Beta Enduro RR 350 2013 Workshop Manual
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Beta Enduro RR 350 2013 Workshop Manual

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  • Page 2: Table Of Contents

    INDEX Low-pressure oil pump and by-pass valve .5.3 Oil pressure control valve .5.4 Paper oil filter .5.5 COUNTERSHAFT PRIMARY GEAR ELECTRIC IGNITION Start motor .8.1 KICKSTARTER EXTERNAL GEARSHIFT UNIT CRANKSHAFT, GEARBOX UNIT AND INTERNAL GEARSHIFT Nut on left side of crankshaft .11.1 Opening crankcase .11.2...
  • Page 3 INDEX Checking piston, pin bolt, and piston rings ASSEMBLY OF INTERNAL GEARBOX AND GEARSHIFT .17.1 Checking the cylinder CLOSING ENGINE BLOCK .17.2 BLOCKING THE CRANKSHAFT AT THE TOP DEAD Assembly clearance .17.2.1 CENTRE AND TIGHTENING THE NUT ON THE LEFT Cylinder head: disassembly and checking auxiliary SIDE OF THE CRANKSHAFT .17.3...

  • Page 4: Carbon Monoxide

    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.

  • Page 5: Special Tools

    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 •...
  • Page 6 www.betamotor.com TECHNICAL FEATURES OF ENGINE Monocilindrico a 4tempi raffreddato a liquido con albero Tipo bilanciatore e avviamento elettrico Bore x stroke RR 350 88x57,4 Bore x stroke RR 400 95x56,2 Bore x stroke RR 450 95 x 63,4 Bore x stroke RR 498 100 x 63,4 Displacement [cm³] RR 350 349,1...
  • Page 7 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; Flywheel Extractor code 3625173 000; Value Piston ring compression band code 006140170 000; Tightening Torque Chain-tensioner release tool code 006140050 000;...

  • Page 8: Engine Disassembly

    ENGINE DISASSEMBLY 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.
  • Page 9 In order to empty the cooling circuit, loosen the screw 4 and have the liquid flow out into a recipient (the cooling circuits holds 1.3l of liquid). Remove the radiator cap. Disconnect the water hoses on the engine side, disconnect the electrical connectors below the tank, the clutch actuator and the exhaust manifold.

  • Page 10: Thermal Unit

    THERMAL UNIT The thermal unit is made up of the head, cylinder and piston. Before removing the cylinder head, bring the piston 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.
  • Page 11 Remove the crankshaft blocking screw 6, remove the copper washer 7 and put the screw (or tool 006140110 000) back into its seat without tightening it all the way. Crankshaft blocking screw 6 with copper washer 7. After having engaged the 6th gear, turn the transmission shaft 8 anti-clockwise - using an open-end spanner or the likes, - until the lines 9 on the toothed profiles of the...

  • Page 12: Cylinder Head: Disassembling Mechanical Tensioner

    .1.1 CYLINDER HEAD: DISASSEMBLING 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.
  • Page 13 Using a plastic rod A or something similar, lever the head surface and the camshaft support 2 in order to lift it and remove it. Uncoupling camshaft support 4 from cylinder head. When uncoupling, be careful of the two cen- tring pins 4 the camshaft support Checking camshafts support Remove the spark plug housing sealing O-...
  • Page 14 CYLINDER HEAD: REMOVING .1.3 CAMSHAFTS Lift the intake camshaft 1, pull out the bea- ring 2 and remove the chain 3 from the gear on the shaft. Attention: the hydraulic tensioner must al- ready have been removed in order to remo- ve the camshafts.

  • Page 15: Cylinder Head: Uncoupling From Cylinder

    CYLINDER HEAD: .1.4 UNCOUPLING 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.
  • Page 16 Remove the head gasket 4 and the two cen- tring 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 17 DISASSEMBLING CYLINDER .1.5 AND PISTON Lift up the cylinder 1 a few centimetres, re- move the two centring bushes 2 (both loca- ted on the chain side) to prevent them from falling inside the crankcases and continue on removing the cylinder. Remove the cylin- der gasket 3.

  • Page 18: Stator And Flywheel

    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 OF IGNITION 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 19 Be careful of the two centring pins on the crankcase half. Two centring pins 5 dedicated to the flywheel cover. Remove the tightening nut 6 which fastens the flywheel 7 to the crankshaft. Once the nut has been unscrewed, pay at- tention to the special elastic washer (8 shown in the following images) placed between the nut and the flywheel.

