Beta Motorcycles X Trainer 300 2T 2015 Workshop Manual Download

Page: 41 / 117

ENGI

E d

SSEM

Removal of crankshaft.

2.8.2 Crankshaft

The crankshaft

can be pulled out by hand.

Delicately hit the crankshaft far right in case of

resistance.

Summary of Contents for X Trainer 300 2T 2015

Page 1: ...CODE 036440030 000...

Page 2: ...liquid pump clutch unit main gear centrifugal unit gearshift organs kickstart 24 2 6 1 Cooling liquid pump removal 27 2 6 2 Removal of centrifugal unit and leverage 28 2 6 3 Removal of main gear and c...

Page 3: ...of pump unit and disassembly centrifugal unit and idler unit 73 3 9 2 Centrifuge unit group assembly 74 3 9 3 Pump unit assembly 77 3 9 4 Assembly of complete clutch cover and pump unit 77 3 10 Elect...

Page 4: ...ldren PREAMBLE This publication has been written in order to make operations for inspection maintenance and repairs of the mo torcycle engine known and understandable to the user of the motorcycle and...

Page 5: ...tly and cause burns Coolant contains dangerous substances which are harmful for the environment When changing it you must be equipped to dispose of it in compliance with existing law Do not disperse c...

Page 6: ...ratio 19 28 4th gear ratio 20 24 5th gear ratio 27 27 6th gear ratio 28 24 Carburetor 300 Version Approv Race Carburetor type PWK 36S AG Main jet 118 155 Slow jet 38 35 Ignition jet 50 85 Needle N84K...

Page 7: ...rankcase Cylinder gasket check plate code 026140020 000 4 Front bracket code 026140030 000 to fix engine to stand code 3625132 000 5 Flywheel blocking tool code 026140040 000 6 Flywheel extractor code...

Page 8: ...ateral sides To take down the tank you must completely unscrew the two screws 1 that fasten the tank to the frame and the screws 2 two per side that fasten the side to the vehicle disconnect the by pa...

Page 9: ...fixing the clutch actua tor to the crankcase half ATTENTION Do not activate the clutch lever with actuator de coupled from engine 8 6 7 9 Remove the exhaust expansion and the silenc er Drain the cool...

Page 10: ...e the com plete coil support out of the intake manifold 10 Disconnect the water hoses from the engine and from the right radiator Disconnect the electrical connectors for the right radiator accessorie...

Page 11: ...e 11 out from the intake manifold and tube hold 12 Cut all straps binding the engine s electric sys tem to the clutch pipe and to the Then disconnect the connectors A TPS sensor B Pick Up C stator uni...

Page 12: ...1 10 REMOVAL OF ENGINE FROM VEHICLE Remove the start motor cable fixing nut Remove the head connections Attention When the mixer tube has been dis connected plug it to prevent emptying...

Page 13: ...l re turn spring 13 Remove the kickstarter lever Optional Remove the gear lever 13 Loosen the carburetor straps from the air filter sleeve and from the manifold Remove the seat rail lower fixing screw...

Page 14: ...ettor from the manifold leaving it connected to the gas cable Remove the swingarm pin 17 and the upper shock absorber pin 16 Remove the engine pins 18 18 17 16 Attention When the carburettor is discon...

Page 15: ...1 13 REMOVAL OF ENGINE FROM VEHICLE Extract the engine from the frame and apply it to the specific stand code 3625132 000 using spe cific front fixing bracket code 026140030 000...

Page 16: ...fixing code 026140030 000 in order to work in comfort and safety Then proceed as follows Remove the spark plug 2 Motor disassembly 2 1 Clutch gear oil drain Remove screw 1 and let the oil drain 1 2 2...

Page 17: ...assembly 2 3 Removal of piston cylinder 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...

Page 18: ...k 5 and remove it Release the control rod 6 Remove the gasket 7 It may be necessary to force the rubber gasket 8 slightly place a metal pin A between the lever and the gasket 8 and force it externally...

Page 19: ...2 17 Engine disassembly Remove the four collar nuts 9 9 Extract the cylinder and base gaskets...

Page 20: ...n bolt with an aluminium cylinder or similar B until the pin bolt is released from the connecting rod foot Remove the piston the pin bolt and the bear ing from the connecting rod foot ATTENTION Try pu...

Page 21: ...cover 2 4 1 Flywheel cover plate removal 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 co...

Page 22: ...r and extract the stator e Disassembly of stator from cover Removal of flywheel nut 2 4 3 Flywheel removal Block the flywheel using special tool A code 026140040 000 and remove the fastening nut secur...

