Malaguti 500 cc 4T User manual

Malaguti 500 cc 4T User manual
FOREWORD
• The present manual specifically addresses to specialised technical personnel (MALAGUTI authorised service centres and single motor mechanics) and contains all the
service interventions indicated by the Manufacturer until the publishing of this document.
• Some basic technical information has been intentionally omitted as it is considered to be common knowledge.
• Additional information is available in the SPARE PARTS CATALOGUE and in the SERVICE MANUAL - FRAME AND RUNNING GEAR section.
• It is important to read all the general information before going through the manual to the specific topics and the maintenance operations to be carried out on the engine in order
to make sure the topics, the technical and safety concepts are clearly understood and the manual can be used as a sure reference text.
• All checks, maintenance, repairs or replacements of spare parts etc... are to be performed by skilled and expert technical personnel with specific experience in state-ofthe-art technology and full knowledge of the quickest and most rational procedures, technical characteristics, setting values, tightening torques and information as to which
may only be properly and exhaustively provided by the manufacturer.
• It is important to adhere strictly to the following instructions. Any operation carried out carelessly or not carried out at all may, damage the engine or simply lead to complaints.
MALAGUTI S.p.A. reserves the right to make any changes and modifications hereto it deems necessary without prior notice.
For further information and details, please contact MALAGUTI S.p.A. Servicing Division.
MALAGUTI S.p.A.
Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY
Tel. 051.62.24.811 - Fax 051.69.47.782
e-mail: [email protected] - http: // www.malaguti.com
1
10/07
GENERAL WORK PROCEDURES
• The recommendations given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment
damage and idle times, and should therefore be strictly adhered to.
• Always listen with attention to the customer’s opinion and complaints about the engine operation, asking specific questions in order to have a complete understanding of all the
symptoms and identify with good approximation the real causes of the trouble. The present manual provides the technical information and the basic indications on the
intervention procedures but these have to be integrated with the personal expertise.
• We suggest planning the service interventions in order to avoid any waste of time or downtime. Try to reduce as much as possible the operations necessary to reach the
components that needs repairing.
• Prepare the components that are likely to be replaced and all the original spare parts you may need.
• Mark the components that may be mis-placed during re-assembly operations.
• Only use quality tools and equipment.
• During operations, always keep tools and equipment at hand, possibly laying them out according to the sequence in which they are to be used.
• Always keep the work area neat and clean.
• When tightening screws or nuts, start with the larger diameter or inner fasteners, and tighten them in progressive “pulls” using a “criss-cross” pattern.
• The torque settings specified in the manual refer to the “final torque”, which must be attained progressively by steps.
• Preferably use open-end box wrenches by “pulling” and not “pushing”.
• For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and co-ordinated beforehand.
• Make sure that each component has been properly mounted before proceeding with assembling the next one.
• Always replace gaskets, O-rings, circlips and split pins at every refitting.
• Only use screwdrivers with sizes suitable to the screws to be loosened or tightened.
Never use open flames for any reason.
Always use low flash point solvents to clean the vehicle components.
When welding, make sure that there are no flammable liquids in the vicinity.
• Never reuse old gaskets or circlips.
• Never use a screwdriver as a lever or chisel.
• Never use pincers to loosen or tighten screws or nuts.
• Never tap the wrench with a hammer or other similar tool to loosen or tighten screws and nuts.
• Never attempt to increase the lever arm by fitting a tube into the wrench.
2
10/07
CONTENTS
DESCRIPTION
SPECIFICATIONS
TIGHTENING TORQUES
AUTOMATIC TRANSMISSION
Transmission cover
Air duct - Air duct filter
Removing the driven pulley shaft bearing
Refitting the driven pulley shaft bearing
BAFFLE ROLLER
Plastic roller
Removing the driven pulley - Inspecting the clutch drum
Removing the clutch
Inspecting the clutch - Pin retaining collar
Removing the driven half-pulley bearing
Inspecting the driven fixed half-pulley
Inspecting the driven sliding half-pulley
Refitting the driven half-pulley bearing
Refitting the driven pulley - Inspecting the clutch spring
Refitting the clutch
Refitting the driven pulley - Drive-belt
Removing the driving pulley
Inspecting the rollers case - Refitting the driving pulley
Refitting the transmission cover
END GEAR
Removing the hub cover - Removing the wheel axle
Removing the hub bearings
Removing the wheel axle bearings
Removing the driven pulley shaft bearing
Inspecting the hub shaft
Inspecting the hub cover
Refitting the driven pulley shaft bearing
Refitting the hub cover bearings
Refitting the hub bearings - Refitting the ub cover
FLYWHEEL COVER
Removing the hub cover
Removing the flywheel cover components
Removing the stator - Inspecting the cover components
Refitting the stator
Refitting the flywheel cover components
Refitting the flywheel cover
1234
1234
1234
1234
DESCRIPTION
P.
1234
1234 FLYWHEEL AND STARTING
33
1234
1234 Removing the starter motor - Removing the flywheel magneto
34
1234
1234
1234
Inspecting
the
flywheel
components
Starter
gear
rim
36
1234
1234
Intermediate
gear
Refitting
the
free
wheel
37
1234
1234 Refitting the intermediate gear - Refitting the flywheel magneto
38
1234
1234
1234
39
1234 Refitting the starter motor
1234 CYLINDER ASSY. AND TIMING SYSTEM
40
1234
1234
1234
Removing the intake manifold - Removing the rocker-arms cover
40
1234
1234
40
1234 Removing the timing system drive
1234
Removing the cam shaft
41
1234
1234
1234 Removing the cylinder head
42
1234
1234 Removing the valves
43
1234
1234
Removing
the
cylinder-piston
assy
Inspecting
the
small
end
Inspecting
the
wrist
pin
44
1234
1234
1234 Inspecting the piston
45
1234
1234 Inspecting the piston rings
46
1234
1234
47
1234 Removing the piston
1234
1234 Choosing the gasket
48
1234
1234
1234 Refitting the piston rings - Refitting the cylinder - Inspecting the cylinder head 49
1234
50
1234 Inspecting the timing system components - Inspecting the valve sealings
1234
1234 Inspecting the valve housings
50
1234
1234
51
1234 Inspecting the valves - Inspecting the valve stem guide clearance
1234
1234
Inspecting the springs and half-cones
52
1234
1234
Refitting the valves - Inspecting the cam shaft
53
1234
1234
54
1234 Refitting the head and timing system components
1234
1234 Refitting the timing chain
58
1234
1234
59
1234 Refitting the rocker-arms cover
1234
Refitting the intake manifold
60
1234
1234
1234 CRANKCASE - CRANKSHAFT
60
1234
1234
Splitting
the
crankcase
halves
Removing
the
crankshaft
61
1234
1234
62
1234 Removing the countershaft - Replacing the countershaft bearings
1234
1234
Inspecting
the
crankshaft
components
Inspecting
the
crankshaft
alignment
64
1234
1234 Inspecting the crankcase halves
65
1234
1234
66
1234 Inspecting the crankshaft plain bearings
1234
1234 Countershaft - Refitting the crankshaft
68
1234
1234 Refitting the crankcase halves
69
1234
1234
1234
LUBRICATION
70
1234
1234 Conceptual diagrams - General characteristics
71
1234
1234
Diagnosis guide
72
1234
1234
1234 Oil pressure check - Oil pump
74
P.
4
5
10
10
11
11
12
12
12
13
13
14
14
15
15
15
16
16
17
17
18
20
21
21
21
22
23
23
23
24
25
26
26
27
27
28
29
30
31
3
10/07
Specifications
TRANSMISSION
ENGINE
Specification
Desc./Quantity
Specification
Desc./Quantity
Type
Single-cylinder, 4-stroke with double spark
plug
Transmission
Automatic expandable pulley variator with
torque server, V belt, automatic clutch.
Bore x Stroke
94 x 71 mm
Cubic capacity
493 cm³
Compression ratio
10.5: 1
Timing system
Four valves, single overhead camshaft, chain
driven.
Valve clearance
Inlet: 0.15 mm
CAPACITY
Outlet: 0.15 mm
Engine idle speed
1,500 ± 100 rpm
Start-up
Electric
Lubrication
Engine lubrication with trochoidal pump
(inside the crankcase), oil filter and pressure
adjustment by-pass.
Specification
Desc./Quantity
Engine oil (at oil and filter change)
1.7 l
Transmission oil
250 cm³
ELECTRICAL SYSTEM
Fuel supply
Electronic injection with electric fuel pump.
Specification
Desc./Quantity
MAX. power
29 kW at 7,500 rpm
Ignition
MAX torque
44 Nm at 5,200 rpm
High efficiency electronic inductive ignition,
integrated with the injection system, with
variable advance and separate HV coil.
Cooling
Forced coolant circulation system.
Spark plug (2)
NGK CR7EKB
4
10/07
Tightening Torques
ENGINE ASSEMBLY
CRANKCASE AND CRANKSHAFT
Name
Torque in Nm
Name
Torque in Nm
Starter motor retainers
11 ÷ 13
Countershaft fixing nut
25 ÷ 29
Engine oil filter
12 ÷ 16
Engine oil drainage plug
24 ÷ 30
Engine-crankcase coupling screws
11 ÷ 13
Oil pump screws
5÷6
Gear mounting on crankshaft screws
10 ÷ 12
Bulkhead screws for oil pump housing cover
8 ÷ 10
THERMAL UNIT AND TIMING SYSTEM
Name
Torque in Nm
Spark plug
12 ÷ 14
Head fixing stud bolts:
***
Head fixing nuts
10 ÷ 12
Exhaust/intake head fixing nuts:
10 ÷ 12
Head lubrication control jet
5÷7
Coolant temperature sensor
10 ÷ 12
Name
Torque in Nm
counterweight mass fixing screw
7 ÷ 8.5
Rear hub cover screws
24 ÷ 27
Tensioner sliding block fixing screw:
10 ÷ 14
Rpm timing sensor fixing screw:
3÷4
Injector fixing screw
3÷4
Rpm timing sensor fixing screw
3÷4
Valve lifter mass stop bell fixing screws:
30 ÷ 35
inlet manifold fixing screws
11 ÷ 13
Tappet cover fixing screws:
7÷9
Throttle body fixing screws
11 ÷ 13
Camshaft retaining bracket fixing screws
4÷6
Head fixing screws
10 ÷ 12
Lambda probe on exhaust manifold
10 ÷ 12
Muffler to bracket fixing screw
14 ÷ 16
FINAL REDUCTION
TRANSMISSION COVER
*** Apply a preliminary torque of 7 Nm in a crossed sequence.
- Tighten by 90° in a crossed sequence.
- Tighten again by 90° in a crossed sequence.
5
10/07
Name
Torque in Nm
Driven pulley nut
92 ÷ 100
Drive pulley nut
160 ÷ 175
Anti-vibration roller screw
16.7 ÷ 19.6
M8 retainers for transmission cover
23 ÷ 26
M6 retainer
11 ÷ 13
Anti-vibration roller retainer
17 ÷ 19
Clutch ring nut
65 ÷ 75
Air deflector unit screws
7÷9
Water pump cover screws
3÷4
Outside transmission cover screws
7÷9
Flywheel cover screws
11 ÷ 13
HEIGHT TO MEASURE PISTON AND CYLINDER
FLYWHEEL COVER
Name
Torque in Nm
Specification
Desc./Quantity
Flywheel fixing nut
115 ÷ 125
A
10 mm
Stator retainers
8 ÷ 10
B
43 mm
Blow-by recovery duct fixing screws
3÷4
Screw fixing freewheel to flywheel
13 ÷ 15
Stator cable harness guide bracket screws
3÷4
CYLINDER - PISTON
LUBRICATION
Name
Torque in Nm
Oil pump cover screws
0.7 ÷ 0.9
Screws fixing oil pump to the crankcase
5÷6
Specification
Desc./Quantity
Cylinder diameter C
94
Piston diameter P
+0,018
-0,01
93.968 ±0,014
COUPLING CATEGORIES
Name
Initials
Cylinder
Piston
Play on fitting
Overhaul data
Cylinder- Piston
A
93.990÷93.997
93.954÷93.961
0.029÷0.043
This section provides the main information for scooter servicing.
Cylinder- Piston
B
93.997÷93.004
93.961÷93.968
0.029÷0.043
Cylinder- Piston
C
94.004÷94.011
93.968÷93.975
0.029÷0.043
Cylinder- Piston
D
94.011÷94.018
93.975÷93.982
0.029÷0.043
Assembly clearances cylinder - piston assy
N.B.
THE PISTON MUST BE INSTALLED WITH THE ARROW FACING TOWARDS THE OUTLET
SIDE, THE PISTON RINGS MUST BE INSTALLED WITH THE WORD "TOP" OR THE
STAMPED MARK FACING UPWARDS.
6
10/07
Piston rings
Crankcase - crankshaft - connecting rod
Diameter of crankshaft bearings.
Measure the capacity on both axes x-y.
*Fit rings "2" and "3" with the word "TOP" facing upwards.
** Position the openings in the rings as shown here.
***Value "A" of sealing ring inside the cylinder.
Check the size of the sealing ring opening:
Compression ring: 0.15 ÷ 0.35 mm. Max. value 0.5 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
Oil scraper ring: 0.25 ÷ 0.50 mm. Max. value 0.65 mm
CRANKSHAFT
Specification
Desc./Quantity
Cat. 1
Standard diameter: 40.010 ÷ 40.016
Cat. 2
Standard diameter: 40.016 ÷ 40.022
Crankshaft alignment
Rings/housing coupling clearances:
Carefully clean the sealing ring housings.
Place a thickness gauge between the ring and the housing as shown in the drawing and check the coupling clearances.
