Beta - BETA RR 4t 250-400-450-525 - Workshop - Manual PDF
Beta - BETA RR 4t 250-400-450-525 - Workshop - Manual PDF
Beta - BETA RR 4t 250-400-450-525 - Workshop - Manual PDF
USEFUL ADVICE
To avoid problems and ensure best results, Betamotor
recommends observing the following guidelines:
Note
Betamotor is committed to constantly improving its prod-
ucts. For this reason, there can be slight differences be-
tween the content of this manual and the vehicle to be re-
paired or serviced. Betamotor products are exported to
many countries characterized by different Highway Codes
and type-approval procedures. In view of this, Betamotor
reserves the right to modify its products and technical doc-
umentation at any time and without notice.
3
GENERAL CONTENTS
1 General information
2 Specific tools
3 Tightening torques - Specifications -
Recommended products
4 Maintenance
5 Bodywork and fittings
6 Engine
7 Carburettor
8 Front suspension/wheel
9 Rear suspension/wheel
10 Braking system
11 Electrical system
CONVENTION . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 9
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Carbon monoxide . . . . . . . . . . . . . . . . Chap. 1 - 10
Petrol . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Engine oil . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Coolant . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 12
TABLES OF CONTENTS
TABLE OF CONTENTS OF EACH CHAPTER Chap. 1 - 12
CONTENTS OF EACH CHAPTER . . . . . . . Chap. 1 - 12
Arrangement of subjects
The manual is divided into chapters that cover the main sub-
assemblies of the vehicle. To make the different chapters easy
to find, the pages of each chapter bear a reference mark that is
aligned with the related title in the general contents.
Description of operations
The removing, fitting and checking operations described in the
manual are accompanied by pictures (drawings or pho-
tographs).
The pictures contain symbols referring to procedures, special
tools and other information. Refer to the key to the symbols for
a description of their meanings.
The procedures are arranged sequentially, step by step.
Updates
Betamotor is committed to continually improving its products. Any significant changes made to the specifications and pro-
cedures contained in this manual will be made known to official dealers and will be included in future editions of the man-
ual. All the information, instructions and technical data provided in this manual were up-to-date when the manual was ap-
proved for print. Betamotor reserves the right to make changes to the manual at any time, without notice and without in-
curring any obligations.
EXAMPLE
Whenever a specific tightening torque is needed, begin by ap- 10 N·m
plying a standard tightening torque (e.g. 10 N·m), then proceed
with the tightening by rotating the part by a predetermined angle
(e.g. 30°).
30°
Lh
Rh
Rh
Lh
Carbon monoxide
• Exhaust gases contain carbon monoxide (CO), a poisonous gas that can cause loss of consciousness and even death.
• Before starting the engine, ensure that the area is well ventilated. Never run the engine indoors.
• The engine can be run indoors only if the area is equipped with specially designed exhausters.
Petrol
• Petrol is highly flammable and, under certain circumstances, explosive.
• Keep all heat sources, sparks and open flames away from the working area.
• Always work in a well ventilated area.
• Never use petrol as a cleaning solvent. Avoid handling it unless absolutely necessary.
• Do not use petrol for cleaning components that need to be blown with compressed air.
• Keep out of the reach of children.
Engine oil
• Repeated and prolonged contact of engine oil with the skin can cause skin diseases.
• In case of contact, wash the contaminated parts with soap and water as soon as possible.
• In case of eye contact, rinse abundantly with water and seek medical attention.
• In case of ingestion, immediately seek medical attention without causing vomit as this could result in the oil being
breathed into the lungs. If the product is believed to have been breathed into the lungs, immediately transport the af-
fected person to the nearest hospital.
• Spent oil contains substances that are dangerous to the environment. Oil can be renewed only by operators that are
equipped for the disposal of spent oils in compliance with applicable laws.
• Avoid disposing of spent oil in the environment.
• Keep out of the reach of children.
Coolant
• Under certain circumstances the ethylene glycol contained in the coolant is flammable and its flame is invisible. Should
the ethylene glycol ignite, its flame, though invisible, could cause serious burns.
• Avoid bringing the coolant into contact with hot parts as these could ignite it.
• The coolant (ethylene glycol) can irritate the skin and is poisonous if ingested.
• In case of skin contact, immediately take off any contaminated clothes or footwear and wash abundantly with soap and
water. In case of eye contact rinse abundantly with clean water and immediately seek medical attention. If the coolant
is ingested, avoid causing vomit as this could cause the product to be breathed into the lungs. Administer clean water
and immediately transport the affected person to the nearest hospital and show the product to health personnel.
• If anybody is exposed to a high concentration of coolant vapours, transport them to an area where they can breath un-
polluted air. If necessary seek medical assistance.
• Do not remove the radiator cap when the engine is hot. Since the coolant in the radiator is subjected to high pressures,
it could spurt out and cause burns.
• The coolant contains substances that are harmful to the environment. The coolant can only be renewed by operators
equipped for the disposal of spent oils/coolant in compliance with the regulations in force.
• Avoid disposing of the coolant in the environment.
• Keep out of the reach of children.
VEHICLE IDENTIFICATION
The frame number is stamped on the right side of the head tube.
The engine number is stamped on the upper crankcase half, next to the swingarm.
