Sales division Technical network leadership WORKSHOP MANUAL 125/151 CC 4-STROKE ENGINE 2 VALVES SYM

Transcription

1 Sales division Technical network leadership WORKSHOP MANUAL - 5/5 CC 4-STROKE ENGINE VALVES SYM

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3 TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS... PRODUCTS DANGER SYMBOLS USED... 3 CHARACTERISTICS... 5 Capacities...5 SPECIAL IMPORTANT POINTS... 6 Oil and fuel...6 TIGHTENING TORQUES... 7 SPECIAL TOOLS... 8 Standard tools...9 OPERATION... 0 Putting the engine on the stand...0 Changing the engine oil...0 PRIMARY TRANSMISSION... Removal of the primary transmission cover... Removal of the drive pulley... Removal of the driven pulley... Changing the drive pulley bearings... Checking the drive belt... Removal of the clutch lining assembly...3 Refitting the clutch lining assembly...4 Removal of the starter system...5 Fitting the starter system...6 SECONDARY TRANSMISSION... 7 Removal of the secondary transmission...7 Replacing the bearings of the relay box...8 Crankcase...8 Relay box cover...8 CARBURETTOR... 9 Removal of the carburettor...9 Removal of the choke...9 Removal of the throttle valve...0 Removal of the float, needle valve and jets...0 Removal of the mixture screw... Removal of the deceleration enrichment device...

4 TABLE OF CONTENTS MAGNETO FLYWHEEL/FREEWHEEL... 4 To remove the magneto flywheel...4 Removal of the overrunning clutch...6 Checking the overrunning clutch...7 Replacing the lip seal...7 Oil pump...7 CYLINDER HEAD/CYLINDER/PISTON... 9 Removal of the pulsair reed valve...9 Removal of the cylinder head...9 Removal of the camshaft and/or rockers...3 Removal of the valves or valve stem seals...33 Removal of the cylinder / piston...35 Checking the cylinder...36 Checking the piston...36 Checking the piston rings...36 Installing the piston rings on the piston...37 Fitting the piston...37 Fitting the cylinder...38 Setting the timing...39 Checking the timing...40 Installing the valve clearance...40 Checking the valve clearance...4 CRANKCASE... 4 Removal of the crankshaft...4 Checking the crankshaft and conrod assembly...43 Replacing the lip seal...43 Fitting the conrod and crankshaft assembly...44

5 PRODUCTS DANGER SYMBOLS USED PRODUCTS DANGER SYMBOLS USED Protection of individuals and of the environment. Möbius band Irritant Recyclable. The product can irritate the skin, eyes and respiratory organs. Means that the product or the package can be recycled. However, this does not guarantee that the product will be recycled. Avoid contact with skin and clothes. Wear gloves, safety glasses and appropriate clothing such as a cotton overall. Do not breath fumes. If in contact, wash thoroughly with water. Flammable The product is flammable. Keep it away from flames or any heat source (barbecue, radiator, heating, etc.). Do not leave the product in the sun. Corrosive The product can damage living tissues or other surfaces. Avoid contact with skin and clothes. Wear gloves, safety glasses and appropriate clothing such as a cotton overall. Do not breath fumes. Explosive The product can explode under certain circumstances (flame, heat, impact, friction). Avoid impacts, friction, sparks and heat. Hazardous to the environment The product affects fauna and flora. Do not dump it in dustbins, sinks or in the environment. The ideal solution is to bring this product to your nearest household waste recycling centre. Toxic Do not throw away into a garbage can The product can seriously affect health if it is inhaled, ingested or in contact with skin. One of the product's component is toxic and can be hazardous to environment. For example: Used batteries. Avoid direct contact with the body, even by inhalation. If you feel unwell, seek medical advice immediately. This symbol informs the consumer that the used product shall not be thrown away into a garbage can, but shall be brought back to the merchant or dropped at a specific collection point. Compulsory gloves Operation that can be dangerous for people. People's safety can be seriously affected if the recommendations are not fully respected. 3

