SERVICE STATION MANUAL

Pure Passion since 1911

Code: B000094195000 Translation of original instructions

 WARNINGS:

This manual has been written by Benelli Q.J. s.r.l., mainly for use by Benelli dealers and their specially trained mechanics. It is not
possible to give a mechanic all of the information they require in a single manual. It is therefore presumed that the persons using this
manual for the maintenance and repairs of Benelli bikes have a basic knowledge of mechanics and the procedures necessary for
repairs and maintenance of this type of vehicle. Without this experience, any repairs or maintenance to this type of vehicle may be
dangerous or ineffective.
It is company policy at Benelli Q.J. s.r.l. to continuously upgrade and improve its models. Any changes or significant modifications
to technical data or procedures will be made known to all authorised Benelli Dealers and will be published in future editions of this
manual.

NOTE:_________________________________
Drawings and specifications are subject to change without prior notice.

IMPORTANT INFORMATION ABOUT THE MANUAL

This manual contains the following important reminders:

Failure to follow the instructions after this symbol may lead to serious injury or even death for the rider,
WARNING people in the vicinity, or people inspecting or repairing this bike.

“Important notice" means that specific precautions are required to avoid causing damage to the bike.
IMPORTANT
NOTICE

NOTE A "Note" provides key information that will make the procedure either easier or clearer.

I-I
 HOW TO USE THIS MANUAL
This manual is a practical reference guide that is both easy to handle and use for mechanics. The explanations of all of the procedures
for installing, removing, disassembling, assembly, repairing, and checking are organised in sequence, one step at a time.

1. Each chapter is divided into sections. The top part of each page contains the title of the current section.
2. To help with the identification of parts and to make the different processes clearer, exploded drawings are provided at the start
of each section dealing with the removal or disassembly of parts.
3. Parts needed lubricating or replacing are marked by symbols. See the "SYMBOLS" section.
4. The exploded drawings is accompanied by a table showing the position on the spare part catalogue, its description, intervention
sequence, symbols used, intervention description, and any notes for the operator.
5. Interventions requiring any other information (e.g., special tools and technical data) are described in sequence.

I - II
 SYMBOLS

SUBJECT SYMBOLS

General Information

Specifications

Inspections and Periodic Adjustments

Frame

Engine

Cooling system

Electrical system

EXPLANATORY SYMBOLS

Wear limits, Backlash Thread locker application

Special tool Recommended fuel

T. R .
Locking torque
Brake fluid

G Grease application
Lubricant

C
IL A Sealant paste application
IS
OR
YV

I - III
 INDEX

General Information
CHAPTER 1

Specifications
CHAPTER 2

Inspections and Periodic Adjustments

CHAPTER 3

Frame
CHAPTER 4

Engine
CHAPTER 5

Cooling system
CHAPTER 6

Electrical system
CHAPTER 7

I - IV
1

1-1
 CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION ...........................................................................................................................................3
MOTORCYCLE IDENTIFICATION .............................................................................................................................................3
FEATURES ....................................................................................................................................................4
INSTRUMENTATION AND INDICATOR LIGHTS .......................................................................................................................4
MULTIFUNCTION DISPLAY .......................................................................................................................................................5
IMPORTANT INFORMATION ........................................................................................................................6
GETTING READY FOR REMOVAL AND DISASSEMBLY OPERATIONS .................................................................................6
SPARE PARTS ..........................................................................................................................................................................6
SEALS, O-RINGS, OIL SEALS, AND BEARINGS ......................................................................................................................7
SAFETY WASHERS/PLATES, COTTER PINS, AND THREAD LOCKER .................................................................................7
SAFETY SNAP RINGS ...............................................................................................................................................................8
CHECKING CONNECTIONS .....................................................................................................................................................8
ENGINE SPECIAL TOOLS .......................................................................................................................................................10
SPECIAL TOOLS .........................................................................................................................................10
SPECIAL FRAME TOOLS ........................................................................................................................................................13

1-2
 IDENTIFICATION
MOTORCYCLE IDENTIFICATION

The identification data are:

1. Serial number of the frame (on the steering sleeve).
2. Serial number of the motor (on the bottom base).
3 3. Type-approval data (on the frame).

1
2

1-3
 FEATURES
INSTRUMENTATION AND INDICATOR LIGHTS

The instruments and lights will switch on when the ignition key is 8. NEUTRAL POSITION INDICATOR LIGHT (GREEN).
turned to "ON". This switches on when the gear is in "Neutral".
After an initial check-up, the information will correspond to the
overall condition of the bike at that time. 9. OIL PRESSURE WARNING LIGHT (RED).
The dashboard has the following instruments: It goes on when the oil pressure value is too low. The electrical
circuit of the light can be checked by turning the key to "ON”.
1. TACHOMETER. Once the engine is running, the light should switch off If the
The tachometer shows the running turnover of the engine so light does not switch on when the key is turned to "ON" or if the
that the rider can keep it within the ideal power range. light stays on, get the electrical circuit checked by an authorised
Benelli centre.
2. SELECT BUTTON.
Buttons to set vehicle data. Press the “SELECT” button to see 10. DIGITAL CLOCK / SETTING.
the partial or total kilometres. Shows the time in hours and minutes.
Push and hold the menu switch “SELECT” for 3 seconds to enter
3. RESET BUTTON. the setting mode “TOTAL KM”.
When viewing partial kilometres (TRIP A/TRIP B), it is possible Press and hold down the ”SELECT“ button for 3 seconds until
to reset them by holding down the ”RESET” button. the reading begins to lash. Set
the hour by pressing the “RESET” button.
4. COOLING FLUID TEMPERATURE GAUGE. Press the ”SELECT“ button to pass on to adjust the minutes. Set
Shows the cooling fluid temperature in °F (Fahrenheit) or C°(Cel- the minutes by pressing the ”RESET“ button. Press the “SE-
sius). LECT” button again to exit.

5. SELF-DIAGNOSIS LIGHT. 11. NEUTRAL GEAR INDICATOR LIGHT.

The light warns the driver of failures of the power supply and The engaged gear display shows the selected gear.
ignition systems, by switching on the engine yellow light (LED) It is a 6-speed gearbox model.
when their parts are faulty and the protective function is acti-
vated. In the event of serious problems, the control unit stops 12. TOTAL/PARTIAL KILOMETRE COUNTER.
the injection/ignition function and it is necessary to contact an The total kilometre counter shows the total distance covered
authorized service centre Benelli at soonest. in kilometres. Set the mode “TRIP A/TRIP B” in the instrument
using the “SELECT” button. The partial kilometre counter (TRIP
6. LEFT DIRECTION INDICATOR LIGHT (GREEN). A/TRIP B) shows the distance covered since the last reset. The
It goes on when the left direction indicator light is activated. partial kilometre counter can be used to estimate the possible
distance to cover with a full tank of fuel. This information may
7. HIGH BEAM INDICATOR LIGHT (BLUE). make it possible to schedule future fuelling stops.
This switches on when the high beam is switched on.
13. FUEL RESERVE LIGHT
The light on shows that the vehicle has a fuel range of about 1.3
litres.

15 10 4 1 6 8 19 7 13 9

11
16
5
17

14
12

18 3 2

1-4
 FEATURES
MULTIFUNCTION DISPLAY
14. SPEEDOMETER. 17. SERVICE LIGHT.
Push and hold the menu switch “SELECT” for 3 seconds to enter It goes on after 1000 km (621 mi) the first time, and then every
the setting mode “TOTAL KM”. The Speedometer indicates the 10,000 km (6213 mi).
vehicle’s speed in km/h or mph. To pass from one to the other, Contact an authorized service centre at soonest and strictly follow
press the “RESET” button. the instructions of the maintenance and check tables contained in
this manual. Press and hold the button (SELECT) for 15/20 secs.
15. RESERVE FUEL GAUGE. to turn the light off.
The digital fuel gauge shows the capacity of the fuel tank. As the
fuel level drops, the lines on the gauge will become closer 18. AMBIENT TEMPERATURE INDICATOR.
and closer to the "E" reserve area. It shows the ambient temperature. The value can be shown in
As soon as the final line starts to blink. degrees centigrade (°C) or in Fahrenheit (°F). The indication field
ranges from -30 and +50 (°C) or -22 e +122 (°F).
16. LIGHT (ABS).
The anti-lock braking system of brakes goes on when starting to 19. RIGHT DIRECTION INDICATOR LIGHT (GREEN).
check the system and turns off few metres after the setting off. It goes on when the right direction indicator light is activated.

15 10 4 1 6 8 19 7 13 9

11
16
5
17

14
12

18 3 2

1-5
 IMPORTANT INFORMATION

GETTING READY FOR REMOVAL AND DISAS-

SEMBLY OPERATIONS

• Before carrying out any removal and disassembly opera-

tions, remove any dirt, mud, dust or foreign bodies.

• Use only suitable cleaning tools and products.

See the paragraph “SPECIAL TOOLS”.

• While disassembling the vehicle, we recommend keeping

coupled parts together at all times. These parts include
gears, cylinders, pistons and other parts, whose surfaces
will be "coupled" during the normal wear and tear of work.
Coupled pieces must always be re-used or replaced in
groups. During the disassembly operation, clean all parts
and place them in a bowl, using the same order as for dis-
assembly. This will make reassembly operations easier and
allows for the correct installation of all parts.

• Keep all parts away from any source of heat.

SPARE PARTS

Use only Benelli original replacement parts. Use only oils and
grease recommended by Benelli to lubricate parts. Other brands
may look similar and operate in a similar manner, but will be of
lower quality.

1-6
 IMPORTANT INFORMATION

SEALS, O-RINGS, OIL SEALS, AND BEARINGS

Always replace all seals, oil seals and O-rings when carrying out
repairs to the engine.
olio E The seal surfaces, oil seal lips and O-rings must always be
labbro labbro motore clean.
During installation, always oil the coupled parts and bearings,
molla and lubricate the oil seal lips with engine oil.
olio

Insert the bearings and oil seals so that the brand or manufac-
a turer's number is facing outwards and visible. To install the oil
seal, lubricate the lips with a fine layer of engine oil.
Always apply plenty of oil to bearings when installing them.

a. Oil seal
b. Bearing
E

IMPORTANT NOTICE
b Never use compressed air to dry bearings, allowing them to turn,
as this will damage the surfaces.

SAFETY WASHERS/PLATES, COTTER PINS, AND

THREAD LOCKER

After removing, replace all of the safety washers "A", the safety
plates and cotters.
After tightening the bolt or nut according to specification, bend
the locking tabs and the ends of the cotter against the flat sides
of the nut.
A

Before applying the thread locker, always degrease both parts

with solvent.

1-7
 IMPORTANT INFORMATION

SAFETY SNAP RINGS

A
Before reassembling them, check all of the snap rings and re-
C place any that have become damaged or are out of shape.
Always replace the snap rings on the pin after using them once.
B When installing a snap ring “A”, make sure the sharp edge “B”
is positioned on the other side compared to the thrust “C” that it
receives.
"D" Shaft
D

CHECKING CONNECTIONS
1
Make sure that there are no marks, rust, moisture, etc. on wiring,
couplers, or connectors.

1. Disconnect:
• the wire
• the coupler
• the connector

2. Check:
2 • the wire
• the coupler
• the connector

If there are traces of moisture → Use a fan to dry.

If there is any rust/marks → Connect and disconnect the parts
several times.

3. Check:
3 • all connections
If there are any loose connections → Reconnect them properly.

NOTE:_________________________________
If the foot of the terminal “A” is bent, raise it.

1-8
IMPORTANT INFORMATION

4. Connect:
4 • the wire
• the coupler
• the connector

NOTE:_________________________________
Make sure all connections are installed tightly.

5. Check:
5 • continuity (using a pocket tester)

NOTE:_________________________________
If there is no continuity, clean the terminals.
For checking wiring, follow the procedure of points from “1” to ”3”.
As quick remedy, it is advisable to use a specific product for the
contacts, which is available in the spare part shops.

1-9
 SPECIAL TOOLS

The special equipment listed here serves for the complete, thorough performance of fine tuning and assembly operations.
The use of this equipment will help to prevent damage caused through using unsuitable tools or makeshift techniques.
When completing an order, please check the list below to avoid any errors.

ENGINE SPECIAL TOOLS

Tool Code Tool Name-Function Image
Pad for valve oil seal
This serves to insert the valve oil seal in
situ.
R180197025000

Clutch disassembly wrench

This serves to block the clutch drum and
loosen the nut.

0320097047000

Pad for piston pin removal

This tool serves to extract the piston pin.

Standard tool commonly found

Tool for valve oil seal removal

This tool serves to extract the valve oil
seal.
Standard tool commonly found

Ring clamp tool

This tool serves to assemble the piston
rings and for the subsequent insertion into
Standard tool commonly found the cylinder.

Gear selection drum assembly tool

This tool serves to assemble the gear se-
lection drum.

0320097051000

Flywheel extractor
This tool serves to extract the flywheel
from the engine shaft.
0320097045000

1 - 10
 SPECIAL TOOLS

ENGINE SPECIAL TOOLS

Tool Code Tool Name-Function Image
Flywheel cover extractor
This tool serves to extract the flywheel
housing cover.
0320097045000

Engine phasing tool

This tool serves to determine the position
of the top dead centre.
R180197022000

Oil filter tool

This tool serves to tighten or remove the
engine oil filter.
Standard tool commonly found

Chain tensioner lock tool

This tool serves to lock the tensioner pis-
ton while installing the chain tensioner.

0320097046001

Tool to remove/assemble the clutch bell

ring nut
This tool is used to disassemble/assemble
of the notched ring nut, which clamps the
03200097052000 clutch bell.

Valve spring compressor tool

This tool is used to remove the valve
springs.

0320097050000

Measuring tool commonly found

This tool is used to measure the inner di-
mensions of bores.
Standard tool commonly found

1 - 11
 SPECIAL TOOLS

ENGINE SPECIAL TOOLS

Tool Code Tool Name-Function Image
Measuring tool commonly found
This tool is used to measure the external
dimensions of parts.
Standard tool commonly found

Measuring tool commonly found

This tool is used to measure thicknesses.
Standard tool commonly found

Flywheel assembly tool

This tool serves to tighten the engine shaft
flywheel.

0320097044000

Tool to remove the magnetic cap from

the alternator cover
This tool serves to unscrew the magnetic
cap of the alternator cover.
0320097043000

Toothed wrench for clutch bell lock

This tool is used to disassemble the clutch
bell.

03200097053000

1 - 12
 SPECIAL TOOLS

SPECIAL FRAME TOOLS

Tool Code Tool Name-Function Image
Tool to tighten the steering sleeve lock
nut
This assembled tool is used to tighten the
lock nut securing the steering head.

R180297129000

Tool to tighten the front wheel axle pin

This tool serves to tighten the front wheel
axle pin.
Standard tool commonly found

Tool to extract the rear swing arm bear-

ings
This tool serves to extract bearings.
Standard tool commonly found

Jack
It allows to lift the frame and the engine.

Standard tool commonly found

1 - 13
Remarks
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2

2-1
 CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................................................................3
TECHNICAL DATA ........................................................................................................................................4
ENGINE SPECIFICATIONS .......................................................................................................................................................4
FRAME SPECIFICATIONS.........................................................................................................................................................9
ELECTRICAL SPECIFICATIONS .............................................................................................................................................13
GENERAL TIGHTENING SPECIFICATIONS ...........................................................................................................................17
TIGHTENING TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS ................................................18
TIGHTENING TORQUES .........................................................................................................................................................18

2-2
 GENERAL SPECIFICATIONS

SIZE STANDARD
Overall length (A) 2160 mm
Overall width (B) 875 mm
Overall height (C) 1160 mm
Wheelbase (D) 1460 mm

WEIGHT STANDARD
Kerb weight (with oil and fuel tank full) 207 kg
Maximum permissible load capacity
397 kg
(with rider and load)

D
A

2-3
 TECHNICAL DATA
ENGINE SPECIFICATIONS

ENGINE STANDARD
Type of engine 4 stroke, 2 cylinders in line,
liquid cooling, 8 valves
Cubic capacity 499.6 cc
Number of cylinders 2
Cylinder layout In line
Inside diameter × stroke 69x66.8 mm
Compression ratio 11.5:1
Idle speed 1400-1600
Distribution Double overhead camshaft, chain control,
with 4 valves per cylinder
Maximum net power 35 k/850 rpm (47.6 C.)
Max. net torque 45 N.m (4.58 Kgm) /6000 rpm

FUEL STANDARD
Recommended fuel premium unleaded petrol RON 95 min

ENGINE OIL STANDARD

Lubrication system forced, wet sump
Total amount 3l
Amount without oil filter cartridge replace-
2.8 l
ment
Amount with oil filter cartridge replace-
3l
ment
Recommended oil:

SAE 10W-50 API SJ-JASO

OIL FILTER STANDARD

Oil filter type Cartridge

OIL PUMP STANDARD

Oil pump type Lobe
Clearance between the inner and outer
0.25 mm max
rotor tips
Clearance between outer rotor and oil
0.2 mm max
pump

STARTING STANDARD
Ignition system type electrical

2-4
 TECHNICAL DATA
ENGINE SPECIFICATIONS

SPARK PLUGS STANDARD

Model (make) x quantity NGKCR8E
Spark plug gap 0.7 ÷ 0.8 mm

CYLINDER HEAD STANDARD

Head gasket maximum warping
0.03 mm

CAMSHAFTS STANDARD
Control system chain transmission
Camshaft diameter Ø 22.957-22.97 mm (Limit 22.94 mm)
Clearance between support and camshaft
0.03 - 0.060
follower
Clearance between camshaft and cam-
0.02-0.050mm
shaft seat
Camshaft radial clearance 0.01mm (Limit 0.02mm)
Camshaft lobe dimensions, intake side
B
Size “A”= 31.95 mm
Size “B”= 25.05 mm
A

Camshaft lobe dimensions, exhaust side

B
Size “A”= 31.95 mm
Size “B”= 25.05 mm
A

Maximum camshaft eccentricity

0.05 mm (0.0019 in)

FUEL STANDARD
Recommended fuel premium unleaded petrol RON 95 min

DISTRIBUTION STANDARD
CHAIN
Automatic tensioning system

2-5
 TECHNICAL DATA
ENGINE SPECIFICATIONS

VALVES, VALVE SEATS, VALVE GUIDES STANDARD

Intake valve clearance (cold) 0.15 ~ 0.20 mm
Exhaust valve clearance (cold) 0.20 ~ 0.25 mm

VALVE SIZE
Intake Ø 25 mm

A Exhaust Ø 22 mm
Head ”A” diameter

Intake 1.9 ~ 2.1 mm

B

Exhaust 1.75 ~ 1.95 mm

Ground surface width ”B”

Intake 1 ~ 1.1 mm
C
Contact bands width ”C” Exhaust 1 ~ 1.1 mm

Intake 3.965 ~ 3.98 mm

Valve stem diameter
Exhaust 3.965 ~ 3.98 mm
Clearance between valve stem and valve guide Intake 0.03 ~ 0.045 mm
Exhaust 0.035 ~ 0.05 mm

0.01 mm
Valve stem eccentricity

VALVE SPRINGS STANDARD

Intake 38.8 mm
Intake/exhaust effective length
Exhaust 41.6 mm

Intake 1.2 mm

Exhaust 1.2 mm

CYLINDERS STANDARD
Cylinder layout parallel inline
Bore 69.00-69.01mm (limit 69.02mm)
Compression ratio 11.5:1
Maximum ovalization 0.05
Maximum taper 0.05

2-6
 TECHNICAL DATA
ENGINE SPECIFICATIONS

PISTON STANDARD
Clearance between piston and cylinder 0.03 ~ 0.05 mm
- 0.002
Piston diameter “A” Ø 69 - 0.003 mm
C
Piston height “B” 25 mm
B
A + 0.002
Pin seat diameter "C" Ø 17 + 0.003 mm

Piston pin outside diameter 0

Ø 17 - 0.008 mm

Top band

B Band type elastic

Overall dimensions
A “B” X ”A”
1 x 2.45 mm

2nd band

B Band type elastic

Overall dimensions
A “B” X ”A”
1 x 2.50 mm

Oil scraper ring

B
Overall dimensions 0.30X1.70 mm
“B” X ”A” 1,30X1,90 mm
A

CONNECTING RODS STANDARD

Bearing colour codes A = Red B = Blue C = Yellow
Rod weight code K1 = Black K2 = Green K3 = White
K4 = Brown K5 = Orange

DRIVE SHAFT STANDARD

C
A
Width “A” 133.10 mm
Diameter “B” 37.99 - 37.95 mm
Side clearance of connecting rod big end 0.1 - 0.25
“C”
Main bearing colour code A = Red B = Blue C = Yellow

2-7
 TECHNICAL DATA
ENGINE SPECIFICATIONS

CLUTCH STANDARD
Clutch type oil bath clutch, multiple discs
Clutch release method wire cable and spring
Clutch release action wire cable action
Operation with left handlebar lever
Clutch cable clearance (at the ends of the clutch lever) 2 ~ 3 mm
Friction plate thickness 2.8 ± 0.05 mm - 3 (0. - 0.1) mm
Number of friction plates 8
Steel disc thickness 1.6 (0. -0.05) mm
Steel disc thickness 7
Disc pack thickness 11.2 mm
Max. warping 0.05 mm
Friction spring effective length 40 ± 0.01 mm
Spring quantity 4

TRANSMISSION STANDARD
Transmission type Straight tooth gear
Main reduction ratio 41/71
Secondary reduction system
Transmission ratio Chain, ratio 14:43
1st 13-37
2nd 19-37
3rd 18-28
4th 24-32
5th 21-25
6th 24-26

GEAR CONTROL MECHANISM STANDARD

Type of gear control mechanism sequential with desmodronic drive and prese-
lector
Maximum warp on gear control rod Straightness 0.02
Roundness 0.005

AIR FILTER STANDARD

Air filter type PAPER

FUEL PUMP STANDARD

Pump type electric pump
Model (make) Delphi
Output pressure 250 KPa

THROTTLED BODIES STANDARD

Diameter 37 mm
Accelerator cable clearance (at the accelerator handgrip 2-3 mm
flange)

2-8
 TECHNICAL DATA
FRAME SPECIFICATIONS

FRAME STANDARD
Front one with steel pipe truss and rear one with
Frame type
steel pipes

FRONT WHEEL STANDARD

Wheel type Aluminium alloy
Size 17 M/C x MT 3.50 DOT-D
Rim
Material aluminium
Wheel travel 125 mm

REAR WHEEL STANDARD

Wheel type Aluminium alloy
Size 17 M/C x MT4.50 Dot -D
Rim
Material aluminium
Wheel travel 128 mm

FRONT TYRE STANDARD

Tyre type tubeless
Size 120/70ZR17 M/C(58W)
Model (manufacturer) N/A
Cold tyre pressure 2.20 KPa

REAR TYRE STANDARD

Tyre type tubeless
Size 160/60ZR17 M/C (69) W
Model (manufacturer) N/A
Cold tyre pressure 2.50 KPa

2-9
 TECHNICAL DATA
FRAME SPECIFICATIONS

FRONT BRAKE STANDARD LIMIT

Brake type half-floating double disc brake
Activation use right hand
Recommended liquid DOT 4
Brake discs
Diameter × Thickness 320 x 5 mm (12.5 x 0.15in)
Minimum thickness 4.5mm (0.17in)
Maximum deformation 0.15mm
Thickness of worn brake
4 mm (0.15 in) 1 mm (0.039 in)
pads
Inside diameter of pump cylinder 16 mm (0.62in)
Inside diameter of calliper cylinder 34 and 34 mm (1.33 and 1.33 in)

REAR BRAKE STANDARD LIMIT

Brake type 1 single disc brake
Activation use right foot
Recommended liquid DOT 4

Brake discs
Diameter × Thickness 260 x 5 mm
Minimum thickness 4.5mm (0.17 in)
Maximum deformation 0.15mm (0,006 in)
Thickness of worn brake
4 mm (0.15 in) 1 mm (0.039 in)
pads
Inside diameter of pump cylinder 12 mm -12.7 mm
Inside diameter of calliper cylinder 34 mm

2 - 10
 TECHNICAL DATA
FRAME SPECIFICATIONS

FRONT SUSPENSION STANDARD

Suspension type Upside-down fork with 50 mm diameter tubes
Wheel travel 125 mm
Spring
Free length 295 mm
Shim length 137 mm
Flexibility (K1) 8.6 Nm
Spring stroke (K1) 0 ~ 120mm (0 ~ 4.72in)
Fork oil
Recommended oil SAE 7.5 Marzocchi 19
Quantity for tube 770cc.
Level (from the top of the
external tube, with the
external tube totally com- 95 mm
pressed and without the
fork spring)

STEERING STANDARD
Steering bearings type ball bearing
Angle from one end of stroke to the other (left) 30°
Angle from one end of stroke to the other (right) 30°

2 - 11
 TECHNICAL DATA
FRAME SPECIFICATIONS

REAR SUSPENSION STANDARD

Steel-alloy swing arm, GAS shock absorber with
Suspension type
adjustable hydraulic extended and preloaded spring
Shock absorber travel 45 mm
Spring
Free length 178+/- 1.5 mm
Shim length 167+/- 1.5 mm
Flexibility (K1) 16 Nm
Spring stroke (K1) 42+/- 1 mm
Gas standard pressure 1200 kPa (12 bar)
Spring preload adjust-
ment positions
Minimum 0
Standard 0
Maximum 5 mm (0.19in)
Rebound damping
adjustment positions Minimum* 0
Standard* 4 clicks from fully closed
Maximum* - 30
* from the fully retracted position

TRANSMISSION CHAIN STANDARD

Model (manufacturer) Benelli
Number of links N/A
Slackness of transmission chain N/A

2 - 12
 TECHNICAL DATA
ELECTRICAL SPECIFICATIONS

SYSTEM VOLTAGE STANDARD

System voltage 12 V

IGNITION COILS STANDARD

Wheel type Aluminium alloy
Wheel travel 125 mm

REAR WHEEL STANDARD

Model (manufacturer) QJ
Resistance of primary coil 0.65 ± 0.07 Ohm
Resistance of secondary coil 4 ± 0.5 kOhm
Inductance of primary coil 1.8 mH
Inductance of secondary coil 4.7 H
Max. permissible current value 10 A

CHARGING SYSTEM STANDARD

System type AC Magnetic
Model (manufacturer) QJ
Rated Power 12 V at 4000 rpm
Voltage adjustment 13.5 + 0.5 V (3000 rpm 25 C°)

STARTING RELAY STANDARD

Model (manufacturer) QJ
Amperage 100 A
Coil resistance 4.4 Ohm at 20°C

BATTERY STANDARD
Model (manufacturer) YTX9-BS
Voltage of battery capacity 12 V 8 Ah
CCA inrush current 120A

HEADLAMP STANDARD
Type of headlamp LED

LAMPS (VOLTAGE WATT x QTY) STANDARD

Headlamps (High/Dipped beam) LED
Front position indicator light LED
Rear position indicator light/brake light LED
Indicator lights LED
License plate light 12 V 5 W x 1
Instrument panel light LED x 1

LIGHTS (VOLTAGE WATT x QTY) STANDARD

Neutral indicator light LED x 1
High beam indicator light LED x 1
Oil level warning light LED x 1
Indicator light LED x 1
Engine fault signal light LED x 1

2 - 13
 TECHNICAL DATA
ELECTRICAL SPECIFICATIONS

ELECTRIC IGNITION SYSTEM STANDARD

Model (manufacturer) QJ
Power output 0.7kw

HORN STANDARD
Horn type low
Model (manufacturer) QJ
Maximum amperage 3A
Performance 105~ 118db (A)

FLASHERS RELAY STANDARD

Relay type Electronic Flasher
Model (manufacturer) QJ 600 45 Flasher
Flashing frequency of indicator lights 80 ~160cycle/min
Watt 130 mA x4

OIL PRESSURE SENSOR STANDARD

Model (manufacturer)/Setting 0.05 ± 0.015MPa

2 - 14
 TECHNICAL DATA
ELECTRICAL SPECIFICATIONS

FUSES (amperage×quantity) STANDARD

Fuse CD1 (ECU) 15 A (Blue)
Fuse lights 15 A (Blue)
Service fuse 15 A (red)
Fuse of the radiator fan 15 A (Blue)
Ignition coil fuse 10 A (Blue)
Fuel pump fuse 15 A (Blue)
ABS motor fuse 40 A (Blue)

THROTTLED BODY SENSOR STANDARD

Model (manufacturer) TGKEYAIR
Resistance 2 KOhm ± 20%

FUEL PUMP STANDARD

Max. amperage/Pressure 2 ± 0.5 A /3 bar
Level sensor external
Min./Max. resistance 90-95 Ω (empty) - (full) 0-18Ω

SAFETY SWITCHES STANDARD

Stand switch N/A
Neutral switch QJ
Tilt QJ 250T-3(QJ)

AIRBOX AIR TEMPERATURE STANDARD

SENSOR
Model (manufacturer) 12160244 (PACKARD)
Resistance 181±8 Ohm 100°C

THROTTLED BODY AIR PRES- STANDARD

SURE SENSOR
MODEL (manufacturer)/Power supply voltage 240600695(DELPHI) /5V

2 - 15
 TECHNICAL DATA
ELECTRICAL SPECIFICATIONS

FLUID TEMPERATURE SENSOR STANDARD

Model (manufacturer) WC -12A (QJ)
Resistance 100 °C 178 Ohm

SPEED SENSOR STANDARD

Model (manufacturer)/GAP 1.1 mm - 2.2 mm

OXYGEN SENSOR STANDARD

Model (manufacturer) OSM (Delphi)

INJECTOR STANDARD
Model (manufacturer) Mini (Delphi) 12±1 Ω

RELAY ASSEMBLY STANDARD

Model (manufacturer) CM1 NAIS

IGNITION SYSTEM STANDARD

Ignition system type BOSCH MSE6.0
Ignition timing 10° before TDC from 900 at 1800 r/min
Phonic wheel sensor (Pick-up) 550±50Ω
Model (manufacturer) DELPHI

STEPPER STANDARD
Model (manufacturer) LOREADA
Stepper type Dual-phase

RADIATOR FAN STANDARD

Model (manufacturer)/Electric consumption Panasonic SSW7109/ 2.76A @ 12V

2 - 16
 TECHNICAL DATA
GENERAL TIGHTENING SPECIFICATIONS

The tightness torques for parts or special assemblies are provid-

ed in each chapter of this manual.
As far as concerns assemblies with multiple fastening elements,
in order to avoid the risk of warping, cross-tighten the parts in
successive stages until the required torque is achieved.
Unless otherwise stated, tightness torques refer to parts with
B clean, dry threads.
A Parts must be at ambient temperature.

“B” GENERAL TIGHTENING

NUT TORQUES
N.m Kgf.m
4 mm 2.3 0.23
5 mm 4.5 0.45
6 mm 10 1.01
8 mm 25 2.54
10 mm 45 4.58
12 mm 80 8.15
14 mm 130 13.25
16 mm 200 20.39
18 mm 240 24.47

2 - 17
 TECHNICAL DATA
TIGHTENING TORQUES

TIGHTENING TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS

The values given in the following table refer to standard tightness, i.e., for metric screws coupled with the relevant nut, or with screw
nut in metal.
The bodies to be tightened must be metal or sufficiently rigid not to required the insertion of bushing or shims.
Coupling is always made with the thread slightly oiled or greased; alternatively, the type of thread locker required must be stated.
Axial preloads related to tightening torque have increased by 10% compared to the value calculated, to take into account the toler-
ance on the nominal torque and the variation that the friction coefficient may undergo from tightening to tightening.

CLASS 8.8 CLASS 10.9 CLASS 12.9

SCREW TIGHTENING AXIAL TIGHTENING AXIAL TIGHTENING AXIAL
TORQUE PRELOAD TORQUE PRELOAD TORQUE PRELOAD
[Nm] [N] [Nm] [N] [Nm] [N]
M4 X 0.7 3 3.870 4.2 5.420 5.2 6.710
M5 X 0.8 6 6.350 7.5 7.930 9 9.520
M6 X 1 10 8.860 13 11.520 16 14.180
M8 X 1.25 22 14.900 30 20.330 40 27.100
M8 X 1 (*) 25 17.280 36 24.890 45 31.110
M10 X 1.5 45 24.680 65 35.640 80 43.870
M10 X 1.25 (*) 50 27.870 70 39.013 85 47.380
M12 X 1.75 80 37.640 110 51.750 135 63.510
M12 X 1.5 (*) 85 40.547 120 57.250 145 69.170
M12 X 1.25 (*) 90 43.550 130 62.900 150 72.580
M14 X 2 130 52.670 185 74.800 220 88.950
M14 X 1.5 (*) 150 62.900 205 85.960 245 102.780
M16 X 2 200 74.070 280 103.690 335 124.060
M16 X 1.5 (*) 225 86.140 310 118.680 360 137.820
M18 X 2.5 265 83.650 370 116.790 450 142.040
M18 X 1.5 (*) 320 104.900 450 147.520 550 180.300
M20 X 2.5 390 111.870 550 257.770 650 186.450
M20 X 1.5 (*) 440 130.620 630 187.020 750 222.650
M22 X 2.5 540 141.950 750 197.150 900 236.580
M22 X 1.5 (*) 600 162.750 850 230.560 1.000 271.240
M24 X 3 670 160.238 950 227.203 1.130 270.252
M24 X 2 (*) 750 184.566 1.050 258.392 1.250 307.610

(*) The metric screw named has a fine pitch.

2 - 18
3

3-1
 CHAPTER 3
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ...................................................................5
MAINTENANCE INTERVALS .....................................................................................................................................................6
ENGINE/AIR BOX ..........................................................................................................................................9
AIR BOX REMOVAL /INSTALLATION ........................................................................................................................................9
ENGINE/THROTTLE CABLE CLEARANCE...............................................................................................11
THROTTLE CABLE CLEARANCE ADJUSTMENT ..................................................................................................................11
ADJUSTMENT OF IDLE SPEED..............................................................................................................................................14
ENGINE/CLUTCH CABLE...........................................................................................................................15
CLUTCH CABLE CLEARANCE ADJUSTMENT.......................................................................................................................15
FRAME/HANDLEBAR .................................................................................................................................16
REAR-VIEW MIRROR ADJUSTMENT .....................................................................................................................................16
ENGINE/ENGINE OIL ..................................................................................................................................17
ENGINE OIL LEVEL CHECK ....................................................................................................................................................17
ENGINE OIL CHANGE .............................................................................................................................................................18
OIL FILTER REMOVAL/INSTALLATION ...................................................................................................................................19
ENGINE/SPARK PLUGS .............................................................................................................................20
REMOVAL OF SPARK PLUGS FROM VEHICLE.....................................................................................................................20
SPARK PLUG CHECK..............................................................................................................................................................21
SPARK PLUG INSTALLATION .................................................................................................................................................23
ENGINE/VALVE CLEARANCE CHECK ......................................................................................................24
VALVE CLEARANCE ADJUSTMENT .......................................................................................................................................24
FRAME/BRAKE ADJUSTMENT .................................................................................................................27
FRONT BRAKE ADJUSTMENT ...............................................................................................................................................27
ADJUSTMENT OF THE REAR BRAKE ...................................................................................................................................28
FRAME/BRAKE FLUID LEVEL CHECK .....................................................................................................29
FRONT BRAKE FLUID LEVEL CHECK/TOP UP .....................................................................................................................29
CHECK REAR BRAKE FLUID LEVEL/TOP UP .......................................................................................................................30
FRAME/ABS PIPE CHECK .........................................................................................................................31
CHECK FOR ANY LEAKS FROM ABS TUBES .......................................................................................................................31
FRAME/BRAKE PAD CHECK .....................................................................................................................32
CHECK FRONT AND REAR BRAKE PADS FOR WEAR ........................................................................................................32
FRAME/BRAKE SYSTEM HOSE CHECK ..................................................................................................33
HOSE CHECK ..........................................................................................................................................................................33
FRAME/TRANSMISSION CHAIN ................................................................................................................34
TRANSMISSION CHAIN CLEARANCE ADJUSTMENT ..........................................................................................................34
TRANSMISSION CHAIN LUBRICATION .................................................................................................................................35
CHAIN GUIDE CHECK .............................................................................................................................................................35
TRANSMISSION CHAIN WEAR CHECK .................................................................................................................................36
TRANSMISSION CHAIN PINION CHECK ...............................................................................................................................37
FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE ................................................................38
CHECK/ADJUSTMENT OF STEERING CLEARANCE ............................................................................................................38
FRAME/FRONT FORK CHECK ..................................................................................................................41
FRONT FORK CHECK .............................................................................................................................................................41
FRAME/FRONT FORK CHECK ..................................................................................................................42
FRONT FORK EXTENSION BRAKE ADJUSTMENT...............................................................................................................42
FRAME/REAR SHOCK ABSORBER CHECK ............................................................................................43
SHOCK ABSORBER ADJUSTMENT .......................................................................................................................................43
FRAME/FRONT/REAR TYRE CHECK ........................................................................................................44
TYRE CHECK ...........................................................................................................................................................................44

3-2
 CHAPTER 3
ELECTRICAL SYSTEM ...............................................................................................................................45
BATTERY CHECK AND CHARGE ...........................................................................................................................................45
FUSES ......................................................................................................................................................................................53
FUSE CHECK ...........................................................................................................................................................................54
HEADLIGHT REPLACEMENT .................................................................................................................................................55
HEADLIGHT ADJUSTMENT ....................................................................................................................................................56
LED REAR LIGHT REPLACEMENT ........................................................................................................................................57
REAR INDICATOR LIGHT REPLACEMENT ............................................................................................................................58
FRONT INDICATOR LIGHT REPLACEMENT..........................................................................................................................59
IGNITION BLOCK REPLACEMENT .........................................................................................................................................60
INSTRUMENT PANEL REPLACEMENT ..................................................................................................................................61
INSTRUMENT PANEL INSTALLATION ....................................................................................................................................62

3-3
REMARKS:
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3-4
 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

NOTE:___________________________________________
In general, maintenance needs to be carried out with the motorcycle on the rear stand, engine off and switch set to OFF.
While checking fluid levels, it is preferable to keep the motorcycle upright without using the rear stand.
Checks need to be made every year, except in cases where maintenance inspections are carried out as part of services linked
to mileage.
Once at 40,000 (24,854 mi), repeat services, commencing from the 13,000 service (8,077 mi). For interventions relating the
items marked, it is advisable to contact a Benelli dealer, given that it is necessary to have specific equipment, information,
and technical skills.

The following section shows all of the maintenance operations.

NOTE:___________________________________________
AIR FILTER
• The air filter needs to be replaced more often when using the vehicle in particularly damp or dusty environments.

HYDRAUILC BRAKE MAINTENANCE

• Check brake fluid levels on a regular basis and top up as necessary.
• Every two years, replace the parts inside the brake pump and callipers. Change the brake fluid.
• Replace brake hoses every 4 years, or before if cracked or damaged.

KEY: PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

I Inspection and adjustment, cleaning, lubrication or replacement, as needed.
R Replacement
T Tighten
Dealer

3-5
 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
MAINTENANCE INTERVALS

1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km

0 Km Annual
Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi)
NO. Part (0 mi) inspec-
nance interventions 1st 2nd 3rd 4th 5th
Pre-delivery tion
Service Service Service Service Service

Check/Top up/Change I R R R R R R
1 Engine oil
Check every 500 km (310 mi).
Replacement R R R R R
2 Oil filter
Or at any engine oil change
Check/Replacement I I R I
3 ◙ Fuel filter

Check/Replacement R R R R
4 ◙ Air filter

Check/Top up I I I I R I I
5 ◙ Cooling fluid
Replace Every 2 years or 13,000 km (8,078 mi)
Check the level of the
cooling fluid.
Cooling I I I I I I I
6 ◙ make sure there are no
system
leaks
of fluid from the vehicle.
Check/Replacement I I R I I
7 ◙ Spark plugs
Check the conditions, clean and restore the spark plug gap.
Check chain tension. I I I I I I
Make sure that the
Transmission
8 ◙ rear wheel is correctly
chain
aligned. Clean and Every 500 km (310 mi) and after every wash or if the motorcycle was used in the rain.
grease.
Check/Lubricate I I I I I I
9 ◙ Chain wheel
Replace every time the chain is replaced.
Pinion/Re- I I I I I I
10 ◙ taining Check/Replacement
washer Replace every time the chain is replaced.

Fuel circuit Check for faults and I I I R

11 ◙
hoses leaks. Replace in any case every 3 years.
Brake fluid Check/Top up I I I I I I I
12 ◙
* clutch Replace Replace every 2 years.

Check function and fluid

level and make sure I I I I I I I
Front brake/
13 ◙ there are
Rear brake
no leaks form the
vehicle.