2) engine number
3) type-approval data
1) frame number
ZD3 E1 XX XXXXXXXXXX
Manufacturer’s data
Vehicle model
Version 00 (250 cc)
01 (400 cc)
02 (450 cc)
03 (525 cc)
DIMENSIONS - RR 250
Maximum length 2270 mm
Maximum width 813 mm
Maximum height above ground 1255 mm
Wheelbase 1490 mm
Saddle height 940 mm
Ground clearance 320 mm
Footrest height 405 mm
RECOMMENDED LUBRICANTS
To keep the vehicle in perfect running order and prolong its life, we recommend using the products listed in the table be-
low:
Note: When renewing the lubricants, be sure to use the products specified in the above table.
Park the vehicle on level ground, remove screw C and drain the
oil into a container.
Thoroughly clean the screw (with the magnet). When the oil has
drained out completely, clean the sealing surface, refit screw C
with the seal ring and tighten to 20 N·m. C
Fit long oil unit 4 using a 300 mm spanner as shown in the fig-
ure, then insert the spanner through the opening in the hole on
the opposite side of the crankcase. Push the oil unit into the 3
crankcase until it stops and remove the spanner. Refit screw 3
and tighten to 15 N·m.
Using a pair of Seeger ring pliers, pull out the two filter elements
3 from the crankcase.
Clean the oil filter covers, the O-ring sealing surfaces and the
crankcase. Check the O-rings and the oil filter covers for dam-
age and replace as necessary.
Turn the vehicle upside down and half fill the two oil filter cas-
ings with engine oil. 3
Fit the long filter unit in the front and the short filter unit in the
back of the crankcase.
Grease the oil filter cover O-rings and fit covers 4. 4
Fit screws 2 and tighten them to 6 N·m.
Tighten screw 1 to 8 N·m.
Lift up the vehicle.
Remove screw fastening 5 from the clutch cover and pour in
1.25 litres of the recommended engine oil (see table in Chapter
3).
NOTE:
spark plug is black: mixture is “rich”
spark plug is light brown: mixture is correct
spark plug is white: mixture is “lean”
To perform the check, simply remove the spark plug cap and un-
screw the spark plug using the spanner provided. Carefully
clean the electrodes using a wire brush. Blow the spark plug
with compressed air to prevent any residues from getting into to
engine.
Also check that the insulator is not cracked and the electrodes
are not corroded. If that is the case, immediately replace the
spark plug.
Lubricate the spark plug thread and, when the engine is cold,
screw in the spark plug by hand until it stops and then tighten it
with the spanner.
Coolant
Chain tensioning
To prolong the life of the drive chain, it is advisable to periodi-
cally check its tensioning.
Always keep the chain clean and lubricated. Whenever the
chain play exceeds 20 mm, adjust the chain tension by follow-
ing these steps:
20 mm
– Tighten nut 1.
1 B
Standard adjustment:
10 clicks from the completely closed position
Standard adjustment:
18 clicks from the completely closed position
Shock absorber
Adjusting the hydraulic compression damping
(high/low speeds)
The shock absorber can be adjusted for both high and low
speeds. C
The expressions ‘high speed’ and ‘low speed’ refer to the move-
ment of the shock absorber, not to the speed of the vehicle.
The low and high speed adjustments affect the behaviour of the
shock absorber during slow and fast compression respectively.
D
Low speed adjustment:
– Using a screwdriver, turn screw C clockwise to decrease the
hydraulic compression damping.
Standard adjustment:
completely open screw, 21/21 clicks
Standard adjustment:
completely open knob, 24/24 clicks
Standard adjustment:
24 clicks from the completely closed position
Depending on the function that is displayed at a given mo- This information is always displayed together with a graphic
ment, pressing a button causes the following: bar. The default unit is km/h. To change to Mph, press the
button and enter the setup menu. If Mph is selected, no ab-
1 - TIME T ≥ 3” and Vel = 0: activates the time setting mode;
T < 3” or Vel > 0: cycles through the functions. breviation is displayed to indicate the selected unit.
2 - LAP T ≥ 3”: resets LAP and TD;
Current time function (TIME)
T < 3”: cycles through the functions.
T ≥ 3” and Vel = 0: enters the time setting mode.
3 - TOD T ≥ 3” and Vel = 0: activates the function for setting
T < 3” or Vel > 0: cycles through the functions.
the circumference, unit and number of pulses for
each wheel turn;
T < 3” or Vel > 0: cycles through the functions. The time can only be adjusted when the vehicle is stationary.
4 - TD T ≥ 3”: resets LAP and TD;
Pressing button C or D for at least 3 seconds activates the
time setting mode. Once the setting is complete, the stan-
T < 3”: cycles through the functions.
dard operating mode is reactivated by pressing the button
5 - COUNTDOWN T ≥ 3” and Vel = 0: enters the countdown setting
mode;
for about 3 seconds. The Time parameter is displayed in the
0-24 format if the selected unit is km/h and in the 0-12 for-
T < 3” or Vel > 0: cycles through the functions.
mat if the selected unit is Mph.
T = Time during which the button is held down;
After entering the setting menu, if the button is not pressed
Vel = Speed of the vehicle. for 20 seconds, the system will automatically return to the
standard operating mode.
