Beta Enduro RR 350 2015 Page 119 Workshop Manual Download

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117

E ASS

LY AN

D CO

NTRO

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

facing the flat part

downwards. Lubricate the upper part of the

valve guide lightly and insert the valve stem

seal

. 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.

* Remember the valve stem seals must be replaced once they

have been taken off.

Insertion of lower cup.

Insertion of valve stem seal.

Summary of Contents for Enduro RR 350 2015

Page 1: ......

Page 2: ...ANKSHAFT 45 2 11 2 OPENING CRANKCASE 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 51 2 12 2 1 INNER OIL FILTER 52 2 12 2 2 EXTRACTION OF DESMODROMIC DEVICE BEARING 52 3 ENGINE ASSE...

Page 3: ...Y 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 112 3 17 4 3 VALVE STEM SEAL AND LOWER STOP WASHER 114 3 17 5 CYLINDER HEAD CHECKING CYLINDER HEAD BODY 114 3 1...

Page 4: ...ut of the reach of children 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 p...

Page 5: ...d it can spurt out violently and cause burns Coolant contains dangerous substances which are harmful for the environment When chan ging 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 th...

Page 6: ... TRANSMISSION RR 350 RR390 RR430 RR480 Primary transmission 28 76 28 76 31 73 31 73 1st gear ratio 12 31 12 31 12 31 12 31 2nd gear ratio 15 28 15 28 15 28 15 28 3rd gear ratio 19 28 19 28 19 28 19 28 4th gear ratio 20 24 20 24 20 24 20 24 5th gear ratio 27 27 27 27 27 27 27 27 6th gear ratio 28 24 28 24 28 24 28 24 SECONDARY TRANSMISSION CHAIN Carburettor RR390 RR430 RR480 Carburettor type Keihin...

Page 7: ...pecial 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 0...

Page 8: ...OM THE VEHICLE Remove the screw 2 to empty the motor oil Remo ve the screw 3 to empty the gear oil ATTENTION Used oil contains dangerous substan ces 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 2 3 Remove the exhaust pipe and the silencer Drain the cooling system through scr...

Page 9: ...mplete ly 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 In the injection versions disconnect the petrol tube by pressing the special button of quick coupling 8 Lift the tank 8 ...

Page 10: ...HE ENGINE FROM THE VEHICLE Disconnect the water hoses from the engine and from the right radiator Remove the left radiator with pipes Disconnect electric connectors 9 and 10 Remove the tank along with the sides 9 10 ...

Page 11: ...s electric system to the clutch pipe and to the frame Disconnect the engine ventilation pipes Disconnect the connectors indicated in the figure Remove the start motor cable fixing nut Electric connectors to disconnect in the carburettor ver sions Electric connectors to disconnect in the injection ver sions ...

Page 12: ...M THE VEHICLE Loosen the carburettor throttle body straps from the air filter sleeve and from the manifold Remove the screw of the carburettor throttle body 12 cover and the cover itself Disconnect rear stop connector 13 12 12 13 ...

Page 13: ...M THE VEHICLE Disconnect the electric connectors indicated in the figure relative to the carburettor throttle body Loosen the adjustment nuts and release the gas cables Carburettor version gas cables Injection versions gas cables ...

Page 14: ...ing the clutch actuator to the crankcase half 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 17 16 ATTENTION Do not activate the clutch lever with actuator decoupled from engine Remove the head connections ...

Page 15: ...E ENGINE FROM THE VEHICLE Release and remove the brake pedal return spring 18 Remove the kickstarter lever 18 Remove the seat rail lower fixing screws 19 one each side and loosen the upper screws 20 one each side 19 20 ...

Page 16: ...1 14 REMOVING THE ENGINE FROM THE VEHICLE Remove the carburetor to the gas cable Remove the carburettor or throttle body based on the specific version Remove upper shock absorber pin 21 21 ...

Page 17: ...e the swingarm pin 22 Move the complete swing arm unit towards the rear Remove the engine pins 23 Extract the engine from the frame and apply it to the specific stand code 3625132 000 using speci fic front fixing bracket code 006140140 000 22 23 23 ...

