hsr-benelli S-series, R-series Service Manual

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SER

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Table of Content

1. GENERAL INFORMATION............................................................................. 6

1.1 Introduction…………………………………………………...……………. 7

1.2 Service quidelines……………………………………….………………… 9

1.2.1 Safety Warnings............................................................................... 9

1.2.2 Service Tools.................................................................................. 10

1.2.3 Operating materials........................................................................ 12

1.2.4 Engine Break-In.............................................................................. 13

1.2.5 Operating the engine on vehicle outside of water ......................... 13

1.3 Unit identification………………….…………………….……………...… 14

1.3.1 HSR-BENELLI Personal Watercraft Identification Numbers…...… 14

1.3.2 VIN number………………….……………………….…………...…… 14

1.3.3 Engine number ………….……………………….…………………… 14

1.3.4 Three stars – ultra low emission ……………………………….…… 15

1.3.5 Safety instructions ……………………………………………….…… 15

1.4 General specifications..........................................................................16

1.4.1 General data.................................................................................. 16

1.4.2 Standard Torque Specifications..................................................... 17

1.4.3 Convertion Chart ........................................................................... 18

2. MAINTENANCE ........................................................................................... 19

2.1 Flushing system attachment ............................................................. 21

2.2 Periodic maintenance chart ............................................................... 22

2.3 Periodic maintenance procedures .................................................... 23

2.3.1 Oil level check................................................................................ 23

2.3.2 Engine oil and filter replacement................................................... 24

2.3.3 Spark plugs replacement............................................................... 25

2.3.4 Valve clearance inspection............................................................ 26

2.3.5 Valve clearance adjustment........................................................... 27

2.3.6 Refilling of coolant.......................................................................... 31

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3. ENGINE.......................................................................................................... 32

3.1 Engine Removal and Installation........................................................ 33

3.2 Engine Disassembly/Assembly.......................................................... 41

3.2.1 CYLINDER HEAD ......................................................................... 41

3.2.2 CYLINDER AND PISTONS .......................................................... 58

3.2.3 ENGINE BOTTOM END ............................................................... 66

3.2.4 Cooling system Thermostat and Water pump .............................. 82

4. TRANSMISSION............................................................................................ 91

4.1 Transmission Dismantling.................................................................. 92

4.2 Transmission Assembling.................................................................. 98

4.3 Center flange bearing........................................................................ 107

5. PUMP........................................................................................................... 109

5.1 Jet Pump overview ............................................................................ 110

5.2 JET PUMP DISASSEMBLING ........................................................... 111

5.3 ASSEMBLING THE JET PUMP ......................................................... 116

5.4 Jet Pump Assembly into the PWC ................................................... 127

5.5 Assembly of the Reverse Gear (For Series – R Pro Model only)... 129

5.6 Assembling riding plate ................................................................... 130

5.7 Steering cable setting ...................................................................... 130

5.8 Trim system bleeding ....................................................................... 131

6. FUEL SYSTEM............................................................................................ 133

6.1 Fuel Tank and Fuel Pump ................................................................ 134

7. EXHAUST SYSTEM..................................................................................... 138

7.1 Muffler and Hoses ............................................................................. 139

7.2 Exhaust Manifold .............................................................................. 141

7.3 Assembling the hoses on exhaust manifold……………………….. 144

7.4 Leak test of the Exhaust hose ......................................................... 145

7.5 Assembling the exhaust manifold on the engine ……………….… 146

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8. COOLING SYSTEM..................................................................................... 147

8.1 Closed circuit cooling system ......................................................... 148

8.2 Opened circuit cooling systems ...................................................... 150

8.2.1 Exhaust cooling system ............................................................... 153

8.2.2 Oil cooling system ....................................................................... 156

9. STEERING SYSTEM ................................................................................... 157

SERIES-R STEERING SYSTEM

9.1 Steering Support Assembly ............................................................ 158

9.2 Assembly of the Steering Support on the PWC ............................. 160

9.3 Handle Bar assembly ........................................................................ 161

SERIES-S STEERING SYSTEM

9.4 Handle Pole Assembly ..................................................................... 164

9.5 Handle Bar Assembly ....................................................................... 170

9.6 Assembly of the Hanle Bar on the PWC ......................................... 171

10. HULL ........................................................................................................... 177

10.1 Dashboard cover ............................................................................... 178

10.2 Drainagebox ...................................................................................... 180

10.3 Baggage Cover .................................................................................. 181

10.4 Side Cover Assembling .................................................................... 184

10.5 Sponsons assembling ...................................................................... 185

11. ELECTRICAL SYSTEM .............................................................................. 186

11.1 General view (SERIES-S wiring diagram) ....................................... 187

11.1.1 Sector A ....................................................................................... 188

11.1.2 Sector B ....................................................................................... 188

11.1.3 Sector C ....................................................................................... 189

11.1.4 Sector D ....................................................................................... 189

11.1.5 Sector E ....................................................................................... 190

11.1.6 Sector F ....................................................................................... 190

11.1.7 Sector G ...................................................................................... 191

11.1.8 Sector H ....................................................................................... 191

11.2 General view (SERIES-R wiring diagram) ....................................... 192

11.2.1 Sector A ....................................................................................... 193

11.2.2 Sector B ....................................................................................... 193

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11.2.3 Sector C ....................................................................................... 194

11.2.4 Sector D ....................................................................................... 194

11.2.5 Sector E ....................................................................................... 195

11.2.6 Sector F ....................................................................................... 195

11.2.7 Sector G ...................................................................................... 196

11.2.8 Sector H ....................................................................................... 196

12. HSR-BENELLI DIAGNOSTIC SYSTEM ..................................................... 197

12.1 HSR-Benelli Utility Diagnostic System (HUDS) installation .......... 198

12.2 HSR Diagnostic Tool settings .......................................................... 204

12.3 Vehicle registration process ............................................................ 205

12.4 Periodic maintenance registration process ................................... 208

13. STORAGE ................................................................................................... 212

14. APPENDIX .................................................................................................. 214

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1. General Information

1.1 Introduction

This manual contains an introductory description of the HSR-Benelli Series-R and
Series-S Personal Water Craft (PWC) together with the procedures for

control/intervention and revision of the main components. It is designed primarily for
use by trained mechanics in a properly equipped workshop. A basic knowledge of
mechanics, the proper use of tools, and workshop procedures must be understood in
order to carry out maintenance and repair satisfactorily. All adjustments,
maintenance, and repair should be carried out only by qualified mechanics in
accordance with this service manual.

* The present manual has been prepared on the basis of state-of-the-art specifications valid at the
date of publication. In the case of modifications carried out after this date, differences may exist
between the contents of the manual and the PWC under review.

* The illustrations in this manual are used to highlight the fundamental principles and procedures of
basic interventions. They may not show exactly the PWC in your possession.

SYMBOLS

Whenever you see these ATTENTION symbols, heed their instructions!
Always follow safe operating and maintenance practices.

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1.2 Service guidelines

1.2.1 Safety Warnings

ATTENTION:

Clean inside and outside of watercraft prior to servicing.
Clean all parts before installing.
Always use a service apron to prevent damage to foot well and top-deck fiberglass.
Watch for sharp edges which can cause personal injury.
Protect hands and arms when working with sharp components.
Always use a soft-faced hammer and extreme care when removing difficult or stuck
components.
Some fasteners are installed with locking agents or lubricants. Use of impact drivers will aid
in fastener removal.
Always follow torques specifications located throughout manual.
Fasteners secured with either too little or too much torque may fail and cause severe
property damage, injury or death.
Always follow torque sequence patterns when founding this manual.
Tighten each fastener evenly and to the specified torque value, and with specified locking
agent.
Always use new gaskets, o- rings and seals, clips, cir- clips, and snap rings when
assembling components.
Never reuse self-locking nuts when assembling components.
Never reuse hose clamps when removed from fuel lines. Replace with small gear clamps.

