MOTO GUZZI V-7 700 Operating Manual

700
OPERATING HANDBOOK
CC
FOR
STRIPPING, ASSEMBLING
CHECKING
AND
SEIMM
SOCIETA ESERC1ZIO INDUSTRIE MOTO MECCANICHE S.p_A. _
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MOTO GUZZI
V-7
OPERATING
FOR
STRIPPING
ASSEMBLING
700
HANDBOOK
,
CHECKING
OPERATIONS
cc.
AND
1
sl
EOITION
I
NTROOUCTION
The purpose carrying
The data provided here are meant to give a general knowledge about the
maln
checking
groups. The handbook is provided with
sary to This hand book
manufacturi such ch perfo rming a good job.
of
this
handbovk
out overhauls and repairs in a rational way.
operations to
carry
out
stripping,
will also be a
ng
characteristics
aracteristics
by repairing personnel will be
is
to
supply the necessary
be
carried
illustrations, drawings and diagrams neces-
checking
guidance
of the parts in concern. The
out
when overhauling the
and assembling operations.
for
those who wish to
an
essential
instructions
different
know
knowledge
factor
'0\
the
of
for
NOTE · The terms
to
are
be
..
RIGHT HAND
considered as seen from the rider astri
.,
and
((
LEFT HAND " used In
de
the
the
text
saddle.
Pog.
MAIN FEATURES. 5
TOOLS FOR OVERHAULING 9 DESCRIPTION OF ENGINE REMOVAL OF
FROM
ENGINE OVERHAUL
Stripping
ROCKER BOX COVERS CYLINDER HEADS
...
FRAME .
of
engine
ENGINE-GEARBOX
..
GROUP
10
11 12
12
VALVES - GUIDES - SPRINGS. 16
Stripping 16
Removal of
Inspection
Inspection and overhaul of valve Valves-valve guides Inspection and overhaul of valve seats in cy-
linder Inspection Inspection Valves sealing Assembling
CYLINDERS - PISTONS - PISTON RINGS AND
Oil
Cylinders Selection of
Pistons
Selection
Piston rings and Piston rings and scrapers-piston slots height clearance Piston ring and oil scrapers clearance . Fitting of piston
CON - RODS - CRANKSHAFT - MAIN BEARING, 23
Flywheel Con-rods Thickness Diameter Small end bushing . Checking Checking Fitting Crankshaft . Diameter Diameter I/O of main bearing, flywheel side . I/O
of
Flywheel side flange ring , 29
Seal Timing side flange
Timing Timing Crankcase .
Inspection and overhaul Wear
SUMMING
MECHANISM PARTS
TIMING DATA 32
Camshaft 32 Diameter sings Checks 32 Tappets Coupling
springs
and
heads 17
of
of
and
overhaul
valves 18
valve
lest.
of
cylinder
valves.
of
coupling
springs.
cylinder
data .
heads on
heads.
guides
cylinders
16
16
16 17
18 18 19
SCRAPERS 20
wear
check
cylinders
of
piston diameter
011
diameter
scrapers 22
20 20
21
22
22
22
pins
side
- MAIN BEARING,
01
big end bearings . 23
of crankshaft pin 23
Timing
22
side
23
24
weights
paraUelism of end axis. 25
up
con-rods on crankshaft . 25
for
engine balancing 24
27
of main journal, flywheel side
of
main journal, timing
side
.
28 28 28
main bearing. timing side
ring
for
flywheel side flange .
cover
cover
seal ring
check
of tappet guides
UP OF DATA PERTAINING TO CRANK
of crankshaft bearings and
on crankcase 32
data of tappets and tappet guides in
complete
c/w
main bearing
of
with main bea-
crankcase.
In
crankcase 30
their
28
']9
29 29 29 29 30
31
hou-
33
I
II
DE
X
crankcase Push rods Rockers 34 Coupling data of Tappet clearance Valve timing 34
SUMMING
TIMING PARTS
ENGINE LUBRICATION
Description Oit Inspection and Oit Oit
011
Oit
Oit pressure gauge ENGINE ASSEMBLING ENGINE FEEDING 43
Fuel tank 43
Air
Carburetors 44
Standard
Idling
Top speed adjustment and main
Stripping of
Servicing ENGINE BRAKE TEST CLUTCH
Removal
Checking
Checking
Checking
Checking
Checking
Clutch assembling operation 50
Clutch
Checking
Checking
Outer body 50
Cage
Inner
Pressure rod 50
Pressure rod cap
Outer body seal ring
Clutch adjustment . GEAR
Gear
Gear
Gear
Gear
Gear
Check
Gear
Seal rings 55
Ball bearings and
Mainshaft 56
Layshaft
Fitting clearance between
Layshaft gears .
