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    84 views82 pages

    Laverda 650 Workshop Manual

    Uploaded by

    Zachery Ball

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
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    Workshop Manual MANUFACTURER'S NOTES: ‘This manual has been written by Moto Laverda for authorized LAVERDA dealers and their skilled mechan- ies, The basic technical knowledge is therefore taken for granted, In all cases safety is the fundamental element on which the entire content is based. “The manufacturer reserves the right to make improvements at any time, should the need arise, and to make any particular changes for the sake of convenience or for any other reason of either a technical or acommer- cial nature. Updated information will be supplied periodically deseriting any such changes made. ‘The most important information in the manual are hightighted as follows: NOTE - Marks key information for greater clarity. ANTE! ‘TION ~ Marks any information necessary to avoid damage to the matontycle. WARNING - Highlights information requiring especial care, since a mistaken procedure could make the motoreyele unsafe, When working on the motorcycle, always take the following precautions 1. Use new gaskets, eirclips, seal rings, oil seals and split pins, 2. Use special tools where indicated. 3. Use original Laverda spare parts and the recommended lubricants. 4, After assembly, check that everything is sealed and working comectly. 5. Donnot use petrol to clean painted parts or parts made of synthetic material, 6. Always tighten nuts and screws at the recommended torque value. 7. Pay special awention to technical circulars giving any variations and updatings of the methods of intervention. “The manual provides a complete description of the LAVERDA 650. ‘The 650 Sport is the new two-eylinder four-stroke sporis motor- eycle with electronic ignition. Making use of the experience in the production of the eight-valve two-cylinder model, the 650 Spart is the maximum technical evolution of the engine and of Laverda itself. It is outstanding not only for its extremely sporty ‘and uggressive styling, but also for its frame made completely of aluminium, its electronic injection, Racing suspensions and top quality components. It is a machine to "look after with loving care and atiention”. All this attention will be amply repaid by re- ally pleasant use Location of the serial numbers ‘The serial numbers are located as follows: Chassis (A): punched on the left side of the rear fork support plate indicating: international VIN code, CUNA numbering and an ad- hesive plate with the DGM approval number. Engine (B): punched on the left side of the upper base indicating: model - engine number. Approval aumber: an aluminium plate riveted onto the chassis beaim on the lett side, Always quote these data when asking for information. Guarantee Injemnational MO.LA. Moto Laverda offers specific guarantee onal] new motorcycles through authorized Agents and Dealers All complaints must be made through the Agent. No complaints will be considered if the correct procedure has not been follawed SUMMARY PRE-DELIVERY = GENERALITY = SERVICING = ADJUSTING AND REGULATING DISMANTLING THE BODYWORK = — ELECTRIC SYSTEM - Diagram =o = = so we " = INJECTION - IGNITION - Diagram OVERHAULING THE CYCLE PARTS: = SPECIFIC EQUIPMENT = BRAKING SYSTEM = TIGHTENING TORQUES ozgzger = SPECIAL INSTRUCTIONS INTERNATIONAL 1.MO.LA, MOTO LAVERDA S.p.a. Motorcycle Technical Service Department INTERNATIONAL LMO.LA. MOTO LAVERDA 5.p.a. Via Monte Pasubio, 119 - ZANE’ - Vicenza - Italy Ist Edition Marzo 96, = ELECTRONIC INIECTION-IGNITION SYSTEM = DISMANTLING AND OVERHAULING THE ENGINE, 4 33 58 89 109 ut 116 OPERATIONS TO BE PERFORMED BEFORE DELIV- ERY OF THE MOTORCYCLE ATTENTION: Before taking the matoreyele out an the road, cer- tain assembly operations and checks must be performed, Remem- ber that all motorcycles have been tested, however we believe itis good safety practice for the dealers to make a further check of the ‘most important components Proceed as follows: = Remove