Polini XP 65 R User manual

USE AND MAINTENANCE MANUAL
XP 65 R
XP65R_instructions.qxd 5-09-2007 10:45 Pagina 1

FOREWORD
INSTRUCTIONS MAY BE REPEATED A NUMBER OF TIMES
IN THE COURSE OF THIS MANUAL.
THIS HAS BEEN DONE PURPOSEFULLY TO EMPHASISE THE
IMPORTANCE OF CERTAIN OPERATIONS AND THE NEED
TO BEAR SAFETY CONSTANTLY IN MIND.
ALL ENGINE MAINTENANCE MUST BE REFERRED TO A
SPECIALIST DEALER.
IMPORTANT
Read this manual carefully throughout before riding your
new motorcycle.
This manual contains important information that will help
you avoid causing unnecessary damage to the machine and
serious or even fatal injury to yourself, to other persons and
things.
To ensure care-free and satisfying offroad riding you must
get to know your new motorcycle thoroughly and set it up
correctly before you start riding.
IMPORTANT LEGAL NOTICE
THIS MOTORCYCLE HAS BEEN DESIGNED AND
MANUFACTURED EXCLUSIVELY FOR COMPETITION USE
AND IS SOLD “AS SEEN” WITH NO WARRANTY.
THIS MOTORCYCLE DOES NOT COMPLY WITH CERTAIN
ROAD SAFETY REGULATIONS AND IT IS THEREFORE
ILLEGAL TO RIDE IT ON PUBLIC ROADS, HIGHWAYS AND
MOTORWAYS.
APPLICABLE LEGISLATION PERMITS THE USE OF THIS
MOTORCYCLE ONLY IN ORGANISED COMPETITIONS OR
CLOSED TRACK SPORTING EVENTS ORGANISED IN
COMPLIANCE WITH LOCAL BY-LAWS.
ALWAYS ENSURE THAT IT IS LEGAL TO OPERATE THE
MOTORCYCLE BEFORE RIDING IT.
IT IS STRICTLY FORBIDDEN TO CARRY PASSENGERS.
This minicross motorcycle has been designed and
manufactured for use by one rider only.
NOTE
Children must always be supervised by an adult when riding
this motorcycle.
READ THIS MANUAL CAREFULLY.
CAUTION!
This text identifies a risk of serious or even fatal
personal injury if the associated instructions are
not followed. The associated instructions must
be followed carefully to avoid damage to the
motorcycle.
WARNING!
This text identifies a risk of personal injury or
damage to the motorcycle. The associated
instructions must be followed carefully to avoid
serious or fatal accidents.
This manual is an integral part of the motorcycle and must
accompany it if it is sold or transferred to a new owner or
keeper.
WELCOME NOTICE
Congratulations on your choice of a Polini minicross
motorcycle. By purchasing a Polini motorcycle you have
become one of a large family of satisfied Polini motorcycle
owners and riders.
NOTE!
This Polini minicross is a high performance
competition motorcycle and incorporates the
latest motocross race technology. It must only be
used in competitive racing by expert riders.
This new Polini minicross model has been designed to
perform as competitively as possible.
Motocross is nevertheless a physical sport and winning
requires more than just a good motorcycle.
To achieve good results you must be in good physical
condition and be a skilful motorcycle rider.
The best results are achieved by riders who exercise
regularly to keep in peak physical form and who practise
their motorcycling skills frequently.
The purpose of this manual is to help you get the greatest
satisfaction possible from you new Polini minicross
motorcycle, both from the performance of the machine itself
and from success in competitions.
PERSONAL PROTECTIVE EQUIPMENT
1- Most deaths in motorcycling are caused by head injuries.
ALWAYS wear a helmet. Whenever possible, also wear a
visor or goggles, as well as protective boots, gloves and
clothes.
2- The exhaust system becomes extremely hot during use
and may remain so for quite some time afterwards.
Do not touch any parts of the exhaust system.
Always wear clothes that completely cover your legs.
