Beta RR 350, RR 390, RR 430, RR 480 Engine Workshop manual
Below you will find brief information for Engine RR 350, Engine RR 390, Engine RR 430, Engine RR 480. The RR 350, RR 390, RR 430, RR 480 engines are designed for performance and reliability. They are equipped with a single cylinder, 4-stroke, liquid-cooled engine with a countershaft and electric starting. This manual provides detailed instructions on how to disassemble, inspect, maintain, and reassemble the engine. The manual includes detailed illustrations and step-by-step instructions for each procedure.
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INDEX
PREAMBLE 2
INfoRMAtIvE NotE
SAfEtY
2
2
1 REMovING tHE ENGINE fRoM tHE vEHICLE 6
2
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
ENGINE DISASSEMBLY tHERMAL UNIt 16
CYLINDER HEAD: DISASSEMBLING MECHANICAL
TENSIONER 18
CYLINDER HEAD: DISASSEMBLING CAMSHAFT
SUPPORT, CHAIN GUIDE AND SPARK PLUG SEAT
O-RING
CYLINDER HEAD: REMOVING CAMSHAFTS
CYLINDER HEAD: UNCOUPLING FROM CYLINDER 21
DISASSEMBLING CYLINDER AND PISTON
2.2
2.2.1
DISASSEMBLY of IGNItIoN UNIt, tIMING
CHAIN AND GUIDES
STATOR AND FLYWHEEL
2.2.2 TIMING CHAIN AND GUIDES
2.2.3 PICK-UP
16
19
20
23
24
24
27
29
2.3
2.4
PINIoN AND SPACER
CLUtCH UNIt AND CooLANt PUMP CovER
29
30
2.5
2.5.1
2.5.2
2.5.3
2.5.4
2.5.5
ENGINE LUBRICAtIoN CIRCUIt
OIL PUMPS CONTROL GEARS
2.6 CoUNtERSHAft
34
35
HIGH-PRESSURE OIL PUMP 35
LOW-PRESSURE OIL PUMP AND BY-PASS VALVE 36
OIL PRESSURE CONTROL VALVE 37
PAPER OIL FILTER 37
38
2.7
2.8
PRIMARY GEAR
ELECtRIC IGNItIoN
39
40
2.8.1
2.9
ELECTRIC KICK-START UNIT 41
KICKStARtER 42
2.10 EXtERNAL GEARSHIft UNIt 44
2.11 CRANKSHAft, GEARBoX UNIt AND INtERNAL
GEARSHIft 45
2.11.1 NUT ON LEFT SIDE OF CRANKSHAFT
2.11.2 OPENING CRANKCASE
45
46
2.11.3 CRANKSHAFT 48
2.11.4 INTERNAL GEARSHIFT UNIT AND COMPLETE
GEARBOX 48
2.12 DISASSEMBLY of PARtS fRoM
CRANKCASES 50
2.12.1 RIGHT CRANKCASE HALF 50
2.12.1.1 PISTON OIL JETS 50
2.12.1.2 EXTRACTION OF COUNTERSHAFT SUPPORT
BEARING 51
2.12.2 LEFT CRANKCASE HALF
2.12.2.1 INNER OIL FILTER
51
52
2.12.2.2 EXTRACTION OF DESMODROMIC DEVICE
BEARING 52
3.8
3.8.1
3.8.2
3.9
3.9.1
3 ENGINE ASSEMBLY AND CoNtRoLS
3.1
3.1.1
CRANKCASE HALvES
EXTERNAL RIGHT SIDE
3.1.1.1 INSERTION OF OIL SEAL AND COUNTERSHAFT
3.1.2
3.1.3
3.1.4
SUPPORT BEARING
INTERNAL RIGHT SIDE
EXTERNAL LEFT SIDE
SINISTRO LATO INTERNO
3.2
3.3
3.4
CHECKING CRANKSHAft AND CoNNECtING
RoD 61
ASSEMBLING CoMPLEtE CRANKSHAft 63
57
58
59
60
53
54
55
3.4.1
3.4.2
3.4.3
3.4.4
GEARBoX UNIt: CoNtRoLS AND
REASSEMBLY 64
CHECKING GEARBOX UNIT
PRIMARY UNIT ASSEMBLY
64
65
SECONDARY UNIT ASSEMBLY
CHECKING THE FORKS, FORK PINS AND
DESMODROMIC DEVICE
66
67
3.5
3.6
3.7
ASSEMBLY of INtERNAL GEARBoX AND
GEARSHIft 69
CLoSING ENGINE BLoCK 72
BLoCKING tHE CRANKSHAft At tHE toP DEAD
CENtRE AND tIGHtENING tHE NUt oN tHE
LEft SIDE of tHE CRANKSHAft 73
EXtERNAL GEARSHIft
CHECKING THE COMPLETE DRIVE SHAFT
ASSEMBLY OF EXTERNAL GEARSHIFT
KICK StARtER 76
CHECKING KICKSTARTER SHAFT UNIT AND
ASSEMBLY 76
74
74
76
INDEX
3.9.2 ASSEMBLY OF KICKSTART DEVICE 78
3.10 ELECTRICAL STARTER UNIT AND MAIN GEAR 79
3.10.1 CHECKING ELECTRICAL STARTER DEVICE
ELEMENTS 79
3.10.2 COUPLING IGNITION AND PRIMARY GEARS TO THE
MOTOR 80
3.11 OIL PUMPS: CONTROL AND REASSEMBLY 82
3.11.1 ASSEMBLY OF LOW PRESSURE PUMP 84
3.11.2 ASSEMBLY OF HIGH-PRESSURE PUMP AND
CONTROL GEAR
3.11.3 CHECKING AND ASSEMBLY OF PRESSURE
CONTROL VALVE
85
86
3.11.4 CHECKING AND ASSEMBLY OF OIL PUMPS
CONTROL GEARS 87
3.11.5 PAPER OIL FILTER INSERTION 88
3.11.6 CHECKING AND COUPLING COUNTERSHAFT 89
3.12 CLUTCH UNIT
3.12.1 CHECKING CLUTCH BASKET, ROLLER BEARING
AND INTERNAL CENTRE BEARING
3.12.2 CHECKING CLUTCH DISCS
91
91
92
3.12.3 CHECKING SPRINGS
3.12.4 CHECKING INNER HUB
3.12.5 CHECKING THRUST BEARING DEVICE
3.12.6 ASSEMBLY OF CLUTCH UNIT
93
93
94
94
3.13 COOLANT PUMP
3.13.1 CHECKING PUMP UNIT AND DISASSEMBLY
3.13.2 ASSEMBLY OF PUMP UNIT
97
97
98
3.14
3.15
ASSEMBLY OF COMPLETE CLUTCH COVER 99
CHECKING AND COUPLING OF TIMING
CHAIN, FIXED AND MOBILE GUIDES 101
3.16 IGNITION SYSTEM
3.16.1 CHECKING IGNITION SYSTEM
101
102
3.16.2 COUPLING IGNITION SYSTEM TO CRANKCASE 102
3.17 THERMAL UNIT 105
3.17.1 CHECKING PISTON, PIN BOLT, AND PISTON
RINGS 105
3.17.2 CHECKING THE CYLINDER
3.17.2.1 ASSEMBLY CLEARANCE
107
107
3.17.3 CYLINDER HEAD: DISASSEMBLY AND CHECKING
AUXILIARY DEVICES 108
3.17.3.1 LUBRICATION JETS AND CENTRING PINS 108
3.17.3.2 FINGER FOLLOWER/SHAFTS UNIT 109
3.17.3.3 SHIMS (CALIBRATED DISCS) FOR VALVE PLAY
ADJUSTMENT 110
3.17.4 CYLINDER HEAD: DISASSEMBLING AND
CHECKING VALVE UNITS 111
3.17.4.1 SPRINGS 112
3.17.4.2 VALVE GUIDES, VALVES AND SEATS
3.17.4.3 VALVE STEM SEAL AND LOWER STOP WASHER
112
114
3.17.5 CYLINDER HEAD: CHECKING CYLINDER HEAD
BODY 114
3.17.6 CHECKING CAMSHAFTS
3.17.7 CHECKING CAMSHAFTS SUPPORT
3.17.8 CYLINDER HEAD: INSERTION OF INNER CUP
AND VALVE STEM SEAL
115
116
117
3.17.9 CYLINDER HEAD: ASSEMBLY OF VALVE UNIT 118
3.17.10 CYLINDER HEAD: REPOSITIONING CALIBRATED
DISCS, ASSEMBLY OF FINGER FOLLOWER SHAFTS
AND FINGER FOLLOWERS AND COUPLING THE
SPARK PLUG 119
3.17.11 CYLINDER HEAD: INSERTION OF OIL JETS,
CENTRING PINS AND SPARK PLUG O-RING 120
3.17.12 PISTON: APPLICATION OF PISTON RINGS AND
OIL-SCRAPER RINGS 121
3.17.13 APPLICATION OF PISTON TO CYLINDER 122
3.17.14 APPLICATION OF PISTON-CYLINDER COUPLING
TO CRANKCASE 124
3.17.15 COUPLING HEAD TO CYLINDER
3.17.16 COUPLING CAMSHAFTS TO CYLINDER HEAD
AND PHASING
3.17.17 VALVE PLAY
126
127
130
3.17.18 CHECKING AND COUPLING OF MECHANICAL
TENSIONER TO ENGINE
3.17.19 COUPLING CYLINDER HEAD COVER GASKETS
AND CYLINDER HEAD COVER
132
134
3.18
3.19
3.20
3.21
PINION COUPLING
RELEASING CRANKSHAFT
COUPLING OIL CAPS
COUPLING GEARSHIFT LEVER 137
135
135
136
4 REASSEMBLY OF ENGINE IN THE VEHICLE
ENGINE/FRAME TABLE OF TIGHTENING TORQUES
RECOMMENDED ENGINE MAINTENANCE
RECOMMENDED LUBRICANTS AND LIQUIDS
138
152
153
154
2
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PREAMBLE
This publication has been written in order to make operations for inspection, maintenance and repairs of the motorcycle engine known and understandable to the user of the motorcycle and to the technical assistance operator.
Read this entire manual with care before operating the engine. Sufficient knowledge of the components that make up the engine and of all the procedures to be followed for inspection and maintenance contribute to lengthen the life of the engine.
The paragraphs have been enhanced with schematic illustrations highlighting each subject in order to make reading immediately understandable.
Informative note
Betamotor S.p.A. is engaged in a policy of ongoing improvement of its products. This is why it could be possible to note slight differences between the contents of this document and the vehicle upon which you are carrying out repairs and/ or maintenance.
Betamotor S.p.A. models are exported to numerous countries in which there are different standards concerning Highways Codes and procedures for approval of the vehicle. Relying on your understanding, Betamotor S.p.A. therefore deems it necessary to reserve the right to modify its products and technical documentation at any time without prior warning.
We respect and defend the environment
All that we do has an impact on the whole Planet and its resources. Betamotor S.p.A., wishing to safeguard the interests of the entire Community, would like to make customers and technical operators aware of ways of using the vehicle and of disposal of its parts in total compliance with standards in force in terms of environmental pollution, waste disposal and recycling.
SAfEtY
Carbon monoxide
•
Exhaust gasses contain carbon which is poisonous. Carbon monoxide can cause loss of conscience and lead to death. When starting the engine, make sure the place you are is wellventilated. Never start the engine in a closed place.
•
Starting the engine closed places can be done only if provided with relevant gas discharge evacuation devices.
Petrol
•
Petrol is extremely flammable and can be explosive in some conditions.
•
Keep heat sources, sparks and flames away from the work area.
•
Always work in a well-ventilated area.
•
Never use petrol as a solvent for cleaning. Do not handle it unless absolutely necessary.
•
Never use petrol to clean components by means of compressed air.
•
Keep out of the reach of children.
Motor oil
•
Motor oil can cause skin illnesses if carried often and for prolonged periods in contact with skin.
•
If you touch motor oil, clean parts with soap and water as soon as possible.
•
In case of contact with the eyes, rinse them abundantly with water and seek medical advice.
•
If swallowed, do not induce vomiting in order to avoid breathing the product into the lungs; seek immediate medical advice. If you believe the product has been breathed into the lungs, bring the concerned person urgently to the hospital.
•
Used oil contains dangerous substances which are harmful for the environment. When changing it, you must be equipped to dispose of it in compliance with existing law.
•
Avoid releasing used oils to the environment.
•
Keep out of the reach of children.
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Coolant
•
In some situations, the ethylene glycol contained in the coolant is flammable and its flame is invisible. Should ethylene glycol catch fire, though its flame is invisible, it can cause burns.
•
Do not bring the coolant in contact with hot parts. These parts could be hot enough to cause the liquid to ignite.
•
The coolant (ethylene glycol) can irritate skin and is poisonous if swallowed.
•
Should the coolant come into contact with the skin, immediately remove contaminated clothing or footwear and wash with soap and water. In case of contact with the eyes, rinse them abundantly with clean water and seek medical advice immediately. Should it be swallowed, do not induce vomiting in order to avoid breathing the product into the lungs. Administer clean water and bring the concerned person immediately to the hospital, showing this product to the hospital staff.
•
In the event of exposure to a high concentration of vapours, bring the concerned person to an uncontaminated atmosphere and seek medical advice if necessary.
•
Do not remove the radiator cap when the en-
•
• gine is still hot. When coolant is pressurised, it can spurt out violently and cause burns.
•
Coolant contains dangerous substances which are harmful for the environment. When changing it, you must be equipped to dispose of it in compliance with existing law.
Do not release coolant to the environment.
Keep out of the reach of children.
Hot parts
•
The engine and the exhaust system get very hot and stay at that temperature for a long time, even after the engine has been turned off. Wait for them to cool off before handling these parts or intervening on areas around them. Use insulated gloves.
WARNINGS
The information contained in this paragraph is important so that the operations out on the engine can be performed without causing damage.
•
Before disassembling, clean the motorcycle thoroughly.
•
While you are disassembling it, clean all the parts and place them in containers respecting the order of disassembly exactly.
•
Always use special tools wherever necessary and when thus prescribed.
•
Always use glues, sealing and lubricants wherever prescribed. Respect the indications concerning their technical features.
•
Always replace parts such as gaskets, O-rings and safety washers with newly supplied parts.
•
When loosening or tightening nuts or screws, always start with the larger ones or from the centre. Always respect the indicated tightening torques.
•
Use only Betamotor original spare parts.
3
4
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tECHNICAL fEAtURES of ENGINE
Bore x stroke RR 350
Bore x stroke RR 400
Bore x stroke RR 450
Bore x stroke RR 498
Displacement [cm³] RR 350
Displacement [cm³] RR 400
Displacement [cm³] RR 450
Displacement [cm³] RR 498
Compression ratio RR 400-450-498
Valve gear
Primary transmission
1st gear ratio
2nd gear ratio
3rd gear ratio
4th gear ratio
5th gear ratio
6th gear ratio
type
RR 350
28/76
12/31
15/28
19/28
20/24
27/27
28/24
SECoNDARY tRANSMISSIoN
Carburettor type
Main jet
Jet needle
Main air jet
Jet needle
Needle position from top
Air mixture screw position (from all closed)
Intake jet
Single cylinder, 4-stroke, liquid-cooled with countershaft and electric starting
88x57,4
88x63,4
95x60,8
100x60,8
349,1
386
431
13,19:1
478
12,5:1
4 valves
tRANSMISSIoN
RR390
28/76
12/31
15/28
19/28
20/24
27/27
28/24
RR430
31/73
12/31
15/28
19/28
20/24
27/27
28/24
CHAIN
CARBUREttoR
RR390 RR430
Keihin FCR-MX 39 Keihin FCR-MX 39
170
40
175
45
100
NCVS
4°
100
NCVS
3°
1+1/2
40
1+1/2
40
11,9:1
RR480
31/73
12/31
15/28
19/28
20/24
27/27
28/24
RR480
Keihin FCR-MX 39
180
45
100
OBDVS
3°
1+1/2
40
11,9:1
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SPECIAL EQUIPMENt
1. Engine support code 3625132 000;
2. Two-leg extractor code 3625081 000;
3. Internal bearing puller code 006140160 000;
4. Extractor for timing gear code 006140150 000;
5. Flywheel Extractor code 3625173 000;
6. Piston ring compression band code 006140170 000;
7. Chain-tensioner release tool code 006140050 000;
8. Valves assembly-disassembly jaw code 0100043 000;
9. Tool for valves assembly-disassembly code 006140030 000;
10. Special ring pliers code 3625097 000;
11. Crankshaft blocking device code 006140110 000;
12. Loctite 243 code 3625001 000;
14. Silicone paste for gaskets code 3625000 000;
15. 36mm socket wrench code 3625000 000;
16. Spark plug wrench code 020440100 000;
17. Connecting rod disassembly tool code 006140070 000;
18. Thickness gauge code 006140210 000;
19. Valve guide gauge code 006140180 000;
20. Clutch cap tool code 006140040 000;
21. Carburettor adjustment spanner code 006140200 000;
22. Engine fixing code 006140140 000.
23. Pin retaining elastic ring tool code 022140200 000 (350cc); cod. 029140300 000 (430cc, 498cc)
Symbology
6Nm
Value
Tightening Torque
Loctite 243/
Sichel 100M
Silicone paste
5
1
1 REMovING tHE ENGINE fRoM tHE vEHICLE
Carefully wash the vehicle
1
Before removing the engine from the vehicle, empty the following liquids:
•
Motor oil;
•
Gear/clutch unit oil;
•
Coolant.
