IH

L-.
tE'
r-

P
P
P
P
F

F.lliBenelli$.p.4.

E
I

p
a
7

a
a
a
e

WI|RII$HIIP
MIIIUII

e
e
a
e
e
e

a
e

a
3

IE
I
-E----

Additionsand change to the workshopmanualfor 500 ouattro - 7s0 sei

I NDEX

MAIN FEATURES

M A I N T E N A N C EO P E R A T I O N S
7
15
16
18
20

page 1

]I ,- .

C l u t c hl e v e ra d j u s t m e n t
Carburation
V a l v eg e a r i n g
Valvetappetclearance
adjustment
l g n i t i o na d v a n c a
edjustment

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

S P E C I A LT O O L S

ENGINE
'l
5
9

1
3
7

Front and rearbrake

F r o n t a n d r e a rw h e e l
Front fork

R e a rs u s p e n s i o n s

ELECTRICALEOUIPMENT
1
2

!I

page I

, page..10

C y l i n d e rh e a d c, y l i n d e rb l o c ka n d p i s t o n s
Clutch
G e a r b o xp, r i m a r yd r i v ea n dd e s m o d r o m i c

FRAME

:I

, page 8

page i9

page 28

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

W I R I N GD I A G R A M

page 31

a
a
a
e
t

MAIN FEATURES

ENGINE

I f o u rs t r o k e

- n u m b e ro f c y l i n d e r s
- bore x stroke

I sixin line
| 60 x 53.4 mm

- displacement
- compression
ratio

| 905.91cc
| 9.53 to 1

a
a
a
e

- revsat max enginespeed

- horsepower

| 8400 rPm
| 80 HP

VALVE GEARING

I c a m s h a fi tn t h e c y l i n d e rh e a d c, h a i nd r i v e n

I o p e n s :11 ob e f o r eT . D . C .- c l o s e s4: 3 oa f t e rB . D . C .
I o p e n s 4: 3 " b e f o r eT . D . C .- c l o s e s1: 1 " a f t e rB . D . C .

7
7
7
7

inlet

- exhaust

r o c k e rc l e a r a n cfeo r v a l v et i m i n g
| 0.8 mm
- normal rocker clearance (cold
l d engine
e n g i n e )| 0 . 1 3 t o 0 . l 5 m m

CARBURATION
- carburettors

I t h r e e" D e l l ' O r t o " t, y p e V H B 2 4 D

{
>

3
3
3

L U B RI C A T I O N

b y p u m p" E A T O N " t y p e

- n o r m a ll u b r i c a t i o np r e s s u r e

3 . 5 t o 4 k g / s q c mo; i l p r e s s u rsee n d eur n i t f o r w a r n i g l i g h t

- oil filter

I r e p l a c e a bcl ea r t r i d g e

GENERATO*
- alternator

|
|

IGNITION

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

14 V - 12A

7
7
7
1

v
t

v
7
I
t
)
E-----

- clearance
betweenthe block on the rotating I
sleeveand the metal endsof each"pick-up" | 0.20 to 0.30 mm
- max ignitionadvance
| 35o beforeT.D.C.at 5000-5500rpm
- sparkplugs
I MarelliCXSL-BoschX260T2-LodgeHBL12
- p l u gp o i n t sg a p
| 0.5mm
- i g r r r i t i ocno i l s
I N. 3
- firing order

s r AR r N G

14-2-6-3-5

I
- electricstarterwith electromagnetic
ratchet I
control
|

12V-0.4HP

d
d

TRANSMISSION
- clutch

m u l t i p l ed i s c sd r y t y p e . H a n dc o n t r o l l e db y l e v e ro n t h e l e f t
s i d eo f t h e h a n d l e b a r

- gearoox

five speed,constant mesh gears,frontal engagement.

Pedal
c o n t r o l l e df r o m t h e L / H s i d eo f t h e v e h i c l e

- g e a rr a t i o s
1st gear

1 t o 2 . 4 5 4( Z : 1 1 1 2 7 1

2nd gear

i t o 1 . 6 6 6( Z : 1 5 1 2 5 1

3rd gear

1 t o 1 . 2 1 1( Z : 1 8 1 2 3 1

4th gear

1 t o 1 . 0 5 0( Z : 2 0 / 2 1 )

5th gear

i t o 0 . 9 0 0( Z = 2 O l 1 8 l

- cardanshaft- bevelgearratio

1 t o 2 . 5 1 1( Z = 2 1 / 5 4 \

FRAME

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

susPENSroN
-

front

- rcar

WHEELS
- f r o n t a n d r e a rr i m s

I
I t e l e s c o p i cf r o n t f o r k w i t h h y d r a u l i cs h o c k a b s o r b e r sa n d
h e l i c o i d as lp r i n g s
II
s ith helicoidal
I s w i n g i n gf o r k a n d h y d r a u l i cs h o c ka b s o r b e rw
spnngs

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

- rear
- front tire pressure
- (eartlre pressure

- front

- rear

d
d

d
d
d
d
d
d
d
d
d
d

T IR E S
- front

BRAKES

l i g h ta l l o vc a s t i n g s w f3v /l 2 . 1 5x 1 8 "

t
d

I d i s c t y p e w i t h c a l i p e rh a v i n g2 c y l i n d e r s .L e v e rc o n t r o l l e d

sideof thehandlebar.
I Ig. Il. yf mm
ora.
ruu
| ?,.,9
ora.J mm
I Lyrrnoer
tvtaster
cyl.dia.12.7mm
I
by
Controlled
I disc type with caliperhaving2 cylinders.
l n t h e c e n t r eR / H s i d eo f t h e b i k e .
r o c k e rp e d a o
D i s cd i a .2 6 0 m m
C y l i n d edr i a .4 8 m m
M a s t ecr y l .d i a .1 5 . 8 7m m

