Page 1
125 - 160cc 4T
Workshop Manual Engine
Page 2
1
125 - 160 cc
C
WORKSHOP MANUAL
GENERAL INDEX
Assembling the piston ...................................................................37
Stripping down the cylinder head .................................................38
Checking valve springs ..................................................................................40
Checking valves ............................................................................................. 40
Checking and adjusting valve seating ..........................................42
Inspection .......................................................................................................42
Change ........................................................................................................... 42
Lapping ..........................................................................................................44
Installing the cylinder .....................................................................50
Installing the cylinder head ............................................................52
Installing the camshaft support .....................................................53
Checking engine timing .................................................................57
Fitting the valves cover ..................................................................58
SPEED VARIATOR-CLUTCH UNIT
..................................60
Trouble shooting .............................................................................
61
Variator unit exploded view ..........................................................
62
Clutch unit exploded view .............................................................63
Clutch pulley exploded view .........................................................64
Clutch shoes assy exploded view ................................................65
Removing the clutch cover ............................................................66
Assembly ........................................................................................................ 67
Primary pulley .................................................................................67
Disassembly ................................................................................................... 67
Checks .............................................................................................70
Drive belt ........................................................................................................ 70
Roller weights ................................................................................................. 71
Mobile primary pulley .....................................................................................71
OIL PUMP ASSY
...........................................................................3
Trouble shooting ...............................................................................................4
Exploded view of oil pump ...............................................................5
Disassembly ......................................................................................6
Removing the oil pump ....................................................................................8
Oil pump body tolerances ................................................................................9
Clearance between oil pump inner and outer rotors ................... 10
Clearance between front surfaces ................................................10
Assembly ......................................................................................... 11
CYLINDER HEAD, VALVES, CYLINDER, PISTON
.....15
Working precautions ......................................................................
15
Trouble shooting .............................................................................
18
Cylinder head exploded view .........................................................19
Cylinder compression pressure ...................................................20
Valve clearance adjustment ...........................................................
21
Removing camshaft support .........................................................23
Removing the camshaft .................................................................26
Checks .............................................................................................27
Camshaft ....................................................................................................... 27
Rocker arms and rocker arm spindles ...........................................................28
Removing the cylinder head ..........................................................29
Removing the cylinder ...................................................................31
Removing the piston ......................................................................32
Cylinder / piston checks .................................................................34
Checking the cylinder ..................................................................................... 34
Checking the piston ........................................................................................ 34
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WORKSHOP MANUAL
GENERAL INDEX
Installing the primary pulley ..........................................................73
Disassembling the clutch ...............................................................
76
Disassembling the clutch unit .......................................................
77
Removing the secondary pulley ...................................................
78
Checks .............................................................................................80
Clutch bell ......................................................................................................80
Clutch linings .................................................................................................. 80
Variator contrast spring ................................................................................. 81
Fixed secondary pulley ..................................................................................81
Mobile secondary pulley ................................................................................. 82
Assembling the clutch ....................................................................83
Installing the clutch bell .................................................................
87
FINAL DRIVE GEARS
.............................................................88
Final drive exploded view...............................................................89
Removing the transmission cover ................................................
90
Remove pulley shaft .......................................................................
92
Transmission cover checks ...........................................................92
Removal and retting of transmission cover bearings
and oil seal.......................................................................................94
Removal and retting of clutch side engine casing bearings
and oil seals.....................................................................................96
Installing the transmission gears ..................................................
97
Installing the transmission cover ..................................................
98
FLYWHEEL COVER, FLYWHEEL MAGNETO,
WATER PUMP
............................................................................ 100
Exploded view of water pump
......................................................101
Exploded view of ywheel cover .................................................102
Removing the ywheel cover.......................................................103
Removing the ywheel magneto .................................................................. 104
Removing the freewheel gear ......................................................................105
Removing the stator/pick-up assy ................................................................ 106
Removing the water pump impeller .............................................................. 106
Installing the water pump .............................................................107
Assembly procedure ....................................................................................107
Installing the stator/pick-up assy ................................................108
Installing the freewheel gear and rotor .......................................
109
Installing the ywheel cover ........................................................ 111
ENGINE CASING, CRANKSHAFT
.................................113
Removing the engine casings .....................................................114
Crankshaft checks ........................................................................ 115
Installing the engine casing .........................................................
117
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WORKSHOP MANUAL
• The oil pump must be serviced after having removed the flywheel cover.
• When the values measured are outside the service limits, renew the oil pump.
• Ensure that no foreign material enters the engine when the oil pump is removed.
• Check for oil leaks once the pump has been installed.
Standard
Oil quantityFor oil change 800 cc.
Total capacity 1000 cc.
Recommended oil
temperature and viscosity
(temperature)
- 10° 0° 10° 20° 30° 40°C
SAE 20W /40
SAE 10W / 50
SAE 10W / 40
SAE 10W / 30
SAE 10W-40 20W-50 Special
for 4-stroke engines
When using alternative oils, select from the following range
API: type SE or SF engine oil
SAE: select from the table alongside on the basis of the outdoor
temperature.
cont’d
OIL PUMP ASSY
07028005
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WORKSHOP MANUAL
OIL PUMP ASSY
Standard Service limit
Oil pump rotor Radial clearance between
inner and outer rotors
0.15 mm 0.20 mm
Pump body radial clearance 0.15 - 0.23 mm 0.25 mm
Front clearance between
surfaces
0.05 - 0.10 mm 0.12 mm
Tightening torques
Pump body screws 10 N*m ± 15%
Pump cover screws 2 N*m ± 15%
Protection plate A assy
10 N*m ± 15%
Protection plate B 10 N*m ± 15%
Trouble shooting
Low oil level; possible causes:
1) Normal consumption (check scheduled service has been performed).