  • Page 20: Timing Chain And Guides

    In the image at the side, the flywheel 7 (rear view), the special elastic washer 8 and the tightening nut 6. Exploded view of flywheel 7, nut 6 and special elastic washer 8. TIMING CHAIN AND GUIDES .2.2 Remove the fixing screws 1 of the mobile 2 and fixed pad 3.
  • Page 21 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 while 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.

  • Page 22: Pick-Up

    PICK-UP .2.3 Once the timing chain guard has been re- moved, 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 Pinion 1, screw 2 and washer 3.
  • Page 23 CLUTCH UNIT AND COOLANT PUMP COVER In order to access the clutch unit, the outer clutch cover 1 must be removed by loose- ning 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 ele- ments housed in the outer right side of the crankcase half or of the engine, the inner...
  • Page 24 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 ac- tuator- outer left side crankcase half by lo- osening the three screws 8 which fasten it...
  • Page 25 Remove the 4 screws 10 which fasten the clutch cap 11 to the inner hub. Remove the clutch cap together with the four washers and relative springs. Clutch cap 11 and four screws 10. Extract the whole pressure plate unit 12 and the clutch disc pack 13.
  • Page 26 To unscrew the nut 15, the inner hub must be blocked with a relevant tool A (code 006140040000). Then remove the nut and relative safety wa- sher. ATTENTION: don’t use pneumatic wrench Removal of inner hub nut with relevant tool G. Extract the inner hub 16, the washer 17, the basket 18, the roller cage 19 and the centre bearing 20.

  • Page 27: Engine Lubrication Circuit

    ENGINE LUBRICATION CIRCUIT The high-pressure pump (or delivery) 1 - with less displacement - sends the oil puri- fied by the paper filter 2, to the crank me- chanism 3, to the piston oil jets 4, to the tensioner 5 and to the cylinder head jets and camshafts* 6.

  • Page 28: Oil Pumps Control Gears

    OIL PUMPS CONTROL GEARS .5.1 The two oil pumps are controlled by a gear unit driven by the clutch gear. In detail, the gear 1 meshes with the clutch gear, 2 it is the idler wheel and 3 it is the oil pumps control gear.

  • Page 29: Low-Pressure Oil Pump And By-Pass Valve

    LOW-PRESSURE OIL PUMP .5.3 AND BY-PASS VALVE The low-pressure pump and the one-way valve are located in the left-hand side cran- kcase (on the outside) inside the ignition unit compartment. They are enclosed under the cover 1, which removed by extracting the three screws 2.

  • Page 30: Oil Pressure Control Valve

    OIL PRESSURE CONTROL VALVE .5.4 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.

  • Page 31: 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 wa- sher 7 and nut 8 have the task of assuring coupling of the complete shaft to the base.

  • Page 32: 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 Primary gear 1 and relative nut 2.

  • Page 33: Electric Ignition

    ELECTRIC IGNITION Electric ignition can be carried out by means of the start motor 1 which meshes on the gear- wheel 4 with the function of torque limiter. The gearwheel 4 (torque limiter) transmits mo- tion to the idler wheel 7, which will then mesh with the starter gear 9.
  • Page 34 Remove the two screws 4 which fasten the start motor to the crankcase and pull out the start motor. Screws 4 fixing start motor to crankcase. In order to extract the kick-start gear 5, di- sassemble the primary gear (see par. 1.7) and the pin 6 which supports the idler whe- el for oil pump control (see par.

  • Page 35: Kickstarter

    KICKSTARTER The kickstarter is made up of the pedal which, attached to the kickstarter shaft 1, moves the kickstarter gear 2. This gear mo- ves the idler wheel 3 which then meshes with the clutch gear. The device moves back thanks to the spring 4. Kickstarter mechanism.
  • Page 36 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 together with the sleeve 9, the spring 10 and the thrust washer 11.

  • Page 37: External Gearshift Unit

    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 con- stitutes the drive of the movable pawl which then has the task of engaging the stop cam 2.

  • Page 38: 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 crankca- ses must be detached. Here are the needed instructions. NUT ON LEFT SIDE OF .11.1 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.
  • Page 39 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 equi- pment and disassemble the crankcase by hand.

