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TM RACING 250 Workshop Manual

4 stroke engine for mx, en, smx, smr-2020
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Workshop Manual
4 STROKE ENGINE
250-300
MX - EN - SMX
SMR - 2020
www.tmracing.it

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Summary of Contents for TM RACING 250

  • Page 1 Workshop Manual 4 STROKE ENGINE 250-300 MX - EN - SMX SMR - 2020 www.tmracing.it...
  • Page 3 TM Racing SPA, declines all liability for any errors in the compilation of this manual, and reserves the right to make any modifications required for the development of its products. Illustrations shown are approximate and, in some cases, may not precisely correspond with the part...
  • Page 4 SMX = COMPETITION SUPERMOTO The displacement, type of power source and type of use define the motorcycle model and engine of each TM Racing motorcycle. The combination of codes 1 and 3 identifies the standard engine type. The combination of the three codes fully identifies the motorcycle model.

  • Page 5: Table Of Contents

    INDEX ADJUSTMENTS/REPLACEMENTS ............7 1.1 ADJUSTING VALVES PLAY (WITH COLD ENGINE) ........8 1.1.1 Valve lifter spring replacement ............ 11 1.2 CAMSHAFTS RE-MOUNTING ..............12 1.3 ENGINE OIL AND FILTER CHANGE ............15 1.4 STANDARD CLUTCH REPLACEMENT ............17 1.5 SLIPPER CLUTCH REPLACEMENT ............19 1.5.1 Disc pack removal ................ 19 1.5.2 Discs replacement and re-mounting of clutch ......21 ENGINE DISASSEMBLY................ 27 2.1 ENGINE COMPONENTS LAYOUT ............28 2.2 PINION REMOVAL ...................29 2.3 CHAIN TENSIONER ..................30 2.3.1 Chain tensioner removal ..............
  • Page 6 INDEX 2.16 IDLE KICK STARTER REMOVAL (ONLY K.S.) ..........64 2.16.1 Starter dismantling ..............64 2.16.2 Re-mounting ................65 2.17 DRUM AND CLUTCH BELL ...............65 2.17.1 Disassembly ................. 65 2.17.2 Re-mounting ................67 2.18 TRANSMISSION SIDE COUNTER GEARS ..........69 2.19 CRANKSHAFT GEAR REMOVAL ..............70 2.20 OIL PUMP REMOVAL................71 2.21 GEARBOX COMMAND SHAFT REMOVAL ..........73 2.22 RATCHET-HOLDER GEAR REMOVAL............74 2.22.1 Ratchet holder gear and gearbox drive shaft clearance adjustment ..............75 2.23 SEMICASE ....................76 2.23.1 Aperture ..................
  • Page 7 Engine oil SAE 10W/50 Engine oil amount (oil change/ 1.25/1.35 litres engine overhaul) Straight tooth gear primary 18 / 59 20 / 59 transmission Clutch with multiple discs in oil bath Gearbox (with front couplings) 6 gears Gearbox ratios (250) (300) 14:30 13:31 16:28 15:27 20:29 16:23 22:27 20:24 24:25 20:21 20:19 22:20 Generator...
  • Page 8 MAINTENANCE MAINTENANCE TABLE • • • Change engine oil and cartridge oil filter • Clean mesh oil filter • • Clean exhaust screw magnet • • • Check engine fixing screw tightness • Replace spark plug and cap check • Check valve play • • Check distribution chain • • Replace distribution chain • • Check cylinder and piston wear • • Replace piston completely • • Check head • Check camshafts and rocker arms • Replace valves, springs, half cones and plates • Replace piston rod completely •...
  • Page 9 TROUBLESHOOTING ENGINE Problem Cause Solution The engine does not start or Insufficient compression struggles to start Replace 1. Piston seizing Replace 2. Rod head or foot seizing Replace 3. Worn piston segments Replace 4. Worn cylinder Tighten 5. Insufficient cylinder head tightening Replace 6. Insufficient head gasket sealing Tighten 7. Spark plug loosened Adjust 8. Incorrect valves play Replace 9.
  • Page 10 TROUBLESHOOTING Problem Cause Solution The shift control pedal 1. Selector switch recall spring weakened or broken Replace does not go back into position 2. Gear forks worn Replace The gears disengage 1. Sliding gears couplings consumed Replace 2. Brake grooves worn Replace 3. Housings for couplings on the gears worn Replace 4. Grooves on the forks command shaft worn Replace 5. Forks command pins worn Replace INSUFFICIENT ENGINE POWER 1. Air filter dirty Clean 2. Low fuel quality...

