Beta Enduro RR 350 2013 Instruction manual

INDEX
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PREAMBLE / WARNINGS 2
TECHNICAL FEATURES OF ENGINE TABLE 4
SPECIAL TOOLS 5
1ENGINE DISASSEMBLY 6
1.1 THERMAL UNIT 8
1.1.1 Cylinder head: disassembling mechanical tensioner 10
1.1.2 Cylinder head: disassembling camshaft support,
chain guide and spark plug seat O-ring 10
1.1.3 Cylinder head: removing camshafts 12
1.1.4 Cylinder head: uncoupling from cylinder 13
1.1.5 Disassembling cylinder and piston 15
1.2 DISASSEMBLY OF IGNITION UNIT,
TIMING CHAIN AND GUIDES 16
1.2.1 Stator and flywheel 16
1.2.2 Timing chain and guides 18
1.2.3 Pick-up 20
1.3 PINION AND SPACER 20
1.4 CLUTCH UNIT AND COOLANT PUMP COVER 21
1.5 ENGINE LUBRICATION CIRCUIT 25
1.5.1 Oil pumps control gears 26
1.5.2 High-pressure oil pump 26
1.5.3 Low-pressure oil pump and by-pass valve 27
1.5.4 Oil pressure control valve 28
1.5.5 Paper oil filter 28
1.6 COUNTERSHAFT 29
1.7 PRIMARY GEAR 30
1.8 ELECTRIC IGNITION 31
1.8.1 Start motor 31
1.9 KICKSTARTER 33
1.10 EXTERNAL GEARSHIFT UNIT 35
1.11 CRANKSHAFT, GEARBOX UNIT AND
INTERNAL GEARSHIFT 36
1.11.1 Nut on left side of crankshaft 36
1.11.2 Opening crankcase 36
1.11.3 Crankshaft 38
1.11.4 Internal gearshift unit and complete gearbox 38
1.12 DISASSEMBLY OF PARTS FROM CRANKCASES 40
1.12.1.1 Right crankcase half 40
1.12.1. 2 Piston oil jets 40
1.12.1. 3 Extraction of countershaft support bearing 41
1.12. 2 Left crankcase half 41
1.12. 2.1 Inner oil filter 42
1.12.2.2 Extraction of desmodromic device bearing 42
2ENGINE ASSEMBLY AND CONTROLS 43
2.1 CRANKCASE HALVES 44
2.1.1 External right side 45
2.1.1.1 Insertion of oil seal and countershaft support bearing 47
2.1.2 Internal right side 48
2.1.3 External left side 49
2.1.4 Internal left side 50
2.2 CHECKING CRANKSHAFT AND CONNECTING ROD 51
2.3 ASSEMBLING COMPLETE CRANKSHAFT 53
2.4 GEARBOX UNIT: CONTROLS AND REASSEMBLY 54
2.4.1 Checking gearbox unit 54
2.4.2 Primary unit assembly 55
2.4.3 Secondary unit assembly 56
2.4.4 Checking the forks, fork pins and
desmodromic device 57

