052 MANUALE REVISIONE REEDSTER INGLpdbamerica.com/files/IAME_Reedster_KF_Overhaul_Manual.pdf ·...

07/11/07 MAN-0521

OVERHAULING MANUAL

REEDSTER 125ccversions: F1 - F2 - F3 - F4

21/01/2009

07/11/07 MAN-0522

INDEX

Page

1. - REEDSTER 125cc ENGINE DISASSEMBLY 1

2. - CRANKSHAFT DISASSEMBLY / ASSEMBLY 13

2.1 - CRANKSHAFT DISASSEMBLY 13

2.2 - CRANKSHAFT ASSEMBLY 15

3. - 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

MAN-0521

1 –REEDSTER 125cc ENGINE DISASSEMBLY

OPERATIONS PICTURES

1. DISCHARGING OIL FROM GEARBOX

- UNSCREW THE M6 SCREW FORDISCHARGING OIL(see Fig.1).

(5mm ALLEN WRENCH – T TYPE)

- TILT THE ENGINE TO FACILITATE OILDISCHARGINGAND CHECK THAT THEGEARBOX BREATHER IS FREE AND(see Fig.2).

2. FIX THE ENGINE ON THE BENCH VICE

- SCREW N°2 SCREWS M8x30 IN THECRANKCASE

TOOL FOR BENCH VICE (see attached drawing)

3. REMOVE THE EXHAUST FITTING

- UNSCREW N°4 SCREWS M6x25 (see Fig.3).


- REMOVE THE N°4 ELASTIC WASHERS

- REMOVE THE EXHAUST FITTING,SPACER AND BOTH GASKETS.

Fig.1

Fig.2

Fig.3

MAN-0522

4. REMOVE THE IGNITION

- REMOVE STATORUNSCREW N°3 M5x25 SCREWS (see Fig.4)(4mm ALLEN WRENCH – T TYPE)

- REMOVE SPARKPLUG AND INSTALL THESPECIAL PISTON RETAINER (P.N. 10271)TO LOCK THE CRANKSHAFT(see Fig.5).

- REMOVE NUT M12 (see Fig.6).

(17mm SOCKET WRENCH)

- EXTRACT ROTOR WITH THE SPECIALTOOL ( P.N. ATT-009)(see Fig.7).

- REMOVE KEY FROM CRANKSHAFT

Fig.4

Fig.5

Fig.6

Fig.7

MAN-0523

5. DISASSEMBLE GEAR COVER

- UNLOOSE N°2 SCREWS M6 FIXING THESTARTER CLAMP.

- UNSCREW N°7 ALLEN HEAD SCREWS M6(see Fig.8).


- REMOVE COVER AND WASHER(see Fig.9).

(WITH THE HELP OF A PLASTIC MALLET IFNECESSARY)

ATTENTION:PAY ATTENTION NOT TO DAMAGE THE OILSEAL LIP

6. REMOVE STARTER

- UNLOOSE N°4 SCREWS M6x35(see Fig.10).

(5mm ALLEN WRENCH -T TYPE )

- REMOVE STARTER(see Fig.11).

NOTE:THE STARTER CAN BE REMOVEDWITHOUT TAKING THE GEAR COVER OFF,BY SIMPLY REMOVING THE COVER CLAMP(see drawing).

Fig.8

Fig.9

Fig.10

Fig.11

M6x20

M6x20

M6x20 M6x30

M6x30

ATT.: screw,crankshaft starter side

MAN-0524

7. REMOVE CLUTCH

- DISASSEMBLE THE CLUTH COVERUNSCREW N°3 SCREWS M6x25(see Fig.12).


- DISCONNECT THE GROUND CABLE FROMCRANKCASEUNSCREW M6x12 SCREW (see Fig.13).


- REMOVE STARTER COUNTERSHAFTCOVER

UNSCREW N°3 SCREWS M6x25(see Fig.14).


- REMOVE PISTON RETAINER FROM HEADAND INSTALL THE STARTER RINGLOCKING TOOL (P.N. S884).

- REMOVE M10 NUT FIXING THE CLUTCHDRUM(see Fig.15).


- REMOVE THE OUTER WASHER, THECLUTCH DRUM, THE ROLLER CAGEAND THE INNER WASHER

Fig.15

Fig.12

Fig.13

Fig.14

MAN-0525

- REMOVE THE M20 NUT FIXING THECLUTCH BODY (see Fig.16).


ATTENTION:TURN CLOCKWISE AS NUT HAS LEFTTHREAD

- REMOVE THE CLUTCH BODY AND THESTARTING GEAR FROM THECRANKSHAFT BY MEANS OF THE CLUTCHDISASSEMBLY TOOL(P.N. 10272-C) (see Fig.17).

(19mm and 27mm- SOCKET WRENCHES)

- REMOVE STARTER GEAR FROM THECLUTCH BODY

UNSCREW N°3 SCREWS M6x12(see Fig.18).

(10mm-SOCKET WRENCH)

- REMOVE THE STARTER COUNTERSHAFT(see Fig.19).

Fig.16

Fig.17

Fig.18

Fig.19

MAN-0526

8. REMOVE WATER PUMP

- REMOVE PUMP COVERUNSCREW N°4 SCREWS M6x20 (seeFig.20).


- REMOVE COVER AND WASHER(see Fig.21).

- INSTALL THE GEAR LOCKING TOOL

(P.N. ATT-008) (see Fig.22).

- UNSCREW SCREW M5X20 AND REMOVEPUMP IMPELLER (see Fig.23).

