REEDSTER 125cc. versions: F1 - F2 - F3 - F4 OVERHAULING MANUAL

Transcription

1 REEDSTER 125cc versions: F1 - F2 - F3 - F4 OVERHAULING MANUAL 07/11/07 21/01/2009 1

2 INDEX Page 1. - REEDSTER 125cc ENGINE DISASSEMBLY CRANKSHAFT DISASSEMBLY / ASSEMBLY CRANKSHAFT DISASSEMBLY CRANKSHAFT ASSEMBLY REEDSTER 125cc ENGINE ASSEMBLY 18 ATTACHMENTS - FASTENER TORQUE TABLE - CROSS PATTERN LOCKING ORDER ON CRANKCASE - MAIN PRESCRIPTIONS - CONROD BIG END AND SMALL ENDS TOLERANCES - OVERHAULING TOOL LIST - Wear Evaluation Table on Bearings/ Halfcrankshafts - Drawing of fixing engine tool 07/11/07 2

3 1 REEDSTER 125cc ENGINE DISASSEMBLY OPERATIONS PICTURES 1. DISCHARGING OIL FROM GEARBOX - UNSCREW THE M6 SCREW FOR DISCHARGING OIL (see Fig.1). Fig.1 (5mm ALLEN WRENCH T TYPE) - TILT THE ENGINE TO FACILITATE OIL DISCHARGING AND CHECK THAT THE GEARBOX BREATHER IS FREE AND (see Fig.2). Fig.2 2. FIX THE ENGINE ON THE BENCH VICE TOOL FOR BENCH VICE (see attached drawing) - SCREW N 2 SCREWS M8x30 IN THE CRANKCASE 3. REMOVE THE EXHAUST FITTING - UNSCREW N 4 SCREWS M6x25 (see Fig.3). (5mm ALLEN WRENCH T TYPE) Fig.3 - REMOVE THE N 4 ELASTIC WASHERS - REMOVE THE EXHAUST FITTING, SPACER AND BOTH GASKETS. 1

4 4. REMOVE THE IGNITION - REMOVE STATOR UNSCREW N 3 M5x25 SCREWS (see Fig.4) (4mm ALLEN WRENCH T TYPE) Fig.4 - REMOVE SPARKPLUG AND INSTALL THE SPECIAL PISTON RETAINER (P.N ) TO LOCK THE CRANKSHAFT (see Fig.5). Fig.5 - REMOVE NUT M12 (see Fig.6). (17mm SOCKET WRENCH) Fig.6 - EXTRACT ROTOR WITH THE SPECIAL TOOL ( P.N. ATT-009) (see Fig.7). - REMOVE KEY FROM CRANKSHAFT Fig.7 2

5 5. DISASSEMBLE GEAR COVER - UNLOOSE N 2 SCREWS M6 FIXING THE STARTER CLAMP. M6x20 M6x30 Fig.8 - UNSCREW N 7 ALLEN HEAD SCREWS M6 (see Fig.8). M6x20 (5mm ALLEN WRENCH T TYPE) M6x20 M6x30 - REMOVE COVER AND WASHER (see Fig.9). (WITH THE HELP OF A PLASTIC MALLET IF NECESSARY) PAY ATTENTION NOT TO DAMAGE THE OIL SEAL LIP Fig.9 6. REMOVE STARTER - UNLOOSE N 4 SCREWS M6x35 (see Fig.10). Fig.10 (5mm ALLEN WRENCH -T TYPE ) - REMOVE STARTER (see Fig.11). ATT.: screw, crankshaft starter side NOTE: THE STARTER CAN BE REMOVED WITHOUT TAKING THE GEAR COVER OFF, BY SIMPLY REMOVING THE COVER CLAMP (see drawing). Fig.11 3

6 7. REMOVE CLUTCH Fig.12 - DISASSEMBLE THE CLUTH COVER UNSCREW N 3 SCREWS M6x25 (see Fig.12). (5mm ALLEN WRENCH T TYPE) - DISCONNECT THE GROUND CABLE FROM CRANKCASE UNSCREW M6x12 SCREW (see Fig.13). Fig.13 (5mm ALLEN WRENCH T TYPE) - REMOVE STARTER COUNTERSHAFT COVER Fig.14 UNSCREW N 3 SCREWS M6x25 (see Fig.14). (5mm ALLEN WRENCH T TYPE) Fig.15 - REMOVE PISTON RETAINER FROM HEAD AND INSTALL THE STARTER RING LOCKING TOOL (P.N. S884). - REMOVE M10 NUT FIXING THE CLUTCH DRUM (see Fig.15). (17mm SOCKET WRENCH) - REMOVE THE OUTER WASHER, THE CLUTCH DRUM, THE ROLLER CAGE AND THE INNER WASHER 4

7 - REMOVE THE M20 NUT FIXING THE CLUTCH BODY (see Fig.16). (30mm SOCKET WRENCH) TURN CLOCKWISE AS NUT HAS LEFT THREAD Fig.16 - REMOVE THE CLUTCH BODY AND THE STARTING GEAR FROM THE CRANKSHAFT BY MEANS OF THE CLUTCH DISASSEMBLY TOOL (P.N C) (see Fig.17). (19mm and 27mm- SOCKET WRENCHES) Fig.17 - REMOVE STARTER GEAR FROM THE CLUTCH BODY UNSCREW N 3 SCREWS M6x12 (see Fig.18). (10mm-SOCKET WRENCH) Fig.18 - REMOVE THE STARTER COUNTERSHAFT (see Fig.19). Fig.19 5

