0N - Engine
1 - Removing - reassembling the complete engine 5
Removing the engine 6
Reassembling the engine 8
2.1 - Lubrication system: oil pump 9
Removing the oil pump 10
Disassembling the oil pump gear 11
Reassembling the oil pump gear 12
Refitting the oil pump 13
2.2 - Lubrication system: oil cooler 14
Removing the oil cooler 15
Oil cooler inspection 17
Refitting the oil cooler 17
2.3 - Lubrication system: oil breather 21
Removing the oil breather 22
Refitting the oil breather 23
4.1 - Head unit: checks and adjustments 25
Checking and adjusting valve clearance 26
Checking engine timing 30
4.2 - Cylinder heads: side covers / timing system 32
Removing the timing side covers 33
Disassembling the timing system 34
Disassembling the mobile tensioner 38
Disassembling the belt rollers 38
Reassembling the timing system 39
Refitting the timing side covers 48
4.3 - Head unit: camshafts 49
Removing the engine oil temperature sensor 51
Refitting the engine oil temperature sensor 51
Disassembling the intake manifolds 52
Refitting the intake manifolds 53
Removing the cam covers 54
Removing the valve covers 56
Refitting the valve covers 57
Camshafts disassembly 58
Checking the camshafts 59
Checking the oil seals 59
Refitting the camshaft 60
Refitting the cam covers 62
4.4 - Head unit: valves - rocker arms 64
Disassembling the engine heads 65
Overhauling the head parts 70
Reassembling the head 79
5 - Cylinder / piston assy 89
Removing cylinder / piston assy 90
Overhauling the cylinder / piston assy 93
Refitting cylinder / piston assy 99
6.1 - Clutch unit: clutch 102
Clutch unit 103
Disassembling the clutch 104
Checking and overhauling the components 108
Reassembling the clutch 110
6.2 - Clutch unit: clutch cover 113
Removing the clutch cover 114
Disassembling the clutch cover 115
Reassembling the clutch cover 116
Refitting the clutch cover 118
6.3 - Clutch unit: primary gears 120
Disassembling the primary drive gears 121
Primary drive gear pair installation – Meshing play inspection 124
7.1 - Gearbox assembly: gear selector levers 126
Removing gear selector levers 127
Removing the gear stopper and ratchet 129
Reassembling gear stopper and ratchet 130
Reassembling the gear selector lever 131
7.2 - Gearbox assembly: gearbox shafts 132
Removing the gearbox 134
Disassembling the gearbox shafts 136
Overhauling the gearbox 141
Inspecting the gear selector forks 142
Inspecting the fork selector drum 143
Reassembling the gearbox shafts 144
Reassembling the gearbox 148
8 - Flywheel - generator 149
Removing the generator cover 151
Disassembling the generator cover 154
Removing the flywheel - generator assembly 155
Checking the flywheel - generator assembly 157
Refitting flywheel / generator assembly 160
Reassembling generator cover 162
9.1 - Casing unit: outer components 165
Removing outer components 167
Reassembling the outer components 170
Removing the timing lay gear 173
Reassembling the timing lay gear 174
Removing the starter motor driven gear 175
Reassembling the starter motor driven gear 176
Checking the engine sensor air gap 177
9.2 - Casing unit: crankcases 178
Opening the casings 179
Overhauling the casings 182
Main bearings 184
Reassembling the casings 186
Shimming the shafts 188
Closing the casings 200
9.3 - Casing unit: connecting rods 203
Removing the connecting rods 204
Disassembling the connecting rods 204
Overhauling the connecting rods 205
Reassembling the connecting rods 211
Refitting the connecting rod unit 213