Beta RR250 Workshop Manual
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Beta RR250 Workshop Manual

2022 race edition
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  • Page 2: Table Of Contents

    TABLE OF CONTENTS CRANKSHAFT, GEARBOX UNIT AND INTERNAL GEARSHIFT ..............40 2.8.1 OPENING THE CRANKCASE ............40 2.8.2 COUNTERWEIGHT SUPPORT SHAFT ........41 2.8.3 CRANKSHAFT ................. 41 2.8.4 INTERNAL GEARSHIFT UNIT AND COMPLETE GEARBOX ..................42 DISASSEMBLY OF PARTS FROM CRANKCASES ..44 2.9.1 RIGHT CRANKCASE HALF ............44 2.9.2 LEFT CRANKCASE HALF .............46...
  • Page 3 TABLE OF CONTENTS 3.9.4 ASSEMBLY OF COMPLETE CLUTCH COVER AND PUMP UNIT ..................84 3.10 ELECTRIC IGNITION UNIT ........... 87 3.10.1 BENDIX COUPLING CHECKS ........... 87 3.10.2 IGNITION UNIT COUPLING TO ENGINE ......87 3.11 IGNITION SYSTEM............88 3.11.1 IGNITION SYSTEM CHECK ............89 3.11.2 COUPLING OF IGNITION SYSTEM TO CRANKCASE ....89 3.12...

  • Page 4: Introduction

    www.betamotor.com INTRODUCTION This publication is intended for workshops specialised in repairing mopeds and motorcycles. Where required, 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 repairs: •...
  • Page 5 www.betamotor.com Coolant liquid Do not remove the radiator cap when the en- • gine is still hot. Since the coolant is pressur- In some situations, the ethylene glycol con- • ised, it may spurt out violently and cause burns. tained in the coolant is flammable and its flame The coolant contains dangerous substances is invisible.

  • Page 6: Engine Technical Specifications

    ENGINE TECHNICAL SPECIFICATIONS CHARACTERISTIC DATA ENGINE RR250 RR300 Bore [mm]/Stroke [mm] 66.4/72 73 x 69.9 Displacement [cm³] 292,6 Compression ratio 13.2:1 11,6:1 TRANSMISSION RR250 RR300 Primary 27/72 27/72 1st gear ratio 12/31 12/31 2nd gear ratio 15/28 15/28 3rd gear ratio...

  • Page 7: Special Equipment

    www.betamotor.com SPECIAL EQUIPMENT Complete EVO 2T crankcase uncoupler 007.14.010.80.00 Symbols Special wrench 037.14.002.50.00 Squish measuring tool 026.14.017.00.00 Front bracket for fastening engine to stand 026.14.003.00.00 Value Flywheel blocking tool 026.14.005.50.00 Tightening torque Flywheel extractor 36.25173.000 Special wrench 026.44.029.00.00 Special wrench 026.44.028.00.00 10.

  • 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 • To dismantle the tank from the vehicle it is necessary to remove the seat, disconnect the tank ventilation pipe, position the fuel valve on OFF and disconnect the fuel pipe from the valve.
  • Page 9 Lift the tank slightly and: remove pipe 3 • disconnect the connector 4 • Lift the tank from the back and remove it backwards.
  • Page 10 Remove the frame guards 5 (one on each • side) and the pinion guard 6. Remove the circlip 7 and extract the pinion. • Rest the chain against the upper wedge 8. Remove the screw 9. • Remove the screws 10. •...
  • Page 11 Remove the screws 11 fastening the clutch • actuator to the crankcase half. ATTENTION! Do not operate the clutch lever with the actuator uncoupled from the engine. Drain the cooling system through the screw • 12 and let the liquid outflow into a contain- er (the cooling circuit contains 1.3l of liquid).
  • Page 12 Remove the fixing screws and remove the left • radiator. Disconnect the water hoses from the engine • and from the right radiator.
  • Page 13 Remove the fixing screws and remove the • right radiator. Disconnect the spark plug cap. • Cut all straps binding the engine's electric • system to the clutch pipe and to the frame. Release the connectors 13, 14, 15 of the en- •...
  • Page 14 Remove the starter motor cable fixing nut. • Remove the head connections and spark plug. • Note: It is advisable to insert a clean cloth into the spark plug housing in order to prevent accidental introduction of dirt into the cylinder. Release and remove the brake pedal return •...
  • Page 15 ATTENTION! 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. Disconnect the connector 19. •...
  • Page 16 Remove the subframe lower fixing screws • 20 (one on each side) and loosen the upper screws 21 (one on each side). Rotate the entire filter box unit. • Remove the carburettor, leaving it connected • to the gas cable. Cut the clamp shown.
  • Page 17 Disconnect the connector 22. • Remove the brake light wiring A and starter • motor cable B from the carburettor.
  • Page 18 23 . Remove the shock-absorber pin • Remove the swingarm pin. Pull the entire • wheel/swingarm unit outwards. Remove the gear lever 24 and the engine pins • Extract the engine from the frame and apply • it to the specific stand, code 3625132 000, using the specific front fixing bracket, code 026140030 000.

