MOTO GUZZI V 35 Instruction manual

WORKSHOP MANUAL
COD. 19920101

SEIMM MOTO GUZZI SERVIZIO PUBBUCAlJOl\I1 1ECNICH£
COD. 19920101

INDEX
•..............................
MAIN FEATURES
MAINTENANCE OPERAT!ONS
1 Engine ICJbrication
2 Heplacing tho 0:1 c3'tredge in the- sump
:3 Cleam»g Ole wi,c gac.ze filler and the su.1'iP
4 L<Jbricaiion of the gea;t:ox
5 l_ubrica\IQrl Q; :ear driv0 box
6
Lubncatlon 0: iro")t :0[-(
7 Sundry lubncahons
8 Con;rols ar.d inslrurrents
9 Ig"IOo(\ Key
10 lIghl sw;ichos
11 Horr< !lash light .and tum signal control
12 s:ar:n9 and emerger.cy slop swHch
13 R:9ht iron\ bra"e control lever
14 Left iront brake and mar brake co:;lto: peda:
1S Gear ;::;:.n!!01
16 C:ucl f-I!er cao
17 ::ronl sod {\Xu br;"ke fllJi,j resecvo.r
13 Fuel :at)s
19 TerP1:nal :)l;)(:k with fuses
20 Sleerir:g lock
21 Seat locklnq device
22 Side stand
23 AdjJsli;,g the cll.:tch control 'ever
24 Adjusting tho r:gh~ f{o~)t brake 'ever
25 Adjusthg the left fronl brake and the ,ear brake peda!
2& Adjusting the th'o!t!e- centro: gr,p
27 Adjus:,ng the steering
28 Adjus:;),\} the swhging arm P:flY
29 A:ljusl:ng !hB (Sdf suspension
30 Adjusling rocker clearance
31 Lubrication and ffla:ntenanCB operations
pag, 13

" TORQUE LOADINGS
SPECIFIC WORSCHOP
TOOLS
Ii ENGINE UNIT
Removal of engine-gearbox front the frame - Separation of
engine from gearbox
2 Removing the rocker box covers
3 Stripping the cylinder heads
4 Removing the cylinder barrels
5 Removing the compression rings and oil scrapers from the piston
6 Removal of pistons
7 Separating the crankcase covers
8 ReplaCing the seal in timing cover (engine mounted)
9 Dismantling the con-rods
10 Dismantling the crankshaft
11 Removing the flywheel
12 Dismantling the timing group
I, LUBRICATION
1 Removing tile oil sump
2 Dismantling tile oil pump
3 Removing the oil pressure relief valve
4 Oil pressure light switch
5 Removing the oil cartridge front the sump
6 Removing the wire gauge filler from the all sump
CARBURATION
1 Carburettors
2 Carburettor setting
3 Levelling the floater
4 Manual adjuslment of carburation and idling speed
5 Adjusting carburalion using a vacuometer
6 Stripping the carburettor
7 Air filter and breather unit
.:. CLUTCH
I' THE GEARBOX
1 Removing the gearbox from the frame and swinging arm
from the gearbox
2 Clutch housing
3 Clutch
4 Gearbox
5 Gearbox cover
6 Gear-shafts assembly
7 Gear selector
pag. 21
pag. 23
pag. 25
pag. 46
pag. 50
pag. 55
pag. 57

KICK START ER OPERATED MODE L (op t iona l)
SWING IN G ARM CO MPLETE WITH REAR DHIVE B OX
1 Drive box.
2 Swinging arm
FR AME
FR O NT FORK
1 For I< sl ee ve
REAR SU SP EN SION
STEERING
WHEELS
1 Front whee !
2 Re ar wheel
3 lyres
4 Wheel bala ncing
5 Removing an fe- fitti ng lhe lyr es
6 How to check and overha ul the braking cir cu its for the right
flo nl and rear t>rakes
7 Cal iper s l or ri ght f ro nt, left and rear brak es
e P ipe s
9 Bra king dis cs
10 Bra king c:irc:u it fauHs
11 Rec ommenda tions
iii ElE T RI C AL EQUIPM ENT
1 Battery
2 Al ternator
3 R
eg ul ator
4 Rectif ier
5 Starl
er mot or (.4 H P)
6 Slatt
er motor (.7 KW)
7 El ec t ronic ignition
, Ch
ec king igniti on timining
9 El
ectr ic eq uipment
C:i KEY TO WIRING DIAGRAM
using a slrobe
1 Key 10 wiri ng di agra m (Police)
lamp
IN C HE S AND MILLIMETERS CONVERSION C HART
pag. 66
pag. 68
pag. 76
pag. 79
pag. 83
pag. 84
pag. 85
pag. 97
pag. 1 07
pag. 109

