Beta Motorcycles 2016 RR 250 2T Instruction manual

040.44.003.00.00

www.betamotor.com
INTRODUCTION 2
ENGINE TECHNICAL SPECIFICATIONS 4
SPECIAL EQUIPMENT 5
1 ENGINE REMOVAL FROM VEHICLE 6
2 ENGINE DISASSEMBLY 17
2.1 CLUTCH/GEAR OIL DRAIN........................................... 17
2.2 REMOVAL OF CLUTCH CONTROL ROD AND PINION
SPACER ........................................................................... 17
2.3 REMOVAL OF PISTON, CYLINDER AND HEAD ........18
2.4 REMOVAL OF IGNITION UNIT.....................................21
2.4.1 REMOVAL OF FLYWHEEL COVER ...........................................21
2.4.2 STATOR REMOVAL........................................................................ 21
2.4.3 REMOVAL OF FLYWHEEL...........................................................22
2.4.4 REMOVAL OF PICK-UP UNIT.................................................... 22
2.5 REMOVAL OF ELECTRIC IGNITION ............................ 23
2.5.1 REMOVAL OF START MOTOR................................................... 24
2.5.2 REMOVAL OF BENDIX COUPLING.........................................24
2.6 REMOVAL OF COOLANT LIQUID PUMP, CLUTCH
UNIT, MAIN GEAR, CENTRIFUGAL UNIT, GEARSHIFT
ORGANS, KICKSTART ...................................................25
2.6.1 REMOVAL OF COOLANT LIQUID PUMP .............................28
2.6.2 REMOVAL OF CENTRIFUGAL UNIT AND LEVERAGE ...... 29
2.6.3 DISASSEMBLY OF CLUTCH UNIT AND COUNTERSHAFT
COUNTERWEIGHT .......................................................................32
2.6.4 PEDAL KICKSTART - OPTIONAL...............................................35
2.6.5 EXTERNAL GEARSHIFT UNIT ...................................................37
2.7 INTAKE SYSTEM.............................................................38
2.8 CRANKSHAFT, GEARBOX UNIT AND INTERNAL
GEARSHIFT .....................................................................39
2.8.1 OPENING THE CRANKCASE .................................................... 39
2.8.2 COUNTERWEIGHT SUPPORT SHAFT....................................40
2.8.3 CRANKSHAFT.................................................................................40
2.8.4
INTERNAL GEARSHIFT UNIT AND COMPLETE GEARBOX 41
2.9 DISASSEMBLY OF PARTS FROM CRANKCASES.......43
2.9.1 RIGHT CRANKCASE HALF .........................................................43
2.9.2 LEFT CRANKCASE HALF.............................................................45
3 ENGINE CHECKS AND ASSEMBLY 46
3.1 CRANKCASE HALF.........................................................46
3.1.1 APPLICATION OF RIGHT CRANKCASE HALF PARTS........ 47
3.1.2 APPLICATION OF LEFT CRANKCASE HALF PARTS...........49
3.2 CONNECTING ROD AND ENGINE SHAFT CHECK...50
3.3 ASSEMBLY OF COMPLETE CRANKSHAFT ................51
3.4 GEAR UNIT: CHECKS AND REASSEMBLY .................52
3.4.1 GEARBOX UNIT CHECK ............................................................52
3.4.2 PRIMARY UNIT ASSEMBLY........................................................ 53
3.4.3 SECONDARY UNIT ASSEMBLY.................................................54
3.4.4 CHECKING THE FORKS, FORK PINS AND DESMODROMIC
DEVICE .............................................................................................55
3.4.5 GEARBOX AND INTERNAL GEARSHIFT ASSEMBLY.........57
3.4.6 COUNTERWEIGHT SUPPORT SHAFT....................................60
3.5 CLOSING THE ENGINE CRANKCASE ......................... 61
3.6 EXTERNAL GEARSHIFT.................................................62
3.6.1 CHECKING THE COMPLETE DRIVE SHAFT ........................62
3.6.2 EXTERNAL GEARSHIFT ASSEMBLY ........................................64
3.7 KICKSTARTER DEVICE - OPTIONAL............................65
3.7.1
CHECKING THE KICKSTART SHAFT UNIT AND ASSEMBLY .. 65
3.7.2 ASSEMBLY OF KICKSTARTER DEVICE....................................66
3.8 COUNTERWEIGHT, PRIMARY GEAR AND CLUTCH
UNIT.................................................................................68
3.8.1 INSPECTION OF COUNTERWEIGHT
AND PRIMARY GEAR...................................................................68
3.8.2 APPLICATION OF PRIMARY GEAR
AND COUNTERWEIGHT ............................................................68
3.8.3 CHECKING THE CLUTCH CASE, ROLLER BEARING AND
INTERNAL CENTRE BEARING.................................................. 70
3.8.4 CHECKING THE CLUTCH DISCS............................................. 71
3.8.5 CHECKING THE SPRINGS......................................................... 71
3.8.6 CHECKING THE CLUTCH DRUM AND CAP ....................... 72
3.8.7 CHECKING THE THRUST BEARING DEVICE...................... 72
3.8.8 CLUTCH UNIT ASSEMBLY.......................................................... 73
3.9
COOLANT LIQUID PUMP AND CENTRIFUGAL UNIT... 76
3.9.1 CHECKING THE PUMP UNIT AND DISASSEMBLY,
CENTRIFUGAL UNIT AND IDLER UNIT ............................... 77
3.9.2 CENTRIFUGE UNIT GROUP ASSEMBLY ............................. 78
3.9.3 PUMP UNIT ASSEMBLY ............................................................ 81
3.9.4 ASSEMBLY OF COMPLETE CLUTCH COVER AND
PUMP UNIT.................................................................................... 81
TABLE OF CONTENTS

