Start the engine and leave it running some three minutes at idle. Stop the engine and wait three minutes; immediately check the oil level via the rod.
Minimum level Maximum level

Dismounting the engine

Loosen the 3 screws that hold the starter clutch cover. One of the 3 also holds the alternator cover.
Remove the starter clutch cover.
Extract the starter clutch.
Loosen the 2 screws that hold the starter motor.
Extract the starter motor. NOTE: The 2005 starter motor turns in the opposite direction to that of 2004.
Loosen the 7 retaining screws that hold the alternator cover. One of them is located in the starter clutch cavity.
Remove the alternator cover.
Loosen the 2 screws that hold the position sensor (Pick-Up) (A).
Remove the de-multiplier pinion (B).
Loosen and extract the spark plug.
Loosen the crankshaft nut. NOTE: The nut loosens towards the right.
Turn the alternator rotor until placing the 7th tooth (A) of the phonic wheel in the center of the position sensor (Pick-Up) hole.
Loosen the 3 screws that hold the cylinder head cover.
Remove the cylinder head cover.
With the help of the extractor (Ref: MFS400134045), remove the alternator rotor.
Loosen the 3 screws that hold the oil extractor pump.
Remove the oil extractor pump cover.
Remove the oil extractor pump.
Loosen the 2 screws that hold the distributor chain tensor.
Remove the distributor chain tensor.
Remove the oil distributor.
Loosen the 2 lateral screws that hold the cylinder head to the cylinder.
Loosen the rear screw that holds the cylinder to the cylinder head.
Loosen the front screw that holds the cylinder to the cylinder head.
Loosen the 8 screws of the covers of the 2 camshafts and the distribution chain skate.
Remove the distributor chain upper skate.
Remove the intake camshaft cover.
Remove the exhaust camshaft cover.
Remove the intake camshaft.
Remove the exhaust camshaft.
Loosen and remove cylinder head lateral screw.
Loosen the 4 locking screws that hold the cylinder head.

Remove the 4 screws.

Remove the cylinder head.
Remove the cylinder head gasket.
Remove the distributor chain front skate.
Loosen the 2 screws that hold the cylinder to the engine housing.
Hold the distributor chain and remove the cylinder.
Remove one of the clips that hold the piston casing and push to remove it.
Remove the cylinder gasket.
Loosen the 5 screws that hold the cover of the clutch disks.
Remove the cover of the clutch disks.
Screw the centering tools into place (supplied together with the tools for the motorbike) and tighten them to 10 Nm. NOTE: This operation is mandatory to ensure the correct dismounting of the clutch.
Remove the 3 screws, the 3 washers and the 3 springs that hold the clutch unit.
Remove the clutch press cover.
Remove the clutch pusher.

Open the washer lug.

Loosen the fixing bolt, blocking the clutch bell turn with the tool Ref. MFS4504500220.

Remove the clutch unit.

Loosen the 3 screws that hold the oil filter cover.
Remove the oil filter cover.
Remove the oil filter and the spring.
Loosen the screws that hold the clutch casing.
Remove the clutch casing.

Remove the clutch bell.

Loosen the screw that holds the distributor chain tensor skate and remove it.
Remove the gear selector axle.
Remove the gear pedal axle spring.
Remove the gear pedal axle unit.
Remove the starter intermediate pinion clip.
Remove the starter intermediate pinion.
Remove the oil pump intermediate pinion.
Remove the clip and remove the oil pump pinion.
Loosen the 2 screws that hold the oil pump cover.
Remove the oil pump cover.
Remove the oil pump gasket.
Open the washer lug and loosen the crankshaft axle nut. NOTE: Turn the nut in a clockwise direction.
Remove the crankshaft pinion.
Remove the distributor chain pinion.
Remove the distributor chain through the upper part of the housing.
Loosen the 10 screws that hold the left housing.
One of the 10 screws that hold the left housing is located in the cavity of the oil pump.
Loosen the 6 screws that hold the oil pump filter registry cover and remove it.
Place the extractor (Ref. ME25950005) and tighten the middle screw to separate the two housings.

Remove the left housing.

Remove thehousing gasket.
Remove the 2 axles of the gearbox pins.

Remove the desmodrome.

Remove the gearbox gears unit.

Engine Mounting

Introduce the gearbox gears unit.

Place the desmodrome.

Place the 2 axles and the 2 gearbox pins.
One of the pins has a groove (A) for its correct position. NOTE: After mounting the axles of the gearbox pins and the pins, check that the gears engage normally. Place the gears of the transmission in a dead point position. The crankshaft pinion and the balance axle pinion have a mark (B) that eases its orientation. NOTE: Do not couple the crankshaft to the housing by tapping with a plastic hammer. Always use the special tool, otherwise the precision of the crankshaft alignment will be affected.

