Beta Enduro RR 250 2016 Instruction manual

COD. 026.44.018.00.00

TABLE OF CONTENTS
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PREAMBLE 2
TECHNICAL FEATURES OF ENGINE 4
SPECIAL EQUIPMENT 5
1 REMOVAL OF MOTOR FROM VEHICLE 6
2 ENGINE DISASSEMBLY 13
2.1 CLUTCH/GEAR OIL DRAIN......................................................13
2.2 REMOVAL OF CLUTCH CONTROL ROD AND PINION
SPACER ......................................................................................13
2.3 REMOVAL OF PISTON, CYLINDER AND HEAD ...................14
2.4 REMOVAL OF IGNITION UNIT ...............................................17
2.4.1 Removal of flywheel coveR........................................................ 17
2.4.2 Removal of statoR ............................................................................. 17
2.4.4 Removal of pick-up............................................................................ 18
2.4.3 Removal of flywheel ....................................................................... 18
2.5 REMOVAL OF ELECTRIC IGNITION .......................................19
2.5.1 Removal of staRt motoR................................................................ 20
2.5.2 Removal of Bendix coupling ..................................................... 20
2.6 REMOVAL OF COOLANT LIQUID PUMP, CLUTCH UNIT,
MAIN GEAR, CENTRIFUGAL UNIT, GEARSHIFT ORGANS,
KICKSTART .................................................................................21
2.6.1 Removal of coolant liquid pump.......................................... 24
2.6.2 Removal of centRifugal unit and leveRage................... 25
2.6.3 Removal of main geaR and clutch unit ............................ 28
2.6.4 pedal kickstaRt..................................................................................... 31
2.6.5 exteRnal geaRshift unit................................................................ 33
2.7 INTAKE SYSTEM........................................................................34
2.8 CRANKSHAFT, GEARBOX UNIT AND INTERNAL
GEARSHIFT ................................................................................35
2.81 opening of cRankcase ................................................................... 35
2.8.2 motoR shaft........................................................................................... 36
2.8.3 inteRnal geaRshift unit and complete geaRBox ........ 36
2.9 DISASSEMBLY OF PARTS FROM CRANKCASES..................37
2.9.1 Right cRankcase half...................................................................... 37
2.9.2 left cRankcase half ......................................................................... 40
3 MOTOR CHECKS AND ASSEMBLY 41
3.1 CRANKCASE HALF ...................................................................41
3.1.1 application of Right cRankcase half paRts.................... 42
3.1.2 application of left cRankcase half paRts........................ 44
3.2 CHECK OF CONNECTING ROD AND MOTOR SHAFT.........45
3.3 ASSEMBLING OF COMPLETE CRANKSHAFT ......................46
3.4 GEAR UNIT: CHECKS AND REASSEMBLY ............................47
3.4.1 check of geaRBox unit................................................................... 47
3.4.2 assemBly of main unit .................................................................... 48
3.4.3 assemBly of secondaRy unit...................................................... 49
3.4.4 check of foRks, foRk pins and desmodRomic
device.......................................................................................................... 50
3.4.5 assemBly of geaRBox and inneR contRol........................ 52
3.5 CLOSING OF ENGINE CRANKCASE.......................................55
3.6 EXTERNAL GEARSHIFT............................................................56
3.6.1 check of complete dRive shaft ............................................... 56
3.6.2 assemBly of exteRnal geaRshift.............................................. 58
3.7 KICK STARTER DEVICE.............................................................58
3.7.1 check of kickstaRt shaft and assemBly ............................ 58
3.7.2 assemBly of kickstaRt device ..................................................... 60
3.8 MAIN GEAR AND CLUTCH UNIT............................................62
3.8.1 check of main geaR .......................................................................... 62
3.8.2 application of main geaR.............................................................. 62
3.8.3 check of clutch case, RolleR BeaRing and inteRnal
centRe BeaRing .................................................................................... 63
3.8.4 check of clutch discs.................................................................... 64
3.8.5 check of spRings .............................................................................. 65
3.8.6 check of clutch dRum................................................................... 65
3.8.7 check of thRust BeaRing device............................................. 66
3.8.8 assemBly of clutch unit............................................................... 66
3.9 COOLANT LIQUID PUMP AND CENTRIFUGAL UNIT ........68
3.9.1 check of pump unit and disassemBly, centRifugal
unit and idleR unit .......................................................................... 69
3.9.2 assemBly of centRifugal unit ................................................. 70
3.9.3 assemBly of pump unit................................................................... 73
3.9.4 assemBly of complete clutch coveR and pump
unit............................................................................................................... 73
3.10 ELECTRIC IGNITION UNIT ......................................................76
3.10.1 Bendix coupling checks .............................................................. 76
3.10.2 ignition unit coupling to motoR ......................................... 76
3.11 IGNITION SYSTEM ..................................................................77
3.11.1 check of ignition system ............................................................ 78
3.11.2 coupling of ignition system to cRankcase.................... 78
3.12 THERMAL UNIT ........................................................................81
3.12.1 checking piston and elastic Bands ..................................... 81
3.12.2 cylindeR check..................................................................................... 82
3.12.3 piston cylindeR coupling play................................................. 83
3.12.4 checks and exhaust valve unit disassemBly.................. 83
3.12.5 exhaust valve unit assemBly ...................................................... 85
3.12.6 piston, pin Bolt, elastic Bands and cylindeR
assemBly .................................................................................................. 87
3.12.7 check of cRankcase/cylindeR gasket thickness........ 89
3.12.8 head application................................................................................. 90
3.12.9 exhaust valve adjustment ........................................................... 91

