Beta Motorcycles RR 125 2T MY 2018 Workshop Manual
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Beta Motorcycles RR 125 2T MY 2018 Workshop Manual

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125 2T
200 2T
WORKSHOP MANUAL

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Summary of Contents for Beta Motorcycles RR 125 2T MY 2018

  • Page 1 125 2T 200 2T WORKSHOP MANUAL...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 2.8.3 INTERNAL GEARSHIFT UNIT AND COMPLETE GEARBOX ..................43 DISASSEMBLY OF PARTS FROM CRANKCASES ..44 2.9.1 RIGHT CRANKCASE HALF ............45 2.9.2 LEFT CRANKCASE HALF ............. 47 ENGINE CHECKS AND ASSEMBLY CRANKCASE HALF............48 3.1.1 APPLICATION OF RIGHT CRANKCASE HALF PARTS ..49 3.1.2 APPLICATION OF LEFT CRANKCASE HALF PARTS ...
  • Page 3 TABLE OF CONTENTS 3.13.1 CHECK OF THE PISTON AND ELASTIC BANDS ..... 100 3.13.2 CYLINDER CHECK ..............101 3.13.3 PISTON CYLINDER COUPLING PLAY ......... 102 3.13.4 EXHAUST VALVE UNIT DISASSEMBLY AND CHECKS ... 102 3.13.5 EXHAUST VALVE UNIT ASSEMBLY ........105 3.13.6 PISTON, ELASTIC BANDS, PIN BOLT AND CYLINDER ASSEMBLY ...................

  • Page 4: Introduction

    www.betamotor.com INTRODUCTION This publication is intended for workshops specialised in repairing motorbikes and motorcycles. Where prescribed, use special Betamotor tools. Use Betamotor spare parts only. For their codes refer to the spare parts manual for the specific vehicle or version. The warranty and liability on vehicle safety lapses when maintenance or repair: •...
  • Page 5 www.betamotor.com • Coolant liquid The coolant contains dangerous substances that are harmful for the environment. In order • In some situations, the ethylene glycol con- to change it one must be equipped for disposal tained in the coolant is flammable and its flame in compliance with applicable laws.
  • Page 6 www.betamotor.com ENGINE TECHNICAL SPECIFICATIONS CHARACTERISTIC DATA ENGINE RR125 / RR125 Racing RR200 Bore [mm]/Stroke [mm] 54 x 54.5 62 x 63 Displacement [cm³] 124.8 13,6:1 Compression ratio 15:1 TRANSMISSION RR125 / RR125 Racing / RR200 Primary 23/73 1st gear ratio 12/33 15/31 2nd gear ratio...

  • Page 7: Special Equipment

    www.betamotor.com SPECIAL EQUIPMENT Symbols Crankcase uncoupler code 007.14.010.80.00 Clutch blocking tool code 035.14.000.80.00 Primary blocking tool code 035.14.006.50.00 Value Crankcase/Cylinder gasket check plate RR125 code 007.44.010.00.00 Tightening torque Crankcase/Cylinder gasket check plate RR200 code 035.14.009.00.00 Flywheel blocking tool code 026.14.005.50.00 Flywheel extractor code 36.25173.000 Special wrench code 026.44.029.00.00 Threadlocker...

  • Page 8: Engine Removal From Vehicle

    ENGINE REMOVAL FROM VEHICLE • Carefully wash the vehicle; • Remove the engine guard plate; • Place the vehicle on an adequate stand • Disconnect the tank ventilation pipe. • Set the fuel valve to OFF and disconnect the fuel pipe from the valve. •...
  • Page 9 • Remove the frame guards 3 (one on each side) and the pinion guard 4. • Remove the circlip 5 and extract the pinion. Rest the chain against the upper wedge 6 • Remove the screws 7 and the side panel8. •...
  • Page 10 • Drain the cooling system through screw 10 and let the liquid outflow into a container (the cooling circuit contains 1.3l of liquid). Remove the radiator cap. • Disconnect the water pipes from the engine. • Disconnect the spark plug cap, discon- nect the engine electrical system connec- tors from the central system.
  • Page 11 • ONLY RR200 Remove the start motor cable fixing nut. • • Pull the clutch lever and hold it in position, Pull the clutch lever and hold it in position, for example by using a plastic clamp. for example by using a plastic clamp. •...
  • Page 12 ATTENTION! The clutch fluid is highly corrosive, therefore be careful not to drop any of it on the painted parts of the vehi- cle. Protective gloves must be worn to perform this operation. WARNING! Do not bring the liquid in contact with skin, eyes or clothing.
  • Page 13 • ONLY RR 200 Pull out the mixer tube 13 from the intake manifold and tube hold 14. WARNING! When the mixer tube has been disconnected, plug it to prevent emptying. • Loosen the carburettor straps from the air fil- ter sleeve and from the manifold.
  • Page 14 • Remove the subframe lower fixing screws 15 (one on each side) and loosen the upper screws 16 (one on each side). • Rotate the entire filter box unit. • Remove the straps binding the electrical wir- ing to the frame. •...
  • Page 15 • Remove the swingarm pin 17 and the upper shock-absorber pin 18. • Remove the engine pins 19. • Extract the engine from the frame and apply it to the specific stand code 36.25132.000 using the specific front fixing bracket code 035.14.008.80.00.