In order to access the oil drain plug, remove the engine guard connected to the frame by means of the three screws 1.
Front engine guard fixing screw.
6
1
Back engine guard fixing screws.
3
2
Remove the screw 2 to empty the motor oil. Remove the screw 3 to empty the gear oil.
ATTENTION: Used oil contains dangerous substances which are harmful for the environment. When changing it, you must be equipped to dispose of it in compliance with existing law.
Avoid releasing used oils to the environment.
Screw 2 for draining motor oil and 3 for draining gear oil.
Remove the exhaust pipe and the silencer.
Drain the cooling system through screw 4 and let the liquid outflow into a container (the cooling circuit contains 1.3l of liquid).
Remove the radiator cap.
4
Place the vehicle onto an adequate stand.
1
5
5
6
5
To dismount the tank, remove the seat, completely loosen the two screws 5 fixing the tank to the frame and screw 6 (one per side) which fixes the side to the radiator.
In the carburettor versions, disconnect petrol tube
7 from the cock, which must be set to OFF.
7
5
In the injection versions, disconnect the petrol tube by pressing the special button of quick coupling 8.
Lift the tank.
6
8
7
8
1
9
10
Disconnect electric connectors 9 and 10.
Remove the tank along with the sides.
Disconnect the water hoses from the engine and from the right radiator.
Remove the left radiator with pipes.
Disconnect the spark plug cap.
Cut all straps binding the engine’s electric system to the clutch pipe and to the frame.
Disconnect the engine ventilation pipes.
1
Disconnect the connectors indicated in the figure.
Electric connectors to disconnect in the carburettor versions.
Electric connectors to disconnect in the injection versions.
Remove the start motor cable fixing nut.
9
1
Loosen the carburettor/throttle body straps from the air filter sleeve and from the manifold.
10
13
12
12
Remove the screw of the carburettor/throttle body
12 cover and the cover itself.
Disconnect rear stop connector 13.
Loosen the adjustment nuts and release the gas cables.
1
Carburettor version gas cables.
Injection versions gas cables.
Disconnect the electric connectors indicated in the figure, relative to the carburettor/throttle body.
11
1
15
Remove the frame guards 14 (one each side) and the pinion guard 15.
14
17
16
Remove the rear wheel nut.
Extract the pin enough to allow the wheel to advance towards the front of the vehicle.
Rotate the rear wheel lifting the chain in the pinion zone, so that the chain of the pinion itself is released.
Rest the chain against the upper wedge 16.
Remove the screws 6 fixing the clutch actuator to the crankcase half.
ATTENTION! Do not activate the clutch lever with actuator decoupled from engine.
Remove the head connections.
12
19
Release and remove the brake pedal return spring
18.
Remove the kickstarter lever..
1
18
20
Remove the seat rail lower fixing screws 19 (one each side) and loosen the upper screws 20 (one each side).
13
1
Remove the carburetor to the gas cable.
Remove the carburettor or throttle body, based on the specific version.
21
Remove upper shock-absorber pin 21.
14
22
Remove the swingarm pin 22.
Move the complete swing-arm unit towards the rear.
1
23
23
Remove the engine pins 23.
Extract the engine from the frame and apply it to the specific stand code 3625132 000 using specific front fixing bracket code 006140140 000.
15
2
2 ENGINE DISASSEMBLY
2.1 tHERMAL UNIt
2
The thermal unit is made up of the head, cylinder and piston.
Before removing the cylinder head, bring the piston to the TDC and block the crankshaft: Proceed as shown hereafter.
1
The four screws 1 of the cylinder head cover 2.
2
3
Remove the 4 screws 1, the cylinder head cover 2 as well as the 4 screw gaskets 3.
The cylinder head cover 2 and the four gaskets 3.
Remove the spark plug gasket 4 and the cover gasket 5.
16
4
5
Spark plug gasket 4 and cylinder head cover gasket 5.
8
7
6
Remove the crankshaft blocking screw 6, remove the copper washer 7 and put the screw (or tool 006140110 000) back into its seat without tightening it all the way.
2
After having engaged the 6th gear, turn the transmission shaft 8 anti-clockwise - using an open-end spanner or the likes, - until the lines 9 on the toothed profiles of the camshafts are aligned.
6
9
Rotate the transmission shaft in that position and, at the same time, turn the shaft blocking screw 6 by hand until it engages in the seat present on the crankshaft, preventing the crankshaft from turning.
In this way the crankshaft is blocked, by means of the screw 6, at the Top Dead Centre
(TDC) and now all the organs can be disassembled.
17
18
2
2
Cap and spring removal.
1
2.1.1 CYLINDER HEAD: DISASSEM-
BLING MECHANICAL TEN-
SIONER
A chain which is not well-tensioned can cause:
• excessive vibrations for the chain which could make it jump teeth on the camshafts thus damaging the engine;
• incorrect and premature wear of the support bearings of the camshafts.
The engine is equipped with a hydraulic tensioner in order to provide the chain with proper tensioning.
4
3
To remove it, proceed as follows: remove the cap 1 and the spring 2.
Fully unscrew the tensioner support 3 from the cylinder.
To slip the piston 4 out, just push it out from the tensioner support 3.
Tensioner support complete with piston.
1
2
3
Fixing screws 1 camshaft support 2 and chain guide 3
The four outer screws circled blue must be taken offfirst.
2.1.2 CYLINDER HEAD: DISAS-
SEMBLING CAMSHAFT
SUPPORT, CHAIN GUIDE
AND SPARK PLUG SEAT
O-RING
2
To remove the camshafts, disassemble the camshaft support 2 and the chain guide
3. Then loosen the seven screws 1 of the camshaft support, starting with the outer ones
(indicated in blue in the figure) and then the inner ones. Remove the chain guide
3.
Attention: disassemble the camshafts only after having disassembled the hydraulic tensioner
Using a plastic rod A or something similar, lever the head surface and the camshaft support
2 in order to lift it and remove it.
2
A
Uncoupling camshaft support 4 from cylinder head.
4
5
Two centring pins 4 and spark plug housing O-ring 5.
When uncoupling, be careful of the two centring pins 4 the camshaft support Checking camshafts support.
Remove the spark plug housing sealing O-ring
5 between the cylinder head and the camshaft support.
19
20
2
1
3
Removal of intake camshaft 1, bearing 2.
3
2
2.1.3 CYLINDER HEAD: REMOVING
CAMSHAFTS
Lift the intake camshaft 1, pull out the bearing 2 and remove the chain 3 from the gear on the shaft.
Attention: the hydraulic tensioner must already have been removed in order to remove the camshafts.
In order to remove the exhaust camshaft 4, repeat the operations described for removal of the intake camshaft.
4
Camshafts (G intake, H exhaust) with bearings.
A
ATTENTION: make sure the chain does not fall inside the compartment dedicated to it. For this purpose, it is recommended to interpose a plastic rod (or the likes) A between the chain and the head.
Plastic rod to support chain.
Chain-side head fixing screw.
2
Head fixing screws 2.
1
2.1.4 CYLINDER HEAD: UN-
COUPLING FROM CYLIN-
DER
Five screws fasten the head to the cylinder.
Remove the cylinder head screw 1 on the outside of the chain-side cylinder head.
2
Remove the four cylinder head fixing screws 2, in a criss-cross pattern. Start with one of the two screws outside the cylinder head compartment.
Then remove the respective washers.
3
Lift the cylinder head 3 with one hand and at the same time with the other hold the chain in tension thus preventing jams during disassembly.
With the cylinder head lifted a few centimetres, drop the chain inside the compartment and pull out the head.
ATTENTION: should the chain fall inside, place it in tension before lifting the head.
ATTENTION: during lifting of the head, pay attention to the centring bushes
Head removal 3.
21
22
2
3
2
1
4
Remove the head gasket 4 and the two centring bushes 5.
Cylinder head elements:
1) M6x80 screw;
2) M10x1.25 cylinder head screws;
3) Complete cylinder head;
4) Cylinder-head gasket;
5) Centring bushes.
5
1
3
2.1.5 DISASSEMBLING CYLIN-
DER AND PISTON
Lift up the cylinder 1 a few centimetres, remove the two centring bushes 2 (both located on the chain side) to prevent them from falling inside the crankcases and continue on removing the cylinder. Remove the cylinder gasket
3.
2
2
Cylinder removal.
A
Place a clean cloth between the piston and the crankcase to keep foreign objects or simple residue from falling inside the base. Using a suitable tool to insert the specific seat A, remove the elastic ring 4 on the right hand side* of the piston 5.
ATTENTION: be careful not to drop the elastic ring inside the engine.
5
4
Removal of elastic ring 4 from right hand side of piston.
B
From the left hand side of the piston, push the pin bolt with an aluminium cylinder B (or the likes), until the pin bolt is freed from the foot of the connecting rod.
Remove the piston.
ATTENTION: Try pulling out the pin bolt by hand first of all. If it is too tight, hit the pin lightly with a rubber hammer, at the same time holding the piston with your hand in order not to stress the connecting rod.
Pin bolt removal.
23
2
4
In figure you can see the piston 5 (bottom view), the circlip 4 and the pin bolt 6.
6
5
Bottom view of piston 5, elastic ring 4 and pin bolt 6.
2
2.2 DISASSEMBLY of IGNItIoN
UNIt, tIMING CHAIN AND
GUIDES
The ignition unit is made up of the flywheel (or rotor), the pick-up and the stator which is one with the flywheel cover.
2.2.1 STATOR AND FLYWHEEL
Remove the screw 1 which connects the gear lever
1 to the drive shaft.
Removal of gear lever.
1
3
Remove the nine screws 3 which fasten the flywheel cover 4 to the left crankcase half. Remove the flywheel cover and the gasket placed between the casing and the cover.
24
4
Fixing screws C of ignition cover D.
Be careful of the two centring pins 5 on the crankcase half.
2
5
Two centring pins 5 dedicated to the flywheel cover
(carburettor version).
5
Two centring pins 5 dedicated to the flywheel cover
(injection version).
7
6
Remove the tightening nut 6 which fastens the flywheel 7 to the crankshaft.
Once the nut has been unscrewed, pay attention to the special elastic washer ( 8 shown in the following images) placed between the nut and the flywheel.
Nut 6 which fastens flywheel 7 to the crankshaft (carburettor version).
7
6
Nut 6 which fastens flywheel 7 to the crankshaft
(injection version).
25
2
A
To remove the flywheel, screw the relevant extractor A (code 3625173) onto the threaded segment on the flywheel and, using a box spanner, tighten the screw on the extractor.
Starter flywheel removal (carburettor version) with special gear puller A.
A
Starter flywheel removal (injection version) with special gear puller A.
6
7B
8
7A
In the image at the side, the flywheel 7 (rear view), the special elastic washer 8 and the tightening nut
6.
26
Flywheel 7a (carburettor version), 7b (injection version), nut 6 and special washer 8.
3
2
2.2.2 TIMING CHAIN AND GUI-
DES
Remove the fixing screws
1 of the mobile 2 and fixed pad 3.
Extract pad 2, then pad 3, by pulling them upwards.
2
1
Fixing screws 1 of mobile 2 and fixed pad 3.
Extract the two pads, pulling them towards the top part of the engine.
Extraction of chain guides.
27
2
5
7
6
Chain guard and oil jet.
4
8
Remove the screw 4 and extract the oil jet 5.
Remove the two screws 6 and then the chain guard
7.
Pay close attention to the respective bushes while extracting the mobile and fixed pads and the timing chain.
Pay close attention to the respective bushes while extracting the mobile and fixed guides and the timing chain.
Removal of timing chain.
2
8
6
4
28
5
3
7
1
Two pad fixings screws 1; mobile pad 2; fixed pad 3; oil jet fixing screw 4; oil jet 5; chain guard fixings screws 6; chain guard 7; timing chain 8.
2
1
2.2.3 PICK-UP
Once the timing chain guard has been removed, the pick-up 1 can be disassembled, by removing the two fixing screws
2.
2
Two screws 2 for fixing pick-up 1.
3
2.3 PINIoN AND SPACER
In order to remove the pinion
1, loosen the screw completely 2 and take off the washer 3.
1
Pinion 1, screw 2 and washer 3.
2
4
After removing the pinion, pull off the spacer 4.
Pinion spacer 3.
29
2
2
1
Outer clutch cover 1 and respective screws 2.
2.4 CLUtCH UNIt AND Coo-
LANt PUMP CovER
In order to access the clutch unit, the outer clutch cover 1 must be removed by loosening the six screws 2.
4
3
On the other hand, when doing a complete overhaul of the clutch unit, of the other elements housed in the outer right side of the crankcase half or of the engine, the inner clutch cover
3 must be removed by loosening the nine screws 4 and the water pump cover 5 loosening the four screws 6.
Inner clutch cover 3 and respective screws 4.
6
30
5
Pump cover 5 and respective screws 6.
Pay attention to the two reference pins
A placed between the right crankcase half and the inner clutch cover while disassembling.
2
A
Two centring pins A for cover coupling Inner clutch.
8
Remove the complete hydraulic actuator 7 -if the tube was disconnect from the actuator- outer left side crankcase half by loosening the three screws 8 which fasten it to the crankcase half. Remove the gasket in between the actuator and the crankcase half.
7
Hydraulic actuator 7 and three screws 8 coupling it to crankcase half.
9
Extract the clutch control rod 9.
Extraction of clutch rod 9.
31
2
10
11
Remove the 4 screws 10 which fasten the clutch cap
11 to the inner hub.
Remove the clutch cap together with the four washers and relative springs.
Clutch cap 11 and four screws 10.
12
Extract the whole pressure plate unit 12 and the clutch disc pack 13.
13
Pressure plate unit 12 and clutch disc pack 13.
Remove special driven disc and the disc spring assembly.
Removal of disc spring assembly.
15
14
32
Opening safety washer with chisel.
In order to complete the disassembly of the clutch unit, open the safety washer 14 using a chisel or similar tool and remove the nut 15.
A
Removal of inner hub nut with relevant tool G.
18
To unscrew the nut
15, the inner hub must be blocked with a relevant tool A (code
006140040000).
Then remove the nut and relative safety washer.
2
ATTENTION: don’t use pneumatic wrench
Extract the inner hub 16, the washer 17, the basket 18, the roller cage 19 and the centre bearing 20.
17
15
16
14
19
22
21
20
Safety washer 14, nut 15, inner hub 16, washer 17, basket 18, roller cage 19 and bush 20, special fiction disc 21, judder spring 22.
33
2
ENGINE LUBRICATION CIRCUIT:
1) High-pressure pump;
2) Paper oil filter;
3) Crank mechanism;
4) Piston oil jets;
5) Hydraulic tensioner;
6) Cylinder head oil jets;
7) High-pressure valve;
8) Internal filter;
9) Low-pressure pump;
10) By-pass valve;
11) Wire metal filter;
A) Ignition unit compartment;
B) Crank mechanism compartment.
2.5 ENGINE LUBRICAtIoN CIR-
CUIt
The high-pressure pump (or delivery) 1 - with less displacement - sends the oil purified by the paper filter 2, to the crank mechanism 3, to the piston oil jets 4, to the tensioner 5 and to the cylinder head jets and camshafts* 6. The valve 7 controls the pressure.
When oil has lubricated the cylinder head and has seeped through the tensioner, it flows along the timing chain to the ignition unit compartment A.
When oil has lubricated the crank mechanism and the piston-cylinder coupling, it goes to the crank mechanism compartment
B from which it is sucked by a low-pressure pump (or recovery) 9 - with higher displacement -, passing through the oil filter 8 and sent to the ignition unit compartment A. There it is sucked once again by the pump 1 after being filtered through the wire metal filter 11.
The one-way valve 10 controls the pressure between the external casing on the ignition unit side and the crank mechanism compartment.
6
34
5
4
2
1
11
7
A
3
* Part of the lubricant sent to the cylinder head is used for the hydrodynamic support of the camshafts.
B
10
9
8
4
3
1
5
Gear unit for oil pump control.