ENGLISH
INDEX
Table of tightening torques of engine components 127
Engine/frame table of tightening torques 129
Recommended engine maintenance 130
Recommended lubricants and liquids 130
2.5 ASSEMBLY OF INTERNAL GEARBOX AND GEARSHIFT 59
2.6 CLOSING ENGINE BLOCK 62
2.7
BLOCKING THE CRANKSHAFT AT THE TOP DEAD
CENTRE AND TIGHTENING THE NUT ON THE LEFT
SIDE OF THE CRANKSHAFT
63
2.8 EXTERNAL GEARSHIFT 64
2.8.1 Checking the complete drive shaft 64
2.8.2 Assembly of external gearshift 66
2.9 KICK STARTER 66
2.9.1 Checking kickstarter shaft unit and assembly 66
2.9.2 Assembly of kickstart device 68
2.10 ELECTRICAL STARTER UNIT AND MAIN GEAR 69
2.10.1 Checking electrical starter device elements 69
2.10. 2 Coupling ignition and primary gears to the motor 70
2.11 OIL PUMPS: CONTROL AND REASSEMBLY 72
2.11.1 Assembly of low pressure pump 74
2.11.2 Assembly of high-pressure pump and control gear 75
2.11.3 Checking and assembly of pressure control valve 75
2.11.4 Checking and assembly of oil pumps control gears 76
2.11.5 Paper oil filter insertion 77
2.11.6 Checking and coupling countershaft 78
2.12 CLUTCH UNIT 80
2.12.1 Checking clutch basket, roller bearing and
internal centre bearing 80
2.12. 2 Checking clutch discs 81
2.12. 3 Checking springs 82
2.12. 4 Checking inner hub 82
2.12. 5 Checking thrust bearing device 83
2.12. 6 Assembly of clutch unit 83
2.13 COOLANT PUMP 86
2.13.1 Checking pump unit and disassembly 86
2.13. 2 Assembly of pump unit 87
2.14 ASSEMBLY OF COMPLETE CLUTCH COVER 88
2.15 CHECKING AND COUPLING OF TIMING CHAIN,
FIXED AND MOBILE GUIDES 90
2.16 IGNITION SYSTEM 90
2.16.1 Checking ignition system 91
2.16. 2 Coupling ignition system to crankcase 91
2.17 THERMAL UNIT 94
2.17.1 Checking piston, pin bolt, and piston rings 94
2.17. 2 Checking the cylinder 96
2.17. 2.1 Assembly clearance 96
2.17. 3
Cylinder head: disassembly and checking auxiliary
devices
97
2.17. 3.1 Lubrication jets and centring pins 97
2.17.3.2 Finger follower/shafts unit 98
2.17.3.3 Shims (calibrated discs) for valve play adjustment 99
2.17. 4 Cylinder head: disassembling and
checking valve units 100
2.17. 4.1 Springs 101
2.17.4.2 Valve guides, valves and seats 101
2.17.4.3 Valve stem seal and lower stop washer 103
2.17. 5 Cylinder head: checking cylinder head body 103
2.17. 6 Checking camshafts 104
2.17. 7 Checking camshafts support 105
2.17. 8 Cylinder head: insertion of inner cup and
valve stem seals 106
2.17. 9 Cylinder head: assembly of valve unit 107
2.17.10
Cylinder head: repositioning calibrated discs,
assembly of finger follower shafts and finger
followers and coupling the spark plug
108
2.17.11 Cylinder head: Insertion of oil jets, centring pins and
spark plug O-ring 109
2.17.12 Piston: application of compression and
oil-scraper rings 110
2.17.13 Application of piston to cylinder 111
2.17.14 Application of piston-cylinder coupling to crankcase 113
2.17.15 Coupling head to cylinder 115
2.17.16 Coupling camshafts to cylinder head and phasing 116
2.17.17 Valve play 119
2.17.18
Checking and coupling of hydraulic tensioner to engine
121
2.17.19 Coupling cylinder head cover gaskets and
cylinder head cover 123
2.18 COUPLING PINION AND BREATHER NOZZLE 124
2.19 RELEASING CRANKSHAFT 124
2.20 COUPLING OIL CAPS 125
2.21 COUPLING GEARSHIFT LEVER 126

PREAMBLE
Carbon monoxide
• Exhaust gasses contain carbon which is poiso-
nous. Carbon monoxide can cause loss of con-
science and lead to death. When starting the
engine, make sure the place you are is well-
ventilated. Never start the engine in a closed
place.
• Starting the engine closed places can be done
only if provided with relevant gas discharge
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 me-
ans 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 ho-
spital.
• Used oil contains dangerous substances which
are harmful for the environment. When chan-
ging it, you must be equipped to dispose of it
in compliance with existing law.
• Avoid releasing used oils to 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 the engine. Sufficient knowledge of the components
that make up the engine and of all the procedures to be followed for inspection and maintenance con-
tribute 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 Highways 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. 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.
2
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SAFETY

PREAMBLE
Coolant
• In some situations, the ethylene glycol contai-
ned 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 cau-
se 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 clo-
thing 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 breathing
the product into the lungs. Administer clean
water and bring the concerned person imme-
diately 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 me-
dical 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 chan-
ging it, you must be equipped to dispose of it
in compliance with existing law.
• Do not release coolant to 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 off before handling these parts
or intervening on areas around them. Use insu-
lated 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 respecting
the order of disassembly exactly.
• Always use special tools wherever necessary
and when thus prescribed.
• Always use glues, sealing 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 out on the
engine can be performed without causing damage.

