NACIONAL MOTOR Derbi Euro 3 Workshop Manual Download Page 27 | Manualshive

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25

D

ISMANTLING

THE

CLUTCH

ASSEMBLY

- Drain the coolant from the engine.

- Drain the oil from the transmission by removing the two
plugs (clutch half-casing and crankcase base).

- Extract the oil pump assembly together with its pipes and
control cable.

- Extract the kick-start lever (on the versions where it is
fitted).

- Extract the bolts from the clutch half-casing and remove
it. This will provide access to the primary transmission ele-
ments, clutch, starter system and selector shaft.

- Remove the set of locking screws and springs on the clu-
tch push plate and remove the plate.

- Extract the set of driven discs and driving disks.

- Free the clutch bell housing nut seal.

- Lock the clutch bell housing with tool number 4 and re-
move the nut.

D

ISMANTLING

THE

CLUTCH

ASSEMBLY

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Summary of Contents for Derbi Euro 3

Page 1: ...moteur derbi euro 3 documentation atelier EN ANGLAIS ...

Page 2: ......

Page 3: ... our brand s dealers and sub dealers Due to its constant commitment to improving its products DERBI NACIONAL MOTOR S A Sociedad Unipersonal reserves the right to introduce any modifications it deems fit without prior warning All the information included in this manual is based on the latest data available at the time of its publication The drawings and photographs in this manual are for reference ...

Page 4: ......

Page 5: ...G THE COOLING SYSTEM DISMANTLING REASSEMBLING THE OIL PUMP DIMANTLING REASSEMBLING THE CYLINDER HEAD DISMANTLING REASSEMBLING THE CYLINDER AND PISTON DISMANTLING REASSEMBLING THE CLUTCH ASSEMBLY DISMANTLING REASSEMBLING THE CRANKSHAFT AND GEAR CHANGE DISMANTLING THE ALTERNATOR MAGNETO Page 4 Page 5 Page 6 Page 10 Page 14 Page 16 Page 18 Page 20 Page 22 Page 25 Page 30 Page 38 ...

Page 6: ...ening a series of nuts or bolts start with the bolts with the larger diameter or start with the ones to the inside or centre of the part and apply the specified tightening torque diagonally in two or three steps Before removing any component from the engine clean it carefully to prevent dirt from getting into the engine Before refitting lubricate all sliding surfaces After reassembly and before st...

Page 7: ...5 ENGINE NUMBER The number is stamped onto the top of the left hand crank case next to the gearbox clutch oil filler plug ...

Page 8: ...rol min 95 octane Reed valve direct to the crankcase 11 5 1 Electronic Kick start depending on model Liquid with pump radiator and thermostat Anticlockwise looking at the magneto Two stroke N A 49cc 39 88 x 40mm Oil pump TRANSMISSION Primary transmission Primary transmission ratio Clutch Gears Gear ratios Transmission oil volume Type 1a 2a 3a 4a 5a 6a By straight gears 3 7 21 78 Multi disk in oil ...

Page 9: ...ngine coolant Fuel and oil pipes Oil pump draught 1000 2 Replace Check Adjust and clean Check Check 5000 12 Replace Adjust and clean Clean Check Check 10000 24 Replace Replace Adjust and clean Clean Check Replace Replace Check 15000 36 Check Replace Adjust and clean Replace Clean Check Check 20000 48 Replace Replace Adjust and clean Clean Check Replace Replace Check 25000 60 Check Replace Adjust a...

Page 10: ...earing seal crankcase sec dev M5x80 10 9 drum control head drum sec dev M1 0x150 oil drain screw crankcase sec dev M6x100 starter stop crankcase sec dev M1 0x100 counterweight pinion counterweight shaft sec dev Release lever release shaft sec dev M6x100 M5x80 seal change output pinion sec dev M6x100 gear sec lever crankcase sec dev M8x125 selector stop crankcase sec dev M5x80 oil pump cover right ...

