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APRILIA M192M Workshop Manual

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engines
1111 2
M192M / M191M
11/2003-01
M245M /M234M/ M282M/ M281M
workshopmanual

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Summary of Contents for APRILIA M192M

  • Page 1 1111 2 M192M / M191M 11/2003-01 M245M /M234M/ M282M/ M281M workshopmanual...

  • Page 2: Foreword

    FOREWORD Engines M192M / M191M / M245M / M234M / M282M / M281M FOREWORD GENERAL INFORMATION SPECIAL TOOLS ENGINE UPDATING ENGINES M192M / M191M 0 - 1...
  • Page 3 FOREWORD Engines M192M / M191M / M245M / M234M / M282M / M281M SUMMARY 0.1. FOREWORD ..............................3 0.1.1. FOREWORD............................3 0.1.2. REFERENCE MANUALS........................4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................5 0 - 2...
  • Page 4 unchanged.

  • Page 5: Reference Manuals

    FOREWORD Engines M192M / M191M / M245M / M234M / M282M / M281M 0.1.2. REFERENCE MANUALS ENGINE WORKSHOP MANUALS aprilia part # (description) 8140680 8140681 8140682 8140683 8140684 PARTS CATALOGUES aprilia part # (description) 6642 SPECIAL TOOLS MANUALS aprilia part # (description)

  • Page 6: Abbreviations/Symbols/Conventions

    FOREWORD Engines M192M / M191M / M245M / M234M / M282M / M281M 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = is less than > = is more than ≤ = is less than or equal to ≥ = is more than or equal to = approximately ∞...
  • Page 7 FOREWORD Engines M192M / M191M / M245M / M234M / M282M / M281M T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition UPSIDE- DOWN = inverted fork = volt = watt Ø = Diameter 0 - 6...
  • Page 8 GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M SUMMARY 1.1. MANUAL LAYOUT ........................... 3 1.1.1. CONVENTIONS USED IN THE MANUAL ................3 1.1.2. SAFETY INFORMATION......................4 1.2. GENERAL RULES ........................... 5 1.2.1. BASIC SAFETY RULES ......................5 1.3.

  • Page 10: Manual Layout

    GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M 1.1. MANUAL LAYOUT 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the sections index.

  • Page 11: Safety Information

    GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M 1.1.2. SAFETY INFORMATION The following conventions are used to identify safety information throughout the manual: This symbol identifies safety-related information. Whenever you see this symbol in the manual or at- tached to the engine, use utmost care to avoid the risk of injury.

  • Page 12: General Rules

    GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- ventilated room.
  • Page 13 GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M GENERAL PRECAUTIONS AND INFORMATION The following indications should be strictly complied with when servicing, disassembling or reassembling the engine. DANGER Never use naked flames when servicing. Before servicing or inspecting the motorcycle: stop the en- gine and remove the key from the ignition switch;...
  • Page 14 GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M ELECTRICAL CONNECTORS To disconnect the electrical connector, follow the procedures below. Failure to comply with these procedures may lead to irreparable damages to connector and wiring.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular condi- tions.

  • Page 16: Running-In

    GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M 1.4. RUNNING-IN 1.4.1. RUNNING-IN RECOMMENDATIONS The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes un- dergo a more effective running-in.

  • Page 17: Using Tools And Spare Parts

    SPARE PARTS Should some parts be replaced, use aprilia Original Spare Parts only. aprilia high-quality Original Spare Parts have been expressly designed and manufactured for aprilia vehicles. WARNING Non-original spare parts can impair the vehicle performance or cause serious damage to the vehicle itself.

  • Page 18: Specifications

    GENERAL INFORMATION Engines M245M / M281M 1.6. SPECIFICATIONS TECHNICAL DATA - 125CC 4T-4V-H O ENGINE 1.6.1. ENGINE Type Single-cylinder 4-stroke engine, 4 valves with auxiliary air system and catalytic muffler Bore 57 mm Stroke 48.6 mm Capacity 124 cm Compression ratio 11.

  • Page 19: Technical Data - 200Cc 4T-4V-H2O Engine

    GENERAL INFORMATION Engines M234M / M282M 1.6.2. TECHNICAL DATA - 200CC 4T-4V-H2O ENGINE ENGINE Type Single-cylinder 4-stroke engine, 4 valves with auxiliary air system and catalytic muffler Bore 72 mm Stroke 48.6 mm Capacity 198 cm Compression ratio 11,5 : 1 Carburettor WALBRO WVF7 ∅...

  • Page 20: Use Of Products

    GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M 1.7. USE OF PRODUCTS 1.7.1. USE OF PRODUCTS For all maintenance operations, use only the product listed below. Listed materials have been tested for many years and are suitable for all the applications specified by the manufacturer.

  • Page 21: Tightening

    GENERAL INFORMATION Engines M192M / M191M / M245M / M234M / M282M / M281M 1.8. TIGHTENING 1.8.1. GENERAL TIGHTENING TORQUE SETTINGS The table shows the tightening toque settings for 8.8 class screws made of steel/aluminum or other similar materials. Screw or bolt...