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a MAIN FEATURES
V 35
ENGINE
- cycle 4-stroke
-number of
cylinders 2
- cylinder disposition V type, go'
-bore 66 mm
- str oke SO.6 mm
- displacement 346.26 cc
-compression ratio 10 .8
-max output 33 .6 HP al 8100 rpm
- nominal power 5 HP
VA LVE GEAR OHV, push rod operated
- inle t opens 18" before TO C
cl oses 50' afler BDC
-exhaust opens 53 " before BDC
closes 15' after -TOC
-rocker cl ea rance for valve timing 1 mm (.039")
-normal rocker clearance:
- inl el
-exhaust
LUBRICATION
-warning li ght l or insufficient
oil pressure
-oil IiIlers
IGNITION
-maximum advance
- gap bet ween rotor b lock
(on c rank Sha f1 ) and meta l
lips of .. PiCKup ..
- spark plugs
- ignition coi ls
CARBURATION
0.10 mm (.0039")
0.15 mm (.0059")
pressure, lobe type pump .
oil tank in crankcase
on panel board
wire gauze and cartridge
I ype. easily repla ceab le
electronic
34" a\ 5000-5500 rpm
0.15 -7- 0.20 mm (. 0059 -;-- . OO78 ~ )
long thread type dia. 14 x1 .2 5
Marelli CW 9 LP
or Bosch W 260 T 30
or Lodge 2 HLN
or Champion N 6 Y
2
down draught
2 Oell'Orto carburettors
Oel1"OrlO type VHB 24 FO (right)
VHB 24
FS (lett)
V 50
2
V type. 90·
74mm
57 mm
490. 291 cc
10.8
45 HP al 7500 rpm
6HP
OHV, push roo op era ted
ope ns 18" be lole TOC
cl oses SO · aH er BOC
ope ns 53' be fore BOC
closes 15 ' aft er TOe
1 mm (.039")
0.10 mm (.0039")
0
.1 5 mm (.0059" )
pressure, l obe type pump,
oil lank in cr ankcase
on panel board
wir e gauze and ca rlridge
t yp e, easi ly r ep l aceable
el ec troni c
34' at 5000·5500 rpm
0.15 -:- 0.20 mm (.0059 -:- .0078")
l ong thr ead type dia . 14x1 . 2S
Marelli Cw 9 LP
or Bosch W 260 T 30
or Lod ge 2 HLN
or Champion N 6 Y
2
down draught
2 Dell'Orto carbure llors
Oell'Orto type VHB 24 FO (right)
VHB 24 FS (IOH)
9

COOLING
EXHAUST SYSTEM
GENERATOR-AL TERNATOA
STARTING
TRANSMISSIONS
CLUTCH
PRIMARY DRIVE
SPEED CHANGE
-internal gear ratios:
low gear
2nd gear
3rd gear
4th gear
high gear
SECONDARY DRIVE
- ralio
-overall gear ratios:
low gear
2nd gear
3rd gear
4th gear
high gear
CYCLE PARTS
FRAME
SUSPENSIONS
10
V3S
by air
dual exhaust pipes and
silencers, interconnected
fitted on front end of
crankshaft (1 4 V - 20 A)
electric slarter,
pedal starter on request
dry tipe, single plate with
diaphr3.gm spring.
controlled by lever on
left side of handl€bar
helical gears. Ratios:
1 to 1.846
(13-24)
5 speeds, constant mesh gears,
frontal engagement, foot
controlled on left side
of machine
1 \02.727 (11/30)
1 to 1.733 (15/26)
1 to 1.277 (18/23)
1 to 1.045 (22/23)
1 to 0.909 (22/20)
cardan shaft with bevel gears
1 to 3.875
1 to 19.506
1 to 12.396
1 to 9,134
1 to 7.475
1 to 6.502
tubular structure, cradle type
telescopic front fork with
hydraulic dampers
rear swinging arm with
externally adjustable springs
vso
by air
dual exhaust pipes and
silencers, interconnected
fitted on front end of
crankshaft (14 V - 20 A)
electric starter,
pedal slarter on request
dry tipe, single plate with
diaphragm spring.
controlled by lever on
left side of handlebar
helical gears, Ratios:
1 to 1.642 (14-23)
5 speeds, constant mesh gears,
frontal engagement , foot
controlled on left side
of machine
1 to 2.727 (11/30)
1 101.733 (15/26)
1
to 1.277 (18/23)
1 to 1.045 (22/23)
1
to 0_909 (22/20)
cardan shaft with bevel gears
1 to 3.875
1 1017.351
11011.026
1to 8.125
1 to 6.649
1 to 5,783
tubular structure, cradle type
telescopic front fork with
hydraulic dampers
rear swinging arm with
externally adjustable springs

