SHOP MANUAL - mega-engine.com

SHOP MANUAL MEGA SC750 SIDECAR ENGINE Version 01/2019

J:\MT\Anleitungen\750 Sidecar\EN Shop Manual

Handbuch – Shop Manual

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Preamble

All the information and procedures of this instruction guideline are at the moment of release on the actual

level of information and are made of to the best of one's knowledge, but excludes any liability.

All rights, technical changes and errors are expected.

Reprinting, translating or duplication, also partly, is only allowed with the written permission of:

RÜBIG Technologie GmbH & Co KG

Schafwiesenstrasse 56

A-4600 Wels / Austria

Telefon: +43 7242 66060

Telefax: +43-7242-66060-3077

www.mega-engine.com

[email protected]

General information

For any information regarding engine repair please ask your dealer or RÜBIG Technologie GmbH (address

see above).

Introduction

We are pleased that you decided on a MEGA SC750 Sidecar engine.

Warning: Before assembling and before starting the engine read the operating instruction and follow the

instruction guide lines.

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1. Adjust the crankshaft on the device left and right to max. 0.03 mm.

2. Measure the width of the crankshaft at the bearing seat.


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3. Measure and note the depth from the housing plan surface to the bearing seat inner ring.

4. Calculate the crankshaft axial clearance using the enclosed form and fix the spacers.

5. Heat the bearing inner rings to approx. 200 ° C and place on the crankshaft stub. If shims are required place them under the bearing inner ring. NOTE: Check for proper seating after the bearing inner ring has cooled down.


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6. Clean the seat of the shaft seal in the crankcase. Lubricate the shaft seal on the outside and insert with Loctite into both housing halves. Then insert transmission shaft seal.

7. Grease crankshaft ring and gear shaft sealing ring well.


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7.1 Then insert the crankshaft and gearbox into the engine housing. Caution: Do not damage oil seals!

7.2 Assemble the gearbox in the correct position in advance.


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7.3 The two upper gears must be flush.

8. Fit the two shift forks for 1st and 4th gear on the output shaft, shift fork for the 3rd gear on the drive shaft. Note: Do not forget the shifting roll.


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8.3 Now insert the long shiftig rod into 1st gear and 3rd gear shift fork. Insert the short shiftig rod in 4th gear selector fork.

8.1 Then insert the shift drum and let the

fork engage in the shift drum.

8.2 Lubricate the shift fork bore with engine oil.


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9. Place the transmission bearing inner race on the drive shaft.

10. After the case gasket has been fitted the two engine cases can be assembled.


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11. Insert the screws of the engine case one after the other and tighten. Observe the prescribed

torque (13 Nm).

12. Fit the o-ring and spacer to the pinionshaft, observing the correct position of the o-ring.


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13. Insert the oil drain plug.

14. Insert the release shaft with needle bearing - well greased - and secure the

simmering ring flush with the motor housing.

14.a Install the flat washer, glue the screws with Loctite and tighten to 8 Nm.


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15. Lubricate the main bearing and the connecting rod bearing in the crankcase with 2 stroke oil and

check the crankshaft for axial clearance, paying attention to the installation clearance. The axial

clearance of the crankshaft should be between 0.25 mm and 0.40 mm.

16. Remove the excess of the case gasket with a knife, so that the sealing surface is flush with the seal.


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17. Make the cone from the primary transmission is free of fat. Glue the nut with Loctite blue and

tighten (120 Nm).

18. Place the shift locator in the correct position (with grain bumps upwards), on the shifting shaft and tighten with screw (Loctite blue). NOTE: To do this, secure the shift drum against twisting, otherwise damage may occur!


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19. Insert the locking lever and check the spring for the locking lever for correct seating. Then insert the shift mechanism. NOTE: Check the function of gear shifting!

20. Lubricate the sliding bush of the kickstarter internal gear and secure with thrust washer and circlip.


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21. Insert the kickstarter shaft with all components. Turn left the stop plate until it snaps into place. Position the spring 90 ° to the spring recess. Pretension the inserted spring by 90 ° and hook it into the recess provided. Insert the cover for the driving hub.

