IMPORTANT

• READ THIS MANUAL AND FOLLOW THE INSTRUCTIONS CAREFULLY. THE ESPECIALLY IMPORTANT
INFORMATION HAS BEEN INDICATED WITH THE WORDS WARNING, CAUTION AND N.B.,
WHICH HAVE VERY PRECISE MEANINGS.

WARNING
CONTAINS A POTENTIAL DANGER THAT MAY CAU-
SE INJURY OR EVEN DEATH.

CAUTION
WARNING OF POSSIBLE DAMAGE TO THE MACHINE.

N.B.
CONTAINS SPECIAL INFORMATION TO AID MAINTE-
NANCE OR CLARIFY SOME POINT IN THE INSTRUC-
TIONS.

THIS SERVICE MANUAL HAS BEEN PREPARED FOR

AUTHORISED DEALERS OF G. H E MOTORHISPANIA,
S.L. AND SHOULD ONLY BE USED BY QUALIFIED
TECHNICAL SERVICE DEPARTMENT MECHANICS.

INEXPERIENCED MECHANICS OR THOSE WITHOUT

THE APPROPRIATE TOOLS AND EQUIPMENT CAN-
NOT CARRY OUT THE SERVICE WORK DESCRIBED
IN THIS MANUAL CORRECTLY.

A POOR REPAIR MAY CAUSE INJURY TO THE ME-

CHANIC, AND THE MACHINE MAY NOT BE IN CON-
DITION TO GUARANTEE THE SAFETY OF THE RIDER
AND PILLION PASSENGERS.

3
 FOREWORD
This manual describes the procedures for the diagnosis, maintenance, adjustments, basic service work, chan-
ging of parts and the dismantling and assembly of the main parts.

Model applicable:
MH7 NAKED with the following and subsequent VIN numbers:
VTVNK01E307XXXXXX ~

This text is classified into sections, each of which has a section number, as can be seen in the Contents on the
following page, and on the first page of every individual section there is a contents list for that section.

Keep this manual to hand so that it can be consulted quickly when carrying out service work.

The specified points must be carefully observed to ensure that the machine functions perfectly in accordance
with the specification.

When changing parts or carrying out service work that involves dismantling, it is recommended to use genuine
G.H.E. MOTORHISPANIA, S.L. spare parts, tools and service materials as specified in the corresponding des-
criptions

All the information, figures and specifications in this manual are based on the latest approved product informa-
tion available at the time of publication.

The main model used for the description throughout this manual is the model with basic specifications.
The figures may therefore appear slightly different from the model in the workshop. G.H.E. MOTORHISPANIA,
S.L. reserves the right to make changes without prior warning.

G.H.E. MOTORHISPANIA. S.L.

SERVICE DEPARTMENT

© Copyright G.H.E. MOTORHISPANIA. S.L. 2007

4
GENERAL CONTENTS

GENERAL INFORMATION 1

SPECIFICATIONS 2

COMMISSIONING 3

CHASSIS 4

ELECTRICAL SYSTEM 5

ENGINE 6

ADJUSTMENT 7

MAINTENANCE 8

TROUBLESHOOTING 9

5
1 GENERAL INFORMATION

CONTENTS
IDENTIFICATION

Machine identification 9

Engine identification 9

7
1 GENERAL INFORMATION
IDENTIFICATION

CHASSIS IDENTIFICATION NUMBER

The chassis identification number is located at the front right-hand

side of the machine.

The chassis number is required when requesting any motorcycle

part.

ENGINE IDENTIFICATION NUMBER

The engine identification number is located at the top right-hand

side of the engine.

The engine number is required when requesting any engine part.

9
2 SPECIFICATIONS
CONTENTS
GENERAL SPECIFICATIONS 13
2
CHASSIS SPECIFICATIONS 14

ENGINE SPECIFICATIONS 15

TIGHTENING TORQUES 16

11
2 SPECIFICATIONS
GENERAL SPECIFICATIONS
2
ELEMENT SPECIFICATIONS

MODEL CODE MH7 NAKED 125cc

DIMENSIONS
Total length: 1980 mm

Total width 750 mm

Height without rear-view mirrors 795 mm

Distance between axles 1310 mm

WEIGHT 120 kg

13
 2 SPECIFICATIONS
CHASSIS SPECIFICATIONS

ELEMENT SPECIFICATIONS

WHEELS
Front wheel 2,75 x 17”
Front tyre Continental 100/ 80 - 17
Front pressure 1,5 bar
Rear wheel 3 x 17”
Rear tyre Continental 130/70 - 17
Rear pressure 2 bar

FRONT BRAKE
Type Hydraulic disk, radial calliper
ø brake pistons 25 mm
ø of disk Ø 300mm
Thickness of disk 4±1
ø main piston (cylinder) Ø 11mm

REAR BRAKE
Type Hydraulic disk
ø brake pistons Ø 25mm
ø of disk Ø 220mm
Thickness of disk 4±1 mm
ø main piston (cylinder) Ø 12mm

FRONT SUSPENSION
Type of suspension: Hydraulic telescopic forks
Type of front forks 41 mm inverted; advanced shaft
Forks capacity 360±4 cc
Travel 90 mm

REAR SUSPENSION
Type of suspension Swinging arm with single central shock absorber
Central hydraulic single shock absorber travel 45±2 mm

STEERING
Tipo Column mounted on ball bearings

14
2 SPECIFICATIONS
ENGINE SPECIFICATIONS

ELEMENT SPECIFICATIONS

ENGINE
Type of engine Single cylinder 4-stroke
Make YAMAHA
Cubic capacity 123,7 cc
Diameter x stroke 54 mm X 54 mm
Maximum power 7,5 Kw a 9000 min-1
Maximum torque ratio 9,4 Nm a 6500 min-1

FUEL
Recommended fuel 95 or 98 octane lead free petrol
Total capacity of fuel tank 12.5 litres
(including reserve)

LUBRICACIÓN
Recommended oil 10W30

Oil tank capacity 1 Litre

COOLING
Type Air

IGNITION
Type Electric
Spark plug NGK; CR6HSA

CARBURETTOR
Type MIKUNI 3D6/10
Main jet #95
Idling jet #15
Needle / Position 5QGJ3 / 2
Float height 18,9 mm
Air screw position 1 1/2 turns

TRANSMISSION
Type Primary by gears
Final by chain
Primary transmission Gears; 68 x 20
Secondary transmission Chain; 52 x 14
Gearbox 5 speed
Gearbox capacity 1,2
Clutch Multidisk- multidisks bathed in oil with manual control.

MAGNETO MORIC; 3D9

STARTER MOTOR Electric/Kick-start lever

15
 2 SPECIFICATIONS
TIGHTENING TORQUES

ITEM TIGHTENING TORQUE

BODYWORK
Side covers 0,1 daN·m (1 N·m)
Front mudguards 0,1 daN·m (1 N·m)
Rear mudguards 0,8/0,1 daN·m (8/1 N·m)
Skirting 0,8/0,1 daN·m (8/1 N·m)

CHASSIS
Front wheel shaft 4,5 daN·m (45 N·m)
Front wheel shaft clamp 1,2 daN·m (12 N·m)
Rear wheel shaft nut 6,5 daN·m (65 N·m)
Suspension arm nut 6,5 daN·m (65 N·m)
Engine chassis mounting 2,8 daN·m (28 N·m)
Shock absorber top mounting 4,3 daN·m (43 N·m)
Shock-absorber base mount 4,3 daN·m (43 N·m)
Forks T-sections 1,5 daN·m (15 N·m)
Front brake calliper 2,5 daN·m (25 N·m)
Rear brake calliper 2,5 daN·m (25 N·m)
Front brake disk 1 daN·m (10 N·m)
Rear brake disk 1 daN·m (10 N·m)
Support on chassis 1,9 daN·m (19 N·m)
Steering lock 0,6 daN·m (6 N·m)

STANDARD
5 mm diameter bolt and nut 0,5 daN·m (5 N·m)
6 mm diameter bolt and nut 1 daN·m (10 N·m)
8 mm diameter bolt and nut 2,2 daN·m (22 N·m)
10 mm diameter bolt and nut 3,5 daN·m (35 N·m)
12 mm diameter bolt and nut 5,5 daN·m (55 N·m)

16
3 COMMISSIONING
CONTENTS
COMMISSIONING

Battery preparation (except maintenance-free batteries) 19

Checking levels 20

Commissioning the fuel and oil circuits 20

Checks before delivery to customer 20

17
3 COMMISSIONING
PREPARING THE BATTERY

3 (EXCEPT MAINTENANCE-FREE BATTERIES)

Regarding use of electrolyte, please read this manual carefully and fill the electrolyte liquid correctly, making sure
not to spill any.

WARNING:
Check to make sure the electrolyte is the same type as in the battery.
The electrolyte must always be filled with the battery removed from the machine.
The fitting of bolts and nuts must be carried out after filling with electrolyte.

PREPARING THE BATTERY:

Place the battery on a flat surface and remove the filling orifice seal.

PREPARING THE ELECTROLYTE:

Remove the electrolyte container from the PVC wrapping and remove the top cover by sliding sideways.

FILLING THE BATTERY WITH ELECTROLYTE:

Fit the electrolyte container vertically into the battery filling orifice and push in with a single movement. This will
cause the seal to break and allow the liquid filling to begin.
N.B.: The electrolyte container needs to be correctly inserted, otherwise the battery may fall over or the sul-
phuric acid may spill out

PLEASE CHECK THE FOLLOWING:

That bubbles are emerging from the 6 reservoirs.
That the liquid level is falling gradually.
Allow to stand for 10 minutes (no more than 12 hours)
N.B.: If there are places where no bubbles are emerging, the liquid can be encouraged to enter by tapping this
part with the finger without removing the electrolyte container.

REMOVING THE ELECTROLYTE CONTAINER:

Check once again that no electrolyte is remaining. If there is electrolyte remaining, tap the container gently.
Remove the electrolyte container carefully.
Clean off any electrolyte that may have splashed onto the battery.

FITTING THE HERMETIC PLUG:

Remove the hermetic plug fitted to the battery and position it gently horizontally lined up with the liquid filling
orifice.
Push down several times with both hands on the 6 parts until it is at the same level as the top of the battery.
N.B.: Do not adopt the method of pushing each hermetic plug once.

PRECAUTIONS FOR HANDLING:

Take care that the electrolyte does not come into contact with the skin or eyes when filling the battery.
In the event of electrolyte coming into contact with clothing or skin, the affected part must be washed immedia-
tely with plenty of water and then washed with soap and water.
In the event of electrolyte coming into contact with the eyes, the effected eye must be washed immediately with
running water and the nearest medical personnel contacted.
Before disposing of the container, it should be made safe by diluting the contents in water or neutralising it and
then washing the contents with water.
Sulphuric acid: 41%
Specific weight: 1.32

19
 3 COMMISSIONING
WARNING
NEXT, THE BATTERY LEVEL MAY NEED TO BE ESTA-
BLISHED AFTER A COMPLETE CHARGE, USING EX-
CLUSIVELY DISTILLED WATER.

CHECKING LEVELS
1) Check the gearbox oil level.

2) Check the coolant level.

3) Check the brake fluid level.

COMMISSIONING THE FUEL AND OIL

CIRCUITS
1) Start up the engine and check that it is running correctly.

2) Fill the tank up with 95 or 98 octane lead-free petrol

CHECKS BEFORE DELIVERY TO CUSTOMER

1) Check the tightness of the wheel nuts.

Front wheel shaft nut tightening torque:

1,2 daN.m (12 N.m)

Rear wheel shaft nut tightening torque:

6,5 daN.m (65 N.m)

2) Check tightness of nuts and bolts (see Tightening torques).

3) Check the adjustment and effectiveness of the brakes.

4) Check the inflation pressure of the tyres when cold.

Front tyre inflation pressure:

1,5 bars

Rear tyre inflation pressure:

2 bars

5) Check that the lights, the turn indicators, the horn and
the brake light are functioning correctly.

6) Check the functioning of the different indicator lights.

7) Carry out a road test.

20
4 CHASSIS
CONTENTS
FRONT COVERS 23
CENTRAL COVERS 23
SEAT 24
PILLION PASSENGER SEAT 25
REAR COWLING 25
GRILL 26
NUMBER PLATE 26
FUEL CAP 27
TANK COVERS 28
FUEL TANK 29
BATTERY SUPPORT 30
FRONT MUDGUARDS. 30
FRONT FOOTRESTS 31
REAR FOOTRESTS 31
CHAIN 32
CHAIN PROTECTOR 33
GEAR CHANGE PEDAL 33
FRONT WHEEL 34
FRONT BRAKE CALLIPER 35
FRONT BRAKE DISK 35
REAR WHEEL 36
REAR BRAKE CALLIPER 38
REAR BRAKE DISK 38
REAR BRAKE FLUID RESERVOIR 39
REAR BRAKE LEVER 39
REAR SPROCKET 40
PROP-STAND 40
FRONT BRAKE LEVER 41
FRONT BRAKE FLUID RESERVOIR 41
THROTTLE CONTROL 42
CLUTCH LEVER 42
COMMUTATOR 43
HANDLEBARS 43
INSTRUMENT PANEL 44
IGNITION SWITCH 44
EXHAUST PIPE 45
AIR FILTER 46
SHOCK ABSORBER 46
SWINGING ARM 47
FORKS 48
CARBURETTOR 50

21
 4 CHASSIS
Allen key FRONT COVERS

REMOVAL

• Unscrew the 3 Allen bolts (A) on each end of the cover.