(8mm- SOCKET WRENCH)

Fig.20

Fig.21

Fig.22

Fig.23

MAN-0527

9. REMOVE GEARS

- REMOVE THE RETAINER RING ON THECOUNTERSHAFT (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

- UNSCREW NUT ON THE CRANKSHAFT(see Fig.25).


- REMOVE THE GEAR LOCKING TOOL

- REMOVE GEAR FROM THE CRANKSHAFT

(USE THE PULLER P.N ATT-010, IFNECESSARY)(see Fig.26).

(19mmSOCKET WRENCH )

ATTENTION:MARK THE GEAR WITH A FELT PEN INORDER TO RECOGNIZE IT WHEN RE-ASSEMBLING.

10. REMOVE COUNTERSHAFT

- REMOVE THE COUNTERSHAFT BEARINGSUPPORTUNSCREW N° 6 SCREWS M6 (see Fig.27).


Fig.24

Fig.25

Fig.26

Fig.27

M6x20

M6x20

M6x60

M6x60

M6x60

M6x60

MAN-0528

- EXTRACT THE BEARING SUPPORT BYPUSHING COUNTER CRANKSHAFT FROMTHE SIDE OF THE WATER PUMP(see Fig.28).

ATTENTION:PAY ATTENTION NOT TO DAMAGE THE OILSEAL LIP

11. REMOVE THE CARB INLET DUCT- UNSCREW N°4 SCREWS M6x25(see Fig.29).


- REMOVE DUCT, REED GROUP ANDWASHERS(see Fig.30).

12. REMOVE EXHAUST VALVE(EXCEPT FOR F3 WHICH DOES NOT HAVEEXHAUST VALVE)

- REMOVE THE STEEL CLIP FROM THEVALVE (see Fig.31).

Fig.28

Fig.29

Fig.30

Fig.31

MAN-0529

- REMOVE VALVE COVER AND RETAININGSPRING(see Fig.32).

- UNSCREW N° 2 SCREWS M6 (see Fig.33).


- EXTRACT THE VALVE FROM THECYLINDER(vedi Fig.34).

- UNSCREW COMPLETELY THE SLIDEBY HAND AND REMOVE IT FROM ITS SEAT(see Fig.35).

Fig.25

Fig.32

Fig.33

Fig.34

Fig.35

MAN-05210

- DETACH THE DIAPHRAGM FROM THEEXHAUST VALVE BODY PULLING ITBY HAND(see Fig.36).

- DISASSEMBLE THE SPRING RINGRETAINING THE DIAPHRAGM ANDVALVE PISTON, ALSO CALLED " “HEAD"AND REMOVE IT.(see Fig.37).

- CLEAN CAREFULLY THE VALVE PARTSAND REMOVE THE EXHAUST GAS AND OILRESIDUES(see Fig.38).

ATTENTIONDO NOT USE AN AGGRESSIVEDEGREASER TO AVOID DAMAGING THERUBBER PARTS

13. REMOVE CYLINDER HEAD

- UNSCREW N°5 M8 NUTS BY HALF TURN(CROSS PATTERN DISASSEMBLY) ANDREMOVE THEM(see Fig.39).

(ALLEN T TYPE - 13mm SOCKETWRENCH).

- REMOVE THE WASHERS.

Fig.39

Fig.36

Fig.37

Fig.38

MAN-05211

14. REMOVE CYLINDER

- UNSCREW N°4 NUTS M8 BY HALF TURN(CROSS PATTERN DISASSEMBLY ) ANDREMOVE THEM(see Fig.40).


- REMOVE WASHERS.

- REMOVE CYLINDER BASE GASKET

15. REMOVE PISTON

- REMOVE PISTON PIN CIRCLIPS FROMPISTON(see Fig.41).

(SCREWDRIVER WITH ROUNDED EDGE)

ATTENTION:PAY ATTENTION NOT TO SCRATCH THEPISTON AND CIRCLIPS SEAT.

- REMOVE PISTON PIN BY USING THESPECIAL PISTON PIN PUNCH TOOL(P.N. 10200)(see Fig.42).

- REMOVE PISTON

- REMOVE ROLLER CAGE

16. OPENING THE CRANKCASE

- UNSCREW N°9 SCREWS M6 (see Fig.43).


- OPEN THE CRANKCASE WITH THE HELPOF A PLASTIC MALLET

(PREVENT THE CRANKSHAFT FROMFALLING)

Fig.40

Fig.43

Fig.41

Fig.42

ATT.: screw on thestarter side

MAN-05212

- REMOVE THE CRANKSHAFT(See Fig.44).

- REMOVE OIL SEALS(USE A SCREWDRIVER)(see Fig.45).

17. REMOVE BEARINGS (IF NECESSARY)

MEASURE THE BEARINGS INTERNALDIAMETER IN DIFFERENT POINTS.REFER TO THE ATTACHED TABLE TOCHECK THE BEARING WEAR STATUS.

- REMOVE BEARINGS FROM CRANKSHAFTWITH THE SPECIAL TOOL(ATT.011/2) (see Fig.46).

- REMOVE THE BALANCE SHAFT OUTERBEARING FROM THE SUPPORT

(see Fig.47).

Fig.46

Fig.47

Fig.44

Fig.31

Fig.451

MAN-05213

- REMOVE THE BALANCE SHAFT INTERNALBEARING WITH THE SPECIAL TOOL AFTERHAVING REMOVED THE OIL SEAL

(ATT.011/3) (see Fig.48).

