Eton America Beamer R4 150CC Service Manual Download

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CONTENTS

1. INFORMATION .............................................................................................................. 4

1.1 SAFETY

........................................................................................................................ 4

1.2 NOTES

.......................................................................................................................... 4

1.3 SERIAL NUMBER

........................................................................................................ 5

1.4 TORQUE VALUES

....................................................................................................... 6

2. MAINTENANCE ............................................................................................................. 8

2.1 MAINTENANCE DATA SPECIFICATIONS

................................................................. 8

2.2 MAINTENANCE SCHEDULE

....................................................................................... 8

2.3 FUEL TUBE

.................................................................................................................. 9

2.4 THROTTLE OPERATION

............................................................................................ 9

2.5 THROTTLE CABLE ADJUSTMENT

............................................................................ 9

2.6 AIR CLEANER

............................................................................................................ 10

2.7 SPARK PLUG

............................................................................................................. 10

2.8 IDLE SPEED

............................................................................................................... 10

2.9 BRAKE SYSTEM

........................................................................................................ 10

2.10 WHEELS AND TIRES

.............................................................................................. 11

2.11 GEAR OIL

................................................................................................................. 11

2.12 ENGINE STOP SWITCH

.......................................................................................... 12

2.13 UPPER – LOWER BEAM CONTROLLER

............................................................... 12

3. ENGINE REMOVAL AND INSTALLATION ................................................................ 13

3.1 ENGINE REMOVAL

................................................................................................... 13

3.2 ENGINE INSTALLATION

........................................................................................... 16

4. CYLINDER HEAD AND VALVES ................................................................................ 17

4.1 SERVICE INFORMATION GENERAL

....................................................................... 17

4.2 TROUBLE SHOOTING

.............................................................................................. 18

4.3 CAMSHAFT COMPOSITION REMOVAL

.................................................................. 18

4.4 CYLINDER HEAD REMOVAL

.................................................................................... 21

5. LUBRICATION ............................................................................................................. 27

5.1 SERVICE INFORMATION GENERAL

....................................................................... 27

5.2 TROUBLESHOOTING

............................................................................................... 28

5.3 ENGINE OIL LEVEL

................................................................................................... 28

5.4 ENGINE OIL & FILTER CHANGE

.............................................................................. 28

5.5 OIL PUMP REMOVAL

................................................................................................ 29

6. CYLINDER / PISTON ................................................................................................ 35

6.1 SERVICE INFORMATION GENERAL

....................................................................... 35

6.2 TROUBLESHOOTING

............................................................................................... 35

6.3 CYLINDER REMOVAL

............................................................................................... 36

6.4 PISTON REMOVAL

.................................................................................................... 37

6.5 PISTON INSTALLTION PISTON RING INSTALLATION

.......................................... 40

6.6 CYLINDER INSTALLATION

....................................................................................... 41

7. TRANSMISSION / KICK STARTER ...................................................................... 43

7.1 SERVICE INFORMATION

.......................................................................................... 43

7.2 TROUBLE SHOOTING

.............................................................................................. 43

7.3 CVT DISASSEMBLY L

............................................................................................... 43

7.4 KICK STARTER DISASSEMBLY

............................................................................... 48

7.5 KICK STARTER ASSEMBLY

..................................................................................... 50

7.6 C.V.T ASSEMBLY

...................................................................................................... 50

7.7 ELECTRIC SELF-STARTER MECHANISM

.............................................................. 53

7.8 KICK STARTER

.......................................................................................................... 53

7.9 REMOVAL OF CVT SYSTEM

.................................................................................... 54

7.10 DISASSEMBLY AND INSPECTION OF THE CVT SYSTEM

................................. 54

8. FRONT WHEEL, BRAKES, AND STEERING SYSTEM .................................. 55

8.1 TROUBLESHOOTING

........................................................................................... 55

8.2 MAINTENANCE DATA

.......................................................................................... 55

8.3 REPLACE SPEEDOMETER CABLE

......................................................................... 56

9. REAR WHEEL AND BRAKE SYSTEM ................................................................ 60

9.1 TROUBLESHOOTING

............................................................................................... 60

9.2 MAINTENANCE DATA

............................................................................................... 60

9.3 REAR WHEEL REMOVAL

......................................................................................... 61

9.4 INSPECTING THE REAR WHEEL

............................................................................ 62

9.5 REAR BRAKE

............................................................................................................. 62

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Summary of Contents for Beamer R4 150CC

Page 1: ...ETON America Beamer R4 150cc Service Manual Covers Beamer R4 PN2F w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

Page 2: ...ENGINE OIL FILTER CHANGE 28 5 5 OIL PUMP REMOVAL 29 6 CYLINDER PISTON 35 6 1 SERVICE INFORMATION GENERAL 35 6 2 TROUBLESHOOTING 35 6 3 CYLINDER REMOVAL 36 6 4 PISTON REMOVAL 37 6 5 PISTON INSTALLTION...

