Beta Enduro RR 350 2015 Instruction manual

INDEX
www.betamotor.com
PREAMBLE 2
INFORMATIVE NOTE 2
SAFETY 2
1 REMOVING THE ENGINE FROM THE VEHICLE 6
2 ENGINE DISASSEMBLY 16
2.1 THERMAL UNIT 16
2.1.1 CYLINDER HEAD: DISASSEMBLING MECHANICAL
TENSIONER 18
2.1.2 CYLINDER HEAD: DISASSEMBLING CAMSHAFT
SUPPORT, CHAIN GUIDE AND SPARK PLUG SEAT
O-RING 19
2.1.3 CYLINDER HEAD: REMOVING CAMSHAFTS 20
2.1.4 CYLINDER HEAD: UNCOUPLING FROM CYLINDER 21
2.1.5 DISASSEMBLING CYLINDER AND PISTON 23
2.2 DISASSEMBLY OF IGNITION UNIT, TIMING
CHAIN AND GUIDES 24
2.2.1 STATOR AND FLYWHEEL 24
2.2.2 TIMING CHAIN AND GUIDES 27
2.2.3 PICK-UP 29
2.3 PINION AND SPACER 29
2.4 CLUTCH UNIT AND COOLANT PUMP COVER 30
2.5 ENGINE LUBRICATION CIRCUIT 34
2.5.1 OIL PUMPS CONTROL GEARS 35
2.5.2 HIGH-PRESSURE OIL PUMP 35
2.5.3 LOW-PRESSURE OIL PUMP AND BY-PASS VALVE 36
2.5.4
OIL PRESSURE CONTROL VALVE 37
2.5.5 PAPER OIL FILTER 37
2.6 COUNTERSHAFT 38
2.7
PRIMARY GEAR 39
2.8 ELECTRIC IGNITION 40
2.8.1 ELECTRIC KICK-START UNIT 41
2.9
KICKSTARTER 42
2.10 EXTERNAL GEARSHIFT UNIT 44
2.11 CRANKSHAFT, GEARBOX UNIT AND INTERNAL
GEARSHIFT 45
2.11.1 NUT ON LEFT SIDE OF CRANKSHAFT 45
2.11.2 OPENING CRANKCASE 46
2.11.3 CRANKSHAFT 48
2.11.4 INTERNAL GEARSHIFT UNIT AND COMPLETE
GEARBOX 48
2.12 DISASSEMBLY OF PARTS FROM
CRANKCASES 50
2.12.1 RIGHT CRANKCASE HALF 50
2.12.1.1 PISTON OIL JETS 50
2.12.1.2 EXTRACTION OF COUNTERSHAFT SUPPORT
BEARING 51
2.12.2 LEFT CRANKCASE HALF 51
2.12.2.1 INNER OIL FILTER 52
2.12.2.2 EXTRACTION OF DESMODROMIC DEVICE
BEARING 52
3 ENGINE ASSEMBLY AND CONTROLS 53
3.1 CRANKCASE HALVES 54
3.1.1 EXTERNAL RIGHT SIDE 55
3.1.1.1 INSERTION OF OIL SEAL AND COUNTERSHAFT
SUPPORT BEARING 57
3.1.2 INTERNAL RIGHT SIDE 58
3.1.3 EXTERNAL LEFT SIDE 59
3.1.4 SINISTRO LATO INTERNO 60
3.2
CHECKING CRANKSHAFT AND CONNECTING
ROD 61
3.3 ASSEMBLING COMPLETE CRANKSHAFT 63
3.4 GEARBOX UNIT: CONTROLS AND
REASSEMBLY 64
3.4.1 CHECKING GEARBOX UNIT 64
3.4.2 PRIMARY UNIT ASSEMBLY 65
3.4.3 SECONDARY UNIT ASSEMBLY 66
3.4.4 CHECKING THE FORKS, FORK PINS AND
DESMODROMIC DEVICE 67
3.5 ASSEMBLY OF INTERNAL GEARBOX AND
GEARSHIFT 69
3.6 CLOSING ENGINE BLOCK 72
3.7 BLOCKING THE CRANKSHAFT AT THE TOP DEAD
CENTRE AND TIGHTENING THE NUT ON THE
LEFT SIDE OF THE CRANKSHAFT 73
3.8 EXTERNAL GEARSHIFT 74
3.8.1 CHECKING THE COMPLETE DRIVE SHAFT 74
3.8.2 ASSEMBLY OF EXTERNAL GEARSHIFT 76
3.9 KICK STARTER 76
3.9.1 CHECKING KICKSTARTER SHAFT UNIT AND
ASSEMBLY 76

