This manual has been produced by Nacional Motor, S.A.U.

for use by DERBI dealer and sub-agency works-

hops. It is assumed that those using this publication for training purposes and for repairing DERBI machines
have a basic knowledge of mechanics and of the methods inherent in the technique of vehicle repair. Signifi-
cant variations in the characteristics of the machines or in the specific repair operations will be communicated
by means of updates to this manual.

Completely satisfactory work cannot however be carried out without the availability of suitable facilities
and tools, which is why we ask you to consult the pages of this manual referring to special tools and imple-
ments.

Particularly important items of information in this manual are distinguished by the following annotations:

N.B.
INDICATES A NOTE GIVING KEY INFORMATION, MAKING THE PROCEDURE EASIER AND CLEARER.

ATTENTION
INDICATES SPECIFIC PROCEDURES THAT MUST BE FOLLOWED TO PREVENT DAMAGE TO THE MACHINE.

WARNING
INDICATES SPECIFIC PROCEDURES THAT MUST BE FOLLOWED TO AVOID POSSIBLE INJURIES TO THE
PERSON REPAIRING THE MACHINE.

NACIONAL MOTOR, S.A.U.

1
 GENERAL INFORMATION Page 4
MAINTENANCE REGULATIONS Page 5
GENERAL TECHNICAL DATA Page 6
MAINTENANCE SPECIFICATIONS Page 11
TIGHTENING TORQUES Page 15
CHASSIS SPECIFICATIONS Page 17
ELECTRICAL SYSTEM SPECIFICATIONS Page 19
GENERAL TIGHTENING TORQUE SPECIFICATIONS Page 21
PERIODICAL INSPECTIONS AND ADJUSTMENTS Page 24
SEAT, FAIRING AND FUEL TANK Page 26
ENGINE Page 28
CHASSIS Page 35
ELECTRICAL SYSTEM Page 40
ENGINE INSPECTION Page 44
DISMANTLING THE ENGINE Page 45
INSPECTION AND REPAIR Page 56
REASSEMBLING THE ENGINE AND MAKING ADJUSTMENTS Page 65
CHASSIS – FRONT WHEEL AND BRAKES Page 96
REAR WHEEL AND BRAKES Page 106
TRANSMISSION Page 116
FORKS Page 119
HANDLEBARS Page 125
SHOCK ABSORBER AND SWINGING ARM Page 129
ELECTRICAL SYSTEM Page 131
INSPECTING THE SWITCHES Page 135
TROUBLESHOOTING Page 136

3
REGULATIONS
This section describes the machine’s general safety and maintenance work rules.

SAFETY REGULATIONS

In the event of having to carry out work on the engine while this is running, ensure that the area is well ven-
tilated, where possible using extractor fans. Never leave engines running in closed spaces. Exhaust gases
are poisonous.

Petrol is extremely inflammable and in certain conditions may explode. Smoking must not be allowed in the
work area, nor should there be naked flames or sparks.

MAINTENANCE REGULATIONS

- Use genuine DERBI spare parts and lubricants recommended by the Manufacturer. Non-genuine or unau-
thorised parts may damage the engine.

- Always use new gaskets and oil seals during re-assembly.

- After dismantling, clean the components with solvents that are non-inflammable or with a high flammability
point. Lubricate all working surfaces before re-assembling, excluding tapered joints.

- After re-assembly, check that all components have been correctly fitted and that they are functioning per-
fectly.

- For dismantling, checking and re-assembly operations, use only tools with metric measurements. Metric
screws, nuts and bolts are not interchangeable with imperial measurement joining devices. Using unsuitable
tools and joining devices may damage the engine.

- In the case of work on the engine involving the electrical circuitry, check that electrical connections have
been correctly fitted.

4
Use genuine DERBI spare parts and lubricants recommen-
ded by the Manufacturer. Non-genuine or unauthorised par-
ts may damage the machine.

Only use the specific tools intended for this machine.

During re-assembly, always use new seals, gaskets, piston
rings and grommets.

After dismantling, clean the components with solvents that

are non-inflammable or that have a high flammability point.
Grease all working surfaces before assembling, excluding
tapered joints.

After assembly, check that all components have been correc-

tly fitted and that they are functioning perfectly.

For dismantling, checking and re-assembly operations, use

only tools with metric measurements. Metric screws, nuts
and bolts are not interchangeable with imperial measure-
ment joining devices. Using unsuitable tools and joining de-
vices may damage the machine.

In the case of work on the machine’s electrical circuitry,

check that electrical connections have been correctly fitted,
especially the earth connections.

VEHICLE IDENTIFICATION

VEHICLE CHASSIS CODE ENGINE CODE

GPR 125 Racing VTHGS1A1A?Hxxxxxx E1 19Exxxxxx

5
RACING 125 GENERAL TECHNICAL DATA

Engine Single cylinder 2-stroke EURO 2

Diameter x stroke 56,0 x 50,7 mm

Cylinder capacity 124,9 cm3
Carburettor Mikuni TM 28-92

Cooling Liquid
Starting Electric

Compression ratio 12,5 : 1

Maximum power 11 kW (14.9 HP) / 8.000

Fuel Lead-free petrol

Greasing system Wet crankcase
Ignition Ignition D.I.U-

Spark plug NGK BR8ES

Primary transmission Gears
Clutch Multi-disk
Gears 6 speed

Front suspension 40 mm Ø hydraulic fork. 110 mm travel

Rear suspension Single shock absorber. 14mm Ø rod. 110 mm travel
Tyres 140/70 x 17”
Front disk brake 300 mm hydraulic disk

Rear disk brake 180 mm Ø hydraulic disk

Battery 12 V 4 Ah

Distance between axles 1.355 mm

Height 1.160 mm
Length 2.024 mm
Width 720 mm
Fuel tank 13 L.

6
PREPARATION FOR REMOVAL AND DISMANTLING

1. Remove all the dirt, grime, dust and other foreign material
before removing and dismantling.

2. Use proper cleaning tools and equipment.

See “SPECIAL TOOLS”.

3. On dismantling the motorcycle, always keep paired par-

ts together. This includes gears, cylinders, pistons and other
parts submitted to natural wear in pairs. Paired parts must
always be reassembled or replaced together.

4. While dismantling the motorcycle, clean all the parts and

lay them out on trays in the order dismantled. This speeds up
reassembly and ensures the correct fitting of all the parts.

5. Keep all parts away from any contact with fire.

7
SPARE PARTS
S

1. Use only genuine DERBI spare parts. For all lubrication

tasks use oils and greases recommended by DERBI. Other
makes may seem similar in their function and appearance,
but are inferior in quality.

SEALS, RETAINING RINGS AND O-RINGS

1. Replace all seals, retaining rings and O-rings when servi-

cing the engine.
All surfaces receiving seals, retaining ring edges and O-rings
must be cleaned.

2. Apply oil to all paired parts and bearings during reassem-

bly. Apply grease to the retaining ring edges.

TAB WASHERS/SPACERS AND SPLIT PINS

1. After removing them, renew all tab/spacer washers (1)

and split pins. Bend the tabs to fit the flat surfaces of the
bolt or nut once they have been tightened to the specified
torque.

BEARINGS
GS AND RETAINING
G RINGS
GS

1. Fit bearings and retaining rings in such a way that the ma-
nufacturers marks remain visible. On fitting retaining rings,
applying a thin film of light lithium soap based grease to
their edges. Where required, apply oil generously when fit-
ting bearings.

WARNING
DO NOT USE COMPRESSED AIR TO DRY BEARINGS. THIS
WILL DAMAGE TO THE BEARING SURFACES.

8
LOCKING RINGS

1. Examine all the locking rings carefully before fitting.

Always replace the gudgeon pin circlips after every use. Re-
place distorted locking rings. On fitting a locking ring (1),
ensure that the sharp edge (2) is on the opposite side to the
force (3) to be applied to it.

See the figure on the side, (4) Axle.

SPECIAL TOOLS

The following special tools are needed for assembly and for
complete and exact adjustments. Only use the proper special
tools; thereby avoiding damage caused by the use of unsui-
table tools or improvised techniques.

1.00M12501258

Gudgeon pin extractor.

This tool is used for dismantling the gudgeon pin.

00M12501259

Magneto flywheel extractor.

This tool is used for dismantling the magneto flywheel.

9
 3. 00M12501260

Clutch holder.

This tool is used to hold the clutch assembly when fitting or

dismantling its axle nut.

4. 00M12501261

Crankcase separator.

This tool is used to separate the crankshaft from the case.

4. 00H05100181

40 mm fork seal inserting tool

This tool is used for inserting the seals into the forks, as des-
cribed in the corresponding section.

10
GENERAL SPECIFICATIONS

MODEL GPR 125 Racing

BASIC WEIGHT
With oil and full fuel tank 131 kg

TYPE OF FLUID AGIP CITY 2-stroke API SJ « DONUT» + JASO MA - PART

Engine oil SYNTHETIC oil, SAE Viscosity: SAE 10W30 or higher

OIL CAPACITY
Engine oil.
Regular oil change. 0,75 L.
Total capacity 0,8 L.

AIR FILTER Wet-type element

FUEL
Type Lead free petrol (95 octane or higher)
Fuel tank capacity 12 L.
Reserve volume 2 L.

CARBURETTOR
Type TM 28-92/1
Manufacturer MIKUNI

SPARK PLUG
Type / Manufacturer NGK BR8ES
Gap between the electrodes 0.7 mm.

CLUTCH TYPECLUTCH TYPE Wet, multi-disk.

TRANSMISSION
Primary reduction system Helicoidal gears
Primary reduction ratio 71/22 (3.227)
Secondary reduction system Transmission chain
Secondary reduction ratio 57/16 (3.563)
Type of transmission Constant gearing, 6 speed
Operation With the left foot
Gear ratio
1 34/12 (2.883)
2 30/16 (1.875)
3 24/17 (1.412)
4 24/21 (1.143)
5 22/23 (0.957)
6 18/22 (0.818)

CHASSIS
Frame type Delta Box
Caster angle 26.4º
Trail 109 mm.

11
 MODEL GPR 125 Racing

NEUMÀTICOSTYRES
Size Tubeless
Front
Rear 110/80 – 17 “
140/70 – 17”

TYRE PRESSURES (COLD)

Rider only
Front 170 kPa (1,7 kg/cm2)
Rear 190 kPa (1,9 kg/cm2)
Rider and passenger
Front 190 kPa (1,9 kg/cm2)
Rear 210 kPa (2,1 kg/cm2)

FRENO
Front brake
Type 300 mm Ø disk. VENTILATED
Operation With the right hand
Front brake
Type 180 mm Ø disk. VENTILATED
Operation With the right foot

SUSPENSION
Front suspension Hydraulic fork
Rear suspension Swnging arm + hydraulic shock absorber

SUSPENSION TRAVEL
Front 110 mm
Rear 110 mm

ELECTRICAL SYSTEM
Ignition system DIU
Charging system Magneto flywheel
Battery type Yuasa MF YTX5L-BS
Battery capacity 12v 4Ah

BULB VOLTAGE AND WATTAGE PER QUANTITY

Headlight 12v 35W dip H11

12v 35W main beam H11
Frontt side-light 12v 2.3W
Rear side/brake light 12v 2,3W/16W
Front turn indicators 12v 10Wx2
Rear turn indicators 12v 2.3Wx2

INDICATOR LIGHTS
Water temperature indicator LED
Oil indicator LED
Fuel indicator LED
Main beam indicator LED
Turn indicators pilot light LED

12
ENGINE SPECIFICATIONS

MODEL GPR 125 Racing

CYLINDER HEAD
<Distortion limit> <0,03 mm>
* The lines indicate measurement at a right angle

CYLINDER
Diameter 56,00 ~ 56,02 mm

Conicity limit 0,05 mm

Ovality limit 0,01 mm

PISTON
Cylinder-piston play 0.045 ÷ 0.050 mm
<Limit> <0.10 mm>
Diameter of piston “D” 55.950 ÷ 55.955 mm

Measurement point “H” 10 mm

Piston off-set 0,5 mm

PISTON RINGS
Top ring: B
Type Keystone
Dimensions (BxT)
T
Top ring (ignition) 1.2 x 2.4 mm
Bottom ring 1.2 x 1.89 mm
Gap between points (fitted)
Top ring 0.300 ÷ 0.450 mm
Bottom ring 0.300 ÷ 0.450 mm
Side play (fitted)
Top ring 0.020 ÷ 0.060 mm
Bottom ring 0.035 ÷ 0.070 mm

CRANKSHAFT

Width “A” 57.90 ÷ 57.95 mm

<Warp limit “C”> <0.03 mm>
Connecting rod bottom play “D” 0.2 ÷ 0.7 mm
< Connecting rod top play limit “F”> <0.026 ÷ 0.040 mm>

13
 MODEL GPR 125 Racing

CLUTCH
Thickness of friction disks 2.9 ÷ 3.1 mm
Quantity 7 parts
<Friction disk wear limit> 2.7 mm
Thickness of the separators 1.05 ÷ 1.35 mm
Quantity 6 parts
<Distortion limit> 0.05 mm
Free length of clutch spring 34.5 mm
Quantity 5 parts
Minimum length 32 mm
Clutch freeing method Internal by lever system
Actioning rod warp limit <0.15 mm>

GEAR SELECTOR
Type Selector and guide bar

CARBURETTOR
Type TM 28-92/1
ID mark 1 DO
Main jet #210
Main pneumatic jet 0.7
Jet needle 5J40 – 2
Needle jet Q2M (#939)
Pilot outlet 0.6
Pilot jet #17.5
Bypass1 1.6
Pilot screw (turns) ¼
Valve seat size 2.8
Choke jet 1 #40
Choke jet 2 #60
Float height 15.5 ÷ 16.5 mm
Chamber level 1.5 ÷ 2.5 mm
Engine idle speed 1250 ÷ 1450 rpm

LUBRICATION SYSTEM
Colour code Dark blue
Minimum run 0.15 ÷ 0.20 mm
Maximum run 1.85 ÷ 2.05 mm
Minimum output 0.38 ÷ 0.50 cm3
Maximum output 4.65 ÷ 5.15 cm3
Pulley adjustment mark Self-adjusting

REED VALVE
Valve thickness 0.5 mm
Stop plate heigh 8.8 mm
Valve bend limit 0.5 mm

14
ENGINE TIGHTENING TORQUES

THREAD TIGHTENING TORQUE

PARTS TO BE TIGHTENED AMNT. OBSERVATIONS
SIZE Nm [Link]

Spark plug 1 M14 x 1.25 20 2.0

Cylinder head Cap nuts 5 M8 x 1.25 22 2.2
Cylinder Stud bolt 9 M8 x 1.25 13 1.3 LOCTITE
bolt securing
adhesive
Nut 4 M8 x 1.25 28 2.8

Exhaust valve support, valve Seal

cover
Stud 6 M5 x 0.8 7 0.7
Exhaust valve pulley Stud M6 x 1.0 10 1.0
Thermostat valve cover Bolt 3 M6 x 1.0 8 0.8
Water pump cover Bolt 2 M6 x 1.0 8 0.8

Water drain bolt 1 M6 x 1.0 10 1

Radiator Stud 2 M6 x 1.0 8 0.8

Radiator cover Bolt 1 M5 x 0.8 5 0.5

Oil pump Bolt 2 M5 x 0.8 5 0.5

Carburettor gasket Stud 4 M6 x 1.0 8 0.8

Air filter Bolt 2 M6 x 1.0 5 0.5
Silencer Nut 2 M8 x 1.25 18 1.8 LOCTITE
Stud bolt 2 M8 x 1.25 10 1.0 bolt securing
adhesive
Stud 3 M6 x 1.0 8 0.8

Oil change drain plug 1 M8 x 1.25 15 1.5

Left hand crankcase cover Bolt 6 M6 x 1.0 5 0.5
Right hand crankcase cover Bolt 6 M6 x 1.0 8 0.8

Oil pump cover Bolt 3 M6 x 1.0 5 0.5

Crankcase Bolt 12 M6 x 1.0 8 0.8

Oil seal support Bolt 1 M8 x 1.25 16 1.6
Cover Bolt 2 M6 x 1.0 8 0.8

Clutch housing Nut 1 M12 x 1.0 70 7

Clutch spring Stud 5 M5 x 0.8 6 0.6

Clutch disk cover Bolt 2 M6 x 1.0 10 1

15
 THREAD TIGHTENING TORQUE
PARTS TO BE TIGHTENED AMNT. OBSERVATIONS
SIZE Nm [Link]

Drive sprocket Nut 1 M6 x 1.0 60 6

Tachometer cog housing Stud 1 M6 x 1.0 5 0.5

Stop lever Stud 1 M6 x 1.0 14 1.4 LOCTITE

bolt securing
adhesive

Change pedal Stud 1 M6 x 1.0 15 1.5

Starter motor

Rotor 1 15 1.5

Nut 1 M12 x 1.25 80 8

16
 MODEL GPR Racing 125 c.c.

STEERING SYSTEM
Type of steering bearing Rigid ball bearing

FRONT SUSPENSION
Free length of forks spring 851 mm
<Limit> 845 mm

Spring strength 20 N/mm

Travel 110 mm

Oil/bar capacity 340 cm3

Type of oil FSAE 7.5W fork oil or higher

REAR SUSPENSION 34 mm
Shock absorber travel 140 mm
Free length of spring 130 mm
Length of spring fitted 100 N/mm (0<32 mm)
Spring strength 170 N/mm (32<50 mm)

