APRILIA STRADA 660 Скачать руководство пользователя | Manualshive

Страница: 169 / 175

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GEARBOX

4 - 11

MY 660

CHECKING THE GEARBOX

With a dial gauge and a centring device, measure primary
shaft runout, change the shaft if reading does not comply
with recommended values.

Maximum primary shaft runout:
0.08 mm (0.0031 in.)

With a dial gauge and a centring device, measure secondary
shaft runout, change the shaft if reading does not comply
with recommended values.

Maximum primary shaft runout:
0.08 mm (0.0031 in.)

Check drive gears for wear and pitting and change faulty
gears, if necessary.

Check gear clutch dogs for cracks, damage and wear and
change the faulty ones.

Check drive gear movement, change the faulty ones.

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Содержание STRADA 660

Страница 1: ...INTRODUCTION 0 1 MY 660 INTRODUCTION 0 ...

Страница 2: ...INTRODUCTION 0 2 MY 660 SUMMARY 0 1 INTRODUCTION 3 0 1 1 FOREWORD 3 0 1 2 REFERENCE MANUALS 4 0 1 3 ABBREVIATIONS SYMBOLS CONVENTIONS 5 ...

Страница 3: ...entered in subsequent editions of the manual Should you need assistance or clarifications about the inspection and repair procedures please contact the aprilia SERVICE DEPT they will be glad to give you any information on the matter or supply you with any detail on updates and technical changes applied to the vehicle aprilia s p a reserves the right to make changes to its products at any time barr...

Страница 4: ...4897 8104894 CHASSIS WORKSHOP MANUAL aprilia part description 8140874 8140877 8140875 8140876 8140878 ENGINE TECHNICAL MANUAL aprilia part description 8140880 8140883 8140881 8140882 8140884 CD FOR THE NETWORK ENGINE aprilia part description 8CM0086 CD FOR THE NETWORK CHASSIS aprilia part description 8CM0084 ...

Страница 5: ... Camshaft ECU Electronic Control Unit rpm revolutions per minute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardisation Organisation kg kilograms kgm kilograms per metre 1 kgm 10 Nm km kilometres km h kilometres per hour kΩ kilo Ohm kPa kiloPascal 1 kPa 0 01 bar KS clutch side from the German Kupplungsseite kW kilowatt ℓ litres LAP racetrack lap LED Light Emitting Diode L...

Страница 6: ...t side SAE Society of Automotive Engineers TEST diagnostic check T B E I crown head Allen screw T C E I cheese head Allen screw T E hexagonal head T P flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V volt W watt Ø diameter ...

Страница 7: ...GENERAL INFORMATION 1 1 MY 660 GENERAL INFORMATION 1 ...

Страница 8: ...60 SUMMARY 1 1 STRUCTURE OF THE MANUAL 3 1 1 1 CONVENTIONS USED IN THE MANUAL 3 1 1 2 SAFETY WARNINGS 4 1 2 GENERAL RULES 5 1 2 1 BASIC SAFETY RULES 5 1 3 DANGEROUS ELEMENTS 8 1 3 1 WARNINGS 8 1 4 RUNNING IN 12 1 4 1 RUNNING IN 12 ...

Страница 9: ...eft are referred to the rider seated on the vehicle in the normal riding position Motorcycle operation and basic maintenance are covered in the OWNER S MANUAL In this manual any variants are identified with these symbols optional catalytic version all versions MP national certification SF European certification EURO 2 limits VERSION Italy Greece Malaysia United Kingdom Holland Chile Austria Switze...

Страница 10: ... a personal injury hazard Non compliance with the indications given in the messages preceded by this symbol may result in grave risks for your and other people s safety and for the vehicle DANGER Indicates a potential hazard which may result in serious injury or even death WARNING Indicates a potential hazard which may result in minor personal injury or damage to the vehicle NOTE The word NOTE in ...

Страница 11: ...after the engine has been stopped Before handling these components wear insulating gloves or wait until the engine and the exhaust system have cooled down USED GEARBOX AND FORK FLUIDS DANGER Wear latex gloves when servicing Gear fluid may cause serious damage to the skin if handled daily and for long periods Wash your hands carefully after handling engine oil Take it to the filling station where y...

Страница 12: ...is suitable for the type of battery used GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing disassembling or reassembling the motorcycle or its components DANGER Using bare flames is strictly forbidden when working on the motorcycle Before servicing or inspecting the motorcycle stop the engine and remove the key from the ignition switch allow for the engine and ex...

Страница 13: ...e the bearings abundantly before assembly Make it a rule to check that all components you have fitted are correctly in place After repairing the motorcycle and after each service inspection perform the preliminary checks and then test ride the motorcycle in a private estate area or in a safe area away from traffic Clean all mating surfaces oil seal edges and gaskets before assembly Apply a thin la...

Страница 14: ... can lead to the engine or gearbox seizure thus causing serious accidents personal injury or even death Gear fluid may cause serious damage to the skin if handled daily and for long periods Wash your hands carefully after use Do not dispose of oil in the environment Take it to the filling station where you usually buy it or to an oil salvage centre WARNING When filling the vehicle with this oil ta...

Страница 15: ...ical advice DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT KEEP AWAY FROM CHILDREN When handling brake fluid take care not to spill it onto plastic or paint finished parts or they will damage DANGER Do not use any brake fluids other than the specified type Never mix different types of fluids to top up level as this will damage the braking system Do not use brake fluid from containers which have b...

