PROTOTYPE DESIGN NOT FOR USE ON PRODUCTION MOTORCYCLE MODELS

Transcription

1 PROTOTYPE DESGN NOT FOR USE ON PRODUCTON MOTORCYCLE MODELS

2 RN~ DESCRlPllON ( DAlE BY *PPROVEO FRONT OF ENGNE UNLESS OTHERWSE SPECFED: SEE SEPARATE BLL OF MATERAL DECMAL mm X XX 2.76.m e.254 SURFACE ROUGHNESS: l " * l 200 EAST TENTH STREET, GLROY, CA PHONE FAX: FNSH: APPROVALS mm8y DATE 1m1m TTLE: Noun Phrase, Adj 1, Adj 2 SZE DRAWNG NO: REV NN-NNN-Name 1 DO NOT SCALE DRAWNG SHEET 2 OF 2 =

3 REV DESCRlPllON DATE A FRSl PRODUCTON RELEASE ~23111/01~ AW BY APPROVED CONVERTED TO SOLDWORKS. REMOVED BRACE a- TORQUE TO 15 Lb-ft SEE SEPARATE BLL OF MATERAL ( UNLESS OTHERWSE SPEClFtEOt DECMAL.NCHES FRACTONS ANGLES.m 2.03.m f.010 DECMAL rnm X f1.50 XX 2.76.m SURFACE ROUGHNESS: 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: FNSH: DO NOT SCALE DRAWNG - AW CHECKED BY: SW ENGNEER: LWlLE 11/u/MOl 1 m 2 D SZE DRAWNG NO: SCALE: 1:l ASSY REV C SHEET 1 OF 2

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5 SECTON B-B VERFY WHAT KYLE WANTS THS DM TO BE MAKE SURE THAT ALL OL PASSAGEWAYS ARE OPEN AND CLEAR

6 FRONT OF ENGNE ALGNMENT MARKS A ENT MARK UNLESS OTHERWSE SPECFED: DECMAL. NCHES FRACTONS ANGLE 1 SEE SEPARATE BLL OF MATERALS GEAR POSTON CAM TMNG DECMAL mm X 2150 XX t.76 -., SURFACE ROUGHNESS: "/ U9DWWBEWEClFl~ MATERAL: FNSH: ' 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: _.-.Q,,.C. --"'P(.'. L'>D -,.. ;, ' -C-.i.^sA'.>.>.,T :.:: ,l.'l! :.jfc>i= >,,.;..e.;->,-.c\.-.?,,..:... -,% rt%+.%-.-. r,<.;,r,:. L;i:r~\.;fi,.,:~ ;>-;..:.',p..*..~-i-:,;.i. 2%.. : : 2 2 :.:>.- s..l.-tlzf.~~i3ii L.=;.\s.\0 APPROVALS W. BARNETT - CHECKED BY: DATE 3/2/3003 TTLE C S<Ch-L3P1 <.%,.:.";'Z'T:;, :::3iL.> p, irs C'-".,.'*. CAM CASE COMPONENTS MC 100 C MOTOR ENGNEER: ASSY DO NOT SCALE DRAWNG K. LANGLMJDS 3/2/3003 SCALE: 1 :l ( SHE- 4 OF 4 \

7 SUB ASSEMBLY CAM-CASE UNLESS OTHERWlSE SPECFED: DECMAL NCHES FRACTONS ANGLE X +D6 f 1/32.XX f.03 XXX caio DECMAL mm X _*S XY 2.76 XXX +254 SURFACE ROUGHNESS: F/ uiman~rnsra MATERAL: w.: -">,.:.a LE.,V-~G u..xlwle-, =+ ~~L~,.~W-L.~L~~~S:. -zk -. <?...-- FNSH: - DO NOT SCALE DRAWNG SEE SEPARATE BLL OF MATERALS L 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: F, s.,~-.,:s :;~~~;,~,., 2,Y&,F--,pcs,.-..-.z, F:Z.iiiZ.?L p<:.o<e..::.-:r 2-11 >%:+A,\- e.i$t,,.?!ti:. T<':(?L<. :,cr?; crs:? : 3. <;,.4T~FL~;~,..~"z;>~<,-~,.~<,**k~:% 2'~...~.ez.~:.~,-2 -c.:+8.e..~ys;;:kc.-.c.?,.c-:<.. \'L. 'C- EF 33Cl5Z.- APPROVALS W BARNEn CHECKED - -- BY: ENGNEER: DATE 3/2/3003 TTLE CAM CASE COMPONENTS, MC 100 C MOTOR u- SZEDRAWNG NO: REV ASSY K LANGLAND 1 SHEET 3 OF 4 \

