1207 4

00/2004-06

Engine M285M

www.serviceaprilia.com

workshopmanual

8140801

UK

Engine M285M

INTRODUCTION

INTRODUCTION

0-1

INTRODUCTION

Engine M285M

SUMMARY
0.1. FOREWORD..................................................................................................................................................... 3 0.1.1. FOREWORD ............................................................................................................................................. 3 0.1.2. REFERENCE MANUALS .......................................................................................................................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ........................................................................................ 5

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Engine M285M 0.1.

0.1.1. -

INTRODUCTION

FOREWORD
FOREWORD This manual provides all information necessary for vehicle servicing. This manual is intended for use by aprilia Dealers and their qualified mechanics. Some information has been omitted intentionally as considered unnecessary. For this reason, people who are using this manual must have a good background on mechanics and procedures for motorcycle servicing. Motorcycles serviced or inspected by incompetent operators might be inefficient or unsafe to ride. As not all servicing and inspection procedures are described in details, proceed with utmost care so to avoid injuries to people and damages to vehicle parts. aprilia s.p.a.'s mission is to enhance the riding pleasure by ever improving products and technical literature. All aprilia Points of Sale and Subsidiaries worldwide are kept updated on major engineering changes and modifications to repair procedures. All changes and modifications are then included in the next release of the relevant manual. When in doubt about some inspection or repair procedure, please contact aprilia CONSUMER SERVICE (A.C.S.) DEPARTMENT staff, who will be glad to provide full information on servicing procedures and technical aspects.

aprilia s.p.a. reserves the right to make changes to its products at any time, being understood that main features as herein described and shown remain unchanged. All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted, are reserved in all countries. Any reference to products or services provided by third parties is for information only and by no means binding. aprilia s.p.a. disclaims all responsibility for their performance or use. Refer to (REFERENCE MANUALS) for further information. First edition: June 2004 Produced and printed by: DECA s.r.l. via Risorgimento, 23/1 - 48022 Lugo (RA) - Italia Tel. +39 - 0545 35235 Fax +39 - 0545 32844 E-mail: deca@decaweb.it www.decaweb.it for: aprilia s.p.a. via G. Galilei, 1 - 30033 Noale (VE) - Italia Tel. +39 (0)41 58 29 111 Fax +39 (0)41 58 29 190 www.aprilia.com www.serviceaprilia.com

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INTRODUCTION
0.1.2. REFERENCE MANUALS

Engine M285M

ENGINE MANUALS aprilia part# (description) 8140797 8140800 8140798 8140799 8140801 8CM0056 CHASSIS WORKSHOP MANUALS ATLANTIC 125-250 aprilia part# (description) 8140802 8140805 8140803 8140804 8140806 8CM0057 CHASSIS WORKSHOP MANUALS SCARABEO 125-250 aprilia part# (description) 8140792 8140795 8140793 8140794 8140796 8CM0066 PARTS CATALOGUES aprilia part# (description) 6642 6603 SPECIAL TOOLS MANUALS aprilia part# (description) H001

0-4

Engine M285M
0.1.3. # < > ~ ABBREVIATIONS/SYMBOLS/CONVENTIONS = number = is less than = is more than = is less than or equal to = is more than or equal to = approximately = infinite = degrees Celsius (centigrade) = degrees Fahrenheit = plus or minus = alternated current =ampere =ampere per hour = American Petroleum Institute = High Tension = Anti-Vibration Double Countershaft = pressure measurement (1 bar =100 kPa) = Direct Current = cubic centimeters = carbon oxide = Central Processing Unit = German industrial standards (Deutsche Industrie Norm) = Double Overhead Camshaft = Electronic Control Unit = revolutions per minute = unburnt hydrocarbons = Idle Speed Control = International Standardization Organization = kilograms = kilograms per meter (1 kgm =10 Nm) = kilometers = kilometers per hour = kiloOhm = kiloPascal (1 kPa =0.01 bar) = clutch side (from the German "Kupplungseite") = kiloWatt = liters = racetrack lap = Light Emitting Diode =left side = meters per second = maximum = millibar (1 mbar =0.1 kPa) = miles = minimum = miles per hour = flywheel side (from the German "Magnetseite") = megaOhm = Not Available = Motor Octane Number = Research Octane Number = Newton per meter (1 Nm =0.1 kgm) = ohm = pick-up = Bottom Dead Center = Top Dead Center = Pneumatic Power Clutch = right side = Society of Automotive Engineers = secondary air system = diagnostic check = crowned-head Allen screw = cheese-headed Allen screw

INTRODUCTION

C F a.c A Ah API HT AV/DC bar DC cu cm CO CPU DIN DOHC ECU rpm HC ISC ISO kg kgm km km/h k kPa KS kW

l
LAP LED LEFT SIDE m/s max mbar mi MIN MPH MS M N.A. N.O.M.M. N.O.R.M. Nm

PICK-UP BDC TDC PPC RIGHT SIDE SAE SAS TEST T.B.E.I. T.C.E.I.

0-5

INTRODUCTION
T.E. T.P. TSI UPSIDEDOWN V W = hexagonal head = flat head screw = Twin Spark Ignition = inverted fork = volt = watt = Diameter

Engine M285M

0-6

Engine M285M

GENERAL INFORMATION

GENERAL INFORMATION

1-1

GENERAL INFORMATION

Engine M285M

SUMMARY
1.1. MANUAL LAYOUT............................................................................................................................................ 3 1.1.1. CONVENTIONS USED IN THE MANUAL ................................................................................................. 3 1.1.2. SAFETY INFORMATION........................................................................................................................... 4 1.2. GENERAL RULES............................................................................................................................................ 5 1.2.1. BASIC SAFETY RULES ............................................................................................................................ 5 1.3. DANGEROUS ELEMENTS............................................................................................................................... 8 1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS .... 8 1.4. RUNNING-IN .................................................................................................................................................... 9 1.4.1. RUNNING-IN RECOMMENDATIONS ....................................................................................................... 9 1.5. SPECIFICATIONS .......................................................................................................................................... 10 1.5.1. ENGINE TECHNICAL DATA ................................................................................................................... 10 1.6. PRODUCTS.................................................................................................................................................... 11 1.6.1. LUBRICANTS CHART............................................................................................................................. 11 1.7. TIGHTENING.................................................................................................................................................. 12 1.7.1. GENERAL TIGHTENING TORQUE SETTINGS ..................................................................................... 12 1.7.2. TIGHTENING TORQUES ........................................................................................................................ 13

1-2

Engine M285M 1.1.

1.1.1.

GENERAL INFORMATION

MANUAL LAYOUT
CONVENTIONS USED IN THE MANUAL This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the sections index. Unless expressly specified otherwise, reassemble/install by following disassembly/removal procedure in the reverse order. The terms left and right are referred to the motorcycle when viewed from the riding position. For instructions on how to use the vehicle and for routine maintenance, please read the vehicle USERS MANUAL.

In this manual any variants are identified with the following symbols: option catalyzed version all versions National homologation European homologations (EURO 1 limits)

MP SF

VERSION: Italy United Kingdom Austria Portugal Finland

Greece Netherlands Switzerland Denmark Japan

Malaysia Chile Croatia Australia United States of America Brazil Republic of South Africa New Zealand Canada

Belgium Germany France Spain

Singapore Slovenia Israel South Korea

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GENERAL INFORMATION
1.1.2. SAFETY INFORMATION

Engine M285M

The following conventions are used to identify safety information throughout the manual: This symbol identifies safety-related information. Whenever you see this symbol in the manual or attached to the vehicle, use utmost care to avoid the risk of injury. Failure to comply with the instructions given after this symbol may put your safety, as well as that of other persons or of the motorcycle at risk! DANGER Failure to comply with given indications may lead to severe injury or death. WARNING Failure to comply with given indications may lead to minor injury or vehicle damage. NOTE The term "NOTE" precedes important information or instructions.

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Engine M285M 1.2.

1.2.1.

GENERAL INFORMATION

GENERAL RULES
BASIC SAFETY RULES

CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a wellventilated room. Avoid starting the engine in closed or badly-ventilated rooms. In case you are working indoors, use a suitable exhauster. DANGER Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of consciousness or even death. FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuel and service the engine in a well-ventilated area with the engine stopped. Do not smoke when refueling and do not stand close to fuel vapors; avoid flames, sparks and anything which might ignite fuel or provoke explosions. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. HOT COMPONENTS The engine and exhaust system become hot and stay hot for some time after engine has been stopped. Before handling these parts, wear heatproof gloves or allow the engine and exhaust system to cool down. USED GEARBOX FLUID AND FORK FLUID DANGER Wear latex gloves during servicing. Prolonged or repeated contact with gearbox oil may cause severe skin damage. Wash your hands carefully after handling this fluid. Deliver it to a waste collection centre or to the supplier or have them collect it. Wear latex gloves during servicing. DO NOT RELEASE INTO THE ENVIRONMENT KEEP AWAY FROM CHILDREN. BRAKE FLUID WARNING Take care not to spill brake fluid onto plastic, rubber or paint-finished parts or they will damage. When servicing the brake system, protect these parts with a clean cloth. Always wear safety goggles when servicing the brake system. The brake fluid is extremely dangerous for your eyes. In case of contact with eyes, rinse with plenty of clean and fresh water and contact a doctor without delay. KEEP AWAY FROM CHILDREN. COOLANT The coolant is composed of ethylene glycol that, under certain conditions, can become inflammable and send out invisible flames causing severe burns.

1-5

GENERAL INFORMATION

Engine M285M

DANGER Do not to spill the coolant on the red-hot parts of the engine and exhaust system: it may catch fire and send out invisible flames. Wear latex gloves when servicing. Even if toxic, coolant has a sweet flavor. Never leave it inside open containers or within the reach of animals. KEEP AWAY FROM CHILDREN. Do not remove the radiator plug when engine is still hot. Coolant is under pressure and could cause scalds. HYDROGEN GAS AND BATTERY FLUID DANGER Battery fluid is toxic, caustic and corrosive; it contains sulphuric acid and contact with skin will cause severe burns. Wear tight-fitting gloves and safety clothing when handling battery fluid. Should it come in contact with your skin, immediately rinse with plenty of fresh water. It is especially important to protect your eyes because even the slightest quantity of battery fluid might cause blindness. Should it come in contact with your eyes, rinse with plenty of fresh water for fifteen minutes and contact an eye specialist without delay. If battery fluid is accidentally swallowed, drink abundant water or milk, then continue with magnesia milk or vegetable oil and seek medical advice immediately. The battery gives off explosive gases and must be kept away from flames and sources of ignition or heat; do not smoke near the battery. Charge or service the battery in a well-ventilated place. KEEP AWAY FROM CHILDREN. Battery fluid is corrosive. Do not spill it, especially on plastic parts. Ensure that the fluid is suitable for the battery to be activated. GENERAL PRECAUTIONS AND INFORMATION The following indications should be strictly complied with when servicing, disassembling or reassembling the vehicle. DANGER Never use naked flames when servicing. Before servicing or inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the engine and exhaust system to cool down; where possible, lift the vehicle using adequate equipment placed on firm and level ground. Do not touch engine and exhaust system hot parts. Risk of scalds and burns. Never put any mechanical parts or other vehicle components in your mouth when you have both hands busy. None of the vehicle components is edible. Unless expressly specified otherwise, install/reassemble by following removal/disassembly procedure in the reverse order. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing any parts unless strictly necessary. Never polish matte-finished surfaces with abrasive substances. Never use fuel as solvent to clean the vehicle. Do not clean the seat or any rubber or plastic parts with alcohol, petrol or solvents. Clean with water and mild detergent. Should you need to use an electric welder, disconnect battery negative cable (-). When two or more persons are servicing the same motorcycle together, special care must be taken to avoid personal injury. BEFORE REMOVING OR DISASSEMBLING ANY COMPONENTS Clean off all dirt, mud and dust and clear any foreign objects from the vehicle before removing or disassembling any parts. Use the model-specific special tools where specified.

