Beta Motorcycles X Trainer 300 2T 2015 Instruction manual

CODE 036440030 000

TABLE OF CONTENTS
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TABLE OF CONTENTS
PREAMBLE ................................................................................................................................................................................................................... 2
ENGINE......................................................................................................................................................................................................................... 4
1 REMovAL of MotoR fRoM vEhIcLE........................................................................................................................................................ 6
2 MotoR dIsAssEMBLy.................................................................................................................................................................................14
2.1 cLutch/GEAR oIL dRAIN ..........................................................................................................................................................14
2.2 REMovAL of cLutch coNtRoL Rod ANd PINIoN sPAcER ...............................................................................................14
2.3 REMovAL of PIstoN, cyLINdER ANd hEAd..........................................................................................................................15
2.4 REMovAL of IGNItIoN uNIt ....................................................................................................................................................19
2.4.1 Flywheel cover plate removal ..................................................................................................................................................19
2.4.2 Stator removal .............................................................................................................................................................................20
2.4.3 Flywheel removal........................................................................................................................................................................20
2.4.4 Pick-up removal...........................................................................................................................................................................21
2.5 REMovAL of ELEctRIc IGNItIoN ........................................................................................................................................... 22
2.5.1 Start motor removal....................................................................................................................................................................23
2.5.2 Bendix clutch removal ................................................................................................................................................................23
2.6
REMovAL of cooLANt LIquId PuMP, cLutch uNIt, MAIN GEAR, cENtRIfuGAL uNIt, GEARshIft oRGANs, kIckstARt 24
2.6.1 Cooling liquid pump removal....................................................................................................................................................27
2.6.2 Removal of centrifugal unit and leverage................................................................................................................................28
2.6.3 Removal of main gear and clutch unit .....................................................................................................................................31
2.6.4 Kickstarter (OPTIONAL)..............................................................................................................................................................34
2.6.5 External gearshift unit.................................................................................................................................................................36
2.7 INtAkE systEM .......................................................................................................................................................................... 37
2.8 cRANkshAft, GEARBox uNIt ANd INtERNAL GEARshIft ................................................................................................ 38
2.8.1 Opening the crankcase...............................................................................................................................................................38
2.8.2 Crankshaft ....................................................................................................................................................................................39
2.8.3 Internal gearshift unit and complete gearbox.........................................................................................................................40
2.9 dIsAssEMBLy of PARts fRoM cRANkcAsEs ........................................................................................................................41
2.9.1 Right crankcase half....................................................................................................................................................................41
2.9.2 Left crankcase half ......................................................................................................................................................................44
3 MotoR chEcks ANd AssEMBLy.............................................................................................................................................................. 45
3.1 cRANkcAsE hALf....................................................................................................................................................................... 45
3.1.1 Special applications for right crankcase half...........................................................................................................................46
3.1.2 Special applications for left crankcase half..............................................................................................................................48

