DIY #21

Repairing a Zane motor - Laverda 650/750 Zané 1997-2002

(Click on the pictures to enlarge)

Here is the process to open a Zane motor. The task here is to replace a worn crankshaft however the process is the same
whatever the work to be done, since the motor has to be lifted out of the frame and opened.
Although different in many aspects, these engines are based on Breganze engines, especially the 500cc Alpino. It is then
not surprising that many steps of the process is very similar.

A big thanks to Phil, webmaster of LaverdaCorsa, for the pictures!

Get the engine out of the frame	Best is to remove the primary and clutch cover before dropping the engine to get a better access to the rear engine fixing points	The engine comes as a single unit with oil cooler and headers	Naked engine
A piece of soft metal can be put between the gears to block the transmission and remove the alterntor nut	28mm wrench, left thread	Remove the head cover	Remove the lubrication plates
Remove the chain clip, check the timing marks	Remove the camshafts	Remove the head nuts in the correct order	A 14mm wrench must be modified (filed) to get access to these nuts
Remove the cylinder head	Cylinder head	Pistons and barrels	Remove clips, pins and pistons
Remove the barrels, clean the gasket surfaces with a special product	Remove the nuts joining the 2 crankcases, lift the upper one	Remove the crankshaft	Fit the new crankshaft
Fit the upper case, the pistons	Check the balancing shaft marks	Center the timing chain	Compress the rings with special tools
Fit the barrels	Fit the cylinder head	Tighten the cylinder head nuts to the correct torque and sequence. Use the special tool for these nuts. Refit the camshafts, check the correct timing and refit the engine into the frame.	Just like Breganze engines, gearbox can be reach by only removing the lower crankcase, without dismantling the top end.