Page 2: Table Of Contents
KICKSTARTER ..............41 2.10 EXTERNAL GEARSHIFT UNIT...........43 2.11 CRANKSHAFT, GEARBOX UNIT AND INTERNAL GEARSHIFT .................44 2.11.1 NUT ON LEFT SIDE OF CRANKSHAFT .........44 2.11.2 OPENING CRANKCASE ..............45 2.11.3 CRANKSHAFT ..............47 2.11.4 INTERNAL GEARSHIFT UNIT AND COMPLETE GEARBOX ...47 2.12 DISASSEMBLY OF PARTS FROM CRANKCASES ...49 2.12.1 RIGHT CRANKCASE HALF ..............49 2.12.1.1 PISTON OIL JETS ............49...
Page 3: Index
INDEX 3.11.4 CHECKING AND ASSEMBLY OF OIL PUMPS CONTROL 3.17.16 COUPLING CAMSHAFTS TO CYLINDER HEAD AND GEARS ....................86 PHASING ................... 127 3.11.5 PAPER OIL FILTER INSERTION ............87 3.17.17 VALVE PLAY ..................130 3.11.6 CHECKING AND COUPLING COUNTERSHAFT......88 3.17.18 CHECKING AND COUPLING OF MECHANICAL TENSIONER TO ENGINE ..............
Page 4: Preamble
www.betamotor.com PREAMBLE This publication has been written in order to make operations for inspection, maintenance and repairs of the motorcycle engine known and understandable to the user of the motorcycle and to the technical assistance operator. Read this entire manual with care before operating the engine. Sufficient knowledge of the components that make up the engine and of all the procedures to be followed for inspection and maintenance con- tribute to lengthen the life of the engine. The paragraphs have been enhanced with schematic illustrations highlighting each subject in order to make reading immediately understandable. Informative note Betamotor S.p.A. is engaged in a policy of ongoing improvement of its products. This is why it could be possible to note slight differences between the contents of this document and the vehicle upon which you are carrying out repairs and/ or maintenance. Betamotor S.p.A. models are exported to numerous countries in which there are different standards concerning Highways Codes and procedures for approval...
Page 5: Hot Parts
www.betamotor.com • Coolant Do not remove the radiator cap when the en- gine is still hot. When coolant is pressurised, it • In some situations, the ethylene glycol contai- can spurt out violently and cause burns. ned in the coolant is flammable and its flame • Coolant contains dangerous substances which is invisible. Should ethylene glycol catch fire, are harmful for the environment. When chan- though its flame is invisible, it can cause burns.
Page 6 www.betamotor.com tECHNICAL fEAtURES of ENGINE Single cylinder, 4-stroke, liquid-cooled with countershaft type and electric starting Bore x stroke RR 350 88x57,4 Bore x stroke RR 390 88x63,4 Bore x stroke RR 430 95x60,8 Bore x stroke RR 480 100x60,8 Displacement [cm³] RR 350 349,1 Displacement [cm³] RR 390 Displacement [cm³] RR 430 Displacement [cm³] RR 480 Compression ratio RR 350-390-430-480 13,19:1 12,5:1 12.3 11,9:1 Valve gear 4 valves tRANSMISSIoN RR 350 RR390 RR430 RR480 Primary transmission 28/76...
Page 7: Special Equipment
www.betamotor.com SPECIAL EQUIPMENt Symbology Engine support code 3625132 000; Two-leg extractor code 3625081 000; Internal bearing puller code 006140160 000; Extractor for timing gear code 006140150 000; Value Flywheel Extractor code 3625173 000; Tightening Torque Piston ring compression band code 006140170 000; Chain-tensioner release tool code 006140050 000; Valves assembly-disassembly jaw code 0100043 000; Tool for valves assembly-disassembly code 006140030 000; Loctite 243/ 10. Special ring pliers code 3625097 000; Sichel 100M 11. Crankshaft blocking device code 006140110 000; 12. Loctite 243 code 3625001 000; 14. Silicone paste for gaskets code 3625000 000; 15. 36mm socket wrench code 3625000 000; 16. Spark plug wrench code 020440100 000; Silicone paste 17. Connecting rod disassembly tool code 006140070 000; 18. Thickness gauge code 006140210 000; 19. Valve guide gauge code 006140180 000; 20. Clutch cap tool code 006140040 000; 21. Carburettor adjustment spanner code 006140200 000; Grease 22. Engine fixing code 006140140 000.
Page 8: Removing The Engine From The Vehicle
REMovING tHE ENGINE fRoM tHE vEHICLE Carefully wash the vehicle Before removing the engine from the vehicle, empty the following liquids: • Motor oil; • Gear/clutch unit oil; • Coolant. In order to access the oil drain plug, remove the engine guard connected to the frame by means of the three screws 1. Front engine guard fixing screw. Back engine guard fixing screws.
Page 9 Place the vehicle onto an adequate stand. To dismount the tank, remove the seat, complete- ly loosen the two screws 5 fixing the tank to the frame and screw 6 (one per side) which fixes the side to the radiator. In the carburettor versions, disconnect petrol tube 7 from the cock, which must be set to OFF. Disconnect the petrol pipe by pressing the rele- vant button of quick coupling 7. Lift the tank. Disconnect electric connectors 8 and 9. Remove the tank along with the sides.
Page 10 Disconnect the water hoses from the engine and from the right radiator. Remove the left radiator with pipes. Disconnect the spark plug cap. Cut all straps binding the engine’s electric system to the clutch pipe and to the frame. Disconnect the engine ventilation pipes.
Page 11 Disconnect the connectors indicated in the figure. Remove the start motor cable fixing nut. Loosen the throttle body straps from the air filter sleeve and from the manifold.
Page 12 Remove the screw of the throttle body 10 cover and the cover itself. Disconnect the rear brake stop connector 11. Loosen the adjustment nuts and release the gas cables. Carburettor version gas cables. Disconnect the electric connectors indicated in the figure, relative to the throttle body.
Page 13 Remove the frame guards 12 (one each side) and the pinion guard 13. Remove the rear wheel nut. Extract the pin enough to allow the wheel to advance towards the front of the vehicle. Rotate the rear wheel lifting the chain in the pinion zone, so that the chain of the pinion itself is released. Rest the chain against the upper wedge 14. Remove the screws 15 fixing the clutch actuator to the crankcase half.
Page 14 Remove the head connections. Release and remove the brake pedal return spring Remove the kickstarter lever. Remove the seat rail lower fixing screws 17 (one each side) and loosen the upper screws 18 (one each side).
Page 15 Remove the carburetor to the gas cable. Remove the throttle body. Remove upper shock-absorber pin 19.
Page 16 Remove the swingarm pin 20. Move the complete swing-arm unit towards the rear. Remove the engine pins 21. Extract the engine from the frame and apply it to the specific stand code 3625132 000 using specific front fixing bracket code 006140140 000.
Page 17: Engine Disassembly
ENGINE DISASSEMBLY tHERMAL UNIt The thermal unit is made up of the head, cylinder and piston. Before removing the cylinder head, bring the pi- ston to the TDC and block the crankshaft: Proceed as shown hereafter. The four screws 1 of the cylinder head cover 2. Remove the 4 screws 1, the cylinder head cover 2 as well as the 4 screw gaskets 3. The cylinder head cover 2 and the four gaskets 3. Remove the spark plug gasket 4 and the cover gasket 5.
Page 18 Remove the crankshaft blocking screw 6, remove the copper washer 7 and put the screw (or tool 006140110 000) back into its seat without tighte- ning it all the way. The crankshaft blocking screw 6 with copper washer After having engaged the 6th gear, turn the transmis- sion shaft 8 anti-clockwise - using an open-end spanner or the likes, - until the lines 9 on the too- thed profiles of the camshafts are aligned.
Page 19: Cylinder Head: Disassembling Mechanical Tensioner
2.1.1 CYLINDER HEAD: DISAS- SEMBLING MECHANICAL TENSIONER A chain which is not well-tensioned can cause: • excessive vibrations for the chain which could make it jump teeth on the camshafts thus da- maging the engine; • incorrect and premature wear of the support bearings of the camshafts. The engine is equipped with a hydraulic tensio- ner in order to provide the chain with proper ten- sioning.
Page 20: Cylinder Head: Disassembling Camshaft Support, Chain Guide And Spark Plug Seat O-Ring
2.1.2 CYLINDER HEAD: DISASSEM- BLING CAMSHAFT SUPPORT, CHAIN GUIDE AND SPARK PLUG SEAT O-RING To remove the camshafts, disassemble the camshaft support 2 and the chain guide 3. Then loosen the seven screws 1 of the camshaft support, starting with the outer ones (indicated in blue in the figure) and then the inner ones. Remove the chain guide 3. Fixing screws 1 camshaft support 2 and chain guide 3 The four outer screws circled blue must be taken off- Attention: disassemble the camshafts only after first.
