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2.8.3
INTERNAL GEARSHIFT UNIT AND COMPLETE
GEARBOX ........................................................................................43
2.9
DISASSEMBLY OF PARTS FROM CRANKCASES .......44
2.9.1
RIGHT CRANKCASE HALF .........................................................45
2.9.2
LEFT CRANKCASE HALF ............................................................. 47
3 ENGINE CHECKS AND ASSEMBLY
48
3.1
CRANKCASE HALF.........................................................48
3.1.1
APPLICATION OF RIGHT CRANKCASE HALF PARTS ........49
3.1.2
APPLICATION OF LEFT CRANKCASE HALF PARTS ...........51
3.2
CONNECTING ROD AND ENGINE SHAFT CHECK ...52
3.3
ASSEMBLY OF COMPLETE CRANKSHAFT ................53
3.4
GEAR UNIT: CHECKS AND REASSEMBLY ......................54
3.4.1
CHECK OF GEARBOX UNIT .....................................................54
3.4.2
ASSEMBLY OF PRIMARY UNIT .................................................55
3.4.3
ASSEMBLY OF SECONDARY UNIT .........................................58
3.4.4
CHECK OF THE FORKS, FORK PINS AND
DESMODROMIC DEVICE ...........................................................62
3.4.5
ASSEMBLY OF GEARBOX AND INNER CONTROL ...........64
3.5
CLOSING THE ENGINE CRANKCASE .........................67
3.6
EXTERNAL GEARSHIFT .................................................68
3.6.1
CHECK OF THE COMPLETE DRIVE SHAFT .........................68
3.6.2
ASSEMBLY OF EXTERNAL GEARSHIFT ................................. 70
3.7
KICKSTARTER DEVICE - OPTIONAL RR200............... 72
3.7.1
CHECK OF STARTER SHAFT UNIT AND ASSEMBLY......... 72
3.7.2
ASSEMBLY OF KICKSTARTER DEVICE - OPTIONAL
RR200 ............................................................................................... 74
3.8
PRIMARY GEAR AND CLUTCH UNIT .......................... 75
3.8.1
CHECK OF PRIMARY GEAR....................................................... 75
3.8.2
PRIMARY GEAR APPLICATION ................................................. 75
3.8.3
CHECK OF THE CLUTCH CASE, ROLLER BEARING AND
INTERNAL CENTRE BEARING .................................................. 76
3.8.4
CHECK OF CLUTCH DISCS ....................................................... 77
3.8.5
CHECK OF SPRINGS .................................................................. 78
3.8.6
CHECK OF CLUTCH DRUM AND PRESSURE PLATE ....... 78
3.8.7
CHECK OF THRUST BEARING DEVICE AND CLUTCH
ACTUATOR ....................................................................................... 79
3.8.8
ASSEMBLY OF CLUTCH UNIT AND CLUTCH ACTUATOR 80
3.9
COOLANT LIQUID PUMP AND CENTRIFUGAL
UNIT .................................................................................86
3.9.1
CHECK OF PUMP UNIT AND DISASSEMBLY,
CENTRIFUGAL UNIT AND IDLER UNIT ............................... 87
3.9.2
CENTRIFUGAL UNIT ASSEMBLY ............................................88
3.9.3
PUMP UNIT ASSEMBLY ............................................................ 91
3.9.4
ASSEMBLY OF COMPLETE CLUTCH COVER AND PUMP
UNIT .................................................................................................. 91
3.10
OUTER CLUTCH COVER COUPLING ................................93
3.11
ELECTRIC IGNITION UNIT - ONLY RR200 - ...................94
3.11.1 BENDIX COUPLING CHECKS .................................................94
3.11.2 IGNITION UNIT COUPLING TO ENGINE .................................94
3.12
IGNITION SYSTEM ........................................................96
3.12.1 CHECK OF THE IGNITION SYSTEM ......................................96
3.12.2 COUPLING OF IGNITION SYSTEM TO CRANKCASE ................. 97
3.13
POWER UNIT ................................................................100
INTRODUCTION 2
TECHNICAL FEATURES OF ENGINE
4
SPECIAL EQUIPMENT
5
1 ENGINE REMOVAL FROM VEHICLE
6
2 ENGINE DISASSEMBLY
14
2.1
CLUTCH/GEAR OIL DRAIN ........................................... 14
2.2
REMOVAL OF PINION SPACER .................................. 14
2.3
REMOVAL OF PISTON, CYLINDER AND HEAD ........ 15
2.4
REMOVAL OF IGNITION UNIT..................................... 18
2.4.1
REMOVAL OF FLYWHEEL COVER ........................................... 18
2.4.2
STATOR REMOVAL ........................................................................ 19
2.4.3
FLYWHEEL REMOVAL .................................................................. 19
2.4.4
PICK-UP UNIT REMOVAL ...........................................................20
2.5
REMOVAL OF ELECTRIC IGNITION - ONLY RR200 ..........21
2.5.1
START MOTOR REMOVAL ..........................................................22
2.5.2
BENDIX COUPLING REMOVAL ................................................22
2.6
REMOVAL OF COOLANT LIQUID PUMP, CLUTCH
UNIT, PRIMARY GEAR, CENTRIFUGAL UNIT,
GEARSHIFT PARTS, KICKSTARTER ............................23
2.6.1
REMOVAL OF COOLANT LIQUID PUMP .............................27
2.6.2
REMOVAL OF CENTRIFUGAL UNIT AND LINKAGE .........28
2.6.3
CLUTCH DISASSEMBLY AND REMOVAL ..............................31
2.6.3.1 CLUTCH DISASSEMBLY ..............................................................33
2.6.3.2 CLUTCH ACTUATOR DISASSEMBLY .......................................36
2.6.4
PRIMARY PINION REMOVAL ....................................................37
2.6.5
PEDAL KICKSTARTER - OPTIONAL RR200 ..........................38
2.6.6
EXTERNAL GEARSHIFT UNIT ...................................................40
2.7
INTAKE SYSTEM ............................................................. 41
2.8
CRANKSHAFT, GEARBOX UNIT AND INTERNAL
GEARSHIFT .....................................................................42
2.8.1
OPENING THE CRANKCASE ....................................................42
2.8.2 CRANKSHAFT .................................................................................43
TABLE OF CONTENTS
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