3- Do not wear loose or flowing clothing. This can become
entangled in the control levers, kick-start lever, footrests,
chain or wheels.
4- Respect the environment.
DANGEROUS MODIFICATIONS
MODIFICATIONS TO OR THE REMOVAL OF
ORIGINAL PARTS FROM THIS MINICROSS
MOTORCYCLE MAY CAUSE IT TO BECOME UNSAFE
OR ILLEGAL. ALWAYS COMPLY WITH ALL LOCAL
AND NATIONAL LAWS, REGULATIONS AND
SAFETY STANDARDS.
THIS MOTORCYCLE HAS BEEN PROJECTED FOR A
DRIVER UNDER A WEIGHT OF:
_ 60 KGS
ENGLISH
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ENGLISH
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ENGLISH
3
For your own safety and for the best performance of your
motorcycle, always insist on original Polini Motori spare
parts for all repairs.
To be able to recognise your motorcycle and to keep track of
its identity in case of theft, make a note here of its specifica-
tions and frame number:
MODEL:
ENGINE CAPACITY:
TYRES: Front. Rear.
FRAME NUMBER:
IDENTITY CODE: 144.000.
LOCATION OF VEHICLE IDENTITY CODE
The motorcycle’s identity code is stamped on the front of the
frame or on the right hand side of the steering head.
1. PREPARING YOUR MOTORCYCLE FOR USE
When you first open the crate you will see that the
motorcycle is not ready for use, but has been partly
disassembled for reasons of packing and transport.
Carefully unpack all the parts from the crate and proceed as
instructed below to check and assemble your motorcycle for
use.
The following instructions give the most practical order for
assembling the various parts of your motorcycle.
1- Remove the motorcycle from the crate (photo 1).
2- Remove all the parts needed to reassemble the motorcycle
from the crate and check them thoroughly (photo 2).
WASHER 6X18X1 No. 4
PLASTIC TIE No. 1
FRONT WHEEL SPINDLE No. 1
WHEEL SPINDLE SPACER No. 1
M12 WHEEL SPINDLE NUT No. 1
FOOTREST SPRING No. 2
TCEI SCREW M8X40 No. 2
TB SCREW M6X16 No. 4
TBEI SCREW M6X40 No. 1
NUMBER PLATE No. 1
NUMBER PLATE SPACER No. 1
RIGHT FOOTREST No. 1
LEFT FOOT REST No. 1
M8 SELF-LOCKING NUT No. 2
TCEI SCREW M8X75 No. 4
HANDLEBAR CLAMP No. 2
HANDLEBAR CLAMP SPACER No. 4
HANDLEBAR WITH FOAM ROLL No. 1
FRONT WHEEL WITH DISK No. 1
FRONT MUDGUARD No. 1
3- Fit the rear shock-absorber, using the M10 hexagonal
head screw and the two washers with the M10 nut.
Fit one of the washers at the bolt side and the other at the
nut side. The nut, bolt, spacers and washers have been
pre-fitted in their seats on the swinging arm (photos 3).
4- Open the front brake disk pads.
5- Fit the front wheel using the special spindle; fit the spacer
on the disk side of the wheel
6- Insert the spindle and the nut and tighten with a torque
wrench (See section 6.2) (photo n.4).
1
2
3
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7- Tighten the spindle locking bolt with a torque wrench
(See section 6.2) (photo 5).
8- Inflate the front and rear tyres (See section 4.12).
9- Fit the front mudguard with the provided 4 screws and
the TBM6X16 washers (photo 6).
10- Cut the transport tie securing the front brake master
cylinder. Fit the handlebar and fix it to the top fork with
the two handlebar clamps and the four Allen bolts
M8X75 (See section 6.2) (photo 7).
11- Regulate the front fork height as per photo No. 8
(see section 6.2 for tightening torque)
ATTENTION! For safety reasons the front fork must be
extracted within notch No. 4 (minimum) and No. 5
(maximum) (photo No. 8).