Page 21: Cylinder Head: Removing Camshafts
2.1.3 CYLINDER HEAD: REMO- VING CAMSHAFTS Lift the intake camshaft 1, pull out the bearing 2 and remove the chain 3 from the gear on the shaft. Attention: the hydraulic tensioner must alre- ady have been removed in order to remove the camshafts.
Page 22: Cylinder Head: Uncoupling From Cylinder
2.1.4 CYLINDER HEAD: UNCOU- PLING FROM CYLINDER Five screws fasten the head to the cylinder. Remove the cylinder head screw 1 on the outside of the chain-side cylinder head. Chain-side head fixing screw. Remove the four cylinder head fixing screws 2, in a criss-cross pattern. Start with one of the two screws outside the cylinder head compartment. Then remove the respective washers. Head fixing screws 2. Lift the cylinder head 3 with one hand and at the same time with the other hold the chain in tension thus preventing jams during disassembly. With the cylinder head lifted a few centimetres, drop the chain inside the compartment and pull out the head.
Page 23 Remove the head gasket 4 and the two centring bushes 5. Cylinder head elements: 1) M6x80 screw; 2) M10x1.25 cylinder head screws; 3) Complete cylinder head; 4) Cylinder-head gasket; 5) Centring bushes.
Page 24: Disassembling Cylinder And Piston
2.1.5 DISASSEMBLING CYLINDER AND PISTON Lift up the cylinder 1 a few centimetres, remove the two centring bushes 2 (both located on the chain side) to prevent them from falling inside the crankcases and continue on removing the cylinder. Remove the cylinder gasket 3. Cylinder removal. Place a clean cloth between the piston and the crankcase to keep foreign objects or simple residue from falling inside the base. Using a suitable tool to insert the specific seat A, remove the elastic ring 4...
Page 25: Disassembly Of Ignition Unit, Timing Chain And Guides
In figure you can see the piston 5 (bottom view), the circlip 4 and the pin bolt 6. Bottom view of piston 5, elastic ring 4 and pin bolt 6. DISASSEMBLY IGNI- tIoN UNIt, tIMING CHAIN AND GUIDES The ignition unit is made up of the flywheel (or rotor), the pick-up and the stator which is one with the flywheel cover.
Page 26 Be careful of the two centring pins 5 on the crankca- se half. Two centring pins 5 dedicated to the flywheel cover (injection version). Remove the tightening nut 6 which fastens the flywheel 7 to the crankshaft. Once the nut has been unscrewed, pay attention to the special elastic washer (8 shown in the following images) placed between the nut and the flywheel. Nut 6 which fastens flywheel 7 to the crankshaft (injection version). To remove the flywheel, screw the relevant extractor A (code 3625173) onto the threaded segment on the flywheel and, using a box spanner, tighten the screw on the extractor.
Page 27 In the image at the side, the flywheel 7 (rear view), the special elastic washer 8 and the tighte- ning nut 6. Flywheel 7, nut 6 and special rose-petal 8.
Page 28: Timing Chain And Guides
2.2.2 TIMING CHAIN AND GUIDES Remove the fixing screws 1 of the mobile 2 and fixed pad 3. Extract pad 2, then pad 3, by pulling them upwards. Fixing screws 1 of mobile 2 and fixed pad 3. Extraction of chain guides.
Page 29 Remove the screw 4 and extract the oil jet 5. Remove the two screws 6 and then the chain guard 7. Pay close attention to the respective bushes whi- le extracting the mobile and fixed pads and the timing chain. Chain guard and oil jet. Pay close attention to the respective bushes while extracting the mobile and fixed guides and the timing chain. Removal of timing chain. Two pad fixings screws 1;...
Page 30: Pick-Up
2.2.3 PICK-UP Once the timing chain guard has been removed, the pick-up 1 can be disassembled, by removing the two fixing screws 2. Two screws 2 for fixing pick-up 1. PINIoN AND SPACER In order to remove the pinion 1, loosen the screw completely 2 and take off the washer 3. Pinion 1, screw 2 and washer 3.
Page 31: Clutch Unit And Coolant Pump Cover
CLUtCH UNIt AND Coo- LANt PUMP CovER In order to access the clutch unit, the outer clutch cover 1 must be removed by loosening the six screws 2. Outer clutch cover 1 and respective screws 2. On the other hand, when doing a complete overhaul of the clutch unit, of the other elements housed in the outer right side of the crankcase half or of the engine, the inner clutch cover 3 must be removed by loosening the nine screws 4 and the water pump cover 5 loosening the four...
Page 32 Pay attention to the two reference pins A placed between the right crankcase half and the inner clutch cover while disassembling. Two centring pins A for cover coupling Inner clutch. Remove the complete hydraulic actuator 7 -if the tube was disconnect from the actuator- outer left side crankcase half by loosening the three screws 8 which fasten it to the crankcase half. Remove the gasket in between the actuator and the crankcase...
Page 33 Remove the 4 screws 10 which fasten the clutch cap 11 to the inner hub. Remove the clutch cap together with the four wa- shers and relative springs. Clutch cap 11 and four screws 10. Extract the whole pressure plate unit 12 and the clutch disc pack 13. Pressure plate unit 12 and clutch disc pack 13. Remove special driven disc and the disc spring assembly. Removal of disc spring assembly. In order to complete the disassembly of the clutch unit, open the safety washer 14 using a chisel or similar tool and remove the nut 15. Opening safety washer with chisel.
Page 34 To unscrew the nut 15, the inner hub must be blo- cked with a relevant tool A (code 006140040000). Then remove the nut and relative safety washer. ATTENTION: don’t use pneumatic wrench. Extract the inner hub 16, the washer 17, the basket 18, the roller cage 19 and the centre bearing 20. Removal of inner hub nut with relevant tool G. Safety washer 14, nut 15, inner hub 16, washer 17, basket 18, roller cage 19 and bush 20, special fiction disc 21, judder spring 22.
Page 35: Engine Lubrication Circuit
ENGINE LUBRICAtIoN CIRCUIt The high-pressure pump (or delivery) 1 - with less displacement - sends the oil purified by the paper filter 2, to the crank mechanism 3, to the piston oil jets 4, to the tensioner 5 and to the cylinder head jets and camshafts* 6. The valve 7 controls the pressure. When oil has lubricated the cylinder head and has seeped through the tensioner, it flows along the timing chain to the ignition unit compartment ENGINE LUBRICATION CIRCUIT:...
Page 36: Oil Pumps Control Gears
2.5.1 OIL PUMPS CONTROL GEARS The two oil pumps are controlled by a gear unit driven by the clutch gear. In detail, gear 1 meshes with the clutch case, and 2 is the oil pump control gear. To dismount gear 1, remove circlip 3 and thrust washers 4 (one below the gear). To disassemble gear 2, simply remove the Benzing ring 5. Gear unit for oil pump control. 1) Gear meshing with clutch gear;...
Page 37: Low-Pressure Oil Pump And By-Pass Valve
2.5.3 LOW-PRESSURE OIL PUMP AND BY-PASS VALVE The low-pressure pump and the one-way valve are located in the left-hand side crankcase (on the outside) inside the ignition unit compartment. They are enclosed under the cover 1, which remo- ved by extracting the three screws 2. Cover and screws of low-pressure pump. Extract the one-way valve consisting in the spring 3 and the ball 4. Then extract the external rotor 5 and the internal rotor 6 together with the roller 7 and the drive shaft 8.
Page 38: Oil Pressure Control Valve
2.5.4 OIL PRESSURE CONTROL VAL- The pressure control valve is located in the bottom of the right-hand side crankcase near the motor oil drain plug. The valve consists of the ball 1 and the spring 2 kept in place by the screw 3 and washer 4. To di- smount, simply remove the protection rivet with a 6mm drill tip. ATTENTION: protect the mechanical parts from any shavings.
Page 39: Countershaft
CoUNtERSHAft The countershaft has the task of balancing a part of the inertial forces produced by the crank mechanism. The countershaft is mainly made up of the shaft 1 and counterweight 2. The elastic washer 7 and nut 8 have the task of assuring coupling of the complete shaft to the base. ATTENTION: don’t use pneumatic wrench. Exploded view of countershaft. 1) Shaft; 2) Counterweight; 7) Elastic washer 8) Nut M12x1 In order to disassemble the shaft, remove the nut 8 which can be accessed through the ignition unit compartment. Extract the elastic washer 7 and the counterweight.