REAR SWINGING ARM

<Play limit> At the end <1,0 mm>
At the side <1,0 mm>

FRONT WHEEL
Type Injected metal
Wheel size 17”
Wheel material Aluminium alloy
<Wheel distortion limit> <0.5 mm>
Radial Side <0.5 mm>

REAR WHEEL
Type Injected metal
Wheel size 17”
Wheel material Aluminium alloy
<Wheel distortion limit> <0.5 mm>
Radial Lateral <0.5 mm>

DRIVE CHAIN
Number of links 130
ChaIn play. 11 mm

17
 MODEL GPR Racing 125 c.c.

FRONT DISK BRAKES

Type VENTILATED hydraulic disk
Disk width 4.0 mm
<Wear limit> 3.5 mm
Brake pad thickness 4.5 mm
<Wear limit> 1.5 mm

REAR DISK BRAKES

Type VENTILATED hydraulic disk
Inner diameter of brake drum 4.0 mm
<Wear limit> 3.5 mm
Brake shoe thickness 4.5 mm
<Wear limit> 1.5 mm

LEVERS AND TWISTGRIP

Brake lever clearance 10 ~ 15 mm
(at the end)

Clutch lever clearance 10 ~ 15 mm

(at the end)

Throttle twist grip clearance 2 ÷ 6 mm

18
 MODEL GPR 125 Racing

VOLTAGE 12V
Ignition system:
Ignition point (B.T.D.C) 17 º a 1.500 rpm
Advance type Digital

DIU
Model of magneto/manufacturer F4FU/YAMAHA
Detector coil resistance 310 Ω ± 20% W/R-W/L
Generator coil resistance 730 Ω ± 20% B/R-G/W
Generator coil resistance 600 Ω ± 20% G/L-G/W
Model of DIU/manufacturer 1D0/YAMAHA

IGNITION COIL
Model 3RW/YAMAHA
Primary winding resistance 0.23 Ω ± 20%
Secondary winding resistance 7.9 k Ω ± 20%

SPARK PLUG CONNECTOR

Type Resin
Resistance 5KΩ ± 20% a 20º C

CHARGING SYSTEM
Type Magneto

Magneto flywheel Model/Manufacturer F4FU / YAMAHA

Output 14V 170 W 5000 rpm

Charging coil resistance 0.6Ω ± 20% a 20º C W-W

(colour of the conductors)

LIGHTING VOLTAGE (Min) 12V / 3.000 rpm

(Max) 15V / 8.000 rpm

RECTIFIER/ REGULATOR
Type Shortcircuit type semiconductor
Model SH629B-11/SHINDENGEN
Voltage regulated without charge 14.1 ~ 14.9 V
Capacity 25 A
Resistance limit voltage 200 V

19
 MODEL GPR 125 Racing

HORN
Type Flat
Quantity 1
Maximum current 1,5 A (12V)

TURN INDICATOR RELAY

Frequency 65 ~ 100 cycles/mínute
Power 10W x 2

SAFETY CIRCUIT
Type Fuse
Individual circuit current x quant.
Main 15A x 1
Reserve 7,5A x 1

STARTER RELAY
Type Electromagnetic
Model 12 V 180 A
Nominal voltage 12 V
Minimum functioning voltage 8V
Coil resistance 4.2 ~ 4.6 Ω a 20 ºC

STARTER MOTOR
Output power 0.2 kW
Length of the brushes 5x7x7 mm
<Limit> <3.5 mm>
Spring pressure 4.9 N ± 20%
Commutator diameter 17.6 mm
<Limit> <16.6mm>
Depth of the mica 1.35 mm

20
The following table specifies torques for standard ISO fixing
devices. The torque specifications for special components or
assemblies are indicated in the respective chapters of this
manual.

To prevent distortions, tighten assemblies with various fixing

devices progressively and in a crossed or alternating manner
until the specified torque is reached. Unless stated otherwise,
the specified torques require threads to be clean and dry.
Components should be at room temperature.

A: Distance between flat surfaces.

B: Outer diameter of the thread.

GENERAL TORQUE SPECIFICATIONS

(A) NUT (B) BOLT
N·m Kgf.m [Link]

10 mm 6 mm 6 0,6 4,3
12 mm 8 mm 15 1,5 11
14 mm 10 mm 30 3,0 22
17 mm 12 mm 55 5,5 40
19 mm 14 mm 85 8,5 61
22 mm 26 mm 130 13,0 94

21
 CHASSIS TIGHTENING TORQUES

TIGHTENING TORQUE MAX. TORQUE

DESCRIPTION OF SECURING DEVICE
(m-Kg) (m-Kg)

M6x100 INSTRUM.-CHASSIS SUPPORT SECURING DEV. 0,8-1 1

M10xl.5 10.9 TOP SEC. SHOCK-CHASSIS [Link]. 4,5-5,5 5,5
MI0x1.5 10.9 [Link] BOTTOM [Link]. 4,5-5,5 5,5
M8x1.25 12.9 ENGINE-CHASSIS CRADLE SEC. DEV 2,5-2,9 2,9
M8x1.25 8.8 REAR SUBCHASSIS – CHASSIS [Link]. 1,7-1,9 1,9
M8X125 12.9 [Link] BRACE-CHASSIS [Link]. 2,5-2,9 2,9

M8x125 12.9 REAR ENGINE-CHASSIS [Link]. 2,5-2,9 2,9

M10x150 12.9 FRONT ENGINE-CHASSIS [Link]. 5,5-5,9 5,9

M8x125 12.9 ENGINE [Link]-BRACE [Link]. 2,5-2,9 2,9

M14x200 SWINGING ARM AXLE- CHASSIS [Link]. 7-8 8

M8x1.25 RIDER FOOTREST SUPPORT-CHASSIS [Link]. 1,7-1,9 1,9
M8x1.25 PILLION FOOTREST SUPPT.-CHASSIS [Link]. 1,7-1,9 1,9
M8x1.25 FOOTREST SUPPT. SCTO.- RIDER FOOTREST S.D. 1,7-1,9 1,9
M20x100 STEERING FORK - CHASSIS [Link]. 3-3,5 3,5
M8x125-8 EXHAUST PIPE-CYLINDER [Link]. 1,7-1,9 1,9
M8x125-8 EXHAUST PIPE-CHASSIS [Link] 1,7-1,9 1,9
SILENCER-SUPPORT [Link].
STEERING LOCK-FORK PLATE [Link]. M8xl25 1,7-1,9 1,9

M8x125 TOP PLATE LOCK SEC. DEV. 1,7-1,9 1,9

M5x80 COUNTERWEIGHT-HANDLEBARS [Link]. 0,35-0,45 0,45

M8x125 SEMI-HANDLEBAR – PLATE [Link]. 1,7-1,9 Sealed 1,9

HANDLEBAR PLATE – PLATE [Link]. 1,7-1,9 1,9

M14x150 FRONT WHEEL – FORK [Link]. 7-8 8

M8x125 FORK ARM LOCK SEC. DEV. 1,7-1,9 1,9
M10x1.5 FRONT BRAKE CALLIPER – FORK [Link]. 3,5-4 Sealed 4
M16x200 REAR WHEEL – SWINGING ARM SEC. DEV. 11-13 15
M8x125 PROP STAND – CHASSIS [Link]. 1,7-1,9 1,9
M6x100 10.9 REAR BRAKE DISK-WHEEL SEC. DEV. 1-1,2 Sealed 1,2
M6x100 WHEEL TENSIONER- SWINGING ARM [Link]. 0,8-1 1

M8x125 10.9 DRAG PLATE- WHEEL [Link]. 2,5-2,9 Sealed 2,9

M6x100 RADIATOR-CHASSIS SEC. DEV. 0,8-1 1

22
 TIGHTENING TORQUE MAX. TORQUE
DESCRIPTION OF SECURING DEVICE
(m-Kg) (m-Kg)

M6x100 10.9 FRONT BRAKE DISK-WHEEL SEC. DEV. 1-1,2 Sealed 1,2
M10x150 10.9 BRAKE BRACE SEC. DEV. 3,5-4 4
M6x18.8 REAR BRAKE CYLINDER SEC. DEV. 0,8-1 1

4.8 AUTHOR. FAIRING SUPPORTS SEC. DEV. 0,1-0,2 0,2

4.8 AUTHOR. FAIRING COVER SEC. DEV. 0,1-0,2 0,2

M5x80 VARIOUS METAL PARTS TO CHASSIS SEC. DEV. 0,35-0,45 0,45

M6x100 VARIOUS METAL PARTS TO CHASSIS SEC. DEV. 0,8-1 1

M8xl25 VARIOUS METAL PARTS TO CHASSIS SEC. DEV. 1,5-1,9 1,9

M5x80 VARIOUS PLASTIC PARTS TO CHASSIS SEC. DEV. 0,1-0,2 0,2
M6x100 VARIOUS PLASTIC PARTS TO CHASSIS SEC. DEV. 0,2-0,35 0,35
LOCKTITE 243-TYPE THREAD SEALER

23
 INTRODUCTION

This chapter contains all the necessary information for carrying out recommended inspections and adjust-
ments. If followed correctly, these preventative maintenance procedures will ensure a reliable operation
of the machine and a longer operating life. The need for costly servicing will be significantly reduced. This
information applies not only to machines already in service but also new machines in preparation for being
sold. All technical assistance staff should familiarise themselves with the whole of this chapter.

PERIODICAL MAINTENANCE/LUBRICATION INTERVALS

1000 5000 10000 15000 20000 25000

Nº ELEMENT SERVICE km/2m km/12m km/24m km/36m km/36m km/60m

1 Crankcase oil Check level X X X

2 Crankcase oil Change X X X
3 Spark plug Check electrode gap X X X X

4 Spark plug Replacement X X

5 Air filter Clean X X X X X X

6 Carburettor Adjust and clean X X X X X X

7 Coolant Check level X X X X

8 Coolant Change X X

9 Radiator Clean externally X X

10 Mileometer resend Lubrication X X X

11 Handlebars Check for damage and distortion X X X X X X

12 Brake levers Lubrication X X X X X X
13 Clutch lever Adjust free play X X X X X X
14 Brake pads Check wear X X X X X X
15 Flexible brake hoses Check condition X X
16 Brake liquid Check level X X X

17 Brake liquid Change Every 2 years

18 Drive chain Check condition and tension X X X X X X

19 Drive chain Replacement X X X X X

20 Security locks Check X X X

21 Drag plate Check the security locks X X X X X

22 Front fork Check X X X X

24
 1000 5000 10000 15000 20000 25000
Nº ELEMENT SERVICE km/2m km/12m km/24m km/36m km/36m km/60m

23 Front forks Change the oil X X

24 Rear shock absorber Check X X
25 Electrical wiring Check X X X X X X
26 Front headlight Height adjustment X X
27 Tyres Check wear X X X X X
28 Tyres Pressure X X X X X X
29 Wheels Check X X X
30 Inlet reeds Check X X
Cylinder head, cylinder Clean X X
31 and piston
32 Piston segments Check X X X

33 Piston segments Replacement X X

34 Cylinder head bolts/nuts Check tightness X X X X

35 Fuel and oil pipes Check X X X X

36 Fuel and oil pipes Replacement X X

37 Brakes Machine test and check X X X X X X

38 Oil pump Check and purge if necessary X X X

* It is recommended that these elements are checked by an authorised DERBI dealer.

25
DISMANTLING
1. Extract:
- Seat.

N.B.
INSERT THE IGNITION KEY, TURN IT CLOCKWISE A QUAR-
TER TURN AND THEN REMOVE THE SEAT.

2. Extract:
Passenger seat.
- The nut under the seat must be unscrewed.
- Pull the seat forwards.

3. Extract:
- Cowling.

The black cover (1) in the figure must be be removed by uns-

crewing the bolts (2) on both sides.

The studs (4) on both sides then need to be unscrewed, and

the clamp securing the exhaust pipe. The cowling (3) can
then be removed by pulling out backwards.

4. Closing:
- Dismantle:
- Top side cover.

To do so, the front air inlet (5) needs to be removed on the

corresponding side together with its securing bolts (6).

Then remove the bolts securing the cover (indicated in the

fugure).

26
5. Dismantle:
Bottom fairing
Remove the screws located at the bottom (keel joint) and
another located at the front.

6. Dismantle:
Fuel tank. Remove the 3 screws in the picture.

N.B.
THE FUELTAP WORKS BY PRESSURE. IF THIS IS WORKING
PROPERLY, THE TANK DISMANTLING PROCESS IS VERY
STRAIGHTFORWARD AND IS OUTLINED BELOW:
- DISCONNECT THE FUEL LEVEL SENSOR (1).
- REMOVE THE ENGINE BREATHER PIPE (2).
- REMOVE THE FUEL OUTLET PIPE (3).

IF HOWEVER THE TAP IS NOT WORKING WELL, THE PRO-

CESS TO FOLLOW IS:
- TURN THE KEY TO THE OFF POSITION.
- DISCONNECT THE NEGATIVE BATTERY TERMINAL.
- OPEN THE FUEL TANK CAP (TO REDUCE THE PRESSURE
IN THE TANK).
- EMPTY THE PETROL FROM THE TANK USING A PUMP.
- THEN FOLLOW THE PROCESS DESCRIBED PREVIOUSLY.

WARNING
THE TANK WILL NEVER BE COMPLETELY EMPTIED. TAKE
CARE THEREFORE TO CLEAN UP ANY SPILLAGES THAT
OCCUR, WHICH MAY DIRTY THE FAIRING OR CHASSIS.

REFITTING
- This is a reversal of the “REMOVAL” procedure.
- Take note of the following points:

Fit:
1) Fuel tank
2) Bottom fairing
3) Front air inlet
4) Top side covers
5) Cowling
6) Seats.

27
CO MEASUREMENT AND VACUUM RUNNING ADJUSTMENT
1. Start the engine and leave to warm up for a few minutes.

2. Connect:
-An inductive tachometer to the spark plug lead.

N.B.
THE IDLING REGULATOR IS ACCESSED FROM THE LEFT
HAND SIDE OF THE MACHINE. SEE THE COVER DISMAN-
TLING METHOD IN THE PREVIOUS SECTION.

3. Check:
- Idle speed (standard).

Outside that specified => Adjust.

Turn the no load running screw (1) inwards or outwards un-

til the specified no load running is obtained.

No load running:
1.250 ~ 1.450 rpm

4. Fit:
- the CO meter into the exhaust silencer.

CO concentration:
3,0 ~ 5,0 %

Outside that specified => Adjust.

28
5. Adjust:
- CO concentration.

Adjustment steps:
- Turn the mixture screw inwards or outwards until the spe-
cified CO concentration is obtained.

Adjustment band:
Rub probe point~ up to 6 turns outwards.

N.B.
TURN THE NO LOAD RUNNING SCREW (2) TO ADJUST
THE ENGINE’S NO LOAD RUNNING, SINCE THE CO
CONCENTRATION ADJUSTMENT MAY AFFECT THE NO
LOAD RUNNING.

- After adjusting, check the CO concentration and remove

the CO probe. Ensure that there are no variations in the
idle speed.

ADJUSTING THE THROTTLE CABLE

N.B.
BEFORE ADJUSTING THE THROTTLE CABLE, THE NO LOAD
RUNNING MUST BE ADJUSTED.

1. Check:
- Throttle cable play (a).

Outside that specified => Adjust.

Clearance:
2÷6 mm.
In the throttle twist grip plate:

2. Adjust:
- Throttle cable play.

Adjustment steps:

N.B.
NEVER ACCELERATE WHILE THE ENGINE IS STOPPING.

29
- Loosen the throttle cable locknut (2).

- Turn the adjuster (1) inwards or outwards until the speci-

fied play is obtained.

Turning inwards (a) = Increasing the play.

Turning outwards (b) = Reducing the play.

- Tighten the locknut.

N.B.
IF THE PLAY IS STILL INCORRECT, ADJUST IT USING THE
ADJUSTER BELOW THE TWIST GRIP.

WARNING
AFTER ADJUSTMENT, TURN THE HANDLE IN BOTH DI-
RECTIONS TO ENSURE THAT THERE IS NO NO-LOAD VA-
RIATION .

INSPECTING THE SPARK PLUG

1. Extract:
- Spark plug connector.

- Spark plug.

ATTENTION
BEFORE REMOVING THE SPARK PLUG, BLOW AROUND IT
WITH COMPRESSED AIR TO REMOVE ANY DIRT, THEREBY
PREVENTING THIS FROM FALLING INTO THE ENGINE.

2. Check:
- Spark plug type

Incorrect => Replace.

Standard spark plug:

NGK BR8ES

3. Inspect:
- Electrode (1).

Damage/wear => Replace.

- Insulator (2).

Abnormal colour => Replace.

The normal colour is light brown.

30
[Link]:
- Spark plug
(Clean the spark plug with a spark plug cleaner or wire
brush)

5. Measurement:
- Gap between the electrodes (a), (using a feeler guage).

Outside that specified => Adjust the gap.

Gap between electrodes:

0,7 mm

6. Fit:
- Spark plug

Spark plug:
20 N.m ( 2 kgf.m)

N.B.
- BEFORE REFITTING THE SPARK PLUG, CLEAN ITS SEA-
TING SURFACE AND GASKET.

- IF NO TORQUE WRENCH IS AVAILABLE, A GOOD WAY

OF JUDGING THE CORRECT TORQUE IS TO TIGHTEN (1)
THE SPARK PLUG BY HAND AND THEN TIGHTEN IT FROM
¼ TO ½ A TURN – AS FAR AS (2).