  • Page 19: Engine Disassembly

    ENGINE DISASSEMBLY Secure the engine to the specific support stand code 3625132000 by means of the front fixing code 026140030 000, in order to work in comfort and safety. Then proceed as follows. CLUTCH/GEAR OIL DRAIN Remove screw 1 and let the oil drain. REMOVAL CLUTCH CONTROL ROD AND PIN-...

  • Page 20: Removal Of Piston, Cylinder And Head

    REMOVAL OF PISTON, CYL- INDER AND HEAD Remove the spigot screws 1 together with the copper washers. Remove the head and the two O-rings. Remove the four screws 2. Remove the three screws 3 and cover 4.
  • Page 21 Release the lock 5 and remove it. 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.
  • Page 22 Remove the four collar nuts 9. ATTENTION! Place a clean cloth between the piston and the crankcase to keep foreign objects or simple solid residues from falling inside the base. Remove the circlip 10 by gripping it with a pair of fine nose pliers A.

  • Page 23: 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 REMOVAL FLYWHEEL COVER Remove the five screws 1 fastening the flywheel cover 2 to the left crankcase. Remove the flywheel cover and the gasket placed between the crankcase and the cover.

  • Page 24: Removal Of Flywheel

    2.4.3 REMOVAL OF FLYWHEEL Block the flywheel using the special tool A (cod. 026140040 000) and remove the fastening nut securing the flywheel to the crankshaft. Note: Once the nut has been unscrewed, pay attention to the special elastic washer placed between the nut and the flywheel.

  • Page 25: Removal Of Electric Ignition

    REMOVAL OF ELECTRIC IG- NITION 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 26: Removal Of Start Motor

    2.5.1 REMOVAL OF START MOTOR Remove the two screws 1 and extract the motor. Removal of start motor. 2.5.2 REMOVAL OF BENDIX COU- PLING Extract the Bendix coupling 1 once the complete flywheel cover and flywheel have been removed (see par. 2.4.1). Removal of Bendix coupling.

  • Page 27: Unit, Main Gear, Centrifugal Unit

    REMOVAL COOLANT LIQUID PUMP, CLUTCH UNIT, MAIN GEAR, CEN- TRIFUGAL UNIT, GEAR- SHIFT ORGANS, KICK- START Remove the cover 1 by loosening the screws 2 to access the coolant liquid pump. Note: remove the coolant liquid pump impeller if having to intervene on the centrifugal unit. Coolant liquid pump cover screws.
  • Page 28 In order to only access the clutch unit, the outer clutch cover 3 must be removed by loosening the screws 4. Outer clutch cover screws.
  • Page 29 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. Inner clutch cover screws. Pay attention to the two reference pins A placed between the right crankcase half and the inner clutch cover while disassembling.

  • Page 30: Removal Of Coolant Liquid Pump

    2.6.1 REMOVAL COOLANT LIQUID PUMP Loosen fixing screw 1 once the coolant liquid pump cover has been removed. 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 31: Removal Of Centrifugal Unit And Leverage

    2.6.2 REMOVAL CENTRIFU- GAL 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 unit consisting of adjusting springs 3, auxiliary springs 4 and the spring guide 5.
  • Page 32 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 33 1) Adjustment cover; 2) Adjustment spring; 3) Auxiliary spring (if any); 4) Spring guide; 5) Rocker arm; 6) Centrifugal control lever; 7) Thrust washers; 8) Screw; 9) Centrifugal unit.

