Eton america Beamer r4 150cc User manual

ETON America

Beamer R4 150cc

Service Manual

Covers:

Beamer R4 PN2F

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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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9.6 REAR SHOCK ABSORBER DRAWING.................................................................... 64

10. PLASTIC PARTS..................................................................................................... 65

10.1 FRONT FENDER...................................................................................................... 65

10.2 BODY COVER.......................................................................................................... 65

10.3 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................................................................................................... 73

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1. INFORMATION

1.1 SAFETY

●Gasoline is extremely flammable and is explosive under certain conditions. Do not

smoke or allow sparks or flames in your work area.

●Never run the engine in a closed area. The exhaust contains poisonous carbon monoxide

gas that may cause loss of consciousness and lead to death.

●The battery electrolyte contains sulfuric acid. Protect your eyes, skin and clothing. If

contact 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 are

base on the latest product information available at the time of approval for printing.

E-TON POWER TECH CO., LTD. reserves the right to make changes at any time without

notice and without incurring any obligation whatever.

No part of this publication may be reproduced without written permission.

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1.3 SERIAL NUMBER

The frame serial number is stamped on the front of the frame, just 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)

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1.4 TORQUE VALUES

FRAME

Part to tightened Thread

size

Tightening torque Remarks

N-m kg-m ft.lb

Handlebar upper holder bolt M10 30-40 3.0-4.0 22.1-29.5

Front fork nut upper M25 55-65 5.5-6.5 40.6-47.9

below 14 1.4 10.3

Front axle nut M10 30-40 3.0-4.0 22.1-29.5

Rear axle nut M20 110-130 11.0-13.0 81.1-95.9

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

Rear brake calliper bolt M8 24-30 2.4-3.0 17.7-22.1 Loctite 271

Brake disk bolt M8 30-40 3.0-4.0 22.1-29.5

Exhaust pipe mounting nut M6 12-15 1.2-1.5 8.9-11.1

Exhaust muffler bolts M8 20-30 2.0-3.0 14.8-22.1

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ENGINE

Part to tightened Thread

size

Tightening torque Remarks

N-m kg-m ft.lb

Spark plug M10 10-12 1.0-1.2 7.4-8.9

Cylinder head bolts M6 10-14 1.0-1.4 7.4-10.3

Tappet adjusting nut M5 7-11 0.7-1.1 5.2-8.1

Oil drain bolt M12 20-30 2.0-3.0 14.8-22.1

Clutch outer nut M10 55 5.5 40.6

Drive face nut 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 95-96 9.5-9.6 68-69.4

GENERALITY

General bolt M5 3.5-5.0 0.3-0.5 2.2-3.7

M6 10.0~14.0 1.0-1.4 7.4-10.4

M8 20.0~30.0 2.0-3.0 14.8-22.1

M10 30.0~4.00 3.0-4.0 22.1-29.5

M12 50.0~60.0 5.0-6.0 36.9-44.2

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2. MAINTENANCE

2.1 MAINTENANCE DATA

SPECIFICATIONS

SPARK PLUG GAP 0.6-0.7 mm

RECOMMENDED SPARK PLUGS NGK CR7HSA

THROTTLE LEVER FREE PLAY 5-10 mm

IDLE SPEED 1700-1 900 rpm

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, conditions. Riding in unusually

dusty areas, require more frequent servicing.

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Maintenance Schedule

Four Stroke Vehicles

WP-0027

Scheduled

Maintenance

300KM Every1000KM Every3000KM Every6000KM Every12000KM

200Miles600Miles2000Miles3700Miles7500Miles

NEW 1Month3Months 6Months 1Year

1Aircleanerelement I*C* R(paper) R(sponge)

2Aircleaner I    

3Oilfilter(Screen) C   C 

4Engineoil Change I Change  

5Tire,pressure I I   

6Battery I I   

7Sparkplug I  I  R

8Carburetor(idlespeed) I   I 

9Steeringbearingandhandles I  I  

10

Checktransmissionforleak‐

age I I   

11Checkcrankcaseforleakage I I   

12Transmissionoil Change   Change

13Drivebelt/roller    I R

14Fueltankswitchandlines I  I  

15

Throttlevalveoperationand

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 

22Front/Rearsuspension I   I 

23Main/Sidestands I   I/L 

24Crankcase(PCV)Valve I  I  

25

Brakemechanism/brakelin‐

ing(pad) I I   

26

TightenallBolts/Nuts&Fas‐

teners

I I   

*=Cleanorreplacetheaircleanerelementmoreoftenwhenthevehicleisoperatedondusty

#=Maintenanceshouldbeperformedmoreoftenifthevehicleisfrequentlyoperatedathigh

speedforprolongedtimeandafterthevehiclehasaccumulated50,000miles.

roadsorinaheavilypollutedenvironment.

Code:

I=Inspection,clean,andadjust

R=Replace

C=Clean(replacedifnecessary)

L=Lubricate

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2.3 FUEL TUBE

Inspect the fuel lines for deterioration, damage, or leaking,

and replace if necessary.

2.4 THROTTLE OPERATION

Inspect the hand grip for smooth full opening and

automatic full closing in all steering positions.

