The crankcase halves must be in good condition and perfectly clean. The mating surfaces must be perfectly flat and free from burrs.
Overhauling the alternator-side crankcase half
The following parts must be present on the internal side of the crankcase half:
The roller bearing (15) with retaining circlip (16) installed in correspondence with the end of the timing belt driveshaft.
Insert the circlip (5) in the crankcase half installing it in its seat on the bearing (4).
Refitting the alternator-side crankcase half
The following parts must be present on the internal side of the crankcase half: the double race ball bearing (9) supporting the selector fork shaft. Apply threadlocker to the screws (11). Fit the retaining plate (10) to the gearbox secondary shaft bearing (9) screwing the screws fully into the chain-side crankcase half (11).
Note
The bearing retaining plate must be positioned so that the countersunk side is facing upwards.
Tighten the screws (11) to a torque of 10 nm (min. 9 Nm - max. 11 Nm) (sect. 3 - 3, Engine torque settings).
Lubricate the ring (6) with denatured alcohol, drive it fully home against the crankcase half, and orient it as shown.
The primary shaft bearing (7) with internal spacer (6), oriented so that the closed side of the plastic roller cage (m) faces The crankcase half: apply grease to the bearing rollers. Fit the inner race (a) removed previously from the bearing. Apply grease to the inner race.
The main bearing (1) with the corresponding bushing (2) (if present).
The bearing (4) with the retaining circlip (5) installed in correspondence with the timing belt driveshaft.
Insert the circlip (5) in the crankcase half installing it in its seat in the crankcase half on the bearing (4).
Note
Bearings do not have a specific mounting position (except main bearings); however it is good practice to install the bearings so that side bearing the writing is facing upwards.
Fit the mesh filter as described in sect. 4 - 3, Changing the engine oil and filter cartridge.
Important
To avoid damaging the filter, insert it by hand only. Do not use hammers or other metal tools.
Above the mesh filter seat there is a plug (19) which closes off the lubrication oilway. If it is to be renewed, apply the prescribed threadlocker to its threads.
Tighten the plug to a torque of 24 nm (min. 21 Nm - max. 27 Nm) (sect. 3 - 3, Engine torque settings).
Key to wiring diagram
Right-hand handlebar switch
Immobilizer
Hands free relay
Hands free
Front fuse box
Right fan
Left fan
Fan relay
Fuel pump relay
Ride-by-wire relay (etv)
Injection control unit (ems)
Rear fuse box
Data acquisition/diagnosis
Starter motor
Fused solenoid
Battery
Wirin ...
Inspecting the final drive
To check the wear of the final drive, visually check the pinion (14) and
sprocket (17). If the teeth are found to worn as
shown in the figure (dotted line), the sprocket must be renewed.
To check the amount of wear on the chain (8), keep the chain taut and measure
16 links.
If the l ...
Airbox - throttle body
Airbox
O-ring
Injector
Throttle body assembly
Screw
Clamp
Intake manifold
Screw
Pressure sensor
Screw
Clamp
Hose
Sealing washer
Intake manifold
Sealing washer
Screw
Screw
Spacer
Bracket
Rubber pad
Clamp
Hose
Clamp
Union
Washer
Hose
Cable gro ...