Malaguti Centro 125, Workshop Manual

Page 1: ...125 160cc 4T Workshop Manual Engine...

Page 2: ...embly 67 Primary pulley 67 Disassembly 67 Checks 70 Drive belt 70 Roller weights 71 Mobile primary pulley 71 OIL PUMP ASSY 3 Trouble shooting 4 Exploded view of oil pump 5 Disassembly 6 Removing the o...

Page 3: ...and oil seal 94 Removal and refitting of clutch side engine casing bearings and oil seals 96 Installing the transmission gears 97 Installing the transmission cover 98 Flywheel cover Flywheel Magneto W...

Page 4: ...leaks once the pump has been installed Standard Oil quantity For oil change 800 cc Total capacity 1000 cc Recommended oil temperature and viscosity temperature 10 0 10 20 30 40 C SAE 20W 40 SAE 10W 5...

Page 5: ...ance between surfaces 0 05 0 10 mm 0 12 mm Tightening torques Pump body screws 10 N m 15 Pump cover screws 2 N m 15 Protection plate A assy 10 N m 15 Protection plate B 10 N m 15 Trouble shooting Low...

Page 6: ...5 125 160 cc C 07028001 7 1 6 3 4 5 2 WORKSHOP MANUAL OIL PUMP ASSY Exploded view of oil pump 1 Pump cover 2 Pump shaft 3 Inner rotor 4 Outer rotor 5 Pump body 6 Locating dowel 7 Screw...

Page 7: ...RKSHOP MANUAL Ensure that no foreign material enters the engine when the oil pump is removed and re tted Disassembly Remove ywheel cover rotor and freewheel gear chain guard A and oil pump assembly Re...

Page 8: ...7 125 160 cc C D E B 07028103 07028104 WORKSHOP MANUAL OIL PUMP ASSY Remove chain ring D and chain E Check chain for damage or excessive wear Remove chain guard B...

Page 9: ...60 cc C G F C V 07028100 DSCN8392 WORKSHOP MANUAL OIL PUMP ASSY Remove pump assy F and pump shaft G Check pump for possible damage or excessive wear Removing the oil pump Undo screw V and remove pump...

Page 10: ...r rotor M from pump body N paying attention to locating dowel Q Oil pump body tolerances Measure outside diameter of outer rotor M and inside diameter of pump body N with callipers and inside micromet...

Page 11: ...nstall inner rotor L and outer rotor M in pump body N measure clearance between inner and outer rotors with feeler gauge Service limit 0 20 mm Clearance between front surfaces Fit inner rotor L and ou...

Page 12: ...RKSHOP MANUAL OIL PUMP ASSY Assembly Wash all parts in clean diesel fuel before re tting Fit inner rotor L and outer rotor M in pump body N paying attention to locating dowel Q Fit pump cover C and ti...

Page 13: ...L Ensure xing holes P of pump body N are aligned with holes in ywheel cover If holes are not aligned screws V2 cannot be tightened Fit and tighten two screws V2 of pump body and chain guard B tighten...

Page 14: ...13 125 160 cc C E D C 07028112 07028113 WORKSHOP MANUAL OIL PUMP ASSY Fit chain ring D and chain E Fit circlip C in shaft groove...

Page 15: ...14 125 160 cc C B A V 07028114 WORKSHOP MANUAL OIL PUMP ASSY Couple chain guard A to chain guard B and tighten screw V Fit rotor assembly and freewheel gear Fit ywheel cover...

Page 16: ...aces shaft and internal hole of rocker arms before reassembling Camshaft assy lubricating oil is fed through oil passages in the cylinder Valve cover cylinder head and cylinder oilways must be perfect...

Page 17: ...er IN 5 000 5 012 mm 5 040 mm EX 5 000 5 012 mm 5 040 mm Valve stem to guide clearance IN 0 100 0 037 mm 0 075 mm EX 0 030 0 057 mm 0 095 mm Valve guide height IN EX 11 9 12 1 mm Valve seating line he...

Page 18: ...n piston pin tolerance 0 002 0 014 mm 0 080 mm Piston pin small end tolerance 0 016 0 040 mm 0 040 mm Piston rings grooves tolerance Ring 1 0 020 0 044 mm 0 070 mm Ring 2 0 020 0 044 mm 0 070 mm Ring...