The rear brake is hydraulicallyconnectedto a secondfront

b r a k e o f s a m e t y p e a n d s i z e a s t h e h a n d o p e r a t e df r o n t
o r aK e .

d
d

&
d
*

#
*

t
I

a
e
7

D I M E N S I O NASN D W E I G H T

- wheelbase(loaded)
- m a x i m u ml e n g t h

- m a x i m u mh e i g h t
- width

a
a
I
7
7
7
7
7

- dry weight

m (57.4"1
1.46O
2 . 1 1 0m ( 8 3 . 0 7 " )
1 . 1 3 0m ( M . 4 8 " 1
0.690m (27.16"1
22Oks (485lbs)

P E RF O R M A N C E S
maximumspeed

2 1 5 k m / h a p p r o x( i 3 3 m . p . h . )

(CUNA)
f u e lc o n s u m p t i o n

8 | x 1 0 0k m ( 1 . 7 6 gx 6 2 m i . )

F U E LA N D O I L C A P A C I T I E S
- f u e lt a n k

petrol98/100 NO-RM)5 lt reserve

16.5 | (supergrade
included

oilsump

3 | ( A G I PS I N T2 0 0 0S A E 1 0 W 5 0 o i l )

front fork oil

60 cc eachleS(AGIP F 1 ATF Dexron)

brakingsystem

A G I P F 1 B r a k eF l u i dS A EJ 1 7 0 3C

E-

7
D

ELECTRICE
AO
L UIPMENT
BATTERY

12V -28 Ah

a
B

LIGHTS
h e a d l i g h( tb e a m )
headlight(town)
taiI light ( parking-stop)

't2v-4045W
12V-4W
12V -5121W

indicatorlights
- Revcounter
speedometer

12V- 21W
't2v-3w

=
J

instrumentpanellights

12V -1.2W

FUSES

N . 4 1 6A

HORN

12V

7
7
I
7
7
7
l

NB - All datahereincontainedareindicativeand aresubiectto modificationwithout orior notice.

s
fl

oPERATtoNs
rvrarNrENANcE

2.7 CLUTCHLEVER ADJUSTMENT

Check that the free play at the handlebaris 34 mm
(.12" to .16"), otherwiseact on screw "4" to restore
the correctplav.
lf this adjustmentis not sufficientand clutchdoesnot
disengaoperatecorrectly(clutch slippingor incomplete
counternut
gement)act on adjuster"C" after slackening
"D" located on the dutch leverat the crankcase.
This
operation can be performedafter removingplug "E".

2.15 CARBURATION
Carburettors
D e l l ' O r t ot y p e V H B 2 4 D ,d o u b l ec o n t r o l s
settings:
Carburettors
Choke
Qzqmm
40
T h r o t t l ev a l v e

Atomizer
Needle
M a i nj e t
l d l i n gj e t
Starterjet
Fl o a t e r

ZOU Atr

E 3 (2ndnotch)
102
45
50
1 4g r

G
G
G
G
G
F
G
G
F

lg*
tt<
tE,4,
g+

La
I
gs

*
t-ra
4

g
*

tsl+

+
lgl
.*-

#
*
F

lL'

+
,
#
F

c
t

4
3

of the carburationand idling speedadjustment

Synchronisation

a
3
3

a
a
e
3
3
7
7
3

e<
,=\\,@\
^<-

7
7
3

,-/

Z--i\-A
(l ,

t ,iJr

lilit

4q! I
tr'9\+=

*_l.li\

I=L

>

3
5
ESr

lEL

J
J
!t)

F o r t h e a b o v eo p e r a t i o n sf o l l o w w h a t i s i n d i c a t e di n t h e
w o r k s h o pm a n u a lf o r 7 5 0 / S e ib u t b e a r i n gi n m i n d t h a t
t h e v a c u o m e t ewr i t h t h r e e m e r c u r yc o l u m n sh a st o b e
connectedto the connectorspurposelyprovidedafter
r e m o v i n gc o m p e n s a t i n gh o s e " A " c o n n e c t i n g t h e
manifolds,
The three connectorsunused have to be temporarily
closed
s f r u b b e rp l u g s" 8 " .
by meano

{
t

{
S

a
4

7
3

7
7

v
7
I

F\

t,t;7*"

2 . 1 6 V A L V EG E A R I N G
To carryout the adiustmentoperateas follows:
- R e m o v teh e f a i r i n ga n d f u e l t a n k .
- R e m o v ec e n t r a h
l u b f r o m d e g r e et i m i n g p l a t e c o o e
7 7 9 9 )v a l i df o r 7 5 0 / S e i .
6 9 . 9 0 . 7 8 . 5(27 0 4 . 0 8 0
- F i t o n t i m i n gp l a t er h e n e w h u b 6 3 . 9 4 . 9 6 . 2 p
0rovided
for model 900 Sei; pay attention to havethe hub key
t r a c e t u r n e d o n r h e i / 6 s t a m p i n gs i d e o n t h e t i m i n g
prate.
- Removethe alternatorfrom the crankshaftL/H side
a n d f i t t h e t i m i n g p l a t ec o m p l e t ew i t h h u b a n d l o c k i t
with bolt 1471.24.59.
- Secure the arrow index for timing check code
63.94.75.20in the crankcase.

