Engine Disassembly - Gas Gas Motorcycles
Contents
1. GAS GAS MOTOS S A C UNICEF n 17 Poligon Industrial Torremirona 17190 Salt Girona SPAIN Tel 34 902 47 62 54 Fax 34 902 47 61 60 E mail officeggegasgasmotos es partsgg gasgasmotos es Web www gasgasmotos es2. Detach the oil filter lid 1 and the oil filter 2 Remove the starter followers 3 the centering devices 4 and the gasket 5 Remove the pressure pump lid 1 and the rotor 2 JOU Remove the coolant pump cover Remove the clutch lid Remove the centering devices 3 and the gasket 4 Loosen the clutch spring screws in a diagonal sequence as illustrated and remove them when they become totally loose Detach the clutch press and the disc assembly Remove the clutch rod Flatten the clutch hub washer 102 Holding the clutch hub with the special tool supplied remove the clutch hub nut Tool Part No Clutch hub fastener Remove the clutch hub and the washer CAUTION The clutch hub has a specific fitting position in respect of the input shaft Mark the position with an indelible marker on the lubrication groove This mark must be taken into account during the installation process Remove the clutch drum assembly Detach the timing chain guide idler 1 OS Om Remove the Seeger ring 3 and the pedal operated starter intermediate gear 4 Detach the foot operated starter assembly Detach the pedal operated starting pawl plate 6 Detach the pedal operated starter intermediate pinion shaft Detach the oil pump intermediate gear 1 and the oil pump follower 2 104 Remove the oil pump assembly Remove the selector shaft assembly Detach the g
3. Y K SERVICE MANUAL MOTOR FSE400 450 2002 2003 Technical tee TED ee 84 Engine Removal and Jnstallation cssssssssses seves ses es esec ee 86 o A AA A E A 96 Inspection and Maintenance of Engine ege e 108 Engine INStalla ton EE 136 et TE En e 156 MODEL ENGINE CP I ICP KT Technical Specifications Ec 400 450 FSE 399 cc 449 cc 4 stroke with 4 valve cylinder head One Water cooled 90 x 62 6 mm 95 x 62 6 mm E F I Magneti Marelli Electronic Fuel Injection System EEL integrated Hydraulic drive disc clutch 6 Gears Deltabox made from Cromoly rectangular tubes Aluminium Rocker Inverted WP 43 mm Diameter 295 mm Stroke Inverted Marzocchi 45 mm Diameter 295 mm Stroke Inverted Ohlins 46 mm Diameter 295 mm Stroke Progressive System fitted with Ohlins Shock Absorber 320 mm Stroke 260 mm Disc Nissin Pump and Nissin single plunger clip 220 mm Disc Nissin Pump and Nissin single plunger clip Type U D I D Rims fitted with Michelin Comp3 Tyres DIMENSIONS 1475 mm 940 mm 340 mm 9 5 Litres Al and Installation SO Engine Removal Before removing the engine from the frame wash it with a steam machine The following steps cover the disassembly sequence Remove the saddle and the frame covers Drain the oil in the engine Remove the engine plate Drain the frame oil reservoir A Drain the engine coolant B Detach the cable from th
4. 10cccseeeeee 120 PISTON and DISTOI D de e E 122 CONNECTING tod cti A 125 Crank E E 126 Sl A T 126 A A A 127 CICR re oases cesac eres et ca eerie soe ee sect cece dats nen teen cueme seme see geen 127 Shifter forks ANd AAA Eaa aa aaaea E E 128 TEEI e EE 129 lo e E APE IAA AE P AE A E A T R sees 130 Ee 133 IOS CAUTION Identify the position of each part Set them in groups exhaust admission so that they may be assembled in their original positions CYLINDER HEAD Disassembly Detach the intake pipe Detach the engine coolant pipe bracket Remove the tappets 1 and the adjustment washers 2 by hand or with a magnet U U Inspection and Maintenance Compress the valve springs and then use the special tools provided to remove the valve rod semicones Tool Part Description valve spring compressor Tool Part Description Adapter Tool Part Description Pliers Y o Remove the valve spring plate 1 and the valve springs 2 U UY Om Remove the valves from the opposite side Use long nosed pliers to remove the valve seals Detach the valve spring washer NOTE The valve detachment completes the standard disassembly operation If you had not detached the valve guides for replacement after inspecting their associated parts follow the instructions given in the valve guide maintenance section Cylinder head deformation Decarbonize the combusti n chamber Using a
5. 20 030 mm Use the micrometer to measure the piston bolt outside diameter at three points If any of the measurements is found to exceed the service limit replace the piston with a new one Tool Description micrometer 0 25 mm DETAILS Piston pin outside diameter Service limit 19 980 mm 124 Om Om Om Om Connecting rod foot inside diameter Use the small calibre gauge to measure the connecting rod foot inside diameter If the connecting rod foot inside diameter is found to exceed the service limit replace the connecting rod with a new one Tool Description Dial caliper DETAILS Connecting rod foot inside diameter Service limit 20 040 mm Connecting rod deflection and connecting rod crank end side clearance The amount of wear at the connecting rod crank end may be estimated by checking the connecting rod foot play This method is also useful in checking the amount of wear shown by the component parts of the connecting rod crank end Tool Description magnetic support Tool Description dial gauge 1 100 mm Tool Description Set of tapered blocks 100 mm DETAILS Connecting rod deflection Service limit 3 mm Push the connecting rod aside and measure the side clearance with a feeler gauge If the clearance is found to exceed the service limit replace the whole crankshaft with a new one or bring the deflection and the side clearance found back into the service limit by replacing thei
6. centre position P M S hold the camshaft firmly Jet and slightly pull the chain upwards to remove YA t any clearance between the camshaft chain driving l j pinion and the exhaust camshaft pinion f FLN The exhaust camshatt pinion bears an arrow mna marked 1 1 Turn the exhaust camshaft in such a manner that the arrow becomes aligned with the surface of the cylinder head gasket Attach the camshaft driving chain to the exhaust camshaft pinion A second arrow marked 2 2 must now be pointing upwards Starting with the link pin situated just above the arrow marked 2 2 count up to 15 link pins moving from the exhaust camshaft side towards the inlet camshaft side Attach link pin 15 to the chain with the arrow marked 3 3 on the inlet pinion Refer to the following illustrations NOTE The camshaft chain must now be fitted to all three pinions Be careful not to move the crankshaft before the camshaft journal brackets and the oO camshaft chain idler are properly secured 150 Fit the centering pins Place the brackets of the camshaft journals and the chain guide in the correct position NOTE Camshaft journal brackets marked EX belong in H the exhaust side and camshaft journal brackets go marked IN belong in the inlet side Tighten the screws on the camshaft journal brackets at the specified torque Camshaft journal bracket screw 10 Nm 1 Kgf m Once t
