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Italjet Dragster 2022, Maintenance Manual

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Italjet Dragster 2022 Maintenance Manual Download Page 134

Refitting the flywheel magneto

•

Fit the flywheel paying attention to in-

sert the cotter adequately.

•

Lock the flywheel nut to the prescribed

torque.

Locking torques (N*m)

Rotor TEF fixing screw - M8x25 (1)

 

25 Nm (18.44

lbf ft) - Loctite 243

Refitting the starter motor

- If the O-ring is damaged, fit a new one on the

starter motor and lubricate it.

- Fit the starter motor on the crankcase and tighten

the 2 screws.

CAUTION

ADEQUATELY COUPLE THE MOTOR GEAR WITH THE
STARTER DOUBLE GEAR.

Locking torques (N*m)

Starter motor EI fixing screws - M6x25 (2)

 

10 Nm

(7.38 lbf ft)

Cylinder assy. and timing system

Removing the rocker-arms cover

•

Undo and remove the four screws.

•

Remove the tappet cover.

134

Summary of Contents for Dragster 2022

Page 1: ...ty Failure to fully comply with these instructions can result in a serious risk of personal injury Environmental protection The symbol indicates proper use of the motorcycle to prevent damage to the e...

Page 2: ...el 18 Clean the Air Filter Element 19 Clean the Transmission Air Filter 20 Spark Plug Check 21 Check Tyres and Relative Tyre Pressure 21 Check the Wear of Brake Pads 23 Check the Front and Rear Brake...

Page 3: ...n 49 Side kickstand optional 50 Central kickstand 51 Check before use 52 Instructions on the Use of Motorcycles 54 Running in instructions 54 Identification of operational problems 54 Oxygen Sensor 55...

Page 4: ...or 129 Refitting the flywheel cover 129 Removing the starter motor 130 Removing the flywheel magneto 131 Intermediate gear 132 Refitting the free wheel 133 Refitting the flywheel magneto 134 Refitting...

Page 5: ...ITALJET Chapter 1 Overview 5...

Page 6: ...arket one by one for you but your ITALJET authorized service shop can help you select high quality accessories and install them properly for you Extreme care must be taken for selecting and installing...

Page 7: ...ect air resistance and maneuverability Be sure to keep the balance on the left and right sides of the motorcycle and firmly install the accessories Important Notes Knowledge of motorcycle running in T...

Page 8: ...the service life of spark plugs exhaust system components and machinery and protect the environment and reduce air pollution Attention Spilled gasoline is harmful to the motorcycle and can damage the...

Page 9: ...ontainers can be used Do not use or mix different types of brake fluid In case of rapid loss of brake fluid it should be checked by an ITALJET dealer or a qualified technician Attention Spilled brake...

Page 10: ...t the oil warm up before driving Before loading the engine let the cold or hot engine idle for about 30 seconds to 1 minute so that the lubricating oil has enough time to lubricate the engine parts Ca...

Page 11: ...ITALJET Chapter 2 Maintenance and Service 11...

Page 12: ...tenance intervals may need to be reduced Warning Poor or improper maintenance of a motorcycle will increase the risk of injury or death during the use of the vehicle Maintenance work should be done by...

Page 13: ...L L Front clutch plastic feather key R R R R R Rear clutch drum C C C C C C C C C C CVT belt R R R R R CVT chamber filter I I I I I Engine oil filter R R R R R R R R R R R Valve clearance A A A A A Hu...

Page 14: ...6 42 48 54 60 EVAP Evaporative System Containers and pipes I I I I I I Cooling system Coolant level I I I I I I I I I I I Cooler C C C C C Fuel supply system Fuel filter R R R R R Fuel pipe I I I I I...

Page 15: ...I I I I I I I Brake fluid I I I I I I Suspension I I I I I Wheels tyres I I I I I I I I I I I Steering system I I I I I I Exhaust system I I I I I Idle speed control A A A A A A I Inspection cleaning...

Page 16: ...en take it out and check whether the oil level is between the minimum oil level mark MIN and the maximum oil level mark MAX When the oil lever is lower than the minimum oil level mark MIN it is requir...

