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PIAGGIO Beverly Tourer 250 i.e. User Manual

PIAGGIO Beverly Tourer 250 i.e.
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SERVICE STATION MANUAL
664962
Beverly Tourer 250 i.e.
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PIAGGIO Beverly Tourer 250 i.e. Specifications

General IconGeneral
Engine TypeSingle cylinder, 4-stroke
Displacement244 cc
Fuel SystemElectronic fuel injection
Front SuspensionHydraulic telescopic fork
Front Brake260 mm disc
Rear Brake240 mm disc
ABSNot available
Fuel Tank Capacity12 liters
Seat Height790 mm
Width780 mm
Power16.2 kW (22 hp) at 8, 250 rpm
TransmissionCVT automatic
Rear SuspensionDual hydraulic shocks with adjustable preload
Rear Tire140/70-14
Front Tire110/70-16

Summary

Rules

Safety rules

General safety guidelines for vehicle maintenance operations, covering ventilation, battery handling, and fuel safety.

Maintenance rules

Guidelines for using genuine parts, appropriate tools, and proper procedures for maintenance and repair.

Characteristics

Vehicle identification

Details on how to identify the vehicle's chassis and engine prefixes using specific markings.

Dimensions and mass

Specifications for the vehicle's overall dimensions, kerb weight, and maximum allowed weight.

Engine

Technical specifications for the engine, including type, capacity, bore, stroke, and power output.

Transmission

Details on the transmission system, including variator type, clutch, and final reduction unit.

Capacities

Fluid capacities for engine oil, transmission oil, cooling system, fuel tank, and fork oil.

Electrical system

Specifications for the vehicle's electrical components and systems, including ignition and battery.

Frame and suspensions

Information on the chassis type, front and rear suspension systems, and their specifications.

Brakes

Details on the braking system, including front and rear disc specifications and hydraulic controls.

Wheels and tyres

Specifications for wheels, tyres, and recommended tyre pressures for the vehicle.

Tightening Torques

Specific torque values for various fasteners in steering, chassis, and suspension systems.

STEERING

Torque specifications for steering components like ring nuts and handlebar screws.

CHASSIS

Torque specifications for chassis components such as center stand and side stand bolts.

FRONT SUSPENSION

Torque specifications for front suspension elements including fork plates and wheel axles.

REAR SUSPENSION

Torque specifications for rear suspension components like shock absorber clamps and wheel axles.

FLYWHEEL

Torque specifications for flywheel-related components like cover screws and nut.

CRANKCASE AND CRANKSHAFT

Torque specifications for crankcase and crankshaft assembly components.

COOLING

Torque specifications for cooling system components like water pump and thermostat covers.

Overhaul data

Technical data and specifications for engine overhaul procedures and component clearances.

Assembly clearances

Specifications for assembly clearances of engine components like the cylinder-piston assembly.

Cylinder - piston assy.

Details on the cylinder and piston assembly, including dimensions and clearances.

ENGINE COUPLING CATEGORY

Categorization of engine coupling based on cylinder and piston specifications.

Crankcase - crankshaft - connecting rod

Procedures for measuring and checking clearances in the crankcase, crankshaft, and connecting rod assembly.

CRANKSHAFT

Specifications for crankshaft categories and their corresponding quantities.

CRANKCASE

Specifications for crankcase categories and their corresponding quantities.

CRANKCASE - CRANKSHAFT COUPLING / CRANKSHAFT HALF-BEARINGS

Details on coupling categories between crankshaft and crankcase halves using specific bearings.

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Specifications and measurement procedures for axial clearance in the crankshaft/crankcase assembly.

Slot packing system

Explanation of the shimming system used to adjust compression ratio correctly.

ENGINE 250 SHIMMING

Table detailing shimming measurements and corresponding thicknesses for engine adjustments.

Products

Table of recommended products for vehicle maintenance and their specifications.

UNIT OF MEASUREMENT - CONVERSION - ENGLISH SYSTEM AND INTERNATIONAL SYSTEM (IS).

Conversions between English and International System units for various measurements.

TOOLING

APPROPRIATE TOOLS

List of specialized tools required for vehicle maintenance and repair, with codes and descriptions.

MAINTENANCE

Maintenance chart

Scheduled maintenance table outlining checks and replacements at specified mileage intervals.

Checking the spark advance

Procedure for checking ignition timing using a diagnostic tester and stroboscopic light.

Spark plug

Instructions for servicing the spark plug, including removal, inspection, and torque specifications.

Hub oil

Procedures for checking and replacing hub oil, including capacity and torque specifications.