ENGLISH
TABLE OF CONTENTS
3.13 CHECK OF INTAKE UNIT AND ASSEMBLY...........................95
3.14 INSERTION OF CLUTCH ROD AND PINION SPACER .........97
4 REASSEMBLY OF MOTOR IN VEHICLE 98
TABLE OF FASTENING TORQUES OF ENGINE COMPONENTS 104
TABLE OF FRAME/MOTOR FASTENING TORQUES 106
TABLE OF SUPERSTRUCTURE FASTENING TO RQUE VALUES 106
RECOMMENDED MOTOR MAINTENANCE 107
RECOMMENDED LUBRICANTS AND LIQUIDS 107

PREAMBLE
Carbon monoxide
• Exhaust gases contain carbon which is poison-
ous. Carbon monoxide can cause loss of con-
science and lead to death. When starting the
engine, make sure the place you are in is well-
ventilated. Never start the engine in a closed
place.
• Starting the engine in closed places can be
done only if provided with relevant gas dis-
charge evacuation devices.
Petrol
• Petrol is extremely flammable and can be ex-
plosive in some conditions.
• Keep heat sources, 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 absolutely necessary.
• Never use petrol to clean components by means
of compressed air.
• Keep out of the reach of children.
Motor oil
• Motor oil can cause skin illnesses if carried of-
ten and for prolonged periods in contact with
skin.
• If you touch motor oil, clean parts with soap
and water as soon as possible.
• In case of contact with the eyes, rinse them
abundantly with water and seek medical ad-
vice.
• If swallowed, do not induce vomiting in order
to avoid breathing the product into the lungs;
seek immediate medical advice. If you believe
the product has been breathed into the lungs,
bring the concerned person urgently to the
hospital.
• Used oil contains dangerous substances which
are harmful for the environment. When chang-
ing it, you must be equipped to dispose of it in
compliance with existing law.
• Avoid dispersing used oils in the environment.
• Keep out of the reach of children.
PREAMBLE
This publication has been written in order to make operations for inspection, maintenance and repairs
of the motorcycle engine known and understandable to the user of the motorcycle and to the technical
assistance operator.
Read this entire manual with care before operating on the engine. Sufficient knowledge of the compo-
nents that make up the engine and of all the procedures to be followed for inspection and maintenance
contribute to lengthen the life of the engine.
The paragraphs have been enhanced with schematic illustrations highlighting each subject in order to
make reading immediately understandable.
Informative note
Betamotor S.p.A. is engaged in a policy of ongoing improvement of its products. This is why it could be
possible to note slight differences between the contents of this document and the vehicle upon which
you are carrying out repairs and/ or maintenance. Betamotor S.p.A. models are exported to numerous
countries in which there are different standards concerning Highway Codes and procedures for approval
of the vehicle. Relying on your understanding, Betamotor S.p.A. therefore deems it necessary to reserve
the right to modify its products and technical documentation at any time without prior warning.
We respect and defend the environment
All that we do has an impact on the whole Planet and its resources. Wishing to safeguard the inter-
ests of the entire Community, Betamotor S.p.A. would like to make customers and technical opera-
tors aware of ways of using the vehicle and of disposing of its parts in full compliance with standards
in force in terms of environmental pollution, waste disposal and recycling.
2
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SAFETY

