Libro_125-160 cc.indb
125 - 160cc 4T
Workshop Manual
Engine
WORKSHOP MANUAL
GENERAL INDEX
C
OIL PUMP ASSY ...........................................................................3
Assembling the piston ...................................................................37
Trouble shooting............................................................................................... 4
Stripping down the cylinder head .................................................38
Exploded view of oil pump ...............................................................5
Checking valve springs .................................................................................. 40
Disassembly ......................................................................................6
Checking valves ............................................................................................. 40
Removing the oil pump .................................................................................... 8
Checking and adjusting valve seating ..........................................42
Oil pump body tolerances ................................................................................ 9
Inspection ....................................................................................................... 42
Clearance between oil pump inner and outer rotors ...................10
Change........................................................................................................... 42
Clearance between front surfaces ................................................10
Assembly ......................................................................................... 11
CYLINDER HEAD, VALVES, CYLINDER, PISTON.....15
Working precautions ......................................................................15
Trouble shooting .............................................................................18
Cylinder head exploded view .........................................................19
Cylinder compression pressure ...................................................20
Valve clearance adjustment ...........................................................21
Removing camshaft support .........................................................23
Removing the camshaft .................................................................26
Checks .............................................................................................27
Camshaft ....................................................................................................... 27
Lapping .......................................................................................................... 44
Installing the cylinder .....................................................................50
Installing the cylinder head ............................................................52
Installing the camshaft support .....................................................53
Checking engine timing .................................................................57
Fitting the valves cover ..................................................................58
SPEED VARIATOR-CLUTCH UNIT ..................................60
Trouble shooting .............................................................................61
Variator unit exploded view ..........................................................62
Clutch unit exploded view .............................................................63
Clutch pulley exploded view .........................................................64
Clutch shoes assy exploded view ................................................65
Rocker arms and rocker arm spindles ........................................................... 28
Removing the clutch cover ............................................................66
Removing the cylinder head ..........................................................29
Assembly........................................................................................................ 67
Removing the cylinder ...................................................................31
Removing the piston ......................................................................32
Cylinder / piston checks .................................................................34
Checking the cylinder ..................................................................................... 34
Checking the piston........................................................................................ 34
125 - 160 cc
Primary pulley .................................................................................67
Disassembly ................................................................................................... 67
Checks .............................................................................................70
Drive belt ........................................................................................................ 70
Roller weights................................................................................................. 71
Mobile primary pulley ..................................................................................... 71
1
Workshop Manual
General index
c
Disassembling the clutch................................................................76
Flywheel cover, Flywheel Magneto,
Water pump.............................................................................100
Disassembling the clutch unit........................................................77
Exploded view of water pump......................................................101
Removing the secondary pulley ....................................................78
Exploded view of flywheel cover..................................................102
Checks..............................................................................................80
Removing the flywheel cover.......................................................103
Installing the primary pulley...........................................................73
Clutch bell....................................................................................................... 80
Clutch linings................................................................................................... 80
Variator contrast spring .................................................................................. 81
Fixed secondary pulley................................................................................... 81
Removing the flywheel magneto................................................................... 104
Removing the freewheel gear....................................................................... 105
Removing the stator/pick-up assy................................................................. 106
Removing the water pump impeller............................................................... 106
Mobile secondary pulley.................................................................................. 82
Installing the water pump..............................................................107
Assembling the clutch.....................................................................83
Assembly procedure..................................................................................... 107
Installing the clutch bell..................................................................87
Installing the stator/pick-up assy.................................................108
Installing the freewheel gear and rotor........................................109
Final drive gears..............................................................88
Final drive exploded view...............................................................89
Installing the flywheel cover......................................................... 111
Removing the transmission cover.................................................90
Engine casing, crankshaft..................................113
Remove pulley shaft........................................................................92
Removing the engine casings...................................................... 114
Transmission cover checks............................................................92
Crankshaft checks......................................................................... 115
Removal and refitting of transmission cover bearings
and oil seal.......................................................................................94
Installing the engine casing.......................................................... 117
Removal and refitting of clutch side engine casing bearings
and oil seals.....................................................................................96
Installing the transmission gears...................................................97
Installing the transmission cover...................................................98
125 - 160 cc
WORKSHOP MANUAL
OIL PUMP ASSY
•
•
•
•
C
The oil pump must be serviced after having removed the flywheel cover.
When the values measured are outside the service limits, renew the oil pump.
Ensure that no foreign material enters the engine when the oil pump is removed.
Check for oil leaks once the pump has been installed.
Oil quantity
For oil change
Total capacity
Recommended oil
temperature and viscosity
- 10°
0°
10°
20°
SAE 10W / 30
SAE 10W / 40
30°
40°C
Standard
1.1 L
1.15 L
SAE 10W-40 20W-50 Special
for 4-stroke engines
When using alternative oils, select from the following range
API: type SE or SF engine oil
SAE: select from the table alongside on the basis of the outdoor
temperature.
SAE 20W /40
SAE 10W / 50
07028005
(temperature)
cont’d
125 - 160 cc
3
WORKSHOP MANUAL
C
OIL PUMP ASSY
Oil pump rotor
Radial clearance between
inner and outer rotors
Pump body radial clearance
Front clearance between
surfaces
Tightening torques
Pump body screws
Pump cover screws
Protection plate A assy
Protection plate B
10 N*m
2 N*m
10 N*m
10 N*m
Standard
0.15 mm
Service limit
0.20 mm
0.15 - 0.23 mm
0.05 - 0.10 mm
0.25 mm
0.12 mm
± 15%
± 15%
± 15%
± 15%
Trouble shooting
Low oil level; possible causes:
1) Normal consumption (check scheduled service has been performed).
2) Oil leaks.
3) Wear or incorrect fitting of piston rings.
4) Wear of valve guide or valve stem.
5) Valve seat rings damaged.
125 - 160 cc
4
WORKSHOP MANUAL
C
OIL PUMP ASSY
Exploded view of oil pump
1)
2)
3)
4)
5)
6)
7)
Pump cover
Pump shaft
Inner rotor
Outer rotor
Pump body
Locating dowel
Screw
7
1
6
3
07028001
4
5
125 - 160 cc
2
5
WORKSHOP MANUAL
C
OIL PUMP ASSY
Ensure that no foreign material enters the engine when the
oil pump is removed and refitted.
Disassembly
Remove:
•
flywheel cover.
•
rotor and freewheel gear.
•
chain guard (A) and oil pump assembly.
A
07028101
Remove circlip (C) from shaft.
07028102
125 - 160 cc
C
6
WORKSHOP MANUAL
C
OIL PUMP ASSY
Remove chain ring (D) and chain (E).
