Beta Enduro RR 250 2016, Workshop Manual

Page 1: ...COD 026 44 018 00 00 ...

Page 2: ...unit 47 3 4 2 Assembly of main unit 48 3 4 3 Assembly of secondary unit 49 3 4 4 Check of forks fork pins and desmodromic device 50 3 4 5 Assembly of gearbox and inner control 52 3 5 CLOSING OF ENGINE CRANKCASE 55 3 6 EXTERNAL GEARSHIFT 56 3 6 1 Check of complete drive shaft 56 3 6 2 Assembly of external gearshift 58 3 7 KICK STARTER DEVICE 58 3 7 1 Check of kickstart shaft and assembly 58 3 7 2 A...

Page 3: ...clutch rod and pinion spacer 97 4 Reassembly of motor in vehicle 98 TABLE OF FASTENING TORQUES OF ENGINE COMPONENTS 104 TABLE OF FRAME MOTOR FASTENING TORQUES 106 TABLE OF SUPERSTRUCTURE FASTENING TO RQUE VALUES 106 RECOMMENDED MOTOR MAINTENANCE 107 RECOMMENDED LUBRICANTS AND LIQUIDS 107 ...

Page 4: ...children 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 on the engine Sufficient knowledge of the compo nents that make up the engine and of all the procedures to be...

Page 5: ...lently and cause burns Coolant contains dangerous substances which are harmful for the environment When chang ing it you must be equipped to dispose of it in compliance with existing law Do not disperse coolant into 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 t...

Page 6: ... ratio 20 24 20 24 5th gear ratio 27 27 27 27 6th gear ratio 28 24 28 24 Carburetor RR250 RR300 Version Approv Race Approv Race Carburetor type PWK 36S AG PWK 36S AG Main jet 118 165 118 165 Slow jet 35 35 38 38 Ignition jet 50 85 50 85 Needle N84K N0ZJ N84K N2ZW Needle position from above 3 1 2 2 4 2 Air screw turns from all closed 1 3 4 1 1 4 2 1 1 4 Flush SI NO SI NO this modification makes the...

Page 7: ...rankcase Cylinder gasket check plate code 026140020 000 4 Front bracket code 026140030 000 to fix engine to stand code 3625132 000 5 Flywheel blocking tool code 026140040 000 6 Flywheel extractor code 3625173 000 7 Engine support stand code 3625132 000 6Nm Pasta siliconica Grease Value Fastening torque Symbols Loctite 243 Sichel 100M ...

Page 8: ...connect the tank ventilation pipe Set the fuel valve to OFF and disconnect the fuel pipe from the valve Remove the seat Grasp the side panel from the front and pull outwards Remove the two screws 1 fastening the tank to the frame and the screw 2 one per side fastening the side panel to the radiator 1 2 1 1 Removal of motor from vehicle ...

Page 9: ...guards 3 one each side and the pinion guard 4 Remove the circlip 5 and extract the pinion Rest the chain against the upper wedge 6 4 3 5 6 Remove the screws 7 fixing the clutch actua tor to the crankcase half 7 ATTENTION Do not activate the clutch lever with actuator decoupled from engine ...

Page 10: ...m the right radiator Remove the right radiator Remove the left radiator with pipes 8 Remove the exhaust expansion and the silen cer Drain the cooling system through screw 8 and let the liquid outflow into a container the co oling circuit contains 1 3l of liquid Remove the radiator cap ...

Page 11: ...move the coil itself Cut all straps binding the engine s electric system to the clutch pipe and to the frame Disconnect the engine ventilation pipes 9 10 Pull the mixer tube 9 out from the intake ma nifold and tube hold 10 ATTENTION When the mixer tube has been disconnected plug it to prevent emptying ...

Page 12: ...al of motor from vehicle Remove the head connections and spark plug Release and remove the brake pedal return spring 7 Remove the kickstarter lever Remove the gear lever 11 Remove the start motor cable fixing nut ...

Page 13: ...or straps from the air fil ter sleeve and from the manifold Remove the seat rail lower fixing screws 12 one each side and loosen the upper screws 13 one each side Rotate the filter box unit Remove the carburetor leaving it connected to the gas cable 12 13 ...

Page 14: ...vehicle Remove the swingarm pin 14 and the upper shock absorber pin 15 Remove the engine pins 16 Extract the engine from the frame and apply it to the specific stand code 3625132 000 using spe cific front fixing bracket code 026140030 000 ...