7. fitting the drive gear to the rocker shaft align the pin with the groove Attach the rocker shaft driven gear by aligning the matching marks Tighten the rocker shaft screw at the specified torque Compensating shaft screw 10 Nm 1 Kgf m 141 After fitting the linchpin attach the input drive gear 1 by holding the alternator rotor with the 17 mm spanner and by tightening the nut on the input drive gear at the specified torque Input drive gear nut 110 Nm 11 Kgf m OIL PUMP Before fitting the oil pump apply motor oil to the sliding surfaces of the pump housing the outer rotor the inner rotor and the shaft When fitting the inner rotor align it with the groove Apply a small amount of LOCTITE to the threaded areas of the screws securing the oil pump and tighten them firmly When fitting the oil pump driven gear align it with the groove AZ STARTING PAWL 1 Starting pawl plate 2 5x15 Allen 3 Spring 4 Starting pawl plate 5 20 Seeger 6 Washer 7 Starting pinion 8 Starting shaft 9 Washer 10 Spring 11 Centering bushing 12 Starter pedal retainer 13 Starter inner pinion 14 Washer 15 Shaft Seeger 10 Fit the pedal operated starter shaft assembly and attach the spring end to the crankshaft protuberance CAMSHAFT TIVING CHAIN Attach the camshaft timing chain 1 to the pinion Tighten the screw securing the camshaft timing chain idler 2 at the specified torque Sc
8. ruler and a feeler gauge check the surface of the cylinder head gasket for signs of deformation Measure the clearance in several places If any of the clearance measurements Is found to exceed the service limit replace the cylinder head with a new one Tool Part Description Feeler gauge DETAILS Cylinder head deformation Service limit 0 05 mm 0 002 in Valve rod offsetting Using tapered blocks to hold the valve measure the valve rod offsetting with a dial gauge as illustrated If the offsetting is found to exceed the service limit replace the valve with a new one Tool Part Description Dial gauge 1 100 mm Tool Part Description Magnetic support Tool Part Description Set of tapered blocks 100 mm DETAILS Valve rod offsetting Service limit 0 05 mm 0 002 in 112 b Om Om DC Valve head radial offsetting Using one tapered block to hold the valve measure the valve head radial offsetting with the dial gauge as illustrated If the offsetting is found to exceed the service limit replace the valve with a new one Tool Part Description Dial gauge 1 100 mm Tool Part Description Magnetic support Tool Part Description Set of tapered blocks 100 mm DETAILS Valve head radial offsetting Service limit 0 03 mm 0 001 in Valve working surface wear Check the working surface of each valve for signs of wear or damage If any unusual signs of wear are found replace the v
9. special attention to the following points CAUTION Before to assemble the engine apply motor oil to all the mobile pieces CRANKSHAFT 1 Crankshaft RH 2 Connecting rod 3 Bearing 4 Pin 5 Crankshaft LH Define the width between crank webs by referring to the figure during crankshaft reassembly DETAILS Width between crank webs Normal 63 mm 0 1 mm Om When attaching the crankshaft to the crankcase use the special tools provided to pull from its LH end towards the crankcase Tool Description crankshaft fitter Tool Description adaptor CAUTION Do not attach the crankshaft to the crankcase by tapping it into position with a plastic hammer Always use the special tool provided otherwise the precision of the crankshaft alignment may be impaired Om Om IBS Engine Assembly DESMODROMIC DEVICE AND SHIFTER FORKS 1 Shifter fork shaft 2 No 1 shifter fork 3 No 2 shifter fork 4 shifter fork shaft 5 No 3 shifter fork 6 Desmodromic device Fit the shifter forks into the shifting grooves in their correct positions and directions Fit the shafts of the shifter forks NOTE After fitting the shafts of the shifter forks and the H forks check to see that the gears are engaging O normally Place the transmission gears in neutral UE CRANKCASE Reverse the above operations to assemble the crankcase Pay special attention to the following points Totally remove t
10. spring properly fitted pour a small amount of petrol through the intake or exhaust port Check to see that no petrol is leaking through the valve seat If a leak is found tighten the sealing surface WARNING Petrol is highly inflammable and explosive Keep the petrol away from heat sources sparks or flames Valve spring The strength of the helical spring keeps the valve seat pressed A weak spring will result in loss of engine power and valve mechanism clattering Check the strength of the valve springs by measuring their unsupported length and the amount of strength required to compress them If the unsupported length of a spring is found to be below the service limit or if the strength required to compress it is not within the specified value replace the inner and outer springs altogether DETAILS Spring unsupported length intake and exhaust Service limit Inner 32 6 mm Outer 36 3 mm DETAILS Valve spring tension intake and exhaust Normal Inner 5 6 6 4 kgf 27 4 mm Outer 12 6 14 5 kgf 30 9 mm JUS Om Om Om CYLINDER HEAD Fitting Fit the valve spring seats Apply a molybdenum oil solution to each valve seal and press the valves into position CAUTION Do not re use valve seals Apply a molybdenum oil solution to the valves as illustrated and then fit them into the guides CAUTION Care must be taken not to damage the valve seal lips when fitting the valves into their guide
11. the camshaft fitted use the plastic gauge to measure the oil clearance Tools Description ssc ssss scs s ssc plastic gauge DETAILS Camshaft bridge oil clearance inlet and exhaust Service limit 0 150 mm Tighten the bridge bracket screws evenly and in a diagonal sequence at the specified torque Camshaft bridge bracket screw 10 Nm 1 Kgf m NOTE Remove the plastic gauge before turning the camshatt Remove the camshaft journal brackets and use the wrap round ruler to measure the width of the compressed plastic gauge This measurement should be carried out at the widest point of the compressed plastic gauge If the camshaft bridge oil clearance is found to exceed the service limit measure the bridge bracket inside diameter and the bridge outside diameter Change either the camshaft or the cylinder head and the camshaft SE whichever is found to exceed the specified value Tool Description ssc ssss ccs s ssc lesser calibre gauge DETAILS Camshaft bridge bracket inside diameter inlet and exhaust Normal 22 012 22 025 mm Tool DescriptiON ccooocccannnnonosoos micrometer 0 25 mm DETAILS Camshaft bridge outside diameter inlet and exhaust Normal 21 972 21 993 mm Camshaft offsetting Using tapered blocks to hold the valve measure the camshaft offsetting with the dial gauge If the offsetting is found to exceed the service limit replace the camshaft with a new one Tools Description eessen d