Check chain for damage or excessive wear.
E
07028103
D
Remove chain guard (B).
07028104
125 - 160 cc
B
7
WORKSHOP MANUAL
C
OIL PUMP ASSY
Remove pump assy (F) and pump shaft (G).
Check pump for possible damage or excessive wear.
G
F
07028100
Removing the oil pump
Undo screw (V) and remove pump cover (C).
C
V
DSCN8392
125 - 160 cc
8
WORKSHOP MANUAL
C
OIL PUMP ASSY
Remove inner rotor (L) and outer rotor (M) from pump body (N), paying
attention to locating dowel (Q).
Q
07028105
Oil pump body tolerances
M
L
N
M
N
Measure outside diameter of outer rotor (M) and inside diameter of pump
body (N) with callipers and inside micrometer; the difference between the
two values is the “radial clearance” of the pump body.
Service limit: 0.25 mm
07028106
125 - 160 cc
9
WORKSHOP MANUAL
C
OIL PUMP ASSY
Clearance between oil pump inner
and outer rotors
Install inner rotor (L) and outer rotor (M) in pump body (N); measure
clearance between inner and outer rotors with feeler gauge.
Service limit: 0.20 mm
N
M
L
07028107
Clearance between front surfaces
L
Fit inner rotor (L) and outer rotor (M) in pump body (N) and use a feeler
gauge to measure axial clearance between rotors and pump body.
Service limit: 0.12 mm
M
N
07028108
125 - 160 cc
10
WORKSHOP MANUAL
C
OIL PUMP ASSY
Assembly
Q
M
Wash all parts in clean diesel fuel before refitting.
Fit inner rotor (L) and outer rotor (M) in pump body (N), paying attention
to locating dowel (Q)
N
L
07028109
Fit pump cover (C) and tighten screw (V) to prescribed torque.
V
Cs-N*m
2 ± 15%
C
V
DSCN8392
125 - 160 cc
11
WORKSHOP MANUAL
C
OIL PUMP ASSY
Ensure fixing holes (P) of pump body (N) are aligned with holes in flywheel
cover.
If holes are not aligned, screws (V2) cannot be tightened.
Fit and tighten two screws (V2) of pump body and chain guard (B); tighten
screws to prescribed torque.
V2
N
Cs-N*m
10 ± 15%
P
07028110
V2
B
125 - 160 cc
07028111
12
WORKSHOP MANUAL
C
OIL PUMP ASSY
Fit chain ring (D) and chain (E).
E
D
07028112
Fit circlip (C) in shaft groove.
C
125 - 160 cc
07028113
13
WORKSHOP MANUAL
C
OIL PUMP ASSY
Couple chain guard (A) to chain guard (B) and tighten screw (V).
Fit rotor assembly and freewheel gear.
Fit flywheel cover.
V
B
A
125 - 160 cc
07028114
14
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Working precautions
• Valves cover, camshaft, camshaft support, rocker arm, cylinder head and cylinder can be removed without
dropping engine from frame.
• Take care not to damage mating surfaces when removing valves cover, cylinder head and cylinder.
• Mark disassembled parts so they can be refit in exactly the same position.
• After disassembly, wash parts and dry with compressed air before checking and measuring them.
• Lubricate cam surfaces, shaft and internal hole of rocker arms before reassembling.
• Camshaft assy lubricating oil is fed through oil passages in the cylinder.
• Valve cover, cylinder head, and cylinder oilways must be perfectly clean prior to assembly.
Standard
Cylinder compression pressure
Valves
IN
clearance
EX
Flatness of cylinder head
Camshaft
Cam height
Rocker arm
125 - 160 cc
Rocker arm shaft bore
diameter
Rocker arm shaft diameter
IN
EX
IN/EX
125 cc
160 cc
2
700 kPa (7 kgf/cm ) @ 260 RPM
0.05 mm
0.20 mm
—
30.74-30.86 mm
30.33-30.45 mm
10.000-10.015 mm
IN/EX
9.978-9.987 mm
Service limit
—
—
—
0.05 mm
30.69 mm
30.28 mm
10.10 mm
9.91 mm
cont’d.
15
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Standard
Valve guide
Valve stem outside diameter
Valve guide inside diameter
Valve springs
Cylinder
125 - 160 cc
Valve stem to guide
clearance
Valve guide height
Valve seating line height
Length
(Outer spring/inner spring)
Internal diameter
Top face flatness
Taper
IN
EX
IN
EX
IN
EX
IN/EX
IN/EX
IN/EX
125 cc
160 cc
4.975-4.990 mm
4.955-4.970 mm
5.000-5.012 mm
5.000-5.012 mm
0.100-0.037 mm
0.030-0.057 mm
11.9-12.1 mm
0.9-1.1 mm
35.0-32.3 mm
C
Service limit
4.965 mm
4.945 mm
5.040 mm
5.040 mm
0.075 mm
0.095 mm
—
1.8 mm
33.5-30.8 mm
52.400-52.419 mm 58.00-58.019 mm 52.449 mm 58.049 mm
—
0.05 mm
—
0.05 mm
16
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Standard
Piston
Piston assembly direction
Piston outside diameter
Piston pin bore diameter
Piston pin diameter
Connecting rod small end diameter
Cylinder / piston tolerance
Piston / piston pin tolerance
Piston pin / small end tolerance
Piston rings / grooves
Ring (1)
tolerance
Ring (2)
Ring gap
Ring (1)
Ring (2)
Scraper ring
Piston ring assembly direction
Tightening torques
Cylinder head screw
Tensioner screw
Cylinder screws
Valves cover screw
Cylinder head nut
Timing sprocket screw
Chain tensioner screw
125 - 160 cc
10 N*m
35 N*m
9 N*m
10 N*m
10 N*m
10 N*m
10 N*m
125 cc
160 cc
“IN” on intake side
52.37-52.39 mm 57.97-57.99 mm
15.002-15.008 mm
14.994-15.000 mm
15.016-15.034 mm
0.02-0.04 mm
0.002-0.014 mm
0.016-0.040 mm
0.020-0.044 mm
0.020-0.044 mm
0.15-0.30 mm
0.10-0.25 mm
0.2-0.7 mm
punch marking at top
Service limit
—
52.32/57.92 mm
15.04 mm
14.980 mm
15.050 mm
15.05 mm
0.080 mm
0.040 mm
0.070 mm
0.070 mm
0.45 mm
0.45 mm
0.9 mm
—
± 15%
± 15%
± 15%
± 15%
± 15%
± 15%
± 15%
17
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Trouble shooting
Compression loss can be identified by measuring pressure directly.
