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MAINTENANCE PERATIONS O 7 15 16 18 20

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T SPECIAL OOLS

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ENGINE 'l 5 9 h , C y l i n d e r e a d c y l i n d e r l o c ka n d p i s t o n s b Clutch G e a r b o xp r i m a r yd r i v ea n dd e s m o d r o m i c ,

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1 3 7 8 Front and rearbrake F r o n t a n d r e a rw h e e l Front fork R e a rs u s p e n s i o n s

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1 2 E l e c t r o n i ci g n i t i o n Alternator-generator

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CARBURATION - carburettors , I t h r e e" D e l l ' O r t o " t y p e V H B 2 4 D

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666 Z :151251 1 t o 1 .. l r o c k e rp e d a o n t h e c e n t r eR / H s i d eo f t h e b i k e .rear . 2 1 1( Z : 1 8 1 2 3 1 ( 1to 1.f r o n t a n d r e a rr i m s d d d d d d d d d d ü ä I l i g h ta l l o vc a s t i n g s w f3 / 2 .(eartlre pressure v 100/90 1BMT 29 v 120lso 18MT 28 2 kg/sqcm (withpasenger kg/sqcm) 2.front I L I d i s c t y p e w i t h c a l i p e rh a v i n g2 c y l i n d e r s . 5 1 1( Z = 2 1 / 5 4 \ m u l t i p l ed i s c sd r y t y p e . 9 0 0( Z = 2 O l 1 8 l 1 t o 2 . # * t I .3kg/sqcm 2. 4 5 4( Z : 1 1 1 2 7 1 ( i to 1.9 ora. e v e rc o n t r o l l e d .cardan shaft. Pedal f c o n t r o l l e dr o m t h e L / H s i d eo f t h e v e h i c l e d d d 4 d d d d FRAME d o u b l e r a d l et.frontal engagement.u b u l a r t r u c t u r e c s susPENSroN front I f a I t e l e s c o p i c r o n t f o r k w i t h h y d r a u l i cs h o c k a b s o r b e r s n d helicoidal rings sp I I f s s I s w i n g i n g o r k a n d h y d r a u l i c h o c k a b s o r b e rw i t h h e l i c o i d a l spnngs . yf mm the ora.050Z:20/21) i t o 0 .bevelgearratio 1 t o 2 . ruu | ?.gearoox .rcar WHEELS .gear atios r 1st gear 2nd gear 3rd gear 4th gear 5th gear .rear handlebar.2 6 0 m m C y l i n d ed i a .front tire pressure . D i s cd i a .4 8 m m r M a s t ec y l .12.constant mesh gears. Il.front . I Lyrrnoer Jö mm tvtaster dia. 1 5x 1 8 " vl T IR E S .clutch .5 d t d d d BRAKES . I by 2 Controlled I disc type with caliperhaving cylinders. H a n dc o n t r o l l e d y l e v e r n t h e l e f t b o s i d eo f t h e h a n d l e b a r five speed..d i a .d TRANSMISSION .7mm cyl. of side I Ig. 8 7 m r m & d * ü The rear brake is hydraulically connected a secondfront to b r a k e o f s a m e t y p e a n d s i z e a s t h e h a n d o p e r a t e df r o n t o r aK e .1 5 .

h . 7 6 g 6 2 m i .wheelbase(loaded) .130 (M.2W N .16"1 22Oks (485lbs) a a I 7 7 7 7 7 ä E- PER ORMANCES F maximumspeed ( f u e l c o n s u m p t i o nC U N A ) ( 2 1 5 k m / ha p p r o x i 3 3 m .All datahereincontained indicative are and aresubiectto modification without orior notice.21W 't2v-3w 12V -1.690 (27.07") 1.dry weight e 7 m 1.width . ) 8 | x 1 0 0k m ( 1 . 4 1 6A 7 a a = J Ä a 7 7 I 7 7 7 l HORN 12V NB .110 (83.5 | (supergrade included 3 | ( A G I PS I N T2 0 0 0S A E 1 0 W 5 0 o i l ) 60 cc eachleS(AGIP F 1 ATF Dexron) F A G I P F 1 B r a k e l u i dS A EJ 1 7 0 3C a J ä a 7 D a B ELECTRICEOUIPMENT AL BATTERY LIGHTS (b headlight eam) (town) headlight taiI light ( parking-stop) indicator lights speedometerRevcounter panellights instrument FUSES 12V -28 Ah t t D 't2v-4045W 12V-4W 12V -5121W 12V.7 3 a e 7 D I M E N S I O NA N D W E I G H T S .f u e lt a n k oilsump front fork oil brakingsystem petrol98/100 NO-RM)5 lt reserve 16.m a x i m u me n g t h l .46O (57.48"1 m m 0. p .4"1 m 2.maximum eight h . ) x F U E LA N D O I L C A P A C I T I E S . .

This operation can be performedafter removingplug "E".15 CARBURATION Carburettors t D e l l ' O r t oy p e V H B 2 4 D .d o u b l ec o n t r o l s : settings Carburettors Choke Qzqmm 40 v Throttle alve Atomizer Need le M a i nj e t j l d l i n ge t Starterjet Fl o a t e r ZOU Atr notch) E 3 (2nd 102 45 50 1 4g r G G G G G F G G lg* tt< tE. # F € + c t .*- ülL' + + ü. I I 2.12" to . lf this adjustmentis not sufficientand clutchdoesnot or disengaoperatecorrectly(clutch slipping incomplete "C" after slackening counternut gement)act on adjuster "D" located on the dutch leverat the crankcase. otherwiseact on screw "4" to restore the correctplav.7 CLUTCHLEVER ADJUSTMENT is Check that the free play at the handlebar 34 mm (.s fl oPERATtoNs rvrarNrENANcE € € € € € 2.16"). g+ F La I gs * t-ra g 4 tsl- * s # * F + + lgl .4.