Fitting clearance between bushings and gears
Sliding muff 57
Clutch
UP
pump
cleaner piping pressure breather
cleaner
carburetor
speed
of
of
clutch pressure plate 50 driven plates 50 intermediate plate 50 s1arting ring gear 50
control
clutch
clutch
c/w body 50
BOX
box
description box control box
stripping box box
cover
and overhaul of the gear box
box and
layshafl 56
on layshaft
shaft
rocker
adjustment
OF
DATA PERTAINING TO
checks
solenoid
on
carburetors
adjustment
carburetor
carburetor
clutch
springs
control
operating
balls 50
cover
roller
arms and
. 34
settings
jet
assembly
lever on gearbox 50
bearings
gear
bushings and
splindles
selection
unit
parts 56
Pa
5~
57
33 33
34
37
38 38 38 38
39
40 40 40 40
41
44
45 45
046
46
48
49 49
49
50
50
51 51
51
52
52 52 53 55 55
5& .55
5~
.50
3
Pog_
Clutch
shelt Inner Cush drive Shaft semi-collar 51 Cush drive plate 57 Cush drive spring Sl
iding
Idle
geer Gear selector drum Preselector Preselector Gearshllt Gear selector forks and fork
Assembling
REAR WHEEL DRIV
DescrlpUon _ _ Stripping Check
sembly
Rear wheel drive box 60 Drive box Ilange 60 Distance shims _ _ 60 Internal toothed sleeve Bevel Cage retaIning ring 60 Rear wneel - drive box distance piece 60 Bear
ing housing 60
Adjusllng Sh
ims Bevel Lockring Lockring Seal rings _ Drive shalt-bevel pinion sleeve Dri
ve
Double Joint
M_
Rubber gaiters 8ali
bearings and Assembling Assembling rear wheel drive
fork
Contact
teeth
REAR SUSPENSION 65
Stripping Check and overhaul 65 Flexib le bushings 65 Fitting up on frame
FRONT SUSPENSION AND STEERING 66
Str
ipping Overhaul Fork rods 67 Top
bushings _ 67 Bottom Fork
bottom Fork Spnng Top
plug
Top
plug seals 68
Steering Steering adjusting Steering tube _ Assembling fork and steering
STRIPPING OF REAR SWINGtNG FORK
Overhaul Nuls
and Support Seals 8all
bear
Fi
tting
WHEELS AND BRAKES
Front wheet Rear wheel Wheels and brakes check Wheels Rims Spokes Brake
seal ring 51
body 57
57
sleeve 57
57 57
shalt
, with
sector
shall
01
gear box
E _
return spr ing
operating lever _ 57
gear
shalls
57 57
57
58
59
y;
01 rear wheet drive
and overhaul
of
rear wheel drive as-
59 &J
for
gear set 60
washers
gear
distance piece
safety washer
shalt
taper
01
rear wheel drive _ _
check
and adjustment 01 bevel gear
rear wheel coupling
roller
bearings
10
_ _ _ _ _ _
RlH arm of rear
61 61 61 61 61 61 61 61 61
~
61 61 61
62
63
from Irame 65
65
Of
tetescopic front fork and steering
01
tetescoplc front fork and steering 67
bushings
springs 68
covers
housings 68
rubber rings
taper
roller bearings 68
lockrings
60
67 67
68
68
68
on
Irame lug
68
70
of rear fork locknuts
spindles
ings
up
rear
and taper
lark
roller
bee rings
70 70
70
70
71 71
72
72 72
73 73
7.
linings
7. 7'
Pall_
Brake springs
Brake cam_ Brake pins Brake drums Rear wheel central Hub seals Tapper Tapper AdJusling weshers Brake cam lever Front brake cable Front brake adjustment Rear Assembling Assembling of fronl Fitting front Assembling rear wheel hub Fitting rear
TAPER ROLLER 8EARINGS AND BALL
BEARINGS
FRAME
Check and overhaul Rear fender and Center and side stand return springs Crashbar Rear brake Alder and pillion fcotrests Assemb!ing
ELECTRICAL EQUIPMENT BATTERY
Features Inspection and maintenance Cleaning Check Electrolyte Charge Common battery faults
GENERATOR
Descr Operati
Regulator unit
Testing data
Adlustmenl of generator belt tension
Generator faults
STARTER MOTOR
Description _ Operatlcn Testing data Slarler
IGNITION SYSTEM
General inlormation Coil
Distributor Automatic spark advance device Contact breaker Condensor Distributor
Spark plugs
Ignition timing Ignition faults
ELECTRIC HORN
Overhaul and repair In Tesllng
Electric horn
LIGHTING 117
Head light 117
instruments panel 117
Tal! light and stop Fuses 117
INSTRUMENTS AND CONTROLS 118
Wiring diagram legend 119
LUBRICATION AND GENERAL MAINTENANCE
CHAAT
roller roller bearings
brake adjustment
01
wheel on fork and drive
conlrol
and smearing
level
ch
eck
iption
on
molar faults
cap
data
body
bearing housings
wheels
wheelan
wheel hub
lark
1001 boxes
lever,
spindle
and
01
terminal blocks
_ _ _
and
rotor
struction
laults
_ 115
light
box
rod
74
7.
7.
74
"
74
"
74 74
75
"
75 75 75 75
76 76 76
n
78 78
78
78 78
78 78
78 79 79
79
79 79
79 79
'"
81
83
83
B3
83
86 87
88
94
9'
95
W
99
103 103 103
10< 10<
105
105 105
105
106
100
113
113 II
117
121
..
MAIN FEATURES
ENGINE
Cycle
Number Cylinder disposition
80"
Stroke
Displacement
Compression ratio
Revs Output at max engine
Crankcase Cylinders
Cylinder
Crankshaft Crankshaft
Connecting rods Pistons
Va O.H.V.,
and
Inlet :
- opens 24° before TOC
- c:oses Exhaust:
- opens
- closes 22" Rccker
- 0,5 mm. (.0196") Normal
- inlet
- exhaust 0.2 mm. (.00787")
Carb Both carb
Carburetor type
La;brificatlon Pressure,
Oil strainer in Ncrmal Ibs/sq.ln.) (Controlled by Electrfcally
Cooling By ai
Ignition By battery
5
Initial advance: 10°.
of
cylinders
:
at
max engine speed
speed
heads
supports
lve
gear
push rod operated via the camshaft
gear
driven by the crankshaft.
sa
n
aller
sa
o
alter after
clearance
rocker
0.1
uratlon
Oell'Orto 5.
lubricating
r.
Cylinder
123
A.
uretors
by
for
clearance
mm. (.OO393
are gravity fed from the tank.
Make:
5.1.
gear
pump
crankcase
relief valve)
controlled
and
with automatic advance Marelll distri
: in
: steel :
:
BOC
BOC TOe
valve
(cold
")
(right and
driven by the crankshaft. .
pressure
oil
pressure gauge.
cylinder
4 strokes
2
..
V~_90
80
70
703.717 cc. (42.93 cu. in.)
mm mm
. .
o
(3
.149
(2
.755")
")
9 to 1
6000 r.p.m.
50
HP
SAE in 1i9ht alloy light
alloy barrels with hard
chrome with
valve
of in suitable housing (as used in all
steel
alloy
in
liming
2.5
linings
light
allo
y,
specia
seals construction
anti-friction
F1
Race car
construction
thin
light alloy
:
engine):
lell)
- 3 kgs.lsq. cm. (35.6 _
heads deeply finned.
hemispherical,
l cast iron inserted
material pressed
s)
wall
with AL-TIN
bearings
In
the crankcase
butor
42.
type
Automatic advance: Ignition Contact Spark Plugs Ignition
Starter Marelli
ratchet control. Ring Exhaust system Dual exhaust pipes and mufflers.
