Beta RR 125-200 Moteur 2T ANG

RACE EDITION
125 / 200
2 Stroke
2022
WORKSHOP MANUAL
www.betamotor.com TABLE OF CONTENTS
2.9 DISASSEMBLY OF PARTS FROM CRANKCASES........44

2.9.1 RIGHT CRANKCASE HALF..........................................................45
2.9.2 LEFT CRANKCASE HALF.............................................................. 47
3 ENGINE CHECKS AND ASSEMBLY 48
3.1 CRANKCASE HALF.........................................................48

3.1.1 APPLICATION OF RIGHT CRANKCASE HALF PARTS.........49
3.1.2 SPECIAL APPLICATIONS FOR LEFT CRANKCASE HALF... 51
3.2 CONNECTING ROD AND ENGINE SHAFT CHECK.... 52
3.3 ASSEMBLY OF COMPLETE CRANKSHAFT................. 53
3.4 GEARSHIFT UNIT: CHECKS AND REASSEMBLY....... 54
3.4.1 CHECK OF GEARSHIFT UNIT .................................................. 54
3.4.2 ASSEMBLY OF PRIMARY UNIT.................................................. 55
3.4.3 SECONDARY UNIT ASSEMBLY.................................................. 58
3.4.4 CHECK OF THE FORKS, FORK PINS AND
DESMODROMIC DEVICE............................................................62
3.4.5 ASSEMBLY OF GEARSHIFT AND INNER CONTROL.........64
3.5 CLOSING THE ENGINE CRANKCASE.......................... 67
INTRODUCTION 2
3.6 EXTERNAL GEARSHIFT DRIVE.....................................68
ENGINE TECHNICAL SPECIFICATIONS 4 3.6.1 CHECK OF THE WHOLE GEARSHIFT SHAFT......................68
3.6.2 ASSEMBLY OF EXTERNAL GEARSHIFT DRIVE.................... 70
SPECIAL EQUIPMENT 5
3.7 KICKSTARTER DEVICE - OPTIONAL RR200............... 72
1 ENGINE REMOVAL FROM VEHICLE 6 3.7.1 CHECK OF STARTER SHAFT UNIT AND ASSEMBLY......... 72
3.7.2 ASSEMBLY OF KICK STARTER DEVICE - OPTIONAL RR200...74
2 ENGINE DISASSEMBLY 16
3.8 PRIMARY GEAR AND CLUTCH UNIT........................... 75
2.1 CLUTCH/GEARSHIFT OIL DRAIN................................. 16 3.8.1 CHECK OF PRIMARY GEAR....................................................... 75
2.2 REMOVAL OF PINION SPACER ................................... 16 3.8.2 PRIMARY GEAR APPLICATION.................................................. 75
3.8.3 CHECK OF CLUTCH CASE, ROLLER BEARING AND
2.3 REMOVAL OF PISTON, CYLINDER AND HEAD......... 17 INTERNAL CENTRE BEARING................................................... 76
2.4 REMOVAL OF IGNITION UNIT..................................... 19 3.8.4 CLUTCH DISC CHECK.................................................................. 77
2.4.1 FLYWHEEL COVER PLATE REMOVAL...................................... 19 3.8.5 CHECK OF SPRINGS ................................................................... 78
2.4.2 STATOR REMOVAL......................................................................... 20 3.8.6 CHECK OF CLUTCH DRUM AND PRESSURE PLATE........ 78
2.4.3 FLYWHEEL REMOVAL................................................................... 20 3.8.7 CHECK OF THRUST BEARING DEVICE AND CLUTCH
2.4.4 REMOVAL OF PICK-UP UNIT..................................................... 21 ACTUATOR........................................................................................ 79
3.8.8 ASSEMBLY OF CLUTCH UNIT AND CLUTCH ACTUATOR....80
2.5 REMOVAL OF ELECTRIC IGNITION - ONLY RR200.. 22
2.5.1 REMOVAL OF START MOTOR.................................................... 23 3.9 COOLANT LIQUID PUMP AND
CENTRIFUGAL UNIT.......................................................85
2.5.2 BENDIX COUPLING REMOVAL................................................. 23
3.9.1 CHECKING THE PUMP UNIT AND DISASSEMBLY,
2.6 REMOVAL OF COOLANT LIQUID PUMP, CLUTCH CENTRIFUGAL UNIT AND IDLER UNIT ................................86
UNIT, MAIN GEAR, CENTRIFUGAL UNIT, GEARSHIFT
3.9.2 CENTRIFUGE UNIT GROUP ASSEMBLY .............................. 87
DRIVE PARTS, KICKSTART ............................................ 24
3.9.3 PUMP UNIT ASSEMBLY .............................................................89
2.6.1 COOLING LIQUID PUMP REMOVAL...................................... 28
3.9.4 ASSEMBLY OF COMPLETE CLUTCH COVER AND
2.6.2 REMOVAL OF CENTRIFUGAL UNIT AND LEVERAGE....... 29
PUMP UNIT.....................................................................................90
2.6.3 CLUTCH DISASSEMBLY AND REMOVAL............................... 31
3.10 OUTER CLUTCH COVER COUPLING.............................92
2.6.3.1 CLUTCH DISASSEMBLY............................................................... 33
2.6.3.2 CLUTCH ACTUATOR DISASSEMBLY........................................ 36 3.11 ELECTRIC IGNITION UNIT - ONLY RR200 - ..............93
2.6.4 PRIMARY PINION REMOVAL..................................................... 37 3.11.1 BENDIX COUPLING CHECKS ..................................................93
2.6.5 PEDAL KICK STARTER - OPTIONAL RR200.......................... 38 3.11.2 IGNITION UNIT COUPLING TO ENGINE .............................93
2.6.6 EXTERNAL GEARSHIFT DRIVE UNIT.......................................40 3.12 IGNITION SYSTEM........................................................... 95
2.7 INTAKE SYSTEM.............................................................. 41 3.12.1 CHECK OF IGNITION SYSTEM ................................................95
3.12.2 COUPLING OF IGNITION SYSTEM TO CRANKCASE........95
2.8 CRANKSHAFT, GEARSHIFT UNIT AND INTERNAL
GEARSHIFT CONTROL...................................................42 3.13 POWER UNIT...................................................................98
2.8.1 OPENING THE CRANKCASE.....................................................42 3.13.1 CHECK OF THE PISTON AND ELASTIC BANDS.................98
2.8.2 CRANKSHAFT..................................................................................43 3.13.2 CYLINDER CHECK.........................................................................99
2.8.3 INTERNAL GEARSHIFT DRIVE UNIT AND COMPLETE 3.13.3 PISTON CYLINDER COUPLING PLAY.................................. 100
GEARSHIFT......................................................................................43 3.13.4 EXHAUST VALVE UNIT DISASSEMBLY AND CHECKS.... 100
TABLE OF CONTENTS
ENGLISH
3.13.5 EXHAUST VALVE UNIT ASSEMBLY........................................ 102
3.13.6 PISTON, ELASTIC BANDS, PIN BOLT AND CYLINDER
ASSEMBLY .................................................................................... 105
3.13.7 CHECK OF CRANKCASE/CYLINDER GASKET
THICKNESS....................................................................................107
3.13.8 HEAD APPLICATION.................................................................. 108
3.13.9 EXHAUST VALVE ADJUSTMENT............................................. 108
3.14 CHECK OF INTAKE UNIT AND ASSEMBLY...............112
3.15 INSERTION OF PINION SPACER AND APPLICATION
OF THE OIL EXHAUST CAP.........................................115
4 ENGINE REASSEMBLY IN THE VEHICLE 116
TABLE OF ENGINE COMPONENTS TIGHTENING TORQUES 126
TABLE OF FRAME/ENGINE FASTENING TORQUES 129
TABLE OF SUPERSTRUCTURE TIGHTENING TORQUES 129
RECOMMENDED ENGINE MAINTENANCE 130

INTRODUCTION www.betamotor.com
INTRODUCTION
This publication is intended for workshops specialised in repairing motorbikes and motorcycles. Where
required, use special Betamotor tools.
Use Betamotor spare parts only. For their codes refer to the spare parts manual for the specific vehicle
or version.
The warranty and liability on vehicle safety lapses when maintenance or repair:
• Are NOT performed by workshops specialised in repair of motorbikes and motorcycles;
• Are NOT carried out carefully by following the requirements contained in the technical documentation;
• Are NOT carried out by using special Betamotor tools, where required;
• Are NOT carried out by using Betamotor official spare parts.
Carefully read this manual in its entirety before working on the engine. Sufficient knowledge of the com-
ponents that make up the engine and of all the procedures to be followed for inspection and mainte-
nance contribute to lengthen the life of the engine.
The paragraphs feature schematic illustrations highlighting each topic in order to make the text immedi-
ately understandable.
Informative note
Betamotor S.p.A. is committed to a policy of ongoing improvement of its products. This is why you might
notice slight differences between the content of this document and the vehicle on which you are about
to carry out repairs and/or maintenance. Betamotor S.p.A. models are exported to a number of countries
where there are different rules concerning the Highway Code and vehicle type-approval procedures. Bet-
amotor S.p.A. therefore reserves the right to modify its products and technical documentation at any time
without prior notice, thank you for your understanding.
We respect and defend the environment

All that we do has an impact on the whole Planet and its resources. Betamotor S.p.A., wishing to
safeguard the interests of the entire Community, would like to make customers and technical opera-
tors aware of ways of using the vehicle and of disposal of its parts in total compliance with standards
in force in terms of environmental pollution, waste disposal and recycling.
SAFETY
Carbon monoxide Engine oil
• Exhaust gases contain carbon monoxide, which • Motor oil can cause skin conditions if it remains
is poisonous. Carbon monoxide may cause loss in contact with the skin often and for prolonged
of consciousness and lead to death. If the en- periods.
gine needs to be started, make sure the loca-
tion is well-ventilated. Never start the engine
• In case of contact with engine oil, wash with
soap and water as soon as possible.
indoors.
• The engine can be started indoors only if fitted • In case of contact with the eyes, rinse them
with plenty of water and seek medical advice.
with the appropriate exhaust gas extraction de-
vices. • If swallowed, do not induce vomiting in order
to prevent the product from entering into the
Petrol lungs; seek immediate medical advice. If you
• Petrol is extremely flammable and can be ex- believe the product has entered the lungs, take
plosive under certain conditions. the person concerned to hospital immediately.
• Keep sources of heat, sparks and flames away • Waste oil contains dangerous substances that
from the work area. are harmful for the environment. In order to
change it one must be equipped for disposal,
• Always work in a well-ventilated area. in compliance with applicable laws.
• Never use petrol as a solvent for cleaning. Do • Do not discard waste oil into the environment.
not handle it unless strictly necessary.
• Keep out of the reach of children.
• Never use petrol to clean components by means
of compressed air.
• Keep out of the reach of children.
2
INTRODUCTION
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Coolant liquid • Do not remove the radiator cap when the en-
gine is still hot. Since the coolant is pressur-
• In some situations, the ethylene glycol con- ised, it may spurt out violently and cause burns.
tained in the coolant is flammable and its flame
is invisible. Should ethylene glycol catch fire, it • The coolant contains dangerous substances
can cause burns even though its flame is invis- that are harmful for the environment. In order
ible. to change it one must be equipped for disposal
in compliance with applicable laws.
• Do not bring the coolant into contact with hot
parts. These parts could be hot enough to cause • Do not disperse coolant into the environment.
the liquid to ignite. • Keep out of the reach of children.
• The coolant (ethylene glycol) may irritate the
skin and is poisonous if swallowed.
• Should the coolant come into contact with the Hot parts
skin, immediately remove contaminated cloth- • The engine and the exhaust system get very hot
ing or footwear and wash with soap and water. and remain at that temperature for a long time,
In the event of contact with the eyes, rinse with even after the engine has been turned off. Wait
plenty of clean water and seek medical advice for them to cool down before handling these
immediately. Should it be swallowed, do not parts or carrying out work on areas around
induce vomiting in order to prevent the prod- them. Wear insulated gloves.
uct from entering the lungs. Administer clean
water, immediately take the person concerned
to hospital, and show this product to hospital
staff.
• In the event of exposure to a high concentra-
tion of vapours, move the person concerned to
an uncontaminated area and seek medical ad-
vice if necessary.
WARNINGS
The information contained in this paragraph is important to ensure the operations carried out
on the engine are performed without causing damage.
• Before disassembly, thoroughly clean the mo- • Always replace parts such as gaskets, O-rings
torcycle. and safety washers with newly supplied parts.
• While disassembling it, clean all the parts and • When loosening or tightening nuts or screws,
place them in containers accurately following always start with the larger ones or from the
the order of disassembly. centre. Always adhere to the specified tight-
ening torques.
• Always use special tools wherever necessary
and when required. • Use only Betamotor original spare parts.
• Always use glues, sealant and lubricants
wherever required. Follow the indications con-
cerning their technical features.
3
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ENGINE TECHNICAL SPECIFICATIONS