1) Gear meshing with clutch gear;
2) Idler wheel
3) Oil pumps control gear;
4) Circlip;
5) Thrust washer;
6) Benzing ring
1
2
3
2
Disassembly of high-pressure pump cover.
6
2.5.1 OIL PUMPS CONTROL GE-
ARS
The two oil pumps are controlled by a gear unit driven by the clutch gear.
In detail, gear
1 meshes with the clutch case, and 2 is the oil pump control gear.
To dismount gear 1, remove circlip 3 and thrust washers 4 (one below the gear).
To disassemble gear 2, simply remove the Benzing ring 5.
2.5.2 HIGH-PRESSURE OIL
PUMP
The high-pressure pump, located in the external right-hand side crankcase, is enclosed under the cover 1 which can be disassembled by removing the roller 2 and the three screws 3.
Having removed the cover, extract the internal rotor 4, the external rotor 5 and the roller 6.
2
4
5
High-pressure pump. 4) Internal rotor; 5) External rotor; 6) Roller.
35
2
1
2.5.3 LOW-PRESSURE OIL PUMP
AND BY-PASS VALVE
The low-pressure pump and the one-way valve are located in the left-hand side crankcase (on the outside) inside the ignition unit compartment. They are enclosed under the cover 1, which removed by extracting the three screws 2.
2
Cover and screws of low-pressure pump.
4
5
3
Low-pressure oil pump and by-pass valve.
6
Extract the one-way valve consisting in the spring 3 and the ball 4.
Then extract the external rotor 5 and the internal rotor 6 together with the roller 7 and the drive shaft
8.
36
6
7
Internal rotor 6, roller 7 and drive shaft 8.
8
3
Pressure control valve layout.
4
1
2
2.5.4 OIL PRESSURE CONTROL
VALVE
2
The pressure control valve is located in the bottom of the right-hand side crankcase near the motor oil drain plug.
The valve consists of the ball 1 and the spring
2 kept in place by the screw 3 and washer 4.
To dismount, simply remove the protection rivet with a 6mm drill tip.
ATTENTION: protect the mechanical parts from any shavings.
In order to disassemble the valve, remove the screw, pull out the washer, the spring and the ball.
Rivet on pressure regulator.
Pressure regulator.
1
2
Paper oil filter cap 1 and relative fixing screws 2.
2.5.5 PAPER OIL FILTER
In order to extract the paper oil filter, remove the cover 1 by loosening the two screws 2 completely. Once the cover has been removed, use a pair of opening pliers A to extract the filter.
While extracting the cover, be careful of the specific O-ring applied onto the cover.
Extraction of filter with pliers A.
A
37
38
2
Exploded view of countershaft.
1) Shaft;
2) Counterweight;
7) Elastic washer
8) Nut M12x1
2.6 CoUNtERSHAft
The countershaft has the task of balancing a part of the inertial forces produced by the crank mechanism.
The countershaft is mainly made up of the shaft 1 and counterweight 2. The elastic washer 7 and nut 8 have the task of assuring coupling of the complete shaft to the base.
ATTENTION: don’t use pneumatic wrench.
In order to disassemble the shaft, remove the nut
8 which can be accessed through the ignition unit compartment. Extract the elastic washer 7 and the counterweight.
Pull the countershaft out through the right-hand side crankcase 1.
Extraction of countershaft.
2
Primary gear 1 and relative nut 2.
A
1
2.7 PRIMARY GEAR
The primary gear 1, located in the right crankcase, is fastened to the crankshaft. In order to disassemble it, remove the nut 2 which must first be previously heated using a blow-dryer or similar instrument.
2
ATTENTION!
The nut 1 must be turned clockwise to be unscrewed.
Extract the primary gear using the relevant extractor A (code 006140150000).
Extraction of primary gear with appropriate extractor
A.
1
Notice that the primary gear houses the free wheel device 2 inside of it, which can be removed by taking out the circlip 3.
2
3
Primary gear 1, complete with free wheel 2 and specific circlip 3.
39
40
2
EXPLODED VIEW OF ELECTRICAL STARTER.
1) Start motor;
4) Torque limiter;
7) Idler wheel;
9) Ignition gear;
10) Roller bearing HK2516;
11) Free wheel.
2.8 ELECtRIC IGNItIoN
Electric ignition can be carried out by means of the start motor 1 which meshes on the gearwheel 4 with the function of torque limiter.
The gearwheel 4 (torque limiter) transmits motion to the idler wheel 7, which will then mesh with the starter gear 9.
The roller bearing 10 supports the starter wheel 9, while the free wheel 11 is internally engaged on the starter wheel
9 and externally on the main gear, thus allowing it, depending on rotation direction, to pull the crankshaft.
4
11
7
9
10
1
1
2.8.1 ELECTRIC KICK-START UNIT
Remove the two screws 4 which fasten the start motor to the crankcase and pull out the start motor.
2
Screws 4 fixing start motor to crankcase.
5
To extract kick-start gear 5, disassemble the primary gear (see par. 2.7), the safety stops 6 and key
7
.
The kickstart gear is pulled out by hand.
6
Removal of pin 6.
7
Torque limiter 8, screw 7 and washer 9.
10
11
8
9
6
In order to disassemble the torque limiter 7, completely loosen the screw
8 which fastens the torque limiter to the crankcase. Pull out the washer 9 together with the limiter itself.
In order to remove the idler wheel 10, just remove the circlip 11 and pull the gear off.
12
Idler wheel 10 of electrical ignition device.
41
42
2
3
Kickstarter mechanism.
3
2
4
1
2.9 KICKStARtER
The kickstarter is made up of the pedal which, attached to the kickstarter shaft 1, moves the kickstarter gear 2. This gear moves the idler wheel 3 which then meshes with the clutch gear.
The device moves back thanks to the spring 4.
Remove the external circlip 5 and pull off the external thrust washer 6, the idler gear 3, the internal thrust washer 7 and the second circlip 8. The circlips and thrust washers are interchangeable.
6
5
Removal of circlip 5 of idler gear 3.
5
8
6
7
Two circlips 5 and 8 and thrust washers 6 and 7.
4
Releasing spring from crankcase.
A
Using a pair of pliers, pull the end A of the spring 4 from the hole on the crankcase and bring it to a rest position having it turn anticlockwise.
2
Turn the shaft anti-clockwise and pull it off together with the sleeve 9, the spring 10 and the thrust washer 11.
Extraction of shaft from crankcase.
2
1
9
4
10
Complete manual kickstart shaft.
11
Note: Be careful of the reference pins for centring the inner clutch cover (par. 1.4)
43
2
2
2.10 EXtERNAL GEARSHIft UNIt
The external gearshift is made up of the drive shaft
1 upon which the movable and fixed pawls are applied. The fixed pawl constitutes the drive of the movable pawl which then has the task of engaging the stop cam 2. This in its turn is fastened to the internal gearshift and is kept in the fixed position by the cam stop lever.
In order to disassemble the drive shaft, just keep the movable pawl return spring 3 pressed and extract the shaft together with specific washer 4.
1
Disassembly of drive shaft.
3
1
Gearshift with washer.
2
6
Disassembly of stop cam.
7
9
8
44
Disassembly of cam stop lever.
A
5
4
In order to disassemble the stop cam 2, keep the cam stop lever moved 5, loosen the screw 6 and pull out the stop cam.
In order to disassemble the stop lever, loosen the screw 7 enough to allow the lever to move axially and overcome the cylinder segment A of the desmodromic device. Bring the return spring 8 to the rest position and remove the screw, the washer 9, the spring together with the spacer (not shown in the image) and finally the cam stop lever.
1
Nut B blocking crankshaft.
2
2.11 CRANKSHAft, GEARBoX
UNIt AND INtERNAL GE-
ARSHIft
2
To access the crankshaft, gearbox unit and internal gearshift, the left and right crankcases must be detached. Here are the needed instructions.
2.11.1 NUT ON LEFT SIDE OF
CRANKSHAFT
In order to loosen the nut 1 on the left-hand side of the crankshaft, heat it with a blow-dryer or similar instrument. Then loosen the nut with a special socket wrench A (code 006140020000) and remove it.
ATTENTION: When re-assembling, the oil seal must be replaced2 since the heating required for disassembly damages it.
A
Removal of crankshaft nut with special socket wrench A.
45
46
2
1
2.11.2 OPENING CRANKCASE
Remove the 15 screws 1 which close the crankcase.
Remove the 13 locking screws 1 on the left side casing and the 4 screws 2 on the right side casing.
Screws 1 for blocking left side casing.
2
Screws 2 for blocking right side casing.
Loosen the two screws A which fasten the engine to the support stand.
2
A
Two screws A blocking engine to engine support stand.
2
Hit the left crankcase half 2 lightly with a rubber or plastic hammer until it detaches from the right crankcase half 3. Remove the two screws blocking the engine to the equipment and disassemble the crankcase by hand.
ATTENTION: The gearbox unit and the crankshaft must remain inside the right crankcase half.
Disassembly of crankcase.
3
Detaching crankcase halves.
5
4
Remove the back 4 and front reference bushes
5 to position the crankcase correctly. Remove the gasket between the two crankcase halves.
The left crankcase half (inside) with references pins
4 and 5.
47
2
1
2.11.3 CRANKSHAFT
Remove the crankshaft fixing screw.
The crankshaft 1 can be pulled out by hand.
Should there be resistance, tap the right end of the crankshaft lightly with a plastic or rubber hammer.
Extraction of crankshaft.
4
1
2
Removal of fork support pins 4.
2
3
4
3
2.11.4 INTERNAL GEARSHIFT UNIT
AND COMPLETE GEARBOX
The internal gearshift unit is made up of the desmodromic device 1 upon which the fork 2 and two forks
3 are engaged. The forks, supported by the pins 4, drive the sliding wheels of the gearbox, allowing engagement of the desired ratio. The desmodromic device is controlled by the stop cam present in the external gearshift unit (par.1.10)
Extract the two pins 4 by hand so that the forks can be released and removed.
Turn the fork 2 which drives the sliding gear on the primary unit clockwise, to free it from the desmodromic control.
Do the same operation, though in the opposite direction, on the forks 3 driving the sliding gears on the secondary shaft.
Extract the desmodromic device.
48
Disengagement of control forks from desmodromic device.
Extract the forks together with the drive bushes
5.
2
5
Extraction of forks from gearbox unit.
ATTENTION: Make sure the circlip on the secondary shaft has been removed (par. 1.9).
Circlip removal.
6
7
Proceed to extract the complete gearbox unit including the primary 6 and secondary unit 7.
Extraction of complete gearbox unit: 6 primary unit,
7 Secondary unit.
49
2
2.12 DISASSEMBLY of PARtS fRoM CRANKCASES
Once the crankcases have been detached, it is necessary to remove the various components attached to it.
The correct positioning of some bearings applied to the crankcase halves is ensured by locking devices such as plates or simple screws. In order to disassembly these bearings, the safety devices must be disassembled as well.
2
4
3
6
1
5
8
7
Safety devices present on the inside of the right crankcase half.
2.12.1 RIGHT CRANKCASE HALF
On the inside, the plates 1 are those which assure the correct positioning of the support bearing of the crankshaft. All you need to do is remove the two screws
2 to disassemble them.
Plate 3 is the one relative to the main shaft support bearing of the gearbox. It can be disassembled by removing screw 4.
Plate 5 holds the bearing of the secondary shaft of the gearbox in place. It can be disassembled by removing screw 6.
Screws 8 hold the retaining plate 7 of the desmodromic device support bearing in place.
9
The oil seal blocking plate 8 is applied on the outside. It can be removed by taking off the two screws
9.
10
1
2.12.1.1 PISTON OIL JETS
It is recommended to remove the piston oil jets 1 and relative O-rings in order to check and clean the lubrication circuit.
The other oil jet is located on the left casing (par.
2.12.2).
50
Location of piston oil jets.
A
2.12.1.2 EXTRACTION OF COUNTER-
SHAFT SUPPORT BEARING
To extract the countershaft bearing, use the extractor A (code 3625081) together with extractor B (code 006140160000). It is recommended to apply the two aluminium plates to be placed between the legs of the extractor and the crankcase half.
2
B
Extraction of countershaft bearing.
2
Inside safety plates of left crankshaft half.
1
2.12.2 LEFT CRANKCASE HALF
Three safety plates are present on the left crankcase half. Two are applied on the inside and one on the outside.
The plates 1 on the inside are the ones relative to the crankshaft support bearing of the gearbox. They can be disassembled by removing the two screws 2.
4
3
The plate 3 is the one relative to the bearing which supports the countershaft. It can be disassembled by removing the screw 4.
For checking and cleaning part of the lubrication circuit, it is advised to use compressed air in the piston 5 oil jet.
5
Outside safety plate of left crankshaft half countershaft.
51
52
2
1
Disassembly of inner filter.
A
2.12.2.1 INNER OIL FILTER
The inner oil filter 1 must be pulled out from the inside of the left crankcase. Its removal can be aided by using a soft pin to push it from the outside towards the inside, tapping with a small hammer.
2.12.2.2 EXTRACTION OF DESMODROMIC
DEVICE BEARING
Removal of bearing dedicated to the device present inside left crankcase half.
Its removal entails use of the extractor
A (code
3625081) together with extractor B (code
006140160000).
To carry out this operation, it is recommended to apply two aluminium plates between the legs of the extractor and the crankcase half.
B
Extraction of desmodromic device bearing.
3 ENGINE ASSEMBLY AND CoNtRoLS
Before reassembling the engine, a series of important controls must be carried out to ensure correct functioning of the engine. The bearings must be replaced if they play or get jammed during rotation. It is however recommended to refer to the periodical maintenance table.
In order to insert the bearings in the crankcase halves, bring the crankcase halves to a temperature of 150°C and keep them at that temperature for 20 minutes.
Place the crankcase halves on a large surface where their whole seal surface can rest. When the bearings cool off, they drop into their seats on their own.
3
53
54
3
EXPLODED VIEW OF ENGINE CRANKCASE HALF
1) Complete engine block;
4) Crankcase gasket;
5) Back reference bush;
6) Front reference bush;
7) Bush 17x21x19;
8) Inner oil filter;
9) O-ring;
15) Piston oil jet;
16) O-ring;
17) Lubrication jet;
18) Lubrication jet;
19) Centring pin;
20) Centring pin;
22) Cap;
23) Plate;
24) Screw M5x10;
30) Screw M5x10;
31) Bush;
32) Oil incline; Copper gasket;
37) Copper washer;
38) Oil pressure control valve screw;
39) Cable gland.
44) Oil jet;
46) O-ring.
3.1 CRANKCASE HALvES
The crankcase halves have some elements that need to have their integrity and use status checked.
Hereafter the controls and assembly operations of the individual elements coupled to the crankcase halves will be described. Clean the threading and oil passages thoroughly using a degreaser and compressed air.
ATTENTION! It is absolutely necessary to replace the crankshaft oil seals present on the outside of the left and right crankcase halves. This is due to the extreme heating they undergo when being disassembled.
In general, the crankcase halves must be replaced when:
∙ the oil pump crankcases show scratches or meshing signs (see their location in detail);
∙ once the new bearings are inserted and the crankcase half is left to cool off, they do not fit into their seats.
3.1.1 EXTERNAL RIGHT SIDE
Pull out the crankshaft oil seal 1 and replace it. Check that the oil seal fixing plate 2 is not bent. If so, have it replaced.
Control the integrity of the oil incline 3. Should it be worn, have it replaced.
Check the state of use of the kickstart ramp
4. It must be replaced if it shows signs of meshing or chipping.
The table below contains indications for fixing the screws of the above-mentioned elements.
3
Screw number
5
6
7
Screw dimensions
Threading diameter [mm]
Threading length
[mm]
M5 10
M5 10
M6 20
Threadlocker application
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Tightening torque
[Nm]
6
6
10
3
6
4
7
10Nm
2
5
6Nm
1
6Nm
Elements present on outside right crankcase half.
55
56
3
B
A
The crankcase half will definitely need to be replaced when:
• the oil pump crankcase A shows deep scratches or meshing signs;
• the two pins B for the idler wheel and torque limiter show traces of abnormal wear or meshing.
Keeping the tightener on the lever 25 facing towards the crankcase half, apply the spacer 27 onto it, by inserting the smaller diameter segment in the lever. Apply the spring 26 so that the hook inserts into the groove present on the lever 25 and then apply the washer 28 and the screw 29 M6x20 whose threading must be spread with medium strength threadlocker.
EXPLODED VIEW OF STOPPING DEVICE
25) Lever;
26) Spring;
27) Spacer;
28) Washer 6x20x1;
29) Screw M6x20.
10Nm
C
Stopping device coupled with the crankcase half.
Apply the entire device on the crankcase half so that the straight segment of the spring rests on the stop C. Tighten the screw at 10Nm.