Check/Replacement I I I I I
14 ◙ Brake pads
Replace if worn up to limit.
Swing arm Check/Replacement I I I I I
15 ◙
chain slide Replace if worn up to limit.
Swing arm Check/Replacement I I I I I
16 ◙ chain guide
slide Replace if worn up to limit.
Check operation and if I I I I I I I
necessary, adjust the
Throttle throttle cable clearance.
17 ◙
handgrip Lubricate the throttle
grip housing and the
cable.
Check operation/Adjust
Throttled I I I I I
18 ◙ clearance
body

Clutch Check/Adjustment I I I I I I I
19 ◙
control
Throttled Check/Adjustment I I I I I
20 ◙
body

3-6
 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
MAINTENANCE INTERVALS

1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km

0 Km Annual
Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi)
NO. Part (0 mi) inspec-
nance interventions 1st 2nd 3rd 4th 5th
Pre-delivery tion
Service Service Service Service Service

Check operation/Adjust
Valve clear- I
21 ◙ clearance
ance
Check clearance every 25,000 km.
Distribution Check/Replacement R
22 ◙
chain Every 25,000 Km (15,534 m)
Distribution Check/Replacement R
23 ◙
chain slides Each distribution chain replacement, every 22,000 km (13671 mi)
Distribution Check/Replacement R
24 ◙ chain
tensioner Each distribution chain replacement, every 22,000 km (13671 mi)
Steering Check/Adjustment T T T T T T T
25 ◙ ring nut and
sleeve
Steering Check/Replacement T T
26 ◙
bearings Lubricate with a lithium-based grease every 19,000 km.
Front/rear Check/Replacement I I
27 ◙ wheel bear-
ings Every 40,000 km (24900 mi)

Swing arm Check/Replacement I I I R

28 ◙
bearings Every 25,000 km (14904 mi)
Check operation and I I I I
make sure there is no
29 ◙ Swing arm excessive is no exces-
sive
clearance. Lubricate.
Check function and I I I I I I
Front sus-
30 ◙ make sure there are no
pension
leaks.
Front sus- R R
31 ◙ Replacement
pension oil

Check/adjust, make I I I I
Rear suspen-
32 ◙ sure that
sion
there are no leaks.
Before every use of the vehicle.
Make sure they are not I I I
33 ◙ Wheels off centre
or damaged. Every 19,000 Km (11,806 m)
Check the depth of I I I I I I
tread and make sure
they are not damaged.
34 ◙ Tyres Replace, if necessary.
Check inflation pres- Replace if worn to the limit.
sure.
Adjust, if necessary.
Check/Operation I I I I I I I
35 ◙ Side stand

Switch Check/Operation I I I I I I I
36 ◙
Side stand
Instruments, Check/Operation I I I I I I I
lights, indica-
37 ◙
tor lights, and
switches
Check/Operation I I I I I I
38 ◙ Headlamp
Adjustment At every change in vehicle set-up
Check/Operation I I I I I I I
39 ◙ Horn

Instrumen- Check/Operation I I I I I I I
40 ◙
tation
Battery Check/Operation I I I I I I I
41 ◙
connections

3-7
 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
MAINTENANCE INTERVALS

1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km

0 Km Annual
Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi)
NO. Part (0 mi) inspec-
nance interventions 1st 2nd 3rd 4th 5th
Pre-delivery tion
Service Service Service Service Service

Electrical Check/Operation I I I I I I I
42 ◙
System
Ignition Check/Operation I I I I I I I
43 ◙
switch
Check/Operation I I I I I I I
44 ◙ Electric fans

Check I I I I I I I
45 ◙ Fuel /CO*
Every 13,000 km (8,077 mi)
Make sure all nuts, bolts T T T T T T
Chassis
46 ◙ and screws are correctly
fasteners
tightened.
Oil sump Replacement T T T T T
47 ◙
screws
Clutch cover T T T T T
48 ◙ Replacement
screws
Catalytic Check for faults and I I I I I
49 ◙
converter leaks. No maintenance required. In case of malfunction replace.
I I I I R
Canister USA Check for faults and
50 ◙
version leaks. No maintenance required. In case of malfunction, replace.

I I I I I I I
Brake/clutch Check for faults and
51 ◙
hoses leaks. Every 4 years

Check/Replacement I I I I I I I
Parts and
52 ◙ wires subject
to movement Before every use of the vehicle.

Oil intake Check/Replacement I I I I

53 ◙
filter

3-8
 ENGINE/AIR BOX
AIR BOX REMOVAL /INSTALLATION

10
3
17 13 2
10
1
15 11
12
10 16
10
8

8
7

2 2 8 14
9

6 4
8
5

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
1 COMPLETE AIR FILTER BOX
2 SCREW
3 AIR TEMPERATURE SENSOR
4 SCREW BAND
5 HOSE
6 HOSE HOLDER CLIP
7 CARTRIDGE FILTER
8 SPRING BAND
9 HOSE
10 SPRING BAND
11 HOSE
12 NON-RETURN VALVE
13 HOSE
14 HOSE
15 VALVE
16 PLATE
17 AIR FILTER

3-9
 ENGINE/AIR FILTER
AIR FILTER REMOVAL/INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Fuel tank, refer to the section “Fuel tank removal, Chapter
4.”.
1
• The screws (1) Fig. A. 2
• The cover (2) Fig. A.
Remove:
• The protection mesh (3) Fig. B.
• The filter element (4) Fig. B.

IMPORTANT NOTICE B
Replace filter element every 6,000 km. If the vehicle is used
in particularly humid climates or in very dusty areas, the air
filter must be substituted more often.

Check:
If the filter element is damaged, replace.

Installation: 3
1. During the installation stage, follow the steps for removing
4
the filter, as described above, only this time in reverse order.

IMPORTANT NOTICE
During the installation stage, be careful to assemble the filter
and mesh in the direction show in Fig. B.

WARNING
Never start the engine if the air filter is not mounted. Unfil-
tered air causes rapid wear to engine parts and might dam-
age the engine. Furthermore, using the engine without air
filter has a negative impact on the fine tuning of the throttles
and this will worsen of engine performance, as well as caus-
ing engine overheating.
Therefore ensure that the air filter is always in a good con-
dition.
The engine life depends mainly on this part.

3 - 10
 ENGINE/THROTTLE CABLE CLEARANCE
THROTTLE CABLE CLEARANCE ADJUSTMENT

4
5 6
7
8
2

14

9 1
13

12

3
15
16 11 10 8 7
9 6 5 4

22
25 ABS

22
20 24 18
19
21 26

23
17

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
1 REAR-VIEW MIRROR (LEFT)
2 REAR-VIEW MIRROR (RIGHT)
3 HANDLEBAR
4 SCREW
5 ELASTIC WASHER
6 WASHER
7 BALANCE BLOCK
8 HANDGRIP CAP
9 HANDGRIP END
10 LEFT HANDGRIP
11 LEFT LIGHTS SWITCH
12 RIGHT LIGHTS SWITCH
13 ACCELERATOR CONTROL
14 RIGHT HANDGRIP
15 ACCELERATOR OPENING CABLE
16 ACCELERATOR CLOSURE CABLE
17 CLUTCH CABLE
18 CLUTCH CONTROL
19 RUBBER BAND
20 CABLE GLAND
21 CLUTCH CONTROL LEVER
22 SCREW
23 SPECIAL NUT
24 SPECIAL SCREW

3 - 11
 ENGINE/THROTTLE CABLE CLEARANCE
THROTTLE CABLE CLEARANCE ADJUSTMENT

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
25 CLUTCH SWITCH
26 ABS SWITCH

3 - 12
 ENGINE/THROTTLE CABLE CLEARANCE
THROTTLE CABLE CLEARANCE ADJUSTMENT

NOTE:___________________________________________
Before adjusting the throttle cable clearance, it is necessary
A
to set the idle state of the engine.
Check initially at 1000 km (621 mi) and then every 600 km
(6,213 mi).

Check:
• The throttle cable clearance (1)
Make sure the throttle handgrip works smoothly. Furthermore, 1
check that the max opening position and the automatic closing
one can be reached in any steering position. If outside range,
adjust, Fig. A.

Throttle cable
Dimensions
clearance (A) B
Throttle cable 2 - 3 mm

Adjust:
• throttle cable clearance.
Handlebar side
1. Loosen the locknut “2”.
2. Turn the adjustment nut “3” clockwise or anticlockwise until
the throttle cable clearance meets specifications, Fig. B.
Throttle cable clearance Clearance
Clockwise Increases clearances 3
2
Counter-clockwise Reduces clearance

3. Tighten the lock nut ”2”.

Make the adjustment to both acceleration controls.

WARNING
After adjusting the throttle cable clearance, start the engine
and turn the handlebar right and left, making sure that the
minimum idle speed of the engine does not change.

3 - 13
 ENGINE/THROTTLE CABLE CLEARANCE
ADJUSTMENT OF IDLE SPEED

Check:
• Start the engine and let it warm up.
A
• Loosen the lock nut “1” and turn the adjustment screw ”2”
until the engine turns over at the right idle speed. Fig. A
• Accelerate and decelerate a few times to make sure the idle 1
speed is within the indicated range. Adjust again, if neces-
sary.

Throttle cable clearance mm 2

Throttle cable clearance (at
3 ~ 5 mm (0.11 ~ 0.19 in)
throttle handgrip flange).

Idle speed rpm

STANDARD 1,400 -1,600

WARNING
If the handlebar movement leads to variations in the idle
speed, the throttle cables may be adjusted or routed improp-
erly or be damaged.
Correct these anomalies before use.

IMPORTANT NOTICE

The use of the vehicle with damaged or improperly adjusted/

routed cables may jeopardize driving safety.

3 - 14
 ENGINE/CLUTCH CABLE
CLUTCH CABLE CLEARANCE ADJUSTMENT

Check: A
• The clutch cable clearance (1) Fig. A.
If outside range, adjust.

Clutch cable clearance Clearance distance

Clutch lever (1) 3 - 4 mm

Adjust:
• Clutch cable clearance.
Handlebar side 1
1. Move the clutch cable cowling.
2. Loosen the ring nut ”2”.
3. Turn the adjustment nut “3” clockwise or anticlockwise until
the clutch cable clearance meets specifications, Fig. B. B
Clutch cable clearance Clearance
Clockwise Increases clearances
Counter-clockwise Reduces clearance

4. Tightening the ring nut ”2” Fig. B.

NOTE:___________________________________________
If the specified clearance of the clutch cable cannot be ob- 3
tained on the handlebar side, use the adjusting nut on the
engine side ”E” Fig. C. 2
1. Prise the dust seal in the middle of the clutch cable.
2. Loosen the lock nut “4” in the middle of the clutch cable.
3. Turn the adjustment nut “5” until the clearance is correct.

4 5

3 - 15
 FRAME/HANDLEBAR
REAR-VIEW MIRROR ADJUSTMENT

The following procedure refer to both rear-view mirrors. A

Install:
1. Screw the mirror (1) on the lever body (2). 1
2. Move the nut to the end of its travel (3).
3. Adjust the mirror position by turning it to the required posi-
tion. 4
4. Tighten the lock nut ”4.”.

3
NOTE:___________________________________________
Carry out the same procedure also with the right mirror.

3 - 16
 ENGINE/ENGINE OIL
ENGINE OIL LEVEL CHECK

Park: A
• the motorcycle on a level surface.

NOTE:___________________________________________
• Place the motorcycle on a suitable support.
• Make sure it is in upright position.
MAX
Start:
• The engine. MIN
Leave it to warm up for a few minutes and then turn it off.
1
IMPORTANT NOTICE

Do not start the engine if the oil level is below the MIN level
shown on the gauge “1”.
3. Turn the oil cover back to its original position.
Check:
• The engine oil level. NOTE:___________________________________________
The engine oil level must be within the references of the mini- To check the engine oil level again, restart the engine, warm
mum (MIN) and maximum (MAX) level marks. it up for some minutes and then turn it off. Wait some min-
If below the minimum level mark, top up to the correct level with utes to allow the oil to flow downwards.
the recommended engine oil.

Recommended oil
SAE 10 W-50 API SJ - JASO MA

Adjust:

To top up with engine oil:

1. loosen the oil cap with the engine turned off.
2. Pour some oil of the recommended type so that the oil level
rises to somewhere between the MAX and MIN level marks.
Fig. A.

NOTE:___________________________________________
The engine contains approx.ly 3.5 l of oil.
Use oil rated API-SJ SAE 10W/50.

IMPORTANT NOTICE

Owing to the fact that the engine oil lubricates also the
clutch, it may cause the clutch slipping if it is not suitable
or contains additives. Therefore, it is advisable not to add
chemical additives and not to use types of oil other than the
one indicated in the table of the engine technical specifica-
tions.
The engine oil, whether new or waste, can be hazardous.
In case of swallowing, it can be noxious for people and
pets. In the event of swallowing, seek medical aid imme-
diately; do not induce vomiting to avoid aspiration of the
product into the lungs. Short contacts with the engine oil
may irritate skin.
• Keep the engine oil out of reach of children and pets.
• Wear long-sleeve clothing and waterproof gloves when
topping up the engine oil.
• Wash with water and soap in the event the engine oil
comes into contact with skin.
• Recycle or dispose the waste oil properly.

3 - 17
 ENGINE/ENGINE OIL
ENGINE OIL CHANGE

Start:
• the engine and leave it to warm up for a few minutes before
A
switching it off.
Remove:
• the oil filler cap ”1” Fig. A.
Position:
• a suitable container underneath the drainage for oil recov-
ery Fig. B.
NOTE:___________________________________________
Oil should first be replaced at 1000 km (621 mi) and then ev-
ery 6000 km (3,726 mi).
1
IMPORTANT NOTICE

Waste oil are environmentally unfriendly.

Dispose waste oil according to applicable law.

B
Remove:
• The magnetic cap “2” (together with the copper seal).
Drain:
• The engine oil from the crankcase.

NOTE:___________________________________________
Replace also the oil filter cartridge.

Replace:
• The magnetic cap seal.
Install:
• The new seal.
2
• The magnetic cap.
Tighten the magnetic cap to the following torque:

T. R .
C
Torque 22 N*m

Fill:
• The crankcase with the recommended engine oil with the MAX
specified amount.
Install:
• The oil cap “1” Fig. A. MIN
Start:
• The engine. 3
Leave it to warm up for a few minutes and then turn it off.

NOTE:___________________________________________
Always make sure that the level is halfway between the MIN
and MAX marks on the gauge “3”, Fig. C.
D
SAE GRADING
Top up the engine oil, if necessary. FOR ENGINE OILS RECOMMENDED ACCORDING TO OUTSIDE TEMPERATURES

Recommended engine oil:

Rating: API SJ-JASO MA2
Viscosity: 10W50
Capacity: 3 l (without removing the filter)
3.2 l (removing the filter)

3 - 18
 ENGINE/ENGINE OIL
OIL FILTER REMOVAL/INSTALLATION

Removal: A
NOTE:___________________________________________
Before removing the oil filter, it is necessary to drain the oil 2
from the engine.

1. Place a suitable container underneath the engine.

2. Use the specific tool (**) to turn the oil filter (2) count-
er-clockwise and remove it Fig. A.

Installation:

NOTE:___________________________________________
Before installing a new oil filter, apply a small amount of en-
gine oil to the contact surfaces of same to lubricate it Fig. B.

1. Proceed using the opposite order to removal. B

Tighten the filter (2) to the following torque:

T. R .

Torque 22 N*m

IMPORTANT NOTICE
Always use original Benelli oil filters.
Other brands of oil filters can be different in terms of thread
(diameter and pitch).
The use of other types of filter may affect the filter perfor-
mance and duration, which will cause possible damage to
the engine or oil leaks.

3 - 19
 ENGINE/SPARK PLUGS
REMOVAL OF SPARK PLUGS FROM VEHICLE

The following procedure applies to all spark plugs.

A
2
WARNING
Replace and check the spark plugs when the engine is cold.
Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove: 1
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Fuel tank, refer to the section “Fuel tank removal, Chapter
4.”.
• Airbox, refer to the section “Airbox removal, Chapter 4”.
B

IMPORTANT NOTICE
Before disassembly of spark plug, remove any dirt from the
groove of the seats with a stream of compressed air to pre-
vent it from falling into cylinders.

Remove: 3
• The screw “1.” Fig. A.
• The bracket “2” Fig. A.
Disconnect:
• The ground cables ”3” Fig. B.
• The coil connectors “4” Fig. C.
• The rubber tips “5” and the two O-rings.

Slide out:
• The coil. C
Screw off: 4
• The spark plug below Fig. D.

3 - 20
 ENGINE/SPARK PLUGS
SPARK PLUG CHECK

The following procedure applies to all spark plugs. E

Check:
• The type of spark plug.
Check:
• Electrodes (1) Fig. E.
• If there is any damage, wear or rounding.
Replace the spark plug.
• The insulating part (2) Fig. E.
Abnormal colour. 2
Replace the spark plug. 1
Generally, the colour is a light, medium brown.

Check:
Measure the spark plug gap [D] using a thickness gauge. F
If the spark plug gap is not correct, replace the spark plug.

Spark plug gap (mm)

3 0.8-0.9

Spark plug type

NGK CR8E

3 - 21
 ENGINE/SPARK PLUGS
SPARK PLUG CHECK

The following section contains a table with the typical conditions

of spark plugs with the different causes of damage and any
remedies.

SOILED OVERHEATED
SPARK PLUG SPARK PLUG
Cause Solutions Cause Solutions
Over rich mix of air/fuel The fuel/carburettor system needs to Ignition too advanced Adjust advanced ignition
-Wrong setting of the carburetion. be fine tuned
Insuffi cient air/fuel mix Adjust air/fuel ratio
Electrical system fault Check the coil connections and
-Imperfect coil connection relevant impedance Insuffi cient coolant and/or Add coolant and/or lubricant
lubricant
Specifi c riding conditions Èvery so often, the bike needs to be
-Prolonged periods at “minimum” taken to speeds of about 80 km/h Spark plug torque too low Tighten to the correct torque
-Long sections at low speed

Spark plug too cold Use a warmer spark plug, as per The spark plug used is too hot Use cooler spark plugs as per
specifications specifi cations

3 - 22
 ENGINE/SPARK PLUGS
SPARK PLUG INSTALLATION

The following procedure applies to all spark plugs Fig. D. D

WARNING 6
Lubricate the spark plug threads with copper grease. 7
8
G

NOTE:__________________________________________ 1
Before installing it, clean the spark plug and surface in con-
tact with the seal.

Install:
• the spark plug on the head, tightening it by hand until you
2
can feel it come into contact with the base of the head. 3
Tighten to the correct torque. 4
T. R .
5
Torque 12 N*m 9
Install:
• The coil (1).
• The rubber tips (2) and the O-rings (3) Fig. D.
10
Connect:
• The coil connector

Install:
• The screw (6).
• The washer (7)
• The bracket (8)
Tighten to the torque.
T. R .

Torque 10 N*m

3 - 23
 ENGINE/VALVE CLEARANCE CHECK
VALVE CLEARANCE ADJUSTMENT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Fuel tank, refer to the section “Fuel tank removal, Chapter
4.”. 1
• Air filter box, refer to the section “Air filter box removal,
Chapter 4”.
• Spark plugs, refer to the section “Spark plug removal,
Chapter 4”.

Disconnect: B
• The throttled body control cables “1”, Fig. A.
Remove:
• Throttled body, refer to the section ”Throttled body remov-
al, Chapter 5”.
• The screws “2” Fig. B. 2

C
• The distribution cap “3” Fig. C.
3
NOTE:__________________________________________
To make it easier to remove the distribution cap, it is nec-
essary to lift it and turn it anticlockwise, as shown in Fig. C.

D
• The cap of the alternator cover “4” Fig. D. 5
• The cap “5” Fig. D.

3 - 24
 ENGINE/VALVE CLEARANCE CHECK
VALVE CLEARANCE ADJUSTMENT

Align:
E
• Turn the drive shaft counter-clockwise, using the nut fasten-
ing the flywheel “6” Fig. E.
• Move the piston 2 to the aligned TDC with the reference
marks “7” and the head top “8” Fig. F and the reference
mark on the magnet flywheel “10” Fig. E.
10

NOTE:_________________________________ 6
The valve clearance must be controlled and regulated while
the engine is cold (ambient temperature).

NOTE:__________________________________________
This procedure is only valid in the case of valve clearance
adjustment with the engine assembled to the frame.
F

Measure: 8
• Valve clearance via thickness gauge “9” Fig. G.

G
Camshaft Tappet-cam clearance 9
Camshaft on exhaust side 0.20 ~ 0.25 mm
Camshaft inlet side 0.15 ~ 0.20 mm

3 - 25
 ENGINE/COOLING SYSTEM
COOLING FLUID LEVEL CHECK

Park the motorcycle on a level surface. A

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

NOTE:__________________________________________
Make sure it is in upright position.
Inspect the level while the engine is cool. 1
Check:
• The level of the cooling fluid “1” Fig. A.

The level of the coolant must be between the maximum level

(MAX) and the minimum one (MIN) if below the minimum level
mark, top up to the correct level with the recommended engine B
oil. Fig. B.

Remove:
• The expansion tank cap. MAX
• Add cooling fluid up to the level line (MAX) Fig. B.

Press the hose “2” between the water pump to the expansion
tank, several times to remove any possible air bubbles Fig. C.
MIN
Position:
• The expansion tank cap.

3 - 26
 FRAME/BRAKE ADJUSTMENT
FRONT BRAKE ADJUSTMENT

Adjust:
• The position of the brake lever Fig. A.
A
(the distance ”x” between the throttle handgrip and the brake 1
lever).

NOTE:__________________________________________
Push the brake lever forward to neutralise the spring thrust
and at the same time, adjust the position turning the ring
nut “1” clockwise or counter-clockwise until the brake lever
reaches the required position.
X
Ring nut position Gap
Position 1 The distance is further from
the handlebar.
Position 4 The distance is nearer to the
handlebars.

WARNING
If the brake lever is soft or spongy to the touch, there might
be air in the braking system. Before using the vehicle, it is
necessary to exhaust air by bleeding the braking system.
The presence of air in the braking system significantly re-
duces the system performance and ultimately may cause a
loss of control of the motorcycle and accidents. Therefore,
check and if necessary, bleed the brake system.

IMPORTANT NOTICE
After adjusting position of the brake handle, make sure that
there is no brake drag.

3 - 27
 FRAME/BRAKE ADJUSTMENT
ADJUSTMENT OF THE REAR BRAKE

Adjust:
• The brake pedal position Fig. A.
A
• Loosen the locknut “1”. 3
• Unscrew the locknut “2”.
• Tighten or loose the threaded pin “3” to increase or reduce
1
clearance on the rear brake Fig. A. 2

Tighten:
• The nut “1”
• Tighten the lock nut ”2”.

Adjust:
• The position of the brake lever Fig. A.
• Turn the eccentric “4” clockwise or counter-clockwise.

WARNING
If the brake lever is soft or spongy to the touch, there might B
be air in the braking system. Before using the vehicle, it is
necessary to exhaust air by bleeding the braking system.
The presence of air in the braking system significantly re-
duces the system performance and ultimately may cause a
loss of control of the motorcycle and accidents.
Therefore, check and if necessary, bleed the brake system.
4
IMPORTANT NOTICE
After adjusting position of the brake pedal, make sure that
there is no brake sticking.

3 - 28
 FRAME/BRAKE FLUID LEVEL CHECK
FRONT BRAKE FLUID LEVEL CHECK/TOP UP

Park: A
• The motorcycle on a level surface.

NOTE:__________________________________________
Place the motorcycle on a stand and make sure it is in up-
right position.

Check:
• The brake fluid level. 1
If the level is below the minimum notch “1” Fig. A, top up with the
recommended brake fluid until it is at the correct level.

Fluid top up procedure:

• Place the motorcycle on a level surface.
• Loosen the screws “2” Fig. B.

Check:
• the seal on the cap. B
If there is any damage/wear,
Replace the seal.

IMPORTANT NOTICE
Brake fluid can damage painted surfaces and plastic parts.
Therefore, wrap the absorbent paper around the pump and
always clean up any brake fluid spills immediately.
2
• Apply the vacuum device to the drain screw ”3” Fig. C.
• Top up the fluid as far as the level in the gauge on the pump
Fig. A.
• Pump the brake fluid until the brake lever moves.
• Once the top up is complete (4) Fig. D, insert the cap and
tighten the two screws fastening the cap.
C
WARNING
Only use the prescribed fluid. Other brake fluids may cause 3
the deterioration of the rubber seals, causing leakages and
malfunctioning of the braking system.
Top up with the same type of brake fluid already in the sys-
tem. Mixing different types of brake fluid may cause a nox-
ious chemical reaction, which may affect the braking system
operation.
While topping up brake fluid, take care not to let any water
enter the container. Water would lower the boiling point of
the brake fluid significantly, causing steam bubbles.

Recommended brake fluid

TOP
4 DOT-4

3 - 29
 FRAME/BRAKE FLUID LEVEL CHECK
CHECK REAR BRAKE FLUID LEVEL/TOP UP

Park: A
• The motorcycle on a level surface.

NOTE:__________________________________________
Place the motorcycle on a stand and make sure it is in up-
right position. MAX

Check: MIN
• The brake fluid level.
If below the minimum notch “A” Fig. A, top up with the recom-
mended brake fluid until it is at the correct level.

Fluid top up procedure:

• Once the bike is positioned on a level surface, loosen the
top cap “1” on the brake pump tank Fig. B.

B
IMPORTANT NOTICE
Brake fluid can damage painted surfaces and plastic parts.
Therefore, wrap the absorbent paper around the pump and 1
always clean up any brake fluid spills immediately.

• Take out the fastening screw from the brake calliper and
loosen the internal fastening screw ”2” Fig. C so as to be
able to lift the brake calliper. This will completely bleed the
circuit, removing all air bubbles.
• Apply the vacuum device to the drain screw ”3” and loosen
the screw.
• Top the liquid up to the MAX level indicated on the graduat-
ed container “D”. Pump the brake fluid by moving the brake
lever.
• Once the top up process is complete, lower the calliper and
tighten the two fastening screws to the following torque: C
3
T. R .

Torque 22. N*m.

• Close the pump cover.

WARNING
Only use the prescribed fluid. Other brake fluids may cause
the deterioration of the rubber seals, causing leakages and
malfunctioning of the braking system. 2
Top up with the same type of brake fluid already in the sys-
tem. Mixing different types of brake fluid may cause a nox-
ious chemical reaction, which may affect the braking system
operation. D
While topping up brake fluid, take care not to let any water
enter the container. Water would lower the boiling point of
the brake fluid significantly, causing steam bubbles.

3 - 30
 FRAME/ABS PIPE CHECK
CHECK FOR ANY LEAKS FROM ABS TUBES

Park:
• The motorcycle on a level surface.
F

NOTE:__________________________________________
Place the motorcycle on a stand and make sure it is in up-
right position.

For the motorcycle models equipped with ABS, it is necessary to 3

check for leakages in the braking system and especially in the
ABS circuit.
3

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• By means of the brake lever/pedal check for brake fluid
leakages from the hoses “2”, the tubes (models equipped
with ABS) “3” and the fittings “1”.
• In case of leaks in any point, check or replace the broken G
part. 2
Check: 1
• The fittings on the ABS control unit “3” Fig. F.
• The hoses and fittings connecting the ABS control unit to
the front brake calliper Fig. G.
• The hoses and fittings connecting the ABS control unit to
the rear brake calliper Fig. H.

2
1

3 - 31
 FRAME/BRAKE PAD CHECK
CHECK FRONT AND REAR BRAKE PADS FOR WEAR

The following procedure applies to brake pads. A

Activate:
• The brake.

Check:

• The front brake pads Fig. A.

• The rear brake pads rear Fig. B.
A
• The wear limit for the front and back brake pads.

In case of wear limits, replace the pads while the

brake is locked.

Pads Wear limit (A)

Front 1 mm
B
Rear 1 mm

NOTE:__________________________________________
To replace the pads, refer to the “Frame” chapter, ”Front
brake pad removal and installation”. B

3 - 32
 FRAME/BRAKE SYSTEM HOSE CHECK
HOSE CHECK

Park:
• The motorcycle on a level surface.
A

NOTE:__________________________________________ 1
Place the motorcycle on a stand and make sure it is in
upright position.
The following procedure applies to all brake hoses and brake 2
hose clamps.

Check:
• The route of the front and rear brake hoses.
If there are any cracks/signs of wear or damage, replace.

Check:
• The fitting and the hose of the front brake pump Fig. A.
• The fitting and the hose of the rear brake calliper Fig. B.
• The fitting and the hose of the right and left front brake B
calliper Fig. C.
• The fitting and the hose of the rear brake calliper pump Fig. 1
D. 2
Check:
• the fitting screws to make sure they are sufficiently tight.

Tighten:
• The fitting screws to the following torque.

T. R .

Torque 25. N*m.

Activate:
• The brake several times.
Recheck: C
• The brake hose. If there is any brake fluid leakage, replace
the damaged hose.

3 - 33
 FRAME/TRANSMISSION CHAIN
TRANSMISSION CHAIN CLEARANCE ADJUSTMENT

NOTE:__________________________________________ A
Never inspect or adjust the transmission chain with the en-
gine running.
Check the transmission chain slackness in the most taut
point.

WARNING
If the chain is too taut, there may be an overload of the en-
gine or other vital parts, while, if it is too slack, it may jump 25-30 mm
out and damage the swing arm bracket or cause an accident.
Therefore, it is advisable to keep the chain slackness within
the specified range.

Park:
• the motorcycle on a level surface.

WARNING B
Support the motorbike correctly, so that it cannot fall over
and so that the rear wheel is raised.

• Rotate the rear wheel several times and determine the tight-
Adjustment screw Wheel axle pin
est position of the chain.

Check:
• If the chain slackness is outside the range, adjust, Fig. A.
Locknut

Transmission chain slack-

25-30 mm
ening

Adjust:
• The slackness of the chain Fig. B. C
• Loosen the wheel axle pin nut on the left ”1” Fig. C and right
“2” Fig. D.
• To tension the transmission chain, turn the tension adjust-
ment screw on each side of the swing arm (counter-clock-
wise).
• To loosen the transmission chain, turn the tension adjust-
ment bolt clockwise and push the rear wheel forwards.
• At the end of adjustment, tighten the wheel axle pin nut to the
following torque:
“1”

T. R .
Left side

Torque 80 N*m.

WARNING
If the chain is too taut, there may be an overload of the en-
D
gine or other vital parts, while, if it is too slack, it may jump
out and damage the suspension arm or cause an accident.
Therefore, it is advisable to keep the chain slackness within
the specified range.

“2”

Right side

3 - 34
 FRAME/TRANSMISSION CHAIN
TRANSMISSION CHAIN LUBRICATION

Introduction:

The transmission chain consists of several parts that interact

with each other.
The chain must be properly maintained to prevent its early wear.
Therefore, it is advisable to maintain the transmission chain,
especially if it is used in very dusty areas.
This motorcycle is equipped with a transmission chain complete
with small rubber O-rings inserted between one side plate and
another.
Do not use steam jets, high-pressure water jets, aggressive
solvents or brushes with too rough bristles to prevent damaging
these O-rings.
Therefore, we recommend exclusive use of recommended prod-
ucts to clean the transmission chain.
Wipe the chain and lubricate it thoroughly using engine oil or
specific lubricant for chains with O-rings.
Do not use other kinds of lubricants on the transmission chain as
they might contain solvents that would damage the O-rings.

Apply:
• A fine, even layer of lubricant to the whole chain, taking care
not to reach the parts around it, especially the tyres.

Recommended lubricant
G Specific spray for chains
with O-rings.

CHAIN GUIDE CHECK

Visually check the chain guide slide (1) Fig. A.

A
Replace:
The chain guide if faulty or damaged.
See:
• Chain slide removal, refer to the section “Chain slide
removal, Chapter 4.”.

3 - 35
 FRAME/TRANSMISSION CHAIN
TRANSMISSION CHAIN WEAR CHECK

Check:
• The transmission chain.
A
Clean and grease, or replace.

Clean:
• The transmission chain.

Clean the transmission chain with a clean rag.

Soak the transmission chain in kerosene and remove any re-
maining dirt.
Remove the transmission chain from the kerosene and leave it
to dry completely.

IMPORTANT NOTICE
This motorbike is equipped with a transmission chain com-
plete with small rubber O-rings (1) Fig. B, inserted between
one side plate and another.
To clean the transmission chain, do not use high-pressure
B
jets of water or air, do not use steam, petrol, aggressive sol-
vents (such as petroleum petrol), or brushes with overly stiff
1
bristles.
Using high-pressure items could force dirt into the cavities
inside the transmission chain, while solvents could cause
the O-rings to deteriorate.
The O-rings could also be damaged by the use of brushes of 2
overly stiff bristles.
Therefore, we recommend exclusive use of white oil to clean
the transmission chain.
3
Check:
• The O-Rings (B).
In the event of damage, replace the transmission chain.
• The transmission chain rollers (2) Fig. B.
In the event of damage/wear, replace the transmission chain. F
• The side plates of the chain (3) Fig. B. 4
In the event of damage/wear, replace the transmission chain.
If there are any cracks, replace the transmission chain and
make sure that the bleeder pipe from the battery is correct and 2
sufficiently distant from the transmission chain and below the 1
swing arm.
Lubricate:
• The transmission chain. 3

NOTE:__________________________________________
Use specific grease.

Check:
• Driving gear
• Rear toothed wheel.
If more than 1/4 for each tooth (4) Fig. F. is worn, replace all of
the chain sprockets.
If the teeth are bent, replace the all of the chain sprockets.

NOTE:__________________________________________
Never install a new chain with worn sprockets.
Both the chain and sprockets need to be in good condition
or the new chain will become quickly worn.

3 - 36
 FRAME/CHAIN PINION
TRANSMISSION CHAIN PINION CHECK

Check:
• The chain pinion.
A

Remove:
• The gear lever, refer to the section “Gear lever removal,
Chapter 4”.
• The pinion cover, refer to the section “Pinion cover remov-
al, Chapter 4”.

Check:
If more than 1/4 on each tooth (1) Fig. B. is worn, replace all of
the chain sprockets.
If the teeth are bent, replace the all of the chain sprockets.

B
1

3 - 37
 FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE
CHECK/ADJUSTMENT OF STEERING CLEARANCE

Park:
• The motorcycle on a level surface.
A
NOTE:__________________________________________
Place the motorcycle on a suitable support so that the front
wheel is raised.

Check:
• The steering sleeve.
Gently oscillate the front fork, holding it by the ends of the tubes
Fig. A.
If there is any jamming/loosening, adjust the steering sleeve.

Remove:
• The upper u-clamps (2) Fig. B.
2 B

• The u-clamp supports (3) Fig. C.

C
3

• The instrument support (4) Fig. B. D

4

3 - 38
 FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE
STEERING SLEEVE BEARING LUBRICATION

• The bolt cap of the steering head (5) Fig. E.

E

• The support screws of the headlamp (6) Fig. F. F

G
• The fastening screws of the steering head (7) Fig. G.

Loosen:
• the steering ring nut (6) with the relevant wrench (7).
H
.
(**) Steering sleeve lock ring nut tightening tool
Code: R180297129000

3 - 39
 FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE
STEERING SLEEVE BEARING LUBRICATION

Remove:
I
• the steering pin ring nut (1) with the relevant wrench (2) and 2
remove the steering ring nut (3). Fig. I.

.
Steering sleeve lock ring nut tightening tool
1
Code: R180297129000

Using a solvent with a high flash point,

wash the top/bottom ball bearings in the retainers, then wipe up
the upper and lower outer races that are installed for interfer-
ence on the frame pipe, remove the grease and dirt.
3

Check:
• Visually check the outer races and the balls. Replace if worn
or damaged Fig. L.
• Insert the balls with some grease, then apply a thin layer of
grease on the outer top/bottom races. L
Assemble:
Once assembled, tighten the steering ring nut to the following
torque:

Steering sleeve lock ring nut tightening tool

Code: R180297129000

T. R .

Torque 60 N*m

G
Specific grease

Assemble:
• the steering pin ring nut with the relevant tool, with the
following torque:

Steering sleeve lock ring nut tightening tool

Code: R180297129000

T. R .

Torque: 15. N*m

3 - 40
 FRAME/FRONT FORK CHECK
FRONT FORK CHECK

Park:
The motorcycle on a level surface.
A
• 1
NOTE:__________________________________________
Prop the motorcycle on suitable supports so that it cannot
fall.

Check:
• The fork stem “1” Fig. A.
• The fork sleeve “2” Fig. A.
In case of damage/scuffing, replace.
• The oil seal.
If there are any leaks, replace 2

Keep:
• The motorcycle in a upright position.
Activate:
• The front brake.

Check:
• The fork operation.

Push hard on the handlebars several times and make sure that
the front fork slides easily back into place.
If the movement is not smooth, replace (see the chapter
FRAME/CHECK AND ADJUSTMENT OF THE STEERING
SLEEVE, section STEERING SLEEVE BEARING LUBRICA-
TION).

3 - 41
 FRAME/FRONT FORK CHECK
FRONT FORK EXTENSION BRAKE ADJUSTMENT

NOTE:__________________________________________ A
Prop the motorcycle on suitable supports so that it cannot
fall.

NOTE:__________________________________________
The following procedure applies to all pistons.

IMPORTANT NOTICE
Always adjust the front fork rods by the same amount. Un-
even adjustment may lead to difficult manoeuvres and loss
of stability.

Adjustment
• To increase rebound damping and therefore, increase
the rigidity of the suspension, turn the adjustment screw
clockwise.
• To decrease rebound damping and therefore, increase
the softness of the suspension, turn the adjustment screw
counter-clockwise.

IMPORTANT NOTICE
To avoid damaging the mechanism, do not try turning over
the maximum or minimum setting.

3 - 42
 FRAME/REAR SHOCK ABSORBER CHECK
SHOCK ABSORBER ADJUSTMENT

NOTE:__________________________________________ A
Prop the motorcycle on suitable supports so that it cannot
fall.

Preload adjustment
• Adjust the spring preload Fig. A.
The rear shock absorber has a spring preload adjustment knob
“1”.

• To increase spring reload and therefore, increase the rigidi-

ty of the suspension, turn the adjustment ring nut clockwise. 1
• To decrease spring reload and therefore, increase the
rigidity of the suspension, turn the adjustment ring nut
counter-clockwise.

IMPORTANT NOTICE B
To avoid damaging the mechanism, do not try turning over
the maximum or minimum setting.

Position Gap
MIN 0 mm 4
3
MAX 10mm

Extension adjustment
To make hydraulic adjustment to the shock extension, it is nec-
essary to

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• The screw “3” and “4” Fig. B. C
• The screws “5” and “6” Fig. C.

Move:
• The right panel ”7” to access the adjustment ring nut Fig. D. 5
• It is possible to adjust the hydraulic brake device using the 6
adjustment ring nut ”8” Fig. D.
• Turn it clockwise to increase the braking action. Turn it
counter-clockwise to reduce the braking action.

IMPORTANT NOTICE
To avoid damaging the mechanism, do not try turning over
the maximum or minimum setting.

D
8

3 - 43
 FRAME/FRONT/REAR TYRE CHECK
TYRE CHECK
The following procedure applies to both tyres.
Check:
A
• If tyre pressure is outside the range, adjust it Fig. A.

WARNING
The tyre pressure must be checked and adjusted only when
the wheel temperature corresponds to the ambient tempera-
ture.
The tyre pressure and the suspension must be adjusted ac- 3

cording to the total weight, including baggage, driver, pas-

0

senger and accessories, and considering the expected driv-

2 1

ing speed.
The use of the overloaded vehicle may cause damages to
tyres, with the risk of an accident or injuries for people.
NEVER OVERLOAD THE VEHICLE IN ANY CASE.

Position Wear limit (A)

Net weight
A B
(with oil and fuel tank See general specifications
full)
Max. load* See general specifications
COLD TYRE PRES-
FRONT REAR
SURE
Up to 90 kg load* C
2.20 bar 2.50 bar

90 kg B
2.20 bar 2.50 bar
~ max. load*

* Including baggage, driver, passenger, and accessories.

WARNING
It is dangerous to drive with the worn tread.
If the tread reaches the wear limit, replace the tyre immedi-
ately.

Check:
• The tyre surface Fig. B.

If there is any damage/wear, replace the tyre.

A. Tread pattern depth.

B. Sidewall.
C. Wear signaller.

WARNING
If tyres are new, the grip on the road is relatively weak until
they are slightly used. Therefore, it is advisable to drive at
normal speed for the first 100 km (62 mi) before driving at
higher speeds.

WARNING
Most countries have their own regulations that prescribe a
minimum depth of the tread. Always remain within the limits
set forth.
Check and balance the wheel when replacing the tyre.

3 - 44
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGE

WARNING
The batteries produce a nitrogen-based explosive gas and
contain electrolyte, which is composed of sulfuric acid, a
poisonous substance and highly caustic.
The following precautions should be always observed:
Wear protective goggles when handling a battery or while
working nearby.
Recharge the batteries in a suitably ventilated area.
Battery must be far away from fire, sparks or open flames
(e.g., welding equipment, lighted cigarettes, etc.).
DO NOT SMOKE during recharging or handling of the bat-
tery.
PUT BATTERIES AND ELECTROLYTE BEYOND THE REACH
OF CHILDREN.
Do not allow electrolyte to come into contact with body parts
to prevent severe burns or permanent injury to eyes.

FIRST AID IN THE EVENT OF CONTACT:

EXTERNAL CONTACT
• Skin: wash with water.
• Eyes: Wash with water jets for 15 minutes and seek imme-
diate medical attention.
SWALLOWING
• Drink large quantities of water or milk, milk of magnesia,
beaten egg or vegetal oil. Seek immediate medical atten-
tion.

IMPORTANT NOTICE
This battery is sealed. Do not remove the sealing caps in any
case, to preserve the equilibrium between the cells and not
to affect the battery performance.
The time, the amperage, and the voltage for recharging the
battery differ from the standard ones. Recharge the battery
as shown in the figures. If the battery is overcharged, the
electrolyte level drops significantly. Therefore, during re-
charging, pay the utmost attention.

NOTE:_________________________________________
As the battery is sealed, the recharging state cannot be
checked by measuring the electrolyte density.
Therefore, check battery charging by measuring the voltage
on the battery terminals.

Remove:
• Rider and passenger seats, refer to the section “Rider seat
and passenger seat removal, Chapter 4”.

3 - 45
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGE

Disconnect:
• The battery cables from the terminals Fig. A.
A

IMPORTANT NOTICE
Disconnect the negative wire “1” of the battery first, then the
positive wire ”2” Fig. A. 2

Remove:
• The battery bracket (3) Fig. B.
• The battery.
• Remove the battery rubber tip and take out the battery “1”. 1

Check:
C
• The battery charge.
Connect a pocket tester to the battery terminals Fig. C.

3 - 46
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGE

Check the battery level as shown in the tables of the following

example Fig. D.
D
13

Voltage at open circuit (V)

NOTE:__________________________________________
12.5 Relation between the open circuit
The charge status of a battery can be checked by measuring voltage and the charge time at 20°C
its open-circuit voltage (that is the voltage when the positive 12
terminal is disconnected).
If the open-circuit voltage is equal to/above 12.8 V, recharg- 11.5
ing is not necessary.

EXAMPLE: 5 6.5 10
- Open-circuit voltage = 12.0 V Charge time (hours)
- Charge time = 6.5 hours These values change according to modifi cations of temperature, battery plates conditions and
electrolyte level
- Battery charge = 20 ~ 30 %
-
Charge:
• Battery (see figure with the appropriate charge method) Fig.
E.
E
IMPORTANT NOTICE 14
13

Voltage at open circuit (V)

Do not subject the battery to a quick charge.
12

WARNING 11
• Never remove the caps that seal the battery.
• Do not use fast battery charger as these devices transfer 10
Room tempe-
a high-amperage current to the battery at high speed, rature 20 °C
therefore the battery may overheat and its parts may be 100 75 50 30 25 0
damaged. 20
If it is not possible to adjust the charging current of the bat- Battery charge status (%)
tery charger, be careful to prevent the battery overcharge.
For charging, disconnect the battery from the vehicle.
(Should it be necessary to recharge with the battery mount-
ed on the vehicle, disconnect the negative cable from the
battery terminal).
To reduce the risk of sparks, connect the battery charger to
the power supply only after having connected the cables to recharge F
the battery. 18
Voltage at open circuit (V)

Before disconnecting the clamps from the battery cables 17

from the battery terminals, remember to switch off the bat-
16
tery charger.
15
Make sure the battery charger cable clamps are completely
in contact with the battery terminals and are not short circuit- 14
ed. A corroded clamp may generate heat in the contact area 13
and an ineffective clamp spring may cause sparks. 12
If the battery overheats during the charging process, dis- 11
connect the battery charger and allow it to cool down before 10
proceeding again. The batteries that overheat may explode!! 0 10 20 30 40 50 60
As shown in Fig. F, the open-circuit voltage of a battery sta- Check voltage at
bilises 30 minutes after the charging end, before measuring open circuit
the open-circuit voltage.

