Derbi Atlantis 50 - 100 4T (en)

W O RKS KSH HO P MA N UA UAL L AT LANT IS 50/100 C .C . 4T

 This  This manual anual has been been crea create ted d by Nacional Nacional Motor Motor,, S.A. for us use in DER DERBI dealer dealer work works shops hops and and sub-age sub-agenncies. It is assumed that those using this publication for entertainment and for repairing DERBI machines, have a basic knowledge of mechanics and of the methods inherent in the technique of machine repair. The significant varia variations tions in the characteristics of the machines or in the specifi specific c repair operations o perations are to be communicacommunicated by means means of updates up dates to this manual. manual. Completely Co mpletely satisfactory satisfactory work cannot however be carried out without the availability of suitable facilities and tools, which is why we ask you to consult the pages of this manual referring to special tools and implements. Particularly important items of information in this manual are distinguished by the following annotations:

N.B. INDICATES A NOTE GIVING KEY INFORMATION, MAKING THE PROCEDURE EASIER AND CLEARER.

ATTENTION IN DIC ATES ATES SPECI SPECIFIC FIC PROC EDURES EDURES THAT THAT MUST BE BE FO LLO LLO WED TO TO PREVEN PREVEN T DAM AGE TO TO THE M ACHIN ACH IN E.

WARNING IN DIC ATES ATES SPECI SPECIFIC FIC PROC EDURES EDURES THAT THAT MUST BE BE FO LLO LLO WED TO TO AVO AVO ID POSSIBL PO SSIBLE E INJ URIES TO TO THE PER PERSON REPAIRING EPAIRING THE MACHIN MACH IN E.

NAC ION AL MOTOR, MOTOR, S.A.U. S.A.U.

 TECHN  TECHN I CAL CHA R ACTERI STI CS

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PERIODICAL PERIODICAL M AIN TENAN CE

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ENGI NE TIGHTE TIGHTENI NI NG

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CHASSIS TIGHTENI TIGHTENI NG

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SPECI SPECI AL TOOLS

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ENGINE – REMOVING THE ENGINE FROM THE FRAME

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50 CC 4-ST 4- STR RO KE EN EN GIN E

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100 CC 4-STROKE ENGINE

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CHECKIN G ENG IN E O IL LEV LEVEL EL

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CHECKING GEARBOX OIL LEVEL

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CHECKING SPARK PLUG AND BATTERY

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DISMANTLING THE ROCKER COVER

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CHECKING THE TIMING

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CHECKING VALVE PLAY

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CHECKIN CH ECKIN G FU LL CO MPRES MPRESSIO SION N PRES PRESSUR SURE E

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DISMANTLING TRAN TRANSMIS SMISSION SION COVE CO VER R

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DISMAN DISMA N TLIN TLIN G AN D ASSEMBL ASSEMBLY Y O F STAR STARTE TER R UNIT UNI T

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DISMANTLING DRIVING-DRIVEN PULLEY

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DISMANTLING THE CLUTCH

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CHECKING DRIVEN SEMI-PULLEY

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ASSEMBLING THE DRIVEN SEMI-PULLEY

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ASSEMBLING CLUTCH-BELT-DRIVING PULLEY

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VARIATOR VARIATO R ROLLERS

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ASSEMBLING FIXED SEMI-PULLEY-CLUTCH-TRANSMISSION COVER

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DISMAN DISMA N TLIN TLIN G REAR AXLE AXLE HOUSIN HO USIN G – WHEEL AXLE

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DISMANTLING DRIVEN SEMI-PULLEY

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ASSEMBLING ASSEMBLING DRIVEN DRIVEN PULLEY PULLEY CA M – WHEEL WHEEL AXLE AXLE AND A XLE XLE HOU SING CO VER

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ASSEMBLING BRAKE CAM AND REAR HOLDING SHOES

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DISMANTLING TURBINE – MAGNETO AND STATOR

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CHECKIN G THE MAGN MAG N ETO ETO

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ASSEMBLING ASSEMBLING THE MAGN ETO ETO

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MAINTENANCE

FRO FRO N T FOR FO RKS/ REAR SHO CK ABSORBER ABSORBER MOTOR

MOTOR

LUBRICATION DISMAN TLIN TLIN G THE OIL O IL RES RESER ERVOIR VOIR – O IL PUMP CHECKIN G THE O IL PUMP PUMP ASSEMB ASSEMBLING LING THE OIL OI L PUMP PUMP – TIMIN G C HAIN COVER ASSEMB ASSEMBLING LING THE O IL RES RESER ERVOIR VOIR – DISMAN DISM ANT TLING CHAIN CH AIN TENSIO TENSIO NER

DISMANT DISMAN TLING THE TIMIN TIMIN G DRIVE DRIVE DISMANTLING THE CAMSHAFT AND ROCKERS HEAD SEAL – DISMANTLING VALVES DISMANTLING THE CYLINDER - PISTON CHECKIN G THE CYLIN CYLINDER DER CHECKING PISTON RINGS PISTON ASSEMBLY – CHECKING PISTON HEIGHT FITTIN FITTING G PISTO PISTO N RINGS IN GS - C YLINDER CHECKING CYLINDER HEAD - VALVES CHECKIN CH ECKING G SPR SPRIN GS, VALVE VALVE HEADS AND STEMS STEMS CHECKING CAMSHAFT CHAIN TENSIO ENSIO NER CHECKING THE ROCKERS ASSEMBLING THE CYLINDER HEAD AND CAMSHAFT ASSEMBLING TIMING COMPONENTS ASSEMBLING THE CHAIN TENSIONER OPENING THE ENGINE CRANKCASE CHECKIN G C RANKSHAFT ALIGNMENT ALIGN MENT - CRAN KSHAFT BEARIN EARING G CRANKSHAFT BEARING DISMANTLING AND ASSEMBLY - SEAL CLOSING ENGINE CRANKCASE FILTER CONTAINER – VACUUM VALVE DISMAN DISMA N TLIN TLIN G THE CARBURE CARBURETT TTO OR ASSEMBLIN ASSEMBLIN G THE CAR CA RBURETT BURETTO OR BATTERY BATTERY CHARGING SYSTEM – STARTER RELAY IGNITION LIGHTING SYST SYSTEM EM AND AUTOM ATIC ATIC C HO KE BATTERY CHARGING AND STARTING IN DICAT DIC ATO O RS AND AN D LEVEL LEVELS S CHECKING PILOT LIGHTS AND INSTRUMENTS CHECKING THE PICK-UP VOLTAGE VOLTAGE REG REG ULATOR ULATO R 50 C.C.4-STROKE WIRING DIAGRAM 100 C.C.4-STROKE WIRING DIAGRAM

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RULES  This  This sect ection des describes ribes the the genera generall safe safety ty rules rules and thos those e for for the mainte aintenanc nance e of the the machin achine. e.

SAFETY RULES - If work on the machine requires the engine to be running, ensure that the location is well ventilated, if  possible making use of extraction fans; never leave engines running in closed spaces. Exhaust fumes are poisonous. - Petrol is extremely extremely inflammable, and under certain conditions can explode. Smoking must must not be permitted in the work area, nor must there be any naked flames or sparks.

MAINTENANCE RULES - Use original DERBI spare parts and lubricants recommended by the Manufacturer. Spare parts that are not original or approved may damage the engine. - Always use new gaskets and oil seals during refitting. - After dismantling, clean the components with solvents solvents that that are non- inflamm infl ammable able or with wi th a high flamm fla mmabil ability ity point. Lubricate all working surfaces before assembly, excluding the conical couplings. - After assembly, check that all the components have been refitted correctly and that they are working perfectly. - For F or dismantling, checking and assembly assembly operations, only use tool tools s with with metric metric measurements measurements.. Metric screws, nuts and bolts are not interchangeable with imperial connecting devices. Using unsuitable tools and connecting devices may damage the engine. - In the case of work on the engine involving the electrical wiring, check the correct fitting of the electrical connections.

ENGINE TE NGINE  TECHN CHN ICAL ICA L CHARACTERISTICS ENGINE

Number of cylinders

1

Cycle

4 stroke

Diameter x stroke

39 x 41,8 mm

Cylinder capacity

49,93 c.c.

Diameter x stroke

50 x50 mm

Cylinder capacity

98,20 c.c. c.c.

Compression ratio  Timing  Timing Depression Depression carburettor carburettor Fuel

11,5 ÷ 12:1 Single overhead camshaft, two valves, chain driven. KEIHIN CVK Ø 18mm - WALBRO WP 16ª. lead-free petrol

CO regulation

3,2% ± 0,5

 Tick-ov  Tick-over er

1900 ÷ 2000 rpm

Air filter

Sponge type

Lighting system

Electric starter/ starter/ Kick starter. starter.

Lubrication

With chain-driven chain- driven lobular pump inside the crankcase crankcase

Max. power

2,6 kw at 7.250 rpm

Max. power

5,0 kw at 9.000 rpm

Coolin Coo ling g system system Valve play (when cold)  Trans  Transmis mission sion Petrol Petrol tank Gearbox oil Engine oil

IGNITION

By forced air Inlet: 0,10mm

Exhaust: 0,15mm

With automatic Variator and reduction gears. Capacity: Ca pacity: 7.5 litres

Reserve: eserve: 1.9 litres

Agip GEAR G EAR SYNTH (SAE 75/90) - 80 c.c AGIP AGI P CITY CI TY 4T - 850 c.c. c.c.

Capacitative discharge electronic ignition, with HT coil incorporated. Varialble ignition i gnition advance advance

Spark plug Magneto Battery Fuse

10º at 1500 rpm

26º at 5000 rpm

Champion RG 4 PHP

Champion RG 4 HC

single phase alternat al ternating ing current 12V-4Ah 4Ah

ENGINE TE NGINE  TECHN CHN ICAL ICA L CHARACTERISTICS LIGHTING SYSTEM

FRAME

DIMENSIONS

Front headlight Rear stop/ stop/ tail light

12v.5W sidelight

12v.10W 12v.10W brake light l ight

Instrument panel

12v 2W temperature warning light

Instrument panel

12v 2W oil warning light

Instrument panel

12v 2W turn indicators warning light

Instrument panel

12v 1.2W main main beam warning light

Instrument panel

12v 1.2W instrument instrument panel light

Instrument panel

12v 10W turn light

 Ty  Type

Constructed of steel tubing reinforced with embossed steel plate

Front suspension

Hydraulic telescopic with springs

Rear Rear suspension suspension

Swinging arm and hydraulic shock absorber

Front suspension travel

65 mm

Rear shock absorber travel

65 mm

Front brake

190 mm. disk

rear brake

140 mm internal expansion

 Tot  Total al lengt length Distance between axles

1.810 mm 1.265 mm

Maximum width

710 mm

Seat height

795 mm

Maximum height Weight

 TYR  TYRES

12v 25/25W lamp la mp

1.115 mm 98 Kg

Front tyre

130/60 130/ 60 x13 x13

Rear tyre

130/60 130/ 60 x13 x13

1 seat front tyre pressure

1,7 Kg/cm2

2 seat front tyre pressure

1,8 Kg/cm2

1 seat rear tyre pressure

1,9 Kg/cm2

2 seat rear tyre pressure

2,1 Kg/cm2

ø ø

PERIODICAL MAINTENANCE  TAB  TABLE LE FREQUENCY

OPERATION Engine oil

Check level/ level/ replenish

Every 3,000Km

Engine oil

Change

Renew every 6 months

Axle housing reducer oil level

Check

Renew every 24 months and check every 6 months

Spark plug/spark plug gap

Check/Renew

Renew every 12 months

Air filter

Clean

First check after 6 months then every 12 months

Oil filter filter

Change

Renew every 6 months

Valve play

Check

Check every 18 months

Check tick-over tick-over speed/Mixture speed/ Mixture

Adjust

Check every 12 months

Gas control

Adjust

Check every 12 months

Roller container

Renew & Check wear

Check every 6 months

 Transm  Transmiss ission ion belt

Change

Renew every 12 months

Cylinder cooling

Check

After the second year check every 24 months

Steering

Adjust

Check every 12 months

Brake control levers

Grease

Check every 12 months

Brake pads & linings

Check condition & wear

Check every 6 months

Flexible brake pressure pipes

Renew

First replacement after 36 months then every 36 months

Brake fluid leve l evell

Check

Check every 6 months

Brake fluid

Change

Every 2 years

 Transm  Transmiss ission ion (ex (excluding gas gas cont control) rol)

Lubrication

First check after 12 months then every 12 months

Locks

Check

Check every 24 months

Suspension

Check

First replacement after 24 months then every 24 months

Electrical wiring & battery

Check

Check every 6 months

Front headlight

Check/adjust Check/a djust

First replacement after 24 months then every 24 months

 Tyr  Tyre e condit condition ion & wear wear

Check condition & wear

First replacement after 12 months then every 6 months

 Tyre  Tyre pressure pressure

Check

Check every 6 months

 Tes  Testt vehicle vehicle & braking braking

Road test

Check every 6 months

NAME

 TIGHTE  TIGHTEN N ING IN G TORQU TORQUES ES (Nw x m)

