MANUAL DE TALLER / WORKSHOP MANUAL

MOTOR FSE 450

2004 / 2005

WORKSHOP MANUAL

ENGINE FSE 450

ENGLISH

Contents
Technical specifications...4 Uninstalling and installing the engine in the chassis.5 Engine dismounting...15 Engine mounting..33 Replacement of the standard clutch with the ADLER clutch APTC...53 Inspection and maintenance of the engine components..59 Periodic maintenance...91

Technical Specifications

MODEL FSE 400 / 450 ENGINE
Displacement in cubic centimetres 399 cc / 443 cc Type 4 stroke DOHC 4 valves No. of Cylinders One Cooling System Water Cooled Bore and stroke 90 x 62,6 mm / 95 x 62,6 mm Injection Fuel injection electronic system Magneti Marelli Ignition Integrated in fuel injection electronic system Clutch Oil bath, multi-disk hydraulic action Gear Box 6 speed

CHASSIS

Frame Type DELTABOX, semi double cradle chassis made from rectangular Cromoly tubes. Aluminium swing arm Front Suspension Inverted Marzocchi Diameter 45 mm Run 295 mm Inverted hlins Diameter 48 mm Run 295 mm Rear Suspension Progressive system with hlins shock absorber Run 320 mm Front brake Disk of 260 mm Nissin Pump and simple / double Nissin calliper Rear brake Disk of 220 mm Nissin Pump and simple / double Nissin calliper Wheels Rims D.I.D. Type U with tyres Michelin Comp3

DIMENSIONS

Wheel base 1.475 mm Seat Height 940 mm Minimum ground clearance 340 mm Fuel Tank Capacity 7.2 litres
Un-installing and installaing the engine in the chassis

Un-installing the engine

Un-installing the engine in the chassis
Before dismounting the engine from the frame, wash it with a steam washer. The dismounting sequence is explained in the following steps.
Dismount the seat and the frame covers.

Empty the engine oil.

Remove the engine plate.
Empty the chassis (A) oil tank. Empty the coolant of the engine (B).
Disconnect the wire (-) of the battery (C) and the engine earth connection (D).
Disconnect the alternator clamp (E) and the phonic wheel sensor wire.
Disconnect the spark plug pipe (F), the engine oil vaporiser tube (G), the engine oil resevoir vent hose (H).
Loosen the cylinder head injector tubing clamp (l).
Disconnect the starter motor connection wire (J). Dismount the starter motor removing the screws (K).
Dismount the water tube (L).
Remove the pedal starter lever (M).
Remove the exhaust collector (N).
Disconnect the 2 radiator tubes.
Disconnect the engine oil tube (O) in the chassis tank.
Remove the gearshift lever (P).
Remove the engine pinion protector (Q).
Remove the clutch cap (R). De-tense the chain.
Remove the output pinion clip (S).
Remove the Engine pinion (T).
NOTE: Observe which is the placement direction of the said pinion.
Remove the carved bolts and the brake pedal.
Remove the motor from the frame.
Installation of the engine in the chassis
Mount the engine in inverse order to de-installation
Fix the screws and engine fixing nuts.
NOTE: In this phase, temporarily tighten the nuts. The engine fixing nuts are self-locking. Once removed they lose their self-locking capability and are useless. PRECAUTION Replace the engine fixing nuts with new ones.
Hold the screw heads with a spanner and tighten the engine fixing screws with the specified torque. Element A B C Nm 66 Kgm 6,6 6,6 6,6
Length of the screws (A): 108 mm (B): 110 mm (D): 103 mm
Fix the brake pedal screw with the specified torque. Brake pedal screw: 29 Nm (2,9 Kg) PRECAUTION Replace the carved bolts with new ones.
Mount the engine pinion. NOTE: Observe which is the placement direction before the said pinion, to be able to achieve the same direction of wear.
Place the engine pinion clip.
Connect the chassis tank tube.
Fix the exhaust collector screw (1), with the specified torque.
NOTE: Apply component NURAL 29 in the exhaust system joints.
NOTE: Apply LOCTITE 243 to the pedal starter lever screw.
Fill 1.2 L of an engine oil classified SF or SG through the API service and with a degree of viscosity SAE 10W-40 through the oil fill mouth in the frame (A) and check the level. DATA Engine oil capacity Change of oil: 1 L Changing the oil and filter: 1.2 L Engine general inspection: 1.2 L