20 the crankcase. 9 6 .94.75.Removethe alternator from the crankshaftL/H side a n d f i t t h e t i m i n g p l a t ec o m p l e t e i t h h u b a n d l o c k i t w with bolt 1471. . 9 4 . . .F i t o n t i m i n gp l a t e h e n e w h u b 6 3 .R e m o v e e n t r a h u b f r o m d e g r e e i m i n g p l a t ec o o e c l t 7 7 6 9 .59.@\ ^<.R e m o v t h ef a i r i n g n df u e lt a n k . 0 8 0 7 9 9 )v a l i df o r 7 5 0 / S e i .7*" . 9 0 . 1 6 V A L V EG E A R I N G To carryout the adiustment operate follows: as . s b 2 . in E { t { S a 4 a 7 3 7 7 v 7 I . t .Secure the arrow index for timing check code 63.iJr F\ 4q! I tr'9= lilit *_l.t. The three connectors unused have to be temporarily " c l o s e d y m e a n o f r u b b e rp l u g s 8 " .\ Z--i\-A (l . 7 8 .=\. e a .-/ t.4 3 of Synchronisation the carburationand idling speedadjustment a 3 3 a a e 3 3 7 7 3 7 7 3 { { I=L e< .24.li\ > 3 5 ESr - lEL J J !t) - F o r t h e a b o v e p e r a t i o n so l l o w w h a t i s i n d i c a t e dn t h e f o i w o r k s h o p a n u a lf o r 7 5 0 / S e ib u t b e a r i n g n m i n d t h a t m i t h e v a c u o m e t e r i t h t h r e e m e r c u r yc o l u m n sh a st o b e w connected the connectorspurposelyprovidedafter to r e m o v i n gc o m p e n s a t i n g o s e " A " c o n n e c t i n g t h e h manifolds. pay attention to havethe hub key t r a c e t u r n e do n r h e i / 6 s t a m p i n g i d e o n t h e t i m i n g s prate. 5(2 0 4 . 2 p r o v i d e d r 0 for model 900 Sei.

with crankshaft in the aboveposition. a ü j r i s t | ' e i rits r r e c e s s a riy t h e c l e a r a n c e i f is too srlall or excess e.R o t a t e c r a n k s h a f tt o b r i n g p i s t o n o f c y l i n d e r n . b u r s t p o s i t i o n . g e a r o n c a m s h a f t . A t t h i s p o i n t p i s t o n 1 o r 6 i s i n p o s i t i o nT .Remove taooet cover. b remove the ignition breaker point cover and the t w e l v e t a p p e t a dj u s t i n gh o l e c a p s " A " . i f t h e trace "E" is alignedwith trace "F" stamped on the c r a n k c a s e . a p l a t e o f 2 . L o c k s c r e w n u t a r r dc h e c k t h e c l e a r a n c e . lf the screw h o l e s d o n o t c o r r e s p o n d .position). 0 . 1 i n T . D . 1 5 m m i (0.0051 to000565") 1 e a d J u s t m e n ti s m a d e b y l o o s e n i n g t h e t a p p e t s c r e .r e m o v e t h e c l r a i n s t r e t c h e ra n d r o t a t e t h e c a m s h a f tt o o b t a i n t h e a b o v e t i m i n g p o s i t i o n .T h e c o m p r e s s i o ns t r o k e o f t h e o n e o r t h e other piston is indicatedby the posirion of the valves (botlrclosed.799) placed against the rear part of the cylinderhead. / v n u t " F " a n d t u r n r n q t h e a d j u s t i n gs c r e w " E " t i l l t h e i c o r r e c t c l e a r a n c es o b t a i n e d . D .080. Note: lt can be that to obtain a correct correspondence y o f h o l e s i t i s n e c e s s a rt o s l i p o f f t h e g e a r f r o m c a m s h a f t and to rotate it bv 180' - d d d d d d d d d d d s d I . P . 2 m m t h i c k n e s sf i t s c o r r e c t l y i n t h e n o t c h on the L/H side of camshaft (this can be obtainedbv plate 61 90. D .u p " c e n t r e . N o t e : t o m a k e e a s y t h i s o p e r a t i o n i t i s a d v i s a b l et o r e m o v et h e s p a r k p l u g s . d i s c o n n e c tt h e r e a r f u e l t a n k r u b b e r a n d r e m o v et h e f u e l t a n k . . 1 3 t o 0 .00 reducing the thickness of (704. t i m i n g p l a t e w i l l i n d i c a t eT . .r o t a t e t h e g e a r o n l y t i l l t h e h o l e sm a t c h . r e n r o v ef u e l l i n e f r o m t h e f u e l v a l v e b o d y . c l o s e t h e f u e l t a p s . a r e m o v e t h e f a i r i n g . r l l b e a s l i g l r t c l r a go f r e s i s t a n c e s t h e a g a L r g es i n s e r t e d . c c d d d d d ä F E d d c Ä i 6 H d r . ec d d d d 2. C . l f t h e c l e a r a n c e i s c o r r e c t t h e r e \ .C o m p l e t et h e a s s e m b l y a y i n ga t t e n t i o nt o s p r e a d p w i t h L o c t i t et h e g e a rf i x i n g b o l t s a n d c h e c kt h e v a l v e tappetclearance.79. P . O" (ascertainhat this indication is correctby fitting a t dial gaugein spark plug hole in order that the member t o u c h i n g t h e u p p e r p a r t o f t h e p i s t o n i n d i c a t e st h e T D P. y C h e c k a n d i f n e c e s s a r r e s t o r et h e v a l v e t a p p e t c l e a r a n c e o p e r a t i n ga s f o l l o w s . c rotate slowly the crankshaftclockwise till stamped t r a c e " G " o n r o t a t i n g s l e e v ei s a l i g n e d w i t h t r a c e " H " s t a m p e do n " P i c k .0. T h e s t a r r r p e ct ia p p r e tc l e a r a r r c e s . ) d c h e c k t h e c l e a r a n c eo f b o t h v a l v e s i r r c o m p r e s s i o n s t r o k e b y i n s e r t i n ga t h i c k n e s sl l a u g e . v N o t e : t h e c l r e c k i n g6 r r Ct h e a d j u s t n r e n ti s b e t t e r c a r r i e d o u t b y f i t t i n g a c i i a l g r a i r g eo g e t h e r w i t h t h e s p e c i a l t s u p p o r t" N " . . I t n e c e s s a r yu n d o t h e t l v o b o l t s l o c k i n g t h e d i s t r i b u t i o n .Check that. Lock the distributiongearon camshaft.18 VALVE TAPPET CLEARANCE AOJUSTMENT l m p o r t a n t : t h e c y i i n d e r sa r e n u m b e r e d f r o m 1 t o 6 f r o m t h e l e f t h a n d s i d e o f t h e r i d e r ' sp o s i t i o n .

