filter (3) and check that it is not clogged/dirty; replace if neces-
sary;
- when refitting, check that the filter (3) is correctly placed in its housing (4).
2
1
Before refitting the filter, check that the contact surfaces between
the filter, the filter box and the cover are completely clean.
H11694
H11695
3
3
H11696 H11697
D.13

Chain tension adjustment

1
Chain should be checked, adjusted and lubricated as per the Maintenance
Chart to ensure safety and prevent excessive wear.
If the chain becomes badly worn or is adjusted incorrectly (i.e., it is too loose or
too tight), it could jump out of the sprocket or break.
A
- Position the motorcycle on the side stand so the chain is not stressed and
2 loaded;
- where the screw (1) is located, lift the chain (2) upwards and measure the
chain travel.
- the correct setting must be 45 mm (1.77 in).
If this is not the case, proceed as follows:

H11744 - make sure that the motorcycle is fully upright on the special rear support
stand (optional).
- on the right side, loosen the locking nut (3) of the wheel axle;
- loosen the check nuts (4) on both chain tensioners;
6 4 - turn the adjuster screws (5) to obtain the correct tension and check on both
sides that the wheel centring sliders (6) are in the same position as the mark-
ings in the chain tensioner slider seats on the swinging arms;
- once adjusted, tighten the check nuts (4) and the wheel axle nut (3).
After adjusting, always check that distance "A" is 45 mm (1.77 in).
5
H11699
4
6
5
Lubricating the chain
Lubricate the chain following these instructions.
H11700
Never use grease to lubricate the chain. Grease helps to accumulate

dust and mud, which act as abrasive and help to rapidly wear out
the chain, the front and rear sprockets.
Do not wash the chain with high-pressure water jets and do not use
harsh or highly flammable solvents.
- After washing the chain using special detergent, dry it and lubricate with suit-
able spray grease.
The chain lubricant must NOT come into contact with the tyres or
the rear brake disc.
D.14

Suspension
The vehicle leaves the factory with standard settings for the front and rear sus-
pension that meet most requirements.
Before making any change and afterwards, if the adjustment is not

satisfactory, always start from the standard suspension setting
and increase or decrease the adjusting clicks, one at a time.
Shock absorber spring preload adjustment
This is easier to do if you lift the motorcycle at the centre so that

the rear wheel is released.
- Adjust the ring nut (1) using the spanner provided; by turning left “A”, the
preload increases;
by turning right “B” the preload decreases.
Be careful not to touch hot exhaust pipe while adjusting the shock
absorber.
H11701
A: Wheelbase
B: Spring in its seat
TERRA
A= 341 ± 1,5 mm (13,4252 ± 0,0591 in.)
1
B= 201 ± 1,5 mm (7,9134 ± 0,0591 in.)
H11702
H11704
STRADA
A= 341 ± 1,5 mm (13,4252 ± 0,0591 in.)
B= 198 ± 1,5 mm (7,7953 ± 0,0591 in.)

1
A B
H11703 H11705
D.15

Rebound shock absorber hydraulic damping adjustment

It is possible to adjust the rebound travel of the shock absorber.
B) REBOUND - Standard setting:

- 11 clicks
(adjuster 1)
1
To reset the standard setting, turn lower adjuster (1) clockwise until reaching fully
closed position. Then turn it back the number of clicks specified above.
In order to obtain a smooth braking action, turn the adjuster counter clockwise.
Vice versa to obtain a harder braking action.
H11706
Fork adjustment
On the fork installed on this motorbike version, it is not possible to perform any
type of adjustment.
1
Fuel supply hose inspection and replacement
- Remove the saddle as described in the relevant paragraph.
- Check fuel supply hose (1) conditions; if cracked, swollen, kinked, etc. it is
necessary to change it as follows:
- Press the ring nut (2) and unfasten the union (3).
- Open the clamps (4) and detach the pipe (1) from the unions (3) and (5).
H11707
During this operation, make sure that you do not damage the hose
holder coupling on the throttle body.
- Replace the pipe (1) and close the clamps (4) on unions (5) and (3).
2
- Refit the union (3) by pressing it down.
H11708
4
3 5
4
H11709 H11710
D.16

Exhaust system check

Perform a visual inspection of the exhaust system first, in order to identify pos-
sible gas leaks from the sealing elements (gaskets), and to ensure that the
Silent-Blocks are not damaged.
Subsequently, inspect the single components by disassembling the exhaust

system.
Also check the tightening of the flange nuts (1) fastening the manifold to the
cylinder head and the clamps (2) fastening the silencers to the manifolds as well
as the tightening of the screw (3) fastening the silencer to its support.
The damaged or broken parts must be replaced.
H11711
1 2
H11712 H11714
H11713
D.17

Idle speed adjustment

The idle speed is pre-set by the control unit (1550 rev/min.) and the stepper
motor ensures that this value is preserved.
No manual adjustment is possible, nor any adjustment through the diagnostic
tool.
Checking and adjustment of valve clearance

4 Remove the filter box and the throttle body as described in the relevant para-
graphs.
Drain the oil from the tank on the chassis as described in the relevant paragraph.
3 2 - Disconnect the connectors (1) and (2) from the coils/tubes (3) and (4).
- Remove the coils/tubes (3) and (4).
- Remove the spark plugs.
When refitting, do not invert the coils / tubes; the coil with the white
ring nut should be fitted on the outer part of the cylinder head and
1 the connector with the white clamp connected to the cable.
H11715
- Loosen the clamps (5) and (6) and remove the two pipes (7) and (8). Place
them so that they do not drip oil.
7
5 8
When refitting, do not invert the position of the two pipes;
Pipe 7 = oil return pipe to tank must go over the ABS pipes;
Pipe 8 = oil delivery pipe must go under the ABS pipes.
H11716
8
H11717
D.18

- Loosen the clamp (9) and remove the intake coupling (10) from the cylinder
head.
10
9 When refitting the intake coupling (10) make sure you place the
prong (A) on the slot (B) of the intake manifold.
- Disconnect the cylinder head from the electrical system.
H11718
10
H11719
- Move the two pipes (11) of the ABS to unscrew the screw (12), then un-
11 screw the screws (13) and remove them.
12
H11720
- Remove the head cover (14) at the back of the motorcycle; if this is difficult,
13 remove the intake manifold (15) by unscrewing the corresponding screws
without losing the corresponding gaskets.
14 - Adjust valve clearance as described in the relevant paragraph in Section F.
13 15
H11721
D.19

ENGINE SETTINGS AND ADJUSTMENTS
Section
F
Refer to chapter F4 for all engine tightening torques.
Workshop Manual Ed.09-2012
F.1

Sommario
VALVE CLEARANCE CHECK....................................................................... F.3
Valve clearance check................................................................................... F.3
Valve clearance measurement...................................................................... F.3
PAD REPLACEMENT .................................................................................. F.4
Locking the crankshaft.................................................................................. F.4
Chain tensioner disassembly........................................................................ F.5
Chain guide disassembly.............................................................................. F.5
Camshaft removal......................................................................................... F.6
Pad replacement........................................................................................... F.6
Camshaft assembly....................................................................................... F.6
Chain tensioner installation........................................................................... F.7
Chain guide installation................................................................................. F.7
Removal of engine block screw..................................................................... F.7
TIMING CHECK ........................................................................................... F.8
ENGINE PHASING ...................................................................................... F.9
F.2

VALVE CLEARANCE CHECK
Remove the coil / spark plug cap, spark plugs and the head cover as described
in chapter "F1".
Valve clearance check

- Remove the screw plug (1).
- Place an Allen wrench into the hole (2) and turn the crankshaft in the normal
sense of rotation until the ignition TDC.
- the marks (3) placed on the crankshaft gears must be coplanar to the sealing
surfaces and the holes (4) must face upwards.
2 - In this position, both cams of the intake and exhaust camshafts must face
1 upwards and be at the same angle relative to the upper face of the head.
H11483
4 Valve clearance measurement

Measure valve clearance using a feeler between the cam and valve bucket both
for the intake (4) and exhaust (5) cams.
Note down the measurements on a measurement sheet.
3 3 3 3
H11485
5
4
H10182
Technical specifications
Intake valve clearance with cold engine 0.23 - 0.28 mm
max. 35 °C 0.0091 - 0.011 in.
H11486
Exhaust valve clea- with cold engine 0.38 - 0.43 mm
rance max. 35 °C 0.015 - 0.016 in.
If the valve clearance does not lie within the correct tolerance, correct clearance
must be restored by replacing the pads beneath the valve buckets.
- Reassemble the screw plug (1) and all other parts removed.
H11484
F.3

PAD REPLACEMENT
Bring the to the top dead centre as described in the previous paragraph and
lock the crankshaft.
.
H11487
Locking the crankshaft

Remove the screw (1) with the sealing ring.
Check that the notch on the crankshaft is visible through the hole.
1
H11751
Fully screw down the retaining screw (2) manually; the screw must perfectly
engage in the notch of the crankshaft.
H11752
F.4

Chain tensioner disassembly

- Remove the screw (1) with the sealing ring (2) and chain tensioner (3).
1
2
3
H11491
H11490
Chain guide disassembly

2 - Remove the screws (1) and chain guide (2).
H11492
F.5

Camshaft removal
1 - Remove the screws (1) with the washers.(2).
2 - Remove the top part of the support (3).
4 3 - Remove the chain (4) from the gears and fix to a point safe to avoid it from
falling into the engine.
- Remove the camshafts (5) with the chain gears.
- Remove the bottom part of the support (6).
- Remove the chain slider (7).
5
5
6
7
H11493
Pad replacement
1 - Mark the valve bucket (1) with a marker (e.g. A= intake valve).
- Extract the valve bucket (1)
2 - According to the measurement of the valve clearance, replace the pads with
those of a size appropriate to restore the correct valve clearance.
- Replace adjustment pad (2) with one having a thickness adequate to restore
the correct value, making sure it is firmly seated in the seat.
- Install the corresponding valve buckets as marked.
H11494
Camshaft assembly
5 - Install the chain slider (1) making sure that the top part of the slider is aligned
4 6 with the sealing surface.
- Mount the bottom part of the support (2).
- Lubricate all contact surfaces with engine oil.
- Fit the camshaft exhaust (3a), then the cam shaft intake (3b) with the timing
3a chain and positioning them in phase.
3b - Mount the top part of the support (4).
- Tighten the screws (5) with the washers (6).
2
1
H11495
F.6

Chain tensioner installation

- Insert the chain tensioner (1) and tighten the screw (2) replacing the gaskets
2 (3).
3
1
H11496
H11497
1 Chain guide installation

- Clean the threading and screws.
- Install the chain guide (1) and tighten the screws (2).
H11498
Removal of engine block screw
- Remove the locking screw (1) and re-tighten the screw (2) to torque, replac-
ing the gasket.
H11499 H11646
F.7

TIMING CHECK
- Remove the coil / spark plug cap, head cover, spark plugs and chain tensioner
and the head cover as described in chapter "F1".
- Remove the screw (1) with the sealing ring.
- Remove the plug (2).
1
H11488
H11500
- Check the position of the camshaft gears.