Page 23: ...3 onto the threaded part on the flywheel Keep the extractor blocked with spanner and tighten the screw on the extractor using a box spanner Release of flywheel using special tool B Removal of pick up...

Page 24: ...ana sull inneseto Bendix 4 The coupling gear axially shifts and meshes onto the ring gear which is one with the flywheel due to the start motor rotation The coupling gear retracts to its rest position...

Page 25: ...Remove the two screws 1 and extract the motor itself Removal of start motor Removal of Bendix coupling 2 5 2 Bendix clutch removal Extract the Bendix coupling once the complete flywheel cover and flyw...

Page 26: ...t main gear centrifugal unit gearshift organs kickstart Remove the cover by loosening the four screws 1 to access the coolant liquid pump 2 Note remove the coolant liquid pump impeller if having to in...

Page 27: ...3 4 2 25 Engine disassembly Remove the outer clutch cover by loosening the five screws 3 to access the clutch unit only 4 Outer clutch cover screws...

Page 28: ...smission 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 crankc...

Page 29: ...l Loosen fixing screw once the coolant liquid pump cover has been removed 1 Cooling pump fixing screw Removal of impeller Removal of pump body and gasket Extract the impeller 2 and the thrust 3 Extrac...

Page 30: ...it and leverage by removing the inner clutch cover Disassemble the adjustment cover by removing the two screws 1 once the pump impeller has been removed par 2 6 1 2 Removal of centrifugal adjustment c...

Page 31: ...d gasket 6 once the screw fixing the rocker arm 7 to the centrifugal control lever has been removed 8 Disassembly of control rod rocker arm unit Removal of centrifugal control lever Extract the centri...

Page 32: ...omplete centrifugal unit 10 Extraction of centrifugal unit 1 Control cover 3 Adjusting spring 4 Auxiliary spring 5 Spring guide 6 Rocker arm 7 Centrifugal control lever 8 Gasket 9 Thrust washers 10 Ce...

Page 33: ...disc pack 2 6 3 Removal of main gear and clutch unit Remove the four screws 1 fastening the clutch cap 2 to the clutch drum Remove the clutch cap together with the four washers and relative springs C...

Page 34: ...must be blocked with a relevant tool A code 026140010 000 Insert the main special tool on the drum so that its inner teeth mesh in those present on the clutch drum the tube on the tool inserts on the...

Page 35: ...t to be able to disassemble the main gear Attention The nut must be turned clockwise Disassembly of the main gear nut Remove the washer 7 the case 8 the roller cage 9 and the centre bearing 10 Safety...

Page 36: ...then meshes with the clutch case The device moves back thanks to the spring 4 Remove the external circlip 5 and pull off the external thrust washer 6 the idler gear 3 the internal thrust washer 7 and...

Page 37: ...rankcase and bring it to a rest position having it turn anti clockwise Turn the shaft anti clockwise and pull it off together with the sleeve 9 the spring 10 and the thrust washer 11 Release of spring...

Page 38: ...e pawl return spring 3 pressed and extract the shaft together with specific washer 4 In order to disassemble the stop cam 2 keep the cam stop lever moved 5 loosen the screw 6 and pull out the stop cam...

Page 39: ...cer 300cc only 2 7 Intake system The intake system mainly consists of the intake manifold 1 and reed valve 2 and spacer in case of 300cc 3 Disassemble by removing the four screws 4 fastening the intak...

Page 40: ...tool B to the right crankcase half following the punching on the tool itself Fix the tool with the four M6x20 screws maximum torque 10Nm Tighten screw C on the special tool Slightly hit the gear seco...

Page 41: ...2 39 Engine disassembly Removal of crankshaft 2 8 2 Crankshaft The crankshaft 1 can be pulled out by hand Delicately hit the crankshaft far right in case of resistance 1...

Page 42: ...t in the external gearshift unit Extract the two pins 4 by hand so that the forks can be released and removed Turn the fork 2 which drives the sliding gear on the primary unit clockwise to free it fro...

Page 43: ...o remove the various components attached to it The bearings must be replaced if they play or get jammed during rotation For removal oven heat the crankcase halves for 20 minutes at about 150 C Place t...

Page 44: ...e disassembly Kickstart ramp 1 optional with kick starter crankshaft spacer 2 and relative O ring oil seal 3 Bearing safety screw Remove the desmodromic control bearing seal screw 4 from the inner sid...

Page 45: ...8 and 9 are removed from the outside to the inside Remove fixing screws 9 to disassemble bearing 10 The centrifugal shaft bearing can be removed by using a universal extractor that must rest onto a p...

