MV Agusta F3 675, F3 Serie ORO Workshop Manual
Engine workshop manual
© 2012
The reproduction, even partial of this document is forbidden without prior written agreement of MV Agusta S.p.A.
Part. N° 8A00B7292 - Edition N° 1
Printed - May 2012
Engine workshop manual
MV AGUSTA F3 675 - F3 SERIE ORO
- 2 -
Statement
This manual, to be used by the MV Agusta authorised workshops, has been realised with
the purpose of assisting authorised personnel in maintenance and repairs operations of
the motorcycle. The knowledge of technical data herein noted, determines the complete
professional training of the technician. With purpose of making the reading of this manual
immediately comprehensible, the paragraphs have been aligned with detailed illustrations
that highlight the argument dealt with.
Useful advice
To prevent any problems and to reach an excellent final result, MV Agusta recommend
skeeping to the following guidelines:
- In the case of an eventual repair, evaluate the client’s impressions who states that there
is an abnormal functioning of the motorcycle and to formulate the right questions to
clarify the symptoms of the problem.
- Clearly diagnose the cause of the abnormality. The basic fundamental theories can be
absorbed by reading this manual that must necessarily be integrated to the personal
experience and the particip ation of training courses that are periodically organised by
MV Agusta.
- Rationally plan the repair to avoid slack periods, e.g. the collection of spare parts, the
preparation of tools and equipment, etc.
- To reach the part to be repaired limiting the work to the essential operations. With
regards to this, a valid help would be to consult this manual with regards to the
sequences of removal demonstrated in this manual.
Informative note
MV Agusta S.p.A. is committed to a policy of continuous improvement of their products. For
this reason, there could be slight differences between that which is written here and the
motorcycle on which repairs and/or maintenance are about to be carried out. MV Agusta
models are exported to many countries where different norms in relation to the highway
code
and homologation procedures are valid. Hoping that you will comprehend these problems,
MV Agusta S.p.A. reserves the right to make modifications to its products and technical
documentation at any moment and without prior announcement.
Respect and defend the environment
Everything that we do has repercussions on the entire planet and its resources. MV Agusta,
wanting to protect the interest of the people, would like to make the client and the
technicians
of the technical assistance centres aware and to adopt modalities of use of the motorcycle
and the disposure of its parts in full respect of the norms in force in terms of environmental
pollution, disposal and the recycling of waste.
- 3 -
General index
GENERAL DESCRIPTIONS ............................................................... A
MAINTENANCE .................................................................................. B
ELECT RICAL CO MPONENT S............................................................ C
HEAD .................................................................................................. D
CLUTCH.............................................................................................. E
GEAR .................................................................................................. F
STARTING........................................................................................... G
COOLING AND LUBRICATION .......................................................... H
ENGINE BLOCK ................................................................................. I
TIGHTENING TORQUES .................................................................... L
SPECIAL TOOLS................................................................................ M
ANAL YTICAL INDEX........................................................................... N
Rev. 0
Rev. 0
Rev. 0
Rev. 0
Rev. 0
Rev. 0
Rev. 0
Rev. 0
Rev. 0
Rev. 0
Rev. 0
Rev. 0
SECTION
REVISION 0
A
- 1 -
General description
A
- 2 -
General description
A
SUMMARY
HOW TO CONSULT THIS MANUAL ......................................................................................Pag. 3
PURPOSE OF THE MANUAL................................................................................................. Pag. 3
GLOSSARY AND SYMBOLS .................................................................................................. Pag. 4
RIGHT HAND AND LEFT HAND STANDARD ........................................................................ Pag. 6
SAFETY ....................................................................................................................................Pag. 7
Carbon Monoxide ................................................................................................................. Pag. 7
Petrol ....................................................................................................................................Pag. 7
Engine oil .............................................................................................................................. Pag. 7
Engine coolant......................................................................................................................Pag. 7
Brake fluid.............................................................................................................................Pag. 8
Thread-locking fluid .............................................................................................................. Pag. 8
Nitrogen - rear shock absorber.............................................................................................Pag. 8
Battery ..................................................................................................................................Pag. 8
Hot parts ............................................................................................................................... Pag. 8
WARNING................................................................................................................................. Pag. 9
INDEX....................................................................................................................................... Pag. 9
OPERATIVE TECHNICAL SPECIFICATIONS ........................................................................Pag. 10
MOTORCYCLE IDENTIFICATION ......................................................................................... Pag. 10
- 3 -
General description
A
HOW TO CONSUL T THIS MANUAL
Order of the subjects
This manual is divided into chapters that deal with the
sub-groups of the motorcycle. To quickly find the
chapter required, the pages of each chapter are
marked with a reference mark aligned to the relative
item in the general index.
