CONTENTS
Page: 2
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CONTENTS
CONTENTS.......................................................................................................................................... 2
CHARACTERISTICS......................................................................................................................... 4
Characteristics ................................................................................................................................................ 4
Capacities ....................................................................................................................................................... 4
Engine markings............................................................................................................................................. 4
SPECIAL IMPORTANT POINTS .................................................................................................... 5
Oil and fuel:.................................................................................................................................................... 5
Starting: .......................................................................................................................................................... 5
Electricity: ...................................................................................................................................................... 5
Special features............................................................................................................................................... 5
TIGHTENING TORQUES................................................................................................................. 6
Tightening torques:......................................................................................................................................... 6
SPECIAL TOOLS ............................................................................................................................... 7
Introduction .................................................................................................................................................... 9
DISASSEMBLY................................................................................................................................... 9
To remove the engine from the machine........................................................................................................ 9
Putting the engine on the stand..................................................................................................................... 10
To remove the cooling system...................................................................................................................... 10
To remove the magneto flywheel................................................................................................................. 11
To remove the stator and sensor assembly................................................................................................... 12
To remove the primary transmission cover.................................................................................................. 12
To remove the drive pulley .......................................................................................................................... 12
To remove the driven pulley ........................................................................................................................ 13
To remove the secondary transmission cover .............................................................................................. 13
To remove the secondary transmission ........................................................................................................ 14
To remove the starter motor ......................................................................................................................... 14
To remove the cylinder head/cylinder assembly.......................................................................................... 14
To remove the air injector ............................................................................................................................ 15
To remove the piston.................................................................................................................................... 15
To remove the inlet manifold and valve....................................................................................................... 16
Opening the casings...................................................................................................................................... 17
To remove the crankshaft ............................................................................................................................. 18
Checking the crank....................................................................................................................................... 19
REFITTING SPECIFIC COMPONENTS...................................................................................... 20
To fit bearings .............................................................................................................................................. 20
Assembling the casings ................................................................................................................................ 21
To fit the piston ............................................................................................................................................ 23
To fit the cylinder ......................................................................................................................................... 24
To fit the cylinder head ................................................................................................................................ 24
To fit the magneto flywheel ......................................................................................................................... 25
To remove the cooling system...................................................................................................................... 25
To fit the injection manifold and compressor .............................................................................................. 26
To fit the drive pulley assembly ................................................................................................................... 26
MISCELLANEOUS OPERATIONS ............................................................................................... 27
To remove the starter system........................................................................................................................ 27
To fit starter system...................................................................................................................................... 27
To remove/refit the drive pulley rollers ....................................................................................................... 28
To remove the clutch lining assembly.......................................................................................................... 29
To refit the clutch lining assembly ............................................................................................................... 29
To remove the fuel tank................................................................................................................................ 30