ENGINE
4
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TECHNICAL FEATURES OF ENGINE
Tipo Monocilindrico a 4tempi raffreddato a liquido con albero
bilanciatore e avviamento elettrico
Bore x stroke RR 350 88x57,4
Bore x stroke RR 400 95x56,2
Bore x stroke RR 450 95 x 63,4
Bore x stroke RR 498 100 x 63,4
Displacement [cm³] RR 350 349,1
Displacement [cm³] RR 400 398
Displacement [cm³] RR 450 449,4
Displacement [cm³] RR 498 497,9
Compression ratio RR 400-450-498 13,3:1 12,4:1 11,95 12,0:1
Valve gear 4 valves
TRANSMISSION
RR 350 RR 400 RR 450 RR 498
Primary transmission 28/76 28/76 31/73 31/73
1st gear ratio 12/31 12/31 12/31 12/31
2nd gear ratio 15/28 15/28 15/28 15/28
3rd gear ratio 19/28 19/28 19/28 19/28
4th gear ratio 20/24 20/24 20/24 20/24
5th gear ratio 27/27 27/27 27/27 27/27
6th gear ratio 28/24 28/24 28/24 28/24
SECONDARY TRANSMISSION CHAIN
CARBURETTOR
RR350 RR400 RR450 RR498
Carburettor type Keihin FCR-MX39 Keihin FCR-MX 39 Keihin FCR-MX 39 Keihin FCR-MX 39
Carburettor-setting
number
006121308 000 006.12.100.8.0 006.12.000.8.0 006.12.200.8.0
Main jet 170 175 175 180
Jet needle NCVQ OBDTS OBDVS OBDVS
Slow jet 40 45 45 45
Main air jet x200 200 200
Idling air jet 100 100 100 100
Needle position 3° 5° 4° 4°
Mixture control screw open 1+1/2 1+1/2 1+1/2 2
Intake jet 40 50 40 40

ENGINE
5
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SPECIAL EQUIPMENT
1. Engine support code 3625132 000;
2. Two-leg extractor code 3625081 000;
3. Internal bearing puller code 006140160 000;
4. Extractor for timing gear code 006140150 000;
5. Flywheel Extractor code 3625173 000;
6. Piston ring compression band code 006140170 000;
7. Chain-tensioner release tool code 006140050 000;
8. Valves assembly-disassembly jaw code 0100043 000;
9. Tool for valves assembly-disassembly code 006140030 000;
10. Special ring pliers code 3625097 000;
11. Crankshaft blocking device code 006140110 000;
12. Loctite 243 code 3625001 000;
14. Silicone paste for gaskets code 3625000 000;
15. 36mm socket wrench code 3625000 000;
16. Spark plug wrench code 020440100 000;
17. Connecting rod disassembly tool code 006140070 000;
18. Thickness gauge code 006140210 000;
19. Valve guide gauge code 006140180 000;
20. Clutch cap tool code 006140040 000;
21. Carburettor adjustment spanner code 006140200 000;
22. Engine fixing code 006140140 000.
23. Pin retaining elastic ring tool code 022140200 000 (350cc);
code 006140300 000 (400cc, 450cc, 498cc)
6Nm
Silicone paste
Value
Tightening Torque
Symbology
Loctite 243/
Sichel 100M

1
6
ENGINE DISASSEMBLY
Front engine guard fixing screw.
Screw 2 for draining motor oil and 3 for draining
gear oil.
Back engine guard fixing screws.
Before removing the engine from the vehicle,
empty the following liquids:
• Motor oil;
• Gear/clutch unit oil;
• Coolant.
•
In order to access the oil drain plug, remove the
engine guard connected to the frame by means
of the three screws 1.
1
1
ENGINE DISASSEMBLY
Remove the screw 2to empty the motor oil.
Remove the screw 3to empty the gear oil.
ATTENTION: Used oil contains dangerous
substances which are harmful for the en-
vironment. When changing it, you must be
equipped to dispose of it in compliance with
existing law.
Avoid releasing used oils to the environment.
2
3

1
7
ENGINE DISASSEMBLY
Screw 4 for draining coolant.
Screws 5 and 6.
Disconnect the water hoses on the engine
side, disconnect the electrical connectors
below the tank, the clutch actuator and the
exhaust manifold.
Loosen the screw 5that fastens the kickstar-
ter to the kickstarter shaft and the screw 6
which fastens the brake pedal return spring
to the engine block.
Once the engine has been unfastened and
removed from the frame, connect it to the
specific engine support code 3625132000
by means of the engine fixing devices code
006140140000, in order to work in comfort
and safety. Then proceed as follows.
In order to empty the cooling circuit, loosen
the screw 4and have the liquid flow out
into a recipient (the cooling circuits holds
1.3l of liquid). Remove the radiator cap.
4
5
6