  • Page 22: Special Tools

    SPECIAL TOOLS Engines M192M / M191M / M245M / M234M / M282M / M281M SPECIAL TOOLS 2 - 1...
  • Page 23 SPECIAL TOOLS Engines M192M / M191M / M245M / M234M / M282M / M281M SUMMARY 2.1. SPECIAL TOOLS ............................3 2.1.1. SPECIAL TOOLS ........................... 3 2 - 2...
  • Page 24 SPECIAL TOOLS Engines M192M / M191M / M245M / M234M / M282M / M281M 2.1. SPECIAL TOOLS 2.1.1. SPECIAL TOOLS Special tools are required for correct part removal, installa- tion and tune-up. Improper and/or makeshift tools might cause damages. The list below includes special tools, which have been especially designed for this engine.
  • Page 25 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M ENGINE 3 - 1...
  • Page 26 3.3.8. ASSEMBLING THE OIL PUMP......................58 3.3.9. ASSEMBLY OF THE CHAINS HOUSING COVER (ENGINES M192M / M234M / M282M) (125 - 200 CC)............................... 59 3.3.10. ASSEMBLY OF THE CHAINS HOUSING COVER (ENGINES M245M / M281M / M191M) (125 - 150 CC)...............................
  • Page 27 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3.11. ASSEMBLING THE BY-PASS AND THE OIL SUMP ................61 3.3.12. LUBRICATION DIAGRAM ........................62 3.4. COOLING...............................64 3.4.1. REMOVING THE WATER PUMP ......................64 3.4.2. CHECKING THE COMPONENTS ......................66 3.4.3.

  • Page 28: Transmission

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1. TRANSMISSION 3.1.1. TRANSMISSION COVER • Remove the plastic cover. • Remove the driven pulley shaft lock nut and washer using the clutch housing lock wrench (8140661).

  • Page 29: Fan Guard

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.2. FAN GUARD • Remove the screws and guard. NOTE 125 c.c. engine fan guard has four fasteners. The 200 c.c. guard has five at two levels.

  • Page 30: Removing The Intake Vent

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.3. REMOVING THE INTAKE VENT • Remove the screws. • Remove the vent. 3 - 6...

  • Page 31: Driven Pulley Shaft Bearing

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.4. DRIVEN PULLEY SHAFT BEARING • Remove the circlip from inside the cover. • Remove the bearing from the case. 3 - 7...

  • Page 32: Installing The Driven Pulley Shaft Bearing

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.5. INSTALLING THE DRIVEN PULLEY SHAFT BEARING • Warm up the case a little from the inside so not to damage outer paintwork. Fit the bearing into its seat.

  • Page 33: Belt Roller (Engines M234M / M282M) (200 Cc)

    ENGINE Engines M234M / M282M 3.1.6. BELT ROLLER (ENGINES M234M / M282M) (200 cc) • Ensure that the roller shows no signs of irregular wear and can turn freely. REMOVING THE ROLLER • Remove the screw, spacer and roller complete with bearing.

  • Page 34: Removing The Driving Pulley

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.7. REMOVING THE DRIVING PULLEY Engines M192M / M245M / M281M / M191M (125 - 150 cc) • Remove the nut and the cup washer, the drive com- mon to all kick-starter versions and the steel washer.

  • Page 35: Removing The Driving Pulley From The Engine

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.8. REMOVING THE DRIVING PULLEY FROM THE ENGINE • Remove the spacer, clutch housing the whole driven pulley assembly and transmission belt. NOTE The assembly can be removed even with the driving pulley still fitted.

  • Page 36: Clutch Housing

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.9. CLUTCH HOUSING • Make sure the clutch housing is neither worn nor dam- aged. • Measure its inside diameter: standard value: Ø 134.2 mm max. value: Ø 134.5 mm NOTE Max.

  • Page 37: Removing The Clutch

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.10. REMOVING THE CLUTCH • Use the adapter ring with its pins facing the clutch to mount the clutch on the specific tool. Universal tool for clutch assemblies: 8140259...

  • Page 38: Pin Collar

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.11. PIN COLLAR • Remove the collar with two screwdrivers (A) or a ring tool (B). • Remove the guide pins (1) and the moving half pulley (2).

  • Page 39: Fixed Driven Half Pulley Bearings

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.12. FIXED DRIVEN HALF PULLEY BEARINGS • Check that parts are not worn out and/or noisy and re- place, if necessary. • Remove the stop ring with two flat-tip screwdrivers.

  • Page 40: Fixed Driven Half Pulley

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.13. FIXED DRIVEN HALF PULLEY • Measure outside diameter of the bushing. Min. diameter allowed: Ø 40.96 mm Standard diameter: Ø 40.985 mm 3 - 16...

  • Page 41: Movable Driven Half Pulley

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.14. MOVABLE DRIVEN HALF PULLEY • Remove the two inner seal rings (1) and the two O- rings (2). • Measure insider diameter of the bushing. Max. diameter allowed: Ø 41.08 mm Standard diameter: Ø...

  • Page 42: Installing Fixed Driven Half Pulley Bearings

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.15. INSTALLING FIXED DRIVEN HALF PULLEY BEARINGS • Take tool number: 8140662 • Fit the support (A) into the driven pulley and fit a new needle bearing (1) with the drift (C) (larger end).

  • Page 43: Assembling The Driven Pulley

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.16. ASSEMBLING THE DRIVEN PULLEY • Fit the new oil seals (1) and O-rings (2) onto the mov- ing half pulley. • Check parts in contact with the belt.

  • Page 44: Spring

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.17. SPRING • Measure the free length of the movable driven half pul- ley spring. Standard length: 106 mm 3 - 20...

  • Page 45: Clutch Weights

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.18. CLUTCH WEIGHTS • Check thickness of friction material on clutch weights. Min. thickness allowed: 1 mm • Weights should show no traces of lubricants. If they do, leak test the driven pulley assembly.

  • Page 46: Installing The Clutch

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.19. INSTALLING THE CLUTCH • Mount the spring, clutch and driven pulley. • Use the adapter ring to mount the clutch on the specific tool. Universal tool for clutch assemblies: 8140269 Adapter for clutch unit disassembly: 8140665 •...

  • Page 47: Drive Belt

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.20. DRIVE BELT • Check drive belt for damage. • Check the correct belt width. L1: ENGINES M192M / M191M / M245M / M281M (125 - 150 CC) Min.