Display of the operations
The operations of disassembly , assembly, removal and
control are presented with the help of illustrations
(designs and photographs).The illustrations contain
symbols that indicate the procedure, special tools and
other information. See the symbols lists for their
significance. The procedures are described step after
step.
EXAMPLE
Fitting countershaft head.
Fit the half-bearing on the countershaft head without
lubricating .
After placement, lubricate the half-bearing with engine
oil.
Check for the presence of the 2 countershaft head
blocking rings on the lower block.
Fit the countershaft head with the arrow stamped on
the back pointing in the direction of travel.
PURPOSE OF THE MANUAL
Principally , this manual has been written for MV Agusta
dealers and qualified mechanics. It is not possible to
document all the knowledge necessary for a mechanic
in a manual. Those who utilise it must have a basic
knowledge of mechanical concepts and the inherent
procedures in the techniques of repairing motorcycles.
Without this knowledge, the maintenance and repair
operations can render the motorcycle unsafe for use.
Updates
MV
Agusta S.p.A. is committed to a policy of continuous
updating of the models produced. The modifications
and significant changes to the specifications and the
procedures will be communicated to the official dealers
and will appear in future editions of this manual. All
information, instructions and technical data included
in this manual are based upon information on the
product updated at the moment of going to print. MV
Agusta S.p.A. reserves the right to carry out changes
at any moment without prior notice and without incurring
any obligation.
- 4 -
General description
A
A TTENTION
WARNING
This signifies that the lack or
the incomplete observance
of this advice can be gravely
dangerous for your safety
and for the safety of other
persons.
This signifies that the lack of
observance of these
instructions can bring the
risk of damage to the
motorcycle and the
equipment.
During this kind of procedure
inflammable vapours might develop
and metallic parts might be expelled
at high velocity.
Thus, it is necessary to:
- work far from exposed flames and
sparks;
- wear protective clothing;
- wear protective eye-glasses.
In case it should be necessary, due
to wear, to substitute a particular, relative to a cylinder, we strongly
suggest that you check and if
necessary, substitute the same
particular in all of the cylinders for
more satisfying results.In particular , we
recommend that at the same time you
substitute:
- pistons with relative elastic bands
and piston pins;
- valves with relative springs, semicones,disks and grazings;
- Valve guides with relative valves,
springs, semi-cones and grazings;
- bed bearing;
- whatever else under goes uniform
wear, a side from the position of
the relative cylinder.
In order to allow the motorto function
under the best conditions, it is
necessary that all of the couplings are
within the accepted tolerances
established. A tight coupling, is in fact,
cause for seizure as soon as the
organs in motion begin to heat, while
a loose coupling is cause for
vibrations which accelerates wear on
the particulars in motion.
GLOSSARY AND SYMBOLS
- 5 -
General description
A
Supplies key information for the best
fulfilment of the operation.
Utilise a specific tool or equipment
for the correct carrying out of the
operation described.
Tighten to the specified torque.
Tolerance or limit of use.
Utilise the tester.
Use the recommended oil.