Page 40: Primary Gear
PRIMARY GEAR The primary gear 1, located in the right crankcase, is fastened to the crankshaft. In order to disassemble it, remove the nut 2 which must first be previously heated using a blow-dryer or similar instrument. ATTENTION! The nut 1 must be turned clockwise to be un- screwed. Primary gear 1 and relative nut 2. Extract the primary gear using the relevant extractor A (code 006140150000). Extraction of primary gear with appropriate extractor Notice that the primary gear houses the free wheel de- vice 2 inside of it, which can be removed by taking out the circlip 3. Primary gear 1, complete with free wheel 2 and spe- cific circlip 3.
Page 41: Electric Ignition
ELECtRIC IGNItIoN Electric ignition can be carried out by means of the start motor 1 which meshes on the gearwheel 4 with the function of torque limiter. The gearwheel 4 (torque limiter) transmits motion to the idler wheel 7, which will then mesh with the star- ter gear 9. EXPLODED VIEW OF ELECTRICAL STARTER. The roller bearing 10 supports the starter wheel 9, 1) Start motor; while the free wheel 11 is internally engaged on the 4) Torque limiter; starter wheel 9 and externally on the main gear, thus 7) Idler wheel; allowing it, depending on rotation direction, to pull 9) Ignition gear;...
Page 42: Electric Kick-Start Unit
2.8.1 ELECTRIC KICK-START UNIT Remove the two screws 4 which fasten the start mo- tor to the crankcase and pull out the start motor. Screws 4 fixing start motor to crankcase. To extract kick-start gear 5, disassemble the primary gear (see par. 2.7), the safety stops 6 and key 7. The kickstart gear is pulled out by hand. Removal of pin 6. In order to disassemble the torque limiter 7, com- pletely loosen the screw 8 which fastens the torque limiter to the crankcase. Pull out the washer 9 toge- ther with the limiter itself. Torque limiter 8, screw 7 and washer 9. In order to remove the idler wheel 10, just remove the circlip 11 and pull the gear off.
Page 43: Kickstarter
KICKStARtER The kickstarter 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 gear. The device moves back thanks to the spring 4. Kickstarter mechanism. Remove the external circlip 5 and pull off the exter- nal thrust washer 6, the idler gear 3, the internal thrust washer 7 and the second circlip 8. The cir- clips and thrust washers are interchangeable.
Page 44 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. Releasing spring from crankcase. Turn the shaft anti-clockwise and pull it off toge- ther with the sleeve 9, the spring 10 and the thrust washer 11. Extraction of shaft from crankcase. Complete manual kickstart shaft. Note: Be careful of the reference pins for centring the inner clutch cover (par. 2.4).
Page 45: External Gearshift Unit
2.10 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. This in its turn is faste- ned to the internal gearshift and is kept in the fixed position by the cam stop lever.
Page 46: Crankshaft, Gearbox Unit And Internal Gearshift
2.11 CRANKSHAft, GEARBoX UNIt AND INtERNAL GEARSHIft To access the crankshaft, gearbox unit and internal gearshift, the left and right crankcases must be de- tached. Here are the needed instructions. 2.11.1 NUT ON LEFT SIDE OF CRANKSHAFT In order to loosen the nut 1 on the left-hand side of the crankshaft, heat it with a blow-dryer or similar instrument. Then loosen the nut with a special so- cket wrench A (code 006140020000) and remove Nut B blocking crankshaft.
Page 47: 2.11.2 Opening Crankcase
2.11.2 OPENING CRANKCASE Remove the 15 screws 1 which close the crankca- Remove the 13 locking screws 1 on the left side casing and the 4 screws 2 on the right side casing. Screws 1 for blocking left side casing. Screws 2 for blocking right side casing.
Page 48 Loosen the two screws A which fasten the engine to the support stand. Two screws A blocking engine to engine support stand. Hit the left crankcase half 2 lightly with a rubber or plastic hammer until it detaches from the right crankcase half 3. Remove the two screws blocking the engine to the equipment and disassemble the crankcase by hand.
Page 49: 2.11.3 Crankshaft
2.11.3 CRANKSHAFT Remove the crankshaft fixing screw. The crankshaft 1 can be pulled out by hand. Should there be resistance, tap the right end of the crankshaft lightly with a plastic or rubber ham- mer. Extraction of crankshaft. 2.11.4 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,...
Page 50 Extract the forks together with the drive bushes 5. Extraction of forks from gearbox unit. ATTENTION: Make sure the circlip on the secondary shaft has been removed (par. 2.9). Circlip removal. Proceed to extract the complete gearbox unit inclu- ding the primary 6 and secondary unit 7. Extraction of complete gearbox unit: 6 primary unit, 7 Secondary unit.
Page 51: Disassembly Of Parts From Crankcases
2.12 DISASSEMBLY PARtS fRoM CRANKCASES Once the crankcases have been detached, it is necessary to remove the various components at- tached to it. The correct positioning of some bearings applied to the crankcase halves is ensured by locking de- vices such as plates or simple screws. In order to disassembly these bearings, the safety devices must be disassembled as well. 2.12.1 RIGHT CRANKCASE HALF On the inside, the plates 1 are those which assure the correct positioning of the support bearing of the crankshaft. All you need to do is remove the two screws 2 to disassemble them.
Page 52: Extraction Of Countershaft Support Bearing
2.12.1.2 EXTRACTION COUNTER- SHAFT SUPPORT BEARING To extract the countershaft bearing, use the extrac- tor A (code 3625081) together with extractor B (code 006140160000). It is recommended to apply the two aluminium plates to be placed between the legs of the extractor and the crankcase half. Extraction of countershaft bearing. 2.12.2 LEFT CRANKCASE HALF Three safety plates are present on the left crankca- se half. Two are applied on the inside and one on the outside. The plates 1 on the inside are the ones relative to the crankshaft support bearing of the gearbox.
Page 53: Inner Oil Filter
2.12.2.1 INNER OIL FILTER The inner oil filter 1 must be pulled out from the inside of the left crankcase. Its removal can be aided by using a soft pin to push it from the outside towards the inside, tapping with a small hammer. Disassembly of inner filter. 2.12.2.2 EXTRACTION OF DESMODRO- MIC DEVICE BEARING...
Page 54: Engine Assembly And Controls
ENGINE ASSEMBLY AND CoNtRoLS Before reassembling the eng ine, a series of im- por tant controls must be carried out to ensure correct functioning of the eng ine. The bearings must be replaced if they play or get jammed during rotation. It is however recommended to refer to the periodical maintenance table. In order to inser t the bearings in the crankcase halves, bring the crankcase halves to a tempe- rature of 150°C and keep them at that tempe- rature for 20 minutes.
Page 55: Crankcase Halves
CRANKCASE HALvES The crankcase halves have some elements that need to have their integrity and use status che- cked. Hereafter the controls and assembly ope- rations of the individual elements coupled to the crankcase halves will be described. Clean the th- EXPLODED VIEW OF ENGINE CRANKCASE HALF reading and oil passages thoroughly using a de- greaser and compressed air. 1) Complete engine block; 4) Crankcase gasket; 5) Back reference bush;...
Page 56: External Right Side
3.1.1 EXTERNAL RIGHT SIDE Pull out the crankshaft oil seal 1 and replace it. Check that the oil seal fixing plate 2 is not bent. If so, have it replaced. Control the integrity of the oil incline 3. Should it be worn, have it replaced. Check the state of use of the kickstart ramp 4. It must be replaced if it shows signs of meshing or chipping.
Page 57 The crankcase half will definitely need to be re- placed when: • the oil pump crankcase A shows deep scratches or meshing signs; • the two pins B for the idler wheel and tor- que limiter show traces of abnormal wear or meshing. Keeping the tightener on the lever 25 facing to- wards the crankcase half, apply the spacer 27 onto it, by inserting the smaller diameter seg- ment in the lever. Apply the spring 26 so that the hook inserts into the groove present on the lever 25 and then apply the washer 28 and the...
Page 58: Insertion Of Oil Seal And Countershaft Support Bearing
INSERTION OF OIL SEAL 3.1.1.1 AND COUNTERSHAFT SUP- PORT BEARING In order to insert the oil seal and countershaft sup- port bearing proceed as follows. Grease the oil seal and bearing housing. Insert the new oil seal 1 greasing the inside of it. Application of oil seal 1. Apply the new bearing 2 paying close attention that it is aligned in its seat. Insertion of bearing 2. Use a press or similar instrument to push the bea- ring until the outside surface is flush with the sur- face A.
