RETROEXCAVADORA – MINIEXCAVADORA – PALA MIXTA

31 Exploded view

32 Throttle Specification

Item Standard

Throttle Grip Free Play 2~3mm

Idling Speed 1200 ± 100 (rpm)

Make, Type Jenvey, Norton Commando

Air Cleaner Element Oil Grade SE or SF Class

Viscosity SAE30

Throttle Grip and Cables

If the throttle grip has excessive free play due to cable stretch or maladjustment, there will be a delay in throttle response. Also, the throttle butterfly may not open fully at full throttle. On the other hand, if the throttle grip has no play, the throttle will be hard to control, and the idle speed will be erratic. Check the throttle grip play periodically in accordance with the Periodic Maintenance Chart, and adjust the play if necessary.

Grip Free Play Inspection

 Check throttle grip free play[A] by lightly turning the throttle grip back and forth

 If free play is improper, adjust the throttle cable  Throttle Grip Free Play

Standard: 2 ~ 3mm Grip Free Play Adjustment

 Loosen the locknut and screw the throttle cable adjuster on the rear cable (no. 1) so there is approximately 2-3mm free play at the throttle grip. Adjust the front cable (no. 2) until there is slight tension on the front cable.

 Tighten the locknuts against the cable adjusters.

 Check that the throttle cam stops against the idle adjusting screw with the throttle grip closed.

 Turn the handlebars from side to side while idling the engine.  If idle speed varies, the cable may be poorly routed or damaged.

Warning: Operation with an improperly adjusted, incorrectly routed, or damaged cable could result in an unsafe riding condition.

Throttle Cable Removal

 Remove: Fuel Tank (see this chapter)

 Take off the adjuster nuts [A] at the throttle body.

33  Slip the inner clips [B] out of the lever

 Remove the right hand guard off the brake level.

 Take the two screws [A] holding the throttle pulley case halves together.

 Slip the inner cable tips from the catches on the throttle pulley, and free cables from the handlebar.

- Inner Cable Tips [A] - Pulley [B]

- Accelerator Cable [C]  Remove the throttle cables.

Throttle Cable Installation

 Lubricate the throttle cables (see Throttle Cable Lubrication and Inspection).

 Be sure to fit the throttle cables into the grooves of the cable guide [A] while turning the throttle grip.

 Install the throttle cables in accordance with the Cable, Wire, and Hose Routing section of the General Information chapter

 After Installation, adjust the cables properly.

Warning: Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding condition.

Throttle Cable Lubrication and Inspection

 Whenever the Cables are removed, and in accordance with the Periodic Maintenance Chart, lubricate the throttle cables (see General Lubrication in the Appendix).

 Apply a thin coating of grease to the cable upper ends.  Use a pressure cable luber to lubricate the cables

 With the cables disconnected at both ends, the cable should move freely in the cable housing.

B _A A B C A A

34

Throttle Body

A dirty or damaged air cleaner can alter the fuel air ratio.

Idle speed Adjustment

 Start the engine and let it warm up thoroughly.

 With the engine idling, turn the handlebar to each side. If the handlebar movement changes idle speed, the throttle cable may be incorrectly routed, or it may be damaged.  Turn the adjuster screw [A] to obtain the slowest smooth

idle speed.

 Check idle speed. If the idle speed is out of the specified range, adjust it.

Idle speed standard: 1200 ± 100 (rpm)

 Open and close the throttle a few times to make sure that the idle speed does not change. Readjust if necessary.

Warning: Operation with an incorrectly routed or improperly adjusted cable could result in an unsafe riding condition. To avoid a serious burn, never touch a hot engine or an exhaust pipe during idle adjustment.

Throttle body Removal

Warning: Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

 Remove:

o Fuel hose from tank o Idle motor air feed

o Throttle body and idle motor power supply  Remove:

o Fuel tank (see this chapter) o Tank breather hose

o Air cleaner housing (see this chapter)  Loosen the cable adjuster nuts [A].

 Slip the throttle cable lower ends out of the throttle cam.  Loosen the clamps [B]

 Remove Four throttle body bolts [A]  Remove the throttle body upward.

B

A

35  Push a clean, lint-free towel into the inlet to keep dirt or other foreign material from entering.

Warning: If dirt or dust is allowed to pass through into the throttle body, the throttle may become stuck, possibly causing an accident

Caution: If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Throttle body Installation

 Apply RED grease to the ‘O’ rings on the throttle body gasket making sure they stay in place.  Torque the four throttle body bolts up

Torque: M6 Bolt - 12NM

 When Installing air box ensure transition piece ridges fit over throttle body correctly

 Tighten clamps [A]  Install:

o Fuel tank (see this chapter) o Tank breather hose

o Air cleaner housing (air box) (see this chapter)  Install:

o Fuel hose from tank o Idle motor air feed

 Throttle body and idle motor power supply  Check fuel leakage from the Throttle body.

Warning: Fuel spilled from the throttle body is hazardous.

