Beta RR 125 LC Manual
  1. Manuals
  2. Brands
  3. Beta Manuals
  4. Motorcycle
  5. RR 125 LC
  6. Manual

Beta RR 125 LC Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

EAS20290
ENGINE SPECIFICATIONS
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Standard compression pressure (at sea level)
Minimum–maximum
Starting system
Fuel
Recommended fuel
Fuel tank capacity
Fuel reserve amount
Engine oil
Lubrication system
Type
Recommended engine oil grade
Engine oil quantity
Total amount
Without oil filter element replacement
With oil filter element replacement
Oil filter
Oil filter type
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Limit
Outer-rotor-to-oil-pump-housing clearance
Limit
Oil-pump-housing-to-inner-and-outer-rotor
clearance
Limit
Relief valve operating pressure
Pressure check location
ENGINE SPECIFICATIONS
Liquid cooled 4-stroke, SOHC
124.7 cm³
Forward-inclined single cylinder
52.0 × 58.6 mm (2.05 × 2.31 in)
11.20 :1
550 kPa/600 r/min (5.5 kgf/cm²/600 r/min, 78.2
psi/600 r/min)
480–620 kPa (4.8–6.2 kgf/cm², 68.3–88.2 psi)
Electric starter
Premium unleaded gasoline only
8.5 L (2.25 US gal, 1.87 Imp.gal)
1.6 L (0.42 US gal, 0.35 Imp.gal)
Wet sump
SAE 10W-30, SAE 10W-40, SAE 15W-40, SAE
20W-40 or SAE 20W-50
API service SG type or higher, JASO standard
MA
1.15 L (1.22 US qt, 1.01 Imp.qt)
0.95 L (1.00 US qt, 0.84 Imp.qt)
1.00 L (1.06 US qt, 0.88 Imp.qt)
Paper
Trochoid
Less than 0.150 mm (0.0059 in)
0.23 mm (0.0091 in)
0.130–0.180 mm (0.0051–0.0071 in)
0.25 mm (0.0098 in)
0.06–0.11 mm (0.0024–0.0043 in)
0.18 mm (0.0071 in)
39.2–78.4 kPa (0.39–0.78 kgf/cm², 5.7–11.4 psi)
Check bolt on cylinder head body

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the RR 125 LC and is the answer not in the manual?

Questions and answers

Related Manuals for Beta RR 125 LC

Summary of Contents for Beta RR 125 LC

  • Page 1 ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 124.7 cm³ Cylinder arrangement Forward-inclined single cylinder Bore × stroke 52.0 × 58.6 mm (2.05 × 2.31 in) Compression ratio 11.20 :1 Standard compression pressure (at sea level) 550 kPa/600 r/min (5.5 kgf/cm²/600 r/min, 78.2 psi/600 r/min) Minimum–maximum...

  • Page 2: Engine Specifications

    ENGINE SPECIFICATIONS Valve opening temperature 80.5–83.5 °C (176.90–182.30 °F) Valve full open temperature 95.0 °C (203.00 °F) Valve lift (full open) 3.0 mm (0.12 in) Radiator core Width 128.0 mm (5.04 in) Height 258.0 mm (10.16 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single suction centrifugal pump...
  • Page 3 ENGINE SPECIFICATIONS Tensioning system Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 9.985–10.000 mm (0.3931–0.3937 in) Limit 10.015 mm (0.3943 in) Rocker arm shaft outside diameter 9.966–9.976 mm (0.3924–0.3928 in) Limit 9.941 mm (0.3914 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm (0.0004–0.0013 in) Limit 0.074 mm (0.0029 in) Valve, valve seat, valve guide...
  • Page 4 ENGINE SPECIFICATIONS Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in)
  • Page 5 ENGINE SPECIFICATIONS Height H 5.0 mm (0.20 in) Offset 0.50 mm (0.0197 in) Offset direction Intake side Piston pin bore inside diameter 14.002–14.013 mm (0.5513–0.5517 in) Limit 14.043 mm (0.5529 in) Piston pin outside diameter 13.995–14.000 mm (0.5510–0.5512 in) Limit 13.975 mm (0.5502 in) Piston-pin-to-piston-pin-bore clearance 0.002–0.018 mm (0.0001–0.0007 in)
  • Page 6 ENGINE SPECIFICATIONS Runout limit C 0.030 mm (0.0012 in) Big end side clearance D 0.110–0.410 mm (0.0043–0.0161 in) Big end radial clearance E 0.004–0.014 mm (0.0002–0.0006 in) Balancer Balancer drive method Gear Clutch Clutch type Wet, multiple-disc Clutch release method Inner push, cam push Clutch lever free play 10.0–15.0 mm (0.39–0.59 in)