  • Page 48: Movable Driving Half Pulley

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.21. MOVABLE DRIVING HALF PULLEY • Measure the outside diameter of the pulley sliding bushing. Min. permitted diameter: Ø 25.95 mm Standard diameter: Ø 25.959 ÷ 25.98 mm •...

  • Page 49: Installing The Fixed Driving Half Pulley (Engines M234M / M282M) (200 Cc)

    ENGINE Engines M234M / M282M 3.1.22. INSTALLING THE FIXED DRIVING HALF PUL- LEY (ENGINES M234M / M282M) (200 cc) • Fit the steel shim against the bushing and the fixed driving half pulley. • Fit the starting sprocket assembly complete with torque limiter.

  • Page 50: Installing Movable Half Pulley And Bushing

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.23. INSTALLING MOVABLE HALF PULLEY AND BUSHING • Preassemble the movable half pulley (1) with the ca- lotte (2); seat the rollers (3). • Fit the assembly complete with bushing onto the crank- shaft.

  • Page 51: Installing The Fixed Driving Half Pulley (Engines M192M / M245M / M281M /M191M) (125 - 150 Cc)

    ENGINE Engines M192M / M191M / M245M M281M 3.1.24. INSTALLING THE FIXED DRIVING HALF PUL- LEY (ENGINES M192M / M245M / M281M /M191M) (125 - 150 cc) • Refit all assembly parts (inner shim, fixed half pulley, outer shim, drive and nut), apply “Super Rapido”...

  • Page 52: Installing The Clutch Housing

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.25. INSTALLING THE CLUTCH HOUSING • Install the clutch housing and the shim. 3 - 28...

  • Page 53: Fitting The Transmission Cover

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.26. FITTING THE TRANSMISSION COVER • Ensure that centering dowels are in position. • Refit the cover and tighten the screws to the specified torque. • Refit the oil filler/dipstick.

  • Page 54: Rear Hub

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.27. REAR HUB • Remove the dipstick. • Drain the rear hub oil through the plughole. • Remove the screws. • Remove the hub cover complete with wheel shaft, idler gear and gasket.

  • Page 55: Removing The Wheel Shaft

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.28. REMOVING THE WHEEL SHAFT • Remove the idler gear. • Remove the wheel shaft complete with gear. 3 - 31...

  • Page 56: Hub Case Bearings

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.29. HUB CASE BEARINGS • Check bearings for wear, play and noise level. In case of troubles, proceed as follows. • Use a suitable extractor to remove the three 15-mm bearings (1) (two on the case and one on the cover).

  • Page 57: Removing The Wheel Shaft Bearing From The Cover

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.30. REMOVING THE WHEEL SHAFT BEARING FROM THE COVER • Remove the circlip from the outside of the hub cover. • Remove the bearing; support the hub cover properly.

  • Page 58: Removing The Driven Pulley Shaft

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.31. REMOVING THE DRIVEN PULLEY SHAFT • Remove the transmission cover and the clutch assem- bly. • Withdraw the driven pulley shaft from the bearing. • Remove the oil seal from the bearing. Be careful not to damage its seat.

  • Page 59: Installing Hub Case Bearings

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.32. INSTALLING HUB CASE BEARINGS • Parts should be warmed up with the heat gun first. • Fit the three 15-mm bearings (1) (two on the case and one on the cover).

  • Page 60: Installing The Driven Pulley Shaft Bearing

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.33. INSTALLING THE DRIVEN PULLEY SHAFT BEARING • Warm the half case with the heat gun. • Fit a new driven pulley shaft bearing with its balls visi- ble from inside the hub.

  • Page 61: Checking Hub Cover

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.34. CHECKING HUB COVER • Ensure that the mating surface is not dented or bent. • Check bearing thrust surfaces. • If necessary, fit a new hub cover.

  • Page 62: Installing The Wheel Shaft Bearing In The Cover

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.35. INSTALLING THE WHEEL SHAFT BEARING IN THE COVER • Warm the cover with the heat gun. • Fit the wheel shaft bearing on the cover. •...

  • Page 63: Checking Hub Shafts

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.36. CHECKING HUB SHAFTS • The three shafts should show no signs of wear or damages to their toothed surfaces; also check bearing and oil seal thrust surfaces.

  • Page 64: Installing Hub Gears

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.37. INSTALLING HUB GEARS • Mount the driven pulley shaft. • Fit the idler. • Fit wheel shaft complete with gear. 3 - 40...

  • Page 65: Fitting The Hub Cover

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.1.38. FITTING THE HUB COVER • Fit a new gasket on the centering dowels. • Fit the cover. Make sure the vent hose is properly posi- tioned.

  • Page 66: Flywheel

    ENGINE Engines M245M / M234M / M282M / M281M 3.2. FLYWHEEL 3.2.1. REMOVING THE COMPLETE FLYWHEEL COVER (ENGINES M245M / M281M / M234M /M282M) (125 - 200 CC) • Remove the clamps and cooling sleeve. • Remove the diaphragm clamp. •...

  • Page 67: Removing The Flywheel

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.2.2. REMOVING THE FLYWHEEL • Lock the flywheel with the special tool: Driving pulley lock wrench (Engines M191M / M234M / M282M) (150 - 200 cc) (adjustable face wrench):...

  • Page 68: Removing The Stator

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.2.3. REMOVING THE STATOR • Remove the wiring clamps. • Remove the terminal from the min. oil pressure switch. • Remove the Pick-Up screws, the screw securing the wiring to the bracket and the stator retaining screws.

  • Page 69: Checking The Stator

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.2.4. CHECKING THE STATOR • Check for continuity between connections 5-3 and 5-1 using a tester. • Check ground insulation of the three-stator phases 5- ground, 3-ground and 1-ground.

