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Eton beamer R2-50, Service Manual, Page: 29 / 63

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Eton beamer R2-50 Service Manual Download Page 29

 

Beamer R2 Rev 1.0 

Page 29 of 56 

6/13/2007 

7. TRANSMISSION SYSTEM 

7.1 TROUBLESHOOTING 

 

 

 

 

Vehicle will not move after engine is started 

 

 

 

¾

 

BELT WORN 

¾

 

FRONT PULLEY WORN OR BROKEN 

¾

 

CLUTCH LINING WORN

 

Vehicle will not attain high speed  

 

 

 

¾

 

BELT WORN 

¾

 

ROLLERS WORN 

¾

 

SPRING OF REAR PULLEY IS DISTORTED

 

¾

 

ELECTRONIC SPEED LIMITER EXCEDED

 

 

 

7.2 THE PARTS DRAWING OF 
TRANSMISSION SYSTEM 

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Summary of Contents for beamer R2-50

Page 1: ...ETON America Beamer R2 50 Service Manual Covers Beamer R2 50 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

Page 2: ...2 ENGINE INSTALLATION 16 4 ENGINE FUEL SYSTEM 17 4 1 TROUBLESHOOTING 17 4 2 CARBURETOR 18 5 ENGINE LUBRICATION AND COOLING SYSTEM 21 5 1 TROUBLESHOOTING 21 5 2 ENGINE LUBRICATION SYSTEM 21 5 3 CAUTIO...

Page 3: ...M 41 9 1 TROUBLESHOOTING 41 9 2 MAINTENANCE DATA 41 9 3 REAR WHEEL REMOVAL 41 9 4 REAR WHEEL INSPECTION 42 9 5 REAR BRAKE 42 9 6 REAR SHOCK ABSORBER PARTS DRAWING 43 10 PLASTIC BODY PARTS 44 10 1 FRON...

Page 4: ...pill the electrolyte on your skin or in your eyes flush thoroughly with water Call a doctor if electrolyte gets in your eyes 1 2 NOTES All information illustrations directions and specifications inclu...

Page 5: ...ear Unit Swing Arm Single Shock Brakes Front Hydraulic Disc Rear Hydraulic Disc Tires Front 120 90 10 Rear 130 90 10 Front Front 18psi 1 25kg cm2 Cold Tire Pressure Rear Rear 25psi 1 75kg cm2 Cold Car...

Page 6: ...7lbs GAWR Rear 165kg 164lbs Red Blue Yellow Available Colors Subject to availability Black 1 4 SERIAL NUMBER The frame serial number is stamped on the front of the frame at the front of the footrest p...

Page 7: ...bolt 18 25 N m 13 3 18 4 lb ft Tie rod lock nut 35 43 N m 25 8 31 7 lb ft King pin nut 30 40 N m 22 1 29 5 lb ft Handlebar lower holder nut 40 48 N m 29 5 35 4 lb ft Front wheel bolt 24 30 N m 17 7 2...

Page 8: ...ECIFICATION SPARK PLUG SPARK PLUG GAP 0 6 0 7 mm RECOMMENDED SPARK PLUGS NGK BPR7HS THROTTLE LEVER FREE PLAY 5 10 mm IDLE SPEED 1600 100 rpm BRAKE LEVER FREE PLAY 15 25 mm TIRES FRONT TIRE SIZE 120 90...

Page 9: ...ng System I I Suspension System I I C V T Air Filter C R Air Induction Reed Valve I C R Transmission Gear Oil I R Note I Inspect and Clean Adjust Lubricate or Replace if necessary C Clean L Lubricate...

Page 10: ...ilter element in gear oil and then squeeze out the excess oil Install the element into the air cleaner carefully 2 7 SPARK PLUG The spark plug is located at the front of the engine Disconnect the spar...

Page 11: ...ther damage Replace or repair if necessary Measure the free play of the brake lever at the end of the brake lever The standard of free play is 15 25 mm Inspect the rear brake lever and cable for exces...

