Before assembling the crankcase halves, calculate the shims required to obtain the correct end float of the crankshaft and gearbox shafts.
To determine the correct shim thickness proceed as follows.
Shimming the crankshaft
Add 0.30 Mm preload for crankshaft axial bearings to bed in correctly into their seats (inner rings seated inside outer ring).
Thus, we obtain: sa=la1+la2+0.30-La.
To calculate the thickness of each shim note that: sa=sa1+sa2 where "sa1" and "sa2" represent the shims for the clutch-side crankcase half 1 and the alternator-side crankcase half 2.
Considering the alignment of the shaft, this gives: sa1=la1+0.15-La/2; and finally, the second shim thickness: sa2=sa-sa1.
In addition to the above procedure, the following is a practical shimming method, providing a guide on how to calculate the crankshaft shim thickness accurately.
Install a shim of minimum thickness (1.90 Mm) on each side of the crankshaft to prevent contact between the crankshaft web and the crankcase.
Install the crankshaft and assemble the two crankcase halves.
Fit four m8 screws in the seats indicated in figure and tighten them to a torque of 19 nm (min. 17 Nm - max. 21 Nm) (sect. 3 - 3, Engine torque settings).
Place a dial gauge (c) with magnetic base on a support plate fixed to crankcase.
Bring the stylus into contact with the end of the crankshaft and set the dial gauge to zero in this position.
Place a lever (d) between crankcase and crank web of the crankshaft pushing towards dial gauge.
Note on the dial gauge the total clearance and add a preload of (0.30 Mm) plus the thickness of the shims used (1.90X2=3.8 Mm).
Divide the resulting value by two to obtain the thickness of the shim packs to be installed at either end of the crankshaft.
Note
After assembling the crankcase halves, the crankshaft should turn with some interference in the new bearings.
Shimming the gearbox shafts
The following thickness spacers are supplied as spare parts.
Shimming the gearbox selector drum
The following thickness spacers are supplied as spare parts.
Swingarm
Swingarm pivot
Washer
Special screw
Bush
Sealing ring
Roller bearing
Special screw
Rear swingarm
Spacer
Bearing
Spacer
Spacer
Hose clip
Pin
Chain slider (lower)
Washer
O-ring
Calliper mounting bracket
Circlip
Spacer
Inner ring
Hub
Cable grommet
Ch ...
Distance travelled on fuel reserve: trip fuel
This function shows the distance travelled on fuel reserve (in km or miles
depending on the specific application).
When the fuel light comes on, the display automatically switches to the "trip
fuel" indicator.
Trip fuel reading remains stored even after key-off until the vehicle is
refue ...
Refitting the throttle twistgrip
Lubricate the ends of the throttle grip cables (10) and the twistgrip race
with the recommended grease.
The closing cable (10) features a writing on the yellow tube, whereas the
opening one (10) features such writing on the
white tube.
To refit the throttle control components, proceed i ...