ENGLISH
TABLE OF CONTENTS
3.2 chEck of coNNEctING Rod ANd cRANkshAft ................................................................................................................ 49
3.3 AssEMBLING of coMPLEtE cRANkshAft............................................................................................................................ 50
3.4 GEARBox uNIt: coNtRoLs ANd REAssEMBLy......................................................................................................................51
3.4.1 Gearbox unit check ....................................................................................................................................................................51
3.4.2 Primary unit assembly................................................................................................................................................................52
3.4.3 Secondary unit assembly ...........................................................................................................................................................53
3.4.4 Check of forks, fork pins and desmodromic device...............................................................................................................54
3.4.5 Assembly of gearbox and inner control...................................................................................................................................56
3.5 cLosING of ENGINE cRANkcAsE ........................................................................................................................................... 59
3.6 ExtERNAL GEARshIft............................................................................................................................................................... 60
3.6.1 Complete gearbox shaft check..................................................................................................................................................60
3.6.2 External gearshift unit.................................................................................................................................................................62
3.7 kIck stARtER dEvIcE (kIck stARtER)(oPtIoNAL) .............................................................................................................. 62
3.7.1 Kickstart shaft unit check and assembly ..................................................................................................................................62
3.7.2 Assembly of kickstart device (kick starter) ..............................................................................................................................64
3.8 MAIN GEAR ANd cLutch uNIt................................................................................................................................................ 66
3.8.1 Primary gear check .....................................................................................................................................................................66
3.8.2 Primary gear application............................................................................................................................................................66
3.8.3 Check of clutch case, roller bearing and internal centre bearing ........................................................................................67
3.8.4 Clutch disc check.........................................................................................................................................................................68
3.8.5 Spring check ................................................................................................................................................................................69
3.8.6 Clutch drum check ......................................................................................................................................................................69
3.8.7 Thrust bearing device check......................................................................................................................................................70
3.8.8 Clutch unit assembly...................................................................................................................................................................70
3.9 cooLANt LIquId PuMP ANd cENtRIfuGAL uNIt............................................................................................................... 72
3.9.1 Check of pump unit and disassembly, centrifugal unit and idler unit ................................................................................73
3.9.2 CENTRIFUGE UNIT GROUP ASSEMBLY ..................................................................................................................................74
3.9.3 PUMP UNIT ASSEMBLY .............................................................................................................................................................77
3.9.4 ASSEMBLY OF COMPLETE CLUTCH COVER AND PUMP UNIT.............................................................................................77
3.10 ELEctRIc IGNItIoN uNIt ......................................................................................................................................................... 80
3.10.1 Bendix coupling checks .............................................................................................................................................................80
3.10.2 Ignition unit coupling to motor ................................................................................................................................................80
3.11 thERMAL uNIt ........................................................................................................................................................................... 82
3.11.1 Checking piston and elastic bands ...........................................................................................................................................82
3.11.2 Cylinder check .............................................................................................................................................................................83
3.11.3 Piston cylinder coupling play ....................................................................................................................................................84
3.11.4 Checks and exhaust valve unit disassembly............................................................................................................................84
3.11.5 Exhaust valve unit assembly......................................................................................................................................................86
3.11.6 Piston, pin bolt, elastic bands and cylinder assembly ..........................................................................................................88
3.11.7 Check of crankcase/cylinder gasket thickness ........................................................................................................................90
3.11.8 Cylinder head application..........................................................................................................................................................91
3.11.9 Exhaust valve adjustment...........................................................................................................................................................92
3.11.10 Cover plate application ..............................................................................................................................................................95
3.12 chEck of IGNItIoN systEM .................................................................................................................................................. 96
3.12.1 Check of ignition system ...........................................................................................................................................................96
3.12.2 C
oupling of ignition system to crankcase ......................................................................................................................................96
3.13 chEck of INtAkE uNIt ANd AssEMBLy................................................................................................................................ 99
3.14 INsERtIoN of cLutch Rod ANd PINIoN sPAcER ..............................................................................................................101
4 REAssEMBLy of ENGINE IN thE vEhIcLE ............................................................................................................................................ 102
tABLE of MotoR coMPoNENts fAstENING toRquEs...................................................................................................................................110
tABLE of MotoR coMPoNENts fAstENING toRquEs...................................................................................................................................111
tABLE of fRAME/MotoR fAstENING toRquEs ...............................................................................................................................................112
REcoMMENdEd LuBRIcANts ANd LIquIds ......................................................................................................................................................113
REcoMMENdEd MotoR MAINtENANcE.............................................................................................................................................................113

PREAMBLE
Carbon monoxide
• Exhaust gases contain carbon which is poisonous.
Carbon monoxide can cause loss of conscience and
lead to death. When starting the engine, make sure
the place you are in is well-ventilated. Never start
the engine in a closed place.
• Starting the engine in closed places can be done
only if provided with relevant gas discharge evacua-
tion devices.
Petrol
• Petrol is extremely flammable and can be explosive
in some conditions.
• Keep heat sources, sparks and flames away from the
work area.
• Always work in a well-ventilated area.
• Never use petrol as a solvent for cleaning. Do not
handle it unless absolutely necessary.
• Never use petrol to clean components by means of
compressed air.
• Keep out of the reach of children.
Motor oil
• Motor oil can cause skin illnesses if carried often and
for prolonged periods in contact with skin.
• If you touch motor oil, clean parts with soap and
water as soon as possible.
• In case of contact with the eyes, rinse them abun-
dantly with water and seek medical advice.
• If swallowed, do not induce vomiting in order to
avoid breathing the product into the lungs; seek im-
mediate medical advice. If you believe the product
has been breathed into the lungs, bring the con-
cerned person urgently to the hospital.
• Used oil contains dangerous substances which are
harmful for the environment. When changing it, you
must be equipped to dispose of it in compliance
with existing law.
• Avoid dispersing used oils in the environment.
• Keep out of the reach of children.
PREAMBLE
This publication has been written in order to make operations for inspection, maintenance and repairs of the mo-
torcycle 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 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.
Informative note
Betamotor S.p.A. is engaged in a policy of ongoing improvement of its products. This is why it could be possible
to note slight differences between the contents of this document and the vehicle upon which you are carrying out
repairs and/ or maintenance. Betamotor S.p.A. models are exported to numerous countries in which there are differ-
ent standards concerning Highway Codes and procedures for approval of the vehicle. Relying on your understanding,
Betamotor S.p.A. therefore deems it necessary to reserve the right to modify its products and technical documenta-
tion at any time without prior warning.
We respect and defend the environment
All that we do has an impact on the whole Planet and its resources. Wishing to safeguard the interests of the
entire Community, Betamotor S.p.A. would like to make customers and technical operators aware of ways of
using the vehicle and of disposing of its parts in full compliance with standards in force in terms of environmen-
tal pollution, waste disposal and recycling.
2
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SAFETY