Once in the setting menu, if the vehicle moves off (Vel > 0),
the system automatically returns to the standard operating
mode.
If the system wakes up from sleep mode through the electronic trans-
mission (i.e. without pressing the button), the instruments will immedi-
ately switch to the standard operating mode without checking the dis-
play and the warning lights and without showing the selected circumfer-
ence and number of wheel pulses.
Pressing the mode button for about 3 seconds while the cor-
responding value is selected will return the system to the
standard operating mode.
High power consumption functions To gain access to the procedure, follow these steps:
Given its high power consumption, the backlight unit and the • Disconnect the instrument panel from the main battery and
warning lights are operated only by the power supplied by the backup battery.
the vehicle. When no power is supplied (and the backup bat- • Connect pin 5 of the input connector (unwired) to 12 V.
tery is activated) the backlighting is turned off and the warn- • Press the button.
ing lights disabled. This, however, does not prevent the in- • Restore the connection with the backup battery or the
struments from working properly. main battery (if present).
The system will then erase all the data contained in the
E2 prom erasing procedure E2prom and activate the default values (wheel circumfer-
When testing and checking an instrument, it is sometimes ence 2154 mm, speeds measured in km/h, distances mea-
useful to erase the E2prom memory. This is a procedure sured km, 1 pulse per wheel turn). There is no way to re-
which, in principle, is not intended for the user. trieve the erased data.
Finally remove the two brace fixing screws N from the top of the
brace.
Close the fuel cock, remove the fuel line and take off the reser-
voir.
Remove the spring that fastens the silencer to the exhaust pipe.
Remove the radiator cap in the upper part of the system and al-
low the coolant to drain completely.
Refit the drain screw using, if necessary, a new seal.
Remove the clamp shown in the figure and disconnect the right-
hand radiator lower pipe from the cylinder.
Rear frame
Remove the two screws 1 to the left and right of the rear frame 2
and loosen the two screws 2.
Release the two springs that support the exhaust pipe with the
cylinder
Remove the screw that fixes the exhaust pipe to the frame.
Find the split link, move it onto the sprocket and remove the re-
tainer as shown in the figure. Undo the chain and remove it.
Loosen the screw shown in the figure and remove the kickstart.
Remove the engine from the frame, extracting it from the left
side. Place the engine on special tool 3625132.
Should the engine oil come into contact with the skin,
wash with plenty of soap and water.
– Unscrew the four screws 4 and remove the ignition cover with
the related gasket from the crankcase.
– The stator will stay fitted to the cover.
2 1
3
4
– Remove roller 6, inner rotor 7 and outer rotor 8 from the oil
pump casing.
8
– Unscrew the four screws and remove water pump cover 2 with
the related gasket.
3 3
– To prevent the timing chain from falling down to the chain cas-
ing, insert a wire clamp into each chain end.
– Remove the camshaft from the cylinder head.
NOTE:
– There is no need to remove these three screws if the cylinder
and the cylinder head require no servicing. The cylinder and
1
the cylinder head can be removed together without having to
replace the cylinder head gasket.
– The screw on the timing chain side is fitted with a copper seal
ring (6x10x1).
When refitting the parts, replace the copper washer with 1
a new one.
1
1
– Remove screws 3 and 4, pull the chain stretcher and the chain
guide up and out of the crankcase.
3
4
– Fit the puller and remove the timing gear from the crankshaft.
– Remove the double gear and the needle roller cage from the
support pin. Remove the support pin from the crankcase.
– Push back the guide plate and pull out the gear shaft and
thrust washer 5 from the crankcase. 8
6
– Remove screw 6 and the gear selector.
5
– Unscrew screw 7 and remove the selector lever together with
the bushing and the spring.
– Pull out from the crankcase the oil pump shaft complete with
the roller, inner rotor 3 and outer rotor 4. 3
4
– Fit the puller and remove the primary torque gear from the
crankshaft.
4 4
6
A
– Jointly remove the driving shaft and the driven shaft from their
seats.
– Clean all the parts, check them for wear and replace as nec-
essary.
Blow all the oil channels with compressed air and ensure that
they are clear.
Check that the two steady pins 1 are firmly seated. If necessary
lock with Loctite 243.
– When the crankcase half has cooled down, ensure that the
bearing is securely seated.
Kickstart release plate 5
When replacing the release plate, apply Loctite 243 to the two
screws and tighten to 8 N·m.
To clean all the oil channels and check that their passa-
ges are clear, it is advisable to remove the two jets and
the by-pass valve (see below).
NOTE: This jet cools down the piston by spraying engine oil on-
to its lower side.
NOTE: : This jet provides the right quantity of oil for the con-
necting rod bearing.
By-pass valve
Check that the valve piston, the sealing surface and the com-
pression spring are not damaged.
Blow all the oil channels with compressed air and check that the
passages are clear.
Clutch cover
Kickstart shaft oil seal 3 3
Remove the old oil seal with a screwdriver.
Fit the new oil seal and push it to its abutting end.
Oil channel 5
Blow with compressed air and check that the passage is clear.
4
Crankshaft
If the connecting rod bearing is replaced, take care to properly
position the coupling shaft. The holes in the shaft section A and
in the coupling shaft B must be aligned.
