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Betamotor EVO 4t Workshop Manual

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WO R KS H O P MA N UA L

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  • Page 1 WO R KS H O P MA N UA L...
  • Page 3 WORKSHOP MANUAL 2009...

  • Page 5: Table Of Contents

    3.11 OIL PUMP (RIGHT-HAND CRANKCASE) ..4.17.2 Fitting the valvegear ............3.12 TIMING SPROCKET ................ 3.13 SPLITTING THE CRANKCASE 4.18 CLUTCH CASING .......................... 3.14 GEARBOX AND SHIFTING MECHANISM 4.19 IGNITION ........................ 3.15 CRANKSHAFT 4.20 FINAL DETAILS ....................................betamotor.com...

  • Page 7: Introduction

    Note for information Betamotor S.p.A. is committed to a policy of continuous improvement of its products. For this reason it is possible that you will encounter slight differences between what is stated in this manual and the vehicle on which you are about to carry out repair and/or mainte- nance.
  • Page 8 • In case of exposure to high concentrations of fumes, take the affected person into an unpolluted environment and if necessary call a doctor. betamotor.com...
  • Page 9 • Always replace parts such as gaskets, O-rings and safety washers with brand new parts. • When loosening or tightening nuts or bolts, always start with the largest or from the cen- tre. Always follow the recommended torque settings. • Use only original Betamotor spare parts. betamotor.com...
  • Page 10 Front brake caliper (upper) 8x1.25L55 [8.8] Front brake caliper (lower) 8x1.25L35 [8.8] Rear brake master cylinder to frame 6x1L16 [8.8] Brake pedal 8x1.25L20 [8.8] Brake disk cover 4x0.7L14 [8.8] EXHAUST Silencer to frame (upper) 6x1L25 [8.8] Silencer to frame (lower) 6x1L10 [8.8] betamotor.com...
  • Page 11 Disc brake 6x1L16 [8.8] Sprocket 8x1.25L33 [8.8] PLASTICS / TANK Front mudguard 6x1L16 [8.8] Rear mudguard 5x0.8L8 [8.8] Headlight mask (upper) 5x0,8L20 [8.8] Headlight mask (lower) 5x0,8L30 [8.8] Tank panels 5x0,8L8 [8.8] Front disc cover (lower screw) 5x0,8L16 [8.8] betamotor.com...
  • Page 12 OIL PUMP GROUP Cover, oil pump LH Screw M6x14 Cover, oil pump RH Screw M6x20 Screw M6x15 Pivot, oil pump idler gear Screw, shallow, M6x25 Intake filter cover, output oil pump M20x1.5 Intake filter cover, scavenge oil pump M20x1.5 betamotor.com...
  • Page 13 Engine mounting bolt, lower Nut M10 Mounting bolt, cylinder head Nut M8 SPECIAL TOOLS 01.00040.000 01.00041.000 01.00042.000 Flywheel extractor Key for water pump shaft Crankcase splitter 01.00043.000 01.00044.000 01.00045.000 Valve spring fitting tool Inner clutch hub locking tool Carburettor adjusting spanner betamotor.com...

  • Page 14: Lubrication Circuit

    The oil in the cylinder head, however, returns to the base of the gearbox passing through the timing case and the inner clutch casing. 1.1 ENGINE OIL Use only fully synthetic oils of a reputable brand (BARDAHL XTC60 15W50). betamotor.com...

  • Page 15: Checking The Engine Oil Level

    Unscrew the oil drainplug and let all the oil flow out into a drain pan. Thoroughly clean the magnet on the drainplug to get rid of the metallic impurities that it has collected. betamotor.com...
  • Page 16 O-rings, and replace them if necessary. Refit all the parts and tighten the plug to 15 Nm. Carry out the same procedure for the output mesh filter, for which the access is via the right-hand en- gine casing. betamotor.com...
  • Page 17 0.81 of engine oil (BARDHAL XTC60 15W50). N.B. If the engine has been opened up for an internal inspection, the quantity of oil to put in is 0.9 litres. Finally, tighten the oil filler plug (A) to 10 Nm. betamotor.com...