ENGLISH
INDEX
3.9.2 ASSEMBLY OF KICKSTART DEVICE 78
3.10 ELECTRICAL STARTER UNIT AND MAIN GEAR 79
3.10.1 CHECKING ELECTRICAL STARTER DEVICE
ELEMENTS 79
3.10.2 COUPLING IGNITION AND PRIMARY GEARS TO THE
MOTOR 80
3.11 OIL PUMPS: CONTROL AND REASSEMBLY 82
3.11.1 ASSEMBLY OF LOW PRESSURE PUMP 84
3.11.2 ASSEMBLY OF HIGH-PRESSURE PUMP AND
CONTROL GEAR 85
3.11.3 CHECKING AND ASSEMBLY OF PRESSURE
CONTROL VALVE 86
3.11.4 CHECKING AND ASSEMBLY OF OIL PUMPS
CONTROL GEARS 87
3.11.5 PAPER OIL FILTER INSERTION 88
3.11.6 CHECKING AND COUPLING COUNTERSHAFT 89
3.12 CLUTCH UNIT 91
3.12.1 CHECKING CLUTCH BASKET, ROLLER BEARING
AND INTERNAL CENTRE BEARING 91
3.12.2 CHECKING CLUTCH DISCS 92
3.12.3 CHECKING SPRINGS 93
3.12.4 CHECKING INNER HUB 93
3.12.5 CHECKING THRUST BEARING DEVICE 94
3.12.6 ASSEMBLY OF CLUTCH UNIT 94
3.13 COOLANT PUMP 97
3.13.1 CHECKING PUMP UNIT AND DISASSEMBLY 97
3.13.2 ASSEMBLY OF PUMP UNIT 98
3.14 ASSEMBLY OF COMPLETE CLUTCH COVER 99
3.15 CHECKING AND COUPLING OF TIMING
CHAIN, FIXED AND MOBILE GUIDES 101
3.16 IGNITION SYSTEM 101
3.16.1 CHECKING IGNITION SYSTEM 102
3.16.2 COUPLING IGNITION SYSTEM TO CRANKCASE 102
3.17 THERMAL UNIT 105
3.17.1 CHECKING PISTON, PIN BOLT, AND PISTON
RINGS 105
3.17.2 CHECKING THE CYLINDER 107
3.17.2.1 ASSEMBLY CLEARANCE 107
3.17.3 CYLINDER HEAD: DISASSEMBLY AND CHECKING
AUXILIARY DEVICES 108
3.17.3.1 LUBRICATION JETS AND CENTRING PINS 108
3.17.3.2 FINGER FOLLOWER/SHAFTS UNIT 109
3.17.3.3 SHIMS (CALIBRATED DISCS) FOR VALVE PLAY
ADJUSTMENT 110
3.17.4 CYLINDER HEAD: DISASSEMBLING AND
CHECKING VALVE UNITS 111
3.17.4.1 SPRINGS 112
3.17.4.2 VALVE GUIDES, VALVES AND SEATS 112
3.17.4.3 VALVE STEM SEAL AND LOWER STOP WASHER 114
3.17.5
CYLINDER HEAD: CHECKING CYLINDER HEAD
BODY 114
3.17.6 CHECKING CAMSHAFTS 115
3.17.7 CHECKING CAMSHAFTS SUPPORT 116
3.17.8 CYLINDER HEAD: INSERTION OF INNER CUP
AND VALVE STEM SEAL 117
3.17.9 CYLINDER HEAD: ASSEMBLY OF VALVE UNIT 118
3.17.10 CYLINDER HEAD: REPOSITIONING CALIBRATED
DISCS, ASSEMBLY OF FINGER FOLLOWER SHAFTS
AND FINGER FOLLOWERS AND COUPLING THE
SPARK PLUG 119
3.17.11 CYLINDER HEAD: INSERTION OF OIL JETS,
CENTRING PINS AND SPARK PLUG O-RING 120
3.17.12 PISTON: APPLICATION OF PISTON RINGS AND
OIL-SCRAPER RINGS 121
3.17.13 APPLICATION OF PISTON TO CYLINDER 122
3.17.14 APPLICATION OF PISTON-CYLINDER COUPLING
TO CRANKCASE 124
3.17.15 COUPLING HEAD TO CYLINDER 126
3.17.16 COUPLING CAMSHAFTS TO CYLINDER HEAD
AND PHASING 127
3.17.17 VALVE PLAY 130
3.17.18 CHECKING AND COUPLING OF MECHANICAL
TENSIONER TO ENGINE 132
3.17.19 COUPLING CYLINDER HEAD COVER GASKETS
AND CYLINDER HEAD COVER 134
3.18 PINION COUPLING 135
3.19
RELEASING CRANKSHAFT 135
3.20 COUPLING OIL CAPS 136
3.21 COUPLING GEARSHIFT LEVER 137
4 REASSEMBLY OF ENGINE IN THE VEHICLE 138
ENGINE/FRAME TABLE OF TIGHTENING TORQUES 152
RECOMMENDED ENGINE MAINTENANCE 153
RECOMMENDED LUBRICANTS AND LIQUIDS 154

