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Transcript of MORINI FRANCO MOTORI S.p.A.morinifrancousa.com/SLC-motor-servicemanual.pdf · Page 6 S6 /C ENGINE...
SERVICE MANUAL
S6-C COMPETITION
50cc – 2 stroke - liquid cooled
Page 1
S6 /CENGINE
INDEX
TECHNICAL SPECIFICATIONS 2
SPECIAL TOOLS 3 - 4
PERIODIC MAINTENANCE 5
LUBRICANTS 6
TROUBLESHOOTING 7 - 14
TIGHTENING TORQUE TABLE 15
ENGINE DISASSEMBLY 16 - 24
ENGINE REASSEMBLY 25 - 37
SPECIAL 3-SHOE CLUTCH DISASSEMBLY/REASSEMBLY 38 - 39
SPECIAL 3-SHOE CLUTCH ADJUSTMENT PROCEDURE 40
ENGINE COMPONENT INSPECTION AND SERVICE 41 - 43
GENERAL PARTS LIST + EXPLODED VIEW TABLES xx
Page 2
S6 /CENGINE
SPECIFICATIONSCYCLE ......................................................... - 2 strokeNr. of CYLINDERS....................................... - 1DISPLACEMENT.......................................... - 49.908 cc.BORE AND STROKE mm............. - 39 X 41.8CYLINDER MATERIAL ................................. - Aluminium with Ni / Si carbide coatingCOMPRESSION RATIO................................ - (15.5 ±0.3) : 1SPARK PLUG .............................................. - CHAMPION C53TIMING SYSTEM .......................................... - Reed valve with 4 carbon fibre flapsMAX. R.P.M. .................................................. - 14500 (rpm) MAXCARBURETOR ............................................ - 12/14/19 mm diameterINTAKE MANIFOLD ..................................... - AdjustableFUEL ............................................................ - EURO UNLEADED NC 623/02 - R.O.N. 95
LUBRICATION OIL MIXER TYPE ................. - 2% AGIP 2T CITYLUBRICATION WITH OIL PUMP .................. - On requestIGNITION ...................................................... - Electronic with microchipPRIMARY DRIVE GEAR ............................... - Straight-tooth gears Z 14/59..................................................................... with safety coupling..................................................................... Ratio 1:4,21
SECONDARY DRIVE GEAR......................... - Sprocket Z 10 or Z11
..................................................................... Chain type 1/2 x 3/16 roller 7.75
CLUTCH ...................................................... - Automatic centrifugal clutch in oil bath..................................................................... Adjustable
TRANSMISSION GEAR OIL ......................... - SAE 20 W quantity 250 ccSTARTER...................................................... - Kick starterCOOLING ...................................................... - With liquid pump
TECNICAL SPECIFICATIONS
Page 3
S6 /CENGINE
143154
143176
143156
143179
143180
143181
CodeFigure Description
SPECIAL TOOLS
BEARING INSTALLERoutput shaft
BEARING INSTALLERcrankshaft
BEARING INSTALLERoutput shaft
OIL SEAL INSTALLERoutput shaft
OIL SEAL INSTALLERcrankshaft (flywheel + clutch)
OIL SEAL MOUNTING PROTECTIONcrankshaft (flywheel + clutch)
Page 4
S6 /CENGINE
140558
143162
143155
SPECIAL TOOLS
CodeFigure Description
OIL PUMP SHAFT INSTALLER(pre-assembled)
FLYWHEEL REMOVER
CRANKCASE PULLER
143294SPECIAL CLUTCH ADJUSTMENT TOOL
Page 5
S6 /CENGINE
PERIODIC MAINTENANCE
RUNNING-IN RECOMMENDATIONS:
During the running-in period, i.e. for approx. the first 500 km on the road, please note as follows:- Do never run the engine at maximum revolutions.- Do never keep the vehicle at maximum speed.- Do not keep the engine at idle speed for longer time.
FIRST MAINTENANCE SERVICE:
to be carried out after 500 - 600 km.
