HVA WR 250 2006 - Off-road motorcycle HUSQVARNA - Free user manual and instructions

USER MANUAL HVA WR 250 2006 HUSQVARNA

USE: with FULL POWER ENGINE

Where not specified, alla the data and the instructions are referred to any and all Countries.

WARNING Park the vehicle where it is unlikely to be bumped into or damaged. Even slight or involuntary bumps can cause the vehicle to topple over, with subsequent risk of serious harm to people or children. To prevent the vehicle from tipping over, never park it on soft or uneven ground, nor on asphalt strongly heated by the sun. Engine and exhaust pipes become very hot during riding. Always park your motorcycle where people or children can not easily reach these parts, in order to avoid serious burns.

1- Front brake lever

3- Engine stop button. (L.H. side WR-USA/CDN; for WR,

7- Fuel tank filler cap

8- Gear change pedal. The

gearbox has five gears. Depress the pedal to shift into 1st gear. Raise the pedal to shift into 2nd, 3rd, 4th, 5th.

Pagina 22 9-Choke (L.H. side) When starting a cold engine, raise the choke knob

10- Fuel valve. When the fuel

valve is turned to "OFF" fuel cannot flow from the fuel tank to the carburetor. When the fuel valve is turned "ON", fuel will flow the tank to the carburetor.

11- Air release plug

12- Compression damper adjustment (bottom side)

13- Extension damper adjustment (top side)

14- Spring preload adjustment

15- Compression damper adjustment (low and high damping speeds)

16- Extension damper adjustment

DIMENSION, WEIGHT, CAPACITY

WARNING*: Be careful not to touch the hot engine while operating the fuel valve. A fuel filter is incorporated in the fuel valves. Accumulation of dirt in the filter will restrict the flow of the fuel to the carburetor. Therefore, the fuel filter should be serviced periodically. To service:

1- Drain the fuel from the fuel

tank. Disconnect the fuel line.

2- Remove the fuel valve by removing the screws. Wash the

fuel screen filter in cleaning solvent.

3- Reassemble the fuel valve in

the reverse order of removal. Turn the fuel valve "ON" and check for leaks.

Pagina 48 - The instrument functions are the following, as shown below.

10- SPEED / RPM (Indication

999.9 km / miles (the data will be

numerical value) (figure 10) - SPEED: motorcycle speedmaximum value: 299 kmh or 299 mph; - RPM: engine r.p.m.; both vertical LED indicator and numerical value are on.

10- SPEED /RPM (Indication

Pagina 62 STEERING LOCK (USA/CDN excluded) The motorcycle is equipped with a steering lock (3) on the righthand side of the steering head tube. To lock it, proceed as follows: - place key in lock and turn anticlockwise; - push key inwards (if necessary, turn to and from); - turn key clockwise and remove it from lock. To unlock the steering lock, reverse the above procedure.

) Selection control High beam LO = ( ) Selection control of Low beam

= Activation of left turn indicators (self cancelling) = Activation of right turn indicators (self cancelling) To deactivate the indicator, press the control lever after its returning to center.

= Lighting control of lowbeams and high beam. = Lighting control of position lights. G = Off

(USA/CDN) On the left side of handlebar, near clutch control, the engine sto button (1) is set.

Pagina 68 REAR BRAKE CONTROL The rear brake control (1) is placed on the right-hand side of the motorcycle. A stop switch (USA-CDN excluded) during braking action, causes the rear light to come on.

The lever (1) is placed on the lefthand side of the engine. After every shift, the lever automatically returns to its central position. First gear is engaged by pushing the lever downwards; all the other gears are engaged, by pushing the lever upwards. The position of the gear shift lever on the shaft can be varied by: - loosening screw; - pulling lever out; - placing lever in new position on the shaft whem the operation is over tighten the screw and then tightening the screw. COMMANDE DU

CAUTION*: Don’t start the engine while voltage regulator is disconneted from main wiring harness (WR; Enduro USA/CDN)

librement. Look for brake fluid leaks and worn cables.