If engine fails to start or idles unevenly, check for smoke in engine casing voids.
Presence of smoke means damaged, broken or worn piston rings.
Irregular full speed
Low compression
High combustion pressure
Blue smoke from exhaust
Anomalous noise
125 - 160 cc
Low compression
Air infiltrating through carburettor couplings
Poor fuel feed
Incorrect valves clearance
Valve burnt or damaged
Incorrect timing
Weak valve spring
Poor valve seal
Pressure loss from head gasket
Head warped or cracked
Incorrect fitting of spark plug
Carbon deposits on piston or in combustion chamber
Damaged valve guide or valve stem
Damaged or worn seat ring
Damage or wear of camshaft assy components
Incorrect valves clearance
Burnt valve or damaged valve spring
Rocker arm or rocker arm shaft damaged
Chain stretched
Chain tensioner malfunction
18
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Cylinder head exploded view
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Valve cotter
Valve upper spring retainer
Inner valve spring
Outer valve spring
1
Valve oil seal
Valve lower spring retainer
Cylinder head
Intake valve
Exhaust valve
Spark plug
3
4
9
7
6
2
5
5
07028109
6
10
2
1
125 - 160 cc
8
4
3
19
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Cylinder compression pressure
NOTE Take measurement with warm engine
A
A
Remove spark plug cap (A) and spark plug.
Fit pressure gauge in spark plug bore to measure compression.
Turn over engine with starter motor and throttle body fully open.
NOTE The pressure gauge and its components must be assembled
in such a way as to avoid pressure losses.
Prolonged use of the starter motor will drain the battery: do
not run starter motor for more than 5 seconds at a time.
Compression pressure: 700 kPa (7 bar) @ 260 RPM
If compression is too high, check for carbon deposits on the piston crown
or in the combustion chamber.
07028116
If pressure is too low, pour a little engine oil into cylinder through spark
plug bore and check measurement again.
Compare the two pressure readings; if pressure increased after adding
oil, measure cylinder, piston and piston rings. If pressure is unchanged,
check cylinder head and valves.
The problem could be:
• Pressure escaping from valves (blow-by)
• Incorrect valves clearance
07028117
125 - 160 cc
20
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Valve clearance adjustment
NOTE Checking and adjusting valve clearance must be carried out
with warm engine.
Remove
• valves cover.
• clutch cover.
DSCN8394
Turn camshaft (by rotating the variator unit nut) until the two timing sprocket
references (B) are parallel with cylinder head machined surface (C) and
camshaft notch (T) is facing upwards.
T
DSCN8399
C
B
DSCN8396
125 - 160 cc
21
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Insert feeler gauge (C) between rocker arm (D) and valve (E) and measure
clearance.
Valve clearance (warm engine) IN: 0.05 mm
EX: 0.15-0.20 mm
E
C
D
DSCN8398
125 - 160 cc
22
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Removing camshaft support
Remove:
• clutch cover.
• valves cover.
Turn camshaft counterclockwise by means of variator unit until the two
timing sprocket references (B) are parallel with cylinder head machined
surface (C) and camshaft notch (T) is facing upwards.
T
E
D
DSCN8399
Undo chain tensioner central screw (V).
Undo chain tensioner fixing screw (V2).
Remove oil fitting (D) and spring (E).
B
C
DSCN8396
V
V2
DSCN8400
125 - 160 cc
23
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Undo screws (V2).
Remove timing sprocket (F).
V2
F
DSCN8401
Unscrew capnuts (D4).
D4
D4
DSCN8402
125 - 160 cc
24
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Remove camshaft support (G).
G
DSCN8403
Remove three circlips (S) relative to rocker arm spindles and camshaft.
S
S
S
DSCN8404
125 - 160 cc
25
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Remove rocker arm spindles (L).
NOTE Remove rocker arm spindles using an M5 screw.
L
DSCN8405
Removing the camshaft
Remove camshaft assy (M).
M
DSCN8406
125 - 160 cc
26
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Checks
C
C
Camshaft
Turn bearings (C) to check that they rotate freely and smoothly.
Renew camshaft (M) in the presence of noise or tendency to jam.
Check cam surfaces for damage and scoring.
Measure cam height with micrometer.
Service limit
IN: 30.69 mm
EX: 30.28 mm
07028118
M
07028119
125 - 160 cc
27
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Rocker arms and rocker arm spindles
Check sliding surfaces (N) of rocker arms (Q) and contact surface (P) with
valve for possible damage or wear.
If wear is excessive, renew rocker arms.
N
P
Q
07028120
Measure inside diameter of each bore in rocker arm (Q).
Service limit: 10.10 mm
Measure outside diameter of each rocker arm spindle (L).
Service limit: 9.91 mm
L
Q
07028121
125 - 160 cc
28
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Removing the cylinder head
Remove
• throttle body (A) complete with manifold (B)
• valves cover.
• camshaft support (see removal)
• temperature sensor assy (C).
C
A
B
C
DSCN8407
125 - 160 cc
29
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Undo screws (V2).
Remove cylinder head (D).
D
V2
DSCN8409
Remove head gasket (E) and locating dowels (F).
F
E
DSCN8410
125 - 160 cc
F
30
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Removing the cylinder
Disconnect coolant inlet hose (T) from cylinder.
T
DSCN8390
DSCN8409
Remove lower chain guide (G).
Undo screw (V).
Remove cylinder (L)
V
L
G
125 - 160 cc
DSCN8410
31
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Removing the piston
Remove piston pin circlip (A).
A
07028122
Remove piston pin (B) and piston (C).
C
B
07028123
125 - 160 cc
32
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Expand piston rings (D) and slide them off over piston (C).
C
D
• Piston rings are fragile. Do not deform excessively.
• Make sure piston rings do not scratch or score surface of
piston.
C
07028124
Scrape carbon deposits off piston (C).
Use an old piston ring (D) to remove carbon deposits from piston ring
grooves.
C
• Do not damage piston ring grooves.
• Do not use wire brushes: risk of damaging piston ring
grooves.
07028125
125 - 160 cc
D
33
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Cylinder / piston checks
Checking the cylinder
Check interior of cylinder for signs of damage or wear.
Measure cylinder inside diameter at top, mid point, and bottom (6
measurements); along direction of piston pin and the direction orthogonal
to it (axes X – Y); make a note of all values and take the highest value
obtained as a reliable reference.
Service limit: 52.449-58.049 mm
07028006
Checking the piston
Measure outside diameter of piston (D) 6 mm above the base and at right
angles to piston pin bore.
07028126
07028127
Service limit: 52.32 / 57.92 mm
Calculate tolerance between piston and cylinder.