Use the recommended grease.
Use the recommended coolant.
Use the recommended thread-locking
fluid.
Use new components.
Substitute the component.
Do not leave litter about.
NOTE
All of the countersigns indicting right, left,
superior, inferior, front and back, refer to
the motor-bike in the normal direction of
march.
The motor supports numbering of the
cylinders and of the attached components,
increases moving from left towards right
in regards to the direction of march.
This symbol indicates "the
procedures to be carried out with
an empty cooling circuit".
Use the recommended sealant.
Use the recommended adhesive.
Carry out accurate cleaning.
- 6 -
General description
A
RIGHT HAND AND LEFT HAND ST ANDARD
To clarify the right hand and left hand standard that is used in this manual, herewith below is a diagram of the
motorcycle and the engine against which are indicated the right and left sides.
Cylinder 1
Cylinder 2
Cylinder 3
Rh Side
Rh Side
Lh Side
Lh Side
- 7 -
General description
A
SAFETY
The information contained in this paragraph is fundamental so that the operations carriedout
on the motorcycle can be conducted with minimum risk to the mechanic.
Carbon Monoxide
• Exhaust gases contain carbon monoxide (CO) that is poisonous. Carbon monoxide can cause the loss of
consciousness and death.
• If it is necessary to switch on the engine, check that the environment is well ventilated. Never switch on the
engine in an enclosed environment.
• Switching on the engine can only be carried out in an enclosed environment when there are the appropriate
devices for the evacuation of exhaust gases.
Petrol
• Petrol is extremely inflammable and under certain conditions can be explosive.
• Keep sources of heat, sparks and flames away from the work area.
• Always work in a well-ventilated area.
• Never use petrol as a cleaning solvent. Generally, avoid handling it unless it is absolutely necessary.
• Do not use petrol for cleaning components by using compressed air.
• Keep petrol out of reach of children.
Engine oil
• Engine oil can cause skin illnesses if in constant and long contact with the skin.
• If the skin comes into contact with engine oil, wash the parts affected as soon as possible with soap and water.
• If engine oil comes into contact with the eyes, rinse abundantly with water and seek medical attention.
• If engine oil is swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs.
Transport the injured person immediately to hospital.
• Used oil contains dangerous substances and poisonous for the environment. To substitute oil, it is necessary
to be equipped to deal with the collection of used oil in respect of the norms in force.
• Do not dispose of used oil in the environment.
• Keep used oil out of the reach of children.
Engine coolant
• Under certain situations, the ethylene glycol contained in the engine coolant is inflammable and its flame is
invisible. Ethylene glycol would cause serious burns if ignited because it is invisible.
• Avoid bringing the engine coolant into contact with hot parts. Such parts could be sufficiently hot to ignite the
coolant.
• The engine coolant (ethylene glycol) can cause irritation of the skin and is poisonous if swallowed.
• If the engine coolant comes into contact with the skin, immediately remove any contaminated clothing and
wash with soap and water. If it comes into cont act with the eyes, abundantly rinse with clean water and immediately
consult a doctor. If swallowed, do not provocate vomiting to avoid the aspiration of the product into the lungs.
Administer clean water and transport the injured person immediately to hospital and show the product to a
doctor.
• If exposed to high concentrations of vapour, transport the injured person to a non-poisonous atmosphere and
if necessary call a doctor.
• Do not remove the radiator cap when the engine is still hot. Being under pressure, the engine coolant can be
violently ejected and therefore provocate burns.
• The engine coolant contains dangerous and poisonous substances and is therefore dangerous for the
environment. To substitute used engine coolant, it is necessary to be equipped to deal with the collection of
used oil/of used engine coolant in respect of the norms in force.
• Do not dispose of engine coolant in the environment.
• Keep engine coolant out of reach of children.
A TTENTION
- 8 -
General description
A
Brake fluid
• Brake fluid is extremely corrosive.
