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ATLANTIS 50/100 C.C.

4T

WORKSHOP MANUAL

This manual has been created by Nacional Motor, S.A. for use in DERBI dealer workshops and sub-agencies. 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 variations in the characteristics of the machines or in the specific repair operations are to be communicated by means of updates to this manual. Completely 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 INDICATES SPECIFIC PROCEDURES THAT MUST BE FOLLOWED TO PREVENT DAMAGE TO THE MACHINE. WARNING INDICATES SPECIFIC PROCEDURES THAT MUST BE FOLLOWED TO AVOID POSSIBLE INJURIES TO THE PERSON REPAIRING THE MACHINE. NACIONAL MOTOR, S.A.U.

TECHNICAL CHARACTERISTICS PERIODICAL MAINTENANCE ENGINE TIGHTENING CHASSIS TIGHTENING SPECIAL TOOLS MAINTENANCE
FRONT FORKS/REAR SHOCK ABSORBER

Pg. 5 Pg. 7 Pg. 8 Pg. 9 Pg. 10

Pg. 11

MOTOR
ENGINE REMOVING THE ENGINE FROM THE FRAME 50 CC 4-STROKE ENGINE 100 CC 4-STROKE ENGINE CHECKING ENGINE OIL LEVEL CHECKING GEARBOX OIL LEVEL CHECKING SPARK PLUG AND BATTERY DISMANTLING THE ROCKER COVER CHECKING THE TIMING CHECKING VALVE PLAY CHECKING FULL COMPRESSION PRESSURE DISMANTLING TRANSMISSION COVER DISMANTLING AND ASSEMBLY OF STARTER UNIT DISMANTLING DRIVING-DRIVEN PULLEY DISMANTLING THE CLUTCH CHECKING DRIVEN SEMI-PULLEY ASSEMBLING THE DRIVEN SEMI-PULLEY ASSEMBLING CLUTCH-BELT-DRIVING PULLEY VARIATOR ROLLERS ASSEMBLING FIXED SEMI-PULLEY-CLUTCH-TRANSMISSION COVER DISMANTLING REAR AXLE HOUSING WHEEL AXLE DISMANTLING DRIVEN SEMI-PULLEY ASSEMBLING DRIVEN PULLEY CAM WHEEL AXLE AND AXLE HOUSING COVER ASSEMBLING BRAKE CAM AND REAR HOLDING SHOES DISMANTLING TURBINE MAGNETO AND STATOR CHECKING THE MAGNETO ASSEMBLING THE MAGNETO

Pg. 12 Pg. 13 Pg. 14 Pg. 15 Pg. 16 Pg. 16 Pg. 17 Pg. 18 Pg. 19 Pg. 20 Pg. 21 Pg. 22 Pg. 23 Pg. 24 Pg. 25 Pg. 26 Pg. 27 Pg. 28 Pg. 29 Pg. 30 Pg. 31 Pg. 32 Pg. 34 Pg. 35 Pg. 36 Pg. 37

MOTOR
LUBRICATION DISMANTLING THE OIL RESERVOIR OIL PUMP CHECKING THE OIL PUMP ASSEMBLING THE OIL PUMP TIMING CHAIN COVER ASSEMBLING THE OIL RESERVOIR DISMANTLING CHAIN TENSIONER DISMANTLING THE TIMING DRIVE DISMANTLING THE CAMSHAFT AND ROCKERS HEAD SEAL DISMANTLING VALVES DISMANTLING THE CYLINDER - PISTON CHECKING THE CYLINDER CHECKING PISTON RINGS PISTON ASSEMBLY CHECKING PISTON HEIGHT FITTING PISTON RINGS - CYLINDER CHECKING CYLINDER HEAD - VALVES CHECKING SPRINGS, VALVE HEADS AND STEMS CHECKING CAMSHAFT CHAIN TENSIONER CHECKING THE ROCKERS ASSEMBLING THE CYLINDER HEAD AND CAMSHAFT ASSEMBLING TIMING COMPONENTS ASSEMBLING THE CHAIN TENSIONER OPENING THE ENGINE CRANKCASE CHECKING CRANKSHAFT ALIGNMENT - CRANKSHAFT BEARING CRANKSHAFT BEARING DISMANTLING AND ASSEMBLY - SEAL CLOSING ENGINE CRANKCASE FILTER CONTAINER VACUUM VALVE DISMANTLING THE CARBURETTOR ASSEMBLING THE CARBURETTOR BATTERY BATTERY CHARGING SYSTEM STARTER RELAY IGNITION LIGHTING SYSTEM AND AUTOMATIC CHOKE BATTERY CHARGING AND STARTING INDICATORS AND LEVELS CHECKING PILOT LIGHTS AND INSTRUMENTS CHECKING THE PICK-UP VOLTAGE REGULATOR 50 C.C.4-STROKE WIRING DIAGRAM 100 C.C.4-STROKE WIRING DIAGRAM

Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg. Pg.

38 39 40 41 42 43 44 45 46 47 48 49 50 51 54 55 56 56 58 59 60 62 63 64 65 66 70 76 77 78 79 80 81 82 83 84 88 89

RULES
This section describes the general safety rules and those for the maintenance of the machine.

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 inflammable, and under certain conditions can explode. Smoking 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 that are non-inflammable or with a high flammability 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 dismantling, checking and assembly operations, only use tools with metric 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

TECHNICAL CHARACTERISTICS
Number of cylinders Cycle Diameter x stroke Cylinder capacity Diameter x stroke Cylinder capacity Compression ratio Timing Depression carburettor Fuel CO regulation Tick-over Air filter Lighting system Lubrication Max. power Max. power Cooling system Valve play (when cold) Transmission Petrol tank Gearbox oil Engine oil Inlet: 0,10mm 1 4 stroke 39 x 41,8 mm 49,93 c.c. 50 x50 mm 98,20 c.c. 11,5 12:1 Single overhead camshaft, two valves, chain driven. KEIHIN CVK 18mm - WALBRO WP 16. lead-free petrol 3,2% 0,5 1900 2000 rpm Sponge type Electric starter/ Kick starter. With chain-driven lobular pump inside the crankcase 2,6 kw at 7.250 rpm 5,0 kw at 9.000 rpm By forced air Exhaust: 0,15mm

ENGINE

With automatic Variator and reduction gears. Capacity: 7.5 litres Reserve: 1.9 litres

Agip GEAR SYNTH (SAE 75/90) - 80 c.c AGIP CITY 4T - 850 c.c.

IGNITION

Capacitative discharge electronic ignition, with HT coil incorporated.