  • Page 7: General Tightening Torque Specifications

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
  • Page 8 TIGHTENING TORQUES Generator cover tightening sequence: 3,11 2,10 Clutch cover tightening sequence: 2,12 3,13 Crankcase tightening sequence: 2,13 3,14 A. Left crankcase B. Right crankcase...

  • Page 9: Engine Oil Lubrication Chart

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART...

  • Page 10: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS...
  • Page 11 LUBRICATION SYSTEM CHART AND DIAGRAMS...

  • Page 12: Adjusting The Valve Clearance

    ENGINE EAS20472 ENGINE EAS20520 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or c.
  • Page 13 ENGINE The ignition timing is not adjustable. L LLL L LLL L LLL L LLL L LLL 4. Remove: • Digital tachometer • Timing light 5. Install: • Timing mark accessing screw (along with the O-ring 6. Measure: • Compression pressure EAS20710 MEASURING THE COMPRESSION Out of specification →...

  • Page 14: Checking The Engine Oil Level

    ENGINE 8. Install: -20 -10 10 20 30 40 50 ˚C • Spark plug SAE 10W-30 Spark plug SAE 10W-40 13 Nm (1.3 m·kgf, 9.4 ft·lbf) SAE 10W-50 9. Connect: SAE 15W-40 • Spark plug cap SAE 20W-40 EAS28920 SAE 20W-50 CHECKING THE ENGINE OIL LEVEL 1.
  • Page 15 ENGINE 4. Check: • Electrode “1” Damage/wear → Replace the spark plug. • Insulator “2” Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 5. Clean: • Spark plug (with a spark plug cleaner or wire brush) 6.
  • Page 16 ENGINE • O-ring • Engine oil drain plug Engine oil drain plug 32 Nm (3.2 m·kgf, 23 ft·lbf) 8. Fill: • Crankcase (with the specified amount of the recom- mended engine oil) Engine oil quantity Total amount 1.15 L (1.22 US qt, 1.01 Imp.qt) Without oil filter element replace- ment 0.95 L (1.00 US qt, 0.84 Imp.qt)
  • Page 17 ENGINE d. Start the engine after solving the problem(s) and check the engine oil pressure again. e. Tighten the oil check bolt to specification. Oil check bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)

  • Page 18: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 19 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 22 Nm (2.2 m kgf, 16 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...

  • Page 20: Removing The Cylinder Head

    CYLINDER HEAD EAS24130 REMOVING THE CYLINDER HEAD To prevent the timing chain from falling into the 1. Align: crankcase, fasten it with a wire “1”. • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) M MMM M MMM...

  • Page 21: Checking The Camshaft Sprocket And Timing Chain Guide

    CYLINDER HEAD EAS22B1004 CHECKING THE CAMSHAFT SPROCKET AND TIMING CHAIN GUIDE 1. Check: • Camshaft sprocket More than 1/4 tooth wear “a” → Replace the camshaft sprocket, timing chain and crank- shaft as a set. 2. Check: • Cylinder head Damage/scratches →...

