INTRODUCTION Engine 450 - 550 INTRODUCTION 0 0-1
INTRODUCTION Engine 450 - 550 SUMMARY 0.1. INTRODUCTION ............................................................................................................................................. 3 0.1.1. FOREWORD.......................................................................................................................................... 3 0.1.2. REFERENCE MANUALS....................................................................................................................... 4 0.1.3.
Engine 450 - 550 0.1. 0.1.1. INTRODUCTION INTRODUCTION FOREWORD This manual provides the information required for normal servicing. This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures.
INTRODUCTION 0.1.2.
Engine 450 - 550 0.1.3. # < > ≤ ≥ ~ ∞ °C °F ± a.c A Ah API AT AV/DC bar d.c. cc CO CPU DIN DOHC ECU rpm HC ISC ISO kg kgm km km/h kΩ kPa KS kW ℓ LAP LED LEFT SIDE m/s max mbar mi MIN MPH MS MΩ N.A. N.O.M.M. N.O.R.M.
INTRODUCTION RIGHT SIDE = right 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.
Engine 450 - 550 GENERAL INFORMATION GENERAL INFORMATION 1 1-1
GENERAL INFORMATION Engine 450 – 550 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...............
GENERAL INFORMATION Engine 450 - 550 1.1. STRUCTURE OF THE MANUAL 1.1.1. • CONVENTIONS USED IN THE MANUAL This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual. Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure. The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position.
GENERAL INFORMATION 1.1.2. Engine 450 – 550 SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.
Engine 450 - 550 1.2. 1.2.1. GENERAL INFORMATION GENERAL RULES BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a wellaerated room. Avoid starting the engine indoors. In case you are working indoors, use a gas exhaust system. DANGER Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of consciousness or even lead to death.
GENERAL INFORMATION Engine 450 – 550 DANGER Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce invisible flames. Wear latex gloves when servicing. Although toxic, it has a sweet taste that might attract animals. Never leave coolant in open container or in a position easily reachable by animals. KEEP AWAY FROM CHILDREN. Do not remove radiator cap when engine is still hot. Coolant is under pressure and might cause burns.
Engine 450 - 550 GENERAL INFORMATION DISASSEMBLING THE COMPONENTS Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use the suitable spanner. Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection using a distinctive symbol or convention. Mark each part clearly to avoid confusion when refitting. Thoroughly clean and wash any components you have removed using a detergent with low flash point.
GENERAL INFORMATION 1.3. 1.3.1. Engine 450 – 550 DANGEROUS ELEMENTS WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours, avoid flames, sparks and any element that could ignite fuel or provoke explosions.
Engine 450 - 550 GENERAL INFORMATION BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly. The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working.
GENERAL INFORMATION Engine 450 – 550 COOLANT DANGER Coolant is toxic when ingested, contact with eyes or skin may cause irritation. In the event of contact with your skin or eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately. DO NOT RELEASE INTO THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. DANGER Take care not to spill coolant onto hot engine parts.
Engine 450 - 550 GENERAL INFORMATION TYRES WARNING If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to ride. In addition, the roadworthiness, mainly on wet surfaces and during cornering, will be impaired. Flat tyres (insufficient pressure) can slip on the rim and make you lose the control of the vehicle. In this case too, both vehicle roadworthiness, manoeuvrability and brake efficiency will be impaired.
GENERAL INFORMATION 1.4. RUNNING-IN 1.4.1. RUNNING-IN Correct engine running-is essential to ensuring proper performance and durability. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more effective running-in. During running-in, change speed. In this way the components are first "loaded" and then "relieved" and the engine parts can thus cool down.
Engine 450 - 550 TECHNICAL INFORMATION TECHNICAL INFORMATION 2 2-1
TECHNICAL INFORMATION Engine 450 - 550 SUMMARY 2.1. TECHNICAL INFORMATION .......................................................................................................................... 3 2.1.1. TECHNICAL DATA ................................................................................................................................ 3 2.1.2. LUBRICANT TABLE............................................................................................................................... 6 2.1.3.
TECHNICAL INFORMATION Engine 450 - 550 2.1. 2.1.1.
TECHNICAL INFORMATION SXV450 TRANSMISSION Gear ratios Ratio Primary 1st 22/56 = 1: 2.545 2nd 3rd 4th 5th RXV450 TRANSMISSION Gear ratios Ratio Primary 1st 22/56 = 1: 2.545 2nd 3rd 4th 5th FUEL SYSTEM Type Throttle FUEL Fuel SPARK PLUGS Standard Spark plug electrode gap Resistance ELECTRIC SYSTEM Generator (with permanent magnet) Starter motor Engine 450 - 550 Secondary 12/30 = 1: 2.307 15/27 = 1: 1.800 16/23 = 1: 1.437 20/23 = 1: 1.150 21/21 = 1: 1.000 Final ratio 15/48 = 1: 3.067 Total ratio 1 : 18.
TECHNICAL INFORMATION Engine 450 - 550 Clutch Type Driving plates 1 Driving plates 2 Clutch plates Clutch springs Lubricating system Type Oil filter Engine oil quantity Cooling system Type Water pump SXV550 TRANSMISSION Gear ratios Ratio Primary 1st 22/56 = 1: 2.545 2nd 3rd 4th 5th RXV550 TRANSMISSION Gear ratios Ratio Primary 1st 22/56 = 1: 2.
TECHNICAL INFORMATION 2.1.2. Engine 450 - 550 LUBRICANT TABLE ENGINE 450 - 550 LUBRICANT Engine oil PRODUCT RACING 4T, SAE 10W – 60. RECOMMENDED As an alternative use top brand oils meeting or exceeding CCMC G-4, A.P.I. SG. SAE 10W-60 specifications. Gearbox fluid RECOMMENDED: GEAR SINTH 75W – 90. Coolant RECOMMENDED: ANTIFREEZE PLUS. Brake fluid RECOMMENDED: BRAKE FLUID DOT 4 PLUS.
