FOREWORD. Some basic technical information has been intentionally omitted as it is considered to be common knowledge.

Transcription

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2 FOREWORD The present manual specifically addresses to specialised technical personnel (MLGUTI authorised service centres and single motor mechanics) and contains all the service interventions indicated by the Manufacturer until the publishing of this document. Some basic technical information has been intentionally omitted as it is considered to be common knowledge. dditional information is available in the SPRE PRTS CTLOGUES of each model. It is important to read all the general information before going through the manual to the specific topics and the maintenance operations to be carried out on the motor-bike in order to make sure the topics, the technical and safety concepts are clearly understood and the manual can be used as a sure reference text. ll checks, maintenance, repairs or replacements of spare parts in our motor-bikes are to be performed by skilled and expert technical personnel with specific experience in state-of-the-art technology and full knowledge of the quickest and most rational procedures, technical characteristics, setting values, tightening torques and information as to which may only be properly and exhaustively provided by the manufacturer. It is important to adhere strictly to the following instructions. ny operation carried out carelessly or not carried out at all may lead to personal injury, damage to the motorcycle or simply to complaints. MLGUTI S.p.. reserves the right to make any changes and modifications hereto it deems necessary without prior notice. For further information and details, please contact MLGUTI S.p.. Servicing or Engineering Division. MLGUTI S.p.. Via Emilia 498, San Lazzaro di Savena (O) - ITLY Tel Fax [email protected] - http: // /07

3 NOTES FOR ESY CONSULTTION REVITIONS TECHNICL DICTIONRY Cs D Dx F G P R Sx T V Torque wrench setting Nut Right Picture Gasket Page Washer Left Table Screw V = (DC) Direct current (battery supply) V ~ (C) lternating current (flywheel supply) : mpere Unit of measurement of the electrical current W : Watt Unit of measurement of the electrical power (product of Volts and mperes; x V = W) Ω : OHM Unit of measurement of the electrical resistance < Lower > Higher bar N * m Lower or equal Higher or equal Unit of measurement of pressure Newton/metre Unit of measurement of the tightening torque EDITING SYMOLS: Symbols have been provided for quick and easy reference, identifying situations requiring utmost attention or providing practical suggestions or simple information. These symbols may appear next to a text (in which case they refer solely to the text itself), next to a figure (in which case they refer to the topic illustrated in the figure and to the relative text), or at the top of the page (in which case they refer to all the topics dealt with in the page). NOTE - The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations. 2 11/07

4 SYMOL LIST DISSSEMLY OPERTIONS CUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity. SFETY GLOVES These operations require the use of safety gloves IDLING ENGINE Switch on the engine, at idling speed, to perfom these interventions. SSEMLY OPERTIONS WRNING! Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment, vehicle or equipment IMPORTNT This topic requires special attention ENGINE OFF Indicates operations to be performed with engine off SYMMETRICL OPERTIONS Operations that must be carried out also on the other side of the unit or component. FIRE HZRD. Indicates operations which may constitute a fire hazard GENERL SERVICE PERSONNEL Skilled electronic or mechanical technician. POWER OFF Indicates that negative pole is to be disconnected from the battery before performing the operation PRESENT MNUL Information on the present manual RISK OF EXPLOSION Indicates operations which may constitute a risk of explosion MECHNICL MINTENNCE Operations to be performed only by an expert mechanic NO! Operations to be absolutely avoided M ENGINE SERVICE MNUL Indicates information which may be obtained by referring to said catalogue TOXIC FUMES Indicates a possibility of intoxication or inflammation of the upper respiratory tract ELECTRICL MINTENNCE Operations be performed only by an expert electrical/ electronic technician EMPTY THE CIRCUIT OIL COOLNT FUEL R SPRE PRTS CTLOGUE Indicates information which may be obtained by referring to said catalogue WRNING! Danger of crashing arms IGNITION KEY ON (ON position) REPLCE WITH NEW, ORIGINL SPRE PRTS 3 11/07

5 GENERL WORK PROCEDURES The recommendations given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment damage and idle times, and should therefore be strictly adhered to. lways listen with attention to the customer s opinion and complaints about the motor-bike operation, asking specific questions in order to have a complete understanding of all the symptoms and identify with good approximation the real causes of the trouble. The present manual provides the technical information and the basic indications on the intervention procedures but these have to be integrated with the personal expertise. We suggest planning the service interventions in order to avoid any waste of time or downtime. Try to reduce as much as possible the operations necessary to reach the components that needs repairing. Prepare the components that are likely to be replaced and all the original spare parts you may need. Use only the original spare parts. Mark the components that may be mis-placed during re-assembly operations. Only use quality tools and equipment. Only use equipment conforming to EU Directives for lifting the vehicle. During operations, always keep tools and equipment at hand, possibly laying them out according to the sequence in which they are to be used. bsolutely avoid putting them on the vehicle itself, out-of-sight or in poorly accessible places. lways keep the work area neat and clean. When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progressive pulls using a criss-cross pattern. The torque settings specified in the manual refer to the final torque, which must be attained progressively by steps. Preferably use open-end box wrenches by pulling and not pushing. efore any servicing, make sure that the vehicle is perfectly stable. The front wheel should be anchored to fixture, which is integral with the lift platform. 4 11/07

6 efore carrying out any operation, wait for all parts to cool down. For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and co-ordinated beforehand. Make sure that each component has been properly mounted before proceeding with assembling the next one. lways replace gaskets, O-rings, circlips and split pins at every refitting. Only use screwdrivers with sizes suitable to the screws to be loosened or tightened. Do not use fuses with a higher rated capacity than indicated: this may cause severe damages to the electrical system and burn a fire as a conse-quence of short circuit. Never use open flames for any reason. Never leave open containers or containers not suitable for holding fuel in passageways, close to heat sources, etc. Never use petrol to clean the vehicle or the floor of the workshop. lways use low flash point solvents to clean the vehicle components. When welding, make sure that there are no flammable liquids in the vicinity. Never suck from or blow into the fuel pipe. Never leave the engine running in closed or poorly ventilated areas. Make sure that the vehicle is stable and not to have to take on awkward working positions. Never reuse old gaskets or circlips. Never use a screwdriver as a lever or chisel. Never use pincers to loosen or tighten screws or nuts because, in addition to not providing a sufficient clamping force, they may also damage the screw head or nut hexagon. Never tap the wrench with a hammer or other similar tool to loosen or tighten screws and nuts. Never attempt to increase the lever arm by fitting a tube into the wrench. 5 11/07

