MO Xtm-Xsm 50 Frame ENG
Contents
1. i aiam _ CHASSIS L Te n CP qi 3 ERR 2 dm f XSM _WORKSHOPMANUALS JL CHASSIS 4 Introduction 5 18112 P INTRODUCTION 1 4 DISASSEMBIY 35 20 Abbreviations Editing symbols 14 9 pC GETTINGTOKNOWYOURMOTORBIKE 2 10 strat Engines 13 Radiator 31 Display 1 1 1 2 15 Tires 16 Fueltank 2 16 Coolant 17 Engmeol 2 AT 19 35 O Frontwhee J38 DISASSEMBLY 3 20 36 Rear brake lever Rear wing 24 Regulator 14214 Tf Rearchasis 3 ASSEMBLY 4 4 Air filter suction box 3 26 Chassis torque wrench settings 0204 30 CHASSIS Introduction INTRODUCTION This Workshop Manual describes the main electrical mechanical checks the essential checks and the as sembly of components supplied disassembled in order to deliver a brand new motorcycle the sequence of operations is not binding It is essential to follow the instructions with great care Work carried out carelessly or worse still work that has not been accomplished can cause injuries and damage or in the less serious cases tiresome complaints Schedules frequency of operations to accomplish during the guarantee period Note These manuals provide the necessary infor2. IDEE IN MOTO SEAT Loosen the screw V 1 and release the seat from the chassis Pull it out rearwards REAR SIDE CASINGS rh Ih e Remove seat Loosen the screws V4 F 2 and remove the rear side casing left or right TAIL SECTION e Remove seat and left right rear side casing Undo fixing screws V2 F 3 and the screws V4 F 3b itc gua CONVEYOR right and left Remove seat Undo the screws V2 F 4 the side screws V F 5 and the front screws V2 F 6 CODON CHASSIS Disassembly XTM XSM CHASSIS Disassembly XTM 5 A SILENCER e Remove seat and left hand side casing Remove the spring D F 9 Undo the screws V2 F 7 and remove the silenc er by pulling it rearwards CAUTION A Before removing make sure the silenc er has cooled down MUFFLER e Remove seat and left hand side casing Remove the springs A and B F 8 fastened to the cylinder Undo the screw V F 8 CAUTION A Before removing make sure the muf fler has cooled down Remove the clamp C F 9 from the tube of the secondary air valve and detach the tube from its fitting Remove the spring D F 9 and remove the muffler by pulling it frontwards 22 900 CHASSIS 2 Disassembly XTM XSM BATTERY e Remove seat Remove the elastic band A F 10 and detach the battery cables B
3. and remove the filler cap R F 13i 4 Remove the drain screw S F 13i and the screw F F 13i to drain oil 5 Reinstall the drain screw S F 13i and tighten it 6 Fill the engine with oil until this is dripping from the level control hole F F 13i Fit the screw back into the hole F F 13i install the oil filler cap R F 13i and tighten it The use of SAE 10W 30 oil is recommended Start the engine and let it warm up for a few minutes While it is warming up check for oil leakage If oil is leaking immediately turn off the engine and locate the cause BRAKE FLUID CHECK When checking the fluid level make sure that the top end of the main cylinder is horizontal when the handle bar is turned Make sure the brake fluid level of the rear brake reser voir is above the minimum level mark As far as the front brake is concerned the level of fluid can be checked through the sight glass on the pump REPLACEMENT Front brake remove the cap A F 14i after loosening the screws V2 F 14i Rear brake remove the cap B F 15i Brake fluid quality must comply with the specified stand ards brake fluid may deteriorate rubber gaskets caus ing leaks and impairing brake operation Recommended brake fluid DOT 4 18 900 A Ls Y TE E PAAR pto F 13i NEM SQ F 14i B cS CHASSIS 2 Getting to know your motorbike IDEE IN MOTO ADJUSTMENT OF
