e ® e e : Reparaturhandbuch oa) Repair manual }) Manuale di officina Type, Tipo 123 to) fori JS ea)Engine removul.. Engine dismantling Removal of electric starter 3 Cylinder heal jacket, combustion chamber 6 Cylinder, : 7 Piston 8 Ignition system 9 Starter pear assy... At Sprocket, oi! pump .. 12 Clutch and primary drive 13 Drive gear, kickstarter AS Water pump. hb Extraction of pi 17 Separating crankcase halves Ik Balance shaft. gearshift, gearbox Crankshaft ... Individual components maintenance Magneto side crankease holf 21 Clutch side crankease half - pa Measuring of crankshaft axial play... 24 Crankshaft 25 Balance shaft, balance drive Transmission . Mainsh: assembly 28 Clutch shaft assemb! rota 29 Gearshift mechanism. gearshift drum 30 Cluteh... Cluich release . Clutch assembly . Rev, counter drive, kickstart drive . Piston, pistoneylinder clearance Piston dimensions, piston wear limit Piston rings ... - . Meas, pistan ti nd gup, piston pin... Exhaust valve RAWE II disassembly Exhaust-valve RAVE Il reassembly. Exhaust valve RAVE-E (electronic Cylinder, cylinder dimensions. Combustion chamber, cyl.head Checking of thermostat Reed valve nesyEngine reassembly Ht Measurements ., Flywheel, starter gear, elecir starter drive Electric starter Installing the ¢rankshaft . mechanism assembly hift mechanism Balance shalt Crankease assem Kickstarter..., Water pump, ‘Balance shait drive Primary drive... Clutch (without kickstarter Clutch (with kickstarter) Clutch cover... Clutch adjustment Fitting cylinder component inder , aust socket, carbu A Compression ratio, checki Ignition unit (without adobe rioting) Ignition adjustment/withour varia, tin Ignition unit (with variable timing) Ignition adjustment (with vertable timing), 26 Starter gear cover, ignition cover Sprocket, electric starter ..... Kickstart lever, gearshift leve: Engine installation, Checking RAVE Il farcumar Checking RAVE-E tales tro Technical data... htening torques Wiring dingram SEM. Wiring dingram SEM WG unit. Repair tools . Gear ratios a Lubrication and service table Trouble shootingEngine removal: Clean engine. Remove exhaust system and carburetor, waterdrainscrew’ nil radiatorscrew cap, Draincooling liquid and disconnect all hoses. Remove magnetic drain screw @ from beneath clutch side crankcase half, and drain gear oil. Disconnect battery and all electrical connections between engine and frame. Remove oil pump cover, discontect control cable for oi! pump drive and for exhaust valve (RAVE II), and remove oil pipe, Remove screw plug ® from clutch cover and disconnect clutch cable, Remove revolution counter drive cable and rear drive chain. Remove engine fixing balts.and engine aut of the frame, ‘The electric starter may be dismounted before removal of the engine from the frame,Sct up the cleaned engine on trestle with adapter @ fo engine type 123, and secure it with fixing screw Removal of electric starter; Unscrew the 2hex. collarserews ® and remove electric starter.Cylinder head cover, combustin chamber: Remove 4 Allen screws M6 @ and cylinder head cover © with the 2 O-rings. Unscrew 5 hex. nuts M7 ® with washers and remove the combustion chamber insert ® with O-ring,Cylinder: Remove the4 hex. nuts M8 Quand washers with wrench 11 and lift the complete cylinder @. ATTENTION; Take care to prevent the piston falling against the craniPiston: Cover crankcase aperture with a cloth and prise out the 2 piston pin circlips @ using. a narrow-blade screwdri- ver @. Drive out piston pin ® with guide bolt, gently tapping the guide bolt if necessary, and remuve piston with necdle bearing. Support the piston by hand to avoid bending the con- necting red.Screw puller @ (276 807) fully into flywhee! thread and remove flywheel @ with lockwasher. Remove starter_gear assy. ® with drive gear @ and thrust washer @.Ignition system: Remove 4 Allen screws M6 @ and the ignition cover Unscrew 2 Allen serews M6 @ and remove the starter gear cover @. ATTENTION: The thrust washer may stick at the inner side of the starter gear housing, Remove plug screw M8 for crankshaft locking. Then set the piston to top dead centre so that the locking bolt groove can be scen through the crankease aperture Fitcrankshait locking screw ® by hand until it engages firmly in the crankshaft recess (turning the magneto flywheel gently to and fro by hand will make this easier), Unserew hex. nut MI2x1 with socket wrench 17, then fit pratection cap (276 790) ome crankshaft thread.Sprocket: Remove retaining ring @ with retaining ring pliers and sprocket @ with O-ring underneath. Oi pump: Tum engine on trestle, clutch side upwards. Remove 2 Allen screws MS @ with lockwashers and oil pump @ with oil tubes, cable grommet and O-ring. Remove I! Allen screws M6 @ from the clutch caver using a wrench 5.Remove 3 Allen screws @ with washers and stator @ with cable grommet © fram stator plute. Remove 4 Allenscrews M5 wilhlock washersand gently lift stator plate @ with ascrewdriver. Remove Woodruff key @ from crankshaft. ATTENTION: The stator plate enly has to be removed if the magneto side all seal is to be re~ placed.Cluteh and primary drive: Liftoff clutchcoverusing 2 large sere wdrivers ®: plied atthe lugs @ provided and remove clutch caver @ with gasket, Don't lever between scaling surfaces. ATTENTION: When taking off the clutch cover. check that the thrust washer of the rev. counter drive pear is not stuck to the clutch cover interior, Remove 6 hex. screws M3 @ from clutch thrust plate @ with wrench & in crosswise Sequence, tuming each screw. no- more than two Lurns at a time to ensure that spring pressure is relaxed evenly, Remove screws, lock washers, clutch thrust plate and clutch springs, Bend back tab-washer on clutch shaft. Place clutch Hub lock- ing tool ® over clutch assembly and turn it so that it is fully engaged in the clutch drum @. The clutch centre nul-MIS may now be removed with wrench 27. Remove locking tool and tub washer,Lift off clutch drum@® with clutch hub and all plates. Remove 2 needle cages @, thrust washer and O-ring from clutch shaft, Remove idler gear ® and rey.counter drive gear @ with thrust washer and siceve. Next remove water pump intermediate gear @ with thrust washer underneath,Drive gear: Remove crankshaft hex, nut M16x 1.5 with wrench 24, then lift off the lockwasher and drive gear @. Take Woodruff key from crankshaft keyway. Remove retaining ny @ from balance shat and the 2 balance drive gears @ Remove O-ring @ from the crankshaft. Kickstarter: Gn models with kickstarter, filthe kickstart Jeveron the starter shaft, depress it atid remove stop screw @ from the crankease. Depress ratchet gear ® with a serewdei- ver and let the starter spring relax, Remove kickstart lever, thrust washer, ratchet gear. shaft and spring.Water pump: Remove Taptite screw M5 and liftoffthe complete water