MV Agusta F3 675 Workshop Manual

MV Agusta F3 675 Workshop Manual

Engine workshop manual
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Summary of Contents for MV Agusta F3 675

  • Page 1 Engine workshop manual...
  • Page 2 © 2012 The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A. Part. N° 8A00B7292 - Edition N° 1 Printed - May 2012...
  • Page 3 Engine workshop manual MV AGUSTA F3 675 - F3 SERIE ORO...
  • Page 4 Statement This manual, to be used by the MV Agusta authorised workshops, has been realised with the purpose of assisting authorised personnel in maintenance and repairs operations of the motorcycle. The knowledge of technical data herein noted, determines the complete professional training of the technician.
  • Page 5 General index GENERAL DESCRIPTIONS ............... Rev. 0 MAINTENANCE .................. Rev. 0 ELECTRICAL COMPONENTS............Rev. 0 HEAD ....................Rev. 0 CLUTCH ....................Rev. 0 GEAR ....................Rev. 0 STARTING................... Rev. 0 COOLING AND LUBRICATION ............Rev. 0 ENGINE BLOCK ................. Rev. 0 TIGHTENING TORQUES ..............
  • Page 7 General description SECTION REVISION 0 - 1 -...
  • Page 8: Table Of Contents

    General description SUMMARY HOW TO CONSULT THIS MANUAL ..................Pag. PURPOSE OF THE MANUAL ....................Pag. GLOSSARY AND SYMBOLS ....................Pag. RIGHT HAND AND LEFT HAND STANDARD ................ Pag. SAFETY ............................ Pag. Carbon Monoxide ......................... Pag. Petrol ............................ Pag. Engine oil ..........................Pag. Engine coolant ........................
  • Page 9: How To Consult This Manual

    Without this knowledge, the maintenance and repair operations can render the motorcycle unsafe for use. Updates MV Agusta S.p.A. is committed to a policy of continuous updating of the models produced. The modifications and significant changes to the specifications and the procedures will be communicated to the official dealers and will appear in future editions of this manual.
  • Page 10: Glossary And Symbols

    General description GLOSSARY AND SYMBOLS ATTENTION This signifies that the lack or During this kind of procedure the incomplete observance inflammable vapours might develop of this advice can be gravely and metallic parts might be expelled dangerous for your safety at high velocity.
  • Page 11 General description Supplies key information for the best All of the countersigns indicting right, left, NOTE fulfilment of the operation. superior, inferior, front and back, refer to the motor-bike in the normal direction of march. The motor supports numbering of the cylinders and of the attached components, increases moving from left towards right in regards to the direction of march.
  • Page 12: Right Hand And Left Hand Standard

    General description RIGHT HAND AND LEFT HAND STANDARD To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the motorcycle and the engine against which are indicated the right and left sides. Lh Side Rh Side Cylinder 3...
  • Page 13: Safety

    General description SAFETY The information contained in this paragraph is fundamental so that the operations carriedout ATTENTION on the motorcycle can be conducted with minimum risk to the mechanic. Carbon Monoxide • Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of consciousness and death.
  • Page 14: Brake Fluid

    General description Brake fluid • Brake fluid is extremely corrosive. • Avoid any contacts with the eyes, skin and the mucous membrane. • If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with soap and water.
  • Page 15: Warning

    • Slackening or tightening nuts or screws, always start withthose of a greater dimension or from the centre. Alwaysrespect the torque values indicated. • Utilise only MV Agusta spare parts. INDEX GENERAL INDEX SUMMARY OF EACH CHAPTER...
  • Page 16: Operative Technical Specifications

    Below is an example of engine and frame registration number: ZCG F 10 AA Y V 000001 Manufacturer identification Vehicle model Progressive frame number MV AGUSTA # # # A C 000001 Engine type Progressive engine number - 10 -...
  • Page 17 Maintenance SECTION REVISION 0 - 1 -...
  • Page 18 Maintenance SUMMARY PLANNED MAINTENANCE SCHEDULE................Page Programmed maintenance schedule ................... Page Table of lubricants and fluids ....................Page Table of wear limits ....................... Page Cleaning the parts ........................ Page Connections ......................... Page General norms for assembling the parts ................Page Measuring compression in the cylinder ................
  • Page 19: Planned Maintenance Schedule

    At least once a year ..Substitution Engine oil filter (utilize only MV Agusta original oil filter) At every substitution of engine oil ..Check level / Top up Engine coolant .
  • Page 20 Maintenance Programmed maintenance schedule 1000 6000 12000 18000 24000 30000 36000 Km (ml) covered (600) (3800) (7500) (11200) (14900) (18600) (22400) pre- Service delivery Check Pinion wheel / Stop washer Substitution At least at each substitution of the transmission chain Check Crown wheel Substitution...
  • Page 21: Table Of Lubricants And Fluids

    Chain lubrication oil D.I.D. CHAIN LUBE * To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. Eni I-Ride motoGP 10W/60 has been manufactured for the F3 engine. If the described oil is not available, MV...
  • Page 22: Table Of Wear Limits

    Maintenance Table of wear limits ITEM STANDARD WEAR LIMIT VALVES Ø Sealing external diameter +0,05 Exhaust ........... 26,7 -0,05 +0,05 Inlet ..........31,8 -0,05 Sealing face thickness +0,1 Exhaust ........... 1,27 +0,1 Inlet ..........Stem - Guide clearance Exhaust ........... 0,02 ÷...
  • Page 23 Maintenance ITEM STANDARD WEAR LIMIT CYLINDER AND PISTONS Piston ovalization ................0,015 mm Piston-Cylinder play ....... 0,016 ÷ 0,042 mm ....0,10 mm Piston-Pin play ........ 0,002 ÷ 0,010 mm ....0,03 mm Wrist pin-Connecting rod clearance 0,015 ÷ 0,029 mm....0,06 mm Piston ring width -0,01...
  • Page 24 Maintenance ITEM STANDARD WEAR LIMIT GEAR SHIFT Gear fork - Groove pivot play..... 0,35 ÷ 0,15 mm ..... 0,65 mm Shift drum groove width ....... 7,05 ÷ 7,15 mm ..... 7,35 mm Ø Fork pivot ......... 6,8 ÷ 6,9 mm ......6,7 mm Minimun idle gear axial play ....
  • Page 25: Cleaning The Parts