2 – CRANKSHAFT DISASSEMBLY / ASSEMBLY

ATTENTION:

THE ASSEMBLY/DISASSEMBLY OPERATIONS ON THE ENGINE CRANKSHAFT, MUST BEPERFORMED ONLY BY AN AUTHORIZED SERVICE CENTER USING THE SPECIALLY DESIGNEDTOOLS. USE OF UNFITTED TOOLS OR OPERATIONS PERFORMED BY UNSKILLED PERSONNELMAY DAMAGE THE CRANKSHAFT BEYOND REPAIR.

TOOLS DESCRIPTION P.N.CRANKSHAFT ASSEMBLY TOOL 10110B-C

CRANKPIN BUSH (INCLUDED IN 10110B-C) 10150ACRANKSHAFT DISASSEMBLY TOOL KIT WITH : 10100A-C2

CRANKSHAFT SUPPORT 10100

CRANKSHAFT PLATE 10104A

CRANKSHAFT INSERT 10106

CRANKPIN PUSHER 10107

2.1 – CRANKSHAFT DISASSEMBLY

OPERATIONS PICTURES

1. PLACE THE DISASSEMBLY TOOL(P.N. 10100A-C2) UNDER THE PRESS(PRESS 5 MeT).

2. PLACE THE CRANSHAFT IN THE TOOLBY INSERTING THE CRANKSHAFT PLATE(P.N. 10104A) BETWEEN THE CRANKSHAFTHALVES (see Fig.1).

Fig.1

Fig.48

MAN-05214

3. PLACE THE CRANKSHAFT INSERT(P.N. 10106) AND USING THE CRANKPINPUSHER ( P.N. 10107 ) PRESS THECRANKPIN OUT(see Fig.2).

4. DISASSEMBLE THE COMPLETE CON-RODWITH WASHERS AND CAGE.REPEAT THE OPERATIONS TO EXTRACTTHE CRANKPIN FROM THE OTHER HALFCRANKSHAFT (see Fig.3).

INSERT A CRANKPIN ORBOARD ROLL INTHE CAGE TO PREVENT THE ROLLERSFROM FALLING.

BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE

a) CHECK STATUS OF CON-ROD (TOPAND BOTTOM).IF OVALIZATION EXCEEDS 0.01mm,REPLACE CON-ROD.

- 0.001 BORE GAUGE WITH CHECK RING Ø26 AND Ø19

b) CHECK STATUS OF CRANKPIN(VISUAL CHECK) – REPLACE IFNECESSARYREPLACE AFTER 30 WORKING HRS.

c) CHECK STATUS OF CAGE (BIG END)(VISUAL CHECK) – REPLACE IFNECESSARYREPLACE AFTER 30 WORKING HRS.

d) CHECK STATUS OF CRANKSHAFTHALVES.CHECK BEARING SEATS INDIFFERENT POINTS.REFER TO THE ATTACHED TABLE TOCHECK THE WEAR STATUS OF THECRANKSHAFT HALVES.

- CENTESIMAL MICROMETER 0÷25 o 25÷50

e) CHECK STATUS OF SILVER SHIMS(VISUAL CHECK) – REPLACE IFNECESSARY .

FOLLOW ATTACHED TABLE FOR MAX. MATCHING PLAY

Fig.2

Fig.3

MAN-05215

2.2 – CRANKSAHFT ASSEMBLY

OPERATIONS PICTURES

1. PLACE THE CRANKSHAFT ASSEMBLYTOOL (P.N. 10110B-C) UNDER THE PRESS,VERTICALLY (PRESS 5 MeT).

2. PLACE THE CRANKSHAFT INTO THEASSEMBLY TOOL.

3. OIL CRANKPIN HOLE ON CRANKSHAFTHALF.

4. PLACE CRANKPIN WITH CRANKPIN BUSH(P.N. 10150A) ON CRANKSHAFT HALF(see Fig.1).

5. BRING UPPER PLATE OF TOOL INCONTACT WITH CRANKPIN (see Fig.2).

6. PROGRESSIVELY PRESS UNTIL CRANKPINIS COMPLETELY DRIVEN IN(see Fig.3).

Fig.1

Fig.2

Fig.3

MAN-05216

7. EXTRACT CRANKPIN BUSH, OILCRANKPIN AND INSTALL:

-SILVER SHIM-CON-ROD WITH ROLLER CAGE-SILVER SHIM(see Fig.4).

ATTENTION:

ROLLERS ARE FREE IN THE CAGE.PREVENT THEM FROM FALLING,WHEN INSERTING THE CAGE ON THECRANKPIN.

8. PLACE CLAMP JIG IN HORIZONTALPOSITION AND PLACE HALF CRANKSHAFT(see fig.5)

9. PLACE THE SECOND CRANKSHAFT INTHE COUNTERPLATE SEAT(see Fig 6)

10. BRING THE 2 PLATES CLOSE UNTIL THETOOL IS HAND PRESSED(see Fig.7).

CHECK THAT CRANKPIN IS CORRECTLYFITTED IN THE HOLE OF THE RECEIVINGCRANKSHAFT HALF.

Fig.4

Fig.5

Fig.6

Fig.7

MAN-05217

11. OIL CRANKPIN AND CRANKPIN HOLE ONHALF CRANKSHAFT.

12. PUT TOOL IN VERTICAL POSITION (seeFig.8).

13. PROGRESSIVELY PRESS THE TWOCRANKSHAFT HALVES TOGETHER.

14. OPEN THE TOOL, PUT IT IN HORIZONTALPOSITION AND EXTRACT CRANKSHAFT.

15. 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, REBUILDTHE CRANKSHAFT.

