LEOPARD 125cc - RL - TaG

ENGINE OVERHAULING
MANUAL

01/10/03 1 MAN-026
 INDEX

Page
1. – LEOPARD 125cc ENGINE DISASSEMBLY 1

2. - CRANKSHAFT DISASSEMBLY/ ASSEMBLY 8

2.1- CRANKSHAFT DISASSEMBLY 8

2.2- CRANKSHAFT ASSEMBLY 10

3. – LEOPARD 125cc ASSEMBLY 13

4. - CHECK CYLINDER TIMING & COMBUSTION CHAMBER 24

VOLUME

ATTACHMENTS

- FASTENER TORQUE VALUE

- CROSS PATTERN LOCKING ORDER ON CRANKCASE

- MAIN PRESCRIPTIONS

- LITTLE/BIG END CONROD BEARING MATCHING PLAY

- OVERHAUL TOOLS LIST

- DRAWING S725/1

01/10/03 2 MAN-026
 1 – LEOPARD 125cc ENGINE DISASSEMBLY

OPERATION TOOLS REQUIRED

INSERT 2 SCREWS M8X60 ON BOTTOM OF -VICE ON BENCH ( TOOL AS PER DRAW. S725/1)
1. CRANKCASE TO POSITION MOTOR ON
BENCH
- 12 POINT WRENCH - 10mm
2. REMOVE EXHAUST PIPE AND EXHAUST
GASKET (see Fig.1):
-3 M6 EXHAUST NUTS Fig.1
-3 WASHERS

3. REMOVE CLUTCH: - 5mm ALLEN

- PISTON FITTING: P.N. 10271
-REMOVE CLUTCH COVER - 12 POINT WRENCH 17mm
3 SCREWS M6 (see Fig.2). - CLUTCH WRENCH: P.N. 10270
REPLACE SPARKPLUG WITH SPECIAL - 12 POINT 24mm
PISTON FITTING (see Fig.3). - 12 POINT WRENCH 19mm
ROTATE CRANKSHAFT UP TO TDC SO - CLUTCH PULLER: P.N. B-55614-C
THAT CRANKSHAFT DOES NOT ROTATE - 12 POINT WRENCH 10mm
WHEN REMOVING THE 1Omm NUT.
Fig.2

Fig.3

1 MAN-026
-REMOVE 10mm NUT
(see Fig.4)

-REMOVE OUTER WASHER , ROLLER

CAGE, CLUTCH DRUM AND INNER
WASHER.

Fig.4
-REMOVE THE PISTON FITTING AND USING
THE CLUTCH WRENCH, REMOVE THE
CLUTCH FIXING NUT (see fig.5).
Fig.5

ATTENTION:
TURN CLOCKWISE AS NUT HAS LEFT
THREAD.

-REMOVE SAFETY WASHER

APPLY CLUTCH PULLER ON CLUTCH AND

REMOVE CLUTCH WITH 19mm SOCKET (see
Fig 6).

REMOVE KEY FROM SHAFT SEAT.

-REMOVE THE START RING FROM THE

CLUTCH Fig.6
3 SCREWS M6 (see Fig.7).

Fig.7

2 MAN-026
 - 4mm ALLEN
4. - REMOVE THE CARB MANIFOLD
4 SCREWS M6X25
4 WASHERS (see fig. 8)

REMOVE THE REED PACK GASKET - Fig.2

OUTER.

Fig.8

-REMOVE THE REED PACK

(see Fig. 9)

-REMOVE THE REED PACK GASKET -

INNER

Fig.9

5. REMOVE THE IGNITION: - 4mm ALLEN

- 5mm ALLEN
- 13mm HEXAGON RING WRENCH
-PISTON FITTING: P.N. 10271

-REMOVE THE IGNITION COVER Fig.10

3 SCREWS M6X18 (see Fig.10)

Fig.11
-REMOVE STATOR
4 SCREWS M5X25 (see Fig.11).

-INSTALL THE PISTON FITTING AND

REMOVE SELF LOCKING NUT M8 WITH
KNURLED WASHER.

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 -REMOVE ROTOR (see Fig.12) Fig.12

- 5mm ALLEN
6. -UNLOOSE THE SCREW M6X30 ON THE
STARTER SUPPORT Fig.13
(see Fig.13)

- REMOVE THE STARTER SUPPORT

Fig.14
3 SCREWS M6X25 (see Fig.14).