Specific tooling
020335Y
Magnetic support for dial gauge
Top ring
Standard coupling clearance: 0.01÷0.06 mm
Maximum clearances allowed after use: 0.10 mm
Intermediate ring
Standard coupling clearance: 0.02÷0.07 mm
Maximum clearances allowed after use: 0.10 mm
MAX. ADMISSIBLE DISPLACEMENT
Oil scraper ring
Standard coupling clearance: 0.01÷0.06 mm
Maximum clearances allowed after use: 0.10 mm
Replace the piston if clearances exceed the maximum
limits specified in the table.
7
10/07
Specification
Desc./Quantity
A
0.15 mm
B
0.010 mm
C
0.010 mm
D
0.10 mm
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
The value of the “M” fixture axial clearance is acceptable within the range of
0.20 ÷ 0.60 mm
Description
Crankshaft-crankcase axial clearance (H)
0.1 ÷ 0.405 mm (when cold)
Dimensions
Transmission-side shoulder
E = 1 ± 0,025
Half-shaft, transmission side
F = 20,9
0
-0.05
Connecting rod
G = 22
-0.10
-0.15
Flywheel side half-shaft
H = 19,6
0
-0.05
Flywheel-side shoulder
I = 1,8 ± 0,025
Complete crankshaft
L = 65,5
Compression ratio
10.5: 1
+0.10
-0.05
8
10/07
BASE GASKET THICKNESS
Slot packing system
Name
Measure A
Thickness
«A» MEASURE TAKEN
- 0.185 - - 0.10
0.4 ± 0.05
«A» MEASURE TAKEN
- 0.10 - + 0.10
0.6 ± 0.05
«A» MEASURE TAKEN
+ 0.10 - + 0.185
0.8 ± 0.05
N.B.
VALUES INDICATED WITH "-" REFER TO PISTON CROWN RECESSES WITH
RESPECT TO THE CYLINDER PLANE.
Shimming system to control compression ratio
N.B.
DISTANCE "A" MUST BE MEASURED WITHOUT ANY GASKET FITTED AT "B"
DISTANCE "A" IS A PROTRUSION OR RECESS VALUE OF THE PISTON
CROWN WITH RESPECT TO THE CYLINDER PLANE.
DISTANCE "A" HELPS DETERMINE THE THICKNESS OF GASKET "B" THAT
HAS TO BE FITTED TO THE CYLINDER HEAD IN ORDER TO RESTORE
COMPRESSION RATIO. BASE GASKET "B" MUST BE THICKER THE MORE
THE PLANE FORMED BY THE PISTON TOP PROTRUDES FROM THE PLANE
FORMED BY THE CYLINDER HEAD. ON THE OTHER HAND, THE MORE THE
PISTON TOP IS RECESSED INTO THE CYLINDER TOP PLANE, THE SMALLER
THE GASKET THICKNESS.
RECOMMENDED LUBRICATING TABLE
9
10/07
Product
Description
Specifications
Q8 ZC90 SAE 80W-90
Rear hub oil
SAE 80W/90 Oil
Q8 FORMULA EXCEL SAE
5W - 40
Engine oil
SAE 5W-40 Synthetic oil
-
Grease for the tone wheel
revolving ring
Soap-based lithium grease
containing
Molybdenum disulphide
- Remove the six M6 screws.
Automatic
transmission
Transmission cover
- Loosen the 4 fastening screws
- Extract the outside plastic
transmission cover.
- Remove the four M8 screws.
- Using a screwdriver, remove the driven
pulley axle cover near the bottom of the
cap.
- Remove the transmission cover.
- Check that the bearing rotates freely,
otherwise replace it.
- Loosen the driven pulley shaft fastening
nut using a misaligned wrench and
prevent the pulley shaft rotation using a
machine hexagon bush.
- Remove the nut and the two washers.
N.B.
DUE TO THE HIGH TIGHTENING TORQUE,
USING DIFFERENT WRENCHES - SUCH AS
A CONVENTIONAL POLYGONAL BUSH MAY DAMAGE THE HEXAGON OBTAINED ON
THE SHAFT OR BREAK THE BUSH ITSELF.
10
10/07
Removing the driven
pulley shaft bearing
Air duct
- Remove the transmission cover.
- Remove the transmission cover.
- Unscrew the two screws shown in the
figure to remove the air conveyor.
- Remove the seeger ring.
Locking torques (N*m)
Air conveyor screws
11 ÷ 12
- Place transmission cover on a wood
surface and use the special tool so that
it is adequately supported.
- Remove the external transmission
cover.
- Unscrew the 4 fastening screws
shown in the figure to remove the
external air conveyor.
- Pull out the bearing using the special
tool.
N.B.
BELL MUST BE PLACED INTO THE
TRANSMISSION COVER, CLOSE TO THE
BEARING SEAT AND THE WOODEN
SURFACE, SINCE WITHOUT BELL THE
ENTIRE COVER STRUCTURE WOULD
BEND.
Air duct filter
Specific tooling
001467Y002
Driver for OD 73 mm bearing
020376Y
Adaptor handle
020375Y
28 x 30 mm adaptor
020439Y
17 mm guide
- Remove the external air conveyor.
- Unscrew the 2 fastening screws shown
in the figure to remove the conveyor filter.
11
10/07
Refitting the driven pulley
shaft bearing
Baffle roller
Plastic roller
- Heat the transmission cover interior
using the heat gun.
- Check that the roller does not show
signs of wear and that it turns freely.
N.B.
BE CAREFUL NOT TO OVERHEAT THE
COVER AS THIS WOULD DAMAGE THE
OUTSIDE PAINTED SURFACE.
- Loosen the retaining bolt using a 13
mm spanner.
- Remove the complete roller with
bearing.
Specific tooling
020151Y
Air heater
N.B.
IF THE ROLLER DOES NOT ROTATE FREELY, REPLACE THE COMPLETE ROLLER.
- Place the bearing onto the special tool
with a little grease to prevent it from
coming out.
Installation of belt anti-vibration roller
- Install the anti-flapping roller with the lip facing the engine crankcase.
- Tighten the central screw to the prescribed torque.
- Install the new bearing using the
special tool.
N.B.
TURN THE DRIVEN AND/OR DRIVING PULLEY UNTIL A CORRECT TENSIONING OF THE
BELT IS OBTAINED.
N.B.
PROPERLY SUPPORT THE OUTSIDE
COVER TO PREVENT DAMAGING THE
PAINTED SURFACE.
Specific tooling
020376Y
Adaptor handle
020358Y
37x40 mm adaptor
020439Y
17 mm guide
Locking torques (N*m)
Anti-vibration roller screw
16.7 - 19.6
12
10/07
Removing the driven
pulley
Removing the clutch
- To remove the clutch with the driven
pulley it is necessary to use the special
tool;
- Remove the clutch bell.
- Arrange the tool with the mean pins
screwed in position "E" on the inside;
- Fit the adapter ring (020444Y010) to
the clutch assembly as shown in the
photograph.
- Install the driven pulley unit onto the
tool inserting the pins into the
ventilation holes;
- Remove the fixed driving half-pulley.
- Move the rear stop screw in abutment
against the fixed driven pulley as shown
in the figure.
- Remove the driven pulley assembly
with the belt.
THE TOOL SHOULD BE FIRMLY
SECURED IN A VICE USING THE
SPECIAL TOOL. DO NOT TIGHTEN THE
REAR SCREW TOO MUCH AS THIS COULD
CAUSE AN IRREVERSIBLE TOOL
DEFORMATION.
USING THE SPECIAL 55-MM
WRENCH, REMOVE THE FASTENING
RING NUT.
Inspecting the clutch
drum
LOOSEN THE TOOL SCREW AND
DISASSEMBLE THE DRIVEN PULLEY
UNIT, CLUTCH, SPRING WITH SHEATH.
- Check that the clutch bell is not worn
or damaged.
- Measure the clutch bell inside diameter.
N.B.
CHECK THE ECCENTRICITY MEASURED:
0.2 MM MAX.
Specific tooling
020444Y
Tool for fitting/ removing the driven
pulley clutch.
Characteristic
Max. value: 160.5 mm
Standard value: 160.2 mm
13
10/07
Inspecting the clutch
- Remove the 4 guide pins.
- Check the thickness of the clutch mass friction material.
- Extract the moving driven half-pulley.
Characteristic
Minimum thickness permitted:
1 mm
- The masses must not show traces of lubricants. Otherwise, check the driven pulley
unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CENTRAL CONTACT SURFACE AND
MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE
CLUTCH TO TEAR.
Removing the driven halfpulley bearing
- Do not open the masses using tools
to prevent a variation in the return spring
load.
- Check that the bushing is free from
wear and damage; otherwise replace
the fixed driven half-pulley.
- Remove the lock ring using pliers.
- Using the special tool inserted through
the roller bearing, pull out the ball
bearing.
Pin retaining collar
N.B.
PROPERLY SUPPORT THE PULLEY TO
PREVENT DAMAGING THE THREADING.
- Extract the collar using 2
screwdrivers.
Specific tooling
020376Y
Adaptor handle
020456Y
Ø 24 mm adaptor
020363Y
20 mm guide
14
10/07
N.B.
IF YOU NEED TO OVERHAUL THE BEARINGS ON AN ASSEMBLED DRIVEN PULLEY UNIT, IT
IS NECESSARY TO SUPPORT THE UNIT BY THE BELL
Inspecting the driven
sliding half-pulley
Specific tooling
- Check that the belt contact surface is
free from wear.
001467Y002
Driver for OD 73 mm bearing
- Remove the 2 inside sealing rings and
the 2 outside O-rings.
- Measure the movable half-pulley
bushing inside diameter.
- Remove the roller bearing using the
special tool, supporting the fixed halfpulley with the bell.
Characteristic
Maximum admissible diameter:
50.05 mm
Standard diameter:
50.00 +0,035
mm
0,00
Specific tooling
020376Y
Adaptor handle
020375Y
28 x 30 mm adaptor
020364Y
25 mm guide
001467Y002
Driver for OD 73 mm bearing
Refitting the driven halfpulley bearing
- Install a new roller bearing using the
special tool.
N.B.
PLACE THE BEARING WITH THE
WRITINGS AND THE EMBEDDED OIL
GUARD FACING OUTWARDS.
Inspecting the driven
fixed half-pulley
- Check that the belt contact surface is
free from wear.
- Properly support the half-pulley to
prevent damaging the threading.
- Measure the outer diameter of the
pulley bushing.
If you are working on the driven pulley
unit fully assembled, use the special
tool.
Characteristic
Specific tooling
Minimum admissible diameter
49.91 mm
Standard diameter:
50.00 -0,015
mm
-0,035
020478Y
Punch for driven pulley roller casing
001467Y002
Driver for OD 73 mm bearing
15
10/07
- Install a new ball bearing using the
special tool.
Inspecting the clutch
spring
Specific tooling
- Measure the length of the spring, while
it is relaxed.
020376Y
Adaptor handle
020477Y
37 mm adaptor
020363Y
20 mm guide
Characteristic
Standard length:
125.5 mm
Admissible limit after use:
120 mm
- Insert the seeger lock ring.
Refitting the clutch
- Prepare the special tool as for removal;
- Preassemble the driven pulley unit
with the drive belt according to its
direction of rotation;
Refitting the driven pulley
- Insert the new oil guards
- Insert the driven pulley unit, the spring
with sheath and clutch into the tool.
- Insert the new O-rings
N.B.
O-RINGS ARE OF TWO SIZES. THE LARGE
ONE IS INSTALLED ON THE MACHINING
END RADIUS, AT THE BASE OF THE HALFPULLEY.
Specific tooling
020444Y
Tool for fitting/ removing the driven pulley
clutch
- Compress the spring and insert the
clutch on the driven pulley bushing.
- Install the half-pulley on the bushing being careful not to damage the top sealing
ring during the introduction.
- Make sure the pins and collar are not worn, reassemble the pins and collar.
N.B.
BE CAREFUL NOT TO DAMAGE THE SHEATH OR THE BUSHING THREADED END.
- Using a bent beak greaser, lubricate the driven pulley unit with about 10 gr. of
grease, this operation should be carried out through one of the two holes into the
bushing to obtain the exit of the grease from the opposite hole. This operation is
necessary to avoid the presence of grease beyond the O-rings.
- Tighten the ring nut by hand and complete the tightening using the special wrench
to the prescribed torque.
Recommended products
Grease for the tone wheel revolving ring
Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-LXBCHB2, DIN KF2K-20
Specific tooling
Locking torques (N*m)
020444Y
Tool for fitting/ removing the driven pulley clutch
Clutch ring nut
65 - 75
- To facilitate reassembly on the engine, turn the moving driven pulley and insert the
belt onto the smaller diameter.
16
10/07
- First fit the 2 retainer clamps of the
special tool onto the pulley so that the
splines are completely engaged.
Refitting the driven pulley
- Install the driven pulley assembly with
belt.
- Then, insert the tool so as to insert
the stud bolts on the ring into the holes
obtained onto the tool itself.
- Tighten the two tool fixing screws,
also manually.
- Loosen the central nut.
- Remove the spring washer and the flat
washer.
- Remove the fixed driving half-pulley.
Drive-belt
- Remove the bushing connection
washer.
- Check that the driving belt is not
damaged.
- Check the width of the belt.
- Move the belt downwards.
Characteristic
- Suitable support the roller contrast
and extract the mobile driving half-pulley
with the relevant bushing and the rear
washer, being careful not to make the
rollers come out.
Minimum width
27.5 mm
Overall width
28.7 mm
- Measure the pulley sliding bushing
outside diameter shown in the figure.
Removing the driving
pulley
- Using a 27 mm wrench, turn the
central pulley nut to horizontally align
the central inside holes and install the
special tool.
Specific tooling
020474Y
Driving pulley lock wrench
17
10/07
Inspecting the rollers case
Refitting the driving pulley
- Check that the inside bushings shown in the figure are not worn and measure the
inside diameter.
