Manuale Officina Beta 400

www.betamotor.
com
INDEX
1.5.3 Low-pressure oil pump and by-pass valve 27
1.5.4 Oil pressure control valve 28
1.5.5 Paper oil filter 28
1.6 COUNTERSHAFT 29
1.7 PRIMARY GEAR 30
1.8 ELECTRIC IGNITION 31
1.8.1 Start motor 31
1.9 KICKSTARTER 33
1.10 EXTERNAL GEARSHIFT UNIT 35
CRANKSHAFT, GEARBOX UNIT AND

1.11 36
INTERNAL GEARSHIFT
1.11.1 Nut on left side of crankshaft 36
1.11.2 Opening crankcase 36
1.11.3 Crankshaft 38
1.11.4 Internal gearshift unit and complete gearbox 38
1.12 DISASSEMBLY OF PARTS FROM CRANKCASES 40
1.12.1.1 Right crankcase half 40

PREAMBLE / WARNINGS 2
1.12.1.2 Piston oil jets 40
TECHNICAL FEATURES OF ENGINE TABLE 4
1.12.1.3 Extraction of countershaft support bearing 41
SPECIAL TOOLS 5
1.12.2 Left crankcase half 41
1.12.2.1 Inner oil filter 42

1 ENGINE DISASSEMBLY 6
1.12.2.2 Extraction of desmodromic device bearing 42
1.1 THERMAL UNIT 8
2 ENGINE ASSEMBLY AND CONTROLS 43
1.1.1 Cylinder head: disassembling hydraulic tensioner 10
Cylinder head: disassembling camshaft support, 2.1 CRANKCASE HALVES 44

1.1.2 10
chain guide and spark plug seat O-ring
2.1.1 External right side 45
1.1.3 Cylinder head: removing camshafts 12
2.1.1.1 Insertion of oil seal and countershaft support bearing 47
1.1.4 Cylinder head: uncoupling from cylinder 13
2.1.2 Internal right side 48
1.1.5 Disassembling cylinder and piston 15
2.1.3 External left side 49
DISASSEMBLY OF IGNITION UNIT,
1.2 16
TIMING CHAIN AND GUIDES 2.1.4 Internal left side 50
1.2.1 Stator and flywheel 16
2.2 CHECKING CRANKSHAFT AND CONNECTING ROD 51
1.2.2 Timing chain and guides 18
2.3 ASSEMBLING COMPLETE CRANKSHAFT 53
1.2.3 Pick-up 20
2.4 GEARBOX UNIT: CONTROLS AND REASSEMBLY 54
1.3 PINION AND SPACER 20
2.4.1 Checking gearbox unit 54
1.4 CLUTCH UNIT AND COOLANT PUMP COVER 21
2.4.2 Primary unit assembly 55
1.5 ENGINE LUBRICATION CIRCUIT 25
2.4.3 Secondary unit assembly 56
1.5.1 Oil pumps control gears 26
Checking the forks, fork pins and
1.5.2 High-pressure oil pump 26 2.4.4 57
desmodromic device
INDEX
ENGLISH
2.5 ASSEMBLY OF INTERNAL GEARBOX AND GEARSHIFT 59 2.17.1 Checking piston, pin bolt, and piston rings 94
2.6 CLOSING ENGINE BLOCK 62 2.17.2 Checking the cylinder 96
BLOCKING THE CRANKSHAFT AT THE TOP DEAD 2.17.2.1 Assembly clearance 96

2.7 CENTRE AND TIGHTENING THE NUT ON THE LEFT 63
SIDE OF THE CRANKSHAFT Cylinder head: disassembly and checking auxiliary
2.17.3 97
devices
2.8 EXTERNAL GEARSHIFT 64
2.17.3.1 Lubrication jets and centring pins 97
2.8.1 Checking the complete drive shaft 64
2.17.3.2 Finger follower/shafts unit 98
2.8.2 Assembly of external gearshift 66
2.17.3.3 Shims (calibrated discs) for valve play adjustment 99
2.9 KICK STARTER 66
Cylinder head: disassembling and
2.17.4 100
checking valve units
2.9.1 Checking kickstarter shaft unit and assembly 66
2.17.4.1 Springs 101
2.9.2 Assembly of kickstart device 68
2.17.4.2 Valve guides, valves and seats 101
2.10 ELECTRICAL STARTER UNIT AND MAIN GEAR 69
2.17.4.3 Valve stem seal and lower stop washer 103
2.10.1 Checking electrical starter device elements 69
2.17.5 Cylinder head: checking cylinder head body 103
2.10.2 Coupling ignition and primary gears to the motor 70
2.17.6 Checking camshafts 104
2.11 OIL PUMPS: CONTROL AND REASSEMBLY 72
2.17.7 Checking camshafts support 105
2.11.1 Assembly of low pressure pump 74
Cylinder head: insertion of inner cup and
2.17.8 106
valve stem seals
2.11.2 Assembly of high-pressure pump and control gear 75
2.17.9 Cylinder head: assembly of valve unit 107
2.11.3 Checking and assembly of pressure control valve 75
Cylinder head: repositioning calibrated discs,
2.11.4 Checking and assembly of oil pumps control gears 76 2.17.10 assembly of finger follower shafts and finger 108
followers and coupling the spark plug
2.11.5 Paper oil filter insertion 77 Cylinder head: Insertion of oil jets, centring pins and
2.17.11 109
spark plug O-ring
2.11.6 Checking and coupling countershaft 78
Piston: application of compression and
2.17.12 110
oil-scraper rings
2.12 CLUTCH UNIT 80
2.17.13 Application of piston to cylinder 111
Checking clutch basket, roller bearing and
2.12.1 80
internal centre bearing
2.17.14 Application of piston-cylinder coupling to crankcase 113
2.12.2 Checking clutch discs 81
2.17.15 Coupling head to cylinder 115
2.12.3 Checking springs 82
2.17.16 Coupling camshafts to cylinder head and phasing 116
2.12.4 Checking inner hub 82
2.17.17 Valve play 119
2.12.5 Checking thrust bearing device 83
2.17.18 Checking and coupling of hydraulic tensioner to engine 121
2.12.6 Assembly of clutch unit 83
Coupling cylinder head cover gaskets and
2.17.19 123
cylinder head cover
2.13 COOLANT PUMP 86
2.18 COUPLING PINION AND BREATHER NOZZLE 124
2.13.1 Checking pump unit and disassembly 86
2.19 RELEASING CRANKSHAFT 124
2.13.2 Assembly of pump unit 87
2.20 COUPLING OIL CAPS 125
2.14 ASSEMBLY OF COMPLETE CLUTCH COVER 88
2.21 COUPLING GEARSHIFT LEVER 126
CHECKING AND COUPLING OF TIMING CHAIN,
2.15 90
FIXED AND MOBILE GUIDES
2.16 IGNITION SYSTEM 90

Table of tightening torques of engine components 127
2.16.1 Checking ignition system 91
Engine/frame table of tightening torques 129
2.16.2 Coupling ignition system to crankcase 91 Recommended engine maintenance 130
2.17 THERMAL UNIT 94 Recommended lubricants and liquids 130
www.betamotor.com
PREAMBLE
PREAMBLE
This publication has been written in order to make operations for inspection, maintenance and repairs
of the motorcycle engine known and understandable to the user of the motorcycle and to the technical
assistance operator.
Read this entire manual with care before operating the engine. Sufficient knowledge of the components
that make up the engine and of all the procedures to be followed for inspection and maintenance con-
tribute to lengthen the life of the engine.
The paragraphs have been enhanced with schematic illustrations highlighting each subject in order to
make reading immediately understandable.
Informative note
Betamotor S.p.A. is engaged in a policy of ongoing improvement of its products. This is why it could be
possible to note slight differences between the contents of this document and the vehicle upon which
you are carrying out repairs and/ or maintenance. Betamotor S.p.A. models are exported to numerous
countries in which there are different standards concerning Highways Codes and procedures for approval
of the vehicle. Relying on your understanding, Betamotor S.p.A. therefore deems it necessary to reserve
the right to modify its products and technical documentation at any time without prior warning.
We respect and defend the environment

All that we do has an impact on the whole Planet and its resources. Betamotor S.p.A., wishing to
safeguard the interests of the entire Community, would like to make customers and technical opera-
tors aware of ways of using the vehicle and of disposal of its parts in total compliance with standards
in force in terms of environmental pollution, waste disposal and recycling.
SAFETY
Carbon monoxide Motor oil
• Exhaust gasses contain carbon which is poiso- • Motor oil can cause skin illnesses if carried of-
nous. Carbon monoxide can cause loss of con- ten and for prolonged periods in contact with
science and lead to death. When starting the skin.
engine, make sure the place you
ventilated. Never start the engine
are is well-
in a closed
• If you touch motor oil, clean parts with soap
and water as soon as possible.
place.
• Starting the engine closed places can be done • In case of contact with the eyes, rinse them
abundantly with water and seek medical ad-
only if provided with relevant gas discharge
vice.
evacuation devices.
• If swallowed, do not induce vomiting in order
to avoid breathing the product into the lungs;
Petrol seek immediate medical advice. If you believe
• Petrol is extremely flammable and can be ex- the product has been breathed into the lungs,
plosive in some conditions. bring the concerned person urgently to the ho-
spital.
• Keep heat sources, sparks and flames away
from the work area. • Used oil contains dangerous substances which
are harmful for the environment. When chan-
• Always work in a well-ventilated area. ging it, you must be equipped to dispose of it
• Never use petrol as a solvent for cleaning. Do in compliance with existing law.
not handle it unless absolutely necessary. • Avoid releasing used oils to the environment.
• Never use petrol to clean components by me- • Keep out of the reach of children.
ans of compressed air.
• Keep out of the reach of children.
2
www.betamotor.com
PREAMBLE
Coolant • Do not remove the radiator cap when the en-
gine is still hot. When coolant is pressurised, it
• In some situations, the ethylene glycol contai- can spurt out violently and cause burns.
ned in the coolant is flammable and its flame
is invisible. Should ethylene glycol catch fire, • Coolant contains dangerous substances which
though its flame is invisible, it can cause burns. are harmful for the environment. When chan-
ging it, you must be equipped to dispose of it
• Do not bring the coolant in contact with hot in compliance with existing law.
parts. These parts could be hot enough to cau-
se the liquid to ignite. • Do not release coolant to the environment.
• The coolant (ethylene glycol) can irritate skin • Keep out of the reach of children.
and is poisonous if swallowed.
• Should the coolant come into contact with the
skin, immediately remove contaminated clo-
thing or footwear and wash with soap and wa-
ter. In case of contact with the eyes, rinse them
Hot parts
abundantly with clean water and seek medical • The engine and the exhaust system get very hot
advice immediately. Should it be swallowed, do and stay at that temperature for a long time,
not induce vomiting in order to avoid breathing even after the engine has been turned off. Wait
the product into the lungs. Administer clean for them to cool off before handling these parts
water and bring the concerned person imme- or intervening on areas around them. Use insu-
diately to the hospital, showing this product to lated gloves.
the hospital staff.
• In the event of exposure to a high concentra-
tion of vapours, bring the concerned person to
an uncontaminated atmosphere and seek me-
dical advice if necessary.
WARNINGS
The information contained in this paragraph is important so that the operations out on the
engine can be performed without causing damage.
• Beforedisassembling, clean the motorcycle • Alwaysreplace parts such as gaskets, O-rings

thoroughly. and safety washers with newly supplied parts.
• While you are disassembling it, clean all the • When loosening or tightening nuts or screws,
parts and place them in containers respecting always start with the larger ones or from the
the order of disassembly exactly. centre. Always respect the indicated tighte-
ning torques.
• Always
use special tools wherever necessary
and when thus prescribed. • Use only Betamotor original spare parts.
• Always use glues, sealing and lubricants whe-
rever prescribed. Respect the indications con-
cerning their technical features.
3
www.betamotor.com
TECHNICAL FEATURES OF ENGINE

ENGINE
4-stroke single-cylinder liquid-cooled with counter-

Type
shaft and electrical starting
Bore x stroke RR 400 95x56.2

Bore x stroke RR 450 95 x 63.4
Bore x stroke RR 520 100 x 63.4
Displacement [cm³] RR 400 398
Displacement [cm³] RR 450 449,4
Displacement [cm³] RR 520 497,9

Compression ratio RR 400-450-520 12,4:1 11,95 12,0:1
Valve gear 4 valves
TRANSMISSION
PRIMARY TRANSMISSION 31/73
RR 400 RR 450 RR 520
1st gear ratio 12/31 12/31 12/31
2nd gear ratio 15/28 15/28 15/28
3rd gear ratio 19/28 19/28 19/28
4th gear ratio 20/24 20/24 20/24
5th gear ratio 27/27 27/27 27/27
6th gear ratio 28/24 28/24 28/24
SECONDARY TRANSMISSION CHAIN
CARBURETTOR
RR400 RR450 RR520
Carburettor type Keihin FCR-MX 39 Keihin FCR-MX 39 Keihin FCR-MX 39
Carburettor-setting 006.12.100.8.0 006.12.000.8.0 006.12.200.8.0
number
Main jet 175 175 180
Jet needle OBDTS OBDVS OBDVS
Slow jet 45 45 45
Main air jet 200 200 200
Idling air jet 100 100 100
Needle position 5° 4° 4°
Mixture control screw open 1+1/2 1+1/2 2
Intake jet 50 40 40
4
www.betamotor.com
SPECIAL EQUIPMENT
ENGINE
Symbology
1. Engine support code 3625132 000;
2. Two-leg extractor code 3625081 000;
3. Internal bearing puller code 006140160 000;
6Nm
4. Extractor for timing gear code 006140150 000;
5. Flywheel Extractor code 3625173 000; Value
6. Piston ring compression band code 006140170 000; Tightening Torque
7. Chain-tensioner release tool code 006140050 000;
8. Valves assembly-disassembly jaw code 0100043 000;
9. Tool for valves assembly-disassembly code 006140030 000;
10. Special ring pliers code 3625097 000;
11. Crankshaft blocking device code 006140110 000;
12. Loctite 243 code 3625001 000; Loctite 243/
13. Loctite 648 code 3625194 000; Sichel 100M
14. Silicone paste for gaskets code 3625000 000;
15. 36mm socket wrench code 3625000 000;
16. Spark plug wrench code 020440100 000;
17. Connecting rod disassembly tool code 006140070 000;
18. Thickness gauge code 006140210 000;
19. Valve guide gauge code 006140180 000;
Silicone paste
20. Clutch cap tool code 006140040 000;
21. Carburettor adjustment spanner code 006140200 000;
22. Engine fixing code 006140140 000.
5
1
ENGINE DISASSEMBLY
ENGINE DISASSEMBLY
Before removing the engine from the vehicle,
empty the following liquids:
• Motor oil;
• Gear/clutch unit oil;
• Coolant.
•
In order to access the oil drain plug, remove the
engine guard connected to the frame by means
of the three screws 1.
Front engine guard fixing screw.
Back engine guard fixing screws.
Remove the screw 2 to empty the motor oil.