4. Rear hydraulic disk type 2218 mm hydraulic disk type 2218 mm Calipers with two pistons Operation right foot operation Suspensions Front telescopic fork Max stroke 190 2mm Rear swingarm Max stroke 44 2 Electrical equipment Ignition system C D I control unit Generator rated power FLYWHEEL MAGNETO 95W Type of battery calling for maintenance Battery capacity 124 Fuel sensor electrical floating probe Horn 12V DC Lights Headlight 12V 35 35 W Tail light 12V P21 5 W Indicators front rear 12V 10W x 4 Indicator lights LED Parking light 12V AW Switzerland version only Low beam indicator light 12V 1 2W Switzerland version only Number plate light 12V 5W Switzerland version only 204 s 0 11 CHASSIS d Getting to know your motorbike A IDEE IN MOTO UNPACKING e Unpack the motorcycle following the instructions printed on the pack which must be disposed of in accordance to the laws in force APPEARANCE CHECK e Make sure all plastic components have been correctly fitted In particular check the vehicle for scratches marks etc REGISTRATION DATA ENGINE REGISTRATION NUMBER Engine registration data P F 1i is on the left crankcase VEHICLE REGISTRATION NUMBER The vehicle s registration number I F2i is stamped on the steering rod The vehicle registration number is used to identify the motorcycle DAY SP 9 lt gt ANTI TAMPERING L
5. dix Before disassembly hold the centre chassis section to prevent the vehicle falling over Unscrew the nut A F 51 loosen the chain tight ening adjusters release the chain from the gear wheel and remove the pin P F 52 Caution When refitting follow the instructions provided in section 2 in ADJUSTING TRANSMISSION CHAIN TIGHTNESS 38 3000 CHASSIS 2 Disassembly XTM XSM e Remove rear wheel Loosen the hydraulic transmission screw V F 52 and detach the pipe T F 52 from the caliper Release the calipers from the fork CAUTION Before disassembly hold the centre chassis section to prevent the vehicle O lii falling over Caution When refitting remember to replace the copper gaskets and bleed using the relevant equipment F 52 REMOVING THE REAR BRAKE CALIPERS MOTARD ENDURO model F 52A REAR DISC BRAKE e Remove front wheel and rear caliper Undo the screws V3 F 53 Caution When refitting use thread locker CHASSIS Disassembly XTM XSM 2 IDEE IN MOTO CHAIN CRANKCASE Undo the screws V3 F 54 F 54 FORK e Remove rear wheel rear brake caliber shock absorber chain crankcase Unscrew the nut D F 55 and remove the pin CAUTION Before disassembly hold the centre chassis section to prevent the veh
6. from its fitting Undo the screws V2 F 25 detach the probe connector C F 25 and release the tank pin P F 26 from the chassis OIL LEVEL PROBE CAUTION A Before removing the probe release the tank from the chassis Detach the probe s connector C F 25 from the main wiring OIL PIPE FITTING WITH FILTER Caution Before removing the fitting release the tank from the chassis Loosen the clamp L F 27 and remove the fitting paying attention not to damage the O ring 28 e 0 0 05 03 O Ais FUEL TANK e Remove seat and top screw of the front con veyors Undo the front fixing screw V F 28 and the rear O fixing screws V2 F 28 ES Disconnect the vacuum pipe D F 28 and the 1 petrol pipe B F 28 from the fuel cock Raise the tank and detach the fuel probe connec tor S F 28 gt A CAUTION Empty the tank FUEL COCK e Remove seat and fuel tank A CAUTION Make sure the tank is empty Loosen the clamp F F 28b and remove the cock o503 wwe DO CHASSIS Disassembly XTM XSM CHASSIS d Disassembly XTM 12 bem IDEE IN MOTO THROTTLE CABLE MIXER Undo the screws V2 F 29 and remove the pump Release cable C F 30 from pump body P F 30 F 29 F 30 CARBURETTOR e Remove seat side casings fuel tan
7. or nut hexagon Never tap the wrench with a hammer or other similar tools to loosen or tighten screws and nuts F 2 Never attempt to increase the lever arm by fitting a tube into the wrench F 3 CHASSIS Introduction 3 112 bem Never use open flames for any reason Never leave open containers or containers not suitable for holding fuel in passageways close to heat sources etc Never use petrol to clean the vehicle or the floor of the workshop Always use low flash point solvents to clean the vehicle components Never suck from or blow into the fuel pipe When welding make sure that there are no flammable liquids in the vicinity Always remove the tank even if completely empty and disconnect the negative cable from the battery Never leave the engine running in closed or poorly ventilated areas Before any servicing make sure that the motorbike is perfectly stable The front wheel should preferably be anchored to the equipment A F 4 integral with the lifting board 900 sse 05 03 CHASSIS v Introduction EDITING SYMBOLS A CAUTION Recommendations and precautions regarding rider safety and motor vehicle integrity B WARNING Situations entailing the risk of personal injury to maintenance or repair mechanics other workshop personnel or third par ties or damage to environment vehicle or equipment C FIREHAZARD Indicates operations which may const