Check spokes and look for worn bearings. Check rims and tyres. Check tyre pressure.

6. Check chain rollers and sprockets

Check wear on chain rollers and sprockets Ensure chain is correctly adjusted and lubricated.

7. Check air filter and intake system

Check that air filter is clean Check all rubber connections and clamps.

8. Check exhaust system

Check hook up, look for cracks Check muffler.

11. Check the electric system

(USA/CDN Enduro) Start the engine and check that the phares, the stop light, the turn indicators (USA excluded), the instrument panel pilot lights (USA/CDN excluded), and the horn, are working correctly.

Pagina 76 For the correct start of a cold engine proceed as follows: - shift the transmission into neutral; - set fuel valve (1) in ON position; - lift the knob lever (3) on the carburetor. Leaving the throttle in closed position operate kick-start (4). Take the knob lever in its initial position as soon as the engine is idling. When starting with an already warmed up engine DO NOT USE the starter. You can start the engine with the gear inserted, after disconnecting of the clutch. If the carburetor is flooded, shut

RUNNING IN To obtain the best settling of the engine moving elements, for driving your motorcycle to the best of your capability, run in the engine for several hours, following these procedures:

1. FROM STOP POSITION. Start the engine

and run at idle, but open the throttle periodically and briefly until the engine is thoroughly warmed up. Within 3-4 minutes the coolant temperature will have reached approximately 60° C/140° F. (Do not ride the motorcycle).

2. Stop the engine, and let it cool down

naturally until its temperature is equal to the ambient air temperature. This will allow the piston to align itself to any imperfections which might exist at the cylinder wall.

3. Repeat steps 1 and 2. (Do not ride the

4. Bring the engine up to normal running

temperature. Ride the motorcycle approximately 10 minutes at moderate speeds. Then repeat cool down procedure. AVOID HARD ACCELERATIONS.

5. Bring engine up to normal temperature.

Ride motorcycle approximately 15 minutes at moderate to high speeds. Again avoid hard accelerations. 6.Repeat cool down procedure.

7. Full throttle operation must be avoided

until the engine has reached operating temperature, even after the break in process is completed. When the above procedure is followed correctly, engine durability and performance will be greatly enhanced. RODAGE Au but d’obtenir un tassement correct des éléments rotatifs moteur pour une correcte utilisation du motocicle, il faudra roder le moteur pour quelques heures, selon les instructions données ci-dessous.

(see page 244). Note*: After break in, install a new spark plug and change the transmission oil.

CHECKING By keeping the motorcycle on a flat surface and in vertical position, remove the control screw (C), and check the level through the hole in the screw.

To completely replace the oil, unscrew the plug (A) under the oil sump and let oil come out, then screw the plug again with its gasket and pour fresh oil from the hole of the loading plug. Use only the prescribed quantity and type of oil (see on page 34,36).

Check level (A) in right-hand radiator when engine is cold (place the motorcycle so that it is perpendicular to the ground). The coolant should be approximately 10 mm above cells.

REPLACEMENT OF COOLING FLUID The filling of cooling fluid is carried out through the radiator cap; about the fluid quantity to be filled, see page 30. For draining, a) remove the pump cover by loosening the two screws (1), or: b) the draining screw (2) set on the pump cover. Let the fluid drain fully, then reassemble the pump cover or the screw previously removed. WARNING*: Coolant on tires will make them slippery and can cause an accident or injury. Periodically check the connecting hoses (see “Periodical maintenance card”): this will avoid coolant leakages and consequent engine seizure: If hoses show cracks, swelling or hardenings due to sheats desiccation, their replacement shall be advisable. Check the correct tightening of the clamps.

