0
Engine
1 - Removing - reassembling the complete engine
5
Removing the engine 6
Reassembling the engine 9
2.1 - Lubrication system: oil pump
10
Lubrication system 11
Removing the oil pump 13
Disassembling the oil pump gear 14
Reassembling the oil pump gear 15
Refitting the oil pump 16
2.3 - Lubrication system: oil breather reservoir
17
Removing the oil breather tank 18
Refitting the oil breather tank 19
4.1 - Head unit: checks and adjustments
20
Checking and adjusting valve clearance 21
Checking engine timing 25
4.2 - Cylinder heads: side covers / timing system
27
Removing the timing side covers 28
Disassembling the timing system 29
Reassembling the timing system 33
Refitting the timing side covers 40
4.3 - Head unit: camshafts
41
Removing the engine oil temperature sensor 42
Refitting the engine oil temperature sensor 43
Disassembling the intake manifold 44
Refitting the intake manifolds 45
Removing the cam covers 46
Removing the valve covers 49
Refitting the valve covers 49
Removing the camshafts 50
Checking the camshafts 52
Checking the oil seals 52
Checking the circlips 53
Checking the bearings 53
Refitting the camshaft 54
Refitting the cam covers 56
4.4 - Head unit: valves - rocker arms
58
Disassembling the engine heads 59
Overhauling the head parts 65
Reassembling the head 72
5 - Cylinder / piston assy
80
Removing cylinder / piston assy 81
Overhauling the cylinder / piston assy 84
Refitting cylinder / piston assy 90
6.1 - Clutch unit: APTC wet clutch
92
APTC clutch unit description 93
Disassembling the APTC system 94
Checking and overhauling the APTC unit 97
Reassembling the APTC unit 101
6.2 - Clutch unit: clutch cover
104
Removing the clutch cover 105
Disassembling the clutch cover 106
Reassembling the clutch cover 108
Refitting the clutch cover 109
6.3 - Clutch unit: primary gears
111
Disassembling the primary drive gears 112
Refitting the primary drive gears and checking meshing play 116
7.1 - Gearbox assembly: gear selector levers
119
Removing the gear selector levers 120
Disassembling the gear selector levers 121
Removing the gear stopper and ratchet 122
Reassembling gear stopper and ratchet 123
Reassembling the gear selector lever 124
Reassembling the gear selector lever 126
7.2 - Gearbox assembly: gearbox shafts
128
Removing the gearbox 129
Disassembling the gearbox shafts 131
Overhauling the gearbox 136
Inspecting the gear selector forks 137
Inspecting the fork selector drum 138
Reassembling the gearbox shafts 139
Reassembling the gearbox 142
8 - Flywheel - generator
143
Removing the generator cover 144
Disassembling the generator cover 146
Removing the flywheel - generator assembly 147
Checking the flywheel - generator assembly 149
Refitting flywheel / generator assembly 152
Reassembling generator cover 154
Checking the engine sensor air gap 157
9.1 - Casing unit: outer components
159
Removing the outer components 160
Reassembling the outer components 163
Removing the timing lay gear 165
Reassembling the timing lay gear 167
Removing the starter motor driven gear 168
Refitting the starter motor driven gear 169
9.2 - Casing unit: crankcases
170
Opening the casings 171
Overhauling the casings 174
Overhauling the main bearings 176
Reassembling the casings 177
Shimming the shafts 179
Closing the casings 189
9.3 - Casing unit: connecting rods
194
Removing the connecting rods 195
Disassembling the connecting rods 195
Overhauling the connecting rods 196
Reassembling the connecting rods 202
Refitting the connecting rod unit 203