Page 15: ...s of front fixing code 026140030 000 in order to work in comfort and safety Then proceed as follows 2 1 CLUTCH GEAR OIL DRAIN Remove screw 1 and let the oil drain 1 2 2 REMOVAL OF CLUTCH CONTROL ROD AND PI NION SPACER Extract the spacer 1 Extract the clutch control rod 2 2 1 2 Engine disassembly ...

Page 16: ...sassembly 2 3 REMOVAL OF PISTON CYLINDER AND HEAD Remove the spigot screws 1 together with the copper washers Remove the head and the two O rings Remove the four screws 2 Remove the three screws 3 and cover 4 1 2 3 4 ...

Page 17: ...ck 5 and remove it Release the control rod 6 Remove the gasket 7 It may be necessary to force the rubber gasket 8 slightly place a metal pin A between the lever and the gasket 8 and force it externally slightly 5 Removal of gasket 7 A 7 6 8 ...

Page 18: ...ir of fine nose pliers A Push the pin bolt with an aluminium cylinder or similar B until the pin bolt is released from the connecting rod foot Remove the piston the pin bolt and the bear ing from the connecting rod foot ATTENTION Try pulling out the pin bolt by hand first of all If it is too tight hit the pin lightly with a rubber hammer at the same time holding the piston with your hand in or der...

Page 19: ...left crankcase Remove the flywheel cover and the gasket placed between the crankcase and the cover Be careful of the two centring pins 3 on the crankcase Fixing screws 1 of flywheel cover 2 The two references pins 3 dedicated to the flywheel cover 1 2 3 2 4 2 Removal of stator Remove the two screws 1 fixing the stator 2 to the flywheel cover 3 Extract the plate 4 and the cable gland 5 from the cov...

Page 20: ...rewed pay attention to the special elastic washer placed between the nut and the flywheel A To remove the flywheel tighten the extractor B code 3625173 onto the threaded part on the flywheel Keep the extractor blocked with spanner and tighten the screw on the extractor using a box spanner Release of flywheel using special tool B Removal of pick up 2 4 4 Removal of pick up Remove pick up 1 by loose...

Page 21: ...the Bendix coupling 4 The coupling gear axially shifts and meshes onto the ring gear which is one with the flywheel due to the start motor rotation The coupling gear retracts to its rest position once the motor action is terminated Exploded view of electric kickstart 1 Start motor 2 O ring 3 Screws 4 Bendix coupling 5 Bush with collar ...

Page 22: ... Remove the two screws 1 and extract the motor itself Removal of start motor Rimozione innesto Bendix 2 5 2 Removal of Bendix cou pling Extract the Bendix coupling 1 once the complete flywheel cover and flywheel itself see par 2 4 1 have been removed 1 1 ...

Page 23: ...H UNIT MAIN GEAR CENTRIFU GAL UNIT GEARSHIFT OR GANS KICKSTART Remove the cover 1 by loosening the four screws 2 to access the coolant liquid pump Note remove the coolant liquid pump impeller if having to intervene on the centrifugal unit Coolant liquid pump cover screws ...

Page 24: ...3 4 2 22 Engine disassembly Remove the outer clutch cover 3 by loosening the five screws 4 to access the clutch unit only Outer clutch cover screws ...

Page 25: ...transmission or centrifugal unit the inner clutch cover 5 must be removed by loosening the nine screws 6 Inner clutch cover screws Pay attention to the two reference pins A placed between the right crankcase half and the inner clutch cover while disassembling Two centring pins A for inner clutch cover coupling A ...

Page 26: ...ump Loosen fixing screw 1 once the coolant liquid pump cover has been removed Cooling pump fixing screw Removal of impeller Removal of pump body and gasket Extract the impeller 2 and the thrust 3 Extract the complete pump body 4 and remove gasket 5 1 2 3 5 4 ...

Page 27: ...nit and leverage by removing the inner clutch cover Disassemble the adjustment cover 1 by removing the two screws 2 once the pump impeller has been removed par 2 6 1 Removal of centrifugal adjustment cover Remove the unit consisting of adjusting 3 and auxiliary 4 springs and the spring guide 5 4 3 5 ...

Page 28: ...nd gasket 8 once the screw fixing the rocker arm 6 to the centrifugal control lever 7 has been removed Disassembly of control rod rocker arm unit Removal of centrifugal control lever Extract the centrifugal control lever 7 together with the two thrust washers 9 8 6 7 7 9 9 ...

Page 29: ...complete centrifugal unit 10 Extraction of centrifugal unit 1 Control cover 3 Adjusting spring 4 Auxiliary spring 5 Spring guide 6 Rocker arm 7 Centrifugal control lever 8 Gasket 9 Thrust washers 10 Centrifugal unit 10 10 8 3 9 6 5 4 1 7 ...

