Beta RS4T USA Specifications

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WORKSHOP MANUAL
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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. Familiarity with the specifications contained herein is a key factor 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 account 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 operator will have to supplement with their personal experience.
- 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 only the operations that are strictly necessary. For best results, always follow the removal procedures described in
this manual.
Note
Betamotor is committed to constantly improving its products. For this reason, there can be slight differences between the content of this manual and the vehicle to be repaired 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 documentation at any time and without notice.
Let us help protect the environment
Everything we do affects the entire planet and its resources.
To protect the common interest, Betamotor urges its customers and service operators to use the vehicles and dispose of their components in compliance with applicable
regulations on environmental pollution control, waste disposal and recycling.
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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
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1
GENERAL INFORMATION
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CONTENTS
HOW TO CONSULT THE MANUAL
GENERAL CONTENTS . . . . . .
Arrangement of subjects . . . .
Description of operations . . . .
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Chap.
Chap.
Chap.
Chap.
1
1
1
1
-
7
7
7
7
PURPOSE OF THE MANUAL . . . . . . . . . . . Chap. 1 - 7
Updates . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 7
TERMS AND SYMBOLS
CONVENTION
. . . . . . . . . . . . . . Chap. 1 - 8
. . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 9
SAFETY . . . . . . . . . .
Carbon monoxide
Petrol . . . . . . . . . .
Engine oil . . . . . .
Coolant . . . . . . . .
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Chap.
Chap.
Chap.
Chap.
Chap.
1
1
1
1
1
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10
10
10
10
10
Brake fluid . . . . . . . . . . . .
Threadlocking fluid . . . . .
Shock absorber nitrogen
Battery . . . . . . . . . . . . . . .
Hot parts . . . . . . . . . . . . .
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. . . . . . . . . Chap. 1 - 11
. . . . . . . . . Chap. 1 - 11
. . . . . . . . . Chap. 1 - 11
. . . . . . . . . Chap. 1 - 11
. . . . . . . . . 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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HOW TO CONSULT THE MANUAL
GENERAL CONTENTS
Arrangement of subjects
The manual is divided into chapters that cover the main subassemblies 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 photographs).
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.
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 principles 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 procedures contained in this manual will be made known to official dealers and will be included in future editions of the manual. All the information, instructions and technical data provided in this manual were up-to-date when the manual was approved for print. Betamotor reserves the right to make changes to the manual at any time, without notice and without incurring any obligations.
EXAMPLE
Whenever a specific tightening torque is needed, begin by applying 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°).
10 N·m
30°
1 - General information
Release 01 Date 09/2007
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TERMS AND SYMBOLS
IMPORTANT
NOTE
8
When performing these operations, flammable vapours
can be released and metal
parts can be ejected at high
speed. It is therefore necessary to:
- Avoid working near sparks
or open flames.
- Wear protective clothing.
- Wear protective goggles.
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 replaced 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 accelerate 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 direction of travel.
Avoid disposing of the parts in the environment.
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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.
Lh
Rh
Rh
Lh
1 - General information
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SAFETY
WARNING
The information contained in this paragraph is designed to minimize the risks the operator runs
when working on the vehicle.
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 affected 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 unpolluted 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.
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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 contaminated 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 assistance.
• In case of accidental contact, rinse abundantly with water and seek medical attention.
• Keep out of the reach of children.
Threadlocking fluid
• Although threadlocking fluid is not classified as dangerous, 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.
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 (electrolyte).
• 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 intense 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 explosive 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 necessary, take the affected person to the nearest hospital.
• In case of eye contact immediately rinse abundantly with
water, seek medical assistance and continue the treatment until the doctor arrives.
• Should the electrolyte be ingested, rinse the mouth with
water without swallowing, immediately transport the affected person to the nearest hospital and show the product to health personnel.
• The battery contains dangerous substances that are
harmful to the environment. Batteries can only be replaced by operators equipped for their disposal in compliance 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.
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. Unstable gases can explode and cause burns.
• To prevent the risk of explosions and burns, avoid keeping the shock absorber close to flames or heat sources.
• Keep out of the reach of children.
1 - General information
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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, observing 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
CONTENTS OF EACH CHAPTER
TABLE OF CONTENTS OF EACH CHAPTER
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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.
2) engine number
3) type-approval data
1) frame number
The following is an example of frame number format:
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)
1 - General information
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SPECIAL TOOLS
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Code
Description
3625132
UNIVERSAL ENGINE MOUNTING TOOL
3625198
RACING ENGINE BRACKET
3625202
CHAIN LINK ASSEMBLING TOOL
3625200
WATER PUMP SEAL FITTING TOOL
POMPA ACQUA
2
3625097
SPECIAL RING PLIERS
3625203
PRIMARY DRIVE PULLER
3625174
PISTON RING ∅ = 75 MM
3625175
PISTON RING ∅ = 89 MM
3625384
PISTON RING ∅ = 95 MM
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Code
Description
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
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Code
Description
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
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Code
Description
3625206
CARBURETTOR ADJUSTING SPANNER
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TIGHTENING TORQUES
SPECIFICATIONS
RECOMMENDED PRODUCTS
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CONTENTS
SPECIFICATIONS - ENGINE . . . . . . . . . . . . Chap. 3 - 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . Chap. 3 - 3
CARBURETTOR TUNING . . . . . . . . . . . Chap. 3 - 4
TIGHTENING TORQUES . . . . . . . . . . . . Chap. 3 - 5
FITS, WEAR LIMITS . . . . . . . . . . . . . . . . Chap. 3 - 6
STANDARD ADJUSTMENTS - FORK Chap. 3 - 6
STANDARD ADJUSTMENTS
- SHOCK ABSORBER . . . . . . . . . . . Chap. 3 - 6
SPECIFICATIONS - FRAME . . . . . . . . . . . . Chap. 3 - 7
- HOMOLOGATION E3 .
- AIS valve . . . . . . . . . .
- The catalytic converter
- Soundproof shell . . . . .
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.Chap.
.Chap.
.Chap.
.Chap.