  • Page 40: Crankshaft

    CRANKSHAFT .11.3 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 hammer. Extraction of crankshaft. INTERNAL GEARSHIFT UNIT AND .11.4 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.
  • Page 41 Extract the forks together with the drive bu- shes 5. Extraction of forks from gearbox unit. Proceed to extract the complete gearbox unit including the primary 6 and secondary unit 7. Extraction of complete gearbox unit: 6 primary unit, 7 Secondary unit.

  • Page 42: Right Crankcase Half

    DISASSEMBLY OF PARTS FROM CRANKCASES Once the crankcases have been detached, it is necessary to remove the various components attached to it. The correct positioning of some bearings ap- plied to the crankcase halves is ensured by lo- cking devices such as plates or simple screws. In order to disassembly these bearings, the safety devices must be disassembled as well.

  • Page 43: Extraction Of Countershaft Support Bearing

    .12.1.2 EXTRACTION OF COUNTERSHAFT SUPPORT BEARING To extract the countershaft bearing, use the extractor A (code 3625081) together with extractor B (code 006140160000). It is re- commended to apply the two aluminium plates to be placed between the legs of the extractor and the crankcase half.

  • Page 44: Inner Oil Filter

    INNER OIL FILTER .12.2.1 The inner oil filter 1 must be pulled out from the inside of the left crankcase. Its re- moval can be aided by using a soft pin to push it from the outside towards the inside, tapping with a small hammer.

  • Page 45: Engine Assembly And Controls

    ENGINE ASSEMBLY AND CONTROLS Before reassembling the eng ine, a series of impor 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 howe- ver recommended to refer to the periodical maintenance table.

  • Page 46: Crankcase Halves

    CRANKCASE HALVES The crankcase halves have some elements that need to have their integrity and use status checked. Hereafter the controls and assembly operations of the individual ele- EXPLODED VIEW OF ENGINE CRANKCASE HALF ments coupled to the crankcase halves will be described.

  • Page 47: External Right Side

    EXTERNAL RIGHT SIDE .1.1 Pull out the crankshaft oil seal 1 and repla- ce 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.
  • Page 48 Keeping the tightener on the lever 25 facing towards the crankcase half, apply the spacer 27 onto it, by inserting the smaller diame- ter segment 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 screw 29 M6x20 who- se threading must be spread with medium...

  • Page 49: Insertion Of Oil Seal And Countershaft Support Bearing

    INSERTION OF OIL SEAL AND .1.1.1 COUNTERSHAFT SUPPORT BEARING In order to insert the oil seal and counter- shaft support bearing proceed as follows. Grease the oil seal and bearing housing. In- sert the new oil seal 1 greasing the inside of it.

  • Page 50: Internal Right Side

    INTERNAL RIGHT SIDE .1.2 Check the flatness of the crankshaft bearing retaining plate 1, of the mainshaft bearing retaining plate 2 and of the secondary shaft bearing retaining plate 3. The table below carries the indications for application of the fixing screws of these pla- tes and for fixing the desmodromic device support bearing.

  • Page 51: External Left Side

    Make sure the piston oil jets 7 are positio- ned correctly and free of obstructions. Make sure the O-rings 8 are positioned correctly, checking their status. Should the O-rings have cracks or deformations, they must be replaced. Piston oil jet O-ring and detail of passage hole. EXTERNAL LEFT SIDE .1.3 Make sure the calibrated screw 1 and the jet 2...

  • Page 52: Internal Left Side

    INTERNAL LEFT SIDE .1.4 Clean the inner filter thoroughly and check the integrity both of the wire metal and the hoo- king device. Should the filter be deteriorated in any of these parts, replace it. Locking devices Check the state of the two crankshaft bea- ring retaining plates 1.
  • Page 53 CHECKING CRANKSHAFT AND CONNECTING ROD After having checked the state of wear of the coupling surfaces, check the offset of the half shaft axes by placing the crankshaft in between two tailstocks or similar instru- ment. Control the maximum measurement variation during a complete turn, using comparators positioned on the coupling surfaces with the crankshaft bearings.
  • Page 54 Make sure that the chain control gear is free of chipping or signs of abnormal wear. Re- place the crankshaft should it be deteriora- ted. The distance between the two opposite si- des of the half shafts must be: 63mm±0,05 (350cc) 65mm±0,05 (400cc, 450cc, 498cc) 63mm±0,05 (350cc) 65mm±0,05...
  • Page 55 Use a bore meter to check the inside diame- ter of the connecting rod foot which must not exceed the following service limit: limite di servizio 18,04mm (350cc) 20,03mm (400cc, 450cc, 498cc) Remember that the measurement must be made placing the axis of the feeler in paral- lel with the axis of the connecting rod.