Page 18: ...nder head cover 2 and the four gaskets 3 2 1 THERMAL UNIT 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 Remove the 4 screws 1 the cylinder head cover 2 as well as the 4 screw gaskets 3 Remove the spark plug gasket 4 and the cover ga sket 5 ...

Page 19: ...t posi tion and at the same time turn the shaft blocking screw 6 by hand until it engages in the seat present on the crankshaft preven ting the crankshaft from turning In this way the crankshaft is blocked by me ans of the screw 6 at the Top Dead Centre TDC and now all the organs can be disas sembled Remove the crankshaft blocking screw 6 remove the copper washer 7 and put the screw or tool 006140...

Page 20: ...incorrect and premature wear of the support bea rings of the camshafts The engine is equipped with a hydraulic tensioner in order to provide the chain with proper tensio ning 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 1 3 2 4 Cap and spring removal T...

Page 21: ... blue in the figure and then the inner ones Remove the chain guide 3 Attention disassemble the camshafts only after having disassembled the hydraulic ten sioner 2 A 2 3 4 1 5 Uncoupling camshaft support 4 from cylinder head Two centring pins 4 and spark plug housing O ring 5 Using a plastic rod A or something similar le ver the head surface and the camshaft support 2 in order to lift it and remove...

Page 22: ...move the camshaf ts In order to remove the exhaust camshaft 4 repeat the operations described for removal of the intake camshaft ATTENTION make sure the chain does not fall insi de the compartment dedicated to it For this purpo se it is recommended to interpose a plastic rod or the likes A between the chain and the head 2 1 3 3 A 4 Removal of intake camshaft 1 bearing 2 Camshafts G intake H exhaus...

Page 23: ... head com partment Then remove the respective washers 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 disas sembly With the cylinder head lifted a few centime tres drop the chain inside the compartment and pull out the head ATTENTION should the chain fall inside pla ce it in tension before lifting the head ATTENTION d...

Page 24: ... DISASSEMBLY Cylinder head elements 1 M6x80 screw 2 M10x1 25 cylinder head screws 3 Complete cylinder head 4 Cylinder head gasket 5 Centring bushes Remove the head gasket 4 and the two centring bushes 5 3 2 1 4 5 ...

Page 25: ...ool 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 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 ...

Page 26: ...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 Remove the nine screws 3 which fasten the flywhe el cover 4 to the left crankcase half Remove the flywheel cover and the gasket placed between the casing and the cover Bottom view of piston 5 elastic ring 4 and pin bolt 6 Removal of gear lever ...

Page 27: ...tention to the special elastic washer 8 shown in the following images placed between the nut and the flywheel Two centring pins 5 dedicated to the flywheel cover injection version Nut 6 which fastens flywheel 7 to the crankshaft car burettor version Two centring pins 5 dedicated to the flywheel cover carburettor version Nut 6 which fastens flywheel 7 to the crankshaft injection version 6 6 7 7 5 5...

Page 28: ... elastic washer 8 and the tightening nut 6 8 7B 7A 6 To remove the flywheel screw the relevant extrac tor A code 3625173 onto the threaded segment on the flywheel and using a box spanner tighten the screw on the extractor Starter flywheel removal injection version with spe cial gear puller A Starter flywheel removal carburettor version with special gear puller A A A ...

Page 29: ...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 Extract the two pads pulling them towards the top part of the engine Fixing screws 1 of mobile 2 and fixed pad 3 Extraction of chain guides ...

Page 30: ...ile 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 ti ming chain 1 2 8 3 4 6 5 7 Chain guard and oil jet Removal of timing chain 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 ...

Page 31: ... be disassembled by re moving the two fixing screws 2 2 3 PINION AND SPACER In order to remove the pinion 1 loosen the screw completely 2 and take off the washer 3 After removing the pinion pull off the spacer 4 2 1 3 2 1 4 Two screws 2 for fixing pick up 1 Pinion 1 screw 2 and washer 3 Pinion spacer 3 ...

Page 32: ...g 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 1 4 3 6 5 2 Outer clutch cover 1 and respective screws 2 Inner clutch cover 3 and respective screws 4 Pump cover 5 and respective screws 6 ...