Loosen, gradually, the 3 screws that fix the clutch unit.
Place the new gasket and the clutch disks cover.
Fix, via the 5 screws, the clutch disks cover.
Place the new oil filter (See maintenance chart).
Fix, via the three screws, the oil filter cover.
Apply oil in the water pump press.
Place the press in its position.
Place the water pump turbine and close the cover.
Check the wear of the segment.
Place the piston. PRECAUTION: Mount the piston with the mark situated in the head oriented towards the exhaust side. NOTE: Use a new piston plastic ring to prevent it from breaking if it folds.
Place the 2 centers in the cylinder.
Place the new gasket in the cylinder base. NOTE: Clean well the surface before placing the gasket.

Place the cylinder.

Place the piston in PMS (upper dead point) to avoid objects falling in the cylinder interior and that may damage it.
Place the distributor chain skate.

Place the 2 centers.

Place the cylinder head gasket. NOTE: Clean well the surface before placing the gasket.

Place the cylinder head.

Place the 4 cylinder head interior fixing screws to the cylinder.
Fix, via the 4 interior screws, the cylinder head to the cylinder. Note: Tightening torque of 4.5 Kg.
Fix, via the exterior screws located in the front and rear part, the cylinder head to the cylinder.
Fix, via the 4 lateral screws, the cylinder to the engine casing.
Place the lateral screw of the distributor chain.
NOTE: Just before coupling the shaft axle to the cylinder head, apply a molybdenum oil solution to the stumps of the shaft axle and to the shaft surfaces. Likewise, apply engine oil to the supports of the stumps of the shaft axle (E).
Place the exhaust cam shaft. NOTE: The groove of the cam shaft has a position mark.
Place the intake camshaft. NOTE: The groove of the camshaft has a position mark.
Camshaft position marks (F).
Place the exhaust camshaft cover.
Place the intake camshaft cover.
Fix, via the 6 screws, the 2 covers and the skate. Cam axle stump support screw: 10 Nm (1 kg).
Place the oil distributor.
Adjust the distributor chain tensor. NOTE: Use a new gasket to avoid possible oil leaks. Distributor chain tensor spring support screw: 8 Nm (0.08 kg).
Place the distributor chain tensor.
Place the cylinder head and the gasket. NOTE: Apply silicon in the indicated zone.

silicon

Fix, via the 3 screws, the cylinder head cover.
Apply a cleaning product as shown in the drawing.
Place the alternator rotor and position the 7th tooth of the phonic wheel in the center of the hole of the position sensor (Pick-Up).

Place the clutch rod.

Place the clutch pincer.
Place the position sensor (Pick-Up)

In the models of 450 cc 4T of enduro produced before 2004 are equipped with a conventionsl clutch that may be substituted by the APTC clutch performingthe following operations. Note: the following operations are performed with the engine installed in the vehicle.

Dismounting:

Place a recipient to collect oil below the engine and remove the sump purge screw.
Loosen and remove the screw that fixes the brake pedal. Remove the brake pedal.
Loosen and remove the clutch cover screws.
Loosen and unscrew in a cross manner the screws that fix the pressure disk springs. Remove the screws from the pressure disk, the washers and the springs.
Dismount the clutch pressure disk and remove the gearbox primary cam point.
Open the security washer lug that locks the gearbox primary cam nut. Remove the clutch disks one by one.
Lock the clutch pail using the special tool MFS450450020. Loosen and remove the nut and the safety washer. Remove the special tool and remove the clutch pail from the gearbox primary cam.
ATTENTION: The washer situated below the pail should stay on the gearbox primary cam. Mounting: The mounting procedure is performed as described from page 41 of this manual. Warning: A moderate use is recommended during the first period of use of the APTC, to allow the normal adjustment of the different components and of the clutch disks. In case of especially intense use the APTC should be periodically subject to inspection and maintenance. The periods of this APTC maintenance depend on the conditions of use. In racing type conditions of use, the inspection and maintenance of the APTC should be performed before each competition. In normal use conditions, the APTC maintenance should be performed in accordance with the conditions defined in the user manual of GAS GAS.
Inspection and maintenance of the engine components
Cylinder head...61 Cam axle unit / automatic decompressor.73 Cylinder...75 Piston and piston ring..76 Connecting rod....78 Crankshaft....79 Starter clutch...79 Oil pump...80 Clutch...80 Gears and gearbox pins..82 Transmission....83 Bearings...84 Retainers...88
Inspection and maintenance
WARNING Identify the position of each one of the parts. Group the parts (exhaust, intake) to be able to again mount them in their original positions.

