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CPI ARAGON Service Manual Download Page 64

CRANK DRIVE / CRANKCASE / CRANKSHAFT 

CR-9 

 

DISMANTLING THE 
ENGINE CASE 

 

 
Loosen and remove the engine case bolts. 
Separate the rightcrankcase half from the 
left one with a suitable puller. 

 

 

Press out the crankshaft from the left 
crankcase with the aid of a standard 
bearing and casing puller. 
 

 

 

 

Remove the crankshaft bearings from the 
crankshaft with a suitable bearing puller. 
 

ggg 

 

 

CRANKSHAFT 

 

 
Check the horizontal and the radial play 
respectively of the big-end bearing with 
the aid of a feeler gauge. 
The radial play shall be determined by a 
crossover measurement. 
 

Maximum horizontal play: 0.55 mm 

 

 

Maximum radial play: 0.05 mm 

 

Summary of Contents for ARAGON

Page 1: ......

Page 2: ......

Page 3: ...g operations are listed with detail of the page numbers The chapter page numbering is built up the following way Example Fl 3 group of Fl page 3 The details contained in this manual and vehicle data correspond to the ones at the moment of printing HANS LEEB Zweirad Handel GmbH reserves the right to end a model production any time and to change specifications and designs without a previous announce...

Page 4: ......

Page 5: ...GENERAL INFORMATION GENERAL INFORMATION GI 2 WARNING AND SAFETY SYMBOLS GI 3 VEHICLE IDENTIFICATION NUMBERS GI 4 MAINTENANCE INSTRUCTIONS GI 5 ...

Page 6: ...ses contain carbon monoxide which can lead to unconsciousness and to death when in higher concentration Batteries contain sulfuric acid electrolyte Avoid any contact with skin eyes and muscous membranes since that acid causes severe injuries Operators have to wear suitable protective clothing and safety goggles according to the stipulations made by the respective professional organizations In the ...

Page 7: ... of this manual WARNING AND SAFETY SYMBOLS The following symbols indicate that the vehicle technician must pay extra attention when performing maintenance works Symbol Description Symbol Description Component parts may get damaged when this instruction is not oberseved It is indispensable to follow this instruction Severe injuries or even the loss of life may result in the case of non observance T...

Page 8: ...be behind the legshield In the case of versions 7 10 Aragon Aragon GP the VIN ist stamped on the rear right hand side of the frame The cover must first be removed from there in order to make it visible The engine number is stamped on the upper part of the left engine case of all vehicle versions R F T J R 4 5 A X 6 L 0 0 0 1 1 0 Serial number Manufacturer L CPI Year of manufacture e g 7 2007 Model...

Page 9: ...uring instruments are available SPECIAL TOOLS Use special tools if stipulated in the chapter REMOVAL OF ENGINE PARTS Before starting any mainrenance works try to track the fault cause Decide whether the removal or disassembly of the part in question is necessary CLEANING OF REUSABLE PARTS All reusable parts have to be cleaned carefully and thoroughly and in a suitable way ...

Page 10: ...g sealant to washers 2 Oiling of moveable parts 3 Oil or lubricating grease must be applied to defined spots e g oil retainers prior to assembling ELECTRICAL EQUIPMENT 1 Always disconnect the cable from the battery s negative terminal first 2 Never pull the cable when disconnecting connections Always remove plugs by pulling the plug 3 Snap in connections are properly made when you can hear a click...

Page 11: ...esses which are routed to the engine or other vibrating vehicle parts This play must be in such a way that the wiring harnesses do not contact adjacent parts due to engine vibrations 3 If any part of a wiring harness is routed along an edge or corner of a vehicle part or if it has contact to that edge or corner that section of the harness has to be wrapped round with tape or the like in order to p...

Page 12: ...lay are sensitive to heat and can easily get damaged If for maintenace works the temperature must be risen above 80 C those electric component parts have to be removed prior to maintenance 7 Loose coupling can cause malfunctions Make sure that all plug connections are adequately made 8 Always pull the connector and not the wiring harness when disconnecting any plug connections ...

Page 13: ... conducting continuity checks or voltage measurements with a circuit tester the test probe must be inserted in the terminals at the wiring harness side In the case of a shielded connection the probe must be inserted through the cable opening of the rubber cap until contact is made with the terminal Pay attention not to damage the insulation and wires Plug connection Test probe Test probe 12 Take i...