justing t h e i g n i t i o n t i m i n g n o p e r i o d i c a l a d j u s t m e n t so r maintenance operations are needed. A 2 . i " T o g e t t h i s v a l u eu n d o t h e s c r e w sD " a n d s u i t a b l y h i f t s t h ep i c k . 2 0 . 0 1 1 8 " ) . w e In caseit shouldbe necessary adjustthese to two marks. except in case ( t r o u b l e si n t h e e l e c t r o n i cc o m p o n e n t s p i c k . b a 7 t t > F o l l o w i n gt h e a d j u s t m e n t s c c o r d i n g o p a r a g r a p h s a t 2 a n d3 . C . 2 0 I G N I T I O N D V A N C EA D J U S T M E N T T h e e l e c t r o n i ci g n i t i o n u n i t d o e s n o t r e q u i r e a n y maintenance operation as it is made of parts which arenot subject mechanical to wear. " u n d ot h e t h r e es c r e w s 8 " a n d s u i t a b l yr o t a t et h e p i c k p upholding late.u p o d v .0 .u p s 0 . e i T o i n s p e c ta n d a d j u s t t h e i g n i t i o nt i m i n g p r o c e e d s a follows: 1 R e m o v et h e c o v e r o n t h e r i g h t s i d e o f t h e e n g i n e ur or rNw)g. 3 0 m m ( 0 .5 5 0 0 p m . 0 0 7 8 . o Such inconveniences easily detecteddue to a poor are w o r k i n g f f i c i e n c yn c y l i n d e r s . Thereforeafter inspectingand if necessary ad. T r T h e i g n i t i o na d v a n c e u r v e i s s h o w n i n t h e d i a g r a m . c 2d J 3 > a I J JOOO l t . 3 Usinga feelergauge checkthat the clearance between t h e b l o c k " C " o n t h e r o t a t i n gs l e e v e n dt h e m e t a le n d s a " o f e a c hp i c k .a t 5 0 0 0 .u pa n d electronicset) or defectivecontactsin electricwirinqs should ccur. D .0 .=t = t t I f check and adjust the valve clearance the other of cylindersafter having rotated the crankshaftaligning the trace "G" on rotating sleevewith the trace on "Pick-up"centreof the other rylinders. t h e m a x i g n i t i o na d v a n c ea t ew i l l b e : r 3 5 ob e f o r e . a e a a I 7 a 7 7 7 { { 2 M a k es u r et h a t t h e m a r k " A " o n t h e i n s p e c t i oh o l e n r i m i s a l i g n e d i t h t h e c r a n k c a sm a r k .

