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• Maximiliano Ripoll

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cover. ThemtingplaleCisattached t0thevalve ThemodelA" theengine serialnumberB andtheperplate. dataarestamped ontherating formance numbermrNbegltanwlpn Ttrcmodelandengineseflal parts. ordefing

Tlpengine serial numberB isshmpedonhecmnk plate. Daswellastherating

Seryice andMaintenance 6.6.1 Checking / AdiustingValue Clearances

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vv O Relrrove tlr0cylin(icr herdcovcr. crartkslraft O l'osiliorr as persclrcrrralir: 6 6.L L o Beforc rrljrrstirrg valve nllowerrginc cleararrce. to for at leasl30 rninltes. cooldol.,rrr Theoil lernpot;thrre shouklbohelo\,v B0 C. \ 0lleckvilveclearance t hetr.,rccrr rockerarnr/ l;tDl)01 conlr(;tface2 an(lvalvcslt)ilr3 r,,rith leeler (;rrq06 {th{leshouldhoorrlyslirlhlresislrutcc l",helr leelerbladeis irrscr lcd) fot llcrrrrissillle valveclgrrlrrr;e.:;ce 9I

O Adjrrst valveclelrarrce if rrenessiry: - Beleaslo e c k r r L4r.t - [ J s callerkr c y / t o t u n ]s e t s c r e v5Js 0 t l n t thcc0rrect cleararrce isattrined aflorlocknrrt 4 hasl) ec nl i g h l e n e r l . O Clteck ar(iarljrjsl valvccletrarrce orrallrcnrairrirrgcyliildefs. O ReJrlar;o cvlirrrltlr lrearl cover(lrsorrewqaskel if neerled )

6.6 Adjustments

adiuslment forualveclearance Schematic parael adjuste deuilvulas deholgura Esquema F Manual1011 Worlshop

poriition Grankshalt

position Crankshaft

? Posicidndelcigiiefral -

delcigiiefral Posici6n of cylinder Turnengine untilvalves No.1 overlap.

furtherbyonecomplete Turnengine (360"). revolution

elmotor,hastaquelasvilvulas Girese ensu N"1 coincidan delcilindro posici6n momentdnea.

girando elmotorporuna Continuese (360') completa rotaci6n

foradjustmen, Notready f1--fn noajustable lU fl

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Ready loradjustment. aiustable

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1.00.09

Valve clearance Juego dev6luulas

Ghecking andadiusting y ajustes Verilicacidn Wortshop Manual 1011F

English

Espafrol

Thestandard valveclearance canbe adiusted:

Elaiustedeljuegoestindardevdlvulas esposible:

withengine coldorwarmaftercooling Conelmotorfrioo conelmotor downlor atleast0.5h. despu€s de caliente deunperiodo enfriamienlo deporlo menos mediahora. oil temoerature s 80"C. < 80'G. Temperatura delaceite:

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llote: Thevalveclearance is to beinNota:Eliuegodev6lvulas debe creased by0.1mmat everycypor0,1mma cada aumentarse linderheadgasket renewal. cambio delaiuntadeculata,. valveclearance Thestandard is Tras500horasdeservicio se to beadiusted aftercompletion aiustara eliuegoestindar. o{500hoursol operatron. headcoverhasbeenremoved. Latapadeculataesti desmonlada. Gylinder 1. Turnengine untilvalves of cyl.No. 1 overlap.

quese 1. Girarelcig[efral hasta crucen lasv6lvulas 1. enelcilindro

Forvalveclearance adiustment seeSpecification Data. schemalic

Pan el esquema deaiusledeliuego devSlvulas, Y6anso losDatos T6cnicos.

l{ole:Valves overlapping means: valveaboutto close. Exhaust Inletvalveaboutto open. pushrod Neither canbeturned inthisposition.