12- Remove the throttle control cover and fit the cable as
shown in photo 9. Re-fit the cover. (See section 4.9).
13- Fit the front brake lever and secure the clamp with the
provided screws
14- Fit the engine stop button and fix it to the handlebar
with its mounting clamp
15- Fit the clutch lever and adjust the travel of the lever as
you prefer using the regulator (photo 10) (See section
4.11). Fit the number plate fixing it with the related
spacers and screw TBEI M6X40 and insert the front
brake cable in the slide.
16- Fit the footrests (photo 11)
17- Fill the engine coolant circuit
(See sections 4.5 and 4.6) (photo 12).
ATTENTION! While filling the cooling system,
open the draining screw on the left radiator till
the liquid comes out.
4
ENGLISH
8
9
5
7
MINIMUM 4 NOTCHES
MAXIMUM 5 NOTCHES
6
4
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CAUTION! The coolant circuit is normally drained for
transport. Make sure that it is topped up before starting the
engine.
18- Take off the protection cap (photo No. 13) and check
the oil level (See section 4.3).
19- Fit the gear lever (photo 14).
20- Fill the fuel tank (See section 4.16).
INTRODUCTION
Always ensure that the motorcycle has been efficiently
serviced and check it over before riding it. Take your
motorcycle to an authorised POLINI MOTORI dealer for all
major servicing and repair.
Because of the manufacturer's policy of continuous
development, and because of constant innovations in
technology, your motorcycle may differ in some details from
what described in the illustrations and text in this manual.
Original POLINI MOTORI spare parts are always made of
the same materials and in the same way as the parts
originally fitted on your minicross motorcycle to ensure a
longer life and improve efficiency to your motorcycle.
Always use original POLINI MOTORI spare parts.
2. STARTING THE ENGINE FOR THE FIRST TIME
Always check over your motorcycle thoroughly before
starting the engine. To start the engine for the first time,
proceed as instructed below.
1- Remove the radiator filler cap.
2- Fill the cooling system with coolant up to the top rim of
the radiator (photo 12). Wait a few minutes for the
coolant to circulate through the system. Top up the
radiator as necessary if the coolant level drops.
3- Screw the radiator filler cap back on tightly.
4- Before starting the bike, check that the gear is at the
neutral position (photo No. 15, gear N)
5- Open the fuel cock located under the fuel tank: position
ON (photo 16).
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ENGLISH
12
13
14
10
11
15
N
1°
2°
3°
4° 5° 6°
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6- If the engine is cold, lift the choke lever on the carburettor.
WARNING! Lower the starter lever again as soon as the
engine starts to warm up.
7- Leave the throttle closed. Pivot the kick-start lever
outwards and push energetically downwards with your
foot to start the engine.
8- Return the kick-start lever to its rest position. Leave the
engine idle for a few minutes to warm it up.
9- Switch the engine off and remove the radiator filler cap.
Check the level of coolant inside and top up as necessary.
10- Screw the radiator filler cap back on tightly. The
motorcycle is now ready for riding.
WARNING! Risk of burns! Only check the coolant level
with the engine cold and switched off.
NOTE. Motocross competition rules forbid the use of coolant
other than water.
WARNING! Never open the throttle abruptly. The
motorcycle could jump forwards, causing you to loose control.
WARNING! Check that the engine stop button stops the
engine effectively before you begin riding the motorcycle.
3. RUNNING IN
1- Run your new motorcycle in as instructed below to ensure
that the engine and transmission bed in correctly and to
ensure continuous reliability in future.
CAUTION! The first time you ride your new motorcycle,
ride for about two hours at low engine speeds to ensure that
it runs in correctly. Also respect the following precautions.
2- Once the engine starts, leave it idle until it warms up to
normal temperature. If you switch the engine off for a
short time, wait for it to cool down completely before you
re-start it.
3- During the running in period, always ride at constant
speed. AVOID RAPID ACCELERATION.
4- Even when riding at low engine speeds, avoid extended
difficult sections of road or track that could cause the
engine to become very hot.