pump ® with a cranked lever @. Remove the counter- sunk screw @ and retaining plate @ for balance shaft bearing. Unscrew 5 countersunk screws @ with serew- driver und remove the retaining plate @ with shims underneath, for muin- und clutch shuts. Remove crank- shaft locking screw @.Extraction of ball bearings: The clutch side bal] bearings of gearbox mainshaft and clutch shaft can be replaced without dismantling the crankcase, For this, a bearing extractor with appropriate ¢: withappropriate leg’ setisrequired, Thedticgs® gage in the bearing outer race @, and the other ends in the extractor nut ®, The bearing will be removed as the extractor bolt @ is grudually tightened ‘o fit a new bearing, » hollow drift of suitable length (to pays over the Shaft) and diumeter must be used to drive only against the bearing outer race. Never drive against the inner race. Use leg set A-3 for ball bearings: 6006 / 6203 / 6203E /'6300 A-4 for ball bearings: 6007 / 6204 /6204E (6205 / 630 / 6302 / 6303 / 6304Separating crankcase halves: Turn engine on trestle, magneto side upwards. Remove 13 Allen serews M6 © and lockwashers with wrench 5. Turn engine-on trestle again, clutch side upwards. Fix pullerplate @ with4 Allen screws. Remove fixing screw from trestle, Turn puller serew ® into puller plate-until clutch side crankease half @ lifts. Take care that the crankcase half lifts: squarely. While applying gentlepressuteto the pulierscrew, gently knock clutch-, main- and gearshift shafts down with a mallet. Separation is facilitated by levering on the lugs @ with @ screwdriver. Don't lever between the sealing surfaces!Lift clutch side crankcase half and detach puller plate. Take care of the thrust washer on mainshaft. | may remain stuck on the inside pf the crankcase half. Whew lifting off the crankcase half. the balance shaft ® may remain in the crankcase. Remove balance shait. There ate no spacer shims on balance shat. Gearshift and gearbox: Remove crankcase centre joint gasket. Mount magneto side crankcase half with a¢curing screw @ and spacer © on trestle. Remove the shifi fork spindle and 3 shift forks, Pull out shift drum @ with shift shaft ®, index lever @, isdex corine and ihe shim undemeathTum crankcase half on trestle into vertical positron, Support both gearbox shatis by hand, and with o mallet gently tap the sprocket end of the mainshaft which will remove both shatiscomplete wilh gears from theirbearing seats. ATTENTION: Take care noi to damage the mainshaft ail seal. Crankshaft: Turn crankease half on trestle. ignition side upwards. Place protection cap (276 790) over crankshaft thread Attach puller plate © to crankcase half and pres’ ow crankshaft @ by turning the extractor screw @ clock. WISe. ATTENTION: Support crankshaft by hand. Take care not ta damage the oi seal. The spucershims foradjustment of crankshaftaxial play are on magneto side, between crankblade und crankshaf bearing. Remove the extractor plate from crankcase half,Crankease: must be cleaned with ih degreasing or cold Crankcuse halyes.and ball bearint gasoline or kerosene only, not cleaning agent Magneto side crankease half: To remove the ball bearings, heat crankcase to 60 + 80 degrees C and remove the 2 dowels @, Plave crankcase half on a flat surface with rubber mat to avaid damage Io the sealing surfaces. To remove the clutch shaft ball bearing, extract it with puller @/276 360), and the hilance shaft ball bearing with puller 276 762.Mainshaft bearing, and if necessary also crankshaft bearing (usually remains on the crankshaft) should be driven from the outside inwards with an appropriate punch @ after removal of the oil seals. Clean crankease half. The same procedure applies to the needle bearing e of the electric suirter drive. Check all beating seats and sealing surlaces. The crankshaft bearings are an interference fit in the crankcase. The maximum interference is 0,05 mm with anew crankcase (bearing larger than housing}. Weer lirait O01 mm. Replace the oil seals of crankshaft und mainshinft Lf the water tube @ has to be replaced. seul and seoure itn position wi bClutch side crankcase half: Heat crankease half to 60 + 80 degrees C and pull out dowels with pli¢rs.Place crankcase half on flat surface with rubber mat. Knock out ball bearing @ for balance shaft from inside outwards, and the other ball bearings from outs | de inwards, Always replace the crankshaft oil seul, ATTENTION: Check lubrication bore ® forcrankshaft bearing in both crankcase halves for free passage. Check all beating seats and sealing surfaces. Remove magneticscrew @andclean it, Cheek the bearing spindle SD fir water cum drive eee for Hakt fiin crankent}meusure the overall width of the crankblades (tnelu- ding cadius ring). Deduct crankshaft value fromthat of crankcase. The resulting figure is the axial play and should be (2 +0,4 min. If iris more, fitshims xs required berween radius ring and ball bearing, but only on magneto side.Measuring crankshaft axial play: Iferankgise or crankshaft are to be replaced, the cranks- hafi axial play (end-float) has to be measured. Heat the 2 crankease halves:to 90+100 degrees C, insert the oil seals for crankshaft with punches 277 875, Fit the ball bearings in the crankcase whilst still hot, lapping witha suitable punch on the outer bearing race. Be sure the bearings are pressed fully down in their housings. ATTENTION: The closed side of the bearing cage O must face towards crankblade to prevent the cage to jump out, Witha depth gauge measure the distances. on each crank- case half between crankease joint surface and the outer besringrace @_ Add these 2 values pluscrankcase gasket logether. Placethe radius rite oncrankshaft, magneto side. ThenCheck the follawing points on crankshaft: ES crankshaft between centres foreccentricity (max, 0,03 mm), measure on bearing seats CS radial play in con rod bearing @ (0,015 to 0,026 mm. max. 0,05 mm) BS con rod axial play (0,390 to 0,937 mm, max. 13 mm) BST piston pin bore in can rod @ (max. play 0,03 mm) rs grooves ® for Woodruff keys v= taper surface OS bearing seats @ and surfaces @ for oil seals EX threads @ on the 2 crankshaft ends,Wiien pressing out the crankshaft, the magneto side ball bearing may remain onthe crankshaft. timay be removed with bearing puller @.876 298, ring halves 276 025 and ring B 977490, Onclutchside the crankshaftis esliding fit. if the-con rod bearing ® is defective. use crankshaft repair kitconsisting of con red crank pin, needle bearing and thrust washers, These party ure matched together and must only be rephiced usa kil, Special equipment is required to press the crankshaft assembly apart, and this work must be entrusted to specilliats. Balunce shaft, balance drive gears: Check the 2 bearing seats ® pid the cirelip groove ®, The balance shaft need not be measured axially. Check