Inspect for deterioration, damage, or kinking in the throttle

cable, and replace it if necessary.

Disconnect the throttle cable at the upper end. Lubricate

the cable 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 switch.

2.5 THROTTLE CABLE ADJUSTMENT

Slide the rubber cap of the adjuster off the throttle

housing, loosen the lock nut, and adjust the free play of

the throttle lever by turning the adjuster on the throttle

housing. Inspect the free play of the throttle lever.

This free play should be 5-10mm.

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2.6 AIR CLEANER

Unscrew the air cleaner cover screws.

Pull out the air filter from the air cleaner case.

Wash the component in non-flammable solvent and

squeeze out the solvent thoroughly. Let it dry completely.

Soak the filter in gear oil and then squeeze out the excess

oil.

Install the component into the air cleaner carefully.

2.7 SPARK PLUG

The spark plug is located at the front of the engine.

Disconnect the spark plug cap and unscrew the spark

plug. Check the spark plug electrodes for wear.

Replace the spark plug if the electrodes and insulator tip

appear unusually fouled or burned.

Discard the spark plug if there is apparent wear or if 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 10-12 N-m.

2.8 IDLE SPEED

Connect a tachometer to the engine. Warm up the engine

for about 10 minutes.

Tune the idle speed adjust screw on the carburetor to

obtain the idle speed. Turn clockwise for higher speed.

Turn counter-clockwise will for lower speed.

Idle speed: 1800±1 00 rpm

2.9 BRAKE SYSTEM

Inspect the front and brake lever and cable for excessive

play or other damage.

Replace or repair if necessary.

Measure the free play of the brake lever at the end of the

brake lever.

The standard free play in those two-brake handle levels

is 15-25 mm.

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Inspect the rear and brake lever and cable for excessive

play or other damage. Replace or repair if necessary.

Measure the free play of the brake lever at the end of the

brake lever.

The standard free play in those two-brake levels are

15-25 mm.

2.10 WHEELS AND TIRES

Inspect the tire surfaces for cuts, nails or other sharp

objects.

Check the tire surfaces when the tires are cold.

The standard tire pressure of front 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

release bolt and let the dirty oil flow out. Allow 15minutes

for the gear oil to drain completely. Reinstall the oil drain

bolt and tighten it, then refill the oil to the gearbox

through the transmission oil filler hole. Then, reinstall

the transmission oil filler bolt.

Transmission Oil Drain

Transmission Oil Filler Hole

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2.12 ENGINE STOP SWITCH

2.13 UPPER – LOWER BEAM CONTROLLER

This controller is located beside right handle bar.

This controls 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 immediately.

OFF

LOWE

UPPE

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3. ENGINE REMOVAL AND INSTALLATION

3.1 ENGINE 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.

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Disconnect the carburetor and throttle cable wires.

Remove the spark plug cap.

Remove the muffler by removing the retaining bolts.

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Remove the air cleaner by removing the

retaining 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.

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Remove engine hanger nut.

Remove the engine from the frame.

3.2 ENGINE INSTALLATION

Install engine in reverse order of 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 tubes and fuel tubes

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4. CYLINDER HEAD AND VALVES

4.1 SERVICE INFORMATION

GENERAL

This section describes maintenance for the cylinder head, valves, camshaft, and related parts. The engine

must be removed from the frame to service cylinder head. Camshaft lubrication oil is fed to the cylinder head

through an oil orifice in the engine case. Before installing the cylinder head, be sure the orifice is not

clogged and the gasket, O-ring, and dowel pins are in place.

SPECIFICATIONS

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 FREE LENGTH IN 32.3 31.2

OUT 35.0 34.1

VALVE STEM O.D. IN 4.975-4.990 4.90

EX 4.955-4.970 4.90

VALVE GUIDE I.D. IN/EX 5.000-5.012 5.30

STEM-TO-GUIDE CLEARANCE IN 0.010-0.037 0.08

EX 0.030-0.057 0.10

VALVE SEAT WIDTH IN 1.0 1.8

EX 1.0 1.8

TORQUE VALUES

Cylinder head bolts 10-14 N-m

Camshaft holder nuts 19-22 N-m

Tappet adjusting nut 7-11 N-m

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4.2 TROUBLE SHOOTING

Engine top-end problems usually affect engine performance. These problems can be diagnosed by a

compression test, or by tracing engine noise to the top end with a sounding rod or stethoscope.

Valve

•Incorrect valve adjustment

•Worn or damaged valve seats

•Burned or bent valve

•Incorrect valve timing

•Weak valve spring

Cylinder head

•Leaking or damaged 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

•Worn or damaged cam chain

•Worn or damaged cam chain tensioner

•Worn cam sprocket teeth

Excessive smoke

•Damaged valve stem seal

•Faulty cylinder or piston rings

4.3 CAMSHAFT COMPOSITION REMOVAL

Remove the rubber tube of gas waste recovery.

Remove the cylinder head cover.

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Remove the air cleaner and carburetor.

Remove the inlet pipe assembly.

Remove the shroud compositions.

Loosen the cam chain adjuster screw.

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 cam chain and remove

the camshaft.

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