• Remove the front cover

ASSEMBLY A

• To assemble, carry out the operations in reverse or-

der.

CAUTION
WHEN YOU REMOVE THE COVERS, LEAVE THEM
FACING UPWARDS TO AVOID DAMAGING THE PAINTWORK

Allen key CENTRAL COVERS

REMOVAL

• Remove the seat (see section). A

• Unscrew the 3 Allen bolts (A) on each end of the cover.

• Remove the central cover.

ASSEMBLY
A A
• To assemble, carry out the operations in reverse order.

23
 4 CHASSIS
SEAT

REMOVAL

• Insert the key in the lock and turn 90º to the left.

• Pull the seat upwards and backwards.

ASSEMBLY

• Fit the central tab (A) under the flange (B).

A
• At the same time, fit the two anchorages (C), located on
both sides of the seat, onto the chassis securing flanges.

• Lower the back of the seat.

• Turn the key 90º to the right and remove it.

24
 4 CHASSIS
Allen key PILLION PASSENGER SEAT
A
REMOVAL

• Remove the seat (see section).

• Unscrew the 4 Allen bolts (A).

• Remove the pillion passenger seat.

ASSEMBLY

• Fit the pillion passenger seat in its position.

• Screw on the 4 Allen bolts and 4 washers.
• Fit the seat (see section).

Allen key
REAR COWLING
A

REMOVAL

• Remove the seat (see section).

• Remove the pillion passenger seat (see section).

• Unscrew the 4 Allen bolts (A).

• Remove the cowling.
A

A A

ASSEMBLY

• To assemble, carry out the operations in reverse order.

CAUTION
WHEN YOU REMOVE THE COVERS, LEAVE THEM
FACING UPWARDS TO AVOID DAMAGING THE
PAINTWORK.

25
 4 CHASSIS
GRILL

REMOVAL

• Remove the front covers (see section).

• Remove the grill, by pulling upwards.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

Allen key NUMBER PLATE

REMOVAL

• Remove the seat (see section). A

• Remove the pillion passenger seat (see section).
• Remove the right and left-hand rear cowling (see section).
• Remove the turn indicators (see section).
• Remove the rear light (see section).

• Unscrew the 3 Allen bolts (A).

• Remove the number plate.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

26
 4 CHASSIS
Allen key FUEL CAP
A C

Llave Torck
REMOVAL

• Remove the cap (A).

• Unscrew the 5 Allen bolts (B).
• Remove the support orifice(C).
B
• Unscrew the 3 screws (D) from the cover.
• Remove the top tank cover (E).
• Remove the joining seal (F).
• Unscrew the 6 Allen bolts (G).

• Remove the tank filler hole.

• Remove the tank filler hole rubber seal.

D E
ASSEMBLY

• To assemble, carry out the operations in reverse order.

D

G F

27
 4 CHASSIS 4
Allen key TANK COVERS
A C
REMOVAL

• Remove the seat (see section).

• Remove the front covers (see section).

• Remove the cap (A).

• Unscrew the 5 Allen bolts (B).
• Remove the support orifice(C).
• Unscrew the 3 bolts (D) from the central cover.
• Remove the cover (E).
• Unscrew the 4 bolts (F) from the side cover.
• Remove the covers.
D E

ASSEMBLY

• To assemble, carry out the operations in reverse order.

CAUTION
WHEN YOU REMOVE THE COVERS, LEAVE THEM
FACING UPWARDS TO AVOID DAMAGING THE
PAINTWORK. F F
F

28
 4 CHASSIS
Phillips FUEL TANK
screwdriver

REMOVAL
A B D

• Remove the seat (see section).

• Remove the front covers (see section).
• Remove the fuel cap (see section).
• Remove the tank covers (see section).

• Disconnect the tap from the general wiring (A).

• Remove the pipe (B) from the tap.

C
• Remove the tank (C).
• Unscrew the clamp (D) and remove the tap.

N.B.
PLACE A CONTAINER UNDERNEATH TO DRAIN THE
FUEL TANK.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

29
 4 CHASSIS
Allen key BATTERY SUPPORT
A A A A
REMOVAL

• Remove the seat (see section).

• Remove the pillion passenger seat (see section).
• Remove the right and left-hand rear cowlings (see section).
• Remove the number plate (see section).
• Remove the battery (see section). A

• Unscrew the 7 bolts (A).

• Remove the support. A A

ASSEMBLY

• To assemble, carry out the operations in reverse order.

Allen key FRONT MUDGUARD

REMOVAL

• Unscrew the 4 bolts (A).

• Remove the front mudguard.

ASSEMBLY A

• To assemble, carry out the operations in reverse order.

CAUTION
WHEN YOU REMOVE THE COVERS, LEAVE THEM
FACING UPWARDS TO AVOID DAMAGING THEPAINT-
WORK

30
 4 CHASSIS
Allen key FRONT FOOTRESTS
B
REMOVAL

• Unscrew the nut (A).

• Remove the bolt Allen (B).
• Remove the footrests. A

ASSEMBLY

• To assemble, carry out the operations in reverse order.

Callipers
REAR FOOTRESTS

REMOVAL

• Remove the clip and the washer (A).

• Remove the key (B) and the washer.
• Remove the spring (C).
• Remove the footrest.

N.B.
REMEMBER THE POSITION OF THE SPRING FOR ITS
SUBSEQUENT REFITTING.
A

WARNING
SECURE THE SPRING WHEN REMOVING THE KEY.

B
ASSEMBLY
C
• To assemble, carry out the operations in reverse order.

31
 4 CHASSIS
Set spanner CHAIN

Allen key
REMOVAL

• Situate the securing clip de (A) where it can be seen.

• Remove the securing clip.
• Remove the chain, by pulling it out.

N.B.
THE MACHINE MUST BE ON A SUPPORT WITH THE
GEAR IN NEUTRAL.
A

ASSEMBLY

• Loosen the tensioner locking nut (A).

• Tighten the bolt (B) right to the end.
• Loosen the 2 shaft nuts (C).
• Push the wheel forwards.
• Remove the sprocket protector D).
• Fit the chain onto the front sprocket and the rear sprocket.
A
• Fit the securing clip.
• Adjust the tensioners.
• Fit the 2 wheel shaft nuts.
B C

N.B.
THE CHAIN SHOULD HAVE A LOOSE PLAY OF 30mm.

30mm

32
 4 CHASSIS
Allen key CHAIN PROTECTOR

REMOVAL

• Unscrew the 4 bolts (A).

• Remove the protector.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

A

Allen key GEAR CHANGE PEDAL

REMOVAL

• Unscrew the 2 bolts (A).

• Remove the gear change pedal.

ASSEMBLY
A A

• To assemble, carry out the operations in reverse order.

33
 4 CHASSIS
Set spanner FRONT WHEEL
E
Allen key
REMOVAL

• Remove the front mudguards (see section).

• Remove the (A) left-hand side wheel shaft nut (B) A
• Remove the mileometer take-off (C).
• Loosen the bolt (D) on the right-hand fork arm securing
the shaft (B).
• Extract the wheel (B) until the separator (E), the wheel C
and the separator (F) are freed.

WARNING
-PLACE THE MACHINE ON A FLAT SURFACE.
-STAND THE MACHINE ON A SUITABLE SUPPORT, IN
SUCH A WAY THAT THE FRONT WHEEL IS OFF THE
GROUND.

N.B.
PAY MAXIMUM ATTENTION TO THE POSITION OF F
THE SEPARATING BUSHES. DO NOT APPLY THE
BRAKE PEDAL DURING THIS OPERATION IF YOU DO
SO, YOU WILL NEED TO DRAIN THE BRAKE FLUID B D
AND OPEN THE PAD TO REINSERT THE BRAKE DISK
WHEN REFITTING THE WHEEL.

ASSEMBLY

• Insert the shaft (B) into the right-hand fork arm.

• Insert the separator (F) on the shaft.
• Fit the wheel and insert the shaft (B).
• Insert the separator (E).
• Insert the shaft (B) into the left-hand fork arm.
• Fit the mileometer take-off (C).
• Fit the nut (A) and tighten it.
• Fit the shaft with the bolt (D).
• Fit the front mudguards (see section).

34
 4 CHASSIS
Set spanner FRONT BRAKE CALLIPER

Allen key
REMOVAL

• Unscrew the banjo bolt (A) from the bottom end of the
brake hose.
A
• Drain the brake fluid.
• Unscrew the 2 bolts (A) and washers.
• Remove the calliper.

N.B.
PLACE A CONTAINER UNDERNEATH TO DRAIN THE B
FLUID.
.

ASSEMBLY

• Fit the calliper.

• Secure with the 2 bolts (B) and washers.
• Fit the banjo bolt (A).
• Refill the fluid reservoir (see section).

Allen key FRONT BRAKE DISK

REMOVAL

• Remove the front wheel (see section).

• Unscrew the 6 bolts (A).

• Remove the disk.

A
ASSEMBLY

• To assemble, carry out the operations in reverse order.

35
 4 CHASSIS
Set spanner REAR WHEEL

Allen key
REMOVAL

• Loosen the tensioner locking nut (A).

• Tighten the bolt (B) right down.
• Remove the 2 nuts (C) from the shaft.
• Remove the 2 tensioners (D).
• Push the wheel forwards.
• Remove the chain (E).
• Pull the shaft to free the brake calliper - support.
• Pull the shaft to free the separator, the wheel and the
other separator. C B A

E
WARNING
-PLACE THE MACHINE ON A FLAT SURFACE.
-STAND THE MACHINE ON A SUITABLE SUPPORT, IN
SUCH A WAY THAT THE REAR WHEEL IS OFF THE
GROUND.

N.B. D
PAY MAXIMUM ATTENTION TO THE POSITION OF
THESEPARATING BUSHES.
DO NOT APPLY THE BRAKE PEDAL DURING THIS
OPERATION. IF YOU DO SO, YOU WILL NEED TO
DRAIN THE BRAKE FLUID AND OPEN THE PADS TO
REINSERT THE BRAKE DISK WHEN REFITTING THE
WHEEL.

36
 4 CHASSIS
Set spanner REAR WHEEL

Allen key
ASSEMBLY
B
N.B.
FIT THE TENSIONERS IN THEIR CORRECT POSITION.

• Fit the tensioner (A) on the swinging arm.

• Insert the shaft in the tensioner.
• Fit the brake calliper - support.
• Fit the separator.
• Fit the wheel.
• Insert the shaft through to the other side of the wheel.

• Fit the chain (B) on the sprocket.

• Fit the other separator.
• Insert the shaft through to the other side of the swin-
ging arm.
• Fit the tensioner.
• Tighten the chain tension (see section).
• Fit the 2 wheel shaft nuts (C).

37
 4 CHASSIS
Set spanner REAR BRAKE CALLIPER

Allen key
REMOVAL

• Unscrew the banjo bolt (A) from the bottom end of the
brake hose.
• Drain the brake fluid.
• Remove the rear wheel (see section). B

• Unscrew the 2 bolts (B) securing the support.

• Remove the calliper.

A
N.B.
PLACE A CONTAINER UNDERNEATH TO DRAIN
THE FLUID.
B

ASSEMBLY

• Fit the banjo bolt (A).

• Fit the calliper on the support.
• Fit the calliper - support on the swinging arm, using the
bolts (B).
• Fit the rear wheel (see section).
• Refill the fluid reservoir (see section).

Set spanner REAR BRAKE DISK

REMOVAL

• Remove the front wheel (see section).

• Unscrew the 6 bolts (A).

• Remove the disk.

ASSEMBLY
A

• To assemble, carry out the operations in reverse order.

38
 4 CHASSIS
Phillips REAR BRAKE FLUID RESERVOIR
screwdriver

Allen key C
REMOVAL

• Open the reservoir cover (A).

• Drain the fluid.
• Unscrew the banjo bolt (C).

• Unscrew the 2 bolts (B). A

• Remove the reservoir.

B
N.B.
PLACE A CONTAINER UNDERNEATH TO DRAIN THE
FLUID.

ASSEMBLY

• Refill the fluid reservoir (see section).

• Fit the fluid reservoir with the 2 bolts (B)

• Fit the banjo bolt (C).

Set spanner REAR BRAKE LEVER

A
Allen key REMOVAL

• Remove the 2 bolts (A) securing the fluid reservoir to

the support.
• Remove the bolt and the nut (B).
• Remove the spring (C).
• Unscrew the bolt (D) and the nut (E) securing the lever
to the support and remove it.
B

C
N.B.
TO REMOVE THE BRAKE LEVER, REMOVE THE CEN-
TRAL, EXHAUST PIPE NUT.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

E D

39
 4 CHASSIS
Set spanner REAR SPROCKET

REMOVAL

• Remove the rear wheel (see section).

• Unscrew the 5 bolts (A).

• Remove the rear sprocket.

A
ASSEMBLY

• To assemble, carry out the operations in reverse order.

Set spanner PROP-STAND

REMOVAL

• Remove the spring (A).

• Unscrew the bolt (B) securing the nut (C) on the inside.

• Remove the prop-stand.

B
ASSEMBLY

• To assemble, carry out the operations in reverse order.

40
 4 CHASSIS
Allen key FRONT BRAKE LEVER

REMOVAL

• Unscrew the bolt (A) and the securing nut.

• Remove the lever.