Recommended products

Recommended oil products for rear hub lubrication and their specifications.

Characteristic

Characteristic specifications for rear hub oil, including capacity.

Air filter

Procedure for accessing, cleaning, and replacing the air filter element.

Engine oil

Instructions for checking and topping up engine oil, including capacity and filter replacement.

Recommended products

Recommended engine oil products and their specifications for the vehicle.

Characteristic

Characteristic specifications for engine oil, detailing capacity and filter replacement frequency.

Oil pressure warning light

Explanation of the oil pressure warning light function and when to check the lubrication system.

Checking the ignition timing

Procedure for checking and verifying the ignition timing using diagnostic tools.

Cooling system

Procedures for checking and maintaining the vehicle's cooling system.

Level check

Procedure for checking the coolant level in the expansion tank and safety warnings.

Recommended products

Recommended coolant product and its specifications for the vehicle.

Braking system

Information and procedures related to the vehicle's braking system components.

Level check

Procedure for checking the brake fluid level in the reservoirs through the sight glass.

Recommended products

Recommended brake fluid products and their specifications for topping up and system changes.

Headlight adjustment

Procedure for adjusting the vehicle's headlights to comply with road regulations.

TROUBLESHOOTING

Engine

Troubleshooting guide for engine performance issues, including starting difficulties and poor operation.

Poor performance

Identifies possible causes for poor engine performance and outlines corrective operations.

Starting difficulties

Lists common causes for difficult engine starting and the corresponding troubleshooting steps.

Excessive oil consumption/Exhaust smoke

Troubleshooting guide for excessive oil consumption or exhaust smoke issues.

Insufficient lubrication pressure

Diagnoses and resolves issues related to insufficient oil pressure in the engine lubrication system.

Transmission and brakes

Troubleshooting for issues related to the transmission and braking systems.

Clutch grabbing or performing inadequately

Addresses problems with clutch engagement or slippage, and their potential causes.

Insufficient braking

Troubleshooting steps for inefficient braking system performance, including pad and disc checks.

Brakes overheating

Diagnoses and resolves causes of brake overheating, such as caliper issues or disc distortion.

Steering and suspensions

Troubleshooting guide for steering and suspension system problems.

Heavy steering

Diagnoses and resolves issues causing heavy or stiff steering.

Excessive steering play

Troubleshooting for excessive play or looseness in the steering system.

Noisy suspension

Identifies potential causes for noise originating from the suspension system.

Suspension oil leakage

Troubleshooting steps for oil leaks from suspension components, focusing on seal faults.

ELECTRICAL SYSTEM

Components arrangement

Diagrams and descriptions of the location of key electrical components on the vehicle.

Front side

Layout and identification of electrical components located on the front side of the vehicle.

Back side

Layout and identification of electrical components located on the back side of the vehicle.

Checks and inspections

Procedures for checking and inspecting various electrical system components.

Immobiliser

Description of the immobilizer system, its components, and function.

Specific tooling

List of specific tools required for immobilizer system diagnostics and programming.

Virgin circuit

Procedure for programming keys and establishing the immobilizer system in a virgin state.

Diagnostic codes

Explanation of diagnostic codes displayed by the immobilizer system via an LED indicator.

Ignition circuit

Details on the ignition system, including HV coil resistance and battery recharge circuit.

No spark plug

Troubleshooting steps for ignition system issues when there is no spark at the spark plug.

Battery recharge circuit

Information on the battery recharge system, including alternator and voltage regulator.

Stator check

Procedure for checking the stator winding resistance and continuity.

Voltage regulator check

Procedure for checking the voltage regulator output and control voltage.

Recharge system voltage check

Steps for checking the overall recharge system voltage and battery condition.

Charging current

Procedure for checking the charging current output of the electrical system.

Starter motor

Details and checks related to the starter motor and its electrical connections.

Horn control

Wiring diagram and checks for the horn control system.

Turn signals system check

Procedure for checking the operation and continuity of the turn signal system.

level indicators

Checks and troubleshooting for various level indicators on the vehicle's electrical system.

Lights list

List of all bulbs used in the vehicle's lighting system with their specifications.

Fuses

Information on the location and specifications of all fuses in the electrical system.

Dashboard

Identification and function of indicators and controls on the vehicle's instrument panel.

Sealed battery

Maintenance and recharging instructions for sealed batteries after open-circuit storage.

INSTRUCTIONS FOR THE RENEWAL RECHARGE AFTER OPEN-CIRCUIT STORAGE

Detailed steps for recharging batteries that have been stored for an extended period.

Dry-charge battery

Instructions for commissioning and charging a new dry-charged battery.