ENGINE
CHARACTERISTIC DATA ENGINE

RR125 RR200
Bore [mm]/Stroke [mm] 54 x 54.5 62 x 63
Displacement [cm³] 124.8 190
Compression ratio 15:1 13,6:1
TRANSMISSION
RR125 / RR200
Primary 23/73
1st gear ratio 12/33
2nd gear ratio 15/31
3rd gear ratio 17/28
4th gear ratio 19/26
4
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SPECIAL EQUIPMENT
ENGINE
Symbols
1. Crankcase uncoupler code 007.14.010.80.00
2. Clutch blocking tool code 035.14.000.80.00 6Nm
3. Primary blocking tool code 035.14.006.50.00
4. Crankcase/Cylinder gasket check plate RR125 code 007.44.010.00.00 Value
4. Crankcase/Cylinder gasket check plate RR200 code 035.14.009.00.00 Tightening torque
5. Flywheel blocking tool code 026.14.005.50.00
6. Flywheel extractor code 36.25173.000
7. Special wrench code 026.44.029.00.00 Medium-strength
8. Special wrench code 007.44.035.00.00 thread locker
9. Engine universal tool code 36.25132.000
10. Engine support code 035.14.008.80.00
High-strength
thread locker
Silicone paste
Grease
5
1 1 ENGINE REMOVAL FROM VEHICLE
• Carefully wash the vehicle;
ENGINE REMOVAL FROM VEHICLE
• Remove the engine guard plate;

• Place the vehicle on an adequate stand .
To dismantle the tank from the vehicle it is nec-

essary to remove the seat, disconnect the tank
ventilation pipe, position the fuel valve on OFF
and disconnect the fuel pipe from the valve.
ATTENTION!
Perform the operation with the engine cold and
in a well-ventilated area.
ATTENTION!
Fire hazard! Fuel is easily flammable.
Do not carry out the operation near

open flames or lit cigarettes and al-
ways turn off the engine.
Wipe off any traces of spilled fuel imme-

diately.
Remove the screw 1 fastening the tank to the

frame, and the screws 2 (one per side) fastening
the side panel to the radiator.
6
Lift the tank slightly and:
• remove the pipe 3;
1

3
• disconnect the connector 4;
Lift the tank from the back and remove it back-

wards.
7
1
ENGINE REMOVAL FROM VEHICLE • Remove the frame guards 5 (one on each
side) and the pinion guard 6.
5
6
• Remove the circlip 7 and extract the pinion.

Rest the chain against the upper wedge 8.
7 8
• Remove the screw 9.
• Remove the screws 10.

• Remove the silencer from the vehicle.
• Remove the exhaust pipe.

10
8
11
• Drain the cooling system by means of the
screw 11 and let the liquid outflow into a
container (the cooling circuit contains 1.3l of
liquid). Remove the radiator cap.
1

• Disconnect the water pipes from the engine.
• Disconnect the spark plug cap, disconnect the

engine electrical system connectors from the
central system. Cut all straps binding the en-
gine's electric system to the vehicle.
• Disconnect the engine ventilation pipes.
• ONLY RR200 Remove the start motor cable

fixing nut.
9
1
ENGINE REMOVAL FROM VEHICLE • Pull the clutch lever and hold it in position,
for example by using a plastic clamp.
• Remove the threaded fitting 12.

12
ATTENTION!
The clutch fluid is highly corrosive,

therefore be careful not to drop any
of it on the painted parts of the
vehicle.
Protective gloves must be worn to

perform this operation.
ATTENTION!
Do not bring the liquid in contact
with skin, eyes or clothing.
In case of contact:
- with eyes, rinse them immediately
with water and week medical advice.
- with skin, clean the concerned
areas immediately with soap and
water. Change the clothing that
came into contact with the liquid.
10
• Remove the head connections.
1

• Release and remove the brake pedal return
spring 13. Remove the kick starter lever.
13
• ONLY RR 200 Pull out the mixer tube 14 from

15 the intake manifold and tube holes 15.
14 15
WARNING!
When the mixer tube has been disconnected,
plug it to prevent emptying.
11
1
ENGINE REMOVAL FROM VEHICLE • Loosen the carburettor straps from the air fil-
ter sleeve and from the manifold.
• Remove the subframe lower fixing screws

17 16 (one on each side) and loosen the upper
screws 17 (one on each side).
16
• R otate the entire filter box unit.
12
• Disconnect the connector 18 and open the
metal clamp indicated.
1
18

• Only on RR 200, cut all the indicated straps.
• Disconnect the connector 19.
19
• Remove the carburettor, leaving it connected

to the gas cable.
13
1
ENGINE REMOVAL FROM VEHICLE • Remove the brake light wiring A and starter
motor cable B from the carburettor.
14
20
• Remove the upper shock-absorber pin 20.

• Remove the swingarm pin 21. Pull the entire
wheel/swingarm unit outwards.
21
• Remove the gear lever 21 and the engine pins

22.
22 21
15
2 2 ENGINE DISASSEMBLY
Secure the engine to the specific support stand
ENGINE DISASSEMBLY
code 3625132000 by means of front fixing

035.14.008.80.00, in order to work in comfort
and safety. Then proceed as follows.
2.1 CLUTCH/GEARSHIFT OIL

DRAIN
Remove screw 1 and let the oil drain.
1
2.2 REMOVAL OF PINION

SPACER
1
Take out the spacer 1.
Remove the O-ring 2.
16
1
2.3 REMOVAL OF PISTON, CYL-
INDER AND HEAD 2
Remove the spark plug 1 and the spigot screws
2 together with the copper washers. Remove the
ENGINE DISASSEMBLY
2 head and the two O-rings.
Remove the three screws 3 and cover 4.

3
Release the lock 5 and remove it.
17
2 7 A
Release the control rod 6.
Remove the gasket 7. It may be necessary to

slightly force the rubber gasket 8; place a metal
pin A between the lever and the gasket 8 and
slightly force it outwards.
ENGINE DISASSEMBLY
Removal of gasket 7.
Remove the four collar nuts 9.

Extract the cylinder and the base gaskets.
ATTENTION!
Place a clean cloth between the piston and the
crankcase to keep foreign objects or simple solid
residues from falling inside the base.
Using a suitable tool to insert the specific seat A,

10 remove the elastic ring 10.
Removal of piston circlip.
18
Remove the pin bolt using a universal extractor
for pin bolts.
Remove the piston, the pin bolt and the bearing
from the connecting rod foot.
2
ENGINE DISASSEMBLY
Disassembling the piston pin bolt.
2.4 REMOVAL OF IGNITION

UNIT
The ignition unit consists of the flywheel (or ro-
tor), the pick-up and the stator which is one with
the flywheel cover.
2.4.1 Flywheel cover plate re-

moval
1
Remove the plastic straps that join the stator and
pick-up wiring.
Remove the four screws 1 fastening the flywheel

cover 2 to the left crankcase.
Remove the flywheel cover and the gasket placed
between the crankcase and the cover.
Fixing screws 1 of flywheel cover 2.
19
2
ENGINE DISASSEMBLY Pay attention to the two centring pins 3 on the
crankcase.
The two designated references pins (3) for the flywheel

cover.
2.4.2 Stator removal

4
1
Remove the two screws 1 fixing the stator 2 to
the flywheel cover 3. Extract the plate 4 and the
cable gland 5 from the cover and take out the
stator.
2
3
Disassembly of stator from cover.
2.4.3 Flywheel removal

Block the flywheel using the special tool A (code
026140040000) and remove the tightening nut
securing the flywheel to the crankshaft.
Note: Once the nut has been unscrewed, pay

attention to the special elastic washer placed
between the nut and flywheel.
Removal of flywheel nut.
20
B
To remove the flywheel, tighten the extractor B
(code 3625173) onto the threaded part on the
flywheel.
Keep the extractor blocked with a spanner and
2
tighten the screw on the extractor using a box
spanner.
ENGINE DISASSEMBLY
Release of flywheel using special tool B.
2.4.4 Removal of pick-up unit
2 Remove the pick-up unit 1 by loosening the two

fixing screws 2.
Pick-up removal.
21
2 2.5 REMOVAL OF ELECTRIC IG-
NITION - ONLY RR200
The electric ignition is carried out by means of
start motor 1 that meshes on the bendix coupling
ENGINE DISASSEMBLY
4. The coupling gear axially shifts and meshes

onto the ring gear, which is one with the flywheel,
due to the start motor rotation. The coupling gear
retracts to its rest position, once the motor action
ends.
EXPLODED VIEW OF ELECTRIC KICKSTART

1) Start motor;
2) O-ring;
3) Screws;
4) Bendix coupling;
5) Bush with collar.
22
2.5.1 Removal of start motor
Remove the two screws 1 and extract the motor.
2
ENGINE DISASSEMBLY
1
2.5.2 Bendix coupling removal

Extract the Bendix coupling 1 once the complete
flywheel cover and flywheel have been removed
(see par. 2.4).
23
2 2.6 REMOVAL OF COOLANT
LIQUID PUMP, CLUTCH
UNIT, MAIN GEAR, CEN-
TRIFUGAL UNIT, GEAR-
ENGINE DISASSEMBLY
SHIFT DRIVE PARTS, KICK-

START
Remove the cover 1 by loosening the four screws
2, to access the coolant liquid pump.
Note: remove the coolant liquid pump impeller

if work needs to be done on the centrifugal unit.
Coolant liquid pump cover screws.
24
Remove the outer clutch cover 3 by loosening the
four screws 4 to access the clutch unit only.
2
ENGINE DISASSEMBLY
3
Outer clutch cover screws.
25
2 When doing a complete overhaul of the engine or
of gearshift drive parts, kickstart, primary trans-
mission or centrifugal unit, the inner clutch cover
5 must be removed by loosening the nine screws
6 after draining the gear oil (Par.2.1).
ENGINE DISASSEMBLY
Inner clutch cover screws.
26
A
Pay attention to the two reference pins A placed
between the right crankcase half and the inner
clutch cover while disassembling. 2
ENGINE DISASSEMBLY
Two centring pins A for inner clutch cover coupling.
27
2 1
2.6.1 Cooling liquid pump re-
moval
Loosen the fixing screw 1 once the coolant liquid
pump cover has been removed (Par.2.6).
ENGINE DISASSEMBLY
Cooling pump fixing screw.
Extract the impeller 2 and the thrust washer 3.