ASSEMBLY

• To assemble, carry out the operations in reverse order. A

Allen key FRONT BRAKE FLUID RESERVOIR

• Remove the rear-view mirror (A).

• Unscrew the brake cable (B).
• Remove the rear brake switch (C).
• Remove the lever (see section).
• Unscrew the banjo bolt (D).
• Drain the brake fluid.
• Unscrew the 2 Allen bolts (E) from the clamp.
• Remove the brake reservoir

C B

A
N.B.
PLACE A CONTAINER UNDERNEATH TO DRAIN THE
FLUID

ASSEMBLY D

• To assemble, carry out the operations in reverse order.

• Refill the fluid reservoir (see section). E

41
 4 CHASSIS
Allen key THROTTLE CONTROL

A B
REMOVAL

• Remove the protective rubber (A).

• Loosen the throttle cable tensioner (B).
• Remove the cover (C).
• Disconnect the cable (D).
• Unscrew the 2 Allen bolts (E) from the clamp.
• Remove the throttle control.

H F

G
ASSEMBLY

• Fit the cable terminal (F).

C
• Fit the cable through the cover guide (G).
• Fit the cable through the tensioner cut-out (H).

Screwdriver CLUTCH LEVER

D
REMOVAL

• Remove the rubber (A).

• Loosen the cable tensioner (B).
• Remove the cable (C).
• Unscrew the bolt and the nut (D) from the securing A
bracket.
• Remove the lever.

B C
ASSEMBLY

• To assemble, carry out the operations in reverse order.

42
 4 CHASSIS
Allen key COMMUTATOR
A
REMOVAL

• emove the rear-view mirror (A).

• Remove the choke cable (B).
• Remove the clutch lever (see section).
• Unscrew the 2 bolts (C).

• Remove the commutator.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

Phillips
screwdriver
HANDLEBARS

Allen key
REMOVAL

• Remove the front brake reservoir (see section).

• Remove the commutator (see section).
• Remove the electric start button (A).

• Unscrew the 4 securing clamp bolts (B).

• Remove the handlebars.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

43
 4 CHASSIS
Phillips INSTRUMENT PANEL
screwdriver
A
REMOVAL

• Disconnect from the general wiring (A).

• Unscrew the 3 support bracket bolts (B).
• Remove the instrument panel.

ASSEMBLY
B
• To assemble, carry out the operations in reverse order.

Allen key IGNITION SWITCH

REMOVAL

• Disconnect from the general wiring (A).

foto cableado general
N.B.
TO AID THE OPERATION, REMOVE THE TANK.

• Unscrew the 2 headlight housing bolts (B).

• Remove the headlight housing. A
• Unscrew the 2 bolts (C).
• Remove the switch.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

44
 4 CHASSIS
Set spanner EXHAUST PIPE

Allen key
REMOVAL

• Unscrew the 2 bolts (A).

• Remove the central nut (B) located at the bottom of
the engine.
• Remove the pipe and the gasket.

WARNING A
CHECK THAT THE EXHAUST PIPE IS COLD.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

B

45
 4 CHASSIS
Phillips AIR FILTER
screwdriver

REMOVAL

• Remove the seat (see section).

• Remove the 6 bolts (A) securing the filter cover.
• Remove the cover (B) by pulling upwards.
• Remove the filter (C) by pulling upwards.

• Check that the filter is soaked in oil.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

Set spanner SHOCK ABSORBER

REMOVAL
Allen key

• Remove the seat (see section).

• Remove the tank (see section).
• Remove the 2 bolts and the 2 securing nuts (A).
• Remove the shock absorber.

N.B
REMEMBER THE POSITION OF THE SHOCK ABSOR-
BER FOR SUBSEQUENT REFITTING.
A

ASSEMBLY

• To assemble, carry out the operations in reverse order.

46
 4 CHASSIS
Set spanner SWINGING ARM

REMOVAL

• Remove the chain protector (see section).

• Remove the chain (see section).
• Remove the rear wheel (see section).
• Remove the shock absorber (the bottom part) (see
section).
• Remove the rear brake cable clamp located at the
bottom of the swinging arm.
• Remove the trim (B).
• Remove chain roller.
A B

• Unscrew the nut (A) on both sides.

• Remove the swinging arm shaft.
• Remove the swinging arm.

CAUTION
-PLACE THE MACHINE ON A FLAT SURFACE.
-STAND THE MACHINE ON A SUITABLE SUPPORT, IN
SUCH A WAY THAT THE REAR WHEEL IS OFF THE
GROUND.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

47
 4 CHASSIS
Allen key FORKS
A

REMOVAL

• Remove the handlebars (see section).

• Remove the front wheel (see section).
• Remove the headlight (see section).
• Remove the instrument panel (see section).
• Remove the ignition switch (see section).

• Remove the front mudguards (see section).

• Remove the mudguard brackets (A).
• Remove the nut and washer (B).
• Loosen the 2 bolts (C) from the top plate.
• Remove the fork tubes from the bottom.
• Remove the top plate

CAUTION
-PLACE THE MACHINE ON A FLAT SURFACE.
-STAND THE MACHINE ON A SUITABLE SUPPORT,
IN SUCH A WAY THAT THE FRONT WHEEL IS OFF
THE GROUND.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

48
4 CHASSIS

• Unscrew the plug (A).

• Remove the O-ring (B), the spacer (C) and the spring (D).

• Drain the hydraulic fluid into a container.

• Unscrew the bolt (E) and the seal (F).

• Remove the dust guard (G), the locking ring (H),

the airtight seal (I) and the ring (J).
J
I
H
• Hydraulic fluid:
TYPE: SAE 15 G

49
 4 CHASSIS
Set spanner CARBURETTOR
A

REMOVAL

• Remove the seat (see section).

• Remove the fuel tank (see section).

• Disconnect the carburettor air intake (A).

• Disconnect the throttle cable (B).
• Disconnect the fuel intake (C).
• Disconnect the choke cable (D).
• Disconnect the gas outlet pipe (E).
• Disconnect the inlet manifold (F). F C
• Disconnect the cables (G).

• Remove the carburettor. B

ASSEMBLY

• To assemble, carry out the operations in reverse order.

D

50
5 ELECTRICAL SYSTEM
CONTENTS
FRONT HEADLIGHT – MAIN BEAM/DIPPED BEAM BULB 53 5
FRONT HEADLIGHT - SIDELIGHT 54

REAR LIGHT 55

FRONT AND REAR TURN INDICATORS 56

NUMBER PLATE LIGHT 57

RELAY 58

E.C.U. 58

COIL 59

REGULATOR 59

FUSE 59

BATTERY 60

INSTRUMENT PANEL 61

51
 5 ELECTRICAL SYSTEM
Allen key FRONT HEADLIGHT
MAIN BEAM/DIPPED BEAM BULB

• Remove the two bolts (A), one on each side, securing

the headlight housing (B).

• Tilt the headlight housing (B) downwards to be able to

access the headlight.

A B

• Loosen the two bolts (C), one on each side, securing

the headlight to the chassis.

• Tilt the headlight (D) forwards to make working easier.

E F
• Remove the bulb connector (E).

• Then remove the dust guard (F) covering the bulb.

H
To remove the bulb:

• Press the securing clips (G).

• Remove the bulb (H).

G

ASSEMBLY

• To assemble, carry out the operations in reverse order.

53
 5 ELECTRICAL SYSTEM
Allen key FRONT HEADLIGHT - SIDELIGHT

• Remove the front headlight main beam/dipped beam

bulb (see section).

• Loosen the two bolts (A) securing the headlight.

• Tilt the headlight (B) forwards. A

C
• Pull down the headlight housing (C) to extract the hea-
D
dlight.

• Then pull out the bulb (D) while holding the headlight
housing with the other hand.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

WARNING
KEEP THE SWITCH DISCONNECTED DURING THIS
OPERATION.

CAUTION
FOLLOW THE MANUFACTURER’S RECOMMENDA-
TIONS FOR FITTING THE BULB.

54
 5 ELECTRICAL SYSTEM
Set spanner REAR LIGHT

REMOVAL

To replace the rear light, these operations must be ca-

rried out by way of the step for the rear wheel:

• Disconnect the light from the wiring (A).

• Hold the light with one hand.

• Remove the two nuts (B) securing the light to the num-
ber plate bracket.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

55
 5 ELECTRICAL SYSTEM
Phillips FRONT AND REAR TURN INDICATOR
screwdriver
LIGHTS
A

REMOVAL

• Loosen the bolt (A) holding the screen.

• Remove the screen (B).

• Turn the bulb (C) to the left and remove it.

ASSEMBLY

• To assemble, carry out the operations in reverse order. C

WARNING
KEEP THE SWITCH DISCONNECTED DURING THIS OPE-
RATION.

56
 5 ELECTRICAL SYSTEM
Allen key NUMBER PLATE LIGHT

REMOVAL

• Remove the bolt (A) holding the screen.

• Then pull out the bulb (B) while holding the bulb holder
(C) with the other hand.

ASSEMBLY

• To assemble, carry out the operations in reverse order.

B C

57
 5 ELECTRICAL SYSTEM
RELAY
A

REMOVAL

• Remove the seat (see section).

• Disconnect the relay (A).

ASSEMBLY

• To assemble, carry out the operations in reverse order.

E.C.U.

A
REMOVAL

• Remove the seat (see section).

• Remove the fuel tank (see section).

• Disconnect the ECU (A).

ASSEMBLY

• To assemble, carry out the operations in reverse order.

58
5 ELECTRICAL SYSTEM
COIL

REMOVAL

• Remove the seat (see section).

• Remove the fuel tank (see section). B

• Remove the 2 bolts (A).

• Remove the coil (B).

ASSEMBLY

• To assemble, carry out the operations in reverse order. A

REGULATOR

B A
REMOVAL

• Remove the seat (see section).

• Remove the fuel tank (see section).

• Remove the 2 bolts (A).

• Remove the regulator (B).

ASSEMBLY

• To assemble, carry out the operations in reverse order.

FUSE
REMOVAL

• Remove the seat (see section).

• Remove the pillion passenger seat (see section).
• Remove the rear right-hand cowling (see section).
• Remove the right-hand central cover (see section).

• Disconnect and remove the fuse.

ASSEMBLY

• To assemble, carry out the operations in reverse order. A

59
 5 ELECTRICAL SYSTEM
BATTERY

REMOVAL A
5
B

• Remove the seat (see section).

• Disconnect the two connecting cables. Negative (A)

Positive (B).

ASSEMBLY

• To assemble, carry out the operations in reverse order.

WARNING
TO FIT A NEW BATTERY, REVIEW THE SECTION
“PREPARING THE BATTERY” ON PAGE 19.

WARNING
TAKE THE BATTERY TO YOUR DEALER, SO THAT
THEY CAN RECYCLE IT.

CAUTION
IF YOU RENEW THE BATTERY, ENSURE THAT THE
NEW ONE DOES NOT EXCEED 12V AND 6AH.

60
5 ELECTRICAL SYSTEM
DASHBOARD CONFIGURATION OR
5 ADJUSTMENT
• The instrument panel has two adjustment buttons:

SET(1) button and MODE(2) button.

• Aim of the buttons is:

Allow functions scrolling.

Regulation of the clock.

Set to zero the TD, AVE , LAP and MAX values.

Entering the Set-up menu to modify the wheel cir-

cumference value, the measurement unit value of dis-
tance, the number of impulses for every turn of the
wheel and of the engine, and finally to associate the
graphic bar to the selected information.

The function scrolling is always possible (it means the

passage from one function to the following one) with the
vehicle stopped or not. To update the instrumentation
with the new function, it’s enough briefly pushing the bu-
tton (tmin = 1 sec.), when it will be left the display will
show the new function.
The setting to zero of TD, of the chronometer, of the
average and max. speed can be done both with the vehi-
cle stopped or in movement as described in the previous
paragraphs. Clock regulation is possible only when vehicle
is stopped.

The entering in the Set-up menu is possible only when the

vehicle is stopped by pushing at the same time the two
buttons for about 4 seconds; the back-up of all data will
be done only when the Mode and Set buttons (it depends
on selected set up chosen) will allow the exit from the
Set-up menu.

61
 5 ELECTRICAL SYSTEM
ATTENTION
BEFORE GOING ON PLEASE CAREFULLY READ ELEC-
TRICAL FEATURES AT
PARAGRAPH 14
VERIFYING THE FUNCTIONAL VOLTAGES FOR OPERA-
TION OF THE SPEEDOMETER

1. AIM
This document constitutes the technical manual with
functional specifications for MHRN speedometer.

2. REFERENCES
M.A.E. electronic devices’ general contract.

3. SYSTEM GENERAL DESCRIPTION

Rpm pointer and lights Display

LCD driver

Stepper motor

E2PROM
Microcontroller

SET button
Connector
MODE button

Vehicle feeding

62
5 ELECTRICAL SYSTEM
4. COMPONENTS DEFINITION

5 4.1. LCD Display

4.2. Mode and Set buttons

Picture 4-1: lcd display
The device has got two buttons normally OPEN that close
on a NEGATIVE.
Button 1: MODE
Button 2: SET
Functions and use of buttons is described in following pa-
ragraphs of the technical manual.

5. FUNCTIONAL CHARACTERISTICS

5.1. Instant speed function

The information is always visualized on digits 5÷7, see

picture 5-1.