Page 12: ...s If the oil contains a high concentration of metal shavings or powder disassemble the transmission for further inspection Reinstall the drain bolt and refill the gear box with 100cc 3 4oz of SAE 80 9...

Page 13: ...on the headlights are set to illuminate at 100 intensity In the center position the headlight will illuminate at 60 intensity Placed in the far left position the headlights will be off NOTE It is reco...

Page 14: ...Remove the seat helmet box and body cover See chapter 10 for complete instructions Disconnect oil tube fuel tube and vacuum line tube Disconnect the wires of the A C generator and the starter motor w...

Page 15: ...Disconnect the wires of the carburetor and the throttle cable Remove the cap from the spark plug Remove the bolt at the low end of the rear shock w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a...

Page 16: ...gine in reverse order of disassembly Torque value M8 nut 15 22 lbf ft M10 nut 22 29 lbf ft M12 nut 36 43 lbf ft After installing the engine check the parts below o All connections A C generator starte...

Page 17: ...N MALFUNCTION FUEL AIR MIXTURE RATIO TOO LEAN OR TOO RICH AIR CLEANER DIRTY INSULATOR LEAKS FUEL TANK CAP BREATHING HOLE CLOGGED LEAN MIXTURE CARBURETOR FUEL JET CLOGGED FUEL TANK CAP BREATHING HOLE C...

Page 18: ...efore removing carburetor you must shut the fuel flow off Remove the carburetor cap Remove the throttle cable from the throttle valve while depressing the throttle valve spring Remove the needle clip...

Page 19: ...damage Disassemble the idle jet main jet idle speed adjustment screw and idle mixture adjustment screw Inspect all jets and screws for wear or damage Clean the passages and jets with compressed air AS...

Page 20: ...cable spring and throttle valve Align the throttle valve groove with the idle speed adjust screw and install the carburetor cap to the carburetor Factory specification is 2 8 3 5mm for the float leve...

Page 21: ...the engine crankshaft Pump gears rotate the plunger shaft in the oil pump This shaft sends the lubricating oil into the crankcase to mix with the mixture of air fuel flow evenly The oil enters and co...

Page 22: ...her end controlling the quantity of oil delivered by the oil pump DISASSEMBLE OIL PUMP Remove the helmet box Disconnect the input and output oil tube Unscrew the oil pump fixing bolts Remove the oil p...

Page 23: ...air is forced to flow through cylinder fin and cylinder head This prevents the cylinder and piston from overheating Disassemble the engine fan cover and cylinder plastic cover Inspect the fan and cyl...

Page 24: ...AMBER EXCESSIVE NOISE PISTON AND CYLINDER WORN OUT EXCESSIVE CARBON BUILD UP EXCESSIVE SMOKE CYLINDER OR PISTON RINGS WORN OUT IMPROPER INSTALLATION OF PISTON RINGS PISTON OR CYLINDER WALLSCORED OR SC...

Page 25: ...move the piston and piston pin Spread each piston ring and remove it Note Don t let the clip drop into the engine crankcase 6 3 CYLINDER AND PISTON INSPECTION Inspect the cylinder bore for wear or dam...

Page 26: ...asure the end gap Service limit 0 5 mm Measure the clearance between the ring and groove Service limit 0 09 mm Measure the pistons outer diameter at 10 mm above the bottom Service limit 39 9 mm w w G...

Page 27: ...the marks facing up Do not damage the piston rings by spreading the ends too far Note The piston ring gap must align with the ring pin in the ring groove of piston Clean the cylinder gasket surface b...

Page 28: ...sket Apply a thin coat of engine oil to the piston rings and cylinder wall Install the cylinder compressing the piston rings Replace the cylinder head gasket Install the cylinder head Tighten the cyli...