COMMISSIONING A NEW DRY-CHARGED BATTERY

Step-by-step guide for preparing and charging a new dry-charged battery.

Remote controls check

Procedure for checking the operation and continuity of remote control components.

Switches check

Procedure for checking the continuity of various switches based on their position.

Connectors

Identification and diagrams of various electrical connectors used in the system.

CONNETTORE GRUPPO STRUMENTI «A»

Details of the instrument cluster connector 'A' and its terminal assignments.

IMMOBILIZER AERIAL CONNECTOR

Details of the immobilizer aerial connector and its wiring.

FUEL PUMP CONNECTOR

Details of the fuel pump connector and its terminal assignments.

ELECTRIC FAN CONNECTOR

Details of the electric fan connector and its wiring.

CONNETTORE CENTRALINA ELETTRONICA PER INIEZIONE

Details of the electronic control unit connector for injection system.

INJECTOR CONNECTOR

Details of the injector connector and its terminal assignments.

Electrical system installation

Procedures and considerations for the installation of the vehicle's electrical system.

ENGINE FROM VEHICLE

Exhaust assy. Removal

Step-by-step instructions for removing the exhaust assembly, including the lambda probe.

Removal of the engine from the vehicle

Detailed procedure for safely removing the engine from the vehicle.

ENGINE

Automatic transmission

Information on the automatic transmission system, including its components and operation.

Transmission cover

Procedure for removing and refitting the transmission cover, including specific tooling.

Air duct

Instructions for removing and refitting the air intake cover for the transmission compartment.

Removing the driven pulley shaft bearing

Procedure for removing the bearing from the driven pulley shaft.

Refitting the driven pulley shaft bearing

Instructions for refitting the driven pulley shaft bearing, with cautions for paint protection.

Baffle roller

Inspection and service for the baffle roller component.

Plastic roller

Inspection and service for the plastic roller, including diameter checks and torque settings.

Removing the driven pulley

Procedure for removing the driven pulley assembly from the engine.

Inspecting the clutch drum

Procedure for inspecting the clutch drum, including diameter and eccentricity checks.

Checking the bell working surface eccentricity

Method for checking the working surface eccentricity of the clutch bell using specialized tools.

Removing the clutch

Procedure for removing the clutch assembly using specific tools and precautions.

Inspecting the clutch

Procedure for inspecting the clutch, including friction material thickness and mass condition.

Pin retaining collar

Procedure for removing the pin retaining collar from the pulley assembly.

Removing the driven half-pulley bearing

Procedure for removing the bearing from the driven half-pulley.

Inspecting the driven fixed half-pulley

Inspection of the driven fixed half-pulley, checking diameter, contact surface, and joints.

Inspecting the driven sliding half-pulley

Inspection of the driven sliding half-pulley, checking diameter, contact surface, and joints.

Refitting the driven half-pulley bearing

Procedure for refitting the bearing into the driven half-pulley.

Refitting the driven pulley

Procedure for refitting the driven pulley assembly, including oil guards and O-rings.

Inspecting the clutch spring

Procedure for inspecting the clutch spring, checking its standard and minimum length.

Refitting the clutch

Procedure for refitting the clutch assembly using specific tools and precautions.

Drive-belt

Inspection of the drive belt for damage and width, and checking for wear signs.

Removing the driving pulley

Procedure for removing the driving pulley from the crankshaft.

Inspecting the rollers case

Inspection of the rollers case, checking bushings, rollers, and housings for wear.

Refitting the driving pulley

Procedure for refitting the driving pulley assembly, including pre-assembly and shaft fitting.

Refitting the transmission cover

Procedure for refitting the transmission cover, ensuring gasket and dowel alignment.

End gear

Procedures for removing and servicing the end gear assembly.

Removing the hub cover

Procedure for removing the hub cover and its gasket.

Removing the wheel axle

Procedure for removing the wheel axle and its associated gears.

Removing the hub bearings

Procedure for removing hub bearings, checking their condition, and using specific tools.

Removing the wheel axle bearings

Procedure for removing wheel axle bearings using appropriate tools.

Removing the driven pulley shaft bearing

Procedure for removing the driven pulley shaft bearing and associated oil guard.

Inspecting the hub shaft

Inspection of the hub shaft for wear or distortion of surfaces and housings.

Inspecting the hub cover

Inspection of the hub cover for surface integrity and bearing condition.

Refitting the wheel axle bearing

Procedure for refitting the wheel axle bearing using specific tools and heat.

Refitting the hub cover bearings

Procedure for refitting hub cover bearings, requiring heating and specific tools.