.\

R o t a t e c r a n k s h a f tt o b r i n g p i s t o n o f c y l i n d e r n . 1 i n
T . D . P . b u r s t p o s i t i o n . t i m i n g p l a t e w i l l i n d i c a t eT . D . P .
O " ( a s c e r t a i nt h a t t h i s i n d i c a t i o n i s c o r r e c t b y f i t t i n g a
dial gaugein spark plug hole in order that the member
t o u c h i n g t h e u p p e r p a r t o f t h e p i s t o n i n d i c a t e st h e
T D P.position).
- Remove taooet cover.
- Check that, with crankshaft in the aboveposition,
a p l a t e o f 2 . 2 m m t h i c k n e s sf i t s c o r r e c t l y i n t h e n o t c h
on the L/H side of camshaft (this can be obtainedbv
plate 61 90.79.00
reducing the
thickness of
(704.080.0.799) placed against the rear part of the
cylinderhead.
I t n e c e s s a r yu, n d o t h e t l v o b o l t s l o c k i n g t h e d i s t r i b u t i o n
g e a r o n c a m s h a f t ,r e m o v e t h e c l r a i n s t r e t c h e ra n d r o t a t e
t h e c a m s h a f tt o o b t a i n t h e a b o v e t i m i n g p o s i t i o n .
-

Lock the distributiongearon camshaft. lf the screw

h o l e s d o n o t c o r r e s p o n d ,r o t a t e t h e g e a r o n l y t i l l t h e
h o l e sm a t c h .
Note: lt can be that to obtain a correct correspondence
o f h o l e s i t i s n e c e s s a r tyo s l i p o f f t h e g e a r f r o m c a m s h a f t
and to rotate it bv 180'

- C o m p l e t et h e a s s e m b l yp a y i n ga t t e n t i o nt o s p r e a d
w i t h L o c t i t et h e g e a rf i x i n g b o l t s a n d c h e c kt h e v a l v e
tappetclearance.

sd

d
d
d

d
d
d
d
d
d
d

ec
d

2.18

VALVE TAPPET CLEARANCE AOJUSTMENT

l m p o r t a n t : t h e c y i i n d e r sa r e n u m b e r e d f r o m 1 t o 6 f r o m
t h e l e f t h a n d s i d e o f t h e r i d e r ' sp o s i t i o n .
C h e c k a n d i f n e c e s s a r rye s t o r et h e v a l v e t a p p e t c l e a r a n c e
o p e r a t i n ga s f o l l o w s .
a r e m o v e t h e f a i r i n g , c l o s e t h e f u e l t a p s , r e n r o v ef u e l
l i n e f r o m t h e f u e l v a l v e b o d y , d i s c o n n e c tt h e r e a r f u e l
t a n k r u b b e r a n d r e m o v et h e f u e l t a n k .
b remove the ignition breaker point cover and the
t w e l v e t a p p e t a dj u s t i n gh o l e c a p s " A " .
c rotate slowly the crankshaftclockwise till stamped
t r a c e " G " o n r o t a t i n g s l e e v ei s a l i g n e d w i t h t r a c e " H "
s t a m p e do n " P i c k - u p " c e n t r e .
N o t e : t o m a k e e a s y t h i s o p e r a t i o n i t i s a d v i s a b l et o
r e m o v et h e s p a r k p l u g s .
A t t h i s p o i n t p i s t o n 1 o r 6 i s i n p o s i t i o nT . D . C . i f t h e
trace "E" is alignedwith trace "F" stamped on the
c r a n k c a s e .T h e c o m p r e s s i o ns t r o k e o f t h e o n e o r t h e
other piston is indicatedby the posirion of the valves
( b o t l r c l o s e d) .

F
E

d c h e c k t h e c l e a r a n c eo f b o t h v a l v e s i r r c o m p r e s s i o n
s t r o k e b y i n s e r t i n ga t h i c k n e s sl l a u g e . l f t h e c l e a r a n c e
i s c o r r e c t t h e r e \ . . r l l b e a s l i g l r t c l r a go f r e s i s t a n c ea s t h e
g a L r g ei s i n s e r t e d ; a j r i s t | ' e i rits r r e c e s s a riyf t h e c l e a r a n c e
i s t o o s r l a l l o r e x c e s sv e .
N o t e : t h e c l r e c k i n g6 r r Ct h e a d j u s t n r e n ti s b e t t e r c a r r i e d
o u t b y f i t t i n g a c i i a l g r a i r g et o g e t h e r w i t h t h e s p e c i a l
s u p p o r t" N " .
T h e s t a r r r p e ct ia p p r e tc l e a r a r r c ei s ; 0 . 1 3 t o 0 . 1 5 m m
( 0 . 0 0 5 11 t o 0 0 0 5 6 5 " )
e a d J u s t m e n ti s m a d e b y l o o s e n i n g t h e t a p p e t s c r e , / v
n u t " F " a n d t u r n r n q t h e a d j u s t i n gs c r e w " E " t i l l t h e
c o r r e c t c l e a r a n c ei s o b t a i n e d .
L o c k s c r e w n u t a r r dc h e c k t h e c l e a r a n c e .

d
d
d
d

c
c
d
d
d
d
d

d
d

H
d
i

=t
=

t
t

f check and adjust the valve clearanceof the other

cylindersafter having rotated the crankshaftaligning
the trace "G" on rotating sleevewith the trace on
"Pick-up"centreof the other rylinders.
2 . 2 0 I G N I T I O NA D V A N C EA D J U S T M E N T

T h e e l e c t r o n i ci g n i t i o n u n i t d o e s n o t r e q u i r e a n y
maintenanceoperation as it is made of parts which
arenot subjectto mechanical
wear.
Thereforeafter inspectingand if necessaryad.justing
t h e i g n i t i o n t i m i n g n o p e r i o d i c a l a d j u s t m e n t so r
maintenanceoperations are needed, except in case
t r o u b l e si n t h e e l e c t r o n i cc o m p o n e n t s( p i c k - u pa n d
electronicset) or defectivecontactsin electricwirinqs
s h o u l do c c u r .
Such inconveniences
are easily detecteddue to a poor
w o r k i n ge f f i c i e n c yi n c y l i n d e r s .
T o i n s p e c ta n d a d j u s t t h e i g n i t i o nt i m i n g p r o c e e da s
follows:

ur or rNw)g.