6 PRODUCTS DANGER SYMBOLS USED People's safety Operation that can be dangerous for people. People's safety can be seriously affected if the recommendations are not fully respected. Important Operation that can be hazardous to the vehicle. Indicate the specific procedures that shall be followed in order not to damage the vehicle. Good operating condition of the vehicle The operation must be carried out in strict compliance with the documents. Serious damage to the vehicle and in certain cases a cancellation of the warranty can be involved if the recommendations are not fully respected. Note Operation that can be difficult. Indicate a note which gives key information to make the procedure easier. Lubricate Lubricate the parts to be assembled. Indicate the specific procedures that shall be followed in order not to damage the vehicle. Grease Grease the parts to be assembled. Indicate the specific procedures that shall be followed in order not to damage the vehicle. GLUE Glue Glue the parts to be assembled. Indicate the specific procedures that shall be followed in order not to damage the vehicle. N New part Use a new part. Indicate the specific procedures that shall be followed in order not to damage the vehicle. 4

7 CHARACTERISTICS CHARACTERISTICS 5 cc 5 cc Marking XSP5QMI-4 XSP57QMJ- Type 4-stroke single-cylinder valves per cylinder with chain driven overhead camshaft Cooling By a circulation of forced air by means of a turbine on the flywheel magneto Bore x stroke 5.4 x 57.8 mm 57.4 x 58. mm Cubic capacity 4.6 cc 50.6 cc Max. power output 6.5 kw at 7500 rpm 7.7 kw at 7500 rpm Max. torque rating 9 Nm at 6000 rpm 0.6 Nm at 6000 rpm Compression Lubrication Transmission Clutch Exhaust Spark plug Magneto flywheel Fuel supply Standards.8 bars at 380 rpm 7 bars. Minimum Trochoid pump driven by a gear set from the crankshaft By variable pulleys and V-type belt Centrifugal automatic Catalytic NGK CR7HSA 80 W Carburettor Deni DPD4J Euro3 Capacities Crankcase Relay box 0.95 l (0.7 I at oil change) SAE 5W40 Synthetic Minimum grade: API SJ 0.8 l (0.7 I at oil change) SAE 80W90 Minimum grade: API GL4 5

8 SPECIAL IMPORTANT POINTS SPECIAL IMPORTANT POINTS Oil and fuel This engine is designed to run on 95 or 98 unleaded fuel only. Never run the machine with a petrol/oil mixture. Fuel pipes must absolutely be changed if there are any signs of wear, cracks, etc. The clips are specific, they must always be changed each time they are removed and replaced with new genuine parts clips. Petrol is highly inflammable, do not smoke in the working area and avoid proximity to flames or sparks. 6

9 TIGHTENING TORQUES TIGHTENING TORQUES Spark plug Engine drain plug Screen Cylinder head Nut Ø8 mm Screw Ø6 mm Cylinder head cover Camshaft gear Valve clearance covers Automatic tensioner Automatic tensioner plug Chain tensioner Inlet manifold Cylinder casings RH casing cover Freewheel Oil pump Transmission cover Relay box cover Relay box drain plug Starter motor Rotor Turbine Stator Engine speed sensor Drive pulley Driven pulley Clutch plate and shoes 5/5 cc Nm 0 Nm 5 Nm 0 Nm Nm 0 Nm Nm 0 Nm 0 Nm 8 Nm 0 Nm 0 Nm Nm Nm 90 Nm 0 Nm 0 Nm Nm 0 Nm 0 Nm 45 Nm 0 Nm 0 Nm 6 Nm 55 Nm 45 Nm 55 Nm 7

10 SPECIAL TOOLS SPECIAL TOOLS Tool N Designation Used with Tool N Designation Used with Engine mount Lip seal push tool Flywheel puller Lip seal push tool 7537 Adjustable pin wrench Clutch compression tool mm pipe wrench Valve stem seal drift Valve lifter Lip seal push tool Bearing extractor tool 8068 Spacer adaptor Piston locking fork Engine mount adapter* (*) New or modified tool 8