TECHNICAL INFORMATION Engine 450 - 550 2.1.3.
TECHNICAL INFORMATION DESCRIPTION Crankshaft stop screw Freewheel outer ring screws Throttle body screws Camshaft gear retaining screw Con-rod cap screw 2-8 Engine 450 - 550 SCREW / NUT M8x1.25 M6x1 M6x1 M16x1 M8x1 TIGHTENING TORQUE SETTINGS Nm 22 (16.23) 13 (9.58) 13 (9.58) 35 (25.82) 15+(48°÷50°) 11.
Engine 450 - 550 2.1.4. TECHNICAL INFORMATION SPECIAL TOOLS In order to perform assembly, reassembly and settings 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. Below is a list of the special tools designed especially for this specific vehicle. If necessary, request the multi-purpose special tools.
TECHNICAL INFORMATION 2 - 10 Pos. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Swinging arm cages drift Drift for swinging arm levers cages Oil seal - Marzocchi fork d.45 Oil seal - Sachs fork d.
Engine 450 - 550 2.1.5. TECHNICAL INFORMATION ASSEMBLING ENGINE TO PLATE • Fit the engine support part no. 9100841 on the aprilia engine support stand. • Assemble the engine on the support using the provided pin holes. • • Secure the engine by means of the proper check nuts. Make sure that retaining eccentric of clutch-side crankcase is properly fixed as it is used to open the two crankcase halves.
TECHNICAL INFORMATION 2.1.6. Engine 450 - 550 LIMIT VALUES LIMIT VALUES CHART Description Max. head deformation Limit value (mm) 0.05 Maximum camshaft out of round 0.05 Rocker arm inner diameter 12.04 Rocker arm shaft outer diameter 11.96 Rocker arm-rocker arm shaft clearance 0.08 Valve wear limit 4.96 Valve-valve guide clearance (intake) 0.08 Valve-valve guide clearance (exhaust) 0.08 Thickness on seal side - intake valve 2.2 Thickness on seal side - exhaust valve 2.
TECHNICAL INFORMATION Engine 450 - 550 2.1.7. COUPLING: MAIN BEARINGS - CONNECTING ROD Before selecting the right spare bearing, please verify the relevant class of original parts and check the correct bearing on the table. Part classes are laser-printed the component. WARNING Crankcase class is printed on both crankcase halves. CONNECTING ROD - CRANKSHAFT CONNECTING ROD CLASS A B 38.000 – 38.013 – 38.012 38.025 CRANKSHAFT CLASS A 34.984 – 34.991 B 34.992 – 35.
TECHNICAL INFORMATION 2.2. ADJUSTMENTS 2.2.1. CYLINDER SYNCHRONISATION • • Release the special hook to remove the seat. Lift the tank and secure it with the special retainer. • Release the two plastic snap-on fasteners to remove the airbox cover and take the filter out. WARNING When disassembling the components, pay special attention and prevent any screw or dirt from falling as once the filter has been removed the two throttles are without protection.
Engine 450 - 550 • Working on the right side, release the tie from oil breather hose. • • • Take the oil breather hose out. Remove the atmospheric pressure pickup hose. Working on the left side release plug cable from rear cylinder. • Release the by-pass hose tie from rear cylinder throttle body. Take by-pass hose out from rear cylinder throttle body. • • TECHNICAL INFORMATION Have another by-pass hose available and connect it to the free fitting.
TECHNICAL INFORMATION • • Connect a differential vacuum meter to both by-pass hoses. Lower tank gently avoiding to squash vacuum meter hoses. WARNING As the vehicle is without air filter, the working area and tank lower side shall be accurately cleaned. • Start the vehicle and check synchronisation of cylinders vacuum reading. • If synchronisation is not achieved, loosen the adjusting screw and position the slot so as to balance vacuum. Once synchronisation is achieved, tighten the adjusting screw.
TECHNICAL INFORMATION Engine 450 - 550 2.2.2.
TECHNICAL INFORMATION SCREEN PAGE DESCRIPTION Engine 450 - 550 APPROXIMATE VALUES MEASURE NOTES UNIT ENGINE PARAMETER READING Engine rpm Atmospheric pressure Front cylinder injection time Rear cylinder injection time Front cylinder ignition advance Rear cylinder ignition advance Throttle position Intake air temperature Engine temperature Battery voltage 1010 - rpm mbar ms ms - ° ° 4.6 - % °C °C V Gear engaged Vehicle speed 2 Km/h Operation time 12:25 hhmm Throttle self-learning, min.
TECHNICAL INFORMATION Engine 450 - 550 SCREEN PAGE APPROXIMATE VALUES Description MEASURE NOTES UNIT ERRORS DISPLAY Engine temperature sensor short-circuit Engine temperature sensor open circuit Faulty barometric pressure sensor Throttle position short-circuit sensor Throttle position open circuit sensor Main relay gnd/open circ. control Main relay control 12V Light relay activation Front injector to Error detected on indicated sensor/actuator circuit.
TECHNICAL INFORMATION SCREEN PAGE Description Engine 450 - 550 APPROXIMATE VALUES MEASURE I UNIT NOTES ERRORS DISPLAY Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off) Error detected on indicated sensor/actuator circuit.
LUBRICATION Engine 450 - 550 LUBRICATION 3 3-1
LUBRICATION Engine 450 - 550 SUMMARY 3.1. REMOVING AND REFITTING THE ENGINE .................................................................................................. 3 3.1.1. REMOVING THE ENGINE..................................................................................................................... 3 3.1.2. REFITTING THE ENGINE ................................................................................................................... 14 3.1.3. REMOVING ENGINE ACCESSORIES .....
