Beta Rev 4T User manual

REV 4T
REV 4T
Betamotor S.p.A. Pian dell’Isola, 72 50067 Rignano Sull’Arno (Firenze) Italia Tel [phone] Fax [phone] [e-mail]
COD 21.73243.000 ENG
2007 OWNER’S MANUAL

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Thank you for choosing Betamotor. We
hope you enjoy your motorcycle.
This booklet provides
the information you will need
to use and maintain
your bike properly.
The details and specifications given in
this manual do not commit BETAMOTOR
S.p.A, who reserve the right to make
changes to their models at any time.
OWNER’S MANUAL

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CAUTION
It is important, after the first hour of break-in, to check
the tightness of all fasteners, paying particular atten-
tion to the following:
• Footrest brackets
• Front and rear brake discs
• Wheel spokes
• Shockabsorber bolt
• Engine bolts
• Rear sprocket
• Exhaust bolts

ENGLISH
Index
CHAPTER 1: GENERAL INFORMATION
INDEX OF TOPICS
Principal parts...........................................................................................................................................................................................................................................................................6
Vehicle identification details ...............................................................................................................................................................................................................................6
Console and controls......................................................................................................................................................................................................................................................6
Technical details..................................................................................................................................................................................................................................................................... 7
Wiring scheme.........................................................................................................................................................................................................................................................................8
CHAPTER 2: OPERATION AND USE
INDEX OF TOPICS
Filling the fuel tank........................................................................................................................................................................................................................................................10
Start-up ..........................................................................................................................................................................................................................................................................................10
Break-in ........................................................................................................................................................................................................................................................................................12
Checks and maintenance before and after use off-road ........................................................................................................................................12
Recommended lubricants and liquids.................................................................................................................................................................................................13
CHAPTER 3: MAINTENANCE AND CHECKS
INDEX OF TOPICS
Lubrication circuit............................................................................................................................................................................................................................................................15
Engine oil......................................................................................................................................................................................................................................................................................16
Brake master cylinder fluid................................................................................................................................................................................................................................19
Brakes circuit bleeding ............................................................................................................................................................................................................................................21
Clutch master cylinder fluid............................................................................................................................................................................................................................. 22
Clutch circuit bleeding.............................................................................................................................................................................................................................................. 22
Fork oil .......................................................................................................................................................................................................................................................................................... 23
Air filter ....................................................................................................................................................................................................................................................................................... 24
Sparkplug .................................................................................................................................................................................................................................................................................. 25
Front brake .............................................................................................................................................................................................................................................................................. 26
Rear brake ................................................................................................................................................................................................................................................................................ 27
Coolant .......................................................................................................................................................................................................................................................................................... 28
Checks after cleaning ................................................................................................................................................................................................................................................ 28
Scheduled maintenance ........................................................................................................................................................................................................................................ 29
CHAPTER 4: ADJUSTMENTS
INDEX OF TOPICS
Brake adjustment ............................................................................................................................................................................................................................................................31
Clutch adjustment ...........................................................................................................................................................................................................................................................31
Carburettor ............................................................................................................................................................................................................................................................................. 32
Tickover adjustment .................................................................................................................................................................................................................................................. 32
Throttle free clearance adjustment ...................................................................................................................................................................................................... 32
Steering paly check and adjustment..................................................................................................................................................................................................... 33
Chain tension ....................................................................................................................................................................................................................................................................... 33
Front suspension adjustment ........................................................................................................................................................................................................................ 34
Rear shockabsorber adjustment ............................................................................................................................................................................................................... 34
CHAPTER 5: WHAT TO DOIN AN EMERGENCY
INDEX OF TOPICS
Troubleshooting................................................................................................................................................................................................................................................................. 36
Index

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Chapter 1
General information
INDEX OF TOPICS
Principal parts
Vehicle identification details
Engine identification details
Console and controls
Technical details
Wiring scheme

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1
General information
ENGLISH
A
B
1452
3
VEHICLE IDENTIFICATION DETAILS
Frame identification
The frame identification details (A) are stamped on
the right-hand side of the headstock.
ENGINE IDENTIFICATION DETAILS
The engine identification details (B) are stamped in
the area indicated in the picture.
CONSOLE AND CONTROLS
1 Clutch lever
2 Front brake lever
3 Throttle twistgrip
4 Hot start lever
5 Lights on/off/engine stop
PRINCIPAL PARTS
1 - Filter box 2 - Fuel tank 3 - Fuel filler cap 4 - Silencer
5 - Kickstart lever 6 - Filter cover
1
6
2
3
5
4