Page 14: ...GENERAL INFORMATION GI 10 NOTES ...

Page 15: ...L DATA SPECIFICATIONS TD 2 ARAGON GP 45 KM H TD 2 ARAGON GP 30 KM H TD 4 ARAGON GP 25 KM H TD 6 ARAGON 45 KM H TD 8 ARAGON 30 KM H TD 10 ARAGON 25 KM H TD 12 FORMULA R 45 KM H TD 14 FORMULA R 30 KM H TD 16 FORMULA R 25 KM H TD 18 ...

Page 16: ...ition jet needle 3 from top Float chamber level 13 0 5 not adjustable mm Air adjustment screw turns Idling speed 1800 100 min 1 Automatic cold start equipment stroke at 12V AC Working time 4 105 mm 5 min sec Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 56J Air pressure front 1 9 bar Air pressure rear 2 0 bar Filling quantities specifications Fuel unleaded 91 ROZ 7 9 l Engi...

Page 17: ...sy Battery charging voltage Battery fully charged 13 5 0 5 V Battery charging current Battery empty 1 8 A Fuse 8 A Bulb low beam Bulb high beam Bulb position lamp 55 H1 55 H1 5 W Bulb rear and stop lamp License plate illumination 21 5 W Bulb winker W Ignition pulse generator blue white green white 340 50 1 5 1900 Ω V min 1 Ignition coil ACG 900 100 125 800 Ω V min 1 Charging coil white Plug discon...

Page 18: ...t needle 2 from top Float chamber level 13 0 5 not adjustable mm Air adjustment screw turns Idling speed 1800 100 min 1 Automatic cold start equipment stroke at 12V AC Working time 4 105 mm 5 min sec Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 56J Air pressure front 1 9 bar Air pressure rear 2 0 bar Filling quantities specifications Fuel unleaded 91 ROZ 7 9 l Engine Oil l...

Page 19: ...sy Battery charging voltage Battery fully charged 13 5 0 5 V Battery charging current Battery empty 1 8 A Fuse 8 A Bulb low beam Bulb high beam Bulb position lamp 55 H1 55 H1 5 W Bulb rear and stop lamp License plate illumination 21 5 W Bulb winker W Ignition pulse generator blue white green white 340 50 1 5 1900 Ω V min 1 Ignition coil ACG 900 100 125 800 Ω V min 1 Charging coil white Plug discon...

Page 20: ...t needle 2 from top Float chamber level 13 0 5 not adjustable mm Air adjustment screw turns Idling speed 2000 100 min 1 Automatic cold start equipment stroke at 12V AC Working time 4 105 mm 5 min sec Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 56J Air pressure front 1 9 bar Air pressure rear 2 0 bar Filling quantities specifications Fuel unleaded 91 ROZ 7 9 l Engine Oil l...

Page 21: ...sy Battery charging voltage Battery fully charged 13 5 0 5 V Battery charging current Battery empty 1 8 A Fuse 8 A Bulb low beam Bulb high beam Bulb position lamp 55 H1 55 H1 5 W Bulb rear and stop lamp License plate illumination 21 5 W Bulb winker W Ignition pulse generator blue white green white 340 50 1 5 1900 Ω V min 1 Ignition coil ACG 900 100 125 800 Ω V min 1 Charging coil white Plug discon...

Page 22: ...t equipment stroke at 12V AC Working time 4 105 mm 5 min sec Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 56J Air pressure front 1 9 bar Air pressure rear 2 0 bar Filling quantities specifications Fuel unleaded 91 ROZ 7 9 l Engine Oil l 2 stroke oil full synthetic 1 4 l Gearbox oil SAE 80W90 100 ml Front fork oil SAE 5W20 100 ml Brake fluid DOT 4 in case of need Fuel suppl...

Page 23: ... Battery charging voltage Battery fully charged 13 5 0 5 V Battery charging current Battery empty 1 8 A Fuse 8 A Bulb low beam Bulb high beam Bulb position lamp 55 H1 55 H1 5 W Bulb rear and stop lamp License plate illumination 21 5 W Bulb winker LED W Ignition pulse generator blue white green white 340 50 1 5 1900 Ω V min 1 Ignition coil ACG 900 100 125 800 Ω V min 1 Charging coil white Plug disc...