  • Page 34: Disassembly Of Clutch Unit And Countershaft Counterweight

    2.6.3 DISASSEMBLY OF CLUTCH UNIT AND COUNTERSHAFT COUNTERWEIGHT Keeping the clutch unit locked using the special tool A (code 037.14.002.50.00) remove the screws 1 that join the ring 2 to the clutch drum. Remove the spring washer 3, the pressure plate 4 together with the ring 5.
  • Page 35 To unscrew the nut 10, the clutch drum must be blocked with the appropriate tool A (code 037.14.002.50.00). Then remove the nut and relevant safety washer. WARNING! Do not use the pneumatic gun. Remove the clutch drum together with the slip pins followed by the spacer washer.
  • Page 36 14 13 2 Ring, 3 Spring washer, 4 Pressure plate, 5 Ring, 6 Thrust bearing, 7 Clutch disc unit, 10 Slip pins, 12 Clutch drum, 13 Needle bearing, 14 Slew bearing, 15 Spacer washer, 16 Clutch bell. Keep the counterweight locked in place 17 using the special tool B (code 026.14.012.50.00) and loosen the screw.
  • Page 37 Extract the primary gear 18. Removal can be facilitated by using a universal extractor. Using the extractor, remove the counterweight 19. Note: it is advisable to keep the locking screw 20 in place, using it as a support for the extractor.

  • Page 38: Pedal Kickstart - Optional

    2.6.4 PEDAL KICKSTART - OP- TIONAL The pedal kickstarter consists of the pedal which, attached to the kickstarter shaft 1, moves the kickstarter 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 39 Using a pair of pliers, pull the end A of the spring 4 out of the housing hole on the crankcase and move it to a resting position by turning it 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 40: External Gearshift Unit

    2.6.5 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 41: 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) Gasket. Disassemble by removing the screws 4 fastening the intake manifold and the reed valve to the crankcases. Fixing screws.

  • Page 42: Crankshaft, Gearbox Unit And Internal Gearshift

    CRANKSHAFT, GEAR- BOX 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 thirteen screws 1 fastening the crankcases.

  • Page 43: Counterweight Support Shaft

    2.8.2 COUNTERWEIGHT SUP- PORT SHAFT Once the crankcase halves have been uncoupled, push the counterweight support shaft inwards 1. 2.8.3 CRANKSHAFT The crankshaft 1 can be pulled out manually. Gently hit the right end of the crankshaft in case of resistance.

  • Page 44: Internal Gearshift Unit And Complete Gearbox

    2.8.4 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. The forks, supported by the pins 4, drive the sliding wheels of the gearbox, allowing the desired ratio to be engaged.
  • Page 45 Extract the whole gearbox unit consisting of primary 6 and secondary 7 unit. Extraction of complete gearbox unit: 6 primary unit, 7 secondary unit. Note: Make sure you have removed circlip 8 on the clutch side gearbox secondary.

  • Page 46: Disassembly Of Parts From Crankcases

    DISASSEMBLY OF PARTS FROM CRANKCASES Once the crankcases have been detached, it may be required to remove the various components attached to them. The bearings must be replaced if there is any play or jamming during rotation. For removal, heat the crankcase halves for 20 minutes at about 150°C.
  • Page 47 Remove the desmodromic control bearing seal screw 4 on the inside. Bearing safety screw. The bearings 5, 6, 7, 8 and 9 are removed from the outside inwards. To disassemble bearing 9 remove the fixing screw The bearing 11 is removed from the outside using a universal extractor, after removing the fixing plate The centrifugal shaft bearing can be removed by using a universal extractor that must rest onto a...

  • Page 48: Left Crankcase Half

    2.9.2 LEFT CRANKCASE HALF Remove the crankshaft oil seal 1, the secondary shaft oil seal 2 and the gearshift shaft oil seal 3 on the external side. Removal of outer side left crankcase half oil seal. The bearings 4, 5, 6, 7 e 8 are removed from the outside inwards.