V35 V 50
WH EE LS
single piece fight alloy casting si ngle pi ece li ght alloy casting
-front
WM 2/ 1,85 x18" CP2 WM2 / 1. 85 x 1 8"CP2
- r ea r
WM3 / 2,1 5x 18" CP2 WM 3/2,15 x
18" CP2
TYRES
-front
Pire lli 90/90 S 18 or 3.00 • 18 Pire lli 100/90 S 18 (MT 1 5)
Metzeler 3.00 - 18 A (B l ock C 5) Metz et er 3.25 - 16 A (Block C 5)
Michelin 3.00 - 16 A (M 38)
Mich elin 3.25 -18 H (M 38)
- r ear
Pirelli S 18 (r ibbed ) Pirelli 100/90 S 18 (MT 15)
Metzeler 3. 00 S 18 (B l OCk C 5) Me lzeler 3.50 S 18 (BlO Ck C 66)
Mic he l in 3.00 S 18 (M 38) Michelin 3.50 S 18 (M 38)
BRAKES
-front disc type
wit h 2 cyli n der s di sc type with 2 cylinders
opera t ed by caliper. ope rated by caliper.
lever co n trolled from the right lev er c ontro ll ed from the rig ht
s
ide ha n dlebar with cab le side hand leba r with cable
co nnectio n from l eve r to con nection from lever 10
mas t er cy lind er. master cylinder.
hvdraulic tran smission hydraulic tr ansmi ss ion
independant
fro m to e rear brake independa nt from the rear brake
di sc di a. 260 mm (20.23"') dis c dia . 260 mm (20.23")
cylinder dia. 32 mm (1 .25") cyli nde r dia. 32 mm (1 .25")
master cy li nder dia. 12 .7 mm (.5") naster cylinder di a. 12.7 mm (.S")
-rear
disc lype w ith doub le cylinder
disc type W ith doub le cyli nd er
fixed caliper. fixed caliper .
pedal opera ted from the peda l operated f rom 1he
right hand si de of the machine. right hand si de of th e mac hine .
cont rol by metal rod from co ntro l by metal rod from
pedal to master cyli nder . pedal to master cylinder.
disc dia. mm 235 (9.25") disc dl3. mm 235 (9.25")
cy lind er dia. 32 mm (1.26") cy l inder dia. 32 mm (1 . 26" )
mas t er cylind er dia . mas ter cylind er dia .
15.875
mm (.6 24) , 5.875 mm (. 6 24)
hydrauli c tr ans mis sion
hydraulic transmission
the rear
brake conn ectio n is th e rear brake c onnection is
by
hydraulic trans mis sion by hydra ulic tran smissio n
In common with a second Irani
in common with a second front
brake of same sizes as the hand brake of same sizes as Ih e hand
lever operated ri ght front brake l eve r operated r ight front brake
OVERALL DIMENSIONS
AND WE IGHTS
-wheel base (fully l oaded)
1. :395 mls (54.5 ") 1.395 mls (54.5 ")
-length 2.080 mts (82·') 2.080
mts (B2")
- width
0.750 O1m (29.85") 0.750 mm (29.85")
-heigth 1.035 (39.''') 1.035 (39.4")
-weiglh (d'y) 152 kg (303 Ibs) 152 kg (303 tbs)
11