Engine 450 - 550 3.1. 3.1.1. • • REMOVING AND REFITTING THE ENGINE REMOVING THE ENGINE • Set the engine support stand. Working on either side, loosen and remove the three side body panel screws. Remove the side body panels. • Remove sump guard and expansion tank. • Prepare a container of suitable capacity under the hose. Release the clamp.
LUBRICATION • • • Remove the hose. Drain the fluid in the container. Open radiator plug to drain all fluid. • Working on either side, release the clamps. • Remove the right and left delivery hoses. • Working on the left side, release the clamp and disconnect the hose.
Engine 450 - 550 • Working on the right side, slide out the hose. • Remove the radiator breather hose. • Working on the right side, loosen the lower screw and collect the nut and washer on the left side. • Working on the right side, loosen the upper screw and collect the nut and washer on the left side. LUBRICATION WARNING Before removing the screw, support the cooling fan or it will fall down.
LUBRICATION • Slide out the radiators in a downward motion. WARNING The radiators are connected one to the other by means of the lower hose. • • Prepare a container of suitable capacity under the oil tank plug. Loosen and remove oil drain cap. • • Remove the top clamp. Slide out the blow-by hose. • Release the clamp.
Engine 450 - 550 • Remove the hose. • • Release the two clamps. Remove the two hoses. • • Working on the right side, loosen and remove the two screws. Working on the left side, remove the two nuts. • Remove oil filler plug.
LUBRICATION • Remove the oil tank from below. • Loosen and remove the two screws on sprocket protection and remove protection; collect two screws and washers (one on enduro RXV, two on motard SXV) Remove the ground cable. • • • Loosen and remove the securing screw from the ground cable. Remove the ground cable. • Undo and remove the nut and collect the washer.
Engine 450 - 550 • • Working on either side, loosen adjuster. Remove the chain. • Unscrew and remove the swinging arm shaft nut. • • • Unscrew and remove the threaded pin (1). Release the spring (2). Remove the rear brake pedal (3).
LUBRICATION • Remove swinging arm shaft. • Grasp and release the handles on either sides to release the air box cover. Slide the cover from the rear end completed with air filter. • NOTE Please ensure the air box is clean before refitting. Remove any dirt that might have entered during the removal procedure. When refitting, pay attention to correctly refit the air scoops. WARNING Ensure the tank retaining cord never touches the battery positive pole. • Release the two throttle cables.
Engine 450 - 550 • Disconnect the clutch cable. • • • Remove the sprocket circlip. Remove the chain from the sprocket. Remove the sprocket. • Disconnect all connectors.
LUBRICATION • • • Slide the protection along the starter motor power cable. Loosen and remove the securing screw. Remove the starter motor power cable. • Unscrew and remove the lower rear pin nut. • Collect the washer. WARNING The number of washers can be different from one side to the other or from vehicle to vehicle: check number and position of washers when removing them.
Engine 450 - 550 • Slide off the lower rear pin. • Loosen and remove the securing screw from the front pin. • Remove the front pin. • • Collect the washer. Move down the engine.
LUBRICATION 3.1.2. REFITTING THE ENGINE • • Position the engine. Fit the washer. • Fit the front pin. • Tighten the front pin securing screw. • Fit the lower rear pin.
Engine 450 - 550 • LUBRICATION Fit the washer. WARNING Refit washers restoring their original number and position. • Tighten the lower rear pin securing nut. • Position the ground cable and tighten the screw. • • • Fit the starter motor power cable. Tighten the fastening screw. Fit the protection element.
LUBRICATION • Connect all connectors. • • Fit sprocket and chain. Fit the chain circlip.
Engine 450 - 550 • Fit the clutch cable. • Fit the two throttle cables. • Fit the air box cover. LUBRICATION NOTE Please ensure the air box is clean before refitting. Remove any dirt that might have entered during the removal procedure. When refitting, pay attention to correctly refit the air scoops. WARNING If it falls to the ground, carefully clean the air filter and the air box from oil coming from the oil tank via the oil breather hose.
LUBRICATION • Fit the swinging arm shaft. • • • Fit the rear brake pedal (3). Fit the spring (2). Tighten the screw (1) retaining the rear brake pedal. • Tighten the swinging arm shaft nut. • • • Fit the rear wheel in its seat onto swinging arm. Wrap the drive chain onto rear sprocket. Adjust chain tension using the adjusters located on the swinging arm.
Engine 450 - 550 • Fit the washer. • Tighten the rear wheel shaft nut. • Fit the sprocket guard together with the two spacers and tighten the two screws. • Fit the engine oil tank.
LUBRICATION • • Working on the right side, fit the two pins. Working on the left side, tighten the two nuts. • Fit the connection lines and fasten ties. • Fit tube. • Fasten tie.
Engine 450 - 550 • • Fit the blow-by hose. Fasten tie. • • Tighten the oil drain nut. Fill the tank with engine oil from the top filler. • Tighten oil plug. • Fit the radiators from bottom up. LUBRICATION WARNING The radiators are connected one to the other by means of the lower hose.
LUBRICATION • Insert the pin, fit the washer and tighten the nut. • Insert the pin, fit the washer and tighten the nut. • Fit the radiator breather hose. • Working on the right side, fit the hose.
Engine 450 - 550 • Working on the left side, fit the hose and clamp. • Fit delivery hoses on either side. • Fasten tie on either side. • Fit the hose.
LUBRICATION • • Fasten tie. Fill the system through the radiator plug. • • Fit the side body panels. Tighten the three side body panel screws on either side.
Engine 450 - 550 3.1.3. • LUBRICATION REMOVING ENGINE ACCESSORIES Position the engine on the engine support plate (part no. 9100841), see (ASSEMBLING THE ENGINE TO PLATE) NOTE Before removing the accessories, drain all fluids from the engine and set a suitable collector under it. • • • • • Loosen and remove the two screws securing the starter motor. Remove the starter motor. Loosen and remove the two screws securing the gearbox position sensor. Remove the gearbox position sensor.