  • Page 49: Engine Checks And Assembly

    ENGINE CHECKS AND ASSEMBLY Before reassembling the eng ine, a series of crucial checks must be carried out to ensure the eng ine is in good working order. In order to inser t the bearings into the crankcase halves, heat the crankcase halves to 150°C and keep them at constant temper- ature for 20 minutes.

  • Page 50: Application Of Right Crankcase Half Parts

    3.1.1 APPLICATION RIGHT CRANKCASE HALF PARTS Apply the bearings 1, 2, 3 and 4 until flush. Block bearing 4 with the specific screw by depositing the threadlockers. Tighten to the specified torque. Positioning of the right crankcase half bearings. Apply the bearing 5 from the crankcase half external side, until it is flush, and bearing 6 as shown in the drawing.
  • Page 51 If present (optional), apply the kickstart ramp 9 and fasten the screws 10 at 10Nm, by depositing a medium strength threadlocker. 10Nm Application of kickstart ramp. Apply the gear stopping device as follows. Keeping the tightener on lever 18 facing towards the crankcase half, apply the spacer 17 onto it, inserting the smaller diameter segment in the lever.

  • Page 52: Application Of Left Crankcase Half Parts

    3.1.2 APPLICATION LEFT CRANKCASE HALF PARTS Apply the bearings 1, 2, 3 e 4 from the crankcase half internal side, until flush. Application of left crankcase half bearings. Apply the bearing 5 from the crankcase half external side, as shown in the drawing. Apply the crankshaft oil seal, gear secondary shaft and gearshift shaft.

  • Page 53: Connecting Rod And Engine Shaft Check

    CONNECTING ENGINE SHAFT CHECK 3.2.1 Slew bearing removal and refitting If the main bearings need to be replaced, for the 250 ONLY, the main slew bearing on the left hand motor semi-axle must also be replaced. To do this, clamp the drive shaft of the semi-axle on which the slew bearing to be replaced is in a vice.
  • Page 54 The distance between the two shoulders must be: 62±0.05 If replacing the inserts, apply the screws with high-resistance threadlocker and tighten at the specified torque. Half-shoulder...

  • Page 55: Assembly Of Complete Crankshaft

    ASSEMBLY OF COMPLETE CRANKSHAFT On the 250 version, if the slew bearing has been removed from the left hand semi-axle (para. 3.2) the new slew bearing will need to be fitted. To do this, clamp the drive shaft of the semi-axle to which the slew bearing is to be fitted with a vice and using an electric hotplate, heat special tool A (code 026.14.018.00.00) to around 150°C and push it on to...

  • 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: Primary Unit Assembly

    3.4.2 PRIMARY UNIT ASSEMBLY Before proceeding with reassembly, clean all the parts thoroughly and oil with gear oil. Always replace the circlips. Clamp the main shaft 1 (using protective jaws), so that the grooved end faces downwards. EXPLODED VIEW OF PRIMARY UNIT: Insert onto the lower cylinder part of the shaft: the roller cage 2, the 5th gear 3 turning the front claw 1) Main shaft;...

  • Page 58: Secondary Unit Assembly

    3.4.3 SECONDARY UNIT ASSEM- Before proceeding with reassembly, clean all the parts thoroughly and oil them by using gear oil. Always replace the circlips. Clamp the secondary shaft 20 (using protective jaws), so that the grooved end faces downwards. Insert onto the lower cylinder part: the roller cage EXPLODED VIEW OF SECONDARY UNIT: 15, the 2nd gear 19 so that the front claw clutches face downwards, the thrust washer 4 (26x32x1.5)

  • Page 59: Checking The Forks, Fork Pins And Desmodromic Device

    3.4.4 CHECKING FORKS, FORK PINS AND DESMO- DROMIC DEVICE The internal gearshift is made up of: two forks 13 which drive two gears on the sec- • ondary 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 the minimum 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 on which they slide have an outside diameter above the limit (to be...