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Engine M285M

GENERAL INFORMATION

REMOVING OR DISASSEMBLING THE COMPONENTS Never use pliers or similar tools to loosen and/or tighten nuts and bolts. Always use a suitable spanner. Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection using a distinctive symbol. Mark each part clearly to avoid confusion when refitting. Thoroughly clean and wash any components you have removed using a detergent with low flash point. Mated parts should always be refitted together. These parts have seated themselves against one another in service as a result of normal wear and tear. Certain components are matched-pair parts and should always be replaced as a set. Keep away from heat. INSTALLING OR ASSEMBLING THE COMPONENTS DANGER Used circlips or snap rings must always be replaced. When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow fitment to the shaft. Make it a rule to check that a newly-fitted circlip or snap ring is properly and firmly seated. Never clean a bearing with compressed air. NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use aprilia ORIGINAL SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly. When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten evenly in subsequent steps until achieving the specified torque. Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have a damaged thread. Lubricate the bearings abundantly before assembly. Make it a rule to check that all components you have fitted are correctly in place. After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate the motorcycle in a private estate area or in a safe area away from traffic. Clean all joint surfaces, oil seal edges and gaskets before assembly. Apply a light coat of lithium grease along the edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).

ELECTRICAL CONNECTORS To disconnect the electrical connector, follow the procedures below. Failure to comply with these procedures may lead to irreparable damages to connector and wiring. Press the special safety hooks, if available. WARNING Do not pull cables to disconnect the two connectors. Grasp the two connectors and disconnect them by pulling them in the two opposite directions. In case of dirt, rust, moisture, etc.., thoroughly clean the inside of the connector with compressed air. Make sure that the cables are correctly crimped to connector terminals.

NOTE The two connectors have just one correct positioning. Make sure to position them in the right direction. Then fit the two connectors. Make sure they are correctly coupled (if equipped with the special hooks, a click will be heard).

TIGHTENING TORQUE SETTINGS DANGER Always remember that the tightening torque settings of all fastening parts on wheels, brakes, wheel shafts or other suspension parts play a fundamental role to ensure vehicle safety. Always tighten to the specified values. Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a torque wrench. Failure to comply with these recommendations could lead to the loosening and detachment of one of these parts with a consequent locking of a wheel or causing other serious troubles affecting the vehicle operation with possible accidents and the risk of serious injuries or death.

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GENERAL INFORMATION 1.3.

1.3.1.

Engine M285M

DANGEROUS ELEMENTS
WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuel and service the engine in a well-ventilated area with the engine stopped. Do not smoke when refueling and do not stand close to fuel vapors; avoid flames, sparks and anything which might ignite fuel or provoke explosions. Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts. In case of accidental fuel spillage, make sure the affected area is fully dry before starting the engine. Fuel expands from heat and when left under direct sunlight. Avoid contact with skin. Do not inhale vapors. Do not swallow fuel. Do not transfer fuel between different containers using a hose. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN.

Use only premium grade unleaded petrol, min. O.N. 95 (R.O.N.) and 85 (M.O.N.). LUBRICANTS DANGER A good engine lubrication ensures the vehicle safety. Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean type of lubricant can lead to engine seizure, thus leading to serious accidents, personal injury or even death. Oil may can cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT. Collect exhausted oil into suitable containers and take it to or have it collected by your Supplier or an authorized collection company. WARNING When filling the engine with oil, take care not to spill it out since it could damage the vehicle paintwork. In case of leaks, do not start the engine. Check and trace the cause of leaks and fix it. COOLANT DANGER Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation. In case of contact with eyes and skin, rinse repeatedly with abundant water and seek medical advice. In case of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately. DO NOT DISPOSE OF COOLANT IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. DANGER Do not to spill the coolant on the red-hot parts of the engine: it may catch fire and send out invisible flames. Wear latex gloves when servicing.

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Engine M285M 1.4.

1.4.1.

GENERAL INFORMATION

RUNNING-IN
RUNNING-IN RECOMMENDATIONS

The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more effective running-in. During running-in, change speed. In this way the components are first "loaded" and then "relieved" and the engine parts can thus cool down. Even if it is important to stress the engine components during running-in, take care not to exceed. WARNING Only after the first 1000 km (621 mi) of running-in you can expect the best performance levels from the vehicle. Keep to the following indications: Do not open the throttle completely and suddenly if the speed is low, both during and after the running-in. During the first 100 km (62 mi) pull the brakes with caution, avoiding sharp and prolonged brakings. This ensures a correct bedding-in of the pads on the brake disc. During the first 500 km (310 mi), never use the vehicle beyond 80% of the max. speed, do not fully open throttle and do not keep the vehicle at a constant speed for a long time. WARNING After the first 1000 km (621 mi), carry out the checks indicated in the column After running-in, in order to avoid injuries to rider and/or other people and/or damaging the vehicle. After the first 1000 km (621 mi), increase speed step by step until reaching top performance.

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GENERAL INFORMATION 1.5.

1.5.1.

Engine M285M

SPECIFICATIONS
ENGINE TECHNICAL DATA

ENGINE
Type Bore Stroke Displacement Compression ratio Carburetor Single-cylinder 4-stroke engine, 4 valves, lubrication with wet sump, overhead camshaft 72 mm (2.835 in.) 60 mm (2.362 in.) 244 cm3 (14.889 in3) 11.0 0.5 : 1 WVF7 29 Walbro CVK 30 KEIHIN Lubrication Fuel Cooling Max. power Max. torque Spark advance Plug Spark plug gap Transmission Valve clearance (cold) Engine oil quantity Transmission fluid Transmission fluid quantity Final drive (wheel) Lobe pump into crankcase controlled by chain; twin-filter: mesh filter and paper filter Premium grade unleaded petrol, min. O.N. 95, through carburetor Water cooling, with forced fluid circulation through centrifugal pump 14.65 Kw (19.64 CV) at 8300 rpm 18.5 Nm (1.89 Kgm) at 7000 rpm Variable (before TDC) 10 1 at 2000 rpm 32 1 at 6500 rpm Standard: NGK CR8EB As an alternative: NGK CR7EB - NGK CR9EB CHAMPION RG6YC - CHAMPION RG4HC 0.7 0.8 mm (0.0275 0.0314 in.) Automatic stepless variator with expandable pulleys, Vbelt, centrifugal clutch, reduction gear with splash lubrication Intake: 0.10 mm (0.00394 in.) Exhaust: 0.15 mm (0.00591 in.)
3 3 3 3 1000 cm (61.023 in ), 1100 cm (67.126 in ) for oil and oil filter change.

forced

TUTELA ZC 90 250 cm3 (15.255 in3) Minimum: 22.36 Maximum: 7.88

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Engine M285M 1.6.

1.6.1.

GENERAL INFORMATION

PRODUCTS
LUBRICANTS CHART

For all maintenance operations, use only the product listed below. Listed materials have been tested for many years and are suitable for all the applications specified by the manufacturer. NOTE Consumer goods with part numbers are available upon request (see table). PRODUCT SPECIFICATIONS LUBRICANT Engine oil

RECOMMENDED: SUPERBIKE 4, SAE 5W 40 or 4T FORMULA RACING, SAE 5W - 40. As an alternative to the recommended oils, it is possible to use select oils having properties in compliance with or even above CCMC G-4, A.P.I. SG specifications. RECOMMENDED: F.C., SAE 75W or GEAR SYNTH, SAE 75W - 90. As an alternative to the recommended oil, use select oils having properties in compliance with or even above A.P.I. GL4 specifications RECOMMENDED: BIMOL GREASE 481 or GREASE SM2. As an alternative to the recommended product, use select grease for rolling bearings, useful temperature range -30C+140C, dripping point 150C230C, highly anticorrosive, water and oxidization resistant. Neutral grease or vaseline. RECOMMENDED: CHAIN SPRAY or CHAIN LUBE

Transmission fluid

Bearings and other lubrication points

Battery terminals Chain grease spray

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GENERAL INFORMATION 1.7.

1.7.1.

Engine M285M

TIGHTENING
GENERAL TIGHTENING TORQUE SETTINGS

The table shows the tightening toque settings for 8.8 class screws made of steel/aluminum or other similar materials. Screw or bolt Wrench thread M4 7 M5 8 M6 10 M8 12 M 10 14 M 12 17 M 14 19 M 16 22 Tightening torque Nm kgm 3 0.3 6 0.6 10 1.0 25 2.5 50 5.0 80 8.0 135 13.5 210 21.0

If not otherwise specified, the tightening torque settings refer to clean, dry threads at ambient temperature. NOTE In order to avoid any possible deformation and/or wrong coupling, please tighten screws and bolts as follows: Tighten all fasteners by hand. Apply half of the recommended tightening torque value and tighten the opposite parts: (A) and (B); (C) and (D). Repeat the above operation by tightening to the specified torque value.

NOTE The pressure on the fastening parts will be thus evenly distributed on the coupling surface.