  • Page 70: Checking The Flywheel

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.2.5. CHECKING THE FLYWHEEL • Check that the inside plastic parts and Pick-UP control plate are not damaged. 3 - 46...

  • Page 71: Installing The Stator Assembly

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.2.6. INSTALLING THE STATOR ASSEMBLY • Replace the stator and Pick-up. NOTE The Pick-Up cable must be placed between the upper screw and the locating dowel. •...

  • Page 72: Installing The Flywheel

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.2.7. INSTALLING THE FLYWHEEL • Install the flywheel; ensure that the key is properly po- sitioned. • Tighten the flywheel nut to the specified torque; lock the flywheel with the special tool:...

  • Page 73: Fitting The Complete Flywheel Cover (Engines M245M / M281M / M234M /M282M) (125 - 200 Cc)

    ENGINE Engines M245M / M234M / M282M / M281M 3.2.8. FITTING THE COMPLETE FLYWHEEL COVER (ENGINES M245M / M281M / M234M /M282M) (125 - 200 CC) • Position the flywheel with its TDC mark aligned with the mark on the crankcase. •...

  • Page 74: Lubrication

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3. LUBRICATION 3.3.1. CHECKING THE OIL PRESSURE • After having removed the flywheel cover as described under section 4, disconnect oil min pressure switch connector (1) and remove switch (2).

  • Page 75: Removing The Oil Sump And The Pressure-Adjusting By-Pass

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3.2. REMOVING THE OIL SUMP AND THE PRES- SURE-ADJUSTING BY-PASS • Remove the oil filler cap, the transmission cover and the driving pulley with belt and sprocket.

  • Page 76: Checking The By-Pass

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3.3. CHECKING THE BY-PASS • Check the free length of the spring. Standard length: 54.2 mm. • Check that piston is free from scoring. • Make sure that piston can run smoothly along casing and that sufficient sealing is ensured.

  • Page 77: Removal Of The Chains Housing Cover (Engines M245M / M281M / M191M) (125 - 150 Cc)

    ENGINE Engines M191M / M245M / M281M 3.3.4. REMOVAL OF THE CHAINS HOUSING COVER (ENGINES M245M / M281M / M191M) (125 - 150 cc) • Undo the attachment screws to remove the chains housing cover. • Extract the cover by means of the lugs. IMPORTANT: Pull the cover parallel to the drive shaft to prevent breaking the lugs.

  • Page 78: Disassembly Of The Chains Housing Cover (Engines M192M / M234M / M282M) (125 - 200 Cc)

    ENGINE Engines M192M / M234M / M282M 3.3.5. DISASSEMBLY OF THE CHAINS HOUSING COVER (ENGINES M192M / M234M / M282M) (125 - 200 cc) • Use the bolts supplied to mount the base of the tool on the cover. •...

  • Page 79: Removing The Oil Pump

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3.6. REMOVING THE OIL PUMP • Take out the two bolts and remove the pump driving pulley cover. • Insert a screwdriver in the pulley to prevent it from turn- ing.

  • Page 80: Checking The Oil Pump

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3.7. CHECKING THE OIL PUMP • Remove the two screws (1) and the oil pump cover (2). • Remove the inner rotor circlip (3). • Remove the oil pump shaft and circlip.
  • Page 81 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Check the axial play of the rotors with a ground bar. Limit: 0.09 mm • Mount the oil pump cover and tighten the attachment screws. 3 - 57...

  • Page 82: Assembling The Oil Pump

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3.8. ASSEMBLING THE OIL PUMP • Check the pump body-shaft for wear. • Check that pump cover is not worn or scored. • In case of excessive wear or scores, change the dam- aged parts or the whole unit.

  • Page 83: Assembly Of The Chains Housing Cover (Engines M192M / M234M / M282M) (125 - 200 Cc)

    ENGINE Engines M192M / M234M / M282M 3.3.9. ASSEMBLY OF THE CHAINS HOUSING COVER (ENGINES M192M / M234M / M282M) (125 - 200 cc) • Prepare the new cover and lubricate the sealing edge. WARNING Do not lubricate the surface used to key the cover on the engine housing.

  • Page 84: Assembly Of The Chains Housing Cover (Engines M245M / M281M / M191M) (125 - 150 Cc)

    ENGINE Engines M191M / M245M / M281M 3.3.10. ASSEMBLY OF THE CHAINS HOUSING COVER (ENGINES M245M / M281M / M191M) (125 - 150 CC) • Check the chain tightener shoe (1) for signs of wear. • If the shoe is worn, change it or mount it in the oppo- site direction so that it works from the opposite side.

  • Page 85: Assembling The By-Pass And The Oil Sump

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3.11. ASSEMBLING THE BY-PASS AND THE OIL SUMP • Refit the by-pass piston (3) into its seat (A). • Install the adjuster spring (2). • Apply a new sump seal (4).

  • Page 86: Lubrication Diagram

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.3.12. LUBRICATION DIAGRAM 3 - 62...
  • Page 87 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M Key: Tappet cover Crankshaft Min. pressure switch Cartridge filter Mesh pre-filter Oil filler By-pass valve Oil pump Oil level in the sump 10. Engine breather 11. Piston cooling nozzle...

  • Page 88: Cooling

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.4. COOLING 3.4.1. REMOVING THE WATER PUMP • In the event of noise at the bearings or oil leaks at the cover inner drain hole, overhaul water pump.
  • Page 89 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Remove ceramic seal static side (1) from flywheel cover (2) with a screwdriver. • Position flywheel cover under a press. Make sure it is perfectly flat.

  • Page 90: Checking The Components

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.4.2. CHECKING THE COMPONENTS • Check that rotor is free from excessive wear or cracks. • Check that rotor shaft is not oxidized. • Check that bearing seats and ceramic seal are not oxidized.