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General information
ENGLISH
TECHNICAL DETAILS
Vehicle weight
- in running order (dry) ......................................................................................................................................................... 75 kg
Dimensions
- overall length ..................................................................................................................................................................2015 mm
- overall width ..................................................................................................................................................................... 825 mm
- overall height ..................................................................................................................................................................1.160 mm
- wheelbase ........................................................................................................................................................................1.319 mm
- seat height ........................................................................................................................................................................ 680 mm
- ground clearance ............................................................................................................................................................ 320 mm
Tyres
- pressure kPa ..........................................................................................................................................front 39-44 / rear 29-34
- tyre sizes ...........................................................................................................................................front 2.75- 21” (Tube Type)
rear 4.00 - 18” (X11Tubeless)
Capacities
- fuel tank ....................................................................................................................... 2.2 litres inclusive of 0.35 litre reserve
- cooling circuit ....................................................................................................................................................................... 600 cc
- engine oil ...........................................................................................................................BARDAHL XT C60 15W50 - 900 cc
Front suspension
- hydraulic forks with 38 mm stanchions, rebound and spring preload adjustment
Fork oil capacities:
- right leg ....................................................................................................................................................................................370 cc
- left leg .....................................................................................................................................................................................350 cc
Rear suspension
- progressive hydraulic monoshock, with rebound and spring preload adjustment
Front and rear brake discs
- disc, with hydraulic control
Engine
- type Single cylinder, 4-stroke, 4 valve head, SOHC. (ZD3E77)
- bore x stroke ..............................................................................................................................................................77x53.6 mm
- displacement (cm3) ..............................................................................................................................................................249.6
- compression ratio ..................................................................................................................................................................11.5:1
- liquid cooling
- digital electronic ignition with magneto flywheel alternator and variable advance
- starting by kickstart
- sparkplug ......................................................................................................................................................................NGK CR7EB
Fuel system
- carburettor ................................................................................................................................................MIKUNI SE BSR 33-79
- jet ......................................................................................................................................................................127.5-27.5 max-min
- runs on unleaded petrol

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General information
ENGLISH
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1WIRING SCHEME
CAUTION: Do not run the engine with the voltage regulator connected to the electrical
generator without also connecting the vehicle wiring harness (central system). Doing so
could cause damage to the regulator itself.
INDEX OF TOPICS
Filling the fuel tank
Start-up
Break-in
Checks and maintenance before
and after use off-road
Recommended lubricants and liquids
GROUND
TEMPERATURE SWITCH
12V ADJUSTER
ELECTRIC FAN
CONSOLE SPARK COIL
GENERATOR
12V-20W
FRONT LAMP
KLAXTON
KLAXTON
SWITCH
STOP SWITCH
ENGINE
LAMP SWITCH
CONTROL GROUP
12V-3W TAIL LAMP
RACE MODEL
COLORS TABLE
Bi WHITE Gi YELLOW
Ve GREEN Rs RED
Mo BROWN Ar ORANGE
Vi PURPLE Az AZUR
Bl BLUE Ro PINK
Ne BLACK Gr GREY
GROUD
ELECTRIC FAN
TEMPERATURE SWITCH
12V ADJUSTER CONSOLE SPARK COIL
GENERATOR
12V-10W TAIL
DX DIRECT.INDICATOR
12V-5/21W
TAIL LAMP
12V-10W TAIL SX
DIRECTION INDICATOR
REAR BRAKE
STOP SWITCH
STABILIZER
12V-10W FRONT SX
DIRECTION INDICATOR
CONTROL GROUP
KLAXTON
STOP SWITCH
FRONT BRAKE
12V-10W FRONT DX
DIRECTION IDICATOR
N°3 LAMP 12V-1,2W
PILOT LIGHT
DIRECT. INDICAT.
PILOT LIGHT
PILOT LIGHT
FRONT LAMP
12V-25/25W
12V-5W
FRONT LAMP
STOP SWITCH
ENGINE
KLAXTON
SWITCH
LAMP DIMMER
SWITCH
DIRECT. INDICAT.
DIMMER SWITCH TYPE-TESTING MODEL
COLORS TABLE
Bi WHITE Gi YELLOW
Ve GREEN Rs RED
Mo BROWN Ar ORANGE
Vi PURPLE Az AZURE
Bl BLUE Ro PINK
Ne BLACK Gr GREY
DRIVING BEAM
ELECTROLYTIC CONDEN-
SER 4700 F –252V
FUEL COCK
CONDENSER