  • Page 61: Gearbox And Internal Gearshift Assembly

    3.4.5 GEARBOX AND INTERNAL GEARSHIFT ASSEMBLY Insert the entire primary 1 and secondary unit 2 into the respective seats on the left crankcase half simultaneously. Remember to oil the gears with plenty of gear oil and to grease the shafts supporting them with graphite grease in the mat- ing areas with the bearing.
  • Page 62 Introduce the forks together with the guide bush- es on the gear tracks. Namely: 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 device.
  • 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 desmo- dromic device with plenty of gear oil.

  • Page 64: Counterweight Support Shaft

    Apply circlip 9 on the clutch side gearbox sec- ondary. 3.4.6 COUNTERWEIGHT SUP- PORT SHAFT Check that the areas where the shaft rests on the bearings are intact and free of any traces of mesh- ing or abnormal wear. Otherwise replace the shaft. Insert the shaft all the way as shown in the figure.

  • Page 65: Closing The Engine Crankcase

    CLOSING ENGINE CRANKCASE Apply a thin layer of grease on all oil seals. Heat up the engine shaft bearing on the left crank- case half, being careful not to burn the oil seal. Press the left crankcase half towards the right, making sure that the shafts and pins on the crank- cases fit into the respective housings and that the crankcase half is not offset.

  • 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 is free from abnormal wear or meshing, the gearshift drive shaft needs more in- depth inspections. 3.6.1 CHECKING THE COMPLETE DRIVE SHAFT...
  • Page 67 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 68: External Gearshift Assembly

    3.6.2 EXTERNAL GEARSHIFT AS- SEMBLY Rotate the gear stop lever 1 clockwise so that the spring is compressed. To keep the lever in this position, an aluminium rod A can be inserted into the small hole, as shown in the figure. Apply the gear stop cam 2 to the protruding end of the desmodromic control.

  • Page 69: Kickstarter Device - Optional

    KICKSTARTER DEVICE OPTIONAL Before coupling the kickstarter to the crankcase half, some checks must be carried out. 3.7.1 CHECKING THE KICKSTART SHAFT UNIT AND ASSEM- In order to disassemble all the parts of the kick- start shaft, pull off the washer 11 at the end of the shaft (on the spring side 16), the spring 16, the kickstart sleeve 14, and the lever return spring 8, which must be pulled in the radial direction...

  • Page 70: Assembly Of Kickstarter Device - Optional

    Remove the kickstart spacer 9, expand the circlip 10, allowing for the removal of washer 11, of kick- start gear 2 together with roller bearing 12 and washer 11. This frees the kickstart shaft 3 from all other parts. Make sure that the side of the kickstart gear teeth 2 has no signs of meshing or notable superficial wear.
  • Page 71 Turn the spring clockwise until it fits into the spe- cific hole C. Insertion of kickstart return spring. Insert in the slot on the protruding segment of the secondary shaft: the circlip 18, the rose-petal 17, the idler wheel 4 followed by the rose-petal 17 and the circlip 18 as shown in the figure.

  • Page 72: Counterweight, Primary Gear And Clutch Unit

    Apply the O-ring 18, the spacer 12 and gear 14 on the right half shaft so the appropriate groove fits with the Woodruff key 17. RR250 Apply the O-ring 18, gear 12 on the right half shaft so the appropriate groove fits with the Woodruff key 17 and gear 14.
  • Page 73 Keeping the primary gear/counterweight cou- pling firmly in place with a special tool B (code 026.14.012.50.00), tighten the screw 2 to the in- dicated torque. 30Nm Apply the lock nut 15 after applying medium strength threadlocker; tighten at the indicated torque.

  • Page 74: Checking The Clutch Case, Roller Bearing And Internal Centre Bearing

    3.8.3 CHECKING CLUTCH CASE, ROLLER BEARING INTERNAL CENTRE BEARING Before reassembling the clutch case, make sure that the sides of the teeth A, designated for main transmission and B, designated for meshing with the kickstart idler gear and oil pumps, have no superficial nicks or abnormal wear.

  • Page 75: Checking The Clutch Discs

    3.8.4 CHECKING CLUTCH DISCS The clutch discs are divided into driving and driv- en: eight driving discs and seven driven discs. ORIGIN The driving discs have cork inserts on both sides which wear out due to the driven discs sliding on ON / OFF ZERO / ABS them.