Check the radial and axial plays of the connecting rod bearing.
Radial play: ) 0.05 mm
Axial play: ) 1.10 mm
Countershaft gear
– To remove the countershaft gear from the crankshaft, it is first
necessary to remove the inner ring nut of the cylindrical roller
bearing (see below).
– Whenever the cylindrical roller bearings are replaced, the in-
ner collars on the crankshaft also need to be replaced.
– To this end, clamp the crankshaft in a vice by the shaft section
fitting the inner collar to be replaced.
– Heat special tool Part No. 3625193 on an electric hotplate to
approximately 150° C and immediately push it onto the inner
collar. Squeeze the special tool hard to obtain good heat tran-
smission and remove the inner collar from the crankshaft.
5
1
7 3
8
6 4
7
7
6
8
7
7
3
Lubrication system
Oil line 1
Ensure that the soldered joints present no capillary cracks. Blow the oil line with compressed air to check whether the pas-
sage is clear. Also check that there are no friction points on the oil line. Always replace the seal rings with new ones
(8x12x1).
O-ring 2
At each oil change, also replace the O-rings.
Oil units 6
Clean the two oil units with low-pressure compressed air.
O-rings 7
Check their porosity and if necessary replace them.
10
4 6
2
11
3
7
7
9 9
8
Adjusting screws 9
The contact surfaces of the adjusting screws should be flat.
Decompressor shaft 2
Check the sliding of the decompressor shaft and its play in the
support hole.
Replace O-ring 11.
modelli 250
Cylinder head
– Unscrew the three screws 1 and remove exhaust flange 2 to-
gether with its gasket.
Sealing surface
Check the spark thread and the valve seats for damage or
cracks. Using a straightedge and a thickness gauge, check to 1 3
see if any distortion is present. Maximum allowable distortion:
2
0.10 mm.
Valve guides
Check the valve guides with limit gauge 4 (Ø 6.05 mm). If the
gauge can be easily inserted into the valve guide, the latter will
have to be replaced.
Valve seats
The valve seats should show no signs of hammering-in. Width
of sealing surface: intake valve max. 1.50 mm; exhaust valve
max. 2.00 mm. If necessary, grind the valves. 4
Valves
Check the valve heads for signs of wear and floating. Maximum
allowable valve head floating: 0.03 mm. The valve seat should
show no signs of hammering-in. The sealing surface should be
at the centre of the valve seat. The valve stem is chromium-pla-
ted; wear generally occurs on the valve guide.
Valve springs
Visually check that the valve springs are not broken or worn.
Measure their length with a vernier caliper. The minimum al-
lowable valve length is 39.20 mm for the outer valve springs and
36.45 mm for the inner valve springs. Replace as necessary.
Valve springs for the 250 cc model
Visually check that the valve springs are not broken or worn.
Measure their length with a vernier caliper. The minimum al-
lowable length for the valve springs is 37.70 mm. Shorter
springs will have to be replaced.
Valve stems linings
Always replace the valve stem linings when the valves are re-
moved.
– Insert the four spring holders 3 into the cylinder head.
– Fit the valve stem linings on the valve guides and lubricate.
– Carefully oil the valve stems and insert the valves into the val-
ve guides. When refitting, ensure that the valves are properly
positioned.
– Fit valve springs 2 and insert spring caps 1 into the valve
springs.
11
8
6
5
9
7 4
8
2
3 1
Camshaft
– Remove Seeger ring 1 and water pump impeller 2.
– Pull out roller 3 from the shaft hole and remove lining holder 4
from the camshaft.
6
9
5
7 8 1
2
6 1
10 3
3 13
12 14
➙
➙
– When refitting, push the dog in the direction indicated by the
arrow so that the pressure pin no longer jams and then fully
insert the pressure pin into the stretcher body.
➦
Valve gear control
Thoroughly clean all the components and check them for wear.
Timing pinion 1
Check the teeth for nicks or signs of wear.
Chain guide 3
Check for signs of sliding on the contact surfaces.
4
Chain coupling 4 2
Replace the open link of the timing chain.
6
5
Starter gear 1
Check the wear of the teeth and the play of the support.
Starter coupling 3
Check the inclined surface and the teeth for signs of wear.
Kickstart shaft 4
Check the support points and the teeth for signs of wear or da- B
mage and ensure that the starter gear oil hole is clear.
D 10
C 6
E
Preassembling the shaft of the gearshift mecha-
nism
– Clamp the short end of the shaft of the gearshift
mechanism in a vice (use protective jaws). 1
11
B 3
2
6 A
7
9 4
1
8
10
2
3
4
6 5
8
9
10
11
Gearbox
Clamp the driving shaft and the driven shaft in vices (using protective jaws). Remove
the gears and check if the following parts show signs of wear or seizure:
• Needle roller cages.
• Bearing surfaces of the driving shaft, driven shaft and idler gears.
• Gear couplings.
• Sides of all gear teeth.
• Tooth profile of the driving and driven shafts and of the related gears.
• Check that the profiles of all the gears can move smoothly.
Thoroughly clean all the parts and replace any faulty components.
Always fit new Seeger rings whenever the transmission is repaired.