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Engine M285M
1.7.2. TIGHTENING TORQUES

GENERAL INFORMATION

DESCRIPTION ENGINE TRANSMISSION Transmission cover (screw) Final transmission cover (screw) Clutch unit (nut) Driven belt roller (nut) Drive belt roller (nut) Belt tensioner roller (screw) FLYWHEEL Flywheel (nut) Stator (screw) Pick-up (screw) LUBRICATION Oil pump baffle plate (screw) Oil pump cover (screw) Oil pump (screw) Oil pump driving roller (screw) Oil sump (screw) COOLING SYSTEM Impeller cover (screw) CRANKCASE AND CRANKSHAFT Starter motor (screw) Crankcase (screw) Inner baffle plate (screw) Oil drain plug CYLINDER, HEAD AND TIMING Cylinder head (nut) (tighten nuts in two steps, working in a cross pattern) (lubricate the nuts with engine oil before assembly) Head fastening side screws Tappets adjustment lock nut Valve lift mass stop plate (screw) Counterweight (screw) Camshaft bracket (screw) Tensioner shoe (screw) Timing chain tensioner fastener (screw) Timing chain tensioner adjustment (screw) Thermostat fitting (screw) Q.TY 12 7 1 1 1 1 Q.TY 1 3 2 Q.TY 2 2 2 1 7 Q.TY 3 Q.TY 2 11 2 1 Q.TY 4 2 5 1 1 2 1 2 1 2

TIGHTENING TORQUE

(Nm) 11 13 24 27 45 50 54 60 75 83 11 13 (Nm) 52 58 34 34 (Nm) 0,7 0,9 0,7 0,9 56 10 14 10 14 (Nm) 34 (Nm) 11 13 11 13 46 24 30 (Nm) 9 11 + 180 11 13 68 11 15 7 8,5 46 10 14 11 13 56 34

(ft-lb) 8.113 9.588 17.701 19.914 33.190 36.878 39.828 44.254 55.317 61.217 8.113 9.588 (ft-lb) 38.353 42.778 2.213 2.950 2.213 2.950 (ft-lb) 0.516 0.664 0.516 0.664 3.688 4.425 7.376 10.326 7.376 10.326 (ft-lb) 2.213 2.950 (ft-lb) 8.113 9.588 8.113 9.588 2.950 4.425 17.701 22.127 (ft-lb) 6.638 8.113 + 180 8.113 9.588 4.425 5.900 8.113 11.063 5.163 6.269 2.950 4.425 7.376 10.326 8.113 9.588 3.688 4.425 2.213 2.950

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Engine M285M

SPECIAL TOOLS

SPECIAL TOOLS

2-1

SPECIAL TOOLS

Engine M285M

SUMMARY
2.1. SPECIAL TOOLS.............................................................................................................................................. 3 2.1.1. SPECIAL TOOLS ...................................................................................................................................... 3

2-2

Engine M285M 2.1.

2.1.1.

SPECIAL TOOLS

SPECIAL TOOLS
SPECIAL TOOLS

Special tools are required for correct part removal, installation and tune-up. Improper and/or makeshift tools might cause damages. The list below includes special tools, which have been especially designed for this engine. Order special tools, if needed, from the special tools manual. WARNING Read the supplied documents before using any special tools.

Legend: Position 1 2 3 4 5 6 7 8 9 10 11 12 Tool description and function Small items for crankshaft axial play Piston ring tool Clutch housing lock wrench Roller bearing drift Adapter for clutch unit disassembly Guide for mobile pulley onto fixed pulley Pressure gauge fitting Universal tool for clutch assemblies Gauge support Multipurpose tool Tool for assembling/removing chain cover Water pump overhaul tool Part number 8140657 8140660 8140661 8140662 8140665 8140664 8140181 8140259 8140266 8140252 8140729 8140663

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Engine M285M

ENGINE

ENGINE

3-1

ENGINE

Engine M285M

SUMMARY
3.1. TRANSMISSION............................................................................................................................................... 4 3.1.1. REMOVING THE TRANSMISSION COVER. ........................................................................................... 4 3.1.2. DRIVEN PULLEY SHAFT BEARING......................................................................................................... 6 3.1.3. INSTALLING THE DRIVEN PULLEY SHAFT BEARING........................................................................... 7 3.1.4. BELT ROLLER .......................................................................................................................................... 8 3.1.5. DISASSEMBLING THE TRANSMISSION UNIT........................................................................................ 9 3.1.6. REMOVING THE CLUTCH...................................................................................................................... 10 3.1.7. PIN COLLAR ........................................................................................................................................... 11 3.1.8. FIXED DRIVEN HALF PULLEY BEARINGS ........................................................................................... 12 3.1.9. FIXED DRIVEN HALF PULLEY............................................................................................................... 13 3.1.10. MOBILE DRIVEN HALF PULLEY ........................................................................................................ 14 3.1.11. INSTALLING FIXED DRIVEN HALF PULLEY BEARINGS .................................................................. 15 3.1.12. ASSEMBLING THE DRIVEN PULLEY................................................................................................. 16 3.1.13. SPRING ............................................................................................................................................... 17 3.1.14. CLUTCH WEIGHTS ............................................................................................................................. 18 3.1.15. INSTALLING THE CLUTCH................................................................................................................. 19 3.1.16. DRIVE BELT ........................................................................................................................................ 20 3.1.17. MOBILE DRIVING HALF PULLEY....................................................................................................... 21 3.1.18. ASSEMBLING THE TRANSMISSION UNIT ........................................................................................ 23 3.1.19. FITTING THE TRANSMISSION COVER ............................................................................................. 24 3.1.20. DISASSEMBLING THE FINAL TRANSMISSION ................................................................................ 25 3.1.21. REMOVING THE WHEEL SHAFT ....................................................................................................... 26 3.1.22. FINAL TRANSMISSION CASE BEARINGS......................................................................................... 27 3.1.23. REMOVING THE WHEEL SHAFT BEARING FROM THE COVER..................................................... 28 3.1.24. REMOVING THE DRIVEN PULLEY SHAFT........................................................................................ 29 3.1.25. ASSEMBLING THE FINAL TRANSMISSION BEARINGS ................................................................... 30 3.1.26. INSTALLING THE DRIVEN PULLEY SHAFT BEARING ..................................................................... 31 3.1.27. CHECKING FINAL TRANSMISSION COVER ..................................................................................... 32 3.1.28. INSTALLING THE WHEEL SHAFT BEARING IN THE COVER .......................................................... 33 3.1.29. CHECKING FINAL TRANSMISSION SHAFTS.................................................................................... 34 3.1.30. INSTALLING FINAL TRANSMISSION GEARS ................................................................................... 35 3.1.31. FITTING THE FINAL TRANSMISSION COVER .................................................................................. 36 3.1.32. TIGHTENING TORQUES .................................................................................................................... 37 3.2. FLYWHEEL..................................................................................................................................................... 38 3.2.1. REMOVING THE COMPLETE FLYWHEEL COVER .............................................................................. 38 3.2.2. REMOVING THE FLYWHEEL................................................................................................................. 40 3.2.3. REMOVING THE STATOR...................................................................................................................... 41 3.2.4. CHECKING THE FLYWHEEL ................................................................................................................. 42 3.2.5. ASSEMBLING THE STATOR UNIT ........................................................................................................ 43 3.2.6. INSTALLING THE FLYWHEEL ............................................................................................................... 44 3.2.7. ASSEMBLING THE FLYWHEEL COVER ............................................................................................... 46 3.2.8. TIGHTENING TORQUES ........................................................................................................................ 47 3.3. LUBRICATION................................................................................................................................................ 48 3.3.1. REMOVING THE OIL SUMP AND THE PRESSURE-ADJUSTING BY-PASS........................................ 48 3.3.2. CHECKING THE BY-PASS ..................................................................................................................... 49 3.3.3. DISASSEMBLING THE CHAIN HOUSING COVER................................................................................ 50 3.3.4. REMOVING THE OIL PUMP ................................................................................................................... 51 3.3.5. CHECKING THE OIL PUMP.................................................................................................................... 52 3.3.6. ASSEMBLING THE OIL PUMP ............................................................................................................... 54 3.3.7. ASSEMBLY OF THE CHAIN HOUSING COVER.................................................................................... 56 3.3.8. ASSEMBLING THE BY-PASS AND THE OIL SUMP .............................................................................. 57 3.3.9. TIGHTENING TORQUES ........................................................................................................................ 58 3.4. COOLING ....................................................................................................................................................... 59 3.4.1. REMOVING THE WATER PUMP............................................................................................................ 59 3.4.2. CHECKING THE WATER PUMP COMPONENTS.................................................................................. 61 3.4.3. ASSEMBLING THE WATER PUMP ........................................................................................................ 62 3.4.4. CHECKING THE THERMOSTAT ............................................................................................................ 64 3.5. CRANKCASE AND CRANKSHAFT................................................................................................................ 65 3.5.1. REMOVING THE STARTER MOTOR ..................................................................................................... 65 3.5.2. CHECKING THE CRANKSHAFT-CRANKCASE END FLOAT ................................................................ 66 3.5.3. OPENING THE CRANKCASE................................................................................................................. 67 3.5.4. CHECKING CRANKCASE....................................................................................................................... 70 3.5.5. CHECKING THE MAIN BEARING........................................................................................................... 71 3.5.6. CLOSING THE CRANKCASE ................................................................................................................. 73 3.5.7. ASSEMBLING THE STARTER MOTOR ................................................................................................. 75 3.5.8. TIGHTENING TORQUES ........................................................................................................................ 76 3.6. CYLINDER HEAD AND TIMING SYSTEM ..................................................................................................... 77 3.6.1. DISASSEMBLY OF THE TAPPET COVER............................................................................................. 77

3-2

Engine M285M

ENGINE

3.6.2. CHECKING THE TIMING SYSTEM .........................................................................................................78 3.6.3. CHECKING/ADJUSTING VALVE CLEARANCE ......................................................................................79 3.6.4. FITTING THE TAPPET COVER...............................................................................................................80 3.6.5. CHECKING END-OF-COMPRESSION PRESSURE ...............................................................................81 3.6.6. CHECKING IGNITION ADVANCE ...........................................................................................................82 3.6.7. DISASSEMBLING THE INTAKE MANIFOLD...........................................................................................83 3.6.8. REMOVING THE THERMOSTAT ............................................................................................................84 3.6.9. REMOVING THE TIMING DRIVE GEAR .................................................................................................85 3.6.10. DISASSEMBLING THE CAMSHAFT AND ROCKER ARMS................................................................87 3.6.11. DISASSEMBLIGN THE HEAD..............................................................................................................88 3.6.12. DISASSEMBLING THE VALVES..........................................................................................................89 3.6.13. DISASSEMBLING THE CYLINDER AND PISTON...............................................................................90 3.6.14. CHECKING CON-ROD SMALL END....................................................................................................92 3.6.15. GUDGEON PIN DIAMETER .................................................................................................................93 3.6.16. PISTON.................................................................................................................................................95 3.6.17. PISTON RINGS ....................................................................................................................................96 3.6.18. ASSEMBLING PISTON ........................................................................................................................97 3.6.19. CHECKING PISTON POSITION...........................................................................................................98 3.6.20. ASSEMBLING PISTON RINGS ............................................................................................................99 3.6.21. ASSEMBLING THE CYLINDER .........................................................................................................100 3.6.22. CHECKING THE HEAD ......................................................................................................................101 3.6.23. CHECKING VALVES FOR WEAR......................................................................................................102 3.6.24. CHECKING VALVE SEATS FOR WEAR............................................................................................103 3.6.25. CHECKING VALVE SEALING ............................................................................................................105 3.6.26. CHECKING COTTERS AND SPRING PLATES .................................................................................106 3.6.27. ASSEMBLING VALVES......................................................................................................................107 3.6.28. CHECKING THE TIMING SYSTEM PARTS.......................................................................................108 3.6.29. CHECKING THE CAMSHAFT ............................................................................................................109 3.6.30. ASSEMBLING HEAD AND TIMING SYSTEM PARTS .......................................................................110 3.6.31. ASSEMBLING TIMING SYSTEM PARTS...........................................................................................111 3.6.32. ASSEMBLING THE THERMOSTAT...................................................................................................114 3.6.33. ASSEMBLING THE INTAKE MANIFOLD ...........................................................................................115 3.6.34. TIGHTENING TORQUES ...................................................................................................................116 3.7. SECONDARY AIR SYSTEM .........................................................................................................................117 3.7.1. SYSTEM DIAGRAM ...............................................................................................................................117

3-3

ENGINE 3.1.
3.1.1.