- The marks (dashes) (3) located on the camshaft gears must be coplanar with
the sealing surface.
- Make sure the notch on the crankshaft is visible through the hole (marks (3)
coplanar to the surface and notch (4) visible indicate a correct timing).
- If the notch cannot be seen through the hole, carefully turn the engine until it
can be seen through the hole, then fully tighten down the retaining screw (5)
manually, blocking the engine at TDC; it must perfectly engage in the notch
3 3 3 3 of the crankshaft.
H11501
If the marks on the camshaft gears are not opposed and parallel to
the sealing surface, a collision between pistons and valves is pos-
sible.
5
4
H11502 H11503
F.8

ENGINE PHASING
Proceed as follows to rephase the engine.
- Remove the head cover as described in chapter "F1".

- Lock the crankshaft as previously described.
- Remove the chain tensioner and guide as previously described.
- Remove the screws (1) with the washers.(2).

3 2
4
4
H11647
- Lift the camshaft (4) from the opposite side of the distribution gears to facilitate
the removal of the chain, then position the camshafts (4) so that the marks
(dashes) (5) are coplanar with the sealing surface.
- Reassemble all parts, in the reverse order compared to disassembly and

tighten the screws to the specified torque.
5 5 5 5
H11506
F.9

GENERAL ENGINE PROCEDURES
Section
F1
F1.1

Sommario
CLUTCH COVER REMOVAL / INSTALLATION..........................................F1.3
Gearbox lever removal/installation........................................................F1.3
Clutch cover removal............................................................................. F1.3
Remove the left engine crankcase cover...............................................F1.3
Coolant pump cover removal.................................................................F1.4
Left engine cover removal..................................................................... F1.4
Gearbox selector shaft oil seal removal/installation...............................F1.4
Clutch engagement lever removal/refitting............................................F1.5
Clutch disengagement shaft removal....................................................F1.5
Clutch disengagement shaft oil seal removal........................................F1.5
Clutch disengagement shaft bearing removal.......................................F1.6
Installation of both clutch disengagement shaft bearings...................... F1.6
Clutch disengagement shaft oil seal installation....................................F1.6
Disengagement shaft installation...........................................................F1.6
Left engine crankcase cover assembly..................................................F1.7
IGNITION COVER REMOVAL/REFITTING................................................F1.7
Crankshaft sensor and stator removal...................................................F1.8
Crankshaft sensor and stator installation...............................................F1.8
Mounting the ignition cover.................................................................... F1.9
Replacement of the gearbox output shaft oil seal..................................F1.9
Flywheel and starter motor idle gear removal......................................F1.10
Removal/installation of the freewheel from/on the flywheel ................ F1.10
Starter motor idle gear removal/installation ........................................ F1.11
Installation of the flywheel with freewheel control gear........................ F1.11
CHAIN SPROCKET REMOVAL/INSTALLATION......................................F1.12
Starter motor removal/installation........................................................F1.12
REMOVING THE NEUTRAL POSITION SENSOR...................................F1.13
REMOVAL/INSTALLATION OF THE COMPLETE CLUTCH.....................F1.13
Clutch pressure plate disassembly......................................................F1.16
PUMPS......................................................................................................F1.17
OIL PUMP REMOVAL/INSTALLATION...............................................F1.17
REPLACEMENT OF THE OIL PRESSURE VALVE AND
UNIDIRECTIONAL VALVE........................................................................F1.18
COOLANT FLUID PUMP REMOVAL/INSTALLATION..............................F1.19
REMOVAL/INSTALLATION OR REPLACEMENT OF THE
TIMING CHAIN..........................................................................................F1.20
F1.2

CLUTCH COVER REMOVAL / INSTALLATION
Gearbox lever removal/installation

Removal:
- Loosen the screw (1) then remove the lever (2).
Installation:
- Fit the lever (2) and tighten the screw to torque (1).
2
1 H11507
2 Clutch cover removal

1
4 - Remove the lever (1) as described in the relevant paragraph.
2 - Remove the screws (2), the screws (3) and cover (4) with relative sealing
ring.
When refitting mount the screws (1) on the top part of the cover (4)
and screws (3) on the bottom part.
3 - Check the sealing ring condition and replace as necessary.

3 H11648
- Tighten the screws at recommended torque in a crosswise sense and refit
the lever (1).
2 1 3
Remove the left engine crankcase cover
- Remove the lever (1) as described in the relevant paragraph.
- Remove the water pump supply pipe (2).
– Loosen the three screws (3);
- Remove the screw (4) and the washers(5).

- Remove the screws (6) paying attention to the gaskets (7).
- Release the oil piping (8) and remove the crankcase cover (9).
9 Check gasket condition when refitting and replace if necessary.

H11649
6
6
6
8
4 5
H11510
F1.3

Coolant pump cover removal

1 - Remove the pipe (1) from the pump cover (2).
- Remove the screws (3).
3 - Remove the coolant pump cover (2) and its gasket.
2
3
H11760
Check gasket condition when refitting and replace if necessary.
- Reassemble all parts, in the reverse order and tighten screws to recommended
torque.
H11761
Left engine cover removal

3 - Remove the water pump cover, the clutch cover and the left casing as de-
scribed in the relative chapters.
- Remove the water pump (1) and oil seal (2) of the gearbox selector shaft as
described in the relative section.
- Replace the casing (3) and reassemble everything following steps in inverse
order.
2
H11512
Gearbox selector shaft oil seal removal/installation

- Using an appropriate tool carefully remove the oil seal from the inside diameter
(1).
- Lubricate the seal lip of the new oil seal; then fit it on the cover, using an
appropriate tool.
- Protect the oil seal lip from possible damage by winding, for example, mask-
ing tape around the shaft broaching.
H11513
F1.4

Clutch engagement lever removal/refitting

2
Removal:
- Undo the screws (1) and slide the lever out upwards (2).
H11514
Installation:
- Manually turn the shaft (3) clockwise until reaching the limit.
4 - Keeping the shaft (3) in place, slide the lever (2) onto the shaft are release.
2
Check the lever (2) when at fill stroke to make sure that there is no
3 interference with the cover (4) of the clutch (see arrow).
H11754
Clutch disengagement shaft removal

1 - Remove the clutch cover as described in the relevant paragraph.
- Remove the retaining ring (1).
- Extract the clutch disengagement shaft (2) by pulling it out upwards.
H11516
Clutch disengagement shaft oil seal removal

- Protect the housing from damage using adhesive tape.
- Lift the oil seal (1) using a suitable tool.
H11762
F1.5

Clutch disengagement shaft bearing removal

- Remove the two needle roller bearing using an appropriate tool (1).
H11519
Installation of both clutch disengagement shaft bearings

- Lightly lubricate both bearings with engine oil.
- Install the needle roller bearings (1) and (2).
- Secure the needle roller bearings using an appropriate tool.
The top bearing (2) must be aligned with the sealing ring seat.
1
2
H11521
Clutch disengagement shaft oil seal installation

- Lubricate the oil seal lip (1) with engine oil.
If the clutch disengagement shaft is installed, cover the notches

with adhesive tape and use an appropriate tool so that the oil seal
is not damaged.
- Install the shaft oil seal (1) using a suitable tool.

- The open side of the sealing ring must face inward of the casing.
1
H11520
Disengagement shaft installation

- Lubricate the clutch disengagement shaft with engine oil.
2 - Insert the clutch disengagement shaft (1), being careful not to damage the
sealing ring.
- Install the retaining ring (2).
1
H11522
F1.6

Left engine crankcase cover assembly

2 - Clean the sealing faces and fit a new gasket.
- Turn the water pump impeller until the transmission sprocket mates correctly.
- Tighten the screws (1) replacing the sealing ring (2).

1
- Check that the broaching of the clutch disengagement shaft mates properly
1
with the clutch centre pin.
1
- Mount the screws (3) with the washers.
Screw in screws (1) and (3) to torque in two steps and in a cross
H11755
pattern.
3 3
H11756
IGNITION COVER REMOVAL/REFITTING

1
- Remove the cover (2) with its gasket and be careful of the washer (3) (arrow)
1 and of the bushing (4), because they may stick to the cover.
1
H11763
H11757
F1.7

Crankshaft sensor and stator removal

- Unscrew the screws (1).
- Remove the bracket (2) with the sensor (4).
- Remove the cable ring (3).
3
1
4
2
H11527
- Unscrew the screws (5).