  • Page 11: Adjustments/Replacements

    1. ADJUSTMENTS/REPLACEMENTS...

  • Page 12: Adjusting Valves Play (With Cold Engine)

    ADJUSTMENTS/REPLACEMENTS ADJUSTING VALVES PLAY (WITH COLD ENGINE) The valve play can be adjusted with the engine mounted on the vehicle or with engine on the bench. NOTE: If the engine is mounted on the motorcycle, the airbox must be removed in order to access disassembly of the head cover. For the sake of convenience, the images shown below refer to an engine positioned on a workbench. Unscrew the screws (1) from the head cover (2). Remove the cover (2) using the corresponding gaskets (3) and (4). Check the status of the gaskets (3) and (4), replace them if worn. If it has not been removed yet, remove the spark plug (5) using a special wrench (6). NOTE: The spark plug (5) is of the long thread type.
  • Page 13 ADJUSTMENTS/REPLACEMENTS Mount a comparator (7) on the head. Remove the cap (8) from the generator cover (9). Check the status of the gasket (10), replace it if worn. Position the gearbox in neutral. Using a socket wrench (11), turn the crankshaft to position the piston at top dead centre, as indicated by the timing points (12) parallel to the edge of the head present on the intake (13) and exhaust (14) camshaft gear. Remove the comparator (7).
  • Page 14 ADJUSTMENTS/REPLACEMENTS Use a thickness gauge (15) to check the play between the cams (16) of the intake camshaft (13) and the valve pad is 0.15mm (0.006 in.). Use a thickness gauge (17) to check the play between the exhaust cams (18) of the intake camshaft (14) and the valve pad is 0.20 mm (0.008 in.). Otherwise the pads positioned on the valve stem head must be replaced, as follows: Unscrew the screws (19) of the clamps (20) and (21). Remove the clamps (20) and (21).

  • Page 15: Valve Lifter Spring Replacement

    ADJUSTMENTS/REPLACEMENTS Remove the camshafts (13) and (14). Lift the rockers (22) and remove the pads (23). 1.1.1 Valve lifter spring replacement In case it is necessary to replace the spring of the valve lifter pin, work as follows: - After dismounting the exhaust camshaft (1), unscrew the screw (2) and remove the plate (3). - Extract the spring (4) and the pin (5); check the status of the pin (5), replace if worn / ruined. - Replace the spring (4) and remount all the components working in the opposite direction.

  • Page 16: Camshafts Re-Mounting

    ADJUSTMENTS/REPLACEMENTS CAMSHAFTS RE-MOUNTING Mount a comparator (1) on the head and position the piston at top dead centre, rotating the crankshaft via the closed-end spanner (2). NOTE: Before remounting the camshafts, check that the gasket (3) is not worn, replace it if necessary. Mount the intake camshaft (4) and the exhaust camshaft (5) so that the tuning points (6) are parallel on the edge of the head.
  • Page 17 ADJUSTMENTS/REPLACEMENTS Mount the clamp (7) by inserting the centring pins in their corresponding seats. Remove the comparator (1). Mount the clamp (8) by inserting the centring pins in their corresponding seats. Screw the screws (9) alternately without tightening, then tighten the screws with a tightening torque of 10 Nm (1,0 kgm, 7,37 ft/lb).
  • Page 18 ADJUSTMENTS/REPLACEMENTS Check that valves play is correct (see “Valves play check” paragraph). Spread some “Tree Bond 1215” sealing paste onto the surfaces of the two crescents (10). Check that the gaskets (11) and (12), located on the head cover (13), are not worn. Replace them if necessary. Mount the head cover (13) by screwing the screws (14) crosswise and then tightening them with a torque of 10 Nm (1 kgm/ 7.37 ft/lb). Mount the spark plug (15). Check the gasket (16), replace it if worn, then remount the plug (17) screw- ing it with a tightening torque of 5 Nm (0,5 kgm, 3,69 ft/lb).

  • Page 19: Engine Oil And Filter Change

    ADJUSTMENTS/REPLACEMENTS ENGINE OIL AND FILTER CHANGE The oil must be changed with the engine off but still warm enough to allow the waste oil to flow out easily. Unscrew the four screws (1) and remove the skid plate (2). Position the motorcycle on a flat surface and prepare a suitable recipient under the same. Loosen the introduction cap (3) positioned on the right side of the engine (clutch cover) and the drain caps (4 and 5) positioned on the lower side of the engine; allow the oil to flow out into the recipient. In the meantime, remove the filter cover (6) situated on the right side of the engine, loosening the relative screws (7) and paying attention to collect the oil escaping.
  • Page 20 ADJUSTMENTS/REPLACEMENTS Extract the cartridge filter (8) and clean the surfaces of the guard and filter cover, check the seal O-rings (9 and 10) and replace them if necessary. Insert the original new TM Racing filter in a way to have the open side towards the outside of the engine. The filter must be inserted completely into its housing. Re-mount the O-rings and the filter cover, tightening the screws (7) to 8 Nm (0.8 kgm, 5.9 ft/lb). Wait for the oil to drain completely through the holes, clean the sealing surfaces, replace the aluminium washers, remove any magnetic debris (11) of the draining caps (4 and 5) and screw the caps back on, tightening to 20 Nm (2 kgm, 14,75 ft/lb). Prepare a measure with the amount of the prescribed engine oil necessary (see table) and pour from the introduction hole. Repeat the oil level check operation.

