4-STROKE

350CC - 500CC

MY 2018-2019

WORKSHOP MANUAL
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2.8.1 ELECTRIC KICKSTART UNIT..................................42

2.9 PEDAL KICKSTART - OPTIONAL...................................43
2.10 EXTERNAL GEARSHIFT UNIT.......................................45
2.11 CRANKSHAFT, GEARBOX UNIT AND INTERNAL
GEARSHIFT......................................................................46
2.11.1 NUT ON LEFT SIDE OF CRANKSHAFT............46
2.11.2 OPENING THE CRANKCASE............................... 47
2.11.3 CRANKSHAFT............................................................49
2.11.4 INTERNAL GEARSHIFT UNIT AND COMPLETE
GEARBOX....................................................................49
2.12 DISASSEMBLY OF PARTS FROM CRANKCASES........ 51
2.12.1 RIGHT CRANKCASE HALF.................................... 51
2.12.1.1 PISTON OIL JETS...................................................... 51
2.12.1.2 EXTRACTION OF COUNTERSHAFT SUPPORT
BEARING..................................................................... 52
2.12.2 LEFT CRANKCASE HALF........................................ 52
2.12.2.1 INNER OIL FILTER.................................................... 53
2.12.2.2 EXTRACTION OF DESMODROMIC DEVICE
TABLE OF CONTENTS BEARING..................................................................... 53

3 ENGINE ASSEMBLY AND CHECKS 54

PREAMBLE 2
3.1 CRANKCASE HALF......................................................... 55
TECHNICAL FEATURES OF ENGINE 4 3.1.1 EXTERNAL RIGHT SIDE.......................................... 56
3.1.1.1 INSERTION OF OIL SEAL AND
SPECIAL EQUIPMENT 5 COUNTERSHAFT SUPPORT BEARING............. 58
3.1.2 INTERNAL RIGHT SIDE.......................................... 59
1 REMOVING THE ENGINE FROM THE VEHICLE 6
3.1.3 EXTERNAL LEFT SIDE.............................................60

2 ENGINE DISASSEMBLY 17 3.1.4 INTERNAL LEFT SIDE............................................. 61

3.2 CHECKING THE CONNECTING ROD AND
2.1 THERMAL UNIT.............................................................. 17 CRANKSHAFT..................................................................62
2.1.1 CYLINDER HEAD: DISASSEMBLING
HYDRAULIC TENSIONER...................................... 19 3.3 COMPLETE CRANKSHAFT ASSEMBLY........................64

2.1.2 CYLINDER HEAD: DISASSEMBLING THE 3.4 GEARBOX UNIT: CHECKS AND REASSEMBLY.........65
CAMSHAFT SUPPORT, FIXED PAD AND SPARK 3.4.1 GEARBOX UNIT CHECK........................................65
PLUG SEAT O-RING ............................................... 20
3.4.2 PRIMARY UNIT ASSEMBLY...................................66
2.1.3 CYLINDER HEAD: REMOVING
3.4.3 SECONDARY UNIT ASSEMBLY............................ 67
CAMSHAFTS.............................................................. 21
3.4.4 CHECKING THE FORKS, FORK PINS AND
2.1.4 CYLINDER HEAD: UNCOUPLING FROM
DESMODROMIC DEVICE......................................68
CYLINDER................................................................... 22
2.1.5 DISASSEMBLING CYLINDER AND PISTON.... 24 3.5 GEARBOX AND INTERNAL GEARSHIFT ASSEMBLY...... 70

2.2 DISASSEMBLY OF IGNITION UNIT, TIMING CHAIN 3.6 CLOSING THE ENGINE CRANKCASE.......................... 73
AND PADS....................................................................... 25 3.7 BLOCKING THE CRANKSHAFT AT THE TOP DEAD
2.2.1 STATOR AND FLYWHEEL....................................... 25 CENTRE AND TIGHTENING THE NUT ON THE LEFT
2.2.2 TIMING CHAIN AND PADS.................................. 28 SIDE OF THE CRANKSHAFT......................................... 74
2.2.3 PICK-UP....................................................................... 30 3.8 EXTERNAL GEARSHIFT.................................................. 75
2.3 PINION AND SPACER.................................................... 30 3.8.1 CHECKING THE COMPLETE DRIVE SHAFT... 75
3.8.2 EXTERNAL GEARSHIFT ASSEMBLY.................... 77
2.4 CLUTCH UNIT AND COOLANT PUMP COVER........... 31
3.9 KICKSTARTER DEVICE (OPTIONAL)............................ 77
2.5 ENGINE LUBRICATION CIRCUIT.................................. 35
3.9.1 CHECKING THE KICKSTART SHAFT UNIT AND
2.5.1 OIL PUMPS CONTROL GEARS........................... 36
ASSEMBLY.................................................................. 77
2.5.2 HIGH-PRESSURE OIL PUMP............................... 36
3.9.2 ASSEMBLY OF KICKSTARTER DEVICE............... 79
2.5.3 LOW-PRESSURE OIL PUMP AND BY-PASS
VALVE............................................................................ 37 3.10 ELECTRICAL STARTER UNIT AND PRIMARY GEAR.. 80
2.5.4 OIL PRESSURE CONTROL VALVE..................... 38 3.10.1 CHECKING ELECTRICAL STARTER DEVICE
ELEMENTS..................................................................80
2.5.5 PAPER OIL FILTER.................................................... 38
3.10.2 COUPLING IGNITION AND PRIMARY GEARS
2.6 COUNTERSHAFT............................................................. 39 TO THE MOTOR....................................................... 81
2.7 PRIMARY GEAR..............................................................40
2.8 ELECTRIC IGNITION....................................................... 41
 TABLE OF CONTENTS

ENGLISH
3.11 OIL PUMPS: INSPECTION AND REASSEMBLY.........83 3.17.11 CYLINDER HEAD: INSERTION OF OIL JETS,
3.11.1 INTAKE PUMP ASSEMBLY.....................................85 CENTRING PINS AND SPARK PLUG
O-RING..................................................................... 122
3.11.2 HIGH-PRESSURE PUMP AND CONTROL GEAR
ASSEMBLY..................................................................86 3.17.12 PISTON: APPLICATION OF THE OIL-SCRAPER
AND SEAL BANDS, APPLICATION OF THE
3.11.3 CHECKING AND ASSEMBLING THE PRESSURE SEEGER..................................................................... 123
CONTROL VALVE...................................................... 87
3.17.12.1 PISTON: APPLICATION OF THE OIL-SCRAPER
3.11.4 CHECKING AND ASSEMBLING THE OIL PUMP AND SEAL BANDS, VERSION
CONTROL GEARS....................................................88 350CC-390CC....................................................... 123
3.11.5 PAPER OIL FILTER INSERTION............................89 3.17.12.2 PISTON: APPLICATION OF THE OIL-SCRAPER
3.11.6 CHECKING AND COUPLING THE AND SEAL BANDS................................................ 124
COUNTERSHAFT......................................................90 3.17.12.3 PISTON: SEEGER APPLICATION...................... 125
3.12 CLUTCH UNIT..................................................................92 3.17.13 APPLICATION OF PISTON TO
3.12.1 CHECKING THE CLUTCH CASE, ROLLER CYLINDER................................................................ 125
BEARING AND INTERNAL CENTRE BEARING.. 92 3.17.14 APPLICATION OF PISTON-CYLINDER
3.12.2 CHECKING THE CLUTCH DISCS........................93 COUPLING TO CRANKCASE............................. 127
3.12.3 CHECKING THE SPRINGS....................................94 3.17.15 COUPLING HEAD TO CYLINDER.................... 129
3.12.4 CLUTCH DRUM AND CAP CHECK....................94 3.17.16 COUPLING CAMSHAFTS TO CYLINDER HEAD
AND PHASING....................................................... 130
3.12.5 CHECKING THE THRUST BEARING DEVICE.95
3.17.17 VALVE PLAY............................................................. 133
3.12.6 CLUTCH UNIT ASSEMBLY.....................................95
3.17.18 CHECKING AND COUPLING OF MECHANICAL
3.13 COOLANT PUMP............................................................99 TENSIONER TO ENGINE.................................... 135
3.13.1 CHECKING PUMP UNIT AND DISASSEMBLY......99 3.17.19 COUPLING CYLINDER HEAD COVER GASKETS
3.13.2 PUMP UNIT ASSEMBLY...................................... 100 AND CYLINDER HEAD COVER........................ 137

3.14 ASSEMBLY OF COMPLETE CLUTCH COVER................... 3.18 PINION COUPLING......................................................138

101
3.19 RELEASING THE CRANKSHAFT.................................138
3.15 CHECKING AND COUPLING OF TIMING CHAIN,
3.20 COUPLING OIL CAPS...................................................139
FIXED AND MOBILE PADS.........................................103
3.21 COUPLING GEARSHIFT LEVER..................................140
3.16 IGNITION SYSTEM........................................................103
3.16.1 IGNITION SYSTEM CHECK ............................... 104 4 REASSEMBLY OF ENGINE IN THE VEHICLE 141
..................................................................................... 104
3.16.2 COUPLING OF IGNITION SYSTEM TO TABLE OF ENGINE COMPONENTS FASTENING TORQUES 156
CRANKCASE........................................................... 104
TABLE OF FRAME/MOTOR FASTENING TORQUES 156
3.17 THERMAL UNIT............................................................107
3.17.1 CHECKING THE PISTON, PIN BOLT AND TABLE OF SUPERSTRUCTURE FASTENING TORQUE VALUES 156
PISTON RINGS........................................................107
3.17.2 CYLINDER CHECK................................................ 109 RECOMMENDED ENGINE MAINTENANCE 157
3.17.2.1 COUPLING PLAY................................................... 109
3.17.3 CYLINDER HEAD: DISASSEMBLING AND RECOMMENDED LUBRICANTS AND LIQUIDS 158
CHECKING AUXILIARY DEVICES.......................110
3.17.3.1 LUBRICATION JETS AND CENTRING PINS..110
3.17.3.2 ROCKER ARM/SHAFTS UNIT............................111
3.17.3.3 CALIBRATED DISCS FOR VALVE PLAY
ADJUSTMENT..........................................................112
3.17.4 CYLINDER HEAD: DISASSEMBLING AND
CHECKING VALVE UNITS....................................113
3.17.4.1 SPRINGS...................................................................114
3.17.4.2 VALVE GUIDES, VALVES AND SEATS...............114
3.17.4.3 OIL-SCRAPER RINGS AND LOWER CUP.......116
3.17.5 CYLINDER HEAD: CHECKING THE CYLINDER
HEAD BODY............................................................116
3.17.6 CHECKING THE CAMSHAFTS...........................117
3.17.7 CHECKING THE CAMSHAFT SUPPORT........118
3.17.8 CYLINDER HEAD: INSERTION OF LOWER CUP
AND OIL-SCRAPER RING....................................119
3.17.9 CYLINDER HEAD: ASSEMBLY OF
VALVE UNIT............................................................. 120
3.17.10 CYLINDER HEAD: REPOSITIONING
CALIBRATED DISCS. ASSEMBLING ROCKER
ARM PINS AND ROCKER ARMS AND
COUPLING THE SPARK PLUG......................... 121
 www.betamotor.com
PREAMBLE

PREAMBLE
This publication is intended for workshops specialised on repair of motorbikes and motorcycles.
Use, where prescribed, special Betamotor tools.
Use Betamotor spare parts only. For their codes refer to the spare parts manual for the specific vehicle
or version.
The warranty and liability on vehicle safety lapses when maintenance or repair:

• Are NOT performed by workshops specialised on repair of motorbikes and motorcycles.

• Are NOT carried out carefully following the requirements contained in the technical documentation;
• Are NOT carried out using special Betamotor tools, where required;
• Are NOT carried out using Betamotor official spare parts.
Read this entire manual with care before operating the engine. Sufficient knowledge of the components
that make up the engine and of all the procedures to be followed for inspection and maintenance con-
tribute to lengthen the life of the engine.
The paragraphs have been enhanced with schematic illustrations highlighting each subject in order to
make reading immediately understandable.

Informative note
Betamotor S.p.A. is engaged in a policy of ongoing improvement of its products. This is why it could be
possible to note slight differences between the contents of this document and the vehicle upon which
you are carrying out repairs and/ or maintenance. Betamotor S.p.A. models are exported to numerous
countries in which there are different standards concerning Highway Codes and procedures for approval
of the vehicle. Relying on your understanding, Betamotor S.p.A. therefore deems it necessary to reserve
the right to modify its products and technical documentation at any time without prior warning.

We respect and defend the environment

All that we do has an impact on the whole Planet and its resources. Betamotor S.p.A., wishing to
safeguard the interests of the entire Community, would like to make customers and technical opera-
tors aware of ways of using the vehicle and of disposal of its parts in total compliance with standards
in force in terms of environmental pollution, waste disposal and recycling.

SAFETY
Carbon monoxide Engine oil
• Exhaust gases contain carbon which is poi- • Motor oil can cause skin illnesses if carried of-
sonous. Carbon monoxide can cause loss of ten and for prolonged periods in contact with
conscience and lead to death. When starting skin.
the engine, make sure the place you are in
is well-ventilated. Never start the engine in a
• If you touch motor oil, clean parts with soap
and water as soon as possible.
closed place.
• Starting the engine in closed places can be • In case of contact with the eyes, rinse them
abundantly with water and seek medical ad-
done only if provided with relevant gas dis-
vice.
charge evacuation devices.
Petrol • If swallowed, do not induce vomiting in order
to avoid breathing the product into the lungs;
• Petrol is extremely flammable and can be ex- seek immediate medical advice. If you believe
plosive in some conditions. the product has been breathed into the lungs,
• Keep heat sources, sparks and flames away bring the concerned person urgently to the
from the work area. hospital.
• Always work in a well-ventilated area. • Used oil contains dangerous substances which
are harmful for the environment. When chang-
• Never use petrol as a solvent for cleaning. Do ing it, you must be equipped to dispose of it in
not handle it unless absolutely necessary. compliance with existing law.
• Never use petrol to clean components by means • Avoid dispersing used oils in the environment.
of compressed air.
• Keep out of the reach of children.
• Keep out of the reach of children.

2
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PREAMBLE
Coolant liquid • Coolant contains dangerous substances which
are harmful for the environment. When chang-
• In some situations, the ethylene glycol con- ing it, you must be equipped to dispose of it in
tained in the coolant is flammable and its flame compliance with existing law.
is invisible. Should ethylene glycol catch fire,
though its flame is invisible, it can cause burns. • Do not disperse coolant into the environment.
• Do not bring the coolant in contact with hot • Keep out of the reach of children.
parts. These parts could be hot enough to cause
the liquid to ignite.
• The coolant (ethylene glycol) can irritate skin Hot parts
and is poisonous if swallowed. • The engine and the exhaust system get very hot
• Should the coolant come into contact with the and stay at that temperature for a long time,
skin, immediately remove contaminated cloth- even after the engine has been turned off. Wait
ing or footwear and wash with soap and wa- for them to cool down before handling these
ter. In case of contact with the eyes, rinse them parts or intervening on areas around them. Use
abundantly with clean water and seek medical insulated gloves.
advice immediately. Should it be swallowed, do
not induce vomiting in order to avoid breath-
ing the product into the lungs. Administer clean
water and bring the concerned person immedi-
ately to the hospital, showing this product to
the hospital staff.
• In the event of exposure to a high concentra-
tion of vapours, bring the concerned person to
an uncontaminated atmosphere and seek med-
ical advice if necessary.
• Do not remove the radiator cap when the en-
gine is still hot. When coolant is pressurised, it
can spurt out violently and cause burns.

WARNINGS
The information contained in this paragraph is important so that the operations carried out on
the engine can be performed without causing damage.

• Before disassembling, clean the motorcycle • Always replace parts such as gaskets, O-rings
thoroughly. and safety washers with newly supplied parts.
• While you are disassembling it, clean all the • When loosening or tightening nuts or screws,
parts and place them in containers exactly re- always start with the larger ones or from the
specting the order of disassembly. centre. Always respect the indicated tighten-
ing torques.
• Always use special tools wherever necessary
and when thus prescribed. • Use only Betamotor original spare parts.
• Always use glues, sealant and lubricants
wherever prescribed. Respect the indications
concerning their technical features.

3
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TECHNICAL FEATURES OF ENGINE

ENGINE

Single cylinder, 4-stroke, liquid-cooled with countershaft

Type
and electric starting

Bore x stroke RR 350 88x57.4

Bore x stroke RR 390 88x63.4
Bore x stroke RR 430 95x60.8
Bore x stroke RR 480 100x60.8
Displacement [cm³] RR 350 349.1
Displacement [cm³] RR 390 386
Displacement [cm³] RR 430 431

Displacement [cm³] RR 480 478

Compression ratio RR 350-390-430-480 13.19:1 12.5:1 12.3:1 11.9:1
Valve gear 4 valves
TRANSMISSION
RR 350 RR390 RR430 RR480
Primary transmission 28/76 28/76 31/72 31/72
1st gear ratio 12/31 12/31 12/31 12/31
2nd gear ratio 15/28 15/28 15/28 15/28
3rd gear ratio 19/28 19/28 19/28 19/28
4th gear ratio 20/24 20/24 20/24 20/24
5th gear ratio 27/27 27/27 27/27 27/27
6th gear ratio 28/24 28/24 28/24 28/24
SECONDARY TRANSMISSION CHAIN

4
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SPECIAL EQUIPMENT

ENGINE
Symbols
1. Engine assembly equipment code 36.25132.000;
2. Extractor code 36.25081.000;
6Nm
3. Internal 20-30 mm bearing extractor code 006.14.016.00.00;
4. Extractor for gears code 006.14.015.00.00; Value
5. Flywheel extractor code 36.25173.000; Fastening torque
6. Set of piston rings code 006.14.017.00.00;
7. Chain-tensioner release tool code 006.14.005.00.00;
8. Valve assemb./disassemb. tool code 01.00043.000;
9. Valve spring assembly tool code 006.14.003.00.00;
10. Special ring pliers code 36.25097.000; Loctite 243/
11. Tool for blocking crankshaft at TDC code 006.14.011.0.000; Sichel 100M
15. 36mm socket spanner code 006.14.002.00.00;
16. Spark plug spanner code 020.44.010.00.00;
17. Connecting rod disassembly tool code 029.14.007.50.00;
18. Valve play gauge code 006.14.021.00.00;
19. Valve guide differential gauge code 006.14.018.00.00; Silicone paste
20. Clutch hub fixing spanner code 006.14.004.00.00;
22. Engine fixing code 006.14.014.00.00;
23. Pin elastic ring tool code 022.14.020.00.00
24. Special wrench code 006.44.000.00.00
25. Special wrench code 029.14.002.50.00 Grease

5
1
REMOVING THE ENGINE FROM THE VEHICLE
1 REMOVING THE ENGINE FROM THE VEHICLE
Carefully wash the vehicle

Before removing the engine from the vehicle,

empty the following liquids:
∙ Motor oil;
∙ Gear/clutch unit oil;
∙ Coolant liquid.
1
In order to access the oil drain plug, remove the
engine guard connected to the frame by means
of the three screws 1.