1
3.1.1.1
INSERTION OF OIL SEAL
AND COUNTERSHAFT
SUPPORT BEARING
3
In order to insert the oil seal and countershaft support bearing proceed as follows.
Grease the oil seal and bearing housing. Insert the new oil seal 1 greasing the inside of it.
Application of oil seal 1.
2
Apply the new bearing 2 paying close attention that it is aligned in its seat.
Insertion of bearing 2.
A
Use a press or similar instrument to push the bearing until the outside surface is flush with the surface A.
Oil seal and bearing unit coupled to the left crankcase half.
57
58
3
3.1.2 INTERNAL RIGHT SIDE
Check the flatness of the crankshaft bearing retaining plates
1, of the main shaft bearing retaining plate
2, of the secondary shaft bearing retaining plate 3, and of the desmodromic device bearing retaining plate 4. The table below carries the indications for application of the fixing screws of these plates and for fixing the desmodromic device support bearing.
Screw number
5
6
7
8
Screw dimensions
Threading diameter
Threading length
M6 12
M6
M6
M5
12
12
10
Threadlocker application
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Tightening torque
[Nm]
8
8
8
6
9
A
8Nm
5
1
Elements present on outside right crankcase half.
6Nm
6
2
4
8
3
7
6Nm
6Nm
B
Insert the two reference bushes A and B in their respective housings
Make sure the piston oil jets
7 are positioned correctly and free of obstructions.
Make sure that O-ring 9 is correctly positioned by checking its state. Should the O-rings have cracks or deformations, they must be replaced.
3
9
Piston oil jet O-ring and detail of passage hole.
3.1.3 EXTERNAL LEFT SIDE
Make sure the calibrated screw 1 and the jet
2 are not obstructed. Should they have been replaced, couple them to the crankcase using a small amount of medium strength threadlocker, being careful that the threadlocker does not block the holes. Then tighten them all the way.
Make sure that the oil passage A is cleaned well. Make sure that the countershaft bearing retaining plate 3 is not deformed. If it is, replace it.
The table below carries the indications for application of the screw for the plate 3.
The crankcase half will definitely have to be replaced if the oil pump crankcase B has deep scratches or signs of meshing
Screw number
4
Screw dimensions
Threading diameter
Threading length
M6 12
Threadlocker application
Loctite 243/
Sichel 100M
Tightening torque
[Nm]
8
1
8Nm
3
4
2
A
B
Elements present on outside left crankcase half.
59
3
3.1.4 SINISTRO LATO INTERNO
Pulire accuratamente il filtro interno e verificare l’integrità sia della rete metallica che del dispositivo di aggancio; qualora il filtro risultasse deteriorato in qualcuna di queste parti sostituirlo.
Locking devices
Verificare lo stato delle due piastrine 1 di ritegno cuscinetto di banco e qualora dovessero risultare deformate sostituirle.
In tabella sotto le indicazioni per l’applicazione delle viti dedicata alle piastrine 1.
Procedere all’inserimento del filtro interno 3 nella sua sede
A presente nel carter e spingerlo a fondo fino sentire scattare il dispositivo di aggancio.
Apply oil jet 4 after application of O-ring 5. Apply screw 6 after application of medium resistance threadlockers. Fasten at 6Nm.
Screw number
2
6
Screw dimensions
Threading diameter
Threading length
M6 12
M4 10
Threadlocker application
Medium strength
Medium strength
Tightening torque
[Nm]
8
6
6Nm
6
4
5
1
3
A
2
8Nm
60
Elements present on inside left crankcase half.
Deflection/Off-centring of crankshaft.
3.2 CHECKING CRANKSHAft
AND CoNNECtING RoD
After having checked the state of wear of the coupling surfaces, check the offset of the half shaft axes by placing the crankshaft in between two tailstocks or similar instrument. Control the maximum measurement variation during a complete turn, using comparators positioned on the coupling surfaces with the crankshaft bearings.
3
Allowed limited: 0.03mm
Check the axial play between the connecting rod head and the half shafts.
Recommended play:
0.42÷0.65mm
Connecting rod axial play.
Check the radial play of the connecting rod head bearing by placing the crankshaft on a stable support. Then position a comparator in axis with the connecting rod, and pressing lightly in the direction of the crank lever axis, check that the measurement detected does not exceed the service limit.
Maximum play 0.04mm
If play is greater replace the connecting rod.
Connecting rod radial play.
61
3
Make sure that the chain control gear is free of chipping or signs of abnormal wear. Replace the crankshaft should it be deteriorated.
The distance between the two opposite sides of the half shafts must be:
64mm±0,05 (350cc, 390cc)
65mm±0,05 (430cc, 480cc)
A
B
64mm±0,05 (350cc, 390cc)
65mm±0,05 (430cc, 480cc)
Crankshaft oil passages.
C
If the two half shafts are detached for replacement of the connecting rod, pay close attention when repositioning the crank lever respect to the half shafts. The holes for oil passage A on the half shaft must coincide with those present on the crank lever
B.
Incorrect positioning would cause an irregular oil flow rate thus damaging the connecting rod head bearing.
The references C which must be aligned are found on the half shaft on the flywheel side and on the crank lever of the pin bolt.
62
Half shaft and crank lever pin bolt references C.
Use a bore meter to check the inside diameter of the connecting rod foot which must not exceed the following service limit:
scope of service 18,04mm (350cc, 390cc)
19,04mm (430cc, 480cc)
Remember that the measurement must be made placing the axis of the feeler in parallel with the axis of the connecting rod.
3
Bore meter verification of inside diameter of connecting rod foot.
3.3 ASSEMBLING CoMPLEtE
CRANKSHAft
When all the aforementioned controls have been carried out and the worn parts replaced, grease the crankshaft oil seal on the right crankcase half and couple the crankshaft to the left crankcase half. Keep the gear present on the crankshaft towards the left. In order to carry out this operation, you must just push the shaft axially towards the crankcase.
Insertion of crankshaft in right crankcase: note the position of the gear.
63
64
3
Checking wear of forks and gearwheels.
3.4 GEARBoX UNIt: CoNtRoLS
AND REASSEMBLY
The gearbox unit is made up of the gearshift and of the gearbox itself. The gearshift is then divided into external and internal gearshift.
The following are the verifications and procedures for checking and reassembling these units to the engine.
3.4.1
CHECKING GEARBoX UNIt
Use protective jaws to clamp the primary and secondary shaft.
Use a thickness gauge to check the axial play between the gearshift forks and the gearwheels. The play detected must not exceed the service limit indicated below:
service limit: 0,5mm
If the detected axial play is greater, before replacing either the gearwheels or the forks, check their state of wear (par. 2.4.4).
Remove the various elements and check that:
•
The support surfaces of the primary and secondary shafts are free of abnormal wear or signs of seizure.
•
The sides of the teeth are free from chipping or abnormal wear.
•
The sliding areas of the gearwheels are free from abnormal wear or traces of seizure.
•
The front claw clutches of the gearwheels are not chipped or rounded.
•
The roller bearings are intact and efficient.
•
None of the thrust washers show traces of abnormal wear or meshing.
Should any of these defects present themselves, replaced the concerned parts.
EXPLODED VIEW OF PRIMARY UNIT:
1) Mainshaft;
2) Roller cage 22x26x13;
3) Fifth gear on mainshaft;
4) Thrust washer;
5) Circlip sw15;
6) Third and fourth gear on mainshaft;
7) Thrust washer;
8) Sixth gear on mainshaft;
9) Second gear on mainshaft;
10) Thrust washer 17x30x1
3.4.2 PRIMARY UNIT ASSEMBLY
Before proceeding with reassembly, clean all the elements thoroughly and oil them with gear oil.
Always replace the circlips.
Clamp the mainshaft
1 (using protective jaws), so that the grooved end faces downwards.
Insert onto the lower cylinder part of the shaft: the roller cage 2, the 5th gear (3) (turning the front claw clutches upwards), the 26x32x1.5 thrust washer 4 and the circlip 5.
Insert the III - IV sliding gear ( 6) so that the smaller gear faces downwards, and then insert the circlip 5.
Insert the 23x32x1.5 thrust washer 7, the roller cage
2, the 6th gear (8) (with the front claw clutch facing downwards), the 2nd gear ( 9)
(with the cavity facing upwards) and finally the
17x30x1 thrust washer 10.
3
65
3
3.4.3 SECONDARY UNIT ASSEMBLY
Before proceeding with reassembly, clean all the elements thoroughly and oil them with gear oil.
Always replace the circlips.
Clamp the secondary shaft 20 (using protective jaws), so that the grooved end faces downwards.
66
EXPLODED VIEW OF SECONDARY UNIT
4) Thrust washer;
5) Circlip sw15;
7) Thrust washer;
10) Thrust washer 17x30x1;
11) First gear on secondary;
12) Roller cage 20x24x10;
13) Thrust washer 20x30x1;
14) Fifth gear on secondary;
15) Roller cage;
16) Third gear on secondary;
17) Fourth gear on secondary;
18) Sixth gear on secondary;
19) Second gear on secondary;
20) Secondary shaft
Insert onto the lower cylinder part: the roller cage
15, the 2nd gear (19) (so that the front claw clutches face downwards), the 26x32x1.5 thrust washer 4 and the circlip 5.
Insert the 6th gear ( 18) (so that the fork seat faces upwards) and the circlip
5.
Insert the 23x32x1.5 thrust washer 7, the two roller cages 15, the 4th gear (17) (with the front claw clutches facing upwards), the 3rd gear ( 16) (with the front claw clutches facing downwards), the
23x32x1.5 thrust washer 7 and the circlip 5.
Insert the 5th gear ( 14) (with the fork seat facing downwards) the 20x30x1 thrust washer 13 the roller cage 12, the 1st gear (11) (with the front claw clutches facing upwards) and finally the 17x30x1 thrust washer
10.
3.4.4 CHECKING THE FORKS,
FORK PINS AND DESMO-
DROMIC DEVICE
3
The internal gearshift is made up of:
• two forks 13 which drive two gears on the secondary unit;
• one fork 14 which drives one gear on the primary unit;
• three drive pin bushes
15;
• two fork pins 16;
• desmodromic gearshift 18 through whose rotation the forks are driven thus selecting the desired gear.
EXPLODED VIEW OF INTERNAL GEARBOX CONTROL
UNIT:
13) I - IV fork;
14) V - VI fork;
15) bush;
16) fork pin;
18) desmodromic control
Check to make sure that the drive pins which support the bushes 15 have no traces of meshing or abnormal wear and that the bushes themselves are not worn.
67
68
3
A
Make sure the distance A between the outer faces of the fork is not less than that indicated below:
Minimum acceptable distance: 4.25mm
Check to make sure that the inside diameter D of the fork pin seats is below the limit:
Fork inside diameter limit: 13,83mm
Make sure that the fork pins upon which they slide have an outside diameter above the limit (to be measured in the sliding areas of the forks and in the housing areas of the crankcases):
Fork pin outside diameter limit: 13,75mm
Make sure that the desmodromic control device has no corroded or worn areas especially in the grooves in which the drive pins of the forks are engaged.
Pin
Di
1
2 3 4
3.5 ASSEMBLY of INtER-
NAL GEARBoX AND GE-
ARSHIft
Insert the entire primary 1 and secondary unit
2 into the respective seats on the left crankcase half simultaneously. Remember to oil the gears abundantly with gear oil and to grease the shafts supporting them in the areas where they are coupled with the bearing with graphitic grease.
Make sure that all the parts slide properly.
3
Insertion of gearbox in left crankcase.
Insert the centre bearing
3 and the O-ring 4 on the secondary unit.
3
4
Detail of centre bearing 3 and O-ring 4 coupled to the secondary shaft.
69
3
5
6
Application of forks to gearwheels.
6
Introduce the forks together with the drive bushes on the gear tracks. To be precise; the smaller fork
5 drives the sliding gear on the primary unit, while the other two ( 6) drive the sliding gears on the secondary unit.
Note: the two forks 6 are interchangeable and their positioning is univocal, since the drive pin must face the desmodromic device. If none of the components in question is replaced, it is recommended to reposition the forks in their original positions.
Insert the desmodromic device in the specific bearing. In order to do this, it is necessary to rotate cam stop lever 7 towards the bottom part of the engine.
7
70
Insertion of desmodromic device in specific bearing.
Note the rotation of the stop lever.
5
8
Position the fork 5 of the primary unit in the central guide of the desmodromic device 8, insert the fork pin inside the fork itself and insert the pin in its proper seat in the crankcase half.
Positioning of primary unit fork 5 in central guide of desmodromic device 8.
8
6
Position the two forks 6 of the secondary unit in the external guides of the desmodromic device
8 and, just like the primary unit fork, insert the fork pin first in the pins and then in its proper seat.
Remember to oil the shafts, forks and the desmodromic device abundantly with gear oil.
3
6
Positioning of the secondary unit forks 6 in the external guides of desmodromic device 8.
Position the new crankcase gasket.
View inside the right crankcase with crankshaft, oil jets, gearbox shafts complete with gearwheels, internal gearshift and gasket.
71
3
3.6 CLoSING ENGINE BLoCK
Press the right crankcase half towards the left, being careful that the shafts and pins on the crankcase fit into the respective housings and that the crankcase half is not upside-down. To facilitate progressive nearing and aligning of the two crankcase halves, connect two screws on opposite sides and tighten them bit by bit. If the crankcase halves tend to capsize, do not insist tightening them. Rather loosen the screws and reposition the crankcase correctly.
Make sure that the two crankcase halves match perfectly one with the other. Assemble the screws according to their length as indicated in the figure.
The table below contains indications for applying these screws.
It is recommended to tighten them in a criss-cross pattern using a torque of 10Nm.
Apply the two screws for fixing the engine to the engine support (code 3625132 000)
Positioning of screws to fasten crankcase.
Screw number
40
41
42
Screw dimensions
Threading diameter
Threading length
M6
M6
M6
30
60
70
Threadlocker application
NO
NO
NO
Tightening torque
[Nm]
10
10
10
Cut the extra piece of gasket in between the two crankcase halves in the area of the cylinder.
This can be done easily by bending the gasket several times.
72
Cutting extra piece of gasket between engine crankcase halves.
To block the crankshaft, apply only the screw 38 to the crankcase.
3.7
3
BLoCKING tHE
CRANKSHAft At tHE toP DEAD CENtRE AND tIGHtENING tHE NUt oN tHE LEft SIDE of tHE CRANKSHAft
To block the crankshaft in the Top Dead
Centre, insert the special conical-end screw
38, without applying washer 37, or the special engine locking tool, code 006140110000, in its seat on the right crankcase. Once the crankshaft is positioned at the Top Dead
Centre, tighten all the way.
150Nm
Nut on left side of crankshaft.
Spread the threading on the left-hand side of the crankshaft with medium strength threadlocker. Tighten the nut using the special socket wrench A (code 006140020000) at a torque of 150Nm.
73
3
0,35÷0,80
3.8 EXtERNAL GEARSHIft
Before reassembling the external gearshift, check its state of use. While for the stop cam it is enough to make sure it’s free from abnormal wear or meshing, the gearshift drive shaft needs more indepth inspections.
3.8.1 CHECKING THE COMPLETE
DRIVE SHAFT
With the device complete, make sure that the distance between the movable pawl and the drive shaft is between 0.35÷0.80mm.
Should the distance be greater, replace the movable pawl.
74
Allowed distance between shaft and pawl.
2
1
4
In order to replace the movable pawl 1, disassemble the return spring of the gearshift 2, the spring guide 3, the spring 4 (which must be compressed and pulled out of its seat) and the pawl, moving it completely towards the shaft 5.
3
5
Complete drive shaft: 1) Movable pawl; 2) Gearshift return spring; 3) Spring guide; 4) Spring; 5) Gearshift drive shaft.
3
EXPLODED VIEW OF GEARSHIFT
5) Thrust washer 14x30x1;
6) Gearshift return spring;
7) Spring guide;
8) Pawl return spring;
9) Movable pawl;
10) Gearshift drive shaft.
For reassembly, couple the movable pawl 9 to the drive shaft 10 and, while compressing it, insert the spring 8 between the movable pawl and the drive shaft. Then apply the spring guide 7, the gearshift return spring 6 and finally the 14x30x1 thrust washer 5.
The gearshift return spring must be positioned as in the figure to be able to carry out its function.
Gearshift drive shaft: note the positioning of the gearshift return spring.
75
76
3
10Nm
3
4 2 1
POSITIONING OF STOP CAM ON DESMODROMIC
DEVICE
1) Stop lever;
2) Stop cam;
3) Screw M6x30;
4) Movable pawl return spring.