ENGLISH
3.10 ELECTRIC IGNITION UNIT ...........................................84
3.10.1 BENDIX COUPLING CHECKS...................................................84
3.10.2 IGNITION UNIT COUPLING TO ENGINE ............................84
3.11 IGNITION SYSTEM.........................................................85
3.11.1 IGNITION SYSTEM CHECK .......................................................86
3.11.2 COUPLING OF IGNITION SYSTEM TO CRANKCASE ....... 86
3.12 THERMAL UNIT .............................................................89
3.12.1 CHECKING THE PISTON AND ELASTIC BANDS ...............89
3.12.2 CYLINDER CHECK........................................................................90
3.12.3 PISTON CYLINDER COUPLING PLAY .................................... 91
3.12.4 CHECKS AND EXHAUST VALVE UNIT DISASSEMBLY...... 91
3.12.5 EXHAUST VALVE ...........................................................................93
UNIT ASSEMBLY............................................................................93
3.12.6 PISTON, PIN BOLT, ELASTIC BANDS AND CYLINDER
ASSEMBLY ......................................................................................95
3.12.7
CHECK OF CRANKCASE/CYLINDER GASKET THICKNESS .. 97
3.12.8 HEAD APPLICATION ....................................................................98
3.12.9 EXHAUST VALVE ...........................................................................99
ADJUSTMENT ................................................................................99
3.13 CHECK OF INTAKE UNIT AND ASSEMBLY..............103
3.14 INSERTION OF CLUTCH ROD AND PINION
SPACER..........................................................................105
4 ENGINE REASSEMBLY IN THE VEHICLE 106
TABLE OF ENGINE COMPONENTS TIGHTENING TORQUES 116
TABLE OF FRAME/ENGINE TIGHTENING TORQUES 118
TABLE OF SUPERSTRUCTURE TIGHTENING TORQUES 118
RECOMMENDED ENGINE MAINTENANCE 119
TABLE OF CONTENTS

INTRODUCTION
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Carbon monoxide
• Exhaust gases contain carbon monoxide, which
is poisonous. Carbon monoxide may cause loss
of consciousness and lead to death. If the en-
gine needs to be started, make sure the loca-
tion is well-ventilated. Never start the engine
indoors.
• The engine can be started indoors only if fitted
with the appropriate exhaust gas extraction de-
vices.
Petrol
• Petrol is extremely flammable and can be ex-
plosive under certain conditions.
• Keep sources of heat, sparks and flames away
from the work area.
• Always work in a well-ventilated area.
• Never use petrol as a solvent for cleaning. Do
not handle it unless strictly necessary.
• Never use petrol to clean components by means
of compressed air.
• Keep out of the reach of children.
Engine oil
• Motor oil can cause skin conditions if it remains
in contact with the skin often and for prolonged
periods.
• In case of contact with engine oil, wash with
soap and water as soon as possible.
• In case of contact with the eyes, rinse them
with plenty of water and seek medical advice.
• If swallowed, do not induce vomiting in order
to prevent the product from entering into the
lungs; seek immediate medical advice. If you
believe the product has entered the lungs, take
the person concerned to hospital immediately.
• Waste oil contains dangerous substances that
are harmful for the environment. In order to
change it one must be equipped for disposal,
in compliance with applicable laws.
• Do not discard waste oil into the environment.
• Keep out of the reach of children.
INTRODUCTION
This publication is intended for workshops specialised in repairing mopeds 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 repairs:
• Are NOT performed by workshops specialised in repairing mopeds and motorcycles;
• Are NOT carried out carefully following the requirements contained in the technical documentation;
• Are NOT carried out using special Betamotor tools, where required;
• Are NOT carried out using Betamotor official spare parts.
Carefully read this manual in its entirety before working on the engine. Good knowledge of all compo-
nents making up the engine and all the procedures to be followed for inspection and maintenance help
extend 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
Everything we do has an impact on the whole Planet and its Resources. To safeguard the interests of
the entire Community, Betamotor S.p.A. would like to raise the awareness of customers and techni-
cal service operators on ways of using the vehicle and disposing of its parts entirely in compliance
with applicable regulations in terms of environmental pollution, waste disposal and recycling.
SAFETY