Page 3: ...3 CANISTER COMP REMOVAL AND INSTALLATION 69 11 ELECTRICAL SYSTEM 70 11 1 TROUBLESHOOTING 70 11 2 IGNITION COIL 71 11 3 BATTERY INSPECTION 71 11 4 CHARGING 72 11 5 STARTER MOTOR 72 11 6 WIRING DIAGRAM...

Page 4: ...act is made with skin flush thoroughly with water and call a doctor if electrolyte gets in your eyes 1 2 NOTES All information illustrations directions and specifications included in this publication...

Page 5: ...ust at the front of footrest plate The engine serial number is stamped on the left side of the engine crankcase Frame serial number Engine serial number 2007 Engine serial number 2008 w w G e t 2 i t...

Page 6: ...5 9 Engine hanger bolt Frame M10 50 60 5 0 6 0 36 9 44 3 Engine 30 40 3 0 4 0 22 1 29 5 Front brake calliper bolt M8 24 30 2 4 3 0 17 7 22 1 Loctite 271 Brake oil tube bolt M8 24 30 2 4 3 0 17 7 22 1...

Page 7: ...ut M12 55 5 5 40 6 Loctite 638 Catalyst 7649 Camshaft holder nuts M8 19 22 1 9 2 2 14 0 1 6 2 Hole cap tap adjusting M30 7 9 0 7 0 9 5 2 6 6 Stud bolt M7 8 12 0 8 1 2 5 9 8 9 Starting clutch outer M22...

Page 8: ...pm BRAKE LEVER FREE PLAY 15 25 mm ENGINE OIL SAE 15W 40 GEAR LUBRICATION OIL SAE 80W 90 gear Oil 2 2 MAINTENANCE SCHEDULE The maintenance internals in the follow table is based upon average riding con...

Page 9: ...nd cable I I 16 Engine bolts and nuts I I 17 Cylinder head cylinder and piston I 18 Exhaust system cleaning carbon I 19 Cam Chain ignition time I I 20 Valve clearance I I I I I 21 Shock absorbers I I...

Page 10: ...with commercially available lubricant to prevent premature wear The BEAMER R2 50 uses a manual choke Check that the choke opens and closes smoothly If it does not check the wire connecting to the swit...

Page 11: ...the insulator is cracked or chipped The spark plug gap should be set to 0 6 0 7mm With the sealing washer attached thread the spark plug in by hand to prevent cross threading Tighten the spark plug to...

Page 12: ...ront wheel is 18 psi The standard tire pressure of rear wheel is 25 psi 2 11 GEAR OIL Gear oil needs to be changed every year There is a gear oil release bolt at the rear of engine Unscrew this releas...

Page 13: ...ontrols the headlight The engine stop switch is located on left handle bar When the engine must be stopped quickly push the switch with your left hand thumb and the engine will stop running immediatel...

Page 14: ...E REMOVAL Remove the seat helmet box and body cover Disconnect the oil tube fuel tube and vacuum tube Disconnect the AC generator and starter motor 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...

Page 15: ...he carburetor and throttle cable wires Remove the spark plug cap Remove the muffler by removing the retaining bolts 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...

Page 16: ...ing bolts as shown Remove the bolt at the bottom of the rear shock absorber Remove the rear disc brake caliper bolts Remove the rear brake tube bolt 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...

Page 17: ...disassembly Torque value M8 nut 20 30 N m M10 nut 30 40 N m M12 nut 50 60 N m After the engine is installed check these parts Wires and connections Carburetor and throttle cable Rear brake cable Oil...