12. worn or burned replace the spark plug with a new one The spark plug must also be replaced if it has a broken insulator a damaged thread etc CAUTION Check the size and length of the thread when replacing a spark plug If the spark plug neck is too short cinder will build up within the spark plug cavity and this may damage the engine 156 DC Spark plug fitting CAUTION In order not to damage the cylinder head thread start by screwing in the spark plug by hand and then use the spark plug spanner to tighten it at the specified torque Torque for tightening the spark plug 11Nm 1 1 Kgf m 8 0 Ib ft ENGINE OIL AND OIL FILTER To be initially replaced after 5 hours operation and then every 60 hours The oil must be replaced with the engine still hot The oil filter is to be replaced with the same frequency as the engine oil Engine oil replacement As the engine oil is within the crankcase by removing the screws 1 on the chassis we can also unscrew the oil reservolrr filling plug 3 This should drain the oil contained in the engine When the oil has been drained insert and tighten the screws at the specified torque and pour a new supply of oil through the filling hole Every time the oil is renewed without replacing the filter the engine will hold about 1 7 L 1 8 US at 1 5 Imp qt of oil Use API compliant SF or SG grade motor oil with a SAE 10W 40 viscosity rank ENGINE OIL DRAINING I
13. Use the valve guide puller to remove the valve guide towards the camshaft side Tool Part Description Valve guide puller fitter NOTE Discard the valve guide Only oversize valve guides are available as spares Use the valve guide reamer and shank to smooth the valve guide holes in the cylinder head Tool Part Description Valve guide reamer 10 8 mm Tool Part Description Reamer shank Oil the rod hole of each valve guide and use the valve guide puller fitter and adaptor to drive the guide into the hole Tool Part Description Valve guide puller fitter Tool Part Description Valve guide fitter adaptor CAUTION i Unless the valve guide hole is oiledas instructed prior to the fitting of the new guide the guide or the cylinder head may be damaged Use the valve guide reamer to smooth the guide inner walls after the valve guides have been fitted Clean and oil the guides after smoothing them Tool Part Description Valve guide reamer 5 mm Tool Part Description Reamer shank 114 Om Om Uy D Oc Om Om Om Valve seat width Use Prussian blue to spray the valve seat evenly Fit the valve and attach a valve burnisher to it Tap the sprayed seat several times in a circular direction to get a clear imprint of the surface contact Tool Part Description Valve burnisher set The ring shaped sprayed imprint left on the valve working surface must be a continuous unbroken one Also t
14. a spanner and tighten the nuts securing the engine at the specified torque Item Nm Kgf m A 66 6 6 B 66 6 6 C 14 1 4 D 66 6 6 Screw length A 108 mm B 110 mm D 103 mm Tighten the brake pedal screw at the specified torque Brake pedal screw 29 Nm 2 9 Kgf m QS U a Attach the engine pinion NOTE The previous CW ACW direction of this pinion must be duly noted so that the same wear CW ACW direction may be preserved Attach the engine pinion Seeger Attach the tube to the frame reservoir Tighten the exhaust manifold screw 1 at the specified torque Apply NURAL 29 component to the exhaust system joints Oz Apply LOCTITE 243 to the screw on the pedal operated starter lever then tighten For 1 9 litre of API compliant SF or SG grade motor oil and SAE 10W 40 viscosity oil into the R SR located in the frame 1 and check the evel DETAILS Engine oil capacity Oil replacement 1 7 Oil and filter replacement 1 9 Overall engine check 1 9 Start the engine and leave it ticking over for about 3 minutes Stop the engine wait for 3 minutes then check the oil level with the dipstick Minimum level K L Maximum level fe ms iy S Za Om SIS CP ROE KOT Detach the alternator cover Turn the alternator rotor until the 7th tonewheel tooth becomes aligned with the position sensor hole centre NOTE The cylinder head lid must be
15. aft Tool Description bearing fitting set Om Rocker shaft LH bearing Remove the LH bearing from the rocker shaft 10 using the special tool provided Tool Description bearing pulling device set Tool Description plexor CAUTION Replace the removed bearing with a new one Uy DC Fit the LH bearing on the rocker shaft Om Tool Description bearing fitting set IBZ SEALS A damaged seal lip may cause air petrol mixture or engine oil leaks Check the seals for signs of wear or damage If any seal is found to be deffective replace it with a new one Fit the seals on the crankcase the clutch cover Pay special attention to the following points Om CAUTION Replace the removed seals with new ones Apply grease on the seal lips Gearbox output shaft seal Remove the bushing 1 Remove the seal from the gearbox output shaft in the LH crankcase 2 using the special tool provided Tool Description H seal pulling device D CAUTION 7 Replace the removed rertainer with a new one O Slowly fit the gearbox output shaft seal in the LH crankcase using the special tool provided Tool Description seal fitting set Om IBS Gearbox output shaft seal Slowly remove the seal from the gearbox output shaft in the LH crankcase 1 using the special tool provided Tool Description seal pulling device CAUTION Replace the removed seal with a new one Slowly fit the ge