Service limit: 0.08 mm
Measure piston pin bore.
D
6mm
D
Service limit: 15.04 mm
125 - 160 cc
34
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Measure outside diameter of piston pin (B) in contact points with piston
and with connecting rod small end (total of three measurements).
C
B
Service limit: 14.8 mm
Calculate tolerance between piston pin (B) and bore in piston.
Service limit: 0.04 mm
Calculate tolerance between piston pin and small end bore.
Service limit: 0.06 mm
07028128
Check piston rings (D) for signs of wear or damage.
Fit rings in corresponding grooves of piston (C) and compress until flush
with piston outer surface.
C
07028129
125 - 160 cc
D
35
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Measure axial clearance between piston ring and groove with feeler
gauge.
Service limit:
• Top piston ring: 0.07 mm
• 2nd ring: 0.07 mm
Position ring horizontally in lower part of cylinder.
Measure ring gap with feeler gauge.
Service limit:
C - Piston: 52.32 / 57.92 mm
E - Top piston ring: 0.45 mm
F - 2nd ring: 0,45 mm
G - Scraper ring: 0.9 mm
07028130
E
F
G
G
07028131
125 - 160 cc
C
36
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Assembling the piston
E
F
Insert rings on piston with rings oriented so that punch markings are facing
upwards.
• Top ring (E) and second ring (F) are not interchangeable.
• Keep piston ring gaps staggered at intervals of 120°.
After assembly ensure rings can turn freely in grooves.
Lubricate connecting rod small end, piston pin (B) and bore in piston.
Install piston and ensure that the punched “IN” on the piston will be aligned
with the intake valve when the camshaft assy is installed.
Fit new circlip (A) for piston pin.
G
G
Circlip (A) must be fitted correctly in its groove.
C
07028131
B
C
Punzonatura “IN”
"IN"
07028132
125 - 160 cc
A
37
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Stripping down the cylinder head
NOTE Removed parts must be set aside separately and refit in their
original positions.
A
Remove valve cotters using specific tool (A).
DSCN8412
125 - 160 cc
38
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Remove tool, remove upper retainer (B), outer spring (C), inner spring
(D), valve oil seal (F) and lower retainer (G).
Once removed, valve oil seal (F) must not be reused.
C
A
D
E
F
G
B
DSCN8413
Remove carbon deposits from combustion chamber (L) and valves.
NOTE Immerse components in petrol to remove carbon deposits.
Camera di combustione
L
Petrol is highly inflammable; work must be performed in
well-ventilated surroundings.
07028133
125 - 160 cc
39
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Checking valve springs
Measure length of outer spring.
Service limit: 33.5 mm
Measure length of inner spring.
Service limit: 30.8 mm
07028134
Checking valves
Insert valve in seat and check movement.
Measure diameter of stem in area affected by valve travel.
Service limit
IN: 4.965 mm
EX: 4.945 mm
DSCN8416
125 - 160 cc
40
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Remove carbon deposits with reamer (M) before measuring inside
diameter of valve guide.
C
M
NOTE Insert valve guide reamer (M) from combustion chamber
side.
Turn reamer clockwise; counterclockwise rotation of reamer
can damage valve guide internal surface.
07028135
Measure inside diameter of valve guide (N).
Service limit
N
IN: 5.04 mm
EX: 5.04 mm
Calculate clearance between stem and valve guide.
Service limit
IN: 0.075 mm
EX: 0.095 mm
07028136
125 - 160 cc
41
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Checking and adjusting valve seating
Inspection
Clean carbon deposits from valve.
Check for possible cracks or distortion of valve seat.
Change
NOTE Valves cannot be repaired.
In the presence of breakages, damage, or areas that do not
seal correctly, renew the valves.
07028137
Remove the valves; check valve seating surface with petrol.
Grind valve seat to remove any abrasions.
If the valve is not perfectly straight, check clearance between valve guide
and valve stem; if clearance is incorrect, renew valve guide.
A Valve seat damaged
B Valve bent
A
B
07028138
125 - 160 cc
42
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
When the valve contact area is located in the upper or lower area of the
valve head, correct the position by means of a valve grinding tool.
A Low contact area
B High contact area
A
B
07028139
Measure depth of the valve seating area.
Standard: 0,91-1,10 mm
Service limit: 1,80 mm
If contact area is irregular, to wide or too narrow, correct with a valve
lapping tool.
C High contact area
125 - 160 cc
C
07028140
43
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Lapping
C
Svasatore
D
per collare valvola
Grind with a valve lapper (D).
Refer to valve lapper handbook.
Lapping must be performed by hand, exerting pressure of 4-5 kg, always
turning the tool in the same direction while working.
Lubricate lapper and remove lapping dust during the
procedure.
07028141
If the contact area with the valve shows signs of abrasion or cracking, use
a 45° grinding tool to eliminate irregularities.
Grind the valve contact area when the valve seat is
replaced.
Take care not to grind excessively.
07028142
125 - 160 cc
44
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Use a 32° stone to grind the outermost surface lightly.
C
A
A Abrasions on valve seat
07028143
Use a 60° stone to grind the contact surface lightly.
B
B Original contact area
07028144
125 - 160 cc
45
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Use a 45° stone to grind contact area to required depth.
07028145
Check valve seating area again.
If contact area is wider, grind first with a 32° stone and then bring it to the
required size with a 45° stone.
If contact area is narrower, grind first with a 60° stone and then bring it to
the required size with a 45° stone.
A
A High seating line
B
B Low seating line
C Original contact area
125 - 160 cc
C
C
07028146
46
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
After correcting, apply a uniform coat of lapping compound and lap the
valve.
NOTE Rotate the valve slowly during the procedure.
Do not work for too long in the same position to avoid wear
due to axial misalignment.
Do not allow lapping compound to penetrate in area between
valve guide and stem.
When repair is completed, clean cylinder head and valves.
After the procedure recheck valve seating area.
07028137
125 - 160 cc
47
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Position lower retainer (G) and new valve oil seal (F) in the valve guide.
Lubricate valve stem and interior of valve guide.
Slowly insert valve (E) into valve guide.
Take care not to damage valve oil seal (F).
C
D
F
G
B
DSCN8413
Fit inner spring (D) and outer spring (C), both with pointed end (A) towards
the combustion chamber.
Fit upper retainer (B).
C D
A
07028147
125 - 160 cc
48
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Compress springs with specific tool (A) and fit cotters.
To avoid weakening springs do not compress more than
necessary.
A
DSCN8412
125 - 160 cc
49
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Installing the cylinder
C
A
Check lower chain guide (A) for signs of abrasion, damage or wear caused
by misalignment.
