Beta REV 4T 2008 Workshop Manual Download

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INDEX

INTRODUCTION

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CHAPTER 1

LUBRICATION CIRCUIT

1.LUBRICATION.CIRCUIT.

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1.1.ENGINE.OIL.

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1.2.CHECKING.THE.ENGINE.OIL.LEVEL.

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1.3.CHANGING.THE.ENGINE.OIL.

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CHAPTER 2

ENGINE REMOVAL AND REFITTING

2.ENGINE.REMOVAL.AND.REFITTING.

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.10

2.1.ENGINE.REMOVAL.

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.10

2.2.REFITTING.THE.ENGINE.

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.17

CHAPTER 3

DISMANTLING

3.DISMANTLING.

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.18

3.1.DRAINING.THE.OIL.

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.18

3.2.IGNITION.

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.19

3.3.CYLINDER.HEAD.

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.19

3.4.CYLINDER.

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.22

3.5.FLYWHEEL.

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.22

3.6.OIL.PUMP.(LEFT-HAND.CRANKCASE).

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.23

3.7.CLUTCH.

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.24

3.8.PRIMARY.TRANSMISSION.

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.26

3.9.KICKSTART.

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.27

3.10.SHIFTING.MECHANISM.

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.27

3.11.OIL.PUMP.(RIGHT-HAND.CRANKCASE).

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.28

3.12.TIMING.SPROCKET.

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.29

3.13.SPLITTING.THE.CRANKCASE.

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.29

3.14.GEARBOX.AND.SHIFTING.MECHANISM.

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.30

3.15.CRANKSHAFT.

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.31

CHAPTER 4

ASSEMBLY

4.1.RIGHT-HAND.CRANKCASE.

......................................................

.32

4.2.LEFT-HAND.CRANKCASE.

...........................................................

.34

4.3.CLUTCH.CASING.

....................................................................................

.35

4.4.GEARBOX.AND.SHIFTING.MECHANISM.

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.37

4.4.1 Mainshaft

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.37

4.4.2 Layshaft

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.38

4.5.CRANK.ASSEMBLY.

..............................................................................

.40

4.6.CLOSING.THE.CRANKCASE.

.....................................................

.41

4.7.SHIFTING.MECHANISM.

...............................................................

.42

4.8.TIMING.SPROCKET.

.............................................................................

.44

4.9.OIL.PUMPS.

...................................................................................................

.45

4.10.KICKSTART.

..................................................................................................

.48

4.10.1 Preassembly of kickstart shaft

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.48

4.10.2 Assembling the kickstart

............................................

.49

4.11.PRIMARY.TRANSMISSION.GEAR.

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.49

4.12.CLUTCH.

...........................................................................................................

.50

4.13.FLYWHEEL.

...................................................................................................

.53

4.14.PISTON.AND.CYLINDER.

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.54

4.14.1 Measurements and checks

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.54

4.14.1.1 Cylinder

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.54

4.14.1.2 Piston

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.54

4.14.2 Fitting

....................................................................................................

.56

4.14.2.1 Studs

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.56

4.14.2.2 Piston

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.56

4.14.2.3 Cylinder

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.57

4.15.CYLINDER.HEAD.COVER.

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.58

4.16.CYLINDER.HEAD.

................................................................................

.59

4.16.1 Checks

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.59

4.16.2 Fitting

.....................................................................................................

.61

4.17.VALVEGEAR.

................................................................................................

.62

4.17.1 Pre-assembly of camshaft

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.62

4.17.2 Fitting the valvegear

........................................................

.63

4.18.CLUTCH.CASING.

................................................................................

.66

4.19.IGNITION.

......................................................................................................

.68

4.20.FINAL.DETAILS.

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.69

Summary of Contents for REV 4T 2008

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Page 4: ...ISM 30 3 15 CRANKSHAFT 31 CHAPTER 4 ASSEMBLY 4 1 RIGHT HAND CRANKCASE 32 4 2 LEFT HAND CRANKCASE 34 4 3 CLUTCH CASING 35 4 4 GEARBOX AND SHIFTING MECHANISM 37 4 4 1 Mainshaft 37 4 4 2 Layshaft 38 4 5 CRANK ASSEMBLY 40 4 6 CLOSING THE CRANKCASE 41 4 7 SHIFTING MECHANISM 42 4 8 TIMING SPROCKET 44 4 9 OIL PUMPS 45 4 10 KICKSTART 48 4 10 1 Preassembly of kickstart shaft 48 4 10 2 Assembling the kickst...

