Husqvarna SM 610 (2006), TE 610 (2006) Workshop Manual

1

Workshop Manual

SM 610, TE 610/ 2006

Part. N. 8000 A4640 (04-2005)

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Copyright by
MV Agusta M otorcycles S.p.A.
Servizio Assistenza Tecnica - Via Nino Bixio, 8
21024 Cassinetta di Biandronno (VA) - Italy
Tel. ++39 0332 254111- Fax ++39 0332 756509 ­www.husqvarna.it

USA m odel
Cagiva U.S.A.
2300 MARYLAND ROAD
WILLOW G RO VE, PA 19090 - 4193
215 - 830 - 3300

1st Edition (04-2005)
Printed in Italy
Print No. 8000 A4640

VALIDITY (from vehicle identification number)

SM 610 (39 KW ): ZC GA100AB5V000001

SM 610 (22 KW ): ZC GA101AB5V000001
TE 610 E (39 KW): ZCG A100AA5V000001
TE 610 E (22 KW): ZCG A101AA5V000001

USA/C DN m odels
SM 610: ZCGAFEK P#6V400000
TE 610: ZCG EAEKP#6V300000

To the best knowledge of M V Agusta Motorcycles S.p.A. - Varese, Inc. the material contained herein is accurate as of the date
this publication was approved for printing. Cagiva Motor S.p.a. - Varese, Inc. reserves the right to change specifications,
equipment, or designs at any time without notice and without incurring obligation. Illustrations in this manual are merely for
demonstration purposes and could not exactly match the detail described. No part of this manual can de reproduced without
permission in writing of the copyright holder. All the motorcycles and their detailed parts taking part in competitions of any
type are excluded from the guarantee.

1st Edition (04-2005)

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Forew ord

This publication intended for HUSQVARN A Workshops has been prepared for the purpose of helping the authorized personnel in
the maintenance and repair work of the motorcycles herewith dealt with. The perfect knowledge of the technical data contained
herein is essential for a m ore complete professional training of the operator.
The paragraphs have been com pleted with schematic illustrations evidencing the subject concerned, in order to enable a more
immediate understanding.
This manual contains information with particular meanings:

Accident prevention rules for the operator and for the personnel working near by.

Possibility of damaging the vehicle and/or its components.

Additional information concerning the operation under way.

Useful suggestions
HUSQV AR NA suggests, in order to prevent troubles and in order to have an excellent final result, to generically com ply with the

following instructions:

in case of repair work, weigh the impressions of the Customer who complains about the im proper operation of the motorcycle,

and formulate proper clearing questions about the symptoms of the trouble.

detect clearly the cause of the trouble. This manual gives the theoretical bases which however shall be integrated by the per-

sonal experience and by the attendance to training courses periodically organized by HUS QV ARNA.

rationally plan the repair work in order to prevent dead time as for instance procurement of spare parts, tool preparation, etc.
reach the component to be repaired and perform only the required operations. In this connection, it will be useful to consult the

disassembly sequence contained in this manual.

1 Always replace the seal rings and split pins with new com ponents.
2 W hen loosening or tightening nuts or bolts, always start from the bigger ones or from the center. Lock at the prescribed torque
wrench setting following a crossed run.
3 Always earm ark the components or positions which could be m istaken one for another at the time of assembly.
4 Use original HU SQVARNA spare parts and the lubricants of the recomm ended brands.
5 Use special tools, where specified.
6 Consult the Service Bulletins as they may contain up-dated adjustment data and repair methodologies.

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- Where not otherwise specified, data and instructions refer to all models.