Remove the screw 3 to empty the gear oil.
3
ATTENTION: Used oil contains dangerous
substances which are harmful for the en-
vironment. When changing it, you must be
equipped to dispose of it in compliance with
existing law.
Avoid releasing used oils to the environment.
Screw 2 for draining motor oil and 3 for draining

gear oil.
6
In order to empty the cooling circuit, loosen
the screw 4 and have the liquid flow out
1
into a recipient (the cooling circuits holds
ENGINE DISASSEMBLY
1.3l of liquid). Remove the radiator cap.
Disconnect the water hoses on the engine

side, disconnect the electrical connectors
below the tank, the clutch actuator and the
4 exhaust manifold.
Screw 4 for draining coolant.
Loosen the screw 5 that fastens the kickstar-

ter to the kickstarter shaft and the screw 6
which fastens the brake pedal return spring
5 to the engine block.
Once the engine has been unfastened and

removed from the frame, connect it to the
specific engine support code 3625132000
by means of the engine fixing devices code
006140140000, in order to work in comfort
and safety. Then proceed as follows.
Screws 5 and 6.
7
1
ENGINE DISASSEMBLY
2 1.1 THERMAL UNIT

The thermal unit is made up of the head,
cylinder and piston.
Before removing the cylinder head, bring the
piston to the TDC and block the crankshaft:
Proceed as shown hereafter.
The four screws 1 of the cylinder head cover 2.
2 Remove the 4 screws 1, the cylinder head

cover 2 as well as the 4 screw gaskets 3.
The cylinder head cover 2 and the four gaskets 3.
Remove the spark plug gasket 4 and the co-

ver gasket 5.
Spark plug gasket 4 and cylinder head cover gasket 5.
8
Remove the crankshaft blocking screw 6,
remove the copper washer 7 and put the
1
screw (or tool 006140110 000) back into its
ENGINE DISASSEMBLY
seat without tightening it all the way.
7
Crankshaft blocking screw 6 with copper washer 7.
After having engaged the 6th gear, turn the

transmission shaft 8 anti-clockwise - using
an open-end spanner or the likes, - until
the lines 9 on the toothed profiles of the
camshafts are aligned.
Rotation of transmission shaft.
Alignment of camshafts.
Rotate the transmission shaft in that posi-

tion and, at the same time, turn the shaft
blocking screw 6 by hand until it engages in
the seat present on the crankshaft, preven-
ting the crankshaft from turning.
In this way the crankshaft is blocked, by me-

ans of the screw 6, at the Top Dead Centre
6 (TDC) and now all the organs can be disas-
sembled.
Blocking crankshaft at TDC. Note the blocking screw
6 and the movement set by the transmission shaft
with the open-end spanner.
9
1 1
1 .1.1 CYLINDER HEAD:
DISASSEMBLING HYDRAULIC
ENGINE DISASSEMBLY
TENSIONER
A chain which is not well-tensioned can cause:

• excessive vibrations for the chain which could
make it jump teeth on the camshafts thus da-
maging the engine;
• incorrect and premature wear of the support
bearings of the camshafts.
The engine is equipped with a hydraulic tensio-

Hydraulic chain tensioner cap. ner in order to provide the chain with proper
tensioning.
In order to remove the tensioner from the engi-
ne, unscrew the tensioner cap 1 completely and
extract the hydraulic tensioner 2.
2
Hydraulic chain tensioner.
1 1 .1.2 CYLINDER HEAD:

DISASSEMBLING CAMSHAFT
SUPPORT, CHAIN GUIDE AND
SPARK PLUG SEAT O-RING
To remove the camshafts, disassemble the

2 camshaft support 2 and the chain guide
3. Then loosen the seven screws 1 of the
camshaft support, starting with the outer
ones (indicated in blue in the figure) and
then the inner ones. Remove the chain gui-
3 de 3.
Fixing screws 1 camshaft support 2 and chain guide 3

The four outer screws circled blue must be taken off-
first.
Attention: disassemble the camshafts only

after having disassembled the hydraulic
tensioner.
10
2 Using a plastic rod A or something similar,
lever the head surface and the camshaft
1
support 2 in order to lift it and remove it.
ENGINE DISASSEMBLY
A
Uncoupling camshaft support 4 from cylinder head.
When uncoupling, be careful of the two cen-

tring pins 4 the camshaft support Checking
camshafts support
Remove the spark plug housing sealing O-
ring 5 between the cylinder head and the
camshaft support.
4 5
Two centring pins 4 and spark plug housing O-ring 5.
11
1 1 .1.3 CYLINDER HEAD: REMOVING
1 2
CAMSHAFTS
ENGINE DISASSEMBLY
Lift the intake camshaft 1, pull out the bea-

ring 2 and remove the chain 3 from the gear
on the shaft.
Attention: the hydraulic tensioner must al-

ready have been removed in order to remo-
ve the camshafts.
3
Removal of intake camshaft 1, bearing 2.
In order to remove the exhaust camshaft 4,

3 repeat the operations described for removal
of the intake camshaft.
Camshafts (G intake, H exhaust) with bearings.
ATTENTION: make sure the chain does not

fall inside the compartment dedicated to it.
For this purpose, it is recommended to in-
terpose a plastic rod (or the likes) A betwe-
en the chain and the head.
A
Plastic rod to support chain.
12
1
1 UNCOUPLING FROM
ENGINE DISASSEMBLY
CYLINDER
Five screws fasten the head to the cylinder.

Remove the cylinder head screw 1 on the
outside of the chain-side cylinder head.
Chain-side head fixing screw.
Remove the four cylinder head fixing screws

2, in a criss-cross pattern. Start with one of
the two screws outside the cylinder head
compartment.
Then remove the respective washers.
Head fixing screws.
Lift the cylinder head 3 with one hand and

at the same time with the other hold the
3 chain in tension thus preventing jams du-
ring disassembly.
With the cylinder head lifted a few centime-
tres, drop the chain inside the compartment
and pull out the head.
ATTENTION: should the chain fall inside,

place it in tension before lifting the head.
Head removal.
13
1 Remove the head gasket 4 and the two cen-
tring bushes 5.
3
ENGINE DISASSEMBLY
2
4
1
Cylinder head elements:
1) M6x80 screw;
2) M10x1.25 cylinder head screws;
3) Complete cylinder head;
4) Cylinder-head gasket;
5) Centring bushes.
14
1 .1.5 DISASSEMBLING CYLINDER
2
1
AND PISTON
ENGINE ASSEMBLY AND CONTROLS

Lift up the cylinder 1 a few centimetres, re-
move the two centring bushes 2 (both loca-
ted on the chain side) to prevent them from
falling inside the crankcases and continue
on removing the cylinder. Remove the cylin-
der gasket 3.
2 3
Cylinder removal.
Place a clean cloth between the piston and

the crankcase to keep foreign objects or
A simple residue from falling inside the base.
Using a suitable tool to insert the specific
seat A, remove the elastic ring 4 on the right
hand side* of the piston 5.
4 ATTENTION: be careful not to drop the ela-

5 stic ring inside the engine.
Removal of elastic ring 4 from right hand side of pi-

ston.
From the left hand side of the piston, push

the pin bolt with an aluminium cylinder B
B (or the likes), until the pin bolt is freed from
the foot of the connecting rod.
Remove the piston.
ATTENTION: Try pulling out the pin bolt by

hand first of all. If it is too tight, hit the pin
lightly with a rubber hammer, at the same
time holding the piston with your hand in
order not to stress the connecting rod.
Pin bolt removal.
* Referred to normal direction of vehicle.
15
1
ENGINE DISASSEMBLY
4
In figure you can see the piston 5 (bottom
view), the circlip 4 and the pin bolt 6.
Bottom view of piston 5, elastic ring 4 and pin bolt 6.
1 .2 DISASSEMBLY OF IGNITION
UNIT, TIMING CHAIN AND
GUIDES
The ignition unit is made up of the flywheel

(or rotor), the pick-up and the stator which
is one with the flywheel cover.
1 .2.1 STATOR AND FLYWHEEL

Remove the screw 1 which connects the
gear lever 1 to the drive shaft.
Removal of gear lever.
Remove the nine screws 3 which fasten the

3 flywheel cover 4 to the left crankcase half.
Remove the flywheel cover and the gasket
placed between the casing and the cover.
Fixing screws C of ignition cover D.
16
Be careful of the two centring pins on the
crankcase half.
1
ENGINE DISASSEMBLY
5
Two centring pins 5 dedicated to the flywheel cover.
Remove the tightening nut 6 which fastens

the flywheel 7 to the crankshaft.
Once the nut has been unscrewed, pay at-
6
tention to the special elastic washer (8
shown in the following images) placed
between the nut and the flywheel.
Nut 6 which fastens the flywheel 7 to the crankshaft.
To remove the flywheel, screw the relevant

extractor A (code 3625173) onto the thre-
A aded segment on the flywheel and, using a
box spanner, tighten the screw on the ex-
tractor.
Removal of ignition flywheel with relevant extractor A.
17
1 7 In the image at the side, the flywheel 7 (rear
view), the special elastic washer 8 and the
tightening nut 6.
ENGINE DISASSEMBLY
Exploded view of flywheel 7, nut 6 and special elastic

washer 8.
3 1 .2.2 TIMING CHAIN AND GUIDES

2
Remove the fixing screws 1 of the movable
2 and fixed guide 3. Extract the two guides
pulling them towards the top part of the en-
gine.
Fixing screws 1 of mobile 2 and fixed guide 3.
Extraction of chain guides.
18
5
Remove the two screws 4 which attach the
chain guard 5 to the crankcase half and di-
1
sassemble this guard. Remove the timing
ENGINE DISASSEMBLY
chain 6, freeing it from the gear on the cran-
kshaft and pull it downwards.
Two chain guard fixing screws C.
Pay close attention to the respective bushes

6 while extracting the mobile and fixed guides
and the timing chain.
Removal of timing chain.
1
2
4
5
4
1) Two guide fixing screws; 2) Mobile guide; 3) Fixed guide; 4) Chain guard screws (complete with bushes); 5) Chain
guard; 6) Timing chain.
19
1 1 .2.3 PICK-UP
1
ENGINE DISASSEMBLY
Once the timing chain guard has been re-

moved, the pick-up 1 can be disassembled,
2 by removing the two fixing screws 2.
Two screws 2 for fixing pick-up 1.
3 1 .3 PINION AND SPACER

In order to remove the pinion 1, loosen the
screw completely 2 and take off the washer
3.
1
2
Pinion 1, screw 2 and washer 3.
After removing the pinion, pull off the spa-

cer 4.
4
Pinion spacer 3.
20
1 .4 CLUTCH UNIT AND COOLANT
1
PUMP COVER
ENGINE DISASSEMBLY
In order to access the clutch unit, the outer
2 clutch cover 1 must be removed by loose-
ning the six screws 2.
1
Outer clutch cover 1 and respective screws 2.
On the other hand, when doing a complete

overhaul of the clutch unit, of the other ele-
ments housed in the outer right side of the
crankcase half or of the engine, the inner
4 clutch cover 3 must be removed by loose-
3 ning the nine screws 4 and the water pump
cover 5 loosening the four screws 6.
Inner clutch cover 3 and respective screws 4.
Pump cover 5 and respective screws 6.
21
1 Pay attention to the two reference pins A
placed between the right crankcase half and
the inner clutch cover while disassembling.
ENGINE DISASSEMBLY
Two centring pins A for cover coupling Inner clutch.
Remove the complete hydraulic actuator 7

-if the tube was disconnect from the ac-
tuator- outer left side crankcase half by lo-
8 osening the three screws 8 which fasten it
to the crankcase half. Remove the gasket
in between the actuator and the crankcase
half.
Hydraulic actuator 7 and three screws 8 coupling it to

crankcase half.
Extract the clutch control rod 9.
Extraction of clutch rod 9.
22
Remove the 4 screws 10 which fasten the
clutch cap 11 to the inner hub.
1
11
10 Remove the clutch cap together with the
ENGINE DISASSEMBLY
four washers and relative springs.
Clutch cap 11 and four screws 10.
12 Extract the whole pressure plate unit 12 and

the clutch disc pack 13.
13
Pressure plate unit 12 and clutch disc pack 13.
In order to complete the disassembly of the

clutch unit, open the safety washer 14 using
a chisel or similar tool and remove the nut
15.
15
14
Opening safety washer with chisel.
23
1 To unscrew the nut 15, the inner hub must
be blocked with a relevant tool A (code
006140040000).
ENGINE DISASSEMBLY
Then remove the nut and relative safety wa-

sher.
Removal of inner hub nut with relevant tool G.

Extract the inner hub 16, the washer 17, the
basket 18, the roller cage 19 and the centre
bearing 20.
17 15
18
14
19 16
20
Safety washer 14, nut 15, inner hub 16, washer 17, basket 18, roller cage 19 and bush 20.
24
1 .5 ENGINE LUBRICATION CIRCUIT
1
ENGINE DISASSEMBLY
The high-pressure pump (or delivery) 1 -
with less displacement - sends the oil puri-
fied by the paper filter 2, to the crank me-
chanism 3, to the piston oil jets 4, to the
tensioner 5 and to the cylinder head jets
and camshafts* 6. The valve 7 controls the
pressure.
When oil has lubricated the cylinder head
ENGINE LUBRICATION CIRCUIT: and has seeped through the tensioner, it
flows along the timing chain to the ignition
1) High-pressure pump; unit compartment A. When oil has lubrica-
2) Paper oil filter; ted the crank mechanism and the piston-
3) Crank mechanism; cylinder coupling, it goes to the crank me-
4) Piston oil jets;
5) Hydraulic tensioner;
chanism compartment B from which it is
6) Cylinder head oil jets; sucked by a low-pressure pump (or recove-
7) High-pressure valve; ry) 9 - with higher displacement -, passing
8) Internal filter; through the oil filter 8 and sent to the igni-
9) Low-pressure pump; tion unit compartment A. There it is sucked
10) By-pass valve;
once again by the pump 1 after being filte-
11) Wire metal filter;
A) Ignition unit compartment; red through the wire metal filter 11.
B) Crank mechanism compartment. The one-way valve 10 controls the pressure
between the external casing on the ignition
unit side and the crank mechanism com-
partment.
10 9
3
1
7
8
A
11
B
* Part of the lubricant sent to the cylinder head is used for the hydrodynamic support of the camshafts.
25
1
ENGINE DISASSEMBLY
1 1 .5.1 OIL PUMPS CONTROL GEARS

The two oil pumps are controlled by a gear
unit driven by the clutch gear.
5 In detail, the gear 1 meshes with the clutch
gear, 2 it is the idler wheel and 3 it is the oil
4 pumps control gear.
In order to disassemble the gears 1 and 2, the
respective circlips 4 and thrust washers 5.
2 In order to disassemble the gear 3, just re-
move the Benzing ring 6.
5
Gear unit for oil pump control.

1) Gear meshing with clutch gear;
2) Idler wheel
3) Oil pumps control gear;
4) Circlip;
5) Thrust washer;
6) Benzing ring
1 .5.2 HIGH-PRESSURE OIL PUMP

3
2 The high-pressure pump, located in the ex-
ternal right-hand side crankcase, is enclosed
under the cover 1 which can be disassem-
bled by removing the roller 2 and the three
screws 3.
Having removed the cover, extract the internal
rotor 4, the external rotor 5 and the roller 6.
Disassembly of high-pressure pump cover.
4 5
High-pressure pump. 4) Internal rotor; 5) External ro-

tor; 6) Roller.
26
1
1 .5.3 LOW-PRESSURE OIL PUMP
1
AND BY-PASS VALVE
ENGINE DISASSEMBLY
The low-pressure pump and the one-way
valve are located in the left-hand side cran-
kcase (on the outside) inside the ignition
unit compartment. They are enclosed under
the cover 1, which removed by extracting
the three screws 2.
Cover and screws of low-pressure pump.
Extract the one-way valve consisting in the

spring 3 and the ball 4.
6 Then extract the external rotor 5 and the in-
5 ternal rotor 6 together with the roller 7 and
the drive shaft 8.
Low-pressure oil pump and by-pass valve.
7
8
Internal rotor 6, roller 7 and drive shaft 8.
27
1
ENGINE DISASSEMBLY
1 .5.4 OIL PRESSURE CONTROL VALVE

The pressure control valve is located in the
bottom of the right-hand side crankcase
near the motor oil drain plug.
The valve consists of the ball 1 and the
spring 2 kept in place by the screw 3 and
washer 4.
In order to disassemble the valve, remove
Location of pressure control the screw, pull out the washer, the spring
valve. and the ball.
4
3
Pressure control valve layout.
1 .5.5 PAPER OIL FILTER

1
In order to extract the paper oil filter, remo-
ve the cover 1 by loosening the two screws
2 completely. Once the cover has been re-
moved, use a pair of opening pliers A to ex-
tract the filter.
While extracting the cover, be careful of the
specific O-ring applied onto the cover.
2
Paper oil filter cap 1 and relative fixing screws 2.
Extraction of filter with pliers A.
28
1 .6 COUNTERSHAFT
1
ENGINE DISASSEMBLY
The countershaft has the task of balancing
a part of the inertial forces produced by the
crank mechanism.
The countershaft is mainly made up of the
shaft 1 and counterweight 2. The elastic wa-
sher 7 and nut 8 have the task of assuring
coupling of the complete shaft to the base.
Exploded view of countershaft.