  • Page 91: Assembling The Water Pump

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.4.3. ASSEMBLING THE WATER PUMP • Use a heat gun to heat the flywheel cover from the in- side. NOTE Overheating may damage the painted surface. •...
  • Page 92 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Fit a new O-ring on the rotor cover. • Remount the rotor cover. • Tighten the retaining screws to the specified torque value. TIGHTENING TORQUE VALUES Screws (3): 3 ÷...

  • Page 93: Checking The Thermostat

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.4.4. CHECKING THE THERMOSTAT • Visually inspect thermostat (1) for damage. • Fill a metal container with about 1 liter of water. • Immerge the thermostat (1). Keep it at the center of container.

  • Page 94: Crankcase And Crankshaft

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.5. CRANKCASE AND CRANKSHAFT 3.5.1. REMOVING THE STARTER MOTOR • First remove transmission cover, driving pulley, driven pulley and belt, rear wheel hub cover, gears, bearings and oil seals.

  • Page 95: Checking Crankshaft Axial Play

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.5.2. CHECKING CRANKSHAFT AXIAL PLAY • Before opening the crankcase, check crankshaft axial play with the specific tools: Dial gauge holder: 8140266 Small parts for crankshaft axial play: 8140657 •...

  • Page 96: Opening The Crankcase

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.5.3. OPENING THE CRANKCASE • Remove the crankcase coupling screws (1). • Detach the two casings. Keep the shaft (2) installed on one of them. WARNING The crankshaft may drop out if this is not done.
  • Page 97 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Check the con-rod radial play. Standard play: 0.036 ÷ 0.054 mm • Check that axial play holding surfaces are not scored and use a gauge to check crankshaft width.
  • Page 98 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M Checking crankshaft alignment • Measure crankshaft misalignment in the four points in- dicated. Max. misalignment allowed: A = 0.15 mm B = 0.01 mm C = 0.01 mm D = 0.10 mm...

  • Page 99: Checking Crankcase

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.5.4. CHECKING CRANKCASE • Before checking the casing, thoroughly clean all sur- faces and lubrication ducts. • On the transmission-side casing, pay particular atten- tion to the oil pump ducts and seat, by-pass duct, main bearings and cooling jet (1).

  • Page 100: Checking The Main Bearing

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.5.5. CHECKING THE MAIN BEARING • Optimal lubrication pressure (4 bar) and good oil deliv- ery are necessary to ensure good lubrication. Bearings must be correctly positioned so to prevent choking of oil delivery lines.
  • Page 101 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M Bearing inner diameter after Bearing category Casing category Assembling possibility assembly 29.025 ÷ 29.040 mm Original 29.019 ÷ 29.034 mm Original and spare 29.028 ÷ 29.043 mm 29.022 ÷...

  • Page 102: Closing The Crankcase

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.5.6. CLOSING THE CRANKCASE • Fit inner guard (1), tighten the two screws (2) to the specified torque. TIGHTENING TORQUE VALUES Screws (2): 4 ÷ 6 Nm •...
  • Page 103 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Tighten the eleven screws (10) to the specified torque value. TIGHTENING TORQUE VALUES Screws (10): 11 ÷ 13 Nm NOTE Remove any excess of the casing-to-cylinder mating gasket to ensure better sealing.

  • Page 104: Ineassembling The Starter Motor

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.5.7. INEASSEMBLING THE STARTER MOTOR • Fit a new O-ring on the starter motor and lubricate it. • Fit starter motor (1) on crankcase (2). Tighten the two screws (3) to the specified torque value.

  • Page 105: Cylinder Head And Timing System

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6. CYLINDER HEAD AND TIMING SYSTEM 3.6.1. DISASSEMBLY OF THE TAPPET COVER • Remove the fasteners. Remove the tappet cover com- plete with settler and automatic valve.

  • Page 106: Checking The Timing System

    TRANSMISSION Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.2. CHECKING THE TIMING SYSTEM • Remove the retaining screws and then remove the fly- wheel cover. • Turn the flywheel to align the case mark to the TDC mark.

  • Page 107: Checking/Adjusting Valve Clearance

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.3. CHECKING/ADJUSTING VALVE CLEARANCE • Align timing marks to check valve clearance. • Check the valve-shim clearance with a feeler gauge. If valve clearance is not as specified, loosen the check nut and adjust the clearance value with a screwdriver.

  • Page 108: Fitting The Tappet Cover

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.4. FITTING THE TAPPET COVER NOTE Fit a new O-ring onto the tappet cover. • Mount the cover complete with settler. • Tighten the fastener to the current torque value.

  • Page 109: Checking End-Of-Compression Pressure

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.5. CHECKING END-OF-COMPRESSION PRESSURE • Remove the spark plug cap when the engine is cold. • Remove the spark plug. • Fit a compression pressure gauge into the spark plug seat tightening the 10-mm spark plug fitting to the specified torque.

  • Page 110: Checking Ignition Advance

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.6. CHECKING IGNITION ADVANCE • For this check, a strobe lamp with induction clamps connected to the spark plug power cable is required. • Connect the clamps to the right poles.

  • Page 111: Intake Manifold Disassembly

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.7. INTAKE MANIFOLD DISASSEMBLY • Open the clamps and disconnect the carburettor cool- ing circuit pipes. • Open the clamps, disconnect the petrol drainpipe from the bowl and remove the carburettor.

  • Page 112: Removing The Thermostat

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.8. REMOVING THE THERMOSTAT • Loosen the screws and remove thermostat cover. • Remove thermostat with seal. 3 - 88...