Rear engine guard fixing screw.

Front engine guard fixing screws.

Remove the screw 2 to empty the motor oil. Re-

move the screw 3 to empty the gear oil.

ATTENTION: Used oil contains dangerous substanc-

3 es which are harmful for the environment. When
changing it, you must be equipped to dispose of it in
2 compliance with existing law.
Do not dispose of used oils in the environment.

Screw 2 for draining motor oil and 3 for draining

gear oil.

6
 Remove the seat, the screws 4 and the side panel
5.
1
This allows easy access to the silencer screw 6.

REMOVING THE ENGINE FROM THE VEHICLE

5
4

Remove the exhaust pipe and the silencer.

Drain the cooling system by means of the screw

7 and let the liquid outflow into a container (the
cooling circuit contains 1.3l of liquid).

Remove the radiator cap.

7
1
REMOVING THE ENGINE FROM THE VEHICLE
Place the vehicle onto an adequate stand.

To dismantle the tank, remove the seat (if it has not

been removed already), completely loosen the two
screws 8 fixing the tank to the frame and screw 9
(one per side) which fixes the side to the radiator.
8
8

Disconnect the petrol pipe by pressing the relevant

button of quick coupling 10.

Lift the tank.

10

Disconnect the electric connectors 11 and 12.

Remove the tank along with the sides.

11

12

8
Disconnect the water hoses from the engine and
from the right radiator.
1

REMOVING THE ENGINE FROM THE VEHICLE

Remove the left radiator with pipes.

Disconnect the spark plug cap. Cut all straps bind-

ing the engine's electric system to the clutch pipe
and to the frame.

Disconnect the engine ventilation pipes.

9
1 Release the connector 13 and cut the e clamp that
fastens the connector 14 to its support.
13
REMOVING THE ENGINE FROM THE VEHICLE

14

Disconnect the connector 14.

14

Remove the start motor cable fixing nut.

Loosen the throttle body straps from the air filter

sleeve and from the manifold.

10
 15
Remove the screw of the throttle body cover 15
and the cover itself.
1

REMOVING THE ENGINE FROM THE VEHICLE

Disconnect the rear brake stop connector 16.

16

Loosen the adjustment nuts and release the gas

cable.

Injection versions gas cables.

Disconnect the electric connectors indicated in

the figure, relative to the throttle body.

11
1 Remove the screw 17 fastening the injector to the
throttle body, using a spanner as shown in the pic-
ture.
REMOVING THE ENGINE FROM THE VEHICLE

Remove the entire injector from the throttle body.

ATTENTION: Make sure no foreign objects get into

the injector housing. We recommend plugging
the housing with a clean cloth.

17

12
 Remove the frame guards 18 (one each side) and
the pinion guard 19.
1
19

REMOVING THE ENGINE FROM THE VEHICLE

18

Remove the rear wheel nut.

Extract the pin enough to allow the wheel to ad-

vance towards the front of the vehicle.

Rotate the rear wheel lifting the chain in the pin-

ion zone, so that the chain of the pinion itself is
released.

Rest the chain against the upper wedge 20.

Remove the screws 21 fixing the clutch actuator

20 to the crankcase half.
21

ATTENTION: Do not activate the clutch lever with

the actuator uncoupled from the engine.

13
1
REMOVING THE ENGINE FROM THE VEHICLE
Remove the head connections.

Release and remove the brake pedal return spring

22.
Remove the kickstarter lever.

22

Remove the seat rail lower fixing screws 23 (one

each side) and loosen the upper screws 24 (one
each side).

24

23

14
 Rotate the entire filter box unit.
1
Remove the throttle body.

REMOVING THE ENGINE FROM THE VEHICLE

Remove the upper shock-absorber pin 25.

25

15
1
REMOVING THE ENGINE FROM THE VEHICLE
Loosen the engine pins 26.

26
26

Remove the swingarm pin 27.

Move the complete swing-arm unit towards the

27 rear.

Remove the engine pins 26.

26
26

Extract the engine from the frame and apply it to

the specific stand code 3625132 000 using the spe-
cific front fixing bracket code 006140140 000.

16
2 ENGINE DISASSEMBLY 2
2.1 THERMAL UNIT

ENGINE DISASSEMBLY
2
The thermal unit is made up of the head, cylinder
and piston.
Before removing the cylinder head, bring the piston
to the TDC and block the crankshaft: proceed as
shown below.

The four screws 1 of the cylinder head cover 2.

Remove the 4 screws 1, the cylinder head cover 2

2 as well as the 4 screw gaskets 3.

The cylinder head cover 2 and the four gaskets 3.

Remove the spark plug gasket 4 and the cover

gasket 5.

Spark plug gasket 4 and cylinder head cover gasket 5.

17
2 Remove the crankshaft blocking screw 6, remove
the copper washer 7 and put the screw back into its
seat without tightening it all the way.
ENGINE DISASSEMBLY

Alternatively, use the special engine locking

tool(code 006140110000).
7
6

Crankshaft blocking screw 6 with copper washer 7.

After having engaged the 6 th gear, turn the trans-

mission shaft 8 anti-clockwise - using an open-
end spanner or similar - until the lines 9 on the
toothed profiles of the camshafts are aligned.

Rotation of transmission shaft.

Alignment of camshafts.

Turn the transmission shaft in such position and,

at the same time, turn the shaft blocking screw 6
by hand until it engages in the seat present on the
crankshaft, preventing its rotation.

This way the crankshaft is blocked, by means of

the screw 6, at the Top Dead Centre (TDC) and
6 now all the parts can be disassembled.

Blocking the crankshaft at TDC. Please note the lock-

ing screw 6 and the movement of the transmission
shaft set with the open-end spanner.

18
 2.1.1 CYLINDER HEAD: DISAS-
SEMBLING THE MECHANI-
2
CAL TENSIONER

ENGINE DISASSEMBLY
A chain which is not well-tensioned can cause:
• excessive vibrations for the chain which could
make it jump teeth on the camshafts thus dam-
aging the engine;
• incorrect and premature wear of the support
bearings of the camshafts.
The engine is equipped with a mechanical ten-
1 sioner in order to provide the chain with proper
2
tensioning.
Cap and spring removal.

To remove it, proceed as follows:

remove the cap 1 and the spring 2.

Fully unscrew the tensioner support 3 from the

cylinder.
4 3
To remove the piston 4, just push it out from the
tensioner support 3.

Tensioner support complete with piston.

19
2 1
2.1.2 CYLINDER HEAD: DISAS-
SEMBLING THE CAMSHAFT
SUPPORT, FIXED PAD AND
ENGINE DISASSEMBLY

SPARK PLUG SEAT O-RING

To remove the camshafts, disassemble the camshaft

2 support 2 and the fixed pad 3. Then loosen the sev-
en screws 1 of the camshaft support, starting with
the four outer ones (indicated in blue in the figure)
and then the inner ones. Remove the fixed pad 3.

Fixing screws 1 camshaft support 2 and fixed pad 3.

The four outer screws circled in blue must be re- Attention: disassemble the camshafts only after
moved first. having disassembled the hydraulic tensioner.

Using a plastic rod A or something similar, lever the

head surface and the camshaft support 2 in order to
2 lift it and remove it.

Uncoupling camshaft support 2 from cylinder head.

When uncoupling, pay attention to the two centring

pins 4 located underneath the camshaft support.
Remove the spark plug housing sealing O-ring 5 be-
tween the cylinder head and the camshaft support

4
5

Two centring pins 4 and spark plug housing O-ring 5.

20
 2.1.3 CYLINDER HEAD: REMOV-
ING THE CAMSHAFTS
2
1

ENGINE DISASSEMBLY
2
Lift the intake camshaft 1, pull out the bearing
2 and remove the chain 3 from the gear on the
shaft.

Attention: the hydraulic tensioner must already

have been removed in order to remove the cam-
shafts.

Removal of intake camshaft 1, bearing 2.

In order to remove the exhaust camshaft 4, repeat

the operations described for the removal of the
3
intake camshaft.

Camshafts (3 intake, 4 exhaust) with bearings.

ATTENTION: make sure the chain does not fall in-

side the dedicated compartment. For this purpose,
it is recommended to interpose a plastic rod (or
the likes) A between the chain and the head.

Plastic rod to support chain.

21
2 2.1.4 CYLINDER HEAD: UNCOU-
PLING FROM CYLINDER
1
ENGINE DISASSEMBLY

Five screws fasten the head to the cylinder.

Remove the cylinder head screw 1 on the outside of
the chain-side cylinder head.

Chain-side head fixing screw.

Remove the four cylinder head fixing screws 2, in a

criss-cross pattern. Start with one of the two screws
outside the cylinder head compartment.
Then remove the respective washers.

Head fixing screws 2.

Lift the cylinder head 3 with one hand and at the

same time with the other hold the chain in tension
thus preventing jams during disassembly.
With the cylinder head lifted a few centimetres,
3 drop the chain inside the compartment and pull out
the head.

ATTENTION: should the chain fall inside, tension it

before lifting the head.

ATTENTION: while lifting the head, pay attention to

the centring bushes.

Head removal 3.

22
 Remove the head gasket 4 and the two centring
bushes 5.
2
3

ENGINE DISASSEMBLY
2
4
1

Cylinder head elements:

1) Screw M6x80;
2) Cylinder head screws M10x1.25;
3) Complete cylinder head;
4) Cylinder-head gasket;
5) Centring bushes.

23
2 2.1.5 DISASSEMBLING THE CYLIN-
DER AND PISTON
1
ENGINE DISASSEMBLY

Lift the cylinder 1 by a few centimetres, remove the

two centring bushes 2 (both located on the chain
3 side) to prevent them from falling inside the crank-
cases and continue removing the cylinder. Remove
the cylinder gasket 3.

Cylinder removal.
Place a clean cloth between the piston and the
crankcase to keep foreign objects or simple solid
residue from falling inside the base. Using a suit-
able tool to insert the specific seat A, remove the
elastic ring 4 on the right hand side of the piston 5.
A

ATTENTION: be careful not to drop the elastic ring

inside the engine.

4
5

Removal of elastic ring 4 from right hand side of pis-

ton.

From the left hand side of the piston, push the pin
bolt with an aluminium cylinder B (or similar), until
the pin bolt is freed from the foot of the connecting
B rod.
Remove the piston.

ATTENTION: Try pulling out the pin bolt by hand

first of all. If it is too tight, hit the pin lightly with
a rubber hammer, at the same time holding the
piston with your hand in order not to stress the con-
necting rod.

Removal of pin bolt.

24
 In the figure you can see the piston 5 (bottom
view), the circlip 4 and the pin bolt 6.
2

ENGINE DISASSEMBLY
4
6

Bottom view of piston 5, elastic ring 4 and pin bolt 6.

2.2 DISASSEMBLY OF IGNI-

TION UNIT, TIMING CHAIN
AND PADS

The ignition unit is made up of the flywheel (or

rotor), the pick-up and the stator which is one
with the flywheel cover.

2.2.1 STATOR AND FLYWHEEL

2
Remove the screw 1 which connects the gear le-
ver 2 to the drive shaft.

Removal of gear lever.

Remove the nine screws 3 which fasten the fly-

wheel cover 4 to the left crankcase half. Remove
3 the flywheel cover and the gasket placed between
the crankcase and the cover.

Fixing screws 3 of ignition cover 4.

25
2
ENGINE DISASSEMBLY
Pay attention to the two centring pins 5 on the
crankcase half.

Two centring pins 5 dedicated to the flywheel cover

(injection version).

Remove the tightening nut 6 which fastens the fly-

wheel 7 to the crankshaft.
Once the nut has been unscrewed, pay attention to
the special elastic washer (8 shown in the following
7 images) placed between the nut and the flywheel.

Nut 6 which fastens flywheel 7 to the crankshaft (in-

jection version).

To remove the flywheel, screw the relevant extractor

A (code 3625173) onto the threaded segment on
the flywheel and, using a box spanner, tighten the
A screw on the extractor.

Starter flywheel removal (injection version) with spe-

cial gear puller A.

26
 7
The image to the side shows the flywheel 7 (rear
view), the special elastic washer 6 and the tight-
2
ening nut 8.

ENGINE DISASSEMBLY
8 6

Flywheel 7, nut 6 and special rose-petal 8.

27
2 2.2.2 TIMING CHAIN AND PADS
Remove the fixing screws 1 of the mobile 2 and
ENGINE DISASSEMBLY

fixed pad 3.
Extract pad 2, then pad 3, by pulling them upwards.
3
2

Fixing screws 1 of mobile 2 and fixed pad 3.

Extraction of chain pads.

28
 5
Remove the screw 4 and extract the oil jet 5. Re-
2
move the two screws 6 and then the chain guard 7.
Pay close attention to the respective bushes while

ENGINE DISASSEMBLY
extracting the mobile and fixed pads and the tim-
ing chain.

6
4

Chain guard and oil jet.

Remove the timing chain 8, freeing it from the

gear on the crankshaft and pull it downwards.
8

Removal of timing chain.

2
6
4

7
3
1

Two pad fixings screws 1; mobile pad 2; fixed pad 3; oil jet fixing screw 4; oil jet 5; chain guard fixings screws 6;
chain guard 7; timing chain 8.

29
2 2
2.2.3 PICK-UP

1 Once the timing chain guard has been removed,

ENGINE DISASSEMBLY

the pick-up 1 can be disassembled, by removing

the two fixing screws 2.

Two screws 2 for fixing pick-up 1.

2.3 PINION AND SPACER

3
In order to remove the pinion 1, loosen the screw
completely 2 and take off the washer 3.

2
1

Pinion 1, screw 2 and washer 3.

After removing the pinion, pull off the spacer 4.

Pinion spacer 4.

30
 1
2.4 CLUTCH UNIT AND COOL-
ANT PUMP COVER
2

ENGINE DISASSEMBLY
In order to access the clutch unit, the outer clutch
cover 1 must be removed by loosening the screws
2.
2

Outer clutch cover 1 and respective screws 2.

On the other hand, when doing a complete over-

haul of the clutch unit, of the other elements
housed in the outer right side of the crankcase
half or of the engine, the inner clutch cover 3
3 must be removed by loosening the screws 4 and
the water pump cover 5 loosening the screws 6.
4

Inner clutch cover 3 and respective screws 4.

Pump cover 5 and respective screws 6.

31
2 A
Pay attention to the two reference pins A placed be-
tween the right crankcase half and the inner clutch
cover while disassembling.
ENGINE DISASSEMBLY

Two centring pins A for inner clutch cover coupling.

If only the clutch actuator pipe was removed dur-

ing the disassembly of the engine from the vehi-
cle, remove the complete hydraulic actuator 7 from
8 the outside left crankcase half by fully undoing the
three screws 8 that secure it to the crankcase half.
Remove the gasket in between the actuator and the
crankcase half.

Hydraulic actuator 7 and three screws 8 for crank-

case half coupling.

Extract the clutch control rod 9.

Extraction of clutch rod 9.

32
 Remove the screws 10 which fasten the clutch cap
11 to the clutch drum.
2
10 Remove the clutch cap together with the four

ENGINE DISASSEMBLY
washers and relative springs.

11

Clutch cap 11 and screws 10.

Extract the complete pressure plate unit 12 and

12 the clutch disc pack 13.

13

Pressure plate unit 12 and clutch disc pack 13.

In order to complete the disassembly of the clutch

unit, open the safety washer 14 using a chisel and
remove the nut 15.

15 ATTENTION: Do not remove the sliding pins 16.

16
14
Opening safety washer with chisel.

To unscrew the nut 15, the clutch drum must

be blocked with a suitable tool A (code
029.14.002.50.00). Then remove the nut and rel-
ative safety washer.

ATTENTION: do not use the pneumatic gun.

Removal of clutch drum nut with relevant tool A.

33
2 Extract the clutch drum 17, the washer 18, the case
19, the roller cage 20 and the centre bearing 21. It
ENGINE DISASSEMBLY

is possible to remove the sliding pins 22.

17

21
20

19

22

18

Washer 17; case 18; roller cage 19; bushing 20; special driven disc 21; disc spring assembly 22.

34
 2.5 ENGINE LUBRICATION CIR-
2
CUIT

ENGINE DISASSEMBLY
The high-pressure pump (or delivery) 1 - with less
displacement - sends the oil purified by the paper
filter 2, to the crank mechanism 3, to the piston
oil jets 4, to the tensioner 5 and to the cylinder
head jets and camshafts* 6. The valve 7 controls
the pressure.
When oil has lubricated the cylinder head and
has seeped through the tensioner, it flows along
ENGINE LUBRICATION CIRCUIT: the timing chain to the ignition unit compartment
A. When oil has lubricated the crank mechanism
1) High-pressure pump; and the piston-cylinder coupling, it goes to the
2) Paper oil filter;
3) Crank mechanism;
crank mechanism compartment B from which it
4) Piston oil jets; is sucked by a low-pressure pump (or recovery)
5) Hydraulic tensioner; 9 – with higher displacement -, passing through
6) Cylinder head oil jets; the oil filter 8 and sent to the ignition unit com-
7) High-pressure valve; partment A. There it is sucked once again by the
8) Internal filter;
pump 1 after being filtered through the wire metal
9) Low-pressure pump;
10) By-pass valve; filter 11.
11) Wire metal filter; The valve 10 controls the pressure between the
A) Ignition unit compartment; external casing on the ignition unit side and the
B) Crank mechanism compartment. crank mechanism compartment.

2
10 9

1 3
7
8
A
11 B

* Part of the lubricant sent to the cylinder head is used for the hydrodynamic support of the camshafts.

35
2
ENGINE DISASSEMBLY

2.5.1 OIL PUMPS CONTROL GEARS

The two oil pumps are controlled by a gear unit driv-

en by the clutch gear.
3 In detail, the gear 1 engages with the clutch case,
1 and 2 is the oil pump control gear.
To dismantle the gear 1, remove the circlip 3 and
thrust washers 4 (one below the gear).
4 To disassemble the gear 2, simply remove the Ben-
zing ring 5.