Refitting the hub cover

Procedure for refitting the hub cover, including gasket and breather pipe alignment.

Flywheel cover

Procedures for removing and refitting the flywheel cover and associated components.

Removing the hub cover

Procedure for removing the hub cover, including hose clips and fixings.

Removing the stator

Procedure for removing the stator and its associated wiring.

Refitting the stator

Procedure for refitting the stator and flywheel, ensuring correct torque and alignment.

Refitting the flywheel cover

Procedure for refitting the flywheel cover, ensuring correct spline and shaft alignment.

Flywheel and starting

Procedures related to the flywheel assembly and engine starting.

Removing the starter motor

Procedure for removing the starter motor from its seat.

Removing the flywheel magneto

Procedure for removing the flywheel magneto, including shaft clip and alignment.

Inspecting the flywheel components

Inspection of internal flywheel components and the Pick-Up control plate.

Refitting the free wheel

Procedure for refitting the free wheel, ensuring clean surfaces and correct screw application.

Refitting the flywheel magneto

Procedure for refitting the flywheel magneto, including free wheel and transmission gear.

Refitting the starter motor

Procedure for refitting the starter motor, including O-ring lubrication and screw torque.

Cylinder assy. and timing system

Procedures related to the cylinder assembly and the engine timing system.

Removing the intake manifold

Procedure for removing the intake manifold and securing it properly upon refitting.

Removing the rocker-arms cover

Procedure for removing the rocker-arms cover.

Removing the timing system drive

Procedure for removing timing system components like the chain, sprockets, and tensioner.

Removing the cam shaft

Procedure for removing the cam shaft and its associated components.

Removing the cylinder head

Procedure for removing the cylinder head, including spark plug and fastening nuts.

Removing the valves

Procedure for removing valves, cotters, springs, and oil guards using specialized tools.

Removing the cylinder - piston assy.

Procedure for removing the cylinder and piston assembly, with cautions for piston support.

Inspecting the small end

Inspection of the small end of the connecting rod, checking diameter and wear.

Inspecting the wrist pin

Inspection of the wrist pin, measuring its diameter and calculating coupling clearance.

Inspecting the piston

Inspection of the piston, checking wrist pin seat, diameter, and ring groove clearances.

Fitting clearance

Specifications for fitting clearances of piston rings and checking cylinder head surface.

Inspecting the cylinder

Procedure for inspecting the cylinder, measuring inner diameter and checking head coupling surface.

Inspecting the piston rings

Procedure for inspecting piston rings, measuring opening and checking clearances.

Removing the piston

Procedure for removing the piston, aligning it with the connecting rod and installing stop rings.

Choosing the gasket

Information on the shimming system for adjusting compression ratio and selecting the correct gasket.

Refitting the piston rings

Procedure for refitting piston rings, ensuring correct orientation and gap offset.

Refitting the cylinder

Procedure for refitting the cylinder, including base gasket and lubrication.

Inspecting the cylinder head

Inspection of the cylinder head surface, camshaft, and rocker components for wear.

Inspecting the timing system components

Inspection of timing system components like guide shoes, chain, and tensioner.

Inspecting the valve sealings

Procedure for inspecting valve sealings by filling the manifold with petrol.

Inspecting the valve housings

Inspection of valve housings, measuring seat width and valve guide diameter.

Inspecting the valves

Inspection of valves, measuring sealing surface width and valve stem diameter.

Inspecting the springs and half-cones

Inspection of valve springs and half-cones for signs of wear or yielding.

Refitting the valves

Procedure for refitting valves, springs, and caps, including lubrication and sealing.

Inspecting the cam shaft

Inspection of the cam shaft for wear on cams, height, and retaining plate.

Refitting the head and timing system components

Procedure for refitting the cylinder head and timing system components, including torque sequences.

Refitting the rocker-arms cover

Procedure for refitting the rocker-arms cover, ensuring proper gasket seating and torque.

Refitting the intake manifold

Procedure for refitting the intake manifold, ensuring correct torque and alignment.

Crankcase - crankshaft

Procedures for splitting and inspecting the crankcase and crankshaft assembly.

Splitting the crankcase halves

Procedure for splitting the crankcase halves, including crankshaft axial clearance check.

Inspecting the crankshaft alignment

Procedure for inspecting the crankshaft alignment on its support.

Inspecting the crankcase halves

Inspection of crankcase halves for cleanliness, surface integrity, and alignment.

Inspecting the crankshaft plain bearings

Inspection of crankshaft plain bearings for lubrication and positioning.

Refitting the crankcase halves

Procedure for refitting the crankcase halves, including gasket, bushings, and screws.

