Refitting the external components
Make sure that the O-rings (13) are fitted on the crankcase.
Fit the engine pickup (10) in its seat in the crankcase half.
Start screw (11) with its washer (12) and tighten to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).
Use a feeler gauge to check the clearance between engine sensor (10) and timing gear (14). The value must be between 0.6 and 0.8 mm.
If previously removed, refit the oil vapour breather valve (2) by tightening the three screws (21) to a torque of 1 Nm ± 10%.
Check the condition of O-rings (2) and renew if necessary.
Install the oil vapour breather valve (1) in the crankcase along with O-rings (2), previously lubricated.
Tighten screw (1) to a torque of 10 Nm (Min. 9 Nm - Max. 11 Nm).
Apply recommended threadlocker to the thread of the nipple (4) that is screwed into the crankcase half.
Screw oil filter cartridge fitting (4) fully into the crankcase half.
Tighten the nipple to a torque of 42 Nm (Min. 38 Nm - Max. 46 Nm).
Fit the seal (7) on the oil drain plug (6). Position the seal that the side with the square edge (B) is facing the chain side crankcase half.
Clean the plug thread, apply a string of THREE BOND TB1215 along the plug thread spreading it by the entire circumference (360°).
Screw drain plug (6) with relevant seal (7) to a torque of 20 Nm (Min. 18 Nm - Max. 22 Nm).
Note
After tightening, remove any excess sealant.
Refit the neutral sensor (8) with seal (5).
Refit the mesh filter (A) (Changing engine oil and filter cartridge).
Fit seal (24) on mesh filter blanking plug (23).
The seal must be oriented so that the square edge (V) faces the crankcase half.
Smear plug thread with recommended threadlocker.
Start plug inside crankcase half, then tighten it to a torque of 25 Nm (Min. 22 Nm - Max. 28 Nm).
After tightening, remove any excessive threadlocker.
Check the conditions of O-rings (17) of stud bolts (9) and replace them if necessary.
Use tool (C) part no. 88713.1920 to fit the O-rings (17) in the corresponding seats (D) of the stud bolts (9).
Now fit the stud bolts (9) in the crankcase halves, applying sealant on the thread and tightening to a torque of 30 Nm (Min. 28 Nm - Max. 32 Nm).
Use the appropriate commercial tool for this operation.
If previously removed, apply specified threadlocker on dowel (18) and tighten it to 15 Nm (Min. 13.5 Nm - Max. 16.5 Nm), fit gasket (19) on service plug (20): gasket must be oriented so that the square edge (V) faces the clutch-side crankcase half.
Apply specified threadlocker on the plug thread (20), insert it in the crankcase half and tighten to a torque of 15 Nm (Min. 13 Nm - Max. 17 Nm).
Refit the mesh filter (Changing engine oil and filter cartridge).
Refit the primary drive gear (Refitting the primary drive gear and checking the backlash).
Refit the oil pump (Refitting the oil pump).
Refit the clutch unit (Refitting the clutch).
Refit the clutch cover (Refitting the clutch cover).
Refit the starter motor (Refitting the starter motor).
Refit the complete generator (Refitting the flywheel/generator unit) and the generator side cover (Refitting the generator cover).
Refit the cylinder/piston assembly (Refitting the cylinder/piston assembly).
Refit the complete cylinder head unit (Refitting the cylinder head assemblies).
Refit the timing belt pulleys (Refitting the head pulleys/idler pulleys).
Refit the timing belts (Refitting the timing belts).
Refit the timing outer covers (Refitting the timing outer covers).
Refit the engine on the frame (Refitting the engine).