07028148
Clean deposits and foreign material from mating surfaces.
Check that coolant passages, oilways and screw holes are clean.
Fit cylinder gasket (B) and insert locating dowels (C).
Fit cylinder over stud screws and DELICATELY bring into position until it
locates against its seat.
C
B
During procedure take care to insert piston CORRECTLY in
cylinder.
Be careful with piston rings and AVOID scoring the cylinder
internal surface.
DSCN8418
125 - 160 cc
50
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Insert washer under screw (V) and snug screw without tightening.
V
DSCN8410
Fit lower chain guide (A).
Turn timing sprocket (lower sprocket) until piston is at TDC (piston surface
flush with cylinder rim).
Do not turn timing sprocket during following operations.
A
07028149
125 - 160 cc
51
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Position head gasket (C) and insert locating dowels (D).
C
D
C
07028150
Installing the cylinder head
Fit head (E) over stud screws and locate it against cylinder.
Insert washers under screws (V2) and snug screws without tightening.
Insert locating dowels.
D
V2
E
DSCN8409
125 - 160 cc
52
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Installing the camshaft support
Fit camshaft (A) in support (B).
A
B
DSCN8406
Lubricate rocker arm spindles (C) sparingly and insert in support (B) and
in rocker arms (D).
B
NOTE Insert rocker arm spindles using an M5 screw.
C
D
DSCN8405
125 - 160 cc
53
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Fit circlips (S) in rocker arm spindle bores and in camshaft bore groove.
Lubricate cam surfaces.
Install assy on cylinder head.
S
S
S
DSCN8404
Fit washers and four cap nuts (D4).
Tighten nuts to prescribed torque in two / three passes.
D4
Cs-N*m
D4
30 ± 15%
Tighten cylinder screw (V) to prescribed torque.
V
V2
Cs-N*m
10 ± 15%
Tighten cylinder head screws (V2) to prescribed torque.
V2
125 - 160 cc
Cs-N*m
10 ± 15%
V
DSCN8402
54
WORKSHOP MANUAL
C
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Install sprocket (E) on camshaft, maintaining reference marks (F) parallel
to head surface (G).
Fit timing chain (L) on timing sprocket (E).
Fit and tighten sprocket screws (V2).
V2
Cs-N*m
9 ± 15%
E
L
V2
G
F
DSCN8401
Press ratchet (M) on tensioner and push tensioner pin (N) into chain
tensioner (P).
P
N
M
DSCN8419
125 - 160 cc
55
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Install chain tensioner and tighten screws (V2) to prescribed torque.
V2
Cs-N*m
10 ± 15%
V
Fit tensioner screw (V) and tighten to prescribed torque.
V
Cs-N*m
• Install throttle body and manifold.
• Install temperature sensor assy.
125 - 160 cc
8 ± 15%
V2
DSCN8400
56
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
C
Checking engine timing
Use a slotted screwdriver to remove timing check cap (Q) located on
flywheel cover (R).
Turn crankshaft by means of variator pulley until aligning reference mark
(S) on rotor with reference mark on flywheel cover (V); piston must be at
TDC.
NOTE If you note absence of reference mark (S) on the rotor during
disassembly phase, the mark must be made with a punch
before removing the rotor.
Q
DSCN8390
R
V
T
Make sure the two camshaft sprocket references (U) are parallel with
cylinder head machined surface (V) and camshaft notch (T) is facing
upwards.
S
DSCN8421
DSCN8399
V
U
125 - 160 cc
DSCN8401
57
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Fitting the valves cover
C
B
Fit gasket (A) and insert locating dowels (B) on valves cover (C).
A
B
C
DSCN8422
Fit spring (D) in oil union (E) then insert oil union into camshaft.
D
E
DSCN8396
125 - 160 cc
58
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Fit valves cover (C).
Tighten screws (V2), paying attention to the respective sealing washers (F).
C
V2
C
F
DSCN8394
125 - 160 cc
59
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Front pulley
Belt thickness
Secondary
pulley
Mobile pulley inside diameter
Pulley sliding bush outside diameter
Roller weights outside diameter
Clutch linings thickness
Clutch bell inside diameter
Speed variator contrast spring length
Fixed secondary pulley outside d
iameter
Mobile secondary pulley inside diameter
Tightening torques
Clutch cover screws
Transmission housing nuts
Clutch bell nut
Special nut
125 - 160 cc
10 N*m
59 N*m
53 N*m
59 N*m
Standard
24.007-24.028 mm
23.959-23.980 mm
19.95-20.05 mm
21.7-23.3 mm
—
124.5-124.2 mm
144-146 mm
33.950-33.975 mm
Service limit
24.070 mm
23.920 mm
19.45 mm
20.7 mm
2.75 mm
125.0 mm
140 mm
33.920 mm
34.000-34.025 mm
34.060 mm
C
± 15%
± 15%
± 15%
± 15%
60
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
C
Trouble shooting
With engine running scooter does
not move
Engine dies or clutch grabs when
scooter pulls away
Low speed
125 - 160 cc
Drive belt
Worn
Ramp guide,
Ramp plate
Clutch linings
Variator contrast spring
Clutch shoes contrast springs
Worn / Damaged
Drive belt
Variator contrast spring
Roller weights
Surfaces of variator pulleys
Worn / damaged
Deteriorated
Worn / damaged
Damaged
Worn / damaged
Damaged
Damaged
61
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Variator unit exploded view
1) Ramp plate
2) Ramp guide,
3) Roller weight
4) Primary pulley bush
5) O-Ring gasket
6) Mobile primary pulley
7) Sliding bush
8) Fixed primary pulley
9) Washer (14x28x2)
10) Nut (M14x1.5)
2
1
3
2
2
4
6
5
8
9
7
07028151
10
125 - 160 cc
62
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
C
Clutch unit exploded view
1)
2)
3)
4)
5)
6)
7)
Clutch nut
Clutch unit
Clutch side spring retainer
Variator contrast spring
Stop washer
Spacer
Secondary pulley
6
4
2
5
07028153
7
3
1
125 - 160 cc
63
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Clutch pulley exploded view
1) Pulley side spring retainer
2) O-Ring gasket
3) Oil seal
4) Mobile secondary pulley
5) Pin
6) Roller
7) Fixed secondary pulley
8) Bearing
9) Circlip
10) Needle roller bearing
10
8
7
3
1
9
6
5
07028152
125 - 160 cc
2
4
64
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Clutch shoes assy exploded view
1)
2)
3)
4)
5)
6)
Disk
Rubber ring
Clutch ground
Snap ring
Clutch shoes contrast springs
Ring
5
4
3
5
1
6
5
07028007
125 - 160 cc
2
65
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Removing the clutch cover
Undo three screws (V3) and screw (V).