1) Shaft;
2) Counterweight; Elastic washer
8) Nut M12x1
In order to disassemble the shaft, remove

the nut 8 which can be accessed through the
ignition unit compartment. Extract the elastic
washer 7 and the counterweight.
Pull the countershaft out through the right-
hand side crankcase1.
Extraction of countershaft.
29
1 2
1 .7 PRIMARY GEAR
1
ENGINE DISASSEMBLY
The primary gear 1, located in the right

crankcase, is fastened to the crankshaft. In
order to disassemble it, remove the nut 2
which must first be previously heated using
a blow-dryer or similar instrument.
ATTENTION!
Primary gear 1 and relative nut 2. The nut 1 must be turned clockwise to be
unscrewed.
Extract the primary gear using the relevant ex-

tractor A (code 006140150000).
A
Extraction of primary gear with appropriate extrac-

tor A.
Notice that the primary gear houses the free

1 wheel device 2 inside of it, which can be remo-
ved by taking out the circlip 3.
2 3
Primary gear 1, complete with free wheel 2 and spe-

cific circlip 3.
30
1 .8 ELECTRIC IGNITION 1
Electric ignition can be carried out by means of
the start motor 1 which meshes on the gear-
ENGINE DISASSEMBLY
wheel 4 with the function of torque limiter.
The gearwheel 4 (torque limiter) transmits mo-
tion to the idler wheel 7, which will then mesh
with the starter gear 9.
The roller bearing 10 supports the starter wheel
EXPLODED VIEW OF ELECTRICAL STARTER. 9, while the free wheel 11 is internally enga-
1) Start motor; ged on the starter wheel 9 and externally on
4) Torque limiter; the main gear, thus allowing it, depending on
7) Idler wheel; rotation direction, to pull the crankshaft.
9) Ignition gear;
10) Roller bearing HK2516;
11) Free wheel.
1 .8.1 START MOTOR

1
In order to easily disassemble the start motor
1, the breather nozzle 2 must be removed, by
taking off its screw 3 along with the two copper
washers.
Start motor 1 and the gearbox breather nozzle.
31
1 Remove the two screws 4 which fasten the
start motor to the crankcase and pull out
the start motor.
ENGINE DISASSEMBLY
Screws 4 fixing start motor to crankcase.
In order to extract the kick-start gear 5, di-

5 sassemble the primary gear (see par. 1.7)
and the pin 6 which supports the idler whe-
el for oil pump control (see par. 1.5.1). The
kickstart gear is pulled out by hand.
Removal of pin 6.
In order to disassemble the torque limiter

7 7, completely loosen the screw 8 which fa-
stens the torque limiter to the crankcase.
Pull out the washer 9 together with the li-
miter itself.
Torque limiter 8, screw 7 and washer 9.
In order to remove the idler wheel 10, just

remove the circlip 11 and pull the gear off.
10
11
Idler wheel 10 of electrical ignition device.
32
1 1 .9 KICKSTARTER
1
The kickstarter is made up of the pedal
ENGINE DISASSEMBLY
which, attached to the kickstarter shaft 1,
moves the kickstarter gear 2. This gear mo-
ves the idler wheel 3 which then meshes
with the clutch gear.
4 The device moves back thanks to the spring 4.
3
2
Kickstarter mechanism.
3 Remove the external circlip 5 and pull off

the external thrust washer 6, the idler gear
3, the internal thrust washer 7 and the se-
cond circlip 8. The circlips and thrust wa-
shers are interchangeable.
Removal of circlip 5 of idler gear 3.
5 8
7
6
Two circlips 5 and 8 and thrust washers 6 and 7.
33
1 Using a pair of pliers, pull the end A of the
spring 4 from the hole on the crankcase and
A bring it to a rest position having it turn anti-
ENGINE DISASSEMBLY
clockwise.
Releasing spring from crankcase.
Turn the shaft anti-clockwise and pull it off

together with the sleeve 9, the spring 10
and the thrust washer 11.
Extraction of shaft from crankcase.
2 9
1
11
4 10
Complete manual kickstart shaft.
Note: Be careful of the reference pins for

centring the inner clutch cover (par. 1.4)
34
2 1
1 .10 EXTERNAL GEARSHIFT UNIT
1
The external gearshift is made up of the
ENGINE DISASSEMBLY
drive shaft 1 upon which the movable and
fixed pawls are applied. The fixed pawl con-
stitutes the drive of the movable pawl which
then has the task of engaging the stop cam
2. This in its turn is fastened to the internal
3 gearshift and is kept in the fixed position by
the cam stop lever.
In order to disassemble the drive shaft, just
keep the movable pawl return spring 3 pres-
sed and extract the shaft together with spe-
Disassembly of drive shaft. cific washer 4.
Gearshift with washer.
In order to disassemble the stop cam 2,

keep the cam stop lever moved 5, loosen
the screw 6 and pull out the stop cam.
2
Disassembly of stop cam.
In order to disassemble the stop lever, loo-

8 sen the screw 7 enough to allow the lever to
move axially and overcome the cylinder seg-
ment A of the desmodromic device. Bring
the return spring 8 to the rest position and
remove the screw, the washer 9, the spring
together with the spacer (not shown in the
image) and finally the cam stop lever.
9
7 A
Disassembly of cam stop lever.
35
1 1 .11 CRANKSHAFT, GEARBOX UNIT
AND INTERNAL GEARSHIFT
2
ENGINE DISASSEMBLY
To access the crankshaft, gearbox unit and

1 internal gearshift, the left and right crankca-
ses must be detached. Here are the needed
instructions.
1 .11.1 NUT ON LEFT SIDE OF

CRANKSHAFT
In order to loosen the nut 1 on the left-

hand side of the crankshaft, heat it with a
blow-dryer or similar instrument. Then loo-
Nut B blocking crankshaft. sen the nut with a special socket wrench A
(code 006140020000) and remove it.
ATTENTION: When re-assembling, the oil

seal must be replaced2 since the heating
required for disassembly damages it.
Removal of crankshaft nut with special socket

wrench A.
1
1 .11.2 OPENING CRANKCASE
Remove the 15 screws 1 which close the
crankcase.
Crankcase blocking screws 1.
36
A
Loosen the two screws A which fasten the
engine to the support stand.
1
ENGINE DISASSEMBLY
Two screws A blocking engine to engine support
stand.
Hit the left crankcase half 2 lightly with a

rubber or plastic hammer until it detaches
from the right crankcase half 3. Remove the
two screws blocking the engine to the equi-
pment and disassemble the crankcase by
hand.
2
ATTENTION: The gearbox unit and the cran-
kshaft must remain inside the right cran-
kcase half.
Disassembly of crankcase.
Remove the back 4 and front reference bu-

shes 5 to position the crankcase correctly.
Remove the gasket between the two cran-
kcase halves.
Detaching crankcase halves.
4 5
The left crankcase half (inside) with references pins The right crankcase half (inside) with crankshaft and
4 and 5. gearbox unit.
37
1
ENGINE DISASSEMBLY
1 1 .11.3 CRANKSHAFT
The crankshaft 1 can be pulled out by hand.
Should there be resistance, tap the right
end of the crankshaft lightly with a plastic
or rubber hammer.
Extraction of crankshaft.
1 4 1 .11.4 INTERNAL GEARSHIFT UNIT AND

4
COMPLETE GEARBOX
The internal gearshift unit is made up of the

desmodromic device 1 upon which the fork
2 and two forks 3 are engaged. The forks,
supported by the pins 4, drive the sliding
wheels of the gearbox, allowing engage-
ment of the desired ratio. The desmodromic
device is controlled by the stop cam present
3 in the external gearshift unit (par.1.10)
2 Extract the two pins 4 by hand so that the
forks can be released and removed.
Removal of fork support pins 4.
Turn the fork 2 which drives the sliding gear

on the primary unit clockwise, to free it from
2 3 the desmodromic control.
Do the same operation, though in the opposi-
te direction, on the forks 3 driving the sliding
gears on the secondary shaft.
Extract the desmodromic device.
Disengagement of control forks from desmodromic

device.
38
Extract the forks together with the drive bu-
shes 5.
1
ENGINE DISASSEMBLY
5
Extraction of forks from gearbox unit.
Proceed to extract the complete gearbox

unit including the primary 6 and secondary
unit 7.
6
7
Extraction of complete gearbox unit: 6 primary unit,

7 Secondary unit.
39
1 1 .12 DISASSEMBLY OF PARTS FROM
CRANKCASES
ENGINE DISASSEMBLY
Once the crankcases have been detached, it is

necessary to remove the various components
attached to it.
The correct positioning of some bearings ap-
plied to the crankcase halves is ensured by lo-
cking devices such as plates or simple screws.
In order to disassembly these bearings, the
safety devices must be disassembled as well.
3 1 .12.1 RIGHT CRANKCASE HALF
2 6 On the inside, the plates 1 are those which assu-

re the correct positioning of the support bearing
of the crankshaft. All you need to do is remove
the two screws 2 to disassemble them.
4 5 The plate 3 is the one relative to the mainshaft
1 support bearing of the gearbox. It can be disas-
sembled by removing the two screws 4.
The plate 5 holds the bearing of the secondary
7 shaft of the gearbox in place. It can be disassem-
bled by removing the two screws 6.
The screw 7holds the support bearing of the de-
Safety devices present on the inside of the right cran-
kcase half. smodromic device in place.
The oil seal blocking plate 8 is applied on

the outside. It can be removed by taking off
9
the two screws 9.
1 .12.1.1 PISTON OIL JETS

1 It is recommended to remove the piston oil
jets 1 and relative O-rings in order to check
and clean the lubrication circuit.
The oil jets are located inside of the right
crankcase half.
Location of piston oil jets.
40
1 .12.1.2 EXTRACTION OF COUNTERSHAFT
1
SUPPORT BEARING
ENGINE DISASSEMBLY
To extract the countershaft bearing, use the
extractor A (code 3625081) together with
extractor B (code 006140160000). It is re-
commended to apply the two aluminium
A plates to be placed between the legs of the
extractor and the crankcase half.
Extraction of countershaft bearing.
1 .12.2 LEFT CRANKCASE HALF

Three safety plates are present on the left cran-
kcase half. Two are applied on the inside and
one on the outside.
The plates 1 on the inside are the ones relative
to the crankshaft support bearing of the gearbox.
They can be disassembled by removing the two
screws 2.
Inside safety plates of left crankshaft half.
The plate 3 is the one relative to the bearing

which supports the countershaft. It can be disas-
sembled by removing the screw 4.
4
3
Outside safety plate of left crankshaft half counter-

shaft.
41
1
ENGINE DISASSEMBLY
1 .12.2.1 INNER OIL FILTER
The inner oil filter 1 must be pulled out

from the inside of the left crankcase. Its re-
1 moval can be aided by using a soft pin to
push it from the outside towards the inside,
tapping with a small hammer.
Disassembly of inner filter.
Removal from low pressure oil pump side.
1 .12.2.2 EXTRACTION OF DESMODROMIC

A DEVICE BEARING
Removal of bearing dedicated to the device

present inside left crankcase half.
Its removal entails use of the extractor A
(code 3625081) together with extractor B
(code 006140160000).
To carry out this operation, it is recommen-
ded to apply two aluminium plates between
the legs of the extractor and the crankcase
half.
Extraction of desmodromic device bearing.
42
ENGINE ASSEMBLY AND CONTROLS 2

Before reassembling the eng ine, a series of
impor tant controls must be carried out to
ensure correct functioning of the eng ine.
The bearings must be replaced if they play
or get jammed during rotation. It is howe-
ver recommended to refer to the periodical
maintenance table.
In order to inser t the bearings in the cran-
kcase halves, bring the crankcase halves to a
temperature of 150°C and keep them at that
temperature for 20 minutes.
Place the crankcase halves on a large sur fa-
ce where their whole seal sur face can rest.
When the bearings cool off, they drop into
their seats on their own.
43
2
2 .1 CRANKCASE HALVES
The crankcase halves have some elements
that need to have their integrity and use
status checked. Hereafter the controls and
EXPLODED VIEW OF ENGINE CRANKCASE HALF assembly operations of the individual ele-
ments coupled to the crankcase halves will
1) Complete engine block; be described. Clean the threading and oil
4) Crankcase gasket; passages thoroughly using a degreaser and
5) Back reference bush; compressed air.
6) Front reference bush;
7) Bush 17x21x19;
8) Inner oil filter; ATTENTION! It is absolutely necessary to re-
9) O-ring; place the crankshaft oil seals present on the
15 Piston oil jet; outside of the left and right crankcase hal-
16) O-ring; ves. This is due to the extreme heating they
17) Lubrication jet;
18) Lubrication jet;
undergo when being disassembled.
19) Centring pin;
20) Centring pin;
21) Cap; In general, the crankcase halves must be re-
22) Cap; placed when:
23) Plate;
24) Screw M5x10;
30) Screw M5x10; ∙ the oil pump crankcases show scratches
31) Bush; or meshing signs (see their location in de-
32) Oil incline; Copper gasket; tail);
34) Gearbox oil vapour breather fitting; ∙ once the new bearings are inserted and
35) Fitting screw; the crankcase half is left to cool off, they
37) Copper washer;
38) Oil pressure control valve screw;
do not fit into their seats.
39) Cable gland.
44
2 .1.1 EXTERNAL RIGHT SIDE
2
Pull out the crankshaft oil seal 1 and repla-

ce it. Check that the oil seal fixing plate 2 is
not bent. If so, have it replaced.
Control the integrity of the oil incline 3.
Should it be worn, have it replaced.
Check the state of use of the kickstart ramp
4. It must be replaced if it shows signs of
meshing or chipping.
The table below contains indications for
fixing the screws of the above-mentioned
elements.
Screw dimensions
Threadlocker Tightening torque
Screw number Threading Threading length application [Nm]
diameter [mm] [mm]
Loctite 243/
5 M5 10 6
Sichel 100M
Loctite 243/
6 M5 10 6
Sichel 100M
Loctite 243/
7 M6 20 10
Sichel 100M
Loctite 243/
29 M6 20 10
Sichel 100M
4 6
7 2
10Nm 3
5
6Nm
1
6Nm
Elements present on outside right crankcase half.
45
2 Keeping the tightener on the lever 25 facing
towards the crankcase half, apply the spacer
27 onto it, by inserting the smaller diame-
ter segment in the lever. Apply the spring

26 so that the hook inserts into the groove
present on the lever 25 and then apply the
washer 28 and the screw 29 M6x20 who-
se threading must be spread with medium
strength threadlocker.
EXPLODED VIEW OF STOPPING DEVICE
25) Lever;
26) Spring;
27) Spacer;
28) Washer 6x20x1;
29) Screw M6x20.
Apply the entire device on the crankca-

10Nm se half so that the straight segment of the
spring rests on the stop C. Tighten the screw
at 10Nm.
Stopping device coupled with the crankcase half.
B The crankcase half will definitely need to be

replaced when:
the oil pump crankcase A shows deep

scratches or meshing signs;
• the two pins B for the idler wheel and
torque limiter show traces of abnormal
wear or meshing;
46
1 2 .1.1.1 INSERTION OF OIL SEAL AND
2
COUNTERSHAFT SUPPORT

BEARING
In order to insert the oil seal and counter-

shaft support bearing proceed as follows.
Grease the oil seal and bearing housing. In-
sert the new oil seal 1 greasing the inside
of it.
Application of oil seal 1.
Apply the new bearing 2 paying close atten-

2 tion that it is aligned in its seat.
Insertion of bearing 2.
Use a press or similar instrument to push

the bearing until the outside surface is flush
A with the surface A.
Oil seal and bearing unit coupled to the left cran-

kcase half.
47
2
2 .1.2 INTERNAL RIGHT SIDE

Check the flatness of the crankshaft bearing
retaining plate 1, of the mainshaft bearing
retaining plate 2 and of the secondary shaft
bearing retaining plate 3.
The table below carries the indications for
application of the fixing screws of these pla-
tes and for fixing the desmodromic device
support bearing.
Screw dimensions
Screw number Threading
Threading length application [Nm]
diameter
Loctite 243/
4 M6 14 8
Sichel 100M
Loctite 243/
5 M5 10 6
Sichel 100M
Loctite 243/
6 M5 10 6
Sichel 100M
Loctite 243/
7 M5 8 6
Sichel 100M
B 8
6Nm
C
A 5
2
3
1
7
4
6
6Nm
8Nm
6Nm
Elementi presenti nel carter destro lato interno.
Blow compressed air into the hole A making

sure the passage is free from any type of im-
purity.Insert the two reference bushes B and
C in their respective housings
48
Make sure the piston oil jets 7 are positio-
ned correctly and free of obstructions.
2
Make sure the O-rings 8 are positioned

correctly, checking their status. Should the
O-rings have cracks or deformations, they
must be replaced.
Piston oil jet O-ring and detail of passage hole.
2 .1.3 EXTERNAL LEFT SIDE

Make sure the calibrated screw 1 and the jet 2
are not obstructed. Should they have been repla-
ced, couple them to the crankcase using a small
amount of medium strength threadlocker, being
careful that the threadlocker does not block the
holes. Then tighten them all the way.
Make sure that the oil passage A is cleaned
well. Make sure that the countershaft bearing
retaining plate 3 is not deformed. If it is, re-
place it.
The table below carries the indications for ap-
plication of the screw for the plate 3.
The crankcase half will definitely have to be
replaced if the oil pump crankcase B has deep
scratches or signs of meshing
Screw dimensions
diameter
Loctite 243/
4 M5 10 6
Sichel 100M
6Nm
Elements present on outside left crankcase half.
49
2
2 .1.4 INTERNAL LEFT SIDE