8 . APPLY ASSY LUBE TO LOBES, GEARS, AND BEARNG SURFACES TORQUE TO FT-LBS END PLAY TO BE LEFT HAND THREAD USE VAR.ATONS SHOWN ON APPLY RED THREAD LOCKER FABR AS REQURED USE JlMS TOOLS P/N A THCKNESS CHOCES ARE: THRUST WASHER THCKNESS S.10 UNLESS OTHERWSE SPECFED: ( SEE SEPARATE BLL OF MATERALS.X 2.06.XX i.03?132?1/2'.xxx DECMAL. mm.x f1.m.xx 2.76.XYJ '254 SURFACE ROUGHNESS: zj UUHLEUO~B~~~EPECFED 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: FNSH: WBAf?Nm 3/2/mo3 APPROVALS DATE TTLE CAM CASE COMPONEN,TS, - MC 100 C MOTOR. ENGNEER: c ASSY B DO NOT SCALE DRAWNG K LANGLANDS 3/2/3003 SCALE: 1 : 1 SHEET 2 OF 4 1

9 1 REVSONS l REV l DESCRPTON DATE BY ( APPROVED 1 A PRODUCTON RELEASE /02 ROUSH B CONVERT TO SW. ADD NOTES AND CNG. VEWS 03/02/03 WB VEW N DRECTON OF ARROW Z /\ FNSH: Do NOT SCALE DRAWNG APPROVALS WBARNET -- CHECKEDY~ - ENGNEER: K LANGLAND.' DATE 3121m 3/2/ m TTLE CAM CASE COMPONENTS, MC 100 C MOTOR SZE DRAWNG NO: c ASSY REV B SCALE: 1 : 1 ( SHEET 1 OF 4

10 REVSONS l E.11 DESCRPTON DATE 1 B 1 APPROVED 1 PRODUCTON RELEASE 2X TORQUE TO FT-LBS NSTALL TO DMENSON AS NOTED APPLY RED THREAD LOCKER AFTER ASSY OF STUD LUBE SEE SEPARATE BLL OF MATERALS L UNLESS OTHERWSE SPECFED: DECMAL lnches FRACTONS ANGLE.X / ' XX 2.03.xXX DECMAL mm SURFACE ROUGHNESS: 1?5/ mtmoaurirrmn ' 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: NSTALL WTH FRE RNG SEAM FACNG FRONT CYLNDER HEAD FNSH: DRAWN BY. CwFrrFn RY. HEAD ASSEMBLY COMPONENTS, BLACK WT POLSHED FNS, MC 100 C t DO NOT SCALE DRAWNG ENGNEER: -K. LANGLAN

11 2X.875t.05 AFTER ASSY OF STUD 1

12 FRONT OF ENGNE HEAD ASSY - FRONT HEAD ASSY - REAR FRONT OF ENGNE TOP VEW HEAD ASSY TORQUE PROCEDURE SEQUENCE: = TORQUE SEQUENCE NUMBER 1. Thoroughly clean the threads of the cylinder head bolts before installation. Friction caused by debris and grime will result in a false torque indication. 2. Lightly coat the threads 2-4 drops) and washer face (1 drop) of the head bolts w~th 20w-50 engine oi \ prior to assembly. Wipe off any excess oil. 3. Lightly snug fasteners 1 thru 4 in sequence. All fasteners must pull snug against head counterbore. f they do not, repeat steps 1 & Torque fasteners 1 thru 4 to 5 ft-lbs, +/- 1 ft-lb, in sequence. 5. Torque fasteners 1 thru 4 to 14 ft-lbs, +/- 1 ft-lb, in sequence. 6. Turn fasteners 1 thru 4 90 degrees (114 turn), +/- 2 degrees, in sequence. F UNLESS OTHERWSE SPECFED: DECMAL NCHES FCTlON ANGLC.X 2.06.XX 2.03?1/32?112'.XXX DECMAL mm.x 213 XX t.76.xxx 22s4 J SURFACE 125 unmromwvaerpeclnm ROUGHNESS: MGFeRGYcLz 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: ~, A 4 SEE SEPARATE BLL OF MATERALS FNSH: DO NOT SCALE DRAWNG APPROVALS W.BARN~ CHEC(CEDy7 Name ENGNEER: K. LANGLANDS 3 3 t DATE 2124~3 2/24/03 2/24/03 TTLE HEAD ASSEMBLY COMONENTS BLACK WTH POLSHED FNS MC 100 C.1. MOTOR SZE DRAWNG NO: REV c ASSY A SCALE: 1 SHEET 3 OF 3