If measurement unit is km/h (default value) the

corresponding digit is visualized; if You push the button
and entering the Set-Up it is possible to select mph unit of
measurement (pic.5-2). Picture 5-1: Speed indication Km/h

The system has got following parameters:

Wheel Circ. [mm] Pulses / lap Max speed Overspeed Resolution

Selected by end user Selected by end user 200 km/h 6% constant all 1 km/h
Min. 1.000 - Max 2.500 Min. 1 - Max 12 (124 mph) over the scale (1 mph)

5.2. Totalizer function (TOTAL)

The information is visualized on digit 8÷12 and accompa-

nied by TOTAL logo, as shown in pic 5-3.

The data is permanently memorized in a non volatile me-

mory (E2prom refresh every km).

If the memory is empty You’ll see numbers 00000

visualised. Picture 5-2: Speed indication mph

This information is always calculated in km. Anyway it

must be expressed in km or mph. You can select the
chosen information by entering the Set-Up menu.

During normal using of the instrumentation it is not

possible to set the information to zero.

Picture 5-3: Total covered distance

63
 5 ELECTRICAL SYSTEM
5.3. Trip function (TD)

This function describes the correct working/visualiza-

tion of the board automatic partial totalizer.
This function is always represented on digit 13÷16
and by logo TD (pic.5-4).

The visualized data represents the vehicle covered

distance expressed in miles or km (depending on
the selected measurement unit), with resolution 0.1 Picture 5-4: Partial covered distance
(miles or km).

This counter is automatic: in fact it automatically

starts with the first pulse arriving from speed sensor.

The data isn’t memorized in a permanent mode.

It is possible setting the counter of this parameter to zero
by pushing the Set button for about 03 sec. (in correspon-
dence of the TD function) till the value 000.0 appears.

It is possible setting to zero the TD function both when the

vehicle is stopped and when it is running, this causes also
the setting to zero of LAP and AVE functions.

If the data gets over 999.9 the system automatically sets

to zero TD, LAP and AVE functions and then starts again
the counting.

Obs.5-1: So: If there is no feeding the TD value is

hopeless lost.

5.4. Time Function (TIME)

This function describes the correct working/visualization

of the current hour. This function is always shown in the
format hh:mm, by using digit 1÷4 (pic.5-5).
Clock is active also when the microcontroller is in sleep
mode phase and regulation of the hour can be done only
when the vehicle is stopped.

This information is not saved in the memory.

Visualized Series:
from 0:00 to 23:59 for method 0-24
from 0:00 to 12:59 for method 0-12 am
from 1:00 to 11:59 for method 0-12 pm

Clock precision: ±2.5 sec/day

Obs. 5-2: If there is no feeding the TIME value is ho-

peless lost.

Picture 5-5: clock

64
5 ELECTRICAL SYSTEM
Clock regulation can be done by pushing Mode button
until when only segments related to TIME function are
active (about 5sec.), while all the others are off (see
picture 5-6).

It’s possible to modify in series: first the hours then the

minutes, this depends by the selected data (that will be
shown blinking with f=1Hz, Duty=50%).

By pushing the Set button the selected parameter Picture 5-6: clock regulation
will add one unit, while by pushing the Mode button it will
be possible to select the chosen parameter (minutes or
hours) and to exit from regulation phase.

Time parameter will be shown in 0-24 format if unit of

measurement chosen is km/h, while it will be shown in
0-12 format if unit of measurement is mph.
In this case on the display You will see on 5 and
6 digits the logo “AM” or “PM” during regulation
phase, see picture 5-7.

Obs. 5-3: Entered the regulation menu, if no bu-

ttons have been pushed, the system will automa-
tically return to standard method of operation (saving
possible modifications). Picture 5-7: clock regulation
format 0-12
Obs. 5-4: Entered the regulation menu, if the
vehicle starts (speed>0), the system will au-
tomatically return to standard method of operation
(saving possible modifications).

65
 5 ELECTRICAL SYSTEM
5.5. Automatic Chronometer Function (LAP)

This function describes the correct working/visualization

of the chronometer related to TD and AVE.
5
This information is visualized by using digit 13÷16
and logo LAP.

The data represents the effective route time of the vehi-

cle in the form mm:ss if hours = 0 (pic.5-8) and in the
form hh:mm if hours > 0 (pic.5-9).

It is automatically activated by the first pulse coming

from the speed sensor and it stops after 3 seconds Picture 5-8: lap in format mm:ss
from receiving of the last pulse which arrives from the
speed sensor.

If hours >0, when LAP is operative, the digit that

separates the hours from the minutes is shown
blinking, while it is shown fixed when LAP is not opera-
tive

If hours = 0, when LAP is operative, the digit

(‘ and “) that separates the minutes from the se-
conds is shown blinking, while it is shown fixed when LAP
is not operative.

The data isn’t memorized in a permanent mode.

It is possible to set to zero the counter of this parame- Picture 5-9: lap in format hh:mm
ter by pushing the Set button for about 2 seconds, in
correspondence of the function LAP till when the value
00’00’’appears.

The setting to zero of LAP, which is possible both

when the vehicle is stopped or when the vehicle is
running, produces the setting to zero of TD and AVE too.

If the data gets over the value 23-59 (which means

23h59’59”), the system provides to set to zero LAP, TD
and AVE, then it starts again the counting.

Obs. 5-5: If there is no feeding the LAP value is

hopeless lost.

5.6. Average speed function (AVE)

This function describes the correct working/visualization

of average speed function related to TD and LAP.
The information is visualized by using digit 13÷16 and
logo AVE (pic.5-10).
The data represents the average speed of the vehicle
(expressed in Km/h or in Mph depending on the selec-
ted measurement unit) that is calculated as ratio bet-
ween covered distance (TD) and the time used to cover
this distance (LAP).

The average speed is updated every 0,1 Km (or

0,1 Miles, depending by measurement unit
selected).

66
5 ELECTRICAL SYSTEM
The data isn’t memorized in a permanent mode.

5 It’s possible to set to zero the counter of this

parameter pushing the Set button for about 2 se-
conds, in correspondence of the function AVE, till when
the value 0.0 appears.

The setting to zero of AVE, which is possible both

when the vehicle is stopped or when the vehicle is run-
ning produces the setting to zero of TD and LAP too. Picture 5-10: Average speed indi-
cation
AVE setting to zero is foreseen when LAP function
arrives to 23:59:59 value or when TD function rises
999.9 value.

If the data is out of range , it will be visualized - - - -, as

shown in picture 5-11

Obs. 5-6: If there is no feeding the AVE value is ho-

peless lost.
Picture 5-11: average speed out of
5.7. Max. speed function (MAX) range

This function describes the correct working/visualization

of maximum speed function.
The information is visualized by using digit 14 16 and
logo MAX (pic.5-11).

The parameter identifies the maximum speed achieved

by the vehicle, expressed in km/h or mph depen-
ding on the selected unit of measurement.

It’s possible to set to zero the counter related to

this parameter, in correspondence of MAX func-
tion, by pushing Set button till value 00 appears. Picture 5-11: Maximum Speed

The setting to zero of MAX function is possible both

when the vehicle is running or stopped.

Changing measurement unit, will cause conversion of

MAX value.

The data isn’t memorized in a permanent mode.

Obs. 5-7: If there is no feeding the MAX value is

hopeless lost.

67
 5 ELECTRICAL SYSTEM
5.8. Battery charge level function

The information is visualized on the bottom left part by

using the graphic bar, accompanied by
5
the battery symbol ignition, as shown in picture 5-12.

The graphic bar, updated every 0,5 seconds, is mana-

ged by the following table:

Picture 5-12: battery level

Voltage [V] Active segments
Till 9,49V 1
From 9,50V to 9,99V 2
From 10,00V to 10,49V 3
From 10,50V to 10,99V 4
From 11,00V to 11,49V 5
From 11,50V to 11,99V 6
From 12,00V to 12,49V 7
Over 12,50V 8

5.9. RPM

The value of rpm is shown by the analogic quadrant.

Overboost: between 10.000 and 12.000 rpm.
The number of rpm pulses are settable between 1 and 8.

6. ALARMS MANAGEMENT

6.1. Battery voltage alarm

Every time that found out voltage value goes down

9,5V, the system starts alarm routine to signal the
possibility that after switching ON of the vehicle, the
speedometer can loose its settled data.

The signal is the graphic bar visualization (regardless Picture 6-1: battery voltage alarm
the current function), by blinking the first segment of
the bar and battery symbol as shown in picture 6-1.

This indication does not change the operation of the

speedometer, that normally continues its activity with
the only difference that when there is this alarm the
previous logo is shown.

When the voltage goes over 9,5V the alarm status turn off.

68
5 ELECTRICAL SYSTEM
6.2. Fuel Level Alarm

Every time that fuel level sensor closes on earth, the

icon is visualized on the display
(fuel reserve symbol) as shown in picture 6-2.

At the same time the microcontroller will turn on

the related light on the dial (see paragraph 7.4).

The icon disappears and the light turned on when

the sensor opens again the contact.

7. BACKLIGHT AND INDICATORS LIGHTS FUNCTION

7.1. High Beam light

The system has to switch on the led when the input

No.12 of the connector is high, at the same time of
High Beam ignition. Picture 6-2: Fuel level alarm

7.2. Indicators lights function

The system has to switch on the led when the inputs

No.2 or No.13 of the connector are high, at the same
time of Indicators lights ignition.

N.B.
SIGNAL MUST ARRIVE TO THE DEVICE ALREADY
ALTERNATE.

7.3. Neutral light function

The system has to switch on the led when the input No.6
of the connector is low, at the same
time of placing of gear lever in neutral position.

7.4. Fuel light function

The system has to switch on the led when the input

No.15 of the connector is low, at the same time of mi-
nimum level of fuel tank.

7.5. Backlighting and dial lights function

LCD and dial backlight is orange and is always ON when

the key is turned on.

69
 5 ELECTRICAL SYSTEM
8. SET-UP MENU

The entry in the set-up menu is only possible when the

vehicle is stopped by pushing at the same time the
Mode and the Set button for about 04 seconds
regardless the visualized function.

On the display the “SET Par” logo will appear fixed (as
in the picture 8-1) for the entry in the set-up menu of
parameters. Picture 8-1: parameters set-up
menu

Obs.8-1: If the input #5 (settings) on the connector

is connected to ground, it is possible to change every
parameter.
If the input #5 (settings) on the connector is not con-
nected to ground (default condition), it is only possi-
ble to change measurement unit.

8.1. Parameters SET-UP menu

This menu allows to modify the following parameters:

• Wheel circumference (min 1.000mm max 2.500mm) (factory)

• Number of pulses for every turn of the wheel (min 1 max 12) (factory)
• Number of pulses for every turn of the engine (min 1 max 8) (factory)
• Measurement unit of distance (km/h or mph) (factory + user)

To save the modifications in the memory, it is necessary

that the set-up procedure is completed using the Mode
button by keeping pressed the Mode button in corres-
pondence of the measurement unit selected.

When the dashboard is in the set-up menu, if :

• Velocity becames >0

• The button is not pushed for 20 seconds.
The dashboard will exit from setup menu without saving
any changes and will restore the previous
values.

Only in the case in which the procedure of Set-Up is

completed in a correct way, the system goes
on with the saving in permanent memory of all the
made selections.

70
5 ELECTRICAL SYSTEM
8.2. Modifications allowed to user (input #5 discon-
nected)

8.2.1. Distance unit measurement regulation

The display the symbols km/h and mph will be shown

and the selected value will be shown first blinking (f=1Hz,
Duty=50%) (picture 8-2).

Pressure on Set button causes the change in shown

blinking unit, while the Mode button pressure, in corres-
pondence of blinking unit, allows to select the same
unit and the passage to following screen (or going out
from regulation, depending on #5 input). Picture 8-2:distance unit misure
regulation

The information concerning the selected measurement

unit is saved in memory.

Obs. 8-1: Changing measurement unit will cause the

conversion of TOTAL and will set to 000.0 TD.

Obs. 8-2: Once inside the regulation menu:

• If 20 sec. will pass without the button mode is pushed, or

• If the vehicle is turned on (speed>0), or
• If the key is turned OFF
The system will be automatically taken to the sta-
dard operating mode and the modifications possibly
produced will be lost.

8.3. Modifications allowed to the factory (input #5

connected to gnd)

8.3.1. Wheel circumference modification

The display is introduced as shown in picture

Picture 8-3: wheel circumference
8-3, where the information of wheel circumference
regulation
is visualized on digit 13÷16, preceded by the letter “crf”
on digit 10÷12.

It’s possible modifying the various digits which

constitute the value of the wheel circumference,
leaving from the most significant digit and moving in
series towards the least significant digit.

Starting from the selected data (that will be shown blin-

king with f = 1 Hz, Duty = 50%), a short pressure
of the Set button will allow an unitary increase,
while a long pressure of Mode button will allow to
select a different digit.

The selected circumference of the wheel is saved in me-

mory.

71
 5 ELECTRICAL SYSTEM
Obs. 8-3: Regulation: from 1.000mm to 2.500mm
with step of 1mm. Setting a value over 2.500mm,
will cause the circumference set to default value
(1.845mm)

Obs. 8-4: Once inside the regulation menu:

• If 20 sec. will pass without the button mode is pushed, or

• If the vehicle is turned on (speed>0), or
• If the key is turned OFF
The system will be automatically taken to the stan-
dard operating mode and the modifications possibly pro-
duced will be lost.

