Gilera Nordwest, Workshop Manual

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INSPECTION
All removed components must be inspected carefully after having been
thoroughly cleaned with kerosene or other solvent and dried with compressed
air. All parts that show signs of damage or wear must be replaced.
Be sure the pinion teeth aren’t excessively worn, freewheel group functions
properly (roller race must not show signs pitting, grooving or similar damage),
as well as the selector drum group.
REASSEMBLY
Reassemble all components in reverse order of disassembly; pay close
attention to the following:
Replace the block’s left side cover gasket and the O-ring found behind the final
drive pinion.
Mount the pinion mounting bolt spring washer, of the freewheel starter group
and generator rotor, with the convex side facing out.
The two pinion mounting bolt spring washers, found behind the generator
rotor, and the timing belt’s large guide washer must be mounted as shown in
fig. 17.
The gap between the pick-up and rotor plate must be between 0.4 and 0.5
mm.
The drum selector control device may be adjusted if necessary. Select either
2nd, 3rd or 4th gear and verify that (in the rest position) either extremity of the
lever is at the same distance to the drum’s adjacent drag grain. Adjustment is
made by turning the cam screw (on the lever) after having loosened the lock
nut.
VALVE TIMING
Put piston at TDC (indicated by aligning the reference mark on the generator
rotor with the fixed mark, as shown in fig. 18.
Place the camshafts with their reference marks facing as shown in fig. 19.
This operation must be carried out without actuating the valves (rotate it clock-
wise or counter-clockwise as necessary).
Install the timing belt and take up the slack with the tensioner pulley.
After loosening the fastening nut, the calibrated spring will set the tensioner
pulley automatically. Be sure to let the belt align on the cam pulleys by turning
the crankshaft several times prior to fastening the nut.
After having fastened the nut, make sure the pulley reference marks align with
the fixed ones. Torque the nut to between 28 and 30 Nm.
Always replace the timing belt according to the scheduled maintenance (every
12,000 km).
The timing belt is never to come in contact with oil, petrol or grease and is to
be handled with clean hands only. Avoid bending or twisting the belt.
The belt must be installed by hand, that is, do not use screwdrivers or other
tools.
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