2
Removal of impeller.
Extract the complete pump body 4 and remove gas-

ket 5.
Removal of pump body and gasket.
28
2.6.2 Removal of centrifugal unit
and leverage
Access the centrifugal unit and linkage by remov-

2
1 ing the inner clutch cover. Disassemble the adjust-
ENGINE DISASSEMBLY
ment cover 1 by removing the two screws 2, once
the pump impeller has been removed (par. 2.6.1).
Removal of centrifugal adjustment cover.

Remove the assembly consisting of adjusting
springs 3, auxiliary springs 4 and spring guide 5.
After removing the screw fixing the rocker arm 6

to the centrifugal control lever 7, extract the rock-
8 er arm with control rod and gasket 8.
6
7
Disassembly of control rod-rocker arm unit.
Extract the centrifugal control lever 7 together

with the two thrust washers 9.
9
Removal of centrifugal control lever.
29
2 Extract the complete centrifugal unit 10.
10
ENGINE DISASSEMBLY
Extraction of centrifugal unit.
7
1
3
10
6 9
4 5
1) Adjustment cover;
3) Adjusting spring;
4) Auxiliary spring;
5) Spring guide;
6) Rocker arm;
7) Centrifugal control lever;
8) Gasket;
9) Thrust washers;
10) Centrifugal unit.
30
2.6.3 Clutch disassembly and re-
moval
Remove the clutch coupling plate 1 together with
2
1 the thrusting bearing 2.
ENGINE DISASSEMBLY
2
Block the entire clutch unit using the special tool

A (code 035.14.000.80.00) as shown in the figure
and loosen the clutch locking nut.
Remove the clutch locking nut 3.
Grasp the entire clutch unit and pull it towards

you.
31
2 Remove the roller cage 4 and the centre bearing
5.
5
ENGINE DISASSEMBLY
5
7
4 3
1 2
1) Clutch coupling plate;

2) Thrusting bearing;
3) Clutch locking nut;
4) Roller bearing;
5) Centre bearing;
6) Schnorr washer;
7) Washer.
32
1
2.6.3.1 Clutch disassembly
Block the clutch case using the soft jaws vice.
Progressively loosen the screws 1 until they are
2
disengaged from their seat.
ENGINE DISASSEMBLY
Remove the spring plate 2 and the springs 3.
2
Remove the clutch hub 4 and the washer 5.
33
2
ENGINE DISASSEMBLY
7
Remove the disc thrust plate 6 together with the
disc unit 7.
After extracting these last parts, the bare clutch
case 8 remains.
The entire clutch unit is disassembled.
6
3
8
1
5
1) Screws;
2) Spring plate;
3) Springs;
4) Hub;
5) Washer;
6) Pressure plate;
7) Clutch discs;
8) Clutch case.
34
9
Note: if you want to check the wear of the
case only, you can disengage it from the
clutch pack 9 by simply lifting the clutch
pack.
2
ENGINE DISASSEMBLY
35
2 A
2.6.3.2 Clutch actuator disassem-
bly
To disassemble the clutch actuator, simply blow
compressed air from the clutch connection duct
ENGINE DISASSEMBLY
A.
ATTENTION!
During this phase, hold the piston

with one hand to allow its slow
release.
ATTENTION!

of it on the painted parts of the
vehicle.

ATTENTION!
In case of contact:
- with skin, clean the concerned
areas immediately with soap and
water. Change the clothing that
came into contact with the liquid.
Remove the complete piston and its spring.
36
2.6.4 Primary pinion removal
After removing the entire clutch unit (Par. 2.6.3),

apply the special tool A (code 035.14.006.50.00)
2
as shown in the figure.
ENGINE DISASSEMBLY
Loosen the primary pinion nut by turning clock-
wise.
A
Remove the pinion 1. Removal can be facilitated

by using a universal extractor.
37
2 1
2.6.5 Pedal kick starter - OP-
TIONAL RR200
The kick starter is made up of the pedal which,

2 attached to the kick starter shaft 1, moves the gear
ENGINE DISASSEMBLY
2. This gear moves the idler wheel 3, which engag-

es in its turn with the clutch case.
The device recoils thanks to the spring 4.
The pedal kickstart.
3 Remove the circlip 5, the thrust washer 6 and the

idler gear 3.
Removal of circlip 5, thrust washer 6 and idler gear 3.
5 6
Circlip 5 and thrust washer 6.
38
4
Pull the end A of the spring 4 from the hole on
the crankcase and bring it to a rest position hav-
ing it turn anti-clockwise. 2
ENGINE DISASSEMBLY
A
Releasing spring from crankcase.
Turn the shaft anti-clockwise and extract it to-

gether with the sleeve 9, the spring 10 and the
thrust washer 11.
Extraction of shaft from crankcase.
2 9
1
11
4 10
Complete pedal kick starter shaft.
39
2 1
3
2.6.6 External
unit
gearshift drive
The external gearshift drive consists of drive shaft 1

on which the movable and fixed pawls are applied.
ENGINE DISASSEMBLY
The fixed pawl is the guide of the movable pawl,

which has the task of engaging the stop cam 2. In its
turn, this is fastened to the internal gearshift drive
and is kept in the fixed position by the cam stop
2 lever.
In order to disassemble the drive shaft, just keep the
movable pawl return spring 3 compressed and ex-
tract the shaft together with the specific washer 4.
Gearshift drive complete with washer.
In order to disassemble the stop cam 2, keep the

cam stop lever moved 5, loosen the screw 6 and pull
out the stop cam 2.
2
6
5
Disassembly of gear stop cam.
In order to disassemble the stop lever, loosen the

screw 7 enough to allow the lever to move ax-
ially and go over the cylinder segment A of the
desmodromic device. Move the return spring 8 to
the resting position and remove the screw, the
washer 9, the spring together with the spacer, the
9 internal washer (not shown in the image) and fi-
8 nally the cam stop lever.
Disassembly of cam stop lever.
40
2.7 INTAKE SYSTEM
The intake system mainly consists of the intake

manifold 1 and reed valve 2 and the spacer 3.
2
ENGINE DISASSEMBLY
1
3
1) Intake manifold;
2) Complete reed valve;
3) Spacer.
Disassemble by removing the four screws 4 fas-

tening the intake manifold and the reed valve to
the crankcases.
Fixing screws RR125
Fixing screws RR200

41
2
ENGINE DISASSEMBLY 2.8 CRANKSHAFT, GEARSHIFT
UNIT AND INTERNAL
GEARSHIFT CONTROL
To access the crankshaft, gearshift unit and internal

gearshift control, the left and right crankcases must
be detached. Below are the required instructions.
1
2.8.1 Opening the crankcase
A
Remove the twelve screws 1 fastening the crank-
cases.
A
WARNING!
Loosen the two equipment fixing screws A.
Removal of crankcase screws.
Apply the special tool B (Code 007.14.010.80.00)

to the left crankcase half following the punching
C B on the tool. Fix the tool with the three M6x15
screws (maximum torque 10Nm). Tighten screw
C on the special tool. Slightly hit the gearshift
secondary with a rubber mallet during said op-
eration.
Once the crankcases have been detached, remove
the fixing screws to the equipment A and remove
the left crankcase.
Crankcase uncoupling stage.
Remove the two rear 2 and front 3 reference pins.

3 Remove the coupling gasket to the two crankcas-
es.
2
Crankcase half reference pins.
42
2.8.2 Crankshaft
The crankshaft 1 can be pulled out manually. Gen-
tly hit the right end of the crankshaft in case of
2
resistance.
ENGINE DISASSEMBLY
1
Removal of crankshaft.
2.8.3 Internal gearshift drive

unit and complete gear-
shift
The internal gearshift drive unit consists of desmo-
dromic device 1 on which the fork 2 and two forks
2 3 are engaged. The forks, supported by the pins 4,
drive the sliding wheels of the gearshift, allowing
4 the desired ratio to be engaged. The desmodromic
device is controlled by the stop cam located in the
external gearshift drive unit.
3 Extract the two pins 4 by hand enough to disengage
them from the crankcase half.
4
1
Removal of fork support pins 1.
Rotate the fork 2 clockwise and fork 3 anti-clock-

wise.
Extract the desmodromic device.
2 3
Disengaging the drive forks from the desmodromic de-

vice.
43
2 Extract the forks together with the guide bushes
5.
Note: it is recommended to mark the two forks

ENGINE DISASSEMBLY
that act on the secondary so that they can be

repositioned in their original position in case it
is not necessary to replace them or sliding gears.
Extraction of forks from gearshift unit.
Extract the whole gearshift unit consisting of pri-

mary 6 and secondary 7.
7
6
Extraction of complete gearshift unit: 6 primary unit,

7 secondary unit.
2.9 DISASSEMBLY OF PARTS

FROM CRANKCASES
Once the crankcases have been detached, it may
be required to remove the various components at-
tached to them.
The bearings must be replaced if there is any play

or jamming during rotation. For removal, heat the
crankcase halves for 20 minutes at about 150°C.
Place the crankcase halves on a large surface where
their whole seal surface can rest. Remove the bear-
ings by following the indications below.
44
2.9.1 Right crankcase half
On the external side, remove the kickstart ramp 1
and the oil seal 2.
2
ENGINE DISASSEMBLY
2
Kickstart ramp 1), oil seal 2).
Remove the desmodromic control bearing seal

screw 3, the screws 4 and the relative primary
bearing seal plates 5 from the inner side.
3
Bearing safety screw.
45
2
ENGINE DISASSEMBLY All bearings shown in the figure are removed from
the outside to the inside.
Where necessary, removing the safety devices 3 and
4 seen above.
The centrifugal shaft bearing can be removed by

using a universal extractor that must rest onto a
purposely created metal plate.
46
2.9.2 Left crankcase half
Remove the crankshaft oil seal 1, the secondary
shaft oil seal 2, the gearshift drive shaft oil seal 3
2
and the bush 4 from the external side.
ENGINE DISASSEMBLY
1
4 3
Removal of outer side left crankcase half details.
The bearings 5, 6, 7 and 8 are removed from the

outside inwards.
8 Remove cap 9.
7
6
9
5
Removal of left crankcase half bearings.
47
3 3 ENGINE CHECKS AND ASSEMBLY
Before reassembling the engine, a series of cru-

ENGINE CHECKS AND ASSEMBLY
cial checks must be carried out to ensure the en-

gine is in good working order.
In order to insert the bearings in the crankcase
halves, bring the crankcase halves to a tempera-
ture of 150°C and keep them at that temperature
for 20 minutes.
Place said crankcase halves on a large surface
where their whole seal surface can rest. When the
bearings cool down, they drop into their seats on
their own.
3.1 CRANKCASE HALF

The crankcase halves have some parts that require
A care, and their integrity and condition must be
checked. The checks and assembly operations of
the individual parts coupled to the crankcases
are described below. Clean the threading and oil
passages A thoroughly by using a degreaser and
compressed air.
Crankshaft bearings lubrication holes.
48
20Nm
3.1.1 Application of right crank-
case half parts
Apply the bearings 1, 2, 3 and 4 until flush.
3
6Nm
Block the bearings 2 and 4 using the specific safe-

ty devices. Apply the high-strength thread locker
threads and tighten the screws to the indicated
1 torques.
2
3
6Nm
4
Positioning of the right crankcase half bearings.
The studs must be mounted after applying the

medium strength thread locker and tightened to
the indicated torque.
ATTENTION!
The part of root A of the stud must be mounted in
the crankcase half.
Apply the bearing 5 from the crankcase half exter-

5 nal side, until flush.
Application of bearing from right crankcase half exter-

nal side.
49
3
ENGINE CHECKS AND ASSEMBLY Apply the bearing 6 and insert it so that the outer
surface is aligned with surface A.
Apply new oil seals, to be pressed
in seat until they are flush.
A
Position of right crankcase half gearshift drive shaft
bearing.
Apply the kickstart ramp 7 and fasten screws 8 to

the torque indicated, prior depositing of medium
strength thread locker.
10Nm
8
7
Application of kickstart ramp.
50
3
2
1
3.1.2 Special applications
left crankcase half
for
Apply the bearings 1, 2, 3 and 4 from the crankcase

3
half internal side, until flush.