  • Page 18: Engine Removal And Refitting

    Deeply clean the whole bike and position it on a steady stand. Disassemble front fender. Disassemble silencer. Unhook the two springs located in front of the en- gine head (A). Then disassemble the exhaust col- lector (B). Disassemble the bumper. betamotor.com...
  • Page 19 Disassemble left panel and disconnect connectors C and D of the electric fan and bulb. Disconnect the coil from radiator and unplug the pipe from the spark plug. Disconnect oil vapour hose (E) and Hot Start hose (F). betamotor.com...
  • Page 20 ENGINE REMOVAL AND REFITTING Make sure that the fuel petcock is closed (lever in position “C”). Disassemble the rear brake oil tank by un- screwing the fixing screw. Loosen the carburettor fixing clamp. betamotor.com...
  • Page 21 Loosen the rear wheel axle and take off the chain from the sprocket. Disassemble the clutch slave cylinder unscrewing the three fixing screws (B). Disassemble regulator support unscrewing the two fixing screws located in the back of the engine. betamotor.com...
  • Page 22 (A). Open the radiator plug (B) in order to drain all the liquid contained in the system. Loosen the clamps used to block the tubes of the cooling system respectively to cylinder (A) and to water pump (B). betamotor.com...
  • Page 23 ENGINE REMOVAL AND REFITTING Unscrew the screws which block connecting rods to frame (A), loosen and take off the engine front fixing pin (B). betamotor.com...
  • Page 24 ENGINE REMOVAL AND REFITTING Disassemble the whole block connecting rods-ra- diator-electric fan. Loosen the three head screws. Loosen the blocking nut of the engine lower fixing pin. betamotor.com...

  • Page 25: Refitting The Engine

    0.6 litres. Caution Do not run the engine with the voltage regulator con- nected to the electrical generator without also con- necting the vehicle wiring harness (central system). Doing so could cause damage to the regulator itself. betamotor.com...

  • Page 26: Dismantling

    3.1 DRAINING THE OIL Remove the oil drainplug and let the oil flow out into a drain pan. Take out the oil filters from the left-hand (1) and right-hand (2) crankcase halves after first removing the filter covers. betamotor.com...

  • Page 27: Ignition

    Remove the sprocket from the output end of the layshaft after first removing the retaining circlip, and then remove the further circlip located behind the sprocket. betamotor.com...
  • Page 28 After you have removed the water pump cover and its retaining bolts, remove the circlip which retains the impeller, and then the impeller itself. Then use the special tool (A) to unscrew the water pump shaft from the gear which takes its drive from the camchain. betamotor.com...
  • Page 29 For the inner bearing, use a slide hammer with a suitable internal extractor. betamotor.com...

  • Page 30: Cylinder

    3.5 FLYWHEEL Unscrew the flywheel retaining nut (A) and extract the flywheel using the special extractor (B). Screw the extractor into the threads in the flywheel and extract it by tightening the central bolt which bears on the crankshaft. betamotor.com...

  • Page 31: Oil Pump (Left-Hand Crankcase)

    _unscrewing the retaining screws (1). Next, extract the pump outer rotor (4) using a pair of circlip pliers, after you have removed the pin (3). Then remove the inner rotor (5) and the O-ring (6) which seals the cover. betamotor.com...

  • Page 32: Clutch

    O-rings. Then unscrew the bolts holding the clutch casing (3) after you have removed the kickstart lever. Unscrew the bolts (1) retaining the clutch springs (3) in diagonal sequence to prevent the friction pla- tes (8) from jamming when the springs are relea- sed. betamotor.com...
  • Page 33 (3) and the clutch pressure plate (4). Next, remove the friction plates (8) and then the pressure plate lifter (7), the needle roller bearing (6) and the corresponding washer (5). Using a screwdriver, release the tabs on the tabwa- sher (10). betamotor.com...