SM 610

TE 610

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Chapter

Section

General

A

Maintenance B
Troubles and remedies C
Settings and adjustments D
General operations E
Engine disassem bly F
Engine overhauling G
Engine re-assembly H
Front suspension I
Rear suspension J
Brakes L
Electric system M
Engine cooling system N
Lubrication circuit O
Specific tools W
Torque wrench settings X
Fram e, wheels Y
Notes for USA/CDN-AUS models Z

Summary

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GENERAL

Section

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Engine A.3
Timing system A.3

Fuel feeding A.3
Lubrication A.3
Cooling A.3
Ignition A.3
Starting A.3
Transmission A.4
Frame A.5
Suspensions A.5
Brakes A.5
Wheels A.5
Tires A.5
Ignition system- electric system A.6
Weights A.7
Overall dimensions A.7

Table of Contents

Capacities A.8

GENERAL

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GENERAL

ENGINE

4-stroke, single cylinder
Bore 3.85 in.
Stroke 3.01 in.
Displacement 35.15 cu. in.
Compression ratio 11.1:1

TIM ING SYSTEM

Single overhead cam shaft; 4 valves
Valve angle in relation to cylinder:
INTAKE 20°
EXHAUST 20°
Valve clearance with cold engine:
INTAKE 0.002 in.
EXHAUST 0.002 in.

FUEL FEEDING

Gravity
Dry type air filter
Carburetor type Keihin FCR-M X 41 with acceleration

pump and T.P.S. (Throttle Position Sensor)

LUBRICATION

Forced type with lobe twin-pum p

COOLING

By fluid with double cooler, electric fan and expansion tank

IGNITION

Electronic with capacitive discharge; Digital controlled variable
spark advance

Spark plug type "NGK" CPR8E
Spark plug gap 0.022÷0.026 in.
STARTING electric

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GENERAL

TRANSMISSION

Multi-plate clutch in oil bath 6-speed gearbox, constant
mesh gear type
Drive between engine and gearbox m ain shaft by straight
toothed gears

Prim ary drive

Drive pinion gear z 32
Clutch ring gear z 75
Transmission ratio 2.343

Gearbox ratios

1st gear 2.615 (z 34/13)
2nd gear 1.812 (z 29/16)
3rd gear 1.350 (z 27/20)
4th gear 1.091 (z 24/22)
5th gear 0.916 (z 22/24)
6th gear 0.769 (z 20/26)

Final drive

Drive between gearbox and rear wheel by 5/8" x 1/4" chain
(with O Rings )

* Transm ission sprocket z 15
Rear wheel sprocket z 45
* Transm ission ratio 3.000
Rear chain size 5/8 x1/4
(112 links)
* Total drive ratios
1st gear 18,389
2nd gear 12,744
3rd gear 9,492
4th gear 7,670
5th gear 6,445
6th gear 5,409

*: replace data on owner s manual no. 8000 A4860 (page 22)

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GENERAL

* FR AM E

Single-beam in steel tubes of circular section splitting approx.
on line with the exhaust; light alloy rear fram e

Steering angle 39° each side
Steering axis angle 27° (SM ); 28° (TE)
Forward travel (in.) 2.7 (SM); 3.9 (TE)
*: replace data on owner s manual no. 8000 A4860 (page 24)

SUS PENSION

Front

MARZO CC HI Overturned forkrod telehydraulic fork with
advanced pin; forkrods 1.77 in. diam eter; hydraulic brake
adjustment both in compression and extension

Axle travel on leg axis (in.) 9.84 (SM); 11.8 (TE)
Rear
Swinging arm in light alloy with progressive damping,

SACHS hydraulic mono-shock absorber with helical spring.
Spring preloading adjustment; hydraulic brake adjustm ent
both in compression (D OUBLE) and in extension.

Wheel travel (in.) 11.4 (SM); 12.6 (TE)

BRAKE S

Front
Drilled fixed disc 10.24 in. dia. with floating caliper (TE);

drilled floating disc 12.6 in. dia. (SM) with fixed caliper
Pads area 5.02 sq. in. (TE); 6.14

sq. in. (SM)

Independent hydraulic circuit and pump with control on the
handlebar right side

Rear
Drilled floating disc ø 8.66 in. with

floating caliper
Pads area 4.57 sq. in.
Independent hydraulic circuit; controlled by pedal and pump

on the motorcycle right side.

