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Additionsand change to the workshopmanualfor 500 ouattro - 7s0 sei

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MAIN FEATURES

page 1

MAINTENANCE PERATIONS O 7 15 16 18 20

]I ,- .

C l u t c hl e v e r d j u s t m e n t a Carburation V a l v eg e a r i n g Valvetappetclearance adjustment lgnition dvancadjustment a e

T O R O U EW R E N C H E T T I N G S S

, page 8

T SPECIAL OOLS

page I

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 ,

, page..10

FRAME
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

page i9

:I

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

page 28

!I

WIRING IAGRAM D

page 31

a a a e
t

MAIN FEATURES

ENGINE - number f cylinders o - bore x stroke - displacement - compression ratio - revsat max enginespeed - horsepower

I f o u rs t r o k e I sixin line | 60 x 53.4 mm | 905.91cc | 9.53 to 1 | 8400 rPm | 80 HP

a a a e
3

VALVE GEARING inlet

n h , I c a m s h a fi t t h e c y l i n d e r e a d c h a i nd r i v e n 1 T : I o p e n s : 1 ob e f o r e . D . C . c l o s e s4 3 oa f t e rB . D . C . o p e n s 4 3 " b e f o r e . D . C . c l o s e s1 1 " a f t e rB . D . C . : T : I

a
7 7 7 7
E

- exhaust - r o c k e rc l e a r a n cfe r v a l v e i m i n g o t

| 0.8 mm - normal rocker clearance (cold e n g i n e ) 0 . 1 3 t o 0 . l 5 m m l d engine |

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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LUBRCATION I - n o r m a ll u b r i c a t i o n r e s s u r e p - oil filter

b y p u m p" E A T O N " t y p e e 3 . 5 t o 4 k g / s q c m ; i l p r e s s u rs e n d eu n i t f o r w a r n i g l i g h t o r la I r e p l a c e a bc e r t r i d g e

3 3 3

GENERATO* - alternator | | 14 V - 12A

e
7 7 7
1

IGNITION

c c I e l e c t r o n iw i t h m a g n e t ic o n t r o l

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t

- clearance betweenthe block on the rotating I sleeve and the metal endsof each"pick-up" | 0.20 to 0.30 mm - max ignitionadvance rpm | 35o beforeT.D.C.at 5000-5500 - sparkplugs I MarelliCXSL-BoschX260T2-LodgeHBL12 - p l u gp o i n t s a p g | 0.5mm - igrrrition ils co I N. 3 - firing order I 14-2-6-3-5

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s r AR r N G

I - electricstarterwith electromagnetic ratchet I control |

I
12V-0.4HP

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TRANSMISSION - clutch - gearoox - gear atios r 1st gear 2nd gear 3rd gear 4th gear 5th gear - cardan shaft- bevelgearratio 1 t o 2 . 4 5 4( Z : 1 1 1 2 7 1 ( i to 1.666 Z :151251 1 t o 1 . 2 1 1( Z : 1 8 1 2 3 1 ( 1to 1.050Z:20/21) i t o 0 . 9 0 0( Z = 2 O l 1 8 l 1 t o 2 . 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 . 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,constant mesh gears,frontal engagement. 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

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d o u b l e r a d l et,u b u l a r t r u c t u r e c s

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front

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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

- rcar

WHEELS - 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

l i g h ta l l o vc a s t i n g s w f3 / 2 . 1 5x 1 8 " vl

T IR E S - front - rear - front tire pressure - (eartlre pressure

v 100/90 1BMT 29 v 120lso 18MT 28 2 kg/sqcm (withpasenger kg/sqcm) 2.3kg/sqcm 2.5

t
d
d d

BRAKES
- front

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 . e v e rc o n t r o l l e d

- rear

handlebar. of side I Ig. Il. yf mm the ora. ruu | ?,.,9 ora. I Lyrrnoer J mm tvtaster dia.12.7mm cyl. I by 2 Controlled I disc type with caliperhaving cylinders.
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 . D i s cd i a .2 6 0 m m C y l i n d ed i a .4 8 m m r M a s t ec y l .d i a .1 5 . 8 7 m r m

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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 .

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D I M E N S I O NA N D W E I G H T S - wheelbase(loaded) - m a x i m u me n g t h l - maximum eight h - width - dry weight

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m 1.46O (57.4"1 m 2.110 (83.07") 1.130 (M.48"1 m m 0.690 (27.16"1 22Oks (485lbs)

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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 . p . h . ) 8 | x 1 0 0k m ( 1 . 7 6 g 6 2 m i . ) x

F U E LA N D O I L C A P A C I T I E S - f u e lt a n k oilsump front fork oil brakingsystem petrol98/100 NO-RM)5 lt reserve 16.5 | (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

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ELECTRICEOUIPMENT AL BATTERY LIGHTS

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NB - All datahereincontained indicative are and aresubiectto modification without orior notice.

