User manual GAS GAS FSE 2003 PART LISTE

[. . . ] 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). B A Disconnect the wire (-) of the battery (C) and the engine earth connection (D). C D 7 Un-installing the engine E Disconnect the alternator clamp (E) and the phonic wheel sensor wire. H G F 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). I Disconnect the starter motor connection wire (J). Dismount the starter motor removing the screws (K). J K 8 Un-installing the engine Dismount the water tube (L). L Remove the pedal starter lever (M). M Remove the exhaust collector (N). N Disconnect the 2 radiator tubes. 9 Un-installing the engine Disconnect the engine oil tube (O) in the chassis tank. O Remove the gearshift lever (P). P Q Remove the engine pinion protector (Q). R Remove the clutch cap (R). De-tense the chain. Remove the output pinion clip (S). S 10 Un-installing the engine Remove the Engine pinion (T). 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. 11 Un-installing the engine Installation of the engine in the chassis Mount the engine in inverse order to de-installation ! Fix the screws and engine fixing nuts. A NOTE: In this phase, temporarily tighten the nuts. [. . . ] Check that the round lip (2) of the valve adjusts well in the groove (3) of the semicone end. Tool ref: Valve spring compressor Tool ref: Adapter Tool ref: Tongs WARNING Make sure to mount all the parts in their original positions. ! ! 72 Inspection and maintenance AUTOMATIC DECOMPRESSOR CAM AXLE UNIT WARNING Do not try to disarm the automatic decompressor/cam axle unit. It can not be repaired. ! Automatic decompressor Manually move the automatic decompressor counterweight to check if it works smoothly. If the automatic decompressor counterweight does not function smoothly, replace it with a new one. Cam wear The wearing of the cams usually provokes the misalignment of the valve adjustment, with the corresponding power loss. Measure the height (H) of the cams with the micrometer. If the wear surpasses the service limit, replace the cam axle with a new one. Tool ref: Micrometer (25-50 mm) DATA Cam height (H) Intake: 36. 934 mm Exhaust: 36. 893 mm Service limit: Intake: 36. 634 mm Exhaust: 36. 593 mm ! ! 73 Inspection and maintenance Cam axle bridge wear With the cam axle mounted, measure the width of the oil with the plastic tool. Tools Ref. : Plastic tool DATA Cam axle bridge oil width (intake and exhaust) Service limit: 0. 150 mm !! Tighten the bridge support screws uniformly and in diagonal sequence with the specified torque. Cam axle bridge support screw: 10 Nm (1 kgm) NOTE: Do not turn the cam axle with the plastic tool placed. Dismount the supports of the stumps and measure the width of the plastic tool compressed with the surrounding ruler. Tool ref. : Thickness gauge DATA Aperture of the free piston ring end (Fig. 4) Service limit: 1º: 5. 5 mm 2º: 9. 2 mm !! Fig. 5 Tool ref. : Thickness gauge DATA Aperture of the piston ring end (Fig. 5) Service limit: 1º: 0. 50 mm 2º: 0. 50 mm Piston bolt holder and bolt interior diameter Measure the piston bolt holder diameter with a small calliper. If the diameter surpasses the service limit, replace the piston with a new one. Tool ref. : Cuadrant gauge (1/1, 000 mm) Tool ref. : Small calliper (18-35 mm) DATA Piston bolt holder interior diameter Service limit: 20. 030 mm Measure the piston bolt holder exterior diameter in three places, with the micrometer. If any of the measurements surpasses the service limit, replace the piston with a new one. Tool ref. : Micrometer (0-25 mm) DATA Piston bolt exterior diameter Service limit: 19. 980 mm !! 77 Inspection and maintenance CONNECTING ROD Connecting rod foot interior diameter Measure the connecting rod foot interior diameter with the small calliper. If the interior diameter of the connecting rod foot exceeds the service limit, replace the connecting rod with a new one. Tool ref. : Cuadrant calibrator compass DATA Connecting rod foot interior diameter Service limit: 20. 040 mm ! [. . . ] NOTE: Before mounting the filter cover make sure of the correct mounting of the spring and replace the filter cover gasket. Makesure that the thoric behind the filter is placed in the correct position. Change the oil filter cover and tighten the safety nut. Add new oil to the engine and check the oil level just as described in the oil change procedure. ! 1 2 DATA: Engine oil capacity Change of oil: 1 L (1. 05 US qt, 0. 8 Imp qt) Changing the oil and oil filter: 1. 2 L (1. 3 US qt, 1 Imp qt) Engine check: 1. 2 L (1. 3 US qt, 1 Imp qt) WARNING Check the correct position of mounting of the filter (according to the images). [. . . ]