Varialble ignition advance

10 at 1500 rpm Champion RG 4 PHP

26 at 5000 rpm Champion RG 4 HC

Spark plug Magneto Battery Fuse

single phase alternating current 12V-4Ah 4Ah

ENGINE

TECHNICAL CHARACTERISTICS
Front headlight Rear stop/tail light Instrument panel Instrument panel Instrument panel Instrument panel Instrument panel Instrument panel 12v 25/25W lamp 12v.5W sidelight 12v.10W brake light

LIGHTING SYSTEM

12v 2W temperature warning light 12v 2W oil warning light 12v 2W turn indicators warning light 12v 1.2W main beam warning light 12v 1.2W instrument panel light 12v 10W turn light Constructed of steel tubing reinforced with embossed steel plate Hydraulic telescopic with springs Swinging arm and hydraulic shock absorber 65 mm 65 mm 190 mm. disk

FRAME

Type Front suspension Rear suspension Front suspension travel Rear shock absorber travel Front brake rear brake

140 mm internal expansion 1.810 mm 1.265 mm 710 mm 795 mm 1.115 mm 98 Kg 130/60 x13 130/60 x13 1,7 Kg/cm2 1,8 Kg/cm2 1,9 Kg/cm2 2,1 Kg/cm2

DIMENSIONS

Total length Distance between axles Maximum width Seat height Maximum height Weight

TYRES

Front tyre Rear tyre


1 seat front tyre pressure 2 seat front tyre pressure
1 seat rear tyre pressure 2 seat rear tyre pressure

PERIODICAL

MAINTENANCE TABLE
OPERATION FREQUENCY Every 3,000Km Renew every 6 months Renew every 24 months and check every 6 months Renew every 12 months First check after 6 months then every 12 months Renew every 6 months Check every 18 months Check every 12 months Check every 12 months Check every 6 months Renew every 12 months After the second year check every 24 months Check every 12 months Check every 12 months Check every 6 months First replacement after 36 months then every 36 months Check every 6 months Every 2 years First check after 12 months then every 12 months Check every 24 months First replacement after 24 months then every 24 months Check every 6 months First replacement after 24 months then every 24 months First replacement after 12 months then every 6 months Check every 6 months Check every 6 months

Engine oil Engine oil Axle housing reducer oil level Spark plug/spark plug gap Air filter Oil filter Valve play Check tick-over speed/Mixture Gas control Roller container Transmission belt Cylinder cooling Steering Brake control levers Brake pads & linings Flexible brake pressure pipes Brake fluid level Brake fluid Transmission (excluding gas control) Locks Suspension Electrical wiring & battery Front headlight Tyre condition & wear Tyre pressure Test vehicle & braking

Check level/replenish Change Check Check/Renew Clean Change Check Adjust Adjust Renew & Check wear Change Check Adjust Grease Check condition & wear Renew Check Change Lubrication Check Check Check Check/adjust Check condition & wear Check Road test

NAME
Cranckase halves joining bolt Cylinder head cover bolt Cylinder-head studs Bolt securing dylinder head and cylinder to the crankcase Spark plug Chain tensioner roller bolt Timing chain tensioner bolt Timing chain tensioner centre bolt Camshaft pulley bolt Rocker shaft and camshaft bearing bolt Valve play adjusting locknut Engine oil pre-filter plug Engine oil drain plug Magneto nut Stator screws Oil pump body bolt Oil pump/timing chain cavity cover bolts Oil delivery labyrinth sheet bolts Pick-up bolts Oil pump crown bolt Bolts securing the oil pump to the crankcase Oil pump connecting bolts Oil sump bolts Scavenge pipe bolts Starter motor bolts Crankcase cooling deflector bolt Clutch assembly locking nut on pulley Driven pulley nut Crankshaft pulley nut Plastic t. oil filler Ttransmission cover screws Gearbox oil drain screw

TIGHTENING TORQUES (Nw x m)


8 - 10 8 - 10 6-7 8 - 10 10 - 15 5-7 8 - 10 5-6 12 - 14 3-4 7-9 25 - 28 25 - 28 40 - 44 3-4 4-5 4-5 7-8 3-4 8 - 10 5-6 0,7 - 0,9 8 - 10 7-9 11 - 13 2 - 2,5 55 - 60 40 - 44 18 - 20 3-5 11 - 13 3-5 +90 +90 +90

NAME
M10x150 8.8 Securing shock - chassis top M10x150 8.8 Sec. Bottom shock - engine M10x150 8.8 Sec. Engine - chassis silentbloc M10x150 8.8 Sec. Engine mounting bolt M8 x125 8.8 Sec. Rear engine - support M10 x150 8.8 Sec. Rear engine - chassis M6X100 8.8 Sec. Engine rear silentbloc flange M14X200 Sec. Rocker M16X125 Sec. Change out. gear housing M35X100 Sec. Change out. gear M6X 100 Sec. Engine - filter container M6x100 Sec. Horn - chassis M24X100 Sec. Steering fork - chassis M6x100 8.8 Sec. Exhaust pipe - cylinder M8x125 8.8 Sec. Exhaust pipe Crankcase M6x100 8.8 Sec. Steering lock - chassis M8x125 8.8 Sec. Handlebars - steering forks M8x125 8.8 Sec. Handlebar flange M5x 80 8.8 Sec. Counterweight - handlebarss M14x200 Sec. Front wheel - forks M8x125 Sec. Fork arm lock M6x100 Sec. Brake disk - front wheel M10x1. 5 Sec.Front rear brake caliper - forks M14x200 Sec. Rear wheel M6X100 10.9 Sec. Drag plate - wheel M8x125 10.9 Sec. Brake disk - rear wheel M8x125 SEC. Sec. Prop stand - chassis M10x150 10.9 Brake rod M8x125 8.8 Sec. Sissy bar - chassis M6x100 Sec. radiator - chassis M5x80 Sec.Various metal parts to chassis M6x100 Sec.Various metal parts to chassis M8x125 Sec.Various metal parts to chassis M5x80 Sec. Various plastic parts to chassis M6x100 Sec. Various plastic parts to chassis Locktite 243-Type thread sealer

TIGHTENING TORQUES (Nw x m


30 - 40 30 - 40 30 - 40 20 - 30 17 - 19 30 - 40 8 - 10 70 - 80 115 - 125 115 - 125 8 - 10 8 - 10 9 - 13 9 - 12 17 - 19 8 - 10 17 - 19 17 - 19 3,4 - 4,5 35 - 50 15 - 19 8 - 10 35 - 40 70 - 80 10 - 12 25 -29 15 - 19 35 - 40 17 - 19 8 - 10 3,5 - 4,5 8 - 10 15 - 19 1-2 2 - 3,5 SEALER SEALER SEALER SEALER SEALER SEALER

SPECIAL

TOOLS

OPERATION
37x40 Adapter 42x47 Adapter 52x55 Adapter 24mm Adapter Vacuum pump bearing fitting base Vacuum pump Oil seal extractor Bearing extractor Magneto flywheel extractor 12mm guide 17mm guide 20mm guide 25mm guide Crankshaft aligning tool Crown wheel immobiliser Forked spanner Handle for punches Starter spring Blowlamp Bell punch Bearing seal punch Seal fitting punch Valve seal fitting punch Magnetic bracket and comparer Shaft fitting tool Assembly/dismantling tool Camshaft dismantling instrument Valve dismantling instrument Valve dismantling instrument Clamp for fitting piston into cylinder Clutch dismantling and assembly instrument 020358Y 020359Y 020360Y 020456Y 020265Y 020329Y 020431Y 004499Y 020162Y 020362Y 020439Y 020363Y 020364Y 020074Y 020451Y 020565Y 020376Y 020432Y 020151Y 001467Y29 020171Y 020340Y 020306Y 020335Y 008119Y009 020452Y 020450Y 020382Y/ 020382Y/11 020288Y 020444Y

FREQUENCY

10

KAYABA

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 remove 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 travel: Diameter of the bars: Oil capacity in each bar: Type of oil : 65mm 26mm 47 c.c. AGIP FORK SAE 7,5 W A

Fork stem assembly is carried out by reversing the dismantling procedure.