 Install the throttle cables (see Throttle Cable Installation)  Adjust the throttle cable (see Grip Free Play Adjustment)  Adjust the idle speed (see Idle Speed Adjustment)

A

36

Throttle Body Disassembly

 Remove:  Throttle body  Remove fuel hose

 Remove:  bolts [13]

 Fuel Injector clips  Fuel rail [2]  Injectors [21]

 Throttle potentiometer bolts [15]  Throttle potentiometer [5]  Four butterfly bolts [12]  Remove the butterflies [7]

 Extract the spindle taking note of the spacer, bearing, spring assembly sequence and location  Warning any damage to the injector system or potentiometer should be replaced not repaired.

37

Throttle Body Assembly

 The Throttle Body assembly Sequence is the reverse of the disassembly sequence (see Throttle Body Disassembly)

 Ensure the throttle cable spring is installed correctly and rotates freely.  Check bushes for Wear and tear, replace if necessary.

 Ensure all seals are intact replaced if any wear or degradation is visible.

 Ensure no daylight is visible between the throttle butterflies and the throttle body hosing and that the butterflies are seated correctly.

Throttle Body Cleaning

Warning: Clean the throttle body in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the throttle bodies. A fire or explosive could result.

Caution: Remove as many plastic parts from the throttle body as possible before cleaning the throttle body with a cleaning solution. This will prevent damage or deterioration of the parts.

 Disassemble the carburettor (see Throttle Body Disassembly).  Immerse all the metal parts in throttle body cleaning solution.  Rinse the parts in water.

 When the parts are clean, dry them with compressed air.  Assemble the throttle body (see Throttle Body Assembly)

Throttle Body Inspection

 Remove the throttle body (see Throttle Body Removal).  Turn the throttle lever [A] to check that the throttle

butterfly valve [B] moves smoothly and returns back with the spring force.

 If any of the O-rings are not in good condition, replace them.

Air Cleaner

Air Cleaner Removal

 Remove:

 Seat (see Frame chapter)  Air cleaner retainer screws [A]  Air cleaner retainer [B]

 Remove air cleaner element.

 After removing the element, push pieces of lint-free, clean cloth into the air cleaner duct to keep dirt out of the

A B

B

38 throttle body and engine.

Warning: If dirt or dust is allowed to pass through into the throttle body, the throttle may become stuck, possible causing an accident.

Caution: If dirt gets through into the engine, excessive engine wear and possibly engine damage will occur.

Air Cleaner Element Installation

 When installing the element, coat the lip of the element with a thick layer of all purpose grease [A] to assure a complete seal against the air cleaner element base. Also, coat the base where the lip of the element fits.

 Be sure the foam gasket [A] is in place in the groove in the element cap.

Air Cleaner Element Cleaning and Inspection

Note: In dusty areas, the element should be cleaned more frequently than recommended interval.

Since repeated cleaning opens the pores of the element, replace it with a new one in accordance with the Periodic Maintenance Chart. Also, is there is a break in the element material or any other damage to the element, replace the element with a new one.

Warning: Clean the element in a well ventilated areas, and take care that there are no sparks or flames anywhere in the working area; this includes any appliance with a pilot light.

Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element.

 Remove the air cleaner element.

 Check all parts the parts of the element for visible damage.  If any parts of the element are damaged, replace it.

 Liberally spray Air Filter Cleaner onto both sides of filter and allow to soak for 10 minutes to loosen the dirt. Do not allow cleaner to dry on air filter.

 Rinse off air filter with cool low-pressure water applied to the clean side out in order to flush the dirt out of the filter. Continue to rinse the filter until all traces of cleaner are gone. It may be necessary to repeat steps 1 and 2.

 After rinsing, gently shake off excess water and only allow filter to dry naturally. Do not oil until the filter is completely dry.

 Apply Air Filter Oil evenly along the crown of each pleat. Allow oil to wick for approximately 20 minutes. Touch up any light areas on either side of filter until there is a uniform colour in all areas.  Install the element

39

Air Cleaner Housing Removal

 Remove:

 Seat (see Frame chapter)  Breather Hoses

 Rear Wheel  Rear Hugger

 Fully loosen off the two jubilee clips [A] securing the transition piece to the air cleaner housing.

 Remove the two hex head bolts [A] at the rear of the air filter housing.

Fuel Tank

Fuel Tank Removal

Warning: Gasoline is extremely flammable and can be explosive under certain conditions. Always stop the engine and do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes appliances with a pilot light.

 Remove:

 Seat (see Frame Chapter)  Breather hoses

 Remove fuel hose, cover hose clips with lint free cloth when taking off as fuel will spill out.

 Remove fuel pump electrical connection.

 Remove hex head tank bolts, one at the front [A] and two at the rear [B].

 Remove tank upwards from the bike

 Drain the fuel tank by siphoning the fuel out through the fuel filler cap into a clean container.