8.3.2. Modification wheel revolution impulses

This parameter expresses the number of impulses

that the speed sensor sends to the instrumentation
for every wheel revolution.

The selected value is shown blinking as in picture

8-4 (f=1Hz, Duty=50%).

Pressure of Set button allows the unit increase im-

pulses, from a minimum of 1 to a maximum of 12. Picture 8-4: wheel turns
regulation
Pressure of Mode button allows the value confir-
mation and the passage to the following screen.

The information concerning the number of im-

pulses which the instrumentation receives from the
speed sensor is saved in memory.

Obs. 8-5: Impulses can also NOT have the same dis-
tance.

Obs. 8-6: Once inside the regulation menu:

• If 20 sec. will pass without the button mode is pushed, or

• If the vehicle is turned on (speed>0), or
• If the key is turned OFF
The system will be automatically taken to the stan-
dard operating mode and the modifications possibly
produced will be lost

8.3.3. Modification engine revolution impulses

This parameter expresses the number of impul-

ses that the vehicle sends to the instrumentation
for every engine tree revolution.

The chosen value is shown blinking (with f=1Hz,

Duty=50%).

Visualization on the display, picture 8-5, has

“RPM” on digit 10÷12. Picture 8-5: engine turns regulation

Pressure of Set button allows the unit increase of

engine turns impulses, from a minimum of 1 to
a maximum of 8.

Pressure of Mode button allows the value confirmation

and the exit from Set-up menu.

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5 ELECTRICAL SYSTEM
The information concerning the number of impulses of
the engine is saved in memory.

Obs. 8-7: Once inside the regulation menu:

• If 20 sec. will pass without the button mode is pushed, or

• If the vehicle is turned on (speed>0), or
• if the key is turned OFF
The system will be automatically taken to the standard
operating mode and the modifications
possibly produced will be lost

8.3.4 Distance unit measurement regulation

See paragraph 8.2.1

8.4. Regulations sequence

Input #11 disconnected MEASUREMENT

UNIT

WHEEL ENGINE
Input #11 connected to GND WHEEL MEASUREMENT
REVOLUTION REVOLUTION
CIRCUMFERENCE UNIT
PULSES PULSES

73
 5 ELECTRICAL SYSTEM
9. MODE AND SET BUTTONS FUNCTION

Aim of the buttons is:

• Allow functions scrolling

• Regulation of the clock
• Set to zero the TD, AVE , LAP and MAX values.
• Entering the Set-up menu to modify the wheel circumfe-
rence value, the measurement unit value of distance,
the number of impulses for every turn of the wheel and
of the engine, and finally to associate the graphic bar to
the selected information.

The function scrolling is always possible (it means

the passage from one function to the following
one) with the vehicle stopped or not. To update
the instrumentation with the new function, it’s enough
briefly pushing the button (tmin = 1 sec.), when it will be
left the display will show the new function.
The setting to zero of TD, of the chronometer, of the
average and max. speed can be done both with the vehi-
cle stopped or in movement as described in the previous
paragraphs.
Clock regulation is possible only when vehicle is stop-
ped.

The entering in the Set-up menu is possible only when

the vehicle is stopped by pushing at the same time the
two buttons for about 4 seconds; the back-up of all data
will be done only when the Mode and Set buttons (it
depends on selected set up chosen) will allow the
exit from the Set-up menu..

Key Mode Set Speed Function allowed

OFF - - - Buttons inhibited
ON ON OFF >0 Scrolling
ON OFF ON >0 Set to zero of selected function
ON ON ON 0 All functions are allowed

9.1. Sequence of represented functions

The function scrolling is always possible, with the vehicle

stopped or not, by using the Mode button as follows:

Mode Button
TD LAP AVE MAX

TD Partial covered distance

LAP Time on turn
AVE Average speed
MAX Max speed

74
5 ELECTRICAL SYSTEM
10. START-UP

At the start-up (key from OFF to ON), the system gives to

the user some information which
are shown in following screens (or pages):

• First page: visualization of the release date and

software’s version (for about 2 seconds).
This information is shown only during the first ins-
tallation of the instrumentation (picture 10-1).

• Second page: display check. All the display segments

are ON for about 2 seconds (picture 10-2).

• Third page: visualization of the wheel circumference,

of the measurement unit selected for the distance, of
the impulses’ number for every turn of the wheel
and of the engine, visualization of symbols associated
to graphic bars (picture 10-3).

• In correspondence of screens over described, the

system start the lights’ check backlighting check: all
lights’ led are active and at display check end they are
off. After all the check, the system will show the normal
visualization.

Sw version release

Sw week release Sw year release

Picture 10-1: first page

Picture 10-2: second page

75
 5 ELECTRICAL SYSTEM

Engine turn impulses

Selected wheel
circumference Distance
measurement unit

Wheel turn impulses

Graphic bar information

Picture 10-3: third page

Obs. 10-1: If during the Start up phase the vehicle

starts (speed>0), the instrumentation will interrupt the
check and will return to the standard operation mode.

Obs. 10-2: If during the Start up phase the key will

be turned off, the instrumentation will interrupt the
check and will return to sleep mode.

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5 ELECTRICAL SYSTEM
11. SLEEP-MODE AND WAKE-UP

11.1. Sleep mode

The microcontroller enters the sleep-mode phase, with

low current absorption, when the key is turned off.

To reach this aim, during sleep mode phase, every activi-

ty will be interrupted, the display and its backlighting will
be off, only the update of current hour is on Sleep-mode
phase can always be reached, regardless from selected
function.

11.2. Wake-Up

Awakening from Sleep mode phase occurs when the key

is turned ON.

Immediately after the microcontroller awakening follo-

wing activities happen:

• Check of the display and of lights for about 2 seconds.

• Visualization of selected wheel circumference, of
wheel turns impulses, of unit of measurement and
of graphic bars for about 2 seconds (see picture 10-3).
• Starting of last visualized function before sleep mode
status and qualification of all functions.

12. FIRST INSTALLATION OF DEVICE

Default values of the device:

• Circumference: 1.845mm
• Measurement unit of distance: km/h for speed and
km for distance
• Turn wheel/impulses: 6
• Turn engine/impulses: 4

To modify one of these parameters You have to

follow the procedure as in Set-up menu paragraph.
During first installation of device the display always
shows the updated software version and date.

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 5 ELECTRICAL SYSTEM
13. TEST MENU

ATTENTION
USING OF TEST PROCEDURE NEEDS ONLY QUALI-
FIED STAFF.
TO AVOID EVERY KIND OF DRAWBACKS OR BAD
FUNCTIONING PLEASE

DO NOT USE
Foreseen menu function and do not disclose the content
of this chapter to final end user.

Entry in test menu is allowed only during installation

phase of device on the vehicle, by placing at earth the
test wire #5 (usually without cable) and keeping pushed
Mode and Set button together.
In these conditions the system will place itself on
Test menu and following operations will be possible:

• Operator check of the device (COLL_MAN)

• Check of the device by using an automatic and optical
test system (television camera COLL_AUTO)
• Erasing of the E2prom (E2PROM)
• Calibrating pointer position on the dial (IND)

To well operate inside the Test Menu some inputs of the

speedometer are set up again as follows:

Input Function
Fuel Up button
Wtemp Md button
Oil Down button

13.1. Manual Test procedure (COLL_MAN)

This is a procedure very useful for an operator to briefly

check in a safe way the instrumentation’s input and the
pointer’s movement.

To enter the procedure the Md button must be

pressed inside the correspondent screen in Test
Menu (by using Up and Down buttons the selection
will occur) (pic. -1)

Picture 13-1: entering manual test

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5 ELECTRICAL SYSTEM
Now the system starts the display check by lighting all
segments in series; at the end of the check screen in
picture 5-2 will be visualized, the total distance covered
from the vehicle appears
(unit of measurement km).

• Every time Mode button is pressed the system

starts pointer’s check, that follows the movement of
all the route foreseen on the dial (from zero to end of the
scale) and return.

• By using Up button it is possible to turn on all the in-

dicators lights and backlighting (only of the dial because
display backlighting is always on).

• By using Down button it is possible to turn off all in-

dicators lights and backlighting (only of the dial because
display backlighting is always on).

In this function is also possible to show the velocity

(without improving TOTAL or TD).

By using Md button it is possible to exit from Manual

Test and come back to Test Menu

13.2. Automatic test procedure (COLL_AUTO)

It’s an useful procedure to verify the instrumentation

through an automatic equipment. To enter the pro-
cedure Md button must be pressed inside the corres-
pondent screen in Test menu (by using Up and Down
buttons the selection will occur, pic.13-2).

Now the system will show the standard screen

(except for the battery charge graphic bar).

By pushing the Mode button it is possible to

change the screen as described: standard all OFF tall ON

For 10 times consecutively before returning to the

test menu.

During the succession of the screening it is possible:

• Turning on all the indicators lights and the backlight by

pushing Up button.
• Turning off all the indicators lights and the backlight by
pushing Down button.
• Viewing the velocity (without increasing the kilometers)
arriving from the SENS IN (#10).
• Moving the pointer (only during standard screen – turn
off the RPM signal before changing screen). Due to
this, RPM (#8) is set up so that the system de-
termine the shifting of the pointer of an equal number Picture 13-2: entering automatic
of steps to the incoming number of impluses. test
The direction of the shifting is determined by the Set
button: button which is not pressed shows an clock di-
rection, while pressed button determines a direction
of shifting of the index in anticlockwise direction.

N.B.4
NB: RPM AND SPEED MUST NOT BE ACTIVE AT THE
SAME TIME

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 5 ELECTRICAL SYSTEM
13.3. Erasing procedure
E2prom (E2PROM)

During the tests and the controls of the instrumen-

tation, it’s useful erasing the E2prom memory.

To enter the procedure the Md button must be pres-

sed inside the correspondent screen in Test Menu (by
using Up and Down buttons the selection will occur,
pic. 13-3).

Now the display shows a warning message (Reset

shown blinking, picture 13-4): this operation IS IRRE-
VERSIBLE and deleted data can’t be recovered.
Picture 13-3: entering E2prom
By using Up or Down button it is possible to fail this erasing
operation and come back to Test menu.

By using Md button it is possible to go on with the ope-

ration and completely erase the whole memory.

A confirmation message (fixed logo Reset) will remem-

ber the operator the possible need to make pointer ca-
libration.

The return to Test menu will be possible by using whate-

ver of the three buttons (Up, Md or Down).

13.4. Pointer’s procedure of calibration (IND.)

The calibration is useful to correct eventual mis-

takes of position made during the phase of setting Picture 13-4: Erasing procedure
out of the pointer. warning
To enter this procedure the Md button must be pres-
sed inside the correspondent screen in Test menu (by
using Up and Down buttons the selection will occur,
pic.13-5).

Now the display will ask to the operator to put in micro

step numbers necessary to allow the pointer to
reach the zero on silk-screen printing.

By using Up button it is possible to start movement of

the pointer in clockwise direction.
By using the Down button it is possible to start
movement of the pointer in anticlockwise direction.

By using Md button it is possible to exit from Auto-

matic test procedure and come back to previous Picture 13-5: Entering pointer
calibration
The selected value will be saved in a permanent me-
mory.

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5 ELECTRICAL SYSTEM
14. ELECTRICAL FEATURES

Maximum working features:

Param. No. Feature Simb. MIn. Max. Units

PM1 Max working voltage VMAX 17 V
PM2 Storage Temperature TSto -20 -85 °C
PM3 Max supplied current from pin 7 IHall 20 mA
PM4 Max current applicable to inputs IInMax 20 mA
PM5 Max current applicable to outputs IoutMax 20 mA

Normal working features:

Param. No. Feature Simb. MIn. Typ. Max. Units

PO1 Supply voltage VDD 7 12 16 V
PO2 Operative Temperature TOp -20 +80 °C
Current absorption during On with all the
PO3 light switched on Ion tbd tbd mA
(Vbatt=13,0V)
Current absorption during On with all the
PO4 light switched off Ion_spie tbd tbd mA
(Vbatt=13,0V)
Current absorption during Sleep Islp
PO5 tbd tbd mA
(Vbatt=13,0V)

Tbd= to be determined

81
 5 ELECTRICAL SYSTEM
15. CONNECTOR PINOUT CONFIGURATION

The connector is directly placed on the bottom side of

the board.

Producer MOLEX
Part Number 43045-1818

# Meaning # Meaning
1 -------- Not connected 10 Sensor input
2 Left Indicator 11 ------- Not connected
3 -------- Not connected 12 High Beam lights
4 -------- Not connected 13 Right Indicator
5 -------- Not connected 14 GND
Settings (if connetcetd to gnd)
6 Neutral 15 Fuel
7 Vcc Sensor 16 ------- ------- Not connected
8 RPM 17 P15
9 Positive battery 18 GND

Male figure – Female insertion side.