Pagina 94 THROTTLE CABLE ADJUSTMENT The throttle cable can be adjusted using the screw set on the throttle, or using the adjusting screw set on the carburettor cover. To check for proper adjustment of throttle cable, proceed as follows: - remove rubber cap; - move transmission sheath to and fro to ensure a play of approx. 1 mm; - should play be greater than 1 mm, loosen lock nut (1) and register (2); should play less than 1 mm, then tighten lock nut and register; - if register (2) should not provide sufficient movement to allow for correct adjustment, then adjust register placed on carburetor. There should be approx. 1 mm play on latter register; should this not be the case, then loosen lock nut (1), and loosen or tighten screw (2), to respectively increase or decrease the play.

Pagina 98 CLUTCH ADJUSTMENT The clutch is adjusted by stretching the cable using the adjusting unit positioned on the handlebar. As a rule it is sufficient to operate on the handlebar register to restore the clearance due to the flexible transmission stretch. The control lever must always have an empty stroke C (3 mm) before starting clutch disengagement. To adjust this clearance, act on register 2 after taking out rubber cap 1; turn the register in the direction indicated by arrow A to reduce the clearance C; turn it in the direction indicated by arrow B to increase the clearance. The adjustment can be also effected with tightener (1) set on the right of the frame. Take care to tighten properly the lock nut. If the clutch slips under load or drags in disengaged position after play has been adjusted, it must be taken apart for inspection. For this operation apply to a Dealer.

If standard spark plug is to be replaced, it is important that new spark plug have the same heat range and thread length.

ADVANCE The spark advance is factory set and must be checked either when replacing the ignition system, or whenever the engine assembly is inaccurate. For this check, make sure that the reference point stamped on the base be aligned with the one stamped on the stator, (either matched with the upper fastening; fig. A). When replacing the halfcasings, reset the accurate spark advance as follows, without reassembling the stator: a) Remove the spark plug and introduce a comparator into its seat; b) Fit special tool (cod. n° 8 pag. 242) on the crankshaft and take the piston to T.D.C. and zeroset the comparator in this position (fig. B);

EXHAUST VALVES “H.T.S.”

The cylinder features a central valve (A), connected to two side valves (B) on the “Booster” by means of gears. This system is driven by a centrifugal regulator placed on the left of the engine. The regulator opens the valves when the engine turns at approx. 6,200 rpm. In this way all engine output is obtained even when the engine is revved up. When closing, the central valve stroke is adjusted by a plate fastened to the rack, and when opening, the stroke is adjusted by another plate fastened near the “Booster”. To adjust the stroke, remove the cylinder head, the exhaust pipe and the timing covers as described on page 112.

1. Plate fastening screw

2. Adjusting plate in the closing phase

3. Valve control rod

4. Adjusting plate in the opening phase

6. Plate fastening screw

7. Reference for the rack

8. Reference for side valve

9. Central valve unit

Turn rear pin (1) anticlockwise, remove the saddle from the front fixing screw. Remove screw (3). Remove air filter (4). Separate filter (5) from frame (6).

AIR FILTER AND CLEANING

ADJUSTMENT To ensure maximum safety, the steering wheel should always be regulated so that the handlebars steering the motorcycle rotate freely without play. To check steering wheel adjustment, place kick stand or other support under the engine so that the front wheel is raised from ground. Place slight pressure on the tips of the handlebars to rotate steering wheel; the handlebars should also rotate without effort. Stand in front of the motorcycle and grasp the lower end of the fork rods sliders moving them in the direction of their axis.

LEVEL The adjuster (2), located on the control lever, allows adjusting of the free play (a). Free play (a) must be at least 3 mm (0.1 in.). The level of the fluid in pump tank must never be below the minimum value (1), which can be seen from the window on the pump body. A decrease of the fuel level will let air into the sustem, hence an extension of the level stroke.