Page 59: Internal Right Side
3.1.2 INTERNAL RIGHT SIDE Check the flatness of the crankshaft bearing re- taining plates 1, of the main shaft bearing re- taining plate 2, of the secondary shaft bearing retaining plate 3, and of the desmodromic device bearing retaining plate 4. The table below car- ries the indications for application of the fixing screws of these plates and for fixing the desmo- dromic device support bearing.
Page 60: External Left Side
Make sure the piston oil jets 7 are positioned cor- rectly and free of obstructions. Make sure that O-ring 9 is correctly positioned by checking its state. Should the O-rings have cracks or deformations, they must be replaced. 3.1.3 EXTERNAL LEFT SIDE Make sure the calibrated screw 1 and the jet 2 are Piston oil jet O-ring and detail of passage hole. not obstructed. Should they have been replaced, cou- ple them to the crankcase using a small amount of medium strength threadlocker, being careful that the...
Page 61: Internal Left Side
3.1.4 INTERNAL LEFT SIDE Clean the inner filter thoroughly and check the integrity both of the wire metal and the hooking device. Should the filter be deteriorated in any of these parts, replace it. Locking devices Check the state of the two crankshaft bearing re- taining plates 1. If they are deformed, have them replaced. The table below carries the indications for appli- cation of the screws for the plates 1. Insert the inner filter 3 in its seat A present in the crankcase and push it all the way down until you hear the hooking device click.
Page 62: Checking Crankshaft And Connecting Rod
CHECKING CRANKSHAft AND CoNNECtING RoD After having checked the state of wear of the cou- pling surfaces, check the offset of the half shaft axes by placing the crankshaft in between two tailstocks or similar instrument. Control the maximum mea- surement variation during a complete turn, using comparators positioned on the coupling surfaces with the crankshaft bearings. Allowed limited: 0.03mm Deflection/Off-centring of crankshaft.
Page 63 Make sure that the chain control gear is free of chipping or signs of abnormal wear. Replace the crankshaft should it be deteriorated. The distance between the two opposite sides of the half shafts must be: 64mm±0,05 (350cc, 390cc) 65mm±0,05 (430cc, 480cc) 64mm±0,05 (350cc, 390cc) 65mm±0,05 (430cc, 480cc) Crankshaft oil passages. If the two half shafts are detached for replace- ment of the connecting rod, pay close attention when repositioning the crank lever respect to the half shafts. The holes for oil passage A on the half shaft must coincide with those present on the crank lever B.
Page 64: Assembling Complete Crankshaft
Use a bore meter to check the inside diameter of the connecting rod foot which must not exceed the following service limit: scope of service 18,04mm (350cc, 390cc) 19,04mm (430cc, 480cc) Remember that the measurement must be made placing the axis of the feeler in parallel with the axis of the connecting rod. ASSEMBLING CoMPLEtE Bore meter verification of inside diameter CRANKSHAft...
Page 65: Gearbox Unit: Controls And Reassembly
GEARBoX UNIt: CoN- tRoLS 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 procedu- res for checking and reassembling these units to the engine. CHECKING GEARBoX UNIt 3.4.1 Use protective jaws to clamp the primary and secondary shaft.
Page 66: Primary Unit Assembly
3.4.2 PRIMARY UNIT ASSEMBLY Before proceeding with reassembly, clean all the ele- ments 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. Insert onto the lower cylinder part of the shaft: the roller cage 2, the 5th gear 3 (turning the front claw clutches upwards), the 26x32x1.5 thrust washer 4 and the circlip 5.
Page 67: Secondary Unit Assembly
3.4.3 SECONDARY UNIT ASSEM- 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; clutches face downwards), the 26x32x1.5 thrust 5) Circlip sw15; washer 4 and the circlip 5. 7) Thrust washer; Insert the 6th gear 18 (so that the fork seat fa- 10) Thrust washer 17x30x1;...
Page 68: Checking The Forks, Fork Pins And Desmodromic Device
3.4.4 CHECKING THE FORKS, FORK PINS AND DESMODROMIC DEVICE The internal gearshift is made up of: • two forks 13 which drive two gears on the secon- dary unit; • one fork 14 which drives one gear on the primary unit; • three drive pin bushes 15; • two fork pins 16; • desmodromic gearshift 18 through whose rota- tion the forks are driven thus selecting the desired gear. EXPLODED VIEW OF INTERNAL GEARBOX CONTROL Check to make sure that the drive pins which sup- UNIT: port the bushes 15 have no traces of meshing or 13) I - IV fork;...
Page 69 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 (to be measured in the sliding areas of the forks and in the housing areas of the crankcases): Fork pin outside diameter limit: 13,75mm Make sure that the desmodromic control device has no corroded or worn areas especially in the grooves in which the drive pins of the forks are engaged.
Page 70: Assembly Of Internal Gearbox And Gearshift
ASSEMBLY of INtERNAL GE- ARBoX AND GEARSHIft Insert the entire primary 1 and secondary unit 2 into the respective seats on the left crankcase half simul- taneously. 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. Make sure that all the parts sli- de properly. Insertion of gearbox in left crankcase. Insert the centre bearing 3 and the O-ring 4 on the secondary unit.
Page 71 Introduce the forks together with the drive bushes on the gear tracks. To be precise; the smaller fork 5 drives the sliding gear on the pri- mary unit, while the other two (6) drive the sli- ding gears on the secondary unit. Note: the two forks 6 are interchangeable and their positioning is univocal, since the drive pin must face the desmodromic device. If none of the components in question is replaced, it is recommended to reposition the forks in their original positions.
Page 72 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 desmodro- mic device abundantly with gear oil. Positioning of the secondary unit forks 6 in the external guides of desmodromic device 8. Position the new crankcase gasket. View inside the right crankcase with crankshaft, oil jets, gearbox shafts complete with gearwheels, internal gearshift and gasket.
Page 73: Closing Engine Block
CLoSING ENGINE BLoCK 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. To facilitate progressive nearing and aligning of the two crankcase halves, connect two screws on opposite sides and tighten them bit by bit. If the crankcase halves tend to capsize, do not insist tightening them. Rather loosen the screws and...
Page 74: Blocking The Crankshaft At The Top Dead
BLoCKING tHE CRANKSHAft At tHE toP DEAD CENtRE AND tIGHtENING tHE NUt oN tHE LEft SIDE of tHE CRANKSHAft To block the crankshaft in the Top Dead Centre, insert the special conical-end screw 38, without applying washer 37, or the special engine locking To block the crankshaft, apply only the screw 38 to tool, code 006140110000, in its seat on the right the crankcase.
Page 75: 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. 3.8.1 CHECKING THE COMPLETE DRIVE SHAFT With the device complete, make sure that the distance between the movable pawl and the 0,35÷0,80 drive shaft is between 0.35÷0.80mm. Should the distance be greater, replace the mo- vable pawl. Allowed distance between shaft and pawl. In order to replace the movable pawl 1, disas- semble the return spring of the gearshift 2, the spring guide 3, the spring 4 (which must be...
Page 76 EXPLODED VIEW OF GEARSHIFT For reassembly, couple the movable pawl 9 to the drive shaft 10 and, while compressing it, insert the 5) Thrust washer 14x30x1; spring 8 between the movable pawl and the drive 6) Gearshift return spring; shaft. Then apply the spring guide 7, the gearshift 7) Spring guide; return spring 6 and finally the 14x30x1 thrust wa- 8) Pawl return spring; sher 5. 9) Movable pawl; 10) Gearshift drive shaft. The gearshift return spring must be positioned as in the figure to be able to carry out its function. Gearshift drive shaft: note the positioning of the gearshift return spring.
Page 77: Assembly Of External Gearshift
3.8.2 ASSEMBLY OF EXTERNAL GEARSHIFT Keeping the stop lever moved 1 in such a way that the spring is compressed, position the stop cam 2 on the protruding end of the desmodro- mic gearshift (external right crankcase). 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 78 EXPLODED VIEW OF COMPLETE KICKSTART SHAFT Widen the circlip 10, thus slipping off the washer 11, and the kickstart gear 2 as well the roller bea- 2) Kickstart gear; ring 12 and the washer 11. This frees the kickstart 3) Kickstart shaft; 8) Kickstart return spring; shaft 3 from all other elements. 9) Kickstart spacer; Make sure that the side of the kickstart gear teeth 10) Circlip 20E; 2 have no signs of meshing or superficial wear. 11) 20x28x1 washer DIN 988;...
Page 79: Assembly Of Kickstart Device
3.9.2 ASSEMBLY OF KICKSTART DEVICE Insert the complete kickstart shaft in its housing 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 (external side). Positioning of sleeve A below ramp B. Turn the spring clockwise until it fits into the specific hole C.