  • Page 16: Engine Disassembly

    ENGINE DISASSEMBLY Secure the eng ine to the specific suppor t stand code 36 25132000 by means of front fixing 035.14.00 8.8 0.00, in order to work in comfor t and safety. Then proceed as follows. CLUTCH/GEAR OIL DRAIN Remove screw 1 and let the oil drain. REMOVAL OF PINION SPACER Take out the spacer 1.

  • Page 17: Removal Of Piston, Cylinder And Head

    REMOVAL OF PISTON, CYL- INDER AND HEAD Remove the spark plug 1 and the spigot screws 2 together with the copper washers. Remove the head and the two O-rings. Remove the three screws 3 and cover 4. Release the lock 5 and remove it.
  • Page 18 Release the control rod 6. Remove the gasket 7. It may be necessary to slightly force the rubber gasket 8; place a metal pin A between the lever and the gasket 8 and slightly force it outwards. Removal of gasket 7. Remove the four collar nuts 9.
  • Page 19 ATTENTION! Place a clean cloth between the piston and the crankcase to keep foreign objects or simple solid residue from falling inside the base. Using a suitable tool to insert the specific seat A, remove the elastic ring 10. Removal of piston circlip. Remove the pin bolt using a universal extractor for pin bolts.

  • Page 20: Removal Of Ignition Unit

    REMOVAL IGNITION UNIT The ignition unit is made up of the flywheel (or rotor), the pick-up unit and the stator, which is one with the flywheel cover. 2.4.1 Flywheel cover plate re- moval Remove the plastic straps that join the stator and pick-up wiring.

  • Page 21: Stator Removal

    2.4.2 Stator removal Remove the two screws 1 fixing the stator 2 to the flywheel cover 3. Extract the plate 4 and the cable gland 5 from the cover and take out the stator. Disassembly of stator from cover. 2.4.3 Flywheel removal Block the flywheel using special tool A (code 026140040000) and remove the fastening nut...

  • Page 22: Pick-Up Unit Removal

    2.4.4 Removal of pick-up unit Remove pick up 1 by loosening the two fixing screws 2. Pick-up removal.

  • Page 23: Removal Of Electric Ignition - Only Rr200

    REMOVAL OF ELECTRIC IG- NITION - ONLY RR200 The electric ignition is carried out by means of start motor 1 that meshes on the bendix coupling 4. The coupling gear axially shifts and meshes onto the ring gear, which is one with the flywheel, due to the start motor rotation.

  • Page 24: Start Motor Removal

    2.5.1 Removal of start motor Remove the two screws 1and extract the motor. 2.5.2 Bendix coupling removal Extract the Bendix coupling 1 once the complete flywheel cover and flywheel have been removed (see par. 2.4).

  • Page 25: Removal Of Coolant Liquid Pump, Clutch Unit, Primary Gear, Centrifugal Unit, 3.9 Gearshift Parts, Kickstarter

    REMOVAL COOLANT LIQUID PUMP, CLUTCH UNIT, MAIN GEAR, CEN- TRIFUGAL UNIT, GEAR- SHIFT ORGANS, KICK- START Remove the cover 1 by loosening the four screws 2, to access the coolant liquid pump. Note: remove the coolant liquid pump impeller if having to intervene on the centrifugal unit.
  • Page 26 Remove the outer clutch cover 3 by loosening the four screws 4 to access the clutch unit only. Outer clutch cover screws.
  • Page 27 When doing a complete overhaul of the engine or of gearshift organs, kickstart, primary transmission or centrifugal unit, the inner clutch cover 5 must be removed by loosening the nine screws 6 after draining the gearbox oil (Par.2.1). Inner clutch cover screws.
  • Page 28 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 inner clutch cover coupling.

  • Page 29: Removal Of Coolant Liquid Pump

    2.6.1 Cooling liquid pump removal Loosen fixing screw 1 once the coolant liquid pump cover has been removed (Par.2.6). Cooling pump fixing screw. Extract the impeller 2 and the thrust washer 3. Removal of impeller. Extract the complete pump body 4 and remove gasket 5.

  • Page 30: Removal Of Centrifugal Unit And Linkage

    2.6.2 Removal of centrifugal unit and leverage Access the centrifugal unit and linkage by removing the inner clutch cover. Disassemble the adjustment cover 1 by removing the two screws 2, once the pump impeller has been removed (par. 2.6.1). Removal of centrifugal adjustment cover. Remove the assembly consisting of adjusting springs 3, auxiliary springs 4 and spring guide 5.
  • Page 31 Extract the centrifugal control lever 7 together with the two thrust washers 9. Removal of centrifugal control lever. Extract the complete centrifugal unit 10. Extraction of centrifugal unit.
  • Page 32 1) Adjustment cover; 3) Adjusting spring; 4) Auxiliary spring; 5) Spring guide; 6) Rocker arm; 7) Centrifugal control lever; 8) Gasket; 9) Thrust washers; 10) Centrifugal unit.

