Beta Enduro RR 350 EFI 2016 Workshop Manual Download Page 150

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148

IGH

tEN

ING

ENGI

E C

tABLE of tIGHtENING toRQUES of ENGINE CoMPoNENtS

Fixing

Threading diameter x

length [mm]

Quantity

Threadlocker

Torque

[Nm]

Notes

Outside right crankcase half

Oil seal fixing plate

M5 x 10

Loctite 243/

Sichel 100M

Oil incline

M5 x 10

Loctite 243/

Sichel 100M

Kickstart ramp

M6 x 20

Loctite 243/

Sichel 100M

Inside right crankcase half

Crankshaft bearing fixing plates

M6 x 12

Loctite 243/

Sichel 100M

Main gearbox shaft bearing

fixing plate

M6 X 12

Loctite 243/

Sichel 100M

Secondary gearbox shaft bearing

fixing plate

M6 X 12

Loctite 243/

Sichel 100M

Desmodromic gearshift bearing

fixing

M5 X 10

Loctite 243/

Sichel 100M

Crankcase coupling

M6 X 60

Crankcase coupling

M6 X 30

Outside left crankcase half

Countershaft bearing fixing

M6 X 12

Loctite 243/

Sichel 100M

Calibrated screw

Loctite 243/

Sichel 100M

Tighten all the

way

Oil jet

Loctite 243/

Sichel 100M

Tighten all the

way

Inside left crankcase half

Crankshaft bearing fixing

plates

M6 x 12

Loctite 243/

Sichel 100M

Crankcase half coupling

M6 x 70

Crankcase half coupling

M6 X 60

Crankshaft

Left-hand side nut

M32

Loctite 243/

Sichel 100M

150

Right-hand side nut

M20

Loctite 243/

Sichel 100M

150

Left

threading

Crankshaft blocking

M8x16

With copper

spacer

Gearshift

Stop cam

M6 x 30

Loctite 243/

Sichel 100M

Stopping device lever

M6 x 20

Loctite 243/

Sichel 100M

Gearshift lever

M6 x 25

Loctite 243/

Sichel 100M

Electrical starter device

Torque limiter

M6 x 25

Loctite 243/

Sichel 100M

Start motor

M6 x 20

Loctite 243/

Sichel 100M

Summary of Contents for Enduro RR 350 EFI 2016

Page 1: ......

Page 2: ...LF 49 2 12 1 1 PISTON OIL JETS 49 2 12 1 2 EXTRACTION OF COUNTERSHAFT SUPPORT BEARING 50 2 12 2 LEFT CRANKCASE HALF 50 2 12 2 1 INNER OIL FILTER 51 2 12 2 2 EXTRACTION OF DESMODROMIC DEVICE BEARING 51 3 ENGINE ASSEMBLY AND CONTROLS 52 3 1 CRANKCASE HALVES 53 3 1 1 EXTERNAL RIGHT SIDE 54 3 1 1 1 INSERTION OF OIL SEAL AND COUNTERSHAFT SUPPORT BEARING 56 3 1 2 INTERNAL RIGHT SIDE 57 3 1 3 EXTERNAL LE...

Page 3: ... CHECKING CYLINDER HEAD BODY 113 3 17 6 CHECKING CAMSHAFTS 114 3 17 7 CHECKING CAMSHAFTS SUPPORT 115 3 17 8 CYLINDER HEAD INSERTION OF INNER CUP AND VALVE STEM SEAL 116 3 17 9 CYLINDER HEAD ASSEMBLY OF VALVE UNIT 117 3 17 10 CYLINDER HEAD REPOSITIONING CALIBRATED DISCS ASSEMBLY OF FINGER FOLLOWER SHAFTS AND FINGER FOLLOWERS AND COUPLING THE SPARK PLUG 118 3 17 11 CYLINDER HEAD INSERTION OF OIL JET...

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: ... Displacement cm RR 430 431 Displacement cm RR 480 478 Compression ratio RR 350 390 430 480 13 19 1 12 5 1 12 3 11 9 1 Valve gear 4 valves 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 2...

Page 7: ...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 00614004...

Page 8: ...f the three screws 1 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 Remove the exhaust pipe and the silencer Drain the cooling system through s...

Page 9: ...hicle onto an adequate stand To dismount the tank remove the seat complete 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 Disconnect electric connectors 8 and 9 Remove the tank along with the sides ...

Page 10: ...the water hoses from the engine and from the right radiator Remove the left radiator with pipes Disconnect the spark plug cap Cut all straps binding the engine s electric system to the clutch pipe and to the frame Disconnect the engine ventilation pipes ...

Page 11: ...EMOVING THE ENGINE FROM THE VEHICLE Disconnect the connectors indicated in the figure Remove the start motor cable fixing nut Loosen the throttle body straps from the air filter sleeve and from the manifold ...