Page 46: ...crankshaft oil seal 1 the secondary shaft oil seal 2 and the gearshift shaft oil seal 3 Removal of outer side left crankcase half oil seal Removal of left crankcase half bearings The bearings 4 5 6 an...

Page 47: ...for 20 minutes Place the crankcase halves on a large surface where their whole seal surface can rest When the bearings cool down they drop into their seats on their own 3 1 Crankcase half The crankcas...

Page 48: ...ft bearing 3 1 1 Special applications for right crankcase half Apply the bearings1 2 3 and 4 until flush Block bearing 4 with specific screw prior depositing of threadlockers Fasten at 6Nm Apply the b...

Page 49: ...e spacer 17 onto it by inserting the smaller diameter segment in the lever Apply the spring 16so that the hook fits into the groove on the lever 18 and then apply the washers 19 and the screw 20 M6x20...

Page 50: ...nal side as shown in the drawing Apply the crankshaft oil seal gear secondary shaft and gearshift shaft Apply the bush with collar 5 Apply new oil seals to be pressed in seat until they are flush Appl...

Page 51: ...s by measuring radial oscillation by placing the crankshaft in between two tailstocks or similar instrument Control the maximum measurement variation during a complete turn using comparators positione...

Page 52: ...e the crankshaft oil seal on the right crankcase half and couple the crankshaft to the left crankcase half Keep the conical part A present on the crankshaft towards yourselves In order to carry out th...

Page 53: ...icated below service limit 0 5mm If the detected axial play is greater before re placing either the gearwheels or the forks check their state of wear par 3 4 4 Remove the various elements and check th...

Page 54: ...Third and fourth on primary 7 Thrust washer 8 Sixty on primary 9 Second on primary 10 Thrust washer 17x30x1 Insert onto the lower cylinder part of the shaft the roller cage 2 the 5th gear 3 turning th...

Page 55: ...protective jaws so that the grooved end faces downwards Insert onto the lower cylinder part the roller cage 15 the 2nd gear 19 so that the front claw clutches face downwards the 26x32x1 5 thrust washe...

Page 56: ...made up of two forks 13 which drive two gears on the sec ondary unit one fork 14 which drives one gear on the pri mary unit three drive pin bushes 15 two fork pins 16 desmodromic gearshift 18 through...

Page 57: ...mit 13 83mm Make sure that the fork pins upon which they slide have an outside diameter above the limit to be measured in the sliding areas of the forks and in the housing areas of the crankcases Fork...

Page 58: ...ber to oil the gears abundantly with gear oil and to grease the shafts supporting them in the areas where they are coupled with the bearing with graphitic grease Make sure that all the parts slide pro...

Page 59: ...ice Place the forks in their original positions if none of the components are replaced Insert the desmodromic device in the specific bearing In order to do this it is necessary to rotate cam stop leve...

Page 60: ...then in its proper seat Remember to oil the shafts forks and the desmo dromic device abundantly with gear oil Apply some grease on the crankcase edge in the coupling area with the gasket and rest a n...

Page 61: ...ing it will be possible to move it close to the right crankcase half by hand Put the clamping screws in place based on the length as illustrated in the figure The table below contains indications for...

Page 62: ...hift drive shaft needs more in depth inspections 3 6 1 Complete gearbox shaft check With the device complete make sure that the distance between the movable pawl and the drive shaft is between 0 35 0...

Page 63: ...te the gearshift return spring position For reassembly couple the movable pawl 9 to the drive shaft 10 and while compressing it in sert the spring 8 between the movable pawl and the drive shaft The ap...

Page 64: ...nit you just need to temporarily couple the external gearshift lever and to simulate the operation of changing gears by lifting and lower ing the gearshift lever and having the main shaft of the gear...

Page 65: ...e side 14 are not chipped Replace any element that has the aforementioned defects Make sure that the front teeth of the sleeve 14 are not chipped and that the spring 16 is capable of putting enough pr...

Page 66: ...ng keeping the thin striped facing outwards and making sure that the ramp A on the kickstart sleeve is positioned below the ramp B bolted onto the right crankcase half external side Turn the spring cl...

Page 67: ...ert 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 Kickstart de...

Page 68: ...application Apply the O ring 18 the spacer 12 and gear14 on the right half shaft so the appropriate groove inserts inside the Woodruff key 17 Apply lock nut 15 prior depositing of medium strength thre...

Page 69: ...start idler gear and oil pumps have no superficial nicks or abnormal wear Also closely check that the teeth C upon which the driving discs engage are not chipped or deeply cut Check the external surfa...

Page 70: ...the thickness of the teeth of each driving disc They must not be less than the minimum value fixed at minimum driving disc tooth thickness 13 3mm Check the state of use of the silent blocks as fol low...