- 5mm ALLEN
7. - REMOVE THE STARTER ASSEMBLY
4 SCREWS M6X45 (see Fig.15). Fig.15

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-REMOVE STARTER FROM SUPPORT Fig.16
3 SCREWS M6X35 (see Fig.16/17).

Fig.17
- REMOVE THE COUNTERSHAFT
SUPPORT COVER
3 SCREWS M6X25 (see Fig.18). Fig.18

- EXTRACT THE COUNTERSHAFT FROM

THE SUPPORT Fig.19
(see Fig.19).

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 8. REMOVE THE HEAD: - 13mm SOCKET T TYPE

-LOOSEN NUTS BY ½ TURN (CROSS

PATTERN DISASSEMBLY) AND THEN
REMOVE:
4 NUTS M8
4 WASHERS
4 O-RINGS Ø7.65mm ON STUDS
1 O-RING Ø60mm HEAD INTERNAL DIAM.
1 O-RING Ø123.5mm HEAD EXTERNAL DIAM

9. REMOVE CYLINDER (see Fig.20). Fig.20

10. REMOVE CYLINDER GASKET.

-SCREWDRIVER WITH ROUNDED EDGES
11. REMOVE CIRCLIPS FROM PISTON (see
Fig.21) Fig.21

ATTENTION:
DO NOT SCRATCH PISTON OR CIRCLIP
SEATS.

12. REMOVE PISTON PIN, PISTON AND CAGE PISTON PIN PUNCH P.N. 10200
USING THE PISTON PIN PUNCH (see Fig.
22).
Fig.22

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13. OPENING THE CRANKCASE: - 5mm ALLEN
- PLASTIC MALLET
-REMOVE 7 FIXING SCREWS
(see Fig.23)
4 SCREWS M6X40
Fig.23
3 SCREWS M6X50

-OPEN THE CRANKCASE (USING A

PLASTIC MALLET)
AVOID CRANKSHAFT FROM FALLING.

- REMOVE OIL SEALS, USE A

SCREWDRIVER (see Fig.24) Fig.24

-REMOVE BEARINGS (if necessary)

HEAT HALFCRANKCASES AT 70°
Fig.25
OR USE PRESS AND SPECIAL
PUSHER AS PER DRAW. S725/1 (see
Fig.25).

-REMOVE SHIMS.

14. OPEN CRANKSHAFT ONLY WITH SPECIAL

TOOL.

ATTENTION:
THIS OPERATION CAN BE PERFORMED
ONLY BY AN AUTHORIZED SERVICE
CENTER.

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 2 – ENGINE CRANKSHAFT DISASSEMBLY/ASSEMBLY

ATTENTION:
THE DISASSEMBLY/ASSEMBLY OPERATIONS ON THE ENGINE CRANKSHAFT, MUST BE
PERFORMED ONLY BY AN AUTHORIZED SERVICE CENTER USING THE SPECIALLY DESIGNED
TOOLS. USE OF UNFITTED TOOLS OR OPERATIONS PERFORMED BY UNSKILLED PERSONNEL
MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR.

TOOLS DESCRIPTION LEOPARD 125cc P.N.

CRANKSHAFT ASSEMBLY KIT 10110-C
CRANKPIN BUSH ( INCLUDED IN 10110-C) 10150
CRANKSHAFT DISASSEMBLY KIT INCLUDES 10100-C2
- CRANKSHAFT SUPPORT/ DISASSEMBLY TOOL 10100
- CRANKSHAFT PLATE / DISASSEMBLY TOOL 10104
- CRANKSHAFT INSERT 10106
- CRANKPIN PUSHER 10107

2.1 – CRANKSHAFT DISASSEMBLY OPERATIONS

OPERATIONS TOOLS REQUIRED

- 5 MeT PRESS
1. PLACE THE DISASSEMBLY TOOL UNDER
THE PRESS. DISASSEMBLY KIT P.N. 10100-C2

2. PLACE THE CRANKSHAFT IN THE TOOL

INSERTING THE CRANKSHAFT PLATE (P.N.
10104) BETWEEN THE CRANKSHAFT
HALVES (see Fig.1).