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.
New engine exhaust outlet (De-vaporization model 2005).
Eliminate completely the remains of sealant and oil in the contact surface of the left and right housings. Place the new gasket (C) and the 2 guides (D) that facilitate the centering during the assembly of the two housings.
Wash the drain filter with solvent and place it.
Assemble the two housings using the guides.
With the help of the tool (Ref ME25950000) press until assembling the two housings.
Place the 10 screws that fix the housing. Apply LOCTITE in the screw that is located in the hole of the oil pump. Housing screw: 11 Nm (1.1 kg) NOTE: After tightening the housing screws, check if the crankshaft, the intermediate axle and the transmision axle turn smoothly. If you detect a great resistance upon turning, try to free the axles by tapping them with a plastic hammer. Place the chain and the distributor pinion.
Place the crankshaft cover.
Place the crankshaft pinion.
Apply LOCTITE in the hole of the screw that holds the distributor chain tensor skate.
Fix the screw that holds the distributor chain tensor skate.
Place the washer and tighten the nut with a dynamometric spanner.

Place the oil tube.

Place the starter intermediate pinion.

Place the starter unit.

Place the oil pump axle. Before mounting the oil pump: apply engine oil to the sliding surfaces of the pump casing, the exterior rotor, the interior rotor and the axle.
Place the engine oil pump gasket.
Place the engine oil pump.
Fix, via the 2 screws, the oil pump cover. NOTE: Check that it turns freely.

Place the oil pump.

Fix, via the 2 screws, the pump cover. NOTE: Apply a small amount of LOCTITE to the threaded parts of the fixing screws of the oil pump and tighten firmly.
Place the pump pinion and fix it with the clip.
Fix the intermediate pinion of the pump with the clip.
Place the gearbox lever axle.

Place the washer.

Place the bearing.

Place the clutch bell.

Insert the clutch casing with a new gasket. Fix it via the screws.

Place the clutch unit.

In the clutch mounting unit in the gearbox primary cam, make sure it is correctly aligned between the groove present in the interior recipient and the one in the primary camshaft of the gearbox. NOTE: In case of an incorrect assembly the correct lubrication of the clutch unit is not guaranteed and, therefore, damage or malfunctions of the clutch unit may be produced.

Fix the fixing bolt with the security washer, blocking the clutch bell turn with the tool (Ref. MFS450450020).

Close the washer lug.

Place the clutch pusher.
Place the clutch press cover.
Place the 3 screws, the 3 washers and the 3 springs that hold the clutch unit.
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)
Check, via a thickness gauge, the distance between the position sensor and the rotor.
Place the de-multiplication pinion.
Place the alternator cover.
Fix the 7 screws that hold the alternator cover. NOTE: One of them is located in the starter clutch cavity.
Place the starter clutch.
Place the starter clutch cover and fix with the 3 screws.
Introduce the starter motor and place the 2 cases of the starter motor.
Replacement of the standard clutch with the clutch ADLER APTC
Replacement of the clutch

GENERAL WARNINGS

Always shut off the engine before starting any work, in particular, when operating in closed environments without gas evacuation facilities. Shut off the engine, remove the contact key and wait until the engine, the exhaust system and the brake unit have cooled enough to avoid burns and risk of fire. Place special attention to the parts still hot of the engine or of the vehicle (ex.: the exhaust system and the brake unit) to avoid burns. Raise the vehicle with the corresponding means over a flat and resistant pavement. The components and liquids coming from the vehicle should be eliminated and treated in accordance with the existing environmental laws. To maintain maximum safety levels, it is recommended to carefully follow the instructions. Responsibility is declined for damage to persons and/or things derived from an erroneous or inappropriate mounting. The inadequate use and modification of the APTC (Adler Power Torque Clutch) clutch, aside from the erroneous mounting not performed in accordance with the instructions, lead to the automatic annulment of any existing guarantee over the product. All the characteristics described in the present documentation, should be understood as valid for vehicles in standard conditions, without faults or anomalies.
SUBSTITUTION OF THE STANDARD CLUTCH BY THE APTC ADLER CLUTCH