.6 1 4 . e lower bolts @8 mm Crankcase o C r a n k c a sl e w e rb o l t s@6 m m n C o n . s e O i l p r e s s u rs w i t c h .8. 8.z.1. o 25. 8 't6.1.7 to.5 5 .J . Screws and nutsÖ 8 ^m. 7.ö-3 2.2 l. . 2 z. 8. 6 mm.7 58 d d d d d d d d 0. 7. O i l c a r t r i d g e o v e rf i x i n gb o l t .c 11. 3 d d d d ä d d d d d d t d d d d d d d . c p r C l u t c hh o u s i n g e t a i n i n g l a r e. 2 l.9 '18 21.4 5. . P l a t e e c u r i n t o d r i v es h a f tc l u t c hp l a t ed r u m s g settings Standard and nuts f.8-2 z.t t.o-tö 5 .r o d e c u r i n g u t s .7.1 7 .8 14.3 . 6 ö .1 .8 .2 21. . e C r a n k c a su p p e rb o l t s0 6 m m .2 2 -2.z . o.5 0.| t .c 0 . n f h C y l i n d e r e a db o l t s C r a n k c a su p p e rb o l t s@ 8 m m .8 .6 .9-18 10. . C l u t c ha s s yf i x i n gn u t s S p a r kp l u g O i l d r a i np l u g.l.5 20.o a A 15.2.8. 5.514.3 .q fl sErrtNG to*ouE wRENcH kgm € ftll bs D i s t r i b u t i og e a r i x i n gb o l t s .18 67R6 0 .8 ..1 . Screws 1.28.

91.92. ) ) ) ) ) ) ) ) ) ) ) ) ) ) ) I ) Pos.30.9Z.28.malepin on cableconnection W r e n c hh o l d i n g l u t c hd r u m .90.90.00 14.20 63.00 62. s e c u r i n g u b t i m i n gp l a t eo n c r a n k s h a f t h W r e n c h .24.71.11 A 62.s p a r kp l u g 1 2 62.93.00 62.90.94.00 65.f lywheel f T o o l .t i m i n gp l a t e A r r o w .67. i n d e xf o r t i m i n gc h e c k Puller.20 63.75.67.i9.91.94. I I 5 6 7 8 I 10 tl 63.O/ .96.90.66.a y s h a fs e c u r i n n u t t g P u n c h l a y s h a fs e c u r i n n u t . Code Description Puller.h o l d i n g l y w h e e l N u t . c P u n c h l.19.) ) ) TOOLS SPECIAL tn additionto those indicatedin the workshopmanualfor 500 Ouattroand 75OSei alsothe followingtools are needed. lh o l d i n g l u t c hg e a r r o w n c c H u b .59 61.00 12 a I 4 % .92. t g Tool.10 02. for assembling securing on layshaft nut T o o l .20 65.

C Y L I N D E RB L O C K . 1 C Y L I N D E R E A D . R O D S g d d t ä d d d d d .P I S T O N N D C O N .d d d d E d 10 I g .!l errrcrrue 5 d d d d d d d d d d d d H A 6 .

t t I I ) Notice The cylinder head gasket is made of rolled sectron k l i n g e r i t ew i t h t h e i n t e r p o s i t i o no f s i x s o f t c o p p e r s e a l r i ng s . ln the area around the timing chain slit apply some s e a l i n gm a t e r i a l H Y L O N 4 A R P L 3 2 M E D I U M o r e q u i valent. w i t h t h e c e n t r a l p a r t i n r e l i e f t u r n e d u p s i d e( t o w a r d st h e c y l i n d e r h e a d ) .t t T I t t ? C O P P E S E A LR I N G R t a ? t t t 7 I t ä ! lz ? t ? tl t9 il ll J . T o a v o i d o i l l e a k sa p p l y s o m e r e t a i n i n g a p e T E F L O N t o n t h r e a d i n g s n t h e l o w e r s t u d sf i x i n g t h e c y l i n d e r h e a d o to crankcase.a s s e m b l y a y a t t e n t i o n t h a t r i n g s a r e p r a c e da s i n d i c a t e d i n t h e d r a w i n g . p O n r e . tl .r h a t i s .

.

010 to (2.390 (2.45 mm (0.020mm A: to Q. Whenthe ringshave been fitted over the piston check the clearance oerween ringsand slotson piston. g t -> t 4 Take the measurement the piston ring ends gap. 3 6 1 0 "t o 2 .980to 59.top andcenter.3622" 2.370 60.3775"1 to J l+.OtO 60.980mm ( 2 .z v t t t t Checkthe sideplay of piston rings. lf the measurement exceeds the indicated l i m i t s o r i f t h e c y l i n d e ri s d e f o r m e d r s c o r e d h i s h a s o t to be replaced. t 0.3625") to e ++ J 7 Da { ä.970to 59.0098" o 0.3625" to 2.? 3 a :' ä I a 7 coNTRoLs Measurethe cylinder bore at three different heights.0177") t 0. of Placethe piston ring in the cylinder bore and check gauge: with a thickness ü !?.0137") t 0.8 mm (0.35 mm (0. 3 6 1 4 " ) Oversize g 3 b E mm to 0 60. 4 0 m m ( 0 .0078" o 0.0314") 7 7 Oil scraper: Wearimit: l . w Cylinder diameter: value Standard Class d OO. 0 1 5 7 " ) o v e r s i z e . I rä 4 N.20 to 0. t > Normal alue v Class"A" 0 59. Piston iameter: d !t 14. b Usinga micrometertake the measurements the diaof 'l meter at 1 mm (0. Should the measurements taken exceedthe use limits it will be necessary re-ream to the cylinder bearingin mind that pistons and piston r i n g sa r e a v a i l a b l e i t h 0 .043") from piston baseat g0o of piston axis.3767" 2. 3 6 1 4 1t"o 2 . top. 3 6 iB " ) "8" Class 0 59. centre and bottom on both axis (longitudinal and transversal). Letters"A" and "8" indicating class the selection are markedon top of the piston and on the upper part o f t h e c y l i n d e r l o c kn e a rt h e l i n i n g .3629") 7 3 3 B: mm Class 0 60.25 to 0.990mm ( 2 .000 60.B. IJ . !l Piston ring.