  • Page 21: Standard Clutch Replacement

    ADJUSTMENTS/REPLACEMENTS STANDARD CLUTCH REPLACEMENT Drain the engine oil as described in the relative paragraph. Unscrew the M5-L65 (1) and M5-L25 (2) screws, then remove the clutch cover (3). Remove the gasket (4). Unscrew the screws (5) of the clutch pack. Remove the spring (6) and the pressure plate (7). Remove the discs (8).
  • Page 22 ADJUSTMENTS/REPLACEMENTS Check that the pressure plate (9) is present. NOTE: On re-mounting the new discs, lubricate them with engine oil and make sure that the first disc mounted is lined, and that the first two smooth discs have thickness of 1.8 mm (the other discs have thickness of 1.5 mm). Remount the pressure plate (7) with the relative springs (6).

  • Page 23: Slipper Clutch Replacement

    ADJUSTMENTS/REPLACEMENTS SLIPPER CLUTCH REPLACEMENT 1.5.1 Disc pack removal Drain the engine oil as described in the relative paragraph. Unscrew the M5-L65 (1) and M5-L25 (2) screws, then remove the clutch cover (3) together with the corresponding gasket. Tighten the columns (4) supplied. Loosen the screws (5) and remove the springs (6). Remove the upper plate (7).
  • Page 24 ADJUSTMENTS/REPLACEMENTS Remove the pressure plate (8). Unscrew the nut (9). Remove the nut (9) and the washer (10). Remove the complete clutch pack (11).

  • Page 25: Discs Replacement And Re-Mounting Of Clutch

    ADJUSTMENTS/REPLACEMENTS Unscrew the columns (4) and remove the upper drum (4a). Extract the disk pack (12). 1.5.2 Discs replacement and re-mounting of clutch Mark the position of the arrow (13) on the lower drum (14), which must coincide with the position of the arrow embossed on the upper drum of the clutch pack.
  • Page 26 ADJUSTMENTS/REPLACEMENTS NOTE: On re-mounting the new discs, lubricate them with engine oil and make sure that the first disc mounted is lined, and that the first two smooth discs have thickness of 1.5 mm (the other discs have thickness of 2 mm). The clutch pack must finish with a smooth disc.
  • Page 27 ADJUSTMENTS/REPLACEMENTS Mount the disk pack (18) on the lower drum (14). Mount the upper drum (4a), making the arrow (19) coincide with arrow (13) of the lower drum and then tighten the columns (4). Mount the clutch pack (11).
  • Page 28 ADJUSTMENTS/REPLACEMENTS Insert the safety washer (10) and the nut (9). Tighten the nut (9) with a torque of 100 Nm/ 10 kgm/ 73.75 ft/lb + Loxeal 82-33. Lock the nut by raising the tabs of the lock washer (10). Mount the pressure plate (8). Mount the upper plate (7).
  • Page 29 ADJUSTMENTS/REPLACEMENTS Mount the screw (5) with the relative springs (6) and bushes (20). Tighten the screws (5) with a torque of 8 Nm (0.8 kgm/ 5.9 ft/lb). Remove the columns (4) supplied. Mount the clutch guard (3) and relative gasket, replace it if worn, and tighten the screws (1) ML-L65 and (2) ML-L25 gradually with a torque of 8 Nm (0.8 kgm/ 5.9 ft/lb). Introduce oil into the engine oil as described in the relative paragraph.
  • Page 30 ADJUSTMENTS/REPLACEMENTS...

  • Page 31: Engine Disassembly

    2. ENGINE DISASSEMBLY...

  • Page 32: Engine Components Layout

    ENGINE DISASSEMBLY ENGINE COMPONENTS LAYOUT Cylinder head cover Cylinder head Chain tensioner Cylinder Starter motor Throttle body connection coupling Temperature sensor Transmission cover Oil filter Water pump Ignition cover Gear sensor Clutch actuator Sprocket...

  • Page 33: Pinion Removal

    ENGINE DISASSEMBLY PINION REMOVAL Remove the clutch actuator with the pinion cover casing, as described in the relative paragraph. Remove the seeger ring (1) and the pinion (2). Slide the bushing (3) out. NOTE: On re-mounting the bush (3), check the status of the O-ring gasket (4) and replace it if worn. Lubricate the bush (3) and the gasket (4) with engine oil before remounting it.

  • Page 34: Chain Tensioner

    ENGINE DISASSEMBLY CHAIN TENSIONER 2.3.1 Chain tensioner removal Unscrew the plug (1) and remove it. Remove the gasket (2) and replace it remounting it on the plug (1). Unscrew the chain tensioner plug (3) and remove it. Remove the copper washer (4), replace it and remount it on the plug (3). Remove the chain tensioner (5). Remove the OR gasket (6).
  • Page 35 ENGINE DISASSEMBLY Place the chain tensioner (5) between the aluminium clamps (7) of a vice. Tighten the vice until end of stroke, making the oil located inside the chain tensioner (5) come out. Remove the chain tensioner (5) from the vice and press it manually until end of stroke, checking that it slides without obstacles. Further press the chain tensioner (5) and release; the mobile part (8) of the chain tensioner (5) must release without obstacles. NOTE: If the mobile part doesn’t slide freely, it is necessary to replace the chain tensioner (5).