- ALWAYS USE A NEW GASKET.

31
INSPECTING THE ENGINE OIL LEVEL

1. Place the motorcycle on a flat surface.

N.B.
MAKE SURE THE MOTORCYCLE IS VERTICAL WHEN CHEC-
KING THE OIL LEVEL.

2. Start the engine and leave to warm up for a few minutes.

3. Stop the engine.

4. Check the oil level in the inspection window (1) (located

in the right hand crankcase cover).

N.B.:
THE OIL LEVEL MUST BE BETWEEN THE MAXIMUM (2) AND
THE MINIMUM (3).

5. If the oil is below the minimum level, add oil up to the

correct level.

RECOMMENDED OIL FOR THE ENGINE

Recommended oil for the engine:

SAE 10W40 or higher

6. Start the engine and leave to warm up for a few minutes.

7. Stop the engine.

N.B.
WAIT A FEW MINUTES FOR THE OIL TO PERCOLATE DOWN
BEFORE RE-CHECKING THE OIL LEVEL.

CHANGING THE ENGINE OIL

1. Start the engine and leave to warm up for a few minutes.

2. Stop the engine and place a container under the engine.

3. Extract:
- Oil filler cap (1).
- Oil drain plug (2).
Drain the oil from the crankcase.

4. Fit:
- Drain plug (1).

Drain plug:
2,0 Kgf.m (20 N.m)

32
5. Replenish:
- Oil in the crankcase.

Quantity of oil:
0,8 L

6. Check:
- The engine oil level.

See “INSPECT THE ENGINE OIL LEVEL” section

INSPECTING THE EXHAUST SYSTEM

1. Inspect:
- Bolts (1) (exhaust pipe)
Loose/damaged => Tighten/replace.

- Gasket (exhaust pipe).

Leaking exhaust fumes => Tighten/replace.

Bolt:
8 N.m (0,8 kgf.m)

2. Inspect:
Bolts securing the exhaust pipe to the chassis.
Loose/damaged => Tighten/replace.

Bolt:
17-19 N.m (1,7-1,9 kgf.m)

RENEWING AIR FILTER

N.B.
IF THE MACHINE IS USED IN THE RAIN OR IN DUSTY CON-
DITIONS, THE FILTER SHOULD BE CHECKED AND REPLACED
MORE FREQUENTLY THAN THAT SET OUT IN THE MAINTE-
NANCE TABLE OR PROGRAMMED IN THE USE AND MAIN-
TENANCE MANUAL.

Extract:
Proceed in the following way:

- Rest the machine on the prop stand. Remove the fuel tank
(see previous sections).

33
 - To remove the top cover, remove the clips securing the filter
body (see picture).

- Extract the foam air filter, wash it in soapy water, then wring
it out and dry it completely. Next, soak it in special oil for fil-
ters and refit it.

Fitting:
- Fit in reverse order to dismantling.

- Then refit the top filter cover.

- Seal the box cover with silicon.

Recommended oil:
AGIP FILTER OIL

WARNING
NEVER USE PETROL TO CLEAN THE AIR FILTER ELEMENT. A
SOLVENT OF THIS TYPE MAY CAUSE FIRE OR EXPLOSION.

ADJUSTING
JUS G THE C
CLUTCH
U C

Check:
- Clutch cable play (a).

Outside that specified => Adjust.

Clearance (clutch lever):

10 – 15mm at the end of the lever.

2. Adjust:
- Clutch cable play.

Adjustment steps:
Lever end.

- Turn the adjuster (1) inwards or outwards until the specified

play is obtained.

Turning inwards (a)= Increases the play.

Turning outwards (b) = Reduces the play.

34
ADJUSTING THE FRONT BRAKES

This machine is fitted with hydraulically activated disk brakes.

This type of brakes comes with adjustment factory set.
You must check that the brake fluid level is between the maxi-
mum and minimum.

N.B.
REMEMBER THAT THE LEVEL WILL BE AFFECTED BY THE DE-
GREE OF BRAKE PAD WEAR.

ADJUSTING THE REAR BRAKES

1. Check:
- Brake pedal clearance (a).

Outside that specified => Adjust.

Clearance:
5 - 10 mm

2. Adjust:
- Brake pedal clearance.

Adjustment steps:
Unscrew the nut (1): Joc palanca fre

Raise or lower the activator (2) to decrease or increase the

lever free clearance.

ATTENTION
ENSURE THAT THE BRAKES ARE NOT BINDING AFTER AD-
JUSTING THE PLAY.

INSPECTING THE BRAKE PADS

1. Apply the brake pedal or lever.

2. Inspect:
- Pads.

- Measure the brake pad lining thickness. If either of them is

below the service limit => Replace both pads.

Service limit (lining) => 1.5mm.

35
ADJUSTING
JUS G THE TIMING
G CHAÍN
C TENSION
SO

1. Put the motorcycle on the centre stand.

2. Check:
- Drive chaIn tension (a).

Outside that specified => Adjust.

(distance between the chain guide and the furthest point
vertically)

Drive chain tension:

11 mm

3. Loosen:
- Axle nut (1) (both sides).

4. Loosen:
- Axle (2).

5. Adjust:
- Drive chain tension.

- Move the axle inwards or outwards using the bolt (3) until
the specified tension is obtained.

6. Tighten the axle nuts to the nominal torque.

Nut (rear wheel axle):

70-80 N.m (7-8 kgf.m)

36
INSPECTING THE TYRES
[Link]:
- Tyre pressure
Outside that specified => Adjust.

WARNING
TYRE PRESSURE SHOULD ONLY BE CHECKED OR ADJUS-
TED WHEN THEIR TEMPERATURE IS THE SAME AS AMBIENT
TEMPERATURE. THE TYRES AND SUSPENSION SHOULD BE
ADJUSTED IN ACCORDANCE WITH THE TOTAL LOAD – RI-
DER, PILLION PASSENGER AND ACCESSORIES (COVERS,
SIDEBAGS, ETC. IF THESE ARE APPROVED FOR THIS MO-
DEL) AND IN ACCORDANCE WITH THE RIDING SPEED OF
THE MOTORCYCLE.

NEVER OVERLOAD THE MOTORCYCLE.

RIDING AN OVERLOADED MOTORCYCLE MAY CAUSE DA-

MAGE TO THE TYRES, ACCIDENTS OR INJURY.

BASIC WEIGHT: With oil and full fuel tank 131 kg

TYRE PRESSURES (COLD): FRONT TYRE REAR TYRE

170 kPa 190 kPa

Rider only
1,7 kg/cm2 1,9 kg/cm2
190 kPa 210 kPa
With pillion passenger
1,9 kg/cm2 2,1 kg/cm2

2. Inspect:
- Tyre surfaces.
Damage/wear => Replace.

Minimum tread depth:

0,8 mm

(1) Tread.
(2) Side wall.
(3) Wear indicator.

37
WARNING
RIDING WITH WORN TYRES IS DANGEROUS. WHEN THE
TYRE TREAD BEGINS TO SHOW SIGNS OF WEAR, THE
TYRES SHOULD BE REPLACED IMMEDIATELY.

MENDING A PUNCTURED INNER TUBE IS NOT RECOM-

MENDED. IF IT IS ABSOLUTELY NECESSARY TO DO SO,
TAKE GREAT CARE, AND REPLACE THE INNER TUBE WITH A
GOOD QUALITY ONE AS SOON AS POSSIBLE.

NEVER USE TUBELESS TYRES ON A WHEEL DESIGNED FOR

TYRES WITH INNER TUBES. THE TYRE MAY FAIL, AND THE
RESULTING BLOW-OUT MAY CAUSE AN ACCIDENT.

Wheels for tubed tyres => use only tubed tyres.

Wheels for tubeless tyres => use only tubeless tyres.

- Ensure that the tube is correctly fitted when using tyres with
inner tubes.

WARNING
AFTER FITTING THE TYRE, DRIVE WITH MODERATION FOR
A PERIOD TO ALLOW PARAFFINS TO BE CLEANED OFF THE
TYRE BY THE ROAD SURFACE.

38
INSPECTING AND TIGHTENING THE SPOKES

1. Inspect:
- Spokes (1).

Warps/damage => Replace.

INSPECTING THE WHEELS

1. Inspect:
- Wheels

Damaged/distorted => Replace.

N.B.
ALWAYS CARRY OUT WHEEL BALANCING WHEN A TYRE
OR A WHEEL IS FITTED OR REPLACED.

WARNING
NEVER ATTEMPT TO REPAIR A WHEEL.

INSPECTING THE BATTERY

1. Extract:
- Fuel tank.

See “SEATS, FAIRING AND FUEL TANK” section.

2. Inspect:
- Battery terminals.

Dirtiness => Clean with wire brush.

Poor connection => Put right.

39
N.B.
AFTER CLEANING THE TERMINALS, APPLY A THIN LAYER
OF GREASE TO THEM.

Replace the battery if:

- The voltage falls below a specific value.

ATTENTION
BEFORE USING THE NEW BATTERY, IT MUST BE CHARGED
TO ENSURE MAXIMUM PERFORMANCE.

3. Fit:
- Battery.

4. Connect:
- Battery cables.

ATTENTION
CONNECT THE POSITIVE CABLE (1) TO THE BATTERY FIRST
AND THEN THE NEGATIVE CABLE (2).

5. Fit:
Fuel tank

See “SEATS, FAIRING AND FUEL TANK” section.

INSPECTING THE FUSES

ATTENTION
ALWAYS DISCONNECT THE MAIN SWITCH WHEN INSPEC-
TING OR REPLACING A FUSE. FAILURE TO DO SO MAY RE-
SULT IN A SHORT CIRCUIT.

1. Lift out and remove to the left

- fuel tank

See “SEATS, FAIRING AND FUEL TANK” section.

– Fuse box (1).

40
2. Inspect:
- Fuse.

Steps for the inspection:

- Connect the multi-meter to the fuse to check if there is a
circuit.

N.B.
ADJUST THE MULTI-METER SELECTOR TO Ω X.

If the meter indicates , replace the fuse.

3. Replacing:
- Blown fuse.

Replacement steps:
- Disconnect the main switch.

- Fit a new fuse with the correct amperage.

- Turn on the switches to check the functioning of the corres-

ponding electrical devices.

- If the fuse blows again immediately, inspect the electrical

circuit.

WARNING
NEVER USE A FUSE WITH AN AMPERAGE OTHER THAN
THAT SPECIFIED. NEVER USE OTHER MATERIALS INSTEAD
OF A FUSE. AN INCORRECT FUSE MAY CAUSE MAJOR DA-
MAGE TO THE ELECTRICAL SYSTEM, MALFUNCTIONING
OF THE LIGHTS AND IGNITION, AND MAY ALSO CAUSE
A FIRE.

4. Fit:
- Fuse box.
- Fuel tank

See “SEATS, FAIRING AND FUEL TANK” section.

41
 ADJUSTING THE HEADLIGHT BEAM

1. Adjustment

- Headlight beam height

To adjust the height, turn the screw (2) in one of two direc-
tions:

SCREWING IN => Lower

UNSCREWING => Raise

2. Adjust:

- Headlight dispersion.
To adjust the headlight width, turn the screw (1) in one of
two directions:

SCREWING IN => Increase

UNSCREWING => Decrease

REPLACING THE HEADLIGHT BULBS

1. Extraiga:
- Headlight bulb holder.

Disconnect the bulb holder, turn it a quarter turn (see photo)

and pull it out.

Change the blown bulb and refit by repeating the process in

the reverse order.

2. If the whole headlight unit needs to be changed, carry

out the following process:
- Disconnect the bulb holder (1).

- Remove the screws (2) at the top, on the bottom inside and
outside under the cover (3).

The headlight can now be removed though the inside of the

front fairing.

42
WARNING
KEEP INFLAMMABLE PRODUCTS AND HANDS AWAY FROM
THE BULB WHILE IT IS LIT, BECAUSE IT WILL BE HOT. DO
NOT TOUCH IT UNTIL IT COOLS DOWN.

ATTENTION
AVOID TOUCHING THE BULB GLASS. KEEP IT FREE OF OIL.
IF NOT, THE TRANSPARENCY OF THE GLASS, THE DURABI-
LITY OF THE BULB AND THE AMOUNT OF LIGHT EMITTED
WILL BE AFFECTED. IF THE BULB BECOMES SOILED WITH
OIL, CLEAN IT CAREFULLY WITH A DAMP CLOTH OR WITH
ALCOHOL OR THINNER.

CHANGING TURN INDICATOR BULBS

1. Extract:
- Glass screw (1).

2. Dismantle:
- Glass cover.
- Power supply terminals

3. Turn the bulb carefully and pull out forwards.

4. Change the bulb (if necessary).

5. Reverse the dismantling process and refit the turn in-

dicator.

CHANGING
G G THE SIDE
S AND BRAKE LIGHT
G BULBS
U S

1. Extract:
- Passenger seat.

2. To remove the BRAKE LIGHT, turn the bulb holder (1) in

an anticlockwise direction and pull out.

3. To remove a SIDE LIGHT bulb, pull out the bulb holder (2).

43
 4. Should the headlight need to be completely dismantled, Piloto 2
the two screws (1) securing the unit to the cowling need
to be removed, and the unit removed by pushing carefully
through the rear of the cowling.

DISMANTLING THE ENGINE

N.B.:
THERE IS NO NEED TO REMOVE THE ENGINE TO DISMAN-
TLE THE FOLLOWING COMPONENTS:
- CYLINDER HEAD
- CYLINDER
- PISTON
- MAGNETO FLYWHEEL

DISMANTLING
S G THE SIDE
S COVERS
CO S AND FUEL
U TANK

4. Extract:
- FRONT covers
- Rider’s seat.
- Fuel tank

See “SEAT, SIDE COVERS AND FUEL TANK” section in

CHAPTER 3.

ENGINE
G O
OIL

1. Drain:
- Engine oil.

See the “CHANGING ENGINE OIL” section in Chapter 3.

BATTERY
1. Disconnect:
- Battery.

ATTENTION
FIRST DISCONNECT THE NEGATIVE CABLE (1) FROM THE
BATTERY AND THEN THE POSITIVE CABLE (2).

44
REMOVING THE ENGINE FROM THE CHASSIS

1. Dismantle side covers.

2. Remove the petrol tank.

3. Remove the exhaust pipe.

4. Remove the gear change lever.

- Remove bolt (1).
- Remove change backlash bush (2).

[Link] chain.
Remove chain coupling link clip.

6. Extract the radiator.

Drain the cooling system.

7. Dismantling the carburettor.

- Remove filter box-carburettor pipe (secured with a jubilee clip).

- Loosen jubilee clip on carburettor pipe to cylinder.

- Remove carburettor.

- Remove jubilee clip and pipe from cylinder head to carburettor.

45
 Remove system inlet (1) and outlet (2) hoses and tank hose (3).

Remove radiator.

8. Extract oil pump cable.

Remove cover.

46
Remove the retaining circlip with pulley and torsion recovery
spring.

- Extract cables and remove them from the engine.

9. Extract the oil tank to engine hose.

- Remove the tank hose and plug it.

- Plug the oil tank outlet.

10. Remove the clutch operating cable.

- Free the clutch cable from the handlebars.
- Remove the the tensioning cable from the crankcase.
- Remove the clutch operating cable.

11. Free exhaust valve operating cable.

- Remove cover (1).

- Loosen cable by screwing in and extract it from the pulley.

- Unscrew the two tensioners and remove the cables.

12. Disconnect:
- Stator coil connector.
- Impulse coil connector.
- Neutral switch connector.

Extract:
- Spark plug connector.

47
 12. Remove electrical connections.
- Remove spark plug connector.
- Remove the temperature meter cable.
- Remove the magneto cable.
- Remove earth cable from right hand side of the crankcase.
- Remove neutral earth cable.
- Remove starter motor power supply cable.
- Remove cables from the coil.

13. Removing the engine cradle.

- Remove the UNEX clamps.
- Remove the 6 bolts securing the cradle to the engine and to
the chassis.
- Withdraw the engine cradle from below the machine.

14. Extracting the engine.

Pull out the swinging arm axle without extracting it complete-
ly, ensuring that it only joins the swinging arm and the chassis.
Insert a support shaft into the other side joining only the swin-
ging arm and chassis, to ensure that the swinging arm and
chassis do not come loose.

Unfasten the engine from the top bracket. Remove the engi-
ne.

N.B.
IT IS ADVISABLE TO PLACE A SUPPORT UNDER THE ENGINE
BEFORE FREEING IT FROM THE CHASSIS, TO AID IN THE
DISMANTLING PROCESS.

CYLINDER HEAD, CYLINDER AND PISTON

1. Extract:
- Nuts and washers (cylinder head).
- The cylinder head and its gasket on the cylinder.

N.B.
LOOSEN EACH OF THE 5 BOLTS A QUARTER TURN IN
TURN, AND REMOVE THEM WHEN THEY ARE COMPLETELY
LOOSE.
LOOSEN THE NUTS IN THE ORDER SHOWN IN THE ADJO-
INING PICTURE.
CLEAN OFF GASKET DEBRIS AND CARBON DEPOSITS
WITHOUT SCRATCHING OR WEARING DOWN THE SUR-
FACES.

2. Extract:
- Nuts and washers (cylinder base).
- Clutch cable securing device.
- Cylinder and its gasket.

48
3. Extract:
- Gudgeon pin circlip.
- Gudgeon pin.
- Piston.
- Connecting rod big end needle bearing assembly.