Page 30: ... the disc spring assembly 2 6 3 Removal of main gear and clutch unit Remove the four screws 1 fastening the clutch cap 2 to the clutch drum Remove the clutch cap together with the four washers and relative springs Clutch cap 2 and four screws 1 Pressure plate unit 3 and clutch disc pack Removal of disc spring assembly 2 1 3 ...

Page 31: ... must be blocked with a relevant tool A code 026140010 000 Insert the main special tool on the drum so that its inner teeth mesh in those present on the clutch drum the tube on the tool inserts on the main gear nut Loosen the clutch nut Attention Do not use the pneumatic gun Extract the clutch drum Opening of the safety washer with chisel Removal of clutch drum nut with relevant tool A 4 5 A ...

Page 32: ...to be able to disassemble the main gear Attention The nut must be turned clockwise Disassembly of the main gear nut Remove the washer 7 the case 8 the roller cage 9 and the centre bearing 10 6 A Safety washer 4 nut 5 washer 7 case 8 roller cage 9 centre bearing 10 special driven disc 11 disc spring assembly 12 5 4 10 9 11 12 8 7 Removal of main gear 13 Extract the main gear 13 ...

Page 33: ...then meshes with the clutch case The device moves back thanks to the spring 4 Remove the external circlip 5 and pull off the external thrust washer 6 the idler gear 3 the internal thrust washer 7 and the second circlip 8 The circlips and thrust washers are interchangeable Kickstarter mechanism Removal of circlip 5 of idler gear 3 Two circlips 5 and 8 and thrust washers 6 and 7 3 5 3 1 2 4 5 6 8 7 ...

Page 34: ...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 Release of spring from crankcase Extraction of shaft from crankcase Complete pedal kickstart shaft 9 2 1 4 10 11 4 A ...

Page 35: ... pawl return spring 3 pressed and extract the shaft together with specific washer 4 In order to disassemble the stop cam 2 keep the cam stop lever moved 5 loosen the screw 6 and pull out the stop cam2 In order to disassemble the stop lever loosen the screw 7 enough to allow the lever to move axially and overcome the cylinder segment A of the desmodromic device Bring the return spring 8 to the rest...

Page 36: ...d valve 3 Spacer 2 7 INTAKE SYSTEM The intake system mainly consists of the intake manifold 1 and reed valve 2 and the spacer 3 Disassemble by removing the four screws 4 fastening the intake manifold and the reed valve to the crankcases Fixing screws 3 2 1 4 ...

Page 37: ... tool B to the right crankcase half following the punching on the tool itself Fix the tool with the four M6x20 screws maximum torque 10Nm Tighten screw C on the special tool Slightly hit the gear secondary with a rubber mallet during said operation Once the crankcases have been detached remove the two fixing screws to the equipment A and remove the left crankcase Remove the two rear 2 and front 3 ...

Page 38: ... of the gearbox allowing engagement of the desired ratio The desmodromic device is controlled by the stop cam present in the external gearshift unit Extract the two pins 4 by hand so that the forks can be released and removed Turn the fork 2 which drives the sliding gear on the primary unit clockwise to free it from the desmodromic control Do the same operation though in the opposite direction on ...

Page 39: ...e crankcases have been detached it is necessary to remove the various components attached to it The bearings must be replaced if they play or get jammed during rotation For removal oven heat the crankcase halves for 20 minutes at about 150 C Place the crankcase halves on a large surface where their whole seal surface can rest Remove the bearings following the indications below 2 9 1 Right crankcas...

Page 40: ...2 38 Engine disassembly Kickstart ramp 1 crankshaft spacer 2 and relative O ring oil seal 3 Bearing safety screw Remove the desmodromic control bearing seal screw 4 from the inner side 3 1 2 4 ...

Page 41: ...7 8 and 9 are removed from the outside to the inside Remove fixing screws 10 to disassemble bearing 9 The centrifugal shaft bearing can be removed by using a universal extractor that must rest onto a purposely created metal plate 7 6 5 9 10 8 ...

Page 42: ... oil seal 1 the secondary shaft oil seal 2 and the gearshift shaft oil seal 3 from the external side Removal of outer side left crankcase half oil seal Removal of left crankcase half bearings The bearings 4 5 6 and 8 are removed from the outside to the inside 1 3 2 6 5 4 7 ...

Page 43: ...rankcase halves on a large surface where their whole seal surface can rest When the bearings cool down they drop into their seats on their own 3 1 Crankcase half The crankcase halves have some elements that need to have their integrity and use status checked Hereafter the checks and assembly operations of the individual elements coupled to the crankcases will be described Clean the threading and o...