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2.7 CLUTCHLEVER ADJUSTMENT is Check that the free play at the handlebar 34 mm (.12" to .16"), otherwiseact on screw "4" to restore the correctplav. 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. This operation can be performedafter removingplug "E".

2.15 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

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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, 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 " . s b 2 . 1 6 V A L V EG E A R I N G To carryout the adiustment operate follows: as - R e m o v t h ef a i r i n g n df u e lt a n k . e a - 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 . 9 0 . 7 8 . 5(2 0 4 . 0 8 0 7 9 9 )v a l i df o r 7 5 0 / S e i . - 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 . 9 4 . 9 6 . 2 p r o v i d e d r 0 for model 900 Sei; 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. - 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 1471.24.59. - Secure the arrow index for timing check code 63.94.75.20 the crankcase. in

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4

7 3

7 7

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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 . 1 i n T . D . P . b u r s t p o s i t i o n . t i m i n g p l a t e w i l l i n d i c a t eT . D . 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.position). - Remove taooet cover. - Check that, with crankshaft in the aboveposition, a p l a t e o f 2 . 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 90.79.00 reducing the thickness of (704.080.0.799) placed against the rear part of the cylinderhead. 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 , g e a r o n c a m s h a f t ,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 . Lock the distributiongearon camshaft. lf the screw h o l e s d o n o t c o r r e s p o n d ,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 . 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

- 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.

ec
d d d
d

2.18

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 . 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 . a r e m o v e t h e f a i r i n g , c l o s e t h e f u e l t a p s , 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 , 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 . 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 " . 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 - 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 . 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 . D . C . i f t h e trace "E" is alignedwith trace "F" stamped on the c r a n k c a s e .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. ) 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 . 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 \ . . 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 ; a 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. 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 " . 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 ; 0 . 1 3 t o 0 . 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 , / 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 . 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 .

c c
d d d
d d

F E

d d

H d
r

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=

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. A 2 . 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. Thereforeafter inspectingand if necessary ad.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, 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 - u pa n d electronicset) or defectivecontactsin electricwirinqs should ccur. 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 . 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.

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 . w e In caseit shouldbe necessary adjustthese to two marks, " 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. 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 - u p s 0 . 2 0 - 0 . 3 0 m m ( 0 . 0 0 7 8 - 0 . 0 1 1 8 " ) . 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 - u p o d v . 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 , 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 . D . C .a t 5 0 0 0 - 5 5 0 0 p m . 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

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fl sErrtNG to*ouE wRENcH
kgm

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D i s t r i b u t i og e a r i x i n gb o l t s .. 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 . e C r a n k c a su p p e rb o l t s0 6 m m . 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 - r o d e c u r i n g u t s .. . s e O i l p r e s s u rs w i t c h . 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. . 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 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. . 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, 6 mm. Screws and nuts 8 ^m. Screws

1.8-2 z.-3 2.3 - 2.5 0.8 - 1.2

11.514.5 20.2 21.7

0 . 8- 1 . 2 z.z - z.c 0 . 8- 1 . 2
l.t t.o

a A

15.9-18 10.8 14.5 5 . 7- 8 . 6 . o- | t . o 25.3 - 28.9 '18 21.7 58

d d d d

d d d

0.8- 1.2 2 -2.4

5.7- 8.6 1 4 . 5- 1 7 . 3

d d d d

d d d d d d

d d d

d d

) )
)

TOOLS SPECIAL
tn additionto those indicatedin the workshopmanualfor 500 Ouattroand 75OSei alsothe followingtools are needed.

) ) ) ) ) ) ) ) ) ) ) ) ) ) ) I )

Pos.

Code

Description Puller,malepin on cableconnection W r e n c hh o l d i n g l u t c hd r u m . c P u n c h l,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 , t g Tool, for assembling securing on layshaft nut T o o l . lh o l d i n g l u t c hg e a r r o w n c c H u b ,t i m i n gp l a t e A r r o w , i n d e xf o r t i m i n gc h e c k Puller,f lywheel f T o o l .h o l d i n g l y w h e e l N u t , 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 ,s p a r kp l u g

1 2

62.90.93.00 62.91.28.00 62.92.67.11

62.92.67.10
02.9Z.O/ . I I

5 6 7 8 I 10
tl

63.90.30.20 63.94.96.20 63.94.75.20 65.90.66.00 65.91.19.00 14.71.24.59 61.90.i9.00

12

a
I

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errrcrrue

5
d d d d
d d d d d d
d d

H A 6 . 1 C Y L I N D E R E A D ,C Y L I N D E RB L O C K ,P I S T O N N D C O N . R O D S

d d

d d d d ,d

d d d

E d
10 I

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T I t t
?