N.B.
BEFORE REMOVING THE CIRCLIP FROM THE GUDGEON
PIN, COVER THE BASE OF THE CYLINDER WITH A CLEAN
CLOTH TO PREVENT ANYTHING FROM FALLING INTO THE
ENGINE.

BEFORE REMOVING THE GUDGEON PIN, ELIMINATE THE

ROUGH EDGES OF THE CICLIP GROOVE AND THE HOLE.
ONCE THE ROUGH EDGING HAS BEEN ELMINATED, AND
IF THERE IS STILL DIFFICULTY IN REMOVING THE GUD-
GEON PIN, USE THE GUDGEON PIN EXTRACTOR.

Gudgeon pin extractor:

00M12501258

DISMANTLING THE REED VALVE

1. Extract:
- The carburettor from the engine unit.
- Closing bolts from the inlet nozzle.
- Reed valve.

MAGNETO
G O

N.B.
THE MAGNETO CAN BE EXTRACTED WHILE THE ENGINE IS
MOUNTED ON THE FRAME, BY DETACHING IT FROM THE
LOWER LEFT HAND FAIRING

1. Extract:
- Left hand crankcase cover.
- Nut (magneto) (1).
- Flat washer (2).

N.B.
RELEASE THE MAGNETO NUT WHILE HOLDING THE MA-
NETO WITH THE UNIVERSAL (MAGNETO) ROTOR HOLDER
(3).

Holding the rotor:

00005253240

49
 2. Extract:
- Magneto flywheel (1).
- Pin.

N.B.
EXTRACT THE MAGNETO FLYWHEEL USING THE ROTOR
EXTRACTOR (2).
CENTRE THE ROTOR EXTRACTOR ON THE MAGNETO
FLYWHEEL. ENSURE THAT THE GAP BETWEEN THE EX-
TRACTOR AND THE FLYWHEEL IS THE SAME AT ALL PO-
INTS AFTER FITTING THE SECURING BOLTS. IF NECESSARY,
LOOSEN ONE OF THE BOLTS TO ADJUST THE EXTRACTOR
POSITION.

ATTENTION
COVER THE END OF THE CRANKSHAFT WITH THE SPAN-
NER TO PREVENT DAMAGE.

Magneto flywheel extractor:

00M12501259

3. Extract:
- Plate (1).
- Starter gear (2).

4. Extract:
- Needle bearings (1).
- Support shaft (2).

5. Extract:
- Nut
- Washer
- Drag pinion

CLUTCH
N.B.
THE CLUTCH ASSEMBLY CANNOT BE REMOVED WITH THE
ENGINE MOUNTED ON THE FRAME. FOR THIS, SEE “RE-
MOVING THE ENGINE FROM THE CHASSIS”.

1. Extract:
- Right hand crankcase cover.

N.B.
LOOSEN THE BOLTS FOLLOWING A DIAGONAL SEQUEN-
CE. DRAIN THE OIL FROM THE CLUTCH UNIT.

50
2. Extract:
- Gasket.
- Guide pins.

3. Extract:
- Pressure plate bolts (1).
- Clutch springs (2).
- Pressure plate (3).
- Friction disks (4).
- Separators (5).
- Spring (6).

N.B.
LOOSEN THE PRESSURE PLATE BOLTS DIAGONALLY.

4. Extract:
- Push rod 1
- Ball
- Locknut

N.B.
FLATTEN OUT THE TAB OF THE TAB WASHER.
LOOSEN THE CLUTCH HOUSING NUT WHILE HOLDING
THE HOUSING WITH THE UNIVERSAL CLUTCH HOLDER .

Universal clutch holder:

00M12501260

51
 5. Extract:
- Clutch housing nut (1).
- Tab washer (2).
- Clutch housing (3).
- Pressure washer (4).
- Clutch bell casing (5).
- Spacer (6).
- Washer (7).

N.B.
HOLD THE MAGNETO FLYWHEEL USING THE ROTOR HOL-
DER. THEN LOOSEN THE ENGINE PINION NUT.

6. Extract:
- Nut.
- Special washer.
- Crankshaft output gear
- Pin.
- Crankshaft housing cover

7. Extract:
- Nut
- Tab washer
- Balancing (anti-vibration) gear.
- Pin.

52
GEAR CHANGE
C G SHAFT
S

N.B.
THE GEAR CHANGE SHAFT CANNOT BE DISMANTLED
WITH THE ENGINE MOUNTED IN THE FRAME. SEE “REMO-
VING THE ENGINE FROM THE CHASSIS”.

1. Extract:
- Gear change shaft (1).
- Bolt (2).
- Positioning cam (3)
- Torsion spring (4).

CRANKCASE
1. Extract:
- Bolts (crankcase).
- Battery cable bracket.

N.B.
UNDO THE BOLTS DIAGONALLY.

LOOSEN EACH BOLT A QUARTER TURN IN TURN, AND RE-

MOVE THEM WHEN THEY ARE COMPLETELY LOOSE.

2. Position:
- The segment of the gear selector in such a way that it can
pass through the hole and enable the crankcases to be se-
parated.

53
 3. Extract:
- Right crankcase

N.B.
PLACE THE ENGINE WITH THE LEFT HAND CRANKCASE FA-
CING DOWN AND THEN INSERT A SCREWDRIVER IN THE
CRANKSHAFT SEPARATING SLOTS (A).

4. Extract:
Guide pins.

BALANCER
C , TRANSMISSION
S SS O AND GEAR
G S
SELECTOR
C O

1. Extract:
- Gear fork 1 guide lever (short).
- Gear fork 2 guide lever (long).
- Gear selector (3).
- Gear fork 1 (4).
- Gear fork 2 (5).
- Gear fork 3 (6).
- Drive shaft assembly (7).
- Driven shaft assembly (8).

2. Extract:
- Balancing counterweight (9).

54
3. Extract:
- Neutral switch.

CRANKSHAFT
1. Extract:
- Crankshaft with the rocker shaft.

N.B.
DETACH THE CRANKSHAFT USING THE CRANKCASE SEPA-
RATOR TOOL (2).

TIGHTEN THE CRANKCASE SEPARATOR BOLTS RIGHT

DOWN, BUT ENSURE THAT THE BODY OF THE TOOL IS PA-
RALLEL WITH THE CASING. IF NECESSARY, LOOSEN ONE
OF THE BOLTS A LITTLE TO ADJUST THE POSITION OF THE
CRANKCASE SEPARATOR.

Crankcase separator:
00M12501261

CYLINDER HEAD

1. Eliminate:
- Carbon deposits sediments (and gasket remains).

N.B.
AVOID USING ANY SHARP EDGED INSTRUMENT THAT CAN
CAUSE DAMAGE AND SCRATCHING:

- IN THE SPARK PLUG THREAD

2. Inspect:
- Cylinder head

Scratches/damage => Replace.

55
3. Measurement:
- Distortion

Outside that specified => Rectify.

Cylinder head distortion:

less than 0.03mm

Steps for measuring the distortion and rectification:

- Place a ruler (1) and a thickness calliper (2) on the head
cylinder surface, as in the figure to the side.

- Measure the distortion.

- If the distortion is outside that specified, rectify the cylinder

head.

- The lines in the picture correspond to the different directio-

ns that need to be checked with the ruler.

- Lay a 400 – 600 file on a flat surface and rectify the cylin-
der head surface by filing with a figure eight movement.

N.B.
TURN THE CYLINDER HEAD SEVERAL TIMES TO AVOID AN
EXCESSIVELY UNEVEN REMOVAL OF MATERIAL.

CYLINDER AND PISTON

1. Inspect:

- Cylinder and piston walls.

Vertical scratches=> Rectify or replace the cylinder and

the piston.

2. Measurement:
- Cylinder-piston play

Steps for measuring:

Step 1:
- Measure cylinder diameter “C” with an internal calliper.

N.B.
MEASURE THE DIAMETER “C” OF THE CYLINDER ACROSS
AND AT A RIGHT ANGLE TO THE CRANKSHAFT. THEN CAL-
CULATE THE AVERAGE MEASUREMENT.

56
 DIAMETER OF THE CYLINDER “C” 56.00 – 56.02 mm

TAPER LIMIT “T” 0.05 mm

OVALNESS “R” 0,01 mm

“C” = D MAXIMUM

“T” = (D1 O D2 MAXIMUM) - (D5 O D6 MAXIMUM)

“R” = (D1, D3 O D5 MAXIMUM) - (D2,D4 O D6 MINIMUM)

- If it is outside that specified , rectify or replace the cylinder

and replace the piston and the rings together.

Step 2:
- Measure the base of the piston “P” with a micrometer. (a)
10 mm from the piston base.

DIAMETER OF THE PISTON P.

STANDARD 55.950 – 59.955 mm

0.25 mm
OVER-MEASUREMENT
0.50 mm

- If it is outside that specified , replace the piston and the

rings together.

Step 3:
- Calcule el juego cilindro - pistón, empleando la siguiente
fórmula:

Cylinder-Piston clearance:
Diameter of the cylinder “C”
Diameter of the piston base “P”.

Clearance (Cylinder-Piston):
0.045 – 0.050 mm
Limit: 0.10 mm

- If it is outside that specified, rectify or replace the cylinder,

the piston and its rings all together.

57
INSPECTING THE PISTON RINGS

1. Measure:
- Lateral clearance.

Outside that specified => Replace the piston and its

rings all together.

N.B.
ELIMINATE THE CARBON DEPOSITS FROM THE PISTON
RING GROOVES, BEFORE MEASURING THE LATERAL PLAY.

Lateral play (piston rings):

Top ring <Limit>:

0.02 – 0.06 mm

Secondary (scraper) ring:

<Limit>:
0.035 – 0.070 mm

2. Position:
- The piston rings (in the cylinder).

N.B.
PUSH THE RING WITH THE HEAD OF THE PISTON IN SUCH
A WAY THAT IT IS POSITIONED PARALLEL TO THE CYLINDER
BASE.

(a) 5mm.

3. Measure:
- Clearance between points

Outside that specified => Replace.

Clearance between
points: Top ring <Limit>:
0.30 – 0.45 mm

Second ring (scraper) <Limit>:

0.30 – 0.45 mm

58
CRANKSHAFT
S

1. Measure:
- Crankshaft lack of alignment

Outside that specified => Replace the crankshaft and/or

bearings.

N.B.
MEASURE CRANKSHAFT POOR ALIGNMENT BY SLOWLY
TURNING THE CRANKSHAFT ASSEMBLY.

Poor alignment limit:

0,03 mm

2. Measure:
- Connecting rod side clearance

Outside that specified => Replace the connecting rod big

end bearing, crankshaft elbow and/or the connecting rod.

Connecting rod side clearance:

0.20 – 0.70 mm

3. Measure:
- Crankshaft width

Outside that specified => Replace the crankshaft.

Crankshaft width:
57.90 ÷ 57.95 mm

INSPECTING THE BALANCER

1. Inspect:
- Balancer shaft

Wear/warping/damage => Replace.

59
INSPECTING
S C G THE C
CLUTCH
U C BELL HOUSING
OUS G

1. Inspect:
- Primary sprocket teeth (1).

- Bell housing sprocket teeth (2).

Wear/damage => Replace both sprockets.

Excessive noise when running => Replace both sprockets.

INSPECTING
S C G THE C
CLUTCH
U C

1. Inspect:
- Friction disks

Wear/damage => Replace the friction disk assembly.

2. Measure:
- Thickness of the friction disks

Outside that specified => Replace the friction disk ass-

embly.

Measure at 4 different positions.

Thickness (friction disks):

2.9 – 3.1 mm
<2.7 mm>

3. Inspect:
- Separators
Damage => Replace the separator assembly.

60
4. Measure:
- Separator distortion

Outside that specified => Replace the separator assembly.

Take the measurement on a flat table with the aid of a thic-

kness calliper (1).

Distortion limit (separators):

less than 0,05mm.

5. Inspections:
- Clutch springs.

Damage => Replace the spring assembly.

6. Measure:
- Free length (springs) (a).

Outside that specified => Replace the spring assembly.

Free length (springs):

34.5 mm
<Limit:32 mm>

7. Inspect:
- Claws (of the bell housing) (1).

Edgings/wear/damage => Eliminate the rough edges or

replace the bell housing.

- Clutch housing slots (2).

Rough edges/wear/damage => Replace the clutch

housing.

N.B.
ROUGH EDGES ON THE CLUTCH CLAWS AND ON THE
CLUTCH HOUSING SLOTS LEAD TO IRREGULAR OPERA-
TION.

61
INSPECTING THE ACTIONING ROD

1. Inspect:
- Ball (1).

- Activating rod (2).

Wear/cracks/damage => Replace.

INSPECTION OF THE FORKS AND GEAR SELECTOR

1. Inspect:
- Fork follower (1).

- Ends of the gear change forks (2).

Scratches/warping/wear/damage => Replace.

2. Inspect:
- Gear selector slots.

Wear/damage/scratches => Replace.

- Gear change selector follower.

Wear/damage => Replace.

3. Inspect:
- Gear change fork 1 centre right (1).
- Gear change fork 2 top left (2).
- Gear change fork 3 bottom left (3).
- Guide bar (4).
- Gear selector (5).
- Guide pin (6).

Roll the guide bar on a flat surface. .

Warping => Replace

WARNING
DO NOT TRY AND STRAIGHTEN A WARPED BAR.

62
4. Check:
- Movement of the gear change forks (in the guide bar)

Irregular movement => Replace the fork and the bar.

N.B.
IF THE GEAR CHANGE FORK AND THE TRANSMISSION
SPROCKETS ARE FOUND TO BE DAMAGED, REPLACE THE
SPROCKETS THAT ARE SIDE BY SIDE ALL TOGETHER.

5. Measure:
- Warping of the shafts (drive and driven)

Use a support between points and a dial gauge for linear

measurement (1).

Outside that specified => Replace the warped shaft.

6. Inspect:
- Sprocket teeth

Blue colouring/grooves/wear => Replace.

- Sprocket claws

Rounded edges/cracks/pieces missing =>Replace.

7. Inspect:
- Gear change shaft (1).

Damage/warping/wear => Replace.

- Return spring (gear change shaft) (2).

- Return spring (limiter rod) (3).

- Circlip (4).

Wear/damage => Replace.

63
CRANKCASES
1. Wash the casings well with petrol.

2. Clean well the seal-bearing surfaces and the casing

contact surfaces.

3. Inspect:

- Crankcases

Cracks/damage => Replace

- Oil passages

Obstructions => Blow through the passages with com-

pressed air.

BEARINGS AND RETAINING RINGS

1. Inspect:
- Bearings

Clean and lubricate, then turn the inner ring by hand.

Roughness => Replace

2. Inspect:
- Retaining rings
Damage/wear => Replace.

LOCKING RINGS AND WASHERS

1. Inspect:
- Locking rings
- Washers

Damaged/loose/distorted => Replace.

64
VALVES, ROCKERS AND CAMSHAFT

1 Complete crankshaft
2 Washer
3 Nut
4 Connecting rod
5 Pin
6 Washer
7 Roller bearing
8 Piston
9 Set of rings
10 Roller bearing
11 Gudgeon pin
12 Circlip
13 Bearing
14 Oil seal
15 Oil seal
16 Collar
17 Key
18 Straight key
19 Traction gear
20 Balancer (Counterweight)
21 Bearing
22 Bearing
23 Straight key
24 Balancer gear

65
 CRANKSHAFT AND BALANCER SHAFT

1. Fit:
- Crankcase separator

Crankcase separator:
00M12501261

2. Fit:
- Crankshaft

N.B.
HOLD THE CONNECTING ROD WITH ONE HAND WHI-
LE TURNIING THE NUT ON THE SPECIAL TOOL WITH
THE OTHER HAND. USE THE TOOL UNTIL YOU FEEL THE
CRANKSHAFT FIT INTO THE BEARING.

ATTENTION
TO PREVENT SCRATCHING TO THE CRANKSHAFT AND TO
HELP ITS FITTING, APPLY GREASE TO OIL SEAL EDGES AND
ENGINE OIL TO THE BEARINGS.

3. Fit:
- Rocker shaft.
Always use new rubber rings.

4. Fit:
- Neutral switch

66
TRANSMISSION

1 Primary shaft 25 Collar

2 2nd gear pinion 26 Ring gear
3 3rd gear pinion 27 Washer
4 5th gear pinion 28 Nut
5 6th gear pinion 29 Plate
6 Washer 30 Bolt
7 Circlip
8 Bearing
9 Roller bearing
10 Secondary shaft
11 1st gear cogwheel
12 2nd gear cogwheel
13 3rd gear cogwheel
14 4th gear cogwheel
15 5th gear cogwheel
16 6th gear cogwheel
17 Flat washer
18 Round spring clip
19 Washer
20 Circlip
21 Washer
22 Bearing
23 Bearing
24 Oil seal

67
 GEAR SELECTOR

1 Selector drum
2 Stop lever
3 Spring
4 Stud
5 Gear change fork 1
6 Gear change fork 2
7 Gear change fork 3
8 Gear change fork 1 guide lever
9 Gear change fork 2 guide lever
10 Round spring clip

68
1. Fit:
- Primary and secondary transmission shafts (driving and
driven).
- Bottom left gear change fork (1).
- Centre right gear change fork (2).
- Top left gear change fork (3).
- Guide bar (1) (short) (4).
- Guide bar (2) (long) (5).