Clean the inner filter thoroughly and check the
integrity both of the wire metal and the hoo-
king device. Should the filter be deteriorated in
any of these parts, replace it.
Dispositivo di aggancio
Check the state of the two crankshaft bea-

ring retaining plates 1. If they are deformed,
have them replaced.
The table below carries the indications for
application of the screws for the plates 1.
Insert the inner filter 3 in its seat A present in
the crankcase and push it all the way down
until you hear the hooking device click.
Blow compressed air in the hole B making
sure it is not obstructed.
Screw dimensions
diameter
2 M6 14 Media intensità 8
3 2
8Nm
Elements present on inside left crankcase half.
50
2 .2 CHECKING CRANKSHAFT AND
2
CONNECTING ROD

After having checked the state of wear of
the coupling surfaces, check the offset of
the half shaft axes by placing the crankshaft
in between two tailstocks or similar instru-
ment. Control the maximum measurement
variation during a complete turn, using
comparators positioned on the coupling
surfaces with the crankshaft bearings.
Allowed limited: 0.12mm
Deflection/Off-centring of crankshaft.
Check the axial play between the connec-

ting rod head and the half shafts.
Recommended play:
0.4÷0.7mm
Connecting rod axial play.
Check the radial play of the connecting rod

head bearing placing the crankshaft on a
stable support, with the axis of the connec-
ting rod inclined about 45° respect to the
horizontal position. Then position a com-
parator in axis and, pressing lightly in the
direction of the crank lever, check that the
measurement detected does not exceed the
service limit.
~45°
Maximum play 0.05mm
If play is greater replace the connecting rod.
Connecting rod radial play.
51
2 Make sure that the chain control gear is free
of chipping or signs of abnormal wear. Re-
place the crankshaft should it be deteriora-
ted.
The distance between the two opposite si-

des of the half shafts must be:
65mm±0,05
65±0,05
Crankshaft oil passages.
If the two half shafts are detached for repla-

C cement of the connecting rod, pay close at-
tention when repositioning the crank lever
respect to the half shafts. The holes for oil
passage A on the half shaft must coincide
with those present on the crank lever B.
Incorrect positioning would cause an irregu-
lar oil flow rate thus damaging the connec-
ting rod head bearing.
The references C which must be aligned are
found on the half shaft on the flywheel side
and on the crank lever of the pin bolt.
Half shaft and crank lever pin bolt references C.
52
Use a bore meter to check the inside diame-
ter of the connecting rod foot which must
2
not exceed the following service limit:

service limit o 20,03mm
Remember that the measurement must be

made placing the axis of the feeler in paral-
lel with the axis of the connecting rod.
Bore meter verification of inside diameter

of connecting rod foot. 2 .3 ASSEMBLING COMPLETE CRAN-
KSHAFT
When all the aforementioned controls have

been carried out and the worn parts repla-
ced, grease the crankshaft oil seal on the
right crankcase half and couple the cran-
kshaft to the left crankcase half. Keep the
gear present on the crankshaft towards the
left. In order to carry out this operation, you
must just push the shaft axially towards the
crankcase.
Insertion of crankshaft in right crankcase: note the position of the gear.
53
2 2 .4 GEARBOX UNIT: CONTROLS AND
REASSEMBLY
The gearbox unit is made up of the gear-

shift and of the gearbox itself. The gearshift
is then divided into external and internal
gearshift.
The following are the verifications and pro-
cedures for checking and reassembling the-
se units to the engine.
2 .4.1 CHECKING GEARBOX UNIT

Use protective jaws to clamp the primary
and secondary shaft.
Use a thickness gauge to check the axial
play between the gearshift forks and the ge-
arwheels. The play detected must not exce-
ed the service limit indicated below:
service limit: 0,5mm
If the detected axial play is greater, before

replacing either the gearwheels or the forks,
check their state of wear (par. 2.4.4).
Remove the various elements and check
that:
∙ The support surfaces of the primary and
secondary shafts are free of abnormal wear
or signs of seizure.
Checking wear of forks and gearwheels.
∙ the sides of the teeth are free from chip-
ping or abnormal wear;
∙ the sliding areas of the gearwheels are
free from abnormal wear or traces of sei-
zure
∙ the front claw clutches of the gearwheels
are not chipped or rounded;
∙ the roller bearings are intact and efficient;
∙ none of the thrust washers show traces of
abnormal wear or meshing.
Should any of these defects present them-

selves, replaced the concerned parts.
54
2 .4.2 PRIMARY UNIT ASSEMBLY
2

Before proceeding with reassembly, clean all
the elements thoroughly and oil them with
gear oil. Always replace the circlips.
Clamp the mainshaft 1 (using protective
jaws), so that the grooved end faces down-
wards.
Insert onto the lower cylinder part of the shaft:
the roller cage 2, the 5th gear (3) (turning the
front claw clutches upwards), the 26x32x1.5
thrust washer 4 and the circlip 5.
Insert the III - IV sliding gear (6) so that the
smaller gear faces downwards, and then in-
sert the circlip 5.
Insert the 23x32x1.5 thrust washer 7, the rol-
EXPLODED VIEW OF PRIMARY UNIT: ler cage 2, the 6th gear (8) (with the front
claw clutch facing downwards), the 2nd gear
1) Mainshaft; (9) (with the cavity facing upwards) and final-
2) Roller cage 22x26x13; ly the 17x30x1 thrust washer 10.
3) Fifth gear on mainshaft;
4) Thrust washer;
5) Circlip sw15;
6) Third and fourth gear on mainshaft;
7) Thrust washer;
8) Sixth gear on mainshaft;
9) Second gear on mainshaft;
10) Thrust washer 17x30x1
55
2
2 .4.3 SECONDARY UNIT ASSEMBLY

Before proceeding with reassembly, clean
all the elements thoroughly and oil them
with gear oil. Always replace the circlips.
Clamp the secondary shaft 20 (using pro-
tective jaws), so that the grooved end faces
downwards.
EXPLODED VIEW OF SECONDARY UNIT

Insert onto the lower cylinder part: the rol-
4) Thrust washer; ler cage 15, the 2nd gear (19) (so that the
5) Circlip sw15; front claw clutches face downwards), the
7) Thrust washer; 26x32x1.5 thrust washer 4 and the circlip 5.
10) Thrust washer 17x30x1;
11) First gear on secondary;
Insert the 6th gear (18) (so that the fork
12) Roller cage 20x24x10; seat faces upwards) and the circlip 5.
13) Thrust washer 20x30x1; Insert the 23x32x1.5 thrust washer 7, the
14) Fifth gear on secondary; two roller cages 15, the 4th gear (17) (with
15) Roller cage; the front claw clutches facing upwards), the
16) Third gear on secondary;
3rd gear (16) (with the front claw clutches
17) Fourth gear on secondary;
18) Sixth gear on secondary; facing downwards), the 23x32x1.5 thrust
19) Second gear on secondary; washer 7 and the circlip 5.
20) Secondary shaft Insert the 5th gear (14) (with the fork seat
facing downwards) the 20x30x1 thrust wa-
sher 13 the roller cage 12, the 1st gear (11)
(with the front claw clutches facing up-
wards) and finally the 17x30x1 thrust wa-
sher 10.
56
2 .4.4 CHECKING THE FORKS, FORK
2
PINS AND DESMODROMIC

DEVICE
The internal gearshift is made up of:
• two forks 13 which drive two gears on the

secondary unit;
• one fork 14 which drives one gear on the
primary unit;
• three drive pin bushes 15;
• two fork pins 16;
• desmodromic gearshift 18 through whose
rotation the forks are driven thus selecting
the desired gear.
Check to make sure that the drive pins which

EXPLODED VIEW OF INTERNAL GEARBOX support the bushes 15 have no traces of me-
CONTROL UNIT:
shing or abnormal wear and that the bushes
13) ¼ fork; themselves are not worn.
14) 5/6 fork;
15) bush;
16) fork pin;
18) desmodromic control
57
2 A
Make sure the distance A between the outer
faces of the fork is not less than that indicated
below:
Minimum acceptable distance: 4.25mm
Check to make sure that the inside diameter

D of the fork pin seats is below the limit:
Fork inside diameter limit: 13,83mm
Make sure that the fork pins upon which

they slide have an outside diameter above
the limit (to be measured in the sliding are-
as of the forks and in the housing areas of
the crankcases):
Fork pin outside diameter limit:

13,75mm
Make sure that the desmodromic control

device has no corroded or worn areas espe-
cially in the grooves in which the drive pins
of the forks are engaged.
Di
Spina guida
58
4
2 .5 ASSEMBLY OF INTERNAL
2
GEARBOX AND GEARSHIFT
3

Insert the entire primary 1 and secondary unit
2 2 into the respective seats on the left cran-
kcase half simultaneously. Remember to oil
the gears abundantly with gear oil and to gre-
1 ase the shafts supporting them in the areas
where they are coupled with the bearing with
graphitic grease. Make sure that all the parts
slide properly.
Insertion of gearbox in left crankcase.
Insert the centre bearing 3 and the O-ring 4

on the secondary unit.
Detail of centre bearing 3 and O-ring 4 coupled to

the secondary shaft.
59
2 6
Introduce the forks together with the drive
bushes on the gear tracks. To be precise; the
5 smaller fork 5 drives the sliding gear on the
primary unit, while the other two (6) drive

the sliding gears on the secondary unit.
Note: the two forks 6 are interchangeable

and their positioning is univocal, since the
drive pin must face the desmodromic devi-
6 ce. If none of the components in question is
replaced, it is recommended to reposition
the forks in their original positions.
Application of forks to gearwheels.
Insert the desmodromic device in the spe-

cific bearing. In order to do this, it is neces-
sary to rotate cam stop lever 7 towards the
bottom part of the engine.
7
Insertion of desmodromic device in specific bearing.

Note the rotation of the stop lever.
Position the fork 5 of the primary unit in the

central guide of the desmodromic device 8,
5 insert the fork pin inside the fork itself and
8 insert the pin in its proper seat in the cran-
kcase half.
Positioning of primary unit fork 5 in central guide of

desmodromic device 8.
60
8 6
Position the two forks 6 of the secondary unit
in the external guides of the desmodromic
2
device 8 and, just like the primary unit fork,

insert the fork pin first in the pins and then in
its proper seat.
Remember to oil the shafts, forks and the de-
smodromic device abundantly with gear oil.
Positioning of the secondary unit forks 6 in the

external guides of desmodromic device 8.
Position the new crankcase gasket.
View inside the right crankcase with crankshaft, oil jets, gearbox shafts complete with gearwheels, internal gearshift
and gasket.
61
2
2 .6 CLOSING ENGINE BLOCK

Press the right crankcase half towards the
left, being careful that the shafts and pins
on the crankcase fit into the respective hou-
sings and that the crankcase half is not upsi-
de-down. To facilitate progressive nearing
and aligning of the two crankcase halves,
connect two screws on opposite sides and
tighten them bit by bit. If the crankcase hal-
ves tend to capsize, do not insist tightening
them. Rather loosen the screws and reposi-
tion the crankcase correctly.
Make sure that the two crankcase halves

match perfectly one with the other. Assem-
ble the screws according to their length as
indicated in the figure.
The table below contains indications for ap-
plying these screws.
It is recommended to tighten them in a
criss-cross pattern using a torque of 10Nm.
Positioning of screws to fasten crankcase.
Screw dimensions
diameter
41 M6 75 NO 10
42 M6 65 NO 10
Cut the extra piece of gasket in between

the two crankcase halves in the area of the
cylinder.
This can be done easily by bending the ga-
sket several times.
Cutting extra piece of gasket between engine cran-

kcase halves.
62
2 .7 BLOCKING THE CRANKSHAFT
2
AT THE TOP DEAD CENTRE AND

TIGHTENING THE NUT ON THE
LEFT SIDE OF THE CRANKSHAFT
In order to block the crankshaft at the Top

Dead Centre, the specific conical-end screw
38 (or tool 006140110 000) must be intro-
duced in its seat on the right crankcase half
without applying the washer 37. Once the
crankshaft is positioned at the Top Dead
Centre, tighten the screw all the way.
To block the crankshaft, apply only the screw 38 to

the crankcase.
Spread the threading on the left-hand side

of the crankshaft with medium strength th-
readlocker. Tighten the nut using the special
socket wrench A (code 006140020000) at a
torque of 150Nm.
150Nm
Nut on left side of crankshaft.
63
2
2 .8 EXTERNAL GEARSHIFT
Before reassembling the external gearshift,
check its state of use. While for the stop cam
it is enough to make sure it’s free from ab-
normal wear or meshing, the gearshift drive
shaft needs more in-depth inspections.
2 .8.1 CHECKING THE COMPLETE

DRIVE SHAFT
With the device complete, make sure that

0,35÷0,80 the distance between the movable pawl and
the drive shaft is between 0.35÷0.80mm.
Should the distance be greater, replace the
movable pawl.
Allowed distance between shaft and pawl.
In order to replace the movable pawl 1, di-

2 1 4 sassemble the return spring of the gearshift
2, the spring guide 3, the spring 4 (which
must be compressed and pulled out of its
seat) and the pawl, moving it completely to-
wards the shaft 5.
3 5
Complete drive shaft: 1) Movable pawl; 2) Gearshift

return spring; 3) Spring guide; 4) Spring; 5) Gearshift
drive shaft.
64
2

EXPLODED VIEW OF GEARSHIFT
For reassembly, couple the movable pawl 9
5) Thrust washer 14x30x1;
to the drive shaft 10 and, while compressing
6) Gearshift return spring;
7) Spring guide; it, insert the spring 8 between the mova-
8) Pawl return spring; ble pawl and the drive shaft. Then apply the
9) Movable pawl; spring guide 7, the gearshift return spring 6
10) Gearshift drive shaft. and finally the 14x30x1 thrust washer 5.
The gearshift return spring must be positio-

ned as in the figure to be able to carry out
its function.
Gearshift drive shaft: note the positioning of the

gearshift return spring.
65
2 2 .8.2 ASSEMBLY OF EXTERNAL GEAR-
SHIFT
Keeping the stop lever moved 1 in such a

way that the spring is compressed, position
the stop cam 2 on the protruding end of the
desmodromic gearshift (external right cran-
kcase). The stop cam has only one correct
position which is determined by the parti-
cular shape of the end of the desmodromic
device and of the bottom part of the stop
cam.
Proceed mounting the tightening screw 3
M6x30 between the stop cam and the de-
smodromic gearshift, after having applied
medium-resistance sealant: tighten it at
10Nm 10Nm.
Insert the drive shaft together with the wa-
1 sher in its seat keeping the return spring 4
of the movable pawl pressed.
Wishing to test the correct functioning of
the entire unit, you just need to temporarily
couple the external gearshift lever and to si-
mulate the operation of changing gears, by
lifting and lowering the gearshift lever and
4 having the mainshaft of the gear unit rotate.
2 The whole device works properly if abnor-
3
mal jamming does not occur.
POSITIONING OF STOP CAM ON DESMODROMIC If the unit runs without oil, the device ma-
DEVICE kes more noise than usual.
1) Stop lever;
2) Stop cam;
3) Screw M6x30;
4) Movable pawl return spring.
2 .9 KICK STARTER
Before coupling the kickstarter to the cran-
kcase half, some controls must be carried
out.
2 .9.1 CHECKING KICKSTARTER SHAFT

UNIT AND ASSEMBLY
In order to disassemble all the parts of the

kickstart shaft, pull off the washer 11 at the
end of the shaft (on the side of the spring
16), the spring 16, the kickstart sleeve 14,
and the lever return spring 8, which to be
unfastened from the shaft must be pulled
in the radial direction so that it is extracted
from its hole. Pull out the kickstart spacer 9.
66
2

EXPLODED VIEW OF COMPLETE KICKSTART SHAFT
Widen the circlip 10, thus slipping off the
2) Kickstart gear; washer 11, and the kickstart gear 2 as well
3) Kickstart shaft; the roller bearing 12 and the washer 11.
8) Kickstart return spring; This frees the kickstart shaft 3 from all other
9) Kickstart spacer; elements.
10) Circlip 20E;
11) 20x28x1 washer DIN 988;
Make sure that the side of the kickstart gear
12) Roller bearing K20x24x10; teeth 2 have no signs of meshing or super-
14) Kickstart sleeve; 16) Spring ficial wear. Make sure that the front teeth
(sleeve side 14) are not chipped. Replace
any element that has the aforementioned
defects.
Make sure that the front teeth of the sleeve
14 14 are not chipped and that the spring 16 is
capable of putting enough pressure on the
sleeve 14 so that it can to pull the gear 2.
Also check to make sure that the washers
have no abnormal or excessive wear. If so,
have them replaced. Make sure that the
spring 8 has no cracks or abnormal defor-
mation. Have it replaced if it is not able to
bring the external kickstart lever back to the
rest position.
For reassembly, proceed inversely compa-
red to the previously-described disassembly
procedures.
Pay attention to the correct positioning of
the sleeve 14 respect to the shaft 3. The
3 front of the shaft has a reference sign, just
as the sleeve does14: the two references
must match.
Positioning of sleeve on small shaft.
67
2 2 .9.2 ASSEMBLY OF KICKSTART
DEVICE
Insert the complete kickstart shaft in its

housing keeping the thin-striped facing ou-
twards and making sure that the ramp A on
the kickstart sleeve is positioned below the
A ramp B bolted onto the right crankcase (ex-
ternal side).
Positioning of sleeve A below ramp B.
Turn the spring clockwise until it fits into the

specific hole C.
C
Insertion of kickstart return spring.
Insert in the slot on the protruding segment

of the secondary shaft: the circlip 18, the
washer 17, the idler wheel 4 followed by
the washer 17 and the circlip 18 as shown
in the figure.
Engine side
Kickstart device unit coupled to the crankcase
68
1
2 .10 ELECTRICAL STARTER UNIT AND
2
MAIN GEAR