Remove plastic cover (A).
V
V3
A
Undo screws (V5).
Remove filter (B) and clutch cover (C).
V5
B
125 - 160 cc
DSCN8423
V5
V5
C
V5
DSCN8424
66
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Remove gasket (F) of clutch cover (C).
Remove locating dowels (E).
C
Assembly
To reassemble, perform the above steps in reverse sequence.
F
E
Primary pulley
Disassembly
Remove clutch cover.
Undo nut (D) and remove its washer. Remove fixed primary pulley (G).
G
D
DSCN8425
125 - 160 cc
67
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Remove drive belt (A).
A
07028155
Immobilise internal part of mobile primary pulley (B); now remove pulley
together with sliding bush (C).
C
B
125 - 160 cc
07028156
68
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Remove pulley sliding bush (C) from mobile primary pulley (B).
B
C
Remove roller ramp plate (E).
C
07028157
E
07028158
125 - 160 cc
69
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Remove roller weights (F).
C
F
07028159
Checks
A
Drive belt
Check drive belt (A) for fraying, wear, or chaffing
Measure belt thickness.
Service limit: 20.7 mm
07028160
125 - 160 cc
70
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Roller weights
F
Check roller weights (F) for possible wear or damage.
Measure roller weights outside diameter.
Service limit: 19.45 mm
07028161
Mobile primary pulley
Measure inside diameter of mobile pulley (B).
B
Service limit: 24.07 mm
07028162
125 - 160 cc
71
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Check that pulley sliding bush (C) is not worn or damaged.
Measure outside diameter of bush (C).
C
Service limit: 23.92 mm
07028163
125 - 160 cc
72
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Installing the primary pulley
F
H
Insert roller weights (F) in races (H) of mobile primary pulley (B).
Seat rollers with end protruding slightly as shown in the photo.
B
Fit roller ramp plate (E).
07028164
E
07028165
125 - 160 cc
73
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Insert sliding bush (C) in mobile primary pulley bore (B).
B
C
07028166
Manually clamp mobile primary pulley (B) and assemble together with
sliding bush (C).
B
125 - 160 cc
C
07028167
74
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Install drive belt (A).
07028168
A
Install fixed primary pulley (G). Apply threadlocker to nut (D) and fit nut
complete with washer.
Tighten nut (D) using a pneumatic nut runner set to the prescribed
tightening torque.
D
Cs-N*m
59 ± 15%
G
125 - 160 cc
D
DSCN8425
75
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Disassembling the clutch
B
Unscrew locking nut (D).
Withdraw cutch bell (A); now remove entire clutch unit and secondary
pulley (B).
A
DSCN8425
Using specific tool (C) compress clutch unit and secondary pulley (B).
Undo nut (D).
Release specific tool (C) and remove clutch unit; remove also secondary
pulley (B) from clutch unit.
C
D
125 - 160 cc
D
B
07028169
76
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Disassembling the clutch unit
E
Remove circlips (E) and ring (A).
A
E
E
Remove clutch shoe contrast springs (F) then remove clutch shoes (G)
from plate (L).
07028009
G
F
L
07028170
125 - 160 cc
77
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Remove rubber rings (M) from disk (L).
M
L
Removing the secondary pulley
C
07028171
A
Remove pulley side retainer (A).
07028172
125 - 160 cc
78
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Remove guide pin (B) complete with roller (C); remove mobile secondary
pulley (E).
Check that guide pin (B) and roller (C) are not damaged or worn.
B C
E
07028173
Remove oil seal (F) and O-rings (G) from mobile secondary pulley (fit new
oil seal and O-rings at time of assembly).
Check condition of fixed secondary pulley bearings.
Renew bearings if necessary
F
G
125 - 160 cc
C
07028174
79
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
C
Checks
Clutch bell
Check clutch bell (L) for signs of damage or excessive wear.
Measure inside diameter of clutch bell.
Service limit: 125 mm
L
Clutch linings
07028175
M
Check clutch linings (M) for signs of wear or damage.
Service limit: 2,75 mm
07028176
125 - 160 cc
80
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
C
Variator contrast spring
Check that variator contrast spring (N) is not weakened or broken.
Measure spring length.
Service limit: 140 mm
N
07028176
Fixed secondary pulley
Check that fixed secondary pulley (A) is not worn or damaged.
Measure fixed secondary pulley outside diameter.
Service limit: 33.92 mm
A
07028178
125 - 160 cc
81
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
C
Mobile secondary pulley
Check that mobile secondary pulley (B) is not worn or damaged.
Measure inside diameter of secondary pulley.
Service limit: 34.06 mm
B
07028179
125 - 160 cc
82
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Assembling the clutch
C
B
Before assembling, degrease sliding surface of fixed
secondary pulley, outer part of clutch and inner part of pulleys
assy.
Degrease and clean surface of mobile secondary pulley (A) in area of
drive belt contact.
Grease lip and fit oil seal (B) with lip on side of internal surface of mobile
secondary pulley.
A
07028180
Grease O-Rings (C) and insert in mobile secondary pulley (A).
Pack lithium grease into 34 mm diameter hole of mobile secondary
pulley.
Also apply adequate amount of lithium grease to fixed secondary pulley
roller bearing and ball bearing.
A
C
125 - 160 cc
07028181
83
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Install mobile secondary pulley (A) on fixed secondary pulley (D).
Grease guide pin (E) and roller (F) before installing fixed secondary
pulley.
E F
D
Fit pulley side retainer (G) on mobile secondary pulley (A).
G
A
07028182
A
07028183
125 - 160 cc
84
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Fit rubber rings (A) on disk (B).
A
B
Fit clutch shoes (C) and clutch shoe contrast springs (D).
07028184
C
NOTE Pay attention to direction of assembly of clutch shoe contrast
spring (D).
D
07028185
125 - 160 cc
85
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
First fit ring (A) and then fit circlips (E).
E
A
E
E
Using specific tool (A) compress clutch unit and secondary pulley (B).
Tighten nut (D) to prescribed torque.
D
07028009
B
Cs-N*m
59 ± 15%
Release specific tool (A) and remove clutch unit; remove also secondary
pulley (B) from clutch unit.
D
A
125 - 160 cc
07028186
86
WORKSHOP MANUAL
C
SPEED VARIATOR-CLUTCH UNIT
Installing the clutch bell
D
B
A
Insert clutch unit and secondary pulley (A) on shaft.
Insert clutch bell (B) and tighten nut (D).
