Bimota DB7 Manuale di istruzioni

BIMOTA DB7

WORKSHOP MANUAL

2008, Bimota Spa.

The reproduction, in whole or part, of the topics covered in this

publication, is forbidden: all rights are reserved to Bimota to

which will require (written) authorization specifying the reasons.

Bimota

MANUAL PURPOSE – WARNINGS

This manual has been written by Bimota SpA primarily intended for use by dealers Bimota and their skilled

mechanics. Describes the service procedures for maintenance, repair and replacement of original parts of the

motorcycle in question. The technicians, that this manual is intended to, must have the adequate experience

and competence: some information has been deliberately omitted, because they have to be part of the indi-

spensable basics that a technician must have. The technicians in the use phase of the manual must comply

with the original technical specications given by the original manufacturer. Bimota assumes no responsibility

for errors or omissions of technical nature, produced in the writing of this manual. All the information provided

shall be updated at the time of printing, Bimota pursues a policy of continuous research and development, the-

refore, reserves the right to make changes of its products without prior notice and without obligation to make

the same changes to products already sold. The modications or signicant changes made to the specica-

tions or procedures will be reported to all Bimota authorized dealers and, where possible, will be included in

subsequent editions of this manual.

SIMBOLS

All indications right or left refer to the direction of travel of motorcycle.

Caution

The non-compliance with the instructions may create a situation of danger and cause serious personal injury

and even the death of the pilot, persons in the proximity, or person intent to repair the bike.

Important

Indicates the possibility of damage to the vehicle and/or its components if the instructions are not performed.

Notes

Provides useful information on the current operation.

USE OF THE MANUAL

This manual is an easy guide for technicians. All the procedures indicated in the manual are illustrated in a

detailed way and regards the operations of disassembly, assembly, inspection and repair.

The manual is divided in chapters. The name and the relative number, placed in a frame on the right upper1.

corner of each page, indicating the current chapter.

Each chapter is divided in sections. In the left upper part of each page is reported the title of the current2.

section, written in capital letters.

Paragraph title, written in small letters respect to the section title.3.

At the beginning of some sections, to make the procedures of disassembly more clear and to help the iden-4.

tication of the bike components, are reported the exploded drawings. It is possible to identify by number

the related piece.

The exploded drawing is accompanied by a list with the piece name and relative characteristics.5.

The instructions for the disassembly/assembly operations are described in sequence.6.

Some operations are accompanied by symbols with the purpose to supply more information and/or possi-7.

ble danger situation for the pilot or motorcycle.

Sez11-1

ENGINE 11

Summary

MANUAL PURPOSE – WARNINGS 4

SIMBOLS 4

USE OF THE MANUAL 5

11.1 - REMOVAL – REFITTING OF THE ENGINE ASSEMBLY SEZ11-4

Removal of the engine ............................................................................................................Sez11-5

Retting engine .......................................................................................................................Sez11-5

11.2 - LUBRICATION SYSTEM: OIL PUMP SEZ11-6

Removal of the oil pump .........................................................................................................Sez11-7

Disassembly of the oil pump ...................................................................................................Sez11-8

Reassembly of the oil pump ...................................................................................................Sez11-9

Retting the oil pump ..............................................................................................................Sez11-10

11.3 - LUBRICATION SYSTEM: OIL COOLER SEZ11-12

Removal of the lubrication system ..........................................................................................Sez11-13

Oil cooler inspection ................................................................................................................Sez11-14

11.4 - COOLING SYSTEM: WATER TANK SEZ11-15

Removal of the water tank .......................................................................................................Sez11-16

11.5 - WATER COOLING: WATER COOLER SEZ11-17

Disassembly water cooler .......................................................................................................Sez11-18

Water cooler inspection ..........................................................................................................Sez11-19

Renewal of the cooling fan ......................................................................................................Sez11-20

Removal of the cooling system hoses and unions ..................................................................Sez11-21

11.6 - COOLING SYSTEM: WATER PUMP SEZ11-25

Removal of the water pump ...................................................................................................Sez11-26

Retting the water pump .........................................................................................................Sez11-29

