Beta EVO 4T 2012 Manuel d'utilisateur

WORKSHOP MANUAL

4INTRODUCTIONbetamotor.comFIXING PART PCS THREAD LOCK TORQUE [NM]ENGINE FIXING Engine front fixing 10x1,5L127 [5.8] 1 25Engine back fixing 10x1.25L100 [

5INTRODUCTIONbetamotor.comFIXING PART PCS THREAD LOCK TORQUE [NM]AIR FILTER BOX Air filter box to frame 5x0,8L12 4 5Filter case cover 5x0,8L12

6INTRODUCTIONbetamotor.comASSEMBLY COMPONENT QTY THREAD LOCK TORQUE (NM)VALVEGEAR GROUPValve adjuster covers Bolt M6x16 4 10Camshaft sprocket Screw

7INTRODUCTIONbetamotor.com01.00040.000 Flywheel extractor01.00041.000 Key for water pump shaft01.00042.000 Crankcase splitter01.00043.000 Valve spring

8LUBRICATION CIRCUITbetamotor.com1 LUBRICATION CIRCUITThe output oil pump (1) draws in oil from the area at the base of the gearbox through its own me

9LUBRICATION CIRCUITbetamotor.com1.2 CHECKING THE ENGINE OIL LEVELThe engine oil level must be checked when the en-gine is warm. Run the engine for

10LUBRICATION CIRCUITbetamotor.comUnscrew the plug in the left-hand casing and use pliers to extract the filter. Clean it carefully and blow it th

11LUBRICATION CIRCUITbetamotor.comPosition a container under the bike, near the cover for the paper filter, and unscrew the bolts on the filter cove

12ENGINE REMOVAL AND REFITTINGbetamotor.com2 ENGINE REMOVAL AND REFITTING2.1 ENGINE DISASSEMBLINGDeeply clean the whole bike and position it on

13ENGINE REMOVAL AND REFITTINGbetamotor.comDisconnect the electrical connectors A and B loca-ted over the carburettor.Disassemble left panel and disco

14ENGINE REMOVAL AND REFITTINGbetamotor.comMake sure that the fuel petcock is closed (lever in position “C”).Disassemble the rear brake oil tank

15ENGINE REMOVAL AND REFITTINGbetamotor.comDisassemble the sprocket cover unscrewing the two blocking screws (A).Loosen the rear wheel axle and take o

16ENGINE REMOVAL AND REFITTINGbetamotor.comPosition a cup under the engine and unscrew the bleeding screw of the cooling system (A).Open the radiator

17ENGINE REMOVAL AND REFITTINGbetamotor.comUnscrew the screws which block connecting rods to frame (A), loosen and take off the engine front fixi

18ENGINE REMOVAL AND REFITTINGbetamotor.comDisassemble the whole block connecting rods-ra-diator-electric fan.Loosen the three head screws. Loose

19ENGINE REMOVAL AND REFITTINGbetamotor.comDisassemble swing arm spindle (A) and pull back the swing arm.Hold up the engine and take off the f

20DISMANTLINGbetamotor.comBefore you start to dismantle the engine it is essen-tial that you also read the next chapter, which deals with assembly, be

21DISMANTLINGbetamotor.com3.2 IGNITIONUndo the 7 bolts retaining the flywheel cover and remove it, together with the stator and pickup that are mounte

22DISMANTLINGbetamotor.comRemove the valve covers and then take out all the bolts securing the cylinder head cover: 2 M6x25 bolts (A), 4 M6x55

23DISMANTLINGbetamotor.comRemove the camchain tensioner by unscrewing the two retaining bolts.Remove the camshaft and its bearings from the hea

WORKSHOP MANUAL 2009

24DISMANTLINGbetamotor.com3.4 CYLINDERSlide the cylinder up until the piston pin is visible. Then remove the retaining circlip and extract the

25DISMANTLINGbetamotor.com3.6 OIL PUMP (LEFT-HAND CRANKCASE)Remove the left-hand oil pump cover (2) after first _unscrewing the retaining screws (1).