    Maintenance Cleaning the parts All of the parts must be cleaned with special biodegradable solvents and dried with compressed air. Proceed with the cleaning process of all the parts before disassembling them as well as after the particular parts have been disassembled. Clean each part even before reassembling.
  • Page 26: Measuring Compression In The Cylinder

    Maintenance Measuring compression in the cylinder The following tools are necessary in order to carry out this procedure: Spark plug key: n°800089013 Compression measurer Adapter for the compression measurer. A) Heat the motor to the usual functioning tem- perature (of regime); B) Switch off the engine, remove the tank, air box and spark plugs;...
  • Page 27: Draining The Coolant Circuit

    Maintenance Draining the coolant circuit If this operation is performed with the engine fitted on the vehicle, it will be necessary to remove the body sides, loosen the strap (1) and disconnect the coolant delivery tube (2) from the radiator to the pump as described in the frame workshop manual.
  • Page 28: Changing The Engine Oil

    Maintenance Changing the engine oil For replacing the oil, refer to the data in the table. Lubricating system Q.ty component Litre scrankcase and oil sump radiator and hoses residual Unscrew the oil filler cap (1), place a container under the engine to catch the used oil and unscrew the oil drain cap (2).
  • Page 29 Maintenance undo the radiator fixing screw (6) to detach the oil radiator. Unscrew the three screws (7) and remove the retaining plate (8). Extract the hoses (9) and (10) with the seal rings; these will be replaced on refitting. - 13 -...
  • Page 30: Refitting

    Maintenance Remove the 2 screws (1) fastening the retaining plates (2) and extract the hoses from the radiator. Keep the radiator in the indicated position to help it to drain. The quantity of oil contained in the radiator NOTE and hoses is around 0.5 L. Refitting The surfaces should be clean and degreased.
  • Page 31: Filling The Oil Circuit

    Maintenance Insert the hoses (1) and (2) with the new greased seal rings in their respective locations in the case. Fit the retaining plate (6), insert the three screws (7) and tighten then to a torque of 10 Nm. Filling the oil circuit Refit the load screw (8) with a new washer and tighten to 40 Nm.
  • Page 32 Maintenance Remove fuse no. 1 for the fuel pump and coils. Turn the key to the RUN position and, keeping the clutch lever in, press the start button twice for approx 4 seconds each time. Turn the key to the OFF position and refit fuse no. 1 in its holder.
  • Page 33 Electrical components SECTION REVISION 0 - 1 -...
  • Page 34 Electrical components SUMMARY ELECTRICAL COMPONENTS ....................Page Engine oil pressure sensor ....................Page Alternator ..........................Page Starter motor ......................... Page PICK-UP ........................... Page COILS ............................Page Coolant temperature sensor ....................Page Gear sensor .......................... Page - 2 -...
  • Page 35: Electrical Components

    Electrical components ELECTRICAL COMPONENTS Tightening torques Thread blockers medium medium medium medium medium Apply motor oil Apply silicone sealing Do not apply neither oil nor other types of substances NO OIL Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 36: Engine Oil Pressure Sensor

    Electrical components Engine oil pressure sensor Remove the connector and check (with a cold engine) that there is no continuity between the pole of the sensor (1) and the engine mass. Otherwise, replace the sensor. Apply a medium strength thread-locking compound on the thread of the sensor and tighten to a torque of 22 Alternator Check:...
  • Page 37: Starter Motor

    Electrical components Remove the gasket (3), taking care not to damage it. Remove the two screws (4) and the cable retaining plate (5). Remove the stator from the cover by unscrewing the three screws (6). Refit, paying attention that the cable is correctly positioned and tightening the screws to the required torque with medium-strength threadlocker.
  • Page 38: Pick-Up

    Electrical components PICK-UP Use a tester to check that the impedance value between the negative and positive poles of the pick-up connector is that given in the table. PHONIC WHEEL GAP To ensure correct operation of the pick-up it is necessary to measure the gap between it and the phonic wheel using a feeler gauge as shown in the figure.
  • Page 39 Electrical components Detach the coils. Use a tester to check that there is an impedance value of 3.8 K ± 10% between pole no. 2 of the connector and the high-voltage positive of each coil. Place the terminals of the tester between poles no. 1 and 2 of the coil connector and check that the impedance value is 1 ±...
  • Page 40: Coolant Temperature Sensor

    Electrical components Coolant temperature sensor Remove the sensor (1) and check the impedance values between its poles with reference to the table. TEMP. °C RESIST. TEMP. °C RESIST. - 40 100,950 + 40 1,598 - 30 53,100 + 50 1,150 - 20 29,121 + 60...
  • Page 41 Head SECTION REVISION 0 - 1 -...
  • Page 42 Head SUMMARY HEAD ............................Page Removing head cover ......................Page Removing thermostat cover ....................Page Removing alternator cover ....................Page DISTRIBUTION CONTROL UNIT ..................Page Chain tensioner ........................Page Removing the valve gear components ................. Page Dismantling the head ......................Page Inspection of the head group ....................
  • Page 43: Head

    Head HEAD Tightening torques 8÷10 10+85° Thread blockers medium sealant medium Apply motor oil Apply silicone sealing Do not apply neither oil nor other types of substances NO OIL Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 44: Removing Head Cover

    Head Removing head cover Remove the 6 fastening nuts (1) and remove the head cover (2), being careful not to damage the gasket . Remove the seal (3). When refitting, it is essential to apply silicon sealant as shown in the figure at the beginning of the chapter.
  • Page 45: Removing Thermostat Cover