  • Page 36: Remounting The Chain Tensioner

    ENGINE DISASSEMBLY 2.3.2 Remounting the chain tensioner Mount a new OR gasket (6) in the seat of the cylinder; use a screwdriver for positioning. Press the chain tensioner (5) until you hear the last click. Grease the chain tensioner (5) using grease. Insert the chain tensioner (5) in the seat of the cylinder. Manually push the chain tensioner (5) so that it inserts correctly on the OR (6) while it enters in its corresponding seat.
  • Page 37 ENGINE DISASSEMBLY Mount the chain tensioner plug (3), screwing it by hand, making sure you replaced the copper washer (4). Tighten the plug (3) with a tightening torque of 33 Nm (3,3 kgm, 24,34 ft/ lb). Use a punch (9) to push the chain tensioner so that the mobile part is re- leased while tensioning the chain. Remount the plug (1) making sure you replaced the OR gasket.

  • Page 38: Head

    ENGINE DISASSEMBLY HEAD 2.4.1 Head removal Remove the head cover, the camshafts and the chain tensioner as de- scribed in the corresponding paragraphs. Unscrew the three screws (1) of the timing system drive gear cover (2). Screw a 6 mm screw (3) on the cover (2). Remove the cover (2) by means of a snug puller (4) Recover shim (5) by removing the cover (2). Remove the gasket (6) of the cover (2) and replace it.
  • Page 39 ENGINE DISASSEMBLY Remove the bushing (8) while keeping the timing system drive gear steady (7). The bushing (8) must come out together with the needle roller bearing (9). Remove the chain (10) from the drive gear (7). Recover the rear shim (11). Completely remove the drive gear (7) complete with the shim (11) and let the chain (10) fall inside the carter.
  • Page 40 ENGINE DISASSEMBLY Loosen the two lateral nuts (12) at the left of the head. Unscrew the nuts (13) of the head studs (exhaust side) and collect the corresponding washers (14). Unscrew the nuts (15) of the head studs (intake side) and collect the cor- responding washers (16). Lift the head (17) and remove it.

  • Page 41: Head Dismantling

    ENGINE DISASSEMBLY Remove the gasket (18). Collect the centring bushings (19). 2.4.2 Head dismantling NOTE: Mark all components in a way to re-mount the exactly in the same place from where they were removed. Retrieve the pads (1) if they have not been already removed. Unscrew the screw (2) of the left intake rocker arm pin locking plate (3) and remove both of them. Screw an M5 screw on the pin (4) and remove it together with the rocker arm (5).
  • Page 42 ENGINE DISASSEMBLY Unscrew the screws (6) of the rocker pins. Check the status of the OR gasket (7), replace it if worn. Screw an M5 screw (8), remove the pin (9) and recover the right intake rocker arm (10). Screw an M5 screw M5 (11) on the pin (12) and remove the rocker arms (13), exhaust side. NOTE: The rocker arm (13a) on the right exhaust side is different from the other rocker arms.
  • Page 43 ENGINE DISASSEMBLY Using the relevant tool, compress the valves. Use a magnet to remove the two half cones (14). NOTE: Pay attention not to damage the support surfaces of the gaskets or of the combustion chamber. Make sure that the separator tool is upright, otherwise the valve stem may bend. Remove the tool and remove the double spring (15) and the relative valve (16). NOTE: Before sliding the valve out, check that there are no burrs on the stem, so that the valve-guide and relative oil seal are not ruined.

  • Page 44: Head Re-Assembly

    ENGINE DISASSEMBLY If ruined, remove the oil seal (17), the valve-guide (18), the relative OR gasket (19) and the valve seat (20). NOTE: The valve seats and the valves are different regarding intake and exhaust. Do not invert. Mark them before disassembling them in order to re-mount them correctly. 2.4.3 Head re-assembly If disassembled, re-mount the valve seat (20), the valve-guide (18) and the...
  • Page 45 ENGINE DISASSEMBLY Lubricate the pin (12) of the exhaust side rocker arms (13) with engine oil, remount them in the same exact position and unscrew the M5 screw (11). Lubricate the pin (9) of the right intake rocker arm (10) with engine oil and remount it in the same exact position and unscrew the screw (8). Lubricate the pin (4) of the left intake rocker arm (5) with engine oil and remount it in the same exact position and unscrew the M5 screw. Screw the screw (2) with the plate (3) applying loctite 243 on the thread.