Страница 16: ...ze up to 60 maximum to the solution if needed Use distilled water in the coolant mixture Tap water will damage the engine Refer to the chart given below and add water with the quantity of antifreeze to obtain a solution with the desired freezing point Freezing point C Coolant of volume 20 35 30 45 40 55 NOTE Coolants have different specifications The protection degree is written on the label WARNI...

Страница 17: ...eating substances on tyres In particular avoid contact with fluid fuels leading to a rapid wear In case of contact with oil or fuel do not clean but change the tyres DANGER Some of the factory assembled tyres of this vehicle are provided with wear indicators There are several kinds of wear indicators For more information on how to check the wear contact your Dealer Visually check if the tyres are ...

Страница 18: ...in During the first 500 km 312 mi pull the brakes with caution avoiding sharp and prolonged brakings This ensures a correct bedding in of the pads on the brake discs During the first 500 km 312 mi never exceed 4000 rpm see table From 500 km 312 mi up to 1000 km 625 mi never exceed 5000 rpm DANGER After the first 1000 km 621 mi have the checking operations indicated in the column After running in c...

Страница 19: ...GENERAL TECHNICAL INFORMATION 2 1 MY 660 GENERAL TECHNICAL INFORMATION 2 ...

Страница 20: ...GENERAL TECHNICAL INFORMATION 2 2 MY 660 SUMMARY 2 1 TECHNICAL INFORMATION 3 2 1 1 TECHNICAL DATA 3 2 1 2 LUBRICANT TABLE 5 2 1 3 TIGHTENING TORQUE SETTINGS 6 2 1 4 SPECIAL TOOLS 8 ...

Страница 21: ...ansistor digital coil Starting Electric starter Spark advance 9 0 BTDC at 1 400 rpm Air filter With dry filter cartridge Clutch Type Multiplate wet clutch with control on the left side of the handlebar Driving plates 1 plates 4 Inner diameter 128 mm Thickness 2 90 3 10 mm 0 114 0 122 in Driving plates 2 plates 2 Thickness 2 92 3 08 mm 0 115 0 121 in Driving plates 3 plates 1 Inner diameter 128 mm ...

Страница 22: ...3 1 1 300 7 028 4th 22 20 1 1 091 5 556 5th 26 20 1 0 960 4 700 FUEL SYSTEM Type Electronic injection Throttle Ø 45 5 mm FUEL SYSTEM Fuel Premium grade unleaded petrol minimum octane rating 95 RON and 85 MON as per DIN 51 607 SPARK PLUGS Standard NGK CR7E Spark plug electrode gap 0 7 0 8 mm 0 027 0 031 in Resistance 5 KΩ ELECTRIC SYSTEM Generator with permanent magnet 12 V 290 W Starter motor 12 V...

Страница 23: ... lubrication points RECOMMENDED AUTOGREASE MP As an alternative to recommended grease use top brand rolling bearing grease that will resist a temperature range of 30 C to 140 C 22 F to 284 F with dripping point 150 C to 230 C 302 F to 446 F high corrosion protection good resistance to water and oxidisation Battery terminals Use neutral grease or Vaseline Chains RECOMMENDED spray grease CHAIN SPRAY...

Страница 24: ...cover plate screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down ...

Страница 25: ...ming cover screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 26: ...ttings correctly special tools suitable for the task must be used The use of special tools avoids the potential risk of damage as a result of inappropriate tools and or improvised methods The special tools developed specifically for this vehicle are listed below Ask for the general special tools if necessary ...

Страница 27: ... Crankshaft installing tool 8140846 8 Crankshaft installing tool 8140847 9 Rocker arm shaft puller weight 8140849 10 Rocker arm shaft puller 8140848 11 Flywheel cover opening 8140850 12 Crankcase separation tool 8140853 13 Connecting rod locking tool 8140840 14 Clutch locking tool 8600391 15 Valve spring compression tool 8140179 16 Valve spring compression tool adapter 0276474 17 Piston ring compr...

Страница 28: ...ENGINE 3 1 MY 660 ENGINE 3 ...

Страница 29: ...EMOVAL 52 3 4 2 CHECK 58 3 4 3 INSTALLATION 61 3 4 4 TIGHTENING TORQUE SETTINGS 66 3 5 CLUTCH 68 3 5 1 REMOVAL 68 3 5 2 CHECK 71 3 5 3 REASSEMBLY 74 3 5 4 TIGHTENING TORQUE SETTINGS 84 3 6 OIL PUMP 86 3 6 1 LUBRICATION SYSTEM DIAGRAM 86 3 6 2 REMOVAL 88 3 6 3 CHECK 90 3 6 4 INSTALLATION 91 3 6 5 TIGHTENING TORQUE SETTINGS 93 3 7 COUNTER SHAFT DRIVEN AND DRIVING GEAR 95 3 7 1 REMOVAL 95 3 7 2 CHECK...

Страница 30: ...no 8140839 NOTE Before removing the accessories drain all fluids from the engine and set a suitable collector under it Undo the two screws and loosen the clips Remove the throttle body Remove the spark plug Loosen and remove the two screws and remove the secondary air hose collect the metal gasket ...

Страница 31: ... delivery hose collect the O ring Release the clamp and remove the oil tank breather hose Loosen and remove the two screws remove the oil hose and collect the four washers Loosen and remove the two screws and remove the starter motor ...