TRANSMISSION C:utch
Twin driven plates, trolled
Gear box Four speeds,
Cush Separate case pedal on the right hand side of the machine.
Engine-gearbox ratio: Internal
-
-
- Third
- High
Seconda ry By constant speed
Bevel layshalt gear-wheel ratio; Overall
FR.f,ME Duplex cradle, tUbular
7
~uspen
Rear Telescopic Telescopic Wheels: 18x3 spoked steel rims, front and rear. Wheels: 18x3 spoked steel rims.
Tires
4.
Front Solo
With
liming
breaker plug: point
coil
molar
slarter
by lever on left
drive
gear
Low
gear
Second
gear
gear
gear
Low
gear Second gear Third gear High gear
slon
swinging
00 x 18
front and rear,
tire
pressure
rider pillion
n.
gap
: Marelli BE 220 D.
spring incorpora
gear
dri
front
front
2So
.
38° full advance .
gap:
0.42.0.48 mm. (.016-.018").
225 in Bosch-Marelll scale
: 0,6 mm. (.023") .
MT
40
H (12 V - .7 HP) with gear
boiled
on
dry
type. located on the lIywheel. Con-
handlebar
fr
onta
l engagement. Constant mesh gears
bolted
on crankcase, operated by
ratios:
ve at rear wheel
homokinet
ratios:
.
ted .
1 to 1.373 (16-22)
ic
double
or
electromagneti
flywheel.
to 1.933 to 1. to 0.954 to 0.
l
oint
1
1
1 to 6.066
1 to
struclure.
fork with external adjustable
fork
incorporating
fork with external
block
1,5 kgms/SQ.
hydraulic
front
type
om
adjustable
and rear.
..
high speed
.
eQuivalent.
263 754
cardan
4.625 (8-37)
to to
springs
.
dampers.
spring
_.
21
P.
S.1.
rocker
(15-29) (19-24) (22-21 ) (24-18)
shal
12292
8.031
4]94
.
c
l
5
Rear
tire
Solo
rider
Wilh
pillon
Note
- The above reeommendation is sing speed). on
motorway
0.2
kgms/sq
!I
using Ihe maehlne
s !he above pressures should be Increased by
. cm. (2,8 P.S.I.).
1.8 kgmslsq. cm. = 25 P.S.I.
2.0
Bntkes
Twin
lead
ing
shoes
exp
hand
lever on the r
Large
rear brake operated by pedal on
mac
hine
.
Overall
dlmen
t lons and
-
Wheelba~e
-
Lenglh
- W
idth
-
Height
- M
-
(dry)
in
imum ground
Curb
weigh!
anding
ight
handlebar.
weight
clearance
kgms
/sq. cm. = al
type
28
lor
normal
eonslanl
Ironl
1.445
2.230 mls. (abl. 87.5" )
0.
1.
O.
high
brake. operate
lell
hand
mls
795
miS.
0SO
miS. (abt. 41.2"')
ISO
mets. (abl. 5.
riding
. (ab
(abt.
P.S.!. (crui·
speed
sioe
t.
56.9
31.2")
243 kgs 536 Lbs
or
d by
of
")
9")
Performance Maximum permissi
each gear.
L
ew
Seco
ty 34%
Tl>
ird gear 120 kms/ h (74.5 m.p.h.)
ty
'<:3
High
Capacities Fuel tank:
solo riding.
gear
nd gear 96
'/0
gear
20
reserve (about 1 USA gl) - Petrol
Sump 3 mission 0.750 liters wheel drive 0.300 Front
1I1ers
lor
k dampers 0.160
ble
speed and
66
Kms/h
(41
kms/h
m.p.h.) Clmblng ability
(59.6 m.p.h.) Cli
170 kms/h (106 m.p.h.)
liters
(5.28 US gla.)
(3'1. Quarts) Shen
(1
~/.
liters
(5/8 Pints) Shell Splrax 90 E. P. -
98
/100
Pln!s) Shell Spirex 90
Multigrade
liters = 5,4
lux 33 -.
gradients
Climbing
inc
lud
ing
No
Climbing
(Regular
climbab
mbing
ability 14l/a
aboul 4 liters
20/40 _ Trans-
E.
P. - Rear
oz USA ~ Shell Tel-
le
in
60%
abili-
abil
oclane)
i-
6
Fig. 1 -
lelt
view
Fig. 2
- RighI view
7
TOOLS REQUIRED
FOR
STRIPPING, CHECKING AND REASSEMBLING
Fig . No .
1 12904700 2 12906900 3 60910500 4 12909500
5 6
7 8 9 12913100
10 12907000
11
12
13 12903000 14 15 16
17 26907800 18 12907100
19 12913600 20 12912900 21 22 12908300
23 24 12905300 25 12913600
Order
12905400 12912700 60907200 12913700
12912600
12912000
12910700
32906302
12911801
12906500
12905900
No.
(see Fig.
Puller Puller
Steering top linking plate puller.
Front fork rods assembling tool. Wrench
L
Valve Puller
Puller for mainshaft roller bearing in transmission box.
Puller for mainshaft and clutch shaft bearings in transmission
cover.
Special
Flange assembling and oil seal locating tool on crankshaft, flywheel
side.
Tool
Bush
Oil
Flywheel
Piston pin
layshaft Tool Special tool
Clutch
Tool
timing
Tool Tool
Tool
for for
ockring
dismantling
for
for
for
pump
for
for
side. for for for
taper
bearing races on rear
roller
bearing race in
for
removal of Jayshaft
adjusting tool for rear dampers.
layshaft ball bearing in transmission
wrench
resr
oil seal
gear
and
and
removing the
dismantling
timing
removal of holding transfer
fork
clut
puller
rear
to
cover
for
puller
check
3)
Description
drive
lockring
and assembling tool.
front fork
taper
fitting
.
ch
unit
.
drive
flange
positioning
and
assembling and oil seal
clutch
crankshaft
of pOSitioning marks
lockring.
roller
bearing adjustment.
on
mainshaft.
holding
bevel
assembling
tool.
holding
c/w
bearing.
marks
shaft.
when removing bevel nut.
fork
box.