WARNING:

Always use HSR-Benelli authorized lubricants, greases, and locking agents when
assembling components. Failure to do so may cause severe engine or vehicle damage.
Always disconnect the black (-) negative cable first from the battery when removing the
battery. When installing the battery, attach the red (+) positive cable first, then the black (-)
negative cable.
Wear appropriate clothing, eye protection, and rubber gloves when working with batteries.
Battery acid contains sulphuric acid and is extremely poisonous. Serious burns can result
when in contact with skin, clothing, eyes or internal body components. If battery acid is
ingested, drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or
vegetable oil. Call a physician immediately. Flush eyes for 15 minutes with water and seek

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prompt medical attention if acid comes in contact with eyes. Thoroughly wash affected
external body parts that come in contact with battery acid with water.
Keep hands, arms, legs, feet and hair away from rotating parts, hot engine and exhaust
components, drive pump and impeller and engine induction when engine is running.
Never attempt engine or driveline inspections and/or repairs without first removing lanyard
and battery cables.
Gasoline is highly flammable and explosive under certain conditions.
Always exercise extreme care when handling gasoline.
Do not smoke or allow open flames in or near the area where refuelling is performed or
where gasoline is stored.
Always refuel the watercraft outdoors and in a well ventilated area.
Do not fill the tank to the fuel cap.
If you get gasoline or oil on your skin or clothing, wash it off immediately with soap and water
and change clothing.
The engine exhaust from this product contains chemicals known to cause cancer, birth
defects or other reproductive harm.
Only run engine outdoors or in a well ventilated area.
Never run the engine for more than 10 seconds without cooling water supply.

1.2.2 Service Tools

HSR-BENELLI DIAGNOSTIC SYSTEM
(Benelli engine version)

IMPELLER TOOL

FLYWHEEL PULLER

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T.D.C. MEASURER
TRANSMISSION GEAR PULLER

GEAR NUT REMOVAL TOOL

COUPLER REMOVING TOOL
VALVE OIL SEAL REMOVING TOOL

OIL REMOVING TOOL

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1.2.3 Operating materials

WARNING:
Using of not recommended operating materials causes
damage to the engine and voiding of the warranty.

Fuel

- Super petrol unleaded DIN 51607, Octane between 95 and 98 ROZ/85 MOZ.

- US premium Unleaded gasoline (91/92/93 Octane) or 95/98 ROZ ISO 5146.

In case of emergency, unleaded fuel with 91 ROZ [RON] or 82.5 MOZ [MON] may be used
for a short time.

ATTENTION:

Lower-quality fuels could only be used in case of
emergency. If used regularly, they cause decreases in
performance and possibly damage to the engine.

Recommended lubricants

LUBRICANT

SPECIFICATIONS

Series-S

Series-R

Engine Oil
specification

HSR-Benelli engine oil 10w60,
ACEA, A3/B3/B4, API SL

Engine Oil
Filling volumes

Initial filling (completely dry system)

Oil change without changing filter

Oil change with filter

2,3 litres

1,7 litres

2,0 litres

2,7 litres

2,1 litres

2,4 litres

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LUBRICANT

SPECIFICATIONS

Series-S

Series-R

Transmission oil

Lubricated by Engine oil
system - HSR-Benelli engine oil

10w60, ACEA, A3/B3/B4, API
SL

see engine
oil volumes

see engine
oil volumes

Coolant

Permanent type of antifreeze

based on monoethylene glycol,

GREEN, freezing point < -38°C

Total
amount:
2,5 litres

Total
amount:
3,0 litres

Trim system liquid

Brake fluid DOT4

1.2.4 Engine Brake-In

WARNING:
HSR-BENELLI recommends not to operate the engine over
6,000 r/min [RPM] during first five hours of operation. This
protective braking-in has a positive effect on the engine„s
lifespan.

1.2.5 Operating the engine on vehicle outside of water

WARNING:
If PWC is outside of water its engine may be operated at idle
speed only for maximum of 30 seconds. Never run the
engine for more than 30 seconds without cooling water
supply.

If it is necessary to operate the engine longer than 30 seconds on vehicle out of water, the
flushing equipment must be used.

Use flushing system to operate vehicle out of water

An auxiliary cooling supply may be used if the watercraft cannot be operated in water during
adjustments.
If possible, always operate the watercraft in water rather than use an auxiliary cooling supply.

See chapter Maintenance – Flushing system connection.

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1.3 Unit identification

1.3.1 HSR-BENELLI Personal Watercraft Identification
Numbers

The engine Serial number and VIN number are used to register the watercraft. They are
unique numbers that distinguish each watercraft from others of the same model.
If the watercraft is ever stolen these numbers will help identify it. The owner should keep a
record of these numbers in a place other than the watercraft

1.3.2 VIN number

AT : Manufacturing Country
HSR : HSR-BENELLI
A: Model Code

1001: Sequential Serial Numbers

Production Month: C (Month code)
Production Year : 8
Model Year : 08 (Model year : 8 = 2008)

You will find the serial number at the right rear side of your PWC

1.3.3 Engine number

Number is beside the starter motor.

Engine Number:
BH33 Engine Type
000001 Serial Number
JJ808 Model and Year Code

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1.3.4 Three stars – ultra low emission

The three-star label identifies engines that meet the Air Resources
Board’s Personal Watercraft and Outboard marine engine 2008
exhaust emission standards. Engines meeting these standards have
65% lower emissions than One Star – Low Emission Engines.

1.3.5 Safety instructions

For Series-S ONLY

Safety Instructions sticker is placed under the handle pole on
the Series-S models.

For Series-R ONLY

Safety Instructions sticker is placed on the Luggage Cover on
the Series-R

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1.4 General specifications

1.4.1 General data

2009 HSR-BENELLI

Series – S Series - R

Length: ..........…………….. 2,32 m Length: ..........………. 3,23m

Width:…………………….. 0,70 m Width:………………… 1,20 m
Height:……………………. 0,67 m Height:……………….. 1,03 m
Dry Weight:………………. 168kg Dry Weight:………….. 263 kg
Category: …………………. Stand-up Category: ……………. Runabout
Riders:…………………….. 1 person Riders:………………….1 – 3 persons

Fuel Capacity: 18 litres 4, 75 US Gal Fuel Capacity: 70 litres 18,47 US Gal

Emission Certification: Three Star - Ultra Low Emission

ENGINE

EMISSION CONTROL SYSTEM

SFI ( Sequential Fuel Injection )

FUEL

Recommended fuel:

- Super petrol unleaded DIN 51607, Octane between 95
and 98 ROZ/85 MOZ.

- US premium Unleaded gasoline (91/92/93 Octane) or
95/98 ROZ ISO 5146.
SPARK PLUG

CHAMPION RG4HC

SPARK PLUG GAP

0,75 – 0,8 mm ( 0.0028 – 0.032 in.)