Page 33: ... 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 actua tor and the crankcase half Extract the clutch control rod 9 A 7 8 9 Two centring pins A for cover coupling Inner clutch Hydraulic actuator 7 and three screws 8 coupling it to crankcase half Extraction of clutch rod 9 ...

Page 34: ... plate unit 12 and the clutch disc pack 13 Remove special driven disc and the disc spring as sembly 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 10 11 13 12 14 15 Removal of disc spring assembly Clutch cap 11 and four screws 10 Pressure plate unit 12 and clutch disc pack 13 Opening safety washer with chisel ...

Page 35: ... safety wa sher 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 A 22 18 21 16 14 19 20 15 17 Removal of inner hub nut with relevant tool G 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 ...

Page 36: ... a low pressure pump or recovery 9 with hi gher 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 betwe en the external casing on the ignition unit side and the crank mechanism compartment 6 5 3 9 8 1 11 2 ENGINE LUBRIC...

Page 37: ...RESSURE OIL PUMP The high pressure pump located in the exter nal right hand side crankcase is enclosed un der 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 3 5 6 4 1 1 2 5 4 3 Gear unit for oil pump control 1 Gear meshing with clutch gear 2 Idler wheel 3 Oil pumps c...

Page 38: ...rtment They are enclosed under the cover 1 which removed by ex tracting the three screws 2 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 1 2 3 6 5 4 7 6 8 Cover and screws of low pressure pump Internal rotor 6 roller 7 and drive shaft 8 Low pressure oil pump and by pass...

Page 39: ...ny shavings In order to disassemble the valve remove the screw pull out the washer the spring and the ball 2 5 5 PAPER OIL FILTER In order to extract the paper oil filter remove the cover 1 by loosening the two screws 2 com pletely 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...

Page 40: ... 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 Exploded view of countershaft 1 Shaf...

Page 41: ...nstrument ATTENTION The nut 1 must be turned clockwise to be un screwed Extract the primary gear using the relevant extrac tor A code 006140150000 Notice that the primary gear houses the free wheel device 2 inside of it which can be removed by taking out the circlip 3 A 1 2 3 2 1 Extraction of primary gear with appropriate extractor A Primary gear 1 complete with free wheel 2 and spe cific circlip...

Page 42: ...he 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 EXPLODED VIEW OF ELECTRICAL STARTER 1 Start motor 4 Torque limiter 7 Idler wheel 9 Ignition gear 10 Roller bearing...

Page 43: ...start gear is pulled out by hand 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 re move the circlip 11 and pull the gear off 11 8 5 1 6 6 7 9 10 12 Screws 4 fixing start motor to crankcase Removal of pin 6 Torque limiter 8 s...

Page 44: ... meshes with the clutch gear The device moves back thanks to the spring 4 Remove the external circlip 5 and pull off the exter nal thrust washer 6 the idler gear 3 the internal thrust washer 7 and the second circlip 8 The cir clips and thrust washers are interchangeable 1 4 2 3 3 6 5 5 6 8 7 Kickstarter mechanism Removal of circlip 5 of idler gear 3 Two circlips 5 and 8 and thrust washers 6 and 7 ...

Page 45: ...o a rest position having it turn anti clockwise Turn the shaft anti clockwise and pull it off to gether with the sleeve 9 the spring 10 and the thrust washer 11 Note Be careful of the reference pins for cen tring the inner clutch cover par 1 4 Releasing spring from crankcase Extraction of shaft from crankcase Complete manual kickstart shaft ...

Page 46: ...rn spring 3 pressed and ex tract the shaft together with specific washer 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 de smodromic device Bring the return spring 8 to the rest position...

Page 47: ...T 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 2 1 A Nut B blocking crankshaft Removal of crankshaft nut...

Page 48: ...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 Screws 2 for blocking right side casing 1 2 ...

Page 49: ...e gearbox unit and the crankshaft must remain inside the right crankcase half Remove the back 4 and front reference bushes 5 to position the crankcase correctly Remove the gasket between the two crankcase halves Loosen the two screws A which fasten the engi ne to the support stand A 2 3 4 5 Two screws A blocking engine to engine support stand Detaching crankcase halves The left crankcase half insi...

Page 50: ...ding 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 desmodro mic control Do the same operation though in the o...

