Beta Motorcycles X Trainer 300 2T 2015 Workshop Manual
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Beta Motorcycles X Trainer 300 2T 2015 Workshop Manual

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Summary of Contents for Beta Motorcycles X Trainer 300 2T 2015

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS PREAMBLE ........................................... 2 ENGINE ............................................4 REMovAL of MotoR fRoM vEhIcLE ................................ 6 MotoR dIsAssEMBLy ....................................14 cLutch/GEAR oIL dRAIN ................................14 REMovAL of cLutch coNtRoL Rod ANd PINIoN sPAcER ....................14 REMovAL of PIstoN, cyLINdER ANd hEAd ..........................15 REMovAL of IGNItIoN uNIt ..............................19 2.4.1 Flywheel cover plate removal ..............................19...
  • Page 3 TABLE OF CONTENTS chEck of coNNEctING Rod ANd cRANkshAft ........................ 49 AssEMBLING of coMPLEtE cRANkshAft ..........................50 GEARBox uNIt: coNtRoLs ANd REAssEMBLy ........................51 3.4.1 Gearbox unit check ..................................51 3.4.2 Primary unit assembly ................................52 3.4.3 Secondary unit assembly ................................53 3.4.4 Check of forks, fork pins and desmodromic device .......................54 3.4.5 Assembly of gearbox and inner control ...........................56 cLosING of ENGINE cRANkcAsE ............................

  • Page 4: Preamble

    www.betamotor.com PREAMBLE This publication has been written in order to make operations for inspection, maintenance and repairs of the mo- torcycle engine known and understandable to the user of the motorcycle and to the technical assistance operator. Read this entire manual with care before operating on the engine. Sufficient knowledge of the components that make up the engine and of all the procedures to be followed for inspection and maintenance contribute to lengthen the life of the engine.

  • Page 5: Hot Parts

    www.betamotor.com Coolant liquid • Coolant contains dangerous substances which are harmful for the environment. When changing it, you • In some situations, the ethylene glycol contained in must be equipped to dispose of it in compliance the coolant is flammable and its flame is invisible. with existing law.

  • Page 6: Engine

    www.betamotor.com TECHNICAL FEATURES OF ENGINE CHARACTERISTIC dATA ENGINE Bore[mm]/Stroke [mm] 72/72 Displacement [cm³] Compression ratio 11.3 TRANSMISSION Main 28/70 1st gear ratio 12/31 2nd gear ratio 15/28 3rd gear ratio 19/28 4th gear ratio 20/24 5th gear ratio 27/27 6th gear ratio 28/24 CARBURETOR Version...
  • Page 7 www.betamotor.com SPECIAL EQUIPMENT Symbols Crankcase uncoupler code 0100042 000 Clutch drum nut/Main tool code 026140010 000 Crankcase/Cylinder gasket check plate code 026140020 000 Front bracket code 026140030 000 to fix engine to stand code 3625132 000 Flywheel blocking tool code 026140040 000 Value Flywheel extractor code 3625173 000 Fastening torque Engine support stand code 3625132 000 Medium-resistance threadlocker Silicone paste...

  • Page 8: Removal Of Motor From Vehicle

    REMOVAL OF MOTOR FROM VEHICLE ∙ Carefully wash the vehicle; ∙ Remove the engine guard plate; ∙ Place the vehicle onto an adequate stand ∙ Remove the seat, the tank and the lateral sides. ∙ To take down the tank you must: - completely unscrew the two screws 1 that fasten the tank to the frame and the screws 2 (two per side) that fasten the side to the...
  • Page 9 ∙ Remove the circlip 6 and extract the pinion. Rest the chain against the upper wedge 7. ∙ Remove the screws8 fixing the clutch actua- tor to the crankcase half. ATTENTION! Do not activate the clutch lever with actuator de- coupled from engine. ∙ Remove the exhaust expansion and the silenc- ∙...
  • Page 10 ∙ Disconnect the water hoses from the engine and from the right radiator. ∙ Disconnect the electrical connectors for the right radiator accessories. ∙ Remove the right radiator. ∙ Remove the left radiator with pipes. ∙ Disconnect the coil from the spark plug, re- move the two screws 10 and take the com- plete coil support out of the intake manifold.
  • Page 11 ∙ Cut all straps binding the engine's electric sys- tem to the clutch pipe and to the. Then, disconnect the connectors: - A TPS sensor; - B Pick-Up; - C stator unit. ∙ Disconnect the engine ventilation pipes ∙ Pull the mixer tube 11 out from the intake manifold and tube hold 12.
  • Page 12 Attention! When the mixer tube has been dis- connected, plug it to prevent emptying. ∙ Remove the start motor cable fixing nut. ∙ Remove the head connections.
  • Page 13 ∙ Release and remove the brake pedal re- turn spring 13. Remove the kickstarter (Optional) . lever ∙ Remove the gear lever. ∙ Loosen the carburetor straps from the air filter sleeve and from the manifold. ∙ Remove the seat rail lower fixing screws 14 (one each side) and loosen the upper screws 15 (one each side).
  • Page 14 ∙ Rotate the filter box unit. ∙ Remove the carburettor from the manifold leaving it connected to the gas cable. Attention! When the carburettor is disconnected from the manifold, and before handling the car- burettor, empty out the tank. ∙ Remove the swingarm pin 17 and the upper shock-absorber pin 16. ∙ Remove the engine pins 18.
  • Page 15 Extract the engine from the frame and apply it to the specific stand code 3625132 000 using spe- cific front fixing bracket code 026140030 000.

