Eton beamer R2-50 User manual

ETON America
Beamer R2-50
Service Manual
Covers:
Beamer R2-50
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Beamer R2 Rev 1.0 Page 2 of 56 6/13/2007
Table of Contents
1. INFORMATION..................................................................................................................................... 4
1.1 SAFETY ........................................................................................................................................... 4
1.2 NOTES.............................................................................................................................................. 4
1.3 Specifications.................................................................................................................................... 5
1.4 SERIAL NUMBER .......................................................................................................................... 6
1.5 Standard Torque Values.................................................................................................................... 7
2. MAINTENANCE ................................................................................................................................... 8
2.1 MAINTENANCE DATA ................................................................................................................. 8
2.2 MAINTENANCE SCHEDULE ....................................................................................................... 9
2.3 FUEL TUBE ..................................................................................................................................... 9
2.4 THROTTLE OPERATION .............................................................................................................. 9
2.5 THROTTLE CABLE ADJUSTMENT .......................................................................................... 10
2.6 AIR CLEANER .............................................................................................................................. 10
2.7 SPARK PLUG ................................................................................................................................ 10
2.8 IDLE SPEED .................................................................................................................................. 11
2.9 BRAKE SYSTEM .......................................................................................................................... 11
2.10 WHEELS AND TIRES................................................................................................................. 12
2.11 GEAR OIL .................................................................................................................................... 12
2.12 ENGINE STOP SWITCH............................................................................................................. 12
2.13 HIGH-LOW BEAM CONTROLLER .......................................................................................... 13
3. ENGINE REMOVAL AND INSTALLATION ................................................................................... 14
3.1 ENGINE REMOVAL..................................................................................................................... 14
3.2 ENGINE INSTALLATION............................................................................................................ 16
4. ENGINE FUEL SYSTEM.................................................................................................................... 17
4.1 TROUBLESHOOTING.................................................................................................................. 17
4.2 CARBURETOR.............................................................................................................................. 18
5. ENGINE LUBRICATION AND COOLING SYSTEM ...................................................................... 21
5.1 TROUBLESHOOTING.................................................................................................................. 21
5.2 ENGINE LUBRICATION SYSTEM............................................................................................. 21
5.3 CAUTION: Fuel/Oil Ratio ............................................................................................................. 21
5.4 OIL PUMP...................................................................................................................................... 22
5.5 COOLING SYSTEM...................................................................................................................... 23
6. ENGINE COMBUSTION SYSTEM ................................................................................................... 23
6. ENGINE COMBUSTION SYSTEM ................................................................................................... 24
6.1 TROUBLESHOOTING.................................................................................................................. 24
6.2 CYLINDER AND PISTON REMOVAL....................................................................................... 25
6.3 CYLINDER AND PISTON INSPECTION ................................................................................... 25
6.4 INSTALLATION ........................................................................................................................... 27
7. TRANSMISSION SYSTEM ................................................................................................................ 29
7.1 TROUBLESHOOTING.................................................................................................................. 29
7.2 THE PARTS DRAWING OF TRANSMISSION SYSTEM.......................................................... 29
7.3 TRANSMISSION POWER PATH ................................................................................................ 30
7.4 AUTOMATIC CONTINUOUS VARIABLE TRANSMISSION.................................................. 31
7.5 CONTINUOUS VARIABLE TRANSMISSION........................................................................... 31