7 CONTENTS DESCRIPTION P. TECHNICL DT 7 IDENTIFICTION INFORMTION: FRME N / ENGINE N - TIRES 8 MINTENNCE CHRT 9 LURICNT CHRT 10 FUEL TNK - COOLNT RESERVOIR 11 MOTOR OIL 12 LEVEL CHECK/ CHNGE 12 TRNSMISSION OIL 13 CHECK LEVEL/ TOPPING UP - CHNGE 13 RKE FLUID 13 CHECK- CHNGE 13 LEEDING THE RKE SYSTEM 14 FRONT CLIPER - RER CLIPER 14 CHECK FRONT/CK RKE PDS ND DISKS 15 REPLCE PDS 15 FRONT RKES - RER RKES 15 FORK 16 CHECK OIL LEVEL IN THE FORK LEG 16 CHNGE FORK OIL 16 SHOCK SORER DJUSTMENTS 16 LOCTION OF THE MIN ELECTRICL ND ELECTRONIC ELEMENTS 17 DSHORD 19 ELECTRIC/ SERVICE WRNING LIGHT- DIGITL CLOCK 19 KEY SWITCH - HNDLER CONTROLS 20 LEFT CONTROL - RIGHT CONTROL 20 ENGINE STRTER 20 LIGHTS 21 HEDLIGHT - LIGHT EM DJUSTMENT- TURN SIGNLS 21 TIL-LIGHT - NUMER PLTE LIGHT 22 FUSES - FUSE REPLCEMENT 23 TTERY 24 TTERY SSEMLY - CHRGE TTERY 24 SPRK PLUG 25 REPLCEMENT 25 DISMNTLING ND REMOVL PROCEDURES FOR COMPONENTS 26 RESSEMLY NOTES - RER-VIEW MIRROR- UPPER COVER 26 FRONT HNDLER COVERS 27 CCESS 28 FRONT SHIELD /07 DESCRIPTION P. CCESS- SET- HELMET CSE 30 SET LOCKING DEVICE 31 CCESS 32 FUEL LEVEL SENSOR - FUEL PUMP SENSOR 33 FUEL TNK 34 TTERY CSE COVER - CCESS- SIDE STRUTS 35 CCESS 36 RER FIRING 37 RER HNDLE 38 NUMER PLTE LIGHT HOUSING- RER LIGHTS SSEMLY 39 FULL RER FIRING 40 CCESS (RIGHT SIDE) 41 (LEFT SIDE) 42 ELECTRONIC CONTROL UNIT- VOLTGE REGULTOR 43 IGNITION COIL - ROLLOVER SENSOR 43 RER FIRING REKDOWN 44 LEGSHIELD 45 CCESS 46 KEYSWITCH - HORN 47 FRONT WHEEL - FRONT RKE DISC 47 SEQUENCE OF FRONT WHEEL RESSEMLY 48 FRONT RKE CLIPER 48 FRONT MUD GURD - FRONT SHIELD 49 CK HNDLER COVER - HNDELR CONTROL - RKE PUMP 50 HNDLER - ELECTRIC FN ND RDITOR 51 EXPNSION TNK 53 FORK -FORK LEG - COMPLETE FORK 54 MUFFLER - OXYGEN SENSOR 55 MNIFOLD EXHUST - RESSEMLY OF EXHUST SYSTEM 56 SHOCK SORERS- REMOUNTING THE SHOCK SORERS 56 RER MUDGURD 57 IR INTKE SSEMLY 58 IR FILTER 59 IR FILTER MINTENNCE - STRTER 60 RER RKE CLIPER 61 RER WHEEL 62 RER RKE DISK - RER WHEEL- ENGINE 63 FRME SIZE CHECK 64 CLE POSITIONING, "PIPE SYSTEM" ND POSITION OF CLMPS 65

8 SPECIFICTIONS Compression Ratio... 10,6 : 1 11,3 : 1 Cooling... liquid Starting system.... electric starter lubrication system... wet sump SPRK PLUG Type... NGK DPR7E9 TRNSMISSION Primary drive: automatic transmission by V-belt speed change gear Final: by gears. utomatic centrifugal dry clutch. F. 1 DIMENSIONS Wheel base () m... 1,360 Max. length () m... 2,050 Max. width (C) m... 0,735 Max. height (D) m... 1,180 Kerb weight kg Max. load with rider, passenger and luggage kg CPCITY Engine oil cm * Transmission oil cm * Fuel tank (total) l... 8,2* (3,0*) FUEL SYSTEM Electronic fuel injection with electric fuel pump. Fuel: unleaded petrol. IGNITION Digital RKES Front brake: disk type Ø 245 mm double piston hydraulic caliper Ø 25 mm Rear brake: disk type Ø 220 mm double piston hydraulic caliper Ø 34 mm CHSSIS High-tensile steel tubes SUSPENSIONS Front: hydraulically fork Ø 33 mm; Stroke: 88 mm. Rear: Swinging engine with double hydraulic shock absorber. Stroke: 74 mm. ENGINE: 2 valve - 4 stroke single cylinder: Type... MLGUTI 01 MLGUTI 02 n Cylinders... 1 ore x stroke mm... Ø 52,4 x 57,8 Ø 58,0 x 57,8 Capacity cm /07 TTERY Type 12V, 9h, maintenance free. TYRES Front: 100/ P (tubeless) Rear: 120/ P (tubeless) * Indicative Value

9 IDENTIFICTION DT: FRME N / ENGINE N The vehicle s identification number (VIN) () is located on the rear side of the chassis, under the helmet compartment. Engine identification data are located on the left-hand engine crankcase (). ny alteration to the vehicle identification data is pursued by the Law. TYRES Type: Tubeless (wiithout inner tube) F. 3 F. 2 Minimum tread depth is 2 mm. There are T.W.I. marks all around the tyre sides. These correspond to tyre wear indicators situated in the tyre s tread; if there is no difference between the thickness of the tyre wear indicators and the tread depth, the tyre must be replaced. F / P 100/ P It is possible to use tyres with load and speed indexes that are higher than or identical to those indicated. It is however necessary for speed indexes to be identical for both tyres. Use only tyres with the relevant type approval (29.0) (29.0) (30.5) (31.9) (33.4) (33.4) 8 11/07 Tyre inflation pressure must be adjusted while the tyre is at ambient temperature.