Cranckase halves joining bolt

8 - 10

Cylinder head cover bolt

8 - 10

Cylinder-head studs

6-7

Bolt securing dylinder head and cylinder to the crankcase

8 - 10

Spark plug

10 - 15

Chain tensioner roller bolt

5-7

 Tim  Timing ing chain hain ten tens sioner ioner bolt bolt

8 - 10

 Tim  Timing ing chain hain ten tens sioner ioner cent entre bolt bolt

5-6

Camshaft pulley bolt

12 - 14

Rocker shaft and camshaft bearing bolt

3-4

Valve play adjusting locknut

7-9

Engine oil pre-filter plug

25 - 28

Engine oil drain plug

25 - 28

Magneto nut

40 - 44

Stator screws

3-4

Oil pump body bolt

4-5

O il pump/timing chain cavity cover cover bolts

4-5

Oil delivery labyrinth sheet bolts

7-8

PickPick- up bolts bol ts

3-4

Oil pump crown bolt

8 - 10

Bolts securing the oil pump to the crankcase

5-6

Oil pump connecting bolts

0,7 - 0,9

Oil sump bolts

8 - 10

Scavenge pipe bolts

7-9

Starter motor bolts

11 - 13

Crankcase cooling deflector bolt

2 - 2,5

Clutch assembly locking nut on pulley

55 - 60

Driven pulley nut

40 - 44

Crankshaft pulley nut

18 - 20

Plastic t. oil filler

3-5

 Tt  Ttrans ransm miss ission cover over screws rews Gearbox oil drain screw

+90º +90º

11 - 13 3-5

+90º

NAME

 TIGHTE  TIGHTEN N ING IN G TORQU TORQUES ES (Nw x m

M10x150 8.8 Securing shock - chassis top

30 - 40

M10x150 M10x150 8.8 Sec. Bottom Bottom shock - engine engi ne

30 - 40

M10x150 8.8 Sec. Sec. Engine - chassis chassis silentbloc silentbloc

30 - 40

M10x150 8.8 Sec. Engine mounting bolt

20 - 30

M8 x125 8.8 Sec. Rear engine - support

17 - 19

M10 x150 8.8 Sec. Rear engine - chassis

30 - 40

M6X100 8.8 Sec. Engine rear silentbloc flange

8 - 10

M14X200 Sec. Rocker

70 - 80

M16X125 Sec. Change out. gear housing

115 - 125

M35X100 Sec. Change out. gear

115 - 125

M6X 100 Sec. Engine - filter container

8 - 10

M6x100 Sec. Horn - chassis

8 - 10

M24X100 Sec. Steering fork - chassis

9 - 13

M6x100 8.8 Sec. Exhaust pipe - cylinder

9 - 12

M8x125 8.8 Sec. Exhaust pipe – Crankcase

17 - 19

M6x100 8.8 Sec. Steering lock - chassis

8 - 10

M8x125 8.8 Sec. Handlebars - steering forks

17 - 19

M8x125 8.8 Sec. Handlebar flange

17 - 19

M5x 80 8.8 Sec. Counterweight - handlebarss

3,4 - 4,5

M14x200 Sec. Front wheel - forks

35 - 50

M8x125 Sec. Fork arm lock

15 - 19

M6x100 Sec. Brake disk - front wheel

8 - 10

SEALER SEALER

M10x1. 5 Sec.Front rear brake caliper - forks

35 - 40

SEALE SEALER R

M14x200 M14x200 Sec. Rear wheel

70 - 80

M6X100 10.9 Sec. Drag plate - wheel

10 - 12

SEALER SEALER

M8x125 10.9 Sec. Brake disk - rear wheel

25 - 29

SEALER SEALER

M8x125 SEC. Sec. Prop stand - chassis

15 - 19

M10x150 10.9 Brake rod

35 - 40

M8x125 8.8 Sec. Sissy bar - chassis

17 - 19

M6x100 Sec. radiator - chassis

8 - 10

M5x80 Sec.Vari Sec.Various ous metal metal parts to to chassis chassis

3,5 - 4,5

M6x100 Sec.Vari Sec.Various ous metal metal parts to chassis chassis

8 - 10

M8x125 Sec.Vari Sec.Various ous metal metal parts to chassis chassis

15 - 19

M5x80 Sec. Various plastic parts to chassis chassis

1-2

M6x100 Sec. Various plastic parts to chassis chassis

2 - 3,5

Locktite Locktite 243-T 243-Type ype thread sealer

SEALER SEALER

SEALER SEALER

SPECIAL T PECIAL  TOO OO LS FREQUENCY

OPERATION 37x40 Adapter

020358Y

42x47 Adapter

020359Y

52x55 Adapter

020360Y

24mm Adapter

020456Y

Vacuum pump bearing fitting base

020265Y

Vacuum pump

020329Y

O il seal extrac extractor tor

020431Y

Bearing extractor extractor

004499Y

Magneto flywheel extractor

020162Y

12mm guide

020362Y

17mm guide

020439Y

20mm guide

020363Y

25mm guide

020364Y

Crankshaft aligning tool

020074Y

Crown wheel immobiliser

020451Y

Forked spanner

020565Y

Handle for punches

020376Y

Starter spring

020432Y

Blowlamp

020151Y

Bell punch

001467Y29

Bearing seal punch

020171Y

Seal fitting punch

020340Y

Valve seal fitting punch

020306Y

Magnetic bracket and comparer

020335Y

Shaft fitting tool

008119Y009

Assembly/ Assembly/dismantling dismantling tool tool

020452Y

Camshaft dismantling instrument

020450Y

Valve dismantling instrument

020382Y/

Valve dismantling instrument

020382Y/11

Clamp for fitting piston into cylinder

020288Y

Clutch dismantling and assembly instrument

020444Y

K AYABA AYABA FORKS FRONT For all ATLANTIS models, incorporating Kayaba hydraulics.

Dismantling fork stems - Loosen the wheel axle nut, remove the washer, loosen the 2 bolts on the front brake calliper, loosen the locking bolt, remove the wheel axle and the wheel spacer, and leaving the return hanging. - Remove the 4 bolts and washers from the front mudguard and remov r emove e the mudguard. - Loosen the strap locking bolt and remove the fork stem assembly. - Carry out the same procedure with the other stem. - Any element of the front suspension can now be renewed, or simply changing of their hydraulic fluid. Suspension Suspension travel: Diameter of the bars: O il capacity in each bar:  Ty  Type of oil oil :

65mm 26mm 47 c.c. AGIP FORK SAE 7,5 W

Fork stem assembly is carried out by reversing the dismantling proce pro cedure. dure.

REAR SHOCK  ABSORBER A TLAN  TLAN TIS 50/100 Shock absorber length Shock absorber travel Spring length Spring compression compression at 30 3 0 mm. Spring compression at 60 mm. Rod

257mm 60mm 191mm 142 Kgf mm 282 Kgf mm 10mm

A

50/100 C.C. 4 STROKE ENGINE Removing the engine from the frame - Disconnect the battery. - Remove the complete silencer. - Remove the rear wheel. - Dismantle the mechanical transmission from the rear brake.

- Disconnect the electrical terminals. - Dismantle the throttle control transmissions transmissions and mixer. mixer. - Disconnect the pipes - petrol, oil and vacuum valve control pipes.

WARNING  TAKE  TAKE THE UTMOST CARE WHEN HANDLING HANDLIN G PET PETRO L.

DISMANTLE ENGINE/ SHOCK  ABSORBER SUPPORT Remove bottom shock absorber nut. Remove emove engine engin e mounting nut nu t and shaft.

MOUNTING THE OUNTING  THE ENGINE IN  THE MACHINE Perform the same operations as for dismantling, butin the reverse order, respecting the tightening torques indicated.

Engine/ shock absorbers tightening torque: 30 - 40N•m

Engine/ engine mounting tightening torque: 33 - 40N•m

ATTENTION WHEN INSTALLING THE BATTERY, FIRST FIT THE POSITIVE CABLE AND THEN THE NEGATIVE CABLE.

WARNING IT IS RECOMMENDED THAT PROTECTIVE GLASSES BE WORN WHEN USIN G PERCUSSION PERCUSSION TO O LS. LS.

50 C.C 4T STROKE ENGINE DESCRIPTION

CHARACTERISTICS  Type

Single cylinder 4-st 4- stroke roke

Diameter

39 mm

Run

41,8 mm

Cylinder capacity

49,93 cm3

Compression Compression ratio

11,5 ÷ 12:1

 Tim  Timing ing Depression carburettor Lubrication

Power supply

Single overhead camshaft, two valves, driven by a chain on the left side. KEIHIN CVK Ø 18mm 18mm

WALBR WALBRO WP 16A

With chain-driven lobular pump (inside the crankcase). Net pre-filter and centrifugal filter housed above the crankshaft. Gravity fed, with lead-free petrol (minimum 95 octane) by way of a carburettor.

Cooling

By forced air

Max. power

2,5 Kw (3,4 HP) at 6500 rpm.

Ignition advance advance

Variable by microprocessor from 8° to 1500 rpm at 24° at 5000 - 6000 rpm

Spark plug

Champion RG 4 PHP

 Tran  Trans smiss ission

Champion RG 4 HC

With an expandable pulley automatic variator, torque compensator, V-belt, automatic clutch, gearbox.

Valve play (when cold)

Inlet: 0,10mm Exhaust: 0,10mm

Recommended engine oil

AGIP CITY 4T (4-stroke)

Quantity

~ 850 c.c.

Axle housing oil

AGIP GEAR SYNTH 75/90

Quantity

80 c.c.

4-stroke transmission variator 50 ratio

Per belt 3.07-0.93

100 C.C 4T STROKE ENGINE DESCRIPTION

CHARACTERISTICS  Ty  Type

Single cylinder cylinder 4-st 4- stroke roke

Diameter

50 mm

Run

50 mm

Cylinder capacity capacity

98,20 cm3

Compression Compression ratio

11,5 ÷ 12:1

 Tim  Timing ing

Single overhead camshaft, two valves, driven by a chain on the left side.

Depression carburettor

KEIHIN CVK Ø 18mm 18mm

Lubrication

With chain-driven lobular pump (inside the crankcase). Netting pre-filter and centrifugal filter housed above the crankshaft.

Power supply

Gravity fed, with lead- free petrol (minimum 95 octane) by way of a carburettor.

Cooling

By forced air

Max. power

5 Kw 9000 rpm

Ignition advance advance

Variable by microprocessor from 8° to 1500 rpm at 24° at 5000 - 6000 rpm

Spark plug

Champion RG 4 PHP

 Tran  Trans smiss ission

WALBR WALBRO WP 16A

Champion RG 4 HC

With an expandable pulley automatic variator, torque compensator, V-belt, automatic clutch, gearbox.

Valve play (when cold)

Inlet: 0,10mm Exhaust: 0,10mm

Recommended engine oil

AGIP CITY 4T

Quantity

~ 850 c.c.

Axle housing oil

AGIP GEAR SYNTH 75/90

Quantity

80 c.c.

4-stroke transmission variator 100 ratio

Per belt 2.89 - 0.79

CHECKING OIL OI L LEVEL Start the engine and bring it up to running temperature. - Turn off the engine and wait 5 – 10 minutes approximately, for the oil to drain into the reservoir. - Check the oil level using the inspection window on the reservoir.

Recommended oil: AGIP AG IP CITY CI TY 4T (4-STRO (4-STRO KE)

CHANGING  THE OIL OI L AND AN D FILTER Carry out the oil change with the engine hot. Place a container under the oil reservoir and remove the oil drain plug O nce the the oil has ha s been drained, the net filter fil ter needs to to be cleaned with a specific solvent and blown through with compressed air. The filter can be accessed by removing cover “A” (see figure). After this final operation, the filter needs to be refitted and the oil drain plug retightened to the prescribed torque using a new ring seal.

Locking torque: 25 – 28 N•m  Tigh  Tighte ten n suc succe ces ssively ively the oil drai drain n plug plug..

 Tightening  Tightening torque: torque: 25 ÷ 28 N·m Fill the engine with AGIP C ITY 4T four-stroke four-stroke oil using the oil filler hole at the top of the oil reservoir.

Engine oil capacity: capacity: ~ 850 cc. Screw the plug tight manually. N.B. RUN THE ENGINE FOR A FEW MINUTES, THEN RECHECK   THE  THE O IL LEVE LEVEL L WITH WITH THE THE ENGIN ENGI N E CO LD; LD; THIS THIS SHO SHO ULD BE ALWAYS BELOW THE MAX. LEVEL. N.B. IN THE CASE OF A FIRST FILLIN G O R A SERVIC SERVICE, E, INSER IN SERT T 850 CC OF ENGINE OIL; IN OTHER CASES, ALMOST 650 CC, AN D THEN AN Y N ECESSAR ECESSARY Y REPL REPLENISHM ENISHM ENT. ENT.

CHECKING THE HECKING  THE GEARBOX OI L LEVEL

AN D RENEWING .

 To  To chec check the the axle axle hous housing oil, oil, remov remove e the the dips dipstick ick plug plug “A” “A” indicated in the figure with the machine placed on the stand on flat ground. - Dry off the dipstick, reinsert and screw down completely, remove remove once more and check the the oil level as indicated in the figure. - To change the oil, remove the screw “B” indicated in the figure and drain the oil completely. - Reinsert the screw and tighten it to the prescribed torque. - Pour approximat app roximately ely 80 cc of oil into i nto the axle axle housing using the dipstick plug hole. - Check the level (with the plug completely screwed down).

Oil used: AGIP AGI P GEAR SYNTH 75/ 75/ 90

Oil drain screw tightening torque: 15 ÷ 17 N·m

SPARK  PLUG  To  To carry carry out inspec inspecttion of the the spark plug, plug, it is neces necess sary to perform the following operations with the engine cold.

1. Unscrew the 3 bolts in the lower seat panel; 2. Disconnect the spark plug HT connector cap; 3. Using the plug spanner from the toolkit, unscrew and remove the spark plug. - Examine it carefully, and if the insulation is chipped or damaged, renew it. - Measure the spark plug gap using a feeler gauge, and if it needs adjusting, very carefully bend the outer electrode. - Ensure that the sealing washer is in a good condition. - Refit the spark plug, screwing it in by hand and then tightening it with the toolkit plug spanner.

 Tightening  Tightening torque: torque: 10 ÷ 15 15 N ·m

Spark plug gap: 0,8 ÷ 0,9 mm

Recommended spark plug: Champion RG 4 HC N GK CR C R9E

INSTRUCTIONS FOR FITTING THE FITTING  THE BATTERY - Unscrew the three bolts from the bottom seating body. - Fit the battery in its housing. - Connect the positive and negative terminals.

- It is very important that the fuseholder is well secured to the battery holding flange.

