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APRILIA M191M, Workshop Manual

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APRILIA M191M Workshop Manual Download Page 24

 

 

                SPECIAL TOOLS

2 - 3

Engines M192M / M191M / M245M / M234M / M282M / M281M

2.1. SPECIAL TOOLS 

2.1.1. 

SPECIAL TOOLS  

Special tools are required for correct part removal, installa-
tion and tune-up. 
Improper and/or makeshift tools might cause damages. The 
list below includes special tools, which have been especially 
designed for this engine. 
Order special tools, if needed, from the special tools manual. 
 

 

WARNING 
Read the supplied documents before using any 
special tools. 

 

 

 

 

Legend. 
 

Position 

Tool description and function 

Part number 

1 

Small items for crankshaft axial play 

8140657 

2 

Piston ring tool (engines M192M / M245M / M281M) (125 cc) 

8140658 

3 

Valve oil seal drift 

8140659 

4 

Piston ring tool (engines M191M / M234M / M282M) (150 - 200 cc) 

8140660 

5 

Clutch housing lock wrench 

8140661 

6 

Driven pulley needle bearing drift  

8140662 

7 

Water pump overhauling tools 

8140663 

8 

Adapter for clutch unit disassembly 

8140665 

9 

Guide for mobile pulley onto fixed roller 

8140664 

10 

Driving pulley lock wrench (engines M192M / M245M / M281M) (125 cc) 

8140535 

11 

Pressure gauge fitting 

8140181 

12 

Driving pulley lock wrench (engines M191M / M234M / M282M) (150 - 200 cc) (adjust-
able face wrench) 

8106702 

13 

Universal tool for clutch assemblies 

8140259 

14 Flywheel 

puller 

8140276 

15 

Dial gauge holder 

8140266 

 

 
 

Summary of Contents for M191M

Page 1: ...www serviceaprilia com workshopmanual engines M192M M191M M245M M234M M282M M281M 1111 2 11 2003 01 8140684 UK ...

Page 2: ...FOREWORD 0 1 Engines M192M M191M M245M M234M M282M M281M FOREWORD 0 GENERAL INFORMATION 1 SPECIAL TOOLS 2 ENGINE 3 UPDATING ENGINES M192M M191M 4 ...

Page 3: ...FOREWORD 0 2 Engines M192M M191M M245M M234M M282M M281M SUMMARY 0 1 FOREWORD 3 0 1 1 FOREWORD 3 0 1 2 REFERENCE MANUALS 4 0 1 3 ABBREVIATIONS SYMBOLS CONVENTIONS 5 ...

Page 4: ...All changes and modifications are then included in the next release of the relevant manual When in doubt about some inspection or repair procedure please contact aprilia CONSUMER SERVICE A C S DEPARTMENT staff who will be glad to provide full information on servicing procedures and technical aspects aprilia s p a reserves the right to make changes to its products at any time being understood that ...

Page 5: ...M245M M234M M282M M281M 0 1 2 REFERENCE MANUALS ENGINE WORKSHOP MANUALS aprilia part description 8140680 8140681 8140682 8140683 8140684 PARTS CATALOGUES aprilia part description 6642 SPECIAL TOOLS MANUALS aprilia part description H001 ...

Page 6: ... per minute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardization Organization kg kilograms kgm kilograms per meter 1 kgm 10 Nm km kilometers km h kilometers per hour kΩ kiloOhm kPa kiloPascal 1 kPa 0 01 bar KS clutch side from the German Kupplungseite kW kiloWatt l liters LAP racetrack lap LED Light Emitting Diode LEFT SIDE left side m s meters per second max maximum mb...

Page 7: ...FOREWORD 0 6 Engines M192M M191M M245M M234M M282M M281M T E hexagonal head T P flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V volt W watt Ø Diameter ...

Page 8: ...GENERAL INFORMATION 1 1 Engines M192M M191M M245M M234M M282M M281M GENERAL INFORMATION 1 ...

Page 9: ... ELEMENTS 8 1 3 1 WARNINGS CONCERNING FUEL LUBRICANTS COOLANT AND OTHER COMPONENT PARTS 8 1 4 RUNNING IN 9 1 4 1 RUNNING IN RECOMMENDATIONS 9 1 5 USING TOOLS AND SPARE PARTS 10 1 5 1 SPARE PARTS 10 1 6 SPECIFICATIONS 11 1 6 1 TECHNICAL DATA 125CC 4T 4V H2O ENGINE 11 1 6 2 TECHNICAL DATA 200CC 4T 4V H2O ENGINE 12 1 7 USE OF PRODUCTS 13 1 7 1 USE OF PRODUCTS 13 1 8 TIGHTENING 14 1 8 1 GENERAL TIGHTE...

Page 10: ...left and right are referred to the motorcycle when viewed from the riding position In this manual any variants are identified with the following symbols option catalyzed version all versions 11KW 11 kw derated version 80km 80km h version f p full power version MP National homologation SF European homologations EURO 1 limits VERSION Italy Greece Malaysia United Kin gdom Netherlands Chile Austria Sw...

Page 11: ...he manual or at tached to the engine use utmost care to avoid the risk of injury Failure to comply with the instructions given after this symbol may put your safety as well as that of other persons or of the motorcycle at risk DANGER Failure to comply with given indications may lead to severe injury or death WARNING Failure to comply with given indications may lead to minor injury or engine damage...

Page 12: ...OF FUEL IN THE ENVIRONMENT KEEP AWAY FROM CHILDREN HOT COMPONENTS The engine becomes hot and stays hot for some time after it has been stopped Before handling engine parts wear heatproof gloves or allow the engine to cool down HUB AND ENGINE OIL DANGER Wear latex gloves when servicing Oil may can cause serious damage to the skin if handled daily and for long periods Wash your hands carefully after...

Page 13: ...th their positions before disconnecting them Identify each connection using a distinctive symbol Mark each part clearly to avoid confusion when refitting Thoroughly clean and wash any components you have removed using a detergent with low flash point Mated parts should always be refitted together These parts have seated themselves against one another in service as a result of normal wear and tear ...

Page 14: ...he two connectors have just one correct positioning Make sure to position them in the right direction Then fit the two connectors Make sure they are correctly coupled if equipped with the special hooks a click will be heard TIGHTENING TORQUE SETTINGS DANGER Always remember that the tightening torque settings of all fastening parts play a fundamental role to ensure engine safety Always tighten to t...

Page 15: ...tion ensures the vehicle safety Failure to keep the lubricants at the recommended level or the use of a non suitable new and clean type of lubricant can lead to engine seizure thus leading to serious accidents personal injury or even death Oil may can cause serious damage to the skin if handled daily and for long periods Wash your hands carefully after use DO NOT DISPOSE OF OIL IN THE ENVIRONMENT ...

Page 16: ... mi of running in you can expect the best performance levels from the vehicle Keep to the following indications Do not open the throttle completely and suddenly if the speed is low both during and after the running in During the first 100 km 62 mi pull the brakes with caution avoiding sharp and prolonged brakings This ensures a correct bedding in of the pads on the brake disc During the first 1000...

Page 17: ... 1 SPARE PARTS Should some parts be replaced use aprilia Original Spare Parts only aprilia high quality Original Spare Parts have been expressly designed and manufactured for aprilia vehicles WARNING Non original spare parts can impair the vehicle performance or cause serious damage to the vehicle itself ...