82
6 ENGINE
TABLE OF CONTENTS
CHARACTERISTICS
6
ENGINE 85

CAPACITIES 85

ENGINE MARKING 85

SPECIAL IMPORTANT POINTS

OIL AND FUEL 86

TIGHTENING TORQUES 87

SPECIAL TOOLS 88

CYLINDER HEAD / CYLINDER / PISTON 89

CHECKING THE CYLINDER 92

CHECKING THE PISTON 92

CHECKING THE PISTON RINGS 92

INSTALLING THE PISTON RINGS ON THE PISTON 93

SETTING THE TIMING 95

CLUTCH 99

CHECKING THE CLUTCH 102

CHECKING AND CLEANING THE OIL FILTERS 103

ADJUSTING THE CLUTCH CONTROL LEVER 107

MAGNETO FLYWHEEL 108

CHECKING THE OVERRUNNING CLUTCH 109

GEARBOX / CONROD AND CRANKSHAFT ASSEMBLY 110

CHECKING THE CRANKSHAFT AND CONROD ASSEMBLY 114

CHECKING THE GEARBOX. 115

MISCELLANEOUS OPERATIONS 122

CHECKING THE VALVE CLEARANCE 124

CARBURETTOR 125

83
6 ENGINE
CHARACTERISTICS

ENGINE

Type 4-stroke single-cylinder

Cooling By natural air circulation

Bore x stroke 54 x 54 mm

Cubic capacity 123.7 cc

By chain
Distribution
Single overhead camshaft, 2 valves

Oil bath multi-disc clutch with manual control (4 smooth discs,

Clutch
5 lining discs)

Gearbox 5 speed

Fuel supply Carburettor Mikuni VM20

Lubrication Trochoidal pump

Spark plug CR7HSA

Starter motor Electric 400 W

Exhaust Non-catalytic

CAPACITIES

1L
Engine oil
10W30

ENGINE MARKING. AR

Engine type E336E

85
 6 ENGINE
SPECIAL IMPORTANT POINTS

OIL AND FUEL

This engine is designed to run on 95 or 98 un-

leaded fuel only.

Fuel pipes must absolutely be changed if there

are any wear marks, cracks, etc.

If they have to be changed, install genuine pi-

pes.

Petrol is highly inflammable, do not smoke in

the working area and avoid proximity to flames
or sparks. Work in a clear and well-ventilated
area.

Before carrying out any work, leave the engine

to cool for at least 2 hours.

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6 ENGINE
TIGHTENING TORQUES

Cylinder head 1 m.daN/2.2 m.daN

Cylinder casings 1 m.daN

Transmission cover 1 m.daN

Inlet manifold 1 m.daN

Camshaft gear 2 m.daN

Camshaft gear cover 1 m.daN

Chain tensioner 1 m.daN

Chain tensioner 1 m.daN

Conrod and crankshaft assembly gear 7 m.daN

Clutch housing 6 m.daN

Clutch pressure plate 0.6 m.daN

Oil pump 0.7 m.daN

Gearshift star 0.8 m.daN

Gearshift lock 1 m.daN

Clutch thrust bearing locknut 0.8 m.daN

Starter motor 1 m.daN

Rotor 7 m.daN

Flywheel magneto cover 1 m.daN

Gearbox drain plug 2 m.daN

Spark plug 1.2 m.daN

87
 6 ENGINE
SPECIAL TOOLS

MH Code Designation Used MH Code Designation Used

with with

Casing Casing
extractor opening Pin nut
2541002000214 2541002000221 2541002000216
and plate +
opening twl pin

Shouldered Clutch lever

2541002000215 centering 2541002000214 2541002000222 lip seal fitting
tool tool

Pin Ø12 Fixed flange

2541002000216 2541002000221 2541002000223
pitch 125 locking tmI

Engine Engine Valve lifter

2541002000217 2541002000224
mount mount
adapter

Engine
2541002000218
Flywheel 2541002000225 2541002000215
mount
clamp
adapter

Externa1
2541002000219 circlips pliers 2541002000226 Flywheel
puller

Protective Casing
2541002000220 end-piece 2541002000214 2541002000227 opening 2541002000214
large model plate

(*) New or modified twmh.

88
6 ENGINE
CYLINDER HEAD / CYLINDER / PISTON

PUTTING THE ENGINE ON THE STAND

• Fit the engine to adapter P/N 758464.

• Put the assembly on stand P/N 64765

clamped in the jaws of a vice.

• Remove the bolt (1) in order to drain off the

gearbox

Tightening torque: 2 m.daN.

REMOVAL OF THE CYLINDER HEAD

• Removal of the camshaft gear cover (1).

• Removal of the timing mark plug (2).
• Removal of the central plug (3).

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 6 ENGINE
• Using a wrench, turn the crankshaft counterclockwise
so as to align the crankshaft gear mark (I) with the cylin-
der head mark (A).

• Immobilize the conrod and crankshaft assembly by

means of the flywheel magneto nut.
• Remove the camshaft gear bolt.

• Removal of the chain tensioner (5) plug (4).

• Removal of the chain tensioner.
• Remove the camshaft gear.

Tie a wire to the timing chain in order to pre-

vent it from falling into the crankcase.

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6 ENGINE
• Slacken off the cylinder head/cylinder 6 mounting bolts
in the order shown, in 2 or 3 stages.
• Remove the cylinder head.

REMOVAL OF THE CYLINDER / PISTON

• Removal of the metal gasket (6) and the 2 centring

pillars (7).
• Remove the chain guide pad (8).
• Removal of the cylinder and its O-ring.

• Remove the base gasket (9) and the 2 centring pillars

(10).
• Remove one of the spring clips (11) using pliers P/N
752000.
• Remove the gudgeon pin.
• Remove the piston.

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 6 ENGINE
CHECKING THE CYLINDER

• The cylinder should show no traces of scoring

or seizure.
• Cylinder diameter: 54.000 to 54.018 mm.

CHECKING THE PISTON

• The piston should show no traces of scoring or seizure.

• The rings must be free in their grooves.
• Measure the piston diameter at 4.5 mm from the
piston skirt.
• Piston diameter: 53.977 to 53.996 mm.
• Cylinder & piston set: 0.020 to 0.028 mm.
• Utilisation limit: 0.15 mm.

CHECKING THE PISTON RINGS

• Carefully remove the piston rings.

• Place a ring in the bore parallel to it and measure the
gap using a feeler gauge.
• Piston ring gap: 0.15 to 0.30 mm.
• Utilisation limit: 0.4 mm.

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6 ENGINE
INSTALLING THE PISTON RINGS ON THE PISTON

• Proceed in the following order in order to install the oil

control rings.
• Install the spring (1) (no special direction).
• Install the 2 piston rings (2) on each side of the
spring by offsetting the gap of each ring (no special
direction).

• Install the compression ring (3) by placing the”TOP”

mark upwards.
• Install the compression ring (4) by placing the “TOP”
mark upwards.

FITTING THE PISTON

• Install the piston with its arrow stamped into the piston
crown pointing at the exhaust.
• Fit the gudgeon pin and circlips.

• The circlip gaps (1) must face upwards or downwards,

but under no circumstances to the side.

The circlips must be changed every time they

are removed.

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 6 ENGINE
• Position the piston ring gap as follows.

1. Top compression ring gap.

2. Compression ring gap.
3. Upper oil control ring gap.
4. Lower oil control ring gap.

FITTING THE CYLINDER

• Install the cylinder base gasket and the 2 guiding pillars
on the crankcase.
• Fit a new O-ring (1) on the cylinder skirt.

• Fit the cylinder over the piston by compressing the pis-

ton rings by hand.
• Fit the chain and the chain guide tensioner into the
timing chain tunnel.

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6 ENGINE
FITTING THE CYLINDER HEAD

• Fit the 2 guiding pillars (1) and the metal gasket (2) on the
cylinder.
• Fit the chain pad (3).

• Install the cylinder head.

• Slightly lubricate the thread of the 6 screws that secure
the cylinder head.
• Fit the 6 screws.
• Tighten in 2 or 3 sequences the 6 screws that secure
the cylinder head in the indicated direction.

Tightening torque:
• 6 mm diameter screw: 1 m.daN.
• 8 mm diameter screw: 2.2 m.daN.

FITTING THE CAMSHAFT GEAR

SETTING THE TIMING

• Pivot the engine to the right.
• Rotate the conrod and crankshaft assembly
so as to align the marks of flywheel magneto
with the mark (A) of the cover..

Remove the wire that holds the timing chain.

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 6 ENGINE
• Fit the gear in the chain on one of the sides.
• Using a tool with a small diameter, finish fitting the chain
around the gear.
• Fit the gear on the camshaft.

• Make sure the mark (I) of the camshaft gear isaligned

with the mark (B) of the cylinder head.
• If necessary, dislodge the gear from the camshaft
without removing it and move the chain around the gear
on the required side.
• Install the camshaft gear.

• Immobilize the flywheel magneto using a wrench and

pre-tighten the camshaft gear.

Tightening torque: 2 m.daN.

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6 ENGINE
• Loosen the chain tensioner as indicated.

• Fit the chain tensioner seal (respect the position of ins-

tallation).
• Install the chain tensioner and the 2 attachment
screws.

Tightening torque: 1 m.daN.

• Install the tensioner cap.

Tightening torque: 0.8 m.daN.

• Check the alignment of the timing marks of the flywheel

magneto with the mark (A) of the cover, and of the cams-
haft gear with the mark (B) of the cylinder head.
• In case of misalignment, start the operation again from
the beginning.

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 6 ENGINE
• Install the timing gear (1) cover.

Tightening torque: 1 m.daN.

• Install the timing mark cap (2).

• Fit the central cap (3).

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6 ENGINE
CLUTCH

REMOVAL OF THE CLUTCH

REMOVAL OF THE OIL PUMP

• Remove the starter motor.
• Remove the transmission cover 9 fixing bolts.
• Remove the transmission cover.

Tightening torque: 1 m.daN.

• Remove the paper gasket (1) and the 2 locating pins (2).

• Remove the 4 bolts and spring (3) from the pressure

plate (4).
• Remove the set of 5 lined discs and the 4 smooth
discs.
• Remove the ball from the transmission input shaft.

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 6 ENGINE
• Fold down the clutch nut (6) lockwasher tab (5).
• Lock the clutch main shaft (7) with tool P/N 753731.
• Remove the nut and the washer.

• Immobilize the gears by fitting a copper washer (A) bet-

ween the gears.
• Loosen and remove the nut (8) from the conrod and
crankshaft assembly and the washer.

• Remove:
• The clutch main shaft. (7)
• The splined bush. (9)
• The clutch housing. (10)
• The plain washer. (11)
• The tapered washer. (12)

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6 ENGINE
• Remove the pinion (13).
• Remove the key (14) from the crank.
• Remove the centrifugal filter (15).
• Remove the drive gear from the oil pump (16).
• Remove washer (17).

• Remove the circlip.

• Remove the pinion (18).
• Remove the tapered washer.
• Remove the oil pump 2 fixing bolts. (20)
• Remove the oil pump and its gasket.

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 6 ENGINE
CHECKING THE CLUTCH

• Measure the thickness of the lined discs.

• Disc thickness: 3 mm.
• Utilisation limit: 2.8 mm.

• Measure the length of the springs.

• Spring length: 33 mm.
• Utilisation limit: 31 mm.

• Check the condition of the notches of the clutch housing

and the condition of the splines of the clutch gear.
• In case of severe wear replace the parts.

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6 ENGINE
CHECKING AND CLEANING THE OIL FILTERS.

• Clean the centrifugal filter by dipping it into a cleanser.

• Blow through the holes (A) of the centrifugal filter with
compressed air.

• Check and clean the strainer. (1)

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 6 ENGINE
FITTING THE OIL PUMP

• Install the oil pump and a new gasket (1).

Tightening torque: 0.7 m.daN.

• Install the tapered washer (2), the humped side to the

oil pump.
• Install the pinion. (3)
• Install the circlips. (4)

FITTING THE CLUTCH

• Install the conrod and crankshaft assembly:

• The washer (1).
• The pinion. (2).
• The centrifugal filter (3), the (F) mark outwards.
• The key. (4)
• The pinion (5) the (C) mark outwards.
• The washer (6) and the nut (7).

• Fit to the primary shaft:

• The tapered washer (8) with the round endtowards
the bearing.
• The plain washer. (9)
• The clutch housing. (10)
• The splined bush. (11)
• The clutch main shaft. (12)
• The tab washer (13) and the nut (14).

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6 ENGINE
• Immobilize the gears by fitting a copper washer (A) bet-
ween the gears.
• Tighten the nut. (15)

Tightening torque: 7 m.daN.

• Lock the clutch main shaft 16 with tool P/N 753731.

• Tighten the nut. (17)

Tightening torque: 6 m.daN.

• Fold over the clutch nut washer locking tab.

• Fit the ball into the input shaft.

• Fit the clutch discs starting with a lined disc (18) and
then alternate smooth and lined discs (19).

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 6 ENGINE
• When re-assembling, ensure that the marks (B) on the
smooth discs are offset by 90° from the others.

• Fit the pressure plate (20) lining up the arrow (C) on

the plate with the round imprint (D) on the clutch main
shaft.

Tightening torque: 0.6 m.daN.

• Fit the pressure plate springs (21) and the 4 bolts and
washers (22).

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6 ENGINE
ADJUSTING THE CLUTCH CONTROL LEVER

• Slacken the pressure plate locknut (1).

• Bring the lever into contact with the control rod.

• Check that the mark (A) of the lever is lined up with the
notch (B) of the crankcase.
• It is isn’t, adjust with the screw (2).
• Tighten the locknut without altering the adjustment.

Tightening torque: 0.8 m.daN.

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 6 ENGINE
MAGNETO FLYWHEEL

TO REMOVE THE MAGNETO FLYWHEEL

• Remove the 7 bolts that secure the cover.

• Remove the flywheel magneto cover.
• Remove the paper gasket and the two 2 centering
pins.