Studs

Checks and replacement procedures for stud bolts in the crankcase.

Lubrication

Information and diagrams related to the engine lubrication system.

Conceptual diagrams

Conceptual diagrams illustrating the engine's lubrication circuit.

LUBRICATION CIRCUIT

Diagram of the engine's lubrication circuit, showing key components and flow.

Oil pressure check

Procedure for checking engine oil pressure at different RPMs and identifying potential issues.

Crankshaft oil seals

Procedures for removing and refitting crankshaft oil seals.

Removal

Steps for removing the oil seal from the crankshaft.

Refitting

Procedure for refitting the oil seal using appropriate tools and lubrication.

Oil pump

Procedures for removing, inspecting, and refitting the engine oil pump.

Removal

Steps for removing the oil pump cover, chain, and pump body.

Inspection

Procedure for inspecting the oil pump rotors and reassembling the unit.

Refitting

Procedure for refitting the oil pump cover, ensuring proper gasket alignment and screw torque.

Removing the oil sump

Procedure for removing the oil sump, including draining oil and removing associated parts.

Inspecting the by-pass valve

Inspection of the by-pass valve, checking spring length, piston condition, and seal.

Refitting the oil sump

Procedure for refitting the oil sump, including by-pass valve, spring, and gasket.

INJECTION

DISPOSIZIONE COMPONENTI

Layout and identification of injection system components on the vehicle.

MIU injection system

Overview of the integrated injection and ignition system and its management parameters.

Precautions

Important precautions and troubleshooting hints related to the MIU injection system.

Troubleshooting hints

Guidance on troubleshooting common MIU system faults, focusing on connections and power supply.

Terminals setup

Diagrams illustrating the terminal setup for the MIU control unit connectors.

DISPOSIZIONE TERMINALI

Table detailing terminal assignments for various connectors in the injection system.

EMS circuit diagram

Electrical schematic diagram for the Engine Management System (EMS).

SCHEMA IMPIANTO

Wiring diagram for the injection system, showing component connections.

Troubleshooting procedure

General troubleshooting steps for engine starting and running issues.

Engine does not start

Troubleshooting for engine starting failures, covering immobilizer, fuel supply, and ignition.

Engine stops at idle

Troubleshooting for engine stalling or unstable idling, related to faults and parameter correctness.

Engine does not rev down

Troubleshooting for engine not returning to idle speed or having excessively high idle speed.

Exhaust backfires in deceleration

Troubleshooting for exhaust backfires occurring during deceleration.

Engine revs irregularly

Troubleshooting for irregular engine performance, especially at slight throttle openings.

Poor performance at full throttle

Troubleshooting for poor engine performance at full throttle or irregular pickup.

Engine knocking

Troubleshooting guide for engine knocking or combustion shock issues.

Fuel supply system

Description of the fuel supply circuit, including pump, filter, regulator, and injector.

Removing the butterfly valve

Procedure for removing the butterfly valve assembly.

Refitting the butterfly valve

Procedure for refitting the butterfly valve, ensuring correct clip and angle alignment.

Pump supply circuit

Diagram of the pump supply circuit, showing connections and injection loads.

INJECTION LOADS

List of electrical loads within the injection system and their specifications.

Circuit leak test

Procedure for performing a circuit leak test on the fuel system using specialized tools.

Fuel filter check

Procedure for checking and replacing the fuel filter.

Inspecting the injector circuit

Checks and procedures for inspecting the injector circuit and its components.

INJECTION LOADS

List of electrical loads within the injection system and their specifications.

Inspecting the injector hydraulics

Procedure for inspecting the injector hydraulics, including manifold removal and seal tests.

Components location

Diagrams showing the physical location of injection system components on the vehicle.

DISPOSIZIONE COMPONENTI

Table identifying and locating injection system components.

Tachometer

Checks and procedures for the tachometer sensor and its connection to the control unit.

HT coil

Information on the High Voltage (HT) coil and its role in the ignition system.

INJECTION LOADS

List of electrical loads within the injection system and their specifications.

Coolant temperature sensor

Checks and resistance values for the coolant temperature sensor.

TEMPERATURE SENSOR

Details on the temperature sensor, its connections, and resistance values.

Zeroing the throttle

Procedure for resetting the throttle valve position sensor (TPS reset).

Resetting the throttle valve position signal (TPS reset)

Step-by-step guide for performing the TPS reset procedure using a diagnostic tester.

Lambda probe

Description and checks for the Lambda sensor, including its function and electrical data.

INJECTION LOADS

List of electrical loads within the injection system and their specifications.