8 8. REMOVE WATER PUMP Fig.20 - REMOVE PUMP COVER UNSCREW N 4 SCREWS M6x20 (see Fig.20). (5mm ALLEN WRENCH T TYPE) - REMOVE COVER AND WASHER (see Fig.21). Fig.21 - INSTALL THE GEAR LOCKING TOOL Fig.22 (P.N. ATT-008) (see Fig.22). - UNSCREW SCREW M5X20 AND REMOVE PUMP IMPELLER (see Fig.23). Fig.23 (8mm - SOCKET WRENCH) 6

9 9. REMOVE GEARS - REMOVE THE RETAINER RING ON THE COUNTERSHAFT (see Fig.24). (PLIERS FOR RETAINER RING) - REMOVE GEAR ON THE COUNTERSHAFT (USE THE PULLER P.N. ATT-010 IF NECESSARY) - REMOVE CONE SAFETY WASHER Fig.24 - UNSCREW NUT ON THE CRANKSHAFT (see Fig.25). Fig.25 (27mm SOCKET WRENCH) - REMOVE THE GEAR LOCKING TOOL - REMOVE GEAR FROM THE CRANKSHAFT Fig.26 (USE THE PULLER P.N ATT-010, IF NECESSARY) (see Fig.26). (19mm SOCKET WRENCH ) MARK THE GEAR WITH A FELT PEN IN ORDER TO RECOGNIZE IT WHEN REASSEMBLING. 10. REMOVE COUNTERSHAFT M6x60 - REMOVE THE COUNTERSHAFT BEARING SUPPORT UNSCREW N 6 SCREWS M6 (see Fig.27). M6x20 M6x60 (5mm ALLEN WRENCH T TYPE) M6x60 M6x60 M6x20 Fig.27 7

10 - EXTRACT THE BEARING SUPPORT BY PUSHING COUNTER CRANKSHAFT FROM THE SIDE OF THE WATER PUMP (see Fig.28). Fig.28 PAY ATTENTION NOT TO DAMAGE THE OIL SEAL LIP 11. REMOVE THE CARB INLET DUCT - UNSCREW N 4 SCREWS M6x25 (see Fig.29). Fig.29 (5mm ALLEN WRENCH T TYPE) REMOVE DUCT, REED GROUP AND WASHERS (see Fig.30). Fig.30 REMOVE EXHAUST VALVE (EXCEPT FOR F3 WHICH DOES NOT HAVE EXHAUST VALVE) Fig.31 - REMOVE THE STEEL CLIP FROM THE VALVE (see Fig.31). 8

11 - REMOVE VALVE COVER AND RETAINING SPRING (see Fig.32). Fig.25 Fig.32 - UNSCREW N 2 SCREWS M6 (see Fig.33). (5mm ALLEN WRENCH T TYPE) Fig.33 - EXTRACT THE VALVE FROM THE CYLINDER (vedi Fig.34). Fig.34 - UNSCREW COMPLETELY THE SLIDE BY HAND AND REMOVE IT FROM ITS SEAT (see Fig.35). Fig.35 9

12 - DETACH THE DIAPHRAGM FROM THE EXHAUST VALVE BODY PULLING IT BY HAND (see Fig.36). - DISASSEMBLE THE SPRING RING RETAINING THE DIAPHRAGM AND VALVE PISTON, ALSO CALLED " HEAD" AND REMOVE IT. (see Fig.37). - CLEAN CAREFULLY THE VALVE PARTS AND REMOVE THE EXHAUST GAS AND OIL RESIDUES (see Fig.38). Fig.36 Fig.37 Fig.38 ATTENTION DO NOT USE AN AGGRESSIVE DEGREASER TO AVOID DAMAGING THE RUBBER PARTS 13. REMOVE CYLINDER HEAD Fig.39 - UNSCREW N 5 M8 NUTS BY HALF TURN (CROSS PATTERN DISASSEMBLY) AND REMOVE THEM (see Fig.39). (ALLEN T TYPE - 13mm SOCKET WRENCH). - REMOVE THE WASHERS. 10

13 14. REMOVE CYLINDER Fig.40 - UNSCREW N 4 NUTS M8 BY HALF TURN (CROSS PATTERN DISASSEMBLY ) AND REMOVE THEM (see Fig.40). (12mm SOCKET WRENCH) - REMOVE WASHERS. - REMOVE CYLINDER BASE GASKET 15. REMOVE PISTON Fig.41 - REMOVE PISTON PIN CIRCLIPS FROM PISTON (see Fig.41). (SCREWDRIVER WITH ROUNDED EDGE) PAY ATTENTION NOT TO SCRATCH THE PISTON AND CIRCLIPS SEAT. - REMOVE PISTON PIN BY USING THE SPECIAL PISTON PIN PUNCH TOOL (P.N ) (see Fig.42). Fig.42 - REMOVE PISTON - REMOVE ROLLER CAGE 16. OPENING THE CRANKCASE Fig.43 - UNSCREW N 9 SCREWS M6 (see Fig.43). (5mm ALLEN WRENCH T TYPE) - OPEN THE CRANKCASE WITH THE HELP OF A PLASTIC MALLET ATT.: screw on the starter side (PREVENT THE CRA NKSHAFT FROM FALLING) 11

14 - REMOVE THE CRANKSHAFT (See Fig.44). Fig.44 - REMOVE OIL SEALS (USE A SCREWDRIVER) (see Fig.45). Fig.45 1 Fig REMOVE BEARINGS (IF NECESSARY) Fig.46 MEASURE THE BEARINGS INTERNAL DIAMETER IN DIFFERENT POINTS. REFER TO THE ATTACHED TABLE TO CHECK THE BEARING WEAR STATUS. - REMOVE BEARINGS FROM CRANKSHAFT WITH THE SPECIAL TOOL (ATT.011/2) (see Fig.46). - REMOVE THE BALANCE SHAFT OUTER BEARING FROM THE SUPPORT Fig.47 (see Fig.47). 12