2) Oil leaks.
3) Wear or incorrect fitting of piston rings.
4) Wear of valve guide or valve stem.
5) Valve seat rings damaged.
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07028001
7
1
6
3
4
5 2
WORKSHOP MANUAL
OIL PUMP ASSY
Exploded view of oil pump
1) Pump cover
2) Pump shaft
3) Inner rotor
4) Outer rotor
5) Pump body
6) Locating dowel
7) Screw
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A
C
07028101
07028102
WORKSHOP MANUAL
Ensure that no foreign material enters the engine when the
oil pump is removed and refitted.
Disassembly
Remove:
• flywheel cover.
• rotor and freewheel gear.
• chain guard (A) and oil pump assembly.
Remove circlip (C) from shaft.
OIL PUMP ASSY
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C
D
E
B
07028103
07028104
WORKSHOP MANUAL
OIL PUMP ASSY
Remove chain ring (D) and chain (E).
Check chain for damage or excessive wear.
Remove chain guard (B).
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G
F
C V
07028100
DSCN8392
WORKSHOP MANUAL
OIL PUMP ASSY
Remove pump assy (F) and pump shaft (G).
Check pump for possible damage or excessive wear.
Removing the oil pump
Undo screw (V) and remove pump cover (C).
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Q M
L N
M N
07028105
07028106
WORKSHOP MANUAL
OIL PUMP ASSY
Remove inner rotor (L) and outer rotor (M) from pump body (N), paying
attention to locating dowel (Q).
Oil pump body tolerances
Measure outside diameter of outer rotor (M) and inside diameter of pump
body (N) with callipers and inside micrometer; the difference between the
two values is the “radial clearance” of the pump body.
Service limit: 0.25 mm
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N
M
L
07028107
N
L
M
07028108
WORKSHOP MANUAL
OIL PUMP ASSY
Clearance between oil pump inner
and outer rotors
Install inner rotor (L) and outer rotor (M) in pump body (N); measure
clearance between inner and outer rotors with feeler gauge.
Service limit: 0.20 mm
Clearance between front surfaces
Fit inner rotor (L) and outer rotor (M) in pump body (N) and use a feeler
gauge to measure axial clearance between rotors and pump body.
Service limit: 0.12 mm
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Q M
L
N
C V
07028109
DSCN8392
WORKSHOP MANUAL
OIL PUMP ASSY
Assembly
Wash all parts in clean diesel fuel before refitting.
Fit inner rotor (L) and outer rotor (M) in pump body (N), paying attention
to locating dowel (Q)
Fit pump cover (C) and tighten screw (V) to prescribed torque.
V
Cs-N*m
2 ± 15%
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P
N
V
2
B
07028110
07028111
WORKSHOP MANUAL
Ensure fixing holes (P) of pump body (N) are aligned with holes in flywheel
cover.
If holes are not aligned, screws (V2) cannot be tightened.
Fit and tighten two screws (V
2
) of pump body and chain guard (B); tighten
screws to prescribed torque.
V
2
Cs-N*m
10 ± 15%
OIL PUMP ASSY
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E
D
C
07028112
07028113
WORKSHOP MANUAL
OIL PUMP ASSY
Fit chain ring (D) and chain (E).
Fit circlip (C) in shaft groove.
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C
B
A
V
07028114
WORKSHOP MANUAL
OIL PUMP ASSY
Couple chain guard (A) to chain guard (B) and tighten screw (V).
Fit rotor assembly and freewheel gear.
Fit flywheel cover.
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WORKSHOP MANUAL
Working precautions
• Valves cover, camshaft, camshaft support, rocker arm, cylinder head and cylinder can be removed without
dropping engine from frame.
• Take care not to damage mating surfaces when removing valves cover, cylinder head and cylinder.
• Mark disassembled parts so they can be refit in exactly the same position.
• After disassembly, wash parts and dry with compressed air before checking and measuring them.
• Lubricate cam surfaces, shaft and internal hole of rocker arms before reassembling.
• Camshaft assy lubricating oil is fed through oil passages in the cylinder.
• Valve cover, cylinder head, and cylinder oilways must be perfectly clean prior to assembly.
Standard Service limit
125 cc 160 cc
Cylinder compression pressure 700 kPa (7 kgf/cm2) @ 260 RPM —
Valves
clearance
IN0,10 mm - 0,12 mm ---
EX0,16 mm - 0,19 mm ---
Flatness of cylinder head — 0.05 mm
Camshaft Cam height IN 30.74-30.86 mm 30.69 mm
EX 30.33-30.45 mm 30.28 mm
Rocker arm Rocker arm shaft bore
diameter
IN/EX 10.000-10.015 mm 10.10 mm
Rocker arm shaft diameter IN/EX 9.978-9.987 mm 9.91 mm
cont’d.