13 REVSONS REV DESCRPTON DATE BY APPROVED A PRODUCTON RELEASE 02/28/03 WB 4X TORQUE TO FT-LBS APPLY BLUE THREAD LOCKER TORQUE N A CROSS PATTERN 0 SUB ASSY TOP FRONT ROCKER BOX SHEET 3 7 T WASHERS MAY ONLY BE USED ONE TME 4X REPLACE AFTER EACH TGHTENNG SUB ASSY SHEET 3 FRONT CYLNDER /\ -.' FNSH: DO NOT SCALE DRAWNG APPROVALS DATE TTLE CHECKEDY? - - ENGNEER: K. LANGLANDS 02/28/03 ROCKER COVERS MC 100 C MOTOR SZEDRAWNG NO: REV ASSY c ( SCALE: 1 : 1 ( SHEET 1 OF 5

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15 2~ APPLY ASSY LUBE r(rght GRDLE) (LEFT GRDLE) Y W APPLY ASSY LUBE SUB ASSY ROCKER ARM SEE SEPARATE BLL OF MATERALS UNLESS OTHERWSE SPECFED: DECMAL. lnche.5 1 FRACTONS ANGLE.X t.06 21/32 21/2' XX 2.03 XXX?a10 DECMAL. mm X 2150 XX 2-76 XXX SURFACE ROUGHNESS: 'YJ"""."" >PC=.". MCEGZmaL 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: FNSH: DO NOT SCALE DRAWNG APPROVALS W. BARNm DATE 02/28/03 -- ~EE~E~EY: -- ENGNEER: K. LANGLANDS 02/28/03 TTLE SZE C ROCKER COVERS MC 100 C1 MOTOR DRAWNG NO: ASSY REV SCALE: 1 :l 1 SHEET 3 O F 5 B

16 (HOSE ADAPTER) TORQUE TO FT-LBS 3X TORQUE TO FT-LBS APPLY BLUE THREAD LOCKER (HOSE ADAPTER) TORQUE TO FT-LBS 6 (BREATHER VALVE HOUSNG) Fw 19 3X TORQUE TO 8-12 FT-LBS APPLY BLUE THREAD LOCK, 5 SUB ASSY TOP FRONT ROCKER BOX SEE SEPARATE BLL OF MATERALS - UNLESS OTHERWSE SPECFED: DECMAL. NCHES FRACTONS ANGLE SURFACE ROUGHNESY 1?5/ 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: FNSH: DO NOT SCALE DRAWNG APPROVALS DATE W- BARNETT 02/28/03 -- CHEClCEDyT -- ENGNEER: K. LANGLANDS 02/28/ TTLE SZE DRAWNG NO: ROCKER COVERS MC 1'00 C MOTOR REV B C ASSY SCALE: 1 : 1 SHEET 4 OF 5

17 FRONT OF ENGNE SEE SEPARATE BLL OF MATERALS UNLESS OTHERWSE SPECFED: DECMAL NCHES FRACTONS ANGLE DECMAL mm.x 2150 XX 276 XXX 2254 SURFACE 125,' UN~ESOWEWSE~?K~~ ROUGHNESS: D APPROVALS DATE TTLE - ROCKER COVERS FNSH: W. B MC 100 C MOTOR CHECkEDy; - SZE DRAWNG NO: REV ENGNEER; C ASSY B DO NOT SCALE DRAWNG K. LANGLANDS 02/28/03 SCALE: 1 : 1 SHEET 5 O F 5

