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Beta RR 4T 400 450 520 Shop Manual 2010-2011 – PDF Download


Beta RR 4T 400 450 520 Shop Manual 2010-2011

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Beta RR 4T 400 450 520 Shop Manual 2010-2011

FILE DETAILS:

Beta RR 4T 400 450 520 Shop Manual 2010-2011

FILE TYPE:PDF
MANUAL LANGUAGE:ENGLISH
PAGES:134
DOWNLOADABLE:YES

DESCRIPTION:

Beta RR 4T 400 450 520 Shop Manual 2010-2011

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 the engine. Sufficient knowledge of the components that make up the engine and of all the procedures to be followed for inspection and maintenance contribute to lengthen the life of the engine. The paragraphs have been enhanced with schematic illustrations highlighting each subject in order to make reading immediately understandable

TABLE OF CONTENTS:

Beta RR 4T 400 450 520 Shop Manual 2010-2011

PREAMBLE / WARNINGS 2
TECHNICAL FEATURES OF ENGINE TABLE 4
SPECIAL TOOLS 5
1 ENGINE DISASSEMBLY 6
1.1 THERMAL UNIT 8
1.1.1 Cylinder head: disassembling hydraulic tensioner 10
1.1.2 Cylinder head: disassembling camshaft support, chain guide and spark plug seat O-ring 10
1.1.3 Cylinder head: removing camshafts 12
1.1.4 Cylinder head: uncoupling from cylinder 13
1.1.5 Disassembling cylinder and piston 15
1.2 DISASSEMBLY OF IGNITION UNIT, TIMING CHAIN AND GUIDES 16
1.2.1 Stator and flywheel 16
1.2.2 Timing chain and guides 18
1.2.3 Pick-up 20
1.3 PINION AND SPACER 20
1.4 CLUTCH UNIT AND COOLANT PUMP COVER 21
1.5 ENGINE LUBRICATION CIRCUIT 25
1.5.1 Oil pumps control gears 26
1.5.2 High-pressure oil pump 26
1.5.3 Low-pressure oil pump and by-pass valve 27
1.5.4 Oil pressure control valve 28
1.5.5 Paper oil filter 28
1.6 COUNTERSHAFT 29
1.7 PRIMARY GEAR 30
1.8 ELECTRIC IGNITION 31
1.8.1 Start motor 31
1.9 KICKSTARTER 33
1.10 EXTERNAL GEARSHIFT UNIT 35
1.11 CRANKSHAFT, GEARBOX UNIT AND INTERNAL GEARSHIFT 36
1.11.1 Nut on left side of crankshaft 36
1.11.2 Opening crankcase 36
1.11.3 Crankshaft 38
1.11.4 Internal gearshift unit and complete gearbox 38
1.12 DISASSEMBLY OF PARTS FROM CRANKCASES 40
1.12.1.1 Right crankcase half 40
1.12.1.2 Piston oil jets 40
1.12.1.3 Extraction of countershaft support bearing 41
1.12.2 Left crankcase half 41
1.12.2.1 Inner oil filter 42
1.12.2.2 Extraction of desmodromic device bearing 42
2 ENGINE ASSEMBLY AND CONTROLS 43
2.1 CRANKCASE HALVES 44
2.1.1 External right side 45
2.1.1.1 Insertion of oil seal and countershaft support bearing 47
2.1.2 Internal right side 48
2.1.3 External left side 49
2.1.4 Internal left side 50
2.2 CHECKING CRANKSHAFT AND CONNECTING ROD 51
2.3 ASSEMBLING COMPLETE CRANKSHAFT 53
2.4 GEARBOX UNIT: CONTROLS AND REASSEMBLY 54
2.4.1 Checking gearbox unit 54
2.4.2 Primary unit assembly 55
2.4.3 Secondary unit assembly 56
2.4.4 Checking the forks, fork pins and desmodromic device 57
Table of tightening torques of engine components 127
Engine/frame table of tightening torques 129
Recommended engine maintenance 130
Recommended lubricants and liquids 130
2.5 ASSEMBLY OF INTERNAL GEARBOX AND GEARSHIFT 59