11.7 - CYLINDER HEAD ASSEMBLIES: CHECKS AND ADJUSTMENTS SEZ11-34

Checking and adjusting the valve clearances .........................................................................Sez11-35

Checking the closing clearance ..............................................................................................Sez11-36

Checking valve lift ...................................................................................................................Sez11-37

Checking the engine timing .....................................................................................................Sez11-39

11.8 - CYLINDER HEAD ASSEMBLIES: TIMING SEZ11-42

Removal of the timing belt covers ..........................................................................................Sez11-43

Removal of the tensioner pulley / timing belt ..........................................................................Sez11-44

Removal of the camshaft pulleys/idler pulley ..........................................................................Sez11-45

Removal of the tensioner and idler pulley mounting studs ......................................................Sez11-46

Disassembly of the camshaft pulleys ......................................................................................Sez11-46

Removal of the timing belt driveshaft pulleys ..........................................................................Sez11-47

Retting the timing belt driveshaft rollers ................................................................................Sez11-49

Retting the idler and tensioner pulley mounting studs ...........................................................Sez11-51

Reassembly of the timing pulleys ............................................................................................Sez11-52

Rimontaggio puleggie testa / tenditori ssi ..............................................................................Sez11-53

Retting the timing belts ..........................................................................................................Sez11-55

Retting the timing covers .......................................................................................................Sez11-58

11.9 - CYLINDER HEAD ASSEMBLIES: CAMSHAFTS SEZ11-59

Removal of the camshafts .......................................................................................................Sez11-60

Sez11-2

ENGINE 11

* Click on the desired item to go to the related section.

Checking the camshafts and supports ....................................................................................Sez11-62

Retting the camshafts ............................................................................................................Sez11-64

Oil seals ...................................................................................................................................Sez11-67

Rocker cover ...........................................................................................................................Sez11-68

Removal of the intake manifold and coolant union ..................................................................Sez11-71

11.10 - CYLINDER HEAD ASSEMBLIES: VALVES - ROCKER ARMS SEZ11-72

Removal of the cylinder heads ................................................................................................Sez11-73

Removal of the valves .............................................................................................................Sez11-74

Removing the valve rocker arms .............................................................................................Sez11-75

Overhaul of cylinder head components ...................................................................................Sez11-79

Valve seat ................................................................................................................................Sez11-80

Valve guides ............................................................................................................................Sez11-82

Checking the valve ..................................................................................................................Sez11-84

Checking the valve seal ..........................................................................................................Sez11-86

Checking the rocker arms .......................................................................................................Sez11-86

Opening and closing shims - Springs ......................................................................................Sez11-87

Reassembly of the cylinder head ............................................................................................Sez11-87

Valve guide seals ....................................................................................................................Sez11-88

Reassembly of the closing rocker arms. .................................................................................Sez11-88

Retting the valves, closing shims and half rings ....................................................................Sez11-91

Retting the opening shims and opening rocker arms ............................................................Sez11-93

Fitting the cylinder head assemblies .......................................................................................Sez11-96

11.11 - CYLINDER / PISTON ASSEMBLIES SEZ11-98

Removal of the cylinder/piston assembly ................................................................................Sez11-99

Overhaul of the cylinder barrel/piston components .................................................................Sez11-103

Checking the piston-cylinder clearance ...................................................................................Sez11-104

Checking the piston ring-grooves clearance ...........................................................................Sez11-106

Checking the piston ring/cylinder clearance ............................................................................Sez11-107

11.12 - CLUTCH ASSEMBLY: CLUTCH SEZ11-108

Description ..............................................................................................................................Sez11-109

Removal of the clutch ..............................................................................................................Sez11-110

Inspection and overhaul of the clutch components .................................................................Sez11-115

11.13 - CLUTCH ASSEMBLY: RIGHT-HAND SIDE CRANKCASE COVER SEZ11-117

Removal of the right-hand side crankcase cover ....................................................................Sez11-118

11.14 - CLUTCH ASSEMBLY: PRIMARY DRIVE GEARS SEZ11-121

Removal of the primary drive gears ........................................................................................Sez11-122

Retting the primary drive gears and checking backlash ........................................................Sez11-125