CYLINDER HEAD, VALVES, CYLINDER, PISTON
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CYLINDER HEAD, VALVES, CYLINDER, PISTON
Standard Service limit
125 cc 160 cc
Valve guide Valve stem outside diameter
IN 4.975-4.990 mm 4.965 mm
EX 4.955-4.970 mm 4.945 mm
Valve guide inside diameter
IN 5.000-5.012 mm 5.040 mm
EX 5.000-5.012 mm 5.040 mm
Valve stem to guide
clearance
IN 0.100-0.037 mm 0.075 mm
EX 0.030-0.057 mm 0.095 mm
Valve guide height
IN/EX 11.9-12.1 mm —
Valve seating line height
IN/EX 0.9-1.1 mm 1.8 mm
Valve springs
Length
(Outer spring/inner spring)
IN/EX 35.0-32.3 mm 33.5-30.8 mm
Cylinder Internal diameter 52.400-52.419 mm 58.00-58.019 mm 52.449 mm 58.049 mm
Top face flatness
— 0.05 mm
Taper
— 0.05 mm
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WORKSHOP MANUAL
Standard Service limit
125 cc 160 cc
Piston Piston assembly direction “IN” on intake side —
Piston outside diameter 52.37-52.39 mm 57.97-57.99 mm 52.32/57.92 mm
Piston pin bore diameter 15.002-15.008 mm 15.04 mm
Piston pin diameter 14.994-15.000 mm 14.980 mm
Connecting rod small end diameter 15.016-15.034 mm 15.050 mm
Cylinder / piston tolerance 0.02-0.04 mm 15.05 mm
Piston / piston pin tolerance 0.002-0.014 mm 0.080 mm
Piston pin / small end tolerance 0.016-0.040 mm 0.040 mm
Piston rings / grooves
tolerance
Ring (1) 0.020-0.044 mm 0.070 mm
Ring (2) 0.020-0.044 mm 0.070 mm
Ring gap Ring (1) 0.15-0.30 mm 0.45 mm
Ring (2) 0.10-0.25 mm 0.45 mm
Scraper ring 0.2-0.7 mm 0.9 mm
Piston ring assembly direction punch marking at top —
Tightening torques
Cylinder head screw 10 N*m ± 15%
Tensioner screw
35 N*m ± 15%
Cylinder screw 10 N*m± 15%
Valves cover screw
10 N*m ± 15%
Cylinder head nut30 N*m± 15%
Timing sprocket screw
10 N*m ± 15%
Chain tensioner screw 10 N*m ± 15%
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Page 19
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WORKSHOP MANUAL
Trouble shooting
Compression loss can be identified by measuring pressure directly.
If engine fails to start or idles unevenly, check for smoke in engine casing voids.
Presence of smoke means damaged, broken or worn piston rings.
Irregular full speed Low compression
Air infiltrating through carburettor couplings
Poor fuel feed
Low compression Incorrect valves clearance
Valve burnt or damaged
Incorrect timing
Weak valve spring
Poor valve seal
Pressure loss from head gasket
Head warped or cracked
Incorrect fitting of spark plug
High combustion pressure Carbon deposits on piston or in combustion chamber
Blue smoke from exhaust Damaged valve guide or valve stem
Damaged or worn seat ring
Anomalous noise Damage or wear of camshaft assy components
Incorrect valves clearance
Burnt valve or damaged valve spring
Rocker arm or rocker arm shaft damaged
Chain stretched
Chain tensioner malfunction
CYLINDER HEAD, VALVES, CYLINDER, PISTON
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CYLINDER HEAD, VALVES, CYLINDER, PISTON
Cylinder head exploded view
1) Valve cotter
2) Valve upper spring retainer
3) Inner valve spring
4) Outer valve spring
5) Valve oil seal
6) Valve lower spring retainer
7) Cylinder head
8) Intake valve
9) Exhaust valve
10) Spark plug
9
7
6
4
3
1
2
5
2
1
3
4
5
6
10
8
07028109
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Cylinder compression pressure
NOTE Take measurement with warm engine
Remove spark plug cap (A) and spark plug.
Fit pressure gauge in spark plug bore to measure compression.
Turn over engine with starter motor and throttle body fully open.
NOTE The pressure gauge and its components must be assembled
in such a way as to avoid pressure losses.
Prolonged use of the starter motor will drain the battery: do
not run starter motor for more than 5 seconds at a time.
Compression pressure: 700 kPa (7 bar) @ 260 RPM
If compression is too high, check for carbon deposits on the piston crown
or in the combustion chamber.
If pressure is too low, pour a little engine oil into cylinder through spark
plug bore and check measurement again.
Compare the two pressure readings; if pressure increased after adding
oil, measure cylinder, piston and piston rings. If pressure is unchanged,
check cylinder head and valves.
The problem could be:
• Pressure escaping from valves (blow-by)
• Incorrect valves clearance
A
07028116
07028117
A
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WORKSHOP MANUAL
Valve clearance adjustment
NOTE Checking and adjusting valve clearance must be carried out
with warm engine.
Remove
• valves cover.
• clutch cover.
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Turn camshaft (by rotating the variator unit nut) until the two timing sprocket
references (B) are parallel with cylinder head machined surface (C) and
camshaft notch (T) is facing upwards.
B
C
T
DSCN8394
DSCN8399
DSCN8396
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Insert feeler gauge (C) between rocker arm (D) and valve (E) and measure
clearance.
Valve clearance (warm engine) IN: 0.05 mm
EX: 0.15-0.20 mm
E
D
DSCN8398
C
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Removing camshaft support
Remove:
• clutch cover.
• valves cover.
Turn camshaft counterclockwise by means of variator unit until the two
timing sprocket references (B) are parallel with cylinder head machined
surface (C) and camshaft notch (T) is facing upwards.
Undo chain tensioner central screw (V).
Undo chain tensioner fixing screw (V
2
).
Remove oil fitting (D) and spring (E).
B
C
D
E
V
V
2
T
DSCN8399
DSCN8396
DSCN8400
Page 25
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Undo screws (V2).
Remove timing sprocket (F).
Unscrew capnuts (D4).
V
2
F
D
4
D
4
DSCN8401
DSCN8402
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Remove camshaft support (G).
Remove three circlips (S) relative to rocker arm spindles and camshaft.
G
S
S
S
DSCN8403
DSCN8404
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Remove rocker arm spindles (L).
NOTE Remove rocker arm spindles using an M5 screw.
Removing the camshaft
Remove camshaft assy (M).
L
M
DSCN8405
DSCN8406
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Checks
Camshaft
Turn bearings (C) to check that they rotate freely and smoothly.