PERFORMANCES
-max speed, solo rider
-fuel consumption
FUEL AND OIL CAPACITIES
- fuel tank
- reserve
-sump
- gear box
- rear drive box
- front fork (each Jeg)
- front and rear
braking circuits
12
V3S V 50
abt 150 km/h (93 mph) abt 170 km/h (105 mph)
3.7 Its (77 mpg Imp. 63 mpg USA) 4 lits (70 mpg Imp. 58 mpg USA)
16.5 Its (3.6 91. Imp. 4.1 gl. USA)
petrol 98/100 NO-AM
2 Its. (3
1
12 pints Imp.
4.2 pints USA)
2.25 Its. (4 pints Imp.
4.7 pints USA)
oil Agip Sin! 2000 SAE 10 W/50)
1 It. (2.1 pi nls USA
1.75 pints Imp.)
oil Agip F.1 Rotra MP (SAE 90)
0.170 Its. (10'/; cu. in.)
of which 0.160 (10 cu. in.)
of oil "Agip F.1 Rotra MP
SAE 140"
and 0.010 ('h cu. in.)
of oil ~Agip Rocol ASO/R"
0.070 It. (2-45 oz. Imp.
2.38 oZ. USA)
liquid Agip F.1 ATF Dexron
fluid Agip F.l Brake fluid
(SAE J 1703)
16.5 Its (3.6 gl. Imp. 4.1 gl. USA)
petrol 98/100 NO-RM
2 Its. (3
1
/2 pints Imp.
4.2 pints USA)
2.25 Its. (4 pints Imp.
4.7 pints USA)
oil Agip Sint 2000 SAE 10 W/SO)
1 It. (2.1 pints USA
1.75 pints Imp.)
oil Agip F.1 Rotra MP (SAE 90)
0.170 Its. (101 1> cu. in.)
of which 0.160 (10 cu. in.)
of oil «Agip F.1 Rotra MP
SAE 140"
and 0.010 ('I> cu. in.)
of oil «Agip Rocol ASQ/R"
0.070 It. (2.45 oz. Imp.
2.38 oz. USA)
liquid Agip F.1 ATF Dexron
fluid Agip F.1 Brake fluid
(SAE J 1703)

B MAINTENANCE OPERATIONS
Th e elfieieo ey and con se rvation of the va rious en-
gine and (ramo compo ~ e n ts are largely dependa nt
on an accurate and periOdical maintenance.
The indicated peri OdS and mileages for the va rio us
operations apply to a ve hicle used normally.
II the motorcycle is used on (lusty or unasphalled
( oa ds or at continuous high speed on motorways.
more frequent co ntrols are necessary Any time your
byke undergoes any impact for any reason whatever.
co ns ull yo ur dealer, al so in case 01li gh t imp ac ts.
Each vehi cle is su pplie d with a suitable sel of 1 001S
lor emergency operations.
2.1 ENGINE LUBRICATION (Fig.
5)
011 level check : every 500 km (300 mi les) or so ch ec k
the oi l level in t he crankcase. The oi l sho uld lust
sk im the top mark on dip S li ck .. A ,. . II not t op up
With oil 01 sa me brand and sp ec ificat io n.
This ch ec k should be carried out when the engine
has run a s hari while and wilh I he f iller cap f ully
sc rewed in.
011 change: every 500- 1 000 km (300-600 miles) and
th en every 3000 km (1 800 miles) chan ge the oil in
the cra nkc ase. Do this on a warm e ngine and allow
all the old oil drain com pl etely from the drain plug.
.. A~ = oil filler cap.
~B~ = rear oil drain cap.
.. C~ =f ro nt oil dr ain cap.
Quantity required : 2.250 li S. (a b" half Imp. gl. -. 47
US gt.).
2 .2 REPLA CI NG THE OIL CARTR IDG E
IN THE S
UMP (fig. 6)
After the fi r st 5()().. 1000 km (300-600 mil eS) and then
every 6000 km (3600 miles). r
ep l ace the cartridge in
the oil s ump as fOllows:
• undo drain caps .. A .. and .. 8 .. fr om sump " C",
• allow all the old 0 11 10 drain from'the sump:
also
fi ll er cap "A .. in fig. 5;
• undo lh e screw and washer securing cartridge
" H ~ and wi th draw lhe cartridge assembly complele
with cover uE", gaskel "F", spring "G" and cartrid-
ge ~ H ";
• replace cartridge "H .. and if necessary seal "F»
on covar "E".
Ra -assemble the complete unit reversing the disman-
tling se quence and In tr oduce the specified quant ity
of
oi l be lore screwing down the filler cap.
- - H
§ :---- G
o F
~ ,---_ E
D
, 5
6
7
13