Page 19: ...t valves clearance Valve burnt or damaged Incorrect timing Weak valve spring Poor valve seal Pressure loss from head gasket Head warped or cracked Incorrect tting of spark plug High combustion pressur...

Page 20: ...N Cylinder head exploded view 1 Valve cotter 2 Valve upper spring retainer 3 Inner valve spring 4 Outer valve spring 5 Valve oil seal 6 Valve lower spring retainer 7 Cylinder head 8 Intake valve 9 Exh...

Page 21: ...rter motor will drain the battery do not run starter motor for more than 5 seconds at a time Compression pressure 700 kPa 7 bar 260 RPM If compression is too high check for carbon deposits on the pist...

Page 22: ...arried out with warm engine Remove valves cover clutch cover CYLINDER HEAD VALVES CYLINDER PISTON Turn camshaft by rotating the variator unit nut until the two timing sprocket references B are paralle...

Page 23: ...60 cc C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Insert feeler gauge C between rocker arm D and valve E and measure clearance Valve clearance warm engine IN 0 05 mm EX 0 15 0 20 mm E D DSC...

Page 24: ...camshaft counterclockwise by means of variator unit until the two timing sprocket references B are parallel with cylinder head machined surface C and camshaft notch T is facing upwards Undo chain ten...

Page 25: ...24 125 160 cc C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Undo screws V2 Remove timing sprocket F Unscrew capnuts D4 V2 F D4 D4 DSCN8401 DSCN8402...

Page 26: ...25 125 160 cc C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Remove camshaft support G Remove three circlips S relative to rocker arm spindles and camshaft G S S S DSCN8403 DSCN8404...

Page 27: ...160 cc C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Remove rocker arm spindles L NOTE Remove rocker arm spindles using an M5 screw Removing the camshaft Remove camshaft assy M L M DSCN8405 D...

Page 28: ...cks Camshaft Turn bearings C to check that they rotate freely and smoothly Renew camshaft M in the presence of noise or tendency to jam Check cam surfaces for damage and scoring Measure cam height wit...

Page 29: ...iding surfaces N of rocker arms Q and contact surface P with valve for possible damage or wear If wear is excessive renew rocker arms Measure inside diameter of each bore in rocker arm Q Service limit...

Page 30: ...C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Removing the cylinder head Remove throttle body A complete with manifold B valves cover camshaft support see removal temperature sensor assy C A...

Page 31: ...30 125 160 cc C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Undo screws V2 Remove cylinder head D Remove head gasket E and locating dowels F D F E F DSCN8409 DSCN8410 V2...

Page 32: ...WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Removing the cylinder Disconnect coolant inlet hose T from cylinder Remove lower chain guide G Undo screw V Remove cylinder L T V L G DSCN8390 DSC...

Page 33: ...32 125 160 cc C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Removing the piston Remove piston pin circlip A Remove piston pin B and piston C A C B 07028122 07028123...

Page 34: ...are fragile Do not deform excessively Make sure piston rings do not scratch or score surface of piston Scrape carbon deposits off piston C Use an old piston ring D to remove carbon deposits from pist...

Page 35: ...to it axes X Y make a note of all values and take the highest value obtained as a reliable reference Service limit 52 449 58 049 mm CYLINDER HEAD VALVES CYLINDER PISTON Checking the piston Measure ou...

Page 36: ...al of three measurements Service limit 14 8 mm Calculate tolerance between piston pin B and bore in piston Service limit 0 04 mm Calculate tolerance between piston pin and small end bore Service limit...

Page 37: ...ing and groove with feeler gauge Service limit Top piston ring 0 07 mm 2nd ring 0 07 mm Position ring horizontally in lower part of cylinder Measure ring gap with feeler gauge Service limit C Piston 5...

Page 38: ...piston ring gaps staggered at intervals of 120 After assembly ensure rings can turn freely in grooves Lubricate connecting rod small end piston pin B and bore in piston Install piston and ensure that...

Page 39: ...SHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Stripping down the cylinder head NOTE Removed parts must be set aside separately and re t in their original positions Remove valve cotters using speci...

Page 40: ...lower retainer G Once removed valve oil seal F must not be reused CYLINDER HEAD VALVES CYLINDER PISTON Remove carbon deposits from combustion chamber L and valves NOTE Immerse components in petrol to...

Page 41: ...springs Measure length of outer spring Service limit 33 5 mm Measure length of inner spring Service limit 30 8 mm Checking valves Insert valve in seat and check movement Measure diameter of stem in ar...