POSITION ADJUSTMENT The position of the rear foot brake pedal as to the footrest may be adjusted according to the individual needs. For the adjusting proceed as follows: - loosen the screw (1); - turn the cam (2) for lowering or rising the pedal; - the operation done, tighten the screw (1). The adjusting operation carried out, adjust the idle stroke “A” of the pedal as indicated in page

ADJUSTMENT The rear brake foot pedal should have a (A) 5 mm idle stroke before starting the true braking action. Should this not happen as follows: - loosen nut (3); - operate the pump rod (4) to increase or decrease the idle stroke; - tighten nut (3) at the end of the operation.

The level (1) must be set between the pump tank notches of MIN and MAX.

CONDITIONS The following information is a useful guide for setting up the suspensions according to the road conditions. Always start from the standard calibration before making any change on the suspensions. Afterwards, increase or decrease the adjusting clicks one at a time.

Pagina 130 ADJUSTING THE FRONT FORK a) COMPRESSION (LOWER REGISTER) Standard calibration: -23 clicks. Remove plug (B) and turn register (A) clockwise until the position of fully closed is reached then, turn back by the mentioned clicks.To obtain a smoother braking action, turn the register anticlockwise. Reverse the operation in order to obtain a harder action. b) EXTENSION (UPPER REGISTER) Standard calibration: - 10 clicks. To reset standard calibration turn register (C) clockwise to reach the position of fully closed; then, turn back by the mentioned clicks. To obtain a smoother braking action, turn the register anticlockwise. Reverse the operation in order to obtain a harder action. c) AIR VENT (to carry out after each competition, or monthly). Set the motorcycle on a central stand and release the fork fully and loosen the air vent valve (D). Once this operation is over, tighten the valve.

WARNING: Never force the adjusting

screws beyond the maximum opening and closure positions.

For the regular fork operation, both legs must be provided with the necessary oil quantity. Remove the forkrods form the fork to check the oil level inside the forkrods. Work as follows: - remove the power rod caps; - remove springs from the stems letting the oil drop into the latter; - bring forks to stroke end; - check that the level is at distance “A” below the upper limit of rods.

A = 80 mm (3.15 in.)

HEIGHT CHANGE The handlebar position (a) and height (b) can be changed for better suiting Your driving requirements. To effect these operations, remove the upper screw (3), upper clamp (1), lower screw (4) then lower clamp (2). a) Handlebar position change Turn the lower clamp (2) 180° to move forward or backward (10mm- 0.04in.) the handlebar position with respect to the original setup. b) Handlebar height change Remove the lower spacer (A) then replace the screw (4) with a new one of L=65 mm (2.56 in.) height. Once these operations are completed, tighten the screws (3) to 2,75-3,05 kgm (27-30 Nm; 19.9-22 Lb/fts) and the screws (4) to 2,0-2,2 kgm (19,621,6 Nm; 14.5-15.9 Lb/fts).

ABSORBER The rear shock absorber must be adjusted according to the rider weight and track conditions. Proceed as follows:

1. With motorcycle on the stand,

measure distance (A).

2. Take the normal riding position

on the motorcycle with all your riding apparel.

3. With somebody’s help, take

the new distance (A).

4. The difference between these

two measurements constitutes the “SAG” of the motorcycle’s rear end. Suggested SAG: 4 in. with cold shock absorber. 3.7 in. with warmed up shock absorber.

5. To get the right SAG according

to your weight, adjust the shock absorber spring preload. REGLAGE DE L’AMORTISSEUR Régler l’amortisseur arrière selon le poids du conducteur et suivant les condition du sol. Agir comme suit:

1. Clean ringnut (1) and adjusting

nut (2) of the spring (3).

2. Either with a hook wrench or

an aluminium punch, loosen the ringnut .

3. Turn the adjusting nut as

4. When the adjusting operation

is over (according to your weight and riding style), tighten the ringnut. (Torque for both ringnuts: 5 Kgm).