Page 44: ...shaft bearing 3 1 1 Application of right crankcase half parts Apply the bearings 1 2 3 and 4 until flush Block bearing 4 with specific screw prior depositing of threadlockers Fasten at 6Nm Apply the bearing 5 from the crankcase half external side until it is flush and bearing 6 as shown in the drawing Apply new oil seals to be pressed in seat until they are flush 3 2 1 4 6 5 6Nm ...

Page 45: ...r 17 onto it by inserting the smaller diameter segment in the lever Apply the spring 16 so that the hook inserts into the groove present on the lever 18 and then apply the washers 19 and the screw 20 M6x20 which threading must be spread with medium strength threadlocker Apply the entire device on the crankcase half so that the straight segment of the spring rests on the bearing seat Tighten the sc...

Page 46: ...nal side as shown in the drawing Apply the crankshaft oil seal gear secondary shaft and gearshift shaft Apply the bush with collar 5 Apply new oil seals to be pressed in seat until they are flush Apply new oil seals to be pressed in seat until they are flush Application of left crankcase half bearings Application of left crankcase half parts Position of left crankcase half gearshift shaft bearing ...

Page 47: ...xes by measuring radial oscillation by placing the crankshaft in between two tailstocks or similar instrument Control the maximum measurement variation during a complete turn using comparators positioned on the coupling surfaces with the crankshaft bearings Allowed limit value 0 02mm Check the axial play between the connecting rod head and the half shafts Recommended play 0 39 0 72mm The distance ...

Page 48: ...ase the crankshaft oil seal on the right crankcase half and couple the crankshaft to the left crankcase half Keep the conical part A present on the crankshaft towards yourselves In order to carry out this operation you must just push the shaft axially towards the crankcase Apply the two centring bushes 1 and 2 Insertion of crankshaft in right crankcase 1 2 A ...

Page 49: ...ndicated below service limit 0 5mm If the detected axial play is greater before replac ing either the gearwheels or the forks check their state of wear par 3 4 4 Remove the various elements and check that the support surfaces of the primary and second ary shafts are free of abnormal wear or signs of seizure the sides of the teeth are free from chipping or abnormal wear the sliding areas of the gea...

Page 50: ...6 Third and fourth on primary 7 Thrust washer 8 Sixty on primary 9 Second on primary 10 Thrust washer 17x30x1 Insert onto the lower cylinder part of the shaft the roller cage 2 the 5th gear 3 turning 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 insert the circlip 5 Insert the 23x32...

Page 51: ...ng protective jaws so that the grooved end faces downwards Insert onto the lower cylinder part the roller cage 15 the 2nd gear 15 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 front claw c...

Page 52: ...s made up of two forks 13 which drive two gears on the sec ondary unit one fork 14 which drives one gear on the pri mary unit three drive pin bushes 15 two fork pins 16 desmodromic gearshift 18 through whose rota tion the forks are driven thus selecting the de sired gear Check to make sure that the drive pins which sup port the bushes 15 have no traces of meshing or abnormal wear and that the bush...

Page 53: ...imit 13 83mm Make sure that the fork pins upon which they slide have an outside diameter above the limit to be measured in the sliding areas of the forks and in the housing areas of the crankcases Fork pin outside diameter limit 13 75mm Make sure that the desmodromic control device has no corroded or worn areas especially in the grooves in which the drive pins of the forks are engaged Check the be...

Page 54: ...mber to oil the gears abun dantly with gear oil and to grease the shafts sup porting 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 Insertion of gearbox in left crankcase 1 2 4 3 Detail of centre bearing 3 and O ring 4 coupled to the secondary shaft 3 4 ...

Page 55: ...vice Place the forks in their original positions if none of the components are replaced Insert the desmodromic device in the specific bearing In order to do this it is necessary to ro tate cam stop lever 7 towards the top part of the engine Position the fork 5 of the primary unit in the cen tral guide of the desmodromic device 8 insert the fork pin inside the fork itself and insert the pin in its ...

Page 56: ... then in its proper seat Remember to oil the shafts forks and the desmo dromic device abundantly with gear oil Apply some grease on the crankcase edge in the coupling area with the gasket and rest a new gas ket Positioning of the secondary unit forks 6 In the external guides of desmodromic device 8 View inside the right crankcase with crankshaft gearbox shafts complete with wheels internal gearshi...

Page 57: ...ssible to move it close to the right crankcase half by hand Put the clamping screws in place based on the length as illustrated in the figure The table below contains indications for applying these screws Tighten according to a cross sequence Positioning of screws to couple crankcase Screw number Screw dimensions Threadlocker application Tightening torque Nm Threading length Threading length 8 M6 ...

