C TWO-STROKE ENGINE AM6 2T XTM - XSM POWER UP 2007 WORKSHOP MANUALS
C - ENGINE TWO-STROKE ENGINE AM6 Introduction CHAPTER C TABLE OF CONTENTS 08.06 S Pr P INTRODUCTION 1 1 4 MANUAL UPDATES 1 1.1 4 NOTES FOR EASY CONSULTATION 1 1.2 5 GENERAL WORK PROCEDURES 1 1.3 8 RECOMMENDATIONS 1 1.4 9 SPARK PLUGS 1 1.5 11 MINARELLI ENGINE 2 2 13 EQUIPMENT KIT 2 2.1 14 LUBRICANTS 2 2.2 14 ENGINE DISASSEMBLY 2 2.3 15 MAINTENANCE 2 2.4 22 ENGINE ASSEMBLY 2 2.5 26 ENGINE SERVICING AND COMMISSIONING SCHEDULE 2 2.
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER 1 Introduction INTRODUCTION • All checks, maintenance, repairs or replacements, etc. on the vehicles manufactured by Malaguti are to be performed by skilled and expert technical personnel with specific experience in state-of-the-art technology and full knowledge of the quickest and most rational procedures, technical characteristics, setting values and tightening torques, which may only be properly and exhaustively provided by the manufacturer.
C - ENGINE TWO-STROKE ENGINE AM6 Introduction CHAPTER C 1.2 NOTES FOR EASY CONSULTATION PAGE LAYOUT Chapter Engine model W Page n° Z Date of issue X Y ENGLISH Y X Z W (RH PAGE) MODIFIED PAGES • Modified pages shall bear the same number as those in the previous edition/pre-modified ones, followed by the letter M, with the date of issue appearing in the appropriate box.
C - ENGINE TWO-STROKE ENGINE AM6 C CHAPTER Introduction EDITING SYMBOLS A) CAUTION! Recommendations and precautions regarding rider safety and motor vehicle integrity. B) WARNING! Situations entailing the risk of personal injury to maintenance or repair mechanics, other workshop personnel or third parties, or damage to environment, vehicle or equipment. C) B ENGLISH FIRE HAZARD Indicates operations which may constitute a fire hazard.
C - ENGINE TWO-STROKE ENGINE AM6 Introduction CHAPTER C ABBREVIATIONS F Cs P Pr S Sc T V Figure Tightening torque Page Paragraph Section Diagram Table Screw ENGLISH Note: the letter V in the illustrations refers to retaining or adjusting screws. The number following this letter refers to the number of the same type of screw in the unit or component described and illustrated. Letters not followed by a number indicate a single screw.
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER 1.3 Introduction GENERAL WORK PROCEDURES • The advice, recommendations and warnings given hereafter are aimed at ensuring maximum work safety as well as at considerably reducing the risk of accidents, personal injury, equipment damage and idle times. They should therefore be strictly adhered to. ADVICE: • Only use quality tools and equipment. • Only use equipment conforming to EU Directives for lifting the vehicle.
C - ENGINE TWO-STROKE ENGINE AM6 Introduction 1.4 CHAPTER C WARNINGS • Before carrying out any operation on the vehicle, wait for all parts to cool down. • For operations requiring two mechanics, make sure that the various steps to be performed by each of them are clearly defined and coordinated beforehand. • Make sure that each component has been properly fitted before proceeding with the next one. • Lubricate all parts (where applicable) before reinstalling them.
C - ENGINE C TWO-STROKE ENGINE AM6 Introduction CHAPTER Never use open flames for any reason. Never leave open containers or containers not suitable for holding fuel in passageways, close to heat sources, etc Never use petrol to clean the vehicle or the floor of the workshop. Always use low flash point solvents to clean the vehicle components. Never suck from or blow into the fuel pipe. When welding, make sure that there are no flammable liquids in the vicinity.
C - ENGINE TWO-STROKE ENGINE AM6 Introduction CHAPTER C 1.5 SPARK PLUGS 1 2 Insulator Body 3 Gasket 4 5 6 Electrode Earth electrode Threads SPARK PLUG CHECK ENGLISH F. 5 1,000 km • Remove the spark plug while the engine is hot (taking utmost care to avoid scalding!). • The carbon deposits and the colour of the insulator (around the central electrode) provide good information as to the heat range of the spark plug and to carburetion, lubrication and general condition of the engine.
C - ENGINE C TWO-STROKE ENGINE AM6 Introduction CHAPTER SPARK PLUG MAINTENANCE • Spark plug maintenance consists essentially of a periodical visual inspection. Remove the spark plug and check for proper condition and gap. • Clean the electrodes and the insulator thoroughly by means of a wire brush. • Remove any residual dirt with a strong jet of compressed air. • Lubricate spark plug thread with engine oil or graphitised grease, and install it by hand until finger tight.