  • Page 76: Checking The Clutch Drum And Cap

    3.8.5 CHECKING CLUTCH DRUM AND CAP The clutch drum engages with the driven clutch discs by means of the sliding pins A: make sure that the area shown in the figure has no meshing or abnormal wear. If so, replace the sliding pins. Guide pin Check that the disc friction area is free from scratches, meshing or abnormal wear.

  • Page 77: Clutch Unit Assembly

    3.8.7 CLUTCH UNIT ASSEMBLY Lubricate the end of the primary gearbox shaft, the internal centre bearing 4 and the roller bearing 5. Fit the roller bearing 5 and the centre bearing 4 on the clutch case 1. Mount the unit on the primary shaft;...
  • Page 78 To tighten the nut 8 the clutch drum must be held blocked with tool A (code 029.14.002.50.00). Tighten to the specified torque. 120Nm Having tightened the nut, fold the two locking fins on the safety plate. Safety washer folding Lubricate the clutch discs with gear oil and apply the driving disc with BLUE edge and a driven disc.
  • Page 79 Insert the thrust bearing assembly 9 (after lubri- cating it with gear oil) in the hole on the gearbox main shaft and check free axial sliding. Thrust bearing assembly Fitting the pressure plate 1, the ring 2 and the spring washer 3. WARNING! The spring washer must be fitted so the side with the larger diameter rests on ring 2.
  • Page 80 Proceed to tighten the six screws in a criss-cross pattern and tighten to the indicated torque. 10Nm facilitate tightening, keep clutch unit clamped using special tool (code 037.14.002.50.00).

  • Page 81: 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 EXPLODED VIEW OF CENTRIFUGAL UNIT AND WATER...

  • Page 82: Check Of Pump Unit And Disassembly, Centrifugal Unit And Idler Unit

    3.9.1 Check of pump unit and disassembly, centrifugal unit and idler unit Refer to par. 2.6.1 to disassemble the entire pump unit. Check oil seal 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 83: Centrifugal Unit Assembly

    3.9.2 Centrifugal unit assembly Insert the centrifugal unit 20 in the inner clutch cover. Insertion of centrifugal unit. Insert the centrifugal control lever 10 together with the washers 8. Insertion of centrifugal control lever.
  • Page 84 Apply the valve control rod gasket and the rocker arm 1 - valve control rod 4 assembly. Application of valve control and rocker arm unit. Apply locking screw 3 after applying medium strength threadlocker. Tighten to 6Nm Centrifugal unit assembly.
  • Page 85 Apply the auxiliary 4 and adjustment 3 springs to the spring guide 5. Spring guide and springs unit. Apply the complete adjustment cover to the inner clutch cover. Apply the locking screws after applying medium strength threadlocker tighten to the indicated torque. 6 Nm Displa Fastening of adjusting cover.

  • Page 86: Pump Unit Assembly

    3.9.3 PUMP UNIT ASSEMBLY Bordo più spesso Grease the oil seal housing on the pump body 1. Position the oil seal 2 so that the thicker 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 87 Apply the seven screws as pictured, tightening them at 10Nm with a criss-cross pattern. Screws positioning. Screw size Number Threadlocker Tightening torque Threading screw application [Nm] Threading length diameter...
  • Page 88 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 89: Electric Ignition Unit

    3.10 ELECTRIC IGNITION UNIT Carry out the following checks before assembly. 3.10.1 BENDIX COUPLING CHECKS Check wear of the gearwheels found on the unit. Replace the whole coupling in case of abnormal wear and signs of chipping of the wheels. Keep the wheel 1 fixed and rotate the mobile coupling 2 anti-clockwise;...

  • Page 90: Ignition System

    Pour about 7cc of gear oil (for specifications refer to the recommended lubricants and liquids table) in area A. Application of oil. Insert Bendix coupling 2 in bush with collar 3 present on the outer side left crankcase half. Insertion of Bendix coupling. 3.11 IGNITION SYSTEM Before reassembling the ignition system, it is rec-...