  • Page 34: Primary Transmission

    Extract the clutch centre (11), the thrust washer (12), the clutch basket (13), the bush (14) and the thrust washer (15). 3.8 PRIMARY TRANSMISSION Unscrew the crankshaft nut (1) and extract the pri- mary transmission gear (2). Also remove the washer located between these two components. betamotor.com...

  • Page 35: Kickstart

    Remove the kickstart ramp (8) after you have relea- sed it by taking out the retaining bolts (7). N.B. To facilitate removal of the ramp, heat it to sof- ten the thread lock on the two retaining bolts.. 3.10 SHIFTING MECHANISM betamotor.com...

  • Page 36: Oil Pump (Right-Hand Crankcase)

    (5, 6). Extract the oil pump shaft (8) together with the pin (9), and then remove the oil pump rotors (10), adopting the same procedure as was used for the oil pump in the left-hand crankcase half. betamotor.com...

  • Page 37: Timing Sprocket

    Use an engineering chisel to remove the woodruff key (2) from its housing in the clutch side crankshaft end, and then extract the timing gear (1). 3.13 SPLITTING THE CRANKCASE Remove the ball and the clutch pushrod. Unscrew all 11 bolts that hold the crankcase together. betamotor.com...

  • Page 38: Gearbox And Shifting Mechanism

    Then screw in the bolt at the end of the special tool until the two crankcase halves are separated, and manually take off the left-hand crankcase half. 3.14 GEARBOX AND SHIFTING MECHANISM Extract the selector fork spindles (1) and the gear- box selector drum (2). betamotor.com...

  • Page 39: Crankshaft

    Then screw in the bolt at the end of the spe- cial tool until the crankshaft is extracted. If the bearings need to be replaced, heat the cran- kcase to 150°C. The bearings will be easy to extract at this temperature. betamotor.com...

  • Page 40: Assembly

    Fit the breather nozzle (7), applying medium-streng- th thread lock to the threads. Fit the oil jets (8) and secure the selector drum be- aring (4) with its retaining bolts (9), applying me- dium-strength thread lock tightening these to 10 betamotor.com...
  • Page 41 Press it in until it is flush, with the open side facing inwards. N.B. Remember to always grease the outer surface of oilseals to help seat them properly in their housings. betamotor.com...

  • Page 42: Left-Hand Crankcase

    Fit the oilseals for the crankshaft (5), layshaft (6) and gearchange shaft (7), all with the open side fa- cing inwards. Remember to grease the outer surfa- ce to facilitate seating. Fit the oilway expansion plug, driving it home with a suitable pin punch. betamotor.com...

  • Page 43: Clutch Casing

    4.3 CLUTCH CASING Fit the kickstart oilseal (1) in its housing with the open side facing inwards, making sure that it goes fully home. Threadlocker Blue betamotor.com...
  • Page 44 Close the oilways with the special oilway expansion plugs (4), using a pin punch. Make sure that the oilway is clear by blowing it through with compressed air. Fit the oil level plug (5), tightening it to 10 Nm. betamotor.com...

  • Page 45: Gearbox And Shifting Mechanism

    17x20.5x1 (6). - 4th idler gear (7) with housings for the dogs fa- cing downwards, spacer (8) and 15x25x1 thrust washer (9). N.B. Check that the gears slide correctly. N.B. Apply molycote grease between shaft and ge- ars. betamotor.com...

  • Page 46: Layshaft

    (A), and between the pegs and the grooves in the selector drum (B). Fit the pegs (2) to the selector forks (1), using gre- ase. betamotor.com...
  • Page 47 N.B. Always remember to oil the various parts in con- tact with each other (pegs/selector drum grooves, selector forks/gears, etc.). N.B. Turn the two gearshafts over by hand to make sure that everything moves correctly. betamotor.com...

  • Page 48: Crank Assembly

    The limit value for this difference is 0.03mm. You also need to check the side-float at the conrod big-end, whose value must be within the following range: Recommended clearance: 0.15-0.35mm Maximum clearance: 0.50mm betamotor.com...

  • Page 49: Closing The Crankcase

    N.B. It is good practice to change the gaskets each time the crankcase is opened. After heating the left-hand main bearing, place the left crankcase half over the right half, and use a pla- stic hammer to close up the two halves until they are positioned correctly. betamotor.com...