Page 11: ...haft oil seal fitting tool Selector shaft oil seal fitting tool Clutch bell housing securing tool Primary shaft needle bush fitting tool Engine opening pusher GPR secondary shaft oil seal guide pivot Alternator magneto extractor Alternator magneto turn locker Senda engine pinion GPR engine pinion Water pump exterior oil seal Water pump interior oil seal Engine pinion fastening tool Counterweight s...

Page 12: ...n spring against the cover and extract the throttle cable terminal through the gas valve channel Dismantle the cold start choke system piston valve securing clamp and extract the assembly 1 Before removing the idling circuit air quantity regula ting screw compensator check its position by counting the number of turns needed to screw it right in without forcing Make a note of this measurement and t...

Page 13: ...weight of the float This is engraved on it 3 5 grams If it exceeds this weight renew it Check that the tapered needle controlling the flow of petrol to the bowl together with the spring on its stem connecting it to the float are in good condition Should this not be the case renew them Check the condition of the cold start system piston valve In the event of the vulcanised closing seat or the metal...

Page 14: ...treme climatic conditions Renew the tapered dosing needle if damage is visible on its circumference Check for the absence of scratches on the minimum cir cuit air regulator screw cone These would affect its per formance Check for the absence of scratches on the sliding valve In the event of these exceeding 25 of its total area re new it Be sure to install one with the same characteristics see mark...

Page 15: ...en wring it out and dry it completely Next soak it in special oil for filters and refit it Then adjust idle speed using the following procedure 1 Start the engine 2 Screw in the screw regulating the sliding valve at rest position until the engine is about to stall 3 Then slowly screw in or unscrew the screw regulating the sliding valve at rest position until an idle speed of 1600 200 rpm is achiev...

Page 16: ...let valve petals and check that there are no cracks in the petals securing base If there are renew the reeds REFITTING THE REED VALVE To refit the reed valve proceed in the reverse order to dismantling paying special attention to the correct posi tioning of the height limiter and the reed with the bevels matching The elimination of the height limiter and the type of reed used will modify the perfo...

Page 17: ...p top washer pump driving pinion its key and the bottom washer Then gently tap the shaft from the inside outwards pulling with it the two seals Change the water seals at the first sign of coolant or oil leaking from the breather bore Also renew the shaft if it shows signs of wear at the circumference where the seals are positioned REFITTING THE COOLING SYSTEM Fit the circlip 1 onto the shaft stem ...

Page 18: ...r pump cover gasket The cooling system should then be refilled and pur ged according to the following procedure 1 Prepare an external feed tank with 18ºC freezing point coolant positioned at a height of approximately 2m from the ground with the aim of filling the cooling system from the expansion tank 2 Start up the engine and keep it ticking over 3 Open the feed tank tap and let the coolant flow ...

Page 19: ...ing thermo contact only in the versions where this is fitted submerge their active part in a container filled with water and heat this up Con nect a multi meter set to read resistances between its metal body and connection terminal and check that as the water temperature rises the sensor s resistance value decreases If this is not the case renew the sen sor The thermostat should be suspended subme...

Page 20: ...ch half housing and extract the pump Turn the pump shaft manually and check that it turns smoothly Check the condition of the O ring and the shaft oil seal Renew them if they are damaged The oil pump is an essential unit for the proper safe func tioning of the engine In the event of faults it should be renewed not dismantled REFITTING THE OIL PUMP Refit by carrying out the removal procedure in rev...

Page 21: ...2 5 Start up the engine and keep it ticking over Move the pump cam manually as far as it will go and hold it there until the oil is seen to flow out of the pump bleed hole without bubbles 6 Fit the pump bleed screw and check that the oil flo ws freely out of the end of the output pipe that is con nected to the carburettor 7 Stop the engine and eliminate the supply with mixtu re Restore the petrol ...

