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Содержание EVO 4t

Страница 1: ...WORKSHOP MANUAL...

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Страница 3: ...WORKSHOP MANUAL 2009...

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Страница 5: ...M 32 3 15 CRANKSHAFT 33 CHAPTER 4 ASSEMBLY 4 1 RIGHT HAND CRANKCASE 34 4 2 LEFT HAND CRANKCASE 36 4 3 CLUTCH CASING 37 4 4 GEARBOX AND SHIFTING MECHANISM 39 4 4 1 Mainshaft 39 4 4 2 Layshaft 40 4 5 CR...

Страница 6: ......

Страница 7: ...ut repair and or mainte nance Betamotor models are exported to numerous countries where different rules apply with respect to highway law and homologation procedures Trusting that you will under stand...

Страница 8: ...l to the environment When changing the oil it is necessary to be equipped for disposing of the waste oil in accordan ce with the relevant law Do not dispose of waste oil into the environment Keep it w...

Страница 9: ...king in areas adjacent to them In addition use insulating gloves WARNINGS The information in this paragraph is important in order for the operations carried out on the motorcycle to be performed witho...

Страница 10: ...onnecting rods to frame 8x1 25L42 10 9 2 30 Stand to swing arm 6x1L20 8 8 2 X 10 Sliding block chain tightener to swing arm 8x1 25L12s 8 8 1 10 Chain tightener spring fixing 5x0 8L20 8 8 1 5 Chain gui...

Страница 11: ...retaining screws 5x0 8L25 8 8 2 5 Lights switch 4x0 7L14 8 8 2 3 FRONT WHEEL Front wheel pin 18x1 5 5 8 1 50 Disc brake 6x1L25 8 8 4 X 10 REAR WHEEL Rear wheel pin 16x1 5 5 8 1 80 Disc brake 6x1L16 8...

Страница 12: ...nkcase Bolt M6x45 2 10 Bolt M6x60 9 10 RH crankcase Clutch casing Bolt M6x25 7 10 Bolt M6x55 1 10 Bolt M6x30 2 10 Selector drum bearing retaining bolt Bolt M6x10 2 X 10 Flywheel cover Bolt M6x30 5 10...

Страница 13: ...ONENT QTY THREAD LOCK TORQUE NM Filter cover output oil pump Screw M6x20 3 10 Oil pressure relief valve Special bolt M12x1 25 1 20 CLUTCH GROUP Pressure plate Bolt M6x16 6 10 Clutch centre Special nut...

Страница 14: ...haft to lubricate the roller bearing on the crankpin the other 7 whose flow is regulated by a calibrated hole in the cylinder base gasket 8 feeds the valvegear 9 The oil then returns to the base of th...

Страница 15: ...ry remove the oil filler plug and top up the level N B Running the engine with too little oil causes ex cessive wear to the engine components 1 3 CHANGING THE ENGINE OIL N B At each oil change the mes...

Страница 16: ...act the filter Clean it carefully and blow it through with compressed air Check for damage to the O rings and replace them if necessary Refit all the parts and tighten the plug to 15 Nm Carry out the...

Страница 17: ...the condition of the O ring too and replace it if neces sary Change the filter and refit the cover tightening the three M6x20 bolts to 10 Nm Refit the oil drainplug tightening it to 20 Nm and refill w...

Страница 18: ...TTING 2 1 ENGINE DISASSEMBLING Deeply clean the whole bike and position it on a steady stand Disassemble front fender Disassemble silencer Unhook the two springs located in front of the en gine head A...

Страница 19: ...connectors A and B loca ted over the carburettor Disassemble left panel and disconnect connectors C and D of the electric fan and bulb Disconnect the coil from radiator and unplug the pipe from the s...

Страница 20: ...INE REMOVAL AND REFITTING betamotor com Make sure that the fuel petcock is closed lever in position C Disassemble the rear brake oil tank by un screwing the fixing screw Loosen the carburettor fixing...

