User manual GAS GAS FSE 2003 PART LISTE

[. . . ] 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). B A Disconnect the wire (-) of the battery (C) and the engine earth connection (D). C D 7 Un-installing the engine E Disconnect the alternator clamp (E) and the phonic wheel sensor wire. H G F 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). I Disconnect the starter motor connection wire (J). Dismount the starter motor removing the screws (K). J K 8 Un-installing the engine Dismount the water tube (L). L Remove the pedal starter lever (M). M Remove the exhaust collector (N). N Disconnect the 2 radiator tubes. 9 Un-installing the engine Disconnect the engine oil tube (O) in the chassis tank. O Remove the gearshift lever (P). P Q Remove the engine pinion protector (Q). R Remove the clutch cap (R). De-tense the chain. Remove the output pinion clip (S). S 10 Un-installing the engine Remove the Engine pinion (T). 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. 11 Un-installing the engine Installation of the engine in the chassis Mount the engine in inverse order to de-installation ! Fix the screws and engine fixing nuts. A NOTE: In this phase, temporarily tighten the nuts. [. . . ] 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 !! 71 Inspection and maintenance 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. ! 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: 1º: 0. 18 mm (0. 0071 in) 2º: 0. 15 mm (0. 0059 in) !2) Normal: FSE 2003 1º: 1. 03 mm 2º: 1. 22 mm FSE 450 1º: 1. 23 mm 2º: 1. 53 mm Lubrication: 2. 01 -2. 03 mm Tool ref. : Micrometer (0-25 mm) DATA Piston rings thickness (Fig. 3) Normal: FSE 2003 1º: 0. 985 mm 2º: 1. 19 mm FSE 450 1º: 1, 19 mm 2º: 1. 49 mm Fig. 3 76 Inspection and maintenance Fig. 4 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. ! Fig. 5 Tool ref. : Thickness gauge DATA Aperture of the piston ring end (Fig. 5) Service limit: 1º: 0. 50 mm 2º: 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. [. . . ] The oil filter is changed in the same intervals of the engine oil. 94 Periodic maintenance Engine oil change The engine oil is found in the tank of the chassis front high part and in the engine sump. To evacuate the oil open the chassis (1) and of the ngine (2) plugs also the fill plug (3). 1 Once the oil comes out screw the screws with the specified torque and then fill the oil again through the fill hole. When performing an oil change (without replacing the oil filter), the engine will store about 1 L (1. 05 US qt, 0. 8 Imp qt) of oil. Use an engine oil that complies with the standard API classifications SF or SG and that it has a range of viscosity SAE 10W-40. 2 ENGINE OIL DRAINAGE In sump (2): 21 Nm (2. 1 Kg, 6. 80 lb-ft) In chassis (1): 18 Nm (1. 8 Kg, 13. 0 lb-ft) WARNING Screw the plug (1) take the precaution of placing the gasket correctly. [. . . ]