8. 40 mm 2 stroke liquid cooled single cylinder vertical 49 cm 40 3 x 39 mm 12 1 0 5 Kickstarter separate lubrication semi synthetic oil according to API TC TS C3 standards 1 1L SAE 10W30 type SE 0 82L 91 premium grade unleaded petrol 6 5L 1 81 PHBN 16 DELL ORTO welded steel tubular bar 28 BR9ES NGK 0 6 0 7 mm Clutch mechanical multiple disc oil bath type Air filter sponge 45ppi Cooling system Type Antifreeze water mixture ratio Total amount 900 water cooled 1 1 0 55L 0 Css 0204 CHASSIS 4 Getting to know your motorbike Mode ENDURO SUPERMOTARD Transmission Primary reduction system helical gears Primary reduction ratio 2711220 3 55 Secondary reduction system chain drive Secondary reduction ratio 250 211 4 54 248 211 4 36 Transmission type mechanical 6 speed Type left foot Gear ratio 1st speed 212 1236 1 3 274 speed 216 233 1 2 06 3 speed 219 229 1 1 52 4 speed 222 1227 1 1 23 o speed 224 225 1 1 04 6 speed 225 224 1 0 96 Tires Type with tube Front 80 90 21 48P 100 80 17 52S Rear 110 80 18 58P 130 70 17 62S Manufacturer PIRELLI Tire pressure ambient temperature Front O 90 kg Rear 0 90 kg Front 90 kg max load Rear 90 kg max load Brakes Front hydraulic disk type 2240 mm hydraulic disk type 2259 mm Calipers with two pistons Operation right hand operation
9. ABEL The anti tampering label A F 2i is located under the seat It bears all the vehicle registration data envis aged by the 97 24 CE Directive If you intend to replace the compartment under the seat make sure it is provided with the anti tampering label When ordering spare parts also quote the vehicle registration data This label identifies the type of flywheel installed on the engine V F 2i this piece of information will be needed to correctly set the functions of the digital instrument board should this be necessary This label must be neither removed nor changed 12 e OO 05 03 CHASSIS 4 Getting to know your motorbike IDEE IN MOTO MAIN COMPONENTS Left hand side 1 Headlight 2 Oil tank 3 Battery 4 Air filter 5 Shift pedal MAIN COMPONENTS Right hand side 6 Radiator 7 Ownerstoolbag 8 Fuse 9 Fuel tank cap 10 Rear brake 11 Passenger foot rests 12 Passenger holder 13 Number plate light number plate holder SWITZERLAND only OO F 4i CHASSIS d Getting to know your motorbike A IDEE IN MOTO CONTROLS Controls Instruments 14 Main switch 14 17 15 Clutch lever 16 Turn signal switch 17 Digital multifunction instrument 3 _ board B B 18 Manual starter lever 19 Front brake pump 20 Mode switch 21 Front brake lever 22 Throttle grip 23 Rear vie
10. AKE CALIPER Loosen the screws V2 F 43 and disconnect the pipe T F 43 after loosening the hydraulic trans mission screw V F 43 Caution When refitting remember to replace the copper gaskets and bleed using the relevant equipment 3000 CHASSIS 2 Disassembly XTM XSM REMOVING THE FRONT BRAKE CALIPERS MOTARD model F 43A REMOVING THE FRONT BRAKE CALIPERS ENDURO model F 43B SPEEDOMETER SENSOR Loosen the screw V F 44 and remove the sen sor release the cable from the U bolts and detach the connector under the headlight Caution When refitting pay attention to the shim washer between the sen sor and the fork CHASSIS Disassembly XSM 2 A IDEE IN MOTO FRONT WHEEL e Remove front caliper and speedometer sensor CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over Loosen the screw V2 F 45b Unscrew the pin P F 45 and remove it Remove the front wheel F 45b Caution When refitting after tighten ing the pin P F 45 remember to the tighten the screws V2 F 45b FRONT BRAKE DISC e Remove front wheel Loosen the screws V6 F 46 Caution When refitting use thread locker Te 9 9000 QO Cose O Ais FORK HEAD e Remove front indicators guard digital instru ment board and handl