The clutch cube consists of two pieces united together by a special helicoidal shape. The output of the clutch is related to the torque applied. In the acceleration phase, to the constant force of the pressure disk springs over the clutch disks package, is also added the force generated by the unit, ensuring the transmission of the engine torque with a necessary charge over the springs greatly reduced with respect to the one of the conventional clutch. During the changing of gears, to the constant and limited force of the pressure disk springs is subtracted the force generated by the unit, ensuring the reduction of transmitted torque and the anti-bounce effect of the rear wheel. Over the clutch control lever is perceived, in any condition of engine use, only and exclusively the load, greatly reduced, of the clutch springs applied over the pressure disk.
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.

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

The paint impression in ring form that stays over the work surface of the valve should be continous, without any interruption. Also, the width of the paint ring, which is the width of the valve seating, should be found within the following specified value. DATA Width of the valve seating (W): 0.9-1.1 mm (0.035 -1.092 mm) If the valve seating is found outside of the specified value, correct it.

Intake

Valve seating maintenance
The intake and exhaust valve seatings are mechanised in three different angles. The contact surface of the seating is cut at 45.
Intake Exhaust N-128 N-128 N-114
Exhaust N-128 N-121 N-114
Tool (United States) Vlave seating knife: N-114, N-121 and N-128 Tools (Rest of the world) Ref.: Valve seating corrector unit Ref.: Knife N-128 Ref.: Knife N-114 Ref.: Knife N-121 NOTE: Use the solid centerer together with the valve seating knifes N-114, N-121 and N-128. WARNING After each cut you should check the valve seating contact surface.
Place the solid centerer (1) and turn it lightly.
Place well the centering tool. Place the 45 knife (2), the adapter (3) and the handle in T (4).
Initial cut of the seating
De-encrust and clean the seating with the 45 knife. Turn the knife one or two turns. Measure the width of the valve seating (W) after each cut.
If the valve seating is bruised or burned, use the 45 knife to finish conditioningthe seating. NOTE: Only cut the minimum amount necessary of the seating to prevent the possibility of having to replace the tack adjustment supplement.

Upper width cut

If the contact surface is too high in the valve or if it is too narrow, use the 30 knife (intake side) and the 15 knife (exhaust side) to lower it and make it narrow.
Contact surface too low and too narrow in the valve work surface.

Final cut of the seating

If the contact surface is too low in the valve, or if it is too narrow, use the 60 knife to elevate it and widen it. If the contact surface is too high in the valve or if it is too wide, use the 15 knife to lower it and narrow it to the correct width. Once the seating correct widths and position are obtained, use the 60 knife very lightly to clean the shavings produced by the previous cutting operations. WARNING Do not use a polishing compound after having performed the final cut. The finished valve seating should present a velvety finish, but not too polished or brilliant. This would give a smooth surface for the valve final seating which will be produced during the first seconds of the engine functioning. NOTE: After performing the valve seating maintenance, check the tack play once the cylinder head is mounted. (2-5 to 2-8)

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.

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

ME250532002 MFS450532001 ME25610018 MFS400110023 MFS400110025 MFS400112019 T0305008 MFS450510000 ME25636056 MFS450536168 T0306035 MFS400112030 ME25612006/2 MFS400110123/2 MFS450510122 T0306016 MFS400116066 MFS450510001 MFS400112008 M01217001A T0305075 ME25636048 T0305035 MFS450510028 T0305016 MFS450510029 T0306045 MFS450510004 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 CONECTRO TUBO DESVAPORIZADOR CRTER / CRANKCASE STEAM HOSE CONNECTOR ALLEN 5X8 / 5X8 ALLEN BOLT SENSOR DE GIRO / TURN SENSOR
MFS400126022 ST950710 T0306012 MFS450510030 BFS450528048 T0305008 MFS450580005

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 CONJUNTO EMBRAGUE ARRANQUE / IGNITION CLUTCH SET 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 MFS450526520 MFS400326023 MFS450526505 MFS450510004 MFS450544004 MFS450534019 MFS450526500 T0305025 T0305006 R233000 T0306016 T0305025 MFS400134011 MFS400134016 MFS450434005 MFS450526550 MFS450526516 MFS400126020 MFS450526540 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 AGUJA 5X8 CIGEAL / 5X8 CRANKSHAFT PIN 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 MFS400112010 MFS400112022 MFS400112100 MFS450512000 MFS450512001 MFS450512003 MFS400116420