PREAMBLE
2
www.betamotor.com
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 advi-
ce.
• 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.
SAFETY

PREAMBLE
3
www.betamotor.com
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
clothing or footwear and wash with soap and
water. In case of contact with the eyes, rinse
them abundantly with clean water and seek
medical advice immediately. Should it be swal-
lowed, do not induce vomiting in order to avoid
breathing the product into the lungs. Admini-
ster clean water and bring the concerned per-
son immediately 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.
•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
www.betamotor.com
TECHNICAL FEATURES OF ENGINE
Type Single cylinder, 4-stroke, liquid-cooled with countershaft
and electric starting
Bore x stroke RR 350 88x57,4
Bore x stroke RR 400 88x63,4
Bore x stroke RR 450 95x60,8
Bore x stroke RR 498 100x60,8
Displacement [cm³] RR 350 349,1
Displacement [cm³] RR 400 386
Displacement [cm³] RR 450 431
Displacement [cm³] RR 498 478
Compression ratio RR 400-450-498 13,19:1 12,5:1 11,9:1 11,9:1
Valve gear 4 valves
TRANSMISSION
RR 350 RR390 RR430 RR480
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
RR390 RR430 RR480
Carburettor type Keihin FCR-MX 39 Keihin FCR-MX 39 Keihin FCR-MX 39
Main jet 170 175 180
Jet needle 40 45 45
Main air jet 100 100 100
Jet needle NCVS NCVS OBDVS
Needle position from top 4° 3° 3°
Air mixture screw position (from all closed) 1+1/2 1+1/2 1+1/2
Intake jet 40 40 40

ENGINE
5
www.betamotor.com
6Nm
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);
 cod.029140300000(430cc,498cc)
Siliconepaste
Value
TighteningTorque
Symbology
Loctite243/
Sichel100M

1
6
REMOVING THE ENGINE FROM THE VEHICLE
Screw 2 for draining motor oil and 3 for draining
gear oil.
Carefully wash the vehicle
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
1 REMOVING THE ENGINE FROM THE VEHICLE
Remove the screw 2to empty the motor oil. Remo-
ve the screw 3to empty the gear oil.
ATTENTION:Usedoilcontainsdangeroussubstan-
ceswhichareharmfulfortheenvironment.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
Remove the exhaust pipe and the silencer.
Drain the cooling system through screw 4and let
the liquid outflow into a container (the cooling cir-
cuit contains 1.3l of liquid).
Remove the radiator cap.
4
Front engine guard fixing screw.
Back engine guard fixing screws.