a
e

a
a
a
7
7
7
{

1 R e m o v et h e c o v e r o n t h e r i g h t s i d e o f t h e e n g i n e
2 M a k es u r et h a t t h e m a r k " A " o n t h e i n s p e c t i ohno l e
r i m i s a l i g n e dw i t h t h e c r a n k c a sm
e ark.
In caseit shouldbe necessary
to adjustthesetwo marks,
u n d ot h e t h r e es c r e w s" 8 " a n d s u i t a b l yr o t a t et h e p i c k u p h o l d i n gp l a t e .
3 Usinga feelergaugecheckthat the clearance
between
t h e b l o c k " C " o n t h e r o t a t i n gs l e e v e
a n dt h e m e t a le n d s
o f e a c hp i c k - u pi s 0 . 2 0 - 0 . 3 0 m m ( 0 . 0 0 7 8 -" 0 . 0 1 1 8 " ) .
T o g e t t h i s v a l u eu n d o t h e s c r e w s" D " a n d s u i t a b l ys h i f t
t h ep i c k - u pb o d v .

a
7

F o l l o w i n gt h e a d j u s t m e n t sa c c o r d i n gt o p a r a g r a p h s2
a n d3 , t h e m a x i g n i t i o na d v a n c e
r a t ew i l l b e :
3 5 ob e f o r eT . D . C .a t 5 0 0 0 - 5 5 0 0r p m .
T h e i g n i t i o na d v a n c ec u r v e i s s h o w n i n t h e d i a g r a m .

t
t

2d

>

3
>

a
I
J

JOOO

q
fl

sErrtNG
to*ouE wRENcH
kgm

D i s t r i b u t i ogne a rf i x i n gb o l t s ..
C y l i n d e rh e a db o l t s
C r a n k c a suep p e rb o l t s@ 8 m m .
C r a n k c a suep p e rb o l t s0 6 m m .
lower bolts @8 mm
Crankcase
o w e rb o l t s@6 m m
C r a n k c a sl e
n u t s .. .
C o n - r o ds e c u r i n g
p
r
e
s
s
u
r
e
switch.
Oil
C l u t c ha s s yf i x i n gn u t s
S p a r kp l u g
O i l d r a i np l u g. .
Oil cartridge
c o v e rf i x i n gb o l t . .
C l u t c hh o u s i n gr e t a i n i n gp l a r e. .
P l a t es e c u r i n tgo d r i v es h a f tc l u t c hp l a t ed r u m

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

- l.c

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

t.o

ftll bs

11.51
- 4.5
20.2 21.7
to.o-t
5 . 7- 8 . 8
' t 6 . 618
67-

R6

15.9-18
1 0 . 8- 1 4 . 5
5 . 7- 8 . 6
. o- | t . o
25.3 - 28.9
'18 21.7
58

Standardsettings
Screwsand nuts f, 6 mm.
Screwsand nuts 8 ^m.

0.8- 1.2
2 -2.4

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

d
d
d

d
d
d
d

d
d
d
d

d
d
d
d
d
d

d
d
d

d
d

SPECIALTOOLS

)
)

tn additionto those indicatedin the workshopmanualfor 500 Ouattroand 75O Sei alsothe followingtools are needed.

Pos.

Code

Description

)
1

62.90.93.00

Puller,malepin on cableconnection

62.91.28.00

W r e n c hh. o l d i n gc l u t c hd r u m

62.92.67.11

P u n c h l,a y s h a fst e c u r i n n
gut

62.92.67.10

P u n c h l, a y s h a fst e c u r i n n
gu t

02.9Z.O/ . I I

Tool, for assembling

securingnut on layshaft

63.90.30.20

T o o l . lh o l d i n gc l u t c hg e a rc r o w n

63.94.96.20

H u b ,t i m i n gp l a t e

63.94.75.20

A r r o w , i n d e xf o r t i m i n gc h e c k

65.90.66.00

Puller,f lywheel

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)
)
)

10

65.91.19.00

T o o l . h o l d i n gf l y w h e e l

tl

14.71.24.59

N u t ,s e c u r i n g
h u b t i m i n gp l a t eo n c r a n k s h a f t

12

61.90.i9.00

W r e n c h ,s p a r kp l u g

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errrcrrue

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

d
d
d
d
d
d
d
d
d
d
d
d

d
d

d
d
d
d
,d

d
d
d

E
d
10

g
I

t
t
T
I
t
t

C O P P ES
RE A LR I N G

a
?
t
t

7
I

lz

ll

tl
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il

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)

Notice
The cylinder head gasket is made of rolled sectron
k l i n g e r i t ew i t h t h e i n t e r p o s i t i o no f s i x s o f t c o p p e r s e a l
r i ng s .
O n r e - a s s e m b l yp a y a t t e n t i o n t h a t r i n g s a r e p r a c e d a s
i n d i c a t e d i n t h e d r a w i n g ,r h a t i s , w i t h t h e c e n t r a l p a r t i n
r e l i e f t u r n e d u p s i d e( t o w a r d st h e c y l i n d e r h e a d ) .

ln the area around the timing chain slit apply some

s e a l i n gm a t e r i a l H Y L O N 4 A R P L 3 2 M E D I U M o r e q u i valent.
T o a v o i d o i l l e a k sa p p l y s o m e r e t a i n i n gt a p e T E F L O N
o n t h r e a d i n g so n t h e l o w e r s t u d s f i x i n g t h e c y l i n d e r h e a d
to crankcase.

tl

?
3

coNTRoLs

a
:'

Measurethe cylinder bore at three different heights,

top, centre and bottom on both axis (longitudinal
and transversal).Should the measurementstaken
exceedthe use limits it will be necessary
to re-ream
the cylinder bearingin mind that pistons and piston
r i n g sa r e a v a i l a b l ew i t h 0 . 4 0 m m ( 0 . 0 1 5 7 " ) o v e r s i z e .

