9.1 -
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
 
 Spare parts catalogue
Important
Bold reference numbers in this section identify parts not shown in the figures alongside the text, but which can be found in the exploded view diagram.
Removing outer components
Remove the alternator-side crankcase cover and the alternator assembly
Unscrew the screw (17) and remove the oil breather valve (1) with the O-rings (2). Check the condition of O-rings (2) and renew them if necessary.
Unscrew and remove the oil filter support nipple (6) and remove also by-pass spring (7).
Remove the mesh filter (A) from the clutch crankcase half (Sect. 4 - 3, Changing the coolant).
Remove the drain plug (10) with its seal (9).
Remove gear position sensor (4) by means of the tool number 88713.3407.
Remove the cylinder head studs (5) with the aid of the appropriate tool.
To remove the engine sensor (23), unscrew the screw (25) and recover the washer (26).
Check the condition of O-rings (22) and renew them if necessary.
Refitting the external components
Make sure that the O-rings (22) are fitted on the crankcase.
Fit the engine pickup (23) in its seat in the crankcase half.
Start the screw (25) with washer (26), and tighten it to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect. 3 - 3, Engine torque settings).
Use a feeler gauge to check the clearance between the engine sensor (23) and the timing gear (13). The value must be between 0.6 and 0.8 mm.
Check the condition of O-rings (2) and renew if necessary.
Install the oil vapour breather valve (1) in the crankcase along with O-rings (2), previously lubricated.
Tighten the screw (17) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm) (Sect. 3 - 3, Engine torque settings).
Position the by-pass spring (7) on the nipple (6) and apply the recommended threadlocker to the end of the nipple to be screwed in the crankcase half. Screw oil filter cartridge fitting (6) fully into the crankcase half, positioning the spring in the seat between the two notches (A). Tighten the nipple to a torque of 42 Nm (Min. 38 Nm - Max. 46 Nm) (Sect. 3 - 3, Engine torque settings).
Fit the seal (9) on the oil drain plug (10). Position the seal that the side with the square edge (B) is facing the chain side crankcase half.
Clean the plug thread, apply a string of THREE BOND TB1215 along the plug thread spreading it by the entire circumference (360°).
Screw the exhaust plug (10) with relevant washer (9), and tighten it to a torque of 6 Nm (Min. 5 Nm - Max. 7 Nm) (Sect. 3 - 3, Engine torque settings).
Note
After tightening, remove any excess sealant.
Refit idle gear position sensor (4) by means of the tool number 88713.3407.
Refit the mesh filter (A) (Sec. 4 - 3, Changing the engine oil and filter cartridge).
Check the condition of O-rings (16) of the stud bolts (5) and replace them if necessary.
Fit, using the tool (C), the O-rings (16) in the corresponding seats (D) of the stud bolts (5).
Fit the stud bolts (5) on crankcase half, by applying sealant on the thread and tightening them to a torque of 30 Nm (Min. 28 Nm - Max. 32 Nm) (Sect. 3 - 3, Engine torque settings). Use the appropriate commercial tool for this operation.
If removed, apply prescribed threadlocker on the dowel (24), tighten the latter to the torque of 15 Nm (Min.13.5 - Max.16.5) (Sect. 3 - 3, Engine torque settings), insert the seal (3) on the service plug (8): the seal must be oriented so that the square edge faces the clutch-side crankcase half. Apply prescribed threadlocker on the plug thread (8), start it in the crankcase half and tighten it to a torque of 15 Nm (Min. 13 Nm - Max. 17 Nm) (Sect. 3 - 3, Engine torque settings).
 
 
Removal of the timing gears
Remove the alternator-side crankcase cover and flywheel/alternator assembly
Slide out driving gear (A) of timing gear pair (13) and remove the Woodruff key (14).
Relieve the staking on the lock washer (12) of the nut (11).
Restrain the driven timing gear by inserting a pin in one of the holes, and unscrew the nut (11).
Remove the nut (11), washer (12), driven timing gear (B) and Woodruff key (15) from the timing belt driveshaft shaft.
Refitting the timing gears
Before reassembling the removed parts, check timing gears (13) for wear. Change, if necessary.
Important
The timing gears (13) must always be renewed as a pair.
 
Refitting is the reverse of removal.
Warning
When introducing the driven gear (B) check that the tongue (15) is correctly fitted on the timing system shaft, align the gear slot with the tongue matching the driving gear timing mark (A) with the gear (B).
Important
On completion of the refitting operations, check that tab washer (12) is staked against nut (11) in such a way as to prevent the nut from working loose.
 
Refit the flywheel/alternator assembly. and alternator side crankcase cover
Removal of the starter motor idler gear
Remove the alternator-side crankcase cover and flywheel/alternator assembly
Slide the gear pin (21) complete with the gear (19) and washer (20).
Warning
Pay attention to the washer (20) since it may fall inside the crankcase half.
At this point, it is possible to remove the starter motor as described in Sect. 6 - 3, Starter motor.
Refitting the starter motor gear
Position the washer (20) and the gear (19) in the pin (21) and take the pin into contact with the crankcase half.
 
Refit the flywheel/alternator assembly. and alternator side crankcase cover