ADJUSTMENT Adjustment of the compression stroke is independent from the rebound stroke. A) COMPRESSION - Standard calibration:

maximum open (register 6) To reset the standard calibration, turn upper registers (4) and (6) clockwise until reaching fully closed position. Return then back for the mentioned clicks. In order to obtain a smooth braking action, turn the registers anticlockwise. Reverse the operation in order to obtain a harder braking action. B) EXTENSION - Standard calibration: -15 clicks. To reset the standard calibration, turn lower register (5) clockwise until reaching fully closed position. Return then back for the mentioned clicks. In order to obtain a smooth braking action, turn the register anticlockwise. Reverse the operation in order to obtain a harder braking action. REGLAGE AMORTISSEUR HYDRAULIQUE La course de compression peut être réglée séparément de celle d’extension. A) REGLAGE FOURCHE Tarage standard:

Pagina 142 CHAIN ADJUSTMENT Chain should be checked, adjusted and lubricated as per the Maintenance Chart to ensure security and prevent excessive wear. If the chains becomes badly worn or is poorly adjusted (i.e., if it is too loose or too taught), it could escape from sprocket or break. To adjust the rear chain it is necessary to lower the rear part of motorcycle so to line up the drive sprocket axle, the rear swing arm axle and the rear wheel axle as shown on drawing. Than let turn three times the rear wheel. Now the chain should not be tight. (Fig. A). Fast adjustment (Fig. B.). Push the chain towards the final part of runner and check that between the two elements a distance "A" from 0 to 2 mm is present. If this is not the case, go on as follows: - Unloose the fastening nut of the wheel pin (1) on the right side; - Unloose the lock nuts (2) on both chain adjusters and turn the screws (3) to obtain the correct tension value; - Tighten the lock nuts. After adjustment check that the wheel is lined up and tighten its axle.

CHECKING THE WEAR OF CHAIN, PINION

AND SPROCKET Proceed as follows: - Fully stretch the chain with the adjusting screws. - Mark 20 chain links. - Measure the distance between 1st pin center and 21st pin center.

LUBRICATING THE CHAIN

The chain should be checked, adjusted and lubricated as shown on the "Maintenance Chart". WARNING * : Never use grease to lubricate the chain. Grease helps to accumulate dust and mud, which act as abrasive and hepl to rapidly wear out the chain, the sprocket, and the crown. Disassembling and cleaning When particularly dirty, remove and clean the chain before lubrication. Work as follows: Set a stand or a block under the engine and see that the rear wheel is lifted from the ground. 1 -Remove the sprocket guard (3), the spring (1), the joint (2) and the chain.

2 - Check that the chain is neither worn out nor

damaged. If the rollers or the links are damaged, replace the chain by following the instructions given in the Periodical Maintenance Table. 3 -Check that neither the sprocket nor the crown are damaged. 4 -Wash and clean the chain as described hereunder. Washing the chain without OR Wash using either oil or diesel oil. When using gasoline or tricloroetilene, clean and lubricate the chain to prevent oxidation. Washing the chain with OR Wash using oil, diesel oil, or paraffin oil. Never use gasoline, tricloroetilene, or solvents, as the OR may suffer damages. Use instead special sprays for chains with OR. Lubricating the chain without OR First dry, then plunge the chain in a bisulphide molybdenum lubricant, or in high viscosity engine oil. Warm up the oil before use. LUBRIFICATION CHAINE Contrôler, lubrifier et régler la chaîne en suivant les instructions du "Tableau d'entretie". AVIS * : Ne jamais utiliser de la graisse pour lubrifier la chaîne, car la graisse aide à ramasser la poussière et la boue qui, en agissant en tant qu’abrasives, provoquent l’usure rapide de la couronne, du pignon et de la chaîne. Démontage et nettoyage Si la chaîne est très sale, la ôter et la nettoyer avant de la graisser. Opérer comme suit: Placet une béquille ou un block dessous le moteur, de façon à avoir la roue arrière soulevée du sol.

Pagina 148 Lubricating the chain with OR Lubricate all metallic and rubber (OR) elements using a brush, and use engine oil with SAE 80-90 viscosity for the internal and external parts.