Страница 21: ...ewing the two blocking screws A Loosen the rear wheel axle and take off the chain from the sprocket Disassemble the clutch slave cylinder unscrewing the three fixing screws B Disassemble regulator sup...

Страница 22: ...the engine and unscrew the bleeding screw of the cooling system A Open the radiator plug B in order to drain all the liquid contained in the system Loosen the clamps used to block the tubes of the coo...

Страница 23: ...17 ENGINE REMOVAL AND REFITTING betamotor com Unscrew the screws which block connecting rods to frame A loosen and take off the engine front fixing pin B B A...

Страница 24: ...18 ENGINE REMOVAL AND REFITTING betamotor com Disassemble the whole block connecting rods ra diator electric fan Loosen the three head screws Loosen the blocking nut of the engine lower fixing pin...

Страница 25: ...reverse For tightening torques consult the rele vant table Once refitting is complete refill the system with coolant through the radiator until the liquid comes out of the bleed hole on the left hand...

Страница 26: ...ich deals with assembly because it discusses all the checks that need to be carried out on individual compo nents 3 1 DRAINING THE OIL Remove the oil drainplug and let the oil flow out into a drain pa...

Страница 27: ...the complete timing system is therefore unlo aded To find TDC set up a dial gauge with suitable sup port in the sparkplug hole and rotate the flywheel by hand until the dial gauge indicates that the...

Страница 28: ...ndles using an M4 bolt screwed into the spindles from the timing case side Do this while the cover is still fitted to the head and secured by the bolts This is because the spin dles are restrained fro...

Страница 29: ...re that the gear does not fall into the crankcase Remove the fixed camchain guide Unscrew the cylinder head retaining nuts which are screwed onto the studs and the bolt on the water pump side Then rem...

Страница 30: ...pi ston together without having to split them You only need to split them when performing operations or measurements on the two components individually see the section devoted to this subject in the...

Страница 31: ...ve the left hand oil pump cover 2 after first _unscrewing the retaining screws 1 Next extract the pump outer rotor 4 using a pair of circlip pliers after you have removed the pin 3 Then remove the inn...

Страница 32: ...remove the two covers and their O rings Then unscrew the bolts holding the clutch casing 3 after you have removed the kickstart lever Unscrew the bolts 1 retaining the clutch springs 3 in diagonal seq...

Страница 33: ...pecial washers 2 the springs 3 and the clutch pressure plate 4 Next remove the friction plates 8 and then the pressure plate lifter 7 the needle roller bearing 6 and the corresponding washer 5 Using a...

Страница 34: ...special tool for locking the clutch centre Extract the clutch centre 11 the thrust washer 12 the clutch basket 13 the bush 14 and the thrust washer 15 3 8 PRIMARY TRANSMISSION Unscrew the crankshaft n...

Страница 35: ...it can cause injury as a result of rapidly springing back to its rest position Remove the kickstart idler gear 5 after you have first removed the retaining circlip 3 At the same time remove the two t...

Страница 36: ...nscrew the retaining bolt 8 and extract first the idler pivot pin 9 and then the detent lever 10 3 11 OIL PUMP RIGHT HAND CRANKCASE Extract the oil pump gear 2 after you have first removed the retaini...

Страница 37: ...unscrewing the retaining bolt 4 Use an engineering chisel to remove the woodruff key 2 from its housing in the clutch side crankshaft end and then extract the timing gear 1 3 13 SPLITTING THE CRANKCAS...

Страница 38: ...he threads for the flywheel cover retaining bolts Turn the engine so that the right hand crankcase half is facing downwards Then screw in the bolt at the end of the special tool until the two crankcas...

Страница 39: ...that the crankshaft extractor which is the same tool as the crankcase splitter has a flat surface to push against Fit the splitting tool to the right hand crankcase half using the threads for the clut...

Страница 40: ...crankcase half If after the crankcase has cooled down the outer race of one of the bearings tends to spin in its hou sing the crankcase itself must be replaced N B Before refitting the bearings check...