3.8.2 ASSEMBLY OF EXTERNAL GE-
ARSHIFT
Keeping the stop lever moved 1 in such a way that the spring is compressed, position the stop cam
2 on the protruding end of the desmodromic gearshift (external right crankcase). The stop cam has only one correct position which is determined by the particular shape of the end of the desmodromic device and of the bottom part of the stop cam.
Proceed mounting the tightening screw 3 M6x30 between the stop cam and the desmodromic gearshift, after having applied medium-resistance sealant: tighten it at 10Nm.
Insert the drive shaft together with the washer in its seat keeping the return spring 4 of the movable pawl pressed.
Wishing to test the correct functioning of the entire unit, you just need to temporarily couple the external gearshift lever and to simulate the operation of changing gears, by lifting and lowering the gearshift lever and having the mainshaft of the gear unit rotate. The whole device works properly if abnormal jamming does not occur.
If the unit runs without oil, the device makes more noise than usual.
3.9 KICK StARtER
Before coupling the kickstarter to the crankcase half, some controls must be carried out.
3.9.1 CHECKING KICKSTARTER
SHAFT UNIT AND ASSEMBLY
In order to disassemble all the parts of the kickstart shaft, pull off the washer 11 at the end of the shaft
(on the side of the spring 16), the spring 16, the kickstart sleeve 14, and the lever return spring 8, which to be unfastened from the shaft must be pulled in the radial direction so that it is extracted from its hole. Pull out the kickstart spacer 9.
3
EXPLODED VIEW OF COMPLETE KICKSTART SHAFT
2) Kickstart gear;
3) Kickstart shaft;
8) Kickstart return spring;
9) Kickstart spacer;
10) Circlip 20E;
11) 20x28x1 washer DIN 988;
12) Roller bearing K20x24x10;
14) Kickstart sleeve;
16) Spring
14
Widen the circlip 10, thus slipping off the washer 11, and the kickstart gear 2 as well the roller bearing 12 and the washer 11. This frees the kickstart shaft 3 from all other elements.
Make sure that the side of the kickstart gear teeth 2 have no signs of meshing or superficial wear. Make sure that the front teeth (sleeve side 14) are not chipped. Replace any element that has the aforementioned defects.
Make sure that the front teeth of the sleeve 14 are not chipped and that the spring 16 is capable of putting enough pressure on the sleeve
14 so that it can to pull the gear 2.
Also check to make sure that the washers have no abnormal or excessive wear. If so, have them replaced. Make sure that the spring 8 has no cracks or abnormal deformation. Have it replaced if it is not able to bring the external kickstart lever back to the rest position.
For reassembly, proceed inversely compared to the previously-described disassembly procedures.
Pay attention to the correct positioning of the sleeve 14 respect to the shaft 3. The front of the shaft has a reference sign, just as the sleeve does 14: the two references must match.
Positioning of sleeve on small shaft.
3
77
3
B
Positioning of sleeve A below ramp B.
A
3.9.2 ASSEMBLY OF KICKSTART DE-
VICE
Insert the complete kickstart shaft in its housing keeping the thin-striped facing outwards and making sure that the ramp
A on the kickstart sleeve is positioned below the ramp B bolted onto the right crankcase (external side).
Turn the spring clockwise until it fits into the specific hole C.
C
Insertion of kickstart return spring.
Insert in the slot on the protruding segment of the secondary shaft: the circlip
18, the washer 17, the idler wheel 4 followed by the washer 17 and the circlip 18 as shown in the figure.
78
Engine side
Kickstart device unit coupled to the crankcase.
1
Idler wheel 1.
2
Torque limiter 2.
5
3.10 ELECtRICAL StARtER
UNIt AND MAIN GEAR
3
Carry out the following controls before assembly.
3.10.1 CHECKING ELECTRICAL
STARTER DEVICE ELE-
MENTS
Make sure that the teeth of all the gearwheels of the device are intact, free from chipping or signs or abnormal wear.
Pay attention to the teeth of the idler wheels
1 and torque limiter 2 and between the gears and respective support pins. Replace them if they show signs of meshing or seizure.
Make sure there are no traces of meshing on the housing of the roller bearing on the starter gear 3. Mount the starter gear temporarily on the crankshaft, together with the roller bearing and check to see if there is excessive play.
To check the correct functioning of the free wheel
4 proceed as follows.
Insert the starter gear 3 on the free wheel 4 and main gear unit 5. Keeping the main gear blocked 5 and turning the kickstart gear
3 clockwise, it must run freely. Turning the kickstart gear 3 anti-clockwise, it must be blocked without idling.
4
Free wheel coupled to main gear.
A
3
5
Main gear complete with free wheel coupled to ignition gear.
To replace the free wheel, disassemble the special circlip A and remove the free wheel.
During disassembly make sure that the lugs on the outer edge of the special circlip A are coupled in the slots of the free wheel and in the groove inside the main gear.
79
3
A
Conical segment A on right side of crankshaft.
3.10.2 COUPLING IGNITION AND
PRIMARY GEARS TO THE MO-
TOR
Thoroughly degrease the conical part A on the right side of the crankshaft and B of the primary gear.
B
Conical segment B main gear.
2
Lubricate the segment C of the starter gear 1 with motor oil and couple it to the crankshaft.
Insert the Woodruff key 2 in the specific seat.
C
1
80
Positioning Woodruff key in specific seat.
3 f
E
150Nm
ANTICLOCKWISE
6Nm
Coupling main gear to crankshaft.
D
Apply the main gear 3 to the crankshaft and while turning the gear clockwise, push it towards the crankcase half until you perceive meshing between the gear and the Woodruff key.
Insert the locking nut F applying the threading with a medium strength threadlocker and tighten at a torque of 150Nm.
Attention: it must be tightened anti-clockwise.
Apply the two safety plates
E bound to the casing with screws F. Fasten at 6Nm.
10Nm
6
Coupling electrical starter gear unit.
4
5
7
8
Grease the two pins D and E with graphitic grease.
Couple the idler wheel 7 to the pin D and apply the circlip 8.
Couple the torque limiter 4 to the pin E turning the gearwheel with the smaller diameter towards the crankcase half. Insert the washer
5 and the screw 6 after having spread the threading with medium strength threadlocker.
Tighten the screw at a torque of 10Nm.
3
Apply a light layer of grease in the area G of the start motor and insert the motor in its housing.
G
Insertion of start motor in crankcase half.
Note zone G to be greased.
9
The two fixing screws 9 of the start motor.
10Nm
Apply medium strength threadlocker on the two screws
9 and tighten them with a torque of 10Nm.
81
3
3.11 oIL PUMPS: CoNtRoL AND
REASSEMBLY
As shown in paragraph 1.5, the motor is equipped with two oil pumps: one is the low pressure (suction) pump (higher displacement) located in the outside of the left crankcase half and the other high-pressure pump (lower displacement) located on the outside of the right crankcase half. The two pumps are driven by a gear cascade meshing with the clutch gear.
82
EXPLODED VIEW OF OIL PUMP UNIT
1) Benzing ring;
2) Oil pump gear;
3) Screw M5x10;
4) Circlip JS24;
5) Oil seal;
6) High-pressure oil pump cover;
7) High-pressure (or delivery) oil pump;
8) Roller;
9) Pump control shaft;
10) Low-pressure (or intake) oil pump;
11) Ball;
12) Spring;
13) Low-pressure oil pump cover;
14) Circlip A13;
15) Thrust washer 13x19x0,5;
16) Oil pump transmission gear;
17) Screw M5x20;
18) Pin;
19) Pin;
21) Lubrication plate;
22) Head Flanged bolt M5x12.
Proper operation of the pump depends:
•
On the sliding surface with the rotors;
•
On the radial play between the two rotors and between the external rotor and the crankcase;
•
On the axial play of the rotors respect to the sliding surfaces;
•
On the O-ring seal and the oil seal (on the highpressure pump cover).
Low pressure pump: note the dot on the two rotors.
The dot must face the inside of the engine.
Should the sliding surfaces with the rotors present deep or evident traces of corrosion, replace the deteriorated part (in this case, the crankcase).
To measure the radial play between the internal and external rotor and between the external rotor and the crankcase, proceed as follows:
Insert the two rotors in their specific seat with the reference dot facing the inside of the engine.
3
Using a thickness gauge, check that the play does not exceed that allowed, equal to:
Maximum radial play: 0,20mm
Take a thickness gauge again and a rectified reference surface and verify that the axial play does not exceed the maximum allowed amount:
Maximum axial play: 0,1mm
Should play be greater, replace the rotors.
Assessment of radial play between and internal and external rotor.
Assessment of radial play between external rotor and crankcase.
Assessment of radial play between rotors sliding surfaces.
As to the high-pressure pump (located in the outside right crankcase half), one must check that the oil seal 5 is not worn (it is recommended to replace it). In order to disassembly it, the circlip 4 must be removed. Check the state of use of the O-ring 20 and replace it if needed.
Exploded view of high-pressure pump cover. 4) Circlip
JS24; 5) Oil seal 10x22.6; 6) Oil pump cover; 20)
O-ring 45x2.
Also check that the drive shaft is not too marked in the zone A where the oil seal slides.
A
Checking oil pump control shaft.
83
84
3
1
2
3
Shaft, low pressure pump, internal rotor and roller unit.
3.11.1 ASSEMBLY OF LOW PRESSURE
PUMP
Insert the internal rotor 1 on the shaft 2 so that the dot on the face of the rotor faces inwards. Then insert the roller 3 on the shaft.
5
4
6
Use motor oil to lubricate the seat of the rotors on the outside of the crankcase half, insert the external rotor 4 and the internal shaft-rotor unit in its proper seat.
Insert the ball 5 (diameter 5.5mm) and the respective compression spring 6.
Lubricate with motor oil and, while rotating the protruding segment of the drive shaft (from the outside of the right crankcase half), make sure it rotates freely and does not jam.
Complete low pressure pump coupled to the crankcase.
Fasten the cover 7 to the crankcase with the three screws 8, which must first be spread with medium strength threadlocker. These screws must be tightened at a torque of 6Nm.
7
8
6Nm
Coupling low pressure pump cover to crankcase.
1
2
3.11.2 ASSEMBLY OF HIGH-
PRESSURE PUMP AND
CONTROL GEAR
3
Lubricate the area where the pump is housed
(outside right crankcase half), and insert the roller in its hole 1. Then insert the internal rotor 2 and the external rotor 3, making sure to position them with the reference dot facing the inside of the engine.
Lubricate the pump body with motor oil.
3
Coupling high-pressure pump rotors to drive shaft.
4
Grease the oil seal, insert the cover in the end of the shaft and press towards the crankcase carefully (pay attention to the oil seal). Insert the three screws 4 after having applied them with spread medium strength threadlocker.
Tighten them at a torque of 6Nm.
Turn the shaft holding on to the protruding end and make sure it rotates freely without getting jammed.
6Nm
Coupling high-pressure pump cover to crankcase.
85
86
3
PRESSURE CONTROL VALVE
40) Screw;
41) Thrust washer;
42) Spring;
43) Ball
20Nm
A
3.11.3 CHECKING AND ASSEMBLY OF
PRESSURE CONTROL VALVE
The pressure control valve is made up of a ball 43, spring 42, calibrated washer 41 and screw 40.
Check the length of the free spring on this component:
Service limit: 29.5mm
Tighten the screw at a torque of 20Nm.
Attention: If one of these elements making up the control valve is not inserted, engine functioning will be jeopardised.
Attention: always restore the original thickness value of the washer 41. If this should be replaced, have it changed with one having the same original thickness.
Attention: once valve assembly is complete, apply a
6 mm diameter x 8 mm length aluminium rivet A in the hexagonal slot. This device prevents accidental dismounting of the pressure regulation valve.
6Nm
4
2
1
Oil pumps control gearwheels support pins.
3.11.4 CHECKING AND ASSEMBLY
OF OIL PUMPS CONTROL
GEARS
3
The oil pumps are controlled by a gear cascade driven by the clutch gear.
The gearwheels, being made of plastic, must not have chips, grains or signs of abnormal wear.
If pump control idler wheel support pin 1 should be dismounted, reconnect it to the crankcase. The pin is fastened to the crankcase with screw 2 (after application of medium strength threadlockers) and locked with 6Nm torque.
Couple the thrust washer 4 to the pin 2 and lubricate it with gear oil.
6
5
7
Coupling pump control gearwheels to crankcase.
Couple the pump control idler wheel 5 to the pin so that the most protruding segment faces the casing.
Then insert the thrust washers 6 and circlips to keep the wheels from coming off the pins.
Insert the roller 7 to the end of the pump control shaft.
Couple the oil pump control wheel 8 to the end of the shaft so that the groove on the gear inserts into the roller. Then apply the benzing ring
9, so that the gear does not slip off.
Coupling pump control wheel.
9
8
87
3
1
3.11.5 PAPER OIL FILTER INSERTION
Lubricate the rubber gasket on the filter. Insert the filter 1 into its housing and push it towards the inside of the engine as far as it can go.
Application of paper oil filter.
3
Paper oil filter cover complete with O-ring.
2
Insert the O-ring 2 onto the oil filter cover 3 and apply the unit to the crankcase.
Apply the two screws 4 M5x16 to be tightened at a torque of 6Nm.
88
4
Two fixing screws of paper oil filter cover.
10Nm
EXPLODED VIEW OF COUNTERSHAFT
1) Shaft;
2) Counterweight;
7) Elastic washer;
8) Nut M12x1
3.11.6 CHECKING AND COUPLING
COUNTERSHAFT
3
Check the state of use of the areas where the shaft rests on the bearing. Should they show signs of abnormal wear, have the shaft replaced. Make sure that the toothed segment of the shaft does not have traces of abnormal wear.
Grease the oil seal and insert the countershaft in its seat. Position it so that the reference sign on the shaft is between the two reference signs on the main gear.
Coupling countershaft to crankcase.
Enlargement of references.
89
3
Coupling counterweight to countershaft.
While keeping the countershaft in place, insert the counterweight on the left side depending on the position set by the grooved shaft.
Detail of grooved profiles for coupling.
50Nm
1
90
Countershaft nut.
Then couple the elastic washer and the nut 1 after having applied medium strength threadlocker on their threading. The nut must be tightened at a torque of 50Nm.
CLUTCH BASKET:
A) Teeth meshing with main gear;
B) Teeth meshing with kickstart idler gear;
C) Teeth meshing with driving discs;
D) External centre bearing.
3.12 CLUtCH UNIt
Before reassembling the clutch unit, carry out some controls on the various components described below.
3.12.1 CHECKING CLUTCH BASKET,
ROLLER BEARING AND IN-
TERNAL CENTRE BEARING
Before reassembling the clutch basket, make sure that the sides of the teeth A, dedicated to main transmission and B dedicated to meshing with the kickstart idler gear and oil pumps, have no superficial nicks or abnormal wear.
Also closely check that the teeth C, upon which the driving discs engage, are not chipped or deeply cut.
Make sure that the centre bearing D with the roller bearing has no traces of meshing or abnormal wear.
If any damage is found, have the piece replaced.
3
C
D
B
A
91
3
1
2
Internal centre bearing and roller bearing of clutch gear.
Check the state of use of the silent-blocks as follows. Clamp the gear
B intended to mesh with kickstart idler gear, using protective elements. Rotate the clutch basket. If there is play between the basket and the gear unit, replace the clutch basket.
Check the state of use of the centre bearing 1 which must have no traces of meshing or abnormal wear.
Check the state of use of the roller bearing 2. If it is worn, have it replaced.
3.12.2 CHECKING CLUTCH DISCS
The clutch discs are divided into friction discs and steel discs: there are eight friction discs and seven steel discs.
The friction discs have friction material applied on both sides which wear out due to the steel discs sliding on them.
Make sure that the thickness of each friction disc is not below the minimum value fixed at:
minimum thickness: 2,8mm
The other value that needs to be checked is the thickness of the teeth of each friction disc. They must not be less than the minimum value fixed at:
minimum friction disc tooth thickness: 13,3mm
Minimum thickness.
92
Minimum disc tooth thickness.
Also check the distortion of the steel discs. This operation is done by placing the steel discs on a perfectly flat surface and using a thickness gauge to check that the clearance between the disc and the surface is not greater than:
allowable distortion steel discs: 0.10mm
3
Measuring steel disc distortion.
Clutch spring length measurement.
3.12.3 CHECKING SPRINGS
To ensure the correct pressure between the clutch discs, the state of the springs must be checked. The minimum acceptable length must be:
minimum clutch spring length:
42 mm
3.12.4 CHECKING INNER HUB
The inner hub meshes with the steel clutch discs by means of the teeth A: Make sure these teeth are not meshed or shaped by abnormal wear. If so, replace the inner hub.
Make sure that the seat B where the support washer of the disc spring slides shows no traces of meshing. If so, replace the drum.