REAR

S OC SHOCK ABSORBER SO

ATLANTIS 50/100
Shock absorber length Shock absorber travel Spring length Spring compression at 30 mm. Spring compression at 60 mm. Rod 257mm 60mm 191mm 142 Kgf mm 282 Kgf mm 10mm

11

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 and mixer. - Disconnect the pipes - petrol, oil and vacuum valve control pipes.

WARNING

TAKE THE UTMOST CARE WHEN HANDLING PETROL.

DISMANTLE S

ENGINE/SHOCK ABSORBER SUPPORT G S OC SO SU O

Remove bottom shock absorber nut. Remove engine mounting nut and shaft.

MOUNTING

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 - 40Nm Engine/ engine mounting tightening torque: 33 - 40Nm

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 USING PERCUSSION TOOLS.

12

50 C.C 4T

STROKE ENGINE

CHARACTERISTICS
Type Diameter Run Cylinder capacity Compression ratio Timing Depression carburettor Lubrication 39 mm 41,8 mm 49,93 cm3 11,5 12:1

DESCRIPTION
Single cylinder 4-stroke

Single overhead camshaft, two valves, driven by a chain on the left side. KEIHIN CVK 18mm 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. By forced air 2,5 Kw (3,4 HP) at 6500 rpm. Variable by microprocessor from 8 to 1500 rpm at 24 at 5000 - 6000 rpm Champion RG 4 PHP Champion RG 4 HC

Power supply

Cooling Max. power Ignition advance Spark plug Transmission

With an expandable pulley automatic variator, torque compensator, V-belt, automatic clutch, gearbox. Inlet: 0,10mm Exhaust: 0,10mm AGIP CITY 4T (4-stroke) ~ 850 c.c. AGIP GEAR SYNTH 75/90 80 c.c. Per belt 3.07-0.93

Valve play (when cold) Recommended engine oil Quantity Axle housing oil Quantity 4-stroke transmission variator 50 ratio

13

100 C.C 4T STROKE ENGINE


CHARACTERISTICS
Type Diameter Run Cylinder capacity Compression ratio Timing Depression carburettor Lubrication 50 mm 50 mm 98,20 cm3 11,5 12:1 Single overhead camshaft, two valves, driven by a chain on the left side. KEIHIN CVK 18mm WALBRO WP 16A With chain-driven lobular pump (inside the crankcase). Netting pre-filter and centrifugal filter housed above the crankshaft. Gravity fed, with lead-free petrol (minimum 95 octane) by way of a carburettor. By forced air 5 Kw 9000 rpm Variable by microprocessor from 8 to 1500 rpm at 24 at 5000 - 6000 rpm Champion RG 4 PHP Champion RG 4 HC

DESCRIPTION
Single cylinder 4-stroke

Power supply

Cooling Max. power Ignition advance Spark plug Transmission

With an expandable pulley automatic variator, torque compensator, V-belt, automatic clutch, gearbox. Inlet: 0,10mm Exhaust: 0,10mm AGIP CITY 4T ~ 850 c.c. AGIP GEAR SYNTH 75/90 80 c.c. Per belt 2.89 - 0.79

Valve play (when cold) Recommended engine oil Quantity Axle housing oil Quantity 4-stroke transmission variator 100 ratio

14

CHECKING C G

O OIL 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 CITY 4T (4-STROKE)

CHANGING G G

THE OIL AND FILTER O

Carry out the oil change with the engine hot. Place a container under the oil reservoir and remove the oil drain plug Once the oil has been drained, the net filter needs 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 Nm Tighten successively the oil drain plug. Tightening torque: 25 28 Nm Fill the engine with AGIP CITY 4T four-stroke oil using the oil filler hole at the top of the oil reservoir. Engine oil capacity: ~ 850 cc. Screw the plug tight manually. N.B. RUN THE ENGINE FOR A FEW MINUTES, THEN RECHECK THE OIL LEVEL WITH THE ENGINE COLD; THIS SHOULD BE ALWAYS BELOW THE MAX. LEVEL. N.B. IN THE CASE OF A FIRST FILLING OR A SERVICE, INSERT 850 CC OF ENGINE OIL; IN OTHER CASES, ALMOST 650 CC, AND THEN ANY NECESSARY REPLENISHMENT.

15

CHECKING THE GEARBOX OIL LEVEL AND RENEWING.


To check the axle housing oil, remove the dipstick plug 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 once more and check 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 approximately 80 cc of oil into the axle housing using the dipstick plug hole. - Check the level (with the plug completely screwed down). Oil used: AGIP GEAR SYNTH 75/90 Oil drain screw tightening torque: 15 17 Nm

SPARK

PLUG UG

To carry out inspection of the spark plug, it is necessary 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 torque: 10 15 Nm Spark plug gap: 0,8 0,9 mm Recommended spark plug: Champion RG 4 HC NGK CR9E

16

INSTRUCTIONS

FOR 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. BEFORE DISMANTLING THE COVER, REMOVE THE CENTRE BOLT FROM THE TIMING CHAIN TENSIONER WITH ITS CORRESPONDING SPRING AND WASHER AN INDISPENSABLE OPERATION TO PREVENT EXCESSIVE TENSION ON THE TIMING CHAIN. THIS IS PRODUCED BECAUSE THE TIMING COVER COMPRESSES THE BOTTOM CHAIN ROLLER. IF THE THRUST BOLT IS NOT REMOVED FROM THE CHAIN TENSIONER, THE LATTER SHOOTS FORWARD ONCE THE COVER IS REMOVED, AND IN REFITTING, THE CHAIN IS TOO TIGHT, WHICH CAN CAUSE DAMAGE TO THE TIMING CHAIN/ROLLER ASSEMBLY. - Remove the 4 rocker cover fixings; Remove the cover with the ring seal.

DISMANTLING

THE THRUST COVER

Oil delivery system The oil delivery system is the labyrinth type, and therefore requires no maintenance. N.B. IN THE EVENT OF HIGH MILEAGE OR LACK OF MAINTENANCE, THE LABYRINTH SHOULD BE SUITABLY CLEANED, BY REMOVING THE FOUR SCREWS AND THE PLATE COVER.

17

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 DURING EXTRACTION OF THE DEFLECTOR, TAKE CARE NOT TO DAMAGE THE ELECTRICAL WIRING OF THE STATOR.

FAN

COVER CASING

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

CHECKING C G

THE TIMING G

Turn the magneto in a clockwise direction until the 2nd groove on it is lined up with the pick-up reference groove, as shown in the figure. Ensure that the reference mark on the camshaft crown wheel is lined up with 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.

18

CHECKING/ADJUSTING

VALVE PLAY

To perform a valve play check, the timing reference 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 different than those indicated, adjust them by loosening 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 SCREWS locking torque: 8 10 Nm

19

CHECKING C G

FULL COMPRESSION PRESSURE U CO SS O SSU

- 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 Nm. Turn the engine over with the starter and with the carburettor fully open until the manometer indicator becomes stable. 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 (piston rings, valves etc, cylinder head and timing).