N.B.
FIT THE GEAR CHANGE FORKS WITH THE ENGRAVED MARK
UPWARDS AND IN ORDER (1,2,3,)

6. Check:
- Gear selector operation

Irregular operation => Adjust.

N.B.
CHECK THAT TRANSMISSION AND FORK OPERATION IS
NORMAL BY TURNING THE GEAR CHANGE SELECTOR BY
HAND.

CRANKCASE (LEFT HAND SIDE)

1. Apply:
- Adhesive
(to the crankcase contact surfaces).

N.B.
DO NOT ALLOW SILICON TO COME INTO CONTACT WITH
THE OIL PASSAGES.

2. Fit:
- Guide pins.

3. Fit:
- Crankcase (right) (onto left crankcase).

N.B.
TAP THE CRANKCASE COVER LIGHTLY WITH A PLASTIC HA-
MMER.

69
4. Tighten:
- Bolts (crankcase cover)

Bolts (casing):
1,0 Kgf.m (10 N.m)

5. Apply:
- 2-stroke engine oil.
(to the crankshaft elbow joints, bearings, oil feed holes).

6. Check:
- Operation of the crankshaft and transmission.

Irregular operation => Repair.

70
GEAR CHANGE
C G SHAFT
S

1 Complete selector shaft

2 Bolt
3 Stop cam
4 Torsion spring

71
1. Fit:
- Torsion spring (1).
- Positioning cam (2)
- Bolt

N.B.
SECURE THE SPRING TO THE STOP CAM AND ENSURE THE
LATTER IS IN THE CORRECT POSITION,
THEN TIGHTEN THE SECURING BOLT TO THE SPECIFIED
TORQUE.

Bolt (limiter rod):

14 N.m (1.4 kgf.m)

2. Fit:
- Gear change shaft assembly (3).

N.B.
APPLY GREASE TO THE RETAINING RING PINS FIT THE ENDS
OF THE SPRING INTO THE LIMITER (4).

72
CLUTCH
U C AND CLUTCH
C U C BELL HOUSING
OUS G

1 Clutch bell housing 25 Spring

2 Clutch housing 26 Flat washer
3 Clutch plate 27 Oil seal
4 Washer 28 Roller bearing
5 Pressure plate
6 Spring
7 Bolt with washer
8 Friction disk
9 Friction disk
10 Spring
11 Primary traction gear
12 Washer
13 Nut
14 Washer
15 Flat washer
16 Washer
17 Nut
18 Separator
19 Push rod 1
20 Washer
21 Nut
22 Sphere
23 Push rod 2
24 Complete push cam

73
INSTALLING THE CLUTCH BELL HOUSING

1. Fit:
- Balancing gear
- Primary gear
- Clutch bell housing

N.B.
TAKE CARE TO FIT THE BALANCING GEAR AND THE PRI-
MARY GEAR WITH THE CENTRING MARKS LINED UP.

FITTING THE CLUTCH

1. Fit:
- Clutch bell casing (1).
- Pressure washer (2).
- Clutch housing (3).
- Tab washer (4).
- Clutch housing nut (5).

2. Tighten:
- Clutch housing nut.

N.B.
TIGHTEN THE CLUTCH HOUSING NUT WHILE HOLDING
THE HOUSING WITH THE UNIVERSAL CLUTCH HOLDER .

Clutch holder:
00M12501260

Clutch housing nut:

70 N.m (7.0 kgf.m)

3. Fold:
- Edge of tab washer (1).
(upwards onto a flat side of the nut)

74
4. Fit:
- Friction disks (1).
- Separators (2).

N.B.
- FIT THE DISKS AND SEPARATORS ALTERNATELY INTO THE
CLUTCH ASSEMBLY, STARTING WITH A FRICTION DISK
AND

ENDING WITH A FRICTION DISK AS WELL.

- LUBRICATE ALL THE DISKS AND SEPARATORS WITH ENGI-

NE OIL BEFORE FITTING.

- BE SURE TO FIT EACH SEPARATOR WITH ITS PROJECTIONS

TURNED AT 90º TO THE PREVIOUS ONE. CONTINUE WITH
THIS PROCEDURE IN A CLOCKWISE DIRECTION UNTIL ALL
THE SEPARATORS HAVE BEEN INSTALLED.

5. Fit:
- Activating rod.
- Ball.

6. Fit:
- Pressure plate (1).
- Compression springs (2).
- Bolts (3).

Bolts (clutch spring):

0,6 Kgf.m (6 N.m)

N.B.
TIGHTEN THE SPRING BOLTS GRADUALLY AND IN A DIA-
GONAL FASHION.

7. Check:
- Position of the activating plate.

Push the lever assembly in the direction of the arrow and

ensure that the alignment marks line up.

75
9. Adjust:
- Position of the activating plate.

Adjustment steps:
- Loosen lock nut (1).

- Turn the adjuster (2) clockwise or anticlockwise to line up

the marks.

- Hold the adjuster to stop it from moving and tighten the

locknut.

ATTENTION
BE CAREFUL NOT TO OVERTIGHTEN THE ADJUSTER (2)
AND ELIMINATE THE CLEARANCE BETWEEN THE TWO AC-
TIVATING RODS.

- Tighten the lock nut (1).

Lock nut:
10 N.m (1kgf.m)

10. Fit:
- Guide pins.
- Crankcase gasket
- Right hand crankcase cover

Crankcase cover bolts:

8 N.m (8kgf.m)

76
MAGNETO
G O AND STARTER
S SYSTEMS
S S S

1 Magneto flywheel support

2 Bolt
3 Starter wheel
4 Roller bearing
5 Intermediate starter gear shaft
6 Flat washer
7 Intermediate starter gear
8 Intermediate starter gear plate
9 Bolt
10 Starter clutch
11 Starter clutch spring cover
12 Pin
13 Spring
14 Bolt
15 Magneto
16 Stator
17 Nut
18 Flat washer
19 Bolt

77
 INSPECTING THE STARTER GEAR

1. Inspect:
- Starter system gear teeth (a) (b) (c).

Rough edges/swarfing/roughness/wear => Replace.

2. Check:
- Operation of the starter clutch.

Push the guide pins in the direction of the arrow.

Non-smooth functioning => Replace.

Checking steps:
- Hold the starter clutch.

- On turning the (big) starter gear clockwise (A), the starter

clutch and the starter gear should be coupled.

- If not, the starter clutch is damaged.

Replace.

- On turning the starter gear in an anticlockwise direction

(b), it should turn freely.

- If not, the starter clutch is damaged.

Replace.

MAGNETO AND STARTER GEAR

1. Fit:
- Intermediate starter gear
- Securing plate

2. Apply:
- 2-stroke engine oil. (to the starter gears).

3. Fit:
- Starter clutch support plate
- Roller bearing
- Starter gear.

4. Fit:
- Key.
- Magneto rotor.

78
N.B.
FIT THE ROTOR PROVISIONALLY, ALIGNING THE KEYWAY
WITH THE KEY. TURN THE STARTER GEAR CLOCKWISE AND
FIT THE ROTOR ONTO THE STARTER GEAR.

5. Tighten:
- Nut (magneto flywheel).

Magneto flywheel nut:

80 N.m (8kgf.m)

N.B.
TIGHTEN THE NUT (1) WHILE HOLDING THE FLYWHEEL (2)
WITH THE ROTOR HOLDER (3).

TAKE CARE NOT TO ALLOW THE ROTOR HOLDER TO

TOUCH THE ROTOR PROTRUSIONS.

6. Fit:
- Guide pins.
- Crankcase cover gasket.
- Left hand crankcase cover

Crankcase cover bolts:

5 N.m (5kgf.m)

79
CYLINDER, S O , C
PISTON CYLINDER HEAD AND EXHAUST
US VALVE

1 Cylinder head 25 Bolt

2 Stud 26 Washer
3 Nut 27 Washer
4 Flat washer 28 Exhaust valve front cable
5 Spark plug 29 Exhaust valve rear cable
6 Head gasket 30 Stud
7 Cylinder 31 Set of piston rings
8 Cylinder gasket 32 Circlip
9 Clutch cable securing plate 33 Piston
10 Stud 34 Gudgeon pin
11 Stud
12 Pin
13 Nut
14 Exhaust valve
15 Right hand exhaust valve cover
16 Bolt
17 Exhaust valve gasket
18 Oil seal
19 SEEGER Ring
20 Clutch valve activation support
21 Bolt
22 Left hand exhaust valve cover.
23 Bolt
24 Exhaust valve pulley

80
FITTING PISTON RINGS, PISTON AND CYLINDER

1. Fit according to the following sequence:

- Secondary ring (scraper) (1).
- Top ring (compression) (2).

N.B.
- LUBRICATE THE PISTON AND THE RINGS WELL WITH EN-
GINE OIL.

2. Fit:
- Piston
- Connecting rod big end needle bearings
- Gudgeon pin
- Circlip

N.B.
- APPLY ENGINE OIL TO THE GUDGEON PIN.

- THE ARROW ON THE PISTON SHOULD BE TOWARDS THE

EXHAUST SIDE.

- BEFORE FITTING THE CIRCLIP, COVER THE CRANKCASE

OPENING WITH A CLEAN CLOTH.

3. Fit:
• Guide pins (1).
• Cylinder gasket.

81
4. Lubricate:
- External surface of the piston
- Rings
- Inner surface of the cylinder

5. Fit:
- Cylinder (1).

N.B.
- FIT THE CYLINDER WITH ONE HAND WHILE COMPRES-
SING THE RINGS WITH THE OTHER.

FITTING THE CYLINDER HEAD

1. Fit:
- Cylinder head gasket

2. Fit:
- Cylinder head
- Nut with washer

Cylinder head nuts tightening torque:

22 N.m (2,2 kgf.m)

N.B.
- APPLY ENGINE OIL TO THE BOLT THREADS.

82
FITTING THE REED VALVE

N.B.
BEFORE FITTING, CHECK THAT THERE ARE NO CRACKS,
DISTORTIONS OR BREAKAGES ON THE REED PETALS. IF
THERE ARE, THEY MUST BE REPLACED IN THE FOLLOWING
WAY:

- REMOVE THE SECURING SCREWS FROM THE HEIGHT

LIMITER AND FROM THE INLET VALVE PETALS.

- CHECK THAT THERE ARE NO CRACKS IN THE PETALS’

SECURING BASE. IF THERE ARE, RENEW THE REEDS.

To refit the reed valve, proceed in the reverse order to dis-

mantling, paying special attention to the correct positioning
of the height limiter and the reed (with the bevels matching).
The elimination of the height limiter and the type of reed
used will modify the performance of the engine and may
make it less reliable.

Check the reed cage O- ring and replace it if damaged.

Valve thickness:
0.5 mm.

Height of the stop plate:

8.8 mm.

Valve flexing limit:

0.5 mm.

83
3. Fit:
- Spark plug

Spark plug:
20 N.m (2.0 kgf.m)

14. Fit:
- Oil drain plug
- Fill with 800 c.c. of SAE 10W30 oil through the plug hole
located on the right hand crankcase cover.

Oil drain plug:

15 N.m (1.5 kgf.m)

REFITTING
G THE ENGINE
G INTO
O THE FRAME

1. Dismantle side covers.

2. Remove the petrol tank.

3. Remove the exhaust pipe.

4. Dismantling the carburettor.

- Remove filter box-carburettor pipe (secured with a jubilee

clip).

- Loosen jubilee clip on carburettor pipe to cylinder.

- Remove carburettor.

- Remove jubilee clip and pipe from cylinder head to carbu-

rettor.

5. Removing the gear change lever.

- Remove bolt (1).

- Remove change backlash bush (2).

6. Removing the chain.

- Remove chain coupling link clip

84
7. Extracting the radiator.
- Drain the cooling system.

Remove system inlet (1) and outlet (2) hoses and tank hose
(3).

Remove radiator.

85
8. Extracting the oil pump cable.
- Remove cover.

Remove the retaining circlip with pulley and torsion recovery

spring

Extract cables and remove them from the engine.

9. Extracting the oil tank to engine hose.

- Remove the tank hose and plug it.

- Plug the oil tank outlet.

10. Removing the clutch operating cable.

- Free the clutch cable from the handlebars.
- Remove the the tensioning cable from the crankcase.
- Remove the clutch operating cable.

11. Freeing the exhaust valve operating cable.

- Remove cover (1).

- Loosen cable by screwing in, and extract it from the pulley.

- Unscrew the two tensioners and remove the cables.

86
12. Removing electrical connections.
- Remove spark plug connector.
- Remove the temperature meter cable.
- Remove the magneto cable.
- Remove earth cable from right hand side of the crankcase.
- Remove neutral earth cable.
- Remove starter motor power supply cable.
- Remove cables from the coil.

13. Removing the engine cradle.

- Remove the UNEX clamps.

- Remove the 6 bolts securing the cradle to the engine and

to the chassis.

- Withdraw the engine cradle from below the machine.

14. Extracting the engine.

- Remove the swinging arm shaft without extracting it com-
pletely, ensuring that it only joins the swinging arm and the
chassis.

- Insert a support shaft into the other side joining only the
swinging arm and chassis, to ensure that the swinging arm
and chassis do not come loose.

- Unfasten the engine from the top bracket.

- Remove the engine.

N.B.
IT IS ADVISABLE TO PLACE A SUPPORT UNDER THE ENGI-
NE BEFORE FREEING IT FROM THE CHASSIS, TO AID IN
THE DISMANTLING PROCESS.

87
 CARBURETTOR
U O

1 Air screw assembly 25 Washer

2 Idler jet 26 Filter
3 Main jet 27 Cover
4 Washer 28 Clip
5 Spray 29 Drain pipe
6 Spray needle
7 Pin
8 Bolt
9 Needle valve
10 Idler screw assembly
11 Spring
12 Seal
13 Bolt
14 Washer
15 Throttle valve
16 Pipe
17 Tube clip
18 Breather tube
19 Drain screw
20 Breather tube
21 Float
22 Ring
23 Sheath
24 Cable adjusting nut

88
DISMANTLING
1. Extract:
- Rider’s seat.
- Fairing.
- Fuel tank.
- Air filter canister.

See “SEAT, SIDE COVERS AND FUEL TANK” section in

CHAPTER 3.

2. Drain:
- Fuel (carburettor bowl).

N.B.
PLACE A CLOTH UNDER THE FUEL DRAIN PIPE TO ABSORB
SPILT FUEL.

WARNING
PETROL IS HIGHLY INFLAMMABLE. AVOID SPILLING
PETROL ON TO A HOT ENGINE.

3. Disconnect:
- Breather pipe.
- Fuel pipe.
- Drain hose.

4. Loosen:
- Pipe clamp screws.
- Bolt (air filter canister).

N.B.
PULL THE MANIFOLD CLAMP BACKWARDS

- Extract the rubber seal between the carburettor and the

filter cansiter.

- Pull the carburettor backwards.

5. Extract:
- Throttle cable.

Remove the carburettor cover together with the closing val-

ve.

- Choke cable.

Remove the choke together with the spring.

- Completely drain the antifreeze.

- Extract the heating hoses from the carburettor.

89
 DISMANTLING
S G

N.B.
THE PARTS BELOW CAN BE CLEANED AND INSPECTED
WITHOUT DISMANTLING THE CARBURETTOR. (ALL THE
INTERNAL PARTS, EXCEPT THE CHOKE, CAN BE CLEANED
AND INSPECTED WITHOUT DISMANTLING THE CARBU-
RETTOR).

- CLOSING VALVE

- CLOSING VALVE NEEDLE

1. Extract:
- Complete carburettor.

2. Extract:
- Throttle cable

N.B.
COMPRESS THE GAS VALVE RETURN SPRING AGAINST THE
COVER AND EXTRACT THE THROTTLE CABLE TERMINAL
THROUGH THE GAS VALVE CHANNEL.

3. Extract:
- Cold start (choke) valve puller bracket.

90
4. Extract:
- Low speed circuit air quantity regulator (“compensator”) screw.
- Spring
- Washer
- O-ring

5. Extract:
- Carburettor bolts and bowl.

N.B.
THIS ENABLES ACCESS TO THE MAXIMUM, MINIMUM AND
COLD START BORES, AS WELL AS THE FLOAT AND ITS NEE-
DLE VALVE.

Compensator screw:
¼ de vuelta.

INSPECTION
S C O

1. Clean:
- All the components of the carburettor with solvent (take
care not to damage the carburettor bowl gasket or the cold
start valve O-ring).

2. Blow:
- Through all the air, oil and petrol passages with compressed air.

3. Check:
- the weight of the float- engraved on it (14 grams) – with
scales. = > If it exceeds this weight, renew it.

- the needle controlling entry of petrol into the bowl, toge-

ther with its float connecting stem spring. => If its condition
is not correct, renew it.

91
 I – The condition of the cold start system piston valve. => In
the event of the vulcanised closing seat or the metal body of
the piston being damaged (scratches and/or corrosion that
exceed 25% of its total area).

- Size of the bores based on the numbers etched onto them.

=> If they are not in agreement with that specified, replace
them with suitable ones. Failure to do so may result in the
performance of the engine being affected.

- The position of the tapered dosing needle. It should be

located in the centre slot of the three available.

N.B.
MOVING THE CIRCLIP ON THE NEEDLE UPWARDS RESULTS
IN A LEANER MIXTURE, AND MOVING IT DOWNWARDS RE-
SULTS IN A RICHER MIXTURE. THIS ALLOWS ADJUSTMENTS
TO BE MADE FOR EXTREME CLIMATIC CONDITIONS.