5 - If the chain has been cut,

reassemble using a joint. 6 -Assemble the joint spring by turning the closed side to the chain direction of rotation as shown in figure. NOTE * : Even if all the joints are reusable when in good conditions, for safety purposes we advise using new joints when reassembling the chain. 6 -Accurately adjust the chain as described on page 142

WARNING: The chain oil has NEVER

to get in contact with the tires or the rear brake disk. Chain tension rollers, chain driving roller, chain guide, chain runner Check the wear of the above mentioned elements and replace them when necessary. WARNING * : Check the chain guide alignement, and remember that a bent element can cause a rapid wear of the chain. In this case, a chain fleeting from the sprocket may ensue. Graissage de la chaîne avec bagues d’étanchéité Lubrifier les éléments en métal et en cautchouc (bagues d’étanchéité) en utilisant une brosse. Enduire d’huile avec viscosité SAE 80-90 les parties intérieures et extérieures de la chaîne. 5 -Si la chaîne a été coupée, la remonter en utilisant un joint.

2- Chain driving roller

1 - Front brake control lever

2 - Front brake pump with oil tank

6 - Rear brake oil tank

10 - Rear brake pump

11 - Rear brake control pedal

DRAIN - Attach a clear plastic hose to the bleed valve on the caliper and turn the other end of the hose into a container. - Loosen bleed valve so fluid begins to drain. - Remove reservoir cap and rubber. - Pump with brake pedal to push brake fluid out of line.

• Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly and call a doctor if your eyes were exposed. ATTENTION! Puisque le fluide des freins ronge rapidement les surfaces vernissées, nettoyer soigneusement les parties intéressées.

Measure the thickness of each disc at the point where it has worn the most. Replace the disc if it has worn past the service limit.

Pagina 166 DISC CLEANING Poor braking can also be caused by oil on the disc. Oil or grease on the disc must be cleaned off with a high flashpoint oil free solvent, such as acetone or lacquer thinner.

• Use only brake fluid from a sealed container (DOT 4). Never use old brake fluid.
• Never allow contaminants (dirt, water, etc.) to enter the brake fluid reservoir.
• Don't leave the reservoir cap off any length of time to avoid moisture contamination of the fluid.
• Handle brake fluid with care because it can damage paint.
• Don't mix two types of fluid for use in the brake. This lowers the brake fluid boiling point and could cause the brake to be ineffective. It may also cause the rubber brake part to deteriorate. ATTENTION!
• Utiliser seulement du fluide pris d’un récipient sigillé (DOT 4). Ne jamais utiliser du fluide usé.

• Brake fluid may cause irritation. Avoid contact with skin or eyes. In case of contact, flush thoroughly and call a doctor if your eyes were exposed. ATTENTION! Puisque le fluide des freins ronge rapidement les surfaces vernissées, nettoyer soigneusement les parties intéressées.

BLEEDING The braking system must be bled when, due to air in the circuit, the lever stroke is long and spongy. To bleed the system: - Disconnect the brake caliper and position it so that the pipe fitting (pump to caliper) is perpendicular to the ground. - Remove the pump body cover (1). - Remove the anti-emulsion disc and fill up the tank with new fluid (DOT 4). - Attach a clear hose to bleed the valve and run into a clear glass container as shown in figure. Make sure that the end of the hose is submerged in brake fluid during the entire bleeding operation. - Open the bleed valve on the caliper and pump the lever. Allow the pads to contact the disc.

BLEEDING The braking system must be bled when, due to air in the circuit, the pedal stroke is long and spongy. To bleed the system: - Remove the reservoir cover rubber boot and top up with (DOT 4) brake fluid. - Attach a clear plastic hose to the bleed valve on the caliper and turn the other end of the hose into a container. - Depress the pedal and keep it full down. - Loosen the bleed union letting out fluid (at first, only air will come out), then, closing the union slightly. - Release the pedal and wait for a few seconds before repeating the operation until only fluid come out of the tube. - Close the bleed union to the prescribed torque and check the fluid level inside the reservoir before replacing the cap.