3
3
3
3
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8
8
8
8
- USA HOMOLOGATION . . . . . . . . . .Chap. 3 - 8
- Canister RS4T USA filter system . . . .Chap. 3 - 8
TIGHTENING TORQUES . . . . . . . . . . . . Chap. 3 - 9
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SPECIFICATIONS - ENGINE
SPECIFICATIONS
Engine
400
Type
450
525
single-cylinder, 4-stroke, liquid-cooled, with countershaft and electric start
Displacement
Bore/stroke
Compression ratio
Fuel
398 cc
448 cc
510 cc
89 / 64 mm
89 / 72 mm
95 / 72 mm
11 : 1
11 : 1
11 : 1
unleaded premium fuel with a minimum of 95 RON
Valve gear
4 rocker-operated valves and 1 overhead camshaft driven by single chain
Camshaft
5532 590/5521
590/5521
590/5521
Diameter of intake valves
35 mm
35 mm
35 mm
Diameter of exhaust valves
30 mm
30 mm
30 mm
Valve cold clearance
intake: 0,12 mm
Valve cold clearance
exhaust: 0,12 mm
Crankshaft bearings
2 cylindrical roller bearings
Small end bearing
needle roller cage
Small end bearing
bronze bearing
Piston
forged alloy
Piston rings
1 compression ring, 1 scraper ring
Lubrication
2 oil pumps
Engine oil
completely synthetic oil of known brands (Bardahl XTM 15 W 50)
Oil quantity
1,25 litres
Primary drive
cylindrical gears with straight teeth, 33:76 teeth
Clutch
wet multiplate
Transmission (with front coupling)
6 speed
6 speed
6 speed
Gear ratios
1st 14:34
1st 14:34
1st 14:34
2nd 17:31
2nd 17:31
2nd 17:31
3rd 19:28
3rd 19:28
3rd 19:28
4th 22:26
4th 22:26
4th 22:26
5th 24:23
5th 24:23
5th 24:23
6th 26:21
6th 26:21
6th 26:21
Ignition system
Dynamo
DC-CDI digital ignition system without breaker, with variable spark advance, KOKUSAN type
12V 150W
12V 150W
Spark plug
NGK DCPR 8 E
Spark gap
0,6 - 0,7 mm
Cooling
liquid cooling, forced liquid circulation by pump
Coolant
1.3 litres, 40% antifreeze, 60% water, at least -25°C
Starting
electric start / kickstart
3 - Tighening torques, specifications, recommended products, Homologation E3
Release 01 Date 09/2007
12V 150W
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SPECIFICATIONS - ENGINE
CARBURETTOR TUNING
400/450
525
Carburettor type
Keihin FCR-MX 39
Keihin FCR-MX 39
Carburettor code
3900A
3900B
178
178
OBDVR
OBDVT
Idling jet
42
42
Main air jet
200
200
Idling air jet
100
100
Needle valve position
3.
3.
Starting jet
85
85
1,25 turns
1,25 turns
15
15
throttle valve stop
throttle valve stop
858 / 2,15 mm
858 / 2,15 mm
Main jet
Jet needle
Fuel mixture adj. screw open by
Throttle valve
Power reduction
Pump diaphragm stop
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SPECIFICATIONS - ENGINE
TIGHTENING TORQUES
Description
Type
Tightening
M6
10 N·m
Oil drain screw
M12x1.5
20 N·m
Short oil unit socket-head screw
M16x1.5
10 N·m
Long oil unit hexagonal-head screw
M20x1.5
15 N·m
M5
6 N·m
M12x1.5
20 N·m
Oilway screw and oil line hollow grub screw
M8
10 N·m
Oil pump cover screws
M5
Loctite 222 + 6 N·m
Cylinder head flange screws - upper section
M6
10 N·m
Cylinder head flange screws - upper section, water pump cover
M6
8 N·m
Exhaust flange screws
M6
Loctite 243 + 8 N·m
Cylinder head screws
M10
40/50 N·m
Camshaft gear socket-head screws
M8
Loctite 243 + 28 N·m
Automatic decompressor lever set screw
M5
Loctite 222 + 8 N·m
Rocker arm pin socket-head end screw
M5
5 N·m
M6x0.75
11 N·m
M6
Loctite 646 + 16 N·m
M20x1.5
Loctite 243 + 150 N·m
M6
Loctite 243 + 8 N·m
M18x1.5
Loctite 243 + 150 N·m
Clutch spring flange screws
M6
8 N·m
Gear selector socket-head screw
M6
Loctite 243 + 10 N·m
Selector lever flange screw
M5
Loctite 243 + 6 N·m
Timing chain stretcher, chain guide, chain guard flange screws
M6
Loctite 243 + 8 N·m
Gearbox desmodromic mechanism flange screw
M5
Loctite 243 + 6 N·m
Chain stretcher flange screws
M6
8 N·m
Chain guard flange screws
M5
Loctite 243 + 6 N·m
Stator flange screws
M6
Loctite 243 + 8 N·m
Pick-up flange screws
M5
Loctite 243 + 6 N·m
M12x1
60 N·m
Kickstart stop plate flange screw
M6
Loctite 243 + 8 N·m
Kickstart spring link flange screw
M6
Loctite 243 + 10 N·m
Starter motor cover flange screw, LH only
M6
Loctite 243 + 8 N·m
Breather pipe bracket flange screw
M6
Loctite 243 + 8 N·m
Kickstart screw
M8
Loctite 243 + 25 N·m
Gearshift lever flange screw
M6
Loctite 243 + 10 N·m
Hexagonal-head chain front sprocket screw
M10
Loctite 243 + 60 N·m
Spark plug
M10
10-12 N·m
Spark plug
M12x1.25
20 N·m
Crankcase, clutch cover, ignition cover flange screws
Oil filter cover flange screw
Bypass valve screw
Valve adjusting screw counternuts
Primary drive gear and free wheel socket-head screw
Primary drive gear hexagonal nut
Countershaft gear socket-head screws
Clutch hub hexagonal nut
Rotor flange nut
3 - Tighening torques, specifications, recommended products, Homologation E3
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SPECIFICATIONS - ENGINE
FITS, WEAR LIMITS
Crankshaft
Small end bearing
Cylinder 450/450
Cylinder 525
Piston 400
Piston 450
Piston 525
Luce segmento
Valves
Valve springs 450 / 525 /400
Oil pump
By-bass valve
Clutch plates
Gear shafts
Rocker arm shafts
Countershafts
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,1 - 0,2 mm
offset between shaft sections . . . . . . . . . . . . . . . . . . . .max. 0,12 mm
radial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0,05 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1,10 mm
size I diameter . . . . . . . . . . . . . . . . . . . . . . . . . .89,000 - 89,012 mm
size II diameter . . . . . . . . . . . . . . . . . . . . . . . . . .89,013 - 89,025mm
size I diameter . . . . . . . . . . . . . . . . . . . . . . . . . .95,000 - 95,012 mm
size II diameter . . . . . . . . . . . . . . . . . . . . . . . . .95,013 - 95,025 mm