Page 80: Electrical Starter Unit And Main Gear
3.10 ELECtRICAL StARtER UNIt AND MAIN GEAR Carry out the following controls before assembly. 3.10.1 CHECKING ELECTRICAL STARTER DEVICE ELEMENTS Make sure that the teeth of all the gearwheels of the device are intact, free from chipping or signs or abnormal wear. Idler wheel 1. Pay attention to the teeth of the idler wheels 1 and torque limiter 2 and between the gears and respective support pins. Replace them if they show signs of meshing or seizure.
Page 81: Coupling Ignition And Primary Gears To The Motor
3.10.2 COUPLING IGNITION AND PRIMARY GEARS TO THE MOTOR Thoroughly degrease the conical part A on the right side of the crankshaft and B of the primary gear. Conical segment A on right side of crankshaft. Conical segment B main gear. Lubricate the segment C of the starter gear 1 with motor oil and couple it to the crankshaft.
Page 82 Grease the two pins D and E with graphitic grease. Couple the idler wheel 7 to the pin D and apply the circlip 8. 10Nm Couple the torque limiter 4 to the pin E turning the gearwheel with the smaller diameter towards the crankcase half. Insert the washer 5 and the screw 6 after having spread the threading with medium strength threadlocker. Tighten the screw at a torque of 10Nm.
Page 83: Oil Pumps: Control And Reassembly
3.11 PUMPS: CoNtRoL AND REASSEMBLY As shown in paragraph 2.5, the motor is equip- ped with two oil pumps: one is the low pres- sure (suction) pump (higher displacement) lo- cated in the outside of the left crankcase half and the other high-pressure pump (lower di- splacement) located on the outside of the right crankcase half. The two pumps are driven by a gear cascade meshing with the clutch gear.
Page 84 Should the sliding surfaces with the rotors present deep or evident traces of corrosion, replace the deteriorated part (in this case, the crankcase). To measure the radial play between the internal and external rotor and between the external rotor and the crankcase, proceed as follows: Insert the two rotors in their specific seat with the refe- rence dot facing the inside of the engine. Using a thickness gauge, check that the play does not exceed that allowed, equal to: Maximum radial play: 0,20mm Take a thickness gauge again and a rectified reference surface and verify that the axial play does not exceed the maximum allowed amount: Maximum axial play: 0,1mm Low pressure pump: note the dot on the two rotors. The dot must face the inside of the engine. Should play be greater, replace the rotors.
Page 85: Assembly Of Low Pressure Pump
3.11.1 ASSEMBLY OF LOW PRES- SURE PUMP Insert the internal rotor 1 on the shaft 2 so that the dot on the face of the rotor faces inwards. Then insert the roller 3 on the shaft. Shaft, low pressure pump, internal rotor and roller unit. Use motor oil to lubricate the seat of the rotors on the outside of the crankcase half, insert the external rotor 4 and the internal shaft-rotor unit in its proper seat. Insert the ball 5 (diameter 5.5mm) and the re- spective compression spring 6. Lubricate with motor oil and, while rotating the protruding segment of the drive shaft (from the outside of the right crankcase half), make sure it rotates freely and does not jam. Complete low pressure pump coupled to the crankca- Fasten the cover 7 to the crankcase with the three screws 8, which must first be spread with medium strength threadlocker. These screws...
Page 86: Assembly Of High-Pressure Pump And Control Gear
3.11.2 ASSEMBLY OF HIGH-PRES- SURE PUMP AND CONTROL GEAR Lubricate the area where the pump is housed (outside right crankcase half), and insert the rol- ler in its hole 1. Then insert the internal rotor 2 and the external rotor 3, making sure to position them with the reference dot facing the inside of the engine. Lubricate the pump body with motor oil.
Page 87: Checking And Assembly Of Pressure Control Valve
3.11.3 CHECKING AND ASSEMBLY PRESSURE CONTROL VALVE The pressure control valve is made up of a ball 43, spring 42, calibrated washer 41 and screw Check the length of the free spring on this com- ponent: Service limit: 29.5mm Tighten the screw at a torque of 20Nm. 20Nm Attention: If one of these elements making up the PRESSURE CONTROL VALVE 40) Screw; control valve is not inserted, engine functioning will 41) Thrust washer; be jeopardised. 42) Spring; 43) Ball Attention: always restore the original thickness value of the washer 41. If this should be replaced, have it changed with one having the same original thickness.
Page 88 3.11.4 CHECKING AND ASSEMBLY OF OIL PUMPS CONTROL GEARS The oil pumps are controlled by a gear cascade dri- ven by the clutch gear. The gearwheels, being made of plastic, must not have chips, grains or signs of abnormal wear. If pump control idler wheel support pin 1 should be dismounted, reconnect it to the crankcase. The pin is fastened to the crankcase with screw 2 (after application of medium strength threadlockers) and locked with 6Nm torque.
Page 89 3.11.5 PAPER OIL FILTER INSER- TION Lubricate the rubber gasket on the filter. Insert the filter 1 into its housing and push it towards the inside of the engine as far as it can go. Application of paper oil filter. Insert the O-ring 2 onto the oil filter cover 3 and apply the unit to the crankcase. Paper oil filter cover complete with O-ring. Apply the two screws 4 M5x16 to be tightened at a torque of 10Nm. 10Nm Two fixing screws of paper oil filter cover.
Page 90 3.11.6 CHECKING AND COUPLING COUNTERSHAFT Check the state of use of the areas where the shaft rests on the bearing. Should they show signs of ab- normal wear, have the shaft replaced. Make sure EXPLODED VIEW OF COUNTERSHAFT that the toothed segment of the shaft does not 1) Shaft; have traces of abnormal wear. 2) Counterweight; 7) Elastic washer; 8) Nut M12x1 Grease the oil seal and insert the countershaft in its seat. Position it so that the reference sign on the shaft is between the two reference signs on the main gear.
Page 91 While keeping the countershaft in place, insert the counterweight on the left side depending on the position set by the grooved shaft. Coupling counterweight to countershaft. Detail of grooved profiles for coupling. Then couple the elastic washer and the nut 1 after having applied medium strength threadlo- cker on their threading. The nut must be tighte- 50Nm ned at a torque of 50Nm. Countershaft nut.
Page 92 3.12 CLUtCH UNIt Before reassembling the clutch unit, carry out some controls on the various components described be- low. 3.12.1 CHECKING CLUTCH BASKET, ROLLER BEARING AND IN- TERNAL CENTRE BEARING Before reassembling the clutch basket, 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 93: Internal Centre Bearing
Check the state of use of the silent-blocks as follows. Clamp the gear B intended to mesh with kickstart idler gear, using protective ele- ments. Rotate the clutch basket. If there is play between the basket and the gear unit, replace the clutch basket. Check the state of use of the centre bearing 1 which must have no traces of meshing or ab- normal wear.
Page 94 Also check the distortion of the steel discs. This operation is done by placing the steel discs on a perfectly flat surface and using a thickness gauge to check that the clearance between the disc and the surface is not greater than: allowable distortion steel discs: 0.10mm Measuring steel disc distortion. 3.12.3 CHECKING SPRINGS To ensure the correct pressure between the clutch discs, the state of the springs must be checked. The minimum acceptable length must be:...
Page 95 3.12.5 CHECKING THRUST BEA- RING DEVICE 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 rota- tion of the front centre bearing A respect to the rear one B. Be careful for presence traces of meshing or wear on the sliding surfaces. Thrust bearing device. 3.12.6 ASSEMBLY OF CLUTCH UNIT After having lubricated the end of the main transmission shaft, insert the internal centre bearing 4 to which the roller bearing must be...
Page 96 To unscrew the nut 8, the inner hub must be blo- cked with a relevant tool A (code 0061400400); the tightening torque is fixed at 120Nm after having ap- plied medium strength threadlocker. Having tightened the nut, bend to two blocking flaps on the safety plate. 120Nm Blocking inner hub with specific tool Code 0061400400. Lubricate the clutch disc with gearbox oil and ap- ply the washer 1 in the seat on the drum, the disc spring 2 so that the concave part faces the washer 1, the washer 3, the special disc 4, a driven disc and...
Page 97 Insert the clutch rod in the seat B from the left side of the engine, turning the smaller section towards the inside of the engine. Insertion of clutch rod in housing B. Apply the gasket 5, the complete hydraulic ac- 10Nm tuator 6 the M6x30 screw 7 and the two M6x20 screws 8 to the left crankcase half. Tighten the three screws at a torque of 10Nm. Application of gasket 5, actuator 6, screw 7 M6x30 and two screws M6x20.