15 - REMOVE THE BALANCE SHAFT INTERNAL BEARING WITH THE SPECIAL TOOL AFTER HAVING REMOVED THE OIL SEAL Fig.48 (ATT.011/3) (see Fig.48). 2 CRANKSHAFT DISASSEMBLY / ASSEMBLY THE ASSEMBLY/DISASSEMBLY OPERATIONS ON THE ENGINE CRANKSHAFT, MUST BE PERFORMED ONLY BY AN AUTHORIZED SERVICE CENTER USING THE SPECIALLY DESIGNED TOOLS. USE OF UNFITTED TOOLS OR OPERATIONS PERFORMED BY UNSKILLED PERSONNEL MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR. TOOLS DESCRIPTION P.N. CRANKSHAFT ASSEMBLY TOOL 10110B-C CRANKPIN BUSH (INCLUDED IN 10110B-C) CRANKSHAFT DISASSEMBLY TOOL KIT WITH : 10150A 10100A-C2 CRANKSHAFT SUPPORT CRANKSHAFT PLATE 10104A CRANKSHAFT INSERT CRANKPIN PUSHER CRANKSHAFT DISASSEMBLY OPERATIONS 1. PLACE THE DISASSEMBLY TOOL (P.N A-C2) UNDER THE PRESS (PRESS 5 MeT). 2. PLACE THE CRANSHAFT IN THE TOOL BY INSERTING THE CRANKSHAFT PLATE (P.N A) BETWEEN THE CRANKSHAFT HALVES (see Fig.1). PICTURES Fig.1 13

16 3. PLACE THE CRANKSHAFT INSERT (P.N ) AND USING THE CRANKPIN PUSHER ( P.N ) PRESS THE CRANKPIN OUT (see Fig.2). Fig.2 4. DISASSEMBLE THE COMPLETE CON-ROD WITH WASHERS AND CAGE. REPEAT THE OPERATIONS TO EXTRACT THE CRANKPIN FROM THE OTHER HALF CRANKSHAFT (see Fig.3). INSERT A CRANKPIN ORBOARD ROLL IN THE CAGE TO PREVENT THE ROLLERS FROM FALLING. Fig.3 BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE a) CHECK STATUS OF CON-ROD (TOP AND BOTTOM). IF OVALIZATION EXCEEDS 0.01mm, REPLACE CON-ROD. b) CHECK STATUS OF CRANKPIN (VISUAL CHECK) REPLACE IF NECESSARY REPLACE AFTER 30 WORKING HRS. c) CHECK STATUS OF CAGE (BIG END) (VISUAL CHECK) REPLACE IF NECESSARY REPLACE AFTER 30 WORKING HRS. d) CHECK STATUS OF CRANKSHAFT HALVES. CHECK BEARING SEATS IN DIFFERENT POINTS. REFER TO THE ATTACHED TABLE TO CHECK THE WEAR STATUS OF THE CRANKSHAFT HALVES. e) CHECK STATUS OF SILVER SHIMS (VISUAL CHECK) REPLACE IF NECESSARY BORE GAUGE WITH CHECK RING Ø26 AND Ø19 - CENTESIMAL MICROMETER 0 25 o FOLLOW ATTACHED TABLE FOR MAX. MATCHING PLAY 14

17 2.2 CRANKSAHFT ASSEMBLY OPERATIONS 1. PLACE THE CRANKSHAFT ASSEMBLY TOOL (P.N B-C) UNDER THE PRESS, VERTICALLY (PRESS 5 MeT). 2. PLACE THE CRANKSHAFT INTO THE ASSEMBLY TOOL. 3. OIL CRANKPIN HOLE ON CRANKSHAFT HALF. 4. PICTURES PLACE CRANKPIN WITH CRANKPIN BUSH (P.N A) ON CRANKSHAFT HALF (see Fig.1). Fig.1 5. BRING UPPER PLATE OF TOOL IN CONTACT WITH CRANKPIN (see Fig.2). Fig.2 6. PROGRESSIVELY PRESS UNTIL CRANKPIN IS COMPLETELY DRIVEN IN (see Fig.3). Fig.3 15

18 7. EXTRACT CRANKPIN BUSH, OIL CRANKPIN AND INSTALL: Fig.4 -SILVER SHIM -CON-ROD WITH ROLLER CAGE -SILVER SHIM (see Fig.4). ROLLERS ARE FREE IN THE CAGE. PREVENT THEM FROM FALLING, WHEN INSERTING THE CAGE ON THE CRANKPIN. 8. PLACE CLAMP JIG IN HORIZONTAL POSITION AND PLACE HALF CRANKSHAFT (see fig.5) Fig.5 9. PLACE THE SECOND CRANKSHAFT IN THE COUNTERPLATE SEAT (see Fig 6) Fig BRING THE 2 PLATES CLOSE UNTIL THE TOOL IS HAND PRESSED (see Fig.7). CHECK THAT CRANKPIN IS CORRECTLY FITTED IN THE HOLE OF THE RECEIVING CRANKSHAFT HALF. Fig.7 16