size I diameter . . . . . . . . . . . . . . . . . . . . . . . . . .88,930 - 88,940 mm
size II diameter . . . . . . . . . . . . . . . . . . . . . . . . .88,941 - 88,950 mm
size I fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,060 - 0,082 mm
size II fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,062 - 0,085 mm
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,12 mm
size I diameter . . . . . . . . . . . . . . . . . . . . . . . . . .88,916 - 88,946 mm
size II diameter . . . . . . . . . . . . . . . . . . . . . . . . .88,926 - 88,956 mm
size I fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,054 - 0,096 mm
size II fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,056 - 0,099 mm
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,12 mm
size I diameter . . . . . . . . . . . . . . . . . . . . . . . . . .94,932 - 94,960 mm
size II diameter . . . . . . . . . . . . . . . . . . . . . . . . .94,940 - 94,968 mm
size I fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,050 - 0,070 mm
size II fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,044 - 0,085 mm
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,12 mm
compression ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0,80 mm
scraper ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 1,00 mm
width of sealing surface, intake . . . . . . . . . . . . . . . . . .max. 1,50 mm
width of sealing surface, exhaust . . . . . . . . . . . . . . . . .max. 2,00 mm
head floating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 0,05 mm
valve guide diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .max. 6,2 mm
spring cup . . . . . . . . . . . . . . . .min. 0,4 mm (mm when new 0,5 mm)
minimum outer spring length . . . . . . . . . . . . . . . . . . . . . . .39,20 mm
minimum inner spring length . . . . . . . . . . . . . . . . . . . . . . .36,45 mm
play btw outer rotor and pump casing . . . . . . . . . . . . .max. 0,20 mm
play btw outer and inner rotors . . . . . . . . . . . . . . . . . .max. 0,20 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,15 mm
minimum spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23,5 mm
minimum spring length . . . . . .min. 41,5 mm (mm when new 43 mm)
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1,7 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,1 - 0,4 mm
axial play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,02 - 0,10 mm
support pin offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0,06 mm
STANDARD ADJUSTMENTS - FORK
STANDARD ADJUSTMENTS - SHOCK ABSORBER
MARZOCCHI
SACHS
Compression adjust range
12 clicks
Rebound adjust range
12 clicks
Compression adjust range
EB-H16 SAE 7,5
Rebound adjust range
Spring preload
Oil type
6
clicks
clicks
21/21 (low speed)
24/24 (high speed)
25
260 mm
Workshop manual RR 4T - 400 - 450 - 525
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Pagina 7
SPECIFICATIONS - CYCLE PARTS
400/450/525
Frame
Single-beam, molybdenum steel frame with double cradle split over exhaust port
Fork
“MARZOCCHI” hydraulic upside-down fork (leg Ø 45)
Front/rear suspension travel
290/300 mm
Rear suspension
SACHS monoshocks with progressive leverage
Front brake
Floating steel disc Ø 255 mm with floating caliper
Rear brake
Steel disc Ø 240 mm with floating caliper
Brake discs
Wear limit 0.4 mm
Front tyre
90/90 - 21”
Tyre pressure, off road
1,0 bar
Tyre pressure, road use
1,5 bar
Rear tyre
140/80 - 18”
Tyre pressure, off road
1,0 bar
Tyre pressure, road use
1,8 bar
WHEEL DIMENSION (ENDURO) secondary clutch gear 15/45
front cover
90/90-21 54R o 54M
rear cover
140/80-18 70R o 70M or 130/90-18 70R only
Pirelli MT 21 Rallycross Tube Type
front rim
21x1,6
rear rim
18 x2,15
WHEEL DIMENSION (MOTARD) secondary clutch gear 15/43
front cover
120/70-17 58W o 58H
rear cover
150/60-17 66W o 66H
front rim
17x3,5
rear rim
17x4,25
Fuel tank capacity
8,5 litres (including 1 litre reserve)
Chain
135 ZRDK / 007
Bulbs
Headlight
12V 25/25W
Parking light
12V 3W
Brake/Rear light
12V 21/5W
Front/rear indicator units
LED
Number plate light
12V 5W
Battery
12V 5Ah
Caster angle
26,5°
DIMENSIONS - RR 250
Maximum length
Maximum width
Maximum height above ground
Wheelbase
Saddle height
Ground clearance
Footrest height
2270 mm
813 mm
1255 mm
1490 mm
940 mm
320 mm
405 mm
N.B: Potential tyre change from ENDURO to MOTARD also implies replacing the 15/45 secondary clutch gear with a 15/43
secondary clutch gear (motard Kit option).
3 - Tighening torques, specifications, recommended products, Homologation E3
Release 01 Date 09/2007
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HOMOLOGATION E3
1
The latest models are E3 type-approved and
they differ from prior approvals in that three devices have been introduced:
AIS valve
It is called AIS 1 and it is an air intake system
which allows to complete the combustion of
some unburned fuels remaining from the thermodynamic cycle.
The catalytic converter
The catalytic converter is located at the end of
the exhaust pipe and is part of the muffler,
fixed to the exhaust pipe by spot welding in
two places.Its function is to reduce the harmful
substances present in the exhaust fumes,
specifically CO (carbon monoxide), the HC
(unburned fuel) and the Nox (nitrogen oxide).
Soundproof shell
This last device 2 located above the ai filter,
has the function of reducing the emission of
polluting gases and sound thus minimising
noise pollution.
2
3
USA HOMOLOGATION
Canister RS4T USA filter system
The extra system with a Canister 4 emission
filter and vacuum valve 5 prevent the release
of vapours into the atmosphere.
