ENGL
ISH
INDEX
3.11.4 CHECKING AND ASSEMBLY OF OIL PUMPS CONTROL
GEARS ....................................................................................................86
3.11.5 PAPER OIL FILTER INSERTION ......................................................87
3.11.6 CHECKING AND COUPLING COUNTERSHAFT......................88
3.12
CLUTCH UNIT ......................................................................90
3.12.1 CHECKING CLUTCH BASKET, ROLLER BEARING AND
INTERNAL CENTRE BEARING .......................................................90
3.12.2 CHECKING CLUTCH DISCS ............................................................91
3.12.3 CHECKING SPRINGS ........................................................................92
3.12.4 CHECKING INNER HUB ..................................................................92
3.12.5 CHECKING THRUST BEARING DEVICE .....................................93
3.12.6 ASSEMBLY OF CLUTCH UNIT .......................................................93
3.13
COOLANT PUMP................................................................96
3.13.1 CHECKING PUMP UNIT AND DISASSEMBLY .........................96
3.13.2 ASSEMBLY OF PUMP UNIT ...........................................................97
3.14
ASSEMBLY OF COMPLETE CLUTCH COVER ..................98
3.15
CHECKING AND COUPLING OF TIMING CHAIN,
FIXED AND MOBILE GUIDES ....................................... 100
3.16
IGNITION SYSTEM .......................................................... 100
3.16.1 CHECKING IGNITION SYSTEM .................................................. 101
3.16.2 COUPLING IGNITION SYSTEM TO CRANKCASE................. 101
3.17
THERMAL UNIT ............................................................... 104
3.17.1
CHECKING PISTON, PIN BOLT, AND PISTON RINGS ........104
3.17.2
CHECKING THE CYLINDER ........................................... 106
3.17.2.1 ASSEMBLY CLEARANCE .........................................106
3.17.3
CYLINDER HEAD: DISASSEMBLY AND CHECKING
AUXILIARY DEVICES ....................................................................... 107
3.17.3.1 LUBRICATION JETS AND CENTRING PINS .... 107
3.17.3.2 FINGER FOLLOWER/SHAFTS UNIT ...................108
3.17.3.3 SHIMS (CALIBRATED DISCS) FOR VALVE
PLAY ADJUSTMENT .................................................109
3.17.4
CYLINDER HEAD: DISASSEMBLING AND CHECKING
VALVE UNITS .................................................................................... 110
3.17.4.1 SPRINGS...................................................................... 111
3.17.4.2 VALVE GUIDES, VALVES AND SEATS ................. 111
3.17.4.3 VALVE STEM SEAL AND LOWER STOP
WASHER ...................................................................113
3.17.5
CYLINDER HEAD: CHECKING CYLINDER HEAD BODY ... 113
3.17.6
CHECKING CAMSHAFTS.............................................................. 114
3.17.7
CHECKING CAMSHAFTS SUPPORT ........................................ 115
3.17.8
CYLINDER HEAD: INSERTION OF INNER CUP AND
VALVE STEM SEAL ........................................................................... 116
3.17.9
CYLINDER HEAD: ASSEMBLY OF VALVE UNIT ..................... 117
3.17.10 CYLINDER HEAD: REPOSITIONING CALIBRATED DISCS,
ASSEMBLY OF FINGER FOLLOWER SHAFTS AND FINGER
FOLLOWERS AND COUPLING THE SPARK PLUG .............. 118
3.17.11 CYLINDER HEAD: INSERTION OF OIL JETS, CENTRING
PINS AND SPARK PLUG O-RING ............................................. 119
3.17.12 PISTON: APPLICATION OF THE SCRAPER RING AND
RETAINING STRAPS, APPLICATION OF SEEGER ............ 120
3.17.12.1 Piston: application of the scraper ring and
retaining straps, version 350cc-390cc ......... 120
3.17.12.2 Piston: application of piston rings and oil-
scraper rings ........................................................... 121
3.17.12.3 Piston: seeger application ................................. 122
3.17.13 APPLICATION OF PISTON TO CYLINDER ............................... 122
3.17.14 APPLICATION OF PISTON-CYLINDER COUPLING TO
CRANKCASE ..................................................................................... 124
3.17.15 COUPLING HEAD TO CYLINDER .............................................. 126
3.17.16 COUPLING CAMSHAFTS TO CYLINDER HEAD AND
PHASING ........................................................................................... 127
3.17.17 VALVE PLAY ....................................................................................... 130
3.17.18 CHECKING AND COUPLING OF MECHANICAL
TENSIONER TO ENGINE .............................................................. 132
3.17.19 COUPLING CYLINDER HEAD COVER GASKETS AND
CYLINDER HEAD COVER ............................................................. 134
3.18
PINION COUPLING .....................................................135
3.19
RELEASING CRANKSHAFT .............................................135
3.20
COUPLING OIL CAPS ......................................................136
3.21
COUPLING GEARSHIFT LEVER ......................................137
4 REASSEMBLY of ENGINE IN tHE vEHICLE
138
tABLE of tIGHtENING toRQUES of ENGINE CoMPoNENtS 148
ENGINE/fRAME tABLE of tIGHtENING toRQUES
151
tABLE of SUPERStRUCtURE fAStENING toRQUE vALUES 151
RECoMMENDED ENGINE MAINtENANCE
152
RECoMMENDED LUBRICANtS AND LIQUIDS
153