DISMANTLING  THE ROCKER COVER N.B. BEFO BEFO RE DISMAN DISMA N TLIN TLIN G THE COVER CO VER,, REMO REMOVE VE THE CENTRE CENTRE BOLT FRO FRO M THE TIMIN G CHAI C HAIN N TENSIO N ER WITH ITS ITS CORRESPONDING SPRING AND WASHER – AN INDISPENSABLE BLE O PERATIO PERATION N TO PREVENT PREVENT EXCESSIVE EXCESSIVE TEN TEN SIO N ON ON  THE  THE TIMIN G CHAIN. CHAI N.  THIS  THIS IS PRO PRO DUCED BECAUSE BECAUSE THE TIMIN TIMIN G COVE CO VER R COM PRESSES THE BOTTOM CHAIN ROLLER. IF THE THRUST BOLT IS NOT REMOVED FROM THE CHAIN TENSIONER,  THE  THE LATT LATTER ER SHOO TS FORWAR FORWARD D O NC E THE THE COVER IS RE REMO VED, VED, AND AN D IN REFITT REFITTIN IN G, THE THE CH CHAIN AIN IS TO O TIGHT TIGH T, WHICH CAN C AN CAUSE C AUSE DAMAGE TO TO THE TIMIN G CHAIN CH AIN / RO LLER ASSEMBLY.

- Remove the 4 rocker cover fixings; Remove the cover with the ring seal.

DISMANTLING  THE THR  THE THRUST UST COVER O il delivery syst system em  The  The oil delivery delivery sy system tem is the the labyrint labyrinth h type type,, and theref therefore ore requires no maintenance.

N.B. IN THE EVENT OF HIGH MILEAGE OR LACK OF MAINTENANCE, THE LABYRINTH SHOULD BE SUITABLY CLEANED, BY REMO REMOVIN VIN G THE FOUR FO UR SCREWS SCREWS AN D THE PLATE PLATE CO VER.

FAN

COVER DEFLECTOR

Remove the 6 fixings indicated in the figure (two of which on the cylinder head side are fitted with knurled nuts).

ATTENTION DUR DU RIN G EXTRACTIO EXTRACTIO N O F THE THE DEFLECTOR, DEFLECTOR, TAKE TAKE CARE N O T TO DA M AGE THE ELEC ELEC TRIC TRICAL AL WIRIN WIRIN G O F THE THE STASTA TO  TO R.

FAN

COVER CASING

Dismantle cooling fan. Remove the three fixings indicated in the figure.

CHECKING THE HECKING  THE TIMIN  TIMING G  Turn  Turn the magnet agneto o in a cloc clockw kwis ise e dire direct ction ion until until the the 2nd 2nd grogroove on it is lined up with the pick-up reference groove, as shown in the figure. Ensure that the reference mark on the camshaf camshaftt crown wheel is lined up with the the reference point on the cylinder head, as shown in the second figure. When the reference mark is on opposite side to the mark on the cylinder head, turn the crankshaft backwards until they line up, since the piston should be in the top dead centre (T.D.S.) position on the ignition stroke.

CHECKING/ ADJUSTING VALVE PLAY  To  To perform perform a valv valve e play check, heck, the the tim timing ing refer referenc ence e marks marks need to coincide as described above.

Use a feeler gauge to check that the play between the valve and the rocker correspond to the values indicated. When the play values, of the inlet and exhaust valves respectively, are a re different dif ferent than those indicated, indi cated, adjust them by looloo sening the locknut and applying a screwdriver to the rocker as shown in the figure.

Inlet (with engine cold): 0,10 mm

Exhaust (with engine cold): 0,10 mm

REFITTING ROCKER COVER Perform the operations in the reverse order to dismantling, tightening the four screws to the prescribed torque.

- Fit the timing chain tensioner thrust bolt with the corresponding spring and seal.

N .B. FIT A NEW RING SEAL TO THE ROCKER COVER.

COVER CO VER SCREWS SCREWS locking torque: 8 ÷ 10 N·m

CHECKING FULL COMPRESSION

PRESSURE

- With the engine cold remove the spark plug HT cap.

Remove the spark plug. Insert a compression manometer tester into the spark plug hole using a 10mm spark plug thread and tighten it to approximately 10 - 15 N•m.  Turn  Turn the the engine engine over over with with the the start starter er and with the the carbucarburettor fully full y open until the manometer manometer indicator indi cator becomes stastable. If the pressure is normal, remove the tool and dismantle in reverse order. If pressures below those indicated are registered, check the engine revs at which the test reading was taken, and if it is low, check the starter installation. When revs are optimal or little higher, check the condition of the cylinder bottom gasket and the seals of the thermal part par t (piston rings, ring s, valves valves etc, etc, cylinder head and timing).

N.B. WHEN THERE ARE DIFFICULTIES IN INSERTING THE MANO METER METERTHREAD HREAD,, DISCON N ECT THE ENG ENG IN E CO NN EC TIO  TIO N BO LT- SWIN SWINGIN GIN G ARM AN D PUSH PUSH BACK THE ENG IN E ASSEMBLY ASSEMBLY EN EN O UG H TO ALLOW THE METER TO BE SCREWED IN.

Full compression compression pressure – Minimum Mi nimum acceptable acceptable value: 11. Kgr.

Engine revs: ~ 630 rpm (turning over with starter).

 TRANSMISSION

COVER

- Unscrew the 11 fixing screws. - Remove the oil filler cap and extract the cover.

N.B.  TO  TO EXT EXTRACT RACT THE COVER, COVER, TAP TAP THE CO RRESPON ESPON DING DIN G PRO PRO  TR  TRUSIONS USIO NS WITH WITH A WO WO O DEN DEN M ALLET ALLET.

If this operation is being performed directly on the machine, the air cooling hose needs to be extracted together with the air filter container fixings.

DISMANTLING  THE STARTER ASSEMBLY - Remove the starter sprocket, pressing the kick-start lever to aid its expulsion. - Remove the bolt and the kick-start lever. - Remove the ring seal and the washer indicated in the figure.

- Extract the splined shaft.

WARNING  THE  THE SHAFT KEEP KEEPS S THE SPR SPRIN ING G LOADED. PAY PAY ATT ATTENTION  TO  TO PREV PREVENT ENT ACCIDENTS. ACCIDENTS.

DISMANTLING  THE SUCTION

NOZZLE

- To dismantle the suction nozzle from the transmission cover only requires removal of the three screws indicated in the figure.

DISMANTLING  THE DRIVEN PULLEY SHAFT SUPPORT BEARING - Slightly heat the crankcase on the inner side to avoid damaging the painted surface, and with the aid of the driven pulley shaft or a bolt of the same diameter, extract the bearing.

ASSEMBLING THE SSEMBLING  THE DRIVEN PULLEY SHAFT SUPPORT BEARING - Fit the bearing with the aid of a bush of the same diameter as the outer outer diameter of the bearing, after a fter having heated the crankcase slightly on the inner side.

N.B. WITH EACH REFITTING, ALWAYS RENEW THE BEARING.

ATTENTION DURING THE BEAR BEARIN IN G REMO REMO VAL AND AN D REFITT REFITTIN IN G O PERAPERA TIO  TIO N S, TAKE CARE CARE NO T TO TO DAMAGE THE PAIN PAINT TED SURSURFACE.

RE- ASSEMBLING  THE STARTER ASSEMBLY - Check for any possible wear to the toothed section, on the splined shaft, on the seat housing in the cover, in the shaft sprocket, the corresponding seat on the crankcase, and the return spring. - Renew all damaged parts. - Grease the spring with AGIP GR MU 3. - Assemble the toothed assembly loading the spring using the special tool. - Fit the washer, the Seeger ring and the kick-start lever.

Special Special tool:  Tool  Tool for for fitt fitting starte tarterr sprin spring: g: 020432Y - Fit the sprocket in its seat while pressing on the kick-start lever. - Fit the suction nozzle ring seal on to the transmission cover.

- Fit the suction nozzle and tighten the 3 screws.

DISMANTLING DRIVING PULLEY - Lock the driving pulley in position using the specified tool.

- Unscrew and remove the centre nut with washer, remove the movement take-off and the plastic fan.

- Remove the fixed semi-pulley.

- Remove the belt and the limiting washer, and extract the mobile semi-pulley with its corresponding bush, paying attention to the expulsion of the rollers fitted freely to the same. - Extract the roller contrast plate with respective guide rollers.

Special Special tool: Driving pulley detaining spanner: 020451Y

DISMANTLING  THE DRIVEN

PULLEY

Lock the clutch bell using the special tool. - Remove the nut, the clutch bell and all the driven pulley assembly

N.B.  THE  THE ASSEMB ASSEMBL LY CAN ALSO ALSO BE DISMANT DISMAN TLED LED WITH WITH THE DRIDRIVING PULLEY FITTED.

Special Special tool: Forked spanner: 020565Y - Check that the clutch bell is not worn or damaged. - Measure the internal diameter of the clutch bell.

Standard Standard value: Ø 107 +0,2 +0 mm.

Max. value: Ø 107,5 107,5 mm

N.B. CHECK THE ECCENTRICITY MEASUREMENT: MAX 0.20 MM

DISMANTLING  THE CLUTCH - Fit the tool with the long bolts tightened on the outside in position “A”, insert the driven pulley assembly into the tool and fit the central bolt.

ATTENTION AN EXCESSIVE TIGHTENING OF THE CENTRAL BOLT WILL DISTORT THE TO TO O L.

- Using a 3 mm Allen key, extract the clutch locking nut. - Loosen the central bolt, unloading the driven pulley assembly spring. - Separate the components.

Special Special tool: Clutch dismantling/assembling tool: 020444Y

BOLT RETAINING COLLAR - Extract the collar with the help of 2 screwdrivers. - Remove the 3 guide bolts and the mobile semi-pulley.

FIXED DRIVEN

SEMI- PULLEY BEARING

- Check for signs of wear and noise, and if these exist, renew them. - Remove the roller bearing using a pin of a suitable diameter (approximately 10 mm) and a hammer, at the side shown in the figure.

N.B. HOLD THE SEMI-PULLEY SUITABLY TO PREVENT THE TRANSMISSIO MI SSION N BEL BELT SLIDIN G SURFACE SURFACE FRO FRO M BEIN BEING G DISTORTED. DISTORTED.

- Expel the the ball bearing beari ng assembly assembly using: a punch holder, 20 mm guide.

Special Special tools: Bell: 001467Y029 Punch holder: 020376Y 20 mm guide: 020363Y.

FIXED DRIVEN

SEMI- PULLEY

- Measure the outer diameter of the pulley bush.

Minimum Mi nimum admitted admitted diamet di ameter: er: Ø 33,96 mm

Standard Standard diameter: diameter: Ø 33,965 ÷ 33,985 mm

MOBILE DRIVEN SEMI- PULLEY. - Remove the 2 internal seals and the two ring seals. - Measure the internal diameter of the mobile semi-pulley bush.

Maximum admitted diameter: Ø 34,08 mm

ASSEMBLING THE SSEMBLING  THE DRIVEN

SEMI- PULLEY BEARINGS

- Fit a new ball bearing assembly using the special tools. - Fit the ball bearing assembly elastic securing ring. - Fit the new roller bearing with the inscription visible on the outside.

ATTENTION HOLD THE SEMI-PULLY SUITABLY TO AVOID DAMAGING  THE  THE THREADE HREADED D END END DURING THE BEAR BEARIN IN G FITTIN FITTING. G.

Special Special tools: Punch holder: 020376Y

Ø 24 mm adapter: adapter: 020456Y

12 mm guide: 020362Y

Punch for roller bearings: 020171Y

ASSEMBLING THE SSEMBLING  THE MOBILE DRIVEN SEMI - PULLEY - Check the surfaces in contact with the belt. - Fit the new oil seals and the ring seals to the mobile semipulley - Fit the semi-pulley onto the bush.

ATTENTION  TAKE  TAKE CARE WHEN FITTIN FITTING G THE MO BILE DRIVE DRIVEN N SEMI-PULLEY NOT TO DAMAGE THE OIL SEALS.

- Check that there is no wear to the bolts and to the collar, and fit the bolts and the collar. - Using a grease gun with a curved nozzle, grease the driven pulley assembly with approx. 6 gm of AGIP GR MU 3 grease. This operation should be performed through one of the holes on the inside of the bush until grease emerges from the opposite hole. This operation is necessary to prevent the presence of grease outside the ring seals.

SPRING. - Measure the free length of the mobile driven semi-pulley spring.

Standar Standard d length: 110 mm - Check the thickness of the clutch plate friction material.

Minimum admitted thickness: 1 mm mm - The material must show no signs of lubricants. If there are any, check the driven pulley assembly.

N.B.  THE  THE FRICTION FRICTION MATER MATERIAL O N THE TURNING SURFA SURFACE CE SHOULD PRESENT A CENTRAL CONTACT SURFACE AND SHOULD SHO ULD NO T DIFFERENT DIFFERENT O N E FRO FRO M THE OTHER. OTHER. DIFFEDIFFERENT CO NDITION ND ITION S MAY C AUSE THE THE CLUTCH TO BRE BREAK AK UP U P.

ATTENTION DO N O T O PEN UP THE M ATERIAL ATERIAL WITH WITH TO TO O LS, TO PREPREVENT A LO LO AD VARIATIO VARIATIO N O F THE THE RET RETURN URN SPRING S.

ASSEMBLING THE SSEMBLING  THE CLUTCH ASSEMBLY - Pre-fit the driven pulley assembly with spring, case and clutch.

- Fit the components to the tool and preload the spring, taking care not to damage the plastic case and the end of the threaded pin. - Fit the clutch assembly in the reverse order to dismantling.

ATTENTION  TO  TO AVO AVO ID DAMAGIN DAM AGIN G THE CLUTCH CLUTCH N UT, UT, USE AN ALLEN ALLEN KEY WITH A SMALL SMA LL BEVEL BEVEL..

 Tightening  Tightening torque: torque: 55 ÷ 60 N·m

 TRANSMISSION

BELT

- Check that the transmission belt is not damaged. - Check the width of the belt. Minimum width: 17, 5 mm

DRIVING PULLEY - Check that the internal bushing shown in the figure is not abnormally abnor mally worn and measure measure the internal diameter di ameter “A” “A”.

Maximum admitted diameter: 20,12 mm

Standar Standard d diameter: diameter: 20,021 mm

ATTENTION DO NOT GREASE OR CLEAN THE BUSHING. - Measure the external diameter “B” of the sliding pulley bush shown in the figure.

