VI ServiceManual-RocketIll

1GeneralInformation

TableofContents

IgnitionSystemSafetyPrecautions 1-3

DangerousSusbstances. 1-3

Fluoroelastomers 1-3

Oils 1-3

HealthProtectionPrecautions 1-3

EnvironmentalProtectionPrecautions 1-4

Brakes. 1-4

SafetyInstructions 1-5

Jackingandlifting 1-5

Precautionsagainstdamage 1-5

Coolant 1-5

Cleaningcomponents 1-6

Lubrication 1-6

Jointsandjointfaces 1-6

Gaskets,0-rings. 1-6

Liquidgasket,non-permanentlockingagent 1-6

ScrewThreads 1-6

LockingDevices 1-7

Fittingasplitpin 1-7

Circlips,retainingrings 1-7

Selflockingnuts 1-7

Encapsulatedbolt 1-7

Oilandgreaseseals 1-7

Press 1-7

Ballbearing. 1-7

Fuel HandlingPrecautions 1-7

General. 1-7

Petrol-Gasoline 1-8

Fueltankremoval 1-8

Chassisrepairs. 1-8

ElectricalPrecautions 1-9

Batterydisconnecting 1-9

Disciplines. 1-9

Electricalwires 1-10

Inspection................................................................. 1-1o

ServiceManual-RocketIll ^1.1

ReplacementParts..........................................................1-1O

Servicedata 1-10

Specification....... ...... .............. ....... ..... .. . .. ... ....... ....... ..1-1O

Servicetools 1-11

Specialservicetools:. 1-11

TorqueWrenchSettings 1-20

Cylinderheadarea 1-20

Clutch. 1-20

Crankshaftandcrankcases 1-20

EngineCovers 1-20

Transmission 1-21

LubricationSystem 1-21

CoolingSystem 1-21

FuelSystem,ExhaustSystemandAirbox. 1-22

RearSuspension 1-22

FrontSuspension. 1-22

Wheels. 1-22

FrontBrakes 1-23

RearBrakes. 1-23

FootrestsandControlPlates 1-23

Bodywork 1-24

Electrical 1-24

Routings. 1-25

ClutchCable Routing. 1-25

HandlebarCableRouting 1-26

MainWiringHarness Routing 1-27

RearMudguardHarness Routing 1-28

FrontBrakeHoseRouting 1-29

RearBrakePipeandHoseRouting. 1-30

ThrottleCableRouting. 1-31

FuelHoseandFuelTankBreatherHoseRouting(non-evaporativeemissioncontrolversions) 1-32

FuelHoseandEvaporative/FuelTankBreatherHoseRouting 1-33

2. ServiceManual-RocketIll

IgnitionSystemSafetyPrecautions

Fluoroelastomers

DangerousSusbstances

Oils

HealthProtectionPrecautions

• Avoidprolongedandrepeatedcontactwithoils,particularlyusedengineoils.

• Wearprotectiveclothing,includingimperviousgloveswherepracticable.

• Donotputoilyragsinpockets.

• Overallsmustbecleanedregularly.Discardheavilysoiledclothingandoilimpregnatedfootwear.

• Firstaidtreatmentshouldbeobtainedimmediatelyforopencutsandwounds.Always

ServiceManual-RocketIll

1.3

beawareofwhoyournearestfirst-aiderisandwherethemedicalfacilitiesarekept.

• Usebarriercreams,applyingbeforeeachworkperiodtoprotecttheskinfromtheeffectsofoilandgreaseandtoaidremovalofthesameaftercompletingwork.

• Washwithsoapandwatertoensurealloilisremoved (skincleansersandnailbrusheswillhelp).Preparationscontaininglanolinreplacethenaturalskinoilswhichhavebeenremoved.

• Donotusepetrol,kerosene,dieselfuel,gasoil,thinnersorsolvents forcleaningskin.

• Ifskindisordersdevelop,obtainmedicaladvicewithoutdelay.

• Wherepracticable,de-greasecomponentspriortohandling.

Brakes

EnvironmentalProtectionPrecautions

Burningofusedengineoilinsmallspaceheatersorboilerscanberecommended onlyforunitsofapproveddesign.Ifindoubt,checkwiththeappropriatelocalauthorityand/ormanufactureroftheapprovedappliance.

Disposeofusedoilandusedfiltersthroughauthorisedwastedisposalcontractors,tolicensedwastedisposalsites,ortothewasteoilreclamationtrade.Ifindoubt,contactyourlocalauthorityforadvice ondisposalfacilities.