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2.1.1 BatingPlafre

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

;i
fl

, rt

fi
J T J

tri5\

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

[[

Ready
loradjustment.
aiustable

ill

II l I H

[il Il

il H lI ilil

lil ill il

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.
despus
de
caliente
deunperiodo
enfriamienlo
deporlo menos
mediahora.
oil temoerature
s 80"C.
< 80'G.
Temperatura
delaceite:

I
;

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.

l'
lr

-::

l
'-"
_-t

0,3mm
0,5mm

Tightening
specification:
20l2 tlm

Prescriocion
dea0riete:
20t 2 llm.

Recheck
theadiustment
wilhleeler
gauge.

Comprobar
nuevamente
elaiuste
electuado,
mediante
lagalgade
espes0res-

'.*

--.q

2.00.01

'\J

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

,t
_/,\

ffi

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.

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.

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.

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 gaugtogetherwhichreleasesthe lock. The gaugeis now secure
and tight on the beh.

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.

"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.

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.