19 11. OIL CRANKPIN AND CRANKPIN HOLE ON HALF CRANKSHAFT. Fig PUT TOOL IN VERTICAL POSITION (see Fig.8). 13. PROGRESSIVELY PRESS THE TWO CRANKSHAFT HALVES TOGETHER. 14. OPEN THE TOOL, PUT IT IN HORIZONTAL POSITION AND EXTRACT CRANKSHAFT. Fig CHECK THE AXIAL PLAY OF THE CON-ROD (see Fig. 9). IT MUST BE MIN. 0.4mm / MAX. 0.7mm. IF PLAY IS HIGHER OR LOWER, REBUILD THE CRANKSHAFT. AFTER ASSEMBLING THE CRANKSHAFT, IT MUST BE ALIGNED, OTHERWISE EXCESSIVE VIBRATIONS, HARD STARTING OR POOR ACCELERATION WILL RESULT. a. PLACE THE CRANKSHAFT BETWEEN THE CENTERS, WITH DIAL INDICATORS READING ON FRONT AND REAR BEARING JOURNALS (see Fig.10). Fig.10 (CENTERS WITH CENTESIMAL DIAL GAUGES AND COPPER HAMMER FOR ALIGNMENT). 17

20 b. c. ROTATE CRANKSHAFT AND CHECK DEFLECTION OF GAUGE NEEDLES THE DEFLECTION MUST BE, AFTER CENTERING, MAX. 0.01mm (see drawing). ADJUST ALIGNMENT WITH A COPPER HAMMER, IF NECESSARY (see Fig.11). Fig.11 3 REEDSTER 125cc ENGINE ASSEMBLY BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE OPERATIONS 1. PICTURES INSTALLING BEARINGS Fig.1 - INSERT EVENTUAL BEARING SHIMS IN THE CRANKSHAFT BEARING SEATS (see Fig. 1) AND PLACE THE CRANKCASE HALVES UNDER THE PRESS. 18

21 - INSERT CRANKSHAFT BEARINGS; BALLS TO BE VISIBLE ON UPPER SIDE DURING ASSEMBLY (see Fig. 2). Fig.2 - OIL OUTSIDE OF BEARINGS AND BEARING SEATS, BEFORE ASSEMBLY. USE SPECIAL TOOL (ATT-011/1) TO INSERT THE BEARINGS (see fig. 3) Fig.3 INSTALL THE INNER BALANCE SHAFT BEARING, BALLS TO BE ON UPPER SIDE (GREASE BALLS BEFORE ASSEMBLING) OIL THE BEARING EXTERNAL AND THE HALF CRANKCASE SEAT. USE THE SPECIAL TOOL (P.N ) TO INSERT THE BEARING (see Fig. 4) Fig.4 INSTALL THE OUTER BALANCE SHAFT BEARING (GEAR SIDE). BALLS TO BE ON LOWER SIDE. OIL THE BEARING OUTER PART AND SUPPORT SEAT BEFORE ASSEMBLING. USE SPECIAL TOOL (P.N ) TO INSERT BEARING. (see Fig. 5) Fig.5 19

22 2. Fig.6 CRANKCASE ASSEMBLY - LUBRICATE THE CRANKSHAFT SEATS, BALL BEARINGS, BIG END CAGE BEFORE ASSEMBLING (vedi Fig.6). - ALSO LUBRICATE THE INNER BALANCE SHAFT BEARING. - INSTALL CRANKSHAFT THE CRANKSHAFT MUST BE IN SAME POSITION AS IN ORIGINAL INSTALLATION (see Fig.7). Fig.7 Fig.8 AS FIRST STEP ASSEMBLE CRANKCASE WITH 4 SCREWS AND CHECK CRANKSHAFT AXIAL PLAY TO BE mm. IF PLAY IS LOWER OR HIGHER DISASSEMBLE CRANKCASE, EXTRACT BEARINGS AND USE DIFFERENT STEEL SHIMS (0.10/0.15/0.20) TO RECOVER PLAY. SHIMS MUST BE EQUALLY POSITIONED (see Fig.8). BEFORE FINAL ASSEMBLING OF CRANKCASE HALVES CLEAN AND DEGREASE CONTACT SURFACES AND APPLY FLUID GASKET (Motorseal or equivalent) ON CRANKCASE HALVES. CLEAN EVENTUAL EXCESS OF PRODUCT FROM THE CONTACT SURFACES (see Fig.9). Fig.9 20

23 - INSERT CRANKSHAFT AND CLOSE CRANKCASE HALVES (see Fig.10). Fig.10 - ASSEMBLE CRANKCASE HALVES N 9 SCREWS M6 (see Fig.11). (CROSS PATTERN LOCKING (SEE ATTAC HED SKETCH) Fig.11 TORQUE AT 8 10 Nm (70 90 lbf*in) (5mm ALLEN WRENCH T TYPE) ATT.: screw starter side 3. FITTING OIL SEALS - APPLY SPECIAL LUBRICANT ON SEAL LIPS. (APPLY MORE LUBRICANT BETWEEN THE OUTER AND INNER OIL SEAL LIPS) WHEN FITTING NEW SEALS, TURNING THE CRANKSHAFT COULD RESULT MORE DIFFICULT, BUT THIS IS NORMAL. - FIT SEALS ON CRANKSHAFT BY USING THE SPECIAL TOOL WITH BUSHING, TO BE INSERTED ON THE CRANKSHAFT (GEAR SIDE) (P.N A) (see Fig.13). (MARK ON SEAL TO BE TURNED TOWARDS OUTSIDE). Fig.12 Fig.13 - INSERT OIL SEAL IN GEAR COVER USING THE SPECIAL TOOL (P.N ) (MARK ON SEAL TO BE TURNED TOWARDS OUTSIDE). OIL SEALS MUST ALWAYS BE REPLACED WHEN DISASSEMBLED. 21