11. ENGINE IDLING SPEED Start the engine and warm it up for several minutes at about 1000 2000 RPM while occasionally revving it to 4000 5000 RPM The engine is warm when it quickly responds to the throttle To adjust engine idling speed turn the throttle stop screw G F 16i Turn the screw clockwise to increase idling speed or counter clockwise to decrease it Check engine idling speed with an electronic revolution counter connected to the spark plug cable F 16i SHOCK ABSORBER ADJUSTMENT The vehicle s seat can be lowered by moving the lower fixing element M F 17i double hole in the bottom fixing bracket F 17i ADJUSTING TRANSMISSION CHAIN TIGHTNESS To adjust chain tightness loosen the wheel fixing nut B F 18i and the lock nut V F 18i and turn the adjustment screw C F 18i After adjusting tighten the lock nut V F 18i and nut B F 18i This operation must be performed on both sides of the rear fork adjustment must be identical on both sides to obtain this con dition refer to the scale G F 18i located on the fork An excessively taut chain will put the en gine and drive components under exces sive strain maintain chain tightness with in the specified limits F 18i A T n 0 oS ky Whilst carrying out these adjustments hold the vehicle firmly in place otherwise it will fall over CODON CHASSIS Disassembly XTM XSM 2 LE rm lH
12. and C F 10b Release the fuse carrier D F 11 from the clamp Caution When refitting the battery pay attention to the exhaust pipe REAR INDICATORS Undo the screw V F 1 Remove the glass cover and detach the lamp sock et cables Undo the fixing screw V F 12 F 12 05 03 wwe C 2 CHASSIS d Disassembly XTM XSM TAIL LIGHT e Remove seat and tail section Disconnect the cables A F 13 and undo the screws V2 F 13b Caution When refitting pay attention to the Fast on sequence see wiring diagram REAR WING e Remove seat side casings and tail section Cut the cable clamp F F 14 Undo the screws V2 F 14 and the screws V4 F 15 on both sides Undo the screws V3 F 14b 24 900 OD CHASSIS 2 Disassembly XTM XSM FILTER CARTRIDGE e Remove seat and battery Undo the screws V2 F 16 and remove the filter cartridge REGULATOR e Remove seat and rear right hand casing Detach the connector C F 17 and undo the screw V F 17 to reconnect the earth cables M A Caution When refitting remember F 17 FLASHLIGHT e Remove seat and rear right hand casing Detach the connector and open the snap lock I F 18 CODON MOTO CHASSIS Disassembly XTM XSM 2 IDEE IN REAR CHASSIS e Remove seat rear side casings tail sect
13. ble jaw tends to open thus risking damaging or not properly tightening the bolt to the correct torque In any case when using an adjustable wrench take care to proceed as shown in Figure 1 Except for occasional customers always make out and deliver to the customer a work sheet specifying the operations performed with notes as to any future checks eventually required RECOMMENDATIONS F 1 Before carrying out any operation on the vehicle wait for all parts to cool down Foroperations requiring two mechanics make sure that the various steps to be performed by each of them are clearly defined and coordinated beforehand Make sure that each component has been properly fitted before proceeding with the next one Lubricate all parts where applicable before reinstalling them Gaskets O rings circlips and split pins must be replaced at every refitting The torque settings specified in the manuals refer to the final torque which must be attained progressively by steps Loosen and tighten aluminium alloy parts covers only after the engine has fully cooled down Only use screwdrivers with sizes suitable to the screws to be loosened or tightened Work in a comfortable position and ensure that the vehicle is stable Never use a screwdriver as a lever or chisel Never use pincers to loosen or tighten screws or nuts because in addition to not providing a sufficient clamping force they may also damage the screw head