3 - 47
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGE

CHARGE METHOD WITH VARIABLE CURRENT (VOLTAGE) CHARGER

NOTE:__________________________________________
• Measure the voltage after 30 minutes from switching off of the appliance.
• Set the charge voltage to 16 ~ 17 V. (A lower setting will not give sufficient charge; an excessively high setting will over-
load the battery).

Battery charger
Caricabatterie
Measure
Misurarethe voltage at aopen
la tensione circuit
circuito before
aperto
Ammeter
Amperometro
prima di procedere
chargingcon la ricarica.

Connect Collegare
a battery charger and anun
alla batteria ammeter
to the battery and
caricabatterie e unstart charging
amperometro
e iniziare la ricarica.

Check theche
Verificare current is highersia
la corrente than
piùthe stan-
elevata
dard value ofstandard
del valore the charge onecorrente
della indicated di
on
YES
SI the battery
ricarica riportato sulla batteria. NO

ByRuotando la rotella
rotating a charge di
voltage
regolazione
setting roller, set the charge
della tensione di ricarica,
voltage to 20 ~ 24 V
impostare
la tensione di ricarica
su 20 ~ 24 V.

YES Tenere sotto controllo

Monitor the amps for 3 ~ 5
l’amperaggio
Regolare la tensione in modo SI minutesper
to check
3 ~ 5 ifminuti
the standard
Set the voltage
tale che lasocorrente
that the sia
current is equal to
al livello chargeper verificare
current is reached
standard
di caricacharge level
standard. se la corrente di carica
standard viene raggiunta.

NO

Impostare
Set il tempo
time according in base
to charge Se la corrente non supera
time suitabledifor
al tempo the voltage
ricarica in
adatto Should current not exceed
la corrente di the
anper
openla circuit.
tensione a circuito carica
standard standard
charge current after
aperto. supplied
Refer to instructions 5 minutes, replace
una volta the battery
trascorsi
Vedere le istruzioni 5 minuti, sostituire la
with the battery batteria.
incluse alla batteria.

In case it takes more than 5 hours for charge, it is recommended to check the charge current after 5 hours.
Se per la ricarica sono necessarie più di 5 ore, è consigliabile controllare la corrente di carica dopo 5 ore.
InSe
the
si event of amps
verificano changes,dell’amperaggio,
variazioni set again the voltage to obtain
regolare the standard
nuovamente la charge current
tensione per ottenere la corrente di
carica standard.

Measure
Misurarethe
la battery
tensioneopen circuit voltage
a circuito apertoafter a downtime
della of 30 averla
batteria dopo minutes.
lasciata per più di 30 minuti inutilizzata.
12.8
12.8VVor
o higher > Charge is complete
superiore La ricarica è completa
12.7
12.7VVor
o lower >Charge necessary
inferiore Ricarica necessaria.
Lower thana12.0V
Inferiore 12.0 V> ReplaceSostituire
the batteryla batteria.

3 - 48
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGE

CHARGE METHOD WITH CONSTANT CURRENT (VOLTAGE) CHARGER

NOTE:__________________________________________
• Measure the voltage after 30 minutes from switching off of the appliance.
• Set the maximum charging time to max. 20 hours.

NOTE:__________________________________________
• To guarantee maximum battery performance and durability, use electronic chargers able to supply charge currents or
voltages based on the specific requirement of the sealed battery technology.

Misurare the
Measure la tensione a circuito
voltage in an open aperto
circuit
prima di procedere con la ricarica.
before charging

Collegare alla batteria un

Connect a battery charger
caricabatterie and an ammeter
e un amperometro
to the battery andlastart
e iniziare charging
ricarica.

Check the current

Verificare is highersia
che la corrente than
piùthe stan-
elevata
dard
delvalue
valoreof standard
the charge onecorrente
della indicateddion
YES
SI the battery
ricarica riportato sulla batteria. NO

This kind tipo

Questo of charger cannot
di caricabat-
be terie
used nonfor può essere
charge these
utilizzato
batteries. It isper ricaricare
recommended
queste
to use abatterie.
chargerSiwith
consiglia
varia-
l’uso di un caricabatterie a
ble voltage
tensione variabile.

Battery charger
Caricabatterie
Charge the battery
Caricare until charge
la batteria finchévoltage
la
reachesdi15
tensione V
carica
non arriva a 15 V. Ammeter
Voltmeter Amperometro
Voltometro

A
V

Measure the la
Misurare open circuit avoltage
tensione after
circuito
a battery
apertodowntime of 30
dopo aver minutes.
lasciato la
batteria per più di 30 minuti
inutilizzata.
12.8
12.8VVor higher. Charge is La
o superiore complete.
ricarica è completa.
12.7 V or lower. Charge necessary.
12.7 V o inferiore Ricarica
necessaria.
Lower than 12.0V. C. Change the
battery
Inferiore a 12.0 V Sostituire
la batteria.

3 - 49
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGE

Battery activation:
Filling Electrolyte
Make sure that the model [A] marked on the electrolyte bottle
matches with the model [B] of the battery. The denominations
must be the same.
Battery model name: YTX9-BS.

WARNING
Every battery is supplied with a bottle of its own electrolyte.
The use of an unsuitable container may cause the leakage
with the wrong electrolyte, thus shortening the battery life
and jeopardizing performance.
Use the electrolyte bottle having the same battery model
name, as the volume and specific gravity of the electrolyte
change according to the type of battery.

WARNING
Tear the aluminium sealing film [A] of the filling ports [B]
only immediately before use. Use the apposite container to
be sure to insert the correct amount of electrolyte.

IMPORTANT NOTICE
The sulfuric acid present in the battery electrolyte may cause
severe burns. To prevent burns from sulfuric acid, before
handling the electrolyte wear protective clothing and safety
goggles.
If the electrolyte comes into contact with eyes, wash the area
with plenty of water and contact a doctor in case of severe
burns.

• Place the battery on a flat surface.

• Make sure the sealing film is not frayed, broken or perforat-
ed.
• Remove the sealing film.

NOTE:__________________________________________
The battery is vacuum sealed. If air come into the battery
through the sealing film, the initial charging may require
more time.

3 - 50
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGE

• Take the electrolyte bottle away from vinyl bag.

• Detach the strip of caps [A] from the bottle and store it for
A
seal the battery subsequently, Fig. A.

NOTE:__________________________________________
Do not puncture or open the sealed cells [B] of the electro-
lyte bottle. Do not try to divide the single cells.

• Topple the electrolyte bottle by aligning the six sealed cells

to the filling ports of battery. By keeping the bottle in hori- B
zontal position, push downwards to break the seals of the
six cells. During filling, some air bubbles will go up to each
cells Fig. B.

NOTE:__________________________________________
Do not tilt the electrolyte bottle.

• Check the electrolyte flow. C

• If there are no air bubbles [A](*) that go up through the filling
ports or the cells do not fill completely, tap the bottle [B]
some times, Fig. C.

NOTE:__________________________________________
Take care not to drop the battery.

• Leave the bottle in its place. Do not remove the bottle from
the battery, since it is necessary that all electrolyte passes
into the battery for its proper operation.

WARNING
The removal of the bottle before it is completely empty may
reduce the technical life of the battery.
Do no remove the container until it is completely empty.

• After filling, leave the battery to rest with the electrolyte bot-
tle in its place for 20-60 minutes so that the electrolyte can
permeate deeply into the plates.
• Check the bottle cells are completely empty and remove the
bottle from the battery.

3 - 51
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGE

• Place the series of caps [A] over the filling ports and press
firmly down with both hands to insert them into the battery,
D
Fig. D (without hitting them) Fig. E. If correctly installed, the
series of caps will be level on the top side of the battery.

WARNING
After installation of the cap strip, do not remove the caps and
do not add water/electrolyte into battery.

NOTE:__________________________________________
Charging immediately after filling may reduce the technical
life of the battery.

Initial Charge:
The sealed battery just supplied require initial charge.
Use a constant voltage battery charger.

Standard charge: 0.9 A × 5 – 10 hours.

• Leave the battery to settle for 30 minutes after the initial

E
charge and then inspect the voltage using a voltmeter. (The
voltage is temporarily high immediately after charge. For
accurate measurement, leave the battery to rest for the time
required).

NOTE:__________________________________________
• The charging values change according to the storage
duration, the temperature and the type of battery charger
used. If the voltage does not reach at least 12.6V, repeat
the charging cycle.
• In order to ensure the biggest battery life and the utmost
customer’s satisfaction, it is suggested to perform 15s
load testing under the three times of ampere hour rate.
Check the voltage again and if it is lower than12.6V, re-
peat the charge cycle and the charge test. If the voltage
is still below 12.6V, the battery is faulty.

3 - 52
 ELECTRICAL SYSTEM
FUSES

The following procedure applies to all fuses.

A
IMPORTANT NOTICE
Set the ignition switch to “OFF”.

Remove:
• Rider and passenger seats, refer to the section “Rider seat
and passenger seat removal, Chapter 4”.
Access:
• The fuse box “1” Fig. A.
1
Check:
• The fuse.

Connect a tester to the fuse and check the continuity.

NOTE:__________________________________________
Move the pocket tester selector to “Ω x 1”

• If the pocket tester reads “ ∞”, replace the fuse.

Replace:
• The blown fuse.

- Turn the main switch to "OFF".

- Install a new fuse with the correct amperage.
- Switch on the switches to make sure that the electrical
circuit is working.
- If the fuse burns out immediately, check the power circuit.

WARNING
Never use fuses with a amperage different from those spec-
ified. The use of improvised techniques or fuses with differ-
ent amperages could cause irreversible damage to the elec-
trical system, or cause functioning defects of the lighting
system and the ignition system and eventually cause a fire.

3 - 53
 ELECTRICAL SYSTEM
FUSE CHECK

KEY: FUSES
Refer to Fig. A.
A
1. Fuel pump
2. Fan
3. lights

10A
4. Ignition coil

15A

15A

15A

15A
15A
5. ECU
6. Services
1 2 3 4 5 6

15A 15A
10A

3 - 54
 ELECTRICAL SYSTEM
HEADLIGHT REPLACEMENT

IMPORTANT NOTICE
The vehicle has a LED projector integrated into the head-
light, and in case of anomaly, it is necessary to replace the
whole light. Headlight removal, refer to the section “Front
optical unit removal, Chapter 4”.

3 - 55
 ELECTRICAL SYSTEM
HEADLIGHT ADJUSTMENT

To carry out the correct adjustment of the two headlights’ lumi-

nous beams:
A

• Position the vehicle approx. 10 metres distance from a verti-

cal wall on a perfectly flat piece of ground Fig. A.
• Sit on the vehicle in the riding position.
• Make sure that the upper limit of the beam as shining on the
wall, is lower than 1/10 of the horizontal axis of the head-
lamp.
• If the beam does not fall within these limits, make the ad- h
justments to set it to the correct position. 9/10

10 m

Adjust:
• The beam from the headlight, using the adjustment screw B
“1” in the top right of the back of the projector, Fig. B.
• Turn counter-clockwise to raise the beam.
• Turn clockwise to lower the beam. 1
.

3 - 56
 ELECTRICAL SYSTEM
LED REAR LIGHT REPLACEMENT

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

To replace the LED rear light, refer to “Rear light removal,

Chapter 4.”.

3 - 57
 ELECTRICAL SYSTEM
REAR INDICATOR LIGHT REPLACEMENT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

NOTE:_________________________________
The following procedure applies to both rear indicator lights. 1
2
Remove:
• The rear light, refer to the section “Rear light removal,
Chapter 4.”.
• The screws “1” Fig. A.
• The cover “2” Fig. A.
• The left/right position indicator. Fig. B
B
Install:
• Proceed using the opposite order to removal.

IMPORTANT NOTICE
The vehicle has integrated LED indicators, and in case of
anomaly, it is necessary to replace the whole light.

3 - 58
 ELECTRICAL SYSTEM
FRONT INDICATOR LIGHT REPLACEMENT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot 2
fall.

NOTE:_________________________________
The following procedure is applicable to both front indica- 1
tors.

Remove:
• The headlight, refer to the section “Front optical unit
removal, Chapter 4.”.
Disconnect:
• The connections “1” and “2” of the right and left indicators,
Fig. A. B
Remove:
• The left/right position indicator. Fig. B

Install:
• Proceed using the opposite order to removal.

IMPORTANT NOTICE
The vehicle has integrated LED indicators, and in case of
anomaly, it is necessary to replace the whole light.

3 - 59
 ELECTRICAL SYSTEM
IGNITION BLOCK REPLACEMENT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The handlebar, refer to the section ” Handlebar removal,
Chapter 4.”. 1
• Base steering top, refer to the section ” Base steering top
removal, Chapter 4”.
Disconnect:
• The connector “1” from the electrical distributor “2” Fig. A.

Remove: 2
• The safety screws “3” Fig. B.
• The ignition block ”4” Fig. B.

Install:
• Proceed using the opposite order to removal.

NOTE:_________________________________________
Each time a new ignition block is installed, it is necessary to B
carry out the mapping of the new block.

3 - 60
 ELECTRICAL SYSTEM
INSTRUMENT PANEL REPLACEMENT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Fuel tank, refer to the section “Fuel tank removal, Chapter
4.”.

• The screws (1) Fig. A.

1

• The screw (2) from the cable support bracket Fig. B. B

C
Disconnect:
• The connector “6” Fig. C. 6
• The connector “7” Fig. C.
• The connector “8” Fig. C.
7

3 - 61
 ELECTRICAL SYSTEM
INSTRUMENT PANEL INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

Tighten:
• The screws (1) Fig. A
To the following torque:
1
T. R .

Torque 5-6 N*m

Use Loctite thread locker to secure.

Loctite 243

3 - 62
4

4-1
 CHAPTER 4
FRAME
FRONT WHEEL AND BRAKE DISCS ...........................................................................................................5
FRONT WHEEL REMOVAL........................................................................................................................................................5
REMOVAL/INSTALLATION OF BRAKE DISCS .........................................................................................................................7
CHECK OF BRAKE DISCS ........................................................................................................................................................9
WHEEL AXLE CHECK ..............................................................................................................................................................10
CHECK/REPLACEMENT OF WHEEL BEARINGS ..................................................................................................................11
FRONT WHEEL INSTALLATION ..............................................................................................................................................12
REAR WHEEL AND BRAKE DISC .............................................................................................................13
REAR WHEEL REMOVAL ........................................................................................................................................................13
SPROCKET AND REAR BRAKE DISC REMOVAL ..................................................................................................................17
WHEEL AXLE CHECK ..............................................................................................................................................................18
CHECK/REPLACEMENT OF WHEEL BEARINGS ..................................................................................................................19
CHECK AND REPLACEMENT OF SPROCKET ......................................................................................................................20
BRAKE DISC INSTALLATION ..................................................................................................................................................21
REAR WHEEL INSTALLATION ................................................................................................................................................22
FRONT AND REAR BRAKES .....................................................................................................................24
REMOVAL AND INSTALLATION OF FRONT BRAKE PADS ...................................................................................................24
REMOVAL AND INSTALLATION OF REAR BRAKE PADS......................................................................................................25
FRONT BRAKE PUMP REMOVAL ...........................................................................................................................................26
REMOVAL OF THE REAR BRAKE PUMP ...............................................................................................................................29
FRONT BRAKE PUMP INSTALLATION ...................................................................................................................................31
REAR BRAKE PUMP INSTALLATION .....................................................................................................................................32
ABS ANTI-LOCK BRAKING SYSTEM ........................................................................................................33
LOCATION OF THE COMPONENTS .......................................................................................................................................33
ROTATION SENSOR CHECK ..................................................................................................................................................35
CHECK OF THE ABS PHONIC WHEEL OF THE FRONT AND REAR WHEEL ......................................................................36
PRECAUTIONS ........................................................................................................................................................................37
REMOVAL OF THE ABS HYDRAULIC UNIT ...........................................................................................................................39
INSTALLATION OF THE ABS HYDRAULIC UNIT....................................................................................................................40
REMOVAL OF THE ABS ROTATION SENSORS – FRONT/REAR WHEEL ............................................................................41
FRONT BRAKE CALLIPER REMOVAL ....................................................................................................................................42
REAR BRAKE CALLIPER REMOVAL ......................................................................................................................................43
FRONT AND REAR CALLIPERS CHECK ................................................................................................................................45
FRONT BRAKE CALLIPER INSTALLATION ............................................................................................................................46
REAR BRAKE CALLIPER INSTALLATION ..............................................................................................................................48
FRONT FORK ..............................................................................................................................................49
FRONT FORK STEM REMOVAL .............................................................................................................................................49
FRONT FORK STEM DISASSEMBLY......................................................................................................................................52
FRONT FORK STEM INSPECTION.........................................................................................................................................55
FRONT FORK STEM ASSEMBLY ............................................................................................................................................56
FRONT FORK STEM INSTALLATION......................................................................................................................................59
HANDLEBAR ...............................................................................................................................................60
HANDLEBAR REMOVAL..........................................................................................................................................................60
HANDLEBAR INSPECTION .....................................................................................................................................................64
HANDLEBAR INSTALLATION ..................................................................................................................................................65
STEERING HEAD ........................................................................................................................................66
STEERING HEAD REMOVAL ..................................................................................................................................................66
STEERING BASE ........................................................................................................................................69
STEERING HEAD BASE REMOVAL........................................................................................................................................69
STEERING HEAD INSPECTION..............................................................................................................................................70
STEERING HEAD INSTALLATION ..........................................................................................................................................71
REAR SHOCK ABSORBER ........................................................................................................................73
REAR SHOCK ABSORBER REMOVAL ...................................................................................................................................73
REAR SHOCK ABSORBER CHECK ........................................................................................................................................76
REAR SHOCK ABSORBER INSTALLATION ...........................................................................................................................77

4-2
 CHAPTER 4
TRANSMISSION CHAIN AND SWINGING ARM ........................................................................................78
TRANSMISSION CHAIN REMOVAL ........................................................................................................................................78
TRANSMISSION CHAIN AND SWINGING ARM ........................................................................................80
REMOVAL OF THE SWINGING ARM ......................................................................................................................................80
SWINGING ARM INSTALLATION ............................................................................................................................................81
FRAME .........................................................................................................................................................82
REMOVAL/INSTALLATION OF FRAME PARTS ......................................................................................................................82
REMOVAL OF THE REAR FRAME ..........................................................................................................................................84
REAR FRAME INSTALLATION ................................................................................................................................................86
REMOVAL OF THE REAR PASSENGER HANDLES ..............................................................................................................87
INSTALLATION OF THE REAR HANDLES ..............................................................................................................................88
INSTALLATION OF THE REAR MUDGUARD SUPPORT .......................................................................................................89
INSTALLATION OF THE REAR MUDGUARD SUPPORT .......................................................................................................90
LICENCE PLATE HOLDER ......................................................................................................................................................91
REMOVAL OF THE LICENCE PLATE HOLDER ......................................................................................................................92
INSTALLATION OF THE LICENCE PLATE HOLDER ..............................................................................................................93
CYCLING .....................................................................................................................................................94
FRONT FOOTRESTS...............................................................................................................................................................94
STAND/FOOTRESTS ...............................................................................................................................................................95
REMOVAL OF THE RIGHT FRONT FOOTREST.....................................................................................................................96
INSTALLATION OF THE RIGHT FRONT FOOTREST .............................................................................................................97
REMOVAL OF THE LEFT FRONT FOOTREST .......................................................................................................................98
INSTALLATION OF THE LEFT FRONT FOOTREST ...............................................................................................................99
SIDE STAND...........................................................................................................................................................................100
REMOVAL OF THE SIDE STAND ..........................................................................................................................................101
INSTALLATION OF THE SIDE STAND ..................................................................................................................................102
REMOVAL OF THE RIGHT/LEFT REAR FOOTREST ...........................................................................................................103
INSTALLATION OF THE LEFT/RIGHT REAR FOOTREST ...................................................................................................104
REMOVAL OF THE LEFT/RIGHT FRONT FOOTREST .........................................................................................................105
LEFT/RIGHT FRONT FOOTREST INSTALLATION ...............................................................................................................106
REMOVAL OF THE GEAR PEDAL.........................................................................................................................................107
INSTALLATION OF THE GEAR PEDAL .................................................................................................................................108
CHAIN SLIDE REMOVAL .......................................................................................................................................................109
CHAIN SLIDE INSTALLATION ...............................................................................................................................................110
REMOVAL OF THE BRAKE CONTOL PEDAL ....................................................................................................................... 111
INSTALLATION OF THE BRAKE CONTROL PEDAL ............................................................................................................112
EXHAUST SYSTEM...................................................................................................................................113
EXHAUST ASSEMBLY ...........................................................................................................................................................113
EXHAUST ASSEMBLY REMOVAL .........................................................................................................................................114
EXHAUST INSTALLATION .....................................................................................................................................................116
FAIRING .....................................................................................................................................................117
FRONT MUDGUARD .............................................................................................................................................................117
FRONT MUDGUARD REMOVAL ...........................................................................................................................................118
REAR MUDGUARD REMOVAL..............................................................................................................................................120
REAR MUDGUARD INSTALLATION ......................................................................................................................................121
REMOVAL OF THE RIDER SEAT ........................................................................................................................................124
INSTALLATION OF THE RIDER SEAT ..................................................................................................................................125
SADDLE OPENING LEVER REMOVAL .................................................................................................................................126
SADDLE OPENING LEVER INSTALLATION .........................................................................................................................127
REMOVAL OF INSTRUMENT SUPPORT PLATE ..................................................................................................................128
INSTALLATION OF INSTRUMENT SUPPORT PLATE ..........................................................................................................130
REMOVAL OF THE FRONT HEADLAMP UNIT .....................................................................................................................131
INSTALLATION OF THE FRONT HEADLAMP UNIT .............................................................................................................132
REMOVAL OF FUEL TANK ....................................................................................................................................................133
TANK FITTING........................................................................................................................................................................135
UPPER TAIL FAIRING ............................................................................................................................................................136
BOTTOM COVER REMOVAL.................................................................................................................................................138

4-3
 CHAPTER 4
BOTTOM COVER INSTALLATION .........................................................................................................................................139
SADDLE LOCK REMOVAL.....................................................................................................................................................140
SADDLE LOCK INSTALLATION .............................................................................................................................................141
REMOVAL OF THE SIDE FAIRINGS .....................................................................................................................................142
INSTALLATION OF THE SIDE FAIRINGS..............................................................................................................................143
REMOVAL OF THE LOWER CENTRAL FAIRING .................................................................................................................144
REMOVAL OF THE REAR LIGHT ..........................................................................................................................................146
INSTALLATION OF THE REAR LIGHTS ................................................................................................................................147
CHAIN PINION COVER..........................................................................................................................................................148
REMOVAL OF THE CHAIN PINION COVER .........................................................................................................................149
INSTALLATION OF THE CHAIN PINION COVER .................................................................................................................150
TANK ..........................................................................................................................................................151
TANK PARTS ..........................................................................................................................................................................151
REMOVAL OF THE TANK CAP SUPPORT ............................................................................................................................152
INSTALLATION OF THE TANK CAP SUPPORT ....................................................................................................................153
REMOVAL OF THE FUEL PUMP ...........................................................................................................................................154
INSTALLATION OF THE FUEL PUMP ...................................................................................................................................155
REMOVAL OF THE TANK FUEL LEVEL SENSOR ................................................................................................................156
INSTALLATION OF THE TANK FUEL LEVEL SENSOR ........................................................................................................157
AIR FILTER ................................................................................................................................................158
AIR FILTER PARTS ................................................................................................................................................................158
REMOVAL OF THE AIR FILTER BOX ....................................................................................................................................159
INSTALLATION OF THE AIR FILTER BOX ............................................................................................................................161

4-4
 FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL REMOVAL

Park:
• The motorcycle on a level surface.
A

NOTE:_________________________________
Place the bike on a suitable support so that the front wheel
is raised. 2
Remove:
• Front mudguard, refer to the section “Removal of front
mudguard, Chapter 4”.

Remove:
1
• The screw “1”.
• The ABS sensor “2” Fig. A.
• The screws ”3” Fig. B.
• The tube guide bracket “4.” Fig. B.

Detach: B
• The right brake calliper.

NOTE:_________________________________
Repeat the above-mentioned procedure for the opposite
front brake calliper.

NOTE:_________________________________
3 4
Do not pull the front brake lever while removing the callipers.

Loosen:
• The setscrews “5” Fig. C.

Remove:
• The front wheel axle pin ”6” Fig. D. D

4-5
 FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL REMOVAL

• The front wheel.

• The right shim ”7” Fig. E.
E

• The shim “8” Fig. F.

F

4-6
 FRONT WHEEL AND BRAKE DISCS
REMOVAL/INSTALLATION OF BRAKE DISCS

1
3

1 11

9
4 2
10
8
12
10
4
1
5

6
1

INTERVENTION
Pos. Description SQ. SYMBOLS REMARKS
DESCRIPTION
1 SCREW
2 FRONT BRAKE DISC
3 LEFT SHIM
4 BEARING
5 FRONT WHEEL RIM (GREY)
6 FRONT WHEEL AXLE PIN
7 VALVE
8 SHIM
9 INTERNAL SHIM
10 OIL SEAL
11 FRONT WHEEL ABS SENSOR
12 FRONT TYRE 120/70-R17

4-7
 FRONT WHEEL AND BRAKE DISCS
REMOVAL/INSTALLATION OF BRAKE DISCS

Remove:
• Front wheel, refer to the section “Removal of the front
A
wheel”. 2
• Brake callipers, refer to the section “Removal of the front
brake callipers”.
• Screws “1” Fig. A.
• Brake disc “2” Fig. A.
1
Install:
• Left front brake disc.
• Screws “1”.

NOTE:_________________________________
Repeat the above-mentioned procedure for the opposite
front disc brake.
B
MEDIUM THREAD LOCK-
ER
1
6

The procedure below applies to both brake discs. 3

4

NOTE:_________________________________
Tighten the bolts on the brake disc in successive steps and 5
2
proceeding in a crossover manner Fig B.

• Tighten to the torque:

T. R .

Torque 22 N*m

4-8
 FRONT WHEEL AND BRAKE DISCS
CHECK OF BRAKE DISCS

The procedure below applies to all brake discs.

Check:
A
• The brake disc.
If there is any damage/abrasion, replace.

Measure:
• The deformation of the brake disc.
Substitute the brake disc if it is outside the specification.

• Place the motorcycle on a suitable support so that the wheel

is raised.
• Before measuring the bending of the front brake disc, turn
the handlebar right and then left to make sure that the front
wheel does not move.
• To remove the brake calliper, refer to the section “Removal
of the brake calliper”.
• Keep the gauge at a right angle to the surface of the brake B
disc.
• Measure the bending, which must be between 0.1 mm and
0.15 mm (0,03-0,059 in) under the edge of the brake disc
Fig. A.

Brake disc Deformation limit

Front 0.1 mm
Rear 0.15 mm 3
Disc (thickness 5 mm)
4.5 mm
Fig. B.

Measure:
• Brake disc thickness.
• Measure the thickness of the brake disc at various different
points - Fig. B.
• If outside specifications, replace.

4-9
 FRONT WHEEL AND BRAKE DISCS
WHEEL AXLE CHECK

Carry out a visual check of the front wheel and rear wheel axle
pin to check for damage.
A
Replace the wheel axle pin if it is damaged or bent.
1

Check:
• Wheel axle.
• Position the wheel axle on two V-shaped blocks approx. 100
mm apart (3) and position a comparator (1) on the wheel
axle at a point halfway between the blocks – Fig. A. 2
• Rotate the wheel axle (2) to measure the lack of centring.
3
The difference between the upper and lower detections of the
comparator represents the measurement of the misalignment.
Substitute the wheel axle pin, if the misalignment exceeds the
service limit.

Wheel axle pin runout /100 mm

Standard LIT 0.1 mm or less B
Service limit LIT 0.2 mm 2

1
IMPORTANT NOTICE
Do not try to straighten the wheel axle if it is warped.
If there is any warping, replace.

Check:
• The tyre.
• The front wheel.
If there is any damage/wear, replace.

Measure:
• The radial eccentricity of the wheel “1” Fig. B.
• The side eccentricity of the wheel “2” Fig. B.
If the specified limit is exceeded, replace.

Eccentricity Limit
Radial(1) 1.5 mm
Side(2) 1.5 mm

4 - 10
 FRONT WHEEL AND BRAKE DISCS
CHECK/REPLACEMENT OF WHEEL BEARINGS

Check:
• The wheel bearings.
A
If the front wheel turns irregularly or is loose, replace the wheel
bearings.

Replace:
• The wheel bearings.
Remove the wheel bearings “1” using a general bearing ex-
tractor Fig. B.
Insert the new wheel bearings, following the removal steps in
reverse order.

IMPORTANT NOTICE
During the bearing insertion, do not touch the inner seat “1”
or the ball bearings of the wheel “2”. Contact must only oc- B
cur with the outer seat of bearing “3” Fig. C.

NOTE:_________________________________ 1
Use a wrench that adapts to the diameter of the external
edge of the wheel bearing.

4 - 11
 FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 1
Prop the motorcycle on suitable supports so that it cannot
fall.

Install:
Proceed using the opposite order to removal.

Tighten to the torque:

• Wheel axle pin “1” Fig. A.

G
Recommended lubricant
NGLI2 GREASE
B
T. R .

Torque 60 N*m
2
• The setscrews ”2” Fig. B.
T. R .

Torque 10 N*m

IMPORTANT NOTICE
Before tightening the front wheel axle pin, push hard on the
handlebars to check that the front fork returns to the station-
ary position in a smooth way.

Install:
C
• Right brake calliper Fig. C. 3
• Tube guide bracket “3” Fig. C.
• Screws (4) Fig. C.

Tighten to the torque:

T. R .
4
Torque 50 N*m

Install:
• ABS sensor Fig. D.
• Screw (5) Fig. D.

NOTE:_________________________________
Repeat the above-mentioned procedure for the opposite
D
brake calliper.
Ensure that there is enough space between the brake pads
before fitting the callipers on the relative brake discs.
Check that the travel of the flexible brake hose is correct.

4 - 12
 REAR WHEEL AND BRAKE DISC
REAR WHEEL REMOVAL

8
11
20
19
9
21

12
18 22

18 15
15 10
13
17
23 16
15
10 10

7
13
14
4
26

6
3 24
5
3 26
25
3 1
2
27

INTERVENTION
Pos. Description SQ. SYMBOLS REMARKS
DESCRIPTION
1 REAR WHEEL AXLE PIN
2 BUSHING
3 SCREW
4 REAR BRAKE DISC
5 VALVE
6 REAR WHEEL RIM
7 INTERNAL SHIM
8 DUST COVER
9 NUT
10 FLEXIBLE COUPLING
11 SHIM
12 O-RING
13 BEARING
14 OIL SEAL
15 SCREW
16 SPROCKET FLANGE
17 SPROCKET
18 NUT
19 SHIM

4 - 13
 REAR WHEEL AND BRAKE DISC
REAR WHEEL REMOVAL

INTERVENTION
Pos. Description SQ. SYMBOLS REMARKS
DESCRIPTION
20 BEARING
21 ELASTIC RING
22 TRANSMISSION CHAIN
23 REAR TYRE
24 CALLIPER HOLDER PLATE
24 CALLIPER HOLDER PLATE
25 SUPPORT PLATE
26 SCREW
27 REAR WHEEL ABS SENSOR

4 - 14
 REAR WHEEL AND BRAKE DISC
REAR WHEEL REMOVAL

Park:
• The motorcycle on a level surface.
A

NOTE:_________________________________
Place the bike on a suitable support so that the rear wheel 2
is raised.

Remove:
• Licence plate holder support arm, refer to the section “Li-
cence plate support arm removal”.
• The screw “1” Fig. A.
• The phonic wheel sensor “2” Fig. A.
1
Remove:
• The screws ”3” Fig. B.
• The brake calliper.
B

Remove: C
• The nut “4” Fig. C.
• The register slide “5” Fig. C.
• The pin “6” Fig. D. 4
• The register slide “7” Fig. D.
5

7
6

4 - 15
 REAR WHEEL AND BRAKE DISC
REAR WHEEL REMOVAL

NOTE:_________________________________
During this phase, be careful in separating the components
E
such as the chain tensioner register on the sprocket side and
the brake disc side and brake calliper support plate ”8” Fig. E.

Remove: F
• The bushing “9” Fig. F.
• The shim “10” Fig. G.

10

4 - 16
 REAR WHEEL AND BRAKE DISC
SPROCKET AND REAR BRAKE DISC REMOVAL

Remove: A
• Rear wheel, refer to the section “Rear wheel removal,
Chapter 4”.
Remove the brake disc:
• The screws (3*) Fig. A.
4
• The brake disc (4*) Fig. A. 26
Take out the sprocket:
• The nuts (18*).
• The sprocket (17*). 3
• The flange (16*).
3
• The screws (15*).
• The flexible couplings (10*). 3

Check:
• The sprocket support flange (16*).
• If there is any cracking/damage, replace.
• The flexible couplings (10*).
• ]f there is any damage or wear, replace.
18 B

NOTE:_________________________________
18 15
The numbers marked (*) are a part of the “Rear wheel and
15 10
brake disc” table. 13
17
16
15
10 10

4 - 17
 REAR WHEEL AND BRAKE DISC
WHEEL AXLE CHECK

Check:
• Wheel axle.
A
1
• Roll the wheel axle “1” on a flat surface Fig. A.
If there is any warping, replace.

WARNING
Do not try to straighten the wheel axle if it is warped.

Check:
• The tyre.
• The front wheel.
If there is any damage or wear, replace.

Measure:
• The radial eccentricity of the wheel “2” Fig. B.
• The lateral eccentricity of the wheel “3” Fig. B.
If the specified limit is exceeded, replace. B
3

2
Eccentricity Limit
Radial(2) 1.5 mm
Side(3) 1.5 mm

4 - 18
 REAR WHEEL AND BRAKE DISC
CHECK/REPLACEMENT OF WHEEL BEARINGS

Check:
A
• The wheel bearings.
If the front wheel turns irregularly or is loose, replace the wheel
bearings.

Replace:
• The wheel bearings.
Remove the wheel bearings “1” using a general bearing ex-
tractor Fig. B.
Insert the new wheel bearings, following the removal steps in
reverse order.

IMPORTANT NOTICE
During the bearing insertion, do not touch the inner seat “1”
or the ball bearings of the wheel “2”. Contact must only oc-
cur with the outer seat of bearing “3” Fig. C.
B
NOTE:_________________________________
Use a wrench that adapts to the diameter of the external
edge “4” of the wheel bearing Fig. C.

C
4

4 - 19
 REAR WHEEL AND BRAKE DISC
CHECK AND REPLACEMENT OF SPROCKET

Check:
A
• The sprocket. 1
If more than 1/4 of each tooth is worn, replace the sprocket.
If the teeth are bent, replace the sprocket.
3
1. 1/4 teeth. 2
2. Correct.
3. Transmission chain roller.
4. Sprocket. 4

Replace:
• The sprocket, refer to the section “Removal of the rear
brake disc, sprocket and phonic wheel”.
• Clean the sprocket holder flange (16*) using a clean cloth,
especially the surfaces that touch the sprocket.
18 B

Solvent with high flash point.

18 15
15 10
13
17
Install: 16
• The new sprocket. 15
• The self-locking nuts (18*) and tighten to the following 10 10
torque:

T. R .

Torque 45 N*m

NOTE:_________________________________
Tighten the self-locking nuts in several stages, proceeding
with a crossover sequence.

NOTE:_________________________________
The numbers marked (*) are a part of the “Rear wheel and
brake disc” table.

4 - 20
 REAR WHEEL AND BRAKE DISC
BRAKE DISC INSTALLATION

Install:
• The brake disc (4*) Fig. A.
A
• Lubricate the screws (26) Fig. A.

4
26
MEDIUM THREAD
LOCKER
3

3
• Tighten to the following torque:
3
T. R .

Torque 10 N*m

NOTE:_________________________________
Tighten the self-locking nuts in several stages, proceeding
with a crossover sequence.

NOTE:_________________________________
The numbers marked (*) are a part of the “Rear wheel and
brake disc” table.

4 - 21
 REAR WHEEL AND BRAKE DISC
REAR WHEEL INSTALLATION

Install:
A
• Position the brake calliper support bracket (1) Fig. A.

• Insert the bushing (2) right side Fig. B. B

• Insert the bushings (3) left side Fig. C. C

• Position the register slide (4) Fig. D. D

4

4 - 22
 REAR WHEEL AND BRAKE DISC
REAR WHEEL INSTALLATION

• Position the register slide (5) Fig. E.

• Position the rear wheel. E
5
Lubricate and install:
• The pin (6) Fig. F.
• The nut (7) Fig. G.

G
Recommended lubricant
NGLI2 GREASE

• tighten to the following torque:

T. R .

Torque 80 N*m
F
Install:
• The brake calliper (8) Fig. H.
• The screws (9) Fig. H.
• Tighten to the following torque:

T. R .

Torque 22 N*m

NOTE:_________________________________ 6
Make sure that there is enough space between the brake pad
before fitting the calliper to the relevant brake disc.

IMPORTANT NOTICE
Check that the travel of the flexible brake hose is correct.
G

H
8

4 - 23
 FRONT AND REAR BRAKES
REMOVAL AND INSTALLATION OF FRONT BRAKE PADS

The procedure that follows is applicable to both front brake

callipers.
A

NOTE:_________________________________
Substitute the brake pads always together to ensure a uni- 1
form pressure.

Remove:
• Pin springs (1) Fig. A.
• Fixing pin (2) Fig. B.
• Remove the brake pads (3) Fig. C.

Measure:
• The wear limit for the brake pads.
If outside specifications, replace the brake pads as a block.

B
Pads Wear limit
Front 1 mm 2

Clean:
• Press the pistons of the calliper inside to permit the installa-
tion of the new brake pads.

Install:
• The brake pads in reverse order of disassembly.
• The brake calliper.

Check:
The brake fluid level “4” Fig. D.
If below the minimum notch, top up with the recommended C
brake fluid until it is at the correct level.
Refer to the Chapter 3, Periodic maintenance, section “Check-
ing and topping up the front brake fluid level”.

Check:
• Brake lever operation.
If the brake lever is soft or spongy to the touch, bleed the brake
circuit.

4 - 24
 FRONT AND REAR BRAKES
REMOVAL AND INSTALLATION OF REAR BRAKE PADS

Remove: A
• The screw “1” Fig. A.
• The calliper body Fig. B.

Take out:
• The brake pads ”2” Fig. B. 1
Measure:
• The wear limit for the brake pads.
If outside specifications, replace the brake pads as a block.

Pads Wear limit

Rear 1 mm

Clean: B
• Inside the calliper.
• The pistons, then dry everything. 2
Press:
• Press the pistons of the calliper inside to permit the installa-
tion of the new brake pads.

Install:
• The brake pads in reverse order of disassembly.
• The brake calliper.
• The screws.
• Tighten to the following torque:

T. R .

Torque 22 N*m
C

Check:
• The brake fluid level “3” Fig. C.
Top up with brake fluid if the level is less that the minimum level
mark. 3
• Brake pedal operation.

IMPORTANT NOTICE
Do not utilise the motorcycle if full efficiency of the brake
pedal cannot be obtained. Full efficiency is activated by op-
erating the brake pedal several times so as to bring the pads
into contact with the disc. If this operation is not carried out,
the brakes will not operate the first time when the pedal is
activated.

4 - 25
 FRONT AND REAR BRAKES
FRONT BRAKE PUMP REMOVAL

21
21
23
2
13 9 22
28
25
20 9
9 27 26
9

20
9 17 12 11
10 19
16 24
9 9 30 14
17 9
9 31

18 15

INTERVENTION
Pos. Description SQ. SYMBOLS REMARKS
DESCRIPTION
1 BRAKE OIL TANK

2 SCREW

3 REAR BRAKE PUMP HOSE- ABS ECU

4 REAR BRAKE CALLIPER HOSE – ABS ECU

5 REAR BRAKE PUMP

6 REAR BRAKE CALLIPER

7 BRAKE PADS PAIR (REAR)

8 REAR IDROSTOP

9 SEAL

10 FRONT BRAKE PUMP HOSE- ABS ECU

11 FRONT BRAKE HOSE

12 FRONT BRAKE CALLIPER PIPE - ECU ABS

13 COMPLETE FRONT BRAKE PUMP

14 LEFT BRAKE CALLIPER (RADIAL)

15 RIGHT BRAKE CALLIPER (RADIAL)

4 - 26
 FRONT AND REAR BRAKES
FRONT BRAKE PUMP REMOVAL

INTERVENTION
Pos. Description SQ. SYMBOLS REMARKS
DESCRIPTION
16 ABS HYDRAULIC UNIT

17 SPRING BAND

18 BRAKE PADS PAIR (FRONT)

19 SPECIAL SCREW

20 SPECIAL SCREW

21 SCREW

22 SPECIAL SCREW

23 SPECIAL SCREW

24 SPECIAL SCREW

25 FRONT BRAKE LEVER

26 SELF-LOCKING NUT

27 SCREW

28 MICROSWITCH

29 BRACKET

30 RUBBER TIP

31 SPECIAL SCREW

32 ELASTIC WASHER

33 SCREW

4 - 27
 FRONT AND REAR BRAKES
FRONT BRAKE PUMP REMOVAL

NOTE:_________________________________
Drain out the brake fluid before proceeding with these oper-
A
ations.
Refer to Chapter 3, Periodic maintenance, section “Checking
and topping up the front brake fluid level”. 2
1
IMPORTANT NOTICE
When removing the pump, avoid spilling onto the surfaces of
the motorcycle brake fluid that has remained in the system.