Page 24: ...needle 2 from top Float chamber level 13 0 5 not adjustable mm Air adjustment screw turns Idling speed 2000 100 min 1 Automatic cold start equipment stroke at 12V AC Working time 4 105 mm 5 min sec Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 56J Air pressure front 1 9 bar Air pressure rear 2 0 bar Filling quantities specifications Fuel unleaded 91 ROZ 7 9 l Engine Oil l 2...

Page 25: ...sy Battery charging voltage Battery fully charged 13 5 0 5 V Battery charging current Battery empty 1 8 A Fuse 8 A Bulb low beam Bulb high beam Bulb position lamp 55 H1 55 H1 5 W Bulb rear and stop lamp License plate illumination 21 5 W Bulb winker W Ignition pulse generator blue white green white 340 50 1 5 1900 Ω V min 1 Ignition coil ACG 900 100 125 800 Ω V min 1 Charging coil white Plug discon...

Page 26: ...e at 12V AC Working time 4 105 mm 5 min sec Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 56J Air pressure front 1 9 bar Air pressure rear 2 0 bar Filling quantities specifications Fuel unleaded 91 ROZ 7 9 l Engine Oil l 2 stroke oil full synthetic 1 4 l Gearbox oil SAE 80W90 100 ml Front fork oil SAE 5W20 100 ml Brake fluid DOT 4 in case of need Fuel supply adjustments Car...

Page 27: ...sy Battery charging voltage Battery fully charged 13 5 0 5 V Battery charging current Battery empty 1 8 A Fuse 8 A Bulb low beam Bulb high beam Bulb position lamp 55 H1 55 H1 5 W Bulb rear and stop lamp License plate illumination 21 5 W Bulb winker W Ignition pulse generator blue white green white 340 50 1 5 1900 Ω V min 1 Ignition coil ACG 900 100 125 800 Ω V min 1 Charging coil white Plug discon...

Page 28: ...6D Position jet needle 2 from top Float chamber level 13 0 5 not adjustable mm Air adjustment screw turns Idling speed 1800 100 min 1 Automatic cold start equipment stroke at 12V AC Working time 4 105 mm 5 min sec Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 56J Air pressure front 1 9 bar Air pressure rear 2 0 bar Filling quantities specifications Fuel unleaded 91 ROZ 5 2 ...

Page 29: ... 8 30 Standard torque for 12 60 screws and nuts without 10 40 special function 8 25 6 12 5 4 Spark plug 14 15 Electrical assy Battery charging voltage Battery fully charged 14 0 5 V Battery charging current Battery empty 0 4 A Fuse 8 A Bulb headlamp 35 35 S2 W License plate illumination W Bulb rear and stop lamp 21 5 W Bulb winker 10 W Ignition pulse generator 500 50 Ω Ignition coil primary 0 3 0 ...

Page 30: ...36 Position jet needle 2 from top Float chamber level 13 0 5 not adjustable mm Air adjustment screw turns Idling speed 2000 100 min 1 Automatic cold start equipment stroke at 12V AC Working time 4 105 mm 5 min sec Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 56J Air pressure front 1 9 bar Air pressure rear 2 bar Filling quantities specifications Fuel unleaded 91 ROZ 5 2 l ...

Page 31: ... 8 30 Standard torque for 12 60 screws and nuts without 10 40 special function 8 25 6 12 5 4 Spark plug 14 15 Electrical assy Battery charging voltage Battery fully charged 14 0 5 V Battery charging current Battery empty 0 4 A Fuse 8 A Bulb headlamp 35 35 S2 W License plate illumination W Bulb rear and stop lamp 21 5 W Bulb winker 10 W Ignition pulse generator 500 50 Ω Ignition coil primary 0 3 0 ...

Page 32: ... 1 Automatic cold start equipment stroke at 12V AC Working time 4 105 mm 5 min sec Fuel supply adjustments Carburetor VM CPI Main jet 47 5 Idling jet 15 Position jet needle 2 from top Float chamber level 14 1 mm Air adjustment screw 1 turns Idling speed 1800 100 min 1 Automatic cold start equipment stroke at 12 V AC 4 mm 5 min Tires filling pressure Front wheel 120 70 12 51J Rear wheel 130 70 12 5...

Page 33: ... 8 30 Standard torque for 12 60 screws and nuts without 10 40 special function 8 25 6 12 5 4 Spark plug 14 15 Electrical assy Battery charging voltage Battery fully charged 14 0 5 V Battery charging current Battery empty 0 4 A Fuse 8 A Bulb headlamp 35 35 S2 W License plate illumination W Bulb rear and stop lamp 21 5 W Bulb winker 10 W Ignition pulse generator 500 50 Ω Ignition coil primary 0 3 0 ...