Page 98 3.13 CooLANt PUMP The water pump must guarantee, depending on the set EXPLODED VIEW OF WATER PUMP rotation speed, the correct flow rate of the coolant in order to extract the needed amount of heat from the 1) Drive shaft thermal unit. 2) O-ring 5.5x1; 3) Bearing 10x19x5; The shaft 1 is supported by two bearings 3 and sealing 4) Oil seal 12x30x7;...
Page 99: Assembly Of Pump Unit
3.13.2 ASSEMBLY OF PUMP UNIT Heat the concerned area to couple the bearings 3 to the inner clutch cover. They must be pushed until they are flush with the shoulders on the pump body. Grease the oil seal housing. Position the oil seal 4 so Thicker that the thicker edge faces the outside of the cover. border Insert the oil seal in the inner clutch cover, having it enter the seat very slowly to keep it from deteriora- ting. Application of oil seal on inner clutch cover. Couple the shaft 1 with the O-ring 2 to the inner clutch cover and then insert the bush 5, the washer 7 and the impeller 6.
Page 100 3.14 ASSEMBLY CoMPLEtE CLUtCH CovER Apply a new gasket 1 placed between the right crankcase half and the inner clutch cover using the two reference pins 2 to keep it in place. Positioning of gasket 1 and centring pins 2. Couple the inner clutch cover to the right crankcase half and turn the water pump impeller until the pump shaft inserts perfectly in the housing on the countershaft which drives it. Application of complete inner clutch cover to right crankcase half.
Page 101 Couple the water pump cover to the inner clutch 10Nm cover applying the four M6x40 screws, making sure to apply the copper washer 3 to the lower screw of the pump cover. Tighten all thirteen screws at a torque of 10Nm following a criss-cross pattern. Coolant pump cover: pay attention to washer 3. If only the outer clutch cover was removed, put it back on the inner cover and fasten the six M6x25 screws as shown in the figure.
Page 102: Fixed And Mobile Guides
3.15 CHECKING AND CoUPLING of tIMING CHAIN, fIXED AND MoBILE GUIDES The chain has the task of transmitting motion from the crankshaft to the camshafts present on the cylinder head. The links must be checked to make sure there is no excessive radial or axial play between them. The fixed and movable guides guarantee a correct move- ment of the chain. The hydraulic chain tensioner ensures correct tensioning. Make sure that the guides do not have deep traces cau- sed by the rotation of the chain. In order to assemble the chain to the engine, just intro- duce it in the vertical passage compartment A on the left crankcase and insert it in the gear on the crankshaft. Insert the fixed guide 1 and the movable guide 2 inside the compartment A. Insert the specific 6.2x9x9 bushes inside the lower eyelets of the guides. After having ap- plied medium strength threadlocker, tighten the relative screws 3 at a torque of 10Nm.
Page 103 3.16.1 CHECKING IGNITION SY- STEM Degrease the various elements and carry on with the controls. The main control is the one concerning the electrical verification which can be done by using a standard tester. The resistance values detected at the termi- nal heads must respect those carried in the table (at 20°C). Element Cables Resistance values Pick up Red – Green 100Ω ± 20% Stator Black - Black 0,46Ω ±20% 3.16.2 COUPLING IGNITION SY- STEM TO CRANKCASE Set the pick-up on the crankcase so that the two ho- les on its support coincide with the two outer holes...
Page 104 Degrease the conical segment of the crankshaft, apply the Woodruff key 21 in the appropriate groove on the crankshaft, couple the flywheel 18, the elastic washer 19 and the nut 20, after having applied the threading with Loctite 243 / Sichel 100M medium strength threadlo- cker. Tighten the nut at a torque of 60Nm. 60Nm EXPLODED VIEW OF FLYWHEEL 18) Flywheel; 19) Elastic washer; 20) Nut M12x1; 21) Woodruff key.
Page 105 Insert the centring pins 6 on the crankcase and fa- sten a new gasket. Grease the oil seals on the cover of the flywheel and secure it on the left guard using the nine 7 M6x25 10Nm screws. Notice that a 12x6.3x1 copper washer C must be ap- plied to the screw. Tighten the screws at a torque of 10Nm. Flywheel cover coupled to crankcase.
Page 106: Thermal Unit
3.17 tHERMAL UNIt Before assembling the thermal unit, thorough controls must be carried out on the cylinder, piston, pin bolt, pi- ston rings, cylinder head and the timing unit described hereafter. 3.17.1 CHECKING PISTON, PIN BOLT, AND PISTON RINGS Eliminate carbonaceous sediment from the top of the piston and wash the entire piston with specific degre- asing agent. Do not use sharp points or tools for cleaning. Then carry out a careful analysis of the piston which must be free from forcing, scratches, cracks or any type of damage. Analyse the outside diameter of the piston whose ser- vice limit is carried in the table below concerning their specific class. The diameter must be measured at a di- stance X from the inner edge of the skirt perpendicu- larly to the axis of the pin bolt.
Page 107 Check the size of the pin bolt seat located on the piston and the size of the pin bolt. This last control must be made at the end of the pin bolt itself in the area where it is engaged with the piston. Size [mm] Displacement [cm³] Pin bolt Pin bolt seat 350 -390 18,04 17,98 430-480 19,04 18,98 Measuring pin bolt seat and pin bolt.
Page 108: Checking The Cylinder
3.17.2 CHECKING THE CYLINDER Make sure the bore is within the service limits of the relevant class carried in the table below. Carry out measurement at a distance A from the top face of the cylinder (surface between cylinder and cylinder head). To measure it correctly, it must be done accor- ding to the X and Y directions orthogonal between them. Consider the maximum measurement to determine the cylinder wear. The difference between the two measurements is the ovalization.
Page 109: Auxiliary Devices
3.17.3 CYLINDER HEAD: DISAS- SEMBLY CHECKING AUXILIARY DEVICES Before disassembling the cylinder head, clean the entire unit thoroughly. The various elements must be cleaned and named bit by bit as they are disassembled. Proceed as follows for disassembly and inspec- tion of the cylinder head. Clamp the cylinder head using protective jaws, gripping it at the head connection A. Disassemble the spark plug using the special spark plug wrench (code 020440100 000).
Page 110 3.17.3.2 FINGER FOLLOWER/SHAFTS UNIT Disassemble the two caps 1 which keep the finger follo- wer shafts in place. Make sure the face of the cap facing the shaft does not have deep traces or signs of wear. If so, replace the caps. Check the state of use of the two O-rings between the caps and the cylinder head. We recommend they be re- placed. Closing caps for finger follower support shaft seats. The finger follower shafts have a threaded hole (M4) at the end so that they can be extracted. To pull them out, just screw a sufficiently long M4 screw A in this hole and pull out. In this way, the finger followers can be extracted. Application of M4 screw to allow pulling out the finger follower support shafts with your fingers. Make sure the outside diameters of the shafts 2 and the inside diameters of the holes on the finger fol- lowers 3 respect the following service limits:...
Page 111 3.17.3.3 SHIMS (CALIBRATED SCS) VALVE PLAY ADJUSTMENT Using a magnet, pull out the calibrated discs 1 from the seats in the cups. Once the calibrated discs are extracted, measu- re them with a thickness gauge. Removal of calibrated discs from seats. The calibrated discs range from 2.00 to 3.30 according to the intervals carried in the table below.
Page 112: Valve Units
3.17.4 CYLINDER HEAD: DISASSEM- BLING AND CHECKING VALVE UNITS Clamp the spring removal jaw A (code 0100043 000) and apply the spring removal tool onto it B (code 006140030 000). Then position the cylinder head and disassemble the springs. Placing cylinder head on device for di- sassembling valve springs. Compress the spring as much as necessary to ex- tract the half-cones 1.
Page 113: Springs
3.17.4.1 SPRINGS Each valve is retained by a spring. The length of these springs must be checked while they are loose: service limit = 42,5mm Should the springs be shorter, have them re- placed. Measuring length of free spring. 3.17.4.2 VALVE GUIDES, VALVES AND SEATS Make sure that the valve guides are free from scratches or any type of nicks. To check the cor- rect diameter, introduce the gauge in the valve guides from the side of the combustion cham-...
Page 114 Taking the valve out, the paint will be missing in the contact zone. Its width must not be greater than the following service limit: Width service limit of valve seat contact zone: 1,9 The contact zone can principally take on three different appearances, as shown in the figure: A - correct; B - incorrect (contact face damaged); C - incorrect (uneven seat width). Valve-seat contact conditions: A) Correct; B) Incorrect - contact face damaged-; C) Incorrect - uneven width-. Also check the correct positioning of the contact area. It must be neither higher (case D) or lower (case E).