- Remove the cable ring (6) and stator (7).
6
5
7
H11528
Crankshaft sensor and stator installation

- Spread sealant on the cable ring (1) and insert into the cover.
1 - Clean the threads of the screws (2) with oil.
- Tighten the screws (2) to torque.
H11529
- Clean and spread sealant on the cable ring (3) and insert into the cover.
- Install the crankshaft sensor (4) with its support (5) and the screws (6) by
tightening these last to torque.
3
The new cover has no threading as it is created by the tapping screw.
In this case no screw sealant must be used.
If reusing the cover, tighten the screws to torque with Loctite 243.
6
4
5
H11530
F1.8

Mounting the ignition cover

- Clean the sealing faces and fit a new gasket.
1 - Install the cover (2), being careful with the washer (3) (arrow) and bushing
(4).
- Install the screws (1) of the engine casing cover, right side, tightening to
1 torque in a cross pattern.
2
1
H11764
H11758
Replacement of the gearbox output shaft oil seal

1 - Remove the sprocket chain as described in the relevant paragraph.
- Use an appropriate tool to remove the oil seal (1) paying attention to avoid
damaging the seat.
- Lubricate the new oil seal lip.
- Cover the shaft toothing (2) with an appropriate tool or adhesive tape, suc-
cessively mount the new oil seal (1) using an appropriate tool.
- Refit the sprocket chain as described in the relevant paragraph.
H11533
H11534
F1.9

Flywheel and starter motor idle gear removal

1 - Remove the right crankcase and fix the engine at the top dead centre, as
described in the relevant paragraphs.
- Heat the flywheel hub (1) to a temperature of approx. 100°C.
2 - Unscrew the nut (2) and washer (3).
- Remove the flywheel together with the freewheel (4) using a suitable puller.
3
H11535
H11536
1
Removal/installation of the freewheel from/on the flywheel
- Heat the freewheel to about 120°C.
- Undo the screws (1), remove the flange (2) and freewheel (3).
3 2 Installation:
- Check the condition of the freewheel (3), and replace it if it is ruined.
- Install the freewheel (3) onto the flywheel with the mark (4) facing the flywheel.
- Fit the flange (2).
- Replace the screws (1) with pre-lubricated screws and tighten to torque or
use Loctite 648.
H11537
H11538
F1.10

Starter motor idle gear removal/installation

- Remove the washer (1) and bushing (2).
- Remove the dual gearbox (4).
1 - Remove the idle gear (3).
4 2
3
H11539
- Remove the freewheel gear (5)
- Reassemble all parts, in the reverse order compared to disassembly.
5
H11540
Installation of the flywheel with freewheel control gear

1 - Clean the collar and internal bearing of the freewheel gear and lubricate with
engine oil.
- Clean the cone of the crankshaft and of the flywheel.
2 - Apply a thin layer of Loctite 648 on the crankshaft cone.
Pay attention that the freewheel bearing does not come into contact
with the Loctite.
3
- Fit the flywheel (1) onto the crankshaft, making sure that the groove and the
H11543 key are aligned and that the freewheel is set on the relevant gear
- Clean the threading on the crankshaft.
- Insert the washer (2) and replace the nut (3) with a pre-lubricated nut and
tighten to torque.
- Refit the right crankcase as indicated in the relevant paragraph.
F1.11

CHAIN SPROCKET REMOVAL/INSTALLATION

4 Removal:
- Remove the screw (1).
3 - Remove the bushing (2) and the tapered washer (3).
2 - Remove the sprocket (4), using a puller if necessary, being careful not to ruin
the shaft threading.
1
H11656
3 2 Installation:
1 - Clean and lubricate the teeth on the main shaft and on the sprocket with
"KLUEBER 46 MR 401" grease.
- Mate the sprocket (4) with the shaft and make sure to keep the side with the
"EXT" marking facing outwards.
- Insert the tapered washer (3) so that the larger diameter rests on the sprocket
and that the taper side of the bushing (2) faces the washer.
- Apply a thin layer of Loctite 243 on the retaining screw (1).
- Tighten the screw (1) on the shaft to torque, being careful to insert the taper
side of the bushing in the hole of the tapered washer.
H11545
STARTER MOTOR REMOVAL/INSTALLATION
Removal:
- Extract the starter motor (2), paying attention to the sealing ring.
2
1
H11546
Installation:
4 - Check the sealing ring (3) for damage and replace it if necessary.
- Clean and lubricate the ring (3), then place it on the starter motor.
- Lubricate the centring tang (4) and the teeth (5).
3 - Fit the starter motor (2) on the crankcase and fix it with the screws (1), tight-
ening them to torque.
5
H11547
F1.12

REMOVING THE NEUTRAL POSITION SENSOR

- Remove the screw (2).
- Remove the connection cable.
- Unscrew the sensor (1) and replace it.
1 - Screw on a new sensor with Loctite 243.
2
H11548
REMOVAL/INSTALLATION OF THE COMPLETE CLUTCH
Removal:
- Remove the gearbox lever, the clutch cover and secure the engine at the top
dead centre, as described in the relevant paragraphs.
- Loosen the screws (1) proceeding with diametrically opposite operations,
3 then remove them with the washers (2) and the springs (3).
- Remove the pressure plate (4).
1 4
2
H11550
6 - Remove the lined plates (5) and the steel plates (6).
- Remove the Belleville washer (7) and coupling washer (8).
5
7 4
8
Z Z
- Insert the special tool (A) on the hub (9) to block rotation.
- Lift the safety tab of the washer (11).
8 7 - Remove the nut (10) with the washer (11).
H11551 - Remove the hub (9) and the tool (A).
10
10 9 11
9 H11552 H11553
F1.13

- Remove the washer (12) and the "OR" gasket (13).

16 - Disassemble the clutch housing (14), paying attention to the needle roller
bearings (15) and to the washer (16).
15
14
12
13
H11554
16 Installation:
15a - Lubricate the needle roller bearings (15) with engine oil.
- Insert both needle roller bearings (15) with the washer (16) into the clutch
housing (14) making sure that the bearing (15a) is positioned towards the
engine.
- Fit the clutch housing (14) all the way down, paying attention to the oil pump
gears.
15 - Fit the OR gasket (13) onto the gearbox shaft.
- Mount the broached washer (12) onto the shaft and push into its seat.
14
12
13
H11555
- Clean the tapered teeth on the primary shaft and on the clutch hub (9) and
lubricate them.
9
The clutch shaft oil nozzle shall not be dirtied with threadlocker.
S
- Insert the special tool (A) on the hub (9) to block rotation.
10 - Fit the corrugated washer (11) and nut (10) with the bevelled edge "S" facing
outwards.
- Tighten nut to torque (10), bend the safety tab on the washer (11) (use Loctite
243).
11 - Remove the special tool (A).
H11556
14
9 H11651
F1.14

- Fit the thrust washer (8) and the Belleville washer (7) so that the greater
5 diameter faces outwards.
6 - Lubricate the lined plates (6) with engine oil.
- Insert first a lined plate (5) then a steel disc (6) and alternate layers until
6 ending with a lined plate.
5
- The plate pack contains seven lined plates and six made of steel.
4
7
8
Z Z
8 7
H11558
- Fit the pressure plate (4).

- Insert the flanged bushings (2) on the springs (3) and fit the springs on the
pressure plate (4).
- Tighten the screws (1) to torque in a diametrically opposite order.
Refit the other parts that were previously removed as described in the relevant
3 paragraph.
1 4
2
H11550
F1.15

Clutch pressure plate disassembly

- Disassemble the pressure plate (1) as described in the paragraph "Clutch
disassembly".
1 - Remove the circlip (2).
- Remove the actuator pin (3), the rounded washer (4) and the Belleville washer
3 (5).
4
5
2
H11559
- Position the pressure plate with the upper side facing downwards.
- Heat the pressure plate to approx. 80°C.
- Remove the disengagement bearing (6) using a suitable puller.
- Clean the housing of the support.
- Lubricate the clutch disengagement bearing with engine oil.
- Heat the pressure plate to approx. 80°C.
H11560
- Fit the clutch disengagement bearing (6) using a suitable tool.
The writing on the bearing must face towards the engine (visible
during installation).
- Refit components (2), (3), (4) and (5) proceeding in reverse order of disas-
sembly.
- Refit the pressure plate (1) as described in the paragraph "Clutch disas-
sembly".
6
1
H11561
F1.16

PUMPS
A
Oil pump removal/installation
Remove the clutch as described in the relevant paragraph.
A) Supply pump
B) Intake oil pump
Removal:
B - Disassemble the gear (3).
- Remove the pin (4).
- Remove the washer (5).
H11652 - Loosen the screws (6) and remove the oil pump cover (7).
- Remove the pin (8), piston (9) and rotor (10).
Oil pump check

Use a feeler gauge to check the clearance between the rotor (10) and casing;
maximum allowed clearance is 0.25 mm (0.01 in.).
Replace the pump if the clearance is greater.
Installation:
- Check pin integrity (11) and (4), and replace if ruined.
- Refit pin (11) onto pivot (8) and insert into the casing.
- Clean the parts and lubricate the engine (10) and the piston (9) with motor
oil and fit into the pin (8), making sure that the reference dot on the engine
10) and the piston (9) fit and that is facing the outside.
Make sure that the pin is positioned properly (11) on the piston (9).
- Fit the cover (3) tightening the screws (6) to torque with Loctite 243.
- Insert the washer (5) into the pivot (8) and mount the pin (4) onto the pivot
(8).
- Fit the gear (3) and retainer ring (2).
11 8
9
10
7
11 8 6
9 4
5
10
3
6
2
7
5 4 3
2
H11563
F1.17

REPLACEMENT OF THE OIL PRESSURE VALVE AND UNIDIRECTIONAL

VALVE
- Position a container under the oil filter cover in order to collect the oil in the
filter seat and oil filter.
2 - Loosen the two screws (1) and remove the oil pump cover (2).
- Remove the oil filter (3).
- Clean the filter box of residual oil.
- Loosen the pressure control valve (4) and the unidirectional valve (5).
- Replace the valves and screw down all the way with Loctite 243.
- Refit the oil filter (3).
1 - Check the condition of the OR gasket (6), replace if ruined, lubricate with
motor oil.
- Fit the cover (2) tightening the screws (1) to torque.
H11564
6
2
3
H11565
4
5
H11566
F1.18

COOLANT FLUID PUMP REMOVAL/INSTALLATION

- Remove the pump cover and left cover as described in the relevant paragraph.
Removal:
- Remove the transmission sprocket (1) of the pump shaft.
- Remove the pin (2) paying attention to the washer (3).
- Extract the impeller (4) with the pin (5) and shaft (6).
- Extract the seal rings (7) and (8) from the left cover.
Installation:
- Check for any signs of wear on the shaft (6) Check the seal rings; replace if
necessary. If replacing the sealing rings or shaft, be sure to replace both in
tandem.
- Insert the sealing ring (7) into the seat of the left cover (use a suitable tool).
- Fill the gaps between the sealing rings with lubricant grease (use Molycote
111).
- Insert the sealing ring (8), using a suitable tool, until the outer lip touches the
edge of the left cover.
- Check that the impeller (4) is not damaged, mount onto the shaft (6) and
secure with the pin (5).
- Mount the shaft (6) and impeller inside the left cover.
- Fit the washer (3).
- Install the pin (2) into the shaft (6) of the pump.
- Mount the transmission sprocket (1) onto the shaft (6) by connecting it to the
pin (2).
2
3
7 8
7 6
4
8
6
5
H11567
F1.19