Page 18: ...FICATIONS ITEM STANDARD SERVICE LIMIT CAM LOBE HEIGHT IN 29 795 29 395 EX 29 560 29 160 ROCKER ARM I D 10 000 10 018 10 10 ROCKER ARM SHAFT O D 9 972 9 987 9 91 CYLINDER HEAD WARPAGE 0 05 VALVE SPRING...

Page 19: ...amaged head gasket Warped or cracked cylinder head Faulty cylinder or piston Excessive noise Incorrect valve adjustment Sticking valve or broken valve spring Worn or damaged rocker arm or camshaft Wor...

Page 20: ...crew Remove the screw and O ring and tighten the cam chain adjusting bolt in the clockwise direction Remove the nuts and washers Remove the camshaft holder and dowel pins Loosen the camshaft gear from...

Page 21: ...d replace them if necessary Screw a 5mm bolt into the rocker arm shaft threaded end Pull on the bolt to remove the shafts and rocker arms Inspect the camshaft holder rocker arms and rocker arm shafts...

Page 22: ...cylinder head gasket and dowel pins Remove the cam chain guide Measure the I D of each rocker arm SERVICE LIMIT 10 10 mm Measure the O D of each rocker arm shaft SERVICE LIMIT 9 91 mm w w G e t 2 i t...

Page 23: ...he spark plug hole and valve area for cracks Measure the cylinder head diagonally for waring with a straight edge and feeler gauge SERVICE LIMIT 0 05 mm Measure the free length of the inner and outer...

Page 24: ...ceeds the service limits determine if a new guide with standard dimensions would bring the clearance within tolerance If so replace guides as necessary and ream to fit If the valve guide is replaced t...

Page 25: ...stall the cam chain guide Install the cylinder head CAMSHAFT COMPOSITION INSTALLATION Install the rocker arms and rocker arm shafts into the camshaft holder w w G e t 2 i t P a r t s c o m w w w G e t...

Page 26: ...I mark aligns with the cylinder head surface and the circle hole forwards front Install the dowel pins and camshaft holder Tighten the washers and nuts TORQUE 20 N m Adjust the clearance between the...

Page 27: ...chain adjusting bolt with counter clockwise direction and install the o ring and screw Install the cylinder head cover 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...

Page 28: ...ication SE or SF ENGINE OIL RECOMMENDATION VISCOSITY SAE 20W 40 When the average temperature in your riding area is within the indicated range you should use the other engine oil viscosities that are...

Page 29: ...level plane Check the oil level with the oil level gauge but do not screw it in when making this check Add the recommended oil up to the upper level if the oil level is below or near lower level line...

Page 30: ...PACITY 0 9 liter at draining Install the oil filter cap Install the oil level gauge Start the engine and let it idle speed for 2 or 3 minutes Stop the engine and check that the oil level at the upper...

Page 31: ...an assembly Remove the AC generator assembly Remove the right crankcase cover Remove the starting clutch outer and gear assy 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...

Page 32: ...ts and oil separator Remove the oil pump chain and oil pump driven sprocket Remove the oil pump assy Disassemble the oil pump 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...

Page 33: ...CE LIMIT 0 12 mm Remove the oil pump shaft and measure the pump end clearance SERVICE LIMIT 0 2 mm OIL PUMP ASSEMBLY INSTALLATION Install the outer rotor inner rotor and oil pump shaft onto the body N...

Page 34: ...lutch outer and gear assembly OIL SEPARATOR Install the oil pump driven sprocket and oil pump chain PS The tighten torque of driven sprocket nut is 8 12 N m OIL PUMP DRIVEN SPROCKET w w G e t 2 i t P...

Page 35: ...he new gasket dowel pins and right crankcase cover Install the AC generator assembly and cooling fan composition 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...

Page 36: ...0 002 0 014 0 02 PISTON TO PIN CLEARANCE TOP 0 015 0 050 0 12 PISTON RING TO RING GROOVE CLEARANCE SECOND 0 015 0 050 0 12 TOP SEC 0 10 0 25 0 5 PISTON RING END GAP OIL 0 2 0 7 CYLINDER TO PISTON CLE...

Page 37: ...nder gasket and dowel pins Clean off any gasket materials from the cylinder surface NOTE Be careful not to damage the gasket surface CYLINDER CYLINDER HEA CYLINDER SURFACE GASKET DOWEL w w G e t 2 i t...

Page 38: ...he crankcase Remove the piston pin from the piston Remove the piston Spread each piston ring and remove it by lifting up at a point opposite the gap INSPECTION Inspect the cylinder walls for scratches...