Page 29: ...ed BELT WORN FRONT PULLEY WORN OR BROKEN CLUTCH LINING WORN Vehicle will not attain high speed BELT WORN ROLLERS WORN SPRING OF REAR PULLEY IS DISTORTED ELECTRONIC SPEED LIMITER EXCEDED 7 2 THE PARTS...

Page 30: ...belt drives the rear driven pulley The force is transmitted through the clutch shoe clutch housing and drive shaft The drive shaft turns the idle gear in gearbox Turning speed is reduced by the final...

Page 31: ...alteration of pitch circle s radius In the drawing H means high speed L means low speed 7 5 CONTINUOUS VARIABLE TRANSMISSION V Belt The belt is made of rubber fiber It is resistant to heat pressure a...

Page 32: ...ved by the drive shaft will be transmitted by the speed reduction of two sets to the rear axle shaft The first gear ratio is 36 13 The second gear ratio is 48 12 DISASSEMBLING THE TRANSMISSION BOX 1 R...

Page 33: ...arter arm is on the left side of engine When the kick starter arm is kicked the gear of the starter shaft will drive the kick starter to turn the crankshaft to start the engine After the engine is sta...

Page 34: ...the screws on the clutch cover at the left side of the engine Take off the clutch cover and gasket The belt front pulley and rear pulley are now visible Unscrew the front pulley fixing nut Remove the...

Page 35: ...HOCK ABSORBERS UNBALANCED FRONT SHOCK ABSORBERS FRONT WHEEL IS WOBBLING BENT RIM IMPROPERLY INSTALLED WHEEL HUB EXCESSIVE PLAY IN WHEEL BEARING DAMAGED TIRE POOR BRAKE PERFORMANCE BRAKE SHOES WORN WOR...

Page 36: ...on the inner line of this cable 8 4 HANDLEBAR REPLACEMENT Remove the rear view mirrors Disassemble the upper cover of handlebar Disconnect the speedometer cable and connectors of switches Disassemble...

Page 37: ...side of the front wheel Pull out the front wheel axle Take off the collar Remove the speedometer gear unit Remove the front wheel assembly Torque when replacing the front wheel M10 nut 22 29 lbf ft N...

Page 38: ...isk brake caliper fixing bolts Take off the front disk brake caliper Torque value when replacing M8 nut 14 22 lbf ft REMOVING THE AIR FROM THE FRONT DISK BRAKE CALIPER Fill the brake reservoir with th...

Page 39: ...t DISASSEMBLING THE FRONT BRAKE DISK Disassemble the front wheel Unscrew the three brake disk fixing bolts Remove the brake disk Torque of these M8 nuts 14 22 lbf ft INSPECT BRAKE DISK Measure the thi...

Page 40: ...ONT FORK INSPECTION Replace if there is any bending or distortion FRONT SHOCK ABSORBER INSPECTION Look for leaks torn seals scratched shafts and loose connections w w G e t 2 i t P a r t s c o m w w w...

Page 41: ...OR WOBBLE BENT RIM DAMAGED TIRED WHEEL AXLE IMPROPERLY TIGHTENED 9 2 MAINTENANCE DATA Brake drum inner diameter Standard 110 mm Limit 110 5 mm Lining thickness Standard minimum 4 0 mm Limit 2 0 mm 9 3...

Page 42: ...INSPECTION Measure the rear brake drum inner diameter Replace if the diameter is over 110 5mm BRAKE LINING INSPECTION Measure the brake lining thickness Replace if it is less than 3 0 mm Standard thi...

Page 43: ...Beamer R2 Rev 1 0 Page 43 of 56 6 13 2007 9 6 REAR SHOCK ABSORBER PARTS DRAWING w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

Page 44: ...en the front fender and leg shield Remove the front fender 10 2 BODY COVER Unscrew the four fixing bolts on the rear handle bar Remove the rear handle bar Unscrew the two fixing screws of each side of...

Page 45: ...crews between the body cover and middle cover Remove the middle cover Unscrew the two fixing screws of the body cover under the middle cover Open and remove the fuel tank cap Unscrew the two fixing sc...