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19 APPLY OL TO BOTH ENDS REAR NTAKE-BLUE APPLY OL TO BOTH ENDS FRONT NTAKE-YELLOW APPLY OL TO BOTH ENDS REAR EXHAUST-PNK APPLY OL TO BOTH ENDS FRONT EXHAUST-GREEN FRONT OF ENGNE SEE SEPARATE BLL OF MATERALS UNLESS OTHERWSE SPECFED: DECMAL lncrej FLCTQNS ANGLE f1/32 f1/2' XX f.03.xxx e.010 DECMAL. mm,\ SURFACE 1?5/ u~imom~~wasr~~cmm ROUGHNESS: 200 EAST TENTH STREET, GLROY, CA " - PHONE: FAX: MATERAL:.:% A,,+.,.~ :-;pc;e- - C= +:F;,tj:5~:,:.-L;%w+T-x 1.: ;x&,r ~=~r=r_\lr~. rh)~i=n~~~r =.r?r!~.;th --s w..:c's,- :.<,-'EC3'= iutz*c> x:.xrl >c-.*.j=qq,n, 5LC'G:5.,,->9., :rieiiiij.al'l'74c:xc$ r ~::~s.h'..5-54i.r-.i CC+PC+2Xt'.,#L'C3.A.v,5.ir >Zltl.,* 3.3:.:.;5\-.-.FE,~;$e\ VS. 2. S?,~~!,Z.~ LE.t7?'B:A 33;Stl) FNSH: DO NOT SCALE DRAWNG APPROVALS DATE W. BARNEn 3131mu --- CHECKED BY: - 3/3/2003 -ENGNEER: K. LANGLANDS 3131M03 TTLE LFTERS/FXED LENGTH PUSHRODS MC 100 C MOTOR SZE DRAWNG NO: C RE\ A ASSY SCALE: 1 :l ( SHEET 2 OF 2

20 REVSONS REV DESCRPTON DATE BY APPROVED UNLESS OTHERWSE SPECFED: DECMAL, NCHES FAGTONS ANGLES.X t.06 t1 /32 $ XX 2.03.XXX +Dl0 DECMAL. mm TORQUE SNUG AND X 2150 ORENTATE AS SHOWN Xi t.76 APPLY WHTE TEFLON SEALER XX 2254 &&~~~!%ZZE~ SURFACE ROUGHNESS: PER PARKER SPEC 200 EAST TENTH STREET, GLROY, CA A- 127 UHLE OTHERWCEPEClRED PHONE: FAX: MATERAL: 7-3 r~,wme:s~~z?~=sr< cc-~t~~: :e:.xc~.~>~,wk~~j ~x~.:~!x~w L-AEE~.~ &h~~c.~cs.5;.! ;+:X,X&:A=. &<? S>?'iCN:E.,?"%s?2FC*CiCiS 70 C*.%. C+Sx* FC< ~qy?uf.zb??'+=:i "ies:issifim-;>vr: WWW A~?~SC%~U,--,-- ;r.->,l?s% MB D?A;'dlK> &'+'+Sl%ErF.i i C,3fF&YBiX FB'C?:<Li?;Cia :;3Eei25SL;ZT BE+i+iilUS.5;q6':.G:y3. A ~ ~ s ~ p. ~ ~ + ; ~ s APPROVALS DATE TTLE DRAWN BY. ENGNE CASE COMPONENTS, FNSH: W BARNm 121~o/mz loo C CHECKEDy; /30/2002 SZE -- DRAWNG NO: REV ENGNEER:' c ASSY A DO NOT SCALE DRAWNG K LANGhND!: 12/3/2002 SCALE: 1 ( SHEET 1 O F 3

21 , CRANKSHAFT CENTERLNE \JT HOLE ALGNMENT HOLE VEW N DRECTON OF ARROW Z (SHEET1 ) ORENTATON OF 90" HOSE FTTNG = RGHT CASE TO LEFT CASE TORQUE SEQUENCE 1. APPLY BLUE THREAD LOCKER TO FASTENERS PROR TO ASSY. 2. PRE-TORQUE FASTENERS 1 THRU 8 TO 2 FT-LBS N SEQUENCE 3. FNAL TORQUE FASTENERS 1 THRU 7 TO 18 FT-LBS N SEQUENCE 4. FNAL TORQUE FASTENER 8 TO FT-LBS ZSJ'W~O~ RW!SES?EC~FW UNLESS OTHERWSE SPECFED: DECMAL lhcwes FACTONS ANGLE SEE SEPARATE BLL OF MATERALS SURFACE ROUGHNESS: 200 EAST TENTH STREET, GLROY. CA ' PHONE: FAX: A A - FNSH: DO NOT SCALE 2 r) DRAWNG -. APPROVALS -BY: WBARNrn - -- ENGNEER: K LANGLANDS DATE 12/3012M)Z 12l3012W l~Q12002 TTLE SZE C ENGNE CASE COMPONENTS, 1OO.C DRAWNG NO: ASSY SCALE: 1 : 1 SHEET 2 OF 3 1 REV A