Installing the roller container
DO NOT LUBRICATE OR CLEAN THE BUSHINGS
- Install the spacer with the internal
chamfer facing towards the inside.
Characteristic
Maximum admissible diameter:
30.12 mm
Standard diameter:
30.021 mm
- Measure the pulley sliding bushing
outside diameter shown in the figure.
- Position the rollers on the half-pulley
as shown in the figure.
Characteristic
- The closed side must rest on the
inside thrust face of the roller container.
Minimum admissible diameter
Ø 29.95 mm
Standard diameter:
Ø 29.959 mm
- Check that the rollers are not
damaged or worn.
Characteristic
Minimum admissible diameter
Ø 24.5 mm
Standard diameter:
Ø 24.9 mm
- Assembly the half-pulley with the roller
contrast plate and sliding blocks.
- Check the guide shoes for the variator
back-plate are not worn.
- Check the wear of the roller housings
and of the belt contact surfaces on both
pulley halves.
18
10/07
- Insert the half-pulley on the
crankshaft.
- Remove the flat washer and the spring
washer as shown in the figure.
- Insert the spacer bushing.
Installing the fixed driving halfpulley
- Insert the nut in the original position
(nut side in contact with the belleville
washer).
- Insert the spacer.
- Turn the central pulley nut to horizontally
align the holes and install the special tool.
- Install the fixed driving half-pulley and
check that it is in contact with the
spacer and with the guide bushing of
the moving driving pulley.
N.B.
CHECK THAT THE STOP WRENCH TOOL IS
EASILY INSERTED INTO THE PULLEY AND IN
THE ENGINE CRANKCASE.
Specific tooling
020474Y
Driving pulley lock wrench
19
10/07
- Install the lock ring from the rear so that
the splines are completely engaged.
- Lock the 7 M6 retainers.
Locking torques (N*m)
- Finally install the tool by siding the
nuts by hand and ensuring the tool is
resting flatly.
M6 retainer
11 ÷ 13
- Tighten the driving pulley fastening nut
to the prescribed torque
- Insert the washers on the driven pulley
shaft.
- Remove the special tool.
N.B.
INSERT THE SMALLER WASHER FIRST,
THEN THE LARGER ONE.
Locking torque (N*m)
Drive pulley nut
160 - 175
- Insert the flanged nut.
Refitting the transmission
cover
- Prepare the torque wrench for LHS
locking hexagon wrench.
- Ensure the correct installation on the
crankcase of the 2 centring dowels.
- Tighten the driven pulley shaft
fastening nut using an offset wrench.
N.B.
DUE TO THE HIGH TIGHTENING TORQUE, USING DIFFERENT WRENCHES - SUCH AS A
CONVENTIONAL POLYGONAL BUSH - MAY DAMAGE THE HEXAGON OBTAINED ON THE
SHAFT OR BREAK THE BUSH ITSELF.
- Insert the transmission cover with the
bearing and install the relevant
retainers.
- Lock the four M8 retainers.
Locking torque (N*m)
Locking torques (N*m)
Driven pulley nut
92 - 100
M8 retainers for transmission cover
23 - 26
20
10/07
- Install the driving pulley shaft cover,
positioning the tooth gap on the lower
part with the reference mark on the
transmission crankcase.
Removing the wheel axle
- Remove the countershaft.
- Remove the wheel axis complete with
gear.
N.B.
ENSURE THAT THE AIR INTAKE AND
EXHAUST OPENINGS ARE COMPLETELY
FREE.
- Install the outside plastic transmission
cover.
Removing the hub
bearings
- Tighten the 4 fastening screws to the
prescribed torque.
- Check all bearings (wear, clearance
and noise).
Locking torques (N*m)
In case of anomalies, proceed as
follows.
Outside transmission cover screws
7÷9
To remove the gear shaft bearing on the
engine crankcase, use the following
parts.
Specific tooling
End gear
001467Y014
Extraction pliers for ø 15 mm bearings
001467Y034
Extraction pliers for ø 15 mm bearings
001467Y031
Bell
Removing the hub cover
- Drain the rear hub oil through the oil
drainage cap located under the engine.
-Remove the 7 fastening screws.
Remove the hub cover and the relevant
gasket.
21
10/07
- Use the special extractor to
disassemble the bearing on the engine
chassis of the countershaft.
- Support the hub cover using the
column kit.
- Pull out the bearing using the special
tool.
Specific tooling
001467Y006
Extraction pliers for 20 mm bearings
001467Y035
Bearing housing outside diameter 47
mm
Specific tooling
- Support the hub cover using the
column kit.
- Remove the oil guard using a
screwdriver.
020476Y
Stud bolt set
020376Y
Adaptor handle
020477Y
37 mm adaptor
020483Y
30 mm guide
- Pull out the bearing using the special
tool.
Specific tooling
020476Y
Stud bolt set
001467Y006
Extraction pliers for 20 mm bearings
001467Y007
Driver for OD 54 mm bearing
Removing the wheel axle
bearings
- Take out the clip on the outside of the
gearbox cover.
22
10/07
Removing the driven
pulley shaft bearing
Inspecting the hub shaft
- Check that the 3 shafts exhibit no wear
or deformation on the grooved surfaces,
at the bearings and at the oil guards.
- If you have to remove the driven pulley
shaft, the relevant bearing and the oil
guard, remove the transmission cover
and the clutch unit as described in the
Automatic transmission chapter.
- In case of faults, replace the damaged
parts.
- Extract the driven pulley shaft from its
bearing.
Characteristic
Connection diameter for
countershaft:
A = diameter 20 -0,01
mm
-0,02
- Remove the oil guard using a
screwdriver into the hub gear box.
- Remove the seeger ring shown in the
figure.
Connection diameter for wheel
shaft:
-0,010
B = diameter 30 -0,023 mm
C = diameter 15
-0,01
-0,02
mm
Connection diameter for shaft
driven pulley:
-0,01
D = diameter 17 -0,02 mm
- Pull out the driven pulley shaft bearing
from the engine crankcase using the
special tool.
E = diameter 20
Specific tooling
F = diameter 25
020376Y
Adaptor handle
020358Y
37x40 mm adaptor
020364Y
25 mm guide
-0,01
-0,02
-0,01
-0,02
mm
mm
Inspecting the hub cover
- Check that the mounting surface is not damaged or deformed.
- Check the bearing bearings.
In case of faults, replace the hub cover.
23
10/07
- Heat the intermediate gear bearing
seat.
Refitting the driven pulley
shaft bearing
- Insert the intermediate shaft bearing
using the special tool.
- Heat the crankcase using the heat
gun.
N.B.
PLACE IT WITH THE BALLS FACING THE
HUB (THIS APPLIES TO BEARINGS WITH
PLASTIC CAGE).
Specific tooling
020151Y
Air heater
Specific tooling
020376Y
Adaptor handle
020359Y
42 x 47 mm adaptor
020363Y
20 mm guide
- Heat the gear shaft bearing seat on
the crankcase.
- Insert the driven pulley shaft bearing
until it abuts against the bottom of the
seat using the special tool.
- Insert the gear shaft bearing in the upper
crankcase seat using the special tool.
N.B.
PLACE IT WITH THE BALLS FACING THE
HUB (THIS APPLIES TO BEARINGS WITH
PLASTIC CAGE).
N.B.
PLACE IT WITH THE BALLS FACING THE
HUB (THIS APPLIES TO BEARINGS WITH
PLASTIC CAGE).
Specific tooling
Specific tooling
020376Y
Adaptor handle
020360Y
52 x 55 mm adaptor
020364Y
25 mm guide
020376Y
Adaptor handle
020359Y
42 x 47 mm adaptor
020412Y
15 mm guide
24
10/07
- Place the safety lock seeger ring of
the driven pulley shaft bearing.
- Insert the intermediate shaft bearing
on the cover using the special tool.
N.B.
PLACE IT IN THE POSITION SHOWN IN
THE FIGURE.
N.B.
PLACE IT WITH THE BALLS FACING THE
HUB (THIS APPLIES TO BEARINGS WITH
PLASTIC CAGE).
Specific tooling
020376Y
Adaptor handle
020360Y
52 x 55 mm adaptor
020363Y
20 mm guide
- Heat the gear shaft bearing seat from
the cover outside.
- Insert the pulley shaft oil guard on the
transmission side.
- Insert the gear shaft bearing on the
cover using the special punch until
abutment.
Specific tooling
020376Y
Adaptor handle
020360Y
52 x 55 mm adaptor
020483Y
30 mm guide
- Replace the snap ring
Refitting the hub cover
bearings
- Heat the bearing seats on the cover
using the heat gun.
- Support the hub cover using the
column kit.
Specific tooling
020151Y
Air heater
020476Y
Stud bolt set
25
10/07
- Support the hub cover using the column
kit.
- Insert the wheel shaft oil guard with the
sealing lip facing the inside of the cover.
- Place the oil guard flush with the
crankcase.
- Position the 7 set screws, tighten them to the prescribed torque, being careful of
the position of the bands holding the vent tube, and the position of the 3 shortest
screws as indicated in the figure.
- Refill with the prescribed oil to the Max. level.
Recommended products
Q8 ZC 90
rear oil hub
SAE 80W/90 Oil that exceeds the API GL3 specifications
Specific tooling
020376Y
Adaptor handle
020360Y
52 x 55 mm adaptor
020476Y
Stud bolt set
Characteristic
Quantity:
approx. 250 cc
Locking torques (N*m)
Rear hub cover screws
24 ÷ 27
Refitting the hub bearings
Flywheel cover
- Place the 3 shafts as shown in the
figure.
- Remove the three bands shown in the
figure for an easier removal of the
flywheel cover. Remove the feed hoses
and disconnect the return hose from the
pump cover.
N.B.
THE BANDS MUST BE REPLACED. TO
REMOVE THEM, OPEN WITH A
SCREWDRIVER OR CUT THEM.
Refitting the ub cover
BE CAREFUL NOT TO DAMAGE THE
PLASTIC UNIONS.
- Check the proper position of the
centring dowels.
- Install a new gasket.
- Fit the gearbox cover, making sure the
breather pipe is in the correct position.
26
10/07
Removing the hub cover
- Loosen the 14 fastening screws.
- Drain the engine oil by removing the
drainage cap.
- Remove the flywheel cover with the
relevant gasket and the cooling system
sleeve support.
- Prepare a suitable container to collect
the oil.
N.B.
THE SCREWS ARE OF 4 DIFFERENT
LENGTHS: NOTE THE RELEVANT
POSITIONS.
REMOVE THE COVER AVOIDING
ANY POSSIBLE INTERFERENCE
BETWEEN STATOR AND ROTOR.
Removing the flywheel
cover components
- Remove the pre-filter.
- Loosen the six mounting screws and
remove the water pump cover.
- Remove the oil filter using a filter tape
or shaped cup wrench.
- Remove the by-pass and the relevant
spring.
- Remove the oil pump seal.
27
10/07
BE CAREFUL TO PREVENT SLIPPAGE
OF THE BY-PASS VALVE AND OF THE
RELEVANT SPRING.
- Remove the blow-by reed valve with the
relevant sealing gasket.
Removing the stator
- Remove the two retaining screws and
the cable guide bracket.
- Unscrew the 3 fastening screws and
remove stator and its wiring.
- Unscrew the fastening screw and
remove the gas outlet union with the
relevant O-ring.
Inspecting the cover
components
- Check that the mounting surface of the
crankcase is not worn or deformed.
- Check that the by-pass valve seat, the torque
limiter and the water pump shaft are free from
wear.
- Loosen the two retaining screws and
remove the reed valve support with
bulkhead.
Characteristic
By-pass housing hole diameter:
13.9 mm
Connection diameter for start-up gear
shaft:
12 mm
Connection diameter for pump shaft:
8 mm
28
10/07
- Check that the oil filter union and
matching surface exhibit no deformations
or wear.
- Check the earth insulation of each
phase.
- Check the condition of the stator and
of the respective cable harness.
- Check that the winding is positioned
so as not to interfere with the heads of
the retaining screws.
- Check the continuity between the 3
phases.
Refitting the stator
- If a fault is discovered, carry out a
close check of the cable harness that
contains two types of cable: Rigid
cables close to the stator and flexible
cables close to the connector.
- Install the stator assembly together
with the wiring harness, tightening the 3
screws to the prescribed torque.
N.B.
VALUES ARE STATED AT AMBIENT
TEMPERATURE. A CHECK WITH THE
STATOR AT OPERATING TEMPERATURE
MAY RESULT IN VALUES HIGHER THAN
THOSE STATED.
N.B.
INSERT THE RUBBER WIRING SEALING
GASKET INTO THE SPECIAL SEAT ON THE
CRANKCASE.
Electric characteristic
Locking torques (N*m)
Resistance:
0.2 - 1 Ω
Stator retainers
8 - 10
29
10/07
- Install the wiring guide bracket
tightening the 2 screws to the prescribed
torque.
- Oil vapour decantation chamber
Locking torques (N*m)
Stator cable harness guide bracket
screws
3-4
Refitting the flywheel
cover components
- Temporarily install the distribution
timing check hole cover and the engine
oil filling cap/bar.
- Before reassembling, check that all
components are perfectly clean.
- Insert the blow-by recovery duct using
a new O-ring.
- For the cover, carefully check all
lubrication channels, in particular:
- Tighten the screws to the prescribed
torque.
- The 3 by-pass channels.
Locking torques (N*m)
Blow-by recovery duct fixing screws
3-4
- Oil pressure sensor feeding duct.
- Insert the spring and the by-pass
piston on the flywheel cover.
N.B.
LUBRICATE THE BY-PASS VALVE.
30
10/07
- Install the supply hose to the cylinder
and connect the return hose to the pump
cover using 3 new clamps.
- Reinstall the blow-by reed valve using
a new sealing gasket.
