FOREWORD The present manual specifically addresses to specialised technical personnel (Moto Morini authorised service centres and single motor mechanics) and contains all the service interventions indicated by the Manufacturer until the publishing of this document. • Some basic technical information has information has been intentionally omitted as it is considered to be common knowledge. • Additional information is available available in theSPARE the SPARE PARTS CATALOGUEand CATALOGUE and in the SERVICE MANUAL - FRAME AND RUNNING GEAR section. It is import important ant to read all the general informat ion before going through the manual to the specific topics and the maintenance opera tions to be carried out on the engine in order to make sure the topics, the technical and safety concepts are clearly understood and the manual can be used as a sure reference text. • All checks, checks, maintenance, repairs or replacements or replacements of spare parts etc... are to be performed by skilled and expert technical personnel with specific experience in state-of -theart technology and full knowledge of the quickest and most rational procedures, technical characteristics, setting values, tightening torques and information as to which may only be properly and exhaustively provided by the manufacturer. • It is important important to adhere strict ly to the following instructio ns. Any operation carr ied out carelessly or not carrie d out at all may, may, damage the engine or simply lead to complaints.
MALAGUTI S.p.A. reserves the right to make any changes and modifications hereto it deems necessary without prior notice. For further information and details, please contact MALAGUTI S.p.A. Servicing Servicing or Engineering Division.
MALAGUTI S.p.A. Via Emilia 498, 40068 - San Lazzaro di Savena (BO) - ITALY Tel. 051.62.24.811 051.62.24.811 - Fax 051.69.47.782 e-mail:
[email protected] - http: // www.malaguti.com
NOTES FOR EASY CONSULTATION ABBREVIATIONS
Cs D Dx
OTHER SYMBOLS
Torque wrench set ting Nut
LOCTITE
Right
F
Picture
G
Gasket
P
Page
R
Washer
Sx
Left
T
Table
V
Screw
Molibdenum disulfite oil
Engine oil
Lithium-soap base grease
bar
Unit of measurement of pressure
N*m
Newton/metre Unit of measurement of the tightening torque
Lithium-soap base grease
EDITING SYMBOLS: • Symbols have been provided for provided for quick and easy reference, reference , identifying situations requiring utmost attention or providing practical suggestions or simple information. • These symbols may symbols may appear next to a text (in text (in which case they refer solely to the text itself), next to a figure (in figure (in which case they refer to the topic illustrated in the figure and to the relative text), or at the top of the page (in page (in which case they refer to all the topics dealt with in the page). NOTE - The meaning of the symbols should be duly memorised memorised as their scope is to avoid having to repeat basic technical concepts or safety recommendations. recommendations.
LIST OF SYMBOLS USED FOR THIS ISSUE
DISASSEMBLY OPERATIONS
These operations require the use of safety gloves
ASSEMBLY OPERATIONS
SYMMETRICAL OPERATIONS Operations that must be carried out also on the other side of the unit or component.
FIRE HAZARD. HAZARD. Indicates operations which may constitute a fire hazard
Skilled electronic or mechanical technician.
RISK OF EXPLOSION Indicates operations which may constitute a risk of explosion
MECHANICAL MAINTENANCE Operations to be performed only by an expert mechanic
TOXIC FUMES Indicates a possibility of intoxication or inflammation of the upper respiratory tract
ELECTRICAL MAINTENANCE Operations be performed only by an expert electrical/ electronic technician
WARNING!
NO! Operations to be absolutely avoided
Information on the present manual
“ENGINE” SERVICE MANUAL
R
SAFETY GLOVES
WARNING! Situations WARNING! Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment, vehicle or equipment
PRESENT MANUAL
M
CAUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity.