Remove:
• The special screw (1) Fig. A.
• The sealing washer (2) Fig. A. 3
• Disconnect the front brake hose (3) Fig. A.
Disconnect:
• The connector of the front brake switch (4) Fig. B.
• The screw (5) Fig. C. B
• The micro-switch (6) Fig. C.
• The nut (7) Fig. C.
• The screw (8) Fig. C.
• The front brake lever (9) Fig. C.
• The screws (10) Fig. C.
• The U-clamp (11) Fig. C.
• Remove the pump body (12) Fig. C.

IMPORTANT NOTICE 4
During the disassembly stage, do not allow any brake fluid
remaining in the circuit to drip onto the vehicle surfaces.

C
10 11

8
6
9
12
5

4 - 28
 FRONT AND REAR BRAKES
REMOVAL OF THE REAR BRAKE PUMP

8
1 9
5 9
2
33 3

17

7 20
21 9
20
9
32 6
16
9
9
20
4

NOTE:_________________________________
The above exploded view is part of the spare parts table of the chapter “Front and rear brakes”, section “Removal of the
front brake pump”.

4 - 29
 FRONT AND REAR BRAKES
REMOVAL OF THE REAR BRAKE PUMP

NOTE:_________________________________
Drain out the brake fluid before proceeding with these oper-
A
ations.
Refer to the Chapter 3, Periodic maintenance, section 2
“Checking and topping up the front brake fluid level”.

Remove:
• Rear footrest support, refer to the section “Removal of the 3
rear footrest support, Chapter 4”.
• Screws (1) Fig. A.
• Idrostop (2) Fig. A.
• Sealing washer (3) Fig. A.
• Release the main brake hose (4) Fig. B.
1
• Release the brake reservoir hose (5) Fig. C.
• Remove the brake pump (6) Fig. C.

B
IMPORTANT NOTICE 4
During the disassembly stage, do not allow any brake fluid
remaining in the circuit to drip onto the vehicle surfaces.

5
6

4 - 30
 FRONT AND REAR BRAKES
FRONT BRAKE PUMP INSTALLATION

WARNING A
Before installing, clean all of the internal parts of the brake,
and lubricate them with clean or new brake fluid.
Never use solvents on the internal parts of the brake.
1

Recommended brake fluid 3

DOT4

• Place the pump body (1) Fig. A.

Install:
• The U-clamp (2) Fig. A.
2
• The screws (3) Fig. A.
Tighten to the following torque:

T. R . B

Torque 8 N*m

Install: 4
• The micro-switch (4) Fig. B.
• The screw (5) Fig. B.
Tighten to the following torque:

T. R .

5
Torque 1.5 N*m

Install:
• The front brake hose to the brake pump (6) Fig. C.
• The sealing washer (7) Fig. C.
• The special screw (8) Fig. C. C
7
Tighten to the following torque:

T. R .

Torque 26 N*m 8
Connect:
• The switch connector (4) Fig. D.
• Position the front brake lever (9) Fig. D.
• Nut (10) Fig. D.
• Screw (11) Fig. D.
6
Tighten to the following torque:
T. R .

D
Torque 7 N*m
11
WARNING
To guarantee the safety of the motorcycle, it is essential for
the path of the brake hose to be correct. 4

NOTE:_________________________________
9
Once topping up operations of the brake fluid have finished,
refer to Chapter 3, Periodic maintenance, section “Checking
and topping up the front brake fluid level”.

10

4 - 31
 FRONT AND REAR BRAKES
REAR BRAKE PUMP INSTALLATION

IMPORTANT NOTICE A
Prop the motorcycle on suitable supports so that it cannot
fall.
1
Proceed to install, following the steps for removal in reverse
order, but taking care to observe the instructions below:

Install:
• the idrostop (1) and tighten to the following torque:

T. R .

2
Torque 12 N*m

• Screws (2) Fig. A.

Tighten to the following torque:

T. R .

Torque 12 N*m

IMPORTANT NOTICE
When assembling, avoid spilling of the brake fluid that has
remained in the system onto the surfaces of the motorcycle.

4 - 32
 ABS ANTI-LOCK BRAKING SYSTEM
LOCATION OF THE COMPONENTS

The components that compose the anti-lock braking system are:

A
• Phonic wheel sensor (1) of the front wheel Fig. A.
• Phonic wheel (2) of the front wheel Fig. A.

• Phonic wheel sensor (3) of the rear wheel Fig. B.

B
• Phonic wheel (D) of the rear wheel Fig. B.

• ABS yellow light (5) Fig. C. C

5

• ABS hydraulic unit (6) Fig. D. D

4 - 33
 ABS ANTI-LOCK BRAKING SYSTEM
LOCATION OF THE COMPONENTS

• Fuse box (7) Fig. E. E

• Connector of the ABS diagnostic system (8) Fig. F. F

4 - 34
 ABS ANTI-LOCK BRAKING SYSTEM
ROTATION SENSOR CHECK

IMPORTANT NOTICE A
The wheel rotation sensor must be handled with caution,
must not receive knocks, e.g., with a hammer, or dropped on
a hard surface.
Do not soak the wheel rotation sensor in water or mud. 2
Do not attempt to repair or disassemble the wheel rotation
sensor.

Remove:
• The screw (1) Fig. A.
• The phonic wheel sensor (2) of the front wheel Fig. A.
Disconnect: 1
• The connector of the phonic wheel.

Carry out a visual check of the rotation sensor of the phonic

wheel. Substitute the wheel rotation sensor if it is cracked, bent
or damaged in anyway. If an electrical fault in the sensors is B
suspected, check the electrical circuit.

Remove:
• The screw (3) Fig. B.
• The phonic wheel sensor (4) of the rear wheel Fig. B.
Disconnect:
• The connector of the phonic wheel.

Carry out a visual check of the rotation sensor of the phonic

wheel. Substitute the wheel rotation sensor if it is cracked, bent 3 4
or damaged in anyway. If an electrical fault in the sensors is
suspected, check the electrical circuit.

NOTE:_________________________________
Place the motorcycle on a suitable support so that the front
wheel is raised.

Check:
Lift the front/rear wheels off the ground and measure the
distance at various points between the sensor and the phonic
wheel.

Air gap
Front Rear
1 – 1.5 mm 1.0 - 1.5 mm

NOTE:_________________________________
It is not possible to adjust the distance of the sensor.

• If the distance does not come within the prescribed values,

check the hub bearing (refer to paragraph Removal/Instal-
lation of the front/rear wheel), the sensor, the phonic wheel
and the assembly conditions of the sensor.

4 - 35
 ABS ANTI-LOCK BRAKING SYSTEM
CHECK OF THE ABS PHONIC WHEEL OF THE FRONT AND REAR WHEEL

Check:
Carry out a visual check of the phonic wheel of the wheel.
E
Substitute the phonic wheel if it is deformed or damaged, such
as damaged teeth (1). Fig. E
Remove any deposits of metal or other magnetic material (2). If
necessary, replace the phonic wheel.

REPLACEMENT OF THE ABS PHONIC WHEEL OF THE

FRONT AND REAR WHEEL F
11

Remove:
• Front wheel, refer to the section “Removal of the front
wheel”.
• The screws (1). 7

• The phonic wheel (11) Fig. F.

• Rear wheel, refer to the section “Removal of the rear 9
wheel”. 4 2
10
• The screws (26). 8
• The phonic wheel integrated in the brake disc (4) Fig. G. 10
4
1
5

6
1

4
26

4 - 36
 ABS ANTI-LOCK BRAKING SYSTEM
PRECAUTIONS

PRECAUTIONS DURING THE MAINTENANCE OF THE ABS

A series of important precautions must be adopted during the maintenance of the ABS system.
• The ABS system has been designed to be fed by a 12V sealed battery. Do not use any other type of battery, only sealed 12V.
• Do not invert cable connections of the battery. It would damage the ABS hydraulic unit.
• To avoid damage to the ABS components, do not disconnect the battery cables or other electrical connections when the start
switch is positioned at ON or when the engine is running.
• Be careful to not cause a short circuit between the cables directly connected to the positive terminal (+) of the battery and the
ground of the frame.
• Do not position the start switch at ON whilst the ABS electrical connectors are disconnected. The hydraulic unit
• of the ABS memorises the maintenance codes.
• Do not spray water onto the electrical components, the components of the Abs, cables, connectors or the cabling.
• If there is a transmitter/receiver installed on the motorcycle, ensure that the functioning of the ABS system is not disturbed by
electromagnetic waves irradiated by the antenna.
• Position the antenna as far away as possible from the ABS hydraulic unit.
• Position the start switch at OFF before disconnecting the electrical connections of the ABS.
• The components of the ABS must never be hit, for example by a hammer or must not be dropped onto a hard surface. These
impacts could cause damage to the components.
• The ABS components cannot be disassembled. Even if there is a fault, substitute the ABS unit, do not try to disassemble and
repair the components.
• The ABS system is made up of numerous circuits, tubes and cables of the brakes.
• Furthermore, the ABS system is not capable of detecting problems of the conventional braking system (abnormal wear of the
brake discs, brake
• pads and other mechanical faults). To avoid inconveniences, check that the brake circuits and tubes are arranged and connect-
ed correctly, the cabling is opportunely laid out and the brakes are equipped with adequate braking power.
• Check that there are no leaks of fluid and then accurately bleed the brake circuits.

IMPORTANT NOTICE
Air in the brake tubes reduces the braking power that could cause a serious accident with severe injuries and even death. If
any union of the brake circuit, including the nuts of the ABS hydraulic unit joint, or the bleed valve are opened, the air entered
into the system must be completely bled from the brake circuit. If the brake lever is spongy when pressed, there could be air
in the tubes of the brake circuit, or the brake could be defective. In that case, do not use the vehicle and immediately repair
the brake system.

IMPORTANT NOTICE
Do not use the motorcycle if there is air in the brake circuit, otherwise the ABS system could function incorrectly.

IMPORTANT NOTICE
The use of tyres that are not recommended could cause malfunctioning of the ABS system and cause an increase in the
braking distance thereby causing a serious accident with severe injuries and even death. Always use the recommended
standard tyres for this motorcycle.

4 - 37
 ABS ANTI-LOCK BRAKING SYSTEM
PRECAUTIONS

IMPORTANT NOTICE A
The LED yellow warning light of the ABS (1) Fig. A could
come on if the tyre pressure is not correct, if tyre not rec-
ommended has been fitted, or if the wheel is deformed. If the
warning light comes on, solve the problem by cancelling the
maintenance code.

4 - 38
 ABS ANTI-LOCK BRAKING SYSTEM
REMOVAL OF THE ABS HYDRAULIC UNIT

IMPORTANT NOTICE A
The ABS hydraulic unit (1) has been adjusted and set with
precision by the manufacturer. Therefore it must be handled
very carefully, must never by hit for example by a hammer, or
dropped on a hard surface. Do not soak the ABS hydraulic
unit in water or mud.

• Bring the start switch to the OFF position. 1

Remove:
• Rider seat, refer to the section “Removal of rider and pas-
senger seats, Chapter 4”.
• Fuel tank, refer to the section “Removal of the fuel tank,
Chapter 4”.
• Discharge the brake fluid from the front and rear brake
circuit utilising the bleed valve and pumping the brake lever
and the brake pedal. B
• Do not forget to place a cloth underneath the ABS hydraulic
unit.
• The nuts of the rigid tubing (2) Fig. B.
• The screw (3) Fig. C.

Disconnect:
• The connector of the ABS hydraulic unit (4) Fig. B by rotat-
ing the lever as indicated in the figure.
2
4
Remove:
• The ABS hydraulic unit.

NOTE:_________________________________
Be careful to not bend the brake hose when removing
the ABS hydraulic unit.

• Close the oil passage holes (A) of the ABS hydraulic unit (B) C
with a cloth to avoid dirt from entering into the unit Fig. D.

IMPORTANT NOTICE
Do not allow dirt to enter into the hydraulic system when the
tubes are disconnected. Brake fluid rapidly damages paint- 3
ed plastic surfaces; completely wash the concerned zones
immediately.

IMPORTANT NOTICE
The ABS hydraulic unit has been adjusted and set with preci-
sion by the manufacturer.
Do not attempt to repair or remove the ABS hydraulic unit.

Check:
D
• Carry out a visual check of the ABS hydraulic unit.
• Replace the ABS hydraulic unit if any component is cracked
or damaged in any way.

4 - 39
 ABS ANTI-LOCK BRAKING SYSTEM
INSTALLATION OF THE ABS HYDRAULIC UNIT

Position the ABS hydraulic unit on the frame. A

Install:
• Install the rigid tubes of the brakes onto the ABS hydraulic
unit and manually screw in the flare nuts without tightening.
• Front brake calliper hose (1) Fig. B.
• Front brake pump hose (2) Fig. B. 5
• Rear brake calliper hose (3) Fig. B.
• Rear brake pump hose (4) Fig. B.
Tighten the union nuts of the rigid tubing Fig. B to the following
torque:

T. R .
B
Torque 18. N*m

Install:
• The screw (5) Fig. A

3
Connect:
• The connector of the ABS hydraulic unit (6) Fig. C. 6 4

Install: 2
To install, reverse the order of the removal operation. 1
• Bleed the air from the brake circuit, refer to the section
“Frame/brake fluid level check, Chapter 3”.

4 - 40
 ABS ANTI-LOCK BRAKING SYSTEM
REMOVAL OF THE ABS ROTATION SENSORS – FRONT/REAR WHEEL

IMPORTANT NOTICE A
The wheel rotation sensor must be handled with caution,
must not receive knocks, e.g., with a hammer, or dropped on
a hard surface.
Do not soak the wheel rotation sensor in water or mud. Do
not attempt to repair or disassemble the wheel rotation sen-
sor.
1
Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Fuel tank, refer to the section “Removal of the fuel tank,
Chapter 4”.
• Front wheel rotation sensor, refer to the section “ABS an-
ti-lock braking system, Rotation sensor check”.
• Disconnect the connector of the front wheel rotation sensor
(1) Fig. A. B
• Disconnect the connector of the rear wheel rotation sensor
(2) Fig. B.

Install:
To install, reverse the order of the removal operation. 2
Place the cable correctly.

4 - 41
 FRONT AND REAR BRAKES
FRONT BRAKE CALLIPER REMOVAL

The following procedure is applied to both brake callipers.

A
NOTE:_________________________________
20
9 17 12 11
Before disassembling the brake calliper, discharge the brake
fluid from the complete braking system, refer to the section 10 19
“Frame/brake fluid level check, Chapter 3”. 16 24
9 9 30 14
Remove:
17 9
• The special screw (24*) and (19*) Fig. A.
• The sealing washer (9*) Fig. A. 9
• The front brake hose (12) Fig. A. 31
• The screws (1) Fig. B.
• Remove both callipers. 18 15

NOTE:_________________________________
Insert the end of the brake hose into a container and slowly
pump out and drain the brake fluid.
1 B
IMPORTANT NOTICE 1
Brake fluid rapidly damages painted plastic surfaces; com-
pletely wash the concerned zones immediately.

Detach:
• The pistons (1) Fig. C.
• The seals (2) Fig. C (first the oil seals – the smallest seals,
then the O-rings – the largest seals).

Secure:
• The pistons of the brake callipers with a block of wood Fig.
D.
• Blow compressed air into the attachment of the flexible
brake hose to push the left pistons outwards from the brake
calliper. C
IMPORTANT NOTICE
Never try to prise out the calliper pistons.

NOTE:_________________________________
Repeat the above-mentioned procedure to force the pistons
out from the opposite brake calliper.
1
Check:
The ring seal of the brake calliper.
The ring seal (piston seal) (2) Fig. C that are found inside the
piston to maintain the clearance between the pads and the disc. 2
If the seal is in bad condition, it can cause excessive wear of the
pads or sticking of the brake, with a consequent increase of the
temperature of the discs or the brake fluid.
D
Replace:
• The seals (2) Fig. C.
Replace the seal if it shows signs of the following:
• Brake fluid leak around the brake pad.
• Brakes overheating.
• Notable difference of wear between the internal and exter-
nal brake pad.
• If the seal and piston are stuck to each other.
Replace the seals when replacing the brake pads.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Front and rear brakes”, section “Removal of the
front brake pump”.

4 - 42
 FRONT AND REAR BRAKES
REAR BRAKE CALLIPER REMOVAL

NOTE:_________________________________
Before disassembling the brake calliper, discharge the brake
A
fluid from the complete braking system, refer to the section 20
“Frame/brake fluid level check, Chapter 3”. 7
21 9
Remove: 20
• The screw (20*) Fig. A. 9
• The sealing washers (9*) Fig. A. 32 6
• The rear brake hose (4.) Fig. A.
16
Remove the calliper.
9
9
NOTE:_________________________________ 20
Insert the end of the brake hose into a container and slowly
pump out and drain the brake fluid. 4

Disassemble:
• The pistons (1) Fig. B. B
• The seals (2) Fig. B
• (first the oil seals – the smallest seals, then the O-rings –
the largest seals).
1

2
D

• Fix the pistons of the brake calliper with a block of wood C

Fig. C.

• Blow compressed air into the attachment of the flexible

brake hose to force the pistons from the brake calliper.

Disassemble:
• The sliding pins (3) and (4) Fig. E.
• Covers against dust (1) and (2) Fig. D.
E

4 - 43
 FRONT AND REAR BRAKES
REAR BRAKE CALLIPER REMOVAL

IMPORTANT NOTICE D
Never try to prise out the calliper pistons.

Replace: 1
• The seals (2) Fig. B.
• The seal if it shows signs of the following: 2
- Brake fluid leak around the brake pad.
- Brakes overheating.
- Notable difference of wear between the internal and exter-
nal brake pad.
- If the seal and piston are stuck to each other.

Replace the seals when replacing the brake pads.

IMPORTANT NOTICE
When the repair has finished, the brake lever and pedal must
pressed several times so that the pads come into contact
with the brake discs, thereby causing a longer braking dis-
tance and an accident with serious injuries or death. Do not
utilise the motorcycle if full efficiency of the brake pedal can-
not be obtained. Full efficiency is activated by operating the
brake pedal several times so as to bring the pads into con-
tact with the disc.

NOTE:_________________________________
The numbers marked (*) are a part of the table at the begin-
ning of the chapter.

4 - 44
 FRONT AND REAR BRAKES
FRONT AND REAR CALLIPERS CHECK

Check:
• The pistons (1) of the brake callipers Fig. A.
A
Replace the brake calliper pistons if there are signs of rust/scor-
ing/traces of wear.
• The cylinders of the brake callipers.
If there are any lines/signs of wear, replace the whole brake
calliper. 1
• The bodies of the brake callipers. 2
If there are any cracks/damage, replace the whole brake calliper.
• Brake fluid delivery passages (brake calliper body).
3
In the event of obstruction, clean with a jet of compressed air.
• The seals (2) and (3) Fig. A
If there is any rust/lines/signs of wear, replace the brake calliper
insulation.
• The sliding pins (4) and (5) of the rear calliper Fig. B.
If there are any lines/signs of wear, replace the whole brake
calliper.
• The rear brake calliper bracket and the couplings on the
B
front fork.
If there are any rust spots/signs of wear, replace. 4

IMPORTANT NOTICE
Every time the brake calliper is removed, replace the piston 5
seals.

4 - 45
 FRONT AND REAR BRAKES
FRONT BRAKE CALLIPER INSTALLATION

NOTE:_________________________________
The procedure mentioned below is applicable to both calli-
A
pers of the front brake.

IMPORTANT NOTICE
Before installing, clean all of the internal parts of the brake,
and lubricate them with clean or new brake fluid.
Never use solvents on internal components of the brake, in-
asmuch that the seals of the pistons would tend to swell and 5
deform.
Every time the brake calliper is removed, replace the piston
seals.
3
4
Recommended brake fluid
DOT4
B
Install: 2
• The largest seals of the pistons (3) Fig. A.
• The smallest seals of the pistons (4) Fig. A.
• The pistons on the brake calliper (5) Fig. A.

Install:
• The brake calliper (1) Fig. B.
• The screws (2) Fig. B 1
to the following torque:

T. R .

Torque 50 N*m
C
Recommended lubricant. 20
9 17 12 11
10 19
Recommended lubricant 16
G
NGLI2 GREASE 24
9 9 30 14
17 9
Install:
• The brake hose (10*) Fig. C.
9 31
• The sealing washer (9*) Fig. B.
• The special screw (20*) Fig. B. 18 15
to the following torque:

T. R .

Torque 18 N*m

IMPORTANT NOTICE
To guarantee the safety of the motorcycle, it is essential for
the path of the brake hose to be correct.

Check:
the level of the brake fluid and top up (refer to Chapter 3 Frame/
Brake fluid level check, section Checking and topping up of
the front brake fluid level).

4 - 46
 FRONT AND REAR BRAKES
REAR BRAKE CALLIPER INSTALLATION

IMPORTANT NOTICE A
Before installing, clean all of the internal parts of the brake,
and lubricate them with clean or new brake fluid. Never use
solvents on internal components of the brake, inasmuch that
the seals of the pistons would tend to swell and deform.
Every time the brake calliper is removed, replace the piston 1
seals.
2
3
Recommended brake fluid
DOT4

Install:
• The largest seals of the pistons (3) Fig. A.
• The smallest seals of the pistons (2) Fig. A. B
• The pistons on the brake calliper (1) Fig. A. 7 20
Install:
• The brake calliper (6*) Fig. B.
21
• The screws (21*) Fig. B. 20
to the following torque: 9
32 6
T. R .

Torque 22 N*m
9
9
Install: 20
• The sliding pins (4) and (5) Fig. D.
• The covers against dust (1) and (2) Fig. C. 4
C

4 - 47
 FRONT AND REAR BRAKES
REAR BRAKE CALLIPER INSTALLATION

Install:
E
• The brake hose (4) Fig. E.
• The sealing washer (9*) Fig. E. 7 20
• The special screw (20*) Fig. E.
21
Tighten to the previous set torque twice after having loosened: 20
9
T. R .

32 6
Torque 15 N*m

Check: 9
the level of the brake fluid (1) Fig. F and top up (refer to Chap- 9
ter 3 Frame/check brake fluid level, section Checking and 20
topping up of the rear brake fluid level)
4
IMPORTANT NOTICE
F
Only use the prescribed fluid. The use of other types of
brake fluid may cause damage to the rubber seals, leading
to leaks and to a drop in brake performance. Top up with the
same type of brake fluid in the system. The brake fluid must 1
never be mixed with fluids of other brands, since this could MAX
cause a dangerous chemical reaction, with a drop in brake
performance as a result.
While topping up brake fluid, take care not to let any water
MIN
enter the container.
Water would considerably reduce the boiling point of the flu-
id and may lead to the formation of vapour bubbles.

Check:
If below the minimum notch, top up with the recommended
brake fluid.

• Brake lever operation.

If the brake lever movement is spongy, bleed brake system.
Refer to Chapter 3 Frame/Brake fluid level check, section
Checking and topping up of the front brake fluid level).

4 - 48
 FRONT FORK
FRONT FORK STEM REMOVAL

3 3
19
5
28
6
8

2
7 7
25
9 9 25
4 1
7
20
10

26 30
16
29
23
18 17 23
18 20
27
11
20 22
12 21
13 21
14
15 32 33
33
15
14 35 24
31
34
34

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 LEFT STEM ASSEMBLY

2 RIGHT STEM ASSEMBLY

3 SCREW

4 SPECIAL SCREW
5 UPPER U-CLAMP
6 LOWER U-CLAMP
7 BUSHING
8 INSTRUMENT SUPPORT
9 HANDLEBAR FIXING PIN
10 NUT
11 STEERING HEAD
12 STEERING PIN RING NUT
13 STEERING RING NUT
14 DUST SEAL
15 BEARING

4 - 49
 FRONT FORK
FRONT FORK STEM REMOVAL

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
16 LOWER STEERING BASE
17 SEEGER
18 SCREW
19 DUST COVER
20 SCREW
21 SCREW
22 SCREW
23 SCREW
24 SCREW
25 REFLECTOR
26 HEADLAMP SUPPORT
27 ABS SPEED SENSOR – REAR WHEEL
28 OIL SEAL
29 TUBE GUIDE
30 CABLE GLAND
31 HEADLAMP SUPPORT
32 SHIM
33 BUSHING
34 SCREW
35 SCREW

4 - 50
 FRONT FORK
FRONT FORK STEM REMOVAL

The following procedure is applied to both front fork stems.

A
Park:
• The motorcycle on a level surface.

NOTE:_________________________________ 20
Place the motorcycle on a suitable support so that the front
wheel is raised.
30
Remove: 29
• The brake calliper, refer to the section “Removal of the
front brake calliper, Chapter 4”. 17
• The front wheel, refer to the section “Front wheel removal, 20
Chapter 4”.
• The front mudguard, refer to the section “Removal of front
mudguard, Chapter 4”. 20
21
Loosen:
• The screws (21*) Fig. A. 21
• The screws (18*) Fig. B.

IMPORTANT NOTICE
Before loosening the setscrews on the top and bottom 4
brackets, install a support for the front fork stem.
7 B
NOTE:_________________________________ 10
The numbers marked (*) are a part of the spare parts table of
the chapter “Front fork”, section “Removal of the front fork
stems”. 26

18
18
11

12 21
13
14
15
15

4 - 51
 FRONT FORK
FRONT FORK STEM DISASSEMBLY

3
4

5
10
15

11

12

13 8
9
14

17
18

Disassemble the pieces in the order listed.

A
NOTE:_________________________________ 1
The following procedure is applied to both front fork stems.

Secure:
• The fork sleeve (10) in a clamp Fig. A.
• Completely unscrew the cap assembly (1) from the support
tube, using a 4 mm wrench (10) Fig. A. 11
• Lower the fork sleeve (11) slowly.

IMPORTANT NOTICE
The fork spring is compressed.
10
Push down:
• The spring (5) Fig. B.
• The preload shim so as to be able to insert a 17 mm wrench B
in the nut (4).
• Hold the cap assembly (1) in place with a 4 mm wrench and
use a 17 mm wrench to loosen the nut (4). 1
• Unscrew and remove the top cap assembly (1).
4
5

4 - 52
 FRONT FORK
FRONT FORK STEM DISASSEMBLY

Slide out from inside the sleeve Fig. C: C

• The tip (2).
• The spring (5).
• The bushing (6). 2
• The shim (7). 8
• The lower bushing (8).
• The tip (9).
9 6 5
Release:
• The stem from the clamp. 7
• Turn the stem towards a suitably sized container so as to
allow the oil that it contains to flow out Fig. D.

NOTE:_________________________________
To facilitate drainage, it is necessary to pump a few times by
pushing the pump rod forwards and backwards (15) Fig. D.
D
IMPORTANT NOTICE
This operation must be carried out only after draining the oil
from inside the stem.

• Lock the wheel shoe (A) in a clamp Fig. E.

Remove:
• The screw (18) fastening the pump unit (15).
• The washer (17).
• The pump unit (15).
15

17
A
18

15

4 - 53
 FRONT FORK
FRONT FORK STEM DISASSEMBLY

IMPORTANT NOTICE F
This operation is only necessary after completely draining
the oil from inside the sleeve.

Remove:
• The dust seal (14) from the seat using a small flat-blade
screwdriver Fig. F.
14
Remove:
• The clip of the oil seal (13) using the small flat-blade screw-
driver Fig. G.
Slide out:
• The fork stem (B) from the fork sleeve (10), Fig. H.

NOTE:________________________________
To separate these two elements, it is necessary to pull them
apart with a little force. G

• The oil seal (12).

• The retaining ring (11).
• The bottom guide bushing (8).

Manually remove:
• The top guide bushing (6).

NOTE:________________________________
If this operation becomes difficult manually, it is possible to
use a flathead screwdriver in the slot in the bushing, to make
it easier.

• The bottom guide bushing (8).

• The retaining ring (11).
• The oil seal (12). H
• The dust seal clip (13).
• The dust seal (14). 8
11
NOTE:________________________________
Once the oil and dust seals have been removed, they may
12
not be re-used.
10

I
6 8 11 12 13 14

4 - 54
 FRONT FORK
FRONT FORK STEM INSPECTION

The following procedure is applied to both front fork stems. A

Check:
• The fork stem “A” Fig. A.
• The fork sleeve (10).
If there is any deformation/damage/wear, replace.

WARNING A
Do not try to straighten the inner fork if bent, since it will be-
come weaker with time and could be dangerous.

Measure:
• The full length (B) of the spring (5). If outside specifications, 10
replace Fig B.

B
The full length of the
Detail
spring.
Spring 295 mm

Check: B
• The damper shaft (15) Fig. C.
If there is any damage or wear, replace.
If there are any obstructions, free all oil passages with com-
pressed air. 5

IMPORTANT NOTICE
The pump unit contains elements that are very sensitive to
foreign bodies.
C
While disassembling and refitting the front fork stem, never
let foreign bodies enter the front fork.
15
Check:
• The O-Ring (3) of the cap (1) Fig. D.
If there is any damage or wear, replace.

4 - 55
 FRONT FORK
FRONT FORK STEM ASSEMBLY

The following procedure is applied to both front fork stems.

A
IMPORTANT NOTICE
The oil and dust seals must not be reused after removal. Be-
fore refitting, check the condition of bushings and guides;
check the guide bushings; if they are lined or scratch, re-
place them. Check the Teflon coating on the guide bushings
as this must be integral.

Apply to the end of the supporting tube:

• Adhesive tape so as to cover the seat for the upper bushing
Fig. A.
• Slightly lubricate the oil and dust seals with grease.

Insert into the dust seal Fig. B:

• The dust seal (14).
• The dust seal clip (13). B
• The oil seal (12).
• The retaining ring (11).
• The bottom guide bushing (8).

IMPORTANT NOTICE
Take note of the direction in which the oil filter is facing (12)
as it needs to be inserted with the hollow part facing the re-
taining ring (11).

• Remove the adhesive tape applied at the end of the fork

stem, together with any traces of adhesive remaining. 8 11 12 13 14
Insert:
• The upper guide bushing (6) Fig. C using the appropriate
tool “X” Fig. C:
C

(**) Tool for stem guide bushing insertion

NOTE:________________________________
If this operation becomes difficult, it is possible to use a flat-
head screwdriver in the slot in the bushing, to make it easier.
6
• Insert the fork stem into the sleeve, very gently to make sure
it does not damage the top guide bushing.

Accompany: X
• The bottom guide bushing (8) as far as sleeve contact with
the fork Fig. D.
• The retaining ring (11).
• The oil seal (12). D

Then place them into the seat.

4 - 56
 FRONT FORK
FRONT FORK STEM ASSEMBLY

Assemble:
• The clip on the oil seal (13) using a small flathead screw-
E
driver, making sure that it is perfectly inserted into the
special raceway and taking care not to scratch the fork stem
Fig. E. 13
Then place the following in the seat:
• The dust seal (14) by pressing down manually Fig. F.

Insert:
• The assembled pump unit (15) into the fork sleeve (10) Fig.
G.
• Mount the fork in a clamp by the wheel foot Fig. H.
• Lower the fork sleeve over the stem.

Insert:
• The washer (17).
• The screw (18) fastening the pump unit.
F

Use an 8 mm Allen key to tighten to the following torque: 14

T. R .

Torque 50 N*m

15

10

17
18

4 - 57
 FRONT FORK
FRONT FORK STEM ASSEMBLY

• Lift the fork sleeve completely Fig. I.

• Using a graduated measuring container, prepare the correct
I
amount of oil to be poured into the stem Fig. I.

h
• Pour about 2/3 of the oil into the fork sleeve (A), then pump
the fork to eliminate any air.
• Continue pouring up to the required amount.
• Lower the fork sleeve over the stem as far as the dust seal
stop on the wheel foot.
• Wait a few minutes and check the air volume then top up if
necessary.
A

IMPORTANT NOTICE
A lower or higher air volume or a different type of oil to that
recommended may change the behaviour of the fork at every
stage. L
Insert the following into the fork sleeve:
• The spring tip (2). 2
• The fork spring (5). 8
• The top spring guide bushing (6).
• The shim (7).
• The bottom spring guide bushing (8). 9 6 5
• The spring tip (9).
7
IMPORTANT NOTICE
In the same direction as spring insertion.
The narrowest section must be facing upwards.

Screw the following fully:

• The closing cap (1) Fig. M.
M
1
Push down:
• The spring (5) Fig. N.
• The preload shim.
• Insert a 17 mm wrench in the nut (4).
• Hold the cap in place with a 4 mm wrench and use a 17 mm
wrench to tighten the nut.
• Tighten to the following torque:

T. R .

Torque 20 N*m
• Lift the fork sleeve over the stem.

Secure:
• The fork sleeve in a clamp. M
• Hold the cap in place with a 4 mm wrench and tighten to the
following torque:
4
T. R .

Torque 20 N*m 5

4 - 58
 FRONT FORK
FRONT FORK STEM INSTALLATION

The following procedure is applied to both front fork stems.

A
Install:
• The front fork stems (1) Fig. A.

tighten provisionally

• The stop screws (19) of the lower steering plate Fig. A.

NOTE:________________________________
Check the assembly position “x” Fig. B, which must be iden-
1
tified considering the bottom section of the steering base
(18) and the end of the steering rod (excluding the dust seal
shim).

B
Tighten:
18
• The setscrews (19) of the lower steering plate to the following
torque:

T. R .
X
Torque 10 N*m

NOTE:________________________________
Tighten in three steps.

Tighten:
• The setscrews (1) from the top steering plate (2) Fig. C to the
following torque:
C
T. R .

Torque 22 N*m

Use:

MEDIUM THREAD LOCK- 1

ER
2

IMPORTANT NOTICE 1
Check that the path of the brake hoses is correct.

4 - 59
 HANDLEBAR
HANDLEBAR REMOVAL

4
5 6
7
8
2

14

9 1
13

12

3
15
16 11 10 8 7
9 6 5 4

22
25 ABS

22
20 24 18
19
21 26

23
17

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 REAR-VIEW MIRROR (LEFT)

2 REAR-VIEW MIRROR (RIGHT)

3 HANDLEBAR
4 SCREW
5 ELASTIC WASHER
6 WASHER
7 ROCKER ARM
8 HANDGRIP CAP
9 HANDGRIP TERMINAL
10 LEFT HANDGRIP
11 LEFT LIGHT SWITCH
12 RIGHT LIGHT CHANGE-OVER SWITCH
13 ACCELERATOR CONTROL
14 RIGHT HANDGRIP
15 ACCELERATOR OPENING CABLE

4 - 60
 HANDLEBAR
HANDLEBAR REMOVAL

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
16 ACCELERATOR CLOSURE CABLE
17 CLUTCH CABLE
18 CLUTCH CONTROL
19 RUBBER BAND
20 CABLE GLAND
21 CLUTCH CONTROL LEVER
22 SCREW
23 SPECIAL NUT
24 SPECIAL SCREW
25 CLUTCH SWITCH
26 ABS SWITCH

4 - 61
 HANDLEBAR
REMOVAL OF HANDLEBAR AND ITS COMPONENTS

Park the motorcycle on a level surface. 1 A

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot 3
fall.
11 10 8 7 6
9 5 4
NOTE:________________________________
Direct a jet of compressed air between the left of the handle-
bar and the relevant handgrip, so that it can be slid off the
handlebar gradually.
22
Remove: 25 ABS

22
• Right rear-view mirror (2*) and left rear-view mirror (1*). 24 18
• Screws (4*) Fig. A.
21 26
• Elastic washer (5*) Fig. A.
• Washer (6*) Fig. A. 23
• Rocker arm (7*) Fig. A.
• Cap (8*) Fig. A.
• Handgrip terminal (9*) Fig. A. B
• Left handgrip (10*) Fig. A.
• Left change-over switch screws Fig. B. 1
• Left change-over switch (11*) Fig. A.
• Clutch control screws (1) Fig. B.
• Clutch control (3) U-clamp (2) Fig. B.
• Complete clutch control (18*) Fig. A. 2

NOTE:________________________________
Disconnect the connector of the LEFT STOP light switch.

5 6
4 C
Remove: 7
8
2
• Right change-over switch screws Fig. D.
• Right change-over switch (12*) Fig. D. 14
• Screws (1) Fig. D accelerator control (13*).
• Accelerator control (13*) 9
13
• Accelerator handgrip (14*).
• Accelerator control cable (15*). 12
• Accelerator Closure Cable (16*).
• Screws (2) Fig. D. of the brake pump. 3
• Pump brake U-clamp (3) Fig. D. 15
16

1
2

4 - 62
 HANDLEBAR
REMOVAL OF HANDLEBAR AND ITS COMPONENTS

Remove:
• Screws (1) Fig. E.
E
• Handlebar u-clamp (2) Fig. E. 1
• Handlebar (3*) Fig. E. 3

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Handlebar”.
2

4 - 63
 HANDLEBAR
HANDLEBAR INSPECTION

Check:
• The handlebar (3) Fig. D.
D
If there is any warping/cracking/damage, replace.

WARNING
Do not try to straighten the handlebar if bent, since it will
become weaker and could be dangerous.

4 - 64
 HANDLEBAR
HANDLEBAR INSTALLATION

IMPORTANT NOTICE E
Prop the motorcycle on suitable supports so that it cannot 1
fall.

Proceed to install, following the steps for removal in reverse

order, but taking care to observe the instructions below:

Install: 2
• Right change-over switch (11*).

NOTE:________________________________
Align the projections (1) of the switch with the hole (2) on the
right side of the handlebar Fig. E.

• Front brake pump.

• Screws (1) Fig. F tighten to the following torque:
F
T. R .

Torque 8 N*m

1
• Accelerator handgrip (14*).
• Accelerator control (13*)
• Accelerator control cable (15*).
• Accelerator Closure Cable (16*).
• Clutch control (18*).
• Screw clutch control tighten to the following torque:

T. R .

Torque 8 N*m
3
G
• Left change-over switch (11*) Fig. G.
• Left handgrip (10*). 11 10 8 7 6
9 5 4
• Handgrip terminal (10*).
• Right rear-view mirror (2*) and left rear-view mirror (1*).

Position the handlebar:

• Handlebar (3*). 22
25 ABS

22
• U-clamp (2) of the handlebar (3*).
24 18
• Screws (1), tighten to the following torque:
21 26
T. R .
23

Torque 22 N*m

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Handlebar”.
H
1
3

4 - 65
 STEERING HEAD
STEERING HEAD REMOVAL

3 3

5
6
8

7 7
9 9
4
7
10

26

18
18
11

12 21
13
14
15
15
14

IMPORTANT NOTICE A
Prop the motorcycle on suitable supports so that it cannot
fall.
1

Remove:
• Handlebar, refer to the section “Removal of handlebar
and its components, Chapter 4”.
• The two upper u-clamps (1) Fig. A.

4 - 66
 STEERING HEAD
STEERING HEAD REMOVAL

• The instrument support bracket (2) Fig. B. B

2

• The screws of the instrument support (3) Fig. C.

C

Remove: D
• The cap (5) with the special tool (6) Fig. D.

(**) Steering head wrench

Code: R300097146000 5
6
• The fastening screws (4) of the steering head Fig. D.
• The steering base (7) Fig. D.

4
7

4 - 67
 STEERING HEAD
STEERING HEAD REMOVAL

Disconnect:
• The connector (8) of the ignition block Fig. E.
E

4 - 68
 STEERING BASE
STEERING HEAD BASE REMOVAL

IMPORTANT NOTICE A
Prop the motorcycle on suitable supports so that it cannot
fall.
1
Remove:
• Handlebar, refer to the section “Removal of handlebar
and its components, Chapter 4”.
• Steering head, refer to the section “Steering head remov-
al, Chapter 4”. 2
• The steering ring nut (1).
• The steering ring nut (2) Fig. A with the wrench for steering
ring nut (3) Fig. B.

B
(**) Tool to tighten the steering sleeve lock nut
Code: R180297129000

WARNING
Firmly support the bottom steering base, so that it cannot
fall.

4 - 69
 STEERING HEAD
STEERING HEAD INSPECTION

Wash: A
• The bearings.
• The bearing races. 12
13
Solvent with high flash point. 14
15
Check:
• The bearings (15) Fig. A. 15
• The dust seal rings (14) Fig. A.
If there is any spotting/damage, replace. 14
Replace:
• The bearings.
• The bearing races. B
• Remove the bearing races (1) from the steering column tube, 1
using a long rod and a hammer (2) Fig. B.
• Remove the outer race of the bearing (3) from the lower
bracket using a chisel (4) and a hammer Fig. B. 2
• Mount a new rubber seal and new bearing races.

3 4
IMPORTANT NOTICE
If the bearing race is not correctly fitted, this could damage
the steering head tube.

NOTE:________________________________
• The bearings and the relative races must always be sub-
stituted together and greased as necessary Fig. C.
• Every time the steering sleeve is removed, a new rubber C
seal must be fitted.

Check:
• The steering head.
• The bottom steering base (along with the sleeve).
• If there is any warping/cracking/damage, replace.

NOTE:________________________________
If necessary:

Lubricate:
• The bearings Fig. A.
• The dust seal rings Fig. A.
• The bearing races Fig. A.

G
Recommended lubricant
NGLI2 GREASE

4 - 70
 STEERING HEAD
STEERING HEAD INSTALLATION

Park the motorcycle on a level surface. A

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Install:
Proceed using the opposite order to removal.
Tighten:
• The steering ring nut (2) Fig. B with the special tool
to the following torque:

T. R .

Torque 16 N*m
B

(**) Tool to tighten the steering sleeve lock nut 2 1

Code: R180297129000

IMPORTANT NOTICE
Do not overtighten the steering ring nut.

• The steering pin ring nut (1.) Fig. B with the special tool and
tighten to the following torque:

T. R .

Torque 22 N*m

C
• Place the top steering head (3) Fig. C.
• The cap (5) Fig. C with the special tool (6) and tighten to the
following torque:

T. R .

5
Torque 60 N*m 6

3
(**) Steering head wrench
Code: R300097146000

The setscrews (1) Fig. d to the following torque: D

T. R .

Torque 22 N*m

4 - 71
 STEERING HEAD
INSTALLATION OF THE STEERING HEAD
Check:
• The steering sleeve Fig. E.
E

Gently oscillate the front fork, holding it by the ends of the tubes.
If there are any sticking/slackening points, adjust the steering
head.

4 - 72
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER REMOVAL

25

24

10
15 10
20 22
16
19

18 23

11
13
14
17 15
8 14
13
9
26 27
12
7 2
6 5 10
3 2
4
1 2
3
3
2
1
21

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 BUSHING

2 SEALING RING
3 BEARING
4 BUSHING
5 BEARING
6 SEEGER RING
7 BUSHING
8 SWINGING ARM
9 TOP CHAIN SLIDE
10 SCREW
11 CHAIN COVER
12 SCREW
13 SCREW
14 GUIDE BUSHING
15 SCREW
16 REAR SHOCK ABSORBER
17 NUT
18 NUT
19 SCREW

4 - 73
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER REMOVAL

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
20 CHAIN TENSIONER SLIDE
21 TUBE GUIDE
22 REAR MUDGUARD SUPPORT
23 RUBBER BAND
24 BRACKET
25 REAR MUDGUARD
26 ELASTIC WASHER
27 WASHER

4 - 74
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Side fairings, refer to chapter “Removal of the side fair-
ings, Chapter 4”.

