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バイクアクセサリー Athena P400250100003のPDF 組立手順をオンラインで閲覧またはダウンロードできます。Athena P400250100003 4 ページ。 Cylinder kit

We thank you for choosing our products and stay at your disposal for any further information you may require.

PRELIMINARY INSTRUCTIONS AND DISASSEMBLY:

• Clean carefully the bike and the engine area. Remove one by one the following components: seat, plastic parts (conveyors

and side covers), fuel tank, exhaust silencer, cylinder hanger plates and rear frame.

• After draining the coolant, disconnect the sleeves from the head, the spark plug and the carburettor.

• Remove the valve cover and the cover on the left side of the carter. Place the piston on the TDC (Top Dead Centre) at the

end of the compression phase (the T mark on the rotor shall be aligned to the notch on the inspection hole), fig. A. Make sure

that the punching on the exhaust cam shaft and the punching on the inlet camshaft are well aligned on the surface of the

cylinder head (fig B).

• Check that the valve clearance is within the motorbike manufacturer range (0,10-0,15 mm inlet – 0,17-0,22 mm exhaust) and

if necessary record it by replacing the break pads.

• Unscrew the M8 hexagonal screw of the belt stretcher and remove it, then remove the fastening grain and the two M6 screws,

which secure it to the cylinder.

• Unscrew the M6 screws and remove the camshaft caps and the fasteners in a criss cross gradual pattern.

• Use a criss cross pattern to loosen each screws of the head, remove it, remove the distribution chain slide raids as well as

the cylinder and the piston. Check the connecting rod side clearance, keeping in mind that maximum limit allowed by the

manufacturer is 3 mm.

• Clean carefully the upper part of the cylinder head from possible encrustations and check the valve tightness.

The health of your engine is guaranteed by the good conditions of these elements.

ASSEMBLING INSTRUCTIONS:

• Clean carefully all the original components you are re-placing and all the new components of the Athena cylinder kit. Be sure that

there are no gasket residua or bruises left inside the various cylinder ports or on the piston.

• Install the piston rings and avoid piston damage during installation. Install the top ring with its marking facing up. Assembly the piston

rings as indicated in picture C.

• Cover the opening in the crankcase with a rag. Position the piston ( ) mark facing to the exhaust valve side.

• After lubricating the piston pin, slide it inside the piston pinhole by pushing it with hand; after assembling the circlips check careful-

ly that they are well tightened inside their seats.

• Place the new cylinder base gasket supplied with the Athena kit and the dowel pins on the crankcase.

• Coat the cylinder bore, piston and piston rings with engine oil and install the cylinder while compressing the piston rings.

N.B. Do not rotate the cylinder, since this may cause the piston rings to break.

Install the cam chain guide by aligning its tabs with the cylinder grooves.

• Install the dowel pins and the new cylinder head gasket supplied in Athena kit.

• Install the cylinder head onto the cylinder with its washers and tighten the bots to the specific torque in a criss-cross pattern in two

or three steps: 25 N•m first and then 59 N•m in the second phase.

• Install and tighten the cylinder head mounting bolts M6 to the specific torque: 12 N•m (1,2 kgf•m).

• Install the hanger plates of the cylinder kit.

• Place the piston on the TDC, stretch the front part of the distribution chain and install firstly the exhaust camshaft and after the inlet

camshaft, (see picture B).

• Install the camshaft holders and tighten them in a criss-cross pattern as shown in picture C. Tighten them gradually to the specific

torque of 9,8 N•m

• Install the chain tensioner, lightly rotate the camshaft clockwise, (few degrees needed) and tighten the fastening grain and the M8 screw in order to avoid the fastening grain from

loosening.

• Place the piston on the TDC another time and check again the position of the camshafts. If all the references are aligned as shown in the picture A-B the valve cover can be instal-

led.

• Check if the valve cover gasket is damaged or worn and replace it with a new one if necessary.

• Install the cylinder head cover and tighten the bolts to the specified torque: 9,8 N•m (1,0 kgf•m).

• Install the spark plug and the spark plug cap.

• Install the caps on the left side of the timing survey.

• Install the carburettor and fix the relative hose band. Connect all the connectors of the electric circuit.

• Install the following components: the secondary frame, the exhaust manifold with the new gasket, the silencer, the engine protectors and the radiator conveyors.

• Connect the manifolds of the cooling circuit.

• Add coolant up to the filler neck if the lever is low.

• Clean and if necessary replace the air cleaner element.

• Install the fuel tank with the fuel valve, the seat and the side covers.

• Check and if necessary adjust the carburetion to the new cylinder kit Athena.

RUNNING-IN, USE AND MAINTENANCE:

For the running in and the maintenance follow carefully the instructions given in the manual "OWNER'S USE AND MAINTENANCE MANUAL". Use petrol containing at least 96

octanes. Do not force the engine during the first 2-3 running hours as you can cause damages to the cylinder kit. The best performance is obtained only after a good running in. As

soon as you feel that the engine power is decreasing we suggest to replace the piston in order not to compromise the roundness of the cylinder tube. Service piston limit: we sug-

gest replacing the piston after 15 running hours.

We remind you that it is not the single part but all the parts as a whole that give your engine the best performance!

The assembling of the article/s included in this kit must be made only by qualified technicians. In case any faults and/or problems are caused by a wrong assembling, we

will not be responsible for any damage or technical or economical request which are claimed to us.

The descriptions contained in this leaflet are not binding. Athena reserves the right to make any changes, if necessary. Are not responsible for any printing errors.

All ATHENA products, which are manufactured with higher displacement and power than those permitted by law of the country where the end user lives, are

intended solely for competition-sports usage. Use on public roads as well as in aeronautics and marine is prohibited. ATHENA is not responsible for any

different usage. The customer takes full responsibility that the distribution of the articles purchased from ATHENA is in line with the current regulations of his

country and therefore frees ATHENA from whatever responsibility in this matter.

FIM/G033

ATHENA SPA - Via delle Albere, 13 - 36040 Alonte (VI) - Italy - Tel. +39-0444-727258 - Fax +39-0444-727222

http://www.athena-ad.com - e-mail: [email protected] (for foreign markets)

BORE SIZE

STROKE

DISPLACEMENT

95,5 mm

62,8 mm

449 cc

100 mm

62,8 mm

493 cc

COMPRESSION RATIO

12,2:1

12:1