Indicates information which may be obtained by referring to said catalogue
SPARE PARTS CATALOGUE Indicates information which may be obtained by
Danger of crashing arms
IMPORTANT This topic requires special attention
GENERAL SERVICE PERSONNEL
EMPTY THE CIRCUIT OIL COOLANT
REPLACE WITH NEW, ORIGINAL SPARE PARTS
GAUGE MEASUREMENTS
MICROMETER MEASUREMENTS
CENTESIMAL COMPARATOR MEASUREMENTS
BORE METER MEASUREMENTS
GENERAL WORK PROCEDURES • The The recommendations given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment damage and idle times, and should therefore be strictly adhered to. • Always Always listen with attention to the customer’s opinion and complaints about the engine operation, asking specific specific questions in order to have a complete understanding understanding of all the symptoms and identify with good approximation the real causes of the trouble. The present manual provides the technical information and the basic indications on the intervention procedures but these have to be integrated with the personal expertise. • We suggest planning the service interventions in order to avoid any waste of time or downtime. Try to reduce as much as possible the operations necessary to reach the components that needs repairing. • Prepare the components components that are likely to be replaced and all the original spare parts you may need. • Mark the components that may be mis-placed during during re-assembly operations. • Only use quality quality tools and equipment. equipment. • During operations, always keep keep tools and equipment at hand, possibly laying them out according according to the sequence in which they are to be used. • Always keep the work work area neat and clean. • When tightening screws screws or nuts, start with the larger diameter or diameter or inner fasteners, and tighten them in progressive “pulls” pulls” using a “criss-cross “criss-cross”” pattern. • The torque settings specified specified in the manual refer to the “final torque”, torque”, which must be attained progressively by steps. • Preferably use open-end open-end box wrenches wrenches by “pulling “pulling”” and not “pushing”. • For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and co-ordinated beforehand. • Make sure that each component has been properly mounted before proceeding with assembling the next one. • Always replace gaskets, replace gaskets, O-rings, circlips and split pins at every refitting. • Only use screwdrivers with sizes suitable to the screws to be loosened or tightened. tightened.
Never use open flames for any reason. Always use low flash point solvents to clean the vehicle components. When welding, welding, make sure that there are no flammable liquids in the vicinity. • Never reuse old gaskets gaskets or circlips. • Never use a screwdriver screwdriver as a lever or chisel. chisel. • Never use pincers to loosen or tighten screws or nuts. Never tap the wrench with wrench with a hammer or other similar t ool to loosen or tighten screws and nuts.
CONTENTS DESCRIPTION
P.
DESCRIPTION
P.
SPECIFICATIONS
6
FRONT FIXED PULLEY
14
IDENTIFICATION DATA: ENGINE N°
6
FRONT MOBILE PULLEY
15
WATER PUMP COVER
7
CHECKS
15
WATER PUMP
7
FREE WHEEL AND STARTING GEARS
16
WATER PUMP ASSEMBLY
8
CHECKS
16
HEAD
9
REASSEMBLY
16
CLEANING
9
CENTRIFUGAL CLUTCH
17
CYLINDER
10
CHECKS
18
CLEANING AND CHECKING
10
TRANSMISSION GEARS
19
DIMENSIONAL CHECKS
10
CHECKS
20
PISTON
10
STARTER MOTOR
21
CHECK AND CLEAN PISTON
11
MAGNET FLYWHEEL
21
CHECK PISTON PIN
11
ROTOR
21
CHECK CLEARANCE OF SPARK PLUG/PISTON
12
STATOR
21
CHECK SEGMENT HOUSING
12
OIL PUMP
21
CHECK SEGMENTS
12
OIL PUMP CONDUCTOR GEAR
22
ASSEMBLY OF SEGMENTS
12
CASE SEPARATION
22
PISTON/CYLINDER COUPLING
12
LAMELLAR VALVE
23
TRANSMISSION
13
CHECK LAMELLAR VALVE
23
TRANSMISSION COVER
13
CASE SPACER
23
PEDAL STARTING UNIT
13
DRIVE SHAFT
24
SPECIFICATIONS TWO-STROKE ENGINE Type ............... ................ ................. ................ ................ ................. .......... 22MA Cylinders. Cylinders. ................. ................ ................ ................. ................ ................ ........ 1 Bore x stroke mm .................. ........................... .................. ................... ................... .................. ................... ............. ... Ø 40 x 39,2 Capacity Capacity cm3.......................... cm3................................... ................... ................... ................... ................... ................... ................... ............... ...... 49 Cooling.......... Cooling.......... ................ ................ ................. ................ ................ ............. liquid Starting system. system. ................ ................. ............ electric starter and/or kick starter SPARK PLUG Type ............... ................ ................. ................ ................ ............... NGK BR8 HS TRANSMISSION Automatic speed variator with expandable pulleys, Vbelt, automatic dry centrifuge clutch, reduction gear.