Page 51: ...Make sure the circlip on the secondary shaft has been removed par 1 9 Proceed to extract the complete gearbox unit including the primary 6 and secondary unit 7 Circlip removal 5 6 7 Extraction of forks from gearbox unit Extraction of complete gearbox unit 6 primary unit 7 Secondary unit ...

Page 52: ...the safety devices must be disassembled as well 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 beari...

Page 53: ...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 gear box They can be disassembled by removing the two screws 2 The plate 3 is the one relative to the bearing which supports the countershaft It can be di sassembled by removing the screw 4 For checking and cleaning part of the lubrication circuit it is adv...

Page 54: ...l 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 1 A B Disassembly of inner fil...

Page 55: ... rotation It is however recommended to refer to the pe riodical maintenance table In order to insert the bearings in the crankcase halves bring the crankcase hal ves to a temperature of 150 C and keep them at that temperature for 20 minutes Place the crankcase halves on a large sur face where their whole seal surface can rest When the bearings cool off they drop into their seats on their own 3 ENG...

Page 56: ...ng they undergo when being di sassembled 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 EXPLODED VIEW OF ENGINE CRANKCASE HALF 1 Complete engine block 4 Crankcase gasket 5 Back reference bush 6 Fro...

Page 57: ...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 4 6 2 1 5 3 6Nm 10Nm 6Nm 7 Elements present on outside right crankcase half Screw number Screw dimensions Threadlocker application Tightening torque Nm Threading diameter mm Threading length mm 5 M5 10 Loctite 243 Sic...

Page 58: ... torque li miter show traces of abnormal wear or meshing Keeping the tightener on the lever 25 facing to wards 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 who se threading must be spread with medium streng...

Page 59: ... the oil seal and bearing housing Insert the new oil seal 1 greasing the inside of it Apply the new bearing 2 paying close atten tion that it is aligned in its seat Use a press or similar instrument to push the bearing until the outside surface is flush with the surface A 1 2 A Application of oil seal 1 Insertion of bearing 2 Oil seal and bearing unit coupled to the left crankca se half ...

Page 60: ...ns for application of the fixing screws of these plates and for fixing the desmodromic device support bearing Insert the two reference bushes A and B in their respective housings Elements present on outside right crankcase half Screw number Screw dimensions Threadlocker application Tightening torque Nm Threading diameter Threading length 5 M6 12 Loctite 243 Sichel 100M 8 6 M6 12 Loctite 243 Sichel...

Page 61: ...e 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 re place it The table below carries the indications for ap plication of the screw for the plate 3 The crankcase half will definitely have to be re placed if the oil pump crankcase B has deep scratch...

Page 62: ... qualora dovessero risultare de formate 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 Ap ply screw 6 after application of medium resistance threadl...

Page 63: ...shaft bearings Allowed limited 0 03mm Check the axial play between the connecting rod head and the half shafts Recommended play 0 42 0 65mm 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 ...

Page 64: ... 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 Half shaft and crank lever pin bolt references C Crankshaft oil passages 64mm 0 05 350cc 390cc 65mm 0 05 430cc 480cc Make sure that the chain control gear is free of chipping or signs of abnormal wear Replace the cranksha...

Page 65: ...g rod 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 repla ced 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...

Page 66: ...ected must not exceed the service limit indica ted 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 secon dary shafts are free of abnormal wear or signs of seizure The sides of the teeth are free from chipping or a...

Page 67: ...th 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 In...

Page 68: ...ry shaft 20 using protective jaws so that the grooved end faces downwards 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 t...

Page 69: ...ift is made up of two forks 13 which drive two gears on the se condary unit one fork 14 which drives one gear on the pri mary unit three drive pin bushes 15 two fork pins 16 desmodromic gearshift 18 through whose ro tation the forks are driven thus selecting the desired gear Check to make sure that the drive pins which support the bushes 15 have no traces of meshing or abnormal wear and that the b...

Page 70: ...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 p...

Page 71: ... Remember to oil the gears abundantly with gear oil and to grease the shaf ts supporting them in the areas where they are coupled with the bearing with graphitic grease Make sure that all the parts slide properly Insert the centre bearing 3 and the O ring 4 on the secondary unit Insertion of gearbox in left crankcase Detail of centre bearing 3 and O ring 4 coupled to the secondary shaft 4 3 2 1 3 ...