16. alve involved with a new one Measure the thickness T of the valve working surface If the thickness is found to exceed the specified value replace the valve with a new one Tool Part Description Vernier calipers DETAILS Thickness T of the valve working surface Service limit 0 5 mm 0 02 in Valve rod deflection Lift the valve about 10 mm from its seat Measure the rod deflection in two directions X and Y at right angles to each other Position the dial gauge as illustrated If the deflection is found to exceed the service limit decide whether it is the valve or the guide that must be replaced with a new one Tool Part Description Dial gauge 1 100 mm Tool Part Description Magnetic support DETAILS Valve rod deflection Service limit 0 35 mm 0 014 in TUS Om Om Oy Om Om Om Valve rod wear Use a micrometer to measure the rod outside diameter If the outside diameter is found to exceed the specified value replace the valve with a new one If the rod outside diameter is found to be within the specified value but the deflection is not within the specified value replace the valve guide with a new one After replacing the valve or guide check the deflection Tool Part Description Micrometer 0 25 mm DETAILS Valve rod outside diameter Normal Inlet 4 975 4 990 mm 0 1959 0 1965 in Exhaust 4 955 4 970 mm 0 1951 0 1957 in Valve guide maintenance
17. and LH 4 bearings from the gearbox output shaft using the special tool provided Tool Description H bearing pulling device set ls CAUTION H Replace the removed bearings with new ones O Fit the RH and LH bearings on the gearbox output shaft using the special tool provided Tool Description bearing fitting set Om Crankshaft bearings Remove the RH 5 and LH 6 bearings from the crankshaft using the special tool provided Tool Description H bearing pulling device set D CAUTION U Replace the removed bearings with new ones Fit the RH and LH bearings on the crankshaft using the special tool provided Om Tool Description bearing fitting set Gearbox desmodromic device RH bearing Remove the RH bearing from the gearbox desmodromic device 7 using the special tool provided CAUTION H Replace the removed bearing with a new one D Fit the RH bearing on the gearbox desmodromic device UBT Gearbox desmodromic device LH bearing Remove the LH bearing from the gearbox desmodromic device 8 using the special tool provided CAUTION Replace the removed bearing with a new one Om Fit the LH cam bearing on the gearbox desmodromic device Rocker shaft RH bearing Remove the RH bearing from the rocker shaft 9 using the special tool provided Tool Description bearing pulling device set CAUTION Replace the removed bearing with a new one O OD Fit the RH bearing on the rocker sh
18. arbox output shaft seal in the LH crankcase using the special tool provided Tool Description seal fitting set Oil check valve Remove the lid 1 the ball in the oil check valve 2 and the RH crankcase spring 3 Attach the spring 3 the oil check valve ball 2 and the lid 1 to the RH crankcase Cleaning the oil filter and the crankshaft hollow strip Remove the oil filter from the RH crankcase Clean it without detaching the filtering strip CAUTION If the filtering strip is found to be defective replace the filter with a new one Detach the crankshaft hollow strip and check to see that it keeps flat and in good condition CAUTION If the hollow strip is found to be defective replace the strip with a new one BS Ua D DC Om CERES Engine Assembly Clank Sha T stn eee einer et 138 Cam and Shifter ee EE 139 A A E a 140 Starter Clutch and alternator FOtOF oocconcccncccincnnccensannnacennarnnarnnnans 141 A A ate E ae ce nee ee cee eee 141 ett OC Ae reia cocoa 142 ege DE 142 EE 143 Camshaft MINO CNA nat EE 143 A O 144 Erankcase Re m n a vevewsesee see 146 AN A O 146 Ee Ee et 146 dE lo e Ea neem a Ser ane resent 147 Piston QI A O 148 A A A 149 Camshaft Automatic decompression assemDlV cccaccccniconananenono 150 Cylinder head EE 151 e e eene Eie lH 152 EE Orar CP ROE KOT Engine Assembly Assembly again the engine in the opposite order of the disassembly Pay
19. base with a clean cloth to prevent the piston bolt spring ring from falling into the crankcase After that use long nose pliers to attach the piston bolt spring ring CAUTION Use a new piston bolt spring ring to prevent it from breaking if bent Apply motor oil to the sliding surface of the piston and the connecting rod crank end Attach the centering pins 1 and a new seal 2 to the crankcase CAUTION Use a new seal to prevent oil leaks Hold the piston rings with their sections properly positioned and attach them to the cylinder Check to see that the rings remain properly held by the cylinder skirt NOTE When fitting the cylinder tighten the camshaft driving chain after attaching it The camshaft driving chain must not get jammed between its pinion and the crankcase when the crankshaft is turning NOTE The crankcase features a moulded bracket for the lower end of the camshaft driving chain guide Check to see that the guide 3 fits correctly as otherwise both the chain and the guide may become jammed 1 KS Om Om Om Om Om sche a CYLINDER HEAD Attach the centering pins 1 and a new cylinder head gasket 2 CAUTION Use a new cylinder head gasket to prevent petrol leaks With the cylinder head properly settled on the cylinder secure the cylinder head by tightening the screws in a diagonal sequence Tighten the cylinder head screws at the specified torque Cylinde
20. dy of the chain idler CAUTION Use a new seal to prevent oil leaks Attach the camshaft driving chain idler to the cylinder and then tighten both Allen screws at the specified torque Camshaft chain tension adjusting screw 10 N 1 kgf m Using a flat pointed screwdriver turn the adjusting screw anticlockwise until the pushing rod becomes unlocked Tighten the screw securing the bracket of the camshaft chain idler spring at the specified torque Screw securing the bracket of the camshaft chain idler spring 8 Nm 0 8 Kgf m 182 Om Om leide SE 156 Engine Oil and Oil EiIer sss s sese eeee seene enesenn ennenen ennenen ee 157 nee ERR DUTT o ee eee 159 154 SPARK PLUG Inspection after 30 hours operation To be replaced after 60 hours operation Detach the fuel tank Detach the spark plug arm and remove the spark plug COLD STANDARD HOT NGK CR9E CR8E CR7E DENSO U27ESR N U24ESR N U22ESR N U31ESR N Cinder buildups Check the spark plug for cinder Remove any cinder buildups with a spark plug cleaning tool or use a point ended tool Spark plug tolerance Use a thickness gauge to measure the tolerance If the spark plug is found to be out of tolerance adjust the tolerance Om DETAILS Standard Tolerance 0 7 0 8 Tool Thickness gauge DZ 0 4 mm 0 028 0 037 im Electrode Check the condition of the electrode If the electrode is found to be extremely