•
8
9 ~\
14
2.3 CLEANING THE WIRE GAUZE
FILTER AND THE SUMP
After the 'i, st 500-1000 km (300·600 miles) i.e. after
the first oil and c artri dg e cha nge , and th en every
15.000 km it is a good rule to di sma ntle the oil sump
fr om the cran kc ase, t ake out I he wir e gauze Iiller
a nd to thorough ly cl ean e very thi ng in a pe tr ol bath.
Then
dry off the l iller and oil ways in t he su mp with
comp ressed air. In re- assemb l ing the sum p don ',
f or get to rep l ac e its ga s ke t.
2.4
LUBRI C ATION OF THE GEAR BOX (Fig. 7)
Checking the oil level : every 3000 km s (1800 miles)
ma ke sur e that the 0.1 level skim s fi ll er cap «A n. If
not, t op up with oil 01 same qu ality and density t ill
II sta ns seeping throug h t he leve l p lug .
Oil change
Every 10. (X)() km s (6000 mil es ) or so the ge arb ox oi l
should
be repl ace d
ThiS ope ration shoold be don e when Ihe g earb ox is
warm
as in Ihi s condlh on the oil IS fl oi d and more
eas il y drained.
All ow a ll the old oil to drain co m pl etely be f or e int ro-
ducing new oil.
.. A ~ = oi l fi ll er plug.
~B ~ = drain p lu g.
Qua n tity : 1 lit er of Ag lp F.l Rotra MP 90 (1.16 pi nt s
Imp. · 2.11 pi nts USA).
2.5 LUBRI C ATION OF REAR DRIVE BOX (fig. 8)
Checking oil level
Every 3000 km (l aOO mi les) ensu re Ihal the oil ski ms
!i ll er and l ev el plug ~A~. If l ow er, t op up wit h 011 01
sa me q uality and d ensity.
Oil c hange
Ev ery 10000 km (6000 mi les) or so repl a ce the oil in
the box. This o pe rati on is besl carri ed out with the
box
wa rm as in this con dit ion t he oil is flu id and mo-
re ea sily dr ained.
Be fore introdu cing any fresh oil. ensure t he old one
has com pl et ely dr ai ned.
"A ~ = I ille r and level plug .
~B ~ = ve nt plug.
"
C" = drain pl ug.
Quan
tity . 0 .1 70 I. (5 .9 oz. Imp . - 5.75 oz . U SA ) of
wh i ch 0.1 60 It. (5.6 oz. Imp . - S .4 oz . US A) Agi p F.l
Ro lr a MP SAE 90 and 0.010 II. (.35 oz. im p. and .034
oz . U SA) of Agip Roco l ASO/ R.
2.6 LUBRIC ATION OF FRONT FORK
(EACH LEG) (fig. 9)
P rocee d as fo ll ow s:
• undo dr ai n p lu g an d wa sher .. A .. ;
• u nd o Allen fi ll er sc rew "B~ .
All ow all the o ld al l to d lai n before an y fresh l iqu id
is intr od uced .
•,A" = dra in sc r ew .
~ B ~ '"" f ille r screw.
Qu ant ity' 0.070 II. (2.45 oz . Imp . - 2.38 oz. USA ) of
A gip F.l ATF D exro n in each leg .