PREAMBLE
Coolant liquid
• In some situations, the ethylene glycol contained in
the coolant is flammable and its flame is invisible.
Should ethylene glycol catch fire, though its flame is
invisible, it can cause burns.
• Do not bring the coolant in contact with hot parts.
These parts could be hot enough to cause the liquid
to ignite.
• The coolant (ethylene glycol) can irritate skin and is
poisonous if swallowed.
• Should the coolant come into contact with the skin,
immediately remove contaminated clothing or foot-
wear and wash with soap and water. In case of con-
tact with the eyes, rinse them abundantly with clean
water and seek medical advice immediately. Should
it be swallowed, do not induce vomiting in order to
avoid breathing the product into the lungs. Admin-
ister clean water and bring the concerned person
immediately to the hospital, showing this product to
the hospital staff.
• In the event of exposure to a high concentration of
vapours, bring the concerned person to an uncon-
taminated atmosphere and seek medical advice if
necessary.
• Do not remove the radiator cap when the engine is
still hot. When coolant is pressurised, it can spurt out
violently and cause burns.
• Coolant contains dangerous substances which are
harmful for the environment. When changing 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 turned off. Wait for them to
cool down before handling these parts or interven-
ing on areas around them. Use insulated gloves.
3
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• Before disassembling, clean the motorcycle thor-
oughly.
• Whileyouaredisassemblingit,cleanalltheparts
and place them in containers exactly respecting
theorderofdisassembly.
• Alwaysusespecialtoolswherevernecessaryand
whenthusprescribed.
• Alwaysuseglues,sealantandlubricantswherev-
erprescribed. Respectthe indicationsconcerning
theirtechnicalfeatures.
• Alwaysreplacepartssuchasgaskets,O-ringsand
safetywasherswithnewlysuppliedparts.
• When loosening or tightening nuts or screws, al-
waysstartwiththelargeronesorfromthecentre.
Alwaysrespecttheindicatedtighteningtorques.
• UseonlyBetamotororiginalspareparts.
WARNINGS
Theinformationcontainedinthisparagraphisimportantsothattheoperationscarriedoutontheen-
ginecanbeperformedwithoutcausingdamage.

ENGINE
4
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TECHNICAL FEATURES OF ENGINE
CHARACTERISTIC DATA ENGINE
300
Bore[mm]/Stroke [mm] 72/72
Displacement [cm³] 293
Compression ratio 11.3
TRANSMISSION
300
Main 28/70
1st gear ratio 12/31
2nd gear ratio 15/28
3rd gear ratio 19/28
4th gear ratio 20/24
5th gear ratio 27/27
6th gear ratio 28/24
CARBURETOR
300
Version Approv. Race*
Carburetor type PWK 36S AG
Main jet 118 155
Slow jet 38 35
Ignition jet 50 85
Needle N84K N1EJ
Needle position
(from above)
4° 2°
Air screw turns
(from all closed)
2 1+1/4
Flush YES NO
* this modification makes the vehicle non-compliant with
the highway code in force. Use must be limited to private
circuits closed to circulation

ENGINE
5
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SPECIAL EQUIPMENT
1. Crankcaseuncouplercode0100042000
2. Clutchdrumnut/Maintoolcode026140010000
3. Crankcase/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
Siliconepaste
Value
Fasteningtorque
Symbols
Medium-resistance
threadlocker

1
6
REMOVAL OF ENGINE FROM VEHICLE
∙ Carefully wash the vehicle;
∙ Remove the engine guard plate;
∙ Place the vehicle onto an adequate stand.
∙ Remove the seat, the tank and the lateral
sides.
∙ To take down the tank you must:
- completely unscrew the two screws 1that
fasten the tank to the frame and the screws
2 (two per side) that fasten the side to the
vehicle;
- disconnect the by-pass petrol pipe by
pressing the quick-coupling 3button.
1 REMOVAL OF MOTOR FROM VEHICLE
- Disconnect the petrol pipe 4from the valve.
∙ Remove the pinion guard 5.
45
3
1
2