14. ebar Unscrew the Allen screws V2 F 47 Unscrew the nut D F 47 and remove the fork head FORK e Remove front indicators guard digital instru ment board front wheel soeedometer sensor front caliper handlebar and fork head Unscrew the ring nut G F 47 remove the dust guard P F 47 and pull out the fork CAUTION A Before disassembly hold the centre chassis section to prevent the vehicle falling over FOOT RESTS right and left Remove the split pin C F 48 pull out the pin P F 48 and remove the spring CHASSIS Disassembly XTM XSM Amount of oil per stem 350cc F 48 37 CHASSIS Disassembly XTM XSM 4 REAR BRAKE LEVER Remove the stick A F 49 by pulling out the pin P F 49 loosen the screw V F 49 and remove the pedal the spring the bushing and the plastic washer Jh F 49 REAR BRAKE PUMP AND REAR BRAKE OIL TANK Remove the clamp F F 50 and empty the con tents of the oil circuit into a container Loosen the screw V F 50 and remove the rear brake oil tank To remove the pump disconnect the cable from the rear stop switch I F 50 and unscrew it Undo the fixing screws V2 F50 paying attention to the eye adjustment plaque Caution When refitting remember to replace the copper gaskets and bleed using the relevant equipment REAR WHEEL CAUTION
15. icle falling over Caution When refitting follow the in structions provided in section 2 in AD JUSTING TRANSMISSION CHAIN TIGHTNESS F 55 200 IO Cose 0204 i i CHASSIS 2 Assembly XTM XSM CHASSIS TORQUE WRENCH SETTINGS TORQUE WRENCH SETTINGS TABLE TOURQUE WRENCH SETTINGS Kg m Remarks Front wheel pin 38 52 17 23 51 69 20 26 120 26 5 7 0 5 0 7 38 52 Front wheel pin fixing element Front brake caliper Muffler side coupler Rear engine fixing screws Fork pin Front engine fixing screws Front pump clamp Rear wheel E 72 98 Ha Gm 30 52 38 52 _ Bottom shock absorber 38 52 38 52 Fork head 18 24 48 24 Handlebar U bolt 18 24 48 24 Steering nut 25 34 25 34 Rear frame 16 24 16 24 Top shock absorber HEGN Greasing grease 050 ODO CHASSIS CHASSIS ee a m 2 Q m 7 I 200 JOC SECTION 3
16. illustration or illustrations will bear the number of the illustration on the former page followed by a letter ADDITIONAL PAGES Any additional pages shall bear the last number of the section to which they belong followed by the letter A and the date of issue EDITING SYMBOLS e Symbols have been provided for quick and easy reference see page 9 identifying situations requiring utmost attention or providing practical suggestions or simple information These symbols may appear next to a text in which case they refer solely to the text itself next to a figure in which case they refer to the topic illustrated in the figure and to the relative text or at the top of the page in which case they refer to all the topics dealt with in the page Note The meaning of the symbols should be duly memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations They are therefore to be considered as veritable memory tags In case of any doubt as to their meaning consult the page in which they are fully described 0505 CO CHASSIS Introduction Fy ABBREVIATIONS Paragraph JJ Diagram Note the letter V in the illustrations refers to retaining or adjusting screws The number following this letter refers to the number of the same type of screw in the unit or component described and illustrated Letters no
17. ion shock absorber guard battery rear brake fluid tank regulator flashlight and silencer Undo the screws V4 F 19 AIR FILTER SUCTION BOX e Remove seat rear side casings tail section battery rear wing silencer and rear chassis Undo the screws V3 F 20 F 21 and loosen the clamp F F 21b F 20 F 21 26 300 05 03 CHASSIS 2 Disassembly XTM XSM SHOCK ABSORBER e Remove the seat rear left hand casing Undo the two screws holding the tank in place on the rear side and remove the rubber protection O Undo the screws V2 F 22 and remove the shock absorber 9 CAUTION Before disassembly hold the centre chassis section to prevent the vehicle falling over Caution Check the direction in which you are fitting the shock ab sorber and tighten the screws V2 to the established torque setting SHIFT LEVER Undo the screw V F 23 and remove the lever CONTROL UNIT e Remove seat and rear right hand casing Undo the self tapping screws V2 F 24 detach the cables and spark plug cap and remove the control unit F 24b CHASSIS E Disassembly XTM XSM 2 IDEE IN MOTO OIL TANK e Remove seat and front left conveyor CAUTION A Empty the tank before disassembly to do so 1 Puta pan under the oil tank 2 Remove the pipe clamp F F 27 and detach the pipe