N.B. WHEN THERE ARE DIFFICULTIES IN INSERTING THE MANOMETER THREAD, DISCONNECT THE ENGINE CONNECTION BOLT- SWINGING ARM AND PUSH BACK THE ENGINE ASSEMBLY ENOUGH TO ALLOW THE METER TO BE SCREWED IN.

Full compression pressure Minimum acceptable value: 11. Kgr. Engine revs: ~ 630 rpm (turning over with starter).

20

TRANSMISSION

COVER

- Unscrew the 11 fixing screws. - Remove the oil filler cap and extract the cover. N.B. TO EXTRACT THE COVER, TAP THE CORRESPONDING PROTRUSIONS WITH A WOODEN MALLET. 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 SHAFT KEEPS THE SPRING LOADED. PAY ATTENTION TO PREVENT 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.

21

DISMANTLING
BEARING

THE DRIVEN PULLEY SHAFT SUPPORT

- 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
BEARING

THE DRIVEN PULLEY SHAFT SUPPORT

- Fit the bearing with the aid of a bush of the same diameter as the outer diameter of the bearing, after having heated the crankcase slightly on the inner side. N.B. WITH EACH REFITTING, ALWAYS RENEW THE BEARING. ATTENTION DURING THE BEARING REMOVAL AND REFITTING OPERATIONS, TAKE CARE NOT TO DAMAGE THE PAINTED SURFACE.

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 tool: Tool for fitting starter spring: 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.

22

DISMANTLING S G

DRIVING PULLEY G U

- 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 tool: Driving pulley detaining spanner: 020451Y

DISMANTLING S G

THE DRIVEN PULLEY U

Lock the clutch bell using the special tool. - Remove the nut, the clutch bell and all the driven pulley assembly N.B. THE ASSEMBLY CAN ALSO BE DISMANTLED WITH THE DRIVING PULLEY FITTED. Special tool: Forked spanner: 020565Y - Check that the clutch bell is not worn or damaged. - Measure the internal diameter of the clutch bell. Standard value: 107 +0,2 +0 mm. Max. value: 107,5 mm N.B. CHECK THE ECCENTRICITY MEASUREMENT: MAX 0.20 MM

23

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 TOOL. - 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 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 TRANSMISSION BELT SLIDING SURFACE FROM BEING DISTORTED. - Expel the ball bearing assembly using: a punch holder, 20 mm guide. Special tools: Bell: 001467Y029 Punch holder: 020376Y 20 mm guide: 020363Y.

24

FIXED

DRIVEN SEMI-PULLEY

- Measure the outer diameter of the pulley bush. Minimum admitted diameter: 33,96 mm Standard diameter: 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: 34,08 mm

ASSEMBLING

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 THREADED END DURING THE BEARING FITTING. Special tools: Punch holder: 020376Y 24 mm adapter: 020456Y 12 mm guide: 020362Y Punch for roller bearings: 020171Y

25

ASSEMBLING SS G

THE MOBILE DRIVEN SEMI-PULLEY O S U

- 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 CARE WHEN FITTING THE MOBILE DRIVEN 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. Standard length: 110 mm - Check the thickness of the clutch plate friction material. Minimum admitted thickness: 1 mm - The material must show no signs of lubricants. If there are any, check the driven pulley assembly. N.B. THE FRICTION MATERIAL ON THE TURNING SURFACE SHOULD PRESENT A CENTRAL CONTACT SURFACE AND SHOULD NOT DIFFERENT ONE FROM THE OTHER. DIFFERENT CONDITIONS MAY CAUSE THE CLUTCH TO BREAK UP. ATTENTION DO NOT OPEN UP THE MATERIAL WITH TOOLS, TO PREVENT A LOAD VARIATION OF THE RETURN SPRINGS.

26

ASSEMBLING

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 AVOID DAMAGING THE CLUTCH NUT, USE AN ALLEN KEY WITH A SMALL BEVEL. Tightening torque: 55 60 Nm

TRANSMISSION

BELT

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

DRIVING G

PULLEY U

- Check that the internal bushing shown in the figure is not abnormally worn and measure the internal diameter A. Maximum admitted diameter: 20,12 mm Standard 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 admitted diameter: 19,95 mm Standard diameter: 19,959 mm

27

VARIATOR

ROLLERS

- Check that the rollers are not damaged or worn. Minimum admitted diameter: 18,5 mm Standard diameter: 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 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 mobile driven semi-pulley manually by pulling 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, the belt is free inside it, to avoid making a false tightening and successive damage to the crankshaft. N.B. IT IS GOOD PRACTICE TO ALWAYS FIT THE BELT WITH THE INSCRIPTIONS READABLE IN THE CASE OF A FITTING DIRECTION NOT BEING INDICATED.

28

ASSEMBLING

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 Nm and perform successively a definitive tightening of 90, using the special tool to prevent the driving pulley from turning. N.B. REPLACE THE NUT WITH A NEW ONE FOR EVERY REFITTING. Tightening torque plus angle: 18 20 Nm + 90 Special tool: Driving pulley holding spanner: 020451Y

ASSEMBLING

THE CLUTCH BELL

- Fit the driven pulley assembly, the clutch bell and the nut, using the special tools. Tightening torque: 40 44 Nm Special tool: Forked spanner: 020565Y

FITTING

THE TRANSMISSION 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 torque: 11 13 Nm

29

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 MACHINE, THE SILENCER FIRST NEEDS TO BE DISMANTLED TOGETHER WITH THE REAR WHEEL.

DISMANTLING S G

REAR BRAKE CONTROL LEVER AND CAM CO O C

- Remove the cam control lever locking screw and extract the cam, taking care with the seal. N.B. FOR EASY EXTRACTION, DO NOT TURN THE CAM DURING DISMANTLING.

REAR

AXLE HOUSING

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

DISMANTLING S G

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 the bearing by pushing from the outer side into the gear assembly cavity using the corresponding punch. Special tools: Punch holder: 020376Y 20 mm guide: 020363Y 37x40 adapter: 020358Y

30

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 tool: Tube for assembling/dismantling driven pulley shaft: 020452Y

CHECKING

THE AXLE HOUSING SHAFT AND 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 tool: Tube for assembling/dismantling driven pulley shaft: 020452Y

31

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 BEARING ASSEMBLY WITH THE INSULATION TOWARDS THE OIL SEAL. 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 for fitting/dismantling driven pulley shaft: 020452Y

32

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. - Fit the Seeger ring and oil seal with the aid of the 42 x 47 mm adapter and the holder. Special tools: Blowlamp: 020151Y Punch holder: 020376Y 20 mm guide: 020363Y 42 x 47 adapter: 020359Y

ASSEMBLING THE WHEEL AXLE AND THE AXLE HOUSING


COVER
- Fit the wheel axle complete. - Fit the intermediate gear, taking care with the adjustment foils. - Apply LOCTITE 510 to the axle housing cover flat 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 CONTACT SURFACES TO REMOVE RESIDUE OF PREVIOUS SEALS BEFORE APPLYING A NEW SEAL. Tightening torque: 24 26 Nm

33

ASSEMBLING

THE REAR BRAKE CAM

- Check that the cam and the rear brake 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 torque: 11 13 Nm

ASSEMBLING

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 with the springs in the opposite order to the dismantling. N.B. IF THE REAR BRAKE IS FOUND TO BE NOISY, CHECK THAT THE SHOES ARE RESTING CORRECTLY ON THE BOLT. FOR THE SAME REASON, THE SPRINGS SHOULD TAKE ON A CURVED POSITION, RESTING ON THEIR RESPECTIVE SUPPORTS LOCATED ON THE AXLE HOUSING.