WHEELS

Rims
Front (TE) "TAKASAG O Excel in

light alloy: 1,6x21

Front (SM) "SANREM O" in light

alloy: 3,50x17

Rear (TE) "Metzeler" MCE KA-

ROO- "Pirelli" MT 21;

140/80x18

* (SM) "Pirelli" MTR 22

DIABLO- "Dunlop"

D208; 150/60x17

*: replace data on owner s manual no. 8000 A4860 (page 26)

Cold tire pressure

(front SM - Road use, driver only)

25.6 psi

(front SM - Road use, driver and pas­senger)

28.4 psi

(rear SM- Road use, driver only)

28.4 psi

(rear SM- Road use, driver and pas­senger)

34.1 psi

(front SM - Racing use, driver only)

20 psi

(rear SM- Racing use, driver only)

22.7 psi

(front TE- Road use, driver only)

17.1 psi

(front TE- Road use, driver and pas­senger)

21.3 psi

(rear TE- R oad use, driver only)

21.3 psi

(rear TE- R oad use, driver and pas­senger)

25.6 psi

(front TE- Racing use, driver only)

14.2 - 15.6 psi

(rear TE- R acing use, driver only)

12.8 - 14.2 psi

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IGNITION SYSTEM - ELECTRIC SYSTEM

The ignition system includes the follow ing elements:

- Generator;

- Ignition coil;

- Electronic power unit;

- Voltage regulator;

- Spark plug;

- Starting motor 12V-700W ;

- Electric start remote control switch.

The electric system includes the following elements:

- SM- Headlamp with two filaments bulb of 12V-55/60W and parking light bulb of 12V-5W ;

- TE- Headlam p with two filaments bulb of 12V-35/35W and parking light bulb of 12V-3W;

- Rear lights with stop bulbs of 12V-21W and parking light bulb of 12V-5W ;

- Turn signals bulb of 12V-10W ;

- Three15 A fuses (one of them is a spare fuse);

- Battery 12V-12Ah.

GENERAL

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WEIG HTS (§)/ D IM ENSIONS mm

GENERAL

SM 610

TE 610

(§): Curb w eight, without fuel

SM 610 .....................kg 142 (313 lbs)

TE 610 ..................... kg 140 (308.6 lbs)

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CAPACITIES

Fuel tank (reserve included) Unleaded gasoline (98 R.O.N.) 2.64 Imp. Gall./ 3.17 U.S. G all.
Fuel reserve

2.64 Imp. Qt./ 3.17 U.S. Qt.

Change gear and main transmission oil AGIP RACING 4T (SAE 10W60) 1.76 Imp. Qt./ 2.11 U.S. Qt.

( oil and oil filter replacement)

1.14 Imp. Qt./ 1.37 U.S. Qt.
( oil replacem ent)

Front fork oil AGIP FORK 7,5 (SAE 7,5; SAE 5 for hard

climatic conditions)

4 in. (oil level) (*)

Oil for rear shock - absorber AGIP FORK 2,5 (SAE 2,5)
Fluid for cooling system AGIP COOL 2.45 Imp. Pints; 2.85 U.S. Pints
Front brake fluid AGIP BRAKE 4 (DO T 4)
Rear brake fluid AGIP BRAKE 4 (DO T 4)
Drive chain lubrication AGIP CHAIN LUBE
Grease lubrication AGIP BIKE GREASE
Electric contact protection AGIP ROCOL MOISTURE GUARD
Fillers for radiator AREXONS liquido
Air filter oil AGIP FORM ULA FILTER "Foam air filter

protection oil"

Air filter detergent AGIP "Filter clean foam air detergent fluid"

GENERAL

WARNING! - Use of additives in fuel or lubricants is not allowed

(*): see page I.9

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Section

MAINTENANCE

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Description Operation Pre-delivery