- THE CONDITION OF THE TAPERED DOSING NEEDLE. =>

IF THERE IS DAMAGE VISIBLE ON ITS CIRCUMFERENCE,
CHANGE IT

92
- The absence of scratches on the minimum circuit air regu-
lator screw cone. These would affect its performance.

- The absence of scratches on the sliding valve. => In the

event of these exceeding 25% of its total area, renew it.

N.B.
BE SURE TO FIT A VALVE WITH THE SAME CHARACTERISIT-
CS (SEE MARKINGS ON ITS BASE).

REFITTING
G

This is a reversal of the “REMOVAL” procedure.

Take care with the following points:

1. Fit:
- Spring (closing valve).
- Closing valve assembly
With the carburettor cover and throttle cable.

- Spring (choke).
- Choke assembly.
With the choke and choke cable.

2. Fit:
- Carburettor.

3. Tighten:
- Clip (air filter box).
- Clamp screws.

4. Connect:
- Drain hose.
- Breather pipe.
- Fuel pipe.

93
5. Adjust:
- Idle speed

See the “MEASURING AND ADJUSTING IDLE SPEED”

section in CHAPTER 3.

6. Adjust:
- Throttle cable play.

See the “ADJUSTING THE THROTTLE CABLE” section in

CHAPTER 3.

ADJUSTING
JUS G THE FUEL
U LEVEL

[Link]:
- Fuel level (a).

Outside that specified => Adjust.

Fuel level:
1.5 – 2.5 mm below the bowl line

Adjustment steps:
- Place the motorcycle on a flat surface.

- Place a jack or a support under the engine to ensure that

the carburettor is positioned vertically.
- Connect the fuel level meter (1) to the drain pipe (2).

- Loosen the drain screw (3).

- Hold the meter vertically and close to the line of the car-
burettor bowl.

- Measure the fuel level (a) with the meter.

- If the level is incorrect, adjust it.

- Remove the carburettor.

- Inspect the valve seat and needle valve.

- If these parts are worn, replace both.

- If they are normal, adjust the float level by bending slight-

ly the edge (4) of the float.

Float height:
15.5 - 16.5 mm

- Fit the carburettor.

- Check the fuel level once again.

94
FRONT
O WHEEL DIAGRAM
G

1 Front 110/80 tyre

2 Front wheel assy.
3 Front wheel axle
4 Disk side bush
5 Flat washer
6 Wheel axle head nut
7 Axle nut protector
8 Bearing 6202
9 Front wheel bearing separator sub-assembly
10 300 mm Ø front disk brake
11 Brake disk securing bolt
12 Front brake calliper
13 M10 bolt
14 Front brake pad
15 Front brake pad securing spring
16 Calliper bleeding assembly
17 M31 radial calliper cover
18 M34 radial calliper cover
19 Bleed nipple
20 Bleed nipple

95
DISMANTLING
WARNING
- ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY
AND THERE IS NO RISK OF IT FALLING.

- PLACE THE MOTORCYCLE ON A FLAT SURFACE.

1. Extract:
- Front brake calliper (Bolts 1 and 2).

2. Extract:
- Nut protecting cover.
- Nut (left side).

3. Raise:
- Front wheel
(Put a suitable support under the engine).

4. Extract:
- Front wheel axle.
- Front brake disk assembly.
- Dustguard/spacer.
- Front wheel.

INSPECTING THE FRONT WHEEL

1. Inspect:
- Front wheel axle. (By rolling it on a flat surface).

Warping => Replace.

WARNING
DO NOT TRY STRAIGHTENING A WARPED AXLE.

Wheel axle warp limit:

0,25 mm

2. Inspect:
- Neumático delantero.

Damage/wear => Replace.

96
See the “INSPECTING THE TYRES” section in CHAPTER 3.
- Front wheel

See the “INSPECTING THE WHEELS” section in CHAPTER 3.

3. Check:
- Spokes.

Warps/damage => Replace.

5. Measure:
- Distortion of the front wheel

Above that specified => Replace.

Distortion limits for the front wheel:

Radial (a):
0,5 mm
Lateral (b):
0,8 mm

6. Check:
- Front wheel bearings.

Bearings allow play in the wheel hub or the wheel does not
turn freely => Replace.

- Retaining rings.

Damage/wear => Replace.

7. Inspect:
- Spacer.

With scratches/worn => Replace the spacer and the

retaining ring.

97
INSPECTING THE SPEEDOMETER

This speedometer is fitted with a Hall Effect sensor. As this is

a precision magnetic device, it should not be dismantled. In
the event of it becoming faulty, the unit must be renewed.

DISMANTLING THE FRONT DISK CALLIPER

- Loosen the banjo bolt (1) from the bottom end of the brake
pipe and tighten it slightly.

- Unscrew the calliper mounting bolts (2) and separate the

calliper (3) backwards from the disk.

PRECAUTION
CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIA-
TELY.

Fitting the front calliper:

- Fit the bottom end of the brake pipe and the calliper.
- Tighten to nominal torque.

Calliper mounting bolts:

35 ÷ 40 N.m (3,5 ÷ 4 kgf.m)

- Tighten the brake banjo bolt.

- Check brake fluid level.

- Bleed the brake system pipe (consult “Bleeding the brake

system pipe” in this chapter).

- Check the condition of the braking force to see if any

resistance is noted or any loss of fluid.

WARNING
DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE
BRAKE LEVER IS OPERATING PROPERLY. PUMP THE LEVER
UNTIL THE PADS ARE AGAINST THE DISK. IF NOT, THE
BRAKES WILL NOT WORK THE FIRST TIME THE LEVER IS
USED.

98
Extracting the front brake pads.
- Remove the front brake calliper (see “Dismantling the front
brake calliper” in this chapter).

Extract:
- Pad springs (1).
- Pin.
- Brake pads (2).

Fitting the front brake pads

- Press the calliper pistons in manually.
- Fit the pads inside the calliper.
- Adjust the pad springs.

WARNING
DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE
BRAKE LEVER IS OPERATING FULLY. THIS IS ACHIEVED BY
PUMPING THE LEVER UNTIL THE PADS ARE AGAINST THE
DISK. IF NOT, THE BRAKES WILL NOT WORK THE FIRST
TIME THE LEVER IS USED.

Inspecting the pads for wear

- Remove the front brake pads.

- Examine both brake pads.

If the wear has caused the wear indicating groove (1) to di-
sappear, both pads must be renewed.

Extracting the front brake cylinder.

- Extract the bolt (1) and remove the flexible pipe from the
brake cylinder reservoir.

99
 N.B.
THE MASTER CYLINDER (1) IS INCORPORATED INTO THE
FRONT BRAKE LEVER ASSEMBLY.

- EXTRACT THE SCREWS (2) AND THE FRONT BRAKE LEVER

ASSEMBLY.

PRECAUTION
CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIA-
TELY.

Extract:
- Brake lever mounting bolt and nut.
- Brake lever.

Fitting the front master cylinder:

- Fit the brake lever assembly and tighten the securing
screw.

- Tighten the flexible brake pipe bolt.

- Bleed the brake system pipe (consult “Bleeding the brake

system pipe” in this chapter).

- Check the condition of the braking force to see if any resis-

tance is noted or any loss of fluid.
Checking the brake lever master cylinder (visual check):

- Extract the master cylinder (consult “Extracting the front

master cylinder” in this section).

- Dismantle the front master cylinder:

- Check that there are no scratches, corrosion or holes on

the inner walls of the master cylinders and on the outer part
of each piston.

- If any damage is discovered on the master cylinder or on

the pistons, change them.

- Examine the primary seal and secondary seal.

- If the seal is worn, soft (perished) or swollen, change the

piston assembly to renew the seals.

- If fluid loss is noticed at the brake lever, change the seals.

100
 Checking the brake calliper main cylinder:
- Check that the anti-dust boots are not damaged.
If they are, change them.

- Check that the piston return is not damaged. If it is, renew it.

- Check that the relief port and feed port are not blocked.
if the relief port is blocked, the brake pads will bind on the
disk. Inject compressed air to clean the ports.

Extracting the brake disk:

- Remove the front wheel.

- Unscrew the mounting bolts and extract the disk.

Fitting the brake disk

- Fit the brake disk onto the front wheel so that side (2) faces
outwards.

- Apply a temporary blocking device to the threads of the

brake disk mounting bolts(1).

- Tighten the front brake disk mounting bolts(1).

Nominal tightening torque:

1,0 ~ 1,2 Kgf.m (10 ~ 12 N.m)

Wear to the brake disk:

- Measure the thickness of the disks (A) at the point where
they are most worn.

- If the disk is more worn than specified in the service limit,

renew it.

Measurement area (B).

Standard thickness of the front brake disk.

3,8 ÷ 4,1 mm

Service limit:
3,50 mm

101
 Brake disk distortion:
- Raise the motorcycle on the jack so that the tyre is clear of
the ground.

- To check the front disk, turn the handlebars completely to

one side.

- Place a dial calibrator against the disk (A) as shown, and

measure the disk’s deviation from centre as the tyre is turned
by hand (B).

- If the deviation from centre exceeds the service limit, renew

the disk.

Disk deviation from centre:

Standard:
less than 0.15mm
Service limit:
0,3 mm

Bleeding the brake system pipe

The brake fluid has a very low compression coefficient, with
the result that almost all the movements of the brake lever are
transmitted directly to the calliper for braking. Air however
compresses easily. When air enters the brake system pipes,
the movement of the brake lever is partially used up in com-
pressing the air. This causes the lever to feel spongy and leads
to a loss of braking power.

WARNING
BE SURE TO BLEED AIR OUT OF THE BRAKE SYSTEM WHEN
THE BRAKE LEVER FEELS SPONGY AFTER CHANGING THE
BRAKE FLUID OR WHEN THE BRAKE SYSTEM PIPE HAS BEEN
LOOSENED FOR ANY REASON.

Extract:
- Bolts (1).

- Reservoir cap (2).

- Fill the reservoir with brake fluid up to the top reservoir

line.

- With the cap removed, pump the brake lever slowly several
times until no bubbles can be seen rising through the liquid.

102
 Purge the air completely from the master cylinder using this
procedure.
- Remove the transparent plastic cap from the bleed nipple
and place the other end of the pipe in a container.

- Repeat the following procedure until there is no air left

emerging from the plastic pipe:

- Pump the brake lever until it becomes hard and holds the
brakes down.

- Open and close the purge valve quickly while keeping the
brake on.

- Release the brake.

N.B.
CHECK THE FLUID LEVEL FREQUENTLY DURING THE BLEE-
DIING OPERATION AND REPLENISH THE RESERVOIR WITH
BRAKE FLUID WHEN NECESSARY. IF THE RESERVOIR EMPTIES
COMPLETELY OF BRAKE FLUID AT ANY TIME THE DURING
BLEEDING PROCEDURE, PERFORM THE BLEEDING PROCE-
DURE ALL OVER AGAIN FROM THE BEGINNING, SINCE AIR
WILL HAVE ENTERED THE PIPE. TAP THE BRAKE PIPE LIGHT-
LY FROM THE CALLIPER TO THE RESERVOIR TO ACHIEVE A
MORE COMPLETE BLEEDING.

- Extract the transparent plastic pipe.

Fit:
- Reservoir cap.

- Cap securing screws.

-Tighten the bleed valve and fit the rubber hood.

- Check brake fluid level.

- Once the bleeding process has been carried out, check the
efficiency of the brake to see if there is any resistance or any
fluid loss.

WARNING
WHEN WORKING WITH THE DISK BRAKE, TAKE THE FOLLO-
WING PRECAUTIONS:

1) NEVER RE-USE BRAKE FLUID.

2) DO NOT USE FLUID FROM A CONTAINER THAT HAS

BEEN LEFT OPEN OR HAS BEEN LEFT UNUSED FOR A PRO-
LONGED PERIOD OF TIME.

103
 3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR
USE IN THE BRAKE. THIS LOWERS THE BRAKE FLUID EVA-
PORATION POINT AND MAY RESULT IN THE BRAKES NOT
WORKING EFFICIENTLY. IN ADDITION, IT MAY CAUSE DE-
TERIORATION OF THE BRAKE PARTS.

4) DO NOT LEAVE THE RESERVOIR CAP OFF AT ANY TIME,

TO PREVENT CONTAMINATION OF THE FLUID.

5) DO NOT CHANGE THE FLUID IN RAINY OR VERY WIN-

DY CONDITIONS.

6) EXCEPT ON THE BRAKE LININGS AND THE DISK, USE

ONLY BRAKE FLUID, ISOPROPILIC ALCOHOL OR ETHYL
ALCOHOL FOR CLEANING BRAKE PARTS. DO NOT USE
ANY OTHER TYPE OF LIQUID FOR CLEANING THESE PAR-
TS.

PETROL, ENGINE OIL OR ANY OTHER PETROLEUM DIS-

TILLATE WILL CAUSE RUBBER PARTS TO DETERIORATE.
IF OIL IS SPILT ON ANY PART, IT WILL BE DIFFICULT TO
CLEAN COMPLETELY AND MAY DETERIORATE THE RUB-
BER USED IN THE DISK BRAKE.

7) ON HANDLING THE DISK BRAKE LININGS OR THE DISK,

TAKE CARE TO ENSURE THAT NO BRAKE FLUID COMES
INTO CONTACT WITH THEM. CLEAN ANY REMAINS OF
BRAKE FLUID THAT ACCIDENTALLY COMES INTO CON-
TACT WITH THE LININGS OR WITH THE DISK WITH A SOL-
VENT WITH A HIGH INFLAMMATION POINT. DO NOT USE
ONE THAT LEAVES GREASY RESIDUES. IF LININGS CAN-
NOT BE CLEANED SATISFACTORILY, CHANGE THEM FOR
NEW ONES.

8) BRAKE FLUID DESTROYS PAINTED SURFACES RAPIDLY.

CLEAN OFF ANY SPILT REMAINS IMMEDIATELY.

9) IF ANY OF THE BRAKE SYSTEM PIPE SECURING SYSTE-

MS OR THE BLEED VALVE OPENS AT ANY TIME, THE AIR
CAN BE BLED FROM THE BRAKE SYSTEM PIPE.

ASSEMBLING THE FRONT WHEEL

1. Fit:
- Speedometer assembly

104
 ASSEMBLING THE FRONT WHEEL

Reverse the “DISMANTLING” procedures. Take care

with the following points:

1. Lubricate:
- Front wheel axle.
- Bearing.
- Retaining rings.

Recommended lubricant:
Lithium soap based grease

2. Fit:
- Front wheel

3. Tighten:
- Front wheel axle.
- Axle nut (front wheel).

ATTENTION
BEFORE TIGHTENING THE WHEEL AXLE, PUSH THE FRONT
FORKS DOWN SEVERAL TIMES, HOLDING THE HANDLE-
BARS, TO CHECK THEIR OPERATION.

Axle nut:
70-80 N.m (7-8 kgf.m)

WARNING
ENSURE THAT THE SPEEDOMETER CABLE GUIDE IS CO-
RRECT.

4. Check:
Front brake functioning
Irregular functioning => Dismantle or check again.

- Brake lever play

See the “ADJUSTING THE FRONT BRAKES “ section in

“CHAPTER 3.

105
 WHEEL DIAGRAM
G

1 Rear wheel assembly

2 140/70 17” rear tyre
3 Rear wheel axle assembly
4 Drag plate securing bolt.
5 M16 hexagonal nut
6 Bearing
7 Bearing separator
8 Rear brake disk
9 Brake disk securing bolt
10 GPR plate separator bush
11 Z-50 drag plate
12 Self locking nut
13 Wheel tensioner
14 Tensioner cap
15 Chain tensioner bolt
16 130P secondary chain
17 Coupling link.
18 Valve

106
 BRAKE DIAGRAM
G

Rear brake calliper Clip

Rear brake calliper bleed nipple Rear calliper bleed valve
Rear brake pad Lever protector
Rear brake pad fixing spring Rear brake puller separator bush
Rear brake cylinder assembly. Bush
Reservoir to cylinder to pipe
Clamp
Brake cylinder protector
Securing screw
Washer
Self locking nut
Brake pedal assembly
Rear brake cylinder bar assy.
Brake fluid reservoir
M50 bolt
Securing washer
Securing nut
Rear brake puller
Securing screw
Washer
M10 nut
Rear brake fluid pipe
Stop switch
Hydraulic pipe outlet

107
 DISMANTLING
WARNING
- ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY
AND THERE IS NO RISK OF IT FALLING.
- PLACE THE MOTORCYCLE ON A FLAT SURFACE.

1. Extract:
- Wheel axle (1).
- Spacer.

N.B.
ON WITHDRAWING THE WHEEL AXLE, THE SPACER WILL
DROP DOWN. TAKE CARE NOT TO LOSE IT.

2. Extract:
- Rear wheel.

N.B.
ON EXTRACTING THE WHEEL, PUSH THE WHEEL FORWARDS
TO REMOVE THE DRIVE CHAIN, THEN EXTRACT THE WHEEL
BACKWARDS TO AVOID THE BRAKE CALLIPER.

DISMANTLING THE REAR DISK CALLIPER

- Loosen the bolt at the bottom end of the flexible brake hose
and tighten it slightly (1)

- Unscrew the bolt securing the brake puller (2) and remove
the clips (3) joining the flexible hose to the puller.

- Extract the wheel axle (4).