C O P P E S E A LR I N G R

a
? t t

7 I
t

lz

? t
?

tl t9
il

ll

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 . p O n r e - 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 ,r h a t i s , 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 ) . 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. 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.

tl

?
3
a :' I a 7

coNTRoLs
Measurethe cylinder bore at three different heights, top, centre and bottom on both axis (longitudinal and transversal). 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 . 4 0 m m ( 0 . 0 1 5 7 " ) o v e r s i z e . w Cylinder diameter: value Standard Class d OO.OtO 60.020mm A: to Q.3625" to 2.3629")

7 3

B: mm Class 0 60.000 60.010 to (2.3622" 2.3625") to

e
++ J

7
Da { , I r 4

N.B. 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 . b Usinga micrometertake the measurements the diaof 'l meter at 1 mm (0.043") from piston baseat g0o of piston axis. 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. Piston iameter: d

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14.

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Normal alue v Class"A" 0 59.980to 59.990mm ( 2 . 3 6 1 4 1t"o 2 . 3 6 iB " ) "8" Class 0 59.970to 59.980mm ( 2 . 3 6 1 0 "t o 2 . 3 6 1 4 " )

Oversize

3 b
E

mm to 0 60.370 60.390 (2.3767" 2.3775"1 to

J
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Take the measurement the piston ring ends gap. of Placethe piston ring in the cylinder bore and check gauge: with a thickness

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Piston ring.top andcenter;

0.25 to 0.45 mm (0.0098" o 0.0177") t 0.20 to 0.35 mm (0.0078" o 0.0137") t 0.8 mm (0.0314")

7 7

Oil scraper: Wearimit: l

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Checkthe sideplay of piston rings. Whenthe ringshave been fitted over the piston check the clearance oerween ringsand slotson piston.
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- Topring: N o r m a lv a l u e W e a ri m i t l - C e n t r ei n g : r Normal alue v Wearimit l - B o t t o mr i n g : Normal alue v W e a ri m i t l 0 . 0 3t o 0 . 0 5 2m m ( 0 0 0 1I " t o 0 . 0 0 2 0 " ) 0 . 1 1m m t0.0043") 0 . 0 3t o 0 . 0 5 2m m (0.001" to 0.0020") 0 .1 5 m m (0.0059") 0 . 0 3t o 0 . 0 5 2m m (0.001 " to 0.0020") 1 0 . 1 8m m (0.0070")

Usinga micrometer checkthe hole in the pistonand the p i s t o np i n d i a m e t e r .

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

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mm 15.000 14.997 to (0 5905" 0.5904") ro o 0 1 5 . 0 0t3 1 5 . 0 0 m m (0.5906" 0 5905") to

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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

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Removal of clutch assembly 1 Undo the two fixing bolts and remove R/H cover.

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p 2 Undo the 4 bolts f ixing pressure late,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 . 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 . 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 , s t o p w a s h e r s ,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- w a s h e r s .
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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. 7 S I i p o f f c l u t c hh o u s i n g .

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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. wearlimit:

3 . 1 5t o 3 3 5 m m lO]24"to0131")
2.9 mm (0.11")

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; if this is over 0.1 mm

ronlere them

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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

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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 . 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 . 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 , 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. Before locking ensure a and if necessary djustto obtain the value "A" 21.5 to 'i 28 mm (108" to .10") in the drawing.Check this measurement after having {ixed and locked trio bolts only. 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 . 2 t o 0 . 3 m m ( 0 . 0 7 8 " t o 0 . 0 1 1 " ) .

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( 0 . 0 0 30 . 0 0 5 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 . " 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 .* i t h t h e f o l l o w i n tg i c k n e s s1 Is - 2 2.4 2.5 mm (0.070 0.078 0'082 0'090 0'094 0 098").

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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. 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 . 1 5 . 9 . l 8m m ( . 6 2 6 ' , , e M i n . a d m i s s i b l f l o a t e rd i a 1 5 . 8 3 2 m m ( . 6 2 2 " ) . 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. 12.843mm (.50") c M i n . a d m i s s i b l { l o a t e r d i a . 1 2 . 5 6 7m m ( . 4 9 8 " ) . 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 , 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 . 3 8 . 0 7 ' l r . e {1.4989,,) M i n . a d m i s s i b l e i s t o n d i a . 3 7 . 9 3 6 m m ( 1. 4 9 3 5 , ' ) 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 .4 8 . 0 7 1 m ( 1 . 9 9 2 , , ) ly r m M i n .a d m i s s i bpes t o n i a .4 7 . 9 3 6 m ( 1 . 8 8 7 " ) li d m

22

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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. lf necessary lacken couns ternut (D) and adjust the length of the rod till the desired position is obtained. 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 .