Engine oil
Coolant Check / Restore level #
Cooling system Check for leakage #
Spark plugs Check / Replace #
Throttle body / C arburetor Check and adjust #
Brakes / Clutch fluid Check level #
Brakes / Clutch Check operation #
Brakes / Clutch Check lines for leakage #
Throttle control Check operation #
Throttle control Check / Adjust play #
Choke control Check operation #
Flexible controls and transmissions Check / Adjust #
Drive chain Check / Adjust #
Tires Check pressure #
Side stand Check operation #
Electrical equipment Check operation #
Instrument panel Check operation #
Lights / Visual signals Check operation #
Horn Check operation #
Headlight Check operation #
Ignition switch Check operation #
Locks Check operation #
Screws and nuts Check / Tighten #
Hose clamps Check / Tighten #
General lubrication
General test

PRE -DELIVERY INSPECTION

MAINTENANCE

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MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

CO UP O N A ­AF T ER
1000 km (6 20
mi.) O R
6 MONTHS

CO UP O N B ­AF T ER
5000 km (3 100
mi.)
OR 12 MONTHS

CO UP O N C ­AF T ER
10000 k m (6200
mi.)
OR 24 MONTHS

CO UP O N D ­AF T ER
15000 k m (9300
mi.)

PR E -DEL IVE R Y
INSPEC T ION

Whichever
com es first

Whichever com es
first

Whichever
com es first

Only if reac hed
within 24 m onths

Coolant C C C S C
Engine oil C S S S S
Engine oil filter cartridge

S

S

Engine oil suction filter

P

P

Valve clearance

C C C C

Spark plug C C

S

Tim ing system chain

S

Clutch flexible coupling

C

Ignition cover

C C C

Starting gears assembly

C

Connecting rod

S

Clutch discs

C

Ignition timing

C

Fuel filter

C S S S

Carburetor C C

P

Carburetor throttle valve

C

Air filter

P S S S

Engine oil pressure

C

Cylinder/Piston checking

C

C
Brakes fluid (**) C C C S C
Brakes hydraulic controls C C C C C
Brakes pads wear

C

C
Flexible controls C C L L L
Throttle control C C C C C
Tires pressure and wear (*) C C C C C
Electric fan C C

C
Headlamp alignment C C
Lights/Visual signals, Horn C C C C C
Battery C C C C C

ITEM

CO UP O N E ­AF T ER
20000 k m
(124 00 m i.)

Only if reac hed
within 24 m onths

S
S
S
P
C
S
S
C
C
C
S
C

S
P
C
S
C
C
S
C
C
L
C
C
C

C
C

SE E P AGE

Instruments C

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MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

ITEM

CO UP O N A -

AF T ER

1000 km (6 20

mi.) O R

6 MONTHS

CO UP O N B -

AF T ER

5000 km (3 100

mi.)

OR 12 MONTHS

CO UP O N C -

AF T ER

10000 k m (6200

mi.)

OR 24 MONTHS

CO UP O N D -

AF T ER

15000 k m (9300

mi.)

CO UP O N E -

AF T ER

20000 k m

(124 00 m i.)

SE E P AGE

PR E -DEL IVE R Y

INSPEC T ION

Whichever

com es first

Whichever com es

first

Whichever
com es first

Only if reac hed

within 24 m onths

Only if reac hed

within 24 m onths

Rims spokes stretch

C C C C C

Steering head bearings play

C

C

C
Transmission chain/Chain rollers C C-L C-L S C-L S
Rear sprocket/Pinion

C S C S
Side stand screws C C C C C C
Wheels hubs bearings

C

C

Fuel tank

P

P

Front fork oil

S-R

S-R
Bolts and nuts general tightening C C C C C C
Lubricating/G reasing C L L L L L
Locks C
Motorcycle general test X X X X X X

KEY FOR M AINTENANCE SC HE DULE
C: Check and/or adjust
L: Lubricate and/or grease
P: Clean
S: Replace
R: overhauling
(*): replace if necessary