Cylinderdiameter:

Standardvalue

to 60.020mm
ClassA: d OO.OtO
Q.3625" to 2.3629")

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

e
++
J

7
Da
{
,
I
r
4

N.B. Letters"A" and "8" indicatingthe classselection

are markedon top of the piston and on the upper part
o f t h e c y l i n d e rb l o c kn e a rt h e l i n i n g .
Usinga micrometertake the measurements
of the dia'l
meter at 1 mm (0.043") from piston baseat g0o of
piston axis. lf the measurement
exceedsthe indicated
l i m i t s o r i f t h e c y l i n d e ri s d e f o r m e do r s c o r e dt h i s h a s
to be replaced.
P i s t o nd i a m e t e r :

14.

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t
>

N o r m a lv a l u e

Class"A"

3
b

0 59.980to 59.990mm
( 2 . 3 6 1 4 1t"o 2 . 3 6 iB " )

Class"8"

Oversize

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

0 59.970to 59.980mm
( 2 . 3 6 1 0 "t o 2 . 3 6 1 4 " )

l+.

t
->

t
4

Take the measurementof the piston ring ends gap.

Placethe piston ring in the cylinder bore and check
gauge:
with a thickness

!?.

Pistonring.top andcenter;

0.25 to 0.45 mm
( 0 . 0 0 9 8 "t o 0 . 0 1 7 7 " )

Oil scraper:

0.20 to 0.35 mm
( 0 . 0 0 7 8 "t o 0 . 0 1 3 7 " )

W e a rl i m i t :

!l

v
t
t
t
t

,z

0.8 mm
(0.0314")

Checkthe sideplay of piston rings.Whenthe ringshave

been fitted over the piston check the clearanceoerween
ringsand slotson piston.
IJ

Usinga micrometercheckthe hole in the pistonand the

p i s t o np i n d i a m e t e r .

- Topring:
N o r m a lv a l u e
W e a rl i m i t

0 . 0 3t o 0 . 0 5 2m m
( 0 . 0 0 11 " t o 0 . 0 0 2 0 " )
0 . 1 8m m
(0.0070")

D i m e n s i o nosf p i s t o np i n h o l e" A " i n p i s t o n

- C e n t r er i n g :
N o r m a lv a l u e
W e a rl i m i t

Q hole " A"

0 . 0 3t o 0 . 0 5 2m m
(0.001" to 0.0020")
0 .1 5 m m
(0.0059")

- B o t t o mr i n g :
N o r m a lv a l u e
W e a rl i m i t

0 . 0 3t o 0 . 0 5 2m m
( 0 0 0 1I " t o 0 . 0 0 2 0 " )
0 . 1 1m m
t0.0043")

Colour

@selectron

black

white

mm
15.000to 14.997
(0 5905"ro 0.5904")
0m
1 5 . 0 0t3o 1 5 . 0 0 m
(0.5906"
to 0 5905")

d
d

0 p i s t o np i n " 8 "
18,805+ 18.905
G

i ilq
Er
2IW2
.t.-t--t-T.l'

Colour

0 selection

black

1 4 . 9 9 1t o 1 4 . 9 9 4m m
( 0 . 5 9 0 4 "t o 0 . 5 9 0 3 " )

white

15 . 0 0 0t o 1 4 . 9 9 7m m
( 0 . 5 9 0 5 t"o 0 . 5 9 0 4 " )

(r'
.t.

C h e c k t h e c o u p l i n g p l a y b e t w e e np i s t o n p i n a n d b i g e n d
b e a r in g .

ct

Check the paralleiism

of both small and big end axis.
M a x i m u m v a l u e :* 0 . 1 0 0 m m o n 2 0 0 m m ( 0 . 0 0 3 9 " o n
7 87"\.

'q
18805i18.
r

d
d
d
d

GI
D i m e n s i o no
s f p i s t o np i n " 8 " d i a m e t e r

-=|-

d
d
d
d

Dopo alesatura

S e l e c t i o no f s m a l l e n d b u s h i n qd i a m e t e r

C L A S S" A "

\-LAJJ

B l u em a r ko n s t e m

B l u em a r ko n s t e m

3 8 . 1 0 3t o 3 8 . 1 0 9m m
( 1 . 5 0 0 1t"o 1 . 5 0 0 3 " )

3 8 . 1 0 9t o 3 8 . 115 m m
( 1 . 5 0 0 3 t" o 1 . 5 0 0 5 " )

GI

d
d
d
d
d
d
d
d
d

d
d
d
d

d
d

d
d

d
d

14

4
il

6.5 CLUTCH

t
3

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3
7
7

7
3
7
7
a
4

7
3
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+
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7
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Removal of clutch assembly

1

Undo the two fixing bolts and remove R/H cover.

2 U n d o t h e 4 b o l t s f i x i n g p r e s s u r ep l a t e , t a k e o u t t h e
springs and spacing washers and remove pressure plate
t o g e t h e rw i t h o t h e r p l a t e s .
3 R e m o v et h e p r e s s u r ec a p a n d s t r a i g h t e nt h e r e t a i n i n g
w a s h e rf l a p s .
4 S e t u p t h e s p e c i a lw r e n c h " 4 " t o h o l d t h e c l u t c h
drum and with tool "8" undo the centrallockingbolt.

5 T a k e o f f t h e b o l t , s t o p w a s h e r s ,r e m o v e t h e c l u t c h
d r u m a n d t h e t w o h a l f- w a s h e r s .
!F

6 S t r a i g h t e nr e t a i n i n gw a s h e r f l a p s a n d w i t h t h e s p e c i a l
tool "C" undo the clutch housing centrai lock ring.
7 S I i p o f f c l u t c hh o u s i n g .

d
d
d
d
d
d
d
d
d
d

a
d

d
d
Checking operations
U s i n g a g a u g e c h e c k t h e w e a r o f t h e d r i v e p l a t e sa n d
r e p l a c e t h e m i f t h e i r t h i c k n e s si s b e l o wt h e w e a r l i m i t :
new platethickness.
wearlimit:

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

P l a c et h e d r i v e n p l a t e so n a p l a n e a n d u s i n g a c o m p a r a tor check their distortion; if this is over 0.1 mm

ln nn?"\

ronlere them

\ v , v v v

C h e c ka n d i f n e c e s s a rrye p l a c et h e t w o r e t a i n i n gr i n g s

(oR).