LUBRICATION • Working on either piston-cylinder assy, remove the spark plug. • Working on clutch side, loosen and remove engine oil filter plug, collect spring. Remove the oil filter.
Engine 450 - 550 3.2. 3.2.1. LUBRICATION WATER PUMP REMOVING THE WATER PUMP WARNING Usually, it is not necessary to remove the water pump except 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. • • Loosen and remove the five pump cover screws. Remove the water pump cover and the gasket. • Remove pump impeller using tool no. 9100938. • Remove the shim.
LUBRICATION • Remove the two centring pins. • Remove the water pump cover spacer.
Engine 450 - 550 3.2.2. LUBRICATION INSTALLING THE WATER PUMP WARNING When installing, only use new seals and clamps. • Fit the water pump cover spacer. • Fit the two centring pins. • Fit shim. • • Fit and fasten water pump impeller Use tool no. 9100938 to tighten it to the specified torque.
LUBRICATION • • Fit the water pump cover and the gasket. Fit and tighten the five water pump cover screws.
Engine 450 - 550 3.3. 3.3.1. LUBRICATION CYLINDER HEAD REMOVING THE CYLINDER HEAD NOTE The following procedure applies to both cylinders. NOTE Ensure that the piston of the cylinder you are working on is at TDC in the combustion stage, before removing the cylinder head. • • Loosen and remove the four screws from head cover and keep the O-rings. Remove the head cover complete with gasket. • Loosen and remove the chain tensioner spring retaining screw.
LUBRICATION • Loosen and remove the head retaining screw on timing side. WARNING Remove this screw before removing the four main screws. • Loosen and remove the four head retaining bolts, use an articulated spanner with rounded tip, if necessary. Remove the head, the head gasket and centring pins.
Engine 450 - 550 3.3.2. • • REMOVING THE ROCKER ARMS AND CAMSHAFT Remove the head, see (REMOVING THE CYLINDER HEAD). Remove the exhaust valve rocker arm shaft snap ring. • Remove the rocker arm shaft of exhaust valves from its seat. • Remove the rear rocker arm. • Lock the camshaft with 6 mm pin (0.24 in) used for cam timing, see (CAM TIMING). Loosen and remove the decompression chamber control retainer screw.
LUBRICATION • Slide off the decompression system together with control spring. • Working on timing side, remove the circlip securing camshaft bearing in place. • Slide off the camshaft together with timing-side ball bearing.
Engine 450 - 550 3.3.3. LUBRICATION REMOVING THE VALVES AND VALVE SPRINGS NOTE The following procedure applies to both cylinders. • Remove the rocker arm controlling exhaust valves and remove the camshaft (REMOVING THE ROCKER ARMS AND CAMSHAFTS). NOTE Before removing the cylinder head components (valves, valve springs, caps and buckets), 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.
LUBRICATION 3.3.4. CHECK CHECKING THE HEAD • • • Check for damages or scratches in the head and change it, if necessary. Check for mineral deposits or rust in the head water jacket, eliminate them. Using a reference bar and a feeler gauge positioned transversally, measure head deformation. Maximum head deformation, see (LIMIT VALUES). CHECKING THE HEAD COVERS • Check for damage or wear, change the faulty parts.
Engine 450 - 550 LUBRICATION CHECKING THE CAMSHAFT GEARWHEEL • Check camshaft gear for proper operation: change timing chain and camshaft gear as a set if you notice damages or hard spots. CHECKING THE CAMSHAFT CAMSHAFT LOBES • Check for blueish stains, pitting, scratches and, if so, change camshaft, its gear and chain. • Check with a micrometer camshaft lobes dimension (a): Camshaft lobes dimensions: limit value (a), see (LIMIT VALUES).
LUBRICATION CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS NOTE The following procedure applies to rocker arms and rocker arm shafts. • Using an inside micrometer gauge, check rocker arm inner diameter and change, if necessary. Rocker arm inner diameter: max wear limit, see (LIMIT VALUES). • • 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.
LUBRICATION Engine 450 - 550 • 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-to-valve guide clearance: max wear limit, see (LIMIT VALUES). • Change the valve guide if clearance is outside specified range. • Carry on checking valves and valve guides by eliminating scale from valve face and seat. Ensure that the valve face does not show pitting or marks of wear; change valve if necessary.
LUBRICATION • • Check that valve stem out of round falls within indicated values, change the valve if needed. Secure the valve in horizontal position, as shown, turn it and check its out of round with a dial gauge; change the part, if needed. NOTE Change valve stem oil seal every time valve is disturbed (removed or changed). Maximum valve stem out of round: see (LIMIT VALUES). CHECKING VALVE SEATS NOTE The following procedure applies to all valves and valve seats.
Engine 450 - 550 3.3.5. LUBRICATION INSTALLING THE VALVES AND VALVE SPRINGS NOTE The following procedure applies to all valves and their components. • Lubricate the valve stem and the valve stem oil seal with oil, see (LUBRICANT TABLE). • Install the valve, lower cap (4), and valve stem oil seal (3). Install valve spring (6) and upper cap (5). • NOTE Install the valve spring end with bigger pitch upward. Install spring with coloured end (red for exhaust, white for intake) facing down.
LUBRICATION • • Fit the two buckets (2) and the two shims below onto both intake valves. Fit the two shims (1) on exhaust valves.
Engine 450 - 550 3.3.6. LUBRICATION INSTALLING THE CAMSHAFT AND ROCKER ARMS NOTE Before refitting, smear bearing with engine oil; see (LUBRICANT TABLE). • • • • • Fit bearing onto camshaft. Lubricate the camshaft (1), see (LUBRICANT TABLE), the spring controlling decompression system and the decompression system itself. Fit the decompression system together with control spring. Lock the camshaft with 6 mm pin (0.24 in) used for cam timing, see (CAM TIMING). Tighten the screw on decompression control.