Fig.1

3. INSERT THE CRANKSHAFT INSERT (P.N.

10106) AND USING THE CRANKPIN
PUSHER (P.N.10107) PRESS THE CRANKPIN
OUT (see Fig.2).

Fig.2

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4. DISASSEMBLE THE COMPLETE CONROD
WITH WASHERS.
REPEAT THE OPERATIONS TO EXTRACT
THE CRANKPIN FROM THE OTHER HALF
CRANKSHAFT (see Fig.3).

Fig.3

BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE

a) CHECK STATUS OF CONROD-TOP -0.01 CENTESIMAL MICROMETER (21/50)

AND BOTTOM .
IF OVALIZATION EXCEEDS 0.01mm. -0.001 BORE GAUGE WITH CHECK RING Ø 24 AND Ø18 DIAM.
REPLACE CONROD

b) CHECK STATUS OF CRANKPIN

VISUAL CHECK – REPLACE IF
NECESSARY BUT ALWAYS AFTER
MAX. 4 WORKING HRS.

c) CHECK STATUS OF ROLLER CAGE

(BIG END) VISUAL CHECK – REPLACE
IF NECESSARY BUT ALWAYS AFTER
MAX 4 WORKING HRS.

d) CHECK STATUS OF CRANKSHAFT

HALVES.
REPLACE IF BEARING SEAT IS
BELOW 0.030 VS. NEW.

e) CHECK STATUS OF SILVER WASHERS

VISUAL CHECK – REPLACE IF
NECESSARY.

FOLLOW ATTACHED TABLE FOR MAX. MATCHING PLAY FOR CON-ROD, CRANKPIN, CAGE

9 MAN-026
 2.2 – CRANKSHAFT ASSEMBLY OPERATIONS

OPERATION TOOLS REQUIRED

1. PLACE THE CRANKSHAFT ASSEMBLY
- 5 MeT PRESS
TOOL (P.N. 10110-C) UNDER THE PRESS,
-CRANKSHAFT ASSEMBLY KIT ( P.N. 10110-C)
VERTICALLY.
PLACE THE CRANKSHAFT HALF INTO THE
2. ASSEMBLY TOOL.

3. OIL CRANKPIN AND CRANKPIN HOLE ON

CRANKSHAFT HALF.

4. PLACE CRANKPIN WITH CRANKPIN BUSH

(P.N. 10150) ON CRANKSHAFT HALF
(see Fig.1).

Fig.1

5. BRING UPPER PLATE OF TOOL IN

CONTACT WITH CRANKPIN (see Fig.2).

Fig.2

6. PROGRESSIVELY PRESS UNTIL

CRANKPIN IS COMPLETELY DRIVEN IN (see
Fig.3).

Fig.3

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7. EXTRACT BUSH FROM CRANKPIN AND Fig.4
PUT TOOL IN HORIZONTAL POSITION
(see.Fig.4).

8. INSERT ON CRANKPIN:
(OIL CRANKPIN)

-SILVER WASHER
-CON-ROD WITH ROLLER CAGE
-SILVER WASHER
(see Fig.5)

ATTENTION:
ROLLERS ARE FREE IN THE CAGE.
PREVENT ROLLERS FROM FALLING FROM
THE CAGE WHEN INSERTING ON
CRANKPIN.

Fig.5

9. PLACE SECOND CRANKSHAFT HALF IN

THE SEAT OF THE COUNTERPLATE
(see Fig.6).

Fig.6

10. BRING THE TWO PLATES CLOSE UNTIL Fig.7

THE TOOL IS HAND PRESSED (see Fig.7).

11 MAN-026
11. OIL CRANKPIN AND CRANKPIN HOLE ON
CRANKSHAFT HALF.

12. PUT TOOL IN VERTICAL POSITION

(see Fig. 8).

Fig.8

13. PROGRESSIVELY PRESS THE TWO

CRANKSHAFT HALVES TOGETHER.

14. OPEN THE TOOL. PUT IT IN HORIZONTAL

POSITION AND EXTRACT THE
CRANKSHAFT.