Page 72: ...it is recommended to repo sition the forks in their original positions Insert the desmodromic device in the specific bea ring In order to do this it is necessary to rotate cam stop lever 7 towards the bottom part of the engine 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 ...

Page 73: ... first in the pins and then in its proper seat Remember to oil the shafts forks and the de smodromic device abundantly with gear oil Position the new crankcase gasket Positioning of the secondary unit forks 6 in the external guides of desmodromic device 8 View inside the right crankcase with crankshaft oil jets gearbox shafts complete with gearwheels internal gearshift and gasket 8 6 6 ...

Page 74: ...hem Rather loosen the screws and reposition the crankcase correctly Make sure that the two crankcase halves match per fectly one with the other Assemble the screws ac cording 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 e...

Page 75: ...rankshaft 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 Spread the threading on the left hand side of the crankshaft with medium strength th readlocker Tighten the nut using the special socke...

Page 76: ...rmal wear or meshing the gearshift drive shaft needs more in depth inspections 3 8 1 CHECKING THE COMPLETE DRIVE SHAFT With the device complete make sure that the di stance between the movable pawl and the drive shaft is between 0 35 0 80mm Should the distance be greater replace the mova ble pawl In order to replace the movable pawl 1 disassem ble the return spring of the gearshift 2 the spring gu...

Page 77: ...t note the positioning of the gearshift return spring 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 gui de 7 the gearshift return spring 6 and finally the 14x30x1 thrust washer 5 The gearshift return spring must be positio ned as in the figure to be able to carry out its...

Page 78: ...turn spring 4 of the movable pawl pressed Wishing to test the correct functioning of the entire unit you just need to temporarily couple the exter nal 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 ro tate The whole device works properly if abnormal jamming does not occur If the unit runs without...

Page 79: ...eth 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 capa ble 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...

Page 80: ...e ramp B bolted onto the right crankcase external side Turn the spring clockwise until it fits into the spe cific hole C 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 B A C Engine side Positioning of sleeve A below ramp B Insertion of kickstart return spring Kick...

Page 81: ... 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 whe el 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 b...

Page 82: ...t and whi le 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 A 1 B C 2 3 E F 150...

Page 83: ...he washer 5 and the screw 6 after having spread the th reading with medium strength threadlocker Tighten the screw at a torque of 10Nm Apply a light layer of grease in the area G of the start motor and insert the motor in its housing Apply medium strength threadlocker on the two screws 9 and tighten them with a torque of 10Nm 10Nm 10Nm Coupling electrical starter gear unit Insertion of start motor...

Page 84: ...PUMPS CONTROL AND REASSEMBLY As shown in paragraph 1 5 the motor is equipped with two oil pumps one is the low pressure suc tion 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 Proper operation of t...

Page 85: ...ount Maximum axial play 0 1mm Should play be greater replace the rotors 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 recom mended 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 Also check that the drive shaft is not too mar ked in...

Page 86: ...e ball 5 diameter 5 5mm and the respec tive compression spring 6 Lubricate with motor oil and while rotating the pro truding segment of the drive shaft from the outside of the right crankcase half make sure it rotates freely and does not jam 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 tighte ned at a ...

Page 87: ...de of the engine Lubricate the pump body with motor oil 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 withou...

Page 88: ...9 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 jeopar dised Attention always restore the original thickness value of the washer 41 If this should be replaced have it chan ged with one having the same original thickness Attention once valve assembly is complete apply a 6 mm diameter x 8 mm length ...

Page 89: ...ked with 6Nm torque Couple the thrust washer 4 to the pin 2 and lubricate it with gear oil 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 con trol shaft Couple the oil pump control wheel 8 to the end of the shaft...

Page 90: ... and push it towards the in side of the engine as far as it can go 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 1 2 4 3 10Nm Application of paper oil filter Paper oil filter cover complete with O ring Two fixing screws of paper oil filter cover ...

Page 91: ... repla ced 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 EXPLODED VIEW OF COUNTERSHAFT 1 Shaft 2 Counterweight 7 Elastic washer 8 Nut M12x1 Coupling countershaft to crankcase Enlargement of refere...