Page 17: ...o screws 3 and remove the cover 4 Remove the oil filter 5 and check its condition Replace it if necessary Reinstall the drain plug 2 and replace the seal gasket 6 Reinstall the filter 5 pay attention...

Page 18: ...check for oil leaks In case of oil leaks stop the engine immediately and find the cause Shut off the engine check the oil level and correct if necessary Reset the maintenance intervals as described in...

Page 19: ...the filter element 3 from the air filter 2 Clean the filter element 3 with appropriate filter element cleaning agent and make it completely dry Warning Do not use gasoline or other flammable solvents...

Page 20: ...cap 5 for dirt If you see any dirt remove the air filter bag and clean it before reassembly Clean the Transmission Air Filter Unscrew the screw 1 and remove the CVT outer cover 2 Unscrew the screw 3...

Page 21: ...Remove the spark plug cap 1 Use the spark plug socket to remove the spark plug 2 Check Tyres and Relative Tyre Pressure Always keep your tyres in good condition and at proper intervals Tyres should b...

Page 22: ...tyres must be the same Using different types of tyres for front and rear tyres will affect the stability and mobility of the motorcycle Note Even if any wear is observed tyres will also be aging Trans...

Page 23: ...tyre surface thus fully developing its characteristics Note To replace a tyre it is required to balance the wheel Always inspect the rim for any crack bending distortion or other damage before each u...

Page 24: ...are worn to the point where the wear indicator almost touches the brake disk replace a pair of brake pads Warning To replace the brake pads you must contact your Jincheng dealer Warning After replaci...

Page 25: ...is too soft there is air in the pipe or a system defect As it is dangerous to ride a motorcycle under these conditions please have your Jincheng dealer check the braking system immediately Attention...

Page 26: ...e fluid level to decrease gradually If the brake fluid level is low the brake pads may be worn and or the brake circuit may be leaking Therefore it is important to check the wear level of the brake pa...

Page 27: ...or drop please have it checked or repaired by your Jincheng dealer Pretension Force Adjustment of Shock Absorber Springs Adjust the front shock absorber 1 and rear shock absorber 2 to adjust the pret...

Page 28: ...d stabilize it and the other person must try to move the wheel 1 in the direction of the arrow A and the arrow B If the clearance is found excessively large please contact your Jincheng dealer to chec...

Page 29: ...h the help of the voltmeter Otherwise the battery needs to be charged To use the DC voltage for the battery charger connect the red positive cable to the positive terminal of the battery first and the...

Page 30: ...ation 5 10 hours Battery specifications 12V 8 6A Warning Battery charging can produce explosive gas Keep ventilation when charging the battery indoors When using a battery charger connect the battery...

Page 31: ...en from the top Lift the front panel 3 with both hands and pull outward until it is removed from the large lampshade The fuse box 4 is located on the upper right side of the motorcycle Fuse 5 15A Lamp...

Page 32: ...isassembly process Carefully insert the plastic clips 8 on the front panel 3 into the square holes 9 Attention Do not use a fuse with the current bigger than the original fuse or otherwise it may caus...

Page 33: ...ld be carried out every 10000km Check whether the rear shock absorber leaks oil and check whether the swing frame moves If any parts are faulty replace them immediately Exhaust Pipe Bolts and Muffler...

Page 34: ...ITALJET Chapter 3 Motorcycle Maintenance 34...

Page 35: ...orcycle Parts Right side view 1 Rider foot pedal 2 Rider seat cushion 3 Passenger seat cushion 4 Passenger armrest 5 Passenger foot pedal 6 Rear shock absorber 7 Exhaust muffler 8 Storage compartment...

Page 36: ...ont brake caliper 4 Front swing arm 5 Front shock absorber 6 Seat cushion lock 7 Voltage regulator 8 Engine 9 Air filter 10 Central kickstand 11 Gearbox air filter 12 Rear brake disc and rear brake ca...

Page 37: ...or 2 Left mirror 3 Right turn indicator lamp 4 Left turn indicator lamp 5 Headlamp 6 Right radiator 7 Left radiator 8 Tail lamp 9 Rear left turn indicator 10 Rear right turn indicator 11 Rear registra...