Page 115: Washer
3.17.4.3 VALVE STEM SEAL AND LO- WER STOP WASHER Should there be excessive oil consumption or a white-like exhaust smoke which cannot be blamed on the oil-scraper rings on the piston, replace the valve stem seals 1, intended to pre- vent excess oil leakage. It is recommended to replace them every time the cylinder head is overhauled.
Page 116: Checking Camshafts
3.17.6 CHECKING CAMSHAFTS Verify the zones A and B on the camshafts making sure they have no traces of meshing or abnormal wear. Make sure the sides of the teeth C are not chipped or have no trace of abnormal wear. The zone A comes into contact with the cylinder head becoming part of a hydrodynamic support bearing. Zone B on the other hand supports the roller bearing.
Page 117: Checking Camshafts Support
Make sure that the cylinder segment D of the decompressor is not worn or chipped. Should it be deteriorated, replace the decom- pressor shaft. In order to extract it, remove the Benzing ring 4 and pull the shaft out. Operate inversely to reassemble it. If replacing the de- compressor shaft, replace the Benzing ring as well.
Page 118: Valve Stem Seal
3.17.8 CYLINDER HEAD: INSERTION OF INNER CUP AND VALVE STEM SEAL If the lower cups and valve stem seals were disas- sembled*, reassemble them as follows. First insert the lower cup 1 facing the flat part downwards. Lubricate the upper part of the valve guide lightly and insert the valve stem seal 2. Pay close attention that while inserting the valve stem seal, its axis is aligned with that of the valve guide. The valve stem seal must be pressed towards the bottom of the cylinder head until it is flush with the valve guide. Insertion of lower cup. Insertion of valve stem seal.
Page 119 3.17.9 CYLINDER HEAD: ASSEM- BLY OF VALVE UNIT Clamp the spring removal jaw A (code 0100043 000) and apply the spring removal tool onto it B (code 006140030 000). Insert the valve stem in the valve guide* from the combustion chamber side. Place the valve in the specific lower housing of the jaw and introduce: • The spring 1, being careful to insert it so that the segment with the smaller pitch faces downwards; • The upper cup 2, turning the flatter part upwards.
Page 120 3.17.10 CYLINDER HEAD: REPOSI- TIONING CALIBRATED DISCS, ASSEMBLY OF FINGER FOL- LOWER SHAFTS AND FINGER FOLLOWERS AND COUPLING THE SPARK PLUG Clamp the cylinder head using protective jaws, grip- ping it at the head connection A. Put the calibrated discs 1 back in place in their original positions (if not deteriorated see par. 3.17.3.3). Insert the finger follower shaft 2 partly in the specific seat as much as needed to be able to insert the ou- termost finger follower into the cylinder head first 3.
Page 121 3.17.11 CYLINDER HEAD: INSER- TION OF OIL JETS, CEN- TRING PINS AND SPARK PLUG O-RING Insert the oil jets 1 with the O-rings 2 in their specific seats on the cylinder head. Oil jet with O-ring. Note the flat part A for reference on the side of the jet. The positioning of the jets is univocal thanks to the specific flat side.
Page 122: Scraper Rings
3.17.12 PISTON: APPLICATION OF THE SCRAPER RING AND RETAI- NING STRAPS, APPLICATION OF SEEGER 3.17.12.1 Piston: application the scraper ring and re- taining straps, version 350cc-390cc Lubricate the seats of the segments with plenty of oil and put the internal scraper ring strap 1 in the Application of the scraper ring strap, lower seat of the piston. version 350cc-390cc. Lay the external scraper ring strap 2 on the internal one with the “TOP” marking facing the top of the piston.
Page 123 3.17.12.2 Piston: application of piston rings and oil- scraper rings Oil the ring seats abundantly and apply the central oil-scraper ring in the lower seat of the piston 1 paying close attention that the two ends face one another but do NOT overlap. The two ends must be aligned in axis with the pin bolt. Application of central oil- scraper band. Detail of positioning of two edges. Apply the two lower 2 and upper oil-scraper rings 3 and then the compression ring 4.
Page 124: Application Of Piston To Cylinder
3.17.12.3 Piston: seeger applica- tion Abundantly lubricate the seats for the pin bolt with motor oil and the circlip 5 in the left pin bolt seat, being careful to position it so that the lug on the circlip inserts itself in the specific seat on the pi- ston. Application of circlip 1 to piston. In order to identify the right and left side of the Right piston, just use as a reference the arrow A stamped on the piston crown which must face the exhaust...
Page 125 Press the piston downwards having the higher segment of the skirt protrude a bit from the band. Rest the unit on the cylinder, making sure that the contact zones of the band rest correctly on the cylinder surface. For this pur- pose, make sure that the upper edge C of the band is perfectly aligned with the contact sur- face of the cylinder. Note: When positioning the complete band-piston unit on the cylinder, be careful to place them so that the arrow stamped on the crown of the piston faces the exhaust manifold.
Page 126 3.17.14 APPLICATION PISTON- CYLINDER COUPLING CRANKCASE Apply a new piston-cylinder gasket 1 to the crankcase and couple the two centring bushes to the left crankca- se 2. Lubricate the foot of the connecting rod abundantly with motor oil. Application of cylinder/crankcase gasket and of cen- tring bushes. Insert the timing chain in the proper compartment in the cylinder and bring the piston/cylinder unit close to the connecting rod.
Page 127 Once the pin bolt reaches its housing in the foot of the connecting rod, push the pin bolt inside until it is inserted all the way. Apply the lug to the circlip 3 in the pin bolt seat. Insert the cylindrical part of the special tool A into the pin bolt and, having one of the two flat surfaces of the tool coincide with the part of the circlip to be inserted, turn and push the special tool towards the engine until the circlip...
Page 128 Apply to the cylinder the two guide bushes 4 and the gasket 5 coupling with the cylinder head. Application of guide bushes 4 and gasket 5 to cylinder. 3.17.15 COUPLING HEAD TO CYLIN- Introduce the timing chain in the compartment on the cylinder head. Keeping the chain tight, place the head on the gasket making sure it inserts perfectly into the two centring bushes on the cylinder.
Page 129 3.17.16 COUPLING CAMSHAFTS TO CYLINDER HEAD AND PHASING Couple the bearings to the camshafts and lubri- cate them with motor oil. Widening the timing chain, insert the exhaust camshaft upon whose gearwheel the timing chain must be placed. It is advisable already in this phase to position the shaft so that the re- ference notches A are horizontal with the cams facing upwards according to the approximate direction B. Positioning camshaft. Lift the camshaft slightly and move the bearing so that it is flush with the shoulder C. Having carried out the above-mentioned po- sitioning, rest the camshaft on the cylinder head.
Page 130 Lift the chain again and insert the intake camshaft placing the chain on the gearwheel. Place the shaft so that the cams face upwards according to the ap- proximate direction D and the references E carved on the gear are horizontal. Position the bearing in the same way as for the exhaust camshaft. Positioning intake camshaft. Holding the camshaft still with one hand, insert an aluminium cylinder F in the housing of the hydrau- lic tensioner as far as needed to be able to push the movable guide against the timing chain. Make sure that the notches engraved on the two wheels are aligned one with the other. Is so, the phasing is...
Page 131 Lubricate the entire camshaft unit with motor oil and apply the support 1, making sure it is perfectly engaged both on the shafts and on the centring pins. Note: check the presence of the oil jets (par. 3.17.11). Apply the chain guide 2 and insert the three M7x38 screws 3 in the holes on the chain side and the four M7x33 screws 4 in the four remai- ning holes.
Page 132: Valve Play
Tighten the seven screws by hand until they are flush. Check the correct position of the camshaft bearings (par. 3.17.7). Proceed with tightening in two moments, following the order indicated in the figure. Carry out the first tightening operation at a torque of 8Nm and the second at 10Nm. At the end of this operation, make sure the camshaft moves freely. 5Nm 10Nm Tightening order of camshaft support screws. 3.17.17 VALVE PLAY Checking for valve play must be carried out by pla- cing a thickness gauge A (code 006140210000) in between the cam and the finger follower. This con-...
Page 133 Check valve play Connect the mechanical Is the valve play tensioner to the motor. correct? (par 3.17.18) Disassemble the Is the tensioner camshaft support coupled to the (par 2.1.1) engine? Disassemble the tensioner (par 2.1.1) Incorrect play on intake side? First dissemble the intake Disassemble only the camshaft and then the...