- Reinstall the support with head and
tighten the screws to the prescribed
torque.
N.B.
TIGHTEN THE CLAMPS USING
APPROPRIATE PLIERS, PAYING
ATTENTION NOT TO CONSTRICT THE
HOSES BUT ALSO TAKING CARE TO
TIGHTEN THE CLAMPS SUFFICIENTLY.
Locking torques (N*m)
Supporting screws with bulkhead
0.3 - 0.4
- Correctly fit a new O-ring, do not allow
it to come into contact with grease or
oil.
FAILURE TO OBSERVE THIS ADVICE
CAN IRRETRIEVABLY DEFORM THE ORING.
- Refit the water pump cover and tighten
the 6 fixing screws to the prescribed
torque.
- Install the pre-filter again and insert the
engine oil drain plug, tightening to the
prescribed torque.
- Refill the engine with the prescribed type
of oil.
Locking torques (N*m)
Pump cover fixing screws:
3÷4
Recommended products
Q8 FORMULA EXCEL
Engine oil
SAE 5W-40, API SL, ACEA A3, JASO
MA Synthetic oil
Locking torques (N*m)
Engine oil drainage plug
24 ÷ 30
Refitting the flywheel
cover
- Lubricate the intermediate gear seat with
torque limiter on the flywheel cover.
- Install a new oil filter, lubricate the
gasket, screw on and finally tighten to
the prescribed torque.
- Align the water pump movement sensor
with a reference and install the flywheel
cover as described in the “Flywheel cover”
chapter.
Locking torques (N*m)
Engine oil filter
12 - 16
31
10/07
- Install a new gasket on the engine
crankcase.
- Tho lock the 14 retaining bolts of the
cover to the prescribed torque.
- Check the presence of the three
centring dowels.
N.B.
THE BOLTS HAVE FOUR LENGTHS:
- THE 3 SHORTEST ARE INSERTED AS
SHOWN IN THE FIGURE.
- THE LONGEST IS INSERTED UNDER THE
ENGINE OIL FILLER PLUG.
THE INTERMEDIATE BOLTS FOR THE
REMAINING MOUNTING POINTS WITH
THE EXCEPTION OF THE BOLT FOR THE
MANIFOLD SUPPORT (SHOWN IN THE
FIGURE) ARE SLIGHTLY LONGER.
- Turn the crankshaft in order to align
the countershaft movement sensor with
a reference point on the crankcase (see
figure).
Locking torques (N*m)
Flywheel cover screws
11 - 13
- Repeat the alignment for the water
pump crankshaft using the same
reference point on the engine.
N.B.
THIS PREPARATION IS USEFUL
PARTICULARLY IN THE EVENT OF
REPAIRS WITH THE WATER PUMP
COVER INSTALLED.
- Install the flywheel cover on the engine,
paying attention to avoid interference
between the stator and rotor.
FAILURE TO OBSERVE THIS
INSTRUCTION MAY RESULT IN
DESTRUCTION OF THE CERAMIC
MAGNETS.
32
10/07
N.B.
IF THE TRAILING SPEED OF THE
CRANKSHAFT IS LOW AND COMBINED
WITH STRANGE NOISE, CHECK THE
FREEWHEEL OF THE TORQUE LIMITER
(SEE THE "FLYWHEEL AND STARTER
SYSTEM" CHAPTER).
Flywheel and starting
- Remove the three bands shown in the figure
for an easier removal of the flywheel cover.
Remove the feed hoses and disconnect the
return hose from the pump cover.
N.B.
THE BANDS MUST BE REPLACED. TO
REMOVE THEM, OPEN WITH A
SCREWDRIVER OR CUT THEM.
STARTER MOTOR
BE CAREFUL NOT TO DAMAGE THE PLASTIC UNIONS.
The starter is sold as a complete part.
Before deciding to replace it, carry out the following tests:
1 - Battery
Check the voltage after not running (a few hours): Voltage >12.5V
Check the density of the electrolyte of each cell: Bé = 30 ÷ 32
Specific weight: 1.25 - 1.26
2 - Make sure the negative terminals (battery negative and starter negative) are
correctly connected to each other and to the frame.
3 - Recharge and if necessary replace the battery.
4 - Connect the diagnostic tester (see chapter "Injection system").
Connect the induction clamp of an ammeter to the positive power supply cable of the
starter motor.
Switch in position "ON" with interrupt switch in position "RUN" and side stand raised.
Select the "PARAMETERS" function.
Start the engine (so that it cannot move) long enough to measure the rpm and starter
absorption.
N.B.
THE DECLARED RPM VALUE IS THAT INDICATED BY THE TESTER, THE RPM READING IS
NOT THE REAL ONE, BUT IS VALID FOR DIAGNOSTIC PURPOSES.
Electric characteristic
Absorption at trailing speed:
80 - 120 A
Revolution speed =
approx. 300-400 rpm
33
Specification
Desc./Quantity
Type
Mitsuba sm13d
Power
0.9 kW
STARTER TRANSMISSION
Specification
Desc./Quantity
Ring gear and freewheel coaxial to the
flywheel.
Intermediate gear with built-in torque limiter.
The starter system has a transmission between the motor armature and engine shaft
equipped with freewheel coaxial to the flywheel and torque limiter on the intermediate
shaft.
The limiter is calibrated to 10 kgm (100 Nm); this component protects the structure
of the engine and the starter kinematic mechanism in the event of incorrect starting
with consequent inverse rotations.
The freewheel is used for a sufficiently silent starting.
The starter control (energised remote control) is slaved to enabling signals by the
side stand and the emergency OFF/RUN switch, which does not allow starting given
dangerous conditions.
The starter control circuit is not controlled by the immobilizer system, therefore
before insisting on the starter system, check the consensus of the immobilizer.
As for checking the consensus circuit, see the "Electrical system" chapter, while for
checking the engine shaft control transmission, follow what is described in the
"Flywheel and starter system" chapter.
10/07
- Tighten the bushing of the flywheel
lock tool on the removing tool threading.
Removing the starter
motor
N.B.
THIS OPERATION MAY ALSO BE CARRIED
OUT WITH FLYWHEEL COVER
ASSEMBLED.
- Loosen the two fastening screws.
- Extract the complete starter motor.
- Insert the special tool as shown in the
figure, making sure that the pins are
perfectly inserted into the previously
aligned holes and that it is perfectly
abutted and almost flush with the
flywheel.
Removing the flywheel
magneto
N.B.
IF YOU MUST REMOVE THE FLYWHEEL, IT
IS NECESSARY TO REMOVE THE CHAIN
GUIDE SLIDING BLOCK RETAIN PLATE
FIRST.
Specific tooling
020472Y
Flywheel lock wrench
- Unscrew the 3 fastening screws and
remove the chain guide sliding block retain
plate and the start-up rim.
- Loosen the magneto flywheel
fastening nut.
- Align the holes obtained on the flywheel
with the crankcase housing to allow the
introduction of the special tool.
- Remove the special tool and the
fastening nut.
34
10/07
- Remove the washer.
- Remove the extractor.
- Remove the nut and extract the flywheel
with the start-up rim.
- Remove the crankshaft key.
- Insert the nut again so as to slightly
uncover the shaft and free the space
that was occupied by the washer.
- To remove the start-up rim from the
freewheel it is necessary to turn it
clockwise and pull it out.
THIS OPERATION IS REQUIRED AS
THE FLYWHEEL IS STRONGLY
LOCKED; THE CONE DETACHMENT MAY
THEREFORE CAUSE THE ROTOR
SLIPPAGE, WITH THE CONSEQUENT
BREAKAGE OF THE MAGNETS.
- Insert the special removing tool.
- Remove the freewheel from the flywheel
by loosening the 6 fastening screws.
- Using a 27-mm wrench and a 19-mm
bushing, release the flywheel.
SINCE THE FREEWHEEL MUST BE
REMOVED, IT IS ADVISABLE TO
LOOSEN THE 6 FASTENING SCREWS IN
ADVANCE WITH THE FLYWHEEL STILL
INSTALLED ON THE CRANKSHAFT.
Specific tooling
020467Y
Flywheel extractor
35
10/07
- The freewheel is coupled to the
flywheel with high precision; if removal
is difficult, use 2 screws as gripping
points and as removing tools, if
required.
Starter gear rim
- Check that there is no wear or
abnormal impressions on the "rollers" of
the freewheel and on the surface of the
starter ring gear hub.
- Check the hub outside diameter.
Characteristic
Hub outside diameter:
Diameter 45.665 +0,008
mm
+0,005
- Extract the intermediate gear provided
with torque limiter.
- Check the inside diameter of the
bushing of the starter gearing.
- Check that the toothing is not worn.
Characteristic
Inside diameter of the bushing:
+0,020
Diameter 27 +0,041 mm
Inspecting the flywheel
components
N.B.
IF THE FAULTS DISCOVERED AFFECT THE HUB, REPLACE THE STARTER RING GEAR AND
FREEWHEEL.
- Check the integrity of the magnets.
IF ONLY THE BUSHING IS WORN, IT IS POSSIBLE TO REPLACE ONLY THE COMPLETE
START-UP RIM. IN THAT CASE, CHECK ALSO THE DIAMETER AND THE SURFACE OF THE
CONNECTION ON THE CRANKSHAFT. IN CASE OR IRREGULARITIES, REPLACE THE
CRANKSHAFT.
- Check that the magnet support cage
is free from deformation or cracks.
- Check that the flywheel splines exhibit
no loosening.
36
10/07
Intermediate gear
Refitting the free wheel
- Check that the toothing is not worn.
- Check the diameter of the two
bearings.
- Make sure the free wheel contact surfaces are in good condition.
- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
- Apply the recommended product to the end of the screws.
Characteristic
Recommended products
Diameter of gear bearing:
12 -0
mm
-0,011
Loctite 243
Medium strength threadlock
Medium Loctite 243 threadlock
Also check the shaft diameter on the
flywheel cover and on the engine
crankcase.
- Fit the freewheel on the magneto
flywheel making sure that the ground
side is in contact with the flywheel
itself, i.e. with wheel Seeger ring visible.
Characteristic
Shaft diameter on the flywheel cover
12 +0,034
mm
-0,016
- Lock the six clamping screws in crisscross fashion to the prescribed torque.
Shaft diameter on the engine
crankcase:
12 +0,034
mm
-0,016
Locking torques (N*m)
Screw fixing freewheel to flywheel
13 - 15
N.B.
THE TORQUE LIMITER IS PROVIDED WITH
4 GEARS THAT HAVE THE FUNCTION OF
CLUTCH DRIVE PLATES.
- Oil the free wheel "rollers".
Driven plates consist of 4 Belleville
springs provided with grooved profiles;
this assembly allows transmitting
torque lower than 10 kgm.
In case of incorrect start-up
manoeuvres, the limiter prevents any
kicks, with consequent reversal of
direction of the crankshaft which would
impair the engine structure.
The limiter assembly cannot be
overhauled. In case of irregularities on
the toothed discs, replace the
assembly.
37
10/07
- Install the start-up rim on the flywheel
turning it clockwise and inserting at the
same time.
Refitting the intermediate
gear
- Lubricate the gear housing on the
engine crankcase.
- Insert the intermediate gear with
torque limiter
Refitting the flywheel
magneto
- Insert the key on the crankshaft.
- Install the flywheel checking the
proper insertion of the key and engaging
the torque limiter gear with the start-up
rim.
- Lubricate the inside bushing and the
starter ring gear hub surface.
- Insert washer and nut on the
crankshaft.
38
10/07
- Tighten the flywheel lock nut to the
prescribed torque.
- Tighten thoroughly the guide bushing
of the flywheel lock tool and loosen by
1/4 turn.
Locking torques (N*m)
N.B.
FAILURE TO OBSERVE THIS RULE
CAUSES THE LOCKING OF THE GUIDE ON
THE FLYWHEEL.
Flywheel fixing nut
115 - 125
Specific tooling
020472Y
Flywheel lock wrench
- Install the chain guide retain plate
tightening the 3 screws to the
prescribed torque.
- Align the 2 holes of the flywheel with
the case housing to allow the
introduction of the special tool.
N.B.
BEFORE TIGHTENING THE SCREWS,
MOVE THE START-UP RIM IN CONTACT
WITH THE CRANKCASE AND CHECK THAT
IT IS FREE TO ROTATE IN
ANTICLOCKWISE DIRECTION.
Locking torques (N*m)
Chain guide sliding block retain
plate fastening screws
3÷4
- Insert the special tool checking that
the pins are perfectly introduced into
the seat.
Refitting the starter motor
Specific tooling
- Insert the starter motor.
- Check that the O-ring is in good
working order and lubricate it.
020472Y
Flywheel lock wrench
- Tighten the 2 fastening screws to the
prescribed torque.
Locking torques (N*m)
Starter screws
11 ÷ 13
39
10/07
Removing the rockerarms cover
Cylinder assy. and
timing system
- Loosen the 6 special screws with stop
and the relevant rubber gaskets.
- Remove the external and internal
transmission cover.
- Remove the tappet cover with relevant
gasket.
- Remove the flywheel cover, the
flywheel and the torque limiter.
Removing the timing
system drive
- Verify that the intake valves are
closed.
- Remove the central screw and the
valve lifting device mass stop bell using
the special tool.
Removing the intake
manifold
- Remove the 3 mounting screws.
Specific tooling
- Remove the intake manifold unit.
020565Y
Flywheel lock calliper spanner
40
10/07
- Remove the return spring and the valve
lifting mass with relevant travel end
washer.
Remove the inside hexagon screw and
the counterweight as shown in the
figure.
N.B.
BE CAREFUL SO AS NOT TO ALLOW THE
WASHER AND SPRING TO FALL INTO THE
ENGINE THROUGH THE CHAIN
COMPARTMENT.