Page 38: ...cover for left handle 2 Left handle switch assembly 3 Rear brake lever 4 Rubber cover for accelerator handle 5 Right handle switch assembly 6 Front brake lever 7 Ignition switch 8 USB socket 9 Instrum...

Page 39: ...e switch assembly is moved to the left the indicator lamp blinks Right turn signal indicator lamp When the control switch of the right handle switch assembly is moved to the right the indicator lamp b...

Page 40: ...serve level about 2 liters indicating that the driving range is limited Please refuel as soon as possible ABS alarm lamp When you turn the ignition key the ABS control unit will diagnose itself and th...

Page 41: ...splay 4 In this part of the display you can view partial km mile travel Travel A or Travel B and relative travel time i e total km mile travel Service reminder indicator 5 When the total mileage reach...

Page 42: ...same time for more than two seconds and the hour and minute indicator lamps start flashing Press Mode to increase the number of hours and press Set to increase the number of minutes Hold the Mode and...

Page 43: ...ing lock position You can remove the key Key removal position By turning the key into the position turn off the engine and lamps and then remove the key from the ignition switch Startup Position From...

Page 44: ...g gear is as follows Turn the handlebar to the far left Insert the key 1 into the position of the ignition switch 2 press the key 1 and turn counterclockwise to the position Remove the key 2 To unlock...

Page 45: ...l flash simultaneously and the left turn symbol and right turn symbol indicator lamps on the instrument panel will also flash Note Use the hazard lamp only when it is necessary to warn other vehicles...

Page 46: ...only under true emergency When the switch is pressed in the position engine startup and operation will be disabled When the switch is pressed in the position the engine can run and start Engine start...

Page 47: ...tion of controls on the handlebar Warning Don t forget to tighten the screws 2 after adjustment Rear brake control The brake handle 1 is located on the left side of the handlebar When braking the brak...

Page 48: ...ermal exhaust system Check that the exhaust system is cooled before maintenance Never run the engine without driving the motorcycle even for a few minutes Idling for long periods of time may cause hea...

Page 49: ...key 1 into the lock 2 and turn until the seat cushion lock is removed Note After opening the storage compartment under the seat cushion you can remove the key from the lock Lift the seat cushion 3 to...

Page 50: ...ed on the side kickstand When the side kickstand is lowered while the motorcycle is running the engine will stop The side kickstand is located on the left side of the frame When keeping the motorcycle...

Page 51: ...ention It is dangerous to sit on the motorcycle when it is parked on the central kickstand thus placing its weight on the parking bracket To lay down the motorcycle from the central kickstand do the f...

Page 52: ...icle inspected by the Italjet dealer Before using this vehicle please check the following items Component Control Fuel Check fuel level in the fuel tank Refuel if necessary Check the fuel circuit for...

Page 53: ...efill oil if necessary please contact your Jincheng dealer for oiling Check the hydraulic system for leaks Side kickstand and central kickstand Ensure their smooth movement Lubricate pivot points if n...

Page 54: ...for long periods of time Avoid long trip without stopping Identification of operational problems A list of any of the following operational problems is generally used to identify the source of the pro...

Page 55: ...y be damaged if it is dropped In such case replace the oxygen sensor with a new one Be careful with the oxygen sensor The oxygen sensor may not be repaired at high temperature Disassembly procedures 1...

Page 56: ...Catalytic Converter Removal installation 1 Remove the screws and hoop using tools 2 Remove the nuts and oxygen sensor using tools 56...

Page 57: ...t 4 Assemble it in the reverse order of disassembly Test Remove the EVAP purge control solenoid Check that air should flow from A to B when only the 12V battery is connected to the EVAP purge control...

Page 58: ...d Diagnostics Removal installation 1 Open the seat cushion to expose ABS and OBD 2 Remove the cover parts and pull out and from behind 3 Pull the other sides of ABS and OBD out from the rear of the fr...

Page 59: ...Electronic Control Unit ECU 1 Remove and and remove the accelerator cable before pull out 2 Remove the hoops and 3 Remove the rubber cover and pull out the ECU 59...

Page 60: ...Brake System Schematic Diagram 60...

Page 61: ...Bushing 16 Clip 5 ABS unit mounting support ABS 11 Bolt 17 6 Bolt 12 Rear brake caliper mounting support 18 Rear Brake Disc Disassembly Remove the muffler Remove the muffler support Remove the rear wh...