2.7 SUNDRY LUBRICATIONS
Lubricate pe riodic ally:
•
•
•
•
•
2.8
steering cups and balls;
swinging arm bearings;
co
ntr ol cable terminals;
articulations 01 prop stands;
speeda
drive .
CONTROLS AND INSTRUMENTS
Panel board (Iig. 10)
1 speed om eler (with p Cl rti Ci I zero rese t) ;
2 rev-co unter;
3 warning light. ne utral indi cator (ora nge ). li gh ls
up with gear change in neut ral po sit ion . ( 0):
4 (I) warning lig h t, parking lig ht (green);
5 (oil) warning li gh t. Oil pressure gauge. Goes out
whe n pressure is suUiclenl for e ngine lub r ication .
If it does not go out. pressure is inco rrect and the
engine
should be immediately stopped for the ne-
ce ssary co n tro ls;
6 (h) warning light (bluo ). high beam "O N»:
7 (gen) warning l ight (red) indi cating current deli-
very from generator. Goes oul when the engine rea-
ches a ce rtain numb er 01revol utions .
Wh en driving in dayligh t, all lights sho uld be off. At
ni ght time the tow beam or eventually the high beam
only
should be lit
2.9 IGNITION KEY (fig. 10)
Th e key has 3 po s il ions:
" OF F ,. In line wi th releren ce ma rk on panel. Ma-
chine a\ stan dsti ll. key re mov able;
"A.. In line wit h referen ce mark on panel (t urned
clockwise) . Mac hin e ready to be st ar ted. All con tacts
"ON .. , key not remo va b le:
" 8,, In line wlltl ref erence mark on panel (turned
clockwise ). Machine stopped. Wi th s wit ch "A ,. (fig.
11) in position " O ~ the parking light s are "O N ". key
removabl e.
2.10 LIGHT SWITCHES (fig. 11)
Are located on lett hand side of th e byke
Switch "A" co ntrols:
•
•
•
park i ng lights (position ,,0» ):
ri di ng lighls (position .. 1 .. ):
lig hts o lf (posit io n .. 2,.).
Switch «B ,.
With switch "A~ in pOSition .. 1 _:
•
•
low beam "ON .. (positio n ,,3,,);
high beam "O N» (position « 4» ).
'0
11
'2
'3
15

15
16
16
2.11 HORN, FLASH LIGHT AND
TURN SIGNAL CONTROL (fig. 11)
On left hand side of the handlebar.
Bullons "C ..
,,5.. ho rn :
,,6.. fl as h light.
Switch "0 ,,
•
•
",7 " co ntrol lo r ri gh t !U rn s ignal ;
.. 8 .. control lor left tu rn signal.
2. 12 ENGINe S TARTING AND EMERGENCY
STOP SWITCH (fig. 12)
On ri gh l hand si de of han dleba r.
With
ignition k ey (fig. 10) in p os iti on .. A .. th e machine
is re ady to be s tart ed.
To sta rl the engine:
•
•
se t swi t ch " 8 ,, \0 position .. 1» (RUN);
pull crut ch lever full y;
• on a cold en gine. move star ter le v er (fig . 82) to
posi ti on "A" (START);
• pr ess button "A" (Slart).
F or an emer gency stop:
• mov e sw itch " B" to position «2» (OFF),
As soo n as the engine is stopped, turn ignition key
(See fi g. 10) clockwise to the point wh ere mark
~ OFF" is lined up with the panel mark and w ithdr aw
the key.
2.13
RIGHT FRONT BRAKE
CO NTROL LEVER (~F." fig. 1 2)
It is on Ihe f ight side of the hand le bar and con t rols
t he r ig ht Ir on t b rake .
2.14
LEFT FRONT BRAKE AND REAR BRAKE
C ONTROL PEDAL ( .. 8 », li g. 13)
Th is pe dal is l oca ted on the ri gh t s id e of t he ma ch in e
an d if is li nk. co n nec t ed to the ma ster cy lin der.
It oper ates both t he fr on t l eft b rake and the rear
br
akes al the same ti me .
2.15
GEAR CONTROL (fig. 14)
The
con trol pedal is located on the left side of the
machine and has two positions :
• <dow» -Lev er towards the ground:
• 2nd. 3rd, 4th, 5th - Lever upw ards:
• neutral - in between low and 2nd ge ar.
Before changing gear, donI forget to pull the clu tch
lever completely.