24 - ASSEMBLE BEARING SUPPORT AND BALANCE SHAFT (see Fig.14). N 6 SCREWS M6 TORQUE AT 8 10 Nm (70 90 lbf*in) Fig.14 M6x60 M6x20 M6x60 (5mm ALLEN WRENCH T TYPE) LUBRICATE THE BALANCE SHAFT EXTERNAL BEARING M6x60 M6x60 M6x20 - INSTALL WATER PUMP SEAL WITH THE SPECIAL TOOL (P.N. ATT-016) (see Fig.15). (MARK ON SEAL TO BE TURNED TOWARDS INSIDE). BEFORE ASSEMBLING THE OIL SEAL, ALWAYS INSERT THE SHAFT GUARD. BE VERY CAREFUL NOT TO DAMAGE THE OIL SEAL LIPS DURING THE ASSEMBLY Fig Fig.16 ASSEMBLING THE GEARS - CHECK THE GEAR TEETH GOOD STATUS, INSERT THE BELLEVILLE WASHER ON THE BALANCE SHAFT AND LOCATE THE GEAR ("5TR" SIDE - LETTERS A AND "C" TO BE VISIBLE) BEING CAREFUL TO ALIGN THE REFERENCE NOTCHES ON THE INTERNAL TOOTHING ( WITH THE HELP OF A PLASTIC HAMMER). (see Fig.16). IF GEARS ARE NOT PROPERLY LOCATED, VIBRATION DAMPING SYSTEM WILL NOT OPERATE PROPERLY. - LOCATE GEAR ON THE CRANKSHAFT ("5TR" SIDE - LETTERS A AND "C" TO BE VISIBLE) ALIGNING THE INTERNAL TEETH REFERENCE NOTCHES ON THE EXTERNAL TEETH REFERENCE NOTCHES ON THE 2 GEARS (CHECK BOTH GEARS TO BE ON THE SAME LEVEL). (see Fig.17) Fig.17 22

25 NOTE: IF GEARS HAVE NOT BEEN REPLACED, REINSTALL THEM IN THEIR ORIGINAL POSITION. ( IDENTIFY THE GEAR MARKED DURING THE DISASSEMBLING AND ASSEMBLE IT ON CRANKSHAFT). Fig.18 INSTALL RETAINING RING ON THE BALANCE SHAFT MAKE SURE THAT RING IS IN PLACE AT BOTTOM OF ITS SLOT (see Fig.18). (PLIERS FOR RETAINING RINGS) - PLACE THE GEAR LOCKING TOOL (P.N. ATT-008). INSTALL THE SAFETY CONE WASHER AND M18 NUT ON THE CRANKSHAFT TORQUE AT Nm ( lbf*in) (TORQUE WRENCH WITH 27mm BUSH ). 5. ASSEMBLING THE WATER PUMP Fig.19 - ASSEMBLE THE WATER PUMP IMPELLER SCREW M5x20 (see Fig.19). TORQUE AT 5 6 Nm (45 55 lbf*in) (8mm SOCKET WRENCH ) THE SHAFT DRAGGING SURFACES MUST MATCH WITH THOSE ON THE IMPELLER. - INSTALL THE GASKET AND THE WATER PUMP COVER N 4 SCREWS M6x20 (see Fig.20). TORQUE AT 8 10 Nm (70 90 lbf*in) Fig.20 (5 mm ALLEN WRENCH T TYPE) 6. INSTALLING THE STARTER Fig.21 - PLACE STARTER IN THE CRANKCASE SEAT (see Fig.21). OIL O RING BEFORE INSERTING. CHECK THAT THE PLASTIC CLAMP FIXING THE STARTER CABLE IS IN PLACE. N 4 SCREWS M6x35 TORQUE AT 8 10 Nm (70 90 lbf*in) (5mm ALLEN WRENCH T TYPE) ATT.: Screw Starter bendix side. 23

26 7. Fig.22 ASSEMBLING THE GEAR COVER - PLACE GASKET ON CRANKCASE (see Fig.21). - POSITION COVER BY INSERTING STARTER END IN ITS PROPER SEAT. (CHECK THAT THE VIBRATION DAMPING FITTING IS IN PLACE AND OIL IT BEFORE INSERTING THE STARTER). N 7 SCREWS M6x16 (see Fig.23). TORQUE AT 8 10 Nm (70 90 lbf*in) (5mm ALLEN WRENCH T TYPE). - TIGHTEN N 2 SCREWS M6 FOR FIXING STARTER CLAMP TORQUE AT 8 10 Nm (70 90 lbf*in) (5mm ALLEN WRENCH T TYPE). Fig.23 M6x20 CHARGING OIL IN THE GEARBOX Fig.23 M6x20 THE COPPER WASHER MUST BE PLACED UNDER THE OIL DISCHARGING SCREW 8. M6x30 M6x20 M6x30 Fig.24 - PUT THE ENGINE PERFECTLY HORIZONTAL REMOVE OIL BREATHER FROM CRANKCASE (see Fig.23). (11mm SOCKET WRENCH) - REMOVE THE OIL LEVEL PLUG (4mm ALLEN T- TYPE) - POUR 40cc SAE 30 OIL IN THE GEAR BOX (see Fig.24). Fig.25 NOTE: IF QUANTITY IS CORRECT YOU WILL NOTE OIL SLIGHTLY OVERFLOWING FROM THE OIL HOLE PLUG. - INSTALL OIL DRAIN PLUG TORQUE AT Nm ( lbf*in) (4mm ALLEN T- TYPE) - REINSTALL BREATHER TORQUE AT Nm ( lbf*in) (11mm SOCKET WRENCH) 24