Страница 41: ...oil pressure relief valve 11 N B Make sure that the number and thickness of wa shers 12x18x1 12x18x1 5 for the oil pressure relief valve are the same as in the factory setup Fit the crankshaft oilsea...

Страница 42: ...hand crankcase N B When fitting the main bearing use a pad on the opposite side to avoid putting excessive stress on the flat surface of the housing under the load from the press Fit the oilseals for...

Страница 43: ...an them and check that there are no obstructions N B Before refitting the bearings check the state of wear of the revolving parts and make sure that the balls run correctly in their tracks in the bear...

Страница 44: ...aining plate and tighten the screws to a torque of 3 Nm after applying medium strength thread lock Fit the oil filter spigot 3 with its O ring N B The spigot is an interference fit in its housing Clos...

Страница 45: ...suitable engine oil N B It is good practice to fit new circlips each time the gearbox is assembled 4 4 1 Mainshaft Position the shaft 1 with the splined end facing downwards and fit the following part...

Страница 46: ...ined bush 10 3rd idler gear 11 with the flat side facing upwards splined washer 8 circlip 12 Sliding 5th gear 13 with the groove for the se lector fork facing downwards 17x24x0 5 thrust washer 14 Bush...

Страница 47: ...s Push the two pins through the forks taking care to use the longer one for the forks on the secondary shaft N B Before fitting the fork spindles make sure that the forks slide freely on them and chec...

Страница 48: ...heck for misalignment of the shafts in the cran kshaft halves by setting up the crankshaft betwe en centres or in a similar instrument and using a pair of dial gauges 1 positioned on the contact surfa...

Страница 49: ...it the crankcase centre gasket cutting it in the cylinder area 2 to avoid interference with the con necting rod during assembly N B Put a little grease on the gasket face of the right hand crankcase i...

Страница 50: ...er will rest Tap the two ends of the crankshaft several times in an axial direction with a rubber hammer in order to release it from residual stresses induced in the crankcase by heating it 4 7 SHIFTI...

Страница 51: ...the movable pawl Position the spring 1 and the detent lever 2 in their housing and hold them in place with the id ler pivot pin 3 Secure with the M6x25 bolt 4 tightened to 10 Nm after applying medium...

Страница 52: ...ifting lever and test the gearbox operation by rotating the mainshaft by hand and changing from one gear to another 4 8 TIMING SPROCKET Fit the timing sprocket 4 after you have applied a sufficient am...

Страница 53: ...d cran kcase half facing upwards Locate the pump 1 in its housing in the right half of the crankcase after oiling it well with the reference marks facing towards the inside so that they are not visibl...

Страница 54: ...er you have fitted the washer 8 and the pin 9 into the top hole in the shaft 2 secure the drive gear 10 with the circlip 11 Ensure that the gear is positioned correctly the side with the larger rai se...

Страница 55: ...the O rings 18 N B The two filters have a tapering internal cavity Use a pin punch with a taper point to facilitate fit ting Refit the filter covers 20 tightened to a torque of 10 Nm after fitting th...

Страница 56: ...the relative position of the hole A for securing the return spring 11 is as shown in the drawing Position the kickstart shaft 2 with the serrated end facing upwards and fit the thrust washer 16x25x0...

Страница 57: ...rts move freely Fit the kickstart idler gear 17 on its shaft together with the two 18x27x0 5 thrust washers 16 18 after you have lubricated the parts in contact with each other and secure it with the...

Страница 58: ...ng the two components and the shaft itself Check the bush for signs of seizure or excessive wear If these are found re place the bush Also measure the clea rance between the steel bush 2 and the bush...

Страница 59: ...tch drive plates 8 which must be not less than 2 8mm thickness when new 3mm Also check both the drive plates 8 and the driven plates 9 for flatness the discs must not undulate excessively as this coul...

Страница 60: ...corresponding washer 12 Check the wear on the needle roller bearing and the contact surfaces Replace the components if they show excess wear Check the length of the springs 14 Minimum value 33 3mm 33...

