User manual GAS GAS FSE 400 - WORKSHOP MANUAL

MANUAL DE TALLER / WORKSHOP MANUAL MOTOR FSE 450 2004 / 2005 WORKSHOP MANUAL ENGINE FSE 450 2004 / 2005 ENGLISH Contents Technical specifications................................................................4 Uninstalling and installing the engine in the chassis..................5 Engine dismounting................................................................15 Engine mounting...................................................................33 Replacement of the standard clutch with the ADLER clutch APTC....................................................................................53 Inspection and maintenance of the engine components.......................................................59 Periodic maintenance...............................................................91 Technical Specifications MODEL FSE 400 / 450 ENGINE Displacement in cubic centimetres 399 cc / 443 cc Type 4 stroke DOHC 4 valves No. of Cylinders One Cooling System Water Cooled Bore and stroke 90 x 62,6 mm / 95 x 62,6 mm Injection Fuel injection electronic system Magneti Marelli Ignition Integrated in fuel injection electronic system Clutch Oil bath, multi-disk hydraulic action Gear Box 6 speed CHASSIS Frame Type DELTABOX, semi double cradle chassis made from rectangular Cromoly tubes. Aluminium swing arm Front Suspension Inverted Marzocchi Diameter 45 mm Run 295 mm Inverted Öhlins Diameter 48 mm Run 295 mm Rear Suspension Progressive system with Öhlins shock absorber Run 320 mm Front brake Disk of 260 mm Nissin Pump and simple / double Nissin calliper Rear brake Disk of 220 mm Nissin Pump and simple / double Nissin calliper Wheels Rims D.I.D. Type U with tyres Michelin Comp3 DIMENSIONS Wheel base 1.475 mm Seat Height 940 mm Minimum ground clearance 340 mm Fuel Tank Capacity 7.2 litres 4 Technical Specifications Un-installing and installaing the engine in the chassis 5 Un-installing the engine Un-installing the engine in the chassis Before dismounting the engine from the frame, wash it with a steam washer. The dismounting sequence is explained in the following steps. ! Dismount the seat and the frame covers. Empty the engine oil. Remove the engine plate. Empty the chassis (A) oil tank. Empty the coolant of the engine (B). B A Disconnect the wire (-) of the battery (C) and the engine earth connection (D). C D 7 Un-installing the engine E Disconnect the alternator clamp (E) and the phonic wheel sensor wire. H G F Disconnect the spark plug pipe (F), the engine oil vaporiser tube (G), the engine oil resevoir vent hose (H). Loosen the cylinder head injector tubing clamp (l). I Disconnect the starter motor connection wire (J). Dismount the starter motor removing the screws (K). J K 8 Un-installing the engine Dismount the water tube (L). L Remove the pedal starter lever (M). M Remove the exhaust collector (N). N Disconnect the 2 radiator tubes. 9 Un-installing the engine Disconnect the engine oil tube (O) in the chassis tank. O Remove the gearshift lever (P). P Q Remove the engine pinion protector (Q). R Remove the clutch cap (R). De-tense the chain. Remove the output pinion clip (S). S 10 Un-installing the engine Remove the Engine pinion (T). T NOTE: Observe which is the placement direction of the said pinion. Remove the carved bolts and the brake pedal. Remove the motor from the frame. 11 Un-installing the engine Installation of the engine in the chassis Mount the engine in inverse order to de-installation ! Fix the screws and engine fixing nuts. A NOTE: In this phase, temporarily tighten the nuts. The engine fixing nuts are self-locking. Once removed they lose their self-locking capability and are useless. PRECAUTION Replace the engine fixing nuts with new ones. ! ! B Hold the screw heads with a spanner and tighten the engine fixing screws with the specified torque. Element A B C Nm 66 66 66 Kgm 6,6 6,6 6,6 Length of the screws (A): 108 mm (B): 110 mm (D): 103 mm C Fix the brake pedal screw with the specified torque. Brake pedal screw: 29 Nm (2,9 Kg) PRECAUTION Replace the carved bolts with new ones. 12 Un-installing the engine Mount the engine pinion. NOTE: Observe which is the placement direction before the said pinion, to be able to achieve the same direction of wear. Place the engine pinion clip. Connect the chassis tank tube. 1 Fix the exhaust collector screw (1), with the specified torque. NOTE: Apply component NURAL 29 in the exhaust system joints. 13 Un-installing the engine NOTE: Apply LOCTITE 243 to the pedal starter lever screw. Fill 1.2 L of an engine oil classified SF or SG through the API service and with a degree of viscosity SAE 10W-40 through the oil fill mouth in the frame (A) and check the level. DATA Engine oil capacity Change of oil: 1 L Changing the oil and filter: 1.2 L Engine general inspection: 1.2 L A ! 