Page 12: ...connectors indicated in the figure relative to the throttle body Remove the screw of the throttle body 10 cover and the cover itself Disconnect the rear brake stop connector 11 10 11 Loosen the adjustment nuts and release the gas cables Carburettor version gas cables ...

Page 13: ...allow the wheel to advance towards the front of the vehicle Rotate the rear wheel lifting the chain in the pinion zone so that the chain of the pinion itself is released Rest the chain against the upper wedge 14 Remove the screws 15 fixing the clutch actuator to the crankcase half 15 14 ATTENTION Do not activate the clutch lever with actuator decoupled from engine ...

Page 14: ...THE VEHICLE Remove the head connections Remove the seat rail lower fixing screws 17 one each side and loosen the upper screws 18 one each side 17 18 Release and remove the brake pedal return spring 16 Remove the kickstarter lever 16 ...

Page 15: ...1 13 REMOVING THE ENGINE FROM THE VEHICLE Remove the carburetor to the gas cable Remove the throttle body Remove upper shock absorber pin 19 19 ...

Page 16: ...act the engine from the frame and apply it to the specific stand code 3625132 000 using specific front fixing bracket code 006140140 000 Remove the swingarm pin 20 Move the complete swing arm unit towards the rear 20 Remove the engine pins 21 21 21 ...

Page 17: ...he 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 gasket 5 4 5 2 engine disassembly The four screws 1 of the cylinder head cover 2 Spark plug gasket 4 and cylinder head cover gasket 5 The cylinder head cover 2 and the four gaskets 3 ...

Page 18: ... it engages in the seat present on the crankshaft preventing the crankshaft from turning In this way the crankshaft is blocked by means of the screw 6 at the Top Dead Centre TDC and now all the organs can be disassembled 7 6 8 9 6 After having engaged the 6th gear turn the transmis sion shaft 8 anti clockwise using an open end spanner or the likes until the lines 9 on the too thed profiles of the ...

Page 19: ...make it jump teeth on the camshafts thus da maging the engine incorrect and premature wear of the support bearings of the camshafts The engine is equipped with a hydraulic tensio ner in order to provide the chain with proper ten sioning 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...

Page 20: ...uide 3 Then loosen the seven screws 1 of the camshaft support starting with the outer ones indicated in blue in the figure and then the inner ones Remove the chain guide 3 Attention disassemble the camshafts only after having disassembled the hydraulic tensioner Using a plastic rod A or something similar lever the head surface and the camshaft support 2 in order to lift it and remove it When uncou...

Page 21: ...in 3 from the gear on the shaft Attention the hydraulic tensioner must alre ady have been removed in order to remove the camshafts In order to remove the exhaust camshaft 4 repeat the operations described for removal of the intake camshaft ATTENTION make sure the chain does not fall in side the compartment dedicated to it For this pur pose it is recommended to interpose a plastic rod or the likes ...

Page 22: ...ross pattern Start with one of the two screws outside the cylinder head compartment 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 disassembly With the cylinder head lifted a few centimetres drop the chain inside the compartment and pull out the head ATTENTION should the chain fall ...

Page 23: ... 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 24: ... to keep foreign objects or simple residue from falling inside the base Using a suitable tool to insert the specific seat A remove the elastic ring 4 on the right hand side of the piston 5 ATTENTION be careful not to drop the elastic ring inside the engine 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 ...

Page 25: ...L Remove the screw 1 which connects the gear le ver 1 to the drive shaft Remove the nine screws 3 which fasten the flywheel cover 4 to the left crankcase half Re move 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 Fixing screws C of ignition cover D In figure you can see the piston 5 bottom view ...

Page 26: ...n 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 injection version 6 7 5 Starter flywheel removal injection version with spe cial gear puller A A To remove the flywheel screw the relevant extractor A code 3625173 onto the threaded segment on the flywheel and using a ...

Page 27: ...2 25 engine disassembly Flywheel 7 nut 6 and special rose petal 8 In the image at the side the flywheel 7 rear view the special elastic washer 8 and the tighte ning nut 6 7 6 8 ...

Page 28: ...embly Fixing screws 1 of mobile 2 and fixed pad 3 Extraction of chain guides 3 2 1 2 2 2 TIMING CHAIN AND GUIDES Remove the fixing screws 1 of the mobile 2 and fixed pad 3 Extract pad 2 then pad 3 by pulling them upwards ...

Page 29: ... Pay close attention to the respective bushes whi le extracting the mobile and fixed pads and the timing chain Pay close attention to the respective bushes while extracting the mobile and fixed guides and the timing chain 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 1 2 8 3 4 6 5 7 ...