Gear unit for oil pump control.

1) Gear meshing with clutch gear;
2) Idler wheel
3) Oil pumps control gear;
4) Circlip;
5) Thrust washer;
6) Benzing ring

2.5.2 HIGH-PRESSURE OIL PUMP

3 The high-pressure pump, located in the external

right crankcase half, is enclosed under the cover 1
2 which can be disassembled by removing the roller 2
and the three screws 3.
After having removed the cover, extract the internal
rotor 4, the external rotor 5 and the roller 6.
1

Disassembly of high-pressure pump cover.

4
5

High-pressure pump. 4) Internal rotor; 5) External ro-

tor; 6) Roller.

36
 2.5.3 LOW-PRESSURE OIL PUMP
2
AND BY-PASS VALVE

ENGINE DISASSEMBLY
1
The low-pressure pump and the one-way valve
are located in the left
crankcase half (on the outside) inside the ignition
unit compartment.
They are enclosed under the cover 1, which is re-
moved by removing the two screws 2.

Cover and screws of low-pressure pump.

Extract the one-way valve consisting in the spring

6 3 and the ball 4.
5 Then extract the external rotor 5 and the internal
rotor 6 together with the roller 7 and the drive
4 shaft 8.

Low-pressure oil pump and by-pass valve.

Internal rotor 6, roller 7 and drive shaft 8.

37
2 2.5.4 OIL PRESSURE CONTROL
1
VALVE
ENGINE DISASSEMBLY

The pressure control valve is located in the bottom

2
of the right-hand side crankcase near the motor oil
drain plug.
The valve consists of the ball 1 and the spring 2
kept in place by the screw 3 and washer 4. To dis-
mount, simply remove the protection rivet with a
6mm drill tip.
4
3 ATTENTION: protect the mechanical parts from any
shavings.
Pressure control valve layout.

In order to disassemble the valve, remove the screw,

pull out the washer, the spring and the ball.

Rivet on pressure reg- Pressure regulator.

ulator.

2.5.5 PAPER OIL FILTER

In order to extract the paper oil filter, remove the

1 cover 1 by loosening the two screws 2 completely.
Once the cover has been removed, use a pair of
opening pliers A to extract the filter.
While extracting the cover, be careful of the specific
2 O-ring applied onto the cover.

Paper oil filter cap 1 and relative fixing screws 2.

Extraction of filter with pliers A.

38
 2.6 COUNTERSHAFT
2

ENGINE DISASSEMBLY
The countershaft has the task of balancing a part
of the inertial forces produced by the crank mech-
anism.
The countershaft is mainly made up of the shaft 1
and counterweight 2. The elastic washer 7 and nut
8 have the task of assuring coupling of the com-
plete shaft to the base.

ATTENTION: do not use the pneumatic gun.

Exploded view of countershaft.

1) Shaft;
2) Counterweight;
7) Elastic washer
8) Nut M12x1.

In order to disassemble the shaft, remove the nut

8 which can be accessed through the ignition unit
compartment. Extract the elastic washer 7 and the
counterweight.
Pull the countershaft out through the right-hand
side crankcase 1.

Extraction of countershaft.

39
2
ENGINE DISASSEMBLY

2.7 PRIMARY GEAR

The primary gear 1, located in the right crankcase

2 half, is fastened to the crankshaft. In order to dis-
assemble it, remove the nut 2 which must first be
previously heated using a blow-dryer or similar in-
1
strument.

ATTENTION!
The nut 1 must be turned clockwise to be un-
screwed.
Primary gear 1 and relative nut 2.

Extract the primary gear using the relevant extractor A.

A (code 006140150000)

Extraction of primary gear with appropriate extractor

A.

Notice that the primary gear houses the free wheel

1 device 2 inside it, which can be removed by taking
out the circlip 3.

2 3

Primary gear 1, complete with free wheel 2 and spe-

cific circlip 3.

40
 2.8 ELECTRIC IGNITION
2

ENGINE DISASSEMBLY
Electric ignition can be carried out by means of
the start motor 1 which engages on the gearwheel
4 with the function of torque limiter.
The gearwheel 4 (torque limiter) transmits mo-
tion to the idler wheel 7, which will then engage
with the starter gear 9.
EXPLODED VIEW OF ELECTRIC KICKSTART. The roller bearing 10 supports the starter wheel 9,
1) Start motor; while the free wheel 11 is internally engaged on
4) Torque limiter;
7) Idler wheel;
the starter wheel 9 and externally on the primary
9) Ignition gear; gear, thus allowing it, depending on rotation di-
10) Roller bearing HK2516; rection, to pull the crankshaft.
11) Free wheel.

7
11

9
10

41
2 1 2.8.1 ELECTRIC KICKSTART UNIT
Remove the two screws 1 which fasten the start
motor to the crankcase and pull out the start motor.
ENGINE DISASSEMBLY

Screws 1 fixing start motor to crankcase.

To extract the kick-start gear 5, disassemble the pri-

5 mary gear (see par. 2.7), the safety stops 6 and key
7. The kickstart gear is pulled out by hand.

6 6
7

Removal of pin 6.

In order to disassemble the torque limiter 8, com-

pletely loosen the screw 9 which fastens the torque
8 limiter to the crankcase. Pull out the washer 10 to-
gether with the limiter itself.

10

Torque limiter 9, screw 8 and washer 10.

In order to remove the idler wheel 11, just remove

the circlip 12 and pull out the gear.

11

12

Idler wheel 11 of electrical ignition device.

42
 2.9 PEDAL KICKSTART - OP-
TIONAL
2
1

ENGINE DISASSEMBLY
The kickstarter is made up of the pedal which, at-
tached to the kickstarter shaft 1, moves the kick-
starter gear 2. This gear moves the idler wheel 3
which then engages with the clutch case.
The device moves back thanks to the spring 4.

3
2

The pedal kickstart.

Remove the circlip 5 and pull off the external

3 thrust washer 6, the idler gear 3, the internal
thrust washer 7 and the second circlip 8. The cir-
clips and thrust washers are interchangeable.

Removal of circlip 5 of idler gear 3.

5 8

7
6

Two circlips 5 and 8 and thrust washers 6 and 7.

43
2 Using a pair of pliers, pull the end A of the spring 4
from the hole on the crankcase and bring it to a rest
position having it turn anti-clockwise.
ENGINE DISASSEMBLY

Releasing spring from crankcase.

Turn the shaft anti-clockwise and pull it off togeth-

er with the sleeve 9, the spring 10 and the thrust
washer 11.

Extraction of shaft from crankcase.

2 9
1

11
4 10

Complete manual kickstart shaft.

Note: pay attention to the reference pins for cen-

tring the inner clutch cover (par. 1.4)

44
 2.10 EXTERNAL
UNIT
GEARSHIFT
2

ENGINE DISASSEMBLY
2
The external gearshift is made up of the drive
shaft 1 upon which the movable and fixed pawls
are applied. The fixed pawl constitutes the guide
1 of the movable pawl which has the task of engag-
ing the stop cam 2. This in turn is fastened to the
internal gearshift and is kept in the fixed position
by the cam stop lever.
In order to disassemble the drive shaft, just keep
the movable pawl return spring 3 pressed and ex-
3 tract the shaft together with specific washer 4.

Crankshaft disassembly.

Gearshift with washer.

In order to disassemble the stop cam 2, keep the

cam stop lever moved 5, loosen the screw 6 and
2 pull out the stop cam.

6 5

Disassembly of stop cam.

In order to disassemble the stop lever, loosen the

7
screw 7 enough to allow the lever to move axially
9 and overcome the cylinder segment A of the des-
modromic device. Bring the return spring 8 to the
8 rest position and remove the screw, the washer 9,
the spring together with the spacer (not shown in
the image) and finally the cam stop lever.

Disassembly of cam stop lever.

45
2 2.11 CRANKSHAFT, GEARBOX
UNIT AND INTERNAL GEAR-
SHIFT
ENGINE DISASSEMBLY

To access the crankshaft, gearbox unit and internal

gearshift, the left and right crankcases must be de-
2 tached. Here are the needed instructions.

2.11.1 NUT ON LEFT SIDE OF CRANK-

SHAFT

In order to loosen the nut 1 on the left-hand side of

1 the crankshaft, heat it with a blow-dryer or similar
instrument. Then loosen the nut with a special sock-
et wrench A (code 006140020000) and remove it.
Nut B blocking crankshaft.

ATTENTION: When re-assembling, the oil seal must

be replaced 2 since the heating required for disas-
sembly damages it.

Removal of crankshaft nut with special socket wrench A.

46
 1
2.11.2 OPENING THE CRANKCASE
2
Remove the 13 locking screws 1 on the left side

ENGINE DISASSEMBLY
casing and the 4 screws 2 on the right side casing.

Screws 1 for blocking left side casing.

Screws 2 for blocking right side casing.

47
2 Loosen the two screws A which fasten the engine to
the support stand.
A
ENGINE DISASSEMBLY

Two screws A blocking engine to engine support

stand.

Hit the left crankcase half 2 gently with a rubber

or plastic hammer until it detaches from the right
crankcase half 3. Remove the two screws blocking
the engine to the equipment and disassemble the
crankcase by hand.
2

ATTENTION: The gearbox unit and the crankshaft

must remain inside the right crankcase half.

Disassembly of crankcase.

Detaching crankcase halves.

5 Remove the back 4 and front reference bushes 5 to

position the crankcase correctly. Remove the gasket
between the two half-casings.
4

The left crankcase half (inside) with references pins

4 and 5.
48
 1
2.11.3 CRANKSHAFT
2
Remove the crankshaft fixing screw.

ENGINE DISASSEMBLY
The crankshaft 1 can be pulled out by hand. Should
there be resistance, tap the right end of the crank-
shaft lightly with a plastic or rubber hammer.

Extract the forks together with the drive bushes.

2.11.4 INTERNAL GEARSHIFT UNIT

1 4
4 AND COMPLETE GEARBOX

The internal gearshift unit is made up of the des-

modromic device 1 upon which the fork 2 and two
forks 3 are engaged. The forks, supported by the
pins 4, drive the sliding wheels of the gearbox, al-
lowing engagement of the desired ratio. The des-
modromic device is controlled by the stop cam
present in the external gearshift unit (par.2.10)
Extract the two pins 4 by hand so that the forks
3
can be released and removed.
2

Removal of fork support pins 4.

Turn the fork 2 which drives the sliding gear on the

primary unit clockwise, to free it from the desmodro-
2 3 mic control.
Do the same operation, though in the opposite
direction, on the forks 3 driving the sliding gears
on the secondary shaft.
Extract the desmodromic device.

Disengaging of drive forks from the desmodromic

device.

49
2
ENGINE DISASSEMBLY
Extract the forks together with the drive bushes 5.

Extraction of forks from gearbox unit.

ATTENTION: Make sure the circlip on the secondary

shaft has been removed (par. 2.9).

Removal of the circlip.

Extract the whole gearbox unit consisting of prima-

6 ry 6 and secondary 7.
7

Extraction of complete gearbox unit: 6 primary unit,

7 Secondary unit.

50
 2.12 DISASSEMBLY OF PARTS
FROM CRANKCASES
2

ENGINE DISASSEMBLY
Once the crankcases have been detached, it is nec-
essary to remove the various components attached
to it.
The correct positioning of some bearings applied
to the crankcases is ensured by locking devices
such as plates or simple screws. In order to dis-
assembly these bearings, the safety devices must
be disassembled as well.

2.12.1 RIGHT CRANKCASE HALF

4 3
2 On the inside, the plates 1 are those which assure
6 the correct positioning of the support bearing of
the crankshaft. All you need to do is remove the
two screws 2 to disassemble them.
The plate 3 is the one relating to the mainshaft
5 support bearing of the gearbox. It can be disas-
1 sembled by removing screw 4.
8 The plate 5 holds the bearing of the secondary
shaft of the gearbox in place. It can be disassem-
7 bled by removing screw 6.
The screws 8 hold the retaining plate 7 of the
Safety devices present on the inside of the right
desmodromic device support bearing in place.
crankcase half.

On the outside the oil seal blocking plate 9 is

9 applied. It can be removed by taking off the two
screws 10.

10

2.12.1.1 Piston oil jets

It is recommended to remove the piston oil jets 1

1
and relative O-rings in order to check and clean
the lubrication circuit.
The other oil jet is located on the left casing (par.
2.12.2).

Location of piston oil jets.

51
2
ENGINE DISASSEMBLY
2.12.1.2 Extraction of countershaft
support bearing

To extract the countershaft bearing, use the extrac-

tor A (code 3625081) together with the extractor B
(code 006140160000). It is recommended to apply
the two aluminium plates to be placed between the
legs of the extractor and the crankcase half.
A

Extraction of countershaft bearing.

2.12.2 LEFT CRANKCASE HALF

Three safety plates are present on the left crankcase

half.
The plates 1 on the inside are the ones relative to
the crankshaft support bearing of the gearbox. They
can be disassembled by removing the two screws 2.

The plate 3 is the one relative to the bearing which

supports the countershaft. It can be disassembled
Inside safety plates of left half-casing crankshaft. by removing the screw 4.

For checking and cleaning part of the lubrication

circuit, it is advised to use compressed air in the
piston 5 oil jet.

4 3
5

Outside safety plate of left half-casing countershaft.

52
 2.12.2.1 Inner oil filter
2
The inner oil filter 1 must be pulled out from

ENGINE DISASSEMBLY
1 the inside of the left crankcase. Its removal can
be aided by using a soft pin to push it from the
outside towards the inside, tapping with a small
hammer.

Disassembly of inner filter.

2.12.2.2 Extraction of desmodromic

A device bearing

For the removal of the bearing dedicated to the

device on the inside left crankcase half.
Its removal entails use of the extractor A (code
3625081) together with extractor B (code
006140160000).
Removal of bearing dedicated to the device pres-
ent inside left crankcase half.

Extraction of desmodromic device bearing.

53
3 3 ENGINE ASSEMBLY AND CONTROLS
Before reassembling the eng ine, a series of im-
por tant controls must be carried out to ensure
ENGINE ASSEMBLY AND CHECKS

correct functioning of the eng ine. The bearings

must be replaced if they play or get jammed
during rotation. It is however recommended to
refer to the periodical maintenance table.
In order to inser t the bearings in the crank-
case halves, bring the crankcase halves to a
temperature of 150°C and keep them at that
temperature for 20 minutes.
Place the crankcase halves on a large sur face
where their whole seal sur face can rest. When
the bearings cool down, they drop into their
seats on their own.

54
 3.1 CRANKCASE HALF
3

ENGINE ASSEMBLY AND CHECKS

The crankcase halves have some elements
that need to have their integrity and use sta-
tus checked. Hereafter the checks and assembly
EXPLODED VIEW OF ENGINE CRANKCASE HALF
operations of the individual elements coupled
to the crankcases will be described. Clean the
1) Complete engine crankcase; threading and oil passages thoroughly using a
4) Crankcase gasket; degreaser and compressed air.
5) Back reference bush;
6) Front reference bush;
ATTENTION! It is absolutely necessary to re-
7) Bush 17x21x19;
8) Inner oil filter; place the crankshaft oil seals present on the
9) O-ring; outside of the left and right crankcase halves.
15) Piston oil jet; This is due to the extreme heating they undergo
16) O-ring; when being disassembled.
17) Lubrication jet;
18) Lubrication jet;
19) Centring pin;
20) Centring pin; In general, the crankcase halves must be re-
22) Cap; placed when:
23) Plate;
24) Screw M5x10; • the oil pump crankcases show scratches or
30) Screw M5x10;
31) Bush;
meshing signs (see their location in detail);
32) Oil incline; Copper gasket; 2.11);
37) Copper washer; • once the new bearings are inserted and the
38) Oil pressure control valve screw; crankcase half is left to cool off, they do not
39) Cable gland. fit into their seats.
44) Oil jet;
46) O-ring.

55
3 3.1.1 EXTERNAL RIGHT SIDE
Pull out the crankshaft oil seal 1 and replace it.
ENGINE ASSEMBLY AND CHECKS

Check that the oil seal fixing plate 2 is not bent. If

so, have it replaced.
Check the integrity of the oil incline 3. Should it be
worn, have it replaced.
Check the state of use of the kickstart ramp 4. It
must be replaced if it shows signs of meshing or
chipping.
The table below contains indications for fixing the
screws of the above-mentioned elements.

Screw dimensions
Threadlocker Tightening torque
Screw number Threading Threading length application [Nm]
diameter [mm] [mm]
Loctite 243/
5 M5 10 6
Sichel 100M
Loctite 243/
6 M5 10 4
Sichel 100M
Loctite 243/
7 M6 20 10
Sichel 100M

4 3 6

7 2

10Nm

4Nm
1

6Nm

Elements present on outside right crankcase half.

56
 B
The crankcase half will definitely need to be re-
placed when:
3

ENGINE ASSEMBLY AND CHECKS

• the oil pump crankcase A shows deep scratch-
es or meshing signs;
• the two pins B for the idler wheel and torque
limiter show traces of abnormal wear or
meshing.

Apply the stopping device as follows.

Keeping the tightener on the lever 25 facing to-
wards the crankcase half, apply the spacer 27
onto it, by inserting the smaller diameter seg-
ment in the lever. Apply the spring 26 so that
the hook inserts into the groove present on
the lever 25 and then apply the washer 28 and
the screw 29 M6x20 whose threading must be
spread with medium strength threadlocker.

EXPLODED VIEW OF STOPPING DEVICE

25) Lever;
26) Spring;
27) Spacer;
28) Washer 6x20x1;
29) Screw M6x20.

Apply the entire device on the crankcase half so

that the straight segment of the spring rests on
10Nm the stop C. Tighten the screw to the indicated
torque.

Stopping device coupled with the crankcase half.

57
3 3.1.1.1 INSERTION OF OIL SEAL AND
COUNTERSHAFT SUPPORT
1
ENGINE ASSEMBLY AND CHECKS

BEARING

In order to insert the oil seal and countershaft sup-

port bearing proceed as follows.
Grease the oil seal and bearing housing. Insert the
new oil seal 1 greasing the inside of it.

Application of oil seal 1.

Apply the new bearing 2 paying close attention that

2 it is aligned in its seat.

Insertion of bearing 2.

Use a press or similar instrument to push the bear-

ing until the outside surface is flush with the sur-
A face A.

Oil seal and bearing unit coupled to the left crank-

case half.