15. CHECK THE AXIAL PLAY OF THE CONROD

(see Fig.9). IT MUST BE MIN.. 0.3mm / MAX.
0.7mm.
IF PLAY IS HIGHER OR LOWER, REBUILD
THE CRANKSHAFT.

Fig.9

AFTER ASSEMBLING THE CRANKSHAFT, IT MUST BE ALIGNED. IF NOT, EXCESSIVE

VIBRATION, HARD STARTING OR POOR ACCELERATION WILL RESULT.

a. PLACE THE CRANKSHAFT BETWEEN THE - CENTERS WITH DIAL GAUGES

CENTERS WITH DIAL INDICATORS - COPPER HAMMER
READING ON FRONT AND REAR BEARING
JOURNALS (see Fig.10).

Fig.10

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b. ROTATE CRANKSHAFT AND LOOK AT
DEFLECTION OF GAUGE NEEDLES. THE
DEFLECTION MUST BE, AFTER CENTERING,
MAX. 0.01mm (see drawing).

c.
ADJUST ALIGNMENT WITH COPPER Fig.11
HAMMER, IF NECESSARY (see Fig.11).

3 – LEOPARD 125cc ENGINE ASSEMBLY

BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE

OPERATIONS REQUIRED TOOLS

CRANKCASE REASSEMBLY:
1.

a) CHECK STATUS OF CRANKCASE

BEARINGS. Fig.1
VISUAL CHECK.
REPLACE AFTER 5 HRS MAX.

b) PLACE CRANKSHAFT HALVES UNDER

PRESS (OR HEAT CRANKCASE HALF AT
70°C).

c) INSERT BEARING SHIMS

(see Fig.1).

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 -SPECIAL TOOL AS PER DRAWING S725/1
d) INSERT BEARINGS – BALLS TO BE ON
UPPER SIDE AND VISIBLE DURING THE Fig.2
ASSEMBLY .
USE TOOL AS PER DRAWING S725/1
(see Fig.2/3).

Fig.3

e) INSERT CRANKSHAFT AFTER OILING Fig.4

THE CRANKSHAFT SEAT IN THE
CRANKCASE – CRANKSHAFT MUST BE
IN SAME POSITION AS IN ORIGINAL
INSTALLATION (see Fig.4)

Fig.4
f) ASSEMBLE CRANKCASE (see Fig.5). - 5mm ALLEN – (SEE DRAWING)
-n°4 SCREWS M6X40
-n°3 SCREWS M6X50 Fig.5
CROSS PATTERN ASSEMBLY
TORQUE AT 10 Nm MAX.

Fig.5

14 MAN-026
 ATTENTION:
AS FIRST STEP ASSEMBLE CRANKCASE
WITH 4 SCREWS ONLY AND CHECK
CRANKSHAFT AXIAL PLAY (see Fig.6)
TO BE 0.20 ±0.05mm, IF LOWER OR HIGHER
DISASSEMBLE THE CRANKCASE, EXTRACT
THE BEARINGS AND USE DIFFERENT STEEL
SHIMS (0.10/0.15/0.20) TO RECOVER PLAY.
SHIMS MUST BE EQUALLY POSITIONED.

Fig.6

ONCE THE CORRECT PLAY IS ACHIEVED,

DISASSEMBLE THE CRANKCASE AND
APPLY FLUID GASKET (Motorseal or
equivalent) ON CRANKCASE HALVES AFTER
CAREFULLY CLEANING THE SURFACES
WITH DILUENT. BE CAREFUL TO CLEAN
EVENTUAL EXCESS OF PRODUCT (see Fig.7).

Fig.7

OIL CRANKSHAFT SEAT BEFORE INSERTION

(see Fig.8).

Fig.8
-SPECIAL TOOL AS PER DRAWING S725/1
2. APPLY SPECIAL LUBRICANT ON OIL SEAL
LIPS AND INSERT OIL SEALS (MARK ON
SEAL TO BE OUTSIDE) (see Fig. 9).

Fig.9

15 MAN-026
 INSTALL THE OIL SEALS BY MEANS OF THE Fig.10
TOOL – DRAW S725/1 (see Fig.10).

ATTENTION:
THE OIL SEAL MUST BE REPLACED AFTER
MAX. 4 HRS AND ALWAYS WHEN
DISASSEMBLED.

