SERVICE MANUAL MOTOR FSE400 / 450 2002 / 2003 Contents Technical Specifications.....................................................84 Engine Removal and Installation.......................................86 Engine Disassembly.........................................................96 Inspection and Maintenance of Engine Components......................................................108 Engine Installation................................................................136 Regular Maintenance............................................................156 T echnical Specifications MODEL ENGINE Cubic Capacity 399 cc. / 449 cc. Type 4-stroke with 4-valve cylinder head Number of Cylinders One Cooling System Water-cooled Bore and Stroke 90 x 62.6 mm. / 95 x 62.6 mm. Injection E.F.I. Magneti Marelli Electronic Fuel Injection System Ignition E.F.I. integrated Clutch Hydraulic-drive disc clutch Gearbox 6 Gears Ec 400 / 450 FSE FRAME Type of Frame Deltabox, made from Cromoly rectangular tubes Aluminium Rocker Front Suspension Inverted WP 43-mm Diameter 295-mm Stroke Inverted Marzocchi 45-mm Diameter 295-mm Stroke Inverted Öhlins 46-mm Diameter 295-mm Stroke Rear Suspension Progressive System fitted with Ohlins Shock-Absorber 320-mm Stroke Front Brake 260-mm Disc Nissin Pump and Nissin single plunger clip Rear Brake 220-mm Disc Nissin Pump and Nissin single plunger clip Wheels Type U D.I.D. Rims fitted with Michelin Comp3 Tyres DIMENSIONS Wheelbase 1475 mm Seat Height 940 mm Minimum Ground Distance 340 mm Fuel Tank Capacity 9.5 Litres 84 T echnical Specifications Engine Removal and Installation 86 Engine Removal and Installation Engine Removal Before removing the engine from the frame, wash it with a steam machine. The following steps cover the disassembly sequence. ! Remove the saddle and the frame covers. Drain the oil in the engine. . Remove the engine plate. B A Drain the frame oil reservoir (A). Drain the engine coolant (B). Detach the cable (-) from the battery (1) and the ground coupler from the engine (2). 2 1 88 Engine Removal and Installation A Detach the wire clamp from the alternator (A) and the sensor cable from the tonewheel. 3 2 1 Detach the spark-plug arm (1), the engine-oil devaporizing tube (2), the engine-oil reservoir breather pipe (3). Loosen the clamp holding the cylinder head injector conduit (4). 4 5 Detach the wire clamp from the water-temperature sensor (5). Detach the connecting cable from the starter (6) and remove the starter. 6 89 Engine Removal and Installation Remove the water tubes (1). 1 Remove the lever from the pedal-operated starter. Remove the exhaust manifold (2). 2 Detach the radiator tubes. 90 Engine Removal and Installation Detach the engine-oil tube (1) in the frame reservoir. 1 Remove the gearbox lever. Remove the engine-pinion cover. Remove the clutch pump. Loosen the chain. 1 Remove the outlet pinion Seeger (1). 91 Engine Removal and Installation Remove the engine pinion. Remove the split pin and the brake pedal. CAUTION! Replace the split pins with new ones. ! Remove the engine from the frame. 92 Engine Removal and Installation Engine Installation Reverse the above operations to install the engine. ! B A Fit the screws and nuts securing the engine. NOTE: At this stage, nuts must only be tightened provisionally. The nuts securing the engine are self-locking. Upon removal, they cease to be self-locking and become useless. CAUTION! Replace the nuts securing the engine with new ones. ! ! D C Secure the screwheads with a spanner and tighten the nuts securing the engine at the specified torque. Item A B C D Nm 66 66 14 66 Kgf-m 6,6 6,6 1,4 6,6 Screw length (A): 108 mm. (B): 110 mm. (D): 103 mm. Tighten the brake-pedal screw at the specified torque. Brake-pedal screw: 29 Nm (2,9 Kgf-m) 93 Engine Installation Attach the engine pinion. A NOTE: The previous CW/ACW direction of this pinion must be duly noted, so that the same wear CW/ACW direction may be preserved. Attach the engine pinion Seeger. Attach the tube to the frame reservoir. 1 Tighten the exhaust manifold screw (1) at the specified torque. Apply NURAL 29 component to the exhaustsystem joints. 