AFTER ASSEMBLING THE CRANKSHAFT, IT MUST BE ALIGNED, OTHERWISE EXCESSIVEVIBRATIONS, HARD STARTING OR POOR ACCELERATION WILL RESULT.

a. PLACE THE CRANKSHAFT BETWEEN THECENTERS, WITH DIAL INDICATORSREADING ON FRONT AND REAR BEARINGJOURNALS(see Fig.10).

(CENTERS WITH CENTESIMAL DIALGAUGES AND COPPER HAMMER FORALIGNMENT).

Fig.8

Fig.9

Fig.10

MAN-05218

b. ROTATE CRANKSHAFT AND CHECKDEFLECTION OF GAUGE NEEDLESTHE DEFLECTION MUST BE, AFTERCENTERING, MAX. 0.01mm(see drawing).

c.ADJUST ALIGNMENT WITH A COPPERHAMMER, IF NECESSARY(see Fig.11).

3 –REEDSTER 125cc ENGINE ASSEMBLYBEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE

OPERATIONS PICTURES

1. INSTALLING BEARINGS

- INSERT EVENTUAL BEARING SHIMS INTHE CRANKSHAFT BEARING SEATS (see Fig.1) AND PLACE THE CRANKCASE HALVESUNDER THE PRESS.

Fig.1

Fig.11

MAN-05219

- INSERT CRANKSHAFT BEARINGS; BALLSTO BE VISIBLE ON UPPER SIDE DURINGASSEMBLY (see Fig. 2).

- OIL OUTSIDE OF BEARINGS AND BEARINGSEATS , BEFORE ASSEMBLY.

USE SPECIAL TOOL (ATT-011/1) TO INSERTTHE BEARINGS (see fig. 3)

INSTALL THE INNER BALANCE SHAFTBEARING, BALLS TO BE ON UPPER SIDE(GREASE BALLS BEFORE ASSEMBLING)OIL THE BEARING EXTERNAL AND THE HALFCRANKCASE SEAT.USE THE SPECIAL TOOL (P.N. 10292) TOINSERT THE BEARING (see Fig. 4)

INSTALL THE OUTER BALANCE SHAFTBEARING (GEAR SIDE). BALLS TO BE ONLOWER SIDE.OIL THE BEARING OUTER PART ANDSUPPORT SEAT BEFORE ASSEMBLING.USE SPECIAL TOOL (P.N. 10293) TO INSERTBEARING. (see Fig. 5)

Fig.2

Fig.3

Fig.4

Fig.5

MAN-05220

2. CRANKCASE ASSEMBLY

- LUBRICATE THE CRANKSHAFT SEATS,BALL BEARINGS, BIG END CAGE BEFOREASSEMBLING(vedi Fig.6).

- ALSO LUBRICATE THE INNER BALANCESHAFT BEARING.

- INSTALL CRANKSHAFTTHE CRANKSHAFT MUST BE IN SAMEPOSITION AS IN ORIGINAL INSTALLATION(see Fig.7).

ATTENTION:AS FIRST STEP ASSEMBLE CRANKCASEWITH 4 SCREWS AND CHECK CRANKSHAFTAXIAL PLAY TO BE 0.20 - 0.25mm.IF PLAY IS LOWER OR HIGHERDISASSEMBLE CRANKCASE, EXTRACTBEARINGS AND USE DIFFERENT STEELSHIMS (0.10/0.15/0.20) TO RECOVER PLAY.SHIMS MUST BE EQUALLY POSITIONED(see Fig.8).

BEFORE FINAL ASSEMBLING OFCRANKCASE HALVES CLEAN ANDDEGREASE CONTACT SURFACES ANDAPPLY FLUID GASKET (Motorseal orequivalent) ON CRANKCASE HALVES. CLEANEVENTUAL EXCESS OF PRODUCT FROMTHE CONTACT SURFACES (see Fig.9).

Fig.6

Fig.7

Fig.8

Fig.9

MAN-05221

- INSERT CRANKSHAFT AND CLOSECRANKCASE HALVES (see Fig.10).

- ASSEMBLE CRANKCASE HALVESN°9 SCREWS M6 (see Fig.11).(CROSS PATTERN LOCKING – (SEEATTACHED SKETCH)

TORQUE AT 8÷10 Nm (70 ÷ 90 lbf*in)


3. FITTING OIL SEALS

- APPLY SPECIAL LUBRICANT ON SEAL LIPS.(APPLY MORE LUBRICANT BETWEEN THEOUTER AND INNER OIL SEAL LIPS)

ATTENTION:WHEN FITTING NEW SEALS, TURNING THECRANKSHAFT COULD RESULT MOREDIFFICULT, BUT THIS IS NORMAL.

- FIT SEALS ON CRANKSHAFT BY USING THESPECIAL TOOL WITH BUSHING, TO BEINSERTED ON THE CRANKSHAFT (GEARSIDE) (P.N. 10295A)(see Fig.13).(MARK ON SEAL TO BE TURNED TOWARDSOUTSIDE).

- INSERT OIL SEAL IN GEAR COVER USINGTHE SPECIAL TOOL (P.N. 10296)(MARK ON SEAL TO BE TURNED TOWARDSOUTSIDE).

ATTENTION:OIL SEALS MUST ALWAYS BE REPLACEDWHEN DISASSEMBLED.