Page 18: ...uel system Premium grade unleaded petrol min O N 95 through carburetor Cooling Water cooling Max power output 11 kw at 10000 rpm Spark advance Microprocessor based variable advance 10 1 at 2000 rpm 34 1 4500 at 10000 rpm Plug Champion RG 4 HC Transmission Automatic variator with expandable pulleys Vee belt automatic clutch reduction gear transmission housing with forced circulation cooling Valve c...

Page 19: ...ilter Fuel system Premium grade unleaded petrol min O N 95 through carburetor Cooling Water cooling Max power output 14 7 kw 20 HP at 8500 rpm Spark advance Variable before TDC 10 1 at 2000 rpm 32 1 6500 rpm Plug NGK CR8EB Transmission Automatic variator with expandable pulleys Vee belt automatic clutch reduction gear transmission housing with forced circulation cooling Valve clearance cold Intake...

Page 20: ...e offered by F A 5W and by F A 20W or FORK 5W and by FORK 20W mix the products as follows SAE 10W F A 5W 67 of the volume F A 20W 33 of the volume FORK 5W 67 of the volume FORK 20W 33 of the volume SAE 15W F A 5W 33 of the volume F A 20W 67 of the volume FORK 5W 33 of the volume FORK 20W 67 of the volume Bearings and other lubrication points RECOMMENDED BIMOL GREASE 481 GREASE SM2 As an alternativ...

Page 21: ...2 17 80 8 0 M 14 19 135 13 5 M 16 22 210 21 0 If not otherwise specified the tightening torque settings refer to clean dry and ambient temperature threads NOTE In order to avoid any possible deformation and or wrong coupling please tighten screws and bolts as follows Tighten all fasteners by hand Apply half of the recommended tightening torque value and tighten the opposite parts A and B C and D R...

Page 22: ...SPECIAL TOOLS 2 1 Engines M192M M191M M245M M234M M282M M281M SPECIAL TOOLS 2 ...

Page 23: ...SPECIAL TOOLS 2 2 Engines M192M M191M M245M M234M M282M M281M SUMMARY 2 1 SPECIAL TOOLS 3 2 1 1 SPECIAL TOOLS 3 ...

Page 24: ...ms for crankshaft axial play 8140657 2 Piston ring tool engines M192M M245M M281M 125 cc 8140658 3 Valve oil seal drift 8140659 4 Piston ring tool engines M191M M234M M282M 150 200 cc 8140660 5 Clutch housing lock wrench 8140661 6 Driven pulley needle bearing drift 8140662 7 Water pump overhauling tools 8140663 8 Adapter for clutch unit disassembly 8140665 9 Guide for mobile pulley onto fixed roll...

Page 25: ...ENGINE 3 1 Engines M192M M191M M245M M234M M282M M281M ENGINE 3 ...

Page 26: ... 1 29 HUB CASE BEARINGS 32 3 1 30 REMOVING THE WHEEL SHAFT BEARING FROM THE COVER 33 3 1 31 REMOVING THE DRIVEN PULLEY SHAFT 34 3 1 32 INSTALLING HUB CASE BEARINGS 35 3 1 33 INSTALLING THE DRIVEN PULLEY SHAFT BEARING 36 3 1 34 CHECKING HUB COVER 37 3 1 35 INSTALLING THE WHEEL SHAFT BEARING IN THE COVER 38 3 1 36 CHECKING HUB SHAFTS 39 3 1 37 INSTALLING HUB GEARS 40 3 1 38 FITTING THE HUB COVER 41 ...

Page 27: ...86 3 6 7 INTAKE MANIFOLD DISASSEMBLY 87 3 6 8 REMOVING THE THERMOSTAT 88 3 6 9 REMOVING THE TIMING GEAR 89 3 6 10 CAMSHAFT AND ROCKER ARMS DISASSEMBLY 91 3 6 11 HEAD DISASSEMBLY 92 3 6 12 VALVES DISASSEMBLY 93 3 6 13 CYLINDER AND PISTON DISASSEMBLY 94 3 6 14 CHECKING CON ROD SMALL END 95 3 6 15 GUDGEON PIN DIAMETER 96 3 6 16 PISTON 98 3 6 17 PISTON RINGS 99 3 6 18 ASSEMBLING PISTON 100 3 6 19 CHEC...

Page 28: ... 1 TRANSMISSION 3 1 1 TRANSMISSION COVER Remove the plastic cover Remove the driven pulley shaft lock nut and washer using the clutch housing lock wrench 8140661 Remove the plug dipstick from engine oil filler Remove the screws Remove the transmission cover ...

Page 29: ...ENGINE 3 5 Engines M192M M191M M245M M234M M282M M281M 3 1 2 FAN GUARD Remove the screws and guard NOTE 125 c c engine fan guard has four fasteners The 200 c c guard has five at two levels ...

Page 30: ...ENGINE 3 6 Engines M192M M191M M245M M234M M282M M281M 3 1 3 REMOVING THE INTAKE VENT Remove the screws Remove the vent ...

Page 31: ...ENGINE 3 7 Engines M192M M191M M245M M234M M282M M281M 3 1 4 DRIVEN PULLEY SHAFT BEARING Remove the circlip from inside the cover Remove the bearing from the case ...

Page 32: ...IVEN PULLEY SHAFT BEARING Warm up the case a little from the inside so not to damage outer paintwork Fit the bearing into its seat Replace the circlip WARNING Place the case on a suitable surface to prevent damage to outer paintwork NOTE Always fit a new bearing when reassembling ...

Page 33: ...hat the roller shows no signs of irregular wear and can turn freely REMOVING THE ROLLER Remove the screw spacer and roller complete with bearing INSTALLING THE ROLLER Install the roller Tighten the screw and spacer to the specified torque value TIGHTENING TORQUE SETTINGS Screw 11 13 Nm ...

Page 34: ...he fixed driving half pulley and the second steel washer Engines M234M M282M 200 cc Fit the special tool into the inner slots and then remove the nut with the cup washer Pulley lock wrench 8106702 Remove the starting sprocket and the torque limiter Remove the fixed driving half pulley and the steel wa sher in contact with the bushing Remove the belt and pull out the movable half pulley with bushin...

Page 35: ...245M M234M M282M M281M 3 1 8 REMOVING THE DRIVING PULLEY FROM THE ENGINE Remove the spacer clutch housing the whole driven pulley assembly and transmission belt NOTE The assembly can be removed even with the driving pulley still fitted ...

Page 36: ... M192M M191M M245M M234M M282M M281M 3 1 9 CLUTCH HOUSING Make sure the clutch housing is neither worn nor dam aged Measure its inside diameter standard value Ø 134 2 mm max value Ø 134 5 mm NOTE Max run out value 0 20 mm ...

Page 37: ...es 8140259 Adapter for clutch unit disassembly 8140665 WARNING The tool must be firmly held in the vice with the middle screw in contact with the tool Over tightening will damage the tool Check the proper insertion of the clutch in the ring be fore locking unlocking the nut Ensure that clutch may be fully fitted into the adapter ring Remove the nut Open the tool and take out the driven pulley spri...

Page 38: ...ENGINE 3 14 Engines M192M M191M M245M M234M M282M M281M 3 1 11 PIN COLLAR Remove the collar with two screwdrivers A or a ring tool B Remove the guide pins 1 and the moving half pulley 2 ...

Page 39: ...heck that parts are not worn out and or noisy and re place if necessary Remove the stop ring with two flat tip screwdrivers Remove the ball bearing with a suitable drift and a hammer Turn the pulley and fit a suitable support Remove the ball bearing with a drift of appropriate diameter and a hammer ...

