Beta Enduro RR 350 2013 Workshop Manual Download

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Summary of Contents for Enduro RR 350 2013

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Page 2: ...LECTRIC IGNITION 31 1 8 1 Start motor 31 1 9 KICKSTARTER 33 1 10 EXTERNAL GEARSHIFT UNIT 35 1 11 CRANKSHAFT GEARBOX UNIT AND INTERNAL GEARSHIFT 36 1 11 1 Nut on left side of crankshaft 36 1 11 2 Opening crankcase 36 1 11 3 Crankshaft 38 1 11 4 Internal gearshift unit and complete gearbox 38 1 12 DISASSEMBLY OF PARTS FROM CRANKCASES 40 1 12 1 1 Right crankcase half 40 1 12 1 2 Piston oil jets 40 1 ...

Page 3: ...G OF TIMING CHAIN FIXED AND MOBILE GUIDES 90 2 16 IGNITION SYSTEM 90 2 16 1 Checking ignition system 91 2 16 2 Coupling ignition system to crankcase 91 2 17 THERMAL UNIT 94 2 17 1 Checking piston pin bolt and piston rings 94 2 17 2 Checking the cylinder 96 2 17 2 1 Assembly clearance 96 2 17 3 Cylinder head disassembly and checking auxiliary devices 97 2 17 3 1 Lubrication jets and centring pins 9...

Page 4: ...hildren PREAMBLE This publication has been written in order to make operations for inspection maintenance and repairs of the motorcycle engine known and understandable to the user of the motorcycle and to the technical assistance operator Read this entire manual with care before operating the engine Sufficient knowledge of the components that make up the engine and of all the procedures to be foll...

Page 5: ...iolently and cause burns Coolant contains dangerous substances which are harmful for the environment When chan ging it you must be equipped to dispose of it in compliance with existing law Do not release coolant to the environment Keep out of the reach of children Hot parts The engine and the exhaust system get very hot and stay at that temperature for a long time even after the engine has been tu...

Page 6: ...ion 28 76 28 76 31 73 31 73 1st gear ratio 12 31 12 31 12 31 12 31 2nd gear ratio 15 28 15 28 15 28 15 28 3rd gear ratio 19 28 19 28 19 28 19 28 4th gear ratio 20 24 20 24 20 24 20 24 5th gear ratio 27 27 27 27 27 27 27 27 6th gear ratio 28 24 28 24 28 24 28 24 SECONDARY TRANSMISSION CHAIN CARBURETTOR RR350 RR400 RR450 RR498 Carburettor type Keihin FCR MX39 Keihin FCR MX 39 Keihin FCR MX 39 Keihin...

Page 7: ...ring pliers code 3625097 000 11 Crankshaft blocking device code 006140110 000 12 Loctite 243 code 3625001 000 14 Silicone paste for gaskets code 3625000 000 15 36mm socket wrench code 3625000 000 16 Spark plug wrench code 020440100 000 17 Connecting rod disassembly tool code 006140070 000 18 Thickness gauge code 006140210 000 19 Valve guide gauge code 006140180 000 20 Clutch cap tool code 00614004...

Page 8: ...oolant In order to access the oil drain plug remove the engine guard connected to the frame by means of the three screws 1 1 1 ENGINE DISASSEMBLY Remove the screw 2 to empty the motor oil Remove the screw 3 to empty the gear oil ATTENTION Used oil contains dangerous substances which are harmful for the en vironment When changing it you must be equipped to dispose of it in compliance with existing ...

Page 9: ...the screw 6 which fastens the brake pedal return spring to the engine block Once the engine has been unfastened and removed from the frame connect it to the specific engine support code 3625132000 by means of the engine fixing devices code 006140140000 in order to work in comfort and safety Then proceed as follows In order to empty the cooling circuit loosen the screw 4 and have the liquid flow ou...

Page 10: ...he four gaskets 3 1 1 1 2 2 3 THERMAL UNIT The thermal unit is made up of the head cylinder and piston Before removing the cylinder head bring the piston to the TDC and block the crankshaft Proceed as shown hereafter Remove the 4 screws 1 the cylinder head cover 2 as well as the 4 screw gaskets 3 Remove the spark plug gasket 4 and the co ver gasket 5 4 5 ...

Page 11: ...il the lines 9 on the toothed profiles of the camshafts are aligned Rotate the transmission shaft in that posi tion and at the same time turn the shaft blocking screw 6 by hand until it engages in the seat present on the crankshaft preven ting the crankshaft from turning In this way the crankshaft is blocked by me ans of the screw 6 at the Top Dead Centre TDC and now all the organs can be disas se...

Page 12: ...ioning To remove it proceed as follows remove the cap 1 and the spring 2 Fully unscrew the tensioner support 3 from the cylinder To slip the piston 4 out just push it out from the tensioner support 3 CYLINDER HEAD DISASSEMBLING CAMSHAFT SUPPORT CHAIN GUIDE AND SPARK PLUG SEAT O RING To remove the camshafts disassemble the camshaft support 2 and the chain guide 3 Then loosen the seven screws 1 of t...

Page 13: ...g a plastic rod A or something similar lever the head surface and the camshaft support 2 in order to lift it and remove it When uncoupling be careful of the two cen tring pins 4 the camshaft support Checking camshafts support Remove the spark plug housing sealing O ring 5 between the cylinder head and the camshaft support 2 A 4 5 ...

Page 14: ...rom the gear on the shaft Attention the hydraulic tensioner must al ready have been removed in order to remo ve the camshafts In order to remove the exhaust camshaft 4 repeat the operations described for removal of the intake camshaft ATTENTION make sure the chain does not fall inside the compartment dedicated to it For this purpose it is recommended to in terpose a plastic rod or the likes A betw...

Page 15: ...fixing screws 2 in a criss cross pattern Start with one of the two screws outside the cylinder head compartment Then remove the respective washers Lift the cylinder head 3 with one hand and at the same time with the other hold the chain in tension thus preventing jams du ring disassembly With the cylinder head lifted a few centime tres drop the chain inside the compartment and pull out the head AT...