the 2 balance shaft drive gears for cracks and the inside and ourside teeth @. Replace these gears every 15.000 km’:Transmission: Fix mainshafi (resp. clutch shuft) in a vice using protective jaws. Remove weurs, and observe the following points: @ Cheek needle bearings for wear. @ Check bearing seats on both shafts. Check gear dogs for wear, ® Check tooth Manks of all gears for wear, @ Check tooth profile ofclutchshaft and mainshaft as well as their matching gears for wear, @ Checkall sliding gears for easy movement along their splines. @ tooth profile for sprocket and groove for circlip Carefully clean all components, replacing atiy damuged parts, Gears should always be replaced in pairs. Check cluteh shaft and mainshaft for truth HeUveeOn Centres.Lubricate and fit the split needle bearing (10mm wide) on the shaft, and fit ®° gear free pinion with collar downwards, and fix with thrust washer and snup-ting (sharp edge upwards), Assemble @™ gear with slow for shift fork facing downwards, fit thrust washer, needle-cage 10mm and O" gear free pinionyyith collar upwards, und fit thrust Washer.Mainshaft assembly (Enduro, Custom, Strada, Rally): Fix mainshafi in vice using protective jaws with splines for chain sprocket downwards. Lubricate the split needle caring (10mm wide), fititen shaft, slide @™ gear free on, collar downwurds, over the bearing and’ fix it with thrust washer and snap-ring (sharp edge facing upwards). Push on @" gear with slot far shift fork upwards; mount snap-ring with sherpedye downwards, slide sneularring with recess downwards over the splines of mainshaft. Lubricate and fit the split needle bewring (1D.amm wide) on the shaft, und fit a: gent free pinion with collar upwards %Main- and clutch shafts for AFL (Strada): Assembly is Sameas for Enduro, Only the pinians and @" pears are different. Enduro StradaCluteh shaft assembly (Enduro, Custom and Rally): Fixclutch shattin vice using protective jaws withthreaded end downwards. Lubricate the split needle bearing (10 Hin Wide), fitit on shaft, slide ®" gear free pinion, dogs upwards, over the bearing and fik It with thrust washer and snap-ring (sharp edge upwards}, Pushon ao) gear pinion with @ gear (smaller dia. gear) downwards, fit thrust washer. lubricated neodic hearing and ®* pear free pinion with dogs downwards. Then fit @* gear pinion (symmetrical).ATTENTION: On engine type 123 Custom with reversed gearshifting sequence there is no pin @punder the neutral positionGearshift’ mechanism: Check shift forks for wear'on their blades @ and engugement pegs Examine (racks ® on shift drum O for wear and make sure that index profile disk @ is securely fastened to the shift drum body. - The index lever roller @ inust tum freely. Check paw! @ of shiftshalt for wear Examine index spring ®, paw! spring ® and hairpin spring @ carefully for cracks and tension, ~ Cheek shift shaft: for eccentricity Gearshitt drom: Peg for neutral gear indicaiion tanking shim jon af index divk (between IM andClutch: Check needle bearings, friction and steel chiteh plates, and retaining plate for wear. All steel and friction plates must be perfectly flat, otherwise the clutch will drag. Check threads M5 and the friction surface @ of the inner pressure plate for flatness, Check the clutch hub splines @ and the flat surface @ for wear. Check the friction plateslats ® of the cluteh drum for wear, Check teeth and tooth flanks of primary drive gears® for wear, Replave O-ring @. ATTENTION; Clutch drum assy. with gear and crank- shaft drive gear are a matched pair and must not be replaced individuallyCluteh release: Normally theclutch release mechanism ® isnot subject to wear. If however necessary, removethe Taplite screw Ms @ socker wrench 8, then the leaf spring @ and release plite ® and check the ball ramps for wear. If necéssary, replace and reassemble.Cluteh assembly: Place clutch plates on clutch hub @ starting with afriction plate @ (3,0 mm thick) and then alternately 5 Stee! plates @ (1 mm thick) and 5 friction plates @ (3.0 mm thick), Then fitthe innerpressure plaie @ ‘The plate package (6 friction plates and 5 steel plates) should measure: 23 mm thickness.Rey. counter drive (not on Rally): To dismantle the rev. coumter drive, unserew the hollow shoulder screw, lift the cable drive shaft @ with worm gear @off itssear®. Then pullthe complete shaftdown. In the hollow collar screw there is.an oil seal, Replace if necessary. Reassemble im reverse sequence. Kickstart drive: Cheek the teeth A on starter gear @ and ratchet gear © as well as the tooth flanks B of the starter gear @ and the idler gear Examine all bronze bushings in the gears, Check kickstart spring: and the splines of kickstart shaft. Replace O-ring on kickstart shaft. On engines with electric statter the kick start drivecan be omitted. On engines without kickstart, the rey, coumler drive is plasticPiston: Remove combustion residues from pistoncrown @, check piston for cracks. Check piston skint surface @ forsigns of seizure. Replace if necessary. Clean piston ring grooves and blast with compressed air. The piston rings must be able to move freely in their grooves. Piston ring groowe/piston ring clearance mustnotexceed 0,2mmmax. Cheek pistonring locating pegs forsecurity. ATTENTION: C ombustionresiduesmusinetberemoved with piston still installed. Piston/cylinder clearance: {23 Enduro, Custom, Strada, Rally: 0,02' + 0,032 mm Inversion "SVIZZERA"(=5 witzerland)0.03 =0.042 mmPiston ring: Check piston rings ® for clean working surfaces. Ring end gap 0,15.+ 0,3 mm. Max. permissible ring end gap (8 mm, Replace piston rings if necessaryPiston dimensions: Standard red $3.98 mm, green 53,99 mm, Oversize $4.00 mm. and $4.01 mim. For version "SVIZZERA": §3,97 mm thlack dot @), ‘o.determine the pistan/eylinder clearance, take piston diameter ay stamped on piston tap (@ = naminal dia) Piston wear limit: Difference betwetn maximuin skirt diménsion and cylinder diameter must not be greater than (11 mm. Replace if necessary,Measuring of piston ring end gap: Insert piston ring squarely into cylinder using the bare piston. The gap B should not exceed max. 0,8 mm and can be-checked with a feeler gauge. If the gap is greater, check piston and cylinder for wear. Tf piston and cylinder wear sre within tolerance limits, replace the piston rings only. Piston pin: The max. play of piston pin incon rod small end bearing: must not exceed 0,03 mm. Check piston pin needle cope for pittings, cracks and discolouration (blueing) indicating Inck of lubrication: and/or overheating. There must be na detectable play between the piston pin and bore in piston.Sand withdrawthe complete valve rod housing with © yi Unscrew exhaust valve and rod from val piston. Remove gasketandsecuringspring @. Push bellow: towards Inside from valve piston @ and remove bellow: from valve