Tightening torque: 1 m.daN.

• Immobilize the rotor (1) using the flywheel clamp

P/N 68570.
• Remove the nut. (2)

Tightening torque: 7 m.daN.

• By means of the 3 screws, secure the flywheel extrac-

tor P/N 758465 to the flywheel magneto.
• Lock the flywheel extractor and turn the thrust bolt until
the rotor is released.
• Remove the rotor and the overrunning clutch.
• Remove the washer under the rotor.

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6 ENGINE
CHECKING THE OVERRUNNING CLUTCH

• Rotate the overrunning clutch by hand.

• It must rotate in direction (A).
• It must be block in direction (B).

• If it doesn’t, replace the overrunning clutch.

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 6 ENGINE
GEARBOX/CONROD AND CRANKSHAFT
ASSEMBLY

REMOVAL OF THE GEARBOX

REMOVAL OF THE CRANKSHAFT

• Remove the cylinder head.

• Remove the cylinder and the piston.
• Remove the primary drive.
• Remove the flywheel magneto rotor.

• Remove the gear shift shaft (1).

• Remove the screw that secures the star

locking lever (2).
• Remove the lever and its spring.
• Remove the star clamping screw (3).
• Remove the star and its 2 centering pins.

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6 ENGINE
• Remove:
• The circlip. (4)
• The washer (5).
• The starter drive pinion. (6) (*)
• The plain washer. (7)
• The circlip. (8)

(*) The kick starter pinion is on the engine but it

is not used.

• Remove the screw which secures (9) the chain tensio-

ner slipper (10).
• Remove the chain tensioner slipper.
• Remove the timing chain and notice its direction of ro-
tation.
• Remove the 2 screws of the starter pinionholder plate (11).
• Remove the starter drive pinion.

111
 6 ENGINE
• Remove the 10 screws from the LH crankcase, 2 of
which are located on the RH crankcase.
• Remove the 2 nuts that secure the engine to the
fixture.
• Remove the RH half crankcase and the 2 centering
pins.
• Fit the 2 nuts that secure the engine to the fixture.

• Remove the balance shaft (12).

• Remove the 2 pins (13) of the shift forks.
• Remove the selector cylinder. (14)
• Remove the shift forks.
• Remove at the same time the input shaft (15) and se-
condary shaft (16) assembly.
• Remove the clutch push rod of the input shaft.

REMOVAL OF THE CRANKSHAFT

• Fit protective cap P/N 69098 to the end of the

crank assembly.

112
6 ENGINE
• Fit to casing with tool P/N 64706 fitted with plate
P/N 758466.
• Fix the assembly to the casing using 4 bolts (1).
• Tighten the tool centre screw holding the crank with
one hand on the other side until it is fully extracted.
• Removing the the cranshaft and conrod assembly.

113
 6 ENGINE
CHECKING THE CRANKSHAFT AND CONROD
ASSEMBLY

• Using a set of shims, check the big end side play.

• The maximum side play on the conrod end must not
exceed: 0.45 mm.

• The out-of-round values measured on the ends of the

crank should not exceed 0.03 mm and must be measu-
red:
• 30 mm from the transmission side end.
• 60 mm from the flywheel magneto end.

• Check the condition of the bearing and timing pinion (1).

• If there is too much play in the bearing or if the ti-
ming pinion is excessively worn, replace the conrod and
crankshaft assembly.

114
6 ENGINE
CHECKING THE GEARBOX

• Check the condition of the ends (A) and the guide (B) of
the shift forks.
• Check the condition of the grooves (C) of the selector
cylinder.

• Check the condition of every gear.

• Check that every gear slides and rotates on the corre-
ponding shaft.
• Check the condition of the sliding gear and idler gear
driving dogs.

If a component has to be changed, replace also

the component which is associated.

115
 6 ENGINE
FITTING THE CRANK ASSEMBLY RH BEARING

• The bearing is positioned into the casing by

means of a press.

FITTING THE SEALS AND GASKETS

• Using tool P/N 753729, fit the clutch lever seal.

• The gearbox output and gear shift shaft seals are to be
positioned flush with the crankcase.

116
6 ENGINE
FITTING THE CONROD AND CRANKSHAFT
ASSEMBLY

• Fit the conrod and crankshaft assembly into the LH

crankcase.
• Tighten pin P/N 64712 at the end of the crank ass-
embly.

• Fit to casing with tool P/N 64706 fitted with plate

P/N 758466.
• Centre the assembly to the casing with 4 bolts (1).
• Fit centring tool P/N 64710 to tool P/N 64706.
• Tighten pin nut P/N 69104 on pin P/N 64712 in
order to bring the crankshat assembly into contact with
the bearing ensuring that the crank is pointing towards
the cylinder side.

FITTING THE GEARBOX

• Put the clutch pushrod (1) in the input shaft.

• Install at the same time the input shaft ans secondary
shaft assembly in the LH crankcase.

117
 6 ENGINE
• Install the shift fork as shown.
• Marking (A) is upwards.

• Install the selector cylinder (2).

• Fit the shift fork guides into the grooves of the cylinder.
• Install the shift fork pins (3).

• Install the balance shaft (4) by lining up the mark of

the balance shaft pinion with the mark of the conrod and
crankshaft assembly.

118
6 ENGINE
• Make sure the gasket seat of the RH and LH crankca-
ses is perfectly clean.
• Fit the 2 centring pins (5).
• Put gasket seal paste on the LH crankcase gasket
seat.
• Place the RH casing over the LH casing assembly.

No tools are necessary for assembling the

casings, which shall be carried out without
effort.

• Fit and tighten the 10 fixing bolts (6).

Tightening torque: 1 m.daN.

119
 6 ENGINE
• Install the starter pinion (7).
• Install the starter pinion holder plate (8).

Tightening torque: 0.8 m.daN.

• Install the timing chain.

• Install the the chain tensioner slipper.

Tightening torque: 1 m.daN.

• Fit:
• The circlip (9).
• The washer (10).
• The starter drive pinion (11).

(*) The kick starter pinion is on the engine but it

is not used.

• The plain washer (12).

• The circlip. (13).

120
6 ENGINE
• Install the star locking lever (10) and its spring (11).

Tightening torque: 1 m.daN.

• Install the star (12) and its 2 centering pins.

NOTE
WHEN RE-INSTALLING, FIT A SCREW WITH
STANDARD THREAD LOCK.

Tightening torque: 0.8 m.daN.

• Install the shift shaft (13).

121
 6 ENGINE
MISCELLANEOUS OPERATIONS

REMOVAL OF THE CAMSHAFT AND/OR ROCKERS

• Remove the cylinder head.

• Remove the stopper plate. (2)
• Remove the camshaft (1).

• Using the intertia extractor.

• Remove the cam follower shafts.
• Remove the inlet (3) and exhaust (4) rockers.

REMOVAL OF THE VALVES OR VALVE STEM SEALS

• Compress the spring of one of the valves using the valve

lifter P/N 754035.
• Remove the 2 half cones.
• Uncompress the spring and remove the tool.

122
6 ENGINE
• Remove:
• The upper cup (1).
• The spring (2).
• The valve (3).
• Remove the 2nd valve in the same way.

NOTE
WHEN RE-INSTALLING, LUBRICATE THE 2 HALF
CONES (4) SO AS TO HOLD THEM IN THE GROOVE
OF THE VALVE’S STEM.

NOTE
DO NOT PLACE THE 2 HALF CONES INTO THE CUP
FORCEFULLY WITH THE TOOL WHEN DECOMPRES-
SING THE SPRING.

• In case you remove the seal of a valve stem (5), replace

it with a new seal after removing all the carbon residues
which could remain inside the cylinder head.

123
 6 ENGINE
CHECKING THE VALVE CLEARANCE

• Removal of the camshaft gear cover (1).

• Removal of the central plug (2)..

• Using a wrench, turn the crankshaft counterclockwise

so as to align the crankshaft gear mark (I) with the cylin-
der head mark (A).

• Using the set of feeler gauges, measure the clearance

of each valve.
Clearances:
• 10/100 at the intake.
• 15/100 at the exhaust.

• If the clearance is not correct, adjust by means

of the cam follower screw.

124
6 ENGINE
CARBURETTOR

REMOVAL OF THE THROTTLE VALVE

• Unscrew the carburettor chamber cap (1).

• Dismantle the valve equipped with its needle, spring and
carburettor chamber cap.

• Dismantle the needle (2) by pushing it out in order to remove

the clips (3).

REMOVAL OF THE FLOAT, NEEDLE VALVE AND JETS

• Remove the 4 screws that secure the float chamber (1).

• Remove the chamber.

125
 6 ENGINE
• Remove the paper gasket.
• Remove the float (3) pin (2).
• Remove the float and the needle valve.

• Remove the idle jet (4).

• Remove the main jet (5).
• Remove the jet spray nozzle (6).

• Check the condition of the needle valve and the needle

valve seat (A).

126
6 ENGINE
REMOVAL OF THE ENGINE SPEED ADJUSTER
SCREW AND MIXTURE CONTROL SCREW

• Turn clockwise the engine speed adjuster screw (1) and

mixture control screw (2) while counting the number of
turns until they are screwed home.
• When re-fitting, this operation allows you to put them
back to their initial adjutment position.
• Remove the idle screw and the mixture control screw
with their spring.

NOTE
DO NOT TURN THE SCREWS HOME
FORCEFULLY.

• Clean the body of the carburettor and its components

with a cleanser.
• Blow into every jet and duct of the carburettor body with
compressed air.

NOTE
DO NOT USE ANY METAL TOOL WHICH
CAN DAMAGE THE DUCTS OF THESE ITE-
MS.

127
 6 ENGINE
RE-FITTING THE JETS, FLOAT AND NEEDLE VALVE

• Fit the jet spray nozzle (1).

• Fit the main jet (2).
• Fit the idle adjuster screw (3).

• Position the needle valve (4) on the tongue of the float (5).
• Install the float on the carburettor body while fitting the
needle valve into its recess.
• Fit the pin (6) into the float.
• Fit the paper gasket.
• Fit teh float chamber.
• Fit and tighten the 4 screws of teh float chamber.

• Re-install all the other components and, if necessary,

when starting the engine, readjust according to the va-
lues indicated on the technical data card.

128
7 ADJUSTMENT
CONTENTS
TRANSMISSION CHAIN TENSION 131 7
LUTCH TENSION 132

THROTTLE CONTROL 132

TENSIONING THE FRONT BRAKE 133

TENSIONING THE REAR BRAKE 133

PEDAL CHANGING 134

CARBURETTOR 134

129
 7 ADJUSTMENT
Set spanner TRANSMISSION CHAIN TENSION
To adjust the tension of the transmission chain, the steps
described below must be carried out on both sides.

• Loosen the two nuts (A) securing the rear wheel.

• Loosen the securing nut (B).

• Using the bolt (C), adjust the tension of the chain.

A C B
• The chain (D) should have a tolerance of some 30mm.

• Set the position using the securing bolt (B).

• Tighten the wheel shaft nuts (A).

30mm

131
 7 ADJUSTMENT
CLUTCH TENSION

B C
To increase or decrease the clutch tension:

• Remove the protective rubber (A).

A
• Loosen the locking wheel (B).

• Turn the wheel (C) to tighten or loosen the cable.

• Use the locking wheel (B) to set the position.

THROTTLE CONTROL
A C B
To increase or decrease the throttle twist-grip tension:

• Remove the protective rubber (A).

• Loosen the locking wheel (B).

• Turn the wheel (C) to tighten or loosen the cable.

• Use the locking wheel (B) to set the position

132
 7 ADJUSTMENT
Allen key TENSIONING THE FRONT BRAKE
To increase or decrease the tension of the front brake: A B

• Loosen the securing nut (A).

• With a No.4 Allen key (B), increase or decrease the

action of the front brake.

• Use the securing nut (A) to set the position.

TENSIONING THE REAR BRAKE

To increase or decrease the tension of the rear brake:

• Loosen the securing nut (A).

• Turn the threaded wheel (B) to increase or decrease

the action of the rear brake. B

• Use the securing nut (A) to set the position.

133
 7 ADJUSTMENT
GEAR CHANGE PEDAL

Adjust the position of the gear change pedal to adapt the

position to your requirements.

• Put the gear change pedal in neutral position.

• Unscrew the bolt (A). A
• Place in the desired position.
• Loosen the nuts (B).
• Adjust the tension using the bar (C).
• Set the position with the nuts (B).
• Set the position with the bolt (A). B C B

CARBURETTOR
• Adjust the carburettor idling speed using the screws.

• Idling speed (1).

• Mixture (2).

134
8 MAINTENANCE
CONTENTS
FRONT BRAKE FLUID 137

REAR BRAKE FLUID 137

FLUID LEVEL 138

SPARK PLUG 138

AIR FILTER CLEANING 139

BRAKE PADS 139

TYRES 139

STEERING 140

MAINTENANCE PLAN 141

135
 8 MAINTENANCE
Philips FRONT BRAKE FLUID
screwdriver
A
The brake fluid reservoir is next to the right-hand lever.

• There is an inspection window (A) in the reservoir to

view the fluid level.

B
• Check that the level is correct. If not, carry out the
following steps:

• Loosen the two bolts (B) from the cover.C C

• Remove the cover (C) and the rubber (D).