Apply the cap 5 (ONLY RR125).
4 5
Application of left crankcase half bearings.
Apply the new oil seals 6, 7 and 8 from the crank-

6 20Nm case half external side, until flush.
Apply the bush with collar 9 (ONLY RR200).
8
9
Application of left crankcase half parts.
Apply the studs prior depositing of medium strength

thread locker.
Tighten to the specified torque.
ATTENTION!
The part of root A of the stud must be mounted in
the crankcase half.
51
3 3.2 CONNECTING ROD AND
ENGINE SHAFT CHECK
After having checked the state of wear of the cou-
pling surfaces, check the offset of the half shaft axes
(by measuring the radial oscillation) by placing the

crankshaft in between two tailstocks or similar in-
strument. Verify the maximum measurement varia-
tion during a complete turn, using comparators posi-
tioned on the coupling surfaces with the crankshaft
bearings.
Allowed limit value: 0.02mm
Deflection/Off-centring of crankshaft.
Check the axial play between the connecting rod

head and the half shafts.
Recommended play:
0.4-0.7mm
Connecting rod axial play.
The distance between the two shoulders must be:

57±0,05.
57±0,05
Crankshaft pack.
If replacing the inserts, apply the screws with

high-strength thread locker and tighten at the
specified torque.
5Nm
Half-shoulder.
52
3.3 ASSEMBLY OF COMPLETE
CRANKSHAFT
When all the aforementioned checks have been car-
3
ried out and the worn parts replaced, grease the

crankshaft oil seal on the right crankcase half and
couple the crankshaft to the left crankcase half. Keep
the conical part A present on the crankshaft towards
yourselves. In order to carry out this operation, you
must just push the shaft axially towards the crank-
case.
Apply the two centring bushes 1 and 2.
2
A
Insertion of the crankshaft in the right crankcase half.
53
3 3.4 GEARSHIFT UNIT: CHECKS
AND REASSEMBLY
The gearshift unit is made up of a control and of the
gearshift itself. The gearshift in its turn is divided into
external and internal gearshift.

The checks and procedures for inspecting and reas-
sembling these units to the engine are set out below.
3.4.1 Check of gearshift unit

While holding the gearshift units horizontal, use a
thickness gauge to check the axial play between
the gearshift forks and the gearwheels. The meas-
ured play must not exceed the service limit indi-
cated below:
service limit: 0.4mm
If the detected axial play is greater, before replac-

ing either the gearwheels or the forks, check their
state of wear (Par. 3.4.4)
Use protective jaws to clamp the main shaft and
secondary shaft.
Remove the various elements and check that:
• the support surfaces of the main shaft and

secondary shaft show no abnormal wear or
signs of seizure;
• the sides of the teeth are free from chipping
or abnormal wear;
• the sliding areas of the gearwheels show no
Check of wear of forks and gearwheels. abnormal wear or traces of seizure;
• the front claw clutches of the gearwheels are
not chipped or rounded;
• the roller bearings are intact and efficient;
• none of the thrust washers show traces of ab-
normal wear or meshing.
Should any of these defects be found, replace the

concerned parts.
Check gear couplings.
54
3.4.2 Assembly of primary unit
Before proceeding with reassembly, clean all the
elements thoroughly and oil them with gear oil.
3
Always replace the circlips.

Clamp the main shaft 1 (using protective jaws),
Apply the roller bearing 2.

2
Apply gear 3 (V gear), washer 4 and circlip 5.
Insert gear 6 (III – IV gear) and circlip 7, taking care

7 to place it in groove A.
55
3 Apply the toothed washer 8 so that it engages in
the broaching and the roller cage 9.
9
Insert the gears 10 (VI gear) and 11 (II gear).

11
10
Insert the washer 12.

12
56
3

EXPLODED VIEW OF PRIMARY UNIT:
2) Gearshift main shaft;

3) Roller cage 18x22x10;
4) Thrust washer 17.25.1;
5) Fifth gear on primary;
6) Second gear on primary;
7) Washer 22.28.1;
8) Circlip SW 22.1,2;
9) Washer 22.26.1;
10) Third and fourth gear on primary;
11) Sixth gear on primary;
57
3 3.4.3 Secondary unit assembly
Before proceeding with reassembly, clean all the
parts thoroughly and oil them by using gear oil.
Always replace the circlips.
Clamp the secondary shaft (using protective

jaws), as shown in the image.
Apply the roller cage 1.
Insert gear 2 (II gear), washer 3 and circlip 4.
Insert the gear 5 (VI gear) and circlip 6.
58
Insert washer 7 and the two roller cages 8.

8
Insert gear 9 (IV gear).
Insert gear 10, washer 11 and circlip 12.

11
12
10
59
3
14
Insert the gear 13 (V gear) and washer 14.
13
Insert roller cage 15 followed by gear 16 (I gear) and

washer 17.
15
17
16
60
3

EXPLODED VIEW OF SECONDARY UNIT:
1) Secondary shaft;
7) Second gear on secondary;
8) Washer thickness;
9) Circlip 24 SW;
10) Sixth gear on secondary;
11) Fourth gear on secondary;
12) Third gear on secondary;
13) Fifth gear on secondary;
14) Washer thickness C72 20.30.1;
16) First gear on secondary;
17) Thrust washer 17x30x1
61
3
ENGINE CHECKS AND ASSEMBLY 3.4.4 Check of the forks, fork
pins and desmodromic de-
vice
The internal gearshift is made up of:
• two gearshift drive forks 19 which drive two

gears on the secondary unit;
• one gearshift drive fork 20 which drives one
gear on the primary unit;
• three drive pin bushes 18;
• two gearshift drive fork pins 17;
• desmodromic drive 9 through whose rotation
the gearshift forks are driven thus selecting
the desired gear.
EXPLODED VIEW OF INTERNAL GEARBOX CONTROL Make sure that the guide pins that support the
UNIT: bushes 18 have no traces of meshing or abnormal
19) gearshift drive fork;
wear and that the bushes are not worn.
20) gearshift drive fork;
18) bush;
17) gearshift drive fork pin;
9) desmodromic control
62
A
Make sure the distance A between the outer fac-
es of the fork is not less than the value indicated
below: 3
Minimum acceptable distance: 4.95mm

Check to make sure that the inside diameter D of
the fork pin seats is below the limit:
Fork inside diameter limit: 13.83mm
Make sure that the fork pins on which they slide

have an outside diameter above the limit (to be
measured in the sliding areas of the forks and in
the housing areas with the crankcases):
Fork pin outside diameter limit: 13.75mm
ID
Guide pin
Roll the fork pin on a perfectly flat surface: if

deformations are present, proceed with replace-
ment.
Slide the gearshift drive forks on the respective
pins: if the movement is difficult and jamming oc-
curs, replace both the fork and the pin.
Fork pin check.
Make sure that the desmodromic control device

has no corroded or worn areas especially in the
grooves in which the guide pins of the forks are
engaged.
Check the bearing on the desmodromic device.
Replace it in the event of signs of meshing or
jams during motion.
Check fork sliding on pin.
63
3 3.4.5 Assembly of gearshift and
inner control
Insert the entire primary 1 and secondary unit 2

2
into the respective seats on the left crankcase half
1 simultaneously. Remember to oil all components

with plenty of gear oil.
Insertion of the gearshift in the left crankcase half.
Introduce the gearshift drive forks together with

the drive bushes on the gear tracks. To be precise;
the smaller fork 3 drives the sliding gear on the
primary unit, while the other two (4) drive the
4
sliding gears on the secondary unit.
3 Note: the two forks 4 are interchangeable and

their positioning is univocal, since the guide pin
must face the desmodromic device. Place the
forks in their original positions if none of the
components are replaced.
Application of forks to gearwheels.
Insert the desmodromic device in the specific

bearing.
Insertion of desmodromic device in the specific

bearing.
64
Position the fork 4 of the primary unit in the cen-
tral guide of the desmodromic device 6, insert the
fork pin inside the fork and insert the pin in its
specific seat in the crankcase half.
3
4

6
Place fork 4 of the primary unit in the central guide of

desmodromic device 6.
Position the two forks 5 of the secondary unit in

the external guides of the desmodromic device 6
and, just like the primary unit fork, insert the fork
pin first in the pins and then in its proper seat.
Remember to oil the shafts, forks and the desmo-
dromic device with plenty of gear oil.
Apply some grease on the crankcase edge in the

5 mating area with the gasket and place a new gas-
ket.
6
5
Positioning of the secondary unit forks 5. In the external

guides of desmodromic device 6.
65
3
View inside the right crankcase with crankshaft, gearshift shafts complete with wheels, internal gearshift drive and
gasket.
66
3.5 CLOSING
CRANKCASE
THE ENGINE
Apply a thin layer of grease on all oil seals.