Carry out the following controls before as-
sembly.
2 .10.1 CHECKING ELECTRICAL STARTER

DEVICE ELEMENTS
Make sure that the teeth of all the gearwhe-

els of the device are intact, free from chip-
Idler wheel 1. ping or signs or abnormal wear.
Pay attention to the teeth of the idler whe-
els 1 and torque limiter 2 and between the
2 gears and respective support pins. Replace
them if they show signs of meshing or sei-
zure.
Make sure there are no traces of meshing

on the housing of the roller bearing on the
starter gear 3. Mount the starter gear tem-
porarily on the crankshaft, together with the
roller bearing and check to see if there is
Torque limiter 2. excessive play.
To check the correct functioning of the free
wheel 4 proceed as follows.
5
Insert the starter gear 3 on the free wheel 4
and main gear unit 5. Keeping the main gear
blocked 5 and turning the kickstart gear 3
clockwise, it must run freely. Turning the
kickstart gear 3 anti-clockwise, it must be
blocked without idling.
4 A
Free wheel coupled to main gear.
To replace the free wheel, disassemble the spe-

cial circlip A and remove the free wheel.
3
During disassembly make sure that the lugs on
the outer edge of the special circlip A are cou-
pled in the slots of the free wheel and in the
groove inside the main gear.
Main gear complete with free wheel coupled to

ignition gear.
69
2 2 .10.2 COUPLING IGNITION AND PRI-
A MARY GEARS TO THE MOTOR
Thoroughly degrease the conical part A on

the right side of the crankshaft and B of the
primary gear.
Conical segment A on right side of crankshaft.
Conical segment B main gear.
2 Lubricate the segment C of the starter gear

1 with motor oil and couple it to the cran-
kshaft.
Insert the Woodruff key 2 in the specific
1 seat.
Positioning Woodruff key in specific seat.
Apply the main gear 3 to the crankshaft and

150Nm
ANTIORARIO while turning the gear clockwise, push it to-
wards the crankcase half until you perceive
meshing between the gear and the Woo-
druff key.
Insert the locking nut F applying the threa-
F ding with a medium strength threadlocker
E and tighten at a torque of 150Nm.
D
3
Attention:
it must be tightened anti-clockwise.
Coupling main gear to crankshaft.
70
10Nm Grease the two pins D and E with graphitic
grease.
2
6 Couple the idler wheel 7 to the pin D and

apply the circlip 8.
8 Couple the torque limiter 4 to the pin E
turning the gearwheel with the smaller dia-
7 5 meter towards the crankcase half. Insert
the washer 5 and the screw 6 after having
spread the threading with medium strength
4 threadlocker. Tighten the screw at a torque
of 10Nm.
Coupling electrical starter gear unit.
Apply a light layer of grease in the area G of

the start motor and insert the motor in its
housing.
Insertion of start motor in crankcase half.

Note zone G to be greased.
Apply medium strength threadlocker on the

two screws 9 and tighten them with a tor-
que of 10Nm.
9
10Nm
The two fixing screws 9 of the start motor.
71
2 2 .11 OIL PUMPS: CONTROL AND
REASSEMBLY
As shown in paragraph 1.5, the motor is

equipped with two oil pumps: one is the
low pressure (suction) pump (higher displa-
cement) located in the outside of the left
crankcase half and the other high-pressure
pump (lower displacement) located on the
outside of the right crankcase half. The two
pumps are driven by a gear cascade me-
shing with the clutch gear.
EXPLODED VIEW OF OIL PUMP UNIT Proper operation of the pump depends:
1) Benzing ring;
• On the sliding surface with the rotors;
• On
2) Oil pump gear;
3) Screw M5x10; the radial play between the two ro-
4) Circlip JS24; tors and between the external rotor and
5) Oil seal; the crankcase;
6) High-pressure oil pump cover; • On the axial play of the rotors respect to
7) High-pressure (or delivery) oil pump; the sliding surfaces;
8) Roller;
9) Pump control shaft; • On the O-ring seal and the oil seal (on
10) Low-pressure (or intake) oil pump; the high-pressure pump cover).
11) Ball;
12) Spring;
13) Low-pressure oil pump cover;
14) Circlip A13;
15) Thrust washer 13x19x0,5;
16) Oil pump transmission gear;
17) Screw M5x20;
18) Pin;
19) Pin
72
Should the sliding surfaces with the rotors pre-
sent deep or evident traces of corrosion, replace
2
the deteriorated part (in this case, the crankcase).

To measure the radial play between the internal
and external rotor and between the external ro-
tor and the crankcase, proceed as follows:
Insert the two rotors in their specific seat with
the reference dot facing the inside of the engine.
Using a thickness gauge, check that the play

does not exceed that allowed, equal to:
Maximum radial play: 0,20mm
Take a thickness gauge again and a rectified refe-

rence surface and verify that the axial play does
not exceed the maximum allowed amount:
Low pressure pump: note the dot on the two rotors. Maximum axial play: 0,1mm
The dot must face the inside of the engine.
Should play be greater, replace the rotors.
Assessment of radial play between Assessment of radial play Assessment of radial play between rotors
and internal and external rotor. between external rotor and sliding surfaces.
crankcase.
As to the high-pressure pump (located in

the outside right crankcase half), one must
check that the oil seal 5 is not worn (it is
recommended to replace it). In order to di-
sassembly it, the circlip 4 must be removed.
Check the state of use of the O-ring 20 and
replace it if needed.
Exploded view of high-pressure pump cover. 4) Circlip

JS24; 5) Oil seal 10x22.6; 6) Oil pump cover; 20)
O-ring 45x2.
Also check that the drive shaft is not too

marked in the zone A where the oil seal sli-
des.
Checking oil pump control shaft.
73
2 1
2 .11.1 ASSEMBLY OF LOW PRESSURE
PUMP
Insert the internal rotor 1 on the shaft 2 so

that the dot on the face of the rotor faces in-
wards. Then insert the roller 3 on the shaft.
2
Shaft, low pressure pump, internal rotor and roller

unit.
Use motor oil to lubricate the seat of the

rotors on the outside of the crankcase half,
insert the external rotor 4 and the internal
shaft-rotor unit in its proper seat.
4 Insert the ball 5 (diameter 5.5mm) and the
respective compression spring 6.
Lubricate with motor oil and, while rotating
the protruding segment of the drive shaft
(from the outside of the right crankcase
half), make sure it rotates freely and does
not jam.
Complete low pressure pump coupled to the crankca-

se.
6Nm
Fasten the cover 7 to the crankcase with the
three screws 8, which must first be spread
7 with medium strength threadlocker. These
screws must be tightened at a torque of
6Nm.
Coupling low pressure pump cover to crankcase.
74
2 .11.2 ASSEMBLY OF HIGH-PRESSURE
2
2 PUMP AND CONTROL GEAR

1 Lubricate the area where the pump is hou-
sed (outside right crankcase half), and in-
sert the roller in its hole 1. Then insert the
internal rotor 2 and the external rotor 3,
making sure to position them with the re-
ference dot facing the inside of the engine.
Lubricate the pump body with motor oil.
Coupling high-pressure pump rotors to drive shaft.
Grease the oil seal, insert the cover in the

end of the shaft and press towards the
crankcase carefully (pay attention to the oil
seal). Insert the three screws 4 after having
applied them with spread medium streng-
th threadlocker. Tighten them at a torque of
6Nm.
Turn the shaft holding on to the protruding
end and make sure it rotates freely without
getting jammed.
6Nm
Coupling high-pressure pump cover to crankcase.
2 .11.3 CHECKING AND ASSEMBLY OF

PRESSURE CONTROL VALVE
The pressure control valve is made up of a

ball 43, spring 42, calibrated washer 41 and
screw 40.
Check the length of the free spring on this
component:
Service limit: 29.5mm
Tighten the screw at a torque of 20Nm.
Attention: If one of these elements making up

20Nm the control valve is not inserted, engine functio-
ning will be jeopardised.
PRESSURE CONTROL VALVE
Attention: always restore the original thickness
40) Screw; value of the washer 41. If this should be repla-
41) Thrust washer; ced, have it changed with one having the same
42) Spring; original thickness.
43) Ball
75
2 2 .11.4 CHECKING AND ASSEMBLY OF
OIL PUMPS CONTROL GEARS
The oil pumps are controlled by a gear ca-

scade driven by the clutch gear.
The gearwheels, being made of plastic, must
not have chips, grains or signs of abnormal
wear.
6Nm
Should the pins 1 and 2 which support the
3 two pump control idler wheels be disassem-
bled, they must be refastened to the cran-
kcase half. These are connected to the cran-
kcase half by means of two screws 3 (after
1 they are applied with medium strength thre-
adlocker) and tightened at a torque of 6Nm.
2 4 Couple the thrust washer 4 to the pin 2 and
lubricate it with gear oil.
Oil pumps control gearwheels support pins.
Couple the two pump control idler wheels 5

5
to the two pins so that the most protruding
segment faces the crankcase.
Then insert the thrust washers 6 and cir-
clips to keep the wheels from coming off
7 the pins.
Insert the roller 7 to the end of the pump
6 control shaft.
Coupling pump control gearwheels to crankcase.
8 Couple the oil pump control wheel 8 to the

end of the shaft so that the groove on the
gear inserts into the roller. Then apply the
benzing ring 9, so that the gear does not
slip off.
9
Coupling pump control wheel.
76
2 .11.5 PAPER OIL FILTER INSERTION
2
1

Lubricate the rubber gasket on the filter. In-
sert the filter 1 into its housing and push it
towards the inside of the engine as far as it
can go.
Application of paper oil filter.
Insert the O-ring 2 onto the oil filter cover 3

and apply the unit to the crankcase.
2
Paper oil filter cover complete with O-ring.
Apply the two screws 4 M5x16 to be tighte-

ned at a torque of 6Nm.
6Nm
Two fixing screws of paper oil filter cover.
77
2 2 .11.6 CHECKING AND COUPLING
COUNTERSHAFT
Check the state of use of the areas where

the shaft rests on the bearing. Should they
EXPLODED VIEW OF COUNTERSHAFT
show signs of abnormal wear, have the shaft
1) Shaft; replaced. Make sure that the toothed seg-
2) Counterweight; ment of the shaft does not have traces of
7) Elastic washer; abnormal wear.
8) Nut M12x1
Grease the oil seal and insert the counter-

shaft in its seat. Position it so that the refe-
rence sign on the shaft is between the two
reference signs on the main gear.
Coupling countershaft to crankcase.
Enlargement of references.
78
While keeping the countershaft in place, in-
sert the counterweight on the left side de-
2
pending on the position set by the grooved

shaft.
Coupling counterweight to countershaft.
Detail of grooved profiles for coupling.
Then couple the elastic washer and the nut

1 after having applied medium strength th-
6Nm
readlocker on their threading. The nut must
be tightened at a torque of 60Nm.
Countershaft nut.
79
2
2 .12 CLUTCH UNIT

Before reassembling the clutch unit, carry
out some controls on the various compo-
nents described below.
2 .12.1 CHECKING CLUTCH BASKET,

ROLLER BEARING AND INTERNAL
CENTRE BEARING
Before reassembling the clutch basket, make

sure that the sides of the teeth A, dedicated to
main transmission and B dedicated to meshing
with the kickstart idler gear and oil pumps, have
no superficial nicks or abnormal wear.
Also closely check that the teeth C, upon which
the driving discs engage, are not chipped or de-
eply cut.
CLUTCH BASKET: Make sure that the centre bearing D with the rol-
A) Teeth meshing with main gear; ler bearing has no traces of meshing or abnormal
B) Teeth meshing with kickstart idler gear; wear.
C) Teeth meshing with driving discs; If any damage is found, have the piece replaced.
D) External centre bearing.
80
Check the state of use of the silent-blocks
as follows. Clamp the gear B intended to
2
mesh with kickstart idler gear, using protec-

tive elements. Rotate the clutch basket. If
there is play between the basket and the
gear unit, replace the clutch basket.
Check the state of use of the centre bearing
1 which must have no traces of meshing or
abnormal wear.
1 Check the state of use of the roller bearing
2
2. If it is worn, have it replaced.
Internal centre bearing and roller bearing of clutch

gear.
2 .12.2 CHECKING CLUTCH DISCS
The clutch discs are divided into friction di-

scs and steel discs: there are eight friction
discs and seven steel discs.
The friction discs have friction material ap-
plied on both sides which wear out due to
the steel discs sliding on them.
Make sure that the thickness of each friction
disc is not below the minimum value fixed
at:
minimum thickness: 2,8mm
Minimum thickness.
The other value that needs to be checked

is the thickness of the teeth of each friction
disc. They must not be less than the mini-
mum value fixed at:
minimum friction disc tooth thickness:

13,3mm
Minimum disc tooth thickness.
81
2 Also check the distortion of the steel discs.
This operation is done by placing the steel
discs on a perfectly flat surface and using a
thickness gauge to check that the clearance

between the disc and the surface is not gre-
ater than:
allowable distortion
steel discs: 0.10mm
Measuring steel disc distortion.
2 .12.3 CHECKING SPRINGS

To ensure the correct pressure between the
clutch discs, the state of the springs must
be checked. The minimum acceptable leng-
th must be:
minimum clutch spring length:

42.5mm (new springs 44.2mm)
Clutch spring length measurement.
2 .12.4 CHECKING INNER HUB

The inner hub meshes with the steel clutch
discs by means of the teeth A: Make sure
these teeth are not meshed or shaped by
abnormal wear. If so, replace the inner hub.
Also control that the radial holes present on
the inner hub are not obstructed and are
free from sediments.
Checking inner hub teeth.
82
2 .12.5 CHECKING THRUST BEARING
DEVICE
2

Check the state of use of the thrust bearing
and the surfaces upon which it rests. In or-
der to check the thrusting bearing, just see
if it slides. When the device is assembled,
simulate rotation of the front centre bearing
B A respect to the rear one B.
A Be careful for presence traces of meshing or
wear on the sliding surfaces.
Thrust bearing device.
2 .12.6 ASSEMBLY OF CLUTCH UNIT

After having lubricated the end of the main
EXPLODED VIEW OF CLUTCH UNIT
transmission shaft, insert the internal centre
1) Complete basket; bearing 4 to which the roller bearing must
2) inner hub; be coupled 5.
3) Clutch pressure cap; Insert the clutch basket 1 followed by the
4) Internal centre bearing;
21.7x38x3 washer 6, upon which the inner
5) Roller bearing 26x30x22;
6) Washer; hub will rest 2. Put on the safety washer 7
7) Safety washer; and after having applied medium strength
8) Nut M18x1,5; threadlocker, couple the lock nut 8. In order
9) Overall thrust bearing; to facilitate insertion of the clutch basket,
10) Clutch body rod coupling; lightly turn the kickstart idler gear, the id-
11) Thrust bearing;
12) Circlip RB14;
ler gear for oil pump control and the basket
13) Clutch spring; itself, thus helping meshing of the various
14) Clutch spring retainer; gears.
15) Screw M6x25;
16) Steel discs;
17) Friction discs.
83
2 8
To unscrew the nut 8, the inner hub must
be blocked with a relevant tool A (code
A 0061400400); the tightening torque is fi-
xed at 150Nm after having applied medium

strength threadlocker.
Having tightened the nut, bend to two blo-
cking flaps on the safety plate.
Blocking inner hub with specific tool Code

0061400400.
Lubricate the clutch discs with gear oil and

proceed to apply the discs, alternating fric-
tion discs and steel discs*.
III Notice that the steel discs must be inserted
so that the radius on the teeth faces inwards
towards the engine.
I Insert the overall thrust bearing 9 (after ha-
ving lubricated it with gear oil) in the hole
on the main gearbox shaft and check its free
axial sliding. Close the clutch unit by me-
ans of the clutch pressure cap 3, the four
II springs 13, the fours spring retainers 14 and
the four screws 15, to be tightened with a
torque of 10Nm, in a criss-cross pattern.
10Nm
IV
Complete clutch and recommended tightening order.
* Refer to the exploded view of the clutch unit for

assembly.
84
Insert the clutch rod in the seat B from the
left side of the engine, turning the smaller
2
section towards the inside of the engine.