  • Page 50: Shifting Mechanism

    (A) and the other on the tang (B) on the movable pawl. - Fit the spring guide (4) and the return spring (5), hooking it onto the pin on the fixed pawl (D) by means of its two ends (C). betamotor.com...
  • Page 51 10 Nm after applying medium-strength thread lock. Threadlocker Move the detent lever out of the way and fit the detent cam (5). Secure with the M6x35 bolt (6) tightened to 10 Nm after applying medium-strength thread lock. betamotor.com...

  • Page 52: Timing Sprocket

    Fit the movable camchain guide (2) and secure it with the M6x12 screw (1), after applying medium- strength thread lock. Tighten to 10 Nm. Fit the camchain, running it round the sprocket and passing it through the slot in the timing case. betamotor.com...

  • Page 53: Oil Pumps

    (3) into the second hole from the top. Use a feeler gauge to check the clearance betwe- en inner rotor and outer rotor. If you find that the- re is play beyond the permitted limits, replace the pump. Maximum clearance 0.20 mm. betamotor.com...
  • Page 54 Fit the O-ring (14) into its seat and refit the cover (15) to the pump. Tighten the M6x14 screws (16) to 10 Nm. Rotate the gear (10) by hand and check again that it moves properly. betamotor.com...
  • Page 55 Use a pin punch with a taper point to facilitate fit- ting. Refit the filter covers (20), tightened to a torque of 10 Nm, after fitting the O-rings (19). Also close the oil drain hole with the drainplug (21) and 16x22.5x1 gasket, tightening it to 20 Nm. betamotor.com...

  • Page 56: Kickstart

    Fit the return spring (11), securing the end in the hole provided (A), and fit the spacer with the recess for the spring facing downwards. Fit the ramp (14) with two M6x20 bolts. Tighten the bolts to 8 Nm after first applying thread lock to the threads. betamotor.com...

  • Page 57: Assembling The Kickstart

    N.B. Before you assemble the various parts, check the wear on the gear teeth and on the contact surfa- ces between the ramp (14) and the kickstart sleeve (3). In the event of excessive wear, replace the da- maged components. 4.11 PRIMARY TRANSMISSION GEAR betamotor.com...

  • Page 58: Clutch

    Unscrew the TDC locking bolt to facilitate assembly of the clutch. Fit the 18.3x35x2 washer (4) after first oiling its housing in the clutch basket assembly (3). betamotor.com...
  • Page 59 N.B. Remember to oil the plates during the assem- bly process. Recommended procedure is to keep the drive plates in an oil-bath for 10-12 hours before as- sembly. betamotor.com...
  • Page 60 Minimum value 33.3mm (33.8mm when new). Fit the clutch pressure plate (13), the clutch springs (14), the special washers (15) and the M6x16 bolts (16). Tighten the bolts (16) in diagonal sequence to 10 Nm. Tighten the TDC locking bolt once more. betamotor.com...

  • Page 61: Flywheel

    Insert the drive key (1) in the keyway machined for it in the left-hand crankshaft journal, using a rubber hammer if necessary. Fit the flywheel (2) and secure it with the flanged nut (3), tightening to a torque of 120 Nm. betamotor.com...

  • Page 62: Piston And Cylinder

    0.1mm Measure the thickness of the two compression rings. Minimum thickness of upper ring: 0.87 mm Minimum thickness of lower ring: 0,77 mm Change the compression rings if their thicknesses are lower than these limits. betamotor.com...
  • Page 63 Measure the diameter of the hole in the piston for housing the piston pin. If the play between the pi- ston pin and its housing exceeds the limit, with the piston pin diameter within the prescribed limits, change the piston. limit of play 0.04mm betamotor.com...

  • Page 64: Fitting

    Check after fitting that the rings can rotate in their grooves without excessive impediment. N.B. When fitted, the piston must be have the arrow (6) facing towards the front of the engine (exhaust side). betamotor.com...