  • Page 56: Checking Gearbox Unit

    GEARBOX UNIT: CONTROLS AND REASSEMBLY The gearbox unit is made up of the gear- shift and of the gearbox itself. The gearshift is then divided into external and internal gearshift. The following are the verifications and pro- cedures for checking and reassembling the- se units to the engine.

  • Page 57: Primary Unit Assembly

    PRIMARY UNIT ASSEMBLY .4.2 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 down- wards. 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 58: Secondary Unit Assembly

    SECONDARY UNIT ASSEMBLY .4.3 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 pro- tective jaws), so that the grooved end faces downwards. EXPLODED VIEW OF SECONDARY UNIT Insert onto the lower cylinder part: the rol- ler cage 15, the 2nd gear (19) (so that the 4) Thrust washer;...
  • Page 59 CHECKING THE FORKS, FORK .4.4 PINS AND DESMODROMIC DEVICE The internal gearshift is made up of: • two forks 13 which drive two gears on the secondary unit; • one fork 14 which drives one gear on the primary unit; •...
  • Page 60 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...
  • Page 61 ASSEMBLY OF INTERNAL GEARBOX AND GEARSHIFT Insert the entire primary 1 and secondary unit 2 into the respective seats on the left cran- kcase half simultaneously. Remember to oil the gears abundantly with gear oil and to gre- ase the shafts supporting them in the areas where they are coupled with the bearing with graphitic grease.
  • Page 62 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 primary unit, while the other two (6) drive the sliding 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 devi-...
  • Page 63 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 de- smodromic device abundantly with gear oil.

  • Page 64: 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 hou- sings and that the crankcase half is not upsi- de-down. To facilitate progressive nearing and aligning of the two crankcase halves, connect two screws on opposite sides and tighten them bit by bit.

  • Page 65: Side Of The Crankshaft

    BLOCKING THE CRANKSHAFT AT THE TOP DEAD CENTRE AND TIGHTENING THE NUT ON THE LEFT SIDE OF THE CRANKSHAFT In order to block the crankshaft at the Top Dead Centre, the specific conical-end screw 38 (or tool 006140110 000) must be intro- duced in its seat on the right crankcase half without applying the washer 37.

  • Page 66: 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 ab- normal wear or meshing, the gearshift drive shaft needs more in-depth inspections. CHECKING THE COMPLETE .8.1 DRIVE SHAFT With the device complete, make sure that...
  • Page 67 EXPLODED VIEW OF GEARSHIFT For reassembly, couple the movable pawl 9 5) Thrust washer 14x30x1; to the drive shaft 10 and, while compressing 6) Gearshift return spring; it, insert the spring 8 between the mova- 7) Spring guide; ble pawl and the drive shaft. Then apply the 8) Pawl return spring;...

  • Page 68: Kick Starter

    ASSEMBLY OF EXTERNAL GEAR- .8.2 SHIFT 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 desmodromic gearshift (external right cran- kcase). The stop cam has only one correct position which is determined by the parti- cular shape of the end of the desmodromic device and of the bottom part of the stop...
  • Page 69 EXPLODED VIEW OF COMPLETE KICKSTART SHAFT Widen the circlip 10, thus slipping off the washer 11, and the kickstart gear 2 as well 2) Kickstart gear; the roller bearing 12 and the washer 11. 3) Kickstart shaft; 8) Kickstart return spring; This frees the kickstart shaft 3 from all other 9) Kickstart spacer;...
  • Page 70 ASSEMBLY OF KICKSTART .9.2 DEVICE Insert the complete kickstart shaft in its housing keeping the thin-striped facing ou- twards and making sure that the ramp A on the kickstart sleeve is positioned below the ramp B bolted onto the right crankcase (ex- ternal side).