LUBRICATION • Install exhaust rocker arm shaft. NOTE Ensure the rocker arm shaft is fully home in the head. • Fit the exhaust rocker arm shaft snap ring.
Engine 450 - 550 3.3.7. • • • • LUBRICATION INSTALLING THE HEAD Install the centring pins. Install a new head gasket. Install the head. Insert the four head bolts with washers. NOTE Lubricate head bolt threads and sealing surfaces with engine oil. • Tighten the four head bolts proceeding in a cross pattern, use an articulated spanner with rounded tip, if necessary. NOTE Tighten the head bolts following the tightening sequence shown and the correct torque, in two stages.
LUBRICATION • • • • • • • Install the chain tensioner as follows: 1 – Release the chain tensioner single-direction cam and push its rod completely inside the chain tensioner housing. 2 – Install tensioner in its seat on head timing side and tighten both screws to the specified torque. 3 -- Install the spring and chain tensioner threaded plug, tighten plug to the specified torque. Proceed with cam timing, see (CAM TIMING). Fit the valve cover complete with gasket. Tighten the four screw with new O-rings.
Engine 450 - 550 3.4. 3.4.1. • • • LUBRICATION CYLINDER AND PISTON REMOVAL Before removing the cylinder it is necessary to remove the head, see (REMOVING THE HEAD) Loosen and remove the inspection screw (2), remove O-ring (mind possible coolant spillage). Using special tool (no. 9100897), remove barrel (1) and keep O-ring. NOTE Before removing the gudgeon pin circlip, block off the casing opening with a clean cloth to prevent the circlip from falling inside the crankcases.
LUBRICATION • • • Using piston pin puller (no. 9100943), remove gudgeon pin. Remove the piston. Remove piston ring (3) and oil scraper ring (4).
Engine 450 - 550 3.4.2. LUBRICATION CHECKING THE LIMIT VALUES NOTE During inspection, check the specified parts for wear, referring to the following wear limit values and change any worn out part, if necessary. DESCRIPTION Bucket diameter Bucket seat diameter on head Cylinder barrel inner diameter Piston outer diameter Piston pin bore inner diameter First piston ring end play Con-rod small end inner diameter LIMIT VALUE (mm) (in) 25.96 (1.022) 26.04 (1.025) 76.02/80.02 (2.993/3.150) 75.94/79.94 – (2.
LUBRICATION 3.4.3. INSTALLATION NOTE When assembling the piston rings, ensure their reference faces up. • Install piston ring (3) with gap facing the exhaust and oil scraper ring (4) gap facing the intake. NOTE Ensure that piston marking is facing the cylinder exhaust side. Before fitting the gudgeon pin, lubricate it with engine oil. • • • • Fit piston into cylinder barrel (1). Fit cylinder barrel (1) to crankcase. Install the gudgeon pin. Fit the gudgeon pin circlip. • Close the plug (2).
Engine 450 - 550 3.5. 3.5.1. • • • LUBRICATION CLUTCH REMOVAL Working in a cross pattern, loosen the five screws on clutch cover by one fourth of a turn at a time until removing all five screws. When you have loosened all screws completely, remove them. Place a container of adequate capacity under the clutch. Remove clutch cover. • Working in a cross pattern, loosen the six screws by one fourth of a turn at a time until removing all six screws. Keep washers and clutch springs.
LUBRICATION • Remove the pushrod together with thrust bearing, shim and bearing support. • Remove the plates. • Straighten the lock washer, fit the clutch locking tool (no. 9100896), loosen and remove the clutch hub nut and collect the lock washer.
Engine 450 - 550 • Remove clutch hub. • Collect the shim.
LUBRICATION • Remove the clutch housing. • Remove spacer and needle roller bearing.
Engine 450 - 550 3.5.2. LUBRICATION CHECK CLUTCH PLATES • Rest the friction plates and steel plates on a flat surface and check for cracks and deformation. Allowed deformation, see (LIMIT VALUES CHART). NOTE The steel plates should not be scratched or stained. 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. Plate pack value, see (LIMIT VALUES CHART).
LUBRICATION CHECKING THE PUSHER PLATE Check the pusher plate and bearing for damages and wear. Change the components, if necessary.
Engine 450 - 550 3.5.3. LUBRICATION REASSEMBLY • Insert needle roller bearing and spacer. • Install the clutch housing. • Fit shim. • Install the clutch hub.
LUBRICATION • Install the wing washer(s). WARNING Refit washers restoring their original number and position. • Install the clutch hub nut. • Using clutch locking tool (no. 9100896, special tool), tighten clutch hub nut to the specified torque. Bend the locking washer. • • • Lubricate driving plates and driven plates with gearbox fluid, see (LUBRICANT TABLE). Install the first friction plate, the first metal 1.
Engine 450 - 550 • Fit the pushrod with thrust bearing and shim. • Fit the pusher plate. • • • Install the clutch springs. Fit screw washers. Tighten the six screws in a cross pattern and in steps.
LUBRICATION • • • Install the clutch cover. Tighten the five clutch cover screws, proceeding in a cross pattern. Check gearbox fluid level.
Engine 450 - 550 3.6. 3.6.1.
LUBRICATION 3.6.2. • • • • REMOVING THE EXTERNAL PUMP Before removing any components, place a container of adequate capacity under the engine. Remove the clutch, see (REMOVING THE CLUTCH). Remove the right crankcase cover, see (HOW TO TAKE THE CRANKCASES APART). Remove circlip (1) retaining oil pump lay gear and remove shim. • Remove oil pump lay gear paying attention to inner roller bearing. • Remove the oil pump gear circlip, keep the shim. • Remove oil pump gear, keep the shim.