Page 40: ...ENGINE 3 16 Engines M192M M191M M245M M234M M282M M281M 3 1 13 FIXED DRIVEN HALF PULLEY Measure outside diameter of the bushing D1 Min diameter allowed Ø 40 96 mm Standard diameter Ø 40 985 mm ...

Page 41: ...91M M245M M234M M282M M281M 3 1 14 MOVABLE DRIVEN HALF PULLEY Remove the two inner seal rings 1 and the two O rings 2 Measure insider diameter of the bushing D2 Max diameter allowed Ø 41 08 mm Standard diameter Ø 41 000 41 035 mm ...

Page 42: ...XED DRIVEN HALF PULLEY BEARINGS Take tool number 8140662 Fit the support A into the driven pulley and fit a new needle bearing 1 with the drift C larger end Turn the pulley and then fit a new ball bearing 2 with the drift C smaller end Mount a new retaining ring with the drift ...

Page 43: ... 3 on the bushing with the special tool Moving pulley to fixed pulley guide 4 8140664 Ensure that pins and collar show no signs of wear and refit them Lubricate the driven pulley assembly with approx 6 g of TUTELA MRM2 grease through a bent end lubrica tor Lubricate through one bushing inner hole until the grease comes out from the opposite one This must be done to prevent the grease from going be...

Page 44: ...ENGINE 3 20 Engines M192M M191M M245M M234M M282M M281M 3 1 17 SPRING Measure the free length of the movable driven half pul ley spring Standard length 106 mm ...

Page 45: ...in thickness allowed 1 mm Weights should show no traces of lubricants If they do leak test the driven pulley assembly NOTE During running in clutch weights should have middle contact surfaces and be all the same If not the clutch may jerk WARNING Do not open clutch weights with any tools to avoid load variations in the return springs ...

Page 46: ...driven pulley Use the adapter ring to mount the clutch on the specific tool Universal tool for clutch assemblies 8140269 Adapter for clutch unit disassembly 8140665 Insert the lever pin in the hole of the adapter ring Tighten the nut to the specified torque value TIGHTENING TORQUE SETTINGS Nut 45 50 Nm 4 5 5 0 kgm ...

Page 47: ...2M M281M 3 1 20 DRIVE BELT Check drive belt for damage Check the correct belt width L1 ENGINES M192M M191M M245M M281M 125 150 CC Min width 21 5 mm Standard width 22 5 0 2 mm L2 ENGINES M234M M282M 200 CC Min width 21 5 mm Standard width 22 5 0 2 mm ...

Page 48: ...125 150 CC Min permitted diameter Ø 18 5 mm Standard diameter Ø 18 9 19 1 mm D5 ENGINES M234M M282M 200 CC Min permitted diameter Ø 20 1 mm Standard diameter Ø 20 5 20 7 mm Check the degree of wear of the brass bush and measure its inside diameter D3 Min permitted diameter Ø 26 12 mm Standard diameter Ø 26 000 26 021 mm WARNING Do not lubricate or clear the brush Ensure that counter plate shoes ar...

Page 49: ...arks are in their closest position for alignment Failure to do this will impair performance of the cooling fan Apply Super Rapido Quick setting Loctite 242 on threading and tighten the nut with washer to the speci fied torque Driving pulley lock wrench 8106702 TIGHTENING TORQUE SETTINGS Driving half pulley nut 75 83 Nm Torque limiter is set to 100 Nm The lock wrench acts on the starting sprocket I...

Page 50: ...1M 3 1 23 INSTALLING MOVABLE HALF PULLEY AND BUSHING Preassemble the movable half pulley 1 with the ca lotte 2 seat the rollers 3 Fit the assembly complete with bushing onto the crank shaft Open the rear pulley and fit the belt in its rotation direc tion ...

Page 51: ...ut apply Super Rapido Quick setting thread locker Loctite 242 and tighten the nut to the specified torque Use the special tool to prevent half pulley rotation Driving pulley lock wrench 8140535 WARNING Be sure to install the driving half pulley with fully free belt so that it can be properly tight ened NOTE The nut should be replaced at each reassembly TIGHTENING TORQUE SETTINGS Driving half pulle...

Page 52: ...ENGINE 3 28 Engines M192M M191M M245M M234M M282M M281M 3 1 25 INSTALLING THE CLUTCH HOUSING Install the clutch housing and the shim ...

Page 53: ... the screws to the specified torque Refit the oil filler dipstick Apply Super Rapido Quick setting thread locker Loctite 242E and then refit the steel washer and the driven pulley shaft nut Tighten the nut to the specified torque using the clutch housing lock wrench 8140661 Fit the plastic cover TIGHTENING TORQUE SETTINGS Cover 11 13 Nm Driven pulley shaft 54 60 Nm ...

Page 54: ...0 Engines M192M M191M M245M M234M M282M M281M 3 1 27 REAR HUB Remove the dipstick Drain the rear hub oil through the plughole Remove the screws Remove the hub cover complete with wheel shaft idler gear and gasket ...

Page 55: ...ENGINE 3 31 Engines M192M M191M M245M M234M M282M M281M 3 1 28 REMOVING THE WHEEL SHAFT Remove the idler gear Remove the wheel shaft complete with gear ...

Page 56: ... M245M M234M M282M M281M 3 1 29 HUB CASE BEARINGS Check bearings for wear play and noise level In case of troubles proceed as follows Use a suitable extractor to remove the three 15 mm bearings 1 two on the case and one on the cover ...

Page 57: ...nes M192M M191M M245M M234M M282M M281M 3 1 30 REMOVING THE WHEEL SHAFT BEARING FROM THE COVER Remove the circlip from the outside of the hub cover Remove the bearing support the hub cover properly Remove the oil seal ...

Page 58: ...ULLEY SHAFT Remove the transmission cover and the clutch assem bly Withdraw the driven pulley shaft from the bearing Remove the oil seal from the bearing Be careful not to damage its seat Pull it out from the transmission side Remove the circlip Withdraw the driven pulley shaft bearing ...

Page 59: ... M192M M191M M245M M234M M282M M281M 3 1 32 INSTALLING HUB CASE BEARINGS Parts should be warmed up with the heat gun first Fit the three 15 mm bearings 1 two on the case and one on the cover APRmo_MOT125_I 3 r_0071_01 jpg ...

Page 60: ...NG THE DRIVEN PULLEY SHAFT BEARING Warm the half case with the heat gun Fit a new driven pulley shaft bearing with its balls visi ble from inside the hub Fit the snap ring with its open side opposite to the bearing Fit a new oil seal flush with the case on the pulley side ...

Page 61: ...ENGINE 3 37 Engines M192M M191M M245M M234M M282M M281M 3 1 34 CHECKING HUB COVER Ensure that the mating surface is not dented or bent Check bearing thrust surfaces If necessary fit a new hub cover ...

Page 62: ...NSTALLING THE WHEEL SHAFT BEARING IN THE COVER Warm the cover with the heat gun Fit the wheel shaft bearing on the cover Fit the circlip Fit the oil seal using the suitable tools It should be flush with the inner surface and its seal lip facing the inside of the hub ...

Page 63: ...2M M191M M245M M234M M282M M281M 3 1 36 CHECKING HUB SHAFTS The three shafts should show no signs of wear or damages to their toothed surfaces also check bearing and oil seal thrust surfaces Replace damaged parts if necessary ...

Page 64: ...ENGINE 3 40 Engines M192M M191M M245M M234M M282M M281M 3 1 37 INSTALLING HUB GEARS Mount the driven pulley shaft Fit the idler Fit wheel shaft complete with gear ...