INSTALL PISTON
3. a) CHECK STATUS OF ROLLER CAGE.
CAGE MUST BE REPLACED EVERY 4
Fig.11
HRS.
b) CHECK STATUS OF PISTON PIN.
PISTON PIN MUST BE REPLACED WHEN
REPLACING PISTON.
SEE ATTACHMENT ON MATCHING
SELECTIONS.

c) INSTALL RING ON THE PISTON.

ATTENTION:
CHECK FIRST THE PISTON RING END GAP
USING A THICKNESS GAUGE.
MEASURE THE END GAP OF THE PISTON
RING WHEN INSERTED IN THE CYLINDER
GAP SHOULD BE 0.25 ÷ 0.30mm (see Fig.12) .
REPLACE THE PISTON RING IF THE END GAP Fig.12''
EXCEEDS 0.4mm.

d) INSTALL PISTON.

ATTENTION:
PLAY BETWEEN PISTON AND LINER MUST
BE 0.11 / 0.12mm.
IF PLAY IS HIGHER THAN 0.14mm
REPLACE PISTON.
FOLLOW ATTACHED INSTRUCTIONS FOR
CORRECT MATCHING,
PISTONS ARE MEASURED AT 17.5mm FROM
THE BOTTOM OF THE PISTON (see Fig.12
attachment).
ALWAYS REPLACE PISTON COMPLETE WITH
RING. Fig.13

e) MATCH PISTON, WRISTPIN, CAGE

FOLLOWING THE PLAYS SHOWN ON
THE ATTACHMENT AND INSERT PIN
AND CAGE ON PISTON.
MAKE SURE THAT ARROW ON TOP OF
PISTON IS TOWARDS EXHAUST.
AS A GENERAL RULE WRISTPIN MUST BE
FORCED IN HOLE. IF WRISTPIN IS LOOSE ,
REPLACE IT WITH A HIGHER DIAMETER PIN.

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 f) POSITION CIRCLIP ON TOOL. GREASE - SPECIAL TOOL P.N. 10120
TOOL TO KEEP CIRCLIP IN PLACE
(see fig,14).

g) INSERT CIRCLIP (see Fig.15).

CHECK THAT CIRCLIPS ARE IN SEAT.

Fig.14

Fig.15

4. INSTALL A NEW CYLINDER GASKET.

5. INSTALL CYLINDER. HAVE FIRST A VISUAL

CHECK (see Fig.16). Fig.16

OIL CYLINDER AND PISTON.

6. CHECK STATUS OF CYLINDER HEAD, CLEAN

FROM DEPOSITS.
DO NOT SCRATCH COMBUSTION CHAMBER.

7. INSTALL HEAD: - 13mm SOCKET T TYPE

4 O-RINGS Ø7.65mm ON STUDS
1 O-RING Ø60mm HEAD INTERNAL DIAM.
1 O-RING Ø123.5mm HEAD EXTERNAL DIAM.
4 NUTS M8 WITH WASHERS
CROSS PATTERN ASSEMBLY
TORQUE AT 18 Nm

17 MAN-026
BEFORE ASSEMBLING THE CLUTCH, WASH WITH DILUENT THE SHAFT TAPER, THE CONNECTING HOLE ON
THE CLUTCH BODY. THE CLUTCH DRUM AND STARTER RING.

- 10mm SOCKET-DYNAMOMETRIC
8. INSTALL THE CLUTCH

a) INSTALL THE STARTER RING ON THE

CLUTCH BODY BY MATCHING THE 3
HOLES AND THE DRAGGING PIN
(3 SCREWS M6).
TORQUE AT 10 Nm AND APPLY LOCTITE
ON THREADS (see Fig.17/18).

ATTENTION:
MAKE SURE TO ALWAYS INSTALL THE Ø 7
DRAGGING PIN , AS OTHERWISE, THE
EVENTUAL KICKBACKS COULD BREAK THE
SCREWS.

Fig.17

Fig.16
Fig.18

b) INSERT KEY ON SHAFT (see Fig.19).

Fig.19

c) INSTALL THE CLUTCH BODY AND

CONE SAFETY WASHER (see Fig.20).