PREAMBLE
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,
though its flame is invisible, it can cause burns.
• Do not bring the coolant in contact with hot
parts. These parts could be hot enough to cause
the liquid to ignite.
• The coolant (ethylene glycol) can irritate 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 wa-
ter. In case of contact with the eyes, rinse them
abundantly with clean water and seek medical
advice immediately. Should it be swallowed, do
not induce vomiting in order to avoid breath-
ing the product into the lungs. Administer clean
water and bring the concerned person immedi-
ately to the hospital, showing this product to
the hospital staff.
• In the event of exposure to a high concentra-
tion of vapours, bring the concerned person to
an uncontaminated atmosphere and seek med-
ical advice if necessary.
• Do not remove the radiator cap when the en-
gine is still hot. When coolant is pressurised, it
can spurt out violently and cause burns.
• Coolant contains dangerous substances which
are harmful for the environment. When chang-
ing it, you must be equipped to dispose of it in
compliance with existing law.
• 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 stay 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 intervening on areas around them. Use
insulated gloves.
3
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•Before disassembling, clean the motorcycle
thoroughly.
•Whileyouaredisassemblingit,cleanallthe
partsandplacethemincontainersexactlyre-
spectingtheorderofdisassembly.
•Alwaysusespecialtoolswherevernecessary
andwhenthusprescribed.
•Alwaysuseglues,sealantandlubricantswhe-
reverprescribed.Respect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 respect the indicated tighte-
ningtorques.
•UseonlyBetamotororiginalspareparts.
WARNINGS
Theinformationcontainedinthisparagraphisimportantsothattheoperationscarriedouton
theenginecanbeperformedwithoutcausingdamage.

ENGINE
4
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TECHNICAL FEATURES OF ENGINE
CHARACTERISTIC DATA ENGINE
RR250 RR300
Bore[mm]/Stroke [mm] 66,4/72 72/72
Displacement [cm³] 249 293
Compression ratio 13,5:1 11,5:1
TRANSMISSION
RR250 RR300
Main 28/70 28/70
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
CARBURETOR
RR250 RR300
Version Approv.Race*Approv.Race*
Carburetor type PWK 36S AG PWK 36S AG
Main jet 118 165 118 165
Slow jet 35 35 38 38
Ignition jet 50 85 50 85
Needle N84K N0ZJ N84K N2ZW
Needle position
(from above)
3°+1/2 2° 4° 2°
Air screw turns
(from all closed)
1+3/4 1+1/4 21+1/4
Flush SI NO SI NO
* this modification makes the vehicle non-compliant with
the highway code in force. Use must be limited to private
circuits closed to circulation

ENGINE
5
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SPECIAL EQUIPMENT
1. Crankcaseuncouplercode0100042000
2. Clutchdrumnut/Maintoolcode026140010000
3. Crankcase/Cylindergasketcheckplatecode026140020000
4. Frontbracketcode026140030000tofixenginetostandcode
3625132000
5. Flywheelblockingtoolcode026140040000
6. Flywheelextractorcode3625173000
7. Enginesupportstandcode3625132000
6Nm
Pastasiliconica
Grease
Value
Fasteningtorque
Symbols
Loctite243/
Sichel100M

1
6
Removal of motoR fRom vehicle
• Carefully wash the vehicle;
• Remove the engine guard plate;
• Place the vehicle onto an adequate stand.
• Disconnect the tank ventilation pipe.
• Set the fuel valve to OFF and disconnect the
fuel pipe from the valve.
• Remove the seat.
• Grasp the side panel from the front and pull
outwards.
• Remove the two screws 1fastening the tank
to the frame and the screw (2- one per side)
fastening the side panel to the radiator.
1
2
1
1 REMOVAL OF MOTOR FROM VEHICLE

1
7
Removal of motoR fRom vehicle
• Remove the tank along with the sides.
• Remove the frame guards 3 (one each side)
and the pinion guard 4.
• Remove the circlip 5 and extract the pinion.
Rest the chain against the upper wedge 6.
4
3
56
• Remove the screws 7 fixing the clutch actua-
tor to the crankcase half.
7
ATTENTION!
Donotactivatetheclutchleverwithactuator
decoupledfromengine.

1
8
Removal of motoR fRom vehicle
• Disconnect the water hoses from the engine
and from the right radiator.
• Remove the right radiator.
• Remove the left radiator with pipes.
8
• Remove the exhaust expansion and the silen-
cer.
• Drain the cooling system through screw 8and
let the liquid outflow into a container (the co-
oling circuit contains 1.3l of liquid). Remove
the radiator cap.