  • Page 33: Clutch Disassembly And Removal

    2.6.3 Clutch disassembly and re- moval Remove the clutch coupling plate 1 together with the thrusting bearing 2. Block the entire clutch unit using the special tool A (Cod. 035.14.000.80.00) as shown in the figure and loosen the clutch locking nut. Remove the clutch locking nut 3.
  • Page 34 Remove the roller cage 4 and the centre bearing 5. 1) Clutch coupling plate; 2) Thrusting bearing; 3) Clutch locking nut; 4) Roller bearing; 5) Centre bearing; 6) Schnorr washer; 7) Washer.

  • Page 35: 2.6.3.1 Clutch Disassembly

    2.6.3.1 Clutch disassembly Block the clutch case using the soft jaws vice. Progressively loosen the screws 1 until they are disengaged from their seat. Remove the spring plate 2 and the springs 3. Remove the clutch hub 4 and the washer 5.
  • Page 36 Remove the disc thrust plate 6 together with the disc unit 7. After extracting these last parts, the bare clutch case 8 remains. The entire clutch unit is disassembled. 1) Screws; 2) Spring plate; 3) Springs; 4) Hub; 5) Washer; 6) Pressure plate;...
  • Page 37 Note: if you want to check the wear of the case only, you can disengage it from the clutch pack 9 by simply lifting the clutch pack.

  • Page 38: 2.6.3.2 Clutch Actuator Disassembly

    2.6.3.2 Clutch actuator disassembly To disassemble the clutch actuator, simply blow compressed air from the clutch connection duct A. ATTENTION! During this phase, hold the piston with one hand to allow its slow re- lease. ATTENTION! The clutch fluid is highly corrosive, therefore be careful not to drop any of it on the painted parts of the vehi- cle.

  • Page 39: Primary Pinion Removal

    2.6.4 Primary pinion removal After removing the entire clutch unit (Par. 2.6.3), apply the special tool A (code 035.14.006.50.00) as shown in the figure. Loosen the primary pinion nut by turning clockwise. Remove the pinion 1. Removal can be facilitated by using a universal extractor.

  • Page 40: Pedal Kickstarter - Optional Rr200

    2.6.5 Pedal kickstarter - OP- TIONAL RR200 The kickstarter is made up of the pedal which, attached to the kickstarter shaft 1, moves the gear 2. This gear moves the idler wheel 3, which engages in its turn with the clutch case. The device recoils thanks to the spring 4.
  • Page 41 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 42: External Gearshift Unit

    2.6.6 External gearshift unit The external gearshift consists of the drive shaft 1 on which the movable and fixed pawls are applied. The fixed pawl is the guide of the movable pawl, which has the task of engaging the stop cam 2. In its turn, this is fastened to the internal gearshift and is kept in the fixed position by the cam stop lever.

  • Page 43: Intake System

    INTAKE SYSTEM The intake system mainly consists of the intake manifold 1 and reed valve 2 and the spacer 3. 1) Intake manifold; 2) Complete reed valve; 3) Spacer. Disassemble by removing the four screws 4 fastening the intake manifold and the reed valve to the crankcases.

  • Page 44: Crankshaft, Gearbox Unit And Internal Gearshift

    CRANKSHAFT, GEARBOX UNIT AND INTERNAL GEARSHIFT To access the crankshaft, gearbox unit and internal gearshift, the left and right crankcases must be detached. Below are the required instructions. 2.8.1 Opening the crankcase Remove the twelve screws 1 fastening the crankcases. ATTENTION! Loosen the two screws A fixing to the equipment.

  • Page 45: Crankshaft

    2.8.2 Crankshaft The crankshaft 1 can be pulled out manually. Gently hit the right end of the crankshaft in case of resistance. Removal of crankshaft. 2.8.3 Internal gearshift unit and complete gearbox The internal gearshift unit is made up of the desmodromic device 1 on which the fork 2 and two forks 3 are engaged.

  • Page 46: Disassembly Of Parts From Crankcases

    Extract the forks together with the guide bushes 5. Note: it is recommended to mark the two forks that act on the secondary so that they can be repositioned in their original position in case it is not necessary to replace them or sliding gears.

  • Page 47: Right Crankcase Half

    2.9.1 Right crankcase half On the external side, remove the kickstart ramp 1 and the oil seal 2. Kickstart ramp 1), oil seal 2). Remove the desmodromic control bearing seal screw 3, the screws 4 and the relative primary bearing seal plates 5 from the inner side.
  • Page 48 All bearings shown in the figure are removed from the outside to the inside. Where necessary, removing the safety devices 3 and 4 seen above. The centrifugal shaft bearing can be removed by using a universal extractor that must rest onto a purposely created metal plate.

  • Page 49: Left Crankcase Half

    2.9.2 Left crankcase half Remove the crankshaft oil seal 1, the secondary shaft oil seal 2, the gearshift shaft oil seal 3 and the bush 4 from the external side. Removal of outer side left crankcase half details. The bearings 5, 6, 7 and 8 are removed from the outside to the inside.