58
 3.1.2 INTERNAL RIGHT SIDE
3

ENGINE ASSEMBLY AND CHECKS

Check the flatness of the crankshaft bearing re-
taining plates 1, of the mainshaft bearing retain-
ing plate 2, of the secondary shaft bearing re-
taining plate 3, and of the desmodromic device
bearing retaining plate 4.
The table below carries the indications for appli-
cation of the fixing screws of these plates and for
fixing the desmodromic device support bearing.

Screw dimensions
Threadlocker Tightening torque
Screw number Threading Threading length application [Nm]
diameter [mm] [mm]
Loctite 243/
5 M6 12 8
Sichel 100M
Loctite 243/
6 M6 12 8
Sichel 100M
Loctite 243/
7 M6 12 8
Sichel 100M
Loctite 243/
8 M5 10 4
Sichel 100M

6Nm

6 B
3
A

2
1
7

6Nm
5
8

8Nm

4Nm
4

Elements present on inside right crankcase half.

Insert the two reference bushes A and B in their

respective housings.

59
3 Make sure the piston oil jets are positioned correctly
and free of obstructions.
Make sure that O-ring 9 is correctly positioned by
ENGINE ASSEMBLY AND CHECKS

checking its state. Should the O-rings have cracks or

deformations, they must be replaced.

Piston oil jet O-ring and detail of passage hole.

3.1.3 EXTERNAL LEFT SIDE

Make sure the calibrated screw 1 and the jet 2 are not
obstructed. Should they have been replaced, couple
them to the crankcase using a small amount of medi-
um strength threadlocker, being careful that the thread-
locker does not block the holes. Then tighten them all
the way.
Make sure that the oil passage A is cleaned well.
Make sure that the countershaft bearing retaining
plate 3 is not deformed.
If it is, replace it. The table below carries the indica-
tions for application of the screw for the plate 3.
The crankcase half will definitely have to be replaced
if the oil pump crankcase B has deep scratches or
signs of meshing.

Screw dimensions
Threadlocker Tightening torque
Screw number Threading Threading length application [Nm]
diameter [mm] [mm]
Loctite 243/
4 M6 12 8
Sichel 100M

1
8Nm
3

Elements present on outside left crankcase half.

60
 3.1.4 INTERNAL LEFT SIDE
3

ENGINE ASSEMBLY AND CHECKS

Clean the inner filter thoroughly and check the
integrity both of the wire metal and the hooking
device. Should the filter be deteriorated in any of
these parts, replace it.

Hooking device

Check the state of the two crankshaft bearing re-

taining plates 1. If they are deformed, have them
replaced.
The table below carries the indications for appli-
cation of the screws for the plates 1.
Insert the inner filter 3 in its seat A present in
the crankcase and push it all the way down until
you hear the hooking device click.
Apply the oil jet 4 after application of O-ring 5.
Apply screw 6 after application of medium re-
sistance threadlockers. Tighten at the specified
torque.

Screw dimensions
Threadlocker Tightening torque
Screw number Threading Threading length application [Nm]
diameter [mm] [mm]

2 M6 12 Medium strength 8

6 M4 10 Medium strength 6

6
4
6Nm

8Nm
A

Elements present on inside left crankcase half.

61
3 3.2 CHECKING THE CONNECT-
ING ROD AND MOTOR SHAFT
ENGINE ASSEMBLY AND CHECKS

After having checked the state of wear of the cou-

pling surfaces, check the offset of the half shaft
axes by placing the crankshaft in between two tail-
stocks or similar instrument. Control the maximum
measurement variation during a complete turn, us-
ing comparators positioned on the coupling surfac-
es with the crankshaft bearings.

Allowed limit value: 0.03 mm

Deflection/Off-centring of crankshaft.

Check the axial play between the connecting rod

head and the half shafts.

Recommended play:
0.42÷0.65mm

Connecting rod axial play.

Check the radial play of the connecting rod head

bearing by placing the crankshaft on a stable sup-
port. Then position a comparator in axis with the
connecting rod, and pressing lightly in the direction
of the crank lever axis, check that the measurement
detected does not exceed the service limit.

Maximum play: 0.04mm

If play is greater, replace the connecting rod.

Connecting rod radial play.

62
 Make sure that the chain control gear is free of
chipping or signs of abnormal wear. Replace the
3
crankshaft should it be deteriorated.

ENGINE ASSEMBLY AND CHECKS

The distance between the two opposite sides of
the half shafts must be :

64mm±0.05 (350cc, 390cc)

65mm±0.05 (430cc, 480cc)

64mm±0.05 (350cc, 390cc) B

65mm±0.05 (430cc, 480cc)

Crankshaft oil passages.

If the two half shafts are detached for replace-

C ment of the connecting rod, pay close attention
when repositioning the crank lever respect to
the half shafts. The holes for oil passage A on
the half shaft must coincide with those present
on the crank lever B.
Incorrect positioning would cause an irregular
oil flow rate thus damaging the connecting rod
head bearing.
The references C which must be aligned are
found on the half shaft on the flywheel side and
on the crank lever of the pin bolt.

Half shaft and crank lever pin bolt references C.

63
3 Use a bore meter to check the inside diameter of
the connecting rod foot which must not exceed the
following service limit:
ENGINE ASSEMBLY AND CHECKS

service limit 18.04mm (350cc, 390cc)

19.04mm (430cc, 480cc)

Remember that the measurement must be made

placing the axis of the feeler in parallel with the
axis of the connecting rod.

Bore meter verification of inside diameter

3.3 COMPLETE CRANKSHAFT
of connecting rod foot. ASSEMBLY

When all the aforementioned controls have been

carried out and the worn parts replaced, grease the
crankshaft oil seal on the right crankcase half and
couple the crankshaft to the left crankcase half. Keep
the gear present on the crankshaft towards the left.
In order to carry out this operation, you must just
push the shaft axially towards the crankcase.

Insertion of crankshaft in the right crankcase: note the position of the gear.

64
 3.4 GEARBOX UNIT: CON-
3
TROLS AND REASSEMBLY

ENGINE ASSEMBLY AND CHECKS

The gearbox unit is made up of the gearshift
and of the gearbox itself. The gearshift is then
divided into external and internal gearshift.
The following are the verifications and pro-
cedures for checking and reassembling these
units to the engine.

3.4.1 GEARBOX UNIT CHECK

Use protective jaws to clamp the mainshaft and

secondary shaft.
Use a thickness gauge to check the axial play
between the gearshift forks and the gearwheels.
The play detected must not exceed the service
limit indicated below:

service limit: 0.5mm

If the detected axial play is greater, before re-

placing either the gearwheels or the forks,
check their state of wear (par. 2.4.4).

Remove the various elements and check that:

• the support surfaces of the mainshaft and

secondary shaft are free of abnormal wear or
signs of seizure;
Check of wear of forks and gearwheels.
• the sides of the teeth are free from chipping
or abnormal wear;
• the sliding areas of the gearwheels are free
from abnormal wear or traces of seizure;
• the front claw clutches of the gearwheels are
not chipped or rounded;
• the roller bearings are intact and efficient;
• none of the thrust washers show traces of ab-
normal wear or meshing.
Should any of these defects present them-
selves, replace the concerned parts.

65
3
ENGINE ASSEMBLY AND CHECKS

3.4.2 PRIMARY UNIT ASSEMBLY

Before proceeding with reassembly, clean all the ele-

ments thoroughly and oil them with gear oil. Always
replace the circlips.
Clamp the mainshaft 1 (using protective jaws), so
that the grooved end faces downwards.
Insert onto the lower cylinder part of the shaft: the
roller cage 2, the 5th gear 3 turning the front claw
clutches upwards, the 26x32x1.5 thrust washer 4 and
the circlip 5.
Insert the III – IV sliding gear (6) so that the smaller
gear faces downwards, and then insert the circlip 5.
Insert the 23x32x1.5 thrust washer 7, the roller cage
2, the 6th gear 8 with the front claw clutch facing
downwards, the 2nd gear 9 with the cavity facing up-
EXPLODED VIEW OF PRIMARY UNIT: wards and finally the 17x30x1 thrust washer 10.

1) Mainshaft;
2) Roller cage 22x26x13;
3) Fifth on primary;
4) Thrust washer;
5) Seeger sw15;
6) Third and fourth on primary;
7) Thrust washer;
8) Sixty on primary;
9) Second on primary;
10) Thrust washer 17x30x1

66
 3.4.3 SECONDARY UNIT ASSEM-
3
BLY

ENGINE ASSEMBLY AND CHECKS

Before proceeding with reassembly, clean all
the elements thoroughly and oil them with gear
oil. Always replace the circlips.
Clamp the secondary shaft 20 (using protective
jaws), so that the grooved end faces down-
wards.

EXPLODED VIEW OF SECONDARY UNIT:

Insert onto the lower cylinder part: the roller
4) Thrust washer; cage 15, the 2nd gear 19 so that the front claw
5) Seeger sw15; clutches face downwards, the 26x32x1.5 thrust
7) Thrust washer; washer 4 and the circlip 5.
10) Thrust washer 17x30x1;
11) First on secondary;
Insert the 6th gear 18 so that the fork seat faces
12) Roller cage 20x24x10; upwards and the circlip 5.
13) Thrust washer 20x30x1; Insert the 23x32x1.5 thrust washer 7, the two
14) Fifth on secondary; roller cages 15, the 4th gear 17 with the front
15) Roller cage; claw clutches facing upwards, the 3rd gear 16
16) Third on secondary;
with the front claw clutches facing downwards,
17) Fourth on secondary;
18) Sixty on secondary; the 23x32x1.5 thrust washer 7 and the circlip 5.
19) Second on secondary; Insert the 5th gear (14) with the fork seat facing
20) Secondary shaft downwards, the thrust washer 13 (20x30x1),
the roller cage 12, the 1st gear (11) with the
front claw clutches facing upwards and finally
the thrust washer 10 (17x30x1)

67
3 3.4.4 CHECKING THE FORKS,
FORK PINS AND DESMO-
ENGINE ASSEMBLY AND CHECKS

DROMIC DEVICE

The internal gearshift is made up of:

• two forks 13 which drive two gears on the sec-
ondary unit;
• one fork 14 which drives one gear on the primary
unit;
• three drive pin bushes 15;
• two fork pins 16;
• desmodromic gearshift 18 through whose rota-
tion the forks are driven thus selecting the desired
gear.

EXPLODED VIEW OF INTERNAL GEARBOX CONTROL Check to make sure that the drive pins which sup-
UNIT: port the bushes 15 have no traces of meshing or
13) I - IV fork;
abnormal wear and that the bushes themselves are
14) V - VI fork;
15) bush; not worn.
16) fork pin;
18) desmodromic control

68
 Make sure the distance A between the outer faces
of the fork is not less than that indicated below:
3
A

ENGINE ASSEMBLY AND CHECKS

Minimum acceptable distance: 4.25mm

Check to make sure that the inside diameter D of

the fork pin seats is below the limit:

Fork inside diameter limit: 13.83mm

Make sure that the fork pins upon which they

slide have an outside diameter above the limit
(to be measured in the sliding areas of the forks
and in the housing areas of the crankcases):

Fork pin outside diameter limit: 13.75mm

Make sure that the desmodromic control device

has no corroded or worn areas especially in the
grooves in which the drive pins of the forks are
engaged.

ID

Drive pin

69
3 2 3 4
3.5 GEARBOX AND INTERNAL
GEARSHIFT ASSEMBLY
ENGINE ASSEMBLY AND CHECKS

Insert the entire primary 1 and secondary unit 2

1 into the respective seats on the left crankcase half
simultaneously. Remember to oil the gears abundant-
ly with gear oil and to grease the shafts supporting
them in the areas where they are coupled with the
bearing with graphitic grease. Make sure that all the
parts slide properly.

Insertion of gearbox in left crankcase.

Insert the centre bearing 3 and the O-ring 4 on the

secondary unit.

Detail of centre bearing 3 and O-ring 4 coupled to

the secondary shaft.

70
 Introduce the forks together with the drive
bushes on the gear tracks. To be precise; the
3
smaller fork 5 drives the sliding gear on the

ENGINE ASSEMBLY AND CHECKS

primary unit, while the other two (6) drive the
5 sliding gears on the secondary unit.
6
Note: the two forks 6 are interchangeable and
their positioning is univocal, since the drive pin
must face the desmodromic device. Place the
forks in their original positions if none of the
components are replaced.
6

Application of forks to gearwheels.

Insert the desmodromic device in the specific

bearing. In order to do this, it is necessary to
rotate cam stop lever 7 towards the bottom part
of the engine.
7

Insertion of desmodromic deice in specific bearing.

Note the rotation of the stop lever.

Position the fork 5 of the primary unit in the

central guide of the desmodromic device 8, in-
sert the fork pin inside the fork itself and insert
5 the pin in its proper seat in the crankcase half.
8

Place fork 5 of the primary unit in the central guide

of desmodromic device 8.

71
3 Position the two forks 6 of the secondary unit in the
external guides of the desmodromic device 8 and,
8 6 just like the primary unit fork, insert the fork pin first
ENGINE ASSEMBLY AND CHECKS

in the pins and then in its proper seat.

Remember to oil the shafts, forks and the desmodro-
mic device abundantly with gear oil.

Positioning of the secondary unit forks 6. In the

external guides of desmodromic device 8.

Position the new crankcase gasket.

View inside the right crankcase with crankshaft, oil jets, gearbox shafts complete with gearwheels, internal gearshift
and gasket.

72
 3.6 CLOSING THE ENGINE
3
CRANKCASE

ENGINE ASSEMBLY AND CHECKS

Press the right crankcase half towards the left,
being careful that the shafts and pins on the
crankcase fit into the respective housings and
that the crankcase half is not upside-down. To
facilitate progressive nearing and aligning of the
two crankcase halves, connect two screws on
opposite sides and tighten them bit by bit. If the
crankcase halves tend to capsize, do not insist
tightening them. Rather loosen the screws and
reposition the crankcase correctly.

Make sure that the two crankcase halves match

perfectly one with the other. Assemble the
screws according to their length as indicated in
the figure.
The table below contains indications for apply-
ing these screws.
It is recommended to tighten them in a criss-
cross pattern using a torque of 10Nm.

Apply the two screws for fixing the engine to the

engine support (code 3625132 000)

Positioning of screws to couple crankcase.

Screw dimensions
Threadlocker Tightening torque
Screw number Threading Threading length application [Nm]
diameter [mm] [mm]
40 M6 30 NO 10
41 M6 60 NO 10
42 M6 70 NO 10

Cut the extra piece of gasket in between the

two crankcase halves in the area of the cylinder.
This can be done easily by bending the gasket
several times.

Cutting extra piece of gasket between engine crank-

case halves.

73
3 3.7 BLOCKING THE CRANK-
SHAFT AT THE TOP DEAD
ENGINE ASSEMBLY AND CHECKS

CENTRE AND TIGHTENING

THE NUT ON THE LEFT SIDE
OF THE CRANKSHAFT

To block the crankshaft in the Top Dead Centre, in-

sert the special conical-end screw 38, without ap-
plying the washer 37 or the special engine locking
To block the crankshaft, apply only the screw 38 to tool code 006140110000, in its seat on the right
the crankcase.
crankcase half. Spread the threading on the left-
hand side of the crankshaft with medium strength
threadlocker.

Cover the threading on the left-hand side of the

crankshaft with medium strength threadlocker.
150Nm
Tighten the nut using the special socket wrench A
(code 006140020000) to the indicated torque.

Nut on left side of crankshaft.

74
 3.8 EXTERNAL GEARSHIFT
3

ENGINE ASSEMBLY AND CHECKS

Before reassembling the external gearshift,
check its state of use. While for the stop cam
it is enough to make sure it's free from abnor-
mal wear or meshing, the gearshift drive shaft
needs more in-depth inspections.

3.8.1 CHECKING THE COM-

PLETE DRIVE SHAFT

0.35÷0.80 With the device complete, make sure that the

distance between the movable pawl and the
drive shaft is between 0.35÷0.80mm.
Should the distance be greater, replace the
movable pawl.

Allowed distance between shaft and pawl.

In order to replace the movable pawl 1, dis-

2 1 4 assemble the return spring of the gearshift 2,
the spring guide 3, the spring 4 (which must be
compressed and pulled out of its seat) and the
pawl, moving it completely towards the shaft 5.

3 5

Complete drive shaft: 1) Movable pawl; 2) Gearshift

return spring; 3) Spring guide; 4) Spring; 5) Gearshift
drive shaft.

75
3
ENGINE ASSEMBLY AND CHECKS

Exploded view of gearshift.

5) Thrust washer 14x30x1; For reassembly, couple the movable pawl 9 to the
6) Gearshift return spring;
drive shaft 10 and, while compressing it, insert
7) Spring guide;
8) Pawl return spring; the spring 8 between the movable pawl and the
9) Movable pawl; drive shaft. The apply the spring guide 7, the gear-
10) Gearshift shaft. shift return spring 6 and finally the 14x30x1 thrust
washer 5.

The gearshift return spring must be positioned as

in the figure to be able to carry out its function.

Gearshift drive shaft: note the gearshift return spring

position.

76
 3.8.2 EXTERNAL GEARSHIFT
3
ASSEMBLY

ENGINE ASSEMBLY AND CHECKS

Keeping the stop lever moved 1 in such a way
that the spring is compressed, position the stop
cam 2 on the protruding end of the desmodro-
mic gearshift (external right crankcase). The
stop cam has only one correct position which is
determined by the particular shape of the end
of the desmodromic device and of the bottom
part of the stop cam.
Proceed mounting the tightening screw 3
M6x30 between the stop cam and the desmo-
dromic gearshift, after having applied medi-
um-resistance sealant: fasten to the indicated
torque.
Insert the drive shaft together with the washer
10Nm
in its seat keeping the return spring 4 of the
movable pawl pressed.
3
Wishing to test the correct functioning of the
entire unit, you just need to temporarily couple
the external gearshift lever and to simulate the
operation of changing gears, by lifting and low-
ering the gearshift lever and having the main-
shaft of the gear unit rotate. The whole device
4 2 1 works properly if abnormal jamming does not
occur.
POSITIONING OF STOP CAM ON DESMODROMIC DE- If the unit runs without oil, the device makes
VICE more noise than usual.

1) Stop lever;
2) Stop cam;
3) Screw M6x30;
4) Movable pawl return spring.

3.9 KICKSTARTER DEVICE -

(OPTIONAL)

Before coupling the kickstarter to the crankcase

half, some controls must be carried out.