Page 34: ...TECHNICAL DATA TD 20 NOTES ...

Page 35: ...SPECIAL TOOLS ST 1 SPECIAL TOOLS DESCRIPTION AND USAGE ST 2 ...

Page 36: ...ng the bearings from the crankshaft Universal fixing tool DER 00005253240 Fixing the variomatic and the clutch Assembling bush CPI 000W 10 Assembling the left crankcase gasket Assembling bush CPI 000W 11 Assembling the right crankcase gasket Con rod holder DER 00G05600371 Fixing the conrod by diverse disassemblings Temperature measuring chalk DAE TKF900120 Mounting the bearing in the crankcase Spa...

Page 37: ...SPECIAL TOOLS ST 3 NOTES ...

Page 38: ......

Page 39: ...YSTEM OVERVIEW FL 2 MAINTENANCE NOTICE FL 3 TOOLS FL 4 FAULT TRACKING FL 4 CARBURETOR REMOVAL FL 5 CHECKING TH CHOKE FL 5 DISASSEMBLY FL 7 FLOAT CHAMBER LEVEL FL 7 SLIDE VALVE FL 7 FACTORY DEFAULT FL 8 REED TYPE INLET VALVE FL 10 ...

Page 40: ...CARBURETOR FL 2 SYSTEM OVERVIEW ...

Page 41: ...arbon monoxide and can lead to the unconsciousness and to death 6 Petrol is bad for health and can cause skin cancer Any unnecessary skin contact has to be avoided 7 Used fuels are hazardous waste They have to be disposed carefully and in line with the local regulations 8 Avoid flying sparks open flames or smoking when working with fuel 9 If necessary mark the position of pipings and their support...

Page 42: ...Carburetor jets bores clogged Fuel tank ventilation fuel filler cap clogged Clogged fuel supply filter clogged supply line squeezed Carburetor float needle valve hangs does not open Carburetor float chamber level too low Engine vacuums parasitic air Air cleaner body leaky A F mixture too rich Choke valve clogged Nozzles clogged Carburetor float needle valve hangs does not open due to soiling Carbu...

Page 43: ... the oil hose from the carburetor Release the pipe clamp from the air cleaner snorkel and remove the carburetor Drained fuel has to be properly disposed CHECKING THE CHOKE Check the cables if they are conductive The resistance should be below 35 Ohm Remove and let cool down the carburetor Check the additional air bore s picture ok when you are able to blow in not ok when you are not able to blow i...

Page 44: ...material takes in fuel so that the seal swells In this case the seal shall be dried in the sun In most cases it can be reused Drive out the float hinge pin with a suitable taper pin punch Remove the float with the needle valve Unscrew the the main jet the idle jet the slide valve stop screw and the idle screw Clean any deposits or cloggings in the the float chamber cover and bores with compressed ...

Page 45: ... overflow tube and the heating cable for damage and aging Connect all lines to the carburetor Adjust the throttle control cable Adjust the free play of the throttle control cable SLIDE VALVE Disassembly Release the screws in the carburetor cover Press the spring into the cover and remove the securing plastic stopper from the slide valve Then unhook the control cable from the slide valve Remove the...

Page 46: ...capacity of the A F mixture can enter the carburetor Assembly 45 km h No stop collar Put the needle jet together with the retaining clip in the slide valve Put the plastic stopper and the spring over the control cable and hook the cable in the slide valve Align the guide slot of the slide valve with the guide in the carburetor body comp photo Place the cover onto the carburetor and fasten the scre...

Page 47: ...air adjustment screw shall be gradually screwed in clockwise by quarter turns When the idle speed decreases during this A F mixture modification the idle speed value has to be set back to the desired value Carry out this adjustment by means of the idling adjusting speed If necessary repeat this step every time the screw is turned in by a quarter turn If the mixture is too rich the idle speed shall...

Page 48: ...t valve and check the reeds for tightness Limit value 0 1 mm Also check the inlet valve for damage and replace it if necessary Install the inlet valve and the intake manifold in reverse order For the proper assembly of the threaded joint a new tear off screw shall be used Check the firm fit of the intake manifold which connects the carburetor and the engine and make sure it is air tight Ensure tha...