Page 46: ...cover at footrest board Remove the battery cover Disconnect the negative terminal of the battery then disconnect the positive terminal Remove battery Unscrew the fixing screws of the lower cover Remov...

Page 47: ...screws near the rear lamp cover Remove rear lamp cover Unscrew two fixing bolts of the footrest board Remove footrest board Torque value M6 5 8 lbf ft M5 3 4 lbf ft w w G e t 2 i t P a r t s c o m w...

Page 48: ...IRCUIT o Faulty generator o Faulty CDI unit o Faulty alternator exciter coil o Loosen contacted terminals o Faulty ignition coil IGNITION SECONDARY CIRCUIT o Faulty plug o Loosen contacted spark plug...

Page 49: ...uld range between 0 1 0 3 Test the secondary coil as shown in this picture Secondary coil resistance should range between 7 4 12 0 k If the test results fall outside the stated ranges replace the igni...

Page 50: ...Beamer R2 Rev 1 0 Page 50 of 56 6 13 2007 Beamer CDI Module Specifications w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

Page 51: ...6 6 13 2007 A C Generator Test Wires Measurement Blue Yellow Black 90 130 White Red White 0 830 1 130 White Red Yellow Red 0 700 0 950 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m...

Page 52: ...y retainer strap Disconnect the negative BLACK battery lead first Disconnect the positive RED battery lead next Use caution when disconnecting lead so as not to cause a spark Remove the battery from t...

Page 53: ...e BLACK lead to the negative terminal of the battery next Check the lead routing to ensure they are clear of obstruction and do not fall between the battery and unit body where they could be abraded o...

Page 54: ...battery on a concrete surface as it can draw the charge from the battery and damage the battery plates 11 5 STARTER MOTOR The starter motor is attached to the engine Unscrew the two starter motor fix...

Page 55: ...Beamer R2 Rev 1 0 Page 55 of 56 6 13 2007 11 6 WIRING DIAGRAM Beamer II PN2B Beamer Matrix PN2C w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

Page 56: ...it will bind in housing and cause brake lights to stay on Ver ify Repair Retest brake lights for proper operation REAR BRAKE CAM LUBE Step 1 Remove rear wheel Step 2 Remove rear brake shoes Step 3 Rem...

Page 57: ...VEHICLES ARE MAINTANCE FREE PROPER SERVICE PROCEDURES ARE AS FOLLOWS 1 FILL BATTERY WITH BATTERY PACK SUPPLIED 2 REMOVE FUNNEL AND LET BATTERY STAND WITH CAP OFF FOR AT LEAST 1 HR 3 ALL FLUID IN BATTE...

Page 58: ...e of the engine just above the RH A arm Bulletin No 0033 Date 04 01 2004 Oil Pump Cable Location To reduce the oil flow you must lengthen the cable by loosening the lock nut and turning the adjusting...

Page 59: ...mounting plate is positioned on the bottom of the luggage box with the smooth side toward the box The 4 bolts and washers are pushed through the box and plate from inside the box using the holes indi...

Page 60: ...ht They may be tucked in under the harness on the left hand side of the unit Note ONLY the Beamer II III and the Matrix Matrix II have been pre wired for the luggage box brake light If you have the ol...

Page 61: ...tory Maximum Viper 70 4 10w 12w Viper 90 4 10w 12w Viper 150 20w 50w Yukon 150 20w 50w Vector 250 35w 90w Beamer II 18w 24w Beamer III 18w 24w Beamer Matrix 18w 24w Beamer R2 18w 24w Beamer R4 18w 50w...

Page 62: ...0cc 2 cycle engines 1 Fill the fuel tank with a pre mix fuel 2 cycle oil mixture at a 50 1 ratio 2 Disconnect the oil pump line at the carburetor 3 Start the engine and count the drops per minute at t...

Page 63: ...Beamer R2 Rev 1 0 Page 56 of 56 6 13 2007 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

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