Page 16: ... DISASSEMBLY Cylinder head elements 1 M6x80 screw 2 M10x1 25 cylinder head screws 3 Complete cylinder head 4 Cylinder head gasket 5 Centring bushes Remove the head gasket 4 and the two cen tring bushes 5 3 2 1 4 5 ...

Page 17: ... or simple residue from falling inside the base Using a suitable tool to insert the specific seat A remove the elastic ring 4 on the right hand side of the piston 5 ATTENTION be careful not to drop the ela stic ring inside the engine From the left hand side of the piston push the pin bolt with an aluminium cylinder B or the likes until the pin bolt is freed from the foot of the connecting rod Remo...

Page 18: ... up and the stator which is one with the flywheel cover 1 2 STATOR AND FLYWHEEL Remove the screw 1 which connects the gear lever 1 to the drive shaft Remove the nine screws 3 which fasten the flywheel cover 4 to the left crankcase half Remove the flywheel cover and the gasket placed between the casing and the cover 1 2 1 Bottom view of piston 5 elastic ring 4 and pin bolt 6 Removal of gear lever F...

Page 19: ...astic washer 8 shown in the following images placed between the nut and the flywheel To remove the flywheel screw the relevant extractor A code 3625173 onto the thre aded segment on the flywheel and using a box spanner tighten the screw on the ex tractor Two centring pins 5 dedicated to the flywheel cover Nut 6 which fastens the flywheel 7 to the crankshaft Removal of ignition flywheel with releva...

Page 20: ...ile 2 and fixed pad 3 Extraction of chain guides In the image at the side the flywheel 7 rear view the special elastic washer 8 and the tightening nut 6 8 7 6 TIMING CHAIN AND GUIDES Remove the fixing screws 1 of the mobile 2 and fixed pad 3 Extract the two pads pulling them towards the top part of the engine 1 2 2 ...

Page 21: ...cting the mobile and fixed pads and the timing chain Pay close attention to the respective bushes while extracting the mobile and fixed guides and the timing chain Chain guard and oil jet Removal of timing chain Two pad fixings screws 1 mobile pad 2 fixed pad 3 oil jet fixing screw 4 oil jet 5 chain guard fixings screws 6 chain guard 7 timing chain 8 6 4 5 6 7 1 2 8 3 4 6 5 7 ...

Page 22: ... 3 PICK UP Once the timing chain guard has been re moved the pick up 1 can be disassembled by removing the two fixing screws 2 PINION AND SPACER In order to remove the pinion 1 loosen the screw completely 2 and take off the washer 3 After removing the pinion pull off the spa cer 4 1 2 3 1 3 1 2 3 2 1 4 ...

Page 23: ...omplete overhaul of the clutch unit of the other ele ments housed in the outer right side of the crankcase half or of the engine the inner clutch cover 3 must be removed by loose ning the nine screws 4 and the water pump cover 5 loosening the four screws 6 1 4 Outer clutch cover 1 and respective screws 2 Inner clutch cover 3 and respective screws 4 Pump cover 5 and respective screws 6 1 4 3 6 5 2 ...

Page 24: ... reference pins A placed between the right crankcase half and the inner clutch cover while disassembling Remove the complete hydraulic actuator 7 if the tube was disconnect from the ac tuator outer left side crankcase half by lo osening the three screws 8 which fasten it to the crankcase half Remove the gasket in between the actuator and the crankcase half Extract the clutch control rod 9 A 7 8 9 ...

Page 25: ...ive springs Extract the whole pressure plate unit 12 and the clutch disc pack 13 Remove special driven disc and the disc spring assembly In order to complete the disassembly of the clutch unit open the safety washer 14 using a chisel or similar tool and remove the nut 15 Clutch cap 11 and four screws 10 Pressure plate unit 12 and clutch disc pack 13 Opening safety washer with chisel 10 11 13 12 ...

Page 26: ... safety wa sher ATTENTION don t use pneumatic wrench Extract the inner hub 16 the washer 17 the basket 18 the roller cage 19 and the centre bearing 20 Removal of inner hub nut with relevant tool G Safety washer 14 nut 15 inner hub 16 washer 17 basket 18 roller cage 19 and bush 20 special fiction disc 21 judder spring 22 A 22 18 21 16 14 19 20 15 17 ...

Page 27: ...low pressure pump or recove ry 9 with higher displacement passing through the oil filter 8 and sent to the igni tion unit compartment A There it is sucked once again by the pump 1 after being filte red through the wire metal filter 11 The one way valve 10 controls the pressure between the external casing on the ignition unit side and the crank mechanism com partment 1 5 6 5 3 10 9 8 1 11 2 ENGINE ...

Page 28: ...ring 6 HIGH PRESSURE OIL PUMP The high pressure pump located in the ex ternal right hand side crankcase is enclosed under the cover 1 which can be disassem bled by removing the roller 2 and the three screws 3 Having removed the cover extract the internal rotor 4 the external rotor 5 and the roller 6 1 5 1 1 5 2 Gear unit for oil pump control 1 Gear meshing with clutch gear 2 Idler wheel 3 Oil pump...

Page 29: ... They are enclosed under the cover 1 which removed by extracting the three screws 2 Extract the one way valve consisting in the spring 3 and the ball 4 Then extract the external rotor 5 and the in ternal rotor 6 together with the roller 7 and the drive shaft 8 1 5 3 3 6 5 4 7 6 8 Cover and screws of low pressure pump Internal rotor 6 roller 7 and drive shaft 8 Low pressure oil pump and by pass val...

Page 30: ...pull out the washer the spring and the ball PAPER OIL FILTER In order to extract the paper oil filter remo ve the cover 1 by loosening the two screws 2 completely Once the cover has been re moved use a pair of opening pliers A to ex tract the filter While extracting the cover be careful of the specific O ring applied onto the cover 1 5 4 1 5 5 Location of pressure control valve Pressure control va...

Page 31: ... have the task of assuring coupling of the complete shaft to the base ATTENTION don t use pneumatic wrench In order to disassemble the shaft remove the nut 8 which can be accessed through the ignition unit compartment Extract the elastic washer 7 and the counterweight Pull the countershaft out through the right hand side crankcase1 1 6 Extraction of countershaft Exploded view of countershaft 1 Sha...