  • Page 46: Head Re-Mounting

    ENGINE DISASSEMBLY Screw the screws (6) checking that the OR gasket (7) has been replaced. Remount the pads (1) in the same position from which they have been removed. 2.4.4 Head re-mounting Position the centring bushings (1) on the stud bolts (2). Replace the gasket (3) at every disassembly, and then mount it on the cylinder.
  • Page 47 ENGINE DISASSEMBLY Insert the head (4) on the studs. Screw the nuts (5) of the stud bolts, making sure the washer (6) has been positioned below. Cross-screw them following these 3 steps: Step one: tighten them with a torque of 20 Nm (2,0 kgm, 14,75 ft/lb). Step two: tighten with a torque of 32 Nm (3,2 kgm, 23,60 ft/lb). Step three: tighten with a torque of 48 Nm (4,8 kgm, 35,40 ft/lb). NOTE: It is recommended to replace the self-locking nuts (5) to guarantee the head is perfectly sealed. Apply graphite grease on the threads and screw the two nuts (7) by hand, then tighten them with a tightening torque of 12 Nm (1,2 kgm, 8,85 ft/lb)
  • Page 48 ENGINE DISASSEMBLY Recover the chain (8) from the inside of the carter by means of a hook or of a magnet. Insert, inside the head, the timing system drive gear (9) together with the corresponding inter- nal shim (10). Correctly place the timing chain (8) on the drive gear (9). Keep the drive gear (9) in position, lubricate the pin (12) and the bearing (11) with engine oil and mount the drive in its corresponding seat of the head, locking it (9) in position. Mount the shim (15) and the cover (13) taking care to replace the gasket (14) and positioning the cover (13) with the writing “TOP” on the top part of the head.

  • Page 49: Cylinder And Piston

    ENGINE DISASSEMBLY Screw the screws (16) with a tightening torque of 1 Nm (0,1 kgm, 0,74 ft/ lb). CYLINDER AND PISTON 2.5.1 Cylinder and piston removal Remove the head as described in the relative section. Remove the cylinder (1) by sliding it from the stud bolts. Remove the lock ring (2) of the piston (3) Extract the pin (4) and remove the piston (3). Remove the gasket (5). Remove the two OR gaskets (6) and remount two new gaskets.

  • Page 50: Strap And Oil Scraper Replacement And Mounting

    ENGINE DISASSEMBLY 2.5.2 Strap and oil scraper replacement and mounting top ring Clean the housing (1) of the straps on the piston from any carbon deposits. NOTE: Apply engine oil on the straps before mounting them on the piston. Be careful not to scratch the piston when re-mounting. Do not widen the straps excessively during mounting, so that they are not damaged.
  • Page 51 ENGINE DISASSEMBLY Insert a new gasket (7). Mount the cylinder (2) when the piston is mounted on the stud bolts and manually insert the piston pin (4) on the connecting rod head (6) with the aid of an aluminium punch (8). Mount the retaining ring (9). Completely insert the cylinder (2) in the stud bolts (10) by inserting the two sliders. NOTE: If the cylinder or the piston have been replaced, it is necessary to check compression by operating as described in paragraph “Compression check”.

  • Page 52: Compression Check

    ENGINE DISASSEMBLY 2.5.5 Compression check With replacement of the cylinder or piston, it is necessary to check that the distance between the piston crown and the upper surface of the cylinder is in within correct tolerance. After having mounted the cylinder, insert the relevant spacers (1) and tighten the nuts (2) with a torque of 25 Nm 2.5 kgm, 18.43 ft/lb . Position the piston at the top dead centre. Position the tool (3) with relative micrometer on the upper surface of the cylinder and zero. Move the pushrod (4) of the micrometer on the top flat part of the piston, first on intake side, then exhaust side, and detect the dimension. Correct compression: 0.55 ± 0.05 mm If the measurement does not lie within the tolerance established, the metal gasket (7) of the spacer must be purchased as a spare part, suitable to return within tolerance.

  • Page 53: Head Exhaust Manifold Replacement

    ENGINE DISASSEMBLY HEAD EXHAUST MANIFOLD REPLACEMENT To remove the exhaust manifold (1), unscrew the three screws (2); at the moment of remounting, use Three bond 1215 paste and screw the screws (2) with a tightening torque of 1,5 Nm (0,15 kgm, 1,11 ft/lb). HEAD COOLING CONNECTION REMOVAL Unscrew the screws (1) and remove the forks (2). Remove the connection (3) and check the OR gasket (4), replace it if worn.

  • Page 54: Clutch

    ENGINE DISASSEMBLY 2.10 CLUTCH 2.10.1 Clutch actuator removal with relative command Unscrew the screws (1) and remove the actuator (2) and the pinion protection (3). Unscrew the screw (4) and remove the bracket (5). Slide the mushroom (6) out. NOTE: On re-mounting, check the status of the gasket (7), replace it if ruined. Slide the clutch rod (8) out.

  • Page 55: Actuator Dismantling

    ENGINE DISASSEMBLY 2.10.2 Actuator dismantling Separate the two parts of the actuator and remove the piston (9). Check the conditions of the seal (10) and the OR gasket (11); replace them if ruined. Check the status of the OR gaskets (12), and replace if ruined. NOTE: On re-mounting, lubricate the gaskets and seal with clutch oil. Re-mount everything, proceeding in the opposite order to disassembly. Tighten the screws (1) with a torque of 8 Nm 0.8 kgm/ 5.9 ft/lb. 2.11 GEAR SENSOR Remove the clutch actuator as described in the relative paragraph. Unscrew the two screws (1). Use a screwdriver to lever and remove the gears sensor (2). NOTE: Re-mount everything in reverse order to disassembly, paying attention to position the cabling (3) of the sensor in the hollow (4).