IMPORTANT NOTICE
This rear shock absorber and the gas cylinder contain a
highly-compressed gas (nitrogen).
Before handling the rear shock absorber and the gas cylin-
der, carefully read the following information and ensure that B
you understand it.
The manufacturer cannot be held responsible for any dam-
age to property or personal injuries deriving from the im-
proper use of the rear shock absorber and the gas cylinder.
• Do not tamper with the rear shock absorber or the gas
cylinder nor try to open them.
• Do not expose the shock absorber or gas cylinder to
open flames or other sources of extreme heat.
• Elevated overheating could cause an explosion due to
the excessive pressure of the gas. 15*
• Do not deform or damage the rear shock absorber or the
gas cylinder in any way. If the rear shock absorber, gas
cylinder or both are damaged, the damping performance
will be prejudiced.

Remove:
C
• The lower screw (15*) of the rear shock absorber unit Fig.
B.
• The relative nut.

NOTE:________________________________
To remove the lower fixing screws of the rear shock absorber
unit, hold the swinging arm to stop it from falling.

• The upper screw (15*) of the rear shock absorber unit Fig. 15*
C.
• The relative nut.

NOTE:________________________________
Lift the swinging arm, then remove the rear shock absorber
unit from the attachment point on the swinging arm.

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Rear swinging arm”, section “Removal of the rear
shock absorber”.

4 - 75
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER CHECK

Check: A
• The rear shock absorber rod.
]If there is any warping/damage, replace the rear shock absorber
assembly.
• The rear shock absorber.
If there is any gas/oil leak, replace the rear shock absorber as-
sembly.
• The spring.
If there is any damage/wear, replace the rear shock absorber as-
sembly.
• The bushings.
If there is any damage or wear, replace.
• The dust seals. 1
If there is any damage or wear, replace.
• The screws.
If there is any warping/damage/signs of wear, replace.

Adjust:
To adjust the preload according to the default conditions, proceed
as follows:
• Rotate the preload adjusting ring nut (1) clockwise until it
stops.
• Rotate the preload adjusting ring nut (1) of 4 “Clicks” count-
er-clockwise.

4 - 76
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER INSTALLATION

Clean:
• The rear shock absorber nuts.
A
• The rear shock absorber screws.

Solvent with high flash point.

Install:
• Proceed using the opposite order to removal, considering
as follows.

NOTE:________________________________ 17*
Lift the swinging arm to install the rear shock absorber unit.
Insert the lower screw (15*) of the rear shock absorber unit.

Tighten:
• The lower nut (17*) of the rear shock absorber Fig. A to the
C
following torque:

T. R .

Torque 50 N*m

Install:
• The upper screw of the rear shock absorber.

Tighten:
• The upper nut (17*) of the rear shock absorber unit to the 17*
following torque:

T. R .

Torque 50 N*m

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Rear swinging arm”, section “Removal of the rear
shock absorber”.

4 - 77
 TRANSMISSION CHAIN AND SWINGING ARM
TRANSMISSION CHAIN REMOVAL

NOTE:________________________________
Prop the motorcycle on suitable supports so that it cannot
A
fall.

Remove the parts in the indicated order.

• Chain pinion cover, refer to the section “Removal of the
chain pinion cover, Chapter 4.”.

Detach: 1
• The transmission chain
(with a suitable tool for transmission chains (1) Fig. A, or with the
dedicated tool according to the transmission chain manufactur-
er’s specifications).

4 - 78
 TRANSMISSION CHAIN AND SWINGING ARM
TRANSMISSION CHAIN REPLACEMENT

Loosen:
• The transmission chain.
A
2
This chain uses a transmission chain with master link with safety
clip link.
• Use the special tool, according to the chain manufacturer’s
specifications and the type of use required.

NOTE:________________________________
Follow the instructions of the manufacturer when using the 3
special tool.

IMPORTANT NOTICE
Never reutilise the old transmission chain, the master link,
the clip link of the master link and the O-rings. 1

Insert:
• The master link (1) Fig. A.
• The O-Ring (2) Fig. A.
• The clip link (3) Fig. A.

IMPORTANT NOTICE
Insert the master link from inside the transmission chain,
then insert the clip link with the ID mark facing out.

• Mount and fix the set of tools for the transmission chain.
• Ensure that the pins of the master link are mounted correct-
ly.
• Rivet the master link pins laterally.
• Ensure that the pins are tapped correctly.

Check:
• The surface affected by the clinched master link.
This must have no apertures.
If there are apertures, replace the master link, seal rings and clip
link.

IMPORTANT NOTICE
Never use a transmission chain with a clip-type master link.

4 - 79
 TRANSMISSION CHAIN AND SWINGING ARM
REMOVAL OF THE SWINGING ARM

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall. 1
3
Remove the parts in the indicated order.
• Rear brake calliper, refer to the section “Removal of the
rear brake calliper, Chapter 4”.
• Rear wheel, refer to the section “Removal of the rear
wheel, chapter 4”.
• Rear shock absorber, refer to the section “Removal of the
rear shock absorber, Chapter 4”.
• Right rear footrest plate, refer to the section “Removal of
the right rear footrest plate, Chapter 4”.
• Left rear footrest plate, refer to the section “Removal of the
left rear footrest plate, Chapter 4”. B
• Rear mudguard, refer to the section “Removal of the rear
mudguard, Chapter 4”.

Remove:
• The fastening pin (1) Fig. A. 2
• The bushing (2) Fig. B.

NOTE:________________________________
Repeat the removal procedure of the components also on
the right side of the vehicle.

• The internal shim (3) Fig. A.

NOTE:________________________________
Position a stand (B) to support the rear swinging arm.

Utilise the appropriate tool for the removal of the internal compo-
nents of the swinging arm:

(**) Tool for removing the rear swinging arm bearing

Refer to Chapter 1 “Special tools for the frame”

4 - 80
 TRANSMISSION CHAIN AND SWINGING ARM
SWINGING ARM INSTALLATION

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Install:
• Proceed using the opposite order to removal, considering
as follows.

Lubricate:
• The bearings.
• The bushings.

G
Recommended lubricant
NGLI2 GREASE

4 - 81
 FRAME
REMOVAL/INSTALLATION OF FRAME PARTS

14

28
29
24

27
26
25 30

14
14 21 19
18 22
20
17
25
3
14 23 22
11 12 13 16
3
14
15
31 11 12
10
8 31 3 3
9 8
7 3 10
3 13 3
7 6

1
2 3 3 4 5

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 SCREW

2 FRAME
3 NUT
4 SPECIAL SCREW
5 NUT
6 SCREW
7 SILENT-BLOCK
8 SCREW
9 SCREW
10 SCREW
11 SCREW
12 RUBBER BUSHING
13 FRAME BRACKET
14 SCREW
15 BRACKET
16 BRACKET
17 RIVET
18 PLATE
19 BRACKET

4 - 82
 FRAME
REMOVAL/INSTALLATION OF FRAME PARTS

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
20 BRACKET
21 CABLE GLAND
22 SCREW
23 SCREW
24 REAR FRAME
25 SCREW
26 LEFT REAR HANDLE
27 RIGHT REAR HANDLE
28 BRACKET
29 SCREW
30 SADDLE OPENING CABLE
31 WASHER

4 - 83
 FRAME
REMOVAL OF THE REAR FRAME

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 1
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Fuel tank, refer to the section “Removal of the fuel tank,
Chapter 4”.
• Filter box, refer to section “Filter box removal, Chapter 4”.
• Battery, refer to section “Battery removal, Chapter 4”.
• Passenger handles, refer to the section “Removal of the
passenger handles, Chapter 4”.
• Bottom cover, refer to the section “Bottom cover removal, B
Chapter 4”.
• Side fairings, refer to the section “Removal of the side
fairings, Chapter 4”.
• Rear light, refer to the section “Removal of the rear light,
Chapter 4”.
• Saddle opening lever, refer to the section “Removal of the 2
saddle opening lever, Chapter 4”.
• Diagnostic connector plate (1) Fig. A.
• Relay box (2) Fig. B.

• ECU (3) Fig. C.

C

• Screws (4) Fig. D.

• Battery box (5) Fig. D.
D

4 5

4 - 84
 FRAME
REMOVAL OF THE REAR FRAME

• ABS ECU support bracket (6) Fig. E.

E
Disconnect: 6
• The ABS ECU connector (7) Fig. E.
7

• The ground cable of the main electrical distributor (8) Fig. F. F

• The starter ground cable (9) Fig. F.

Remove:
G
• The screws (22*) Fig. G.
24
• The screws (23*) Fig. G.
• The nuts (3*) Fig. G.
• The rear frame (24*) Fig. G.
22
NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
3
chapter “Frame”, section “Installation/removal of frame 23 22
parts”.
3

4 - 85
 FRAME
REAR FRAME INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 24
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation: 22
Proceed using the opposite order to removal.
23 22
Install:
• The rear frame (24*) Fig. G.
• The screws (22*) Fig. A. 3
• The screws (23*) Fig. A.
• The nuts (3*) Fig. A.
to the following torque:

T. R .

Torque: 25. N*m

4 - 86
 FRAME
REMOVAL OF THE REAR PASSENGER HANDLES

Park the motorcycle on a level surface. A

26* 27*
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The screws (25*) Fig. A.
• The rear handles (26-*27*) Fig. A.
•
NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Frame”, section “Installation/removal of frame 25*
parts”.

4 - 87
 FRAME
INSTALLATION OF THE REAR HANDLES

Park the motorcycle on a level surface. A

26* 27*
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

Tighten:
• The screws (25) Fig. A.
To the following torque:
25*
T. R .

Torque 22 N*m

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Frame”, section “Installation/removal of frame
parts”.

4 - 88
 FRAME
INSTALLATION OF THE REAR MUDGUARD SUPPORT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove: 1
• The screws (1) Fig. A.
Disconnect:
• The licence plate light wire (2) Fig. B.

B
2

4 - 89
 FRAME
INSTALLATION OF THE REAR MUDGUARD SUPPORT

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation: 1
Proceed using the opposite order to removal.

Tighten:
• The screws (1) Fig. A.
To the following torque:

T. R .

Torque 22 N*m
Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

4 - 90
 FRAME
LICENCE PLATE HOLDER

12

13
8
10
9

4
11
2

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 FLAP GUARD

2 SCREW
3 BUSHING
4 LICENCE PLATE HOLDER SUPPORT
5 SCREW
6 BUSHING
7 NUT
8 LICENCE PLATE LIGHT
9 SCREW
10 NUMBER PLATE HOLDER
11 REFLECTOR
12 SCREW
13 NUT

4 - 91
 FRAME
REMOVAL OF THE LICENCE PLATE HOLDER

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 1
Prop the motorcycle on suitable supports so that it cannot
fall.

Disconnect:
• The licence plate light wire (1) Fig. A.

Remove:
• The screws (2) Fig. B.
• The complete licence plate holder support (3) Fig. B.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Frame”, paragraph “Licence plate holder”.

3
2

4 - 92
 FRAME
INSTALLATION OF THE LICENCE PLATE HOLDER

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
• Proceed using the opposite order to removal.

4 - 93
 CYCLING
FRONT FOOTRESTS

20
23

22

25
20
18
24
2
33
4 1
3
4
14
30
6 21
22
2
29
27 12 18 11 7
32 9 6
28 31 12 13 5
26

19
12 10
17 16
15 14 8

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 LH FRONT FOOTREST SUPPORT PLATE

2 SPECIAL SCREW
3 INTERNAL SHIM
4 PIN
5 SCREW
6 SCREW
7 GEAR PEDAL
8 SCREW
9 BUSHING
10 BALL JOINT
11 NUT
12 NUT
13 GEAR TRANSFER ROD ASSEMBLY
14 SCREW
15 BALL JOINT
16 GEAR LEVER
17 NUT

4 - 94
 CYCLING
STAND/FOOTRESTS

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
18 SCREW
19 LEFT FRONT FOOTREST
20 PIN
21 LEFT REAR FOOTREST
22 ELASTIC RING
23 RIGHT REAR FOOTREST
24 RIGHT FRONT FOOTREST SUPPORT PLATE
25 RIGHT FRONT FOOTREST
26 BRAKE PEDAL
27 ECCENTRIC
28 SCREW
29 THREADED PIN
30 THREADED PIN
31 SPRING
32 BALL JOINT
33 ADJUSTMENT ROD

4 - 95
 CYCLING
REMOVAL OF THE RIGHT FRONT FOOTREST

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The spring (31*) Fig. A.
31*
NOTE:_________________________________
In order to access the screw (28*).
• The screw (28*) Fig. B.
• The special screw (2*) Fig. B.
• The right rear footrest support (24*) Fig. B.

NOTE:_________________________________ B
22
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.
18
24
2
33

14
30
6

29
27 12
28 32
26 31

4 - 96
 CYCLING
INSTALLATION OF THE RIGHT FRONT FOOTREST

Park the motorcycle on a level surface. 24

2 A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation: 14
30
• Proceed using the opposite order to removal. 6
Tighten:
• The screw (28*) Fig. A.
To the following torque: 29
27
T. R .
28 31
Torque 22 N*m

Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

Tighten:
• The special screw (2*) Fig. A.
To the following torque:

T. R .

Torque 35 N*m

Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.

4 - 97
 CYCLING
REMOVAL OF THE LEFT FRONT FOOTREST

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 7*
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The screw (8*) Fig. A. 6*
• The special screws (6*) Fig. A.
• The shift lever (7*) Fig. A.

NOTE:_________________________________ 8*
In order to access the screw (5*).
• The screw (5*) Fig. B.
• The special screw (2*) Fig. B.
• The left rear footrest support (1*) Fig. B.
B

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, 7*
chapter “Cycling” section “Front footrests”.

2* 1*

4 - 98
 CYCLING
INSTALLATION OF THE LEFT FRONT FOOTREST

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot 1
fall.

Installation:
• Proceed using the opposite order to removal. 2
Tighten: 18 11 7
9 6
• The screw (2*) Fig. A. 12 13 5
To the following torque:

T. R .
12 10
17 16
15 14 8

Torque 35 N*m

Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

Tighten:
• The special screw (6*) Fig. A.
To the following torque:

T. R .

Torque 22 N*m

Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.

4 - 99
 CYCLING
SIDE STAND

6
5 4
7

10
8 9

12

11

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 SPECIAL SCREW

2 WASHER
3 SIDE STAND
4 WASHER
5 SCREW
6 SIDE STAND SUPPORT PLATE
7 SCREW
8 SIDE STAND SENSOR
9 NUT
10 BELLEVILLE WASHER
11 EXTERNAL SCREW
12 INTERNAL SPRING

4 - 100
 CYCLING
REMOVAL OF THE SIDE STAND

Park the motorcycle on a level surface.

A
15
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The left front footrest, refer to the section “Removal of the
left front footrest, Chapter 4”.

Disconnect:
• The connector of the side stand sensor (8*) Fig. A. 8*
Remove:
• The internal spring (11*) Fig. B.
• The external screw (12*) Fig. B.
• The safety nut (15*) Fig. A.
• The special screw (1*) Fig. B.
B
• The stand support plate (6*) Fig. B. 6
5 4
7

NOTE:_________________________________ 1
The numbers marked (*) are a part of the spare parts table, 2
chapter “Cycling” section “Side stand”.
3

10
8 9

12

11

4 - 101
 CYCLING
INSTALLATION OF THE SIDE STAND

Park the motorcycle on a level surface.

A
15
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

Tighten:
• The safety nut (15*) Fig. A. 1*
To the following torque:

T. R .

Torque 45 N*m

Use Loctite

Loctite 243

• The special screw (1*) Fig. A.

To the following torque:

T. R .

Torque 35 N*m

Use Loctite

Loctite 243

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Side stand”.

4 - 102
 CYCLING
REMOVAL OF THE RIGHT/LEFT REAR FOOTREST

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot 22*
fall.

Remove:
• The elastic ring (22*) Fig. A.
• The pin (20*) Fig. A.
• The footrest (1) Fig. B.
• The plate (2) Fig. B.
• The ball (3) Fig. B. 20*
• The internal spring (4) Fig. B.

NOTE:_________________________________
Carry out the following operation for the right rear footrest
(23*). B
4 3
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.

4 - 103
 CYCLING
INSTALLATION OF THE LEFT/RIGHT REAR FOOTREST

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

4 - 104
 CYCLING
REMOVAL OF THE LEFT/RIGHT FRONT FOOTREST

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 5
Prop the motorcycle on suitable supports so that it cannot
fall.
2
Remove:
• The cotter pin (1) Fig. A.
• The washer (2) Fig. A.
• The pin (3) Fig. B.
• The spring (4) Fig. B. 25*
• The left front footrest (25*) Fig. A.
1
NOTE:_________________________________
Replace the rubber cover of the right footrest (5) if it is worn.
B
NOTE:_________________________________ 3
Carry out the following operation for the right front footrest
(19*).

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, 4
chapter “Cycling” section “Front footrests”.

4 - 105
 CYCLING
LEFT/RIGHT FRONT FOOTREST INSTALLATION

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

4 - 106
 CYCLING
REMOVAL OF THE GEAR PEDAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The screw (8*) Fig. A.
• The special screw (6*) Fig. B.
• The gear pedal (7*) Fig. B.

NOTE:_________________________________ 8*
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.

6*
7*

4 - 107
 CYCLING
INSTALLATION OF THE GEAR PEDAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
6*
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.
Tighten:
• The screw (6*) Fig. A.
To the following torque:
8*
T. R .

Torque 22 N*m
B
NOTE:_________________________________
Make use of grease around the unthreaded collar during the
assembly Fig. B.

G
Recommended lubricant
NGLI2 GREASE

Tighten:
• The screw (8*) Fig. A.
To the following torque:

T. R .

Torque 10 N*m

Use medium Loctite thread locker to secure.

MEDIUM THREAD
LOCKER

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.

4 - 108
 CYCLING
CHAIN SLIDE REMOVAL

Park the motorcycle on a level surface. A

IMPORTANT NOTICE 10*
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The left front footrest, refer to the section “Removal of the
left front footrest, Chapter 4”.
• The screws (10*) Fig. A.
• The chain slide (9*) Fig. A.
9*
NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Rear swinging arm”, section “Removal of the rear
shock absorber”.

4 - 109
 CYCLING
CHAIN SLIDE INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall. 9
Installation:
Proceed using the opposite order to removal.
Tighten:
• The screws (10*) Fig. A
To the following torque:
10
T. R .

Torque 8 N*m

Use medium Loctite thread locker to secure.

MEDIUM THREAD
LOCKER

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.

4 - 110
 CYCLING
REMOVAL OF THE BRAKE CONTOL PEDAL

Park the motorcycle on a level surface.

14* A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The screw (14*) Fig. A.

• The spring (31*) Fig. B. B

31*

• The screw (6*) Fig. C

• The pedal (26*) Fig. C.
C
6*
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.

26*

4 - 111
 CYCLING
INSTALLATION OF THE BRAKE CONTROL PEDAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 6*
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.
Tighten:
• The screw (6*) Fig. A
To the following torque:

T. R .

Torque: 25. N*m

B
Use medium Loctite thread locker to secure.

MEDIUM THREAD
LOCKER

NOTE:_________________________________
Make use of grease around the unthreaded collar during the
assembly Fig. B.

G
Recommended lubricant
NGLI2 GREASE

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” section “Front footrests”.

4 - 112
 EXHAUST SYSTEM
EXHAUST ASSEMBLY

14 10
11

15 16
9 17 13

1
12

8
4

11
6 10
9
5

3
7

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 EXHAUST GASKET

2 OXYGEN SENSOR
3 NUT
4 EXHAUST MANIFOLD
5 GRAPHITE SEAL
6 SCREW BAND
7 MUFFLER
8 RUBBER TIP
9 SCREW
10 BUSHING
11 RUBBER TIP
12 SCREW BAND
13 SILENCER
14 SCREW
15 WASHER
16 NUT
17 RIGHT FLANGE

4 - 113
 EXHAUST SYSTEM
EXHAUST ASSEMBLY REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Loosen:
6*
• The screw band (12*) Fig. A.

Remove:
• The screw (14*) Fig. A. B.
• The silencer (13*) Fig. B.
B
14*

13*

C
Loosen:
• The screw band (6*) Fig. C.

6*

Remove:
• The screw (9*) Fig. D. D

9*

4 - 114
 EXHAUST SYSTEM
EXHAUST ASSEMBLY REMOVAL

• The screw (9*) on the left side of the vehicle Fig. E. E

9*

Disconnect: F
• The Oxygen sensor (2*) Fig. F.

2*

Remove: G
• The exhaust manifolds (4*) Fig. G.

4*
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Exhaust system”, section “exhaust system”.

4 - 115
 EXHAUST SYSTEM
EXHAUST INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.
Tighten:
• The nuts (3*) Fig. A. 3*
To the following torque:

T. R .

Torque 22 N*m

NOTE:_________________________________
Lubricate the nuts with copper grease during the assembly B
phase.
2*

G
Recommended lubricant
COPPER GREASE

• The Oxygen sensor (2*) Fig. B.

To the following torque:

T. R .

Torque 40 N*m

NOTE:_________________________________
During the assembly phase of the oxygen sensor is neces-
sary to lubricate the threads with copper grease for high tem-
peratures.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Exhaust system”, section “exhaust system”.

4 - 116
 FAIRING
FRONT MUDGUARD

9
1

12

2 3

32
4

6
5
8 7 5 4
10
11

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 FRONT MUDGUARD COVER
2 SCREW
3 NYLON WASHER
4 SCREW
5 MUDGUARD SUPPORT PLATE
6 LEFT BRACKET
7 RIGHT BRACKET
8 FRONT MUDGUARD
9 LION FRIEZE
10 WASHER
11 SCREW
12 CABLE GLAND

4 - 117
 FAIRING
FRONT MUDGUARD REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 12*
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• The front brake pipes (1) from the cable gland (12*) Fig. A. 1
• The screws (2*) from both sides Fig. B.
• The lower mudguard (8*) Fig. C.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Fairing”, section “Front mudguard”.

2*

8*

4 - 118
 FAIRING
FRONT MUDGUARD INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.
Tighten:
• the screws (2*) Fig. A
To the following torque:
2*
T. R .

Torque 10 N*m

Use medium Loctite thread locker to secure.

MEDIUM THREAD
LOCKER

4 - 119
 FAIRING
REAR MUDGUARD REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
10*
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rear wheel, refer to the section “Removal of the rear
wheel and brake disc, Removal of rear wheel, Chapter
4”.
25*
• The screws (10*) Fig. A.
• The rear mudguard (25*) Fig. A.

NOTE:_________________________________
The numbers marked (*) are shown in the replacement parts
table in the chapter “Rear shock absorber”, section “Rear
shock absorber removal”.

4 - 120
 FAIRING
REAR MUDGUARD INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
10*
fall.

Installation:
Proceed using the opposite order to removal.
Tighten:
• The screws (10*) Fig. A.
To the following torque:

T. R .

Torque 8 N*m

4 - 121
 FAIRING
REMOVAL OF THE UPPER CHAIN GUARD

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall. 12*
Remove:
• The screws (12*) Fig. A.
• The screw (2) Fig. B.
• The chain guard (11*) Fig. B.

NOTE:_________________________________
The numbers marked (*) are shown in the replacement parts
table in the “Rear shock absorber” chapter, “Rear shock ab-
sorber removal” section.

C
11*

4 - 122
 FAIRING
INSTALLATION OF THE UPPER CHAIN GUARD

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall. 12*
Installation:
Proceed using the opposite order to removal.

Tighten:
• The screws (12*) Fig. A
To the following torque:

T. R .

Torque 22 N*m
Use medium Loctite thread locker to secure.

MEDIUM THREAD
LOCKER

NOTE:_________________________________
The numbers marked (*) are shown in the replacement parts
table in the “Rear shock absorber” chapter, “Rear shock ab-
sorber removal” section.

4 - 123
 FAIRING
REMOVAL OF THE RIDER SEAT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 1
Prop the motorcycle on suitable supports so that it cannot
fall.

Disassemble:
• The rider seat (1) using the supplied spanner (2) Fig. A.

4 - 124
 FAIRING
INSTALLATION OF THE RIDER SEAT
Park the motorcycle on a level surface.
A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.
3

Installation:
Proceed using the opposite order to removal.

Insert:
• La rider seat (1) Fig. A.
following the specified arrows.

4 - 125
 FAIRING
SADDLE OPENING LEVER REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• The wire cable lug (1) Fig. A.
• The screws (2) Fig. B.
1

4 - 126
 FAIRING
SADDLE OPENING LEVER INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

Tighten:
• The screws (2) Fig. A.
To the following torque:
2
T. R .

Torque 10 N*m
Use medium Loctite thread locker to secure.

MEDIUM THREAD
LOCKER

4 - 127
 FAIRING
REMOVAL OF INSTRUMENT SUPPORT PLATE

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 3
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Tank, refer to the section “Fuel tank removal, Chapter 4”.
• Handlebar, refer to the section “ Removal of handlebar,
Chapter 4”.

• The u-clamp supports (3) Fig. A.

• The instrument support (4) Fig. B. 4 B

• The screws “9” Fig. B.

• The screw (5) of the wire support bracket Fig. C. C

Disconnect:
• The connector “6” Fig. D.
• The connector “7” Fig. D.
D
• The connector “8” Fig. D. 6

4 - 128
 FAIRING
REMOVAL OF INSTRUMENT SUPPORT PLATE

Separate:
• The instrument board “10” from the instrument support “4”
E
Fig. E
4

10

4 - 129
 FAIRING
INSTALLATION OF INSTRUMENT SUPPORT PLATE

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot 9
fall.

Installation:
Proceed using the opposite order to removal.

Tighten:
• The screws (9) Fig. A.
To the following torque:

T. R .

Torque 6 N*m
Use medium Loctite thread locker to secure.
B
3
MEDIUM THREAD
LOCKER

• the u-clamp support (3) Fig. B.

To the following torque:

T. R .

Torque 35 N*m
Use medium Loctite thread locker to secure.

MEDIUM THREAD
LOCKER

4 - 130
 FAIRING
REMOVAL OF THE FRONT HEADLAMP UNIT

Park the motorcycle on a level surface. A

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

The vehicles’ front headlight is a LED light. If it needs to be

replaced, carry out the following procedure:

The following procedure applies to headlamps only.

1
Remove:
• The screws “1” Fig. A.
• The screw “2" Fig. B.
Disconnect:
• The headlamp from the electrical distributor “3” Fig. B.
Remove: B
• The screws “4” Fig. C.
• The headlight “5” Fig. D.

3
2

D
5

4 - 131
 FAIRING
INSTALLATION OF THE FRONT HEADLAMP UNIT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.
Install:
• The screws “1” Fig. A.
to the following torque: 1
T. R .

Torque 8-10 N*m

Use medium Loctite thread locker to secure.
B
MEDIUM THREAD
LOCKER

• The screws ”4” Fig. B.

to the following torque: 4

T. R .

Torque 5-6 N*m

4 - 132
 FAIRING
REMOVAL OF FUEL TANK

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
1
Chapter 4”.
Loosen:
• The screw (1) right side Fig. A.

• The screw (2) left side Fig. B. B

C
Remove:
• The screws (3) Fig. C.
• The tank (4) Fig. C.

3
4

Disconnect: D
• The fuel pipe (5) Fig. D.

4 - 133
 FAIRING
REMOVAL OF FUEL TANK

Disconnect: E
• The connector of the level sensor (6) Fig. E.

• The tube of the non-return valve (7) Fig. F. F

4 - 134
 FAIRING
TANK FITTING

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.
Tighten:
3
• The screws (3) Fig. A.
to the following torque:

T. R .

Torque 10 N*m

4 - 135
 FAIRING
UPPER TAIL FAIRING

3
4
5

13
3
4
5 7 12
6 7
3 7 7 11 3
4 5 11 4
25 5 4 5
9 20 6 7 6
3
21 21 3 7
6 26 26 4
7 5 6
8

16 2
19 6 7 1 20
8 9
10 22 6
15
17
23
18 16
17
19
18 14
24

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 LEFT TAIL FAIRING
2 RIGHT TAIL FAIRING
3 SCREW
4 BUSHING
5 RUBBER TIP
6 SCREW
7 SNAP-ON CLIP
8 ADHESIVE SUPPORT
9 ADHESIVE
10 BOTTOM COVER
11 SCREW
12 REAR CENTRAL FAIRING
13 LOWER CENTRAL FAIRING
14 LEFT EXTERNAL FAIRING
15 RIGHT EXTERNAL FAIRING
16 SCREW
17 SNAP-ON CLIP
18 PAD
19 METAL LOGO
20 BIADHESIVE
21 SCREW
22 LOWER CENTRAL FAIRING

4 - 136
 FAIRING
UPPER TAIL FAIRING

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
23 LOWER FAIRING
24 SCREW
25 SEAT
26 WASHER

4 - 137
 FAIRING
BOTTOM COVER REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat, 6*
Chapter 4”.
• Passenger handles, refer to the section “Removal of the
passenger handles, Chapter 4”.
• The screws (6*) right/left side Fig. A

• The saddle opening cable (1) Fig. B.

B
NOTE:_________________________________ 1
The numbers marked (*) are a part of the spare parts table,
chapter “Fairing”, section “Upper tail fairing”.

4 - 138
 FAIRING
BOTTOM COVER INSTALLATION

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

4 - 139
 FAIRING
SADDLE LOCK REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Passenger handles, refer to the section “Removal of the
passenger handles, Chapter 4”.
• Bottom cover, refer to the section “Bottom cover removal,
Chapter 4”.
1
• The spring (1) Fig. A.
Take out:
• The complete lock block Fig. B.
B

4 - 140
 FAIRING
SADDLE LOCK INSTALLATION

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

4 - 141
 FAIRING
REMOVAL OF THE SIDE FAIRINGS

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall. 6*
Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Passenger handles, refer to the section “Removal of the
passenger handles, Chapter 4”.
• Bottom cover, refer to the section “Bottom cover removal,
Chapter 4”.

• The screws (6*) right/left side Fig. A.

• The fixing screws (6*) right/left side Fig. B.
B
6*

Remove:
• The left tail fairing (1*) Fig. C. C
NOTE:_________________________________
Repeat the same procedure on the right tail fairing.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Fairing”, section “Upper tail fairing”.

4 - 142
 FAIRING
INSTALLATION OF THE SIDE FAIRINGS

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

4 - 143
 FAIRING
REMOVAL OF THE LOWER CENTRAL FAIRING

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat, 6*
Chapter 4”.
• Passenger handles, refer to the section “Removal of the
passenger handles, Chapter 4”.
• Bottom cover, refer to the section “Bottom cover removal,
Chapter 4”.
• Side fairings, refer to the section “Removal of the side
fairings, Chapter 4”.

• The screws on the right/left side (6*) Fig. A. B

• The screws on the right/left side (11*) Fig. B.
• The screws on the right/left side (3*) Fig. B. 11*

3*

• The screws on the right/left side (3*) Fig. C. C

3*

Disconnect: D
• The rear light connector (1) Fig. D.

4 - 144
 FAIRING
REMOVAL OF THE LOWER CENTRAL FAIRING

• The left/right indicator light wires (2) Fig. E. E

NOTE:_________________________________
During this phase, it is advisable to sign the correspondenc-
es of the connectors of the rear indicator light wires with the
ones coming from the electrical distributor.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Fairing”, section “Upper tail fairing”.

4 - 145
 FAIRING
REMOVAL OF THE REAR LIGHT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat, 11*
Chapter 4”. 12*
• Passenger handles, refer to the section “Removal of the
passenger handles, Chapter 4”.
• Bottom cover, refer to the section “Bottom cover removal,
Chapter 4”.
• Side fairings, refer to the section “Removal of the side
fairings, Chapter 4”.
• Bottom central fairings, refer to the section “Removal of
the bottom central fairings, Chapter 4”. B
• The screws (11*) Fig. A.
• The fixing cover (12*) Fig. A.
• The screws (1) Fig. B.
• The rear light (2) Fig. C.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Fairing”, section “Upper tail fairing”.

C
2

4 - 146
 FAIRING
INSTALLATION OF THE REAR LIGHTS

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

4 - 147
 FAIRING
CHAIN PINION COVER

11 12
7
6 1
9 14

2 13
1
3

15
5
4
10
8

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 BUSHING
2 O-RING
3 THREADED CAP
4 MAGNETIC CAP
5 O-RING
6 SCREW
7 PHASE SENSOR
8 SCREW
9 ALTERNATOR COVER
10 PINION COVER
11 PLATE
12 SCREW
13 FLYWHEEL COVER SEAL
14 SCREW
15 SCREW

4 - 148
 FAIRING
REMOVAL OF THE CHAIN PINION COVER

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 3
Prop the motorcycle on suitable supports so that it cannot
fall.
1

Remove:
• Gear pedal, refer to section “Gear pedal removal, Chapter
2
4”.
• The screw (1) Fig. C.
• The gear lever (2) Fig. A.

NOTE:________________________________
Before removing the gear lever (2), use a marker pen to mark
the position of the lever compared to the gear hub (3) Fig. A.

• The screws (15*) Fig. B.

B
• The protective cover (10*) Fig. C.

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Fairings”, section “Chain pinion cover”. 15*

10*

4 - 149
 FAIRING
INSTALLATION OF THE CHAIN PINION COVER

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall. 1
Installation:
Proceed using the opposite order to removal.
Install:
• The screw (1) Fig. A
To the following torque:

T. R .

Torque 10 N*m

Use medium Loctite thread locker to secure. B

MEDIUM THREAD
LOCKER

• The screws (15*).

To the following torque:
15*
T. R .

Torque 8 N*m

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Fairings”, section “Chain pinion cover”.

4 - 150
 TANK
TANK PARTS

8
7
8 7 1

2
7 3
4

18 6

18
5
14
11
9 15
13
11 12
10
16
12 19
17
12

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 SCREW

2 WASHER
3 BUSHING
4 BUSHING
5 VIBRATION DAMPING RUBBER
6 FUEL TANK
7 SCREW
8 SCREW
9 RUBBER TIP
10 FUEL TANK LEVEL PROBE (FRONT)
11 SEAL
12 SCREW
13 FUEL TANK LEVEL PROBE (REAR)
14 FUEL PUMP
15 FUEL HOSE
16 FUEL FILTER
17 FUEL HOSE
18 RUBBER TIP
19 FILTER SUPPORT

4 - 151
 TANK
REMOVAL OF THE TANK CAP SUPPORT

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 8*
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove: 7*
• The fixing screws (8*) Fig. A. 8*
• The fixing screw (7*) Fig. A.
8*
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Tank”, section “Tank parts”.

4 - 152
 TANK
INSTALLATION OF THE TANK CAP SUPPORT

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

4 - 153
 TANK
REMOVAL OF THE FUEL PUMP

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Tank, refer to the section “Fuel tank removal, Chapter 4”.
• The screws (12*) Fig. A.
• The fuel pump (14*) Fig. A.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, 12*
chapter “Tank”, section “Tank parts”.

14*

4 - 154
 TANK
INSTALLATION OF THE FUEL PUMP

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

Tighten:
• The screws (12*) Fig. A.
To the following torque:

T. R .

12*
Torque 10 N*m

Use medium Loctite thread locker to secure.

14*
MEDIUM THREAD
LOCKER

NOTE:_________________________________
At the moment of reassembly of the pump, grease must be
smeared around the base of the housing (2) of the pump (14*),
which must be inserted in reverse order of removal Fig. B.

G
Recommended lubricant
NGLI2 GREASE

2
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Tank”, section “Tank parts”.

4 - 155
 TANK
REMOVAL OF THE TANK FUEL LEVEL SENSOR

Park the motorcycle on a level surface. A

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot 10*
fall. 12*

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Tank, refer to the section “Fuel tank removal, Chapter 4”.
• The fixing screws (12*) Fig. A. 12*
• The rear fuel level sensor (13*) Fig. A.
• The front fuel level sensor (10*) Fig. A.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Tank”, section “Tank parts”.
13*

4 - 156
 TANK
INSTALLATION OF THE TANK FUEL LEVEL SENSOR

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation: 12*
Proceed using the opposite order to removal.

Tighten:
• The screws (12*) Fig. A.
to the following torque:

T. R .

Torque 8 N*m
Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

NOTE:_________________________________
Such procedure can be applied to both level probes.

NOTE:_________________________________
At the moment of reassembly, insert the probes sensor at the
same direction of the connecting wires as the one of disas-
sembly.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Tank”, section “Tank parts”.

4 - 157
 AIR FILTER
AIR FILTER PARTS

10
3
17 13 2
10
1
15 11
12
10 16
10
8

8
7

2 2 8 14
9

6 4
8
5

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 COMPLETE AIR FILTER BOX
2 SCREW
3 AIR TEMPERATURE SENSOR
4 SCREW BAND
5 SLEEVE
6 HOSE HOLDER CLIP
7 CARTRIDGE FILTER
8 SPRING BAND
9 PIPE
10 NON-RETURN VALVE
11 PIPE
12 VALVE
13 SPRING BAND
14 PIPE
15 PIPE
16 PLATE
17 SCREW
18 AIR FILTER

4 - 158
 AIR FILTER
REMOVAL OF THE AIR FILTER BOX

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider seat, refer to the section “Removal of rider seat,
Chapter 4”.
• Tank, refer to the section “Fuel tank removal, Chapter 4”.
Loosen:
• The bands (1) Fig. A
1

Remove:
• The screws (2) right/left side Fig. B.
B

Disconnect: C
• The breather hose (3) from the filter casing Fig. C.

• The connector (4) from the cover Fig. D.

D

4 - 159
 AIR FILTER
REMOVAL OF THE AIR FILTER BOX

Remove: E
• The filter box (5) Fig. E.

IMPORTANT NOTICE
Never switch on the engine if the air filter is not installed.
The unfiltered air causes a quick wear of the engine parts
and might damage the engine. Furthermore, using the en-
gine without air filter, setting of the throttle bodies is affect-
ed, causing a worsening of engine performance, as well as
its overheating. 5
Therefore ensure that the air filter is always in a good con-
dition.
The long life durability of the engine greatly depends on this
component.

4 - 160
 AIR FILTER
INSTALLATION OF THE AIR FILTER BOX

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

4 - 161
Remarks
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5

5-1
 CHAPTER 5

ENGINE
ENGINE ..........................................................................................................................................................4
REMOVAL OF THE ENGINE FROM THE FRAME ....................................................................................................................4
INSTALLATION OF THE ENGINE ON THE FRAME ..................................................................................................................8
HEAD DISTRIBUTION .................................................................................................................................11
COILS AND SPARK PLUGS REMOVAL ..................................................................................................................................12
COILS AND SPARK PLUGS ASSEMBLY.................................................................................................................................13
DISTRIBUTION COVER ASSEMBLY .......................................................................................................................................15
DISTRIBUTION CHAIN TENSIONER REMOVAL ....................................................................................................................16
DISTRIBUTION CHAIN TENSIONER ASSEMBLY...................................................................................................................17
INTAKE AND EXHAUST CAMSHAFT REMOVAL ....................................................................................................................18
CAMSHAFT CHECK.................................................................................................................................................................19
EXHAUST CAMSHAFT INSTALLATION ..................................................................................................................................20
INTAKE CAMSHAFT INSTALLATION ......................................................................................................................................21
DISTRIBUTION CHAIN SLIDES REMOVAL ............................................................................................................................22
DISTRIBUTION CHAIN SLIDE ASSEMBLY .............................................................................................................................23
DISTRIBUTION CHAIN REMOVAL ..........................................................................................................................................24
DISTRIBUTION CHAIN INSTALLATION ..................................................................................................................................25
VALVE CLEARANCE ADJUSTMENT .......................................................................................................................................26
TAPPET VALVE AND CALIBRATED PAD REMOVAL ..............................................................................................................27
HEAD REMOVAL......................................................................................................................................................................30
VALVE AND VALVE SPRING REMOVAL .................................................................................................................................31
CHECK OF VALVES AND GUIDES ..........................................................................................................................................32
VALVE SEAT CHECK ...............................................................................................................................................................34
VALVE OIL SEAL REMOVAL-INSTALLATION..........................................................................................................................35
VALVE SPRING TEST ..............................................................................................................................................................36
VALVE AND VALVE SPRING INSTALLATION..........................................................................................................................37
CYLINDER CHECK ..................................................................................................................................................................39
HEAD INSTALLATION ..............................................................................................................................................................40
PISTONS ......................................................................................................................................................41
PISTON REMOVAL ..................................................................................................................................................................43
PIN CHECK: .............................................................................................................................................................................44
PISTON RING CONTROL ........................................................................................................................................................45
PISTON CHECK .......................................................................................................................................................................46
PISTON ASSEMBLY .................................................................................................................................................................47
PISTON INSTALLATION...........................................................................................................................................................48
REMOVAL OF CONNECTING RODS ......................................................................................................................................49
CRANKCASE...............................................................................................................................................49
CHECK OF CONNECTING RODS AND CONNECTING ROD HALF BEARING .....................................................................51
CONNECTING ROD AND CONNECTING ROD HALF BEARING INSTALLATION .................................................................52
MAIN HALF BEARING AND DRIVE SHAFT INSTALLATION ..................................................................................................54
DRIVE SHAFT CHECK.............................................................................................................................................................57
DRIVE SHAFT INSTALLATION ................................................................................................................................................58
CLUTCH .......................................................................................................................................................59
CLUTCH AND DISC REMOVAL ...............................................................................................................................................60
FRICTION DISC CHECK ..........................................................................................................................................................62
STEEL DISC CHECK ...............................................................................................................................................................63
DISC ASSEMBLY .....................................................................................................................................................................64
CLUTCH ASSEMBLY ...............................................................................................................................................................65
LUBRICATION SYSTEM .............................................................................................................................66
OIL SUMP AND INTAKE FILTER REMOVAL ...........................................................................................................................67
OIL SUMP AND INTAKE FILTER INSTALLATION....................................................................................................................68
PRESSURE-RELIEF VALVE INSTALLATION ..........................................................................................................................69
PRESSURE RELIEF VALVE REMOVAL ..................................................................................................................................70
OIL PUMP REMOVAL...............................................................................................................................................................71

5-2
 CHAPTER 5

OIL PUMP ASSEMBLY .............................................................................................................................................................73

NEUTRAL POSITION/GEAR INDICATOR SENSOR REMOVAL .............................................................................................74
NEUTRAL POSITION/GEAR INDICATOR SENSOR INSTALLATION .....................................................................................75
GEAR ...........................................................................................................................................................76
GEAR ASSEMBLY ....................................................................................................................................................................79
GEAR SHIFT CONTROL ..........................................................................................................................................................81
STARTER .................................................................................................................................................................................85
STARTING ...................................................................................................................................................85
STARTER REMOVAL ...............................................................................................................................................................86
STARTER INSTALLATION .......................................................................................................................................................87
FLYWHEEL REMOVAL.............................................................................................................................................................88
FLYWHEEL INSTALLATION .....................................................................................................................................................91
STARTER GEAR REMOVAL ....................................................................................................................................................92
STARTER GEAR INSTALLATION ............................................................................................................................................93
PHASE SENSOR......................................................................................................................................................................94
PHASE SENSOR REMOVAL ...................................................................................................................................................95
PHASE SENSOR INSTALLATION ...........................................................................................................................................96
POWER SYSTEM ........................................................................................................................................97
THROTTLED BODY ASSEMBLY .............................................................................................................................................97
THROTTLED BODY REMOVAL ...............................................................................................................................................99
THROTTLED BODY INSTALLATION .....................................................................................................................................100

5-3
 ENGINE
REMOVAL OF THE ENGINE FROM THE FRAME

IMPORTANT NOTICE A
1
Prop the bike on suitable supports so that it cannot fall.