4
5
8
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SPECIFICATIONS - FRAME
TIGHTENING TORQUES
4 fork foot screws
M6
10 N·m
Front brake caliper
M8 CH10
Loctite 243 + 30 N·m
Front brake disc
M6
Loctite 243 + 15 N·m
Rear brake disc
M8 CH10
Loctite 243 + 20 N·m
Upper fork plate clamping screws
M8 CH10
20 N·m
Lower fork plate clamping screws
M8 CH10
20 N·m
Rear wheel spindle flange nut
M20x1.5 CH27
90 N·m
Swingarm pin hexagonal nut
M16x1.5 CH19
100 N·m
Handlebar clamp screws
M8 CH10
20 N·m
Handlebar support screws
M10 TCEI
Loctite 243 + 40 N·m
Upper shock absorber screw
M10x1.25
Loctite 243 + 80 N·m
Lower shock absorber screw
M12
Loctite 243 + 80 N·m
M8 10.9
Loctite 243 + 25-30 N·m
Chain sprocket screws, special screw
Brake pedal screw
Brake pedal ball joint screw
M8 CH10
M6
Loctite 243 + 10 N·m
Engine fixing screws
M10x1.25 CH14
45 N·m
Other frame screws
M6
M8
M10
10 N·m
25 N·m
45 N·m
Other frame flange nuts
M6
M8
M10
15 N·m
30 N·m
50 N·m
3 - Tighening torques, specifications, recommended products, Homologation E3
Release 01 Date 09/2007
9
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Workshop manual RR 4T - 400 - 450 - 525
04_Inghilterra_059311
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18:10
Pagina 1
MAINTENANCE
4
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Pagina 2
CONTENTS
PLANNED MAINTENANCE . . . . . . . . . . . . Chap. 4 - 3
How to clean parts . . . . . . . . . . . . . . . . Chap. 4 - 4
Fits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 4
Part fitting guidelines . . . . . . . . . . . . . . Chap. 4 - 4
SUSPENSIONS . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 20
Fork
Adjusting the rebound damping . . Chap. 4 - 20
Adjusting the compression damping . Chap. 4 - 20
Shock absorber
Adjusting the hydraulic compression damping
(high/low speeds) . . . . . . . . . . . . . . Chap. 4 - 20
Oil circuit . . . . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 5
Checking the engine oil level . . . . . . . . Chap. 4 - 5
Changing the engine
oil and the oil filter . . . . . . . . . . . . . . Chap. 4 - 5
Adjusting the spring preload . . . . . . . Chap. 4 - 21
Adjusting the hydraulic
rebound damping . . . . . . . . . . . . . Chap. 4 - 21
Charging the battery . . . . . . . . . . . . . . Chap. 4 - 21
RECOMMENDED LUBRICANTS . . . . . . . . Chap. 4 - 3
Cleaning the short oil unit . . . . . . . . . . Chap. 4 - 6
Cleaning the long oil unit . . . . . . . . . . . Chap. 4 - 6
Replacing the oil filter . . . . . . . . . . . . . . Chap. 4 - 7
Checking the front brake fluid level . . . Chap. 4 - 8
Restoring the front brake fluid level . . . Chap. 4 - 8
Bleeding the front brake . . . . . . . . . . . . Chap. 4 - 8
Checking the rear brake fluid level . . . . Chap. 4 - 9
Restoring the rear brake fluid level . . . Chap. 4 - 9
Bleeding the rear brake . . . . . . . . . . . . Chap. 4 - 9
DIGITAL SPEEDOMETER
(version E3 and RR4T USA) . . . . . . . . . . . Cap. 4 - 22
ScrollL pushbutton . . . . . . . . .
Warning lights . . . . . . . . . . . . .
Instrument panel operation . . . .
Speed RPM indicator functions
Checking the level of the
hydraulic clutch oil . . . . . . . . . . . . Chap. 4 - 11
Bleeding the hydraulic clutch . . . . . . . Chap. 4 - 11
Controls . . . . . . . . . . . . . . . . . . . . . . . .Chap. 4 - 12
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Cap.
Cap.
Cap.
Cap.
4
4
4
4
-
23
23
24
24
Conversion procedure Km/h - Mph and wheel
selection . . . . . . . . . . . . . . . . . . . . . . . . Cap. 4 - 24
Odometer ODO functions . . . . . . . .Cap. 4 - 24
Clock CLK functions
. . . . . . . . . . . . . Cap. 4 - 24
TRIP odometer TRIP function . . . . . . Cap. 4 - 24
STP chronometer function
Checking the front brake pads . . . . . . Chap. 4 - 10
Checking the rear brake pads . . . . . . Chap. 4 - 10
....
....
....
...
. . . . . . . . Cap. 4 - 24
DIGITAL SPEEDOMETER (RS4T USA)
. . . Cap. 4 - 25
Cycling through the functions . . . . . . . . . Cap. 4 - 25
Button functions . . . . . . . . . . . . . . . . . . . Cap. 4 - 25
Current speed functions . . . . . . . . . . . . . . Cap. 4 - 25
Automatic TRIP functions (TD) . . . . . . . . Cap. 4 - 26
Fork oil . . . . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 14
Countdown TRIP functions (Countdown) . Cap. 4 - 26
SLEEP-MODE . . . . . . . . . . . . . . . . .Cap. 4 - 26
Air filter . . . . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 15
Spark plug . . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 16
WAKE-UP (from Sleep-mode) . . . . . . . . . . . Cap. 4 - 26
Changing the wheel circumference
and the unit . . . . . . . . . . . . . . . . . . . . . . . Cap. 4 - 27
Carburettor Idle speed adjustment . . . . . . . . . Chap. 4 - 17
Basic information on carburettor wear Chap. 4 - 17
Emptying the float chamber . . . . . . . . Chap. 4 - 18
Coolant . . . . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 18
Chain maintenance . . . . . . . . . . . . . . . Chap. 4 - 19
Chain wear . . . . . . . . . . . . . . . . . . . . . Chap. 4 - 19
Chain tensioning . . . . . . . . . . . . . . . . . Chap. 4 - 19
2
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PLANNED MAINTENANCE
Interval
hours (h)
3
after/every 15
fuel (litres)
20
100
Air filter (after each off-road ride)
C
C
Valves
K
K
Spark plug (replace every 30 hours)
-
K
Idle speed
K
K
Throttle cable play
K
K
Clutch
K
K
Engine oil
R
R
Engine oil filter
R
R
Engine oil gauze strainer
C
C
Exhaust pipe bolts
-
T
Brakes
K
K
Brake lines (replace every 4 years)
K
K
Brake fluid (renew every 2 years)
K
K
Tyres
-
K
Steering
K
K
Fork
-
K
Rear suspension
-
K
Frame bolts / nuts and oil line
T
T
Chain tensioning
K
K
Item
K
C
R
T
=
=
=
=
Check and adjust, clean, lubricate or replace as necessary.
Clean
Replace/renew
Tighten
RECOMMENDED LUBRICANTS
To keep the vehicle in perfect running order and prolong its life, we recommend using the products listed in the table below:
PRODUCT TYPE
SPECIFICATIONS
ENGINE OIL
BARDAHL XTM 15W 50
BRAKE FLUID
BARDAHL BRAKE FLUID DOT4
FORK OIL
EB-H16 SAE 7,5
LINKAGE GREASE
BARDAHL MPG2
CLUTCH OIL
IP ECOBLU
Note: When renewing the lubricants, be sure to use the products specified in the above table.
4 - Maintenance
Release 01 Date 09/2007
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How to clean parts
Clean all parts with suitable biodegradable solvents and
then dry them with compressed air.
Clean the assemblies before disassembling them as well
as the individual parts after disassembly. Also clean each
part before reassembly.