18. itute a fire hazard D RISK OF EXPLOSION Indicates operations which may constitute a risk of explo sion E TOXIC FUMES Indicates a possibility of intoxication inflammation or corro sion F MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic G ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical elec tronic technician H NO Operations to be absolutely avoided I ENGINE SERVICE MANUAL Indicates information which may be obtained by referring to said manual L SPARE PARTS CATALOGUE Indicates information which may be obtained by referring to said catalogue 0 CHASSIS Getting to know your motorbike SPECIFICATIONS ENDURO SUPERMOTARD Dimensions Length Width Height Wheel base Seat height Minimum ground clearance Minimum turning radius Front wheel stroke Rear wheel stroke Weight Kerb weight Maximum load Engine Type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubricating system Type of oil Engine oil Total amount Transmission oil Total amount Fuel Type Fuel tank capacity Reserve amount Carburettor Type Manufacturer Chassis Chassis Caster angle Spark plug Type Manufacturer Electrode gap 2050 mm 850 mm 1160 mm 1350 mm 20 910 mm 345 mm 2320 mm 190 mm 220 mm 2000 mm 1115 mm 880 mm 315 mm 22
19. k Remove the throttle cable coupler F 31 and the starter coupler S F 31 by loosening the screws V2 F 31 the pipe clamps and detach the pipes T F 31 Detach the carburettor from the suction manifold after loosening the spring Caution If you are removing the en gine only the carburettor can be left attached to the engine 0000 CHASSIS 2 Disassembly XTM XSM ENGINE e Remove seat tank side conveyors and muf fler Detach the two pipes of the cylinder head heater R F 32 remove the suction manifold screws and detach the spark plug cap P F32 Detach the white green cable from the thermistor F F 32 Detach the neutral cable under the engine near the shift levers and the cables of the flywheel and control unit releasing them from their clamps Remove the mixer cover and disconnect the trans mission Remove the mixer pump by loosening the two Allen screws Empty the coolant circuit by means of the drain age screw on the pump body V F 33 F 32 Remove the head radiator B F 32 and pump radiator L F 33 couplings Remove the pinion cover CAUTION A Before disassembly hold the centre chassis section to prevent the vehicle falling over Remove the lock nut and pull out the fork pin Loosen the nut of the front engine pin and remove the pin Pull the engine out from the left hand side by first pulling out the fro
20. mation and instructions for routine maintenance and servicing This information has been given to us by the engine manufacturers We therefore decline all responsibility for any error omission or misrepresentation MALAGUTI reserves the right to make any changes and modifications hereto it deems necessary without prior notice For further information and details please contact the Malaguti S p A Service Division MANUAL UPDATES Updated pages of this publication will be delivered by us in a reasonable time already punched and therefore ready to be incorporated in the Manual The superseded sheets should not be removed from the manual as they remain applicable to the servicing of pre modified engines he table of contents will be duly updated in the event that new pages are inserted which render the consulta tion of the manual difficult IMPORTANT The Workshop Manuals are to be considered as essential tools to be properly kept up to date so as to maintain their validity over time L200 QOO see 0503 CHASSIS 2 Introduction NOTES FOR EASY CONSULTATION PAGE LAYOUT Chapter ES Section title Date of issue RIGHT HAND PAGE MODIFIED PAGES Modified pages shall bear the same number as those in the previous edition pre modified ones followed by the letter M with the date of issue appearing in the appropriate box Modified pages may contain new illustrations in this case the added