Page 22: ...een the cylinder head and the ra diator Disconnect the temperature sensor connector Disconnect the spark plug HT cable connector cap and extract the spark plug First loosen diagonally and then remove the five M6 bol ts and remove the cylinder head cover Loosen the four M7 cylinder head nuts diagonally and extract them DISMANTLING THE CYLINDER HEAD ...

Page 23: ...at the mating surfa ces both on the cylinder head and the top of the cylinder are properly cleaned Do not apply any kind of sealant Fit the cylinder head and tighten the M7 nuts provisiona lly prior to applying a diagonal tightening torque of 1 9 2 2 m kg Fit the cylinder head cover and tighten the five M6 bolts provisionally prior to applying a diagonal tightening tor que of 0 8 1 m kg Correctly ...

Page 24: ...g rod firmly and on the opposite side to the pushing direction with the aim of avoiding possible da mage or distortion of the connecting rod Clean all surfaces and gently eliminate gasket debris and carbon deposits taking care not to scratch the piston circumference Check the condition of the connecting rod big end visua lly If any damage is visible on the contact surface with the needle bearings ...

Page 25: ...e it based on the dimensions set out in the attached cylinder family table Piston Check the piston on two axis and at three height levels Service limit 0 05 mm Check the diameter of the piston on the transverse axis to the gudgeon pin at a distance of 15mm from the bottom of the piston base Service limit 0 01 mm CHECKING THE CYLINDER AND PISTON MI MI A B C D 39 850 39 855 39 860 39 865 Family ØPis...

Page 26: ... their chan nel Compress the piston rings inside their channels taking care that they do not lie over the fixed stops Lubricate the inside of the cylinder as well as the piston and its rings Fit the cylinder checking that the piston slides smoothly within it Fit a new cylinder head gasket and refit the cylinder head and cylinder head cover Fit a new spark plug Reconnect the temperature sensor and ...

Page 27: ...the versions where it is fitted Extract the bolts from the clutch half casing and remove it This will provide access to the primary transmission ele ments clutch starter system and selector shaft Remove the set of locking screws and springs on the clu tch push plate and remove the plate Extract the set of driven discs and driving disks Free the clutch bell housing nut seal Lock the clutch bell hou...

Page 28: ...ion nut 2 insert tool number 14 Engine pinion extraction tool Models with balance shaft Standard Tool Models without balance shaft Tool number 10 Check the thickness of the clutch lining on each disk with the aid of a thickness calliper Service limit 3 8 mm Renew the disk if there is a loss of lining thermal fati gue discoloration distortion or if the external notching is damaged Check the clutch ...

Page 29: ...g clutch bell housing 1 Notch slots 2 Clearance of the rivets and silent blocks joining with the gearing 3 Condition of the turning bush on the primary shaft If severe damage is seen renew it Check that there are no scratches or grooves on the ma ting surface of the disks If there are replace the affected element Check the push plate assembly and its axial needle bea ring and renew any damaged ele...

Page 30: ...ITTING THE CLUTCH Refit in the opposite order to dismantling Remember to fit the clutch bell housing driving and dri ven support washers Take into account the following steps when fitting the balance shaft in those engines where it is fitted poor fit ting will result in a high level of vibration Inserting the balance shaft Align the mark 1 on the engine shaft with the mark 2 on the balance shaft d...

Page 31: ... way that the DER BI logo fits into the slot incorporated into the driven clu tch drum Be sure to apply the required tightening torque for the clutch pressure plate securing bolts and their springs 0 35 0 45 m kg Fit a new clutch cover gasket Fit new sealing washers on the oil drain bolts crankcase and clutch half casing and tighten them Fill the gearbox clutch assembly with 650 c c of SAE 10W40 o...

Page 32: ...the balance shaft from the left hand side of the engine First loosen and then completely extract all the crankca se securing bolts twelve 6x100 bolts from the left hand side of the engine Extract the intermediate starter gearing housed on the end of the secondary gear change shaft together with the speed fixing resend 1 and its star 2 Heat up the crankcase unit around the bases of the pri mary and...