B
Insertion of clutch rod in housing B.
Apply the gasket 5, the complete hydrau-

10Nm lic actuator 6 the M6x30 screw 7 and the
7 two M6x20 screws 8 to the left crankcase
half. Tighten the three screws at a torque
of 10Nm.
5
8
Application of gasket 5, actuator 6, screw 7 M6x30

and two screws M6x20.
85
2
2 .13 COOLANT PUMP

EXPLODED VIEW OF WATER PUMP The water pump must guarantee, depending on
the set rotation speed, the correct flow rate of the
1) Drive shaft coolant in order to extract the needed amount of
2) O-ring 5.5x1;
heat from the thermal unit.
3) Bearing 10x19x5;
4) Oil seal 12x30x7; The shaft 1 is supported by two bearings 3 and
5) Bush 8x12x10; sealing of coolant and gear oil is ensured by the
6) Impeller; O-ring 2 and oil seal 4.
7) Washer; The impeller 6 is fastened to the shaft 1 and the
8) Blind nut M6x1;
coupling is ensured by tightening the nut 8 onto
9) Gasket;
10) Gasket cover; the shaft 1.
11) Washer;
12) Screw M6x40.
2 .13.1 CHECKING
PUMP UNIT AND
DISASSEMBLY
Disassembly of the entire pump unit can be

done only with the entire clutch cover removed.
Disassembly of the pump unit is performed by
removing the nut 8 which allows you to extract
the impeller 6, the washer 7, and the shaft 1.
This can be removed by pressing the threaded
part of shaft 1 towards the inside of the clutch
cover.
Extract the oil seal 4 and, heating the bearings 3,
remove them.
Once the shaft is pulled off 1 from the crankcase,
Complete internal clutch cove of water pump.
it is recommended to replace the O-ring 2.
Replace the oil seal 4 every time and if the bush
5 is marked in the area of contact with the oil
seal, replace it as well.
86
2 .13.2 ASSEMBLY OF PUMP UNIT
2

Heat the concerned area to couple the bearings
3 to the inner clutch cover. They must be pu-
shed until they are flush with the shoulders on
the pump body.
Bordo più
spesso Grease the oil seal housing. Position the oil seal
4 so that the thicker edge faces the outside of
the cover. Insert the oil seal in the inner clutch
cover, having it enter the seat very slowly to keep
it from deteriorating.
Application of oil seal on inner clutch cover.
Couple the shaft 1 with the O-ring 2 to the inner

10Nm
clutch cover and then insert the bush 5, the wa-
sher 7 and the impeller 6.
Then couple the blind nut 8 to the threaded seg-
ment of the shaft after having applied medium
strength threadlocker. Tighten it at a torque of
10Nm.
Complete coolant pump unit.
When coupling is complete, check that the pump

unit turns freely without meshing or friction.
Check the axial play of the pump unit. Make sure
it is not beyond 0.3 mm.
It is recommended to replace the gasket in
between the inner clutch cover and the pump
cover.
87
2 2 .14 ASSEMBLY OF COMPLETE
CLUTCH COVER
Apply a new gasket 1 placed between the right

crankcase half and the inner clutch cover using
the two reference pins 2 to keep it in place.
2
1
Positioning of gasket 1 and centring pins 2.
Couple the inner clutch cover to the right cran-

kcase half and turn the water pump impeller un-
til the pump shaft inserts perfectly in the housing
on the countershaft which drives it.
Application of complete inner clutch cover to right

crankcase half.
Apply the nine M6x25 screws as shown in the

figure, tightening them by hand until they are
flush.
Positioning of M6x25 screws.
88
10Nm
Couple the water pump cover to the inner
clutch cover applying the four M6x40 screws,
2
making sure to apply the copper washer 3

to the lower screw of the pump cover.
Tighten all thirteen screws at a torque of
10Nm following a criss-cross pattern.
Coolant pump cover: pay attention to washer 3.
If only the outer clutch cover was removed,

put it back on the inner cover and fasten the
six M6x25 screws as shown in the figure.
4 screws that fasten the outer clutch cover to the

inner cover.
The M6x30 screw 5, not present in the figu-

re, is coupled to the engine applied to the
vehicle because this maintains a spacer in
position upon which the brake pedal return
5 spring in engaged.
Detail of screw 5 to be applied with the engine

coupled to a vehicle.
89
2 1
2 .15 CHECKING AND COUPLING OF
TIMING CHAIN, FIXED AND
MOBILE GUIDES
The chain has the task of transmitting motion

2 from the crankshaft to the camshafts present on
the cylinder head. The links must be checked to
make sure there is no excessive radial or axial
play between them.
The fixed and movable guides guarantee a cor-
rect movement of the chain. The hydraulic chain
A tensioner ensures correct tensioning.
Make sure that the guides do not have deep tra-
ces caused by the rotation of the chain.
In order to assemble the chain to the engine, just
introduce it in the vertical passage compartment
A on the left crankcase and insert it in the gear
on the crankshaft.
Insert the fixed guide 1 and the movable guide
2 inside the compartment A. Insert the specific
6.2x9x9 bushes inside the lower eyelets of the
guides. After having applied medium strength
threadlocker, tighten the relative screws 3 at a
torque of 10Nm.
10Nm 3
Timing chain with relative fixed and movable guides.
Mounting bushes in lower eyelets of guides.
2 .16 IGNITION SYSTEM

Before reassembling the ignition system, it is re-
commended to check its correct functioning.
The ignition system is made up of the magnetic
pick-up, the stator unit and the flywheel. The sy-
stem is completed by the electronic control unit,
the ignition coil and the spark plug, which are
not dealt with in this text.
90
2 .16.1 CHECKING IGNITION SYSTEM
2
Degrease the various elements and carry on with

the controls.
The main control is the one concerning the elec-
trical verification which can be done by using a
standard tester. The resistance values detected at
the terminal heads must respect those carried in
the table (at 20°C).
Element Cables Resistance values

Pick-up Red – Green 100Ω ± 20%
Red/Black – White/Red 14,7Ω ±15%
Stator Yellow – Mass 0.61Ω ±15%
Yellow – White 0.18Ω ±15%
2 .16.2 COUPLING IGNITION SYSTEM TO

CRANKCASE
Set the pick-up on the crankcase so that the two

1 holes on its support coincide with the two outer
holes on the crankcase.
Apply the threading of the two screws 1 with
medium strength threadlocker and tighten them
at a torque of 6Nm.
Lay the cable on the crankcase, apply the groo-
2 ve of the cable gland 2 with gasket paste (code
6Nm 3625000000) and insert it in the specific hou-
sing n the crankcase, removing excess paste.
Coupling pick up to crankcase.

Attention: pay close attention so that the
cables are well fastened to the wall of the
crankcase halves near the cable gland.
6Nm
Couple the chain guard to the crankcase, insert

the two 6.2x9x9 bushes in the lower eyelets and
couple the two screws 1 after having applied
them with medium strength threadlocker. Then
tighten them at a torque of 10Nm.
32
Coupling chain guard to crankcase. Mounting bushes in lower eyelets of chain guard.
91
2 Degrease the conical segment of the crankshaft,
apply the Woodruff key 21 in the appropriate
groove on the crankshaft, couple the flywheel
18, the elastic washer 19 and the nut 20, after

having applied the threading with Loctite 243
/ Sichel 100M medium strength threadlocker.
Tighten the nut at a torque of 60Nm.
60Nm
EXPLODED VIEW OF FLYWHEEL

18) Flywheel; 19) Elastic washer; 20) Nut M12x1;
21) Woodruff key.
Couple the stator to the flywheel cover by

means of the two screws 1. Apply the th-
reading with medium strength threadlocker
and tighten them at a torque of 8Nm.
Insert the cable gland in its specific seat and
check its perfect sealing.
8Nm
Coupling stator to flywheel cover.
2 3 Check the state of use of the two oil seals

4 2. If they are deteriorated, they must be re-
placed.
Blow compressed air in the hole A making
sure the lubrication pipe is perfectly clean.
Also check the state of use of the chain gui-
de 3. If it is deteriorated, it must be replaced.
In that case, before putting on the screw 4,
6Nm apply it with medium strength threadlocker
2
and tighten it at a torque of 6Nm.
Detail of flywheel cover.
92
B
Reposition the plate 5 which must be inserted
in the relevant guides and pressed towards the
2
outside of the cover.

When coupling it to the left crankcase half, apply
a drop of gasket paste (code 3625000000) in
the two zones B, in order to ensure perfect sea-
ling between the cover and the crankcase half in
the concerned zone.
Application of cable protection plate 5. Note the two

zones A where a drop of gasket paste must be
applied.
Insert the centring pins 3 on the crankcase and

fasten a new gasket. Grease the oil seal on the
flywheel cover and couple it to the left crankcase
6 with the nine M6x25 screws 4.
Application of centring pins on left crankcase half

for coupling with flywheel cover.
93
2
10Nm
Notice that a 12x6.3x1 copper washer 4 must be
applied to the screw.
Tighten the screws at a torque of 10Nm.
Flywheel cover coupled to crankcase.
2 .17 THERMAL UNIT

Before assembling the thermal unit, thorough
controls must be carried out on the cylinder, pi-
ston, pin bolt, piston rings, cylinder head and the
timing unit described hereafter.
2 .17.1 CHECKING PISTON, PIN BOLT,

X AND PISTON RINGS
Eliminate carbonaceous sediment from the top

of the piston and wash the entire piston with
specific degreasing agent.
Do not use sharp points or tools for clea-
ning.
Then carry out a careful analysis of the piston
Quota at which to measure the outside diameter of which must be free from forcing, scratches,
the piston. cracks or any type of damage.
Analyse the outside diameter of the piston who-
se service limit is carried in the table below con-
cerning their specific class. The diameter must be
measured at a distance X from the inner edge of
the skirt perpendicularly to the axis of the pin
bolt.
Service limits based on relevant class [mm]

Displacement [cm³] Quota X [mm]
1 2
400 7 94,915 94,925
450 7 94,915 94,925
520 7 99,905 99,915
94
Check the size of the pin bolt seat located on the
piston and the size of the pin bolt. This last con-
2
trol must be made at the end of the pin bolt itself

in the area where it is engaged with the piston.
Size
Displacement
[cm³] limit
Spinotto
[mm]
Pin bolt
Pin bolt
seat
Measuring pin bolt seat and pin bolt.
See the relative chapter regarding crankshaft

and connecting rod controls for controls on
connecting rod foot (par. 1.2).
In order to check the state of use of the pi-

ston ring and oil-scraper ring, the ring must
be inserted in the cylinder so that its axis is
aligned with the axis of the cylinder. Then
measure the distance between the two op-
posite edges.
The respective service limits are carried in
the table below.
Checking the wear limit of the elastic band. Service

Service limits of
Displace- limit of upper and
compres-
ment [cm³] lower oil-
sion ring scraper ring
[mm] [mm]
400-450-520 0,8 1,0
95
2
2 .17.2 CHECKING THE CYLINDER

Make sure the bore is within the service limits of
the relevant class carried in the table below.
Carry out measurement at a distance A from the
top face of the cylinder (surface between cylin-
der and cylinder head). To measure it correctly,
it must be done according to the X and Y di-
rections orthogonal between them. Consider the
maximum measurement to determine the cylin-
der wear.
The difference between the two measurements
is the ovalization.
This measurement must be carried out by

placing the bore meter in such a way that
its axis is perpendicular to the axis of the
crankshaft.
Service limits based on relevant

Displace- Quota A class [mm]
ment [cm³] [mm] Ovalization
1 2
[mm]
400 40 95,022 95,034 0,015
450 40 95,022 95,034 0,01
520 40 100,022 100,035 0,01
2 .17.2.1 ASSEMBLY CLEARANCE

The following table carries the coupling play
between the cylinder and piston.
In order to calculate the coupling play between
the cylinder and the piston, a subtraction must
be carried out between the diameter of the cylin-
der and that of the piston.
Coupling play based on relevant Coupling play limit based on relevant

Displacement class [mm] class [mm]
[cm³] Class 1 Class 2
Class 1 Class 2
Min Max Min Max
400 0,035 0,057 0,037 0,060 0,10 0,10
450 0,035 0,057 0,037 0,060 0,10 0,10
520 0,045 0,067 0,047 0,070 0,12 0,12
96
A 2 .17.3 CYLINDER HEAD: DISASSEM-
2
BLY AND CHECKING AUXILIARY

DEVICES
Before disassembling the cylinder head, cle-

an the entire unit thoroughly. The various
elements must be cleaned and named bit by
bit as they are disassembled.
Proceed as follows for disassembly and in-
spection of the cylinder head.
Clamp the cylinder head using protective
jaws, gripping it at the head connection A.
Disassemble the spark plug using the spe-
cial spark plug wrench (code 020440100
Blocking cylinder head on vice. 000).
2 .17.3.1 LUBRICATION JETS AND

1
CENTRING PINS
Pull out the two oil jets 1 for lubricating the cylin-
der head and make sure the holes are free from
any impurity. Take off the O-rings- If damaged,
replace them.
Oil jets 1 for lubrication of cylinder head and two

centring pins 2.
Detail of oil jet lubrication 1.
97
2
2 .17.3.2 FINGER FOLLOWER/SHAFTS UNIT
Disassemble the two caps 1 which keep the fin-

ger follower shafts in place.
Make sure the face of the cap facing the shaft
does not have deep traces or signs of wear. If so,
replace the caps.
Check the state of use of the two O-rings betwe-
en the caps and the cylinder head. We recom-
mend they be replaced.
1
Closing caps for finger follower support shaft seats.
The finger follower shafts have a threaded hole

(M4) at the end so that they can be extracted. To
pull them out, just screw a sufficiently long M4
screw A in this hole and pull out. In this way, the
finger followers can be extracted.
Application of M4 screw to allow pulling out the

finger follower support shafts with your fingers.
Make sure the outside diameters of the

shafts 2 and the inside diameters of the ho-
les on the finger followers 3 respect the fol-
3 lowing service limits:
Shaft service limit: 6.98mm

finger follower service limit: 7.03mm
Play limit: 0.05mm
Check to see that the contact areas between

the finger followers and the calibrated discs,
and between the finger followers and the
2 cams are not chipped or particularly worn.
If so, replace the finger follower.
finger follower /shafts unit.
98
2 .17.3.3 SHIMS (CALIBRATED DISCS) FOR
2
VALVE PLAY ADJUSTMENT

Using a magnet, pull out the calibrated discs
1 from the seats in the cups.
Once the calibrated discs are extracted, me-
asure them with a thickness gauge.
Removal of calibrated discs from seats.
The calibrated discs range from 2.00 to 3.30

according to the intervals carried in the ta-
ble below.
Intervallo
Step [mm]
spessori[mm]
2,000 ÷ 2,300 0,050
2,325 ÷ 3,000 0,025
3,050 ÷ 3,200 0,050
Measure shim.
Once you have done the measurement, take
note and mark the calibrated disc depen-
ding on its original position.
Should the calibrated discs be deteriorated,
replace them with others having the same
dimensions. Thus you can know whether to
replace it with a thicker or thinner calibra-
ted disc when determining the valve play.
99
2 2 .17.4 CYLINDER HEAD:
A DISASSEMBLING AND
CHECKING VALVE UNITS
Clamp the spring removal jaw A (code 0100043

000) and apply the spring removal tool onto it
B (code 006140030 000). Then position the
cylinder head and disassemble the springs.
B
Placing cylinder head on device for di-

sassembling valve springs.
Compress the spring as much as necessary

to extract the half-cones 1.
Extraction of half-cones.
Having extracted the half-cones, release the

spring and extract the cup 2, the spring 3
and the valve 4.
2
3
ATTENTION! Mark all the pieces you disas-

semble. Pay particular attention to the val-
ves.
4
1
Valve unit.
100
2 .17.4.1 SPRINGS
2

Each valve is retained by a spring. The leng-
th of these springs must be checked while
they are loose:
service limit = 42,5mm
Should the springs be shorter, have them

replaced.
Measuring length of free spring.
2 .17.4.2 VALVE GUIDES, VALVES

AND SEATS
Make sure that the valve guides are free

from scratches or any type of nicks. To check
the correct diameter, introduce the gauge in
the valve guides from the side of the com-
bustion chamber (code 006140180 000). If
the gauge can enter, the valve guide must
be replaced at a rectification workshop.
To this purpose, keep to the data carried in
the drawing.
Remember that if replacing the valve gui-
des, the seats of the valves must be repas-
sed as described later on.
Brush the valve mushroom head thoroughly
and degrease the entire valve.
Make sure that the valve stems are free from
scratches or any type of nicks. Measure the
diameter of the valve stems, making sure it
is not less than the service limit:
Valve stem diameter service limit:

Reference dimensions for processing and fitting 5,95mm
valve guide.
If it is, replace the valve. Play between the
valve and the valve guide must not be grea-
ter than the limit carried below:
Play limit between valve and valve guide:

0,08mm
If play is greater, first try to replace the valve.