DISMANTLING S G

THE TURBINE COVER U CO

- Remove the turbine cover by unscrewing the 6 securing screws. ATTENTION DURING THE EXTRACTION, REMOVE THE CONNECTOR FROM ITS HOUSING ON THE TURBINE COVER.

34

DISMANTLING

THE COOLING TURBINE

- 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 USE OF A FORKED SPANNER THAT IS NOT PART OF THE BASIC EQUIPMENT MAY DAMAGE THE STATOR COILS. Using the extractor, carry out the extraction of the magneto. 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.

35

36

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 values derive from distortions caused to the pick-up support. N.B. A VARIATION OF THE AIR GAP DISTANCE MAY CAUSE A VARIATION IN THE IGNITION ADVANCE THAT MAY LEAD TO BACKFIRING, ETC. Tightening torques: Magneto flywheel nut: 40 44 Nm Magneto fan screws: 3 4 Nm Cooling deflector screws: 2 2,5 Nm

ASSEMBLING SS G

TURBINE COVER/MAGNETO DEFLECTOR U CO G O C O

- Fit the fan onto the magneto flywheel. - Fit the fan cover, tightening the 6 screws. ATTENTION PAY ATTENTION TO THE CORRECT POSITION OF THE MAGNETO CONNECTOR. - Ensure that the spacers are fitted to the two rear deflector fixings. - The long spacer must be fitted at the top.

37

LUBRICATION U C O

38

DISMANTLING

THE OIL 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 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 TURNING DIRECTION IS MAINTAINED.

39

CHECKING

THE OIL 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.

- Use a feeler gauge to check 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 THAT THE FLAT BAR IS RESTING CORRECTLY ON THE TWO POINTS OF THE PUMP BODY SURFACE.

40

ASSEMBLING

THE OIL 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. - 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 crankcase 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 WASHER WITH THE OUTER (CURVED) PERIMETER IN CONTACT WITH THE PULLEY. Centre bolt tightening torque: 12 14 Nm Cover screws tightening torque: 0,7 0,9 Nm Oil pump bolt tightening torque: 5 6 Nm 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. - Operations involving the chain cover oil seal should 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 ( 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.

41

- 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 tools: Holder for adapters: 020376Y 37 x 40 mm adapter: 020358Y Tightening torque: 4 5 Nm

ASSEMBLING SS G

THE OIL RESERVOIR O S O

- Clean and degrease the contact surfaces. - Apply LOCTITE 510 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 torque: 8 10 Nm

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 TO THE LATTER.

DISMANTLING

THE TIMING CHAIN TENSIONER

- 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 bracket, taking care to recover the seal.

42

DISMANTLING

THE TIMING 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 washer. - Remove the rocker cover. - Remove the centre bolt and the cup washer indicated in the figure, locking the camshaft crown wheel with the special tool.

N.B. TO AID THE EXTRACTION OF THE CYLINDER HEAD COMPONENTS, IT IS ADVISABLE TO PUT THE CRANKSHAFT AT COMPRESSION STROKE TOP DEAD CENTRE. (T.D.C). 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 TURNING DIRECTION IS MAINTAINED. THE BOTTOM CHAIN GUIDE ROLLER CAN BE EXTRACTED FROM THE CYLINDER HEAD, EXTRACTING UPWARDS.

43

DISMANTLING

THE CAMSHAFT AND 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 EVENT OF THE CAMSHAFT BEARING SEPARATING, A NEW BEARING MUST BE FITTED.

Special tools: Tool for dismantling/assembling the camshaft: 020450Y Bearing extractor: 004499Y (equipped with parts: 1, 2, 3, 6, 27)

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

N.B. MARK THE FITTING POSITION OF THE ROCKERS TO PREVENT SWITCHING THE INLET WITH THE EXHAUST.

44

HEAD

GASKET

The engines mentioned are built with two head gasket solutions: - Fibre gasket - Steel gasket with cylinders of 56.44 mm height. with cylinders of 57.15 mm height.

Con el objeto de garantizar una correcta relacin de compresin las dos juntas se acoplan con cilindros de distinta altura: - Junta de fibra - Junta de acero con cilindro de 56,45 mm de altura. con cilindro de 57,15 mm de altura.

Both gaskets are supplied as replacement parts for carrying out servicing. The gudgeon pin piston cylinder assemblies supplied for replacement parts are all with cylinders of 57.44 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 CAMSHAFT AND ROCKERS, AND WITHOUT REMOVING THE DRIVEN PULLEY ASSEMBLY, BUT FOR THIS, THE TIMING CHAIN NEEDS TO BE SECURED WITH A METAL WIRE AND THE CHAIN TENSIONER ADJUSTED DURING ASSEMBLY.

DISMANTLING

THE VALVES

- Using the special tool (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 tool: Tool for dismantling/assembling valves: 020382Y

45

- Remove the oil seal with the corresponding tool. - Remove the bottom spring supports. Special tool: Valve oil seal extractor: 020431Y

DISMANTLING

PISTON CYLINDER

- Remove the cylinder. Paying attention to the 2 cylinder centring pins on the crankcase. - Remove the cylinder bottom gasket. ATTENTION TO PREVENT DAMAGE TO THE PISTON, HOLD IT DURING THE CYLINDER DISMANTLING. - Remove the 2 stop rings, the gudgeon pin and the piston. - Remove the 3 piston rings. N.B. TAKE CARE NOT TO DAMAGE THE PISTON RINGS DURING DISMANTLING

CHECK

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 GREATER THAN THE ADMITTED DIAMETER, APPEARS WORN OR OVERHEATS, REPLACE THE CRANKSHAFT AS DESCRIBED IN THE CRANKCASE AND CRANKSHAFT CHAPTER. - Check the outer diameter of the gudgeon pin. Standard diameter: 13 -0 -0.004 mm Minimum admitted diameter: 12.990 mm

46

- Calculate the piston gudgeon pin coupling play. Standard piston diameter: 13+0.010 +0.005 mm Standard play: 0.005 - 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 C G

THE CYLINDER C

- 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 coupling is done in pairs (A-A, B-B,C-C,D-D).

REBORING

THE CYLINDER

- The operation of cylinder reboring must be performed with a finish that respects the original angulations: at 120 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. - Oversized pistons are available for rebored cylinders, subdivided 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.