Tighten nut (D) using a pneumatic nut runner set to the prescribed
tightening torque.
Cs-N*m
53 ± 15%
D
DSCN8425
125 - 160 cc
87
WORKSHOP MANUAL
FINAL DRIVE GEARS
Transmission
Oil capacity
For oil change
For disassembly
Recommended transmission oil
Tightening torques
Level/drain plug
125 - 160 cc
C
0,15 l
0,15 l
SAE10W-40/SF grade
22 N*m (± 15%)
88
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Final drive exploded view
1) Pulley shaft
2) Pulley shaft bearing
3) Reduction gear shaft
4) Intermediate gear
5) Washer
6) Intermediate gear bearing
7) Output shaft
8) Output shaft oil seal
9) Output shaft bearing
10) Transmission cover gasket
11) Transmission cover
12) Locating dowel
11
9
8
7
12
10
12
6
5
2
4
3
07028002
1
125 - 160 cc
89
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Removing the transmission cover
V6
Remove clutch unit.
Unscrew oil drain plug and allow all oil to flow out.
V7
NOTE Dispose of spent oil in compliance with local legislation.
Undo screws (V7).
V7
V7
07028187
Remove transmission cover (A)
Remove locating dowels (B) and gasket (C).
B
07028188
125 - 160 cc
C
A
B
90
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Remove output shaft (D).
Remove reduction gear shaft (E) and intermediate gear (F).
F
07028189
E
D
Remove thrust washer (G).
07028190
125 - 160 cc
G
91
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Remove pulley shaft
Strike end (A) of pulley shaft with plastic mallet and extract main shaft.
Check pulley shaft and bearings for wear or damage. Renew parts if
necessary.
A
07028191
Transmission cover checks
B
Turn inner races of bearings (B, C and D) of transmission cover (E)
and clutch side engine casing; check bearings turn smoothly without
sticking.
Renew bearings if necessary
C
D
E
07028192
125 - 160 cc
92
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Check for possible damage or abrasion in transmission case and clutch
side engine casing bearing seats (B, C and D).
D
C
B
07028193
Check output shaft (E) and its bearings for wear and damage.
Renew bearings if necessary.
Check reduction gear shaft (F), its bearings, and intermediate gear (G),
for wear or damage.
Renew bearings if necessary.
G
07028194
125 - 160 cc
F
E
93
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Removal and refitting of transmission cover
bearings and oil seal
Remove output shaft oil seal (A) from transmission cover.
A
07028195
Remove output shaft bearing (B) by means of a puller.
Use a puller and perform removal procedure in reverse to reassemble.
B
07028196
125 - 160 cc
94
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Remove pulley shaft bearing (C) and reduction gear shaft bearing (D)
from transmission cover side, utilising puller (E).
D
C
Insert new pulley shaft bearing (C) correctly, with punched side facing
upwards, in seat in transmission cover, and drive it fully home.
E
07028197
Repeat same procedure also to install reduction gear shaft bearing (D).
D
125 - 160 cc
C
07028198
95
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Lubricate lip of new oil seal (F) of output shaft and insert with lip facing
transmission cover interior.
Fit oil seal so that it is straight with respect to hole; take care
not to cover breather hole.
F
07028195
Removal and refitting of clutch side engine
casing bearings and oil seals
07028187
Remove pulley shaft oil seal (A).
Refer to “Removal and refitting of transmission cover bearings and oil seal”
for disassembly of pulley shaft bearing, reduction gear shaft bearing, and
output shaft bearing from clutch side transmission casing (B).
A
125 - 160 cc
B
96
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Insert new pulley shaft bearing (B) correctly, with punched side facing
upwards, in seat in clutch side casing, and drive it fully home.
Repeat same procedure also to fit output shaft bearing (C) and reduction
gear shaft bearing (D).
C
D
B
07028199
Installing the transmission gears
The layout of transmission gears is illustrated in the exploded view on
page 89.
125 - 160 cc
97
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Installing the transmission cover
Fit clearance washer (A).
A
07028200
Fit intermediate gear (B) and reduction gear shaft (C) in transmission
cover; ensure thrust washer is fitted on reduction gear shaft.
Fit output shaft (D).
B
07028201
125 - 160 cc
C
D
98
WORKSHOP MANUAL
C
FINAL DRIVE GEARS
Position gasket (E) and insert locating dowel (F).
Mount transmission cover (G) to clutch side engine casing.
F
G
E
07028202
Insert screws (V7); tighten to prescribed torque.
V7
Cs-N*m
22 ± 15%
V7
V7
Reassemble clutch unit.
Fill transmission case with oil.
V7
07028187
125 - 160 cc
V7
99
WORKSHOP MANUAL
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
C
• Flywheel cover, flywheel magneto assy and flywheel must be disassembled with cold engine.
• Flywheel cover can be removed without dropping engine from scooter.
• Flywheel magneto can be removed without dropping engine from scooter.
Tightening torques
Flywheel magneto nut tightening
Flywheel cover screws
Water pump cover screws
125 - 160 cc
59 N*m ± 15%
12 N*m ± 15%
12 N*m ± 15%
100
WORKSHOP MANUAL
C
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Exploded view of water pump
1) Snap ring
2) Bearing
3) Water pump shaft
4) Bearing
5) Water pump oil seal
6) Water pump gland
7) Thrust washer
8) Water pump impeller
9) Locating dowel
10) Water pump gasket
11) Water pump cover
12) Washer
13) Screw
14) Screw
3
4
1
2
5
6
7
8
9
10
11
13
9
07028003
13 12 14
125 - 160 cc
14
101
WORKSHOP MANUAL
C
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Exploded view of flywheel cover
1) Locating dowel
2) Flywheel cover
3) Oil breather union
4) Gasket
5) Oil dipstick
6) O-Ring gasket
7) Oil filter
8) Oil filter spring
9) O-Ring gasket
10) Blank insert
11) Gasket
12) Screw
13) Screw
14) Timing inspection cap
15) Screw
16) Clamp
17) Nut
18) Breather hose
19) Washer
20) Casing screw
21) Oil drain screw washer
22) Oil drain screw
125 - 160 cc
18
1
16
3
4
11 14
1
07028004
13
20
5
6
2
21
22
20
12
17 13
15
15
9
7
13
10
8
102
WORKSHOP MANUAL
C
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Removing the flywheel cover
A
Remove water inlet hose (A).
Undo screws (VA2) and (VB2) and remove water pump cover (B).
VA2
B
DSCN8390
VA2
VB2
VB2
Remove gasket (C) and locating dowels (D).
Unscrew plug (T) and drain out all the engine oil.
