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MODEL FSE 400 / 450 ENGINE
Frame Type DELTABOX, semi double cradle chassis made from rectangular Cromoly tubes. Aluminium swing arm Front Suspension Inverted Marzocchi Diameter 45 mm Run 295 mm Inverted hlins Diameter 48 mm Run 295 mm Rear Suspension Progressive system with hlins shock absorber Run 320 mm Front brake Disk of 260 mm Nissin Pump and simple / double Nissin calliper Rear brake Disk of 220 mm Nissin Pump and simple / double Nissin calliper Wheels Rims D.I.D. Type U with tyres Michelin Comp3
Wheel base 1.475 mm Seat Height 940 mm Minimum ground clearance 340 mm Fuel Tank Capacity 7.2 litres
Un-installing the engine in the chassis
Before dismounting the engine from the frame, wash it with a steam washer. The dismounting sequence is explained in the following steps.
Dismount the seat and the frame covers.
Empty the engine oil.
Remove the engine plate.
Empty the chassis (A) oil tank. Empty the coolant of the engine (B).
Disconnect the wire (-) of the battery (C) and the engine earth connection (D).
Disconnect the alternator clamp (E) and the phonic wheel sensor wire.
Disconnect the spark plug pipe (F), the engine oil vaporiser tube (G), the engine oil resevoir vent hose (H).
Loosen the cylinder head injector tubing clamp (l).
Disconnect the starter motor connection wire (J). Dismount the starter motor removing the screws (K).
Dismount the water tube (L).
Remove the pedal starter lever (M).
Remove the exhaust collector (N).
Disconnect the 2 radiator tubes.
Disconnect the engine oil tube (O) in the chassis tank.
Remove the gearshift lever (P).
Remove the engine pinion protector (Q).
Remove the clutch cap (R). De-tense the chain.
Remove the output pinion clip (S).
Remove the Engine pinion (T).
NOTE: Observe which is the placement direction of the said pinion.
Remove the carved bolts and the brake pedal.
Remove the motor from the frame.
Installation of the engine in the chassis
Mount the engine in inverse order to de-installation
Fix the screws and engine fixing nuts.
NOTE: In this phase, temporarily tighten the nuts. The engine fixing nuts are self-locking. Once removed they lose their self-locking capability and are useless.
PRECAUTION Replace the engine fixing nuts with new ones.
Hold the screw heads with a spanner and tighten the engine fixing screws with the specified torque. Element A B C Nm 66 Kgm 6,6 6,6 6,6
Length of the screws (A): 108 mm (B): 110 mm (D): 103 mm
Fix the brake pedal screw with the specified torque. Brake pedal screw: 29 Nm (2,9 Kg) PRECAUTION Replace the carved bolts with new ones.
Mount the engine pinion. NOTE: Observe which is the placement direction before the said pinion, to be able to achieve the same direction of wear.
Place the engine pinion clip.
Connect the chassis tank tube.
Fix the exhaust collector screw (1), with the specified torque.
NOTE: Apply component NURAL 29 in the exhaust system joints.
NOTE: Apply LOCTITE 243 to the pedal starter lever screw.
Fill 1.2 L of an engine oil classified SF or SG through the API service and with a degree of viscosity SAE 10W-40 through the oil fill mouth in the frame (A) and check the level. DATA Engine oil capacity Change of oil: 1 L Changing the oil and filter: 1.2 L Engine general inspection: 1.2 L
Start the engine and leave it running some three minutes at idle. Stop the engine and wait three minutes; immediately check the oil level via the rod.
Minimum level Maximum level
Dismounting the engine
Loosen the 3 screws that hold the starter clutch cover. One of the 3 also holds the alternator cover.
Remove the starter clutch cover.
Extract the starter clutch.
Loosen the 2 screws that hold the starter motor.
Extract the starter motor. NOTE: The 2005 starter motor turns in the opposite direction to that of 2004.
Loosen the 7 retaining screws that hold the alternator cover. One of them is located in the starter clutch cavity.
Remove the alternator cover.
Loosen the 2 screws that hold the position sensor (Pick-Up) (A).
Remove the de-multiplier pinion (B).
Loosen and extract the spark plug.
Loosen the crankshaft nut. NOTE: The nut loosens towards the right.
Turn the alternator rotor until placing the 7th tooth (A) of the phonic wheel in the center of the position sensor (Pick-Up) hole.
Loosen the 3 screws that hold the cylinder head cover.
Remove the cylinder head cover.
With the help of the extractor (Ref: MFS400134045), remove the alternator rotor.
Loosen the 3 screws that hold the oil extractor pump.
Remove the oil extractor pump cover.
Remove the oil extractor pump.
Loosen the 2 screws that hold the distributor chain tensor.
Remove the distributor chain tensor.
Remove the oil distributor.
Loosen the 2 lateral screws that hold the cylinder head to the cylinder.
Loosen the rear screw that holds the cylinder to the cylinder head.
Remove the cylinder head.
Remove the cylinder head gasket.
Remove the distributor chain front skate.
Loosen the 2 screws that hold the cylinder to the engine housing.
Hold the distributor chain and remove the cylinder.
Remove one of the clips that hold the piston casing and push to remove it.
Remove the cylinder gasket.
Loosen the 5 screws that hold the cover of the clutch disks.
Screw the centering tools into place (supplied together with the tools for the motorbike) and tighten them to 10 Nm. NOTE: This operation is mandatory to ensure the correct dismounting of the clutch.
Remove the 3 screws, the 3 washers and the 3 springs that hold the clutch unit.
Remove the clutch press cover.
Remove the clutch pusher.
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