F. 1
FUEL SYSTEM Carburettor make / type: GURTNER PY 12 automatic starter. Fuel: unleaded petrol. petrol. IGNITION Electronic. CAPACITY
A
Transmission oil Q8 OILS - T35 - 80W ................. ................. ................. .. cc 110
IDENTIFICATION DATA: ENGINE N° • Engine identification data are located located on the left-hand engine crankcase crankcase (A).
Any alteration to the vehicle identification data is pursued by the Law.
F. 2
DISASSEMBLY ENGINE WATER PUMP COVER
A
V3
• V2.
• Clamp Clamp (A). (A). • V3.
V3
7
V2 F. 3
F. 4
V3
• Extract Extract pin pin (C). (C).
WATER PUMP
C DURING REASSEMBLY REA SSEMBLY:: the pin ( C ) must be inserted into the groove (D).
• Seeger Seeger (A).
A
• Disc Disc (B). (B).
B F. 5
F. 6
V3
• V3.
E
• Remove Remove the impeller impeller (F).
• Water Water pump cover cover (E).
F
D
• O-Ring O-Ring (G).
• Bearings (I) (external and and internal and relevant spacer – L-F.11).
• Oil seal seal (H). (H).
H P G
I
F. 9
F. 10
WATER PUMP ASSEMBLY
E V3
L C B A G F H
I
V3
7
• Spark plug plug (A) (not essential). essential). • D4. • Head Head (B) (B)..
HEAD NOTE - Removing the head, head, the pressure of the cylinder cylinder on the bottom gasket decreases; it is therefore necessary to remove the gasket and replace it. In view of this operation, extract the cover (1).
D4
B 13 ÷ 15
A
1 D4 F. 12
E D • V2. • Thermos Thermostat tat (C). (C). • O-Ring O-Ring (D).
C
V2 F. 15
CLEANING • Remove the carbon carbon deposits using a suitable scraper. Do not damage the threading of the spark plug housing.
• O-Ring O-Ring (E).
V2
F. 13
5 ± 20% F. 15
• Remove Remove the gasket gasket (A).
CYLINDER • Extract Extract the cylinder cylinder with with care. Do not use any tool for this operation.
A F. 16
F. 17
CLEANING AND CHECKING • Remove the carbon carbon deposits especially especially in the exhaust exhaust duct, using a suitable scraper. Do not use very sharp tools.
• Check the internal part of the cylinder. If scraped or excessively worn, replace.
F. 18
DIMENSIONAL CHECKS
PISTON
• Measure the internal diameter of the cylinder. cylinder. • Remove Remove piston piston pin ring. • Standard Ø : 39.99 - 40.01 mm • Wear limit: 40.1 mm • Max conicity: 0.05 mm • Max ovalisation: 0.01 mm NOTE - The out-of-tolerance out-of-tolerance cylinder cylinder must be replaced (or reconditioned) reconditioned)
Before removing the piston pin ring, cover the opening of the engine case with a clean cloth, to avoid the ring falling inside.
• Remove Remove the piston piston pin pin without using any tool. • Extract Extract the piston piston..
• Extract Extract piston pin pin from the piston. • Remove remaining ring.
A
In reassembling the piston, the arrow (A) must be directed towards the exhaust.
F. 20
F. 21
CHECK AND CLEAN PISTON
• Extract Extract the bearing bearing from the connecting rod, checking that it slides correctly. If hardness, sticking, strange attrition is found, replace the bearing with a new, original one.
• Remove the carbon carbon residues. residues. • Check there there are no scraping scrapings s that are too pronounced, otherwise replace the piston.