21. e battery 1 and the ground coupler from the engine 2 Engine Removal and Installation Detach the wire clamp from the alternator A and the sensor cable from the tonewheel Detach the spark plug arm 1 the engine oil devaporizing tube 2 the engine oil reservoir breather pipe 3 Loosen the clamp holding the cylinder head injector conduit 4 Detach the wire clamp from the water temperature sensor 5 Detach the connecting cable from the starter 6 and remove the starter E Remove the water tubes 1 Remove the lever from the pedal operated starter Remove the exhaust manifold 2 Detach the radiator tubes QO Detach the engine oil tube 1 in the frame reservoir Remove the gearbox lever Remove the engine pinion cover Remove the clutch pump Loosen the chain Remove the outlet pinion Seeger 1 Sin Remove the engine pinion Remove the split pin and the brake pedal CAUTION Replace the split pins with new ones Remove the engine from the frame SIS Oc Engine Installation Reverse the above operations to install the engine Fit the screws and nuts securing the engine NOTE At this stage nuts must only be tightened provisionally The nuts securing the engine are self locking Upon removal they cease to be self locking and become useless CAUTION Replace the nuts securing the engine with new ones Secure the screwheads with
22. ear centering device plate 3 Remove the crankshaft pinion bolt the washer the gear the timing chain and the timing chain gear CAUTION The crankshaft pinion bolt has a left hand thread Om Remove the alternator rotor bolt and washer Holding the puller with a spanner loosen the rotor Tool Part No MFS400134045 FSE400 flywheel puller DC OS Use the special tool supplied to detach the alternator rotor CAUTION Tapping the alternator rotor with a hammer might damage it Remove the lower oil reservoir lid Remove the crankcase left hand set screws Detach the crankcase using the special tool supplied Tool Part No ME2595000 crankcase detachment tool NOTE Fit the crankcase detachment tool on the left hand side so that ts plate becomes parallel with the surface of the crankcase end Remove the centering devices 106 DC Remove the shafts of the shifter forks 1 and the forks 2 Detach the gearbox input shaft assembly 3 and the gearbox output shaft assembly 4 Detach the crankshaft 5 and the rocker shaft 6 NOTE Should this detachment operation prove difficult tap both shafts with a plastic mallet in an alternating pattern Remove the oil intake filter and clean it 107 DC CEP KCI KT Inspection and Maintenance of Engine Components Cylinder AAA cei eee eee eee ee eee eee eee 110 Camshaft Automatic decompression ASSEMDI
23. en fork and fork groove Service limit 0 50 mm Om Om DETAILS Shifter fork groove width Normal 4 8 4 9 mm Om DETAILS Shifter fork thickness Normal 4 6 4 7 mm DC ZS WO G Gn QA O hy 18X40X0 6 WASHER PRIMARY II PINION DIN 471 CIRCLIP 31 5x 25x22 x1 GROOVING WASHER PRIMARY VI PINION PRIMARY II AND IV PINION 25 2x31 5x1 GEAR WASHER PRIMARY V PINION K25 29 10 NEEDLES BEARING PRIMARY AXIS SECUNDARY AXIS DIN 983 CIRCLIP SECUNDARY II PINION SECUNDARY VI PINION SECUNDARY III PINION SECUNDARY IV PINION SECUNDARY V PINION 20 8x29x1 GEAR WASHER SECUNDARY I PINION K20x24x10 NEEDLES BEARING 213 EXIT PINION GEAR EXIT SEAL EXIT PINION SEAL 30X40X7 SEAL GEAR 6205 BEARING GEAR SET GEAR 6305 BEARING Disassembly Detach the transmission gears as illustrated Fitting aa Reverse the disassembly operations to fit the transmission Pay special attention to the following points NOTE Before fitting the gears apply engine oil to the inner surface of each gear and bushing CAUTION Never re use a spring ring Elastic rings detached from their shaft must be discarded and replaced with new ones When fitting a new spring ring expand the end opening just enough for the ring to slide along the shatt After fitting a new spring ring check to see that its is fully settled within its groove and securely attached NOTE When reassemblying the transmission pay special attention to the locat
24. ew seal and the screws A on the clutch disc cover as illustrated ALTERNATORROTOR COVER Fit the starter driven gears 2 the centering devices 3 and the new seal 4 CAUTION Use a new seal to prevent oil leaks Tighten the screws on the alternator rotor cover firmly always diagonally to each other EG Om b Om PISTON RINGS Start by fitting the lubrication ring followed by the 2nd ring and finally by the 1st ring NOTE Piston rings 1 1 and 2 2 have different shapes Piston rings 1 and 2 must be attached with their marks facing upwards Start by fitting a spacer 1 into the lubrication ring groove and then fit both side guides 2 The spacer and the side guides have no specific top and bottom They may be fitted in any position CAUTION When fitting the spacer prevent ts two ends from overlapping in the groove A Wrong B Right Place the piston ring openings as illustrated Before fitting the piston into the cylinder check to see that the openings are properly positioned A Exhaust side B Inlet side 3 2nd ring and lower side guide 4 Upper side guide 5 1st ring and spacer vez Om Om PISTON AND CYLINDER Reverse the above operations to install the piston and cylinder NOTE Fit the piston with the mark on its crown facing the exhaust side Apply a molybdenum oil solution to the piston bolt and the connecting rod foot Cover the cylinder
25. hat would take the spark plug in the cylinder head Make sure that the connection has been properly carried out Keep the butterfly valve in the fully open position Press the start button and have the engine running for a few seconds Record the highest pressure gauge readout Tool Description Pressure gauge Adaptor 189 Om U a Om Low or high pressure may indicate some of the conditions below Low oil pressure Clogged oil filter Leaking in oil ducts Damaged ring seal Defective oil pump Acombination of the defects above High oil pressure Oil viscosity too high Blocked oil ducts Acombination of the defects above Oil pressure check Check the oil pressure regularly This should provide useful information on the condition of the engine moving parts DETAILS Oil pressure Up 40 Kpa 0 4 Kgf cm 5 7 psi Up 140 Kpa 1 4 Kgf cm 19 9 psi at 3000 rpm Oil pressure check procedure Attach a tachometer to the high voltage cable Remove the plug from the main oil circuit Warm up the engine as follows Summer 10 minutes at 2000 rpm Winter 20 minutes at 2000 rpm After warming up the engine incrase the turning speed to 3000 rpm check the tachometer and record the oil pressure readout from the tachometer Tool Description Pressure gauge Adaptor 16 DC Om U SIT