Page 65: ...t on the centering dowels Fit the cover Make sure the vent hose is properly posi tioned Position the shortest screw Fit the remaining screws and tighten them to the speci fied torque value TIGHTENING TORQUE SETTINGS Screws 24 27 Nm Mount the oil drain plug complete with a new seal Insert the dipstick ...

Page 66: ... 200 CC Remove the clamps and cooling sleeve Remove the diaphragm clamp Unscrew the diaphragm screws Unscrew the air duct screws Discount the SAS delivery pipe and remove the duct and diaphragm Remove the four fasteners and the flywheel cover Check that inside and outside secondary air cleaner and inlet and outlet holes are not clogged ...

Page 67: ...wrench Engines M191M M234M M282M 150 200 cc adjustable face wrench 8106702 Driving pulley lock wrench Engines M192M M245M M281M 125 cc 8140535 Remove the nut WARNING Use only the adjustable face wrench supplied to prevent damage to the stator coils Remove the flywheel Flywheel puller 8140276 NOTE The 200 c c flywheel has a larger inertia weight ...

Page 68: ... M282M M281M 3 2 3 REMOVING THE STATOR Remove the wiring clamps Remove the terminal from the min oil pressure switch Remove the Pick Up screws the screw securing the wiring to the bracket and the stator retaining screws Remove stator and wiring ...

Page 69: ...nce for each phase 0 7 0 9 Ω Checking min oil pressure switch Check for continuity between connection 4 and ground engine off using a tester Checking the Pick Up Check for a resistance of about 105 124 Ω at 20 C between connection 2 and ground If different values are measured replace defective parts NOTE The above values apply for tests carried out at room temperature If a stator is checked when a...

Page 70: ...ENGINE 3 46 Engines M192M M191M M245M M234M M282M M281M 3 2 5 CHECKING THE FLYWHEEL Check that the inside plastic parts and Pick UP control plate are not damaged ...

Page 71: ...ck Up cable must be placed between the upper screw and the locating dowel Connect the minimum oil pressure switch terminal Clamp the wiring Mount the wiring bracket and tighten the attachment screw Tighten the stator and Pick up attachment screws to the specified torque value TIGHTENING TORQUE SETTINGS Stator and Pick up screws 3 4 Nm ...

Page 72: ...adjustable face wrench A 8106702 Driving pulley lock wrench Engines M192M M245M M281M 125 cc 8140535 TIGHTENING TORQUE SETTINGS Engines M192M M245M M281M M191M 125 150 cc flywheel nut 52 58Nm 5 2 5 8 kgm Engines M234M M282M 200 cc flywheel nut 54 60Nm 5 4 6 0 kgm Check that Pick Up air gap is between 0 34 and 0 76 mm The air gap is not adjusted when the Pick Up is installed A warped Pick Up suppor...

Page 73: ...Fit the outside SAS cleaner and mount the cover Fit the inside SAS cleaner WARNING Make sure the two centering dowels are pre sent Fit the cover on the engine fit the three rods into the holes for the water pump drive WARNING Ensure that the flywheel connector is properly fitted Tighten the cover screws Connect the diaphragm to the SAS delivery pipe and close the clamp Position the air duct Tighte...

Page 74: ...e of 90 C check that oil pressure is between 0 5 and 1 2 atm With the engine running at 6000 rpm and the oil at a temperature of 90 C check that oil pressure is be tween 3 2 and 4 2 atm Once finished remove the special tools previously in stalled on engine then refit oil pressure switch 1 with its washer Tighten switch to the specified torque con nect the oil min pressure switch 1 connector and re...

Page 75: ...MOVING THE OIL SUMP AND THE PRES SURE ADJUSTING BY PASS Remove the oil filler cap the transmission cover and the driving pulley with belt and sprocket Drain the sump Unscrew the attachment screws Remove the sump Remove spring by pass piston seal and centering dowels ...

Page 76: ...KING THE BY PASS Check the free length of the spring Standard length 54 2 mm Check that piston is free from scoring Make sure that piston can run smoothly along casing and that sufficient sealing is ensured If necessary remove foreign bodies or change the faulty parts ...

Page 77: ...AL OF THE CHAINS HOUSING COVER ENGINES M245M M281M M191M 125 150 cc Undo the attachment screws to remove the chains housing cover Extract the cover by means of the lugs IMPORTANT Pull the cover parallel to the drive shaft to prevent breaking the lugs ...

Page 78: ...234M M282M 3 3 5 DISASSEMBLY OF THE CHAINS HOUSING COVER ENGINES M192M M234M M282M 125 200 cc Use the bolts supplied to mount the base of the tool on the cover Screw the threaded bar on the base of the tool and ex tract the cover ...

Page 79: ...ulley cover Insert a screwdriver in the pulley to prevent it from turn ing Remove center screw with Belleville washer Remove the pulley and chain NOTE It is advisable to mask the chain so as to maintain its original turning direction Remove drive sprocket washer and O ring To remove the oil pump loosen the two screws Remove the oil seal ...

Page 80: ...mp shaft and circlip Remove rotors 4 and 5 Thoroughly wash with pet rol and blow with compressed air Reassemble rotors on pump body 6 Make sure that the two marks 7 are visible Replace the pump shaft and circlip Use a feeler gauge to check the distance between the outer rotor and the pump body Max permitted gap 0 20 mm Check the distance between the rotors Max permitted gap 0 12 mm ...

Page 81: ...ENGINE 3 57 Engines M192M M191M M245M M234M M282M M281M Check the axial play of the rotors with a ground bar Limit 0 09 mm Mount the oil pump cover and tighten the attachment screws ...

Page 82: ...it pump to crankcase Pump can be positioned in one way only Tighten screws to the specified torque TIGHTENING TORQUE VALUES Pump retaining screws 5 6 Nm Fit washer and sprocket with a new O ring Fit chain in the turning direction indicated when disas sembling Fit pulley Belleville washer and center screw Tighten to the specified torque TIGHTENING TORQUE VALUES Pulley screw 10 14 Nm NOTE Fit the Be...

Page 83: ...mplete cover tool on the drive shaft until contact is made with the housing WARNING Set the cover with the chain channel down wards If this is not done the oil shield lead sheath will be incorrectly positioned Install the tool bracket to correctly position the cover Screw the threaded bar right down on the drive shaft Use the nut on the base of the tool to check that the cover is driven fully home...

Page 84: ... mount it in the oppo site direction so that it works from the opposite side Remove the oil shield Fit a new oil shield flush with the outer edge Fit a new O ring 3 and lubricate it with grease Position the cover on the engine housing and mount it in its seat with the three screws and copper washers Tighten the three screws to the specified torque value TIGHTENING TORQUE VALUES Cover screws 3 5 4 ...

Page 85: ...ply a new sump seal 4 Refit the three centering dowels 5 Install sump and fit the spring into the tailpiece B Refit sump screws 1 Tighten the screws to the specified torque value TIGHTENING TORQUE VALUES Screws 1 10 14 Nm Refit drive belt roller assembly belt roller sprocket and transmission cover For con rod lubrication troubleshooting please refer to Crankcase and crankshaft ...

Page 86: ...ENGINE 3 62 Engines M192M M191M M245M M234M M282M M281M 3 3 12 LUBRICATION DIAGRAM ...

Page 87: ...M191M M245M M234M M282M M281M Key 1 Tappet cover 2 Crankshaft 3 Min pressure switch 4 Cartridge filter 5 Mesh pre filter 6 Oil filler 7 By pass valve 8 Oil pump 9 Oil level in the sump 10 Engine breather 11 Piston cooling nozzle ...