3
Warm up the crankshaft bearing on the left crank-

case half.
ATTENTION!
Take care not to burn the oil seal.
To avoid this, protect it with paper or metal buffer
with an outer diameter of 24mm.
Press the left crankcase half towards the right,

making sure that the shafts and pins on the crank-
cases fit into the respective housings and that the
crankcase half is not offset.
By heating the bearing it will be possible to man-

ually move close to the right crankcase half.
Put the clamping screws in place based on length,

as pictured.
The table below contains indications for applying
the screws.
Positioning of crankcase coupling screws.
Screw size
Thread locker Tightening torque
Screw number Threading
Threading length application [Nm]
diameter
8 M6 40 NO 10
9 M6 50 NO 10
Proceed with tightening according to the order in

x the figure.
Attention: screw “X” must be tightened later in
9 7 conjunction with the assembly of the cylinder
(Par.3.13.7).
4 2
Cut the extra piece of gasket between the two
1
crankcase halves in the area of the cylinder and
6 5 reed valve seat.
3
8
11 10
At the end of the operation, use a rubber mal-
let to position the crankshaft by striking both the
right and left half shafts until the shaft rotates
freely.
Crankcase half tightening order.
67
3 3.6 EXTERNAL
DRIVE
GEARSHIFT
Before reassembling the external gearshift drive,

check its state of use. While for the stop cam it
is enough to make sure it is free from abnormal

wear or meshing, the gearshift drive shaft needs
more in-depth inspections.
3.6.1 Check of the whole gear-

shift shaft
0.35-0.50 With the device complete, make sure that the dis-
tance between the movable pawl and the drive
shaft is between 0.35-0.60mm.
Should the distance be greater, replace the mov-
able pawl.
Allowed distance between shaft and pawl.
In order to replace the movable pawl 1, disas-

1 4 semble the return spring of the gearshift drive 2,
2
the spring guide 3, the spring 4 (which must be
compressed and pulled out of its seat) and the
pawl, moving it completely towards the shaft 5.
3 5
Complete drive shaft: 1) Movable pawl; 2) Gearshift

drive return spring; 3) Spring guide; 4) Spring; 5) Gear-
shift drive shaft.
68
3

Exploded view of gearshift drive. For reassembly, couple the movable pawl 9 to
5) 14x30x1 thrust washer; the drive shaft 10 and, while compressing it, in-
6) Gearshift drive return spring;
sert the spring 8 between the movable pawl and
7) Spring guide;
8) Pawl return spring; the drive shaft. Then apply the spring guide 7,
9) Movable pawl; the gearshift drive return spring 6 and finally the
10) Gearshift drive shaft. thrust washer 5 (14x30x1).
The gearshift drive return spring must be posi-

tioned as in the figure to be able to carry out its
function.
Gearshift drive shaft: note the gearshift return spring

position.
69
3
ENGINE CHECKS AND ASSEMBLY 3.6.2 Assembly of external gear-
shift drive
Apply the gear stopping device as follows.
Keeping the tightener on the lever 16 facing to-

wards the crankcase half, apply the spacer 15
onto it, by inserting the smaller diameter seg-
ment in the lever. Apply the spring 14 so that the
hook fits into the groove on the lever 16 and then
apply the washers 13 and the screw 11 M6x20,
spreading with medium strength thread locker on
the thread.
Stopping device.
Apply the entire device on the crankcase half so

that the straight segment of the spring rests on C.
Tighten the screw to the indicated torque.
10Nm
At the end of the assembly, check that the lever

can rotate freely. If it is blocked, repeat the as-
sembly as described above.
70
2
Keeping the stop lever moved 1 in such a way
that the spring is compressed, position the stop
cam 2 on the protruding end of the desmodromic
control. The stop cam has only one correct posi-
3
tion, which is determined by the specific shape
of the end of the desmodromic device and of the

bottom part of the stop cam.
10Nm 1
Fit the screw after having applied medium-strength
thread locker: tighten to the indicated torque.
Insert the gearshift drive shaft together with the

washer in its seat keeping the return spring 4 of
the movable pawl pressed.
Should you wish to test correct operation of the

4
entire gear unit, just temporarily couple the exter-
nal gearshift lever and simulate the operation of
changing gears, by lifting and lowering the gear-
shift lever and having the main shaft of the gear-
shift unit rotate. The whole device works properly
if no abnormal jamming occurs.
Please note that if the unit operates without oil,

the device is noisier than usual.
Positioning of external gearshift device components.
71
3 3.7 KICKSTARTER DEVICE
OPTIONAL RR200
Before coupling the kick starter to the crankcase
-
half, some important checks must be carried out.

3.7.1 Check of starter shaft unit

and assembly
In order to disassemble all the parts of the kick-

start shaft, pull off the washer 9 at the end of the
shaft (on the side of the spring 16), the spring 16,
the kickstart sleeve 14 and the lever return spring
8, which must be pulled in the radial direction so
that it is extracted from its hole to be unfastened
from the shaft.
EXPLODED VIEW OF COMPLETE KICKSTART SHAFT:

2) Kickstart gear;
3) Kickstart shaft;
8) Kickstart return spring;
7) Kickstart spacer;
10) Retainer ring 17x1;
11) Washer;
14) Kickstart sleeve;
16) Spring.
72
14
Remove the kickstart spacer 7, expand the circlip
10, allowing removal of washer 11, of kickstart
gear 2 and washer 11. This frees the kickstart
shaft 3 from all other parts.
3
Make sure that the side of the kickstart gear teeth
2 has no signs of meshing or notable superficial

wear. Make sure that the front teeth (sleeve side
14) are not chipped. Replace any part that shows
the aforementioned defects.
Positioning of sleeve on small shaft. Make sure that the front teeth of the sleeve 14
are not chipped and that the spring 16 is capable
of exerting enough pressure on the sleeve 14 so
that this can pull the wheel 2.
Also check to make sure that no washers have
any abnormal or excessive wear. If so, replace
them. Make sure that the spring 8 has no cracks
or abnormal deformation. Replace if it is not able
to bring the external kickstart lever back to the
rest position.
For reassembly, follow the above disassembly
procedure in reverse order.
Pay attention:
7 • to the correct positioning of the spacer 7 (the
area with the groove must go outwards);
• to the alignment of the reference between
shaft 3 and sleeve 14.
73
3 3.7.2 Assembly of kick starter
device - OPTIONAL RR200
Insert the complete kickstart shaft in its housing,
keeping the ribbed facing outwards and making
sure that the lever A on the kickstart sleeve is po-

B sitioned below the lever B bolted onto the right
crankcase half (external side).
Positioning of sleeve A below lever B.
Turn the spring clockwise until it fits into the spe-

cific hole C.
Insertion of kickstart return spring.
Insert in the slot on the protruding segment of

1 the secondary shaft: the idler wheel 1 followed
by the washer 2 and the circlip 3 as shown in the
figure.
Kickstart device unit coupled to the crankcase.
74
3.8 PRIMARY
CLUTCH UNIT
GEAR AND
Before reassembling the clutch unit, carry out

3
some checks on the various components de-

scribed below.
3.8.1 CHECK OF PRIMARY GEAR

Check teeth of primary gear is without nicks or
abnormal wear. If so, replace it
3.8.2 PRIMARY GEAR APPLICA-

TION
Apply the O-ring 18, and gear 14 on the right half
shaft so the appropriate groove inserts inside the
Woodruff key 17. Apply lock nut 15 after applying
medium strength thread locker. Fastening torque
must be as shown in the figure.
160Nm
Exploded view of pinion unit.
This operation is possible using the special pri-

mary tool A (code 035.14.006.50.00).
ATTENTION!
The nut is fastened anti-clockwise.
Tightening of the primary gear nut.
75
3 3.8.3 Check of clutch case, roller
bearing and internal cen-
tre bearing
For complete disassembly, see Par. 2.6.3.
Before reassembling the clutch case, make sure

that the sides of the teeth A, dedicated to main
transmission and B, dedicated to meshing with
the kickstart idler gear and oil pumps, have no
superficial nicks or abnormal wear.
Also closely check that the teeth C, upon which
the driving discs engage, are not chipped or deep-
CLUTCH CASE: ly cut.
A. Teeth meshing with primary gear; Check the external surface D does not show trac-
B. Teeth meshing with kickstart idler gear; es of meshing or abnormal wear.
C. Teeth meshing with driving discs; If any damage is found, have the piece replaced.
D. External washer.
D
A
76
Check the state of use of the silent-blocks as fol-
lows. Clamp gear B using protective elements and
impose a rotation to the clutch case. If there is
play between the case and the gear unit, replace
3
the clutch case.
Check the condition of the internal centre bear-

ing 1 which must show no traces of meshing or
abnormal wear.
Check the condition of the roller bearing 2. If
worn, it must be replaced.
1 2
Internal centre bearing and roller bearing of clutch

case.
3.8.4 Clutch disc check
The clutch discs are divided into driving and driv-

en: seven driving discs and six driven discs of
which four in aluminium and two in steel.
The driving discs have cork inserts on both sides
which wear out due to the driven discs sliding on
them.
Make sure that the thickness between the two
inserts positioned on the opposite faces of each
driving disc is not below the minimum value fixed
at:
minimum distance between two opposite in-

serts: 2.8mm
Minimum distance between two opposite inserts.
The other measurement that needs to be checked

is the thickness of the teeth of each driving disc,
which must not be less than the minimum set at:
minimum driving disc tooth thickness: 13.3mm
Minimum driving disc tooth thickness.
77
3 Also check the distortion of the driven discs. This
operation is carried out by placing the driven discs
on a perfectly flat surface and using a thickness
gauge to check that any gap between the disc and
the surface is not greater than:
allowable distortion
driven discs: 0.10mm
Measuring driven disc distortion.
3.8.5 Check of springs

To assure the correct pressure between the
clutch discs, the condition of the springs must be
checked. The minimum acceptable length must
be: 38mm.
Clutch spring length measurement.
3.8.6 Check of clutch drum and

pressure plate
The clutch drum and pressure plate mesh with
the clutch discs driven by means of teeth A and
with the driving discs by means of surfaces B.
Check that:
• The teeth A and the surfaces B do not have
abnormal gears or wear shapes. If so, replace
the worn details;
A • The radial holes C on the clutch drum are not
clogged and are free from sediments.
C B
Check of clutch drum teeth.
78
3.8.7 Check of thrust bearing
device and clutch actuator
Check the state of use of the thrust bearing and
3
the surfaces A and B.

A B
Thrust bearing device.
In order to check the thrusting bearing, just see if

it slides. When the device is assembled, simulate
rotation of the front centre bearing C with respect
to the rear one D.
Pay attention to the presence of traces of mesh-
ing or wear on the sliding
surfaces.
C D
Check that the actuator cylinder walls E are free

from traces of meshing or abnormal wear. If worn,
replace the clutch outer cover.
E
Make sure that the piston is intact and free from

abnormal wear: otherwise, replace the piston
with the OR.
Check that the sealing ORs are intact and not

pinched: otherwise, replace them.
79
3
ENGINE CHECKS AND ASSEMBLY 3.8.8 Assembly of clutch unit
and clutch actuator
Place the clutch drum as shown in the figure.
Lubricate the clutch discs with gear oil and apply

to the clutch drum by alternating a driving disc
with a driven disc, according to the diagram in
the figure.
A
Note: the driven discs must be inserted so that
the radius on the teeth faces inwards towards the
engine.
Clutch disc assembly RR125

Key:
A - Aluminium;
S - Steel.
Clutch disc assembly RR200.
80
A
B
Apply pressure plate 1 so that reference A and
reference B match.
3

1
Overturn the assembled unit and apply springs 2,

spring plate 3 and two screws M6x25 to be re-
moved at a later stage: tighten the latter enough
to slightly compress the springs.
M6x25
Apply the washer 4 as shown in the figure.