    Head Removing thermostat cover Remove the two screws (4) fixing the thermostat cover. Remove the cover (5), the gasket (6) and the thermostat (7). Remove the screws (8) with the retaining plate (9) and extract the degassing tube (10). - 5 -...
  • Page 46 Head Removing alternator cover From the left-hand side of the engine, remove the cover (1) of the phonic wheel (and the alternator) by undoing the 8 screws (2) , together with the gasket (3). Put the cover away in a location away from moisture and dust.
  • Page 47 Head Turn the crankshaft by turning the alternator nut with a 19 mm socket wrench until piston no. 3 reaches TDC in the exhaust-intake phase. In this position the “M” notch on the phonic wheel is lined up with the reference notch on the crankcase. The reference notches on the control wheels of the cam shafts are in horizontal position and positioned externally.
  • Page 48: Distribution Control Unit

    Head DISTRIBUTION CONTROL UNIT Tightening torques Thread blockers medium Apply motor oil Apply silicone sealing Do not apply neither oil nor other types of substances NO OIL Apply HSC Molikote Apply grease Apply mastic for gaskets - 8 -...
  • Page 49: Chain Tensioner

    Head Chain tensioner Remove the central screw-cap and withdraw the spring and the pin. Remove the screws fixing the chain tensioner to the head. Remove the chain tensioner. Remove the pad's screw. Disassembly the chain tensioner and check the correct working of each part.
  • Page 50: Removing The Valve Gear Components

    Head Removing the valve gear components Firstly remove the outermost screws of the camshaft head following the indicated scheme in order to balance the pressure exerted by the valve springs. Removing the shaft head. Release the distribution chain. - 10 -...
  • Page 51 Head First remove the intake side camshaft. Sustain the distribution chain and remove the exhaustside camshaft. Support the distribution chain with a metallic bar in orderto get it back in the following operations. Extract the two spacers by using a screw M8 as shownin the figure.
  • Page 52: Dismantling The Head

    Head Remove the seal rings, taking care not to damage them. Dismantling the head Unscrew the 10 fastening screws of the head, starting with the external ones and working inwards, working in diagonal pairs. Remove the head and place it onto a clear place. - 12 -...
  • Page 53 Head Avoid placing the head upside down. Remove the gasket which will be replaced on refitting if necessary. Remove the two blocking rings. Remove the first link block for the distribution chain by undoing the fastening pin. If it should be necessary to replace the distribution chain at the expected mileage (see the scheduled maintenance table), it is advisable to also replace the camshafts.
  • Page 54: Inspection Of The Head Group

    Head Remove the sliding block by extracting the fastening pin. Extract the distribution chain. Inspection of the head group Remove carbon deposits from the combustion chambers. Clean away eventual encrustments from the canalizations of the cooling liquid. Check to be sure that are no crack and that the holding surfaces are free of crevices, runs or any other kind of damage.
  • Page 55: Dismounting Cylinder Head Pieces

    Head Dismounting cylinder head pieces In order to carry out this procedure the following tools 800094798 are necessary: tool no. 800094796 for valve removal tool no.8000B7254 for valve removal tool no.8000B7255 to remove semi cones tool no. 800094798 to take out rubber holdings Each piece relative to the same valve (cup, spring, semi-cone,...
  • Page 56 Head Then remove in the following order: B) The spring (4) C) If necessary remove the rubber holdings using tool n° 800094798 D) Remove the lower valve spring washers (5). Before of slide out the titanium valves, in order to avoid the damaging of the valve guides, remove the burrs caused by by half- cones carefully using an oil stone.
  • Page 57: Maintenance Of The Valve Slot

    Head Maintenance of the valve slot Check the stroke surface [A] between the valve [B] and the slot [C] : no traces of pitting or cracks must appear. Measure the external diameter [D] of the stroke surface on the valve slot. If this should appear to be too elevated it is possible to repair the slot.
  • Page 58: Substitution Of The Valve Slot

    Head Substitution of the valve slot The following tools are necessary for this procedure: prick-puncher n°800095319 for inlet slot; prick-puncher n°800095318 for exhaust slot Proceed as follows: A) Remove the worn slots carefully milling them so as not to damage the head lodging B) Check the lodging diameter on the head and choose the oversized valve slot considering that the assembling interference should be 0,10÷0,15 mm.
  • Page 59: Valve Guide Check And Maintenance

    Head Valve guide check and maintenance In order to carry out this procedure the following tools 800095429 are necessary: Control tampon n° 800095429 Punch n° 8000A2385 valve stem-valve guide play: 0,01÷0,03 mm inlet 0,02÷0,04 mm exhaust coupling limit : 0,08 mm inlet 0,1 mm exhaust internal guide Ø...
  • Page 60: Guide Valve Installation

    Head Guide valve installation Assemble an oversized valve guide as follows: Oil the external valve guide surface. Slowly and evenly heat the cylinder head up to 150°. If necessary cool the valve guides with (N2) nitrogen liquid; or dry ice. Insert the valve guide using the special n°8000A2385 tampon up to the stroke and let rest until the tempera- ture has stabilized.
  • Page 61: Valve-Guide Valve Coupling

    Head Valve-guide valve coupling Coupling play at assembly must be: 0,01 ÷0,03 mm inlet 0,02 ÷0,04 mm exhaust The maximum coupling limit permitted is even to 0,08 mm inlet 0,10 mm exhaust If a major play should result, substitute valve and valveguide.
  • Page 62 Head Assembling the valve. Insert in the order of: A) Insert the spring. B) Slide the semi cones into the superior disk slot and thus place the disk on the springs. C)Fit the head on the valve removal tool no. 800094796 with base plate no.
  • Page 63: Head Assy Assembly