the motorcycle from the packing case. - Fitthe front wheel and brake calipers, Ensure thatthe front whee! spindle and front caliper hts are tightened to the correct torque. Fit the front mudguard, - Pull the front and rear bruke levers until risistance is felt through the levers and the beakes are up to pressure: > Check the levels of brake Muid in the rear (B) and front: brake reservoirs and alse-the clutch fluid reservoir. = Check drive chain tension is correct (1). + Check engine oi! level, - Check for correct tightening torque on both whee! spin dies, brake caliper bolts and all major nuts and bolts. Tightening torque-are listed at the rear of this manual artenrion: Use unleaded fuel. Remember that this type of petrol has properties that corrode parts made of ordinary rubber: the motorcycle is provided with special materials that resist unleaded fuel, If they have to be replaced, we recommend using only original spure pants 50 as toavoid encoun- tering severe problems. Fit the front wheel and the brake calipers. Fit the front mudguard. Check the brakes. Chock the hydraulic fluid in the brakes and clutch. Check the engine oil, Tighten the wheel pins and the nuts and bolts Charge the battery, 1 2, 3. 4 5. 6 Check the tyre pressure. ; 8 9. Fill up with untemded fuel Atthis point it is necessary to check correct fighting of the lamps and services (headlamp, tail lamp, flashing indicators, brake lights, dashboard pilot lights} by means of the electric controls on the handlebar (C). Check the alignment of the headlamp (F) and adjust it if neces- sary, Now you can start the engine, proceeding as follows: 1, Turn the ignition key in a clockwise direction: (A) 2. A this point you will hear the hum of the injection pump which is loading the system. After a few seconds the pump switches off, indicating that the injection system is under pres- sure; you can now start the engine, pressing the button provided (8), Do not start the engine before the pump has finished loading the system. ATTENTION: ‘The stating motor might be turning but the en- gine may not star; in this case the side stand could be in open position. Close the stand and the engine will start cornectly. LAVERDA 7 Now you can try out the motorcycle on the road, being particularly careful for the first kilometres. This will enable you to get familiar with the vehicle and its controls. NOTE. Use this manual as a guide to specific jobs. This manual has been prepared with the aim of pro- viding important technical support for al! personnel involved in the maintenance and repair of the LLAVER- DA 650, Remember that itis indispensable to have direct knowledge of the lechisical data provided, which is of decisive importance for the professional training of mechanical or electronic aperators. Always remember to assess the Customer's indications carefully, ‘Make a clear note of any malfunctions and organize your work rationally t0.8 to avoid wasted time. Make sure you have the necessary spare parts and special equipment before starting the job. Removing the battery 1 Remove the rider’s saddle, unscrewing the rear screw under the pillion. Remove the fuel cap and then the tool tray, Remove the rear tail unit. ey Remove the mudguard that covers the battery, nee Slip out the battery, turning it sideways. ‘COMPONENTS ENGINE VALVES ‘Valve timing diagram LUBRICATION Engine sump oil Circuit capacity COOLING Cooling diagram TRANSMISSION Claich Clutch hydraulic control diagram Gearbox Primary transmission Secondary transmission INJECTION - IGNITION Electronic injection-ignition system Spark advance Spark plugs FUEL SYSTEM CHASSIS - CYCLE PART WHEELS SUSPENSIONS BRAKING SYSTEM TYRES Tyre pressure DIMENSIONS LUBRICANTS AND'SUPPLIES ELECTRIC SYSTEM ALO AlO AlO A10 Alo All Add AL All AL AZ AI AMZ Az ANZ AAS AIS Ald Add Alt ALS ALG Addo ALG AT ENGINE GENERAL CHARACTERISTICS Type 4-stroke twin eylinder Arrangement front inclined forward at 20 degrees Bore 785mm Stroke 69 mam ‘Total displacement 667.9 ce ‘Compression ratio Lo ‘Max. power HP 70HP at speed mpm 8900 cpm Max. torque NM 60.NM at speed 7000 rpm Redline 9000 rpm