26DISMANTLINGbetamotor.com3.7 CLUTCHUnscrew the bolts retaining the clutch cover (1) and the oil filter cover (2) and remove the two covers and their

27DISMANTLINGbetamotor.comThen extract, in sequence, the special washers (2), the springs (3) and the clutch pressure plate (4). Next, remove the

28DISMANTLINGbetamotor.comWhich locks the retaining nut (9) for the clutch hub (11) and unscrew the nut, using the special tool for locking the clutch

29DISMANTLINGbetamotor.com3.9 KICKSTARTExtract the kickstart shaft complete (1) together with the thrust washer (2), ensuring that the assem-bly

30DISMANTLINGbetamotor.comTake out the gearchange shaft (1), pushing back the movable pawl with a screwdriver to prevent it from interfering with the

31DISMANTLINGbetamotor.com23.12 TIMING SPROCKETAfter removing the camchain, take out the movable guide (3) by unscrewing the retaining bolt (4).Use an

32DISMANTLINGbetamotor.comOnce you have removed the gasket from the cylinder base, use the special tool for splitting the crankcase, securing it to th

33DISMANTLINGbetamotor.comRemove the selector forks (3) and then extract the mainshaft and layshaft as a unit, complete with all the gears.3.15 CRANKS

34ASSEMBLYbetamotor.com994.1 RIGHT-HAND CRANKCASEHeat the crankcase in an oven to 150c°. Fit the ball bearings into their housings (main bearing 1, ma

35ASSEMBLYbetamotor.comFit the oil expansion plug (10), driving it home with a suitable pin punch, after having checked that the oilways are not block

36ASSEMBLYbetamotor.com12345674.2 LEFT-HAND CRANKCASEFit the bearings (main bearing 1, mainshaft bearing 2, layshaft bearing 3, gearchange shaft needl

37ASSEMBLYbetamotor.comMake sure that the oil pump housing is free from scoring and signs of seizure.Blow compressed air through all the oilways to cl

38ASSEMBLYbetamotor.com23Fit the crankshaft oilseal (2) in its housing, with the open side facing inwards. Remember to grease the outer surfac

39ASSEMBLYbetamotor.com4.4 GEARBOX AND SHIFTING MECHANISMBefore proceeding to the reassembly of the gear-box mainshaft and layshaft, carry out

40ASSEMBLYbetamotor.com4.4.2 layshaftPosition the shaft (1) with the splined end facing downwards after fitting the 20x27x1 washer (2) and the

41ASSEMBLYbetamotor.comFit the complete selector forks into the gearbox, po-sitioning them in their guides in the gears.Check the wear on the guides i

42ASSEMBLYbetamotor.com11224.5 CRANK ASSEMBLYIf the crankshaft has been dismantled for the pur-pose of replacing the connecting rod or inspecting the

43ASSEMBLYbetamotor.com4.6 CLOSING THE CRANKCASE Heat the main bearing in the right-hand crankcase half so as to facilitate insertion of the crankshaf

Vbetamotor.comINDEXINTRODUCTION ... 1CHAPTER 1 LUB

44ASSEMBLYbetamotor.comRotate the mainshaft and the layshaft by hand to verify that the gearbox moves correctly and that all the gearbox compo

45ASSEMBLYbetamotor.comAfter you have fitted the gearchange shaft, check the axial play between the two pawls, which must be between 0.50mm and

46ASSEMBLYbetamotor.comFit the shifting shaft into its roller bearings after oiling it well, and push back the movable pawl so that it can tak

47ASSEMBLYbetamotor.com4.9 OIL PUMPSN.B. The pumps have reference marks both on the outer rotor (A) and on the inner rotor (B). During as-sembly these

48ASSEMBLYbetamotor.com14Measure the clearance between the outer rotor and the pump housing, using a feeler gauge for this too.Standard cleara

49ASSEMBLYbetamotor.comInsert the two filters (17) into their holes, after first lubricating them with oil and fitting the O-rings (18).N.B. Th

50ASSEMBLYbetamotor.comA4.10 KICKSTART4.10.1 Preassembly of kickstart shaftClamp the kickstart shaft (2) with the serrated end facing downwards and

