User manual GAS GAS FSE 400 WORKSHOP MANUAL

[. . . ] MANUAL DE TALLER / WORKSHOP MANUAL MOTOR FSE 450 2004 / 2005 WORKSHOP MANUAL ENGINE FSE 450 2004 / 2005 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 Öhlins Diameter 48 mm Run 295 mm Rear Suspension Progressive system with Öhlins 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 4 Technical Specifications Un-installing and installaing the engine in the chassis 5 Un-installing the engine Un-installing the engine in the chassis Before dismounting the engine from the frame, wash it with a steam washer. [. . . ] Tool ref: Valve spring compressor Tool ref: Adapter Tool ref: Tongs WARNING Make sure to mount all the parts in their original positions. ! ! 72 Inspection and maintenance 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. 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 ! ! 73 Inspection and maintenance 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 ! !! 74 Inspection and maintenance 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. 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. Tool Ref. : Cylinder gauge unit DATA Cylinder interior diameter FSE 400: 90. 000 - 90. 015 mm FSE 450: 95. 000 ­ 95. 015 mm 75 Inspection and maintenance 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 ! [. . . ] To check the oil level place the motorcycle in the functioning position. Stop the motorcycle and wait three minutes, check the oil level with the oil stick. The oil level should be between the level lines "L" and "F". NOTE: The oil extends and the same level increases when the engine oil is hot. ! ! 3 95 Periodic maintenance Oil filter change Remove the oil filter cover (1) and the oil filter (2). [. . . ]