Engine 450 - 550 • Remove oil pump gear transmission roller. • • Remove the shim (2). Loosen and remove the four screws (3). • Remove the complete oil pump. • Remove the oil pump inner transmission roller.
LUBRICATION 3.6.3. REMOVING THE INTERNAL PUMP NOTE To disassemble the oil pump inner part, it is necessary to separate the crankcases, see (HOW TO TAKE THE CRANKCASES APART), and remove the external pump, see (REMOVING THE EXTERNAL PUMP). • • Loosen and remove the three screws. Remove the cover and oil filter. • • Remove pump impellers and slide off stator. Remove transmission roller.
Engine 450 - 550 3.6.4. LUBRICATION INSTALLING THE INTERNAL PUMP • • Fit transmission roller. Install pump impellers and slide off stator. • • Fit the oil filter and cover. Tighten the three retaining screws. NOTE Close the crankcases, see (ASSEMBLING THE CRANKCASES).
LUBRICATION 3.6.5. • • INSTALLING THE EXTERNAL PUMP Refit the internal pump, see (INSTALLING THE INTERNAL PUMP). Fit the oil pump inner transmission roller. WARNING Internal and external pump impellers have a longer roller, while gear features a shorter roller. • Fit the oil pump together with O-ring. • Fit the shim (2) and tighten the four fastening screws (3). • Fit oil pump gear transmission roller.
Engine 450 - 550 • Fit oil pump gear with the shim. • Fit a new circlip to secure oil pump gear in place. • Install oil pump control gearwheel paying attention to inner roller bearing. • Fit a new circlip to secure the oil pump drive gear in place, install shim.
LUBRICATION 3.7. PRIMARY TRANSMISSION GEAR 3.7.1. • • • • • REMOVING THE PRIMARY GEAR Before removing any components, place a container of adequate capacity under the engine. Remove the clutch, see (REMOVING THE CLUTCH). Remove the right crankcase cover, see (HOW TO TAKE THE CRANKCASES APART). Unscrew and remove the primary gear nut. Use the special tool (no. 9100843) to remove primary gear nut. WARNING Nut has a left-hand thread. • Remove the sprocket. • Remove the shim.
Engine 450 - 550 3.7.2. LUBRICATION INSTALLING THE PRIMARY GEAR WARNING One side of the shim is galvanised (friction proof treatment) and it should be facing the sprocket. • • Install shim, ensure to fit it in the correct direction. Check O-ring on gearwheel shaft for wear, renew if necessary. • Fit the primary gear. • Tighten primary gear nut to the specified torque. WARNING Nut has a left-hand thread.
LUBRICATION 3.8. GEAR SHIFT SELECTOR 3.8.1. REMOVAL, INSPECTION, REFITTING REMOVAL • • • • Remove the clutch, see (REMOVING THE CLUTCH). Remove the right crankcase flange, see (HOW TO TAKE THE CRANKCASES APART). Working on clutch side, slide off gear selector control shaft. Loosen and remove the two screws securing the selector sprocket. • Remove selector sprocket with plate. • Loosen and remove the selector drum screw.
Engine 450 - 550 • Move down ratchet lever and slide off selector drum lower part. • Remove ratchet, washer and spring. LUBRICATION CHECK CHECKING THE STOP LEVER Check the stop lever for damages or wear and ensure that roller can turn freely. Change the components, if necessary. Check for gear 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.
LUBRICATION Engine 450 - 550 CHECKING THE RATCHET Check clearance of washer and riveted pin passing through plate. If it is excessive, change the ratchet. REASSEMBLY • Lubricate and then reassemble following disassembly procedure in the reverse order.
Engine 450 - 550 3.9. 3.9.1. LUBRICATION GENERATOR SIDE REMOVAL • • • Loosen and remove the eleven screws. Mark the screws with different length. Remove flywheel-side cover together with generator, keep gasket and two pilot dowels. • Remove the two gears connecting starter motor to flywheel.
LUBRICATION • • Using the suitable tool (no. 8140838), lock the flywheel rotor. Loosen and remove flywheel nut and remove washer. • Using the suitable flywheel puller (no. 9100839), remove the flywheel. • Remove the roller cage.
Engine 450 - 550 • Loosen and remove the screw on external oilways retaining plate. • Remove the two external oilways. • Loosen and remove the screws securing the two retaining plates for internal oilways. • Slide off the oil delivery and return line.
LUBRICATION 3.9.2. CHANGING BEARINGS AND OIL SEALS WARNING before performing any removing/assembling operation, heat the crankcase with a heat gun in order to avoid any damage to the housings. WARNING Secure the crankcase on the special support plate, part no. 9100841, before performing the described operations. FLYWHEEL-SIDE CRANKCASE MAIN BEARINGS REMOVAL • To remove the crankshaft bearings use the special tool, part no. 9100884, and a rubber mallet.
Engine 450 - 550 • • LUBRICATION Heat the crankcase. Remove the bearing using an internal puller. REASSEMBLY • • Reassemble the bearing using the special tool, part no. 9100886 Refit retaining screw with relevant plate. DESMODROMIC SELECTOR DRUM BEARING REMOVAL • • Heat the crankcase. Remove the bearing using an internal puller REASSEMBLY • Reassemble the bearing using the special tool, part no. 9100892.
LUBRICATION GEARBOX SECONDARY SHAFT BEARING REMOVAL • Remove bearing retaining screws and relevant plate. • Remove the circlip. • Working on crankcase external side, remove oil seal, heat crankcase and remove the bearing using an internal puller. REASSEMBLY • Reassemble the bearing using the special tool, part no. 9100885 WARNING Check that plate adjustable support is fully home and warm coupling areas of the bearing properly. • Refit circlip, plate and relevant screw.