5 9 0 4 "t o 0 . 0 3t o 0 .C e n t r ei n g : r Normal alue v Wearimit l . 1 8m m (0.997 to (0 5905" 0.5904") ro o 0 1 5 .0059") 0 . 5 9 0 5t o 0 . o M a x i m u m v a l u e :* 0 . ct C h e c k t h e c o u p l i n g p l a y b e t w e e np i s t o n p i n a n d b i g e n d n beari g.5005") " d d d d d d 14 d d d d d s .0043") 0 .B o t t o mr i n g : Normal alue v W e a ri m i t l 0 . 5 9 0 3 " ) m 15 . Check the paralleiismf both small and big end axis. r Dopo alesatura 'q 18805i18. 0 0 3 9 " o n 7 87"\.001" to 0.109 m ( 1 . 0 3t o 0 . 0 5 2m m ( 0 0 0 1I " t o 0 .1 5 m m (0.805+ 18.0070") Usinga micrometer checkthe hole in the pistonand the p i s t o np i n d i a m e t e r . 0 0 m m (0.905 G i Er ilq 2IW2 . 0 5 2m m (0.Topring: N o r m a lv a l u e W e a ri m i t l .5906" 0 5905") to d d d d d d d d d d d d d d d d d d d d GI D i m e n s i o n o f p i s t o np i n " 8 " d i a m e t e r s p 0 piston in"8" -=|- 18.000 14.0020") 0 .t.t.991o 14. 9 9 7 m t ( 0 . 0 0 0 o 1 4 .103o 38. o S e l e c t i o n f s m a l l e n d b u s h i n qd i a m e t e r " CLASS A" B l u em a r ko n s t e m m t 38. D i m e n s i o no f p i s t o np i n h o l e" A " i n p i s t o n s Q hole " A" Colour 1 black white @selectron 2 mm 15. 5 0 0 1t"o 1 ..994 m t ( 0 . 0 0t3 1 5 .001 " to 0.1 5 mm (1. 0 0 2 0 " ) 0 . 1 0 0 m m o n 2 0 0 m m ( 0 . 1 1m m t0.109o 38. 5 9 0 4 " ) " GI 2 white @ (r' .5003to 1.-t--t-T. 5 0 0 3 " ) \-LAJJ D B l u em a r ko n s t e m 1 t 38. 0 5 2m m (0.0020") 1 0 . 0 3t o 0 .l' Colour black 0 selection m 14.

5 CLUTCH t 3 v e 3 7 7 t e 7 3 7 7 a 4 d 7 3 E a + .4 il 6.! 7 > ü 4 t t 7 t t t t I t . tc .

t 3 R e m o v et h e p r e s s u r e a p a n d s t r a i g h t e n h e r e t a i n i n g c w a s h e rf l a p s . s t o p w a s h e r s . 0 7 8 " t o 0 . 2 t o 0 .w a s h e r s .s p r i n g s a n d f i x everything with the 4 bolts.e Removal of clutch assembly 1 Undo the two fixing bolts and remove R/H cover. After the pressureplate has been assembledcheck that a c t i n g o n c l u t c h l e v e rt h e p l a t e t u r n s w i t h a m a x i m u m c o m p l a n a t i o no f 0 . t G p 2 Undo the 4 bolts f ixing pressure late. wearlimit: 3 . w a s h e r s . 4 S e t u p t h e s p e c i a lw r e n c h " 4 " t o h o l d t h e c l u t c h drum and with tool "8" undo the centrallockingbolt. 5 T a k e o f f t h e b o l t . 7 S I i p o f f c l u t c hh o u s i n g .11") P l a c et h e d r i v e n p l a t e so n a p l a n e a n d u s i n g a c o m p a r a tor check their distortion.r e m o v e t h e c l u t c h d r u m a n d t h e t w o h a l f. To lock the bolts follorv the torque wrench settings i n di c a t e d . A s s e m b l e t h e p r e s s u r ep l a t e . 3 m m ( 0 .5 to 'i 28 mm (108" to . 4 4 d J 16 i J . v v v ronlere them 4 4 1 r re t C h e c ka n d i f n e c e s s a r y p l a c e h e t w o r e t a i n i n g i n g s (oR). 0 1 1 " ) . 4 C h e c k t h e e f f i c i e n c yo f t h e t w o c l u t c h h o u s i n g s p r i n g s . Before locking ensure a and if necessary djustto obtain the value "A" 21.9 mm (0. 1 5t o 3 3 5 m m lO]24"to0131") 2. !F 6 S t r a i g h t e nr e t a i n i n gw a s h e r f l a p s a n d w i t h t h e s p e c i a l tool "C" undo the clutch housing centrai lock ring.take out the springs and spacing washers and remove pressure plate t o g e t h e rw i t h o t h e r p l a t e s . if this is over 0. Re-assembly R e v e r s et h e d i s m a n t l i n go p e r a t i o n sp a y i n g a t t e n t r o n t o o e l i m i n a t e f r o m c l u t c h p l a t e st h e p r e s e n c e f o i l o r o t h e r l u b r i c a nt .10") in the drawing. d d d d d d d d d d G a d d ä d d Checking operations U s i n g a g a u g e c h e c k t h e w e a r o f t h e d r i v e p l a t e sa n d r e p l a c e t h e m i f t h e i r t h i c k n e s si s b e l o wt h e w e a r l i m i t : new platethickness.1 mm ln nn?"\ \ v .Check this measurement after having {ixed and locked trio bolts only.