Page 58: ...hift drive shaft needs more in depth inspections 3 6 1 Check of complete drive shaft With the device complete make sure that the dis tance between the movable pawl and the drive shaft is between 0 35 0 80mm Should the distance be greater replace the mov able pawl Allowed distance between shaft and pawl 0 35 0 50 In order to replace the movable pawl 1 disassem ble the return spring of the gearshift...

Page 59: ...ft note the gearshift return spring position For reassembly couple the movable pawl 9 to the drive shaft 10 and while compressing it in sert the spring 8 between the movable pawl and the drive shaft The apply the spring guide 7 the gearshift return spring 6 and finally the 14x30x1 thrust washer 5 The gearshift return spring must be positioned as in the figure to be able to carry out its function ...

Page 60: ... of the en tire unit you just need to temporarily couple the external gearshift lever and to simulate the op eration of changing gears by lifting and lower ing the gearshift lever and having the main shaft of the gear unit rotate The whole device works properly if abnormal jamming does not occur If the unit runs without oil the device makes more noise than usual 3 7 KICK STARTER DEVICE Before coup...

Page 61: ...front teeth sleeve 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 this can to pull the wheel 2 Also check to make sure that the washers have no abnormal or excessive wear If so have them re placed Make sure that the s...

Page 62: ...ping the thin striped facing outwards and mak ing sure that the ramp A on the kickstart sleeve is positioned below the ramp B bolted onto the right crankcase half external side Turn the spring clockwise until it fits into the spe cific hole C B A Positioning of sleeve A below ramp B Insertion of kickstart return spring C ...

Page 63: ...Y 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 shown in the figure Kickstart device unit coupled to the crankcase ...

Page 64: ...f main gear Apply the O ring 18 the spacer 12 and gear 14 on the right half shaft so the appropriate groove inserts inside the Woodruff key 17 Apply lock nut 15 prior depositing of medium strength thread locker Fastening torque must be at 160Nm This is possible once the clutch case is inserted using primary special tool A code 026140010 000 See Par 3 8 3 to apply the clutch case Attention The nut ...

Page 65: ...ckstart idler gear and oil pumps have no superficial nicks or abnormal wear Also closely check that the teeth C upon which the driving discs engage are not chipped or deeply cut Check the external surface D does not show trac es of meshing or abnormal wear If any damage is found have the piece replaced CLUTCH CASE A Teeth meshing with main gear B Teeth meshing with kickstart idler gear C Teeth mes...

Page 66: ...is the thickness of the teeth of each driving disc They must not be less than the minimum value fixed at minimum driving disc tooth thickness 13 3mm Check the state of use of the silent blocks as fol lows Clamp gear B using protective elements and impose a rotation to the clutch case If there is play between the case and the gear unit replace the silent block Check the state of use of the internal...

Page 67: ...een the clutch discs the state of the springs must be checked The minimum acceptable length must be 42mm Clutch spring length measurement Check of clutch drum teeth 3 8 6 Check of clutch drum The clutch drum meshes with the driven clutch discs by means of the teeth a Make sure these teeth are not meshed or shaped by abnormal wear If so replace the drum Make sure that the seat B where the support w...

Page 68: ...4 to which the roller bearing must be coupled 5 Insert the clutch case 1 followed by the 21 7x38x3 washer 6 upon which the clutch drum will rest 2 Put on the safety washer 7 and after having ap plied medium strength threadlocker couple the lock nut 8 Slightly rotate the kickstart idler gear and the clutch case to facilitate inserting the clutch case A B EXPLODED VIEW OF CLUTCH UNIT 1 Complete case...

Page 69: ...e disc spring 35 so that the concave part faces the washer 19 the washer 19 the special disc 18 a driven disc and then the other discs alternating a driving disc and a driven disc Notice that the driven discs must be inserted so that the radius on the teeth faces inwards to wards the engine Insert the overall thrust bearing 9 after having lubricated it with transmission oil in the hole on the main...

Page 70: ...and centrifugal unit The water pump must guarantee depending on the set rotation speed the correct flow rate of the coolant in order to extract the needed amount of heat from the thermal unit The centrifugal unit activates the whole exhaust valve control lever age based on the engine rotation speed while springs 6 and 7 give the correct contrast to the centrifugal action caused by 20 in order to g...

Page 71: ...l Check the device s axial stroke A is between 6 4 6 6mm On the contrary replace the unit View in centrifugal unit section stroke A Exploded view of centrifugal unit Exploded view of bearings and centrifugal control lever Check of centrifugal control lever A area Remove circlip 19 and check use status of the roller axial cage 16 Replace it in case of anoma lies Check the roller bushes 9 do not jam...