Replace any spring which does not meet with this specification.

Pagina 200 COMPRESSION RATIO CONTROL To check if the compression ratio is correct, proceed as follows; a) remove the cylinder together with the head from the block; b) remove the piston from the connecting rod, properly clean it, insert it in the cylinder till it touches the corresponding profile on the explosion chamber (this chamber too must be free from incrustations); c) screw a comparator in the sparking plug hole and reset it on the piston position as decribed at fig. A; d) remove the piston and reassemble it on the connecting rod; e) remount the cylinder together with the head by placing a 0.0197 in. gasket on the block; f) place the piston at the top dead center and control the reading on the comparator, which must be: 0.055÷0.059 in. (g) in case of different readings, reset the right condition by using a cylinder base gasket having the right thickness.

TEMPERATURE For reasons of safety, should height and temperature be included between two series of values of the side diagram, select jets of greater dimensions. (The list of jets supplied on request is found on pages 208-212).

- Adjust the idle air screw as indicated at page 96. - Judge if the pilot jet is correct. If mixture is rich, use a smaller jet; if is lean, use a larger jet. Example: With standard pilot jet size 40, if mixture is rich, mount a jet size 35. If mixture is lean, mount a jet size 45.

MAIN CIRCUIT ADJUSTMENT

With throttle control opened from 3/4 to full, adjust the main circuit after idle circuit adjustment. - If the jet size is between two values (see diagram at page 207), choose the larger jet not to damage the piston. - Adjust the main circuit before intermediate circuit adjustment.

TEMPERATURA DA 10 A 25° C

(Taratura di serie) Particolare The lists below show the standard carburetor setting in different environmental and riding conditions; refer to this list when change the carburetor setting.

NORMAL TRACK CONDITIONS AND

TEMPERATURE FROM 10°C (76°F) TO

NORMAL TRACK CONDITIONS AND

NORMAL TRACK CONDITIONS AND

J8.6DJ8-60 (3rd) 1 -1/2

SAND TRACK CONDITIONS AND

SAND TRACK CONDITIONS AND

SAND TRACK CONDITIONS AND

Pagina 224 WHEEL SPOKES Check to make sure that all the nipples are tight; tighten them if necessary. Remember that an insufficient stretch jeopardizes the motorcycle stability. For an instant check, use a metal point (for instance, a screwdriver) to beat the spokes with. A live sound accounts for an accurate tightening, while a dull sound means that a new tightening is necessary.

DIAGRAM (WR, USA/CDN

excluded- "Enduro" USA/CDN) A. Headlamp B. RH front indicator C. LH front indicator D. Left switch E. Horn F. Rear stop switch G.Front stop switch H. Regulator

L. Turn signal flash device M. H.T. coil N. Spark plug O. RH rear indicator P. LH rear indicator Q.Rear light R. Instrument lighting S. Parking light. T. Electronic module U. Scroll

Yellow D Electronic coil E Engine stop switch F Spark plug G Voltage regulator

These optional parts may be ordered from your Dealer:

5 - Rear sinterd pad couple (for

800080260 7 - Rear shock absorber oil

Dopo la gara, pulire il motociclo come sottoriportato poi ispezionare il veicolo ponendo particolare attenzione ai punti indicati nel paragrafo “MANUTENZIONE” come filtro aria, carburatore, freni etc. Effettuare una lubrificazione generale ed eventualmente le registrazioni necessarie. APPENDIX

AFTER-RACE CHECK POINTS

After racing, first clean the motorcycle and then inspect the entire motorcycle, with special attention to the items listed in «MAINTENANCE», such as the air cleaner, carburetor, brakes, etc. Carry out general lubrication, and make adjustment as necessary. APPENDICE

CONTROLES APRES CHAQUE

1) Preparation for washing

Before washing, precautions must be taken to keep water out of the following places:

Clutch and brake levers, hand grips, engine stop button: - Cover with plastic bags. Air cleaner intake: - Close up the opening with tape, or stuff in rags.