CHAPTER SECTION 2 Minarelli Engine WORKSHOP MANUALS ISSUE 08.
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER Minarelli Engine 2.1 EQUIPMENT KIT ENGLISH Minarelli code n° 9920200 2.2 LUBRICANTS LUBRICANTS TABLE LUBRICANTS FOR TWO-STROKE ENGINES 1) Synthetic mix oil 2) Gearbox oil SAE 10W30, type SE GENERAL PURPOSE LUBRICANTS 3) Grease for moving parts 14 PAGE ISSUE SECTION 2 08.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine 2.3 CHAPTER C DISASSEMBLY OF THE ENGINE After removing the spark-plug and carburettor proceed as follows: 1) DRAIN the engine oil by removing the relevant drain bolt. 2) UNSCREW the coolant drainage screw (1-F1); remove the water pump cover by undoing the two fixing screws (2-F1). Pay attention to the dowel bolts (1-F2). 2 F. 1 ENGLISH 1 1 F.2 3) UNDO the fixing screws of the flywheel cover (left hand side) and remove it.
C - ENGINE C TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER 3 1 1 2 F.5 F.6 ENGLISH 6) REMOVE the sliding stop screw for starting from clutch side (1 - F.5). 7) REMOVE the fixing screws of the plastic oil pump cap (1 - F.6). Undo the screws securing the oil pump to the cover; then remove the pump. 2 1 3 2 1 3 F.7 F.8 8) REMOVE the cover/crankcase fixing screws (of which one M6x55 (2 - F.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER C 1 1 2 F.10 ENGLISH F.9 11) DISENGAGE the nut from its fixing tab (1 - F.9); using the appropriate wrench (1 - F.10), unscrew and remove the fixing nut (2 - F.10) of the clutch boss. 12) REMOVE the following pieces in this order: clutch boss (1-F.11), spacer (2-F.11), clutch gear (3-F.11), shim washer (1-F.12), tapered washer (2-F.
C - ENGINE C TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER 15) UNSCREW the nut (2-F.14) with a 19 mm wrench, whilst holding the flywheel in place with the special wrench; then remove the following parts in this order: drive pinion, countershaft drive gear, key, spacer bushing and O-ring. 16) BLOCKING the rotor of the magneto flywheel with the special locking wrench (1-F.15), unscrew the rotor retaining nut with a 15 mm wrench. 1 ENGLISH 1 F.15 F.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER C 20) DISASSEMBLING the thermal section: F.18 ENGLISH a) unscrew the 4 cylinder head holding nuts and remove the relevant washers; remove the head, its O-ring, the cylinder, the cylinder gasket and the four O-ring on the stud bolts. F.19 CAUTION: before removing the circlips of the piston pin, put a clean cloth into the opening on the crankcase, to prevent the circlips dropping into the engine. 21) REMOVE the two circlips (F.
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER Minarelli Engine 25) PUT the neutral signal pin in the position shown in the photo (F. 22), hence remove the shift shaft and its relevant lower shim washer (1 - F. 23). 1 ENGLISH F.22 F.23 26) PULL OUT the fork guiding rod and remove the top fork (F.24); to take the fork out of its seat, remove the desmodronic shaft (F.25) and raise the gear on the secondary shaft carrying the forks. F.24 F.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER C 30) IF the oil pump needs to be replaced, proceed as follows (F.27): 1 4 2 4 5 3 ENGLISH F.27 a) Detach the oil pump supply pipe (1) and put a plug into it to prevent oil leaks. b) Detach the oil delivery pipe leading from the pump to the carburettor (2). c) Disconnect the control cable fastened to the pump’s lever (3). d) Undo the pump fixing screws (4) and remove the pump. e) Fit the new pump in its seat and replace the O-ring.
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER Minarelli Engine 2.4 MAINTENANCE GENERAL WARNINGS Before reassembling the engine either totally or partially, thoroughly clean the parts by washing them with petrol, drying them with compressed air and making sure that they are sufficiently oiled and in perfect working order. It is always advisable to replace the gaskets because old ones may be leaky.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER C PREVENTIVE CARE 1) WASH the two crankcases and the bearings with petrol and blow them with compressed air, checking that the bearings run freely and noiselessly. 2) MAKE SURE the connecting rod is in perfect working order and check for faults, especially in the bearing seats. Make sure assembly on flywheel side has been properly accomplished. Using a comparator, check the eccentricity of the two connecting rod axle shafts.