Page 30: ...r 3 2 2 3 PICK UP Once the timing chain guard has been removed the pick up 1 can be disassembled by removing the two fixing screws 2 2 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 ...

Page 31: ...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 Outer clutch cover 1 and respective screws 2 Inner clutch cover 3 and respective screws 4 Pump cover 5 and respective screws 6 1 4 3 6 5 2 ...

Page 32: ...o reference pins A placed between the right crankcase half and the inner clutch cover while disassembling Remove the complete hydraulic actuator 7 if the tube was disconnect from the actuator outer left side crankcase half by loosening the three screws 8 which fasten it to the crankcase half Remove the gasket in between the actuator and the crankcase half Extract the clutch control rod 9 A 7 8 9 ...

Page 33: ... plate unit 12 and the clutch disc pack 13 Remove special driven disc and the disc spring assembly 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 Clutch cap 11 and four screws 10 Pressure plate unit 12 and clutch disc pack 13 Removal of disc spring assembly Opening safety washer with chisel 10 11 13 12 14 15 ...

Page 34: ...en remove the nut and relative safety washer 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 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 35: ...B from which it is sucked by a low pressure pump or recovery 9 with higher displacement passing through the oil filter 8 and sent to the ignition unit com partment A There it is sucked once again by the pump 1 after being filtered through the wire me tal filter 11 The one way valve 10 controls the pressure between the external casing on the ignition unit side and the crank mechanism compartment EN...

Page 36: ...ng ring 5 2 5 2 HIGH PRESSURE OIL PUMP The high pressure pump located in the external right hand side crankcase is enclosed under the cover 1 which can be disassembled by removing the roller 2 and the three screws 3 Having removed the cover extract the internal rotor 4 the external rotor 5 and the roller 6 Gear unit for oil pump control 1 Gear meshing with clutch gear 2 Idler wheel 3 Oil pumps con...

Page 37: ...nition unit compartment They are enclosed under the cover 1 which remo ved by extracting 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 Cover and screws of low pressure pump Internal rotor 6 roller 7 and drive shaft 8 Low pressure oil pump and by pass ...

Page 38: ...al parts from any 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 completely Once the cover has been removed use a pair of opening pliers A to extract the filter While extracting the cover be careful of the specific O ring applied ...

Page 39: ... 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 40: ...or similar instrument ATTENTION The nut 1 must be turned clockwise to be un screwed Extract the primary gear using the relevant extractor A code 006140150000 Notice that the primary gear houses the free wheel de vice 2 inside of it which can be removed by taking out the circlip 3 Extraction of primary gear with appropriate extractor A Primary gear 1 complete with free wheel 2 and spe cific circlip...

Page 41: ...s motion to the idler wheel 7 which will then mesh with the star ter 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 ...

Page 42: ...s 6 and key 7 The kickstart gear is pulled out by hand In order to disassemble the torque limiter 7 com pletely loosen the screw 8 which fastens the torque limiter to the crankcase Pull out the washer 9 toge ther with the limiter itself In order to remove the idler wheel 10 just remove the circlip 11 and pull the gear off Screws 4 fixing start motor to crankcase Removal of pin 6 Torque limiter 8 s...

Page 43: ...er wheel 3 which then meshes with the clutch gear The device moves back thanks to the spring 4 Remove the external circlip 5 and pull off the 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 Kickstarter mechanism Removal of circlip 5 of idler gear 3 Two circlips 5 and 8 and thrust washers 6 and 7 ...

Page 44: ...to a rest position having it turn anti clockwise Turn the shaft anti clockwise and pull it off toge ther with the sleeve 9 the spring 10 and the thrust washer 11 Note Be careful of the reference pins for centring the inner clutch cover par 2 4 Releasing spring from crankcase Extraction of shaft from crankcase Complete manual kickstart shaft ...

Page 45: ...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 46: ...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 so cket wrench A code 006140020000 and remove it ATTENTION When re assembling the oil seal 2 must be replaced since the heating required for di sassembly damages it 2 1 A Nut B blocking crankshaft Removal of crankshaft nu...

Page 47: ...ING CRANKCASE Remove the 15 screws 1 which close the crankca se 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 ...

Page 48: ...TENTION The 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 engine to the support stand Two screws A blocking engine to engine support stand Detaching crankcase halves The left crankcase half insid...

Page 49: ...s 4 drive the sliding wheels of the gearbox allowing engagement of the desired ratio The desmodromic device is controlled by the stop cam present in the external gearshift unit par 2 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 operatio...

Page 50: ...TION Make sure the circlip on the secondary shaft has been removed par 2 9 Proceed to extract the complete gearbox unit inclu ding the primary 6 and secondary unit 7 Circlip removal Extraction of forks from gearbox unit Extraction of complete gearbox unit 6 primary unit 7 Secondary unit ...