CYLINDER HEAD Dismounting
Dismount the intake tube.
Dismount the support of the engine coolant tubes.
Remove the tacks (1) and the adjustment pads (2), manually or with a magnet.
Compress the valve springs and next remove the semi-icons of the valve rod with the special tools. Ref.: Valve spring compressor Ref.: Adapter Ref.: Tongs
Remove the valve spring plate (1) and the valve springs (2).
Remove the valves through the cylinder head lower side.
Remove the valve retainers with some long nosed pliers. Dismount the valve spring washers.
NOTE: The normal dismounting work ends with the dismounting of the valves. If the valve guides have not been dismounted for its replacement after checking the associated parts, continue the described procedure in the box related to the maintenance of the guide valves.
Cylinder head deformation
De-carbonise the combustion chamber. With a ruler and thickness gauge, check if the surface of the cylinder head gasket is deformed. Measure the looseness in various places. If any of the looseness measurements surpass the service limit, replace the cylinder head with a new one. Tool ref.: Thickness gauge DATA Cylinder head deformation: Service limit: 0.05 mm (0.002 in)

Valve rod de-centering

Hold the valve with trapezoidal locks and measure the de-centering of the rod with a quadrant gauge, as shown. If the de-centering surpasses the service limit, replace the valve with a new one.
Tool ref.: Cuadrant gauge (1/100 mm) Tool ref.: Magnetic support Tool ref.: Trapezoidal lock units (100 mm) DATA Valve rod de-centering: Service limit: 0.05 mm (0.002 in)
Valve head radial de-centering
Hold the valve with a trapezoidal lock and measure the radial de-centering of the head with a quadrant gauge, as shown. If the de-centering surpasses the service limit, replace the valve with a new one. Tool ref.: Cuadrant gauge (1/100 mm) Tool ref.: Magnetic support Tool ref.: Trapezoidal lock units (100 mm) DATA Valve head radial de-centering: Service limit: 0.03 mm (0.001 in)

Valve work surface wear

Visually check if the work surface of each valve is worn out or damaged. If abnormal wear is detected, replace the respective valve with a new one. Measure the thickness (T) of the valve work surface. If the thickness is not found within the specified value replace the valve with a new one. Tool ref.: Thickness gauge DATA Valve work surface thickness (T): Service limit: 0.5 mm (0.02 in)

Valve rod deflection

Remove the valve some 10 mm from the seat. Measure the rod deflection in two directions, X and Y, perpendicular to each other. Place the cuadrant gauge as shown. If the deflection surpasses the service limit, replace the valve or the guide with a new one. Tool ref.: Cuadrant gauge (1/100 mm) Tool ref.: Magnetic support DATA Valve rod deflection: Service limit: 0.35 mm (0.014 in)

Valve rod wear

Measure the wear exterior diameter with a micrometer. If the exterior diameter is not found within the specified value, replace the valve with a new one. If the rod exterior diameter is found within the specified value but not the deflection, replace the valve guide with a new one. After replacing the valve or the guide, check the deflection. Tool ref.: Micrometer (0-25 mm) DATA Valve rod exterior diameter: Intake: 4.975-4.990 mm (0.1959 - 0.1965 in) Exhaust: 4.955-4.970 mm (0.1951 - 0.1957 in)

Valve guide maintenance

Extract the valve guide towards the cam axle side with the valve guide extractor. Tool ref.: Extractor/valve guide mounter NOTE: Discard the valve guide. Oversized valve guides are only available as spares.
Rectify the valve guide holes in the cylinder head with the valve guide tool and the handle. Tool ref.: Valve guide tool (10.8 mm) Tool ref.: Tool handle
Apply oil to the rod hole of each one of the valve guides and introduce the guide in the hole with the valve guide extractor/mounter and the adapter. Tool ref.: Extractor/valve guide mounter Tool ref.: Valve guide mounter adapter WARNING If the valve guide hole is not lubricated before introducing the new guide, this or the cylinder head may be damaged.
After mounting the valve guides, adjust the guide interior walls with the valve guide tool. Clean and lubricate the guides after adjusting them. Tool ref.: Valve guide tool (5 mm) Tool ref.: Tool handle

Valve seating width

Paint uniformly with Prussian blue the valve seating. Mount the valve and couple to it a valve polisher. Apply light taps to the painted seating in circles to obtain a clear impression of the surface contact. Tool ref.: Valve polishing set

Valve seating hermetic status check
With the valve and the spring mounted, pour a small amount of gasoline through the leading tube of the intake or exhaust. Check that no gasoline comes out of the valve seating. If a leak is observed, correct the lock surface. ATTENTION The gasoline is highly flammable and explosive. Maintain heat sources, sparks and flames far from the gasoline.

Valve spring

The helicoidal spring force maintains tightened the valve seating. With the spring weakened the engine power is reduced and a valve mechanism failure is produced. Check the force of the valve springs, measuring its free length, as well as the force necessary to compress them. If the spring free length is lower than the service limit or if the force necessary to compress them is not found within the specified value, replace the interior and exterior springs as a set.
DATA Spring free length (intake and exhaust) Service limit: Interior: 32.6 mm Exterior: 36.3 mm DATA Valve spring tension (intake and exhaust) Normal: Interior: 5.6 - 6.4 kgf / 27.4 mm Exterior: 12.6 14.5 kgf / 30.9 mm

CYLINDER HEAD Mounting

Mount the seatings of the valve springs. Apply a molybdenum oil solution to all the valve retainers and introduce them under pressure in its position. WARNING Do not re-use the valve retainers.
Apply a molybdenum oil solution, as shown, and then introduce them in the guides. WARNING When introducing the valve in the guide, avoid damaging the valve retainer lips.
Mount the valve spring with the smaller pass end towards the cylinder head. (A) Smaller pass (B) Greater pass (C) Below
Place the spring holder by pressing it with the valve pusher. Place the semi-icons in the end of the rod and release the valve pusher so that the semi-icons (1) set in place between the holder and the rod. Check that the round lip (2) of the valve adjusts well in the groove (3) of the semicone end. Tool ref: Valve spring compressor Tool ref: Adapter Tool ref: Tongs WARNING Make sure to mount all the parts in their original positions.
AUTOMATIC DECOMPRESSOR CAM AXLE UNIT
WARNING Do not try to disarm the automatic decompressor/cam axle unit. It can not be repaired.