Page 72: ...LY 3 9 2 Assembly of centrifugal unit Insert the centrifugal unit 20 in inner clutch cover Insert the centrifugal control lever 10 together with the washers 8 Insertion of centrifugal Insertion of centrifugal control lever 20 8 10 ...

Page 73: ...the valve control rod gasket and the rocker arm unit 1 valve control rod 4 Apply blocking screws 3 prior depositing of me dium strength threadlocker Fasten at 6Nm Application of valve control and rocker arm unit Centrifugal unit 4 1 3 6Nm ...

Page 74: ...nner clutch cover Apply the blocking screw prior ap plication of medium strength threadlocker and fasten at 6Nm 3 4 5 Spring guide and springs unit Fastening of adjusting cover Displacement cm3 Adjusting spring Auxiliary spring Colour Colour 250 White White 300 Green White The vehicles equip the following auxiliary and ad justing springs 6 Nm ...

Page 75: ...al edge must be at the same quota of the pump body outer side 3 9 4 Assembly of complete clutch cover and pump unit Apply a new gasket 1 placed between the right crankcase half and the inner clutch cover using the two reference pins 2 to keep it in place Couple the inner clutch cover to the right crank case half and rotate the centrifugal shaft until the shaft meshes in the main gear 2 1 Thicker e...

Page 76: ... screws as shown in figure fas tening them at 10Nm with a criss cross pattern Screws positioning Screw number Screw dimensions Threadlocker application Tightening torque Nm Threading length Threading length 6 M6 20 NO 10 7 M6 25 NO 10 8 M6 50 NO 10 ...

Page 77: ...the body to the clutch cover Apply washer 6 and water pump impeller 7 Apply screw 8 prior application of the medium strength threadlocker and fasten at 6Nm Couple the water pump cover to the pump body by applying the two M6x60 screws 9 and the two M6x30 screws 10 Fasten all screws at a torque of 10Nm following a criss cross pattern Insertion of water hose Application of water pump impeller Complet...

Page 78: ...xed and rotate the mobile cou pling 2 anti clockwise this must slide without jams By releasing the mobile coupling this must go back to rest position without jams Replace the whole unit if anomalies are detected during these two checks 3 10 2 Ignition unit coupling to motor Apply a thin layer of grease on the O ring present on the start motor Insert the start motor in its seat and block it with th...

Page 79: ... left crankcase half 3 11 Ignition system Before reassembling the ignition system it is rec ommended to check its correct functioning The ignition system is made up of the magnet ic pick up the stator unit and the flywheel The system is completed by the ignition coil and the spark plug which are not dealt with in this text A Application of oil Insertion of Bendix coupling 2 3 ...

Page 80: ...cation of the isolating silicone paste Cover the two screws 1 with medium strength threadlocker and tighten them at a torque of 6Nm Thoroughly degrease the crankshaft conical sec tion apply the Woodruff key 8 in the appropri ate groove present on the crankshaft couple the flywheel 9 the elastic washer 5 and the nut 4 after having spread the threading with medium strength threadlocker Element Cable...

Page 81: ...adlocker and tighten them at a torque of 10Nm Insert the cable gland in its specific seat and check its perfect sealing Apply a few drops of silicone in the guides for housing the plate 1 Apply the plate 11 to be in serted in its guides and pressed When coupling it to the left crankcase half apply a drop of gasket paste code 3625000000 in area B Flywheel fastening Coupling of stator to flywheel co...

Page 82: ... 13 and the three M6x20 screws 14 Tighten in a criss cross pattern at a torque of 10Nm Note When doing a complete overhaul of the en gine or intervening on the thermal unit do not apply the cover as it has to be removed to find the Top Dead Centre Application of flywheel cover centring pins Flywheel cover coupled to crankcase 12 14 13 14 13 10Nm ...

Page 83: ...nce X from the inner edge of the skirt perpendicularly to the axis of the pin bolt Refer to the following table for the piston s selec tion classes Quota at which to measure the outside diameter of the piston X Displace ment cm Quota X mm Bore mm A B C 250 24 66 335 66 345 66 345 66 355 66 355 66 365 300 18 71 935 71 945 71 945 71 955 71 955 71 965 In order to check the state of use of the elastic...

Page 84: ...he contrary replace it Measure the bore at a distance A from the top face of the cylinder surface between cylinder and head Take the correct measurement by fol lowing direction X Displacement cm Quota A mm 250 300 31 5 X A Bore measurement is required to know the cou pling play between cylinder and piston ...