- Remove the brake calliper (5).

PRECAUTION
CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIATELY.

108
 Fitting the rear calliper
- Fit the bottom end of the flexible brake pipe and the calliper.

Fit the wheel axle, the brake puller and the flexible hose se-
curing clips.

Nominal torque (wheel axle):

110-130 N.m (11-13 kgf.m)

Tighten to nominal torque (brake puller):

35-40 N.m (3,5 – 4 kgf.m)

- Tighten the brake banjo bolt.

- Check brake fluid level.

- Bleed the braking system pipe (consult “Bleeding the brake

system pipe”, in the chapter corresponding to the front
brakes).

- Check the condition of the braking force to see if any resis-

tance is noted or any loss of fluid.

WARNING
DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE
BRAKE LEVER IS OPERATING PROPERLY. PUMP THE LEVER
UNTIL THE PADS ARE AGAINST THE DISK. IF NOT, THE
BRAKES WILL NOT WORK THE FIRST TIME THE LEVER IS
USED.

Extracting the rear brake pads

- Remove the rear brake calliper (see “Dismantling the rear
brake calliper”, in this chapter).

Extract:
- Pad springs (1).

- Brake pads.

Fitting the rear brake pads.

- Press the calliper pistons in manually.

- Fit the pads inside the calliper.

- Adjust the pad springs.

109
 WARNING
DO NOT ATTEMPT TO RIDE THE MOTORCYCLE UNTIL THE
BRAKE PEDAL IS OPERATING FULLY. PUMP THE LEVER UN-
TIL THE PADS ARE AGAINST THE DISK. IF NOT, THE BRAKE
WILL NOT WORK THE FIRST TIME THE PEDAL IS USED.

Inspecting the pads for wear

- Removing the rear brake pads.
- Examine both brake pads.

If the wear has caused the wear indicating groove (1) to

disappear, both pads must be renewed.

Extracting the rear main cylinder

- Remove the cover protecting the main cylinder. (The bol-
ts securing the cover also support the cylinder)

- Extract the bolt and remove the flexible hose from the
brake cylinder reservoir.

PRECAUTION
CLEAN OFF ANY SPILT BRAKE FLUID REMAINS IMMEDIA-
TELY.

Fitting the rear main cylinder.

- Fit the rear main cylinder and its protective cover.

- Tighten the brake flexible hose bolt.

- Bleed the brake system pipe (consult “Bleeding the brake

system pipe” in this chapter).

- Check the condition of the braking force to see if any

resistance is noted or any loss of fluid.

110
 Checking the rear main cylinder (visual check)
- Extract the main cylinder (consult “Extracting the rear
main cylinder” in this section).

- Dismantle the rear main cylinder.

- Check that there are no scratches, corrosion or holes in

the inner walls of the main cylinder and on the outer part
of each piston.

If any damage is discovered on the master cylinder or

on the pistons, change them.
- Examine the primary and secondary seals.

- If a seal is worn, soft (perished) or swollen, change the

piston assembly to renew the seals.

- If you notice loss of fluid in the brake cylinder, change

the seals.

Checking the rear calliper main cylinder

- Check that the anti-dust boots are not damaged.
If they are, change them.

- Check that the piston return is not damaged. If it is, renew it.

- Check that the relief port and feed port are not blocked.
if the relief port is blocked, the brake pads will bind on the
disk. Inject compressed air to clean the ports.

Extracting the brake disk

- Extract the rear wheel.

- Unscrew the mounting bolts and extract the disk.

Fitting the brake disk

- Fit the brake disk to the rear wheel in such a way that the
engraved side faces outwards.

- Apply a temporary blocking device to the threads of the

brake disk mounting bolts.

- Tighten the rear brake disk securing bolts.

Nominal tightening torque:

10 – 12 N.m (1,0 – 1,2 kgf.m)

111
 Brake disk wear
- Measure the thickness of the disks (A) at the point where
they are most worn.

- If the disk is more worn than specified in the service limit,

renew it.

Measurement area (B).

Standard brake disk thickness:

3,80 – 4,10 mm

Service limit:
3,50 mm

Brake disk distortion

- Raise the motorcycle on the jack so that the tyre is clear of
the ground.

- Place a dial calibrator against the disk (A) as shown, and

measure the disk’s deviation from centre as the tyre is turned
(B) by hand.

- If the deviation from centre exceeds the service limit, renew

the disk.

Disk deviation from centre:

Standard:
Inferior a 0,15 mm

Service limit:
0,3 mm

Bleeding the brake system pipe

The brake fluid has a very low compression coefficient, with
the result that almost all the movements of the brake lever
are transmitted directly to the calliper for braking. Air howe-
ver compresses easily. When air enters the brake system pi-
pes, the movement of the brake lever is partially used up in
compressing the air. This causes the pedal to feel spongy and
leads to a loss of braking power.

WARNING
BE SURE TO BLEED AIR OUT OF THE BRAKE SYSTEM WHEN
THE BRAKE LEVER FEELS SPONGY AFTER CHANGING THE
BRAKE FLUID OR WHEN THE BRAKE SYSTEM PIPE HAS BEEN
LOOSENED FOR ANY REASON.

112
 Extract:
Reservoir cap (threaded)
- Fill the reservoir with brake fluid up to the top reservoir
line.

- With the cap removed, pump the brake pedal slowly several
times until no bubbles can be seen rising through the liquid.
Purge the air completely from the main cylinder using the
following procedure:

- Remove the transparent plastic cap from the bleed valve

and place the other end of the pipe in a container.

- Repeat the following procedure until there is no air left

emerging from the plastic pipe:

- Pump the brake pedal until it becomes hard and holds the
brakes down.

- Open and close the purge valve quickly while keeping the
brake on.

- Release the brake.

NOTA
CHECK THE FLUID LEVEL FREQUENTLY DURING THE
BLEEDIING OPERATION AND REPLENISH THE RESERVOIR
WITH BRAKE FLUID WHEN NECESSARY. IF THE RESERVOIR
EMPTIES COMPLETELY OF BRAKE FLUID AT ANY TIME THE
DURING BLEEDING PROCEDURE, PERFORM THE BLEEDING
PROCEDURE ALL OVER AGAIN FROM THE BEGINNING,
SINCE AIR WILL HAVE ENTERED THE PIPE. TAP THE BRAKE
PIPE LIGHTLY FROM THE CALLIPER TO THE RESERVOIR TO
ACHIEVE A MORE COMPLETE BLEEDING.

- Extract the transparent plastic pipe.

Fit:
- Reservoir cap.

- Tighten the bleed valve and fit the rubber hood.

- Check brake fluid level.

- Once the bleeding process has been carried out, check the
efficiency of the brake to see if there is any resistance or any
fluid loss.

113
 WARNING
WHEN WORKING WITH THE DISK BRAKE, TAKE THE FO-
LLOWING PRECAUTIONS:

1) NEVER RE-USE BRAKE FLUID.

2) DO NOT USE FLUID FROM A CONTAINER THAT HAS

BEEN LEFT OPEN OR HAS BEEN LEFT UNUSED FOR A PRO-
LONGED PERIOD OF TIME.

3) DO NOT MIX TWO TYPES OR BRANDS OF FLUID FOR

USE IN THE BRAKE. THIS REDUCES THE BRAKE FLUID EVA-
PORATING POINT AND MAY RESULT IN THE BRAKES NOT
WORKING EFFICIENTLY. IN ADDITION, IT MAY CAUSE DE-
TERIORATION OF THE BRAKE PARTS.

4) DO NOT LEAVE THE RESERVOIR CAP OFF AT ANY TIME,

TO PREVENT CONTAMINATION OF THE FLUID.

5) DO NOT CHANGE THE FLUID IN RAINY OR VERY WIN-

DY CONDITIONS.

6) EXCEPT ON THE BRAKE LININGS AND THE DISK, USE

ONLY BRAKE FLUID, ISOPROPILIC ALCOHOL OR ETHYL AL-
COHOL FOR CLEANING BRAKE PARTS. DO NOT USE ANY
OTHER TYPE OF LIQUID FOR CLEANING THESE PARTS.
PETROL, ENGINE OIL OR ANY OTHER PETROLEUM DISTI-
LLATE WILL CAUSE RUBBER PARTS TO DETERIORATE. IF OIL
IS SPILT ON ANY PART, IT WILL BE DIFFICULT TO CLEAN
COMPLETELY AND MAY DETERIORATE THE RUBBER USED
IN THE DISK BRAKE.

7) ON HANDLING THE DISK BRAKE LININGS OR THE

DISK, TAKE CARE TO ENSURE THAT NO BRAKE FLUID CO-
MES INTO CONTACT WITH THEM. CLEAN ANY REMAINS
OF BRAKE FLUID THAT ACCIDENTALLY COMES INTO CON-
TACT WITH THE LININGS OR WITH THE DISK WITH A SOL-
VENT WITH A HIGH INFLAMMATION POINT. DO NOT USE
ONE THAT LEAVES GREASY RESIDUES. IF LININGS CAN-
NOT BE CLEANED SATISFACTORILY, CHANGE THEM FOR
NEW ONES.

8) BRAKE FLUID DESTROYS PAINTED SURFACES RAPIDLY.

CLEAN OFF ANY SPILT REMAINS IMMEDIATELY.

9) IF ANY OF THE BRAKE SYSTEM PIPE SECURING SYSTEMS

OR THE BLEED VALVE OPENS AT ANY TIME, THE AIR CAN BE
BLED FROM THE BRAKE SYSTEM PIPE.

114
 INSPECTING THE REAR WHEEL

1. Inspect:
- Rear wheel axle
- Rear wheel
- Rear wheel bearings
- Retaining rings

See the “REAR WHEEL” section

2. Measure:
- Distortion of the rear wheel

See the “REAR WHEEL” section

FITTING
G THE REAR WHEEL

Reverse the “DISMANTLING” procedures. Take care with

the following points:

1. Fit:
- Rear wheel.

2. Adjust:
- Drive chain tension
See the “ADJUSTING THE DRIVE CHAIN” section in
“CHAPTER 3.

3. Tighten:
- Rear wheel axle.
- Axle nut (rear wheel) (1).

Nut (rear wheel axle):

110-130N.m (11- 13kgf.m)

4. Check:
- Brake pedal play

See the “ADJUSTING THE REAR BRAKES” section in

CHAPTER 3.

115
 DISMANTLING
1. Place the motorcycle on a flat surface.

WARNING
ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY
AND THERE IS NO RISK OF IT FALLING.

2. Extract:
- Gear change pedal
- Left hand crankcase cover
- Pinion

See the “DISMANTLING THE ENGINE” section in CHAP-

TER 4.

3. Extract:
- Rear wheel

See the “REAR WHEEL” section.

4. Extract:
- Coupling circlip(1).
- Coupling plate (2).
- Coupling link.
- Drive chain

5. Extract:
- Chain sprocket, by removing the bolts.

116
 INSPECTING THE DRIVE CHAIN

1. Inspect:
- Chain stiffness

Stiffness => Clean and lubricate, or replace.

2. Inspect:
- Drive chain (1).
- Chain sprocket (2).

More than ½ tooth of wear => Replace the whole chain.

3. Clean:
- Drive chain

Place the chain in a container with petrol and brush it to re-

move as much of the dirt as possible. Then remove the chain
from the petrol, dry and lubricate it.

Lubricant for the drive chain:

Engine oil

CHAIN SPROCKET

1. Fit:
- Chain sprocket.
- Nut.

Chain sprocket nuts:

25 – 29 N.m (2,5 – 2,9 kgf.m)

117
 FITTING THE CHAIN SPROCKET AND THE DRIVE CHAIN

1. Fit:
- Chain sprocket assembly

2. Fit:
- Drive chain (1).
- Coupling link (2).
- Coupling plate (3).

3. Fit:
- Circlip (1).

ATTENTION
FIT THE CHAIN COUPLING CIRCLIP FACING IN THE DIREC-
TION INDICATED IN THE FIGURE

4. Fit:
- Pinion
- Gear change pedal

See the “DISMANTLING THE ENGINE” section in CHAP-

TER 4.

5. Adjust:
- Drive chain tension

See the “ADJUSTING THE DRIVE CHAIN TENSION” sec-

tion in CHAPTER 3.

6. Tighten:
- Wheel axle.

118
 FORK
O

1 Forks 2 (with the numbers ...

2 Forks top plate
3 Rod-bottom plate sub-assembly
4 Rod-forks securing nut
5 Securing washer
6 M8 Allen screw
7 Hydraulic tube sub-assembly
8 Fork stem plug
9 Stem pipe plug O-ring
10 Fork spring
11 Fork stem tube assembly
12 Fork stem guide bush
13 Fork stem retaining ring
14 Fork-stem retaining ring base washer
15 Dust boot
16 Right hand fork end mounting
17 Left hand fork end mounting
18 M8 Allen screw
19 Washer
20 M8 Allen screw

119
 DISMANTLING FRONT SUSPENSION
ATTENTION
TO CARRY OUT THE PROCESS OF DISMANTLING THE FOR-
KS WITHOUT REMOVING THEM FROM THE BOTTOM PLATE.
TO DO SO, HOLD THE FORKS IN A BENCH VICE BY THE
STEERING COLUMN, THEREBY PREVENTING THEM FROM
BEING SCRATCHED.

- Extract the top closing bolt.

- Remove the top bolt.

ATENCIÓN
THE BOTTOM BAR OF THE FORKS WILL COME FREE. HOLD
IT TO PREVENT IT FROM FALLING.

Have ready a suitable sized container in which to drain off

the hydraulic fluid from each bar (pump the fork stem assem-
bly in order to ensure it is completely drained).

120
 Extract the spring and the preload spacer.

- Extract the oil seal dust guard together with its security
circlip.

- Firmly separate the bar from the fork stem.

Extract the elements:

- Dust guard (1).
- Oil seal (2).
- Washer (3).
- Scraper (4).

121
 - Proceed with cleaning and degreasing all the front sus-
pension components, so that they can be subsequently chec-
ked.

INSPECTING THE FRONT FORKS

- Check the degree of wear on the suspension bar guide
bush. Replace it in the event of it being damaged on over
30% of its total surface.

- With the aid of some X-shaped chocks and a comparison

meter fitted on a fixed support, determine the degree of
non-alignment of the bar.

Service limit:
0,4 mm.

- Check the length of the suspension spring, as well as its

distortion and/or lack of parallelism.

- Check the state of the rebound spring and the airtight O-

ring. Replace them in the event of evident distortion or da-
mage.

Clean and degrease all the elements making up the assem-

bly, ready for reassembly.

122
 Reassemble the assembly, paying special attention to the tig-
htening of the fork stem, as well as the fitting of the oil seal,
putting a little oil on its edges and inserting it with the aid of
the special tool. Refill the hydraulic fluid and do not forget to
insert the preload bush between the spring and the closing
plug.

N.B.
TO FIT THE OIL SEAL, USE THE SPECIAL TOOL DESIGNED
SPECIALLY FOR THIS OPERATION (AS IN THE PHOTO).

Ø 40 fork oil seal fitting tool:

00H05100101

SUSPENSION FREE LENGTH OF SPRING (MM) cm3 OIL/ BAR TYPE OF OIL

SEBAC 851 ± 3 340 C.C. SAE 7,5 W

Fork elements tightening torques:

- Guide fork to the chassis

30-35 N.m (3 – 3.5 kgf.m)

- Top plate closing

17-19 N.m (1.7-1.9 kgf.m)

- Fork stem closing

17-19 N.m (1.7-1.9 kgf.m)

1. Refit all the components:

- Readjust forks to the chassis.
- Secure the top plate to the forks (bolts 1)
- Secure the top plate to the chassis (bolt 2)
- Refit the front fairing.
- Connect the headlight cables, the turn indicators and the
dashboard.

123
 N.B.
TIGHTEN ALL BOLTS TO THEIR NOMINAL TORQUE.

- Top forks to the chassis:

30-35 N.m (3 – 3.5 kgf.m)

- Top plate to the forks:

17-19 N.m (1.7-1.9 kgf.m)

2. Dismantle:
Front fairing
- Disconnect lighting connections.
- Disconnect dashboard connections.
- Remove the front fairing securing bolts with the frame (1).

3. Dismantle:
Top plate – Top plate bolts-forks (1) and plate-chassis (2).

4. Separate:
Forks wheel assembly (downwards).

5. Check:
- Functioning (top and bottom bearings). Push the handle-
bars down several times.

Irregular functioning => Repair.

See “FRONT FORKS” in CHAPTER 6.

124
 HANDLEBARSS

1 Right hand semi-handlebar sub-assembly 25 Clutch lever tensioner

2 Left hand semi-handlebar sub-assembly 26 Clutch cable sub-assembly
3 M8 bolt 27 Air cable sub-assembly
4 Handlebar counterweight 28 Stop switch
5 Silentblock bush 29 Switch hood
6 M5 Allen screw 30 Cable protector
7 Throttle twist-grip assembly 31 M6 Allen screw
8 Electric starter switch assembly 32 Allen screw
9 Handlebar securing clamp 33 Clamp
10 Throttle cable sub-assembly 34 Front brake calliper outlet
11 M5 bolt 35 M6 bolt
12 Front brake cylinder assembly. 36 Securing nut
13 M6 Allen screw
14 Brake fluid reservoir cover
15 Brake fluid reservoir cover gasket
16 Brake fluid cover bolt
17 Front brake lever
18 Front brake fluid pipe
19 Hydraulic pipe outlet
20 Outlet seal washer
21 Left hand lever holder assembly
22 Clutch grip
23 Light switch assembly
24 Clutch lever

125
 DISMANTLING
WARNING
- ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY
AND THERE IS NO RISK OF IT FALLING.

- PLACE THE MOTORCYCLE ON A FLAT SURFACE.