11.15 - GEARBOX ASSEMBLY: GEARCHANGE MECHANISM SEZ11-128

Removal of the gearchange mechanism .................................................................................Sez11-129

Disassembly of gear interlock plunger and pawl assembly .....................................................Sez11-131

11.16 - GEARBOX ASSEMBLY: GEARBOX SHAFTS SEZ11-132

Removal of the gearbox assembly ..........................................................................................Sez11-133

Disassembly of the gearbox shafts .........................................................................................Sez11-135

Disassembly of the gearbox output shaft ................................................................................Sez11-135

Disassembly of the gearbox input shaft ..................................................................................Sez11-138

Overhaul of the gearbox ..........................................................................................................Sez11-141

Inspection of the gear selector forks .......................................................................................Sez11-142

Inspection of the gear selector drum .......................................................................................Sez11-143

Sez11-3

ENGINE 11

* Click on the desired item to go to the related section.

11.17 - FLYWHEEL-ALTERNATOR SEZ11-144

Removal of the left-hand side crankcase cover ......................................................................Sez11-145

Disassembly of the left-hand crankcase cover ........................................................................Sez11-147

Removal of the ywheel/alternator assembly ..........................................................................Sez11-149

Overhaul of the ywheel/alternator assembly .........................................................................Sez11-150

Disassembly of the ywheel/alternator ....................................................................................Sez11-151

Reassembly of the ywheel-alternator assembly ....................................................................Sez11-152

11.18 - CRANKCASE ASSEMBLY: EXTERNAL COMPONENTS SEZ11-157

Removal of external components ............................................................................................Sez11-158

Retting the external components ...........................................................................................Sez11-161

Removal of the timing gears ....................................................................................................Sez11-166

Removal of the starter motor idler gear ...................................................................................Sez11-167

Checking the engine sensor air gap ........................................................................................Sez11-168

11.19 - CRANKCASE ASSEMBLY: CRANKCASE HALVES SEZ11-170

Separation of the crankcase halves ........................................................................................Sez11-171

Overhaul of the crankcase halves ...........................................................................................Sez11-174

Main bearings ..........................................................................................................................Sez11-178

Shimming the shafts ................................................................................................................Sez11-179

Shimming the crankshaft .........................................................................................................Sez11-180

Shimming the gearbox shafts ..................................................................................................Sez11-183

Shimming the gearbox selector drum ......................................................................................Sez11-184

11.20 - CRANKCASE ASSEMBLY: CONNECTING RODS SEZ11-185

Removal of the connecting rods assembly ..............................................................................Sez11-186

Disassembly of the connecting rods ........................................................................................Sez11-186

Overhaul of the connecting rods .............................................................................................Sez11-187

Renewal of the small end bushing ..........................................................................................Sez11-188

Connecting rod bearings .........................................................................................................Sez11-188

Crankshaft ...............................................................................................................................Sez11-189

Big-end bearing shell-journal clearance ..................................................................................Sez11-192

Reassembly of the connecting rods ........................................................................................Sez11-192

Retting the connecting rods. ..................................................................................................Sez11-195

Sez11-4

ENGINE 11

11.1 - REMOVAL – REFITTING OF THE ENGINE ASSEMBLY

1) Engine spindle

2) Nut M12x1,25

3) Spacer

Sez11-5

Removal of the engine

In order to remove engine you must rst remove a series of other components from the motorcycle.

Most of these removal procedures are described in the relative sections of this manual.

This section describes only the operations to be carried out after having removed all the parts listed belowe:

- Tail, Fuel tank, side fairing, front fairing

- Throttle control, airbox, throttle body, exhaust system

- Foot lever gearshift assembly, rear brake pump, Clutch piston assembly, engine driving pinion

- Engine wiring, battery box mount, oil cooler and pipes, cooling system

- Swingarm, swingarm plate dx-sx, shock absorber rocker

Place a stand beneath the engine to support it during removal from the frame.

Loosen the two spindle nuts (2) on the left or the right side.

Take the spindles (1) off. In this moment the engine unit is detached by the frame.

Take the engine off from the frame pulling it down and forward.

Retting engine

To reassemble repeat the assembling operation in reverse order.

Important

Add grease under the nuts (2) and tighten to specied torque.

ENGINE 11

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