rod housingExhaust valve RAVE If (pneumatic): The height of the exhaust port can be varied by the exhaust valve, which is driven by pressure of exhaust gases, Pressiite passes from the exhaust port to the exhaust valve mechanism via a small bore. The optimum r.p.m, switehing paint for actuation ofthe valycis controlled by pre-tension af ihepressure spring. Gn type API there are 2 aduitional shims under the vulve spring. ine adjustment with the red adjustment screw @ in the valve cover, Self-cleaning system via cable to foothrake Disassembly of RAVE I: vove spring clip @, valve cover @ with adjustment screw ©. pressure spring and distance shims (iF any) underieuth, Remove valve lever with leal spring. Check for tightness, Remove the 2 Allen serews and spring Washers with wrenchCheck O-ring® on valverad, replace if necessary. This O-ring serves for shock absorption. Loosen hex. nut @ and unscrew valve cod ® with shim © from exhaust valve, Clean and check all parts. Clean exhaust Valve add valve port in the cylinder from combustion residues. Check bore @ of valverod housing for wear. Check bore @ for exhaust valve aciuation for free passage. Clean if necessary, Check bellows for cracks and porasity:and replace if necessary, @ = attachment for spring clipCheck valve piston & for cracks duc to excessive Ugh- tening and deformation by overheating. ‘The pressure spring is responsible for correct function of the system, Pressure spring Enduro/AF1 Free length mm spring pressure at 14 mm spring length 8.8 .N Ag the exhaust valve is dependant upon exhaust gas pressure, a leaking bull joint @ will affect its efficient operation, Check this joint carefully, and replace if necessary.Reassembly of RAVE If: Screw hex. nut M6 @ to the longer thread of the valve rad @. Screw valve rod with shim @ completely into the exhaust valve @ and lock with hex, nut. Ontype 123 Rally theshim ® andhex. nut@are different, ATTENTION: Secure hex. nut M6, valve and valve rod with LOCTITE 648 (strong), If this nut loosens, the valve will cause severe engine damage. Fit O-ring @ and push exhaust valve with sharp edge upwards into the cylinder, Place gaskel correetly and fit Valve tod housing with 2 Allen screws @ and spring washers. Cheek valve rod for free movement. If necessary, loosen the 2 Allen serews and reposition housingPush bellows. onto valve rod housing (rim must be well seated in the grove). Screw valve piston @ carefully by hand onto the valve-rod taking care not to damage it by overtightening. Fit bellows very carefully using a blunt tool. and secure bellows with the spring fastener. Insert leaf-spring @ into valve lever ®, position lever in the valve piston and mount It on the 2 supports onthe valve rod housing. Fit distance shim (if there was one when dismantled) and pressure spring © on valve piston. Fit valve cover with. adjustment screws. then fil spring clip and fix valve cover. Tighten red adjustment sctew until level with cover, ATTENTION: Check exhaust vilve for free movement Tr mst en no account protrude into the cylinder bore, Check adequate clearance berween edge af valveand piston when fully closed (min. 04 mm). Check with an engineer's ruler @ (see ill.) and a 0.4 mm dia wire.the complete valve assembly with gasket.Push protection cap @ back, pull the cable ® back umil it ean be removed from the valve rod. Remove the exhaust vilve with rod, gisket and spring. in the valve rod housing @ there is un O-ring und a shaft gasket, Check and replace ifnecessury, Ifnecessary, unserew valve rod frony valve. Clean valve and valve port in the ylinder from combustion residues and makes visual check. ‘The bore in the cylinder for pneumatic valve contro! must be blocked. Free length of exhaust valve spring: 36,3:mm. Spring pressure at 18mm spring length: 7,3. Reassenibly with new gasket @® in reverse sequence. ATTENTION: The threads.on valve rod and fock-nutmust besccured by treansof LOCTITE G48 preen (strong), Te this nut loosens, the valve will couse severr da- mage. ATTENTION: Check exhaust valve for free movement. It must on no account protrude into the cylinder bore. Check adequate clewrance between edge of valve and piston when fully closed (min, Ot mm). Check with an engineer's ruler and a 0,4. mm dia wire,Exhaust valve RAVE-E (¢lectronicr: Inthiscase the exhaust Valveis operated by anelectro-magnetic servo, via Rowden cable. The servo ls controlied by an electronic box which reads engine RPM from the low-voltage side of the ignition rircuit. Farcheck and setting procedures see page 82. Disassembly of RAVE-E: ews Remove the2 Allen se ith lock Washers and withdrawCylinder: Chtck cylinder hore working surface for wear, The cylinder diameter must oot exceed {he nominal dia. (= 34,03 mm) by more thin 0.07 mim. Ovality and taper tolerance: 0,02 mm Clean the bore © for exhiust valve actuation, Remove combustion residues from exhaust port, Clean O-ring grooves and theck them. Allsealing surfacesmust beperfeetly flat. Check threads for studs @. Cylinder diameters (for all versians 123): Cylinder 'A* (red) 54,00 - $4,012 mm Cylinder "B’ (preen) = 54.012 - $4,024 mm Cylinder!piston clearance: See chapter “Piston”.Combustion chamber insert: Check sealing surfaces to be clean and flat. Clean combustion residues fromcombustionchamberandeheck for cracks. Check spark plug threads. cylinder head jack In the cylinder head jacket is the thermostat and threads. for temperature sensor. Check for clean O-ring sealing surfaces @. Checking of thermostat: Place thermostat @ into a pan of water and gently heat it, With a thermometer note thatat approx. 55 ~ 60 ° © the thermostat must be completely open, The plunger ® only moves approx. 4mm. HW necessary, replace the thermostat. Check spring & and thermostat holder ®,Reed valve assy.: Check reed valve petals @ for cracks or other defects. The petals must lie completely flat against the valve body @. To check, hold against light. Cheek perfect condition of rubber coating on reed valve body, and valve petal fixing screws M4 ® for tightness. If reed petals have to be replaced, secure Allen screws M4 wilh, LOCTITE 48 (strong), Ih case OF a’teed valve body Without rubber coating in the ares of Sealing surface ®, a paper gasket 250 520 must be used.Carburetor Nange: Check forcracksand possible porosity of rubber coating In case-of the angular carburetor flange @, it is an advantage to shorten it in the aren @ toa min, 4mm distance to the reed petals, to avoid blocking of reed petals duc to swollen carburetor flange. Exhaust socket: Cheek the ball joint ® for damage and the bore forspring mounting brackets @ Aduntight ball jointcauses malfuction of the pneumatic exhaust valve.Alter connection of the oil lines, the oil pump hus lo be verted. Open the vent screw @ until oil without wir bubbles comes out. Also the oi] feed line must be tree of air bubbles. Check function of oi] pump.on the pressure tube with engine running. Framengine serial no. isfitted Gniype | 23 Ri of serial production. 