Page 51: ...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 52: ...ankca se half Two are applied on the inside and one on the outside The plates 1 on the inside are the ones relative to the crankshaft support bearing of the gearbox They can be disassembled by removing the two screws 2 The plate 3 is the one relative to the bearing which supports the countershaft It can be disassembled by removing the screw 4 For checking and cleaning part of the lubrication circu...

Page 53: ...small hammer 2 12 2 2 EXTRACTION OF DESMODRO MIC DEVICE BEARING Removal of bearing dedicated to the device pre sent 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 Disassembly of inner fil...

Page 54: ...g rotation It is however recommended to refer to the periodical maintenance table In order to insert the bearings in the crankcase halves bring the crankcase halves to a tempe rature of 150 C and keep them at that tempe rature for 20 minutes Place the crankcase halves on a large surface where their whole seal surface can rest When the bearings cool off they drop into their seats on their own 3 ENG...

Page 55: ...ing they undergo when being disassembled In general the crankcase halves must be repla ced 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 Fr...

Page 56: ...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 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 Sichel 100M 6 6 M5 10 Loctite ...

Page 57: ... tor que limiter 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 seg ment in the lever Apply the spring 26 so that the hook inserts into the groove present on the lever 25 and then apply the washer 28 and the screw 29 M6x20 whose threading must be spre ad with medium stren...

Page 58: ... the oil seal and bearing housing Insert the new oil seal 1 greasing the inside of it Apply the new bearing 2 paying close attention that it is aligned in its seat Use a press or similar instrument to push the bea ring until the outside surface is flush with the sur face A Application of oil seal 1 Insertion of bearing 2 Oil seal and bearing unit coupled to the left crankca se half 1 2 A ...

Page 59: ...ns for application of the fixing screws of these plates and for fixing the desmo dromic device support bearing 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 100M 8 7 M6 12 Loctite 243 Sichel 100M 8 8 M5 10 Loctite 243 Sichel 100M 4 9 1 A 5 6 B 4 3 7 2 8 8Nm 4Nm 6Nm 6Nm Ins...

Page 60: ...L LEFT SIDE Make sure the calibrated screw 1 and the jet 2 are not obstructed Should they have been replaced cou ple them to the crankcase using a small amount of medium strength threadlocker being careful that the threadlocker does not block the holes Then tighten them all the way Make sure that the oil passage A is cleaned well Make sure that the countershaft bearing retaining plate 3 is not def...

Page 61: ...are deformed have them replaced The table below carries the indications for appli cation of the screws for the plates 1 Insert the inner filter 3 in its seat A present in the crankcase and push it all the way down until you hear the hooking device click Apply oil jet 4 after application of O ring 5 Ap ply screw 6 after application of medium resis tance threadlockers Fasten at 6Nm Screw number Scre...

Page 62: ...kshaft 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 63: ...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 crankshaf...

Page 64: ...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 replaced grease the crankshaft oil seal on the right crankcase half and couple the crankshaft to the left crankcase half Keep the gear present on the crankshaft towards the left In order to carry out this operation ...

Page 65: ...ected must not exceed the ser vice limit indicated below service limit 0 5mm If the detected axial play is greater before re placing either the gearwheels or the forks check their state of wear par 3 4 4 Remove the various elements and check that The support surfaces of the primary and se condary shafts are free of abnormal wear or signs of seizure The sides of the teeth are free from chip ping or...

Page 66: ...with gear oil Always replace the circlips Clamp the mainshaft 1 using protective jaws so that the grooved end faces downwards Insert onto the lower cylinder part of the shaft the roller cage 2 the 5th gear 3 turning the front claw clutches upwards the 26x32x1 5 thrust washer 4 and the circlip 5 Insert the III IV sliding gear 6 so that the smaller gear faces downwards and then insert the circlip 5 ...

Page 67: ...ary 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 fa ces upwards and the circlip 5 Insert the 23x32x1 5 thrust washer 7 the two roller cages 15 the 4th gear 17 with...

Page 68: ...ift is made up of two forks 13 which drive two gears on the secon dary unit one fork 14 which drives one gear on the primary unit three drive pin bushes 15 two fork pins 16 desmodromic gearshift 18 through whose rota tion the forks are driven thus selecting the desired gear Check to make sure that the drive pins which sup port the bushes 15 have no traces of meshing or abnormal wear and that the b...

Page 69: ...eats 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 dr...

Page 70: ...ul taneously Remember to oil the gears abundantly with gear oil and to grease the shafts supporting them in the areas where they are coupled with the bearing with graphitic grease Make sure that all the parts sli de 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 shaf...