Renew camshaft (M) in the presence of noise or tendency to jam.
Check cam surfaces for damage and scoring.
Measure cam height with micrometer.
Service limit IN: 30.69 mm
EX: 30.28 mm
C
M
07028118
07028119
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Rocker arms and rocker arm spindles
Check sliding surfaces (N) of rocker arms (Q) and contact surface (P) with
valve for possible damage or wear.
If wear is excessive, renew rocker arms.
Measure inside diameter of each bore in rocker arm (Q).
Service limit: 10.10 mm
Measure outside diameter of each rocker arm spindle (L).
Service limit: 9.91 mm
N
P
L
Q
Q
07028120
07028121
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Removing the cylinder head
Remove
• throttle body (A) complete with manifold (B)
• valves cover.
• camshaft support (see removal)
• temperature sensor assy (C).
A
B
C
DSCN8407
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Undo screws (V2).
Remove cylinder head (D).
Remove head gasket (E) and locating dowels (F).
D
F
E
F
DSCN8409
DSCN8410
V
2
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Removing the cylinder
Disconnect coolant inlet hose (T) from cylinder.
Remove lower chain guide (G).
Undo screw (V).
Remove cylinder (L)
T
V
L
G
DSCN8390
DSCN8409
DSCN8410
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CYLINDER HEAD, VALVES, CYLINDER, PISTON
Removing the piston
Remove piston pin circlip (A).
Remove piston pin (B) and piston (C).
A
C
B
07028122
07028123
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Expand piston rings (D) and slide them off over piston (C).
• Piston rings are fragile. Do not deform excessively.
• Make sure piston rings do not scratch or score surface of
piston.
Scrape carbon deposits off piston (C).
Use an old piston ring (D) to remove carbon deposits from piston ring
grooves.
• Do not damage piston ring grooves.
• Do not use wire brushes: risk of damaging piston ring
grooves.
D
C
D
C
07028124
07028125
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WORKSHOP MANUAL
Cylinder / piston checks
Checking the cylinder
Check interior of cylinder for signs of damage or wear.
Measure cylinder inside diameter at top, mid point, and bottom (6
measurements); along direction of piston pin and the direction orthogonal
to it (axes X – Y); make a note of all values and take the highest value
obtained as a reliable reference.
Service limit: 52.449-58.049 mm
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Checking the piston
Measure outside diameter of piston (D) 6 mm above the base and at right
angles to piston pin bore.
Service limit: 52.32 / 57.92 mm
Calculate tolerance between piston and cylinder.
Service limit: 0.08 mm
Measure piston pin bore.
Service limit: 15.04 mm
D
6mm
07028127
07028006
07028126
D
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Measure outside diameter of piston pin (B) in contact points with piston
and with connecting rod small end (total of three measurements).
Service limit: 14.8 mm
Calculate tolerance between piston pin (B) and bore in piston.
Service limit: 0.04 mm
Calculate tolerance between piston pin and small end bore.
Service limit: 0.06 mm
Check piston rings (D) for signs of wear or damage.
Fit rings in corresponding grooves of piston (C) and compress until flush
with piston outer surface.
B
C
D
07028128
07028129
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Measure axial clearance between piston ring and groove with feeler
gauge.
Service limit:
• Top piston ring: 0.07 mm
• 2nd ring: 0.07 mm
Position ring horizontally in lower part of cylinder.
Measure ring gap with feeler gauge.
Service limit:
C - Piston: 52.32 / 57.92 mm
E - Top piston ring: 0.45 mm
F - 2nd ring: 0,45 mm
G - Scraper ring: 0.9 mm
E
F
G
G
C
07028130
07028131
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Assembling the piston
Insert rings on piston with rings oriented so that punch markings are facing
upwards.
• Top ring (E) and second ring (F) are not interchangeable.
• Keep piston ring gaps staggered at intervals of 120°.
After assembly ensure rings can turn freely in grooves.
Lubricate connecting rod small end, piston pin (B) and bore in piston.
Install piston and ensure that the punched “IN” on the piston will be aligned
with the intake valve when the camshaft assy is installed.
Fit new circlip (A) for piston pin.
Circlip (A) must be fitted correctly in its groove.
Punzonatura “IN”
E F
G
G
C
B
A
C
"IN"
07028131
07028132
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Stripping down the cylinder head
NOTE Removed parts must be set aside separately and refit in their
original positions.
Remove valve cotters using specific tool (A).
A
DSCN8412
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WORKSHOP MANUAL
Camera di combustione
Remove tool, remove upper retainer (B), outer spring (C), inner spring
(D), valve oil seal (F) and lower retainer (G).
Once removed, valve oil seal (F) must not be reused.
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Remove carbon deposits from combustion chamber (L) and valves.
NOTE Immerse components in petrol to remove carbon deposits.
Petrol is highly inflammable; work must be performed in
well-ventilated surroundings.
A
B
C
D
E
F
G
L
DSCN8413
07028133
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Checking valve springs
Measure length of outer spring.
Service limit: 33.5 mm
Measure length of inner spring.
Service limit: 30.8 mm
Checking valves
Insert valve in seat and check movement.
Measure diameter of stem in area affected by valve travel.
Service limit IN: 4.965 mm
EX: 4.945 mm
07028134
DSCN8416
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Remove carbon deposits with reamer (M) before measuring inside
diameter of valve guide.
NOTE Insert valve guide reamer (M) from combustion chamber
side.
Turn reamer clockwise; counterclockwise rotation of reamer
can damage valve guide internal surface.
Measure inside diameter of valve guide (N).
Service limit IN: 5.04 mm
EX: 5.04 mm
Calculate clearance between stem and valve guide.