Страница 32: ...lease the clamp and remove the crankcase breather tank hose Loosen and remove the screw and remove the speed sensor Loosen the screw and disconnect the neutral sensor Loosen and remove the screw and remove the cable guide ...

Страница 33: ...el and the snap ring Loosen and remove the screw 1 remove the cable ring 2 Loosen and remove the two screws remove the oil delivery hose and collect the four washers Refit the accessories as above described following the procedure in the reverse order ...

Страница 34: ...screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5 3...

Страница 35: ...crews 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 36: ...pt in case the coolant level is extremely low or the coolant contains engine oil NOTE Before removing the components set a rag under the pump Unscrew and remove the two screws 1 Collect the washer 2 Loosen and remove the three screws 3 Remove water pump cover 4 Remove the gasket 5 Release and remove the two screws ...

Страница 37: ...Y 660 Remove the pump unit Release and remove the clamps Remove water jacket joint 6 Slide out the water pump breather hose 7 Unscrew and remove the screw Slide out the water pump outlet hose and collect the O ring ...

Страница 38: ...ENGINE 3 11 MY 660 Remove the seal ...

Страница 39: ...ENGINE 3 12 MY 660 3 2 2 DISASSEMBLY Remove the circlip Remove the crankshaft gear Slide out pin and washer Remove the rotor shaft assembly WARNING Carefully remove the component do not damage it ...

Страница 40: ...e component do not damage the rotor Remove the water pump seal using a small screwdriver WARNING Carefully work in the direction indicated by the arrow to avoid damaging the water pump seal edge Remove the oil seal 3 and the bearing 4 WARNING Carefully work in the direction indicated by the arrow to avoid damaging the components Remove the seal ...

Страница 41: ...that the water pump outlet hose radiator outlet hose water jacket outlet seat are not damaged or worn Replace if necessary SEALS Check that all seals are intact change them if they are damaged or worn BEARINGS Manually turn the inner ring 1 it should turn smoothly with no noise and or hard spots No axial play should be noticed Faulty bearings should be changed ...

Страница 42: ...ulsified solution to the outer diameter to help installation see LUBRICANT TABLE WARNING Never lubricate the water pump seal with oil or grease NOTE Before refitting the rubber damper apply an emulsified solution to the outer surface to help installation see LUBRICANT TABLE Install a new rubber damper 5 and a new support 6 NOTE Ensure that the rubber damper and its support are flush with the rotor...

Страница 43: ... damper 6 and support 7 installation Install the crankshaft assembly Slide in washer and pin Install the rotor shaft gear with marking facing out in view Install a new circlip NOTE Once installed manually turn the rotor shaft and ensure it turns smoothly with no jamming and or noise ...

Страница 44: ...on the oil seal outer diameter to help installation see LUBRICANT TABLE Install the seal Slide in the water pump outlet hose together with O ring Tighten the screw Install the water pump breather hose 1 and water jacket joint 2 NOTE Install water pump breather hose so that it contacts the water jacket joint jut Change the two clamps with new parts of the same type Secure the two clamps ...

Страница 45: ...ENGINE 3 18 MY 660 Install the pump unit Tighten the two screws Install the gasket 3 Install water pump cover 4 Install the washer 5 Tighten the two screws 6 Tighten the three screws 7 ...

Страница 46: ... cooling system with specified quantity of recommended coolant Ensure there are no leaks repair or change any faulty parts if necessary Measure radiator cap opening pressure and change it if reading is lower than threshold value ...

Страница 47: ... screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5 ...

Страница 48: ...screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 49: ... cover giving access to the crankshaft Using the suitable special tool no 8140850 loosen and remove the flywheel cover giving access to the timing reference Turn the crankshaft counter clockwise so to bring the piston to top dead centre in the combustion stage This position is reached when flywheel reference mark I matches flywheel cover mark ...

Страница 50: ...ve the two screws Remove the gearwheel inspection cover collect the seal Ensure that reference mark I on camshaft gearwheel matches cylinder head fixed reference mark Loosen and remove the two screws and remove the timing chain tensioner ...

Страница 51: ... flywheel nut with a wrench loosen and remove the two screws on the camshaft gearwheel Remove the camshaft gearwheel Fix the timing chain with a tie Loosen and remove the four stud bolts in the order shown and collect the washers ...

Страница 52: ...ENGINE 3 25 MY 660 Release and remove the two screws ...

Страница 53: ...ENGINE 3 26 MY 660 Remove the cylinder head pay attention to the timing chain and to the decompression system since it is free to move in its housing Collect the seal and the two centring dowels ...

Страница 54: ...MOVING THE ROCKER ARMS AND CAMSHAFT Working on either side loosen and remove the four screws Working on either side remove the tappet cover collect the O ring Loosen and remove the two adjuster screws Remove the bearing snap ring ...

Страница 55: ... the suitable puller no 8140848 remove the decompression shaft Using the suitable puller no 8140848 remove the exhaust rocker arm shaft Remove the exhaust rocker arm Using the suitable puller remove the intake rocker arm shaft ...

Страница 56: ...ENGINE 3 29 MY 660 Remove the intake rocker arm The camshaft hole is shaped to ease removal Carefully remove the camshaft pay attention to the decompression chamber lever pin ...

Страница 57: ...HE CAMSHAFTS NOTE Before removing the cylinder head components valves valve springs valve seats ensure that the valves are closed and seal correctly NOTE While removing carefully mark the position of each part to ensure installation in the correct position Using valve spring compression tool no 8140179 and adapter no 0276474 remove the valve collets Remove the valve spring retainer Remove the valv...