• Top up with fluid, if necessary. D

Recommended fluid DOT 3; DOT 4

Philips REAR BRAKE FLUID

screwdriver
A

Allen key The brake fluid reservoir is located behind the lever. C

• There is an inspection window (A) in the reservoir to

view the fluid level
D

• Check that the level is correct. If not, carry out the

following steps:

• Remove the two bolts (B) and place the reservoir in a

horizontal position.
B
• Loosen the two bolts (C) on the cover (D).

• Remove the cover D) and the rubber.

• Top up with fluid, if necessary.

Fluid: DOT 3; DOT 4

137
 8 MAINTENANCE
OIL LEVEL
A

Before carrying out this operation, turn off the engine

and remove the oil cap located on the right-hand side of
the engine.

• The cap incorporates a dipstick (A) that will indicate the

level of the oil.

• Remove the cap.

• Wipe the dipstick dry (A).

• Refit the cap.

• Remove the cap again and check the level marked on

the dipstick (A).

Recommended oil: SAE 10W30.

SPARK PLUG

ATTENTION
BEFORE REMOVING THE SPARK PLUG, BLOW THE
AREA AROUND IT WITH COMPRESSED AIR TO ELI-
MINATE ANY DIRT, TO ENSURE THAT NOTHING FA-
LLS INTO THE ENGINE.

• Standard spark plug: B

CR6HSA
C

• Abnormal colour: A
Renew
(The normal colour is light brown).

• Inspect:
Electrode (A).
Insulator (B).

• Measure:
Gap between electrodes (C):
0.6 mm - 0.7 mm

138
8 MAINTENANCE
BRAKE PADS

• Measure the thickness (A) of the lining of the pads.

• Service limit (lining): 1mm.

CLEANING THE AIR FILTER

• Remove the air filter sponge.

• Wash with AGIP FILTER CLEAN,
• Rinse and dry the filter.
• Impregnate with AGIP FILTE oil.
• Eliminate the excess by pressure.

TYRES

Tyre pressure.

FRONT REAR

1,5 bar 2 bar

Minimum tread depth:

0,8 mm.

139
 8 MAINTENANCE
Allen key STEERING

REMOVAL A
8
• Loosen the 3 bolts (A) on the 2 plates.
• Remove the front calliper (see section).
• Free the wheel-forks assembly from the top plate.

• Remove the plug (B) and the washer.

• Remove the top plate-handlebars assembly (C).

A
CAUTION
-PLACE THE MACHINE ON A FLAT SURFACE.
-STAND THE MACHINE ON A SUITABLE SUPPORT,
IN SUCH A WAY THAT THE FRONT WHEEL IS OFF
THE GROUND.

D
The inside of the steering:

• Remove the oil seal (D).

• Remove the spacer pipe (E). E
• Remove the oil seal (F).

ASSEMBLY

• To assemble, carry out the operations in reverse order.

140
8 MAINTENANCE
This section includes all the information needed for per-
forming all the recommended maintenance and com-
missioning operations. Observing these procedures will
ensure the machine functions more reliably and has a
longer useful life, while reducing the need for costly repair
work.

REINFORCED MAINTENANCE PLAN

Reinforced maintenance is aimed at machines used in
“severe” conditions: driver mood, short journeys with a
cold engine, dusty regions or an ambient temperature of
above 30ºC.

CHECK

MAINTENANCE OPERATIONS 500 km or 3 months Every 3.000 km Every 6.000 km

REINFORCED MAINTENANCE Every 1.500 km Every 3.000 km

Adjust idling speed X X X

Throttle cable and oil pump X X X

Front and rear brake cables X X X

Functioning of the front and rear brakes X X X

Functioning of the electrical equipment X X X

Fuel circuit X X X

Oil circuit X X X

Front and rear brake fluid piping X X X

Coolant circuit X X X

Carburettor heating circuit X

Tyre pressures X X

Condition, pressure and wear of tyres X X X

Front and rear brake fluid level X X X

Coolant level X X X

Battery electrolyte level X X X

Tightening nuts and bolts X X

Charging the battery X X

141
 8 MAINTENANCE
RENEWING

MAINTENANCE OPERATIONS 500 km or 3 months Every 3.000 km Every 6.000 km

REINFORCED MAINTENANCE Every 1.500 km Every 3.000 km

Intake filter element X X

Front and rear brake pads (where appropriate) X X

Gearbox oil X X

Chain-sprocket-crown wheel (where appropriate) X X

Clutch disks (where appropriate) X

CHECKING AND DECARBONISING

MAINTENANCE OPERATIONS 500 km or 3 months Every 3.000 km Every 6.000 km

REINFORCED MAINTENANCE Every 1.500 km Every 3.000 km

Piston Every 10.000 km

Cylinder head Every 10.000 km

Exhaust port Every 10.000 km

(1) The need to decarbonise can be estimated by checking the quantity of carbonisation present in the cylinder exhaust outlet.

CHECKING AND GREASING

MAINTENANCE OPERATIONS 500 km or 3 months Every 3.000 km Every 6.000 km

REINFORCED MAINTENANCE Every 1.500 km Every 3.000 km

Chain tension and condition X X X

CHECKING AND ADJUSTING

MAINTENANCE OPERATIONS 500 km or 3 months Every 3.000 km Every 6.000 km

REINFORCED MAINTENANCE Every 1.500 km Every 3.000 km

Clutch cable X X

Oil pump control X X

Spark plug X X X

Tension of the wheel spokes X X X

CHECKING AND ADJUSTING

MAINTENANCE OPERATIONS 500 km or 3 months Every 3.000 km Every 6.000 km

REINFORCED MAINTENANCE Every 1.500 km Every 3.000 km

Carburettor X X

142
9 TROUBLESHOOTING
ÍNDICE
FAILURE TO START 145

INCORRECT IDLING SPEED 146

FAULTY GEAR-CHANGE 146

FAULTY CLUTCH 147

OVERHEATING 147

POOR BRAKING 147

FAULTY FRONT FORK ARMS 148

UNSTABLE HANDLING 148

FAULTY LIGHTS OR TURN INDICATOR SYSTEM 149

143
9 TROUBLESHOOTING
N.B.:
The following troubleshooting guide does not cover all the
possible causes of faults. It may however prove useful as
a guide for basic fault findingUse this manual to consult
the corresponding checking, adjusting and part renewal
procedures.

FAILURE TO START

ENGINE

. Loose park plug.

. Cylinder or cylinder head damaged.
. Damaged cylinder head gasket.
. Damaged cylinder gasket.
. Cylinder worn or damaged.
. Incorrect valve clearance.
. Seized valve.
. Wrongly fitted piston ring.
. Damaged, worn or fatigued piston ring.
. Seized piston ring.
. Seized or damaged piston.
. Air filter incorrectly fitted.
. Air filter element obstructed.
. Crankcase fitted incorrectly.
. Seized crankshaft.Cylinder head gasket damaged

FUEL SYSTEM
. Fuel tank empty.
. Fuel tank drain pipe blocked.
. Altered or contaminated fuel.
. Carburettor air suction blocked.

ELECTRICAL SYSTEMS

. Flat battery.
. Faulty battery.
. Fuse blown, damaged or incorrect.
. Fuse fitted incorrectly.
. Incorrect spark plug gap.
. Oiled-up spark plug.
. Electrode worn or damaged.
. Insulation worn or damaged.
. Faulty spark plug cap.
. Primary or secondary coils broken or short-circuited.
. Faulty spark plug cable.
. Faulty main switch.
. Faulty engine stop switch.
. Broken or short-circuited wiring.
. Faulty neutral light switch.
. Faulty starter switch.
. Loose connections.
. Faulty starter motor.

145
 9 TROUBLESHOOTING
INCORRECT IDLING SPEED

ENGINE

. Incorrect valve clearance.

. Air filter element obstructed.

FUEL SYSTEM

. Incorrectly adjusted engine idling.

. Incorrect throttle cable clearance.
. Flooded throttle body.
. Faulty air intake system.

ELECTRICAL SYSTEMS

. Flat battery.
. Faulty battery.
. Fuse blown, damaged or incorrect.
. Fuse fitted incorrectly.
. Incorrect spark plug gap.
. Oiled-up spark plug.
. Electrode worn or damaged.
. Insulation worn or damaged.
. Faulty spark plug cap.
. Primary or secondary coils broken or short-circuited.
. Faulty spark plug cable

FAULTY GEAR-CHANGE

DIFFICULTY CHANGING GEAR

See “The clutch is dragging” in this section.

THE GEAR PEDAL DOES NOT MOVE

. Bent gear-change shaft.

. Foreign object in the selection drum slot.
. Seized gear change fork.
. Bent gear-change fork guide bar.
. Seized gearbox gearing.
. Foreign object between the gearbox gears.
. Incorrectly fitted gearbox.

THE GEARS JUMP

. Incorrect gear change pedal position.

. Incorrect stop lever return.
. Worn gear selector fork.
. Worn selection drum slot.
. Worn gear securing device.

146
9 TROUBLESHOOTING
FAULTY CLUTCH

THE CLUTCH SLIPS

. Clutch incorrectly fitted.

. Clutch cable incorrectly adjusted.
. Loose or fatigued clutch spring.
. Worn friction plate.
. Worn clutch plate.
. Incorrect oil level.
. Incorrect oil viscosity (low).
. Oil altered.

THE CLUTCH DRAGS

. Uneven clutch spring tension.

. Bent pressure plate.
. Bent clutch plate.
. Distorted friction plate.
. Bent clutch push bar.
. Broken clutch lobe.
. Marks not aligned.
. Incorrect oil level.
. Incorrect oil viscosity (high).
. Oil altered.

OVERHEATING

ENGINE
. Coolant passages blocked.
. Large accumulation of carbon deposits.
. Incorrect oil level
. Incorrect oil viscosity.
. Inferior oil quality.

CHASSIS

. Brakes activated.

ELECTRICAL SYSTEMS

. Incorrect spark plug electrode gap.

POOR BRAKING:

. Worn brake pads.

. Worn brake disk.
. Air in the hydraulic brake system.
. Leaking brake fluid.
. Damaged brake calliper seal.
. Damaged brake pipe.
. Oil or grease on the brake disk.
. Oil or grease on the brake pad.
. Incorrect brake fluid level.

147
 9 TROUBLESHOOTING
DAMAGED FRONT FORK ARMS

LEAKING OIL

. Inner tube bent, damaged or rusted..

. Outer tube cracked or damaged.
. Oil seal fitted incorrectly.
. Damaged oil seal lip..
. Incorrect fluid level (high).
. Loose shock absorber bar assembly bolt.
. Damaged shock absorber bar assembly copper washer.

INCORRECT FUNCTIONING

. Inner tube bent or damaged.

. Outer tube bent or damaged.
. Damaged forks spring.
. Outer tube hose worn or damaged.
. Shock absorber bar bent or damaged.
. Incorrect oil viscosity.
. Incorrect oil level.

UNSTABLE HANDLING

. Handlebars bent or incorrectly fitted.

. Top support incorrectly fitted.
. Bottom support fitted incorrectly (badly tightened lock nut).
. Bent steering shaft.
. Damaged ball bearings or bearing guide ring.
. Uneven fluid levels (in the two front fork arms).
. Uneven fork spring tension (in the two front fork arms).
. Broken fork spring.
. Inner tube bent or damaged.
. Outer tube bent or damaged.
. Worn bearing or hose.
. Swinging arm bent or damaged.
. Faulty rear shock absorber spring.
. Oil or gas leak.
. Uneven tire pressures (front and rear).
. Incorrect tyre pressure.
. Uneven tyre wear.
. Incorrect wheel balancing.
. Broken or loose spokes.
. Damaged wheel bearing.
. Bent or loose wheel shaft.
. Excessive decentring of the wheel.
. Bent frame.
. Damaged steering column tube.
. Incorrectly fitted bearing guide ring.

148
9 TROUBLESHOOTING
FAULTY LIGHTS OR TURN INDICATOR SYSTEM

THE HEADLIGHT DOES NOT COME ON

. Incorrect headlight bulb.

. Too many electrical accessories.
. Excessive load
. Incorrect connection.
. Circuit incorrectly connected to earth.
. Faulty contacts (main switch).
. Blown headlight bulb.

BLOWN HEADLIGHT BULB

. Incorrect headlight bulb

. Battery faulty
. Headlight bulb blown

THE REAR LIGHT / BRAKE LIGHT DOES NOT COME ON

. Blown rear light bulb / Brake light bulb.

. Too many electrical accessories.
. Incorrect connection.
. Blown rear light bulb / Brake light bulb.

BLOWN REAR LIGHT BULB / BRAKE LIGHT BULB

. Incorrect rear light/brake light bulb.

. Battery faulty.
. Incorrectly adjusted rear brake light switch..
. Rear light/brake light bulb reached end of life.

THE TURN INDICATORS DO NOT COME ON

. Faulty turn indicator switch.

. Blown turn indicator bulb.
. Incorrect connection.
. Damaged or faulty wiring loom.
. Battery faulty.
. Fuse blown, damaged or incorrect.

THE TURN INDICATORS BLINK SLOWLY

. Faulty turn indicator switch.

. Incorrect turn indicator bulb.

THE TURN INDICATORS BLINK RAPIDLY

. Incorrect turn indicator bulb.

. Blown turn indicator bulb.

THE HORN DOES NOT SOUND

. Horn incorrectly adjusted.

. Horn damaged or faulty.
. Faulty horn switch.
. Battery faulty.
. Fault in wiring loom.

149
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