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Beamer R2 Rev 1.0 Page 3 of 56 6/13/2007
7.6 TRANSMISSION BOX ................................................................................................................. 32
7.7 ELECTRIC STARTER MOTOR ................................................................................................... 33
7.8 KICK STARTER............................................................................................................................ 33
8. FRONT WHEEL, BRAKE AND STEERING SYSTEM .................................................................... 35
8.1 TROUBLESHOOTING.................................................................................................................. 35
8.2 MAINTANENCE DATA ............................................................................................................... 35
8.3 SPEEDOMETER CABLE REMOVAL ......................................................................................... 36
8.4 HANDLEBAR REPLACEMENT.................................................................................................. 36
8.5 FRONT WHEEL ............................................................................................................................ 37
8.6 FRONT BRAKE............................................................................................................................. 38
8.7 FRONT FORK................................................................................................................................ 40
9. REAR WHEELAND BRAKE SYSTEM......................................................................................... 41
9.1 TROUBLESHOOTING.................................................................................................................. 41
9.2 MAINTENANCE DATA ............................................................................................................... 41
9.3 REAR WHEEL REMOVAL .......................................................................................................... 41
9.4 REAR WHEEL INSPECTION....................................................................................................... 42
9.5 REAR BRAKE ............................................................................................................................... 42
9.6 REAR SHOCK ABSORBER PARTS DRAWING ....................................................................... 43
10. PLASTIC BODY PARTS............................................................................................................... 44
10.1 FRONT FENDER......................................................................................................................... 44
10.2 BODY COVER............................................................................................................................. 44
11. ELECTRICAL SYSTEM ............................................................................................................... 48
11.1 TROUBLESHOOTING................................................................................................................ 48
11.2 IGNITION COIL .......................................................................................................................... 49
11.3 IGNITION TIMING, CDI SPECIFICATION, AND A/C GENERATOR TEST........................ 49
11.4 BATTERY INSPECTION AND MAINTENANCE.................................................................... 51
11.5 STARTER MOTOR ..................................................................................................................... 54
11.6 WIRING DIAGRAMS ................................................................................................................. 55
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Beamer R2 Rev 1.0 Page 4 of 56 6/13/2007
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 you spill the
electrolyte on your skin or in your eyes, flush thoroughly with water. Call a doctor if electrolyte gets in
your eyes.
1.2 NOTES
All information, illustrations, directions and specifications included in this publication are based on the
latest product information available at the time of approval for printing.
E-TON Dynamic Technology Industry 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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Beamer R2 Rev 1.0 Page 5 of 56 6/13/2007
1.3 Specifications
Engine
Type Two cycle air cooled oil injected
Displacement 49.3cc
Bore / Stroke φ40.0 * 39.2mm
Compression - Ratio / Pressure 6.8 : 1 / 90-120psi
Torque / BHP 5.2N m @ 7000rpm / 1.5BHP
Estimated MPG 65mpg
Starting Electrical with Kick starter back up
Transmission
Type Automatic (C.V.T. V-Belt)
Chassis
Overall Length 1830mm / 72.0"
Overall Width 650mm / 25.6"
Overall High 1100mm / 43.3"
Wheel Base 1260mm / 49.6"
Dry Weight 82kg / 180.7lb
Suspension
Front Telescopic Fork
Rear Unit Swing Arm / Single Shock
Brakes
Front Hydraulic Disc
Rear Hydraulic Disc
Tires
Front 120/90-10
Rear 130/90-10
Front Front 18psi / 1.25kg/cm2 (Cold)
Tire Pressure Rear Rear 25psi / 1.75kg/cm2 (Cold)
Carburetor
Make/Size Mikuni 18mm (Manual Coke)
Main Jet 85mm
Pilot Jet 20mm
Air Mixture Adjustment Back out ¾ - 1¼ turns
Idle Speed Idle 1700 - 1900rpm
Battery
Jell Acid (Maintenance Free) 12V-4AH/5AH - GTX5L-BS
Fluids
Type Unleaded Gasoline 89 octane
Fuel Volume 5.5liters / 1.5gal
Type High grade synthetic 2 cycle injector oil
2 Cycle Oil Volume 1.1 liters / 1.2qts
Type SAE 80/90 weight
Transmission Volume 100cc / 3.4oz
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Beamer R2 Rev 1.0 Page 6 of 56 6/13/2007
Spark Plug
NGK (recommended) BPR7HS
Nipendenso W22FRP-U
Champion QL82YC
Electrode Gap 0.6-0.7mm / 0.023"
GVWR 240kg. / 530lbs.
GAWR (Front) 76kg. / 167lbs.
GAWR (Rear) 165kg. / 164lbs.
Red
Blue
Yellow
Available Colors
*Subject to availability Black
1.4 SERIAL NUMBER
The frame serial number is stamped on the front of the frame, at the front of the footrest plate.
The engine serial number is stamped on the left side of the engine crankcase.