26. he camshaft journals have been fitted you must proceed to the valve clearance adjustment Tool ref Thickness gauge D DATA H Exhaust valves 0 25 mm g Intake valves 0 15 mm Using the thickness gauge the clearance between the camshaft and the valve s top cup should be checked If the clearance does not correspond to the one expressed in DATA the valve shim must be changed by another one that corresponds to the adequate setting CYLINDERHEAD COVER Totally remove any oil from the contact surfaces of the cylinder head and its cover Apply silicone to the end plugs of the cylinder head cover joint as illustrated Tool Description U Silicone e NOTE When tightening the screws on the cylinder head H cover the piston must be in the inner dead centre position of the compression stroke Apply motor oil to both faces of the washer 1 Tighten the screws on the cylinder head cover slightly in a diagonal sequence and then tighten them at the specified torque Cylinder head cover screw Initial 10 N 1 kgf m Final 14 N 1 4 kgf m CAUTION Use new washers 1 and a new rubber seal 2 151 Om Om CAMSHAFT DRIVING CHAN IDLER Attach the camshaft driving chain idler Pay special attention to the following points Apply motor oil to the pushing rod Using a flat pointed screwdriver turn the adjusting screw clockwise until the pushing rod becomes locked Attach a new seal to the bo
27. he sealer and oil stains from the contact surface of both the RH and LH crankcases Prior to fitting the sump filter wash it with solvent and then dry it with compressed air Attach the centering devices to the LH crankcase Apply motor oil to the connecting rod crank end and to the transmission gears Should the engine feature an oil sump gasket replace the gasket Otherwise with no sump gasket apply silicone on the right sump contact surfaces and to the A parts of both sumps as indicated in the picture Tighten the crankcase screws at the specified torque Crankcase screw 11 Nm 1 1 Kgf m After tightening the crankcase screws check to see that the crankshaft the jackshaft and the transmission shaft are turning smoothly If you notice that there is a considerable degree of resistance try to improve the turning of the shafts by tapping them with a plastic mallet STARTER CLUTCH AND ALTERNATOR ROTOR Remove the grease from the tapered area of the crankcase and the alternator rotor Fit the linchpin 1 and the alternator rotor 2 Use a 17 mm spanner to tighten the alternator rotor nut at the specified torque Alternator rotor nut 100 Nm 10 Kgf m ROCKER SHAFT 1 Rocker or vibration absorbant shaft 2 Bearing 3 Rocker shaft driven gear 4 Washer 5 Water pump retainer 6 Water pump turbine 7 Washer A Rocker shaft nut Element Nm Kgf m A 10 1 SEN 0 gt OG 0 A d ng When
28. he width of the sprayed ring which is equivalent to the width of the valve seat must not exceed the following specified value DETAILS Valve seat width W Normal 0 9 1 1 mm 0 035 0 043 in Grind the valve seat as required if it is found to exceed the specified value Valve seat maintenance Inlet and exhaust valve seats are machined at three different angles The seat contact surface is cut at a 45 angle Inlet Exhaust 45 N 128 N 128 15 N 121 30 N 128 60 N 114 N114 Tool United States Valve seat knife N 114 N 121 and N 128 Tools Other countries Description Valve seat grinding set Description seen N 128 Knife Description seen N 114 Knife Description seen N 121 Knife NOTE Use the solid centering device together with the N 114 N 121 and N 128 valve seat knives CAUTION The valve seat contact surface should be checked after each cutting operation 118 Om Om Om Om When fitting the solid centering device 1 turn it slightly Settle the centering device properly Fit the 45 knife 2 the adaptor 3 and the T shaped shank 4 Initial seat cutting operation Use the 45 knife to descale and clean the seat Turn the knife around once or twice Measure the valve seat width W after each cutting operation If the valve seat appears to be pitted or burnt use the 45 knife to complete the seat conditioning operation NOTE Cut only as little as pos
29. ial gauge 1 100 mm Description ssc ssss cesse sss magnetic support Description Set of tapered blocks 100 mm DETAILS Camshaft offsetting Service limit 0 10 mm 121 Om Om Om Oy Uy Om Om Om CYLINDER Cylinder deformation Using a ruler and a feeler gauge check the surface of the cylinder block gasket for signs of deformation Measure the clearance in several places If any of the clearance measurements is found to exceed the service limit replace the cylinder block with a new one Tool Description feeler gauge DETAILS Cylinder deformation Service limit 0 05 mm 0 002 in Om Om Inner cylinder wall Check the inner cylinder wall for scratches notches or any other signs of damage Measure the cylinder inside diameter at six points Tool Description cylinder gauge set DETAILS Cylinder inside diameter FSE400 90 000 90 015 mm FSE450 95 000 95 015 mm O 7 OD PISTON ANDPISTON RING Piston diameter Use the micrometer to measure the piston diameter at 15 mm from the skirt end If the piston diameter is found to exceed the service limit replace the piston with a new one Tool Description Micrometer 75 100 mm DETAILS Piston diameter Service limit FSE400 89 880 mm Service limit FSE450 94 880 mm Oo 7 On Fig 1 Clearance between piston ring and groove Using the feeler gauge measure the side clearances of the rings on pistons 1 and 2 If a
30. illustrated above Improper filter fitting may result in damage to the engine IOS Om Om DC Low compression may indicate some of the conditions below Cylinder walls excessively worn out Worn out piston or rings Rings stuck in their seats Valve seats in bad condition Cylinder head may be broken or have other defects NOTICE When compression is low verify the engine for the conditions listed above To be initially inspected after 5 hours operation and then every 30 hours Check to see that no engine oil pipes show signs of damage or leaks If any kind of damage is found replace the pipes with new ones Check compression A cylinder with the proper compression means that conditions inside the cylinder are good Decisions to check cylinders are usually based on the results of cylinder compression measurements Inspections carried out by dealers should include a cylinder compression check Compression DETAILS Standard 1000 Kpa 10 0 Kgf cm Compression check procedure NOTE Before checking the engine compression make sure that the cylinder head screws have been tightened at the specified torque and that the valves have been properly adjusted Warm up the engine before commencing the compression check Make sure that the battery is fully charged Carry out the compression measurement as follows Remove the spark plug Insert the pressure gauge into the thread t