REMOVAL/INSTALLATION OR REPLACEMENT OF THE TIMING CHAIN

- Remove the head cover and the camshafts as described in the relevant
paragraphs.
- Fix the timing chain with metal wire so that it does not slip into the engine.
- Remove the left cover as described in the relevant paragraph.
- Unscrew the nut (1) and remove the spring washer (2).
- Press the chain tensioner towards the rear of the engine (3).
5 - Remove the dual gearbox (4) from the shaft and remove the timing chain (5).
- Check the chain tensioner slide (3) for wear, replace if worn by undoing screw
(6).
3
- Insert the timing chain (5) into the recess and position it around the crankshaft,
6 push towards the chain tensioner slider (3) rear of the engine.
4 - Mount the dual gearbox (4) onto the crankshaft.
- Fit the chain (5) onto the dual gearbox (4).
- Fit the split washer (2).
1 - Clean the threads of crankshaft and hex nut (1).
- Tighten the nut (1) to torque with Loctite 243.
2
- Refit all the previously removed components as described in the relevant
H11568
paragraph and perform phasing operations.
F1.20

CYLINDER HEAD REMOVAL/DISASSEMBLY
Section
F2
F2.1

Sommario
Removal of the ignition coils........................................................................F2.3
Cylinder head cover removal/installation.....................................................F2.3
Chain tensioner removal/installation...........................................................F2.4
Locking the crankshaft................................................................................F2.4
Crankshaft locking screw removal...............................................................F2.5
Camshaft removal/replacement..................................................................F2.5
Checking the decompression lever.............................................................F2.6
Removing the decompression lever............................................................F2.6
Installing the decompression lever..............................................................F2.6
Camshaft assembly.....................................................................................F2.7
Timing chain slider replacement..................................................................F2.7
Cylinder head removal/installation -
replacement of cylinder head gasket.....................................................F2.8
Valve removal............................................................................................F2.10
F2.2

Removal of the ignition coils

- Using an appropriate tool remove the coil (1) of the main spark plug, and the
1 coil (2) of the secondary spark plug.
Do not mount coils in inverse positions.

The coil with the with gasket covering must be placed towards the
2 outside, that having the black gasket covering towards the inside.
H11569
Cylinder head cover removal/installation

1
1 Removal:
- Remove the head cover (2) with the gasket (3).
Installation:
- Clean the gasket (3) and the sealing surfaces on the cover (2) and head (3).
- Lubricate the gasket and the sealing surfaces.
- Fit the gasket (3) and the cover (2) tightening the screws (1) to torque.
1
H11574
3
3
H11575
F2.3

Chain tensioner removal/installation
1 Removal:
- Remove the screw (1) with the sealing ring (2).
- Remove the chain tensioner (3) from the hole.
2
Installation:
3 - Insert the chain tensioner (3) into the hole.
- Replace the sealing ring (2) and tighten the screw (1) to torque.
H11491
H11490
Locking the crankshaft

Rotate the motor in the normal direction of rotation, as indicated in the previous
paragraph, until the markings (dashes) on the gears of the camshafts are in
position coplanar with the sealing surface.
Remove the screw (1) with the sealing ring.
Check that the notch on the crankshaft is visible through the hole.
Fully screw down the retaining screw (2) manually; the screw must perfectly
engage in the notch of the crankshaft.
H11487
H11488 H11653
F2.4

Crankshaft locking screw removal

- Remove the locking screw (1) and re-tighten the screw (2) to torque, replac-
ing the gasket.
H11499
H11654
Camshaft removal/replacement
- Remove the head cover and lock the engine at the top dead centre, as de-
scribed in the relevant paragraphs.
1 Removal:
- Remove the screws (1) with the washers.(2).
4 3 - Remove the chain (4) from the gears and fix to a point safe to avoid it from
falling into the engine.
- Remove the camshafts (5) with the chain gears.
5
5
H11493
F2.5

Checking the decompression lever

- With the spring fully extended, the minimum projection of the weight is equal
to A: 0.7 mm (0.03 in).
- When activated, the projection of the centrifugal weight on the base circum-
ference of the cam must not be less than the measurement (A).
- Replace the decompression lever if the distance is lower.
H11576
Removing the decompression lever

- Use a punch to extract the pin (1) from the weight (2).
- Remove the spring (3).
1
H11577
Installing the decompression lever

- Insert the new spring (1) into the camshaft (2).
- Install the weight (3), install the pin (4).
4 2
H11578
F2.6

Camshaft assembly
3 - Lubricate all contact surfaces with engine oil.
2 4 - Fit the camshaft exhaust (1a), then the cam shaft intake (1b) with the timing
chain and positioning them in phase.
- Mount the top part of the support (2).
- Tighten the screws (3) with the washers.(4).
1a - Reassemble all parts previously removed, in the reverse order compared to
1b disassembly.
H11655
Timing chain slider replacement

- Remove the head cover, the chain tensioner, the intake camshaft and the
clutch as described in the relative paragraphs.
- Unscrew the screw (1).
- Remove the mobile chain tensioner slider (2) towards the top.
2
H11579
- Remove the fixed slider (3) of the timing chain towards the top.
- Check the chain sliders for wear and replace them if worn.
3 - Insert the slider (2).
- Clean the threading.
- Tighten the screw (1) to torque with Loctite 243.
- Install the slider (3) making sure that it is correctly positioned on the timing
chain and that the top section is aligned with the sealing surface.
- Reassemble all parts previously removed, in the reverse order compared to
disassembly, as in the relative paragraphs.
H11580
F2.7

Cylinder head removal/installation - replacement of cylinder head gasket

- Remove the camshafts, timing chain sliders as described in the relevant
paragraphs.
Removal:
- Undo screws (1) and (2)
2
H11581
- Undo screws (3) and (4)
4
H11582
- Unscrew the screw (5).
- Unscrew the nuts (6).
5
6
H11583
- Remove the cylinder head (7).
H11584
F2.8

- Remove the gasket (8).
10 Installation:
- Clean the sealing surfaces and eliminate all traces of oil and grease.
9 - Replace the gasket (8) and position it on the cylinder.

8
- Pull the timing chain (9) through the well.
- Mount the cylinder head (7) while paying attention not to damage the timing
chain (9) and the chain tensioner slider (10).
H11585
- Tighten the screws (6) in a cross pattern with a first pre-tightening torque,
then tighten with a final specified torque.
H11586
- Tighten the screws (1), (2), (3), (4) and (5) without securing them.
- Tighten the screws (1), (2), (3), (4), and (5) at the torque specified, according
to sequence A to F as shown in the figure.
- Reassemble all parts previously removed, in the reverse order compared to

2 disassembly, as in the relative paragraphs.
A
1 F
H11587
3 5
D C
4 E
4 B
H11588 H11589
F2.9

Valve removal
1 - Mark the valve buckets (1) so that they can be refit in the same positions,
use a suitable tool to remove them.
- Remove the pads (2) and position on their respective valve buckets.
H11590
- Place the cylinder head on the support plate (3) so that the valves do not
come into contact with the work bench.
H11591
- Mount the appropriate tool to remove the valves, pre-load the spring to remove
the collets (4).
1 - Widen and remove the collets using a screwdriver (4).
8 7 2 - Remove the valve removal tool by releasing the valve springs.
4 - Extract the top retainer (5), the valve spring (6), the valve stem gasket (7)
5 and the bottom retainer (8) from the cylinder head and position near their
respective valve buckets.
7
- Disassemble the valves (9) and place near their respective components
6
(springs, valve buckets, etc...).
8 9
Refit after all necessary checks and/or repairs have been made.
- Insert the valve.
- Fit the cylinder head to the jig (No. 3).
- Insert the bottom retainer (8) into the cylinder head.
Make sure that the inner lip of the oil seal (7) is not damaged during
installation due to the profile of the shaft.
- Install the valve stem seal (7) using a suitable tool.
- Insert the valve spring (6) and the top retainer (5) from the cylinder head.
- Screw the cylinder head onto the support plate.
- Remount the appropriate tool to install the valves and compress the springs.
- Lubricate and install the valve collets (4).
- Remove the tool used to install the valves, install the pads and the valve
buckets on the respective valves.
H11592 - Refit all the previously removed components as described in the relevant
paragraphs.
F2.10

CRANKCASE DISASSEMBLY
Section
F3
F3.1

Sommario
Cylinder disassembly/installation................................................................F3.3
Piston removal/ installation..........................................................................F3.4
Measurement of a piston and cylinder........................................................F3.5
CRANKCASE DISASSEMBLY....................................................................F3.6
Crankshaft disassembly..............................................................................F3.8
Crankshaft and countershaft installation...................................................F3.10
Crankshaft axial clearance check..............................................................F3.10
Removal/refitting the countershaft and checking axial clearance............. F3.11
Countershaft clearance check...................................................................F3.12
Crankshaft and countershaft gear removal...............................................F3.12
Removal of the countershaft gear.............................................................F3.12
Gear installation........................................................................................F3.12
Crankshaft gear removal...........................................................................F3.13
Gear installation........................................................................................F3.13
Replacement of the countershaft bearings................................................F3.13
GEARBOX SHAFTS REMOVAL/INSTALLATION.....................................F3.14
Removal of the gear engage forks............................................................F3.14
Gearbox shafts removal............................................................................F3.14
Gearbox shafts installation........................................................................F3.15
Fork installation.........................................................................................F3.15
Engagement system check.......................................................................F3.15
Disassembly/assembly of the gearbox input shaft (shaft removed).......... F3.16
Disassembly/assembly of the gearbox output shaft (shaft removed)........ F3.17
Replacement of the gearbox control shaft (engine disassembled)........... F3.18
Engagement system check.......................................................................F3.18
Replacement of the selector drum (engine disassembled)...................... F3.19
IEngagement system check......................................................................F3.19
Replacement of the gearbox shaft bearings (shafts removed).................. F3.20
Mesh oil filter.............................................................................................F3.20
F3.2

Cylinder disassembly/installation
Removal:
- Remove the head cover as described in the relevant paragraph.
- Remove the complete head as described in the relevant paragraph.