47

THE

PISTON S O

- 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:


1st segment 2nd segment Oil scraper Values in mm 0,030 0,065 0,020 0,055 0,040 0,160

Admitted plays after use


0,080 0,070 0,20

PISTON S O

S G SEGMENTS S

- 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 COUPLING PLAY WITH THE SLOTS AND THE PISTON WITH THE CYLINDER ARE RESPECTED. IN ANY EVENT, NEW PISTON RINGS FITTED TO A USED CYLINDER MY PRESENT SEATING CONDITIONS DIFFERENT TO THE STANDARD CONDITION.

Standard value
1st segment 2nd segment Oil scraper Valores en mm 0,08 0,20 0,05 0,20 0,20 0,70

Maximum value
0,35 0,30 0,8

48

ASSEMBLING SS G

THE PISTON S O

- Fit the piston and the gudgeon pin onto the connecting rod, with the arrow pointing towards the exhaust. - Insert the gudgeon pin stop ring in the special tool. Special tool: Tool for fitting gudgeon pin stop 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 90 bevel is always pointing upwards as indicated in the figure. - Fit the gudgeon pin using the rod. ATTENTION THE USE OF A HAMMER TO FIT THE RETAINS MAY DAMAGE THE STOP SEAT HOUSINGS.

CHECKING C G

PISTON HEIGHT S O G

- 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 comparators rotation inversion point) - Measure the protrusion of the piston relative to the head surface and use the 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. Standard compression ratio: R.C. 11,5 12 : 1

49

CYLINDER HEIGHT
Head gasket thickness (fibre) Measurement detected 0,9 0,05 1 0,05

56,45 0,05 0,95 0,06 Bottom gasket thickness 0,4 0,5 57,15 0,05 0,3 0,05 Bottom gasket thickness 0,4 0,5

ALTURA CILINDRO
Bottom gasket thickness (steel) Measurement detected 0,20 0,05 0,30 0,05

ASSEMBLING

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 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 OBTAIN A BETTER SEATING OF THE 2 SEALING RINGS, THEY ARE MADE WITH A TAPERED SECTION IN CONTACT WITH THE CYLINDER. FOR THIS REASON IT IS IMPORTANT TO RESPECT THE FITTING OF THE RINGS WITH THE T INDICATION FACING UPWARDS. STAGGER THE RING GAPS AT 120 AS INDICATED IN THE FIGURE. GREASE THE PARTS WITH MOTOR GREASE.

50

ASSEMBLING SS G

THE CYLINDER C

- 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 THROUGH THE LUBRICATION DUCT AND GREASE THE CYLINDER WALL.

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

CHECKING C G

THE CYLINDER HEAD C

- Use a flat bar to check that the cylinder head surface is flat, and check that it has no signs of wear or distortions. Maximum admitted deviation from 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 B C 32,015 32,025 16,0 16,018 11,0 11,018

51

CHECKING C G

VALVE SEALING S G

- 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 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.

EXHAUST GUIDE

Standard diameter: 5 +0 +0,012 mm Wear limit: 5,022 mm

INLET GUIDE

Standard 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.

52

CHECKING C G

THE VALVES S

- 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 the play between the valve and 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 operation should be done delicately, using fine grain grinding paste. During the grinding operation, keep the cylinder head in a vertical position, to prevent grinding paste residue from penetrating into the valve stem/valve guide coupling. ATTENTION TO AVOID SCRATCHING THE CONTACT SURFACE, DO NOT CONTINUE ROTATION ONCE THE GRINDING PASTE HAS BEEN USED UP. WASH THE CYLINDER HEAD AND THE VALVES CAREFULLY WITH A PRODUCT SUITABLE FOR THE GRINDING PASTE USED.

53

VALVE

AIRTIGHTNESS TEST G SS S

- 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 C G

THE SPRINGS, PLATES AND COLLETS S GS S CO S

- Check that the spring top retainer plates and the collets show no signs of abnormal 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 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 into their respective stem cut-outs. Special tool: Valve spring compressor: 020382Y

54

CHECKING C G

TIMING COMPONENTS G CO O S

- 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 found, renew the parts; in the event of wear to the chain, sprocket or pulley, renew the whole assembly.

CHECKING

THE TIMING CHAIN TENSIONER

- 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 CAMSHAFT

- Check that there is no excessive wear to the camshaft supports


STANDARD DIAMETER

Support A : 12 +0,002 +0,010 mm Support B : 16 -0,015 0,023 mm


MINIMUM ADMITTED DIAMETER

Support A : 11,98 mm Support B : 15,96 mm

STANDARD HEIGHT

Inlet: 25,935 mm Exhaust: 25,935 mm N.B. THERE IS A BALL BEARING ASSEMBLY FITTED TO SUPPORT A; THEREFORE SUPPORT B IS THE MORE IMPORTANT SINCE IT OPERATES DIRECTLY ON THE CYLINDER HEAD ALUMINIUM. Maximum axial play admitted: 0,5 mm - If values other than the set ones are found, renew the defective parts.

55

CHECK

ROCKERS

- Check that the rocker shaft is not scratched or worn. - Measure diameter A. Minimum admitted diameter: 10,970 mm - Check the internal diameter of each rocker: height B. Maximum admitted diameter: 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 G G

THE CYLINDER HEAD NUTS C U S

In case of renewal of the four double-ended cylinder studs, in the engines in question, it is necessary to tighten the cylinder head bolts by following the procedure indicated below. Cylinder head nuts tightening (only for renewed studs) 67 N*m + 135 + 90 Cylinder head nuts tightening (only for renewed studs) 67 N*m + 90 + 90 + 90 The reduction of 45 in the turning of the spanner is necessary to prevent possible stretching of the studs.

ASSEMBLING

THE CYLINDER HEAD AND CAMSHAFT

- Rest the cylinder head in a stable manner on a flat work surface. - Press the camshaft 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.

56

- 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 Nm. 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 torque: 3 4 Nm

- Finish tightening the cylinder head according to the following procedure: tighten with an initial torque of 6-7 Nm in two passes crossing diagonally the four cylinder head nuts. Finally tighten the nuts with 2 turns of 90 carried out in two diagonal cross passes. N.B. IN THE CASE OF RENEWING THE ENGINE CRANKCASE OR THE CYLINDER STUDS, IT IS NECESSARY TO PERFORM AN INITIAL TIGHTENING OF 6-7 NM PLUS 3 FINAL TIGHTENINGS OF 90 PERFORMED IN 3 DIAGONAL CROSS PASSES. - Complete the tightening of the cylinder head to the crankcase with the 2 side bolts. Tightening torque: 8 10 Nm

57

ASSEMBLY

OF TIMING 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 correct movement of the tensioner roller. Tightening torque: 5 7 Nm - 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.

58

- 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 torque: 12 14 Nm - 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 torque: 8 10 Nm Special tool Forked spanner: 020565Y

ASSEMBLING

CHAIN TENSIONER

- 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 torque: 8 10 Nm - Fit the spring with the centre bolt and washer, and tighten the cover to the prescribed torque. Tightening torque: 5 6 Nm

FITTING

THE SPARK PLUG

Tightening torque: 10 15 Nm Prescribed spark plug: Champion RG 4 PHP Champion RG 4 HC Spark plug gap: 0,7 0,8 mm

59

-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 torque: 7 9 Nm - Fit the carburettor to the inlet manifold and tighten the clamp.