11 DC 0A 00 m 0 m Ω VAC VDC OFF VΩ COM ma Ω STANDARD TOOLS STANDARD TOOLS Wrenches with interchangeable end fittings for valve clearance adjustment Type : Marolotest P/N Set of shims Slide calipers Multimeter Heat gun Automatic resetting type torque wrench 5 to 5 Nm Type : Facom R.306A5 Intertia type extractor tool for bearings from 6 to 8 mm Type : Facom U.49PJ3 Automatic resetting type torque wrench 0 to 50 Nm Type : Facom J.08A50 Automatic resetting type torque wrench 40 à 00 Nm Type : Facom S.08A00 9

12 OPERATION OPERATION Putting the engine on the stand - Fit the engine to adapter P/N Put the assembly on stand P/N clamped in the jaws of a vice Changing the engine oil To drain the engine remove the cap and let the oil drip. Tightening torque: 0 Nm. N Replace the seal each time you change the oil. - Remove the strainer cap () and clean the strainer (). Tightening torque: 5 Nm. Every time oil is changed, the filter () must be cleaned and the O-ring changed (3). N 3 0

13 PRIMARY TRANSMISSION PRIMARY TRANSMISSION Removal of the primary transmission cover - Remove the transmission cover (8 screws). - Remove the paper gasket and the two centering pins. Tightening torque: 0 Nm. Removal of the drive pulley - Hold the fixed flange with tool P/N Remove the nut () and washer () from the fixed flange. - Remove the fixed flange. Tightening torque: 55 Nm Pull the belt aside (3). - Remove the drive pulley (4) with the guide hub (5)

14 PRIMARY TRANSMISSION Removal of the driven pulley - Lock the clutch drum () with the pin wrench P/N Remove the nut (). - Remove the clutch drum and the clutch and drive pulley assembly. Tightening torque: 45 Nm Changing the drive pulley bearings - Remove the holder () and its 3 plastic guides (). - Remove the moving flange (4) 6 bearings (3). The bearings must be changed if they show major signs of wear. The guides shall be replaced if they show signs of wear. 4 3 Checking the drive belt - Measure the width of the belt (A). Minimum width: 7.5 mm. A - Make sure the belt is not cracked.

15 PRIMARY TRANSMISSION Reassembly: - Proceed in reverse order to disassembly and do not grease the bearings. - When refitting, respect the way the rollers are installed. - Grease the moving flange bore lightly (high temperature grease). Removal of the clutch lining assembly - Using the depth calliper, measure the thickness of the clutch linings. Mini. thickness: mm. - Compress the clutch and driven pulley assembly using tool equipped with the protection spacer P/N Remove the nut using spanner P/N Slacken tool P/N

16 PRIMARY TRANSMISSION - Remove the clutch linings (), the upper centring sleeve (3), the spring (4), and the lower centring sleeve (5). - Remove the 3 pins (6) from the variable speed drive seat. - Separate the fixed (7) and rotating (8) flanges. - Make sure surface of the plates in contact with the belt does not show any cracks or signs of abnormal wear Refitting the clutch lining assembly - After checking the lip seals (9) and the O- rings (0) of the rotating flange (8) are in good condition, grease the governor seat 3 pins (6) (high temperature grease) and assemble the parts in reverse order to removal. - Compress the clutch and driven pulley assembly using tool equipped with the protection spacer P/N Tighten the nut (). Tightening torque: 55 Nm. 9 Before fitting the clutch drive pulley and driven pulley to the input shaft, fit the belt into the pulley bottom by opening the flanges by hand. - Fit the clutch drive pulley and driven pulley assembly. - Fit the clutch cover. - Fit and tighten the nut. Tightening torque: 45 Nm. - Fit the locating pins and a new paper gasket. - Fit the drive pulley with its guide hub onto the connecting rod. - Fit and tighten the nut. Tightening torque: 55 Nm. - Install the transmission cover (8 screws). Tightening torque: 0 Nm