51ASSEMBLYbetamotor.com4.10.2 assembling the kickstartInsert the kickstart shaft (1) into its housing after first oiling it well and fitti

52ASSEMBLYbetamotor.comFit the idler gear (1) on its pivot pin with the con-cave side facing outwards, fit the special 11x17x0.5 washer (2), and secur

53ASSEMBLYbetamotor.comCheck the wear on the teeth (A) of the clutch centre which engage with the driven plates.Fit the clutch hub (5) and secure it w

54ASSEMBLYbetamotor.comAfter you have fitted all the friction plates, fit the pressure plate lifter (10) in the central hole in the clutch ba

55ASSEMBLYbetamotor.com4.13 FLYWHEELCarefully degrease the taper on the crankshaft befo-re proceeding to fit the flywheel.Insert the drive key (1) in

56ASSEMBLYbetamotor.com7mm4.14 PISTON AND CYLINDER4.14.1 measurements and checks4.14.1.1 CylinderCheck whether the lower and upper surfaces of the cyl

57ASSEMBLYbetamotor.comFit the piston ring into the cylinder and use a feeler gauge to measure the gap between the two ends of the ring. When insertin

58ASSEMBLYbetamotor.comMeasure the internal diameter of the conrod small end and then determine the play with the piston pin. If this value exceeds

59ASSEMBLYbetamotor.com4.14.2.3 CylinderFit the M6x12 bolt (1) for draining the cooling wa-ter, with the corresponding washer 6x12x1. Tighten the bolt

60ASSEMBLYbetamotor.com1231camchain passes freely through the timing case on the right-hand side of the engine.Insert the two dowels (1) and the

61ASSEMBLYbetamotor.comFit the inlet rocker (2) and the exhaust rocker (3) as indicated in the photo, inserting the 12x17x0.5 thrust washers (7) be

62ASSEMBLYbetamotor.comthe seat. Then insert the valve into the guide until it is pressing against the seat, and rotate it on its axis. When the valve

63ASSEMBLYbetamotor.com4.16.2 fittingInsert the oil plug (1) using a pin punch.Fit the lower spring caps (2) and then the valve gui-de oilseals (3). T

1INTRODUCTIONbetamotor.comFOREWORDThis publication is addressed to the user of the motorcycle and to technical assistance staff. It has been written w

64ASSEMBLYbetamotor.comABApply a few taps to the upper spring caps with a double rubber hammer to help the split collets to settle.Fit the t

65ASSEMBLYbetamotor.comFit the decompressor weight (4) and the relative spring (5). The spring must be preloaded by half a turn when fitted. Th

66ASSEMBLYbetamotor.comPass the camchain around the camshaft sprocket, and fit onto the camshaft first the sealed bearing (8) and then the bearing on

67ASSEMBLYbetamotor.comSeal the holes in the head cover for the rocker spin-dles with the appropriate gaskets (18) and plugs (19).Adjust the va

68ASSEMBLYbetamotor.comAAABCheck that the tensioner plunger (A) moves freely, and check the teeth (B) on the plunger for wear. Before fitting

69ASSEMBLYbetamotor.comGrease the areas adjacent to the threaded holes so as to help the clutch casing gasket (1) to adhere, and thus to prevent it f

70ASSEMBLYbetamotor.com4.19 IGNITIONInsert the two dowels (1) into the left-hand cran-kcase and apply some grease in the area of the thread

71ASSEMBLYbetamotor.comFit the flywheel cover to the left-hand crankcase half and retain it with the bolts indicated in the picture above. Tighten the

72ASSEMBLYbetamotor.comFit the exhaust flange (12) with four M6x15 screws (14) tightened to 10 Nm. Under the heads of the screws fit the two plate

2INTRODUCTIONbetamotor.comPetrol• Petrol is highly flammable and in certain conditions can cause explosions.• Keep heat sources, sparks and flames w

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3INTRODUCTIONbetamotor.com• Do not remove the radiator filler cap when the engine is still hot. The coolant, being under pressure, can spurt out viol