Page 5: ......

Page 6: ...y out repair and or maintenance Betamotor models are exported to numerous countries where different rules apply with respect to highway law and homologation procedures Trusting that you will understand Betamotor S p A therefore believes that it must reserve the right to make alterations to its products and technical documentation at any time and without prior notice We respect and defend the envir...

Page 7: ...ly to hospital Waste oil contains dangerous substances which are harmful to the environment When changing the oil it is necessary to be equipped for disposing of the waste oil in accord ance with the relevant law Do not dispose of waste oil into the environment Keep it well out of the reach of children Coolant In certain circumstances the ethylene glycol in coolant is flammable and its flame is in...

Page 8: ...tched off Wait for them to cool down before handling these parts or working in areas adjacent to them In addition use insulating gloves WARNINGS The information in this paragraph is important in order for the operations carried out on the motorcycle to be performed without damaging the motorcycle itself Before dismantling clean the vehicle thoroughly During dismantling clean all parts and put them...

Page 9: ...e Nut M14x1 5 1 120 TDC locking bolt Special bolt M8 1 25 Crankcase group RH crankcase LH crankcase Bolt M6x45 2 10 Bolt M6x60 9 10 RH crankcase Clutch casing Bolt M6x25 7 10 Bolt M6x55 1 10 Bolt M6x30 2 10 Selector drum bearing retaining bolt Bolt M6x10 2 X 10 Flywheel cover Bolt M6x30 5 10 Bolt M6x35 2 10 Clutch cover Screw M6x20 4 10 Head Cylinder Crankcase Stud M10x1 25 4 X 30 Nut M10x1 25 4 3...

Page 10: ...ow M6x25 1 X 10 Intake filter cover output oil pump M20x1 5 1 15 Intake filter cover scavenge oil pump M20x1 5 1 15 Filter cover output oil pump Screw M6x20 3 10 Oil pressure relief valve Special bolt M12x1 25 1 20 Clutch group Pressure plate Bolt M6x16 6 10 Clutch centre Special nut M14x1 25 1 90 Clutch actuator body Bolt M6x16 3 10 Frame Engine Swing arm bolt Nut M16 1 90 Stay RH Bolt M8 2 25 St...

Page 11: ...shaft to lubricate the roller bearing on the crankpin the other 7 whose flow is regulated by a calibrated hole in the cylinder base gasket 8 feeds the valvegear 9 The oil then returns to the base of the crank chamber from the piston the con rod assembly and the cylinder walls and is drawn in by the scavenge pump 10 through the mesh filter 11 It is pumped through special jets 12 and lubricates the ...

Page 12: ...ary remove the oil filler plug and top up the level N B Running the engine with too little oil causes ex cessive wear to the engine components 1 3 CHANGING THE ENGINE OIL N B At each oil change the mesh filters must be cleaned and the paper filter replaced N B The oil change must be carried out when the engine is at working temperature Be careful not to scald yourself with the hot oil After the en...

Page 13: ...act the filter Clean it carefully and blow it through with compressed air Check for damage to the O rings and replace them if necessary Refit all the parts and tighten the plug to 15 Nm Carry out the same procedure for the output mesh filter for which the access is via the right hand en gine casing ...

Page 14: ...the condition of the O ring too and replace it if neces sary Change the filter and refit the cover tightening the three M6x20 bolts to 10 Nm Refit the oil drainplug tightening it to 20 Nm and refill with 0 81 of engine oil BARDHAL XTC60 15W50 N B If the engine has been opened up for an internal inspection the quantity of oil to put in is 0 9 litres Finally tighten the oil filler plug A to 10 Nm A ...

Page 15: ...ITTING 2 1 ENGINE REMOVAL Thoroughly clean the entire motorcycle and put it on a stable stand Remove the rear mudguard Unhook the two springs in front of the cylinder head A Next remove the exhaust manifold B by pulling it forwards Remove the plate under the engine B A A ...