2.6 CLOSING ENGINE BLOCK 62
2.7 BLOCKING THE CRANKSHAFT AT THE TOP DEAD CENTRE AND TIGHTENING THE NUT ON THE LEFT SIDE OF THE CRANKSHAFT 63
2.8 EXTERNAL GEARSHIFT 64
2.8.1 Checking the complete drive shaft 64
2.8.2 Assembly of external gearshift 66
2.9 KICK STARTER 66
2.9.1 Checking kickstarter shaft unit and assembly 66
2.9.2 Assembly of kickstart device 68
2.10 ELECTRICAL STARTER UNIT AND MAIN GEAR 69
2.10.1 Checking electrical starter device elements 69
2.10.2 Coupling ignition and primary gears to the motor 70
2.11 OIL PUMPS: CONTROL AND REASSEMBLY 72
2.11.1 Assembly of low pressure pump 74
2.11.2 Assembly of high-pressure pump and control gear 75
2.11.3 Checking and assembly of pressure control valve 75
2.11.4 Checking and assembly of oil pumps control gears 76
2.11.5 Paper oil filter insertion 77
2.11.6 Checking and coupling countershaft 78
2.12 CLUTCH UNIT 80
2.12.1 Checking clutch basket, roller bearing and internal centre bearing 80
2.12.2 Checking clutch discs 81
2.12.3 Checking springs 82
2.12.4 Checking inner hub 82
2.12.5 Checking thrust bearing device 83
2.12.6 Assembly of clutch unit 83
2.13 COOLANT PUMP 86
2.13.1 Checking pump unit and disassembly 86
2.13.2 Assembly of pump unit 87
2.14 ASSEMBLY OF COMPLETE CLUTCH COVER 88
2.15 CHECKING AND COUPLING OF TIMING CHAIN, FIXED AND MOBILE GUIDES 90
2.16  IGNITION SYSTEM 90
2.16.1 Checking ignition system 91
2.16.2 Coupling ignition system to crankcase 91
2.17 THERMAL UNIT 94
2.17.1 Checking piston, pin bolt, and piston rings 94
2.17.2 Checking the cylinder 96
2.17.2.1 Assembly clearance 96
2.17.3 Cylinder head: disassembly and checking auxiliary devices 97
2.17.3.1 Lubrication jets and centring pins 97
2.17.3.2 Finger follower/shafts unit 98
2.17.3.3 Shims (calibrated discs) for valve play adjustment 99
2.17.4 Cylinder head: disassembling and checking valve units 100
2.17.4.1 Springs 101
2.17.4.2 Valve guides, valves and seats 101
2.17.4.3 Valve stem seal and lower stop washer 103
2.17.5 Cylinder head: checking cylinder head body 103
2.17.6 Checking camshafts 104
2.17.7 Checking camshafts support 105
2.17.8 Cylinder head: insertion of inner cup and valve stem seals 106
2.17.9 Cylinder head: assembly of valve unit 107
2.17.10 Cylinder head: repositioning calibrated discs, assembly of finger follower shafts and finger followers and coupling the spark plug 108
2.17.11 Cylinder head: Insertion of oil jets, centring pins and spark plug O-ring 109 2.17.12
Piston: application of compression and oil-scraper rings 110
2.17.13 Application of piston to cylinder 111
2.17.14 Application of piston-cylinder coupling to crankcase 113
2.17.15 Coupling head to cylinder 115
2.17.16 Coupling camshafts to cylinder head and phasing 116
2.17.17 Valve play 119
2.17.18 Checking and coupling of hydraulic tensioner to engine 121
2.17.19 Coupling cylinder head cover gaskets and cylinder head cover 123
2.18 COUPLING PINION AND BREATHER NOZZLE 124
2.19 RELEASING CRANKSHAFT 124
2.20 COUPLING OIL CAPS 125
2.21 COUPLING GEARSHIFT LEVER 126 PREAMBLE

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