• Avoid any contacts with the eyes, skin and the mucous membrane.
• If brake liquid comes into contact with the skin, remove all contaminated clothing and wash immediately with
soap and water.
• If brake fluid comes into contact with the eyes, abundantly rinse with water and call a doctor.
• If swallowed, do not provocate vomiting to avoid aspiration of the product into the lungs. Immediately call a
doctor.
• Take the injured person immediately to hospital, if he has breathed brake fluid into the lungs.
• In the case of exposure to high concentrations of vapour, move the injured person to a non-poisonous
atmosphereand if necessary call a doctor.
• In the case of accidental contact, rinse abundantly with water and call a doctor.
• Keep brake fluid out of reach of children.
Thread-locking fluid
• As it is not classified as dangerous, the prolonged contact with the skin, particularly with regards to abrasions
can provocate sensitiveness and dermatitis. In the case of contact with the skin, rinse abundantly with running
water.
• Move the injured person into the open air and call a doctor if the injured person feels ill after having breathed
in the product.
• In the case of contact with the eyes, rinse abundantly with water for at least 15 minutes.
• If the thread-locking fluid has been swallowed, drink an abundant quantity of water or milk. Do not provocate
vomiting to avoid the aspiration of the product into the lungs. Immediately call a doctor.
• Keep out of reach of children.
Nitrogen - rear shock absorber
• The rear shock absorber contains nitrogen under pressure.
• Before disposing of used shock absorbers, discharge the nitrogen via the depressurising valve.
• Utilise only nitrogen to pressurise the shock absorber. The use of unstable gases can cause explosions that
could cause burns.
• Do not place the shock absorber near to flames or sources of heat as this could cause explosions with
consequent burns.
• Keep out of reach of children.
Battery
• The battery produces explosive gases. Keep it away from sparks, flames or cigarettes. During recharging,
adequately ventilate the environment.
• The battery contains a solution of sulphuric acid (electrolyte).
• Sulphuric acid is corrosive and it destroys many materials and clothing. On contact with small quantities of
water it generates a violent reaction that manifests itself by creating large quantity of heat and spurts of hot
acid. Sulphuric acid attacks many metals thereby liberating hydrogen: an inflammable gas that forms an
explosive mixture when mixed with air .
• Contact with sulphuric acid can cause burns. In the case of contact, remove immediately all contaminated
clothing and wash the skin with abundant quantities of water. Take the injured person to hospital if necessary.
• In the case of contact with the eyes, rinse immediately with abundant water. Call a doctor and continue with the
treatment until the doctor arrives.
• If the electrolyte is swallowed, rinse the mouth with water without swallowing. Take the injured person immediately
to hospital and explain to the doctor there what the injured person has swallowed.
• The battery contains dangerous substances that are poisonous for the environment. It is necessary to be
equipped to dispose of this product in respect of the norms in force.
• Do not dispose of used batteries in the environment.
• Keep out of reach of children.
Hot parts
• The engine and the exhaust system become very hot and maintain this temperature for some time after the
engine has been switched off. Wait for these parts to cool down before handling them or working on the
motorcycle near to them. Use protective gloves.
- 9 -
General description
A
WARNING
The information contained in thisparagraph is important
so that the operations carried out on the motorcycle
can be conducted without damaging the motorcycle.
• Thoroughly clean the motorcycle before
disassembling it.
• During disassembly, clean all parts and place them
in containers respecting exactly the order of
disassembly.
• Always use the special utensils where necessary
andeach time where prescribed.
• Always use adhesives, sealants and lubricants where
prescribed. Respect the instructions about their
technicalcharacteristics.
• Always substitute parts such as gaskets, O-rings,
securitywashers with new parts.
• Slackening or tightening nuts or screws, always start
withthose of a greater dimension or from the centre.
Alwaysrespect the torque values indicated.
• Utilise only MV Agusta spare parts.