Page 62: ...r If the minimum thickness even at a single point on the brake disc is less than the minimum value replace the brake disc Warning The brake disc must be mounted on the wheel before operation Performan...

Page 63: ...hub Remove the brake disc Note Manually tighten all bolts Warning After reassembly use the recommended product onto the brake disc bolt threads Inspection of Brake Discs Visually check the surface of...

Page 64: ...ke disc is less than the minimum value replace the brake disc Warning The brake disc must be mounted on the wheel before operation Performance parameter Minimum brake disc thickness 3 5mm Use a dial i...

Page 65: ...ont Brake Pad Disassembly Unscrew the two bolts 1 to remove the front brake caliper Tightening torque N m Tightening torque of the front brake caliper bolt 1 25N m Unscrew and remove the thread cap 2...

Page 66: ...may detach from its plunger bore thus resulting in the leakage of brake fluid Warning Replace both brake pads at the same time and make sure they are properly placed in the slots For refitting follow...

Page 67: ...Tightening torque N m Tightening torque of M8 screws fastening the rear brake caliper 25N m Remove the clasp 67...

Page 68: ...Slide down the pin Remove the spring Warning The arrow printed on the spring must always turn in the direction of travel Slide down the brake pad 68...

Page 69: ...bore thus resulting in the leakage of brake fluid Warning Always replace both brake pads and make sure they are properly placed in the slots Brake System Air Removal Warning In consideration of any h...

Page 70: ...end of the hose into the container to collect the brake fluid Quickly and repeatedly press the brake handle and then press it down completely Loosen the vent valve 1 4 turn to allow the brake fluid to...

Page 71: ...uid into the brake fluid Check whether brake fluid is always present in the liquid storage tank during operation Tighten the vent valve and remove the transparent hose Fill with brake fluid until the...

Page 72: ...r end of the hose into the container to collect the fluid Quickly and repeatedly press the brake handle and then press it down completely Loosen the vent valve 1 4 turn to allow the brake fluid to flo...

Page 73: ...ke fluid level is obtained Remount the rubber protective cover Replacement of brake fluid Remove the rubber protective cover Insert the transparent plastic hose into the exhaust valve 1 of the caliper...

Page 74: ...with brake fluid Loosen the exhaust valve 2 about half turn again Check brake fluid from the hose When the brake fluid color changes from dark to light it is required to tighten the exhaust valve 2 an...

Page 75: ...Cooling System Schematic Diagram 75...

Page 76: ...5 Water inlet rubber tube 25 Hoop 35 Spring washer 6 Water storage tank inlet pipe 16 Coolant bypass pipe 26 Hoop 36 Flat washer 7 Overflow pipe 17 Water outlet rubber tube 27 Hoop 37 Locking plate 8...

Page 77: ...d at least 55 cm 21 65 in off the ground Filling Remount the coolant delivery line and tighten it with a pipe clamp Fill the cooling tank with coolant until the level reaches the MAX reference mark Fi...

Page 78: ...Check the water level of water storage tank and radiator fill them with water to the correct level if necessary Remount the front baffle Tightening torque N m Coolant water pipe hoop 3N m 78...

Page 79: ...Suspension Schematic Diagram of Front Wheel Removal 79...

Page 80: ...ancing weight 3 Washer 9 Bolt 15 Needle bearing 4 Retainer ring 10 Front brake disc 16 Front hub assembly 5 Front hub 11 Screw 6 Front wheel rim 12 Screw Warning The support device under the vehicle i...

Page 81: ...1 Warning After disassembly modification please be careful not to damage the brake line disc and brake pad Warning Do not step on the brake after removing the wheel Otherwise the caliper plunger may d...

Page 82: ...g 1 The inner ring must rotate smoothly without obstacles and or noise No axial clearance is allowed The bearings with these problems must be replaced Warning Check whether all parts are in good condi...

Page 83: ...runout B of the rim 3 do not exceed the limit Eccentricity is usually caused by bearing wear or damage If the value is not within the specified range after replacing the bearing please replace the ri...