- Press the chain tensioner forward and extract the cylinder with care, making
1 sure that the piston does not strike the engine casing.
H11595
Installation:
- Insert a new gasket (1) into the stud bolts (2).
4 - Lubricate the piston rings.
2 - Install the timing chain (3) through the slot on the cylinder (4).
- Fit the cylinder (4) onto the stud bolts (2) while paying attention to the chain
tensioner slider (5).
6 - Place the piston (6) into the cylinder (4) pressing the rings and paying atten-
3 tion not to scratch the piston barrel.
- Tighten the screws (7) to torque.
5
1
H11596
H11597
F3.3

Piston removal/ installation

- Remove the cylinder as described in the relevant paragraph.
Removal:
- Cover the engine crankcase with paper.
- Mark the exhaust side of the piston crown with a marker.
- Remove the piston pin retainer rings (1) from both sides of the piston.
- Extract the piston pin (2) using a suitable tool.
- Remove the piston (3).

1
H11598
2
H11599
Installation:
1 - Visually inspect the piston rings and grooves of the piston.
- Pay attention that the gaps between the sealing rings do not coincide with
the piston pin axis.
2 - Turn both the piston ring gaps (3) approx. 30° with respect to each other.
- Offset the gaps of the other piston rings (2), (1) respectively 120° with respect
to the upper gap of the scraper ring.
3 - Lubricate the piston pin with motor oil.
- Install the piston on the connecting rod.
- Use a suitable tool to insert the piston pin (4) into the piston.
- Mount the retainer rings (5) from both sides of the piston.
- Remove the paper covering the crankcase.
H11600 - Refit all the previously removed components as described in the relevant
paragraphs.
4 5
H11601 H11602
F3.4

Measurement of a piston and cylinder
Inspecting the cylinder:

- Check that the cylinder liner and sealing surfaces are not damaged.
1
- Using a bore gauge for internal areas, measure the cylinder diameter in three
2 3 points (1), (2) and (3).
Measurement when Wear limit

new
Cylinder bore diameter 100 + 0.025 mm 100.05 mm
3.937 + 0.001 in. 3.939 in.
H11603
- If the cylinder is damaged or falls out on tolerance, replace the cylinder and
piston assembly.
Checking piston diameter:

- Measure the piston diameter (dimension A) transversely relative to the axis of
the pin at a distance of 16mm (0.63 in.) above the lower edge of the piston.
Measurement when Wear limit

new
Piston diameter 99.985 + 0.015 mm 99.95 mm
0,63 in.
16 mm
3.9364 + 0.0006 in. 3.935 in.

- Replace the piston if its diameter falls out of tolerance.
A
H11604
Checking piston ring clearance:

- Use a feeler to measure the clearance, in height, between piston ring and
1 groove.
2
Technical speci- Measurement when
3 fications new Wear limit
1^ groove 0.03...0.065 mm max. 0.15 mm
0.0012 ... 0.0026 in. max. 0.0059 in.
2^ groove 0.03...0.065 mm max. 0.15 mm
0.0012 ... 0.0026 in. max. 0.0059 in.
H11605
3^ groove 0.03...0.065 mm max. 0.15 mm
0.0012 ... 0.0026 in. max. 0.0059 in.
- Replace the piston if the clearance in height falls out of tolerance.
F3.5

Crankcase disassembly:
- Remove the starter motor.
- Remove the flywheel.
- Remove the starter motor idle gear.
- Remove the chain sprocket.
- Remove the coolant pump cover.
- Remove the complete clutch.
- Remove the drive gear and the oil pump gears.
- Remove the transmission gear for the coolant pump
- Remove the cylinder and piston.
Refer to the relevant paragraphs/chapters for the removal operations.
Disassembly:
2 - Disassemble the oil filter cover (2) and the filter.
1
H11606
- Disassemble the switch (3) of the neutral position.

4 - Undo screws (4) and (5)
4
When refitting correctly position the relevant housing in the screws (4)
and (5) as they are of two different lengths:
3 Screws 4= 45 mm (1.77 in.).
5 Screws 5= 75 mm (2.95 in.).
4 - Position the engine with left crankcase side (clutch side) facing upwards.
4 H11607
- Tighten the knurled screws (6).
The bearings may be damaged if the crankcase is not disassembled/

6 assembled vertically.
Do not rock the engine crankcase during disassembly and assembly.
- Lift the left engine cover, beat alternately with light blows (plastic mallet) on
the main shaft and countershaft transmission, so that they remain on the
right crankcase.
H11608
F3.6

Assembly:
- Check that the washers (1) are installed correctly (also see the relevant
3 paragraph on checking the axial clearance).
4 - Clean the sealing faces and fit a new gasket (2).
- Check that the crankshaft (3) and countershaft (4) are timed correctly (see
relative paragraph).
1
2 H11609
5 - Check that the oil seal valve (5) is installed properly.

- Check that the pins (6) of the gearbox forks, the drum (7), the ratchet (8),
6 the lever (9) and the spring (10) are installed properly.
The bearings may be damaged if the crankcase is not disassembled

and assembled vertically.
Do not rock the engine crankcase during disassembly and assembly.
7 8
10
9
H11610
- Mount the left-side crankcase onto the left side casing.

11 - Tighten the screws (11 and 12) to torque:
Screws 11= 45 mm (1.77 in.) length.
Screws 12= 75 mm (2.95 in.) length.
11 - Clean the threading and install the neutral switch (13).
- Screw to torque with Loctite 243.
13
12
11
11 H11611
- Check that the O-ring of the oil filter cover is not damaged, replace if neces-
sary.
- Insert the oil filter and install the cover (14) with the screws (15).
14
15 - Refit all the previously removed components as described in the relevant
paragraphs.
15
H11612
F3.7

Crankshaft disassembly
- Disassemble the crankcase as described in the relevant paragraph.
Removal:
- Match the marking (1) of the countershaft and marking (2) of the crankshaft
with the crankcase marking (3).
1
3 2
H11613
- First remove the crankshaft (4), followed by the countershaft (5), paying at-
4 tention to the spacer rings of the crankshaft.
- Check piston ring wear by measuring inside diameter. wear limit ø 46.8 mm
5 (1.81 in.).
Replace the rings if this value is exceeded.
H11614
F3.8

- Check the wear of the crankshaft in correspondence of the "Z" contact area
of the bushings: wear limit ø 45.96 mm (1.81 in.).
Replace the crankshaft and bearings if this value is exceeded.
Bearings disassembly:
- Use a suitable tool to remove the bearings (6) and (7) from the left and right
side casings, heat the two semi-casings if needed.
Bearings installation:
If bearings are installed incorrectly, lubrication may be insufficient

with consequential seizure.
Do not invert the bearings: the bearings with the inner groove should
be mounted on the right half, the smooth bearings are mounted on
the left crankcase half.
- Place the bearings (6a) and (7a) in the lower part taking care to align the
hole in the bushing with the one present in the crankcase halves.
- Use an appropriate tool to install, heat the two crankcase halves if needed.
- Lubricate the bearings with temperature resistant oil.
6a
7
Z
Z
7a
H11615
F3.9

Crankshaft and countershaft installation

- Place the right crankcase half with the flywheel side facing down.
2 - Oil the crankcase bearing seats.
1 - Position the crankshaft washer on the right casing.
- Insert the countershaft (1) and the crankshaft (2) in the crankcase and
phase them; match the marking (3) of the countershaft and marking (4) of
the crankshaft with the crankcase marking (5).
- Make sure that the washers (6) are positioned correctly and lubricate with
motor oil.
H11616
4
5
3
H11617
Crankshaft axial clearance check

- On the right crankcase half of the engine with an appropriate tool measure
the distance from the crank arm to the outer surface of the crankcase (B).
- On the left crankcase half of the engine with an appropriate tool measure
the distance from the outer surface of the casing to the contact surface of
the crankshaft washer
- Calculate the axial clearance of the engine according to the following formula,
paying attention to the thickness of the crankcase gasket.
B Crankcase gasket thickness: 0.4 mm (0.02 in.).
- A: distance from the external casing surface to the contact surface of the
crankshaft washer.
H11618
- B: Distance from the crank arm to the outer surface of the casing.
- G: Casing gasket thickness:
- X: Crankshaft axial clearance
- A + G - B= X
- Axial clearance of the crankshaft must be equal to 0.1 ... 0.3 mm (0.0039 ...
0.0118 in.).
- If this condition is not satisfied, use a spacer washer of appropriate thickness

to obtain the correct clearance.
A
- Refit the right crankcase half as described under the relevant paragraph.
H11619
F3.10

Removal/refitting the countershaft and checking axial clearance

Removal:
1 - Match the marking (1) of the countershaft and marking (2) of the crankshaft
with the crankcase marking (3).
3 2
H11613
- First remove the crankshaft (4), followed by the countershaft (5), paying at-
4 tention to the spacer rings of the crankshaft.
5
H11614
Installation:
- Place the right crankcase half with the flywheel side facing down.
- Oil the crankcase bearing seats.
- Position the crankshaft washer on the right casing.
2 - Insert the countershaft (5) and the crankshaft (4) in the crankcase, placing
3 them aligned with the marking (1) on the countershaft and the mark (2) on
the crankshaft must coincide with the mark (3) on the crankcase.
- Insert the oiled thrust washer for crankshaft into the crankcase.
1
H11620
4
5
H11614
F3.11

Countershaft clearance check

- On the right crankcase half of the engine with an appropriate tool measure the
distance from countershaft bearing seat to the outer surface of the crankcase
(B).
- On the left crankcase half of the engine with an appropriate tool measure the
distance from the outer surface of the casing to the internal ring of the ball
bearing.
- Calculate the axial clearance of the countershaft according to the following
formula, paying attention to the thickness of the crankcase gasket.
B
Crankcase gasket thickness: 0.4 mm (0.02 in.).
- A: distance from the outside surface of the crankcase to the internal ring of
H11621 the ball bearing.
- B: distance from the bearing seat to the outside surface of the crankcase.
- G: Crankcase gasket thickness
- X: Countershaft axial clearance
A + G - B= X
- Axial clearance of the countershaft must be equal to 0.1 ... 0.3 mm (0.0039
... 0.0118 in.).
- If this condition is not satisfied, use a spacer washer of appropriate thickness

to obtain the correct clearance.
A
- Refit the right crankcase half as described under the relevant paragraph.
H11622
Crankshaft and countershaft gear removal

- Remove the crankshaft and countershaft as described in the relative para-
graphs.
The gears must be replaced in tandem!
Removal of the countershaft gear