Also control that the radial holes present on the inner hub are not obstructed and are free from sediments.
Checking inner hub teeth.
B
A
93
3
B
Thrust bearing device.
A
3.12.5 CHECKING THRUST BEARING
DEVICE
Check the state of use of the thrust bearing and the surfaces upon which it rests. In order to check the thrusting bearing, just see if it slides. When the device is assembled, simulate rotation of the front centre bearing A respect to the rear one B.
Be careful for presence traces of meshing or wear on the sliding surfaces.
3.12.6 ASSEMBLY OF CLUTCH UNIT
After having lubricated the end of the main transmission shaft, insert the internal centre bearing
4 to which the roller bearing must be coupled 5.
Insert the clutch basket 1 followed by the 21.7x38x3 washer 6, upon which the inner hub will rest 2. Put on the safety washer 7 and after having applied medium strength threadlocker, couple the lock nut 8.
In order to facilitate insertion of the clutch basket, lightly turn the kickstart idler gear, the idler gear for oil pump control and the basket itself, thus helping meshing of the various gears.
94
EXPLODED VIEW OF CLUTCH UNIT 1) Complete basket; 2) inner hub; 3) Clutch pressure cap; 4) Internal centre bearing;
5) Roller bearing 26x30x22; 6) Washer; 7) Safety washer; 8) Nut M18x1,5; 9) Overall thrust bearing; 10) Clutch body rod coupling; 11) Thrust bearing; 12) Circlip RB14; 13) Clutch spring; 14) Clutch spring retainer; 15) Screw M6x25;
16) Steel discs; 17) Friction discs; 18) special fiction disc; 19) washer; 35) judder spring.
A
8
To unscrew the nut 8, the inner hub must be blocked with a relevant tool A (code 0061400400); the tightening torque is fixed at 120Nm after having applied medium strength threadlocker.
Having tightened the nut, bend to two blocking flaps on the safety plate.
3
120Nm
Blocking inner hub with specific tool Code
0061400400.
3
2
Lubricate the clutch disc with gearbox oil and apply the washer 1 in the seat on the drum, the disc spring 2 so that the concave part faces the washer 1, the washer 3, the special disc 4, a driven disc and then the other discs alternating a driving disc and a driven disc.
4
Juddere spring assembling.
1
III
I
II
10Nm
Iv
Complete clutch and recommended tightening order.
Insert the overall thrust bearing
9 (after having lubricated it with gear oil) in the hole on the main gearbox shaft and check its free axial sliding. Close the clutch unit by means of the clutch pressure cap 3, the four springs 13, the fours spring retainers 14 and the four screws
15, to be tightened with a torque of 10Nm, in a criss-cross pattern.
95
3
B
Insert the clutch rod in the seat B from the left side of the engine, turning the smaller section towards the inside of the engine.
Insertion of clutch rod in housing B.
10Nm
7
Apply the gasket 5, the complete hydraulic actuator
6 the M6x30 screw 7 and the two M6x20 screws 8 to the left crankcase half. Tighten the three screws at a torque of 10Nm.
96
5
8
6
Application of gasket 5, actuator 6, screw 7 M6x30 and two screws M6x20.
EXPLODED VIEW OF WATER PUMP
1) Drive shaft
2) O-ring 5.5x1;
3) Bearing 10x19x5;
4) Oil seal 12x30x7;
5) Bush 8x12x10;
6) Impeller;
7) Washer;
8) Blind nut M6x1;
9) Gasket;
10) Gasket cover;
11) Washer;
12) Screw M6x40.
3.13 CooLANt PUMP
The water pump must guarantee, depending on the set rotation speed, the correct flow rate of the coolant in order to extract the needed amount of heat from the thermal unit.
The shaft
1 is supported by two bearings 3 and sealing of coolant and gear oil is ensured by the
O-ring 2 and oil seal 4.
The impeller 6 is fastened to the shaft 1 and the coupling is ensured by tightening the nut 8 onto the shaft 1.
3
Complete internal clutch cove of water pump.
3.13.1 CHECKING PUMP UNIT
AND DISASSEMBLY
Disassembly of the entire pump unit can be done only with the entire clutch cover removed.
Disassembly of the pump unit is performed by removing the nut 8 which allows you to extract the impeller 6, the washer 7, and the shaft 1. This can be removed by pressing the threaded part of shaft 1 towards the inside of the clutch cover.
Extract the oil seal 4 and, heating the bearings 3, remove them.
Once the shaft is pulled off 1 from the crankcase, it is recommended to replace the O-ring 2.
Replace the oil seal 4 every time and if the bush 5 is marked in the area of contact with the oil seal, replace it as well.
97
98
3
Bordo più spesso
3.13.2 ASSEMBLY OF PUMP UNIT
Heat the concerned area to couple the bearings 3 to the inner clutch cover. They must be pushed until they are flush with the shoulders on the pump body.
Grease the oil seal housing. Position the oil seal
4 so that the thicker edge faces the outside of the cover. Insert the oil seal in the inner clutch cover, having it enter the seat very slowly to keep it from deteriorating.
4
Application of oil seal on inner clutch cover.
10Nm
Couple the shaft 1 with the O-ring 2 to the inner clutch cover and then insert the bush 5, the washer 7 and the impeller 6.
Then couple the blind nut 8 to the threaded segment of the shaft after having applied medium strength threadlocker. Tighten it at a torque of 10Nm.
8
6
Complete coolant pump unit.
When coupling is complete, check that the pump unit turns freely without meshing or friction.
Check the axial play of the pump unit. Make sure it is not beyond 0.3 mm.
It is recommended to replace the gasket in between the inner clutch cover and the pump cover.
3.14 ASSEMBLY of CoMPLEtE
CLUtCH CovER
3
Apply a new gasket 1 placed between the right crankcase half and the inner clutch cover using the two reference pins 2 to keep it in place.
2
Positioning of gasket 1 and centring pins 2.
1
Couple the inner clutch cover to the right crankcase half and turn the water pump impeller until the pump shaft inserts perfectly in the housing on the countershaft which drives it.
Application of complete inner clutch cover to right crankcase half.
Apply the nine M6x25 screws as shown in the figure, tightening them by hand until they are flush.
Positioning of M6x25 screws.
99
3
10Nm
Couple the water pump cover to the inner clutch cover applying the four M6x40 screws, making sure to apply the copper washer 3 to the lower screw of the pump cover.
Tighten all thirteen screws at a torque of 10Nm following a criss-cross pattern.
3
Coolant pump cover: pay attention to washer 3.
If only the outer clutch cover was removed, put it back on the inner cover and fasten the six M6x25 screws as shown in the figure.
4
4 screws that fasten the outer clutch cover to the inner cover.
100
1
2
A
10Nm
3
Timing chain with relative fixed and movable guides.
3.15 CHECKING AND CoU-
PLING of tIMING CHAIN, fIXED AND MoBILE GUI-
DES
The chain has the task of transmitting motion from the crankshaft to the camshafts present on the cylinder head. The links must be checked to make sure there is no excessive radial or axial play between them.
The fixed and movable guides guarantee a correct movement of the chain. The hydraulic chain tensioner ensures correct tensioning.
Make sure that the guides do not have deep traces caused by the rotation of the chain.
In order to assemble the chain to the engine, just introduce it in the vertical passage compartment A on the left crankcase and insert it in the gear on the crankshaft.
Insert the fixed guide 1 and the movable guide 2 inside the compartment A. Insert the specific 6.2x9x9 bushes inside the lower eyelets of the guides. After having applied medium strength threadlocker, tighten the relative screws 3 at a torque of 10Nm.
3
Mounting bushes in lower eyelets of guides.
3.16 IGNItIoN SYStEM
Before reassembling the ignition system, it is recommended to check its correct functioning.
The ignition system is made up of the magnetic pickup, the stator unit and the flywheel. The system is completed by the electronic control unit, the ignition coil and the spark plug, which are not dealt with in this text.
101
3
3.16.1 CHECKING IGNITION SYSTEM
Degrease the various elements and carry on with the controls.
The main control is the one concerning the electrical verification which can be done by using a standard tester.
The resistance values detected at the terminal heads must respect those carried in the table (at 20°C).
Element
Pick up
Carburettor version stator
Injection version stator
1
Coupling pick up to crankcase.
3
6Nm
Cables
Red – Green
Red/Black – White/Red
Yellow – Mass
Giallo – Bianco
Black - Black
Resistance values
100Ω ± 20%
14,7Ω ±15%
0,61Ω ±15%
0,18Ω ±15%
0,46Ω ±20%
3.16.2 COUPLING IGNITION SYSTEM
TO CRANKCASE
2
Set the pick-up on the crankcase so that the two holes on its support coincide with the two outer holes on the crankcase.
Apply the threading of the two screws 1 with medium strength threadlocker and tighten them at a torque of
6Nm.
Lay the cable on the crankcase, apply the groove of the cable gland 2 with gasket paste (code 3625000000) and insert it in the specific housing n the crankcase, removing excess paste.
Couple the chain guard to the crankcase, insert the two
6.2x9x9 bushes in the lower eyelets and couple the two screws 1 after having applied them with medium strength threadlocker. Then tighten them at a torque of 10Nm.
Attention: pay close attention so that the cables are well fastened to the wall of the crankcase halves near the cable gland.
Apply the oil jet 3 so that the bottom edge enters the hole of the cover. Insert the screw 4 previously spread with medium strength threadlocker.
Tighten the screws at a torque of 6Nm.
102
10Nm
32
Coupling chain guard to crankcase.
4
6Nm
Mounting bushes in lower eyelets of chain guard.
Degrease the conical segment of the crankshaft, apply the Woodruff key 21 in the appropriate groove on the crankshaft, couple the flywheel 18, the elastic washer 19 and the nut 20, after having applied the threading with Loctite 243 / Sichel 100M medium strength threadlocker. Tighten the nut at a torque of
60Nm.
3
60Nm
EXPLODED VIEW OF FLYWHEEL
18) Flywheel; 19) Elastic washer; 20) Nut M12x1;
21) Woodruff key.
Couple the stator to the flywheel cover by means of screws 1. Apply the threading with medium strength threadlocker and tighten them at a torque of 8Nm.
Insert the cable gland in its specific seat and check its perfect sealing.
8Nm
1
Coupling stator to flywheel cover (carburettor version).
8Nm
1
2
6Nm
3
4
A
Detail of flywheel cover (injection version).
2
Check the state of use of the two oil seals 2. If they are deteriorated, they must be replaced.
Blow compressed air in the hole A making sure the lubrication pipe is perfectly clean. Also check the state of use of the chain guide 3. If it is deteriorated, it must be replaced. In that case, before putting on the screw 4, apply it with medium strength threadlocker and tighten it at a torque of 6Nm.
103
3
B
Reposition the plate 5 which must be inserted in the relevant guides and pressed towards the outside of the cover.
When coupling it to the left crankcase half, apply a drop of gasket paste (code 3625000000) in the two zones
B, in order to ensure perfect sealing between the cover and the crankcase half in the concerned zone.
5
Application of cable protection plate 5. Note the two zones B where a drop of gasket paste must be applied.
Insert the centring pins 6 on the crankcase and fasten a new gasket.
6
Application of centring pins on left crankcase half for coupling with flywheel cover.
6
104
C
7
10Nm
Notice that a 12x6.3x1 copper washer 4 must be applied to the screw.
Tighten the screws at a torque of 10Nm.
3
Flywheel cover coupled to crankcase.
3.17 tHERMAL UNIt
Before assembling the thermal unit, thorough controls must be carried out on the cylinder, piston, pin bolt, piston rings, cylinder head and the timing unit described hereafter.
X
Quota at which to measure the outside diameter of the piston.
3.17.1 CHECKING PISTON, PIN
BOLT, AND PISTON RINGS
Eliminate carbonaceous sediment from the top of the piston and wash the entire piston with specific degreasing agent.
Do not use sharp points or tools for cleaning.
Then carry out a careful analysis of the piston which must be free from forcing, scratches, cracks or any type of damage.
Analyse the outside diameter of the piston whose service limit is carried in the table below concerning their specific class. The diameter must be measured at a distance X from the inner edge of the skirt perpendicularly to the axis of the pin bolt.
Displacement [cm³]
350
390
430
480
Quota X [mm]
6
6
6
5,5
Service limits based on relevant class [mm]
1 2
87,92
87,92
94,92
99,92
87,93
87,93
94,93
99,93
105
3
Measuring pin bolt seat and pin bolt.
Checking the wear limit of the elastic band.
Check the size of the pin bolt seat located on the piston and the size of the pin bolt. This last control must be made at the end of the pin bolt itself in the area where it is engaged with the piston.
Displacement
[cm³]
350 -390
430-480
Size [mm]
Pin bolt seat
18,04
19,04
Pin bolt
17,98
18,98
See the relative chapter regarding crankshaft and connecting rod controls for controls on connecting rod foot (par. 1.2).
In order to check the state of use of the piston ring and oil-scraper ring, the ring must be inserted in the cylinder so that its axis is aligned with the axis of the cylinder. Then measure the distance between the two opposite edges.
The respective service limits are carried in the table below.
Displacement [cm³]
350 - 400
450 - 498
Service limit of compression ring
[mm]
0,8
Service limits of upper and lower oilscraper ring
[mm]
1,0
106
3.17.2 CHECKING THE CYLINDER
Make sure the bore is within the service limits of the relevant class carried in the table below.
Carry out measurement at a distance A from the top face of the cylinder (surface between cylinder and cylinder head). To measure it correctly, it must be done according to the
X and Y directions orthogonal between them. Consider the maximum measurement to determine the cylinder wear.
The difference between the two measurements is the ovalization.
3
This measurement must be carried out by placing the bore meter in such a way that its axis is perpendicular to the axis of the crankshaft.
Displacement [cm³]
350
390
430
480
Quota A
[mm]
30
30
30
30
Service limits based on relevant class [mm]
1 2
Ovalization
[mm]
88,022
88,022
95,022
88,034
88,034
95,034
100,022 100,034
0,015
0,015
0,015
0,015
X
Y
A
Displacement
[cm³]
350
390
430
480
Coupling play based on relevant class [mm]
Min
Class 1
Max Min
Class 2
Max
0,035
0,035
0,057
0,057
0,037
0,037
0,060
0,060
0,035
0,045
0,057
0,067
0,037
0,047
0,060
0,070
3.17.2.1 ASSEMBLY CLEARANCE
The following table carries the coupling play between the cylinder and piston.
In order to calculate the coupling play between the cylinder and the piston, a subtraction must be carried out between the diameter of the cylinder and that of the piston.
Coupling play limit based on relevant class [mm]
Class 1 Class 2
0,10
0,10
0,10
0,12
0,10
0,10
0,10
0,12
107
3
A
Blocking cylinder head on vice.
1
3.17.3 CYLINDER HEAD: DISASSEM-
BLY AND CHECKING AUXILIA-
RY DEVICES
Before disassembling the cylinder head, clean the entire unit thoroughly. The various elements must be cleaned and named bit by bit as they are disassembled.
Proceed as follows for disassembly and inspection of the cylinder head.
Clamp the cylinder head using protective jaws, gripping it at the head connection A.
Disassemble the spark plug using the special spark plug wrench (code 020440100 000).
3.17.3.1 LUBRICATION JETS AND CENTRING
PINS
Pull out the two oil jets 1 for lubricating the cylinder head and make sure the holes are free from any impurity. Take off the O-rings- If damaged, replace them.
2
Oil jets 1 for lubrication of cylinder head and two centring pins 2.
108
Detail of oil jet lubrication 1.
1
Closing caps for finger follower support shaft seats.
3.17.3.2 FINGER FOLLOWER/SHAFTS
UNIT
3
Disassemble the two caps 1 which keep the finger follower shafts in place.
Make sure the face of the cap facing the shaft does not have deep traces or signs of wear. If so, replace the caps.
Check the state of use of the two O-rings between the caps and the cylinder head. We recommend they be replaced.
The finger follower shafts have a threaded hole
(M4) at the end so that they can be extracted. To pull them out, just screw a sufficiently long M4 screw A in this hole and pull out. In this way, the finger followers can be extracted.
A
Application of M4 screw to allow pulling out the finger follower support shafts with your fingers.
3
finger follower /shafts unit.
2
Make sure the outside diameters of the shafts
2 and the inside diameters of the holes on the finger followers 3 respect the following service limits:
Shaft service limit: 6.98mm
finger follower service limit: 7.03mm
Play limit: 0.05mm
Check to see that the contact areas between the finger followers and the calibrated discs, and between the finger followers and the cams are not chipped or particularly worn. If so, replace the finger follower.
109
3
3.17.3.3 SHIMS (CALIBRATED DISCS) FOR
VALVE PLAY ADJUSTMENT
Using a magnet, pull out the calibrated discs 1 from the seats in the cups.