  • Page 71: Checking Electrical Starter Device Elements

    ELECTRICAL STARTER UNIT AND MAIN GEAR Carry out the following controls before as- sembly. CHECKING ELECTRICAL STARTER .10.1 DEVICE ELEMENTS Make sure that the teeth of all the gearwhe- els of the device are intact, free from chip- ping or signs or abnormal wear. Idler wheel 1.
  • Page 72 COUPLING IGNITION AND PRI- .10.2 MARY 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 cran- kshaft.
  • Page 73 Grease the two pins D and E with graphitic 10Nm grease. Couple the idler wheel 7 to the pin D and apply the circlip 8. Couple the torque limiter 4 to the pin E turning the gearwheel with the smaller dia- meter towards the crankcase half.
  • Page 74 OIL PUMPS: CONTROL AND REASSEMBLY As shown in paragraph 1.5, the motor is equipped with two oil pumps: one is the low pressure (suction) pump (higher displa- cement) located in the outside of the left crankcase half and the other high-pressure pump (lower displacement) located on the outside of the right crankcase half.
  • Page 75 Should the sliding surfaces with the rotors pre- sent 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 ro- tor and the crankcase, proceed as follows: Insert the two rotors in their specific seat with the reference dot facing the inside of the engine.
  • Page 76 ASSEMBLY OF LOW PRESSURE .11.1 PUMP Insert the internal rotor 1 on the shaft 2 so that the dot on the face of the rotor faces in- wards. Then insert the roller 3 on the shaft. Shaft, low pressure pump, internal rotor and roller unit.
  • Page 77 ASSEMBLY OF HIGH-PRESSURE .11.2 PUMP AND CONTROL GEAR Lubricate the area where the pump is hou- sed (outside right crankcase half), and in- sert the roller in its hole 1. Then insert the internal rotor 2 and the external rotor 3, making sure to position them with the re- ference dot facing the inside of the engine.
  • Page 78 CHECKING AND ASSEMBLY OF .11.4 OIL PUMPS CONTROL GEARS The oil pumps are controlled by a gear ca- scade driven by the clutch gear. The gearwheels, being made of plastic, must not have chips, grains or signs of abnormal wear. Should the pins 1 and 2 which support the two pump control idler wheels be disassem- bled, they must be refastened to the cran-...

  • Page 79: Paper Oil Filter Insertion

    PAPER OIL FILTER INSERTION .11.5 Lubricate the rubber gasket on the filter. In- sert 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.
  • Page 80 CHECKING AND COUPLING .11.6 COUNTERSHAFT Check the state of use of the areas where the shaft rests on the bearing. Should they EXPLODED VIEW OF COUNTERSHAFT show signs of abnormal wear, have the shaft replaced. Make sure that the toothed seg- 1) Shaft;...
  • Page 81 While keeping the countershaft in place, in- sert the counterweight on the left side de- pending 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 th- 50Nm readlocker on their threading.

  • Page 82: Clutch Unit

    CLUTCH UNIT Before reassembling the clutch unit, carry out some controls on the various compo- nents described below. CHECKING CLUTCH BASKET, .12.1 ROLLER BEARING AND INTERNAL 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 83: Checking Clutch Discs

    Check the state of use of the silent-blocks as follows. Clamp the gear B intended to mesh with kickstart idler gear, using protec- tive elements. 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 abnormal wear.

  • Page 84: Checking Springs

    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 gre- ater than: allowable distortion steel discs: 0.10mm...

  • Page 85: Assembly Of Clutch Unit

    CHECKING THRUST BEARING .12.5 DEVICE Check the state of use of the thrust bearing and the surfaces upon which it rests. In or- der 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 86 To unscrew the nut 8, the inner hub must be blocked with a relevant tool A (code 0061400400); the tightening torque is fi- xed at 120Nm after having applied medium strength threadlocker. Having tightened the nut, bend to two blo- cking flaps on the safety plate.
  • Page 87 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 hydrau- 10Nm lic actuator 6 the M6x30 screw 7 and the two M6x20 screws 8 to the left crankcase half.

  • Page 88: Coolant Pump

    COOLANT PUMP The water pump must guarantee, depending on EXPLODED VIEW OF WATER PUMP the set rotation speed, the correct flow rate of the 1) Drive shaft coolant in order to extract the needed amount of 2) O-ring 5.5x1; heat from the thermal unit. 3) Bearing 10x19x5;...

  • Page 89: Assembly Of Pump Unit

    ASSEMBLY OF PUMP UNIT .13.2 Heat the concerned area to couple the bearings 3 to the inner clutch cover. They must be pu- shed until they are flush with the shoulders on the pump body. Bordo più Grease the oil seal housing. Position the oil seal spesso 4 so that the thicker edge faces the outside of the cover.
  • Page 90 ASSEMBLY OF 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 cran- kcase half and turn the water pump impeller un- til the pump shaft inserts perfectly in the housing...
  • Page 91 Couple the water pump cover to the inner 10Nm clutch 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.