10 MINTENNCE TLE Nr. : coupon : check : clean : adjust : replace NOTE - Maintenance operations should be performed more frequently if the vehicle is used in rainy weather, in dusty places or on rough terrain. Due to their simplicity, checks with no asterisk CN also be carried out by technicians not authorised by MLGUTI, but under their direct responsibility. 9 11/07

11 LURICNT TLE NOTE - Use only recommended products. LURICNTS ENGINE OIL (4 STROKE) CLSS 10W 40 ENGINE TRNSMISSION OIL CLSS 10W 40 IR FILTER LURICNT RDITOR FLUID IR FILTER OIL TOP FLUID RKE CIRCUIT FLUID RKE FLUID DOT 4 FORK ROD OIL FORK OIL 10 11/07

12 FUEL TNK The fuel tank cap () is accessible by raising the seat, using the ignition key and turning it clockwise. Use unleaded fuel. F. 5 COOLNT TNK Open the case with the ignition key. Remove the plastic protection piece (). Check the fluid level in the inspection window (C) found under the shield. If it needs to be topped up, use the product specified in the lubricants chart. F. 6 C Do not remove the cap when the motor is hot. F /07

13 ENGINE OIL CHECK LEVEL every 2,000 km The engine must be cold and the vehicle on level ground. The level is shown on the cap/ dipstick (). Top with the oil specified in the lubricant chart. CHNGE fter the first 1,000 Km Every 4,000 KM F. 8 Warm up the engine for a few minutes and then shut it off. Place an appropriate drain pan under the engine (with the vehicle on flat ground). Pull out the cap/ dipstick (). Unscrew the drain plug (S) and let all the used oil drain out. Remove the filter/plug (F). Wash the screen (1) with solvent or if it is damaged, replace it. Check the wear conditions of the O-Ring (3) and replace if necessary. Reassembly: O-Ring (3)- Spring (2)- Screen (1) and tighten the filter/plug. Screw on and tighten the drain plug (S). Top up the engine with 800 cc of Q8 CLSS 10W40 oil and replace the cap/ dipstick. F S Start the engine; leave it running for a few minutes, and check that there are no leaks. F. 9 F. 10 Dispose of used oil in accordance with current laws in force /07

14 TRNSMISSION OIL CHECK LEVEL/ TOP UP Cold engine Vehicle on level ground. Place a drip pan under the engine. Unscrew the oil filler screw (). If necessary, top up with oil specified in the lubricant chart until the oil starts to overflow. Screw on the screw (). F. 11 fter the first 1,000 Km CHNGE Every 12,000 Km Cold engine Vehicle on level ground Place a drip pan under the engine. Unscrew the oil filler screw (). Unscrew the drain screw () Drain out all the used oil. Clean the threads of the drain screw and screw back on. Refill the crankcase with oil specified in the lubricant chart until the oil starts to overflow. Screw back on the screw (). RKE FLUID CHECK every 30 days Visually check by way of the warning signal (S) located on the front and back brake reservoir, with the vehicle on level ground and perfectly straight. The fluid level must be 3mm from the lower limit of the warning signal. S S Do not mix different oil types when topping off. F. 12 CHNGE Every 12,000 Km or 24 months If there is any debris or water in the brake fluid, it is essential that it be completely changed and the brake system must be bled. Excessive elasticity in the brake lever is usually an indication that air is in the system /07

15 LEED RKE SYSTEM FRONT CLIPER NOTE - Position the vehicle in a stabile manner and perfectly on level ground. Remove the (right side) oil pump reservoir cover (), unscrewing the relative screws (V"), in order to be able to top off the fluid. Fill the right brake fluid reservoir () to the highest level. Remove the rubber hood (C) of the bleeder screw (V) and insert a rubber tube to recover the brake fluid. Pump the right brake lever (D), prime it and bring the system in pressure. Keeping the brake lever pumped, loosen the bleeder screws (V), to allow air to escape. Then, tighten the bleeder screw (V) V2 D F. 13 F. 14 C V V 12 ± 16% Repeat the operation, until only liquid comes out of the rubber tube. Top up the brake fluid level in the reservoir (). V2 C V RER CLIPER To bleed the rear caliper, follow the same operation above, but pump the left brake lever (S). S F /07 F. 16

16 CHECK FRONT/CK RKE PDS ND DISKS Check the condition of front and back brake pads and discs every 2,000 Km. Carry out a visual check on the thickness of the brake pads as shown in the illustration. The minimum thickness of the brake pad friction material must not be less than 2mm. Replace the pads if they are close to the allowed limit, or if they are damaged. F. 17 F. 18 REPLCING PDS NOTE - The procedures for replacing front and back brake pads can be deduced from the illustration shown below. F. 19 FRONT RKE RER RKE F. 20 F /07