• Prop the rear side of the swinging arm with a single stay.
• Activate the brake lever slowly and hold it.

IMPORTANT NOTICE 2
Make sure the front brake is activated when moving the
engine to prevent the motorcycle from falling and avoid
accidents and injury.

Drain:
• Engine oil, refer to section “Change of engine oil, Periodic
maintenance, Chapter 3”.
• Coolant liquid, refer to section “Change of cooling fluid, B
Cooling system, Chapter 6”.
3
Remove:
• Radiator, refer to section “Radiator removal, Chapter 6,
Cooling system”.
• Rider seat, refer to section “Removal of rider seat, Chap-
ter 4”.
• Tank, refer to section “Fuel tank removal, Chapter 4”.
• Air filter box, refer to section “Air filter box removal, Chap-
ter 4”.
• Throttle body, refer to section ”Throttle body removal”.
• Expansion tank, refer to section “Expansion tank removal,
Chapter 6”.
• Thermostat, refer to section “Thermostat removal, Chap-
ter 6” and relevant pipes.
• Exhaust system, refer to section “Exhaust assembly re- C
moval, Chapter 4”.
• Driving gear, refer to section “Driving gear removal”.
• Gear pedal, refer to section “Gear pedal removal, Chapter
4”. 4
• Side stand, refer to section “Removal of the side stand,
Chapter 4”.

• The screw (1) Fig. A.

• The rear brake oil circuit tank (2) Fig. A.
Disconnect:
• The clutch control cable (3) Fig. B.

Remove:
• The clutch cable support plate (4) Fig. C.

D
Disconnect:
• The engine temperature connector (5) Fig. D.
5

5-4
 ENGINE
REMOVAL OF THE ENGINE FROM THE FRAME

• The starter positive cable (6) Fig. E.

E

• The ground cable of the engine mass electrical system (7)

Fig. F. F

G
Disconnect:
• The gear shift sensor connector (8) Fig. G.
8

• Phase sensor connector (9) Fig. H.

H

5-5
 ENGINE
REMOVAL OF THE ENGINE FROM THE FRAME

Disconnect:
• The horn connector (10) Fig. I.
I

10

• The oil pressure sensor connector (11) Fig. L. L

11

M
• The safety fall detection switch connector (12) Fig. M. 12

Remove:
• The horn support bracket (13) Fig. M. N

13

5-6
 ENGINE
REMOVAL OF THE ENGINE FROM THE FRAME

• The brake hoses support bracket (14) Fig. O.

O

14

Remove:
• In sequence screws n. 1-2-3 Fig. P. P
2

• In sequence screws n. 4-5 Fig. Q. Q

NOTE:_________________________________
Repeat the same procedure on the engine left side.

5-7
 ENGINE
INSTALLATION OF THE ENGINE ON THE FRAME

IMPORTANT NOTICE A
Prop the bike on suitable supports so that it cannot fall. 2
Install:
Proceed using the opposite order to removal.
Tighten: 3
• The screws (1-2-3) Fig. A.
To the following torque:

T. R .

Torque 45 N*m
1
Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK- B

ER
5
• The screws (4-5) Fig. B.
To the following torque:

T. R .

4
Torque 45 N*m

Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

NOTE:_________________________________
Repeat the same procedure on the engine left side.

5-8
 ENGINE
DRIVING GEAR REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Chain pinion cover, refer to section “Removal of the chain 1
pinion cover, Chapter 4”.
• The spring washer (1) Fig. A.
• The nut (2) Fig. B.

NOTE:_________________________________
When the driving gear loosen, lock the rear brake.

• Loosen the transmission chain clearance.

(refer to section ”Adjustment of the transmission chain, Chapter
3”). B

• The pinion (3) Fig. C.

5-9
 ENGINE
DRIVING GEAR INSTALLATION

IMPORTANT NOTICE A
Prop the bike on suitable supports so that it cannot fall.

Install:
Proceed using the opposite order to removal.
Tighten: 1
• The nut (1) Fig. A.
To the following torque:

T. R .

Torque 85-95 N*m

IMPORTANT NOTICE
After tightening of the driving gear nut, fold the safety
washer over the nut. If damaged, it must be replaced with a
new one.

5 - 10
 HEAD DISTRIBUTION
DISTRIBUTION COVER REMOVAL

6
7
8

2
3
4
5
9

10

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 COIL
2 RUBBER TIP
3 O-RING
4 SCREW
5 BUSHING
6 SCREW
7 SPECIAL WASHER
8 BRACKET
9 DISTRIBUTION COVER
10 DISTRIBUTION COVER SEAL

5 - 11
 HEAD DISTRIBUTION
COILS AND SPARK PLUGS REMOVAL

Remove:
• The screw (6*) Fig. A.
A
• The washer (7*) Fig. A.
• The bracket (8*) Fig. A.
• The coils (1*) Fig. B.
• The spark plugs, using the special wrench.
6* 8*

NOTE:_________________________________
Numbers marked (*) are part of the spare parts tables in 7*
Chapter 5 “Engine”, section entitled “Distribution cover
removal”.

NOTE:_________________________________
To check the spark plugs, refer to the chapter “Routine
maintenance” in the section “Spark plugs removal”.

1*

5 - 12
 HEAD DISTRIBUTION
COILS AND SPARK PLUGS ASSEMBLY

The following procedure applies to all of the spark plugs (Fig. C).
C
WARNING
Lubricate the spark plug threads with copper grease.

G Grease

NOTE:__________________________________________
Before installing it, clean the spark plug and surface in
contact with the seal.

Install:
• The spark plug on the head, tightening it by hand until you D
can feel it comes into contact with the base of the head.
Then tighten to the correct torque.
T. R .
4
Torque 12 N*m

Install:
• The rubber tips (2*).
• The OR seals (3*) Fig. D.
• The coils (1*).
• The screws (6*).
• The washers (7*).
• The bracket (8*).

Tighten to torque.
T. R .

Torque 10 N*m

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Engine”, section entitled “Distribution cover
removal”.

5 - 13
 HEAD DISTRIBUTION
DISTRIBUTION COVER REMOVAL

Take care with the seal on the distribution cover (10*) Fig. E.
during removal.
E
9*
NOTE:_________________________________ 10*
In case of seal breakage on the distribution cover (10),
replace.

During the assembly of the cover, apply sealing paste type

THREE BOND 1104 /1207B on the surface, as shown in Fig. F.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Engine”, section entitled “Distribution cover
removal”.

5 - 14
 HEAD DISTRIBUTION
DISTRIBUTION COVER ASSEMBLY
1
Assemble: E
Proceed in the opposite direction to removal.

2
NOTE:_________________________________ 3
During the assembly stage of the distribution cover, re- 4
placement of the rubber tips (5*) is recommended. 5
Tighten: 9
Tighten the screws (4*) to the following torque:

T. R .

10
Torque 10 N*m

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Engine”, section entitled “Distribution cover
removal”.

5 - 15
 HEAD DISTRIBUTION
DISTRIBUTION CHAIN TENSIONER REMOVAL

Remove: G
• The screws (1).
• The screw (2). 2
• The washer. 1
• The seal.

NOTE:_________________________________
Operation to perform with the engine in TDC.
Using the special tool during the removal stage, keep the
tensioner retracted, Fig. I., then remove the two screws “1”
Fig. G.

(*) Tool: Chain tensioner lock tool

Code: 0320097046001

5 - 16
 HEAD DISTRIBUTION
DISTRIBUTION CHAIN TENSIONER ASSEMBLY

During the assembly stage, take care to ensure that the seal (4) H
Fig. H is undamaged and unworn, otherwise replace.

Move:
The tensioner to the retracted position and insert it into its hous-
ing using the special equipment (*).

(*) Tool: Chain tensioner lock tool

Code: 0320097046001

Insert the tensioner into the seat and the seal.

4
Tighten:
• The fastening screws (1), Fig. I, to the following torque:
T. R .

Torque 10 N*m I
• The screw (2), Fig. I, to the following torque: 2
T. R .
1

Torque 8 N*m

5 - 17
 HEAD DISTRIBUTION
INTAKE AND EXHAUST CAMSHAFT REMOVAL

Remove:
Coils and Spark plugs, see the section entitled “Coils and
B
• 2 2
spark plugs removal”. 1
• Distribution cover, see section entitled “Distribution cover 1
removal”.

NOTE:_________________________________
During the removal stage, use a marker pen to mark the po-
sition of the holders since, when reassembling, they need
to be in their original positions, Fig. E.
The “arrows” pressed into the holders show the direction in
which they need to be mounted towards the distribution.

Remove:
• The fastening screws of the holders (1) Fig. B. C
• The holders (2).
• The intake camshaft Fig. C.
• The exhaust camshaft (3) Fig. D.

5 - 18
 HEAD DISTRIBUTION
CAMSHAFT CHECK

Make a visual check of the camshaft lobes and, if there is any

blue discolouration/pitting or lines, replace.
E

• Measure the size of the lobes.

A
If the measures taken (Fig. E) are not compliant with specifica-
tions, replace the shaft.
Specifications Table:

Limit Limit
Camshaft
(A) (A)
Camshaft exhaust side 31.95 mm 31.90 mm
Camshaft intake side 31.95 mm 31.90 mm

• Measure the eccentricity of the camshaft

F
If the measures taken (Fig. E) are not compliant with specifica-
tions, replace the shaft.
Specifications Table:

Camshaft Eccentricity limit

Camshaft exhaust side 0.05 mm
Camshaft intake side 0.05 mm

• Measurement of clearance between bearing journals

G
and holder

If the measures taken (Fig. G) are not compliant with specifica-

tions, replace the head and holder block.
Specifications Table:

Clearance between bearing

Camshaft
journal and holder
Camshaft exhaust side 0.03 - 0.06 mm
Camshaft intake side 0.02 - 0.05 mm

• Measure the diameter of the camshaft support

If the measurements taken (Fig. H) are not within the specifica-

tions, proceed with shaft replacement. H
Specifications Table: C
Measurement of main bear-
Camshaft
ing (C)
Camshaft exhaust side
Ø 23 mm (-0.03/-0.045)
Camshaft intake side

5 - 19
 HEAD DISTRIBUTION
EXHAUST CAMSHAFT INSTALLATION

Insert:
Install the special tool (*) into the spark plug seat to check the
A
top dead centre Fig. A.
(*) Tool: Engine tuning tool
Code: R180197022000

Once the TDC has been identified, proceed to assemble the

camshaft, exhaust side.

NOTE:_________________________________
During this assembly, it is important for the lobes of the
cylinder shaft 1 (Y) to be positioned outwards, Fig. B., and
the two reference notches ”X” of the distribution gear are
aligned as in Fig. B. B

NOTE:_________________________________
When assembling the holders, it is necessary to lubricate
them with special grease to prevent the shafts from rotating
dry during initial starting.

X
Teflon-based paste or
G of other lubricants, as
graphite, ceramics.

When installing the holders, proceed in the opposite direction to

removal, tightening the screws to the following torque:

T. R .

Torque 13 N*m

NOTE:_________________________________
Lubricate the screws with copper grease.

G Copper grease

NOTE:_________________________________
Check the correct alignment of the exhaust camshaft using
the special tool (*).

(*) Tool: Engine tuning tool

Code: R180197022000

5 - 20
 HEAD DISTRIBUTION
INTAKE CAMSHAFT INSTALLATION

Install the relevant tool (*) into the spark plug seat to check the A
top dead centre Fig. A.
(*) Tool: Engine tuning tool
Code: R180197022000

Once the drive shaft TDC has been identified, proceed to as-
semble the camshaft, exhaust side.

NOTE:_________________________________
During assembly, it is important for the lobes of cylinder 1
shaft are positioned outwards, and the two reference notch-
es ”X” of the two distribution gears are aligned, as in Fig. B.

NOTE:_________________________________ B
When assembling the holders, it is necessary to lubricate
them with special grease to prevent the shafts from rotating
dry during initial starting.

G Sintoflon Grease
X

When installing the holders, proceed in the opposite direction to

removal, tightening the screws to the following torque:

T. R .

Torque 10-13 N*m

C
NOTE:_________________________________
Lubricate the screws with copper grease.

G Copper grease

Turn the camshaft clockwise, using the fastening nut to the

flywheel, moving the TDC so it lines up with the reference mark-
ings “X” on the head surface, Fig. B, and the reference mark on
the magnet flywheel (2) Fig. D. D.

2
1

5 - 21
 HEAD DISTRIBUTION
DISTRIBUTION CHAIN SLIDES REMOVAL

Remove:
• Coils and Spark plugs, refer to the section “Coils and spark
G
plugs removal”.
1. Distribution gear, refer to the section “Distribution cover
removal”.
2. Chain tensioner, refer to the section“Chain tensioner
removal”.
3. Exhaust camshaft, refer to the section “Exhaust camshaft
removal”. 4
4. Intake camshaft, refer to the section “Intake camshaft
removal”.
5. Flywheel, refer to the section “Flywheel removal”.
6. Starter gear assembly, refer to the section “Starter gear
assembly removal”.

Remove:
• The fixed chain slide (4) sliding it upwards. 5
• The safety plate (5) Fig. H.
• The mobile chain slide (6) Fig. I.
• The fixing pin (7) Fig. I.

CHECK OF THE CHAIN SLIDES

Check:
• The contact surface of the fixed slide.
• The contact surface of the mobile slide.
If there is any damage or wear, replace.
I

6
7

5 - 22
 HEAD DISTRIBUTION
DISTRIBUTION CHAIN SLIDE ASSEMBLY

To assemble the chain slides, follow the removal process in the

opposite order.

NOTE:_________________________________
Operation to perform with the engine in TDC.

At the end of assembly, proceed to load the distribution chain

tensioner. Refer to the section “Distribution chain tensioner
fitting”.

5 - 23
 HEAD DISTRIBUTION
DISTRIBUTION CHAIN REMOVAL

Remove:
1. Coils and Spark plugs, refer to the section “Coils and spark
I
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.
3. Chain tensioner, refer to the section“Chain tensioner
removal”.
4. Exhaust camshaft, refer to the section “Exhaust camshaft
removal”.
5. Intake camshaft, refer to the section “Intake camshaft
removal”.
6. Flywheel removal, refer to the section “Flywheel removal”.
7. Starter gear removal, refer to the section “Starter gear
removal”.
8. Chain slides, refer to the section “Chain slide removal”.

• Once the parts listed above have been removed, proceed to

take out the same Fig. I.

DISTRIBUTION CHAIN CHECK C

The following process applies to all of the toothed wheels on the 2
camshafts and all of the distribution chain guides.

Check:

• The distribution chain (2) Fig. C.

In case of damage/lack of flexibility/locked links, replace the
distribution chain and camshaft gear block.

NOTE:_________________________________
In any case the distribution chain needs to be replaced after
20,000 km.

5 - 24
 HEAD DISTRIBUTION
DISTRIBUTION CHAIN INSTALLATION

Insert: A
• The distribution chain (1) into the camshaft pinion, as in Fig.
A.
• Insert the fixed and mobile chain tensioner slides, refer to
the section“Distribution chain assembly”.
• The two camshafts, making sure that both are mounted with
the phasing references “aligned” with the floor” as in Fig. B.

1
NOTE:_________________________________
For the distribution chain assembly it is necessary always
taking into account the fact that the engine needs to be in
TDC condition (Fig. B), refer to the section “Intake camshaft
installation”.

(*) Engine tuning tool

Code: R180197022000
B
NOTE:_________________________________
During this operation, it is necessary to lubricate the chain
and distribution gears with engine oil.

NOTE:_________________________________
Every time that the chain is replaced, it is also necessary to
replace the slides.

5 - 25
 HEAD DISTRIBUTION
VALVE CLEARANCE ADJUSTMENT

Remove: A
1. Coils and Spark plugs, refer to the section “Coils and spark
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.

NOTE:_________________________________
Valve clearance must be checked and adjusted when the
engine is cool (ambient temperature).

Check:
Use a feeler gauge to check the clearance between the cam and
the tappet valve, as shown in Fig. A.
If the measurement is outside specifications, replace the cali-
brated pad.

NOTE:_________________________________
The measurement must be taken on all cams and tappets.

Camshaft Tappet-cam clearance

Camshaft exhaust side 0.20 ~ 0.25 mm
Camshaft intake side 0.15 ~ 0.20 mm

NOTE:_________________________________
In case of valve clearance correction, replace the calibrated
pads (see the following table).

5 - 26
 HEAD DISTRIBUTION
TAPPET VALVE AND CALIBRATED PAD REMOVAL

1
20 22

19
21 22 4
23
25
26 25
18 3 27 26
5 27
28 28
33 29
6 30
17 30

32 31

7 2

16 15 7
14

11 8
10
24
13 9

12

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 BUSHING
2 SCREW
3 BUSHING
4 WASHER
5 VALVE RUBBER
6 CYLINDER HEAD
7 STUD BOLT
8 SCREW
9 THERMOSTAT CUP
10 THERMOSTAT
11 GRUB SCREW
12 HEAD GASKET
13 WATER TEMPERATURE SENSOR
14 COUPLING
15 RETAINING WASHER
16 SCREW
17 O-RING
18 SUCTION PIPE
19 WASHER
20 SCREW
21 SCREW BAND
22 SCREW
23 CAP

5 - 27
 HEAD DISTRIBUTION
TAPPET VALVE AND CALIBRATED PAD REMOVAL

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
24 PLUG
25 TAPPET VALVE
26 VALVE PAD
27 VALVE RUBBER
28 TOP SHIELDED BULB
29 EXTERNAL VALVE SPRING
30 BOTTOM SHIELDED BULB
31 EXHAUST VALVE
32 INTAKE VALVE
33 INTERNAL VALVE SPRING

5 - 28
 HEAD DISTRIBUTION
TAPPET VALVE AND CALIBRATED PAD REMOVAL

Remove:
A
1. Coils and Spark plugs, refer to the section “Coils and spark
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.

To remove the intake and exhaust valve lifter, proceed as fol-

lows: 1
• Use a magnet to take out the tappet valve lifter (1) and then
the calibrated pad (5) Fig. A.
• Make a visual check of the tappet valve lifter, ensuring that 5
there is no damage or lines, and if not, replace.
• Check the outside diameter using a micrometre to exclude
any deformation Fig. B.

NOTE:_________________________________
During installation, lubricate the tappet valve lifter, using:
B
Teflon-based paste or
G of other lubricants, as
graphite, ceramics.

NOTE:_________________________________
At the end of the check of the parts, check the valve clear-
ance, as in the section “Valve clearance removal”.

5 - 29
 HEAD DISTRIBUTION
HEAD REMOVAL

Remove:
1. Coils and Spark plugs, refer to the section “Coils and spark
C
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.
3. Chain tensioner, refer to the section“Chain tensioner
removal”.
4. Exhaust camshaft, refer to the section “Intake and exhaust
camshaft removal”. 6
5. Chain slides, refer to the section “Chain slide removal”.

Remove:
• The screws (6) Fig. C.
• The fastening screws (7) Fig. D.

NOTE:_________________________________
Loosen each screw by 1/2 turn. D
Then remove all screws.

• Head gasket.
7

5 - 30
 HEAD DISTRIBUTION
VALVE AND VALVE SPRING REMOVAL

Remove:
1. Coils and Spark plugs, refer to the section “Coils and spark
A
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.
3. Chain tensioner, refer to the section“Chain tensioner *
removal”.
4. Exhaust camshaft, refer to the section “Exhaust camshaft
removal”.
5. Intake camshaft, refer to the section “Intake camshaft
removal”.

Use the special tool to remove the valves (Fig. A).

(**) Valve removal tool

Code: 0320097050000
B
Remove:
• Tappet valve.
• Pad.
• Cotters.
• Top door.
• Spring.
• Bottom plate.
• Oil seal. 1
NOTE:_________________________________
During removal of the two cotters to lock the valve, use a
magnet (1) to recover them Fig. B.

5 - 31
 HEAD DISTRIBUTION
CHECK OF VALVES AND GUIDES

The following process applies to all of the valves and valve

guides.
A

Check: 1
• The valve seals.
If there are leaks from the valve seats, check the contact sur-
face, the seat and the width of the valve seat.

• Pour clean solvent (1) into the intake doors.

• Make sure the valves have a suitable seal.
NOTE:_________________________________
There should not be any leaks from the valve seat (2) Fig. A.

Replace:
• The valve guide. B
NOTE:_________________________________
To make valve guide removal and installation operations
easier and to maintain correct assembly, heat the head in an
oven, taking it to 100° C (212° F).
3
• Remove the valve guide with a special extractor (3) Fig. B.
• Install the new valve guide with the special installer (4) and
extractor (3) Fig. C.
• After inserting the valve guide, bore it with a reamer (5) to
create the correct clearance between the valve guide and
stem.

NOTE:_________________________________
C
After reinserting the valve guide, pass over the seat.

5 - 32
 HEAD DISTRIBUTION
CHECK OF VALVES AND GUIDES

Eliminate:
• The carbon deposits (5) from the contact surface and the
E
valve seat, Fig. E.

Check:
• The contact surface of the valve (7) Fig. F. F
If there is any pitting/wear, grind the contact surface of the valve.
• The end of the valve stem (6) Fig. F.
If there is a shape or a diameter of the mushroom that is larger
than the body of the valve stem, replace the valve. 6

Measure:
• The eccentricity of the valve stem Fig. G. G
If outside specifications, replace the valve.

NOTE:_________________________________
If installing a new valve, always replace the relevant guide
If the valve is removed or reassembled, always replace the
oil seal.

Valve Valve stem eccentricity

Intake
0.01 mm
Exhaust

5 - 33
 HEAD DISTRIBUTION
VALVE SEAT CHECK

The following process is applied to all valves and valve seats

Fig. H. H

Eliminate:
• The carbon deposits from the contact surface and the valve
seat (A). B
Check:
• The valve seat (A). A A
If there are marks/signs of wear, replace the head.

Measure:
• The width of the valve seat (A).
If outside specifications, replace the head.

Valve Width of valve seat

Intake 1~ 1.1 mm I
Exhaust 0.9 ~ 1.1 mm

1. Apply some blue colorant (Dykem) for mechanics to the

contact surface of the valve (B).
2. Install the valve in the head.
3. Push the valve into the guide and against its seat to leave a
well-defined mark. C
4. Measure the valve seat width.

NOTE:_________________________________
Where the valve seat and valve face are in contact with one
another, the Prussian blue liquid will have been removed.

Lap:
• The valve contact surface. L
• The valve seat Fig. L.

NOTE:_________________________________
After replacing the head or the valve and the relevant guide,
it is necessary to lap the seat and contact surface of the
valve.

• Apply a paste for rough lapping of the valve contact surface

(C). Fig. I.

IMPORTANT NOTICE
Do not allow the lapping paste to enter the area between the
valve stem and the guide.

• Apply molybdenum disulphide oil to the valve stem.

• Install the valve in the head.
• Turn the valve until the contact surface and the seat have
been polished evenly, then remove all the lapping paste.

NOTE:_________________________________
To get the best results from lapping, gently tap on the valve
seat while turning it forwards and back manually Fig. L.

5 - 34
 HEAD DISTRIBUTION
VALVE OIL SEAL REMOVAL-INSTALLATION

Remove:
Once the valve has been removed, using the special tool (*) to
B
take out the oil seal (1) Fig. B.
(*) Tool for valve oil seal removal
1

**
Install:
Proceed to mount the oil seal (1), Fig. D, using the special tool
(**), Fig. C.
(**) Oil seal insertion tool
Code: R180197025000

5 - 35
 HEAD DISTRIBUTION
VALVE SPRING TEST

The following process is applied to all valve springs.

A
Measure:
• The free length of the valve springs (A) Fig. A.

Valve spring Dimension (A)

Intake 38.8 mm - 36.60 mm
Exhaust 41.6 mm - 40.1 mm

NOTE:________________________________
If not compliant with specifications, replace the valve A
spring.

5 - 36
 HEAD DISTRIBUTION
VALVE AND VALVE SPRING INSTALLATION

Install into the head:

A
NOTE:________________________________ 1
Lubricate the valve stem and oil seal.
2
E

A1
3 E

Engine oil
E

4
• Valve bottom spring plate (4).
• Valve oil seal (3) Fig. A1, refer to the section “Valve oil seal
removal-installation”.
• The valve (5).
• The valve spring (2).
• The valve top spring plate (1). A2
• The cotters.

NOTE:________________________________ E

Deburr the end of the valve stem with an oiling stone (A2).

NOTE:________________________________
Make sure that every valve has been remounted in its origi- A3
nal position.
5
NOTE:________________________________
Reposition the valve cotter pin, pressing the spring on each
valve with the special compression tool (*) Fig. B.

(*) Valve spring compressor tool

Code: 0320097050000 B

5 - 37
 HEAD DISTRIBUTION
VALVE AND VALVE SPRING INSTALLATION

Secure: C
• The cotters on the valve stems.
Gently tap on the valve tip with a soft hammer, Fig. C.

IMPORTANT NOTICE
Hitting the valve tip with too much force could damage the
valve.

Install:
• The calibrated pad (1) Fig. D.
• The tappet valve (2) Fig. D.

NOTE:________________________________
Lubricate the tappet valve with grease MOLYKOTE with
graphite.
Manually turn the tappet valve, which must be able to slide
smoothly.
Reassemble each tappet valve and pad to its original posi-
D
tion.

G
Graphite-based
grease 2
1
The following process applies to all of the valves and relevant
components.

5 - 38
 HEAD DISTRIBUTION
CYLINDER CHECK

Remove:
1. Coils and Spark plugs, refer to the section “Coils and spark
A
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.
3. Head, refer to the section “Head removal”.

The following procedure applies the whole cylinder group.

Check:
• The cylinder walls with a special tool Fig. A.

If there are any vertical lines, replace the cylinder and the piston
all together and the relevant rings.

Measure:
• Cylinder stroke Fig. B.
Make different measurements at different distances of 10-43-90
B
mm from the head coupling surface.
The highest value is considered when calculating wear limits.
CYLINDER bore (C) = 69 (+0.01 , +0.02)
- 0.002
C=Max D1 or D2 - 0.003 mm

Limit taper:
• Max D1= 0.05 mm
• Max D2= 0.05 mm
• Max D3= 0.05 mm
• Max D4= 0.05 mm
• Max D5= 0.05 mm
Limit eccentricity:
• Max D1= 0.05 mm
• Max D2= 0.05 mm
• Max D3= 0.05 mm
• Max D4= 0.05 mm
• Max D5= 0.05 mm
Max difference between the cam and the piston:
• Max= 0.1 mm

5 - 39
 HEAD DISTRIBUTION
HEAD INSTALLATION

Before assembling the head, replace the seal (2).

Make sure that the alignment dowels (1) are in position Fig. C.
C
1
2

• Position the head and tighten the screws (3), following the D
sequence stated in Fig. D.
8
• Then the screws (4). 5 2 3
NOTE:_________________________________
During assembly of the head, lubricate the head screws
with copper grease. 8
8

G Copper grease
4 1 6

8
Tighten:
• The screws (8) Fig. D to torque in three steps:

T. R .

E
Step one:
Torque 12.5 N*m
Step two:
Torque 25 N*m
Step three:
Torque 55 N*m
3
Tighten: 4
• The screws (4) Fig. E to torque.
T. R .

Torque 12 N*m

To assemble the head, tighten the fastening screws (3) Fig. E,

after the screws (4).

NOTE:_________________________________
During assembly of the head, lubricate the head screws
with copper grease.

5 - 40
 PISTONS

1
2

2 1
3
4
3
2

9 5 8
5 8
20
9
7
11 10
12 6
13 15 24
14 23 22
21

16 25
17 18 19

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 PISTON SEGMENT SERIES
2 PIN RETAINING RING
3 PISTON PIN
4 PISTON
5 CONNECTING ROD
6 PLUG
7 SCREW
8 GUIDE BUSHING
9 CONNECTING ROD HALF BEARING
10 COUNTERSHAFT
11 NUT
12 WASHER
13 FULL DRIVE SHAFT
14 SPLINE
15 PLUG
16 GEAR
17 DRIVE SHAFT GEAR

5 - 41
 PISTONS

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
18 WASHER
19 NUT
20 BEARING
21 NUT
22 COUNTERSHAFT GEAR
23 GUIDE BUSHING
24 BEARING
25 BEARING RETAINER

5 - 42
 PISTONS
PISTON REMOVAL

The following removal process applies to all pistons.

A
Remove:
1. Coils and Spark plugs, refer to the section “Coils and spark 1
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
2
removal”.
3. Head, refer to the section “Head removal”. 2 1
4. Top base, refer to the section “Connecting rod removal”.
3
4
Remove:
• The outer piston ring (2) Fig. A. 3
• The piston pin (3) Fig. A. 2
• The piston (4) Fig. A.
• The inner piston ring (2) Fig. A.

NOTE:_________________________________
To remove the piston pin, use a “pad*” Fig. B. B

NOTE:_________________________________
Never use hammers to remove the pins.

5 - 43
 PISTONS
PIN CHECK:

The following procedure applies to all piston pins.

B
Check:
• The piston pin.

If there is blue discolouration or grooves, replace the piston pin

and check the lubrication system.

Measure:
• The outer diameter of the piston pin Fig. B.

If not compliant with specifications, replace the pin using the

measuring tool (A).

Measure:
• The inner diameter of the piston pin bore Fig. C.
C
If outside specifications, replace the piston.

Internal bore (1) Size

Pin bore Ø17 mm +0.0/+0.006

5 - 44
 PISTONS
PISTON RING CONTROL

The following procedure is applied to all piston rings (1).

A
Check:
• The absence of lines and traces of forcing on each ring Fig.
1
A.

If outside specification, replace the relevant rings and pistons.

NOTE:_________________________________
Before measuring side clearance between the piston rings,
remove any carbon deposits from the piston rings and
grooves.

Measure:
• The side clearance between piston rings, using a thickness
gauge Fig. B.
B
If outside specifications, replace the piston and the relevant
rings all together.

Ring Piston ring side clearance.

Top ring 0.04÷0.08 mm
Second ring 0.05÷0.09 mm

Measure:
• The thickness of the top ring.
• The thickness of the second ring.
See Fig. C.
C
Ring Piston ring thickness
Top ring 0.8 -0.01/-0.03 mm
Second ring 0.8 -0.02/-0.04 mm

5 - 45
 PISTONS
PISTON CHECK

The following procedure applies to both pistons.

D
Check:
• The walls of the piston (1) Fig. D.
If there are any vertical lines, replace the piston all together with
the relevant rings.

Measure:
• The diameter of the piston skirt (2) with a micrometre,
considering a distance from the bottom edge of around 10.5
mm Fig. E.
1

CLASS Piston skirt

A Ø69(-0.025/ -0.03)
B Ø69(-0.02/ -0.025)
E
If outside specifications, replace the cylinder and the relevant
rings all together.
If outside specifications:
Wrong tolerance (excessive) between the piston and the cam,
limit max 0.1 mm. 2
IMPORTANT NOTICE
The piston is marked by a letter stating its class. The
cylinder-piston coupling must be made between the same
classes.

5 - 46
 PISTONS
PISTON ASSEMBLY

The following procedure applies to all pistons.

A
3

D
Install:
in the following order:

PVD
1. Oil scraper clip
2. Second ring.
3. Top ring.
2
See Fig. A.
1
NOTE:_________________________________
The first and second ring are marked with the letter D on the
top side and PVD Fig. A.
Remember to install the piston rings so that the letters are
facing upwards.
Lubricate the rings with engine oil during the insertion
stage.
B
The first element to insert in the oil scraper slot is the shim (D).
After positioning the shim, insert its side rings (E) Fig. B.

NOTE:_________________________________
The shim and side rings have no top or bottom side, mean- E
ing they can be inserted in any way.
D
IMPORTANT NOTICE
When installing the shim (D), make sure that its ends do not
E
overlap the slot Fig. C.

Wrong

Correct

5 - 47
 PISTONS
PISTON INSTALLATION

NOTE:_________________________________
To assemble the pistons (1), first insert the inner rings (2),
C
then the pins (4) and finally the outer rings (3) Fig. C.
1
To insert the pistons into the cylinders, it is necessary to use a 4
specific piston clamp to hold the rings. 2
General piston clamp.

NOTE:_________________________________ 3
During this stage, lubricate parts with engine oil

IMPORTANT NOTICE
The pistons must be inserted in the sequence in which
they were removed. Do not change the assembly order and
above all, make sure that the mark on the piston Fig. D is D
facing the intake side.

5 - 48
 CRANKCASE
REMOVAL OF CONNECTING RODS

Remove:
1. Coils and Spark plugs, refer to the section “Coils and spark
E
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.
3. Chain tensioner, refer to the section“Chain tensioner
removal”.
4. Exhaust camshaft, refer to the section “Exhaust camshaft
removal”.
5. Intake camshaft, refer to the section “Intake camshaft
removal”.
6. Head, refer to the section “Head removal”.
7. Flywheel, refer to the section “Flywheel removal”.
8. Mobile chain slides, refer to the section “Mobile chain
slides removal”.
9. Clutch, refer to the section “Clutch removal”.
10. Oil sump, refer to the section “Oil sump removal”.
40 40 40 F
11. Oil pump, refer to the section “Oil pump removal”. 40

Remove: 40
• The base screws Fig. F.
• Raise the top base. 41
41
41

40 40 40 42

Remove: G
• The gearbox output shaft (1) Fig. G.
• The gearbox intake shaft.
• The counter shaft (2) Fig. G.
• The connecting rod screws (3) Fig. G. 1
3

5 - 49
 CRANKCASE
REMOVAL OF CONNECTING RODS

Remove:
• Take out the drive shaft, and slide out the connecting rod,
H
including the pistons, from the cylinder group.
• Remove the pistons, refer to the section “Piston removal”.

5 - 50
 CRANKCASE
CHECK OF CONNECTING RODS AND CONNECTING ROD HALF BEARING

Check:
• For any breakages or excessive clearance on the connect-
A
ing rod (5) and half bearings of the connecting rod big end 8
(8) Fig. A. 5
If replacing the connecting rod, check the class of origin marked
on the big end.

Measure:
• Furthermore, it is necessary to measure the internal dimen-
sion of the connecting rod big end to check for any anom-
alies using the special gauge Fig. B. Before measuring,
assemble the big end, tightening the fastening screws to the
following torque:
T. R .

B
Torque 25 N*m

• It is also necessary to measure the dimensions of the small

end and check for any anomalies with the relevant tool,
commercially available Fig. B.

Item Reference size

Connecting rod big end Ø 33 mm (-0/+0.01)
Connecting rod small end Ø17 mm -0/+0.01)

Before assembling the bushings (8) of the connecting rod big C

end, measure them with a specific micrometre, see Fig. C.

5 - 51
 CRANKCASE
CONNECTING ROD AND CONNECTING ROD HALF BEARING INSTALLATION

Install:
• The connecting rod half bearings:
D

Assemble the top and bottom half bearings into the big end in A
the connecting rod and the bottom bearing in the connecting rod
big end of the connecting rod cap.

NOTE:_________________________________
Align the projections “A” on the half bearings of the big end
with the slots “B” in the connecting rod and the relevant
B
cap Fig D.

5 - 52
 CRANKCASE
CONNECTING ROD AND CONNECTING ROD HALF BEARING INSTALLATION

NOTE:_________________________________
Do not mix up the connecting rod bushings and the con-
E
necting rods. To achieve the correct clearance between the
connecting rod support and the big end half bearing and to
prevent engine damage, the big end half bearings must be
mounted in their original positions Fig. E.
K4/
102600 A B C
According to the bushing type, make the envisaged couplings,
see table:

CONNECTING ROD HALF BEARING

STD COLOUR THICKNESS
A Green 1,503~1,506 mm
B Blue 1,506~1,509 mm
C Yellow 1,500~1,503 mm
F
Ø std seat A green Ø 33 mm (+0.008/0)

Ø std seat B blue Ø 33 mm (+0.008/+0.016)

Ø std seat C yellow Ø 33 mm (-0.034/-0.041)
K4/
10K1
2600
According to the class shown on the side of the connecting rod
Fig. F, combine the different types making reference to the table
below:

SELECTION TABLE
Connecting rod internal Ø
1 2
33,000 - 33,008 33,008 - 33,016 G
-0.034 +0.003 -0.006
Crank pin A Ø 30 A (yellow)
-0.041 0 B (green) -0.003
external Ø
-0.041 -0.006 -0.009
B Ø 30 -0.048 B (green) -0.003 C (brown) -0.006

After all of these checks, install the fastening screws (6) Fig. G
and tighten to the following torque:
T. R .

Torque 25 N*m 6 6

NOTE:_________________________________
Every time that the big end is assembled, it is necessary to
replace the fastening screws.

5 - 53
 CRANKCASE
MAIN HALF BEARING AND DRIVE SHAFT INSTALLATION

34 39
18 39 38
38
14 17 36
21 37
19 22 23
10
11 20 37
18 24
9 37
37
45
26 44 27
12 13 45 26
8 4 25 5
3
2 15
16
28
35
7 43 46
31
40 40 40 40 30
29

40 6
26 40 13
41
41 12
41 42
40 29 1
38
39
40
38 40 33
36 40
32 41
41 41
41

42 34 41 37
40 40 40
41

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 ENGINE CASING
2 O-RING
3 NEUTRAL SENSOR
4 SCREW
5 CAP
6 OIL SEAL
7 PLATE
8 SCREW
9 SCREW
10 PLATE
11 PLUG
12 SPECIAL SCREW
13 RETAINING WASHER
14 COUPLING
15 O-RING
16 SPECIAL SCREW
17 RUBBER TIP
18 CENTERING BUSHING
19 BUSHING
20 O-RING
21 WATER FITTING
22 SCREW

5 - 54
 CRANKCASE
MAIN HALF BEARING AND DRIVE SHAFT INSTALLATION

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
23 OIL FILTER
24 JOINT
25 OIL PRESSURE SENSOR
26 WASHER
27 BEARING
27 BEARING
27 BEARING
27 BEARING
28 DISTRIBUTOR
29 SCREW
30 FLANGE
31 SEAL
32 OIL PRESSURE VALVE
33 SPECIAL SCREW
34 SCREW
35 JOINT
36 SCREW
37 WASHER
38 SCREW
39 SCREW
40 SCREW
41 SCREW
42 SCREW
43 GRUB SCREW
44 INSERT
45 CENTERING BUSHING
46 O-RING

5 - 55
 CRANKCASE
MAIN HALF BEARING AND DRIVE SHAFT INSTALLATION

Install:
• Clean the main half bearing (6).
A
• The main half bearings.
• Install the main half bearings in the relevant seats from the
top and bottom base.
6

NOTE:_________________________________ A
Align the projections of the main half bearings with the
slots in the top base Fig. A.
Use copper grease for assembly.

Teflon-based paste or
G of other lubricants, as
graphite, ceramics.

IMPORTANT NOTICE
Do not get the main half bearings mixed up.
To achieve the correct clearance between the connecting
rod support and the main half bearings and to prevent
engine damage, the half bearings must be reassembled in
their original position.

• The main half bearings are in different sizes, marked with

different letters and colours, as shown in the table.

MAIN HALF BEARINGS

STD COLOUR THICKNESS
A Green 1.5(0/0 + 0.003) mm
B Blue 1.5(0/0 + 0.006) mm C
C Yellow 1.5(0/0 + 0.009) mm
Ø std seat A green Ø 41(0.007+0.14)
Ø std seat B blue Ø 41(0+0.007)
Ø std seat C yellow Ø 41(0.014+0.021)
Ø std seat only A Ø 41(0/+0.007)
B Ø 41(0.007+0.014)
C Ø 41(0.014+0.021)

• The main half bearing layout is shown on the bottom casing,

as illustrated in Fig. C.

NOTE:_________________________________
In case of replacement of the drive shaft, it is necessary to
replace the main half bearings.

5 - 56
 CRANKCASE
DRIVE SHAFT CHECK

Measure:
• The eccentricity of the drive shaft.
A
1*
1*
If outside specifications, replace the drive shaft.

Drive shaft eccentricity Size

Drive shaft 1*: Ø 38 (-0.01, -0.05) mm
2*: Ø 30 (-0.028, -0.042) mm

Check:
• The main support surfaces (1*) Fig. A. 2*
• The connecting rod support surfaces (2*) Fig. A.
If there is any rust/lines/signs of wear, replace the drive shaft.

5 - 57
 CRANKCASE
DRIVE SHAFT INSTALLATION

Once the drive shaft has been inserted, proceed to assemble

the big ends Fig. B.
B
Tighten the nuts to the following torque:
T. R .

Torque 25 N*m

NOTE:_________________________________
Lubricate the big end pins with copper grease.

Measure:
Once the big ends have been assembled, use a thickness gauge
to measure the drive shaft-big end collar Fig. C.

Measuring Size
C
Drive shaft - connecting
0.1~0.25 mm
rod big end

NOTE:_________________________________
Measure both big ends.