Service limit IN: 0.075 mm
EX: 0.095 mm
M
N
07028135
07028136
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WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Checking and adjusting valve seating
Inspection
Clean carbon deposits from valve.
Check for possible cracks or distortion of valve seat.
Change
NOTE Valves cannot be repaired.
In the presence of breakages, damage, or areas that do not
seal correctly, renew the valves.
Remove the valves; check valve seating surface with petrol.
Grind valve seat to remove any abrasions.
If the valve is not perfectly straight, check clearance between valve guide
and valve stem; if clearance is incorrect, renew valve guide.
A Valve seat damaged
B Valve bent
A B
07028137
07028138
Page 44
43
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
When the valve contact area is located in the upper or lower area of the
valve head, correct the position by means of a valve grinding tool.
A Low contact area
B High contact area
Measure depth of the valve seating area.
Standard: 0,91-1,10 mm
Service limit: 1,80 mm
If contact area is irregular, to wide or too narrow, correct with a valve
lapping tool.
C High contact area
A
C
07028139
07028140
B
Page 45
44
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Lapping
Grind with a valve lapper (D).
Refer to valve lapper handbook.
Lapping must be performed by hand, exerting pressure of 4-5 kg, always
turning the tool in the same direction while working.
Lubricate lapper and remove lapping dust during the
procedure.
Svasatore
per collare valvola
If the contact area with the valve shows signs of abrasion or cracking, use
a 45° grinding tool to eliminate irregularities.
Grind the valve contact area when the valve seat is
replaced.
Take care not to grind excessively.
D
07028141
07028142
Page 46
45
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Use a 32° stone to grind the outermost surface lightly.
A Abrasions on valve seat
Use a 60° stone to grind the contact surface lightly.
B Original contact area
07028143
07028144
A
B
Page 47
46
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Use a 45° stone to grind contact area to required depth.
Check valve seating area again.
If contact area is wider, grind first with a 32° stone and then bring it to the
required size with a 45° stone.
If contact area is narrower, grind first with a 60° stone and then bring it to
the required size with a 45° stone.
A High seating line
B Low seating line
C Original contact area
A
B
C
C
07028145
07028146
Page 48
47
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
After correcting, apply a uniform coat of lapping compound and lap the
valve.
NOTE Rotate the valve slowly during the procedure.
Do not work for too long in the same position to avoid wear
due to axial misalignment.
Do not allow lapping compound to penetrate in area between
valve guide and stem.
When repair is completed, clean cylinder head and valves.
After the procedure recheck valve seating area.
07028137
Page 49
48
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Position lower retainer (G) and new valve oil seal (F) in the valve guide.
Lubricate valve stem and interior of valve guide.
Slowly insert valve (E) into valve guide.
Take care not to damage valve oil seal (F).
The internal and external springs (D-C), have variable coils distance shape
must be assembly with close coils shape (A) to the combustion chamber.
Fit upper retainer (B).
B
C
D
F
G
C D
A
DSCN8413
07028147
Page 50
49
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Compress springs with specific tool (A) and fit cotters.
To avoid weakening springs do not compress more than
necessary.
DSCN8412
A
Page 51
50
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Installing the cylinder
Check lower chain guide (A) for signs of abrasion, damage or wear caused
by misalignment.
Clean deposits and foreign material from mating surfaces.
Check that coolant passages, oilways and screw holes are clean.
Fit cylinder gasket (B) and insert locating dowels (C).
Fit cylinder over stud screws and DELICATELY bring into position until it
locates against its seat.
During procedure take care to insert piston CORRECTLY in
cylinder.
Be careful with piston rings and AVOID scoring the cylinder
internal surface.
A
C
B
07028148
DSCN8418
Page 52
51
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Insert washer under screw (V) and snug screw without tightening.
Fit lower chain guide (A).
Turn timing sprocket (lower sprocket) until piston is at TDC (piston surface
flush with cylinder rim).
Do not turn timing sprocket during following operations.
V
A
DSCN8410
07028149
Page 53
52
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Position head gasket (C) and insert locating dowels (D).
Installing the cylinder head
Fit head (E) over stud screws and locate it against cylinder.
Insert washers under screws (V2) and snug screws without tightening.
Insert locating dowels.
D
C
E
V
2
07028150
DSCN8409
D
Page 54
53
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Installing the camshaft support
Fit camshaft (A) in support (B).
Lubricate rocker arm spindles (C) sparingly and insert in support (B) and
in rocker arms (D).
NOTE Insert rocker arm spindles using an M5 screw.
A
B
C
D
B
DSCN8406
DSCN8405
Page 55
54
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Fit circlips (S) in rocker arm spindle bores and in camshaft bore groove.
Lubricate cam surfaces.
Install assy on cylinder head.
Fit washers and four cap nuts (D4).
Tighten nuts to prescribed torque in two / three passes.
D
4
Cs-N*m
30 ± 15%
Tighten cylinder screw (V) to prescribed torque.
V
Cs-N*m
10 ± 15%
Tighten cylinder head screws (V
2
) to prescribed torque.
V
2
Cs-N*m
10 ± 15%
S
S
S
DSCN8404
DSCN8402
D
4
V
2
V
Page 56
55
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Install sprocket (E) on camshaft, maintaining reference marks (F) parallel
to head surface (G).
Fit timing chain (L) on timing sprocket (E).
Fit and tighten sprocket screws (V2).
V
2
Cs-N*m
9 ± 15%
Press ratchet (M) on tensioner and push tensioner pin (N) into chain
tensioner (P).
L
F
G
E
M
P
N
V
2
DSCN8401
DSCN8419
Page 57
56
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Install chain tensioner and tighten screws (V2) to prescribed torque.
V
2
Cs-N*m
10 ± 15%
Fit tensioner screw (V) and tighten to prescribed torque.