17 FORK CHECK OIL LEVEL IN THE FORK LEG Remove the fork leg. If a "limit switch" of the fork is found, or if they produce abnormal sounds, the oil level inside the pins must be checked. Removal of the legs can be seen in F. 22. Insert a ruler or gauge and check that the oil is at least 75mm from the upper edge of the leg. If necessary, top up with oil: FORK OIL CHNGE FORK OIL Place an appropriate drip pan under the slider and remove the screws (V). Drain out as much oil as possible. Proceed to dismantle the fork legs, as previously described. Turn the fork legs upside-down, to let the remaining oil drain out. Hydraulic oil is corrosive and may cause personal injury. Do not improperly dispose of used oil in the environment. Remount the drain screw (V). NOTE - When remounting, replace the copper washer located under the screw (V). V 17 ± 15% Carefully pour the "new" oil in the fork. Quantity per fork 90 cc. SHOCK SORER DJUSTMENTS Check the oil level, as previously described. Reassemble the fork components and the fork on the motorcycle. 5) adjustment positions are included: 1) driver only (to 75 kg) 2) driver only (over 75 kg) 3) driver and case 4) driver and passenger 5) driver, passenger, and case. F. 22 V Perform adjustments using the special key equipped on the ring nut (), located on the upper part of the shock absorbers; turning it anti- clockwise will increase the strength of the spring (increase in load) djust both shock absorbers using these instructions. Uneven adjustment can compromise the stability of the vehicle /07 F. 23

18 LOCTION OF THE MIN ELECTRICL ND ELECTRONIC ELEMENTS F /07

19 F /07

20 DSHORD 1) Speedometer 2) Odometer 3) Turn signal warning light (green) 4) High beams warning light (blue) 5) Electric/SERVICE Malfunction warning light (orange) 6) coolant temperature too high warning light (red) 7) Fuel gauge indicator 8) Coolant temperature indicator (red zone: temperature too high) 9) Digital clock DIGITL CLOCK F. 26 Date and month readout Press the top button once (after a few seconds the clock will automatically reappear). Seconds readout Press the top button twice; to restore the initial configuration, press the button again ELECTRIC/SERVICE MLFUNCTION WRNING LIGHT When the starter key is turned in the switch in the position, without starting the engine, the warning light (as well as the warning light ) will remain on for a few seconds to verify the functioning, and it will normally shut off after this. If it stays on longer (fully and/or flickering) it means: Electrical Malfunction (blinking light): indicates a malfunction in the electrical system. SERVICE (15 short blinking lights): indicates the need to perform programmed maintenance (see the Maintenance Chart on page 9). In both cases, reset the signal after performing the necessary operations. The warning light interval of the SERVICE sign of the may have different meanings as shown in the Maintenance Chart, depending on the vehicles conditions of use. To set the clock and calendar, use the two buttons on the right hand side of the dial, starting with the time display. Setting the month Press the lower button twice; and then with the top button select the exact number. Setting the date Press the lower button three times; and then using the top button select the exact number. Setting the time Press the lower button four times, and then using the top button select the exact number. Setting the minutes Press the lower button four times, and then using the top button select the exact number. Press the lower button once again to return to the time display. Confirm modifications by pressing the top button /07

21 KEY SWITCH Ignition inhibited (extractable key) Preset starting position (non extractable key) Steering lock insert (Ignition inhibited: extractable key). In case both of the equipped keys are lost the entire locking kit must be replaced. HNDLER CONTROLS LEFT CONTROLS 1) Horn button 2) Turn signals switch. 3) Turn signals shutoff switch 4) Turn on lights: high beam low beam RIGHT CONTROLS ) light switch: right= off center= tail and dashboard lights left= high/low beams ) Electric starter button STRTING THE ENGINE efore pushing the starter button to start the motor, first pull the front or rear brake lever and keep it pulled. Do not start the engine in a closed ambient, because the exhaust is highly toxic. To not damage the injection system, never operate the "STRT" button if the fuel tank is empty, or turn the key switch to "ON". If the engine does not start, release the starter switch, wait a moment, and then press it again. In order not to drain the battery, do not operate the starter for more than 10 seconds on each try. Do not rev the engine to its limit when it is cold. 3 4 Start the engine with the headlights off. 2 1 F /07

22 LIGHTS HEDLIGHT The headlights are quartz lamps (halogen). High/Low beam lights (). Halogen ulb 12V - 60/55W (H4). Tail lights (). ulb 12V - 5W (W5W). With a Philips screwdriver, adjust the headlight adjustment screws ( R), keeping in mind that turning clockwise lowers the light beam and vice versa. djust the beam so that the lower line of the beam is about 95 cm off the ground when projected on a wall. R LIGHT EM DJUSTMENTS Place the vehicle in gear, 10 m from a wall. Turn on the low beam and keep the vehicle vertical without the kickstand and without people sitting on it. F. 28 F. 29 CHNGE LIGHT UL For information on access to the headlight bulb consult page 28). TURN SIGNLS Front Orange bulb ( C) 12V - 10W (RY 10W). D LIGHT UL REPLCEMENT For information on access to the turn signal light bulbs see page 46). RER Light bulb (D) 12V - 10W (RY 10W). C D LIGHT UL REPLCEMENT For information on access to the rear turn signal light bulbs see page 39). C F /07 F. 31

23 TIL LIGHTS Tail light () Light bulb 12V - 5W (W5W). brake light (S) Light bulb 12V - 10W (R10W). Turn signal (E) 12V-10W light bulb W E S S W E LIGHT UL REPLCEMENT Remove the number plate light (see the next paragraph). Remove the taillight cover by unscrewing the two screws (V). Remove the parabola by unscrewing the two screws (W). V V Tail lights () Take out the lamp holder from inside the headlight. Replace the light bulb. Reposition the rubber lamp holder (pressure) and remount the cover. Stop light (S) and turn signal light (E) Remove the coloured hood that is held by two hooks. Replace the light bulb. Reposition the coloured hood and remount the cover. F. 32 When performing the operations described above, be very careful to not damage the near by parts (transmission, cables, gaskets, etc.). F. 33 NUMER PLTE LIGHT Light bulb 12V - 5W (W5W) To check that a light bulb (C ) is properly functioning, position the light switch, which is located on the right control panel, in the center position and turn the key to the starting position. F. 34 C LIGHT UL REPLCEMENT Remove the number plate light (F), unscrew the screws (V). Remove the rubber lamp holder from the plastic cover. Replace the light bulb. Reposition the lamp holder and remount the cover. When performing the operations described above, be very careful not to damage the near by parts (transmission, cables, gaskets, etc.). F V F /07