Page 42: ...ide NOTE Insert valve guide reamer M from combustion chamber side Turn reamer clockwise counterclockwise rotation of reamer can damage valve guide internal surface Measure inside diameter of valve gui...

Page 43: ...NOTE Valves cannot be repaired In the presence of breakages damage or areas that do not seal correctly renew the valves Remove the valves check valve seating surface with petrol Grind valve seat to r...

Page 44: ...area of the valve head correct the position by means of a valve grinding tool A Low contact area B High contact area Measure depth of the valve seating area Standard 0 91 1 10 mm Service limit 1 80 mm...

Page 45: ...kg always turning the tool in the same direction while working Lubricate lapper and remove lapping dust during the procedure Svasatore per collare valvola If the contact area with the valve shows sig...

Page 46: ...P MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Use a 32 stone to grind the outermost surface lightly A Abrasions on valve seat Use a 60 stone to grind the contact surface lightly B Original contact are...

Page 47: ...valve seating area again If contact area is wider grind rst with a 32 stone and then bring it to the required size with a 45 stone If contact area is narrower grind rst with a 60 stone and then bring...

Page 48: ...he valve NOTE Rotate the valve slowly during the procedure Do not work for too long in the same position to avoid wear due to axial misalignment Do not allow lapping compound to penetrate in area betw...

Page 49: ...ve guide Lubricate valve stem and interior of valve guide Slowly insert valve E into valve guide Take care not to damage valve oil seal F The internal and external springs D C havevariablecoilsdistanc...

Page 50: ...49 125 160 cc C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Compress springs with speci c tool A and t cotters To avoid weakening springs do not compress more than necessary DSCN8412 A...

Page 51: ...aterial from mating surfaces Check that coolant passages oilways and screw holes are clean Fit cylinder gasket B and insert locating dowels C Fit cylinder over stud screws and DELICATELY bring into po...

Page 52: ...STON Insert washer under screw V and snug screw without tightening Fit lower chain guide A Turn timing sprocket lower sprocket until piston is at TDC piston surface ush with cylinder rim Do not turn t...

Page 53: ...ISTON Position head gasket C and insert locating dowels D Installing the cylinder head Fit head E over stud screws and locate it against cylinder Insert washers under screws V2 and snug screws without...

Page 54: ...ALVES CYLINDER PISTON Installing the camshaft support Fit camshaft A in support B Lubricate rocker arm spindles C sparingly and insert in support B and in rocker arms D NOTE Insert rocker arm spindles...

Page 55: ...ore groove Lubricate cam surfaces Install assy on cylinder head Fit washers and four cap nuts D4 Tighten nuts to prescribed torque in two three passes D4 Cs N m 30 15 Tighten cylinder screw V to presc...

Page 56: ...rocket E on camshaft maintaining reference marks F parallel to head surface G Fit timing chain L on timing sprocket E Fit and tighten sprocket screws V2 V2 Cs N m 9 15 Press ratchet M on tensioner and...

Page 57: ...S CYLINDER PISTON Install chain tensioner and tighten screws V2 to prescribed torque V2 Cs N m 10 15 Fit tensioner screw V and tighten to prescribed torque V Cs N m 8 15 Install throttle body and mani...

Page 58: ...igning reference mark S on rotor with reference mark on ywheel cover V piston must be at TDC NOTE If you note absence of reference mark S on the rotor during disassembly phase the mark must be made wi...

Page 59: ...MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Fitting the valves cover Fit gasket A and insert locating dowels B on valves cover C Fit spring D in oil union E then insert oil union into camshaft B A B...

Page 60: ...59 125 160 cc C WORKSHOP MANUAL CYLINDER HEAD VALVES CYLINDER PISTON Fit valves cover C Tighten screws V2 paying attention to the respective sealing washers F V2 C F DSCN8394...

Page 61: ...3 mm 20 7 mm Secondary pulley Clutch linings thickness 2 75 mm Clutch bell inside diameter 124 5 124 2 mm 125 0 mm Speed variator contrast spring length 144 146 mm 140 mm Fixed secondary pulley outsi...

Page 62: ...Worn Ramp guide Ramp plate Worn Damaged Clutch linings Worn damaged Variator contrast spring Damaged Engine dies or clutch grabs when scooter pulls away Clutch shoes contrast springs Damaged Low spee...