  • Page 56: Flywheel Removal

    ENGINE DISASSEMBLY 2.12 FLYWHEEL REMOVAL 2.12.1 Flywheel cover Unscrew the M5-L20 screws (1) and M5-L25 screws (2). Remove the flywheel cover (3). Remove the gasket (4). Retrieve the two centring bushes (5). NOTE: On re-mounting, check that the two centring bushes (5) are positioned correctly and that the gasket (4) is not ruined, otherwise replace. Tighten the screws (1) and (2) with a torque of 8 Nm (0.8 kgm/ 5.9 ft/lb).

  • Page 57: Stator

    ENGINE DISASSEMBLY 2.12.2 Stator Disassembly Remove the flywheel cover as described in the relative section. Unscrew the screws (1) that secure the stator (2). Unscrew the screws (3) and remove the stop plate (4). Remove the stator (2) with the relative cabling. Mounting Re-mount the stator (2), tightening the screws (1) to a torque value of 5 Nm (0.5 Kgm - 3.68 ft/lb + Loxeal 82-33). Make sure the rubber cap (5) is fitted correctly on the cover and then tighten the two screws (3) of the stop plate (4) with a torque of 4 Nm (0.4 kgm, 2.95 ft/lb). 2.12.3 Pick-up Unscrew the two screws (1) and remove the pick-up (2). On re-mounting, check that the bushes (3) and the washers (4) are positioned correctly.

  • Page 58: Rotor

    ENGINE DISASSEMBLY 2.12.4 Rotor Disassembly Block rotor rotation (1) and use an impact gun to loosen the nut (2) with relative curve washer. Screw the extractor (3) onto the thread of the rotor (1) and tighten the screw (4) to detach the rotor (1) from the crankshaft. Remove the complete rotor (1). Retrieve the key (5).
  • Page 59 ENGINE DISASSEMBLY Remove the distribution chain (6). NOTE: Check that the distribution chain (6) and the relative gear (7) on the crankshaft are not worn, otherwise replace (refer to the relative paragraph for replacement of the crankshaft). Unscrew the screws (8) and remove the sliders (9), recover the spacers (10).

  • Page 60: Starter Motor

    ENGINE DISASSEMBLY 2.13 STARTER MOTOR 2.13.1 Disassembly Remove the flywheel cover as described in the relative section. Remove the idler (1) with the relative roller bearing cage. Remove the idler (2) with the relative roller bearing cages. Unscrew the screw (3) and remove it with the relative washer. Unscrew the two starter motor fastening screws (4).
  • Page 61 ENGINE DISASSEMBLY Tighten the M5 screw (5) onto the bush (6) and tighten until the bush (6) moves forward. Remove the starter motor (7).

  • Page 62: Re-Mounting

    ENGINE DISASSEMBLY 2.13.2 Re-mounting Make sure the “OR” gaskets (8) are not ruined and, if so, replace them. Check the status of the “OR” gasket (9) positioned on the starter motor (7); replace it if ruined. Lubricate the gasket (9) and the gaskets (8) with engine oil and then mount the starter motor (7). Use an aluminium or brass punch to push the bush (6) towards the inside of the engine, making the milled part coincide (6a) with the screw housing (6b). NOTE: If the bush (6) is forced, grease abundantly. Tighten the screw (3) with relative washer to a torque value of 6 Nm (0.6 Kgm - 4.42 ft/lb) + Loxeal 82-33.

  • Page 63: Water Pump

    ENGINE DISASSEMBLY Re-mount the idler (2) with the relative roller bearing cages and lubricating with engine oil. Re-mount the idler (1) with the relative roller bearing cage and lubricating with engine oil. 2.14 WATER PUMP NOTE: If water escapes from the little hole (1), the pump seal must be replaced. Loosen the screws (2) and (2a) M5-L20, screw (3) M5-L45 and screw (4) M5-L50.
  • Page 64 ENGINE DISASSEMBLY Remove the cover (5) with the relative gasket (6). Insert a “T”-shaped wrench (7) through the flywheel cover to block crankshaft rotation. Loosen the pump impeller (8). Use a screwdriver to remove the seal (9). NOTE: Lubricate the seal (9) with engine oil before mounting it. Re-mount the impeller (8) tightening with a torque of 6 Nm (0.6 kgm/ 4.42 ft/lb), greasing the thread. Re-mount the pump cover (5) checking that the gasket (6) is not ruined; replace it if necessary. Tighten the screws (2), (3), (4) with a torque of 8 Nm (0.8 kgm/ 5.9 ft/lb), replacing the aluminium washer of the screw (2a).