  • Page 50: Engine Checks And Assembly

    ENGINE CHECKS AND ASSEMBLY Before reassembling the engine, a series of crucial checks must be carried out to ensure the engine is in good working order. In order to insert the bearings in the crankcase halves, bring the crankcase halves to a temperature of 150°C and keep them at that temperature for 20 minutes.

  • Page 51: Application Of Right Crankcase Half Parts

    3.1.1 Application of right crank- case half parts 20Nm Apply the bearings 1, 2, 3 and 4 until flush. Block the bearings 2 and 4 using the specific safety devices. Apply the high-resistance threadlocker threads and tighten the screws to the indicated torques.
  • Page 52 Apply the bearing 6 and insert it so that the outer surface is aligned with surface A. Apply new oil seals, to be pressed in seat until they are flush. Position of right crankcase half gearshift shaft bearing. Apply the kickstart ramp 7 and fasten screws 8 to the torque indicated, prior depositing of medium resistance threadlocker.

  • Page 53: Application Of Left Crankcase Half Parts

    3.1.2 Special applications left crankcase half Apply the bearings 1, 2, 3 and 4 from the crankcase half internal side, until flush. Apply the cap 5 (ONLY RR125). Application of left crankcase half bearings. Apply the new oil seals 6, 7 and 8 from the crankcase half external side, until flush.

  • Page 54: Connecting Rod And Engine Shaft Check

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

  • Page 55: Assembly Of Complete Crankshaft

    ASSEMBLY OF COMPLETE CRANKSHAFT When all the aforementioned checks have been carried out and the worn parts replaced, grease the crankshaft oil seal on the right crankcase half and couple the crankshaft to the left crankcase half. Keep the conical part A on the crankshaft facing you. In order to carry out this operation, you must just push the shaft axially towards the crankcase.

  • Page 56: Gear Unit: Checks And Reassembly

    GEAR UNIT: CHECKS AND REASSEMBLY The gearbox unit is made up of the gearshift and of the gearbox itself. The gearshift in its turn is divided into external and internal gearshift. The checks and procedures for inspecting and reassembling these units to the engine are set out below.

  • Page 57: Assembly Of Primary Unit

    3.4.2 Assembly of primary unit 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), as shown in the figure. Apply the roller bearing 2. Apply gear 3 (V gear), washer 4 and circlip 5.
  • Page 58 Apply the toothed washer 8 so that it engages in the broaching and the roller cage 9. Insert gears 10 (VI gear) and 11 (II gear). Insert washer 12.
  • Page 59 EXPLODED VIEW OF PRIMARY UNIT: 2) Gear mainshaft; 3) Roller cage 18x22x10; 4) Thrust washer 17.25.1; 5) Fifth gear on primary; 6) Second gear on primary; 7) Washer 22.28.1; 8) Circlip SW 22.1,2; 9) Washer 22.26.1; 10) Third and fourth gear on primary; 11) Sixth gear on primary.

  • Page 60: Assembly Of Secondary Unit

    3.4.3 Secondary unit assembly Before proceeding with reassembly, clean all the parts thoroughly and oil them by using gear oil. Always replace the circlips. Clamp the secondary shaft (using protective jaws), as shown in the image. Apply the roller cage 1. Insert gear 2 (II gear), washer 3 and circlip 4.
  • Page 61 Insert washer 7 and the two roller cages 8. Insert gear 9 (IV gear). Insert gear 10, washer 11 and circlip 12.
  • Page 62 Insert gear 13 (V gear) and washer 14. Insert roller cage 15 followed by gear 16 (I gear) and washer 17.
  • Page 63 EXPLODED VIEW OF SECONDARY UNIT: 1) Secondary shaft; 6) Roller cage 22x26x10; 7) Second gear on secondary; 8) Washer thickness; 9) Circlip 24 SW; 10) Sixth gear on secondary; 11) Fourth gear on secondary; 12) Third gear on secondary; 13) Fifth gear on secondary; 14) Washer thickness C72 20.30.1;...

  • Page 64: Check Of The Forks, Fork Pins And Desmodromic Device

    3.4.4 Check of the forks, fork pins and desmodromic de- vice The internal gearshift is made up of: • two gearshift forks 19 which drive two gears on the secondary unit; • one gearshift fork 20 which drives one gear on the primary unit;...
  • Page 65 Make sure the distance A between the outer faces of the fork is not less than the minimum indicated below: Minimum acceptable distance: 4.95mm 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 on which they slide have an outside diameter above the limit (to be...

  • Page 66: Assembly Of Gearbox And Inner Control

    3.4.5 Assembly of gearbox and inner control Insert the entire primary 1 and secondary unit 2 into the respective seats on the left crankcase half simultaneously. Remember to oil all components with plenty of gearbox oil. Insertion of the gearbox in the left crankcase half. Introduce the gearshift forks together with the drive bushes on the gear tracks.
  • Page 67 Position the fork 4 of the primary unit in the cen- tral guide of the desmodromic device 6, insert the fork pin inside the fork itself and insert the pin in its proper seat in the crankcase half. Place fork 4 of the primary unit in the central guide of desmodromic device 6.
  • Page 68 View inside the right crankcase with crankshaft, gearbox shafts complete with wheels, internal gearshift and gasket.