Страница 58: ...ENGINE 3 31 MY 660 Remove the valve stem oil seal 1 and valve spring seat 2 Remove the valve ...

Страница 59: ...ng a reference bar and a feeler gauge positioned transversally measure head deformation Maximum head oval 0 03 mm 0 0012 in CHECKING THE TAPPETS COVERS AND THE CAMSHAFT GEARWHEEL COVER Check for damage or wear change the faulty part s CHECKING THE TIMING CHAIN TENSIONER Check for damages and change the part if necessary Check single direction cam operation if movement is jamming change chain tensi...

Страница 60: ...eck with a micrometer camshaft lobes dimensions a and b Camshaft lobes dimensions Value Limit Intake a 43 488 43 588 mm 1 7121 1 7161 in 43 388 mm 1 7062 in b 36 959 37 059 mm 1 4551 1 4590 in 36 840 mm 1 4504 in Exhaust a 43 129 43 229 mm 1 6980 1 7019 in 42 983 mm 1 6922 in b 37 007 37 107 mm 1 4570 1 4609 in 36 886 mm 1 4522 in Secure the camshaft in horizontal position as shown turn it and che...

Страница 61: ...ker arm inner diameter 12 000 12 018 mm 0 4724 0 4731 in Service limit 12 036 mm 0 4739 in Check that the rocker arm shaft outer diameter does not show blueish stains pitting scratches and if so change the part Using a micrometer check rocker arm shaft outer diameter and change if necessary Rocker arm inner diameter 11 981 11 991 mm 0 4717 0 4721 in Service limit 11 955 mm 0 4707 in Calculate rock...

Страница 62: ...eter C Using an inner micrometer gauge measure valve guide inner diameter D Calculate valve stem to valve guide clearance G as follows G c d Valve stem valve guide clearance Value Limit Intake 0 010 0 037 mm 0 0004 0 0015 in 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in 0 10 mm 0 0039 in Change the valve guide if clearance is outside specified range ...

Страница 63: ...uide too Change valve stem oil seal every time valve is disturbed removed or changed Maximum stem runout 0 010 mm 0 0004 in CHECKING VALVE SEATS NOTE The following procedure applies to all valves and the valve seats Eliminate scale from valve face and valve seat Ensure that the valve seat does not show pitting or marks of wear change cylinder head if necessary Check that valve seat complies with t...

Страница 64: ... grain lapping compound to valve face and repeat steps B C and D F After lapping ensure you remove any trace of lapping compound from valve face and seat G Apply Prussian blue Dykem on valve face H Install the valve to the head I Press the valve in the valve guide and in its seat so as to leave a clear mark J Using a gauge measure valve seat width again Should reading not fall within specified val...

Страница 65: ... indicated values change valve spring Compressed valve spring force installed 171 197 N at 35 00 mm 17 44 20 09 kg at 35 00 mm 38 44 44 29 lb at 1 38 in Resting on a reference surface and using a square measure valve spring inclination H In case reading is not within indicated values change valve spring Maximum spring inclination 2 5 1 8 mm 2 5 0 071 in ...

Страница 66: ...ve stem oil seal with oil see LUBRICANT TABLE Install the valve Install the valve spring seat 1 and seal ring 2 NOTE Lubricate the oil seal before installing see LUBRICANT TABLE Apply an emulsified solution on the oil seal outer diameter to help installation see LUBRICANT TABLE Install the valve spring NOTE Install the valve spring end with bigger pitch upward Install the spring with coloured end ...

Страница 67: ...ner Compress the spring with suitable tool no 8140179 and install valve collets using adapter no 0276474 Lightly tap with a mallet onto valve tip to secure valve collets to valve stem WARNING Do not tap excessively hard on the valve or it might damage ...

Страница 68: ...tall bearing to camshaft so as the value a is 0 mm 0 in Lubricate the camshaft 1 see LUBRICANT TABLE the decompression lever pin 2 and decompression lever 3 Install the compression lever pin and decompression lever to camshaft as indicated Install the camshaft upward NOTE Carefully install the camshaft pay attention to the decompression lever pin NOTE Lubricate shafts and rocker arms before instal...

Страница 69: ...42 MY 660 Install the exhaust rocker arm Using puller no 8140848 install the intake rocker arm shaft NOTE Ensure the rocker arm shaft is fully home in the head Fit intake rocker arm Install the bearing snap ring ...

Страница 70: ...ENGINE 3 43 MY 660 Fit and tighten the two screws ...

Страница 71: ...ead Insert four new washers NOTE Install washers with rounded surface facing the bolt seat Lubricate head bolt threads and sealing surfaces with engine oil Tighten the four head bolts in the sequence shown NOTE Tighten the head bolts following the tightening sequence shown and the correct torque in two stages Tighten the two longer head bolts on the right side to the specified torque Tighten the t...

Страница 72: ...ENGINE 3 45 MY 660 Tighten the two lower bolts to the specified torque ...

Страница 73: ... the position shown Set the flywheel rotor so as reference I b matches fixed reference c on magnet cover Install the timing chain to the camshaft gearwheel Install the gearwheel to the camshaft insert jut d on decompression lever slot a NOTE When installing the gearwheel ensure to keep the timing chain taut at the exhaust end Ensure reference I e on gearwheel matches fixed reference f on the cylin...