5- Once you have run in your motorcycle following all these
instructions, take it to a Polini Motori dealer for its
post-running-in service. Apart from a change of spark
plug and engine oil, this service also includes the
disassembly of the cylinder to check on the condition of
the spark plug, cylinder head, piston and cylinder.
The service also includes the replacement of the spark
plug and of the transmission oil.
CAUTION! Scored pistons can lead to a drop in
performance and to rapid deterioration of the cylinder.
The nature of the carbon deposits that form on the cylinder
head, spark plug and exhaust port gives important
information about the fuel mixture burning in your engine.
Remember that mixtures that contain too much oil do not
extend the life of your engine.
4. SERVICING: INTERVALS AND OPERATIONS
The servicing described below is intended to keep your
motorcycle in peak condition. It consists of tasks that should
be done regularly, or on all occasions before you start
riding. All the tasks and adjustments described below can be
done easily by following the instructions given in this
manual. Refer to your POLINI MOTORI dealer for scheduled
services and repairs, and insist that only original spare parts
are used to replace worn or broken components.
Refer to the servicing tables in sections 5.1 and 5.2 below
for the frequency with which the various service operations
must be performed.
4.1 REMOVING THE SEAT
Unscrew the seat fixing nut, lift the seat gently and slide it
out towards the rear mudguard.
To refit the seat, engage the front seat catch with the screw
on the fuel tank and push the seat onto the frame member.
Once the seat is firmly in position, turn the seat lock 180
degrees clockwise to lock the seat in place.
4.2 REMOVING AND CLEANING THE AIR FILTER
Dirty air filters are one of the most common causes of poor
engine performance.
Proceed as follows to clean the air filter.
- Remove the seat (See section 4.1).
- Remove the cover from the filter box (photo 17).
- Remove the air filter and wash it in hot water with neutral
soap (photo 18)
- Rinse the filter and squeeze it dry, then dampen it with oil
for filters.
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ENGLISH
16
OFF
ON
18
17
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If the filter becomes clogged with fine dust as well as normal
dirt, replace it with a new one.
CAUTION! Dirty air filters choke the engine and cause
poor performance. Torn or broken filters can allow dirt to
enter the engine and cause rapid deterioration of the piston
rings and barrel.
4.3 CHECKING THE ENGINE OIL LEVEL
- Stand the motorcycle upright.
- Remove the oil level screw from the gearbox casing on the
right hand side of the engine (photo 19).
- Check that the oil level reaches the bottom edge of the
hole.
4.4 CHANGING THE ENGINE OIL
WARNING! Risk of burns! Wait for the engine to cool
before removing the oil drain screw.
- Stand the motorcycle upright.
- Remove the oil drain screw from the bottom of the gearbox
casing (photo 20) and leave the old oil drain out.
Do not throw spent oil into the environment. Dispose of it
correctly through authorised collection points.
- Screw the drain screw back in. Add 600 grams of SAE
20W50 engine oil. Only employ highly detergent engine
oil classified for service API SF or SG.
4.5 CHECKING THE COOLANT LEVEL
WARNING! Risk of burns! Wait for the engine to cool
before removing the radiator filler cap.
When the engine is cold, unscrew the radiator filler cap and
check the level of the coolant inside. Top up as necessary.
(See section 2, “Starting the engine for the first time”).
4.6 CHANGING THE COOLANT
- Stand the motorcycle upright.
- Unscrew the radiator filler cap.
-Unscrew the coolant drain screw on the engine casing on
the water pump (photo 19).
- Wait until all the old coolant has drained out.
- screw the filler cap and refill the cooling system
(See section 2, “Starting the engine for the first time”).
4.7 ADJUSTING ENGINE IDLING SPEED
- Warm up the engine before adjusting the idling speed and
leave it run at neutral position (gear N).
- Leave the engine idle with the throttle closed.
- Turn the idle speed adjustment screw on the right hand side
of the carburettor in or out to achieve the lowest engine
speed possible without running becoming irregular
(photo 21).