N.B. TURN THE CARBURETTOR USING THE LUG LOCATED ON THE MANIFOLD. - Previously extract the following assemblies:transmission 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 the cylinder-piston-cylinder head assembly as described in the Cylinder - Cylinder Head Timing 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.

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- Remove the crankshaft. ATTENTION ON THE MAGNETO SIDE OF THE SHAFT THERE IS A CENTRIFUGAL OIL FILTER. IT IS THEREFORE RECOMMENDED NOT TO WASH WITH SOLVENT OR TO BLOW THROUGH WITH COMPRESSED AIR, SO AS NOT TO CAUSE IMPURITIES TO EMERGE. THE CENTRIFUGAL OIL FILTER HAS A LIFESPAN 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. Standard play: 0,15 0,30 mm Maximum 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. Standard play: 0,06 0,018 mm Maximum play: 0,25 mm

- Check that the surfaces of the half-shafts show no signs of scratching, and use a calliper meter to check the width of the crank as indicated in the figure. Standard measurement: 45 mm

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CHECK

CRANKSHAFT ALIGNMENT.

- Refit the crankshaft onto its support and measure the alignment deviation at the 4 points indicated in the figure. Max. admitted deviation: A = 0,15 mm B = 0,02 mm C = 0,02 mm D = 0,10 mm N.B. IF VALUES ARE FOUND THAT ARE ONLY A LITTLE HIGHER THAN THOSE ADMITTED, PERFORM A STRAIGHTENING OF THE CRANKSHAFT USING A WOODEN WEDGE INSERTED BETWEEN THE HALF-SHAFTS OR COMPRESSING THE LATTER IN A VICE IF NECESSARY. IF IN THIS CASE VALUES ARE FOUND WHICH ARE DIFFERENT FROM THE ADMITTED ONES, REPLACE WITH A NEW CRANKSHAFT.

Special tools: Crankshaft alignment tool: 020074Y Magnetic support and comparator: 020335Y

DISMANTLING

AND ASSEMBLING THE TRANSMISSION SIDE MAIN BEARING


- Secure the crankcase on a flat surface with the crankshaft axis vertical. - Heat up the crankcase to 120C 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 into the crankcase; where necessary, use a mallet, but taking great care not to damage the stop on the engine crankcase. Special tools:
DISMANTLING:

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


FITTING:

020359Y 020364Y 020376Y 020360Y 020364Y 020376Y

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

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DISMANTLING

AND ASSEMBLING THE TRANSMISSION S SIDE MAIN BEARING G


- Using the special tool, remove the magneto side bearing, fitted to the crankshaft. Special tool: Bearing extractor 004499Y, equipped with parts: 1, 2, 3, 6, 34.

- Heat a new main bearing up in oil to 120C. - 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 OIL FILTER. IT IS THEREFORE RECOMMENDED NOT TO WASH WITH SOLVENT OR TO BLOW THROUGH WITH COMPRESSED AIR, SO AS NOT TO CAUSE IMPURITIES TO EMERGE. Special tool: Base for fitting bearings: 020265Y Tube (shaft fitting 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 TOOL MAY LEAD TO POOR SEATING AND A CONSEQUENTLY POOR OIL SEAL PERFORMANCE. Special tool: Punch for fitting magneto side oil seal 020340Y

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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 LOCTITE 510 to the flat surfaces on the crankcase transmission side section after having carefully greased the two contact surfaces. - Fit the magneto crankcase section. - Screw in the 10 bolts and tighten to the prescribed torque. Tightening torque: 8 10 Nm N.B. DURING ASSEMBLY OF THE CRANKCASE SECTIONS AND THE CRANKSHAFT, TAKE CARE NOT TO DAMAGE THE THREADED PINS OF THE 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 torque: 25 28 Nm

FITTING G

THE STARTER MOTOR S O O

- Fit a new ring seal onto the starter motor and grease it. - Fit the starter motor onto the engine crankcase and tighten the 2 bolts to the prescribed torque. Tightening torque: 11 13 Nm

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FILTER

CANISTER

- To clean the filter element, carry out the following operations: 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 in an equal mixture of Agip Filter Oil and 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 COMPLY WITH THESE INSTRUCTIONS MAY LEAD TO INCORRECT VACUUMS INSIDE THE FILTER CANISTER, WITH RESULTING VARIATION IN CARBURATION.

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 FILTER CAN BE UNSCREWED FROM THE VALVE TO AID THE CLEANING OPERATION.

65

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. - Connect the vacuum tube to the collector. - Fit the fuel pipe with the outlet at the same height as the valve. - Turn the engine over with the starter for 5 seconds with the throttle closed. - Extract fuel using a graded test tube. Minimum flow:: 20 c.c. Special tool: MITYVAC-type vacuum pump: 020329Y N.B. A FALSE MEASUREMENT MAY ARISE DUE TO AN INCORRECT NUMBER OF TURNS OR AN INCORRECT PIPE POSITION. IN THIS CASE, THE TENDENCY IS TO OBTAIN A REDUCED FUEL FLOW. THE VACUUM INLET ON THE MANIFOLD HAS A REDUCED 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.

66

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

- Remove the protection, the stirrup and the choke, by removing the screw in the figure. ATTENTION THE CARBURETTOR IS FITTED WITH A RUBBER ANTI-VIBRATION PAD LOCATED ON THE BOTTOM LUG OF THE THROTTLE PUMP BODY. TO FIT THE CARBURETTOR ONTO THE ENGINE, IT IS RECOMMENDED THAT THIS PLUG BE PRESENT IN ORDER TO PREVENT EMULSIFYING OF THE PETROL PRESENT IN 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 PREVENT THE SPRING FROM FLYING OUT ACCIDENTALLY. - 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 screws on the throttle pump membrane cover.

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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.

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DISMANTLING

THE CARBURETTOR

- Remove the atomiser by tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO PREVENT THE LOSS OF THE ATOMISER DURING THE CARBURETTOR BODY CLEANING PHASE. WHEN THE ATOMISER IS STUCK IN ITS SEAT, DO NOT ATTEMPT TO REMOVE IT, TO AVOID DAMAGING IT. - Remove the idle jet.

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

ATTENTION DO NOT ATTEMPT TO EXTRACT THE COMPONENTS ANCHORED TO THE CARBURETTOR BODY, I.E.: FUEL SUPPLY DUCT, NEEDLE SEAT, CHOKE JET, BUTTERFLY VALVE DRIVE SHAFT. AVOID DISMANTLING THE SCREWS CONNECTING THE BUTTERFLY VALVE TO ITS SHAFT. THE SCREWS ARE RIVETED AFTER ASSEMBLY, AND THEIR EXTRACTION MAY LEAD TO DAMAGE TO THE SHAFT.

69

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.

- 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. - 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 PREVENT DAMAGE, AVOID INSERTING METAL OBJECTS INTO THE CALIBRATED SECTIONS.

70

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 with the corresponding screw. N.B. MAKE SURE THE RETURN SPRING IS CORRECTLY 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.

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ASSEMBLING

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.

VERIFICACIN C C

NIVEL CARBURANTE EN CUBETA C U CU

- 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 ASSEMBLY, ALWAYS USE NEW RETAINS AND SEALS. WARNING THE SCREW FITTED TO THE BOTTOM OF THE BOWL IS ONLY A DRAIN SCREW AND ONLY REQUIRES CLEANING.