Engine M285M

TRANSMISSION
REMOVING THE TRANSMISSION COVER. Remove the driven pulley shaft lock nut and washer using the clutch housing lock wrench (8140661).

Remove the plug/dipstick from engine oil filler. Remove the screws. Remove the transmission cover.

Loosen the screws, remove the plastic air conveyor and the filter underneath.

3-4

Engine M285M
Loosen the screws and remove the guard. Loosen the screws and remove the filter plastic shield.

ENGINE

3-5

ENGINE
3.1.2. DRIVEN PULLEY SHAFT BEARING Remove the circlip from inside the cover.

Engine M285M

Remove the bearing from the case.

3-6

Engine M285M
3.1.3. INSTALLING THE DRIVEN PULLEY SHAFT BEARING Warm up the case a little from the inside so not to damage outer paintwork. Fit the bearing into its seat. Replace the circlip. WARNING Place the case on a suitable surface to prevent damage to outer paintwork. NOTE Always fit a new bearing when reassembling.

ENGINE

3-7

ENGINE
3.1.4. BELT ROLLER Ensure that the roller shows no signs of irregular wear and can turn freely.

Engine M285M

REMOVING THE ROLLER Remove the screw, spacer and roller complete with bearing.

INSTALLING THE ROLLER Install the roller. Tighten the screw and spacer to the specified torque value.

3-8

Engine M285M
3.1.5. DISASSEMBLING THE TRANSMISSION UNIT Remove the nut, the Belleville washer and the washer using the suitable tool. Multipurpose tool: 8140252 Remove the fixed driving half pulley and the steel washer.

ENGINE

Remove the clutch housing and the belt roller together with timing belt.

Slide out the mobile half-pulley with relevant bushing, pay attention because rollers are loose and might fall out.

Remove roller counter plate and its shoes.

3-9

ENGINE
3.1.6. REMOVING THE CLUTCH

Engine M285M

Use the adapter ring with its pins facing the clutch to mount the clutch on the specific tool. Universal tool for clutch assemblies: 8140259 Adapter for clutch unit disassembly: 8140665

WARNING The tool must be firmly held in the vice with the centre screw in contact with the tool. Over-tightening will damage the tool. Check the proper insertion of the clutch in the ring before locking/unlocking the nut. Ensure that clutch may be fully fitted into the adapter ring. Remove the nut. Open the tool and take out the driven pulley, spring and clutch.

3 - 10

Engine M285M
3.1.7. PIN COLLAR Remove the collar with two screwdrivers or a ring tool.

ENGINE

Remove the guide pins and the mobile half pulley.

3 - 11

ENGINE
3.1.8. FIXED DRIVEN HALF PULLEY BEARINGS Check that parts are not worn out and/or noisy and replace, if necessary. Remove the stop ring with two flat-tip screwdrivers.

Engine M285M

Fit the pulley onto a proper support and remove the ball bearing with a suitable drift and a hammer.

Turn the pulley and remove the roller bearing with a drift of appropriate diameter and a hammer.

3 - 12

Engine M285M
3.1.9. FIXED DRIVEN HALF PULLEY Measure outer diameter of the bushing.

ENGINE

D1: Min. diameter allowed: 40.96 mm (1.6125 in.). Standard diameter: 40.985 mm (1.6135 in.).

3 - 13

ENGINE
3.1.10. MOBILE DRIVEN HALF PULLEY

Engine M285M

Remove the two inner seal rings and the two O-rings. Measure inner diameter of the bushing.

Max. inner diameter allowed: 41.08 mm (1.6173 in.) Standard inner diameter: 41.000 41.035 mm (1.6141 1.6155 in.).

3 - 14

Engine M285M
3.1.11. INSTALLING FIXED DRIVEN HALF PULLEY BEARINGS

ENGINE

Take tool number: 8140662 Fit the support (A) into the driven pulley and fit a new needle bearing (1) with the drift (C) (larger end).

Turn the pulley and then fit a new ball bearing (2) with the drift (C) (smaller end). Mount a new retaining ring with the drift.

3 - 15

ENGINE
3.1.12. ASSEMBLING THE DRIVEN PULLEY

Engine M285M

Fit the new oil seals (1) and O-rings (2) onto the mobile half pulley. Check parts in contact with the belt.

Fit the half pulley on the bushing with the special tool: Mobile pulley-to-fixed pulley guide: 8140664 Ensure that pins and collar show no signs of wear and refit them. Lubricate the driven pulley assembly with approx. 6 g of TUTELA MRM2 grease through a bent-end lubricator. Lubricate through one bushing inner hole until the grease comes out from the opposite one. This must be done to prevent the grease from going beyond the O-rings.

3 - 16

Engine M285M
3.1.13. SPRING

ENGINE

Measure the free length of the mobile driven half pulley spring.

Standard length: 123 mm (48.425 in.) Service limit -after use: 118 mm (46.456 in.)

3 - 17

ENGINE
3.1.14. CLUTCH WEIGHTS

Engine M285M

Check thickness of friction material on clutch weights.

Min. thickness allowed: 1 mm (0.0393 in.). Weights should show no traces of lubricants. If they do, leak test the driven pulley assembly seals.

NOTE During running-in, clutch weights should have middle contact surfaces, and be all the same. If not, the clutch may jerk. WARNING Do not open clutch weights with any tools to avoid load variations in the return springs.

3 - 18

Engine M285M
3.1.15. INSTALLING THE CLUTCH

ENGINE

Mount the spring, clutch and driven pulley. Use the adapter ring to mount the clutch on the specific tool. Universal tool for clutch assemblies: 8140259 Adapter for clutch unit disassembly: 8140665 Insert the lever pin in the hole of the adapter ring. Tighten the nut to the specified torque value.

3 - 19

ENGINE
3.1.16. DRIVE BELT

Engine M285M

Check drive belt for damage. Check the correct belt width.

Min. width: 19.5 mm (0.7677 in.) Standard width: 21.3 0.2 mm (0.8358 0.0787 in.)

3 - 20

Engine M285M
3.1.17. MOBILE DRIVING HALF PULLEY

ENGINE

Measure the outside diameter of the pulley sliding bushing.

Min. permitted diameter: 25.95 mm (1.0216 in.) Standard diameter: 25.959 25.98 mm (1.0220 1.0228 in.)

Check the rollers for damage or wear.

Min. allowed diameter: 20.1 mm (1.0228 in.) Standard diameter: 20.5 20.7 mm (0.8070 0.814 in.)

Check the degree of wear of the brass bush and measure its inside diameter.

Max. allowed diameter: 26.12 mm (1.0283 in.) Standard diameter: 26.000 26.021 mm (1.0236 1.0244 in.) WARNING Do not lubricate or clean the bush

Ensure that counter plate shoes are not worn out. Check the wear of roller recesses.

3 - 21

ENGINE
Check the wear of belt contact surfaces on both half pulleys.

Engine M285M

3 - 22

Engine M285M
3.1.18. ASSEMBLING THE TRANSMISSION UNIT

ENGINE

Preassemble the mobile half-pulley with the roller counter plate, positioning the rollers in the suitable housing. Fit the unit together with bushing onto crankshaft.

Open the driven pulley and insert the belt in it, ensure to stick to correct direction of rotation. Seat the driven pulley complete with belt. WARNING It is of utmost importance that the fixed driving half pulley is carried out with completely slack belt in order to avoid wrong tightening of the driving half pulley.

Insert the washer, the fixed driven half-pulley, the spacer and Belleville washer.

Prevent half-pulley rotation using the suitable tool (multipurpose tool: 8140252) and tighten the nut to the specified torque. Refit the clutch housing.

3 - 23

ENGINE
3.1.19. FITTING THE TRANSMISSION COVER

Engine M285M

Ensure that centering dowels are in position.

Refit the cover and tighten the screws to the specified torque. Refit the oil filler/dipstick. Apply Super Rapido (Quick-setting) thread locker Loctite 242E and then refit the steel washer and the driven pulley shaft nut.

Tighten the nut to the specified torque using the clutch housing lock wrench (8140661).

3 - 24

Engine M285M
3.1.20. DISASSEMBLING THE FINAL TRANSMISSION

ENGINE

Remove the dipstick. Drain the rear transmission fluid through the drain plug. Remove the screws.

Remove the final transmission cover complete with wheel shaft, idler gear and gasket.

3 - 25

ENGINE
3.1.21. REMOVING THE WHEEL SHAFT

Engine M285M

Remove the idler gear. Remove the wheel shaft complete with gear.

3 - 26

Engine M285M
3.1.22. FINAL TRANSMISSION CASE BEARINGS

ENGINE

Check bearings for wear, play and noise level. In case of troubles, proceed as follows. Use a suitable extractor to remove the three 15-mm (0.590 in.) bearings (1) (two on the case and one on the final transmission cover).

3 - 27

ENGINE
3.1.23. REMOVING THE WHEEL SHAFT BEARING FROM THE COVER

Engine M285M

Remove the circlip from the outside of the final transmission cover.

Remove the bearing; support the final transmission cover properly.

Remove the oil seal.

3 - 28

Engine M285M
3.1.24. REMOVING THE DRIVEN PULLEY SHAFT

ENGINE

Remove the transmission cover and the clutch assembly. Withdraw the driven pulley shaft from the bearing.

Remove the oil seal from the bearing. Be careful not to damage its seat. Pull it out from the transmission side.

Remove the circlip.

Withdraw the driven pulley shaft bearing.

3 - 29

ENGINE
3.1.25. ASSEMBLING THE FINAL TRANSMISSION BEARINGS

Engine M285M

Parts should be warmed up with the heat gun first. Fit the three 15-mm (0.590 in.) bearings (1) (two on the case and one on the final transmission cover).

3 - 30

Engine M285M
3.1.26. INSTALLING THE DRIVEN PULLEY SHAFT BEARING

ENGINE

Warm the case with the heat gun. Fit a new driven pulley shaft bearing with its balls visible from inside the final transmission. Fit the circlip with its open side opposite to the bearing.

Fit a new oil seal flush with the case on the pulley side.

3 - 31

ENGINE
3.1.27. CHECKING FINAL TRANSMISSION COVER

Engine M285M

Ensure that the mating surface is not dented or bent. Check bearing thrust surfaces. If necessary, fit a new final transmission cover.

3 - 32

Engine M285M
3.1.28. INSTALLING THE WHEEL SHAFT BEARING IN THE COVER

ENGINE

Warm the final transmission cover with the heat gun. Fit the wheel shaft bearing on the cover. Fit the circlip.