Page 85: ... cylinder and piston In order to calcu late the coupling play between the cylinder and the piston a subtraction must be carried out be tween the diameter of the cylinder and that of the piston 3 12 4 Checks and exhaust valve unit disassembly Remove screw 1 fastening the valve control unit to the booster then remove screw 2 fixing the bearings Displace ment cm Maximum play of piston cylinder 250 30...

Page 86: ...e chamber side Note Should it be necessary to descale the valve unit remove the screws 2 and 3 and extract the booster without removing the valve control unit Tighten one M5 screw to the booster control unit side and pull externally Use a pair of pliers or similar tool if required Repeat the operation with the booster on reso nance chamber side using one M6 screw ...

Page 87: ...ms during functioning or excessive play once the unit has been cleaned and descaled On the contrary replace Check pins 5 6 and relative seats are not abnor mally worn On the contrary replace the worn parts Extraction of pin The exhaust valve unit Area A of the exhaust valve A 5 4 6 3 12 5 Exhaust valve unit assem bly Insert the right and left exhaust valve in the ex haust pipe so part A is facing ...

Page 88: ...he pin engages in the open slot in the valves the booster s area B is facing the front of the cylinder Apply the other booster Apply the four bearings two each side that sup port the boosters and fully press them in seat Apply the booster bearings fixing screws with washer Apply on the medium resistance sealant threading and fasten at 10Nm B 10Nm 10Nm ...

Page 89: ...nd seat in piston Insert the pin bolt in the piston from opposite side to where the circlip was inserted leaving enough space to allow connecting rod coupling to piston Place a piston so that the arrow stamped on the crown is facing the front of the engine outlet port Couple the piston to the connecting rod by fully pushing the pin bolt until flush with the previously inserted circlip It may be he...

Page 90: ...piston must be inserted in the cylinder fastening the elastic bands between the fingers The cylinder must be positioned so that the outlet port is fac ing the front of the engine Push the cylinder towards the base Apply the four collar nuts and fasten them at 30Nm following the criss cross pattern Coupling of cylinder to piston and crankcase Fastening of cylinder nuts 30Nm ...

Page 91: ...calibrated plates set out in the table The use of the plates is described below Rest the specific plate making sure it comes into contact with the cylinder s upper surface Bring the piston to top dead centre and us ing a thickness gauge check play between the piston and plate is between 0 0 10mm If play between piston and plate is higher by 0 10mm reduce the cylinder crankcase gasket thickness and...

Page 92: ...in four different thick nesses 0 3mm 0 4mm 0 5mm that can also be stacked thus obtaining the nec essary height for the right thickness Note the above described check must be carried out once all four crankcase cylinder coupling nuts have been fastened at the set torque 30Nm If the piston pushes the plate failing contact cylinder plate Measure play with thickness gauge and increase gasket thickness...

Page 93: ...ke end lever is flush with screw 2 fixing the booster bearings Check the ball head 3 and the seat 4 are perfectly aligned On the contrary loosen the lock nut adjust the seat and fasten the lock nut Positioning of valve control Incorrect positions of the control rod seat Correct position of the control rod seat 2 1 3 4 OK NO NO ...

Page 94: ...e control rod is able to rotate around its axis making equal angles respect to the ball head axis Apply gasket 5 and insert the control rod Apply the stop 6 Check of control rod rotation Insertion of control rod and application of stop 5 6 ...

Page 95: ...lows Bring the screw to all open position Tighten the number of turns indicated in the table The effects obtained from modifying the position of the adjustment screw respect to the positions in the above table are shown in the table Attention Do not tighten the adjustment screw for more than three and a half turns from the all open position Displacement cm Regulation of adjustment screw from all o...

Page 96: ... valve control unit cover and relative screws Fasten at 6Nm Apply the resonance chamber side gasket and cover Apply the screws and fasten at 6Nm Application and fastening of valve control unit cover screws Application of resonance chamber cover and relative screws 6Nm 6Nm ...

Page 97: ...ssembly Check the manifold 1 is intact and without cracks On the contrary replace it Check that the multiflap 2 of the reed valve 3 are intact and not deformed On the contrary replace them Remove the multiflap by pressing the central body as shown in figure and remove the outer multiflap 3 2 1 ...

Page 98: ...owing the just de scribed procedure in reverse order For assembly of the entire intake system apply the manifold to the reed valve the gasket 4 the spacer 5 and another gasket Tighten the screws 6 to 10Nm Disassembly of central wedges The extraction of only one is shown in figure Application of reed valve 10Nm 4 6 5 ...

Page 99: ...pinion spacer Apply the pinion spacer 5 to the secondary of the gearbox 1 so that the groove is facing inside the engine Note check the O ring 4 is present On the con trary apply it Insert the gearbox rod in seat from the lower di ameter side Insertion of clutch rod ...