    Head Head assy assembly Insert the distribution chain from above onto the phonic wheel gear. Insert the centering bushes between the head and the cylinder. Insert the fixed and sliding blocks after carefully degreasing them and their pins. - 23 -...
  • Page 64 Head Fit the gasket on the cylinder head. Attention: the contact surfaces between the cylinders and the head must be scrupulously clean and free of scratches. Attention: the head gasket must be replaced if it is bent or shows changes in colour. Before placing the head in position, lubricate the female threads (on the engine block), screw threads and under the screw heads as indicated.
  • Page 65 Head Pay attention that the screws are properly engaged. The positioning of the head with the NOTE screws is given as a rough guide. The screws may be inserted after the head has been positioned. Once the head has been positioned, screw the screws in by hand without tightening them.
  • Page 66 Head Tighten the 8 screws initially to 10 Nm in opposing pairs. Screw Nr. Operation Value Pre-tightening 10 Nm Loosening Intermediate 10 Nm tightening Final angle 85 ± 1° tightening 9-10 Tightening 10 Nm - 26 -...
  • Page 67 Head Loosen the 8 screws. Retighten them to 10 Nm. Tighten them finally to 85° ± 1° using an angle tightening wrench, ensuring that the corresponding torque is between 53.5 and 61.5 Nm. If the final angle tightening of 85 ± 1° does not correspond to a torque of 53.5 - 61.5 Nm it will be necessary to replace the screw with a new one and repeat the whole head...
  • Page 68: Camshaft And Driving Shaft Timing

    Head Reinsert the two spacers with the previously greasedseal rings. The seal rings must always be replaced on refitting. CAMSHAFT AND DRIVING SHAFT TIMING Keep the chain tightened. Turn the crankshaft clockwise so as to line up the “” notch on the phonic wheel with the reference mark on the engine block.
  • Page 69 Head In this position piston no. 3 is at TDC. Keeping the chain tight, insert the exhaustcamshaft so that the phase notch “M” on the conveyor wheel is parallel to the head plane and facing outwards. EXHAUST SIDE - 29 -...
  • Page 70 Head Insert the intake camshaft with the “M” mark on the 30th pin of the distribution chain, starting to count from the mark “M” of the exhaust camshaft. In this position the minimum pressure is NOTE obtained from the valve springs on the camshafts, serving to facilitate removal and refitting operations.
  • Page 71 Head Lubricate the parts of the chain tensioner and install the assembly with the chain tensioner in the minimum extension position (all in the main body). Lock the screw cap by hand till you feel the tensioner extend. Lock it with to 12 Nm torque. Acting this way the chain tensioner is adjusted.
  • Page 72: Regulating Valve Play

    Head Once you have tightened the screws on stand fitted chain tensioner,make some turns unloaded crankshaft to verify that the timing is correct. Lining up the notch on the phonic wheel with that on the case (3rd cylinder at TDC), the two “M” marks on the camshafts should be opposite and horizontal to the head plane.
  • Page 73 Head inlet valve play exhaust valve play 0,15 ÷0,24 mm 0,20 ÷0,29 mm C)Calculate the D difference between the compared play and optimal play shown on the chart D)Read the value of S thickness on the tablet; E) Choose a new tablet with an S+D thickness. During reassembly never use a valve shim with a thickness less than 1,6 mm.
  • Page 74 Head Apply a layer of gasket silicone on the semi moons on the head in correspondence with the camshaft. Place the gasket in position and fit the valve cover. Manually position the screws, thus tighten at 8 Nm. Refit the sparkplugs, the coils and the filter case support plate, tightening the screws to a torque of 8 Nm.
  • Page 75 Clutch SECTION REVISION 0 - 1 -...
  • Page 76 Clutch SUMMARY CLUTCH ........................... Page Clutch disassembly ......................Page Clutch overhauling ........................ Page Clutch reassembly ....................... Page - 2 -...
  • Page 77: Clutch

    Clutch CLUTCH Tightening torques Thread blockers medium medium Apply motor oil Apply silicone sealing Do not apply neither oil nor other types of substances NO OIL Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 78: Clutch Disassembly

    Clutch Clutch disassembly Remove the 8 screws which fasten the clutch cap to the Crankcase. Remove the clutch cap together with the gasket. Remove the 6 disk pusher plate tightening screws together with the springs and the relative holders. Remove the disk pusher plate. - 4 -...
  • Page 79 Clutch Manually remove all of the attrition disks that you can. Unscrew the nut using tool n°800079015 to hold the clutch hub still and remove it. To execute this operation the following tool is necessary: Tool n° 800079015 800079015 Remove the nut and the washer. - 5 -...
  • Page 80 Clutch Extract the clutch hub (1). Remove the washer (2) and the clutch housing (3). - 6 -...
  • Page 81 Clutch Remove the roller cage (4), the spacer (5) and the shim washer (6). If it is necessary to remove the clutch housing, check that the rubber stoppers (7) are not scratched or cracked. Reinstall, paying attention to the correct orientation of the rubbers on the flange (8).
  • Page 82: Clutch Overhauling

    Clutch Clutch overhauling Check the rod for straightness and wear. Check the friction plates for wear. The standard thickness is 3 mm. Maximum allowed wear limit : 2,8 mm. No signs of burning, grooves or other damages are allowed. Replace the whole plates group even if only one is damaged.
  • Page 83: Clutch Reassembly

    Clutch Clutch reassembly Reposition the shim washer with the smallestdiameter facing towards the engine. Make attention to the correct positioningof the washer. ENGINE SIDE Position the spacer, the roller cage and the clutch housing. - 9 -...
  • Page 84 Clutch Alternate pushing the clutch case in and rotating it in order to help it mesh with the pump transfer and countershaft gears and avoid them grinding. Fit the washer. Make sure the washer is positioned in front of the friction drum, since it was sheared and therefore has a sharp corner and a rounded corner.
  • Page 85 Clutch Grease the side of the washer in contact with the hub. Insert the nut, screwing it down manually until it makes contact with the washer. Use the tool no. 800079015 to lock the clutch housing, thentighten the nut to 110 Nm. 800079015 - 11 -...
  • Page 86 Clutch Notice: three types of packed disks are used; to assemble them, see the diagram. Attention: before installation, lubricate the friction discs with engine oil. First fit in one of the two disks (1) with the larger friction cells and a plain disk (3). Fit in the spring holder (5), the spring (6) with the narrower diameter facing the engine and the packed disk with the larger inner diameter (4);...
  • Page 87 Clutch Once the discs have been fitted, install the clutch- disc pusher, the springs, the self-centring washers and the screws; tighten the screws to the prescribed torquein following a crossed run. - 13 -...
  • Page 88 Clutch If necessary, replace the cover gasket, lining it up with the centring pins. The contact surfaces must always be clean and degreased. Position the clutch cover, put the plate in position (1) and tighten the screws by hand. 8 Nm Tighten the screws to 8 Nm.
  • Page 89 Transmission SECTION REVISION 0 - 1 -...
  • Page 90 Transmission SUMMARY TRANSMISSION ........................ Page Removing the transmission.................... Page Overhauling the transmission..................Page Transmission breakdown ....................Page Main shaft ........................Page Lay shaft ......................... Page Gear selector drum (Desmo) ..................Page Gear shift ........................Page Transmission assembly ....................Page - 2 -...
  • Page 91: Transmission