1
9
Removal of motoR fRom vehicle
• Disconnect the spark plug cap, the connec-
tors from the coil and remove the coil itself.
Cut all straps binding the engine’s electric
system to the clutch pipe and to the frame.
• Disconnect the engine ventilation pipes
9
10
• Pull the mixer tube 9out from the intake ma-
nifold and tube hold 10.
ATTENTION!
Whenthemixertubehasbeendisconnected,
plugittopreventemptying.

1
10
Removal of motoR fRom vehicle
• Remove the head connections and spark plug.
• Release and remove the brake pedal return
spring 7. Remove the kickstarter lever.
• Remove the gear lever.
11
• Remove the start motor cable fixing nut.

1
11
Removal of motoR fRom vehicle
• Loosen the carburetor straps from the air fil-
ter sleeve and from the manifold.
• Remove the seat rail lower fixing screws 12
(one each side) and loosen the upper screws
13 (one each side).
• Rotate the filter box unit.
• Remove the carburetor leaving it connected
to the gas cable.
12
13

14
15
16
1
12
Removal of motoR fRom vehicle
• Remove the swingarm pin 14 and the upper
shock-absorber pin 15.
• Remove the engine pins 16.
Extract the engine from the frame and apply it to
the specific stand code3625132000 using spe-
cific front fixing bracket code026140030000.

2
13
EnginE disassEmbly
Secure the engine to the specific support stand
code 3625132000 by means of 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.
1
2.2 REMOVAL OF CLUTCH
CONTROL ROD AND PI-
NION SPACER
Extract the spacer 1.
Extract the clutch control rod 2.
2
1
2 ENGINE DISASSEMBLY

2
14
EnginE disassEmbly
2.3 REMOVAL OF PISTON,
CYLINDER 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.
1
2
3
4

2
15
EnginE disassEmbly
Release the lock 5and remove it.
Release the control rod 6.
Remove the gasket 7. It may be necessary to force
the rubber gasket 8slightly; place a metal pin A
between the lever and the gasket 8and force it
externally slightly.
5
Removal of gasket 7.
A
7
68

2
16
EnginE disassEmbly
Remove the four collar nuts 9.
9
Extract the cylinder and base gaskets.
ATTENTION!
Placeacleanclothbetweenthepistonandthe
crankcase to keep foreign objects or simple
solidresiduefromfallinginsidethebase.
Remove the circlip 10 by gripping it with a pair
of fine nose pliers A.
Push the pin bolt with an aluminium cylinder
(or similar) B, until the pin bolt is released
from the connecting rod foot
Remove the piston, the pin bolt and the bear-
ing from the connecting rod foot.
ATTENTION: Try pulling out the pin bolt by
hand first of all. If it is too tight, hit the pin
lightly with a rubber hammer, at the same
timeholdingthepistonwithyourhandinor-
dernottostresstheconnectingrod.
A
10
Removal of piston circlip.
Removal of pin bolt.
B

2
17
EnginE disassEmbly
2.4 REMOVAL OF IGNITION
UNIT
The ignition unit is made up of the flywheel (or
rotor), the pick-up and the stator which is one
with the flywheel cover.
2.4.1 Removal of flywheel cover
Remove the five screws 1fastening the flywheel
cover 2to the left crankcase.
Remove the flywheel cover and the gasket placed
between the crankcase and the cover.
Be careful of the two centring pins 3on the
crankcase.
Fixing screws 1 of flywheel cover 2.
The two references pins 3 dedicated to the flywheel cover.
1
2
3
2.4.2 Removal of stator
Remove the two screws 1fixing the stator 2to the
flywheel cover 3. Extract the plate 4and the cable
gland 5from the cover and extract the stator.
Disassembly of stator from cover.
1
2
4
53

2
18
EnginE disassEmbly
Removal of flywheel nut.
2.4.3 Removal of flywheel
Block the flywheel using special tool A(code
026140040 000) and remove the fastening
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theflywheel.
A
To remove the flywheel, tighten the extractor B
(code 3625173) onto the threaded part on the
flywheel.
Keep the extractor blocked with spanner and
tighten the screw on the extractor using a box
spanner.
Release of flywheel using special tool B.
Removal of pick-up.
2.4.4 Removal of pick-up
Remove pick up 1by loosening the two fixing
screws 2.
B
1
2