Page 88: ...ith water pump from en gine Undo the three fasteners 3 and remove rotor cover 2 Position flywheel cover on ring base NOTE To avoid damage to the cover surface used to the coolant sealing surface of the cover position the ring bases with its machined surface facing the flywheel cover Use a press and the drift B of tool 8140663 to push the shaft and rotor out of the drive and bearings Remove the sha...

Page 89: ...34M M282M M281M Remove ceramic seal static side 1 from flywheel cover 2 with a screwdriver Position flywheel cover under a press Make sure it is perfectly flat Use drift B of tool 8140663 in reversed position to push out the two ball bearings ...

Page 90: ... 3 4 2 CHECKING THE COMPONENTS Check that rotor is free from excessive wear or cracks Check that rotor shaft is not oxidized Check that bearing seats and ceramic seal are not oxidized Check that the drive is free from cracks and integral with the steel hub ...

Page 91: ...tic mallet Assemble the ceramic ring with rubber seal The cham fered edge of the ring must face the seal Lubricate rubber seal and install unit on flywheel cover If necessary use drift B of tool 8140663 NOTE Always use new ceramic ring and seal If a ceramic ring is not fitted manually it may be damaged Position drive on a suitable support Position the flywheel cover Lubricate the rotor shaft and f...

Page 92: ...t a new O ring on the rotor cover Remount the rotor cover Tighten the retaining screws to the specified torque value TIGHTENING TORQUE VALUES Screws 3 3 4 Nm NOTE Do not lubricate the O ring Failure to comply with this recommendation leads to ring deformation ...

Page 93: ...ainer with a thermal gun Check thermostat opening start temperature Engines M245M M281M 125 cc H2O Opening start tem perature 69 5 72 5 C Engines M234M M282M 200 cc Opening start tempera ture 77 5 80 5 C Continue heating until thermostat is fully open Engines M245M M281M 125 cc H2O Opening stroke 3 5 mm a 80 C Engines M234M M282M 200 cc Opening stroke 3 5 mm a 88 C WARNING For a correct test proce...

Page 94: ...ulley driven pulley and belt rear wheel hub cover gears bearings and oil seals Remove the oil sump the by pass the chain compart ment cover and the oil pump Remove the flywheel cover with water pump the fly wheel and stator Remove the oil filter and the oil pressure switch Remove the head piston cylinder assembly Remove the two fasteners and the starter motor ...

Page 95: ... specific tools Dial gauge holder 8140266 Small parts for crankshaft axial play 8140657 Mount the dial gauge holder and the parts needed to measure the axial play Install a dial gauge in the holder and tighten it with the knob Measure crankshaft axial play Standard play 0 15 0 40 mm If this value is exceeded the crankcase crankshaft mating surfaces are worn ...

Page 96: ...E The crankshaft of the 200 cc version is installed with two re timing steel washers Mark washers assembly posi tion WARNING When opening the crankcase and removing the crankshaft make sure that its threaded ends do not damage the main bearings Remove the oil precleaner Remove the screws and guard Remove the flywheel side oil seal Remove the oil pressure sensor Remove the oil filter Remove flywhee...

Page 97: ...shaft can be re used if its width is within the standard values and its surfaces are not scored Shims 200 cc only Check shim thickness Standard thickness 2 175 2 225 mm Check shims for scoring NOTE Refit shims in their original assembly position If the crankshaft axial play is above the standard val ues and the crankshaft is not damaged the problem is due to wear or to faulty crankcase machining C...

Page 98: ...on If necessary change the crankshaft NOTE Main bearings cannot be ground Con rod big end bearings cannot be changed Con rods cannot be changed for the same reason when cleaning the crankshaft take special care to prevent dirt from entering the crankshaft lubrication hole To avoid damage to con rod bearings do not clean lubrica tion duct with compressed air Make sure that the two buffers are corre...

Page 99: ...ication pressure adjustment On the flywheel pay particular attention to the side main bearings lubrication ducts oil delivery to head duct and oil seal drain duct NOTE Oil delivery to head drain duct is equipped with a shutter jet this allows a head low pressure lubrication in order to keep the sump oil temperature low In case jet is blocked head and timing system mechanisms lubrication will be im...

Page 100: ...to the cylinder axis The section of the ducts is influenced by the depth to which the bearings are driven Standard driving depth 1 35 1 6 NOTE To keep bearings in their correct position on casing they are fine fitted on steel rings when the casings are cast Check bearings diameter in the three directions Repeat readings on the other half bearing NOTE Do not take readings on the mating surface betw...

Page 101: ...7 mm Original NOTE Casings for spares are of the same category and are equipped with bearings of the B blue category Match crankshaft with two shoulders of category 1 with casing of category 1 or cat 2 with cat 2 A spare casing cannot be combined with a crankshaft composed of mixed categories Crankshaft for spares is equipped with axle shafts belonging to the same category Casing Axle shaft Bearin...

Page 102: ...ied torque value TIGHTENING TORQUE VALUES Oil filter connector 3 28 30 Nm Position gasket 4 with centering dowels 5 preferably on the transmission side casing Lubricate main bearings 6 install crankshaft 7 in transmission side casing 8 Mate the two casings 8 and 9 NOTE When assembling the casings and the crankshaft take care not to damage main bearings with crankshaft threaded ends For version 200...

Page 103: ... NOTE Remove any excess of the casing to cylinder mating gasket to ensure better sealing Lubricate flywheel side oil seal Refit oil seal Install a new O ring on pre filter and lubricate it Install pre filter with plug on engine Tighten to the specified torque value TIGHTENING TORQUE VALUES Oil drain plug 24 30 Nm Lubricate the gasket and mount the oil filter ...

Page 104: ...O ring on the starter motor and lubricate it Fit starter motor 1 on crankcase 2 Tighten the two screws 3 to the specified torque value TIGHTENING TORQUE VALUES Screws 3 11 13 Nm Fit sheet cover with fastening screw Refit the other parts head cylinder and timing system lubrication flywheel and transmission ...

Page 105: ...es M192M M191M M245M M234M M282M M281M 3 6 CYLINDER HEAD AND TIMING SYSTEM 3 6 1 DISASSEMBLY OF THE TAPPET COVER Remove the fasteners Remove the tappet cover com plete with settler and automatic valve Remove the gasket ...

Page 106: ...at the 4V mark on the camshaft pulley is aligned with the mark on the head as shown in the second figure If the mark on the camshaft is opposite to the mark on the head turn the drive shaft once The TDC mark is also applied in the area between fly wheel fan and flywheel cover To use this mark re move the spark plug and turn the engine in the oppo site direction using an adjustable face wrench on t...

Page 107: ...learance Check the valve shim clearance with a feeler gauge If valve clearance is not as specified loosen the check nut and adjust the clearance value with a screwdriver Engines M245M M281M M191M M234M M282M 125 H2O 150 200 cc Intake 0 10 mm cold Exhaust 0 15 mm cold Engine M192M 125 cc Aria Intake 0 13 mm cold Exhaust 0 23 mm cold ...

Page 108: ...5M M234M M282M M281M 3 6 4 FITTING THE TAPPET COVER NOTE Fit a new O ring onto the tappet cover Mount the cover complete with settler Tighten the fastener to the current torque value TIGHTENING TORQUE SETTINGS Tightening torque 11 13 Nm ...

