Gilera 600 - User Manual

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Index2
Safety Procedures4
Maintenance Procedures4
Model Identification4
Technical Data6
Engine Overhaul Data9
Tightening Torque10
Special Tools19
Maintenance25
Fuel Passages28
Carburetor28
Adjustments31
Fuel Level31
Air Filter31
Engine Speed at Idle31
Cylinder Compression32
Engine Oil and Filter Replacement32
Spark Plug32
Throttle Control35
Clutch35
Drive Chain35
Rear Brake Pedal Height Adjustment36
Chain Replacement36
Gearshift Lever Height Adjustment36
Troubleshooting36
Rear Mudguard38
Exhaust Pipe38
Maintenance Programme39
Engine Oil Level Check40
Carburetor Check and Removal40
Valve Clearance Adjustments43
Compression Pressure Check43
Hydraulic Clutch44
Handlebar Master Cylinder Lever44
Clutch Transmission Cylinder on the Engine47
Starter48
Clutch Control48
Adjustment of the Rear Brake Light Switch51
Steering Sleeve Bearings51
Suspensions52
Front Suspension52
Rear Suspension52
Wheels - Spokes52
Nuts - Bolts - Connection Components54
Side Covers Disassembly55
Handlebar Protection55
Side Protection55
Front and Rear Mudguard55
Saddle and Front Side Cover56
Front Mudguard and under Crankcase Protection56
Front Side Covers56
Fuel Tank56
Undercrankcase Protection57
Warning57
Fuel Pipe58
Removal and Checking of Carburettors58
RC 600 R Air Filter59
Depression System60
Timing Belt Tension60
Transmission61
Throttle Gas Cable61
Front Brake61
Rear Brake61
Transmission Chain62
Chain Tension Check62
Chain Tension Adjustment63
Lubrication63
Engine Removal - Installation67
Working Procedures68
Engine Removal/Installation69
Engine Installation70
Engine Removal73
Generator - Timing Belt - Gearbox Selector75
Inspection79
Reassembly79
Valve Timing80
Torque Wrench Settings80
Cylinder Head - Valvetrain Components83
Valves87
Springs88
Rocker Arms88
Camshaft88
Cylinder - Piston91
Cylinder92
Piston92
Piston Rings92
Gudgeon Pin95
Clutch - Primary Drive - Oil Pump97
Crankcase - Gearbox - Crankshaft - Components103
Crankshaft104
Connecting Rod104
Gearbox106
Crankcase Inner Measure Inspection106
Crankcase107
Front Wheel111
Spindle Straightness Inspection112
Rim112
Bearing Inspection112
Brake Disc Inspection112
Bearing Disassembly115
Bearing Reassembly115
Stiff Steering116
Front Wheel Oscillation116
Suspension too Soft116
Noisy Front Suspension116
Wheel Installation120
Front Suspension - Steering125
Steering Sleeve Lower Bearing Replacement126
Steering Sleeve Assembly126
Stanchion-Leg Disassembly126
Stanchion Inspection129
Fork Spring Inspection129
Oil Seal Replacement129
Fork133
Fork Reassembly134
Handlebars137
Handlebar Removal139
Handlebar Installation139
Steering Sleeve139
Paioli Fork144
Oil Seal Removal and Replacement144
Right Side Leg144
Left Side Leg144
Kayaba Fork146
Rear Suspension - Wheel149
Motorcycle Oscillations and Vibrations150
Noisy Suspension150
Wheel Removal150
Wheel Spindle Inspection150
Chain Sprocket Inspection153
Sprocket Flange Bearings Reassembly153
Wheel Reassembly154
Suspension Removal154
Suspension Reassembly154
Damper Pivot Joint and Swing Fork154
Bushings and Pivot Bolts Inspection157
Bushings Reassembly157
Pivot Bolts Inspection157
Swing Form Reassembly157
Final Drive158
Chain, Drive and Driven Sprockets Inspection158
Chain Check158
Chain Status Inspection158
Wheel Spindle Straightness Check160
Wheel Bearings Check160
Final Driven Gear Check160
Driven Flange Bearings Disassembly160
Rear Damper163
Driven Flange Bearings Reassembly163
Wheel Bearings Disassembly163
Wheel Bearings Reassembly163
Swing Fork Bearings Replacement164
Rear Wheel Removal167
Rear Wheel Reassembly167
Wheel Removal and Checks169
Rear Absorber Shock170
Brake171
Fluid Drainage172
Brake Fluid Filling172
Brake Pads Replacement172
Front Master Cylinder Inspection172
Front Brake Caliper Inspection175
Rear Master Cylinder Inspection175
Rear Brake Caliper Inspection175
Servicing Information176
Brake Pedal Is Soft or Spongy176
Brake Pedal Is too Hard176
Brakes Drag176
Master Cylinder178
Brake Caliper178
Piston Inspection181
Rear Disc Brake185
Disc Brake System186
Pistons Check188
Disc188
Pads Replacement190
Battery - Charging Circuit193
Battery Voltage194
Battery Charging194
Charging System194
Leakages Checks194
Rectifier Check197
Alternator Stator Coil Check197
No Voltage with the Key in the on Position198
Low Voltage with the Key in the on Position198
Battery Removal198
Battery Inspection198
Battery Reinstallation199
Capacity Discharge Ignition System201
Flywheel Magneto202
C.D.I. Control Unit202
Revolution Reductor202
The Engine Start to Run but Not Regularly206
Spark Lack to the Spark Plug206
H.T. Coil207
Pick-Up Coil Test208
H.T. Coil Test208
CDI Control Unit Test208
Revolution Reduction Test208
Inductive Discharge Ignition System210
Checks210
Ignition Coil Test210
Control Unit Test211
Spark Plug Cap Resistance211
Starter Motor214
Casing Insulation Check214
Starter Motor Doesn't Turn214
Starter Motor Turns Engine Slowly214
Switches - Horn - Lights217
Instruments218
Headlamp218
Tail Lamp218
Turn Signal Indicators218
Temperature Indicator221
Oil Pressure Sensor221
Reserve Fuel Indicator221
Thermoswitch221
Brake Light Switches222
Horn222
Bulb Replacement222
Instrument Panel Bulb Replacement222
The Engine Doesn't Start or Starts with Difficulty229
Poor Performance230
Poor Road Handling232

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Gilera 600 Specifications

General

Brand	Gilera
Model	600
Category	Engine
Language	English

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