Minimum Mi nimum admitted admitted diamet di ameter: er: Ø 19,95 19,95 mm

Standar Standard d diameter: diameter: Ø 19,959 19,959 mm

VARIATOR ROLLERS - Check that the rollers are not damaged or worn.

Minimum Mi nimum admitted admitted diamet di ameter: er: Ø 18,5 mm

Standar Standard d diameter: diameter: Ø 18,9 mm - Check that the roller contrast plate runners are not worn. - Check the condition of the roller seating slots and of the surfaces where the belt makes contact with both semi-pulleys (mobile and fixed).

ASSEMBLING  THE MOBILE SEMI- PULLEY AND AN D BUSH - Prefit the mobile semi-pulley with the roller contrast plate, fitting the rollers as in the figure, i.e. during insertion, the closed side must be to the left, at the pushing part of the pulley. - Fit the assembly with the bush on the crankshaft.

- Separate the mobil mobile e driven semisemi-pulley pulley manually by pulling pulli ng towards the clutch assembly, and fit the belt, respecting the turning direction of the original assembly. It is very important that at the moment of securing the driven pulley pull ey,, the belt is free inside i nside it, to avoid making a false tightening and succes successive sive damage to the crankshaft.

N.B. IT IS GO G O O D PRACTICE PRACTIC E TO TO ALWAYS ALWAYS FIT THE THE BELT BELT WITH THE INSCRIPTIONS READABLE IN THE CASE OF A FITTING DIRECTIO ECTIO N NO T BEING BEING IN DICATED DICATED..

ASSEMBLING THE SSEMBLING  THE FIXED SEMI- PULLEY - Assemble the parts that make up the assembly (roller cage assembly with bush, limiting washer, fixed semi-pulley, cooling fan, belt with drive take-off, washer and nut).

- Tighten the locking nut to torque 20 N•m and perform successively a definitive tightening of 90º, using the special tool to prevent the driving pulley from turning.

N.B. REPLACE THE THE NUT N UT WITH A NEW N EW ON E FOR EVER EVERY REFITTIN REFITTING. G.

 Tightening  Tightening torque torque plus angle: 18 ÷ 20 N·m + 90°

Special Special tool: Driving pulley holding spanner: 020451Y

ASSEMBLING THE SSEMBLING  THE CLUTCH BELL - Fit the driven pulley assembly, the clutch bell and the nut, using the special tools.

 Tightening  Tightening torque: torque: 40 ÷ 44 N ·m

Special Special tool: Forked spanner: 020565Y

FITTING  THE TR  THE TRAN ANSMIS SMISSION SION

COVER

- Ensure that the centring pins and the sealing gasket on the oil reservoir are present. - Fit the cover by tightening the 11 screws to the prescribed torque. - Fit the oil filler plug.

Cover tightening tightening torque: 11 ÷ 13 N·m N ·m

ASSEMBLING REAR BRAKE HOLDING SHOES - Remove the rear brake holding shoes by turning one of the two as in the figure.

N.B. WHEN THIS OPERATION IS CARRIED OUT ON THE MACHIN E, THE SILENC SILENC ER FIRST N EEDS TO BE DISMA N TLED TLED TO TO GETHER WITH THE REAR WHEEL.

DISMANTLING

REAR BRAKE CONTROL LEVER AN D CAM

- Remove the cam control lever locking screw and extract the cam, taking care with the seal.

N.B. FOR FO R EASY EASY EXTR EXTRACTIO ACTION, N, DO N O T TURN TURN THE CAM CA M DURING DURIN G DISMANTLING.

REAR AXLE HOUSING - Drain the rear axle housing housing oil. - Remove the 5 screws indicated in the figure. - Remove the axle housing cover with the driven pulley shaft.

DISMANTLING  THE WHEEL AXLE - Remove the intermediate gear assembly and the wheel axle with the gear assembly. - When the intermediate gear assembly is extracted, pay attention to the adjustment washers.

DISMANTLING

WHEEL AXLE BEARING

- Remove the oil seal and the Seeger ring. - Remove emove the bearing beari ng by pushing from the outer side into in to the gear assembly cavity using the corresponding punch.

Special Special tools: Punch holder: 020376Y

20 mm guide: 020363Y

37x40 adapter: 020358Y

DISMANTLING  THE DRIVEN

SEMI- PULLEY

- Fit the special tube onto the internal bearing guide and on the side of the pulley shaft teeth as indicated in the figure and expel the pulley shaft with the aid of a press.

Special Special tool:  Tube  Tube for ass assemblin embling/dism g/dismant antling ling driven driven pulley pulley shaft: haft: 020452Y

CHECKING THE HECKING  THE AXLE HOUSING SHAFT AND AN D COVER - Check that the three shafts show no wear or distortions to the toothed surfaces, in the bearing surfaces and the oil seals. - If anomalies are detected, the toothed parts should be renewed. - Check that the flat joining surface has no indentations or distortions. - If any anomalies are detected, renew the axle housing cover.

DISMANTLING  THE DRIVEN

PULLEY SHAFT BEARING

- Remove the Seeger ring in the inside of the cover. - Remove the oil seal from the outside. - Remove the two centring pins and place the cover on a flat surface. - Fit the special tool onto the internal bearing guide and with the aid of a press, expel the latter.

Special Special tool:  Tube  Tube for ass assemblin embling/dism g/dismant antling ling driven driven pulley pulley shaft: haft: 020452Y

ASSEMBLING DRIVEN

PULLEY SHAFT BEARING

- Slightly heat the axle housing cover and insert the bearing with a suitable punch. - Fit the elastic ring with the concave or radiated part on the bearing side.

N.B. FIT THE BALL BALL BEARING BEARING ASSEMBLY ASSEMBLY WITH THE IN SULATIO N  TOWAR  TOWARDS DS THE O IL SEAL. SEAL.

Special Special tools: Blowlamp: 020151Y

Punch holder: 020376Y

17 mm guide: 020439Y

37 x 40 mm adapter: 020358Y

ASSEMBLING DRIVEN

PULLEY SHAFT

- Hold the internal bearing guide through the outer side of  the axle housing cover with the special tool fitted under the press, and insert the driven pulley axle. - Fit the oil seal flush with the cover.

Specific tool:  Tube  Tube for fitt fitting/dism ing/dismantling antling driven driven pulley pulley shaft: haft: 020452Y

ASSEMBLING  THE WHEEL AXLE BEARING - Heat up the transmission side of the casing half using a blowlamp. - Insert the bearing, having greased the outer plate, using the adapter and with the aid of a hammer. hammer. - Fit the Seeger ring and oil seal with the aid of the 42 x 47 mm adapter and the holder.

Special Special tools: Blowlamp: 020151Y

Punch holder: 020376Y

20 mm guide: 020363Y

42 x 47 adapter: 020359Y

ASSEMBLING THE SSEMBLING THE WHEEL AXLE AND AN D THE AXLE HOUSING COVER - Fit the wheel axle complete. - Fit the intermediate gear, taking care with the adjustment foils. - Apply Appl y LO LO C TITE 510 to to the axle housing cover cover flat fla t contact contact surfaces and fit the cover with the driven pulley shaft. - Insert the 5 screws and tighten to the prescribed torque.

N.B. CLEAN THE AXLE HOUSING COVER AND HALF CASING CO N TACT SURFACES SURFACES TO TO REMOVE EMO VE RESIDUE OF O F PREVIO PREVIOUS US SEALS BEFO BEFOR RE APPLYIN APPLYIN G A N EW SEAL. SEAL.

 Tightening  Tightening torque: torque: 24 ÷ 26 N·m

ASSEMBLING THE SSEMBLING  THE REAR BRAKE CAM - Check Che ck that that the cam and the rear brake b rake axle are not showing signs of wear. - If anomalies are found, renew the cam. - Fit a new ring seal, greased with AGIP GR MU 3. - Fit the cam and the lever onto the engine crankcase, taking care to line up the two sections using the double cog indicated in the figure. - Tighten the bolt to the prescribed torque.

 Tightening  Tightening torque: torque: 11 ÷ 13 N·m N ·m

ASSEMBLING THE SSEMBLING  THE REAR BRAKE SHOES - Check the minimum thickness of the friction material on the brake shoes. - Minimum thickness 1 mm. - Check that there is no wear to the cam supports and the bolt.

- Check that the springs are not worn or damaged. - If anomalies are found, renew the shoes. - Fit the shoes together together with the springs in the opposite order to the dismantling.

N.B. IF THE REAR REAR BRAKE IS FOUN FO UN D TO TO BE N O ISY, CHECK THAT  THE  THE SHO SHO ES ARE ARE RES REST TING IN G CO C O RRECTLY CTLY O N THE BO BO LT. FOR  THE  THE SAME REASON REASON,, THE SPR SPRIN GS SHOU LD TAKE ON ON A CUR CU RVED PO PO SITIO N , REST RESTIN IN G O N THEIR RESP RESPECTIVE ECTIVE SUPPORTS PPORTS LO LO CATED CATED O N THE AXLE HO USIN G.

DISMANTLING  THE TUR  THE TURB BIN E COVER - Remove the turbine cover by unscrewing the 6 securing screws.

ATTENTION DURING THE EXTRACTION, REMOVE THE CONNECTOR FROM ITS HOUSING ON THE TURBINE COVER.

DISMANTLING  THE COOLING  TURB  TURBINE IN E - Remove the cooling fan by unscrewing the 3 fixings indicated in the figure.

DISMANTLING  THE MAGNETO - Prevent the magneto flywheel from turning using the forked spanner. - Extract the nut.

ATTENTION  THE  THE USE O F A FORKED FORKED SPAN SPANNER NER THAT IS NO T PART ART O F THE BASIC BASIC EQUIPMENT EQU IPMENT MAY M AY DAMAGE DAM AGE THE STAT STATO O R COILS COI LS..

Using the extractor extractor,, carry out the extraction extraction of o f the magneto.

Special Special tools: Forked spanner: 020565Y Magneto extractor: 020162Y

DISMANTLING  THE STATOR - Remove the 2 screws on the pick-up and the 2 stator securing screws indicated in the figure. - Remove the stator and the corresponding wiring.

REFITTING  THE MAGNETO - Fit the magneto, taking care to insert the cotter pin correctly

- Tighten the magneto flywheel nut to the prescribed torque. - Check that the pick-up air gap is between 0.5 and 0.6 mm.

Assembly of the pick-up does not involve adjustment of the airgap. Different Dif ferent values derive from distortions caused to the pickpick- up support.

N.B. A VARIATION OF THE AIR GAP DISTANCE MAY CAUSE A VARIATION IN THE IGNITION ADVANCE THAT MAY LEAD  TO  TO BACKFIRIN BACKFIRING, G, ETC. ETC.

 Tightening  Tightening torques torques:: Magneto flywheel nut: 40 ÷ 44 N ·m Magneto fan screws: 3 ÷ 4 N·m Cooling deflector screws: 2 ÷ 2,5 2,5 N·m N ·m

ASSEMBLING  TURB  TURBIN E COVER/ MAGNETO

DEFLECTOR

- Fit the fan onto the magneto flywheel. - Fit the fan cover, tightening the 6 screws.

ATTENTION PAY ATTE ATTEN N TION TO THE CO RRECT PO PO SITIO SITIO N O F THE THE MAG NETO NETO CO NN ECTO CTO R.

- Ensure that the spacers are fitted to the two rear deflector fixings. - The long spacer must be fitted at the top.

LUBRICATION

DISMANTLING  THE OIL OI L RESERVOIR - Remove the oil filler plug, the transmission cover, the driving pulley assembly and the sprocket. - Drain the oil from the collector by removing the oil drain plug “A” indicated in the figure. - Remove the 6 bolts indicated in the figure.

DISMANTLING  THE OIL OI L PUMP - Remove the chain housing cover by unscrewing the 3 securing bolts indicated in the figure.

- Extract the cover using the lugs welded to the cover itself.

- Remove the pump drive gear ring cover with the 2 fixings indicated in the figure. - Stop the oil pump drive gear from turning by using a screwdriver inserted into the inside through one of its holes.

- Extract the centre bolt with the cup washer indicated in the figure.

- Extract the chain with the gear ring. - Extract the drive sprocket from the crankshaft. - Extract the oil pump by undoing the 2 fixings indicated in the figure. - Extract the seal.

N.B. IT IS ADVISABLE TO MARK THE CHAIN TO ENSURE THAT  THE  THE TURNIN G DIRECT DIRECTIO IO N IS MAIN TAIN ED. ED.

CHECKING  THE OIL OI L PUMP - Remove the two screws and the oil pump cover. - Remove the elastic internal rotor retaining ring. - Remove the rotors, and thoroughly clean them using a degreasing. - Fit the rotors to the pump body, keeping the 2 reference marks in sight. Fit the securing ring.

- U se a feeler gauge to check the the gap between the rotors (inner rotor/outer rotor) in the position indicated in the figure.

Admitted play limit: 0,15 mm

- Check the gap between the outer rotor and the pump body – see figure.

Admitted play limit: 0,20 mm

- Check the axial play of the rotors using a flat bar as a reference level, as in the figure.

Admitted value limit: 0,09 mm

N.B. ENSURE EN SURE THAT THAT THE FLAT BAR IS RESTIN RESTING G CO C O RRECTL RRECTLY Y ON  THE  THE TWO TWO PO INTS IN TS O F THE THE PUMP BO DY SURFA SURFACE. CE.

ASSEMBLING THE SSEMBLING  THE OIL OI L PUMP - Check that there is no wear to the shaft-pump body. - Check that the pump cover is not worn or scratched. - If values are wrong or scratches present, renew the faulty parts or the whole assembly. assembly. - Fit the cover to the pump, taking care to line up the holes (2 on the cover and 2 on the pump body) for securing the oil pump to the crankcase. - Fit the oil pump to the crankc crankcase ase and tighten the two screws to the prescribed torque. - Fit the pulley to the pump, with the centre bolt tightened to the prescribed torque and the cup washer. - Check that the pulley rotates without catching and/or rubbing.

N.B. FIT THE CUP CU P WASHER WITH THE OUTER O UTER (CU RVED) PERIM PERIM E TER  TER IN CO N TACT WITH WITH THE THE PULLE PULLEY. Y.