    Transmission TRANSMISISON Tightening torque (M8) Threadlocker type medium/ medium/ strength strength Apply engine oil Apply silicone sealant Do not apply oil or other substances Apply Molikote HSC NO OIL Apply grease Apply gasket sealant - 3 -...
  • Page 92: Removing The Transmission

    Transmission Removing the transmission Remove the clutch following the instructions in the relative paragraph. Remove the clutch rod. Remove the 8 fastening screws from the transmission cover. Using a rubber mallet, delicately strike the main shaft (1) from the clutch end holding a hand on the transmission cover until it moves from the crankcase.
  • Page 93: Overhauling The Transmission

    Transmission Overhauling the transmission - Place the transmission assembly (2) on the transmission overhaul device (3) (Cod. 8000B7177). - On the rear part insert the spacer (4) on the main shaft and lock it by manually screwing down the flywheel (5). - 5 -...
  • Page 94: Main Shaft

    Transmission - Fix the front of the transmission assembly to the device, fastening the flange (6) with the three screws (7). - Check the condition of the front clutching teeth of the gears which must be in perfect shape and sharp edged.
  • Page 95 Transmission Figure B Lay shaft A= 30.30 - 30.81 with 2 gear engaged B= 41.00 - 41.71 with 3 gear engaged 83.54 - 84.15 with 4 gear engaged 94.60 - 95.31 with 1 gear engaged - Visually inspect the gear selection forks to look for bending or other damage.
  • Page 96 Transmission Transmission breakdown - Straighten the safety washer (9) and, blocking the pinion (10), unscrew the nut (11) then remove the pinion and washer. - It is necessary to manually engage 6th gear in order to separate the main and lay shaft, then unscrew the nut (12) fastening the selector drum (desmo) to the gearshift.
  • Page 97 Transmission - Unscrew the three screws (7) and remove the flange (6). - Unscrew the flywheel (5) and remove the spacer (4), freeing the main shaft. - 9 -...
  • Page 98 Transmission - Extract the transmission shafts from the plate and place them on the bench. - Remove the selector drum (desmo) (13) and detach the main shaft (1) from the lay shaft (8). - 10 -...
  • Page 99 Transmission Main shaft Stop ring Shim washer gear gears; Z= 16 Roller cage Z= 13 gear gears; Z= 22 Shim washer Stop ring Z= 21 gear gears; Z= 18 gear gears; Z= 19 Z= 19 Stop ring Z= 18 10) Shim washer 11) Roller cage 12) 5 gear gears;...
  • Page 100 Transmission Lay shaft Z= 37 Z= 30 Z= 30 Z= 32 Z= 29 Z= 34 Grooved washer Lay shaft gear gears; Z= 30 Roller cage Roller cage gear gears; Z= 34 Grooved washer Grooved washer Stop ring Stop ring gear gears; Z= 30 gear gears;...
  • Page 101 Transmission - Disassemble the lay shaft starting with the removal of the stop ring (21), removing all the components as in the figure. - Check that the gear teeth are intact and the threads and grooves of the shafts and gears are in perfect condition.
  • Page 102: Gear Selector Drum (Desmo)

    Transmission Gear selector drum (Desmo) - Remove the stop ring (1), remove the fork pin (2) and then the fork (3), then repeat the same operations for fork (4) and fork (5). Examine the selector drum (6) (“Desmo”), whose grooves (7) must not be smoothed from wear. The play between the fork pin (2) and grooves (7) with new components is 0.05 - 0.15 mm.
  • Page 103: Gear Shift

    Transmission Gear shift If necessary, disassemble the gear shift assembly as follows: - Remove the shift control rod (1), unhooking it from the gear selector (2). - Position the rod (1) in a vice, using aluminium plates so as not to damage it, unhook the spring and separate it.
  • Page 104 Transmission - Check spring (2), spring (3), the shaft (1) and the plate (4) for wear; if any component is found to be damaged it should be replaced. - Refit the rod, following the removal procedure in reverse, without fitting it to the shift flange. - Check that the gear locker pawl (5) moves freely without obstruction and the thumbwheel (6) turns freely without excessive play;...
  • Page 105 Transmission - Move the pawl and remove the shift selector (2). - Unscrew the nut (10) to disassemble the selector; check the state of the shift selector, the cams must not be worn and be free of impediments. Check that the bearing (11) turns freely and that there are no worn parts in the pin, spring and ball assembly (12).
  • Page 106: Transmission Assembly

    Transmission Transmission assembly - Position the main (1) and lay shaft (2) gears in neutral. - Bring the two shafts together and position the selector drum (3) inserting fork (4) between the gears of 2 and 6 gear, fork (5) between the gears of 4 and 5 gear of the lay shaft (2) and fork (6) in...
  • Page 107 Transmission - Fasten the main shaft, positioning the spacer (8) and screwing on the flywheel by hand (9). - Place the gear selector (10) in neutral, aligning the pawl wheel (11) with the longest pin (12) of the selector. - 19 -...
  • Page 108 Transmission - Fit the flange (13) introducing the pin (12) of the selector in the marked hole (14) of the selector drum. - Fasten the flange (13) with the three screws (15). - 20 -...
  • Page 109 Transmission - Place the gear selector in 1 gear. - Screw the nut (16) down to a torque of 25 Nm + Loctite 243. - 21 -...
  • Page 110 Transmission Place the transmission in neutral before screwing on the pinion nut. - After placing the transmission in neutral, refit the pinion (17) on the lay shaft, replacing the safety washer, then screw on the nut (18) to 12 - 13 Nm + Loctite 243 then fold down the safety washer.
  • Page 111 Transmission and 6 GEAR >>> - Once you have ensured the transmission is operating correctly, remove it from the device, following the assembly operations in reverse. - Place the gasket (19) on the flange, lightly greasing it so that it does not come out of its seat when reinstalling the transmission - Refit the transmission assembly (20) on the engine, ensuring that the blocking rings are present (21),...
  • Page 112 Transmission then tighten the eight screws (22) to a torque of 25 - Assembly the pinion, the safety washer and the nut. By blocking the pinion, tighten to a couole of 140 Nm with medium threadblockers. - Hammer the new washer down onto the two opposite faces of the hexagon as indicated.
  • Page 113 Starting SECTION REVISION 0 - 1 -...
  • Page 114 Starting SUMMARY STARTING ..........................Page Starter transfer gear ......................Page Starter free wheel ......................... Page Refitting the starter assembly ....................Page Refitting the starter transfer gear cover ................Page - 2 -...
  • Page 115: Starting

