User manual GAS GAS EC FSE 450 - SERVICE MANUAL 2002 & 2003

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 valve for signs of wear or damage. If any unusual signs of wear are found, replace the valve involved with a new one. Measure the thickness (T) of the valve working surface. If the thickness is found to exceed the specified value, replace the valve with a new one. Tool Part Description: Vernier calipers DETAILS Thickness (T) of the valve working surface Service limit: 0.5 mm (0.02 in) ! ! Valve rod deflection Lift the valve about 10 mm from its seat. Measure the rod deflection in two directions, "X" and "Y", at right angles to each other. Position the dial gauge as illustrated. If the deflection is found to exceed the service limit, decide whether it is the valve or the guide that must be replaced with a new one. Tool Part Description: Dial gauge (1/100 mm) Tool Part Description: Magnetic support DETAILS Valve rod deflection Service limit: 0.35 mm (0.014 in) ! ! 113 Inspection and Maintenance Valve rod wear Use a micrometer to measure the rod outside diameter. If the outside diameter is found to exceed the specified value, replace the valve with a new one. If the rod outside diameter is found to be within the specified value, but the deflection is not within the specified value, replace the valve guide with a new one. After replacing the valve or guide, check the deflection. Tool Part Description: Micrometer (0-25 mm) DETAILS Valve-rod outside diameter Normal: Inlet: 4.975-4.990 mm (0.1959 ­ 0.1965 in) Exhaust: 4.955-4.970 mm (0.1951 ­ 0.1957 in) ! ! Valve-guide maintenance Use the valve-guide puller to remove the valve guide towards the camshaft side. Tool Part Description: Valve-guide puller/fitter NOTE: Discard the valve guide. Only oversize valve guides are available as spares. ! ! ! Use the valve-guide reamer and shank to smooth the valve-guide holes in the cylinder head. Tool Part Description: Valve-guide reamer (10.8 mm) Tool Part Description: Reamer shank Oil the rod hole of each valve guide and use the valve-guide puller/fitter and adaptor to drive the guide into the hole. Tool Part Description: Valve-guide puller/fitter Tool Part Description: Valve-guide fitter adaptor ! ! CAUTION! Unless the valve-guide hole is oiled as instructed prior to the fitting of the new guide, the guide or the cylinder head may be damaged. Use the valve-guide reamer to smooth the guide inner walls after the valve guides have been fitted. Clean and oil the guides after smoothing them. Tool Part Description: Valve-guide reamer (5 mm) Tool Part Description: Reamer shank ! 114 Inspection and Maintenance Valve-seat width Use Prussian blue to spray the valve seat evenly. Fit the valve and attach a valve burnisher to it. Tap the sprayed seat several times in a circular direction to get a clear imprint of the surface contact. Tool Part Description: Valve-burnisher set ! The ring-shaped sprayed imprint left on the valve working surface must be a continuous, unbroken one. Also, the width of the sprayed ring, which is equivalent to the width of the valve seat, must not exceed the following specified value. DETAILS Valve-seat width (W) Normal: 0.9-1.1 mm (0.035 ­ 0.043 in) ! Grind the valve seat as required, if it is found to exceed the specified value. Valve-seat maintenance Inlet- and exhaust-valve seats are machined at three different angles. The seat contact surface is cut at a 45º angle. Inlet 45º 15º 30º 60º N-128 N-128 N-114 Exhaust N-128 N-121 N114 Tool (United States) Valve-seat knife: N-114, N-121 and N-128 Tools (Other countries) Description: Valve-seat grinding set Description:................N-128 Knife Description:................N-114 Knife Description:................N-121 Knife ! NOTE: Use the solid centering device together with the N-114, N-121 and N-128 valve-seat knives. CAUTION! The valve-seat contact surface should be checked after each cutting operation. ! ! 115 Inspection and Maintenance When fitting the solid centering device (1), turn it slightly. Settle the centering device properly. Fit the 45º knife (2), the adaptor (3) and the T-shaped shank (4). Initial seat-cutting operation Use the 45° knife to descale and clean the seat. Turn the knife around once or twice. Measure the valve-seat width (W) after each cutting operation. If the valve seat appears to be pitted or burnt, use the 45º knife to complete the seat-conditioning operation. NOTE: Cut only as little as possible off the seat, to avoid the risk of having to replace the tappet shim. ! 116 Inspection and Maintenance Upper narrowing cutting operation If the contact surface is too high up the valve, or if it is too wide, use the 30º knife (inlet side) and the 15º knife (exhaust side) to lower and narrow it. Contact surface is too high and too wide on the valve working area. Final seat-cutting operation If the contact surface is too low down the valve, or if it is too narrow, use the 60º knife to lift and widen it. If the contact surface is too high up the valve, or if it is too wide, use the 15º knife to lower and narrow it to the correct width. Contact surface is too low and too narrow on the valve working area. Upon achievement of the correct seat position and width, use the 60º knife very slightly to remove any burrs resulting from the previous cutting operations. CAUTION! Do not use any burnishing compounds after completing the final cutting operation. A completed valve seat must show a velvety finishing, but this should not be exceedingly polished or bright. This should provide a smooth surface for the final settling of the valve, which will have place during the first few seconds of the running of the engine. ! NOTE: After completing the maintenance of the valve seats, fit the cylinder head and checl the clearance of the tappets. (2-5 to 2-8) ! 