ENGINE DISPLACEMENT

1130 cc

NUMBER OF CYLINDER

3

CYLINDER LINING SURFACE

Nicasil

BORE x STROKE

88 x 62 mm

COMPRESSION RATIO

12 -13:1

CYLINDER COMPRESSION

9,6 +/- 1 bar ( 140 +/- 14,5 psi )

MAXIMUM HORSEPOWER

Series-S Pro Edition - 142 hp,
Series-S Race Edition - 162 hp,
Series-R Naked Edition - 142 hp,
Series-R Pro Edition - 172 hp

COOLING SYSTEM

- closed loop with thermostat;

- auxiliary opened loop oil & exhaust cooling systems

THERMOSTAT

70°C

EXHAUST OVERHEATING WARNING

Exhaust Manifold Overheat switch – engine limiter
activation

COOLANT OVERHEATING WARNING

Cooling manifold Sensor – 90° engine limiter activation

ENGINE LUBRICATION SYSTEM

Wet Sump

ENGINE OIL SPECIFICATIONS

HSR-BENELLI Engine oil 10w60,
ACEA, A3/B3/B4, API SL

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RPM LIMITER

9200 – 9300 1/min – Determined by ECU

EXHAUST SYSTEM

Waterbox with water injector

ENGINE MANAGEMENT SYSTEM

FUEL DELIVERY

WALBRO Multi-point fuel injection

IDLE SPEED

1700 1/min +/- 50

MAGNETO GENERATOR OUTPUT

13.5V / 48A at 5000 rpm

BATTERY

Series-R: 12 Volts 20Ah
Series-S: 12 Volts 14Ah

FUSES

30A – Alternator, 15A – Fuel Pump, 7,5A – Stop switch,
30A - Main

STARTER

Electric Motor 12V – 850 W

PROPULSION

JET PUMP TYPE

SOLAS – Axial Flow – 12 Veins – Steel stator

IMPELLER

Stainless steel – 3 blade
Series-S Pro Edition – 14/25,
Series-S Race Edition – 15/26,
Series-R Naked Edition – 11/19,
Series-R Pro Edition – 11/19 XL

COUPLING TYPE

Six piece coupler + Damper

MINIMUM DEPH FOR OPERATION

60cm (2 Ft)

HULL / BODY

HULL MATERIAL

Fiberglass, RTM Process

1.4.2 Standard Torque Specifications

The following torque specifications are to be used as a general guideline.
Use standard torque values for the appropriate size fastener when torque values are not
specified.

Always consult the specific manual section for torque values of fasteners and use of
locking agent.

RECOMMENDED TORQUE SPECIFICATION

STAINLESS STEEL FASTENERS (METRIC)

4 mm

3 -3,5 NM (40–42 in.lbs.)

5 mm

4 – 4,5 NM (45-52 in.lbs.)

6 mm

5,5 – 6,5 NM (66-78 in.lbs.)

7 mm

17 – 23 NM (13-16 ft.lbs.)

10 mm

35 – 40 NM (26-30 ft.lbs.)

12 mm

54 – 60 NM (40-44 ft.lbs.)

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1.4.3 Convertion Chart

ft. lbs.

x 12

= in. lbs.

in. lbs.

x 0,0833

= ft. lbs.

ft. lbs.

x 1,356

= Nm

in. lbs.

x 0,115

= kg-m

Nm

x 0,7376

= ft. lbs.

kg-m

x 7,233

= ft. lbs.

kg-m

x 86,796

= in. lbs.

kg-m

x 10

= Nm

in.

x 25,4

= mm

mm

x 0,03937

= in.

in.

x 2,54

= cm

mile (mi.)

x 1,6

= km

Km

x 0,6214

= mile (mi.)

Ounces (oz.)

x 28,35

= Grams (g)

Grams (g)

x 0,035

= Ounces (oz.)

lb.

x 0,454

= kg

kg

x 2,2046

= lb.

Cubic inches (cu in)

x 16,387

= Cubic centimeters (cc)

Cubic centimeters (cc)

x 0,061

= Cubic inches ( cu in)

Imperial pints (Imp pt)

x 0,568

= liters (l)

Liters (l)

x 1,76

= Imperial pints (imp pt)

Imperial quarts (Imp qt.)

x 1,137

= liters (l)

Liters (l)

x 0,88

= Imperial quarts (Imp qt)

Imperial quarts (Imp qt.)

x 1,201

= US quarts (US qt)

Liters (l)

x 1,057

= US quarts ( US qt)

US gallons (US gal)

x 3,785

= Liters (l)

Liters (l)

x 0,264

= US gallons (US gal)

Pounds – force per square inch

(psi)

x 6,895

= Kilopascals (kPa)

Kilopascals (kPa)

x 0,145

= Pounds – force per square inch (psi)

Kilopascals (kPa)

x 0,01

= Kilograms- force per square cm

Kilograms- force per square cm

x 98,1

= Kilopascals (kPa)

C to F: 9 ( C + 40) 5 - 40 = F F to C: 5 ( F + 40) 9 - 40 = C

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2 Maintenance

The table in chapter Periodic maintenance table provides the manufacturer’s
recommended intervals for maintenance work. Following the maintenance recommendations,
a long life span of the vehicle can be achieved and unnecessary environmental damage
prevented. The Maintenance intervals specified in the table should not be exceeded by more
than 10%.
All activities described in this manual must be carried out by trained service staff.

In case of warranty repairs HSR-BENELLI reserves the right to request warranty approval
documents for performed periodic maintenance of eligible PWC.

ATTENTION:
The vehicle owner or user is responsible adhering to the
maintenance intervals. HSR assumes no liability for damage
that arises due to maintenance not carried out.

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2.1 Flushing system attachment

For service purposes engine of vehicle could be started out of water using Flushing system
to provide cooling by tap water.

ATTENTION:

Engine could be operated only at idle rpm even if flushing kit is
attached. Do not run engine when flushing kit is attached
continuously for a period over 5 miutes to prevent overheating.

Flushing system hose (Series-R, LEFT SIDE) Flushing system fitting

Flushing system hose (Series-S, RIGHT SIDE)

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2.2 Periodic maintenance chart

Jobs to be performed

After the

first 10

hours of

operation

At 25 h of
operation

At 50 h of
operation

At 75 h of
operation

At 100 h

of

operation

Each

additional

25 h

Each

additional

100 h

Visual Check of all hoses,
pipes, hose clips,

x x x x x x x

Visual Check of all nuts,
bolts and fixing elements

x x x x x x x

Change oil and oil filter

x x x x x x x

Lubricate throttle housing
cable connection

x x x x x x x

Lubricate steering pivot
(dismantle)

x x x x x x x

Check valve clearance and
adjust in necessary

x x x x x x x

Check clean Flame Arrestor

x x x x x x x

Check / tighten engine
mount bolts

x x x x x x x

Check valve for fuel
ventilation

x x x x x x x

Check throttle operation
system

x x x x x x

Check and clean jet pump
(including cooling system
sieve)

x x x x x x

Check / renew drive damper

x x x x x x

Check steering and lanyard
operation

x x x x x x

Replace rubber duckbills if
necessary (Series-S only)

x x x x x x

Check and grease Battery
clamps

x x x x x x

Check/ adjust TPS

x x x x x x

Check impeller torque 100
Nm

x x x x x x

Replace Pump Seal, check
Pump Bearing / replace if
necessary

x x x x x x

Change Spark plugs

x x

Check free play of the
damper coupler and replace
if necessary

x x x x x x

Check the transmission oil
line banjo bolts for tightness

x x x x x x

Replace inline Filter in the
exhaust cooling (water
injection) system

x x x x x x

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2.3 Periodic maintenance procedures

2.3.1 Oil level check

NOTE:
Use a clean, lint-free cloth

PWC must be leveled to perform oil level verification. Check
the oil level when engine is cold by pulling the oil dipstick out
of the engine. The oil level must be within the minimum and
maximum marks. When engine is warm proceed the same
way but insure your check is done five minutes after engine is
stopped to enable the remaining oil to go back to the bottom
of the engine. Oil level may be higher than at cold engine
since the oil volume increases in warm condition.

WARNING:
Engine oil may be hot.

Note: Engine must be cold

If the valve clearance is out of specifications take note about
your current reading for adjustment.

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2.3.2 Engine oil and filter replacement

Remove the dipstick.
To suck the oil out with an oil removing pump, put the suction
hose as deep as possible into the engine into dipstick tube.
Suck the oil out of the engine completely.