17 PRIMARY TRANSMISSION Removal of the starter system - Remove the plate (7 screws). - Actuate the kick starter gear sector () by hand and remove the kick starter drive piece () and washer. 4 - Remove the lock ring (3), using circlip pliers. - Remove the washer. - Remove the elastic washer. - Remove the starter gear sector () and the washer (4) from the drive train cover. 3 5

18 PRIMARY TRANSMISSION Fitting the starter system - Fit the return spring (4), hook the longest buckle on the cover's pin (A). - Fit the starter gear sector () into the lubricated bearing sleeve. - Hook the second buckle (B) of the spring onto the starter gear sector. - Wind the spring so as to position the kick starter sector on the stop (C) of the cover. C A B 4 - Turn over the cover, fit the washer and the circlip on the the gear sector spindle. - Fit the washer (5) on the housing of the kick starter drive piece. - Wind approximately /8th of a turn the gear sector so as to place the kick starter drive piece (). - Position the pin (6) on the kick starter drive piece in the cover housing (D). 5 6 D 6

19 SECONDARY TRANSMISSION SECONDARY TRANSMISSION Removal of the secondary transmission Remove the screw (A) in order to drain the relay box. Tightening torque: 0 Nm. Use a drip pan to catch the transfer box oil when the cover is removed. - Remove the secondary transmission cover (7 screws). Tightening torque: Nm. A - Remove the paper gasket () and the locating pins (). - Remove the countershaft (3). - Remove the secondary shaft (4). Make a note of the way the secondary shaft pinion is installed The primary shaft can be drifted out of the casing using a mallet (5). 5 7

20 SECONDARY TRANSMISSION Replacing the bearings of the relay box Crankcase Wear gloves in order not to get burnt. - Remove the seal. - Using a heat gun, heat the crankcase to a temperature between 80 and 90 C. - Use an inertia type extractor tool to remove the bearings. - While the casing is expanded fit the new bearing fully home in its housing. - Using fitting tool P/N , fit a new lightly greased gasket () Relay box cover - Remove the seal. - Place the cover on its gasket seat surface, heat it (80 to 90 C) until the bearing falls out by itself. - While the casing is expanded fit the new bearing fully home in its housing. - Using fitting tool P/N , fit a new lightly greased gasket ()

21 CARBURETTOR CARBURETTOR Removal of the carburettor - Disconnect the vacuum hose. - Loosen the collar. - Remove the carburettor. Removal of the choke - Remove the choke cap. - Locate the position of the choke () and then remove it ( screws). - Remove the choke holder () ( screws). - Remove the O-ring (3). 3 9

22 CARBURETTOR Removal of the throttle valve - Remove the chamber cap ( screws). - Remove the spring. - Remove the needle, valve and membrane assembly. - Remove the needle stop () and its spring (3) by pulling it out. - Remove the needle and its washer (4). The height oif the needle is factory set and cannot be modified. Check that the membrane is in good condition. 3 4 Removal of the float, needle valve and jets - Remove the float chamber and its O-ring (4 screws). 0

23 CARBURETTOR - Remove the float (6) pin (5). - Remove the float and the needle valve Remove the idle jet (7). - Remove the main jet (8). - Remove the needle well (9) Check the condition of the needle valve and the needle valve seat (A). Check the condition of the float chamber O-ring. A

24 CARBURETTOR Removal of the mixture screw - Turn clockwise the mixture control screw () while counting the number of turns until it is screwed home. When re-fitting, this operation allows you to put it back to its initial adjustment position. - Remove the mixture screw and its spring. - Remove the washer and the O-ring (). Removal of the deceleration enrichment device - Remove the cover ( screws).