251833 the ol] pump 293 LY7 inwas fitted from beginningOil pump: Remove the 2 Allen screws @ with lock-washers and the oil pump. Remove banjo @ und check valve @ clean und check for free passage. Carefully clean oil tank, oul filter und oi line, Uf the oil pump is looking. the cover gaskets, O-ring, sealing ring und oil Seal cun be replaced. of a new oi] pump muy be fitted. = When eonneering the oil pump control cuble, the cable must be adjusted sv that the marks @ on pump lever and pump housing are in aligament ul burelor idle position, ATTENTION: The check valve must lock indipection towards oil pump.Water pump: Remove the slotted spring pin @ with a suitable punch and remove the impeller ® (1ake care not to damage the impeller). Withdraw pump shaft, pump gear and washer, Push pump gearinwards to remove it from shafl. Check parts und replace if necessary. Ifthe pump shatt housing is worn, replace water pump housing. If the water pump is leaking, repluce the 2 oil seals @ and both O-rings @, Grease the inner oil seal, fititwithopenside outwards, with punch 276770 pressed fully down, Grease the second oil seal and press it into the water pump housing to be Jevel with the housing tace, Check that water passage @ and lubrication bore for pumpshaft aré clear. Grease oil seals. with water pump grease, e.g MOLYKOTE 111. Itis usually preferable to replace the complete pump if any parts are worn,Ignition unit and generator SEM 123 Custom, Enduro, Strada, Rally: Engine type 123 has an electronic (breakerless} SEM unit with variable ignition timing and integral 2 12 180W. AC lighting output at 6000 fioiina hasno wearing partsand requires no maintenance. Stator, magneto flywheel and ignition coilare not matched and can be replaced individually. Early productionmadeis ol type | 23E-CUSTOM( frame 0.01101 to 01480)have anignitionunit without viriable iming, and such units can be recognized by the absence of bore O in the flywheel and black ignition coil. me components (stator @, flywheel ®, ignition coil cannot be repaired successfully, and complete splice ment isacvised inthe eventof malfunction, On the stator there is a slot ® necessary for ignition timing adjust- ment. For version without variable timing (Custom) he scale @ is relevant Tenition coil black wilhout variable liming. Tenitinn coil blue: wilh variable timingSEM ignition unit with variable ignition timing Checking values ¥ for checking the star) green - black = 170 + 1% black - stator mass «0.5 Qiresponsible for function of orange shor- ting cubled green ~ red = in practice normensurable red ~ black = in practice not measurable blue =~ ‘blue = 0,502 blue + black == Values for i ignition coi red-orange ©05.2 red ~ black inpractice nol measurable green - black orange - black black ignition- cable = 22k + 20% in practice net messurable inpractice apt measurable In case of doubt, test with new ignition coil.in one direction. Check that the drive shaft @ tur easily inthe worm gear, Take care that the securis cireclip @ js wellMagneto flywheel with electric starter gear: Check the magneto flywheel interior @ fordamage (pants of magnets broken off), taper surface @ and keyway. Check the teeth ® of the sree gs r If replacement of the sturter gear @ is necessary, tt is recommended to replace the flywheel complete with Starter gear. ENDURO and RALLY models are produced both with and without electric starter, Non-electric start versions ean be converted to electric starting - referto spare parts list fornecessary items, Secure thesturtergearon magneto flywheel with LOCTITE 648. Electric starter drive gear: Check pinions and spring. The gear @ must lock firmlyBild AElectric startert After dismantling cheek the fallowing parts @ Armature: Check for out-of round. inspest visually. If cessary, rework canofully ond lathe. Use i-fine.saiw blade trim back the insulation leaves between communitor stements (sce ill, A), The insulation should be 0.5 mm leeper than the-segments. Check armature at 24 Volts with test hip hetween commutater and iron core forconmection to carth. Uf the lamp lights up, indicating # shart-cireuilt, the armature musi be replaved. Check armature windings at2 to 4 Volts. and ammeter (measuring range 60) A) for open circuit (see HB). Hl the ammeter imdicates big dif- ferences between the individual seginents, the drmature hus io be replaced: Check the splines and radial pluy. © Needle bearing and bushing: Replace if necessary. ® Check starter drive tor patient function of free-wheel. check tooth Hanks, replace if necessary O Carbon brushes: Must be able to move freely within theit housings. Repluce brushes that are warn to less than’8 mm. Check spring pressure @ Check starter coil at 24 Volts with test lamp betwee connection of windings and housing for mass connec- tion, If test lamp lights up, the windings are bumed out, Replace starter housing. With an Ohmmeter check for interrupting of windings, @ Replace O-ring,Installing the crankshaft: Hearmagnetoside crankcase halftomin. 90+] 00degrees Cand fix itontresile with screw @ and spacer @. tnstall new cranksharl- mainshuft oil seals and crankcase ning using appropriate punches from inside (see also pages 23 and 24), Grease oil seals. With the crankcase still hot (min, 90 degrees C) insert the crankshaft ima turing. If ne ry. dup gently on crankshaft with & mallet. Do not strike the crankshaft threads. Fit the oil seal for mainshaft with punch from inside. Fit ball bearings f with an appropriate punch ind mainshaftsGearbox assembly: Fit oil seal guide sleeve @ on mainshaft. Invert main: shaft and clutch shaft together into the crankease half, gently tapping With a mallet, Remove guide sleeve and cheek oi] seal lip from outside. ATTENTION: Apply slide paste (c.g. LOCTITE Antiseize) on the bearing seats @ to prevent metal galling. Assembly of gearshift mechanism: Place index spring in crankcase half, together with pre- assembled shift shaft, index: lever (with bend facing downwards) and thrust washer, Inititlly. the shift shaft must not he pushed fully into position; Carefully insert it so that the lever arm @ rests upon the boss @:Locate spring in index lever, Press lever @ with ascrew- driver outwards and insert shift drum. Release lever, push paw! @ inwards towards the shift drum, Now press index lever with a screwdriver oupwards and push the complete shiftshaft fully into the crankcase half. ATTENTION: Be careful not to force the shift shafi into the crankcase to avoid bending the pawl. Locate paw! spring ® and greuse gearshift shalt Engage shift fork for 2°44" gear 6 (inseription upwards}, shift fork for 31/6" gear @ and shift fork for 1'/3" gear @ (both with insenption downwards) in geurson mainshalt and clutch shafi and in shift dram Slide: in shift fork shut @.Balance shaft: Apply LOCTITE Antiseize to bath bearing seats @ and fit balance shaft @ (slide fit!), No spacer shims are fitted.Checking of gearshift mechanism: Clutch shaft, mainshaft, gearshift shaft, shift fork shat and shift drum: must all be fully pressed Into position in their bearings. Fit gearshift lever on shift shaft and shift all 6 gears Cheek in each gear position that gears tum freely, anc that all shift forks are free. without sideways pressure that could indicate that a shaft is not fully sedted. Turnshiftshafttoleft and right untitstap. Inthis position the shift pawl must hove some play which should be equal in both directions. If not, check shift shaft, shifl pawl and shift drum and replace defective’ parts. The play of the shifishaft should be equal to left and right, seen from its idle position, Oil all parts of the gearshif! mechanism.Crankcase assembly: Remove fixing screw and spacer from trestle: Install the 2 dowel: in the magneto side crankcase. Slide thrust washer @ for kiekstary shaft on gearshift shaft. Warm clutch side crankcase half to 70+90 degrees C. Fil new oil seal, with sealing lip outwards, with an Appropriate punch (see also page 24), Fill sealing lips with grease Fil cold bull bearing for crankshaft fram inside inte the crankcase helt, ATTENTION: The closed side of the bearing cage must faee inwards (towards crankshaft),Apply LOCTITE Antiseize to the bearing seat © for clutch side ball bearing. Place new gasket @ on crank- case halfand trim excess gasket material from crankcase mouth ® (the gasket is made with abridge" at this point to be more durable in storige). ATTENTION: The gasket may have:shrunk during storage. Hf too small, dip it into water and position it on crankcase wilh some ail. Cheek for correct position in areas @ to avoid loss of water or gear oil Mount crankcase half, if necessary tapping gently with a mallet on the engine mounting points (don't tap on sealing surtaees!). ATTENTION: Be careful not iu damage the oi! seal!Place distincé shims @ on bearings of chitch- and itainshafts (leaving 0, 1+0.2 mm clearance to crank~ ease level. Fil beating retaining plate @ applying LOCTITE 221 on 5 countersunk screws MS ATTENTION: Shims must not be displaced. If necessury, keep them in position with grease, it gearshift lever und shift wil 6 pears,Mountthecrankcaszintothe assemblytrestle withtixa screws. Fit ball bearings for main- and clutchshafts with an appropriate punch in the crankcase still warm. Insert ne ball bearing for balance shaft with punch (closed side of cage facing autwards). The ball bearing is retained by the plate @ and countersunk serew @, Use LOCTITE 221, Turn crankense in assembly trestle ignition side upwards, Secure crankcise halves with 13 Allen screws M6 and lock washers and with | Allen screw M8 and sealing ring, Tum crankease on trestle clutchside upwards. Check thatall shafts urn easily tapping gently on bearing inner races if necessary to free anwend-loading resulting fram assembly, Tap the ball bearings of clutch shaft and ainshaft firmly intKickstarter: Slide O-ring and starter shaft on shift shaft. Turn release screw into erankease by about 4 tums. Slide kick- Starter spring with large dia. end over starter shaft and engage the inner spring peg in the bore @ of crankcase. Slide oiled ratchet gear ® onto starier shaft with ratchet teeth upwards, and hook in kickstarter spring. Depress sleniey pet with screwdriver on the splines of starter shaft and keep it in this position. With kickstart lever ® fined. 1urn starter shaft cloek- wise until the stop screw @ can be fully installed thus locking the ratchet gear, Turn starter shaft slowly back until ratchet gear is locked on its stop ®. Tighten stop serew at 75 Nm.Water pump: Coat the O-rings af the pre-assembled water pump @ with-some grease, slide the pump into the crankease and fix it with Taptite screw MS, Balance shafi drive: Insert Woodraif key into keyway on crankshaft. Screw in crankshaft iocking screw @ by hand and fix crank shaft at top dead centre. The crankshaft locating screw | has to engage firmly in the bore on erankblade Pur O-ring 18x3,5 @ into the groove on crankshatt, Piace balance gear onto spline on balance shult so thut marks @ correspond with the mark on balance shaft. Siide 2nd dulance gear onto the crankshaft so that the marks @ correspond. Fil circlip ®. ATTENTION; The 2 balance gears are ide 1. bis unadvantape to wann them slightly before assembly.Primary drive: Fit drive gear @, with shoulder facing outwards, and lockwasher on crankshaft. Apply LOCTITE 221 onhex, nut @ and tighten at 70 Nm. Place thrust washer on idle gear shaft @ and place idler gear ® so that the marks é correspond as exactly as possible with the boss @ on crankease. This ismecessary to allow the oilpump shaft to engage. ATTENTION: For this procedure it is very important that the crankshaft is locked at top dead centre by crankshaft lacking screwClutch (version without kickstarter): Fit intermediate gear @ with large collar downwards (inscription upwards) on mainshafl. Slide thrust washer. rev. counterdrive gear @ with helical gear ® and thrust washer @ on shift shah. Turn the 2 pinions and check for easy movement.Fil thrust washer (2 mm thick) and oiled needle cages on clutch shaft and fit Q-ring Fit clutch drum-and thrust washer (3 mm thick) over O-ring @ and fit pre-assembled set of clutch plates in clutch dram. Te facilitate assembly. serew 2hea, serews M5 into pressure plate @, Shift into gear so that by turning the mainshaft, the clutch hub and clutch shaft splines@ engage. ATTENTION: Cliiteh shift splines @ must project by abeut | mm from cluich hub @ to engige with tab washer.Clutch (version with kickstarteri: Fit intermediate gear @ with collar downwards on mainshafi. Slide thrust washer and starter gear 8. with splines inwards, on starter shaft, Turn the 2 pinions and check for easy movement. Fit helical gear @ snd thrust washer @ on starter shafi. Fit O-ring. Fit thrust washer (2 mm thick) and oiled needle cages on clutch shaft, Fit clutch drum and thrust washer (3 mo thick) aver O-ring @ and fit pre-assembled set uf clutch phites in clutch drum. To facilitate asembly, screw hex, screws MS into pressure plate. Shift into rso that by turning the meinshaft, the clutch hub and clutch shaft splines engage, ATTENTION: Clutch shaft splines @ must project by about | mm from cluch hub @ to engage with tabUsing clutch hub locking tool place tsb washer, secure hex. nut with LOCTITE 221 and tighten to 80 Nm. Note that the hex, nut must be fitted with chamfered side inwards, towards tab washer. Remove the cluich hub locking tool, . ATTENTION: The clutch hub @ must tum easily, Slacken