Page 16: ...regulator connector regulated voltage 3A connector regulator to flywheel alternating cur rent 3B regulator connector alternating current 4A connector killswitch cable to generator 4B connector killswitch cable to vehicle wiring har ness 5A connector electric fan to vehicle wiring harness 5B electric fan connector 6A thermoswitch connector 6B connector thermoswitch to vehicle wiring har ness Discon...

Page 17: ...ITTING betamotor com Disconnect from the electric tap A the electrical connector and the fuel pipe located on the inner side of the bike after closing the tap itself lever in position C Disconnect the oil vapour breather pipe 1 ...

Page 18: ...he filter box and pull the carburettor backwards see the arrow in the illustration until the carburettor is completely disconnected from the rubber flange Remove the sprocket cover casing by unscrewing the two retaining bolts A Slip the chain off the sprocket after slacking off the rear wheel spindle Remove the clutch actuator by unscrewing the three retaining bolts B A A A B B B ...

Page 19: ...n bolt for the cooling system A Then open the radiator cap B to allow all the liquid in the system to flow out Loosen the clamps that secure the cooling system pipes respectively to the cylinder A and the water pump B Pull off the sparkplug cap and unscrew the upper bolt A securing the coil support A B A ...

Page 20: ...r com Loosen the clamps that secure the cooling system pipes respectively to the cylinder A and the water pump B Unscrew the bolts that secure the stay to the frame A and take out the front engine mounting bolt B after unscrewing it B A A A B ...

Page 21: ...ing the radiator and then remove the entire radiator stay assembly after dis connecting the connectors for the electric fan and the radiator sensor Take out the bolt securing the cylinder head to the frame Slack off the nut securing the lower engine frame mounting bolt ...

Page 22: ...e refill the system with coolant through the radiator until the liquid comes out of the bleed hole on the left hand side of the cylinder head Tighten the bleed screw and continue pouring the liquid into the radiator until it reaches the flared sec tion in proximity to the filler cap The total quantity of liquid to put in is 0 6 litres Caution Do not run the engine with the voltage regulator con ne...

Page 23: ...hich deals with assembly because it discusses all the checks that need to be carried out on individual compo nents 3 1 DRAINING THE OIL Remove the oil drainplug and let the oil flow out into a drain pan Take out the oil filters from the left hand 1 and right hand 2 crankcase halves after first removing the filter covers 1 2 ...

Page 24: ...d the complete timing system is therefore un loaded To find TDC set up a dial gauge with suitable sup port in the sparkplug hole and rotate the flywheel by hand until the dial gauge indicates that the pis ton has reached its highest point Then tighten the crankshaft locking bolt without the washer and check that the crank is locked by trying to rotate the flywheel Remove the sprocket from the outp...

Page 25: ...indles using an M4 bolt screwed into the spindles from the timing case side Do this while the cover is still fitted to the head and secured by the bolts This is because the spin dles are restrained from rotating which helps when screwing in the extracting bolt Before you undertake the removal of the camshaft attend to the water pump This is because the cam chain tends to lock the water pump gear w...

Page 26: ...care that the gear does not fall into the crankcase Remove the fixed camchain guide Unscrew the cylinder head retaining nuts which are screwed onto the studs and the bolt on the water pump side Then remove the head and the head gasket taking care also to remove the dowels If the water pump shaft bearings are to be replaced extract the one on the outer side by pressing it with a padded drift toward...

Page 27: ...d pis ton together without having to split them You only need to split them when performing operations or measurements on the two components individually see the section devoted to this subject in the chap ter on assembly 3 5 FLYWHEEL Unscrew the flywheel retaining nut A and extract the flywheel using the special extractor B Screw the extractor into the threads in the flywheel and extract it by ti...

Page 28: ...ve the left hand oil pump cover 2 after first _unscrewing the retaining screws 1 Next extract the pump outer rotor 4 using a pair of circlip pli ers after you have removed the pin 3 Then re move the inner rotor 5 and the O ring 6 which seals the cover B 1 1 2 4 6 5 3 ...

Page 29: ...d remove the two covers and their O rings Then unscrew the bolts holding the clutch casing 3 after you have removed the kickstart lever Unscrew the bolts 1 retaining the clutch springs 3 in diagonal sequence to prevent the friction plates 8 from jamming when the springs are re leased 1 1 1 1 2 2 2 3 3 3 3 3 3 3 3 3 1 ...