  • Page 113: Removing The Timing Gear

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.9. REMOVING THE TIMING GEAR • First remove the following parts: transmission cover, driving belt roller and belt, sprocket, oil sump with spring and by-pass piston, oil pump pulley cover, crankshaft O-ring and washer between sprockets.
  • Page 114 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Remove automatic valve-lifter return spring, valve-lifter with stop washer. • Remove inner hexagon screw and counterweight. • Remove camshaft drive pulley and washer. • Remove screw, spacer and tensioner sliding shoe.

  • Page 115: Camshaft And Rocker Arms Disassembly

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.10. CAMSHAFT AND ROCKER ARMS DISASSEM- • Remove the two screws and the camshaft bracket. • Remove camshaft. • Working from flywheel side, remove pinions and rocker arms.

  • Page 116: Head Disassembly

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.11. HEAD DISASSEMBLY • Unscrew and disconnect the SAS pipe. Save the washers. • Remove the spark plug. • Remove the two side fasteners. • Working crossways, loosen cylinder head fastening nuts.

  • Page 117: Valves Disassembly

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.12. VALVES DISASSEMBLY • Use the special tool with adapter to remove valve cot- ter, washers, springs and valves. WARNING Arrange valves so as to indicate their original positioning on the head.

  • Page 118: Cylinder And Piston Disassembly

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.13. CYLINDER AND PISTON DISASSEMBLY • Remove the timing chain. • Remove chain-sliding shoe. • Remove the clamps and detach the cooling sleeve. • Slide out cylinder.

  • Page 119: Checking Con-Rod Small End

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.14. CHECKING CON-ROD SMALL END • Using an inside micrometer gauge, check con-rod small end diameter. Standard diameter: 15.015 ÷ 15.025 mm Max. allowed diameter: 15.030 mm...

  • Page 120: Gudgeon Pin Diameter

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.15. GUDGEON PIN DIAMETER • Check gudgeon pin outside diameter (A). Diameter (A) (Engines M192M / M245M / M281M / M234M / M282M) (125 - 200 cc): Ø 14,996 ÷ 15,000 mm Diameter (A) (Engine M191M) (150 cc): Ø...
  • Page 121 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Use a suitable bore gauge to measure cylinder inner diameter (D1 and D2) in the directions shown in the figure. Take readings at three heights (H1, H2, and H3).

  • Page 122: Piston

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.16. PISTON • Thoroughly clean piston ring locations. • Use suitable probes to measure the clearance between piston rings and grooves. • If the clearance exceeds the permitted values change the piston.

  • Page 123: Piston Rings

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.17. PISTON RINGS • Install the three piston rings one by one in the cylinder area with original diameter. Use the piston to set the rings at right angles to the cylinder axis.

  • Page 124: Assembling Piston

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.18. ASSEMBLING PISTON • Fit piston and gudgeon pin to on rod by setting the po- sition piston with the arrow facing the exhaust side. • Protect the crankshaft sent.

  • Page 125: Checking Piston Position

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.19. CHECKING PISTON POSITION • Temporarily fit cylinder on piston, without bottom gas- ket. • Install a dial gauge on special tool. Dial gauge holder: 8140266 •...

  • Page 126: Assembling Piston Rings

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.20. ASSEMBLING PISTON RINGS • Position scraper ring spring on piston. • To fit the ring, keep its opening opposite the spring joint with the word top facing the piston crown. The chamfered edge must face the piston crown.

  • Page 127: Assembling The Cylinder

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.21. ASSEMBLING THE CYLINDER • Blow through the lubrication duct and oil the cylinder liner. • Fit the centering dowels. • Install cylinder base gasket according to the previously calculated thickness.

  • Page 128: Checking The Head

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.22. CHECKING THE HEAD • Using a ground bar and a feeler gauge, check that the head surface is not worn or out of shape. Max. misalignment allowed: 0.05 mm •...

  • Page 129: Checking Valves For Wear

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.23. CHECKING VALVES FOR WEAR • Measure valve seats and valves sealing surface width. WARNING Do not change valves assembling position (RH- LH). Sealing surface depth (Engines M245M / M281M / M234M / M282M) (125 - 200 cc): (L) Standard: Intake and exhaust: 0.99 ÷...

  • Page 130: Checking Valve Seats For Wear

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.24. CHECKING VALVE SEATS FOR WEAR • Measure "V" mark depth on valve seat. Max. wear limit 1.6 mm. • Clean valve guide from any carbon deposits.
  • Page 131 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M Standard clearance Intake: 0.013 ÷ 0.040 mm Exhaust: 0.025 ÷ 0.052 mm Max. allowed clearance Intake: 0.062 mm Exhaust: 0.072 mm • Check the surface mating the shim joint terminal for wear.

  • Page 132: Checking Valve Sealing

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.25. CHECKING VALVE SEALING • Install valves into head. • Alternatively test intake and exhaust valves. • To carry out this test, fill manifold with fuel and check that head does not leak at the valves (keep valves pressed with your fingers).

  • Page 133: Checking Collets And Spring Plates

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.26. CHECKING COLLETS AND SPRING PLATES • Check that springs upper bearing plates (1) and collets (2) are not excessively worn. 3 - 109...

  • Page 134: Assembling Valves

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.27. ASSEMBLING VALVES • Install valves, springs and plates. Use the special tool with adapter to compress springs and install cotters into seats. NOTE Do not confuse valve-assembling position. Fit valve springs with the reference color facing the cotters (longer turns).

  • Page 135: Checking The Timing System Parts

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.28. CHECKING THE TIMING SYSTEM PARTS • Make sure the chain is not worn. • Check that guide sliding shoe and tensioner sliding shoe are not excessively worn.