24 FUSES The electric wiring includes eight fuses that are located in the front case and protect the main components from any malfunctions. S S P FUSE REPLCEMENT Open the case and take out the fuse and replace it with one having equal capacity. Spare fuses are located inside the compartment (S). Do not replace fuses with others that have a higher capacity, as it could seriously damage the electrical system and cause the vehicle to catch fire if there is a short circuit. It is important to identify the cause of blown fuses. F. 36 NOTE - Use the appropriate grippers (P) when replacing a fuse /07

25 TTERY (12V-9H) The battery housing is located in the central tunnel. TTERY SSEMLY (PRE-DELIVERY OPERTION) Take the battery that has been previously charged pply the adhesive strip () supplied in the kit, by removing the protective film located on the end of the adhesive area, shown by the arrows (P). Remove the 30 general protection fuse (F). Unscrew the three screws (V3) and remove the central panel under the seat. Remove the battery fastening cover by removing the screws (V2). Insert the battery, ensuring it fits in its housing. Connect the battery to the cables - positive pole (+) RED/LUE wires - negative pole (-) LCK wires Properly tighten the battery clamps. Properly position the battery clamps. Replace the previously removed 30 general protection fuse in its place. F. 37 Check that the battery and cables are properly positioned; then remount the battery fastening cover. Remount the central panel under the seat. P NEVER invert the cable connections. Do not use the battery without the battery inserted and connected to wires of the main harness. This could cause breakdowns and short circuits in the electrical system and components. It is advisable to use gloves and protective eyewear, when the battery must be removed from its housing; for example, when it needs to be recharged. F F. 38 F. 39 V2 V3 CHRGE TTERY To carry out this operation, it is advisable to remove the battery from its housing, unless the special electrical outlet is used. Disconnect cables. It is a good rule to recharge using amperage that is equal to 1/10 of the power of the battery charger. Remount the battery, paying attention to connect the positive cable (red/blue) to the + pole and the negative cable to the - pole. Properly tighten the battery clamps. It is important that the battery always remains fully charged; therefore, during the winter months or when the vehicle remains unused, it should be recharged at least once a month. Danger of explosion! Do not use open flames (lighters, matchsticks, etc.). The battery contains highly toxic sulphuric acid. void contact with the eyes, skin, and clothes. Keep the battery out of reach from children. If for charging/ maintenance of the battery the special electrical outlet connection is used (), open the battery case to permit proper ventilation. F. 40 F /07

26 SPRK PLUG REPLCEMENT every 12,000 km Remove the spark plug when the engine is cold. Type of spark plug to be used: NGK DPR7E9 For maintenance, disassemble the central panel under the seat (P), remove the fastening screws (V3) and lift the internal profile (with the help of a screwdriver) that is held on two lugs in the foot rest board, carefully extract the hood (C ), with small clockwise and anti clockwise movements; then unscrew the spark plug. Examine the condition of the sparkplug. Deposits and colorations of the insulator provide useful information on the thermal grade, on the carburetion, on the lubrication and on the general condition of the engine. If there is a light brownish color on the insulator around the central electrodes, it means that it functions properly. fter removing the sparkplug, proceed to clean thoroughly the electrodes and insulators, using a metallic brush. djust the electrode gap, using a laminar feeler gauge: the gap must be 0,6 0,7 mm F. 42 P V3 Spark plugs with a thermal grade that is different than that deduced by the advised symbols may seriously damage the engine. Replace all spark plug with cracks on the insulator or corroded electrodes. C Remove any residue, using jets of compressed air. Grease the sparkplug threads with motor oil and manually rescrew it. Tightening the spark plugs: 17,5 F /07

27 PROCEDURES FOR DISMNTLING ND REMOVING COMPONENTS Unscrew the window holder stud bolt (). RESSEMLY NOTE RER VIEW MIRRORS Uncover and loosen the nut (D). D F. 45 " Unscrew the window holder arm, by turning it anti-clockwise. " Remove the protection (). NOTE - The left stud bolt is noted by the groove (C). C F. 44 F. 46 V2 V2. UPPER COVER Remove the upper cover, sliding it towards the rear part. F. 47 F /07

28 FRONT HNDLER COVER V4 V. V4. V 1 ± 10% V4 1 ± 10% V F. 49 F. 50 V4 To clear the front handlebar cover, push the area indicated in the figure (on both sides), paying attention to not damage the hooking points. Free and partially extract the handlebar unit, carefully, as to not damage the paint of the under shield or rip the electrical headlight wires. F. 51 F /07

29 Disconnect the lamp holder () Extract the taillights lamp holder (). Remove the front handlebar cover. F. 53 F V2 2 V CCESS (FTER REMOVING THE FRONT HNDLER COVER) 1) Clock connector 2) Clock (fastened with screws - V2) 3) Front brake "stop" switch 4) Rear brake "stop" switch 5) Dashboard connectors 6) Hydraulic front brake pump union 7) Hydraulic rear brake pump union 8) Fastening ring nut transmission odometer 9) Right switch connector 10) Left switch connector 11) Dashboard lighting lamps F /07

30 V2. FRONT SHIELD V2 W. V2 1 ± 10% W 1 ± 10% W F. 56 F. 57 Unscrew the screws (V5) to separate the grille from the shield. V5 1 ± 10% Remove the shield with moderation, being careful to not damage the hooking elements. V5 F. 58 F /07

31 CCESS (FTER REMOVING THE SHIELD) G E C D2. SET ) Electric fan ) Radiator C) Radiator cap F D2 3 ± 20% D2 D) Diagnosis socket E) Electric fan connector D F) ntitheft preset connector G) Key switch connector F. 61 F. 60 HELMET COMPRTMENT Cap (). Droplet catcher cup (), after having removed the clamp (C) of the breather pipe (D). C D F. 62 F /07

32 V5. V5 5 ± 20% Partially lift the helmet compartment, as it is constrained by the seat locking device cable (). F. 64 F. 65 V5 V2 SET LOCKING DEVICE V2. Remove the locking/opening unit, complete with the transmission cable. V2 3 ± 20% F. 66 F /07