Once the calibrated discs are extracted, measure them with a thickness gauge.
Removal of calibrated discs from seats.
1
Measure shim.
The calibrated discs range from 2.00 to 3.30 according to the intervals carried in the table below.
Interval thickness[mm]
2,000 ÷ 2,300
2,325 ÷ 3,000
3,050 ÷ 3,200
Step [mm]
0,050
0,025
0,050
Once you have done the measurement, take note and mark the calibrated disc depending on its original position.
Should the calibrated discs be deteriorated, replace them with others having the same dimensions.
Thus you can know whether to replace it with a thicker or thinner calibrated disc when determining the valve play.
110
B
A
3.17.4 CYLINDER HEAD: DISAS-
SEMBLING AND CHECKING
VALVE UNITS
Clamp the spring removal jaw A (code 0100043
000) and apply the spring removal tool onto it B
(code 006140030 000). Then position the cylinder head and disassemble the springs.
3
Placing cylinder head on device for disassembling valve springs.
Compress the spring as much as necessary to extract the half-cones 1.
Extraction of half-cones.
3
1
2
Having extracted the half-cones, release the spring and extract the cup 2, the spring 3 and the valve 4.
ATTENTION! Mark all the pieces you disassemble. Pay particular attention to the valves.
Valve unit.
4
1
111
3
3.17.4.1 SPRINGS
Each valve is retained by a spring. The length of these springs must be checked while they are loose:
service limit = 42,5mm
Should the springs be shorter, have them replaced.
Measuring length of free spring.
Reference dimensions for processing and fitting valve guide.
3.17.4.2 VALVE GUIDES, VALVES AND SEATS
Make sure that the valve guides are free from scratches or any type of nicks. To check the correct diameter, introduce the gauge in the valve guides from the side of the combustion chamber (code
006140180 000). If the gauge can enter, the valve guide must be replaced at a rectification workshop.
To this purpose, keep to the data carried in the drawing.
Remember that if replacing the valve guides, the seats of the valves must be repassed as described later on.
Brush the valve mushroom head thoroughly and degrease the entire valve.
Make sure that the valve stems are free from scratches or any type of nicks. Measure the diameter of the valve stems, making sure it is not less than the service limit:
Valve stem diameter service limit: 5,95mm
If it is, replace the valve. Play between the valve and the valve guide must not be greater than the limit carried below:
Play limit between valve and valve guide:
0,08mm
If play is greater, first try to replace the valve. Should play still not be within the aforementioned limits, intervene on the valve guide.Check the valve mushroom head zone, making sure that the area of contact with the seat is not dented: if so, replace the valve.
Check the state of wear of the valve seats and the sealing surface. In order to do this, apply a light layer of Prussian blue paint on the contact zone of the valve with the seat.
Then insert the guide valve until you press it against the seat and turn it on its own axis.
112
Taking the valve out, the paint will be missing in the contact zone. Its width must not be greater than the following service limit:
Width service limit of valve seat contact zone:
1,9 mm.
The contact zone can principally take on three different appearances, as shown in the figure:
A - correct;
B - incorrect (contact face damaged);
C - incorrect (uneven seat width).
3
A B C
Valve-seat contact conditions: A) Correct; B) Incorrect - contact face damaged-; C) Incorrect - uneven width-.
D
E
Also check the correct positioning of the contact area.
It must be neither higher (case D) or lower (case E).
Should the incorrect conditions described above occur, the valve seats must be rectified, respecting the conditions carried in the following drawing.
Positioning of contact area: D) too high; E) too low
Geometric features of valves seats.
If the valve seats are beyond recovery, replace the cylinder head.
113
3
1
2
Extraction of valve stem seals from valve stems.
3.17.4.3 VALVE STEM SEAL AND LOWER STOP
WASHER
Should there be excessive oil consumption or a white-like exhaust smoke which cannot be blamed on the oil-scraper rings on the piston, replace the valve stem seals 1, intended to prevent excess oil leakage.
It is recommended to replace them every time the cylinder head is overhauled.
In order to replace them, use needle-nose pliers to pull them out, being careful not to nick the valve guide.
Once the valve stem seal is extracted, the lower cup can be pulled out 2.
3.17.5 CYLINDER HEAD: CHECKING
CYLINDER HEAD BODY
Check the flatness between the head and cylinder coupling surfaces.
This can be done using a rectified block and a thickness gauge by positioning the block according to the directions shown in the figure.
The service limit is:
cylinder head flatness service limit: 0.05mm
Checking flatness of cylinder head.
B
C
Check that the state of use of the sliding zones A with the camshafts and B of the camshaft support bearing housing are free of scratches or signs of meshing.
Clean the oil passages for lubricating the cylinder head by blowing compressed air into the holes C,
D and E.
A
E
D
114
C
B
Cam zone to be checked.
A
3.17.6 CHECKING CAMSHAFTS
Verify the zones A and B on the camshafts making sure they have no traces of meshing or abnormal wear. Make sure the sides of the teeth C are not chipped or have no trace of abnormal wear.
The zone A comes into contact with the cylinder head becoming part of a hydrodynamic support bearing. Zone B on the other hand supports the roller bearing.
Make sure that the shafts in the cam zones are free of abnormal colouring which is typical when working without oil.
3
Use a thickness gauge to check the wear limit of the cams referring to the values carried in the table.
Sometimes the cams show small run marks.
This can be accepted, if the finger followers are without wear and the cam height is inside the tolerance.
Cam height measurement.
Displacement
[cm³]
350 - 390
430
480
Nominal size
[mm]
Intake
34,1
34,1
33,75
Size limit
[mm]
34,0
34,0
33,65
Nominal size
[mm]
Exhaust
33,75
33,75
33,75
Size limit
[mm]
33,65
33,65
33,65
D
3
1
Check on the exhaust camshaft that the spring
1 of the centrifugal decompressor recalls the rest of the device so that the cylinder segment
D of the rod 2 protrudes completely without any play.
Turn the lever 3 all the way to make sure the device is not jammed.
2
115
3
4
Make sure that the cylinder segment D of the decompressor is not worn or chipped.
Should it be deteriorated, replace the decompressor shaft. In order to extract it, remove the Benzing ring 4 and pull the shaft out. Operate inversely to reassemble it. If replacing the decompressor shaft, replace the Benzing ring as well.
Extraction of Benzing ring from decompressor shaft.
C
A
B
3.17.7 CHECKING CAMSHAFTS SUP-
PORT
The camshafts supports fasten the shafts so they maintain the correct position while operating. The support in the zone A has a channel B intended to lubricate the camshaft to allow the hydrodynamic support of the shaft itself. Therefore you must make sure that the zones A are free from scratches or traces of corrosion.
Make sure the zones C for housing the roller bearings have no traces of meshing or scratches.
Attention: If the support needs to be replaced, the cylinder head must be replaced as well.
116
1
Insertion of lower cup.
3.17.8 CYLINDER HEAD: INSER-
TION OF INNER CUP AND
VALVE STEM SEAL
If the lower cups and valve stem seals were disassembled*, reassemble them as follows.
First insert the lower cup 1 facing the flat part downwards. Lubricate the upper part of the valve guide lightly and insert the valve stem seal 2. Pay close attention that while inserting the valve stem seal, its axis is aligned with that of the valve guide. The valve stem seal must be pressed towards the bottom of the cylinder head until it is flush with the valve guide.
3
2
Insertion of valve stem seal.
* Remember the valve stem seals must be replaced once they have been taken off.
117
3
B
A
2
1
3.17.9 CYLINDER HEAD: ASSEMBLY
OF VALVE UNIT
Clamp the spring removal jaw A (code 0100043
000) and apply the spring removal tool onto it B
(code 006140030 000).
Insert the valve stem in the valve guide* from the combustion chamber side.
Place the valve in the specific lower housing of the jaw and introduce:
•
The spring 1, being careful to insert it so that the segment with the smaller pitch faces downwards;
•
The upper cup 2, turning the flatter part upwards.
Placing cylinder head on device for disassembling valve springs.
Compress the spring as much as necessary to extract the two half-cones 3. To facilitate their insertion, apply a small amount of grease on the stem in the half-cone housing zone.
3
Spring compression, half-cones insertion. Note the application of grease on the upper part of the stem.
* If the valves, valves guides and their seats have not been replaced, the valves must be put back in their original positions.
118
3
A
2
1
Insertion of shaft 1 on outermost finger follower 2.
10Nm
3.17.10 CYLINDER HEAD: REPO-
SITIONING CALIBRATED
DISCS, ASSEMBLY OF FIN-
GER FOLLOWER SHAFTS
AND FINGER FOLLOWERS
AND COUPLING THE
SPARK PLUG
3
Clamp the cylinder head using protective jaws, gripping it at the head connection A.
Put the calibrated discs 1 back in place in their original positions (if not deteriorated see par.1.17.3.3).
Insert the finger follower shaft
2 partly in the specific seat as much as needed to be able to insert the outermost finger follower into the cylinder head first 3. Having fastened the outermost finger follower to the shaft, push the shaft further until it reaches the seat of the innermost finger follower. Having coupled the innermost finger follower to the shaft push it all the way into the cylinder head.
Couple the two caps 4 with the O-rings to the cylinder head. They must be tightened at a torque of 10Nm.
4
Application of two finger follower shaft caps.
17Nm
Apply the spark plug on the special wrench B
(code 020440100 000), introduce the unit in the specific housing and tighten at a torque of 17Nm.
B
119
3
1
2
3.17.11 CYLINDER HEAD: INSERTION
OF OIL JETS, CENTRING PINS
AND SPARK PLUG O-RING
Insert the oil jets 1 with the O-rings 2 in their specific seats on the cylinder head.
A
Oil jet with O-ring. Note the flat part A for reference on the side of the jet.
1
4
3
Overhead view of complete cylinder head.
The positioning of the jets is univocal thanks to the specific flat side.
Apply the centring pins 3 to the cylinder head and the spark plug seal O-ring 4 between the cylinder head and the camshaft support.
120
Application of central oilscraper band.
1
3.17.12 PISTON: APPLICATION OF
PISTON RINGS AND OIL-
SCRAPER RINGS
Oil the ring seats abundantly and apply the central oil-scraper ring in the lower seat of the piston 1 paying close attention that the two ends face one another but do NOT overlap.
The two ends must be aligned in axis with the pin bolt.
3
Detail of positioning of two edges.
4
3
1
2
Apply the two lower 2 and upper oil-scraper rings
3 and then the compression ring 4.
The two oil-scraper rings must be placed so that their openings face the higher segment of the skirt and at 180° between them. Assembly of the compression ring 4 must be done keeping the reference (letter or number) facing upwards and the opening must face the some way as the opening of the lower oil-scraper ring 2.
Application of piston rings.
121
3
5
Abundantly lubricate the seats for the pin bolt with motor oil and the circlip 5 in the left pin bolt seat, being careful to position it so that the lug on the circlip inserts itself in the specific seat on the piston.
Application of circlip 5 to piston.
Destro
A
In order to identify the right and left side of the piston, just use as a reference the arrow A stamped on the piston crown which must face the exhaust manifold.
Sinistro
Identification of piston right and left side.
A
122
B
Preparation of ring compression band A.
3.17.13 APPLICATION OF PISTON TO
CYLINDER
To couple the piston to the cylinder, place the cylinder while keeping the top facing upwards. Oil the cylinder with plenty of motor oil.
Prepare the ring compression band A (code
006140170000) as shown in the figure.
Press the green locking lever B and turn the hex key anti-clockwise until the band reaches a dimension near that of the piston. Oil the inside of the band abundantly and insert the piston with all its rings inside of it. Press the green locking lever again and turn the hex key clockwise to tighten the rings and piston well.
Attention: the compression band has edges which could be sharp. Be very careful when handling it.
C
Press the piston downwards having the higher segment of the skirt protrude a bit from the band. Rest the unit on the cylinder, making sure that the contact zones of the band rest correctly on the cylinder surface. For this purpose, make sure that the upper edge C of the band is perfectly aligned with the contact surface of the cylinder.
3
Note: When positioning the complete band-piston unit on the cylinder, be careful to place them so that the arrow stamped on the crown of the piston faces the exhaust manifold.
Application of the complete piston band on cylinder.
Insertion of piston in cylinder.
Holding the band firm with one hand, push the piston inside the cylinder, making sure that the axis of the piston is aligned with that of the cylinder. Towards the end of insertion it might be necessary to use the wooden handle of a hammer or a similar tool to lightly tap the piston crown in order to facilitate its complete insertion in the cylinder.
Attention: during the whole operation, hold the band firm with one hand without moving it. Make sure that the piston rings insert themselves correctly in the cylinder when passing through the band. Should there be excessive resistance when inserting the piston into the cylinder, do not insist in order not to deteriorate the parts. Find out the cause.
When the piston has been inserted into the cylinder and the band has been removed, press the piston towards the bottom of the cylinder so that the pin bolt seats come out from the lower edge. Apply the pin bolt 1 into the right-hand seat as much as needed to allow it to be coupled with the connecting rod.
1
Application of pin bolt to piston.
123
3
1
2
3.17.14 APPLICATION OF PISTON-
CYLINDER COUPLING TO
CRANKCASE
Apply a new piston-cylinder gasket 1 to the crankcase and couple the two centring bushes to the left crankcase 2.
Lubricate the foot of the connecting rod abundantly with motor oil.
Application of cylinder/crankcase gasket and of centring bushes.
Insert the timing chain in the proper compartment in the cylinder and bring the piston/cylinder unit close to the connecting rod.
124
Passage of chain in cylinder.
Added seeger.
A
3
Once the pin bolt reaches its housing in the foot of the connecting rod, push the pin bolt inside until it is inserted all the way. Apply the lug to the circlip 3 in the pin bolt seat. Insert the cylindrical part of the special tool A into the pin bolt and, having one of the two flat surfaces of the tool coincide with the part of the circlip to be inserted, turn and push the special tool towards the engine until the circlip is fully inserted into a seat.
3
Push the cylinder towards the crankcase making sure the two centring bushes on the left crankcase are correctly inserted in the seats in the lower part of the cylinder.
Coupling cylinder to crankcase.
125
3
5
Application of guide bushes 4 and gasket 5 to cylinder.
4
Apply to the cylinder the two guide bushes 4 and the gasket 5 coupling with the cylinder head.
3.17.15 COUPLING HEAD TO CYLIN-
DER
Introduce the timing chain in the compartment on the cylinder head. Keeping the chain tight, place the head on the gasket making sure it inserts perfectly into the two centring bushes on the cylinder.
Lubricate the four washers 8 and insert them into their specific seats on the outside and inside of the cylinder head. Then insert the four M10x1.25 screws
9 - after having lubricated them- and the M6x80 screw
14 which connect the head and cylinder to the crankcase.
126
Application of components for coupling cylinder head and cylinder to crankcase.
II
Iv
30÷40Nm 55Nm
I
III
10Nm
Tightening order of screws coupling the head and cylinder to crankcase.
In two moments, proceed tightening the four screws in a criss-cross pattern. Start with one of the two screws inside the cylinder head.
The first tightening can be done at 30÷40Nm, while the second and last one is fixed at 55Nm.
The screw
14 must be tightened at a torque of
10Nm.
Keep the chain lifted so that it does not fall inside the chain compartment.
B
Positioning camshaft.
A
3.17.16 COUPLING CAMSHAFTS
TO CYLINDER HEAD AND
PHASING
3
Couple the bearings to the camshafts and lubricate them with motor oil.
Widening the timing chain, insert the exhaust camshaft upon whose gearwheel the timing chain must be placed. It is advisable already in this phase to position the shaft so that the reference notches A are horizontal with the cams facing upwards according to the approximate direction B.
Lift the camshaft slightly and move the bearing so that it is flush with the shoulder C.
Having carried out the above-mentioned positioning, rest the camshaft on the cylinder head.
Positioning camshaft bearing.
C
Detail of positioning bearing against shoulder C.
127
3
D
Lift the chain again and insert the intake camshaft placing the chain on the gearwheel. Place the shaft so that the cams face upwards according to the approximate direction D and the references E carved on the gear are horizontal.
Position the bearing in the same way as for the exhaust camshaft.
Positioning intake camshaft.
E f
Phasing check. Note the pressure that the cylinder B exercises on the chain.
Holding the camshaft still with one hand, insert an aluminium cylinder F in the housing of the hydraulic tensioner as far as needed to be able to push the movable guide against the timing chain. Make sure that the notches engraved on the two wheels are aligned one with the other. Is so, the phasing is correct. If not, release the cylinder F, lift the timing chain so that the gearwheels disengage allowing the needed rotation to obtain correct phasing.
Having checked phasing, extract the cylinder F.
Detail of correct alignment of engraved notches on gearwheels of camshafts.