  • Page 136: Checking The Camshaft

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.29. CHECKING THE CAMSHAFT • Check that camshaft thrust surfaces are not exces- sively worn and measure their diameters. Standard diameter Thrust surface A (Engines M192M / M245M / M281M / M234M / M282M) (125 - 200 cc) Ø: 36.95 ÷...
  • Page 137 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Check that the cam and the rubber stop on holding guard are not worn. • Check that the automatic valve-lifter, end of travel roller and counterweight for signs of wear.

  • Page 138: Assembling Head And Timing System Parts

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.30. ASSEMBLING HEAD AND TIMING SYSTEM PARTS • Fit the centering dowels. • Fit the gasket with the word "ALTO" facing the cylinder head. • Fit the retaining rings.

  • Page 139: Assembling Timing System Parts

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.31. ASSEMBLING TIMING SYSTEM PARTS • Install the rocker arms and pins. • Lubricate the rocker arms through the upper holes. • Mount the camshaft • Insert the bracket and tighten the screws to the speci- fied torque value.
  • Page 140 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Fit the camshaft drive pulley and its washer. • Make sure the 4v mark on the on the pulley is in line with the reference mark on the head. If it is opposite to the head, turn the crankshaft once.
  • Page 141 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Position the spring and washer and tighten the centre screw to the specified torque value. TIGHTENING TORQUE VALUES Screw: 5 ÷ 6 Nm • Mount the tappet cover •...

  • Page 142: Assembling The Thermostat

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.32. ASSEMBLING THE THERMOSTAT • Position thermostat with the bleed hole in the highest position. • Make sure that rubber seal is correctly positioned. • Fit thermostat cover with the union for carburetor heat- ing tube facing the flywheel.

  • Page 143: Assembling The Induction Manifold

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.6.33. ASSEMBLING THE INDUCTION MANIFOLD • Fit manifold and tighten its three bolts. • Fit the carburettor, connect the petrol drainpipe to the bowl and clamp the carburetor.

  • Page 144: Secondary Air

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.7. SECONDARY AIR 3.7.1. DESCRIPTION General notes The SAS operating system for Euro 2 200cc leader engine is almost identical to the SAS system. The only difference is that: secondary air, instead of entering the muffler, enters directly head exhaust duct.
  • Page 145 ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M • Through a rigid, flanged duct connected to the head, air reaches the exhaust connector so as to release oxygen to the unburnt gases before the catalyzer, by thus favoring a better reaction of this last component.

  • Page 146: Troubleshooting

    ENGINE Engines M192M / M191M / M245M / M234M / M282M / M281M 3.7.2. TROUBLESHOOTING PROBLEM POSSIBLE CAUSE ACTION REFERENCE The exhaust noise level is The reed valve on the sec- Change device and hose Disassembling the secon- too high...
  • Page 147 UPDATING ENGINES M192M / M191M Engines M192M / M191M UPDATING ENGINES M192M / M191M 4 - 1...
  • Page 148 UPDATING ENGINES M192M / M191M Engines M192M / M191M SUMMARY 4.1. SPECIFICATIONS............................3 4.1.1. TECHNICAL DATA: 125 CC, FOUR-STROKE, TWO-VALVE AIR ............3 4.1.2. TECHNICAL DATA: 150 CC, FOUR-STROKE, TWO-VALVE AIR ............4 4.2. ENGINE ................................5 4.2.1. KICK-START COVER ..........................5 4.2.2.

  • Page 149: Specifications

    UPDATING ENGINES M192M / M191M Engines M192M 4.1. SPECIFICATIONS 4.1.1. TECHNICAL DATA: 125 CC, FOUR-STROKE, TWO-VALVE AIR ENGINE Type Single-cylinder, 4-stroke, 2-valve Bore 57 mm Stroke 48,6 mm Capacity 124,01 cm Compression ratio 10,5:1 Carburettor Walbro WVF-6E Lubrication Chain-driven lobe pump inside crankcase with a wire...

  • Page 150: Technical Data: 150 Cc, Four-Stroke, Two-Valve Air

    UPDATING ENGINES M192M / M191M Engines M191M TECHNICAL DATA: 150 CC, FOUR-STROKE, TWO-VALVE AIR 4.1.2. ENGINE Type Single-cylinder, 4-stroke, *1 Bore 62,6 mm Stroke 48,6 mm Capacity 149,58 cm Compression ratio 10,1÷11,1:1 Carburettor WALBRO WVF6 Lubrication Chain-driven lobe pump inside crankcase with a wire...

  • Page 151: Engine

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2. ENGINE KICK-START COVER 4.2.1. Unscrew the starter sector gear housing attach- • ment bolts 4 - 5...

  • Page 152: Diassembly Of Sector Gear And Pinion

    UPDATING ENGINES M192M / M191M Engines M192M / M191M DIASSEMBLY OF SECTOR GEAR AND 4.2.2. PINION • Press the drive lever to remove the starter pinion. • Unscrew the kick-start bolt and remove the lever. • Remove the circlip and washer.

  • Page 153: Assembly Of Sector Gear And Pinion

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.3. ASSEMBLY OF SECTOR GEAR AND PINION • Grease the spring with JOTA 3 FS. • Mount the spring. • Replace the sector gear and load the spring with the specific tool.

  • Page 154: Disassembly Of The Clutch

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.4. DISASSEMBLY OF THE CLUTCH • Mount the clutch on the specific tool. Universal clutch tool: 8140259 WARNING The tool must be firmly held in the vice with the middle screw in contact with it. Over tightening will damage the tool.

  • Page 155: Assembly Of The Clutch

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.5. ASSEMBLY OF THE CLUTCH • Assemble the spring, clutch and driven pulley. • Mount the clutch on the specific tool. Universal clutch tool: 8140259 • Insert the lever pin in one hole of the clutch.

  • Page 156: Disassembly Rear Brake Shoes Ganasce

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.6. DISASSEMBLY REAR BRAKE SHOES GA- NASCE • Turn one of the two rear brake shoes to remove them both. 4 - 10...