Page 32: ...ment ATTENTION The nut 1 must be turned clockwise to be unscrewed Extract the primary gear using the relevant ex tractor A code 006140150000 Notice that the primary gear houses the free wheel device 2 inside of it which can be remo ved by taking out the circlip 3 1 7 Extraction of primary gear with appropriate extrac tor A Primary gear 1 complete with free wheel 2 and spe cific circlip 3 Primary g...

Page 33: ... 9 The roller bearing 10 supports the starter wheel 9 while the free wheel 11 is internally enga ged on the starter wheel 9 and externally on the main gear thus allowing it depending on rotation direction to pull the crankshaft START MOTOR In order to easily disassemble the start motor 1 the breather nozzle 2 must be removed by taking off its screw 3 along with the two copper washers 1 8 1 8 1 2 3...

Page 34: ... par 1 5 1 The kickstart gear is pulled out by hand In order to disassemble the torque limiter 7 completely loosen the screw 8 which fa stens the torque limiter to the crankcase Pull out the washer 9 together with the li miter itself In order to remove the idler wheel 10 just remove the circlip 11 and pull the gear off Screws 4 fixing start motor to crankcase Removal of pin 6 Torque limiter 8 scre...

Page 35: ...es with the clutch gear 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 the se cond circlip 8 The circlips and thrust wa shers are interchangeable 1 9 Kickstarter mechanism Removal of circlip 5 of idler gear 3 Two circlips 5 and 8 and thrust washers 6 and 7 1 4 2 3 3 6 5 5 6 8 7 ...

Page 36: ... Using a pair of pliers pull the end A of the spring 4 from the hole on the crankcase 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 Note Be careful of the reference pins for centring the inner clutch cover par 1 4 ...

Page 37: ...n spring 3 pres sed and extract the shaft together with spe cific 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 In order to disassemble the stop lever loo sen the screw 7 enough to allow the lever to move axially and overcome the cylinder seg ment A of the desmodromic device Bring the return spring 8 to the rest positio...

Page 38: ...n the nut 1 on the left hand side of the crankshaft heat it with a blow dryer or similar instrument Then loo sen the nut with a special socket wrench A code 006140020000 and remove it ATTENTION When re assembling the oil seal must be replaced2 since the heating required for disassembly damages it OPENING CRANKCASE Remove the 15 screws 1 which close the crankcase Nut B blocking crankshaft Crankcase...

Page 39: ... must remain inside the right cran kcase half Remove the back 4 and front reference bu shes 5 to position the crankcase correctly Remove the gasket between the two cran kcase halves Loosen the two screws A which fasten the engine to the support stand Two screws A blocking engine to engine support stand Detaching crankcase halves The left crankcase half inside with references pins 4 and 5 The right...

Page 40: ...e gearbox allowing engage ment of the desired ratio The desmodromic device is controlled by the stop cam present in the external gearshift unit par 1 10 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 from the desmodromic control Do the same operation though in the opposi te directio...

Page 41: ...rks together with the drive bu shes 5 Proceed to extract the complete gearbox unit including the primary 6 and secondary unit 7 Extraction of forks from gearbox unit Extraction of complete gearbox unit 6 primary unit 7 Secondary unit 5 6 7 ...

Page 42: ...nents attached to it The correct positioning of some bearings ap plied to the crankcase halves is ensured by lo cking devices such as plates or simple screws In order to disassembly these bearings the safety devices must be disassembled as well RIGHT CRANKCASE HALF On the inside the plates 1 are those which assu re the correct positioning of the support bearing of the crankshaft All you need to do...

Page 43: ...hree safety plates are present on the left cran kcase half Two are applied on the inside and one on the outside The plates 1 on the inside are the ones relative to the crankshaft support bearing of the gearbox They can be disassembled by removing the two screws 2 The plate 3 is the one relative to the bearing which supports the countershaft It can be disas sembled by removing the screw 4 Inside sa...

Page 44: ...OMIC DEVICE BEARING Removal of bearing dedicated to the device present inside left crankcase half Its removal entails use of the extractor A code 3625081 together with extractor B code 006140160000 To carry out this operation it is recommen ded to apply two aluminium plates between the legs of the extractor and the crankcase half Disassembly of inner filter Removal from low pressure oil pump side ...

Page 45: ...g rotation It is howe ver recommended to refer to the periodical maintenance table In order to insert the bearings in the cran kcase halves bring the crankcase halves to a temperature of 150 C and keep them at that temperature for 20 minutes Place the crankcase halves on a large surfa ce where their whole seal surface can rest When the bearings cool off they drop into their seats on their own ENGI...

Page 46: ...being disassembled In general the crankcase halves must be re placed when the oil pump crankcases show scratches or meshing signs see their location in de tail once the new bearings are inserted and the crankcase half is left to cool off they do not fit into their seats EXPLODED VIEW OF ENGINE CRANKCASE HALF 1 Complete engine block 4 Crankcase gasket 5 Back reference bush 6 Front reference bush 7 ...

Page 47: ...kstart ramp 4 It must be replaced if it shows signs of meshing or chipping The table below contains indications for fixing the screws of the above mentioned elements Elements present on outside right crankcase half Screw number Screw dimensions Threadlocker application Tightening torque Nm Threading diameter mm Threading length mm 5 M5 10 Loctite 243 Sichel 100M 6 6 M5 10 Loctite 243 Sichel 100M 6...

Page 48: ... be spread with medium strength threadlocker Apply the entire device on the crankca se half so that the straight segment of the spring rests on the stop C Tighten the screw at 10Nm The crankcase half will definitely need to be replaced when the oil pump crankcase A shows deep scratches or meshing signs the two pins B for the idler wheel and torque limiter show traces of abnormal wear or meshing EX...

Page 49: ... seal and bearing housing In sert the new oil seal 1 greasing the inside of it Apply the new bearing 2 paying close atten tion that it is aligned in its seat Use a press or similar instrument to push the bearing until the outside surface is flush with the surface A Application of oil seal 1 Insertion of bearing 2 Oil seal and bearing unit coupled to the left cran kcase half 1 2 2 1 1 1 A ...