Страница 74: ...chain tensioner housing 3 Install the tensioner and the timing chain seal 6 to the cylinder assy tighten the two screws to the specified torque NOTE Install the gasket with the chamfered side facing the chain tensioner end Install the spring 3 and chain tensioner threaded plug 1 tighten plug to the specified torque Turn the crankshaft a few times counter clockwise and check reference I NOTE Set th...

Страница 75: ...t aligned correct by repeating the same indicated operations restart from installation of the camshaft gearwheel Tighten the two gearwheel screws WARNING Tighten the two screws to the specified torque loose parts might seriously damage the engine Measure the valve clearance and adjust if necessary see ADJUSTING THE VALVE CLEARANCE ...

Страница 76: ...mear the O ring with grease see LUBRICANT TABLE Once renewed the O ring install the tappet cover in its seat Working on either side tighten the four screws of both covers Fit the camshaft gearwheel cover Tighten the two screws ...

Страница 77: ... screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5 ...

Страница 78: ...screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 79: ...YLINDER AND PISTON 3 4 1 REMOVAL Before removing the cylinder first remove the cylinder head Remove the timing chain slider on the exhaust side Release and remove the two screws Remove the cooling system union collect the seal ...

Страница 80: ...ENGINE 3 53 MY 660 Loosen and remove the four stud bolts in the order shown and collect the washers ...

Страница 81: ...ENGINE 3 54 MY 660 Release and remove the two screws Remove the cylinder pay attention not to damage the chain and the piston Collect the centring dowels and the seal ...

Страница 82: ...n cloth to prevent the circlip from falling inside the crankcases Mark the piston crown exhaust side to ensure correct reassembly Remove the gudgeon pin circlip Using the puller for piston gudgeon pin no 8600388 remove the gudgeon pin WARNING Do not use a hammer to remove the gudgeon pin Remove the piston ...

Страница 83: ...ENGINE 3 56 MY 660 Remove the top ring the second ring and the three scraper rings ...

Страница 84: ...ENGINE 3 57 MY 660 ...

Страница 85: ...t of round limit R 0 05 mm 0 002 in R max D1 D3 D5 min D2 D4 D6 If reading does not comply with given range change cylinder piston and piston rings as a set Measure diameter of piston skirt P with a micrometer a 10 mm 0 39 in from piston bottom edge Calculate piston cylinder clearance as follows Piston cylinder clearance G C P Piston cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Service limit...

Страница 86: ...36 in Second piston ring 0 35 0 50 mm 0 0138 0 0197 in Service limit 0 85 mm 0 0335 in Oil scraper ring 0 20 0 70 mm 0 0079 0 0276 in GUDGEON PIN Remove combustion residues from piston crown and from above top piston ring Check if there are cracks in the piston or shrinkage marks on piston sliding surface seizure change piston if necessary NOTE Small streaks on piston liner are allowed Measure gud...

Страница 87: ...pin inner diameter 23 004 23 015 mm 0 9057 0 9061 in Service limit 23 045 mm 0 9073 in Calculate gudgeon pin to gudgeon pin hole clearance change gudgeon pin and piston as a set if reading is out of allowed tolerance Gudgeon pin piston clearance G b a 0 004 0 024 mm 0 0002 0 0009 in Service limit 0 074 mm 0 0029 in ...

Страница 88: ...LLATION NOTE When installing the piston rings ensure the manufacturer reference or marking is facing up Install the top piston ring the second ring the oil scraper spring ring the bottom oil scraper ring and the top oil scraper ring ...

Страница 89: ...arking is facing the cylinder exhaust side Before fitting the gudgeon pin lubricate it with engine oil NOTE Before fitting the gudgeon pin circlip block off the casing opening with a clean cloth to prevent it from falling inside Change the gudgeon pin circlip Install a new cylinder gasket ...

Страница 90: ...engine oil Check piston rings misalignment measure ring end gap angles as shown a top ring b top oil scraper ring c oil scraper spring ring d bottom oil scraper ring e second ring f 20 mm 0 79 in A exhaust side Using the suitable special tool no 0276357 compress the piston rings and install the cylinder ...

Страница 91: ...new washers with rounded surface up WARNING Cylinder stud bolts are similar in pairs The ones on timing side are longer Fit the four cylinder stud bolts install the two punched bolts on timing side NOTE Lubricate cylinder bolt threads and sealing surfaces with engine oil Tighten the four cylinder stud bolts to the tightening torque specified for each one ...

Страница 92: ...ENGINE 3 65 MY 660 Tighten the two screws Change the seal tighten the two screws and secure the cooling system fitting ...

Страница 93: ... screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5 ...

Страница 94: ...screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 95: ...ng all seven screws When you have loosened all screws completely remove them Place a container of adequate capacity under the clutch Remove the clutch cover collect the seal and the two centring dowels Working in a cross pattern loosen the five screws by one fourth of a turn at a time until removing all five screws Collect the clutch springs ...

Страница 96: ...ENGINE 3 69 MY 660 Remove the pressure plate collect disengagement shaft and pushrod Remove the thirteen clutch plates Remove the clutch damper spring and its housing ...

Страница 97: ...traighten the lock washer fit the universal clutch locking tool tool no 8600391 loosen and remove the clutch hub nut and collect the lock washer Remove the clutch hub and collect the thrust washer Remove the clutch housing ...

Страница 98: ...ng plate thickness 2 2 92 3 08 mm 0 115 0 121 in Service limit 2 80 mm 0 110 in Driving plate thickness 3 2 90 3 10 mm 0 114 0 122 in Service limit 2 80 mm 0 110 in NOTE Check the clutch plates for wear measuring the complete plate pack Do not measure the steel plates and the friction plates separately since this value is unimportant for wear check CLUTCH SPRINGS NOTE The following procedure appli...