Centre bolt tightening torque: 12 ÷ 14 N·m

Cover screws tightening torque: 0,7 ÷ 0,9 N·m

Oil pump bolt tightening torque: 5 ÷ 6 N·m

Chain cover: - VCheck that there is no wear to the chain guide roller.

- If wear is found, renew it or fit it the other way round, so that it runs on the other side. - O perations involving the chain chain cover oil seal s shoul hould d be performed with the cover lying on the workbench on the oil pump chain cover side. - Remove the oil seal using a length of tubing of approx. 30 mm diameter (Ø 32 mm Max.). - Fit a new oil seal flush with the outer edge, with the aid of the special tools indicated below. - Fit a new ring seal and grease it.

- Fit the cover to the engine crankcase, insert the three bolts and fit the cover into its seat. - Tighten the 3 bolts to the prescribed torque.

Special Special tools: Holder for adapters: 020376Y 37 x 40 mm adapter: 020358Y  Tigh  Tighte tening ning torqu torque: e: 4 ÷ 5 N·m

ASSEMBLING THE SSEMBLING  THE OIL OI L RESERVOIR - Clean and degrease the contact surfaces. - Apply Appl y LO LO C TITE 510 to to the collector surface and tighten the 6 securing bolts to the prescribed torque. - Fit the driving pulley assembly, the belt, the sprocket and the transmission cover.

 Tightening  Tightening torque: torque: 8 ÷ 10 N·m

DISMANTLING COOLING DEFLECTORS - Loosen the clamp and remove the carburettor from inside the collector. - Remove the collector by unscrewing the 2 fixings indicated in the figure. - Remove the two self tapping bolts, right and left, and the side securing bolt on the base of the crankshaft. - Remove the two deflectors. - Remove the gasket sealing the deflectors to the cylinder head.

ATTENTION IF THE MAGNETO DEFLECTOR HAS NOT BEEN REMOVED, IT IS ALSO NECESSARY TO REMOVE THE TWO SPHERICAL SCREWS FITTED FI TTED TO TO THE LATTER.

DISMANTLING  THE TIMIN  THE TIMING G CHAIN  TEN  TEN SIONER IO NER - Previously loosen the chain tensioner centre bolt and extract it with its spring and washer.

- Loosen the 2 fixings indicated in the figure and remove the tensioner tensioner bracket b racket,, taking care to recover the the seal.

DISMANTLING  THE TIMIN  THE TIMING G DRIVE - Previously remove the parts indicated below: transmission cover, driving pulley with belt, starter sprocket, oil reservoir, chain cover, oil pump pulley protection, chain and oil pump pulley and the sprocket separator separator washer. washer. - Remove the rocker cover. - Remove emove the centre bolt and the cup washer indicated in dicated in the figure, locking the camshaft crown wheel with the special tool.

N.B.  TO  TO AID THE EXT EXTRACTION RACTION O F THE THE CYLINDER HEAD COM PON PO N ENTS, IT IS ADVISABLE TO PUT THE THE CRAN KSHAFT KSHAF T AT CO MPRESSIO MPRESSION N STRO STRO KE TO TO P DEAD CENTRE. CENTRE.

(T.D.C). Special Special tool: Forked spanner: 020565Y

- Remove the camshaft drive sprocket and the spacer found below it.

- Remove the timing drive sprocket from the crankshaft.

- Remove the bolt indicated in the figure, the spacer and the tensioner roller.

N.B. IT IS ADVISABLE TO MARK THE CHAIN TO ENSURE THAT  THE  THE TURN TURN ING IN G DIRE DIRECTION IS MAINTAINED. MAI NTAINED.  THE  THE BOTT BOTTO O M C HAIN GUIDE GU IDE RO RO LLER LLER CAN BE EXT EXTRACTE RACTED D FROM THE CYLINDER HEAD, EXTRACTING UPWARDS.

DISMANTLING  THE CAMSHAFT AND AN D ROCKERS - Removing the securing nut from the bearing indicated in the figure.

- Remove the camshaft with the bearing, using the special tool shown in the figure.

- Remove the bearing from the camshaft with the aid of the special tool, taking care to fit a bolt on to the camshaft to protect the shaft thread.

N.B. IN THE EVEN EVEN T OF THE CAMSHAFT CA MSHAFT BEARIN BEARIN G SEPARASEPARA TING,  TING, A NEW BEARIN EARING G MUST BE FITTED FITTED..

Special Special tools:  Tool  Tool for for dism dismantling antling// ass assemblin embling g the the cams amshaft: haft: 020450Y Bearing extractor: extractor: 004499Y (equipped with parts: 1, 2, 3, 6, 27)

- Extract Extract the rocker shaft from the magneto side and at the same time remove the rockers.

N.B. M ARK THE THE FITTING FITTIN G PO SITION SITIO N O F THE THE RO RO CKER CK ERS S TO TO PREPREVENT SWITCHING THE INLET WITH THE EXHAUST.

HEAD GASKET  The  The engin engines es ment mentione ioned d are built built wit with h two two head gask gasket sosolutions:

- Fibre gasket - Steel Steel gasket

with cylinder cylinderss of 56.44 mm height. with wi th cylinders cylinder s of 57.1 57.15 5 mm height. heigh t.

Con el objeto de garantizar una correcta relación de compresión las dos juntas se acoplan con cilindros de distinta altura:

- J unta de fibra - J unta de acero

con cilindro de 56,45 mm de altura. con cilindro de 57,1 57,15 5 mm de altura.

Both gaskets are supplied as replacement parts for carrying out servicing.  The  The gudgeo gudgeon n pin pin pis piston ton cy cylinder linder ass assemblie emblies s supplied upplied for replacement parts are all with cylind cylinders ers of 57.44 .4 4 height.

DISMANTLING  THE CYLINDER HEAD - Remove the cooling deflectors, the timing drive, the camshaft and the rockers. - Remove the spark plug. - Remove the 2 side fixings indicated in the figure. - Loosen in two or three goes and in cross sequence the 4 cylinder head securing bolts - Remove the cylinder head, the 2 centring pins and the gasket.

N.B. IN CASE OF NEED, THE CYLINDER HEAD CAN BE EXTRACTED WITH THE THE CAMSHAFT CA MSHAFT AND ROC KERS, KERS, AND WITHO UT REMO REMO-VIN G THE DRIVEN PULLEY PU LLEY ASSEMBLY, ASSEMBLY, BUT FO R THIS, THI S, THE TIMING CHAIN NEEDS TO BE SECURED WITH A METAL WIRE AND AN D THE CHAIN TEN TEN SIONER SIO NER ADJU STED STED DURING ASSEMBL ASSEMBLY.

DISMANTLING  THE VALVES - U sing the special special tool (020382Y/ ( 020382Y/ 11) with the part in the figure, carry out the dismantling of the collets, the retaining plates and the springs of both valves.

Special Special tool:  Tool  Tool for for dism dismantling antling// ass assemblin embling g valv valves es:: 020382Y

- Remove the oil seal with the corresponding tool.

- Remove the bottom spring supports.

Special Special tool: Valve oil seal extractor: 020431Y

DISMANTLING

PISTON CYLINDER

- Remove emove the cylinder. Paying attention to the 2 cylinder centring pins on the crankcase. - Remove the cylinder bottom gasket.

ATTENTION  TO  TO PREV PREVENT ENT DAM DAM AGE TO TO THE PIST PISTO N, HO LD IT DURIN DURING G  THE  THE CYLINDER DISMANTLING.

- Remove the 2 stop rings, the gudgeon pin and the piston. - Remove the 3 piston rings.

N.B.  TAKE  TAKE CARE NO T TO DAM AGE THE PIST PISTO N RIN RINGS GS DURIN DURING G DISMANTLING

CHECK  THE HECK  THE CONNECTING ROD SMALL END - Use a micrometer to measure the inner diameter of the small end.

Standard diameter: 13+0.025 +0.015 mm Maximum admitted diameter: 13.030 mm N.B. WHEN THE CONNECTING ROD SMALL END DIAMETER IS G REATER REATERTHAN THA N THE TH E ADMITTED ADM ITTED DIAMETER DIA METER,, APPEARS WORN WO RN O R O VERHEATS VERHEATS,, REPLACE REPLACE THE CRAN KSHAFT KSHAF T AS DESCRIDESCRIBED BED IN THE “CRAN “CRANKCASE KCASE AND C RANKSHAFT” CHAPTE CH APTER R. - Check the outer diameter of the gudgeon pin.

Standard diameter: 13 -0 -0.004 mm Minimum admitted diameter: 12.990 mm

- Calculate the piston gudgeon pin coupling play.

Standard piston diameter: 13 +0.010 +0.005 mm Standard Standard play: 0.005 - 0.014 0.014 mm

CHECKING  THE PISTON - Measure the outer diameter of the piston at right angles to the gudgeon pin axis. - Carry out the measurement at 27mm from the piston port, as shown in the figure.

CHECKING  THE CYLINDER - Use a calliper gauge to measure the inner diameter of the cylinder, according to the directions indicated in the figure and at the three different heights. - Check that the flat surface mating with the cylinder head show no signs of wear or distortion.

Maximum admitted unevenness: 0,05 mm - Pistons and cylinders are classified according to diameter.  The  The coupling oupling is done done in pairs pairs (A-A, B-B,C-C,DB-B,C-C,D- D).

REBORING  THE CYLINDER - The operation operation of o f cylinder reboring must be performed with a finish that respects the original angulations: at 120º crossed.

- The cylinder surface must present a roughness of R.A. = 0.30 ÷ 0.50. - This is indispensable to ensure a good fitting of the piston rings, thereby ensuring reduced oil consumption and optimum performance. - O versized versized pistons are available availabl e for rebored cylind cylinders, ers, subsubdivided into two categories, 1st and 2nd, equal to an increase of 0.2-0.4 mm. These are also classified into the 4 categories A-A, B-B, C-C, D-D.

 THE PISTON - Carry out a thorough cleaning of the piston ring housing slots with the aid of an old piston ring. - Using a feeler gauge, measure the coupling play between the piston rings and their slots as shown in the figure. - If a greater play than that shown in the table is found, renew the piston and the piston rings.

Standard coupling play:

Admitted plays after use

1st segment

0,030 ÷ 0,065

0,080

2nd segment

0,020 ÷ 0,055

0,070

O il scraper scraper

0,040 ÷ 0,160

0,20

Values in mm

PISTON

SEGMENTS

- Insert the 3 piston rings into the cylinder in rotation, in the area where the latter maintains its original diameter. Insert the piston rings at right angles to the cylinder axis, using the piston for this purpose. - Measure the piston ring gap (see figure) using a feeler gauge.

- If greater values than those shown in the table are found, replace the segments.

N.B. BEFORE PROCEEDING TO REPLACE THE SEGMENTS, ENSURE THAT THE INSTRUCTIONS REGARDING PISTON RING CO UPLING UPLIN G PLAY WITH THE THE SLOTS SLOTS AND AN D THE PIST PISTO O N WITH  THE  THE CYLINDER ARE ARE RESPE SPECTED. CTED. IN ANY EVENT, NEW PISTON RINGS FITTED TO A USED CYLIN DER MY PRES PRESENT ENT SEAT SEATIN IN G CO C O N DITION DITIO N S DIFFERENT DIFFERENT  TO  TO THE STAN STANDAR DARD D CON DITIO DITIO N.

Standard value

Maximum value

1st segment

0,08 ÷ 0,20

0,35

2nd segment

0,05 ÷ 0,20

0,30

O il scraper scraper

0,20 ÷ 0,70

0,8

Valores en mm

ASSEMBLING  THE PISTON - Fit the piston piston and the gudgeon gudgeo n pin onto on to the connecting connecting rod, with the arrow pointing towards the exhaust. - Insert the gudgeon pin stop ring in the special tool.

Special Special tool:  Tool  Tool for for fitt fitting gudge gudgeon on pin pin st stop rings: rings: 020448Y - With the opening in the position indicated on the tool, fit the gudgeon pin stop ring in position in the tool, using the punch. - Rest the tool against the piston, taking care that the part with the 90º bevel is always pointing upwards as indicated in the figure. - Fit the gudgeon pin using the rod.

ATTENTION  THE  THE USE O F A HAM MER TO FIT THE RETAIN ETAIN S MAY DAMAGE  THE  THE STO STO P SEAT SEAT HO USING S.

CHECKING PISTON HEIGHT - Fit the cylinder provisionally onto the piston, without the bottom gasket. - Fit a comparator to the special tool, resting both on a resting surface. - Adjust the comparator to zero on the resting surface maintaining the zero position, fit the tool onto the cylinder and tighten it with 2 nuts as shown in the figure. - Turn the crankshaft to T.D.C. (the comparator’s rotation inversion point) - Measure the protrusion of the piston relative to the head surface and use the thickness thickness table shown below to determine the thickness of the gasket to be used. The correct identification of the bottom gasket thickness is essential for maintaining the right compression ratio. - Remove the special tool and the cylinder.

Standar Standard d compression compression ratio: R.C. 11,5 ÷ 12 : 1

CYLINDER HEIGHT Head gasket thickness (fibre) Measurement detected

56,45 ± 0,05 0,95 ± 0,06 Bottom gasket thickness

0,9 ± 0,05

0,4

1 ± 0,05

0,5

ALTURA CILINDRO Bottom gasket thickness (steel)

Measurement detected

57,15 ± 0,05 0,3 ± 0,05 Bottom gasket thickness

0,20 ± 0,05

0,4

0,30 ± 0,05

0,5

ASSEMBLING THE SSEMBLING  THE SEGMENTS - Assemble the oil scraper ring starting with the spring, taking care that the ends of this do not overlap. Fit the 2 piston rings in such a way that their gaps and those of the oil scraper are never never lined up. - Fit the 2nd sealing ring with the “T” identifying letter facing the top of the piston. - Fit the 1st sealing ring with the “T” identifying letter facing the top of the piston.