- Replace the engine oil- Check the carburation and adjust if necessary- Check the tightness of nuts and bolts.(See table “tightening torques” pag. 15)
Page 6
S6 /CENGINE
LUBRICANTS
N.B.Use original MORINI FRANCO MOTORI spare parts only
N.B. TRANSMISSION OIL LEVEL CHECKRemove the oil filler cap on the clutch cover and check the transmission oil levelthrough window.
RECOMMENDED LUBRICANTS / ADHESIVES
DESCRIPTION CHARACTERISTICS
Transmission oil AGIP RADULA 68 SAE 20W
Assembly of various parts GR/SM2 GREASE
Special assembly GRAPHITISED MOLYCOTE type GREASE
Thread-locking glue LOXEAL 82-21
Clamping glue LOXEAL 83-54
Page 7
S6 /CENGINE
TROUBLESHOOTING
Possible CAUSE of the fault
The following flow charts give a general outline of the causes and effects when the engine is notrunning correctly.Descriptions of solutions for a specific cause are general; for more details the reader shouldconsult the disassembly-reassembly manual.
LEGEND OF SYMBOLS
EFFECT (fault noticed by the user)
Possible general SOLUTION to the fault
Page 8
S6 /CENGINE
YES
NO
NO
Starting problems
Faulty spark plugor wrong spark plug
heat rating
YES Check spark plug andreplace if necessary.
Engine floodedYES
Start the engine with thethrottle fully open.
Remove the spark plug,rev the engine, install adry spark plug and restartthe engine.
The enginestarts
Sparking starts athigh r.p.m.
Replace the ignition coil
NO
Page 9
S6 /CENGINE
YES
YES
YES
NO
NO
YES
NO
Maximum indicated runningspeed cannot be reached
Soiled orclogged
filter
Disassemble, wash sponge with a50% solution of petrol and 2T oil;leave to dry. Clean the filter boxusing compressed air; re-assemble.
Silencerobstructed
Check the silencer for clogging.Replace if necessary.
Cylinderexhaust portsoiled with
carbondeposits
Disassemble the cylinder and checkthat the exhaust pipe is clean. If theexhaust pipe is partly obstructed bycarbon deposits, clean it thoroughlyusing a scraper.
Poorcompression
Disassemble the cylinder head,cylinder and piston.Remove the piston rings, placethem in the cylinder liner and checkthe amount of wear.Replace if excessively worn.
Page 10
S6 /CENGINE
YES
YES
NO
Poor acceleration / pickup
Clutch
Irregularacceleration
Check the cluth shoe thickness andthe clutch springs for stretching.If excessively worn they should bereplaced.
Check the exact number of turnsof the air adjusting screw on thecarburetor.
Page 11
S6 /CENGINE
YES
YES
YES
YES
NO
NO
YES
YES
Incorrect idling speed
Idling speedtoo high or
too low
Adjust the RPM of the idling speed(with engine warm) by adjusting thescrew on the throttle valve of thecarburetor.
Disassemble the carburetor andclean all parts (nozzles, throttle val-ve, jet needle, float chamber andbody) with solvent and dry by usingcompressed air.
False airintake fromcarburetormanifold
Check the integrity of thecarburetor manifold gaskets.
Check the integrity of the rubbercoupling sleeve that connects thecarburetor and air filter box .
Check the reed valve gasket.
False airintake
from enginecrankshaftoil seals
Check the integrity of thecrankshaft oil seals. Replaceeven if only slightly damaged.
Page 12
S6 /CENGINE
YES
YES
NO
NO
YES
Noisy engine
Incorrecttransmission
gearsassembly
Loosetransmission
nut
Transmissionnoise and rearwheel drag atidling speed.
Check the assembly of all gears andparts of the transmission.
Check the tightening torque of theclutch nut.
Check the clutch unit
Page 13
S6 /CENGINE
YES
YES
YES
YES
NO
NO
Noisy engine
Noisy gears
Check the oil level.Refill if necessary.
Check the teeth of the drive gearsvisually.Replace if signs of damage orwear are evident.
Noisycylinder
unit
Check the clearance between thepiston and the cylinder. If it doesnot correspond to the prescribedvalue, replace the cylinder andpiston.