Страница 99: ...nd wear that might affect clutch operation Change the housing if necessary CHECKING THE PUSHER PLATE Check the pusher plate and bearing for damages and wear Change the components if necessary CHECKING THE RELEASE LEVER SHAFT AND RELEASE ROD Check release lever shaft 3 sprocket teeth and release rod teeth 4 for damage or wear Change all parts as a set if necessary Check the release rod support for ...

Страница 100: ... primary driven gear for damages or wear and change the primary drive driving gear and the clutch housing as a set if necessary Check that it is not excessively noisy during operation change primary drive driving gear and the clutch housing as a set if necessary ...

Страница 101: ...ENGINE 3 74 MY 660 3 5 3 REASSEMBLY Install the clutch housing Insert the washer Install the clutch hub Install a new locking washer ...

Страница 102: ...1 tighten clutch hub nut to the specified torque Bend the locking washer Turn the clutch housing with arrows up Lubricate the driving plates and the driven plates with engine oil Install the damper spring seat and the spring with OUTSIDE reference outward ...

Страница 103: ...ENGINE 3 76 MY 660 Install the thirteen clutch plates position them correctly ...

Страница 104: ...ENGINE 3 77 MY 660 ...

Страница 105: ...ENGINE 3 78 MY 660 ...

Страница 106: ...ENGINE 3 79 MY 660 Position the clutch pusher plate with disengagement shaft Install the springs Tighten the screws with washers to the specified torque ...

Страница 107: ... 80 MY 660 Install the centring dowels Change the gasket and install the right casing Correctly fit the screws and tighten in a cross sequence Turn the disengagement shaft so as teeth face the vehicle rear end ...

Страница 108: ...ENGINE 3 81 MY 660 Install the centring dowels Install a new seal Install the clutch casing Tighten the screws in a cross pattern ...

Страница 109: ...ENGINE 3 82 MY 660 Fit the spring Set the release lever with UP upward Align the release lever reference mark to the clutch casing one Fit shim Fit the circlip ...

Страница 110: ...ENGINE 3 83 MY 660 Install the spring to the release lever ...

Страница 111: ... screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5 ...

Страница 112: ...screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 113: ...E 3 86 MY 660 3 6 OIL PUMP 3 6 1 LUBRICATION SYSTEM DIAGRAM Key A To oil tank 1 Oil delivery hose 2 2 Oil delivery tube 2 3 Oil filter 4 Oil pump rotor 1 5 Oil pump rotor 2 6 Main shaft 7 Oil delivery tube 3 ...

Страница 114: ...ENGINE 3 87 MY 660 Key 8 Camshaft 9 Oil delivery tube 1 10 Oil filter 11 Main shaft 12 Driving shaft 13 Crankshaft ...

Страница 115: ...r of adequate capacity under the engine Remove the clutch see REMOVING THE CLUTCH Loosen and remove the two screws and remove the oil baffle plate Remove the safety snap ring 1 and the oil pump gear 2 Release and remove the two screws Remove the oil baffle plate collect the O ring ...

Страница 116: ...ENGINE 3 89 MY 660 Unscrew and remove the screw Loosen and remove the three screws and remove the filter Remove the oil pump unit collect the two O rings ...

Страница 117: ...ENGINE 3 90 MY 660 3 6 3 CHECK Check oil pump driven gear for damages wear or cracks Change the part if necessary Check oil pump operation change the oil pump as a set if faulty ...

Страница 118: ...0 3 6 4 INSTALLATION Change the two O rings and install the oil pump unit Fit the filter and secure it tightening the three screws Tighten the screw Change the O ring Install the baffle plate and tighten the two screws ...

Страница 119: ...ENGINE 3 92 MY 660 Tighten the two screws Install the oil pump gear 2 and change the safety snap ring 1 Install the baffle plate and tighten the two screws ...

Страница 120: ... screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5 ...

Страница 121: ...screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 122: ...iner of adequate capacity under the engine Remove the water pump unit see REMOVING THE WATER PUMP Remove the clutch housing see DISASSEMBLING THE CLUTCH Remove the right casing cover see HOW TO TAKE THE ENGINE CRANKCASES APART Straighten the safety washer Loosen and remove the balancer driven gear nut collect the washer ...

Страница 123: ...e driven gear and collect the key Using the connecting rod locking tool no 8140387 lock the con rod while loosening and removing the balancer driven gear nut Collect the washer Remove the washer Remove the water pump driving gear ...

Страница 124: ...ENGINE 3 97 MY 660 Remove the primary drive driving gear Remove the balancer driving gear and remove the key Remove the washer ...

Страница 125: ...ENGINE 3 98 MY 660 3 7 2 CHECK Check counter shaft driven gear and driving gear water pump driving gear and primary drive gear for damage or wear Change the parts if necessary ...

Страница 126: ...ENGINE 3 99 MY 660 3 7 3 INSTALLATION Insert the washer Install counter shaft driving gear Install the key with rounded surface up Install the primary drive driving gear ...

Страница 127: ...60 Install the water pump driving gear Insert a new washer Install a new lock washer and nut WARNING Ensure that the washer edge is inside keyway Tighten primary drive gear nut to the specified torque and bend the edges ...