Fit the oil seal using the suitable tools. It should be flush with the inner surface and its seal lip facing the inside of the final transmission.

3 - 33

ENGINE
3.1.29. CHECKING FINAL TRANSMISSION SHAFTS

Engine M285M

The three shafts should show no signs of wear or damages to their toothed surfaces; also check bearing and oil seal thrust surfaces. Replace damaged parts, if necessary.

3 - 34

Engine M285M
3.1.30. INSTALLING FINAL TRANSMISSION GEARS

ENGINE

Fit the driven pulley shaft. Fit the idler gear. Fit wheel shaft complete with gear.

3 - 35

ENGINE
3.1.31. FITTING THE FINAL TRANSMISSION COVER

Engine M285M

Fit a new gasket on the centring dowels. Fit the cover. Make sure the vent hose is properly positioned. Position the shortest screw (colour-marked). Fit the remaining screws and tighten them to the specified torque value. Mount the oil drain plug with a new seal. Insert the oil dipstick.

3 - 36

Engine M285M
3.1.32. TIGHTENING TORQUES
TRANSMISSION Transmission cover (screw) Final transmission cover (screw) Clutch unit (nut) Driven belt roller (nut) Drive belt roller (nut) Belt tensioner roller (screw) Q.TY 12 7 1 1 1 1 (Nm) 11 13 24 27 45 50 54 60 75 83 11 13

ENGINE

(ft-lb) 8.113 9.588 17.701 19.914 33.190 36.878 39.828 44.254 55.317 61.217 8.113 9.588

3 - 37

ENGINE 3.2.
3.2.1.

Engine M285M

FLYWHEEL
REMOVING THE COMPLETE FLYWHEEL COVER Remove the screw from the secondary air system filter box. Loosen the two screws and disconnect the cylinder head rigid fitting with the relevant gasket.

Loosen the valve retaining screw and remove the complete secondary air unit.

Remove the clamp and disconnect the cooling coupling. Loosen the bracket retaining screws, the remaining screws and remove the flywheel cover.

3 - 38

Engine M285M
Remove the water pump spring. Remove the flywheel cover gasket.

ENGINE

3 - 39

ENGINE
3.2.2. REMOVING THE FLYWHEEL Refit (if removed) the driving half pulley in its seat. Lock the crankshaft using the multipurpose tool (tool no.: 8140252). Loosen and remove the flywheel nut and the relevant spacer.

Engine M285M

Position a suitable puller and remove the flywheel by turning the puller screw.

Remove the key from the crankshaft.

Remove the starter motor gear. Loosen the screw and remove the sprocket bracket. Remove the flywheel sprocket.

3 - 40

Engine M285M
3.2.3. REMOVING THE STATOR Remove the wiring bracket screws. Loosen and remove the stator fastening screws.

ENGINE

Remove stator and wiring.

3 - 41

ENGINE
3.2.4. CHECKING THE FLYWHEEL Check that the inside plastic parts and Pick-UP control plate are not damaged.

Engine M285M

3 - 42

Engine M285M
3.2.5. ASSEMBLING THE STATOR UNIT Position the stator with wiring in place. Tighten the stator fastening screws to the specified torque.

ENGINE

Fit the wiring bracket and tighten the screws to the specified torque.

3 - 43

ENGINE
3.2.6. INSTALLING THE FLYWHEEL Fit the starter clutch gear to the flywheel and check that the bearing works properly.

Engine M285M

Fit the starter clutch gear in place. Tighten the retaining bracket screw to the specified torque. WARNING Protect the crankshaft seat in the proper way.

Insert the starter motor drive gear.

Insert the key onto crankshaft.

Fit the flywheel, ensure the key is properly fitted.

NOTE To help flywheel assembly operations, slightly rotate it counterclockwise during insertion.

3 - 44

Engine M285M
Fit the washer and flywheel nut. Tighten the flywheel nut to the specified torque using the suitable tool fitted to the drive pulley. Multipurpose tool: 8140252

ENGINE

3 - 45

ENGINE
3.2.7. ASSEMBLING THE FLYWHEEL COVER Put the water pump drive spring in place. Fit the flywheel cover gasket.

Engine M285M

WARNING Ensure that the centering dowels are in place. Put the cover in place paying attention to the correct meshing of the drive spring on water pump shaft. Check for water pump proper operation. Position the bracket in its seat, fit the screws and tighten them to the specified torque.

Connect the coolant coupling and close the fastener. Fit the secondary air system in place. Tighten the filter securing screw and the secondary air system valve fastening screw.

Fit a new gasket and tighten the cylinder head rigid fitting screws to the specified torque.

3 - 46

Engine M285M
3.2.8. TIGHTENING TORQUES
FLYWHEEL Flywheel (nut) Stator (screw) Pick-up (screw) Q.TY 1 3 2 (Nm) 52 58 34 34

ENGINE

(ft-lb) 38.353 42.778 2.213 2.950 2.213 2.950

3 - 47

ENGINE 3.3.
3.3.1.

Engine M285M

LUBRICATION
REMOVING THE OIL SUMP AND THE PRESSURE-ADJUSTING BY-PASS Remove the oil filler cap, the transmission cover and the driving pulley with belt and sprocket. Drain the sump Unscrew the securing screws. Remove the sump, pay attention because the by-pass spring might fall off.

Remove spring and by-pass piston.

Slide out the seal and remove the centring dowels.

3 - 48

Engine M285M
3.3.2. CHECKING THE BY-PASS Check the free length of the spring.

ENGINE

Standard length: 54.2 mm (2.133 in.). Check that piston is free from scoring. Make sure that piston can run smoothly along casing and that sufficient sealing is ensured. If necessary, remove foreign bodies or change the faulty parts.

3 - 49

ENGINE
3.3.3. DISASSEMBLING THE CHAIN HOUSING COVER Use the bolts supplied to mount the base of the tool on the cover. Tool to fit /remove chain cover: 8140729

Engine M285M

Screw the threaded bar on the base of the tool and extract the cover.

3 - 50

Engine M285M
3.3.4. REMOVING THE OIL PUMP Take out the two bolts and remove the pump driving pulley cover.

ENGINE

Insert a screwdriver in one of the holes of the oil pump drive pulley to prevent it from turning. Remove centre screw with Belleville washer. Remove the pulley and chain.

NOTE It is advisable to mark the chain so as to maintain its original direction of rotation.

Remove drive sprocket, washer and O-ring.

To remove the oil pump, loosen the two screws. Remove the oil seal.

3 - 51

ENGINE
3.3.5. CHECKING THE OIL PUMP Remove the two screws (1) and the oil pump cover (2).

Engine M285M

Remove the inner rotor circlip (3). Remove the oil pump shaft. Remove rotors (4) and (5). Thoroughly wash with petrol and blow with compressed air. Reassemble rotors on pump body (6). Make sure that the two marks (7) are visible. Refit the pump shaft and circlip.

Use a feeler gauge to check the distance between the outer rotor and the pump body.

Max. allowed gap: 0.20 mm (0.0078 in.)

Use a feeler gauge to check the distance between the rotors.

Max. allowed gap: 0.12 mm (0.0047 in.)

3 - 52

Engine M285M
Check the axial play of the rotors with a ground bar.

ENGINE

Limit: 0.09 mm (0.0035 in.) Mount the oil pump cover and tighten the retaining screws.

3 - 53

ENGINE
3.3.6. ASSEMBLING THE OIL PUMP Check the pump body-shaft for wear. Check that pump cover is not worn or scored. In case of excessive wear or scores, change the damaged parts or the whole unit. Fit the pump cover so as to align the holes of the retaining screws.

Engine M285M

Make sure that gasket is correctly positioned and refit pump to crankcase. Pump can be positioned in one way only. Tighten screws to the specified torque.

Fit washer and sprocket with a new O-ring.

Fit chain in the direction of rotation indicated upon disassembly. Fit pulley, Belleville washer and center screw. Tighten to the specified torque.

NOTE Fit the Belleville washer, with its outer edge resting against the pulley. Check that pump turns freely.

3 - 54

Engine M285M
To refit the pump cover guard, tighten the two screws to the specified torque.

ENGINE

3 - 55

ENGINE
3.3.7. ASSEMBLY OF THE CHAIN HOUSING COVER Prepare the new cover and lubricate the sealing edge. WARNING Do not lubricate the surface used to key the cover on the crankcase. Preassemble the cover with the special tool and start the screws in their thread. Tool to fit /remove the chain cover 8140729 Insert the tool bush on the crankshaft.

Engine M285M

Insert the tool together with the chain cover on the crankshaft until contact is made with the crankcase. WARNING Set the cover with the channel downwards. Failure to do so, the oil seal seat will be incorrectly positioned.

Install the tool bracket to correctly position the cover.

Screw the threaded bar right down on the crankshaft. Turn the nut on the base of the tool to check that the cover is driven fully home. Remove the tools. WARNING Failure to comply with this assembly procedure is likely to result in serious damage to the engine due to incorrect tightening of the oil pump drive chain.

3 - 56

Engine M285M
3.3.8. ASSEMBLING THE BY-PASS AND THE OIL SUMP Refit the by-pass piston into its seat. Install the adjuster spring.

ENGINE

Refit the three centering dowels. Apply a new sump seal.

Install sump and fit the spring into the tailpiece.

Refit sump screws. Tighten the screws to the specified torque value. Refit drive pulley assembly, belt, sprocket and transmission cover.

3 - 57

ENGINE
3.3.9. TIGHTENING TORQUES
LUBRICATION Oil pump baffle plate (screw) Oil pump cover (screw) Oil pump (screw) Oil pump driving roller (screw) Oil sump (screw) Q.TY 2 2 2 1 7 (Nm) 0,7 0,9 0,7 0,9 56 10 14 10 14

Engine M285M

(ft-lb) 0.516 0.664 0.516 0.664 3.688 4.425 7.376 10.326 7.376 10.326

3 - 58

Engine M285M 3.4.

3.4.1.

ENGINE

COOLING
REMOVING THE WATER PUMP In the event of noise at the bearings or fluid leaks at the cover inner drain hole, overhaul water pump. Remove flywheel cover with water pump from engine and remove the stator together with its wiring.

Undo the fasteners and remove rotor cover. Remove the rotor cover gasket.

Position flywheel cover on ring base (tool 8140662)

NOTE To avoid damage to the cover sealing surface, position the ring base with its machined surface facing the flywheel cover. Use a press and the drift (tool 8140663) to push the shaft and rotor out of the drive and bearings.

3 - 59

ENGINE
Remove the seal from the shaft and drive.

Engine M285M

Use a screwdriver to remove the oil seal from the cover. Remove ceramic seal static side from flywheel cover with a screwdriver.

Position flywheel cover under a press. Make sure it is perfectly flat.

Use a suitable punch, upside-down, and remove the two ball bearings.

3 - 60

Engine M285M
3.4.2. CHECKING THE WATER PUMP COMPONENTS Check that rotor shaft is not oxidized. Check that rotor is free from excessive wear or cracks.