Page 30: ... special washers 2 the springs 3 and the clutch pressure plate 4 Next remove the friction plates 8 and then the pressure plate lifter 7 the needle roller bearing 6 and the corresponding washer 5 Using a screwdriver release the tabs on the tabwasher 10 1 4 2 7 ...

Page 31: ... special tool for locking the clutch centre Extract the clutch centre 11 the thrust washer 12 the clutch basket 13 the bush 14 and the thrust washer 15 3 8 PRIMARY TRANSMISSION Unscrew the crankshaft nut 1 and extract the pri mary transmission gear 2 Also remove the washer located between these two components 1 2 ...

Page 32: ...d it can cause injury as a result of rapidly springing back to its rest position Remove the kickstart idler gear 5 after you have first removed the retaining circlip 3 At the same time remove the two thrust washers 4 6 located either side of it on the idler shaft Remove the kickstart ramp 8 after you have re leased it by taking out the retaining bolts 7 N B To facilitate removal of the ramp heat i...

Page 33: ...Unscrew the retaining bolt 8 and extract first the idler pivot pin 9 and then the detent lever 10 3 11 OIL PUMP RIGHT HAND CRANKCASE Extract the oil pump gear 2 after you have first removed the retaining circlip 1 Remove the pin 3 which carries the drive from the gear 2 to the oil pump shaft 8 and then the thrust washer 4 Remove the oil pump cover 7 after first unscrewing the retaining screws 5 6 ...

Page 34: ...unscrewing the retaining bolt 4 Use an engineering chisel to remove the woodruff key 2 from its housing in the clutch side crank shaft end and then extract the timing gear 1 3 13 SPLITTING THE CRANKCASE Remove the ball and the clutch pushrod Unscrew all 11 bolts that hold the crankcase together Threadlocker Blue ...

Page 35: ...the threads for the flywheel cover retaining bolts Turn the engine so that the right hand crankcase half is facing downwards Then screw in the bolt at the end of the special tool until the two crankcase halves are separated and manually take off the left hand crankcase half 3 14 GEARBOX AND SHIFTING MECHANISM Extract the selector fork spindles 1 and the gear box selector drum 2 1 1 2 ...

Page 36: ... that the crankshaft extractor which is the same tool as the crankcase splitter has a flat surface to push against Fit the splitting tool to the right hand crankcase half using the threads for the clutch casing bolts to re tain it Then screw in the bolt at the end of the spe cial tool until the crankshaft is extracted If the bearings need to be replaced heat the crank case to 150 C The bearings wi...

Page 37: ...he crankcase half If after the crankcase has cooled down the outer race of one of the bearings tends to spin in its hous ing the crankcase itself must be replaced N B Before refitting the bearings check the state of wear of the revolving parts and make sure that the balls run correctly in their tracks in the bearing While the crankcase is still hot use a press to fit the shaft 6 for the kickstart ...

Page 38: ...e oil pressure relief valve 11 N B Make sure that the number and thickness of washers 12x18x1 12x18x1 5 for the oil pressure relief valve are the same as in the factory setup Fit the crankshaft oilseal 12 lubricating its outer surface with grease to make it easier to insert it into its housing Press it in until it is flush with the open side facing inwards N B Remember to always grease the outer s...

Page 39: ...t hand crankcase N B When fitting the main bearing use a pad on the opposite side to avoid putting excessive stress on the flat surface of the housing under the load from the press Fit the oilseals for the crankshaft 5 layshaft 6 and gearchange shaft 7 all with the open side fac ing inwards Remember to grease the outer surface to facilitate seating Fit the oilway expansion plug driving it home wit...

Page 40: ...ean them and check that there are no obstructions N B Before refitting the bearings check the state of wear of the revolving parts and make sure that the balls run correctly in their tracks in the bearing 4 3 CLUTCH CASING Fit the kickstart oilseal 1 in its housing with the open side facing inwards making sure that it goes fully home 1 Threadlocker Blue ...

Page 41: ...taining plate and tighten the screws to a torque of 3 Nm after applying medium strength thread lock Fit the oil filter spigot 3 with its O ring N B The spigot is an interference fit in its housing Close the oilways with the special oilway expansion plugs 4 using a pin punch Make sure that the oilway is clear by blowing it through with compressed air Fit the oil level plug 5 tightening it to 10 Nm ...