  • Page 22: Checking The Decompression System

    CYLINDER HEAD d. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner hous- ing smoothly. If there is rough movement, re- place the timing chain tensioner. e. Install the timing chain tensioner cap. L LLL L LLL L LLL L LLL...
  • Page 23 CYLINDER HEAD e. While holding the camshaft, temporarily tight- en the camshaft sprocket bolt. f. Remove the wire from the timing chain. L LLL L LLL L LLL L LLL L LLL 4. Install: • Timing chain tensioner gasket • Timing chain tensioner M MMM M MMM M MMM...
  • Page 24 CYLINDER HEAD 5. Turn: • Crankshaft (several turns counterclockwise) 6. Check: • “I” mark “a” Align the “I” mark on the generator rotor with the stationary pointer “b” on the generator cover. • “I” mark “c” Align the “I” mark on the camshaft sprocket with the stationary pointer “d”...
  • Page 25 CAMSHAFT EAS23730 CAMSHAFT Removing the rocker arms and camshaft 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...

  • Page 26: Checking The Camshaft

    CAMSHAFT EAS23840 EAS23880 CHECKING THE CAMSHAFT CHECKING THE ROCKER ARMS AND 1. Check: ROCKER ARM SHAFTS • Camshaft lobes The following procedure applies to all of the Blue discoloration/pitting/scratches → Re- rocker arms and rocker arm shafts. place the camshaft. 1.

  • Page 27: Installing The Camshaft And Rocker Arms

    CAMSHAFT 5. Calculate: 4. Install: • Rocker-arm-to-rocker-arm-shaft clearance • Rocker arms • Rocker arm shafts “1” Calculate the clearance by subtracting the rock- er arm shaft outside diameter from the rocker • Make sure that the cutout “a” in each rocker arm inside diameter.

  • Page 28: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Rocker arms/Camshaft Valve cotter Upper spring seat Valve spring Intake valve Exhaust valve Valve stem seal Lower spring seat Valve guide...

  • Page 29: Removing The Valves

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 30 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position (intake) Limit 17.0–17.4 mm (0.669–0.685 in) 0.080 mm (0.0032 in) Valve guide position (exhaust) Valve-stem-to-valve-guide clear- 14.0–14.4 mm (0.551–0.567 in)

  • Page 31: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 3. Eliminate: EAS24300 CHECKING THE VALVE SEATS • Carbon deposits The following procedure applies to all of the (from the valve face and valve seat) valves and valve seats. 4. Check: 1. Eliminate: • Valve face •...

  • Page 32: Checking The Valve Springs

    VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. M MMM M MMM M MMM M MMM M MMM a.

  • Page 33: Installing The Valves

    VALVES AND VALVE SPRINGS Free length (intake) Spring tilt (intake) 41.71 mm (1.64 in) 2.5°/1.8 mm Limit Spring tilt (exhaust) 39.62 mm (1.56 in) 2.5°/1.8 mm Free length (exhaust) 41.71 mm (1.64 in) Limit 39.62 mm (1.56 in) EAS24340 INSTALLING THE VALVES The following procedure applies to all of the valves and related components.
  • Page 34 VALVES AND VALVE SPRINGS • Valve “3” • Valve spring “4” • Upper spring seat “5” (into the cylinder head) • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up.

  • Page 35: Cylinder And Piston

    CYLINDER AND PISTON EAS24350 CYLINDER AND PISTON Removing the cylinder and piston 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cylinder head Cylinder Cylinder gasket Dowel pin Piston pin clip Piston pin Piston Top ring 2nd ring...

  • Page 36: Removing The Piston

    CYLINDER AND PISTON EAS24380 REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...

  • Page 37: Checking The Piston Rings

    CYLINDER AND PISTON EAS24430 “C” = maximum of D –D CHECKING THE PISTON RINGS 1. Measure: “T” = maximum of D or D - maximum of D • Piston ring side clearance or D Out of specification → Replace the piston “R”...

  • Page 38: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: 3. Measure: • Piston ring end gap • Piston pin bore inside diameter “b” Out of specification → Replace the piston Out of specification → Replace the piston. ring. Piston pin bore inside diameter 14.002–14.013 mm (0.5513– The oil ring expander end gap cannot be mea- 0.5517 in) sured.
  • Page 39 CYLINDER AND PISTON 2. Install: a. Top ring • Piston “1” b. Upper oil ring rail • Piston pin “2” c. Oil ring expander d. Lower oil ring rail • Piston pin clips “3” e. 2nd ring f. 20 mm (0.79 in) •...