Noisycrankshaftbearings
BEARING INSPECTIONRotate the bearing inner race by fin-ger to inspect for abnormal play, noiseand smooth rotation while thebearings are mounted in thecrankcase.Replace the bearing if anythingunusual is found.
Page 14
S6 /CENGINE
YES
YES
YES
NO
NO
YES
NO
Smokey exhaust
Percentage ofmixer oil
Replace the fuel in the tank withnew fuel mixed with 2% of the typeof oil indicated in the handbook.
Mixer oilCheck that the oil is 100%synthetic for separate oil mixerpump use.
Carbondeposits
Disassemble the cylinder andremove any carbon deposits;check the silencer for clogging.
Oil mixerpump
Disassemble the oil mixer pumpand check the flow rate.
Page 15
S6 /CENGINE
TIGHTENING TORQUES
DENOMINATION TORQUE(Nm)
Cranckcase bolts 10 - 12
Clutch cover bolts 10 - 12
Flywheel cover bolts 3 - 4
Carburetor manifold bolts 9 -10
Stator clamping bolts 3 - 4
Oil pump clamping bolts 5 - 6
Carburetor clamping screw 3 - 4
Kick starter lever bolt 8 - 10
Oil drain plug 8 - 10
Clutch nut 50 - 55+ Loxeal 83-54
Flywheel nut 8 -10+ Loxeal 83-54
Head nuts 12 - 14
Head clamping bolts 10 - 12
Pulley clamping bolts 3 - 4+ Loxeal 83-54
Water pump rotor5 - 6
+ Loxeal 83-54
Spark plug 20 - 25
S6 / C
Page 16
ENGINE
ENGINE DISASSEMBLY
CARBURETOR UNIT
TOOLCODEDIAGRAM DESCRIPTION NOTES
Disassemble the CARBURETOR
Loosen the SCREWS and remove theCARBURETOR MANIFOLD
Remove the CARBURETORMANIFOLD BASE including theREED VALVE
BEFORE LOOSENTHE SCREWSCHECK ACTUALMANIFOLD ANGLEPOSITION
THE MANIFOLD ISCOMPOSED BY 4ELEMENTS.
S6 / C
Page 17
ENGINE
CYLINDER HEAD - CYLINDER - PISTON
Remove the SPARK PLUG
Remove the 4 CYLINDER HEADBOLTS
Remove the 4 CYLINDER HEADNUTS
Remove the CYLINDER HEAD PAY ATTENTION TOTHE DOWEL PINS
TOOLCODEDIAGRAM DESCRIPTION NOTES
Check the condition of the O-RING(HEAD GASKET).Replace if excessively worn.
S6 / C
Page 18
ENGINE
Disassemble the CYLINDER andremove the CYLINDER BASEGASKET
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 19
ENGINE
FLYWHEEL SIDE
Loosen the clamping BOLTS andremove the FLYWHEEL COVER
MIND THE BRACKETINSIDE THE COVER
Disassemble the FLYWHEELSTATOR
Disassemble the FLYWHEELROTOR
ROTOR LOCK NUTCLAMPED WITHLOXEAL
143151
Remove the PULLEY CLAMPINGBOLT
Remove the DRIVEN PULLEY
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 20
ENGINE
The following operations can only be carried out after opening the crankcase
Unscrew the WATER PUMP ROTORBLOCK THE PUMPSHAFT
Remove the PUMP SHAFT UNITincluding the bearings.The pump shaft seal ring must bereplaced by every disassembly.The 2 bearing snap rings on thewater pump must be replaced byevery disassembly.
PAY ATTENTIONTO THE SPACERSBETWEEN THEBEARINGS
Remove the PUMP DRIVE BELT
Remove the SPECIAL SNAP RING
Remove the SPACER RING
TOOLCODEDIAGRAM DESCRIPTION NOTES
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 21
ENGINE
CLUTCH SIDE
ONLY IF CLUTCHNEEDS TO BEADJUSTED
Compass tool CLAMPED WITHLOXEAL.