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Beamer R2 Rev 1.0 Page 7 of 56 6/13/2007
1.5 Standard Torque Values
ENGINE
¾Cylinder head nut 28-30 N-m (20.7-22.1 lb./ft)
¾Spark plug 12-19 N-m (8.9-14.0 lb./ft)
¾Cylinder head bolt 20-30 N-m (14.8-22.1 lb./ft)
¾Alternator bolt 8-12 N-m (5.9- 8.9 lb./ft)
FRAME
¾Handlebar upper holder bolt 24-30 N-m (17.7-22.1 lb./ft)
¾Steering shaft nut 50-60 N-m (36.9-44.3 lb./ft)
¾Steering shaft bushing holder nut 24-30 N-m (17.7-22.1 lb./ft)
¾Wheel rim bolt 18-25 N-m (13.3-18.4 lb./ft)
¾Tie rod lock nut 35-43 N-m (25.8-31.7 lb./ft)
¾King pin nut 30-40 N-m (22.1-29.5 lb./ft)
¾Handlebar lower holder nut 40-48 N-m (29.5-35.4 lb./ft)
¾Front wheel bolt 24-30 N-m (17.7-22.1 lb./ft)
¾Front axle nut 55-65 N-m (40.6-47.9 lb./ft)
¾Front brake arm nut 4-7 N-m (3.0- 5.2 lb./ft)
¾Rear brake arm nut 7-12 N-m (5.2- 8.9 lb./ft)
¾Rear axle nut 60-80 N-m (44.3-59.0 lb./ft)
¾Rear wheel bolt 24-30 N-m (17.7-22.1 lb./ft)
¾Exhaust muffler mounting bolt 30-35 N-m (22.1-25.8 lb./ft)
¾Engine hanger bolt 24-30 N-m (17.7-22.1 lb./ft)
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Beamer R2 Rev 1.0 Page 8 of 56 6/13/2007
2. MAINTENANCE
2.1 MAINTENANCE DATA
2.2 MAINTENANCE SCHEDULE
2.3 FUEL TUBE
2.4 THROTTLE OPERATION
2.5 THROTTLE CABLE ADJUSTMENT
2.6 AIR CLEANER
2.7 SPARK PLUG
2.8 IDLE SPEED
2.9 BRAKE SYSTEM
2.10 WHEELS AND TIRES
2.11 STEERING SYSTEM
2.12 GEAR OIL
2.1 MAINTENANCE DATA
SPECIFICATION
SPARK PLUG:
SPARK PLUG GAP: 0.6-0.7 mm
RECOMMENDED SPARK PLUGS: NGK BPR7HS
THROTTLE LEVER FREE PLAY: 5-10 mm
IDLE SPEED: 1600±100 rpm
BRAKE LEVER FREE PLAY: 15-25 mm
TIRES:
FRONT TIRE SIZE 120/90-10
REAR TIRE SIZE 130-90-10
FRONT/REAR TIRE PRESSURE 2.5± 0.3 kgf/cm2
TORQUE VALUES
SPARK PLUG 12-19 N-m
TIE-ROD LOCK NUT 35-43 N-m
LUBRICATION:
ENGINE OIL JASO FC Grade or same degree oil
GEAR LUBRICATION OIL SAE 40
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Beamer R2 Rev 1.0 Page 9 of 56 6/13/2007
2.2 MAINTENANCE SCHEDULE
The maintenance intervals in the follow table are based upon average riding conditions. Riding in
unusually dusty areas may require more frequent servicing. E-TON recommends that all maintenance
and inspections be performed ONLY by a qualified and fully trained technician.
INITIAL
SERVICE REGULAR SERVICE
(First week) (Every 30 operating
days)
EVERY
YEAR
Fuel Line I
Throttle Operation I I I
Air Filter system &
Element I C R
Spark Plug I R
Carburetor Idle Speed I I I
Brake Shoe Wear I I I
Brake System I I I
Nut, Bolt, Fastener I I I
Wheels & Wheel Nuts I I I
Steering System I I
Suspension System I I
C.V.T. Air Filter C R
Air Induction Reed Valve I C/R
Transmission Gear Oil I R
Note –
I: Inspect and Clean, Adjust, Lubricate, or Replace (if necessary)
C: Clean
L: Lubricate
R: Replace
2.3 FUEL TUBE
Inspect the fuel lines for deterioration, damage, or
leaks, and replace if necessary.