Page 63: ...51 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Variator unit exploded view 1 Ramp plate 2 Ramp guide 3 Roller weight 4 Primary pulley bush 5 O Ring gasket 6 Mobile primary pulley 7 Sliding bush 8 Fixed...

Page 64: ...2 1 3 5 6 7 07028153 WORKSHOP MANUAL Clutch unit exploded view 1 Clutch nut 2 Clutch unit 3 Clutch side spring retainer 4 Variator contrast spring 5 Stop washer 6 Spacer 7 Secondary pulley SPEED VARI...

Page 65: ...152 WORKSHOP MANUAL Clutch pulley exploded view 1 Pulley side spring retainer 2 O Ring gasket 3 Oil seal 4 Mobile secondary pulley 5 Pin 6 Roller 7 Fixed secondary pulley 8 Bearing 9 Circlip 10 Needle...

Page 66: ...125 160 cc C 3 1 5 2 6 5 5 4 07028007 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Clutch shoes assy exploded view 1 Disk 2 Rubber ring 3 Clutch ground 4 Snap ring 5 Clutch shoes contrast springs 6 Rin...

Page 67: ...V V3 A B C V5 V5 DSCN8423 DSCN8424 V5 V5 WORKSHOP MANUAL Removing the clutch cover Undo three screws V3 and screw V Remove plastic cover A SPEED VARIATOR CLUTCH UNIT Undo screws V5 Remove lter B and...

Page 68: ...e gasket F of clutch cover C Remove locating dowels E Assembly To reassemble perform the above steps in reverse sequence SPEED VARIATOR CLUTCH UNIT Primary pulley Disassembly Remove clutch cover Undo...

Page 69: ...8 125 160 cc C A B C 07028155 07028156 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Remove drive belt A Immobilise internal part of mobile primary pulley B now remove pulley together with sliding bush C...

Page 70: ...69 125 160 cc C B C E 07028157 07028158 WORKSHOP MANUAL Remove pulley sliding bush C from mobile primary pulley B Remove roller ramp plate E SPEED VARIATOR CLUTCH UNIT...

Page 71: ...160 cc C F A 07028159 07028160 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Remove roller weights F Checks Drive belt Check drive belt A for fraying wear or chaf ng Measure belt thickness Service limit...

Page 72: ...NUAL SPEED VARIATOR CLUTCH UNIT Roller weights Check roller weights F for possible wear or damage Measure roller weights outside diameter Service limit 19 45 mm Mobile primary pulley Measure inside di...

Page 73: ...72 125 160 cc C C 07028163 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Check that pulley sliding bush C is not worn or damaged Measure outside diameter of bush C Service limit 23 92 mm...

Page 74: ...07028165 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Installing the primary pulley Insert roller weights F in races H of mobile primary pulley B Seat rollers with end protruding slightly as shown in t...

Page 75: ...cc C B C B C 07028166 07028167 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Insert sliding bush C in mobile primary pulley bore B Manually clamp mobile primary pulley B and assemble together with slidi...

Page 76: ...HOP MANUAL SPEED VARIATOR CLUTCH UNIT Install drive belt A Install xed primary pulley G Apply threadlocker to nut D and t nut complete with washer Tighten nut D using a pneumatic nut runner set to the...

Page 77: ...isassembling the clutch Unscrew locking nut D Withdraw cutch bell A now remove entire clutch unit and secondary pulley B Using speci c tool C compress clutch unit and secondary pulley B Undo nut D Rel...

Page 78: ...C E E E A G F L 07028009 07028170 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Disassembling the clutch unit Remove circlips E and ring A Remove clutch shoe contrast springs F then remove clutch shoes G...

Page 79: ...78 125 160 cc C M L A 07028171 07028172 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Remove rubber rings M from disk L Removing the secondary pulley Remove pulley side retainer A...

Page 80: ...emove mobile secondary pulley E Check that guide pin B and roller C are not damaged or worn SPEED VARIATOR CLUTCH UNIT Remove oil seal F and O rings G from mobile secondary pulley t new oil seal and O...

Page 81: ...SPEED VARIATOR CLUTCH UNIT Checks Clutch bell Check clutch bell L for signs of damage or excessive wear Measure inside diameter of clutch bell Service limit 125 mm Clutch linings Check clutch linings...