C h e c k t h e e f f i c i e n c yo f t h e t w o c l u t c h h o u s i n g s p r i n g s .
Re-assembly
R e v e r s et h e d i s m a n t l i n go p e r a t i o n sp a y i n g a t t e n t r o n t o
e l i m i n a t e f r o m c l u t c h p l a t e s t h e p r e s e n c eo f o i l o r o t h e r
l u b r i c a nt .
To lock the bolts follorv the torque wrench settings
i n di c a t e d .
A s s e m b l e t h e p r e s s u r ep l a t e , w a s h e r s ,s p r i n g s a n d f i x
everything with the 4 bolts. Before locking ensure
a n d i f n e c e s s a r ya d j u s t t o o b t a i n t h e v a l u e " A " 2 1 . 5 t o
'i
28 mm (108" to .10") in the drawing.Check this
measurement after having {ixed and locked trio bolts
only.
After the pressureplate has been assembledcheck that
a c t i n g o n c l u t c h l e v e rt h e p l a t e t u r n s w i t h a m a x i m u m
c o m p l a n a t i o no f 0 . 2 t o 0 . 3 m m ( 0 . 0 7 8 " t o 0 . 0 1 1 " ) .

16

4
4
1

4
4
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I

6.9 GEARBoX

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17
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s p a c et h e
N . B . O n a s s e m b l yp a y a t t e n t i o n t o c a r e f u l l y
"
A
"
a
v
a i l a b l ea s
w
a
s
h
e
r
s
c h a i n s p r o c k e ta c t i n g o n t h r u s t
t
h
i
cknesses
m
m
0
'
5
0
.
1
5
spare parts wirh 0.10

( 0 . 0 0 30 . 0 0 5- 0 . 0 1 9 " 1

gears
C h e c k t h a t t h e g e a r s h i f ft o r k s f u l l y e n g a g et h e
w i t h n o d i ff i c u l t i e s .
e ss p a r e
T o a d j u s ta c t o n t h r u s t w a s h e r s" 8 " a v a i l a b l a
-21 -23'
p u r t .* i t h t h e f o l l o w i n tgh i c k n e s s1eIs - 2
2.4 2.5 mm (0.070 0.078 0'082 0'090 0'094
0 098").

vrs

u u Lr $ u u f [l u Nt[ [,] u [t,tt,ll u [! u [, l! tt U U U t! U t!,U t

462

Q,"
139,5

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7.1 BRAKES
Handcontrolledfront brake

G
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3{
.4-

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trs

&
4

tss'
4,,

H
--,-

.s

-1^

ttr.
1-

Its

4
5
1,

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A
ttllb
1
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s

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lntegral brake

I
3
7
7
3
3
7
3
7
7

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7
7
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7
b
E.

b,

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7
7,
3
11
L I

M A S T E RC Y L I N D E RF R O N TB R A K E

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1 1---r'ZS\

l4 13

Brake lever

M a s t e rc y l i n d e r b o d y

Pistonreturn spring

Piston

Lip seal

Piston stop washer

Wiper ring

Wiper ring srop washer

9
10

Bellow
Plug

11

Seal

12

P l u gc o m p l e t e

13

L e v e r a d l u s t i n gs c r e w

14

C r i n k l ew a s h e r

15

Leverfixing scrqru

16

Washer

17

S e l { l o c k i n gn u t

18

M a s t e rc y l i n d e r f i x i n g s c r a r u

M A S T E RC Y L I N D E RF O R L E F T F R O N TA N D R E A RB R A K E S( I N T E G R A L )

Fluid connection

M a s t e rc y l i n d e r b o d y

Piston return spring

Piston

Lip seal

Spring ring

Dust guard cap

Rubber bush

Master cylinders

Brakecalipers

W h e n r e v i s i o n i n gt h e m a s t e r c y l i n d e r s c h e c k t h e i n n e r
diameter ol the cyiinder and the outer diameterof the
f loater.

W h e n r e v i s i o n i n gt h e b r a k e c a l i p e r s e
, n s u r et h a t r h e
i n n e r d i a m e t e ro f t h e c y l i n d e ra n d t h e o u t e r d i a m e t e r
O f P i s t o na r en o t w o r n

Master cylinder for left front and rear brakes(integral)

M a x a d m i s s i b l ce y l i n d e rd i a . 1 5 . 9 . l 8m m ( . 6 2 6 ' , ,
M i n . a d m i s s i b l fel o a t e rd i a 1 5 . 8 3 2 m m ( . 6 2 2 " ) .

F r o n t b r a k e sc a l i p e r s
M a x a d m i s s i b l cey l i n d e rd i a . 3 8 . 0 7 ' l r .
{1.4989,,)
M i n . a d m i s s i b l ep i s t o n d i a . 3 7 . 9 3 6 m m ( 1. 4 9 3 5 , ' )

M a s t e rc y l i n d e r f o r r i g h t f r o n t b r a k e
M a x a d m i s s i b l ec y l i n d e r d i a . 1 2 . 8 4 3 m m ( . 5 0 " )
M i n . a d m i s s i b l {el o a t e r d i a . 1 2 . 5 6 7m m ( . 4 9 8 " ) .

R e a rb r a k ec a l i D e r
M a xa d m i s s i bcl ey l i n d edr i a .4 8 . 0 7 1m m ( 1 . 9 9 2 , , )
M i n .a d m i s s i bpl ei s t o nd i a .4 7 . 9 3 6m m ( 1 . 8 8 7 " )

22

I
t

Adjusting the pedal position of front left and rear

brake (integral)

Check that the free play on brake pedal (B) is 5 10 mm before the extremity of rod (C) operates on
t h e f l o a t e r o f t h e c a l i p e r . l f n e c e s s a r ys l a c k e n c o u n ternut (D) and adjust the length of the rod till the
desired position is obtained. Should vou wish to
change the position of pedal (B) act on screw (E)
varying at the same time the length of rod (C) rill
t h e a b o v e m e n t i o n e dp l a y i s o b t a i n e d .

v
v
v
v
v
7

v
7

v
v
7

v
>.

