Beta RR 4T-400 Instruction manual

WORKSHOP MANUAL
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3
INTRODUCTION
This publication has been designed to assist authorized
service personnel of Betamotor Workshops in maintaining
and repairing the vehicle referred to in the manual. Famil-
iarity with the specifications contained herein is a key fac-
tor in the technical training of operators. In order to make
the manual easy to read and understand, the different
paragraphs are marked with icons that point out the subject
dealt with.
USEFUL ADVICE
To avoid problems and ensure best results, Betamotor
recommends observing the following guidelines:
- Whenever a repair is needed, analyse the customer’s ac-
count of the malfunction and ask any questions that can
help to clarify the symptoms.
- Clearly diagnose the causes of the malfunction. This
manual provides basic operating principles which the op-
erator will have to supplement with their personal experi-
ence.
- Carefully plan the repair so as to avoid wasting time in
obtaining spare parts, preparing tools, etc.
- Gain access to the parts to be repaired by performing on-
ly the operations that are strictly necessary. For best re-
sults, always follow the removal procedures described in
this manual.
Note
Betamotor is committed to constantly improving its prod-
ucts. For this reason, there can be slight differences be-
tween the content of this manual and the vehicle to be re-
paired or serviced. Betamotor products are exported to
many countries characterized by different Highway Codes
and type-approval procedures. In view of this, Betamotor
reserves the right to modify its products and technical doc-
umentation at any time and without notice.
Let us help protect the environment
Everything we do affects the entire planet and its re-
sources.
To protect the common interest, Betamotor urges its cus-
tomers and service operators to use the vehicles and dis-
pose of their components in compliance with applicable
regulations on environmental pollution control, waste dis-
posal and recycling.
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4
GENERAL CONTENTS
1 General information
2 Specific tools
3 Tightening torques - Specifications -
Recommended products
4 Maintenance
5 Bodywork and fittings
6 Engine
7 Carburettor
8 Front suspension/wheel
9 Rear suspension/wheel
10 Braking system
11 Electrical system
Workshop manual RR 4T - 400 - 450 - 525
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Pag. 5
GENERAL INFORMATION 1
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6Workshop manual RR 4T - 400 - 450 - 525
CONTENTS
HOW TO CONSULT THE MANUAL . . . . . . . Chap. 1 - 7
GENERAL CONTENTS . . . . . . . . . . . . . Chap. 1 - 7
Arrangement of subjects . . . . . . . . . . . Chap. 1 - 7
Description of operations . . . . . . . . . . . Chap. 1 - 7
PURPOSE OF THE MANUAL . . . . . . . . . . . Chap. 1 - 7
Updates . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 7
TERMS AND SYMBOLS . . . . . . . . . . . . . . Chap. 1 - 8
CONVENTION . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 9
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Carbon monoxide . . . . . . . . . . . . . . . . Chap. 1 - 10
Petrol . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Engine oil . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Coolant . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Brake fluid . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 11
Threadlocking fluid . . . . . . . . . . . . . . . Chap. 1 - 11
Shock absorber nitrogen . . . . . . . . . . Chap. 1 - 11
Battery . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 11
Hot parts . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 11
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 12
TABLES OF CONTENTS
TABLE OF CONTENTS OF EACH CHAPTER Chap. 1 - 12
CONTENTS OF EACH CHAPTER . . . . . . . Chap. 1 - 12
OPERATING SPECIFICATIONS . . . . . . . . Chap. 1 - 13
VEHICLE IDENTIFICATION . . . . . . . . . Chap. 1 - 13
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1 - General information Release 01 Date 09/2007
HOW TO CONSULT THE MANUAL
Arrangement of subjects
The manual is divided into chapters that cover the main sub-
assemblies of the vehicle. To make the different chapters easy
to find, the pages of each chapter bear a reference mark that is
aligned with the related title in the general contents.
Description of operations
The removing, fitting and checking operations described in the
manual are accompanied by pictures (drawings or pho-
tographs).