2.4 THROTTLE OPERATION
Inspect for smooth throttle lever full opening and
automatic full closing in all steering positions.
Inspect for deterioration, damage, or kinking
in the throttle cable. Replace if necessary.
Check the throttle lever. Free play is 5-10 mm at the tip
of the throttle lever.
Disconnect the throttle cable at the upper end.
Lubricate the cable with commercially available lubricant to prevent premature wear.
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Beamer R2 Rev 1.0 Page 10 of 56 6/13/2007
2.5 THROTTLE CABLE
ADJUSTMENT
Slide the rubber adjuster cap off the throttle
housing, loosen the locking 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.
2.6 AIR CLEANER
Unscrew the air cleaner cover screws.
Pull out the air filter element from the air cleaner
case. Wash the element in non-flammable solvent.
Squeeze out the solvent thoroughly.
Let it dry. Soak the filter element in gear oil and
then squeeze out the excess oil.
Install the element 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 remove
the spark plug. Check the spark plug electrodes
for wear. Change 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.
Torque the spark plug to 12-19 N-m.
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Beamer R2 Rev 1.0 Page 11 of 56 6/13/2007
2.8 IDLE SPEED
Connect a tachometer.
Warm up the engine for at least 10 minutes.
Turn the idle-speed adjust screw on the carburetor
to obtain the idle speed. "Turn in" (clockwise)
to get higher speed. "Turn out" (counter clockwise)
to get lower speed.
IDLE SPEED: 1600±100 rpm
2.9 BRAKE SYSTEM
Inspect the front 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 of free play is 15-25 mm.
Inspect the rear brake lever and cable for
excessive play or other damage.
Replace or repair if necessary.
Measure the free play of the rear brake lever at
the end of the lever. The standard is 15-25 mm.
Adjust the free play of the rear brake lever by
turning the adjuster on the rear axle.
Idle Ad
j
ustment Screw
Air Mixture
Ad
j
ustment Screw
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Beamer R2 Rev 1.0 Page 12 of 56 6/13/2007
2.10 WHEELS AND TIRES
Inspect the tire surfaces for cuts, nails, or other sharp
objects. Check the tire pressure at cold tire condition.
The standard tire pressure is 2.5±0.3 kgf/cm2
2.11 GEAR OIL
Transmission gear oil needs to be changed every year
or after every 3000 miles of service.
The drain bolt is located at the rear of engine.
Remove the drain bolt and loosen the fill bolt to drain
the transmission gear box.
Inspect the drained oil for foreign materials. If the oil
contains a high concentration of metal shavings or
powder, disassemble the transmission for further
inspection.
Reinstall the drain bolt and refill the gear box with
100cc / 3.4oz of SAE 80-90 Gear Oil
Note: for best results, drain the transmission while
the engine is warm.
2.12 ENGINE STOP SWITCH
The engine stop switch is located beside the left handle bar.
In an emergency, pushing this switch will stop the engine.
The stop switch must be place in the on position, the top of the
switch pressed down, for the engine to start.
If your engine fails to start, check the switch.
Drain Bol
t
Fill Plug
Turn
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Beamer R2 Rev 1.0 Page 13 of 56 6/13/2007
2.13 HIGH-LOW BEAM CONTROLLER
This controller is located beside right handle bar and
controls the headlight intensity setting.
When the switch is placed in the full right position, the
headlights are set to illuminate at 100% intensity. In the
center position the headlight will illuminate at 60%
intensity. Placed in the far left position, the headlights
will be off.
NOTE: It is recommended that you have the headlight
on at all times when operating the vehicle to improve
your visibility to other traffic.
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Beamer R2 Rev 1.0 Page 14 of 56 6/13/2007
3. ENGINE REMOVAL AND INSTALLATION
3.1 ENGINE REMOVAL
Remove the seat, helmet box, and body cover.
(See chapter 10 for complete instructions)
Disconnect oil tube, fuel tube, and vacuum line tube.