Take out old oil filter
Before installation of new oil filter, grease filter O-ring slightly
with engine oil.
Install new oil filter and tighten with specified tightening torque.

Open oil filling cap on engine valve cover (shown by arrow).
Refill the engine with new engine oil.

ATTENTION:

ALWAYS USE HSR-BENELLI ENGINE OIL.

NOTE: FOR SERIES-S
Volumes of oil in the engine: min 1,7 litres (without change of oil filter), max 2,0 litres

(change of oil filter included). In case of completely dry engine: 2,3 litres.

Required torque for oil filter cover: 24 Nm
Required torque for ignition coils: 10 Nm
Required torque for spark plugs: 12 Nm

WARNING:
Never fill with more than 2,3 l of oil into the engine (oil filter included).

NOTE: FOR SERIES-R
Volumes of oil in the engine: min 2,1 litres (without change of oil filter), max 2,4 litres

(change of oil filter included). In case of completely dry engine: 2,7 litres.

Required torque for oil filter cover: 24 Nm
Required torque for ignition coils: 10 Nm
Required torque for spark plugs: 12 Nm

WARNING:
Never fill with more than 2,7 l of oil into the engine (oil filter included).

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2.3.3 Spark plugs replacement

ATTENTION:
Replace spark plugs only when engine is COLD. In other case there is a risk to
damage cylinder head thread. Use only spark plugs of recommended type in
order to avoid engine damage.

NOTE: RECOMMENDED SPARK PLUGS
CHAMPION RG4HC

Replace engine spark plugs every 100 hrs. Check electrode gap and spark plug condition
after the break-in period (10-12hrs).

1 Unscrew nut A

2. Remove ignition plate B

3. Remove ignition coil C

4. Unscrew spark plug
To reinstall:
Follow the procedure exactly in the opposite way.

WARNING:
Do not tighten spark plugs with torque over 12Nm not to damage cylinder head

thread.

Electrode gap spark plug: 0,75 – 0,80 mm

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2.3.4 Valve clearance inspection

ATTENTION:
Valve clearance must be checked and
adjusted when the engine is cold (room
temperature)

Remove cylinder head cover to access cylinder head
(See Head cover Removal)
Taking the engines cylinder 1 to the TDC verify that also
the marks and of the Camshaft sprockets are aligned
between them and with the head plain.

Measure the clearance between camshaft and valve cap
by a thickness gauge making sure that the clearance is
in the specific range.

Start from measuring clearance on:

Cylinder 2 EXHAUST valves;
Cylinder 3 INTAKE valves

Proceed the measurement for other valves, rotating the
engine using a wrench on a special nut of camshaft
(measure the clearance when the cams corresponding to
eligible valves are in upwards position):

Cylinder 1 EXHAUST valves;
Cylinder 2 INTAKE valves

and

Cylinder 3 EXHAUST valves;
Cylinder 1 INTAKE valves

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SPECIFIC VALUE
Intake = 0.30 ~ 0.35 mm
Exhaust = 0.35 ~ 0.40 mm

Note: Engine must be cold

If the valve clearance is out of specifications take note about your current reading for
adjustment.

2.3.5 Valve clearance adjustment

ATTENTION:
To prevent falling of removed parts into
crankcase please use proper sealing material
at timing chain drive casing.

Remove the chain pad (6), unscrewing the two fixing
screws (7).

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ATTENTION:
Make sure that the distribution chain does not
fall into the casing.

Remove the chain tensioner.

ATTENTION:
Mark the removed elements for correct
reassembling (cylinder number, camshaft
IN/EX, etc).

Remove mounting screws of camshaft holders (8) and
remove them. Take care of removing metal bushings of
each holder.
Remove the bridge (9), unscrewing the fixing screws.

Raise the camshaft paying attention to keep all teeth of
the timing chain in place, allowing the removal of the valve
caps (1).

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Remove the cap (2) of the valve which requires
adjustment using a magnet. To change the valve
clearance, replace the shim with one of a different
thickness. Measure the thickness of the removed shim.

NOTE:
Mark and record the locations of the valve caps and
shims so that they can be reinstalled in their original
positions.

Valve clearance calculation:

In order to set a proper valve clearance, please follow the points below:

1. Measure the clearance of each individual valve and make note about this reading (at
cold engine).

2. Check the present shim size.

3. Calculate the thickness of the replacement shim.

Example: your reading on the intake valve is 0,27mm (spec. 0.30 ~ 0,35mm)

Clearance is less than specified. The shims are available in 0,025 mm steps of thickness.
Present shim gives 0,27mm clearance with its thickness 2,350 mm.

Shim size calculation:

Present clearance: 0,27mm. 0,30 ~ 0,35mm needs to be achieved by reducing shim size.
Using of 2 size thinner shim 2,300mm (=2,350mm – 2x0,025mm) increases the valves
clearance: 0,27mm+2x0,025mm=0,32mm. The result meets specified range.
The present 2,350mm shim is to be replaced by 2,300mm shim.

4. Assemble the removed pats of cylinder head (see Camshaft installation above),
tighten the fasteners according to given specifications.

5. Remeasure the valve clearance and readjust if necessary.

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Installing Cylinder Head cover

ATTENTION:
Always use new gaskets.

Position the gaskets of the head cover (1 and 2 ).

ATTENTION:
Make sure that gaskets (2) do not fall into the
head during cover installation.

*Apply THREEBOND® paste as shown on the drawing.

Install the cylinder head cover and insert rubber
bushings and the screws (3) and (4) as shown on the
figure.

NOTE:
Replace the rubber bushings of the screws (3) and
(4) during reassembly.

Tighten the head cover mounting screws to the
specific torque, take care not to cut or damage
rubber bushings.

Tightening torque: 10 N·m (1 Kg-m)

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2.3.6 Refilling of coolant

WARNING:

This process is a very sensitive and requires special attention. The risk is that
air bubbles remain in the cooling system so that the heat of the engine cannot
be transferred into the radiator of the Jet Pump.

The total volume of coolant is:
for SERIES-S 2,5 litres;
for SERIES-R 3,0 litres.

1. Fill the cooling system with cooling liquid of recommended
type as much as possible.

2. Press on the coolant hoses and ensure to get a maximum of
air bubbles out of it. Add more coolant.

3. Repeat this process 2-3 times until no more coolant can be
added.

4. Do a test run in the water to heat the engine. Stop the engine
couple of times and check the anti freeze coolant level. Add
coolant if necessary.

5. Repeat this process couple of times until the thermostat has
opened and the entire amount of coolant circulates in the cooling
system.

WARNING:

If the engine is hot the Jet Pump is hot too and might be
dangerous for your health.

NOTE: Ensure the engine is fully filled with coolant after thermostat was opened.

WARNING:

Changing the battery ensure that engine is cold.

NOTE: Use only high quality coolant (See recommended lubricants)

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3 Engine

3.1 Engine Removal and Installation

The installation of the engine and engine subsystems is the reverse to their removal. During
engine installation, several important notes must be made.

Always verify the correct number of engine mounting strap shims are installed on

each engine mounting post. Remove the pump to check driveshaft alignment, add
shims to move the engine up or down to align properly.

Always verify that the engine does not interfere with critical routings such as the

steering cable, cooling hoses, and main wiring harness.

Steering cable must be fixed on front left engine mounts to avoid damage from

engine.

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Engine installation into the PWC:

(shown for Series-R Pro)

Lift the engine into the PWC using a lifting device.

Insure you hook on the exhaust hose and the and inline the
Spider Couplers.

Position the Engine into the 4 x engine supports on the hull.

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Ensure the exhaust hose and the Spider Couplets are properly
aligned.