.
tool.
flywheel side.
on
tool.
on
.
box
timing
locating
timing
.
gears.
on crankshaft.
gear
.
box
1-IJ
8~
2~
9~
3~4
10~
12
@
.
~
19
5
14
~
~15
1
Y
6
18
7
Fig. 3
17
~'6
~+
~22
24
~
.21
25
rJ23
~
l'
I
9
DESCRIPTION OF ENGINE
..
(see Fig. 4 &
The"
V7»
model is
der 90' V engine.
rels
with
hard
finned Cylinder
for
cooling
bottoms fit into
equipped
Cylinders
crame
.
lining
5)
with a
have
s and are deeply
suitab
light
le
housings
twin-cylin-
alloy
crankcase.
Crankcase (four long, cylinder Cylinder
cast iron inserted valve seats.
Rocker tion
crankshaft
main bearings, pressed in suitable housings.
Steel
ings
ends.
Piston in piston pin
(oil scraper), O.H.V. valve gear, tappets, push rods and rockers. Camshaft
driven Pressure
in
ligllt
alloy ,
two
short)
heads.
heads are in
box
covers
construction
at big
ends
light
rings
and
by
crankshaft. Carburetors lubrication
in
light
on
two
special
con-rods
and bronze bush es at small
alloy. with 4 rings: 3
one
oil
operated
from oil sump
provided
to
secure
light
alloy. Steel
scraper)
with
cylinders
alloy, with special
tin-aluminium
with thin
over
through camshaft,
are
six
construc-
wall
pin (t
and 1
gravity
through
bolts
alloy
bear-
belo
gear gear
bar-
in
and
wo
w
fed.
.:.
,
'\'(r~'
";'~
:Y·!~
-
.
'.
..
'
,',
,
..
,
~
.. ' ..
,
'j:
••••••
~~
..
~
....
~
, \. '".
""':
'.
pump
driven by crankshaft. Oit recovery by vity. Wire gauze Lubrication Breather box
from which,
into
sump. Pressure tube
. Engine is
heads are
Ignition by battery ,
by
crankshaft
ctric
Ele
pressure control
tube
conveys
is discharged
air
suitably
through
starting,
Fig. "
type
oil
cleaner
led by relief valve .
oil
vapors Into
after
condensation.
outside
cooled. Cylinders
finned . coil
and
distributor
built-in
electrically
gear
controlled.
in
crankcase
breather
oil
returns
through
and
cylinder
operated
.
gra-
.
vent
10
Fig. 5
REMOVAL OF " ENGINE·GEARBOX» GROUP FROM FRAME
For
the
removal of the
from
frame"
battery
cab
les from
speedo
gearbox. saddle, fuel
remove the
covers (UH & RlH)
battery
control
tank
holder bracket.
throttle without
battery
from lever on gearbox, cables and neutral box. coil, after
and
air
disconnecting
support
disconnnecting
(see Fig.
..
engine·gearbox,.
following:
and
.
cable
and battery , after removal
plate,
from
transmission
cables two-ways adapter,
cables.
clutch
starter
indicator
control
control
cable
electric
group
disconne
cable
electric
from gear-
cables;
dis-
ct
in
of
6)
tributor cables;
generator
generator mufflers,
Put
engine nuts group front wheel)
it
from frame .
N.B.: The After removal
with petrol and dry by compressed air.
strip
cap, after distributor
covers;
unit.
large
band
on a
support
extract
to frame; move the
carried
engine
bolts
securing
tilting
above
it to
operation
out by two mechanicians.
of
group
assy from
disconnecting
rotor.
generator
on
rubber
and
«engine·gearbox»
group
the
right
is suggested
from frame, wash same
gearbox
spark
belt
gaiters.
after
unscrewing
forward
then
assy.
guard
(towards
extracting
plugs
and
to
be
Then
11
ENGINE OVERHAUL
ENGINE STRIPPING
To
strip remove the following:
drain oil from sump plug (see B on Fig. 7).
remove spark plugs.
ignition
unscrewing bolts securing same to crankcase
and removing gasket.
generator
cotter pins and pins .
generator
bolts securing same to crankcase.
clutch
ring gear by means of ring wrench and tool
No. 12911801 (see 16 on Fig. 8). that such bolts must be unscrewed in crossed sequence. After removal of ring
distributor
secur ing band,
support
unit
, unscrewing bolts securing starter
by
unscrewing
unit c/w support,
after
removal
bracket, after
unscrewing
Bear
gear
oil
drain
after
in mind
remove
01
Fig. a
12
Jj
..
Fig
. 7
n.
S.
clutch plate, intermediate plate,
plate , pressure plate, washer and
generator
­on crankshaft by means of ring wrench and tool No. 12911801.
timing
­same
driving
cover,
to
crankcase.
pulley,
after
after
unscrewing bolts securing
1.5.
springs
unscrewing
clutch
.
nut
seal ring from
cam
wheel , removing nut securing same to camshaft, by means No. 12911801 (see 16 on Fig.
timing
cover.
of
ring wrench and tool
9)
.
oil pump (see No. 32906302 (see
distribution
flywheel. screw by means of
gear
, by means of
16
on Fig. 10) and
15
gear.
After
flattening the
bolts securing flywheel to crankshaft ,
box
12911801 (see 16 on Fig. 11).
cylinder
rocker gaskets.
-
rocker
head
lubrication
cover screws, then remove covers and :;
spindle
bolts and washers.
1001
No. 12911801
oil
pump
on Fig. 10).
wrench and tool No.
oil
lock
pipe.
gear
puller
plates , un-
"
Fig.
10
--16
Fig.
11
..
13
rocker springs
arm spindles,
rocker
and washers (see Fig. 12). Remove
tappet adjusting screws push rods.
arms,
after
loosening nuts.
rocker
arm
rocker long which crankcase
cylinder Using tool No. 60907200 (see 7 on Fig. move from
arms support,
bolts and the two
secure
after
cylinder
unscrewing the
short
bolts (each head)
and
cylinder
.
heads c/w valves and remove gasket.
cylinder
head the semlcones,
head
13)
four
to
re-
top collars, springs, bottom collars and then ex­tract
valves from inside. cylinders tappets
piston pin, by means (see
the
oil same to
and relative gasket.
from housing on
17 on Fig. 14),
crankcase
of
puller
after
No. 26907800
removal of circlips.