crankshaft locking serew, tum crankshaft and check all gears for easy movement. A small amount of backlash between drive gear and clutch gear (= primary drive) is: important, Lock crankshaflagesin to topdead centre. Bend up clutch centretab washer. Install the belutch springs, fil presstire platc @ with release ball @ outwards and tighten ornss- wise with 6 hex. serews MS and lock-washers. Take up clutch spring pressure evenly, by taking care noltolightenany screw more than 2 turns atatime: Insert 2 dowels in crankease cover joint face and place anew paske: for clutch cover.Clutch cover: Ensure that intermediate gear corresponds with mark (see page 63, point 5). Fitnew oil seal and plastic bushing (depending on execution) for starter shaft, witha punch (sealing lips towards inside). Mount ofl pump in clutch cover, Turn oil pump shaft so that lug @ is aligned with the cover timing marks @. Fit cluich cover and tighten 11 Allen screws M6 in crosswise Sequence, Fit sealing ring on gearshift shaft (on version with kickstarter) ATTENTION: Do not overtighten the cover screws, or the gasket will be distorted!Clutch adjustment: Unscrew the 2 plastic plugs with O-ring, loosen locknut 11 @ with wrench @. Turn adjustment screw M8 fully inwards. until free play is justiaken up, then slacken by L/2 tum, and kept in this position, tighten locknut again, The lever @ for clutch eable must have approx. 6mm free play. Refit plug with O-ring. @ = oil level che king screwFitting cylinder components: Trim possibly excessive crankcase gasket. Fit appro- priate cylinder base gasket 0.5 or 0.3 mm. Insert oiled needle cage for piston pin in the vennecting rod, hold piston aver con red and insect piston pin. ATTENTION: The arrow on the pistoncrown must point towards © x A aust port Cover crinkease opening with a cloth, Fix. piston pin with new curclips ©. The circlip apening @ must face downwards. Remove clath covering crankcase. Fit the piston rings intheir grooves, carefully locating the gaps over their locating pegs. and then slide piston ringclamp inin position over the rings and fit oiled cylinder. ATTENTION: Only pistons and cylinders of same tolerance group (= colour marks) cin be fitied together [see also pape 36 and 44), Remove piston ring clamp.Cylinder: Tighter: cylinder with 4 washers @ and nus Ms @ (wrench 11} crosswise. Tightening torque 30 Nm. Insert O-ring for combustion chamber. Fit combustion chamber insert on the location bosses © and tighten crosswise with § shims 7,4 @ and nuts M? (wrench 11) @. Tightening torque 20 Nm ATTENTION: Don’) squeeze the O-ring. Insert O-ring © andtighien cylinder head cover @ with O-ring und installed thermostat with 4 Allen serews M6x20 & crosswise. Relightencylinderhead nuts after the first S00 km, when the engine is cold,Exhaust socket: Fitexhaust socket @ with gasket and spring brackets@ and tighten with 2 Allen serews MB. Tightening torque 20. Nm. Carburetor flange: Insert the complete reed valve ® and carburetor flange @ according tw their shupe into the cylinder and tighten crosswise with § Allen serews M6 x 25.of spark plug when installed), _ swept volume + volume of Compression = shin mn cha volume of combustion chamber = Vh+ Ve= 14,2 20,5 for Enduro/AFl/Custom Ve 12,5 £0,5 for Enduro ETX Svizzera 13.3: £0.5 for Rally cylinder base gaskets of different thickness, the prescribed compression ratio can bé achieved (see parts lst. Remove crankshaft locking screw, turn crankshaft and let oi! flow our through extiust port. Refit crankease and water drain screws MB with sealing rings, and also, after cleaning, the magnetic gearbox drain screw.Checking the compression ratio: The combustion chamber must be completely cleaned of combustion residues, Set piston at top dead centre by means of crankshaft locking screw. From a burette containing a measured quantity of two-stroke oil, carefully fill the combustion chamb tothe lop © of the spark plug hole, Allow su me for the oil to drain down the wallsof the burette, then calculate the amount added to the combustion chamber. Calculation of compression rali Deduct 2c.c. from the volume of oil asured (= volumeLock erankshafl at top dead centre with crankshaft locking screw. Inthispoxition the mark @ on magneto flywheel mustcorrespond withthe |4degrees mark @ on stator. If not, the magneto flywheel has to be removed and the stator moved a4 required.Fitting of SEM ignition unit: (type 123 E Custom without variable timing, fitted on frames no. OLN 16 O1480), Turn engine on trestle magneto side upwards. Place Woodruff key ® into crankshaft. Insert the starter trans- mission gear @ with thrust washers @ on cach side into the bore with needle bearing, Fix armature plate ® with 3 Allen screws M5 and lock washers, using LOCTITE 221. Tighten stator with 3 slotted head screws MS and washers in central position (using LOCTITE 221). Degtense tapers of crankshaft and magnero flywheel, Don't use LOCTITE on tapers. it magneto flywheel, aligning key and keyway and tighten, but only slightly.In case of checking the ignition timing with Ignition adjustment: senboscopal lamp? Type 123E Custom with out variable timing oie 4 "i The mark on the magneto flywheel has to align with Cheiking wtih 3. dlél gauges the ‘Udegrees' mark on the stator at 5000 r.p,m. When Screw dial gauge into cylinder head combustion cham- satisfied that the ignition liming is correctly set. ber. Loasen the crankshaft locking screw and turn the ft lockwasher, hex, nut MI2x1 using LOCTI- cmunkshaft backwands 14degrees(=1(mmpistonstroke), TE 648 and tighten to 70Nm, Don'tapply LOCTITE Inthis position the cast mark must correspond with mark ' the ‘0 degrees’ on'statur taper! Finally, check the ignition timing with the engine running at 5000 t.p.m. using « stroboscope lamp,aligning key. and keyway andtighten, butonly slightly. Loosen crankshaft locking screw. insert dial gauge into spark plug threads, and set dial gauge to "D’ Tum flywhee! backwards by 1,84 mm = 19° for type Endure, Custom, AF | 1,30 mm = 16 ° for type Enduro ETX-Svizzera 2.03 mm = 20" for type 123 Rally, in this position the 2: mm peg @ pushed thraugh the hore in flywheel must engage in the slot @ of the stator. Otherwise remove magneto flywheel and turn Stator as required,Fitting of SEM ignition unit: (types 123 with variable timing) Tutn engine on trestle, magneto side upwards. Place Woodruff key @ intocrankshaft, Insert the starter trans- mission gear @ with thrust washers ® on each side into the bore with needle bearing. Fix armature plate @ with 3 Allen screws MS'and lock washers, using LOCTITE 221, Tighten stator with 3 slotted head screws M5 and washers in central position (using LOCTITE 221). Degrease tapers of crankshaft and magneto flywheel, Don't use LOCTITE on tapers. Fit magneto flywheel,Fit lockwasher, apply LOCTITE 648 to the