3.9.1 CHECKING THE KICK-

START SHAFT UNIT AND
ASSEMBLY

In order to disassemble all the parts of the kick-

start shaft, pull off the washer 11 at the end
of the shaft (on the side of the spring 16), the
spring 16, the kickstart sleeve 14 and the lever
return spring 8, which must be pulled in the
radial direction so that it is extracted from its
hole to be unfastened from the shaft. Pull out
the kickstart spacer 9.

77
3
ENGINE ASSEMBLY AND CHECKS

EXPLODED VIEW OF COMPLETE KICKSTART SHAFT:

2) Kickstart gear; Widen the circlip 10, thus slipping off the washer
3) Kickstart shaft;
11, and the kickstart gear 2 as well the roller bear-
8) Kickstart return spring;
9) Kickstart spacer; ing 12 and the washer 11. This frees the kickstart
10) Circlip 20E; shaft 3 from all other elements.
11) Washer thickness 20x28x1 DIN 988; Make sure that the side of the kickstart gear teeth
12) Roller bearing K20x24x10; 2 have no signs of meshing or superficial wear.
14) Kickstart sleeve;
Make sure that the front teeth (sleeve side 14)
16) Spring.
are not chipped. Replace any element that has the
aforementioned defects.
Make sure that the front teeth of the sleeve 14 are
not chipped and that the spring 16 is capable of
putting enough pressure on the sleeve 14 so that
14 this can pull the wheel 2.
Also check to make sure that the washers have no
abnormal or excessive wear. If so, have them re-
placed. Make sure that the spring 8 has no cracks
or abnormal deformation. Have it replaced if it is
not able to bring the external kickstart lever back
to the rest position.
For reassembly, proceed inversely compared to
the previously-described disassembly procedures.
Pay attention to the correct positioning of the
sleeve 14 with respect to the shaft 3. The front of
the shaft has a reference sign, just as the sleeve
does 14: the two references must match.

Positioning of sleeve on small shaft.

78
 3.9.2 ASSEMBLY OF KICKSTART-
3
ER DEVICE

ENGINE ASSEMBLY AND CHECKS

Insert the complete kickstart shaft in its housing
keeping the thin-striped facing outwards and
making sure that the ramp A on the kickstart
A sleeve is positioned below the ramp B bolted
B onto the right crankcase half (external side).

Positioning of sleeve A below ramp B.

Turn the spring clockwise until it fits into the

specific hole C.

Insertion of kickstart return spring.

Insert in the slot on the protruding segment of

the secondary shaft: the circlip 18, the washer
17, the idler wheel 4 followed by the washer 17
and the circlip 18 as shown in the figure.

Engine side

Kickstart device unit coupled to the crankcase.

79
3 1
3.10 ELECTRICAL STARTER UNIT
AND PRIMARY GEAR
ENGINE ASSEMBLY AND CHECKS

Carry out the following checks before assembly.

3.10.1 CHECKING ELECTRICAL

STARTER DEVICE ELEMENTS

Make sure that the teeth of all the gearwheels of

the device are intact, free from chipping or signs
or abnormal wear.
Idler wheel 1. Pay attention to the teeth of the idler wheels 1
and torque limiter 2 and between the gears and
respective support pins. Replace them if they
2 show signs of meshing or seizure.

Make sure there are no traces of meshing on the

housing of the roller bearing on the starter gear 3.
Mount the starter gear temporarily on the crank-
shaft, together with the roller bearing and check
to see if there is excessive play.
To check the correct functioning of the free wheel
4 proceed as follows.
Insert the starter gear 3 on the free wheel 4 and
primary gear unit 5. Keeping the primary gear
Torque limiter 2. blocked 5 and turning the kickstart gear 3 clock-
wise, it must run freely. Turning the kickstart gear 3
anti-clockwise, it must be blocked without idling.
5

To replace the free wheel, disassemble the special

circlip A and remove the free wheel.
During disassembly make sure that the lugs on
the outer edge of the special circlip A are coupled
in the slots of the free wheel and in the groove
inside the primary gear.

4 A
Free wheel coupled to the primary gear.

Primary gear complete with free wheel coupled to

ignition gear.

80
 A
3.10.2 COUPLING IGNITION AND
3
PRIMARY GEARS TO THE

ENGINE ASSEMBLY AND CHECKS

MOTOR

Thoroughly degrease the conical part A on the

right side of the crankshaft and B of the primary
gear.

Conical segment A on right side of crankshaft.

Conical segment B main gear.

Lubricate the segment C of the starter gear 1
2 with motor oil and couple it to the crankshaft.
Insert the Woodruff key 2 in the specific seat.

Positioning Woodruff key in specific seat.

Apply the primary gear 3 to the crankshaft

and while turning the gear clockwise, push it
3 towards the crankcase half until you perceive
meshing between the gear and the Woodruff
E key.
F
Insert the locking nut D applying the threading
150Nm with a medium strength threadlocker and tight-
ANTICLOCKWISE
en to the indicated torque.

Attention:
D it must be tightened anti-clockwise.
4Nm
Apply the two safety plates E bound to the cas-
Coupling primary gear to crankshaft.
ing with screws F. Tighten to 4Nm.

81
3 4
Couple the idler wheel 7 to the pin and apply the
circlip 8.
Couple the torque limiter 4 to the pin turning the
ENGINE ASSEMBLY AND CHECKS

10Nm
5 gearwheel with the smaller diameter towards the
crankcase half. Insert the washer 5 and the screw
7 6 after having spread the threading with medium
strength threadlocker.
6 8 Tighten the screw to the indicated torque.

Coupling electrical starter gear unit.

Apply a light layer of grease in the area G of the

start motor and insert the motor in its housing.

G
Insertion of the start motor in the crankcase half.
Note zone F to be greased.

Apply medium strength threadlocker on the two

screws 9 and tighten them to the indicated torque.

10Nm

The two fixing screws 9 of the start motor.

82
 3.11 OIL PUMPS: INSPECTION
3
AND REASSEMBLY

ENGINE ASSEMBLY AND CHECKS

As shown in paragraph 1.5, the motor is
equipped with two oil pumps: one is for in-
take (higher displacement) located in the out-
side of the left crankcase half and the other for
high-pressure (less displacement) located on
the outside of the right crankcase half. The two
pumps are driven by a gear cascade meshing
with the clutch case.

EXPLODED VIEW OF OIL PUMP UNIT.

1) Benzing ring; Proper operation of the pump depends:
2) Oil pump gear;
3) Screw M5x10;
4) Circlip JS24; • On the sliding surface with the rotors;
5) Oil seal; • On the radial play between the two rotors
6) High-pressure pump cover; and between the external rotor and the
7) High-pressure (or delivery) oil pump; crankcase;
8) Roller; • On the axial play of the rotors respect to the
9) Pump drive shaft;
10) Low-pressure (or intake) oil pump; 11) Ball; sliding surfaces;
12) Spring; • On the O-ring seal and the oil seal (on the
13) Low-pressure pump cover; high-pressure pump cover).
14) Circlip A13;
15) Thrust washer 13x19x0.5;
16) Oil pump idler gear;
17) Screw M5x20;
19) Pin;
20) O-ring
21) Lubrication plate;
22) Flanged bolt M5x12.

83
3 Should the sliding surfaces with the rotors pres-
ent deep or evident traces of corrosion, replace
the deteriorated part.
ENGINE ASSEMBLY AND CHECKS

To measure the radial play between the internal

and external rotor and between the external rotor
and the crankcase, proceed as follows:
Insert the two rotors in their specific seat with the
reference dot facing the inside of the engine.

Using a thickness gauge, check that the play does

not exceed that allowed, equal to:
Maximum radial play: 0.20mm

Take a thickness gauge again and a rectified ref-

erence surface and verify that the axial play does
not exceed the maximum allowed amount:
Maximum axial play: 0.1mm
Should play be greater, replace the rotors.
Oil intake pump: note the dot on the two rotors. The
dot must face the inside of the engine.

Evaluation of radial play Evaluation of radial play between Evaluation of axial play between rotors
between internal and external external rotor and crankcase. and sliding surfaces.
rotor.

As to the high-pressure pump (located in the out-

side right crankcase half), one must check that the
oil seal 5 is not worn (it is recommended to re-
place it). In order to disassembly it, the circlip 4
must be removed. Check the state of use of the
O-ring 20 and replace it if needed.

Exploded view of high-pressure pump cover. 4)

Circlip JS24; 5) Oil seal 10x22.6; 6) Oil pump cover;
20) O-ring 45x2.

Also check that the drive shaft is not too marked

in the area A where the oil seal slides.

Checking oil pump control shaft.

84
 1
3.11.1 INTAKE PUMP ASSEMBLY
3

ENGINE ASSEMBLY AND CHECKS

Insert the internal rotor 1 on the shaft 2 so that
the dot on the front of the rotor faces inwards.
Then insert the roller 3 on the shaft.

Shaft intake pump internal rotor and roller unit.

Use motor oil to lubricate the seat of the rotors

on the outside of the crankcase half, insert the
5 4 external rotor 4 and the internal shaft-rotor unit
in its proper seat.
Insert the ball 5 (diameter 5.5mm) and the re-
spective compression spring 6.
Lubricate with motor oil and, while rotating the
protruding segment of the drive shaft (from the
6 outside of the right crankcase half), make sure
it rotates freely and does not jam.

Complete intake pump coupled to the crankcase.

Fasten the cover 7 to the crankcase with the

three screws 8, which must first be spread with
medium strength threadlocker. These screws
must be tightened to the indicated torque.
7

8
4Nm

Coupling the oil intake pump cover to the crank-

case.

85
3 3.11.2 HIGH-PRESSURE PUMP
AND CONTROL GEAR AS-
2
ENGINE ASSEMBLY AND CHECKS

1 SEMBLY

Lubricate the area where the pump is housed

(outside right crankcase half), and insert the roll-
er in its hole 1. Then insert the internal rotor 2
and the external rotor 3, making sure to position
them with the reference dot facing the inside of
the engine.
Lubricate the pump body with motor oil.

Coupling the high-pressure pump rotors to the

control shaft. Grease the oil seal, insert the cover in the end of
the shaft and press towards the crankcase. Insert
the three screws 4 after having applied them with
spread medium strength threadlocker. Tighten
them to the indicated torque.
Turn the shaft holding on to the protruding end
and make sure it rotates freely without getting
jammed.

4Nm

Coupling high-pressure pump cover to crankcase.

86
 3.11.3 CHECKING AND ASSEM-
BLING THE PRESSURE
3
CONTROL VALVE

ENGINE ASSEMBLY AND CHECKS

The pressure control valve is made up of a ball
43, spring 42, calibrated washer 41 and screw
40.
Check the length of the free spring on this com-
ponent:
Service limit: 29.5mm

Tighten the screw to the indicated torque.

20Nm
Attention: if one of these elements making up
the control valve is not inserted, engine func-
tioning will be jeopardised.
PRESSURE CONTROL VALVE.
40) Screw;
41) Thrust washer; Attention: always restore the original thick-
42) Spring; ness value of the washer 41. If this must be re-
43) Ball. placed, replace it with one of the same original
thickness.

Attention: once valve assembly is complete,

apply a 6 mm diameter x 8 mm length alumin-
ium rivet A in the hexagonal slot. This device
prevents accidental dismounting of the pres-
sure regulation valve.

87
3 3.11.4 CHECKING AND ASSEM-
BLING THE OIL PUMP CON-
ENGINE ASSEMBLY AND CHECKS

6Nm
TROL GEARS

The oil pumps are controlled by a gear cascade

driven by the clutch case.
The gearwheels, being made of plastic, must not
have chips, grains or signs of abnormal wear.

2 If pump control idler wheel support pin 1 is dis-

4 mantled, reconnect it to the crankcase half. The pin
is fastened to the crankcase half with screw 2 (af-
ter application of medium strength threadlockers)
1 and locked at the indicated torque.
Couple the thrust washer 4 to the pin and lubricate
it with gear oil.
Oil pumps control gearwheels support pins.

Couple the pump control idler wheel 5 to the pin

so that the most protruding segment faces the cas-
ing.
Then insert the thrust washers 6 and circlips to pre-
5 vent the wheels from coming off the pins.
Insert the roller 7 at the end of the pump control
6 shaft.

Coupling pump control gearwheels to crankcase.

Couple the oil pump control wheel 8 to the end of

the shaft so that the groove on the gear inserts into
the roller. Then apply the benzing ring 9, so that
the gear does not slip off.

Coupling pump control wheel.

88
 3.11.5 PAPER OIL FILTER INSER-
3
TION

ENGINE ASSEMBLY AND CHECKS

Lubricate the rubber gasket on the filter. Insert
the filter 1 into its housing and push it towards
1 the inside of the engine as far as it can go.

Oil pumps control gearwheels support pins.

Insert the O-ring 2 onto the oil filter cover 3

and apply the unit to the crankcase half.
2

Paper oil filter cover complete with O-ring.

Apply the two screws 4 M6x16 to be tightened

to the indicated torque.

10Nm

The two paper oil filter cover fastening screws.

89
3 3.11.6 CHECKING AND COUPLING
THE COUNTERSHAFT
ENGINE ASSEMBLY AND CHECKS

Check the state of use of the areas where the shaft

rests on the bearing. Should they show signs of ab-
normal wear, have the shaft replaced. Make sure
EXPLODED VIEW OF COUNTERSHAFT that the toothed segment of the shaft does not have
1) Shaft; traces of abnormal wear.
2) Counterweight;
7) Elastic washer
8) Nut M12x1

Grease the oil seal and insert the countershaft in

its seat. Position it so that the reference sign on
the shaft is between the two reference signs on the
primary gear.

Coupling countershaft to crankcase.

Enlargement of references.

90
 While keeping the countershaft in place, insert
the counterweight on the left side depending
3
on the position set by the grooved shaft.

ENGINE ASSEMBLY AND CHECKS

Coupling counterweight to countershaft.

Detail of grooved profiles for coupling.

Then couple the elastic washer and the nut 1

after having applied medium strength thread-
50Nm locker on their threading. The nut must be tight-
ened to the indicated torque.

Countershaft nut.

91
3
ENGINE ASSEMBLY AND CHECKS

3.12 CLUTCH UNIT

Before reassembling the clutch unit, carry out some

checks on the various components described be-
low.

3.12.1 CHECKING THE CLUTCH

CASE, ROLLER BEARING AND
INTERNAL CENTRE BEARING

Before reassembling the clutch case, make sure

A that the sides of the teeth A, dedicated to main
transmission and B dedicated to meshing with the
kickstart idler gear and oil pumps, have no superfi-
cial nicks or abnormal wear.

1 2
Check the state of use of the internal centre bearing
1 which must have no traces of meshing or abnor-
mal wear. Check the state of use of the roller bear-
ing 2. If it is worn, have it replaced.

92
 3.12.2 CHECK OF CLUTCH DISCS
3

ENGINE ASSEMBLY AND CHECKS

The clutch discs are divided into driving and
INC
ORIGIN
driven: eight driving discs and seven driven
discs.
0 10 20 30 100 110 120
mm

The driving discs have cork inserts on both

ON / OFF ZERO / ABS

sides which wear out due to the driven discs

sliding on them. It is necessary to check that
the thickness of the clutch pack (driven and
driving discs) is not lower than a minimum set
value equal to:
minimum thickness of complete disc pack:
31.6mm

The other value that needs to be checked is

the thickness of the teeth of each driving disc.
They must not be less than the minimum value
fixed at:
minimum driving disc tooth thickness:
13.3mm

Also check the distortion of the driving discs.

This operation is done by placing the driving
discs on a perfectly flat surface and using a
thickness gauge to check that the gap between
the disc and the surface is not greater than:
allowable distortion of driven discs: 0.10mm

93
3
ENGINE ASSEMBLY AND CHECKS

3.12.3 CHECKING THE SPRINGS

ORIGIN
To ensure the correct pressure between the clutch
INC
discs, the state of the springs must be checked.
0 10 20 30 40
mm The minimum acceptable length must be:
ON / OFF ZERO / ABS

minimum clutch spring length:

45mm

3.12.4 CLUTCH DRUM AND CAP

CHECK

The clutch drum engages with the driven clutch

discs by means of the sliding pins a: make sure that
the area shown in the figure is free from meshing
or abnormal wear. If so, replace the sliding pins.

Check that the disc friction area is free from

scratches, meshing or abnormal wear. If so, re-
place the clutch drum
Also control that the radial holes present on the
clutch drum are not obstructed and are free from
sediments.

94
 3.12.5 CHECKING THE THRUST
3
BEARING DEVICE

ENGINE ASSEMBLY AND CHECKS

Check the state of use of the thrust bearing and
the surfaces upon which it rests.
In order to check the thrusting bearing, just see
if it slides. When the device is assembled, sim-
ulate rotation of the front centre bearing A with
respect to the rear one B.
B A Pay attention to the presence of traces of mesh-
ing or wear on the sliding surfaces. In the event
of signs of deterioration replace the entire unit.
Thrust bearing device.

3.12.6 CLUTCH UNIT ASSEMBLY

Lubricate the end of the primary gearbox shaft,

the internal centre bearing 4 and the roller
bearing 5. Fit the roller bearing 5 and the cen-
tre bearing 4 on the clutch case 1. Mount the
unit on the primary shaft; in order to facilitate
insertion of the clutch case, slightly turn the
kickstart idler gear (optional), the idler gear for
oil pump control and the case itself, thus facili-
tating meshing. Mount the washer 6, which the
clutch drum 2 rests against. Fit the sliding pins
35 on the drum. Fit the safety washer 7 and
after having applied medium strength thread-
locker, couple the lock nut 8.

EXPLODED VIEW OF CLUTCH UNIT.

1) Complete case; 2) Clutch drum; 3) Clutch cap; 4) Internal centre bearing; 5) Roller bearing 26x30x22; 6) Washer;
7) Safety washer; 8) Nut M18x1.5; 9) Overall thrust bearing; 10) Clutch body rod coupling; 11) Thrust bearing; 12)
Circlip RB14; 13) Clutch spring; 14) Clutch spring retainer; 15) Screw TCCE 6.20; 16) Driven discs; 17) Driving discs –
GREEN edge; 18) Driving disc – BLUE edge; 35) Guide pin; 36) Thrust bearing washer.

95
3 To unscrew the nut 8 the clutch drum must
be blocked with a relevant tool A (code
8 A 029.14.002.50.00). Tighten at the specified torque.
ENGINE ASSEMBLY AND CHECKS

120Nm

Having tightened the nut, bend the two blocking

flaps on the safety plate.