I I 7 ? I 17 >-- .9 GEAR t t t ? 7 7 ? t 7 t .-l t t I BoX 6.

0 0 5 0 .4 2. B . O n a s s e m b l yp a y a t t e n t i o n t o c a r e f u l l y "A" available s a c h a i n s p r o c k e ta c t i n g o n t h r u s t w a s h e r s 0'5 mm thicknesses 0.2 2.* i t h t h e f o l l o w i n tg i c k n e s s1 Is . " e T o a d j u s ta c t o n t h r u s t w a s h e r s8 " a v a i l a b l a s s p a r e -21 -23' h e p u r t .078 0'082 0'090 0'094 0 098").s p a c et h e N .10 ( 0 .15 spare parts wirh 0. 0 1 9 " 1 gears t t C h e c k t h a t t h e g e a r s h i f f o r k s f u l l y e n g a g eh e w i t h n o d i ff i c u l t i e s . 0 0 30 .5 mm (0.070 0. lö .

vrs u u Lr $ u u üf [l u üN [.tt.U t t[ 462 Q. l! tt U U U t! U t!.5 o) o (t o. @ 't I 'l tzs 156 (o zg+ .ll u ü [! u [." 139.] u [t.

I e 7. € 1 s ä 4 .a_ 3{ r 20 > d s g{- .l- .4 |!E.4. ttr.. -1^ Its 4 €5 1.s H --. 1- !3r- A ttllb 1 e3 .- 4.1 BRAKES front brake Handcontrolled G € € G € € G G G € e € e @ .L trs @ € & tss' 4 .

t 7 > L 7 3 7 7.I . a t I 3 7 7 3 3 7 3 7 7 lntegral brake I G ä v 7 7 )a I 7 b E. = > ü 7 + . t t b. 3 11 L I .

4 8 . 1 5 . 3 7 . . e Brakecalipers W h e n r e v i s i o n i n gh e b r a k e c a l i p e r s e n s u r et h a t r h e t .4989. 4 9 3 5 . 8 8 7 " ) li d m 22 . 6 2 6 ' . 6 2 2 " ) .4 7 .a d m i s s i bpes t o n i a . a d m i s s i b l { l o a t e r d i a . 1 2 . 9 9 2 . 9 3 6 m ( 1 . a d m i s s i b l e i s t o n d i a . a d m i s s i b l f l o a t e rd i a 1 5 .843mm (. e M a s t e rc y l i n d e r f o r r i g h t f r o n t b r a k e Max admissible ylinder dia. 9 . e M i n .) M i n .. Master cylinder for left front and rear brakes(integral) M a x a d m i s s i b l c y l i n d e rd i a . e {1. 4 9 8 " ) .50") c M i n . 8 3 2 m m ( . l 8m m ( . .M A S T E R Y L I N D E RF R O N TB R A K E C fo 12< 1 1---r'ZS\ @ \vr' l4 13 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Brake lever M a s t e rc y l i n d e r b o d y Pistonreturn spring Piston Lip seal Piston stop washer Wiper ring Wiper ring srop washer Bellow Plug Seal P l u gc o m p l e t e L e v e r a d l u s t i n gs c r e w C r i n k l ew a s h e r Leverfixing scrqru Washer S e l { l o c k i n gn u t M a s t e rc y l i n d e r f i x i n g s c r a r u M A S T E R Y L I N D E RF O R L E F T F R O N TA N D R E A RB R A K E S I N T E G R A L ) C ( 1 2 3 4 5 6 7 I Fluid connection M a s t e rc y l i n d e r b o d y Piston return spring Piston Lip seal Spring ring Dust guard cap Rubber bush Master cylinders W h e n r e v i s i o n i n gt h e m a s t e r c y l i n d e r s c h e c k t h e i n n e r diameter ol the cyiinder and the outer diameterof the f loater. 12. 3 8 . 9 3 6 m m ( 1. 0 7 ' l r . ' ) p R e a rb r a k ec a l i D e r M a xa d m i s s i bce l i n d ed i a . 5 6 7m m ( . ) ly r m M i n . 0 7 1 m ( 1 . i n n e r d i a m e t e r f t h e c y l i n d e ra n d t h e o u t e r d i a m e t e r o O f P i s t o n r en o t w o r n a F r o n tb r a k e s a l i p e r s c M a x a d m i s s i b l c y l i n d e rd i a .