1
8
ENGINE DISASSEMBLY
The four screws 1 of the cylinder head cover 2.
Spark plug gasket 4 and cylinder head cover gasket 5.
The cylinder head cover 2 and the four gaskets 3.
1.1
1
2
2
3
THERMAL UNIT
The thermal unit is made up of the head,
cylinder and piston.
Before removing the cylinder head, bring the
piston to the TDC and block the crankshaft:
Proceed as shown hereafter.
Remove the 4screws 1, the cylinder head
cover 2as well as the 4screw gaskets 3.
Remove the spark plug gasket 4and the co-
ver gasket 5.
4
5

1
9
ENGINE DISASSEMBLY
Crankshaft blocking screw 6 with copper washer 7.
Rotation of transmission shaft.
Alignment of camshafts.
Blocking crankshaft at TDC. Note the blocking screw
6 and the movement set by the transmission shaft
with the open-end spanner.
After having engaged the 6th gear, turn the
transmission shaft 8anti-clockwise - using
an open-end spanner or the likes, - until
the lines 9on the toothed profiles of the
camshafts are aligned.
Rotate the transmission shaft in that posi-
tion and, at the same time, turn the shaft
blocking screw 6by hand until it engages in
the seat present on the crankshaft, preven-
ting the crankshaft from turning.
In this way the crankshaft is blocked, by me-
ans of the screw 6, at the Top Dead Centre
(TDC) and now all the organs can be disas-
sembled.
Remove the crankshaft blocking screw 6,
remove the copper washer 7and put the
screw (or tool 006140110 000) back into its
seat without tightening it all the way.
7
6
8
9
6

1
10
ENGINE DISASSEMBLY
Fixing screws 1 camshaft support 2 and chain guide 3
The four outer screws circled blue must be taken off-
first.
CYLINDER HEAD:
DISASSEMBLING
MECHANICAL TENSIONER
A chain which is not well-tensioned can cause:
• excessive vibrations for the chain which could
make it jump teeth on the camshafts thus da-
maging the engine;
• incorrect and premature wear of the support
bearings of the camshafts.
The engine is equipped with a hydraulic tensio-
ner in order to provide the chain with proper
tensioning.
To remove it, proceed as follows: remove the
cap 1 and the spring 2.
Fully unscrew the tensioner support 3 from the
cylinder.
To slip the piston 4 out, just push it out from the
tensioner support 3.
CYLINDER HEAD:
DISASSEMBLING CAMSHAFT
SUPPORT, CHAIN GUIDE AND
SPARK PLUG SEAT O-RING
To remove the camshafts, disassemble the
camshaft support 2and the chain guide
3. Then loosen the seven screws 1of the
camshaft support, starting with the outer
ones (indicated in blue in the figure) and
then the inner ones. Remove the chain gui-
de 3.
Attention: disassemble the camshafts only
after having disassembled the hydraulic
tensioner.
2
3
1.1.1
1.1.2
1
Cap and spring removal.
Tensioner support complete with piston.
1
3
2
4

1
11
ENGINE DISASSEMBLY
Uncoupling camshaft support 4 from cylinder head.
Two centring pins 4 and spark plug housing O-ring 5.
Using a plastic rod Aor something similar,
lever the head surface and the camshaft
support 2in order to lift it and remove it.
When uncoupling, be careful of the two cen-
tring pins 4the camshaft support Checking
camshafts support
Remove the spark plug housing sealing O-
ring 5between the cylinder head and the
camshaft support.
2
A
45

1
12
ENGINE DISASSEMBLY
Removal of intake camshaft 1, bearing 2.
Camshafts (G intake, H exhaust) with bearings.
Plastic rod to support chain.
CYLINDER HEAD: REMOVING
CAMSHAFTS
Lift the intake camshaft 1, pull out the bea-
ring 2and remove the chain 3from the gear
on the shaft.
Attention: the hydraulic tensioner must al-
ready have been removed in order to remo-
ve the camshafts.
In order to remove the exhaust camshaft 4,
repeat the operations described for removal
of the intake camshaft.
ATTENTION: make sure the chain does not
fall inside the compartment dedicated to it.
For this purpose, it is recommended to in-
terpose a plastic rod (or the likes) Abetwe-
en the chain and the head.
2
1
3
3
A
4
1.1.3