Take a metal ruler like shown on the picture and check the
alignment of the Spider coupler to see if the engine is
positioned properly according to propulsion system.

If the engine position needs to be adjusted use special washer
with 0,5 and 1 mm thickness to align the system.

NOTE: If the engine needs to be heightened you have to
use washers on all four engine supports.

Apply blue Loctite on the screws and tighten the screws of the
engine support with specified torque.

Tightening torque: 30 N·m

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Tighten the exhaust hose with a screw driver.
Plug in the cooling hose for the 3 in 1 hose.
Plug in the water relieve hose for the 3 in 1 hose.

Plug in the water relieve hose for the exhaust manifold

Tighten the fuel hose to the fuel rail

NOTE: Take care to install the sealing rings

Plug in the cooling water supply lines as shown on the picture
into the oil cooler.

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Plug in the water relieve hoses from the oil cooler.

Plug in the water supply hose for the waterpump.

Plug in the coolant hose for the temperature thermostat.

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Plug in the Ignition wires for the ignition coils.

NOTE: Ignition wires are marked with numbers of
corresponding cylinders.

Plug in the wires for the injectors.
NOTE: Injector wires are marked with numbers of corresponding cylinders.

Plug in the connector for t he heat sensor.

Plug in the TPS sensor.

Plug in the pick-up coil sensor.

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Plug in the oil pressure sensor.

Plug in the SSSA connector.

ö

Tighten the ground wire.

Connect the wires of the voltage regulator on the ignition cover.

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Connect the positive wire from the starter to the starter relays.

Connect the positive starter cable to the positive starter
connector.

Connect the acceleration wire to the throttle bodies.

For adjustment of the acceleration wire insure the throttles
are on open wide throttle position.

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Adjust the acceleration wire until specified free play
on throttle lever is given.

SPECIFIC VALUE
CLEARANCE (A) = 2 - 3 mm

NOTE: Insure that engine oil and coolant liquid are on proper level.

NOTE: REMOVING THE ENGINE IS A REVERSE PROCEDURE TO DESCRIBED ABOVE

3.2 Engine Disassembly/Assembly

3.2.1 CYLINDER HEAD

Head cover removal

Loosen and remove self-locking nuts (3) and coil support
rods (2).

Slip off ignition coils (4).
Remove the spark plugs using 16mm spark plug wrench.
Unscrew 8 valve cover mounting screws (5)

ATTENTION:
Take note of the position of the screws for correct
reassembling.

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NOTE:
Replace 8 screws rubber bushings (5) during
reassembling.

Removing Camshafts

Remove the head cover.
Remove the chain pad (6),
Unscrewing the two fixing screws (7).

ATTENTION:
Make sure that the distribution chain does not fall
into the casing.

Remove the chain tensioner.

ATTENTION:
Note the position of the elements for correct
remounting.

Unscrew the fixing screws of the large caps (8) and
remove them.
Remove the bridge (9), unscrewing the fixing screws.
Remove the camshafts and the chain.

Camshafts Inspection

Check that camshafts with a micrometer, as shown on the
picture.
If the value does not enter within the specific measure,
change the element.

INTAKE SHAFT VALUE LIMIT:

A= 36.6 mm B= 27.85 mm
EXHAUST SHAFT:
A= 36.6 mm B= 27.85 mm

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Check the deformation of the camshaft with a comparator,
as shown on the picture.
If the value does not enter within the specific measure,
change the element.

INTAKE AND EXHAUST SHAFT DIMENSIONS

LIMIT:

MAX. VALUE = 0.03 mm

The maximum play between the distribution camshaft and seat
is 0.1 mm.
If the value does enter within the specific value, change the
element.

VALUE LIMIT

CAMSHAFT AND SEAT

Max. play= 0.01 mm

Chain, Sprocket Wheels and Camshaft Chain Guide Inspection

Check the state of wear of the camshaft distribution chain
(1). If the element has blocked links, is excessively worn,
change it.

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Visually check the timing chain guides:

1) Fixed guide (FRONT PART)

2) Mobile guide (REAR PART)

3) Upper guide (FIXED ON HEAD)
If one or more elements are worn, change it/them.

NOTE
Always replace chain guides if timing chain is to be
replaced.

Chain Tensioner Inspection

Check the free sliding of the chain stretcher rod.
Check the state of the chain stretcher spring.
Check the integrity of the chain stretcher.
If an element or its components are damaged or ruined,
change it/them.

Camshafts installation

Using a special tool set the piston of cylinder #1 to TDC
position.

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NOTE: Ensure that during assembling engine
crankshaft is not moved from 1st cylinder TDC
position and camshafts marks are aligned as shown
on the picture.

Position the exhaust shaft and the timing chain, position
the holders in their original direction (written on the
outside) and tighten the fixing screws according to the
diagram in the figure.

Tightening torque:

1st phase: 6 N·m;
2nd phase: 13 N·m

Position the intake shaft and the timing chain, position
the holders in their original (mark on the outside of
holder should match the number engraved on inside of
cylinder head) and tighten the fixing
screws according to the diagram in the figure.

Tightening torque:

1st phase: 6 N·m;
2nd phase: 13 N·m

INTAKE

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Position the timing chain on the camshaft sprockets.
Position the bridge and the upper chain pad and tighten the fixing screws in two phases in
shown sequence.

Tightening torque:

1st phase: 6 N·m;
2nd phase: 13 N·m

NOTE:
Always oil the sliding parts with Teflon SINTOFLON paste.

Position the chain tensioner (1) complete with O-ring (2) and
tighten two screws (6).

Tightening torque: 10 N·m

Position the rod pushing spring (3) and the washer (4) and
tighten tensoiner cap nut (5).

Tightening torque: 7 ÷ 8 N·m

ATTENTION:
Always check that chain tensioner is in

position 0 before mounting it.

Align the marks on the camshaft sprockets as shown on the
figure.
Count 30 chain pins from position 1 to position 30 as indicated
on the figure.

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Check that cylinder 1 cams are turned towards each other as
on the figure.

Remove Cylinder Head

Remove the chain tensioner, chain pads, camshafts
(see above).

Loosen and remove the eight nuts and washers (1)
indicated in the figure according to the shown sequence
and two screws on the right side of the engine (timing
chain side).

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Cylinder Head Inspection

WARNING:

Do not use a pointed instrument to avoid
damaging or scatching:
Spark plug hole threading
Valve seats

Check and eventually eliminate carbon deposits in the
combustion
chamber with a rounded-off scraper.

If the surface is damaged or scratched, change the
element. Check the distortion of the cylinder head as
indicated in the figure. If is is outside the specific value,
rectify the head.

VALUE LIMIT
HEAD DISTORTION
max. distortion = 0.2 mm

Mounting Cylinder Head

NOTE:
Always use new gaskets. Clean and degrease the
head surface and the cylinders.

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Position the head/cylinder gasket.
Position the cylinder head. Position the fixing washers and nuts.

Tighten to the specified torque following the shown sequence in following
phases:

1st phase: 10 Nm;
2nd phase: 30 Nm;
3rd phase: 45 Nm;
4th phase: angle of 100°;

5th phase: tighten 2 bolts on timing chain side with

10.8 Nm

NOTE:
Apply grease to the fixing nuts to oil the threading

(MOLIKOTE® BR2 PLUS grease).

Valves and Valve Spring

Remove Valves

Remove the cylinder head (see ("REMOVE CYLINDER
HEAD").
Position the head on a slightly inclined surface to show the
valves to remove, perpendicular to the surface.

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To remove the valves use a valve dismantling instrument (2)
with correct attachment (3), press the valve down and take off
the two semi-cones.
Loosen the clamp and remove the valve and its components
as shown on picture.