MAKE SURE TODRAIN THEENGINECOMPLETELY
Disassemble the CLUTCHADJUSTING PLUG
Remove the OIL DRAIN PLUG(cross head)
Loosen the clamping BOLTS on thecover and remove the CLUTCHCOVER
Remove the SPECIAL FRONTCLUTCH NUT and theBELLEVILLE WASHER
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 22
ENGINE
Disassemble the SPECIAL CLUTCHand the 2.5mm SPACER RING
Remove the CLUTCH BELL and the0.8mm SPACER RING
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 23
ENGINE
143162
CRANKCASE “OPENING”
Remove the cylinder STUD BOLTS ifnecessary BLOCKED WITH
LOXEAL
Remove the 8 CRANKCASE BOLTS
Open the CRANKCASE
THE CRANKSHAFTIS DRIVEN ONTOTHE BEARINGS.OPEN THECRANKCASE FROMFLYWHEEL SIDEUSING THEPULLER TOOL
Remove the DOWEL PINS and theCRANKCASE GASKET.Remove the crankshaft if necessary
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 24
ENGINE
Remove the OUTPUT SHAFT SNAPRING
Remove the OUTPUT SHAFT
Inspect the OUTPUT SHAFTBEARING for abnormal play and noise.Replace the bearing if anythingunusual occurs.
Remove the SNAP RING
Remove the BEARING by using astandard bearing remover set.
To replace the CRANKSHAFTBEARING and the OUTPUT SHAFTROLLER CAGE (flywheel side) followthe same procedure as describedabove.
THE BEARING ISDRIVEN INTO THEBEARING HOUSING
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 25
ENGINE
ENGINE REASSEMBLY
WATER PUMP PREASSEMBLY
Preassemble the WATER PUMPSHAFT UNIT by mounting thecomponents in the following order:snap ring + bearing + spacer + bearingand secure with the snap ring.
Insert the complete unit in the HALFCRANKCASE FLYWHEEL SIDE
Insert the SPACER RING
Insert the SPECIAL SNAP RING
Insert the SEAL RING
Reassemble theWATER PUMP ROTOR
THE SEAL RINGMUST ALWAYS BEREPLACED WITH A
NEW ONE
Tightening torque5 - 6 Nm +
Loxeal 83 - 54
TOOLCODEDIAGRAM DESCRIPTION NOTES
143155
S6 / C
Page 26
ENGINE
CRANKCASE PREASSEMBLY
143176
143154
143156
TOOLCODEDIAGRAM DESCRIPTION NOTES
Drive the OUTPUT SHAFT BEARINGinto the half crankcase clutch side andsecure with the snap ring
LUBRICATE THEHOUSING
LEAVE THE PRINTON THE BEARING
VISIBLE
Drive the CRANKSHAFT BEARINGSinto the half crankcase clutch side andinto the half crankcase flywheel side.
LUBRICATE THEHOUSING
LEAVE THE PRINTON THE BEARING
VISIBLE
Drive the ROLLER CAGE OUTPUTSHAFT into the half crankcaseflywheel side.
LUBRICATE THEHOUSING
LEAVE THE PRINTON THE BEARING
VISIBLE
S6 / C
Page 27
ENGINE
CRANKCASE “CLOSING”
Insert the DRIVE SHAFT in the halfcrankcase clucth side
Insert the SNAP RING onto thesecond output shaft slot (neartransmission gear)
Insert the OUTPUT SHAFT into the halfcrankcase clutch side and secure withSNAP RING
Insert the DOWEL PINS
TOOLCODEDIAGRAM DESCRIPTION NOTES
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 28
ENGINE
Fix 1 x BOLT M6X60 in the postionbetween the stud bolts and the reedvalve zone.
143179143180143181
Lubricate the CRANKCASE GASKETon both sides.
Apply the CRANKCASE GASKET onthe half crankcase clutch side usingthe 2 dowel pins for centering.
Assembly the HALF CRANKCASES
Grease the oil seal housing and theoil seal lip carefully.
Install the CRANKSHAFT OIL SEALRINGS and the OUTPUT SHAFT OILSEAL RING.
Trim the crankcase gasket (cylinderzone and carburetor zone.)
Fix the remaining 7 X BOLTS M6X50.Cross-tighten the bolts using atightening torque of 10-12 Nm.Check to make sure that thecrankshaft and output shaft rotatesmootly.