128
3
Lubricate the entire camshaft unit with motor oil and apply the support 1, making sure it is perfectly engaged both on the shafts and on the centring pins.
3
Note: check the presence of the oil jets (par 1.17.11).
Apply the chain guide 2 and insert the three
M7x38 screws 3 in the holes on the chain side and the four M7x33 screws 4 in the four remaining holes.
4
4 1 4 4
3
2 3
Application of camshaft support 1, chain guide 2, three M7x38 screws 3 and four M7x33 screws 4.
129
3
Iv
II III v
Tighten the seven screws by hand until they are flush. Check the correct position of the camshaft bearings once more (page 116).
Proceed with tightening in two moments, following the order indicated in the figure. Carry out the first tightening operation at a torque of 8Nm and the second at 10Nm. At the end of this operation, make sure the camshaft moves freely.
5Nm 10Nm
vI
I vII
Tightening order of camshaft support screws.
A
Checking valve play with thickness gauge.
3.17.17 VALVE PLAY
Checking for valve play must be carried out by placing a thickness gauge A (code 006140210000) in between the cam and the finger follower. This control can be done even without the hydraulic tensioner coupled to the engine.
Attention:
The piston must be positioned at the Top Dead Centre (par 1.7)! Following the order of this text, this position is already fixed.
Play must be within the values carried on the table below.
Side
Intake
Exhaust
Minimum
[mm]
0,10
0,125
Maximum
[mm]
0,175
0,20
If the play measured is greater than that indicated, the calibrated disc must be replaced with a thicker one. On the contrary, if the valve play is less than that indicated, replace the calibrated disc with a thinner one.
The value of the needed thickness can easily be assessed by calculating the difference between the detected play value and the one required.
The following is a layout for calibrated disc replacement.
130
Check valve play
Is the valve play correct?
NO
YES
Couple the hydraulic tensioner to the engine (par 2.17.18)
Is the tensioner coupled to the engine?
YES
Disassemble the tensioner (par 1.1.1)
NO
Disassemble the camshaft support
(par 1.1.1)
First dissemble the intake camshaft and then the exhaust (par. 1.1.1)
Couple the camshaft support (par 2.17.16)
NO
Incorrect play on intake side?
YES
Disassemble only the intake camshaft
(par 1.1.1)
Disassemble the calibrated disc to be replaced (par 2.17.3.3)
Apply a new disc according to requirements.
First couple the exhaust camshaft and then the intake
(par 2.17.16)
NO
Couple the intake camshaft (par 2.17.16)
Has only the intake side camshaft been disassembled?
YES
3
131
3
1 2 3 4
1 mm
3.17.18 CHECKING AND COUPLING
OF MECHANICAL TENSIONER
TO ENGINE
The mechanical tensioner consists in:
1. a piston;
2. a spring;
3. a support;
4. a cap
Make sure the piston shows no signs of abnormal meshing.
Insert the piston into the support and push it until it sticks out of the edge of the support by approximately 1 millimetre.
25Nm
Insert the tensioner support in the specific seat on the cylinder, tightening it at a torque of 25Nm and push the piston towards the front of the engine.
132
8Nm
Inser t the spring in the suppor t and apply the cap to be tightened at a torque of
8Nm.
3
133
3
1
Application of spark plug gasket.
1
A
3.17.19 COUPLING CYLINDER HEAD
COVER GASKETS AND CYLIN-
DER HEAD COVER
Apply the spark plug gasket 1 to the camshaft support inserting the two pegs A in the specific seats and positioning it so that it recopies the shape on the support.
2
Edges where the gasket paste must be applied.
Apply a few drops of gasket paste in the edges of the cylinder head cover gasket 2.
Insert the gasket in the cylinder head cover so that the protruding part fits perfectly into the groove in the cover.
134
Insertion of gasket in groove on cylinder head cover.
Place the complete cover on the cylinder head making sure that the gasket covers the surface correctly.
Apply the four rubber rings 3 to the cover and insert the four screws
4 which fasten the cover to the cylinder head. Tighten the screws in a criss-cross pattern at a torque of 8Nm.
3
8Nm
3
4
Application of rubber rings 3 and fixing screws 4.
60Nm
3.18 PINIoN CoUPLING
If the O-ring 25 is not coupled to the secondary shaft (par 1.5), insert it followed by the spacer
26.
Then apply the pinion 27, the washer 28 and the screw 29 which must be spread with medium strength threadlocker: tighten at a torque of 60Nm.
Exploded view of pinion. 25) O-ring 25x12x1.78; 26)
Spacer 27) Pinion; 28) Washer; 29) Screw.
Attention: do not use pneumatic devices!
3.19 RELEASING CRANKSHAft
Remember that according to the order of this text, the crankshaft is blocked at the Top Dead
Centre.
It must be released by removing the screw 38
(respectively tool 006140110 000) and applying the copper washer 37 to screw 38. Therefore reapply the screw-washer unit, tightened at a torque of 15Nm.
15Nm
135
3
3.20 CoUPLING oIL CAPS
Couple the engine oil drain plug 24 in the lower part of the right crankcase, complete with O-ring
25, with wire metal filter 27 and O-ring 26. Tighten at a 20Nm torque.
Apply the magnetic screw 28 with the O-ring 29 to the gear oil drain hole: tighten at a torque of 20Nm.
136
EXPLODED VIEW OF OIL DRAIN CAPS.
24) Motor oil drain plug;
25) O-ring 27x2;
26) O-ring 20x1.5;
27) Metal filter;
28) Magnetic screw;
29) O-ring 11x2.5
15Nm
20Nm
A
Positioning of gearshift lever.
10Nm
1
3.21 CoUPLING GEARSHIft
LEvER
3
Couple the gearshift lever to the drive shaft by positioning it so that the part
A of the lever coincides with the upper edge of the oil level inspection window.
Tighten the screw 1 at a torque of 10Nm after having applied medium strength threadlocker.
137
4
4 REASSEMBLY of ENGINE IN tHE vEHICLE
Insert the engine in the frame. We recommend insertion from the frame’s left side.
Insert the engine pins 1.
1
Insertion of engine pins.
Insert the upper shock absorber pin 2 and the swingarm pin 3. Fasten the shock absorber pin at 70Nm.
70Nm
2
Insertion of upper shock absorber pin.
3
138
Insertion of swing-arm pin.
.
Apply head connections.
35Nm
35Nm
35Nm
35Nm
35Nm
Attachment
Bracket for head connection to frame. Front attachment
Bracket for head connection to frame. Rear attachment
Brackets for head connection to motor
Motor pins
Fork pins
Screw
M8 x 20
M8 x 16
M8 x 65
Special
M16 x 245
Fasten the nuts and bolts following the table below
Torque [Nm]
35
Threadlocker
Medium resistance
35
35
45
125
Medium resistance
In the carburettor version, apply the carburettor to the manifold making the breather tubes pass in the appropriate metal cable gland.
In the injection versions, apply the throttle body to the manifold.
4
35Nm
4
35Nm
5
Rotate the filter box in its normal position. Apply the lower fixing screws 4 (one each side) prior application of medium strength threadlocker and fasten at 35Nm.
Tighten the upper screws 5 to 35Nm.
Note: We recommend removing the upper screws
(one each side) and apply medium strength threadlocker.
139
4
Make sure the filter box sleeve is correctly inserted inside the carburetor, fasten the two filter box side and manifold side straps.
140
CLOSE
OPEN
In the carburettor versions, set the gas cables on the right side of the frame and make them pass through the head connections.
In the injection versions, set the gas cable on the left side of the frame and make it pass outside the head connection.
Apply the gas cables to the carburettor/throttle body and tighten the nuts.
Note (carburettor versions): the gas cable that says “OPEN” must be inserted in the bottom slot, the one that says “CLOSE” in the upper slot
Attention! At the end of the operation, check for correct gas play.
Apply the carburettor/throttle body cover and the relative screw.
Connect the stop connectors.
4
Connect the electric connectors indicated in the figure, relative to the carburettor/throttle body.
141
4
6
10Nm
Apply the unit clutch actuator to the two fixing screws 6.
Fasten at 10Nm.
Apply the spark plug cap.
10Nm
Apply the start motor cable and fasten the nut at 10
Nm. Cover the connection using the specific protective cap.
Make the electric cables from the engine (stator and pick-up) pass through the head connections.
142
Connect the connectors indicated in the figure.
.
4
Carburettor version..
Injection version.
Electric connectors in the recess (carburettor versions).
Insert the connectors and cables in the recess on the frame.
Apply the straps as in the figure.
Electric connectors in the recess (injection versions).
.
143
4
6
10Nm
Connect the ventilation pipes to the engine.
Fix the cables from the engine to the gear actuator tube.
Apply the left radiator to the frame.
10Nm
Apply the screws and fasten at 10Nm.
Apply the protective grid.
144
Connect the radiators to the engine.
Fasten the clamp straps and introduce the coolant liquid, letting the air bleed through the screw cap A.
4
Spurgo aria.
10Nm
10Nm
15Nm
A
Apply the loading cap and fasten the bleed screw at 10Nm.
Apply the silencer to the vehicle, then the exhaust manifold; fasten according to the torque indicated in the figure.
Attention! Position the exhaust manifold in order to have a 5÷10mm gap with the water hose.
145
4
6
10Nm
25Nm
Apply the Kickstart lever.
Apply the medium- resistance sealant threading on the screw and fasten at 25Nm.
Apply the brake pedal return spring 7.
Mount the chain on the pinion.
.
7
Move the wheel towards the rear, mounting the adjustment frames according to the image.
Attention! Before fastening the rear wheel, check for its correct alignment.
Fasten the nut at 130Nm.
130Nm
146
10
10Nm
11
10Nm
Apply the pinion guard 10 and the frame side guards 11 and 12. Fasten the screws at 10Nm and apply the fixing straps between the side guards and frame.
4
10Nm
12
Apply the tank making sure the gas cable is between the tank and frame. Fix the tank using the relative screws. Fasten at 10Nm.
When the plug is protruding towards its slot in the little end, push it in the slot until completely inserted. In this phase, an aluminium cylinder
(or similar tool) could be useful.
147
4
In the injection versions, apply the tank as follows.
Connect the connectors indicated in the figure.
Insert the tank in its seat.
Connect the quick-release petrol couplings.
148
OK
NO
Attention! Make sure that the petrol quick-release couplings are properly set.
Apply the seat.
Reapply the paramotor plate with the tree fixing screws, once the motorcycle is removed from the stand. Fasten at 10Nm.
tABLE of tIGHtENING toRQUES of ENGINE CoMPoNENtS
Fixing
Oil seal fixing plate
Oil incline
Kickstart ramp
Crankshaft bearing fixing plates
Main gearbox shaft bearing fixing plate
Secondary gearbox shaft bearing fixing plate
Desmodromic gearshift bearing fixing
Threading diameter x length [mm]
Quantity
Outside right crankcase half
Threadlocker
M5 x 10 2
Loctite 243/
Sichel 100M
M5 x 10
M6 x 20
2
1
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Inside right crankcase half
M6 x 12
M6 X 12
M6 X 12
M5 X 10
2
2
2
2
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Crankcase coupling M6 X 60 2
Torque
[Nm]
6
6
10
8
8
8
6
10
Notes
Crankcase coupling 10
Countershaft bearing fixing
Calibrated screw
Oil jet
Crankshaft bearing fixing plates
Crankcase half coupling
Crankcase half coupling
Left-hand side nut
Right-hand side nut
Crankshaft blocking
Stop cam
Stopping device lever
Gearshift lever
Torque limiter
Start motor
M6 X 30 2
Outside left crankcase half
M6 X 12 12
M5
M4
1
1
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Inside left crankcase half
M6 x 12 2
Loctite 243/
Sichel 100M
M6 x 70 4
M6 X 60
Crankshaft
9
M32
M20
1
1
M8x16
M6 x 30
Gearshift
1
1
M6 x 20 1
M6 x 25 1
Electrical starter device
M6 x 25 1
M6 x 20 2
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
8
8
10
10
150
150
15
10
10
10
10
10
Tighten all the way
Tighten all the way
Left threading
With copper spacer
149
150
Fixing
Oil jet
Oil pump covers
Chain oil jet
Oil pressure control screw
Threading diameter x length [mm]
M4
Quantity
Engine lubrication
10
Threadlocker
M5 x 10
M5 x 12
5
1
Medium strength
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
M12 x 10 1
Paper oil filter cap
Locking nut
Inner hub / clutch basket
M6 x 16
M12
M18
2
Countershaft
1
Clutch
1
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Clutch pressure cap
Clutch actuator
Clutch actuator
Outer clutch cover
M6 x 25
M6 x 20
M6 x 30
M6 x 25
1
6
4
2
Torque
[Nm]
50
120
10
10
10
10
6
6
6
20
10
Outer clutch cover M6 x 30 1 10
Inner clutch cover
Impeller blind nut
Cover
Fixed and movable guides
Chain guide on flywheel cover
Chain guard
Pick-up
Stator winding
Flyweel
Spark plug
Cover
M6 x 25 9
M6
Water pump
1
Loctite 243/
Sichel 100M
M6 x 40 4
Timing chain guards
M6 x 25 2
M5 x 10
M6 x 20
1
2
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
M5 x 12
Ignition system
2
M6 x 25
M12
2
1
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
Loctite 243/
Sichel 100M
M12
M6x25
1
9
10
10
10
10
6
10
6
8
60
17
10
Notes
See water pump cover screws as well
Fixing
Finger follower shaft caps
Threading diameter x length
[mm]
Quantity Threadlocker
Engine lubrication
M10 2
Torque
[Nm]
10
Cylinder head
Cylinder head
Camshaft support
Camshaft support
Exhaust flange stud
Electric fan sensor
AIS valve fitting
Cover
Tensioner cap
Small tensioner cap
Pinion
Bored screw
Motor oil plug
Magnetic screw gearbox oil plug
Kickstart lever
M10
M6
M7 x 38
4
1
3
M7 x 33 4
M8 x 30 2
Loctite 243/
Sichel 100M
M12
M10
1
1
M6 x 12 4
Mechanical tensioner
M24 1
M16 1
Chain pinion
M10 x 18 1
Loctite 243/
Sichel 100M
M6x1
Gearbox oil vapour breather
1
Loctite 243/
Sichel 100M
Oil drains
M20 1
M14
M8 x 26
1
Kickstarter
1
Loctite 243/
Sichel 100M
20
10
8
25
8
15
20
Notes
40 55
Lubricate threading and washers. Follow a criss-cross pattern
10
8 10
8 10
Follow a criss-cross pattern
Follow a criss-cross pattern
60
6
25
Do not use pneumatic devices!
Do not use pneumatic devices!
151
152
ENGINE/fRAME tABLE of tIGHtENING toRQUES
Fixing
Front engine pin
Threading diameter x worm
[mm]
M10 x 1,25
Quantity Threadlocker
1
Lower engine pin
Head connection bracket to front frame
Head connection bracket to rear frame
Head connection brackets engine
to
Swingarm pivot
M10 x 1,25
M8x20
M8x16
M8x65
M16 x 1,5
1
2
2
1
Loctite243/
Sichel 100M
Loctite243/
Sichel 100M
Loctite243/
Sichel 100M
Torque
[Nm]
35
35
45
45
35
125
Notes
RECoMMENDED ENGINE MAINtENANCE
The required engine maintenance is strongly depending on the level of use and on the accordingly done periodic checks and service. The below mentioned maintenance intervals are for standard competition use, subject to the condition that the engine was never running under extraordinary conditions and the periodic service was done accurately.
30h
200l
60h
400l
90h
600l
120h
600l
150h
800l
180h
1200l
Clutch disc wear
Clutch springs
Gearbox bearing
(crankcase side)
Clutch hub/basket wear
Cylinder
Piston and segments
Camshaft wear
Valve springs
Valves
Valve guide wear
Connecting rod
Countershaft bearings
Crankshaft bearings
Wear of complete gearbox
Pressure control valve spring length
Water pump oil seals
Oil pumps control gearwheels
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I = INSPECT AND REPLACE IN CASE OF NECESSARY S = REPLACE
153
154
RECoMMENDED LUBRICANtS AND LIQUIDS
APPLICATION
Gearbox and clutch
Engine
COOLANT
PRODUCT
Liqui Moly racing 10W40
Liqui Moly racing Synth 10W50
Liqui Moly Coolant ready mix RAF 12 PLUS
QUANTITY
800 ml* - 750ml**
800 ml* - 750ml**
1300 ml*
* Following the complete engine revision.
** Following routine maintenance interventions.
NotE:
155
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Key features
- Single cylinder, 4-stroke, liquid-cooled
- Countershaft and electric starting
- Detailed disassembly and reassembly instructions
- Step-by-step instructions with illustrations
- Performance and reliability