The pictures contain symbols referring to procedures, special
tools and other information. Refer to the key to the symbols for
a description of their meanings.
The procedures are arranged sequentially, step by step.
EXAMPLE
Whenever a specific tightening torque is needed, begin by ap-
plying a standard tightening torque (e.g. 10 N·m), then proceed
with the tightening by rotating the part by a predetermined angle
(e.g. 30°).
PURPOSE OF THE MANUAL
This manual is chiefly intended for qualified Betamotor dealers and mechanics. A mechanic should not expect to find all
the information he requires in a manual. Anybody who uses this manual should have a working knowledge of the princi-
ples of mechanics and of motorcycle repairing techniques. Performing repairs or maintenance operations without this
knowledge may render the vehicle unusable and even dangerous.
Updates
Betamotor is committed to continually improving its products. Any significant changes made to the specifications and pro-
cedures contained in this manual will be made known to official dealers and will be included in future editions of the man-
ual. All the information, instructions and technical data provided in this manual were up-to-date when the manual was ap-
proved for print. Betamotor reserves the right to make changes to the manual at any time, without notice and without in-
curring any obligations.
30°
10 N·m
GENERAL CONTENTS
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TERMS AND SYMBOLS
Workshop manual RR 4T - 400 - 450 - 525
When performing these oper-
ations, flammable vapours
can be released and metal
parts can be ejected at high
speed. It is therefore neces-
sary to:
- Avoid working near sparks
or open flames.
- Wear protective clothing.
- Wear protective goggles.
IMPORTANT
Whenever a worn cylinder
part needs to be replaced,
we recommend checking
and if necessary replacing all
the parts that are related to it.
In particular, the following
parts should always be re-
placed at the same time:
- Piston, piston rings and
piston pins.
- Valves, valve springs,
valve cotters, caps and
thrust washers.
- Valve guides with related
valves, springs, caps,
valve cotters and thrust
washers.
- Crankshaft bearings.
- Any part subject to even
wear.
To keep the engine in perfect
running order, ensure that all
fits are within the prescribed
tolerances. A close fit can
lead to seizure as soon as
the moving parts heat up; on
the other hand, a loose fit
causes vibrations that accel-
erate the wear and tear of
moving parts.
NOTE Whenever the words left, right, upper,
lower, front and rear are used, reference
is made to the vehicle in its normal direc-
tion of travel.
Avoid disposing of the parts in the envi-
ronment.
NOTE
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1 - General information Release 01 Date 09/2007
CONVENTION
In order to clarify the left/right convention used in this manual, a diagram of the vehicle and engine are provided below
with an indication of how the two sides are referred to in the manual.
Rh
Rh
Lh
Lh
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10 Workshop manual RR 4T - 400 - 450 - 525
SAFETY
Carbon monoxide
• Exhaust gases contain carbon monoxide (CO), a poisonous gas that can cause loss of consciousness and even death.
• Before starting the engine, ensure that the area is well ventilated. Never run the engine indoors.
• The engine can be run indoors only if the area is equipped with specially designed exhausters.
Petrol
• Petrol is highly flammable and, under certain circumstances, explosive.
• Keep all heat sources, sparks and open flames away from the working area.
• Always work in a well ventilated area.
• Never use petrol as a cleaning solvent. Avoid handling it unless absolutely necessary.
• Do not use petrol for cleaning components that need to be blown with compressed air.
• Keep out of the reach of children.
Engine oil
• Repeated and prolonged contact of engine oil with the skin can cause skin diseases.
• In case of contact, wash the contaminated parts with soap and water as soon as possible.
• In case of eye contact, rinse abundantly with water and seek medical attention.
• In case of ingestion, immediately seek medical attention without causing vomit as this could result in the oil being
breathed into the lungs. If the product is believed to have been breathed into the lungs, immediately transport the af-
fected person to the nearest hospital.