- Place the countershaft in a vice with protection clamp.
H11623 - Use a puller to extract the gear.
Gear installation
- Heat the gear to approx. 100°C.
- Insert the gear into the countershaft all the way down by using a suitable tool.
F3.12

Crankshaft gear removal

- Place the crankshaft in a vice with protection clamps.
- Use a puller to extract the gear.
H11624
Gear installation
- Heat the gear to approx. 140°C.
- Fit a pin (1) into the gear (2) and mount onto the crankshaft until it stops by
using a suitable tool, centring the pin (1) with the hole in the crankshaft.
1
2
When installed, check that the pin (1) does not protrude from the
gear.
H11625
Replacement of the countershaft bearings

- Remove the countershaft as described in the relevant paragraph.
Removal:
- Remove the oil seal by extracting it from the outside section of the crankcase.
- Heat the left crankcase half to 100°C.
- Use a puller to remove the bearing towards the internal part of the crankcase.
- Disassembly the right bearing in the same way.
H11626
F3.13

Installation:
- Heat the left crankcase half to approx. 100°C.
- Use an appropriate tool to install the bearing (1) into the crankcase half with
the closed side towards the outside.
- When the crankcase has cooled, insert a new oil seal using an appropriate
tool.
- Repeat on the right side of the crankcase.
H11627
H11628
GEARBOX SHAFTS REMOVAL/INSTALLATION

Removal of the gear engage forks

1 - Extract the pins (1) from the forks (2).
- Tip the forks (2) outwards and extract them.
H11629
3 Gearbox shafts removal

- Remove the input shaft assembly (3) and the output shaft (4) by tapping the
4 portion of output shaft that projects from the crankcase with a plastic mallet.
H11630
F3.14

Gearbox shafts installation

3
- Oil the gearbox shaft main bearing seats.
- Install the input shaft (3) and output shaft (4) of the gearbox.
4 - Use a plastic mallet to tap the shafts until they are fully mated with their seats.
Fork installation
- During installation pay attention to the proper fork and shaft coupling.
- Install the engagement fork (5) onto the input shaft (3).
- Install the engagement forks (6) and (7) onto the output shafts.
- Insert the engagement forks (5), (6) and (7) into the corresponding sliding
gears of the gearbox shaft.
- Rotate the forks inwards and insert the ratchet guides into the selector drum
(8).
H11630 - Insert the pins (1) into their seats.
1
1
5 7
H11631
Engagement system check

- Test proper gearbox operation by checking if the ratchet engages and dis-
1 engages all the gears correctly from the star positioned on the selector drum
(You should hear a "click" at engagement).
H11632
F3.15

Disassembly/assembly of the gearbox input shaft (shaft removed)
Disassembly:
2
3 - Secure the gearbox input shaft (1) in a vice with protective clamps.
4 - Remove the cogwheels (2) and (3).
6
8
9
Be careful not to damage the needle roller bearings during disas-
5 1 sembly.
7
- Extract the needle roller bearings (4) and ring (5).
- Extract the cogwheel (6).
- Extract the washer (8) and gear (9).
H11633
Re-assembly:
During operation, the gear pairs slide towards each other. If just one
coupling gear is replaced, the load bearing capacity on gears may
become significantly worse.
Replace the paired gears, but one at a time!
- All components must be checked before installation and replaced if neces-

sary.
- Secure the gearbox input shaft (1) in a vice with protective clamps.
- Install the cogwheel (9) and the washer (8).
- Fit a new retaining ring (7) in its seat.
- Install the cogwheel (6).
- Install the ring (5) and the needle roller bearing (4).
- Install the cogwheels (3) and (2).
F3.16

Disassembly/assembly of the gearbox output shaft (shaft removed)
1
16
14
12
10
17
8
15 6
5
13
7 11
9
4
3 2 H11634
Disassembly:
- Secure the gearbox output shaft (1) in a vice with protective clamps.
- Remove the ring (2).
- Extract the gear (3) and (4) with the needle roller bearing (5) and washer (6).
- Use an appropriate tool to push back the retainer ring (7), to remove the ring (8) locked in place by ring (9).
Be careful not to damage the needle roller bearings during disassembly.

- Extract gear (10) with the needle roller bearings (11) and ring (12).
- Extract the gear (13).
- Disassemble the retaining ring (14) and the washer (15).
- Extract the cogwheel (16).
- Extract the needle roller bearing (17).
Re-assembly:
During operation, the gear pairs slide towards each other. If just one coupling gear is replaced, the load bearing ca-
pacity on gears may become significantly worse.
Replace the paired gears, but one at a time!
- All components must be checked before installation and replaced if necessary.
- Secure the gearbox output shaft (1) in a vice with protective clamps.
- Install the lubricated needle roller bearing (17).
- Install the gear (16) so that the front teeth of the sliding gear (13) mate properly.
- Install the ring (15).
- Fit the new retaining ring (14).
- Install the sliding gear (13).
- Fit a new retaining ring (7) in its seat.
- Install the washer (12), the needle roller bearing (11) and gear (10).
- Install the ring (9).
- Fit the new retaining ring (8).
- Position the retainer ring (7) using an appropriate tool into the groove.
- Install the cogwheel (4) and the washer (6).
- Install the oiled needle roller bearing (5) and the gear (3) so that the front teeth of the sliding gear (4) mate properly.
- Fit the washer (2).
F3.17

Replacement of the gearbox control shaft (engine disassembled)
Removal:
- Move the lever (1) outwards and extract the gearbox shaft (2) complete with
2 lever (1).
- Extract the ratchet (3) and spring
H11635
Installation:
- Insert into the crankcase the ratchet (2) with the spring (1) in correspondence
with the star of the selector drum.
2
1
H11636
- Latch the spring (3) to the lever (4).

- Insert the spring (5) with the bushing (6) and the thrust washer (7) onto the
2 gearbox shaft (8).
5 - Insert into the crankcase the gearbox shaft (8) placing it into the ratchet (2).
8 - Make sure that the spring (5) is properly inserted into the retainer (9).
6
3 7
4
H11637

engages all the gears correctly from the star positioned on the selector drum
5
9
H11638
F3.18

Replacement of the selector drum (engine disassembled)
- Lift the pins (1) slightly until extracting them from the crankcase.
1 2 1 - Move the pins and forks to free the drum (2).
- Extract the selector drum (2).
H11639
- Check that the guides (3) of the selector drum and the insulating washer (4)
are not worn.
H11640
Installation:
- Move the ratchet (1) so that the drum (2) can be easily fit.
- Check that the ratchet (1) is properly positioned on the drum star (2).
- Turn the selector drum (2) to the neutral position (arrow).
2
(The ratchet (1) is in the position shown in figure (arrow)).
- Rotate the pins (3) towards the drum (2) with the relative forks inserting the
ratchets (4) into the relative drum slots.
- Use a plastic mallet to tap the pins (3) into their seats.
1

engages all the gears correctly from the star positioned on the selector drum
H11641
3
2
H11642 H11643
F3.19

Replacement of the gearbox shaft bearings (shafts removed)
Removal:
- Heat the crankcase to about 80-100°C.
- Extract the bearing (1) of the input shaft and the bearing (2) of the output
shaft with a puller.
- Repeat for the bearings on the right crankcase half.
1 Installation:
- Heat the engine crankcase to about 80-100°C.
- Install the bearings (1) and (2) on the crankcase with appropriate tools, mak-
ing sure that the closed side of the bearings faces outwards.
2
H11644
Mesh oil filter

During engine overhaul we recommend cleaning the mesh oil filter (A) using
compressed air.
- Remove the screws (1) and the plate (2).
- Extract the mesh oil filter (A) and clean with compressed air being careful to
A avoid damaging it.
- Replace the filter (A) paying attention to the correct direction of mounting,
2 mount the plate (2) and screws (1) tightening to torque.
1
H11766
H11767
F3.20

ENGINE TORQUE FIGURES
Section
F4
Tighten all nuts and screws to the specified torque using a torque wrench. An insufficiently tightened screw or nut
could get damaged or come completely loose, damaging the motorcycle and/or injuring the rider. A screw or nut
tightened beyond the permitted max. torque value might get damaged or break and therefore come completely loose.
The specified values refer to clean threads.
F4.1

KEY
A : Lubricate with engine oil.
B : Grease.
C : Tighten manually.
CONVERSION TABLE
1 Nm = 0.1 Kgm
1 Nm = 0.73756 ft/lb
F4.2

20 Nm
38 Nm
H11772
F4.3

12 Nm +
12 Nm + Loctite 243 Loctite 243
12 Nm
193 ± 1mm
3 Nm + Loctite 243
A A
12 Nm A
A A
17 Nm
H11773
F4.4

10 ÷ 12 Nm
10 Nm
H11774
F4.5

10 Nm
30 Nm
16 Nm
22 ± 1 mm
20 Nm
60 Nm
25 Nm
30 Nm
30 Nm
H11775
F4.6

10 Nm
10 Nm
H11776
F4.7

12 Nm
11 Nm
12 Nm
12 Nm
H11777
F4.8

4 Nm
4 Nm
10 Nm
AIR BOX
11 Nm
H11778
F4.9

H11779
F4.10

60 Nm + Oil
40 Nm
10 Nm
60 Nm + Oil
10 Nm +
Loctite 243
180 Nm + Loctite
H11780
F4.11

10 Nm
PRESSURE
PUMP
6 Nm + Loctite 243
A
SCAVENGE
PUMP
6 Nm + Loctite 243
40 Nm
H11781
F4.12

10 Nm
A
H11782
F4.13

10 Nm
H11783
F4.14

8 Nm
B 6 Nm
10 Nm
H11784
F4.15

35 Nm
+ Loctite 648 7 Nm
+ Loctite 243
180 Nm
10 Nm
+ Loctite 243
H11785
F4.16

6 Nm
H11786
F4.17

13 Nm
H11787
F4.18

140 Nm
+ Loctite 243
10 Nm
H11788
F4.19

40 Nm
V
III
IV II
II
V
I
III
IV
H11789
F4.20

ENGINE PARTS WEAR LIMITS
Section
F5
F5.1

Table of Contents
Engine block............................................................................................... F5.3
Cylinder head and cover.............................................................................F5.3
Crankshaft and bearings ............................................................................F5.3
Connecting rods and bearings ...................................................................F5.3
Piston with rings and bearings ...................................................................F5.3
Countershaft ...............................................................................................F5.4
Camshaft ....................................................................................................F5.4
Valve with springs .......................................................................................F5.4
F5.2