INTRODUCTION
Coolant liquid
• In some situations, the ethylene glycol con-
tained in the coolant is flammable and its flame
is invisible. Should ethylene glycol catch fire, it
can cause burns even though its flame is invis-
ible.
• Do not bring the coolant into contact with hot
parts. These parts could be hot enough to cause
the liquid to ignite.
• The coolant (ethylene glycol) may irritate the
skin and is poisonous if swallowed.
• Should the coolant come into contact with the
skin, immediately remove contaminated cloth-
ing or footwear and wash with soap and water.
In the event of contact with the eyes, rinse with
plenty of clean water and seek medical advice
immediately. Should it be swallowed, do not
induce vomiting in order to prevent the prod-
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.
• Do not remove the radiator cap when the en-
gine is still hot. Since the coolant is pressur-
ised, it may spurt out violently and cause burns.
• The coolant contains dangerous substances
that are harmful for the environment. In order
to change it one must be equipped for disposal
in compliance with applicable laws.
• Do not disperse coolant into the environment.
• Keep out of the reach of children.
Hot parts
• The engine and the exhaust system get very hot
and remain at that temperature for a long time,
even after the engine has been turned off. Wait
for them to cool down before handling these
parts or carrying out work on areas around
them. Wear insulated gloves.
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• Before disassembly, thoroughly clean the mo-
torcycle.
• While disassembling it, clean all the parts and
place them in containers accurately following
the order of disassembly.
• Always use special tools wherever necessary
and when required.
• Always use glues, sealant and lubricants
wherever required. Follow the indications con-
cerning their technical features.
• Always replace parts such as gaskets, O-rings
and safety washers with newly supplied parts.
• When loosening or tightening nuts or screws,
always start with the larger ones or from the
centre. Always adhere to the specified tight-
ening torques.
• Use only Betamotor original spare parts.
WARNINGS
The information contained in this paragraph is important to ensure the operations carried out
on the engine are performed without causing damage.

ENGINE
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ENGINE TECHNICAL SPECIFICATIONS
CHARACTERISTIC DATA ENGINE
RR250 RR300
Bore [mm]/Stroke [mm] 66.4/72 72/72
Displacement [cm³] 249 293
Compression ratio 13.2:1 11.9:1
TRANSMISSION
RR250 RR300
Primary 27/72 27/72
1st gear ratio 12/31 12/31
2nd gear ratio 15/28 15/28
3rd gear ratio 19/28 19/28
4th gear ratio 20/24 20/24
5th gear ratio 27/27 27/27
6th gear ratio 28/24 28/24

ENGINE
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SPECIAL EQUIPMENT
1. Complete EVO 2T crankcase uncoupler 007.14.010.80.00
2. Special wrench 029.14.002.50.00
3. Squish measuring tool 026.14.010.00.00
4. Front bracket for fastening engine to stand 026.14.003.00.00
5. Flywheel blocking tool 026.14.005.50.00
6. Flywheel extractor 36.25173.000
7. EXC engine universal assembly equipment 36.25132.000
8. Special wrench 026.44.029.00.00
9. Special wrench 026.44.028.00.00
10. Special wrench 007.44.035.00.00
11. Special wrench 026.14.012.50.00.
Symbols
6Nm
Silicone paste
Value
Tightening torque
Threadlocker
medium-resistance
Grease
High-resistance
threadlocker

1
6
1
2
ENGINE REMOVAL FROM VEHICLE
• Carefully wash the vehicle;
• Remove the engine guard plate;
• Place the vehicle on an adequate stand.
1 ENGINE REMOVAL FROM VEHICLE
To dismantle the tank from the vehicle it is
necessary 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
always turn off the engine.
Wipe off any traces of spilled fuel
immediately.
Remove the screw 1fastening the tank to the
frame, and the screws 2(one per side) fastening
the side panel to the radiator.