31. ion and position of washers and spring rings The sectional view shows the correct positions for gears washers and spring rings When fitting a spring ring attention must be paid to its direction fit it facing the drive side The rounded face must be fitted against the gear surface A Drive B Sharp edge 128 Om Om Om Pay Wash the bearings with a solvent and lubricate them with motor oil before checking them Check to see that the inner guide ring turns smoothly Any bearing that does not turn smoothly or noiselessly or that shows signs of any anomaly is deffective and must be replaced with a new one as follows Gearbox input shaft RH bearing Remove the RH bearing on the gearbox input shaft 1 using the special tool provided Tool Description g bearing pulling device set O CAUTION Replace the removed bearing with a new one U Fit the RH bearings on the gearbox input shaft using the special tool provided Tool Description bearing fitting set Om Gearbox input shaft LH bearing Remove the LH bearing on the gearbox input shaft 2 using the special tool provided Tool Description bearing pulling device Tool Description plexor CAUTION Replace the removed bearing with a new one Om Om Fit the LH bearing on the gearbox input shaft using the special tool provided Tool Description bearing fitting set Om BO Gearbox output shaft bearings Remove the RH 3
32. n the crankcase 1 21 Nm 2 1 Kgf m 15 0 Ib ft In the chassis 2 18 Nm 1 8 Kgf m 13 0 Ib ft CAUTION When inserting the seal screw 2 position the seal as illustrated To check the oil level place the motorcycle in its operating position Attach the oil reservoir plug 3 Start the motorcycle engine and keep it ticking over for 3 minutes Cut the engine wait for 3 minutes and then use the dipstick 4 to check the oil level The oil level should reach between level marks L and F NOTE The oil in the engine expands and its level rises when hot 157 Om Om Om Om Oil filter replacement Follow the same procedure as for replacing the engine oil Remove the oil filter lid 1 and the oil filter 2 Replace the filter with a new one NOTE Before fitting the oil filter lid make sure that the spring 3 and a new O ring seal 4 have been attached correctly Check to see that the O ring seal 5 behind the filter has been positioned correctly Replace the oil filter lid and tighten the lock nut Replace the supply of new oil in the engine and check the oil level as described for the oil replacement procedure DETAILS Engine oil capacity Oil replacement 1 7 L 1 8 US qt 1 5 Imp qt Oil and filter replacement 1 8 L 1 9 US qt 1 6lmp Imp qt Engine inspection 1 9 L 2 0 US qt 1 7 Imp qt CAUTION When fitting the oil filter make sure that it has been installed as
33. ny of the clearances is found to exceed the service limit replace the piston and the rings Tool Description feeler gauge DETAILS Clearance between piston ring and groove Fig 1 Service limit 1 0 18 mm 0 0071 in 2 0 15 mm 0 0059 in DETAILS Piston ring groove width Fig 2 Normal FSE400 1 1 03 mm 22 1 22 mm FSE450 12 1 23 mm 22 1 53 mm Lubrication 2 01 2 03 mm Tool Description Micrometer 0 25 mm DETAILS Piston ring thickness Fig 3 Normal FSE400 1 0 985 mm 22 1 19 mm FSE450 12 1 19 mm 22 1 49 mm Piston ring free end opening and piston ring end opening Start by measuring the piston ring free end opening with the vernier calipers then place the piston ring across the cylinder and measure the ring end opening with the feeler gauge Tool Description Vernier calipers DETAILS Piston ring free end opening Fig 4 Service limit 1 5 5 mm 2 9 2 mm Tool Description feeler gauge DETAILS Piston ring end opening Fig 5 Service limit 1 0 50 mm 2 0 50 mm IS Om Om Om Om Om Oc DC Oc DC Piston bolt and inside diameter of pin Use a small calibre gauge to measure the piston bolt inside diameter If the diameter is found to exceed the service limit replace the piston with a new one Tool Description Dial gauge 1 1000 mm Tool Description small calibre gauge 18 35 mm DETAILS Piston bolt inside diameter Service limit
34. r head screw Initial 25 N 2 5 kgf m Final 46 N 4 6 kgf m NOTE Apply motor oil to the threaded areas of the cylinder head screws and their washers Position the washers with their rounded faces upwards After tightening the cylinder head screws at the specified torque tighten the cylinder head screws 1 and the cylinder screws 2 at the specified torque Cylinder head screw 10 N 1 kgf m Cylinder screws 10 N 1 kgf m Tighten the cylinder head side screw 3 at the specified torque Cylinder head side screw 14 Nm 1 4 Kgf m 148 Om Om Om Om CAMSHAFT AUTOMATIC DECOMPRESSOR ASSEMBLY Position the crankshaft with the piston at inner dead centre P M S CAUTION If the crankshaft turns without lifting the camshaft driving chain the chain will become jammed between the crankcase and the pinion DC Le j NOTE cken e E E Just a moment before attaching the camshaft to e gr A the cylinder head apply a molybdene oil solution di w i D to the camshaft journals and to the cam surfaces CP Fa t A 2 A Y Also apply motor oil to the camshaft journal id 7 d i CLI brackets DC N M pat 4 vi d L Place each camshaft in the correct position N N f d A d l if NOTE K PUN Camshafts marked EX belong in the exhaust side f fL and camshafts marked IN belong in the inlet side Om X V l l ly Having the camshaft with the piston at inner dead MAP 1 U
35. r worn parts connecting rod connecting rod crank end bearing crankshaft pin etc Tool Description feeler gauge DETAILS Connecting rod crank end side clearance Service limit 1 mm 125 lo DC Om Om Om Om CRANKSHAFT Crankshaft offsetting Using tapered blocks to hold the crankshaft measure the amount of offsetting with the dial gauge as illustrated If the offsetting is found to exceed the service limit replace the crankshaft with a new one Tool Description dial gauge 1 100 mm Tool Description magnetic support Tool Description Set of tapered blocks 100 mm DETAILS Crankshaft offsetting Service limit 0 08 mm Om Om STARTER CLUTCH Remove the hexagonal screws 1 Starter clutch screw 26 Nm 2 6 Kgf m Fit the starter clutch in the correct direction as illustrated Apply engine oil to the starter clutch Apply LOCTITE to the hexagonal screws and tighten them at the specified torque while holding the rotor with a spanner Attach the gear 1 to the starter clutch Check to see that the rotor 2 is turning in the direction marked by the arrow while holding the gear and make sure that it never turns in the opposite direction 125 OIL PUMP Check all the components The screws securing the pump to the engine casing must be fitted with LOCTITE and given a specific torque Om Oil pump 10 N m 1 0 kgf m CLUTCH Clutch driving discs Measu