The following procedure is applied to the valves (4), the springs
(5 and 6) and relative components (7, 8 and 9).

NOTE:
Make sure that valve (4) has a perfect seal by pouring
petrol into the conduits and making sure that
there are no losses through the valves. Make sure
that the valves are perfectly sealed.

Remove the small bowls taking note of the position on each
valve and coupling them to their pads.

Free the pusher spring plate (7) using the specified instrument
to remove the two lock cones.
Remove the external spring (5), the internal spring (6), valve (4),
the valve seal ring and the lower cup.

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Valves and Valve Guide Inspection

The following procedure must be carried out on all valves and relative valve guides.
Check that values (A) and (B) are within the tolerance of the specific values.
If values (A) and (B) are not within the value limits, change the elements.

INTAKE VALVE DIAMETER LIMIT

A max. = 5.05 mm
B min. = 4.965 mm

EXHAUST DIMENSION LIMITS

A max. = 5.05 mm

B min. = 4.955 mm

Check condition of the surfaces of the valves.
Eliminate eventual carbon deposits.
If the surface is excessively ruined, change the element.

Check thickness (A) indicated in the figure.

VALVE THICKNESS VALUE LIMIT

A= 1,0 ÷ 1,3 mm

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Check the deformation of the legs of the valve.
If the concentricity value does not enter within
the margin, change the element.

VALVE REFORMATION

VALUE LIMIT

0.01 mm

Valve Seat Inspection

The following procedure must be applied to all
the valve seats. Eliminate eventual carbon deposits.

Apply the tincture of bluing (b) on the face of the valve.
Install the valve into the appropriate seat.

Press it using the guide on the seat to leave an evident
impression.
Measure the width of the seat of the valve.

NOTE:
It will be necessary to remove the bluing at the point
at which the seat and the face of the valve touch.

NOTE:
If the trace is not partial or not uniform, carry out a

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smoothing operation on the face and the seat of the
valve.

Smooth:

• the face of the valve

• the seat of the valve

NOTE:
After having changed the cylinder head or the valve
and the relative guide, it will be necessary to smooth
the seat and face of the valve.

Apply a coarse grained paste (a) for smoothing on the
face of the valve.

ATTENTION:
Do not allow the smoothing paste to enter into the
space between the stem of the valve and the guide.

Apply disulfide of molybdenum to the stem of the valve.
Insert the valve into the cylinder head.
Rotate the valve until its face and seat shine uniformly,
Then remove the smoothing paste.

NOTE:
To obtain optimum smoothing results, strike the seat
of the valve lightly while turning it forwards and
backwards in your hands.

Apply a fine grained paste to the face of the valve and
repeat the above operations.
Completely eliminate the smoothing paste from the face and
the seat of the valve at the end of each operation.
Apply the tincture of bluing (b) on the face of the valve.
Install the valve in the cylinder head.
Press the valve through the valve guide and on the valve
seat to leave a clear trace.

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Valve Spring Inspection

The following procedure is valid for all valve springs.
Measure the length (a) of the free valve.

If the value does not enter within the envisaged limits, change
the spring.

FREE VALVE SPRING LENGTH

External valve spring
Tollerance limit: 37 mm
Internal valve spring:
Tollerance limit: 34.0 mm

Bring the spring to a value length (c) and check the value of
the
load:

VALUE LIMIT

External spring length: 23.2 mm
Load value limit: 565 N
Internal spring length: 21.2 mm
Load value limit: 314 N

Check the inclination (a) of the valve spring as illustrated in
the figure.
If (a) does not enter within the specific value, change it.

VALUE LIMIT

INCLINATION SUCTION SPRING A = 2 mm
INCLINATION EXHAUST SPRING A = 2 mm

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Valve Caps Inspection

The following procedure must be applied to all valve caps.
Check that caps are not broken or scratched, in other case
replace them.

Mount Valve

The following procedure must be applied to all the valves and
relative components.
Oil the valve stem with the recommended oil.

RECOMMENED OIL
Disulfide of molybdenum oil

Mount the lower small cup (1).
Check that the thickness of the small cap is 1.5 mm.

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WARNING:
Always use new gaskets and oil seals.

Mount the rubber valve seal (2) with the appropriate pad (3).

ATTENTION:
Intake valves are larger than the exhaust valves.

Insert the valves (4).

Position the internal (5) and external (6) springs as shown in
the figure.

Insert the two lock cones (7) into the upper small cup (8).

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Position the small cap as shown in the figure.
Use the dismantling valve instrument making sure that the
valve is correct.

Position the calibrated pads (9) and valve caps (10).

ATTENTION

Make sure that the individual valve lifters and

the valve guide are re-mounted in the original
position.

NOTE:
Check that valve caps turn easily by rotating them
with a finger.

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3.2.2 Cylinder and Pistons

Dismantle Cylinder Body

Remove the cylinder head (see "REMOVE CYLINDER
HEAD").
Remove the gasket of the head, the cylinder body (1) and
the base of the cylinders gasket beneath.

Check that the walls do not present signs of seizure with the
pistons. Check the ovalisation of the cylinders
as indicated in the figure.

ATTENTION:
In the case of changing the cylinder block also
change the pistons and the elastic straps, if necessary.
The cylinder is distinguished by a letter that indicates
the class it belongs to. The cylinder-piston coupling
must be carried out among the same classes that they
belong to.

The letters are on the external front part (exhaust side) of the
cylinder.

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Dismantle Water Collector

Unscrew and remove the three screws (1) and remove the
collector (2).

Check Water collector

Check eventual breaks on the collector and if necessary change
the piece.

Mount Water Collector

ATTENTION:
Always use new gaskets.

Position the gasket (1)and the collector (2) and tighten the screws
(3).

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Piston

Dismantle Piston

Remove the cylinder (see "DISMANTLE CYLINDER BODY").

The following procedure must be applied to all 3 pistons.
Remove the elastic ring (1).

ATTENTION:
Do not use hammers for the piston pin removal (2).

Remove pin (2) and remove piston (3).

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Check Piston

The following procedure must also be applied to all the other
pistons.
Check eventual breaks on the piston.
Use a micrometer, as shown in the figure, to check that the
value (P) enters within the specific value.

ATTENTION:
In the case of changing one or more pistons:
The piston is distinguished by a letter that indicates the class it belongs to.
The cylinder-piston coupling must be carried out among the same classes that they belong to.

NOTE:
The maximum play of the piston is of 0.1 mm.

Change the piston if necessary.

Check Piston Rings

The following procedure must be applied to all the piston rings.
Check the absence of scuffing and traces of shrinkage on every
Piston ring.
Check that the edge of the section is well defined and free in the
housings.
Whenever wear in the segments is found, change the pistons
as well.

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Piston Ring Play

Measure the lateral play of the 1st and 2nd segment using a feeler.
If one of the two plays exceeds the limit specified, change both
the piston and the segments.

PISTON RING PLAY
SERVICE LIMIT:(1st): 0.20 mm

(2nd): 0.18 mm

PISTON RING WIDTH
STANDARD:(1st ): 1.02 – 1.04 mm
(2nd): 1.01 – 1.03 mm
(OIL RING): 2.01-2.03

PISTON RING THICKNESS
STANDARD:(1st): 0.97 – 0.99 mm
(2nd): 0.97-0.99 mm

Check Piston Pin

The following procedure must be applied to all the piston pins.
Check that value (a) enters within the specific value.

NOMINAL VALUE

a = 18,995 ÷ 19,000 mm

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Check the value of (b).

NOMINAL VALUE
b = 19,002 ÷ 19,008 mm

NOTE:
If the play between the piston pin and the pin is
more than 0.03 mm, change the piston.