72

73

- Use a 12v battery to power the automatic choke and check that the piston reaches maximum protrusion. Maximum protrusion: 15 mm Max. time: 5 mn - 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 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.

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ADJUSTING

TICK-OVER

- The engine does not require frequent tick-over 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, the spark plug is in optimum condition, the air filter is clean and fitted airtight, and there are no leaks in the exhaust system. - Using the analysers rev counter or another separate one, adjust the idle screw until a rate of 1900 to 2000 rpm is obtained.

N.B. THE IGNITION SYSTEM IS THE LOST SPARK TYPE, WHICH GIVES A CONSIDERABLE VOLTAGE. DIFFICULTIES IN READING THE REVS MAY ARISE WITH NON-CALIBRATED REV COUNTERS. Specific tool: Digital rev counter: 020332Y

ATLANTIS 50 C.C. 4-stroke KEIHIN 18


Type Main jet Pilot jet Choke jet Emulsifying tube Naca type tapered needle 18,9 pressure 75 35 48 2,1 (without grooves) 1,2

ATLANTIS 100 C.C. 4-STROKE KEIHIN 20


20,9 pressure 72 35 48 2,1 (without grooves) 1,2

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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.

PUTTING THE BATTERY INTO OPERATION:

- This battery is the sealed type. Never remove the plugs or add water. - 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 capacity after filling is approximately 75%.
SPECIAL CONDITIONS IN WHICH THE BATTERY SHOULD BE CHARGED:

- When the temperature falls below 0C. - After a long period of storage. - When the original seal has been broken. - In general, it should be charged whenever the voltage after filling is below the standard 12.5 volts. Cleaning the battery: The battery should be kept clean at all times, especially the top part, and the terminals protected with Vaseline. ATTENTION USE OF A FUSE OF AN AMPERAGE GREATER THAN THAT RECOMMENDED. THE USE OF A FUSE OF THE WRONG AMPERAGE MAY CAUSE DAMAGE TO THE VEHICLE AS A WHOLE, AS WELL AS THE RISK OF FIRE. ATTENTION THE SEALED BATTERY MUST BE CHARGED TO OPERATING CONDITION BEFORE FINAL DELIVERY.

76

77

ON

1 2 3 4 5 6 7

Magneto Pick-Up Ignition key switches Eelectronic switch on device 4 AMP fuse Voltage regulator 12V-4Ah battery

78

LIGHTS

AND AUTOMATIC CHOKE SYSTEM

1 2 3 4 5 6 7 8 9 10 11

Voltage regulator 12V-25/25W projector bulb 12V- 1.2 W full beam pilot light 12V-5W sidelight bulb 12V-1.2W instrument light 12V-2W bulb for illuminating instrument 12V-1,2W pilot light 12V-5W rear sidelight Automatic choke Dipswitch

79

BATTERY

CHARGING AND STARTER

1 2 3 4 5 6 7 8 9

Magneto Starter motor 4 Amp fuse 12V-4Ah battery Ignition key switch contacts Voltage regulator Starter solenoid Starter button Stop button on the front and rear brake

80

INDICATORS

AND LEVELS

1 2 3 4 5 6 7 8

Voltage regulator Fuel level indicator Fuel level transmitter Stop button on the front and rear brake 4 Amp fuse 12V-4Ah battery Filament for stop light AT 12V-10W Ignition key switch contacts

81

CHECKING

PILOT LIGHTS AND INSTRUMENTS

1 2 3 4 5 6 7 8 9

Turn indicatior switch Horn button Horn 12V-2W indicators pilot light 12V-10W indicator light Voltage regulator Ignition key switch contacts 4 AMP fuse 12V - 4Ah battery

82

83

VOLTAGE O G

REGULATOR GU O

Depending on the type of damage, a faulty voltage regulator can produce the following problems: Battery not charging Turn indicators not functioning Blown BULBS

The regulator is fitted with an earth supplied by the electrical wiring, and the regulator body does not therefore have the function of providing an earth for its internal circuits. The insulation between each of the regulators terminals and its body should be measured (using the tester for checking electrical resistances).

Access the voltage regulator, start up the engine and keep it ticking over with the vehicles light circuit switched off. Insert the testers contact probe (set the tester to measure alternating current) into terminal No.1 (Yellow cable), and the negative probe into terminal No.2 (Yellow/Green 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.

84

VOLTAGE O G

REGULATOR GU O

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

Disconnect the regulator connector and place a tester between the Red/White cable (4) and earth, for measurements of alternating current (see figure). - The voltage distributed at 2000 rpm should be approximately 2535V If no value is obtained with this test, replace the regulator, as it must be faulty.

BATTERY

NOT CHARGING

A fault in the c.c. section of the voltage regulator may, depending on the type of fault, result in the following problems: Blowing of the protective fuse due to voltage overload (regulator in short circuit) and no charging of the battery. The battery is not charging (regulator interrupted) 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 position and with the regulator connector disconnected, the wiring and devices closest to the key switch need to be checked to ensure that there is no short circuit to earth.

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BATTERY

NOT CHARGING O C G G

Battery not charging adequately (regulator interrupted). To check for the presence of anomalies in the voltage regulators charging section, the first thing is to connect 2 testers to the battery (one for 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 vehicles 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 vehicles lights, brake light and horn should give a meter voltage reading of 13.5-138v (the regulators threshold voltage). If values are measured that do not conform to the above, replace the regulator; otherwise check the wiring and the connections.

TURN

INDICATORS NOT 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/Black cable (3) and the Yellow/ Green cable (2). - Turn the ignition key switch to the ON position and check the battery voltage. If no voltage is detected, repeat the test between the White/Red cable and earth. If a negative result is obtained even in this case, check the wiring and the contacts on the ignition key switch and on the battery. If however a battery voltage is measured, check the yellow/green regulator earth wiring Turn indicators not working.

86

If the above mentioned checks have been successful, make a bridge between connector contacts 5 (Orange) and 3 (Red/ Black), turn the ignition key switch to the ON 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.

87

ATLANTIS 50 C.C. 4T

1 1A 1B 2 2A 2B 2C 2D 3 3A 4 5 5A 5B 5C 6 6A 7 8 9
10 11 12 13

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


Dashboard --Turn indicator control pilot light 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 light assembly Tail bulb 12V 5W Brake bulb 12V 10W Indicator bulb 12V 10W ----Engine switch Brake light switch Lights switch Turn indicators switch Horn switch Horn ---

14 15 16 17
18 19 20 21 22 23 24

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

88

ATLANTIS 100 C.C. 4T

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

Headlight assembly Bulb 12V 25/25W Indicator bulb 12V 10W Position bulb 12V 5W Dashboard --Turn indicator control pilot light12V 2W High beam control pilot light 12V 1,2W Dashboard light 12V 1,2W Ignition switch Mobil phone connector Regulator + turn indicator central Tail light assembly Tail bulb 12V 5W 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 indicators switch Horn switch Horn

13 14 15 16 17 18 19 20 21 22 23 24

--Fuel level sensor Electric choke Resistence choke 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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