Page 42: ... suitable engine oil N B It is good practice to fit new circlips each time the gearbox is assembled 4 4 1 Mainshaft Position the shaft 1 with the splined end facing downwards and fit the following parts onto it from above in the following order 5th idler gear 2 with the dogs facing upwards followed by the relative splined washer 3 Se cure with the circlip 4 The latter must be fitted such that the ...

Page 43: ...plined bush 10 3rd idler gear 11 with the flat side facing upwards splined washer 8 circlip 12 Sliding 5th gear 13 with the groove for the se lector fork facing downwards 17x24x0 5 thrust washer 14 Bush 15 1st idler gear 16 with the more con cave side facing downwards N B Check that the gears slide correctly N B Apply molycote grease between shaft and gears Fit mainshaft A and layshaft B as a pair...

Page 44: ...es Push the two pins through the forks taking care to use the longer one for the forks on the secondary shaft N B Before fitting the fork spindles make sure that the forks slide freely on them and check the spindles for wear N B Always remember to oil the various parts in con tact with each other pegs selector drum grooves selector forks gears etc N B Turn the two gearshafts over by hand to make s...

Page 45: ... Check for misalignment of the shafts in the crank shaft halves by setting up the crankshaft between centres or in a similar instrument and using a pair of dial gauges 1 positioned on the contact surfaces for the main bearings 2 to measure the maximum variation during a complete revolution of the crank The limit value is 0 08mm If a variable difference is found between the point measurements of th...

Page 46: ...fit the crankcase centre gasket cutting it in the cylinder area 2 to avoid interference with the con necting rod during assembly N B Put a little grease on the gasket face of the right hand crankcase in order to help the gasket to ad here N B It is good practice to change the gaskets each time the crankcase is opened After heating the left hand main bearing place the left crankcase half over the r...

Page 47: ...der will rest Tap the two ends of the crankshaft several times in an axial direction with a rubber hammer in order to release it from residual stresses induced in the crankcase by heating it 4 7 SHIFTING MECHANISM To assemble the shifting shaft follow these steps Clamp the shaft 1 with the serrated end facing upwards Fit the movable pawl 2 with the pin facing downwards and insert the pin into the ...

Page 48: ...he movable pawl Position the spring 1 and the detent lever 2 in their housing and hold them in place with the idler pivot pin 3 Secure with the M6x25 bolt 4 tightened to 10 Nm after applying medium strength thread lock Move the detent lever out of the way and fit the detent cam 5 Secure with the M6x35 bolt 6 tightened to 10 Nm after applying medium strength thread lock 5 2 Threadlocker Blue ...

Page 49: ...hifting lever and test the gearbox operation by rotating the mainshaft by hand and changing from one gear to another 4 8 TIMING SPROCKET Fit the timing sprocket 4 after you have applied a sufficient amount of grease to the outer surface that comes into contact with the oilseal Lock the sprocket with the Woodruff key 3 tapping it sever al times if necessary with a rubber hammer to help it to seat p...

Page 50: ...hand crank case half facing upwards Locate the pump 1 in its housing in the right half of the crankcase after oiling it well with the reference marks facing towards the inside so that they are not visible once the pump is fitted Insert the shaft 2 with the part with the two holes facing upwards fitting the pin 3 into the second hole from the top Use a feeler gauge to check the clearance between in...

Page 51: ...fter you have fitted the washer 8 and the pin 9 into the top hole in the shaft 2 secure the drive gear 10 with the circlip 11 Ensure that the gear is positioned correctly the side with the larger raised part must face downwards Rotate the gear 10 by hand and check that the pump moves without being forced Position the engine bottom end with the left half of the crankcase facing upwards and fit the ...

Page 52: ...g the O rings 18 N B The two filters have a tapering internal cavity Use a pin punch with a taper point to facilitate fit ting Refit the filter covers 20 tightened to a torque of 10 Nm after fitting the O rings 19 Also close the oil drain hole with the drainplug 21 and 16x22 5x1 gasket tightening it to 20 Nm 17 21 20 ...