Lubricate the clutch discs with gear oil and apply

the driving disc with BLUE edge and a driven disc.
Then alternate the driving discs with GREEN edge
and the driven discs.
The other driving disc with BLUE edge will close
the disc pack.

Notice that the driven discs must be inserted so

that the radius on the teeth faces inwards towards
the engine.

Insert the overall thrust bearing 9 (after having lu-

bricated it with transmission oil) in the hole on the
gearbox mainshaft and check its free axial sliding.

96
 Close the clutch unit with the clutch cap 3,
the springs 13, the spring retainers 14 and the
3
screws 15.

ENGINE ASSEMBLY AND CHECKS

Tighten the screws to the indicated torque.
10Nm

97
3 Insert the clutch rod in the seat B from the left side
of the engine, turning the smaller section towards
the inside of the engine.
ENGINE ASSEMBLY AND CHECKS

Insertion of clutch rod in housing B.

If only the clutch actuator pipe was removed during

10Nm
the disassembly of the engine from the vehicle, op-
7 erating on the actuator as well, proceed as follows.
Apply the gasket 5, the complete hydraulic actuator
6 the M6x30 screw 7 and the two M6x20 screws 8
to the left crankcase half. Tighten the three screws
to the indicated torque.

Application of the gasket 5, actuator 6, screw 7

M6x30 and two screws 8 M6x20.

98
 3.13 COOLANT PUMP
3

ENGINE ASSEMBLY AND CHECKS

The water pump must guarantee, depending
EXPLODED VIEW OF WATER PUMP on the set rotation speed, the correct flow rate
1) Drive shaft of the coolant in order to extract the needed
2) O-ring 5.5x1; amount of heat from the thermal unit.
3) Bearing 10x19x5; The shaft 1 is supported by two bearings 3 and
4) Oil seal 12x30x7;
5) Bush 8x12x10;
sealing of coolant and gear oil is ensured by the
6) Impeller; O-ring 2 and oil seal 4.
7) Washer; The impeller 6 is fastened to the shaft 1 and the
8) Blind nut M6x1; coupling is ensured by tightening the nut 8 onto
9) Gasket; the shaft 1.
10) Gasket cover;
11) Washer;
12) Screw M6x40.

3.13.1 CHECKING PUMP UNIT

AND DISASSEMBLY

Disassembly of the entire pump unit can be

done only with the entire clutch cover removed.
Disassembly of the pump unit is performed by
removing the nut 8 which allows you to extract
the impeller 6, the washer 7, and the shaft 1.
This can be removed by pressing the threaded
part of shaft towards the inside of the clutch
cover.
Extract the oil seal 4 and, heating the bearings
3, remove them.
Once the shaft is pulled off 1 from the crank-
Complete internal clutch cove of water pump. case, it is recommended to replace the O-ring 2.
Replace the oil seal 4 every time and if the bush
5 is marked in the area of contact with the oil
seal, replace it as well.

99
3
ENGINE ASSEMBLY AND CHECKS

3.13.2 PUMP UNIT ASSEMBLY

Heat the concerned area to couple the bearings 3

to the inner clutch cover. They must be pushed un-
til they are flush with the shoulders on the pump
body.
Thicker edge
Grease the oil seal housing. Position the oil seal
4 so that the thicker edge faces the outside of the
cover. Insert the oil seal in the inner clutch cover,
having it enter the seat very slowly to keep it from
deteriorating.

Application of oil seal on inner clutch cover.

Couple the shaft 1 with the O-ring 2 to the inner

clutch cover and then insert the bush 5, the washer
7 and the impeller 6.
6Nm
Then couple the blind nut 8 to the threaded seg-
ment of the shaft after having applied medium
strength threadlocker. Tighten it to the indicated
torque.

Complete coolant pump unit.

When coupling is complete, check that the pump

unit turns freely without meshing or friction.
Check the axial play of the pump unit. Make sure it is
not beyond 0.3 mm.
It is recommended to replace the gasket in between
the inner clutch cover and the pump cover.

100
 3.14 ASSEMBLY OF COMPLETE
3
CLUTCH COVER

ENGINE ASSEMBLY AND CHECKS

Apply a new gasket 1 placed between the right
crankcase half and the inner clutch cover using
the two reference pins 2 to keep it in place.

2
1

Positioning of gasket 1 and centring pins 2.

Couple the inner clutch cover to the right crank-

case half and turn the water pump impeller un-
til the pump shaft inserts perfectly in the hous-
ing on the countershaft which drives it.

Application of complete inner clutch cover on right

crankcase.

Apply the nine M6x25 screws as shown in the

figure, tightening them by hand until they are
flush.

Positioning of M6x25 screws.

101
3 10Nm
Couple the water pump cover to the inner clutch
cover applying the M6x40 screws, making sure to
apply the copper washer 3 to the lower screw of
ENGINE ASSEMBLY AND CHECKS

the pump cover.

Fasten all thirteen screws at the indicated torque
following a criss-cross pattern.

Coolant pump cover: pay attention to the washer 3.

If only the outer clutch cover was removed, put it

back on the inner cover and fasten the 4 and tight-
en to the indicated torque.

10Nm

The screws 4 that fasten the outer clutch cover to the

internal cover.

102
 3.15 CHECKING AND COUPLING
3
2 OF TIMING CHAIN, FIXED
1

ENGINE ASSEMBLY AND CHECKS

AND MOBILE PADS

The chain has the task of transmitting motion

from the crankshaft to the camshafts present on
the cylinder head. The links must be checked to
A make sure there is no excessive radial or axial
play between them.
The fixed and movable guides guarantee a cor-
rect movement of the chain. The hydraulic chain
tensioner ensures correct tensioning.
Make sure that the guides do not have deep
traces caused by the rotation of the chain.
In order to assemble the chain to the engine,
just introduce it in the vertical passage compart-
ment A on the left crankcase and insert it in the
gear on the crankshaft.
Insert the fixed pad 1 and the movable pad 2
inside the compartment A. Insert the specif-
ic 6.2x9x9 bushes inside the lower eyelets of
10Nm 3 the pads. After having applied medium strength
threadlocker, tighten the relative screws 3 to the
indicated torque.

Timing chain with relative fixed and movable pads.

Mounting bushes in lower eyelets of pads.

3.16 IGNITION SYSTEM

Before reassembling the ignition system, it is

recommended to check its correct functioning.
The ignition system is made up of the magnetic
pick-up, the stator unit and the flywheel. The
system is completed by the electronic control
unit, the ignition coil and the spark plug, which
are not dealt with in this text.

103
3 3.16.1 IGNITION SYSTEM
CHECK
ENGINE ASSEMBLY AND CHECKS

Accurately degrease the various elements and carry

on with the checks.
The main check is the one concerning the electrical
verification which can be done by using a standard
tester. The resistance values detected at the termi-
nal heads must respect those carried in the table
(at 20°C).

Element Cables Strength values

Pick up Red – Green 100Ω ± 20%
Stator Black - Black 0,46Ω ±20%

3.16.2 COUPLING OF IGNITION

SYSTEM TO CRANKCASE

Set the pick-up on the crankcase so that the two

holes on its support coincide with the two outer
1 holes on the crankcase.
Cover the threading of the two screws 1 with me-
dium strength threadlocker and tighten them to
the indicated torque.
2 Lay the cable on the crankcase half, apply the
groove of the cable gland 2 with gasket paste
(code 3625000000) and insert it in the spe-
6Nm
cific housing n the crankcase, removing excess
paste.

Couple the chain guard to the crankcase half,

insert the two 6.2x9x9 bushes in the lower eye-
Coupling of pick up to crankcase. lets and couple the two screws 32 after having
applied them with medium strength threadlock-
er. Then tighten them to the indicated torque

Attention: pay close attention so that the ca-

bles are well fastened to the wall of the crank-
case halves near the cable gland.
3

Apply the oil jet 3 and the respective screw 4

that must be previously covered with medium
strength threadlocker and then tightened to the
indicated torque

4
10Nm 6Nm

32
Coupling chain guard to crankcase.
Mounting bushes in lower eyelets of chain guard.

104
 Thoroughly degrease the crankshaft conical sec-
tion, apply the Woodruff key 21 in the appro-
3
priate groove present on the crankshaft, couple

ENGINE ASSEMBLY AND CHECKS

the flywheel 18, the elastic washer 19 and the
nut 20, after having spread the threading with
medium strength threadlocker. Tighten the nut
to the indicated torque.

60Nm

Exploded view of flywheel. 18) Flywheel; 19) Elastic

washer; 20) Nut M12x1; 21) Woodruff key

Couple the stator to the flywheel cover by means

3 6Nm
of screws 1. Cover the threading with medium
strength threadlocker and tighten them at the
torque indicated.
4 Insert the cable gland in its specific seat and
2 check its perfect sealing.

2 Check the state of use of the two oil seals 2.

If they are deteriorated, they must be replaced.
Blow compressed air in the hole A making sure
8Nm 1 the lubrication pipe is perfectly clean. Also
A check the state of use of the chain guide 3. If it
is deteriorated, it must be replaced. In that case,
before putting on the screw 4, apply it with me-
dium strength threadlocker and tighten it to the
indicated torque.

Reposition the plate 5 which must be inserted

B in the relevant guides and pressed towards the
outside of the cover.
When coupling it to the left crankcase half, ap-
ply a drop of gasket paste (code 3625000000)
in the two areas B, in order to ensure perfect
sealing between the cover and the crankcase
half in the concerned zone.

Application of cable protection plate 5. zones B

where a drop of gasket paste must be applied.

105
3
ENGINE ASSEMBLY AND CHECKS

Insert the centring pins 6 on the crankcase and fas-

ten a new gasket.

Grease the oil seal on the flywheel cover and cou-

10Nm ple it to the left crankcase with the nine M6x25
screws 7.

Notice that a copper washer (12x6.3x1) C must be

applied to the screw.
C Tighten the screws at a torque of 10Nm.
7

Flywheel cover coupled to crankcase.

106
 3.17 THERMAL UNIT
3

ENGINE ASSEMBLY AND CHECKS

Before assembling the thermal unit, thorough
controls must be carried out on the cylinder,
piston, pin bolt, piston rings, cylinder head and
the timing unit described hereafter.

3.17.1 CHECKING THE PISTON,

PIN BOLT AND PISTON
RINGS

Eliminate carbonaceous sediment from the top

X of the piston and wash the entire piston with
specific degreasing agent.
Do not use sharp points or tools for cleaning.
Then carry out a careful analysis of the piston
which must be free from forcing, scratches,
cracks or any type of damage.
Analyse the outside diameter of the piston
whose service limit is carried in the table be-
low concerning their specific class. The diame-
Quota at which to measure the outside diameter of
the piston.
ter must be measured at a distance X from the
inner edge of the skirt, perpendicularly to the
axis of the pin bolt.

Service limits based on relevant class [mm]

Displacement [cm³] Quota X [mm]
1 2
350 6 87.92 87.93
390 6 87.92 87.93
430 6 94.92 94.93
480 5.5 99.92 99.93

107
3 Check the size of the pin bolt seat located on the
piston and the size of the pin bolt. This last control
must be made at the end of the pin bolt itself in the
ENGINE ASSEMBLY AND CHECKS

area where it is engaged with the piston.

Size
Displacement limit [mm]
[cm³]
Pin bolt
Pin bolt
seat
350 -390 18.04 17.98
430-480 19.04 18.98
Measurement of pin bolt seat and pin bolt.

See the relative chapter regarding crankshaft and

connecting rod controls for controls on connecting
rod foot (par. 2.2).

In order to check the state of use of the piston ring

and oil-scraper ring, the ring must be inserted in
the cylinder so that its axis is aligned with the axis
of the cylinder. Then measure the distance between
the two opposite edges.
The respective service limits are carried in the table
below.

Service
Service limits of
Displace- limit of upper and
ment [cm³] elastic lower oil-
band [mm] scraper ring
Elastic band wear limit check. [mm]
350-390
0.8 1.0
430-480

108
 3.17.2 CYLINDER CHECK
3

ENGINE ASSEMBLY AND CHECKS

Make sure the bore is within the service limits
of the relevant class carried in the table below.
Carry out measurement at a distance A from
the top of the cylinder (surface between cylin-
der and cylinder head). To measure it correct-
ly, it must be done according to the X and Y
directions orthogonal between them. Consider
the maximum measurement to determine the
cylinder wear.
The difference between the two measurements
is the ovalization.

This measurement must be carried out by plac-

ing the bore meter in such a way that its axis
is perpendicular to the axis of the crankshaft.

Service limits based on

Displace- relevant class [mm]
Quota A
ment
[mm] Ovalization
[cm³] 1 2
[mm]
350 30 88.022 88.034 0.015
390 30 88.022 88.034 0.015
430 30 95.022 95.034 0.015
480 30 100.022 100.034 0.015

3.17.2.1 Coupling play

The following table carries the coupling play be-

tween the cylinder and piston.
In order to calculate the coupling play between
the cylinder and the piston, a subtraction must
be carried out between the diameter of the cyl-
inder and that of the piston.

Coupling play based on relevant class Coupling play limit based on relevant
Displacement [mm] class [mm]
[cm³] Class 1 Class 2
Class 1 Class 2
Min Max Min Max
350 0.035 0.057 0.037 0.060 0.10 0.10
390 0.035 0.057 0.037 0.060 0.10 0.10
430 0.035 0.057 0.037 0.060 0.10 0.10
480 0.045 0.067 0.047 0.070 0.12 0.12

109
3 3.17.3 CYLINDER HEAD: DISASSEM-
A BLING AND CHECKING AUX-
ENGINE ASSEMBLY AND CHECKS

ILIARY DEVICES

Before disassembling the cylinder head, clean the

entire unit thoroughly. The various elements must
be cleaned and named bit by bit as they are disas-
sembled. Proceed as follows for disassembly and
inspection of the cylinder head. Clamp the cylinder
head using protective jaws, gripping it at the head
connection A. Disassemble the spark plug using the
special spark plug wrench (code 020440100 000).

Blocking cylinder head on vice.

3.17.3.1 Lubrication jets and centring

pins
1
Pull out the two oil jets 1 for lubricating the cylin-
der head and make sure the holes are free from any
impurity. Take off the O-rings- If damaged, replace
them.
Pay attention to the two centring pins 2.

The oil jets 1 for the lubrication of the cylinder head

and the two centring pins 2.

Detail of the lubrication oil jet 1.

110
 3.17.3.2 Rocker arm/shafts unit
3

ENGINE ASSEMBLY AND CHECKS

Disassemble the two caps 1 which keep the
rocker arm pins in place.
Make sure the face of the cap facing the shaft
does not have deep traces or signs of wear. If
so, replace the caps.
Check the state of use of the two O-rings be-
tween the caps and the cylinder head.

Closing caps for rocker arm support shaft seats.

The rocker arm pins have a threaded hole (M4)

at the end so that they can be extracted. To
pull them out, just screw a sufficiently long M4
screw A in this hole and pull out. In this way,
the rocker arms can be extracted.

Application of M4 screw to allow the removal of the

rocker arm support shafts.

Make sure the outside diameters of the pins 2

3 and the inside diameters of the holes on the
rocker arms 3 respect the following service lim-
its:

Shaft service limit: 6.98mm

rocker arm service limit: 7.03mm
Play limit: 0.05mm

Check to see that the contact areas between

the rocker arm and the calibrated discs, and
2 between the rocker arm and the cams are not
chipped or particularly worn. If so, replace the
rocker arm.
Rocker arm/shafts unit.

111
3 3.17.3.3 Calibrated discs for valve
play adjustment
ENGINE ASSEMBLY AND CHECKS

Using a magnet, pull out the calibrated discs 1 from

the seats in the cups.
Once the calibrated discs are extracted, measure
them with a thickness gauge.

Removal of calibrated discs from seats.

The calibrated discs range from 2.00mm to 3.200

according to the intervals carried in the table be-
low.

Interval
Step [mm]
thickness[mm]
2.000 ÷ 2.300 0.050
2.325 ÷ 3.000 0.025
3.050 ÷ 3.200 0.050

Calibrated discs measured with a (digital) thickness

gauge. Once you have done the measurement, take note
and mark the calibrated disc depending on its orig-
inal position.
Should the calibrated discs be deteriorated, replace
them with others having the same dimensions.
Thus you can know whether to replace it with a
thicker or thinner calibrated disc when determining
the valve play.

112
 3.17.4 CYLINDER HEAD: DISAS-
3
SEMBLING AND CHECK-

ENGINE ASSEMBLY AND CHECKS

ING VALVE UNITS

Clamp the spring removal/assembly jaw A (code

A 0100043 000) and apply the spring removal/as-
sembly tool onto it B (code 006140030 000).
B Then position the cylinder head and disassem-
ble the springs.

Positioning of cylinder head on device

for valve spring disassembly.

Compress the spring as much as necessary to

extract the half-cones 1.

Extraction of half-cones.

After extracting the half-cones, release the

2 spring and extract the cup 2, the spring 3 and
3 the valve 4.

ATTENTION! Mark all the pieces you disassem-

ble. Pay particular attention to the valves.

4
1

Valve unit.

113
3
ENGINE ASSEMBLY AND CHECKS

3.17.4.1 Springs

Each valve is retained by a spring. The length of

these springs must be checked while they are loose:

service limit = 42 mm

Should the springs be shorter, have them replaced.

Measuring length of free spring.

3.17.4.2 Valve guides, valves and seats

Make sure that the valve guides are free from

scratches or any type of nicks. To check the correct
diameter, introduce the gauge in the valve guides
from the side of the combustion chamber code
006140180 000. If the gauge can enter, the valve
guide must be replaced at a rectification workshop.
To this purpose, keep to the data carried in the
drawing.
Remember that if replacing the valve guides, the
seats of the valves must be repassed as described
later on.
Brush the valve mushroom head thoroughly and
degrease the entire valve.
Make sure that the valve stems are free from
scratches or any type of nicks. Measure the diam-
eter of the valve stems, making sure it is not less
than the service limit:

Valve stem diameter service limit: 5.95mm

If it is, replace the valve.

Play between the valve and the valve guide must
not be greater than the limit carried below:

Play limit between valve and valve guide:

0.08mm
Reference dimensions for processing and fitting the
valve guide.

Check that the valve mushroom and seat contact

area is not dented: if so, replace the valve.
Check the state of wear of the valve seats and the
sealing surface. In order to do this, apply a light
layer of Prussian blue paint on the contact zone of
the valve with the seat. Then insert the guide valve
until you press it against the seat and turn it on its
own axis.