N.B.  TO  TO O BTAIN A BETT BETTER ER SEAT SEATIN ING G O F THE THE 2 SEAL SEALIN IN G RIN RIN GS,  THEY  THEY ARE ARE MADE WITH WITH A TAPE TAPER RED SECT SECTIO IO N IN CO NTACT NTACT WITH THE CYLIN CY LINDER DER.. FOR FO R THIS REASO REASON N IT I T IS IMPO RTAN T  TO  TO RESP RESPECT ECT THE FITTIN FITTIN G O F THE THE RINGS IN GS WITH WITH THE “T” “T” IN DICATION FACING UPWARDS. STAGGER THE RING GAPS AT 120º 120º AS IN DIC ATED ATED IN THE FIG URE. G REASE THE PARTS PARTS WITH MO TOR GREASE.

ASSEMBLING THE SSEMBLING  THE CYLINDER - Fit the bottom gasket with the thickness previously determined - Carry out the cylinder fitting as indicated in the figure

- It is possible to keep the piston away from the crankshaft surface using the corresponding tool.

N.B. BEFORE FITTING THE CYLINDER, BLOW CAREFULLY  THR  THRO O UGH THE LUBR LUBRICATION DUCT AND GREASE GREASE THE CYLINDER WALL.

Special Special tool: Fork for fitting piston to cylinder: 020288Y

CHECKING THE HECKING  THE CYLINDER HEAD - Use a flat fl at bar to check that that the cylind cylinder er head surface surf ace is flat, and check that it has no signs of wear or distortions.

Maxim Ma ximum um admitted admitted deviation from fro m flat: 0,05 m - Check that the camshaft supports and the rocker shaft do not show signs of wear. - Check that there is no wear to the surface of the cylinder head, inlet manifold and exhaust manifold.

STANDARD DIAMETER(MM) A

Ø 32,015 32,015 ÷ 32,025

B

Ø 16,0 ÷ 16,018

C

Ø 11,0 ÷ 11,018

CHECKING VALVE SEALING - Measure the width of the sealing surface on the valve seats.

Sealing surface width Inlet: 1,5 mm

Exhaust: 1,6 mm

CHECKING VALVE GUIDES AND AN D SEATS - Clean any possible carbon residue from the guides. - Measure the internal diameter of each valve guide. - Perform the measurement according to the rocker push direction at three different heights.

EXHAU EXHAU ST GUIDE

Standard Standard diameter: diameter: 5 +0 +0,012 mm

Wear limit:

5,022 mm

INLET GUIDE

Standard Standard diameter: diameter: 5 +0 +0,012 mm

Wear limit:

5,022 mm

- When the values of the width of the impression on the valve seat or the diameters of the valve guides are greater than the set limits, these should be replaced. Check the width of the impression on valve seat “V” with a max. wear limit of 1.6 mm.

CHECKING THE HECKING  THE VALVES - Check the diameter of the valve stem at the three points indicated in the figure.

MINIMUM ADMITTED DIAMETER

Inlet: 4,970 mm

Exhaust:

4,960 mm - Calculate Ca lculate the play between the the valve valve and valve valve guide. STANDARD PLAY:

Inlet: 0,015 ÷ 0,042 mm

Exhaust:

0,025 ÷ 0,052 mm MAXIMUM ADMITTED PLAY

Inlet: 0,052 mm

Exhaust:

0,062 mm - Check that there are no signs of wear on the contact surface with the rocker arm adjuster pad. STANDARD VALVE LENGTH

Inlet: 70,1 mm

Exhaust:

69,2 mm - When the airtight valve surface is higher than the set limit, chipped in one or more places or curved, replace with a new the valve. - If the checks described above do not detect anomalies, it is possible to use the same valves. To obtain the best airtightness characteristics, it is recommended to grind the valves.  This  This operat operation ion should should be done delicat delicately ely, using using fine grain grinding grindi ng paste. During Duri ng the grinding grindi ng operation, operatio n, keep the cylinder head in a vertical position, to prevent grinding paste residue from penetrating into i nto the valve stem stem// valve guide coupling.

ATTENTION  TO  TO AVO AVO ID SCRAT SCRATCHIN CHIN G THE CO NTACT NTACT SURFA SURFACE, CE, DO NOT CONTINUE ROTATION ONCE THE GRINDING PASTE HAS BEEN USED UP. WASH THE CYLINDER HEAD AND THE VALVES VALVES C AREFULLY WITH A PRO PRO DUC DU C T SUI SUIT TABLE FOR THE THE GRINDIN GRIN DIN G PASTE ASTE USED. USED.

VALVE AIRTIGHTNESS TE AIRTIGHTNESS TEST ST - Insert the valves in the cylinder head. - Test the 2 valves in turn. - The test should be performed by filling the collector with petrol and checking that the petrol does not leak past the valves when they are pressed closed with a finger.

CHECKING  THE SPRINGS, PLATES AND AN D COLLETS - Check that the spring top retainer plates and the collets show no signs of abnormal abnor mal wear. wear.

ASSEMBLING VALVES - Grease the valve guides with graphite grease. - Fit the lower valve spring retainers onto the cylinder head. - Using the punch, insert the 2 oil seals in turn.

Special Special tool: Punch for fitting valve oil seals: 020306Y

- Fit the valves, the springs and the top retainers. - Using the special tool, compress the springs and insert the collets coll ets into their thei r respective stem stem cut-outs. cut-outs.

Special Special tool: Valve spring compressor: 020382Y

CHECKING TIMIN HECKING  TIMING G COMPONENTS - Check that the guide runner and the tensioner runner are not excessively worn. - Check that there is no wear to the chain assembly, drive pulley, camshaft and sprocket. - If wear is i s found, renew the parts; in the event event of wear to the chain, sprocket or pulley pull ey,, renew ren ew the whole whol e assembly. assembly.

CHECKING THE HECKING  THE TIMIN  TIMING G CHAIN  TEN  TEN SIONER IO NER - Remove the central bolt with the washer and the tensioner spring.Ensure that there is no wear to the one-way mechanism. - Check that the tensioner spring is in good condition. - If wear is found, renew the whole assembly.

CHECKING THE HECKING  THE CAMSHAFT - Check that there is no excessive wear to the camshaft supports STANDARD DIAMETER

Support Support A Ø: Ø: 12 +0,002 +0,010 mm

Support B Ø:

16 -0,015 –0,023 mm MINIMUM ADMITTED DIAMETER

Support Support A Ø: Ø: 11,98 mm

Support B Ø: 15,96 mm STAN STANDAR DARD D HEIG HT

Inlet: 25,935 mm Exhaust: 25,935 mm N.B.  THER  THERE E IS A BALL BALL BEAR BEARIN ING G ASSEMBL ASSEMBLY Y FITTED FITTED TO TO SUPPO SUPPO RT “A”; “A”; THEREFO THEREFORE RE SUPPO RT “B” IS THE THE MO RE IMPO IM PORT RTAN T SIN CE IT O PERATE PERATES S DIRECTLY DIRECTLY ON THE CYLIN CY LINDER DER HEAD ALUMINIUM.

Maxim Ma ximum um axial play pl ay admitted: admitted: 0,5 mm - If values other than the set ones are found, renew the defective parts.

CHECK  ROCKERS - Check that the rocker shaft is not scratched or worn. - Measure Mea sure diameter “A” “A”.

Minimum admitted diameter: Ø 10,970 mm - Check the internal diameter of each rocker: height “B”.

Maximum admitted diameter: Ø 11,030 mm - Check that there is no wear to the cam followers or to the rocker arm studs. - If anomalies are found, renew the damaged parts.

 TIGHTENING  THE CYLINDER HEAD NUTS In case of renewal of the four double-ended cylinder studs, in the engines engin es in question, it i t is necessary necessary to tighten the cylincylinder head bolts by following the procedure indicated below.

Cylinder head hea d nuts tightening tightening (only for renewed studs) studs) 67 N*m + 135º + 90º Cylinder head hea d nuts tightening tightening (only for renewed studs) studs) 67 N*m + 90º + 90º + 90º  The  The redu reduct ction ion of 45º in the the turn turning ing of of the the span spanner ner is neces neces-sary to prevent possible stretching of the studs.

ASSEMBLING THE SSEMBLING  THE CYLINDER HEAD AND AN D CAMSHAFT - Rest the cylinder head in a stable manner on a flat work surface. - Press the the camshaf camshaftt fitting tool as far as the stop on the inner bearing guide. - Drive the camshaft home with the bearing in the seat, using a mallet. - Remove the tool.

- Fit the cylinder head gasket after carefully cleaning the contact surfaces. - Fit the cylinder head over the cylinder studs and tighten the securing nuts to a prescribed torque of 6 – 7 N•m.

Special Special tool: Camshaft assembling/dismantling tool: 020450Y

N.B. IN THE EVENT OF THE CAMSHAFT BEARING BEING DISMANTLED, IT IS ESSENTIAL TO RENEW THE BEARING. - Loosen the tappets. - Fit the shaft, the inlet rocker and the exhaust rocker. - Grease the 2 rockers through the holes.

- Tighten the shaft and crankshaft retaining screw with washer as indicated in the figure, tightening to the prescr bed torque.

 Tightening  Tightening torque: torque: 3 ÷ 4 N•m

- Finish tightening the cylinder head according to the following procedure: tighten with an initial torque of 6-7 N•m in two passes crossing diagonally the four cylinder head nuts. Finally tighten the nuts with 2 turns of 90º carried out in two diagonal cross passes.

N.B. IN THE CASE OF RENEWING THE ENGINE CRANKCASE OR  THE  THE CYLIN CYLIN DER DER STUDS, STUDS, IT IS NECESS NECESSAR ARY Y TO PERFORM PERFORM AN INITIAL TIGHTENING OF 6-7 N•M PLUS 3 FINAL TIGHTENINGS OF 90º PERFORMED IN 3 DIAGONAL CROSS PASSES. - Complete the tightening of the cylinder head to the crankcase with the 2 side bolts.

 Tightening  Tightening torque: torque: 8 ÷10 N•m

ASSEMBLY OF  TIMING  TIMIN G COMPONENTS - Fit the timing chain runners into their respective seatings, the bolt and the spacer, as indicated in the figure. - Tighten to the prescribed torque and check the the correct movement vement of the tensioner roller. ro ller.

 Tightening  Tightening torque: torque: 5 ÷ 7 N•m - Fit the timing sprocket to the crankshaft with the bevel facing the insertion side (towards the main bearing). - Fit the timing chain onto the crankshaft.

- Fit the spacer onto the camshaft. - Position the piston at top dead centre using the referencemarks between the magneto and the engine crankcase.

- Maintaining this operation, fit the chain over the camshaft drive sprocket, keeping the reference mark in line with the point located on the cylinder head. - Fit the sprocket onto the camshaft. - Fit the cup washer with the outer edge in contact with the sprocket. - Screw in the bolt without tightening completely.

- Press lightly on the tensioner runner to check the correct timing setting. - Lock the camshaft crown wheel with the special tool and tighten the bolt.

 Tightening  Tightening torque: torque: 12 ÷ 14 N•m - Adjust the valve play. - Renew the ring seal on the rocker cover. - Fit the rocker cover and tighten with the 4 securing screws indicated in the figure.

 Tightening  Tightening torque: torque: 8 ÷ 10 N•m

Special tool Forked spanner: 020565Y

ASSEMBLING CHAIN  TENSIO  TENSION N ER - Fit the tensioner runner in the rest position. - Fit the tensioner onto the cylinder using a new seal, and tighten the 2 bolts to the prescribed torque.

 Tightening  Tightening torque: torque: 8 ÷ 10 N•m - Fit the spring with the centre bolt and washer, and tighten the cover to the prescribed torque.

 Tightening  Tightening torque: torque: 5 ÷ 6 N•m

FITTING  THE SPARK  PLUG  Tightening  Tightening torque: torque: 10 ÷ 15 N•m

Prescribed spark plug: Champion RG 4 PHP Champion RG 4 HC

Spark plug gap: 0,7 ÷ 0,8 mm

-Fit the deflector airtight seal onto the cylinder head. - Fit the 2 deflectors. - Fit the inlet manifold and tighten the 2 bolts to the prescribed torque.

 Tightening  Tightening torque: torque: 7 ÷ 9 N•m - Fit the carburettor to the inlet manifold and tighten the clamp.

N.B.  TURN  TURN THE THE CARBURE CARBURETT TTO O R USING THE LUG LOCAT LOC ATED ED O N  THE  THE MAN IFOLD.

- Previously extract extract the the followin fol lowing g assemblies: assemblies:transm transmission ission cover, driving pulley, driven pulley and belt, rear axle housing, gears, bearings and oil seals. - Remove the oil reservoir, the chain cavity cover and the oil pump. - Remove the deflector covering the magneto, the fan, the magneto, the stator as described in the Magneto chapter. - Drain the engine oil and remove the plug with net pre-filter.

- Remove emove the cylinder-pistoncylinder- piston-cylinder cylinder head hea d assembly assembly as described in the the Cylinder - Cylinder Cylind er Head Timing Timing chapter. chapter. - Remove the 2 fixings indicated in the figure and the starter motor with the cable assembly.

APERTURA CARTER MOTOR - Remove the 10 crankcase fixing screws. Separate the crankcase sections, keeping the crankshaft inserted in the transmission side of the crankcase.

ATTENTION FAILURE TO COMPLY WITH THIS RULE MAY CAUSE THE CRANKSHAFT TO FALL ACCIDENTALLY.

- Remove the crankshaft.

ATTENTION ON THE MAGNETO SIDE OF THE SHAFT THERE IS A CEN TR  TRIFUGAL O IL FILT FILTER. ER. IT IS THEREF HEREFO O RE RECO RECO MMENDE MMEN DED D NOT TO WASH WITH SOLVENT OR TO BLOW THROUGH WITH CO MPRESSE MPRESSED D AIR, SO SO AS NO T TO C AUSE IMPUR IMPU RITIES  TO  TO EMER EMERGE. THE CENTRIFUGAL CENTRIFUGAL O IL FILT FILTER HAS A LIFESLIFESPAN EQUAL TO THAT OF THE ENGINE AND REQUIRES NO MAINTENANCE.

- Remove the oil seal on the magneto side. - Check the axial play of the connecting rod.