Page 109: ... keeping the carburettor fully open until the gauge indicator reads a stabile value If pressure is over 8 9 bar remove the tool following the above procedure in the reverse order If pressure is under the above value check engine rotation speed during the test If under 450 rpm check starting system If engine rotation speed is right or just over the optimal value check timing system Ensure that gask...

Page 110: ...stable flash or rpm reading increase resis tive load on spark plug power line Remove the plastic plug from the flywheel cover slot Turn lamp flash control and match the flywheel cover mark with the water pump drive level Read advance degrees shown by the strobe lamp Check the correspondence between advance degrees and rev speed as shown in the tables In case of problems check Pick up and CPU power...

Page 111: ...M282M M281M 3 6 7 INTAKE MANIFOLD DISASSEMBLY Open the clamps and disconnect the carburettor cool ing circuit pipes Open the clamps disconnect the petrol drainpipe from the bowl and remove the carburettor Unscrew and remove the induction manifold ...

Page 112: ...ENGINE 3 88 Engines M192M M191M M245M M234M M282M M281M 3 6 8 REMOVING THE THERMOSTAT Loosen the screws and remove thermostat cover Remove thermostat with seal ...

Page 113: ...rocket oil sump with spring and by pass piston oil pump pulley cover crankshaft O ring and washer between sprockets Remove tappet cover Loosen tensioner center screw Remove the two fasteners Remove tensioner and seal ENGINES M245M M281M 125 cc Remove side screw 1 and center screw 2 Slide out washers 3 and 4 ENGINES M234M M282M 200 cc Remove screw and valve lifter holder ...

Page 114: ...eight Remove camshaft drive pulley and washer Remove screw spacer and tensioner sliding shoe Remove driving sprocket 17 and timing chain 18 NOTE Before disassembly mark chain so that it can be refit ted in its original direction of rotation To remove tensioner sliding shoe work on the transmission side To remove lower chain guide sliding shoe first disassemble the head ...

Page 115: ...1 Engines M192M M191M M245M M234M M282M M281M 3 6 10 CAMSHAFT AND ROCKER ARMS DISASSEM BLY Remove the two screws and the camshaft bracket Remove camshaft Working from flywheel side remove pinions and rocker arms ...

Page 116: ...emove the two side fasteners Working crossways loosen cylinder head fastening nuts Loosen in two or three steps Remove the head the piston rings the two centering dowels and gasket NOTE If needed head can be removed with camshaft rocker arm shafts and fastening bracket It can also be re moved without disassembling the chain and drive shaft chain tensioner ...

Page 117: ...92M M191M M245M M234M M282M M281M 3 6 12 VALVES DISASSEMBLY Use the special tool with adapter to remove valve cot ter washers springs and valves WARNING Arrange valves so as to indicate their original positioning on the head ...

Page 118: ... the clamps and detach the cooling sleeve Slide out cylinder WARNING Support the piston so as not to damage it Remove cylinder base gasket and centering dowels Protect the crankshaft seat before removing Remove the two snap rings gudgeon pin and piston Remove the two piston rings from piston NOTE During disassembly take care not to damage piston rings ...

Page 119: ... END Using an inside micrometer gauge check con rod small end diameter Standard diameter 15 015 15 025 mm Max allowed diameter 15 030 mm NOTE Should con rod small end diameter be above the specified limits be worn or overheated change crankshaft as described in Crankcase and crankshaft ...

Page 120: ...geon pin piston clearance Standard clearance 0 001 0 010 mm NOTE Gudgeon pin seats have lubrication ducts Take di ameter reading along piston axis Measure piston outer diameter B1 and B2 at right an gles to the gudgeon pin axis Take reading in the position shown in the figure C1 Engines M245M M281M 125 cc 41 1 mm from piston crown C1 Engine M192M M191M 125 150 cc 36 5 mm from piston crown C2 Engin...

Page 121: ...ce mating with head is not worn or out of shape Max permitted misalignment 0 05 mm Pistons and cylinders are classified by diameter cate gories Couples cylinders with pistons from the same category A A B B C C D D Cylinders can be ground to the original angle Cylinder surface roughness must be 0 9 micron This ensures correct piston ring bedding reduced oil consumption and top performance Engines M...

Page 122: ...or the 200 cc engine measure the clearance by in serting the feeler gauge from the 2nd piston ring side Standard coupling clearance Max allowed clearance after use 1 st piston ring 0 025 0 07 mm 0 08 mm 2 nd piston ring 0 015 0 06 mm 0 07 mm Engines M192M M245M M281M M191M 125 150 cc Scraper ring 0 015 0 06 mm 0 07 mm 1 st piston ring 0 015 0 06 mm 0 07 mm 2nd piston ring 0 015 0 06 mm 0 07 mm Eng...

Page 123: ...rings Standard opening Max value 1 st piston ring 0 20 0 40 mm 1 mm 2 nd piston ring 0 10 0 30 mm 1 mm Engines M192M M245M M281M M234M M282M 125 200 cc Scraper ring 0 15 0 35 mm 1 mm 1 st piston ring 0 15 0 30 mm 0 40 mm 2nd piston ring 0 20 0 40 mm 0 40 mm Engine M191M 150 cc Scraper ring 0 20 0 40 mm 0 50 mm NOTE Before changing only piston rings make sure that the rings piston groove and piston...

Page 124: ...NG PISTON Fit piston and gudgeon pin to on rod by setting the po sition piston with the arrow facing the exhaust side Protect the crankshaft sent Install snap ring on piston Fit a ring on each side WARNING Be careful not to score or damage ring seats or piston inner surface ...

Page 125: ...easure piston drawback Use the table below to determine the thickness of the cylinder bottom gasket to be used at reassembly and thus ensure the correct compression Remove special tool and cylinder Note The standout is measured on the 125 cc engine the drawback on the 200 cc engine Measured standout Gasket thickness 2 25 2 35 mm 0 4 0 05 mm 2 35 2 55 mm 0 6 0 05 mm Engines M192M M245M M281M 125 cc...

Page 126: ... face the piston crown Fit 2 nd ring with its identification mark or the word top facing the piston crown The working step must be op posite the piston crown Fit the 1st ring with its identification mark or the word top facing the piston crown NOTE The surface of the two rings mating the cylinder is ta pered to ensure better settling Stagger the ring openings at 120 Lubricate with engine oil On th...

Page 127: ...on duct and oil the cylinder liner Fit the centering dowels Install cylinder base gasket according to the previously calculated thickness Take the following tools Engines M245M M281M 125 cc 8140658 Engines M234M M282M 200 cc 8140660 Use the piston ring tool to fit the cylinder Connect and clamp the cooling sleeves ...

Page 128: ...e is not worn or out of shape Max misalignment allowed 0 05 mm Check camshaft and rocker arm shaft thrust surfaces for wear Check head cover intake manifold and exhaust mani fold surfaces for wear Standard diameter A 12 000 12 018 B 20 000 20 021 C Engines M192M M245M M281M M234M M282M 125 200 cc 37 000 37 025 C Engine M191M 150 cc 32 500 32 525 ...

Page 129: ...sembling position RH LH Sealing surface depth Engines M245M M281M M234M M282M 125 200 cc L Standard Intake and exhaust 0 99 1 27 mm L After use Intake and exhaust 1 6 mm Sealing surface depth Engines M192M M191M 125 150 cc L Intake 3 1 mm L Exhaust 3 mm In case valve sealing surface is wider that the recom mended limit interrupted in one or more points or bent change valve ...