Fits
To keep the engine in perfect running order, ensure that all
fits are within the prescribed tolerances. The use of reduced tolerances can lead to seizure; on the other hand,
using excessive tolerances causes vibrations that accelerate the wear and tear of components.
Part fitting guidelines
When refitting parts, follow the removing procedures in reverse order, paying attention to any specific operations that
are pointed out. Always replace gaskets, oil seals, metal
retainers, sealing washers made of deformable materials
and self-locking nuts.
Bearings are designed to last a given number of hours. It is
therefore advisable to periodically replace them, all the
more so that their wear is difficult to verify. This approach
is recommended in addition to the dimensional checks of
the various components mentioned in the related paragraphs.
It is essential to thoroughly clean all components. Bearings
and other wear-prone parts should be lubricated with engine oil before they are fitted. Screws and nuts must be
tightened to the prescribed torques.
The following is a description of the removal, overhauling
and refitting operations to be used for the different assemblies and subassemblies that make up the engine, in a sequence that leads to the complete disassembly of the engine.
Remove the engine from the frame as described in the related paragraph. Drain the oil from the sump, remove the
spark plugs taking care to block up their holes with clean
rags so as to prevent small items (washers, etc.) from
falling into the engine.
4
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Oil circuit
Oil pump 3 sucks the engine oil from the gearbox oil sump
through long oil unit 4. The oil flows through oil line 5 into the
cylinder head to camshaft lubrication point 6. The oil quantity is
adjusted by means of oilway screw 7. A pipe branches off to long
oil unit 8, where the coarser particles are filtered from the oil.
The oil then comes to short oil unit 9, which filters off the finer
particles. Once it has been so cleaned, the engine oil is pumped
through bypass valve 10 to connecting rod bearing 11 and then
sprayed from below onto the piston through jet 12. The second
oil pump 13 sucks the oil from the crankcase through short oil
unit 14, lubricating gears 15.
Checking the engine oil level
The engine oil level can be checked indifferently when the engine is cold or hot.
Place the vehicle in an upright position on level ground (do not
use the side stand).
When the engine is cold, the oil should reach the lower edge of
sight A.
When the engine is hot, the oil should reach the upper edge of
the sight.
If necessary top up with engine oil.
A
WARNING: An insufficient quantity of engine oil or the
use low quality oil lead to early engine wear.
B
Changing the engine oil and the oil filter
Before performing this operation, remove (if present) lower
bumper A after unscrewing the three screws B as shown in the
figure.
Whenever the oil is changed, be sure to clean the short and long
oil units and replace both oil filters.
Renew the oil while the engine is at operating temperature.
WARNING: An engine at operating temperature and the
oil it contains are very hot and can cause burns.
Park the vehicle on level ground, remove screw C and drain the
oil into a container.
Thoroughly clean the screw (with the magnet). When the oil has
drained out completely, clean the sealing surface, refit screw C
with the seal ring and tighten to 20 N·m.
B
C
ENVIRONMENT: Dispose of spent oils in compliance
with applicable laws.
4 - Maintenance
Release 01 Date 0/2007
5
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Cleaning the short oil unit
Short oil unit 1 is fitted into socket-head screw 2 on the lower
side of the engine. Insert an Allen key into the socket and unscrew the oil drain screw.
Remove the oil unit, thoroughly clean its components and blow
them with low-pressure compressed air. Check the O-rings for
damage and if necessary replace them.
Replace the oil unit with the screw and tighten the latter to 10
N·m.
2
1
Cleaning the long oil unit
The long oil unit is fitted into hexagonal-head screw 3 next to the
engine number. Remove the screw with the oil unit, thoroughly
clean the components and blow them with low-pressure compressed air. Check the O-rings for damage and if necessary replace them.
3
Fit long oil unit 4 using a 300 mm spanner as shown in the figure, then insert the spanner through the opening in the hole on
the opposite side of the crankcase. Push the oil unit into the
crankcase until it stops and remove the spanner. Refit screw 3
and tighten to 15 N·m.
3
4
The oil unit is fitted at an angle (see figure). To avoid malfunctions, be sure to observe this position.
6
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Replacing the oil filter
Remove screw 1 and place a container under the engine to collect the drained oil. Remove the four screws 2 and take off the
two oil filter covers.
1
2
ENVIRONMENT: Dispose of spent oils in compliance
with applicable laws.
2
Using a pair of Seeger ring pliers, pull out the two filter elements
3 from the crankcase.
Clean the oil filter covers, the O-ring sealing surfaces and the
crankcase. Check the O-rings and the oil filter covers for damage and replace as necessary.
Turn the vehicle upside down and half fill the two oil filter casings with engine oil.
3
Fit the long filter unit in the front and the short filter unit in the
back of the crankcase.
Grease the oil filter cover O-rings and fit covers 4.
Fit screws 2 and tighten them to 6 N·m.
Tighten screw 1 to 8 N·m.
Lift up the vehicle.
Remove screw fastening 5 from the clutch cover and pour in
1.25 litres of the recommended engine oil (see table in Chapter
3).
4
WARNING: Before actually starting the engine, actuate
the kickstart several times to allow the oil to spread
throughout the system.
Subsequently start the engine and check all screw fastenings
and oil filter covers for signs of leakage. Finally check the engine
oil level and top up as necessary.
5
4 - Maintenance
Release 01 Date 09/2007
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Checking the front brake fluid level
Check the brake fluid level by looking through sight A. The level should never fall below the mark in the sight.
Restoring the front brake fluid level
To restore the brake fluid level, unscrew the two screws 1, lift
cap 2 and pour in fresh fluid (IP DOT 4) until the level is 5 mm
below the upper rim of the reservoir.
A
IMPORTANT: We recommend using DOT 4 brake fluid. Should
this fluid be unavailable, use DOT 5.1 instead. Do not on any account use DOT 5 brake fluid, a purple liquid with a base of silicone requiring special seals and tubes.
WARNING: Brake fluid is highly corrosive. Take care not to drip
it onto the paintwork.
2
1
Bleeding the front brake
To bleed air from the front brake circuit, follow these steps:
– Remove rubber cap B from valve C.
– Open the brake fluid reservoir cap.
– Insert one end of a small tube into valve C and place the other end in a container.
– Unscrew valve C (while pulling the lever) and repeatedly pull
the brake lever until the oil comes out in an uninterrupted flow
with no air bubbles. During this operation it is important that
the brake lever should never be released completely. Keep
pouring brake fluid into the brake pump reservoir to compensate for the fluid that is flowing out.
– Tighten the valve and remove the tube.
– Replace the cap.
– Fit the reservoir cap on the brake pump.