.
piston and from same remove piston rings.
sump ,
after
unscrewing screws securing
crankcase
. Also remove
oil
sump
gasket.
oil
pump,
after
removing screws securing sa­me to crankcase. From pump remove key, driven
gear
and driving shaft.
Fig.
13
co mplete oil cleaner and
15)
Fig.
. Cleaner cons ists of: 2 retaining bolts,
gasket
(see B on
bottom plate, wire gauze and cleaner body . oil pipe (see A on Fig. 15), after flattening
lo
ck
plates and
unscrewing
securing bolts and washers . Remove from pipe the pressure r
",!
ief valve , cons isting of: pl
ott
om
b con-rod
plate and plug .
caps,
after
flattening
unger, spring
lock
plates and
unscrewing nuts. Then extract con- rods from
,
Fig.
12
Fig. 14
top
of crankcase. Remove
con-rods.
camshaft, flange
after
to
crankcase.
half
bearings from
unscrewing bolts securing
flange c/w after
flatten ing lock
bo
lts securing flange to crankcase.
crankshaft
bushing,
plates and
timing
unscrewing
flange c/w main bearing, flywheel side, after flattening securing flange of
tool No. 12913600 (see 19 on Fig.
ve
flange c/w main bearing from crankcase .
lock
plates and unscrewing bolts
to
crankcase. Then, by means
16)
crankshaft.
oil
pressure solenoid .
oi l
filler
plug
(see A on Fig. 7).
After the above operations the crankcase is pletely stripped,
except
for
the
long and
bolts.
N.B.:
During ed
rod-piston
stripping
to
keep well apart
..
groups.
it
is
strong ly recommend-
the
two
..
cylinder-
side,
remo -
Fig. 15
com-
short
To remove timing cover from frame,
- after removing unscrew sembly. Extra ct
it is necessary to proceed as
belt
the
three bolts securing pulley as-
pulley
without
cover and
removing engine
generator
outer
flange and
washers.
using the three bolts previously securing pul­ley, fit tool No. 12905300 on 24
on Fig. 17) and thus
unscrew crankshaft nut
pulley hub (see
holding
by
crankshaft
means
of
wrench.
unscrew
tool,
block
the
inner
or
support
three
body
bolts
and remove special
of
pulley and pulley
engine.
remove bottom frame/engine stud.
rem ove screws securing
timing
cover
crankcase.
follows
belt.
a ring
hub
.
Ie
:
16
Fig.
,
Fig.
17
15
ROCKER BOX COVERS - CYLIN­DER
HEADS - VALVES - GUIDES
- SPRINGS
Cylinder
se
nuts secure STRIPPING
Removal and stripping of
quired
loss being imputable and also
order
c
hamber.
When engine is on frame,
ping
Disconnect:
- sparks cables.
-
- exhaust pipes and muffler
-
-
-
Then remove cylinder head No linde overhaulfng and assembling operations, and re· quired graphs:
heads, in light alloy, are finned to increa-
coo
ling surface. Long bolts, short bolts and
cylinder
when loss of compression
after
to remove carbon deposits in combustion
Is
carried
air
inlet tubes and
distributor rocker
rocker
difficulties
r heads
tools, are lIsted in the
Qut
cap .
box
arms and
are involved
into
heads to crankcase.
cylinder
to
defective valve sealing,
a certain period
cylinder
as follows:
carburetors
s.
covers.
rocker
parts.
arms supports.
s.
in
strippi
In
any case all stripping,
heads are re-
is
noticed, such
of
operation, in
heads strip-
.
ng
down
following
cy·
para·
Fig.
18
REMOVAL OF SPRINGS AND VALVES
PositIon 7 on Fig. the co linder
INSPECTION AND OVERHAUL
OF CYLINDER HEADS
Using a chamfered move
INSPECTION AND OVERHAUL OF
Valve cylinder ried
& 19). Valve
excessive lash between its hole and the valve stem, whenever such lash simply After reamed same Negative housings exhaust valves. is mm.
cylinder
13)
valve top co llar so to remove semicones,
llar
, spring, bottom plate and, from inside
head,
carbon
VALVE GUIDES
guides
heads. Removal and refitting
out
by means
replacing valve.
pressing
wit
h a
to
size as shown
allowance on
0.046 and 0.075 (.0018 - .(0295).
head on tool No. 60907200 (see
and with the arm of same press on
the
valve.
scraper
deposits
are pressed in
of
a round punch (see Fig. 18
guide
cylinder
must be replaced in case
guide
straight
in
to
and a wire brush re-
and Inspect valve seats.
their
housings in
are
is
not
eliminable
in housing , hole must be
reamer in
In
coupl ing
pressing
heads,
be
order
data
guides
for
both inlet and
comprised
to bring
in their
between
top cy-
car-
of
by
chart.
f
r
fi
Fig.
19
t
Fig. 1
9/
1
16
Inlel
va lve
Exhaust valve
VALVES-VALVE GUIDES COUPLING DATA
Valve
guide
I.D.
8.000 + 8.022 mm.
{.3149 - .3158"}
Valve slem
di
ameter
7.987
7.980
rnm.
mm.
7.972
+
(.3138 - .3144") (.0005 - .0019")
7.965
-+
(.3136 - .3142") (.0008 - .0022
0.013
0.020
Clearances
-+
0.050
~
0.057 mm.
mm
")
.
INSPECTION AND OVERHAUL OF VALVE SEATS IN CYLINDER HEADS
In
order
valve seats must be regrinded. Angles of
tion of the seats are as follows:
- exhaust valve: 45°
to
obtain a perfect
inlet valve:
60025
25'
match
'
with
valves,
inclina-
7.987
7.
972
Regrinding is cutter, After
it
emery paste .
guided
milling, in
is necessary to
rated that normal milling will not
replacement of same will then be required.
carried
by a stem inserted
Should
out
by
order
to
obtain a perfect
grind
the valve
valve seats be so
means of a
in
valve
in
its seat
be
milling
guide
match
deterio-
sufficient ,
7.980 7965
8.