25 CARBURETTOR - Remove the spring (). - Remove the membrane (). Check that the membrane is in good condition. - Clean the carburettor body with Biosane cleanser ref or use an ultrasonic cleaning tank. - Blow into every jet and duct of the carburettor body with compressed air. Do not use any metal tool which can damage the ducts of these items. - Re-install all the other components and, if necessary, when starting the engine, readjust according to the values indicated on the technical data card. 3

26 MAGNETO FLYWHEEL/FREEWHEEL MAGNETO FLYWHEEL/FREEWHEEL To remove the magneto flywheel - Remove the carburettor. - Remove the inlet coupling ( nuts). Tightening torque: 0 Nm. - Remove the plastic spacer. The paper gasket must be changed each time it is removed. - Remove the pneumatic valve (). - Remove the volute () (6 screws). - Remove the cylinder cover. Right-hand side (3) (4 screws). 3 - Remove the turbine (4 screws). Tightening torque: 0 Nm. 4

27 MAGNETO FLYWHEEL/FREEWHEEL - Lock the rotor with the adjustable pin wrench P/N Remove the nut and the washer Tightening torque: 45 Nm. - Tighten flywheel extractor P/N on the rotor. - Lock the flywheel extractor and turn the thrust bolt until the rotor is released Remove the sheath holder (4). - Remove the stator and sensor assembly (3) ( screws each). Stator: 4 Tightening torque: 0 Nm. Sensor: Tightening torque: 6 Nm. 5

28 MAGNETO FLYWHEEL/FREEWHEEL Removal of the overrunning clutch - Remove the flywheel magneto.. A B C - Remove the 0 bolts that secure the RH cover. A. Screw Length: 30 mm. B. Screw Length: 95 mm. C. Screw Length: 00 mm. B A - Remove the RH cover. Tightening torque: Nm. C B - Remove the paper gasket () and the locating pins (). - Remove the starter ring (3). - Remove the starter dog (4) Using pin spanner ref. 7537, immobilise the overrunning clutch (5). The notched nut of the overrunning clutch has a left-hand thread Using tool P/N , remove the notched nut and the washer of the overruning clutch Tightening torque: 90 Nm. - Remove the overrunning clutch. 6

29 MAGNETO FLYWHEEL/FREEWHEEL Checking the overrunning clutch - Rotate the overrunning clutch by hand: It must rotate in direction (A). It must be block in direction (B). - If it doesn't, replace the overrunning clutch. A B Replacing the lip seal - Remove the lip seal. - Using fitting tool P/N , fit a new lightly greased gasket () Oil pump - Remove the plate ( screws). 7

30 MAGNETO FLYWHEEL/FREEWHEEL - Remove the circlip (). - Remove the oil pump gear (). - Remove the pin. - Remove the oil pump ( screws). 8

31 CYLINDER HEAD/CYLINDER/PISTON CYLINDER HEAD/CYLINDER/PISTON Removal of the pulsair reed valve - Remove the cover () (3 screws). - Remove the pulsair reed valve (). The paper gasket must be changed each time it is removed. Removal of the cylinder head - Remove the pneumatic valve (). - Remove the volute () (6 screws). - Remove the cylinder cover. Right side. (3) (4 screws). - Disconnect the pipe from the pulsair reed valve ( nuts). - Remove the rocker cover (4 screws). 3 Tightening torque: 0 Nm. - Using a wrench, turn the crankshaft in the direction of operation to as to line up the marks on the camshaft gear (A) with the cylinder head gasket face. A 9

32 CYLINDER HEAD/CYLINDER/PISTON - Removal of the chain tensioner plug (4). - Remove the O ring. 4 - Using a screwdriver, slacken the chain tensioner (5). - Removal of the chain tensioner. 5 - Remove the camshaft gear (6) ( screws). - Tie a wire to the timing chain in order to prevent it from falling into the crankcase. 6 30