27 9. INSTALLING THE PISTON Fig.26 - CHECK STATUS OF THE PISTON PIN CAGE. IT IS RECOMMENDED TO REPLACE IT AFTER 30 HRS AND ALWAYS WHEN OVERHAULING THE ENGINE. - CHECK STATUS OF PISTON PIN. REPLACE IT WHEN REPLACING PISTON. ( SEE ATTACHMENT ON MATCHING SELECTIONS BETWEEN PISTON PIN / CAGE). - INSTALL PISTON RING ON PISTON (see Fig.26). CHECK PLAY BETWEEN RING ENDS TO BE WITHIN 0.25 AND 0.30mm. PLAY MUST BE CONTROLLED WITH A THICKNESS GAUGE AND INSERTING THE PISTON RING IN THE CYLINDER (see Fig.27). REPLACE PISTON RING WHEN PLAY EXCEEDS 0.4mm. Fig.27 PLAY BETWEEN PISTON AND LINER MUST BE BETWEEN mm. IF PLAY EXCEEDS 0.14mm REPLACE PISTON. FOLLOW INSTRUCTIONS ON THE ATTACHMENT FOR PROPER MATCHING. PISTONS TO BE MEASURED AT 18mm FROM BOTTOM (see attachment). ALWAYS REPLACE PISTON AND PISTON RING TOGETHER. Fig.28 - LUBRICATE CAGE AND INSERT IT IN THE CON-ROD SMALL END. INSERT PISTON PIN WITH SPECIAL PISTON PIN PUNCH (P.N ) (see Fig.28). MAKE SURE THAT ARROW ON THE TOP OF PISTON IS TURNED TOWARDS EXHAUST. AS GENERAL RULE THE PISTON PIN MUST BE INSERTED BY HAND IN THE HOLE. - INSTALL CIRCLIP ON SPECIAL TOOL (ATT-006). GREASE TOOL TO KEEP CIRCLIP IN POSITION. (see Fig.29). Fig.28 25

28 - IINSERT CIRCLIPS (see Fig.30). CHECK CIRCLIPS TO BE IN SEAT. Fig.30 THE CIRCLIP ENDS MUST BE OPPOSITE TO THE PISTON EXTRACTION NOTCH 10. INSTALLING THE CYLINDER Fig.31 - PLACE A NEW GASKET ON THE CYLINDER BASE. OIL CYLINDER LINER AND PISTON. INSTALL CYLINDER (see Fig.31). N 4 NUTS M8 WITH WASHERS CROSS PATTERN ASSEMBLY TORQUE AT Nm ( lbf*in ) (12mm SOCKET WRENCH) Fig.32 - PLACE THE O RINGS: (see Fig.32) - ON INTERNAL OF CYILINDE - ON EXTERNAL OF CYLINDER - ON TIE-RODS 11. INSTALLING THE CYLINDER HEAD Fig.33 - CLEAN COMBUSTION CHAMBER FROM DEPOSITS. PAY ATTENTION NOT TO SCRATCH THE COMBUSTION CHAMBER. - INSTALL HEAD (see Fig.32). N 5 NUTS M8 WITH WASHERS CROSS PATTERN ASSEMBLY TORQUE AT Nm ( lbf*in ). (TORQUE WRENCH WITH 13mm BUSH) ALL THE NUTS MUST BE IN CONTACT BEFORE PROCEEDING WITH CROSS PATTERN TORQUING. 26

29 12. ASSEMBLING THE IGNITION AND ENGINE Fig.34 TIMING - INSERT KEY ON SHAFT (see Fig.34). - INSTALL ROTOR ON SHAFT - INSTALL PISTON RETAINER (P.N ) ON HEAD AND INSERT M12 NUT ON SHAFT. (see Fig.35). TORQUE AT Nm ( lbf*in) Fig.35 (17mm SOCKET WRENCH) Fig.36 - INSTALL STATOR N 3 SCREWS M5x25 (see Fig.36). NOTE: DO NOT TIGHTEN THE SCREWS TO END BEFORE HAVING ADJUSTED THE IGNITION TIMING (4mm ALLEN T-TYPE) - REMOVE THE PISTON RETAINER - BRING PISTON TO TDC WITH A CENTESIMAL DIAL GAUGE (see Fig.37). Fig.37 27

30 - AFTER HAVING SET TO "0" THE DIAL GAUGE ROTATE CRANKSHAFT IN THE OPPOSITE DIRECTION VS THE DIRECTION OF OPERATION (CLOCKWISE, LOOKING AT THE IGNITION): 2.3mm for F1 2.6mm forr F2 4.9mm for F3 4.1mm for F4 (see Fig.38). - PREVENTING THE CRANKSHAFT FROM TURNING, ROTATE IGNITION STATOR UNTIL THE REFERENCE NOTCH MATCHES TOGETHER WITH THE NOTCH ON ROTOR. (see Fig.39). Fig.38 Fig.39 - FIX STATOR N 3 ALLEN SCREWS M5x25 (see Fig.40). TORQUE AT 5 6 Nm (40 50 lbf*in) Fig.40 (4mm ALLEN T- TYPE) 13. INSTALL STARTER COUNTERSHAFT Fig.41 - OIL THE TWO COUNTERSHAFT ENDS AND INSERT IT ITS THE CRANKCASE SEAT (see Fig.41). 28