114
 Taking the valve out, the paint will be missing in
the contact zone. Its width must not be greater
3
than the following service limit:

ENGINE ASSEMBLY AND CHECKS

Width service limit of valve seat contact
zone: 1.9 mm.

The contact zone can principally take on three

different appearances, as shown in the figure:

A - correct;
B - incorrect (contact face damaged);
C - incorrect (uneven seat width)

A B C

Valve-seat contact conditions: A) Correct; B) Incorrect - contact face damaged-; C) Incorrect - uneven width.

Also check the correct positioning of the con-

tact area. It must be neither higher (case D) or
lower (case E).
Should the incorrect conditions described
above occur, the valve seats must be rectified,
D E respecting the conditions carried in the follow-
ing drawing.

Positioning of contact area: D) too high; E) too low.

Taking the valve out, the paint will be missing in the contact zone.

If the valve seats are beyond recovery, replace

the cylinder head.

115
3 3.17.4.3 Oil-scraper rings and lower cup

Should there be excessive oil consumption or a

ENGINE ASSEMBLY AND CHECKS

white-like exhaust smoke which cannot be blamed

on the oil-scraper bands on the piston, replace the
oil-scraper rings 1, intended to prevent excess oil
leakage.
It is recommended to replace them every time the
cylinder head is overhauled.
1 In order to replace them, use needle-nose pliers to
pull them out, being careful not to nick the valve
guide.
Once the oil-scraper ring is extracted, the lower cup
can be pulled out 2.

Removal of valve stem oil scraper rings.

3.17.5 CYLINDER HEAD: CHECKING

THE CYLINDER HEAD BODY

Check the flatness between the head and cylinder

coupling surfaces.
This can be done using a rectified block and a thick-
ness gauge by positioning the block according to
the directions shown in the figure.
The service limit is:
cylinder head service limit: 0.05mm

Reference dimensions for processing and fitting

Check that the state of use of the sliding zones A

B with the camshafts and B of the camshaft support
bearing housing are free of scratches or signs of
C meshing.
Clean the oil passages for lubricating the cylinder
head by blowing compressed air into the holes C,
D and E.

E D

116
 3.17.6 CHECKING CAMSHAFTS
3
C

ENGINE ASSEMBLY AND CHECKS

Verify the zones A and B on the camshafts mak-
ing sure they have no traces of meshing or ab-
normal wear. Make sure the sides of the teeth
C are not chipped or have no trace of abnormal
wear.
The zone A comes into contact with the cylinder
head becoming part of a hydrodynamic support
A bearing. Zone B on the other hand supports the
B roller bearing.

Cam zone to be checked.

Make sure that the shafts in the cam zones are

free of abnormal colouring which is typical when
working without oil.
Use a thickness gauge to check the wear limit
of the cams referring to the values carried in the
table.
Sometimes the cams can be scratched and this
can be accepted, provided that the profile is
within the envisaged limits of wear.

Cam height measurement.

Intake Exhaust

Displacement
Nominal size [mm] Size limit [mm] Nominal size [mm] Size limit [mm]
[cm³]

350 - 390 34.1 34.0 33.75 33.65

430 34.1 34.0 33.4 33.3
480 33.75 33.65 33.4 33.3

Check on the exhaust camshaft that the spring

3 1 of the centrifugal decompressor recalls the
rest of the device so that the cylinder segment
1 D of the rod 2 protrudes completely without
D
any play.
Turn the lever 3 all the way to make sure the
device is not jammed.
Make sure that the cylinder segment D of the
decompressor is not worn or chipped.
Should it be deteriorated, replace the decom-
2 pressor shaft.

117
3 4
In order to extract it, remove the Benzing ring 4 and
pull the shaft out. Operate inversely to reassemble
it. When replacing the decompressor shaft, replace
ENGINE ASSEMBLY AND CHECKS

the Benzing ring as well.

Extraction of Benzing ring from decompressor shaft.

3.17.7 CHECKING CAMSHAFTS SUP-

PORT

The camshafts supports fasten the shafts so they

C maintain the correct position while operating. The
support in the zone A has a channel B intended to
lubricate the camshaft to allow the hydrodynamic
support of the shaft itself. Therefore you must make
sure that the zones A are free from scratches or
B traces of corrosion.
Make sure the zones C for housing the roller bear-
ings have no traces of meshing or scratches.
A

Attention: if the support needs to be replaced, the

cylinder head must be replaced as well.

118
 3.17.8 CYLINDER HEAD: INSER-
3
TION OF LOWER CUP AND

ENGINE ASSEMBLY AND CHECKS

OIL-SCRAPER RING

If the lower cups and oil-scraper rings were dis-

assembled*, reassemble them as follows.
First insert the lower cup 1 facing the flat part
downwards. Lubricate the upper part of the
valve guide lightly and insert the oil-scraper
ring 2. Pay close attention that while inserting
the valve stem seal, its axis is aligned with that
of the valve guide. The oil-scraper ring must
be pressed towards the bottom of the cylinder
head until it is flush with the valve guide.

Insertion of lower cup.

Insertion of oil-scraper ring.

Remember the valve stem seals must be replaced once they

have been taken off.

119
3 2
3.17.9 CYLINDER HEAD: ASSEMBLY
OF VALVE UNIT
ENGINE ASSEMBLY AND CHECKS

Clamp the spring removal jaw A (code 0100043

1
000) and apply the spring removal/assembly tool
onto it B (code 006140030 000).
Insert the valve stem in the valve guide* from the
combustion chamber side.
A Place the valve in the specific lower housing of the
jaw and introduce:
• The spring 1, being careful to insert it so that
the segment with the smaller pitch faces down-
B wards;
• The upper cup 2, turning the flatter part up-
wards.

Positioning of cylinder head on device for valve

spring disassembly/assembly.

Compress the spring as much as necessary to ex-

tract the two half-cones 3. To facilitate their inser-
tion, apply a small amount of grease on the stem in
the half-cone housing zone.

Spring compression, half-cones insertion. Insertion

of valve stem seal.

* If the valves, valves guides and their seats have not been re-
placed, the valves must be put back in their original positions.

120
 3.17.10 CYLINDER HEAD: REPO-
3
A SITIONING CALIBRATED

ENGINE ASSEMBLY AND CHECKS

2 DISCS. ASSEMBLING ROCK-
ER ARM PINS AND ROCKER
ARMS AND COUPLING THE
3 SPARK PLUG

Clamp the cylinder head using protective jaws,

gripping it at the head connection A.
Put the calibrated discs 1 back in place in their
original positions (if not deteriorated see par.
1 2.17.3.3).
Insert the rocker arm shaft 2 partly in the specif-
ic seat as much as needed to be able to insert
Insertion of pin 1 external rocker arm 2. the outermost rocker arm into the cylinder head
first 3. Having fastened the outermost rocker
arm to the shaft, push the shaft further until it
reaches the seat of the innermost rocker arm.
Having coupled the innermost rocker arm to the
shaft push it all the way into the cylinder head.

Couple the two caps 4 with the O-rings to the

10Nm cylinder head. They must be tightened to the
indicated torque.

Application of two rocker arm pin caps.

Apply the spark plug on the special wrench B

17Nm (code 020440100 000), introduce the unit in
the specific housing and tighten to the indicat-
ed torque.

121
3 3.17.11 CYLINDER HEAD: INSERTION
1 OF OIL JETS, CENTRING PINS
2
ENGINE ASSEMBLY AND CHECKS

AND SPARK PLUG O-RING

Insert the oil jets 1 with the O-rings 2 in their spe-

cific seats on the cylinder head.

A
Oil jet with O-ring. Note flat reference area A on the
side of the jet.

The positioning of the jets A is univocal thanks to

the specific flat side.
If the centring pins 3 have been removed, put them
back in place on the cylinder head. Apply the spark
plug housing sealing O-ring 4 between the cylinder
head and the camshaft support.
1

Overhead view of complete cylinder head.

122
 3.17.12 PISTON: APPLICATION OF
3
THE OIL-SCRAPER AND SEAL

ENGINE ASSEMBLY AND CHECKS

BANDS, APPLICATION OF
THE SEEGER

3.17.12.1 Piston: application of

the oil-scraper and
seal bands, version
350cc-390cc
The indications in this paragraph refer to the ve-
Application of the hicles listed in the table below:
scraper ring strap,
version 350cc-390cc. Model
Version up to no. VIN (included)
Year
RR 350 2018 All
RR 390 2018 All

RR 350 2019 ZD3E615C0K0100723

RR 390 2019 ZD3E616C0K0200478

Lubricate the seats of the segments with plenty

1
of oil and put the internal scraper ring strap 1 in
the lower seat of the piston.
Lay the external scraper ring strap 2 on the in-
ternal one with the "TOP" marking facing the top
2 of the piston.

Picture showing positioning of the external scraper

ring strap.

Put the seal band 3 in the upper seat.

The oil-scraper ring and retaining straps must
be laid so that their openings face the higher
3 segment of the skirt and at 180° between them.
The seal band 3 must be assembled with the
reference (letter or number) facing upwards.
2

Application of piston segments.

123
3 3.17.12.2 Piston: application of
1 the oil-scraper and seal
ENGINE ASSEMBLY AND CHECKS

bands
The indications in this paragraph refer to the vehi-
cles listed in the table below:

Version/Model Year (MY) up to no. VIN (included)

RR 350 2019 ZD3E615C0K0100724

RR 390 2019 ZD3E616C0K0200479

RR 430 2018-2019 All

Application of the central oil- RR 480 2018-2019 All
scraper band.

Oil the segment seats abundantly and apply the

central oil-scraper band in the lower seat of the
piston 1 paying close attention that the two ends
face one another but do NOT overlap.
The two ends must be aligned in axis with the pin
bolt.

Detail of positioning of two edges.

Apply the two lower 2 and upper oil-scraper rings 3

and then the seal band 4.
The two oil-scraper rings must be placed so that
4
their openings face the higher segment of the skirt
and at 180° between them. Assembly of the seal
3 band 4 must be done keeping the reference (letter
or number) facing upwards and the opening must
face the some way as the opening of the lower
oil-scraper ring 2.
1
2

Application of piston segments.

124
 3.17.12.3 Piston: seeger appli-
3
1 cation

ENGINE ASSEMBLY AND CHECKS

Generously lubricate the seats for the pin bolt
with motor oil and the circlip 1 in the left pin
bolt seat, being careful to position it so that the
lug on the circlip inserts itself in the specific
seat on the piston.

Application of circlip 1 to piston.

Right

In order to identify the right and left side of

the piston, just use as a reference the arrow A
A stamped on the piston crown which must face
the exhaust manifold.

Left

Identification of piston right and left side.

3.17.13 APPLICATION OF PISTON

TO CYLINDER

To couple the piston to the cylinder, place the

cylinder while keeping the top facing upwards.
Oil the cylinder with plenty of motor oil.
A Prepare the elastic friction band A (code
006140170000) as shown in the figure.
Press the green locking lever B and turn the
hex key anti-clockwise until the band reaches a
dimension near that of the piston. Oil the inside
of the band abundantly and insert the piston
with all its rings inside of it. Press the green
locking lever again and turn the hex key clock-
wise to tighten the segments and piston well.

Attention: the elastic band has edges which

could be sharp. Be very careful when handling
B it.

Preparation of elastic friction band A.

125
3 C
Press the piston downwards having the higher
segment of the skirt protrude a bit from the band.
Rest the unit on the cylinder, making sure that the
ENGINE ASSEMBLY AND CHECKS

contact zones of the band rest correctly on the cyl-

inder surface. For this purpose, make sure that the
upper edge C of the band is perfectly aligned with
the contact surface of the cylinder.
Note: When positioning the complete band-piston
unit on the cylinder, be careful to place them so
that the arrow stamped on the crown of the piston
faces the exhaust manifold.

Application of the complete piston band on cylinder.

Holding the band firm with one hand, push the

piston inside the cylinder, making sure that the
axis of the piston is aligned with that of the cylin-
der. Towards the end of insertion it might be nec-
essary to use the wooden handle of a hammer or a
similar tool to lightly tap the piston crown in order
to facilitate its complete insertion in the cylinder.

Attention: during the whole operation, hold the

band firm with one hand without moving it. Make
sure that the segments insert themselves correctly
in the cylinder when passing through the band.
Should there be excessive resistance when insert-
ing the piston into the cylinder, do not insist in or-
der not to deteriorate the parts: assess the cause.

Insertion of piston into the cylinder.

When the piston has been inserted into the cyl-

inder and the band has been removed, press the
piston towards the bottom of the cylinder so that
the pin bolt seats come out from the lower edge.
Apply the pin bolt 1 into the right-hand seat as
much as needed to allow it to be coupled with the
connecting rod.

Application of pin bolt to piston.

126
 1
3.17.14 APPLICATION OF PIS-
3
TON-CYLINDER COUPLING
TO CRANKCASE

ENGINE ASSEMBLY AND CHECKS

Apply a new piston-cylinder gasket 1 to the
crankcase and couple the two centring bushes
to the left crankcase 2.
2 Lubricate the foot of the connecting rod abun-
dantly with motor oil.

Application of cylinder/crankcase gasket and of cen-

tring bushes.

Insert the timing chain in the proper compart-

ment in the cylinder and bring the piston/cylin-
der unit close to the connecting rod.
Once the pin bolt reaches its housing in the
foot of the connecting rod, push the pin bolt
inside until it is inserted all the way. It may be
helpful to use an aluminium cylinder (or similar
tool) during this phase.

Passage of chain in cylinder.

127
3 Apply the lug to the circlip 3 in the pin bolt seat.
Insert the cylindrical part of the special tool A into
A the pin bolt and, having one of the two flat surfaces
ENGINE ASSEMBLY AND CHECKS

of the tool coincide with the part of the circlip to be

inserted, turn and push the special tool towards the
engine until the circlip is fully inserted into a seat.

Circlip insertion.

Push the cylinder towards the crankcase making

sure the two centring bushes on the left crankcase
are correctly inserted in the seats in the lower part
of the cylinder.

Coupling cylinder to crankcase.

128
 Apply to the cylinder the two guide bushes 4
and the gasket 5 coupling with the cylinder
3
head.

ENGINE ASSEMBLY AND CHECKS

5

Application of guide bushes 4 and gasket 5 to

cylinder.

3.17.15 COUPLING HEAD TO CYL-

INDER

Introduce the timing chain in the compartment

on the cylinder head. Keeping the chain tight,
place the head on the gasket making sure it in-
serts perfectly into the two centring bushes on
the cylinder.
Lubricate the four washers 8 and insert them
into their specific seats on the outside and in-
side of the cylinder head. Then insert the four
M10x1.25 screws 9 - after having lubricated
them- and the M6x80 screw 14 which connect
the head and cylinder to the crankcase.

Application of components for coupling the head and

cylinder to crankcase.

IV
II Tighten the four screws in two stages following
a criss-cross pattern and starting with one of
the two screws inside the head.
The first tightening can be done at 30÷40Nm,
while the second and last one is fixed at 55Nm.
The screw 14 must be tightened to the indicat-
30÷40Nm 55Nm
ed torque. Keep the chain lifted so that it does
not fall inside the chain compartment.

III

10Nm

Tightening order of screws coupling the head and

cylinder to crankcase.

129
3 3.17.16 COUPLING CAMSHAFTS TO
B CYLINDER HEAD AND PHAS-
ENGINE ASSEMBLY AND CHECKS

ING

Couple the bearings to the camshafts and lubricate

them with motor oil.
Widening the timing chain, insert the exhaust cam-
shaft upon whose gearwheel the timing chain must
A be placed. It is advisable already in this phase to
position the shaft so that the reference notches A
are horizontal with the cams facing upwards ac-
cording to the approximate direction B.
Positioning camshaft.

Lift the camshaft slightly and move the bearing so

that it is flush with the shoulder C.
Having carried out the above-mentioned position-
ing, rest the camshaft on the cylinder head.

Positioning camshaft bearing.

Detail of positioning bearing against shoulder C.

130
 D
Lift the chain again and insert the intake cam-
shaft placing the chain on the gearwheel. Place
3
the shaft so that the cams face upwards accord-

ENGINE ASSEMBLY AND CHECKS

ing to the approximate direction D and the ref-
erences E carved on the gear are horizontal.
Position the bearing in the same way as for the
exhaust camshaft.

Application of components for coupling cylinder

head.

Holding the camshaft still with one hand, insert

an aluminium cylinder F in the housing of the
hydraulic tensioner as far as needed to be able
to push the movable guide against the timing
chain. Make sure that the notches engraved on
the two wheels are aligned one with the other.
Is so, the phasing is correct. If not, release the
cylinder F, lift the timing chain so that the gear-
wheels disengage allowing the needed rotation
to obtain correct phasing.
Having checked phasing, extract the cylinder F.

Phasing check. Note the pressure that the cylinder F

exerts on the chain.

Detail of correct alignment of engraved notches on

gearwheels of camshafts.

131
3 Lubricate the entire camshaft unit with motor oil and
apply the support 1, making sure it is perfectly en-
gaged both on the shafts and on the centring pins.
ENGINE ASSEMBLY AND CHECKS

Note:
check the presence of the oil jets (par. 1.17.11).

Apply the fixed pad 2 and insert the three M7x38

screws 3 in the holes on the chain side and the four
M7x33 screws 4 in the four remaining holes.

4 4 1 4 4

3
2 3
3

Application of camshaft support 1, chain guide 2, three M7x38 screws 3 and four M7x33 screws 4.

132
 IV II III
Tighten the seven screws by hand until they are
flush.
3
V Check the correct position of the camshaft bear-

ENGINE ASSEMBLY AND CHECKS

ings as described on page 116.
Proceed with tightening in two moments, fol-
lowing the order indicated in the figure.
Carry out the first tightening operation at a
5Nm 10Nm torque of 5Nm and the second at 10Nm. At the
end of this operation, make sure the camshaft
moves freely.

VI VII
I

Tightening order of camshaft support screws.

3.17.17 VALVE PLAY

Checking for valve play must be carried out by plac-

ing a thickness gauge A (code 006140210000)
in between the cam and the rocker arm. This
control can be done even without the hydraulic
tensioner coupled to the engine.

Attention:
The piston must be positioned at the Top Dead
A Centre (par. 2.7)! Following the order of this
text, this position is already fixed.

Play must be within the values carried on the ta-

Checking valve play with thickness gauge. ble below.

Minimum Maximum
Side
[mm] [mm]
Intake 0.10 0.175
Exhaust 0.125 0.20

If the play measured is greater than that indicat-

ed, the calibrated disc must be replaced with a
thicker one. On the contrary, if the valve play is
less than that indicated, replace the calibrated
disc with a thinner one.
The value of the needed thickness can easily be
assessed by calculating the difference between
the detected play value and the one required.
The following is a layout for calibrated disc re-
placement.