Engine 450 - 550 • LUBRICATION Fit a new oil seal by means of the special tool, part no. 9100894 LAYSHAFT BEARING REMOVAL • Warm the crankcase and then remove the bearing using an internal puller. REASSEMBLY Reassemble the bearing using the special tool, part no. 9100893 CLUTCH-SIDE CRANKCASE MAIN BEARINGS Proceed as described for the flywheel-side crankcase. WARNING before performing any removing/assembling operation, heat the crankcase with a heat gun in order to avoid any damage to the housings.
LUBRICATION GEARBOX BEARINGS REMOVAL Proceed as described for the flywheel-side crankcase. • Remove the three retaining screws. • Heat the crankcase and then remove the bearings using an internal puller. REASSEMBLY • Reassemble the bearings using the special tools. WARNING Check that plate adjustable support is fully home and warm coupling areas of the bearing properly. • Refit retaining screws.
Engine 450 - 550 LUBRICATION LAYSHAFT BEARING REMOVAL • Remove bearing retaining screws and relevant plate. • • Heat the crankcase. Remove the bearing using an internal puller. REASSEMBLY • Reassemble the bearing using the special tool, part no. 9100889. • Refit retaining screw and relevant plate.
LUBRICATION 3.10. ENGINE CRANKCASES 3.10.1. • • • • • • • • • • • • • HOW TO TAKE THE ENGINE CRANKCASES APART Before removing any components, place a container of adequate capacity under the engine. Remove the accessories, see (REMOVING ENGINE ACCESSORIES) Disassemble parts on generator side, see (REMOVING GENERATOR SIDE) Remove the clutch, see (REMOVING THE CLUTCH). Remove the oil pump, see (REMOVING THE OIL PUMP). Remove the gear selector, see (REMOVAL, INSPECTION, REFITTING).
Engine 450 - 550 • Slide out the rear cylinder timing gearwheel. • Remove the timing chain. • • Remove the key. From generator side, remove the timing lay shaft completed with front cylinder timing gearwheel. • Loosen and remove the fifteen crankcase bolts, fourteen are on left side and one is on right side. LUBRICATION WARNING Seven of the left side securing screws are M7 and seven are M6.
LUBRICATION • Remove the gearbox fluid plug screw. • • • Raise by 2-3 cm [(0.79-1.18) in] both cylinder barrels. Separate the crankcases using a mallet. Remove the generator side casing.
Engine 450 - 550 3.10.2. LUBRICATION CHECK CHECKING THE BEARINGS AND OIL SEALS Carefully clean with a mild solvent the two crankcases, the ball bearings and all bearings seats. Clean the sealing surfaces and ensure they are not damaged. NOTE Set the two crankcases on the suitable support plate (no. 9100942) to avoid damaging them. Check that the casings are not cracked or damaged. Ensure that all threads are in good condition. Check that all oil seals that are in place are not worn or damaged.
LUBRICATION 3.10.3. CHANGING BEARINGS AND OIL SEALS WARNING before performing any removing/assembling operation, heat the crankcase with a heat gun in order to avoid any damage to the housings. WARNING Secure the crankcase on the special support plate, part no. 9100841, before performing the described operations. FLYWHEEL-SIDE CRANKCASE MAIN BEARINGS REMOVAL • To remove the crankshaft bearings use the special tool, part no. 9100884, and a rubber mallet.
Engine 450 - 550 • • LUBRICATION Heat the crankcase. Remove the bearing using an internal puller. REASSEMBLY • • Reassemble the bearing using the special tool, part no. 9100886 Refit retaining screw with relevant plate. DESMODROMIC SELECTOR DRUM BEARING REMOVAL • • Heat the crankcase. Remove the bearing using an internal puller REASSEMBLY • Reassemble the bearing using the special tool, part no. 9100892.
LUBRICATION GEARBOX SECONDARY SHAFT BEARING REMOVAL • Remove bearing retaining screws and relevant plate. • Remove the circlip. • Working on crankcase external side, remove oil seal, heat crankcase and remove the bearing using an internal puller. REASSEMBLY • Reassemble the bearing using the special tool, part no. 9100885 WARNING Check that plate adjustable support is fully home and warm coupling areas of the bearing properly. • Refit circlip, plate and relevant screw.
Engine 450 - 550 • LUBRICATION Fit a new oil seal by means of the special tool, part no. 9100894 LAYSHAFT BEARING REMOVAL • Warm the crankcase and then remove the bearing using an internal puller. REASSEMBLY Reassemble the bearing using the special tool, part no. 9100893 CLUTCH-SIDE CRANKCASE MAIN BEARINGS Proceed as described for the flywheel-side crankcase. WARNING before performing any removing/assembling operation, heat the crankcase with a heat gun in order to avoid any damage to the housings.
LUBRICATION GEARBOX BEARINGS REMOVAL Proceed as described for the flywheel-side crankcase. • Remove the three retaining screws. • Heat the crankcase and then remove the bearings using an internal puller. REASSEMBLY • Reassemble the bearings using the special tools. WARNING Check that plate adjustable support is fully home and warm coupling areas of the bearing properly. • Refit retaining screws.
Engine 450 - 550 LUBRICATION LAYSHAFT BEARING REMOVAL • Remove bearing retaining screws and relevant plate. • • Heat the crankcase. Remove the bearing using an internal puller. REASSEMBLY • Reassemble the bearing using the special tool, part no. 9100889. • Refit retaining screw and relevant plate.
LUBRICATION 3.10.4. ASSEMBLING THE CRANKCASES NOTE Before reassembling, change and lubricate the oil seals and lubricate the bearing balls. • • • • • • Install oil seals and bearings to the casings. Install the complete crankshaft in right casing. Fit primary and secondary gearbox shafts with drum and levers, see (REASSEMBLING THE GEARBOX). Fit cylinder barrels as outward as possible. Fit cylinder barrels with reference mark matching the crankcase jointing line.