33 CCESS (after removing the helmet compartment) Fuel tank Fuel level gauge () Fuel level gauge connector () Fuel Pump ( C) Pump connector (D). 2 C D 3 4 F. 68 1) Temperature gauge (coolant) 2) Inlet air temperature sensor connector 3) T.P.S. connector 4) Injector connector 5) O2 sensor connector 5 F /07

34 FUEL LEVEL SENSOR During operations, screw the tank cap on the union (E), to avoid that any foreign matter falls inside. Disconnect the connector (H). V4. Open the clamp (). E H R F V4 I NOTE - When reassembling, insert the floater (l) so that the base () remains as it was originally. It is advisable to mark the correct position before removal. Check the condition of the gaskets (L) and replace them if necessary. F. 70 V4 C D G F. 71 L F Reposition the clamp (). V4 2 ± 10% Do not smoke or use open flames, during operations on the fuel tank. FUEL PUMP Disconnect the connector (D). Disconnect the gas hose (F), pressing on the fitting with one finger (R). Keep a rag close by to swab up any leaking fuel. Unscrew the ring nut (G). Take out the pump (C). G C F /07

35 FUEL TNK V4 O Do not smoke or use open flames, while operating on the fuel tank. During the operation, screw the tank cap, on the union (E), to avoid that any foreign matter falls inside. Disconnect the connector (D). Disconnect the gas hose (F), pressing on the fitting with one finger ( R). Keep a rag close by to swab up any leaking fuel. Open the clamp (T). Disconnect the connector (H). Unscrew the screws (v4), being careful not to lose the anti-vibration pads (M), bushings (N) and clamps (O). E T H D F V4 O N M V4 N M Remove the tank and place it far from heat sources and sparks and/or open flames. V4 5 ± 10% F. 72/a 34 11/07

36 V3. Door (). TTERY COVER COMPRTMENT CCESS attery (). Spark plugs pipette (C). NOTE - For information concerning the battery, consult page 24. F. 73 F. 74 V3 C SIDE STRUTS W. V2. Washer (R). R W F. 75 V2 F /07

37 Open the strut with moderation, starting from the rear part and take it off by pushing on the front part, being careful to not damage the hooking points (C-F. 80); be careful not to lose the prestoles (P). When remounting, insert the strut in the front drive (). P F. 77 F. 78 C CCESS 1) Electronic control unit 2) Ignition coil 3) Rollover sensor 4) Voltage regulator F F /07

38 V3. RER FIRING (including the foot rest panel) Unscrew the screw (V), holding the self locking nut (D). V V3 5 ± 10% V3 D F. 81 F. 82 V V Unscrew the screws (V), remove the pillion staff and recuperate the underlying spring (M). Clean and grease the fulcrum pin (P). G P D F. 83 M F /07

39 RER HNDLE Cap (). V. V F. 85 F. 86 V2 V2. ushing (). V V2 43 ± 15% V Remove the rear handle including the opening/ locking seat device. F. 87 F /07

40 NUMER PLTE LIGHT SUPPORT V. Number plate light support (). V2 V2 RER LIGHT UNIT V2. Rear light frame assembly (). Rear light glass assembly (C). C V F. 90 F. 89 V2 V2. Carefully take out the rear light unit. Disconnect the wires. F. 91 F /07

41 FULL RER FIRING V2. Lift slightly the rear fairing, complete with the footrest panel and number plate holder guards. V2 V2 F. 93 V2 5 ± 10% F. 94 Take the fairing out of the frame, as illustrated in figure F /07

42 CCESS (RIGHT SIDE) 1) Three-phase stator connectors connettore regolatore 2) Flasher relay 3) Electric fan relay 4) Injection system relay 5) Starter relay 6) Pick-up connector 7) Ground assembly 8) Regulator connector system connector The reassembly stage of any interventions on the wiring involves repositioning these as illustrated, and fastening them with new clamps that must be placed in the original points. NOTE - ccess to the various mechanical components can be deduced from the illustrations F /07

43 (LEFT SIDE) 1) Ignition coil 2) Valve (manage minimum) "IDLE" 3) Electronic control unit 4) Voltage regulator 5) Rollover sensor 6) Horn 7) Fuel hose fastening clamp F /07

44 ELECTRONIC CONTROL UNIT Disconnect the connector (). V2. V2 VOLTGE REGULTOR Disconnect the connector (M) and the connector (N).. V2a. V2 IGNITION COIL Disconnect the connector (). Unscrew the screws (V2) and remove the coil complete with the support staff. V2/a C D ROLLOVER SENSOR Disconnect the connector (C). Free the sensor (D) from its housing. F. 98 When reassembling, be careful to reposition the sensor in a horizontal position as it was originally. N M 43 11/07

45 RER FIRING REKDOWN FROM THE FOOT REST PNEL RER FIRING REKDOWN FROM THE NUMER PLTE HOLDER GURD. V3. V3. V3 V3 F. 99 F /07

46 LEGSHIELD V2. ag holder hook (). Extract the cover () of the key switch. V2 V V4 V2 5 ± 10% V2 F. 101 Unscrew the fixing screws (V") of the fuse holder. V. V4 C Open (carefully) the leg shield, on the right side. Remove the fuse holder box (C). Disconnect the connector (D). Remove the leg shield unit. F. 102 D V 5 ± 10% V4 2 ± 10% F /07

47 CCESS (after the legshield is removed) ) Front turn signals NOTE - It is not necessary to move the leg shield to replace the front turn signals. They are accessible through the side grille of the leg shield ) Key switch C) Horn D) Expansion reservoir E) Handlebar fixing nuts F) Steering wheel play regulator ferrules E D F C F. 104 F. 105 F /07