  • Page 65: Transmission Guard

    ENGINE DISASSEMBLY 2.15 TRANSMISSION GUARD Unscrew the screws (1): M5-L25 screw M5-L30 screw M5-L65 screw M5-L45 screw M5-L50 screw Remove the guard (2), with the aid of a rubber hammer. Remove the gasket (3) and recover the two centring bushes (4). Remove the water pump return (5).

  • Page 66: Bearing And Water Pump Oil Seal Removal

    ENGINE DISASSEMBLY 2.15.1 Bearing and water pump oil seal removal Heat the bearing to a temperature of 50°C and remove the bearing (6). WARNING: Use suitable personal protection equipment; Burns hazard. Remove the oil seal (7), operating from the external part of the guard with water pump disassembled. NOTE: On re-mounting, first mount the bearing (6) and then the seal (7), lubricating it with engine oil. 2.15.2 Seal and oil passage bored disc removal Remove the seeger (8), the seal (9) and the bored disc (10).

  • Page 67: Transmission Cover Re-Assembly

    ENGINE DISASSEMBLY 2.15.4 Transmission cover re-assembly Clean the surface of the lid and the semicase from any residues. Check that the two centring bushes (4) are in their respective housing. Replace and re-mount the gasket (3). Mount the water pump return (2) on the cover (5). Mount the cover (2), centring it on the bushes (4), paying attention not to ruin the seals.

  • Page 68: Idle Kick Starter Removal (Only K.s.)

    ENGINE DISASSEMBLY Tighten the screws (1) crosswise, positioning them in the relative housing, depending on their length. M5-L25 screw M5-L30 screw M5-L65 screw M5-L45 screw M5-L50 screw First screw without tightening with a torque of 8 Nm (0.8 kgm/ 5.9 ft/lb). 2.16 IDLE KICK STARTER REMOVAL (ONLY K.S.) Remove the transmission cover and the clutch bell as described in the relative paragraphs. Release the spring (1) from the relative housing, turn the starter (2) anti- clockwise by 1/4 of a turn. Remove the starter (2) complete with spring (3) and washer (4). 2.16.1 Starter dismantling In sequence, remove the washer (4), spring (3), bush and ratchets (5), the seeger (6), shim (7), gear (8), shaft (9), bush (10) and the spring (1).

  • Page 69: Re-Mounting

    ENGINE DISASSEMBLY 2.16.2 Re-mounting Re-mount the idle kick start in the relative housing and then turn the starter (2) clockwise by 1/4 of a turn and insert the pin (1) in the hole in the guard. NOTE: Lubricate the fitting hole abundantly with graphite grease. 2.17 DRUM AND CLUTCH BELL 2.17.1 Disassembly Remove the transmission cover as described in the relative paragraph. Remove the clutch discs as described in the relative paragraph. Remove the clutch mushroom (1), con un punzone aprire la rondella di sicureza (2).
  • Page 70 ENGINE DISASSEMBLY Remove the drum (3). Remove the washer (5). Remove the bell (6). Remove the two roller bearings (7) and the spacer (8).

  • Page 71: Re-Mounting

    ENGINE DISASSEMBLY Remove the washer (9). 2.17.2 Re-mounting Insert the washer (9). Re-mount everything, proceeding in the reverse order to disassembly. Make sure that the spacer (8) and ball bearings cage (7) are re-mounted correctly and lubricate them with engine oil. Proceed exactly with the reverse procedure. Re-mount the bell (6).
  • Page 72 ENGINE DISASSEMBLY Insert the washer (5). After having re-mounted the bell (6) and the drum (3), make sure the safety washer (2) has been positioned correctly. Screw the nut (4), blocking drum rotation with a spanner, with torque of 100 Nm 10.0 kgm 73.75 ft/lb + strong threadlocker (green). Lock the nut by raising the tabs of the lock washer (2).

  • Page 73: Transmission Side Counter Gears

    ENGINE DISASSEMBLY 2.18 TRANSMISSION SIDE COUNTER GEARS Components layout: Oil pump return gear. Idle gear kick starter removal. Kick starter (only for K.S.). Gearbox primary shaft. Gearbox command shaft. Ratchet-holder gear. Oil pump. Crankshaft gear. Remove the seeger (9) and the washer (10). Remove the oil pump return gear (1). Remove the roller bearing cage (11) and the washer (12).

  • Page 74: Crankshaft Gear Removal

    ENGINE DISASSEMBLY Remove the seeger (13). Remove the shim (14) and the gear (2). Remove the roller bearing cage (15) and the shim (16). NOTE: To re-mount the gears and relative roller bearing cages, proceed in reverse order to disassembly and lubricate with engine oil. 2.19 CRANKSHAFT GEAR REMOVAL Remove the seeger (1). Remove the gear (2).