Page 50: ... desmodromic device support bearing Blow compressed air into the hole A making sure the passage is free from any type of im purity Insert the two reference bushes B and C in their respective housings Elementi presenti nel carter destro lato interno Screw number Screw dimensions Threadlocker application Tightening torque Nm Threading diameter Threading length 4 M6 14 Loctite 243 Sichel 100M 8 5 M5 ...

Page 51: ...hem to the crankcase using a small amount of medium strength threadlocker being careful that the threadlocker does not block the holes Then tighten them all the way Make sure that the oil passage A is cleaned well Make sure that the countershaft bearing retaining plate 3 is not deformed If it is re place it The table below carries the indications for ap plication of the screw for the plate 3 The c...

Page 52: ...n until you hear the hooking device click Blow compressed air in the hole B making sure it is not obstructed Locking devices Elements present on inside left crankcase half 2 1 4 INTERNAL LEFT SIDE Clean the inner filter thoroughly and check the integrity both of the wire metal and the hoo king device Should the filter be deteriorated in any of these parts replace it Screw number Screw dimensions T...

Page 53: ...2mm Check the axial play between the connec ting rod head and the half shafts Recommended play 0 4 0 7mm Check the radial play of the connecting rod head bearing placing the crankshaft on a stable support with the axis of the connec ting rod inclined about 45 respect to the horizontal position Then position a com parator in axis and pressing lightly in the direction of the crank lever check that t...

Page 54: ...ate thus damaging the connec ting rod head bearing The references C which must be aligned are found on the half shaft on the flywheel side and on the crank lever of the pin bolt Half shaft and crank lever pin bolt references C Crankshaft oil passages Make sure that the chain control gear is free of chipping or signs of abnormal wear Re place the crankshaft should it be deteriora ted The distance b...

Page 55: ...ng rod Bore meter verification of inside diameter of connecting rod foot ASSEMBLING COMPLETE CRAN KSHAFT When all the aforementioned controls have been carried out and the worn parts repla ced grease the crankshaft oil seal on the right crankcase half and couple the cran kshaft to the left crankcase half Keep the gear present on the crankshaft towards the left In order to carry out this operation ...

Page 56: ...t not exce ed the service limit indicated below service limit 0 5mm If the detected axial play is greater before replacing either the gearwheels or the forks check their state of wear par 2 4 4 Remove the various elements and check that The support surfaces of the primary and secondary shafts are free of abnormal wear or signs of seizure the sides of the teeth are free from chip ping or abnormal w...

Page 57: ... oil Always replace the circlips Clamp the mainshaft 1 using protective jaws so that the grooved end faces down wards Insert onto the lower cylinder part of the shaft the roller cage 2 the 5th gear 3 turning the front claw clutches upwards the 26x32x1 5 thrust washer 4 and the circlip 5 Insert the III IV sliding gear 6 so that the smaller gear faces downwards and then in sert the circlip 5 Insert ...

Page 58: ... 20 using pro tective jaws so that the grooved end faces downwards Insert onto the lower cylinder part the rol ler cage 15 the 2nd gear 19 so that the front claw clutches face downwards the 26x32x1 5 thrust washer 4 and the circlip 5 Insert the 6th gear 18 so that the fork seat faces upwards and the circlip 5 Insert the 23x32x1 5 thrust washer 7 the two roller cages 15 the 4th gear 17 with the fro...

Page 59: ...ade up of two forks 13 which drive two gears on the secondary unit one fork 14 which drives one gear on the primary unit three drive pin bushes 15 two fork pins 16 desmodromic gearshift 18 through whose rotation the forks are driven thus selecting the desired gear Check to make sure that the drive pins which support the bushes 15 have no traces of me shing or abnormal wear and that the bushes them...

Page 60: ...s below the limit Fork inside diameter limit 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 are as of the forks and in the housing areas of the crankcases Fork pin outside diameter limit 13 75mm Make sure that the desmodromic control device has no corroded or worn areas espe cially in the grooves in which the drive ...

Page 61: ...mber to oil the gears abundantly with gear oil and to gre ase the shafts supporting them in the areas where they are coupled with the bearing with graphitic grease Make sure that all the parts slide properly Insert the centre bearing 3 and the O ring 4 on the secondary unit 2 5 Insertion of gearbox in left crankcase Detail of centre bearing 3 and O ring 4 coupled to the secondary shaft 4 3 2 1 3 4...

Page 62: ...it is recommended to reposition the forks in their original positions Insert the desmodromic device in the spe cific bearing In order to do this it is neces sary to rotate cam stop lever 7 towards the bottom part of the engine Position the fork 5 of the primary unit in the central guide of the desmodromic device 8 insert the fork pin inside the fork itself and insert the pin in its proper seat in ...

Page 63: ... first in the pins and then in its proper seat Remember to oil the shafts forks and the de smodromic device abundantly with gear oil Position the new crankcase gasket Positioning of the secondary unit forks 6 in the external guides of desmodromic device 8 View inside the right crankcase with crankshaft oil jets gearbox shafts complete with gearwheels internal gearshift and gasket 8 6 6 ...

Page 64: ...es tend to capsize do not insist tightening them Rather loosen the screws and reposi tion the crankcase correctly Make sure that the two crankcase halves match perfectly one with the other Assem ble the screws according to their length as indicated in the figure The table below contains indications for ap plying these screws It is recommended to tighten them in a criss cross pattern using a torque...

Page 65: ...ankshaft at the Top Dead Centre the specific conical end screw 38 or tool 006140110 000 must be intro duced in its seat on the right crankcase half without applying the washer 37 Once the crankshaft is positioned at the Top Dead Centre tighten the screw all the way Spread the threading on the left hand side of the crankshaft with medium strength th readlocker Tighten the nut using the special sock...

Page 66: ... wear or meshing the gearshift drive shaft needs more in depth inspections CHECKING THE COMPLETE DRIVE SHAFT With the device complete make sure that the distance between the movable pawl and the drive shaft is between 0 35 0 80mm Should the distance be greater replace the movable pawl In order to replace the movable pawl 1 di sassemble the return spring of the gearshift 2 the spring guide 3 the sp...