DO NOT TIGHTEN
TOOLCODEDIAGRAM DESCRIPTION NOTES
GREASE TYPEGR/SM2
S6 / C
Page 29
ENGINE
FLYWHEEL SIDE
Tightening torque8 - 10 Nm +
Loxeal 83 - 54
143151
Mount the DRIVEN PULLEY on thewater pump shaft and position thePUMP DRIVE BELT on the splinedsection of the crankshaft.
Secure the pulley with bolt M4x14
Mount the SPROCKET and securewith the SNAP RING
Place the UNDER ROTOR SPACERon the crankshaft.
Caulk the key seat on the crankshaftand insert the FLYWHEEL KEY.
Mount the FLYWHEEL ROTOR with theblack side facing the crankcase.
TOOLCODEDIAGRAM DESCRIPTION NOTES
Tightening torque3 - 4 Nm +
Loxeal 83- 54
S6 / C
Page 30
ENGINE
Drive in the 2 elastic dowel pins in thecover. and make sure that they doNOT INTERFERE with the bracketmounting face.
Assemble the BRACKET on theflywheel cover.
Assemble the FLYWHEEL COVERplacing the rubber fairleads in theirproper seats on the cover.
Secure the FLYWHEEL COVER using:
3 SCREWS M5X50 + WASHER.1 SCREW M5X20 + WASHER.
Tightening torque3-4 N.m.
Install the FLYWHEEL STATOR withthe output cable facing the crankcase.
TOOLCODEDIAGRAM DESCRIPTION NOTES
Secure the flywheel stator with2 BOLTS M4 x 18
Tightening torque3 - 4 Nm
S6 / C
Page 31
ENGINE
CYLINDER - PISTON - HEAD UNIT
Assemble the ROLLER CAGE,PISTON and PISTON PIN andsecure with CIRCLIPS.
OIL THE PISTON
Insert the CYLINDER BASE GASKETand mount the CYLINDER
Insert the CYLINDER HEAD DOWELPINS
Apply the O-RING SEAL on theCYLINDER HEAD
Install the CYLINDER HEAD on theCYLINDER using the dowel pins ascentering reference
TOOLCODEDIAGRAM DESCRIPTION NOTES
WHENINSTALLING THEPISTON TURNTHE ARROWMARK ON THEHEAD OF THEPISTON TO THEEXHAUST SIDE
S6 / C
Page 32
ENGINE
Install the SPARK PLUG and tighten Tightening torque20 - 25 Nm.
Fit the 4 CYLINDER HEAD NUTS onthe stud bolts and tighten
(Cross tighten)Tightening torque
12 - 14 Nm.
Fit the 4 CYLINDER HEAD BOLTS andtighten
(Cross tighten)Tightening torque
10 - 12 Nm.
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 33
ENGINE
CARBURETOR UNIT
Insert the CARBURETOR MANIFOLDBASE including the REED VALVE.
Assemble the CARBURETORMANIFOLD on the base and securewith 4 BOLTS M6X25.
TOOLCODEDIAGRAM DESCRIPTION NOTES
Check the angleposition of theMANIFOLD beforetightening thebolts.
Tightening torque9 - 10 Nm.
Assemble the CARBURETOR andtighten the CLAMP SCREW.
Tightening torque3 - 4 Nm.
S6 / C
Page 34
ENGINE
CLUTCH COVER
Assemble the SPRING on the slidinggear as shown on the figure.
Lubricate the inside of the spring usingGR MU/3 grease.
Assemble the SLIDING GEAR onthe cover and secure the SPRINGbetween the two stops.
Assemble the SPACER RING andO-RING on the KICK STARTERSHAFT.
Lubricate the O-ring area usingGR MU/3 grease.
Lubricate the KICK STARTERSHAFT in the clutch cover operatingzone using grease type MOLYCOTE.Install KICK STARTER SHAFT in theclutch cover and make sure that thegear section is engaged properly withthe sliding gear.After assembly check that the springof the sliding gear is correctlypositioned between the two stops.
Drive the WATER CIRCUIT DELIVERYPIPE into place
TOOLCODEDIAGRAM DESCRIPTION NOTES
143167
S6 / C
Page 35
ENGINE
Install and load the RETURN SPRINGon the kick starter shaft.