Page 82: ...Variator contrast spring Check that variator contrast spring N is not weakened or broken Measure spring length Service limit 140 mm Fixed secondary pulley Check that xed secondary pulley A is not worn...

Page 83: ...cc C B 07028179 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Mobile secondary pulley Check that mobile secondary pulley B is not worn or damaged Measure inside diameter of secondary pulley Service limi...

Page 84: ...leys assy Degrease and clean surface of mobile secondary pulley A in area of drive belt contact Grease lip and t oil seal B with lip on side of internal surface of mobile secondary pulley Grease O Rin...

Page 85: ...7028183 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Install mobile secondary pulley A on xed secondary pulley D Grease guide pin E and roller F before installing xed secondary pulley Fit pulley side re...

Page 86: ...D 07028184 07028185 WORKSHOP MANUAL SPEED VARIATOR CLUTCH UNIT Fit rubber rings A on disk B Fit clutch shoes C and clutch shoe contrast springs D NOTE Pay attention to direction of assembly of clutch...

Page 87: ...D VARIATOR CLUTCH UNIT First t ring A and then t circlips E Using speci c tool A compress clutch unit and secondary pulley B Tighten nut D to prescribed torque D Cs N m 59 15 Release speci c tool A an...

Page 88: ...AL Installing the clutch bell Insert clutch unit and secondary pulley A on shaft Insert clutch bell B and tighten nut D Tighten nut D using a pneumatic nut runner set to the prescribed tightening torq...

Page 89: ...160 cc C WORKSHOP MANUAL Transmission Oil capacity For oil change 0 15 l For disassembly 0 15 l Recommended transmission oil SAE10W 40 SF grade Tightening torques Level drain plug 22 N m 15 FINAL DRIV...

Page 90: ...exploded view 1 Pulley shaft 2 Pulley shaft bearing 3 Reduction gear shaft 4 Intermediate gear 5 Washer 6 Intermediate gear bearing 7 Output shaft 8 Output shaft oil seal 9 Output shaft bearing 10 Tr...

Page 91: ...AL Removing the transmission cover Remove clutch unit Unscrew oil drain plug and allow all oil to ow out NOTE Dispose of spent oil in compliance with local legislation Undo screws V7 FINAL DRIVE GEARS...

Page 92: ...91 125 160 cc C F E D G 07028189 07028190 WORKSHOP MANUAL FINAL DRIVE GEARS Remove output shaft D Remove reduction gear shaft E and intermediate gear F Remove thrust washer G...

Page 93: ...y shaft with plastic mallet and extract main shaft Check pulley shaft and bearings for wear or damage Renew parts if necessary Transmission cover checks Turn inner races of bearings B C and D of trans...

Page 94: ...le damage or abrasion in transmission case and clutch side engine casing bearing seats B C and D Check output shaft E and its bearings for wear and damage Renew bearings if necessary Check reduction g...

Page 95: ...INAL DRIVE GEARS Removal and re tting of transmission cover bearings and oil seal Remove output shaft oil seal A from transmission cover Remove output shaft bearing B by means of a puller Use a puller...

Page 96: ...ft bearing C and reduction gear shaft bearing D from transmission cover side utilising puller E Insert new pulley shaft bearing C correctly with punched side facing upwards in seat in transmission cov...

Page 97: ...o that it is straight with respect to hole take care not to cover breather hole Removal and re tting of clutch side engine casing bearings and oil seals Remove pulley shaft oil seal A Refer to Removal...

Page 98: ...orrectly with punched side facing upwards in seat in clutch side casing and drive it fully home Repeat same procedure also to t output shaft bearing C and reduction gear shaft bearing D Installing the...

Page 99: ...01 WORKSHOP MANUAL FINAL DRIVE GEARS Installing the transmission cover Fit clearance washer A Fit intermediate gear B and reduction gear shaft C in transmission cover ensure thrust washer is tted on r...

Page 100: ...WORKSHOP MANUAL FINAL DRIVE GEARS Position gasket E and insert locating dowel F Mount transmission cover G to clutch side engine casing Insert screws V7 tighten to prescribed torque V7 Cs N m 22 15 Re...

Page 101: ...ngine Flywheel cover can be removed without dropping engine from scooter Flywheel magneto can be removed without dropping engine from scooter Tightening torques Flywheel magneto nut tightening 59 N m...