Fig.12

Fig.11

Fig.13

Fig.10

ATT.: screwstarter side

MAN-05222

- ASSEMBLE BEARING SUPPORT ANDBALANCE SHAFT(see Fig.14).N°6 SCREWS M6TORQUE AT 8÷10 Nm (70÷90 lbf*in)


LUBRICATE THE BALANCE SHAFTEXTERNAL BEARING

- INSTALL WATER PUMP SEAL WITH THESPECIAL TOOL

(P.N. ATT-016) (see Fig.15).(MARK ON SEAL TO BE TURNED TOWARDSINSIDE).

ATTENTION:BEFORE ASSEMBLING THE OIL SEAL,ALWAYS INSERT THE SHAFT GUARD.BE VERY CAREFUL NOT TO DAMAGE THEOIL SEAL LIPS DURING THE ASSEMBLY

4. ASSEMBLING THE GEARS

- CHECK THE GEAR TEETH GOOD STATUS,INSERT THE BELLEVILLE WASHER ON THEBALANCE SHAFT AND LOCATE THE GEAR("5TR" SIDE - LETTERS “A” AND "C" TO BE

VISIBLE) BEING CAREFUL TO ALIGN THEREFERENCE NOTCHES ON THE INTERNALTOOTHING ( WITH THE HELP OF A PLASTICHAMMER). (see Fig.16).

ATTENTION:IF GEARS ARE NOT PROPERLY LOCATED,VIBRATION DAMPING SYSTEM WILL NOTOPERATE PROPERLY.

- LOCATE GEAR ON THE CRANKSHAFT("5TR" SIDE - LETTERS “A” AND "C" TO BEVISIBLE) ALIGNING THE INTERNAL TEETHREFERENCE NOTCHES ON THE EXTERNALTEETH REFERENCE NOTCHES ON THE 2GEARS(CHECK BOTH GEARS TO BE ON THE SAMELEVEL). (see Fig.17)

Fig.14

Fig.15

Fig.16

Fig.17

M6x20

M6x20

M6x60

M6x60

M6x60

M6x60

MAN-05223

NOTE:IF GEARS HAVE NOT BEEN REPLACED,REINSTALL THEM IN THEIR ORIGINALPOSITION .( IDENTIFY THE GEAR MARKED DURING THEDISASSEMBLING AND ASSEMBLE IT ONCRANKSHAFT).

INSTALL RETAINING RING ON THE BALANCESHAFTMAKE SURE THAT RING IS IN PLACE ATBOTTOM OF ITS SLOT(see Fig.18).

(PLIERS FOR RETAINING RINGS)

- PLACE THE GEAR LOCKING TOOL (P.N.ATT-008).INSTALL THE SAFETY CONE WASHER ANDM18 NUT ON THE CRANKSHAFTTORQUE AT 50÷55 Nm (440÷485 lbf*in)

(TORQUE WRENCH WITH 27mm BUSH ).

5. ASSEMBLING THE WATER PUMP

- ASSEMBLE THE WATER PUMP IMPELLERSCREW M5x20 (see Fig.19).TORQUE AT 5÷6 Nm (45÷55 lbf*in)

(8mm SOCKET WRENCH )

ATTENTION:THE SHAFT DRAGGING SURFACES MUSTMATCH WITH THOSE ON THE IMPELLER.

- INSTALL THE GASKET AND THE WATERPUMP COVERN°4 SCREWS M6x20 (see Fig.20).TORQUE AT 8÷10 Nm (70 ÷ 90 lbf*in)

(5 mmALLEN WRENCH – T TYPE)

6. INSTALLING THE STARTER

- PLACE STARTER IN THE CRANKCASE SEAT(see Fig.21).OIL “O’RING” BEFORE INSERTING.CHECK THAT THE PLASTIC CLAMP FIXINGTHE STARTER CABLE IS IN PLACE.

N°4 SCREWS M6x35TORQUE AT 8÷10 Nm (70 ÷ 90 lbf*in)


Fig.21

Fig.18

ATT.: ScrewStarter bendix side.

Fig.20

Fig.19

MAN-05224

7. ASSEMBLING THE GEAR COVER

- PLACE GASKET ON CRANKCASE(see Fig.21).

- POSITION COVER BY INSERTING STARTEREND IN ITS PROPER SEAT.(CHECK THAT THE VIBRATION DAMPINGFITTING IS IN PLACE AND OIL IT BEFOREINSERTING 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 M6FOR FIXING STARTER CLAMPTORQUE AT 8÷10 Nm (70 ÷ 90 lbf*in)(5mm ALLEN WRENCH – T TYPE).

ATTENTION:THE COPPER WASHER MUST BE PLACEDUNDER THE OIL DISCHARGING SCREW

8. CHARGING OIL IN THE GEARBOX

- PUT THE ENGINE PERFECTLY HORIZONTALREMOVE OIL BREATHER FROMCRANKCASE(see Fig.23).


- REMOVE THE OIL LEVEL PLUG

(4mm ALLEN T- TYPE)

- POUR 40cc SAE 30 OIL IN THE GEAR BOX(see Fig.24).

NOTE:IF QUANTITY IS CORRECT YOU WILL NOTEOIL SLIGHTLY OVERFLOWING FROM THE OILHOLE PLUG.