Страница 128: ...erence mark to driven gear mark Tighten countershaft driven gear nut to the specified torque Bend the lock washers edges Install the right casing cover see HOW TO ASSEMBLE THE ENGINE CRANKCASES Install the clutch housing see REASSEMBLING THE CLUTCH Install the water pump unit see INSTALLING THE WATER PUMP ...

Страница 129: ... screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5 ...

Страница 130: ...screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 131: ...Remove the clutch see REMOVAL Remove the right casing see HOW TO TAKE THE ENGINE CRANKCASES APART Working on clutch side release gear shift selector spring Working on generator side remove the snap ring Working on clutch side remove the gear shift selector and collect washer and oil seal ...

Страница 132: ...Check the stop lever for damages or wear and ensure that roller can turn freely Change the components if necessary Check for gear shift selector spring damage or wear Change the part if necessary CHECKING THE GEAR SELECTOR Check selector shaft and its teeth for damage or wear Change the part if necessary Check for lever spring damage or wear Change the part if necessary REASSEMBLY Lubricate the oi...

Страница 133: ...ENGINE 3 106 MY 660 3 9 GENERATOR SIDE 3 9 1 REMOVAL Release and remove the four screws Remove the cover together with torque limiter Collect the centring dowel ...

Страница 134: ...Loosen the nine screws in a cross pattern Mark the screws with different length Remove the flywheel cover with gasket starter motor idle gear four dowels and two O rings Undo and remove the flywheel nut Collect the washer ...

Страница 135: ...tly locked WARNING Do not touch the top projecting part of the flywheel with the locking tool Heat the flywheel with a suitable heater Using the suitable puller remove the flywheel from the crankshaft Remove the key Remove the starter clutch and the roller bearing Remove the washer ...

Страница 136: ...ENGINE 3 109 MY 660 Release and remove the two screws Remove the rear chain slider Remove the timing chain from crankshaft ...

Страница 137: ...at all threads are in good condition Check that all oil seals that are in place are not worn or damaged Check play smooth movement and deformation of all ball bearings NOTE Lubricate the ball bearings with engine oil before checking In case the inner ring does not move smoothly and is noisy it is faulty and should be changed CHECKING THE TIMING CHAIN AND GUIDES Check timing chain for damage and ha...

Страница 138: ...ENGINE 3 111 MY 660 3 9 3 REASSEMBLY Fit the rear chain slider Tighten the two screws Fit the timing chain to crankshaft Insert the washer ...

Страница 139: ...ENGINE 3 112 MY 660 Install the roller cage Install the starter gear Fit the key into the crankshaft Install the flywheel pay attention to the correct positioning of the key in its seat ...

Страница 140: ...840 and flywheel tools no 8140838 WARNING Avoid touching the flywheel projecting parts with the locking tool Fit the washer into the crankshaft Tighten the nut to the specified torque Position the two front and two rear dowels with O rings to the crankcases ...

Страница 141: ...ENGINE 3 114 MY 660 Install a new seal Set the starter motor idle gear Insert the pin Fit the flywheel cover complete with stator ...

Страница 142: ...ENGINE 3 115 MY 660 Correctly fit the nine screws and tighten in a cross sequence Fit the starter motor torque limiter Fit the centring dowel Install the torque limiter cover with a new gasket ...

Страница 143: ...ENGINE 3 116 MY 660 Correctly fit the four screws and tighten in a cross sequence ...

Страница 144: ... screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5 ...

Страница 145: ...screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 146: ...GINE CRANKCASES APART Before removing any components place a container of adequate capacity under the engine Remove all accessories Loosen and remove the two screws and collect the washers Lift the timing chain guide on intake side and remove it Remove the timing chain ...

Страница 147: ...ENGINE 3 120 MY 660 Straighten the washer Undo and remove the nut and collect the washer Remove the front chain sprocket Remove the circlip ...

Страница 148: ...screws by one fourth of a turn at a time until removing all seven screws Release and remove all screws Loosen and remove the two screws and remove the support Remove the circlip and the oil pump gear Unhook the spring and remove the complete gearbox shaft stop lever ...

Страница 149: ...time until removing all six screws Release and remove all screws Use the connecting rod locking tool no 8600840 and the crankcase puller no 8140853 and separate the two crankcase halves Tap the crankcases lightly with a hammer to separate the crankcases After they become separated remove both tools ...

Страница 150: ...ENGINE 3 123 MY 660 Remove the right casing Tie the gearbox shafts with rubber bands Remove the counter shaft Remove the gearbox shafts assembly ...

Страница 151: ...ENGINE 3 124 MY 660 NOTE Secure crankcase to engine supporting plate no 8140839 Use the crankcase puller no 8140853 to remove the crankshaft ...

Страница 152: ...damaged Check play smooth movement and deformation of all ball bearings NOTE Lubricate the ball bearings with engine oil before checking In case the inner ring does not move smoothly and is noisy it is faulty and should be changed CHECKING THE TIMING CHAIN AND GUIDES Check timing chain for damage and hard spots Change the timing chain and camshaft gearwheels as a set if necessary Check timing chai...

Страница 153: ...ENGINE 3 126 MY 660 Check oil delivery tube for damage Change the part if necessary Ensure that the oil delivery tube holes are not clogged and blow with compressed air to clean them if necessary ...

Страница 154: ...and the bearing balls Install oil seals and bearings to the casings Using the special tool no 8140846 install the crankshaft to the left casing Install the complete gearbox to the left casing ensure that shafts can smoothly turn Install the counter shaft Apply some sealant on the sealing surfaces of both casings ...

