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Beamer R2 Rev 1.0 

Page 24 of 56 

6/13/2007 

6. ENGINE COMBUSTION SYSTEM 

 

6.1 TROUBLESHOOTING 

 

 

 

 

LOW COMPRESSION 

 

 

 

¾

 

HEAD GASKET LEAKING OR DAMAGED  

¾

 

WARPED OR CRACKED CYLINDER HEAD   

¾

 

CYLINDER

 

OR

 

PISTON

 

RINGS

 

WORN

 

OUT 

 

 

HIGH COMPRESSION 

¾

 

EXCESSIVE CARBON BUILD

-

UP ON PISTON HEAD OR IN 

COMBUSTION CHAMBER

 

 

 

EXCESSIVE NOISE 

 

¾

 

PISTON AND CYLINDER

 

WORN 

OUT

 

¾

 

EXCESSIVE CARBON BUILD

-

UP

 

 

 

EXCESSIVE SMOKE 

 

 

¾

 

CYLINDER

 

OR

 

PISTON

 

RINGS

 

WORN

 

OUT 

¾

 

IMPROPER

 

INSTALLATION

 

OF

 

PISTON

 

RINGS 

¾

 

PISTON

 

OR

 

CYLINDER

 

WALL

 

SCORED

 

OR

 

SCRATCHED

 

 

 

 

OVERHEATING 

 

 

 

 

¾

 

EXCESSIVE

 

CARBON

 

BUILD-UP

 

ON

 

THE

 

PISTON

 

OR

 

COMBUSTION

 

CHAMBER 

¾

 

ENGINE

 

COOLING

 

SYSTEM

 

(FAN,

 

CYLINDER

 

COVER,

 

ETC.)

 

WORKING

 

IMPROPERLY 

¾

 

OIL

 

QUANTITY

 

LOW 

¾

 

WRONG

 

IGNITION

 

TIMING 

www.Get2itParts.com

www.Get2itParts.com

www.Get2itParts.com

Содержание beamer R2-50

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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