Nola:Crucedev6lvulas signilica: La v6lvula deescaoe arinnoestd y la deadmisi6n cerrada comienza a abrirse. Enesta posici6n, girarlas noesposible dosvarillas deempuje.

2. Adiustvalveclearance on respectivecylinder withleelergauge.

2. Ajustareljuegodevilvulasenel cilindro corresoondiente mediante lagalgadeespesores.

llote:lnletvalveclearance:0.3mm Exhaust valveclearance:0.5 mm

llota: Juegodevdlvulas - admision: - escape:

3. Tightenlocknut.

3. Aprebrlacontratuerca.

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0,3mm 0,5mm

Tightening specification: 20l2 tlm

Prescriocion dea0riete: 20t 2 llm.

Recheck theadiustment wilhleeler gauge.

Comprobar nuevamente elaiuste electuado, mediante lagalgade espes0res-

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2.00.01

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Checking andadjusting y ajustes Uerificacion

Valve clearance Juego dev6luulas

Wortshop Manual1011 F English

Espafiol

4. Putgasketin place.

4- Colocar laiunta

Fitcylinder headcover. Tighten bolts.

Montarlatapadeculata. Apretar lostornillos.

Iighteningspecification: 8.5 l{m

Prescripcion deapriete:8,5 Nm.

2.00.02

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ServiceTraining

NE$TE SERTfTSH TOOTHEDBELTINSTALLATION B/FL/M1O11IFIE BELTREPLACEMENT AT SPECIFIED MAINTENANCE INTERVAL

T10 11 /11 /96 BLTMIANT.PUB

Preparedby.:D.Hensel

BIFL 1O11lE DriveTrain 1. 2. 3.

Toothedbelt Crankshaftgear Tensioningpulley

4. 5.

Oil pump Camshaftgear

The belt (1) is locatedat the blowerend of the engine. lt is drivenby the crankshaft(2) and driving the camshaft (5) and the extemally mounted engine oil pump (4). lt is tensionedby the tensioningpulley(3). The use of a toothed belt, instead of gears, has two main advantages:flexibilityof selecting the camshaft location and low noise emission. A reinforcedplastic cover protectsthe drive train. A duct suppliesair to the belt for cooling and cleaning,thus extendingthe life expectancyby 50%, When replacingthe toothed belt on an enginethat is still assembled,the following must be removed to have easy access to the belt rocker brackets,V-belt pulley, dust cover, fuel injectionpumps. The followingspecialtools are required: 1 set lockingpins P/N 030 1093 1 tensionmeasuringgauge P/N 030 1095 1 wrench;camshaftgear clampingwasherP/N 030 1129 Prep by DHensel

July 25, 1996

KIIFI

.-.

oEfifz Service Trainincl

CrankshaftLockingPosition It is necessaryto time the camshaftto the crankshaft.This determinesthe fud iniection timing and valvetiming. For this procedure,the crankshaftand camshafthave to be position. locked into a pre-determined Removethe hex head screw plug from the crankcaselocatedon the right side at the blowerend right abovethe crankcaserim (lookingat the enginefrom the blowerend). Turn the crankshaftin rotatingdirection. Whileshininglightthroughthe screwplughole,a machinedsurfaceon the crankjoumal web becomesvisible,when turningthe crankshaft.Insertthe lockingpin (specialtool) and tighten. Slowlyturn crankshaftin rotatingdirectionuntilit contactsthe pin.

2

oEl$F-SeruiceTraining

CamshaftLockingPosition To be able to lock the camshaftin its corect position,removethe screwplug d the right end. The plug is locatedbehindthe clamflng side of the crankcasenearestthe flyr,vheel bracketfor the cowlingcover (the engineshouldbe lookedat ftom the flyrvheelend). Shininglight throughthe openingof the crankcase,camshaftjournal#1 eanbe seen. Turnthe camshaftuntilthe locatingholebecomesvisible. lt mightalso be necessaryto movethe shaft in axialdirectionto alignthe locatingholewith the bore in the crankcase. Insertthe lockingpin and turn it in untilit bottomsout againstthe crankcase. Both camshaftand crankshaftare timedto eachother.