Page 134 3.17.18 CHECKING AND COUPLING OF MECHANICAL TENSIONER TO ENGINE The mechanical tensioner consists in: 1. a piston; 2. a spring; 3. a support; 4. a cap. Make sure the piston shows no signs of abnormal meshing. 1 mm Insert the piston into the support and push it until it sticks out of the edge of the support by approxi- mately 1 millimetre. Insert the tensioner support in the specific seat on the cylinder, tightening it at a torque of 25Nm and 25Nm push the piston towards the front of the engine.
Page 135 I n s e r t t h e s p r i n g i n t h e s u p p o r t a n d a p - p l y t h e c a p t o b e t i g h t e n e d a t a t o r q u e o f 8 N m .
Page 136 3.17.19 COUPLING CYLINDER HEAD COVER GASKETS AND CYLIN- DER HEAD COVER Apply the spark plug gasket 1 to the camshaft sup- port inserting the two pegs A in the specific seats and positioning it so that it recopies the shape on the support.
Page 137 Place the complete cover on the cylinder head making sure that the gasket covers the surface correctly. Apply the four rubber rings 3 to the cover and insert the four screws 4 which fasten the cover to the cylinder head. Tighten the screws in a criss-cross pattern at a torque of 8Nm. Application of rubber rings 3 and fixing screws 4. 3.18 PINIoN CoUPLING 60Nm If the O-ring 25 is not coupled to the secondary shaft (par. 3.5), insert it followed by the spacer Then apply the pinion 27, the washer 28 and the screw 29 which must be spread with me- dium strength threadlocker: tighten at a torque of 60Nm.
Page 138 3.20 CoUPLING oIL CAPS Couple the engine oil drain plug 24 in the lower part of the right crankcase, complete with O-ring 25, with wire metal filter 27 and O-ring 26. Tighten at a 20Nm torque. Apply the magnetic screw 28 with the O-ring 29 to the gear oil drain hole: tighten at a torque of 20Nm. 20Nm 15Nm EXPLODED VIEW OF OIL DRAIN CAPS. 24) Motor oil drain plug;...
Page 139 3.21 CoUPLING GEARSHIft LEvER Couple the gearshift lever to the drive shaft by positioning it so that the part A of the lever coincides with the upper edge of the oil level inspection window. Tighten the screw 1 at a torque of 10Nm after having applied medium strength threadlocker. 10Nm Positioning of gearshift lever.
Page 140 REASSEMBLY of ENGINE IN tHE vEHICLE Insert the engine in the frame. We recommend in- sertion from the frame’s left side. Insert the engine pins 1. Insertion of engine pins. Insert the upper shock absorber pin 2 and the swin- garm pin 3. Fasten the shock absorber pin at 70Nm. 70Nm Insertion of upper shock absorber pin. Insertion of swing-arm pin.
Page 141 Apply head connections. 35Nm 35Nm 35Nm 35Nm Fasten the nuts and bolts following the table be- 35Nm low. Attachment Screw Torque [Nm] Threadlocker Bracket for head connection M8 x 20 Medium resistance to frame. Front attachment Bracket for head connection M8 x 16 Medium resistance to frame. Rear attachment Brackets for head connection M8 x 65 to motor Motor pins...
Page 142 Make sure the filter box sleeve is correctly inserted inside the throttle body, fasten the two filter box side and manifold side straps. Set the gas cable on the left side of the frame and make it pass outside the head connection. Apply the gas cables to the throttle body and tighten the nuts. Attention! At the end of the operation, check for correct gas play.
Page 143 Apply the unit clutch actuator to the two fixing screws 6. Fasten at 10Nm. 10Nm Apply the spark plug cap. Apply the start motor cable and fasten the nut at 10Nm. Cover the connection using the speci- fic protective cap. Make the electric cables from the engine (stator and pick-up) pass through the head connections. 10Nm Connect the connectors indicated in the figure. Injection version.
Page 144 Insert the connectors and cables in the recess on the frame. Apply the straps as in the figure. Electric connectors in the recess (injection versions). Connect the ventilation pipes to the engine. Fix the cables from the engine to the gear actuator tube. Apply the left radiator to the frame.
Page 145 Apply the screws and fasten at 10Nm. Apply the protective grid. 10Nm Connect the radiators to the engine. Fasten the clamp straps and introduce the co- olant liquid, letting the air bleed through the screw cap A. Apply the loading cap and fasten the bleed screw at 10Nm. Spurgo aria.
Page 146 Apply the silencer to the vehicle, then the exhaust manifold; fasten according to the torque indicated 10Nm in the figure. Attention! Position the exhaust manifold in order to have a 5÷10mm gap with the water hose. 10Nm 15Nm Apply the Kickstart lever. Apply the medium- resistance sealant threading on the screw and fasten at 25Nm. Apply the brake pedal return spring 7. Mount the chain on the pinion. 10Nm 25Nm Move the wheel towards the rear, mounting the adjustment frames according to the image. Attention! Before fastening the rear wheel, check for its correct alignment.
Page 147 Apply the pinion guard 10 and the frame side guards 11 and 12. Fasten the screws at 10Nm and apply the fixing straps between the side guards and frame. 10Nm 10Nm 10Nm Apply the tank as follows. Connect the connectors indicated in the figure.
Page 148 Put the tank in place making sure the gas cable is between the tank and frame. Connect the quick-release petrol couplings. Attention! Make sure that the petrol quick-release couplings are properly set. Fasten the screws in the tank at the indicated torque. Apply the seat. Reapply the paramotor plate with the tree fixing screws, once the motorcycle is removed from the stand. Fasten at 10Nm.
Page 149 Grease the rear fastener and tighten the screws at the indicated torque values. 10Nm Apply the seat. 10Nm...
Page 150 tABLE of tIGHtENING toRQUES of ENGINE CoMPoNENtS Threading diameter x Torque Fixing Quantity Threadlocker Notes length [mm] [Nm] Outside right crankcase half Loctite 243/ Oil seal fixing plate M5 x 10 Sichel 100M Loctite 243/ Oil incline M5 x 10 Sichel 100M Loctite 243/ Kickstart ramp...
Page 151 Threading diameter Torque Fixing Quantity Threadlocker Notes x length [mm] [Nm] Engine lubrication Medium Oil jet strength Loctite 243/ Oil pump covers M5 x 10 Sichel 100M Loctite 243/ Chain oil jet M5 x 12 Sichel 100M Oil pressure control screw M12 x 10 Paper oil filter cap M6 x 16...
Page 152 Threading Torque Fixing diameter x length Quantity Threadlocker Notes [Nm] [mm] Engine lubrication Finger follower shaft caps Lubricate threading Cylinder head and washers. Follow a criss-cross pattern Cylinder head Follow a criss-cross Camshaft support M7 x 38 pattern Follow a criss-cross Camshaft support M7 x 33 pattern...
Page 153 ENGINE/fRAME tABLE of tIGHtENING toRQUES Threading Torque Fixing diameter x worm Quantity Threadlocker Notes [Nm] [mm] Front engine pin M10 x 1,25 Lower engine pin M10 x 1,25 Head connection bracket to Loctite243/ M8x20 front frame Sichel 100M Head connection bracket to Loctite243/ M8x16 rear frame...
Page 154 RECoMMENDED ENGINE MAINtENANCE The required engine maintenance is strongly depending on the level of use and on the accordingly done periodic checks and service. The below mentioned maintenance intervals are for standard competition use, subject to the condition that the engine was never running under extraordinary conditions and the periodic service was done accurately. 120h 150h 180h 200l 400l 600l 600l 800l 1200l Clutch disc wear Clutch springs Gearbox bearing (crankcase side) Clutch hub/basket wear Cylinder Piston and segments Camshaft wear Valve springs Valves Valve guide wear Connecting rod Countershaft bearings Crankshaft bearings...
Page 155 RECoMMENDED LUBRICANtS AND LIQUIDS APPLICATION PRODUCT QUANTITY Gearbox and clutch 800 ml* - 750ml** Liqui Moly racing 10W40 Engine Liqui Moly racing Synth 10W50 800 ml* - 750ml** COOLANT Liqui Moly Coolant ready mix RAF 12 PLUS 1300 ml* * Following the complete engine revision. ** Following routine maintenance interventions.
Page 156 NotES:...

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Enduro rr 390 efi 2016 Enduro rr 430 efi 2016 Enduro rr 480 efi 2016

Beta Enduro RR 350 EFI 2016 Workshop Manual

Index

Preamble

Informative Note

Safety

SPECIAL Equipment

1 Removing the ENGINE from the Vehicle

2 Engine Disassembly

3 ENGINE ASSEMBLY and Controls

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