03
9- ORDINARY SERVICING
ATTENTION: THE SERVICING OPERATIONS MUST BE DONE
BY QUALIFIED PEOPLE ONLY. IF THE INSTRUCTIONS MENTIONED
BELOW WILL RESULT NOT CLEAR, WE SUGGEST ASKING FOR
SPECIALISTS BY POLINI MOTORI RETAILERS OR WHOLESALERS.
FOLLOW CAREFULLY WHAT DESCRIBED BELOW.
Maintenances and servicing necessary for the best set up of your
engine should be done regularly, or on all occasions before you
start flying. All the tasks and adjustments described below can be
done easily by following the instructions given in this manual.
Refer to your POLINI MOTORI dealer for scheduled services and
repairs, and insist that only original spare parts are used to
replace worn or broken components. Refer to the servicing tables
in sections 12 below for the frequency with which the various ser-
vicing operations must be performed.
9.1- REMOVE AND CLEAN THE AIR FILTER
Dirty air filter is one of the most common causes of poor engine
performance.
Clean the filter periodically or change it. Remove the filter loose-
ning the clamps, unscrew the 4 screws using a cross screwdriver,
remove the filter cover and then the filter. Wash the filtering
material with water and mild soap,
After rinsing and wringing the filter, moisten it with oil for filters.
Clean filter box inside using a cloth and check the presence of
foreign bodies. Now reassemble all the parts being careful to
place correctly the 4 bars that maintain the filter in its position
and screw the 4 screws again. Wash the filter for maximum 2-3
times, then replace it.
WARNING. If the filter becomes clogged with fine dust as
well as normal dirt, replace it with a new one.
WARNING. Dirty air filters choke the engine and cause poor
performance. Torn or broken filters can allow dirt to enter the
engine and cause rapid deterioration of the piston rings, piston
and barrel.
9.2- CHECKING OF THE GEAR OIL LEVEL
Operate when the engine is cold. Maintain the engine in vertical
position and remove the oil level screw on the transmission
crankcase. (photo 4). Check that the oil level reaches the lower
edge of the level hole. If there is too much oil, let it flow out
from the level hole until it stops flowing and collect the oil in a
suitable container. If there is not enough oil, top up as required
through the breather hole located at the top. After checking it,
tighten the screws. Use ELF Moto Gear Oil 10 W 40 ANTI Clutch
Slippage or Shell advance gear SAE 10 W 40 API GL-3
04
OIL LEVEL
A
9.3 GEAR OIL REPLACEMENT
Change the oil when the engine is cold. Unscrew the screw on the
lower side of the clutch/gear group. Collect the oil flowing out in
a suitable container. Wait till the oil has completely flown out
and, if necessary, tilt the engine to the side to make this opera-
tion easier. Tighten the screws. Unscrew the breather pipe in the
top side of the crankcase and fill it out with:
(FOR THOR 100 ENGINE) 25cc of ELF MOTO GEAR OIL 10 W 40
ANTI CLUTCH SLIPPAGE. Place the connection/breather again.
(FOR THOR 200 ENGINE) 100cc of ELF MOTO GEAR OIL 10 W 40
ANTI CLUTCH SLIPPAGE. Place the connection/breather again.
Another option is: Shell Advance Gear SAE 10 W 40 API GL-3
WARNING: Do not throw spent oil into the environment. Dispose
of it correctly through authorised collection points.
9.4-STARTER ROPE REPLACEMENT
Remove the starter from the engine unscrewing the 4 screws
(Photo 5).
Remove the handle rope. Be careful since the central wheel will
turn till the complete spring discharge: keep it and discharge it
slowly to avoid damages or possible injuries. Remove the central
screw and its cover (photo 5.1).
Attention! Under the cover there are two teeth for the starter
jaw (check their condition and if worn replace them); under them
2 small callipers. Be very careful not to lose these small parts.
Prepare the new rope and tie a knot at the top. Remove the pla-
stic wheel and the old rope.
05
5.1
Thread the new rope in its hole (photo 6), wind the rope on the
wheel (according to the entrance sense of the rope on the wheel)
(Photo 7). Now insert the plastic wheel in its housing again, the
spring, the teeth for the starter jaw and screw the cover again.
Now go on by charging the return spring: take the head of the
rope leaving 5-7 cm coming out the hole with “u” shape on the
wheel side. Turn the wheel three times in anti clock wise sense till
it stops in front of the exit hole on the aluminium case. Keeping
the plastic wheel stopped make the rope go through the case
hole. Insert the handle and the washer and tie a single knot as
shown in photo 8.
Reassemble the starter in the engine and screw the 4 M5 screws
with strength (see the tightening torque values table).
06
07
08
9.5- WALBRO WG8 AND WB37 CARBURETOR
DIAPHRAGM CHANGING
Remove the filter unscrewing the clamp by using a cross screwdri-
ver. After removing the accelerator cable from the carburettor,
the supplementary spring, the carburettor pipe and the diffusion
pipe unscrew the two socket head screws and remove the carbu-
rettor from the engine. Now place the parts on a flat plane.
Remove the upper cover by unscrewing the 4 screws , remove the
diaphragm and the gasket, check that the inside part is clean and
reassemble by using the new diaphragm and the new gasket
(photo 09).
09
ATTENTION: The carburettor is made of many small and
fragile parts. Be very careful during all the phases with particular
attention to the idling and its springs; they both must not be tou-
ched.
To Next Page
Loading...