Standar Standard d play: 0,15 ÷ 0,30 mm

Maxim Ma ximum um play: 0,5 mm

- Check the radial play of the connecting rod, holding the crankshaft manually and measuring play with a comparator positioned on the end of the big end, moving the connecting rod vertically as shown in the figure.

Standar Standard d play: 0,06 ÷ 0,018 mm

Maxim Ma ximum um play: 0,25 mm

- Check that the surfaces of the half-shafts show no signs of  scratching, scratching, and use a calliper callip er meter meter to check the width of the crank as indicated in the figure.

Standard measurement: 45 mm

CHECK  CRANKSHAFT ALIGNMENT. - Refit the crankshaft onto its support and measure the alignment deviation at the 4 points indicated in the figure.

Max. Ma x. admitted admitted deviation: A = 0,15 mm B = 0,02 mm C = 0,02 mm D = 0,10 mm N.B. IF VALUES ARE FO UN D THAT ARE O N LY A LITTLE LITTLE HIGHER HIG HER  THAN THO SE ADMITTED ADMITTED,, PER PERFORM A STRAIGHTE STRAIGHTEN N ING IN G OF THE CRANKSHAFT USING A WOODEN WEDGE INSER TED  TED BETWE BETWEEN EN THE HALF-SHAFTS HALF-SHAFTS OR O R COMPRES COMPRESSING SING THE LATTER IN A VICE IF NECESSARY. IF IN THIS CASE VALUES ARE FOUND WHICH ARE DIFFERENT FROM THE ADMITTED O N ES, ES, REPLACE REPLACE WITH A NEW CRAN KSHAFT KSHAF T.

Special Special tools: Crankshaft alignment tool: 020074Y

Magnetic Ma gnetic support and comparator: 020335Y

DISMANTLING

AND AN D ASSEMBLING  THE TR  THE  TRAN ANSMIS SMISS SION IO N SIDE MAIN BEARING - Secure the crankcase on a flat surface with the crankshaft axis vertical. - Heat up the crankcase to 120ºC using a blowlamp. - Prepare the punch with guide and adapter, fit the bearing to the punch using grease (to stop it falling off). - Insert the bearing beari ng into the crankcase; where necessary, necessary, use a mallet, but taking great grea t care not to damage the stop stop on the engine crankcase. crankcase.

Special Special tools: DISMANTLING:

42 x 47 mm adapter: 25 mm guide: Holder for adapters:

020359Y 020364Y 020376Y

FITTING:

52 x 55 mm adapter: 25 mm guide: Holder for adapters:

020360Y 020364Y 020376Y

DISMANTLING AND AN D ASSEMBLING  THE TR  THE  TRAN ANSMIS SMISSION SION SIDE MAIN BEARING - Using the special tool, remove the magneto side bearing, fitted to the crankshaft.

Special Special tool: Bearing extractor 004499Y, equipped with parts: 1, 2, 3, 6, 34.

- Heat a new main bearing up in oil to 120ºC. - Position the crankshaft on the support base and insert the bearing with the aid, if necessary, of a suitable length of  tubing.

N.B. ALWAYS REFIT WITH A NEW BEARING.

ATTENTION ON THE MAGNETO SIDE OF THE SHAFT THERE IS A CENTRIFUGAL FUG AL OIL O IL FILTER FILTER.. IT IS THEREFORE THEREFORE RECO RECO MM ENDED END ED NO T TO WASH WITH SOLVENT OR TO BLOW THROUGH WITH COMPRESSED AIR, SO AS NOT TO CAUSE IMPURITIES TO EMERGE.

Special Special tool: Base for fitting bearings: 020265Y

 Tube  Tube (shaft (shaft fitting fitting tool): tool): 008119Y009

DISMANTLING

AND ASSEMBLY OF MAGNETO SIDE OIL SEAL

- Extract the magneto side oil seal from the inside of the crankcase, taking care not to damage or scratch the crankcase. - Cover the oil seal and corresponding seat in the crankcase with engine oil. - Working from the outer side, and using the special punch, drive home the oil seal right down into the seat in the crankcase.

N.B. FAILURE TO USE THE THE TO TO O L MAY LEAD TO TO POO PO O R SEATIN SEATING G AND A CONSEQUENTLY POOR OIL SEAL PERFORMANCE.

Special Special tool: Punch for fitting magneto side oil seal 020340Y

CLOSING  THE ENGINE CRANKCASE - Carefully position the two centring pins, preferably on the magneto side crankcase section.

- Fit the crankshaft into the transmission crankcase section. - Apply Appl y LO LO C TITE 510 to to the flat surfaces on the crankcase crankcase transmission transmission side side section section after having carefully greased the the two contact surfaces. - Fit the magneto crankcase section. - Screw in the 10 bolts and tighten to the prescribed torque.

 Tightening  Tightening torque: torque: 8 ÷ 10 N•m

N.B. DURING ASSEMBLY OF THE CRANKCASE SECTIONS AND  THE  THE CRANKSHAFT, CRANKSHAFT, TAKE CARE NO T TO DAMAGE THE  THR  THREADE EADED D PIN PIN S O F THE THE CRANKSHAFT. CRANKSHAFT.

- Fit a new ring seal onto the net oil filter and onto the drive cover and grease them. -Insert the filter into the engine and tighten the cover to the prescribed torque.

 Tightening  Tightening torque: torque: 25 ÷ 28 N•m

FITTING  THE STARTER MOTOR - Fit a new ring seal onto the starter motor and grease it. - Fit the starter starter motor onto on to the engine crankcase and tighten the 2 bolts to the prescribed torque.

 Tightening  Tightening torque: torque: 11 ÷ 13 N•m

FILTER CANISTER - To clean the filter element, element, carry out the following operatioo perations: after loosening the 5 fixing screws, and extracting the filter element. Clean the element by washing it with soap and water, then dry with a cloth and small jets of compressed air, and submerge submerge in an equal mixture of Agip Filter O il and an d petrol. Next, squeeze it out gently by hand without wringing tight, leave it to dry and refit. - Ensure that the filter material is correctly positioned. - Check that the air passage sections are not distorted. - Check that the joint between the canister and cover is airtight.

N.B. FAILURE TO CO C O MPLY WITH THESE THESE IN STR STRUC TION TIO N S MAY LEAD TO TO IN CO RRECT VACU VACUUM UMS S INSIDE IN SIDE THE THE FILTER FILTER CACA N ISTER ISTER,, WITH RESULT ESULTIN IN G VARIATION ARIATION IN CAR CA RBURATION BURATION .

CLEANING  THE VACUUM VALVE FILTER - Completely drain the petrol tank. - Remove the petrol flow pipe and the vacuum pipe. - Loosen the clamp and remove the valve. - Clean the tank and the valve filter with a special solvent. - Refit the valve, ensuring that the ring seal is present. - Fit the valve facing the same way as before dismantling, and tighten the clamp.

N.B.  THE  THE FILT FILTER CAN BE UN SCREW SCREWED ED FRO FRO M THE THE VALVE ALVE TO AID  THE  THE CLEAN CLEANIN ING G O PERA PERAT TIO N.

VACUUM VALVE - Disconnect the fuel feed pipe and the carburettor vacuum inlet pipe. - Check both pipes for fuel leaks. - Close the fuel outlet duct. - Using a MITYVAC pump, apply 0.1 bars of vacuum to the valve. - Ensure that the vacuum is kept stable and that there are no fuel infiltrations. infiltrations. - Connect the vacuum tube to the collector. - Fit the fuel pipe with the outlet at the same height as the valve. - Turn the engine engi ne over with the starter for 5 seconds seconds with the throttle closed. - Extract fuel using a graded test tube.

Minimum flow:: 20 c.c.

Special Special tool: MITYVAC-type vacuum pump: 020329Y

N.B. A FALSE MEASUREMENT MAY ARISE DUE TO AN INCORRECT NUMBER NU MBER O F TURN TURNS S OR AN IN CO RRECT PIPE PIPE POSITIO SITIO N . IN THIS CASE, THE TEN TEN DENCY DENC Y IS TO O BTAIN A REDUCED EDUC ED FUEL FLOW.  THE  THE VACUUM VACUUM INLET I NLET O N THE MAN IFOLD IFO LD HAS A RED REDUCED UCED DIAMETER TO IMPROVE VACUUM PULSES, THUS ENSURING A CONSTANT FLOW FROM THE VALVE.

DISMANTLING  THE CARBURETTOR - To disconnect the carburettor from the engine, extract the two clamps anchoring the carburettor to the inlet manifold and to the air filter hose. - Remove the petrol feed pipe.

- Disconnect the choke device connection. - Disconnect the throttle cable and sleeve from the support plate. - Extract the carburettor.

- Remove emove the protection, the stirrup and the choke, by removing the screw in the figure.

ATTENTION  THE  THE CARBURE CARBURETT TTO O R IS FITTED FITTED WITH WITH A RUBBER UBBER ANT AN TI-VIBRAI-VIBRA TIO  TIO N PAD LO CATED CATED O N THE BOTTO OTTO M LUG LUG O F THE THRO HRO  TTLE  TTLE PUMP BO DY. DY. TO TO FIT THE CARBURE CARBURETT TTO O R O NTO THE ENGINE, IT IS RECOMMENDED THAT THIS PLUG BE PRESENT IN ORDER TO PREVENT EMULSIFYING OF THE PE TR  TRO L PRE PRESENT SENT IN THE THE BOWL.

- Remove the 2 fixing screws indicated in the figure, the depression chamber cover and the spring.

WARNING DURING THE DISMANTLING OF THIS COVER, TAKE CARE  TO  TO PREV PREVENT ENT THE SPRIN SPRING G FRO FRO M FLYIN FLYING G O UT ACCIDENACC IDEN TALL  TALLY.

- Remove the depression valve together with the membrane; the needle, the spring and the plastic guide.

- Remove the 3 fixing screws and the bowl with its respective seal.

- Dismantle the bowl components according to the following procedure.

- Loosen the 2 fixing fi xing screws screws on the throttle pump membrane membrane cover.

DISMANTLING  THE CARBURETTOR - Remove the cover, paying attention to the spring fitted beneath it, extract the spring, remove the protective rubber, the membrane with pin and the duct ring seal.

- Remove the throttle pump jet with ball spring.

- Remove the screw indicated in the figure securing the float pin. - Remove the float and the needle.

- Remove the main jet.

- Remove the emulsifying tube.

DISMANTLING  THE CARBURETTOR - Remove the atomiser by tilting the carburettor body.

N.B.  THIS  THIS O PERA PERAT TIO N IS NECESSAR NECESSARY Y TO PREV PREVENT ENT THE LO SS O F THE ATOM ATOMISER ISER DURIN G THE CARB C ARBURETT URETTO O R BODY CLEANING PHASE. WHEN THE ATOMISER IS STUCK IN ITS SEAT SEAT, DO N O T ATTE ATTEMPT MPT TO TO REMOVE EMO VE IT, IT, TO AVOID AVO ID DAM DA M AGING IT.

- Remove the idle jet.

- Remove the idle flow screw with ring seal, washer and spring.

ATTENTION DO NOT ATTEMPT TO EXTRACT THE COMPONENTS ANCHO CH O RED TO TO THE CAR CA RBURETT BURETTO O R BO BO DY, DY, I.E.: I .E.: FU EL SUPPL SUPPLY Y DUC DU C T, N EEDLE SEAT, SEAT, CHO C HO KE J ET, ET, BUTTERFLY BUTTERFLY VALVE VALVE DRIVE SHAFT. AVOID DISMANTLING THE SCREWS CONNECTING THE BUTTERFLY VALVE VALVE TO TO ITS SHAF SH AFT T. THE THE SCREWS ARE RIVETED AFTER ASSEMBLY, ASSEMBLY, AN D THEIR EXTRAC EXTRACTIO TIO N M AY LEAD TO TO DAMAGE TO THE SHAFT.

CARBURETTOR ASSEMBLY - Before assembly, ensure that the carburettor body is carefully cleaned using a degreasing solvent and compressed air.

- Pay special attention to the carburettor inlet port and the needle seat. seat.

- For the idle circuit, pay special attention to the correct cleaning of the following points: air calibration, output section controlled by the flow screw, and the progression holes near the butterfly valve.

- For the choke circuit, take special care with the connection with the jet, since the jet bracket conceals hidden calibrations in its inaccessible interior. - Blow carefully into the throttle jet. - Its output section is extremely small and faces towards the butterfly valve. valve. - Check that the idle circuit producing port closing ball is in place on the carburettor body. - Check that the flat surfaces joining the bowl and the membrane have no dents. - Check that the depression valve housing port is not scratched. - Check that the butterfly valve and shaft have no irregularities. - Check that the needle seat shows no irregular wear. - If any irregularities are found, the carburettor should be replaced.

N.B.  TO  TO PREV PREVENT ENT DAMAGE, AVO AVO ID INSER INSERTING IN G METAL METAL O BJ ECTS INTO THE CALIBRATED SECTIONS.

CARBURETTOR ASSEMBLY - Clean and carefully blow through the idle jet and assemble it.

- Clean and carefully blow through the components of the main jet circuit, atomiser, emulsifying tube and jet. - Insert the jet into the carburettor body with the wider part of the cylinder facing towards the emulsifying tube. - Fit the emulsifying tube. - Fit the main jet.

- Check that the tapered needle has no wear on the surface sealing with the damper pin and return spring. - If wear is found, the needle should be replaced. - Check that the float has no wear in the float pin housing or on the contact plate with the needle, or fuel infiltrations. - If anomalies are found, the float should be replaced. - Fit the float with the pin and needle in their corresponding seats and lock lo ck with the corresponding correspondin g screw. screw.

N.B. M AKE AK E SURE THE THE RETURN RETURN SPRIN G IS I S CO RRECTL RRECTLY Y FITTED ONTO THE FLOAT PLATE.

- Insert the ball into the throttle pump. - Insert the spring. - Insert the throttle pump jet.

WARNING WHEN ASSEMBLING, PAY PARTICULAR ATTENTION TO THE COMPONENTS, SINCE THEY ARE VERY SMALL.