    Starting 2xM6-L40 STARTING 3xM6-L30 Tightening torques Thread blockers Apply motor oil Apply silicone sealing Do not apply neither oil nor other types of substances NO OIL Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 116: Starter Transfer Gear

    Starting Starter transfer gear After removing the starter motor as described in Sec. C, unscrew the 4 screws (1) and screws (2). Delicately use a screwdriver on the tip of the lever to separate the starter cover from the upper half-case. To remove the cover it is necessary to remove the screws (2) as they are not perpendicular to the support plane.
  • Page 117: Starter Free Wheel

    Starting Refitting the transfer components requires the tool: 8000B7299 Starter transfer gear 1° assembly tool : cod.8000B7299 Insert the tool into the seat of the pin, oriented as shown in the figure. Oil the shaft (4) and fit the O-ring. Always use a new O-ring to perform this operation.
  • Page 118 Starting Refit the free wheel on the shaft with the arrow pointing outwards. Fit the safety ring. Refit the roller cage and the free wheel gear. Check that by blocking the shaft (1), the free wheel gear (2) turns only in the direction indicated by the arrow.
  • Page 119: Refitting The Starter Assembly

    Starting Refitting the starter assembly Ensure all surfaces are clean and degreased when refitting. Fit the starter assembly and place the shim washer (3) and the cap (4). Check that the assembly has a little play along the shaft axis. Refitting the starter transfer gear cover Spread a little gasket sealant on the previously cleaned and degreased contact surfaces of the starter cover.
  • Page 120 Starting Refit the cover in place on the half-case, taking care that the sealant does not come into contact with the gears. Insert the 3 screws (5) and the two screws (6), tightening them to the specified torque. - 8 -...
  • Page 121 Cooling - Lubrication SECTION REVISION 0 - 1 -...
  • Page 122 Cooling - Lubrication SUMMARY Lubrication .......................... Page Removing the oil filter ......................Page Removing the lubrication system ..................Page Refitting the lubrication system ..................Page Refitting the oil filter ......................Page - 2 -...
  • Page 123 Cooling - Lubrication Tightening torque Threadlocker type Apply motor oil Apply silicone sealing Do not apply neither oil nor other types of substances NO OIL Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 124: Lubrication

    Cooling - Lubrication Lubrication: The oil and coolant must be drained from their respective circuits as described in the maintenance section before performing this operation. Removing the oil filter Unscrew the screws (1). Remove the oil filter cover (2) and the spring (3). Remove the oil filter (4).
  • Page 125: Removing The Lubrication System

    Cooling - Lubrication Removing the lubrication system Unscrew the screws (1). Remove the oil sump (2), keeping the gasket (3) and bushings (4). Remove the coolant pump discharge tube (5). - 5 -...
  • Page 126 Cooling - Lubrication Unscrew the two screws (6) and remove the submerged intake (7). Unscrew the two screws (8) and remove the oil delivery tube (9) from the pump to the heater exchanger with its O-rings. - 6 -...
  • Page 127 Cooling - Lubrication Unscrew the two screws (10) and remove the coolant delivery tube (11). Recover the O-rings (12) and (13). - 7 -...
  • Page 128 Cooling - Lubrication Unscrew the two screws (14) and remove the coolant intake manifold (15), recovering the relative O-rings. Unscrew the screw (17) and washer (18). Remove the blocking ring (19) with needle-nose pliers. - 8 -...
  • Page 129: Refitting The Lubrication System

    Cooling - Lubrication Raise the pump assembly from the gears and remove it from the engine. Refitting the lubrication system Insert the pump assembly (20), inserting the part of the pump body in its seat in the engine block, then mesh the gears (21) with the crankshaft transfer gear.
  • Page 130 Cooling - Lubrication Screw on the screw (17) and washer (18) to fasten the pump assembly (20). Grease the seats of the oil delivery tube (7) gaskets. Check that the O-ring gaskets are not damaged; if they are replace them. Then refit the tube (9), applying light pressure so that the gaskets and the tube insert themselves correctly into the seat.
  • Page 131 Cooling - Lubrication Screw down the tube’s (9) two screws (8). Grease the seats (22) and (23) of the coolant delivery tube. Check that the O-ring gaskets are not damaged; if they are replace them. Then insert gasket (13) on the engine block and gasket (12) on the tube (11).
  • Page 132 Cooling - Lubrication Screw down the tube’s (11) two screws (10). Grease the seat (24) of the submerged intake (7) and fasten it in position by screwing down the screws (6). Check that the O-ring gaskets (25) and (26) of the coolant drain tube (5) are not damaged;...
  • Page 133 Cooling - Lubrication Position the blocking rings (4) in their seats, then fit the gasket (3) and the oil sump (2). Screw down the screws (1), those corresponding with the blocking rings first and then the others. Tightening torque 10 Nm. It is preferable to fit the oil filter before NOTE refitting the oil sump to the engine.
  • Page 134: Refitting The Oil Filter