  • Page 16: Motor Disassembly

    MOTOR dISASSEMBLY Secure the engine to the specific support stand code 3625132000 by means of front fixing code 026140030 000, in order to work in comfort and safety. Then proceed as follows Remove the spark plug CLUTCH/GEAR OIL dRAIN Remove screw 1 and let the oil drain. REMOVAL OF CLUTCH CONTROL ROd ANd PINION SPACER...

  • Page 17: Removal Of Piston, Cylinder And Head

    REMOVAL OF PISTON, CYLINdER ANd HEAd Remove the spigot screws 1 together with the copper washers. Remove the head and the two O-rings. Remove the four screws 2. Remove the three screws 3 and cover 4.
  • Page 18 Release the lock 5 and remove it. Release the control rod 6. Remove the gasket 7. It may be necessary to force the rubber gasket 8 slightly; place a metal pin A between the lever and the gasket 8 and force it externally slightly.
  • Page 19 Remove the four collar nuts 9. Extract the cylinder and base gaskets.
  • Page 20 ATTENTION! Place a clean cloth between the piston and the crankcase to keep foreign objects or simple solid residue from falling inside the base. Remove the circlip 10 by gripping it with a pair of fine nose pliers A. Removal of piston circlip. Push the pin bolt with an aluminium cylinder (or similar) B, until the pin bolt is released from the connecting rod foot Remove the piston, the pin bolt and the bear- ing from the connecting rod foot.

  • Page 21: Removal Of Ignition Unit

    REMOVAL OF IGNITION UNIT The ignition unit is made up of the flywheel (or rotor), the pick-up and the stator which is one with the flywheel cover. 2.4.1 Flywheel cover plate removal Remove the five screws 1 fastening the flywheel cover 2 to the left crankcase.

  • Page 22: Stator Removal

    2.4.2 Stator removal Remove the two screws 1 fixing the stator 2 to the flywheel cover 3. Extract the plate 4 and the cable gland 5 from the cover and extract the stator.e. Disassembly of stator from cover. 2.4.3 Flywheel removal Block the flywheel using special tool A (code 026140040 000) and remove the fastening nut securing the flywheel to the crankshaft.

  • Page 23: Pick-Up Removal

    To remove the flywheel, tighten the extractor B (code 3625173) onto the threaded part on the flywheel. Keep the extractor blocked with spanner and tighten the screw on the extractor using a box spanner. Release of flywheel using special tool B. 2.4.4 Pick-up removal Remove pick up 1 by loosening the two fixing...

  • Page 24: Removal Of Electric Ignition

    REMOVAL OF ELECTRIC IGNITION L’avviamento elettrico viene effettuato tramite il motorino di avviamento 1 che ingrana ExplODED vIEW OF ElEcTRIc kIckSTART: sull’inneseto Bendix 4. The coupling gear axially shifts and meshes onto the ring gear which is one 1) Start motor; with the flywheel, due to the start motor rotation.

  • Page 25: Start Motor Removal

    2.5.1 Start motor removal Remove the two screws 1 and extract the motor itself. Removal of start motor. 2.5.2 Bendix clutch removal Extract the Bendix coupling once the complete flywheel cover and flywheel itself (see par. 2.4.1), have been removed 1. Removal of Bendix coupling.

  • Page 26: Removal Of Coolant Liquid Pump, Clutch Unit, Main Gear, Centrifugal Unit, Gearshift Organs, Kickstart

    REMOVAL OF COOLANT LIQUId PUMP, CLUTCH UNIT, MAIN GEAR, CENTRIFUGAL UNIT, GEARSHIFT ORGANS, kICkSTART Remove the cover by loosening the four screws 1 to access the coolant liquid pump.2. Note: remove the coolant liquid pump impeller if having to intervene on the centrifugal unit. coolant liquid pump cover screws.
  • Page 27 Remove the outer clutch cover by loosening the five screws 3 to access the clutch unit only 4. Outer clutch cover screws.
  • Page 28 When doing a complete overhaul of the engine or of gearshift organs, kickstart, main transmission or centrifugal unit, the inner clutch cover 5 must be removed by loosening the nine screws 6. Inner clutch cover screws. Pay attention to the two reference pins A placed between the right crankcase half and the inner clutch cover plate while disassembling.