22. Insert the clutch basket.


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23. Install the middle cover gasket on the engine case. Thread the middle cover on the kickstarter and the shifter shaft, lubricate the aluminum feed in the middle cover and carefully mount the middle cover. NOTE: Pay attention to the water pump wheel, this must be mounted in the correct position relative to the crankshaft to allow the middle cover to seat!

24. Now insert the screws of the correct length into the middle cover and tighten to the

recommended torque (10 Nm).


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25. Insert the piston pin bearing using the mounting sleeve. Oil the piston pin hole. Place the piston on

the connecting rod and put the piston pin through. Then insert the piston pin clips.

NOTE: Pay particular attention to the bending of the piston pin clips. If the piston pin clips are

bent, always replace them!

26. Lubricate the piston pin bearing, the piston rings and the cylinder surface with 2 stroke oil. Then place the cylinder gasket on the middle cover and carefully thread the cylinder onto the piston.


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27. Install the flange nuts, tighten them hand-tight crosswise and then tighten them again crosswise with the torque wrench (60 Nm).

28. Install the O-rings in the groove and check for correct seating. Then install the cylinder head and tighten the cylinder head crosswise with the cylinder head bolts and the copper sealing rings. Hand tight at first, then tighten to 35 Nm with the torque wrench.


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29. Measure the dimension X of the crimping edge with 2 strips of metal plumb bob (DM 2mm) by inserting the two wires in the cylinder parallel to the piston pin on the left and right. Turn the piston above TDC and then measure the squeezed metal slot using a vernier caliper. If the desired dimension is not achieved, replace the cylinder base gasket with the correct dimension X.

30. If the squish edge has been determined correctly, disassemble the cylinder head and adjust the

exhaust control as follows: Move the centrifugal unit to the open position and use the threaded rod to

set the correct opening of the Power Valve roller.

NOTE: The PV roller should be flush with the outlet edge. Counterhold the nuts on the threaded rod

and again check the outlet roller for correct position. Check free movement of the ball joints !


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31. After correct adjustment of the PV roller, loosen the threaded rod again from the ball stud, mount the control tube sealing collar and the timing cover gasket. NOTE: When reassembling the threaded rod, do not forget the hinge lock!

32. After attaching the control cover, move the clearance of the PV roller by means of check for complete

opening.


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33. Mount water pump cover and gasket.

34. Insert support disk 4 mm.


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35. Insert the coupling driver and check the projection to the gear shaft. A minimum of approx. 0.5mm

should be found here. If the measurement is lower, the next thicker support disk must be used with

4mm. Insert the lock washer and nut. Tighten the clutch driver to 120Nm

NOTE: Secure the clutch driver to twist!

Secure locking plate to nut.

36. Insert the sintered plate coupling and the steel disc coupling one after the other. Starting with the clutch plate. NOTE: The last steel disc has a thickness of 1.5 mm!


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37. Now mount the clutch push rod with the pressure cap. Then each 6 pcs springpens insert clutch

springs, spring plates and M6 bolts and tighten crosswise to 15 Nm.

38. Now the position of the release lever for the clutch is set. The upper mark on the release lever should

always be approx. 40 - 45 ° to the motor housing. If this is not the case, the push rod must be

adjusted via the thread with the pressure pin.


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39. Once the correct setting has been made, secure the pressure pin to the push rod with a split pin.

40. Before the clutch cover gasket is fitted, the engine sealing compound must be fitted to the described

position (red marking) on the intermediate cover, after which the gasket and cover can be attached.

NOTE: After having opened and fastened the clutch cover several times, you must

the screws are replaced!.


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41. Now attach the remaining parts to the engine as shown on the picture.

42. Install the stator on the engine and turn counterclockwise to the left until the bolts stop and tighten

to 5 Nm.


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43. Install the rotor and tighten the nut to a torque of 50 Nm.

Now check the ignition, this should be set to 6 - 7 ° after TDC.

Then the engine oil must be filled and the engine is ready for use!

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SHOP MANUAL - mega-engine.com