Page 71: ... is replaced it is recommended to reposition the forks in their original positions Insert the desmodromic device in the specific bearing In order to do this it is necessary to rotate cam stop lever 7 towards the bottom part of the engine Position the fork 5 of the primary unit in the central guide of the desmodromic device 8 in sert the fork pin inside the fork itself and insert the pin in its pro...

Page 72: ...rk pin first in the pins and then in its proper seat Remember to oil the shafts forks and the desmodro mic 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 ...

Page 73: ... the two crankcase halves connect two screws on opposite sides and tighten them bit by bit If the crankcase halves tend to capsize do not insist tightening them Rather loosen the screws and reposition the crankcase correctly Make sure that the two crankcase halves match perfectly one with the other Assemble the screws according to their length as indicated in the figure The table below contains in...

Page 74: ... the crankshaft in the Top Dead Centre insert the special conical end screw 38 without applying washer 37 or the special engine locking tool code 006140110000 in its seat on the right crankcase Once the crankshaft is positioned at the Top Dead Centre tighten all the way Spread the threading on the left hand side of the crankshaft with medium strength threadlocker Tighten the nut using the special ...

Page 75: ... it s free from abnormal 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 distance between the movable pawl and the drive shaft is between 0 35 0 80mm Should the distance be greater replace the mo vable pawl In order to replace the movable pawl 1 disas semble the return spring of the gearsh...

Page 76: ...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 guide 7 the gearshift return spring 6 and finally the 14x30x1 thrust wa sher 5 The gearshift return spring must be positioned as in the figure to be able to carry out its ...

Page 77: ...ping the return spring 4 of the movable pawl pressed Wishing to test the correct functioning of the entire unit you just need to temporarily cou ple the external gearshift lever and to simula te the operation of changing gears by lifting and lowering the gearshift lever and having the mainshaft of the gear unit rotate The whole de vice works properly if abnormal jamming does not occur If the unit ...

Page 78: ...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 capable of putting enough pressure on the sleeve 14 so that it can to pull the gear 2 Also check to make sure that the washers have no abnormal or excessive wear If so have them re placed Make sure that the spring 8 has...

Page 79: ...low the ramp B bolted onto the right crankcase external side Turn the spring clockwise until it fits into the specific 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 Engine side Positioning of sleeve A below ramp B Insertion of kickstart return spring Kicks...

Page 80: ... gear temporarily on the crankshaft together with the roller bearing and check to see if there is excessive play To check the correct functioning of the free wheel 4 proceed as follows Insert the starter gear 3 on the free wheel 4 and main gear unit 5 Keeping the main gear blocked 5 and turning the kickstart gear 3 clockwise it must run freely Turning the kickstart gear 3 anti clockwise it must be...

Page 81: ...at Apply the main gear 3 to the crankshaft 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 threa ding 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 ...

Page 82: ...he washer 5 and the screw 6 after having spread the threading 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 83: ...MPS CONTROL AND REASSEMBLY As shown in paragraph 2 5 the motor is equip ped with two oil pumps one is the low pres sure suction pump higher displacement lo cated in the outside of the left crankcase half and the other high pressure pump lower di splacement 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 ...

Page 84: ...amount Maximum axial play 0 1mm Should play be greater replace the rotors As to the high pressure pump located in the out side right crankcase half one must check that the oil seal 5 is not worn it is recommended to repla ce 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 marked ...

Page 85: ...proper seat Insert the ball 5 diameter 5 5mm and the re spective compression spring 6 Lubricate with motor oil and while rotating the protruding segment of the drive shaft from the outside of the right crankcase half make sure it rotates freely and does not jam Fasten the cover 7 to the crankcase with the three screws 8 which must first be spread with medium strength threadlocker These screws must...

Page 86: ...ing the inside 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 careful ly 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 4Nm Turn the shaft holding on to the protruding end and make sure it rotates ...

Page 87: ... limit 29 5mm Tighten the screw at a torque of 20Nm Attention If one of these elements making up the control valve is not inserted engine functioning will be jeopardised Attention always restore the original thickness value of the washer 41 If this should be replaced have it changed with one having the same original thickness Attention once valve assembly is complete apply a 6 mm diameter x 8 mm l...

Page 88: ...hreadlockers and locked with 6Nm torque Couple the thrust washer 4 to the pin 2 and lubrica te 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 control shaft Couple the oil pump control wheel 8 to ...

Page 89: ...to its housing and push it towards the inside 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 10Nm Application of paper oil filter Paper oil filter cover complete with O ring Two fixing screws of paper oil filter cover ...

Page 90: ...t replaced Make sure that the toothed segment of the shaft does not have traces of abnormal wear Grease the oil seal and insert the countershaft in its seat Position it so that the reference sign on the shaft is between the two reference signs on the main gear EXPLODED VIEW OF COUNTERSHAFT 1 Shaft 2 Counterweight 7 Elastic washer 8 Nut M12x1 Coupling countershaft to crankcase Enlargement of refere...