33 CYLINDER HEAD/CYLINDER/PISTON - Remove the bolts (7). - Gradually loosen in a crosswise order the 4 nuts which secure the cylinder head (8). - Remove the 4 nuts. - Remove the plate (9) Remove the cylinder head. - Removal of the metal gasket (0) and the centring pillars (). 0 3

34 CYLINDER HEAD/CYLINDER/PISTON Removal of the camshaft and/or rockers - Remove the cylinder head. - Remove the stopper plate (). Tightening torque: 0 Nm. - Remove the pins from the rockers using a 5mm screw(). - Remove the inlet (3) and exhaust (4) rockers. - Remove the springs (5) Remove the camshaft (6). 6 3

35 CYLINDER HEAD/CYLINDER/PISTON Removal of the valves or valve stem seals - Compress the spring of one of the valves using the valve lifter P/N Remove the half cones (). - Uncompress the spring and remove the tool Remove: The upper cup (). The spring (3). The valve (4). The valve stem seal (5). - Remove the nd valve in the same way When removing a valve, always change the valve stem seal Using tool P/N , fit a new valve stem seal. 33

36 CYLINDER HEAD/CYLINDER/PISTON - When re-installing, fit the valve springs, the closest coils against the cylinder head. - When re-installing, lubricate the half cones () so as to hold them in the groove of the valve's stem. - Do not place the half cones into the cup forcefully with the tool when decompressing the spring. - When re-installing the rocker pins, position the indentation of the axles towards the outside of the cylinder head to fit the cylinder studs. - To assemble the holder plate, position the rocker pins with the screwdriver slits vertical. When re-installing, the camshaft bearings, the rocker shafts and the contact between the rockers and the valves shall well lubricated in order to avoid any risk of seizure when starting the engine (Use lithium soap grease). Seals and valve stems must be lubricated. 34

37 CYLINDER HEAD/CYLINDER/PISTON Removal of the cylinder / piston - Remove the cylinder head. - Remove the chain guide pad (). - Remove the cylinder. - Remove the base gasket () and the centring pillars (3). 3 - Remove one of the circlips (4) with pliers. - Remove the gudgeon pin. - Remove the piston. 4 35

38 CYLINDER HEAD/CYLINDER/PISTON Checking the cylinder - The cylinder should show no traces of scoring or seizure. 5 cc 5 cc Cylinder diameter to 5.45 mm to mm Utilisation limit 5.5 mm 57.5 mm Checking the piston - The piston should show no traces of scoring or seizure. - The rings must be free in their grooves. - Measure the piston diameter at 9 mm from the piston skirt. 9 mm 5 cc 5 cc Piston diameter to mm to mm Utilisation limit 5.9 mm 57.9 mm Checking the piston rings - Carefully remove the piston rings. - Place a ring in the bore parallel to it and measure the gap using a feeler gauge. Piston ring gap: Top compression ring gap: 0. to 0.4 mm. Compression ring gap: 0.5 to 0.4 mm. Oil control ring gap: 0. to 0.7 mm. 36

39 CYLINDER HEAD/CYLINDER/PISTON Installing the piston rings on the piston - Proceed in the following order in order to install the oil control rings. Fit the spring () (no special direction). Fit the piston rings () on each side of the spring offsetting the gap of each ring (no special direction). - Install the compression ring (3) by placing the R mark upwards. - Install the top compression ring (4) by placing the R mark upwards. 4 3 Fitting the piston - Install the piston so that the mark IN is on the inlet side. - Fit the gudgeon pin and circlips. - The circlip gaps () must face upwards or downwards, but under no circumstances to the side. N Use new rings. 37

40 90 CYLINDER HEAD/CYLINDER/PISTON Fitting the cylinder - Position the piston ring gap as follows: A. Top compression ring gap. B. Compression ring gap. C. Upper oil control ring gap. D. Lower oil control ring gap. B 0 90 A D C - Install the cylinder base gasket and the guiding pillars on the crankcase. - When refitting the cylinder, we recommend locking the piston using the fork part number in order to facilitate assembly. - Fit the cylinder over the piston by compressing the piston rings by hand Lubricate the cylinder. - Fit the chain and the chain guide tensioner into the timing chain tunnel. - Fit the chain pad (). - Fit the guiding pillars () and the metal gasket on the cylinder (3). 3 38