to c € n n o t t a n dt h e e t c h i n g c t i o no f m i n e r ao i l s .remove plastic cap from caliper. .a v o i d i n g d a m a g ets i t . . a The caliper gasketsare subject to sticking to the piston.23"1.' 3 3 3 3 t I t zö l .s o l v e n t s s a l and/or diesel oil which are sometimesused to wash d o w nt h e m a c h i n e .When carryingout these operations.ooerate at a). make sure not to change position of the pads. J > € > ü b E a + a e 5 + - 3 3 e .a f f e c t i n gi t s sliding ction. w i l l m e l t a n d g l u e s t o t h e J l o a t e r . Should vou wish to change the position of pedal (B) act on screw (E) varying at the same time the length of rod (C) rill t h e a b o v e m e n t i o n e dp l a y i s o b t a i n e d . v v v v v 7 v 7 RECOMMENDATIONS p ( A l l r u b b e r a r t so f t h e b r a k i n g i r c u i t s f o r m a s t e c y l i n c r der: gaskets. These parts.4 m o n t h s . i t s r u b b e rp a i t sa n d t h e d i s c . scraperring and gaiter. o .B. p I t i s s o m e t i m e s o s s i b l e h a t C u r i n g s t o r a g eo f t h e t c a l i p e r s e f o r e a s s e m b l y r w h e n t h e m a c h i n ei t s e l f b o is left unused or long periods f time.refit the pad. . b lf this leadto no result: . s Shouldthis happen.r e t u r n t h e p i s t o n t o i t s o r i g i n a lp o s i t i o n .removea pad and actuatethe mastercylinder so as to allow the piston to come out of its housing by 4-6 mm (.proceed for likewise the other pad. For instanceit may occur that the master c y l i n d e rs c r a p e r w i t h c o n t a c t w i t h g a s o l i n e r d i e s e l . operate follows: as a Actuate the control lever or pedal severaltimes until the correct pad-disc clearance is restored. A c c o r d i n g l y . however. )t h i s p h e n o m e n om a y o c c u r . . a m b i e n t t n c o n d i t i o ne t c . the v v 7 v >.a c c o r d i n go 2 t t h e i n f l u e n c e f n e g a t i v e a c t o r ss u c h a s m a c h i n i n g o f t o l e r a n c e s . in a relatively f o s h o r t p e r i o d ( f o r i n s t a n c e . lf necessary lacken couns ternut (D) and adjust the length of the rod till the desired position is obtained.i t i s s t r o n g l y r e c o m m e n d e d o a v o i d t contact of these liguids with the rubber parts in the .for caliperhalves: gasketand dust guard cap) are madeof a special compound resisting brake fluid. . o l e r a n c e si n t h e c o m p o u n d . circuit. as N. o o i l .I t u 7 Adjusting the pedal position of front left and rear brake (integral) Check that the free play on brake pedal (B) is 5 10 mm before the extremity of rod (C) operates on the floater of the caliper.15-.

.3 WHEELS l)\ 1i\ '\ /'-zl ###BOT_TEXT###gt;-.--11\r I 24 .7.

0118") The admissible erroris o n t h i sa xi s ftHril The admissible error is on this axis a >. 0 11 8 " ) Otlser 0 3 mm (.il 7 3 W H E E L SN S P E C T I O N I r n 7 7 3 7 Paralle. preventing on the also overloads tools. with arrow turned againstthe riding direction.3mm (.front wheel.0118") . never use tools that have ribbings or sharp edgeson the sides contacting the r i m s : t h e c o n t a c t i n g u r f a c eo f s u c h t o o l i n g h a s t o s be very wide. 0 1 1 8 " )| Olfset 0.D E E d .0118") I + Parallelism 0. I n 7 7 7 7 7 7 Concentriciry i 0 3 m m ( . .3mm (. smooth and with rounded edges. 0.0118") j Concentricity 0.the use of any lubricants vailable n the market for o a w t h e s e p u r p o s e s i l l g r e a t l yf a c i l i t a t e y r e s l i d i n ga n d t settling on the rim. rit > d P>. 3 m m ( .3 mm (.3mm (.lism 03nrm (0118")>| Parallelism 0. rc b L.F I T T I N G Y R E SO N R I M S A T T h i s m o t o r c y c l ei t s l i g h t a l l o y r i m s w h i c h o f f e r v e r y f high mechanical resistance but might suffer damage f rom a f unctional and aestetic aspect if improper tooling is usedfor removing operations.1C . - * E .01 8") 1 Qf f5et .with arrowturned in the ridingdirection.3mm (.01 8") 1 CoÄcentricity 0. lt is also very important for the tyre beadsto be properly entered into the center rim groove. Tyres that have an arrow on their side have to be f i t t e di n t h e f o l l o w i n g a y : w rea(wheel.0118") I I I Concentricrty 0 .3mm t. and assembly Under these circustances. - Pjl r! P{ r! >-' 15 qE t- R E M O V I N G N D R E .

1 4 "+ 1 5 % ) 9 B .c o m p r e s s e d 3 2 8 m m ( 1 2 .-/q wffiore _<:o4 oePo F R O N T O R KS P R I N G S F h a E n s u r eh e f o r k s h o r ts p r i n g a st h e f o l l o w i n gs i z e s n d t l o a dn g s : i ( A .f r e el e n g t h 3 6 m m + 1 .7 . 3 9 " )s h o u l dg i v ea l o a d td ( o f 9 0 7 k Q* 3 o / o1 9 9l b s ) h E n s u r e h e f o r k l o n gs p r i n g a st h e f o l l o w i n gs i z e s n d a t l o a dn g s : i " A . 7k g + 3 % ( 1 9 9l b s ) . 9 m m ( 2 . 5 % ) 3 B .f r e el e n g t h 5 m m t 1 S o l o3 . 3 k g+ 3 0 / o 2 0l b s ) C .c o m p r e s s e o 9 1 . 5 %( 1 3 . 3 k g + 3 0 Ä( 2 0 l b s ) give load C . d d d d d d d d d d d d d d d d d d ä d d d d d d z-o . 6 0 " )s h o u l dg i v ea l o a d td ( o f 9 . 7 F R O N TF O R K ^A\ -'w<x \='-ä^ q .c o m p r e s s e d 2 5 7 m m ( 1 0 . 1 4 " 1 h o u l dg i v ea l o a d to s o f 9 . i1 " ) s h o u l dg i v ea l o a d to o { 9 0 . 5 m m ( 3 . ' 1 4+ 1 .c o m p r e s s e o 6 0 .