C
B
8
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Checking the rear brake fluid level
Ensure the brake fluid level by looking through sight D. The level should never fall below the mark in the sight.
Restoring the rear brake fluid level
To restore the brake fluid level, unscrew cap 3 and pour in fresh
fluid (IP DOT 4) until the level reaches the mark in sight D.
D
IMPORTANT: We recommend using DOT 4 brake fluid.
Should this fluid be unavailable, use DOT 5.1 instead. Do
not on any account use DOT 5 brake fluid, a purple liquid
with a base of silicone, as it requires special seals and tubes.
WARNING: Brake fluid is highly corrosive. Take care not
to drip onto the paintwork.
3
Bleeding the rear brake
To bleed air from the rear brake circuit, follow these steps:
– Remove rubber cap E from valve F.
– Unscrew the brake fluid reservoir cap.
– Insert one end of a small tube into valve F and place the other end in a container.
– Unscrew valve F (while operating the pedal) and repeatedly
actuate the brake pedal until the oil comes out in an uninterrupted flow with no air bubbles. During this operation it is important that the brake pedal should never be released completely. Keep pouring brake fluid into the brake pump reservoir
to compensate for the fluid that is flowing out.
– Tighten the valve and remove the tube.
– Replace the cap.
– Fit the reservoir cap on the brake pump.
F
E
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Checking the front brake pads
To check the wear of the front brake pads, visually inspect the
caliper from below. The lining on the visible ends of the two
brake pads should be at least 2 mm thick. Should the lining be
thinner, immediately replace the brake pads.
NOTE: Perform the check at the intervals specified in the Maintenance table in Chapter 3.
WARNING: Any delay in the replacement of the brake
pads can result in poor braking and lead to brake disc
damage.
Checking the rear brake pads
To check the wear of the rear brake pads, visually inspect the
caliper from behind. The lining on the visible ends of the two
brake pads should be at least 2 mm thick. Should the lining be
thinner, immediately replace the brake pads.
NOTE: Perform the check at the intervals specified in the Maintenance table in Chapter 3.
WARNING: Any delay in the replacement of the brake
pads can result in poor braking and lead to brake disc
damage.
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Checking the level of the hydraulic clutch fluid
To check the level of the fluid in the clutch pump, it is first necessary to remove cover 2.
Remove the two screws 1 and take off cover 2 together with the
rubber bellows.
When the clutch pump is in a horizontal position, the fluid should
be 4 mm below the upper rim.
If necessary, top up with hydraulic fluid of the recommended
type (see Chapter 3).
1
2
Bleeding the hydraulic clutch
Before bleeding the clutch, it is first necessary to remove the
clutch pump cover. Remove the two screws 1 and take off cover 2 together with the rubber bellows. Remove the breather
valve from clutch pump cylinder 3 and replace it with the bleeding syringe filled with SAE 10 hydraulic fluid. Inject fluid until it
comes out with no air bubbles from clutch pump hole 4. Ensure
that no fluid flows over. After completing the bleeding, check the
level of the fluid in the clutch cylinder and if necessary top up
with hydraulic fluid of the recommended type (see Chapter 3).
It is essential that only mineral oil should be used.
3
4
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CONTROLS
1
Clutch lever
Clutch lever 1 is fitted to the left-hand side of the handlebars.
Screw A can be used to alter the home position of the lever (see
Adjustments).
6
A
Front brake lever
Front brake lever 2 is fitted to the righthand side of the handlebars. Screw B can be used to adjust the home position of the lever (see Adjustments).
5
Starter button
Starte button 3 is located on the right-hand side of the handlebars and operate the electri engine starter. Push the button until the engine sterts.
Do not press the button 3 while the engine is running.
4
LH switch
2
Dip switch 4 has three positions:
lights off
low beam on
high beam on
Button 5 operates the horn.
Switch 6 is used to stop the engine.
Press the button until the engine stops.
B
3
Gearchange lever
Gearchange lever 7 is fitted to the left side of the engine.
The positions corresponding to the different gears are shown in
the figure.
The neutral position is between the 1st and 2nd gears.
6ª•
5ª•
4ª•
3ª•
2ª•
Folle•
1ª•
7
Brake pedal
The home position of brake pedal 4 can be altered by turning
adjusting screw 9 after loosening the counternut located under
dust cap 10. Loosen the counternut and turn the adjusting screw
until the desired height is obtained. Retighten the counternut
after completing the operation.
8
9
10
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CONTROLS (RR4t USA)
Starter button
Starte button 3 is located on the right-hand side of the handlebars and operate the electri engine starter. Push the button until the engine sterts.
Do not press the button 3 while the engine is running.
LH switch
Switch 11 is used to stop the engine. Press the button until the
engine stops.
While button 12 turns on the lights.
12
11
CONTROLS RS4T USA
RH switch
Starte button 13 is located on the right-hand side of the handlebars and operate the electri engine starter. Push the button until the engine sterts.
Do not press the button 13 while the engine is running.
While button 14 turns off the engine.
14
Caution:
Before turning it on, make sure the switch 14 is on ON.
13
LH switch
Dip switch 4 has three positions:
lights off
low beam on
high beam on
Button 5 operates the horn.
Switch 6 is used to stop the engine.
Press the button until the engine stops.
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Release 01 Date 09/2007
ON
OFF
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Fork oil
B
Left/right fork leg
To renew the oil, follow these steps:
– Unscrew the four screws B fastening handlebar clamp C and
remove the handlebars.
C
– Loosen leg clamping screws D and E.
D
E
– Remove lower plug F and upper plug A (pay attention to the
spring).
– Allow the oil to drain completely from the fork leg.
– Screw on lower plug F again.
F
– Pour in fresh oil of the type specified in the table in Chapter 3.
– Screw on upper plug A again.
– Tighten screw D, then screw E and then screw D again.
14
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Air filter
A dirty air filter blocks the passage of air, reduces engine power
and increases fuel consumption. For these reasons, it is essential to maintain the oil filter on a regular basis.
1
To gain access to the filter, follow these steps:
– Remove the saddle.
– Lift and rotate battery 1.
– Release filter fastener 2.
– Pull out air filter 3.
– Carefully wash the filter in soap and cold water or using a suitable detergent.
– Dry the filter.
– Wet the filter with filter oil, taking care to remove any excess
oil so as to prevent dripping.
WARNING: Do not clean the filter in foam containing
petrol or petroleum as these substances may corrode it.
Do not clean the filter with hot water.
Do not start the engine if the air filter is not in place: dust and dirt
getting into the engine could cause damage and excessive
wear.
3
– If necessary, also clean the inside of the filter casing.