Engine 450 - 550 • • Fit timing layshaft on generator shaft. Fit the key. • • Fit rear cylinder timing gear. Fit rear cylinder timing chain. • • Fit the timing closure flange. Tighten the three screws from timing closure flange.
LUBRICATION • • • • • • Fit primary gear, see (REMOVING THE PRIMARY GEAR). Use the suitable special tool (no. 9100843) to tighten primary gear nut. Fit timing driving gear, lining up reference mark with the one on primary gear. Fit the lock washer (1). Tighten nut (2) on timing driving gear. Bend washer tab (1).
Engine 450 - 550 LUBRICATION 3.11. TIMING 3.11.1. CAM TIMING • • • Ensure timing chains are correctly tight. Remove the blanking screw from timing hole. Fit special tool (no. 9100844) in its seat. • Turn the crankshaft by turning primary transmission nut until front cylinder is at TDC. Fit pin into special tool (no. 9100844) so to lock out crankshaft rotation. • WARNING Special tool (no. 9100844) is only used to find crankshaft correct position. Do not use it for tightening.
LUBRICATION • • Tighten front cylinder camshaft gear retaining nut. Remove front camshaft and crankshaft locking tools. • Using the primary shaft nut, turn crankshaft clockwise over 283° taking the rear cylinder piston to TDC and repeat the procedure performed on front cylinder.
GEARBOX Engine 450 - 550 GEARBOX 4 4-1
GEARBOX Engine 450 - 550 SUMMARY 4.1. GEARBOX SHAFTS........................................................................................................................................ 3 4.1.1. DIAGRAM .............................................................................................................................................. 3 4.1.2. DISASSEMBLING THE GEARBOX ....................................................................................................... 5 4.1.3. CHECK........
Engine 450 - 550 4.1. 4.1.1.
GEARBOX Key: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. Selector shaft+pawls Selector pin Spring Circlip Flanged hex.head screw Complete index lever Washer Spring Oil seal Complete Desmodromic unit Roller Gear selector drum Threaded pin M8x1.25 Gear selector stop plate Flanged hex.
Engine 450 - 550 4.1.2. GEARBOX DISASSEMBLING THE GEARBOX • To gain access to gearbox, it is necessary to remove generator-side casing, see (HOW TO TAKE THE ENGINE CRANKCASES APART). • • Remove the fork shafts. Turn the selector forks outward and remove the selector drum • Remove desmodromic gear selector drum. • • Slide off 4th and 5th speed fork. Slide off 1st and 3rd speed fork and 2nd speed fork.
GEARBOX • Slide off primary and secondary shafts at the same time. DISASSEMBLING THE PRIMARY SHAFT • • • • • • • • • • • Remove the shim (1) from the generator side. Slide off 2nd speed gear (2). Remove the bush (3). Slide off 4th speed gear (4). Remove the special washer (5). Remove the circlip (6). Slide off 3rd speed gear (7). Remove the circlip (8). Remove the plain washer (9). Slide off 5th speed gear (10). Remove the bush (11).
Engine 450 - 550 4.1.3. GEARBOX CHECK CHECKING THE GEARBOX FORKS NOTE The following procedure applies to all gearbox forks. Check selector fork cam bush (1), selector fork tooth (2) for damage, deformation and wear. Change the selector fork, if needed. Ensure that selector fork slides on the shaft, change the forks if movement is not smooth. CHECKING THE DESMODROMIC SELECTOR DRUM Check selector drum for damage, scratches and wear; change the unit if necessary.
GEARBOX 4.1.4. • REASSEMBLING THE GEARBOX Correctly couple gearbox primary and secondary shafts and insert them into clutch-side crankcase. WARNING Use grease to ensure secondary shaft shim stays in place. NOTE Ensure every selector fork is fitted with the small sliding bush. • Grease the small bushes. • • Slide in 1st and 3rd speed fork and 2nd speed fork. th th Slide in 4 and 5 speed forks. • Install desmodromic gear selector drum.
Engine 450 - 550 • Install the fork shafts. • Refit generator-side crankcase, see (ASSEMBLING THE CRANKCASE).
ELECTRICAL SYSTEM Engine 450 - 550 ELECTRICAL SYSTEM 5 5-1
ELECTRICAL SYSTEM Engine 450 - 550 SUMMARY 5.1. ELECTRIC COMPONENTS ............................................................................................................................ 3 5.1.1. INSTRUMENT PANEL ...........................................................................................................................
Engine 450 - 550 5.1. 5.1.1. ELECTRICAL SYSTEM ELECTRIC COMPONENTS INSTRUMENT PANEL INSTRUMENT PANEL SET-UP The set-up function allows you to select and enter values relevant to monitoring symbols and units of measurement: • Measure unit for speed and distance, • Hours before next oil change, • Km or hours before next service coupon. When instrument panel is off, press SCROLL on handlebar, or MODE on odometer, and keep it pressed.
ELECTRICAL SYSTEM Resetting the monitoring parameters Activate set-up when monitoring symbols are activated because their set value has been reached (symbols are displayed on LCD). Follow the set-up procedure until the relevant symbol is displayed on LCD. When the symbol is on, hold SCROLL pressed until dashes - - - are displayed when it is released, the wording NO will be displayed. Press SCROLL briefly to shift to wording YES.
Engine 450 - 550 ELECTRICAL SYSTEM Select the measure unit and press SCROLL until it goes off. The newly set value will be displayed after releasing the button; to change it, proceed as described under “Changing the values”. After confirming, wait until the symbol goes off. Counter is reset automatically and the symbol goes off. Press SCROLL briefly and End is displayed. When End is displayed, press SCROLL briefly to go back to the starting page.