hex. nut M12x1 and tighten it at 70 Nm, Don't use LOCTITE on the taper. Ignition adjustment types 123 with variable timing: The final cheek of ignition timing is done on the engine running at 10,000 'r.p.m. using a stroboscope lamp. To check for correct ignition timing with stroboscope lamp make & mark on crat se and magneto flywheel al the moment of ignition, Le. O74 mm = 12° BTDC for type Enduro, AF1.Custom O4l mm = 9 © for type 123 Enduro ETX Swizzera, 0.87 mm = 13" for type 123 Ratly, These marks must correspond at 10.000 rp.m.Starter gear cover: Fit starter gear cover @ and fix il with spring washer @ ond Allenscrew MG x 20. Tightening torque 4.5Nm, ATTENTION: Fil the spring washer with is back® {= convex side) towards the screw head, lo avoid damaging the cover. Ignition cover: Coat the ignition cover joint face ® with SILASTIC and fis the ignition caver ® with 4 Allen screws M6 x 25. Tightening torque 4,5 Nm,Sprocket: Engage 1" gear, Place O-ring © inw the groove of the malnshaft. Position sprocket @, press it iowards O-ring and secure with new circlip ®, ATTENTION: The circlip must be securely sealed in ils groave, with its sharp edge outwards! Remove crankshaft locking screw and fit Allen screw wilh sealing ring. Fitting of electric starter: pur the darter gears and check for free movement. jicose the sinner pinion with MOLYKOTE 111, insert the ae —+—— me sop biue blue _! —B— LH reguiator |eee Spark pl col /— a Po rete slop ( : ) rey yellow _¢. i s | yetow 3 | Te Stator in WG-version has yellow lighting cables and must imperatively be used with WG-ignitian coil (SEM no, 101 888 00 printed on it, The WG-ignition coil can however be used together with previous stator (blue lighting cables). red green blackpart oo, crunkshaft, magneto and clutch side IU, Beseription qty 1 | insertion jig for oj! seal 230 355. kickstart shaft 1 | 277 450 2 | insertion jig for ofl seal 230 425, L | zr a7s 3 | insertion jig for oil xeul 930 675. mainshafe 4 | insertion jig for ail sealx 230 195 and [250450 hump shaft, shift shat bushing | 1 | 276 770 insertion ty call seal 930 $00, P fev, counter shatt b | 2277090 Protection cup for crankshaft magnets side 1 | 276 THO t puller aady., for magneto My wheel L | 278 807 8 | crimkshaft locking screw —_ [1 [2st ons 9 | guide sleeve for oil seal 930 675 1 | 277 97h 10) pistog, ring spanner.for piston $4 mm t [876 973 11 | clutch adjustinent wrench ft 236 a 12) Bull bearing puller set lib 277 yee 12| puller assy. ball bearing 6203, | | 276 360 clutch shafi, magneto side {4 | bolt for puller, ball benring 6203 1 | 276 380 15 | patter sleeve 1 [276 370 16 “support plite 1/276 390 17) hex. et MI), fot puller bolt _ 2) [242.090 \ lye 362 18) puller ney s for bearing 6302, holanice shalt, muugneter sithe 19)| bolt for puller, bouring 6302 20 | puller sleeve, for bearing 6302 support plate 1 | 276 390) hex. aut MR, for puller bolt 2 | 242 201 24 puller plate assy,, for eruikshatt removal i err aagREPAIR TOOLS, GASKET SETS Descriptions putt tio) es. screw MI6xb.38150 clutch hub tacking Iot insert kit for trestle ask adaptor wtsy hos, nut ME x 20 washer 8,4 bolt, odapear hex, nut M8 spaver 10, S24/15 ai) 785 cocentrlg sleeve, fir engine 123 ring: half. for ball bearing 6206 ring: for ring halves puller assy, for beating, erankshal} fess. sere Allen screw MBia0. far pull S40 681 LOGTITE Ant-Seize 76710 297 431 ab MOLYKOTE (11 LOCTITE:271, vik screw, Securing Compe LOCTIVE O44 green, Screw Securing Compound, strong SILASTIC 732 RTV. 100 ue Lithium grease, 280) gr gasket set, ¢ Ravkot set, for edinplete engiite sy? 141ratio ry drive gear ratios with 64 straight g £20 = 3,200 Ist gear 34: 10 = 3,400 i I 2nd gear 30 : 13 = 2,308 3rd gear 27: 16 = 1,688 5: 19= 1316 “Sth gear 1 = 1,095 4th gear he Gear ratios-Sirada (AF 1) Primary drive gear ratios ratio Straight gears Ist gear 34: 10-= 3.400 64520 = 3.200 | 2nd g 13 = 2.308 3rd.gear 27; | 1.688 4th gear 25: 19 = 1,316 Sth gear 24; 2) = 1.143 6th pear 23 ; 22 = 1,045MC LOCO UMP mereR a Om es Change gear oil Check gear oil level Check RAVE (for tightness and free movement) Examine play of clutch relense Check oi and fuel tubes Clean carburetor and readjust idling Check electronic jenition and timing lean Spark plug, adjust electro: [every 3000 km de fevery 6000 kin ee] alter S00 kin, | * [| every 15000 kin > >] ><] 24 |X] >Engine falls to start: CAUSE Incorreet handling open REMEDY Switeh ‘on ignition, open fuel endure full fuel supply, Fuel line blocked and fucl fine, Spark plug sooty. wet or bridged Eleetnd® pap 100 late Ignition cable or spark plug protecor damaged Clean fel cock. fuel tankand fueitine. Clean or fephice spark plug Adjust elevtrode gap. Fit new ignition ‘eo protector Oe /spiirhe plu re chated in cable harness (short aireuit), Ignition svdeeh a kill button tau Insufficien! ignition voltage No ignition voltage ino spark) Engine cannot be stop- ped Water is carberetr a Jets obstructed Disconnect plug with black-white / black cable and test for spark. If ther isu spark (i.e ignitianunitisin order), check for possible cable damage isherveireulry, Ghedk ignition itch onel kif Duct Check ignition system Disconnectorangeshortingcable from ignition coil and: start again Mass defeci in stator Dismaritle und clean carburetor, Reed valve defective: Chirck and roptace if necessaryEngi CAUSE will not idle: REMEDY idling. jer Mocked lle mixture sorew in cortect adjustment Ignition unit defective Clean idle jer Adjust idle mixtuee be Check Jgnitivn unit, Filter element. intake sytem leaking Cheek and replace Reed valve defective Replace Engine splatters inte carburetor: CAUSE REMEDY Inbulficlent Fuel ane car buretar Check and clean fuel system, Engine air intake fins bn intake sidie, Chock of replace seals and flan. Bes Engine knocks under full load: REMEDY CAL Cathureior seming tsp je overteats Adjust carburetor. Cheek cooling liquid and ther- MHOnM HL sloomuch Fuel octine rating too tern Cheok ign rpm. 1m Hioving ar imax Use fuel with higher octane ra ting Cheek sion rath.ROUBL Engine does not reach full specd: cal | E Carburewr flooding. float level et too high. float needle seat dimly or dams ged, Gose curburetar jets. Hoi puncumred REMEDY. ett teplace War it jaidjust flout level Defective ignition Lack of engine perfor! CAUSE Chock ignition, mance: REMEDY Fuel supply intermittent of Witterdtier in carburetor Air filter dirty Clein fuel eysiem and eirbure tot, Clean of replace air filter Loss.af compritss loose wpark pli combustion chamber insert, defective O-ring Cheek forleaksand replace faulty parts, Etegironie (gnition timing faulty Cheekeles ie igsith Exhuuel ledkingor blucket! Tighien exhuulet flange, replace faulty parts RAVE dogs not open Clear and chock RAV nenis, Clean pmpalse bore i eyiinder empe: Replace defective parts Check compression,