Page 92: ...pling Countershaft nut While keeping the countershaft in place insert the counterweight on the left side depending on the position set by the grooved shaft 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 tor que of 50Nm ...

Page 93: ...smission 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 CLUTCH BASKET A Teeth mesh...

Page 94: ...ECKING 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...

Page 95: ...s 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 di scs 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 tra ces of meshing If so replac...

Page 96: ...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 transmis sion shaft insert the internal centre bearing 4 to which the roller bearing must be coupled 5 Insert the clutch baske...

Page 97: ...lutch 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 Insert the overall thrust bearing 9 after ha ving lubricated it with gear oil in the hole on the main gearbox shaft and check its free axial slidin...

Page 98: ...7 M6x30 and two screws M6x20 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 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 ...

Page 99: ... the shaft 1 and the coupling is ensured by tightening the nut 8 onto the shaft 1 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 re moving 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...

Page 100: ...oil seal in the inner clutch cover having it enter the seat very slowly to keep it from deteriorating 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 threadlo cker Tighten it at a torque of 10Nm When coupling is complete che...

Page 101: ...Couple the inner clutch cover to the right crankca se half and turn the water pump impeller until the pump shaft inserts perfectly in the housing on the countershaft which drives it Apply the nine M6x25 screws as shown in the figu re tightening them by hand until they are flush Positioning of gasket 1 and centring pins 2 Application of complete inner clutch cover to right crankcase half Positionin...

Page 102: ...to the lower screw of the pump cover Tighten all thirteen screws at a torque of 10Nm fol lowing a criss cross pattern 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 3 4 10Nm Coolant pump cover pay attention to washer 3 4 screws that fasten the outer clutch cover to the inner cover ...

Page 103: ...duce 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 in side the compartment A Insert the specific 6 2x9x9 bushes inside the lower eyelets of the guides Af ter having applied medium strength threadlocker tighten the relative screws 3 at a torque of 10Nm 3 16 IGNITION SYSTEM Before reassembli...

Page 104: ...que 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 re moving 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 ...

Page 105: ...ngth threadlocker Tighten the nut at a torque of 60Nm Couple the stator to the flywheel cover by means of screws 1 Apply the threading with medium strength threadlocker and tighten them at a tor que of 8Nm Insert the cable gland in its specific seat and check its perfect sealing Check the state of use of the two oil seals 2 If they are deteriorated they must be replaced Blow compressed air in the ...

Page 106: ... flywheel cover B 5 6 6 Reposition the plate 5 which must be inserted in the re levant 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 Insert the centring pins 6 on the crankcase and fasten ...

Page 107: ...cific 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 per pend...

Page 108: ...he 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 Measuring pin bolt seat and pin bolt Checking the wear limit of the elastic band Displace ment cm Service limit of compres sio...

Page 109: ...cular to the axis of the crankshaft 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 Displacement cm Coupling play based on relevant class mm Coupling play limit based on re...

Page 110: ...ylinder head Clamp the cylinder head using protective jaws grip ping 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 A 1 2 Blocking cyli...

Page 111: ... M4 screw A in this hole and pull out In this way the finger followers can be extracted 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 calibrat...

Page 112: ...o the intervals carried in the table below Once you have done the measurement take note and mark the calibrated disc depending on its ori ginal position Should the calibrated discs be deteriorated repla ce 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 1 Interval thickness mm Step mm 2 00...

Page 113: ...n the cylin der head and disassemble the springs Compress the spring as much as necessary to extract the half cones 1 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 disassem ble Pay particular attention to the valves B A 1 3 2 1 4 Placing cylinder head on device for disas sembling valve springs Extraction of h...

Page 114: ... sure that the valve stems are free from scratches or any type of nicks Measure the diame ter 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 ...

Page 115: ... damaged C incorrect uneven seat width 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 oc cur the valve seats must be rectified respecting the conditions carried in the following drawing If the valve seats are beyond recovery replace the cylinder head A D E B C Valve seat contact conditions A Co...

Page 116: ...e 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 Check that the state of use of the sliding zones A ...

Page 117: ...ness 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 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 protrude...

Page 118: ...FTS 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 hydrodyna mic 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 bea rings have no trac...