Fig.20

18 MAN-026
 -LOCK WRENCH: P.N. 10270
d) INSTALL THE 16x1 NUT USING THE -HEXAGON RING WRENCH 24mm
CLUTCH WRENCH (see Fig.21).
TORQUE AT 40÷50 Nm. Fig.21

ATTENTION:
TURN COUNTERCLOCKWISE AS NUT HAS
LEFT THREAD.

e) INSTALL THE INNER WASHER

(see Fig.22).

ATTENTION:
INSTALL WASHER WITH BEVEL TOWARDS
INTERNAL PART OF ENGINE.

CLEAN ROLLER CAGE AND GREASE IT

BEFORE INSTALLING ON THE CRANKSHAFT
(see Fig.23).

Fig.22

Fig.23

f) INSTALL THE CLUTCH DRUM AND Fig.24

EXTERNAL WASHER. (see Fig.24).

ATTENTION:
INSTALL WASHER WITH BEVEL TOWARDS
SHAFT.

19 MAN-026
g) INSTALL THE PISTON FITTING - PISTON FITTING: P.N. 10271
ROTATE CRANKSHAFT UP TO TDC SO - 17mm SOCKET
THAT CRANKSHAFT DOES NOT
ROTATE.

INSTALL 1Omm NUT (see Fig.26). Fig.25

TORQUE AT 30 ÷ 40 Nm.

Fig.26

h) INSTALL CLUTCH COVER - 5mm ALLEN

3 SCREWS M6 (see Fig.27).
TORQUE AT 8÷10 Nm,

Fig.27

20 MAN-026
9. INSTALL THE IGNITION: - PISTON FITTING: P.N. 10271

a) INSTALL PISTON FITTING ON HEAD.

b) INSERT KEY ON SHAFT Fig.28

(see Fig.28).

- 13mm SOCKET
c) INSTALL IGNITION ROTOR ON SHAFT
(WITH TIMING PLATE TOWARDS THE Fig.29
EXTERNAL) (see Fig.29).

INSTALL THE KNURLED WASHER AND

THE SELF LOCKING NUT M8.
(see Fig.30).
TORQUE AT 18÷22 Nm.

Fig.30

- 4mm ALLEN
d) INSTALL STATOR
4 SCREWS M5X25 (see Fig.31).
Fig.31

21 MAN-026
 - 5mm ALLEN
e) INSTALL IGNITION COVER
3 SCREWS M6X18 (see Fig.32). Fig.32

10. INSTALL THE REED PACK:

a) INSTALL THE INNER GASKET.

b) INSTALL REED PACK

(WITH “IAME” ON THE TOP)
(see Fig.33).

ATTENTION:
FIRST CHECK STATUS OF REED PETALS.
REPLACE IF PETALS ARE CRACKED OR, IF
LOOKING WITH BACK LIGHT, THE PETALS
DO NOT SHUT PERFECTLY, LOOSEN THE 8
SCREWS AND INSERT PETALS WITH
BOTTOM CUT TOWARDS RIGHT).

Fig.33

- 4mm ALLEN
c) INSTALL OUTER GASKET .MAKE SURE
THAT HOLE ON GASKET MATCHES
WITH CARBURETOR PRESSURE HOLE
ON REED PACK.

d) INSTALL CARB. MANIFOLD

4 SCREWS M6X25 WITH WASHERS
(see Fig.34).

Fig.34

11. INSTALL THE STARTER ASSEMBLY:

a) INSTALL STARTER COUNTERSHAFT

IN THE STARTER SUPPORT.
(see Fig.35).

Fig.35

22 MAN-026
 - 5mm ALLEN
b) INSTALL THE COUNTERSHAFT
SUPPORT
3 SCREWS M6X25 (see Fig.36).

Fig.36

c) INSTALL STARTER. OIL THE “OR” AND

PRESS THE STARTER IN SEAT. MAKE
SURE THAT GEARS ENGAGE.
3 SCREWS M6X35 (see Fig.37).

d) INSTALL THE STARTER ASSEMBLY ON

ENGINE.
Fig.37
4 SCREWS M6X45 (see Fig.38).
Fig.38

e) INSTALL THE STARTER SUPPORT

3 SCREWS M6X25 (see Fig.39).

Fig.39

23 MAN-026
 f) TORQUE THE FIXING SCREW - 5mm ALLEN
1 SCREW M6X30 (seeFig.40).
Fig.40

4– CHECK CYLINDER TIMING AND COMBUSTION CHAMBER VOLUME

1. CHECK THE TIMING: - SPECIAL TOOL : P.N. 10192

REMOVE HEAD CLEAN THE CYLINDER. Fig.1

2. INSERT SPECIFIC TOOL (P.N.10192) FROM

TOP.
(see Fig.1).