  • Page 157: Disassembly Of The Brake Lever And Cam

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.7. DISASSEMBLY OF THE BRAKE LEVER AND • Remove the rear brake shoes. • Unscrew the attachment holt, extract the cam and re- move the linkage. 4 - 11...

  • Page 158: Rear Hub

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.8. REAR HUB • Remove the dipstick. • Drain the hub oil through the drain hole. • Remove the rear brake shoes. • Unscrew the attachment bolt, extract the cam and re- move the linkage.

  • Page 159: Removing The Wheel Shaft

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.9. REMOVING THE WHEEL SHAFT • Remove the driven pulley shaft. • Remove the idler gear. • Remove the shaft complete with gear. 4 - 13...

  • Page 160: Assembly Of The Hub Gears

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.10. ASSEMBLY OF THE HUB GEARS • Refit the wheel shaft complete with gear. • Refit the idler gear. • Refit the driven pulley shaft. 4 - 14...

  • Page 161: Reassembly Of Hub Cover

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.11. REASSEMBLY OF HUB COVER • Fit a new gasket on the hub cover centring dowels. • Refit the cover. Make sure the vent hole is properly po- sitioned. • Insert the screws and the two vent pipe support plates.

  • Page 162: Assembly Of The Brake Lever And Cam

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.12. ASSEMBLY OF THE BRAKE LEVER AND CAM • Check the cam and rear brake stem for signs of wear. • If necessary, change the cam. • Mount two new O-rings and lubricate them with Fiat Z2 grease.

  • Page 163: Assembly Of The Brake Shoes

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.13. ASSEMBLY OF THE BRAKE SHOES • Check the thickness of the linings. Minimum thickness: 1 mm • Check the cam and pinion supports for signs of wear. • Make sure the springs are not worn or damaged.

  • Page 164: Disassembly Of The Fan Muff

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.14. DISASSEMBLY OF THE FAN MUFF • Remove the attachment screws. • Remove the muff by slipping off the connector lodged inside it. 4 - 18...

  • Page 165: Disassembly Of The Fan Muff

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.15. DISASSEMBLY OF THE FAN MUFF • Remove the attachment screws. • Remove the muff by slipping off the connector lodged inside it. 4 - 19...

  • Page 166: Checking The Timing System

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.16. CHECKING THE TIMING SYSTEM • Turn the flywheel to align the case mark with the TDC mark. • Ensure that the 2V mark on the camshaft pulley is in line with the mark on the head. If the mark on the cam- shaft is opposite the mark on the head, turn the drive shaft once.

  • Page 167: Disassembly Of The Timing Gear

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.17. DISASSEMBLY OF THE TIMING GEAR • Remove the transmission cover, the driving belt roller, the sprocket, the oil sump with spring and by-pass pis- ton, the oil pump pulley cover, the O-ring on the drive shaft and the washer between the sprockets.
  • Page 168 UPDATING ENGINES M192M / M191M Engines M192M / M191M • Remove the camshaft drive pulley and its washer. • Remove the screw, spacer and tensioner shoe. • Remove the chain and the sprocket. NOTE It is advisable to mark the chain to ensure that its original turning direction is maintained.

  • Page 169: Disassembly Of The Camshaft And Rocker Arms

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.18. DISASSEMBLY OF THE CAMSHAFT AND ROCKER ARMS • Remove the two bolts and the camshaft attachment bracket. • Remove the camshaft. • Remove the pinion and rocker arms through the hole on the flywheel side.

  • Page 170: Head Disassembly

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.19. HEAD DISASSEMBLY • Remove the spark plug. • Remove the two side fasteners. • Working crossways, loosen cylinder head fastening nuts. Loosen in two or three steps. • Remove the head, the two centering dowels and gas- ket.

  • Page 171: Cylinder And Piston Disassembly

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.20. CYLINDER AND PISTON DISASSEMBLY • Remove the timing chain. • Remove chain-sliding shoe. • Slide out cylinder. WARNING Support the piston, so as not to damage it. • Remove cylinder base gasket and centering dowels.

  • Page 172: Assembling Piston

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.21. ASSEMBLING PISTON • Fit piston and gudgeon pin to on rod by setting the po- sition piston with the arrow facing the exhaust side. • Protect the crankshaft sent. •...

  • Page 173: Assembling The Cylinder

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.22. ASSEMBLING THE CYLINDER • Blow through the lubrication duct and oil the cylinder liner. • Fit the centring dowels. • Install cylinder base gasket according to the previously calculated thickness.

  • Page 174: Assembling Head And Timing System Parts

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.23. ASSEMBLING HEAD AND TIMING SYSTEM PARTS • Fit the centring dowels. • Fit the gasket with the word "ALTO" facing the cylinder head. • Fit the chain guide-sliding shoe. NOTE Before assembling the head, make sure that the lubri- cation duct is perfectly clean.

  • Page 175: Assembling Timing System Parts

    UPDATING ENGINES M192M / M191M Engines M192M / M191M 4.2.24. ASSEMBLING TIMING SYSTEM PARTS • Mount the rocker arms, the metal ring and the pinion. • Lubricate the rocker arms through the upper holes. • Mount the camshaft. • Position the camshaft attachment bracket and tighten the bolts to the specified torque value.
  • Page 176 UPDATING ENGINES M192M / M191M Engines M192M / M191M • Mount the camshaft drive pulley with its washer. • Ensure that the 2V mark on the camshaft pulley is in line with the mark on the head. If the mark on the cam- shaft is opposite the mark on the head, turn the drive shaft once.
  • Page 177 UPDATING ENGINES M192M / M191M Engines M192M / M191M 4 - 31...

This manual is also suitable for:

M191mM234mM282mM281mM245m

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