16
15
14
13
12
11 10
9
7 8
6
5
4
3
2
Gearbox
Clamp the driving shaft and the driven shaft in vices (using protective jaws). Remove
the gears and check if the following parts show signs of wear or seizure:
• Needle roller cages.
• Bearing surfaces of the driving shaft, driven shaft and idler gears.
• Gear couplings.
• Sides of all gear teeth.
• Tooth profile of the driving and driven shafts and of the related gears.
• Check that the profiles of all the gears can move smoothly.
Thoroughly clean all the parts and replace any faulty components.
Always fit new Seeger rings whenever the gearbox is repaired.
3
5
A
4
Idler gear 1
Check the teeth and the bearing surface of the idler gear for signs of wear. Also check the idler gear support pin for signs
of seizure.
Double gear 2
Check the teeth and the bearing surface of the double gear for signs of wear. Also check the double gear support pin for
signs of seizure. Fit the double gear together with the needle roller cage on the support pin and check the play.
Free wheel 4
Thoroughly clean the free wheel with petroleum and compressed air. Check the free wheel segments for wear and oil it
generously.
NOTE: If double gear 2 or toothed free wheel 5 show signs of damage that warrant their replacement, remember that the
two parts (2 and 5) can only be replaced together.
Starter motor 6
Replace O-ring 7 on the flange.
2 A
– Turn the crankshaft until mark A is at the front and then insert
the countershaft into its bearing. Ensure that crankshaft mark
A is between the two countershaft marks B. A
B
– Attach the four springs 4 to the fork guide rods with a little
grease. 4
4
4
2 2
60
45
75
60
45
45
NOTE: This diagram shows all the
lengths of the carter fixing screws.
45
60 60
– Using a cloth, carefully clean the rest surface of the oil pump
cover. A
– Position the inner and outer rotors in the crankcase so that the
two centres A and B are placed next to each other.
– Fit roller 6.
– Degrease the thread of the two screws (M5x16) and apply
Loctite 222.
– Fill the oil pump casing with oil.
– Fasten the oil pump cover with the two screws and tighten
them to 6 N·m.
– After fitting the oil pumps, check their smoothness by turning
the oil pump gear.
1 3 4
2
5
1
2
– Heat the clutch hub to approx. 150° C and key it on the driving
shaft.
– Fit a new safety plate.
– Degrease the driving shaft thread and apply Loctite 243 to it. 6
– Position the special tool (see removal procedure), fit flange
nut 5 and tighten it to 150 N·m.
– Secure the flange nut with safety plate 6 as shown in the fig-
ure.
– Bring the crankshaft to the top dead centre and fit the crank-
shaft fixing screw without fitting the seal ring.
Fit the chain stretcher shoe, locking the screw in the seat
in the crankcase B.
B
NOTE: AFTER TIGHTENING THE CHAIN STRETCHER
SHOE, ENSURE THAT IT CAN SLIDE FREELY.
– Fit the timing chain so that the two stretches have the same
length.
7
NOTA: The timing chain can also be fitted after fitting the cylin-
der and the cylinder head.
– Oil the threads and the contact surfaces of the four flange
screws and fit them along with the related washers.
– Tighten the flange screws in three steps following a crosswise
pattern:
1st step – tighten until a slight resistance is felt.
2nd step – tighten to 40 N·m.
3rd step – tighten to 50 N·m.
2 1
– Fit the timing chain on the camshaft gear and then fit a new
chain joint 1. 1
– First fit the insert of the special tool as shown in the figure and
then press the chain joint.
– Fit the insert of the special tool as shown in the figure and riv-
et the chain joint.
NOTE:
– Fit the M6x75 screw with a new copper ring 6x10x1.
M6x... 55 55
45
NOTE: The dia-
gram shows the
lengths of the 30 75 30
cylinder head
c l a m p i n g
45 50
screws.
Fit the fitting cap, grease the O-rings and fit the seal holder so
that its abutting end faces the camshaft gear.
– Remove the fitting cap, insert the roller into the camshaft and
fit the water pump impeller with the Seeger ring.
– Fit the water pump cover with a new seal. Tighten the screws
(M8x20) to 8 N·m following a crosswise pattern.
– Fit the two valve covers 2 with new gaskets and with screws
(M6x20) complete with retaining rings (6x10x1). Tighten the
screws to 8 N·m.
– Screw in the spark plug and tighten it to 12 N·m.
2
– Fit a new gasket and fasten the ignition cover with the four
screws (4 and 5). Tightening torque: 10 N·m. 4
5
NOTE: Fit the two longer screws 4 (M6x35) in the holes with the
centring bushes.
5
5
Clutch plates
– Place the twelve dragging bushes 3 in the hub. If
necessary fix them with a little grease.
– Starting with a middle plate 6, alternate eight middle
plates with seven lined plates 5, ending with a thin
middle plate 6 at the top.
M6x30 M6x30
Position the oil line so that it does not come into contact
with the engine. Also, when tightening, ensure that the oil
line is not taut.
– Oil distance ring 5 and slide it onto the driven shaft with the
groove for the O-ring facing inward.
– Fit the chain sprocket with the high collar facing inward. 5
– Degrease the flange nut thread, apply Loctite 243 to it and
tighten the screw with the spring washer to 60 N·m.