1
7
REMOVING THE ENGINE FROM THE VEHICLE
55
5
6
6
7
5
Place the vehicle onto an adequate stand.
To dismount the tank, remove the seat, complete-
ly loosen the two screws 5fixing the tank to the
frame and screw 6(one per side) which fixes the
side to the radiator.
In the carburettor versions, disconnect petrol tube
7from the cock, which must be set to OFF.
In the injection versions, disconnect the petrol
tube by pressing the special button of quick
coupling 8.
Lift the tank.
8

1
8
REMOVING THE ENGINE FROM THE VEHICLE
Disconnect the water hoses from the engine and
from the right radiator.
Remove the left radiator with pipes.
Disconnect electric connectors 9and 10.
Remove the tank along with the sides.
9
10

1
9
REMOVING THE ENGINE FROM THE VEHICLE
Disconnect the spark plug cap.
Cut all straps binding the engine’s electric system
to the clutch pipe and to the frame.
Disconnect the engine ventilation pipes.
Disconnect the connectors indicated in the figure.
Remove the start motor cable fixing nut.
Electric connectors to disconnect in the carburettor ver-
sions.
Electric connectors to disconnect in the injection ver-
sions.

1
10
REMOVING THE ENGINE FROM THE VEHICLE
Loosen the carburettor/throttle body straps from
the air filter sleeve and from the manifold.
Remove the screw of the carburettor/throttle body
12 cover and the cover itself.
Disconnect rear stop connector 13.
12
12
13

1
11
REMOVING THE ENGINE FROM THE VEHICLE
Disconnect the electric connectors indicated in
the figure, relative to the carburettor/throttle
body.
Loosen the adjustment nuts and release the gas
cables.
Carburettor version gas cables.
Injection versions gas cables.

1
12
REMOVING THE ENGINE FROM THE VEHICLE
Remove the frame guards 14 (one each side) and
the pinion guard 15.
15
14
Rest the chain against the upper wedge 16.
Remove the screws 6 fixing the clutch actuator to
the crankcase half.
Remove the rear wheel nut.
Extract the pin enough to allow the wheel to
advance towards the front of the vehicle.
Rotate the rear wheel lifting the chain in the
pinion zone, so that the chain of the pinion itself
is released.
17 16
ATTENTION!Donotactivatetheclutchleverwith
actuatordecoupledfromengine.
Remove the head connections.

1
13
REMOVING THE ENGINE FROM THE VEHICLE
Release and remove the brake pedal return spring
18.
Remove the kickstarter lever..
18
Remove the seat rail lower fixing screws 19 (one
each side) and loosen the upper screws 20 (one
each side).
19
20

1
14
REMOVING THE ENGINE FROM THE VEHICLE
Remove the carburetor to the gas cable.
Remove the carburettor or throttle body, based on
the specific version.
Remove upper shock-absorber pin 21.
21

1
15
REMOVING THE ENGINE FROM THE VEHICLE
Remove the swingarm pin 22.
Move the complete swing-arm unit towards the
rear.
Remove the engine pins 23.
Extract the engine from the frame and apply it to
the specific stand code 3625132 000 using speci-
fic front fixing bracket code 006140140 000.
22
23
23

2
16
ENGINE DISASSEMBLY
1
2
2
3
4
5
2 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.
2.1 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 4 screws 1, the cylinder head cover 2
as well as the 4 screw gaskets 3.
Remove the spark plug gasket 4and the cover ga-
sket 5.

2
17
ENGINE DISASSEMBLY
76
8
9
6
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.

2
18
ENGINE DISASSEMBLY
2.1.1 CYLINDER HEAD: DISASSEM-
BLING MECHANICAL TEN-
SIONER
A chain which is not well-tensioned can cause:
• excessive vibrations for the chain which could
make it jump teeth on the camshafts thus dama-
ging the engine;
• incorrect and premature wear of the support bea-
rings of the camshafts.
The engine is equipped with a hydraulic tensioner
in order to provide the chain with proper tensio-
ning.
To remove it, proceed as follows: remove the cap 1
and the spring 2.
Fully unscrew the tensioner support 3from the
cylinder.
To slip the piston 4out, just push it out from the
tensioner support 3.
1
3
2
4
Cap and spring removal.
Tensioner support complete with piston.