5 - 58
 CLUTCH

11

16
17 15
10

20 9 8
19

3
12
1 14
18
4 13
5

2 7
6

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 GUIDE BUSHING
2 CLUTCH BELL
3 ROLLER BEARING
4 SHIM
5 OIL PUMP PINION
6 WASHER
7 BEARING
8 PRESSURE PLATE
9 DRIVEN CLUTCH DISC
10 STEEL CLUTCH DISC
11 CLUTCH DRUM
12 CLUTCH SPRING
13 SCREW
14 COMPLETE CLUTCH
15 BELLEVILLE WASHER
16 DRIVEN CLUTCH DISC 9
17 SEAL
18 FLANGE
19 NOTCHED NUT
20 WASHER

5 - 59
 CLUTCH
CLUTCH AND DISC REMOVAL

Remove:
• The clutch cover screws Fig. A.
A
• Clutch cover.
• The seal.

NOTE:_________________________________
In case of seal anomalies, insert a new one.

Remove:
• The guide bushing (1) Fig. B.
• The clutch control shaft (2) Fig. B.

2
1

• Remove the bearing (11*) Fig. C.

C

7*

• Remove the fastening nut (1*) and ring (10*) as shown in D

the figure, Fig. D.

(*)Tool for clutch bell ring nut removal/assembly

Code: 03200097052000
10
(**)
(**)Toothed wrench to lock the clutch bell (*)
Code: 03200097053000
1

5 - 60
 CLUTCH
CLUTCH AND DISC REMOVAL

NOTE:_________________________________
Part numbers marked (*) are part of the spare parts table in
E
Chapter 5 “Clutch”.
6*

Remove:
• The disc pack (6*) Fig. E.
• The clutch drum washer (10*) Fig. E.
• The guide shim (13*) Fig. E.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Clutch”.
10*

9*

13*

5 - 61
 CLUTCH
FRICTION DISC CHECK

The following procedure applies to all friction discs.

A
Check:
• The friction disc.
If there is any damage/wear, replace the friction discs.

Measure:
• The thickness of the friction disc Fig. A.
If not within specifications, replace the friction discs together.

Disc Size
Friction disc Thickness 2.7(±0.05) mm

NOTE:_________________________________
Measure the friction disc in four points.

5 - 62
 CLUTCH
STEEL DISC CHECK

The following procedure applies to all steel discs.

B
Check:
• The steel disc.
If there is any damage/wear, replace the steel discs all together.

Measure:
• The warping of the steel discs Fig. B.
If not within specifications, replace the steel discs together.

Disc Warping limit

Steel disc 0.1 (0,-0.05) mm

NOTE:_________________________________
Carry out the check, placing the disc on a reference surface
and take the measurements using a thickness gauge.

5 - 63
 CLUTCH
DISC ASSEMBLY

Assemble the discs in the opposite order to their removal, start-

ing with the ring (8*) and then the Belleville washer (7*) on the
C
clutch drum (9*).

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in 7*
Chapter 5 “Clutch”.

9*

5 - 64
 CLUTCH
CLUTCH ASSEMBLY

Assemble:
• The oil pump pinion (complete with chain) (1).
D
• The guide shim (4*). **
• The clutch bell (8*).
• The washer (6*).
• The clutch drum complete with discs (8*).
• The disc pusher plate (11*).
1
• Using a specific tool (**) assemble the fastening ring nut
(18) and washer (6) as shown in the figure Fig. D.
• The clutch spring (12*).
• The flange (18*).
• The fastening screws (13*) to the following torque:
T. R .

Torque 105 N*m

E
(**)Tool to remove/install the clutch bell ring nut.
Code: 03200097052000

(**)Toothed wrench to lock the clutch bell.

Code: 03200097053000

NOTE:_________________________________
Use a punch driver to rebate the fastening ring nut Fig. E.

• Insert the bearing (7*).

• Reposition the guide bushing and the clutch control shaft (2)
on the cover.
• Insert the seal.
• Place the clutch cover, inserting and tightening the cover F
fastening screws to the engine casing.
T. R .

Torque 12 N*m

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Clutch”.

5 - 65
 LUBRICATION SYSTEM

14 14
19
20 19
18 20
13

12
8
21 7 1
11
10 6
15

5
16 9

2
9
4 3
17

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 OIL PUMP CHAIN
2 COMPLETE OIL PUMP
3 SCREW
4 WASHER
5 OIL PUMP PINION
6 OIL PUMP COVER
7 OIL PUMP SHAFT
8 ROLLER
9 SCREW
10 OUTER ROTOR
11 INNER ROTOR
12 WASHER
13 OIL PUMP BODY
14 BUSHING
15 SCREW
16 INTAKE FILTER FITTING
17 INTAKE FILTER
18 THREADED CAP
19 PLUG
20 O-RING
21 SCREW

5 - 66
 LUBRICATION SYSTEM
OIL SUMP AND INTAKE FILTER REMOVAL

Remove:
1. Coils and Spark plugs, refer to the section “Coils and spark
A
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.
3. Chain tensioner, refer to the section“Chain tensioner
removal”.
4. Exhaust camshaft, refer to the section “Exhaust camshaft
removal”.
E
5. Intake camshaft, refer to the section “Intake camshaft
removal”.
6. Head, refer to the section “Head removal”.
7. Flywheel, refer to the section “Flywheel removal”.
8. Mobile chain slides, refer to the section “Mobile chain
slides removal”.
9. Clutch, refer to the section “Clutch removal”.

NOTE:_________________________________ B
C
Before removing the oil sump, first drain out any oil in the A
engine, removing the magnetic cap.
D
Remove:
• The oil sump fastening screws (E) Fig. A.

Check:
• The oil sump.
If there is any damage, replace.
B
Remove:
• The seal (A) Fig. B.
• The intake filter fitting (B.) Fig. B.
• The intake filter (C.) Fig. B.
• The pressure relief valve (D) Fig. B.

NOTE:_________________________________
If there is any damage to the above parts, replace.

NOTE:_________________________________
If there is any sediment or residue, clean the filtering area
carefully with solvent.

5 - 67
 LUBRICATION SYSTEM
OIL SUMP AND INTAKE FILTER INSTALLATION

Install: C
Proceed using the opposite order to removal.

Tighten:
• The screws (2) Fig. C to the following torque:
T. R .

Torque 10 N*m 2
• The magnetic cap, complete with copper washer, to the
following torque:
T. R .

Torque 25 N*m

NOTE:_________________________________
Add engine oil once these steps have been completed.

5 - 68
 LUBRICATION SYSTEM
PRESSURE-RELIEF VALVE INSTALLATION

Remove:
• Oil sump, refer to the section “Oil sump and intake filter
A
removal”.

Check:
Before installing the valve, make sure all the parts are free from
anomalies Fig. A.
If there is any damage or wear, replace.

Install:
The pressure relief valve (1) with O-ring inside the bottom cas-
ing, by slotting it in Fig. B.

NOTE:_________________________________ B
Lubricate the pressure relief valve during insertion.

5 - 69
 LUBRICATION SYSTEM
PRESSURE RELIEF VALVE REMOVAL

Remove:
• Oil sump, refer to the section “Oil sump and intake filter
A
removal”.
• The pressure relief valve (1).

5 - 70
 LUBRICATION SYSTEM
OIL PUMP REMOVAL

Remove:
1. Clutch, refer to the section “Clutch removal”.
A
• Use a wrench to block the pump control gear (5*) .
• Unscrew the screw (3*).
• Take out the washer (4*) Fig. A.
• Take out the pump pinion (5*).
2. Oil sump, refer to the section “Oil sump and intake filter
removal”.
4*
5* 3*

Remove:
• The screws (1) Fig. B.
• Slide out the pump body (13*) Fig. B.
B

1 13*

Check:
• The integrity of the two pins (19*).
• The two O-rings (20*) Fig. C. C
19*
NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Lubrication circuit”.

20*

5 - 71
 LUBRICATION SYSTEM
OIL PUMP REMOVAL

Remove:
• The screws (9*).
C
• The pump cover (6*).
C A
• Outer rotor (10*).
• Inner rotor (11*).
• Roller (8*).
• Oil pump shaft (7*).

Check:
• The pump body (13*) Fig. D.
If there are any lines/damage/wear, replace.

• The pump pinion (5*).

If there is any damage or wear to the gears, replace.
B

Measure:
• The tolerance between the inner rotor (11*) and the outer
rotor (10*) ”C”. Fig. E and Fig. C. (A).
• The tolerance between the outer rotor (11*) and the oil
pump housing (6*) ”E”.Fig. E and Fig. C (B).
• The flatness of both rotors compare to the oil pump housing
(6*) “C”.Fig. C.

Clearance Tolerance
between the inner rotor
D
0.15 mm
and the outer rotor ”A”.
between the outer rotor
13*
and the oil pump housing +0.06, +0.09 mm
“B”

Check:
• The oil pump operation.
Turn the pump pinion (5*) as shown in Fig. F.
If the movement is not smooth, check the inner/outer rotor seat. 5*
If there are any lines/damage, replace the
faulty part/s.

NOTE:_________________________________
This check is carried out after securing the oil pump in the D E
engine body and inserting the pump pinion (5*) in its seat.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Lubrication circuit”.

5 - 72
 LUBRICATION SYSTEM
OIL PUMP ASSEMBLY

Install:
Proceed using the opposite order to removal.
A
Tighten the assembly screws (1) Fig. A to the following torque: 1
T. R .
1
Torque 12 N*m

Tighten the assembly screws (3*) with the pump pinion (5*) Fig.
B to the following torque:
T. R . 1

Torque 7 N*m
Use medium Loctite thread locker to secure.
1
MEDIUM THREAD LOCK-
ER
B
NOTE:_________________________________
For tightening the pump pinion (5*), use an apposite
wrench.

NOTE:_________________________________
Add engine oil once the steps have been completed.
5* 3*
NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Lubrication circuit”.

5 - 73
 GEAR
NEUTRAL POSITION/GEAR INDICATOR SENSOR REMOVAL

Remove:
• The screws (5).
A

Take out: 5
• The pin (3) Fig. A.
• The spring (2) Fig. A.
• The neutral position/gear indicator sensor (1) Fig. A.
• The seal (4) Fig. B. 2

B
1 4 3
5 2

5 - 74
 GEAR
NEUTRAL POSITION/GEAR INDICATOR SENSOR INSTALLATION

Install: A
• Insert the spring (2) Fig. A.
• The pin (3) Fig. A.
• The seal (4) Fig. B. 5
• The neutral position/gear indicator sensor (1).

NOTE:_________________________________
Before assembly, check the continuity of the sensor (see 2
the chapter entitled “Electrical system”).

Tighten the two screws (5) of the sensor to the following torque: 3
T. R .

1
Torque 0.6 N*m
Use medium Loctite thread locker to secure.

MEDIUM THREAD B
LOCKER 4
1 3
5 2

5 - 75
 GEAR

35
26 44
27 41
28
29 40
30
31
32 39
36
34 36
39

37
38
33 38
37 32
33
42
43
25
24
37
23 38
21 45 46
22

7 13 21
8
9
10
11 20
6 12 19 35
5 13 18
4 14
3 17
2 15
16
1

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 SELECTOR SHAFT
2 STOP SPRING
3 SHIM
4 BUSHING
5 ELASTIC RING
6 SCRAPING
7 PLUG
8 SPRING
9 DESMODROMIC
10 PIN
11 BEARING
12 PLATE
13 SCREW
14 GEAR DRUM
15 WASHER
16 SCREW
17 SCREW

5 - 76
 GEAR

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
18 GEAR FIXING CLICK ASSEMBLY
19 WASHER
20 HAIRSPRING
21 SPRING
22 PIN
23 GEAR SELECTION FORK 5th/6th
24 GEAR SELECTION FORK 1st/4th - 2nd/3rd
25 GEAR SELECTION FORK 5th/6th
26 NUT
27 WASHER
28 PINION
29 OIL SEAL
30 BROACHED BUSHING
31 O-RING
32 BEARING
33 BEARING RETAINER
34 COMPLETE MAIN SHAFT
35 BEARING
36 ELASTIC RING
37 SCRAPING
38 ELASTIC RING
39 NOTCHED WASHER
40 NOTCHED WASHER
41 NOTCHED WASHER
42 NOTCHED WASHER
43 NOTCHED WASHER
44 SEAL
45 COMPLETE SECONDARY SHAFT
46 SCRAPING

5 - 77
 GEAR
GEAR DISASSEMBLY

Remove:
1. Coils and Spark plugs, refer to the section “Coils and spark
E
plugs removal”.
2. Distribution cover, refer to the section “Distribution cover
removal”.
3. Chain tensioner, refer to the section“Chain tensioner
removal”.
4. Exhaust camshaft, refer to the section “Exhaust camshaft
removal”.
5. Intake camshaft, refer to the section “Intake camshaft
removal”.
6. Head, refer to the section “Head removal”.
7. Flywheel, refer to the section “Flywheel removal”.
8. Mobile chain slides, refer to the section “Mobile chain
slides removal”.
9. Clutch, refer to the section “Clutch removal”.
10. Neutral position/gear indicator sensor, see chapter entitled F
“Neutral position/gear indicator sensor removal”.
11. Oil sump, refer to the section “Oil sump removal”.
12. Oil pump, refer to the section “Oil pump removal”. 2
Remove:
• The base screws Fig. E.
• Raise the lower base Fig. F.

Remove: 1
• The gearbox output shaft (1) Fig. F.
• The gearbox intake shaft (2) Fig. F.

5 - 78
 GEAR
GEAR ASSEMBLY

Measure:
Use a specific gauge to check the size of the hole (1) in the top A
right casing Fig. A.

Housing port
size: Ø 47 (0,+0.022) mm
desmodronic

If outside specifications, replace the bottom casing. 1

Check:
• The grooving on the desmodromic shaft (9) Fig. B.
In the presence of damage/lines/signs of wear, replace the
whole desmodromic shaft. B
Assemble:
• The desmodronic (9*) inside the casing.
• Install the bearing (11*) Fig. C.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Gear”.
9*
Assemble:
• The gear drum (14*).
Use the special tool(**) Fig. C.

C
14* 11*
(**) Gear selector drum assembly tool
Code: 0320097051000

• The washer (15*). 16*

• The screw (16) Fig. C to the following torque:

T. R .

Torque 12 N*m
15*
Use medium Loctite thread locker to secure. (**)
MEDIUM THREAD
LOCKER

D
NOTE:_________________________________
To tighten the screw (16*), use an aluminium pad (1) to keep
the desmodronic in place Fig. D.

5 - 79
 GEAR
GEAR ASSEMBLY

Assemble:
• The plate (12).
F
• The 2 screws (13*) Fig. F to the following torque:
12*

T. R .

Torque 12 N*m

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Gear”. 13*

5 - 80
 GEAR
GEAR SHIFT CONTROL

Measure:
The following procedure is applied to all gear shift control rods,
G
Fig. G.

Check:
• The follower of the gear shift control rod cam (A). B
• The tooth of the gear shift control rod (B).
A
If there is warping/damage/lines/traces of wear, replace the shift
control rod.

Measure:
• The thickness of the gear shift control rod, using a slide
gauge.

Part Size
Gear shift control rod 5.85 ± 0.05 mm
H
Check:
• The guide pin of the gear shift control rod (23*).

Roll the guide pin of the gear shift control rod on a flat surface
Fig. H.
If there is any warping, replace.

NOTE:________________________________ 23*
Do not try to straighten the control rod guide if it is warped.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Gear”.

5 - 81
 GEAR
GEAR ASSEMBLY

Assemble: I
1. Spring (21*).
2. Gear selection fork 1st/4th - 2nd/3rd (25*). 21*
3. Gear selection fork 5th/6th (24*).
4. Gear selection fork 5th/6th (23*). 24*
5. Spring (21*).
25*
NOTE:_________________________________
Refer to the sequence in Fig. I.
23*
Check:
• The two bearing stops (33) Fig. L. 5
If there is any warping/damage/lines/signs of wear, replace.

Check:
• The seats for the two bearing stops (33) Fig. L.
If there is any warping/damage/lines/signs of wear, replace.
L

Assemble:
For the assembly sequence of the full input shaft (47), see the
exploded drawing at the beginning of the chapter.
33* 33*
For the assembly sequence of the full output shaft (34), see the
exploded drawing at the beginning of the chapter.

Position:
• The full main shaft (47) Fig. M.
• The full secondary shaft (34) Fig. M.

NOTE:_________________________________
Make sure the grooves on the two bearings (32) match
correctly.
M
47 32
NOTE:_________________________________
Before assembling the two half casings, top and bottom, it
is necessary to apply sealant paste along the whole profile
of the top casing, in order to achieve a good hold. 32

G
PASTE THREEBOND
1207B
34

Assemble:
Assemble the bottom casing over the top, taking care to insert
the follower (A) correctly in the segment corresponding to the N
desmodronic shaft and the forks (23*-24*-25*) in their respective
seats Fig. N.
23*
NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Gear”. B 24*

A 25*

5 - 82
 GEAR
GEAR ASSEMBLY

Check:
That the end of the gear lock spring (2*) is in its seat on the
O
1*
selector plate (1*).

Check:
That in the neutral position, the clearance between the two ends
of the spring and the strike pin is “0” Fig. O.

Assemble:
• The selector shaft as in Fig. O. “0”

2*

Q
Position: 1
• The gear (2).
• The drive shaft gear (1), locking it into place with the spline
(3) Fig. Q. 2

3
4

R
Install:
• The guide bushing (5).
• The counter shaft gear (6).
5
• The spline (7) Fig. R.

6
7

S
NOTE:________________________________
Bring the two points of shaft phasing and drive shaft check
Fig. S.

5 - 83
 GEAR
GEAR ASSEMBLY

Install:
• The washer.
S
• The counter shaft gear nut (6). 2
T. R .

6
Torque 90-100 N*m

Install:
• The washer.
• The drive shaft gear nut (2).

T. R .

(**)
Torque 115-125 N*m

41
40

41
NOTE:________________________________
To keep the two drive shafts still, it is necessary to use the
tool (**) in Fig. S.

42
(**) Gear wrench 40
Code: 03200097053000

40 40
40 40

Assemble:
After assembling the two half casings, tighten the screws Fig. Q
to the following torque:

41
40

40
T. R .

Position screws (40): (M6)

Position screws (41): (M8)
Position screws (42): (M10)
R
36
38

Rotate the complete casing through 180° and tighten the screws
Fig. R to the following torque:

Position screws (38): (M8)

34
Position screws (36): (M8)
Position screws (34): (M10)
39

Use lubricant while tightening.

Lubricate
38

Casing closure tightening torque

Sequence Size Phases

1°Phase 12 N.m
1 M10: 2°Phase 24 N.m
3°Phase 45 N.m
1°Phase 12 N.m
2 M8
2°Phase 30 N.m
1°Phase 10 N.m
3 M6
2°Phase 12 N.m

5 - 84
 STARTING
STARTER

3 3

2
5
4

7
6

8
9

10

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 STARTER MOTOR
2 O-RING
3 SCREW
4 IGNITION SHAFT
5 DOUBLE GEAR
6 START GEAR
7 FLYWHEEL ROTOR
8 SCREW
9 MAGNET FLYWHEEL
10 COMPLETE FREEWHEEL

5 - 85
 STARTING
STARTER REMOVAL

Remove:
1. The screws (3*) Fig. A.
A
2. The starter motor (1*) from the clutch side Fig. B.

Check:
• The starter motor operation.
3*
NOTE:_________________________________
If the starter motor turns with force, replace the part.

• The O-ring.
If there is any damage/spotting/traces of wear, replace the
O-ring.

NOTE:_________________________________
Lubricate the O-ring and take care not to damage it.
B

5 - 86
 STARTING
STARTER INSTALLATION

Install:
Proceed using the opposite order to removal.
A

Assemble:
• The screws (3*) Fig. A to the following torque.

T. R .

Torque 12 N*m
3*
Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

NOTE:_________________________________
Once the starter motor is assembled, proceed with the cur-
rent wire connection.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Starting”.

5 - 87
 STARTING
FLYWHEEL REMOVAL

Remove:
• The cap (1).
A
Use the tool* (2) for this operation Fig. A.

(*) Tool to remove the magnetic cap from the alternator

cover
Code: 0320097043000.

2
1

Remove:
• The screws (3) Fig. B. B
• Take out the magnet flywheel cover Fig. B.
Use the tool* (4) for this operation Fig. B.

(*) Flywheel cover extractor

Code: 0320097042000

3
4

Remove: C
• The nut (5) Fig. C.
• The washer (6) Fig. C. 7
Use the tool* (7) for this operation Fig. C.
(*) Tool to Tighten/Loosen the flywheel
Code: 0320097044000

Remove:
• The flywheel rotor magnet (8). D
Use the tool* (8) for this operation Fig. D.
(*) Flywheel cover extractor
Code: 0320097045000

5 - 88
 STARTING
FREEWHEEL REMOVAL

Disassemble:
D
The assembled freewheel elements (6*) Fig. D.
• The 6 screws (8*). 6*
Check:
• The roller cage and support.
If there are any anomalies or signs of wear, replace the whole
freewheel (6*).

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Starting”.

5 - 89
 STARTING
FREEWHEEL INSTALLATION

Install:
1
Proceed in the opposite order to removal.
A
7
6
Assemble:
• The screws (8*) Fig. A to the following torque:
8
T. R .

Torque 35 N*m
10
Use medium Loctite thread locker to secure.

MEDIUM THREAD LOCK-

ER

5 - 90
 STARTING
FLYWHEEL INSTALLATION

Install:
proceed in the opposite order to removal.
A

Assemble:
• The nut (5) Fig. A.
• The washer (6) Fig. A.
Tighten the nut (5) to the following torque:

T. R .

Torque 90 N*m

Assemble:
• The flywheel magnet cover. B
• The seal (7).

NOTE:_________________________________
When closing the magnet flywheel cover Fig. B pay atten-
tion to the seal.
If the seal is damaged, it must be replaced with a new one.

Assemble:
• The screws (3) Fig. C.
To the following torque:

T. R .

Torque 12 N*m

5 - 91
 STARTING
STARTER GEAR REMOVAL

Remove: E
1. Flywheel, refer to the section “Flywheel removal”. 1

Remove:
• The satellite starter gear (1) Fig. E.
• The freewheel starter gear (2) Fig. F.
• The spline (3) Fig. F.

5 - 92
 STARTING
STARTER GEAR INSTALLATION

Install:
Proceed in the opposite order to removal.

5 - 93
 STARTING
PHASE SENSOR

11 12
7
6 1
9 14

2 13
1
3

15
5
4
10
8

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 BUSHING
2 O-RING
3 THREADED CAP
4 MAGNETIC CAP
5 O-RING
6 SCREW
7 PHASE SENSOR
8 SCREW
9 ALTERNATOR COVER
10 PINION COVER
11 PLATE
12 SCREW
13 FLYWHEEL COVER GASKET
14 SCREW
15 SCREW

5 - 94
 STARTING
PHASE SENSOR REMOVAL

Disconnect:
• The electric connector from the phase sensor (7*).
A
Remove:
• The screw (6*) Fig. A. 7*
• The phase sensor (7*) Fig. A.
Check:
The integrity of the phase sensor.

6*

5 - 95
 STARTING
PHASE SENSOR INSTALLATION

Assemble: B
• The phase sensor (7*).
• The fastening screw (6*) to the following torque Fig. B: 7*
T. R .

Torque 12 N*m

Measure: 6*
• The distance (A) between the phase sensor (7*) and the
pick-up on the flywheel magnet Fig. B.

NOTE:_________________________________
A
Use a thickness gauge to take this measurement.

Gap 0.8-1.0 mm

5 - 96
 POWER SYSTEM
THROTTLED BODY ASSEMBLY

21
35 29
5
28 8
31 9 51
34
33 27
32
9 26
31 30
20
38 15 7
48 19
39 40 18
25
17
45 36 23
15 22
16
48 47 24
50 49
23
41 11
35 45 40 50 49 10
38 15
37
14
52
38 6
42 12
5 3
46 13
4 2
43 1
14 12
44
14

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
1 NUT
2 SCRAPING
3 FLANGE
4 WASHER
5 WASHER
6 OIL SEAL
7 SHAFT
8 THROTTLED BODY FLANGE
9 SCREW
10 BUSHING
11 SPRING
12 SCREW
13 BRACKET
14 STEERING RING NUT
15 SCREW
16 INSERT
17 CAP
18 INJECTOR
19 BRACKET
20 MAP SENSOR
21 SCREW
22 PIPE
23 PIPE GLAND CLIP
24 INSERT

5 - 97
 POWER SYSTEM

INTERVENTION
Pos. Description Qty SQ. SYMBOLS REMARKS
DESCRIPTION
25 SEALING RING
26 PLATE
27 SCREW
28 ROLLER BEARING
29 SEEGER
30 PLATE
31 SCREW
32 POTENTIOMETER
33 WASHER
34 SCREW
35 SCREW
36 THROTTLED BODY
37 PIPE
38 BAND
39 PIPE
40 PIPE
41 SPECIAL PLATE
42 O-RING
43 STEPPER MOTOR
44 SPECIAL WASHER
45 BUSHING
46 PIPE
47 DISTRIBUTOR
48 VIBRATION DAMPING RUBBER
49 SCREW
50 O-RING
51 SCREW
52 THROTTLED BODY

5 - 98
 POWER SYSTEM
THROTTLED BODY REMOVAL

Remove:
• Rider and passenger seats, refer to the section “Removal
A
of rider and passenger seats, Chapter 4”. 3
• Fuel tank, refer to the section “Fuel tank removal, Chapter
4”.
• Air filter, refer to the section “Air filter removal, Chapter 2
4”.

Remove:
• The 2 intake pipes (1) Fig. A.
• The seals. 1
• The screws (2) Fig. A.
• Loosen the screw bands (3) Fig. A.

Disconnect:
• The injector connections (3). B
• The connections of the pressure sensor (4) from the electric
backbone to the throttled body assembly, Fig. B.

• The connection (5) of the distributor, Fig. C.

C

Disconnect:
• The bottom ends of the accelerator cable (6) before loosen- D
ing the cable nut supports (7). 8
• The bottom nuts (8) Fig. D.
• Take out the throttled body. 6 7

5 - 99
 POWER SYSTEM
THROTTLED BODY INSTALLATION

Install:
Proceed using the opposite order to removal.
E

IMPORTANT NOTICE
During assembly of the accelerator cables, take care to 9
insert the hood (9) on the control line (10) Fig. E. 10

5 - 100
6

6-1
 CHAPTER 6

COOLING SYSTEM
WATER PUMP ...............................................................................................................................................3
WATER PUMP REMOVAL ..........................................................................................................................................................4
WATER PUMP INSTALLATION ..................................................................................................................................................5
THERMOSTAT ...............................................................................................................................................6
THERMOSTAT REMOVAL..........................................................................................................................................................6
THERMOSTAT INSTALLATION ..................................................................................................................................................7
WATER MANIFOLD .......................................................................................................................................8
WATER MANIFOLD REMOVAL..................................................................................................................................................8
WATER MANIFOLD INSTALLATION ..........................................................................................................................................9
HEAT EXCHANGER ....................................................................................................................................10
HEAT EXCHANGER REMOVAL...............................................................................................................................................10
HEAT EXCHANGER INSTALLATION .......................................................................................................................................11
RADIATOR ...................................................................................................................................................12
RADIATOR REMOVAL .............................................................................................................................................................14
RADIATOR INSTALLATION......................................................................................................................................................16
ELECTRIC FAN REMOVAL ......................................................................................................................................................17
ELECTRIC FAN INSTALLATION ..............................................................................................................................................18
EXPANSION TANK REMOVAL.................................................................................................................................................19
EXPANSION TANK INSTALLATION .........................................................................................................................................20

6-2
 WATER PUMP

21

20

19 18
21
14
11 1
9 15
4
10 2

5 19

12 13 6 17
7
3 6
16
8

INTERVENTION
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
1 WATER PUMP IMPELLER
2 SEALING RING
3 OIL SEAL
4 WATER PUMP COVER
5 O-RING
6 BEARING
7 SEEGER RING
8 WATER PUMP SHAFT
9 SCREW
10 COMPLETE WATER PUMP
11 L-SHAPED JOINT
12 SCREW
13 WASHER
14 WATER PUMP BODY
15 SCREW
16 BUSHING
17 SEEGER RING
18 SLEEVE
19 SCREW BAND
20 PIPE
21 SPRING

6-3
 WATER PUMP
WATER PUMP REMOVAL

Remove:
• Gear lever, refer to the Chapter 4, section “Gear lever
A
installation”.
• The bands (19*) Fig. A.
• The water inlet manifold (2) Fig. A.
• The water return manifold (3) Fig. A. 19*
• The screws (9*) Fig. A.
3
NOTE:_________________________________
Drain out all cooling fluid by taking out the screw (12*) 9*
before proceeding with removal operations, as shown in
Fig. A. 12*
2
• Take out all of the parts in the order shown in the exploded
drawings and check to ensure each part is intact.
Parts showing signs of wear must be replaced.
B
IMPORTANT NOTICE
In case of faulty seals (2*), it is possible to notice leaks from the
hole shown in Fig. B.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in the
Chapter entitled “Cooling Circuit”, in the “radiator removal”
section.

Check:
• Water pump impeller (1*) Fig. C.
• The sealing ring (2*) Fig. C.
• The O-ring (5*) Fig. C.
• The oil seal (3*) Fig. C.
C
• The bearing (6*) Fig. C.
• The bushing (16*) Fig. C. 1
• The water pump shaft (8*) Fig. C.
2

3 6
16
8

6-4
 WATER PUMP
WATER PUMP INSTALLATION

Install: A
Proceed to assemble the pump, lubricating it with engine oil:
• The pump shaft (8*)
• The bushing (16*).
• The bearings (6*).

NOTE:_________________________________
When inserting the pump, take care to ensure that the
groove on the water pump shaft (8*) is facing in the direc-
tion shown in Fig. A.

Install:

• The screws (9) and tighten to the following torque:

T. R .

Torque 12 N*m

Use Loctite thread locker to secure.

Loctite 242/243

6-5
 THERMOSTAT
THERMOSTAT REMOVAL

Remove:
• Right side fairings, refer to the Chapter 4, section “front
A
fairing”.
• The screws (3) Fig. A.
• The thermostat (4) Fig. B.
3
NOTE:_________________________________
Drain out the cooling fluid before proceeding with these
operations.

Check:
• The by-pass port (1) B.
If there is any clogging, replace.
• The thermostat (4) Fig. B.
If this does not open at 75° ~ 90° C (167~ 194° F), replace.

Thermostat check:
1. Immerse the thermostat in a container full of water Fig. C B
2. Slowly heat the water.
3. Immerse a thermometer in water.
4. Mixing the water, monitor the thermostat and the tempera- 1
ture reading on the thermometer.
5. When the temperature of 75°C is reached, the thermostat
valve will start to open, reaching a temperature of 90°C. The
thermostat valve will open to at least 7 mm. 4
Key Fig. C

1. Thermometer
2. Container
3. Water
4. Thermostat

Thermostat opening/closure chart Fig. D.

A. Fully closed
C
B. Fully open
1

IMPORTANT NOTICE
If there are any doubts as to thermostat precision, it is 2
better to replace it. A faulty thermostat can cause serious
overheating or overcooling. 3
4

B
7
apening (mm, in)

A
0
75°C (167°F) 90°C (194°F)
temperature

6-6
 THERMOSTAT
THERMOSTAT INSTALLATION

Install:
• Install the thermostat so that the bypass port (A) Fig. A is
A
facing upwards.
• The screws (3) and tighten to the following torque: A
T. R .

Torque 12 N*m
5

Use Loctite thread locker to secure the screws.

Loctite 242/243

NOTE:_________________________________
Fill with cooling fluid after completing these operations.

6-7
 WATER MANIFOLD
WATER MANIFOLD REMOVAL

Remove:
• Cooling fluid
A
• Manifolds drain, refer to the section “Exhaust assembly
removal” in Chapter 4.
• The bands (1) Fig. A.
• The screws (3) Fig. A.
• The water manifold (2) Fig. A. 2
• The seal (4) Fig. B.

If there is any damage/breakage, replace the above parts.

3 1

6-8
 WATER MANIFOLD
WATER MANIFOLD INSTALLATION

Install:
Carry out the removal steps in reverse order.
A

• The screws (3) and tighten to the following torque:

T. R .

Torque 12 N*m

Use Loctite thread locker to secure the screws.

3
Loctite 242/243

NOTE:________________________________
Fill with cooling fluid after completing these operations.

6-9
 HEAT EXCHANGER
HEAT EXCHANGER REMOVAL

Remove:
• Cooling fluid
A
• Manifolds drain, refer to the section “Exhaust assembly
removal” in Chapter 4.
• The bands (1) Fig. A.
• The bands (2) Fig. A.
2
• The hose (3) Fig. A.
• The distributor cap (4) Fig. A-B. 1
• The seal (6) Fig. B.

1 3

Check: B
• Visually inspect the distributor cap for any build up or break-
ages.
• The seal (6) Fig. B.

NOTE:________________________________
If any of the parts should show signs of damage/breakage,
replace.

Remove:
• The special screw (7) Fig. C.
• The distributor (8) Fig. C. 4 6
• The fitting (9) Fig. C.
• The seal (10) Fig. C.

NOTE:________________________________
If any of the parts should show signs of damage/breakage, C
replace.
9
8
7

10

6 - 10
 HEAT EXCHANGER
HEAT EXCHANGER INSTALLATION

Install:
Proceed to install the distributor following the removal steps in
D
reverse order.
7
• The special screw (7) Fig. D
to the following torque:

T. R .

Torque 60 N*m

• The distributor cap (4) Fig. E

to the following torque:

T. R .

Torque 25. N*m

E
NOTE:________________________________
If not worn, re-use the previously removed bands; other-
wise, fit new ones.

NOTE:________________________________
Fill with cooling fluid after completing these operations.

6 - 11
 RADIATOR

31
37
6 9 12 34 34
33
2 35
4 3 8 11
3 10 12 38
1 34
36

5
40 34
5 32
6
7
13 17
18
34
13
1 2 3 19 30 28 27
29 34
16 39
15 23
14

23 26
15 25
24
22

21

20

INTERVENTION
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
1 SPECIAL SCREW
2 BUSHING
3 RUBBER TIP
4 WATER RADIATOR
5 SCREW
6 RADIATOR GUARD
7 PIPE
8 RUBBER TIP
9 WATER TANK
10 WATER TANK CAP
11 EXPANSION TANK CAP
12 SCREW
13 BAND
14 SLEEVE
15 SCREW BAND
16 SLEEVE
17 SCREW
18 ELASTIC WASHER
19 BAND
20 PINION COVER
21 SCREW
22 CABLE GLAND

6 - 12
 RADIATOR

INTERVENTION
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
23 SCREW (M6X12)
24 BIADHESIVE
25 ADHESIVE SUPPORT
26 ADHESIVE
27 ADHESIVE
28 ADHESIVE SUPPORT
29 BIADHESIVE
30 CABLE GLAND
31 VIBRATION RUBBER TIP
32 PIPE
33 PIPE GLAND CLIP
34 BAND
35 PIPE
36 SLEEVE
37 PLUG
38 SLEEVE
39 SLEEVE
40 BAND

6 - 13
 RADIATOR
RADIATOR REMOVAL

Remove:
• Fuel tank, refer to the section “Removal of the fuel tank,
A
Chapter 4”.

NOTE:_________________________________
Drain out all cooling fluid by taking out the screw (12) before
proceeding with removal operations, as shown in Fig. A.
15*
• The band (15*) Fig. A. 3
• The water inlet manifold (2) Fig. A.
• The water return manifold (3) Fig. A.

NOTE:________________________________ 12
To make it easier to drain out cooling fluid, it is necessary 2
to open also the radiator cap at the same time.

Disconnect:
• The sleeve (16*) Fig. B. B

16*

• The pipe (7*) Fig. C.

7*

• The fan connector (3) Fig. D.

D

6 - 14
 RADIATOR
RADIATOR REMOVAL

Remove:
• The screws (1*) fastening the radiator bracket to the frame
E
Fig. E.

1*

• The screws (1*) fastening the lower bracket to the frame F

Fig. F.

1*

• The complete radiator (4*) Fig. G. G

Check:
• The radiator fins.
If clogged, clean.
Use a jet of compressed air on the back of the radiator.

NOTE:________________________________
4*
Straighten any bent fins using a fine flathead screwdriver

Check:
• the radiator hoses.
• the radiator pipes.
If there is any cracking/damage, replace.
• The radiator fan
In the event of damage, replace.
In case of malfunction, check and repair.

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Radiator”.

6 - 15
 RADIATOR
RADIATOR INSTALLATION

Install:
Once each individual part has been checked, proceed to install
A
the radiator following the removal steps in reverse order.

• The screws to fasten the radiator to the bracket on the

frame, tightening to the following torque:

T. R .

Torque 10 N*m

• The bands must always be replaced once they have been

opened. 2
• Once the parts have been assembled, connect the wiring to
the radiator bulb and fan and proceed to fill the circuit.

NOTE:________________________________
While filling the circuit, pinch the sleeve as the fluid (2) is
being delivered Fig. A, to remove any air bubbles.

6 - 16
 RADIATOR
ELECTRIC FAN REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall. 2
Remove:
• Fuel tank, refer to the section “Removal of the fuel tank,
Chapter 4”. 1
• Radiator, refer to the chapter “Radiator, section Radiator
removal”.
• The screws (1) Fig. A.
• The electric fan (2) Fig. A.

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Radiator”.

6 - 17
 RADIATOR
ELECTRIC FAN INSTALLATION

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.
Tighten: 1
• The screws (1) Fig. A
To the following torque:

T. R .

Torque 10 N*m

Use Loctite thread locker to secure.

Loctite 243

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Radiator”.

6 - 18
 EXPANSION TANK
EXPANSION TANK REMOVAL

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot 12*
fall.

Remove: 10*
• Fuel tank, refer to the section “Removal of the fuel tank,
Chapter 4”.
• The screws (12*) Fig. A.
• The cap (10*) Fig. A.
Disconnect:
• The pipe (7*) Fig. B.
Remove:
• The tank (9*) Fig. C.

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
B
chapter “Radiator”.

7*

C
9*

6 - 19
 EXPANSION TANK
EXPANSION TANK INSTALLATION

Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

Installation:
Proceed using the opposite order to removal.

NOTE:________________________________
If the fastening bands of the pipes are damaged, replace
with new bands.

6 - 20
7

7-1
 ELECTRICAL SYSTEM
SENSORS ......................................................................................................................................................3
DESCRIPTION OF THE ENGINE MANAGEMENT SYSTEM ....................................................................................................3
COOLING FLUID TEMPERATURE SENSOR ............................................................................................................................4
GEAR POSITION SENSOR .......................................................................................................................................................5
PHASE SENSOR........................................................................................................................................................................6
AIR TEMPERATURE SENSOR ..................................................................................................................................................7
SIDE STAND SWITCH ...............................................................................................................................................................8
OXYGEN SENSOR ....................................................................................................................................................................9
OIL PRESSURE SENSOR .......................................................................................................................................................10
FRONT BRAKE MICROSWITCH: ............................................................................................................................................11
IDROSTOP ...............................................................................................................................................................................12
CLUTCH SWITCH ....................................................................................................................................................................13
MAP SENSOR (MANIFOLD ABSOLUTE PRESSURE) ...........................................................................................................14
POSITION SENSOR OF THE THROTTLED BODY UNIT (POTENTIOMETER) .....................................................................15
DEVICES ......................................................................................................................................................16
DEVICES POSITION ................................................................................................................................................................16
RIGHT ELECTRIC DEVICE......................................................................................................................................................17
STARTING RELAY (REMOTE CONTROL SWITCH) ...............................................................................................................18
HORN .......................................................................................................................................................................................19
INSTRUMENTATION DASHBOARD ........................................................................................................................................20
MASTER SWITCH ....................................................................................................................................................................22
VOLTAGE REGULATOR ..........................................................................................................................................................23
LEFT ELECTRIC DEVICE ........................................................................................................................................................24
DROP SENSOR ......................................................................................................................................................................25
INJECTION ECU ......................................................................................................................................................................27
INJECTION ECU CONNECTIONS ...........................................................................................................................................29
INDICATOR LIGHT INTERMITTENCE .....................................................................................................................................30
ABS BUTTON ...........................................................................................................................................................................31
SERVICES RELAY ...................................................................................................................................................................32
STATOR ....................................................................................................................................................................................33
ACTUATORS ...............................................................................................................................................34
POSITION OF ACTUATORS ....................................................................................................................................................34
IDLE AIR CONTROL SYSTEM (STEPPER) .............................................................................................................................35
INJECTORS..............................................................................................................................................................................36
IGNITION COILS ......................................................................................................................................................................37
COOLING FAN .........................................................................................................................................................................38
FUEL PUMP..............................................................................................................................................................................39
FUEL LEVEL SENSOR.............................................................................................................................................................40
STARTER .................................................................................................................................................................................41
STARTER .................................................................................................................................................................................42
ECU ABS ..................................................................................................................................................................................43
DIAGNOSTICS.............................................................................................................................................46
BRAKE FILLING/BLEEDING DIAGNOSTICS ..........................................................................................................................46
BATTERY .....................................................................................................................................................48
VEHICLE BATTERY .................................................................................................................................................................48
BATTERY EFFICIENCY CONTROL .........................................................................................................................................49
ELECTRICAL SYSTEM ...............................................................................................................................50
ELECTRICAL WIRING DIAGRAM ...........................................................................................................................................50
COLOUR KEY ..........................................................................................................................................................................51

7-2
 SENSORS
DESCRIPTION OF THE ENGINE MANAGEMENT SYSTEM

Each model has an electronic control system for the engine, with a control including both ignition and fuel distribution.
The Electronic Control Module (ECM) uses information from the sensors around the engine, the cooling system and intake system,
calculating with precision, the advance ignition time and fuel needs for all engine speeds and loads.
The system also has a hardware diagnostics system in line with the needs of the state of California USA for on-board diagnostics.
This function makes sure that if a breakdown occurs in the system, the type of breakdown and engine data at the time of the prob-
lem are stored in the ECM memory.
The stored data can be recovered by means of an apposite service equipment available at any Benelli Dealer (see Texa instruction
manual).
This way, there can be exact diagnosis of the breakdown and prompt, efficient repair of the fault.

7-3
 SENSORS
COOLING FLUID TEMPERATURE SENSOR

It is situated close to the cylinder head (1), Fig. A.

It calculates the cooling fluid temperature data received from the
A
ECM and used to optimise supply at all engine temperatures to
calculate the supply needs when starting up from hot and cold.