Page 119: ...s 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 1 2 Remember the valve stem seals must be replaced once they have been taken off Inserti...

Page 120: ...that the segment with the smaller pitch faces downwards The upper cup 2 turning the flatter part upwards Compress the spring as much as necessary to ex tract the two half cones 3 To facilitate their inser tion apply a small amount of grease on the stem in the half cone housing zone A B 3 If the valves valves guides and their seats have not been replaced the valves must be put back in their origina...

Page 121: ... the outermost finger follower into the cylinder head first 3 Having fastened the outermost fin ger 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 tor que...

Page 122: ...eci fic seats on the 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 1 2 A 1 4 3 Oil jet with O ring Note the flat part A for reference on the side of the jet Overhead view of complete cylinder head ...

Page 123: ...the pin bolt 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 kee ping the reference letter or number facing upwards and the opening must face the some way as the opening of the lower oil scra...

Page 124: ...hile 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 le...

Page 125: ...e 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 cor rectly in the cylinder when passing through the band Should there be excessive resistance when in...

Page 126: ...nd couple the two centring bushes to the left crankca se 2 Lubricate the foot of the connecting rod abundantly with motor oil Insert the timing chain in the proper compartment in the cylinder and bring the piston cylinder unit close to the connecting rod 1 2 Application of cylinder crankcase gasket and of cen tring bushes Passage of chain in cylinder ...

Page 127: ... 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 Push the cylinder towards the crankcase ma king sure the two centring bushes on the left crankcase are correctly inserted in the seats in the lower part of the cyl...

Page 128: ...10x1 25 screws 9 after having lubricated them and the M6x80 screw 14 which connect the head and cylinder to the 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 Kee...

Page 129: ... be placed It is advisable already in this phase to position the shaft so that the re ference 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 po sitioning rest the camshaft on the cylinder head Positioning camshaft Positioning...

Page 130: ...n the housing of the hydrau lic 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 ex...

Page 131: ...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 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 remai ning holes 4 3 3 4 1 4 4 3 2 ...

Page 132: ...e hydraulic tensio ner coupled to the engine Attention The piston must be positioned at the Top Dead Cen tre 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 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 i...

Page 133: ...e tensioner par 1 1 1 First dissemble the intake camshaft and then the exhaust par 1 1 1 NO NO NO NO YES YES YES YES Couple the camshaft support par 2 17 16 First couple the exhaust camshaft and then the intake par 2 17 16 Couple the intake camshaft par 2 17 16 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 r...

Page 134: ...ng 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 approxi mately 1 millimetre 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 25Nm 1 mm ...

Page 135: ...3 133 ENGINE ASSEMBLY AND CONTROLS Insert the spring in the support and ap ply the cap to be tightened at a torque of 8Nm 8Nm ...

Page 136: ...ts and positioning it so that it recopies the shape on the support 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 1 A 1 2 Application of spark plug gasket Edges where the gasket paste must be applied Insertion of gasket in groove on cylinder head ...

Page 137: ...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 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 ap plying the copper ...

Page 138: ...omplete 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 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 ...

Page 139: ...he 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 10Nm Positioning of gearshift lever ...

Page 140: ...ion from the frame s left side Insert the engine pins 1 Insert the upper shock absorber pin 2 and the swin garm pin 3 Fasten the shock absorber pin at 70Nm Insertion of engine pins Insertion of upper shock absorber pin Insertion of swing arm pin 1 2 70Nm 3 4 Reassembly of engine in the vehicle ...

Page 141: ...ower 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 35Nm 35Nm 35Nm 35Nm 35Nm Attachment Screw Torque Nm Threadlocker Bracket for head connection to frame Front attachment M8 x 20 35 Medium resistance Bracket for head...

Page 142: ...e 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...

Page 143: ...y of engine in the vehicle Apply the carburettor throttle body cover and the relative screw Connect the stop connectors Connect the electric connectors indicated in the figure relative to the carburettor throttle body ...

Page 144: ...e two fixing screws 6 Fasten at 10Nm Apply the start motor cable and fasten the nut at 10 Nm Cover the connection using the specific protec tive cap Make the electric cables from the engine stator and pick up pass through the head connections Apply the spark plug cap 10Nm 10Nm 6 ...