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Chapter 2
Operation and Use
INDEX OF TOPICS
Filling the fuel tank
Start-up
Break-in
Checks and maintenance before
and after use off-road
Recommended lubricants and liquids

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Operation and Use
ENGLISH
A
A
ON
OFF
FILLING THE FUEL TANK
Remove filler cap A. The capacity of the fuel tank is ap-
proximately 2.2 litres, of which 0.35 litres is reserve.
START-UP
1 Put the gearbox in neutral.
2WITHOUTopeningthethrottle,pressthekickstartlever
progressivelydownwards,avoidingviolentstrokes,tothe
bottom of its travel.
NOTE:
A long period with the engine out of use, such
as when the vehicle is on its side, can lead to a
lowering of the fuel level in the carburettor float
bowl, making the bike hard to start.
In this case, open the supplementary/reserve fuel
tap by pressing knob A, and follow the start-up
procedure again.
Once the engine has started, reclose the fuel
tap knob.
STARTING THE ENGINE FROM COLD
1 Put the gearbox in neutral.

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Operation and Use
ENGLISH
B
C
2 Operate the choke lever (B) by pulling it outwards.
3 WITHOUTopeningthethrottle,pressthekickstartlever
progressively downwards, avoiding violent strokes, to
the bottom of its travel.
4 Reclose the choke as soon as the engine has warmed
up (the radiator will be warm).
STARTING THE ENGINE WHEN HOT
1 Put the gearbox in neutral.
2 Operate the Hot Start lever (C) located on the clutch
master cylinder reservoir.
3 WITHOUTopeningthethrottle,pressthekickstartlever
progressively downwards, avoiding violent strokes, to
the bottom of its travel.
STARTING WHEN THE BIKE HAS FALLEN
OVER
If the bike falls over, the carburettor float bowl may
empty.
1 Operate the supplementary/reserve fuel tap by press-
ing knob A.
2 Put the gearbox in neutral.
3 Operate the Hot Start lever (C) located on the clutch
master cylinder reservoir.
4 WITHOUTopeningthethrottle,pressthekickstartlever
progressively downwards, avoiding violent strokes, to
the bottom of its travel.
5 Close the supplementary/reserve fuel tap.

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Operation and Use
ENGLISH
BREAK-IN
The break-in period lasts for about 10 hours of use. During this period,
please observe the following recommendations:
1 Forthe first 3hours ofuse, theengineshould only beused atup to 50%of its power. Theengine speedshould
not exceed 7000 rpm.
2 For the next 7 hours of use, the engine should only be used at up to 75% of its power.
3 Warm the engine up well before using the bike.
4 Avoid travelling at a constant speed: varying the speed makes the components bed in uniformly and in less
time.
CAUTION:
After the first three hours (or two fills of petrol), change the engine oil.
• Always use super unleaded petrol.
• After the first trip off-road, check all the nuts and bolts.
CHECKS AND MAINTENANCE BEFORE AND AFTER USE OFF-ROAD
To avoidunpleasantsurpriseswhileoperatingthevehicle,werecommendthatyouperformaseriesofchecksand
maintenancejobsbothbeforeandafteruse.Infact,dedicatingjustafewminutestothesechecksandjobswillnot
only make riding safer, but can save you time and money. Proceed as follows:
Tyres
Check the pressure, general condition and tread depth.
Spokes
Check that the tension is correct.
Nuts and bolts
Go over all the nuts and bolts.
Chain
Check the tension (clearance 20 mm) and, if necessary, grease it.
Air filter
Clean the filter and soak it in air filter oil.
Note:
Check that you have the vehicle’s identification documents. On cold days, before setting off we advise
that you run the engine, as a minimum, for the time required to reach the correct operating tempera-
ture. Every time the vehicle is used off-road it needs to be cleaned carefully.
RECOMMENDED LUBRICANTS AND LIQUIDS

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Operation and Use
ENGLISH
To promote better operation and longer life, we recommend that you preferably use the products listed in the
table:
TYPE OF PRODUCT TECHNICAL SPECIFICATIONS
Engine oil Bardahl XT C60 15W50
Brake and clutch fluid Bardahl brake fluid dot 4
Fork oil Idemitsu oj-racing-01
Bel ray “mc 10sae 5”
Grease for linkages Bardahl outboard grease
Coolant Bardahl permanent
Filter oil Bardahl oil filter
NOTE:
When changing the fluids, we recommend that you adhere strictly to the table shown.