41 CYLINDER HEAD/CYLINDER/PISTON - Install the cylinder head. - Fit the plate (4). - Tighten the cylinder head securing 4 nuts working diagonally in or 3 steps (5). 4 Tightening torque: 0 Nm. - Fit and tighten the fixing bolts (6). Tightening torque: Nm. 5 6 Setting the timing - Turn the magnetic wheel to line up the "T" mark with the the crankcase boss (A). A - Fit the timing chain on the camshaft gear. - Make sure the camshaft marks (B) are parallel with the gasket seat surface (C). - If necessary, dislodge the gear from the camshaft without removing it and move the chain around the gear on the required side. - Fit the screws. Tightening torque: Nm. B C 39

42 CYLINDER HEAD/CYLINDER/PISTON - Fit the chain tensioner gasket. - Install the chain tensioner and the attachment screws (). Tightening torque: 0 Nm. - Using a flat blade screwdriver, unlock the chain tensioner screw. - Fit the O-ring. - Install the tensioner cap. Tightening torque: 8 Nm. Checking the timing - Rotate the engine twice: revolutions in the engine's operating direction. - Turn the magnetic wheel to line up the "T" mark with the the crankcase boss (A). - Make sure the camshaft marks (B) are parallel with the gasket seat surface. - If the marks are not alined, reset the valve timing. A B Installing the valve clearance - Remove the rocker cover.. Tightening torque: 8 Nm. - Using a wrench, turn the crankshaft in the direction of operation to as to line up the marks on the camshaft gear (B) with the cylinder head gasket face. B 40

43 CYLINDER HEAD/CYLINDER/PISTON - Using the set of feeler gauges, measure the clearance of each valve. Clearances: 0. ± 0.0 mm at the intake. 0. ± 0.0 mm at the exhaust. - If the clearance is not correct, adjust by means of the cam follower screw. Checking the valve clearance At the intake a 0.5 mm feeler gauge shouldn't go. At the exhaust a 0.5 mm feeler gauge shouldn't go. - On the contrary, if the fealer gauge goes, reset the clearances. 4

44 CRANKCASE CRANKCASE Removal of the crankshaft - Remove the primary drive. - Remove the overrunning clutch. - Remove the cylinder and the piston. - Remove the starter motor ( screws). Tightening torque: 0 Nm. - Remove the screws that secure the RH half casing. - Remove the RH casing. - Remove the centring pillars and the paper gasket. - Disengage the timing chain from the crankshaft gear. - Removing the the cranshaft and conrod assembly. - Remove the timing chain and notice its direction of rotation. 4

45 CRANKCASE Checking the crankshaft and conrod assembly - Using a set of shims, check the big end side play. - The maximum side play on the conrod end must not exceed: 0.55 mm. The out-of-round values measured on the ends of the crank should not exceed 0. mm and must be measured: - 80 mm from the transmission side end mm from the flywheel magneto end mm mm Replacing the lip seal - Remove the lip seal. - Using fitting tool P/N , fit a new lightly greased gasket ()

46 CRANKCASE Fitting the conrod and crankshaft assembly - Position the LH casing horizontally. - Fit the timing chain () through the timing well. - Fit the conrod and crankshaft assembly into the LH crankcase. - Fit the guiding bushes (3) to the LH casing and a new paper gasket (4), do not use oil or grease. - Place the RH casing over the LH casing assembly

47 CRANKCASE - Fit and tighten the clamping bolts. Tightening torque: Nm. - Trim the casing gasket in (A). A 45

48 P/N MA000GB In our permanent concern to make improvements PEUGEOT MOTOCYCLES reserves the right to suppress, modify, or add any reference mentioned. DC/APV 06/00 (non contractual pictures)