Page 84: ...of the vehicle Replace the tire when it is worn or the worn tread diameter is greater than 5 mm Some tire types have been homologized for the vehicle s characteristic wear indicator Check whether the...

Page 85: ...Schematic Diagram of Rear Wheel Removal 85...

Page 86: ...Rear rim 26 Rear hub 35 Muffler hanger bracket assembly 6 Flat washer 16 Rear brake disc 27 Speed sensor rear mounting plate 7 Muffler hanger bracket 17 Screw 28 Screw 8 Bolt 18 Rear tyre 29 Corrugate...

Page 87: ...ove the rear axle nuts and then collect bushings Unscrew and remove bolts from the muffler bracket and the rear fender bracket 1 2 3 4 5 and collect nuts and washers Remove the muffler bracket Collect...

Page 88: ...eakage Check the fastening of all components and correct operation of rear suspension joints Disassembly To remove the shock absorber follow these steps Remove the helmet box Operate from the right si...

Page 89: ...the lower crew 1 holding the shock absorber Remove the shock absorber Tightening torque N m Shock absorption after bolt fixation 50N m Muffler hanger bracket To remove the muffler plate follow these...

Page 90: ...collect nuts Tightening torque N m Shock absorption after bolt fixation 50N m Operate the rear brake with the help of the second operator loosen and remove the rear nuts of fixing plates and then col...

Page 91: ...e and exhaust muffler are cooled Make sure the vehicle is completely safe and has no side frame To remove the center bearing bracket and its support follow these steps Ensure that the vehicle can be s...

Page 92: ...low these steps Ensure that the vehicle can be supported without the help of the center bearing bracket Remove the spring 2 from the central kickstand and spring connecting pins on both sides Loosen a...

Page 93: ...Starting relay Starting relay resistor power on terminals 1 and 2 connected Starting relay resistor power off terminals 1 and 2 disconnected 2 Horn Horn activated voltage battery voltage Horn disable...

Page 94: ...3 Headlamp Front position lamp 12V 4 6W High beam low beam 12V 66W 38W Front turn indicator lamp 12V 4 6 W 4 Voltage regulator Output voltage 13V to 15 V 94...

Page 95: ...5 Starting motor Relay voltage supply battery voltage Resistance 0 5 6 Tail lamp Rear position lamp brake lamp 12V 5 9W 7 5W Rear turn indicator lamp 12V 1 9 W Registration plate lamp 12V 0 7W 95...

Page 96: ...coolant temperature sensor Coolant temperature C resistance OHM Coolant temperature Characteristic injection exposure value Dashboard exposure value 50 807 820 120 105 80 6 8 Spark plug Standard NGK...

Page 97: ...ension coil Primary resistance 0 5 Secondary resistance 3 1 k 10 Fuel level sensor Operational check of the fuel level sensor removed from the vehicle Fuel pump black Fuel pump red Sensor black Sensor...

Page 98: ...8 6Ah 12 Auxiliary fuse 15A fuse from the ignition switch to all light loads registration plate lamp direction indicator lamps and horns 15A fuse Ignition injection and starting power source 15A fuse...

Page 99: ...ery voltage 12 V 300 W 6000 rpm Rated power 300 W Resistance 0 36 0 44 Resistance between cable and stator bracket infinite Crankshaft angle sensor resistance 129 10 14 Flasher assembly Voltage 13 5V...

Page 100: ...15 Velocity transducer 16 Dumping switch Horizontal position 61 9 k Tilt position 45 0 100...

Page 101: ...17 Control unit accelerator body 18 Injection nozzle Resistance at ambient temperature 14 5 19 Relay Cooling fan Electronic fuel injection system EFI 101...

Page 102: ...Electrical Diagram 102...

Page 103: ...ring Loctite 243 8 Frame connector assembly 25 30 Loctite 243 9 Engine pylon assembly 60 72 10 Front hub and steering knuckle mounting 75 90 11 Front swing arm subassembly gluing the front axle combin...

Page 104: ...e hanger buffer bushing mounting 50 60 24 Engine mounting 50 60 25 Rear disc brake clamp mounting 25 30 Loctite 243 26 Rear wheel mounting 50 60 Loctite 243 27 Rear wheel fastening 90 108 Loctite 243...