Chapter 3
Maintenance and checks
INDEX OF TOPICS
Lubrication Circuit
Engine Oil
Brake master cylinder fluid
Brakes circuit bleeding
Clutch master cylinder fluid
Clutch circuit bleeding
Fork oil
Air filter
Sparkplug
Front brake
Rear brake
Coolant
Checks after cleaning
Scheduled maintenance
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9
8
75
3
6
1
2
12
8
4
10
11
12
Maintenance and checks
ENGLISH
LUBRICATION CIRCUIT
Theoutputoilpump(1) drawsin oilfromthe areaatthe
base of the gearbox through its own mesh oil filter (2)
and then sends it to the paper oil filter (3). From here
the oil, starting from the bypass valve (4), is directed in
three different directions: by means of a jet (5) it lubri-
catesthepistonpinandtakesheatfromthecrownofthe
piston;andit passesthroughtwopipes,oneof which(6)
takes it to the crankshaft to lubricate the roller bearing
on the crankpin; the other (7), whose flow is regulated
by a jet (8), feeds the valvegear (9). The oil then returns
to the base of the crank chamber from the piston, the
conrod assembly and the cylinder walls, and is drawn in
by the scavenge pump (10) through the mesh filter (11).
It is pumped through special jets (12) and lubricates the
transmissiongears.Theoilinthecylinderhead,however,
returns to the base of the gearbox passing through the
timing case and the inner clutch casing.

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MIN
MAX
Maintenance and checks
ENGLISH
ENGINE OIL
Use only fully synthetic oils of a reputable brand (BAR-
DAHL XTC60 15W50).
CHECKING THE ENGINE OIL LEVEL
The engine oil level must be checked when the engine
is warm. Run the engine for several minutes and then
switch itoff.Placethe bikeona flatsurfaceinsuchaway
that it is perfectly vertical.
Wait a few minutes and then check the oil level in the
sightglass located in the clutch casing (right-hand side of
the engine). The level must be between the limits indi-
cated in the picture.
If necessary, remove the oil filler plug and top up the
level.
N.B. Running the engine with too little oil causes
excessive wear to the engine components.
CHANGING THE ENGINE OIL
N.B. At each oil change, the mesh filters must be
cleaned and the paper filter replaced.
N.B. The oil change must be carried out when the
engine is at working temperature. Be careful not
to scald yourself with the hot oil.
After the engine has reached operating temperature,
switch the bike off and stand it upright.

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Maintenance and checks
ENGLISH
Unscrewtheoildrainplugandletalltheoilflowoutintoa
drainpan.Thoroughlycleanthemagnetonthedrainplug
to get rid of the metallic impurities that it has collected.
Unscrew the plug in the left-hand casing and use pliers
to extract the filter. Clean it carefully and blow it through
with compressed air. Check for damage to the O-rings,
and replace them if necessary. Refit all the parts and
tighten the plug to 15 Nm.

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Maintenance and checks
ENGLISH
Carry out the same procedure for the output mesh filter,
for which the access is via the right-hand engine casing.
Positionacontainerunderthebike,nearthecoverforthe
paper filter, and unscrew the bolts on the filter cover.

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A
A
C
B
Maintenance and checks
ENGLISH
Thenextractthepaperfilterusingpliers.Checkthecondi-
tion of the O-ring too, and replace it if necessary.
Change the filter and refit the cover, tightening the three
M6x20 bolts to 10 Nm.
Refit the oil drainplug, tightening it to 20 Nm, and refill
with 0.9 litres of engine oil (BARDHAL XTC60 15W50).
Finally, tighten the oil filler plug (A) to 10 Nm.
BRAKE MASTER CYLINDER FLUID
Front brake
Use the sight-glass (A) to check the brake fluid level.
There must always be enough brake fluid for the level
to be visible in the sight-glass. If there is not enough, the
fluid must be brought up to the correct level. To do this,
refill the reservoir by unscrewing the two screws (B), re-
moving the filler cap (C) and topping up the fluid.