A

A

B

Note: 2nd on other side of frame A

40

Fuel Tank Installation

 Check the rubber damper [A] on the frame and fuel tank.  If the dampers are damaged or deteriorated, replace them.  Be sure the fuel hose is clamped to the spigot to prevent

leakage.

Warning: Fuel spilled from the fuel spigot connecter is hazardous.

 Install:

o Seat (see Frame Chapter) o Breather Hoses

o Fuel Hose

o Fuel Pump Electrical Connection.

 Install hex head tank bolts, two at the front one at the rear.

Torque: Tank Mount Bolts - 9NM

Fuel Tank Cleaning

 Remove the fuel tank and drain it (see Fuel Tank Removal)

 Pour some high-flash point solvent into the fuel tank and shake the tank to remove dirt and fuel deposits.

Warning: Clean the tank in a well-ventilated area and take care that there is no spark or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low flash point solvents to clean the tank. A fire or explosion could result.

 Pour the solvent out the tank.

 Pour high-flash point solvent through the fuel spigot.  Dry the tank and tap with compressed air.

 Install the fuel tank.

41

Fuel Pump

Note: The fuel pump, fuel filter and low fuel level sensor is a sealed for life unit and must be replaced as a complete assembly.

Fuel Pump Removal

 Remove the fuel tank and drain it (see Fuel Tank Removal).

Warning: Observe the warning advice given in general information sections on the safe handling of fuel and fuel containers. A fire, causing personal injury and damage to property, could result from spilled fuel or fuel not handled or stored correctly.

 Invert the fuel tank and place on a protective surface to prevent paint damage.

 Remove the fixings securing the fuel pump [A].

 Lift the fuel pump assembly and manoeuvre it from the tank aperture.

Fuel Pump Installation

 Install the fuel pump assembly and manoeuvre it into the tank aperture, ensure the gasket is seated correctly and all gasket faces are clean.

 Install the six fuel pump bolts.

Torque: Fuel Pump Mount Bolts - 3NM

 Install the fuel tank (see Fuel Tank Installation).

Fuel Pump Inspection

Note: Fuel Pump Pressure test requires Inline pressure gauge, and fuel pump fly lead (extension cable) available from Norton Motorcycles (UK) Ltd.

 Remove the Fuel tank (see Fuel Tank Removal).

 Attach Extension cable to pump electrical connection, and wiring harness.  Attach Inline Pressure tester to Pump and throttle bodies.

 Place the pressure gauge in a visible position with the fuel tank upright on a flat surface, with a soft cloth to stop paintwork damage.

 Start the motorcycle and observe the fuel pressure.

Fuel Pressure Nominal: 3 Bar

42  When finished remove extension cable and inline pressure tested and install the fuel tank (see fuel

tank installation. Idle Motor

Idle Motor Removal

 Remove:

o Idle motor hose clips o Hoses

o Electrical connections

 Remove idle motor bracket bolts [A].  Remove idle motor bolts [B].

Idle Motor Installation

 Install:

o Idle motor hoses o Electrical connector o Hoses clips

 Install and tighten idle motor bracket bolts

Torque – Idle Bracket Bolts: 5Nm

 Torque Idle motor bolts

Torque – Idle Motor Bolts: 5Nm

Idle Motor Inspection

 Visually inspect the idle motor for damage/cracks, and or deterioration  Replace if any issues are visible.

A

43

Cooling System

Exploded View ... 45 Flow Chart ... 47 Specification ... 48 Engine Oil and Filter ... 49

Oil Level Inspection ... 49 Oil Draining ... 49 Oil Filling ... 50 Oil Pump ... 50

Oil Pump Removal ... 50 Oil Pump Installation ... 51 Oil Pump Inspection ... 51 Oil Cooler ... 51 Oil Cooler Removal ... 51 Oil Cooler Installation ... 52 Oil Cooler Inspection ... 52 Oil Cooler Cleaning ... 52 Hose Inspection ... 52 Head Temperature Sensor ... 53 Head Temperature Sensor Removal ... 53 Head Temperature Sensor Installation ... 53 Head Temperature Sensor Inspection ... 53

44

Oil Coolant Flow

Note: Oil is sucked from the back of the oil tank [1] and pumped under pressure through the engine oil feed system.

Oil is scavenged from the sump by the oil pump [2] and pumped through the radiator [3] into the oil tank [4].

The oil tank LH breather [5], breathes into the back of the head. The crank case breather [6] breathes into the LH rocker cover. The RH rocker cover breather [7] breathes into the air box.

1 2 3 4 5 7 6

46

REF. NO. PART DESCRIPTION TORQUE REMARKS

1 SWITCH, OIL PRESSURE, 0.2 BAR 20 THREEBOND 1327

8 PUMP ASSY, OIL

11 PIN, DOWEL, 1/8 X 5/8, SOLID USED WITH OIL PUMP DRIVE

12 PIN, DOWEL, 4.0 X 16.00MM, SOLID USED WITH PUMP TO CASE

In document Proyecto de obra: PREVENCIÓN DE INCENDIOS EN PRAHUA CANDAMO (página 47-52)