4
81
3
ENGINE CHECKS AND ASSEMBLY Insert the assembled clutch drum unit as above,
proceeding to align the teeth of the driving discs
to the respective slots on the clutch case.
Lubricate and apply roller bearing 5 with the cen-

tre bearing to the clutch base.
Insert the entire clutch unit on the secondary

shaft of the gearshift. To facilitate insertion, it is
advisable to engage a gear and have the outlet
shaft make small rotations and, if necessary, to
the idle gear of the kick starter.
Apply the three screws M6x20 and tighten them

M6x25 with a cross pattern, until the spring plate is flush.
Remove the two previously applied screws M6x25
and replace them with the other two M6x20.
M6x20
M6x20
M6x25
M6x20
82
Apply washer 7, a new Schnorr washer 21 and
nut 8 after having applied the medium strength
thread locker.
3

Keep the clutch unit blocked using the special
tool C (Code 035.14.000.80.00) and tighten to
the specified torque.
120Nm
Keep the clutch nut blocked by using the socket

or pipe wrench D and tighten the spring plate
screws with a cross pattern to the indicated
torque.
10Nm
83
3
10Nm
1
3
4
5
2
Lubricate and apply the entire pressure plate unit

6.
Proceed as follows to reassemble the actuator

unit:
1 • Apply a very light layer of silicone grease on
2 the piston complete with OR;
• Apply spring 1 in the cylinder and then the
complete piston 2;
• Push the piston inside the cylinder.
84
3.9 COOLANT LIQUID PUMP
AND CENTRIFUGAL UNIT
The water pump must assure the correct flow rate
3
of coolant, depending on the set rotation speed,

in order to remove the required amount of heat
from the power unit. The centrifugal unit activates
the whole exhaust valve control linkage based on
the engine rotation speed, while springs 6 and 7
EXPLODED VIEW OF CENTRIFUGAL UNIT AND WATER
provide the appropriate resistance to the centrif-
PUMP UNIT
1) Rocker arm; ugal action generated by 20, in order to assure
2) Washer 5x15x2; optimal supply of torque and power.
3) M5x12 screw; The impeller 11 is keyed onto shaft 20 and cou-
4) Complete valve control rod; pling is assured by tightening nut 3 on shaft 20.
5) Spring guide;
6) Auxiliary spring;
7) Adjustment spring;
8) 10x16x1 washer;
9) Roller bush;
10) Centrifugal control lever;
11) Water pump impeller;
12) Water pump washer;
15) Complete centrifugal unit;
16) Axial roller cage;
17) Centre bearing;
18) Spacer;
19) Circlip;
20) Complete centrifugal shaft;
31) Ball joint retainer ring;
32) Bearing 6x19x6.
85
3 3.9.1 Checking the pump unit
and disassembly, centrifu-
gal unit and idler unit
A
Refer to par. 2.6.1 to disassemble the entire pump
unit.
Check oil seal condition. Replace if worn.
Check centrifugal unit shaft condition. Replace

the entire centrifugal unit if dented in the area in
contact with the oil seal.
Check the device's axial stroke A is between 4.2-
4.4mm.
Otherwise replace the unit.
View in centrifugal unit section: stroke A.
Remove circlip 19 and check use status of the

roller axial cage 16. Replace it in case of anom-
alies.
Exploded view of centrifugal unit.
Check the roller bushes 9 do not jam during their

operation and check the centrifugal control lever
10 moves correctly.
Exploded view of bearings and centrifugal control

lever.
Also check area A of lever 10 is not worn.
Check of centrifugal control lever area A.
86
3.9.2 Centrifuge unit group as-
sembly
Insert the centrifugal unit in the inner clutch cov-
3
er.

Insertion of centrifugal.
Insert the centrifugal control lever 10 together

10 with the washers 8.
Insertion of centrifugal control lever.
Apply the valve control rod gasket and the rocker

arm unit 1 - valve control rod 4.
4
Application of valve control and rocker arm unit.
87
3
ENGINE CHECKS AND ASSEMBLY Apply blocking screws 3 prior depositing of me-
dium strength thread locker. Tighten to the spec-
ified torque.
6Nm
Centrifugal unit assembly.
Apply the auxiliary 4 and adjustment 3 springs to

the spring guide 5.
4
3
Valve control lever and spring unit.
WARNING!
Auxiliary spring 4 has a variable pitch and must
be assembled as shown in the figure.
88
Apply the complete adjustment cover to the in-
ner clutch cover. Apply the blocking screw prior
application of medium strength thread locker and
fasten to the indicated torque.
3

6Nm
Fastening of adjusting cover.
Thinner edge 3.9.3 Pump unit assembly

1 Grease the oil seal housing on the pump body 1.
Position the oil seal 2 so that the thinner edge
faces the outside of the pump body. Insert the oil
seal, having it enter the seat very slowly to pre-
vent it from deteriorating. The oil seal edge must
be at the same height as the pump body (outer
side).
Application of the oil seal to the pump body.
89
3 2 1
3.9.4 Assembly of complete
clutch cover and pump unit
Apply a new gasket 1 placed between the right
crankcase half and the inner clutch cover using
the two reference pins 2 to keep it in place.
Couple the inner clutch cover to the right crank-

case half and rotate the centrifugal shaft until the
shaft meshes in the main gear.
Positioning of gasket and reference pins.
Apply the seven screws as shown in figure, fas-

tening them at the torque indicated in the table,
with a criss-cross pattern.
Positioning of screws.
Screw size
Number Thread locker Tightening torque
screw Threading application [Nm]
Threading length
diameter
6 M6 20 NO 10
7 M6 25 NO 10
Grease the O-rings on the water hose and insert

4 the hose 4 in the right crankcase half.
Insertion of water hose.
90
7 6
Apply the gasket between the pump body and
clutch cover. Grease the inner diameter of the oil
seal on the pump body 5 and apply the body to
the clutch cover.
3
Apply washer 6 and water pump impeller 7.

5
Application of water pump impeller.
Apply screw 8 prior application of the medium
strength thread locker and fasten to the indicated
8 torque.
6Nm
Note: to facilitate the tightening, keep the clutch

unit blocked using the special tool A (code
035.14.000.80.00).
Complete water pump.

After checking the correct insertion of the seal on
the water pump cover, couple the water pump
9
cover to the pump body by applying the two
M6x60 9 screws and the two M6x30 10 screws.
Fasten all screws at the indicated torque follow-
ing a criss-cross pattern.
10Nm
10
Pump cover.
91
3 3.10 OUTER CLUTCH
COUPLING
COVER
Check the correct insertion of the sealing O-ring

1.
Ensure the presence of the centring pins 2.
Apply the outer clutch cover, screws 3 and 4 and

tighten, with a criss-cross pattern, to the torque
indicated in the table.
4
Screw size
Number Thread locker Tightening torque
screw Threading application [Nm]
Threading length
diameter
3 M6 50 NO 10
4 M6 25 NO 10
92
3.11 ELECTRIC IGNITION UNIT -
ONLY RR200 -
Carry out the following checks before assembly.
3

3.11.1 Bendix coupling checks
1
Check wear of the gearwheels found on the unit.
Replace the whole coupling in case of abnormal
wear and signs of chipping of the wheels.
Keep wheel 1 fixed and rotate the mobile cou-
pling 2 anti-clockwise; this must slide without
seizing.
When releasing the mobile coupling, it must go
back to rest position without seizing.
Replace the whole unit if abnormalities are ob-
served during these two checks.
3.11.2 Ignition unit coupling to

engine
Apply a thin layer of grease on the O-ring located
1 on the starter motor. Insert the start motor in its
seat and block it with the two screws 1, prior ap-
plication of medium strength thread locker.
10Nm
93
3
ENGINE CHECKS AND ASSEMBLY Pour about 7cc of gear oil (for specifications refer
to the recommended lubricants and liquids table)
in area A.
Insert Bendix coupling 2 in bush with collar 3

found on the outer side left crankcase half.
94
3.12 IGNITION SYSTEM
Before reassembling the ignition system, it is rec-
ommended to make sure it is in good working
3
order.

The ignition system consists of the magnetic
pick-up unit, the stator unit and the flywheel. The
system is completed by the ignition coil and the
spark plug, which are not dealt with here.
3.12.1 Check of ignition system

Accurately degrease the various elements and
carry out the checks.
The main check is the one concerning the elec-
trical inspection which can be done by using a
standard tester. The measured strength values
must comply with those in the table.
Element Cables strength values

Pick-up unit Red – Green 100Ω ± 20%
Red/Black – White/Red 14.7Ω ±15%
Stator Yellow – Mass 0.61Ω ±15%
Yellow – White 0.18Ω ±15%
3.12.2 Coupling of ignition sys-

6Nm tem to crankcase
Apply the pick-up to the crankcase by inserting
the gasket in the specific seat, prior application
of the isolating silicone paste.
Cover the two screws 1 with medium strength

thread locker and tighten them at the torque in-
dicated.
Coupling of pick-up to crankcase.

Thoroughly degrease the crankshaft conical sec-
tion, apply the Woodruff key 2 in the appropriate
groove on the crankshaft, couple the flywheel 3,
the elastic washer 4 and the nut 5, after spread-
ing the threading with medium strength thread
locker.
4
3
2 60Nm
Exploded view of flywheel.

5) Nut M12x; 4) Elastic washer;
2) Woodruff key; 3) Flywheel.
95
3 Fasten the nut to the torque indicated, keep-
ing the flywheel blocked with special tool A
(code026.14.005.50.00).
A
Flywheel fastening.
Couple the stator to the flywheel cover by means
of the two screws 6. Cover the threading with me-
10Nm
dium strength thread locker and tighten them at
the torque indicated.
Insert the cable gland in its specific seat and
check its perfect tightness.
Stator coupling to the flywheel cover.
Apply a few drops of silicone in the guides for

housing the plate 7. Apply the plate 7 to be in-
7 serted in its guides and pressed.
Application of stator plate.
Insert the centring pins 7 on the crankcase and

fasten a new gasket.
Application of flywheel cover centring pins.
96
8
Apply the flywheel cover, the three M6x20 screws
8 and the two M6x25 screws 9. Tighten in a criss-
cross pattern to the torque indicated. 3

Note: When performing a complete overhaul of
the engine or intervening on the thermal unit, do
not apply the cover as it has to be removed to
find the Top Dead Centre.
10Nm
8
9
10Nm
Flywheel cover coupled to crankcase.
97
3 3.13 POWER UNIT
Before assembling the power unit, thorough
checks must be carried out on the cylinder, pis-
ton, pin bolt and elastic bands, described below.
3.13.1 Check of the piston and

elastic bands
Remove carbon sediment from the top of the pis-
ton and wash the entire piston with specific de-
greasing agent.
Do not use sharp points or tools for cleaning.
Then carry out a careful analysis of the piston
which must be free from forcing, scratches, cracks
or any type of damage.
Analyse the external diameter of the piston.
The diameter must be measured at a distance X
from the inner edge of the skirt, perpendicularly
to the axis of the pin bolt.
X
Refer to the following table for the piston's selec-

tion classes.
Position to measure the outside diameter of the

piston.
Displace- Measure- Bore [mm]

ment [cm³] ment X [mm] A B C
125 18 53.945-53.954 53.955-53.964 53.965-53.975
200 21 61.965-61.974 61.975-61.984 61.985-61.995
In order to check the condition of the elastic

bands, the band must be inserted in the cylinder
so that its axis is aligned with the axis of the cylin-
der. Then measure the distance between the two
opposite ends.
The elastic bands must be positioned at about
6mm from the cylinder's upper edge.
The respective service limits are set out in the
table below.
First check of elastic bands. Displace- Service limit of elastic

ment [cm³] band [mm]
125 - 200 0.2
98
3.13.2 Cylinder check
Check the cylinder is without signs of seizure.
Otherwise replace it.
3
Measure the bore at a distance A from the top

face of the cylinder (surface between cylinder
and head). Take the correct measurement by fol-
lowing direction X.
Displacement [cm³] Measurement A [mm]
125 24,3
200 35
Bore measurement is required to know the cou-

pling play between cylinder and piston.
X
A
The cylinder's specific class is punched inside the

valve control compartment.
Cylinder class punching.
99
3 3.13.3 Piston
play
cylinder coupling
The following table sets out the coupling play be-

tween cylinder and piston. In order to calculate
the coupling play between cylinder and piston,

a subtraction must be carried out between the
diameter of the cylinder and that of the piston.
Displace- Maximum Minimum

piston/cylinder cylinder/piston
ment play play
[cm³] [mm] [mm]
125 0.08 0.045
200 0.08 0.035
3.13.4 Exhaust valve unit disas-

sembly and checks
Remove screws 1 to allow the exhaust flange 2
and its gasket 3 to be disassembled.
3
Flange.
Remove screws 4, cover 5 and related gasket 6.
6 5
4
Left side valve cover.
100
7
Remove screw 7 fastening the valve control unit
to the booster; then remove screw 8 fixing the
bearings. 3

8
Apply one control unit side M5 screw and pull

externally.
Repeat the operation from the opposite side us-

ing one M6 screw.
After extracting the boosters and related pin, ex-

A tract the valve pin 9 by pushing it with a metal
cylinder A and then extract valve 10.
101
3
10
Check the bearings 11 supporting the booster are

efficient, without seizing during operation or ex-
cessive play, once the assembly has been cleaned
and descaled. Otherwise replace.
Check pins 12, 13 and their seats are not abnor-
13 mally worn. Otherwise replace the worn parts.
11
12 Descale all passages involving the exhaust. Abso-

lutely avoid the use of abrasives.
3.13.5 Exhaust valve unit assem-

bly
Insert valve 1 in its seat with the back facing up-
wards.
102
2
Insert pin 2 while holding valve 1 in position.