2) Where to be careful

11-07-2005 13:52 Pagina 274 Noise emission warranty MV Agusta Motorcycles S.p.A. warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers. Warranty claims should be addressed to Cagiva U.S.A. 2300 MARYLAND ROAD.

WILLOW GROVE, PA 19090-4193

215-830-3300 Tampering warning Tampering with Noise Control System Prohibited. Federal law prohibits the following acts or causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, and (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below.

1) Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.

2) Removal or puncturing of any part of the intake system.

3) Lack of proper maintenance.

4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts

other than those specified by the manufacturer. Warning statement This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

11-07-2005 13:52 Pagina 275 SPARK ARRESTER The WR model is equipped with a U.S. Forest Service approved spark arrester for maximum efficienty and performance.

“ SPARK ARRESTER” MAINTENANCE AND CLEANOUT INSTRUCTIONS

Proceed as follows: A: Remove the screws (1) and the R.H. side panel (2). B: Remove the two screws (3) fastening the muffler to the rear frame. Extract the silencer from the union manifold to the exhaust pipe. Note*: If silencer or exhaust are difficult to remove, help to slide them apart by tapping gently with a rubber or plastic hammer. C: remove the four screws (4) and the endcap (5) from silencer’s body; D: examinate SPARK ARRESTER conditions and remove, if necessary, carbon particles from the SPARK ARRESTER screen; E: if necessary, inflate air on the SPARK ARRESTER screen, in the opposite direction in respect of the exhausted gas flow; F: assemble the front endcap on the silencer’s body, mounting the screws in the correct position, providing a tight connection between endcap and silencer’s body, using, if necessary, a silicone paste; G: re-assemble the silencer on motorbike. Due to the SPARK ARRESTER position on the silencer, if you need only to check the SPARK ARRESTER conditions you can: A: disassemble the silencer from motorbike; B: check SPARK ARRESTER conditions simply looking into the silencer from front endcap opening; C: if the check is positive, you can proceed in re-assembling the silencer on the motorbike; D: if the check is negative, proceed with the maintenance and cleanout procedure.

11-07-2005 13:52 Pagina 276 AUS Tampering Warning: Tampering with Noise Control System Prohibited. Federal law prohibits the following acts or causing therefor: 1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, and

2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below.

1) Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.

2) Removal or puncturing of any part of the intake system.

3) Lack of proper maintenace.

4) Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. This product should be checked for repair or replacement if the motorcycle noise has increased significantly through use. Otherwise, the owner may become subject to penalities under state and local ordinances.

Description Operation Engine oil Two-stroke mix oil level Coolant Cooling system Electric fans Spark plugs Throttle body / Carburettor Brakes / Clutch fluid Brakes / Clutch Brakes / Clutch Throttle control Throttle control Choke control Flexible controls and transm. Drive chain Tyres Side stand Check level Check level Check / Restore level Check for leakage Check operation Check / Replace Check and adjust Check level Check operation Check lines for leakage Check operation Check / Adjust play Check operation Check / Adjust Check / Adjust Check pressure Check operation Pre-delivery

Description Side stand switch Electrical equipment Instrument panel Lights / Visual signals Horn Headlight Ignition switch Locks Screws and nuts Hose clamps General lubrication General test Operation Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check operation Check / Tighten Check / Tighten : only for motorcycles with 2 stroke engine : only for some models Pre-delivery

ATTACCHI MANUBRIO E FISSAGGI- HANDLEBAR HOLDERS AND FASTENING

(with LIMITED POWER ENGINE)

(with LIMITED POWER ENGINE)

ATTACCHI MANUBRIO E FISSAGGI- HANDLEBAR HOLDERS AND FASTENING

(with LIMITED POWER ENGINE)