Should play still not be within the aforementio-
ned limits, intervene on the valve guide.Check
the valve mushroom head zone, making sure
that the area of contact with the seat is not den-
ted: if so, replace the valve.
Check the state of wear of the valve seats and
the sealing surface. In order to do this, apply a
light layer of Prussian blue paint on the contact
zone of the valve with the seat. Then insert the
guide valve until you press it against the seat and
turn it on its own axis.
101
2 Taking the valve out, the paint will be missing in
the contact zone. Its width must not be greater
than the following service limit:
Width service limit of valve seat contact zone:

1,9 mm.
The contact zone can principally take on three

different appearances, as shown in the figure:
A - correct;
B - incorrect (contact face damaged);
C - incorrect (uneven seat width).
A B C
Valve-seat contact conditions: A) Correct; B) Incorrect - contact face damaged-; C) Incorrect - uneven width-.
Also check the correct positioning of the contact

area. It must be neither higher (case D) or lower
(case E).
Should the incorrect conditions described abo-
ve occur, the valve seats must be rectified, re-
D E specting the conditions carried in the following
drawing.
Positioning of contact area: D) too high; E) too low
Geometric features of valves seats.
If the valve seats are beyond recovery, replace

the cylinder head.
102
2 .17.4.3 VALVE STEM SEAL AND LOWER
2
STOP WASHER

Should there be excessive oil consumption
or a white-like exhaust smoke which cannot
be blamed on the oil-scraper rings on the
piston, replace the valve stem seals 1, inten-
ded to prevent excess oil leakage.
1 It is recommended to replace them every
time the cylinder head is overhauled.
In order to replace them, use needle-nose
pliers to pull them out, being careful not to
nick the valve guide.
Once the valve stem seal is extracted, the
2 lower cup can be pulled out 2.
Extraction of valve stem seals from valve stems.
2 .17.5 CYLINDER HEAD: CHECKING

CYLINDER HEAD BODY
Check the flatness between the head and

cylinder coupling surfaces.
This can be done using a rectified block and
a thickness gauge by positioning the block
according to the directions shown in the fi-
gure.
The service limit is:
cylinder head flatness service limit:

Checking flatness of cylinder head. 0.05mm
B Check that the state of use of the sliding

zones A with the camshafts and B of the
C camshaft support bearing housing are free
of scratches or signs of meshing.
Clean the oil passages for lubricating the
cylinder head by blowing compressed air
into the holes C, D and E.
A
E D
103
2
C
2 .17.6 CHECKING CAMSHAFTS
Verify the zones A and B on the camshafts
making sure they have no traces of meshing
or abnormal wear. Make sure the sides of
the teeth C are not chipped or have no trace
of abnormal wear.
The zone A comes into contact with the
A cylinder head becoming part of a hydrody-
B namic support bearing. Zone B on the other
hand supports the roller bearing.
Cam zone to be checked. Make sure that the shafts in the cam zones
are free of abnormal colouring which is typi-
cal when working without oil.
Use a thickness gauge to check the wear li-

mit of the cams referring to the values carri-
ed in the table.
Sometimes the cams show small run marks.
This can be accepted, if the finger followers
are without wear and the cam height is insi-
de the tolerance.
Cam height measurement.
Intake Exhaust
Displacement Nominal size Size limit Nominal size Size limit

[cm³] [mm] [mm] [mm] [mm]
400 34,1 34,0 33,75 33,65

450 33,75 33,65 33,75 33,65
520 33,75 33,65 33,75 33,65
3 Check on the exhaust camshaft that the

D spring 1 of the centrifugal decompressor re-
1 calls the rest of the device so that the cylin-
der segment D of the rod 2 protrudes com-
pletely without any play.
Turn the lever 3 all the way to make sure the
device is not jammed.
104
4
Make sure that the cylinder segment D of
the decompressor is not worn or chipped.
2
Should it be deteriorated, replace the de-

compressor shaft. In order to extract it, re-
move the Benzing ring 4 and pull the shaft
out. Operate inversely to reassemble it. If
replacing the decompressor shaft, replace
the Benzing ring as well.
Extraction of Benzing ring from decompressor shaft.
2 .17.7 CHECKING CAMSHAFTS

C
SUPPORT
The camshafts supports fasten the shafts

so they maintain the correct position whi-
B le operating. The support in the zone A
has a channel B intended to lubricate the
camshaft to allow the hydrodynamic sup-
port of the shaft itself. Therefore you must
A
make sure that the zones A are free from
scratches or traces of corrosion.
Make sure the zones C for housing the rol-
ler bearings have no traces of meshing or
scratches.
Attention: If the support needs to be repla-

ced, the cylinder head must be replaced as
well.
105
2 2 .17.8 CYLINDER HEAD: INSERTION OF
INNER CUP AND VALVE STEM
SEAL
If the lower cups and valve stem seals were

disassembled*, reassemble them as follows.
First insert the lower cup 1 facing the flat
part downwards. Lubricate the upper part of
the valve guide lightly and insert the valve
stem seal 2. Pay close attention that while
inserting the valve stem seal, its axis is ali-
gned with that of the valve guide. The valve
stem seal must be pressed towards the bot-
tom of the cylinder head until it is flush with
the valve guide.
Insertion of lower cup.
Insertion of valve stem seal.
* Remember the valve stem seals must be replaced once

they have been taken off.
106
A 2 2 .17.9 CYLINDER HEAD: ASSEMBLY OF
2
VALVE UNIT

1 Clamp the spring removal jaw A (code
B 0100043 000) and apply the spring removal
tool onto it B (code 006140030 000).
Insert the valve stem in the valve guide*
from the combustion chamber side.
Place the valve in the specific lower housing
of the jaw and introduce:
• The spring 1, being careful to insert it so

that the segment with the smaller pitch
faces downwards;
• The upper cup 2, turning the flatter part
upwards.
Placing cylinder head on device for disassembling

valve springs.
Compress the spring as much as necessary

to extract the two half-cones 3. To facilita-
te their insertion, apply a small amount of
grease on the stem in the half-cone housing
zone.
Spring compression, half-cones insertion. Note the

application of grease on the upper part of the stem.
* If the valves, valves guides and their seats have not been
replaced, the valves must be put back in their original po-
sitions.
107
2 A
REPOSITIONING CALIBRATED
2
DISCS, ASSEMBLY OF FINGER

FOLLOWER SHAFTS AND FINGER
FOLLOWERS AND COUPLING
3
THE SPARK PLUG
Clamp the cylinder head using protective jaws,

gripping it at the head connection A.
Put the calibrated discs 1 back in place in
1 their original positions (if not deteriorated see
par.1.17.3.3).
Insert the finger follower shaft 2 partly in the
Insertion of shaft 1 on outermost finger follower 2. specific seat as much as needed to be able to
insert the outermost finger follower into the
cylinder head first 3. Having fastened the ou-
termost finger follower to the shaft, push the
shaft further until it reaches the seat of the
innermost finger follower. Having coupled the
innermost finger follower to the shaft push it
all the way into the cylinder head.
10Nm
Couple the two caps 4 with the O-rings to

the cylinder head. They must be tightened
at a torque of 10Nm.
Application of two finger follower shaft caps.
Apply the spark plug on the special wrench

17Nm B (code 020440100 000), introduce the unit
in the specific housing and tighten at a tor-
que of 17Nm.
108
1
2 .17.11 CYLINDER HEAD: INSERTION OF
2
2 OIL JETS, CENTRING PINS AND

SPARK PLUG O-RING
Insert the oil jets 1 with the O-rings 2 in

their specific seats on the cylinder head.
A
Oil jet with O-ring. Note the flat part A for reference
on the side of the jet.
The positioning of the jets is univocal than-

ks to the specific flat side.
Apply the centring pins 3 to the cylinder head
and the spark plug seal O-ring 4 between
1 the cylinder head and the camshaft support.
Overhead view of complete cylinder head.
109
2 1
2 .17.12 PISTON: APPLICATION OF PI-
STON RINGS AND OIL-SCRAPER
RINGS
Oil the ring seats abundantly and apply the

central oil-scraper ring in the lower seat of
the piston 1 paying close attention that the
two ends face one another but do NOT over-
lap.
The two ends must be aligned in axis with
the pin bolt.
Application of central oil-
scraper band.
Detail of positioning of two edges.
Apply the two lower 2 and upper oil-scraper

rings 3 and then the compression ring 4.
The two oil-scraper rings must be placed so
4 that their openings face the higher segment
of the skirt and at 180° between them. As-
3 sembly of the compression ring 4 must be
done keeping the reference (letter or num-
ber) facing upwards and the opening must
face the some way as the opening of the
1 lower oil-scraper ring 2.
2
Application of piston rings.
110
5
Use motor oil to lubricate the seats of the
pin bolt and apply the circlip 5 in the left
2
pin bolt seat, positioning its opening either

downwards or upwards.
Application of circlip 5 to piston.
Right In order to identify the right and left side of

the piston, just use as a reference the arrow
A stamped on the piston crown which must
A face the exhaust manifold.
Left
Identification of piston right and left side.
2 .17.13 APPLICATION OF PISTON TO

CYLINDER
To couple the piston to the cylinder, place

A
the cylinder while keeping the top facing
upwards. Oil the cylinder with plenty of mo-
tor oil.
Prepare the ring compression band A (code
006140170000) as shown in the figure.
Press the green locking lever B and turn the
hex key anti-clockwise until the band rea-
ches a dimension near that of the piston.
Oil the inside of the band abundantly and
insert the piston with all its rings inside of
it. Press the green locking lever again and
turn the hex key clockwise to tighten the
B rings and piston well.
Preparation of ring compression band A.
Attention: the compression band has edges

which could be sharp. Be very careful when
handling it.
111
2 C Press the piston downwards having the
higher segment of the skirt protrude a bit
from the band. Rest the unit on the cylinder,
making sure that the contact zones of the

band rest correctly on the cylinder surface.
For this purpose, make sure that the upper
edge C of the band is perfectly aligned with
the contact surface of the cylinder.
Note: When positioning the complete band-

piston unit on the cylinder, be careful to place
them so that the arrow stamped on the crown of
the piston faces the exhaust manifold.
Application of the complete piston band on cylinder.
Holding the band firm with one hand, push

the piston inside the cylinder, making sure
that the axis of the piston is aligned with
that of the cylinder. Towards the end of in-
sertion it might be necessary to use the wo-
oden handle of a hammer or a similar tool
to lightly tap the piston crown in order to
facilitate its complete insertion in the cylin-
der.
Attenzione: Attention: during the whole opera-

tion, hold the band firm with one hand without
moving it. Make sure that the piston rings insert
themselves correctly in the cylinder when pas-
sing through the band. Should there be excessi-
ve resistance when inserting the piston into the
cylinder, do not insist in order not to deteriorate
Insertion of piston in cylinder. the parts. Find out the cause.
When the piston has been inserted into the

cylinder and the band has been removed,
press the piston towards the bottom of the
cylinder so that the pin bolt seats come out
from the lower edge. Apply the pin bolt 1
into the right-hand seat as much as needed
to allow it to be coupled with the connec-
ting rod.
Application of pin bolt to piston.
112
1
2 .17.14 APPLICATION OF PISTON-CYLIN-
2
DER COUPLING TO CRANKCASE

Apply a new piston-cylinder gasket 1 to the
crankcase and couple the two centring bushes
2 to the left crankcase 2.
Lubricate the foot of the connecting rod abun-
dantly with motor oil.
Application of cylinder/crankcase gasket and of cen-

tring bushes.
Insert the timing chain in the proper com-

partment in the cylinder and bring the pi-
ston/cylinder unit close to the connecting
rod.
Passage of chain in cylinder.
113
2 3 Once the pin bolt reaches its housing in the
foot of the connecting rod, push the pin bolt
inside until it is inserted all the way. The
help of an aluminium cylinder (or similar

tool) could be useful at this phase. Place
a clean cloth between the piston and the
crankcase to keep foreign objects or simple
solid residue from falling inside the cran-
kcase.
Apply the circlip 3 in the pin bolt seat (right)
positioning its opening either downwards or
upwards.
Application of circlip on piston coupled to the

connecting rod.
Push the cylinder towards the crankcase

making sure the two centring bushes on the
left crankcase are correctly inserted in the
seats in the lower part of the cylinder.
Coupling cylinder to crankcase.
114
Apply to the cylinder the two guide bushes
4 and the gasket 5 coupling with the cylin-
2
der head.

5
Application of guide bushes 4 and gasket 5 to

cylinder.
2 .17.15 COUPLING HEAD TO CYLINDER

Introduce the timing chain in the compart-
ment on the cylinder head. Keeping the chain
tight, place the head on the gasket making
sure it inserts perfectly into the two centring
bushes on the cylinder.
Lubricate the four washers 8 and insert them
into their specific seats on the outside and
inside of the cylinder head. Then insert the
four M10x1.25 screws 9 - after having lubri-
cated them- and the M6x80 screw 14 which
connect the head and cylinder to the cran-
kcase.
Application of components for coupling cylinder head

and cylinder to crankcase.
IV In two moments, proceed tightening the

II four screws in a criss-cross pattern. Start
with one of the two screws inside the cylin-
der head.
The first tightening can be done at 30÷40Nm,
while the second and last one is fixed at
55Nm.
30÷40Nm 55Nm
The screw 14 must be tightened at a torque
of 10Nm.
Keep the chain lifted so that it does not fall
I inside the chain compartment.
III
10Nm
Tightening order of screws coupling the head and

cylinder to crankcase.
115
2 B 2 .17.16 COUPLING CAMSHAFTS TO
CYLINDER HEAD AND PHASING
Couple the bearings to the camshafts and lu-

bricate them with motor oil.
Widening the timing chain, insert the exhaust
camshaft upon whose gearwheel the timing
chain must be placed. It is advisable already
A in this phase to position the shaft so that the
reference notches A are horizontal with the
cams facing upwards according to the appro-
ximate direction B.
Positioning camshaft.
Lift the camshaft slightly and move the be-

aring so that it is flush with the shoulder C.
Having carried out the above-mentioned
positioning, rest the camshaft on the cylin-
der head.
Positioning camshaft bearing.
Detail of positioning bearing against shoulder C.
116
D
Lift the chain again and insert the intake
camshaft placing the chain on the gearwhe-
2
el. Place the shaft so that the cams face up-

wards according to the approximate direc-
tion D and the references E carved on the
gear are horizontal.
Position the bearing in the same way as for
the exhaust camshaft.
Positioning intake camshaft.
Holding the camshaft still with one hand,

insert an aluminium cylinder F in the hou-
sing of the hydraulic tensioner as far as ne-
eded to be able to push the movable guide
against the timing chain. Make sure that the
notches engraved on the two wheels are
aligned one with the other. Is so, the pha-
sing is correct. If not, release the cylinder F,
lift the timing chain so that the gearwheels
disengage allowing the needed rotation to
obtain correct phasing.
Having checked phasing, extract the cylin-
der F.
F
Phasing check. Note the pressure that the cylinder B
exercises on the chain.
Detail of correct alignment of engraved notches

on gearwheels of camshafts.
117
2 Lubricate the entire camshaft unit with mo-
tor oil and apply the support 1, making sure
it is perfectly engaged both on the shafts and
on the centring pins.
Note: check the presence of the oil jets

(par 1.17.11).
Apply the chain guide 2 and insert the three

M7x38 screws 3 in the holes on the chain
side and the four M7x33 screws 4 in the four
remaining holes.
4
1
Application of camshaft support 1, chain guide 2, three M7x38 screws 3 and four M7x33 screws 4.
118
IV II III
V
Tighten the seven screws by hand until they
are flush. Check the correct position of the
2
camshaft bearings once more (page 116).