  • Page 40: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS22B1006 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) •...
  • Page 41 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 14 Nm (1.4 m kgf, 10 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf)

  • Page 42: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 ECA13880 REMOVING THE GENERATOR NOTICE 1. Remove: To protect the end of the crankshaft, place an • Generator cover appropriate sized socket between the fly- wheel puller set center bolt and the crank- Loosen each bolt 1/4 of a turn at a time, in stag- shaft.

  • Page 43: Checking The Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24570 EAS24600 CHECKING THE STARTER CLUTCH INSTALLING THE STARTER CLUTCH 1. Check: 1. Install: • Starter clutch rollers “1” • Starter clutch assembly • Starter clutch spring caps “2” • Starter clutch bolts “1” • Starter clutch springs “3” Starter clutch bolt Damage/wear →...
  • Page 44 GENERATOR AND STARTER CLUTCH • While holding the generator rotor “2” with the sheave holder “3”, tighten the generator rotor nut. • Do not allow the sheave holder to touch the projections on the generator rotor. 3,11 2,10 3. Apply: •...

  • Page 45: Electric Starter

    ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor yoke O-ring Armature assembly Starter motor front cover/brush holder set Brush Brush spring...

  • Page 46: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter “a” Armature coil Out of specification → Replace the starter Commutator resistance “1” motor. 0.0315–0.0385 Ω Insulation resistance “2” Limit Above 1 MΩ...

  • Page 47: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the starter motor. 8. Check: • Bearing • Oil seal Damage/wear → Replace the starter motor front cover/brush holder set. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor front cover/brush holder set “1” •...
  • Page 48 CLUTCH EAS25061 CLUTCH Removing the clutch cover 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
  • Page 49 CLUTCH Removing the clutch 70 Nm (7.0 m kgf, 50 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Locknut Clutch spring Pressure plate...
  • Page 50 CLUTCH Removing the clutch 70 Nm (7.0 m kgf, 50 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Conical spring washer For installation, reverse the removal proce- dure.
  • Page 51 CLUTCH Removing the push lever Order Job/Parts to remove Q’ty Remarks Exhaust pipe Clutch push lever Clutch push lever spring Circlip Oil seal Bearing...

  • Page 52: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH Measure the friction plate at four places. 1. Remove: • Clutch cover Friction plate 1 thickness 2.90–3.10 mm (0.114–0.122 in) Loosen each bolt 1/4 of a turn at a time, in stag- Wear limit es and in a crisscross pattern. After all of the 2.80 mm (0.110 in) bolts are fully loosened, remove them.

  • Page 53: Checking The Clutch Plates

    CLUTCH EAS25110 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • Clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • Clutch plate warpage (with a surface plate and thickness gauge “1”) Out of specification →...
  • Page 54 CLUTCH EAS25170 CHECKING THE PRESSURE PLATE Install the conical spring washer as shown in the 1. Check: illustration. • Pressure plate Cracks/damage → Replace. EAS22B1007 CHECKING THE CLUTCH PUSH LEVER AND SHORT CLUTCH PUSH ROD 1. Check: • Clutch push lever •...
  • Page 55 CLUTCH 4. Tighten: • Clutch boss nut “1” Clutch boss nut 70 Nm (7.0 m·kgf, 50 ft·lbf) While holding the clutch boss “2” with the univer- sal clutch holder “3”, tighten the clutch boss nut. 8. Install: • Pressure plate •...
  • Page 56 CLUTCH • With the clutch push lever fully pushed in di- rection “c”, turn the short clutch push rod “3” in or out until the projection “a” aligns with the mark “b”. • Hold the short clutch push rod to prevent it from moving, and then tighten the locknut to specification.

  • Page 57: Oil Pump

    OIL PUMP EAS24911 OIL PUMP Removing the oil pump 4 Nm (0.4 m kgf, 2.9 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch housing Balancer drive gear Oil baffle plate Oil pump assembly Oil pump drive gear...
  • Page 58 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing cover Oil pump driven gear Oil pump inner rotor Oil pump outer rotor Oil pump housing...