lf any spring has deformed or is not within the above limits. L e n g t hu n d e r a l o a d o f 1 0 3 k g 1 9 7m m ( 7. . 3 3 " ) . Lengthunder a load of 232 kg 1 3 5m m ( 5 .C 235 Closed L. 7 5 " 1 .61").C T h e f r e e l e n g t ho f t h e s p r i n gi s Lengthunder a load of 52 kg 2 3 1m m ( 9 .5 Zll t) P o s i t i o n3 : 2 2 2 Closed F. replace. 280 mm (11. Lengthundera load of 145 kg '168 mm(6.ü 3 o o 3 7 . 27 . 8 R E A RS U S P E N S I O N S a 0 I b 3 7 7 7 7 7 7 7 7 " open320 t l Position 2 i 229. a 7 . ( 1 1 4 l b s ) s h o u l db e ( 2 2 6 l b s ) s h o u l db e ( 3 2 0 l b s ) s h o u l db e ( 5 1 0 l b s ) s h o u l db e o N. E E .B. 3 1 " ) .t. N T J 7.023").

c o i l electronic set plug spark With ignition switch in closed position.u p t h a t r e a c h e st h e e l e c t r o n i c s w i t c h ( t r a n s i s t o r n s i d eh ee l e c t r o n is e t . o 28 .1 ELECTRONIC NITION r| '--\ N ( I I le $y= 'tlü + I r ff I t /\ rtn$ D IG ELECTRONIC NITION EVICES O O O O e O battery rotor switch H . the battery current through the electronic switch (transistor) situated inside the electronic set reaches the matn c i r c u i to { t h e i g n i t i o nc o i l . V . g h T h e i m p u l s e e n e r a t e dn t h e p i c k u p t h a t r e a c h ets e i e l e c t r o n i cs e t i s i n d i p e n d e n t f t h e b a t t e r yc u r r e n t . i) t c l n t h i s w a y a b r e a ko f t h e c o i l m a i n c i r c u i ti s o b t a i n e d in circuit of the same as a consequence the secondary f i n c o i l t h e h i g hv o l t a g e e e d e do r t h e i g n i t i o n sg e n e r a t e d to and by meansof a high voltagecableis transmitted t h e s p a r kp l u g . During the rotation of the rotor when the metal block o n t h e r o t o r i s a p p r o a c h i n g( p o s i t i o n w e l l d e f i n e d ) t h e metal ends of the pick-up an electric impulseis generat e d i n t h e p i c k .fl EeurPMENr er-ecrRrcAL IG 8.

o . c o i l sa n d e l e c t r o n is e t sh a v e e e nl o c a t e dn a i r v c b i p l a c e s h u s t o a l l o w a c o r r e c tc o o l i n g . c a 7 -t -t 7 J 8.Should you needto charge the battery it is advisable to disconnect it from the electricalsystem to avoid of set.s l i p off rotor from crankshaft. the electronic .u p a b l e s . To check usea tester(ohmmeter) connecting the cable e n d st o t h e t w o p i c k .c o i l ) . l : I lv .A v o i d t o m a k e t m o d i f i c a t i o n s h a t m i g h t c h a n g et h e c o o l i n g o f t h e t components.r o t a t i n gp a r t ( i n d u c t o r ) i t t e d d i r e c t l yo n c r a n k s h a f t f . spacer and washer .H . . V . V .With engineat standstill not forget to disconnect do the ignition switch to avoid battery dischargeand ( d a m a g eh e c o m p o n e n t o f t h e i g n i t i o n p a r t i c u l a r lty e t s h H .f i x p a r t( i n d u c e d ) .R e s i s t e n c e t h e c i r c u i tw i t h p i c k u p a t a t e m p e r a t u r e of o f a b o u t2 0 " C . . a 4 Lock againscrew"8" 5 Screwin the outer part of puller "C". to damages the electronic the samein case electric weldings n themotorcycle.T h e b a t t e r yi s c h a r g e d y t h es a m e b a l t e r n a t o rt h r o u g h a c u r r e n t r e g u l a t o ra n d r e c t i f i e r .2 ALTERNATOR ENERATOB G r T h eg e n e r a t oh a sa p o w e ro f 1 4 V . 7 J J 7 I 1 e -'t Removing alternator€enerator the 1 Remove the L/H sidecover 2 | it on the outer part of the generator the special tool "A" 3 Undo centralbolt "8".up.The reversal the polarity of the batterycandamage of set.3 3 3 -9 9 9 3 -{ A^ Cautions .1 2 A a n ds u p p l yt h e c u r r e n t t o a l l t h e e l e c t r i c a le q u i p m e n td i r e c t l y o r t h r o u g ht h e b a t t e r y . Values the electrical for checking pick. . 2 2 Oo h m + 15 . Acting on the c e n t r a n u t o f t h e p u l l e r . The generator composed : is of . of l n c a s eo f i g n i t i o ni r r e g u l a r i t i e s e c kt h e e f f i c i e n c v f ch o pick-up.