117 Inspection and Maintenance Valve-seat tightness check With the valve and spring properly fitted, pour a small amount of petrol through the intake- or exhaust port. Check to see that no petrol is leaking through the valve seat. If a leak is found, tighten the sealing surface. WARNING Petrol is highly inflammable and explosive. Keep the petrol away from heat sources, sparks or flames. ! Valve-spring The strength of the helical spring keeps the valveseat pressed. A weak spring will result in loss of engine power and valve-mechanism clattering. Check the strength of the valve springs by measuring their unsupported length and the amount of strength required to compress them. If the unsupported length of a spring is found to be below the service limit, or if the strength required to compress it is not within the specified value, replace the inner and outer springs altogether. DETAILS Spring unsupported length (intake and exhaust) Service limit: Inner: 32.6 mm Outer: 36.3 mm ! ! DETAILS Valve-spring tension (intake and exhaust) Normal: Inner: 5.6-6.4 kgf/27.4 mm Outer: 12.6-14.5 kgf/30.9 mm 118 Inspection and Maintenance CYLINDER HEAD Fitting Fit the valve-spring seats. Apply a molybdenum-oil solution to each valve seal and press the valves into position. CAUTION! Do not re-use valve seals. ! Apply a molybdenum-oil solution to the valves, as illustrated, and then fit them into the guides. CAUTION! Care must be taken not to damage the valve-seal lips when fitting the valves into their guides. ! Fit the valve spring with the lesser-pitch end facing the cylinder head. (A) Lesser pitch (B) Greater pitch (C) Down Fit the spring clip by pressing it with the tappet. Fit the semicones on the rod end and release the tappet so that the semicones (1) become jammed between the clip and the rod. Check to see that the valve rounded lip (2) fits properly into the groove (3) in the semicone end. Tool Description: valve-spring compressor Tool Description: adaptor Tool Description: pliers CAUTION! Make sure to fit all the parts into their original positions. ! ! 119 Inspection and Maintenance CAMSHAFT - AUTOMA TIC DECOMPRESSOR ASSEMBL Y CAUTION! Do not try to disassemble the camshaft / automatic decompressor assembly. It cannot be repaired. ! Automatic decompressor Move the automatic-decompressor counterweight by hand to make sure that it works smoothly. If the automatic-decompressor counterweight does not work smoothly, replace it with a new one. Cam wear Cam wear usually results in the loss of the valve settings and in a subsequent loss of power. Use the micrometer to measure the cam height (H). If the wear is found to exceed the service limit, replace the camshaft with a new one. Tool Description: Micrometer (25-50 mm) DETAILS Cam height (H) Normal size: Inlet: 36.934 mm Exhaust: 36.893 mm Service limit: Inlet: 36.634 mm Exhaust: 36.593 mm ! ! ! 120 Inspection and Maintenance Camshaft-bridge wear With the camshaft fitted, use the plastic gauge to measure the oil clearance. Tools Description:.......................plastic gauge DETAILS Camshaft-bridge oil clearance (inlet and exhaust) Service limit: 0.150 mm ! ! Tighten the bridge-bracket screws evenly and in a diagonal sequence, at the specified torque. Camshaft-bridge bracket screw: 10 Nm (1 Kgf-m) NOTE: Remove the plastic gauge before turning the camshaft. ! Remove the camshaft-journal brackets and use the wrap-round ruler to measure the width of the compressed plastic gauge. This measurement should be carried out at the widest point of the compressed plastic gauge. If the camshaft-bridge oil clearance is found to exceed the service limit, measure the bridge-bracket inside diameter and the bridge outside diameter. Change either the camshaft or the cylinder head and the camshaft bracket, whichever is found to exceed the specified value. Tool Description:.......................lesser-calibre gauge DETAILS Camshaft-bridge bracket inside diameter (inlet and exhaust) Normal: 22.012-22.025 mm Tool Description:.......................micrometer (0-25 mm) DETAILS Camshaft-bridge outside diameter (inlet and exhaust) Normal: 21.972-21.993 mm ! ! ! Camshaft offsetting Using tapered blocks to hold the valve, measure the camshaft offsetting with the dial gauge. If the offsetting is found to exceed the service limit, replace the camshaft with a new one. Tools Description:.....................dial gauge (1/100 mm) Description:.......................magnetic support Description: Set of tapered blocks (100 mm) DETAILS Camshaft offsetting Service limit: 0.10 mm ! ! 