1
Apply the left side booster unit complete with pin

and bearings in its seat: pin 3 must be inserted in
the specific slot in the valve.
Apply the right side booster unit in its seat.
Apply gasket 4, cover 5 and screws 6. Tighten to

the specified torque.
4 5
6
10Nm
103
3
7
Apply screw 7 complete with the washer after ap-
plying medium-intensity thread locker and tight-
en at the specified torque.
10Nm
Apply the stroke end lever 8 on the control side.

Then apply all other parts.
Screw 9 must be covered with medium strength
thread locker and fastened to the indicated
torque.
Try moving the assembly and check the entire
mechanism slides perfectly, once assembly is
completed.
6Nm
Valve control.
Apply gasket 10, flange 11 and screws 12.

10
11
10Nm
12
Flange.
104
3.13.6 Piston, elastic bands, pin
bolt and cylinder assembly
Insert a circlip for retaining the pin bolt in one of
3
the seats on the piston's side, placing the circlip

open part either upwards or downwards.
Apply the roller cage in the connecting rod's foot,
and lubricate it.
Oil pin bolt and seat in piston. Insert the pin bolt
in the piston from the side opposite where the
circlip was inserted, leaving enough space to al-
low the connecting rod to mate with the piston.
Place the piston so that the arrow stamped on the
crown is facing the front of the engine (exhaust
opening). Couple the piston to the connecting
rod by fully pushing the pin bolt until flush with
the previously inserted circlip. It may be helpful
to use an aluminium cylinder (or similar tool)
during this phase.
WARNING!
Place a clean cloth between the piston and the
crankcase to keep foreign objects from falling
inside the crankcase.
Insert the second circlip in the specific seat of

the piston, placing the open part either upwards
or downwards. Remove the previously inserted
cloth.
Oil the skirt of the piston with plenty of engine oil
and insert the elastic bands, the edges of which
must face the area with the stop pin.
OK NO!
Positioning of elastic bands on the piston.
105
3
ENGINE CHECKS AND ASSEMBLY Apply the gasket between crankcase and cylinder.
Note: keep
crankcases.
the silicone edge facing the
Accurately oil the entire cylinder using engine oil

and insert the piston in the cylinder. The piston
must be inserted in the cylinder while holding the
elastic bands with one’s fingers tightly. The cylin-
der must be positioned so that the exhaust gap is
facing the front of the engine.
Push the cylinder towards the crankcase.
Coupling of cylinder to piston and crankcase.
Apply the four collar nuts and fasten them to the

indicated torque, following the cross pattern.
20Nm
Tightening of cylinder nuts.
106
3.13.7 Check of crankcase/cylin-
der gasket thickness
The thickness of the gasket between cylinder and
3
crankcase must be checked every time the follow-

ing are replaced:
• Cylinder;
• Piston;
• Crankshaft;
• Connecting rod;
• Crankcase.
The check is necessary as said thickness affects
engine performance. The check must be carried
out using the specific calibrated plates set out in
the table.
For this check, it is necessary:
• to remove the flywheel cover (Par. 2.4.1)
• to move the piston to the top dead centre,
using the flywheel.
Displacement [cm³] Model Year Code Side
125 2020 007.44.010.00.00 B

200 2020 035.14.009.00.00 A
The use of the plates is described below.

• Place the specific plate making sure it comes
into contact with the cylinder's upper surface.
• Move the piston to top dead centre and, using
a thickness gauge, check the play between
piston and plate is between 0-0.025mm.
If the play between piston and plate is higher

than required, reduce the cylinder/crankcase gas-
ket thickness and carry out the check again.
Case where the plate and piston do not touch: check

distance between plate and piston.
Measure the play with a thickness gauge if the

piston pushes the plate upwards, causing con-
tact to be lost between plate and cylinder: if the
play is greater than 0.025, the thickness of the
cylinder/casing gasket must be increased and the
check must be done again.
The gaskets are supplied in different thicknesses
that can also be stacked, thus obtaining the re-
quired height for the right thickness.
Note: the above-described check must be carried

Case where the piston pushes the plate causing out once all four crankcase cylinder coupling
cylinder/plate contact to be lost nuts have been fastened at the set torque.
At the end of the operation:

-tighten the crankcase screw A to the indicated
torque;
-reassemble the flywheel cover (Par. 3.12.2).
10Nm
107
3 15Nm
20Nm
3.13.8 Head application
Apply the two O-rings to the cylinder. Place the
head so that the water hose is facing the front of
the engine. Grease the screws and apply them to
the head, together with the copper washers. Fol-

lowing a cross pattern, tighten in two steps:
1. 15Nm;
2. 20Nm
Tightening of head.
Apply the spark plug complete with gasket 1 and
tighten to the indicated torque.
25Nm
3.13.9 Exhaust valve adjustment

Bring the valve control unit 1 in the fully closed
position, so the stroke end lever is flush with
screw 2 fixing the booster bearings.
2
4
3
Check that the ball head 3 and the seat 4 are

perfectly aligned.
If so, loosen the lock nut, adjust the seat and fas-
ten the lock nut.
Positioning of valve control.
108
NO! NO! OK
3

Incorrect positions of the control rod seat. Correct position of the control rod
seat.
Ensure the control rod is able to rotate around its

axis, making equal angles with respect to the ball
head axis.
Check of control rod rotation.
109
3
5
Apply gasket 5 and insert the control rod.
Apply the stop 6.
Insertion of control rod and application of stop.
Intervene on screw 7 for the dynamic adjustment

of the exhaust valve unit, thus modifying the char-
acteristic curve of the engine.
The positions indicated in the table below are
those considered optimal for engine operation.
Setting the adjustment

Displacement [cm³]
screw (from all open)
125 1+3/4
7
200 1
The "fully open" position is for perfect alignment

between adjustment screw head and adjustment
cover.
Adjustment must, therefore, be carried out as fol-
lows.
∙ Bring the screw to the “fully open” position;
∙ Tighten the number of turns indicated in the
table.
Fully open reference.
110
The table shows the effects obtained from mod-
ifying the position of the adjustment screw with
respect to the positions in the above table.
Anti-clockwise
3
Clockwise rotation
rotation of

of adjustment screw
adjustment screw
Greater acceleration
Softer flow-rate and
and lower torque at
less over-rev
low speeds
WARNING!
Do not tighten the adjustment screw for more
than three and a half turns from the all open po-
sition.
3.13.10 Cover plate application

Apply the valve control unit cover and relative
6Nm
screws. Tighten to the specified torque.
Application and tightening of valve control unit cover

screws.
111
3 3.14 CHECK OF INTAKE UNIT
AND ASSEMBLY
Check the manifold 1 is intact and without cracks.
Otherwise replace it.
Check that the petals 2 of the reed valve 3 are

intact and not deformed. If so, replace them.
To disassemble the multiflap:

-remove the flow guide;
-press the central body as shown in the
figure;
-remove the outer multiflap.
Disassembly of reed valve body.
112
Remove the two central wedges and remove the
multiflap.
3

Assemble the petals by following the procedure
just described, in reverse order.
Disassembly of central wedges. The extraction of only

one is shown in figure.
NO ATTENTION!
The flow guide is asymmetrical. When reassem-
bling, make sure that the flow guide, once cou-
pled with the manifold, is centred.
OK!
Flow guide positioning.
113
3
ENGINE CHECKS AND ASSEMBLY To assemble the whole intake system, apply the
manifold to the reed valve, the gasket.
Tighten the screws 6 to the indicated torque.
10Nm
Application of reed valve.
10Nm
114
3.15 INSERTION OF PINION
SPACER AND APPLICA-
TION OF THE OIL EXHAUST
3
CAP

Apply the O-ring 1 on the secondary shaft of
the gearshift 2, followed by spacer 3 so that the
groove is facing inside the engine.
Note: remember to apply grease on the oil seal.
Apply the oil exhaust cap, making sure the related

O-ring is present.
15Nm
Insertion of clutch rod.
115
4 4 ENGINE REASSEMBLY IN THE VEHICLE
• Insert the engine in the frame. We recom-
ENGINE REASSEMBLY IN THE VEHICLE
mend insertion from the frame’s left side.
• Insert the engine pins 1 and the swingarm

pin 2.
2
1
Note: pay attention that the notch on the pin

head is aligned with the notch on the frame.
• Insert the upper shock-absorber pin 3. Fas-

ten the shock absorber pin to the indicated
3 torque.
70Nm
• Apply the carburettor to the manifold mak-

ing the breather tubes pass in the appropriate
metal cable gland.
116
• Apply the head connections paying attention
to feed the cables and clutch pipe as indicat-
ed in the figures. 4

• Tighten the nuts and bolts as indicated in the
figure, applying medium strength thread lock-
35Nm er where indicated.
35Nm
35Nm
45Nm
125Nm
45Nm
117
4 5
• Rotate the filter box in its normal position.
Apply the lower fixing screws 4 (one each
side) prior application of medium strength
thread locker and fasten to the indicated
torque. Tighten the upper screws 5 to the in-
dicated torque.
35Nm
Note: We recommend removing the upper screws
(one each side) and apply a medium strength
thread locker.
35Nm
• Make sure the filter box sleeve is correctly in-

serted inside the carburettor, fasten the two
filter box side and manifold side straps.
• Only on 200 feed through the starter motor

cable A behind the carburettor breather tubes
118
• Then feed through the brake light wiring B
behind the carburettor vents.
4

B
• Connect the connector 6.
• Feed through the cables as shown; secure

them to the metal cable gland as shown in
the figure.
119
4
ENGINE REASSEMBLY IN THE VEHICLE • ONLY RR200 Remove the cap applied to the
mixer tube (see page 11).
• Insert the tube through the tube hole 7 and

connect it to the nozzle 8 on the intake man-
ifold.
7
7
8
• Connect the connector 9.
• Apply the clutch pipe and position it as shown

in the figure. Replace the two copper gaskets
to be applied above and below the fitting. Ap-
ply the threaded fitting and tighten to 15Nm.
15Nm
120
ATTENTION!

4
of it on the painted parts of the vehi-

cle.

ATTENTION!

In case of contact:
- with skin, clean the concerned are-
as immediately with soap and water.
Change the clothing that came into
contact with the liquid.
• Remove the device to hold the clutch lever

pulled.
• Check that the entire clutch actuator hydrau-

lic control is purged.
• Connect the engine’s electrical system to the

central system.
121
4
ENGINE REASSEMBLY IN THE VEHICLE • Fasten everything to the frame as shown in
the figure.
• Connect the coil to the spark plug.
• Connect the engine vent pipe.