Mounting Piston Rings:

Install the piston rings in the order: oil ring , 2nd piston ring
, 1st piston rings.
The first element to insert into the slot of the oil ring
is the spacer (1). After having positioned the spacer, insert its
lateral rings (2).

NOTE:
The spacer and the lateral rings do not possess a
particular upper or lower side so they can be inserted
in any way.

WARNING:
When installing the spacer, pay attention so that its
ends are not superimposed in the cable.

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Install the 2nd piston ring (3) and the 1st piston ring (4).

NOTE:
The form and width of the 1st and 2nd piston ring are
different.

W4 = 3.1 ± 0.1 mm

W3 = 3.7 ± 0.1 mm

The 1st and 2

nd

piston ringhave the letter “N” on the upper side.

Make sure that the marked side is turned upwards when being
installed on the piston.

Piston Installation

Position the two piston rings (1) and the oil ring (2) on the
piston, positioning the opening at 120° from each other.

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Position the piston (3), as shown in the figure, with the arrow on
the piston pointing towards the exhaust.
Insert the pin (4).

ATTENTION:

Always use new elastic rings for mounting the pistons.
To avoid breaks that can take place with the rings bent.

Position the two elastic rings (5), one for each side pay attention
not to deform them.

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3.2.3 Engine Bottom end

Crankcase Disassembling

Remove the cylinder head (see “CYLINDER HEAD REMOVAL”)
Remove the cylinder block (see “DISMANTLING CYLINDER BLOCK”)
Remove the pistons (see “DISMANTLING PISTONS").

ATTENTION:
Ensure that there is no oil left inside the engine before dismantling crankcase.
Remove engine oil using oil pump tool if necessary.

ATTENTION: After reassembling ensure to rotate the engine with its electric
starter without spark plugs but with transmission installed on it and filled
with engine oil for 60 seconds before installing the engine into the PWC to
ensure that all bearings are sufficiently lubricated with oil before the first test
run in the PWC.

Remove the roll-over valve block unscrewing 6 mounting
screws shown on the figure.

Remove the fixing bolt under roll-over valve cover (shown
on the figure).
Remove 5 crankcase bolts shown by circle marks.

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Remove the oil pump cover:

Oil Pump and Oil Sump removal

Rotate the engine 180° to access its bottom side.

Remove the oil hose attachment from the oil sump cover.
Remove the dipstick tube connection.
Untighten and remove oil sump cover mounting screws.

Remove the oil sump cover.

Dismantle Oil Pump intake tube and Oil Sump filter assy.

ATTENTION:
Note the position of the screws for correct
remounting

Remove the screws shown by circle marks on the figure.

Then remove 8 crankcase bolts shown by oval marks.

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Remove 2 balance shaft screws shown on the picture.

Remove the lower crankcase part pulling it up. Use a soft
hummer if necessary.

NOTE:
Pay attention to prevent crankshaft and balance shaft
of falling down during casing removal.

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Remove 2 large plastic lock nuts on both sides of balance
shaft. (14).

Remove the ring (15).

Remove the balance shaft.
Remove engine crankshaft.

ATTENTION:
Take note of crankshaft plain bearings position for correct reassembling.

Remove the plain bearings.

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Dismantling Balance Shaft

Remove the circlip (1).
Remove the ball-bearing (2) and the toothed wheel (3).

Remove the ball-bearing (4).

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Dismantling Crankshaft

ATTENTION:
Take note of crankshaft parts position for
correct reassemling.

The following procedure must be applied to all connecting
rods mounted on the crankshaft shaft.

Unscrew and remove bolts (1).
Remove connecting rod (2) from the crankshaft (3).

Check Engine Shaft and Connecting Rod

Check eventual breaks or excessive wear on the whole engine
shaft (1).
Change the piece if necessary.
Support the engine shaft with two “V” blocks and with the two
ends resting upon the blocks,
install a comparator and turn the engine shaft slowly.

Check the deformation of the engine shaft at the points indicated
in the figure.
If the deformation does not enter within the specific value, change
the piece.

DEFORMATION
VALUE LIMIT = 0,040 mm

Check eventual breaks or excessive play on the connecting rod
(2) and on the two semi-bronze bearings.
In case of replacement of the connecting rod, verify the
belonging class marked on the shank (1).

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Internal Diameter Connecting Rod Foot

Using a caliber for small holes, measure the internal diameter
of the connecting rod foot.

INTERNAL DIAMETER CONNECTING ROD FOOT
SERVICE LIMIT: 19.040 mm

If the internal diameter of the connecting rod foot exceeds the
specified limit, change the connecting rod.

Connecting Rod Head Lateral Play:

Check the lateral play of the connecting rod with a feeler.
If the play exceeds the specified limit, remove the connecting

rod and check the width of the connecting rod head and pin.
If the width exceeds the specified limit, change the connecting
rod or the engine shaft.

CONNECTING ROD HEAD LATERAL PLAY
SERVICE LIMIT: 0.40 mm

CONNECTING ROD HEAD WIDTH
STANDARD: 2,18 - 2,19 mm

CONNECTING ROD PIN WIDTH
STANDARD: 22,0 - 22,05 mm

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Crankcase Assembling

Mounting Crankshaft

NOTE:
There are 3 different sizes of connecting rod plain
bearings marked by colors mentioned in the chart.

Position each con-rod plain bearings according to
the marks on the rod flange (see picture).

Take care the bearings are installed to relative slots.

ATTENTION:
Two marks shown on the figure must couple
for connection rod body (1) and big end cap
(2).

Assemble the connecting rod on the crankshaft so that
the marks (1) and (2) are aligned as shown on picture.

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NOTE: Apply MOLIKOTE® grease on the inner halves of con-rod plain bearings and
ensure the outer halves and the con-rod bodies are cleaned with fuel to increase the
friction between both parts.

RECOMMENDED OIL
MOLIKOTE® BR2 PLUS GREASE

ATTENTION:
Always change connecting rod bolts by new
after each dismantling.

Oil the thread and the diameter under the flanging of the
fixing bolts (3) with the recommended grease.
Tighten the fixing bolts (3) slightly.

RECOMMENDED OIL
MOLIKOTE® BR2 PLUS GREASE

NOTE: Apply MOLIKOTE® grease on the inner halves of crankshaft plain bearings
and ensure the outer halves and their crankcase seats are cleaned with fuel to
increase the friction between both parts.

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Position the crankshaft on the upper part of crankcase.

Tighten connecting rod bolts in three phases:

Tightening torque:

1st phase: 15 N·m (1,5 Kg-m)

2nd phase: 25 N·m (2,5 Kg-m)

3rd phase: + 50°

NOTE:
An angle torque control wrench is required to carry out the third tightening phase.

Mounting Balance Shaft

Position the ball-bearing (1) and fix with the circlip (2).

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Position the bushing (4).
Position the ring(5).
Position the roller bearing (3) on the balance shaft.

Mounting Casting

NOTE:
There are 3 different sizes of crankshaft plain
bearings marked by colors mentioned in the chart.

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NOTE:

Reading the letters must always be carried out
starting from timing chain side.

Position and center four semi-bronze plain bearings (25)
each slotted with the correct color according to its letter
stamped on the exhaust side of the crankcase (24).

Position the crankshaft as shown on the figure.

Position the balance shaft.

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NOTE:
Make sure that sprocket wheels marks of the balance
shaft and the crankshaft are aligned as shown on the
figure.

Position balance shaft ring (28).

Install 2 large plastic lock nuts on both sides of balance
shaft. (29).

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NOTE:
Apply proper amount of recommended sealant to the contact surfaces of both
crankcase parts.

RECOMMENDED SEALANT
LOCTITE 5699 FLANGE SEALANT

Position the lower casing part on the upper.

ATTENTION:
Follow the mounting phases correctly.