Page 91: ...ling 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 threadlo cker on their threading The nut must be tighte ned at a torque of 50Nm ...

Page 92: ...in transmission and B dedicated to meshing with the kickstart idler gear and oil pumps have no superficial nicks or abnormal wear Also closely check that the teeth C upon which the dri ving discs engage are not chipped or deeply cut Make sure that the centre bearing D with the roller bea ring has no traces of meshing or abnormal wear If any damage is found have the piece replaced CLUTCH BASKET A T...

Page 93: ...2 CHECKING CLUTCH DISCS The clutch discs are divided into friction discs and steel discs there are eight friction discs and seven steel discs The friction discs have friction material applied on both sides which wear out due to the steel discs sliding on them Make sure that the thickness of each friction disc is not below the minimum value fixed at minimum thickness 2 8mm The other value that need...

Page 94: ...ings must be checked The minimum acceptable length must be minimum clutch spring length 42 mm 3 12 4 CHECKING INNER HUB The inner hub meshes with the steel clutch discs by means of the teeth A Make sure these teeth are not meshed or shaped by abnormal wear If so replace the inner hub Make sure that the seat B where the support wa sher of the disc spring slides shows no traces of meshing If so repl...

Page 95: ...ng just see if it slides When the device is assembled simulate rota tion of the front centre bearing A respect to the rear one B Be careful for presence traces of meshing or wear on the sliding surfaces 3 12 6 ASSEMBLY OF CLUTCH UNIT After having lubricated the end of the main transmission shaft insert the internal centre bearing 4 to which the roller bearing must be coupled 5 Insert the clutch ba...

Page 96: ...on the safety plate Lubricate the clutch disc with gearbox oil and ap ply 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 having lu bricated it with gear oil in the hole on the main gearbox s...

Page 97: ...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 ac tuator 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 98: ... the shaft 1 and the cou pling 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 removing the nut 8 which allows you to extract the impeller 6 the washer 7 and the shaft 1 This can be removed by pressing the threaded part...

Page 99: ...the oil seal in the inner clutch cover having it enter the seat very slowly to keep it from deteriora ting Couple the shaft 1 with the O ring 2 to the inner clutch cover and then insert the bush 5 the washer 7 and the impeller 6 Then couple the blind nut 8 to the threaded segment of the shaft after having applied medium strength threadlocker Tighten it at a torque of 6Nm When coupling is complete ...

Page 100: ... Couple the inner clutch cover to the right crankcase half and turn the water pump impeller until the pump shaft inserts perfectly in the housing on the countershaft which drives it Apply the nine M6x25 screws as shown in the figure 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 Positioning...

Page 101: ...washer 3 to the lower screw of the pump cover Tighten all thirteen screws at a torque of 10Nm following 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 Coolant pump cover pay attention to washer 3 4 screws that fasten the outer clutch cover to the inner cover ...

Page 102: ...ntro 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 inside the compartment A Insert the specific 6 2x9x9 bushes inside the lower eyelets of the guides After having ap plied medium strength threadlocker tighten the relative screws 3 at a torque of 10Nm 3 16 IGNITION SYSTEM Before reasse...

Page 103: ...s support coincide with the two outer holes on the crankcase Apply the threading of the two screws 1 with me dium strength threadlocker and tighten them at a torque of 6Nm Lay the cable on the crankcase apply the groo ve of the cable gland 2 with gasket paste code 3625000000 and insert it in the specific housing n the crankcase removing excess paste Couple the chain guard to the crankcase insert t...

Page 104: ...erfect 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 hole A making sure the lubrication pipe is perfectly clean Also check the state of use of the chain guide 3 If it is deteriora ted it must be replaced In that case before put ting on the screw 4 apply it with medium strength threadlocker and tighten it at a torque ...

Page 105: ... fa sten a new gasket Flywheel cover coupled to crankcase C 7 Grease the oil seals on the cover of the flywheel and secure it on the left guard using the nine 7 M6x25 screws Notice that a 12x6 3x1 copper washer C must be ap plied to the screw Tighten the screws at a torque of 10Nm 10Nm ...

Page 106: ...e entire piston with specific degre asing 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 ser vice limit is carried in the table below concerning their specific class The diameter must be measured at a di stance X from the inner...

Page 107: ...ng rod controls for controls on con necting rod foot par 2 2 In order to check the state of use of the piston ring and oil scraper ring the ring must be in serted 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 Displace ment cm Service li mit of com pressi...

Page 108: ...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 cylin der 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 r...