Automatic decompressor

Manually move the automatic decompressor counterweight to check if it works smoothly. If the automatic decompressor counterweight does not function smoothly, replace it with a new one.

Cam wear

The wearing of the cams usually provokes the misalignment of the valve adjustment, with the corresponding power loss. Measure the height (H) of the cams with the micrometer. If the wear surpasses the service limit, replace the cam axle with a new one. Tool ref: Micrometer (25-50 mm) DATA Cam height (H) Intake: 36.934 mm Exhaust: 36.893 mm Service limit: Intake: 36.634 mm Exhaust: 36.593 mm

Cam axle bridge wear

With the cam axle mounted, measure the width of the oil with the plastic tool. Tools Ref.: Plastic tool DATA Cam axle bridge oil width (intake and exhaust) Service limit: 0.150 mm
Tighten the bridge support screws uniformly and in diagonal sequence with the specified torque. Cam axle bridge support screw: 10 Nm (1 kgm)
NOTE: Do not turn the cam axle with the plastic tool placed. Dismount the supports of the stumps and measure the width of the plastic tool compressed with the surrounding ruler. This measurement should be performed in the wider part of the compressed plastic tool. If the cam axle bridge oil width surpasses the service limit, measure the bridge support interior diameter and the bridge exterior diameter. Replace the cam axle or the cylinder head and the cam axle support, depending on which one exceeds the specified value. Tool Ref.: Lower calibration gauge DATA Cam axle bridge support interior diameter (intake and exhaust) Normal: 22.012 - 22.025 mm Tool Ref.: Micrometer (0-25 mm) DATA Cam axle bridge exterior diameter (intake and exhaust) Normal: 21.972 21.993 mm

Cam axle de-centering

Hold the valve with trapezoidal locks and measure the de-centering of the cam axle with the cuadrant gauge. If the de-centering surpasses the service limit, replace the cam axle with a new one. Tools Ref.: Cuadrant gauge (1/100 mm) Ref.: Magnetic support Ref.: Trapezoidal lock units (100 mm) DATA Cam axle de-centering. Service limit: 0.10 mm
CYLINDER Cylinder deformation
With a ruler and thickness gauge, check if the surface of the cylinder block gasket is deformed. Measure the looseness in various places. If any of the looseness measurements surpass the service limit replace the cylinder block with a new one. Tool ref.: Thickness gauge DATA Cylinder deformation Service limit: 0.05 mm (0.002 in)

Cylinder interior wall

Check if the cylinder interior wall presents scratches, nicks or other damage. Measure the cylinder interior diameter in six places. Tool Ref.: Cylinder gauge unit DATA Cylinder interior diameter FSE 400: 90.000 - 90.015 mm FSE 450: 95.000 95.015 mm

PISTON AND PISTON RING Piston diameter
Measure the piston diameter with a micrometer at 15 mm of the end of the skirt. If the piston diameter is lower than the service limit, replace the piston with a new one. Tool ref.: Micrometer (75-100 mm) DATA Piston diameter Service limit FSE 400: 89.880 mm Service limit FSE 450: 94.880 mm
Space between the piston ring and the groove Fig.1
Measure the side spaces of the 1st and 2nd piston rings with the thickness gauge. If any of the spaces exceeds the service limit, replace the piston and the rings. Tool ref.: Thickness gauge DATA Space between the piston ring and the groove (Fig. 1) Service limit: 1: 0.18 mm (0.0071 in) 2: 0.15 mm (0.0059 in)
DATA Piston rings groove width (Fig. 2) Normal: FSE 400 1: 1.03 mm 2: 1.22 mm FSE 450 1: 1.23 mm 2: 1.53 mm Lubrication: 2.01 -2.03 mm Tool ref.: Micrometer (0-25 mm) DATA Piston rings thickness (Fig. 3) Normal: FSE 400 1: 0.985 mm 2: 1.19 mm FSE 450 1: 1,19 mm 2: 1.49 mm
Free piston ring end aperture and piston ring end aperture
First measure the piston ring free end aperture with the calliper and then place the piston ring transversally in the cylinder and measure the aperture of the ring end with the thickness gauge. Tool ref.: Thickness gauge DATA Aperture of the free piston ring end (Fig. 4) Service limit: 1: 5.5 mm 2: 9.2 mm

! ! ! !