  • Page 75: Oil Pump Removal

    ENGINE DISASSEMBLY 2.20 OIL PUMP REMOVAL Remove the clutch bell and the oil pump return gear, as described in the relevant paragraphs. Unscrew the screws (1). Remove the pump (2) by lifting it. Remove the two centring pins (3). Remove the two external selectors (4).
  • Page 76 ENGINE DISASSEMBLY Remove the internal rotor (5) Remove the pin (6) and the rotor (7). Remove the pin (8). Remove the separation plate (9). Remove the two internal sectors (10), (11) and the dragging pin. Extract the shaft (12) by pushing it. Remove the seeger (13), the washer (14) and remove the spring (15) of the oil maximum pressure valve. NOTE: On re-mounting, lubricate with engine oil and check that the dragging pins are correctly mounted and tighten the screws (1) with torque of 8 Nm (0.8 Kgm, 5.79 ft/lb).

  • Page 77: Gearbox Command Shaft Removal

    ENGINE DISASSEMBLY 2.21 GEARBOX COMMAND SHAFT REMOVAL Remove the transmission guard as described in the relative paragraph. Lift the shaft (1) and extract it from the engine. If it must be dismantled, release the spring (2) from the contrast pin (3) and remove it with the relative bush (4). To remove the pin (3) loosen the nut (5) with relative washer (6). NOTE: To re-mount, proceed in reverse order to the disassembly operations, paying attention that the spring (2) inserts correctly into the pin ( 7) fixed on the engine guard and that the two timing bolts (8), one on the shaft and the other on the ratchet-holder gear, are aligned.

  • Page 78: Ratchet-Holder Gear Removal

    ENGINE DISASSEMBLY 2.22 RATCHET-HOLDER GEAR REMOVAL Remove the gearbox command shaft and the oil pump return gear, as described in the relevant paragraphs. Unscrew the two screws (1). Unscrew the two screws (2). Remove the plate (3) and the plate (4). Lift and remove the Ratchet-holder gear (5).

  • Page 79: Ratchet Holder Gear And Gearbox Drive Shaft Clearance Adjustment

    ENGINE DISASSEMBLY Dismantle the ratchets (6) and (7) with the relative tips (8) and springs (9). NOTE: On re-mounting, make sure the ratchets (6) and (7) are inserted correctly in the relative housing; they cannot be inverted. Re-mount everything in reverse order to the disassembly operations, checking that the two timing bolts (10), one on the shaft and the other on the ratchet-holder gear, are aligned.

  • Page 80: Semicase

    ENGINE DISASSEMBLY 2.23 SEMICASE Remove the heating unit as described in the relevant paragraph. Remove all parts on the flywheel side and transmission side as described in the relative paragraphs. 2.23.1 Aperture Unscrew the screws (1): M6-L55 screw M6-L50 screw M6-L35 screw Use a rubber hammer to open the two semicases (2) and (3). Retrieve the two bushes (4) and (5). NOTE: There is a lamella (6) positioned on the semicase (2); loosen the screws (7) to remove it.

  • Page 81: Re-Assembly

    ENGINE DISASSEMBLY 2.23.2 RE-ASSEMBLY Check that all components are correctly positioned in their housing and that the centring bushes (4) and (5) are mounted. Clean the contact surface from any residual sealant paste and then spread a Treebond type sealing paste. Re-position the screws (1) in the relative housing depending on their length and tighten them with torque of 12 Nm (1.2 kgm, 8.68 ft/lb): M6-L55 screw M6-L50 screw M6-L35 screw 2.24 CRANKSHAFT, GEARBOX, GEARS DRUM Open the guards as indicated in the relative section. 2.24.1 COMPONENTS POSITION Crankshaft Gearbox primary shaft Gearbox secondary shaft Gears selector drum Ratchet Mesh oil filters...

  • Page 82: Gear Shafts Removal

    ENGINE DISASSEMBLY 2.24.4 Gear shafts removal Extract the secondary shaft fork pin (7). Release the forks (8) and (9) of the secondary shaft from the selector drum and remove them. Slide the primary shaft fork pin (10) out. Use a screwdriver to move the ratchet (11), releasing the drum (12), and then remove the drum from the semicase.

  • Page 83: Primary Shaft, Gear Sequence

    ENGINE DISASSEMBLY Remove the fork (13) of the primary shaft. Remove the complete gear assy (14). 2.24.5 Primary shaft, gear sequence Primary shaft First Fifth Third Fourth Sixth Second 2.24.6 Secondary shaft, gear sequence Secondary shaft First Fifth Third Fourth Sixth Second 2.24.7 Ratchet removal Unscrew the screw (15) and remove the ratchet (5) with the relative spring (16).

  • Page 84: Bearings Replacement

    ENGINE DISASSEMBLY 2.24.8 Bearings replacement Unscrew the screw (1) with relative primary shaft bearing safety washer (2). Heat the guards and remove the bearings. NOTE: After having replaced the bearings, re-position the safety washers and tighten the screws again and applying Loxeal 82-33 on the thread. 2.24.9 Components re-mounting Re-mount the components, proceeding in reverse order to disassembly, lubricating with engine oil and, when re-mounting the gearbox unit, paying attention to correctly position the forks (7) and (10) in the relevant positions:...
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