RIGHT HAND HALF HANDLEBAR

1. Extract:
- Right hand light switch assembly.
- Front brake lever assembly.
- Handlebar counterweight
- Throttle twist-grip.

2. Extract:
- Half handlebar securing bolts.

LEFT HAND HALF HANDLEBAR

1. Extract:
- Left hand switch assembly.
- Clutch lever assembly.
- Handlebar counterweight
- Left-hand grip.

N.B.
TO REMOVE THE GRIP, BLOW WITH COMPRESED AIR BET-
WEEN THE HANDLEBAR AND THE SIDE RECEIVING THE
ADHESIVE.

2. Extract:
- Half handlebar securing bolts.
- Half handlebar.

126
 INSPECTING THE HALF HANDLEBARS

1. Inspect:
- Half handlebars

Warping/cracks/damage => Replace.

WARNING
DO NOT ATTEMPT TO STRAIGHTEN A WARPED HANDLE-
BAR. THIS MAY SERIOUSLY WEAKEN THE HANDLEBARS.

DISMANTLING THE STEERING COLUMN

1. Extract:
- Top plate closing plug.
- Top plate (with half handlebars fitted to it).

2. Lift up the front of the motorcycle. The front wheel will

descend.

N.B.
SUPPORT THE STEERING SHAFT FIRMLY TO PREVENT ANY
RISK OF THE MACHINE FALLING.

INSPECTING THE STEERING COLUMN

- Extract the steering bearings. If they are in poor condition,
change them.

N.B.
THE STEERING BEARINGS ON THIS MACHINE ARE BUILT
DIRECTLY INTO THE CHASSIS.

FITTING THE STEERING COLUMN

Reverse the “DISMANTLING” procedures. Take note of the
following points:

1. Lower the front of the machine (remove it from its su-

pport).

127
 2. Place the front wheel in its correct position.

3. Fit:
- Top plate, with half handlebars fitted to it.
- Top plate nut.

Top plate nut:

30-35N.m(3-3.5kgf.m)

FITTING THE HALF HANDLEBARS

1. Fit:
- Components corresponding to the side to be fitted.

2. Fit:
- The half handlebars onto the top plate.

Fitting torques:
- Plate to half handlebar nut:
17 - 19 N.m with sealer (1.7 – 1.9 kgf.m)

- Handlebar counterweight:
3.5 - 4.5 N.m (0.35 -0.45 kgf.m)

N.B.
- APPLY A THIN LAYER OF LITHIUM SOAP BASED GREASE
TO THE RIGHT HAND END OF THE HANDLEBARS.

WARNING
CHECK THE FUNCTIONING OF THE THROTTLE TWIST-
GRIP.

3. Adjustment
- Throttle cable play.
- Functioning of the brakes.

See the “ADJUSTING THE BRAKE CABLES/ADJUSTING

THE BRAKE LEVER” section in CHAPTER 3.

128
 1 Swinging arm assembly
2 Swinging arm shaft assembly
3 M14 hexagonal nut
4 Needle bearing
5 Swinging arm adhesive
6 Swinging arm stop bush
7 Shock absorber separator bottom bush
8 Shock absorber assembly
9 M10 hexagonal head bolt
10 D10 washer
11 M10 hexagonal nut
12 M10 hexagonal head bolt
13 Chain cover
14 Countersunk head bolt
15 Chain rubbing plate
16 Self-locking bolt
17 Flat washer
18 Shock absorber separator top bush

129
 DISMANTLING
1. Place the motorcycle on a flat surface.

WARNING
ENSURE THAT THE MOTORCYCLE IS SUPPORTED FIRMLY
AND THERE IS NO RISK OF IT FALLING.

2. Extract:
- Rear wheel.
- Wheel sprocket.
- Brake disk.
- Rear calliper.

See the “GEAR RATIO” section.

3. Extract:
- Nut (top and bottom).
- Shock absorber.

4. Extract:
- Swinging arm shaft nut.
- Wheel axle nut.
- Washers (swinging arm).
- Shafts.
- Swnging arm.

INSPECTION
1. Inspect:
- Swinging arm play
Play => Tighten the joint shaft nut or replace the bushes.

- Swinging arm vertical movement

Irregular movement/warping/stains => Replace the bushes.

- Swinging arm vertical movement

Irregular movement/warping/stains => Replace the bushes.

2. Inspect:
- Shock absorber Fluid leaks/damage => Replace the shock
absorber.

130
 1 Front electrical wiring system 25 Flasher relay
2 Rear electrical wiring system 26 M6 crosshead screw
3 Front right hand headlight assembly 27 Front shield securing bolt
4 Front left hand headlight assembly 28 Cable protector
5 Bolt 29 Horn assembly
6 Flat washer 30 M6 bolt sub-assembly
7 Front headlight bulb 31 Securing nut
8 Front pilot light assembly 32 Electric starter relay assembly
9 Pilot light fitting 33 Starter relay elastic support
10 Pilot light brake bulb 34 Regulator
11 Pilot light sidelight bulb 35 M6 crosshead screw
12 Sidelight cluster sub-assembly 36 7.5A fuse
13 Screw 37 Sidelight bulb assembly
14 Clutch spring stop washer 38 Sidelight light unit assembly
15 Rear right hand turn indicator assembly. 39 Number plate light assembly
16 Rear leftt hand turn indicator assembly. 40 Number plate light bulb holder assembly
17 Washer 41 M5 Allen screw
18 M10 hexagonal nut 42 M5 self-locking nut
19 Battery 43 Turn indicators control unit assembly
20 Battery stop foam 44 Mechanised flat washer
21 Battery support 45 DIU
22 Cable joining fastener 46 DIU securing clip
23 Cable joining fastener 47 M5 crosshead screw
24 Cable joining fastener 48 Flat washer

131
 49 Securing nut
50 15A fuse
51 M6 self-locking nut
52 M6 Crosshead screw
53 Coil separator bush
54 Neutral switch
55 Seal
56 Coil
57 Spark plug cap
58 Escape valve motor.
59 Exhaust valve pulley
60 Bolt
61 Escape valve motor cover
62 Anti-vibration rubber
63 Bush
64 M6 crosshead screw
65 M6 bolt
66 Washer
67 M6 self-locking nut
68 M6 fairing nut
69 Clip
70 Turn indicator light

132
 O - Orange

GR - Green

B - Black

BR - Brown

W - White

G - Grey

Y - Yellow

BL - Blue

R - Red

P- Pink

VI - Violet

1 Front headlight 15 Fuel reserve sensor

1A 12v 35W R/H front headlight dipped beam 16 Starter relay
1B 12v 35W L/H front headlight main beam 17 Starter motor
1C 12v 2.3W sidelight bulb 18 15A fuse
2 Dashboard assembly 18A 7.5A fuse
2A Water temperature indicator LED 19 12V 4Amp Battery
2B Oil level LED 20 Magneto
2C Fuel level LED 21 Electronic HT converter
2D Main beam indicator LED 22 Anti-interference plug cap
2E Turn indicator LED 23 Spark plug
3 Ignition switch 24 12v30/20A lights relay
4 12v 10W front R/H turn indicator light 25 12v 10/10w turn indicator unit
5 12v 10W front L/H turn indicator light 26 Electronic resend (Hall effect)
6 12v 2.3W rear R/H turn indicator light 27 DIU
7 12V 2.3W rear L/H turn indicator light 28 SERVO-MOTOR
8 Pilot light 29 Neutral switch
8A 12v 2.3W pilot light 30 Direct current 12v regulator
8B 12V 16W stop light
9 Stop and start switch
10 Horn-turn indicator-flasher switch.
11 Stop switch
12 Horn
13 Water temperature thermocontact
14 Oil reserve sensor

133
 CHECKING CONNECTORS
Check for corrosion, damp etc. in the connectors.

1. Disconnect:
- Connectors

2. Dry each of the terminals with compressed air.

3. Connect and disconnect two or three times.

4. Pull the conductor to check if it is loose.

5. If the terminal comes loose, bend the pin (1) and refit
the terminal in the connector.

6. Connect:
- Connector

N.B.
THE TWO PARTS OF THE CONNECTOR MAKE A SOUND
WHEN THEY FIT TOGETHER.

7. Check the circuit with a Multimeter.

N.B.
- IF THERE IS NO CIRCUIT, CLEAN THE TERMINALS.

- FOLLOW THE STEPS FROM (1) TO (7) ABOVE ON INSPEC-

TING THE ELECTRICAL SYSTEM.

- AS A PROVISIONAL SOLUTION, USE A CONTACT CLEANER.

- USE THE MULTIMETER IN ACCORDANCE WITH THAT IN-

DICATED IN THE FIGURE.

134
 INSPECTION STEPS
Using a multimeter, check the circuit between the terminals
to make sure that they are correctly connected. Replace the
component if any of the combinations gives an incorrect rea-
ding.

N.B.
- SWITCH THE “ON” AND “OFF” SWITCH ON AND OFF
SEVERAL TIMES.

- ADJUST THE METER SELECTOR TO THE “X1” POSITION.

- ADJUST THE GAUGE TO “ZERO”.

CONNECTIONS FOR THE SWITCHES SHOWN IN THIS MANUAL

This manual contains connection tables like this one in the
figure on the left, showing the switch terminal connections
(main switch, brake switch, light switch, etc.).

The column on the far left indicates the different switch po-
sitions, the top line indicates the colours of the conductors
connected to the switch terminals.

“ ”indicates the terminals between which there is closed

circuit at a determined switch position.

In this table:
“BR and “R” have a closed circuit with the switch in the “ON”
position.

135
 IF THE IGNITION SYSTE FAILS (NO SPARK OR INTERMIT-
TENT SPARK)

PROCEDURES
Check:

1. Spark plug.
2. Gap between electrodes
3. Resistance of the connector
4. Ignition coil.
5. Main switch.
6. Resistance of the impulse coil.
7. Resistance of the field coil.
8. Ignition system connections.

N.B.
- REMOVE THE FOLLOWING PARTS BEFORE DIAGNOSIS: 1)
FAIRING AND SEATS

1. Spark plug Standard spark plug

NGK BR8ES
- Check the spark plug condition.
- Check the type of spark plug.
- Check the gap between the electrodes.

See “SPARK PLUG INSPECTION” in CHAPTER 3. OUTSIDE THAT SPECIFIED

Gap between electrodes:

0.7 ÷ 0.8 mm

CONFORMS TO SPECIFICATIONS Renew the spark plug.

2. Gap between electrodes

- Disconnect the spark plug connector.

- Connect the spark tester (1) as in the figure (2) Spark plug.

- Turn the main switch to “ON”.

- Check the gap between the electrodes (a).

- Start the engine and increase the gap until the spark
begins to fail.

Minimum electrode gap:

6 mm CONFORMS TO SPECIFICATIONS

OUTSIDE THAT SPECIFIEDOUTSIDE

THAT SPECIFIED The ignition system is normal.

136
 3. Resistance of the spark plug connector Terminal (+) Spark plug side(1).
Terminal (-) Spark plug lead side (2).
- Remove the connector.
- Connect the Multimeter (Ω x 1) to the spark plug connector.

N.B.
- ON REMOVING THE SPARK PLUG CONNECTOR, DO
NOT PULL IT WITH THE SPARK PLUG LEAD.

REMOVAL =>TURN IN AN ANTI-CLOCKWISE DIREC-

TION.
FITTING => TURN IN A CLOCKWISE DIRECTION.

- CHECK THE SPARK PLUG LEAD WHEN CONNECTING

THE CONNECTOR.

- ON CONNECTING THE CONNECTOR, CUT THE SPARK

PLUG LEAD BACK APPROCIMATELY 5MM.
OUTSIDE THAT SPECIFIED

Resistance of the connector

5KΩ ± 20% a 20°C

CONFORMS TO SPECIFICATIONS
Renew the spark plug connector

3. Ignition coil resistance Terminal (+) Green/Black Terminal (1).

Terminal (- Yellow/Green Terminal (2).
- Disconnect the ignition coil connector from the electrical
system.

- Connect the Multimeter (Ωx 1) to the ignition coil.

- Check the resistance of the coil primary winding.

Resistance of the primary winding:

0.23 ± 20 % a 20°C

137
 Terminal (+) Orange / Green (1)
Terminal (-) Spark plug lead (2)

- Connect the Multimeter (Ω x 1) to the ignition coil.

- Check the resistance of the coil secondary winding.

Secondary winding resistance:

7.9 ± 20 % a 20°C OUTSIDE THAT SPECIFIED

BOTH CONFORM TO
SPECIFICATIONS Renew the ignition coil.

5. Main switch (ignition key) NO CIRCUIT

See the “INSPECTING THE SWITCHES” section.

CIRCUIT Renew the main switch (ignition key)

6. Impulse coil resistance

- Disconnect the impulse coil connector from the electrical

system.

- Connect the Multimeter (x 100) to the impulse coil con-

nector.

Terminal (+) White/Red Terminal

Terminal (-) White/Blue Terminal

- Check the resistance of the impulse coil.

Resistance of the impulse coil: 250Ω ±

250Ω ± 20% a 20°C OUTSIDE THAT SPECIFIED

CONFORMS TO SPECIFICATIONS
Replace the impulse coil.

138
 7. Charging coil resistance
- Disconnect the field coil connector from the electrical
system.

- Connect the Multimeter (x 100) to the field coil con-

nector

Terminal (+) Black/Red Terminal

Terminal (-) Green/White Terminal

- Check the resistance of the field coil.

Resistance of the field coil.

730 ± 20 % a 20°C OUTSIDE THAT SPECIFIED

CONFORMS TO SPECIFICATIONS

8. Generating coil resistance Outside that specified. Renew generating

coil.
- Disconnect the generating coil connector from the electrical
system.

- Connect the Multimeter (x 100) to the generating coil con-

nector.

Terminal (+) Green/Blue Terminal.

Terminal (-) Green/White Terminal.

Check the resistance of the generating coil.

Generator coil resistance:

600 ± 20% a 20ºC POOR CONNECTION

CONFORMS TO SPECIFICATIONS

9. Ignition system connections Renew field coil.

- Check all the ignition system connections.

See the “CIRCUIT DIAGRAM”

POOR CONNECTION

CORRECT

Replace the DIC unit. Put right.

139
 STARTER MOTOR NOT WORKING

PROCEDURES
Check:

1. Main fuse.
2. Battery.
3. Starter motor.
4. Starter relay.
5. Ignition key.
6. Starter switch.
7. Connections.

1. Main fuse NO CIRCUIT

- Remove the fuse.

- Connect the Multimeter (Ω x 1) to the fuse.

- Check that there is a circuit in the fuse. Fuse defective, replace.

CIRCUIT

2. Battery

- Check the condition of the battery.

INCORRECT
See the “INSPECTING THE BATTERY” section in
CHAPTER 3.

Minimum voltage:
12 V Recharge or renew the battery.

CORRECT

140
 3. Starter motor WARNING
THE CONDUCTOR USED FOR BRIDGING
- Connect the positive terminal of the battery (1) and the MUST HAVE A CAPACITY COMPATIBLE
starter motor cable (2), using a bridging conductor (3) on WITH THAT OF THE STARTER MOTOR. IF
the relay (4) as shown in the figure. NOT, THE MOTOR MAY BURN OUT.
*as in the figure.

DOES NOT TURN OVER

- Check starter motor functioning. Defective starter motor – repair or replace.

TURNS OVER

4. Starter relay
- Disconnect the starter relay connection from the electri-
cal system.
- Connect the battery to the starter relay, using bridging
connectors (1).

DOES NOT TURN OVER

Check starter motor functioning. Defective starter relay – replace.

WARNING
TURNS OVER TAKE CARE NOT TO REVERSE THE BATTERY
CONNECTIONS, OR DAMAGE MAY BE
CAUSED TO THE DIODE TAKE CARE NOT
TO CAUSE A SHORT CIRCUIT BETWEEN
THE POSITIVE AND NEGATIVE TERMINALS
WHEN CONNECTING THE BATTERY AND
THE RELAY.
141
 TURNS OVER

5. Main switch

- Disconnect the main switch connection from the electri-

cal system.
- Check the circuit between the Red and Red/Black con-
ductors.
See the “INSPECTING THE SWITCHES” section.

O GR BL R/W
LOCK

OFF

ON INCORRECT

TURNS OVER
Defective main switch - replace.

6. Neutral switch.
- Disconnect the neutral switch conductor from the electri-
cal system.

- Check the circuit between the “Blue” (1) and the “Earth”.

See the “INSPECTING THE SWITCHES” section.

142
 BL
NEUTRAL
IN GEAR
INCORRECT
80

Defective neutral switch – replace.

CORRECT

7. Starter switch
- Disconnect the starter switch conductor from the electri-
cal system.

- Check the starter switch circuit between the “Red/Black”

(1) and “Black” (2) conductors.

See the “INSPECTING THE SWITCHES” section.

STOP ENGINE ENGINE

Y/GR GR/B R/B W/B
OFF
ON INCORRECT

Defective starter switch – replace.

CORRECT

8. Connections

Check the ignition system connections. See the

“INSPECTING THE SWITCHES” section.
INCORRECT CONNECTION

Put right.

143