ENGINE

Check that bearing seats and ceramic seal are not oxidized. Check that the drive is free from cracks.

3 - 61

ENGINE
3.4.3. ASSEMBLING THE WATER PUMP Use a heat gun to heat the flywheel cover from the inside.

Engine M285M

NOTE Overheating may damage the painted surface. Position flywheel cover on ring base (tool 8140663). Position the two bearings on special drift.

NOTE Always use new bearings. Use grease to keep bearings on tool. Drive bearings fully home into casing with a plastic mallet.

Assemble the ceramic ring with rubber seal. The chamfered edge of the ring must face the seal. Lubricate rubber seal and install unit on flywheel cover.

NOTE Always use new ceramic ring and seal. If a ceramic ring is not fitted manually, it may be damaged.

Position the flywheel cover. Lubricate the rotor shaft and fit its seal. Use a press to fit the shaft in the rotor.

NOTE Make sure that drift is perfectly centered on rotor. Put shaft under stress and make sure flywheel cover turns in a flat plane. Failure to comply with this recommendation can cause damage to the drive.

3 - 62

Engine M285M
Use a heat gun to heat up the water pump drive. Position the drive onto a suitable support and insert it tapping with a rubber mallet.

ENGINE

Fit a new oil seal.

Fit a new O-ring on the rotor cover. Refit the rotor cover. Tighten the retaining screws to the specified torque value.

NOTE Do not lubricate the O-ring. Failure to comply with this recommendation leads to ring deformation.

3 - 63

ENGINE
3.4.4. CHECKING THE THERMOSTAT Visually inspect thermostat (1) for damage. Fill a metal container with about 1 liter of water. Immerge the thermostat (1). Keep it at the center of container. Immerge multimeter thermal probe close to the thermostat. Heat container with a thermal gun. Check the temperature at which thermostat starts opening:

Engine M285M

Opening start temperature: 77.5 80.5C (171.5 176.9F)

Continue heating until thermostat is fully open: Opening stroke: 3.5 mm (0.137 in.) at 88C (190.4F) WARNING For a correct test procedure, avoid direct contact between thermostat and container. In case of faulty operation, change thermostat.

3 - 64

Engine M285M 3.5.

3.5.1.

ENGINE

CRANKCASE AND CRANKSHAFT

REMOVING THE STARTER MOTOR Remove the following assemblies: transmission, cylinder head, cylinder, flywheel, oil and water pumps. Loosen the screws and remove the starter motor. Remove the O-ring.

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ENGINE
3.5.2. CHECKING THE CRANKSHAFT-CRANKCASE END FLOAT Remove the flywheel cover. Fit a dial gauge to the engine, using a suitable magnetic bar, so to measure the crankshaft end float on the flywheel.

Engine M285M

NOTE For a correct measurement of the crankshaft end float, ensure that the gauge is on the same axis as the crankshaft. Reset the dial gauge. Manually move the crankshaft and measure end float.

Standard end float with cold parts: 0.15 0.40 mm (0.005905 0.015748 in.)

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Engine M285M
3.5.3. OPENING THE CRANKCASE Loosen the engine oil drain plug with gasket and drain all engine oil. Remove the oil prefilter and detach the relevant gasket.

ENGINE

Remove the ten crankcase coupling screws. Detach the two casings. Keep the shaft installed on one of them. WARNING The crankshaft may drop out if this is not done.

Remove the case coupling gasket. Remove the crankshaft. WARNING When opening the crankcase and removing the crankshaft, make sure that its threaded ends do not interfere with the main bearings or they will damage.

Remove the screws and guard. Remove the oil pressure sensor. Remove the oil filter.

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ENGINE
Check the con-rod axial play.

Engine M285M

Standard play: 0.20 0.50 mm (0.0078 0.0196 in.)

Check the con-rod radial play.

Standard play: 0.036 0.054 mm (0.00141 0.00212 in.) Check that axial play holding surfaces are not scored and use a washer to check crankshaft width.

NOTE Make sure that the measurement is not altered by the fillet radius with crankshaft bearings. Standard dimensions: 55.67 55.85 mm (2.1917 2.1988 in.)

If the crankshaft axial play is above the standard values and the crankshaft is not damaged, the problem is due to wear or to faulty crankcase machining.

Check diameters of both bearing seats on the crankshaft. Shafts are classified into two categories: Cat. 1 and Cat. 2, as shown in the table below. Cat.1 Cat.2 Standard diameter 28.994 29.000 mm (1.1414 1.1417 in.) 29.000 29.006 mm (1.1417 1.1419 in.)

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Engine M285M
Checking crankshaft alignment Measure crankshaft misalignment in the points indicated. Check that crankshaft taper, keyway, oil seal seat, splined end and threaded dowels are in good condition. If necessary change the crankshaft.

ENGINE

NOTE Main bearings cannot be ground. Con-rod big-end bearings cannot be changed. For the same reason, con-rods cannot be changed when cleaning the crankshaft, take special care to prevent dirt from entering the crankshaft lubrication hole.

To avoid damage to con-rod bearings, do not clean lubrication duct with compressed air. Make sure that the two buffers are correctly installed on crankpin. Lubrication pressure to con-rod bearings can be impaired if one buffer is not correctly installed.

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ENGINE
3.5.4. CHECKING CRANKCASE Before checking the casing, thoroughly clean all surfaces and lubrication ducts. On the transmission-side casing, pay particular attention to the oil pump ducts and seat, by-pass duct, main bearings and transmission-side cooling jet.

Engine M285M

NOTE Jet is fed through main bearings. Piston crown cooling is improved if this circuit is working properly. In case of obstruction, some hidden problems (piston temperature increase) will arise. If this part is not installed or if it leaks, main bearings and con-rod bearings lubrication pressure could be abruptly reduced. As already described under lubrication section, the by-pass seat should not be worn in order not to affect correct sealing of the piston regulating lubrication pressure.

On the flywheel-side case pay particular attention to the side main bearings lubrication ducts, oil delivery to head duct and oil seal drain duct.

NOTE Oil delivery to head drain duct is equipped with a shutter jet: this allows a head low-pressure lubrication in order to keep the sump oil temperature low. In case jet is clogged, head and timing system mechanisms lubrication will be impaired. In case jet is not present, main bearings and con-rod bearings lubrication pressure will be reduced.

Check that surfaces are neither dented or out of shape, carefully inspect casing-cylinder and casing mating surfaces. In the event of a fault of the casing jointing gasket or the surfaces, pressurized oil could leak and lower the main bearings and con-rod bearings lubrication pressure. Check crankshaft axial play holding surfaces for wear. For dimensional check, follow the instructions given to check axial play and to take crankshaft readings.

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Engine M285M
3.5.5. CHECKING THE MAIN BEARING Optimal lubrication pressure (4 bar) and good oil delivery are necessary to ensure good lubrication. Bearings must be correctly positioned so to prevent choking of oil delivery lines. Main bearings are composed of two half-bearings; one is solid, the other is provided with special slots for lubrication. The solid half-bearing withstands the thrusts due to combustion and is positioned opposite the cylinder.

ENGINE

To prevent choking of the oil delivery lines, the mating surface of the two half bearings must be at right angles to the cylinder axis as shown. The section of the ducts is influenced by the depth to which the bearings are driven.

Standard driving depth: 1.35 1.6 mm (0.053 0.062 in.). NOTE To keep bearings in their correct position on casing, they are tight-fitted on steel rings when the casings are cast.

Check bearings diameter in the three directions. Repeat readings on the other half bearing.

NOTE Do not take readings on the mating surface between the two shells, as the outer edges are chamfered to allow distortion during driving operations.

Standard bearing diameter after driving varies and is determined by the coupling class. Bearing locations on casing are classified into 2 categories, like the crankshaft, namely Cat. 1 and Cat. 2. Bearings are divided into three categories, based on the thickness. See table below: TYPE A B C DESCRIPTION Red Blue Yellow

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ENGINE
Bearing category A B C Casing category 1 1 2 2 Bearing inner diameter after assembly 29.025 29.040 mm (1.1427 1.1433 in.) 29.019 29.034 mm (1.1424 1.1430 in.) 29.028 29.043 mm (1.1428 1.1434 in.) 29.022 29.037 mm (1.1425 1.1431 in.)

Engine M285M
Assembling possibility Original Original and spare Original

NOTE Casings for spares are of the same category and are equipped with bearings of the B (blue) category. Match crankshaft with two shoulders of category 1 with casing of category 1 (or cat. 2 with cat.2). A spare casing cannot be combined with a crankshaft composed of mixed categories. Crankshaft for spares is equipped with axle shafts belonging to the same category. Casing CAT.1 CAT.2 CAT.1 CAT.2 Axle shaft CAT.1 CAT.2 CAT.2 CAT.1 Bearing B B A C

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Engine M285M
3.5.6. CLOSING THE CRANKCASE Lubricate the gasket and fit the oil filter. Change the gasket and tighten the oil pressure sensor to the specified torque.

ENGINE

Fit the inner baffle plate and tighten the two screws to the specified torque. Lubricate the main bearing, the crankshaft and fit it into the transmission-side case. Position the gasket onto the transmission-side case.

NOTE During gasket insertion, pay particular attention to the centring dowel areas. A wrong refitting of the gasket would compromise engine lubrication and sealing.

Lubricate the flywheel-side main bearing and mate the cases.

NOTE When reassembling the crankcase and crankshaft, pay special attention not to damage the main bearing shells with the shaft threaded ends.

Fit the ten bolts and tighten them in a cross pattern to the specified torque.

NOTE Remove any possible exceeding paste from cylinder surface to ensure sealing.

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ENGINE
Fit a new O-ring onto prefilter and fit the prefilter.

Engine M285M

Fit a new gasket and tighten the oil drain plug to the specified torque.

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Engine M285M
3.5.7. ASSEMBLING THE STARTER MOTOR Fit a new O-ring on the starter motor and lubricate it.

ENGINE

Fit starter motor on crankcase. Tighten the two screws to the specified torque value.

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ENGINE
3.5.8. TIGHTENING TORQUES

Engine M285M

CRANKCASE AND CRANKSHAFT Starter motor (screw) Crankcase (screw) Inner baffle plate (screw) Oil drain plug

Q.TY 2 11 2 1

(Nm) 11 13 11 13 46 24 30

(ft-lb) 8.113 9.588 8.113 9.588 2.950 4.425 17.701 22.127

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Engine M285M 3.6.

3.6.1.

ENGINE

CYLINDER HEAD AND TIMING SYSTEM

DISASSEMBLY OF THE TAPPET COVER Remove the fasteners. Remove the tappet cover complete with expansion tank and automatic valve.

Remove the gasket.

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ENGINE
3.6.2. CHECKING THE TIMING SYSTEM Loosen and remove the plastic plug used for checking engine timing on the flywheel side.

Engine M285M

Use a multipurpose tool (8140252) applied to the drive pulley to turn the flywheel until the reference mark corresponds to the mark on the crankcase (TDC).