000
.022
. ,
with
38
38
.6
38.4
Fig. 20
14.064
14.075
34
34.6
34.4
17
INSPECTION OF VALVES
Check stem data valve stem Grinder table tion as
- exhaust valve:
valves
and
guide
chart
(see Fig.
so
that valve
follows:
integrity
(for
and
Fig.
20)
In
self-centering
21) will
4Se 25
and
clearance
. To
and
have an
existing
regrind
chuck
adjust
' +
1~'
lash between
refer
to
coupling
valves, insert
of
Universal
chuck
angle
of
swivel
inclina-
Whenever
to
check ween 37 mm. and by
adopting
between spring and cylinder head . INSPECTION OF VALVE SPRINGS
Check
have
Spring, compressed at show a load
regrinding
that valve
that valve
not
lost
valve seats, it is advisable
springs
38
mm . (1.456 - 1.496").
suitable
springs
their
elasticity.
of
Kg. 33 + 2 (72 Ibs - 12 ozsl
are
compressed
washers at
are
not cracked
37
mm. (1.456"), must
o
bottom
bet-
Adjust
collar
and
,
-
inlet
valve :
After
grinding
max. dia. to be
Sho
uld surface at stem end
mation.
regrind
SO
check
not
same on
Fig. 22).
U
25
'
thickness
Jess
o
+ 15'
of
valve head at
than 0.8 mm. (.0315") .
show
grinding
any defor-
wheel (see
(closed Spring, compressed at
show a load
(open valve position). Springs apparatus (see Fig. 23). As to load and
tion data refer to Fig. 24.
VALVE SEALING TEST After reassembling valves
up
if
any, will
bustion
valve position).
flexibility
inlet
and exhaust
be
chamber.
of
Kg.
can
ducts
detected
28
mm. (1.024"), must
o
60
+ 2 (132 Ibs - 4 ozs)
be
checked
on
cylinder
with gasoline. Losse
by
liquid
by
leaking
suitable
deforma-
head, fill
s.
in
com-
18
Fi
g.
23
J
.-J
~
:.J
.aooo
48.010
37
2t
Kq
33
Kg60.g
j (
r
(
r
(
Fig. 24
ASSEMBLING OF CYLINDER HEADS ON
CYLINDERS
Assembling of
ried
out
- reposition a and
cylinder
tion openings in gasket match with
holes
-
secure
crankcase.
-
fit
rocker
- position
-
screw down crossed sequence , without tightening. Using a
torque ft.lb) nuts
Fig.
25
cylinder
as
follows
in
cylinder
the head assembly
arms
washer
nuts
wrench
gradually
accordingly
(1-2-3-4-5-6).
heads on
:
new
gasket
head,
making
and
cylinder
support.
on
cylinder
on
long
rated at Kg/m. 3.800 (27.48
tighten
to
cylinders
between
sure that
head.
to
the
bolts
and
short
long
and
sequence
lubrication
six
.
cylinder
bolts
short shown
is car-
lubrica-
bolts
, in
bolt
in
in
punch by
-
fit rocker
-
fit head in
connect
-
- insert head.
-
fit
-
fit fit
-
-
connect
Repeat same assembling cylinder
insert
bolt
a new gasket
rocker
inlet
air
inlet
air
inlet
distributor
head.
spindle
and washer.
box
cover
box
cover
crossed
cylinder
tube
tube
tube
cap.
sparks
between
.
sequence
head
reducing
seal. complete
cable.
and secure it to
cylinder
and
screw
lubricating
operations
.
bush on
with
carburetor
it
to
for
support
head
cylinder
pipe
.
cylinder
second
and
.
N.B
.:
In
heads
ti
positioned, fit
Iy
c/w
After
order
to
avoid
during
ons
must be
adjusting
having lined them all up,
screw
deformation
assembling, above
strictly on
followed
support , spring and washer.
of
.
the
rocker
by
means of a
cylinder
instruc-
arms
Fi
g.
25
19
CYLINDERS - PISTONS - PISTON RINGS
CYLINDERS WEAR CHECK Measurement
must
be
transversal and longitudinal directions. Dial gauge must previously be set to zero on ring
gauge
Fig. 27).
Should sea rings ovalization
ing 0
ing (see
then be replaced.
SELECTION OF CYLINDERS DIAMETER
N.B.: Cylinders must always
(see Fig.
.1
0
Class "A"
80.000
(3.14963")
80.006 (3.1
4987")
piston of same class.
of
internal
taken at three
26)
and measurement
mm
. (.00394") be noticed in chrome lin-
top
portion
rnm
. 80.006 mm.
mm
.
60.01
diameter
different
or
of
cylinders) ,
Class
"8"
(3.14987") (3.15010
2
mm
(3.15010
. 80.018
")
of
cylinders
heights, both in
chart
any wear exceed-
cylinders
Class "
80.012 mm.
(3.15034 " )
be
matched with
C"
")
mm
(see
must
.
• h:'
..
.'#
.
'.,
..
"
.
:
.
...
. .
,
..
"
.
..
.
.
..
...
.
Fig. 26
'"
20
eo.OOO+80
3tMisuraz.
.018
Fig.
27
PISTONS
When overhauling, decarbonize piston crowns
and
ring slots. Then
ance (see Fig. 28).
If clearance exceeds measurement stated by chart, then replace cylinders and pistons. For engine balancing, both pistons must be of
some
ference is 1.5 grammes
Selection must be taken at 18.5 mm. (.7283") bottom to piston have to be 0.055 :- 0.065 mm.
less than selection size.
weight.
As
to sizes refer to chart
measurements
edge, In
pin
axis
check
Maximum
orthogonal
(see Fig. 30) Qvalization shall
cylinder-piston
permissible
(23
grains) (see Fig.
on
Fig.
31.
shown
in
sense with
(.OO21
weight
chart
from
-;-.
clear-
dif
29)
below
piston
respect
.0025")
-
.
Fig.
29
Fig. 28
1.990
..JL
1.978
03+045
0.25'0.40
2.
490
2.478
22.00'
Q3"'0.45
rCJ:::::::J
0~.40
3.990
3.978
Fig.
31
18.5
/
~
Sele
Fig. 30
'"
,
ianatur
i~~70
7
.952
..