  • Page 29: Cooling Liquid Pump Removal

    2.6.1 COOLING LIQUId PUMP REMOVAL Loosen fixing screw once the coolant liquid pump cover has been removed 1. cooling pump fixing screw. Extract the impeller 2 and the thrust 3. Removal of impeller. Extract the complete pump body 4 and remove gasket 5.

  • Page 30: Removal Of Centrifugal Unit And Leverage

    2.6.2 REMOVAL OF CENTRIFUGAL UNIT ANd LEVERAGE Access the centrifugal unit and leverage by removing the inner clutch cover. Disassemble the adjustment cover by removing the two screws 1 once the pump impeller has been removed (par. 2.6.1) 2. Removal of centrifugal adjustment cover. Remove the unit consisting of adjusting 3 and auxiliary 4 springs and the spring guide 5.
  • Page 31 Extract the rocker arm complete of control rod and gasket 6 once the screw fixing the rocker arm 7, to the centrifugal control lever has been removed 8. Disassembly of control rod-rocker arm unit. Extract the centrifugal control lever 7 together with the two thrust washers 9.
  • Page 32 Extract the complete centrifugal unit 10. Extraction of centrifugal unit. 1) control cover; 3) Adjusting spring; 4) Auxiliary spring; 5) Spring guide; 6) Rocker arm; 7) centrifugal control lever; 8) Gasket; 9) Thrust washers; 10) centrifugal unit.

  • Page 33: Removal Of Main Gear And Clutch Unit

    2.6.3 REMOVAL OF MAIN GEAR ANd CLUTCH UNIT Remove the four screws 1 fastening the clutch cap 2 to the clutch drum. Remove the clutch cap together with the four washers and relative springs. clutch cap 2 and four screws 1. Extract the whole pressure plate unit 3 and the clutch disc pack.
  • Page 34 In order to complete the disassembly of the clutch unit, open the safety washer 4 using a chisel or similar tool and remove the nut 5. Opening of the safety washer with chisel. To unscrew the nut 5, the clutch drum must be blocked with a relevant tool A (code 026140010 000).
  • Page 35 Using the special primary tool A (code 026140010 000), disassemble the nut that tightens the primary gear 6 onto the crankshaft. NOTE: the clutch case must be in its seat to be able to disassemble the main gear. Attention! The nut must be turned clockwise Remove the washer 7, the case 8, the roller cage 9 and the centre bearing 10.

  • Page 36: Kickstarter (Optional)

    2.6.4 kickstarter (OPTIONAL) The kickstater is made up of the pedal which, attached to the kickstarter shaft 1, moves the kickstarter gear 2. This gear moves the idler wheel 3 which then meshes with the clutch case. The device moves back thanks to the spring 4. kickstarter mechanism.
  • Page 37 Using a pair of pliers, pull the end A of the spring 4 from the hole on the crankcase and bring it to a rest position having it turn anti-clockwise. Release of spring from crankcase. Turn the shaft anti-clockwise and pull it off together with the sleeve 9, the spring 10 and the thrust washer 11.

  • Page 38: External Gearshift Unit

    2.6.5 External gearshift unit The external gearshift is made up of the drive shaft 1 upon which the movable and fixed pawls are applied. The fixed pawl constitutes the drive of the movable pawl which then has the task of engaging the stop cam 2.

  • Page 39: Intake System

    INTAkE SYSTEM The intake system mainly consists of the intake manifold 1 and reed valve 2 and spacer in case of 300cc 3. 1) Intake manifold; 2) complete reed valve; 3) Spacer (300cc only). Disassemble by removing the four screws 4 fastening the intake manifold and the reed valve to the crankcases.

  • Page 40: Crankshaft, Gearbox Unit And Internal Gearshift

    CRANkSHAFT, GEARBOx UNIT ANd INTERNAL GEARSHIFT To access the crankshaft, gearbox unit and internal gearshift, the left and right crankcases must be detached. Here are the needed instructions. 2.8.1 Opening the crankcase Remove the thirteen screws 1 fastening the crankcases. Attention! Loosen the two equipment fixing screws A.

  • Page 41: Crankshaft

    2.8.2 Crankshaft The crankshaft 1 can be pulled out by hand. Delicately hit the crankshaft far right in case of resistance. Removal of crankshaft.

  • Page 42: Internal Gearshift Unit And Complete Gearbox

    2.8.3 Internal gearshift unit and complete gearbox The internal gearshift unit is made up of the desmodromic device 1 upon which the fork 2 and two forks 3 are engaged. The forks, supported by the pins 4, drive the sliding wheels of the gearbox, allowing engagement of the desired ratio.