NOTE: Before tightening the screw, lock the crankshaft and shift
into first gear.
– Oil the O-rings on the oil filter covers and fix covers 2 with the
four screws (M5x16), applying a tightening torque of 6 N·m.
– Fit the kickstart and the gearshift lever. 2
– Remove the clamping screw from the clutch cover and pour in
1.20 litres of 10W-50 engine oil (see table in Chapter 3 Tight-
ening torques - Specifications - Recommended products).
– Replace the clamping screw and check the seal of the engine. API: SG, SH
NOTE: Check the engine oil level after reinstalling the engine on
TEMPERATUR
the vehicle.
- WE RECOMMEND USING ONLY SYNTHETIC OILS – 0°C
32°F
+
OF KNOWN BRANDS HAVING OR EXCEEDING THE
QUALITY REQUIREMENTS OF API CLASSES SG OR
SH (CHECK THE INFORMATION PROVIDED ON THE CON-
TAINERS).
10W 40 15W 40
- AN INSUFFICIENT QUANTITY OF OIL, OR AN OIL OF IN- 10W 50 15W 50
FERIOR QUALITY, LEADS TO PREMATURE WEAR OF THE
ENGINE.
– Remove the saddle and the fuel tank with the deflectors.
– Loosen the clamp screw on the float chamber, drain the fuel
into a suitable container, then tighten the screw again.
– Unplug the valve sensor connector.
– Disconnect the sleeve.
– Remove the carburettor from the frame top.
– Refit the throttle twist grip and check that the cables can slide
freely.
– Loosen the two screws 1 and remove all breather pipes from
the carburettor.
1 1
– Remove the two screws 2 and remove the throttle valve cov-
er from the carburettor with the related gasket.
2 2
– Remove screw 3 and pull the jet needle out of the throttle
valve.
– Remove screw 4. 3
– Pull up the throttle valve lever and remove the throttle valve
complete with roller 5 and the throttle valve plate from the car- 5
burettor.
– Remove the two seal rings, the spring and the diaphragm from
the pump casing.
– Remove the float chamber screws and detach the float cham-
ber.
– Remove float pin 1 and remove the float together with the nee-
dle valve. 2
– Remove main jet 2.
– Remove screw 3 and pull the connecting piece out of the car-
burettor.
– Loosen the two screws and remove the suction pump and O-
ring 4 from the carburettor.
– Unscrew choke idling jet 5 and choke main jet 6. 4
– Clean all the jets and the other components and blow them
with compressed air.
– Clean the carburettor body and blow all the ducts inside it.
– Check the condition of all the gaskets and replace any dam-
aged ones. 6 6
1 2
– Insert the fuel connection into the carburettor and fasten it with
screw 4.
– Fit the spring, the washer and the O-ring on mixture adjusting
screw 7 and tighten the screw until it stops. 7
– Unscrew the mixture adjusting screw by the number of turns
that was taken note of during disassembly.
8
10
Original carburettor adjustment: see table in Chapter 3
Specifications.
– Fit idling jet 8, starting jet 9 and the nozzle complete with main 9
jet 10.
11
– Fit the carburettor float chamber complete with its gasket, po-
sition adjusting screw support 2 and fasten the float chamber
by means of screws 3. 2
3 4
– Fit the throttle sensor so that the flat area on the carburettor
engages the throttle sensor slot and fasten it by means of
screws 10.
10
10
– Pull up the throttle valve lever and insert the throttle valve
along with roller 8 and the plate in the carburettor, ensuring 9 8
that rollers 9 engage the throttle valve (see figure).
– Check the smoothness of the throttle valve.
– Position the throttle valve cover with the related gasket and
fasten it with the two screws 3.
3 3
– Fasten the breather pipes with the two float chamber screws
4.
4 4
– Now connect the multimeter to the yellow (+) and black (–)
wires of the throttle sensor.
– When the throttle twist grip is rotated slowly, the resistance Bl
should vary evenly.
Bl Gi
Bl = blue Ne
Gi = yellow
Ne = black
– When fitting the throttle sensor, ensure that the flat section of
the throttle pin engages the throttle sensor slot.
– Fit the two screws without tightening them and adjust the po-
sition of the throttle sensor.
10 34 36 37 43 45 46
48 39 24 13 30 31 72 5
19 21 25 73 28 32 8
Unscrew the four screws on the left side and the four screws on
the right side and then remove the fork from the brackets.
Removal
– Before performing this operation, thoroughly clean leg 6.
– Using a small screwdriver, pry dust scraper 12 off sheath 13
taking care not to score the fork leg.
– Push down the wiper seal along the leg and, using a jet of 12
compressed air, clean the wiper seal inside and its seat on the
6
sheath.
– Make the legs complete a short travel and remove any dirt
from the supporting tubes.
– Lubricate the wiper seal and the visible surface of the seal ring
with silicone grease.
Installation 12
- Manually press wiper seal 12 back into its seat.
Removal
– Using a cross-tip screwdriver, unscrew air bleed screw 14 on
each fork leg, in the upper part of the leg holder, to release the 14
pressure that may have built up inside. Perform this operation 50
on a monthly basis in case of standard road use, or after each
competition.
– Check the condition of seal ring 50 and if necessary replace
it.