"
SELECTION OF PISTON DIAMETER
Class
"A"
79
.952 mm.
(3.14nq
79.958
mm
. 79.964 mm.
(3.14798
N.B.: Pistons must always be matched with cy-
")
linders of same class.
Class "B" Class "
79.958 mm. 79.964 mm.
(3
.14798'·) (3.14821")
79.970
(3.14821'·) (3.14845"\
C"
mm
'
.
-::t:::::::!:m:~:·.m:.!!.
,
............
!!
..
··t·,·
;;:.:.:t:;:::,;w::;:·
_
.:·_······
::.:.::
....
• 1"'" : ;
. .:::*'
..
. -
-
:
...•.........
...
r.··· · ..
·····1
.•
·:1:···
::;:::
.. : ..
:::
..
..
. .
...
..
:.
-:.
:
Fig.
..
32
PISTON RINGS ANO OIL SCRAPERS
When fitting rings over piston pay attention the position of
line with each other. Check clearance between rings and slots on pi­ston (see Fig. 32). Such clearance must be within
ston rings and scrapers-piston slots height clear­ance
". Before fitting rings over piston, ble
to
ance
at ends (see Fig. ragraph
ance
".
PISTON RINGS AND SCRAPERS -
PISTON SLOTS HEIGHT CLEARANCE Vertical clearances :
1 st -
of
end gap which must be placed
measurements shown in paragraph
it
is indispensa-
insert them in
..
Piston rings and oil scrapers end clear-
Piston ring
0.030 - 0.062
cylinder
33)
to be as shown in pa-
mm
. (.001 - .0024")
and check
to
out
..
Pi-
clear-
Between oil scraper ends:
0.25 - 0.40
FITTING
Before about dilatation pin. To
Fig. 14
Negative allowance between piston pin and hole in piston:
OF
fitling
60 °c (140 t
of
fil
pin use tool No. 26907100 (see
).
0.001
mm
. (.010 - .016
PISTON PI
pins
, pistons should be heated at
the
hole
mm. (.00004").
NS
F)
in
order
. thus easing
")
to
cause a slight
introduction
17
of
on
2nd - Piston ring
0.030 - 0.062
3rd Oil
4th Oil
PISTON RINGS AND OIL SCRAPER END CLEARANCE
Between piston ring ends:
22
scraper
0.030 - 0. scraper
0.030 - 0.062
0.30 - 0.45
mm
062
mm.
mm
mm
. (.012 - .018")
. (.001 - .0024")
(.001
- .0024
. I .
001
- .0024" I
")
,
H.l'l
Fig. 33
CON-RODS
CRANKSHAFT MAIN BEARING, Flywheel side
MAIN BEARING, Timing side
CON-RODS,
When overhauling con-rods. check the following:
-
conditions ance
- weight
parallelism big
end bearings.
Big end
of
small end
bushings
and_ c
between same and piston pins.
of
both con-rods.
of
the
two
axis.
bearings
are of
thin
wall
type, in
lear-
antifric-
tion alloy, and do not allow for any adjustment.
Therefore are place. When must be shaft pin, measure wear of
o/s
if
scoring,
detected,
replacing
reconditioned.
point
(see Fig. 44) in
replacement
positive
diameter
bearing
excessive
replacement bearings, Before
of same at
order
and
wear
or
seizing
must
crankshaft
regrinding
to
select
consequently
take
pin
crank-
major
class
to
which
diameter reground. bearings»
crankshaft
Refer
to
and
"Diameter of
charts
..
25.020
5.041
Fig.
34
pin shall have to be
Thickness
crankshaft
of
big
end
pin
D.
Original
Thickness
1.534 - 1.543 mm. (.06039 - .06074"')
Original
Diameter
44.013 - 44.033 mm.
1.7334 - 1.7336
"')
THICKNESS OF BIG END BEARINGS
Oversize
0.254 mm. (.010"') (.020") (.030")
1.661
- 1.670 mm. 1.788 - 1
(.
06539 - .065748"')
DIAMETER
0.254 mm. 0.508 mm. 0.762 mm.
(.010")
43
.759 - 43.779 mm. 43.505 - 43.525 mm .
(1.7226 - 1.7236
"')
0.508 mm . 0.762 mm .
.797
(.07
OF
CRANKSHAFT PIN
(.
(1.7126 - 1.7136
mm.
- .07074") (.07539 - .07574"')
Undersize
020
")
")
1.915 - 1.
43.251 (1.7028 - 1.7036" )
924
(.030")
-43.
271
mm.
mm.
1.
016
mm.
(.040"')
2.042 -
42
2.051
(.08039 - .08074"')
1.016 mm. (.040"')
.997 - 43.017 mm .
(1.6926
- 1.6935")
mm.
23
SMALL
END BUSHING
Bushing surfa
is
pressed in con
ce
must not show any seizing mark,
-fod
and
scoring or excessive wear. II so, it
placed. Deteriorat
from con-rod
After
new
bushing
be
drilled
in
in con-rod (see
then be reamed
in
following
I/O
01
after pressing-In
22.020 -22.041
0.014 - 0.040
bushing
and reaming
(.8669 - .8678 ") (.8662 - .8663" )
Pin-bushing
clearance
(.0005 - .0015")
ed
bushing must be removed
by
means of suitable round punch.
Is pressed-In, the
correspondence
Fig. 30).
to
bring
chart
(see Fig. 35).
mm
.
mrn
.
with
Inside of bushing must
dia
meter to sizes shown
Piston pin
22.001 - 22.006
its internal
must
same
holes
existing
dis.
mm
deep
be
must
.
re-
Weigh t grams
of
complete
(1
Ib 33/ 4 ozs).
Fig. 36
con-rod
as
above:
560 +
~O
CHECKING WEIGHT FOR ENGINE BALANCING
Con-rods, bolts
and
complete
lock
plate
with
sma ll end bushing, nut,
s,
must be
of
same weight.
Maximum
perm
issible
grains) (see Fig. 36) .
difference
: 3
grams
(46
Fig. 35
Fig. 37
CHECKING PARALLELISM OF END AXIS
Before fitting meaning
holes deformations wit
Maximum
measured
(.00118").