- Align the reference marks on the
timing chain rim with those on the head.
- Remove the timing belt rim from the
camshaft.
- Remove the timing belt rim.
- Loosen the central screw on the
tensioner first.
Removing the cam shaft
- Unscrew the 3 fastening screws and
remove camshaft retaining bracket.
- Unscrew the 2 fastening screws and
remove the tensioner with relevant
gasket.
N.B.
REMOVING THE FASTENING SCREWS
MAY BE DIFFICULT. BE CAREFUL NOT TO
DAMAGE THE INSIDE HEXAGON. IF
NECESSARY, SEPARATE THE THREADS IN
ADVANCE.
41
10/07
- Remove the cam shaft.
- Remove the coolant temperature
sensor.
N.B.
THE SENSOR CONTROLS BOTH
INJECTION AND THE ANALOGUE
INSTRUMENT ON THE PANEL. TO CHECK
THIS COMPONENT, SEE “THE INJECTION”
CHAPTER.
- Remove pins and rocking levers by the
transmission side holes.
- Remove the 2 fastening nuts on the
head, on the exhaust and on the intake
side.
Removing the cylinder
head
- Remove the two M6 screws into the
distribution channel and the M6 screw
on the spark plug side with the
thermostat support.
- Remove the spark plugs.
- Remove the cooling system outlet
sleeve with thermostat.
N.B.
IF NECESSARY, THE HEAD MAY BE
REMOVED WITH THE CAMSHAFT, PINS,
ROCKING LEVERS AND MOUNTING
BRACKET.
42
10/07
- Loosen the 4 head-cylinder fastening
nuts in 2 or 3 times and in a crossed
sequence.
- Remove the head, the 2 centring
dowels, the gasket and the lower chain
guide sliding block.
- Remove the oil guards using the
special tool.
Specific tooling
020431Y
Valve oil seal extractor
N.B.
DO NOT REMOVE THE DOWELS IF THEY
ARE FORCED INTO THEIR SEAT.
WHEN YOU HAVE TO REMOVE THE
HEAD, PREPARE A SUITABLE
CONTAINER SINCE THE THERMAL UNIT
CONTAINS COOLANT.
Removing the valves
- Remove the spring supports.
- Using the appropriate tool fitted with
an adapter, remove the cotters,
washers, springs and valves.
N.B.
BLOW THE SEATS WITH COMPRESSED
AIR TO FACILITATE THE SPRING
SUPPORT REMOVAL.
Specific tooling
020382Y
Valve cotters equipped with part 012
removal tool
020382Y012
bush (valve removing tool)
ARRANGE THE VALVES SO AS TO
RECOGNISE THE ORIGINAL
POSITION ON THE HEAD (FLYWHEEL SIDE
AND TRANSMISSION SIDE).
43
10/07
Removing the cylinder piston assy
- Remove the piston sealing rings and
the oil scraper.
- Remove the timing chain.
CAUTION
NOTE THE ASSEMBLY POSITIONS
OF THE LININGS TO PREVENT INVERTING
THE POSITION IN CASE OF REUSE.
- Loosen the fastening screw and
remove the spacer and the tightening
sliding block.
N.B.
BE CAREFUL NOT TO DAMAGE THE
SEALING RINGS DURING REMOVAL.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN
ORDER TO ENSURE THAT THE INITIAL
DIRECTION OF ROTATION IS MAINTAINED.
Inspecting the small end
- Extract the cylinder with the relevant
gasket and the centring dowel.
- Using a bore gauge, measure the
connecting rod small end diameter.
N.B.
THE SECOND CENTRING IS ENSURED BY
A PIN SET INTO THE CYLINDER.
N.B.
IF THE CONNECTING ROD SMALL END
DIAMETER EXCEEDS THE STANDARD
DIAMETER, EXHIBITS WEAR OR
OVERHEATING, PROCEED TO REPLACE
THE CRANKSHAFT AS DESCRIBED IN
CHAPTER CRANKCASE AND CRANKSHAFT.
TO PREVENT DAMAGES TO THE
PISTON, SUPPORT IT WHILE
REMOVING THE CYLINDER.
Characteristic
Standard diameter:
22 +0,025
mm
+0,015
- Remove the 2 piston pin locking rings
by the specific housings.
Inspecting the wrist pin
- Extract the pin and remove the piston.
- Check the pin outside diameter using a micrometer.
N.B.
USE PAPER OR A CLOTH TO CLOSE THE
CYLINDER HOUSING MOUTH ON THE
CRANKCASE TO PREVENT SLIPPAGE OF
ONE OF THE PIN LOCKING RINGS INTO
THE CASE.
Characteristic
Standard diameter:
22 00,004 mm
44
10/07
- Calculate the coupling clearance
between pin and connecting rod end.
Characteristic
A:
10 mm
Piston diameter:
94 mm nominal value
Characteristic
Standard clearance:
0.015 ÷ 0.029 mm
- Measure the capacity diameter on the
piston.
- Using a bore meter, measure the
cylinder inner diameter at a given height
according to the directions shown in the
figure.
Characteristic
Characteristic
Standard diameter:
+0,006
22 +0,001 mm
- Calculate the piston pin coupling
clearance.
B:
43 mm
Standard diameter:
94 mm nominal value
Inspecting the piston
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION
CHANNELS. FOR THIS REASON,
MEASUREMENT MUST BE MADE
ACCORDING TO THE PISTON AXIS.
Characteristic
Standard clearance:
0.001 ÷ 0.010 mm
- Check that coating is free from flakes.
- Measure the outside diameter of the
piston, perpendicular to the gudgeon pin
axis.
- Check that the head matching surface exhibits no deformations or wear.
Characteristic
- Take the measurement in the position
shown in the figure.
Maximum allowable run-out:
0.05 mm
N.B.
SEE PAG. 6 FOR THE SIZES OF THE
PISTON AND THE CYLINDER-PISTON
COUPLING CLEARANCES.
- Pistons and cylinders are classified into categories based on their diameter. The
coupling is carried out in pairs (A-A, B-B, C-C, D-D).
N.B.
SEE PAG. 6 FOR THE SIZES OF THE CYLINDER AND THE CYLINDER-PISTON COUPLING
CLEARANCES.
45
10/07
Rings/housing coupling clearances:
Inspecting the piston
rings
Carefully clean the sealing ring
housings.
- Alternately insert the three sealing
rings into the cylinder, in the area where
it retains its original diameter. Using the
piston, insert the rings perpendicularly
to the cylinder axis.
Place a thickness gauge between the
ring and the housing as shown in the
drawing and check the coupling
clearances.
Top ring
Standard coupling
clearance:0.01÷0.06 mm
- Make sure that each single sealing
ring evenly adheres to the cylinder liner.
If it does not, this means the ring is
worn. Replace it.
Maximum clearances allowed after
use: 0.10 mm
- Measure the opening (see figure) of
the sealing rings using a feeler gauge.
Intermediate ring
Standard coupling
clearance:0.02÷0.07 mm
- If higher values than those prescribed
are measured, replace the linings.
Maximum clearances allowed after
use: 0.10 mm
Check the size of the sealing ring
opening:
Compression ring: 0.15 ÷ 0.35 mm.
Max. value 0.5 mm
Oil scraper ring
Standard coupling
clearance:0.01÷0.06 mm
Oil scraper ring: 0.25 ÷ 0.50 mm.
Max. value 0.65 mm
Maximum clearances allowed after
use: 0.10 mm
Oil scraper ring: 0.25 ÷ 0.50 mm.
Max. value 0.65 mm
Replace the piston if clearances exceed
the maximum limits specified in the
table.
46
10/07
- Place the wrist pin stop ring into
position using a punch
Removing the piston
- Install piston and wrist pin onto the
connecting rod, aligning the piston
arrow the arrow facing towards the
exhaust.
- Insert the locking ring into the special
tool, with the opening in the position
indicated on the tool.
- Install the pin lock using the key
shown in the figure.
Specific tooling
S = left
020470Y
Pin retainers installation tool
D= right
N.B.
THE TOOL FOR INSTALLING THE STOP
RINGS MUST BE USED MANUALLY.
USING A HAMMER MIGHT DAMAGE
THE STOPS' HOUSING.
47
10/07
- Provisionally fit the piston into the cylinder, without any base gasket.
- Identify the thickness of the cylinder base gasket to be used for reassembly by the
table below. Correctly identify the cylinder base gasket thickness to keep the correct
compression ratio.
- Install a comparator on the special tool using the short union, as shown in the figure.
- Remove the special tool and the cylinder.
Choosing the gasket
N.B.
IF DEVIATIONS (OR RECESSES OR PROJECTIONS) CLOSE TO THE CHANGE OF
CATEGORY ARE MEASURED, REPEAT THE MEASUREMENT AT THE OPPOSED SIDE. TO
DO SO, REPEAT THE TOOL INSTALLATION BY INVERTING ITS POSITION.
Specific tooling
020475Y
Piston position checking tool
- Using an abutment plane, reset the
comparator with a preload of a few
millimetres.
Characteristic
Recess / Projection measured 1
- 0.185 - - 0.10
Gasket thickness 1
0.4 ± 0.05
Recess / Projection measured 2
- 0.10 - + 0.10
Gasket thickness 2
0.6 ± 0.05
Recess / Projection measured 3
+ 0.10 - + 0.185
Gasket thickness 3
0.8 ± 0.05
- Finally fix the comparator.
- Check the perfect sliding of the feeler
pin.
- Install the tool on the cylinder without
changing the comparator position.
- Lock the tool using the original head
fixing nuts.
- Rotate the crankshaft until TDC (the
inverted point of the dial gauge rotation)
- Measure the deviation from the reset
value.
48
10/07
Refitting the piston rings
Refitting the cylinder
- Place the scraper ring spring on the
piston.
- Insert the cylinder base gasket with
the thickness determined above.
- Install the scraper ring keeping the
opening opposed to the spring junction
and with the writing "top" facing the
piston top. The chamfered side of the oil
scraper ring should always be facing
the piston crown.
- Using the fork and the band clamp,
install the cylinder as shown in the
figure.
N.B.
BEFORE INSTALLING THE CYLINDER,
CAREFULLY BLOW THE LUBRICATION
DUCT AND LUBRICATE THE CYLINDER
LINER. CHECK THE PRESENCE OF THE
TWO REFERENCE DOWELS.
- Fit the second lining with the
identification letter or the writing "top"
facing the piston crown. In any case,
the step must be facing opposite the
piston top.
Specific tooling
020468Y
Piston fitting band
020512Y
Piston fitting fork
- Install the first compression lining in
the direction imposed by the housing.
- It is advisable to use a fitter to
facilitate the installation of the linings.
Inspecting the cylinder head
N.B.
THE TWO PISTON RINGS ARE MADE
WITH A TAPERED CYLINDRICAL CONTACT
CROSS-SECTION. THIS IS TO ACHIEVE A
BETTER BEDDING.
- Using a trued bar and feeler gauge check that the cylinder head surface is not worn
or distorted.
Characteristic
Maximum allowable run-out:
0.1 mm
- Misalign the lining openings at 120° as
shown in the figure.
- In case of irregularities, replace the
head.
- Check the sealing surfaces for the
intake and exhaust manifold.
- Check that the camshaft and the
rocker pin capacities exhibit no wear.
- Check that the head cover surface is
not worn.
- Check that the coolant sealing pad
exhibits no oxidation.
- Lubricate the components with engine
oil.
- The engine uses the first compression
lining with an L section.
49
10/07
Inspecting the timing
system components
Inspecting the valve
sealings
- Check that the guide shoe and the
tensioner shoe are not worn out.
- Visually inspect the valve sealing
surface.
- Check that the crankshaft pinion and
the camshaft timing gear and
crankshaft pinion exhibit no wear.
DO NOT REVERSE THE FITTING
POSITIONS OF THE VALVES
(RIGHT - LEFT).
In case of wear of the sliding blocks,
replace them. In case of wear of the
chain or rim, replace the entire unit.
- If the sealing surface of the valve is found
to be interrupted at one or more points or
is not flat, replace the valve.
N.B.
IF THE CHAIN HAS DAMAGED THE PINION, REPLACE THE CRANKSHAFT AS DESCRIBED
IN CHAPTER CRANKCASE AND CRANKSHAFT.
Chain tensioner:
- Remove the centre screw with the
washer and the tensioner spring. Check
that the one-way mechanism is not
worn.
- Insert the valves into the cylinder head.
- Alternatively check the intake and
exhaust valves.
- The test is carried out by filling the
manifold with petrol and checking that the
head does not ooze through the valves
when these are just pressed with the
fingers.
Inspecting the valve
housings
- Clean the valve seats of any carbon
residues.
- Using the Prussian Blue, check the
width of the impression on the valve
seat "V".
- Check the condition of the tensioner
spring.
- If examples of wear are found, replace
the whole assembly.
Characteristic
Standard value:
1 - 1.3 mm
Admissible limit:
1.6 mm
- If the impression width on the valve seat is larger than the prescribed limits, true the
seats with a 45° mill and then grind.
- In case of excessive wear or damages, replace the head.
50
10/07
Inspecting the valves
Inspecting the valve stem guide clearance
- Measure the diameter of the valve stems in the three positions indicated in the
diagram.
- After measuring the valve guide diameter and the valve stem diameter, check the
clearance between guide and stem.
STANDARD DIAMETER
Specification
Desc./Quantity
Inlet:
4.987 - 4.972 mm
Outlet:
4.975 - 4.960 mm
INLET
Specification
Desc./Quantity
Standard clearance:
0.013 - 0.04 mm
Admissible limit:
0.08 mm
MINIMUM ADMISSIBLE DIAMETER
Specification
OUTLET
Desc./Quantity
Inlet:
4.96 mm
Outlet:
4.945 mm
Specification
Desc./Quantity
Standard clearance:
0.025 ÷ 0.052 mm
Admissible limit:
0.09 mm
- Calculate the clearance between valve
and valve guide.