Installation
- Tighten air bleed screw 14 to the prescribed torque (see table
in Cap. 3 Tightening torques - Specifications - Recommended
products), taking care not to damage seal ring 50.
20
21
– Remove plug 48, spring guide cup 20, spring 21 and preload
tube 25.
– Remove adjuster inside transmission rod 32 from the end of 48
rod 31.
– Release fork leg 5 from the vice and turn it upside down over 20 31
a suitable container to collect the oil it contains. Pump a few
times to facilitate the outflow.
21
NOTE: The appearance, density and quality of the spent oil is a
clue to the condition of the seals and guides. If the oil is dense
and dark and contains solid particles, replace the guide bushes
25
and the seals. 32
41
In the upper part of the tool there are two diametrically
opposite holes where a pin can be inserted to facilitate its
locking. However, the tool must on no account be turned
but should only be used to hold the fork leg inside components
in place.
21
28
29
27
35
Separating the fork leg from the leg holder and removing the
seal rings
12
11
11
39
10
12
35
33
34
36
37
38
36
Only use genuine Betamotor fins and pistons. Do not
modify the components. 34
38
Removal 42
– Clamp in a vice the foot screw through spanner slot 47.
– Unscrew nut 42 with a 13-mm spanner.
– Remove in succession nut 42, spring 33, fin 43, piston 45
complete with O-ring 44, compression adjusting reed or reeds
46.
47
42
33
44
43
45
46
46
Only use genuine Betamotor fins and pistons. Do not
modify the components.
47
Reassembling the fork leg and the sheath - Fitting the seal
rings
Never reuse any removed seal rings and wiper seals. Be-
fore reassembly, check the condition of the guide bush-
es. If they are scored or scratched, replace them. Ensure
that the Teflon lining of the guide bushes is intact.
10
11
12
– Gently insert the fork leg into the sheath, taking care to ensure
that the upper guide bush does not receive damage.
– Move the lower guide bush until it comes into contact with the
sheath, the cup and the seal ring.
10
– Using a small flat blade screwdriver, fit retaining ring 11, en-
suring that it is perfectly seated in the groove and taking care
not to score the fork leg.
11
12
– Insert stop pad tip 29 into rod 32 so that the side with the
spanner slot faces case 30 and the tip goes past wire groove
F.
F
27
29
23
24
32
23
In the upper part of the tool there are two diametrically op-
posite holes where a pin can be inserted to facilitate its
5
locking. However, the tool must on no account be turned
but should only be used to hold the fork leg inside components
in place.
41
Adding oil
– Push the sheath all the way up along the fork leg.
– Prepare the oil to be poured into the fork leg in a measuring
h
cup (see table in Chapter 3 Tightening torques - Specifications
- Recommended products).
– Pour approximately 2/3 of the oil into sheath 13, then pump a
few times to remove the air.
– Pour in the rest of the oil.
– Lower the leg holder on the fork leg until the wiper seal comes
into contact with the wheel holding foot.
– Wait a few minutes and then measure the volume of the air
(see table in Chapter 3 Tightening torques - Specifications - 13
Recommended products) and if necessary restore the level.
25 31
21
48
To ensure proper operation of the fork, fit the wheel on the fork
by following these steps:
– Insert the pin through the right-hand wheel holder, the wheel
and the left-hand wheel holder.
– Screw tight the pin nut on the left side.
– Push the fork legs completely and then release them a few
times.
– Tighten the two screws on the right-hand wheel holder in the
sequence 1-2-1.
1
2
– Push the brake caliper towards the disc so that the pistons
can reach their base position.
– Loosen grub screw A.
– Pull out pin B while supporting the two brake pads as shown
in the figure.
– Remove the pads taking care not to drop the leaf spring lo-
cated underneath.
– To refit the parts, follow the reverse procedure. When fitting
A
the brake pads, ensure that the leaf spring is properly posi-
tioned.
WARNING: Always keep the brake disc free from oil and
grease as these substances greatly reduce the braking
action.
Every time the braking system is serviced, operate the brake
lever to bring the pads into contact with the disc, restore the cor-
rect pressure point and ensure proper operation of the braking C
system.
Loosen the two screws C and remove the brake caliper. Re-
peatedly pull the brake lever. In these conditions, without the
brake pads in place, the pistons will come out of their seats, al-
lowing the pistons and the related oil seals to be removed. Re-
place the parts with those contained in the spare kit.
– Push the brake caliper towards the disc so that the pistons
can reach their base position. A
– Loosen grub screw A.
– Pull out pin B while supporting the two pads (see figure).
– Remove the pads taking care not to drop the leaf spring above
them.
– To refit the parts, follow the reverse procedure. When fitting
the brake pads, ensure that the leaf spring is properly posi-
tioned.
WARNING: Always keep the brake disc free from oil and
grease as these substances greatly reduce the braking
action.
Every time the braking system is serviced, operate the brake B
lever to bring the pads into contact with the disc, restore the cor-
rect pressure point and ensure proper operation of the braking
system.
After removing the caliper and the brake pads, repeatedly actu-
ate the brake lever until the piston comes out of its seat, then re-
move the piston and the oil seal and replace them with new
parts from a spare kit.