48 KEY SWITCH Disconnect the connector from the wiring. Unscrew the tamperproof screws (V). HORN Disconnect the "faston" (). V - V2 10 ± 15% V 7 ± 10% V V2 F. 107 F. 108 FRONT WHEEL Unscrew the nut (D), holding the wheel pin with a wrench. FRONT RKE DISC When removing the front wheel, check the condition of the brake disc. In case of deep scoring or if the thickness is below the minimum limit of 3.5 mm, remove it by unscrewing the screws and replace it. Remove the wheel pin (P). Take off the wheel. Do not use the brake lever, with the wheel removed. V4 11 ± 10% D P pply Loctite threadlocker (Strong type) on the screw threading. F. 109 V4 F /07

49 SEQUENCE OF FRONT WHEEL RESSEMLY Spacer () P R Odometer transmission () Washer (R ) Wheel pin (P) Spacer (C) Wheel pin (D) D 53 ± 10% FRONT RKE CLIPER Place an appropriate drain pan under the brake calliper. Unscrew the hydraulic fitting (). Empty the hydraulic circuit completely, pouring the fluid in a special container for proper disposal in accordance with specific waste disposal laws. F. 111 C D V2. Remove the calliper. V2 Hydraulic oil is corrosive and may cause personal injury. Remove the calliper, taking care that fluid line does not get damaged and the disc and pads do not get dirty. t the end of removal and replacement operations, check that there are no losses, dry up any traces of fluid and bleed the system as indicated in page 14. G During reassembly, change the gaskets (G). V2 V2 30 ± 20% 20 ± 20% F /07

50 FRONT MUDGURD V V3 V1 Clamp () Clamp (C) V3 V C V1 V3 3 ± 10% F. 113 F. 114 P V2 Spacer () Remove the mudguard (P). V2 FRONT SHIELD V Do not forget to remount the spacers () and clamps (-C). W Lower screws (W-F 115) Top screws (V) Take out the shield (with care) W V 5 ± 10% F. 115 F /07

51 CK HNDLER COVER Unscrew the screws (V4), to free the handlebar commands. E V4 2 ± 15% Central screw (V) Disconnect the dashboard connector (). Unscrew the ring nut () of the odometer cable. Remove (with care) the rear handlebar cover including the dashboard. V4 C F V4 HNDLER CONTROLS V4 Disconnect the throttle transmission (C). Disconnect the connectors (D-E) F. 117 V D F V2/a V V2/a RKE PUMP V2/a rackets (). Disconnect the "faston" (F). Remove the brake pump and place it in a vertical position on a dry cloth. rake fluid is corrosive. V F /07

52 HNDLER Remove beforehand: - Front handlebar (page 27) - Front shield (page 49). D P N L M - rake pump (page 50). - Right switch and left switch (M). - Counterweights (P). - Handlebars (N) M N P - Cut the cable and tube holding ties. - Remove the throttle cable () Loosen the nuts and slide the pin off (H), taking care not to damage the cables and tubes. Slide off the grips. H D F. 119 D 50 ± 20% ELECTRIC FN ND RDITOR efore any operations on the cooling system, check that the fluid is below 50 C. Remove the front shield (page 49). Cut the cable and tube holding ties. Unscrew the radiator cap (). Position the engine in a container suitable for collecting the used coolant. Loosen the clamps (F) and slide the tube off (T) of the water pump. Disconnect the tube (). F. 120 F. 121 F T 51 11/07

53 Disconnect the electric fan connector (). Unscrew the radiator and electric vent housing fixing screws (V4) Remove the housing and electric fan. Unscrew the screws (V3). Separate the electric fan unit from its housing. V4 V3 F. 122 F. 123 F. 124 V4 Free the radiator from the hoses (M). Separate the radiator from its housing (S). S F. 125 M The cooling system is "self-bleeding". ut if, after the radiator is reassembled, filled with fluid and tested with the engine idling for a few minutes, an abnormal rise in temperature is found, manually bleed it by following these steps: Partially lift and rotate the helmet case sideways (page 30). Wait until the fluid has cooled down, unscrew the cap () and completely fill the radiator. Slide off the tube (T) (after freeing it from the clamps); Liquid should come out from F. 125/a the union, in abundance. Insert the tube (T) and the cap () efore replacing the helmet case, start the engine and check that there is no abnormal rise in temperature. T 52 11/07

54 EXPNSION TNK efore any operations on the cooling system, check that the fluid is below 50 C. V2. Place an appropriate drain pain under the expansion tank. Disconnect the tube () and empty the expansion tank; remove the filling cap () to make it easier to empty. F. 126 V2 F. 127 R V2 V2. Remove the expansion tank. V2 V2 3 ± 15% When remounting, insert the washers (R). R V2 F. 128 F /07

55 FORK FORK LEG NOTE - When removing the fork leg, as well as the full fork, the following should be removed beforehand: - Front wheel (page 47) - Front mudguard (page 49) - Front brake calliper (page 48) - Odometer transmission (page 48) For the full fork, also remove the: - Front shield (page 29) - Handlebar (page 20) To check the oil level and to change oil, see page 16). Loosen (V) Raise the fork leg a few millimetres (). Take out the elastic ring () Slide out the fork leg () downwards. V 30 ± 20% F. 130 V S C FULL FORK Upper ring nut () Lower ring nut () NOTE - When extracting the fork unit, take care with the bearings (S) spilling out. S C Remove grease the seat of the caps (C). Check the usage conditions and if necessary replace them. Grease and remount the fork unit. Top bearings (Ø 3/16") n 22 Lower bearings (Ø 1/4") n ± 10% 140 ± 15% F. 131 F /07

56 MUFFLER efore operating on the muffler and the exhaust pipe, ensure that the components are cool. Loosen the clamp fixing screws (V) of the muffler/ exhaust pipe. Remove the muffler. V3. V 24 ± 10% V V3 F. 132 F. 133 O2 SENSOR Free the O2 sensor cables from the various ties (). Disconnect the O2 sensor connector (). F. 134 F /07