CONFIGURATION Four valves per cylinder, double overhead cam shaft (DOHC) controlled by a single central chaim, acting directly on the valve tappet. Adjustment by means of a calibrated shim between tappet and valve ‘Valve timing - valve clearance net Opening 39° before TDC (37°) Closing 78° afier BDC (78°) Exhaust ‘Opening 74° before TDC (49°) Closing 30° after TOC (51°) ‘Cammes clearance starting from engine n, 1546 between brackets, Valve diameter Inlet 30.6 mm ‘Exhaust 27.4 mm Valve lift Inlet mm Exhaust 8.5 mum Valve clearance Inlet 0.20 /0.25 mm Exhaust 0.30 70.35 mm ‘The tappet clearance is measured when the engine is cald. LUBRICATION Engine sump oil Forced lubrication with gears, gauze an scavenge. By-pass valves sprung for pressure regulation, Inter- changeable cartridge on delivery with safety valve against clogging. Cireuit eapaeity: 4it Pump flow rate 15 Ieamin, at 1000 rpm Grade SW -50 COOLING Mised ainoil with pumped oil circuit by means of a gear pump, he cooling circuit om the head is by means ‘of oil passages close to the combustion chamber and oil sprayers on the piston skirt. Two oil coolers sit- tuated alongside the engine contribute to the cooling of the oil in the system, Cooling diagram 1 - Oil pipe fitting 2- Oil filling cap 3- Sight glass 4 - Filter 5 - Temperature sensor 6 - Oi coolers (2) ‘TRANSMISSION ‘Clutch: Multiple plates in an oil bath with 8 delving and 9 driven plates. Motorcycles with serial number up to 1461; 7 driving and 8 driven plates. The clutch is operated by a hydraulic control system. ‘Clutch hydraulic control diagram 1 - Clutch master cylinder 2- Clutch lever 3- Connecting pipe 4 Thaust piston 5 - Push rod 6 - Prestre plate 7 Clutch gasket 8 - Bleed nipple 9 Fluid resivair LAVERDA A 12 ‘Gearbox: 6 ratios with constant mesh gears; control pedal on the left of the vehicle. Primary transmission: Engine pinion 229 ‘Clutch crown gear 27 Drive ratior 2.655 Drive ratios Gear engaged Z gears Total ratio Speed kanwh Ist 39/18 14.38 67 Ind 3403 9.812 98 3nd 30727 1375 130 di 27130 5974 161 Sih 25/32 5.185 186 oth 2n4 4.490 215 Seeondary transmission: Gearbox output pinion Z16 Rear crown gear Z40 Secondary drive chain Make Regina ‘Type 135-ORS, Dimensions sre No. links 110 INJECTION - IGNITION Make WEBER Type LAW. 44DCFD injectors per cylinder 10 WEBER injection-ignition system (1.A.W.) The WEBER injection-ignition system is of the “alpha/" type in which the engine speed and the throttle position are used to measure the quantity of air taken in; when the quantity of air is known, the amount of fuel metered according o the engine requirements, Other sensors in the system allow correction of the ba- sic strategy in particular working conditions ‘The quantity of air taken in by each cylinder, for each cyele, depends on the density of the air in the i id, on the unit displacement and on volumetric efficiency, As regards volumetric efficiency, thi established during engine research and development test throughout its entire operating range, ‘The control of the cylinder injectors is of the "phased sequential” type, that is the injectors are controlled according to the intake sequence, while delivery for cach cylinder may begin when the intake stage starts. LAVERDA A 13 The delivery timing is stored in a map in the electronic contro! unit, ‘The ignition is of the type with static inductive discharge with dwell control in the power medule (COTL) and advance curves stored in the electronic control unit. Spark advance ° (fixed up to 950 rpm, then the control unit varies the value according to the signals received from the sen- $0n8,) ‘Composition of the system components. 