F. 22
F. 23
CHECK PISTON PIN
• Remove Remove any any light light scrapings, using sand paper grain: 600-800 (dampened) working with crossover movement.
• If the spark spark plug is scraped scraped,, scratched or of a blue colour, it must be replaced and the lubrication system checked. • Measure Measure the diameter diameter (A) and if out-of-tolerance, out-of-tolerance, replace the spark plug.
A
CHECK CLEARANCE OF SPARK SP ARK PLUG/PISTON PLUG /PISTON
CHECK SEGMENT HOUSING
• Measure Measure the diameter diameter of the spark plug housing, on the piston. If out-of tolerance, replace piston.
• Check lateral clearance using a thickness gauge (1). The excessive clearance requires replacement of piston and relevant segments.
Standard diameter of spark plug housing: 10.004 -10.015 mm
Standard lateral clearance: 0.03 -0.05 mm
1 CHECK SEGMENTS
F. 26
F. 27
1
• Insert the segment to check inside the cylinder, cylinder, pushing it with the lower part of the piston so the ring is perfectly at right angles to the cylinder. • Using a thickness gauge gauge (1) measure measure the “gap” between the two ends of the segment. If out-of-tolerance, replace the couple of segments.
ASSEMBLY OF SEGMENTS • Insert the upper upper (1) and and lower lower (2) segment staggered as in figure e and with the bevel turned upwards.
2
Gap segment: 0.15 ÷ 0.35 mm F. 28
F. 29
PISTON/CYLINDER COUPLING NOTE - The The piston pistons s and cylinders are classified in categories, depen- ding on the diameter.
Measure the external diameter of the piston at the height heigh t shown in F. 30
Category of coupling
Clearance on assembly
Identification mark
Cylinder
Piston
A
- 0,007 ÷ - 0
- 0,043 ÷ - 0,037
B
- 0,001 ÷ + 0,006
- 0,036 ÷ - 0,030
0,029 ÷ 0,042
TRANSMISSION
A
• Gasket Gasket (B). • Do not remove remove the centring centring bushes (C).
1
TRANSMISSION COVER
B
C
• Remove the starting lever from the shaft (1). • V12. V12. • Remove Remove the lid (A) (A) without without any tool.
C
V12
F. 31
V 12
F. 32
12
D
F
E
PEDAL STARTING UNIT • Extract Extract the sliding sliding gear (D). (D).
• Seeger Seeger ring ring (E). • Washe Washerr (F). (F).
F. 33
F. 34
I
G • Remove Remove the starting starting shaft shaft (G) with moderation, taking care of the spring (H) which will drain itself, unhooking itself instantly.
• Spring Spring (H). • Bush Bush (I). (I).
• Check the the elasticity elasticity of the the starting return spring, if it is collapsed, replace.
PEDAL STARTING STARTING UNIT CHECKS • Check wear of the the starting shaft, if there are evident signs of excessive wear, replace it.
F. 37
F. 38
• Using a dynamometer dynamometer,, measure the tension of the spring/gear If out-of- tolerance, replace.
• Check wear wear of the starting sliding gear. gear. If there are evident signs of excessive wear, replace.
F. 40
Tensione standard: 150 - 250 g F. 39
• Remove the components components outside of the fixed front pulley (A).
FRONT FIXED PULLEY • D.
A
D
33
D D
• Remove the front mobile pulley (C) without any tool.
FRONT MOBILE PULLEY • Remove the washer washer (A) and the spacer (B).
B C
A
F. 43
F. 44
F
E
D CHECKS
• Turn front mobile pulley upside down (C). • Remove the cap cap (D) and the three drawing blocks (E). • Remove the bushing bushing (F) and the six centrifugal masses (G) from the pulley (C).
• Clean the housings of the centrifugal masses, masses, with a jet of compressed air. • Check for absence of excessive excessive signs of wear of all the components. • If there are anomalous scrapings, or excessive excessive wear, replace the components. • Check bush (F) slides correctly. correctly. F. 45
C
G • Check wear of the transmission transmission belt (1), if there is excessive wear, cuts, fissures, replace with a new original one. • Measure the width width (2) if off limit, replace the belt.