CHECKLIST

7-4
 SENSORS
GEAR POSITION SENSOR

It is situated on the left side of the engine, close to the pinion,

and detects the position of the gear.

Disconnect:
• The electrical coupling.
Remove:
• The gear position sensor from the half casing.
Check:
• The continuity.

Ø 3: Neutral
Ø 3.5: Grey for Neutral
1. brown/yellow first gear
2. green/black second gear
3. green/blue third gear
4. yellow/blue fourth gear
5. brown/red fifth gear
6. yellow/red sixth gear

7-5
 SENSORS
PHASE SENSOR

It is situated close to the left engine casing (1), Fig. A.

A
A position sensor on the crankshaft detects the movement of a 1
toothed wheel fixed at the right end of the drive shaft, by reading
a specific wheel formed by 28 equidistant teeth alongside a triple
length space.
The interpreted reading is used by the ECM to identify the posi-
tion of the drive shaft compared to the point in which the fuel is
injected, and the need for the fuel ignition.

Disconnect:
• The main wiring connector.
Measure:
• The resistance value at points A and B of engine Fig. B

B
550± 50 Ω
Standard
(20°C)

NOTE:________________________________
If the measured resistance is lower than the stipulated val-
ue, the inner coil might be an open circuit or short-circuited,
therefore it is necessary to replace it.

7-6
 SENSORS
AIR TEMPERATURE SENSOR

Working principle of intake air temperature sensor

Within the sensor temperature range, the resistance varies
A
according to the various temperature. It is distinguished by the
negative temperature coefficient resistor. It is a part that can not
be maintained.
Appearance of air temperature sensor (Fig. A):

Measured temperature Resistance value

(°C) (Ω)
0 9.399
5 7.263
10 5.658
15 4.441
20 3.511
25 2.795
30 2.240

Sensor
Converter

7-7
 SENSORS
SIDE STAND SWITCH

It is situated near the supporting plate of the side stand (1), Fig. G. G
If the gear is engaged with the stand open, therefore with the
circuit open, the control unit will prevent use and will switch off
engine, if running.

Check:
• Continuity with a multitester 1

CRUTCH PIN 1 PIN 2

Raised
• •
Lowered
• •
NOTE:________________________________
When the above conditions are fulfilled, the sensor is work-
ing, otherwise replace the part.

7-8
 SENSORS
OXYGEN SENSOR

They are situated on the exhaust manifold (1), Fig. L.

The oxygen sensor serves to detect the oxygen concentration in
L
the exhaust gases. More precisely, the lambda value indicates MULTIMETER

the air/petrol ratio, in which: 0 10 20 30

• Value 1, when combustion is stoichiometric

• <1, in case of fuel excess
• <1, in case of air excess
The sensor transmits the electric signal to the ECU, which con- - +
trols the insertion of fuel and air into the combustion chamber.
2
- Threshold value of air-fuel ratio: >750 mVcc. 1
- Dilute threshold of air-fuel ratio: <120 mVcc.
- Heating power of oxygen sensor: 7.0 W.
- 450°C exhausted gas temperature, 70% duty ratio, 10Hz, 3 1
13.5V voltage.
- Heating power: 9.6±1.5Ω (measured at 21°C).
- Operating temperature range: 260-850°C.

CHARACTERISTIC OPERATING CURVE

CONNECTOR

7-9
 SENSORS
OIL PRESSURE SENSOR

On the bottom half casing, measure the pressure of the oil in the
bush gallery (1) Fig. M.
M

Shows sufficient oil pressure on the dashboard.

Disconnect:
• The electrical coupling.
Remove: 1
• The oil pressure sensor from the half casing.
Check:
• The continuity between the PIN1 and the sensor ground
by means of an air pressure regulator with insertion on the
detection hole.
• Set the air pressure regulator at 2 bar.
• Reduce pressure gradually to reach 0.2 - 0.3 bar.

Continuity between PIN1 and

0.2 - 0.3 bar
ground

NOTE:________________________________
If there is no continuity between PIN1 and engine ground,
replace the part.

7 - 10
 SENSORS
FRONT BRAKE MICROSWITCH:

It is a switch in contact with the brake lever, situated on the front

brake pump, which serves to switch on the stop lights (1), Fig. N.
N

Check:
• Continuity 1
with the multitester on the symbol →|- (diode/continuity test
function), check operation as shown in the table.

SENSOR PIN 1 PIN 2

Brake lever Pulled
• •
Brake lever Released
• •
NOTE:________________________________
When the above conditions are fulfilled, the front brake sen-
sor is working properly, otherwise replace the part.

7 - 11
 SENSORS
IDROSTOP
A switch on the front brake pump that works by reading the oil
O
pressure on the pump. 1
It serves to switch the stop lights on (1), Fig. O.

Check:
• Continuity
with the multitester on PIN 1 and PIN 2, check the table.

BRAKE PIN 1 PIN 2

Pulled
• •
Released
• •
NOTE:________________________________
When the above conditions are fulfilled, the front brake sen-
sor is working properly, otherwise replace the part.

7 - 12
 SENSORS
CLUTCH SWITCH

On the clutch lever, to ensure that the engine will not start until
the lever is completely pulled (1) Fig. P.
P
1
Disconnect:
• The clutch switch cables.
Use:
• The tester and check the clutch switch pins referring to the
table.

CLUTCH PIN 1 PIN 2

Pulled
• •
Released
• •
NOTE:________________________________
When the above conditions are fulfilled, the front brake sen-
sor is working properly, otherwise replace the part.

7 - 13
 SENSORS
MAP SENSOR (MANIFOLD ABSOLUTE PRESSURE)

It is situated close to the throttled body and serves to detect

the absolute pressure on the intake manifold. It reflects the size
of inlet pressure, which can be converted to air intake volume
accessing the combustion chamber of the engine.

7 - 14
 SENSORS
POSITION SENSOR OF THE THROTTLED BODY UNIT (POTENTIOMETER)

It is situated on the right end of the shaft of the throttled Q

body unit. A
Position sensor of the throttled body group (potentiometer),
controlled and supplied directly by the ECM, gives out a signal,
which identifies the throttle opening position used by the ECM to
determine fuel dosage and ignition advance (A), Fig. Q.

Disconnect:
• The electrical coupling.
Check:
• The resistance using the multitester on symbol Ω between
pin 3 and pin 2.
1 2 3
Throttle location RESISTANCE
Fully closed throttle 1.050 KΩ±20%
Fully open throttle 2.5 KΩ±20%

7 - 15
 DEVICES
DEVICES POSITION

1 5

2 6

4
7

9
10

12
8

Ω
11

Position Device
1 RIGHT ELECTRIC DEVICE
2 STARTING RELAY
3 HORN
4 INSTRUMENTS
5 IGNITION SWITCH
6 REGULATOR
7 LEFT ELECTRIC DEVICE
8 INJECTION ECU
9 LIGHT CONTROL RELAY
10 SERVICES RELAY
11 STATOR
12 DROP SENSOR

7 - 16
 DEVICES
RIGHT ELECTRIC DEVICE

On the right side of the handlebar Fig.1, the electrical device is

comprised of:
1
• RUN/OFF button (A)
A
it serves to break contact to the electric device in
case of emergency.
• Ignition button (C)
it serves to start the engine.
• Hazard lights switch (B)
B
it serves to activate the hazard lights in case of emer-
gency.

Check:
• Continuity C
with the multitester positioned on the RUN/OFF button set to
ON.

Check:
• Continuity
with the multitester positioned on the ignition switch, pressed to
ON.

Check:
• Continuity
with the multitester positioned on the hazard lights switch set to
ON.

Refer to the table.

AR/BL AR/GR N R MR/GR VE/GL

7 - 17
 DEVICES
STARTING RELAY (REMOTE CONTROL SWITCH)

It is situated close to the fuse block and breaks power contact

on the starter (1) Fig. A.
A
Apply:
• 12 volt to terminals (2) and (3) Fig. B 1
Check:
• The continuity between power terminals.
If there is continuity, the ignition relay is operational.

WARNING
Do not apply the battery voltage to the starter relay for more
than 5 seconds to prevent overheating and damages to
winding.

Check:
• The winding Fig. B.
If it is “open” or “grounded” and if there is resistance.
Winding is in good condition if the resistance is:
B
Starting relay resistance 3-6Ω

2 3

7 - 18
 DEVICES
HORN

It is situated on the left side of the frame close to the radiator (1) A
Fig. A.
The horn is an electromechanical device serving as an acoustic
warning device.
1
Connect:
• PIN1 and PIN2 to the battery and check operation.
Check:
• After the external horn being connected to rechargeable
battery, if there is any sound, it refers to normal operation.

Resistance value 3.2 Ω

7 - 19
 DEVICES
INSTRUMENTATION DASHBOARD

On the headlamp instrumentation support frame, the instrumen-

tation provides the rider with all the information needed concern-
A
ing the motorcycle operation Fig. A:

INDICATOR LIGHTS:
• high beam light
• left indicator light
• right indicator light
• neutral position indicator light
• injection fault indicator light
• ABS light
• oil pressure warning light

COOLING FLUID TEMPERATURE GAUGE

• It indicates the cooling fluid temperature.
TACHOMETER
• It indicates the number of revolutions per minute of the
engine. B
SPEED
• It indicates the vehicle speed in km or miles.
TRIP
• It indicates the distance travelled from the reset.
TOTAL
• It indicates the total distance travelled.

Pin-out (see table)

On the instrumentation dashboard outlet are three connectors
Fig. B:

• The connector 1 Fig. C.

• The connector 2 Fig. D.
• The connector 3 Fig. E.

CODE COLOUR
B Black
BL Blue
GR Green
W White
Y Yellow
O Orange
R Red D
Dg Dark grey
P Purple
N Brown
G Grey
LR Pink

7 - 20
 DEVICES
INSTRUMENTATION DASHBOARD

Pos. Colour Function Symbol Colour/LED Verification signal

It goes on when the vehicle
1 Instrument light
starts

2 G/W Right turn signal Green 12V-

3 R/W Key 12V+

4 W/BL Fuel level

5 G/BL Odometer

6 R/Y ABS Yellow

7 B/BL Negative sensor

8 BL High beam Blue 12V+

9 G/B Left turn signal Green 12V-

10 Y/W Oil indicator Red 12V-

11 Br/B Engine diagnostic light Yellow 12V-

12 Br Water temperature K line diagnosis

13 B Battery negative terminal 12V-

14 R Battery 12V+

15 R/Br RPM signal

16 Gr Neutral N Green

17 Br/Y 1st Gear 1 Black

18 B/G 2nd Gear 2 Black

19 G/R 3rd Gear 3 Black

20 Y/BL 4th Gear 4 Black

21 Br/R 5ft Gear 5 Black

22 P/R 6th Gear 6 Black

7 - 21
 DEVICES
MASTER SWITCH

The ignition switch (1), Fig. A, is positioned behind the steering A

sleeve and serves to:
• Give the main contact for the electrical system 1
• Close the steering block
• Leave on the parking lights for all of the above conditions SH

PU
required

Check:
• Continuity
using the multitester to check the table

COLOUR V/G R/B

PIN PIN 1 PIN 2

Key ON
• •
Key OFF

Lock

If the above conditions are met, then the ignition switch is oper-
ating: if not, replace the component.

• Key in position “ON”

All power circuits are active, instruments and lights carry out
auto diagnostics; the engine can be switched on.
The key cannot be removed.

• Key in position “OFF”

All power circuits are deactivated; the key can be removed.

• Key in position “LOCK”

All power circuits are deactivated; the steering is locked.
The key can be removed.

7 - 22
 DEVICES
VOLTAGE REGULATOR

It is situated on the left side of the vehicle close to the water

radiator and allows balancing of electrical consumption via the A
battery recharge.
5
1. Multimeter selection: diode test Fig. B.
2. Connect the black probe to the red line terminal (4) of -
voltage regulator. The red probe is to connect the white line 4
terminal of voltage regulator (white 1 - 2 - 3). The pointer +
shows a certain value (value range 0.1~0.5V) indicating the 3
need of replacing the regulator.
3. Connect the red probe to the red line terminal (4) of voltage 2
regulator. The black probe is to connect the white line termi-
nal of voltage regulator (white 1 - 2 - 3). The pointer shows
a certain value (value range 0.3~0.8V) indicating the need
1
of replacing the regulator.

MULTIMETER
B
20 30
0 10

- +

- +

7 - 23
 DEVICES
LEFT ELECTRIC DEVICE

It is situated on the left side of the handlebar (Fig. A), the left
electric device consists of:
A
• Light change-over control (1) 4
for switching-over the high/dipped beam. 1
• Direction indicator control (2)
move the control from right to left to enable the relevant direction
indicators.
The control returns to the centre; press to deactivate the direc-
tion indicators.

• Horn button (3) 2

press to start the sound.
3
• High beam flash button (4)
Used to signal the driver’s presence when visibility is poor.

Check:
• Continuity with a multitester, positioning it on the relevant
terminals with the button pressed.

Check:
• Continuity
with a multitester, positioning it on the relevant terminals with the
button pressed.

Check:
• Continuity
with the multitester on the relevant reference terminals for the
selection (lh/rh).

Check:
• Continuity
with the multitester on the relevant reference terminals for the
selection (bright/dim).

Check the table.

Red/
WIRE COLOURING Red/Yel Light Blue Blue Red/Whi Gre/Bla Oran Gre/Whi Bro
Wh

Right indicator light

• •
Left indicator light
• •
High beam
• •
Dipped beam
• •
Flash button
High beam • •
Horn
• •
If the above conditions are met, then the horn, light switch control, high beam flash button are operating: if not,
replace the components.

7 - 24
 DEVICES
DROP SENSOR
Situated close to the rear frame, in case of falling, it cuts off the
fuel supply to the injection system (1) Fig. A. A
Check:
Position the drop sensor in the condition of normal use of the
motorcycle (horizontal) Fig. B.

NOTE:________________________________
The test will be carried out with the electrical circuit closed, 1
that is with the sensor connector stably connected to the
electrical system. The tips will be inserted behind the con-
nector.

Insert: B
• The red tip of the multimeter (+) into the pin 3 Fig. B.
• The black tip of the multimeter (-) into the pin 1 Fig. B.

Rotate the key of the ignition block to “ON”.

Check:
The voltage between the pin 3 and pin 1 must correspond to the
battery one (12 or more Vcc).

C
Insert:
• The red tip of the multimeter (+) into the pin 2 Fig. C.
• The black tip of the multimeter (-) into the pin 1 Fig. C.

Check:
The voltage between the pin 2 and pin 1 must correspond to the
battery one (12 Vcc or more).

If the check between the pin 2 and the pin 1 is positive,

place the drop sensor in vertical position Fig. D.

Insert:
• The red tip of the multimeter (+) into the pin 2 Fig. D.
• The black tip of the multimeter (-) into the pin 1 Fig. D. D

Check:
The voltage between the pin 2 and pin 1 must be below 2Vcc.

IMPORTANT NOTICE
When the above conditions are fulfilled, the drop sensor is
working properly, otherwise replace the part.

7 - 25
 DEVICES
DROP SENSOR

NOTE:________________________________
Every time the sensor is positioned vertically, it activates
E
and the output voltage from pin 2 goes below 2/3 Vcc, the
ECU memorizes such condition and to proceed with motor
starting it is necessary to proceed as described below.

• Position the drop sensor in horizontal and install in the cor-

rect position on-board.
• Rotate the key in the ignition block to OFF.
• After few seconds, rotate the key in the ignition block to ON
and check that the voltage to pins 1 and 2 is the one of the
battery (12 Vcc or more). If the outcome is positive, proceed
with the engine start test.

7 - 26
 DEVICES
INJECTION ECU

Check the various utilities situated close to the seat, according

to the diagram below.
Hereunder is a table indicating the meaning corresponding to
the error code detected.

ERROR TABLE

Error code Error description

P0030 1st oxygen sensor heater cylinder - open/short circ.

P0031 1st oxygen sensor heater cylinder - ground open/short circ.
P0032 1st oxygen sensor heater cylinder - positive open/short circ.
P0053 1st resistance oxygen sensor heater coil cylinder - abnormal value
P0036 2nd oxygen sensor heater cylinder - open/short circ.
P0037 2nd oxygen sensor heater cylinder - ground open/short circ.
P0038 2nd oxygen sensor heater cylinder - positive open/short circ.
P0059 2nd resistance oxygen sensor heater coil cylinder - abnormal value
P0105 MAP sensor - abnormal response (no variation)
P0106 MAP sensor - abnormal response (out of range values)
P0107 MAP sensor - abnormal circuit grounded
P0108 MAP sensor - abnormal circuit on positive
P0112 Air temperature sensor - output voltage too low
P0113 Air temperature sensor - output voltage too high
P0116 ECT (Engine coolant temperature) - abnormal response (out of range)
P0117 ECT (Engine coolant temperature) - abnormal response (too low voltage)
P0118 ECT (Engine coolant temperature) - abnormal response (too high voltage)
P0122 TPS - abnormal response (too low voltage)
P0123 TPS - abnormal response (too high voltage)
P0130 1st lambda sensor cylinder - abnormal value (out of range)
P0131 1st oxygen sensor cylinder - abnormal value (too low voltage)
P0132 1st oxygen sensor cylinder - abnormal value (too high voltage)
P0134 1st oxygen sensor cylinder - open circuit
P0136 2nd oxygen sensor cylinder - abnormal value (out of range)
P0137 2nd oxygen sensor cylinder - abnormal value (too low voltage)
P0138 2nd oxygen sensor cylinder - abnormal value (too high voltage)
P0140 2nd oxygen sensor cylinder - open circuit
P0201 1st injector - open circuit
P0261 1st injector - ground short circuit
P0262 1st injector - positive short circuit

7 - 27
 DEVICES
INJECTION ECU

ERROR TABLE

Error code Error description

P0202 2nd injector - open circuit

P0264 2nd injector - ground short circuit
P0265 2nd injector - positive short circuit
P0321 Drive shaft position sensor - failure (out of range)
P0322 Drive shaft position sensor - failure (open circuit)
P0444 Vapour exhaust checking valve - open circuit
P0458 Vapour exhaust checking valve - too low circuit voltage
P0459 Vapour exhaust checking valve - too high circuit voltage
P0501 Speed sensor - failure (out of range)
P0506 High minimum speed target compared to the limit of air control system
P0507 Low minimum speed target compared to the limit of air control system
P0508 IAC (idle air control) - ground short circuit
P0509 IAC (idle air control) - positive short circuit
P0511 IAC (idle air control) - open circuit
P0560 Abnormal system voltage response (out of range)
P0562 Too low system voltage
P0563 Too high system voltage
P0602 ECU map - coding error
P0627 Fuel pump relay check - open circuit
P0628 Fuel pump relay check - short circuit to ground
P0629 Fuel pump relay check - positive short circuit
P0650 Lamp circuit error - MIL indication
P2177 Too high CLL value
P2178 Too low CLL value
P1105 Canister purge valve - positive short circuit
P1116 Too high engine temperature
P1117 Canister purge valve - short circuit to ground
P1118 Canister purge valve - open circuit
P0571 Brake switch - failure
P1136 K line - open circuit

7 - 28
 DEVICES
INJECTION ECU CONNECTIONS

E_A_DKG
E_A_TMOT

B_D_CANL
36 E_S_DIAG1

B_D_CANH
E_A_TANS
10 M_R_SEN1

21 E_S_DIAG2
E_S_KL15

A.S.LSHVK2
A.S.LSHVK1
E_F_DGA
E_F_DGB

A_T_EV2

A_S_SAL
A_T_EV1
A_U_5V1

E.A.LSVK2
U_U_UBD
M_M_ZUE

E.A.LSVK1
U.U.UBR

A.P.ZUE1

A.P.ZUE2
12
30
13
42
43

11

48

47

16
32
33

15
9
8

20
1

4
5

19
2

R 68K
R 68K
36 21

10/5
10/4

82
20

81
80
19

1
2

82/1

82/2
21 34 21 34

7
1 2 2 1

10/1

10/6
10/2
30/1

30/2
t

13

83

88
92
10/3
t

42
43

11

48

47

4
12
9
A B A B 2 1+ 2 1+ 2 1+
1 2 3 1 2 A B C - - -

3 3

LAMBDA SENSOR LAMBDA SENSOR Zyl.1 GND TO GND TO Zyl.2

ENGINE ENGINE

15
IGNITION IGNITION

16
P
UPSTREAM 1 UPSTREAM 2
COIL 1 COIL 2
VDD
THROTTLE LSF LSF INTAKE TEMP. ZS-K1X1 ZS-K1X1
INTAKE
ENGINE COOLANT PRESSURE POSITION SENSOR INJECTOR 1 INJECTOR 2 SECOND AIR
TEMP. SENSOR SENSOR SENSOR TANS (CYL.1) SOLENOID
(CYL.2)
TMOT DS-S3 DKG EV14 EV14 SAL
CDI CAN INTERFACE
CAN

FUSE 5A
FUSE 5A
CAN口

92

83
80

81

88
33
32

82
8

kl.87(HR)
5

UB kl.15
UB kl.30 SSW 熄火开关

GROUND P
A_P_DMTN

A.S.LAMP
E_S_KL15

B_D_DIAK

E.A.DUMP

A.S.FAN1

A_S_EKP
E_F_VFZ
M_M_ZUE

U_U_UBD
U_U_UBR

A_S_MIL

A.T.SMA

A.T.SMC
A.T.SMD

A.T.SMB

A.S.HR
O.S.CPV
38
29

44
32
33

34

14
41

40

46
27

28
17
18

45
5
8

94
46

96
95

95
120
119

30 85 86 87 1 2 3 4
45

112

114
113

115

116
137

44
14
30 85 86 87
6

30 85 86 87 30 85 86 87
2- 1
+ M
27

28
17

18
41

A D C B
40

FAN 1
RELAY
FUSE
38

FUEL PUMP RELAY ELECTRIC FUEL PUMP

29
34

VEHICLE FAN1 MAIN HEAD LIGHT

ENGINE CANISTER RELAY RELAY EKP-RELAY EKP
FUSE

FUSE
DUMP SPEED
MIL FUNCTION SENSOR SPEED PURGE HR
SIGNAL HLR
DIAK INDICATOR LAMP OUTPUT VALVE

FUSE 30A
VFZ TEV
MIL (TD/TN)
119

STEPPER MOTOR

STEPPER

96
137

112

113
114

115

116
120
33
32
8

kl.87(HR)
5

UB kl.15
UB kl.30 SSW

GROUND P

7 - 29
 DEVICES
INDICATOR LIGHT INTERMITTENCE

It is situated inside the storage compartment, underneath the

vehicle seat, and allows to control the indicator flashers.

7 - 30
 DEVICES
ABS BUTTON

It is situated on the left side of the control handlebar (3), Fig. A,

and allows to manage the insertion/release of ABS control.
A

3
Disconnect:
• The electrical coupling.
Check:
• The resistance using the multitester on symbol Ω between
pin 1 and pin 2.
1
Resistance:
• 0Ω

7 - 31
 DEVICES
SERVICES RELAY

It is situated inside the storage compartment, underneath the ve-

hicle seat (Fig. A). The relay assembly is managed by the ECM
A
to control each load at best, such as:

• The lighting system

The ECM ensures that the lights turn on in certain conditions.
• The fuel pump
The fuel pump is activated only when the starter lets the engine
rotate.
• The electric fans
• The injection
The ECM controls the injection relay pull-in according to the
relevant conditions, as ignition, shutdown, and use of the vehi-
cle, thus allowing a stable supply to ECM, which can carry out
any correct procedure of storage and setting of the parameters
in the standstill phase, by continuing its self-powering for some
seconds after the instrument panel shutdown.
• Services B
All devices “with ignition on”, as dashboard, various safety devic- 30
es and lighting system, are connected to the services relay.
87
Check:
• The resistance using the multitester on symbol “Ω” between 86
85
pin 85 and pin 86 (Fig. B).
87

Resistance 12 ± 2 Ω

Use:
• The tester and, referring to the table, check on relay pins,
by powering the PIN 85 and the PIN 86 to the battery.

RELAY PIN 87 PIN 30 PIN 87A

Powered on battery
• •
Not powered on
battery • •

NOTE:________________________________
When the above conditions are fulfilled, the relays are oper-
ating properly, otherwise replace the parts.

7 - 32
 DEVICES
STATOR

Three types of failures may occur on the magnetoelectric gener-

ator (stator): 1 2 3
• Short circuit. A
• Line break (wire burnt).
• Lack/reduction of the magnetic field.
Ω
Short circuit or open circuit of coil wires that cause low output or
even no output.
Disappearing of rotor magnetism will lead to low output, which
may be caused by AC electric generator or striving. Or it may be
because of aging.

Turn off the ignition switch.

Disconnect:
• The connector of the 3-pole magnetoelectric generator.
Measure:
• The resistance value among the three black terminals of the
magnetoelectric generator with a multimeter.

Standard 0.18 Ω ± 0.01Ω at 25°C

• If the resistance is greater than the aforementioned values,

or it is not possible to measure (infinite value) one of the
two wires using the multimeter, it shall be replaced. When it
is far lower than the resistance, it refers to a stator short-cir-
cuit. It shall be replaced.

• Measure the resistance between every single black wire

and frame grounding with a multimeter in the highest resis-
tance range.

• Use tester coil to check whether the engine is through. If

yes, it refers to a short-circuit of the coil and engine. Check
the charge coil.

• If the resistance of stator coil is normal, but the voltage

check detects a failure of the magnetoelectric generator, the
rotor magnets might have become loose. At this moment,
replace the rotor.

Start up the engine:

• Run the revolutions per minute (rpm) according to Table 1.

• Record the voltage readings (three measurement values in
total).

Table 1 Output voltage of magnetoelectric generator

Wiring Readings at
Range of tester
Tester (+) to Tester (-) to 5000 rpm

Another black 55 V or high-

750 V AC Black wire
wire er

NOTE:________________________________
If the output voltage indicated is within the value of the
table, the magnetoelectric generator works properly.
If the output voltage indicated is much lower than the value
within the value of the table, problems occur on the gener-
ator.

7 - 33
 ACTUATORS
POSITION OF ACTUATORS

1
2

3
4

7 5

Position Device
1 STEPPER
2 INJECTORS
3 IGNITION COILS
4 COOLING FAN
5 FUEL PUMP
6 STARTER
7 ABS ECU

7 - 34
 ACTUATORS
IDLE AIR CONTROL SYSTEM (STEPPER)

The system is situated inside the air filter case, contains a valve
for checking air flow underneath the throttled body throttles and
is equipped with a stepper motor.
The system controls the following parameters:
• Idle speed.
• Air supply in case of engine overspeed.
• Adjustment of air/fuel ratio by working at idle speed at
altitudes above sea level.
• Adjustment of air/fuel ratio in cold/hot setting-off.
When enabled, the stepper opens the valve by a certain amount
to check the passage of air, allowing a set amount to flow down
a series of hoses in the group of throttles.

Operating voltage 12V DC

Minimum /maximum operat- 14V DC/ 7.5V
ing voltage DC
Impedance per coil (27°C) 53±5.3Ω
Minimum impedance 35 Ω
Distance 0.04167 mm
8.5 mm (204
Maximum travel
steps)
A
B
Resonant frequency range 70-120 pps C
D

7 - 35
 ACTUATORS
INJECTORS

They are positioned on the throttled body unit. A

The engine is equipped with three four-jet injectors (1), Fig. A.
The number of jets from the injectors is constant, but the amount
of time each injector remains open will vary.
The duration of each injection is calculated by the ECM based
on data from the different system sensors.

Disconnect:
• The electrical coupling.
1

Check:
• The resistance
using the multitester on symbol Ω between PIN1 and PIN2 (2),
Fig. B.

Resistance 12 ± 2 Ω MULTIMETER
B
20 30
0 10

- +

1 2
2

7 - 36
 ACTUATORS
IGNITION COILS

The ignition coil is situated directly on the head of each spark

plug (1), Fig. A, and provides high voltage and ignition energy
A
necessary to produce high-voltage sparks between the elec-
trodes of the spark plug.

Check:
• The measurement of the coil terminal impedance. 1

Primary coil 0.65±0.07Ω

Secondary coil 4±0.5 kΩ

The optimal condition is achieved when the resistance value is

within the standard value.
Resistance value "∞" indicates coil wire disconnection”, there-
fore it is necessary to replace the ignition coil.

7 - 37
 ACTUATORS
COOLING FAN

It is situated on the radiator body (1.) Fig. A. The ECM enables

and disables the cooling fan according to a signal received by
A
the cooling fluid temperature sensor.
When the cooling fluid temperature reaches the upper threshold
temperature, the cooling fan is enabled by a command.
When the cooling fluid temperature has lowered enough (to the
lower threshold temperature), the cooling fan is disabled by a
command from the ECM.

Check:
• The load current of the fan motor by connecting an amme-
ter, as shown in Fig. B.
1
The voltmeter serves to check that the battery powers the 12 volt
motor.
When the fan is turning at full speed, the ammeter must not read
any more than 5 amps. B
If the motor is not turning, replace the fan motor with a new one.
A
NOTE:________________________________ Fan Ammeter
It is not necessary to remove the cooling fan from the radia- motor
tor to carry out the above test.

7 - 38
 ACTUATORS
FUEL PUMP

The electric pump is situated in the fuel tank (1), Fig. A, and
provides fuel in the supply circuit via a pressure regulator at a
A
constant pressure of 3.5 bar.
The ECM directly controls pump action, guaranteeing, from
when the panel is switched on with a timed function, that the fuel
is at the correct pressure to start the engine, with a continued
operation for the successive use of the bike.

Check:
• The fuel pump.

1. Put the outlet pipe into a container to drain out the fuel Fig. A.
2. Connect the battery (12 V) to the fuel pump.
• RED/BLACK positive wire + 1
• BLACK negative wire -

- +

7 - 39
 ACTUATORS
FUEL LEVEL SENSOR

It is situated close to the fuel pump (1-2), Fig. A, and provides A

an outlet value of variable resistance according to the present
fuel level.

Check:
• The resistance depending on fuel level (Fig. B) by position-
ing the multitester on symbol Ω between the PIN1 - PIN2.

MULTIMETER
B
20 30
0 10

- +

Brown Red
Black Blue

Indicated level 6 5 4 3 2 1 0
Resistive value Ω 0-18 19-24 25-36 37-52 53-69 70-89 90-95
Tank fuel (Lt) 20 15.3 12.7 10 7.7 5.1 2.7
Extension (mm) 262 228±3 207±3 186±3 165±3 144±3 112±3

7 - 40
 ACTUATORS
STARTER

The starter (1), Fig. A, is a part that can be replaced totally. If the
starter is damaged, replace it.
A

Remove:
• Release the coiled spring of brushes.
• Remove the casing framework.
• Use an ohmmeter to measure the resistance between the
wire terminal and the insulated brush.

Reading should be max 0.3 ohm.

Measure the resistance between the wire terminal and the 1

brush holder.
• Make sure the brush does not come in contact with the
casing.
• Reading should be infinite (no reading).
•
Remove: B
• The brush holding plate and the brushes.
Measure:
• The brush length and replace in case of wearing exceeding
the allowed limit.

Brush wear limit (length)

Standard 10 mm
Service Limit 5.0 mm

Check:
• The switch surface for wearing or discoloration.
• The framework test. C
Make sure the insulating washer of the terminal bolt is inserted
properly into its housing and the tab on the brush holding plate
engages the housing notch of the plate.
• Remove the magnet housing by keeping the framework and
the brush holder united.

FRAMEWORK TEST

Check:
• The switch surface.
Replace if overly worn or damaged.

Measure:
• The resistance between each segment of the switch Fig. C.
A digital multitester is used for measurement.

NOTE:________________________________
Reading should be max 3 ohm.

Continuity of lower framework

coil resistance 3 Ω at 20°C (68°F)

7 - 41
 ACTUATORS
STARTER

Measure:
• The resistance between each segment of the switch and
D
the framework shaft (Fig. D). Reading should be infinite (no
reading).

Insulation check
Ω infinite 20°C (68°F)

Check:
• The switch segments for discoloration.

NOTE:________________________________
The presence of discoloured segments in pairs refers to
short circuits of coils that require the replacement of the
starter.

• Position the framework in a short circuit detector.

• Switch on the detector and position longitudinally a saw
blade or a thickness gauge for 3 mm (1/8”) above the lami-
nates of the framework coil.
• Turn the framework by 360°.

NOTE:________________________________
If the saw blade is attracted towards a pole of the frame-
work, the latter has a short circuit and must be replaced.

Check:
• The permanent magnets in the starter housing.

NOTE:________________________________
Make sure they are not cracked or far away from the hous-
ing.

7 - 42
 ACTUATORS
ECU ABS

It is situated underneath the fuel tank Fig. A.

A
Precautions

There are several precautions to follow concerning the ABS

system.
• The power supply of the ABS system must be equipped with
a 12 V sealed battery. Do not use other types of batteries.
• Do not reverse the battery connections to prevent damages
to the ABS hydraulic control.
• Do not disconnect the battery wire or other electric parts
when the main switch is on or the engine is operating to
prevent damages to the ABS parts.
• Do not short circuit the positive electrode of the battery (+)
on the frame.
• Do not activate the main switch when the ABS electric parts
are disconnected. The ABS control unit stores the diagnos-
tic fault code.
• Do not spray water on electric parts, ABS parts, connectors,
wires, and conductors.
• Make sure the motorcycle transceiver does not interfere
with the ABS system. Keep antennas as far away from ABS
ECU as possible.
• Switch the master switch before disconnecting the ABS
electrical parts.
• Never strike the ABS parts with a hammer or leave them fall
on hard surfaces to prevent damages to the ABS parts.
• Do not disassemble or try to repair the ABS parts, even in
case of malfunctioning of the ABS.
• The ABS system cannot detect malfunctioning of the
conventional braking system (burnt/worn discs, worn pads
or other mechanical failures). To avoid problems, keep
checked the hoses and the wiring for a correct layout. For
the standard braking performance, check for any brake fluid
leaks. Make sure the system is properly drained.

WARNING
If the linking parts of the brake hoses are removed, includ-
ing the connecting screws of the ABS hydraulic system or
the air bleed screws, bleed air in the circuit carefully.

IMPORTANT NOTICE
Do not ride the vehicle if the system is not drained properly
as the presence of air may jeopardize the efficiency of the
ABS and the brakes.

7 - 43
 ACTUATORS
ECU ABS

Please refer to the features on the Texa diagnostic device for

managing the diagnostics. Hereunder are the main fault codes
and the necessary corrective actions.

DTC (Hex) Fault codes Solutions

5055
5019
5017
Replace ABS unit.
5013
5018
5014
5053
Check battery voltage.
5052
5035 Replace ABS unit.
5043
Check connection of the speed sensors using a new sensor.
5045
5042
Check phonic wheel for deformation or faults.
5044
5025 Check speed sensors, distance, phonic wheel, and tyre specifications.
5122
Replace ABS unit.
5223

7 - 44
 ACTUATORS
ECU ABS

Diagram

Position Code
1 GND_ECU
2 CAN1P
3 WSS_F
4 WAU_IN1
5 DIAGK
6 BLS - input_PD -SW2H_NO
7 DIAGL
8 WSO_F
9 UB_VR
10 GND_MR
11 CAN1M
12 WSP_F
13 WSP_R
14 WSS_R
15 ABS_OFF -input_PU - SW2L_NO
16 WSO_R
17 NABS_SLAMP
18 UB_MR

7 - 45
 DIAGNOSTICS
BRAKE FILLING/BLEEDING DIAGNOSTICS

This procedure is carried out every time it is necessary to

change the brake fluid or when it is necessary to replace the
A
brake fluid hoses.

Remove:
• Rider seat, refer to section “Removal of rider seat, Chap- 2
ter 4”.
Connect:
• The ECU pin (1) to the female connector (2) situated on the 1
motorcycle Fig. A.
Follow:
• The instructions of the diagnostic device Fig. B.

After having completed the first stage of instructions, enter the C

first page of the software and select “ACTIVATIONS” (3) Fig. C.

Select “Brake circuit emptying and filling” (4) Fig. C.

Fill and bleed by activating the braking system manually when

requested by the software. D
At the end of the procedure, the screen will appear Fig. D.
Press “Confirm” to proceed.

7 - 46
 DIAGNOSTICS
BRAKE FILLING/BLEEDING DIAGNOSTICS

Brake bleeding function:

At the end of the system filling, select the “setting” function (5)
E
Fig. E.
And then “Brake bleeding” (6) Fig. E.
Follow:
• The instructions of the diagnostic device.
5
6

7 - 47
 BATTERY
VEHICLE BATTERY

IMPORTANT NOTICE 1
Do not use batteries other than the indicated ones (A), Fig. 1.

The MF battery (maintenance-free) mounted on this vehicle

does not require maintenance operations, as electrolyte level
control and topping up of distilled water.
Please note that the charging system of the MF battery differs
from the one of a standard one.
Therefore, do not replace the MF battery with a standard one.
The recommended battery is 12V-9Ah.

A
IMPORTANT NOTICE
Hydrogen is not produced during the normal recharge of the
battery, but it can be produced when the battery is recharged
excessively.
Please keep flames away from battery during recharge.

In case of corroded terminals, remove the battery, pour warm

water on it and clean using a metal brush.
At the end of connection, grease slightly.
Mount a cap on the positive terminal.

7 - 48
 BATTERY
BATTERY EFFICIENCY CONTROL

CHECKING BATTERY CURRENT LOSSES

2
Connect:
• The multitester between the negative terminal and the mA
negative wire of the battery as ammeter in direct current (B)
Fig. 2. +

IMPORTANT NOTICE
Since the current losses may be high in case of malfunctioning,
use a high range of the multitester first to prevent damages.
Do no position the ignition switch to ON whilst measuring the
current.
When the panel is off, the current losses must be >/- Ã
2~2.5 mA. - +

• Otherwise, find out the source of such absorption by dis-

connecting the connectors of each utility powered by the
battery directly.

NOTE:________________________________
In the event an anti-theft device is installed, disconnect it
before carrying out the modifications.

7 - 49
 7 - 50
Idle speed control valve
Y/R Gr
Main relay
R/W Y/R Gr/Y Y/P
W/Y P/N
฀色 COLOR CODE
R/W B/Y1A Headlight relay
Starter relay In5408
Fusibili Batteria (+) Throttle grip Sidestand switch
Rear brake Flasher 黑色 Black B
Serbatoio Elettro Power lock Left handlebar grip USB Switch
Luci ECU ABS Fuse TPS
Benzina ventola
40A Port
Ignition switch
Interruttore freno anteriore 40A BL/Y
15A 15A 15A 15A 15A 40A ฀色 Blue BL
B/W1
Meter M 1左 1右 2右 2左 N/W3 Gr/Y3 R/W R/W LR/BL BL/G3 B B/BL
R 1左 1右 2右 2左 Gr/G2 R/W
O/BL B P Y/R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Light
淡฀色 LBL
R1 BL/B R1 B/LR B/LR B/LR P/Y G/Gr LR/BL R/W B N/P O/BL B B/Y1A G/B1 O3 O/W3 G/R2 blue
Gr/G2 R1 Y/B N G/Gr R R LG/W R/W BL Gr/Y3 N/W3 R/W P/Y LG LGA G/W1 R/W G/Y2 B
棕色 Brown N
P P/W6 W2 G/Gr O3 LR/N5 N/O1 B/N R/BL N/BL N/Y
R/W LR/W4 Gr O/B P/B BL R/W LR/G3 R/W G BL/P O/W3
฀色 Green G
Carbon canister
Solenoid valve
Y/W
橙色 Orange O
R/LBL1
LG/W Rear right turn signal lamp
G/Y2
黄色 Yellow Y
Starter diode N/W3
Gr
G/R2
G/W1 ฀色 Red R
Right turn indicator B/W3 Gr/Y3
Rear left turn signal lamp Pink LR
粉฀色
B
LR/BL B
R/W R/W
Head light 白 White W
BL P
Tail/brake light
G/B1 紫 Purple P
Left turn indicator Gr/Y3
灰 Gray Gr
B
Clutch switch
LG/W
B
Horn
N/P
R/W
G/N
Fan relay
Y/B
O/G
R
R/W
B
ABS diagnostic connector
LR/Y
G/BL
Y/W
Fuel pump relay
BL/B
R/B
N/Y
Oil pressure sensor
Y/G2
LG
ECU relay N
Y/W
B/N
G/P
N/R
Efi diagnostic tool connector
LR
G
N
Battery(+)
Battery(-) Y/P LR W/N B/P BL/LR1 Y/N3 W/Y BL/B R/N LR/B N BL/Y R/LBL1 W/P G/BL BL/G3 BL/W O/B B/R
B Gr/BL1 LR/Y B LR/W1 R/P N/BL2 P/N N/R Y/G2 B/W1 B/BL O/BL3 Gr/Y1 Y/BL W/B P/R G/P LG P/W6 LR/W4 W2 Gr
P/B B W/R G/N W/G BL/P Y/W
R/P B R/W R Y/Gr Gr/R BL/P R LR/N5 LR/G3 N/O1
WW W W W W B R1 R B
Gr/BL1 LR/W1 O/G B R/BL B/BL B/BL Y/W B/R B Y/W Y/W Y/W B/BL W/B B/R B BL/Y B/BL R/N Y/W BL/W B/BL
Y/Gr Gr/R B B/N R/W LR/B W/N B Y/W W/B W/R1 W/P1 Y/N3 Y/BL P/R BL/B R/B BL/LR1 B/BL O/BL3 W/G B/P
Rectifier
1#2 1#1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
1#2 1#1 1#1 1#2
1 2 3 4 5 6 7 8 9 10 11 1213141516 17 18 Battery
ABS Magneto
Fan Fuel pump Cylinder 1 Crankshaft ECU
ABS control unit Roll-over sensor Coolant temp sensor Cylinder 2 Position
Fuel level sensor Sensor IAT Gear position sensor
Resistance MAP sensor
Ignition coil Injector
ABS switch Front
Wheel-speed
Sensor Rear wheel-speed sensor
ELECTRICAL WIRING DIAGRAM
ELECTRICAL SYSTEM
 ELECTRICAL SYSTEM
COLOUR KEY

CODE COLOUR
B Black
BL Blue
GR Green
W White
Y Yellow
O Orange
R Red
Dg Dark grey
P Purple
N Brown
G Grey
LR Pink

7 - 51
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 Pure Passion since 1911

SERVICE STATION MANUAL

2017, Benelli Q.J. s.r.l.
First edition, October 2017
All rights reserved.
Any reprint or unauthorised use
are strictly prohibited
without the written permission of
Benelli Q.J. s.r.l.