94 Engine Installation Apply LOCTITE 243 to the screw on the pedaloperated starter lever, then tighten. For 1.9 litre of API-compliant SF- or SG-grade motor oil and SAE 10W-40-viscosity oil into the oil inlet located in the frame (1) and check the level. DETAILS Engine oil capacity Oil replacement: 1.7 l Oil and filter replacement: 1.9 l Overall engine check: 1.9 l 1 ! 3 min. Start the engine and leave it ticking over for about 3 minutes. Stop the engine, wait for 3 minutes, then check the oil level with the dipstick. Minimum level Maximum level 95 Engine Installation Engine Disassembly 96 Engine Disassembly Detach the alternator cover. Turn the alternator rotor until the 7th tonewheel tooth becomes aligned with the position-sensor hole centre. NOTE: The cylinder-head lid must be removed with the piston in the compression stroke PMS. ! 2 1 Remove the cap bolt (1) and the timing-chain idler (2). 5 Remove the spark plug (5). Then, remove the cylinder-head lid screws in a diagonal sequence and detach the cylinder-head cover. 6 Remove the chain guide (6) and the brackets of the camshaft journals (7). 7 98 Engine Disassembly 1 2 3 Remove the centering devices (1), the input camshaft (2) and the output camshaft (3). NOTE: Prevent the centering devices from falling into the crankcase. ! Remove the cylinder-head side screw. Remove all four cylinder-head screws in a diagonal sequence. NOTE: Prior to loosening the cylinder-head screws, loosen the cylinder-head screws (6 mm) and the cylinder-base screws. ! Remove the cylinder-head screws and then the cylinder head. NOTE: In case of difficulty removing the cylinderhead, tap it with a plastic mallet. ! 99 Engine Disassembly 1 Remove the cylinder-head gasket (1) and the centering devices (2). 2 3 Remove the timing-chain guide (3). Remove the cylinder-base screws (4) and then the cylinder. 4 5 NOTE: In case of difficulty removing the cylinder, tap it with a plastic mallet. ! Remove the cylinder gasket (5) and the centering devices (6). 6 Cover the cylinder base with a clean cloth to prevent the piston-bolt spring ring from falling into the crankcase. 7 Remove the piston-bolt spring ring. (7) Remove the piston-bolt and the piston. 100 Engine Disassembly 1 2 Detach the oil-filter lid (1) and the oil filter (2). 5 Remove the starter followers (3), the centering devices (4) and the gasket (5). 3 4 1 2 Remove the pressure-pump lid (1) and the rotor (2). 101 Engine Disassembly Remove the coolant-pump cover. Remove the clutch lid. 3 3 Remove the centering devices (3) and the gasket (4). 4 Loosen the clutch-spring screws in a diagonal sequence (as illustrated) and remove them when they become totally loose. Detach the clutch press and the disc assembly. Remove the clutch rod. Flatten the clutch-hub washer. 102 Engine Disassembly Holding the clutch hub with the special tool supplied, remove the clutch-hub nut. Tool Part No.: Clutch-hub fastener ! Remove the clutch hub and the washer. CAUTION! The clutch hub has a specific fitting position in respect of the input shaft. Mark the position with an indelible marker on the lubrication groove. This mark must be taken into account during the installation process. ! Remove the clutch-drum assembly. 1 Detach the timing-chain guide idler (1). 103 Engine Disassembly 3 4 Remove the Seeger ring (3) and the pedal-operated starter intermediate gear (4). 5 Detach the foot-operated starter assembly. 6 Detach the pedal-operated starting pawl plate (6). Detach the pedal-operated starter intermediate pinion shaft. 1 Detach the oil-pump intermediate gear (1) and the oil-pump follower (2). 2 104 Engine Disassembly Remove the oil-pump assembly. Remove the selector-shaft assembly. 3 Detach the gear-centering device plate (3) Remove the crankshaft pinion bolt, the washer, the gear, the timing chain and the timing-chain gear. CAUTION! The crankshaft pinion bolt has a left-hand thread. ! Remove the alternator-rotor bolt and washer. Holding the puller with a spanner, loosen the rotor. Tool Part No.: MFS400134045, FSE400 flywheel puller ! 105 Engine Disassembly Use the special tool supplied to detach the alternator rotor. CAUTION! Tapping the alternator rotor with a hammer might damage it. ! Remove the lower oil-reservoir lid. Remove the crankcase left-hand set screws. Detach the crankcase using the special tool supplied. Tool Part No.: ME2595000: crankcase-detachment tool NOTE: Fit the crankcase-detachment tool on the lefthand side, so that its plate becomes parallel with the surface of the crankcase end. ! ! Remove the centering devices. 