1
7
3
4
ENGINE REMOVAL FROM VEHICLE
Lift the tank slightly and:
• remove pipe 3
• disconnect the connector 4
Lift the tank from the back and remove it
backwards.

1
8
5
6
78
9
10
ENGINE REMOVAL FROM VEHICLE
• Remove the frame guards 5(one on each
side) and the pinion guard 6.
• Remove the circlip 7and extract the pinion.
Rest the chain against the upper wedge 8.
• Remove the screw 9.
• Remove the screws 10.
• Remove the silencer from the vehicle.
• Remove the exhaust pipe.

1
9
11
12
ENGINE REMOVAL FROM VEHICLE
• Remove the screws 11 fastening the clutch
actuator to the crankcase half.
ATTENTION!
Do not operate the clutch lever with the actuator
uncoupled from the engine.
• Drain the cooling system through the screw
12 and let the liquid outflow into a contain-
er (the cooling circuit contains 1.3l of liquid).
Remove the radiator cap.
Note: To make the circuit easier to empty, it is
advisable to slightly tilt the vehicle on the left side.
• Remove the protection grids from the radia-
tors.
• Disconnect the water hoses from the engine
and from the left radiator.

1
10
ENGINE REMOVAL FROM VEHICLE
• Remove the fixing screws and remove the left
radiator.
• Disconnect the water hoses from the engine
and from the right radiator.

1
11
15
14
13
ENGINE REMOVAL FROM VEHICLE
• Remove the fixing screws and remove the
right radiator.
• Disconnect the spark plug cap.
• Cut all straps binding the engine's electric
system to the clutch pipe and to the frame.
• Release the connectors 13, 14, 15 of the en-
gine ignition unit and disconnect them from
the electrical system.

1
12
16
17
18
ENGINE REMOVAL FROM VEHICLE
• Remove the head connections and spark plug.
• Remove the starter motor cable fixing nut.
Note: It is advisable to insert a clean cloth into the
spark plug housing in order to prevent accidental
introduction of dirt into the cylinder.
• Release and remove the brake pedal return
spring 16. Remove the kickstarter lever (op-
tional).
• Remove the gear lever.
• Pull out the mixer tube 17 from the intake
manifold and tube hole 18.

1
13
19
ENGINE REMOVAL FROM VEHICLE
ATTENTION!
When the mixer tube has been disconnected,
plug it to prevent emptying.
• Loosen the carburettor straps from the air fil-
ter sleeve and from the manifold.
• Disconnect the connector 19.

1
14
20
21
ENGINE REMOVAL FROM VEHICLE
• Remove the subframe lower fixing screws
20 (one on each side) and loosen the upper
screws 21 (one on each side).
• Rotate the entire filter box unit.
• Remove the carburettor, leaving it connected
to the gas cable.
• Cut the clamp shown.

1
15
22
A
B
ENGINE REMOVAL FROM VEHICLE
• Disconnect the connector 22.
• Remove the brake light wiring Aand starter
motor cable Bfrom the carburettor.

1
16
23
25
24
ENGINE REMOVAL FROM VEHICLE
• Remove the swingarm pin. Pull the entire
wheel/swingarm unit outwards.
• Extract the engine from the frame and apply
it to the specific stand, code 3625132 000,
using the specific front fixing bracket, code
026140030 000.
• Remove the shock-absorber pin 23.
• Remove the gear lever 24 and the engine pins
25.

2
17
1
2
1
ENGINE DISASSEMBLY
Secure the engine to the specific support stand
code 3625132000 by means of the front fixing
code 026140030 000, in order to work in comfort
and safety. Then proceed as follows.
2.1 CLUTCH/GEAR OIL DRAIN
Remove screw 1and let the oil drain.
2.2 REMOVAL OF CLUTCH
CONTROL ROD AND PIN-
ION SPACER
Pull out the spacer 1.
Pull out the clutch control rod 2.
2 ENGINE DISASSEMBLY

2
18
3
4
1
2
ENGINE DISASSEMBLY
2.3 REMOVAL OF PISTON, CYL-
INDER AND HEAD
Remove the spigot screws 1together with the
copper washers. Remove the head and the two
O-rings.
Remove the four screws 2.
Remove the three screws 3and cover 4.