2.16 FUEL FILTER CAP (fig. 15)
This
cap is op e ned by pr ess ing bull on «A".
2.17 FRONT AND REAR BRAKES
FLUID RESERVOIR (fig. 1 6)
Press bullon "A" (fig. 15) to get acce ss to this and
to raise the cover with ca p.
To
check the fluid level, remove cap ,, 8 .,. from reser-
voir «A» and ens ur e the ilui O top s alw ays the sepa-
rator which divides the reservoir in tw o parts. one for
the
front br a!c e and lh e ot he r lor lh e rear brake .
2.18 FUEL TAPS (fig. 17)
A re l oc ated al lhe rear of Ihe f ue l tank s. The t ap s
lever (
FUEl) has 3 p OS itions:
.. ON " open, ve rt i ca l, up wards:
~RES " rese rve, ver ti ca l. d ownwa r ds ;
" OFF ~ cl osed. h orizon tal.
2.19 TERMINAL BLOCK WtTH FUSES (fig. 18)
It is centr ally lo cated on Ih e machine s. It is accessi-
ble by raising the seat (See Ch apter « Seat locking
dev ice .. ) and removing th e cove r after undoing the
screw securing it to the fuse holder box.
This box cont ains 4 fuses «16 A» .
•
Fu se 1 - R ear s to p lig ht - Fl aSh,
• Fu se 2 - Stan er re lay, rear b ra ke stop light , flash
ligh t relay, horn.
• Fuse 3 - Warn i ng lig ht s (GEN- OIL - n) . high beam
a nd ils i ndi tato r ti gh t. lo w beam .
• Fuse 4 • Par kin g li gh ts - panel lighl s - W arning
li gh t «I ».
Belare re pl aC in g any fu se it is necessary 10 l oo k fOf
and ·e lim i nate the cause f or its burning.
2.20 STEERtNG LOCK (fig. 19)
To
lo ck a nd unl oc k Ihe ste ering , proceed as follows:
Locking
Turn Ih e handl eba r tully 10 Ih e right.
In ser l lh e key i nl O the l oc k se t. lurn it co unlerclock-
wise and p us h it f ull y in, release it. and take il ol f.
Unlocking
Insert Ih e k ey inl O t he l oc k se l. turn it co unl erclo ck-
wise, release it a nd s lip i1 0 11.
17
17

20
21
18
2.21 SEAT LOCKING OEVICE (fig. 20)
It is located at the left rear end of the seal
To uniock
Operate on lever "A,. shifti ng it t owards the fronl
wheel (See arrow) so as to unh ook hooks .. 8 .. that
keep I he seal secured 10 the device. Then lift Ihe
seat.
To lock
L ower Ih e seat until hooks «E» snap.
2.22 SIDE
STAND ( << A .. fig. 21)
Th
is st and should be used only for brief sl ops . When
r e-starling ensure it is fully raised or else serious
trouble may o cc ur . The pictu re shows the fir st type
of side st and : the second type has 2 return s prings .
2.23
ADJUSTING THE CLUTCH
CONTROL LEVER (fig. 22)
If the play at the handlebar lever is more or less
than 3-4 mm (1/8 ") ope r ate on adjuster «A» to obtain
the correcl distance .
Th
is adjustm ent can also be made by lo os ening
co un ternu ts ~ C" and operating on adju ster .. 8 .. , T he
co unternuts are located on the right hand side of the
gearb ox.
2..24 ADJUSTIN G THE RIG HT FRONT BRAKE
LEVER (fig. 23)
This lever shou ld be adj usted when the play al Ihe
handlebar is more or les s than 3-4 mm (1/ 8"). Ope-
rate on thu mb screw "A .. to obtain the correct play .
This adjustment can al so be made by opera ting on
ad
lus ter «8 » aller sl aCkening co unternuts ~C».
2.25 ADJUSTING THE LEFT FRONT BRAKE
AND THE REAR BRAKE PEDAL (fig. 13)
Chec k the play betw een master cylinder control lin-
kage ad control l ever .. I.. as follows:
• set up a leeler gaug e .. A ,. between linkage and
lever end;
• a dmi s sible play : 0.005 -0.15 mm (.00 19- .00591 .
If the play is nol w ith in these limits :
Remove c
otte r pin .. C". withdraw pin <. D» , loo sen
cou nl ernut "E,. and screw in or out fork .. F» untif the
idea l position for pe<lal .. 8 .. is found. Re-fit pin relain-
ing rod <t o .. a nd colte r pin .. C».
Finall
y, l oosen counl ern ut .. G» and adjust l ever «H»
return sp ring .