Tool ref.: Thickness gauge DATA Aperture of the piston ring end (Fig. 5) Service limit: 1: 0.50 mm 2: 0.50 mm
Piston bolt holder and bolt interior diameter
Measure the piston bolt holder diameter with a small calliper. If the diameter surpasses the service limit, replace the piston with a new one. Tool ref.: Cuadrant gauge (1/1,000 mm) Tool ref.: Small calliper (18-35 mm) DATA Piston bolt holder interior diameter Service limit: 20.030 mm Measure the piston bolt holder exterior diameter in three places, with the micrometer. If any of the measurements surpasses the service limit, replace the piston with a new one. Tool ref.: Micrometer (0-25 mm) DATA Piston bolt exterior diameter Service limit: 19.980 mm
CONNECTING ROD Connecting rod foot interior diameter
Measure the connecting rod foot interior diameter with the small calliper. If the interior diameter of the connecting rod foot exceeds the service limit, replace the connecting rod with a new one. Tool ref.: Cuadrant calibrator compass DATA Connecting rod foot interior diameter Service limit: 20.040 mm

Connecting rod deflection and connecting rod side space
The connecting rod head wear may be estimated by checking the movement of the connecting rod foot. This method may be also used to check the degree of wear of the connecting rod head parts. Tool ref.: Magnetic support Tool ref.: Cuadrant gauge (1/100 mm) Tool ref.: Trapezoidal lock units (100 mm) DATA Connecting rod deflection Service limit: 3 mm
Push the connecting rod head to one side and measure the side space with a thickness gauge. If the space exceeds the service limit, replace the crankshaft unit with a new one or correct the deflection and the side space within the service limit replacing the worn parts (connecting rod, connecting rod head bearing, crankshaft bolt, etc.) Tool ref.: Thickness gauge DATA Connecting rod head side space Service limit: 1 mm
CRANKSHAFT Crankshaft de-centering
Hold the crankshaft with trapezoidal locks and measure the de-centering with a quadrant gauge, as shown. If the de-centering surpasses the service limit, replace the crankshaft with a new one. Tool ref.: Cuadrant gauge (1/100 mm) Tool ref.: Magnetic support Tool ref.: Trapezoidal lock units (100 mm) DATA Crankshaft de-centering Service limit: 0.08 mm

STARTER CLUTCH

Remove the hexagonal screws (1). Starter clutch screw: 26 Nm (2.6 kgm)
Nount the starter clutch in the correct direction, as shown. Apply engine oil to the starter clutch. Apply LOCTITE to the hexagonal screws and later tighten with the specified torque while holding the rotor with a spanner.
Couple the gears (1) to the starter clutch. Check that the rotor (2) turns in the direction indicated by the arrow while holding the gears and pay attention so that the rotor never turns in the opposite direction to that of the arrow.

OIL PUMP

Check all the components. The screws that fix the pump to the engine sump should be placed with LOCTITE and a specified torque.
Oil pump: 10 Nm (1.0 kgm)

CLUTCH

Place the clutch unit in a bench press using protective gags. Gradually loosen the 3 assembly screws and unscrew them completely.

Remove the clutch unit from the press and support it over a clean work surface with the interior pail upwards, as shown in the image.
Remove carefully the interior pail from the exterior.
Place the interior pail over the bench with the arrow directed in the direction contrary to the operator. Remove the aperture springs of the APTC pails that stayed in the exterior pail and introduce them in the interior pail. Remove the conductors and conducting disks from the interior pail of the clutch unit. Carefully clean all the clutch unit components. It is preferable to use detergents similar to percloretylene (PCC). After the cleaning, dry all the components using compressed air. Check the wear of all the components and replace the damaged or worn out components using original GAS GAS.
Notes: Do not use pointed tools or aggressive detergents to clean the components of the clutch unit, since some of the surfaces of the same components are covered with an antiwear covering with low friction coefficients. The conducting and conducting disk package should be replaced when the total package thickness of the 8 covered conducting disks is lower than 21 mm. The thickness of the 8 covered conducting disks lower than 21 mm does not guarantee the correct functioning of the clutch unit. The use of non-original GAS GAS components does not guarantee the correct functioning of the clutch unit.
Before assemblingthe clutch unit it is necessary to lubricate allthe components using oil for engines conforming to the GAS GAS prescriptions. Support the exterior pail over a flat surface, as shown in the image, and introduce alternately the 8 covered conducting disks and the 7 conducted disks starting with a covered conducting disk. Support in the work bench the interior pail with opening springs in the upper part.
Maintain pressed the disk package with the fingers against the exterior pail and over turning it, introduce it in the interior pail taking care in making sure that the reference marks of bothpails coincide. Tighten the interior pail with the clutch disks corresponding to the positions of the opening springs in the exterior pail. Make sure that the opening springs are correctly placed in their seating in the exterior pail. Without stopping the clutch disk package pressure with thefingers, also hold the exterior pail. WARNING: Check that the upper conductive disk is not moved nor slides outside of the exterior pail.
Without letting go of the pressure on both pails, tighten the clutch unit in a bench press with protective gags. Tighten lightly to close the screw. Screw the three assembly screws and remove the clutch unit from the bench press. WARNING: Make sure that the conductive disk on the fixed pail side does not move and does not fall from the moving pail teeth. WARNING: Do not fully tighten the assembly screws, in a manner that it would be possible to ensure the possibility of movement relative to the conducting disks in the clutch unit group.