Page 71: ...pressure between the clutch discs the state of the springs must be checked The minimum acceptable length must be 42mm Clutch spring length measurement Check of clutch drum teeth 3 8 6 Clutch drum chec...

Page 72: ...ernal centre bearing 4 to which the roller bearing must be coupled 5 Insert the clutch case 1 followed by the 21 7x38x3 washer 6 upon which the clutch drum will rest 2 Put on the safety washer 7 and a...

Page 73: ...discs with gear oil and pro ceed to apply the discs alternating driving discs and driven discs Notice that the driven discs must be inserted so that the radius on the teeth faces inwards to wards the...

Page 74: ...gal unit The water pump must guarantee depending on the set rotation speed the correct flow rate of the coolant in order to extract the needed amount of heat from the thermal unit The centrifugal unit...

Page 75: ...Check the device s axial stroke A is between 6 4 6 6mm On the contrary replace the unit View in centrifugal unit section stroke A Exploded view of centrifugal unit Exploded view of bearings and centr...

Page 76: ...3 9 2 Centrifuge unit group assembly Insert the centrifugal unit 20 in inner dutch cover Insert the centrifugal control lever 10 together with the washers 8 Insertion of centrifugal Insertion of cent...

Page 77: ...he valve control rod gasket and the rock er arm unit 1 valve control ros 4 Apply blocking screws 3 prior depositing of me dium strength threadlocker Fasten at 6Nm Application of valve control and rock...

Page 78: ...the inner clutch cover Apply the blocking screw prior ap plication of medium strength threadlocker and fasten at 6Nm 3 4 5 Spring guide and springs unit Fastening of adjusting cover Displacement cm3...

Page 79: ...edge must be at the same quota of the pump body outer side 3 9 4 Assembly of complete clutch cover and pump unit Apply a new gasket 1 placed between the right crankcase half and the inner clutch cover...

Page 80: ...screws as shown in figure fas tening them at 10Nm with a criss cross pattern Screws positioning Screw number Screw dimensions Threadlocker application Tightening torque Nm Threading length Threading l...

Page 81: ...ody to the clutch cover Apply washer 6 and water pump impeller 7 Apply screw 8 prior application of the medium strength threadlocker and fasten at 6Nm Couple the water pump cover to the pump body by a...

Page 82: ...ed and rotate the mobile cou pling 2 anti clockwise this must slide without jams By releasing the mobile coupling this must go back to rest position without jams Replace the whole unit if anomalies ar...

Page 83: ...EMBLY Pour about 7cc of gearbox oil PANOLIN OFF ROAD 4T SYNTH 10W 40 in area A Insert Bendix coupling 2 in bush with collar 3 present on the outer side left crankcase half A Application of oil Inserti...

Page 84: ...st be measured at a distance X from the inner edge of the skirt perpendicularly to the axis of the pin bolt Refer to the following table for the piston s se lection classes Quota at which to measure t...

Page 85: ...the contrary 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 cm Quot...

Page 86: ...he cylinder and piston In order to cal culate the coupling play between the cylinder and the piston a subtraction must be carried out between the diameter of the cylinder and that of the piston 3 11 4...

Page 87: ...chamber side Note Should it be necessary to descale the valve unit remove the screws 2 and 3 and extract the booster without removing the valve control unit Tighten one M5 screw to the booster control...

Page 88: ...s during functioning or excessive play once the unit has been cleaned and descaled On the contrary replace Check pins 5 6 and relative seats are not abnor mally worn On the contrary replace the worn p...

Page 89: ...e pin engages in the open slot in the valves the booster s area B is facing the front of the cylinder Apply the other booster Apply the four bearings two each side that sup port the boosters and fully...

Page 90: ...n the piston from opposite side to where the circlip was inserted leaving enough space to allow connecting rod coupling to piston Place a piston so that the arrow stamped on the crown is facing the fr...

Page 91: ...iston must be inserted in the cylinder fastening the elastic bands between the fingers The cylinder must be positioned so that the outlet port is fac ing the front of the engine Push the cylinder towa...

Page 92: ...calibrated plates set out in the table The use of the plates is described below Rest the specific plate making sure it comes into contact with the cylinder s upper sur face Bring the piston to top de...

Page 93: ...d in four different thick nesses 0 3mm 0 4mm 0 5mm that can also be stacked thus obtaining the nec essary height for the right thickness Note the above described check must be car ried out once all fo...

Page 94: ...troke lever is flush with the booster bearing clamping screw 2 Check the ball head 3 and teh seat 4 are per fectly aligned On the contrary loosen the lock nut adjust the seat and fasten the lock nut P...