- INSTALL OIL DRAIN PLUGTORQUE AT 12÷15 Nm (105 ÷ 130 lbf*in)

(4mm ALLEN T- TYPE)

- REINSTALL BREATHERTORQUE AT 12÷15 Nm (105 ÷130 lbf*in)


Fig.24

Fig.25

Fig.22

Fig.23

M6x20

M6x20

M6x20 M6x30

M6x30

Fig.23

MAN-05225

9. INSTALLING THE PISTON

- CHECK STATUS OF THE PISTON PIN CAGE.IT IS RECOMMENDED TO REPLACE ITAFTER 30 HRS AND ALWAYS WHENOVERHAULING THE ENGINE.

- CHECK STATUS OF PISTON PIN.REPLACE IT WHEN REPLACING PISTON.(SEE ATTACHMENT ON MATCHINGSELECTIONS BETWEEN PISTON PIN /CAGE).

- INSTALL PISTON RING ON PISTON(see Fig.26).

ATTENTION:CHECK PLAY BETWEEN RING ENDS TO BEWITHIN 0.25 AND 0.30mm.PLAY MUST BE CONTROLLED WITH ATHICKNESS GAUGE AND INSERTING THEPISTON RING IN THE CYLINDER (see Fig.27).REPLACE PISTON RING WHEN PLAYEXCEEDS 0.4mm.

ATTENTION:PLAY BETWEEN PISTON AND LINER MUSTBE BETWEEN 0.11÷0.12mm.IF PLAY EXCEEDS 0.14mm REPLACEPISTON.

FOLLOW INSTRUCTIONS ON THEATTACHMENT FOR PROPER MATCHING.PISTONS TO BE MEASURED AT 18mm FROMBOTTOM (see attachment).ALWAYS REPLACE PISTON AND PISTONRING TOGETHER.

- LUBRICATE CAGE AND INSERT IT IN THECON-ROD SMALL END. INSERT PISTON PINWITH SPECIAL PISTON PIN PUNCH (P.N.10200) (see Fig.28).

MAKE SURE THAT ARROW ON THE TOP OFPISTON IS TURNED TOWARDS EXHAUST.AS GENERAL RULE THE PISTON PINMUST BE INSERTED BY HAND IN THE HOLE.

- INSTALL CIRCLIP ON SPECIAL TOOL(ATT-006).GREASE TOOL TO KEEP CIRCLIP INPOSITION. (see Fig.29).

Fig.26

Fig.27

Fig.28

Fig.28

MAN-05226

- IINSERT CIRCLIPS(see Fig.30).CHECK CIRCLIPS TO BE IN SEAT.

ATTENTION:THE CIRCLIP ENDS MUST BE OPPOSITE TOTHE PISTON EXTRACTION NOTCH

10. INSTALLING THE CYLINDER

- PLACE A NEW GASKET ON THE CYLINDERBASE.

OIL CYLINDER LINER AND PISTON.

INSTALL CYLINDER (see Fig.31).

N°4 NUTS M8 WITH WASHERSCROSS PATTERN ASSEMBLYTORQUE AT 18÷22 Nm (160÷195 lbf*in)


- PLACE THE O’RINGS: (see Fig.32)- ON INTERNAL OF CYILINDE- ON EXTERNAL OF CYLINDER- ON TIE-RODS

11. INSTALLING THE CYLINDER HEAD

- CLEAN COMBUSTION CHAMBER FROMDEPOSITS.PAY ATTENTION NOT TO SCRATCH THECOMBUSTION CHAMBER.

- INSTALL HEAD (see Fig.32).N°5 NUTS M8 WITH WASHERSCROSS PATTERN ASSEMBLYTORQUE AT 18÷22 Nm (160 ÷ 190 lbf*in ).

(TORQUE WRENCH WITH 13mm BUSH)

ATTENTION:ALL THE NUTS MUST BE IN CONTACTBEFORE PROCEEDING WITH CROSSPATTERN TORQUING .

Fig.31

Fig.32

Fig.33

Fig.30

MAN-05227

12. ASSEMBLING THE IGNITION AND ENGINETIMING

- INSERT KEY ON SHAFT(see Fig.34).

- INSTALL ROTOR ON SHAFT

- INSTALL PISTON RETAINER (P.N. 10271)ON HEAD AND INSERT M12 NUT ON SHAFT.(see Fig.35).TORQUE AT 20÷26 Nm (175÷230 lbf*in)


- INSTALL STATORN°3 SCREWS M5x25 (see Fig.36).

NOTE:DO NOT TIGHTEN THE SCREWS TO ENDBEFORE HAVING ADJUSTED THE IGNITIONTIMING

(4mm ALLEN T-TYPE)

- REMOVE THE PISTON RETAINER

- BRING PISTON TO TDCWITH A CENTESIMAL DIAL GAUGE(see Fig.37).

Fig.34

Fig.35

Fig.36

Fig.37

MAN-05228

- AFTER HAVING SET TO "0" THE DIAL GAUGEROTATE CRANKSHAFT IN THE OPPOSITEDIRECTION VS THE DIRECTION OFOPERATION(CLOCKWISE, LOOKING AT THE IGNITION):2.3mm for F12.6mm forr F24.9mm for F34.1mm for F4(see Fig.38).

- PREVENTING THE CRANKSHAFT FROMTURNING, ROTATE IGNITION STATORUNTIL THE REFERENCE NOTCH MATCHESTOGETHER WITH THE NOTCH ON ROTOR.(see Fig.39).

- FIX STATORN°3 ALLEN SCREWS M5x25 (see Fig.40).TORQUE AT 5÷6 Nm (40÷50 lbf*in)

(4mm ALLEN T- TYPE)

13. INSTALL STARTER COUNTERSHAFT

- OIL THE TWO COUNTERSHAFT ENDSAND INSERT IT ITS THE CRANKCASE SEAT(see Fig.41).