Page 67: ...t note the positioning of the gearshift return spring For reassembly couple the movable pawl 9 to the drive shaft 10 and while compressing it insert the spring 8 between the mova ble pawl and the drive shaft Then apply the spring guide 7 the gearshift return spring 6 and finally the 14x30x1 thrust washer 5 The gearshift return spring must be positio ned as in the figure to be able to carry out its...

Page 68: ...pring 4 of the movable pawl pressed Wishing to test the correct functioning of the entire unit you just need to temporarily couple the external gearshift lever and to si mulate the operation of changing gears by lifting and lowering the gearshift lever and having the mainshaft of the gear unit rotate The whole device works properly if abnor mal jamming does not occur If the unit runs without oil t...

Page 69: ...leeve 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 pressure on the sleeve 14 so that it can to pull the gear 2 Also check to make sure that the washers have no abnormal or excessive wear If so have them replaced Make sure that the spring 8 has no cr...

Page 70: ...ng the thin striped facing ou twards and making sure that the ramp A on the kickstart sleeve is positioned below the ramp B bolted onto the right crankcase ex ternal side Turn the spring clockwise until it fits into the specific hole C Insert in the slot on the protruding segment of the secondary shaft the circlip 18 the washer 17 the idler wheel 4 followed by the washer 17 and the circlip 18 as s...

Page 71: ...sure there are no traces of meshing on the housing of the roller bearing on the starter gear 3 Mount the starter gear tem porarily on the crankshaft together with the roller bearing and check to see if there is excessive play To check the correct functioning of the free wheel 4 proceed as follows Insert the starter gear 3 on the free wheel 4 and main gear unit 5 Keeping the main gear blocked 5 and...

Page 72: ...gear Lubricate the segment C of the starter gear 1 with motor oil and couple it to the cran kshaft Insert the Woodruff key 2 in the specific seat Apply the main gear 3 to the crankshaft and while turning the gear clockwise push it to wards the crankcase half until you perceive meshing between the gear and the Woo druff key Insert the locking nut F applying the threa ding with a medium strength thr...

Page 73: ... and apply the circlip 8 Couple the torque limiter 4 to the pin E turning the gearwheel with the smaller dia meter towards the crankcase half Insert the washer 5 and the screw 6 after having spread the threading with medium strength threadlocker Tighten the screw at a torque of 10Nm Apply a light layer of grease in the area G of the start motor and insert the motor in its housing Apply medium stre...

Page 74: ...CONTROL AND REASSEMBLY As shown in paragraph 1 5 the motor is equipped with two oil pumps one is the low pressure suction pump higher displa cement located in the outside of the left crankcase half and the other high pressure pump lower displacement located on the outside of the right crankcase half The two pumps are driven by a gear cascade me shing with the clutch gear Proper operation of the pu...

Page 75: ...al rotor and between the external ro tor and the crankcase proceed as follows Insert the two rotors in their specific seat with the reference dot facing the inside of the engine Using a thickness gauge check that the play does not exceed that allowed equal to Maximum radial play 0 20mm Take a thickness gauge again and a rectified refe rence surface and verify that the axial play does not exceed th...

Page 76: ... 5 diameter 5 5mm and the respective compression spring 6 Lubricate with motor oil and while rotating the protruding segment of the drive shaft from the outside of the right crankcase half make sure it rotates freely and does not jam Fasten the cover 7 to the crankcase with the three screws 8 which must first be spread with medium strength threadlocker These screws must be tightened at a torque of...

Page 77: ...carefully pay attention to the oil seal Insert the three screws 4 after having applied them with spread medium streng th threadlocker Tighten them at a torque of 6Nm Turn the shaft holding on to the protruding end and make sure it rotates freely without getting jammed CHECKING AND ASSEMBLY OF PRESSURE CONTROL VALVE The pressure control valve is made up of a ball 43 spring 42 calibrated washer 41 a...

Page 78: ... adlocker and tightened at a torque of 6Nm Couple the thrust washer 4 to the pin 2 and lubricate it with gear oil Couple the two pump control idler wheels 5 to the two pins so that the most protruding segment faces the crankcase Then insert the thrust washers 6 and cir clips to keep the wheels from coming off the pins Insert the roller 7 to the end of the pump control shaft Couple the oil pump con...

Page 79: ...r cover PAPER OIL FILTER INSERTION Lubricate the rubber gasket on the filter In sert the filter 1 into its housing and push it towards the inside of the engine as far as it can go Insert the O ring 2 onto the oil filter cover 3 and apply the unit to the crankcase Apply the two screws 4 M5x16 to be tighte ned at a torque of 6Nm 2 11 5 1 2 4 3 6Nm ...

Page 80: ...d Make sure that the toothed seg ment of the shaft does not have traces of abnormal wear Grease the oil seal and insert the counter shaft in its seat Position it so that the refe rence sign on the shaft is between the two reference signs on the main gear 2 11 6 EXPLODED VIEW OF COUNTERSHAFT 1 Shaft 2 Counterweight 7 Elastic washer 8 Nut M12x1 Coupling countershaft to crankcase Enlargement of refer...

Page 81: ...untershaft nut While keeping the countershaft in place in sert the counterweight on the left side de pending on the position set by the grooved shaft Then couple the elastic washer and the nut 1 after having applied medium strength th readlocker on their threading The nut must be tightened at a torque of 50Nm 1 50Nm ...

Page 82: ...B dedicated to meshing with the kickstart 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 de eply cut Make sure that the centre bearing D with the rol ler bearing has no traces of meshing or abnormal wear If any damage is found have the piece replaced 2 12 2 12 1 CLUTCH BASKET A Teeth mes...

Page 83: ...mum value fixed at minimum thickness 2 8mm The other value that needs to be checked is the thickness of the teeth of each friction disc They must not be less than the mini mum value fixed at minimum friction disc tooth thickness 13 3mm Check the state of use of the silent blocks as follows Clamp the gear B intended to mesh with kickstart idler gear using protec tive elements Rotate the clutch bask...