Page 33: ...ot use levers on the crankcase mating surfaces if these become damaged they will need to be replaced Now fit tool number 6 onto the threads fitted next to the crankshaft on the right hand crankcase and extract the crankshaft Pre heat the crankshaft bearing support base on the crankcase to approximately 60ºC Extract the selector fork guide shafts together with the selector drum and the forks themse...

Page 34: ...ice limit 0 04 mm Renew the connecting rod and its bearings if the service limit is exceeded Fit the crankshaft onto a lathe and turn it checking the gap between its crank blades with the aid of a pair of comparison meters placed perpendicularly to the cir cumference of the support shafts check that there is no burring or grooving Service limit 0 05 mm DISMANTLING REASSEMBLING THE CRANKSHAFT AND G...

Page 35: ...a freezer This will allow the bearing to be easily fitted without the need for hardly any pushing If neces sary however the bearing can be pushed into place Clean and completely degrease the gear change assem bly and then examine it carefully Make a visual examination of the gear change gearing teeth If there are thermal fatigue marks discoloration loss of surface hardness covering or uneven wear ...

Page 36: ...ich to lay out the parts as they are detached Check that there is no burring and or uneven wear to the nipples and the mounting holes of the movable gea ring speed setting system nor to its knurlings Check the degree of wear on the secondary free gears turning bushes If they are damaged on 25 or more of their surface area renew them At the same time renew the assembly s fixed position circlips ...

Page 37: ... rrectly to prevent the assembly from malfunctioning and jamming Shaft right hand part 1 Secondary shaft 2 4th secondary pinion z 24 3 3rd secondary pinion z 27 4 23 3x16x1 toothed washer 5 Pinion segment ring 6 5th movable pinion z 23 7 25 x14 2x1 washer 8 14x18x8 needle housing ring 9 1st secondary pinion z 34 10 28x14 2x1 85 friction washer Left hand shaft part 11 6th movable pinion z 22 12 25 ...

Page 38: ...I GL 4 oil Check the correct action of the gear change by selec ting the different speeds and turning the selector drum in both directions If it jams recheck the correct fitting Leave it selected in neutral and check the free turning of the assembly s elements Fit the crankshaft into the right hand crankcase Fit a new crankcase joining gasket paying attention to the free section in the inlet area ...

Page 39: ... gear change shaft It should be between 0 2 and 0 4 mm With the aid of a specific fitting device tools number 1 and 18 fit new crankshaft oil seals after first applying a film of API TC synthetic 2 stroke oil to the sealing edges Refit the primary transmission assembly Refit the magneto ignition assembly Refit the cylinder piston and cylinder head assembly Refill and bleed the engine cooling syste...

Page 40: ...e magneto flywheel and then loosen the nut securing the magneto to the crankshaft Insert tool number 8 and extract the magneto flywheel Extract the stator coil assembly by loosening and extrac ting the bolts that secure it to its support Finally extract the support plate bolted to the crankcase Disconnect the alternator magneto connector DISMANTLING THE ALTERNATOR MAGNETO ...

Page 41: ...tor magneto supply coil Checking the pick up Checking the HT coil secondary circuit without spark plug connector cap Checking the spark plug connector cap Disconnect it from its joint with the secondary cable and measure its resistance value between the two ends of the connection This should be 5 0 kΩ 15 CABLE COLOUR EARTH RED 80 Ω 10 CABLE COLOUR EARTH THICK BLACK 3 4 KΩ 15 CABLE COLOUR WHITE CAB...

Page 42: ...ine up the mark on the plate with the centre of the arrow on the crankcase Refit the alternator magneto coil assembly onto the coil holding plate refit the magneto flywheel check that the inner magnet is free of breakages or imperfections re new it if this is not the case with the help of tool number 9 to stop it from turning Apply the corresponding tightening torque The ignition timing setting re...

Page 43: ...create by w w w c i a n d i s s e n y c o m ...

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