Fig.41

Fig.38

Fig.39

Fig.40

MAN-05229

BEFORE ASSEMBLING THE CLUTCH, WASH WITH DILUENT THE SHAFT TAPER, THE STARTER RINGFIXING HOLE, THE CLUTCH BODY AND THE CLUTCH DRUM.14.

INSTALLING THE CLUTCH- INSTALL STARTER RING ON CLUTCH BODYBY MATCHING THE 3 HOLES AND THEDRAGGING PIN(see Fig.42).

- INSTALL N°3 SCREWS M6x12APPLY LOCTITE ON THE THREADS(Loctite 243) .TORQUE AT 10÷12Nm (80 ÷100 lbf*in)

(10mm SOCKET TYPE - TORQUE METER)

ATTENTION:MAKE SURE TO ALWAYS INSTALL THE

Ø 7mm DRAGGING PIN, AS OTHERWISE THEEVENTUAL KICKBACKS COULD BREAK THESCREWS.

- APPLY “LOCTITE 641” ON THE TAPERSHAFT FOR COAXIAL LOCKINGS(see Fig.43).

-INSTALL THE STARTER RING WITH CLUTCHBODY ON CRANKSHAFT

- INSTALL THE STARTER RING LOCKINGTOOL NUT (P.N. S884)

- INSTALL M20 STARTING GEAR FIXING NUTTORQUE AT 100÷110 Nm (885 ÷ 970 lbf*in)(see Fig.44).

(30mm SOCKET TYPE - TORQUEMETER )

ATTENTION:TURN COUNTERCLOCKWISE AS NUT HASLEFT THREAD.

NOTE:DO NOT USE THE PISTON FITTING TOOL TOPREVENT THE SHAFT FROM TURNING.

- INSTALL INNER WASHER

ATTENTION:INSTALL WASHER WITH BEVEL TOWARDSSHAFT

- INSTALL ROLLER CAGE, CLEAN ANDGREASE IT BEFORE INSTALLING IT ON THESHAFT. DO NOT EXCEED WITH GREASE.(see Fig.45).

Fig.16

Fig.42

Fig.43

Fig.44

Fig.45

MAN-05230

- INSTALL CLUTCH DRUM, OUTER WASHERAND M10 NUT (see Fig.46).

ATTENTION:INSTALL WASHER WITH BEVEL TOWARDSCRANKSHAFT

- APPLY “LOCTITE 243” ON THREADS ANDTIGHTEN THE M10 CLUTCH DRUMRETAINING NUT(see Fig.47).TORQUE AT 30÷40 Nm (265 ÷350 lbf*in)


- REMOVE THE STARTER RING LOCKINGTOOL TOOL AND INSTALL THECOUNTERSHAFT COVER(see Fig.48).N°3 SCREWS M6x25TORQUE AT A 6÷8 Nm (50 ÷70 lbf*in)

(5mm ALLEN WRENCH T TYPE)

- FIX THE GROUND CABLE ON THECRANKCASE

ALLEN SCREW M6x12 (see Fig.49).TORQUE AT 8÷10 Nm (80 ÷100 lbf*in)


Fig.46

Fig.49

Fig.47

Fig.48

MAN-05231

- INSTALL CLUTCH COVERN°3 M6x25 ALLEN SCREWS (see Fig.50).TORQUE AT 8÷10 Nm (80 ÷100 lbf*in)


15. INSTAL THE REED GROUP

- INSTALL INTERNAL GASKET, REED VALVE,EXTERNAL WASHER AND INLET DUCT,WITH PRESSURE AIR INTAKE HOLETOWARDS UPPER SIDE

(see Fig.51).

ATTENTION:CHECK BEFORE THE STATUS OF REEDPETALS.IF REED PETALS ARE SCRATCHED OR IF,LOOKING THROUGH THE REED GROUP ,AGAINST THE LIGHT THE PETALS DO NOTCLOSE PERFECTLY REPLACE THEM..(REMOVE N° 8 SCREWS AND PLACE REEDPETALS WITH 45° CUT ON THE BOTTOM TOBE TOWARDS LEFT SIDE).

- FIX REED GROUPN°4 SCREWS M6X25 (see Fig.52).TORQUE AT 8÷10 Nm (80 ÷100 lbf*in)


16. INSTALL EXHAUST VALVE(NOT FOR F3)

- INSTALL DIAPHRAGM ON THE VALVE BODYBY HAND PRESSING.(see Fig.53).

Fig.50

Fig.51

Fig.52

Fig.53

MAN-05232

- INSTALL HEAD ON THE DIAPHRAGM ANDINSERT THE RETAINING SPRING WITH THESPECIAL TOOL

(see Fig.54).

- INSTALL GASKET, SPACER AND O'RING,SLIDE SPINDLE AND SCREW IT IN THE"HEAD" UNTIL CONTACT BUT WITHOUTFORCING IT(see Fig.55).

ATTENTIONCHECK THAT THE GASKET PRESSUREHOLE MATCHES THE ONE ON THE VALVEBODY.

- CHECK THE DISTANCE BETWEEN THESLIDE LOWER- MID PART AND THE "HEAD"UPPER PARTPROPER DISTANCE MUST BE 86.5mm.(see Fig.56a)

STARTING FROM THE VALVE ’09 MODELTHE CORRECT VALUE IS OF 85 mm.(see Fig.56b)

NOTE:CLEAN THE SURFACE CONTACTS ON THECYLINDER AND VALVE BEFORE RE-ASSEMBLING.