  • Page 91: 3.11.1 Ignition System Check

    3.11.1 IGNITION SYSTEM CHECK Accurately degrease the various elements and carry out the checks. The main check is the one concerning the elec- trical inspection which can be done by using a standard tester. The measured resistance values must comply with those in the table. Element Cables Resistance values...
  • Page 92 Tighten the nut to torque 60Nm, keeping the flywheel blocked with the special tool A (code 026140040 000). Flywheel fastening. Couple the stator to the flywheel cover by means of the two screws 10. Cover the threading with medium strength threadlocker and tighten them at a torque of 10Nm.
  • Page 93 Insert the centring pins 12 on the crankcase and fit a new gasket. Application of flywheel cover centring pins. Apply the flywheel cover, the two M6x25 screws 13 and the three M6x20 screws 14. Tighten in a criss-cross pattern at a torque of 10Nm. 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...

  • Page 94: Thermal Unit

    3.12 THERMAL UNIT Before assembling the thermal unit, thorough checks must be carried out on the cylinder, pis- ton, pin bolt, elastic bands described hereafter. 3.12.1 CHECKING 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 95: 3.12.2 Cylinder Check

    3.12.2 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] 31.3...

  • Page 96: Piston Cylinder Coupling Play

    3.12.3 PISTON CYLINDER COU- PLING 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. Maximum Minimum Displace-...
  • Page 97 Remove screw 6 that keeps the left side bearings and the booster in their housing. Apply one M5 screw on control unit side and pull outwards. Repeat the operation on the opposite side using one M6 screw. After extracting the boosters and relevant pin, ex- tract the valve pin 7 by pushing it with a metal cylinder A and then extract valve 8.

  • Page 98: 3.12.5 Exhaust Valve

    Check the bearings 9 supporting the booster are efficient, without seizing during operation or ex- cessive play, once the assembly has been cleaned and descaled. Otherwise replace. Check pins 10, 11 and their seats are not abnor- mally worn. Otherwise replace the worn parts. Descale all passages involving the exhaust.
  • Page 99 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. Apply the right side booster unit in its seat. Apply screws 4 and 5 complete with washer after applying medium-resistance threadlocker and tighten at the specified torque.

  • Page 100: Piston, Pin Bolt, Elastic Bands And Cylinder Assembly

    Apply spacer 5 to the control side. Then apply all other parts. Screw 6 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 101 Insert the second circlip in the specific seat of the piston, placing the open part either upwards or downwards. Remove the previously inserted cloth. Abundantly oil the skirt of the piston with engine oil and insert the elastic bands, which edges must face the area with the stop pin.

  • Page 102: Check Of Crankcase/Cylinder Gasket Thickness

    3.12.7 CHECK CRANKCASE/ CYLINDER GASKET THICK- NESS 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 103: 3.12.8 Head Application

    Measure the play with a gauge if the piston push- es the plate upwards, causing contact to be lost between plate and cylinder: if the play is greater than 0.05 mm, the thickness of the cylinder/cas- ing gasket must be increased and the check must be done again.

  • Page 104: 3.12.9 Exhaust Valve

    3.12.9 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 105 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 106 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. Displacement Regulation of adjustment screw [cm³] (from all open) 1 + 1/2...
  • Page 107 3.12.10 APPLICATION OF COVERS Apply the valve control unit cover and relative screws. Tighten to the specified torque. Application and tightening of valve control unit cover screws. Apply the expansion chamber side gasket and cover. Apply the screws and tighten them to the specified torque.

  • Page 108: Check Of Intake Unit And Assembly

    3.13 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. Remove the petals by pressing the central body as shown in the picture and remove the outer petals.
  • Page 109 Remove the two central wedges and remove the petals. Assemble the multiflap by following the just de- scribed procedure, in reverse order. Disassembly of central wedges. The extraction of only one is shown in figure. For assembly of the entire intake system, apply the manifold to the reed valve, the gasket 4, the spacer 5 and another gasket.

  • Page 110: Insertion Of Clutch Rod And Pinion Spacer

    3.14 INSERTION CLUTCH ROD AND PINION SPACER Apply the pinion spacer 5 to the secondary of the gearbox 1, so that the groove is facing inside the engine. Note: check the O-ring 4 is present. If so, apply it. Insert the gearbox rod in its seat from the lower diameter side.