4.8 ADJUSTING THE AIR SCREW
The air screw can be adjusted in order to obtain better
performance when the bike is out of idling speed.
- If the engine has difficulty in curve (rich mixture) unscrew
the air screw.
- If the engine has difficulty in curve (poor mixture) screw
the air screw.
WARNING! The adjusting screw is near the cylinder.
Pay attention not to scald oneself while adjusting it.
4.9 ADJUSTING THE THROTTLE CONTROL AND
CABLE
- Make sure that the throttle twist grip operates smoothly.
- Make sure that the play in the throttle cable measures
3-5 mm. If play exceeds this measurement, reduce play by
screwing out the adjuster on the top of the carburettor.
(Photo n. 22)
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ENGLISH
21
19
20
OIL LEVEL CAP
OIL LEVEL
FLUID LEVEL CAP
22
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CAUTION! Failure to keep this parts in peak condition
and to make repairs whenever necessary can lead to serious
personal accidents and serious damage to the motorcycle.
4.10 ADJUSTING BRAKES
This modes is provided with a front and a rear hydraulic
brake. When the brake pads wear, the oil brake level goes
down. Therefore, periodically check the brake oil level and
the wear of the brake pads
WARNING! When you add brake fluid, make sure that
the tank is in horizontal position before removing the cap to
avoid spilling the fluid.
WARNING! Incorrectly positioned brake lines can be
damaged by contact with moving parts, leading to serious
accidents. The braking system must also be run in before it
achieves maximum efficiency. Apply the brakes at least one
hundred times before considering them to be fully efficient.
Proceed with great caution throughout this period. At the
end of this period, adjust the brakes and also check that all
the fixing bolts are tight. Adjust the travel of the back brake
pedal to suit the stature of the rider. To do so, loosen the lock
nut and turn the adjuster on the master cylinder control rod
(photo n. 24).
CAUTION! Use only DOT 4 hydraulic brake fluid from
clean new containers.
WARNING! Brake fluid is highly corrosive to paintwork
and can cause injury if it comes into contact with the eyes or
skin. Consult a doctor immediately in case of accident.
Change the brake fluid every two years.
DO NOT THROW SPENT BRAKE FLUID INTO THE
ENVIRONMENT.
Front and rear brake pads
Check the brake pads through the wheel to determine the
wear. If one of the pads should be worn up to a thickness of
1mm, replace both the pads.
General controls
Make sure there are no drippings. Check if hoses and joints
show wear or cracks.
4.10.1 ADJUSTING HYDRAULIC BRAKES
To adjust the lever position, manually act on the screw “A”
and adjust the distance “B” in relation to the rider's needs
(photo 23). After adjusting, make sure that the lever keeps a
3/4 mm play. The adjusting of the play can be done through
screw “C” (photo 23). The rear hydraulic brake, on the
contrary, must have a bigger play (photo 24).
4.11 ADJUSTING CLUTCH
Make sure that the clutch lever keeps play before the
coupling. The adjusting of the play can be done through the
related adjuster (photo 25)
4.12 TYRE PRESSURES
Correct tyre pressure ensures maximum stability and control
and also extends tyre life.
Check tyre pressure frequently and adjust as necessary.
Always measure tyre pressure when tyres are cold.
4.13 TRANSMISSION CHAIN
The final drive chain is an extremely important component
and deserves special care and regular servicing.
WARNING! When working on the chain, take care not
to jam your fingers between the chain and sprocket.
1- Check the chain tension with the motorcycle standing
upright and with no pressure on the suspensions. Measure
chain movement at the position shown in photo 26.
Chain movement must be 35-39 mm as shown in the
figure. If necessary, proceed as follows to adjust the chain
tension (photo 27).
- Loosen the nut (3) on the rear wheel spindle.
- Loosen the two lock nuts (1) and turn the two adjusters (2)
anti-clockwise to tighten or clockwise to slacken the chain.