1
13
ENGINE DISASSEMBLY
Chain-side head fixing screw.
Head fixing screws.
Head removal.
1
2
3
CYLINDER HEAD:
UNCOUPLING FROM
CYLINDER
Five screws fasten the head to the cylinder.
Remove the cylinder head screw 1on the
outside of the chain-side cylinder head.
Remove the four cylinder head fixing screws
2, in a criss-cross pattern. Start with one of
the two screws outside the cylinder head
compartment.
Then remove the respective washers.
Lift the cylinder head 3with one hand and
at the same time with the other hold the
chain in tension thus preventing jams du-
ring disassembly.
With the cylinder head lifted a few centime-
tres, drop the chain inside the compartment
and pull out the head.
ATTENTION: should the chain fall inside,
place it in tension before lifting the head.
1.1.4

1
14
ENGINE DISASSEMBLY
Cylinder head elements:
1) M6x80 screw;
2) M10x1.25 cylinder head screws;
3) Complete cylinder head;
4) Cylinder-head gasket;
5) Centring bushes.
Remove the head gasket 4and the two cen-
tring bushes 5.
3
2
1
4
5

1
15
ENGINE DISASSEMBLY
Cylinder removal.
Removal of elastic ring 4 from right hand side of pi-
ston.
Pin bolt removal.
1
3
4
5
B
A
2
DISASSEMBLING CYLINDER
AND PISTON
Lift up the cylinder 1a few centimetres, re-
move the two centring bushes 2(both loca-
ted on the chain side) to prevent them from
falling inside the crankcases and continue
on removing the cylinder. Remove the cylin-
der gasket 3.
Place a clean cloth between the piston and
the crankcase to keep foreign objects or
simple residue from falling inside the base.
Using a suitable tool to insert the specific
seat A, remove the elastic ring 4on the right
hand side* of the piston 5.
ATTENTION: be careful not to drop the ela-
stic ring inside the engine.
From the left hand side of the piston, push
the pin bolt with an aluminium cylinder B
(or the likes), until the pin bolt is freed from
the foot of the connecting rod.
Remove the piston.
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
order not to stress the connecting rod.
1.1.5
* Referred to normal direction of vehicle.

In figure you can see the piston 5(bottom
view), the circlip 4and the pin bolt 6.
1
2
4
3
4
5
6
1
16
ENGINE DISASSEMBLY
DISASSEMBLY OF IGNITION
UNIT, TIMING CHAIN AND
GUIDES
The ignition unit is made up of the flywheel
(or rotor), the pick-up and the stator which
is one with the flywheel cover.
1.2
STATOR AND FLYWHEEL
Remove the screw 1which connects the
gear lever 1 to the drive shaft.
Remove the nine screws 3which fasten the
flywheel cover 4to the left crankcase half.
Remove the flywheel cover and the gasket
placed between the casing and the cover.
1.2.1
Bottom view of piston 5, elastic ring 4 and pin bolt 6.
Removal of gear lever.
Fixing screws C of ignition cover D.

1
17
ENGINE DISASSEMBLY
Be careful of the two centring pins on the
crankcase half.
Remove the tightening nut 6which fastens
the flywheel 7to the crankshaft.
Once the nut has been unscrewed, pay at-
tention to the special elastic washer (8
shown in the following images) placed
between the nut and the flywheel.
To remove the flywheel, screw the relevant
extractor A(code 3625173) onto the thre-
aded segment on the flywheel and, using a
box spanner, tighten the screw on the ex-
tractor.
Two centring pins 5 dedicated to the flywheel cover.
Nut 6 which fastens the flywheel 7 to the crankshaft.
Removal of ignition flywheel with relevant extractor A.
6
7
A
5

3
2
1
1
18
ENGINE DISASSEMBLY
Exploded view of flywheel 7, nut 6 and special elastic
washer 8.
Fixing screws 1 of mobile 2 and fixed pad 3.
Extraction of chain guides.
In the image at the side, the flywheel 7(rear
view), the special elastic washer 8and the
tightening nut 6.
8
7
6
TIMING CHAIN AND GUIDES
Remove the fixing screws 1of the mobile 2
and fixed pad 3.
Extract the two pads, pulling them towards
the top part of the engine.
1.2.2