Page 105: ...ITALJET Chapter 4 Engine Maintenance 105...

Page 106: ...Undo and remove the twelve external screws of the cover Remove the transmission cover Remove the bushing from the support ing bearing of the driven pulley shaft on the transmission cover by placing a...

Page 107: ...ove the screw of the air box cover Remove the air box cover Remove the air filter Proceed to clean or replace the air fil ter Removing the driven pulley shaft bearing Remove the transmission cover Rem...

Page 108: ...LE SURFACE TO AVOID DAMAGING THE COVER COAT NOTE ALWAYS REPLACE THE BEARING WITH A NEW ONE AT EVERY REFIT Specific tooling 020703Y Clutch shaft support bearing punch 15x35x11 on crankcase cover Removi...

Page 109: ...bell working surface eccentricity Fit the bell on a driven pulley shaft with 2 bearings inside diameter 15 and 17 mm Lock with the original spacer and nut Place the bell shaft assembly on the support...

Page 110: ...ickness 1 mm Removing the clutch Fit the special driven pulley spring compressor tool Fit the driven pulley assembly on the tool by inserting the three pins in the ventilation holes in the ground hold...

Page 111: ...Remove the retainer ring using two flat blade screwdrivers Using a hammer and pin knock the ball bearing out as shown in the figure Remove the bearing and the rollers with the spe cific extractor NOT...

Page 112: ...ter of the movable half pulley bushing Characteristic Minimum diameter allowed 41 08 mm Standard diameter 41 035 mm Refitting the driven half pulley bearing Fit the new roller bearing using the specif...

Page 113: ...half pulley on the bushing with the appro priate protection sheath Make sure the pins and collar are not worn refit the pins and the collar Using a curved spout grease gun lubricate the driven pulley...

Page 114: ...ert the lever pin in the hole of the adaptor ring Tighten the fixing nut to the prescribed torque NOTE WHEN PRELOADING THE SPRING BE CAREFUL NOT TO DAMAGE THE PLASTIC STOP OF THE SPRING AND THE BUSHIN...

Page 115: ...ley fixing flanged nut M12x1 1 60 Nm 44 25 lbf ft Loctite 243 Drive belt Make sure that the driving belt is not damaged Check belt for correct width Characteristic Driving belt width 125 200 minimum 2...

Page 116: ...ission cover Unscrew the fixing nut with the specific tool Specific tooling AP8140535 driving pulley lock wrench Remove the fixing nut and collect the washer Remove the fixed driving half pulley Remov...

Page 117: ...the driving belt Remove the bushing Remove the movable half pulley take care that the free rollers fitted on it do not come off Remove the support plate and the rel ative guide sliders Remove the spa...

Page 118: ...k that fixed driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt CAUTION DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS Characteristic Mova...

Page 119: ...ir housings with the larger support surface touching the pulley according to the direction of rotation Check that the roller contact plate does not show flaws or is damaged on the grooved edge Fit the...

Page 120: ...E FORE TIGHTENING THE NUT NOTE REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT Prevent fixed driving half pulley rota tion using the specific tool Tighten the fixing nut to the prescribed torque Specifi...

Page 121: ...cm 12 screws for 125 cm Fit the air duct Locking torques N m CVT cover EI fixing screws M6x35 10 Nm 7 38 lbf ft End gear Removing the hub cover Drain the rear hub oil through the oil drainage plug loc...

Page 122: ...emove the hub cover Remove the intermediate gear Remove the two shim washers from the intermediate gear Remove the wheel axle with the gear Extract the driven pulley shaft from the bearing See also Re...

Page 123: ...ankcase Remove the bearing using the specific extractor Removing the driven pulley shaft bearing Remove the driven pulley shaft Remove the oil seal using a screwdriv er working from inside the bearing...

Page 124: ...both the bearings and the wheel oil seal In case of faults replace the damaged parts Refitting the driven pulley shaft bearing Heat the parts with the specific heat gun Refit the bearing using the sp...

Page 125: ...g bearings the parts must be heated with the spe cific heat gun Fit the bearing in its position 1 on the cover of the hub housing on the driven pulley shaft using the specific tool Specific tooling 02...