SPEED GEARBOX PINS AND GEARS Space between the pin and the pin groove The space of each gearbox pin plays an important role in the smoothness and positive functioning of the gearbox. Measure the space of the pins in the groove of their respective seatings, with the thickness gauge. If the space exceeds the specified value, change the pin, its respective seating or both. Tool ref.: Thickness gauge Tool ref.: Thickness gauge DATA Space between the pin and the pin groove Service limit: 0.50 m
DATA Gearbox pins groove width Normal: 4.8 -4.9 mm
DATA Gearbox pins thickness: Normal: 4.6 -4.7 mm

TRANSMISSION Dismounting

Dismount the transmission gears as shown.
01) washer 18x31.5x0.7 gearbox 02) primary pinion II 03) circlip d.25 din 471 reduced 04) washer 31.5x(25x22)x1 striated 05) primary pinion VI 06) primary pinion III and IV 07) washer 25.2x31.5x1 gearbox 08) primary pinion V 09) bearing needles k25-29-10 10) primary axle 11) bearing needles k20x24x10 12) secondary pinion I 13) washer 20.8x29x1 gearbox
14) secondary pinion V 15) secondary pinion III 16) secondary pinion IV 17) secondary pinion VI 18) secondary pinion II 19) circlip d.25 din.983 20) secondary axle 21) retainer 22) gearbox bearing 23) toric 25x2 nbr pinion output 24) dolly retainer output gearbox 25) output pinion z. 13 26) circlip d.25 diminished

Mounting

Mount the transmission in inverse order to the dismounting. Take special care in the following points: NOTE: Before mounting the gears, apply engine oil to the internal surface of each bearing and plug. WARNING Never re-use a plastic ring. Once the axle is removed, discard it and place a new one. If a new elastic ring is placed, do not expand the end opening more than necessary to slide the ring through the axle. After placing a new elastic ring, check that it is completely seated in its groove and firmly coupled. NOTE: When again mounting the transmission, pay attention to the location and position of the washers and the elastic rings. In the sectional view are shown the correct positions of the gears, the washers and the elastic rings. When placing an elastic ring, pay attention to its direction (place it towards the drag side). The rounded face should be against the gears surface. (A) Drag (B) Sharp edge

BEARINGS

Wash the bearings with a solvent and lubricate them with engine oil before inspecting them. Turn the interior guide ring and check if it turns easily. If it does not turn easily and without noise, or it presents signs of any anomaly, the bearing is defective and should be replaced by a new one in the following manner.
Gearbox primary axle right bearing
Remove the gearbox primary axle right bearing (1) with the special tool. Tool ref.: Bearing extractor unit WARNING Replace the extracted bearing with a new one. Mount the gearbox primary axle right bearings with the special tool. Tool ref.: Bearing mounting unit

Selector axle retainer

Slowly remove the selector axle retainer of the left sump (1) with the special tool. Tool ref.: Retainer extractor
WARNING Replace the extracted retainer with a new one. Slowly place the selector axle retainer in the left sump with the special tool. Tool ref.: Retainer mounting unit

Oil retention valve 2

Remove the cover (2), the oil retention valve ball (3) and the spring (4) of the right sump.
To again mount the oil retention valve place the spring (4), the oil retention valve ball (3) and the cover (2) in the right sump.
Crankshaft cavity sheet and oil filter cleaning
Dismount the oil filter from the right sump interior. Proceed to its cleaning without dismounting the filter sheet. WARNING If the filter is deteriorated, replace it with a new one.
Dismount the crankshaft cavity sheet and check its completeness and good condition. WARNING If the crankshaft cavity sheet is deteriorated, replace it with a new one.

Periodic maintenance

Spark plug....93 Oil filter and engine oil..94 Engine oil tubes...97

SPARK PLUG

Inspection after 30 hours of functioning. Replace after 60 hours of functioning.
Dismount the fuel tank. Disconnect the spark plug pipe and remove the spark plug.
COLD NGK DENSO STANDAR HOT

CR9E U27ESR-N U31ESR-N

CR8E U24ESR-N

CR7E U22ESR-N

Soot deposits
Check if there is soot in the spark plug. If there is soot deposited, remove it using a wire prong brush.

Spark plug tolerance

Measure the tolerance using a thickness gauge. If the spark plug is out of tolerance, adjust the tolerance. DATA: Standard: Tolerance 0.7 0.8 mm Tool: Thickness gauge.