(**): system bleeding if necessary

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TROUBLESHOOTING

Section

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TROUBLESHOOTING

ENG INE
Trouble Cause Rem ed y

Engine don

t start or starts with

difficulty
Inadequate com pression 1. Piston seizure Replace

2. Con-rod small or big end seized Replace

3. Piston rings worn Replace

4. Cylinder worn Replace

5. Low torque cylinder head nuts Tighten

6. Head gasket blowing Replace

7. Spark plug loose Tighten

8. Incorrect valve play Adjust

9. Valve springs weak or seized Replace

10. Valves seized Replace

11. Incorrect decom pressor adjustment Adjust

No or w eak spark 1. Spark plug faulty Replace

2. Spark plug dirty or wet Clean or dry

3. Spark plug gap too large Adjust

4. Ignition coil faulty Replace

5. H.T. leads dam aged or short circuiting Check

6. Electronic device faulty Replace

7. R.H. switch faulty Replace

Fuel not reaching carburetor 1. Fuel tank cap breather blocked Clean

2. Fuel cock blocked Clean

3. Fuel feed hose blocked Clean

4. Carburetor fuel filter dirty Clean

5. Worn out float valve or worn out floats Replace

6. Rocker blocking float valve Free

Carburetor flooding 1. High fuel level in float bowls Adjust

2. Worn out float valve or worn out floats in open position Replace or free

Worn out clutch sw itch on the
handlebar

Clutch switch cable connected incorrectly or short circuit Connect correctly or replace

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TROUBLESHOOTING

Trouble Cause Rem ed y

Engine cuts out easily 1. Spark plug dirty Clean

2. Electronic control unit faulty Replace

3. Carburetor jets blocked Clean

4. Idling low Adjust

Engine noisy
Piston noise 1. Excessive play between cylinder liner and piston Replace

2. Piston rings or piston rings seats worn Replace

3. Excessive carbon layers inside the combustion cham­ber or on the piston top

Clean

4. Worn rocker arm Replace

5. Excessive valve play Adjust

6. Valve springs weak or seized Replace

7. Cam chain worn Replace

Crankshaft noise 1. Main bearings worn Replace

2. High radial and axial play at con-rod big end Replace

3. Crankshaft gear damaged Replace

4. Crankshaft nut loose Tighten

Clutch noise 1. Discs worn Replace

2. Excessive free play between clutch drum and driving
discs

Replace

Gearbox noise 1. Gears worn Replace

2. Gear splines worn Replace

Rear transmission chain noise 1. Chain stretched or badly adjusted Replace or adjust