2.26 ADJUSTING THE THROTTLE CONTROL GRIP
( .. E ~ fig. 12)
To
ad just the travel Of the t wi st gr ip . SCr ew in or
out screw .. 0 .. .
To harden the retu rn of the grip . scr ew in or ou t
screw .. C».
2.27 ADJUSTING THE STEERING (fig. 2 4)
For safe riding, the st ee ring should be so ad justed as
to allow free movement to the ha ndlebar but without
excessive play.
To take up excessive play:
III loosen steering head fixing bolt "A,.;
• undo st
ee ring head sec uring nul "a .. ;
• Sc rew in or oul adjuster .. C .. by m ea ns of a ce n-
t er punch un til the co rr ect pl ay is o bt ained.
AH
er th is has bee n don e, r oc k nul .. 8 .. and sl eeri ng
head
fi x ing bolt .. A,..
2.28 ADJUSTING THE SWINGING ARM PLAY
(fig. 18)
The swinging a rm h as to oscillate freely wi thout any
play.
It is prope rl y adjusted when both end spindles pro-
ject by th e s am e amount. Ttlis adjustment is made
using speCial tool n. 10903100 (45 in
fig . 25). At the
end
01 t hiS operation tight en both nuts "A».
2.29 ADJUSTING THE REAR SUSPENSION (fig.26)
The external spring of the re ar suspension can be
a dju sl ed to 3 p os itio ns by means 01 sp a nne r "A .. in
the 1
00 1 kit.
If the
damp ers' act ion is ir re gul ar , have Ihem ch ec-
ked by your deale r.
Don'l forg el th at gOOd machine stab ilily dep ends
on both dam pe rs being adjus ted to t ile same po-
si ti on.
2.30 ADJUSTING ROCKER CLEARANCE (fig. 27)
This ad justment h as to be done in strict accordance
with the pr escribed valve gear ing timing diagram and
on a COLD ENGINE
with piston at TOG, i.e with both
valves clos
ed al tho end 01 the compre ssion stroke .
Adjust by removing
the r ocker box cover, as follow s:
1 slacken nut ~ B ~:
2 sc re w in or ou\ adjuster «A»:
3 insert th e feeler gauge «C .. blade between valve
and rocker and ensure play is as specifie d i .e . 0.10
mm (.0039") for the inlet valve and .015 mm (.0059")
l or Ihe exhaust valve.
Finally. keep a firm hold on ad just er .. A" and li ghten
nut "B".
23
24
19

27
20
2.31 LUBRICATION AND MAINTENANCE
OPERATIONS
Monthly (or every 3000 km • 1800 miles)
Check the electrolyte level in battery.
Periodically
Check tyre pressure.
lubr ic ate cable end s and prop st and s a rticulations .
Ev ery SOO km (300 miles)
Check oil level in crankcase.
Aft er the first 500-1000 km (300-600 miles)
Replace t he c rankca se oil.
Che ck tight ness of all nut s an d bolt s.
Check ro ck er clearance.
Every 3000 km (a bl 2000 miles)
R~place the cran k case oil.
Che ck rocker cl earance
Che ck oil level in gearbox .
Check oi l level in rear drive box.
Every 5000 km (3000 miles)
Ch ec k brake flu id level in reservoi r.
Every 6000 km (3600 mlles)
Replace the oil filter c ar.ridge in suml;'.
Ellery 10.000 km (6000 mile s)
Repl ac e t he air lilter cartridge .
Cl ean the fuel tank, filte rs, taps, a nd fuel line s.
Repla ce the ge ar b ox oil.
Cl
ea n and gre a se all ballery co nne c tions ,
Every 15.000 km (9000 miles)
Repl ac e the fluid in the braking c ir cuits.
Every 20.000 km (12.000 miles)
Che ck condition of wheel bearings .
Ensure that all
steering bearings and c up s ar e well
gr ease d.
Re
plac e the oil in the fork legs.
Clean the sta rter motor and generator co mmut ators
with 8
pe trol moistened rag .