Motor8

Embrague / Clutch
PIN CIGEAL TRANS. PRIMARIA / PRIM. TRANS. CRANK SHAFT PIN. ARANDELA PRECINTO PIN CIGEAL / CRANKSHAFT SPROCKET WASHER TUERCA CIGEAL LADO EMBRAGUE / CRANK SHAFT NUT ARANDELA CAMPANA EMBRAGUE / CLUTCH WASHER CASQUILLO CAMPANA EMBRAGUE / PRIMARY DRIVEN GEAR BUSHING COJINETE CAMPANA EMBRAGUE / PRIMARY DRIVEN GEAR BEARING CTO. CORONA EMBRAGUE / CLUTCH SPROCKET SET CUBO EMBRAGUE / CLUTCH BOSS ARANDELA PRECINTO EMBRAGUE / CLUTCH LOCK WASHER TUERCA FIJACIN CUBO EMBRAGUE / CLUTCH BOSS NUT DISCO EMBRAGUE HIERRO / IRON CLUTCH DISK DISCO EMBRAGUE FORRADO / COVERED CLUTCH DISK EMPUJADOR EMBRAGUE / CLUTCH PULLER ARANDELA COJINETE / BEARING WASHER JAULA AGUJAS / NEEDLE BEARING PRENSA EMBRAGUE / PRESSURE PLATE BEARING SEEGER EMPUJADOR EMBRAGUE / CLUTCH PULLER SEEGER ALLEN 5X25 / ALLEN BOLT 5X25 ARANDELA 6X18X1,5 / 6X18X1,5 WASHER MUELLE / SPRING VARILLA EMBRAGUE / CLUTCH ROD TAPN SANGRADOR / BLEEDER CAP SANGRADOR PINZA EMBRAGUE / BLEEDER ARANDELA LATIGUILLO / HOSE WASHER PINZA EMBRAGUE HIDRULICO / HYDRAULIC CLUTCH CALIPER TRICA BOMBA EMBRAGUE / CLUTCH PUMP ORING KIT REPARACIN PINZA EMBRAGUE / CLUTCH CALIPER KIT ARANDELA CAMPANA EMBRAGUE / CLUTCH BELL WASHER CASQUILLO COJINETE CAMPANA EMBRAGUE / CLUTCH BELL BUSHING BEARING RACOR PINZA EMBRAGUE / RACORD CLUTCH CALIPER CONJUNTO PINZA EMBRAGUE FSE / FSE CLUTCH CALIPER KIT MUELLE CUBO EMBRAGUE / CLUTCH BOSS SPRING ARANDELA ELSTICA / WELT WASHER TAPA CUBO EMBRAGUE / CLUTCH BOSS COVER ARANDELA 18X13X1,5 / 18X13X1,5 WASHER CORONA EMBRAGUE / CLUTCH SPROCKET
MFS400112004 MFS450532017 MFS400132018 MFS400132011 MFS400132012 ME25632029 MFS450532003 MFS450532005 MFS450532022 ME25632028 ME25632037 ME25632007 ME25632014 ME25632016 ME25632046 MFS450532051 MFS450532054 T0305025 T4006018 MFS450532054 MFS400132040/2 BE25622055 BE25622060 BE25622007 ME25632026 ME25632024 BE25622050 MFS400132011 MFS400132036 M01030000 MFS400132026 MFS450332015 MFS450532055 MFS450532052 MFS450532053 MFS400132003

Motor9

Cilindro / Cylinder

5A 5B 6 7

TORNILLO ESPECIAL 6X25 / 6X25 SPECIAL SCREW CILINDRO FSE 450-2005 / FSE 450-2005 CYLINDER SET JUNTA CILINDRO FSE 500-2005 / FSE 500-2005 CLINDER GASKET CASQUILLO CENTRADOR CULATA / HEAD CYLINDER BUSHING CONJUNTO PISTN A / A PISTON SET CONJUNTO PISTN B / B PISTON SET CONJUNTO AROS PISTN / PISTON ORING SET CONJUNTO CILINDRO Y PISTON / PISTON CYLINDER SET