FITTING-UP CON-RODS ON CRANKSHAFT
When tion
are set as
N.B.: Viewing
Bearing­mm . (.000433 - .0024
must
h forked lever (see Fig. 37).
fitting
that
Upward, for
Downwa
marked on with bers must be on same side (see Fig. 38).
con-rods, check
that
the
two
be
parallel to
can be eliminated
permissible
at
200
mm.
up
con-rods
lubrication
follows
rd,
number
crankshaft
(see A
UH
for
RiH
engine
con-rod
pin ")
axis
of
big
each
offset
(7.874
on
crakshaft
ducts
cylinder
marked
in
on
Fig . 38) :
con-rod
cylinder
from c
(see Fig. 39).
lutch
big
on cap. Both
clearance
their",
to
") is ±
con-rod
squaring
and small end
other. Possible
operating
the
two
0.03
, pay atten-
big
con-rod
side,
number
end
must
is
0.011 -0.061
on rod
match
",
axis ,
mm
ends
num-
.
Con-rod-c
0.5
mm. (.0118-.0196") [see Fig.
Fit
con
means
fUbs.). See Fig.
rod assembly . As
43.
rankshaft side
-rods
on
crankshaft
of
torque
41
Fig. 39
clea
rance must be 0.3
40)
and
tighten
wrench at 3.500
Fig
42
shows
to
measurements. refer
dismantled
.
nuts by
Kg
/m. (25.31
to
con-
Fig.
Fig.
3B
.-
. ,
.
"
,to
,
.
,
.
: 1,
..
, ,
Fi
g. 40
25
--.~
....
....
-, . '
.
••
.
..
..
.....
....
..
,
.. , •••••
..
.
..
..
!:
..
-.
.
.
.
":::1
..
'.
~
Fig. 41
22.020
22.041
22.001
22.006
25
.030
2~050
1.534 1543
26
47 47
.130 .142
CRANKSHAFT
Crankshaft main bearings, with
of steel
construction,
suitably
on
two
special
counterweighted
crank.
Check ing marks are
crank-pin
detected,
and main shafts. If
they can
be
slight
seiz-
eliminated
using very fine carborundum, but should surfaces
show the or size range is the
0.4
deep sea
regrinding
bushings
mm.
(.01574") - 0.6
rings
must take
be
adopted.
following:
or
remarkable
place
Main
mm.
ovalization,
and
ols
bearings
bearings
0.2 mm. (.00787") ­(.02362") - 0,8
under-
mm.
(.03149").
Spare flange.
following:
- 0.762 mm. (.030") - 1.016 mm. (.040"),
As previously said, before and main shafts wear cide
main bearings are always meant to
Crankpin
0.254 mm. (.010") - 0.508 mm. (.020")
bearings undersize range is the
regrinding
point
new
carefully
(see Fig. 44-45-46-47) in
diameter
taking
measure them at
order
into
account
be
c/w
crank-pin
major
to
de-
undersize
ranges and necessary clearances.
Fig. 44
Ciearances are the
Mainshaft-bearing, mm. (.00098 - .00224")
following:
timing
side:
0.025 - 0.057
Fig.
45
Fig. 4S
17
Mainshaft-bearing, flywheel side: 0.030 - 0.068 mm. (.00118 - .0027")
Crankpin-bearing:
.0024")
Static
balancing
plying a weight
(3.112
When which mm. (.118")
lb •.
).
regrinding
are
1.5 mm. (.059") for for
Original
diameter
53.97a mm. 53.770 mm. 53.570 mm . 53.370 rnm.
(2
.1248") (2.1169
53.931
mm.
(2.1233") (2.1162")
0.011
- 0.061 mm. (.0004-
of
crankshaft
of Kg. 1.586 ±
, restore
is obtained by ap-
.0
15 on crankpin
shoulder
relief radiuses,
crankpin
mains haft, flywheel side.
DIAMETER OF MAINSHAFT, FLYWHEEL SIDE
0.2 mm.
(.00787
")
")
53.751
mm.
DIAMETER OF MAINS HAFT, TIMING SIDE
and 3
Undersize
0.4 mm . 0.6 mm.
(.
01574
")
(2.1090")
53.551
mm
(2.1033") (2.1004")
.
(.02362")
(2.1013")
53.351
mm
0.8 mm.
(.03149")
53.170 mm. (2.093")
mm
.
53.151
(2
.0926")
.
Original
illmeter
d
37.975 Mm. (1.4951··) (1.4872") (1.4793·
37.959 mm. (1.4944") (1.4866
0.2 mm. 0.4 mm. 0.6 mm. ")
(.00787
37.775
mm.
37
.759 mm . 37.559 mm . 37.359 mm.
")
(.01574
37.575 mm. 37.375 mm.
(1.4787") (1.4707")
110 OF MAIN BEARING, FLYWHEEL SIDE
Or
igin
al
diameter
54.000 mm . (2.1260")
54.019
mm.
(2.1267")
0.2 Mm. 0.4 Mm . 0.6 mm. (.00787")
53
.800 mm 53.600 mm
(2.11 71")
53.819
mm.
(2.1188'
·)
(.01574")
(2.11
53
.619 mm .
(2.1109")
110 OF MAIN BEARING, TIMING SIDE
Original
diameter
0.2 mm. (.
00787
")
0.4 mm . (.01574
")
02")
")
Undersize
·)
Undersize
Undersi
(.02362")
(1.4715" )
(.02362
53.400 (2
53.419 mm. (2.1031
ze
0.6 mm.
(.02362")
")
mm.
.1024")
")
mm.
0.8
(.03149" )
37.175 mm. (1.4636")
37.159 mm. (1.4629")
0.8 mm.
(.03149
")
53.200 mm. (2.0945")
53.219 Mm.
(2
.0952")
0.8
mm.
(.03149")
28
mm. 37.800 mm.
38.000 (1.496''')
38.016 mm . 37.816
(1.4967
")
(1.4883")
(1.4889" )
mm.
37.600 mm. (1
.4803") (1.4725")
37
.616 mm . 37.4
(1.4809") (1.4731")
37.400 mm .
16
mm.
37
.200 mm.
(1.5646
37
.216 mm.
(1
.5652
")
")
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