RECOMMENDATIONS
A l l r u b b e rp a r t so f t h e b r a k i n gc i r c u i t s( f o r m a s t e cr y l i n der: gaskets,scraperring and gaiter;for caliperhalves:
gasketand dust guard cap) are madeof a specialcompound resistingto brake fluid. These parts, however,
c n n o ts t a n dt h e e t c h i n ga c t i o no f m i n e r aol i l s ,s o l v e n t s
and/or diesel oil which are sometimesused to wash
d o w nt h e m a c h i n e .
A c c o r d i n g l y ,i t i s s t r o n g l y r e c o m m e n d e dt o a v o i d
contact of these liguids with the rubber parts in the
c i r c u i t . F o r i n s t a n c e i, t m a y o c c u r t h a t t h e m a s t e r
c y l i n d e rs c r a p e r w
, i t h c o n t a c t w i t h g a s o l i n eo r d i e s e l
o i l , w i l l m e l t a n d g l u e s t o t h e J l o a t e r ,a f f e c t i n gi t s
s l i d i n ga c t i o n .

>

>

The caliper gasketsare subject to sticking to the

piston.

I t i s s o m e t i m e sp o s s i b l et h a t C u r i n g s t o r a g eo f t h e
c a l i p e r sb e f o r e a s s e m b l yo r w h e n t h e m a c h i n ei t s e l f
i s l e f t u n u s e df o r l o n g p e r i o d so f t i m e , i n a r e l a t i v e l y
s h o r t p e r i o d ( f o r i n s t a n c e2 - 4 m o n t h s ,a c c o r d i n gt o
t h e i n f l u e n c eo f n e g a t i v ef a c t o r ss u c h a s m a c h i n i n g
t o l e r a n c e s ,t o l e r a n c e si n t h e c o m p o u n d , a m b i e n t
n a yo c c u r .
c o n d i t i o nest c . )t h i s p h e n o m e n om

a
+
a
e

Shouldthis happen,operateas follows:

a Actuate the control lever or pedal severaltimes
until the correct pad-disc clearance is restored.
b

lf this leadto no result:

- removeplasticcap from caliper;

- removea pad and actuatethe mastercylinder so as
to allow the piston to come out of its housing by
4-6 mm (.15-.23"1;
- r e t u r n t h e p i s t o n t o i t s o r i g i n a lp o s i t i o n ,a v o i d i n g
d a m a g etso i t , i t s r u b b e rp a i t sa n d t h e d i s c ;
- refit the pad;
- proceedlikewisefor the other pad;
- ooerateasat a).
N.B. - When carryingout these operations,make sure
not to changethe position of the pads.

5
+

3
3
e

.'

3
3
3
3
t

I
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7.3 WHEELS

1i\

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24

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7
3

r
n
7
7
3
7

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

Paralle.lism
03nrm (0118")>|

Parallelism
0.3mm (.0118") I

7
7
7
7

Parallelism
0.3mm (.0118")

I
I
I

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

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

Qf f5et

0.3mm t.0118")

Olfset
0.3mm (.0118")

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

j Concentricity
0 . 3 m m ( . 0 11 8 " )

ftHril

7
7

The admissible
erroris
o n t h i sa xi s

Cocentricity
0.3 mm (.0118")

The admissible
error is
on this axis

a
>.

rc

b
L.

rit
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d
P>,

Pjl

r!
P{

r!
>-'
15
qE
t-

E
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E
E
d

REMOVING
ANDRE-FITTING
T Y R E SO N R I M S
T h i s m o t o r c y c l ef i t s l i g h t a l l o y r i m s w h i c h o f f e r v e r y
high mechanicalresistancebut might suffer damage
f rom a f unctional and aestetic aspect if improper
tooling is usedfor removingand assemblyoperations.
Under these circustances.
never use tools that have
ribbings or sharp edgeson the sides contacting the
r i m s : t h e c o n t a c t i n gs u r f a c eo f s u c h t o o l i n g h a s t o
be very wide, smooth and with rounded edges;the
u s e o f a n y l u b r i c a n t sa v a i l a b l eo n t h e m a r k e t f o r
t h e s e p u r p o s e sw i l l g r e a t l yf a c i l i t a t et y r e s l i d i n ga n d
settling on the rim, preventingalso overloadson the
tools. lt is also very important for the tyre beadsto
be properly entered into the center rim groove.
Tyres that have an arrow on their side have to be
f i t t e d i n t h e f o l l o w i n gw a y :

rea(wheel,with arrowturned in the ridingdirection;

- front wheel. with arrow turned againstthe riding

direction.

.1C

7 . 7 F R O N TF O R K

^A\

-'w<x

\\='-^
q
- -/q

wffiore _<:o4
oePo

F R O N TF O R KS P R I N G S
E n s u r et h e f o r k s h o r ts p r i n gh a st h e f o l l o w i n gs i z e sa n d
l o a di n g s :
( 3 . 1 4 "+ 1 5 % )
A - f r e el e n g t h9 5 m m t 1 S o l o
B - c o m p r e s s et o
d 9 1 . 5 m m ( 3 . 6 0 " )s h o u l dg i v ea l o a d
o f 9 . 3 k g + 3 0 / o( 2 0 l b s )
C - c o m p r e s s et o
d 6 0 . 9 m m ( 2 . 3 9 " )s h o u l dg i v ea l o a d
o f 9 0 7 k Q* 3 o / o( 1 9 9l b s )
E n s u r et h e f o r k l o n gs p r i n gh a st h e f o l l o w i n gs i z e sa n d
l o a di n g s :
A - f r e el e n g t h3 3 6 m m + 1 . 5 %( 1 3 . ' 1 4+" 1 . 5 % )
B - c o m p r e s s et d
o 3 2 8 m m ( 1 2 . 1 4 " 1s h o u l dg i v ea l o a d
o f 9 . 3 k g + 3 0 ( 2 0 l b s )
i v ea lload
give
oad
o 2 5 7 m m ( 1 0 . i1 " ) s h o u l dg
C - c o m p r e s s et d
o { 9 0 . 7k g + 3 % ( 1 9 9l b s ) .