106 Engine Disassembly 1 1 2 2 Remove the shafts of the shifter forks (1) and the forks (2). 3 4 Detach the gearbox input-shaft assembly (3) and the gearbox output-shaft assembly (4). 5 6 Detach the crankshaft (5) and the rocker shaft (6). NOTE: Should this detachment operation prove difficult, tap both shafts with a plastic mallet in an alternating pattern. ! Remove the oil-intake filter and clean it. 107 Engine Disassembly Inspection and Maintenance of Engine Components Cylinder head.........................................................................110 Camshaft / Automatic decompression assembly.....................120 Piston and piston ring..............................................................122 Connecting rod...........................................................................125 Crankshaft....................................................................................126 Starter clutch ...............................................................................126 Oil pump.......................................................................................127 Clutch...........................................................................................127 Shifter forks and gear................................................................128 Transmission...............................................................................129 Bearings........................................................................................130 Seals.......................................................................................133 108 Inspection and Maintenance CAUTION! Identify the position of each part. Set them in groups (exhaust, admission) so that they may be assembled in their original positions. ! CYLINDER HEAD Disassembly Detach the intake pipe. Detach the engine-coolant pipe bracket. 1 2 Remove the tappets (1) and the adjustment washers (2), by hand or with a magnet. 110 Inspection and Maintenance Compress the valve springs and then use the special tools provided to remove the valve-rod semicones. Tool Part Description.: valve-spring compressor Tool Part Description: Adapter Tool Part Description: Pliers ! 1 2 1 Remove the valve-spring plate (1) and the valve springs (2). 111 Inspection and Maintenance Remove the valves from the opposite side. Use long-nosed pliers to remove the valve seals. Detach the valve-spring washer. NOTE: The valve detachment completes the standard disassembly operation. If you had not detached the valve guides for replacement after inspecting their associated parts, follow the instructions given in the valve-guide maintenance section. ! Cylinder-head deformation Decarbonize the combustión chamber. Using a ruler and a feeler gauge, check the surface of the cylinder-head gasket for signs of deformation. Measure the clearance in several places. If any of the clearance measurements is found to exceed the service limit, replace the cylinder head with a new one. Tool Part Description: Feeler gauge DETAILS Cylinder-head deformation Service limit: 0.05 mm (0.002 in) ! ! Valve-rod offsetting Using tapered blocks to hold the valve, measure the valve-rod offsetting with a dial gauge, as illustrated. If the offsetting is found to exceed the service limit, replace the valve with a new one. Tool Part Description: Dial gauge (1/100 mm) Tool Part Description: Magnetic support Tool Part Description: Set of tapered blocks (100 mm) DETAILS Valve-rod offsetting Service limit: 0.05 mm (0.002 in) ! 112 Inspection and Maintenance Valve-head radial offsetting Using one tapered block to hold the valve, measure the valve-head radial offsetting with the dial gauge, as illustrated. If the offsetting is found to exceed the service limit, replace the valve with a new one. Tool Part Description: Dial gauge (1/100 mm) Tool Part Description: Magnetic support Tool Part Description: Set of tapered blocks (100 mm) DETAILS Valve-head radial offsetting Service limit: 0.03 mm (0.001 in) ! ! Valve working-surface wear Check the working surface of each va ...