2. Engine sprocket and rear wheel sprocket worn Replace

Clutch slip 1. Insufficient clutch adjuster free play Adjust

2. Clutch springs weak Replace

3. Clutch discs worn Replace

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TROUBLESHOOTING

Trouble Cause Rem ed y

Clutch drag 1. Excessive clutch adjuster free play Adjust

2. Spring tension uneven Replace

3. Clutch discs bent Replace

Gears not engaging 1. Gearshift forks bent or seized Replace

2. Gear change pawls worn Replace

3. Gearshift forks

control pins damaged Replace

Gear change lever doesn

t return 1. Selector return spring weak or broken Replace

2. Gearshift forks worn Replace

Slips out of gear 1. Sliding dogs worn Replace

2. Gear splines worn Replace

3. Sliding dog seats on gears worn Replace

4. Splines gearshift forks

control shaft worn Replace

5. Gearshift forks control pins worn Replace

Engine lacks pow er 1. Air filter dirty Clean

2. Carburetor m ain jet blocked or wrong size Clean or replace

3. Poor quality fuel Replace

4. Intake manifold loose Tighten

5. Spark plug gap too large Adjust

6. Inadequate compression Find cause

7. Incorrect valve play Adjust

8. Faulty valve guides or seats Replace

9. Valve springs weak or seized Replace

Engine overheating 1. Excessive coke on combustion chamber and/or piston

crown

Clean

2. Insufficient engine oil, or wrong oil used Top up or replace

3. Radiator air flow blocked Clean

4. Poor seal at cylinder head gasket Replace

5. Clutch slipping Adjust

6. Faulty electric fan Replace thermo switch

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TROUBLESHOOTING

FRAME W HEELS AND SUSPEN­SION

Trouble Cause Rem ed y

Difficult to turn handlebars 1. Low tire pressure Inflate

2. Steering head bearings

adjustment ring nut or steering

stem nut too tight

Adjust

3. Bent steering head stem Replace steering bracket

4. Steering head bearings worn or seized Replace

Handlebar vibrates 1. Front fork legs bent Replace

2. Front wheel axle bent Replace

3. Frame bent Replace

4. Front wheel rim bent Replace

5. Front wheel bearings worn Replace

Suspension too hard 1. Insufficient oil in front fork stanchions Top up

2. Too low viscosity of front fork stanchion oil Replace

3. Weak front fork spring Replace

4. Weak rear shock absorber spring Replace

5. Rear shock absorber badly adjusted Adjust

Wheel (front and rear)
vibrates

1. Wheel rim bent R eplace

2. Wheel hub bearings worn Replace

3. Wheel spokes loose Tighten

4. Wheel axle nut loose Tighten

5. Rear swinging arm bearings worn Replace

6. Chain tensioner incorrectly set Adjust

7. Wheel not balanced correctly Balance

Rear suspension noisy 1. Link rod bearings or spacers worn Replace

2. Shock absorber ball joints worn Replace

3. Shock absorber faulty Replace

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TROUBLESHOOTING

Trouble Cause Rem ed y

Poor (front and rear) braking 1. Air in the brake system Bleed

2. Insufficient fluid in reservoir Top up

3. Pads and/or disc worn Replace

4. Disc damaged R eplace

5. Brake lever- pedal incorrectly adjusted Adjust

6. Water inside the braking system Replace the fluid

ELECTR ON IC S

Spark plug becomes dirty too
frequently

1. Mixture too rich Adjust carburetor

2. Air filter dirty Clean

3. Piston rings worn Replace

4. Piston or cylinder worn Replace

Spark plug overheats 1. Mixture too lean Adjust carburetor

2. Spark plug gap too small Adjust

3. Too high heat rating Replace the spark plug

Generator charging too low or
not at all

1. Wires to voltage regulator connected incorrectly or short
circuiting

Connect correctly or replace

2. Faulty voltage regulator Replace

3. Generator coil faulty Replace

Generator charging too high 1. Voltage regulator faulty Replace

The battery is discharged fast 1. Battery terminals dirty Clean

Start motor w on't start or slips 1. Battery flat Recharge

2. Control button on right hand switch unit faulty Replace

3. Starter relay faulty Replace

4. Starter motor faulty Repair or replace

5. Starter gears worn Replace

6. Free wheel rollers worn or damaged Replace free wheel

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SETTINGS AND ADJUSTMENTS

Section

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SETTINGS AND ADJUSTMENTS

Table of Contents

Adjustm ent of valves play

D.3

Compression check D.3
Carburetor adjustm ent D.4
Idle adjustment D.4
Checking the engine oil level D.4
Oil change, cleaning and changing oil filters D.5
Cleaning the bag filters D.6
Coolant level check D.6
Replacem ent of coolant D.7
Air filter check and cleaning D .8
Throttle cable adjustm ent D.9
Clutch adjustm ent D.10
Adjustment of front brake control lever and

fluid level

D.11

Adjustment of rear control pedal D.12
Steering bearings play adjustm ent D.13
Front fork adjustment and oil level checking D.14
Adjusting the shock absorber D.15
Secondary transmission chain adjustm ent D.16

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SETTINGS AND ADJUSTMENTS

Adjustm ent of valves play

Remove seat, spoilers, fuel tank, coolers and expansion tank as shown at
chapter

General Operations .
Drain the engine oil as indicated on page D. 5 then, with COLD ENGINE,
operate as follows:

- Rem ove the spark plug and insert a dial gauge into its seating;

- Rem ove the L.H. crankcase half cover (A) and position the tool (B) code
800090875 as shown in the figure;

- Bring the piston to the top dead center (TDC), with the

T notch on the rotor
coincident with the notch on the tool; set the dial gauge to zero on this
position;

- Rem ove the adjusting screw caps and checks the valve play using a
gauge. The play must be 0.002 in. both for the intake and the exhaust;

- lf the above play is not met, loosen the counter-nuts (1) and act as required
other screws (2) until the required play is obtained;

- Torque again the counter-nuts (1) and install all parts previously rem oved.