  • Page 59: Checking The Oil Pump

    OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump drive gear Less than 0.150 mm (0.0059 in) • Oil pump driven gear Limit 0.23 mm (0.0091 in) • Oil pump housing Outer-rotor-to-oil-pump-housing • Oil pump housing cover clearance Cracks/damage/wear →...

  • Page 60: Installing The Oil Pump

    OIL PUMP 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-49. EAS25020 INSTALLING THE OIL PUMP 1. Install: • Oil pump assembly Oil pump assembly screw 4 Nm (0.4 m·kgf, 2.9 ft·lbf) ECA22B1011 NOTICE After tightening the screws, make sure the oil pump turns smoothly.

  • Page 61: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch housing Shift pedal Shift shaft Circlip Shift shaft spring Stopper lever Stopper lever spring Oil seal...

  • Page 62: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever 3. Install: Bends/damage → Replace. • Shift shaft “1” Roller turns roughly →...

  • Page 63: Balancer Gears

    BALANCER GEARS EAS22B1008 BALANCER GEARS Removing the primary drive gear and balancer gears 60 Nm (6.0 m kgf, 43 ft Ibf) • • 50 Nm (5.0 m kgf, 36 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch housing Primary drive gear nut Balancer driven gear nut Washer...

  • Page 64: Removing The Primary Drive Gear And Balancer Gears

    BALANCER GEARS EAS22B1009 EAS22B1011 REMOVING THE PRIMARY DRIVE GEAR INSTALLING THE PRIMARY DRIVE GEAR AND BALANCER GEARS AND BALANCER GEARS 1. Loosen: 1. Install: • Primary drive gear nut “1” • Balancer driven gear “1” • Lock washer Place an aluminum plate “a” between the bal- •...
  • Page 65 BALANCER GEARS • Place an aluminum plate “b” between the bal- ancer drive gear “3” and the balancer driven gear “4”, and then tighten the primary drive gear nut. 3. Bend the lock washer tab along a flat side of the nut.
  • Page 66 CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 67 CRANKCASE Separating the crankcase 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
  • Page 68 CRANKCASE Removing the oil seal and bearings 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Crankshaft/Balancer Transmission Oil seal Bearing retainer Bearing...
  • Page 69 CRANKCASE EAS22B1012 ECA22B1021 SEPARATING THE CRANKCASE NOTICE 1. Remove: Tap on one side of the crankcase with a soft- • Crankcase bolts face hammer. Tap only on reinforced por- tions of the crankcase, not on the crankcase Loosen each bolt 1/4 of a turn at a time, in stag- mating surfaces.

  • Page 70: Installing The Bearing Retainer

    CRANKCASE • Oil seal Damage/wear → Replace. EAS22B1016 INSTALLING THE BEARING RETAINER 1. Install: • Bearing retainer “1” Do not allow any sealant to come into contact with the oil gallery. • Install the bearing retainer “1” with its “OUT” mark “a”...
  • Page 71 CRANKCASE 2,13 3,14 A. Left crankcase B. Right crankcase...
  • Page 72 CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft and balancer Order Job/Parts to remove Q’ty Remarks Crankcase Balancer Crankshaft...

  • Page 73: Removing The Crankshaft

    CRANKSHAFT EAS22B1017 REMOVING THE CRANKSHAFT 1. Remove: • Crankshaft “1” • Remove the crankshaft with the crankcase separating tool “2”. • Make sure the crankcase separating tool is centered over the crankshaft. ECA22B1006 2. Measure: NOTICE • Big end side clearance •...
  • Page 74 CRANKSHAFT ECA22B1022 NOTICE To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other.
  • Page 75 TRANSMISSION EAS26241 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Crankcase Shift fork guide bar Spring Shift drum assembly Shift fork-R Shift fork-C Shift fork-L Drive axle assembly Main axle assembly Long clutch push rod...
  • Page 76 TRANSMISSION Disassembling the main axle Order Job/Parts to remove Q’ty Remarks 2nd pinion gear 6th pinion gear 3rd/4th pinion gear Circlip Toothed washer 5th pinion gear Main axle/1st pinion gear...
  • Page 77 TRANSMISSION Disassembling the drive axle Order Job/Parts to remove Q’ty Remarks Washer 2nd wheel gear 6th wheel gear Washer 1st wheel gear Spacer 5th wheel gear Circlip Toothed washer 4th wheel gear 3rd wheel gear Drive axle...

