Specifications

1
ENGLISH
INDEX
FOREWORD 2
1 REMOVING THE ENGINE FROM THE VEHICLE 4
1
.1 Exhaust manifold 5
1
.2 Engine protection plat 5
1
.3 Transmission oil plug 5
1
.4 Water cooling radiator 6
1
.5 Flywheel casing, clutch actuator and pinion 8
1
.6 Electronic control box 8
1
.7 Carburettor clamp 9
1
.8 Quadripole and monopole connector release 9
1
.9 Engine bolts 10
2 DISASSEMBLING THE ENGINE 11
2
.1 Thermal unit 11
2
.1.1 Head 12
2
.1.2 Cylinder 13
2
.1.3 Piston 13
2
.2 Intake system 14
2
.3 Ignition system 14
2
.3.1 Flywheel 15
2
.3.2 Pick-up and stator 16
2
.4 Clutch unit 17
2
.5 Primary gear 19
2
.6 Start-up devic 20
2
.7 Gearbox unit 21
2
.7.1 External transmission control 21
2
.7.2 Internal transmission control and transmission gears 22
2
.8 Motor shaft 22
2
.9 Bearings and oil seals 23
3 ASSEMBLING AND TESTING THE ENGINE 24
3
.1 Testing the motor shaft and connecting rod 24
3
.2 Mounting the complete motor shaft 25
3
.3 Gearbox unit: testing and reassembling 25
3
.3.1 Testing the toothed wheels and shafts 25
3
.3.2
Testing the forks, fork pins and desmodromic
device
26
3
.3.3 Assembling the internal transmission control 27
3
.4 Closing the engine casing 29
3
.5 External transmission control 30
3
.5.1 Testing the complete gear shaft 30
3
.5.2 Assembling the external transmission control 31
3
.6 Start-up device 32
3
.6.1 Testing the ignition shaft and the assembly
32
3.6.2
Mounting the start-up device 33
3.7
Primary gear and clutch unit 34
3.7.1
Testing the clutch bell and replacing the
silent-block
35
3.7.2
Testing the clutch discs 36
3.7.3
Testing the springs 37
3.7.4
Testing the clutch drum 37
3.8
Assembling the clutch 38
3.9
Internal cover of the clutch 40
3.10
Ignition system 41
3.10.1
Testing the ignition stator 41
3.10.2
Stator and pick-up winding 41
3.10.3
Flywheel 42
3.11
Thermal unit 43
3.11.1
Testing the piston, piston pin and piston rings 43
3.11.2
Testing the cylinder and head 44
3.12
Assembling the piston, piston ring, piston pin,
crank case/cylinder gasket and cylinder
46
3.12.1
Thickness check of cylinder/crankcases gasket 47
3.13
Assembling the head 49
3.14
Intake system 50
3.14.1
Testing the lamella pack 50
3.14.2
Mounting the intake system 50
3.15
Start-up and gear lever 50
3.16
Water pump unit 51
3.16.1
Disassembling and reassembling the water pump 51
4
MOUNTING THE ENGINE ON THE VEHICLE
AND REPOSITIONING THE COMPONENTS
52
4.1
General guidelines 52
4.2
Coupling the engine to the frame 53
4.3
Coupling the clutch actuator, pinion and
flywheel casing
54
4.4
Electronic control box 55
4.5
Connecting the engine cable to the main system
and mounting the rear mudguard
55
4.6
Remounting the complete water radiator
and coil
56
4.7
Engine protection plate 57
4.8
Exhaust manifold 58
Table of tightening torques of the engine components 59
Table of tightening torques of the engine-frame 60
Engine specifications 60
Recommended lubricants and liquid 60