V
Cs-N*m
8 ± 15%
• Install throttle body and manifold.
• Install temperature sensor assy.
V
DSCN8400
V
2
Page 58
57
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Checking engine timing
Use a slotted screwdriver to remove timing check cap (Q) located on
flywheel cover (R).
Turn crankshaft by means of variator pulley until aligning reference mark
(S) on rotor with reference mark on flywheel cover (V); piston must be at
TDC.
NOTE If you note absence of reference mark (S) on the rotor during
disassembly phase, the mark must be made with a punch
before removing the rotor.
Make sure the two camshaft sprocket references (U) are parallel with
cylinder head machined surface (V) and camshaft notch (T) is facing
upwards.
Q
R
DSCN8390
DSCN8421
S
V
T
V
U
DSCN8399
DSCN8401
Page 59
58
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Fitting the valves cover
Fit gasket (A) and insert locating dowels (B) on valves cover (C).
Fit spring (D) in oil union (E) then insert oil union into camshaft.
B
A
B
C
D
E
DSCN8422
DSCN8396
Page 60
59
125 - 160 cc
C
WORKSHOP MANUAL
CYLINDER HEAD, VALVES, CYLINDER, PISTON
Fit valves cover (C).
Tighten screws (V
2
), paying attention to the respective sealing washers (F).
V
2
C
F
DSCN8394
Page 61
60
125 - 160 cc
C
WORKSHOP MANUAL
Standard Service limit
Front pulley Mobile pulley inside diameter 24.007-24.028 mm 24.070 mm
Pulley sliding bush outside diameter 23.959-23.980 mm 23.920 mm
Roller weights outside diameter 19.95-20.05 mm 19.45 mm
Belt thickness 21.7-23.3 mm 20.7 mm
Secondary
pulley
Clutch linings thickness — 2.75 mm
Clutch bell inside diameter 124.5-124.2 mm 125.0 mm
Speed variator contrast spring length 144-146 mm 140 mm
Fixed secondary pulley outside d
iameter
33.950-33.975 mm 33.920 mm
Mobile secondary pulley inside diameter
34.000-34.025 mm 34.060 mm
Tightening torques
Clutch cover screws 10 N*m ± 15%
Transmission housing nuts
59 N*m ± 15%
Clutch bell nut 53 N*m ± 15%
Special nut 59 N*m ± 15%
SPEED VARIATOR-CLUTCH UNIT
Page 62
61
125 - 160 cc
C
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Trouble shooting
With engine running scooter does
not move
Drive belt Worn
Ramp guide,
Ramp plate
Worn / Damaged
Clutch linings Worn / damaged
Variator contrast spring
Damaged
Engine dies or clutch grabs when
scooter pulls away
Clutch shoes contrast springs Damaged
Low speed Drive belt Worn / damaged
Variator contrast spring
Deteriorated
Roller weights Worn / damaged
Surfaces of variator pulleys Damaged
Page 63
62
125 - 160 cc
C
2
1
2
2
3
4
5
6
7
8
9
10
07028151
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Variator unit exploded view
1) Ramp plate
2) Ramp guide,
3) Roller weight
4) Primary pulley bush
5) O-Ring gasket
6) Mobile primary pulley
7) Sliding bush
8) Fixed primary pulley
9) Washer (14x28x2)
10) Nut (M14x1.5)
Page 64
63
125 - 160 cc
C
4
2
1
3
5
6
7
07028153
WORKSHOP MANUAL
Clutch unit exploded view
1) Clutch nut
2) Clutch unit
3) Clutch side spring retainer
4) Variator contrast spring
5) Stop washer
6) Spacer
7) Secondary pulley
SPEED VARIATOR-CLUTCH UNIT
Page 65
64
125 - 160 cc
C
10
8
9
5
7
3
4
2
1
6
07028152
WORKSHOP MANUAL
Clutch pulley exploded view
1) Pulley side spring retainer
2) O-Ring gasket
3) Oil seal
4) Mobile secondary pulley
5) Pin
6) Roller
7) Fixed secondary pulley
8) Bearing
9) Circlip
10) Needle roller bearing
SPEED VARIATOR-CLUTCH UNIT
Page 66
65
125 - 160 cc
C
3
1
5
2
6
5
5
4
07028007
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Clutch shoes assy exploded view
1) Disk
2) Rubber ring
3) Clutch ground
4) Snap ring
5) Clutch shoes contrast springs
6) Ring
Page 67
66
125 - 160 cc
C
V
V
3
A
B
C
V
5
V
5
DSCN8423
DSCN8424
V
5
V
5
WORKSHOP MANUAL
Removing the clutch cover
Undo three screws (V
3
) and screw (V).
Remove plastic cover (A).
SPEED VARIATOR-CLUTCH UNIT
Undo screws (V
5
).
Remove filter (B) and clutch cover (C).
Page 68
67
125 - 160 cc
C
F E
C
G
D
DSCN8425
WORKSHOP MANUAL
Remove gasket (F) of clutch cover (C).
Remove locating dowels (E).
Assembly
To reassemble, perform the above steps in reverse sequence.
SPEED VARIATOR-CLUTCH UNIT
Primary pulley
Disassembly
Remove clutch cover.
Undo nut (D) and remove its washer. Remove fixed primary pulley (G).
Page 69
68
125 - 160 cc
C
A
B
C
07028155
07028156
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Remove drive belt (A).
Immobilise internal part of mobile primary pulley (B); now remove pulley
together with sliding bush (C).
Page 70
69
125 - 160 cc
C
B
C
E
07028157
07028158
WORKSHOP MANUAL
Remove pulley sliding bush (C) from mobile primary pulley (B).
Remove roller ramp plate (E).