  • Page 78: Checking The Shift Forks

    TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum groove Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.

  • Page 79: Assembling The Main Axle And Drive Axle

    TRANSMISSION EAS29020 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1. Install: • Toothed washer “1” • Circlip “2” • Be sure to install the circlip so that its sharp edge “a” is facing away from the toothed wash- er and gear. 3.
  • Page 80 TRANSMISSION The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence: “R”, “C”, “L”. 2. Check: • Transmission Rough movement → Repair. • Apply engine oil to each gear and bearing thor- oughly.
  • Page 81 THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 18 Nm (1.8 m kgf, 13 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Coolant Fuel tank cover assembly Coolant temperature sensor coupler Coolant temperature sensor Thermostat cover Thermostat...

  • Page 82: Checking The Thermostat

    THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat 3. Check: Does not open at 80.5–83.5 °C (176.9–182.3 • Radiator inlet hose °F) → Replace. Cracks/damage → Replace. EAS26480 INSTALLING THE THERMOSTAT 1.

  • Page 83: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Coolant Fuel tank cover assembly Radiator outlet hose Water pump breather hose Cylinder head breather hose Water pump assembly...
  • Page 84 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Water pump housing cover Water pump housing cover gasket Impeller shaft retainer Impeller shaft Water pump housing plate...

  • Page 85: Disassembling The Water Pump

    WATER PUMP EAS26510 ECA14080 DISASSEMBLING THE WATER PUMP NOTICE 1. Remove: Never lubricate the water pump seal surface • Water pump seal “1” with oil or grease. Remove the water pump seal from the inside of the water pump housing “2”. 2.

  • Page 86: Installing The Water Pump

    WATER PUMP • Impeller shaft retainer “3” 3. Check: • Cooling system Impeller shaft retainer bolt Leaks → Repair or replace all faulty parts. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 4. Measure: LOCTITE® 5. Radiator cap opening pressure Below the specified pressure → Replace the radiator cap.

  • Page 87: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 88: Electrical Components

    ELECTRICAL COMPONENTS Starter relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) R R/W Radiator fan motor relay 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4.

  • Page 89: Checking The Diode

    ELECTRICAL COMPONENTS Br/W The pocket tester or the analog pocket tester readings are shown in the following table. No continuity b. Set the main switch to “ON”. Positive tester probe → c. Measure the turn signal relay input voltage. blue/black “1” L LLL L LLL L LLL...

  • Page 90: Checking The Ignition Coil

    ELECTRICAL COMPONENTS Resistance 5.0 kΩ M MMM M MMM M MMM M MMM M MMM a. Remove the spark plug cap from the spark plug lead. b. Connect the pocket tester (Ω × 1k) to the spark plug cap as shown. c.
  • Page 91 ELECTRICAL COMPONENTS Minimum ignition spark gap 6.0 mm (0.24 in) If the ignition spark gap is within specification, the ignition system circuit is operating normally. M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the spark plug.

  • Page 92: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS EAS28150 EAS28940 CHECKING THE STATOR COIL CHECKING THE STARTER MOTOR 1. Disconnect: OPERATION 1. Check: • Stator coil coupler 2. Starter motor operation (from the wire harness) Does not operate → Perform the electric 2. Check: • Stator coil resistance starting system troubleshooting, starting with Out of specification →...
  • Page 93 ELECTRICAL COMPONENTS Charging voltage 14 V at 5000 r/min M MMM M MMM M MMM M MMM M MMM a. Set the engine tachometer to the spark plug lead. b. Connect the pocket tester (DC 20 V) to the rectifier/regulator coupler as shown. •...

Table of Contents

Save PDF