Page 84: ...INGS To ensure the correct pressure between the clutch discs the state of the springs must be checked The minimum acceptable leng th must be minimum clutch spring length 42 mm CHECKING INNER HUB The inner hub meshes with the steel clutch discs by means of the teeth A Make sure these teeth are not meshed or shaped by abnormal wear If so replace the inner hub Make sure that the seat B where the supp...

Page 85: ...rusting bearing just see if it slides When the device is assembled simulate rotation of the front centre bearing A respect to the rear one B Be careful for presence traces of meshing or wear on the sliding surfaces ASSEMBLY OF CLUTCH UNIT After having lubricated the end of the main transmission shaft insert the internal centre bearing 4 to which the roller bearing must be coupled 5 Insert the clut...

Page 86: ...he seat on the drum the disc spring 2 so that the concave part faces the washer 1 the washer 3 the special disc 4 a driven disc and then the other discs alternating a driving disc and a driven disc Insert the overall thrust bearing 9 after ha ving lubricated it with gear oil in the hole on the main gearbox shaft and check its free axial sliding Close the clutch unit by me ans of the clutch pressur...

Page 87: ... screws M6x20 Insert the clutch rod in the seat B from the left side of the engine turning the smaller section towards the inside of the engine Apply the gasket 5 the complete hydrau lic actuator 6 the M6x30 screw 7 and the two M6x20 screws 8 to the left crankcase half Tighten the three screws at a torque of 10Nm 7 5 6 8 B 10Nm ...

Page 88: ... shaft 1 and the coupling is ensured by tightening the nut 8 onto the shaft 1 CHECKING PUMP UNIT AND DISASSEMBLY Disassembly of the entire pump unit can be done only with the entire clutch cover removed Disassembly of the pump unit is performed by removing the nut 8 which allows you to extract the impeller 6 the washer 7 and the shaft 1 This can be removed by pressing the threaded part of shaft 1 ...

Page 89: ...l in the inner clutch cover having it enter the seat very slowly to keep it from deteriorating Couple the shaft 1 with the O ring 2 to the inner clutch cover and then insert the bush 5 the wa sher 7 and the impeller 6 Then couple the blind nut 8 to the threaded seg ment of the shaft after having applied medium strength threadlocker Tighten it at a torque of 10Nm When coupling is complete check tha...

Page 90: ... a new gasket 1 placed between the right crankcase half and the inner clutch cover using the two reference pins 2 to keep it in place Couple the inner clutch cover to the right cran kcase half and turn the water pump impeller un til the pump shaft inserts perfectly in the housing on the countershaft which drives it Apply the nine M6x25 screws as shown in the figure tightening them by hand until th...

Page 91: ...crews making sure to apply the copper washer 3 to the lower screw of the pump cover Tighten all thirteen screws at a torque of 10Nm following a criss cross pattern If only the outer clutch cover was removed put it back on the inner cover and fasten the six M6x25 screws as shown in the figure The M6x30 screw 5 not present in the figu re is coupled to the engine applied to the vehicle because this m...

Page 92: ...used by the rotation of the chain In order to assemble the chain to the engine just introduce it in the vertical passage compartment A on the left crankcase and insert it in the gear on the crankshaft Insert the fixed guide 1 and the movable guide 2 inside the compartment A Insert the specific 6 2x9x9 bushes inside the lower eyelets of the guides After having applied medium strength threadlocker t...

Page 93: ...em at a torque of 6Nm Lay the cable on the crankcase apply the groo ve of the cable gland 2 with gasket paste code 3625000000 and insert it in the specific hou sing n the crankcase removing excess paste Couple the chain guard to the crankcase insert the two 6 2x9x9 bushes in the lower eyelets and couple the two screws 1 after having applied them with medium strength threadlocker Then tighten them ...

Page 94: ...n the nut at a torque of 60Nm Couple the stator to the flywheel cover by means of the two screws 1 Apply the th reading with medium strength threadlocker and tighten them at a torque of 8Nm Insert the cable gland in its specific seat and check its perfect sealing Check the state of use of the two oil seals 2 If they are deteriorated they must be re placed Blow compressed air in the hole A making s...

Page 95: ...st be inserted in the relevant guides and pressed towards the outside of the cover When coupling it to the left crankcase half apply a drop of gasket paste code 3625000000 in the two zones B in order to ensure perfect sea ling between the cover and the crankcase half in the concerned zone Insert the centring pins 3 on the crankcase and fasten a new gasket Grease the oil seal on the flywheel cover ...

Page 96: ...bonaceous sediment from the top of the piston and wash the entire piston with specific degreasing agent Do not use sharp points or tools for clea ning Then carry out a careful analysis of the piston which must be free from forcing scratches cracks or any type of damage Analyse the outside diameter of the piston who se service limit is carried in the table below con cerning their specific class The...

Page 97: ...ing rod controls for controls on connecting rod foot par 1 2 In order to check the state of use of the pi ston ring and oil scraper ring the ring must be inserted in the cylinder so that its axis is aligned with the axis of the cylinder Then measure the distance between the two op posite edges The respective service limits are carried in the table below Displace ment cm Service limit of compres si...

Page 98: ...o the axis of the crankshaft ASSEMBLY CLEARANCE The following table carries the coupling play between the cylinder and piston In order to calculate the coupling play between the cylinder and the piston a subtraction must be carried out between the diameter of the cylin der and that of the piston 2 17 2 2 17 2 1 Displacement cm Coupling play based on relevant class mm Coupling play limit based on r...

Page 99: ...s must be cleaned and named bit by bit as they are disassembled Proceed as follows for disassembly and in spection of the cylinder head Clamp the cylinder head using protective jaws gripping it at the head connection A Disassemble the spark plug using the spe cial spark plug wrench code 020440100 000 LUBRICATION JETS AND CENTRING PINS Pull out the two oil jets 1 for lubricating the cylin der head ...

Page 100: ...e recom mend they be replaced The finger follower shafts have a threaded hole M4 at the end so that they can be extracted To pull them out just screw a sufficiently long M4 screw A in this hole and pull out In this way the finger followers can be extracted Make sure the outside diameters of the shafts 2 and the inside diameters of the ho les on the finger followers 3 respect the fol lowing service...

