Beta Enduro RR 350 EFI 2016 Instruction manual

INDEX
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PREAMBLE 2
INFORMATIVE NOTE 2
SAFETY 2
SPECIAL EQUIPMENT 5
1 REMOVING THE ENGINE FROM THE VEHICLE 6
2 ENGINE DISASSEMBLY 15
2.1 THERMAL UNIT .............................................................15
2.1.1 CYLINDER HEAD: DISASSEMBLING MECHANICAL
TENSIONER ....................................................................................17
2.1.2 CYLINDER HEAD: DISASSEMBLING CAMSHAFT
SUPPORT, CHAIN GUIDE AND SPARK PLUG SEAT
O-RING ...........................................................................................18
2.1.3 CYLINDER HEAD: REMOVING CAMSHAFTS......................19
2.1.4 CYLINDER HEAD: UNCOUPLING FROM CYLINDER.......20
2.1.5 DISASSEMBLING CYLINDER AND PISTON.........................22
2.2 DISASSEMBLY OF IGNITION UNIT, TIMING CHAIN
AND GUIDES ..................................................................23
2.2.1 STATOR AND FLYWHEEL............................................................23
2.2.2 TIMING CHAIN AND GUIDES.................................................. 26
2.2.3 PICK-UP............................................................................................ 28
2.3 PINION AND SPACER ...................................................28
2.4 CLUTCH UNIT AND COOLANT PUMP COVER ..........29
2.5 ENGINE LUBRICATION CIRCUIT .................................33
2.5.1 OIL PUMPS CONTROL GEARS................................................ 34
2.5.2 HIGH-PRESSURE OIL PUMP....................................................34
2.5.3 LOW-PRESSURE OIL PUMP AND BY-PASS VALVE............35
2.5.4
OIL PRESSURE CONTROL VALVE ...............................................36
2.5.5 PAPER OIL FILTER..............................................................................36
2.6 COUNTERSHAFT ............................................................ 37
2.7
PRIMARY GEAR .................................................................38
2.8 ELECTRIC IGNITION ..........................................................39
2.8.1 ELECTRIC KICK-START UNIT .....................................................40
2.9 KICKSTARTER......................................................................41
2.10 EXTERNAL GEARSHIFT UNIT...........................................43
2.11 CRANKSHAFT, GEARBOX UNIT AND INTERNAL
GEARSHIFT .........................................................................44
2.11.1 NUT ON LEFT SIDE OF CRANKSHAFT.................................44
2.11.2
OPENING CRANKCASE...................................................................45
2.11.3 CRANKSHAFT .....................................................................47
2.11.4 INTERNAL GEARSHIFT UNIT AND COMPLETE GEARBOX ...47
2.12 DISASSEMBLY OF PARTS FROM CRANKCASES...........49
2.12.1 RIGHT CRANKCASE HALF ..............................................................49
2.12.1.1 PISTON OIL JETS.........................................................49
2.12.1.2 EXTRACTION OF COUNTERSHAFT SUPPORT
BEARING ........................................................................50
2.12.2 LEFT CRANKCASE HALF..................................................................50
2.12.2.1 INNER OIL FILTER.......................................................51
2.12.2.2 EXTRACTION OF DESMODROMIC DEVICE
BEARING ........................................................................51
3 ENGINE ASSEMBLY AND CONTROLS 52
3.1
CRANKCASE HALVES.........................................................53
3.1.1 EXTERNAL RIGHT SIDE ...................................................................54
3.1.1.1 INSERTION OF OIL SEAL AND COUNTERSHAFT
SUPPORT BEARING...................................................56
3.1.2 INTERNAL RIGHT SIDE....................................................................57
3.1.3 EXTERNAL LEFT SIDE.......................................................................58
3.1.4 INTERNAL LEFT SIDE .......................................................................59
3.2 CHECKING CRANKSHAFT AND CONNECTING ROD...60
3.3 ASSEMBLING COMPLETE CRANKSHAFT......................62
3.4 GEARBOX UNIT: CONTROLS AND REASSEMBLY ........63
3.4.1 CHECKING GEARBOX UNIT........................................63
3.4.2 PRIMARY UNIT ASSEMBLY.............................................................64
3.4.3 SECONDARY UNIT ASSEMBLY......................................................65
3.4.4 CHECKING THE FORKS, FORK PINS AND DESMODROMIC
DEVICE...................................................................................................66
3.5 ASSEMBLY OF INTERNAL GEARBOX AND
GEARSHIFT .........................................................................68
3.6 CLOSING ENGINE BLOCK ................................................71
3.7 BLOCKING THE CRANKSHAFT AT THE TOP DEAD
CENTRE AND TIGHTENING THE NUT ON THE LEFT
SIDE OF THE CRANKSHAFT.............................................72
3.8 EXTERNAL GEARSHIFT.....................................................73
3.8.1 CHECKING THE COMPLETE DRIVE SHAFT .............................73
3.8.2 ASSEMBLY OF EXTERNAL GEARSHIFT ......................................75
3.9 KICK STARTER ....................................................................75
3.9.1 CHECKING KICKSTARTER SHAFT UNIT AND ASSEMBLY ...75
3.9.2 ASSEMBLY OF KICKSTART DEVICE..............................................77
3.10 ELECTRICAL STARTER UNIT AND MAIN GEAR ............78
3.10.1 CHECKING ELECTRICAL STARTER DEVICE ELEMENTS .......78
3.10.2 COUPLING IGNITION AND PRIMARY GEARS TO THE
MOTOR ..................................................................................................79
3.11 OIL PUMPS: CONTROL AND REASSEMBLY .................81
3.11.1 ASSEMBLY OF LOW PRESSURE PUMP .....................................83
3.11.2 ASSEMBLY OF HIGH-PRESSURE PUMP AND CONTROL
GEAR ......................................................................................................84
3.11.3 CHECKING AND ASSEMBLY OF PRESSURE CONTROL
VALVE......................................................................................................85