Make sure that the edges of the spindle plates are
perpendicular to the swing arm and measure distance
“A” between the swing arm and the plates. Make sure
that distance “A” is the same on both sides.
- Tighten the rear spindle nut (3) (photo 28). See section 6.2
for the tightening torque.
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ENGLISH
23
A
C
B
24
ADJUSTABLE CONTROL ROD
5/10 mm.
25
ADJUSTER
FRONT
1,0 BAR - 14,5 PSI
REAR
1,0 BAR - 14,5 PSI
RECOMMENDED TYRE PRESSURES
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- Measure the chain movement again and repeat the
adjustment procedure if necessary.
- Gently turn the adjuster (2) to bring it into firm contact with
the axle plates. Hold the adjusters firmly with a spanner
and tighten the lock nut (1).
2- Whenever you check chain tension, also check the chain
and the front and rear sprockets for wear or damage.
3- Always lubricate the chain after washing the motorcycle.
Dirty chains can be cleaned with diesel fuel.
A good quality chain lube spray reduces chain wear and
improves the efficiency of the transmission.
4- If you need to remove or change the chain, remember to
replace the clip on the split link with the closed end facing
in the direction of travel (photo 29).
CAUTION! Never fit a new chain to worn sprockets or
vice-versa. Incorrect wheel alignment not only causes rapid
chain and sprocket wear but also affects the handling and
control of the motorcycle.
WARNING! Loose, worn or badly aligned chains can
break or come off the sprockets. If this occurs the chain can
jam the rear wheel and cause accidents with serious
personal injury and damage to the motorcycle.
4.14 ADJUSTING THE REAR SHOCK
The swinging arm is damped by a hydraulic monoshock with
oil and nitrogen gas reservoir. Gas pressure in the reservoir
is maintained by a rubber diaphragm. The pring preload of
the monoshock, (compression and travel) must be adjusted to
suit the weight of the rider and the circuit conditions.
WARNING! Never attempt to open the oil reservoir,
since it also contains nitrogen gas at high pressure.
Incorrect handling of the reservoir can lead to the unit
exploding, causing potentially serious personal injury.
The monoshock can be adjusted in four different ways:
1- Spring preload (photo 30). The bike is equipped with a
80
Newton spring, to be used for riders with a weight of
50/60 Kgs. If the weight is inferior, we suggest your
replacing with a 75 Newton spring, listed in the Polini
Catalogue.
2- Hydraulic adjusting in compression (photo 31).
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27
26
2
3
A
1
28
29
30
31
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3- Hydraulic rebound (turn clockwise for greater damping,
anti-clockwise for faster action) (photo 32).
4- Suspension height (photo 33). When your motorcycle is
new, run the suspensions in with their factory settings for
at least one hour before making any personal adjustments
ATTENTION! The shock is set up in the factory and has
no user adjustments. Never exceed the line indicated on the
register
SERVICING
1- Check the spring for damage or wear.
2- Bounce the rear of the motorcycle up and down and
check that the rear suspension functions smoothly.
3- Check that the shock rod is perfectly straight and that
there are no oil leaks around it.
4- Push the rear wheel sideways to check for play in the
swing arm bushings. Replace the bushings immediately if
any play is detected.
4.15 ADJUSTING THE FRONT FORK
The front fork is set up in the factory and no adjustments can
be done by users.
SERVICING
1- Check that the fork seals are clean and free from oil, dust
and dirt.
2- Check the legs for oil leaks. Replace damaged fork seals
before using the motorcycle.
3- Apply the front brake and bounce the front of the
motorcycle up and down to check that the front fork is
functioning smoothly.
4.16 FUEL
Your bike is equipped with a 2 stroke engine which needs a
2% synthetic oil and fuel mixture. Only use car petrol with
an octane rating of 96 to 100 or more. In case of
pre-ignition (knocking) try a different brand of fuel or a
higher octane rating. Fuel tank capacity is 3 litres.
4.17 FUEL FILTER
The fuel filter is incorporated in the fuel tap under the tank.
