Preliminary Procedures - Malossi 5919140 Manual Del Usuario

Assembly Instructions

Preliminary procedures

• Clean the entire vehicle
thoroughly and the entire
engine in particular.
ENGINE disassembly
• Disconnect the battery.
• Disconnect all cables making
up the electrical system that
goes to the engine head.
• Disassemble the complete
exhaust unit.
• Remove the air filter housing.
• Disassemble the fuel system
from the cylinder head, leaving
it connected to the frame.
ORIGINAL crankshafts
disassembly
• Remove the timing mark plug.
• Bring the crankshaft to
top dead centre on the
compression stroke. To check
the exact position of top
dead centre you have to align
a
notch on the flywheel with
the notch b on the crankcase
(Fig. 1).
N.B.: TDC on the compression
stroke is obtained when the
camshaft lobes are opposing
each other.
• Remove the timing chain
tensioner and its gaskets.
• Remove the camshaft covers
and locating pins.
ATTENTION:
To avoid damaging the head,
camshafts or camshaft covers,
loosen the camshaft cover bolts
in a criss-cross pattern, from the
outer to the inner.
8
• Remove the two camshafts
making sure not to let the
timing chain fall inside the
bottom end of the engine.
Crankshafts assembly
• Rotate the crankshaft to top
dead centre by aligning the
flywheel timing mark a
the crankcase timing mark
(Fig. 1).
• Tilt the camshafts so to go
under the timing chain with
the camshaft timing gears and
then insert the camshafts onto
the cylinder head.
• Adjust the timing gear chain
on the exhaust camshaft
gear first; maintain tension
in the chain for the exhaust
side and proceed with the
intake camshaft.
to
b