1 + Electronic control unit 2- Power module (one per cylinder) 3- Control relay for injectors and ECU 4- Pump contro! relay 5- Connector for IAW system diagnosis 6 - Throttle potentiometer T- Oil temperature sensor 8 - Motor crankshaft position sensor 9 Engine revs sensor 10- Air temperature sensor 11 = Injectors (one per cylinder) 12 - Absolute pressure sensor 13 ~ Electronic ignition bimodule 14 - Ignition coil (one per cylinder) 15 ~Petrol pump. 16 - Key commutator Spark plugs Make CHAMPION ‘Type RASHC Distance between the electrodes 0.6mm FUEL SYSTEM The fuel system is closely connected with the injection system and is characterized by the fuel tank located under the saddle. The components of the fuel system are located inside the tank and are therefore not visible from outside, Important: the mooreycle has been designed and built for use only with UNLEADED PETROL. ‘The system is composed of: (A) - Foel pump + Fuel filter - Fuel filling eap - Breather valve ~ Fuel warning light wEune LAVEROA A 14 CHASSIS - CYCLE PART Extruded light alloy 7003 tubular section. Removable light alloy rear frame. Trail i Castor Sweering angle: 3e°DNTRL = 26°SX7LH. WHEELS Light alloy rims with three spokes Front Make MARCHESINI Dimensions 3.50.x 17" Rear Make MARCHESINI mensions 5.50017" SUSPENSIONS Front Upside-down hydroulic fork with external regulation of both rebound and bump damping of the hydraulic brake, Make WHITE POWER Type EBS 92 RO Liner diameter 40 mm Travel 120 mm Oil capacity per leg 0.500 It Rear Progressivesuspension with swinging Hight alloy fork, oleopneumatic monoshack-absorber with adjustable rebound, bump damping, and spring preload. Make WHITE POWER Type SAIC ‘Travel 55 mm For greater smooth running and long life, the articulations of the fork and the suspension linkages turn on roller cages. BRAKING SYSTEM Front (page 15-A) Make BREMBO With double steel dise Dise diameter Control by means of a lever and int iprrap Josie oh the ight of te Wandlebar Pump make REMBO LAVERDA A 15 Pump eylinder diameter 16mm Calipers with four differentiated pistons Make BREMBO ‘Type P4 30/34 “Gold Series” Braking surface 12.5 sq. cm. Friction material FREN-DO 222 Rear (3) Make BREMBO ‘With single steel disc Disc diameter 245 mm Control by means of a lever and hydraulic pump. Pump make BREMBO Pump eylinder diameter 13mm Caliper with differentiated pistens: Make BREMBO Type P2 "Gold Series” Braking surface 12.5 sq. cm Friction material FREN-DO FD 72GG Radial tubeless type. Make PIRELLI Type Dragon Dimensions 120/70" Rear Make ‘Type Dimensions ressure: Inflation pressure ‘Front Rear DIMENSIONS LUBRICANTS AND SUPPLIES: Petrol tank (including 3 litres fuel reserve) Engine sump and filier Front suspensions (each leg) Brakes circuit and clutch control Secondary drive chain Protection for electric contacts Speedometer transmission cable and gas/starter cable Steering pin bearings Tightening screws and bolts PIRELLI Bragon 170/60" bar kplem2 22 224 2. 2.35 TYPE ‘Unleaded petral AGIP 41 Super Racing W.P. REZ SAE 7.50. AGIP Brake Fluid DOT 4. AGIP Rocol Chain Spray AGIP PI 160 Spray AGIP Fl Grease 30 AGIP GR MU3 grease AGIP GR SM grease QUANTITY 16 It. AS SOO ELECTRIC SYSTEM “The entire clectric system is equipped with special watertight connectors, materials and components with = high degree of reliability and resisiance. ‘The main components are: Headlamp with single projector and halogen lamp 12V-ss/60W ‘Fail lamp with service light and brake light 1nV-521 Direction indicators 10W | Dashboard with pilot lights and instrument lights 12V-2W Horn Electric controls on the handlebar Battery 12V-18.Ah Alternator 12V -350W Starting motor 12V -0.4 kW Fuses ISA | The fuse box és located under the rider's saddle. The fuses may be checked and changed if necessary by removing the protective cover (A). Relays: ‘The relay boxes are located under the rider's saddle and the pillion, ‘The relays may be checked! and changed if necessary by removing the protective covers (B and C). Fuses 1 Lights power 2- Various services 3+ Injection power 4- Side stand tose | Relays § = Control unit power 6- Fuel pump power T- Stand switeh SERVICING OPERATIONS General recommendations Changing the engine oi] and fiker Adjusting the chain Checking the tyre pressure Checking the fastenings Cheeking the fluid level in brakes and clutch Routine servicing Routine servicing B20 B20 B20 B20 Bl B24 B.22 B23 19 SERVICING OPERATIONS ‘General recommendations Laverda recommends regular check-ups based on a table of distances or minimum periods. More frequent ovethauls are needed on