3 min Start the engine and leave it running some three minutes at idle. Stop the engine and wait three minutes; immediately check the oil level via the rod. Minimum level Maximum level 14 Un-installing the engine Dismounting the engine 15 Dismounting the engine Loosen the 3 screws that hold the starter clutch cover. One of the 3 also holds the alternator cover. Remove the starter clutch cover. Extract the starter clutch. Loosen the 2 screws that hold the starter motor. Extract the starter motor. NOTE: The 2005 starter motor turns in the opposite direction to that of 2004. 17 Dismounting the engine Loosen the 7 retaining screws that hold the alternator cover. One of them is located in the starter clutch cavity. Remove the alternator cover. Loosen the 2 screws that hold the position sensor (Pick-Up) (A). A Remove the de-multiplier pinion (B). Loosen and extract the spark plug. 18 Dismounting the engine Loosen the crankshaft nut. NOTE: The nut loosens towards the right. A Turn the alternator rotor until placing the 7th tooth (A) of the phonic wheel in the center of the position sensor (Pick-Up) hole. Loosen the 3 screws that hold the cylinder head cover. Remove the cylinder head cover. With the help of the extractor (Ref: MFS400134045), remove the alternator rotor. 19 Dismounting the engine Loosen the 3 screws that hold the oil extractor pump. Remove the oil extractor pump cover. Remove the oil extractor pump. Loosen the 2 screws that hold the distributor chain tensor. Remove the distributor chain tensor. 20 Dismounting the engine Remove the oil distributor. Loosen the 2 lateral screws that hold the cylinder head to the cylinder. Loosen the rear screw that holds the cylinder to the cylinder head. Loosen the front screw that holds the cylinder to the cylinder head. Loosen the 8 screws of the covers of the 2 camshafts and the distribution chain skate. 21 Dismounting the engine Remove the distributor chain upper skate. Remove the intake camshaft cover. Remove the exhaust camshaft cover. Remove the intake camshaft. Remove the exhaust camshaft. 22 Dismounting the engine Loosen and remove cylinder head lateral screw. Loosen the 4 locking screws that hold the cylinder head. Remove the 4 screws. Remove the cylinder head. Remove the cylinder head gasket. 23 Dismounting the engine Remove the distributor chain front skate. Loosen the 2 screws that hold the cylinder to the engine housing. Hold the distributor chain and remove the cylinder. Remove one of the clips that hold the piston casing and push to remove it. Remove the cylinder gasket. 24 Dismounting the engine Loosen the 5 screws that hold the cover of the clutch disks. Remove the cover of the clutch disks. Screw the centering tools into place (supplied together with the tools for the motorbike) and tighten them to 10 Nm. NOTE: This operation is mandatory to ensure the correct dismounting of the clutch. Remove the 3 screws, the 3 washers and the 3 springs that hold the clutch unit. Remove the clutch press cover. 25 Dismounting the engine Remove the clutch pusher. Open the washer lug. Loosen the fixing bolt, blocking the clutch bell turn with the tool Ref. MFS4504500220. Remove the clutch unit. Loosen the 3 screws that hold the oil filter cover. 26 Dismounting the engine Remove the oil filter cover. Remove the oil filter and the spring. Loosen the screws that hold the clutch casing. Remove the clutch casing. Remove the clutch bell. 27 Dismounting the engine Loosen the screw that holds the distributor chain tensor skate and remove it. Remove the gear selector axle. Remove the gear pedal axle spring. Remove the gear pedal axle unit. Remove the starter intermediate pinion clip. 28 Dismounting the engine Remove the starter intermediate pinion. Remove the oil pump intermediate pinion. Remove the clip and remove the oil pump pinion. Loosen the 2 screws that hold the oil pump cover. Remove the oil pump cover. 29 Dismounting the engine Remove the oil pump gasket. Open the washer lug and loosen the crankshaft axle nut. NOTE: Turn the nut in a clockwise direction. Remove the crankshaft pinion. Remove the distributor chain pinion. Remove the distributor chain through the upper part of the housing. 30 Dismounting the engine Loosen the 10 screws that hold the left housing. One of the 10 screws that hold the left housing is located in the cavity of the oil pump. Loosen the 6 screws that hold the oil pump filter registry cover and remove it. Place the extractor (Ref. ME25950005) and tighten the middle screw to separate the two housings. Remove the left housing. 