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER Minarelli Engine 6) ENSURE that the clutch assembly is in working order. To do so, ensure that the iron discs are in good condition, that the notches on the cork discs are not too deformed and that their coating is not burnt. Check that the grooves on the clutch boss are not too deeply marked; perform the same check on the slots of the clutch housing. Also check that the clutch springs are not shorter than the permissible threshold of 29.5 mm (F.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER C Repeat the measurements in several positions along the cylinder jacket, between the top face of the cylinder and the exhaust gap (F.34). Then check the diameter of the piston and compare it with that of the cylinder (F.33). POSITION THE THERMOSTAT HOLE, AS SHOWN ENGLISH 10 mm F.34 The maximum end float is 0.10 mm, exceeding which, the piston should be replaced. See the chart below. COUPLING CHART ENGINE TYPE AM 50 (WATER COOLED) MIN./MAX.
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER 2.5 Minarelli Engine ENGINE REASSEMBLY 1) PLACE the clutch crankcase (right hand side) on a flat surface. Then, fit the spring and the gear selection poppet ball in their seats and apply grease to prevent them falling out. 2) PREPARE the transmission assembly (primary/secondary) keeping all components together (F.36). Put a 0.6 mm shim washer under the 1st speed gear and position the fork in the 3rd and 4th primary gear (F.36).
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine 3) CHAPTER C FIT the desmodronic shaft (F.40). Insert the fork guide pins into the desmodronic shaft (F.41). Fit the fork guide rod into its seat (F.42). Turn the desmodronic shaft until it reaches the position shown in the figure (F.43). ENGLISH N.B.: these operations must be effected without forcing (with a hammer or other tools). 08.06 F.40 F.41 F.42 F.
C - ENGINE C TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER 4) INSERT the shift shaft with the lower washers (0.6 mm thick) (1- F.44) and insert the return spring hooks in the relevant anchoring bridge (F.45) then check that: - By putting the desmodronic shaft in 3rd speed, make sure the rollers of the cam are at an equal distance from the fork hooks. On the contrary, slightly bend the ends of the spring until obtaining the requested condition. 1 ENGLISH F.44 F.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER C 10) FIT the key for the magneto flywheel; put the stator in its seat and fasten in place with the fixing screws (Cs 0.25 ÷ 0.3 kg*m). Fit the rotor and tighten the nut (Cs 4.3 ÷ 4.5 kg*m), using the usual wrench (F48). 11) Fit the sprocket: snap ring (1-F49) - sprocket (2) - snap ring (1) - fit the clutch control pin (3- F49) with its return spring (4-F49). F.43 3 4 1 ENGLISH 2 F.48 F.
C - ENGINE C TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER 2 1 2 ENGLISH F.52 F.53 14) PROCEED in reverse order. Refit the clutch assembly and remember to replace the nut fixing washer with a new one; fit the clutch boss fixing nut (Cs 5.5 ÷ 6.0 kg*m) and bend the tab. 15) FIT the following components on the output shaft, in the order given: clutch rod (grease beforehand), ball and disc pusher. 16) FIT the clutch disc assembly in the order shown in (F.54); the iron discs (1-2-3 F.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER C 17) FIT the springs and fixing screws and tighten (Cs 0.3 ÷ 0.5 kg*m). 18) Correct operating position of the clutch is obtained when the lever, in the position indicated by the arrow (F.55), is parallel to the cover resting surface. To obtain this condition, turn the adjustment screw (1-F.56) on the last disc, using the special wrench (2- F.56). Tighten the nut (Cs 2.6 ÷ 2.8 kg*m) .
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER Minarelli Engine 22) Before assembly, CHECK the condition of the cage on the piston pin and its rollers. Fit the piston, making sure that the arrow marked on the top is facing towards the exhaust side (F.59), and therefore towards the piston pin and its circlips. ENGLISH F. 59 F.
C - ENGINE TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER C 2.
C - ENGINE C TWO-STROKE ENGINE AM6 Minarelli Engine CHAPTER 2.7 PARTS AND THEIR TORQUE WRENCH SETTINGS ENGLISH N° PART POSITION PART NAME SCREWS TORQUE W. SETTING N*m Kg*m QTY 1 Spark plug Spark plug M14 x 1.25 20÷25 2 ÷ 2.5 1 2 Cylinder head Nut M7 x 1 14÷16 1.4 ÷ 1.6 4 3 Cylinder head Pipe fitting M8 x 1.25 24÷26 2.4 ÷ 2.6 1 4 Cylinder head Temperature probe M14 x 1.25 16÷20 1.6 ÷ 2.0 1 5 Countershaft Hex. nut M12 x 1 45÷50 4.5 ÷ 5.
C - ENGINE TWO-STROKE ENGINE AM6 CHAPTER C PAGE 35 ENGLISH Minarelli Engine 08.
C - ENGINE C TWO-STROKE ENGINE AM6 CHAPTER Minarelli Engine 2.8 EXPLODED VIEW OF THE ENGINE R ENGLISH 36 PAGE ISSUE SECTION 2 08.