  • Page 43: Disassembly Of Parts From Crankcases

    Proceed to extract the complete gearbox unit including the primary 6 and secondary unit 7. Extraction of complete gearbox unit: 6 main unit, 7 sec- ondary unit. dISASSEMBLY OF PARTS FROM CRANkCASES Once the crankcases have been detached, it is necessary to remove the various components attached to it.
  • Page 44 kickstart ramp 1) optional with kick-starter, crankshaft spacer 2 (and relative O-ring), oil seal 3). Remove the desmodromic control bearing seal screw 4 from the inner side. Bearing safety screw.
  • Page 45 The bearings 5, 6, 7, 8 and 9 are removed from the outside to the inside. Remove fixing screws 9 to disassemble bearing The centrifugal shaft bearing can be removed by using a universal extractor that must rest onto a purposely created metal plate.

  • Page 46: Left Crankcase Half

    2.9.2 Left crankcase half Remove the crankshaft oil seal 1, the secondary shaft oil seal 2 and the gearshift shaft oil seal 3. Removal of outer side left crankcase half oil seal. The bearings 4, 5, 6 and 7 are removed from the outside to the inside.

  • Page 47: Motor Checks And Assembly

    MOTOR CHECkS ANd ASSEMBLY Before reassembling the engine, a series of important checks must be carried out to en- sure correct functioning of the engine. In order to insert the bearings in the crank- case halves, bring the crankcase halves to a temperature of 150°C and keep them at that temperature for 20 minutes.

  • Page 48: Special Applications For Right Crankcase Half

    3.1.1 Special applications for right crankcase half Apply the bearings1, 2, 3 and 4 until flush. Block bearing 4 with specific screw, prior depositing of threadlockers. Fasten at 6Nm. placing of right crankcase half bearings. Apply the bearing 5 from the crankcase half external side, until it is flush, and bearing 6 as shown in the drawing.
  • Page 49 Apply the kickstart ramp 7 and fasten screws 8 10Nm at 10Nm, prior depositing of medium strength threadlocker. Application of kickstart ramp. Apply the stopping device as follows. Keeping the tightener on the lever 18 facing towards the half-casing, apply the spacer 17 onto it, by inserting the smaller diameter segment in the lever.

  • Page 50: Special Applications For Left Crankcase Half

    3.1.2 Special applications for left crankcase half Apply the bearings 1, 2 and 3 from the crankcase half internal side, until flush. Application of left crankcase half bearings. Apply the bearing 4 from the crankcase half external side, as shown in the drawing. Apply the crankshaft oil seal, gear secondary shaft and gearshift shaft.

  • Page 51: Check Of Connecting Rod And Crankshaft

    CHECk OF CONNECTING ROd ANd CRANkSHAFT After having checked the state of wear of the coupling surfaces, check the offset of the half shaft axes (by measuring radial oscillation) by placing the crankshaft in between two tailstocks or similar instrument. Control the maximum measurement variation during a complete turn, using comparators positioned on the coupling surfaces with the crankshaft bearings.

  • Page 52: Assembling Of Complete Crankshaft

    ASSEMBLING OF COMPLETE CRANkSHAFT When all the aforementioned checks have been carried out and the worn parts replaced, grease the crankshaft oil seal on the right crankcase half and couple the crankshaft to the left crankcase half. Keep the conical part A present on the crankshaft towards yourselves.

  • Page 53: Gearbox Unit: Controls And Reassembly

    GEARBOx UNIT: CONTROLS ANd REASSEMBLY The gearbox unit is made up of the gearshift and of the gearbox itself. The gearshift is then divided into external and internal gearshift. The following are the verifications and procedures for checking and reassembling these units to the engine.

  • Page 54: Primary Unit Assembly

    3.4.2 Primary unit assembly Before proceeding with reassembly, clean all the elements thoroughly and oil them with gear oil. Always replace the circlips. Clamp the mainshaft 1 (using protective jaws), so that the grooved end faces downwards. ExplODED vIEW OF pRIMARY UNIT: Insert onto the lower cylinder part of the shaft: the roller cage 2, the 5th gear (3) (turning the 1) Main shaft;...

  • Page 55: Secondary Unit Assembly

    3.4.3 Secondary unit assembly Before proceeding with reassembly, clean all the elements thoroughly and oil them with gear oil. Always replace the circlips. Clamp the secondary shaft 20 (using protective jaws), so that the grooved end faces downwards. ExplODED vIEW OF SEcONDARY UNIT: Insert onto the lower cylinder part: the roller cage 15, the 2nd gear (19) (so that the front claw 4) Thrust washer;...