SPEED VARIATOR-CLUTCH UNIT
Page 71
70
125 - 160 cc
C
F
A
07028159
07028160
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Remove roller weights (F).
Checks
Drive belt
Check drive belt (A) for fraying, wear, or chaffing
Measure belt thickness.
Service limit: 20.7 mm
Page 72
71
125 - 160 cc
C
F
B
07028161
07028162
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Roller weights
Check roller weights (F) for possible wear or damage.
Measure roller weights outside diameter.
Service limit: 19.45 mm
Mobile primary pulley
Measure inside diameter of mobile pulley (B).
Service limit: 24.07 mm
Page 73
72
125 - 160 cc
C
C
07028163
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Check that pulley sliding bush (C) is not worn or damaged.
Measure outside diameter of bush (C).
Service limit: 23.92 mm
Page 74
73
125 - 160 cc
C
F H
B
E
07028164
07028165
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Installing the primary pulley
Insert roller weights (F) in races (H) of mobile primary pulley (B).
Seat rollers with end protruding slightly as shown in the photo.
Fit roller ramp plate (E).
Page 75
74
125 - 160 cc
C
B
C
B
C
07028166
07028167
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Insert sliding bush (C) in mobile primary pulley bore (B).
Manually clamp mobile primary pulley (B) and assemble together with
sliding bush (C).
Page 76
75
125 - 160 cc
C
A
G
D
DSCN8425
07028168
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Install drive belt (A).
Install fixed primary pulley (G). Apply threadlocker to nut (D) and fit nut
complete with washer.
Tighten nut (D) using a pneumatic nut runner set to the prescribed
tightening torque.
D
Cs-N*m
59 ± 15%
Page 77
76
125 - 160 cc
C
A
D
B
C
B
D
DSCN8425
07028169
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Disassembling the clutch
Unscrew locking nut (D).
Withdraw cutch bell (A); now remove entire clutch unit and secondary
pulley (B).
Using specific tool (C) compress clutch unit and secondary pulley (B).
Undo nut (D).
Release specific tool (C) and remove clutch unit; remove also secondary
pulley (B) from clutch unit.
Page 78
77
125 - 160 cc
C
E
E
E
A
G
F
L
07028009
07028170
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Disassembling the clutch unit
Remove circlips (E) and ring (A).
Remove clutch shoe contrast springs (F) then remove clutch shoes (G)
from plate (L).
Page 79
78
125 - 160 cc
C
M
L
A
07028171
07028172
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Remove rubber rings (M) from disk (L).
Removing the secondary pulley
Remove pulley side retainer (A).
Page 80
79
125 - 160 cc
C
B C
E
F
G
07028173
07028174
WORKSHOP MANUAL
Remove guide pin (B) complete with roller (C); remove mobile secondary
pulley (E).
Check that guide pin (B) and roller (C) are not damaged or worn.
SPEED VARIATOR-CLUTCH UNIT
Remove oil seal (F) and O-rings (G) from mobile secondary pulley (fit new
oil seal and O-rings at time of assembly).
Check condition of fixed secondary pulley bearings.
Renew bearings if necessary
Page 81
80
125 - 160 cc
C
L
M
07028175
07028176
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Checks
Clutch bell
Check clutch bell (L) for signs of damage or excessive wear.
Measure inside diameter of clutch bell.
Service limit: 125 mm
Clutch linings
Check clutch linings (M) for signs of wear or damage.
Service limit: 2,75 mm
Page 82
81
125 - 160 cc
C
N
A
07028176
07028178
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Variator contrast spring
Check that variator contrast spring (N) is not weakened or broken.
Measure spring length.
Service limit: 140 mm
Fixed secondary pulley
Check that fixed secondary pulley (A) is not worn or damaged.
Measure fixed secondary pulley outside diameter.
Service limit: 33.92 mm
Page 83
82
125 - 160 cc
C
B
07028179
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Mobile secondary pulley
Check that mobile secondary pulley (B) is not worn or damaged.
Measure inside diameter of secondary pulley.
Service limit: 34.06 mm
Page 84
83
125 - 160 cc
C
B
A
A
C
07028180
07028181
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Assembling the clutch
Before assembling, degrease sliding surface of fixed
secondary pulley, outer part of clutch and inner part of pulleys
assy.
Degrease and clean surface of mobile secondary pulley (A) in area of
drive belt contact.
Grease lip and fit oil seal (B) with lip on side of internal surface of mobile
secondary pulley.
Grease O-Rings (C) and insert in mobile secondary pulley (A).
Pack lithium grease into 34 mm diameter hole of mobile secondary
pulley.
Also apply adequate amount of lithium grease to fixed secondary pulley
roller bearing and ball bearing.
Page 85
84
125 - 160 cc
C
E F
D A
G
A
07028182
07028183
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Install mobile secondary pulley (A) on fixed secondary pulley (D).
Grease guide pin (E) and roller (F) before installing fixed secondary
pulley.
Fit pulley side retainer (G) on mobile secondary pulley (A).
Page 86
85
125 - 160 cc
C
A
B
C
D
07028184
07028185
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
Fit rubber rings (A) on disk (B).
Fit clutch shoes (C) and clutch shoe contrast springs (D).
NOTE Pay attention to direction of assembly of clutch shoe contrast
spring (D).
Page 87
86
125 - 160 cc
C
E
E
E
A
B
A
07028009
07028186
D
WORKSHOP MANUAL
SPEED VARIATOR-CLUTCH UNIT
First fit ring (A) and then fit circlips (E).
Using specific tool (A) compress clutch unit and secondary pulley (B).
Tighten nut (D) to prescribed torque.
D
Cs-N
*
m
59 ± 15%
Release specific tool (A) and remove clutch unit; remove also secondary
pulley (B) from clutch unit.