Страница 155: ...sary NOTE Ensure that shafts turn correctly Install the six screws on left casing Tighten the six screws to the specified torque in a cross pattern Install the seven screws on right casing Tighten the seven screws to the specified torque in a cross pattern Install the complete selector shaft ...

Страница 156: ...ENGINE 3 129 MY 660 Secure the spring Insert the circlip ...

Страница 157: ...e screws 1 0 8 1 2 Loctite 620 on thread Clutch cover screws 1 and 2 0 8 1 2 Water pump and water pump union screw 0 8 1 2 Speed sensor and oil filter cover screws 0 8 1 2 Oil filter bleed screw 0 3 0 7 Cylinder screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder side screws 0 8 1 2 Head screws 4 8 5 2 Engine oil 10W 40 on thread head and washer Cylinder head upside down screws 3 5...

Страница 158: ...screws 0 8 1 2 Oil channel hose screws 1 1 6 2 0 Spark plug 1 0 1 5 Oil channel hose screws 2 1 7 2 3 Oil channel hose side screw 2 0 8 1 2 Intake manifold clamps screws 0 3 0 4 AIS tube screws 0 8 1 2 Sensor 1 6 2 0 Thermostat cover screws 0 8 1 2 Exhaust stud bolts 1 3 1 7 Camshaft plate screws 0 8 1 2 Loctite 242 on thread ...

Страница 159: ...GEARBOX 4 1 MY 660 GEARBOX 4 ...

Страница 160: ... MY 660 SUMMARY 4 1 GEARBOX SHAFTS 3 4 1 1 DIAGRAM 3 4 1 2 MAIN SHAFT DISASSEMBLY 5 4 1 3 TRANSMISSION SHAFT DISASSEMBLY 8 4 1 4 CHECK 10 4 1 5 REFITTING THE PRIMARY SHAFT 12 4 1 6 REFITTING THE SECONDARY SHAFT 15 ...

Страница 161: ...GEARBOX 4 3 MY 660 4 1 GEARBOX SHAFTS 4 1 1 DIAGRAM Key 1 Counter shaft 2 Primary shaft 3 Secondary shaft 4 Chain 5 Wheel shaft ...

Страница 162: ...GEARBOX 4 4 MY 660 Key 6 Gearbox fork C 7 Gearbox fork R 8 Gearbox fork L 9 Gearbox drum 10 Primary shaft assembly 11 Spacer 12 Secondary shaft assembly ...

Страница 163: ...EARBOX 4 5 MY 660 4 1 2 MAIN SHAFT DISASSEMBLY Remove the circlip Remove the second speed gear Remove the safety retaining washer Remove the fifth speed gear and collect retainer spacer and safety washer ...

Страница 164: ...GEARBOX 4 6 MY 660 Remove the circlip Remove the third speed gear Remove the circlip Remove the safety washer ...

Страница 165: ...GEARBOX 4 7 MY 660 Remove the fourth speed gear ...

Страница 166: ...GEARBOX 4 8 MY 660 4 1 3 TRANSMISSION SHAFT DISASSEMBLY Remove the circlip Remove the first speed gearwheel and collect the washer Remove the fourth speed gearwheel Remove the circlip ...

Страница 167: ...GEARBOX 4 9 MY 660 Remove the third speed gearwheel and collect the safety washer Remove the fifth speed gearwheel Remove the circlip and then the second speed gearwheel collect safety washer and seal ...

Страница 168: ...eformation and wear Change the gear shift fork if needed Check fork movement change the forks if it is not smooth CHECKING THE GEAR SHIFT DRUM UNIT Check gear shift drum for damage scratches and wear change the unit if necessary Check gear shift drum area 3 for damage and wear change the unit if necessary Check gear shift drum bearing 4 for damage and pitting change the unit if necessary ...

Страница 169: ...t 0 08 mm 0 0031 in With a dial gauge and a centring device measure secondary shaft runout change the shaft if reading does not comply with recommended values Maximum primary shaft runout 0 08 mm 0 0031 in Check drive gears for wear and pitting and change faulty gears if necessary Check gear clutch dogs for cracks damage and wear and change the faulty ones Check drive gear movement change the faul...

Страница 170: ...GEARBOX 4 12 MY 660 4 1 5 REFITTING THE PRIMARY SHAFT Install fourth speed gear Insert the safety washer Change the circlip Install third speed gear ...

Страница 171: ...GEARBOX 4 13 MY 660 Change the circlip Fit the safety washer the spacer the retainer and install the fifth speed gear Fit the safety washer Install second speed gear ...

Страница 172: ...0 Change the circlip NOTE Ensure that the sharp edge a of circlips 2 is on the opposite side with respect to safety washers 1 and relevant gears NOTE Install circlips so that both edges are at the centre of every groove ...

Страница 173: ...X 4 15 MY 660 4 1 6 REFITTING THE SECONDARY SHAFT Install second speed gear completed with seal and safety washer Change the circlip Install the fifth speed gear Install the third speed gear and safety washer ...

Страница 174: ...GEARBOX 4 16 MY 660 Change the circlip Install the fourth speed gear Install the first speed gear and washer Change the circlip ...

Страница 175: ...4 17 MY 660 NOTE Ensure that the sharp edge a of circlips 2 is on the opposite side with respect to safety washers 1 and relevant gears NOTE Install circlips so that both edges are at the centre of every groove ...

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