36. re the thickness of the clutch driving discs with vernier calipers If any of the clutch driving discs is found to exceed the service limit replace all the clutch discs Tool Description H Vernier calipers D DETAILS 7 Driving disc thickness O Service limit 2 62 mm DETAILS Driving disc hook width Normal 13 9 mm Service limit 13 5 mm Om Clutch driven discs Using the feeler gauge measure the amount of deformation shown by the clutch driven discs If any of the clutch driven discs is found to exceed the service limit replace all the clutch discs Tool Description H feeler gauge DETAILS 7 Driven disc deformation L Service limit 0 10 mm Clutch spring unsupported length Measure the unsupported length of each clutch spring with the vernier calipers If any of the springs is found to exceed the service limit replace all the springs Tool Description vernier calipers DETAILS Clutch spring unsupported length Service limit 49 9 mm 127 Uy Dec Clearance between fork and fork groove The amount of clearance for each shifter fork plays an outstanding role in the achievement of a smooth positive operation of the gearbox Use the feeler gauge to measure the clearance of each fork in the groove of its gear If the clearance is found to exceed the specified value replace the fork its gear or both Tool Description feeler gauge Tool Description vernier calipers DETAILS Clearance betwe
37. removed with the piston in the compression stroke PMS Remove the cap bolt 1 and the timing chain idler 2 Remove the spark plug 5 Then remove the cylinder head lid screws in a diagonal sequence and detach the cylinder head cover Remove the chain guide 6 and the brackets of the camshaft journals 7 95 Engine Disassembly Om Remove the centering devices 1 the input camshaft 2 and the output camshaft 3 NOTE Prevent the centering devices from falling into the crankcase Om Remove the cylinder head side screw Remove all four cylinder head screws in a diagonal sequence NOTE Prior to loosening the cylinder head screws H loosen the cylinder head screws 6 mm and y the cylinder base screws Remove the cylinder head screws and then the cylinder head NOTE In case of difficulty removing the cylinder head tap it with a plastic mallet Om GIZ Remove the cylinder head gasket 1 and the centering devices 2 Remove the timing chain guide 3 Remove the cylinder base screws 4 and then the cylinder NOTE In case of difficulty removing the cylinder tap it with a plastic mallet Remove the cylinder gasket 5 and the centering devices 6 Cover the cylinder base with a clean cloth to prevent the piston bolt spring ring from falling into the crankcase Remove the piston bolt spring ring 7 Remove the piston bolt and the piston 100 U a
38. rew securing the camshaft transmission chain idler 10 Nm 1 Kgf m VES CLUTCH 1 Crankshaft pinion 2 20 125 bevelled washer 3 Crankshaft pinion lock nut 4 22 1x42x2 8 clutch drum washer 5 Clutch crown gear washer 6 Drum crown gear pinion 7 Silentblock rubber 8 Clutch drum crown gear assembly 9 Clutch drum bearing 10 Clutch drum bushing 11 Bushing 12 Clutch hub 13 Clutch seal washer 14 Clutch hub lock nut 15 Clutch rod 16 A Driving disc 7 items 16 B Driving disc 1 item 17 driven disc 7 items 18 Clutch mushroom 19 Exhaust valve needle cage 20 Needle plate and exhaust valve 21 Clutch 15 shaft Seeger 22 Clutch press 23 Clutch spring 24 Aluminium clutch spring bushing 25 Susp cart clutch ta 6x25 Allen Element Nm Kgf m A 70 7 CEE Holding the clutch hub with the special tool provided tighten the clutch hub nut at the specified torque Tool Description Clutch hub holder Clutch hub nut 70 Nm 7 Kgf m Bend the washer tongue firmly Fit the clutch driving discs and driven discs into the clutch hub one by one and in the prescribed order Tighten the screws on the clutch plate springs in a diagonal sequence as illustrated IAS Om CLUTCHCOVER Fit the centering devices 1 and a new seal CAUTION Use a new seal to prevent oil leaks Tighten the screws on the clutch cover firmly Tighten the screws on the clutch disc cover firmly NOTE Fit the n
39. s Fit the valve spring with the lesser pitch end facing the cylinder head A Lesser pitch B Greater pitch C Down Fit the spring clip by pressing it with the tappet Fit the semicones on the rod end and release the tappet so that the semicones 1 become jammed between the clip and the rod Check to see that the valve rounded lip 2 fits properly into the groove 3 in the semicone end Tool Description valve spring compressor Tool Description adaptor Tool Description pliers CAUTION Make sure to fit all the parts into their original positions 119 Om Om CAMSHAFT AUTOMATIC DECOMPRESSOR ASSEMBLY CAUTION Do not try to disassemble the camshaft automatic decompressor assembly It cannot be repaired Automatic decompressor Move the automatic decompressor counterweight by hand to make sure that it works smoothly If the automatic decompressor counterweight does not work smoothly replace it with a new one Cam wear Cam wear usually results in the loss of the valve settings and in a subsequent loss of power Use the micrometer to measure the cam height H If the wear is found to exceed the service limit replace the camshaft with a new one Tool Description Micrometer 25 50 mm DETAILS Cam height H Normal size Inlet 36 934 mm Exhaust 36 893 mm Service limit Inlet 36 634 mm Exhaust 36 593 mm 120 Om Om Om UY Camshaft bridge wear With
40. sible off the seat to avoid the risk of having to replace the tappet shim 116 a x Upper narrowing cutting operation If the contact surface is too high up the valve or if it is too wide use the 30 knife inlet side and the 15 knife exhaust side to lower and narrow it Contact surface is too high and too wide on the valve working area Final seat cutting operation If the contact surface is too low down the valve or if it is too narrow use the 60 knife to lift and widen it If the contact surface is too high up the i valve or if it is too wide use the 15 knife to lower KA and narrow it to the correct width Contact surface is too low and too Upon achievement of the correct seat position narrow on the valve working area and width use the 60 knife very slightly to remove any burrs resulting from the previous cutting operations CAUTION Do not use any burnishing compounds after completing the final cutting operation A completed valve seat must show a velvety finishing but this should not be exceedingly polished or bright This should provide a smooth surface for the final settling of the valve which will have place during the first few seconds of the running of the engine Om NOTE After completing the maintenance of the valve seats fit the cylinder head and checi the clearance of the tappets 2 5 to 2 8 Om U TU Z Valve seat tightness check With the valve and
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