z-o

d
d
d
d
d
d
d
d
d
d
d
d
d
d
d
d
d
d

d
d

d
d
d

o
o

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

a
0
I
b
3
7
7
7
7
7
7
7
7

Position

" open320 t l

P o s i t i o n3 : 2 2 2

2 i 229.5

Closed L.C

T h e f r e e l e n g t ho f t h e s p r i n gi s 2 8 0 m m ( 1 1 . 0 2 3 " ) .
L e n g t h u n d e r a l o a d o f 5 2 k g ( 1 1 4 l b s ) s h o u l db e
2 3 1m m ( 9 . 3 3 " ) .
L e n g t hu n d e r a l o a d o f 1 0 3 k g ( 2 2 6 l b s ) s h o u l db e
1 9 7m m ( 7. 7 5 " 1 .
L e n g t h u n d e r a l o a d o f 1 4 5 k g ( 3 2 0 l b s ) s h o u l db e
'168
mm(6.61").
L e n g t h u n d e r a l o a d o f 2 3 2 k g ( 5 1 0 l b s ) s h o u l db e
1 3 5m m ( 5 . 3 1 " ) .
N.B. - lf any spring has deformed or is not within the
abovelimits, replace.

Zll

t)

Closed F.C 235

E
E

.t.
N

T
J

7,
a

7
,

27

fl

EeurPMENr
er-ecrRrcAL

IGNITION
8.1 ELECTRONIC

|r- '--\

I
le

N
(
I

$y=
'tl

ff
t

/\
rtn$

I G N I T I O ND E V I C E S
ELECTRONIC

battery

rotor

switch

H . V .c o i l

electronic
set
sparkplug

With ignition switch in closed position, the battery

current through the electronic switch (transistor)
situated inside the electronic set reaches the matn
c i r c u i to { t h e i g n i t i o nc o i l .
During the rotation of the rotor when the metal block
o n t h e r o t o r i s a p p r o a c h i n g( p o s i t i o n w e l l d e f i n e d ) t h e
metal ends of the pick-up an electric impulseis generat e d i n t h e p i c k - u p t h a t r e a c h e st h e e l e c t r o n i c s w i t c h

28

( t r a n s i s t o ri n
) s i d et h e e l e c t r o n i sc e t .
l n t h i s w a y a b r e a ko f t h e c o i l m a i n c i r c u i ti s o b t a i n e d
in the secondarycircuit of the same
as a consequence
c o i l t h e h i g hv o l t a g en e e d e df o r t h e i g n i t i o ni sg e n e r a t e d
and by meansof a high voltagecableis transmittedto
t h e s p a r kp l u g .
T h e i m p u l s eg e n e r a t e d
i n t h e p i c k u p t h a t r e a c h etsh e
e l e c t r o n i cs e t i s i n d i p e n d e n to f t h e b a t t e r yc u r r e n t .

3
3
3
-9
9
9
3
-{

Cautions
- The reversalof the polarity of the batterycandamage
the electronicset.
- Should you needto chargethe battery it is advisable
to disconnect it from the electricalsystem to avoid
to the electronicset;the samein caseof electric
damages
w e l d i n g so n t h e m o t o r c y c l e .
- H . V . c o i l sa n d e l e c t r o n isce t sh a v eb e e nl o c a t e di n a i r v
p l a c e st h u s t o a l l o w a c o r r e c tc o o l i n g .A v o i d t o m a k e
m o d i f i c a t i o n st h a t m i g h t c h a n g et h e c o o l i n g o f t h e
components.

- With engineat standstilldo not forget to disconnect

the ignition switch to avoid battery dischargeand
d a m a g et h e c o m p o n e n t o
s f t h e i g n i t i o n( p a r t i c u l a r ltyh e
H . V .c o i l ) .
Valuesfor the electricalcheckingof pick,up.
l n c a s eo f i g n i t i o ni r r e g u l a r i t i ec sh e c kt h e e f f i c i e n c vo f
pick-up.
- R e s i s t e n coef t h e c i r c u i tw i t h p i c k u p a t a t e m p e r a t u r e
o f a b o u t2 0 " C . 2 2 Oo h m + 15 .
To check usea tester(ohmmeter)connectingthe cable
e n d st o t h e t w o p i c k - u pc a b l e s .

A^

a
7
-t
-t
7
J

7
J

8 . 2 A L T E R N A T O RG E N E R A T O B
T h eg e n e r a t ohr a sa p o w e ro f 1 4 V - 1 2 A a n ds u p p l yt h e
c u r r e n t t o a l l t h e e l e c t r i c a le q u i p m e n td i r e c t l y o r
t h r o u g ht h e b a t t e r y .T h e b a t t e r yi s c h a r g e db y t h es a m e
a l t e r n a t o rt h r o u g h a c u r r e n t r e g u l a t o ra n d r e c t i f i e r .
The generatoris composedof :
- r o t a t i n gp a r t ( i n d u c t o r )f i t t e d d i r e c t l yo n c r a n k s h a f t
- f i x p a r t( i n d u c e d ) .

7
I
1
e

Removingthe alternatorenerator
1 Removethe L/H sidecover
2 | it on the outer part of the generatorthe special
tool "A"
3 Undo centralbolt "8", spacerand washer

-'t

,
,
a

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

:
I

lv