Page 109: ...elements must be cleaned and named bit by bit as they are disassembled Proceed as follows for disassembly and inspec tion of the cylinder head Clamp the cylinder head using protective jaws gripping it at the head connection A Disassemble the spark plug using the special spark plug wrench code 020440100 000 3 17 3 1 LUBRICATION JETS AND CENTRING PINS Pull out the two oil jets 1 for lubricating the ...

Page 110: ...er head We recommend they be re placed The finger follower shafts have a threaded hole M4 at the end so that they can be extracted To pull them out just screw a sufficiently long M4 screw A in this hole and pull out In this way the finger followers can be extracted Make sure the outside diameters of the shafts 2 and the inside diameters of the holes on the finger fol lowers 3 respect the following...

Page 111: ...th a thickness gauge The calibrated discs range from 2 00 to 3 30 according to the intervals carried in the table below Once you have done the measurement take note and mark the calibrated disc depending on its original position Should the calibrated discs be deteriorated re place them with others having the same dimen sions Thus you can know whether to replace it with a thicker or thinner calibra...

Page 112: ...val jaw A code 0100043 000 and apply the spring removal tool onto it B code 006140030 000 Then position the cylinder head and disassemble the springs Compress the spring as much as necessary to ex tract 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 disassemble Pay particular attention to the ...

Page 113: ...scribed later on Brush the valve mushroom head thoroughly and degrease the entire valve Make sure that the valve stems are free from scratches or any type of nicks Measure the dia meter 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...

Page 114: ... Width service limit of valve seat contact zone 1 9 mm The contact zone can principally take on three different appearances as shown in the figure A correct B incorrect contact face damaged C incorrect uneven seat width Also check the correct positioning of the contact area It must be neither higher case D or lower case E Should the incorrect conditions described above occur the valve seats must b...

Page 115: ...being careful not to nick the valve guide Once the valve stem seal is extracted the lower cup can be pulled out 2 3 17 5 CYLINDER HEAD CHE CKING CYLINDER HEAD BODY Check the flatness between the head and cylin der coupling surfaces This can be done using a rectified block and a thickness gauge by positioning the block accor ding to the directions shown in the figure The service limit is cylinder h...

Page 116: ... typical when working without oil Use a thickness gauge to check the wear limit of the cams referring to the values carried in the ta ble 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 tha...

Page 117: ...G CAMSHAFTS SUPPORT The camshafts supports fasten the shafts so they maintain the correct position while opera ting The support in the zone A has a channel B intended to lubricate the camshaft to allow the hydrodynamic support of the shaft itself There fore 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 be arings have...

Page 118: ...wards 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 Remember the valve stem seals must be replaced once they have been taken off Inserti...

Page 119: ...sert it so 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 extract the two half cones 3 To facilitate their insertion apply a small amount of grease on the stem in the half cone housing zone If the valves valves guides and their seats have not been re placed the valves must be put back in their ori...

Page 120: ...d to be able to insert the ou termost finger follower into the cylinder head first 3 Having fastened the outermost finger follower to the shaft push the shaft further until it reaches the seat of the innermost finger follower Having coupled the innermost finger follower to the shaft push it all the way into the cylinder head Couple the two caps 4 with the O rings to the cylin der head They must be...

Page 121: ... 2 in their specific 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 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 122: ...ps version 350cc 390cc Lubricate the seats of the segments with plenty of oil and put the internal scraper ring strap 1 in the lower seat of the piston Lay the external scraper ring strap 2 on the internal one with the TOP marking facing the top of the piston Put the retaining strap 3 in the upper seat The oil scraper ring and retaining straps must be laid so that their openings face the higher se...

Page 123: ...tention that the two ends face one another but do NOT overlap The two ends must be aligned in axis with 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 let...

Page 124: ...wn which must face the exhaust manifold 3 17 13 APPLICATION OF PISTON TO CYLINDER To couple the piston to the cylinder place the cylin der while keeping the top facing upwards Oil the cylinder with plenty of motor oil Prepare the ring compression band A code 006140170000 as shown in the figure Press the green locking lever B and turn the hex key anti clockwise until the band reaches a dimension ne...

Page 125: ...r making sure that the axis of the piston is aligned with that of the cylinder Towards the end of insertion it might be necessary to use the wooden handle of a hammer or a similar tool to lightly tap the piston crown in order to facilitate its complete insertion in the cylinder Attention during the whole operation hold the band firm with one hand without moving it Make sure that the piston rings i...

Page 126: ...e and 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 With the piston pin facing its seat in the foot of the connecting rod push the piston pin all the way in An aluminium cylinder or similar tool...