22 NSTALLATON FNSH: DO NOT SCALE DRAWNG APPROVALS 0RAW.N BY: WBARNm CHECKED BY: - /\ -- ENGNEER: K LANGLAND! DATE OJ ZW2 TTLE ENGNE CASE COMPONENTS, 100 c1 SZE DRAWNG NO: c REV A ASSY SCALE: 1 : 1 ( SHEET 3 OF 3

23 4 3 2 REVSONS 1 APPLY ASSY LUBE ON GEAR REV A DESCRPTON DATE PRODUCTON RELEASE 1 3/2/ WB BY APPROVED TGHTEN AS PER PARKER NPT FlTNG SPECFCATON ORENT AS SHOWN TGHTEN AS PER PARKER NPT FTTNG SPECFCATON ORENT AS SHOWN 6X LGHTLY SNUG ROTATE ENGNE 2 REVOLUTONS CCW FROM DRVE SDE (N DRECTON OF NORMAL ENGNE ROTATON) TORQUE TO 8-12 FT-LBS APPLY BLUE THREAD LOCKER SUB-ASSEMBLY OL PUMP PARALLEL SPLT 25" CRANKCASE ORENTATON OF HOSE FTTNGS UNLESS OTHERWSE SPECFED: 1 X 2.06 XX t.03.xxx DECMAL rnm X +150.XX t.76 XXX 2254 SURFACE ROUGHNESS: ""O~~EE."",w +132 ~112' SEE SEPARATE BLL OF MATERALS g ~ ~ ~ ~ ~ y 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: FNSH: APPROVALS W.BARNm DATE TTLE ~1~ PUMP NSTALLATON, 100 C DO N OT SCALE DRAWNG /\ ASSY ( A SHEET 1 OF S

24 FRONT OF ENGNE FRONT OF ENGNE SEE SEPARATE BLL OF MATERALS UNLESS OTHERWSE SPECFED: DECMAL lhches FACnONS ANGLE DECMAL. mm 1 \ NSTALL FLTER UNTL SEAL TOUCHES CASE THEN TURN 1 /4 ROTATON BY HAND??? APPLY OL LGHTLY TO SEAL SURFACE ROUGHNESS: 1?5/ UNLS OlHERWKESWClnW FNSH: - APPROVALS W. BARNETT - CHECKED BY: Name EAST TENTH STREET, GLROY, CA PHONE: FAX: DATE oulll m TTLE OL PUMP NSTALLATON;'OO C SZE DRAWNG NO: (REV ASSY DO NOT SCALE DRAWNG 1 SHEET 2 O F 2

25 RMSONS REV DESCRPTON DATE BY 1 APPROVED A PRODUCTON RELEASE 1 3/3/ WB TOP COMPRESSON RlNG -', 2ND COMPRESSON RNG (NSTALL WlTH DOT UP) TOP AND 2ND COMPRESSON RlNG GAP ( ]" NSTALLED TOP AND 2ND COMPRESSON RlNG GAPS 180M APART TOP AND BOTTOM OL CONTROL RlNG GAPS 180 M APART ALL ALGN RNG WTH GAPS WRST SHOULD PN AXS PSTON KT ASSEMBLY ( ) SEE SEPARATE BLL OF MATERAL r C*i FRONT CYLNDER 200 EAST TENTH STREE, GLROY, Ck PHONE: FAX: ::%itr.~+%z. ~<X~~~?:~CL~X:L~.:~Z:~T.:.ZW~*T;.:+~ e.33 ESC.:+?m rlcil;;feal) WCFxLZs?%SE &?Y:e:f:w?&~?jf=F-p~5S37~r(~~W~%?ih.;~TNTNTNTN~~:~:i?~B~i~CC?QiM 6Wti4T.:GK> L w C-:WS u l EC-: ~ ~ L~.=TS-JJBJ?~Z YS~_L:L: FFF ip%= >c.>zz'fi *iia~u-~.%~~...%..- :.- APPROVALS 1 DATE TTLE: DRAWN BY. CYLNDER ASSEMBLY COMPONENTS 8.* CHECKED BY: ENGNEER: C LANGLANDS 3 / 3 m 3/3/2003 SZE D DRAWNG NO: ASSY SCALE: 1: REV A SHEET 1 OF 2

26 aquqrevge 200 EAST TENTH STREET, GLROY, CA PHONE: FAX: CYLNDER ASSEMBLY COMPONENTS, CHECKED BY: - ENGNEER: K LANGLANDS 3/3/2W3 D 3~ C SZE DRAWNG NO: ASSY REV A DNS SHEET 2 OF 2