• Check the external external diameter of the centrifugal masses, if off limit, replace them. Standard diameter: 15 mm Max. limit: 14.5 mm
1
2
Standard width: 16.8 mm Max. limit: 15,5 mm F. 46
F. 47
V2
D
A
• Intermediate Intermediate gear (D). • Washer Washer (C1). (C1).
G
• Spacer Spacer (E).
B
• Toothed crown crown (F). • Roller cage cage (G).
F
E F. 49
1 F. 48
CHECKS
H
• Work on the rollers (1) anticlockwise, anticlockwise, if there is strange sliding, replace the entire unit.
• Pin (H). (H). • Flanged bush bush for starting crown (I). F. 51
REASSEMBLY
G
I
V2
F. 50
• Check wear wear of the teeth of the starting crown. If there is excessive wear, replace. Also check the intermediate gear. • Insert the roller cage (G) and flanged bush bush into the toothed crown. Check the correct movement of the roller cage and if there is strange attrition or hardness, replace it.
C
• V2. V2. • Stop plate plate (B). • Washer Washer (C). (C).
FREE WHEEL AND STARTING GEARS • Remove the free wheel wheel (A) complete.
C1
9
F
E I
G
A C1
D C H
B
• Extract the clutch clutch unit (B).
CENTRIFUGAL CLUTCH
D
• Hold the clutch bell (A) and unscrew the nut (D).
D
40
B
A F. 54
F. 55
• Using the special tool, compress the spring and unscrew the fixing nut of the clutch unit (D1).
D1
• Loosen with care care and remove the spring compression tool. • Dismantle the clutch unit.
50 F. 56
D1
F. 57
1) Lock holder holder disc 2) Mobile secondary secondary pulley spring spring 3) Fixed pulley pulley 4) Variator Variator guide guide roller roller 5) Spring Spring suppo support rt 6) Mobile secondary pulley
• Extract the spring support support (5) and the spring.
5
• Remove the guide roller.
• Separate the two pulleys.
F. 61
F. 60
CHECKS
A
• Check the two pulleys pulleys show no sign of evident wear. Otherwise replace. • In the same way, way, check the guide roller and the corresponding corresponding sliding slots. • Check wear of the rear ( A) and lower (B) oil seal and if necessary replace.
C
B • After reassembly reassembly of the two pulleys, check correct sliding movement. • Replace the O-Rings O-Rings (C) and grease.
F. 62
• Measure the free length of the spring (secondary pulley). If off limit, replace. Standard length: 121.7 mm Limit: 106.7 mm
F. 63
1
• Visually check the wear of the attrition material of the clutch locks. If necessary renew the surface with large grain sand paper. • Measure the width width of the attrition material. If out-of- tolerance, replace the entire lock holder disc. Standard width: 4.0 mm Wear limit: 2.5 mm
• Measure the internal diameter diameter (a) of the clutch bell. If out-of-tolerance, replace bell.
TRANSMISSION GEARS • V6. V6.
Standard diameter: 105.0 mm Wear limit: 105,4 mm
V6
12
a
F. 66
V6 F. 67
• Washer Washer (A). • Disc spring spring (B).
B
NOTE In reassembling, the disc spring is inserted with the rounded part, resting on the gear.
• Gear cover, cover, inclusive of transmission shaft.
A F. 68
F. 69
C
D
• Gasket Gasket (C): NOTE - Do n not ot remov remove e lid reference dowels (D).
• Output Output shaft.
• Intermediate Intermediate double gear. gear.
P
CHECKS • Check wear of bearings bearings (2). If there is hardness or strange attrition, replace them.
C2 F. 72
F. 73
P • Check wear of transmission transmission shaft. If there is excessive wear, replace.
• In the same way, way, check the intermediate double gear.
• Check correct movement of the the bearing (A). If there is strange attrition, replace.
A F. 75 F. 74
• From the opposite side side of the case, check the level of sliding of the bearing (C) and if necessary, necessary, replace it freeing it from the seeger (A).