Page 145: ... indicated in the figure Insert the connectors and cables in the recess on the frame Apply the straps as in the figure Carburettor version Injection version Electric connectors in the recess carburettor ver sions Electric connectors in the recess injection versions ...

Page 146: ... in the vehicle 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 Apply the screws and fasten at 10Nm Apply the protective grid 10Nm 6 10Nm ...

Page 147: ...o olant liquid letting the air bleed through the screw cap A Apply the loading cap and fasten the bleed screw at 10Nm Apply the silencer to the vehicle then the ex haust 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 Spurgo aria A ...

Page 148: ...ading on the screw and fasten at 25Nm Apply the brake pedal return spring 7 Mount the chain on the pinion 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 10Nm 6 25Nm 130Nm 7 ...

Page 149: ...g straps between the side guards and frame 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 10Nm 10Nm 10Nm ...

Page 150: ...tors indicated in the figure Insert the tank in its seat Connect the quick release petrol couplings Apply the seat Reapply the paramotor plate with the tree fixing screws once the motorcycle is removed from the stand Fasten at 10Nm Attention Make sure that the petrol quick release couplings are properly set OK NO ...

Page 151: ...g M6 X 60 2 10 Crankcase coupling M6 X 30 2 10 Outside left crankcase half Countershaft bearing fixing M6 X 12 12 Loctite 243 Sichel 100M 8 Calibrated screw M5 1 Loctite 243 Sichel 100M Tighten all the way Oil jet M4 1 Loctite 243 Sichel 100M Tighten all the way Inside left crankcase half Crankshaft bearing fixing plates M6 x 12 2 Loctite 243 Sichel 100M 8 Crankcase half coupling M6 x 70 4 10 Cran...

Page 152: ...ch pressure cap M6 x 25 4 10 Clutch actuator M6 x 20 2 10 Clutch actuator M6 x 30 1 10 Outer clutch cover M6 x 25 6 10 Outer clutch cover M6 x 30 1 10 Inner clutch cover M6 x 25 9 10 See water pump cover screws as well Water pump Impeller blind nut M6 1 Loctite 243 Sichel 100M 10 Cover M6 x 40 4 10 Timing chain guards Fixed and movable guides M6 x 25 2 Loctite 243 Sichel 100M 10 Chain guide on fly...

Page 153: ...M7 x 33 4 8 10 Follow a criss cross pattern Exhaust flange stud M8 x 30 2 Loctite 243 Sichel 100M Electric fan sensor M12 1 20 AIS valve fitting M10 1 10 Cover M6 x 12 4 8 Mechanical tensioner Tensioner cap M24 1 25 Small tensioner cap M16 1 8 Chain pinion Pinion M10 x 18 1 Loctite 243 Sichel 100M 60 Do not use pneumatic devices Gearbox oil vapour breather Bored screw M6x1 1 Loctite 243 Sichel 100...

Page 154: ...readlocker Torque Nm Notes Front engine pin M10 x 1 25 1 45 Lower engine pin M10 x 1 25 1 45 Head connection bracket to front frame M8x20 2 Loctite243 Sichel 100M 35 Head connection bracket to rear frame M8x16 2 Loctite243 Sichel 100M 35 Head connection brackets to engine M8x65 Loctite243 Sichel 100M 35 Swingarm pivot M16 x 1 5 1 125 ...

Page 155: ...riodic service was done accurately 30h 200l 60h 400l 90h 600l 120h 600l 150h 800l 180h 1200l Clutch disc wear I I S I I S Clutch springs I I S I I S Gearbox bearing crankcase side S S Clutch hub basket wear I I I I I I Cylinder I I Piston and segments S S Camshaft wear I I Valve springs I S Valves I S Valve guide wear I I Connecting rod S S Countershaft bearings S S Crankshaft bearings S S Wear of...

Page 156: ...ox and clutch Liqui Moly racing 10W40 800 ml 750ml Engine Liqui Moly racing Synth 10W50 800 ml 750ml COOLANT Liqui Moly Coolant ready mix RAF 12 PLUS 1300 ml RECOMMENDED LUBRICANTS AND LIQUIDS Following the complete engine revision Following routine maintenance interventions ...

Page 157: ...155 NOTE ...

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