– When refitting, make sure of the seal of the rubber gasket.
– Reattach filter fastener 2.
WARNING: After working on the filter, ensure that no object is left inside the filter casing.
Clean the filter every time the vehicle is used off road.
2
2
3
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Spark plug
Maintaining the spark plug in good condition makes for reduced
fuel consumption and optimum engine performance. It is preferable to remove the spark plug when the engine is hot (obviously after switching it off) as the carbon formation and the colour of
the insulator provide important information on carburation, lubrication and the general condition of the engine.
NOTE:
spark plug is black: mixture is “rich”
spark plug is light brown: mixture is correct
spark plug is white: mixture is “lean”
To avoid serious hand burns, wear protective gloves and
perform the operation with great caution.
To perform the check, simply remove the spark plug cap and unscrew the spark plug using the spanner provided. Carefully
clean the electrodes using a wire brush. Blow the spark plug
with compressed air to prevent any residues from getting into to
engine.
Using a thickness gauge, check that the spark gap is 0.6-0.7
mm. If necessary, correct the distance by bending the earth
electrode.
Also check that the insulator is not cracked and the electrodes
are not corroded. If that is the case, immediately replace the
spark plug.
Perform the check by referring to the indications provided in the
table Maintenance in Chapter 3.
Lubricate the spark plug thread and, when the engine is cold,
screw in the spark plug by hand until it stops and then tighten it
with the spanner.
NOTE: Always use NGK DCPR 8 E spark plugs.
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Carburettor - Idle speed adjustment
The adjustment of the idle speed strongly affects engine starting, i.e. an engine whose idle speed is properly adjusted is easier to start than an improperly tuned engine.
The idle speed is adjusted by means of adjusting roller 1 and
mixture adjusting screw 2. The adjusting roller alters the base
position of the throttle valve; the mixture adjusting screw adjusts
the idle speed mixture, which comes to the engine through the
idle speed system. Turning the screw clockwise decreases the
quantity of fuel (lean mixture); turning it anticlockwise increases
the quantity of fuel (rich mixture).
1
To properly adjust the idle speed, follow these steps:
– Turn in mixture adjusting screw 2 until it stops, then turn it to
obtain the basic adjustment prescribed by BETAMOTOR (see
engine specifications in Chapter 3).
– Warm up the engine.
– Using adjusting roller 1, adjust the standard idle speed (1400
- 1500 rpm).
– Slowly turn mixture adjusting screw 2 clockwise until the idle
speed begins to decrease. Memorize this position. Now slowly turn the mixture adjusting screw anticlockwise until the engine speed starts to decrease again. Choose the point between these two positions where the idle speed is higher.
Should the engine speed increase considerably, reduce it to
the standard level and repeat the above procedure.
NOTE: Failure to successfully complete the above procedure
may be due to an idling jet of unsuitable size.
a)If the mixture adjusting screw is turned until it stops and the
idle speed does not change, fit a smaller idling jet.
b)If the engine stalls while the mixture adjusting screw is still two
turns open, fit a larger idling jet.
Obviously, once the jet has been replaced, the adjusting procedure will have to be restarted from the beginning.
– Now use the adjusting roller to obtain the desired idle speed.
– The idle speed needs to be adjusted again in case of marked
changes in the outside temperature and the riding altitude.
2
Basic information about carburettor wear
The throttle valve, the jet needle and the needle jet are subject
to heavy wear and tear due to engine vibrations.
This could result in carburettor malfunctions (e.g. a richer mixture).
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Emptying the float chamber
Should the float chamber need to be emptied, use the following
procedure when the engine is cold. Close the fuel cock and
place pipe 4 in a container to collect the fuel that will flow out.
Open drain screw 5 and drain the fuel. Close the drain screw
again, open the fuel cock and check the seal of the system.
5
4
WARNING: Fuel is toxic and highly flammable. Handle it
with the utmost care. Never work on the fuel system near
heat sources or open flames. Always allow the engine to
cool down. Clean any excess fuel with a rag. Materials soaked
in fuel are also highly flammable. In case of ingestion or contact
with sensitive body parts, immediately seek medical attention.
Dispose of fuel in accordance with the law.
Coolant
Check the coolant level when the engine is cold. Follow
these steps:
A
– Unscrew cap A and visually check the level of the coolant.
When the engine is cold, the liquid should be about 10 mm
above the radiator fins.
– If the coolant does not cover the radiator fins, add coolant until the level is restored.
The capacity of the circuit is shown in the table in Chapter 3.
WARNING: To avoid burns, never unscrew the radiator
filler cap when the engine is hot.
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Chain maintenance
The life of the chain mainly depends on its maintenance. Chain without X-rings should be regularly cleaned in petroleum
and then immersed in hot chain oil or treated with chain spray.
The maintenance of X-ring chains is reduced to a minimum. The best way to clean them is to use plenty of water. Never
attempt to clean an X-ring chain with brushes or solvents. Once the chain has dried, it is possible to use a spray for Xring chains.
Take special care in ensuring that the lubricant does not come into contact with the rear tyre or the brake disc, otherwise the grip of the tyre or the braking action would be considerably reduced, making the vehicle difficult to control.
Chain wear
Carefully follow the procedure described below to check the
wear of the chain.
Change into neutral, pull up the upper chain stretch with a force
of 10-15 kg (see figure). Now measure the length of 18 links on
the lower chain stretch. If the measurement is equal to or
greater than 272 mm, replace the chain. Chains do not always
wear out evenly. For this reason the measurement should be
taken at different points along the chain.
10-15 Kg
18 steps
When fitting a new chain, it is advisable to change the
front and rear sprockets as well. New chains wear out
faster when fitted on old and worn-out front sprockets.
In case of replacement, adjust the chain tension.
OK < 272
Chain tensioning
To prolong the life of the drive chain, it is advisable to periodically check its tensioning.
Always keep the chain clean and lubricated. Whenever the
chain play exceeds 30 ÷ 35 mm, adjust the chain tension by following these steps:
30 ÷ 35 mm
– Loosen wheel spindle nut 1.
– Loosen counternuts A on both fork arms.
A
B
– Turn adjusting screw B on either side to obtain the desired
tension.
– Tighten counternuts A on both fork arms.
– Tighten nut 1.
A
1
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B
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SUSPENSIONS
Fork
Adjusting the rebound damping
The hydraulic rebound damping unit determines the behaviour
of the fork during the rebound phase and is adjusted by means
of screw A. Turning the screw clockwise (towards the + sign) or
anticlockwise (towards the – sign) respectively increases or decreases the rebound damping.