INDEX
GENERAL INDEX SUMMARY OF EACH CHAPTER
- 10 -
General description
A
OPERATIVE TECHNICAL SPECIFICATIONS
MOTORCYCLE IDENTIFICA TION
The registration number of the motorcycle is stamped on the right side of the steering head.
The engine registration number is stamped on the upper engine casing, near the forks.
Below is an example of
engine and frame registration number:
Manufacturer identification
Vehicle model
Progressive frame number
ZCG F 10 AA Y V 000001
MV AGUSTA # # #
A C 000001
Engine type
Progressive engine number
2) Engine
registration
number
3) Homologation
data
1) Frame
registration number
SECTION
REVISION 0
B
- 1 -
Maintenance
B
- 2 -
Maintenance
B
SUMMARY
PLANNED MAINTENANCE SCHEDULE ................................................................................ Page 3
Programmed maintenance schedule ................................................................................... Page 3
Table of lubricants and fluids ................................................................................................ Page 5
Table of wear limits............................................................................................................... Page 6
Cleaning the parts ................................................................................................................ Page 9
Connections ......................................................................................................................... Page 9
General norms for assembling the parts..............................................................................Page 9
Measuring compression in the cylinder................................................................................ Page 10
Draining the coolant circuit ................................................................................................... Page 11
Changing the engine oil ........................................................................................................ Page 12
Removing the oil radiator ...................................................................................................... Page 12
Refitting ................................................................................................................................ Page 14
Filling the oil circuit................................................................................................................Page 15
- 3 -
Maintenance
B
PLANNED MAINTENANCE SCHEDULE
The following diagram shows the recommended planned maintenance intervals.
Periodic maintenance is essential to keep the vehicle in perfect running order and to ensure optimum cost efficiency .
Intervals are expressed in Kilometers.
Use shorter maintenance intervals if the vehicle is used in particularly harsh conditions.
Let us help protect the environment
Everything we do affects the entire planet and its resources.
To protect the common interest, MV Agustaurges its customers and service operators to use the vehicles and
dispose of their components in com-pliance with applicable regulations on environmental pollution control, waste
disposal and recycling.
Programmed maintenance schedule
0 1000 6000 12000 18000 24000 30000 36000
Km (ml) covered
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Service
pre-
ABCDEFG
delivery
Description Operation
.......
Engine oil Substitution
At least once a year
Substitution
.......
Engine oil filter (utilize only MV Agusta
original oil filter) At every substitution of engine oil
Check level / Top up
........
Engine coolant
Substitution every 2 years
Cooling Check for leakages
........
Electric fan Check functioning ........
Valves Check / adjustment ...
Check ..
Timing chain
Substitution .
Check / Substitution ..
Timing movable pad .
Substitution
At least every substitution of the timing chai
Timing chain tensioner Check / Substitution
...
Check / Substitution ...
Spark plugs
Substitution
...
Fuel filter Check / Substitution ...
Throttle body Check and adjustment .......
Air filter Check / Substitution ......
Check level ..... ..
Brake and clutch fluid .
Substitution
every 2 years
Check Functioning and Circuit
........
Brake / Clutch
Cleaning of contact lever and
........
pump piston area
Brake pads (front and rear) Check / Substitution
.......
Check for defects and leakages ...
Fuel tubes
Substitution every 3 years
Check functioning
........
Accelerator control
Verify / adjust play
........
Starter control Check functioning ........
Transmission / flexible controls
Check / Adjustment ........
Check / Adjustment ........
Transmission chain Lubricate .. . .
Substitution ...
WARNING
- 4 -
Maintenance
B
Programmed maintenance schedule
0 1000 6000 12000 18000 24000 30000 36000
Km (ml) covered
(600) (3800) (7500) (11200) (14900) (18600) (22400)
Service
pre-
ABCDEFG
delivery
Check
.. . .
Pinion wheel / Stop washer ...