As dirt builds up in the filter it gradually impedes the flow of
fuel to the carburettor.
For this reason the filter must be cleaned regularly.
SERVICING
1- Drain the fuel out of the tank into a clean petrol can.
2- Unscrew the two fixing screws and remove the fuel tap
from the tank.
3- Wash the filter in water with neutral soap. Leave the filter
dry, in the sun if possible.
4- Replace the fuel tap on the tank, making sure that the seal
is correctly seated.
WARNING! Petrol is extremely inflammable and petrol
vapour can explode easily. Only drain the tank in a well
ventilated area and with the engine switched off.
Refrain from smoking and avoid all naked flames or sparks
while draining fuel or refuelling.
4.18 WASHING THE MOTORCYCLE
Cover the following parts to prevent water from entering
before washing your motorcycle:
- the throttle control
- the brake controls
- the air intake and filter
- the exhaust hole.
Avoid directing jets of water directly on to the following
parts:
- the wheel hubs
- the swinging arm pivot
- the steering head
- the brake callipers
- the spark plug hood.
On completion of washing, lubricate the above parts as
necessary then start the engine and leave it run for a few
minutes.
WARNING! Make sure that the brakes are fully efficient
before you start riding the motorcycle.
5. PRE-RACE INSPECTION AND PREPARATION
5.1 DAILY CHECKS: TO BE PERFORMED ALWAYS
BEFORE RIDING THE MOTORCYCLE
- Engine oil: check for leaks; check oil level.
- Carburettor: check that the throttle cable operates smoothly
and without sticking.
- Coolant: check for leaks; check level; check that the hose
clamps are tight.
- Radiator filler cap: check for tightness.
- Fuel filler cap: check for tightness.
- Air filter and filter box: check that filter and box are free
from dust and dirt.
- Brakes: check that the brakes lines are not kinked or
pinched and that the callipers are clean.
- Seat: check that the seat is correctly fitted and locked in
place.
- Chain: check that the chain is free from caked mud and
that it is well lubricated and correctly tensioned.
- Sprockets: check that the sprockets are free from dirt and
stones.
- Handlebars: check that the handlebar clamp bolts are tight.
- Tyres: check the tyre pressures.
- Front fork: check functioning and cleanliness.
- Steering: check the steering head for play.
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= INSPECT/ADJUST
= CLEAN
= LUBRICATE
= REPLACE
C= CAUTION!
W= WARNING!
: In dusty race conditions, clean the air filter after every heat.
5.2 REGULAR CHECKS: TO BE
PERFORMED EACH RACE AND AFTER
LAYING UP
AFTER 1 RACE
APPROX.2 HOURS
AFTER 3 RACE
APPROX.6 HOURS
AFTER 9 RACE
APPROX.18HOURS
W: WARNING!
C: CAUTION!
INTERVAL RISK LEVELS SECTION
CHAIN
SPROCKETS AND GEARS
CHAIN ROLLER
CHAIN GUARD - CHAIN SLIDE
BRAKES
COOLING LIQUID - RADIATOR