21. nt section RADIATOR e Remove seat and right hand conveyor Caution Before removing the radia N tor drain the coolant using the drain screw on the pump cover V F 33 Undo the screws V3 F 34 and remove the radia tor F 34 3030 CHASSIS Disassembly XTM XSM 2 IDEE IN MOTO SIDE STAND CAUTION A Before disassembly hold the centre chassis section to prevent the vehi cle falling over This operation must be performed with the side stand in its idle position Release the screws M F 35 and undo the screw V F 35 Caution When reassembling use a N high strength threadlocker F 35 FRONT INDICATORS right and left Undo the screw V F 1 Remove the glass cover and detach the lamp sock et cables Undo the fixing screw V F 36 GUARD FRONT WING e Remove front indicators Undo the screws V4 F 37 of the front wing Caution Remember to retrieve the bearings in the bottom section 32 1 900 CHASSIS 2 Disassembly XTM XSM HEADLIGHT e Remove guard Remove the fast ons of the wiring A F 38 and remove the headlight by folding the tabs outwards L2 F 38 To access the lamp open the clip C F 38 Caution When reassembling pay attention to the fast on assembly se quence see wiring diagram DISPLAY F 38 e Remove the front indicators and gua
22. otal 6 5 L Reserve amount 1 81 16 900 F 9i 05 03 CHASSIS 2 Getting to know your motorbike IDEE IN MOTO COOLANT CHECK 1 Remove the cap T F 10i when the engine is cold and exhaust C gr any residual pressure posa is Ef 2 The coolant level must be checked a cold engine since the 1 level varies with engine temperature The coolant should be be ADR tween the minimum and maximum level marks 3 If the level is low add coolant 4 Refit the cap F 10i REPLACEMENT Changing the coolant 1 Park the vehicle on a level surface and put a pan under the radiator 2 Remove the clamp F 11i Detach the pipe U F 11i If you need too much coolant to reach the recommended level or if you need to top up too frequently check the entire cooling system F 11i ENGINE OIL There is an electrical contact inside the tank that turns the red reserve light of the instrument board on when the tank is running out of lubricant To add oil remove the cap T F 12i and carefully pour the oil inside Recommended oil SYNTHETIC 2 STROKE ENGINE OIL JASO FC or ISO LEGA F 12i 3030 17 CHASSIS Getting to know your motorbike TRANSMISSION OIL Replacement Park the vehicle on flat ground 2 Start the engine and warm it up for several minutes 3 Stop the engine Place an oil pan under the engine
23. rd Detach the connector C F 39 and unscrew the fixing screws V2 F 39 THROTTLE CONTROL Remove the MODE button P F 40 by unscrew ing the fixing screw Remove the front cover C F 40 and release the throttle cable G F 40 Remove the knob M F 40 Undo the screws V2 F 40 and remove the throt tle control Caution To reduce friction during knob removal and refitting use com pressed air FRONT BRAKE PUMP Detach the fast ons of the stop switch wiring F 40 Undo the hydraulic transmission screw R F 40 paying attention to oil leaks Loosen the screws V2a F 40 and remove the pump CAUTION When refitting remember to replace the copper gaskets H F 40 and bleed using the relevant equipment R F 40 o503 wwe DO CHASSIS E Disassembly XTM XSM A IDEE IN MOTO CLUTCH CONTROL Detach the clutch cable F F 41 and the starter cable S F 41 and remove the mirror A F 41 Loosen the screws V2b F 41 remove the start er lever body L F 41 and the left hand knob Loosen the screws V2a F 41 and remove the left hand control 0 F 41 HANDLEBAR e Remove right and left controls Loosen the screws V4 F 42 to remove the U bolts holding the handlebar in place N Caution When refitting remember to tighten the front screws first FRONT BR