ENGLISH
INDEX
3.11.4 CHECKING AND ASSEMBLY OF OIL PUMPS CONTROL
GEARS....................................................................................................86
3.11.5 PAPER OIL FILTER INSERTION......................................................87
3.11.6 CHECKING AND COUPLING COUNTERSHAFT......................88
3.12 CLUTCH UNIT......................................................................90
3.12.1 CHECKING CLUTCH BASKET, ROLLER BEARING AND
INTERNAL CENTRE BEARING.......................................................90
3.12.2 CHECKING CLUTCH DISCS............................................................91
3.12.3 CHECKING SPRINGS........................................................................92
3.12.4 CHECKING INNER HUB..................................................................92
3.12.5 CHECKING THRUST BEARING DEVICE.....................................93
3.12.6 ASSEMBLY OF CLUTCH UNIT .......................................................93
3.13 COOLANT PUMP................................................................96
3.13.1 CHECKING PUMP UNIT AND DISASSEMBLY .........................96
3.13.2 ASSEMBLY OF PUMP UNIT ...........................................................97
3.14 ASSEMBLY OF COMPLETE CLUTCH COVER ..................98
3.15 CHECKING AND COUPLING OF TIMING CHAIN,
FIXED AND MOBILE GUIDES ....................................... 100
3.16 IGNITION SYSTEM.......................................................... 100
3.16.1 CHECKING IGNITION SYSTEM .................................................. 101
3.16.2 COUPLING IGNITION SYSTEM TO CRANKCASE................. 101
3.17 THERMAL UNIT............................................................... 104
3.17.1 CHECKING PISTON, PIN BOLT, AND PISTON RINGS........104
3.17.2 CHECKING THE CYLINDER ........................................... 106
3.17.2.1 ASSEMBLY CLEARANCE.........................................106
3.17.3 CYLINDER HEAD: DISASSEMBLY AND CHECKING
AUXILIARY DEVICES....................................................................... 107
3.17.3.1 LUBRICATION JETS AND CENTRING PINS .... 107
3.17.3.2 FINGER FOLLOWER/SHAFTS UNIT...................108
3.17.3.3 SHIMS (CALIBRATED DISCS) FOR VALVE
PLAY ADJUSTMENT.................................................109
3.17.4 CYLINDER HEAD: DISASSEMBLING AND CHECKING
VALVE UNITS .................................................................................... 110
3.17.4.1 SPRINGS...................................................................... 111
3.17.4.2 VALVE GUIDES, VALVES AND SEATS................. 111
3.17.4.3 VALVE STEM SEAL AND LOWER STOP
WASHER...................................................................113
3.17.5
CYLINDER HEAD: CHECKING CYLINDER HEAD BODY... 113
3.17.6 CHECKING CAMSHAFTS.............................................................. 114
3.17.7 CHECKING CAMSHAFTS SUPPORT ........................................ 115
3.17.8 CYLINDER HEAD: INSERTION OF INNER CUP AND
VALVE STEM SEAL........................................................................... 116
3.17.9 CYLINDER HEAD: ASSEMBLY OF VALVE UNIT..................... 117
3.17.10 CYLINDER HEAD: REPOSITIONING CALIBRATED DISCS,
ASSEMBLY OF FINGER FOLLOWER SHAFTS AND FINGER
FOLLOWERS AND COUPLING THE SPARK PLUG.............. 118
3.17.11 CYLINDER HEAD: INSERTION OF OIL JETS, CENTRING
PINS AND SPARK PLUG O-RING ............................................. 119
3.17.12 PISTON: APPLICATION OF THE SCRAPER RING AND
RETAINING STRAPS, APPLICATION OF SEEGER............ 120
3.17.12.1 Piston: application of the scraper ring and
retaining straps, version 350cc-390cc......... 120
3.17.12.2 Piston: application of piston rings and oil-
scraper rings........................................................... 121
3.17.12.3 Piston: seeger application................................. 122
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
TABLE OF TIGHTENING TORQUES OF ENGINE COMPONENTS 148
ENGINE/FRAME TABLE OF TIGHTENING TORQUES 151
TABLE OF SUPERSTRUCTURE FASTENING TORQUE VALUES 151
RECOMMENDED ENGINE MAINTENANCE 152
RECOMMENDED LUBRICANTS AND LIQUIDS 153