Page 100: ...sertion from the frame s left side Insert the engine pins 1 Insert the upper shock absorber pin 2 and the swingarm pin 3 Fasten the shock absorber pin at 70Nm Apply the spark plug and fasten it at 28Nm Apply the carburetor to the manifold making the breather tubes pass in the appropriate metal cable gland 1 2 3 70Nm ...

Page 101: ...n bracket to frame Front fixing M8 x 20 35 Medium resistance Head connection bracket to frame Rear fixing M8 x 16 35 Medium resistance Head connection brackets to motor M8 x 65 35 Engine pins Speciale 45 Swingarm pin M16 x 245 125 35Nm 35Nm 5 4 Rotate the filter box in its normal position Ap ply the lower fixing screws 4 one each side prior application of medium strength thread locker and fasten a...

Page 102: ...connect the engine electric system to the central one By means of straps fasten the engine electric sys tem to the clutch pipe and to the frame Apply the coil by means of relative screws and fasten at 10Nm Note the two loop connectors on the electric sys tem must be secured to the coil using the lower fixing screw Connect the coil to the spark plug 10Nm 10Nm 8 10Nm 10Nm 6 7 Remove the cap applied ...

Page 103: ...entilation pipes to the engine Apply the left radiator to the frame Apply the screws and fasten at 10Nm Apply the protec tive grid Apply the right radiator relative screws to be fastened at 10Nm and the protective grid Connect the radiators to the engine Fasten the clamp straps and introduce the coolant liquid letting the air bleed through the screw cap A 10Nm A ...

Page 104: ...ply the Kickstart lever Apply the medium resistance sealant threading on the screw and fasten at 25Nm Apply the brake pedal return spring 9 Insert the pinion in the chain and fasten it onto the gearbox outlet shaft Assemble the relative circlip 10 checking its in its seat Apply the pinion guard 11 and the frame side guards 12 and 13 Fasten the screws at 10Nm and apply the fixing straps between the...

Page 105: ...r to get into the tube itself To avoid any lubrication problems with the thermal unit and crankshaft use fuel with a 1 blend for the first fill up Use the oil recommended on page 107 in the Recommended lubricants and liquids table Reconnect the tank to carburetor fastening the tube using the specific clamp straps Apply seat and filter box side Reapply the paramotor plate with the two fix ing screw...

Page 106: ...Sichel 100M 10 Clutch main transmission Main transmission pinion nut 1 Loctite 243 Sichel 100m 160 Drum nut and clutch case 1 Loctite 243 Sichel 100m 120 Do not use the pneumat ic device Clutch 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 20 2 10 Outer clutch cover M6 x 50 3 10 In common with inner clutch cover Inner clutch cover M6 x 20 2 10 I...

Page 107: ... M6 x 16 2 Loctite 243 Sichel 100m 10 Right cover M5 x 16 3 6 Left cover M5 x 16 4 6 Ignition system Spark plug M14 x 1 25 1 28 Pick up M5 x 12 2 Loctite 243 Sichel 100m 6 Stator M6 x 25 2 Loctite 243 Sichel 100m 10 Flywheel nut 1 Loctite 243 Sichel 100m 60 Cover M6 x 20 2 10 Cover M6 x 25 3 10 Cylinder Cylinder nuts 4 30 Head Head screws M8 x 35 6 27 Crankcase half Crankcase half screws M6 x 50 1...

Page 108: ...s to rear frame M8 x 16 2 Loctite 243 Sichel 100m 35 Head connection brack ets to motor M8 x 65 1 35 TABLE OF FRAME MOTOR FASTENING TORQUES TABLE OF SUPERSTRUCTURE FASTENING TO RQUE VALUES TABLE OF SUPERSTRUCTURE FASTENING TO RQUE VALUES Fixing Threading diameter x worm mm length mm Quantity Threadlocker Torque Nm Notes Tank on the frame fixing on the front M6 x 1 25 1 10 Tank on the frame fixing ...

Page 109: ...E IF REQUIRED S REPLACE P Cleaning RECOMMENDED MOTOR MAINTENANCE RECOMMENDED LUBRI CANTS AND LIQUIDS 30h 60h 90h Coated clutch discs I S Clutch springs length I S Gearbox bearings S Case clutch hub I Cylinder I Piston and segments S Connecting rod S Crankshaft bearings S Gearbox superficial look I Water hose oil seal S Exhaust valve I P Reed valve I S Spark plug S APPLICATION PRODUCT QUANTITY Gear...

Page 110: ......