Page 130: ...e D Standard diameter 5 000 5 012 mm D Allowed limit 5 022 Intake valve guide D Standard diameter 5 000 5 012 mm D Allowed limit 5 022 If the valve seat mark depth values or the valve guide diameter are above the specified limits change the head Checking valves Check valve stem diameter d D in the three points shown in the figure Standard diameter D1 D2 and D3 Intake 4 972 4 987 mm d1 d2 and d3 Ex...

Page 131: ...5 200 cc Exhaust 94 4 mm l Engine M191M 150 cc Exhaust 79 6 mm If after the above checks all the values are within the specified limits use the same valves To ensure per fect sealing grind valves with fine emery cloth When grinding position the head with the valve axes in hori zontal position to prevent emery cloth residues from entering the valve guide stem coupling see figure WARNING To avoid sc...

Page 132: ... M282M M281M 3 6 25 CHECKING VALVE SEALING Install valves into head Alternatively test intake and exhaust valves To carry out this test fill manifold with fuel and check that head does not leak at the valves keep valves pressed with your fingers ...

Page 133: ...ENGINE 3 109 Engines M192M M191M M245M M234M M282M M281M 3 6 26 CHECKING COLLETS AND SPRING PLATES Check that springs upper bearing plates 1 and collets 2 are not excessively worn ...

Page 134: ... 27 ASSEMBLING VALVES Install valves springs and plates Use the special tool with adapter to compress springs and install cotters into seats NOTE Do not confuse valve assembling position Fit valve springs with the reference color facing the cotters longer turns ...

Page 135: ...ssively worn Check that camshaft drive belt roller chain unit and sprocket are not worn In case of wear change the parts If chain sprocket and belt rollers are worn change the whole unit Remove center screw with washer and tensioner spring Make sure that the one way mechanism is not worn Check tensioner spring In case of wear change the whole unit Use the stop to check the travel of the tensioner ...

Page 136: ...92M M245M M281M M234M M282M 125 200 cc Intake 30 285 mm D Engines M192M M245M M281M M234M M282M 125 200 cc Exhaust 29 209 mm C and D Engine M191M 150 cc Intake and Exhaust 27 8 mm Check rocker arm pins for wear and scoring and measure their diameter E Engines M192M M245M M281M M234M M282M 125 200 cc Standard diameter Ø 11 977 11 985 mm E Engine M191M 150 cc Min allowed Ø 11 970 mm Check that the s...

Page 137: ...1M Check that the cam and the rubber stop on holding guard are not worn Check that the automatic valve lifter end of travel roller and counterweight for signs of wear Check that the valve lifter spring has not yielded In case of wear change the worn parts ...

Page 138: ...g rings Fit the chain guide sliding shoe NOTE Before assembling the head make sure that the lubri cation duct is perfectly clean Blow with compressed air Mount the cylinder head Tighten the timing chain side nuts and bolts crosswise to the specified torque values in a 2 or 3 steps TIGHTENING TORQUE VALUES Nuts 28 30 Nm Screws 11 13 Nm Connect the SAS pipe to the head with a new gasket Tighten the ...

Page 139: ...acket and tighten the screws to the speci fied torque value TIGHTENING TORQUE VALUES Screw 4 6 Nm Turn the flywheel to bring its reference mark in line with the TDE on the crankcase MOT125_I Fit the timing chain in the turning direction indicated when disassembling and the drive pinion Fit the tensioner shoe and spacer and tighten the screw to the specified torque value TIGHTENING TORQUE VALUES Sc...

Page 140: ... end of travel washer and restrain the return spring Fit the valve lifter holder and tighten its screw to the specified torque value TIGHTENING TORQUE VALUES Screw 11 15 Nm ENGINES M245M M281M 125 CC Install the two washers Insert and tighten the side screw and centre screw Remove the centre screw washer and tensioner spring and check one way mechanism for wear Check the soundness of the spring In...

Page 141: ...entre screw to the specified torque value TIGHTENING TORQUE VALUES Screw 5 6 Nm Mount the tappet cover Fit the pinions separation washer and O ring on the crankshaft the oil pump pulley cover the sump with spring and by pass piston the starting pinion the driv ing pulley and belt and the transmission cover ...

Page 142: ...T Position thermostat with the bleed hole in the highest position Make sure that rubber seal is correctly positioned Fit thermostat cover with the union for carburetor heat ing tube facing the flywheel Tighten the screws to the specified torque values TIGHTENING TORQUE VALUES Screws 3 4 Nm ...

Page 143: ...34M M282M M281M 3 6 33 ASSEMBLING THE INDUCTION MANIFOLD Fit manifold and tighten its three bolts Fit the carburettor connect the petrol drainpipe to the bowl and clamp the carburetor Connect the carburetor cooling circuit pipes and clamp them ...

Page 144: ... exhaust duct The unit indicated with an arrow in the figure is equipped with a cut off connected to the vacuum port of the intake manifold to cut air infeed during deceleration so as to avoid any burst inside muffler System description Air is sucked through hole 1 and then it passes through the first filter 2 and hole 3 under rubber gasket Through the hole indicated in the figure air reaches the ...

Page 145: ... M245M M234M M282M M281M Through a rigid flanged duct connected to the head air reaches the exhaust connector so as to release oxygen to the unburnt gases before the catalyzer by thus favoring a better reaction of this last component ...

Page 146: ...amage to the rubber hose between this device and the head tube Change device and hose Disassembling the secon dary air device No rubber seal on the first filter Install the missing seal The vacuum port tube from the secondary air device is disconnected or cracked Change tube Bursts at the muffler when throttle control is released Cut off valve on secondary air device Change secondary air de vice D...

Page 147: ...UPDATING ENGINES M192M M191M 4 1 Engines M192M M191M UPDATING ENGINES M192M M191M 4 ...

Page 148: ...BRAKE LEVER AND CAM 11 4 2 8 REAR HUB 12 4 2 9 REMOVING THE WHEEL SHAFT 13 4 2 10 ASSEMBLY OF THE HUB GEARS 14 4 2 11 REASSEMBLY OF HUB COVER 15 4 2 12 ASSEMBLY OF THE BRAKE LEVER AND CAM 16 4 2 13 ASSEMBLY OF THE BRAKE SHOES 17 4 2 14 DISASSEMBLY OF THE FAN MUFF 18 4 2 15 DISASSEMBLY OF THE FAN MUFF 19 4 2 16 CHECKING THE TIMING SYSTEM 20 4 2 17 DISASSEMBLY OF THE TIMING GEAR 21 4 2 18 DISASSEMBL...

Page 149: ...em Petrol minimum 95 octane unleaded carburettor with vacuum pump Cooling Forced air Max power output 6 5 kw a 7500 rpm Spark advance By microprocessor from 10 1 at 1650 rpm to 26 1 at 6000 rpm Plug Champion RG6YC NGK CR7EB Transmission Automatic variator with expandable pulleys Vee belt automatic clutch reduction gear transmission housing with forced circulation cooling Valve clearances cold Inta...

Page 150: ...etrol minimum 95 octane unleaded carburettor with vacuum pump Cooling Forced air Max power output 9 kw a 7500 rpm Spark advance By microprocessor from 10 1 at 1650 rpm to 26 1 at 6000 rpm Plug Champion RG 4 HC Transmission Automatic variator with expandable pulleys Vee belt automatic clutch reduction gear transmission housing with forced circulation cooling Valve clearances cold Intake 0 10 mm Exh...

Page 151: ...UPDATING ENGINES M192M M191M 4 5 Engines M192M M191M 4 2 ENGINE 4 2 1 KICK START COVER Unscrew the starter sector gear housing attach ment bolts ...

