Segment:
Dual-purpose/Enduro Motorcycle
Competitors 1987:
Yamaha XT600, Honda XR600R, Suzuki DR600, BMW GS series (though higher displacement).
Design Philosophy:
Robust Italian engineering combined with off-road capability, suitable for touring and light off-roading.
Manual Value Proposition:
Provides essential technical data for maintaining and repairing a classic Italian dual-sport motorcycle, addressing the scarcity of original documentation.
Engine Overhaul:
Detailed procedures for engine disassembly, inspection, repair, and reassembly for both 350cc and 500cc variants.
Fuel System:
Carburetor tuning, cleaning, repair, fuel pump diagnosis, fuel line maintenance.
Ignition System:
Spark plug specifications, timing adjustments, coil testing, CDI unit diagnosis.
Transmission And Drivetrain:
Gearbox inspection, clutch adjustment and replacement, chain drive maintenance, differential service (if applicable).
Braking System:
Hydraulic system bleeding, brake pad and disc inspection/replacement, caliper service, master cylinder repair.
Suspension And Steering:
Fork service, shock absorber overhaul, steering head bearing adjustment, linkage lubrication.
Electrical System:
Wiring diagrams, component testing (lights, horn, indicators), battery maintenance, charging system diagnosis (stator, regulator).
Cooling System:
Air-cooled engine specifications, fin cleaning, potential oil cooler maintenance (if fitted).
Chassis And Bodywork:
Frame inspection, fairing removal/installation, seat, tank, and fender mounting procedures.
Routine Maintenance:
Oil change intervals, filter replacement, chain lubrication, bolt torque checks, air filter cleaning.
Troubleshooting Guide:
Systematic diagnostic procedures for common performance issues, starting problems, and electrical faults.
Repair Procedures:
Step-by-step guides for component replacement and overhaul, including engine components, brake assemblies, and electrical parts.
Adjustment Procedures:
Carburetor synchronization, throttle cable adjustment, clutch lever free play, brake lever travel.
Special Tool Requirements:
Identification of specific tools needed for certain repair tasks, such as piston ring compressors or valve spring compressors.
Diagnostic Capability:
Advanced diagnostics for engine performance tuning, electrical system troubleshooting, and chassis alignment.
Rebuild Scope:
Complete engine and transmission rebuild instructions, including clearances, tolerances, and part specifications.
Torque Specifications:
Comprehensive list of torque values for all critical fasteners and engine components.
Wiring Diagrams:
Detailed electrical schematics for comprehensive system understanding and troubleshooting.
Engine Type:
Four-stroke, single-cylinder (typically air-cooled, SOHC)
Bore X Stroke 350:
Approx. 76mm x 73mm (exact spec may vary by sub-model)
Bore X Stroke 500:
Approx. 84mm x 90mm (exact spec may vary by sub-model)
Displacement 500:
478 cc (approx.)
Horsepower 350:
Approx. 25-30 HP (estimated)
Horsepower 500:
Approx. 30-35 HP (estimated)
Torque 350:
Approx. 25-30 Nm (estimated)
Torque 500:
Approx. 30-35 Nm (estimated)
Carburetor Type:
Single or Dual Dell'Orto or Mikuni (model dependent, e.g., PHF 30/32 for 350, PHM 40 for 500)
Fuel Delivery:
Gravity Feed with Fuel Pump (sometimes electric or vacuum operated)
Safety Ratings:
Not Applicable (Motorcycle, no formal NCAP equivalent for this era)
Braking System Type:
Disc brakes front and rear
Front Brake Spec:
Single Disc, Hydraulic Actuation, often 260-280mm diameter with 2-piston caliper
Rear Brake Spec:
Single Disc, Hydraulic Actuation, often 240mm diameter with 1 or 2-piston caliper
Lighting:
Headlight, taillight, brake light, front and rear turn signals.
Oil Change Interval:
Every 3,000-5,000 km or annually (refer to specific manual recommendations).
Spark Plug Replacement:
Every 6,000-10,000 km (depending on plug type).
Valve Clearance Check:
Every 6,000-12,000 km (critical for performance).
Engine Oil Type:
SAE 10W-40 or 20W-50 motorcycle specific, API SG or higher.
Engine Oil Capacity:
Approx. 1.8 - 2.2 Liters (depending on model and filter change).
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Transmission Oil Type:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90.
Electrical Reliability:
Older Italian electrical systems can be prone to corrosion and intermittent connections. Wiring loom integrity is key.
Carburetor Tuning:
Sensitive to altitude and air density changes; requires regular cleaning and adjustment for optimal performance.
Suspension Seals:
Fork seals and shock absorber seals can degrade over time, leading to leaks.
Cam Chain Tensioner:
May require adjustment or replacement if rattling noise develops.