Secure the spring on the backstop inthe clutch cover.
Assemble the SPRING WASHER andsecure with the SNAP RING.
Place the SPACER on the kick startershaft and secure with the snap ring.
Assemble the KICK STARTER LEVERand fasten by using the bolt M7x25.
KICK STARTER LEVER POSITION*Steel lever = 109°*Aluminium lever = 96°
Check axial clearance: 0.1 - 0.3 mm
TOOLCODEDIAGRAM DESCRIPTION NOTES
Tightening torque8-10 N.m.
KICK STARTER LEVER POSITION
*Aluminium lever = 96°*Steel lever = 109°
S6 / C
Page 36
ENGINE
CLUTCH SIDE
Insert the 0.8mm SPACER RING onthe crankshaft clutch side.
Lubricate the clutch bell operating zoneof the crankshaft using the grease typeROCOL ASP MOLYCOTE.
Install the CLUTCH BELL
Insert the 2.5 mm SPACER RING
Install the CLUTCH ON THECRANKSHAFT, INSERT THEBELLEVILLE WASHER and clampthe clutch using the SPECIALFRONT-CLUTCH NUT.(LEFT HAND THREAD)
Add LOXEAL 83-54 to the clutch nutand tighten
Tightening torque 50-55 N.m.
Check the axial clearance of theclutch bell: 0.3 - 0.5 mm
Assemble the clutch cover gasket.
Compass tool
CAUTION
In order to avoidany clutch hubjamming on thespline shaft and toensure any futuredisassemblyoperation of theclutch unit, makesure to applyLOXEAL 83-54exclusively on thecluth nut and NOTon shaft end.
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 37
ENGINE
Tightening torque10-12 N.m.
Tightening torque 8-10 N.m.
RecommendedOil type:
AGIP RADULA 68SAE 20W
Mount the clutch cover and securewith 6 BOLTS M6 x 30.
Insert the OIL DRAIN PLUG +WASHER and tighten.
Pour 250 cc of oil type AGIPRADULA 68 SAE 20W and fit theOIL FILLER CAP + GASKET.
AFTER COMPLETED ASSEMBLYCHECK THAT THE ENGINEROTATES SMOOTHLY
TOOLCODEDIAGRAM DESCRIPTION NOTES
S6 / C
Page 38
ENGINE
143155
143342
S6 OIL MIXER PUMP
Preassemble the 2 BEARINGS andSPACER on the OIL MIXER PUMPDRIVE SHAFT and secure with 2SNAP RINGS.
The print on the bearings should facethe drive end of the shaft.
Lubricate the bearing housing.Drive the OIL MIXER PUMP DRIVESHAFT UNIT into the half crankcaseflywheel side.
Insert the CLEARANCE SPACER.Assemble the BEARING SNAPRING.
Insert the DRIVE BELT onto theDRIVEN PULLEY.
Install the pulley on the oil mixer pumpshaft and the drive belt onto the splinedpart of the crankshaft.
Assemble the oil mixer pump on thesupport bracket and tighten thescrew M5x12.
In order to simplify the assemblyoperation of the oil mixer pump,make sure that the timing of thedriven pulley and the oil mixerpump shaft do match.
Install the BRACKET with OILMIXER PUMP into the housing of thehalf crankcase flywheel side.
TOOLCODEDIAGRAM DESCRIPTION NOTES
Tightening torque5 - 6 Nm
S6 / C
Page 39
ENGINE
SPECIAL 3-SHOE CLUTCH
DISASSEMBLY
Remove the 3 special clutch adjusting screws.
ATTENTIONEach screw contains 1 spring an 2 balls.
Remove the 21 Belleville washers.
Take note of the assembly configuration.
Remove the screw couplings.
Unscrew the clutch shoe retainer pawls andremove the flat spring.
Disassemble the clutch shoes, the bushingsand the 3 clutch shoe socket screws M4x14.
S6 / C
Page 40
ENGINE
SPECIAL 3-SHOE CLUTCH REASSEMBLY
Grassare = Lubricate
Apply a thin film of molycote grease on the shoe-holder plate.Insert the clutch shoe socket screws.