• Connect the cooling system to the engine.
Tighten the hose clamps and introduce the
coolant.
• After the filling, purge the engine unit using

screw A. After the purging, check the liquid
level and top-up if necessary.
• Apply the Kickstart lever (Optional RR200).

Apply the medium-strength thread locker on
the screw and tighten at 25Nm. Apply the
brake pedal return spring 10.
10
122
•
•
Apply the start motor cable and tighten the
nut to the indicated torque.
Cover the connection using the specific pro-
tective cap.
4

10Nm
• Apply the exhaust expansion by first assem-

bling the front springs and then applying the
two fixing screws.
• Apply the spacer and fasten the two fixing
screws to the indicated torque. Fasten the ex-
7Nm
pansion fixing screws to the frame at 7Nm.
• Apply the gearshift pedal and fasten the screw

at 10Nm prior thread locker application.
• Insert the pinion in the chain and fasten it
onto the gearshift outlet shaft. Assemble the
relative circlip 11, checking it is in its seat.
11
• Apply the pinion guard 12 and the frame side

10Nm guards 13 and 14. Fasten the screws at 3Nm
and apply the fixing straps between the side
12 guards and frame.
13
3Nm
123
4
14
3Nm
• Place the tank on the vehicle and connect

connector 15.
15
• Insert the pipe 16 observing its path as shown

in the figure.
• Push the tank towards the front and down-
wards.
16
• Tighten the tank screws to the indicated

torque.
• Reconnect pipe 17 to the tank.
17
10Nm
7Nm
124
• Reconnect the tank to the carburettor and se-
cure the tube using the specific tube straps.
4

ATTENTION!
(ONLY RR200)
Disconnecting the mixer tube from the intake
manifold could cause air to get into the tube it-
self. To avert any lubrication problems with the
power unit and crankshaft, use fuel with 1% mix
for the first fill-up.
Use the oil recommended on page 132 in the
"Recommended lubricants and liquids" table.
7Nm • Reconnect the tank to the carburettor and se-

cure the tube using the specific tube straps.
• Apply the seat.
• Reapply the paramotor plate with the two fix-

ing screws, once the motorcycle is removed
from the stand. Tighten to the specified
torque.
125
TABLE OF ENGINE COMPONENTS TIGHTENING TORQUES
Torque
Fixing Diameter x Length Quantity Thread locker Notes
[Nm]
TABLE OF ENGINE COMPONENTS
TIGHTENING TORQUES
Outer side right crankcase half

Medium-
Kickstarter lever M6 x 20 1 strength 10
thread locker
Inner side right crankcase half
High-strength
Main shaft fixing M5 x 10 2 6
thread locker
Desmodromic control High-strength
M5 x 8 1 6
bearing fixing thread locker
Crankshaft
Securing the half- High-strength
M6 x 12 6 5
shoulders thread locker
Gearshift drive
Medium-
Stop cam M6 x 30 1 strength 10
thread locker
Gear stopping device Medium-
M6 x 20 1 strength 10
lever thread locker
Medium-
Gearshift lever M6 x 25 1 strength 10
thread locker
Electric kick starter device - only RR 200
Medium-
Starter motor M6 x 25 2 strength 10
thread locker
Pedal kick starter device - OPTIONAL RR200
Medium-
Securing the lever M8 x 26 1 strength 25
thread locker
Clutch - primary transmission
Primary transmission Medium-

1 strength 160
pinion nut thread locker
Medium- Do not use
Drum nut and clutch
1 strength 120 pneumatic
case thread locker device
Clutch cap M6 x 20 6 10
Outer clutch cover M6 x 25 2 10
In common
Outer clutch cover M6 x 50 2 10 with inner
clutch cover
Inner clutch cover M6 x 20 3 10
Inner clutch cover M6 x 25 2 10
In common
Inner clutch cover M6 x 60 2 10 with outer
clutch cover
Clutch actuator pipe M10 X 1 1 15
126
Torque
[Nm]

TIGHTENING TORQUES
Water pump
In common
Cover M6 x 60 2 10 with inner
clutch cover
Cover M6 x 30 2 10
Medium-
Impeller M5 x 12 1 strength 6
thread locker
Exhaust valve control
Medium-
Flange M6 x 20 3 strength 10
thread locker
Complete control Medium-
rocker arm thread locker
Medium-
Control lever M5 x 20 1 strength 6
thread locker
Medium-
Booster bearings M6 x 15 2 strength 10
thread locker
Right cover M5 x 16 3 6
Left cover M5 x 16 2 6
Medium-
Control cover M5 X 20 2 strength 6
thread locker
Ignition system
Spark plug M14 x 1.25 1 25
Medium-
Pick-up unit M5 x 12 2 strength 6
thread locker
Medium-
Stator M6 x 25 2 strength 10
thread locker
Medium-
Flywheel nut 1 strength 60
thread locker
Cover M6 x 20 3 10
Cover M6 x 30 2 10
Cylinder
Medium-
Studs M8 4 strength 20
thread locker
Cylinder nuts 4 20
Head
Pre-tighten-
ing thread-
Head screws M8 x 35 6 20
ing greasing
15Nm
Crankcase half
Crankcase half screws M6 x 50 9 10
Crankcase half screws M6 x 40 3 10
127
Torque
[Nm]
TIGHTENING TORQUES
Intake
Reed valve M6 x 25 3 10
Screw
Reed valve M6 x 25 1 10 tamper-
proof
Oil drain
Cap 1 15
128
TABLE OF FRAME/ENGINE FASTENING TORQUES
Diameter x Thread Torque

Fixing Quantity Notes
Length locker [Nm]
TABLE OF FRAME/ENGINE
FASTENING TORQUES
Front and lower engine
M10 x 1.25 2 45
connections
Swingarm pin M16 x 1.5 1 125
Head - frame connection Medium-

bracket (front fixing) thread locker
Head - frame connection
M8 x 60 1 35
bracket (rear fixing)
Head connection brack- Medium-

ets to engine thread locker
Shock absorber upper Medium-
M10 x 45 strength 70
fixing thread locker
TABLE OF SUPERSTRUCTURE TIGHTENING TORQUES
TABLE OF SUPERSTRUCTURE
FASTENING TORQUE VALUES
Diameter x length Torque
Fixing Quantity Thread locker Notes
[mm] [Nm]
Tank to the frame

M6 x 25 1 10
(front fixing)
Tank to the frame Application of

M6 x 30 1 10
(rear fixing) grease
Tank side panel to the

M6 x 20 2 7
radiator
Frame arms to the Medium-

frame thread locker
Medium-
Frame to the frame M8 x 30 2 strength 35
thread locker
M6 x 45 1 7 Front fixing
Silencer
M6 x 30 1 7 Rear fixing
Right side filter box side

M6 x 16 2 7
panel
M6 x 45 1 7 Front fixing
Pinion protection
M6 x 30 1 7 Rear fixing
Frame protection M6 x 20 2 3
Engine protection M6 x 20 2 7
129
RECOMMENDED ENGINE MAINTENANCE
The requested engine maintenance only depends on the level of use and respect of the periodical
inspections. The following intervals refer to normal use, as long as the engine has not worked in ex-
traordinary conditions and that periodical inspections and interventions have been correctly carried out.
RECOMMENDED ENGINE
MAINTENANCE
30h 40h 60h 90h
Driving and driven clutch discs C - R C
Clutch springs length C - C R
Gearshift bearings - - - R
Case / clutch hub C - C C
Cylinder - - C -
Piston and segments - R - -
Connecting rod - - R -
Crankshaft bearings - - R -
Gearshift superficial appearance - - - C
Water pump oil seal - - - R
Exhaust valve - - C/P -
Reed valve shims - - C -
Spark plug C - R -
C = INSPECT AND REPLACE IF NECESSARY S = REPLACE C = Cleaning
RECOMMENDED LUBRICANTS AND LIQUIDS

RECOMMENDED LUBRICANTS
AND LIQUIDS
APPLICATION PRODUCT QUANTITY
Gearshift and clutch LIQUI MOLY RACING 10W-50 720ml*
Coolant liquid LIQUI MOLY COOLANT READY MIX RAF12 PLUS 1300ml*
Fuel tank
LIQUI MOLY RACING SYNTH 2T 2.5% blend
(RR125)
Fuel tank (only for

Liqui Moly 2-STROKE MOTOR OIL, SELF-MIXING 1%
running-in RR200)
Mixer tank (RR200) Liqui Moly 2-STROKE MOTOR OIL, SELF-MIXING 550ml*
* Refer to Use and Maintenance Manual for levels
130
131

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RACE EDITION

2.9 DISASSEMBLY OF PARTS FROM CRANKCASES........44

3 ENGINE CHECKS AND ASSEMBLY 48

3.1 CRANKCASE HALF.........................................................48

4 ENGINE REASSEMBLY IN THE VEHICLE 116

TABLE OF ENGINE COMPONENTS TIGHTENING TORQUES 126

TABLE OF FRAME/ENGINE FASTENING TORQUES 129

TABLE OF SUPERSTRUCTURE TIGHTENING TORQUES 129

RECOMMENDED ENGINE MAINTENANCE 130

We respect and defend the environment

ENGINE TECHNICAL SPECIFICATIONS

CHARACTERISTIC DATA ENGINE

• Remove the engine guard plate;

To dismantle the tank from the vehicle it is nec-

Do not carry out the operation near

Wipe off any traces of spilled fuel imme-

Remove the screw 1 fastening the tank to the

ENGINE REMOVAL FROM VEHICLE

• disconnect the connector 4;

Lift the tank from the back and remove it back-

• Remove the circlip 7 and extract the pinion.

• Remove the screw 9.

• Remove the screws 10.

• Remove the exhaust pipe.

ENGINE REMOVAL FROM VEHICLE

• Disconnect the spark plug cap, disconnect the

• ONLY RR200 Remove the start motor cable

• Remove the threaded fitting 12.

The clutch fluid is highly corrosive,

Protective gloves must be worn to

ENGINE REMOVAL FROM VEHICLE

• ONLY RR 200 Pull out the mixer tube 14 from

• Remove the subframe lower fixing screws

• R otate the entire filter box unit.

ENGINE REMOVAL FROM VEHICLE

• Disconnect the connector 19.

• Remove the carburettor, leaving it connected

ENGINE REMOVAL FROM VEHICLE

• Remove the gear lever 21 and the engine pins

code 3625132000 by means of front fixing

2.1 CLUTCH/GEARSHIFT OIL

2.2 REMOVAL OF PINION

Remove the three screws 3 and cover 4.

Release the lock 5 and remove it.

Remove the gasket 7. It may be necessary to

Remove the four collar nuts 9.

Using a suitable tool to insert the specific seat A,

Removal of piston circlip.

2.4 REMOVAL OF IGNITION

2.4.1 Flywheel cover plate re-

Remove the four screws 1 fastening the flywheel

Fixing screws 1 of flywheel cover 2.

The two designated references pins (3) for the flywheel

2.4.2 Stator removal

Disassembly of stator from cover.

2.4.3 Flywheel removal

Note: Once the nut has been unscrewed, pay

Removal of flywheel nut.

2.4.4 Removal of pick-up unit

2 Remove the pick-up unit 1 by loosening the two

• R otate the entire filter box unit.