Page 49: ...CARBURETOR FL 11 NOTES ...

Page 50: ......

Page 51: ...OIL PUMP LB 1 OIL PUMP SYSTEM OVERVIEW LB 2 REMOVAL LB 3 INSPECTION LB 3 INSTALLATION LB 3 BLEEDING LB 4 ...

Page 52: ...OIL PUMP LB 2 SYSTEM OVERVIEW ...

Page 53: ... suitable plugs so that no oil can flow out Unhook the oil pump control cable Loosen the fastening screws of the oil pump and remove the oil pump INSPECTION Check the oil pump for leakage Check the O ring the drive sprocket and the shaft seal for wear and damage Check the driving tab for wear Do not dismantle the oil pump INSTALLATION The O ring seal has to be replaced prior to reinstalling Provid...

Page 54: ...l fuel mixture ratio in order to ensure that it is sufficiently lubricated Loosen the bleeder bolt and wait until the oil drains out without bubbling Put the cable in the pump and adjust it as per marking The minimum marking must be coherently oriented when the twist grip is closed and the maximum marking must be coherently oriented when the grip is fully opened Remove the delivery line at the car...

Page 55: ...OIL PUMP LB 5 NOTES ...

Page 56: ... OVERVIEW CR 2 CYLINDER HEAD DISASSEMBLY CR 3 CYLINDER DISASSEMBLY CR 3 PISTON DISASSEMBLY CR 4 PISTON ASSEMBLY CR 7 CYLINDER ASSEMBLY CR 7 COMPRESSION PRESSURE TESTING CR 7 CRANKCASE CRANKSHAFT CR 8 DISMANTLING THE ENGINE CASE CR 9 CRANKSHAFT CR 9 ASSEMBLING THE CRANKCASE CR 11 ...

Page 57: ...CRANK DRIVE CRANKCASE CRANKSHAFT CR 2 SYSTEM OVERVIEW ...

Page 58: ...e air filter body Remove the fan covers Remove the spark plug Loosen the cylinder head nuts Remove the cylinder head Check the mating surfaces of the cylinder head with a straightedge for warpage Limit value 0 05 mm CYLINDER DISASSEMBLY Remove the cylinder head Remove the cylinder Remove he cylinder base gasket The gasket surfaces shall be properly cleaned prior to reassembling ...

Page 59: ...three different areas of the tread each staggered by 90 TDC ring area Middle ring area BDC ring area Wear limit 40 09 mm PISTON DISASSEMBLY Keep the piston on position and remove the circlip of the piston pin with a suitable tool by holding it on one side Press out the piston pin towards that side Remove the piston and remove the needle bearing from the piston boss Fill the opening of the engine w...

Page 60: ...e diameter wear limit Aragon Formula R 39 84 mm Aragon GP mm The maximum clearance between piston and cylinder must not exceed the defined limit value In case of deviations from the limit value both the piston and cylinder have to be replaced Clearance limit value Aragon Formula R 0 1 mm Aragon GP mm Measure the ovality and the conicity Ovality and conicity wear limit Aragon Formula R Ovality 0 05...

Page 61: ...osition spigots Lubricate the piston rings and the ring grooves with a small amount of two stroke oil If piston rings shall be reused then they have to be checked for wear before they are mounted The piston rings have to be pressed in at about 10mm into the slightly oiled cylinder and have to be aligned at a right angle to the tread Measure the ring gap of the piston with a feeler gauge in order t...

Page 62: ...e aligned with the direction of movement of the piston Check the connecting rod small end Wear limit 14 06 mm CYLINDER ASSEMBLY Mount a new cylinder base gasket Slightly lubricate the cylinder the piston and the piston rings and mount the cylinder Torque 15 Nm COMPRESSION PRESSURE TESTING Make sure that the engine has reached its operating temperature and that the throttle valve is fully opened Re...

Page 63: ...CRANK DRIVE CRANKCASE CRANKSHAFT CR 8 CRANK DRIVE CRANKCASE CRANKSHAFT CR 8 CRANKCASE CRANKSHAFT ...

Page 64: ... from the left crankcase with the aid of a standard bearing and casing puller Remove the crankshaft bearings from the crankshaft with a suitable bearing puller ggg CRANKSHAFT Check the horizontal and the radial play respectively of the big end bearing with the aid of a feeler gauge The radial play shall be determined by a crossover measurement Maximum horizontal play 0 55 mm Maximum radial play 0 ...