WEAR VALUE TABLE FOR ENGINE

Description Condition UL
Engine block
100.00 + 0.025 mm
New, from top edge 60 mm (2.3622 in.)
3.937 + 0.001 in.
Cylinder bore diameter
100.05 mm
Wear limit from top edge 60 mm (2.3622 in.)
3.939 in.
max. 46.08 mm
Internal diameter of crankshaft main bearings. Wear limit
1.8142 in.
max 45.96 mm
Diameter of crankshaft main bearings on crankshaft Wear limit
1.8094 in.
194 ± 1 mm
Projection of the cylinder drag link in the crankcase.
7.6378 ± 0.0394 in.
Cylinder head with cover
28 +1 -0 mm
Projection measured from the sealing surface. Stud bolt (exhaust manifold)
1.1024 ± 0.0394 -0
in.
Crankshaft with bearings
0.03 ... 0.07 mm
New
0.0012 ... 0.0028 in.
Crankshaft main bearing clearance
0.10 mm
Wear limit
0.0039 in.
0.10 ... 0.30 mm
Crankshaft axial clearance
0.0039 ... 0.0118 in.
Connecting rod and bearings
0.30 ... 0.65 mm
New
0.0118 ... 0.0256 in.
Connecting rod axial clearance
max 0.8 mm
Wear limit
max 0.0315 in.
max 0.08 mm
Radial clearance of large connecting rod eye Wear limit
max 0.0031 in.
22.015 ... 22.025 mm
New
0.8667 ... 0.8671 in.
Diameter of small connecting rod eye
max 22.04 mm
Wear limit
max 0.8677 in.
Piston with rings and pins
New: measure taken transversally at the piston pin
99.985 ± 0.015 mm
axis, at 16 mm (0.6299 in.) from the bottom edge of
3.9364 ± 0.0006 in.
the piston.
Piston diameter
Wear limit: measure taken transversally at the piston
min 99.95 mm
pin axis, at 16 mm (0.6299 in.) from the bottom edge
min 3.935 in.
of the piston.
0.015 ... 0.040 mm
New
0.0006 ... 0.0016 in.
Piston installation clearance:
max 0.090 mm
Wear limit
max 0.0035 in.
Piston ring assembly direction "TOP" mark pointing up
min 21.996 mm
New
0.866 in.
Pin diameter
min 21.98 mm
Wear limit
min 0.8654 in.
F5.3

WEAR VALUE TABLE FOR ENGINE

Description Condition UL
0.015 ... 0.029 mm
New
0.0006 ... 0.0011 in.
Radial clearance of the pin in the connecting rod
max 0.050 mm
Wear limit
max 0.002 in.
0.012 ... 0.022 mm
Radial clearance of the piston pin inside the piston New
0.0005 ... 0.0009 in.
0.20 ... 0.40 mm
New
Gap between piston segments 0.0079 ... 0.0157 in.
1^ groove max 1.00 mm
Wear limit
max 0.0394 in.
0.20 ... 0.40 mm
New
Wear limit
max 0.0394 in.
0.20 ... 0.40 mm
New
Wear limit
max 0.0394 in.
Countershaft
0.10 ... 0.30 mm
Axial clearance of the countershaft
0.0039 ... 0.0118 in.
Camshaft
min 0.7 mm
Centrifugal force decompressor Centrifugal weight projection
min 0.0276 in.
Valve with springs
0.23 - 0.28 mm
Intake valve clearance With cold engine max. 35 °C
0.009 - 0.011 in.
0.38 - 0.43 mm
Exhaust valve clearance With cold engine max. 35 °C
0.015 - 0.017 in.
F5.4

TIGHTENING TORQUE FIGURES
Section
X
Tighten all nuts and screws to the specified torque using a torque wrench. If not tightened securely, a nut or a screw
might become damaged or work itself loose, causing damage to motorcycle and injury to rider. An overtightened nut
or screw might become damaged, its thread might strip, or the nut/screw might fail and work itself loose. Listed in the
table are the tightening torque figures for the most important nuts and screws, which have determined in accordance
with thread diameter, pitch and specific application. These figures are obtained after cleaning the threads with solvent.
X.1

Description of tasks
Safety
Assembly cycle Nm Comment
torque
Fastening of tank assembly screw on LH side 8,0
Fastening of mesh oil filter on chassis 10,0
Fastening of oil pipe clamps 3,0
Fastening of plug on union for oil drainage from chassis 24,0
Insert bushing for adjustment of swinging arm clearance on chassis seat GREASE
Fastening of oil delivery/return/breather pipes on engine 38,0 S
Fastening of rigid pipes on engine cylinder head seat 12,0
Fastening of engine to chassis on LH side 5,0
Fastening of oil refuelling cap on chassis 10,0
Fastening of ECU to support 8,0
Fastening of ECU support to chassis 8,0
Fastening of ignition/starter lock 19,0
Fastening of handlebar clamps 19,0 S
Fastening of steering upper plate nut 80,0 S
Fastening of handlebar clamp screws 19,0 S
Fastening of fork plate side screws 19,0 S
Fastening of brake pipe screws to pumps/callipers/ABS ECU 24,0 S
Remove the two screws of the bottom yoke on LH side and refit with plate 12,0
Tightening of bushing for adjustment of swinging arm clearance 6,0
Insert the swinging arm pin on the LH side part GREASE
Fastening of swinging arm pin to chassis 120,0 S
Fastening of engine lower screw on chassis 38,0 S
Fastening of engine LH screw to chassis 38,0 S
Fastening of engine RH screw to chassis with spacer 38,0 S
Fastening of engine front clamp nuts 24,0 S
Fastening of engine clamp plate - close 56,0 S
Retrieve the lower clamp upper screw - reclose 56,0 S
Retrieve the lower clamp lower screw - reclose 56,0 S
Fastening of clamp on throttle body coupling 0,6
Fit fuel pipe on union and then on throttle body GREASE
Fastening of earth cable to engine cylinder RH side 8,0 S
Fastening of nut for starter motor cable 6,0
Fastening of neutral sensor cable to engine RH side 0,8
Fastening of turn indicator screws 2,0
Fastening of light support to upper plate 5,0
Fastening of front fairing support bracket screws to light support 2,0
Fastening of filter box air temperature sensor 2,0
Fastening of cover to filter box base 2,0
Fastening of central front locking to filter box base 2,0
Fastening of filter drawer to filter box base 1,5
Fastening of filter drawer to filter box 2,0
X.2

Safety
torque
Insert piston pin in swinging arm seat GREASE
Insert piston pins in seats of rear suspension kinematic mechanisms GREASE
Fastening of top of shock absorber 56,0 S
Fastening of bottom of shock absorber 56,0 GREASE S
Fastening of rear suspension kinematic mechanisms 80,0 GREASE S
Fastening of airbox to RH seat of chassis 2,0
Fastening of expansion tank to chassis (LH side) 1,0
Fastening of airbox to chassis (LH side) 8,0
Fastening of pinion guard 4,0
Fastening of rear chassis 28,0 S
Fastening of fuel tank to rear chassis 8,0
Fastening of fuel tank to chassis (RH side) 8,0
Fastening of gear shift pedal to chassis 13,0
Fastening of number plate holder to rear chassis 2,0
Screws for fastening saddle release onto chassis 8,0
Screws for fastening saddle release onto chassis 3,0
Fastening of rear mudguard lower clamp to chassis 2,0
Fastening of ECU to support plate 6,0
Damping pads for fastening of ECU support plate to rear mudguard GREASE
Fastening of ECU support plate to rear mudguard 1,5
Fastening of sprocket 19,0 S
Screw for fastening footrest fixing plate onto support 8,0
Fastening of rear brake master cylinder 8,0
Fastening of rear stop switch cover 0,7
Fastening of stop switch support 2,0
Bushing in rear brake lever seat GREASE
Fastening of rear brake lever 28,0 S
Screw for fastening footrest fixing plate onto support 8,0
Spacer for fixing side stand GREASE
Fastening of side stand 38,0 S
Fastening of side stand switch 5,0
Fastening of silencer to chassis 19,0
Fastening of silencer and manifold clamps 19,0
Fastening of front manifold to cylinder head 19,0
Fastening of Lambda sensor to manifold 45,0
Fastening of heat-protecting cover onto exhaust manifold 8,0
Fastening of RH and LH footrest supports to chassis 56,0 S
ABS - Fasten rear brake pipe to master cylinder using screw and two washers 10,0 S
ABS - Fasten rear brake pipe to master cylinder using screw and two washers 24,0 S
Fasten the delivery and return pipes to engine seat 3,0
Fastening of top of radiator to chassis 8,0
X.3

Safety
torque
Fastening of BLOW-BY pipe from filter box to engine ignition cover 2,0
Fastening of BLOW-BY pipe to filter box 2,0
Fastening of horn 5,0
Fastening of voltage regulator plate to engine 5,0
Fastening of front mudguard / fork guards 5,0
Grease front wheel axle GREASE
Fastening of front wheel axle 80,0 S
Fastening of screws on fork feet 8,0
Fastening of front brake calliper 38,0 S
Connect and fasten front brake pipe to brake calliper seat 24,0 S
Terra-fastening of wire guide plate to LH fork guard 1,5
Strada-fastening of wire guide plate to mudguard 1,5
Fastening of front wheel speed sensor 8,0
Fastening of voltage regulator 8,0
Grease the rear wheel axle GREASE
Nut for rear wheel assembly pin 30,0
Tighten rear wheel axle to torque 100,0 S
Screw for fastening brake hose ring to swinging arm seat 7,0
Fastening of rear wheel speed sensor 8,0
Fastening of chain casing 8,0
Terra-fastening of pushrod to front mudguard tail 1,5
Fastening of front fairing / front mudguard lower clamp to plate 8,0
Front fastening of front fairing lower clamp to light support 2,0
Rear fastening of front fairing lower clamp to light support 2,0
Fastening of front headlight to support 2,0
Fastening of voltage regulator guard 5,0
Fastening of anti-theft cover 2,0
Fastening of rear brake oil tank 2,0
Fastening of chain slider to swinging arm 5,0
Fastening of clutch control assy clamp 5,0
Fastening of LH switch to handlebar 2,0
Fastening of front master cylinder to handlebar 5,0
Fastening of RH switch to handlebar 2,0
Fastening of throttle control to handlebar 3,0
Fastening of front brake disc to rim 11,0 S
Fastening of rear brake disc to rim 11,0 S
Fastening of tone wheel to brake disc 5,0
Fastening of chain roller 8,0
Fastening of fuel pump ring nut to tank 6,0 S
Fastening of fuel cap ring nut 3,0
Fastening of reflectors to number plate holder 0,8
X.4