SUSPENSIONS

Front

Procedures related to the front suspension system, including wheel and hub overhaul.

Removing the front wheel

Step-by-step instructions for removing the front wheel.

Front wheel hub overhaul

Procedure for overhauling the front wheel hub, including bearing replacement.

Refitting the front wheel

Procedure for refitting the front wheel, including greasing and torque specifications.

Handlebar

Procedures for removing and refitting the handlebar assembly.

Removal

Steps for removing the handlebar, including covers, mirrors, and steering tube connection.

Refitting

Procedure for refitting the handlebar, ensuring alignment and proper torque.

Front fork

Procedures for removing, overhauling, and refitting the front fork.

Removal

Steps for removing the front fork components, including stem and springs.

Overhaul

Procedure for overhauling the front fork, including disassembly and component checks.

COMPONENT CHECK

Instructions for cleaning and checking all components of the front fork assembly.

Refitting

Procedure for refitting the front fork components, including oil seals and hydraulic rod.

Recommended products

Recommended oil and grease products for front fork lubrication and assembly.

Characteristic

Specifications for oil quantity per fork stem.

Steering column

Procedures for bleeding the hydraulic rod and refitting the steering column components.

Removal

Steps for removing the handlebar components, including covers, cables, and steering tube nuts.

Refitting

Procedure for refitting the steering column, including fifth wheel tracks and lubrication.

Recommended products

Recommended grease products for steering bearings and related components.

Removal

Procedure for removing steering bearing components, including cleaning and inspection.

STEERING FIFTH WHEEL TRACK REMOVAL

Procedure for removing steering fifth wheel tracks from the chassis and headstock.

Specific tooling

List of specific tools required for removing steering fifth wheel tracks.

Refitting

Procedure for refitting steering fifth wheel tracks and seats, including lubrication.

STEERING FIFTH WHEEL TRACK FITTING

Procedure for fitting new steering fifth wheel tracks onto the headstock and steering tube.

Recommended products

Recommended grease products for steering fifth wheel tracks and bearings.

Rear

Procedures related to the rear suspension system, including wheel and swing-arm.

Removing the rear wheel

Step-by-step instructions for removing the rear wheel.

Refitting the rear wheel

Procedure for refitting the rear wheel, observing tightening torques.

Swing-arm

Procedures for removing, overhauling, and refitting the swing-arm assembly.

Removal

Steps for removing the swing-arm, including loosening nuts and spindles.

Overhaul

Procedure for overhauling the swing-arm, including silent bloc inspection and removal.

Specific tooling

Specific tool required for silent bloc removal and fitting.

Characteristic

Specifications for swing-arm axial clearance and allowable limits.

Refitting

Procedure for refitting the swinging arm assembly, including clamp positioning and bolt tightening.

Shock absorbers

Procedures for removing and refitting the shock absorbers.

Removal

Steps for removing the shock absorbers, including engine lifting and muffler removal.

Refitting

Procedure for refitting the shock absorbers, in reverse order of removal.

Exhaust bracket

Procedures for removing and overhauling the exhaust bracket.

Removal

Steps for removing the exhaust bracket components, including bearings.

Overhaul

Procedure for overhauling the exhaust bracket, including bearing removal.

Specific tooling

Specific tools required for exhaust bracket overhaul.

Refitting

Procedure for refitting the exhaust bracket components, including bearing installation.

Centre-stand

Procedures for removing and refitting the centre stand.

Side stand

Procedures for removing and refitting the side stand.

Removal of the side stand

Steps for removing the side stand, including springs and nuts.

Fitting

Procedure for fitting the side stand, in reverse order of removal.

BRAKING SYSTEM

Interventions rules

Rules and warnings for working on the braking system, emphasizing fluid safety and handling.

Rear brake calliper

Procedures for removing and refitting the rear brake caliper.

Removal

Steps for removing the rear brake caliper, including fluid hose fittings.

Refitting

Procedure for refitting the rear brake caliper, including system bleeding and copper washers.

Front brake calliper

Procedures for removing and refitting the front brake caliper.

Removal

Steps for removing the front brake caliper, including retainer and pipe fittings.

Refitting

Procedure for refitting the front brake caliper, including system bleeding.

Rear brake disc

Procedures for removing and refitting the rear brake disc.

Removal

Steps for removing the rear brake disc, involving wheel removal and screw loosening.

Refitting

Procedure for refitting the rear brake disc, ensuring correct orientation and torque.

Disc Inspection

Procedure for inspecting the brake disc, checking for cleanliness, scoring, and axial run-out.

Front brake disc

Procedures for removing, refitting, and inspecting the front brake disc.