Page 39: ...in an X and Y axis Take the maximum reading to determine the taper SERVICE LIMIT 0 10 mm Calculate the cylinder out of round at three levels in an X and Y axis Take the maximum reading to determine th...

Page 40: ...nto the cylinder with the top of the piston to be sure they are squarely set in the cylinder SERVICE LIMITS TOP 0 5 mm SECOND 0 5 mm Measure the piston pin O D SERVICE LIMIT 14 960 mm Measure the pist...

Page 41: ...TALLATION Clean the piston ring grooves thoroughly and install the piston rings with the marks facing up NOTE Don t interchange the top and second rings Avoid piston and piston ring damage during inst...

Page 42: ...ith the piston cutout NOTE Do not allow the clip to fall into the crankcase 6 6 CYLINDER INSTALLATION Clean any gasket material from the crankcase surface NOTE Be careful not to damage the gasket surf...

Page 43: ...install the cylinder NOTE Avoid piston rings damage cylinder bore during installation Do not allow the cam chain fall into the crankcase Install the cylinder head w w G e t 2 i t P a r t s c o m w w...

Page 44: ...4 098 Drive face boss O D 23 96 23 98 23 92 Clutch outer I D 124 8 125 2 125 5 Clutch weight lining thickness 1 5 Driven face spring length 168 4 169 4 164 0 TORQUE VALUES Clutch outer nut 55 N m Driv...

Page 45: ...ER REMOVAL Loosen the band screw and remove the C V T inlet duct Disassemble the ground wire as shown Remove the bolts and L cranks case cover 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...

Page 46: ...Loosen the flange nut and remove kick starter ratchet Remove the drive face Loosen the flange nut Remove the drive pulley assy and driven belt Remove the drive face boss and movable driven face assem...

Page 47: ...the driven belt for wear tears or damage Measure the width of driven belt SERVICE LIMIT 19 0 mm Inspect the weight roller for wear or damage and replace them if necessary Measure the O D of weight rol...

Page 48: ...boss for wear or damage Measure the O D of drive face boss SERVICE LIMIT 23 92 mm Inspect the clutch outer for wear or damage Measure the I D of clutch outer SERVICE LIMIT 125 5 mm Inspect the clutch...

Page 49: ...ssary 7 4 KICK STARTER DISASSEMBLY RemovetheLcrankcasecover Remove the kick starter Remove the ex circle clip and washer from kick starter spindle composition DRIVEN FACE SPRING KICK STARTER L CRANK C...

Page 50: ...the kick spindle bush INSPECTION Inspect the kick starter spindle composition for wear or damage Inspect the kick return spring for fatigue or damage Inspect the kick spindle bush for wear or damage...

Page 51: ...return spring and spindle assembly Install the kick driven gear and spring Install the kick starter 7 6 C V T ASSEMBLY Assemble the driven face assembly spring and driven plate composition MACHINING...

Page 52: ...e face assembly and boss Install the drive face and kick starter ratchet Install the driven belt and driven pulley assembly DRIVEN BELT DRIVEN PULLEY ASSY KICK STARTER RATCHET MOVABLE DRIVE FACE DRIVE...

Page 53: ...all the dowel pins and gasket Install the L crank case cover Install the gas waste recovery and C V T ducts 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...

Page 54: ...engine is started the kick started will stop transferring power to the kick starter driven gear When the kick starter lever is released the kick starter gear will go back to its original position Sta...

Page 55: ...ove the screws on the clutch cover at the left side of engine Take off the clutch cover and gasket to uncover the belt front pulley and rear pulley Remove the front pulley fixing nut Remove the front...

Page 56: ...CED 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 WORN BRAKE DISK BRAKE DIS...

Page 57: ...grease to the inner line of this cable 8 4 REPLACE HANDLEBAR Remove the left and right mirrors Remove the handlebar cover Disconnect the speedometer cable and switch connections Disassemble the rear b...

Page 58: ...ECTING THE FRONT WHEEL AXLE Check the axle for warping Maximum Limit 0 2 mm Remove the front wheel axle Remove the collar Remove the speedometer gear unit Take out the front wheel assembly Reinstall t...

Page 59: ...crew and lock the release valve on the disk brake caliper Squeeze the front brake lever to force air out of the caliper Close the valve and release the brake lever Repeat the process of opening the va...

