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PRELIMINARY INSTRUCTIONS AND DISASSEMBLY:
Clean the bike and the engine area thoroughly. Remove one by one the following components: seat, plastic parts (conveyors and side
covers), fuel tank, exhaust silencer, exhaust manifold, cylinder hanger plates and rear frame. After draining the coolant, disconnect
the water hose from the head, the water hose in front of the cylinder, the valve cover vent pipe, the spark plug and the carburettor.
Remove the valve cover and the covers on the left hand side 1 and 2 (picture A) of the crankshaft hole. Place the piston on the TDC
(Top Dead Centre) on the exhaust stroke. Turn the crankshaft anticlockwise and align the TDC mark 1 on the rotor with the index
mark 2 on the crankcase cover (picture B). Make sure that the punching 1 on the exhaust cam shaft and the punching 2 on the inlet
camshaft are well aligned on the surface of the cylinder head (picture C). Unscrew the screw of the timing chain 1 and take off the
chain tensioner 2 (picture D). Unscrew the screws 1 (to avoid warping the camshaft holders and the cylinder head, to loosen each
nut about ¼ turn) and remove the camshaft caps 2 and the fasteners (picture E). Remove the exhaust camshaft 1 and the inlet
camshaft 2 by connecting the distribution timing chain with a string 3 to prevent it from falling into the crankcase (picture F). Be
careful not to drop any foreign bodies into the crankcase. Remove the three-way oil feeding pipe, the cylinder head, the gasket and
the dowel pins, slip the cylinder off and cover the crankcase opening to prevent impurities from falling into it. Remove the base gasket
and the piston. Check the following components: cylinder head: clean the combustion chamber from carbon incrustations; connec-
ting rod: check the piston pin clearance by referring to the use and maintenance manual, inlet-exhaust valves: check the tightness
and the clearance by referring to the use and maintenance manual.
The health of your engine is guaranteed by the good conditions of these elements.
ASSEMBLING INSTRUCTIONS:
Carefully clean all the original components you are replacing and all the new components of the Athena cylinder kit. Make sure that
there are no residues left inside the various cylinder channels or on the piston.
Install the piston rings and avoid piston damage during installation. Install the top ring with its marking facing up. Place the piston
rings as indicated in picture G.
Cover the opening in the crankcase with a rag. Position the piston arrow mark facing to the exhaust valve side.
After lubricating the piston pin, slide it inside the piston pinhole by pushing it with your hand; after assembling the circlips carefully
check that they are well tightened inside their seatings.
Place the new cylinder base gasket supplied with the Athena kit and the dowel pins on the crankcase.
Lubricate the cylinder bore, piston and piston rings with clean engine oil and install the cylinder while compressing the piston
rings.
NOTE: Do not rotate the cylinder, since this may cause the piston rings to break.
Install the dumper timing chain by aligning its tabs with the cylinder grooves.
Install and tighten the M6 cylinder mounting bolt to the specified torque: 10 N•m (1,0 kgf•m) after locking the four bolts to the
head.
Install the dowel pins and the new cylinder head gasket supplied in the Athena kit.
Install the cylinder head onto the cylinder with its washers and tighten the bolts to the specific torque in a criss-cross pattern in two
or three steps: 45 N•m (4,6 kgf•m).
Install and tighten the M6 cylinder head mounting bolts to the specific torque: 10 N•m (1,0 kgf•m).
Install the hanger plates of the cylinder kit.
Install the exhaust camshaft 1 and the inlet camshaft 2 (picture F). Note: align the TDC mark 1 on the rotor with the reference 2 on
the crankcase cover when the piston is on PMS during the compression phase.
Install the timing chain on the two toothed wheels of the camshaft. Note: the camshaft has to be assembled on the cylinder head so
as the punching 1 and 2 (picture C) are well aligned and perpendicular to the cylinder head surface.
Install the fasteners and the cam shaft caps.
In order to avoid any damage to the head, install and tighten evenly all the bolts of the camshaft caps to the specific torque: 10 N•m
(1,0 kgf•m). Install the chain tensioner with the gasket supplied in the Athena kit and tighten the bolts to the specific torque: 10 N•m
(1,0 kgf•m).
Unscrew the central screw of the chain tensioner, which will automatically tighten up.
Screw up the close nipple of the chain tensioner with its gasket to the specific torque: 7 N•m (0,7 kgf•m).
Rotate the crankshaft anticlockwise for some turns. Check that the mark TDC mark on the rotor is aligned with the reference on the
crankcase cover (picture B) and that the punching on the toothed wheel of camshafts is aligned and perpendicular to the surface of
the cylinder head (picture C).
ATTENTION! The reference on the rotor should not be considered as a positioning of the piston with respect to the TDC.
Check if the valve cover gasket is damaged or worn and replace it with a new one if necessary.
Install the cylinder head cover and tighten the bolts to the specified torque: 10 N•m (1,0 kgf•m).
Install the spark plug, the spark plug cap and the vent pipe of the cylinder head cover.
Install the caps on the left side of the timing survey.
Install the carburettor and fix the corresponding hose band. Connect all the connectors of the electric circuit.
Install the following components: the secondary frame; the oil breather tube, the exhaust manifold with the new gasket, the silencer,
the engine protectors and the radiator conveyors.
Connect the manifolds of the cooling circuit. Add coolant up to the filler neck.
Clean and if necessary replace the air cleaner element.
Install the fuel tank with the fuel valve, the seat and the side covers.
RUNNING IN, USE AND MAINTENANCE:
For the running in and the maintenance follow carefully the instructions given in the manual "OWNER'S USE AND MAINTENANCE
MANUAL". Use petrol containing at least 96 octanes. Do not force the engine during the first 2-3 running hours as you can cause
damage to the cylinder kit. The best performance is obtained only after a good running-in. As soon as you feel that the engine power
is decreasing we suggest to replace the piston in order not to compromise the roundness of the cylinder tube. Service piston limit: we suggest replacing the piston after 15
running hours.
We remind you that it is not the single part but all the parts as a whole that give your engine the best performance.
Only qualified technicians must make the assembling of the articles included in this kit. In case a wrong assembling causes any faults and/or problems, we will not be responsible for any damage or technical or economical request which are
claimed to us. The descriptions contained in this leaflet are not binding. Athena reserves the right to make any changes, if necessary. We are not responsible for any printing errors.
All ATHENA products, which are manufactured with higher displacement and power than those permitted by law of the country where the end user lives, are intended solely for competition-sports usage. Use on public roads as well
as in aeronautics and marine is prohibited. ATHENA is not responsible for any different usage.
The customer takes full responsibility that the distribution of the articles purchased from Athena is in line with the current regulations of his country and therefore frees Athena from whatever responsibility in this matter.
FIM/G061
ATHENA SPA - Via delle Albere, 13 - 36045 Alonte (VI) - Italy - Tel. +39-0444-727258 - Fax +39-0444-727222
ASSEMBLY INSTRUCTIONS CYLINDER KIT
www.athena-ad.com - e-mail: sales@athena-ad.com
BORE SIZE
STROKE
DISPLACEMENT
97 mm
60,8 mm
449,3 cc
102 mm
60,8 mm
496,8 cc
COMPRESSION RATIO
12,4:1
12,2:1
A
B
C
D
E
F
G
GB
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