Страница 61: ...on the crankshaft befo re proceeding to fit the flywheel Insert the drive key 1 in the keyway machined for it in the left hand crankshaft journal using a rubber hammer if necessary Fit the flywheel 2...

Страница 62: ...of the cylinder exhaust side is marked with the letter for the selection grade This is needed for correct matching with the piston as both must be of the same grade the piston is marked on the crown...

Страница 63: ...or the oil scraper ring of carbon residues from com bustion Use a feeler gauge to measure the play between the compression rings and the ring grooves in the piston If these values exceed the maximum w...

Страница 64: ...lied a thread lock Use a nut and locknut 2 for screwing in the studs Tighten to 30 Nm Fit the cylinder base gasket taking care that it does not obstruct the oilway 3 4 14 2 2 Piston Fit the oil scrape...

Страница 65: ...art of the circlip is facing either up wards or downwards Slide the cylinder down between the studs until the small end of the conrod is aligned with the piston pin housing Then insert the piston pin...

Страница 66: ...excessive wear or scoring Measure their external diameter and if this is below the limit replace the rocker spindle Limit value 11 93mm Check that the rollers 4 in the rocker arms run freely If you d...

Страница 67: ...de must be replaced Check whether the valve stems show signs of wear scoring or damage Then measure their diameter and if this value is below the limit replace the val ve Minimum diameter 4 978mm Chec...

Страница 68: ...ust be recut Recut the seat also if excessive roughness is visible or if there is damage due to impact Check the free length L0 of the inner and outer val ve springs Change the springs if their free l...

Страница 69: ...guide oilseals each time an inspection of the head is carried out and the valves are removed Fit the outer springs 4 and the inner springs 5 and then the spring caps N B springs have a coloured paintm...

Страница 70: ...with the open side facing outwards so as to avoid water leaks from the pump into the ti ming case This last oilseal must be fitted in its hou sing to a depth of 1 mm Remember to apply grease to the o...

Страница 71: ...them in diagonal sequen ce starting with the studs in proximity to the do wels after applying molycote grease Tighten in dia gonal sequence to 30 Nm Then using a protractor disc A continue tightening...

Страница 72: ...s is explained further on in this manual This facilitates the fitting of the head cover and consequently the rockers N B The correct way to check the timing is to tension the camchain by pressing on t...

Страница 73: ...is correct tighten the locknuts to 11 Nm and seat the O rings for sealing the valve covers in the grooves machined in the head cover Use silicone sealant to help the O ring adhere in its groove and to...

Страница 74: ...d its gasket retaining it with M6x16 bolts tightened to 8 Nm Use a screwdriver to push the plunger so as to put the camchain un der tension Then insert the spring and washer and finally screw in the b...

Страница 75: ...O rings for the clutch cover 3 and the oil filter cover 4 into the grooves formed in the clutch casing applying some grease to make sure they adhere to their housings Fit the output oil filter 5 and...

Страница 76: ...8 to adhere N B Before you apply the gasket cut off the excess section as shown in the picture above Fit the stator 3 to the flywheel cover 2 retaining it with three M5x25 screws 4 Tighten the screws...

Страница 77: ...ain has been passed around the sprocket once the motor cycle is assembled 4 20 FINAL DETAILS Insert first the ball 1 and then the clutch pushrod 2 after you have lubricated them with engine oil Fit th...

Страница 78: ...ng the exhaust collector support springs These plates are fitted to the top right and bottom left bolts looking at the engine from the front exhaust side Fit the special washer between the TDC bolt an...

Страница 79: ......

Страница 80: ...BETAMOTOR S P A PIAN DELL ISOLA 72 50067 RIGNANO SULL ARNO FIRENZE ITALIA TEL 39 055 83 48 741 FAX 39 055 83 48 984 WWW BETAMOTOR COM INFO BETAMOTOR COM COD 22 19818 000 2009...

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