Disc Inspection

Procedure for inspecting the front brake disc, checking thickness, scoring, and axial run-out.

Front brake pads

Procedures for removing, checking, and replacing the front brake pads.

Removal

Steps for removing the front brake pads, including caliper and pin loosening.

Characteristic

Minimum thickness specification for front brake pads.

Refitting

Procedure for refitting the front brake pads, ensuring correct caliper positioning and torque.

Rear brake pads

Procedures for removing, checking, and replacing the rear brake pads.

Removal

Steps for removing the rear brake pads, including caliper and pin loosening.

Refitting

Procedure for refitting the rear brake pads, ensuring correct caliper positioning and torque.

Fill

Instructions for filling the braking system after pad replacement.

Rear - combined

Procedure for bleeding the combined rear braking system.

Front

Procedure for bleeding the front braking system.

Brake fluid level check

Procedure for checking the brake fluid level in the reservoirs.

Front brake pump

Procedures for removing and refitting the front brake pump.

Removal

Steps for removing the front brake pump, including handlebar cover and brake line disconnection.

Refitting

Procedure for refitting the front brake pump, including hydraulic line tightening and system purging.

Rear brake pump - combined

Procedures for removing and refitting the combined rear brake pump.

Removal

Steps for removing the rear brake pump, including handlebar cover and brake line disconnection.

Refitting

Procedure for refitting the rear brake pump, including hydraulic line tightening and system purging.

COOLING SYSTEM

Circuit diagram

Diagram illustrating the coolant flow circuit, identifying key components.

Electric fan check

Procedure for checking the electric fan operation and battery voltage.

System bleed

Procedure for bleeding the cooling system to remove air bubbles.

Removal

Steps for removing the thermostat cover and thermostat.

Check

Procedure for checking the thermostat's operation by testing its opening temperature.

Refitting

Procedure for refitting the thermostat and cover, ensuring correct alignment and torque.

RADIATOR

Procedures for replacement of radiator components like expansion tank and fan.

CHASSIS

Seat

Procedure for removing the vehicle's saddle.

Side fairings

Procedure for removing the side fairings and bumper components.

Rear rack

Procedure for removing the rear luggage rack.

Rear handlebar cover

Procedure for removing the rear handlebar cover, including windshield and mirrors.

Instrument panel

Procedure for removing the instrument panel from the handlebar cover.

Front handlebar cover

Procedure for removing the front handlebar cover and headlight assembly.

Headlight assy.

Procedure for removing the headlight assembly.

Frame central cover

Procedure for removing the central frame cover, including fuel tank access.

Legshield

Procedure for removing the legshield components.

Knee-guard

Procedure for removing the knee-guard components.

Removing the ignition key-switch when on *off*

Procedure for removing the ignition key-switch when in the 'off' position.

Removing the ignition key-switch when on *lock*

Procedure for removing the ignition key-switch when in the 'lock' position.

Front wheel housing

Procedures for removing the front wheel housing components.

Taillight assy.

Procedure for removing the taillight assembly.

Footrest

Procedure for removing the vehicle's footrests.

Frame central cover

Procedure for removing the central frame cover components.

Side fairings

Procedure for removing the side fairings, including saddle and luggage rack.

Air filter

Procedure for removing and accessing the air filter.

Rear mudguard

Procedure for removing the rear mudguard.

Helmet bay

Procedure for removing the helmet bay components, including fairings and battery.

Fuel tank

Procedures for removing the fuel tank, including electrical connections and fuel lines.

Front mudguard

Procedure for removing the front mudguard.

Radiator fan

Procedure for removing the radiator fan assembly.

Flyscreen

Procedure for removing the flyscreen and windshield.

PRE-DELIVERY

Aesthetic inspection

Check of the vehicle's appearance, including paintwork, plastics, and cleanliness.

Tightening torques inspection

Inspection of critical tightening torques on suspension, brake, and electrical components.

Electrical system

Pre-delivery check of the main electrical system functions, including lights and switches.

Levels check

Check of essential fluid levels: brake, hub oil, coolant, and engine oil.

Road test

Procedure for conducting a road test to evaluate vehicle performance and handling.

Test ride

Specific checks to perform during the road test, including cold start and throttle response.

Static test

Static checks performed after the road test, including engine restart and tyre pressure.

Functional inspection

Final functional checks of braking, clutch, engine, and other vehicle systems.

TIME

Engine

Repair time estimates for engine-related operations like removal, oil change, and complete service.

Crankcase

Repair time estimates for crankcase operations, including gasket and crankcase replacement.