  • Page 69: Closing The Engine Crankcase

    CLOSING ENGINE CRANKCASE Apply a thin layer of grease on all oil seals. Warm up the crankshaft bearing on the left crank- case half. WARNING! Take care not to burn the oil seal. To avoid this, protect it with paper or metal buffer with an outer diameter of 24mm.

  • Page 70: 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 is free from abnormal wear or meshing, the gearshift drive shaft needs more in- depth inspections. 3.6.1 Check complete...
  • Page 71 For reassembly, couple the movable pawl 9 to the Exploded view of gearshift. 5) 14x30x1 thrust washer; drive shaft 10 and, while compressing it, insert 6) Gearshift return spring; the spring 8 between the movable pawl and the 7) Spring guide; drive shaft.

  • Page 72: Assembly Of External Gearshift

    3.6.2 Assembly of external gear- shift Apply the gear stopping device as follows. Keeping the tightener on the lever 16 facing to- wards the crankcase half, apply the spacer 15 onto it, by inserting the smaller diameter seg- ment in the lever. Apply the spring 14 so that the hook fits into the groove on the lever 16 and then apply the washers 13 and the screw 11 M6x20, spreading with medium strength threadlocker on...
  • Page 73 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 control. The stop cam has only one correct posi- tion, which is determined by the specific shape of the end of the desmodromic device and of the bottom part of the stop cam.

  • Page 74: Kickstarter Device - Optional Rr200

    KICKSTARTER DEVICE - OPTIONAL RR200 Before coupling the kickstarter to the crankcase half, some important checks must be carried out. 3.7.1 Check of starter shaft unit and assembly In order to disassemble all the parts of the kick- start shaft, pull off the washer 9 at the end of the shaft (on the side of the spring 16), the spring 16, the kickstart sleeve 14 and the lever return spring 8, which must be pulled in the radial direction so...
  • Page 75 Remove the kickstart spacer 7, expand the circlip 10, allowing removal of washer 11, of kickstart gear 2 and washer 11. This frees the kickstart shaft 3 from all other parts. Make sure that the side of the kickstart gear teeth 2 have no signs of meshing or superficial wear.

  • Page 76: Assembly Of Kickstarter Device - Optional Rr200

    3.7.2 Assembly kickstarter device - OPTIONAL RR200 Insert the complete kickstart shaft in its housing, keeping the ribbed facing outwards and making sure that the lever A on the kickstart sleeve is po- sitioned below the lever B bolted onto the right crankcase half (external side).

  • Page 77: Primary Gear And Clutch Unit

    PRIMARY GEAR CLUTCH UNIT Before reassembling the clutch unit, carry out some checks on the various components de- scribed below. 3.8.1 CHECK OF PRIMARY GEAR Check teeth of primary gear is without nicks or abnormal wear. If so, replace it. 3.8.2 PRIMARY GEAR APPLICA- TION...

  • Page 78: Check Of The Clutch Case, Roller Bearing And Internal Centre Bearing

    3.8.3 CHECK of clutch case, roll- er bearing and internal centre bearing For complete disassembly, see Par. 2.6.3. Before reassembling the clutch case, make sure that the sides of the teeth A, dedicated to main transmission and B, dedicated to meshing with the kickstart idler gear and oil pumps, have no superficial nicks or abnormal wear.

  • Page 79: Check Of Clutch Discs

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

  • Page 80: Check Of Springs

    Also check the distortion of the driven discs. This operation is carried out by placing the driven discs on a perfectly flat surface and using a thickness gauge to check that any gap between the disc and the surface is not greater than: allowable distortion driven discs: 0.10mm Measuring driven disc distortion.

  • Page 81: Check Of Thrust Bearing Device And Clutch Actuator

    3.8.7 Check of thrust bearing device and clutch actuator Check the state of use of the thrust bearing and the surfaces A and B. Thrust bearing device. In order to check the thrusting bearing, just see if it slides. When the device is assembled, simulate rotation of the front centre bearing C with respect to the rear one D.

  • Page 82: Assembly Of Clutch Unit And Clutch Actuator

    3.8.8 Assembly of clutch unit and clutch actuator Place the clutch drum as shown in the figure. Lubricate the clutch discs with gear oil and apply to the clutch drum by alternating a driving disc with a driven disc, according to the diagram in the figure.
  • Page 83 Apply pressure plate 1 so that reference A and reference B match. Overturn the assembled unit and apply springs 2, spring plate 3 and two screws M6x25 to be re- moved at a later stage: tighten the latter enough to slightly compress the springs. M6x25 Apply washer 4 as shown in the figure.
  • Page 84 Insert the assembled clutch drum unit as above, proceeding to align the teeth of the driving discs to the respective slots on the clutch case. Lubricate and apply roller bearing 5 with the cen- tre bearing to the clutch base. Insert the entire clutch unit on the secondary shaft of the gearbox.
  • Page 85 Apply the three screws M6x20 and tighten them with a cross pattern, until the spring plate is flush. M6x25 Remove the two previously applied screws M6x25 and replace them with the other two M6x20. M6x20 M6x20 M6x25 M6x20 Apply washer 7, a new Schnorr washer 21 and nut 8 after having applied the medium strength threadlocker.
  • Page 86 Keep the clutch nut blocked by using the socket or pipe wrench D and tighten the spring plate screws with a cross pattern to the indicated torque. 10Nm 10Nm Lubricate and apply the entire pressure plate unit 6.
  • Page 87 Proceed as follows to reassemble the actuator unit: • Apply a very light layer of silicone grease on the piston complete with OR; • Apply spring 1 in the cylinder and then the complete piston 2; • Push the piston inside the cylinder.