Page 101: ... discs range from 2 00 to 3 30 according to the intervals carried in the ta ble below Once you have done the measurement take note and mark the calibrated disc depen ding on its original position Should the calibrated discs be deteriorated replace them with others having the same dimensions Thus you can know whether to replace it with a thicker or thinner calibra ted disc when determining the valv...

Page 102: ...A code 0100043 000 and apply the spring removal tool onto it B code 006140030 000 Then position the cylinder head and disassemble the springs Compress the spring as much as necessary to extract the half cones 1 Having extracted the half cones release the spring and extract the cup 2 the spring 3 and the valve 4 ATTENTION Mark all the pieces you disas semble Pay particular attention to the val ves ...

Page 103: ...rush the valve mushroom head thoroughly and degrease the entire valve Make sure that the valve stems are free from scratches or any type of nicks Measure the diameter of the valve stems making sure it is not less than the service limit Valve stem diameter service limit 5 95mm If it is replace the valve Play between the valve and the valve guide must not be grea ter than the limit carried below Pla...

Page 104: ... Width service limit of valve seat contact zone 1 9 mm The contact zone can principally take on three different appearances as shown in the figure A correct B incorrect contact face damaged C incorrect uneven seat width Also check the correct positioning of the contact area It must be neither higher case D or lower case E Should the incorrect conditions described abo ve occur the valve seats must ...

Page 105: ...reful not to nick the valve guide Once the valve stem seal is extracted the lower cup can be pulled out 2 CYLINDER HEAD CHECKING CYLINDER HEAD BODY Check the flatness between the head and cylinder coupling surfaces This can be done using a rectified block and a thickness gauge by positioning the block according to the directions shown in the fi gure The service limit is cylinder head flatness serv...

Page 106: ...g without oil Use a thickness gauge to check the wear li mit of the cams referring to the values carri ed in the table Sometimes the cams show small run marks This can be accepted if the finger followers are without wear and the cam height is insi de the tolerance Check on the exhaust camshaft that the spring 1 of the centrifugal decompressor re calls the rest of the device so that the cylin der s...

Page 107: ...ace the Benzing ring as well CHECKING CAMSHAFTS SUPPORT The camshafts supports fasten the shafts so they maintain the correct position whi le operating The support in the zone A has a channel B intended to lubricate the camshaft to allow the hydrodynamic sup port of the shaft itself Therefore you must make sure that the zones A are free from scratches or traces of corrosion Make sure the zones C f...

Page 108: ...e lower cup 1 facing the flat part downwards Lubricate the upper part of the valve guide lightly and insert the valve stem seal 2 Pay close attention that while inserting the valve stem seal its axis is ali gned with that of the valve guide The valve stem seal must be pressed towards the bot tom of the cylinder head until it is flush with the valve guide 2 17 8 1 2 Remember the valve stem seals mu...

Page 109: ...alve guide from the combustion chamber side Place the valve in the specific lower housing of the jaw and introduce The spring 1 being careful to insert it so that the segment with the smaller pitch faces downwards The upper cup 2 turning the flatter part upwards Compress the spring as much as necessary to extract the two half cones 3 To facilita te their insertion apply a small amount of grease on...

Page 110: ...nger follower shaft 2 partly in the specific seat as much as needed to be able to insert the outermost finger follower into the cylinder head first 3 Having fastened the ou termost finger follower to the shaft push the shaft further until it reaches the seat of the innermost finger follower Having coupled the innermost finger follower to the shaft push it all the way into the cylinder head Couple ...

Page 111: ...INSERTION OF OIL JETS CENTRING PINS AND SPARK PLUG O RING Insert the oil jets 1 with the O rings 2 in their specific seats on the cylinder head The positioning of the jets is univocal than ks to the specific flat side Apply the centring pins 3 to the cylinder head and the spark plug seal O ring 4 between the cylinder head and the camshaft support 2 17 11 1 2 A 1 4 3 ...

Page 112: ...hat the two ends face one another but do NOT over lap The two ends must be aligned in axis with the pin bolt Apply the two lower 2 and upper oil scraper rings 3 and then the compression ring 4 The two oil scraper rings must be placed so that their openings face the higher segment of the skirt and at 180 between them As sembly of the compression ring 4 must be done keeping the reference letter or n...

Page 113: ...he exhaust manifold APPLICATION OF PISTON TO CYLINDER To couple the piston to the cylinder place the cylinder while keeping the top facing upwards Oil the cylinder with plenty of mo tor oil Prepare the ring compression band A code 006140170000 as shown in the figure Press the green locking lever B and turn the hex key anti clockwise until the band rea ches a dimension near that of the piston Oil t...

Page 114: ...sure that the axis of the piston is aligned with that of the cylinder Towards the end of in sertion it might be necessary to use the wo oden handle of a hammer or a similar tool to lightly tap the piston crown in order to facilitate its complete insertion in the cylin der Attenzione Attention during the whole opera tion hold the band firm with one hand without moving it Make sure that the piston r...

Page 115: ...YLIN DER COUPLING TO CRANKCASE Apply a new piston cylinder gasket 1 to the crankcase and couple the two centring bushes to the left crankcase 2 Lubricate the foot of the connecting rod abun dantly with motor oil Insert the timing chain in the proper com partment in the cylinder and bring the pi ston cylinder unit close to the connecting rod 2 17 14 1 2 ...

Page 116: ...olt and having one of the two flat surfaces of the tool coincide with the part of the circlip to be inserted turn and push the special tool towards the en gine until the circlip is fully inserted into a seat Push the cylinder towards the crankcase making sure the two centring bushes on the left crankcase are correctly inserted in the seats in the lower part of the cylinder Attention the seeger nib...

Page 117: ... perfectly into the two centring bushes on the cylinder Lubricate the four washers 8 and insert them into their specific seats on the outside and inside of the cylinder head Then insert the four M10x1 25 screws 9 after having lubri cated them and the M6x80 screw 14 which connect the head and cylinder to the cran kcase In two moments proceed tightening the four screws in a criss cross pattern Start...

Page 118: ...ing the timing chain insert the exhaust camshaft upon whose gearwheel the timing chain must be placed It is advisable already in this phase to position the shaft so that the reference notches A are horizontal with the cams facing upwards according to the appro ximate direction B Lift the camshaft slightly and move the be aring so that it is flush with the shoulder C Having carried out the above me...