1
7
REMOVAL OF ENGINE FROM VEHICLE
∙ Remove the circlip 6and extract the pinion.
Rest the chain against the upper wedge 7.
∙ Remove the screws8fixing the clutch actua-
tor to the crankcase half.
ATTENTION!
Donotactivatetheclutchleverwithactuatorde-
coupledfromengine.
8
67
9
∙ Remove the exhaust expansion and the silenc-
er
∙ Drain the cooling system through screw 9and
let the liquid outflow into a container (the
cooling circuit contains 1.3l of liquid). Remove
the radiator cap.

1
8
REMOVAL OF ENGINE FROM VEHICLE
∙ Remove the left radiator with pipes.
∙ Disconnect the coil from the spark plug, re-
move the two screws 10 and take the com-
plete coil support out of the intake manifold.
10
∙ Disconnect the water hoses from the engine
and from the right radiator.
∙ Disconnect the electrical connectors for the
right radiator accessories.
∙ Remove the right radiator.
Note: when the coil support has been taken
down, we recommend putting the screws
back in place, without tightening them.

1
9
REMOVAL OF ENGINE FROM VEHICLE
∙ Pull the mixer tube 11 out from the intake
manifold and tube hold 12.
∙ Cut all straps binding the engine's electric sys-
tem to the clutch pipe and to the.
Then, disconnect the connectors:
- ATPS sensor;
- BPick-Up;
- Cstator unit.
∙ Disconnect the engine ventilation pipes
11
12
A
B
C

1
10
REMOVAL OF ENGINE FROM VEHICLE
∙ Remove the start motor cable fixing nut.
∙ Remove the head connections.
Attention! When the mixer tube has been dis-
connected, plug it to prevent emptying.

1
11
REMOVAL OF ENGINE FROM VEHICLE
∙ Release and remove the brake pedal re-
turn spring 13. Remove the kickstarter
lever(Optional).
∙ Remove the gear lever.
13
∙ Loosen the carburetor straps from the air filter
sleeve and from the manifold.
∙ Remove the seat rail lower fixing screws 14
(one each side) and loosen the upper screws
15 (one each side).
14
15

1
12
REMOVAL OF ENGINE FROM VEHICLE
∙ Rotate the filter box unit.
∙ Remove the carburettor from the manifold
leaving it connected to the gas cable.
∙ Remove the swingarm pin 17 and the upper
shock-absorber pin 16.
∙ Remove the engine pins 18.
18
17
16
Attention! Whenthecarburettorisdisconnected
fromthemanifold,andbeforehandlingthecar-
burettor,emptyoutthetank.

1
13
REMOVAL OF ENGINE FROM VEHICLE
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.

2
14
ENGINE DISASSEMBLY
Secure the engine to the specific support
stand code 3625132000 by means of front
fixing code026140030000, in order to work
in comfort and safety. Then proceed as follows
Remove the spark plug
2 MOTOR DISASSEMBLY
2.1 CLUTCH/GEAR OIL DRAIN
Remove screw 1and let the oil drain.
1
2.2 REMOVAL OF CLUTCH
CONTROL ROD AND
PINION SPACER
Extract the spacer 1.
Extract the clutch control rod 2.
2
1

2
15
ENGINE DISASSEMBLY
2.3 REMOVAL OF PISTON,
CYLINDER AND HEAD
Remove the spigot screws 1together with the
copper washers. Remove the head and the two
O-rings.
Remove the four screws 2.
Remove the three screws 3and cover 4.
1
2
3
4

2
16
ENGINE DISASSEMBLY
Release the lock 5and remove it.
Release the control rod 6.
Remove the gasket 7. It may be necessary to
force the rubber gasket 8slightly; place a metal
pin Abetween the lever and the gasket 8and
force it externally slightly.
5
Removal of gasket 6
A
7
68

2
17
ENGINE DISASSEMBLY
Remove the four collar nuts 9.
9
Extract the cylinder and base gaskets.

2
18
ENGINE DISASSEMBLY
ATTENTION!
Placeacleanclothbetweenthepistonandthe
crankcase to keep foreign objects or simple
solidresiduefromfallinginsidethebase.
Remove the circlip 10 by gripping it with a pair
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ordernot
tostresstheconnectingrod.
A
10
Removal of piston circlip.
Removal of pin bolt.
B