    Cooling - Lubrication Refitting the oil filter Introduce the oil filter (4) into the sump. Insert the spring (3) in the filter seat, then lubricate the gasket (5) and fit the cover (2). Screw down the screws (1). - 14 -...
  • Page 135 Crankcase SECTION REVISION 0 - 1 -...
  • Page 136 Crankcase SUMMARY CRANKCASE ........................Page Crankcase disassembly ....................Page Removing the countershaft ....................Page Removing the crankshaft ....................Page Removing the big ends ...................... Page Removing the pistons ......................Page Cylinder revision ........................ Page Piston revision ........................Page Piston-cylinder coupling ..................... Page Piston pin revision......................
  • Page 137: Crankcase

    Crankcase CRANKCASE Tightening torques 10+85° 10+40° Thread blockers strong medium strong Apply motor oil Apply silicone sealing Do not apply neither oil nor other types of substances NO OIL Apply HSC Molikote Apply grease Apply mastic for gaskets - 3 -...
  • Page 138: Crankcase Disassembly

    Crankcase Crankcase disassembly Remove as follows as indicated in the relative paragraphs: A) The head B) The clutch C) The gear D) Starter E) Lubrication and cooling system. Remove: F) Working on the upper part of the engine, remove the 12 6mm screws starting with the outermost ones and the central 8mm screw.
  • Page 139 Crankcase At this point it will be necessary to ensure the upper half-case is fully fastened to the engine support and eliminate the lower fastenings to make it possible to separate the half-cases. Add a fastening point (A) to the upper half-case using the hole of the central M6 screw.
  • Page 140 Crankcase G) Remove the 2 M6 screws. H) Remove the 8 M8 screws, following the order shown in the figure. It is recommended you use an articulated NOTE driver to remove the screws inside the engine block. - 6 -...
  • Page 141 Crankcase Remove the screws using a flathead screwdriver. I) Separate the two cases (1 and 2) by applying leverage on the protrusion. L) Remove the lower half-case and rest it on a flat, clean surface. - 7 -...
  • Page 142: Removing The Countershaft

    Crankcase Removing the countershaft Loosen the 2 screws (1). Remove the countershaft head with the two rings and the half-bearing. - 8 -...
  • Page 143 Crankcase Remove the countershaft. In the case of temporary removal of the NOTE bearings (1) it is recommended you mark the shaft, the support number and the case they belong to with a marker pen. For example the bearing removed from the countershaft of the no.
  • Page 144: Removing The Crankshaft

    Crankcase Removing the crankshaft Disengage the crankshaft from the piston-connecting rods assembly by removing the big ends. Tool no. 8000B7214 is required to perform this operation. Fit the tool on main journals no. 1 and no.4. Hand tighten the screws (1) of the tool to lock the crankshaft in place.
  • Page 145 Crankcase Remove each big end from its connecting rod, marking it to avoid confusion on refitting. Remove tool no. 8000B7214. Remove the crankshaft and place it on a support of the type shown in the figure. In the case of temporary removal of the NOTE bearings (1) it is recommended you mark the shaft, the support number and the...
  • Page 146: Removing The Pistons

    Crankcase Removing the pistons Turn the upper half-case. Mark the top of every piston with a marker NOTE pen in order to ensure the correct position is respected on reassembly. Extract the pistons moving the connecting rods up from bottom as indicated, and make attention not to damage the elastic bands.
  • Page 147: Cylinder Revision

    Crankcase Cylinder revision Check to be sure that enclosures show no sign of seizures with the pistons. Check piston ovalization in the following way: A) Measure the nominal diameter of each cylinder at a distance of 20 mm from the superior edge as indicated in the figure.
  • Page 148: Piston-Cylinder Coupling

    Crankcase Piston-cylinder coupling The cylinder-piston groups are furnished already coupled; if there should be an exchange of cylinders and pistons between them it would be necessary to proceed surveying coupling plays. Measure the diameter of the (ND) pipe at 20 mmfrom the superior plane, as indicated on the sketch.
  • Page 149: Piston Pin - Connecting Rod Coupling

    Crankcase Piston pin - connecting rod coupling Play between piston pin and connecting rod must be of 0,015÷0,032 mm. Maximum wear limit allowed 0,06 mm. Piston rings Verify the absence of lines and traces of shrinkage on each piston ring. Verify that the edge of the segment is well defined and free in the piston rings.
  • Page 150: Mainshaft

    Crankcase MAINSHAFT Tightening torque 90° (50÷60) Angle strong Thread blockers Do not apply neither oil nor other types of substances Apply motor oil NO OIL Apply grease Apply silicone sealing Apply HSC Molikote Apply mastic for gaskets - 16 -...
  • Page 151: Coupling Of Piston Pin-Small End Bush

    Crankcase Coupling of piston pin-small end bush Check that the bearing is under good condition and that there are not wear marks. Verify that the internal diameter of the small end bush is between 16,015÷16,025 mm. The play between the small end bush and the piston pin must be between 0,015 and 0,032 mm.
  • Page 152 Crankcase - Connecting rod CONNECTING ROD SCREW The measure of the connecting rod must be effected TIGHTENING TORQUE after having tightened the connecting rod without Operation Value half-bearings to the prescribed torque. Pre-load 5 Nm recommended execute Intermediate tightening 20 Nm measurement re-using the original used Final tightening 90±5°...
  • Page 153: Overhauling The Crankshaft And Countershaft

    Crankcase Overhauling the crankshaft and countershaft Clean and check that the teeth of the gears of the two shafts are intact and have sharp edges. Check that there are no signs of anomalous wear and the surfaces are smooth. Overhauling the half-cases Replace the main bearings if there is any doubt as to their condition.
  • Page 154: Reassembly

    Crankcase REASSEMBLY Cylinder and piston assembly The ringss must be assembled on the piston with the writing “R” “RN” turned upwards and by following the outline in the figure. Assemble the internal ring on the piston. Assemble the internal ring on the piston. Assembly the pistons complete with the previouslydegreased and cleaned connecting rod.
  • Page 155 Crankcase Insert the centering bush and lubricate the cylinder barrels with engine oil. The following tool is required to perform this operation: Piston installation device cod. 8000B7207 Position the device on the half-case as indicted, centring the blocking rings and lubricating the liners with engine oil.
  • Page 156 Crankcase Push the pistons with connecting rods down into their respective cylinders. Insert the pistons compressing the segments manually to avoid damage. Pull the connecting rods downward until complete inserting of the pistons into the cylinder. Once inserted all the pistons, dismantle the tooland turn the half-crankcase.
  • Page 157: Refitting The Half-Cases