HYDRAULIC BRAKE CALIPERS
BRAKE PADS
HYDR. BRAKE OIL LEVEL
THROTTLE CONTROL
THROTTLE CABLES
AIR FILTER
TYRE PRESSURE
WHEEL BEARINGS
SPOKES
ENGINE OIL
STEERING HEAD ACTION
STEERING HEAD BEARINGS
FRONT FORK
REAR FORK
FUEL LINE
FUEL FILTER
REED VALVE
CARBURETTOR
SPARK PLUG
SPARK PLUG HOOD
ELECTRICAL SYSTEM
EXHAUST
SILENCER
CYLINDER HEAD PISTON AND BARREL
PISTON
PISTON RING
ENGINE CASING
CRANKSHAFT
MAIN BEARINGS
ALL ENGINE BEARINGS
PRIMARY / SECUNDARY GEAR
CLUTCH SPRING DRIVE GEAR
CLUTCH GEAR
KICK-START BOLTS
KICK START GEAR
NUTS, BOLTS, FIXINGS
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+
+
+
+
W
W
W
C
W
W
C
C
C
C
C
W
W
W
W
C
C
C
C
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
W
C
4.13
4.13
4.10
4.5
4.10
4.10
4.10
4.9
4.9
4.2
4.12
4.3
4.15
4.17
4.17
4.8
+
+
+
+
XP65R_instructions.qxd 5-09-2007 10:45 Pagina 11

12
ENGLISH
6 TECHNICAL SPECIFICATIONS
ENGINE
COOLING SYSTEM
BORE AND STROKE
DISPLACEMENT
COMPRESSION RATIO
CARBURETTOR
IGNITION
FUEL
INDUCTION
STARTING
TRANSMISSION
FRAME steel
FRONT MECHANICAL BRAKE
REAR MECHANICAL BRAKE FRONT
TYRE
REAR TYRE
FRONT SUSPENSION MARZOCCHI
REAR SUSPENSION OHLINS
FUEL TANK CAPACITY
EMPTY WEIGHT
SEAT HEIGHT
WHEELBASE
XP 65 R
single cylinder two stroke
liquid
45x40,8
64,9
14,2:1
Mikuni 24
electronic
2% unleaded fuel
reed valve in crankcase
kick-start
6 Speed
steel
Ø 180 mm.
Ø 150 mm.
60/100 - 14”
80/100 - 12”
hydraulic fork, Ø 35 mm, adjusting usp
hydraulic monoshock
3 litres
56,5 Kg
790 mm.
1.145 mm.
FRONT WHEEL SPINDLE
FRONT WHEEL SPINDLE LOCKING BOLT
HANDLEBAR FIXING SCREWS
REAR WHEEL SPINDLE
ENGINE/SWING ARM SPINDLE
FRONT ENGINE MOUNTING BOLT
TOP FORK PLATES
BOTTOM FORK PLATES
BRAKE DISK SCREWS
HYDR. BRAKE CALIPER FIXING SCREWS
STEERING HEAD NUT
STEERING HEAD ADJUSTMENT RING NUT
6.2 TIGHTENING TORQUE VALUES FOR FRAME AND CHASSIS
M
M12
M6
M8
M14
M12
M8
M8
M6
M6
M6
N.m
50
10
20
60
50
25
18
9
10
10
80
6
Kgf.m
5
1
2
6
5
2,5
1,8
0,9
1
1
8
0,6
Lbf.t
37
7,4
14,8
44,40
37
18,,5
13,32
6,7
7,4
7,4
59,2
4,44
LOCKING COMPOUND
LOCTITE 242
LOCTITE 242
HEAD BOLTS
CRANKCASE NUT (CLUTCH SIDE)
CRANKCASE NUT (IGNITION SIDE)
DRIVEN GEAR NUT
SPARK PLUG
ENGINE SMALL PARTS TORQUE WRENCH SETTING N.m / Lbf. ft
M
M7
M10
M10
N.m
15
45
40
18
Kgf.m
1,5
4,5
4,0
1,8
Lbf.t
11,1
33,3
29,6
13,32
LOCKING COMPOUND
LOCTITE 270
LOCTITE 242
The torque values listed in the
tables above cover the most
important nuts and bolts on the
motorcycle.
Apply the following standard
tightening torque values to all
nuts and bolts not listed above.
5 mm NUTS AND BOLTS
6 mm NUTS AND BOLTS
8 mm NUTS AND BOLTS
10 mm NUTS AND BOLTS
12 mm NUTS AND BOLTS
STANDARD TIGHTENING TORQUE VALUES
N.m
6
10
25
45
55
Kgf.m
0,6
1
2,5
4,5
5,5
Lbf.t
4,44
7,40
18,50
33,30
40,70
STANDARD SPARK PLUG
NGK B9, NGK BR9EG
COLDER SPARK PLUG
NGK B10, NGK BR10EG
XP65R_instructions.qxd 5-09-2007 10:45 Pagina 12