- INSTALL VALVE ON THE CYLINDER SOTHAT SLIDE BEVEL IS DOWNWARDS ANDTHE CYLINDERPRESSURE INTAKE HOLEMATCHES BOTH THE VALVE BODY ANDGASKET HOLES(see Fig.57).

Fig.57

Fig.54

Fig.55

Fig.56a

Fig.56b

MAN-05233

- FIX VALVE BODIESN°2 SCREWS M6 (see Fig.58).TORQUE AT8÷10 Nm (70 ÷90 lbf*in)PROCEED AS FOLLOW:

SCREW IN THE M6 SCREWS WITHOUTTORQUING

CHECK THAT VALVE IS FREELY SLIPPINGTORQUE SCREWS AT 4÷5 Nm(35 ÷45 lbf*in)

CHECK AGAIN VALVE SLIPPING TORQUE DEFINITELY AT 8÷10 Nm

(80 ÷100 lbf*in)

(5mm ALLEN WRENCH T- TYPE)

- PLACE SPRING ON THE VALVE PISTONAND INSTALL COVER CHECKING THATSPRING IS COMPLETELY IN SEAT(see Fig.59).

- KEEP COVER IN POSITION AND SECURE ITWITH STEEL CLAMPCHECK THAT THE CLAMP END ISPROPERLY HOOKED TO THE BODY VALVE(see Fig.60).

NOTE:REFER TO THE INSTRUCTION MANUAL FORPROPER VALVE SETTING .

17. INSTALL EXHAUST FITTING

- ASSEMBLE GASKETS, SPACER ANDEXHAUST FITTING,N°4 SCREWS M6x25 WITH WASHERS(see Fig. 61).TORQUE AT 8÷10 Nm (80 ÷100 lbf*in)


Fig.61

Fig.58

Fig.59

Fig.60

MAN-05234

COUPLES ON TIGHTENING OF NUTS AND SCREWS

MAN-05235

CROSS PATTERN LOCKING ORDER ON CRANKCASE

MAN-05236

MAIN PRESCRIPTIONS

CRANKSHAFT

- Bearing seat diameter on new engine

For halfcrankshaft wear, please refer to theattached table.

MATCHING THE PISTON

ATTENTION:Play between piston and liner must be0.11÷0.12mm.If play is higher than 0.14mm replace piston

Piston to be measured at 18mm from the base.

The piston size is marked on the top with a greenor 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 sizemarked on the piston to match the liner size.

-a red dot or letter R: add 0.12 mm to sizemarked on the piston to match the liner size.

MAX ALLOWED OVALIZATION OF CON-RODBIG-END

Max. allowed ovalization between A and B onnew conrod: 0.002mmMax. allowed ovalization between A and B onused conrod: 0.01mm

MAN-05237

MAN-05238

OVERHAUL TOOL LIST

SPECIFIC TOOLS AVAILABLE AT IAME

DESCRIPTION P.N.

GEAR DISASSEMBLY TOOL ATT-010 ROTOR DISASSEMBLY TOOL ATT-009 PISTON FITTING 10271 CLUTCH DISASSEMBLY TOOL 10272-C PISTON PIN FITTING TOOL 10200 ? ? CRANKSHAFT ASSEMBLY KIT

It includes:- crankpin bush

10110B-C

10150A CRANKSHAFT DISASSEMBLY KIT

It includes:- crankshaft plate- crankshaft support- crankpin pusher- crankshaft insert

10100A-C2

10104A101001010710106

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

1029110293102901029210295

10295A10296

ATT-016

ENGINE FIXING TOOL ON BENCH VICE (see attacheddrawing)

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

4mm5mm10mm11mm12mm17mm19mm27mm13mm8mm27mm30mm20.8mm

10/13/27/30mm

MAN-02239

TABLE FOR WEAR EVALUATION ON BEARINGS/ HALFCRANKSHAFTS

NOTE:ALWAYS CHECK DIMENSIONS IN DIFFERENT POINTS ON CIRCUMFERENCE, LOOKING FOREVENTUAL OVALIZATIONS

On the following Table are shown the ovalization limits above which replacement is required

MEASURED PART(MEASURING INSTRUMENT)

LIMITS

CRANKSHAFT – BEARING SEAT(MICROMETER 0÷25 1/100) MIN. Ø24.96

BALANCE SHAFT – EXTERNAL BEARING SEAT(MICROMETER 0÷25 1/100) MIN. Ø24.96

BALANCE SHAFT – INTERNAL BEARING SEAT(MICROMETER 0÷25 1/100) MIN. Ø14.96

CRANKSHAFT BEARINGS(1/100 BORE GAUGE WITH CHECK RING Ø25) * MAX. Ø25.03

BALANCE SHAFT - EXTERNAL BEARING(1/100 BORE GAUGE WITH CHECK RING Ø25) * MAX. Ø25.03

BALANCE SHAFT – INTERNAL BEARING(1/100 BORE GAUGE WITH CHECK RING Ø15) * MAX. Ø15.03

* ATTENTION:THE MEASURED VALUE ON THE BEARING MUST ALWAYS BE COMPARED WITH THE SEATVALUE (ON SHAFT AND/OR BALANCE SHAFT), TO CHECK THAT PLAY, BETWEEN SHAFT ANDBEARING DOES NOT EXCEED THE LIMIT VALUE OF 0.05mm.

39

MAN-02240

FIXING ENGINE TOOL ON BENCH VICE

40

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