57 EXHUST MNIFOLD D2. Remove the exhaust manifold and related gaskets. D D2 REMOUNTING THE EXHUST SYSTEM Screw the O2 sensor (D) on the exhaust connector (1). Position the collector (1) in correspondence with the engine, inserting the gasket (2) that should be replaced if they are deteriorated. Screw and tighten the nuts (D2). Insert the gasket (3). Insert the muffler (4) on the manifold exhaust. Screw and tighten the screws (V3), after having inserted the washers (R ). Tighten the clamps (F). D 45 ± 10% D2 30 ± 10% 4 R V3 2 D2 1 F 3 D F. 138 F. 139 VS V3 42 ± 15% SHOCK SORERS Support the central part of the frame. Lower screws (Vi) Top screws (Vs) Extract the shock absorbers. R V3 REMOUNTING THE SHOCK SORERS First, insert the top screws (Vs) with the washers (R) and nuts (D). Insert the lower screws (Vi) and relevant washers ( R). D R VS Vs 45 ± 15% Vi Vi Vi Vi 24 ± 15% R F. 140 F. 141 F /07

58 Right side V2. RER MUDGURD Left side V. V V2 F. 143 F. 144 When remounting the rear mudguard, do not forget to insert the bushing () and the washers (-C). Check the inserted prestole (D) is properly. V2 V 3,5 ± 20% V2 3,5 ± 20% D C V F /07

59 INTKE SYSTEM Unhook the clamp (). Disconnect the tube (C ) "IDLE" valve- filter box sleeve. Remove the clamps (-F. 147). Disconnect the vapour recovery tube (C1-F. 147). Cut the ties (E). Disconnect the connector (F) (Inlet air temperature sensor) Loosen the clamps (G). C C1 F. 146 F. 147 F E G The ties that have been cut in order to remove various components must be replaced with identical ones, and placed in the original position /07

60 Unscrew the fixing screws (V1) of the filter boxrear mudguard. Unscrew the fixing screws (V) of the flexible air intake tube. Unscrew the screws (V2). V1 V Remove the whole air intake system. To remove the intake air sensor () unscrew the screws (V2). V2 V V1 V2 5 ± 10% F. 149 V2 F. 148 When remounting the inlet air sensor, check the condition of the O-ring (); replace if necessary. V2 Unscrew the screws (V5), remove the cover and take out the filtering element. IR FILTER V5 F. 150 F /07

61 IR FILTER MINTENNCE Soak the filtering element () in a special solvent solution for filters, for a few minutes. Squeeze the filter (wearing rubber gloves) until all traces of the solvent are eliminated. pply oil for air filters on the entire surface of the filter, eliminating any extra oil; the result should be a uniformly impregnated filter without excess oil dripping off. If the filter element is damaged, replace it with a new original one. C When remounting the air filter unit, check that the filter casing seals () and the filter cover, are correctly inserted in the relative housing. Position the cover and fasten it with screws (V5). V5 F. 152 STRTER Disconnect the "faston" from the connector (). Unscrew the screws (V2). V2 10 ± 10% V2 F /07

62 RER RKE CLIPER Place an appropriate drain pan under the brake calliper. Unscrew the hydraulic fitting (R). R Empty out the hydraulic circuit, pouring the fluid in a special container for disposal in accordance with specific waste disposal laws. Unscrew the screws (V2) and remove the calliper. rake fluid is corrosive and can cause personal injury. V2 Remove the calliper, taking care that fluid line does not get damaged and the disc and pads do not get dirty. When the removal and replacement operations are finished, check that there are no losses, dry up any traces of fluid and bleed the system as indicated in page 14. F. 154 G During reassembly, change the gaskets (G). R 20 ± 10% V2 30 ± 20% F /07

63 RER WHEEL V F G Remove beforehand: - Muffler (page 55) - Rear mudguard (page 57) - Rear brake calliper (page 61) V2 H Position the motorcycle on the stand and place a suitable support under the engine. V2 E Unscrew the lower screws (V) of the right shock absorber. Rotate and anchor the shock absorber up high. D 100 ± 20% D V2 I C F. 156 F. 157 V2 45 ± 15% C Unscrew the wheel nut (D). Unscrew the fixing screws (V") of the slider arm. Extract the external spacer (). Remove the slider arm (). Slide off the wheel pin the internal spacer (C). Check the wear conditions of the oil seals (E- F) and replace it if necessary. Check the condition of the silent-block (G). appropriate puller must be used for bearing (H) replacement operations, after having removed the Seeger ring (l). Slide off the wheel with care, ensuring that the vehicle is stable. F /07

64 RER RKE CLIPER When removing the back wheel, check the state of use of the brake disc. In case of scoring or thickness below the minimum limit of 3.5 mm, remove it by unscrewing the screws (V4) and replace it. RER WHEEL efore remounting the rear wheel, grease the shaft in points -. V4 11 ± 10% F. 160 pply Loctite threadlocker (Strong type) on the screw threading. F. 159 V4 ENGINE Remove beforehand: - Rear fairing (page 40) - Rear mudguard (page 57) - Lower fixing screws, shock absorbers (page 56) - ir filter unit (page 59) - Muffler (page 55) - Slider arm (page 62) It is essential that all the tube and cable ties are cut from the engine and all relevant connectors are disconnected. fter remounting the previously removed components, all cables, pipelines and ties should result as they were originally; in concern to this, carefully consult the following pages /07

65 Unscrew the nut (D) and slide off the pin (). D 45 ± 15% Raise the rear part of the motorcycle before sliding off the engine pin. It is advisable to have a second operator available to help carry out this operation. Removing the engine from the frame is a task that should be performed with care and the utmost attention, in order to avoid crushing of the hands, lower limbs and safeguard the integrity of the engine. F. 161 The removal of parts and components that allow the engine to be separated from the frame includes a certain number of bands being cut. These must be replaced and positioned as they were originally. For this purpose, consult the illustrations on the following pages. D F. 162 FRME SIZE CHECK In case of suspected deformation (even slight) of the frame following an accident, perform a size check of the frame. Check that the distance = 1168 mm ( ± 2mm tolerance) If it results to be outside of the tolerance, replace the frame. It is absolutely forbidden to deform the frame to restore the original distance (). F /07

66 CLE POSITIONING, "PIPE SYSTEM" ND NCHORING TIES. F. 164 F /07

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