Proceed with tightening in two moments,
following the order indicated in the figure.
Carry out the first tightening operation at
8Nm 12Nm
a torque of 8Nm and the second at 12Nm.
At the end of this operation, make sure the
camshaft moves freely.
VI VII
I
Tightening order of camshaft support screws.
2 .17.17 VALVE PLAY

Checking for valve play must be carried
out by placing a thickness gauge A (code
006140210000) in between the cam and
the finger follower. This control can be done
even without the hydraulic tensioner cou-
pled to the engine.
A
Attention:
The piston must be positioned at the Top
Dead Centre (par 1.7)! Following the order
Checking valve play with thickness gauge. of this text, this position is already fixed.
Play must be within the values carried on the

table below.
Minimum Maximum
Side
[mm] [mm]
Intake 0,10 0,175
Exhaust 0,125 0,20
If the play measured is greater than that in-

dicated, the calibrated disc must be repla-
ced with a thicker one. On the contrary, if
the valve play is less than that indicated, re-
place the calibrated disc with a thinner one.
The value of the needed thickness can ea-
sily be assessed by calculating the differen-
ce between the detected play value and the
one required.
The following is a layout for calibrated disc
replacement.
119
2
Check valve play
YES Couple the hydraulic

Is the valve play
correct? tensioner to the
engine (par 2.17.18)
NO
Is the hydraulic NO
Disassemble the
tensioner coupled to camshaft support
the engine? (par 1.1.1)
YES
Disassemble the
hydraulic tensioner
(par 1.1.1) Incorrect play on
NO intake side?
YES
First dissemble the intake Disassemble only the

camshaft and then the intake camshaft
exhaust (par. 1.1.1) (par 1.1.1)
Disassemble the
calibrated disc to be
replaced (par 2.17.3.3)
Couple the camshaft Apply a new disc

support (par 2.17.16) according to
requirements.
First couple the exhaust NO

Has only the intake
camshaft and then the intake
side camshaft been
(par 2.17.16)
disassembled?
Couple the intake YES

camshaft (par 2.17.16)
120
A
2 .17.18 CHECKING AND COUPLING OF
2
HYDRAULIC TENSIONER TO

ENGINE
Before inserting the hydraulic tensioner in it

1 housing in the cylinder, it must be compres-
sed according to the following indications.
Position the tensioner 1 vertically on a flat
surface so that the pressure point A faces up-
2-3mm
wards. Take a 3mm thick washer B and place
its side next to the tensioner. Compress the
tensioner until it is flush with the upper side
of the washer. When releasing the tensioner,
B it must stay blocked without extending.
Preparation for hydraulic tensioner compression.
Compression of hydraulic tensioner.
Insert the compressed tensioner in the spe-

A cific seat C in the cylinder, keeping the pres-
sure point A facing towards the outside of
the engine.
Insertion of hydraulic tensioner in cylinder.
Screw the tensioner cap 28 with the O-ring

27 (which it is advisable to replace) to the
cylinder by hand. In this phase, the small cap
11 with the O-ring 12 must not be mounted.
Exploded view of tensioner unit.

11) O-ring; 12) Small tensioner cap;
26) Tensioner; 27) O-ring; 28) Tensioner cap.
121
2 Insert the special tool
006140050) 0 0 0 i n t h e t e n s i o n e r c a p
D (code
and push it forcefully towards the en-

D
g i n e i n o r d e r t o r e l e a s e t h e t e n s i o n e r.
Once the tensioner is extended, try to
push it again with the special tool D.
Expansion of tensioner by means of special tool D.
Should play be perceived, extract the spe-

cial tool, unscrew the tensioner cap slowly
until it clicks, thus causing a further expan-
CLICK! sion of the tensioner. Screw in the tensioner
cap and use tool D to check the presence
of play once more. If there is, turn the ten-
sioner cap out again until hearing a further
click. After, screw in the cap a check the play
once more
Process for further tensioner expansion.
At the end of the operation, extract the spe-

10Nm cial tool D and tighten the tensioner cap at a
torque of 25Nm.
Apply the small tensioner cap with the O-
ring and tighten it at a torque of 10Nm.
25Nm
Tightening of tensioner cap and small cap.
122
2 .17.19 COUPLING CYLINDER HEAD
2
COVER GASKETS AND CYLINDER

HEAD COVER
Apply the spark plug gasket 1 to the camshaft

support inserting the two pegs A in the spe-
cific seats and positioning it so that it reco-
pies the shape on the support.
Application of spark plug gasket.
Apply a few drops of gasket paste in the ed-

ges of the cylinder head cover gasket 2.
2
Edges where the gasket paste must be applied.
Insert the gasket in the cylinder head cover

so that the protruding part fits perfectly into
the groove in the cover.
Insertion of gasket in groove on cylinder head cover.
123
2 Place the complete cover on the cylinder
head making sure that the gasket covers the
surface correctly.
8Nm Apply the four rubber rings 3 to the cover

and insert the four screws 4 which fasten
the cover to the cylinder head. Tighten the
screws in a criss-cross pattern at a torque
of 8Nm.
3
4
Application of rubber rings 3 and fixing screws 4.
2 .18 COUPLING PINION AND BREA-

60Nm
THER NOZZLE
If the O-ring 25 is not coupled to the secon-

dary shaft (par 1.5), insert it followed by the
spacer 26.
Then apply the pinion 27, the washer 28 and
the screw 29 which must be spread with me-
dium strength threadlocker: tighten at a tor-
que of 60Nm.
Exploded view of pinion. 25) O-ring 25x12x1.78; 26)

Spacer 27) Pinion; 28) Washer; 29) Screw.
Attention: do not use pneumatic devices!
3 Apply the breather nozzle to the left crankca-

se half, first coupling the copper washer 1,
2
then the breather nozzle 2, the copper wa-
sher 1 and the bored screw 3 to be tightened
at a torque of 10Nm.
1
10Nm
Gear oil vapour breather device.
2 .19 RELEASING CRANKSHAFT

Remember that according to the order of
this text, the crankshaft is blocked at the Top
Dead Centre.
It must be released by removing the screw
38 (respectively tool 006140110 000) and
applying the copper washer 37 to screw 38.
Therefore reapply the screw-washer unit,
tightened at a torque of 15Nm.
15Nm
124
2 .20 COUPLING OIL CAPS
2
Couple the motor oil plug 24 with the O-ring

25 in the bottom part of the right crankcase
half. Before inserting it in the drain hole, ap-
ply the wire metal filter 27 with the O-ring
26. Tighten at a torque of 25Nm.
Apply the magnetic screw 28 with the O-ring
29 to the gear oil drain hole: tighten at a
torque of 20Nm.
20Nm
25Nm
EXPLODED VIEW OF OIL DRAIN CAPS.

24) Motor oil drain plug;
25) O-ring 27x2;
26) O-ring 20x1.5;
27) Metal filter;
28) Magnetic screw;
29) O-ring 11x2.5
125
2 2 .21 COUPLING GEARSHIFT LEVER
Couple the gearshift lever to the drive shaft
by positioning it so that the part A of the le-

ver coincides with the upper edge of the oil
level inspection window.
Tighten the screw 1 at a torque of 10Nm af-
ter having applied medium strength threa-
dlocker.
10Nm
Positioning of gearshift lever.
126
TABLE OF TIGHTENING TORQUES OF ENGINE COMPONENTS
Fixing
Threading diameter x
length [mm]
Quantity Threadlocker
Torque
[Nm]
Notes
2

Outside right crankcase half
Loctite 243/
Oil seal fixing plate M5 x 10 2 6
Sichel 100M
Loctite 243/
Oil incline M5 x 10 2 6
Sichel 100M
Loctite 243/
Kickstart ramp M6 x 20 2 10
Sichel 100M
Inside right crankcase half
Crankshaft bearing fixing Loctite 243/
M6 x 14 2 8
plates Sichel 100M
Main gearbox shaft Loctite 243/

M5 x 10 2 6
bearing fixing plate Sichel 100M
Secondary gearbox shaft Loctite 243/

M5 x 10 2 6
bearing fixing plate Sichel 100M
Desmodromic gearshift Loctite 243/

M5 x 8 1 6
bearing fixing Sichel 100M
Outside left crankcase half

Countershaft bearing Loctite 243/
M5 x 10 10 6
fixing Sichel 100M
Loctite 243/ Tighten all
Calibrated screw M5 1
Sichel 100M the way
Loctite 243/ Tighten all
Oil jet M4 1
Sichel 100M the way
Inside left crankcase half
Crankshaft bearing Loctite 243/
M6 x 14 2 8
fixing plates Sichel 100M
Crankcase half
M6 x 75 2 10
coupling
Crankcase half
M6 x 65 13 10
coupling
Crankshaft
Loctite 243/
Left-hand side nut M32 1 150
Sichel 100M
Loctite 243/ Left
Right-hand side nut M20 1 150
Sichel 100M threading
Crankshaft blocking M8x16 1 15
Gearshift
Loctite 243/
Stop cam M6 x 30 1 10
Sichel 100M
Loctite 243/
Stopping device lever M6 x 20 1 10
Sichel 100M
Loctite 243/
Gearshift lever M6 x 25 1 10
Sichel 100M
Electrical starter device
Loctite 243/
Torque limiter M6 x 25 1 10
Sichel 100M
Loctite 243/
Start motor M6 x 20 2 10
Sichel 100M
127
2 Fixing
Threading
diameter x length
[mm]
Quantity
Engine lubrication
Threadlocker
Torque
[Nm]
Notes
Loctite 243/
Oil pump covers M5 x 10 6 6

Sichel 100M
Oil pump control idler Loctite 243/

M5 x 20 2 6
gears support pins Sichel 100M
Oil pressure control

M12 x 10 1 20
screw
Paper oil filter cap M5 x 16 2 6
Countershaft
Loctite 243/
Locking nut M12 1 60
Sichel 100M
Clutch
Inner hub / clutch Loctite 243/
M18 1 150
basket Sichel 100M
Clutch pressure cap M6 x 25 4 10
Clutch actuator M6 x 20 2 10
Clutch actuator M6 x 30 1 10
Outer clutch cover M6 x 25 6 10
Outer clutch cover M6 x 30 1 10
See water
Inner clutch cover M6 x 25 9 10 pump cover
screws as well
Water pump
Loctite 243/
Impeller blind nut M6 1 10
Sichel 100M
Cover M6 x 40 4 10
Timing chain guards
Fixed and movable Loctite 243/
M6 x 25 2 10
guides Sichel 100M
Chain guide on Loctite 243/
M5 x 10 1 6
flywheel cover Sichel 100M
Loctite 243/
Chain guard M6 x 20 2 10
Sichel 100M
Ignition system
Loctite 243/
Pick-up M5 x 12 2 6
Sichel 100M
Loctite 243/
Stator winding M6 x 25 2 8
Sichel 100M
Loctite 243/
Flyweel M12 1 60
Sichel 100M
Spark plug M12 1 17
Cover M6x25 9 10
128
Fixing
Threading
diameter x
length [mm]
Quantity Threadlocker
Cylinder head
Torque
[Nm]
Notes 2

Finger follower shaft caps M10 2 10
Lubricate threading
Cylinder head M10 4 40 55 and washers. Follow a
criss-cross pattern
Cylinder head M6 1 10
Follow a criss-cross
Camshaft support M7 x 38 3 8 12
pattern
Follow a criss-cross
Camshaft support M7 x 33 4 8 12
pattern
Loctite 243/
Exhaust flange stud M8 x 30 2
Sichel 100M
Electric fan sensor M12 1 20
AIS valve fitting M10 1 10
Cover M6 x 12 4 8
Hydraulic tensioner
Tensioner cap M24 1 25
Small tensioner cap M10 1 10
Chain pinion
Loctite 243/ Do not use
Pinion M10 x 18 1 60
Sichel 100M pneumatic devices!
Gearbox oil vapour breather
Bored screw M10 1 10
Oil drains
Motor oil plug M30 1 25
Magnetic screw gearbox

M14 1 20
oil plug
Kickstarter
Loctite 243/ Do not use
Kickstart lever M8 x 26 1 25
Sichel 100M pneumatic devices!
ENGINE/FRAME TABLE OF TIGHTENING TORQUES

Threading Torque
Fixing diameter x Quantity Threadlocker Notes
worm [mm] [Nm]
Front engine pin M10x1,25 1 60
Lower engine pin M10x1,25 1 60
Swingarm pivot M16x1,5 1 125
129
2 RECOMMENDED ENGINE MAINTENANCE
The required engine maintenance is strongly depending on the level of use and on the accordingly done
periodic checks and service. The below mentioned maintenance intervals are for standard competition
use, subject to the condition that the engine was never running under extraordinary conditions and the
periodic service was done accurately.
30h 60h 90h 120h 150h 180h

200l 400l 600l 600l 800l 1200l
Clutch disc wear I I S I I S
Clutch springs length I I S I I S
Gearbox bearing
- - S - - S
(crankcase side)
Clutch hub/basket wear I I I I I I
Cylinder wear - - I - - I
Piston and segments - - S - - S
Camshaft wear - - I - - I
Valve springs - - I - - S
Valves - - I - - I
Valve guide wear - - I - - I
Connecting rod - - S - - S
Countershaft bearings - - S - - S
Crankshaft bearings - - S - - S
Wear of complete gearbox

- - I - - I
including gearshift
Pressure control valve

- - I - - I
spring length
I = INSPECT AND REPLACE IN CASE OF NECESSARY S = REPLACE
RECOMMENDED LUBRICANTS AND LIQUIDS

APPLICATION PRODUCT QUANTITY
Gearbox and clutch BARDAHL GEAR BOX 20W40 800 ml (1000ml) *#
Engine BARDAHL XTC 10W50 800 ml*
COOLANT BARDAHL ANTIFREEZE PLUS 1,300ml*
* Refer to Use and Maintenance Manual for levels

# In case of extensive clutch use (under hard e.g. sandy/muddy conditions) we recommend ti use an increased oil
quantity of 1000ml
130
NOTE:
131
2

Manuale Officina Beta 400

Uploaded by

Copyright:

Available Formats

Manuale Officina Beta 400

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manuale Officina Beta 400

Uploaded by

Copyright:

Available Formats

www.betamotor.

1.5.3 Low-pressure oil pump and by-pass valve 27

1.5.4 Oil pressure control valve 28

1.5.5 Paper oil filter 28

1.7 PRIMARY GEAR 30

1.8 ELECTRIC IGNITION 31

1.8.1 Start motor 31

1.10 EXTERNAL GEARSHIFT UNIT 35

CRANKSHAFT, GEARBOX UNIT AND

1.11.1 Nut on left side of crankshaft 36

1.11.2 Opening crankcase 36

1.11.4 Internal gearshift unit and complete gearbox 38

1.12 DISASSEMBLY OF PARTS FROM CRANKCASES 40

1.12.1.1 Right crankcase half 40

1.12.2.1 Inner oil filter 42

Cylinder head: disassembling camshaft support, 2.1 CRANKCASE HALVES 44

2.6 CLOSING ENGINE BLOCK 62 2.17.2 Checking the cylinder 96

BLOCKING THE CRANKSHAFT AT THE TOP DEAD 2.17.2.1 Assembly clearance 96

2.16 IGNITION SYSTEM 90

We respect and defend the environment

• Beforedisassembling, clean the motorcycle • Alwaysreplace parts such as gaskets, O-rings

TECHNICAL FEATURES OF ENGINE

4-stroke single-cylinder liquid-cooled with counter-

Bore x stroke RR 400 95x56.2

Displacement [cm³] RR 520 497,9

Front engine guard fixing screw.

Back engine guard fixing screws.

Remove the screw 2 to empty the motor oil.

Screw 2 for draining motor oil and 3 for draining

Disconnect the water hoses on the engine

Screw 4 for draining coolant.

Loosen the screw 5 that fastens the kickstar-

Once the engine has been unfastened and

2 1.1 THERMAL UNIT

The four screws 1 of the cylinder head cover 2.

2 Remove the 4 screws 1, the cylinder head

The cylinder head cover 2 and the four gaskets 3.

Remove the spark plug gasket 4 and the co-

Spark plug gasket 4 and cylinder head cover gasket 5.

Crankshaft blocking screw 6 with copper washer 7.

After having engaged the 6th gear, turn the

Rotation of transmission shaft.

Rotate the transmission shaft in that posi-

In this way the crankshaft is blocked, by me-

A chain which is not well-tensioned can cause:

The engine is equipped with a hydraulic tensio-

Hydraulic chain tensioner.

1 1 .1.2 CYLINDER HEAD:

To remove the camshafts, disassemble the

Fixing screws 1 camshaft support 2 and chain guide 3

Attention: disassemble the camshafts only

Uncoupling camshaft support 4 from cylinder head.

When uncoupling, be careful of the two cen-

Two centring pins 4 and spark plug housing O-ring 5.

Lift the intake camshaft 1, pull out the bea-

Attention: the hydraulic tensioner must al-

Removal of intake camshaft 1, bearing 2.

In order to remove the exhaust camshaft 4,

Camshafts (G intake, H exhaust) with bearings.

ATTENTION: make sure the chain does not