31 BEFORE ASSEM BLING THE CLUTCH, WASH WITH DILUENT THE SHAFT TAPER, THE STARTER RING FIXING HOLE, THE CLUTCH BODY AND THE CLUTCH DRUM. 14. INSTALLING THE CLUTCH - INSTALL STARTER RING ON CLUTCH BODY BY MATCHING THE 3 HOLES AND THE DRAGGING PIN (see Fig.42). - INSTALL N 3 SCREWS M6x12 APPLY LOCTITE ON THE THREADS (Loctite 243). TORQUE AT 10 12Nm ( lbf*in) (10mm SOCKET TYPE - TORQUE METER) MAKE SURE TO ALWAYS INSTALL THE Ø 7mm DRAGGING PIN, AS OTHERWISE THE EVENTUAL KICKBACKS COULD BREAK THE SCREWS. Fig.42 - APPLY LOCTITE 641 ON THE TAPER SHAFT FOR COAXIAL LOCKINGS (see Fig.43). Fig.43 Fig.16 Fig.44 -INSTALL THE STARTER RING WITH CLUTCH BODY ON CRANKSHAFT - INSTALL THE STARTER RING LOCKING TOOL NUT (P.N. S884) - INSTALL M20 STARTING GEAR FIXING NUT TORQUE AT Nm ( lbf*in) (see Fig.44). (30mm SOCKET TYPE - TORQUE METER ) TURN COUNTERCLOCKWISE AS NUT HAS LEFT THREAD. NOTE: DO NOT USE THE PISTON FITTING TOOL TO PREVENT THE SHAFT FROM TURNING. Fig.45 - INSTALL INNER WASHER INSTALL WASHER WITH BEVEL TOWARDS SHAFT - INSTALL ROLLER CAGE, CLEAN AND GREASE IT BEFORE INSTALLING IT ON THE SHAFT. DO NOT EXCEED WITH GREASE. (see Fig.45). 29

32 - INSTALL CLUTCH DRUM, OUTER WASHER AND M10 NUT (see Fig.46). Fig.46 INSTALL WASHER WITH BEVEL TOWARDS CRANKSHAFT - APPLY LOCTITE 243 ON THREADS AND TIGHTEN THE M10 CLUTCH DRUM RETAINI NG NUT (see Fig.47). TORQUE AT Nm ( lbf*in) Fig.47 (17mm SOCKET WRENCH) - REMOVE THE STARTER RING LOCKING TOOL TOOL AND INSTALL THE COUNTERSHAFT COVER (see Fig.48). N 3 SCREWS M6x25 TORQUE AT A 6 8 Nm (50 70 lbf*in) Fig.48 (5mm ALLEN WRENCH T TYPE) - FIX THE GROUND CABLE ON THE CRANKCASE Fig.49 ALLEN SCREW M6x12 ( see Fig.49). TORQUE AT 8 10 Nm ( lbf*in) (5mm ALLEN WRENCH T TYPE) 30

33 - INSTALL CLUTCH COVER N 3 M6x25 ALLEN SCREWS (see Fig.50). TORQUE AT 8 10 Nm ( lbf*in) Fig.50 (5mm ALLEN WRENCH T TYPE) 15. INSTAL THE REED GROUP Fig.51 - INSTALL INTERNAL GASKET, REED VALVE, EXTERNAL WASHER AND INLET DUCT, WITH PRESSURE AIR INTAKE HOLE TOWARDS UPPER SIDE (see Fig.51). CHECK BEFORE THE STATUS OF REED PETALS. IF REED PETALS ARE SCRATCHED OR IF, LOOKING THROUGH THE REED GROUP, AGAINST THE LIGHT THE PETALS DO NOT CLOSE PERFECTLY REPLACE THEM.. (REMOVE N 8 SCREWS AND PLACE REED PETALS WITH 45 CUT ON THE BOTTOM TO BE TOWARDS LEFT SIDE). Fig.52 - FIX REED GROUP N 4 SCREWS M6X25 (see Fig.52). TORQUE AT 8 10 Nm ( lbf*in) (5mm ALLEN WRENCH T TYPE) 16. INSTALL EXHAUST VALVE (NOT FOR F3) Fig.53 - INSTALL DIAPHRAGM ON THE VALVE BODY BY HAND PRESSING. (see Fig.53). 31

34 - INSTALL HEAD ON THE DIAPHRAGM AND INSERT THE RETAINING SPRING WITH THE SPECIAL TOOL (see Fig.54). Fig.54 - INSTALL GASKET, SPACER AND O'RING, SLIDE SPINDLE AND SCREW IT IN THE "HEAD" UNTIL CONTACT BUT WITHOUT FORCING IT (see Fig.55). Fig.55 ATTENTION CHECK THAT THE GASKET PRESSURE HOLE MATCHES THE ONE ON THE VALVE BODY. - CHECK THE DISTANCE BETWEEN THE SLIDE LOWER- MID PART AND THE "HEAD" UPPER PART PROPER DISTANCE MUST BE 86.5mm. (see Fig.56a) Fig.56a STARTING FROM THE VALVE 09 MODEL THE CORRECT VALUE IS OF 85 mm. (see Fig.56b) NOTE: CLEAN THE SURFACE CONTACTS ON THE CYLINDER AND VALVE BEFORE REASSEMBLING. Fig.56b - INSTALL VALVE ON THE CYLINDER SO THAT SLIDE BEVEL IS DOWNWARDS AND THE CYLINDER PRESSURE INTAKE HOLE MATCHES BOTH THE VALVE BODY AND GASKET HOLES (see Fig.57). Fig.57 32