Page 102: ...YWHEEL COVER FLYWHEEL MAGNETO WATER PUMP Exploded view of water pump 1 Snap ring 2 Bearing 3 Water pump shaft 4 Bearing 5 Water pump oil seal 6 Water pump gland 7 Thrust washer 8 Water pump impeller 9...

Page 103: ...Exploded view of ywheel cover 1 Locating dowel 2 Flywheel cover 3 Oil breather union 4 Gasket 5 Oil dipstick 6 O Ring gasket 7 Oil lter 8 Oil lter spring 9 O Ring gasket 10 Blank insert 11 Gasket 12...

Page 104: ...D C T WORKSHOP MANUAL FLYWHEEL COVER FLYWHEEL MAGNETO WATER PUMP Removing the ywheel cover Remove water inlet hose A Undo screws VA2 and VB2 and remove water pump cover B Remove gasket C and locating...

Page 105: ...V12 WORKSHOP MANUAL Undo screws V12 Remove ywheel cover E FLYWHEEL COVER FLYWHEEL MAGNETO WATER PUMP Removing the ywheel magneto Remove Oil tting F and its spring G Locating dowel L and ywheel cover...

Page 106: ...7028205 07028206 D C B V A WORKSHOP MANUAL FLYWHEEL COVER FLYWHEEL MAGNETO WATER PUMP Remove ywheel magneto A using puller D Removing the freewheel gear Remove bolt V remove retainer B and extract sta...

Page 107: ...MANUAL FLYWHEEL COVER FLYWHEEL MAGNETO WATER PUMP Removing the stator pick up assy Undo screws VA2 and VB2 and remove stator A and pick up B Remove circlip C Removing the water pump impeller Remove wa...

Page 108: ...Fit bearing A on pump shaft B then t shaft in ywheel cover Fit bearing C on pump shaft B and secure with circlip D Apply sealant to outer surface of oil seal E and install on ywheel cover Fit pump gl...

Page 109: ...ollowing components in ywheel cover A Inspection cap B and relative seal Dipstick C Oil lter assy D Drain plug E and relative washer Installing the stator pick up assy Install stator F and pick up G a...

Page 110: ...ts in seat A inserting rst number 1 then number 2 Apply sealant Installing the freewheel gear and rotor Install freewheel gear B in the ywheel side engine casing C position restraint D and tighten scr...

Page 111: ...WHEEL COVER FLYWHEEL MAGNETO WATER PUMP Install rotor E and tighten nut D to prescribed torque value insert oil tting F and relative spring D Cs N m 59 15 Install double intermediate gear G with relat...

Page 112: ...cover A tighten screws V12 working alternately at opposite corners in two or three passes V12 Cs N m 12 15 Pay attention to correct pump shaft timing Fit locating dowels gasket and cover of pump B an...

Page 113: ...112 125 160 cc C D DSCN8390 C WORKSHOP MANUAL FLYWHEEL COVER FLYWHEEL MAGNETO WATER PUMP Fit water inlet hose C and breather hose D Fill cooling circuit Fill engine with required oil quantity...

Page 114: ...ING CRANKSHAFT Standard Service limit Connecting rod big end End play 0 160 0 304 mm 0 50 mm Radial play 0 005 0 017 mm 0 05 mm Crankshaft eccentricity 0 10 mm Tightening torques Removable casing scre...

Page 115: ...0 B WORKSHOP MANUAL ENGINE CASING CRANKSHAFT Removing the engine casings Unscrew pin V and extract chain guide A Unscrew screws V8 of clutch side engine casing B Place ywheel side engine casing on a b...

Page 116: ...engine casings Do not prise with a screwdriver etc in area of contact between casings if it proves dif cult to remove ywheel side casing Tap lightly with a plastic mallet and keep clutch side engine c...

Page 117: ...60 cc C A B 07028215 07028216 WORKSHOP MANUAL Measure radial play of connecting rod big end A Service limit 0 05 mm 62 mm 80 mm Measure crankshaft eccentricity B Service limit 0 10 mm ENGINE CASING CR...

Page 118: ...ING CRANKSHAFT Measure connecting rod small end diameter C Service limit 15 05 mm Installing the engine casing Lubricate internal lip of new oil seal A and apply sealant to external side before instal...

Page 119: ...connecting rod assy Install chain guide D and pin V Tighten to prescribed torque V Cs N m 13 15 Do not damage casing mating surfaces during installation procedures Join left and right casings Tighten...