PREAMBLE
2
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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
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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
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Type Single cylinder, 4-stroke, liquid-cooled with countershaft
and electric starting
BorexstrokeRR350 88x57,4
BorexstrokeRR390 88x63,4
BorexstrokeRR430 95x60,8
BorexstrokeRR480 100x60,8
Displacement[cm³]RR350 349,1
Displacement[cm³]RR390 386
Displacement[cm³]RR430 431
Displacement[cm³]RR480 478
CompressionratioRR350-390-430-480 13,19:1 12,5:1 12.3 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
TECHNICAL FEATURES OF ENGINE

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

1
6
REMOVING THE ENGINE FROM THE VEHICLE
1
1
1 REMOVING THE ENGINE FROM THE VEHICLE
2
3
4
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.
Removethescrew2toemptythemotoroil.Remo-
vethescrew3to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.
Removetheexhaustpipeandthesilencer.
Drainthe coolingsystemthrough screw4and let
theliquidoutflowintoacontainer(thecoolingcir-
cuitcontains1.3lofliquid).
Removetheradiatorcap.
Front engine guard fixing screw.
Back engine guard fixing screws.

1
7
REMOVING THE ENGINE FROM THE VEHICLE
5
6
5
Disconnectthe petrol pipeby pressingtherele-
vantbuttonofquickcoupling7.
Liftthetank.
7
8
9
Placethevehicleontoanadequatestand.
Todismountthetank,removetheseat,complete-
lyloosenthetwoscrews5fixing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
7fromthecock,whichmustbesettoOFF.
Disconnectelectricconnectors8and9.
Removethetankalongwiththesides.

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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.