• Spent oil contains substances that are dangerous to the environment. Oil can be renewed only by operators that are
equipped for the disposal of spent oils in compliance with applicable laws.
• Avoid disposing of spent oil in the environment.
• Keep out of the reach of children.
Coolant
• Under certain circumstances the ethylene glycol contained in the coolant is flammable and its flame is invisible. Should
the ethylene glycol ignite, its flame, though invisible, could cause serious burns.
• Avoid bringing the coolant into contact with hot parts as these could ignite it.
• The coolant (ethylene glycol) can irritate the skin and is poisonous if ingested.
• In case of skin contact, immediately take off any contaminated clothes or footwear and wash abundantly with soap and
water. In case of eye contact rinse abundantly with clean water and immediately seek medical attention. If the coolant
is ingested, avoid causing vomit as this could cause the product to be breathed into the lungs. Administer clean water
and immediately transport the affected person to the nearest hospital and show the product to health personnel.
• If anybody is exposed to a high concentration of coolant vapours, transport them to an area where they can breath un-
polluted air. If necessary seek medical assistance.
• Do not remove the radiator cap when the engine is hot. Since the coolant in the radiator is subjected to high pressures,
it could spurt out and cause burns.
• The coolant contains substances that are harmful to the environment. The coolant can only be renewed by operators
equipped for the disposal of spent oils/coolant in compliance with the regulations in force.
• Avoid disposing of the coolant in the environment.
• Keep out of the reach of children.
WARNING The information contained in this paragraph is designed to minimize the risks the operator runs
when working on the vehicle.
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1 - General information Release 01 Date 09/2007
Brake fluid
• The brake fluid is highly corrosive.
• Avoid contact with the eyes, the skin and the mucous
membranes.
• In case of skin contact, immediately take off any conta-
minated clothes or footwear and wash abundantly with
soap and water.
• In case of eye contact, rinse abundantly with water and
seek medical attention.
• In case of ingestion, immediately seek medical attention
without causing vomit as this could cause the oil to be
breathed into the lungs.
• If the product is believed to have been breathed into the
lungs, immediately transport the affected person to the
nearest hospital.
• If anybody is exposed to a high concentration of coolant
vapours, transport them to an area where they can
breath unpolluted air. If necessary seek medical assis-
tance.
• In case of accidental contact, rinse abundantly with wa-
ter and seek medical attention.
• Keep out of the reach of children.
Threadlocking fluid
• Although threadlocking fluid is not classified as danger-
ous, prolonged contact with the skin, especially if
bruised, can lead to sensitization or dermatitis. In case of
skin contact, rinse with running water.
• In case of sickness due to inhalation of the product, take
the affected person into the open air and seek medical
assistance.
• In case of eye contact, rinse abundantly with water for at
least 15 minutes.
• In case of ingestion, drink large quantities of water or
milk. Seek medical attention without causing vomit as
this could cause the oil to be breathed into the lungs.
• Keep out of the reach of children.
Shock absorber nitrogen
• The rear shock absorber contains pressurized nitrogen.
• Before disposing of used shock absorbers, release the
nitrogen through the inflating valve.
• Only use nitrogen to pressurize the shock absorber. Un-
stable gases can explode and cause burns.
• To prevent the risk of explosions and burns, avoid keep-
ing the shock absorber close to flames or heat sources.
• Keep out of the reach of children.
Battery
• The battery produces explosive gases. Keep it away
from sparks, flames and cigarettes. Only recharge it in
well ventilated places.
• The battery contains a solution of sulphuric acid (elec-
trolyte).
• Sulphuric acid is corrosive to many materials and
clothes. When it comes into contact with small quantities
of water it produces a violent reaction which releases in-
tense heat and spurts of hot acid. Sulphuric acid attacks
many metals and in the process releases hydrogen, a
flammable gas that combines with air to produce an ex-
plosive mixture.
• Contact with sulphuric acid can cause burns. In case of
contact immediately take off any contaminated garments
and rinse the skin with large quantities of water. If nec-
essary, take the affected person to the nearest hospital.