35 Fig.58 - FIX VALVE BODIES N 2 SCREWS M6 (see Fig.58). TORQUE AT 8 10 Nm (70 90 lbf*in) PROCEED AS FOLLOW: SCREW IN THE M6 SCREWS WITHOUT TORQUING CHECK THAT VALVE IS FREELY SLIPPING TORQUE SCREWS AT 4 5 Nm (35 45 lbf*in) CHECK AGAIN VALVE SLIPPING TORQUE DEFINITELY AT 8 10 Nm ( lbf*in) (5mm ALLEN WRENCH T- TYPE) - PLACE SPRING ON THE VALVE PISTON AND INSTALL COVER CHECKING THAT SPRING IS COMPLETELY IN SEAT (see Fig.59). Fig.59 - KEEP COVER IN POSI TION AND SECURE IT WITH STEEL CLAMP CHECK THAT THE CLAMP END IS PROPERLY HOOKED TO THE BODY VALVE (see Fig.60). Fig.60 NOTE: REFER TO THE INSTRUCTION MANUAL FOR PROPER VALVE SETTING. 17. INSTALL EXHAUST FITTING Fig.61 - ASSEMBLE GASKETS, SPACER AND EXHAUST FITTING, N 4 SCREWS M6x25 WITH WASHERS (see Fig. 61). TORQUE AT 8 10 Nm ( lbf*in) (5mm ALLEN WRENCH T TYPE) 33

36 COUPLES ON TIGHTENING OF NUTS AND SCREWS 34

37 CROSS PATTERN LOCKING ORDER ON CRANKCASE 35

38 MAIN PRESCRIPTIONS CRANKSHAFT MATCHING THE PISTON Play between piston and liner must be mm. If play is higher than 0.14mm replace piston - Bearing seat diameter on new engine For halfcrankshaft wear, please refer to the attached table. Piston to be measured at 18mm from the base. MAX ALLOWED OVALIZATION OF CON-ROD BIG-END The piston size is marked on the top with a green or red dots or with the letters V or R. If the size on piston top is marked with : -a green dot or letter V: add 0.11mm to size marked on the piston to match the liner size. -a red dot or letter R: add 0.12 mm to size marked on the piston to match the liner size. Max. allowed ovalization between A and B on new conrod: 0.002mm Max. allowed ovalization between A and B on used conrod: 0.01mm 36

39 37

40 OVERHAUL TOOL LIST SPECIFIC TOOLS AVAILABLE AT IAME DESCRIPTION P.N. GEAR DISASSEMBLY TOOL ROTOR DISASSEMBLY TOOL PISTON FITTING CLUTCH DISASSEMBLY TOOL PISTON PIN FITTING TOOL? CRANKSHAFT ASSEMBLY KIT It includes: - crankpin bush CRANKSHAFT DISASSEMBLY KIT It includes: - crankshaft plate - crankshaft support - crankpin pusher - crankshaft insert CRANK BEARING DISASSEMBLY TOOL EXTERNAL BALANCE SHAFT BEARING ASSY/DISASSEMB. TOOL CRANK BEARING ASSEMBLY TOOL INTERNAL BALANCE SHAFT BEARING ASSY/DISASSY TOOL OIL SEAL ASSEMBLY TOOL (without crankshaft) OIL SEAL ASSEMBLY TOOL (with installed crankshaft) GEAR COVER OIL SEAL ASSEMBLY TOOL WATER PUMP OIL SEAL ASSEMBLY TOOL ATT-010 ATT C 10200? 10110B-C 10150A 10100A-C A A ATT-016 ENGINE FIXING TOOL ON BENCH VICE (see attached drawing) GENERAL TOOLS ALLEN WRENCH- T TYPE ALLEN WRENCH- T TYPE SOCKET WRENCH SOCKET WRENCH SOCKET WRENCH SOCKET WRENCH SOCKET WRENCH HEXAGON RING WRENCH HEXAGON RING WRENCH T- TYPE WRENCH WITH HEXAGONAL BUSH WRENCH WITH HEXAGONAL BUSH WRENCH WITH HEXAGONAL BUSH SPARKPLUG WRENCH CENTERS WITH CENTESIMAL DIAL GAUGE SCREWDRIVER WITH ROUNDED EDGES PLASTIC MALLET COPPER MALLET TORQUE WRENCH WITH BUSH PLIERS FOR RETAINING RINGS 50 MeT PRESS 38 4mm 5mm 10mm 11mm 12mm 17mm 19mm 27mm 13mm 8mm 27mm 30mm 20.8mm 10/13/27/30mm

41 TABLE FOR WEAR EVALUATION ON BEARINGS/ HALFCRANKSHAFTS NOTE: ALWAYS CHECK DIMENSIONS IN DIFFERENT POINTS ON CIRCUMFERENCE, LOOKING FOR EVENTUAL OVALIZATIONS On the following Table are shown the ovalization limits above which replacement is required MEASURED PART LIMITS (MEASURING INSTRUMENT) CRANKSHAFT BEARING SEAT (MICROMETER /100) MIN. Ø24.96 BALANCE SHAFT EXTERNAL BEARING SEAT MIN. Ø24.96 (MICROMETER /100) BALANCE SHAFT INTERNAL BEARING SEAT MIN. Ø14.96 (MICROMETER /100) CRANKSHAFT BEARINGS (1/100 BORE GAUGE WITH CHECK RING Ø25) BALANCE SHAFT - EXTERNAL BEARING (1/100 BORE GAUGE WITH CHECK RING Ø25) BALANCE SHAFT INTERNAL BEARING (1/100 BORE GAUGE WITH CHECK RING Ø15) * MAX. Ø25.03 * MAX. Ø25.03 * MAX. Ø15.03 * THE MEASURED VALUE ON THE BEARING MUST ALWAYS BE COMPARED WITH THE SEAT VALUE (ON SHAFT AND/OR BALANCE SHAFT), TO CHECK THAT PLAY, BETWEEN SHAFT AND BEARING DOES NOT EXCEED THE LIMIT VALUE OF 0.05mm MAN-022

42 FIXING ENGINE TOOL ON BENCH VICE 40 MAN-022