• Check the output shaft and if there is excessive wear, replace.
F. 76
STARTER MOTOR
V
S
• Remove Remove the starter starter motor. motor. • Check Check wear of the O-ring O-ring (C) and if necessary replace.
A
• Inserti Inserting ng a hexagonal spanner through hole (A), unscrew the screw (V).
C
F. 79
V
D
13
B
S
P
V2
F. 78
STATOR
R
MAGNET FLYWHEEL ROTOR
D
NOTE - Remove the nut (D-F.78) and the underlying underlying washer (R-F.80) keeping the rotor blocked (B). Screw the extractor tool and remove the rotor.
D
• Free Free the rubber rubber pad (A) (A) to allow the cable to pass through the case. • Unscrew Unscrew screws screws (V2). (V2). • Remove Remove the stator stator (S), including the plate (P).
V2
38
A
8
B F. 80
F. 81
T C OIL PUMP
• Spanne Spannerr (C). • Gasket Gasket (G). (G).
• Extract Extract lid lid (1). (1). • Free Free the tube tube (T).
G 1
• V2.
• Extract Extract the full oil oil pump.
V2
V2
5 ± 20%
V
When the oil pump is replaced, always drain it through the special screw (V).
V2 F. 84 F. 85
P
I OIL PUMP CONDUCTOR GEAR
• Conductor Conductor gear pin (P). (P). • V. • Oil seal seal stop plate plate (B). (B).
• Seeger Seeger (A). • Oil pump conduc conductor tor gear (I).
V
A
B
F. 86
F. 87
CASE SEPARATION NOTE - After having having disassem disassembled bled the oil pump and the relevant conductor gear, continue to remove the components of the right case, described below. To remove the full f ull connection rod of the drive shaft, it is necessary to separate the two cases after having previously removed the intake manifold, the lamellar valve
C • Oil seal seal (C). (C).
P
• Lamellar valve valve (B) inclusive of of paper gasket.
LAMELLAR LAMEL LAR VALVE VALVE • V4. • Intake Intake manifold manifold (A). (A).
V4
A
B F. 90
F. 91
CHECK LAMELLAR VALVE VALVE
• Check Check the curvature curvature limit (1) of the lamellar valve. If out-of- tolerance, replace unit.
• Check the lamellar valve unit. unit. If damaged replace.
Standard curvature: 0. 2 mm F. 92
A CASE SPACER • Remove the spacer spacer (A) after having freed it from the seegers (S).
S • Measure the the block height (2). If out-of-tolerance, replace unit. Standard height: height: 4.0 ÷ 4.4 mm
• Separate the two cases using an extractor, extractor, or with light strikes of the plastic hammer in various points (reinforced) in a uniform way, way, without the use of any other tool.
DRIVE SHAFT
V6
V6
6
10 ÷ 12
2
Tighten the screws with “X” sequence in numeric order.
4
During separation the two cases should be kept perfectly axial.
In coupling the two cases, apply a sealing product on both surfaces. F. 96
1 5
3
F. 95
A
• Check the reference dowels dowels (A) are correctly inserted. • Remove Remove the drive drive shaft (B).
B
NOTE - The bearing bearing on on the side side of the the right case (C) remains inside the case, after the connecting rod unit is removed.
• Remove the bearing bearing (C). (C).
C
A F. 98
F. 97
DRIVE SHAFT CHECKS
• From From the other side side of the left case, remove the oil seal (D).
• Check the bearings slide correctly correctly.. • If there is strange attrition, hardness, hardness, etc.. replace them.
P
• Measure Measure eccentricit eccentricity y Max. limit: 0.03 mm If off limit, replace drive shaft.
D F. 99
F. 100
Check the radial play of play of the piston rod, keeping the motor shaft still by hand.
PACKAGING INSPECTIONS • Measure Measure the axial play of play of the piston rod with a lamellar thickness gauge. Standard clearance: clearance: 0,20 - 0,70 mm
Standard clearance: clearance: 0,004 - 0,017 mm F. 101
F. 102