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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, scraperring and gaiter;for caliperhalves: gasketand dust guard cap) are madeof a special compound resisting brake fluid. These parts, however, 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 ,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 . A c c o r d i n g l y ,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 , circuit. 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 , o o i l , 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 ,a f f e c t i n gi t s sliding ction. a The caliper gasketsare subject to sticking to the piston. 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, 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 - 4 m o n t h s ,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 , o l e r a n c e si n t h e c o m p o u n d , a m b i e n t t n c o n d i t i o ne t c . )t h i s p h e n o m e n om a y o c c u r . s Shouldthis happen, operate follows: as a Actuate the control lever or pedal severaltimes until the correct pad-disc clearance is restored. b lf this leadto no result: - remove plastic cap from caliper; - removea pad and actuatethe mastercylinder so as to allow the piston to come out of its housing by 4-6 mm (.15-.23"1; - 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 ,a v o i d i n g d a m a g ets i t , i t s r u b b e rp a i t sa n d t h e d i s c ; o - refit the pad; - proceed for likewise the other pad; - ooerate at a). as N.B. - When carryingout these operations, make sure not to change position of the pads. the

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W H E E L SN S P E C T I O N I

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Paralle.lism 03nrm (0118")>|

Parallelism 0.3mm (.0118") I

Parallelism 0.3mm (.0118")

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Concentricrty 0 . 3 m m ( . 0 11 8 " )

Otlser 0 3 mm (.01 8") 1

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Concentriciry i 0 3 m m ( . 0 1 1 8 " )|

Olfset 0.3mm (.0118")

j Concentricity 0.3mm (.01 8") 1

Cocentricity 0.3 mm (.0118")

The admissible erroris o n t h i sa xi s

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R E M O V I N G N D R E - 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. and assembly Under these circustances. 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, smooth and with rounded edges;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, preventing on the also overloads tools. 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,with arrowturned in the ridingdirection; - front wheel. with arrow turned againstthe riding direction.

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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 5 m m t 1 S o l o3 . 1 4 "+ 1 5 % ) 9 B - c o m p r e s s e o 9 1 . 5 m m ( 3 . 6 0 " )s h o u l dg i v ea l o a d td ( o f 9 . 3 k g+ 3 0 / o 2 0l b s ) C - c o m p r e s s e o 6 0 . 9 m m ( 2 . 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 - f r e el e n g t h 3 6 m m + 1 . 5 %( 1 3 . ' 1 4+ 1 . 5 % ) 3 B - c o m p r e s s e d 3 2 8 m m ( 1 2 . 1 4 " 1 h o u l dg i v ea l o a d to s o f 9 . 3 k g + 3 0 ( 2 0 l b s )

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7 . 8 R E A RS U S P E N S I O N S

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Position 2 i 229.5 Zll t)

P o s i t i o n3 : 2 2 2 Closed F.C 235

Closed L.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 . 3 3 " ) . 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. 7 5 " 1 . Lengthundera load of 145 kg '168 mm(6.61"). Lengthunder a load of 232 kg 1 3 5m m ( 5 . 3 1 " ) .

280 mm (11.023"). ( 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.B. - lf any spring has deformed or is not within the above limits, replace.

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IG 8.1 ELECTRONIC NITION

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D IG ELECTRONIC NITION EVICES

O O O O e O

battery rotor switch H . V .c o i l electronic set plug spark

With ignition switch in closed position, 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 . 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 - 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 . 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 . 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 . o

28

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Cautions - The reversal the polarity of the batterycandamage of set. the electronic - Should you needto charge the battery it is advisable to disconnect it from the electricalsystem to avoid of set; to damages the electronic the samein case electric weldings n themotorcycle. o - H . V . 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 .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.

- 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 . V .c o i l ) . Values the electrical for checking pick,up. 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. - 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 . 2 2 Oo h m + 15 . To check usea tester(ohmmeter) connecting the cable e n d st o t h e t w o p i c k - u p a b l e s . c

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8.2 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 - 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 .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 . The generator composed : is of - 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 - f i x p a r t( i n d u c e d ) .

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Removing alternatorenerator the 1 Remove the L/H sidecover 2 | it on the outer part of the generator the special tool "A" 3 Undo centralbolt "8", spacer and washer

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4 Lock againscrew"8" 5 Screwin the outer part of puller "C". Acting on the c e n t r a n u t o f t h e p u l l e r ,s l i p off rotor from crankshaft. l

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