Position eight crankcase screws with washers, apply
recommended grease for their threads and tighten to
specified torque in three phases according to the
sequence marked on engine carter.

RECOMMENDED OIL
MOLIKOTE® BR2 PLUS GREASE

Tightening torque:

1st phase: 13 N·m (1,3 Kg-m)

2nd phase: 25 N·m (2,5 Kg-m)

3rd phase: 45 N·m (4,5 Kg-m)

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Tighten balance shaft M8 screws shown by arrows in two
phases:

Tightening torque:

1st phase: 10 N·m (1,0 Kg-m)

2nd phase: 25 N·m (2,5 Kg-m)

Tighten screws shown by circle marks with specified
torque:

Tightening torque: 10 N·m (1,0 Kg-m)

ATTENTION:
Always use new gaskets.

Install Oil pump intake tube, Oil sump filter and oil sump
cover. Tighten cover screws with a specified torque:

Oil sump filter mounting screws: 10 N·M (1,0 Kg-m) +
LOCTITE 243®

Tightening torque: 10 N·m (1,0 Kg-m)

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Rotate the engine 180° to be placed on its bottom side.

Tighten the bolt under roll-over valve in two phases (shown
in oval-mark)

Tightening torque:

1st phase: 10 N·m (1,0 Kg-m)
2nd phase: 25 N·m (2,5 Kg-m)

Tighten five screws (shown in circle-marks) with specified torques:

Tightening torque: 10 N·m (1,0 Kg-m)

Install Oil pump cover and tighten its screws with specified
torque:

Tightening torque: 10 N·m (1,0 Kg-m)

Install roll-over valve assembly and tighten its fasteners
with a specified torque.

Tightening torque: 10 N·m (1,0 Kg-m)

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3.2.4 Cooling system Thermostat and Water pump

Thermostat:

Dismantling Thermostat:

WARNING:
Always use new gaskets and oil seals.

Disconnect cooling system hose, loosen and remove
mounting screws and remove the thermostat cover.

Remove the thermostat (5).
Verify that the by-pass hole (6) is not obstructed.

Check Thermostat

The thermostat begins and opens at around 75°C and reaches
7 mm minimum opening at 90°C, as shown in the diagram on
the figure.

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Check whether the thermostat pad is cracked.
Pass a cord through the flange as indicated in the figure.

Check the above-mentioned conditions by immerging the
thermostat (1) in a container with water, maintaining it in
suspension.
Slowly heat the water and check the temperature with a
thermometer (2).
When a temperature of 75°C is reached, the thermostat valve
begins to open and arrives at a temperature of 90°C.
The thermostat valve reaches an opening of at least 7 mm.

Change thermostat if necessary.
Check that the thermostat cover and the tubes connected to it are not broken, otherwise
change the damaged element.

Mounting the Thermostat

WARNING:
The thermostat must be mounted with the by-pass
hole (2) turned upwards, as shown on the figure.

Position thermostat (1) as indicated on the figure.

Position the thermostat cover and tighten with the two
mounting screws with specified torque:

10 N·m 1 Kg-m

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Dismantle Water Pump

Loosen and remove the two screws (4) and the small
plates (5).
Remove the entry elbow (6).
Loosen and remove the two screws (3) and remove the
water pump from the engine.

Remove O-Ring (7).

Loosen and remove two screws (8).

Remove the cover (9).

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Loosen and remove the nut (10) and remove the rotor (11).

Remove the external circlip (12), the internal circlip (13)
and the ball-bearing beneath.

Remove the liner (14), the shaft (15), the ball-bearing (16)
and oil seal beneath.

Remove the mechanical seal (17).

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Check the state of wear of the various components of the
pump.
Check that the various elements are not broken.
Change worn or damaged elements if necessary.

Water Pump Assembly

Position the pump body (1) on a support.

ATTENTION:
The oil seal must be inserted downwards with the
lip closed.

Position oil seal until it touches (2).

Grease the shaft (4) at the points indicated on the figure.

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Position the shaft (4) inside the pump body (1).

Position the first ball-bearing (5), using a press to make it
touch.

Position the liner (6).

Position the second ball-bearing (7), using a press to make it
touch.

Fix the ball-bearings with the external (8) and internal
(9)circlips.

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ATTENTION:
While mounting the counter-face and mechanical
seal make sure that they are clean and bear no traces
of grease.

Position the counter face as in the figure (10).

Position the mechanical seal (11) until it touches as shown in
the figure.

Position the rotor (12) making it meets clutch (A).

Position the sealing washer (13) and fix it tight with the nut
(14).

8 N·m 0.8 Kg-m

Always use LOCTITE 243®

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Position the cover and lock it tight with the two screws (15).

Position the sealing washer (16) and tightly screw the purge
screw (17) up.

10 N·m 1 Kg-m

Always use LOCTITE 243®

Position the O-Ring (18) on the pump body.

Position the entry elbow (19) and fix with the two small plates
(20) and the two screws (21) tightly.

10 N·m 1 Kg-m

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Position the pump (1) as in the figure and screw the two
screws
(2) up tightly.

10 N·m 1 Kg-m

Always use LOCTITE 243®

Reposition the entry and exit tubes (3) of the pump,
tightening two hose clamps (4).

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4 Transmission

4.1 Transmission Dismantling

Remove engine out of the PWC (see Engine Removal
chapter).

Remove the engine oil by opening the oil plug screw on
the bottom of the engine

(19 mm socket required). Use suitable equipment to
collect the engine oil.

Remove the following parts:

- Oil return line to the bottom of the engine

- Oil supply line

- Rear engine Support

- Coupler cover

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Remove 2 x short and 10 x long 5mm mounting screws
Take note of short screw position (shown on figure)

Remove transmission cover with a suitable tool.

NOTE: do not damage the gasket surface of the
casting.

Remove the right hand thrust washer carefully and place
beside.

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Remove carefully the left hand transmission gear assy
and place beside.

Remove carefully the second thrust washer and place
beside.

Remove carefully the 3 x needle cage bearings and place
beside.

Remove carefully the left had thrust bearing and place it
beside.

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Remove Nut ( 41 mm) with an impact tool

Remove transmission gear with the gear wheel
remover.

Tighten the screws of gear wheel remover in X-method,
stopping the gear with a suitable tool.

Remove the gear and place it beside.

Remove 2 x transmission casing mounting screws and lower
banjo bolt.

NOTE: Remove the copper washer of lower banjo bolt.

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Remove transmission gear box casing and place it
beside.

Disassembling transmission cover

Support the transmission cover and use special tools to
open the coupler. Loosen and remove the coupler.

NOTE: The washer in between the bearing and the
gear has a thickness of 4,5mm

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Remove circlip and bearing

NOTE: The washer in between the oil seal and the bearing has a thickness of
1,5mm.

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Disassembling transmission housing:

Remove the oil seal and the O-ring.

4.2 Transmission Assembling

Assembling the transmission cover

Grease new oil seal on the seal lips and o the oil seal
groove. Press in the oil seal by hand.

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Press in the bearing and put in place the circlip to secure the bearing.

Subassembly of the PTO gear.

Press and glue the aluminum plug into the PTO gear with Loctite 648 as
shown on the pictures below. Put the washer ( 4,5 mm ) in place.

Install washer (1,5mm) in between the oil seal and the bearing using suitable tool.

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Assemble coupler into the PTO gear using grease and tighten the coupler with
specified torque.

Tightening torque: 80 N·m

Assembling transmission housing

Apply grease on the inside and sealing lips of the oil seal. Press in the oil seal.

NOTE: The greased side of the oil seal needs to be on the same side like the
painted side of the oil seal cover.

Put in place the O- ring. Apply Loctite 5699 on the O – Ring.