3. THE GAUGE IS “NO GO ” BOTH ON THE

EXHAUST AND ON THE INLET SIDE. (see
drawing).

1. CHECK THE COMBUSTION CHAMBER -GRADUATED BURET

VOLUME -VOLUMETER P.N. 10277

REMOVE THE HEAD AND CLEAN THE

COMBUSTION CHAMBER FROM OIL
DEPOSITS WITHOUT SCRATCHING IT.

24 MAN-026
2. PLACE HEAD ON SPECIFIC TOOL (P.N.
10277) INSERT WASHERS AND NUTS M8. Fig.2
TORQUE NUTS BY HAND (see Fig.2).

3. PLACE THE GRADUATED BURET FILLED

WITH GASOLINE
(60% GASOLINE / 40% OIL).

4. FILL THE COMBUSTION CHAMBER UP TO

UPPER EDGE OF SPARKPLUG HOLE (see
Fig.3). Fig.3

5. READ GRADUATED BURET.

25 MAN-026
26 MAN-026
 CROSS PATTERN LOCKING ORDER ON CRANKCASE

7 3

2 1

4 6

27 MAN-026
 MAIN PRESCRIPTIONS

ENGINE CRANKSHAFT MATCHING THE PISTON

- bearing seat diameter on new engine

ATTENTION:
play between piston and liner must be:
replace when size is lower than 0.03mm vs.
0.11 / 0.12mm.
original.
If play is higher than 0.14mm.
Replace piston.

Pistons are measured at 17.5mm from bottom.

MAX ALLOWED OVALIZATION ON CONROD Size of the liner to be matched with piston is
marked on top of piston with a green or red dot or
with letter V (green) or R (red).

If the size on piston top is marked with :

-a green dot or with letter V: add 0.01mm to
size marked on the piston to match the liner size .

-a red dot or with letter R: add 0.02mm to size

marked on the piston to match the liner size.

Max. allowed ovalization between A and B on

new conrod: 0.002mm
Max. allowed ovalization between A and B on
used conrod: 0.01mm

28 MAN-026
29 MAN-026
 OVERHAUL TOOL LIST

SPECIFIC TOOLS AVAILABLE AT IAME

DESCRIPTION P.N.

• PISTON FITTING 10271

• CLUTCH LOCKING WRENCH 10270
• CLUTCH DISSASSEMBLY TOOL B-55614-C
• PISTON PIN FITTING 10200
• PISTON CIRCLIP ASSEMBLY TOOL 10120
• CRANKSHAFT ASSEMBLY KIT 10110-C
it includes:
- crankpin bush 10150
• KIT CRANKSHAFT DISASSEMBLY KIT 10100-C2
it includes:
- Crankshaft plate 10104
- Crankshaft support 10100
- Crankpin pusher 10107
- crankshaft insert 10106
• TIMING CHECK TOOL 10192
• VOLUMETER 10277

SPECIFIC TOOLS – DRAWINGS ONLY – Draw. S725/1

• ENGINE FIXING TOOL

• BEARING DISASSEMBLY TOOL
• BEARING ASSEMBLY TOOL
• CIRCLIP ASSEMBLY TOOL

STANDARD TOOLS
• ALLEN WRENCH 4mm
• ALLEN WRENCH 5mm
• HEXAGON RING WRENCH 13mm

• 12 POINT WRENCH 10mm

• 12 POINT WRENCH 13mm
• 12 POINT WRENCH 17mm
• 12 POINT WRENCH 19mm
• HEXAGON RING WRENCH 24mm
• SPARKPLUG WRENCH 20.8mm
• SCREWDRIVER WITH ROUNDED EDGES
• PLASTIC MALLET
• SOCKET TYPE-DYNAMOMETRIC 13mm/10mm

- 5 MeT PRESS

30 MAN-026
 Drawing S725/1

MAN-026 31