Electrode

Check the electrode status. If the electrode is extremely worn out or burned replace the spark plug with a new one. Also replace the spark plug if the isolator is broken, the thread damaged, etc. WARNING Check the shape and length of thread when replacing the spark plug. If the neck of the spark plug is too short, the soot will be deposited in the space of the glowplug and the engine may be damaged.
Installation of the spark plug
WARNING To avoid damaging the thread of the first cylinder head screw the spark plug with the hand. Then tighten with the specified torque using the spark plug spanner. Spark plug tightening torque: 11 Nm (1.1 Kgm, 8,0 lb-ft).

ME250532002 MFS450532001 ME25610018 MFS400110023 MFS400110025 MFS400112019 T0305008 MFS450510000 ME25636056 MFS400136168 T0306035 MFS400112030 ME25612006/2 MFS400110123/2 MFS450610122 T0306016 MFS400116066 MFS450510001 MFS400112008 M01217001A T0305075 ME25636048 T0305035 MFS450510028 T0305016 MFS450510029 T0306045 MFS450610004 T0306055 T0306065 T0306060 MFS400122311 MFS400122315 ME25616033 MFS400122310 MFS400122150 T0306012 BE250210047 MFS400126563

Motor 6

RODAMIENTO AGUJAS HK1010 EC400-4T / HK 1010 EC400-4T NEEDLES BEARING ARANDELA 7X18X2,7 / 7X18X2,7 WASHER ALLEN 6X12 / 6X12 ALLEN BOLT ARANDELA COBRE 14X18X1,5 / 14X18X1,5 COOPER WASHER CONECTOR TUBO DESVAPORIZADOR CRTER / CRANKCASE STEAM HOSE CONNECTOR ALLEN 5X8 / 5X8 ALLEN BOLT SENSOR DE GIRO / TURN SENSOR TORNILLO CAMPANA ASPIRACIN / CHAIN ASPIRATION VISOR NIVEL ACEITE / OIL LEVEL VIEW FINDER TAPN ACEITE / OIL CAP
MFS400126022 ST950710 T0306012 MFS450510030 BFS450528048 T0305008 MFS450580005 MFS450622558 ME25610015 BFS450610079

Encendido / Ignition

ALLEN 5X75 / 5X75 ALLEN BOLT ALLEN 5X16 / 5X16 ALLEN BOLT SUB-TAPA ARRANQUE FSE 450-2005 / FSE 450-2005 START COVER PIN INTERMEDIO ARRANQUE ELCTRICO 24X21 / 24X21 ELECTRIC STARTER INTERMEDIATE SPROCKET RODAMIENTO AGUJAS HK1012 / HK1012 NEEDLES BEARING EJE PIN ARRANQUE INTERMEDIO / INTERMEDIATE STARTER SPROCKET AXIS TAPA VOLANTE MAGNTICO / IGNITION COVER JUNTA TAPA VOLANTE FSE450-2005 / FSE450-2005 IGNITION COVER GASKET PLETINA SOPORTE CABLES MOTOR ENCENDIDO FSE 2005 / FSE 2005 IGNITION CABLING HOLDER MOTOR DE ARRANQUE FSE 450-2005 / FSE 450-2005 START ENGINE ALLEN 6X25 / 6X25 ALLEN BOLT ALLEN 5X6 / 5X6 ALLEN BOLT CASQUILLO DISTANCIADOR ARRANQUE / STARTER SPACER BUSHING ALLEN 6X16 / 6X16 ALLEN BOLT ALLEN 5X25 / 5X25 ALLEN BOLT TUERCA VOLANTE / IGNITION NUT CHAVETA VOLANTE / IGNITION PIN VOLANTE MAGNTICO / IGNITION MOBILE ARANDELA 10X19X0,5 / 10X19X0,5 WASHER RODAMIENTO DE AGUJAS ARRANQUE / STARTER NEEDLE BEARING CORONA DE ARRANQUE / STARTER SPROCKET RODAMIENTO AGUJAS HK 1010 EC400-4T / HK 1010 EC400-4T NEEDLES BEARING CTO. PIN ARRANQUE EMBRAGUE / CLUTCH STARTER SPROCKET SET ESCOBILLAS MOTOR ARRANQUE / STARTER ENGINE BRUSHES
T0305075 T0305016 MFS450510028 MFS450626520 MFS400326023 MFS450626505 MFS450510004 MFS450544004 MFS450534019 MFS450526500 T0305025 T0305006 R233000 T0306016 T0305025 MFS400134011 MFS400134016 MFS450434005 MFS450526516 MFS400126020 MFS450626540 MFS400126022 MFS450526510CT MFS400326501