Page 65: ...place it on a vee block for measuring Measure the lateral runout with the aid of two dial gauges The actual value is the half of the measured value Maxiumum lateral runout 0 1 mm Check the crankshaft bearing clearance In case of noises or abnormal clearance the bearings shall be replaced ...

Page 66: ...o driving in the bearing Use temperature indicating chalk Special tool TKF900120 Mount the crankshaft bearing in the right crankcase The crankcase shall be heated up to approx 120 C prior to driving in the bearing Use temperature indicating chalk Special tool TKF900120 Heat up the crankcase half with the mounted bearing to approx 120 C Mount the crankshaft in the bearing ...

Page 67: ... right crankcase to approx 120 C and mount the crankshaft bearing Use temperature indicating chalk Mount the crankshaft in the crankcase Mount the left crankshaft seal Grease the shaft seal prior to mounting Pay attention not to chock the shaft seal The sealing lip must not get damaged The shaft seal shall be positioned below the crankcase edge Special tool 000W 10 After the mounting of the cranks...

Page 68: ...e the shaft seal prior to mounting Pay attention not to chock the shaft seal The sealing lip must not get damaged Special tool 000W 10 Put together bowth crankcase halves with the crankshaft Insert the crankcase mounting bolts and tighten them as per defined torque Torque 10 Nm ...

Page 69: ...CRANK DRIVE CRANKCASE CRANKSHAFT CR 14 NOTES ...

Page 70: ......

Page 71: ...E COVER AND BELT DRIVE REMOVAL VT 3 V BELT VT 4 ROLLER WEIGHT MEASURING VT 5 ROLLER WEIGHTS CHECK VT 5 MOVABLE DRIVE FACE VT 6 CLUTCH SHOE UNIT VT 7 DISASSEMBLING THE CLUTCH UNIT VT 7 FAST PULLEY VT 8 CLUTCH SPRING VT 8 MOVABLE PULLEY VT 8 REASSEMBLY VT 9 TRANSMISSION VT 9 FINAL DRIVE VT 9 ...

Page 72: ...VARIOMATIC TRANSMISSION VT 2 SYSTEM OVERVIEW ...

Page 73: ...ut of the centrifugal clutch and remove the entire clutch together with the V belt Torque 35 40 Nm Special tool ACC ST8362070 Loosen the securing nut of the continuously variable belt transmision system and remove the variomatic transmission unit Torque 35 40 Nm Special tool ACC 00005253240 Remove the overrunning clutch and the spacer sleeve ...

Page 74: ... side Upper side wear limit 16 5 mm Lower side wear limit 12 mm Replace the drive belt if the wear limit is exceeded If the lower side width is less than the defined wear limit the angle of the V belt shape is changed Note that the proper functioning of the belt transmission is not ensured if the belt width is less than the defined wear limit ...

Page 75: ...e Replace damaged or excessively worn roller weights Check the roller weights for roundness If roller weights are flatted too much they shall be replaced on the technician s own discretion Excessively worn damaged or flatted roller weights have negative effect on the proper functioning of the continuously variable belt transmission The torque power ratio is no longer given particularly upon the ve...

Page 76: ... mm Check the guide sleeve for scuffing cracks etc and replace it if necessary Measure the diameter of the guide sleeve Wear limit 20 90 mm Measure the inside diameter of the clutch bell housing Wear limit 112 4 mm Note Any blue tint of the clutch bell housing has no negative effect on the functioning of the clutch friction ...

Page 77: ...l not get jammed or stuck Check whether the rubber stop pins are available Check the stop pins for wear crackings or aging DISASSEMBLING THE CLUTCH UNIT When disassembling the clutch unit make sure that all components are adequately cleaned This will ensure that they can be properly measured Fix the clutch unit with a specially designed tool Loosen the 38 mm clutch nut Release the clutch spring an...

Page 78: ...ter of the fast pulley Limit value 32 90 mm Fast pulley CLUTCH SPRING Measure the free length of the clutch spring Cluch spring length JR 67 mm 103 mm Aragon GP 25 km h 30 45 km h Aragon 25 30 km h 45 km h Formula R 25 30 km h 45 km h MOVABLE PULLEY Measure the inside and the outside diameter of the movable pulley Check the O rings and the sealing rings for damage and wear Wear limit 33 10 mm ...