Ensure that the reference mark 4V punched on camshaft pulley matches the reference mark on cylinder head. Should the reference mark be at opposite side with respect to the head mark, make crankshaft rotate by one more turn.

the the the the

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Engine M285M
3.6.3. CHECKING/ADJUSTING VALVE CLEARANCE Align timing marks to check valve clearance.

ENGINE

Check the valve-shim clearance with a feeler gauge. If valve clearance is not as specified, loosen the check nut and adjust the clearance value with a screwdriver. Intake: 0.013 0.040 mm (0.000511 0.000157 in.) (cold) Exhaust: 0.025 0.052 mm (0.00098 0.00204 in.) (cold)

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ENGINE
3.6.4. FITTING THE TAPPET COVER

Engine M285M

NOTE Fit a new O-ring onto the tappet cover. Mount the cover complete with expansion tank.

Tighten the screws to the current torque value.

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Engine M285M
3.6.5. CHECKING END-OF-COMPRESSION PRESSURE

ENGINE

Remove the spark plug cap when the engine is cold. Remove the spark plug. Fit a compression pressure gauge into the spark plug seat tightening the 10-mm spark plug fitting to the specified torque. Crank the engine by means of the starter motor, keeping the carburettor fully open, until the gauge indicator reads a stabile value. If pressure is over 8-9 bar, remove the tool following the above procedure in the reverse order. If pressure is under the above value, check engine rotation speed during the test. If under 450 rpm, check starting system. If engine rotation speed is correct or just over the optimal value, check timing system. Ensure that cylinder base gasket is correct. Also check piston-cylinder assy for possible leaks (piston rings-valves).

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ENGINE
3.6.6. CHECKING IGNITION ADVANCE For this check, a strobe lamp with induction clamps connected to the spark plug power cable is required. Connect the clamps to the right poles. Set the lamp selector to its middle position (1 spark = 1 turn of the shaft as in 2-stroke engines). Start the engine; ensure that the lamp works properly and the rev counter can read up to e.g. 8000 rpm. In case of instable flash or rpm reading, increase resistive load on spark plug power line.

Engine M285M

Remove the plastic plug from the flywheel cover slot. Turn lamp flash control and match the flywheel cover mark with the flywheel mark. Read advance degrees shown by the strobe lamp. Check the correspondence between advance degrees and rev speed as shown in the tables. In case of failure, check Pick-up and CPU power supplies (positive-negative). Replace CPU, if necessary. A virgin CPU prevents the engine from exceeding 2000 rpm. A programmed CPU allows the engine to run within the set limits. A = Advance B = Ignition advance curve

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Engine M285M
3.6.7. DISASSEMBLING THE INTAKE MANIFOLD Unscrew and remove the intake manifold.

ENGINE

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ENGINE
3.6.8. REMOVING THE THERMOSTAT Loosen the screws and remove thermostat cover.

Engine M285M

Remove thermostat with seal.

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Engine M285M
3.6.9. REMOVING THE TIMING DRIVE GEAR First remove the following parts: transmission cover, driving pulley and belt, sprocket, oil sump with spring and by-pass piston, oil pump pulley cover, crankshaft O-ring and washer between sprockets. Remove tappet cover.

ENGINE

Loosen tensioner centre screw. Remove the side screws. Remove tensioner and seal.

Fit (if not present) the fixed drive half-pulley to the crankshaft. Prevent chain rotation by locking the drive pulley with the multipurpose tool (8140252) and loosen the stop plate screw. Remove the screw and the valve lifter stop plate

Remove automatic valve-lifter return spring, valve-lifter with stop washer. Remove inner hexagon screw and counterweight.

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ENGINE
Remove camshaft drive pulley and washer.

Engine M285M

Remove screw, spacer and tensioner sliding shoe. Remove driving sprocket and timing chain.

NOTE Before disassembly, mark chain so that it can be refitted in its original direction of rotation. To remove tensioner-sliding shoe, work on the transmission side. To remove lower chain guide-sliding shoe first disassemble the head.

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Engine M285M
3.6.10. DISASSEMBLING THE CAMSHAFT AND ROCKER ARMS

ENGINE

Remove the two screws and the camshaft bracket.

Remove camshaft.

Working from flywheel side, remove rocker arms and their shafts.

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ENGINE
3.6.11. DISASSEMBLIGN THE HEAD

Engine M285M

Remove the spark plug.

Remove the two side fasteners. Working crossways, loosen cylinder head fastening nuts. Loosen in two or three steps.

Remove the head, the two centering dowels and gasket.

NOTE If needed, head can be removed with camshaft, rocker arm shafts and fastening bracket. It can also be removed without disassembling the chain and chain tensioner from crankshaft.

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Engine M285M
3.6.12. DISASSEMBLING THE VALVES

ENGINE

Use the special tool with adapter to remove valve cotters, shims, springs and valves. WARNING Arrange valves so as to indicate their original positioning on the head.

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ENGINE
3.6.13. DISASSEMBLING THE CYLINDER AND PISTON

Engine M285M

Remove the clamp and detach the cooling sleeve. Remove chain-sliding shoe.

Raise the cylinder and remove the seals. Slide out cylinder. WARNING Support the piston, so as not to damage it.

Remove cylinder base gasket and centering dowels.

Protect the crankshaft seat. Remove the two snap rings, gudgeon pin and piston.

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Engine M285M
Remove the piston rings from piston.

ENGINE

NOTE During disassembly, take care not to damage piston rings.

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ENGINE
3.6.14. CHECKING CON-ROD SMALL END

Engine M285M

Using a bore micrometer gauge, check con-rod small end diameter.

Standard diameter: 15.015 15.025 mm (0.59113 0.59153 in.) Max. allowed diameter: 15.030 mm (0.59173 in.) NOTE Should con-rod small end diameter be above the specified limits, be worn or overheated, change crankshaft as described in Crankcase and crankshaft.

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Engine M285M
3.6.15. GUDGEON PIN DIAMETER

ENGINE

Check gudgeon pin outer diameter (A).

Diameter (A): 14.996 15.000 mm (0.59039 0.59055 in.) Check gudgeon pin - small end clearance.

Standard clearance: 0.015 0.029 mm (0.00059 0.00114 in.)

Measure thrust surface diameter on piston.

Standard diameter: 15.001 15.006 mm (0.59059 0.59079 in.) Calculate gudgeon pin-piston clearance.

Standard clearance: 0.001 0.010 mm (0.00004 0.00039 in.) NOTE Gudgeon pin seats have two lubrication ducts. Take diameter reading along piston axis.

Measure piston outer diameter at right angles to the gudgeon pin axis.

Use a suitable bore gauge to measure cylinder inner diameter (D1 and D2) in the directions shown in the figure. Take readings at three heights (H1, H2, and H3).

Standard diameter: D1 and D2= 72 mm (2.834637 in.) Check that cylinder surface mating with head is not worn or out of shape.

Max. permitted misalignment: 0.05 mm (0.00197 in.) Pistons and cylinders are classified according to their diameter. Match cylinders with pistons from the same category (A-A, B-B, C-C, D-D).

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ENGINE
Cylinders can be ground to the original angle. Cylinder surface roughness must be 0.9 micron (0.00354 in.). This ensures correct piston ring bedding, reduced oil consumption and top performance.

Engine M285M

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Engine M285M
3.6.16. PISTON

ENGINE

Thoroughly clean piston ring locations. Use suitable gauges to measure the clearance between piston rings and grooves. If the clearance exceeds the allowed values change the piston.

1st piston ring 2nd piston ring Scraper ring

Standard coupling clearance 0.015 0.06 mm (0.00059 0.00236 in.) 0.015 0.06 mm (0.00059 0.00236 in.) 0.015 0.06 mm (0.00059 0.00236 in.)

Max. allowed clearance after use 0.07 mm (0.0027 in.) 0.07 mm (0.0027 in.) 0.07 mm (0.0027 in)

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ENGINE
3.6.17. PISTON RINGS

Engine M285M

Install the three piston rings one by one in the cylinder area with original diameter. Use the piston to set the rings at right angles to the cylinder axis. Measure rings opening with a feeler gauge. If the allowed values are exceeded, change the rings.

1st piston ring 2nd piston ring Scraper ring

Standard opening 0.15 0.30 mm (0.0059 0.0118 in.) 0.10 0.30 mm (0.0039 0.0118 in.) 0.15 0.35 mm (0.0059 0.0137in.)

NOTE Before changing only piston rings, make sure that the rings-piston groove and piston-cylinder clearance values are observed. Installing new piston rings on a worn cylinder could result in non-standard bedding.

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Engine M285M
3.6.18. ASSEMBLING PISTON

ENGINE

Protect the crankshaft seat. Lubricate the con-rod small end and the gudgeon pin. Fit piston and gudgeon pin to con-rod by setting the piston with the arrow facing the exhaust side.

Install snap ring on piston. Fit a ring on each side. WARNING Be careful not to score or damage ring seats or piston inner surface.

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ENGINE
3.6.19. CHECKING PISTON POSITION

Engine M285M

Temporarily fit cylinder on piston, without base gasket. Install a dial gauge on special tool. Dial gauge holder: 8140266 Reset dial gauge on a reference surface. With dial gauge set at zero, fit tool on cylinder and lock it in place with two of the four head fastening nuts. Turn camshaft to TDC (dial gauge index will reverse direction of rotation).

Position dial gauge on piston as shown in the figure and measure. Use the table below to determine the thickness of the cylinder base gasket to be used at reassembly and thus ensure the correct compression ratio. Remove special tool and cylinder. Measured value 3.70 3.60 mm (0.1456 0.1417 in.) 3.60 3.40 mm (0.1417 0.1338 in.) 3.40 3.30 mm (0.1338 0.1299 in.) Gasket thickness 0.4 0.05 mm (0.0157 0.0019 in.) 0.6 0.05 mm (0.0236 0.0019 in.) 0.8 0.05 mm (0.0314 0.0019 in.)

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Engine M285M
3.6.20. ASSEMBLING PISTON RINGS

ENGINE

Position scraper ring spring on piston. To fit the ring, keep its opening opposite the spring joint with the word top facing the piston crown. The chamfered edge must face the piston crown.

Fit 2nd ring with its identification mark or the word top facing the piston crown. The chamfered end must be opposite the piston crown. Fit the 1st ring with its identification mark or the word top facing the piston crown.

NOTE The surface of the two rings mating the cylinder is tapered to ensure better settling. Set the ring openings offset by 120. Lubricate with engine oil. The 1st ring has an L-shaped cross-section.

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ENGINE
3.6.21. ASSEMBLING THE CYLINDER

Engine M285M

Fit the centering dowels.

Install cylinder base gasket. Take the tool: 8140660 Lubricate the cylinder, then assemble it using the suitable tool.

Connect and clamp the cooling sleeve.

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Engine M285M
3.6.22. CHECKING THE HEAD

ENGINE

Using a ground bar and a feeler gauge, check that the head surface is not worn or out of shape.