Motor7

Cigeal / Crankshaft
CADENA DISTRIBUCIN / CAM SHAFT DRIVE CHAIN GUA CADENA DISTRIBUCIN DELANTERA / CAM CHAIN GUIDE GUA CADENA DISTRIBUCIN TRASERA / CAM CHAIN TENSIONER TORNILLO FIJACIN PATILLA GUA CADENA DISTRIBUCIN / CHAIN GUIDE SCREW JUNTA TENSOR DISTRIBUCIN FSE 4T / CHAIN TENSOR GASKET ARANDELA 6,25X21X1 / 6,25X21X1 WASHER PASADOR ELSTICO D2X12 FSE 4T / D2X12 FSE 4T ELASTIC PIN APRETADOR TENSOR CADENA DISTRIBUCIN / CHAIN TENSOR PUSHER CRUZ TENSOR CADENA DISTRIBUCIN / CHAIN TENSOR BUSHING MUELLE TORSIN TENSOR CADENA / CHAIN TENSOR SPRING TUBO TENSOR CADENA DISTRIBUCIN / CAM SHAFT CHAIN TENSOR HOSE TUERCA EMPUJADOR TENSOR CADENA / CHAIN TENSOR PUSHER WASHER ANILLO ELSTICO TENSOR CADENA / CHAIN TENSOR ELASTIC RING TORNILLO EMPUJADOR TENSOR CADENA / CHAIN TENSOR PUSHER BOLT TENSOR CADENA DISTRIBUCIN / CHAIN TENSOR ARANDELA KLINGERIT 6X15X0,5 / 6X15X0,5 WASHER ARANDELA 17,5X25,8X0,5 / 17,5X25,8X0,5 WASHER TORNILLO HEXAGONAL 6X8 / HEXAGONAL BOLT 6X8 ALLEN 6X25 / 6X25 ALLEN BOLT PIN CADENA DISTRIBUCIN / CAM CHAIN DRIVE SPROCKET ENGRANAJE RBOL DE LEVAS FSE 4T / FSE 4T CAMSHAFT SPROCKET CHAVETA LADO EMBRAGUE FSE 4T / FSE 4T CLUTCH SIDE KEY CONJUNTO BIELA / CONNECTING ROD CONJUNTO CIGEAL / CRANKSHAFT SET PIN EJE DE BALANCE / DRIVE GEAR CONJUNTO EJE DE BALANCE / CRANK BALANCER SET CONJUNTO TENSOR CADENA / CHAIN TENSION ADJUSTER SET
MFS400116360 MFS400116364 MFS400116363 MFS400116365 MFS400144025 MFS450410107 MFS400116409 MFS400116403 MFS400116402 MFS400116410 MFS400116404 MFS400116405 MFS400116411 MFS400116406 MFS400116400 MFS400116407 M03625000 T0106008 T0306025 MFS400116361 MFS400116370 MFS450612010 MFS400112100 MFS450612000 MFS450512001 MFS450512003 MFS400116420

Motor8

Embrague / Clutch
PIN CIGEN. TRANS PRIM. / PRIMARY TRANSMISION CRANK SHAFT PINION ARANDELA BISELADA DE. 20/125 / WASHER 20/125 TUERCA BLOCAJE PIN CIGEAL / CRANK SHAFT PINION LOCKING NUT ARANDELA CAMPANA EMBRAGUE 22,1X42X2,8 / WASHER 22.1X42X2.8 CASQUILLO CAMPANA EMBRAGUE / PRIMARY DRIVEN GEAR BUSHING COJINETE CAMPANA EMBRAGUE / PRIMARY DRIVEN GEAR BEARING CTO. CORONA CAMPANA EMBRAGUE / PRIMARY DRIVEN GEAR SET CUBO EMBRAGUE / CLUTCH BOSS ARANDELA PRECINTO EMBRAGUE / CLUTCH LOCK WASHER TUERCA FIJ. CUBO EMBRAGUE / CLUTCH BOSS NUT GOMA SILENBLOCK / SILENBLOCK RUBBER REMACHES CAMPANA EMBRAGUE / PRIMARY DRIVEN GEAR RIVETS ARANDELA CORONA EMBRAGE / CLUTCH BOSS WASHER DISCO EMBRAGUE HIERRO / IRON CLUTCH DISK DISCO EMBRAGUE FORRADO / COVERED CLUTCH DISK BOLET EMBRAGE / CLUTCH PIN PLACA AGUJA Y VALV. ESCAPE / EXHAUST PIN WASHER JAULA AGUJA VALV. ESCAPE / NEEDLES BEARING PRENSA EMBRAGUE / PRESSURE PLATE SEEGER EJE 15 EMBRAGUE / CLUTCH SEEGER AXLE 15 ALLEN 6X20 TA. EMBRAGUE,CART,SUSP. / ALLEN BOLT 6X20 CASQ. MUELLE EMBRAGUE ALUMINIO / ALUMINIUM CLUTCH SPRING BUSHING MUELLE EMBRAGUE VERDE / GREEN CLUTCH SPRING VARILLA EMBRAGUE / CLUTCH ROD TAPN SANGRADOR / BLEEDER CAP SANGRADOR / BLEEDER ARANDELA LATIGUILLO / HOSE WASHER PINZA EMBRAGUE HIDRA. / HYDRAULIC CLUTCH CALIPER TRICA BOMBA EMBRAGUE / CLUTCH PUMP ORING KIT PINZA EMBRAGUE / CLUTCH CALIPER KIT RACORD PINZA EMBRAGUE / RACORD CLUTCH CALIPER TORNILLO ESPECILA 6X20 / SPECIAL SCREW