133
3
ENGINE ASSEMBLY AND CHECKS

Check valve play

YES Connect the mechanical

Is the valve play
correct? tensioner to the motor.
(par 3.17.18)

NO

Is the tensioner NO Disassemble the

coupled to the camshaft support
engine? (par 2.1.1)

YES

Disassemble the
tensioner (par 2.1.1)
Incorrect play on
NO intake side?

YES

First dissemble the intake Disassemble only the

camshaft and then the intake camshaft (par
exhaust (par. 2.1.1) 2.1.1)

Disassemble the
calibrated disc to be
replaced (par 3.17.3.3)

Couple the camshaft Apply a new disc

support according to
(par 3.17.16) requirements.

First couple the exhaust NO

camshaft and then the intake Has only the intake
(par 3.17.16) side camshaft been
disassembled?

Couple the intake

YES
camshaft (par 3.17.16)

134
1 2 3 4
3.17.18 CHECKING AND COU-
3
PLING OF MECHANICAL

ENGINE ASSEMBLY AND CHECKS

TENSIONER TO ENGINE

The mechanical tensioner consists in:

1. a piston;
2. a spring;
3. a support;
4. a cap

Make sure the piston shows no signs of abnor-

mal meshing.
1 mm Check that the length of the spring is not lower
than the following limit value:
Spring limit length: 74mm
Insert the piston into the support and push it
until it sticks out of the edge of the support by
approximately 1 millimetre.

25Nm
Insert the tensioner support in the specific seat
on the cylinder, tightening it to the indicated
torque and push the piston towards the front of
the engine.

135
3
ENGINE ASSEMBLY AND CHECKS

Insert the spring in the support and apply the

cap to be tightened to the indicated torque.

8Nm

136
 3.17.19 COUPLING CYLINDER HEAD
3
COVER GASKETS AND CYL-

ENGINE ASSEMBLY AND CHECKS

INDER HEAD COVER

Apply the spark plug gasket 1 to the camshaft

support inserting the two pegs A in the specific
seats and positioning it so that it recopies the
shape on the support.

Application of spark plug gasket.

Apply a few drops of gasket paste in the edges

of the cylinder head cover gasket 2.
2

Edges where the gasket paste must be applied.

Insert the gasket in the cylinder head cover so

that the protruding part fits perfectly into the
groove in the cover.

Insertion of gasket in groove on cylinder head cover.

137
3 Place the complete cover on the cylinder head mak-
ing sure that the gasket covers the surface correctly.
Apply the four rubber rings 3 to the cover and in-
ENGINE ASSEMBLY AND CHECKS

sert the four screws 4 which fasten the cover to the

cylinder head. Tighten the screws in a criss-cross
8Nm
pattern to the indicated torque.

3
4

Application of rubber rings 3 and fixing screws 4.

3.18 PINION COUPLING

60Nm
If the O-ring 25 is not coupled to the secondary shaft
(par. 2.5), insert it followed by the spacer 26.
Then apply the pinion 27, the washer 28 and
the screw 29 which must be spread with medi-
um strength threadlocker: tighten to the specified
torque.

Attention:
do not use pneumatic devices!
Exploded view of pinion unit. 25) O-ring 25x12x1.78;
26) Spacer 27) Pinion; 28) Washer; 29) Screw.

3.19 RELEASING
THE CRANKSHAFT

Remember that according to the order of this text,

the crankshaft is blocked at the Top Dead Centre.
It must be released by removing the screw 38 and
applying the copper washer 37. Therefore reapply
the screw-washer unit, tightened to the specified
torque.

15Nm

138
 3.20 COUPLING OIL CAPS
3

ENGINE ASSEMBLY AND CHECKS

Couple the engine oil drain plug 24 in the lower
part of the right crankcase half, complete with
O-ring 25, with wire metal filter 27 and O-ring
26. Tighten at the specified torque.
Apply the magnetic screw 28 with the O-ring 29
to the gear oil drain hole: tighten to the indicat-
ed toque.

20Nm

15Nm

EXPLODED VIEW OF OIL DRAIN CAPS.

24) Motor oil drain plug;
25) O-ring 27x2;
26) O-ring 20x1.5;
27) Metal filter;
28) Magnetic screw;
29) O-ring 11x2.5

139
3 3.21 COUPLING GEARSHIFT LE-
VER
ENGINE ASSEMBLY AND CHECKS

Couple the gearshift lever to the drive shaft by po-

sitioning it so that the part A of the lever coincides
with the upper edge of the oil level inspection win-
dow.
Tighten the screw 1 to the specified torque after hav-
ing applied medium strength threadlocker.

10Nm

Positioning of gearshift lever.

140
4 REASSEMBLY OF ENGINE IN THE VEHICLE
Insert the engine in the frame. We recommend
insertion from the frame’s left side.
4
Insert the engine pins 1.

REASSEMBLY OF ENGINE IN THE VEHICLE

1

Insertion of engine pins.

Insert the upper shock absorber pin 2 and the

swingarm pin 3. Fasten the shock absorber pin to
the indicated torque.

70Nm

Insertion of upper shock absorber pin.

Insertion of swing-arm pin.

141
4
REASSEMBLY OF ENGINE IN THE VEHICLE

Apply the head connections.

35Nm

35Nm

35Nm

35Nm

35Nm Fasten the nuts and bolts following the table below.

Fixing Screw Torque [Nm] Threadlocker

Head connection bracket to frame.

M8 x 20 35 Medium-resistance
Front fixing
Head connection bracket to frame.
M8 x 16 35 Medium-resistance
Rear fixing
Head connection brackets to
M8 x 65 35
engine
Engine pins Special 45
Swingarm pin M16 x 245 125

Put the throttle body on the manifold.

35Nm

Rotate the filter box in its normal position. Apply the

lower fixing screws 4 (one each side) prior applica-
tion of medium strength threadlocker and fasten to
5 the indicated torque.

Tighten the upper screws 5 to the indicated torque.

35Nm

Note: we recommend removing the upper screws

4 (one each side) and apply medium strength thread-
locker.

Attention! During rotation, make sure the injector

does not hit anything.

142
 Make sure the filter box sleeve is correctly insert-
ed inside the throttle body, fasten the two filter
4
box side and manifold side straps.

REASSEMBLY OF ENGINE IN THE VEHICLE

Set the gas cable on the left side of the frame
and make it pass outside the head connection.
Apply the gas cables to the throttle body and
tighten the nuts.

Attention! At the end of the operation, check

for correct gas play.

Apply the throttle body cover and the relative

screw.
Connect the stop connectors.

Apply a drop of medium resistance threadlocker

to threaded bore A.
Remove the protective cloth applied previously
in the injector housing.
A Put the injector into its seat on the throttle body
and push it all the way in.

143
4 Fit the screw 6.

ATTENTION! Take the utmost care to make sure

REASSEMBLY OF ENGINE IN THE VEHICLE

screw 6 is perfectly aligned with the respec-

tive threading. Should the screw not be perfect-
ly aligned with the threading, DO NOT FORCE IT
while tightening. Instead, remove it and reposi-
tion it properly. We recommend using a key like
the one shown in the figure during handling. Tight-
6 en at the specified torque.

5 Nm

Connect the electric connectors indicated in the fig-

ure, relative to the throttle body.

Note. Before making the connection, it is advisable

to blow compressed air in the connectors and treat
them with spray for electrical contacts.

144
 Apply the unit clutch actuator to the two fixing
screws 7.
4
Tighten to 10Nm.

REASSEMBLY OF ENGINE IN THE VEHICLE

7
10Nm

Apply the spark plug cap.

Apply the start motor cable and tighten the nut

to the indicated torque.
Cover the connection using the specific protec-
tive cap.

8 Nm Note. It is advisable to protect the electrical

connector with a light veil of technical vase-
line.

Disconnect the connector 8.

Fasten the connector 8 with a plastic tie, feeding
it through the specific hole 9.
8 9

145
4
REASSEMBLY OF ENGINE IN THE VEHICLE

Connect the connector 10.

10

Apply a plastic tie 11 in order to collect the cables

11 and pipes as shown.

Connect the stop connector 12.

12

146
Connect the ventilation pipes to the engine.
4
Fix the cables from the engine to the gear actu-

REASSEMBLY OF ENGINE IN THE VEHICLE

ator tube.

Apply the left radiator to the frame.

147
4
REASSEMBLY OF ENGINE IN THE VEHICLE

Apply the respective screws and tighten to the

specified torque.

Apply the protective grid.

10Nm

Connect the radiators to the engine.

Fasten the clamp straps and introduce the coolant

liquid, letting the air bleed through the screw cap A.

Apply the loading cap and fasten the bleed screw

at 10Nm.

Air bleeding.

148
 Apply the Kickstart lever (optional). Apply the
4
dedicated medium-strength threadlocker on the

REASSEMBLY OF ENGINE IN THE VEHICLE

screw and fasten at 25Nm.
6 Apply the brake pedal return spring 13.

Mount the chain on the pinion.

13

Move the wheel towards the rear, mounting the

adjustment frames according to the image.

Attention! Before fastening the rear wheel,

check for its correct alignment.

Tighten the nut to the indicated torque.

130Nm

Apply the silencer to the vehicle, then the ex-

7Nm haust manifold; fasten according to the torque
indicated in the figure.

Attention! Position the exhaust manifold in or-

7Nm
der to have a 5÷10mm gap with the water hose.

15Nm

149
4
REASSEMBLY OF ENGINE IN THE VEHICLE

Apply the side panel 14 and tighten the screws 15 to

the specified torque.
14
7Nm

15

7Nm

Apply the pinion guard 16 and the frame side guards

17 and 18.
Fasten the screws at 10Nm and apply the fixing
16
straps between the side guards and frame.

17

10Nm
3Nm

18

3Nm

Apply the tank as follows.

Connect the connectors indicated in the figure.

150
 Put the tank in place making sure the gas cable is
between the tank and frame.
4

REASSEMBLY OF ENGINE IN THE VEHICLE

Connect the quick-release petrol couplings.

OK Attention! Make sure that the petrol quick-re-

lease couplings are fitted properly.

Fasten the screws in the tank to the indicated

torque.

Apply the seat.

Reapply the paramotor plate with the tree fixing

NO screws, once the motorcycle is removed Tighten
to 10Nm.

151
4 Grease the rear fastener and tighten the screws at
the indicated torque values.
10Nm
REASSEMBLY OF ENGINE IN THE VEHICLE

Apply the seat.

10Nm

7Nm

Apply the engine guard and relative screws.

Tighten at the specified torque.

7Nm

7Nm

152
 TABLE OF ENGINE COMPONENTS FASTENING TORQUES
TABLE OF ENGINE COMPONENTS FASTENING TORQUES
Threading diameter x Torque
Fixing Quantity Threadlocker Notes
length [mm] [Nm]
Outer side right crankcase half
Medium-resistance
Oil seal fixing plate M5 x 10 2 6
threadlocker
Medium-resistance
Oil incline M5 x 10 2 4
threadlocker
Medium-resistance
Kickstart ramp M6 x 20 1 10
threadlocker
Inner side right crankcase half
Crankshaft bearing fixing Medium-resistance
M6 x 12 2 8
plates threadlocker
Gearbox mainshaft bearing Medium-resistance
M6 X 12 2 8
fixing plate threadlocker
Secondary gearbox shaft Medium-resistance
M6 X 12 2 8
bearing fixing plate threadlocker
Desmodromic control bearing Medium-resistance
M5 X 10 2 4
fixing threadlocker

Crankcase half coupling M6 X 60 2 10

Crankcase half coupling M6 X 30 2 10

Outside left crankcase half

Medium-resistance
Countershaft bearing fixing M6 X 12 12 8
threadlocker
Medium-resistance Tighten all
Calibrated screw M5 1
threadlocker the way
Medium-resistance Tighten all
Oil jet M4 1
threadlocker the way
Inside left crankcase half
Crankshaft bearing fixing Medium-resistance
M6 x 12 2 8
plates threadlocker

Crankcase half coupling M6 x 70 4 10

Crankcase half coupling M6 X 60 9 10

Crankshaft
Medium-resistance
Left-hand side nut M32 1 150
threadlocker
Medium-resistance Left
Right-hand side nut M20 1 150
threadlocker Thread.
With copper
Crankshaft blocking M8x16 1 15
spacer
Gearshift
Medium-resistance
Stop cam M6 x 30 1 10
threadlocker
Medium-resistance
Stopping device lever M6 x 20 1 10
threadlocker
Medium-resistance
Gearshift lever M6 x 25 1 10
threadlocker
Electric kickstarter device
Medium-resistance
Torque limiter M6 x 25 1 10
threadlocker
Medium-resistance
Start motor M6 x 20 2 10
threadlocker

153
TABLE OF ENGINE COMPONENTS FASTENING TORQUES
Threading diameter Torque
Fixing Quantity Threadlocker Notes
x length [mm] [Nm]

Engine lubrication
Medium-resistance
Oil jet M4 10 6
threadlocker

Medium-resistance
Oil pump covers M5 x 10 5 4
threadlocker
Medium-resistance
Chain oil jet M5 x 12 1 6
threadlocker
Oil pressure
M12 x 10 1 20
control screw

Paper oil filter cap M6 x 16 2 10

Countershaft

Medium-resistance
Locking nut M12 1 50
threadlocker

Clutch

Medium-resistance
Drum nut and clutch case M18 1 120
threadlocker

Clutch pressure cap M6 x 25 6 10

Clutch actuator M6 x 20 2 10

Clutch actuator M6 x 30 1 10

Outer clutch cover M6 x 25 6 10

Outer clutch cover M6 x 30 1 10

See water
Inner clutch cover M6 x 25 9 10 pump cover
screws as well
Water pump

Medium-resistance
Impeller blind nut M6 1 6
threadlocker

Cover M6 x 40 4 10

Timing chain guards

Fixed and movable Medium-resistance

M6 x 25 2 10
guides threadlocker

Chain guide on flywheel Medium-resistance

M5 x 10 1 4
cover threadlocker

Medium-resistance
Chain guard M6 x 20 2 10
threadlocker

Ignition system

Medium-resistance
Pick-up M5 x 12 2 6
threadlocker

Medium-resistance
Stator winding M5 x 30 3 6
threadlocker
Medium-resistance
Flyweel M12 1 60
threadlocker

Spark plug M12 1 17

Cover M6x25 9 10

154
 TABLE OF ENGINE COMPONENTS FASTENING TORQUES
Threading
Torque
Fixing diameter x length Quantity Threadlocker Notes
[Nm]
[mm]

Head

Rocker arm pin caps M10 2 10

Lubricate
threading and
Head M10 4 40 55
washers. Follow a
criss-cross pattern

Head M6 1 10

Follow a criss-
Camshaft support M7 x 38 3 8 10
cross pattern

Follow a criss-
Camshaft support M7 x 33 4 8 10
cross pattern
Medium-
Exhaust flange stud M8 x 30 2 resistance
threadlocker

Electric fan sensor M12 1 20

AIS valve fitting M10 1 10

Cover M6 x 12 4 8

Mechanical tensioner

Tensioner cap M24 1 25

Small tensioner cap M16 1 8

Chain pinion
Medium-
Do not use
Pinion M10 x 18 1 resistance 60
pneumatic devices!
threadlocker
Gearbox oil vapour breather
Medium-
Bored screw M6x1 1 resistance 6
threadlocker
Oil drains

Motor oil plug M20 1 15

Magnetic screw gearbox

M14 1 20
oil plug

Kickstarter
Medium-
Do not use
Kickstart lever M8 x 26 1 resistance 25
pneumatic devices!
threadlocker

155
 TABLE OF FRAME/ENGINE FASTENING TORQUES
TABLE
OF FRAME/ENGINE FASTENING TORQUES
Threading
Torque
Fixing diameter x worm Quantity Threadlocker Notes
[Nm]
[mm]

Front engine pin M10 x 1.25 1 45

Lower engine pin M10 x 1.25 1 45

Head connection bracket to Medium-resistance

M8x20 2 35
front frame threadlocker
Head connection bracket to Medium-resistance
M8x16 2 35
rear frame threadlocker
Head connection brackets Medium-resistance
M8x65 35
to engine threadlocker

Swingarm pin M16 x 1.5 1 125

TABLE OF SUPERSTRUCTURE FASTENING TORQUE VALUES

Thread-
TABLE OF
SUPERSTRUCTURE FASTENING TORQUE VALUES

ing di-
Length Threadlock- Torque
Fixing ameter Quantity Notes
[mm] er [Nm]
x worm
[mm]
Tank to the frame
M6 x 1 25 1 10
(front fixing)
Tank to the frame Application of
(rear fixing)
M6 x 1 30 1 10 grease
Tank side panel to the
radiator
M6 x 1 20 2 7

156
RECOMMENDED ENGINE MAINTENANCE

The requested engine maintenance only depends on the level of use and respect of the periodical in-
spections. The following intervals refer to normal use, as long as the engine has not worked in extraor-
dinary conditions and that periodical inspections and interventions have been correctly carried out.

RECOMMENDED ENGINE MAINTENANCE

30h 60h 90h 120h 150h 180h
200l 400l 600l 600l 800l 1200l

Clutch disc wear I I S I I S

Clutch springs I I S I I S

Gearbox bearing (mainshaft) - - S - - S

Case / clutch hub I I I I I I

Cylinder - - I - - I

Piston and segments - - S - - S

Camshaft wear - - I - - I

Valve springs - - I - - S

Valves - - I - - S

Valve guide wear - - I - - I

Connecting rod - - S - - S

Countershaft bearings - - S - - S

Crankshaft bearings - - S - - S

Gearbox superficial look - - I - - I

Pressure control valve

- - I - - I
spring length

Seals for water pump + bush - - S - - S

Oil pumps control

- - S - - S
gearwheels

I = INSPECT AND REPLACE IN CASE OF NECESSARY S = REPLACE

157
 RECOMMENDED LUBRICANTS AND LIQUIDS

APPLICATION PRODUCT QUANTITY

Gearbox and clutch Liqui Moly racing Synth 10W50 800 ml* - 750ml**
RECOMMENDED LUBRICANTS AND LIQUIDS

Engine Liqui Moly racing Synth 10W50 800 ml* - 750ml**

COOLANT LIQUID Liqui Moly Coolant ready mix RAF 12 PLUS 1300 ml*

* Following the complete engine overhaul.

** Following routine maintenance interventions.

158
NOTE:

159