  • Page 92: Ignition System

    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.

  • Page 93: Checking Ignition System

    CHECKING IGNITION SYSTEM .16.1 Degrease the various elements and carry on with the controls. The main control is the one concerning the elec- trical verification which can be done by using a standard tester. The resistance values detected at the terminal heads must respect those carried in the table (at 20°C).
  • Page 94 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 threadlocker. Tighten the nut at a torque of 60Nm.
  • Page 95 Reposition the plate 5 which must be inserted in the relevant guides and pressed towards the outside of the cover. When coupling it to the left crankcase half, apply a drop of gasket paste (code 3625000000) in the two zones B, in order to ensure perfect sea- ling between the cover and the crankcase half in the concerned zone.

  • Page 96: Thermal Unit

    Notice that a 12x6.3x1 copper washer 4 must be 10Nm applied to the screw. Tighten the screws at a torque of 10Nm. Flywheel cover coupled to crankcase. THERMAL UNIT Before assembling the thermal unit, thorough controls must be carried out on the cylinder, pi- ston, pin bolt, piston rings, cylinder head and the timing unit described hereafter.
  • Page 97 Check the size of the pin bolt seat located on the piston and the size of the pin bolt. This last con- trol 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]...

  • Page 98: Checking The Cylinder

    CHECKING THE CYLINDER .17.2 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 cylin- der and cylinder head). To measure it correctly, it must be done according to the X and Y di- rections orthogonal between them.

  • Page 99: Lubrication Jets And Centring Pins

    CYLINDER HEAD: DISASSEM- .17.3 BLY AND CHECKING AUXILIARY DEVICES Before disassembling the cylinder head, cle- an 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 in- spection of the cylinder head.

  • Page 100: Finger Follower/Shafts Unit

    .17.3.2 FINGER FOLLOWER/SHAFTS UNIT Disassemble the two caps 1 which keep the fin- ger follower 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 betwe- en the caps and the cylinder head.
  • Page 101 SHIMS (CALIBRATED DISCS) FOR .17.3.3 VALVE PLAY ADJUSTMENT Using a magnet, pull out the calibrated discs 1 from the seats in the cups. Once the calibrated discs are extracted, me- asure 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 ta- ble below.

  • Page 102: Cylinder Head

    .17.4 CYLINDER HEAD: DISASSEMBLING 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.

  • Page 103: Springs

    SPRINGS .17.4.1 Each valve is retained by a spring. The leng- th of these springs must be checked while they are loose: service limit = 42,5mm Should the springs be shorter, have them replaced. Measuring length of free spring. VALVE GUIDES, VALVES .17.4.2 AND SEATS Make sure that the valve guides are free...
  • Page 104 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 mm. The contact zone can principally take on three different appearances, as shown in the figure: A - correct;...

  • Page 105: Valve Stem Seal And Lower Stop Washer

    VALVE STEM SEAL AND LOWER .17.4.3 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, inten- ded to prevent excess oil leakage. It is recommended to replace them every time the cylinder head is overhauled.

  • Page 106: Checking Camshafts

    CHECKING CAMSHAFTS .17.6 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 hydrody- namic support bearing.
  • Page 107 Make sure that the cylinder segment D of the decompressor is not worn or chipped. Should it be deteriorated, replace the de- compressor shaft. In order to extract it, re- move the Benzing ring 4 and pull the shaft out. Operate inversely to reassemble it. If replacing the decompressor shaft, replace the Benzing ring as well.
  • Page 108 CYLINDER HEAD: INSERTION OF .17.8 INNER CUP AND VALVE STEM SEAL If the lower cups and valve stem seals were disassembled*, 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.
  • Page 109 CYLINDER HEAD: ASSEMBLY OF .17.9 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: •...

  • Page 110: Followers And Coupling The Spark Plug

    CYLINDER HEAD: .17.10 REPOSITIONING CALIBRATED DISCS, ASSEMBLY OF FINGER FOLLOWER SHAFTS AND FINGER FOLLOWERS AND COUPLING THE SPARK PLUG Clamp the cylinder head using protective jaws, gripping it at the head connection A. Put the calibrated discs 1 back in place in their original positions (if not deteriorated see par.1.17.3.3).
  • Page 111 CYLINDER HEAD: INSERTION OF .17.11 OIL JETS, CENTRING 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.
  • Page 112 PISTON: APPLICATION OF PI- .17.12 STON 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 over- lap.
  • Page 113 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 piston. Application of circlip 5 to piston.
  • Page 114 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 purpose, make sure that the upper edge C of the band is perfectly aligned with the contact surface of the cylinder.