    Crankcase Refitting the half-cases Carefully degrease and clean from any paste residues. Fit the bearings in their respective seats (previously marked during disassembly) in the case without lubricating them. After having positioned them put oil on each bush. Oil the main, rod and countershaft bearings with engine oil.
  • Page 158: Fitting The Crankshaft

    Crankcase Lubricate journal no. 2 from both sides as it performs the function of centring the crankshaft. Fitting the crankshaft Place the crankshaft in place, bringing the connecting rods into contact. Use a feeler gauge to check that the crankshaft has end play of between 0.1 and 0.25 mm from the main journals.
  • Page 159: Fitting The Connecting Rods

    Crankcase Fitting the connecting rods Tool no. 8000B7214 is required to perform this operation. Fit the tool on main journals no. 1 and no.4. Hand tighten the screws (1) of the tool to lock the crankshaft in place. Fit the bearings to the previously cleaned and degreased big ends, lubricating them with engine oil.
  • Page 160 Crankcase • Manually tighten the screws to a torque of 5 Nm. • Intermediate tightening to the torque of 20 Nm. • Fully tighten them by turning the screws 90° ±5° clockwise (1/4 turn), using an angle tightening wrench, checking that the torque value is 50÷60 CONNECTING ROD SCREW TIGHTENING TORQUE Operation Value...
  • Page 161 Crankcase Lubricate the seal rings and insert them in their respective seats, previously cleaned of coolant. Fitting the crankshaft cap. Assembly the centering bushes. - 27 -...
  • Page 162: Refitting The Countershaft

    Crankcase Insert the half-bearings in the respective seats on thepreviously degreased and cleaned lower crankcase. Lubricate the bearings with engine oil. Refitting the countershaft Fit the counterbalance shaft. - 28 -...
  • Page 163 Crankcase Insert the grooved bearing on the cleaned and degreased countershaft cap. Insert the two blocking rings (1) and fit the cap with the arrow pointing in the direction of travel. Tighten the two screws (2) to a torque of 25 Nm. - 29 -...
  • Page 164 Crankcase Ensure that the blocking rings are installed on the upper half-case. Spread a layer of "THREEBOND" type garnish on the stroke points of the two half crankcases paying attention to prevent the paste from coming into contact with the bushings. - 30 -...
  • Page 165: Crankshaft Timing

    Crankcase Crankshaft timing Orient the gears of the main shaft and countershaft on their respective half-cases so that the timing notches on them can be easily lined up during assembly. Bring the half-cases together, paying attention to line up the two notches on the gears in order to achieve correct timing.
  • Page 166 Crankcase Manually drive the M8 and M6 screw without tightening. All screws have either an equal or visibly NOTE different length; it is therefore impossible to mix them up during reassembly. Tighten the 8 screws of the cylinder bank, following the order indicated, Screw Nr.
  • Page 167 Crankcase Tighten the two M6 screws of the countershaft to a torque of 12 Nm. Rotate the engine 180°. Restore engine support fastenings (B) and (C) and eliminate the upper half-case fixing point (A) which uses the M6 screw hole. Insert the M8 central screw and the other 12 M6 screws.
  • Page 168 Crankcase Tighten first the central screw M8 to a couple of 25 Tight the other 12 screws at a couple of 10 Nmproceeding outwards from center. - 34 -...
  • Page 169 Tightening torques SECTION REVISION 0 - 1 -...
  • Page 170 Tightening torques SUMMARY TIGHTENING TORQUES ....................Page - 2 -...
  • Page 171: Tightening Torques

    Tightening torques TIGHTENING TORQUES TABLE DESCRIPTION Thread blockers HEAD Stand screws Head tightening screws (M10x1,5-L70) 10 Nm + 85° Chain tightening cap Chain tightening screws medium Sliding block distribution screws Valve cap screws Spark plug coil screws Exhaust pipes stud bolts medium CLUTCH Clutch nut...
  • Page 172 Tightening torques TIGHTENING TORQUES TABLE DESCRIPTION Thread blockers CRANKCASE 2nd bearing plate screw M6x1-L20 Main bearing plate screw M6x1-L20 Cylinder bank screws M8x1,25-L85mm 10+ 60° Countershaft cap screws M8x1,25-L35 Countershaft screws M6x1-L35 Central upper crankcase screw M8x35mm Fixing screws M6 M6 clutch cover screws COOLING LUBRICATION Oil drain plug...
  • Page 173 Service tools SECTION REVISION 0 - 1 -...
  • Page 174 Service tools - 2 -...
  • Page 175 Service tools F3 ORO DESCRIPTION Code Q.ty Note 8000B7177 • • GEAR CHANGE MOUNTING TOOL 800079015 • • CLUTCH BLOCKING TOOL 8000B7293 • • PAD FOR EXHAUST VALVE SEAT 8000B7294 • • PAD FOR INTAKE VALVE SEAT 8000B7295 • • CYLINDER HEAD GASKET KIT 8000B7296 •...
  • Page 176 Analytical index SECTION REVISION 0 - 1 -...
  • Page 177 Analytical index ANALYTICAL INDEX WORKSHOP MANUAL F3 Sec. A - General description Sec. D - Head Battery............A-8 Camshaft and driving shaft timing ..... D-28 Brake fluid ............A-8 Chain tensioner ..........D-9 Carbon monoxide .......... A-7 Cylinder-head tightening sequence ... D-26 Engine coolant ..........
  • Page 178 Analytical index Sec. G - Starting Sec. L - Tightening torques Refitting the starter assembly ......G-7 Tightening torques ..........L-3 Refitting the starter transfer gear cover .... G-7 Starting ............G-3 Starter free wheel ..........G-5 Sec. M- Service tools Starter transfer gear ........

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