Page 127: ...bolt seat Insert the cylindrical part of the special tool A into the pin bolt and having one of the two flat surfaces of the tool coincide with the part of the circlip to be inserted turn and push the special tool towards the engine until the circlip is fully inserted into a seat Push the cylinder towards the crankcase ma king sure the two centring bushes on the left crankcase are correctly insert...

Page 128: ...t inserts perfectly into the two centring bushes on the cylinder Lubricate the four washers 8 and insert them into their specific seats on the outside and inside of the cylinder head Then insert the four M10x1 25 screws 9 after having lubricated them and the M6x80 screw 14 which connect the head and cylinder to the crankcase In two moments proceed tightening the four screws in a criss cross patter...

Page 129: ...il Widening the timing chain insert the exhaust camshaft upon whose gearwheel the timing chain must be placed It is advisable already in this phase to position the shaft so that the 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 a...

Page 130: ...ces E carved on the gear are horizontal Position the bearing in the same way as for the exhaust camshaft Holding the camshaft still with one hand insert an aluminium cylinder F in 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 phasin...

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 3 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: ...between the cam and the finger follower This con trol can be done even without the hydraulic tensio ner coupled to the engine Attention The piston must be positioned at the Top Dead Cen tre par 3 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 ...

Page 133: ...e tensioner par 2 1 1 First dissemble the intake camshaft and then the exhaust par 2 1 1 NO NO NO NO YES YES YES YES Couple the camshaft support par 3 17 16 First couple the exhaust camshaft and then the intake par 3 17 16 Couple the intake camshaft par 3 17 16 Disassemble only the intake camshaft par 2 1 1 Disassemble the calibrated disc to be replaced par 3 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 Application of spark plug gasket Edges where the gasket paste must be applied Insertion of gasket in groove on cylinder head cover 1 ...

Page 137: ...on the cylinder head making sure that the gasket covers the surface correctly Apply the four rubber rings 3 to the cover and insert the four screws 4 which fasten the cover to the cylinder head Tighten the screws in a criss cross pattern at a torque of 8Nm 3 19 RELEASING CRANKSHAFT Remember that according to the order of this text the crankshaft is blocked at the Top Dead Centre It must be release...

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: ...UPLING GEARSHIFT LEVER Couple the gearshift lever to the drive shaft by positioning it so that the part A of the lever coincides with the upper edge of the oil level inspection window Tighten the screw 1 at a torque of 10Nm after having applied medium strength threadlocker 10Nm ...

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 1 2 70Nm 3 4 Reassembly of engine in the vehicle Insertion of engine pins Insertion of upper shock absorber pin Insertion of swing arm pin ...

Page 141: ...cker 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 connection to frame Rear attachment M8 x 16 35 Medium resistance Brackets for h...

Page 142: ...e head connection Apply the gas cables to the throttle body and tighten the nuts Attention At the end of the operation check for correct gas play Apply the throttle body cover and the relative screw Connect the stop connectors Connect the electric connectors indicated in the figu re relative to the throttle body Note Before making the connection it is advisable to blow compressed air in the connec...

Page 143: ...10Nm Apply the start motor cable and fasten the nut at 10Nm Cover the connection using the speci fic protective cap Make the electric cables from the engine stator and pick up pass through the head connections Apply the spark plug cap 10Nm 6 10Nm Connect the connectors indicated in the figure Injection version ...

Page 144: ...s and cables in the recess on the frame Apply the straps as in the figure Electric connectors in the recess injection versions 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 ...

Page 145: ...and fasten at 10Nm Apply the protective grid 10Nm Connect the radiators to the engine Fasten the clamp straps and introduce the co olant liquid letting the air bleed through the screw cap A Apply the loading cap and fasten the bleed screw at 10Nm Spurgo aria A ...

Page 146: ...er to have a 5 10mm gap with the water hose Apply the Kickstart lever Apply the medium resistance sealant threading on the screw and fasten at 25Nm Apply the brake pedal return spring 7 Mount the chain on the pinion 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 ...

Page 147: ...0 11 Apply the pinion guard 10 and the frame side guards 11 and 12 Fasten the screws at 10Nm and apply the fixing straps between the side guards and frame 10Nm 10Nm 12 10Nm Apply the tank as follows Connect the connectors indicated in the figure ...

Page 148: ...at the indicated torque 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 Put the tank in place making sure the gas cable is between the tank and frame ...

Page 149: ...4 147 Reassembly of engine in the vehicle Grease the rear fastener and tighten the screws at the indicated torque values Apply the seat 10Nm 10Nm 7Nm ...

Page 150: ...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 151: ...tch 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 6 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 152: ...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 153: ...10 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 Fixing Threading diameter x worm mm length mm Quantity Threadlocker Torque Nm Notes Tank on the frame fixing on the front M6 x 1 25 1 10 Tank ...

Page 154: ...dic 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 co...

Page 155: ...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 ...

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