Lubricate the outer diameter working zone of the 3 bushings withmolycote grease.Insert the bushings in the clutch shoe fulcrums.
Position and install the clutch shoes on the shoe-holder plate usingthe bushings as centering references.Apply a thin film of molycote grease on the working area of the flatspring.
Assemble the flat spring on the clutch with the 3 clutch shoeretainer pawls and tighten.
Tightening torque 5.8 - 6.8 Nm
Lubricate the square holes in the flat spring and insert the 3 screwcoupling.
Grassare = Lubricate
Insert 7 Belleville washers in each hole maintaining the correct assembly configuration.
See figure.
S
Sede molle = Spring seat.
Place 2 balls and 1 spring in each of the 3 special clutch adjusting screws.
Install the 3 adjusting screws making sure that the balls and the the springs remain positioned correctly in the screw housings.
S6 / C
Page 41
ENGINE
SPECIAL 3-SHOE CLUTCH ADJUSTMENT PROCEDURE
Place the clutch on the special tool code 143294 and block it using the screw knob “C”.Position the clutch with one of the shoes blocked against the tool clutch shoe stop.Mount the main tool screw knob “C” and apply a constant torque of 8,5 Nm by using adynamometric spanner tool with direct torque reading.
When keeping the torque constant, check the clearance “X” between the shoe and the checkpin “A” using a thickness gauge.
CAUTIONThe thickness gauge must make minimal friction against the parts: it should not pass freelyand should not stick between the clutch shoe and the check pin.
Make sure that the thickness gauge do pass along the entire thickness “Y” of the shoes.
ADJUSTMENT PROCEDURE (1 clutch shoe at a time)1/Unload the dynamometric spanner tool.2/To increase the clearance “X” turn the screw “B” clockwise.3/To decrease the clearance “X” turn the screw “B” aniti clockwise.4/Repeat the procedure for each clutch shoe.
Clutch shoe stop
Check pin “A”
Clearance “X” = 0.25 mm
Screw knob “C”
Page 42
S6/CENGINE
ENGINE COMPONENT INSPECTION AND SERVICE
CYLINDER - PISTON TABLE
PartValue (mm)
50cc
CylinderPistonPiston rings :1)Piston ring 1st slot2)Piston ring 2nd slot
Ø 39Ø 39
Ø 39 x 2 - 0.01 - 0.025Ø 39 x 1.25 - 0.01 - 0.025
Page 43
S6/CENGINE
+ 0,010
+0,005
+ 0,015
+ 0,010
+ 0,020
+ 0,015
+ 0,025
+ 0,020
+ 0,030
+ 0,025
+ 0,035
+ 0,030
- 0,025
- 0,020
- 0,025
- 0,015
- 0,020
- 0,010
- 0,015
- 0,030
- 0,005
- 0,010
- 0
- 0,005
CYLINDER - PISTONASSEMBLY SELECTION TABLE
CHECK POSITIONFor correct dimension control
SIZE CODE(stamped on part)
CYLINDER - PISTONDIMENSIONS mm ASSEMBLY
CLEARANCECYLINDER PISTON
A ø 39 ø 39
B ø 39 ø 39
C ø 39 ø 39 0.030 - 0.040mm
D ø 39 ø 39
E ø 39 ø 39
F ø 39 ø 39
Page 44
S6/CENGINE
+0,18
CYLINDER CHECK-Check the internal surface of the cylinder for signs of seizure or abnormal wear.-Measure the internal diameter of the cylinder using a bore gauge.-Wear limit: Minimum indicated cylinder selection diameter + 0.03mm.-Take measurements in three different positions along the axis of the cylinder.-In each position take two measurements, one parallel with and the other perpendicular to the crankshaft axis.
PISTON CHECK
-Remove the piston rings and check the piston for abnormal signs and wear.
N.B.The piston rings are fragile, handle with care.
RING-TO-GROOVE MEASUREMENT.Wear limit: 0,08 mm max.
PISTON BORE MEASUREMENT.-Maximum permitted diameter:12 + 0,18 mm
-Measure the piston outside diameter in the direction perpendicular to the piston axis at 14,5 mm from the skirt.