  • Page 56: Check Of Forks, Fork Pins And Desmodromic Device

    3.4.4 Check of forks, fork pins and desmodromic device internal gearshift made • two forks 13 which drive two gears on the sec- ondary unit; • one fork 14 which drives one gear on the pri- mary unit; • three drive pin bushes 15; • two fork pins 16;...
  • Page 57 Make sure the distance A between the outer faces of the fork is not less than that indicated below: Minimum acceptable distance: 4,25mm Check to make sure that the inside diameter D of the fork pin seats is below the limit: Fork inside diameter limit: 13,83mm Make sure that the fork pins upon which they slide have an outside diameter above the limit...

  • Page 58: Assembly Of Gearbox And Inner Control

    3.4.5 Assembly of gearbox and inner control Insert the entire primary 1 and secondary unit 2 into the respective seats on the left half-cas- ing simultaneously. Remember to oil the gears abundantly with gear oil and to grease the shafts supporting them in the areas where they are coupled with the bearing with graphitic grease.
  • Page 59 Introduce the forks together with the drive bush- es on the gear tracks. To be precise; the smaller fork 5 drives the sliding gear on the primary unit, while the other two (6) drive the sliding gears on the secondary unit. Note: the two forks 6are interchangeable and their positioning is univocal, since the drive pin must face the desmodromic device. Place the...
  • Page 60 Position the two forks 6 of the secondary unit in the external guides of the desmodromic device 8 and, just like the primary unit fork, insert the fork pin first in the pins and then in its proper seat. Remember to oil the shafts, forks and the desmo- dromic device abundantly with gear oil.

  • Page 61: Closing Of Engine Crankcase

    CLOSING OF ENGINE CRANkCASE Apply a thin layer of grease on all oil seals. Heat up the motor shaft bearing on the left crankcase half, being careful not to burn the oil seal. Press the right crankcase half towards the left, being careful that the shafts and pins on the crankcase fit into the respective housings and that the crankcase half is not upside-down.

  • Page 62: External Gearshift

    ExTERNAL GEARSHIFT Before reassembling the external gearshift, check its state of use. While for the stop cam it is enough to make sure it's free from abnormal wear or meshing, the gearshift drive shaft needs more in-depth inspections. 3.6.1 Complete gearbox shaft check With the device complete, make sure that the 0,35÷0,50...
  • Page 63 Exploded view of gearshift. 5) Thrust washer 14x30x1; For reassembly, couple the movable pawl 9 to 6) Gearshift return spring; the drive shaft 10 and, while compressing it, in- 7) Spring guide; sert the spring 8 between the movable pawl and 8) pawl return spring;...

  • Page 64: External Gearshift Unit

    3.6.2 External gearshift unit Keeping the stop lever moved 1 iin such a way that the spring is compressed, position the stop cam 2 on the protruding end of the desmodro- mic control. The stop cam has only one correct position which is determined by the particular shape of the end of the desmodromic device and of the bottom part of the stop cam.
  • Page 65 ExplODED vIEW OF cOMplETE kIckSTART SHAFT: 2) kickstart gear; Remove the kickstart spacer 9, expand the cir- 3) kickstart shaft; clip 10, allowing removal of washer 11, of kick- 8) kickstart return spring; start gear 2 together with roller bearing 12 and 9) kickstart spacer;...

  • Page 66: Assembly Of Kickstart Device (Kick Starter)

    3.7.2 Assembly of kickstart device (kick starter) Insert the complete kickstart shaft in its hous- ing keeping the thin-striped facing outwards and making sure that the ramp A on the kickstart sleeve is positioned below the ramp B bolted onto the right crankcase half (external side). positioning of sleeve A below ramp B.
  • Page 67 Insert in the slot on the protruding segment of the secondary shaft: the circlip 18, the rose-petal 17, the idler wheel 4 followed by the rose-petal 17 and the circlip 18 as shown in the figure. kickstart device unit coupled to the crankcase.

  • Page 68: Main Gear And Clutch Unit

    MAIN GEAR ANd CLUTCH UNIT Before reassembling the clutch unit, carry out some checks on the various components de- scribed below. 3.8.1 Primary gear check Check teeth of main gear is without nicks or ab- normal wear. On the contrary, replace it 3.8.2 Primary gear application...

  • Page 69: Check Of Clutch Case, Roller Bearing And Internal Centre Bearing

    3.8.3 Check of clutch case, roller bearing and internal centre bearing Before reassembling the clutch case, make sure that the sides of the teeth A, dedicated to main transmission and B, dedicated to meshing with the kickstart idler gear and oil pumps, have no superficial nicks or abnormal wear.

  • Page 70: Clutch Disc Check

    Check the state of use of the silent-blocks as fol- lows. Clamp gear B using protective elements and impose a rotation to the clutch case. If there is play between the case and the gear unit, re- place the silent-block. Check the state of use of the internal centre bearing 1 which must have no traces of meshing or abnormal wear.