- Check the deviation of the valve stem by
resting it on a "V" shaped abutment and
measuring the extent of the deformation by
a comparator.
STANDARD VALVE LENGTH
Characteristic
Limit values admitted:
0.01 mm
Specification
Desc./Quantity
Inlet:
95.0 ± 0.3 mm
Outlet:
94.2 ± 0.3 mm
- Check that there are no signs of wear on the surface of contact with the articulated
register terminal.
- Check the concentricity of the valve head
by arranging a comparator at right angle
relative to the valve head and rotate it on a
"V" shaped abutment.
Characteristic
Admissible limit:
0.03 mm
51
10/07
- If the checks above give no failures,
you can use the same valves. To obtain
better sealing performance, grind the
valve seats. Grind the valves gently with
a fine-grained lapping compound. During
the grinding, keep the cylinder head
with the valve axes in a horizontal
position. This will prevent the lapping
compound residues from penetrating
between the valve stem and the guide
(see figure).
Inspecting the springs and
half-cones
TO AVOID SCORING THE CONTACT SURFACE, DO NOT KEEP ROTATING THE VALVE
WHEN NO LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD
AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND
BEING USED.
- Measure the free length of the spring.
- Check that the upper and lower
supporting spring washers, the cotters
and the oil seal show no sign of
abnormal wear. Replace a component
when worn.
DO NOT REVERSE THE FITTING POSITIONS OF THE VALVES (RIGHT - LEFT).
52
Characteristic
Standard length:
44.4 mm
Admissible limit after use:
42.4 mm
10/07
Refitting the valves
Inspecting the cam shaft
- Place the valve spring support
washers on the head.
- Alternately insert the 4 oil guards
using the special tool.
- Lubricate the oil guards and the valve
guides.
- Check that the camshaft ends exhibit no scratches or irregular wear.
- Using a micrometer, measure the camshaft capacity.
STANDARD DIAMETER
Specification
Desc./Quantity
Bearing A Ø:
Specific tooling
Bearing B diameter:
020306Y
Punch for assembling valve seal rings
42
-0,060
-0,085
mm
20
-0,020
-0,041
mm
MINIMUM ADMISSIBLE DIAMETER
- Fit the valves, the springs and the
spring retaining washers. Using the
appropriate tool with adapter, compress
the springs and insert the cotters in
their seats.
Specification
Desc./Quantity
Bearing A Ø:
41.910 mm
Bearing B diameter:
19.940 mm
-Using a gauge,
measure the cam
height.
Specific tooling
020382Y
Valve cotters equipped with part 012
removal tool
020382Y012
bush (valve removing tool)
STANDARD HEIGHT
Specification
Desc./Quantity
intake
33.774 mm
discharge
N.B.
DO NOT CHANGE THE VALVE FITTING
POSITION. FIT THE VALVE SPRINGS WITH
THE REFERENCE COLOUR ON COTTER
SIDE (TURNS WITH GREATER PITCH).
mm
33.273
ADMISSIBLE LIMITS
53
10/07
Specification
Desc./Quantity
intake
33.526 mm
discharge
33.026 mm
Standard axial clearance:
0 - 0.22 mm
Maximum admissible axial clearance:
0.3 mm
- If any of the above dimensions are
outside the specified limits, or there are
signs of excessive wear, replace the
defective components with new ones.
Refitting the head and
timing system
components
- Check that the retaining plate seat
shown in the figure exhibits no wear.
- Insert the chain guide sliding block.
- Insert the two centring dowels between
head and cylinder.
- Install the head gasket.
N.B.
THE FIGURE SHOWS THE INSERTION
POSITION OF THE TWO CENTRING
DOWELS BETWEEN HEAD AND CYLINDER.
THE DIRECTION OF INSTALLATION FOR THE
GASKET IS FORCED BY THE DOWELS.
- Check that the automatic valve lifting
device cam, the travel end roller and the
rubber abutment on the containment
bell are free from wear.
- Check that the valve lifting spring has
not yielded.
- Replace any relevant defective or worn
components.
- Check that the rocking lever pins
exhibit no scratches or wear.
- The head gasket is made of steel and
has a standard thickness.
Characteristic
- Check that the head lubrication
channel is perfectly clean. Clean with
compressed air jets, if required.
- Insert the head.
- Lubricate the stud bolts and the 4
fastening columns.
- Tighten the 4 fastening columns
crosswise to the prescribed torque as
shown in the figure.
Standard diameter:
13 -0,010
mm
-0,018
- Measure the inside diameter of each
rocking lever.
Characteristic
Standard diameter:
+0,026
13 +0,015
mm
- Check that the cam contact sliding
block and the articulated register plate
is free from wear.
- In case of wear, replace the
component.
Locking torques (N*m)
Head fixing stud bolts:
***
*** Apply a preliminary torque of 7 Nm
in a crossed sequence.
- Tighten by 90° in a crossed sequence.
54
10/07
- Tighten again by 90° in a crossed
sequence.
- Install the coolant temperature sensor
with the washer and tighten to the
prescribed torque.
FAILURE TO OBSERVE THE
TIGHTENING TORQUE CAN
DAMAGE THE SENSOR.
Locking torques (N*m)
coolant temperature sensor:
10 - 12
Locking torques (N*m)
- Fit the spark plugs and tighten them
to the prescribed torque.
- Tighten the fastening nuts on the
exhaust and on the intake side to the
prescribed torque.
Spark plug
12 ÷ 14 Nm
- Insert the timing control belt on the
crankshaft according to the initial
direction of rotation.
- Install the tensioner shoe with its
spacer, tightening the bolt to the
prescribed torque, using the
recommended product.
Locking torques (N*m)
Exhaust / intake head fixing nuts:
10 - 12
Recommended products
Loctite 243
Medium strength threadlock
Medium Loctite 243 threadlock
- Tighten the 3 side screws to the
prescribed torque.
- Insert pins and rocking levers on the
flywheel side.
- Lubricate the two rocking levers
through the holes at the top.
Locking torques (N*m)
Head fixing screws
10 - 12
55
10/07
Locking torques (N*m)
Tensioner sliding block fixing screw:
10 - 14
- Using the TORX wrench, remove the
timing check cap
- Clean the camshaft by blowing with
little compressed air jets, especially the
retaining plate housing.
- Lubricate the 2 shafts.
- Insert the camshaft into the head with
the cams opposite the rocking levers.
- Insert the belt on the camshaft control
timing rim.
- Remove any LOCTITE residues from
the screws fixing the camshaft retaining
bracket using a brush.
- Apply the recommended product to
the fixing screws and tighten to the
prescribed torque.
- Insert the timing rim on the camshaft
checking that the references are
aligned.
N.B.
DURING THE STROKE CHECK, KEEP THE
BELT TENSIONED BY PRESSING ON THE
TIGHTENER COMPARTMENT SIDE.
Recommended products
Loctite 243
Medium strength threadlock
Medium Loctite 243 threadlock
- Insert the camshaft retain bracket with
visible countersinks and tighten the 3
fastening screws to the prescribed
torque, being careful not to damage the
inside hexagon.
- Install the intermediate gear with
torque limiter, the flywheel and its cover,
as described in Chapter "Flywheel and
start-up system", and in Chapter
"Flywheel cover".
Locking torques (N*m)
Camshaft retaining bracket fastening
screws:
4÷6
- Keeping the belt slightly pulled, turn
the crankshaft using the driving pulley
to make the reference on the magnet
support collimate with that on the
flywheel cover.
N.B.
FOR MORE CONVENIENCE, INSTALL THE
FLYWHEEL COVER WITHOUT THE
COOLING SYSTEM SLEEVES.
56
10/07
- Turn the crankshaft to move the
references to the top as shown in the
figure (intake end).
- Insert the valve lifting device mass stop
bell.
- Tighten the retaining screw to the
prescribed torque, using the
recommended product.
- Install the counterweight mass.
- Centre using the bell fastening screw.
- Lock the mass fixing screws to the
prescribed torque, using the
recommended product.
Recommended products
Loctite 243
Medium strength threadlock
Medium Loctite 243 threadlock
N.B.
THE BELL TIMING IS ENSURED BY THE
COUNTERWEIGHT MASS FASTENING
SCREW HEAD.
Locking torques (N*m)
Recommended products
Counterweight screw
7 ÷ 8.5 Nm
Loctite 243
Medium strength threadlock
Medium Loctite 243 threadlock
- Remove the central screw.
- Install the valve lifting mass being
careful to the proper positioning of the
travel end ring.
- Check that the counterweight mass is
free and that it is pulled by the spring.
- Lubricate the mass and decompressor control pin.
Locking torques (N*m)
- Install the return spring and load it by
about 3/4 turn.
- Place the tightener cursor in the rest
position, keeping the retain tab pressed.
Valve lifter mass stop bell fixing
screws:
30 - 35
57
10/07
Refitting the timing chain
- Install a new tightener on the cylinder
using a new gasket.
- Tighten the two fastening screws to
the prescribed torque.
The ignition advance is determined electronically on the basis of parameters known
by the control unit. For this reason it is not possible to declare the reference values
based on the engine rpm.
Locking torques (N*m)
The ignition timing value is detectable any time using the diagnostic tester.
Tightener fastening screws:
11 ÷ 13
It is possible to check whether the ignition advance determined by the system does
in fact correspond with the value actually activated on the engine, by means of the
stroboscopic light.
Specific tooling
- Insert the spring with the central screw
and the washer.
- Tighten the central screw to the
prescribed torque.
020460Y
Scooter diagnosis and tester
020330Y
Stroboscopic light for timing control
Locking torques (N*m)
Tightener screw:
5-6
Proceed as follows:
- Place the engine with the valve
clearance adjustment timing references
aligned with the head.
- Check the clearance between valve and rocking lever using a thickness gauge.
- Remove the outside transmission
cover as described in the automatic
transmission chapter.
PRESCRIBED CLEARANCE
Specification
Desc./Quantity
Inlet
0.15 mm (engine cold)
drainage
0.15 mm (engine cold)
- In case different values are found, adjust
by loosening the lock nut and use a
screwdriver for the set screw as shown in
the figure.
- Remove the TDC reference inspection
cap between flywheel and crankcase
cover. See the “Flywheel cover” chapter.
58
10/07
Specific tooling
- By the driving pulley, turn the engine
to find the alignment of the references
to identify the TDC.
020460Y
Scooter diagnosis and tester
If the values do not match, check:
- distribution timing
- revolution-timing sensor
- Injection control unit
Refitting the rocker-arms
cover
- Repeat for the reference between
driving pulley and transmission housing.
- Check that the gasket is in good
working order.
- Replace the inspection cap on the
flywheel side.
- Connect the diagnostic tester.
- Start the engine.
- Select the menu on the "parameter"
function.
- Select the stroboscopic light
command in the traditional four-stroke
engine position (1 spark 2 revs).
- Check that the real values of rpm and
ignition advance match those measured
using the diagnostic tester.
- Tighten the two screws indicated in
the figure with "1" and "2" to limit the
reciprocal sliding of the cover surface
with the head surface.
- Tighten the remaining 4 screws in a
crossed sequence (3, 4, 5, 6).
N.B.
CHECK THE PROPER POSITION OF THE
GASKET.
Locking torques (N*m)
Tappet cover fixing screws:
7-9
59
10/07
- Install the transmission cover and the
relevant net filter and the outside
transmission cover as described in the
"Automatic transmission" chapter.
Crankcase - crankshaft
- Remove the outside and inside transmission cover and the complete driving pulley as
described in "Automatic transmission".
- Remove the flywheel cover with the cooling system sleeves, as described in the
"Flywheel cover" chapter.
- Remove the flywheel with the starting system following the instruction given in "Flywheel
and Starting system".
- Remove the thermal unit (cylinder, head, piston) as described in the Thermal unit and
timing system chapter.
- Before opening the crankcase, check the crankshaft axial clearance.
For this purpose, use a plate (e.g. the special tool) and a support with special tool
comparator.
Specific tooling
- Install the cooling system sleeves
using new bands, as described in the
"Flywheel cover" chapter.
020262Y
Crankcase splitting strip
020335Y
Magnetic support for dial gauge
Characteristic
Standard clearance:
0.10 - 0.50 mm
Admissible increase limit after use:
0.60 mm
- Upper clearances are an indication of wear on the surfaces of the crankshaft casing
support.
- To carry out an accurate measurement, measure the clearance in both directions
between crankcase and crankshaft.
Refitting the intake
manifold
- Install the intake manifold on the engine.
- Insert the 3 fastening screws, one of
which with a support band for the cooling
system sleeve, and tighten to the
prescribed torque.
Locking torques (N*m)
Inlet manifold screws
11 ÷ 13
60
10/07
Splitting the crankcase
halves
Removing the crankshaft
- Before removing the crankshaft, check
the timing with the countershaft. To
carry out this check, turn the crankshaft
to align the two holes obtained on the
crankshaft with the hole on the
countershaft control gear.
- Remove the engine support retain
screw on the flywheel side halfcrankcase.
This is an optimal position also to
remove the crankshaft.
- Remove the 14 crankcase coupling
screws.
- Remove the crankshaft with the shim
adjustment washer on the flywheel side.
WHILE OPENING THE CRANKCASE
AND REMOVING THE CRANKSHAFT,
CHECK THAT THE SHAFT THREADED
ENDS DO NOT INTERFERE WITH THE
MAIN BEARINGS. FAILURE TO OBSERVE
THIS PRECAUTION CAN DAMAGE THE
MAIN BEARING.
N.B.
THE FASTENING SCREWS ARE OF 3
DIFFERENT LENGTHS. NOTE THEIR
CORRECT POSITION.