  • Page 88: Coolant Liquid Pump And Centrifugal Unit

    COOLANT LIQUID PUMP AND CENTRIFUGAL UNIT The water pump must assure the correct flow rate of coolant, depending on the set rotation speed, in order to remove the required amount of heat from the power unit. The centrifugal unit activates the whole exhaust valve control linkage based on the engine rotation speed, while springs 6 and 7 EXPLODED VIEW OF CENTRIFUGAL UNIT AND WATER...

  • Page 89: Centrifugal Unit And Idler Unit

    3.9.1 Checking the pump unit and disassembly, centrifu- gal unit and idler unit Refer to par. 2.6.1 to disassemble the entire pump unit. Check oil seal condition. Replace if worn. Check centrifugal unit shaft condition. Replace the entire centrifugal unit if dented in the area in contact with the oil seal.

  • Page 90: Centrifugal Unit Assembly

    3.9.2 Centrifuge unit group as- sembly Insert the centrifugal unit in the inner clutch cov- Insertion of centrifugal unit. Insert the centrifugal control lever 10 together with the washers 8. Insertion of centrifugal control lever.
  • Page 91 Apply the valve control rod gasket and the rocker arm unit 1 - valve control rod 4. Application of valve control and rocker arm assembly. Apply locking screw 3 after applying medium strength threadlocker. Tighten to the specified torque. Centrifugal unit assembly.
  • Page 92 Apply the auxiliary 4 and adjustment 3 springs to the spring guide 5. Valve control lever and spring unit. WARNING! Auxiliary spring 4 has a variable pitch and must be assembled as shown in the figure. Apply the complete adjustment cover to the inner clutch cover.

  • Page 93: Pump Unit Assembly

    3.9.3 Pump unit assembly Thinner edge Grease the oil seal housing on the pump body 1. Position the oil seal 2 so that the thinner edge faces the outside of the pump body. Insert the oil seal, having it enter the seat very slowly to pre- vent it from deteriorating.
  • Page 94 Grease the O-rings on the water hose and insert the hose 4 in the right crankcase half. Insertion of water hose. Apply the gasket between the pump body and clutch cover. Grease the inner diameter of the oil seal on the pump body 5 and apply the body to the clutch cover.

  • Page 95: Outer Clutch Cover Coupling

    3.10 OUTER CLUTCH COVER COUPLING Check the correct insertion of the sealing O-ring 1. Ensure the presence of the centring pins 2. Apply the outer clutch cover, screws 3 and 4 and tighten, with a criss-cross pattern, to the torque indicated in the table.

  • Page 96: Electric Ignition Unit - Only Rr200

    3.11 ELECTRIC IGNITION UNIT - ONLY RR200 - Carry out the following checks before assembly. 3.11.1 Bendix coupling checks Check wear of the gearwheels found on the unit. Replace the whole coupling in case of abnormal wear and signs of chipping of the wheels. Keep wheel 1 fixed and rotate the mobile cou- pling 2 anti-clockwise;...
  • Page 97 Pour about 7cc of gear oil (for specifications refer to the recommended lubricants and liquids table) in area A. Insert Bendix coupling 2 in bush with collar 3 present on the outer side left crankcase half.

  • Page 98: Ignition System

    3.12 IGNITION SYSTEM Before reassembling the ignition system, it is rec- ommended to make sure it is in good working order. The ignition system consists of the magnetic pick-up unit, the stator unit and the flywheel. The system is completed by the ignition coil and the spark plug, which are not dealt with here.

  • Page 99: Coupling Of Ignition System To Crankcase

    3.12.2 Coupling of ignition sys- tem to crankcase Apply the pick-up to the crankcase by inserting the gasket in the specific seat, prior application of the isolating silicone paste. Cover the two screws 1 with medium strength threadlocker and tighten them at the torque in- dicated.
  • Page 100 Couple the stator to the flywheel cover by means of the two screws 6. Cover the threading with me- 10Nm dium strength threadlocker and tighten them at the torque indicated. Insert the cable gland in its specific seat and check its perfect tightness. Stator coupling to the flywheel cover.
  • Page 101 Apply the flywheel cover, the three M6x20 screws 8 and the two M6x25 screws 9. Tighten in a criss- cross pattern to the torque indicated. Note: When performing a complete overhaul of the engine or intervening on the thermal unit, do not apply the cover as it has to be removed to find the Top Dead Centre.