  • Page 71: Spring Check

    Also check the distortion of the driving discs. This operation is done by placing the driving discs on a perfectly flat surface and using a thickness gauge to check that the gap between the disc and the surface is not greater than: allowable distortion driven discs: 0,10mm Measuring driven disc distortion.

  • Page 72: Thrust Bearing Device Check

    3.8.7 Thrust bearing device check Check the state of use of the thrust bearing and the surfaces upon which it rests. In order to check the thrusting bearing, just see if it slides. When the device is assembled, simulate rotation of the front centre Bearing A respect to the rear one B.
  • Page 73 To unscrew the nut 8 the clutch drum must be 120Nm blocked with a relevant tool A (cod. 026140010 000); the clamping torque is set at 120Nm. Having tightened the nut, bend the two blocking flaps on the safety plate. clutch drum blocking by means of specific tool code 026140010 000.

  • Page 74: Coolant Liquid Pump And Centrifugal Unit

    COOLANT LIQUId PUMP ANd CENTRIFUGAL UNIT The water pump must guarantee, depending on the set rotation speed, the correct flow rate of the coolant in order to extract the needed amount of heat from the thermal unit. The centrifugal unit ExplODED vIEW OF cENTRIFUGAl UNIT AND WATER pUMp UNIT activates the whole exhaust valve control lever- 1) Rocker arm;...

  • Page 75: Check Of Pump Unit And Disassembly, Centrifugal Unit And Idler Unit

    3.9.1 Check of pump unit and disassembly, centrifugal unit and idler unit Refer to par. 2.6.1 to disassemble the entire pump unit. Check oil seal use status. Replace if worn. Check centrifugal unit shaft use status. Replace the entire centrifugal unit if dented in the area in contact with the oil seal.

  • Page 76: Centrifuge Unit Group Assembly

    3.9.2 CENTRIFUGE UNIT GROUP ASSEMBLY Insert the centrifugal unit 20 in inner dutch cover. Insertion of centrifugal. Insert the centrifugal control lever 10 together with the washers 8. Insertion of centrifugal control lever.
  • Page 77 Apply the valve control rod gasket and the rock- er arm unit 1 - valve control ros 4. Application of valve control and rocker arm unit. Apply blocking screws 3 prior depositing of me- dium strength threadlocker. Fasten at 6Nm centrifugal unit.
  • Page 78 Apply the auxiliary 5 and adjusting 4springs to the spring guide 3. Spring guide and springs unit. Apply the complete regulator cover to the inner clutch cover. Apply the blocking screw prior ap- plication of medium strength threadlocker and fasten at 6Nm. 6 Nm Fastening of adjusting cover.

  • Page 79: Pump Unit Assembly

    Thicker edge 3.9.3 PUMP UNIT ASSEMBLY Grease the oil seal housing on the pump body 1. Position the oil seal 2so that the thicker edge faces the outside of the pump body. Insert the oil seal, having it enter the seat very slowly to keep it from deteriorating.
  • Page 80 Apply the seven screws as shown in figure, fas- tening them at 10Nm with a criss-cross pattern. Screws positioning. Screw Screw dimensions Threadlocker Tightening torque [Nm] application Threading length Threading length number...
  • Page 81 Grease the O-rings on the water hose and insert the hose 4 in the right crankcase half. Insertion of water hose. Apply the gasket between the pump body and clutch cover. Grease the inner diameter of the oil seal on the pump body 5 and apply the body to the clutch cover.

  • Page 82: 3.10 Electric Ignition Unit

    3.10 ELECTRIC IGNITION UNIT Carry out the following checks before assembly. 3.10.1 Bendix coupling checks Check wear of the gearwheels present on the unit. Replace the whole coupling in case of ab- normal wear and signs of chipping of the wheels. Keep wheel 1 fixed and rotate the mobile cou- pling 2 anti-clockwise;...
  • Page 83 Pour about 7cc of gearbox oil (PANOLIN OFF ROAD 4T SYNTH 10W/40) in area A. Application of oil. Insert Bendix coupling 2 in bush with collar 3 present on the outer side left crankcase half. Insertion of Bendix coupling.

  • Page 84: 3.11 Thermal Unit

    3.11 THERMAL UNIT Before assembling the thermal unit, thorough checks must be carried out on the cylinder, pis- ton, pin bolt, elastic bands described hereafter. 3.11.1 Checking piston and elastic bands Eliminate carbonaceous sediment from the top of the piston and wash the entire piston with specific degreasing agent.

  • Page 85: Cylinder Check

    3.11.2 Cylinder check Check the cylinder is without signs of seizure. On the contrary, replace it. Measure the bore at a distance A from the top face of the cylinder (surface between cylinder and head). Take the correct measurement by fol- lowing direction X.