- Split the crankcases while keeping the
crankshaft inserted on the flywheel side
half-crankcase.
Removing the oil pump and
countershaft control gear.
- To remove the control gear, loosen the
4 fastening screws.
- Remove the coupling gasket.
N.B.
THE BUSHING SUPPORT CAN BE LEFT IN
THE FLYWHEEL SIDE HALF-CRANKCASE.
Remove the gear only if actually
required.
THE SCREWS HAVE A
COUNTERSUNK HEAD AND THEIR
THREADING IS LOCKED BY LOCTITE. BE
CAREFUL NOT TO DAMAGE THE
CONTROL HEXAGON. TO OBTAIN BETTER RESULTS IT IS PREFERABLE TO USE AN
INSIDE HEXAGON SOCKET WRENCH.
61
10/07
Removing the
countershaft
Replacing the
countershaft bearings
- Place the special tool as shown in the
figure.
- Check that the bearings are free from
irregular noise or clearance. If it is,
replace it.
Specific tooling
Flywheel-side half-crankcase
020479Y
Countershaft lock wrench
- Remove the inside seeger ring.
- Remove the fastening nut with relevant
washer.
- Upturn the half-crankcase.
- Remove the bearing from the flywheel
side half-crankcase using the special
tool and a mallet.
Specific tooling
020376Y
Adaptor handle
020358Y
37x40 mm adaptor
020439Y
17 mm guide
- Remove the special tool and extract
the countershaft with the control gear.
- Remove the bearing from the
transmission side half-crankcase using
the special tool.
Specific tooling
001467Y008
Extraction pliers for ø 17 mm bearings
001467Y007
Driver for OD 54 mm bearing
62
10/07
- Before installing a new bearing, heat
the flywheel side half-crankcase using
the special tool.
- Fit the seeger ring.
- Before installing the new bearing on
the transmission side crankcase, heat
the seat using the special tool.
- Place the half-crankcase on a wooden
base.
Specific tooling
Specific tooling
020151Y
Air heater
020151Y
Air heater
- Insert a new bearing on the special
tool after greasing the guide seat.
- Insert a new bearing on the special
tool after greasing the guide seat.
- Install the new bearing on the engine
crankcase using the special tool.
- Install the new bearing on the halfcrankcase using the special tool.
N.B.
IF A BEARING WITH PLASTIC CAGE IS
USED, KEEP THE BALLS VISIBLE FROM
THE CRANKCASE INTERNAL SIDE.
N.B.
IF A BEARING WITH PLASTIC CAGE IS
USED, KEEP THE BALLS VISIBLE FROM
THE CRANKCASE INTERNAL SIDE.
Specific tooling
020376Y
Adaptor handle
020359Y
42 x 47 mm adaptor
020439Y
17 mm guide
Specific tooling
020376Y
Adaptor handle
020359Y
42 x 47 mm adaptor
020439Y
17 mm guide
63
10/07
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH FALLS WITHIN THE
STANDARD VALUES AND THE SURFACES ARE FREE FROM SCRATCHES.
Inspecting the crankshaft
components
Shimming
- Check the overall height of the crankshaft - shoulders - gear assembly.
- Check the axial clearance on the
connecting rod.
Characteristic
Standard thickness:
71.804 - 72.000 mm
- Check that shim adjustment is free from scratches.
Characteristic
Standard clearance:
0.20 ÷ 0.60 mm
N.B. - IN CASE OF NEW UTILISATION, MAINTAIN THE FIRST FITTING POSITION.
Specific tooling
020074Y
Support base for checking crankshaft alignment
- If the crankshaft - crankcase axial clearance is higher than the standard value and the
crankshaft exhibits no irregularity, the problem is caused by wear or by a wrong machining
on the engine crankcase.
- Check the connecting rod diametrical
clearance.
- Check the diameters of both the bearings
of the crankshaft in accordance with the
axes and surfaces shown in the figure.
Half-shafts are classified into two
categories: Cat. 1 and Cat. 2.
Characteristic
Standard clearance:
0.046 ÷ 0.076 mm
STANDARD DIAMETER
Specification
Desc./Quantity
Cat. 1
40.010 ÷ 40.016
Cat. 2
40.016 ÷ 40.022
Inspecting the crankshaft
alignment
-Check the surfaces that limit the axial
free-play are not scored and measure the
width of the crankshaft between these
surfaces, as shown in the diagram.
- Install the crankshaft on the support
and measure the displacement at the 4
points shown in the figure.
Specific tooling
020074Y
Support base for checking
crankshaft alignment
MAX ADMISSIBLE DISPLACEMENT
N.B.
BE CAREFUL NOT TO LET THE
MEASUREMENT BE AFFECTED BY THE
UNIONS WITH THE CRANKSHAFT ENDS.
Specification
Desc./Quantity
A
0.15 mm
Characteristic
B
0.01 mm
Standard dimensions:
63.6 - 63.45 mm
C
0.01 mm
D
0.10 mm
64
10/07
Inspecting the crankcase
halves
- Check that the driving shaft cone, the
tab seat, the oil seal capacity, the
toothed gear and the threaded tangs are
in good working order.
- Before proceeding to check the
crankcase halves, thoroughly clean the
all surfaces and oil ducts.
- For the transmission-side halfcrankcase, special attention should be
given to the bushings, to the cooling jet
on the transmission side (see figure)
and to the lubrication duct.
- In case of failures, replace the
crankshaft.
N.B.
MAIN BEARINGS CANNOT BE MODIFIED.
The connecting rod cannot be replaced. To check the connecting rod small end
diameter, see chapter "Thermal unit and timing system".
- When cleaning the crankshaft, be careful to prevent any impurity from entering into
the shaft lubrication hole.
N.B.
IN CASE OF REPLACEMENT OF A CRANKSHAFT CONSISTING OF TWO HALF-SHAFTS OF
DIFFERENT CATEGORY, REPLACE THE TWO HALF-CRANKCASES AS WELL, COUPLING
THE TWO COMPONENTS (SHAFT AND CRANKCASE) WITH THE SAME CATEGORY.
- To check the gearing of the
crankshaft, see section "Thermal unit
and timing system".
N.B.
THE JET IS FED THROUGH THE MAIN
BUSHINGS. PROPER OPERATION OF THIS
COMPONENT IMPROVES THE PISTON
TOP COOLING. CLOGGING HAS EFFECTS
THAT ARE DIFFICULT TO DETECT (PISTON
TEMPERATURE INCREASE). FAILURE OR
LEAK CAN CONSIDERABLY DECREASE
THE MAIN BUSHING AND CONNECTING
ROD LUBRICATION PRESSURE.
- For the flywheel side half-crankcase,
special attention should be given to the
lubrication channels for the main
bearings and to the compartment and
the channels for the oil pump, as well
as to the duct for the by-pass located
on the flywheel cover.
See also
Cylinder assy. and timing system
65
10/07
N.B.
AS ALREADY DESCRIBED IN THE "LUBRICATION" CHAPTER, IT IS ESPECIALLY
IMPORTANT THAT THE BY-PASS HOUSING ON THE FLYWHEEL COVER IS FREE FROM
WEAR THAT MAY IMPAIR THE PROPER SEALING OF THE LUBRICATION PRESSURE
ADJUSTMENT PISTON. THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A
SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION. THIS CHOICE WAS
MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP.
The jet clogging impairs the head lubrication and the timing mechanisms.
A jet failure causes a decrease of the main bearing and connecting rod lubrication
pressure.
- Check that the surfaces are free from dents or deformations, with special attention
to the crankcase coupling and the crankcase-cylinder surfaces.
- Any defects in the crankcase gasket or matching surfaces (see Flywheel cover
coupling) can cause pressurised oil leaks, thereby affecting the connecting rod and
main bearing lubrication pressure.
- Check the main bearing seats that limit axial clearance in the crankshaft show no
signs of wear. For the dimensional check, refer to the instructions relating to the axial
clearance and dimensions check on the crankshaft
Inspecting the crankshaft
plain bearings
- To obtain a good bushing lubrication it
is necessary to have both an optimal
lubricating pressure (4 bar) and a good
oil flow rate; the bushings must be
correctly positioned so as not to
obstruct the oil supply channels.
- The main bushings are comprised of
two half-bearings, one containing holes
and channels for lubrication and the
other solid.
- The solid half-bearing is intended to stand the thrusts caused by combustion, and
for this reason it is arranged opposed the cylinder.
- To prevent shutters in the oil feeding channels, the matching surface of the two halfbearings must be perfectly orthogonal to the cylinder axis, as shown in the figure.
- The oil supply channel section is also affected by the bushings driving depth
compared with the crankshaft axial clearance of the limiting surface.
N.B.
TO KEEP SUCH POSITION OF THE BUSHINGS ON THE CRANKCASE, DRIVING IS FORCED
ON CAST-IRON RINGS INSERTED IN THE CASTING OF BOTH HALF-CRANKCASES.
- Check the inside diameter of the main
bushings in the three directions
indicated in the diagram.
- Repeat the measurements for the
other bushing half. see diagram.
N.B.
DO NOT TAKE THE MEASUREMENT ON
THE TWO HALF-SHELL COUPLING
SURFACE SINCE THE ENDS ARE
RELIEVED TO ALLOW BENDING DURING
THE DRIVING OPERATION.
66
10/07
Before assembling, check that the clearance between the engine crankcase bushing
and the crankshaft is within the predetermined limits.
Characteristic
Crankshaft-bushing maximum clearance admitted:
0.08 mm
- The standard bushing diameter after driving is variable on the basis of a coupling
selection.
- The crankcase bushing seats are classified into 3 categories while the crankshaft
ones, into 2 categories.
- Bushings are subdivided into 4 categories according to their thickness (see the table).
Description
Dimensions
Type A - Red
1.971 ÷ 1.974
Type B - Blue
1.974 ÷ 1.977
Type C - Yellow
1.977 ÷ 1.980
Type D - Green
1.980 ÷ 1.983
Initials
X = Crankshaft category
Y = Crankcase half-shell category
A = Red
B = Blue
C = Yellow
D = Green
In case of breakdown, crankcases are together with bushings and are classified
according to the centre to centre distance of the countershaft. Find below the
possible couplings.
- Complete FC1 type crankcase equipped with bushings for housing a category 1
crankshaft and a countershaft with centre to centre distance A.
- Complete FC2 type crankcase equipped with bushings for housing a category 2
crankshaft and a countershaft with centre to centre distance A.
CHECK THE BENCH BUSH
Name
KEY
Quantity
- Complete FC3 type crankcase equipped with bushings for housing a category 1
crankshaft and a countershaft with centre to centre distance B.
- Complete FC4 type crankcase equipped with bushings for housing a category 2
crankshaft and a countershaft with centre to centre distance B.
N.B.
THE CRANKSHAFT CATEGORY IS STAMPED ON THE COUNTERWEIGHT SHOULDER.
A spare crankcase cannot be combined with a driving shaft with mixed categories.
Spare shafts have half-shafts of the same category.
Coupling chart
The following kinds of bushings indicated in the table must be used according to the
kind of coupling between the crankshaft and the crankcase.
N.B.
TO REPLACE THE HALF-SHAFTS, REMOVE THE COUNTERSHAFT BEARINGS AS
DESCRIBED ABOVE. REMOVE THE COMPLETE DRIVEN PULLEY AND THE ANTI-FLAPPING
ROLLER FROM THE TRANSMISSION SIDE HALF-CRANKCASE, AS DESCRIBED IN
CHAPTER "AUTOMATIC TRANSMISSION", AND THE HUB COVER WITH THE RELEVANT
GEARS AND BEARINGS AS DESCRIBED IN CHAPTER "FINAL REDUCTION".
67
10/07
Recommended products
Countershaft
Loctite 243
Medium strength threadlock
Medium Loctite 243 threadlock
- Repeat the same procedure for the 4 fastening screws.
- Insert the control gear on the crankshaft with the hole countersink visible.
- Tighten the 4 fastening screws to the prescribed torque.
- Using a micrometer, measure the 2
bearings of the countershaft as shown
in the figure.
Characteristic
Standard diameter:
17 -0,01
-0,02 mm
N.B.
TO AVOID DAMAGING THE SCREW CONTROL HEXAGON, IT IS PREFERABLE TO USE AN
INSIDE HEXAGON SOCKET WRENCH.
- Check that the water pump drive
spindle is not worn.
Locking torques (N*m)
Refitting the crankshaft
- Check that the oil pump and countershaft control gear are free from deformations or
dents. Replace, if required.
N.B.
IF YOU HAVE TO REPLACE THE OIL PUMP AND COUNTERSHAFT CONTROL GEAR IT IS
NECESSARY TO REPLACE THE COUNTERSHAFT GEAR AS WELL.
Gear mounting on crankshaft screws
10 -12
- Lubricate the main bearing on the
flywheel side half-crankcase.
- Lubricate the shim adjustment washer.
- Insert the shim adjustment washer on
the crankshaft in its original position.
- Insert the special timing tool in the
hole on the countershaft.
Specific tooling
020471Y
Pin for countershaft timing
- Before installing the gear on the
crankshaft, carefully clean the two
matching surfaces removing any
residues of LOCTITE from the holes
using a brush.
- Insert the crankshaft on the pin and
into the bushing.
Blow with compressed air and degrease
the mounting holes on both surfaces to
make the new LOCTITE grip.
- Insert thoroughly and remove the
special tool.
Apply the recommended product to the
holes again.
N.B.
WHEN INSERTING THE SHAFT ON THE HALF-CRANKCASE, BE CAREFUL NOT TO DAMAGE
THE MAIN BEARING WITH THE THREADED TANG OF THE CRANKSHAFT AND WITH THE
TIMING CONTROL TOOTHED PINION.
- Before inserting thoroughly, make the
oil pump gear align with the control
gear.
68
10/07
- Install the oil pump closing plate.