24. t followed by a number indicate a single screw In case of different screws being referred to in the illustration the letter V is followed by a number and a small letter for instance V4a Unless otherwise specified units and components are reassembled by proceeding in the reverse order of re moval 1 200 OO Cose osos CHASSIS 2 Introduction GENERAL WORK PROCEDURES he advice recommendations and warnings given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents personal injury equipment damage and idle times They should therefore be strictly adhered to ADVICE Only use quality tools and equipment Only use equipment conforming to EU Directives for lifting the vehicle During operations always keep tools and equipment at hand possibly laying them out according to the sequence in which they are to be used Absolutely avoid putting them on the vehicle itself out of sight or in poorly accessible places Always keep the work area clean and tidy When tightening screws or nuts start with the larger diameter or inner fasteners and tighten them in progressive pulls in accordance to a criss cross pattern Preferably use open end box wrenches by pulling and not pushing Adjustable wrenches F 1 should only be used in case of emergency i e when a properly sized wrench is not available they should preferably not be used as the mova
25. tor light This light blinks when the turn indicator is pushed towards left or towards right 2 Low beam indicator light This light comes on when the low beam of the head light is switched on 3 Fuel level warning light This light comes on when the fuel level is low re serve Fill the fuel tank A 1 Coolant temperature warning light This light comes on when the temperature of the coolant is too high When this light comes on stop the engine at once I Neutral indicator light N This light comes on when the transmission is in neutral position 6 Oil level warning light This warning light comes on when the oil level is low 7 Low beam indicator light SWITZERLAND version only This indicator comes on when the low beam headlight is operated ewe 9030 15 CHASSIS d Getting to know your motorbike TIRES Dimensions 80 90 21 48P enduro front 110 80 18 58P enduro rear 100 80 17 525 supermotard front 130 70 17 625 supermotard rear TIRE PRESSURE CHECK Tire pressure must be checked when the tires are cold ENDURO SUPERMOTARD FUEL TANK The tap of the fuel tank is of the pressure type it therefore calls for no manual intervention Unscrew the cap and fill the tank Do not overfill the fuel tank T F 9i Immediately wipe off spilled fuel Use regular unleaded petrol with an octane of RESEARCH 95 Fuel tank capacity T
26. w mirror 24 Horn switch 25 Low beam high beam light switch GREAT BRITAIN version the rear view mirror is on the right hand side of the handlebar FS SWITZERLAND version there are two rear view mirrors one on the right and one on the left hand side of the handlebar SWITZERLAND version only START SWITCH KEYS e The main switch controls the ignition circuit and steering lock F 6i Up to chassis n 7086713 From chassis n 7086714 all electrical contacts are disconnected all electrical contacts are disconnected O the contacts are activated the engine can O the contacts are activated the engine can start start and the lights come on lights are the steering lock is c e the steering lock is 200 IO Cose CHASSIS 4 Getting to know your motorbike IDEE IN MOTO KEYS The vehicle is supplied with two keys featuring a code number which have the following functions e Providing the ignition contact e Turning the lights on Locking the steering system STEERING LOCK Locking turn the handlebar all the way to the right or left push the key in and turn it counter clockwise Disengaging turn the key clockwise SIDE STAND Make sure the sidestand is correctly fitted and that it moves correctly check the spring holding the sidestand in place on a regular basis F 7i DISPLAY 1 Turn indica
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