  • Page 86: Piston Cylinder Coupling Play

    The cylinder's specific class is punched inside the resonance chamber compartment. punching of cylinder class. 3.11.3 Piston cylinder coupling play The following table carries the coupling play be- tween the cylinder and piston. In order to cal- culate the coupling play between the cylinder and the piston, a subtraction must be carried out between the diameter of the cylinder and that of the piston.
  • Page 87 Remove screw3 fixing the bearings, located on the resonance chamber side. Note: Should it be necessary to descale the valve unit, remove the screws 2 and 3 and extract the booster, without removing the valve control unit. Fixing of booster bearings resonance chamber side. Tighten one M5 screw to the booster control unit side and pull externally. Use a pair of pliers or similar tool if required.

  • Page 88: Exhaust Valve Unit Assembly

    Extract the control valve pin if it has not come away with one of the boosters. Extract the valve pin by pushing it using a metal cylinder A and then extract the valve, that is di- vided into two pieces (right and left). Check the bearings 4 supporting the booster Extraction of pin.
  • Page 89 Apply the valve control pin to one of the two boosters and insert the unit in the cylinder, so that: ∙ the pin engages in the open slot in the valves; ∙ the booster's area B is facing the front of the cylinder.

  • Page 90: Piston, Pin Bolt, Elastic Bands And Cylinder Assembly

    Apply spacer 4 and the complete stroke end lever on the control side 5. Then apply all other parts. Screw 6 must be covered with medium strength threadlocker and fastened at 6Nm. Try moving the unit and check the entire mechanism perfectly slides, once assembly is completed.
  • Page 91 Apply the gasket between crankcase and cylin- der. Accurately oil the entire cylinder using engine oil and insert the piston in the cylinder. The piston must be inserted in the cylinder fastening the elastic bands between the fingers. The cylinder must be positioned so that the outlet port is fac- ing the front of the engine.

  • Page 92: Check Of Crankcase/Cylinder Gasket Thickness

    3.11.7 Check of crankcase/ cylinder gasket thickness The thickness of the gasket between the cylinder and crankcase must be checked every time the following are replaced: ∙ Cylinder; ∙ Piston; ∙ Crankshaft; ∙ Connecting ; ∙ Crankcase. The check is necessary as such thickness affects the engine performances.

  • Page 93: Cylinder Head Application

    Measure play with thickness gauge and increase gasket thickness so contact between plate and cylinder is guaranteed, if the piston pushes the plate upwards failing contact between plate and cylinder. Carry out the check again. If the piston pushes the plate failing contact cylinder/plate The gaskets are supplied in four different thick- nesses: ∙...

  • Page 94: Exhaust Valve Adjustment

    3.11.9 Exhaust valve adjustment Bring the valve control unit 1 in all closed po- sition so the end stroke lever is flush with the booster bearing clamping screw 2. Check the ball head 3 and teh seat 4 are per- fectly aligned.
  • Page 95 The the control rod is able to rotate around its axis, making equal angles respect to the ball head axis. check of control rod rotation. Apply gasket 5 and insert the control rod. Apply the stop 6. Insertion of control rod and application of stop.
  • Page 96 Intervene on screw 7 for the dynamic adjust- ment of the escape valve unit, thus modifying the characteristic curve of the engine. The positions indicated in the below table are those considered excellent for engine function- ing. Regulation of Displacement [cm³] adjustment screw (from all open) 3 1/2...

  • Page 97: 3.11.10 Cover Plate Application

    3.11.10 Cover plate application Apply the valve control unit cover and relative screws. Fasten at 6Nm. Application and fastening of valve control unit cover screws. Apply the resonance chamber side gasket and cover. Apply the screws and fasten at 6Nm Application of resonance chamber cover and relative screws.

  • Page 98: Check Of Ignition System

    3.12 CHECk OF IGNITION SYSTEM Before reassembling the ignition system, it is rec- ommended to check its correct functioning. The ignition system is made up of the magnetic pick-up, the stator unit and the flywheel. The system is completed by the ignition coil and the spark plug, which are not dealt with in this text.
  • Page 99 Degrease the conical segment of the crankshaft, apply the Woodruff key 8 in the appropriate groove on the crankshaft, couple the flywheel 9, the elastic rose-petal 5 and the nut 4, after having applied the thread with medium strength thread- locker.
  • Page 100 Insert the centring 12 pins 12 on the crankcase and fasten a new gasket. Application of flywheel cover centring pins. Apply the flywheel cover plate, the twoscrews 13 M6x25 and the three screws 14 M6x20. Tighten in a criss-cross pattern at a torque of 10Nm. 10Nm Flywheel cover coupled to crankcase.