Max. misalignment allowed: 0.05 mm (0.00196 in.) Check camshaft and rocker arm shaft thrust surfaces for wear. Check head cover, intake manifold and exhaust manifold surfaces for wear.

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ENGINE
3.6.23. CHECKING VALVES FOR WEAR

Engine M285M

Measure valve seats and valves sealing surface width. WARNING Do not change valve assembling position (RHLH).

Sealing surface depth (L) Standard: Intake and exhaust: 0.99 1.27 mm (0.0389 0.0499 in.) (L) After use: Intake and exhaust: 1.6 mm (0.0629 in.) In case valve sealing surface is wider that the recommended limit, interrupted in one or more points, or bent, change valve.

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Engine M285M
3.6.24. CHECKING VALVE SEATS FOR WEAR

ENGINE

Measure "V" mark width on valve seat. Max. wear limit 1.6 mm (0.0629 in.). Clean valve guide from any carbon deposits. Measure the inner diameter of all valve guides (D). Make the measurements at three different heights in the rocker arm thrust direction.

Exhaust valve guide D = Standard diameter: 5.000 5.012 mm (0.1968 0.1973 in.) D = Allowed limit: 5.022 mm (0.1977 in.) Intake valve guide D = Standard diameter: 5.000 5.012 mm (0.1968 0.1973 in.) D = Allowed limit: 5.022 mm (0.1977 in.) If the valve seat mark width values or the valve guide diameter are above the specified limits, change the head.

Checking valves Check valve stem diameter (d D) in the three points shown in the figure. Standard diameter D1, D2 and D3=Intake: 4.972 4.987 mm (0.1957 0.1963 in.) d1, d2 and d3=Exhaust: 4.96 4.975 mm (0.1952 0.1958 in.) Min. allowed diameter D1, D2 and D3=Intake: 4.96 mm (0.1952 in.) d1, d2 and d3=Exhaust: 4.95 mm (0.1948 in.) Calculate clearance between valve and valve guide.

Standard clearance Intake: 0.013 0.040 mm (0.000511 0.000157 in.) (with cold parts) Exhaust: 0.025 0.052 mm (0.00098 0.00204 in.) (with cold parts) Max. allowed clearance Intake: 0.062 mm (0.00244 in.) Exhaust: 0.072 mm (0.00283 in.) Check the surface mating the shim joint terminal for wear.

Valve standard length (L l) L =Intake: 94.6 mm (3.7243 in.) l =Exhaust: 94.4 mm (3.7165 in.)

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ENGINE
If after the above checks all the values are within the specified limits, use the same valves. To ensure perfect sealing, grind valves with fine lapping compound. When grinding, position the head with the valve axes in horizontal position to prevent lapping compound residues from entering the valve guide stem coupling (see figure).

Engine M285M

WARNING To avoid scoring the mating surface, do not overturn valve when the lapping compound is finished. Thoroughly wash head and valves with a product suitable to the lapping compound used. NOTE Do not confuse valve assembling position.

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Engine M285M
3.6.25. CHECKING VALVE SEALING

ENGINE

Install valves into head. Alternatively test intake and exhaust valves. To carry out this test, fill manifold with fuel and check that head does not leak at the valves (keep valves pressed with your fingers).

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ENGINE
3.6.26. CHECKING COTTERS AND SPRING PLATES

Engine M285M

Check that springs upper bearing plates (1) and cotters (2) are not excessively worn.

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Engine M285M
3.6.27. ASSEMBLING VALVES

ENGINE

Install valves, springs and plates. Use the special tool with adapter to compress springs and install cotters into seats.

NOTE Do not confuse valve assembling position. Fit valve springs with the reference color facing the cotters (larger turns).

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ENGINE
3.6.28. CHECKING THE TIMING SYSTEM PARTS

Engine M285M

Make sure the chain is not worn. Check that guide sliding shoe (1) and tensioner sliding shoe (2) are not excessively worn. Check that camshaft drive belt roller and sprocket (3) are not worn. In case of wear, change the parts. If chain, sprocket and belt rollers are worn, change the whole unit.

Remove center screw with washer and tensioner spring. Make sure that the one-way mechanism is not worn. Check tensioner spring. In case of wear, change the whole unit. Use the stop to check the slides of the tensioner.

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Engine M285M
3.6.29. CHECKING THE CAMSHAFT not

ENGINE

Check that camshaft thrust surfaces are excessively worn and measure their diameters.

Standard diameter Thrust surface A : 36.95 36.975 mm (1.4547 1.4557 in.) Thrust surface B : 19.959 19.98 mm (0.7857 0.7866 in.) Min. allowed diameter Thrust surface A : 36.94 mm (1.4543 in.) Thrust surface B : 19.950 mm (0.7854 in.)

Check cam (C and D) heights.

Standard height C =Intake: 30.285 mm (0.7854 in.) D =Exhaust: 29.209 mm (1.1499 in.) Check rocker arm shafts for wear and scoring and measure their diameter.

E =Standard diameter: 11.977 11.985 mm (0.47153 0.47184 in.) Check that the sliding shoe (3) in contact with cam and shim joint plate (4) is not worn. Check inside diameter (F) of all rocker arms

F =Rocker arm inner diameter: 12.000 12.011 mm (0.4724 0.4728 in.) Measure the clearance between the groove and the retaining plate.

Standard axial play: 0.11 0.41 mm (0.0043 0.0161 in.) Max. axial play allowed: 0.42 mm (0.0165 in.) Check the groove and the plate for signs of wear. In case of wear or if values are outside the permitted limit, change faulty parts.

Check that the cam and the rubber stop on plate are not worn. Check that the automatic valve-lifter, end of travel roller and counterweight for signs of wear. Check that the valve lifter spring has not yielded. In case of wear, change the worn parts.

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ENGINE
3.6.30. ASSEMBLING HEAD AND TIMING SYSTEM PARTS

Engine M285M

Fit the seals. Fit the centering dowels. Position a new gasket to the cylinder.

Fit the chain sliding shoe.

NOTE Before assembling the head, make sure that the lubrication duct is perfectly clean. Blow with compressed air. Fit the cylinder head. Tighten the timing chain side nuts and bolts crosswise to the specified torque values in 2 or 3 steps.

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Engine M285M
3.6.31. ASSEMBLING TIMING SYSTEM PARTS

ENGINE

Install the rocker arms and shafts. Lubricate the rocker arms through the upper holes.

Fit the camshaft Insert the bracket and tighten the screws to the specified torque value.

Turn the flywheel to bring its reference mark in line with the flywheel cover mark (TDC).

Fit the timing chain in the direction of rotation indicated when disassembling and the drive sprocket.

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ENGINE
Fit the tensioner shoe and spacer, and tighten the screw to the specified torque value.

Engine M285M

Fit the camshaft drive pulley and its washer. Make sure the 4V mark on the camshaft pulley is in line with the reference mark on the head. If it is opposite to the head, make the crankshaft perform one more turn.

Fit the counterweight and tighten its screw to the specified torque value.

Fit the automatic valve lifter with washer and secure the return spring. Fit the valve lifter holder and tighten its screw to the specified torque value.

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Engine M285M
Remove the centre screw, washer and tensioner spring and check one-way mechanism for wear Check the spring condition In the event of wear, change the entire unit Press the locking tooth to bring back the tensioner. Fit a new seal, chain tensioner and tighten its screws to the specified torque value.

ENGINE

Position the spring and washer and tighten the centre screw to the specified torque value. Fit the tappet cover. Fit the sprocket separation washer and O-ring on the crankshaft, the oil pump, pulley cover, the sump with spring and by-pass piston, the starting sprocket, the driving pulley and belt, and the transmission cover.

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ENGINE
3.6.32. ASSEMBLING THE THERMOSTAT

Engine M285M

Position thermostat with the bleed hole in the highest position. Make sure that rubber seal is correctly positioned. Fit thermostat cover with the union for carburettor heating tube facing the flywheel. Tighten the screws to the specified torque values.

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Engine M285M
3.6.33. ASSEMBLING THE INTAKE MANIFOLD

ENGINE

Fit manifold and tighten its bolts.

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ENGINE
3.6.34. TIGHTENING TORQUES
CYLINDER, HEAD AND TIMING Cylinder head (nut) (tighten nuts in two steps, working in a cross pattern) (lubricate the nuts with engine oil before assembly) Head fastening side screws Tappets adjustment lock nut Valve lift mass stop plate (screw) Counterweight (screw) Camshaft bracket (screw) Tensioner shoe (screw) Timing chain tensioner fastener (screw) Timing chain tensioner adjustment (screw) Thermostat fitting (screw) Q.TY 4 2 5 1 1 2 1 2 1 2 (Nm) 9 11 + 180 11 13 68 11 15 7 8,5 46 10 14 11 13 56 34

Engine M285M

(ft-lb) 6.638 8.113 + 180 8.113 9.588 4.425 5.900 8.113 11.063 5.163 6.269 2.950 4.425 7.376 10.326 8.113 9.588 3.688 4.425 2.213 2.950

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Engine M285M 3.7.

3.7.1.

ENGINE

SECONDARY AIR SYSTEM

SYSTEM DIAGRAM

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ENGINE
Legend: 1. 2. 3. 4. 5. Intake manifold; Cut-off; Secondary air valve; Air intake from flywheel cover; Exhaust.

Engine M285M

SAS The Secondary Air System (SAS) has been developed to reduce carbon oxide and unburnt hydrocarbon emissions in vehicles that are not equipped with a lambda sensor. Natural air (which is rich in oxygen) is channelled into the exhaust stream to trigger a post-combustion process that raises the temperature of the exhaust gasses for a quick light-off of the catalyst. The secondary air system is especially useful when the engine is idling and during warm-up, as the catalyst alone is not capable of triggering post-combustion under these operating conditions.

DESCRIPTION OF THE SYSTEM The secondary air system operates on pressure fluctuation in the exhaust system. During depression stages, the exhaust takes in oxygen-rich air from the secondary air system so unburnt gasses in the exhaust stream can complete the combustion. During overpressure stages, the secondary air reed valve cuts air supply to prevent backflow. On 4-stroke engines, the reed valve is equipped with a cutoff device that shuts down additional air during cut-off stages, as exceedingly lean exhaust gasses would lead to exhaust blowing, resulting in exhaust valve and catalytic converter damage.

DETAILS OF SAS Natural air is taken in through a tube (1) placed on the left side of the engine and is made to pass through a suitable filter (2). To gain access to this second filter, loosen and remove the screws (3) and remove cover (4).

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Engine M285M
Remove the secondary air filter; clean or replace as required.

ENGINE

Another tube (5), routed behind the carburettor, conveys filtered air to the secondary air valve (6) mounted to right side of engine; air is channelled through a tube (7) to cylinder head.

The secondary air tube is connected to a flanged metal fitting (8) attached directly to the head exhaust duct.

The secondary air valve is fitted with a cut-off device (9), that is operated through the vacuum take-up point in the intake manifold (10) and cuts air supply during the cut-off stage to prevent exhaust blowing.

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aprilia s.p.a. via G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com