121 Inspection and Maintenance CYLINDER Cylinder deformation Using a ruler and a feeler gauge, check the surface of the cylinder-block 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 block with a new one. Tool Description: feeler gauge DETAILS Cylinder deformation Service limit: 0.05 mm (0.002 in) ! ! Inner cylinder wall Check the inner cylinder wall for scratches, notches, or any other signs of damage. Measure the cylinder inside diameter at six points. Tool Description: cylinder-gauge set DETAILS Cylinder inside diameter FSE400: 90.000 - 90.015 mm FSE450: 95.000 - 95.015 mm ! ! PISTON AND PISTON RING Piston diameter Use the micrometer to measure the piston diameter at 15 mm from the skirt end. If the piston diameter is found to exceed the service limit, replace the piston with a new one. Tool Description: Micrometer (75-100 mm) DETAILS Piston diameter Service limit: FSE400: 89,880 mm Service limit: FSE450: 94,880 mm ! ! 122 Inspection and Maintenance Clearance between piston ring and groove Using the feeler gauge, measure the side clearances of the rings on pistons 1 and 2. If any of the clearances is found to exceed the service limit, replace the piston and the rings. Tool Description: feeler gauge DETAILS Clearance between piston ring and groove (Fig.1) Service limit: 1: 0.18 mm (0.0071 in) 2: 0.15 mm (0.0059 in) DETAILS Piston-ring groove width (Fig.2) Normal: FSE400 1º: 1,03 mm 2º: 1,22 mm FSE450 1º: 1,23 mm 2º: 1,53 mm Lubrication: 2,01-2,03 mm Tool Description: Micrometer (0-25 mm) DETAILS Piston-ring thickness (Fig.3) Normal: FSE400 1º: 0,985 mm 2º: 1,19 mm FSE450 1º: 2º: 1,19 mm 1,49 mm Fig.1 ! ! ! ! ! Fig.2 Fig.3 Piston-ring free end opening and piston-ring end opening Start by measuring the piston-ring free end opening with the vernier calipers, then place the piston ring across the cylinder and measure the ringend opening with the feeler gauge. Fig.4 Tool Description: Vernier calipers DETAILS Piston-ring free end opening (Fig. 4) Service limit: 1: 5.5 mm 2: 9.2 mm Tool Description: feeler gauge DETAILS Piston-ring end opening (Fig. 5) Service limit: 1: 0.50 mm 2: 0.50 mm ! ! ! ! Fig.5 123 Inspection and Maintenance Piston bolt and inside diameter of pin Use a small-calibre gauge to measure the pistonbolt inside diameter. If the diameter is found to exceed the service limit, replace the piston with a new one. Tool Description: Dial gauge (1/1000 mm) Tool Description: small-calibre gauge (18-35 mm) DETAILS Piston-bolt inside diameter Service limit: 20.030 mm ! ! ! ! Use the micrometer to measure the piston-bolt outside diameter at three points. If any of the measurements is found to exceed the service limit, replace the piston with a new one. Tool Description: micrometer (0-25 mm) DETAILS Piston pin outside diameter Service limit: 19.980 mm 124 Inspection and Maintenance CONNECTING ROD Connecting-rod foot inside diameter Use the small-calibre gauge to measure the connecting-rod foot inside diameter. If the connecting-rod foot inside diameter is found to exceed the service limit, replace the connecting rod with a new one. Tool Description: Dial caliper DETAILS Connecting-rod foot inside diameter Service limit: 20.040 mm ! ! Connecting-rod deflection and connecting-rod crank end side clearance The amount of wear at the connecting-rod crank end may be estimated by checking the connectingrod foot play. This method is also useful in checking the amount of wear shown by the component parts of the connecting-rod crank end. Tool Description: magnetic support Tool Description: dial gauge (1/100 mm) Tool Description: Set of tapered blocks (100 mm) DETAILS Connecting-rod deflection Service limit: 3 mm ! ! Push the connecting rod aside and measure the side clearance with a feeler gauge. If the clearance is found to exceed the service limit, replace the whole crankshaft with a new one, or bring the deflection and the side clearance found back into the service limit by replacing their worn parts (connecting rod, connecting-rod crank end bearing, crankshaft pin, etc.). Tool Description: feeler gauge DETAILS Connecting-rod crank end side clearance Service limit: 1 mm ! ! 125 Inspection and Maintenance CRANKSHAFT Crankshaft offsetting Using tapered blocks to hold the crankshaft, measure the amount of offsetting with the dial gauge, as illustrated. If the offsetting is found to exceed the service limit, replace the crankshaft with a new one. Tool Description: dial gauge (1/100 mm) Tool Description: magnetic support Tool Description: Set of tapered blocks (100 mm) DETAILS Crankshaft offsetting Service limit: 0.08 mm ! ! 1 ST ARTER CLUTCH Remove the hexagonal screws. (1). Starter-clutch screw: 26 Nm (2.6 Kgf-m) Fit the starter clutch in the correct direction, as illustrated. Apply engine oil to the starter clutch. Apply LOCTITE to the hexagonal screws and tighten them at the specified torque while holding the rotor with a spanner. 2 Attach the gear (1) to the starter clutch. Check to see that the rotor (2) is turning in the direction marked by the arrow, while holding the gear, and make sure that it never turns in the opposite direction. 1 126 Inspection and Maintenance OIL PUMP Check all the components. The screws securing the pump to the engine casing must be fitted with LOCTITE and given a specific torque. Oil pump: 10 N.m (1.0 kgf-m)