| 1. Drift the bearings and shaft for the water pump |
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2. Using circlip plyers and a screwdrive press home the circlip |
| 3. Place the water impeller in postion and tightn, NOTE! it's got a
reverse thread! |
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Replace the crank into the right hand side crankcase, (use a drift
if neccessary) make sure that the crank is in streight. |
| 5 Smear a small amount of gasket compund in the edges of the crancase.
Ind replace the two dowels. |
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6 Then replace the crank and otherside of the crankcase into position,
and gently using a wooden block (rotate the postion of the block to keep
the casing as streight as possable) and a lump hammer tap the crankcase
together |
| 7. Replace the crankcase bolts and torque them correctly (12-13 Nm
in this case) |
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Small end bearing goes in first
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Then the gudgeon pin fits through the piston and the bearing
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last the circlip fit into the groove in the piston where the gudgeon
pin fits.
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8. Replace the piston into the con rod making sure that you don't lose
the circlips into the crankcase. Double check that both sides if the piston
have circlips, falier to do so will cause the gudgeon pin (wrist pin) slide
out of position and leave a bad groove in the barrel, or worse. |
9. Place the base gasket into position
Gently ease the barrel into postion, use a couple of screwdrivers to
close the compression rings. Note make sure that the ends of each ring
aleigns with the two pins in the piston |
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10. Replace the rubber head gasket and place the head into position
over the barrel |
11. Replace the four head nuts and torque them to correct settings
(10-11Nm) |
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12.Place the rubber gasket in the water jacket and place the jacket
into position over the head. Replace the four bolts and tighten |
| 13. replace the rubber tube and 3 way pipe. from the water jacket to
the right hand crankcase |
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14. feed the starter motor lead through the hole of the right hand
half of the crankcase and put th rubber in postion |
| 15. repalce the stator plate into postion, use an impact driver and
a little lock thread to the threads, to make sure they are not going to
undo due to vibration. |
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16. Replace the genorator flywheel, making sure that the woodruff key
fits into the grove provided.. |
| 17. Replace the pick ups and the wire run plate into position |
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18. Replace the thrust washer onto the water pump shaft and replace
the belt drive wheel |
| 19.Replace the belt drive wheel into the crankshaft, |
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20. Replace the belt |
| 21. and the two plates |
Note, don't put the two bottom screws in, untill you replace the second
plate,
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and the throttle control
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the "key" fits into the groove in the water pump drive wheel which
you can see in the hole of the second plate.
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replace the throttle cable
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22. Grease the 6 rollers and the centre collar.
NOTE, the damaged casing from the old variator
is not replaced as the new polini version does not have one. |
| 23. Assemble the variator |
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24. Place the variator onto the crankshaft. |
| 25. Place the drive belt into position. |
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26. Replace the electric starter gearing.into the brass bush in the
crankcase |
| 27. Replace the starter drive gear and fins |
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28. Replace the starter pinion and the nut onto the crankshaft.
29. Replace the other kickstart pinion onto postion in the outer casing |
| 30. Replace the casing, making sure that the electric gearing fits
into the brass bush in the casing. |
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