  • Page 102: Power Unit

    3.13 POWER UNIT Before assembling the power unit, thorough checks must be carried out on the cylinder, pis- ton, pin bolt and elastic bands, described below. 3.13.1 Check of the piston and elastic bands Remove carbon sediment from the top of the pis- ton and wash the entire piston with specific de- greasing agent.

  • Page 103: Cylinder Check

    3.13.2 Cylinder check Check the cylinder is without signs of seizure. Otherwise replace it. Measure the bore at a distance A from the top face of the cylinder (surface between cylinder and head). Take the correct measurement by fol- lowing direction X. Displacement [cm³] Measurement A [mm] 125 / 125 Racing...

  • Page 104: Piston Cylinder Coupling Play

    3.13.3 Piston cylinder coupling play The following table sets out the coupling play be- tween cylinder and piston. In order to calculate the coupling play between cylinder and piston, a subtraction must be carried out between the diameter of the cylinder and that of the piston. Displace- Maximum piston cylinder play...
  • Page 105 Remove screw 7 fastening the valve control unit to the booster; then remove screw 8 fixing the bearings. Apply one control unit side M5 screw and pull externally. Repeat the operation from the opposite side us- ing one M6 screw.
  • Page 106 After extracting the boosters and related pin, ex- tract the valve pin 9 by pushing it with a metal cylinder A and then extract valve 10. Check the bearings 11 supporting the booster are efficient, without jams during functioning or ex- cessive play, once the unit has been cleaned and descaled.

  • Page 107: Exhaust Valve Unit Assembly

    3.13.5 Exhaust valve unit assem- Insert valve 1 in its seat with the back facing up- wards. Insert pin 2 while holding valve 1 in position. Apply the left side booster unit complete with pin and bearings in its seat: pin 3 must be inserted in the specific slot in the valve.
  • Page 108 Apply the right side booster unit in its seat. Apply gasket 4, cover 5 and screws 6. Tighten to the specified torque. 10Nm Apply screw 7 complete with the washer after ap- plying medium-intensity threadlocker and tighten at the specified torque. 10Nm...
  • Page 109 Apply the stroke end lever 8 on the control side. Then apply all other parts. Screw 9 must be covered with medium strength threadlocker and fastened to the indicated torque. Try moving the assembly and check the entire mechanism slides perfectly, once assembly is completed.

  • Page 110: Piston, Elastic Bands, Pin Bolt And Cylinder Assembly

    3.13.6 Piston, elastic bands, pin bolt and cylinder assembly Insert a circlip for retaining the pin bolt in one of the seats on the piston's side, placing the circlip's open part either upwards or downwards. Apply the roller cage in the connecting rod's foot, and lubricate it.
  • Page 111 Apply the gasket between crankcase and cylinder. Note: keep the silicone edge facing the crank- cases. Accurately oil the entire cylinder using engine oil and insert the piston in the cylinder. The piston must be inserted in the cylinder while holding the elastic bands with one’s fingers tightly.

  • Page 112: Check Of The Crankcase/Cylinder Gasket Thickness

    3.13.7 Check of crankcase/cylin- der gasket thickness The thickness of the gasket between the cylinder and crankcase must be checked every time the following are replaced: ∙ Cylinder; ∙ Piston; ∙ Crankshaft; ∙ Connecting rod; ∙ Crankcase. The check is necessary as said thickness affects engine performance.

  • Page 113: 3.13.8 Head Application

    Measure the play with a thickness gauge if the piston pushes the plate upwards, causing con- tact to be lost between plate and cylinder: if the play is greater than 0.025, the thickness of the cylinder/casing gasket must be increased and the check must be done again.

  • Page 114: 3.13.9 Exhaust Valve Adjustment

    3.13.9 Exhaust valve adjustment Bring the valve control unit 1 in the fully closed position, so the stroke end lever is flush with screw 2 fixing the booster bearings. Check that the ball head 3 and the seat 4 are perfectly aligned.
  • Page 115 Ensure the control rod is able to rotate around its axis, making equal angles with respect to the ball head axis. Check of control rod rotation. Apply gasket 5 and insert the control rod. Apply the stop 6. Insertion of control rod and application of stop.
  • Page 116 Intervene on screw 7 for the dynamic adjustment of the exhaust valve unit, thus modifying the char- acteristic curve of the engine. The positions indicated in the table below are those considered optimal for engine operation. Setting the adjustment Displacement [cm³] screw (from all open) 1+3/4 The "fully open"...
  • Page 117 3.13.10 Cover plate application Apply the valve control unit cover and relative screws. Tighten to the specified torque. Application and tightening of valve control unit cover screws.

  • Page 118: Check On Intake Unit And Assembly

    3.14 CHECK OF INTAKE UNIT AND ASSEMBLY Check the manifold 1 is intact and without cracks. Otherwise replace it. Check that the petals 2 of the reed valve 3 are intact and not deformed. If so, replace them. To disassemble the multiflap: -remove the flow guide;...
  • Page 119 Remove the two central wedges and remove the multiflap. Assemble the petals by following the procedure just described, in reverse order. Disassembly of central wedges. The extraction of only one is shown in figure. ATTENTION! The flow guide is asymmetrical. When reassem- bling, make sure that the flow guide, once cou- pled with the manifold, is centred.
  • Page 120 To assemble the whole intake system, apply the manifold to the reed valve, the gasket. Tighten the screws 6 to the indicated torque. 10Nm Application of reed valve. 10Nm...