- Insert the gasket on the flywheel side
half-crankcase.
- Tighten the 2 flanged fastening screws
to the prescribed torque.
Locking torques (N*m)
Bulkhead screws for oil pump
housing cover
8 - 10
- Lubricate the main bearing on the
transmission side half-crankcase.
- Couple the 2 half-crankcases being
careful not to damage the bushing on the
transmission side half-crankcase with the
threaded tang of the crankshaft.
- Insert the engine support retain screw
on the flywheel side half-crankcase
without tightening.
- Insert the 14 fastening screws by
arranging the single shorter screw "A"
and the single longer screw "B" as shown in the figure.
- Tighten the screws thoroughly and tighten to the
prescribed torque.
- Check that the crankshaft rotates freely.
Refitting the crankcase
halves
- Remove the oil guard from the
transmission side half-crankcase using
a screwdriver.
- Install a new oil guard after lubricating
it, using the special tool, arranging it at
a 0.5 mm recess from the crankcase
plane.
Locking torques (N*m)
Engine-crankcase coupling
screws
11 ÷ 13
N.B.
REMOVE ANY EXCESS FROM THE CRANKCASE COUPLING GASKET ON THE CYLINDER
PLANE, TO ENSURE BETTER SEALING PERFORMANCE.
A WRONG POSITIONING OF THE
OIL GUARD AFFECTS THE
LUBRICATION OIL CIRCULATION.
- Install the thermal unit (cylinder, head, piston) as described in section "Thermal unit
and timing system".
- Install the flywheel with start-up control as described in the "Flywheel and start-up"
chapter.
- Install the flywheel cover with the cooling system sleeves, as described in the
"Flywheel cover chapter".
- Install the complete driving pulley, the transmission cover and the relevant mesh
filter and the outside transmission cover as described in the section "Automatic
transmission".
Specific tooling
020360Y
52 x 55 mm adaptor
020376Y
Adaptor handle
See also
Cylinder assy. and timing system Flywheel cover
69
10/07
Lubrication
TECHNICAL SPECIFICATIONS
OIL FILTER
SUMP CAPACITY
Specification
Desc./Quantity
Specification
Desc./Quantity
Overhaul
1.7 l
Type
Oil and filter replacement
1.5 l
Paper with pressure relief and anti-cavitation
by-pass
OIL MINIMUM PRESSURE INDICATOR LIGHT SWITCH
RECOMMENDED ENGINE OIL
Product
Description
Specifications
Q8 FORMULA EXCEL
Engine oil
SAE 5W-40, API SL, ACEA
A3, JASO MA Synthetic oil
Specification
Desc./Quantity
Calibration
0.3 ÷ 0.6 bar
HEAD LUBRICATION CONTROL JET
OIL PUMP
Specification
Desc./Quantity
Type
Trochoidal
Rotor thickness
8 mm
Assembly clearances
Lobe ends 0.05-0.008 mm
Outside rotor radial clearance
0.05 ÷ 0.12 mm
Rotor axial clearance
0.025 ÷ 0.065 mm
Desc./Quantity
Diameter
1 ± 0.05 mm *
* Tightening torque 5 ÷ 7 Nm
PISTON COOLING NOZZLE
Specification
Desc./Quantity
Diameter
0.8 ± 0.05 mm
BASE VENTILATION CHECK
BY-PASS
Specification
Desc./Quantity
Type
Piston
Plunger diameter
Specification
13
-0,039
-0,057
mm
Spring free length
62.5 mm
Calibration pressure
4 bar
PRE-FILTER
Specification
Desc./Quantity
Type
Mesh, plastic
70
10/07
Specification
Desc./Quantity
Device
Decantation chamber and metal reed valve
Conceptual diagrams
General characteristics
Lubrication circuit is split into two sections:
- High pressure
- Low pressure
The high pressure section includes all components located on the engine crankcase,
while the low pressure section only refers to the thermal unit.
The trochoidal pump is installed into the sump and is controlled through a couple of
gears.
To guarantee the integrity of the pump, a pre-filter is installed.
The pre-filter is of the screw-in type and the plug serves at the same time as an
engine oil drain plug.
The pump is controlled by means of a piston by-pass calibrated to 4 bar. This is
located before the cartridge filter and both are installed on the flywheel cover, so that
the seal of the filter is subject to the pressure of the circuit.
The by-pass located before the cartridge filter improves the operating conditions for
the filter proper, particularly with cold oil.
The filter is equipped with an anti-cavitation valve and a pressure relief valve; the latter
intervenes when the filtering element causes a pressure drop exceeding 1± 0.2 bar.
PRINCIPLE DIAGRAM
Specification
Desc./Quantity
A
Camshaft
B
Cylinder-head plane
C
Cylinder-crankcase plane
D
Water pump impeller
E
Minimum oil pressure sensor
F
Oil filter cartridge
G
To the oil sump
H
By-pass valve
L
Oil pump
M
Mesh pre-filter
N
Crankshaft
O
Connecting rod
These conditions naturally occur only with cold oil and at high engine revs or if the
filter is clogged.
The filtered oil is used to lubricate the shaft of the water pump and once at the engine
crankcase, to lubricate the crankcase bearings, the connecting rod head and the
piston cooling nozzle located on the bearings on the transmission side.
The crankcase bearing on the transmission side is provided with an oil seal and the
respective drain line.
The supply line for the timing system comes from the flywheel-side bearing; the
supply to the head is controlled by the respective spray jets in the engine crankcase.
The components of the timing system function with low-pressure oil.
71
10/07
The camshaft bearings are marked directly on the aluminium of the head; the axial
clearance of the camshaft is partly compensated by the oil supplied to the small end
bearings.
Diagnosis guide
The camshaft supplies the lubricant to the rocking levers via the bores provided;
these are installed in a position to ensure that the lubrication is maintained even after
the scooter has stopped. This is achieved when the camshaft reaches its most usual
and likely position when the engine is switched off.
AHEAD - go to 2
The oil used to lubricate the head returns to the sump via the ducts in the chain
casing and hence also provides lubrication for the chain.
YES - go to 3 NO - go to 11
1 - Minimum oil pressure warning light on with hot engine.
2 - Remove the minimum pressure switch electric connector.
Check that the warning light turns off.
3 - Check the actual oil pressure.
In order to avoid the gas collecting in the bottom of the tank carrying oil out of the
housing, a non-return valve and a decantation chamber are used. The one-way valve
is of metal sheet design; the decantation chamber is provided with a drainage bore. If
they fail oil can get into the pipe supplying air to the engine.
AHEAD - go to 4
4 - Remove the switch and install the special tool with the relevant gasket.
Specific tooling
Excessive oil vapours may result in a blockage in the ducts of the throttle body.
In order to signal low oil pressure in the circuit, a pressure switch is used, located
immediately after the oil filter outlet.
The lubrication circuit does not include the countershaft; its lubrication comes from
the oil transported by the gearing or by the centrifugal effect of the crankshaft.
The same applies to the piston or the pin, but in this case the cooling nozzle is
particularly important.
020193Y
Oil pressure gauge
020434Y
Oil pressure control fitting
- Remove the bar with the oil filler plug and insert a cap with the temperature probe
supplied with the special tool.
Insert the probe to feel contact with the case bottom and pull back a few millimetres.
Specific tooling
020331Y
Digital multimeter
AHEAD - go to 5
5 - Measure pressure with cold and
idling engine.
72
10/07
11 - Check and restore the electrical system.
STANDARD VALUES
Specification
Desc./Quantity
20°C Temperature
approx. 4.5 bar
12 - If pressure lower than 4 bar is measured.
AHEAD - go to 9
1400 rpm
13 - Remove the flywheel cover and check the by-pass and the cover sealing gasket
efficiency towards the case internal side, as described in the "Flywheel cover"
chapter.
N.B.
RPM CAN BE MEASURED BOTH BY THE EXHAUST GAS ANALYSER AND BY THE
DIAGNOSTIC TESTER
YES - go to 14 NO - go to 15
14 - Check whether there is an irregular clearance on the crankshaft:
- axial clearance (see the "Crankcase and crankshaft" chapter)
Specific tooling
- radial clearance, especially in the direction of the cylinder axis
020460Y
Scooter diagnosis and tester
- clearance according to the direction of rotation with the connecting rod in
quadrature
YES - go to 6 NO - go to 12
YES - go to 16 NO - go to 17
6 - Let the engine warm up and repeat the check with hot engine.
15 - Replace the faulty components ("Flywheel cover" chapter).
16 - Overhaul the engine ("Crankcase and crankshaft" chapter).
STANDARD VALUES
Specification
Desc./Quantity
80°C Temperature
approx. 1.5 bar
17 - Open the engine crankcase and remove the oil pump, as described in the
"Crankcase and crankshaft" chapter.
- Check the oil pump as described in the following pages.
1400 rpm
- Check that the cooling nozzle and the timing feeding jet are properly installed.
- Visually inspect the crankshaft couplings and their size ("Crankcase and
crankshaft" chapter).
YES - go to 7 NO - go to 8
N.B.
ANY FAILURES OF THE COUPLINGS AND OF THE TIMING COMPONENTS CANNOT BE
DETECTED BY THE INSPECTION OF THE LUBRICATION PRESSURE. THE FAILURES MAY
BECOME EVIDENT BY AN INCREASE OF NOISE.
7 - Replace the oil minimum pressure switch.
8 - If pressure lower than 1.3 - 1.5 bar is measured.
AHEAD - go to 9
N.B.
IN CASE OF IRREGULAR PRESSURE ON THE BASE, CARRY OUT A VISUAL AND
DIMENSIONAL INSPECTION OF THE TIMING COMPONENTS (SEE THERMAL UNIT AND
TIMING SYSTEM CHAPTER).
9 - Replace the oil filter and repeat the pressure check with oil at 80°C.
YES go to 10 NO - go to 13
10 - The failure was fixed.
It is recommended to respect the suggested number of kilometres covered.
73
10/07
Oil pressure check
Oil pump
1 - In case of oil leaks from the oil filter or from the flywheel cover coupling gasket,
check the lubrication pressure.
Removal
- Remove the closing plate of the oil
pump housing by loosening the 2
retaining screws with their washers.
AHEAD - go to 2
2 - Install the special tool.
Specific tooling
020193Y
Oil pressure gauge
020434Y
Oil pressure control fitting
AHEAD - go to 3
- Remove the oil pump complete with
the gearing by loosening the 2 retaining
screws through the eyes machined in
the gearing proper.
3 - Check the system pressure with cold engine and medium - high speed.
Standard pressure < 6 bar
YES - go to 4 NO - go to 5
4 - Replace the damaged components.
5 - Check the adjustment by-pass efficiency (see "Flywheel cover" chapter) and
restore the proper sliding.
N.B.
STANDARD PRESSURES ARE OBTAINED USING OIL WITH THE PRESCRIBED VISCOSITY.
A HIGHER VISCOSITY CAUSES AN INCREASE OF THE SYSTEM PRESSURE.
1 - If oil consumption is higher than 250 g/1000 km on run-in engine, proceed as
follows.
AHEAD - go to 2
- Remove the gasket.
2 - Check the presence of oil at the recovery duct on the filter box.
YES - go to 3 NO - go to 4
3 - Check the unidirectional reed valve and the decantation chamber drainage hole.
YES - go to 5 NO - go to 4
4 - Check the thermal unit seals (piston rings, valve guides and oil guards), see
"Thermal unit and timing system" chapter.
5 - Restore the valve or the drainage hole efficiency.
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- Remove the two screws and the oil
pump cover.
- Reassemble the rotors in the pump
body, keeping the two reference marks
visible
- Insert the shaft with the gear and
install the lock ring; then, turn it with
the opening opposed to the shaft face.
- Check any irregular clearance
between shaft and pump body.
- Using a thickness gauge, check the
distance between the rotors in the
position shown in the figure.
- Remove the inside rotor retaining snap
ring turning it to move the opening at
the shaft face.
Characteristic
Admissible limit clearance:
0.012 mm
- Check the distance between outside
rotor and pump body; see figure.
- Remove and wash the rotors
thoroughly with petrol and compressed
air.
Characteristic
- Extract the shaft with its gear and
check that it is in good working order
and free from wear.
Admissible limit clearance:
0.25 mm
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- Check the rotor axial clearance using
a rectified bar as reference plane, as
shown in the figure.
- Lubricate the internal rotors.
Characteristic
- If non-conforming values or signs of
wear are found, replace the pump.
- Check there are no signs of scoring or
wear on the oil pump cover.
Limit values admitted:
0.1 mm
- Fit the pump cover in the position that
permits the crankcase fixing screws to
be aligned.
- Tighten the two fastening screws to
the prescribed torque.
Locking torques (N*m)
Oil pump cover screws
0.7 ÷ 0.9
Refitting
- Insert the oil pump with gear
- Make sure the gasket is in the correct
position.
- Insert the 2 retaining screws through the slots on the gear and tighten to the
prescribed torque.
N.B.
THE TOOTH OF THE GASKET MUST BE IN
ITS SEAT.
N.B.
THE ASSEMBLY POSITION OF THE PUMP IS FIXED BY INSTALLATION OF THE SCREWS.
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Failure to observe the tightening torque
may alter the coupling clearance of the
rotors with the pump body.
- Keep the countershaft in position and
insert the washer with the nut.
- Tighten the nut to the prescribed
torque, using the recommended
product.
Locking torques (N*m)
Screws fixing oil pump to the
crankcase
5-6
- Remove the special tool.
Recommended products
Loctite 243
Medium strength threadlock
Medium Loctite 243 threadlock
Locking torques (N*m)
Countershaft fixing nut
25 - 29
- Insert the countershaft with gearing
into the flywheel-side half-crankcase.
- Install the special tool in the position
shown in the figure.
Specific tooling
020479Y
Countershaft lock wrench
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