Page 53: ... the relative position of the hole A for securing the return spring 11 is as shown in the drawing Position the kickstart shaft 2 with the serrated end facing upwards and fit the thrust washer 16x25x0 5 7 the caged roller bearing 8 the gear 9 with the side ratchet side facing downwards and the 16x25x0 5 thrust washer 10 Fit the return spring 11 securing the end in the hole provided A and fit the sp...

Page 54: ...rts move freely Fit the kickstart idler gear 17 on its shaft together with the two 18x27x0 5 thrust washers 16 18 after you have lubricated the parts in contact with each other and secure it with the circlip 19 En sure that the convex side of the gear is facing to wards the crankcase Check that the parts move correctly with respect to each other N B Before you assemble the various parts check the ...

Page 55: ...ng the two components and the shaft itself Check the bush for signs of seizure or excessive wear If these are found re place the bush Also measure the clear ance between the steel bush 2 and the bush in the clutch basket 3 Standard clearance 0 010 0 112mm Before you fit the clutch basket check the wear on the teeth of the primary transmission gear A and on the gear B which carries the drive to the...

Page 56: ...utch drive plates 8 which must be not less than 2 8mm thickness when new 3mm Also check both the drive plates 8 and the driven plates 9 for flatness the discs must not undulate excessively as this could lead to low friction when the two are in engagement Fit a drive plate first into the clutch basket and then the others taking care that no two plates of the same type are in contact with each other...

Page 57: ... corresponding washer 12 Check the wear on the needle roller bearing and the contact surfaces Replace the components if they show excess wear Check the length of the springs 14 Minimum value 33 3mm 33 8mm when new Fit the clutch pressure plate 13 the clutch springs 14 the special washers 15 and the M6x16 bolts 16 Tighten the bolts 16 in diagonal sequence to 10 Nm Tighten the TDC locking bolt once ...

Page 58: ... on the crankshaft be fore proceeding to fit the flywheel Insert the drive key 1 in the keyway machined for it in the left hand crankshaft journal using a rubber hammer if necessary Fit the flywheel 2 and secure it with the flanged nut 3 tightening to a torque of 120 Nm ...

Page 59: ...de of the cylinder exhaust side is marked with the letter for the selection grade This is needed for correct matching with the piston as both must be of the same grade the piston is marked on the crown with its diameter measurement selection grade A 76 960 0 005mm B 76 970 0 005mm C 76 980 0 005mm 4 14 1 2 Piston Check the sliding surfaces for wear and scoring and look for dark areas below the oil...

Page 60: ...for the oil scraper ring of carbon residues from com bustion Use a feeler gauge to measure the play between the compression rings and the ring grooves in the piston If these values exceed the maximum with piston ring thicknesses within the prescribed limits the piston must be replaced Maximum play 0 12mm Measure the diameter of the piston pin and if this value is below the limit replace the piston...

Page 61: ...plied a thread lock Use a nut and locknut 2 for screwing in the studs Tighten to 30 Nm Fit the cylinder base gasket taking care that it does not obstruct the oilway 3 4 14 2 2 Piston Fit the oil scraper ring 3 in the lower ring groove in the piston inserting the spring 1 first followed by the two flat sections 2 with their gaps facing in opposite directions Fit the two compression rings 4 5 into t...

Page 62: ...part of the circlip is facing either up wards or downwards Slide the cylinder down between the studs until the small end of the conrod is aligned with the piston pin housing Then insert the piston pin from the side which is still open and lock it with its circlip having previously lubricated the surfaces of the piston pin itself and of its housing N B Ensure that the cylinder base gasket is in pos...

Page 63: ...t excessive wear or scoring Measure their external diameter and if this is below the limit replace the rocker spindle Limit value 11 93mm Check that the rollers 4 in the rocker arms run freely If you detect excessive radial clearance re place the rocker arms Check the adjuster nuts 6 to ensure that the sur faces that bear on the rocker arms are flat Measure the diameter of the spindle hole in the ...

Page 64: ...uide must be replaced Check whether the valve stems show signs of wear scoring or damage Then measure their diameter and if this value is below the limit replace the valve Minimum diameter 4 978mm Check the valve stem valve guide play To do this locate the valve in its guide with the top surface of the valve stem flush with the guide and measure the maximum radial oscillation of the valve head Pla...