  • Page 65: Cylinder

    N.B. Ensure that both circlips are fitted with the ope- ning facing either upwards or downwards. Bring the cylinder down until it makes contact with the crankcase, if necessary with the help of a rub- ber hammer to settle it in position. Ensure that the betamotor.com...

  • Page 66: Cylinder Head Cover

    If the play of the spindle in the hole is outside the limit value, replace the rocker arm. limit of play 0.10mm Insert the oil plug (1) in its housing using a pin punch. Fit the adjuster screws (5) and the adjuster nuts on both rockers. betamotor.com...

  • Page 67: Cylinder Head

    Check the wear and the sealing surface of the valve seats. To do this, apply a thin layer of engineer’s Prussian blue to the contact area of the valve with betamotor.com...
  • Page 68 Measure the compression strength of the valve springs with a pressure dynamometer at length L1: outer spring: F=200±9n at l1=30mm inner spring: F=110±6n at l1=26.5mm Using a suitable tester, check how well the valves seal once the head is assembled. betamotor.com...

  • Page 69: Fitting

    (inlet 7, exhaust 8), secure them with the split collets (9) using the special tool (A). The operation must be carried out individually for each valve. N.B. Used valves must always be refitted in the same guide as they were in before dismantling. betamotor.com...

  • Page 70: Valvegear

    Standard length of cam 33.258±0.030mm diameter of cam base circle 28±0.015mm Fit the camshaft sprocket (2) onto the camshaft (1) with the flat face towards the cams, securing it with the M6x10 screws and tightening to 10 Nm after applying medium-strength thread lock. betamotor.com...

  • Page 71: Fitting The Valvegear

    Check the diameter of the water pump shaft in the area where it makes contact with the seals. Signs of wear may be visible in this area. If the diameter is less than the limit value, replace the shaft to avoid sealing problems. Minimum diameter 9.7mm betamotor.com...
  • Page 72 Fit the head cover bolts: two M6x25 (13), four M6x55 (15) with the corresponding washers (14), and four M6x35 (16), tightening them to 10 Nm. betamotor.com...
  • Page 73 Fit the water pump impeller (19), securing it with the circlip (20). Apply some grease in the area of the threads in order to help the gasket (21) to adhe- re, and fit the cover (22) to the pump, tightening the three M6x20 bolts to 10 Nm. betamotor.com...

  • Page 74: Clutch Casing

    Before you proceed to fit the clutch casing, oil all the moving parts well, and also the areas which that have oil passing through them, such as the cran- kshaft and the oil jet. Then locate the dowels (A). betamotor.com...
  • Page 75 Fit the clutch cover (8) and the oil filter cover (7), retaining them with M6x20 bolts (four for the clutch cover and three for the oil filter cover). Tighten the bolts to 10 Nm. Refit the oil filler plug (10) after first applying the O-ring (9) to it. betamotor.com...

  • Page 76: Ignition

    M5x25 screws (4). Tighten the screws to 6 Nm. Take care that the stator cable guide plate is facing towards the inside of the cover. Fit the cable retaining plate (5) and the pickup (6), tightening the two M6x12 retaining bolts to 8 Nm. betamotor.com...

  • Page 77: Final Details

    Fit the air bleed screw for the cooling circuit (9) with its washer (8) and the water drain screw (7) with its washer (6), tightening both of them to 8 Nm. Connect the carburettor flange (10) and tighten the two M6x16 bolts (11) to 10 Nm. betamotor.com...
  • Page 78 (exhaust side). Fit the special washer between the TDC bolt and its housing on the crankcase. As a result, the crankshaft is no longer locked. Fit the kickstart lever and check that the whole kick- start system moves correctly. betamotor.com...
  • Page 80 BETAMOTOR S.P.A. PIAN DELL’ISOLA, 72 50067 RIGNANO SULL’ARNO (FIRENZE) ITALIA TEL. +39 055 83 48 741 FAX +39 055 83 48 984 WWW.BETAMOTOR.COM INFO@BETAMOTOR.COM...

This manual is also suitable for:

Evo 4t 2009

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