Page 79: ... clutch component parts Check the functioning of the clutch i e its free movement subsequent to the reassembly TRANSMISSION Remove the transmission output shaft and the intermediate shaft When removing the inter mediate shaft pay attention to the thrust washer It must not get lost upon the removal of the intermediate shaft FINAL DRIVE Check all gears and shafts for wear and damage Oil filling capa...

Page 80: ...VARIOMATIC TRANSMISSION VT 10 NOTES ...

Page 81: ...TANCE CHECK DUMMY CONSUMERS ES 5 IGNITION COIL ES 5 MAGNETO IGNITION ES 6 PULSE GENERATOR ES 6 IGNITION TIMING ADJUSTMENT ES 6 STARTING MOTOR RELAY ES 7 FUEL LEVEL SENSOR ES 8 FUEL LEVEL INDICATOR ES 8 OIL LEVEL SENSOR ES 8 HEADLIGHT DIMMER ES 9 STARTER BUTTON ES 9 LIGHT CONTROL ES 9 TURN SIGNAL SWITCH ES 9 HORN SWITCH ES 9 IGNITION AND STARTER SWITCH ES 9 WIRING DIAGRAMS ES 10 ...

Page 82: ... Remove the seat and the helmet box Remove the blower hood Loosen the impeller screws and remove the impeller Immobilize the flywheel with a suitable tool and loosen the lock nut with a socket wrench Torque 35 Nm Special tool ACC 00G05300011 ...

Page 83: ...el with a suitable puller Special tool AB 09 Disconnect the plug in connection from the generator Loosen the securing bolts of the stator assembly and remove the stator GENERATOR INSTALLATION The generator shall be installed in reverse order ...

Page 84: ... are suited for those battery types e g Optimate Tec Mate International S A B 3300 Tienen Belgium The use of non suited chargers may cause damages to the starter battery Charging current 0 4 A Charging time 5 0 5 hours LIGHT CHARGING COIL Light coil Measure the resistance between the green red and black cables Desired value 0 8 0 4 Ω at 20 C ambient temperature Charging coil Measure the resistance...

Page 85: ...4 0 2 Ω at 20 C ambient temperature IGNITION COIL Measure the primary coil winding with an ohmmeter Desired value 0 4 0 6 Ω at 20 C ambient temperature Measure the secondary coil winding with an ohmmeter Desired value at 20 C ambient temperature With spark plug connector 10 1 kΩ Without plug connector 3 0 5 kΩ ...

Page 86: ... 50 Ω at 20 C IGNITION TIMING ADJUSTMENT The ignition point shall be adjusted when the engine has reached its operating temperature Use a stroboskopic lamp for the ignition point checking Procedure Mark the engine case with an ignition marking Unplug the spark plug connector Screw off the spark plug Insert tool in spark plug hole until it meets the piston Turn the magnet wheel to the right until t...

Page 87: ...DC marking on the engine case Desired value 17 1800 rpm STARTING MOTOR Connect a fully charged starter battery and measure the engine capacitance Current consumption approx 20A Special tool AB 239917 STARTING MOTOR RELAY Connect the starting motor relay 30 contact and the ground contact to a 12V current source green red yellow and measure the continuity between the two screw terminals Continuity o...

Page 88: ...e the float up and check whether the fuel level indicator also moves from E to F Move the float down and check whether the indicator moves from F to E as well OIL LEVEL SENSOR Remove the seat and the helmet box Disconnect the plug connection of the oil level sensor Remove the the sensor from the oil reservoir Measure the continuity of the red white and blue cables Float Position OK NOK Up X O Down...

Page 89: ...TER BUTTON Color Position Green Yellow Brown Black OFF ON LIGHT CONTROL Color Position Yellow Red Green Red Brown White Yellow Pink Off Parking light Running light TURN SIGNAL SWITCH Color Position Green White Orange Green Black Left Neutral Right HORN SWITCH Color Position Brown Black On Off IGNITION AND STARTER SWITCH Color Position Red Dark green Black Red White Gray Off On Check ...

Page 90: ...ELECTRICAL SYSTEM ES 10 WIRING DIAGRAMS Aragon GP ...

Page 91: ...ELECTRICAL SYSTEM ES 11 Aragon ...

Page 92: ...ELECTRICAL SYSTEM ES 12 Formula R ...

Page 93: ...ELECTRICAL SYSTEM ES 13 NOTES ...

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