C
D
T
125 - 160 cc
D
DSCN8391
103
WORKSHOP MANUAL
C
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Undo screws (V12).
Remove flywheel cover (E).
E
V12
V12
DSCN8391
Removing the flywheel magneto
Remove:
• Oil fitting (F) and its spring (G).
• Locating dowel (L) and flywheel cover gasket (M).
• Starter motor relay gear (N) and its shaft (P).
M
F G
125 - 160 cc
N P
L
07028204
104
WORKSHOP MANUAL
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
C
Remove flywheel magneto (A) using puller (D).
A
D
07028205
Removing the freewheel gear
Remove bolt (V), remove retainer (B) and extract starter crown wheel (C).
C
V B
07028206
125 - 160 cc
105
WORKSHOP MANUAL
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Removing the stator/pick-up assy
C
B
Undo screws (VA2) and (VB2) and remove stator (A) and pick-up (B).
Remove circlip (C).
A
VB2
C
VA2
07028207
Removing the water pump impeller
Remove water pump impeller (D) by unscrewing it in clockwise
direction.
D
DSCN8391
125 - 160 cc
106
WORKSHOP MANUAL
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
C
Installing the water pump
Assembly procedure
• Fit bearing (A) on pump shaft (B)
then fit shaft in flywheel cover.
B
• Fit bearing (C) on pump shaft (B)
and secure with circlip (D).
• Apply sealant to outer surface of
oil seal (E) and install on flywheel
cover.
A
D
C
E
F
G
L
• Fit pump gland (F) in flywheel
cover and press fully home.
• Insert thrust washer (G) on
pump shaft, screw down impeller
(L) on shaft (B) by turning it
COUNTERCLOCKWISE.
125 - 160 cc
07028003
107
WORKSHOP MANUAL
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Install following components in flywheel cover (A):
• Inspection cap (B) and relative seal.
• Dipstick (C).
• Oil filter assy (D).
• Drain plug (E) and relative washer.
C
B
A
C
D
Installing the stator/pick-up assy
DSCN8391
E
G
Install stator (F) and pick-up (G) and tighten screws (VA2) and (VB2)
respectively.
Secure stator and pick-up wires with ties.
F
VB2
Smear threadlocker on fixing screw threads.
VA2
125 - 160 cc
07028207
108
WORKSHOP MANUAL
C
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Fit cable grommets in seat (A), inserting first number 1 then number 2.
1
2
Apply sealant.
A
07028208
Installing the freewheel gear and rotor
Install freewheel gear (B) in the flywheel side engine casing (C), position
restraint (D) and tighten screw (V).
Adjust restraint (D) so that it does not come into contact with or interfere
with the tips of the freewheel gear teeth (B).
B
C
D V
125 - 160 cc
07028209
109
WORKSHOP MANUAL
C
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Install rotor (E) and tighten nut (D) to prescribed torque value; insert oil
fitting (F) and relative spring.
D
N
Cs-N*m
G L
D
M
59 ± 15%
Install double intermediate gear (G) with relative shaft (L).
Fit locating dowel (M) and flywheel cover gasket (N).
E
F
07028210
125 - 160 cc
110
WORKSHOP MANUAL
C
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Installing the flywheel cover
Install flywheel cover (A), tighten screws (V12) working alternately at
opposite corners in two or three passes.
V12
V12
V12
Cs-N*m
12 ± 15%
Pay attention to correct pump shaft timing.
A
V12
DSCN8391
Fit locating dowels, gasket and cover of pump (B) and tighten screws (VA2)
and (VB2) to prescribed torque value.
VA2
Cs-N*m
12 ± 15%
VB2
VA2
Cs-N*m
12 ± 15%
Tighten screws working alternately at opposite corners in
two or three passes.
B
DSCN8390
125 - 160 cc
VB2
VA2
VB2
111
WORKSHOP MANUAL
C
FLYWHEEL COVER, FLYWHEEL MAGNETO, WATER PUMP
Fit water inlet hose (C) and breather hose (D).
Fill cooling circuit.
Fill engine with required oil quantity.
D
C
DSCN8390
125 - 160 cc
112
WORKSHOP MANUAL
ENGINE CASING, CRANKSHAFT
Connecting rod big end
Crankshaft eccentricity
Tightening torques
Removable casing screws
Chain tensioner pin
125 - 160 cc
Standard
0.160-0.304 mm
0.005-0.017 mm
—
End play
Radial play
C
Service limit
0.50 mm
0.05 mm
0.10 mm
12 N*m ± 15%
13 N*m ± 15%
113
WORKSHOP MANUAL
C
ENGINE CASING, CRANKSHAFT
Removing the engine casings
V
A
Unscrew pin (V) and extract chain guide (A).
07028211
Unscrew screws (V8) of clutch side engine casing (B).
Place flywheel side engine casing on a bench and withdraw clutch side
engine casing (B).
B
V8
V8
V8
125 - 160 cc
07028010
114
WORKSHOP MANUAL
C
ENGINE CASING, CRANKSHAFT
Remove gasket (C) and locating dowels (D).
Remove oil seals (E) from engine casings.
C
D
Do not prise with a screwdriver etc. in area of contact
between casings if it proves difficult to remove flywheel
side casing. Tap lightly with a plastic mallet and keep
clutch side engine casing raised.
E
07028213
Crankshaft checks
A
Measure end play of connecting rod big end (A).
Service limit: 0.5 mm
07028214
125 - 160 cc
115
WORKSHOP MANUAL
C
ENGINE CASING, CRANKSHAFT
Measure radial play of connecting rod big end (A).
Service limit: 0.05 mm
A
07028215
Measure crankshaft eccentricity (B).
Service limit: 0.10 mm
B
62 mm
80 mm
07028216
125 - 160 cc
116
WORKSHOP MANUAL
C
ENGINE CASING, CRANKSHAFT
Measure connecting rod small end diameter (C).
C
Service limit: 15.05 mm
07028217
Installing the engine casing
C
B
Lubricate internal lip of new oil seal (A) and apply sealant to external side
before installing in flywheel side engine casing.
Fit locating dowels (B) and gasket (C).
07028213
125 - 160 cc
A
117
WORKSHOP MANUAL
C
ENGINE CASING, CRANKSHAFT
Install complete connecting rod assy.
Install chain guide (D) and pin (V). Tighten to prescribed torque.
V
V
D
Cs-N*m
13 ± 15%
Do not damage casing mating surfaces during installation
procedures.
07028211
Join left and right casings. Tighten screws (V8) to prescribed torque.
V8
V8
Cs-N*m
12 ± 15%
Tighten screws in two or three passes, working alternately.
V8
07028010
125 - 160 cc
V8
118
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