Disconnect the wires of the A/C generator and the
starter motor.
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Beamer R2 Rev 1.0 Page 15 of 56 6/13/2007
Disconnect the wires of the carburetor and the
throttle cable.
Remove the cap from the spark plug.
Remove the bolt at the low end of the rear shock.
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Beamer R2 Rev 1.0 Page 16 of 56 6/13/2007
Remove the engine hanger nut.
Remove the rear brake cable adjusting nut.
Pull the engine out from the frame.
3.2 ENGINE INSTALLATION
Install engine in reverse order of disassembly.
Torque value:
M8 nut 15 - 22 lbf-ft
M10 nut 22 - 29 lbf-ft
M12 nut 36 – 43 lbf-ft
After installing the engine, check the parts below:
oAll connections (A/C generator,
starter motor, etc)
oCarburetor throttle cable
oRear brake cable
oOil tubes and fuel tubes
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Beamer R2 Rev 1.0 Page 17 of 56 6/13/2007
4. ENGINE FUEL SYSTEM
4.1 TROUBLESHOOTING
ENGINE WILL NOT START ¾NO FUEL IN TANK
¾NO FUELIN CYLINDER
¾TOO MUCH FUEL INTO CYLINDER
¾NO SPARK AT PLUG
¾AIR CLEANER CLOGGED
ENGINE IDLES UNSTEADILY,STALLS,
OR RUNS POORLY
¾IMPROPER ADJUSTMENT OF THE
IDLE SPEED SCREWAT CARBURETOR
¾IGNITION MALFUNCTION
¾FUEL/AIR MIXTURE RATIO TOO LEAN OR
TOO RICH
¾AIR CLEANER DIRTY
¾INSULATOR LEAKS
¾FUEL TANK CAP BREATHING HOLE
CLOGGED
LEAN MIXTURE ¾CARBURETOR FUEL JET CLOGGED
¾FUEL TANK CAP BREATHING HOLE
CLOGGED
¾FUEL FILTER CLOGGED
¾FUEL FLOWS IN THE TUBE IRREGULARLY
¾FLOAT LEVEL IN CARBURETOR TOO LOW
RICH MIXTURE ¾FLOAT NEEDLE VALVE IN CARBURETOR
FAULTY
¾FLOAT LEVELTOO HIGH
¾AIR DUCT IN CARBURETOR IS CLOGGED
¾AIR CLEANER DIRTY
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Beamer R2 Rev 1.0 Page 18 of 56 6/13/2007
4.2 CARBURETOR
REMOVAL
Remove the air cleaner.
Disconnect the fuel line and auto-choke electric wire.
Unscrew the intake pipe mounting bolts at the
carburetor, and then remove the carburetor.
Note: Before removing carburetor, you must shut the
fuel flow off.
Remove the carburetor cap.
Remove the throttle cable from the throttle valve
while depressing the throttle valve spring.
Remove the needle clip retainer, the jet needle, and
needle clip. Inspect the throttle valve and jet needle
surface for wear, scratches, or dirt.
Carbureto
r
Air Cleane
r
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Beamer R2 Rev 1.0 Page 19 of 56 6/13/2007
DISASSEMBLY
Unscrew the float chamber screws and remove the
float chamber.
Disassemble the float arm pin, float and float needle
valve.
Inspect the seat of the float needle valve for wear or
damage.
Disassemble the idle jet, main jet, idle speed
adjustment screw, and idle mixture adjustment screw.
Inspect all jets and screws for wear or damage.
Clean the passages and jets with compressed air.
ASSEMBLY
Clean all parts in solvent and blow it dry with
compressed air. Assembly is the reverse order of
disassembly.
Main Je
t
Pilot Je
t
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Beamer R2 Rev 1.0 Page 20 of 56 6/13/2007
THROTTLE VALVE ASSEMBLY
Install the needle clip on the jet needle.
Install the jet needle into the throttle valve.
Assemble the throttle cable, spring, and throttle
valve. Align the throttle valve groove with the idle
speed adjust screw and install the carburetor cap to
the carburetor.
Factory specification is 2.8~3.5mm for the float level.
Adjustment may be necessary if insufficient fuel
or excess fuel in carburetor.
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