Page 60: ...um limit 3 1 mm INSPECT BRAKE SHOES LINING Measure the thickness of the brake shoe lining Standard thickness 4 0 mm Using limit 3 0 mm NOTE Do not allow grease to contact the lining surfaces of the br...

Page 61: ...N BRAKE DRUM BRAKE ARM SETTING IMPROPERLY ENGAGED VIBRATION OR WOBBLE BENT RIM DAMAGED TIRED WHEEL AXLE IMPROPERLY TIGHTENED 9 2 MAINTENANCE DATA Brake drum inner diameter Standard 110 mm Limit 110 5...

Page 62: ...ttom of the rear shock absorber Unscrew the rear bracket bolt Unscrew the rear wheel axle nut Disassemble the rear wheel Torque value M16 nut 60 80 N m w w G e t 2 i t P a r t s c o m w w w G e t 2 i...

Page 63: ...bracket with brake oil Do not spill any brake oil Unscrew and lock the valve bolt on the disc brake caliper Press the brake lever to force air out of the brake system from the caliper valve With the...

Page 64: ...he brake disc Standard thickness 3 5 mm Using limit 3 1 mm BRAKE SHOES LINING INSPECTION Measure the thickness of brake lining Standard thickness 4 0 mm Using limit 3 0 mm NOTE Do not allow any grease...

Page 65: ...9 6 REAR SHOCK ABSORBER DRAWING w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

Page 66: ...screws between the front fender and leg shield Remove the front fender 10 2 BODY COVER Unscrew the 4 fixing bolts on the rear carrier Remove the rear carrier w w G e t 2 i t P a r t s c o m w w w G e...

Page 67: ...screw the upper body cover fixing bolts Unscrew the fixing bolts between the body cover and middle cover Remove the middle cover Unscrew the body cover fixing bolts under the middle cover w w G e t 2...

Page 68: ...crew the 2 tail light fixing bolts near the fuel tank Disconnect the negative pole of battery then disconnect the positive pole Remove the battery Unscrew the two side protection cover fixing bolts w...

Page 69: ...leg shield fixing bolts Unscrew the 6 fixing bolts on the footrest board Remove the leg shield and footrest board Reinstalling torque values M6 7 11 N m M5 3 5 5 N m w w G e t 2 i t P a r t s c o m w...

Page 70: ...e the canister composition every 2 years or 9000 miles 15000km 3 CARBURETOR ASSY 5 FUEL TANK ASSY 6 VAPOR CONTROL 2 CANISTER COMP 4 FUEL PETCOCK 1 AIR CLEANER ASSY w w G e t 2 i t P a r t s c o m w w...

Page 71: ...lternator exciter coil o Loosen contacted terminals o Faulty ignition coil IGNITION SECONDARY CIRCUIT o Faulty plug o Loosen contacted spark plug wire IMPROPER IGNITION TIMING o Faulty generator or CD...

Page 72: ...ure the primary coil resistance STANDARD 0 1 0 30 20 11 3 BATTERY INSPECTION The battery is located under the seat Measure the battery voltage using a voltmeter VOLTAGE Fully charged 13 1 V Undercharg...

Page 73: ...hour Quick charging Keep flames and sparks away from a battery being charged Quick charging should be limited to an emergency Normal charging is preferred 11 5 STARTER MOTOR The starter motor is loca...

Page 74: ...11 6 WIRING DIAGRAM FOR BEAMER R4 150 w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c o m w w w G e t 2 i t P a r t s c...

Page 75: ...VEHICLES ARE MAINTANCE FREE PROPER SERVICE PROCEDURES ARE AS FOLLOWS 1 FILL BATTERY WITH BATTERY PACK SUPPLIED 2 REMOVE FUNNEL AND LET BATTERY STAND WITH CAP OFF FOR AT LEAST 1 HR 3 ALL FLUID IN BATTE...

Page 76: ...mounting plate is positioned on the bottom of the luggage box with the smooth side toward the box The 4 bolts and washers are pushed through the box and plate from inside the box using the holes indi...

Page 77: ...ht They may be tucked in under the harness on the left hand side of the unit Note ONLY the Beamer II III and the Matrix Matrix II have been pre wired for the luggage box brake light If you have the ol...

Page 78: ...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...

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Eton America Beamer R4 150CC, Service Manual

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