  • Page 111: Engine Reassembly In The Vehicle

    ENGINE REASSEMBLY IN THE VEHICLE ∙ Insert the engine in the frame. We recommend insertion from the frame’s left side. ∙ Insert the engine pins 1 and the swingarm pin Note: pay attention that the notch on the pin head is aligned with the notch on the frame. ∙...
  • Page 112 ∙ Apply the head connections by passing the gas cable and part of the electrical system, as shown in the figures. ∙ Fasten the nuts and bolts following the table below. Fixing Screw Torque [Nm] Threadlocker Medium- Head connection bracket to frame. M8 x 16 resistance Head connection brackets to engine...
  • Page 113 ∙ Make sure the filter box sleeve is correctly in- serted inside the carburettor, fasten the two filter box side and manifold side straps. ∙ Remove the cap applied to the mixer tube (see page 13). ∙ Slide the tube through the tube hole 5 and connect it to the nozzle 6 on the intake man- ifold.
  • Page 114 ∙ Connect the connector 7. ∙ Feed through the cables as shown; secure them to the metal cable gland as shown in the figure. Connect the connector 8 to the electrical system and secure the cable as shown in the figure.
  • Page 115 Connect the engine ignition unit to the electrical system. The Faston connectors must be connected ac- cording to the corresponding colours (white cable with white cable, yellow cable with yellow cable). ∙ Apply the unit clutch actuator to the two 9 fix- ing screws.
  • Page 116 Apply the right radiator to the frame. The opera- tion is easier if pipes are inserted observing the order shown in the figure. Apply the fixing screws and tighten them to the specified torque. 10Nm Tighten the clamps indicated.
  • Page 117 Apply the left radiator to the vehicle. The opera- tion is easier if pipes are inserted observing the order shown in the figure. Apply the fixing screws and tighten them to the specified torque. 10Nm Tighten the clamps indicated. Apply the radiator grids paying attention to their correct insertion.
  • Page 118 ∙ Apply the exhaust expansion by first assem- bling the front springs and then applying the two fixing screws. ∙ Apply the silencer and fasten the two fixing screws to the indicated torque. Fasten the ex- pansion fixing screws to the frame at 7Nm. ∙...
  • Page 119 Place the tank on the vehicle and connect con- nector 15. Insert pipe 16 observing its path as shown in the figure. Push the tank towards the front and downwards. Tighten the tank screws to the indicated torque. Reconnect pipe 17 to the tank. 10Nm Reconnect the tank to the carburettor and secure the tube using the specific tube straps.
  • Page 120 ∙ Grease the rear fastener and tighten the screws at the indicated torque values. ∙ Apply the seat. ATTENTION! Disconnecting the mixer tube from the intake manifold could cause air to get into the tube it- self. To avoid any lubrication problems with the thermal unit and crankshaft, use fuel with a 1% blend for the first fill-up.

  • Page 121: 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-strength Kickstarter lever M6 x 20 Optional (optional) threadlocker Inner side right crankcase half Desmodromic control Medium-strength M5 x 8 bearing fixing threadlocker Crankshaft...
  • Page 122 Torque Fixing Diameter x Length Quantity Threadlocker Notes [Nm] Counterweight unit Medium-strength Counterweight M8 X 15 threadlocker Water pump In common Cover M6 x 60 with inner clutch cover Cover M6 x 30 Medium-strength Impeller M5 x 12 threadlocker Exhaust valve control Medium-strength Flange M6 x 20...

  • Page 123: Table Of Frame/Engine Tightening Torques

    TABLE OF FRAME/ENGINE TIGHTENING TORQUES Torque Diameter x Fixing Quantity Threadlocker Notes Length [Nm] Engine pins Special Swingarm pin M16 x 245 Head connection Medium- bracket to frame. M8 x 16 strength Front fixing threadlocker Head connection M8 x 65 brackets to engine TABLE OF SUPERSTRUCTURE TIGHTENING TORQUES Diameter...

  • Page 124: Recommended Engine Maintenance

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

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