• In case of eye contact immediately rinse abundantly with
water, seek medical assistance and continue the treat-
ment until the doctor arrives.
• Should the electrolyte be ingested, rinse the mouth with
water without swallowing, immediately transport the af-
fected person to the nearest hospital and show the prod-
uct to health personnel.
• The battery contains dangerous substances that are
harmful to the environment. Batteries can only be re-
placed by operators equipped for their disposal in com-
pliance with the regulations in force.
• Avoid disposing of spent batteries in the environment.
• Keep out of the reach of children.
Hot parts
• The engine and the exhaust system become and remain
very hot for some time, even after the engine has been
stopped. Allow them to cool down and put on insulating
gloves before handling these parts or working near them.
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NOTES
The information contained in this paragraph is designed
to prevent damage to the vehicle.
• Thoroughly clean the vehicle before removing parts.
• After removing parts, clean them and place them in containers
taking care to observe the order of removal.
• Always use special tools whenever necessary or directed.
• Always use glues, sealants and lubricants as directed, ob-
serving the indications about their specifications.
• Always replace parts such as gaskets, O-rings and safety
washers with new ones.
• When loosening or tightening nuts or screws, always start
from the bigger ones, or from the centre. Always observe the
prescribed tightening torques.
• Only use genuine Betamotor spares.
TABLES OF CONTENTS
TABLE OF CONTENTS OF EACH CHAPTER
12 Workshop manual RR 4T - 400 - 450 - 525
CONTENTS OF EACH CHAPTER
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1 - General information Release 01 Date 09/2007
2) engine number
3) type-approval data
OPERATING SPECIFICATIONS
VEHICLE IDENTIFICATION
The frame number is stamped on the right side of the head tube.
The engine number is stamped on the upper crankcase half, next to the swingarm.
ZD3 E1 XX XXXXXXXXXX
Manufacturer’s data
Vehicle model
Version 11 (400 cc Euro 3)
12 (450 cc Euro 3)
13 (525 cc Euro 3)
The following is an example of frame number format:
1) frame number
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SPECIAL TOOLS 2
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3625132 UNIVERSAL ENGINE MOUNTING TOOL
3625198 RACING ENGINE BRACKET
3625202 CHAIN LINK ASSEMBLING TOOL
3625200 WATER PUMP SEAL FITTING TOOL
POMPA ACQUA
3625097 SPECIAL RING PLIERS
3625203 PRIMARY DRIVE PULLER
3625174 PISTON RING ∅= 75 MM
3625175 PISTON RING ∅= 89 MM
3625384 PISTON RING ∅= 95 MM
2Workshop manual RR 4T - 400 - 450 - 525
Code Description
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3625001 LOCTITE 243 BLUE 6CCM
3625081 BUSH PULLER
3625082 INNER BEARING PULLER 12-16MM
3625083 INNER BEARING PULLER 18-23MM
3625084 INNER BEARING PULLER 5-7MM
3625204 VALVE GUIDE CHECKING TOOL
3625207 INNER CLUTCH RING FITTING TOOL
3625208 SHAFT PROTECTING COVER
3625205 GEAR PULLER
3625201 VALVE SPRING TOOL
3625193 INNER RING FITTING TOOLS NJ206
3
2 - Special tools Release 01 Date 09/2007
Code Description
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3625238 CHECKING SPANNER
3625173 FLYWHEEL PULLER
3625000 SILICONE (TUBE)
3625098 TIMING CHAIN FITTING TOOL
3625209 SPARK PLUG SPANNER 13/16
3625090 CLUTCH BLEEDING OIL SYRINGE
3625194 LOCTITE 648 GREEN 24ML
3625199 CLUTCH PULLER
Workshop manual RR 4T - 400 - 450 - 525
Code Description
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2 - Special tools Release 01 Date 09/2007
Code Description
3625206 CARBURETTOR ADJUSTING SPANNER
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