Page 65: ... must be recut Recut the seat also if excessive roughness is visible or if there is damage due to impact Check the free length L0 of the inner and outer valve springs Change the springs if their free length is below the minimum value Minimum L0 outer spring 38 6mm 39mm when new Minimum L0 inner spring 31 5mm 31 8mm when new Measure the compression strength of the valve springs with a pressure dyna...

Page 66: ... guide oilseals each time an inspection of the head is carried out and the valves are removed Fit the outer springs 4 and the inner springs 5 and then the spring caps N B springs have a coloured paintmark Fit them with this mark facing upwards After you have greased the valves and fitted them into their guides inlet 7 exhaust 8 secure them with the split collets 9 using the special tool A The oper...

Page 67: ...3 with the open side facing outwards so as to avoid water leaks from the pump into the tim ing case This last oilseal must be fitted in its hous ing to a depth of 1 mm Remember to apply grease to the outer surfaces of the oilseal 4 17 VALVEGEAR 4 17 1 Pre assembly of camshaft Check the wear on the contact surfaces of the cams with the rockers and if you detect excessive wear or damage replace the ...

Page 68: ...g them in diagonal se quence starting with the studs in proximity to the dowels after applying molycote grease Tighten in diagonal sequence to 30 Nm Then using a pro tractor disc A continue tightening the nuts on the studs forcing them through a rotation of 70 If such a tool is not available tighten the nuts to 50 Nm Tighten the M6x25 bolt 4 to 10 Nm Fit the water pump drive sprocket 5 into its ho...

Page 69: ... is explained fur ther on in this manual This facilitates the fitting of the head cover and consequently the rockers N B The correct way to check the timing is to ten sion the camchain by pressing on the movable chain guide with a screwdriver Screw the water pump shaft 6 into the gear 5 which is locked by the camchain using the appro priate special tool Locate the dowels 11 in the head and fit the...

Page 70: ... is correct tighten the locknuts to 11 Nm and seat the O rings for sealing the valve covers in the grooves machined in the head cover Use silicone sealant to help the O ring adhere in its groove and to prevent it from moving when the valve cover is removed Fit the valve covers using M6x16 bolts and tighten them to 8 Nm Fit the water pump impeller 19 securing it with the circlip 20 Apply some greas...

Page 71: ...nd its gasket retaining it with M6x16 bolts tightened to 8 Nm Use a screw driver to push the plunger so as to put the camchain under tension Then insert the spring and washer and finally screw in the bolt 4 18 CLUTCH CASING Before you proceed to fit the clutch casing oil all the moving parts well and also the areas which that have oil passing through them such as the crank shaft and the oil jet Th...

Page 72: ...e O rings for the clutch cover 3 and the oil filter cover 4 into the grooves formed in the clutch casing applying some grease to make sure they adhere to their housings Fit the output oil filter 5 and the spring 6 after you have oiled the filter seat Fit the clutch cover 8 and the oil filter cover 7 retaining them with M6x20 bolts four for the clutch cover and three for the oil filter cover Tighte...

Page 73: ...t 8 to adhere N B Before you apply the gasket cut off the excess section as shown in the picture above Fit the stator 3 to the flywheel cover 2 retaining it with three M5x25 screws 4 Tighten the screws to 6 Nm Take care that the stator cable guide plate is facing towards the inside of the cover Fit the cable retaining plate 5 and the pickup 6 tightening the two M6x12 retaining bolts to 8 Nm ...

Page 74: ...hain has been passed around the sprocket once the motorcy cle is assembled 4 20 FINAL DETAILS Insert first the ball 1 and then the clutch pushrod 2 after you have lubricated them with engine oil Fit the front sprocket 4 to the output end of the layshaft retaining it with the two circlips 3 5 Fit the air bleed screw for the cooling circuit 9 with its washer 8 and the water drain screw 7 with its wa...

Page 75: ...ng the ex haust collector support springs These plates are fit ted to the top right and bottom left bolts looking at the engine from the front exhaust side Fit the special washer between the TDC bolt and its housing on the crankcase As a result the crankshaft is no longer locked Fit the kickstart lever and check that the whole kick start system moves correctly ...

Page 76: ...COD 22 19818 100 2008 ...

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