1) RH FRONT INDICATOR WITH 12V-10W BULB 21) REAR LIGHT WITH 12V- 5/21Wh BULB Bi = White
2) FRONT BRAKE LIGHT BUTTON 22) RH REAR INDICATOR WITH 12V-10W BULB Ve = Green
3) STARTER BUTTON 23) BATTERY POSITIVE TERMINAL Ma = Brown
4) WHEEL REVOLUTION SENSOR 24) 12V-4Ah BATTERY Vi = Purple
5) HIGH BEAM WARNING LIGHT 25) DYNAMO Bl = Blue
6) INDICATOR WARNING LIGHT 26) 10A FUSE Ne = Black
11 - Electrical system
7) DISPLAY 27) EARTH BRAID Gi = Yellow
8) LOW BEAM WARNING LIGHT 28) STARTING RELAY Rs = Red
9) DISCONNECTED 29) STARTER MOTOR Ar = Orange
10) MODE BUTTON 30) BATTERY NEGATIVE TERMINAL Az = Light Blue
11) ENGINE STOP BUTTON 31) CONTROL UNIT Ro = Pink
12) HORN BUTTON 32) HV COIL Gr = Grey
3
Checking for leakage currents
Check for leakage currents before inspecting the regulator-rec-
tifier.
– Disconnect the ignition and remove the earth cable from the
battery.
– Connect and ampere meter between the earth cable and the
negative terminal of the battery.
0,00
IMPORTANT:
– NEVER REMOVE THE BATTERY PLUGS.
– TO RECHARGE THE BATTERY, FIRST CONNECT THE
BATTERY TO THE CHARGER AND THEN TURN ON THE
Voltage di
Tensione at rest Batterydicahrge
riposo Stato carica Charge duration
Durata di carica Charge voltage
Tensione di
CHARGER. Volts
Volt %
% aat 0,5
0,5 AA carica
– IF THE BATTERY IS CHARGED INDOORS, TAKE CARE TO >12,7 100 ––
ENSURE PROPER VENTILATION. DURING THE CHARGE ~12,5 75 4h
THE BATTERY PRODUCES EXPLOSIVE GASES. ~12,2 50 7h Max.
– IF THE BATTERY IS OVERCHARGED, OR IF THE CHAR- ~12,0 25 11 h 14,4 V
GING VOLTAGE IS EXCESSIVE, THERE MAY BE AN OUT- ~11,8 0 14 h
FLOW OF ELECTROLYTE THROUGH THE SAFETY VAL- <11,5 0 20 h
NOTE: After filling the battery, allow it to rest for at least half an
hour without charging it.
RED probe
Puntale ROSSO
1 2
1 2 3 4
probe
Puntale NERO
'
' ==Corresponds
Corrispontetoall’indicazione
the multimeter reading when
che fornisc 3
4
Black
White
4 3
ilthe RED quando
tester and BLACK terminalsROSSO
i terminali are note in contact
NERO no
with one
sono another. tra di loro.
in contatto
1 2 3
probe
2 0,8 / 6150
tion switch and the wiring harness components.
– If the ignition system is correctly powered but no spark is pro- 3 6150 6150 /
duced, check the following: Tolerance ± 10 %
• Earth connection of the CDI unit and the ignition coil. Tolleranza ± 10%
• Wire connecting the CDI unit to the ignition coil. Tester for measurements up to 20.000 1
Tester per misure fino a 20.000 1
• Stator.
• Ignition coil.
WARNING:
Do not on any account fit a fuse of greater power or attempt to
“fix” the damaged fuse. Unsuitable servicing could cause dama-
ge to the entire electrical system.
4
NOTE: A slight click can be heard when the starting relay trips.
Instrument panel
To modify the instrument panel, it is advisable to replace it with
one that is known to be in working order, or perform a check as
shown in the table.
1 18
2 17
3 16
4 15
5 14
6 13
7 12
Puntale
RED ROSSO
probe
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
1 / ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' '
2 ' / ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' '
3 ' ' / ' ' ' ' ' ' ' ' ' ' ' ' ' ' '
4 ' ' ' / ' ' ' ' ' ' ' ' ' ' ' ' ' '
5 ' ' ' ' / ' ' ' ' ' ' ' ' ' ' ' ' '
6 ' ' ' ' ' / ' ' ' ' ' ' ' ' ' ' ' '
7 ' ' ' ' ' ' / ' ' ' ' ' ' ' ' ' ' '
BLACK NERO
probe
8 ' ' ' ' ' ' ' / ' ' ' ' ' ' ' ' ' '
9 ' ' ' ' ' ' ' ' / ' ' ' ' ' ' ' ' '
Puntale
10 ' ' ' ' ' ' ' ' ' / ' ' ' ' ' ' ' '
11 ' ' ' ' ' ' ' ' ' ' / ' ' ' ' ' ' '
12 ' ' ' ' ' ' ' ' ' ' ' / ' ' ' ' ' '
13 ' ' ' ' ' ' ' ' ' ' ' ' / ' ' ' ' '
14 ' ' ' ' ' ' ' ' ' ' ' ' ' / ' ' ' '
15 ' ' ' ' ' ' ' ' ' ' ' ' ' ' / ' ' '
16 ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' / ' '
17 ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' / '
18 ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' ' /