Substitution
At least at each substitution of the transmission chain
Check
.. . .
Crown wheel ...
Substitution
At least at each substitution of the transmission chain
Crown wheel tension regulator
Check / Substitution ...
Steering head flange ring Check / Adjustment ....
Check / Adjustment ....
Steering bearings
Lubrication
.
Check for pressure ........
Tyres
Check for wear
.......
........
Wheel rims Visual check
Every tyre substitution
.....
Front wheel bearings
Check
Every tyre substitution
Substitution
.
Side stand Check functioning ........
Check functioning ........
Side stand switch
Substitution
........
Check / Lubricate
..
Rear wheel hub
roller bearings and guide
Substitution / Lubricate
.
roller bearings and guide
Rear fork bearings Check / Lubrication
.
Chain guide frame plate Check / Adjustment .......
Rear shock absorber Check / Adjustment ....
Front fork oil Substitution .
Battery connections Check and clean .......
Electrical system Check functioning ........
Instruments Check functioning ........
Lights / Visual signals Check functioning ........
bulb replacement
Horn Check functioning
........
Check functioning ........
Front headlight bulb replacement
Adjust at every variation of riding set-up of the motorcycles
Ignition switch Check functioning
........
Locks Check functioning ........
Torque settings - nuts and bolt
Check / Tightness ........
Tube band fasteners Check / Tightness ........
General lubrication ........
General check ........
- 5 -
Maintenance
B
Description Recommended product Specification
Engine lubrication oil ENI I-RIDE MOTOGP 10W/60 (*) SAE 10W/60 - API SG
Ethylene - Glycol
Engine coolant AGIP ECO PERMANENT Diluited with 50 %
of Distilled Water
Clutch and brake fluid AGIP BRAKE FLUID DOT 4 DOT 4
Chain lubrication oil D.I.D. CHAIN LUBE -
Table of lubricants and fluids
Engine Oil
SAE 10 W-60
API SG
ACEA A3
JASO MA
* To find the recommended product, MV Agusta suggests going directly to the authorised MV Agusta dealers. Eni
I-Ride motoGP 10W/60 has been manufactured for the F3 engine. If the described oil is not available, MV
The above specifications indicated are marked either on
their own or together with others on the container of the
lubricating oil.
Agusta suggests using completely synthetic oils with characteristics
that conform or exceed the following norms:
– Conforming to API SJ
– Conforming to ACEA A3
– Conforming to JASO MA
– Grade SAE 20 W-50 or 10 W-60
NOTE
- 6 -
Maintenance
B
ITEM STANDARD WEAR LIMIT
V ALVES
Ø Sealing external diameter
+0,05
Exhaust ........................................... 26,7 mm
-0,05
+0,05
Inlet.................................................. 31,8 mm
-0,05
Sealing face thickness
+0,1
Exhaust ........................................... 1,27 mm
-0
+0,1
Inlet.................................................. 1,0 mm
-0,
Stem - Guide clearance
Exhaust ........................................... 0,02 ÷ 0,04 mm ..................... Coupling: 0,10 mm
Inlet.................................................. 0,01 ÷ 0.03 mm ..................... Coupling: 0,08 mm
+0
Ø inner guide.................................. 4,5 mm ........................ 4,55 mm
+0,012
Valve stem
Exhaust ........................................... 4,4725 ± 0,0075 mm............. 4,4425 mm
Inlet.................................................. 4,4825 ± 0,0075 mm ............. 4,4525 mm
Valve Spring :
Exhaust ........................................... 45 mm.................................... 44,5 mm
Inlet.................................................. 42 mm .................................... 41,5 mm
Valve - Cam clearance
Exhaust ........................................... 0,20 ÷ 0,29 mm
Inlet.................................................. 0,15 ÷ 0,24 mm
Table of wear limits
- 7 -
Maintenance
B
ITEM STANDARD WEAR LIMIT
CYLINDER AND PISTONS
Piston ovalization............................ ............................................... 0,015 mm
Piston-Cylinder play ....................... 0,016 ÷ 0,042 mm................. 0,10 mm