Page 126: ...Refitting the hub bearings Assemble the 3 shafts in the engine crankcase as shown in the figure 126...

Page 127: ...quately positioned Place the hub cover Tighten the eight screws operating di agonally Fill with hub oil Locking torques N m Transmission cover EI fixing screws M6x30 8 10 Nm 7 38 lbf ft Flywheel cover...

Page 128: ...ITH A NEW ONE OF SIMILAR TYPE FOLLOW THE REMOVAL STEPS BUT IN REVERSE ORDER Removing the stator Remove the flywheel cover Undo and remove the two pick up screws Undo and remove the three screws fix in...

Page 129: ...HE STATOR Refit the stator and the flywheel carry ing out the removal steps but in reverse order tighten the retainers to the speci fied torque Locking torques N m Stator EI fixing screws M6x25 3 10 N...

Page 130: ...sitioned Locking torques N m Ignition cover fixing screws M6x110 5 11 Nm 8 11 lbf ft Ignition cover fixing screws M6x140 1 11 Nm 8 11 lbf ft Ignition cover fixing screws M6x170 1 11 Nm 8 11 lbf ft Ign...

Page 131: ...o Remove the flywheel cover Lock the crankshaft with the specific special tool Specific tooling 0240880 Threaded bolt for locking crankshaft at TDC Undo and remove the screw Collect the washer Extract...

Page 132: ...Remove the cotter Intermediate gear FITTING Fit the intermediate gear REMOVAL 132...

Page 133: ...gear See also Removing the flywheel magneto Refitting the free wheel Fit the cotter in its seat be careful to position it as indicated in the photo graph Fit the gear plus the pre assembled freewheel...

Page 134: ...ing the starter motor If the O ring is damaged fit a new one on the starter motor and lubricate it Fit the starter motor on the crankcase and tighten the 2 screws CAUTION ADEQUATELY COUPLE THE MOTOR G...

Page 135: ...olt for locking crankshaft at TDC Get two 6 3 mm 0 25 in pins Place the pins in their positions on the overhead camshafts Undo and remove the screw 1 and collect the spring Remove the screws 2 and tak...

Page 136: ...Removing the flywheel magneto Removing the cam shaft Remove the timing system control Remove the chain tensioner Undo and remove the eight screws Remove the cam tower cap Remove both camshafts See al...

Page 137: ...short screws 2 and collect the washers Undo and remove both central long screws 3 and collect the washers Remove the head Collect the lower chain slider See also Removing the cam shaft Removing the v...

Page 138: ...Compress the valve spring using the specific tool Specific tooling AP8140179 Valve spring compressor AP9100838 Tool for valve pressure plate Remove both cotter pins Release the valve springs Remove t...

Page 139: ...the cylinder piston assy Remove the head Remove the water delivery sleeve Remove the two dowels and the gasket between the cylinder and the head Slide off the cylinder Remove the gasket between the cy...

Page 140: ...the connecting rod small end using a spe cific micrometer NOTE IF THE DIAMETER OF THE CONNECTING ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANK...

Page 141: ...is Take the measurement at 6 mm 0 24 in from the base at the position shown in the figure Carefully clean the sealing rings hous ings Measure the sealing rings grooves coupling clearance using suitabl...

Page 142: ...ximum run out allowed 0 05 mm CYLINDER PISTON COUPLING CLEARANCE 125 CM Coupling categories with cast iron cylinder NAME ABBREVIA TION CYLINDER PISTON FITTING CLEARANCE min max min max min max Cylinde...

Page 143: ...eeger ring fitting With the opening in the position indicated on the tool set the retainer ring into position with the punch Fit the pin stop ring using the plug as shown in the figure NOTE THE TOOL F...

Page 144: ...r Specific tooling 0240880 Threaded bolt for locking crankshaft at TDC Characteristic Compression ratio 125 12 1 Compression ratio 200 11 6 1 BASE GASKET SELECTION 125 Specification Desc Quantity Size...

Page 145: ...p piston ring with the identifi cation letter T facing the piston crown Offset the piston ring gaps on the three rings by 90 as shown in the figure Lubricate the components with engine oil Refitting t...