ASSEMBLING THE SSEMBLING  THE CARBURETTOR - Check that the membrane is intact and assemble the other parts of the throttle pump in the following order: - Insert the ring seal into the port. - Insert the membrane with pin and the corresponding spring.

N.B. REPLACE THE MEMBRANE IF IT IS CRACKED, BROKEN OR EXCESSIVELY HARDENED. - Fit the throttle pump membrane cover and tighten the 2 securing screws, making sure the return spring beneath it is correctly fitted. - Fit the rubber boot protecting the pin in the top of the throttle pump.

VERIFICACIÓN

NIVEL CARBURANTE EN CUBETA

- Tilt the carburettor in such a way that the fuel inlet needle valve is closed but the weight of the float is not resting on it. - Check that the flat closing surface of the membrane is parallel with the central line on the float, as indicated in the figure. - Fit the bowl with the corresponding seal onto the carburettor body using the 3 securing screws, once this has been carefully blown through.

N.B. FOR FO R ASSEMBL ASSEMBLY, Y, ALWAYS ALWAYS USE NEW N EW RET RETAI AIN N S AND AN D SEALS.

WARNING  THE  THE SCREW SCREW FITTED FITTED TO THE THE BOTTO OTTO M O F THE BOWL IS O N LY A DRAIN SCREW AND ONLY REQUIRES CLEANING.

- Use a 12v battery to power the automatic choke and check that the piston reaches maximum protrusion.

Maximum protrusion: 15 mm

Max. Ma x. time: time: 5 mín - The effective heating time depends on the outside temperature. - If protrusions, resistances or times are found to be different to those set out, the choke should be replaced. - Fit the starter, the bracket stirrup and the protector using the screw shown in the figure.

ASSEMBLING THE SSEMBLING  THE CARBURETTOR - Insert the rubber bowl ventilation pipe. - Fit the ring seal, the washer, the spring and the idle flow screw in their corresponding seats.

- Fit the carburettor to the engine, connecting the throttle cable together with its sleeve to the bracket plate and the electrical connection for the choke device. - Connect the petrol feed pipe and tighten the 2 clamps anchoring the carburettor to the inlet manifold and to the air filter hose.

ADJUSTING  TICK - OVER - The engine does not require requi re frequent tick-over adjustments, adjustments, but it is very important for adjustments to be made by following certain rules. - Before proceeding to adjust the carburettor, ensure that everything is well greased, the valves play and timing are correct, correct, the spark spark plug is in optimum condition, the air filter is clean clean and fitted airtight, and tthere here are no leaks in the the exhaust system. - Using the analyser’s rev counter or another separate one, adjust the idle screw until a rate of 1900 to 2000 rpm is obtained.

N.B.  THE  THE IGN IG N ITION SYST SYSTEM EM IS THE LO LO ST SP SPARK ARK TYPE, TYPE, WHICH GI VES A CO N SIDERABLE SIDERABLE VOLTAGE. VOLTAGE. DIFFICU DIFFI CU LTIES IN REAREADIN G THE REVS REVS M AY ARISE ARISE WITH WITH NO N O N - C ALIBRATED ALIBRATED REV REV COUNTERS.

Specific tool: Digital rev counter: 020332Y

ATLANTIS 50 C.C. 4-stroke KEIHIN KEIHIN 18 Ø Ø 18,9 pressure

ATLANTIS 100 C.C. 4-STROKE KEIHIN KEIHIN 20 Ø Ø 20,9 pressure

Main jet

75

72

Pilot jet

35

35

Choke jet

48

48

Ø 2,1

Ø 2,1

(without grooves) Ø 1,2

(without grooves gr ooves)) Ø 1,2

 Ty  Type

Emulsif Emulsifying ying tube Naca type tapered needle

BATTERY - Before the battery is put into service, it needs to be filled with the acid that comes with it.

- First, remove the sealing strip. - Upturn the electrolyte container with the six sealed parts in line with the six battery filling holes. Push the container down to break the seals. - Check that all the electrolyte has been poured in.

SEALING THE BATTERY: - Fit the plug strip firmly into the filling holes. - Never remove the plug strip nor add water or electrolyte. - The battery is the 12v 4 Ah type. When installing it, it is important not to reverse the polarity, as this may damage certain electronic devices. devices.

PUTTING THE BATTERY INTO OPERATION: battery is the se sealed aled typ type. e. Never Never remov remove e the the plugs or add water water.. - This battery - After 30 minutes, check the voltage at the terminals.

Standard voltage 12.5 volts minimum Under normal conditions there should be no need to charge the battery.  The  The capac capacity ity after after filling filling is approx approxim imat ately ely 75%. 75%. SPECIAL SPECIAL CON DITION S IN WHIC H THE BATT BATTER ERY Y SHOU LD BE BE CHARGED:

- When the temperature falls below 0ºC. - After a long period of storage. - When the original seal has been broken. - In I n general, it should be charged whenever whenever the voltage voltage after af ter filling fillin g is below the standard standard 12.5 volts. volts.

Cleaning Clean ing the battery: battery: The  The batt battery should hould be kept kept clean at all times imes,, espec especially ially the top top part, part, and the term terminal inals s protected with Vaseline.

ATTENTION USE OF A FUSE FU SE O F AN A MPERAGE GREATE GREATER R THAN THAT RECOM ECO M MEN DED. THE THE USE OF A FUSE OF THE WRO WRO N G AMPERAGE A MPERAGE MAY CAU SE DAM AGE AG E TO THE VEHICLE VEHIC LE AS A WHOLE WHO LE,, AS WELL WELL AS THE THE RISK RISK OF OF FIRE.

ATTENTION  THE  THE SEALE SEALED D BAT BATT TERY ERY MUST BE CHARGED TO O PERA PERAT TIN G CO NDITIO N BEFORE BEFORE FINAL DELIV DELIVER ERY. Y.

ON

1

Magneto

2

Pick-Up

3

Ignition key switches

4

Eelectronic switch on device

5

4 AMP fuse

6

Voltage regulator

7

12V-4Ah 12V-4Ah battery battery

LIGHTS AND AN D AUTOMATIC

CHOKE SYSTEM

1

Voltage regulator

2

12V-25/ 12V-25/25W 25W projector bulb

3

12V- 1.2 W full beam pilot light

4

12V-5W sidelight bulb

5

12V-1.2W 12V-1.2W instrum i nstrument ent light li ght

6

12V-2W bulb for illuminating instrument

7

12V-1,2W pilot light

8

12V- 5W 5W rear sidelight

9

Automatic choke

10

Dipswitch

11

BATTERY CHARGING AND AN D STARTER

1

Magneto

2

Starter motor

3

4 Amp fuse

4

12V-4Ah 12V-4Ah battery battery

5

Ignition key switch contacts

6

Voltage regulator

7

Starter solenoid

8

Starter button

9

Stop butt utton on the fron frontt and and re rear brak rake

INDICATORS AND AN D LEVELS

1

Voltage regulator

2

Fuel level indicator

3

Fuel level transmitter transmitter

4

Stop button on the front and rear brake

5

4 Amp fuse

6

12V-4Ah 12V-4Ah battery battery

7

Filament for stop light AT 12V-10W

8

Ignition Igni tion key switch contacts

CHECKING PILOT LIGHTS AND AN D INSTRUMENTS

1

 Turn  Turn indic indicat atior ior switch witch

2

Horn button

3

Horn

4

12V-2W indicators pilot light

5

12V-10W indicator light

6

Voltage regulator

7

Ignition key switch contacts

8

4 A MP fuse

9

12V - 4Ah battery

VOLTAGE REGULATOR Depending Dependin g on the type of damage, a faulty voltage voltage regulator regul ator can produce the following problems:

• Battery not charging • Turn indicat in dicators ors not functioning • Blown BULBS

 The  The regula regulattor is fitte fitted d with with an earth earth supplied upplied by the the elect electric rical al wiring, and the regulator body does not therefore have the function of providing an earth for its internal circuits.  The  The insulat insulation ion betwe between en each each of the regulat regulator’ or’s s terminals erminals and its body should be measured (using the tester for checking electrical resistances). resistances).

Access the voltage regulator, start up the engine and keep it ticking over with the the vehicle’s vehicle’s light circuit switched switched off.

Insert the tester’s contact probe (set the tester to measure alternating current) into terminal No.1 (Yellow cable), and the negative negative probe into terminal terminal N o.2 (Yellow/ G reen cable), cable), and check that there is voltage (see figure).

If no voltage is detected, try inserting the negative contact probe directly to earth; if no voltage is detected, check the regulator earth wiring; otherwise, replace the voltage regulator as it is faulty.

VOLTAGE REGULATOR As a final check, the voltage supplied by the stator can be checked:

Disconnect the regulator connector and place a tester between the Red/ Red/ White cable (4) and earth, for measurements of alternating current (see figure).

- The voltage distributed at 2000 rpm should be approximately 25÷35V

If no value is obtained with this test, replace the regulator, as it must be faulty.

BATTERY N OT CHARGING A fault faul t in the c.c. section of the voltage regulator regula tor may, may, depending on the type of fault, result in the following problems:

Blowing Blowi ng of the protec pro tective tive fuse due to to voltag voltage e overl overload oad (regulator in i n short circuit) and no charging of the battery. battery.  The battery battery is not charging (regulator (regulator interrupt interrupted) ed) Blown protective fuse (regulator in short circuit). Check that the wiring from the protective fuse to the ignition key switch is not damaged and causing a short circuit to earth (avoiding in this way damage to the regulator); if the protective fuse blows only after switching to the key switch “ON “O N ” position position and with the regulator connector connector disconnected, the wiring wirin g and devices clo closest sest to the key key switch need to be checked to ensure that there is no short circuit to earth.

BATTERY NO T CHARGING Battery Battery not charging chargin g adequately (regulator interrupted).  To  To check heck for the pres presenc ence of anom anomalies alies in the voltage oltage regulator’s charging section, the first thing is to connect 2 testers testers to the battery (one for fo r measuring the voltage and the other for measuring the current) as indicated in the second figure, and follow the procedure indicated below: Start up the engine (by connecting the red cable temporarily to the battery positive to avoid prevent damage to the instrument measuring the current). Check that there is a voltage of at least 13v (battery charged) and a charge current of 1 – 1.5 amps with the vehicle’s lights on. Increasing the engine revs should increase the current and charge voltage progressively. At engine speeds above 4000 rpm a charge current of 2.0 amps should be measured; turning on the vehicle’s vehicle’s lights, brake light and horn should give a meter meter voltage voltage reading readin g of 13.5-138v (the regulator’s regula tor’s thresthreshold voltage). If values are measured that do not conform to the above, replace the regulator; otherwise check the wiring and the connections.

 TURN INDICATORS N OT WORKING If the turn indicators are not working, proceed in the following way: - Remove the voltage regulator connector, insert the tester probes between the Red/ Red/ Black cable cable (3) (3 ) and the Yellow/ Yellow/ Green cable (2). - Turn the ignition igni tion key switch switch to to the ON O N position and check the battery voltage. If no voltage is detected, repeat the test between the White/ White/R Red cable and earth. If I f a negative result result is obtained even in this case, check the wiring and the contacts tacts on the ignition i gnition key switch switch and on the battery. If however however a battery voltage is measured, check the yellow/green regulator earth wiring

 Turn  Turn indicators indicators not working.

If the above mentioned checks have been successful, make a bridge between b etween connector connector contacts 5 (O range) and 3 (Red/ (Red/ Black), turn turn the ignition key switch switch to to the ON O N position and switch the indicator switch to left turn and right turn to see the indicator lights come on without blinking (as they are now being powered directly by the battery). If the indicators fail to light up when this procedure is carried out, check the wiring and whether the switch is working; if the problem is not found here, replace the regulator because it must be faulty.

A TLAN  TLAN TIS 50 C.C. 4T

1

Headlight Headli ght assembly assembly

14

Fuel level sensor

1A 1B

Bulb 12V 12V 25/25W 25/ 25W Indicator bulb 12V 10W

Electric choke Resistence Resistence choke cho ke

2 2A

Dashboard -- -

15 16 17

2B

 Turn  Turn indic indicat ator or cont control rol pilot pilot light light 12V 12V 2W

2C 2D

High beam control pilot light li ght 12V 1,2W 1,2W Dashboard light 12V 1,2W Ignition switch switch

3 3A 4 5 5A 5B 5C 6 6A 7 8 9 10 11 12 13

18 19 20 21

Mobil phone connector

22 23

Regulator Regulator + turn indicator central

24

 Tail  Tail light light assem assembly bly  Tail  Tail bulb bulb 12V 5W Brake bulb 12V 10W Indicator bulb 12V 10W -- -- Engine switch Brake light switch Lights switch  Turn  Turn indicat indicators ors switc switch h Horn switch switch Horn -- -

Starter Starter relay rela y Starter motor Fuse 4 AMP Battery 12V 4AH Flywheel magneto magneto Electronic converter A.T. Spark plug anti-radio interferences Spark plug

A TLAN 100  TLAN TIS 100

1 1A 1B 1C 2 2A 2B 2C 2D 3 3A 4 5 5A 5B 5C 6 6A 7 8 9 10 11 12

C.C.

4T

Headlight Headli ght assembly assembly Bulb 12V 12V 25/25W 25/ 25W Indicator bulb 12V 10W

13 14

Position bulb 12V 5W

16 17

Dashboard --  Turn  Turn indic indicato atorr cont control rol pilot pilot light light12V 12V 2W High beam control pilot light 12V 1,2W Dashboard light 12V 1,2W Ignition switch Mobil phone connector Regulator + turn indicator central  Tail  Tail light light assem assembly bly  Tail  Tail bulb bulb 12V 12V 5 5W W Brake bulb 12V 10W Indicator bulb12V 10W Licence plate light assembly with reflector Licence plate bulb 12V 5W Engine switch Brake light switch Lights switch  Turn  Turn indicat indicators ors switc switch h Horn switch switch Horn

15

18 19 20 21 22 23 24

-- Fuel level sensor Electric choke Resistence Resistence choke cho ke Starter relay Starter motor Fuse 4 AMP Battery 12V 4AH Flywheel magneto Electronic converter A.T. Spark plug anti-radio interferences Spark plug

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