Beta RR250 - Page 54

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5Nm

ENGINE CHECKS AND ASSEMBLY

If replacing the inserts, apply the screws with

high-resistance threadlocker and tighten at the

specified torque.

Half-shoulder

The distance between the two shoulders must

be: 62±0.05

Main Page

Table of Contents2
Introduction4
Engine Technical Specifications6
Special Equipment7
Engine Removal from Vehicle8
Engine Disassembly19
Clutch/Gear Oil Drain19
Removal of Clutch Control Rod and19
Removal of Piston, Cylinder and Head20
Removal of Ignition Unit23
Removal of Flywheel Cover23
Stator Removal23
Removal of Flywheel24
Removal of Pick-Up Unit24
Removal of Electric Ignition25
Removal of Start Motor26
Removal of Bendix Coupling26
Unit, Main Gear, Centrifugal Unit27
Gearshift Organs, Kickstart27
Removal of Coolant Liquid Pump30
Removal of Centrifugal Unit and Leverage31
Disassembly of Clutch Unit and Countershaft Counterweight34
Pedal Kickstart - Optional38
External Gearshift Unit40
Intake System41
Crankshaft, Gearbox Unit and Internal Gearshift42
Opening the Crankcase42
Counterweight Support Shaft43
Crankshaft43
Internal Gearshift Unit and Complete Gearbox44
Disassembly of Parts from Crankcases46
Right Crankcase Half46
Left Crankcase Half48
Engine Checks and Assembly49
Crankcase Half49
Application of Right Crankcase Half Parts50
Application of Left Crankcase Half Parts52
Connecting Rod and Engine Shaft Check53
Slew Bearing Removal and Refitting53
Assembly of Complete Crankshaft55
Gear Unit: Checks and Reassembly56
Gearbox Unit Check56
Primary Unit Assembly57
Secondary Unit Assembly58
Checking the Forks, Fork Pins and Desmodromic Device59
Gearbox and Internal Gearshift Assembly61
Counterweight Support Shaft64
Closing the Engine Crankcase65
External Gearshift66
Checking the Complete Drive Shaft66
External Gearshift Assembly68
Kickstarter Device - Optional69
Checking the Kickstart Shaft Unit and Assembly69
Assembly of Kickstarter Device - Optional70
Counterweight, Primary Gear and Clutch Unit72
Inspection of Counterweight and Primary Gear72
Application of Primary Gear and Counterweight72
Checking the Clutch Case, Roller Bearing and Internal Centre Bearing74
Checking the Clutch Discs75
Checking the Clutch Drum and Cap76
Checking the Thrust Bearing Device76
Clutch Unit Assembly77
Coolant Liquid Pump and Centrifugal Unit81
Check of Pump Unit and Disassembly, Centrifugal Unit and Idler Unit82
Centrifugal Unit Assembly83
Pump Unit Assembly86
Assembly of Complete Clutch Cover and Pump Unit86
Electric Ignition Unit89
3.10.1 Bendix Coupling Checks89
Ignition Unit Coupling to Engine89
Ignition System90
3.11.1 Ignition System Check91
Coupling of Ignition System to Crankcase91
Thermal Unit94
Checking the Piston and Elastic Bands94
3.12.2 Cylinder Check95
Piston Cylinder Coupling Play96
Checks and Exhaust Valve Unit Disassembly96
3.12.5 Exhaust Valve98
Unit Assembly98
Piston, Pin Bolt, Elastic Bands and Cylinder Assembly100
Check of Crankcase/Cylinder Gasket Thickness102
3.12.8 Head Application103
3.12.9 Exhaust Valve104
Adjustment104
Check of Intake Unit and Assembly108
Insertion of Clutch Rod and Pinion Spacer110
Engine Reassembly in the Vehicle111
Table of Engine Components Tightening Torques121
Table of Frame/Engine Tightening Torques123
Table of Superstructure Tightening Torques123
Recommended Engine Maintenance124

Beta RR250 - Page 54

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