Page 146: ...mshaft driving pulleys and the sprocket wheel are not worn Replace the parts if signs of wear are found CHAIN TENSIONER Remove the central screw with the washer and the tensioner spring Check that the...

Page 147: ...ach valve guide Measure according to the thrust direction at three different heights Characteristic Intake guide standard diameter 4 012 mm 0 1579 in Intake guide Wear limit 4 020 mm 0 1582 in Dischar...

Page 148: ...the valve with a new one CAUTION DO NOT CHANGE THE VALVE FITTING POSITION RH LH Characteristic Minimum diameter allowed Intake 3 96 mm 0 1559 in Minimum diameter allowed Exhaust 3 95 mm 0 1555 in Sta...

Page 149: ...AREA Specific tooling 0240880 Threaded bolt for locking crankshaft at TDC Use a feeler gauge to check clearance on the four valves If the values measured differ from the values specified record the d...

Page 150: ...e to restore the correct clearance Fit the camshaft the gears and the chain in their correct positions using the references marked when these parts were removed Fit the cam tower and tighten the eight...

Page 151: ...pecific tooling AP0277512 Fitting buffer Fit the valves the springs and the caps Using the appropriate tool compress the springs and fit the cotters in their seats Specific tooling AP9100838 Tool for...

Page 152: ...kshaft does not rotate at TDC Specific tooling 0240880 Threaded bolt for locking crankshaft at TDC Fit the chain guide slider onto the cyl inder Fit the head gasket and the alignment dowels Fit the he...

Page 153: ...the chain tensioner pad of the head and lock it with the fixing screw Locking torques N m Chain tensioner guide slider EI fixing screws M6 1 10 Nm 7 38 lbf ft Loctite 243 Insert the camshafts in thei...

Page 154: ...ion Keep the camshafts locked with the pins and screw but do not tighten the screws fixing the gears using Loctite 243 Fit the chain tensioner on the cylinder using a new gasket and tighten the two sc...

Page 155: ...0x1 2 27 Nm 19 91 lbf ft Loctite 243 Crankcase crankshaft Splitting the crankcase halves Before opening the crankcase drain out all engine oil remove the driving pulley the starter motor the flywheel...

Page 156: ...itting the crankshaft bearings Using the suitable tool fit the new bushings on both crankcase halves Use bushings blue This coupling almost always meets the diametral clearance specifications It shoul...

Page 157: ...and 0 06 mm 0 0024 in for both sides If this condition is not fulfilled the half bearings should be replaced The big end bushings cannot be replaced Therefore the connecting rod cannot be replaced ei...

Page 158: ...limit crankshaft axial clearance show no signs of wear To measure and check sizes follow the procedure described previously for checking crankshaft axial clearance and dimensions Inspecting the crank...

Page 159: ...iving depth 0 5 0 1 mm from internal stop Refitting the crankshaft Using the suitable special tool fit the main bushings Fit the new oil seal using a commer cially available punch Specific tooling 020...

Page 160: ...ch and then remove the switch Check that the oil pressure reading is 1 8 atm minimum with engine idling at 1700 100 rpm and oil at the required temperature wait for at least one electric ventilation C...

Page 161: ...seals Removal Remove the crankshaft Remove the main bushing oil seal working from the transmission side CAUTION BE CAREFUL NOT TO DAMAGE THE SEAT OF THE MAIN BUSHING OIL SEAL Refitting Thoroughly clea...

Page 162: ...ate Unscrew and remove the two screws Slide off the gears the oil pump and the chain IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE DIRECTION OF ROTATION IS MAIN TAINED See also Removi...

Page 163: ...Detach the shaft and remove the sec ond external driving pin as well Take out the shaft and collect the com ponents Measure distance between rotors with a feeler gauge at the position shown in the pi...

Page 164: ...ristic Limit value allowed 0 09 mm See also Removal Refitting Preassemble the entire oil unit the chain observing the direction of rota tion marked when fitting and the crankshaft driving gear Insert...

Page 165: ...ate and tighten the four screws with Loctite 243 Fit the flywheel and tighten the nut with Loctite 243 Refit the flywheel cover Locking torques N m Oil pump plate EI screws M5x12 4 6 Nm 4 42 lbf ft Lo...

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