Safety
torque
Fastening of turning indicators 2,0
Fastening of licence plate light to number plate holder seat 3,0
Fastening of tail light to number plate holder seat 3,0
Fastening of radiator guards 1,8
Fastening of sides to chassis 1,8
Fastening of side connecting cover 1,8
Fastening of scoops 1,8
Fastening of tank cover 1,8
Fastening of heat-protecting covers onto silencers 5,0
Fastening of front fairing 1,8
Fastening of luggage rack 19,0 S
X.5

CHASSIS AND WHEELS
Section
Y
Y.1

CHASSIS AND WHEELS
Sommario
Chassis.......................................................................................................... Y.3
Lubrication points (lubricant)......................................................................... Y.3
Front wheel.................................................................................................... Y.6
Front wheel.................................................................................................... Y.7
Removing the front wheel ............................................................................. Y.8
Reassembling the front wheel....................................................................... Y.9
Rear wheel.................................................................................................. Y.10
Rear wheel.................................................................................................. Y.11
Removing the rear wheel (procedure valid for all models).......................... Y.12
Wheel axle warpage.................................................................................... Y.13
Axle runout over 100 mm............................................................................ Y.13
Wheel rim warpage..................................................................................... Y.13
Rear chain sprocket, secondary drive sprocket and chain.......................... Y.14
Checking sprocket wear.............................................................................. Y.14
Y.2

CHASSIS AND WHEELS
Chassis
The chassis is a tubular steel trellis type with stainless steel removable rear small chassis.
In case of violent shocks or accidents, if you think that the chassis might be bent or damaged, proceed with an im-
mediate inspection and, if necessary, replace it.
Lubrication points (lubricant)
H11722
1 Steering bearings (grease)
Y.3

CHASSIS AND WHEELS
A
A
H11746
C
1
C
1 B
1
C
1
B
1
B
1
B
1
B
1
C
1
H11723
Y.4

CHASSIS AND WHEELS
Check the assemblies shown in the figure for cracks or damage.

If any are found, replace the part.
A ENGINE MOUNTING SCREWS
B REAR CHASSIS MOUNTING SCREWS
C FOOTREST-PINS-SPRINGS
Y.5

CHASSIS AND WHEELS
Front wheel
STRADA
17
1
12
14
15
13
13 18
19
16
14
1
13
1
10
1
11
1 12
1
H11724
1) Tyre
2) Rim
3) Ball beraing
4) Sealing ring
5) Internal spacer
6) Spacer
7) Wheel axle
8) Brake disc
9) Tone wheel
10) Washer
11) Tone wheel and disc retaining screw
12) Washer
13) Axle fixing nut
14) Valve
For technical characteristics regarding the front wheel, see section “A” Gen-
eral Information of this manual.
Y.6

CHASSIS AND WHEELS
Front wheel
TERRA
6 2
18
3
4 11
7
5 9 13
8 10
16
8 17
14 12 15
H11725
Legend
1) Tyre
2) Inner tube
3) Front wheel assy
4) Spoke
5) Nipple
6) Wheel axle
7) Sealing ring
8) Ball bearing
9) Hub
10) Bushing
11) Brake disc
12) Tone wheel and disc retaining screw (ABS version)
13) Tone wheel (ABS version)
14) Spacer
15) Washer
16) Nut
17) Washer
18) Gasket
For technical characteristics regarding the front wheel, see section “A” Gen-
eral Information of this manual.
Y.7

CHASSIS AND WHEELS
Removing the front wheel

Set a stand or a block under the engine and see that the front wheel is lifted
from the ground.
H11726
Loosen the bolts (1) holding the wheel axle (2) to the front fork mounts.
Hold the wheel axle head in place and simultaneously unscrew the nut (3) on
the opposite side, then remove the wheel axle.
2
Do not operate the front brake lever when the wheel has been re-
H11727 moved; this causes the calliper pistons to move outwards.
After removal, lay down the wheel with brake disc on top.
1
2
H11747 H11729
Y.8

CHASSIS AND WHEELS
Reassembling the front wheel

Fit the L.H. spacer (1) on the wheel hub.
Fit the wheel between the fork legs so as to set the brake disc into the calliper.
Fit the wheel axle (2) from the R.H. side, after greasing it and push it fully
home against the L.H. fork leg; during this operation, the wheel should be
turned.
1 Tighten the nut (3) on the left-hand side of the fork WITHOUT locking it. Now,
pump for a while, pushing the handlebar downwards until you are sure that the
fork legs are perfectly aligned. Lock: the screws (4) on the right-hand fork leg (8
Nm, 0.8 kgm, 5.9 ft/lb), the nut (3) on the left-hand side (80 Nm, 8 kgm, 59.005
H11731 ft/lb) and the screws (1) on the left-hand fork leg (8 Nm, 0.8 kgm, 5.9 ft/lb).
After reassembly, pull the brake control lever until the pads are
against the brake disc.
H11732
H11748
4
4
H11733
Y.9

CHASSIS AND WHEELS
Rear wheel
STRADA
4 1
3
10
2
4
18 5 17
13
12 21 6 8
7
4 19
11 16 12
20
14
6
4
5
15
12 9
H11734
1) Tyre
2) Rim
3) Internal spacer
4) Ball bearing
5) Retaining circlip
6) Sealing ring
7) Spacer
8) Tone wheel
9) Spacer
10) Anti-vibration buffer rubber ring
11) Sprocket carrier
12) Spacer
13) Chain sprocket
14) Brake disc
15) Wheel axle
16) Valve
17) Screw
18) Screw
19) Washer
20) Nut
21) Spacer
Y.10

CHASSIS AND WHEELS
Rear wheel
TERRA
5
3
4
16
11
1
27 2
17 26
5 6
23 21
14 7
13 10
19 8
24
5
12 25 22
15
5
6 9
18
20
H11735
1) Tyre
2) Air chamber
3) Rim
4) Spacer
5) Ball bearing
6) Retaining circlip
7) Sealing ring
8) Spacer
9) Spacer
10) Tone wheel
11) Anti-vibration buffer rubber ring
12) Sprocket carrier
13) Spacer
14) Chain sprocket
15) Brake disc
16) Spoke
17) Nipple
18) Wheel axle
19) Sealing ring
20) Spacer
21) Screw
22) Screw
23) Screw
24) Washer
25) Nut
26) Gasket
27) Hub
Y.11

CHASSIS AND WHEELS
Removing the rear wheel (procedure valid for all models)

Set a stand or a block under the engine and see that the rear wheel is lifted
from the ground.
Unscrew the nut (1) of the wheel axle (3) and extract it. It is not necessary
to loosen the chain tensioners (2); in this way, the chain tension will remain
2 unchanged after reassembly. Remove the chain (4) and remove the full wheel
paying attention to the spacers on the sides of the hub. For reassembly follow the
removal procedure in the reverse order by inserting the brake disc in the calliper.
Refit the chain tensioner sliders (5) correctly so that the head of the axle (3) and
the washer (6) slot into the corresponding slider housings.
1
The flat part (A) of the chain tensioner sliders must face the chain
H11749 tensioner screw.
Check the cush drive dampers for wear (7); if only one of the ap-
pears to be damaged, all of them must be replaced.
Do not operate the rear brake pedal when the wheel has been re-
2 moved; this causes the calliper pistons to move outwards.
After removal, lay down the wheel with brake disc on top.
After reassembly, depress the brake pedal until the pads are against
the brake disc.
3
H11750 Tightening of rear wheel axle nut (1): 100 Nm - 10 kgm - 73.75 ft/lb.
A
6
4 H11738 H11740
7
3
A
H11739 H11741
Y.12

CHASSIS AND WHEELS
PIN Wheel axle warpage

REAR Use a feeler gauge to check the pint out-of-round; if the value of the warpage
exceeds the max allowed limit, replace it.
Axle runout over 100 mm
Wheel axle Standard Max. limit

Wheel axle less than 0.1 mm 0.2 mm (0.079 in.)
less than 0.039 in.
H10901
PIN
FRONT
H10902
1
Wheel rim warpage
The table below reports the allowed limits for wheel rim warpage. An excessive
side runout and out-of-round are generally caused by worn out bearings. In
1 the bearings and the sealing rings. If this does not solve
these cases, replace
12 the problem, change the wheel rim or the wheel.
1
16 Standard Max. limit
C 1
Side runout less than 0.5 mm (0.02 in.)
2
1 2 mm (0.079 in.)
MAXOut-of-round less than 0.8 mm (0.03 in.)
1
H10903
MIN
Y.13

CHASSIS AND WHEELS
Rear chain sprocket, secondary drive sprocket and chain

The figure at the side shows the profiles of a normally worn and an exceedingly
worn sprocket.
1 Normal wear
1
2 Exceeding wear
2
H10904
If the sprocket is exceedingly worn, replace it after loosening the six nuts (1) that
retain it to the cush drive damper.
Chain and sprockets must always be replaced as a set.
H11742
Checking sprocket wear
Check the transmission sprocket for damage or wear. When worn down like the
sprocket shown in the figure, it must be replaced.
Wheel misalignment causes abnormal wear, making the motorcycle

unsafe to ride.
Y.14

TR 650 TERRA 2013 TR 650 STRADA 2013: Workshop Manual

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TR 650 TERRA 2013

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Workshop Manual Ed. 09-2012

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TR 650 TERRA 2013

1st edition (09-2012) - Rev. 00

MODELS COVERED (from serial number onwards)

TR 650 TERRA (43 kW): ZKH0H11A#DV000001

1. Chassis serial number

Workshop Manual Ed. 09-2012

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Accident-prevention rules for operator and persons working nearby.

Additional information concerning the operation covered in the text.

Workshop Manual Ed. 09-2012

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Workshop Manual Ed. 09-2012

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