Page 119: ...ces E carved on the gear are horizontal Position the bearing in the same way as for the exhaust camshaft Holding the camshaft still with one hand insert an aluminium cylinder F in the hou sing of the hydraulic tensioner as far as ne eded to be able to push the movable guide against the timing chain Make sure that the notches engraved on the two wheels are aligned one with the other Is so the pha s...

Page 120: ...tire camshaft unit with mo tor oil and apply the support 1 making sure it is perfectly engaged both on the shafts and on the centring pins Note check the presence of the oil jets par 1 17 11 Apply the chain guide 2 and insert the three M7x38 screws 3 in the holes on the chain side and the four M7x33 screws 4 in the four remaining holes 2 3 4 1 ...

Page 121: ... than that indicated re place the calibrated disc with a thinner one The value of the needed thickness can ea sily be assessed by calculating the differen ce between the detected play value and the one required The following is a layout for calibrated disc replacement Tightening order of camshaft support screws Checking valve play with thickness gauge Tighten the seven screws by hand until they ar...

Page 122: ...le the tensioner par 1 1 1 First dissemble the intake camshaft and then the exhaust par 1 1 1 NO NO NO NO YES YES YES YES Couple the camshaft support par 2 17 16 First couple the exhaust camshaft and then the intake par 2 17 16 Couple the intake camshaft par 2 17 16 Disassemble only the intake camshaft par 1 1 1 Disassemble the calibrated disc to be replaced par 2 17 3 3 Apply a new disc according...

Page 123: ... a cap Make sure the piston shows no signs of ab normal meshing Insert the piston into the support and push it until it sticks out of the edge of the support by approximately 1 millimetre Insert the tensioner support in the specific seat on the cylinder tightening it at a torque of 25Nm and push the piston towards the front of the engine 2 17 18 1 2 3 4 25Nm 1 mm ...

Page 124: ...2 122 ENGINE ASSEMBLY AND CONTROLS Insert the spring in the support and ap ply the cap to be tightened at a torque of 8Nm 8Nm ...

Page 125: ...sitioning it so that it reco pies the shape on the support Apply a few drops of gasket paste in the ed ges of the cylinder head cover gasket 2 Insert the gasket in the cylinder head cover so that the protruding part fits perfectly into the groove in the cover 2 17 19 Application of spark plug gasket Edges where the gasket paste must be applied Insertion of gasket in groove on cylinder head cover 1...

Page 126: ...breather nozzle 2 the copper wa sher 1 and the bored screw 3 to be tightened at a torque of 10Nm Place the complete cover on the cylinder head making sure that the gasket covers the surface correctly Apply the four rubber rings 3 to the cover and insert the four screws 4 which fasten the cover to the cylinder head Tighten the screws in a criss cross pattern at a torque of 8Nm RELEASING CRANKSHAFT ...

Page 127: ...rting it in the drain hole ap ply the wire metal filter 27 with the O ring 26 Tighten at a torque of 25Nm Apply the magnetic screw 28 with the O ring 29 to the gear oil drain hole tighten at a torque of 20Nm 2 20 EXPLODED VIEW OF OIL DRAIN CAPS 24 Motor oil drain plug 25 O ring 27x2 26 O ring 20x1 5 27 Metal filter 28 Magnetic screw 29 O ring 11x2 5 25Nm 20Nm ...

Page 128: ... GEARSHIFT LEVER Couple the gearshift lever to the drive shaft by positioning it so that the part A of the le ver coincides with the upper edge of the oil level inspection window Tighten the screw 1 at a torque of 10Nm af ter having applied medium strength threa dlocker 2 21 10Nm ...

Page 129: ... Sichel 100M 6 Outside left crankcase half Countershaft bearing fixing M5 x 10 10 Loctite 243 Sichel 100M 6 Calibrated screw M5 1 Loctite 243 Sichel 100M Tighten all the way Oil jet M4 1 Loctite 243 Sichel 100M Tighten all the way Inside left crankcase half Crankshaft bearing fixing plates M6 x 14 2 Loctite 243 Sichel 100M 8 Crankcase half coupling M6 x 75 2 10 Crankcase half coupling M6 x 65 13 1...

Page 130: ...100M 120 Attention Don t use pneumatic wrench Clutch pressure cap M6 x 25 4 10 Clutch actuator M6 x 20 2 10 Clutch actuator M6 x 30 1 10 Outer clutch cover M6 x 25 6 10 Outer clutch cover M6 x 30 1 10 Inner clutch cover M6 x 25 9 10 See water pump cover screws as well Water pump Impeller blind nut M6 1 Loctite 243 Sichel 100M 10 Cover M6 x 40 4 10 Timing chain guards Fixed and movable guides M6 x ...

Page 131: ...ric fan sensor M12 1 20 AIS valve fitting M10 1 10 Cover M6 x 12 4 8 Mechanical tensioner Tensioner cap M24 1 25 Small tensioner cap M16 1 8 Chain pinion Pinion M10 x 18 1 Loctite 243 Sichel 100M 60 Do not use pneumatic devices Gearbox oil vapour breather Bored screw M10 1 10 Oil drains Motor oil plug M30 1 25 Magnetic screw gearbox oil plug M14 1 20 Kickstarter Kickstart lever M8 x 26 1 Loctite 2...

Page 132: ...mp oil seals S I S Oil pumps control gearwheels I I S APPLICATION PRODUCT QUANTITY Gearbox and clutch PANOLIN OFF ROAD 4T SYNT 10W 50 850 ml Engine PANOLIN OFF ROAD 4T RACE 10W 40 850 ml COOLANT PANOLIN ANTI FROST MT 325 1 300ml RECOMMENDED LUBRICANTS AND LIQUIDS Refer to Use and Maintenance Manual for levels I INSPECT AND REPLACE IN CASE OF NECESSARY S REPLACE RECOMMENDED ENGINE MAINTENANCE The r...

Page 133: ...2 131 ENGINE ASSEMBLY AND CONTROLS NOTE ...

Page 134: ......

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