Piston-Pin play................................ 0,002 ÷ 0,010 mm ................. 0,03 mm
Wrist pin-Connecting rod clearance 0,015 ÷ 0,029 mm................. 0,06 mm
Piston ring width
-0,01
1° segment ..................................... 0,8 mm ........................... 0,75 mm
-0,03
0
2° segment. .................................... 0,8 mm ........................... 0,75 mm
-0,02
-0,03
Oil scraper ...................................... 1,5 mm ........................... 1,38 mm
-0,08
Maximum piston ring-cylinder clearance
1° segment ..................................... 0,2 ÷ 0,4 mm ......................... 0,6 mm
2° segment ..................................... 0,2 ÷ 0,4 mm ......................... 0,6 mm
Oil scraper ...................................... 0,2 ÷ 0,7 mm ......................... 1 mm
CLUTCH
Friction drive plate thickness ......... 3 mm ...................................... 2,8 mm
Springs ............................................ 51,7 mm................................. 49,5 mm
- 8 -
Maintenance
B
ITEM STANDARD WEAR LIMIT
GEAR SHIFT
Gear fork - Groove pivot play. ............ 0,35 ÷ 0,15 mm ..................... 0,65 mm
Shift drum groove width....................... 7,05 ÷ 7,15 mm ..................... 7,35 mm
Ø Fork pivot......................................... 6,8 ÷ 6,9 mm ......................... 6,7 mm
Minimun idle gear axial play ................ 0,10 mm
Maximum gear fork play ...................... ............................................... 0,70 mm
Primary gear limit................................. ............................................... 5,60 mm
Secondary gear limit............................ ............................................... 4,60 mm
Fork selection gear limit
Primary (5a - 6a) .............................. ............................................... 4,65 mm
Secondary (1a - 2a, 3a - 4a) ........... ............................................... 3,65 mm
Fork - Pit play. ..................................... 0,2 ÷ 0,3 mm ......................... 0,7 mm
CRANKCASE - DRIVE SHAFT
Crankshaft - crankcase plain
bearing clearance ............................... 0,014 ÷ 0,044 mm ................. 0,06 mm
Connecting rod - crankshaft plain
bearing clearance ............................... 0,029 ÷ 0,057 mm ................. 0,08 mm
Crankshaft axial clearance.................. 0,2 mm
- 9 -
Maintenance
B
Cleaning the parts
All of the parts must be cleaned with special
biodegradable solvents and dried with compressed air .
Proceed with the cleaning process of all the parts
before disassembling them as well as after the particular
parts have been disassembled. Clean each part even
before reassembling.
Connections
In order to allow the motor to function in the best
conditions it is absolutely necessary that all of the
connections meet the standards established by the
manufacturer. A connection with reduced standards
could cause seizing, while a connection with excessive
toleration causes vibrations which accelerate the wear
of the components.
General norms for assembling the parts
For reassembling invert the disassembling procedure,
paying careful attention to the specified procedures.
Gaskets, oil spill protector, metallic locks.
Tightening rings in deformable material and self blocking
nuts must always be substituted.
The bearings are dimensioned for a determined
number of working hours. Substitution is therefore
recommended in consideration of the difficulty in
checking wear.
The above mentioned is in addition suggested for
dimensional controls of the single components
mentioned in the relative paragraphs.
It is absolutely necessary to carefully clean all of the
components; the bearings and all of the other parts
subject to wear must be lubricated with motor oil before
reassembling.
Nuts and screws must be locked to the pre established
torques.
Following are the descriptions of the disassembling,
revision and reassembling procedures of the various
parts and sub parts constituting the motor, in the
finalized sequence of a completely disassembled motor.