Page 152: ...2 2 DIASSEMBLY OF SECTOR GEAR AND PINION Press the drive lever to remove the starter pinion Unscrew the kick start bolt and remove the lever Remove the circlip and washer Slide off the sector gear WARNING The sector gear loads the spring Prevent acci dents ...

Page 153: ...ce the sector gear and load the spring with the specific tool Spring compression tool 8140264 Refit the washer and circlip and tighten the kick start lever to the specified torque value TIGHTENING TORQUE VALUES Bolt 12 13 Nm 1 2 1 3 kgm Use the lever to load the spring and insert the pinion Refit the kick start cover and tighten its attachment bolts ...

Page 154: ...the specific tool Universal clutch tool 8140259 Insert the lever pin in one hole of the clutch Remove the nut open the tool and remove the clutch spring and driven pulley assembly WARNING The tool must be firmly held in the vice with the middle screw in contact with it Over tightening will damage the tool ...

Page 155: ...OF THE CLUTCH Assemble the spring clutch and driven pulley Mount the clutch on the specific tool Universal clutch tool 8140259 Insert the lever pin in one hole of the clutch Tighten the nut to the specified torque value TIGHTENING TORQUE VALUES Nut 55 60 Nm 5 5 6 0 kgm ...

Page 156: ...UPDATING ENGINES M192M M191M 4 10 Engines M192M M191M 4 2 6 DISASSEMBLY REAR BRAKE SHOES GA NASCE Turn one of the two rear brake shoes to remove them both ...

Page 157: ...UPDATING ENGINES M192M M191M 4 11 Engines M192M M191M 4 2 7 DISASSEMBLY OF THE BRAKE LEVER AND CAM Remove the rear brake shoes Unscrew the attachment holt extract the cam and re move the linkage ...

Page 158: ...B Remove the dipstick Drain the hub oil through the drain hole Remove the rear brake shoes Unscrew the attachment bolt extract the cam and re move the linkage Remove the rubber plug Unscrew the attachment bolts Remove the hub cover complete with wheel shaft and gasket ...

Page 159: ...UPDATING ENGINES M192M M191M 4 13 Engines M192M M191M 4 2 9 REMOVING THE WHEEL SHAFT Remove the driven pulley shaft Remove the idler gear Remove the shaft complete with gear ...

Page 160: ...UPDATING ENGINES M192M M191M 4 14 Engines M192M M191M 4 2 10 ASSEMBLY OF THE HUB GEARS Refit the wheel shaft complete with gear Refit the idler gear Refit the driven pulley shaft ...

Page 161: ... OF HUB COVER Fit a new gasket on the hub cover centring dowels Refit the cover Make sure the vent hole is properly po sitioned Insert the screws and the two vent pipe support plates Tighten the screws to the specified torque values TIGHTENING TORQUE VALUES Screws 24 27 Nm ...

Page 162: ...and rear brake stem for signs of wear If necessary change the cam Mount two new O rings and lubricate them with Fiat Z2 grease Assemble the cam and the lever on the engine casing Use the double tooth to align the two profiles Tighten the screw to the specified torque value TIGHTENING TORQUE VALUES Screw 11 13 Nm ...

Page 163: ... 1 mm Check the cam and pinion supports for signs of wear Make sure the springs are not worn or damaged If necessary change the shoes Mount the shoes and springs NOTE If the rear brake is noisy check that the shoes are properly supported on the pinion For the same reason the springs may become curved and rest on the supports on the hub cover ...

Page 164: ...UPDATING ENGINES M192M M191M 4 18 Engines M192M M191M 4 2 14 DISASSEMBLY OF THE FAN MUFF Remove the attachment screws Remove the muff by slipping off the connector lodged inside it ...

Page 165: ...UPDATING ENGINES M192M M191M 4 19 Engines M192M M191M 4 2 15 DISASSEMBLY OF THE FAN MUFF Remove the attachment screws Remove the muff by slipping off the connector lodged inside it ...

Page 166: ...16 CHECKING THE TIMING SYSTEM Turn the flywheel to align the case mark with the TDC mark Ensure that the 2V mark on the camshaft pulley is in line with the mark on the head If the mark on the cam shaft is opposite the mark on the head turn the drive shaft once ...

Page 167: ... cover the O ring on the drive shaft and the washer between the sprockets Remove the tappets cover Unscrew the bolts and take off the cylinder guard Slacken the central bolt of the tensioner Remove the attachments Remove the tightener with its gasket Remove the screw and valve lifter holder Remove the automatic valve lifter return spring and the valve lifter with its stop washer Remove the inside ...

Page 168: ... the screw spacer and tensioner shoe Remove the chain and the sprocket NOTE It is advisable to mark the chain to ensure that its original turning direction is maintained The tensioner shoe must be removed from the transmission side The lower chain guide shoe can only be removed after the head is dis assembled ...

Page 169: ...gines M192M M191M 4 2 18 DISASSEMBLY OF THE CAMSHAFT AND ROCKER ARMS Remove the two bolts and the camshaft attachment bracket Remove the camshaft Remove the pinion and rocker arms through the hole on the flywheel side Save the metal ring ...

Page 170: ...fasteners Working crossways loosen cylinder head fastening nuts Loosen in two or three steps Remove the head the two centering dowels and gas ket NOTE If needed head can be removed with camshaft rocker arm shafts and fastening bracket It can also be re moved without disassembling the chain and drive shaft chain tensioner ...

Page 171: ...ain sliding shoe Slide out cylinder WARNING Support the piston so as not to damage it Remove cylinder base gasket and centering dowels Protect the crankshaft seat before removing Remove the two snap rings gudgeon pin and piston Remove the two piston rings from piston NOTE During disassembly take care not to damage piston rings ...

Page 172: ... PISTON Fit piston and gudgeon pin to on rod by setting the po sition piston with the arrow facing the exhaust side Protect the crankshaft sent Install snap ring on piston Fit a ring on each side WARNING Be careful not to score or damage ring seats or piston inner surface ...

Page 173: ...low through the lubrication duct and oil the cylinder liner Fit the centring dowels Install cylinder base gasket according to the previously calculated thickness Take the following tools Engine M192M 125 cc 8140658 Engine M191M 150 cc 8140660 Use the piston ring tool to fit the cylinder ...

Page 174: ...LTO facing the cylinder head Fit the chain guide sliding shoe NOTE Before assembling the head make sure that the lubri cation duct is perfectly clean Blow with compressed air Mount the cylinder head Tighten the timing chain side nuts and bolts crosswise to the specified torque values in a 2 or 3 steps TIGHTENING TORQUE VALUES Nuts 28 30 Nm Screws 11 13 Nm ...

Page 175: ...e camshaft attachment bracket and tighten the bolts to the specified torque value TIGHTENING TORQUE VALUE Screws 4 6 Nm Turn the flywheel to align the case mark with the TDC mark Mount the timing chain in the turning direction marked during the disassembly together with the drive pinion Mount the tightener shoe and spacer and tighten the attachment screw to the specified torque value TIGHTENING TO...

Page 176: ...NG TORQUE VALUE Screw 11 15 Nm Remove the central screw with the washer and tight ener spring Check the one way mechanism for signs of wear Check the soundness of the tightener spring If necessary change the entire unit Press the locking tooth and bring the tightener block fully home Mount a new gasket and the chain stretcher Tighten the attachment screws to the specified torque value TIGHTENING T...

Page 177: ...UPDATING ENGINES M192M M191M 4 31 Engines M192M M191M ...

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