Page 88
87
125 - 160 cc
C
A
D
B
DSCN8425
WORKSHOP MANUAL
Installing the clutch bell
Insert clutch unit and secondary pulley (A) on shaft.
Insert clutch bell (B) and tighten nut (D).
Tighten nut (D) using a pneumatic nut runner set to the prescribed
tightening torque.
D
Cs-N*m
53 ± 15%
SPEED VARIATOR-CLUTCH UNIT
Page 89
88
125 - 160 cc
C
WORKSHOP MANUAL
Transmission
Oil capacity For oil change 0,15 l
For disassembly 0,15 l
Recommended transmission oilSAE10W-40/SF grade
Tightening torques
Level/drain plug 22 N*m (± 15%)
FINAL DRIVE GEARS
Page 90
89
125 - 160 cc
C
11
9
8
7
10
3
4
5
6
12
2
1
12
07028002
WORKSHOP MANUAL
Final drive exploded view
1) Pulley shaft
2) Pulley shaft bearing
3) Reduction gear shaft
4) Intermediate gear
5) Washer
6) Intermediate gear bearing
7) Output shaft
8) Output shaft oil seal
9) Output shaft bearing
10) Transmission cover gasket
11) Transmission cover
12) Locating dowel
FINAL DRIVE GEARS
Page 91
90
125 - 160 cc
C
V
7
V
7
B
C
07028187
07028188
A B
V7
V
7
WORKSHOP MANUAL
Removing the transmission cover
Remove clutch unit.
Unscrew oil drain plug and allow all oil to flow out.
NOTE Dispose of spent oil in compliance with local legislation.
Undo screws (V7).
FINAL DRIVE GEARS
Remove transmission cover (A)
Remove locating dowels (B) and gasket (C).
Page 92
91
125 - 160 cc
C
F
E D
G
07028189
07028190
WORKSHOP MANUAL
FINAL DRIVE GEARS
Remove output shaft (D).
Remove reduction gear shaft (E) and intermediate gear (F).
Remove thrust washer (G).
Page 93
92
125 - 160 cc
C
A
B C D
E
07028191
07028192
WORKSHOP MANUAL
FINAL DRIVE GEARS
Remove pulley shaft
Strike end (A) of pulley shaft with plastic mallet and extract main shaft.
Check pulley shaft and bearings for wear or damage. Renew parts if
necessary.
Transmission cover checks
Turn inner races of bearings (B, C and D) of transmission cover (E)
and clutch side engine casing; check bearings turn smoothly without
sticking.
Renew bearings if necessary
Page 94
93
125 - 160 cc
C
CD B
G
F E
07028193
07028194
WORKSHOP MANUAL
FINAL DRIVE GEARS
Check for possible damage or abrasion in transmission case and clutch
side engine casing bearing seats (B, C and D).
Check output shaft (E) and its bearings for wear and damage.
Renew bearings if necessary.
Check reduction gear shaft (F), its bearings, and intermediate gear (G),
for wear or damage.
Renew bearings if necessary.
Page 95
94
125 - 160 cc
C
A
B
07028195
07028196
WORKSHOP MANUAL
FINAL DRIVE GEARS
Removal and refitting of transmission cover
bearings and oil seal
Remove output shaft oil seal (A) from transmission cover.
Remove output shaft bearing (B) by means of a puller.
Use a puller and perform removal procedure in reverse to reassemble.
Page 96
95
125 - 160 cc
C
D C
E
D C
07028197
07028198
WORKSHOP MANUAL
FINAL DRIVE GEARS
Remove pulley shaft bearing (C) and reduction gear shaft bearing (D)
from transmission cover side, utilising puller (E).
Insert new pulley shaft bearing (C) correctly, with punched side facing
upwards, in seat in transmission cover, and drive it fully home.
Repeat same procedure also to install reduction gear shaft bearing (D).
Page 97
96
125 - 160 cc
C
F
A
07028195
07028187
B
WORKSHOP MANUAL
FINAL DRIVE GEARS
Lubricate lip of new oil seal (F) of output shaft and insert with lip facing
transmission cover interior.
Fit oil seal so that it is straight with respect to hole; take care
not to cover breather hole.
Removal and refitting of clutch side engine
casing bearings and oil seals
Remove pulley shaft oil seal (A).
Refer to “Removal and refitting of transmission cover bearings and oil seal”
for disassembly of pulley shaft bearing, reduction gear shaft bearing, and
output shaft bearing from clutch side transmission casing (B).
Page 98
97
125 - 160 cc
C
D B
07028199
C
WORKSHOP MANUAL
FINAL DRIVE GEARS
Insert new pulley shaft bearing (B) correctly, with punched side facing
upwards, in seat in clutch side casing, and drive it fully home.
Repeat same procedure also to fit output shaft bearing (C) and reduction
gear shaft bearing (D).
Installing the transmission gears
The layout of transmission gears is illustrated in the exploded view on
page 89.
Page 99
98
125 - 160 cc
C
A
B
C D
07028200
07028201
WORKSHOP MANUAL
FINAL DRIVE GEARS
Installing the transmission cover
Fit clearance washer (A).
Fit intermediate gear (B) and reduction gear shaft (C) in transmission
cover; ensure thrust washer is fitted on reduction gear shaft.
Fit output shaft (D).
Page 100
99
125 - 160 cc
C
F
E
G
07028202
V
7
V
7
07028187
V
7
V
7
WORKSHOP MANUAL
FINAL DRIVE GEARS
Position gasket (E) and insert locating dowel (F).
Mount transmission cover (G) to clutch side engine casing.
Insert screws (V7); tighten to prescribed torque.
V
7
Cs-N*m
22 ± 15%
Reassemble clutch unit.
Fill transmission case with oil.
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