Disassemble the motor from its frame as described in
the relative paragraph;
Drain the oil from the oil cup;
Remove the spark plugs covering the openings with
clean rags to avoid small objects (rings, etc.) from falling
into the motor.
- 10 -
Maintenance
B
Measuring compression in the cylinder
The following tools are necessary in order to carry out
this procedure:
Spark plug key: n°800089013
Compression measurer
Adapter for the compression measurer.
A) Heat the motor to the usual functioning tem-
perature (of regime);
B) Switch off the engine, remove the tank, air box
and spark plugs;
C) Measure cylinder compression.
Drag the motor into rotation by means of the starting
motor with the butterfly valve completely open until the
compression measurer indicator (compression meter)
no longer rises; the compression measurement
obtained is the maximum.
Be sure the battery is completely charged.
Cylinder compression control (280 rpm-min.)
Engine Type Min Press. (bars) Max Press. (bars)
F3 7,5 14
- Repeat the procedure for the other cylinders.
N.B.: If the compression in the cylinder is lower than
the minimum value of the reported range, check the
following points:
A) carbon deposits on the walls of the combustion
chamber and on the piston ceiling;
B)the head gasket is not of the correct
measurements;
N.B.: If the compression in the cylinder is lower than
the minimum value of the reported range, check the
following points:
A) The seat of one or more valves is damaged and the
valves do not maintain the compression
pressure;
B) One or more valves have null functioning play;
C) The piston, cylinder play is excessive;
D) The cylinder head is twisted and/or the head gasket
is damaged;
E) Excessive play between ring and cable.
Before carrying out the compression trial,
accurately check the battery tension since
the compression value which appears is
quite influenced by the rotation velocity
of the motor, and consequently by the
battery tension.
NOTE
- 11 -
Maintenance
B
Draining the coolant circuit
If this operation is performed with the engine fitted on
the vehicle, it will be necessary to remove the body sides,
loosen the strap (1) and disconnect the coolant delivery
tube (2) from the radiator to the pump as described in
the frame workshop manual.
Place a container under the engine and unscrew the
coolant drain cap (3), tilting the engine to aid the
drainage.
Replace the aluminium washer when refitting (cod.
800089426) and tighten the cap to a torque of 25 Nm
with medium-strength thread lock.
1
2
3
800089426
- 12 -
Maintenance
B
Changing the engine oil
For replacing the oil, refer to the data in the table.
Lubricating system
component
Q.ty
Litre
scrankcase and oil sump
2.5
radiator and hoses 0.5
residual 0.2
Unscrew the oil filler cap (1),
place a container under the engine to catch the used
oil and unscrew the oil drain cap (2).
The quantity of oil which drains off from the
sump should be about 2.5 L.
To complete the procedure properly it is
also recommended to replace the oil
contained in the oil radiator.
If the engine is installed on the vehicle, it may be
necessary to remove the oil radiator.
Removing the oil radiator
Detach the bracket (3) from the plate (4) and the
(coolant) radiator (5)
NOTE
1
2
3
4
5
- 13 -
Maintenance
B
6
9
7
8
10
undo the radiator fixing screw (6) to detach the oil
radiator.
Unscrew the three screws (7) and remove the retaining
plate (8).
Extract the hoses (9) and (10) with the seal rings; these
will be replaced on refitting.
- 14 -
Maintenance
B
Remove the 2 screws (1) fastening the retaining plates
(2) and extract the hoses from the radiator.
Keep the radiator in the indicated position to help it to
drain.
The quantity of oil contained in the radiator
and hoses is around 0.5 L.
Refitting
The surfaces should be clean and degreased.
Always fit new seal rings (3) on the ends of the hoses;
these must be greased before refitting.
Refit the radiator hoses in the opposite order they were
removed, tightening the fastening screws (1) for the
plates (2) to 10 Nm torque.
1
2
3
GREASE
NOTE
Loading...