Spark plug 8.8 ft-lb
L.H. cover fastening screw 5.8 ft-lb
Nut for valve adjusting screw 5.8 ft-lb
Valve cover fastening screw 5.8 ft-lb

TIG HTENING TORQUES

Com pression check

Compression should be checked as follows:

- Rem ove the spark plug and fit a pressure gauge in its place;

- Turn completely the throttle twist-grip;

- Turn the engine over by using the electric starter switch and take a reading
on the pressure gauges. The pressure reading should not be lower than: 8
bar (113 PSI).

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SETTINGS AND ADJUSTMENTS

Carburetor adjustment

Adjust the carburetor with warm engine and with the throttle control in closed
position.
Proceed as follows:

- Turn slow running adjusting screw (1) on the left side of the bike, until the
engine is turning over at fairly high rpm (turn the screw clockwise to increase
the engine r.p.m. , and counterclockwise to decrease the engine r.p.m .).

- Turn adjusting screw (2) clockwise until the fully closed position is reached
then turn back 1,5 turns.

- Progressively loosen adjusting screw (1) to obtain the slow running required.

Idle adjustment

Adjust the carburetor with warm engine and with the throttle control in closed
position.
Proceed as follows:

- Turn slow running adjusting screw (1) on the left side of the bike, near the
fuel cock, until the required idle condition is reached (turn the screw
clockwise to increase the engine r.p.m ., and counterclockwise to decrease
the engine r.p.m.).

Checking the engine oil level

Put off the engine and wait for some minutes to allow the oil setting inside the
sump. With the motorcycle set in vertical position, and looking through window
(C), check that the level is between the two notches (A) and (B) placed at the
back of the rear brake pedal, as shown in figure.

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SETTINGS AND ADJUSTMENTS

Be careful not to touch hot engine oil.

Oil change , cleaning and changing oil filters
Drain the oil w ith warm engine.

Work as follows:

- Set the motorcycle in vertical position and place a vessel under the engine;

- Rem ove oil filler cap (1) and drain plugs (2) and (3) under the sump to
drain all the oil;

- First rem ove possible particles from the magnetized care of the right plug,
then set the drain plugs and the gasket in position again (M14 plug: 24 Nm/
2,45 Kgm/ 18.1 ft-lb; M22 plug: 60 Nm/ 6,1 Kgm/ 44 ft-lb).
Add the required amount of oil through the oil filler (see page A.8).
Slowly turn the engine for some m inutes, the turn it off and wait for some
minutes to allow the oil setting inside the sump. With the motorcycle set in
vertical position, and looking through window (C), check that the level is
between the two notches (A) and (B) placed at the back of the rear brake
pedal, as shown in figure. To change the filter cartridge (5), unscrew the two
retaining screws (6), remove the cover (7) and the

O ring . Remove both
spring (8) and cartridge; replace the O-ring and reverse the operations when
reassembling (screw 6: 9,3 Nm / 0,95 Kgm / 6.9 ft-lb).

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6

SETTINGS AND ADJUSTMENTS

Cleaning the bag filters

The filters (1) et (2) are set on the right side between the cover and the sum p
(transmission to the scavenge pump), and on the left sump (twin-filter,
transmission to the pressure pum p).
Clean the filters using gasoline and compressed air. Replace the old OR
gaskets with new and greased ones.

Pay attention to the filter (1) reassem bling sense.

Coolant level check

Check the level (2) in the right radiator with cold engine and with motorcycle in
vertical position. The cooler must be flush with the lower side of the filling pipe
union. The level inside the expansion tank must never be under the MIN (1).
Otherwise, ALWAYS and ONLY fill through the plug under the right radiator, or from
the expansion cap in case of level restoration.

Avoid removing the cap of the radiator w hen the engine is hot. There is a
risk that the coolant will spout and cause burns.

The coolant may not come on painted surfaces. lf this is the case w ash
with w ater.

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