  • Page 115: Application Of Piston-Cylinder Coupling To Crankcase

    .17.14 APPLICATION OF PISTON-CYLIN- DER COUPLING TO CRANKCASE Apply a new piston-cylinder gasket 1 to the crankcase and couple the two centring bushes to the left crankcase 2. Lubricate the foot of the connecting rod abun- dantly with motor oil. Application of cylinder/crankcase gasket and of cen- tring bushes.
  • Page 116 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...

  • Page 117: Coupling Head To Cylinder

    Apply to the cylinder the two guide bushes 4 and the gasket 5 coupling with the cylin- der head. Application of guide bushes 4 and gasket 5 to cylinder. COUPLING HEAD TO CYLINDER .17.15 Introduce the timing chain in the compart- ment on the cylinder head.
  • Page 118 COUPLING CAMSHAFTS TO .17.16 CYLINDER HEAD AND PHASING Couple the bearings to the camshafts and lu- bricate 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 reference notches A are horizontal with the cams facing upwards according to the appro-...
  • Page 119 Lift the chain again and insert the intake camshaft placing the chain on the gearwhe- el. Place the shaft so that the cams face up- wards according to the approximate direc- tion D and the references E carved on the gear are horizontal.
  • Page 120 Lubricate the entire camshaft unit with mo- tor 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 1.17.11). 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 remaining holes.

  • Page 121: Valve Play

    Tighten the seven screws by hand until they are flush. Check the correct position of the camshaft bearings once more (page 116). 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.
  • Page 122 Check valve play Couple the hydraulic Is the valve play tensioner to the correct? engine (par 2.17.18) Is the hydraulic Disassemble the tensioner coupled to camshaft support the engine? (par 1.1.1) Disassemble the tensioner (par 1.1.1) Incorrect play on intake side? First dissemble the intake Disassemble only the camshaft and then the...
  • Page 123 CHECKING AND COUPLING OF .17.18 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 ab- normal meshing. 1 mm Insert the piston into the support and push it until it sticks out of the edge of the support by approximately 1 millimetre.
  • Page 124 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 125 COUPLING CYLINDER HEAD .17.19 COVER GASKETS AND CYLINDER HEAD COVER Apply the spark plug gasket 1 to the camshaft support inserting the two pegs A in the spe- cific seats and positioning it so that it reco- pies the shape on the support. Application of spark plug gasket.

  • Page 126: Releasing Crankshaft

    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.

  • Page 127: Coupling Oil Caps

    COUPLING OIL CAPS Couple the motor oil plug 24 with the O-ring 25 in the bottom part of the right crankcase half. Before inserting it in the drain hole, ap- ply the wire metal filter 27 with the O-ring 26. Tighten at a torque of 25Nm. Apply the magnetic screw 28 with the O-ring 29 to the gear oil drain hole: tighten at a torque of 20Nm.

  • Page 128: Coupling Gearshift Lever

    COUPLING GEARSHIFT LEVER Couple the gearshift lever to the drive shaft by positioning it so that the part A of the le- ver coincides with the upper edge of the oil level inspection window. Tighten the screw 1 at a torque of 10Nm af- ter having applied medium strength threa- dlocker.

  • Page 129: Table Of Tightening Torques Of Engine Components

    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 130 Threading Torque Fixing diameter x length Quantity Threadlocker Notes [Nm] [mm] Engine lubrication Loctite 243/ Oil pump covers M5 x 10 Sichel 100M Loctite 243/ Chain oil jet M5 x 12 Sichel 100M Oil pump control idler Loctite 243/ M5 x 20 gears support pins Sichel 100M Oil pressure control...

  • Page 131: Engine/Frame Table Of Tightening Torques

    Threading Torque Fixing diameter x Quantity Threadlocker Notes [Nm] length [mm] Cylinder head Finger follower shaft caps Lubricate threading Cylinder head 40 55 and washers. Follow a criss-cross pattern Cylinder head Follow a criss-cross Camshaft support M7 x 38 8 10 pattern Follow a criss-cross Camshaft support...

  • Page 132: Recommended Engine Maintenance

    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.
  • Page 133 NOTE:...

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Enduro rr450 2013Enduro rr400 2013Enduro rr498 2013

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