  • Page 121: Insertion Of Pinion Spacer And Application Of The Oil Exhaust Cap

    3.15 INSERTION PINION SPACER APPLICA- TION OF THE OIL EXHAUST Apply the O-ring 1 on the secondary shaft of the gearbox 2, followed by spacer 3 so that the groove is facing inside the engine. Note: remember to apply grease on the oil seal. Apply the oil exhaust cap, making sure the related O-ring is present.

  • Page 122: Engine Reassembly In The Vehicle

    ENGINE REASSEMBLY IN THE VEHICLE • Insert the engine in the frame. We recom- mend insertion from the frame’s left side. • Insert the engine pins 1. • Insert the upper shock absorber pin 2 and the swingarm pin 3. Fasten the shock ab- sorber pin to the indicated torque.
  • Page 123 ∙ Apply the head connections paying attention to pass cables A, B and clutch pipe C as indi- cated in the figures.
  • Page 124 • Tighten the nuts and bolts as indicated 35Nm in the figure, applying medium strength threadlocker where indicated. 35Nm 35Nm 45Nm 45Nm 125Nm • Rotate the filter box in its normal position. Apply the lower fixing screws 4 (one each side) prior application of medium strength threadlocker and fasten to the indicated torque.
  • Page 125 • Make sure the filter box sleeve is correctly inserted inside the carburettor, fasten the two filter box side and manifold side straps. • ONLY RR200 Remove the cap applied to the mixer tube (see page 123). • Insert the tube through the tube hole 6 and connect it to the nozzle 7 on the intake manifold.
  • Page 126 • Pass the rear stop cable 8 as in the figure. • Apply the plastic clamps as indicated in the figure. Connect the connectors 9.
  • Page 127 • Apply the clutch pipe and position it as shown in the figure. Replace the two copper gaskets to be applied above and below the fitting. Ap- ply the threaded fitting and tighten to 20Nm. 20Nm ATTENTION! The clutch fluid is highly corrosive, therefore be careful not to drop any of it on the painted parts of the vehi- cle.
  • Page 128 • Secure the engine wiring as shown in the fig- ure. • Connect the engine electrical system to the central system and secure everything to the frame as shown in the figure. • Connect the coil to the spark plug. •...
  • Page 129 • Apply the Kickstart lever (Optional RR200) by positioning it as shown in the figure. Apply the medium-resistance sealant threading on the screw and fasten to the indicated torque. Apply the brake pedal return spring 10. 25Nm • Apply the exhaust expansion by first assem- bling the front springs and then applying the two fixing screws.
  • Page 130 • Apply the screws 12. • Tighten to the specified torque. • Apply the gearbox pedal and fasten the screw at 10Nm prior threadlocker application. • Insert the pinion in the chain and key it onto the gearbox outlet shaft. Assemble the rela- tive circlip 13, checking that it is in its seat.
  • Page 131 • Apply the tank making sure the gas cable is between the tank and frame. • Grease the rear fastener and tighten the screws at the indicated torque values. 10Nm 10Nm • Reconnect the tank to the carburettor and se- cure the tube using the specific tube straps.

  • Page 132: Table Of Engine Components Tightening Torques

    TABLE OF ENGINE COMPONENTS TIGHTENING TORQUES Torque Fixing Diameter x Length Quantity Threadlocker Notes [Nm] Outer side right crankcase half Medium- Kickstarter lever M6 x 20 resistance threadlocker Inner side right crankcase half High- Main shaft fixing M5 x 10 resistance threadlocker High-...
  • Page 133 TABLE OF ENGINE COMPONENTS TIGHTENING TORQUES Torque Fixing Diameter x Length Quantity Threadlocker Notes [Nm] Water pump In common Cover M6 x 60 with inner clutch cover Cover M6 x 30 Medium- Impeller M5 x 12 resistance threadlocker Exhaust valve control Medium- Flange M6 x 20...
  • Page 134 TABLE OF ENGINE COMPONENTS TIGHTENING TORQUES Torque Fixing Diameter x Length Quantity Threadlocker Notes [Nm] Intake Reed valve M6 x 25 Screw Reed valve M6 x 25 tamper- proof Oil drain...
  • Page 135 TABLE OF FRAME/ENGINE TIGHTENING TORQUES Torque Diameter x Fixing Quantity Threadlocker Notes Length [Nm] Front and lower engine M10 x 1.25 connections Swingarm pin M16 x 1.5 Medium- Head - frame connection M8 x 16 resistance bracket (front fixing) threadlocker Head - frame connection M8 x 60 bracket (rear fixing)

  • Page 136: Recommended Engine Maintenance

    RECOMMENDED ENGINE MAINTENANCE The requested engine maintenance only depends on the level of use and respect of the periodical inspections. The following intervals refer to normal use, as long as the engine has not worked in ex- traordinary conditions and that periodical inspections and interventions have been correctly carried out. Driving and driven clutch discs Clutch springs length Gearbox bearings...

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