31 Dismounting the engine Remove thehousing gasket. Remove the 2 axles of the gearbox pins. Remove the desmodrome. Remove the gearbox gears unit. 32 Dismounting the engine Engine Mounting 33 Engine Mounting Introduce the gearbox gears unit. Place the desmodrome. Place the 2 axles and the 2 gearbox pins. One of the pins has a groove (A) for its correct position. NOTE: After mounting the axles of the gearbox pins and the pins, check that the gears engage normally. Place the gears of the transmission in a dead point position. The crankshaft pinion and the balance axle pinion have a mark (B) that eases its orientation. NOTE: Do not couple the crankshaft to the housing by tapping with a plastic hammer. Always use the special tool, otherwise the precision of the crankshaft alignment will be affected. A B 35 Engine Mounting New engine exhaust outlet (De-vaporization model 2005). D D Eliminate completely the remains of sealant and oil in the contact surface of the left and right housings. Place the new gasket (C) and the 2 guides (D) that facilitate the centering during the assembly of the two housings. C Wash the drain filter with solvent and place it. Assemble the two housings using the guides. With the help of the tool (Ref ME25950000) press until assembling the two housings. 36 Engine Mounting Place the 10 screws that fix the housing. Apply LOCTITE in the screw that is located in the hole of the oil pump. Housing screw: 11 Nm (1.1 kg) NOTE: After tightening the housing screws, check if the crankshaft, the intermediate axle and the transmision axle turn smoothly. If you detect a great resistance upon turning, try to free the axles by tapping them with a plastic hammer. Place the chain and the distributor pinion. Place the crankshaft cover. Place the crankshaft pinion. Apply LOCTITE in the hole of the screw that holds the distributor chain tensor skate. 37 Engine Mounting Fix the screw that holds the distributor chain tensor skate. Place the washer and tighten the nut with a dynamometric spanner. Place the oil tube. Place the starter intermediate pinion. Place the starter unit. 38 Engine Mounting Place the oil pump axle. Before mounting the oil pump: apply engine oil to the sliding surfaces of the pump casing, the exterior rotor, the interior rotor and the axle. Place the engine oil pump gasket. Place the engine oil pump. Fix, via the 2 screws, the oil pump cover. NOTE: Check that it turns freely. Place the oil pump. 39 Engine Mounting Fix, via the 2 screws, the pump cover. NOTE: Apply a small amount of LOCTITE to the threaded parts of the fixing screws of the oil pump and tighten firmly. Place the pump pinion and fix it with the clip. Fix the intermediate pinion of the pump with the clip. Place the gearbox lever axle. Place the washer. 40 Engine Mounting Place the bearing. Place the clutch bell. Place the washer. Insert the clutch casing with a new gasket. Fix it via the screws. Place the clutch unit. 41 Engine Mounting In the clutch mounting unit in the gearbox primary cam, make sure it is correctly aligned between the groove present in the interior recipient and the one in the primary camshaft of the gearbox. NOTE: In case of an incorrect assembly the correct lubrication of the clutch unit is not guaranteed and, therefore, damage or malfunctions of the clutch unit may be produced. Fix the fixing bolt with the security washer, blocking the clutch bell turn with the tool (Ref. MFS450450020). Close the washer lug. Place the clutch pusher. Place the clutch press cover. 42 Engine Mounting Place the 3 screws, the 3 washers and the 3 springs that hold the clutch unit. Loosen, gradually, the 3 screws that fix the clutch unit. Place the new gasket and the clutch disks cover. Fix, via the 5 screws, the clutch disks cover. Place the new oil filter (See maintenance chart). 43 Engine Mounting Fix, via the three screws, the oil filter cover. Apply oil in the water pump press. Place the press in its position. Place the water pump turbine and close the cover. Check the wear of the segment. 44 Engine Mounting Place the piston. PRECAUTION: Mount the piston with the mark situated in the head oriented towards the exhaust side. NOTE: Use a new piston plastic ring to prevent it from breaking if it folds. Place the 2 centers in the cylinder. Place the new gasket in the cylinder base. NOTE: Clean well the surface before placing the gasket. Place the cylinder. Place the piston in PMS (upper dead point) to avoid objects falling in the cylinder interior and that may damage it. 45 Engine Mounting Place the distributor chain skate. Place the 2 centers. Place the cylinder head gasket. NOTE: Clean well the surface before placing the gasket. Place the cylinder head. Place the 4 cylinder head interior fixing screws to the cylinder. 46 Engine Mounting Fix, via the 4 interior screws, the cylinder head to the cylinder. Note: Tightening torque of 4.5 Kg. Fix, via the exterior screws located in the front and rear part, the cylinder head to the cylinder. Fix, via the 4 lateral screws, the cylinder to the engine casing. Place the lateral screw of the distributor chain. E NOTE: Just before coupling the shaft axle to the cylinder head, apply a molybdenum oil solution to the stumps of the shaft axle and to the shaft surfaces. Likewise, apply engine oil to the supports of the stumps of the shaft axle (E). 47 Engine Mounting Place the exhaust cam shaft. NOTE: The groove of the cam shaft has a position mark. Place the intake camshaft. NOTE: The groove of the camshaft has a position mark. F Camshaft position marks (F). Place the exhaust camshaft cover. Place the intake camshaft cover. 48 Engine Mounting