Crankshaft

Repair time estimates for crankshaft replacement.

Cylinder assy.

Repair time estimates for cylinder-piston assembly, pin, rings, and service.

Cylinder head assy.

Repair time estimates for cylinder head, valves, gasket, and sensor replacement.

Rocker arms support assy.

Repair time estimates for rocker arm valve, camshaft, and decompressor replacement.

Cylinder head cover

Repair time estimates for spark plug, head cover, gasket, and vapour recovery pipe replacement.

Oil filter

Repair time estimates for oil filter, oil pressure sensor, and net oil filter replacement.

Flywheel cover

Repair time estimates for flywheel cover, gasket, water pump, and oil seal replacement.

Driven pulley

Repair time estimates for clutch, driven pulley, and clutch bell replacement.

Oil pump

Repair time estimates for oil pump components like chain guides, chain, and cover flap.

Final gear assy.

Repair time estimates for final reduction gear, wheel axle, and breather pipe replacement.

Driving pulley

Repair time estimates for driving pulley components, belt, and variator rollers.

Transmission cover

Repair time estimates for transmission cover, crankcase cover, and bearing replacement.

Water pump

Repair time estimates for water pump cover and head-pump coupling replacement.

Starter motor

Repair time estimates for starter motor, driven gearing, and pinion replacement.

Flywheel magneto

Repair time estimates for stator, rotor, flywheel, and freewheel replacement.

Butterfly valve

Repair time estimates for throttle body, injector, and intake manifold replacement.

Exhaust pipe

Repair time estimates for muffler, lambda probe, and exhaust manifold replacement.

Air cleaner

Repair time estimates for air filter box, filter element, and cleaner/carburettor union replacement.

Frame

Repair time estimates for chassis replacement and footrest bracket replacement.

Centre-stand

Repair time estimates for centre stand bolt and stand replacement.

Legshield spoiler

Repair time estimates for legshield, shield rim, and central cover replacement.

Side fairings

Repair time estimates for rear side panels and rear fairing replacement.

Rear cover

Repair time estimates for shield back plate and glove box door replacement.

Central cover

Repair time estimates for fuel tank lid, central chassis cover, and spark plug flap replacement.

Underseat compartment

Repair time estimates for underseat band, glove-box switch, and helmet compartment components.

Plate holder

Repair time estimates for license plate holder support and holder replacement.

Mudguard

Repair time estimates for front mudguard, spoiler, and rear mudguard replacement.

Fuel tank

Repair time estimates for fuel tank breather, fuel tank, and tank float replacement.

Rear shock-absorber

Repair time estimates for muffler support arm and rear shock absorber replacement.

Handlebar covers

Repair time estimates for front and rear handlebar cover replacement.

Handlebar components

Repair time estimates for throttle control, knobs, and mirrors replacement.

Swing-arm

Repair time estimates for swing-arm, engine attachment, silent-block, and flange replacement.

Brake hoses

Repair time estimates for brake piping, pads, caliper, and fluid system replacement.

Seat

Repair time estimates for saddle and saddle cover replacement.

Instrument panel

Repair time estimates for odometer, glass, warning lights, and clock replacement.

Rear rack

Repair time estimates for luggage rack and luggage rack cover replacement.

Locks

Repair time estimates for anti-theft lock, saddle lock, and immobilizer aerial replacement.

Turn signal lights

Repair time estimates for front and rear lights, bulbs, and indicators replacement.

Front wheel

Repair time estimates for front wheel axle, bearings, tyre, rim, and brake disc replacement.

Rear wheel

Repair time estimates for rear wheel, tyre, rim, and brake disc replacement.

Fuel pump

Repair time estimates for fuel pump and injector pump pipe replacement.

Electric devices

Repair time estimates for voltage regulator, HV coil, and spark plug cap replacement.

VOLTAGE REGULATOR

Repair time estimates for voltage regulator replacement.

REMOTE CONTROLS

Repair time estimates for remote controls, battery, and switches replacement.

WIRE UNIT

Repair time estimates for fuse holder and electrical system replacement.

Electronic controls

Repair time estimates for headlight switch, horn button, and starter button replacement.

Transmissions

Repair time estimates for transmission assembly, cable, and fuel tank cap drive replacement.

Front suspension

Repair time estimates for fork, sheath, stem, and oil seal replacement.

Cooling system

Repair time estimates for radiator components like expansion tank and fan replacement.

RADIATOR

Repair time estimates for radiator, fan, and coolant pipe replacement.

Windscreen

Repair time estimates for windscreen glass replacement.

Stickers

Repair time estimates for plates and stickers replacement.

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