Page 95: ...control rod is able to rotate around its axis making equal angles respect to the ball head axis Apply gasket 5 and insert the control rod Apply the stop 6 Check of control rod rotation Insertion of c...

Page 96: ...follows Bring the screw to all open position Tighten the number of turns indicated in the table The effects obtained from modifying the posi tion of the adjustment screw respect to the posi tions in t...

Page 97: ...valve control unit cover and relative screws Fasten at 6Nm Apply the resonance chamber side gasket and cover Apply the screws and fasten at 6Nm Application and fastening of valve control unit cover s...

Page 98: ...r application of the isolating silicone paste Apply the thread of the two screws 1 with me dium strength threadlocker and tighten them at a torque of 6Nm Element Cables Strength values Pick up Red Gre...

Page 99: ...ue of 10Nm Insert the cable gland in its specific seat and check its perfect sealing Fasten the nut to torque 60Nm keeping the flywheel blocked with special tool A code 026140040 000 Flywheel fastenin...

Page 100: ...rankcase and fasten a new gasket Apply the flywheel cover plate the twoscrews 13 M6x25 and the three screws 14 M6x20 Tighten in a criss cross pattern at a torque of 10Nm Application of flywheel cover...

Page 101: ...sembly Check the manifold 1 is intact and without cracks On the contrary replace it Check that the multiflap 2 of the reed valve 3 are intact and not deformed On the contrary replace them Remove the m...

Page 102: ...der For assembly of the entire intake system apply the manifold to the reed valve followed by the gasket 4 the spacer 5 and another gasket 4 Tighten the screws 6 a 10Nm Place the two screws 7 in the t...

Page 103: ...pinion spacer Apply the pinion spacer 5 to the secondary of the gearbox 1 so that the groove is facing inside the motor Note check the O ring 4 is present On the con trary apply it Insert the gearbox...

Page 104: ...insertion from the frame s left side Insert the engine pins 1 Apply the spark plug and fasten it at 28Nm 1 2 3 70Nm Apply the carburetor to the manifold making the breather tubes pass in the appropria...

Page 105: ...Head connection brackets to engine M8 x 60 35 Engine pins Special 45 Swingarm pin M16 x 245 125 Rotate the filter box in its normal position Apply the bottom clamping screws 4 one on each side before...

Page 106: ...e is correctly inserted inside the carburetor fas ten the two filter box side and manifold side straps Remove the cap applied to the mixer tube see page 10 Slide the tube through the tube hole 6 and c...

Page 107: ...earbox lever and fasten the screw at 10Nm prior application medium strength threadlocker Fasten the motor electric system and the start motor cable to the clutch cable Connect the connectors A TPS sen...

Page 108: ...nect the electrical accessories of the right radiator to the electrical system Apply the start motor cable and fasten the nut at 10 Nm Cover the connection using the specific protective cap Connect th...

Page 109: ...4 107 Reassembly of motor in vehicle Connect the radiators to the engine Fasten the tube clamp straps and introduce the cool ant liquid letting the air bleed through the screw plug A A...

Page 110: ...10Nm Apply the Kickstart lever optional Apply the medium resistance sealant threading on the screw and fasten at 25Nm Apply the brake pedal return spring 7 Insert the pinion in the chain and fasten i...

Page 111: ...d cause air to get into the tube itself To avoid any lubrication problems with the thermal unit and crankshaft use fuel with a 1 blend for the first fill up Use the oil recommended on page 133 in the...

Page 112: ...e 10 Clutch main transmission Main transmission pinion nut 1 Medium resistance 160 Drum nut and clutch case 1 Medium resistance 120 Do not use the pneumatic device Clutch cap M6 x 25 4 10 Clutch actua...

Page 113: ...ance 10 Right cover M5 x 16 3 6 Left cover M5 x 16 4 6 Ignition system Spark plug M14 x 1 25 1 28 Pick up M5 x 12 2 Medium resistance 6 Stator M6 x 25 2 Medium resistance 10 Flywheel nut 1 Medium resi...

Page 114: ...uantity Threadlocker Torque Nm Notes Front and lower engine connections M10 x 1 25 2 45 Swingarm pin M16 x 1 5 1 125 Brackets to connect head to frame M8 x 16 2 Medium resistance 35 Head connection br...

Page 115: ...e only depends on the level of use and respect of the periodical inspections The following intervals refer to a competitive use as long as the engine has not worked in extraordinary conditions and tha...

Page 116: ...114 NOTES...

Page 117: ......

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Beta Motorcycles X Trainer 300 2T 2015, Workshop Manual

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