motorcycles used in particularly harsh conditions, dusty or hot at- mospheres, frequent use in city traffic, habitual use of the motorcycle at maximum performance, etc. Below ‘are described some of the servicing operations listed above. Further information may be found in the spe- cific paragraphs, ‘Changing the engine oil and filter ‘Allow the engine reach its normal operating temper- ‘ature, then proceed as follows: Remove the bottom of the fairing - Remove the filling cap (D). - Unscrew the sump cap (A), Remove the oi! and let it drain off for a few minutes. - Replace the oil cap, - Remove the filter eartridge (C) and change it. 3 Fill with oil up to the level. sy Check the oil level on the sight glass on the left casing (E), cnsuring that it reaches the MAX mark. Checking and adjusting the tenshon of the secondary drive chain ‘To adjust the chain tension (A), the nuts holding the rear wheel (1) must first be loosened: unscrew the nut (3) and then tum the screw (2) until the right tension as achieved. Now tighten the wheel nuts again, checking that the data camespond to those on the adhesive plate on the rear fork (4), When measuring the tension, the values given in figure 'B’ must he considered Checking the {yre pressure (when cold) Use a good pressure gauge (page 21 - A) Inflate both the tyres to the correct pressure: ~ rider only Front 2.2 - Rear 2 ~ rider and passenger Front 2.3 ~ Rear 2.6 LMERDA B 21 ‘Check the general conditions of the tyres, In spect the wheels, ensuring that they are net de- formed, dented orcracked. ‘The alignment and halaneing of the wheels are also very impor- tant. Checking the fastenings Check in particular: the (wo wheel spindles, the footrest, the brake calipers and the exhaust fastenings. Checking the fluid Jevel in brakes and clutch ‘There are three fluid tanks: two on the handlebar (clutch and front brake - B) and one behind the right side of the fairing (rear brake -C). There are MAX and MIN marks on the tanks; the fluid level must clearly be between these two marks, preferably closer to MAX, WARNING - Use only new fluid. Hydraulic fluid can spoil paint and clothing, Do not cleam with al- cohol or compressed alr Routine servicing chart. Gn the following page isa table indicating the routine servicing operations for correct usc of the motorcycle, ‘The operations indicated should be followed scrupulously, since the working life of the motorcycle, ils sale- ty and the pleasure that it gives the rider depend! largely on the respect of these precise rules. IMPORTANT: Always observe serupulously the indications and distanees given, ROUTINE SERVICING ‘The table below lise 22 the recommended intervals for all the servicing operations necessary to keep the mo- toreyele running at maximum performance and economy. ‘Throttle body: timing and idling *| Operations After Every. Operation symbol 1000 Km | 1000 |10000 }20000 Engine oil level c 4 Engine oil "Ss a A Engine oil filter #8 A A Engine oil inlet filter < A A Head tightening oa a Valve clearance A 4 Cam ehain A a (Changing the cam chain *3 A Spark plugs cs A Fue! filter +s cP Air fitter Cylinder compression Brake and clutch control oll level bl elele|e ‘Changing brake and clutch fluid Brake and clutch hydraulic controls: Engine contol Dashboard instruments Lights and signals. systein Headlamp position, locks and hinges Battery charge General cleaning Testing the motoreyele Flexible controls LAVERDA B 23 Tyres: wear and pressure c ie 4 4 Steering bearings clearance *c A A a Chain tension and alignment c Secondary drive °C 4 a A Brake pads wear “CHS 4 a ‘Wheel hub bearings + a | Rear wheel flexible coupling | *C | «YA a Fuel tank =P a Changing the oil in the front fork “3 A General tightening of nuts and bolts “Cc 4 A Lubrication and general greasing 1 a a Checking level of electrolyte in the battery] 4 a Operation identification symbol * This symbol inclicates that it is recommended that this operation is performed by a qualified Laverda workshop Check and adjust Lubricate and/or grease Clean Change Check with motor running

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