3

SeruiceTraining "E$F-

CamshaftLocking Position One the camshaftis locked in position,loosenthe center bolt that holds the camshaft gear in place. For safetyreasons,use the DeuE specialtool to holdthe gearclampingwasher. lf required,removegearassemblyand cleanallpartsfrom oil. All contastsurfacesmust be free of oil and completelyClqt.

4

SeruiceTraining "EUF-

ToothedBelt lnstallation RotatetensioningpulleyUratthe openingfor the allenwrenchis locatedtorrrardsthe oil sump sealingsurface. Fit toothedbeftto all gears. Equallyspacethe belt aroundits assembly,i.e. measurethe distancefromthe crankcasesurfaceto the edge of the bett. The spacingshouldmeasure8 - 9mm. Note: Makesure the crankshaftis restingsecurelyagainstthe lockingpin. Slide tension measuringgauge onto the toothed belt. The procedureshould be as follows: Pressthe two leversof the gaugetogether. Pushin the brlttonon the gaugeand hold. Releasethe two levers. The measuringdeviceis now tensionedand tocked. The bslt tension should be measuredbetweencamshaftgear and oif pump gear. Slide the instument onto the bett and makesure that the rollersare fluslr wittr ne edge and the tensioningfinger is betweentwo teeth of the belt. Pressthe leversof the gaug€togetherwhichreleasesthe lock. The gaugeis now secure and tight on the beh.

5

offi- ServiceTraininL

ToothedBeltTensioning 1. 2. 3.

Camshaftgear Crankshaftgear Tensioningpulley

4. 5.

Oil pumpdrtve Tensioningmeasuringgauge

Note:Makesurethe belttensioningdeviceis not touchingany enginecomponents,€.9. pump gear, cam gear. Pre-tensiontoothed belt. Tum tensioningpulleywith the aid of an allenwrench@unterclockwise. Turn until a scale readingof $3.5 is achieved. Tightenthe tensioningpufleyboft with 45-49Nm.

6

"ES*

ServiceTraining

CamshaftGearTightening Hold camshaft gear clampingwasher with specialtool. Pre-loadcamshaftbolt with 30Nm. Note: Pay specialattentionto the bottgrade. Tightenthe camshaftboh as follows: 1. Boltgrade10.9 tightento 150" 2Bolt grade 12.9 tightento 210" Removeadiuslingpins from crankshaftand camshaft.Removeatsotensionmeasuring gauge.

7

ToothedBeltTensioningGheck Tum crankshaft in rotatingdirectionthroughfour completerotations. Reinstalltension measuringgaugeas describedearlier.A readingof 6.5 - 9.5 shouldbe obtained.lf the the belttension,following the previousprocedure. scalereadingis notobtained,re.adjust Note: A toothedbett,that has beenin operationfor morethan200 operatinghours,must not be reused.

Prep. by D.Hensel

July 25, 1996

'ESP- ServiceTraininq

ValveTimingCheck It is necessarythat the hex head screwplugs are removed. Installgamshaftlockingpin and tum it intothe crankcaseas tar as it will go. Attacha torque wrenchto the centralcrankshaftbolt. Apply a torque of 4ONmin the directionof crankshaft rotation. Do not hold the load, slowly release it and remove the torque wrench. Tum the crankshaft lockingfln into the crankcaseuntil it makesslightcontact with the crankshaft.Markthe positionof the lockingpin. The timingis conectwhenthe pin stilfcan be turnedin for Vtor 2Titurnsuntilit bottomsout. lf the pin cannotbe turned in that far, repeatall previousprocedures.lf the checksare withinspecification,remove both locking pins. Glosethe holeswtththe screw plugs, applyingnew copper seals. Reassembleengine.

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