  • Page 101: Check Of Intake Unit And Assembly

    3.13 CHECk OF INTAkE UNIT ANd ASSEMBLY Check the manifold 1 is intact and without cracks. On the contrary, replace it. Check that the multiflap 2 of the reed valve 3 are intact and not deformed. On the contrary, replace them. Remove the multiflap by pressing the central body as shown in figure and remove the outer multiflap.
  • Page 102 Remove the two central wedges and remove the multiflap. Assemble the multiflap by following the just de- scribed procedure, in reverse order. Disassembly of central wedges. The extraction of only one is shown in figure. For assembly of the entire intake system, apply the manifold to the reed valve, followed by the gasket 4, the spacer 5 and another gasket 4.

  • Page 103: Insertion Of Clutch Rod And Pinion Spacer

    3.14 INSERTION OF CLUTCH ROd ANd PINION SPACER Apply the pinion spacer 5 to the secondary of the gearbox 1 so that the groove is facing inside the motor. Note: check the O-ring 4 is present. On the con- trary, apply it. Insert the gearbox rod in seat from the lower diameter side.

  • Page 104: Reassembly Of Engine In The Vehicle

    REASSEMBLY OF ENGINE IN THE VEHICLE ∙ Insert the engine in the frame. We recom- mend insertion from the frame's left side. ∙ Insert the engine pins 1. ∙ Apply the spark plug and fasten it at 28Nm. ∙ Insert the upper shock absorber pin 2 and the swingarm pin 3.
  • Page 105 ∙ Apply the head connections. 35Nm ∙ Fasten the nuts and bolts following the ta- ble below. Fixing Screw Torque [Nm] Threadlocker Medium- Head connection bracket to frame. M8 x 16 resistance Head connection brackets to engine M8 x 60 Engine pins Special Swingarm pin...
  • Page 106 ∙ Assicuratisi che il manicotto cassa filtro sia correttamente inserito nel carburatore, ser- rare le due fascette lato cassa filtro e lato collettore.Make sure the filter box sleeve is correctly inserted inside the carburetor, fas- ten the two filter box side and manifold side straps.
  • Page 107 ∙ Apply the unit clutch actuator to the two 6 fix- ing screws. Fasten at 10Nm. 10Nm ∙ Apply the gearbox lever and fasten the screw at 10Nm prior application medium strength threadlocker. 10Nm ∙ Fasten the motor electric system and the start motor cable to the clutch cable.
  • Page 108 • Apply the start motor cable and fasten the nut at 10 Nm. Cover the connection using the specific protective cap. 10Nm • Connect the ventilation pipes to the engine • Apply the left radiator to the frame. Apply the screws and fasten at 10Nm.
  • Page 109 • Connect the radiators to the engine. Fasten the tube clamp straps and introduce the cool- ant liquid,letting the air bleed through the screw plug A.
  • Page 110 ∙ Apply the exhaust expansion by first as- sembling the front springs and then apply- ing the two fixing screws. ∙ Apply the spacer and fasten the two fixing 25Nm screws at 10Nm. Fasten the expansion fix- ing screws to the frame at 10Nm. ∙...
  • Page 111 ∙ Apply the tank to the vehicle, ensuring that 10Nm the electrical wiring and clutch tube are be- tween frame and tank. ∙ Apply the tank, complete with lateral sides, by tightening the screws at the required torque. ∙ Connect the two quick couplings on the bypass tube.

  • Page 112: Table Of Motor Components Fastening Torques

    TABLE OF FASTENING TORQUES OF ENGINE COMPONENTS Torque Fixing Diameter x length Quantity Threadlocker Notes [Nm] Outer side right crankcase half Medium- kickstart ramp M6 x 20 resistance Inner side right crankcase half Desmodromic control Medium- M5 x 8 bearing fixing resistance Gearshift Medium-...

  • Page 113: Table Of Motor Components Fastening Torques

    Torque Fixing Diameter x length Quantity Threadlocker Notes [Nm] Exhaust valve control Medium- cover M5 x 20 resistance complete control rocker Medium- M5 x 12 resistance Medium- control lever M5 x 20 resistance Medium Booster bearings M6 x 16 resistance Right cover M5 x 16 left cover...

  • Page 114: Table Of Frame/Motor Fastening Torques

    TABLE OF FRAME/MOTOR FASTENING TORQUES Torque Diameter x Fixing Quantity Threadlocker Notes length [Nm] Front and lower engine M10 x 1.25 connections Swingarm pin M16 x 1.5 Brackets to connect head Medium- M8 x 16 to frame resistance Head connection brackets M8 x 60 to engine...

  • Page 115: Recommended Lubricants And Liquids

    RECOMMENdEd MOTOR MAINTENANCE The requested engine maintenance only depends on the level of use and respect of the periodical inspections. The following intervals refer to a competitive use, as long as the engine has not worked in extraordinary conditions and that periodical inspections and interventions have been correctly carried out.
  • Page 116 NOTES:...

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