A
Standard adjustment:
12 clicks from the completely closed position
Adjusting the compression damping
The hydraulic compression damping unit determines the behaviour of the fork during the compression phase and can be adjusted by means of screw B at the lower end of the fork legs.
Turning the screw clockwise or anticlockwise respectively increases or decreases the compression damping.
B
Standard adjustment:
12 clicks from the completely closed position
Shock absorber
Adjusting the hydraulic compression damping
(high/low speeds)
The shock absorber can be adjusted for both high and low
speeds.
The expressions ‘high speed’ and ‘low speed’ refer to the movement of the shock absorber, not to the speed of the vehicle.
The low and high speed adjustments affect the behaviour of the
shock absorber during slow and fast compression respectively.
C
D
Low speed adjustment:
– Using a screwdriver, turn screw C clockwise to decrease the
hydraulic compression damping.
Standard adjustment:
completely open screw, 21/21 clicks
High speed adjustment:
– Turn knob D anticlockwise to decrease the hydraulic compression damping.
Standard adjustment:
completely open knob, 24/24 clicks
WARNING: If the knob is turned anticlockwise (closing
direction) from the standard position, the central screw
will rotate together with knob. This is normal, and the
screw will be in the completely open position in any case.
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Adjusting the spring preload
Use the following procedure to adjust the spring preload.
Loosen locknut 1, turn ring nut 2 clockwise to increase the
spring preload (and consequently the shock absorber preload)
and anticlockwise to decrease it. Once the desired preload has
been obtained, turn locknut 1 until it comes into contact with adjusting ring nut 2.
1
Spring preload: 260 mm
2
Adjusting the rebound damping
The rebound damping is adjusted by means of screw 3.
Turning the screw anticlockwise (out) decreases the damping
action.
Standard adjustment:
24 clicks from the completely closed position
3
Charging the battery
Remove the battery and check its charge. Using an open-circuit
multimeter (10-12 hours after the activation), check that the voltage is greater than 12.6 V. If it is lower, recharge the battery.
Depending on the recharger that is available, recharge the battery using one of the following procedures:
– Constant voltage: charge the battery with a voltage of 14.4-15
V for about 12 hours. 10-12 hours after the charging is complete, measure the voltage as previously described.
– Constant current: charge the battery at 0.5/0.8 A until the voltage between the terminals settles around 14.5 V.
WARNING: The battery is sealed. When recharging, do
not remove the seal plug nor add any liquid.
WARNING: To recharge the battery, first connect it to the
battery charger and then turn on the charger.
When recharging indoors, take care to ensure proper
ventilation. During the charging the battery produces explosive gases.
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DIGITAL RPM INDICATOR (RR4T Euro 3 version)
SCROLL PUSHBUTTON
The instrument panel has a pushbutton A which changes and sets the main functions.
WARNING LIGHTS
The instrument panel has three warning lights. Warning light B, GREEN, indicates turn indicators have been activated.
Warning light C, BLUE, indicates when the high-beam light is ON.
Warning light D, YELLOW, indicates the reserve (not activated)
B
C
D
A
Important:
When cleaning operation using a high-pressure water jet cleaner, avoid aiming the jet to the digital instrument panel.
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INSTRUMENT PANEL OPERATION
Every time the battery is connected, the instrument panel
checks all the functions.
Once the CHECK phase is complete (around 2 seconds), the
last preset operation is displayed.
Every time the vehicle is turned off, the instrument panel stops
showing the current information.
If the SCROLL pushbutton is pushed repeatedly, the functions
are displayed in sequenced screens in the following order:
1st screen
- SPEED rpm indicator
- Odometer ODO
2nd screen
- SPEED rpm indicator
- Clock CLK
3rd screen
- SPEED rpm indicator
- Trip odometer TRIP
4th screen
- SPEED rpm indicator
- STP chronometer
1st screen
- SPEED rpm indicator
- Odometer ODO ....and so on.
SPEED RPM INDICATOR FUNCTIONS
It indicates the vehicle speed in km/h or Mph.
Maximum value: 199 km or mph
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CONVERSION PROCEDURE Km/h - Mph and wheel
selection
In order to convert km/h to mph, proceed as follows:
- Set the instrument panel on the 1st screen, turn off the
vehicle and press the SCROLL pushbutton.
- Start the vehicle keeping the SCROLL pushbutton
pushed until the symbol "Km/h" is displayed.
- "Km/h" and "Mph Miles" will be displayed alternately.
Press the SCROLL key when the intended unit of measurement is displayed.
- After the conversion, and for a short period of time,
the two wheel circumferences available will be shown.
Confirm the value to be saved by pressing the
SCROLL key at the moment it is shown on the display.
ODOMETER ODO FUNCTIONS
The ODO function saves the kilometres travelled
by the vehicle, even with the instrument panel is OFF.
Saving interval: every 2 km
Maximum indication: 99999 km
CLOCK CLK FUNCTIONS
It indicates hours and minutes from 0:00 to 23:59 :59
In order to set the clock, it is necessary to select the
screen 2 and hold down the SCROLL pushbutton for approximately three seconds. After this time has elapsed,
the desired hour can be selected by pressing the
SCROLL key.
When the pushbutton is released after three seconds,
the instrument panel will automatically shift to the minutes. Select the minutes by pressing repeatedly the
SCROLL pushbutton.
TRIP ODOMETER TRIP FUNCTION
It indicates the distance travelled from the last resetting.
Maximum indication: 999.9 km
This parameter can be reset on screen 3 by pushing
and holding down the SCROLL key for approximately 3
seconds.
Remark:
The information from this function is lost when the battery is disconnected or tension drops below 6V.
STP CHRONOMETER FUNCTION
It indicates a range from 0 to 99:59.99
(Minutes:Seconds.Hundredths of a second)
This counter is controlled by pressing (once the function
is displayed) the SCROLL key for approximately 0.5
second.
1st Push: function activation
2nd Push: counters are stopped
3rd Push: STP reset
4th Push: function activation
5th Push: counters are stopped and so on ....
Remark:
The information from this function is lost when the battery is disconnected or tension drops below 6V.
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DIGITAL SPEEDOMETER
(RR4T USA RS4T USA version)
A
CYCLING THROUGH THE FUNCTIONS
It is always possible to cycle through the different functions while
the vehicle is stationary or in motion. Pressing button A displays
the following functions in succession:
TIME - LAP - TOD - TD - COUNTDOWN
BUTTON FUNCTIONS
The functions of the buttons change with the function currently
displayed:
1 - TIME
T≥ 3” and Vel=0 activates time setting mode T<3” or Vel>0 cycles through functions
2 - LAP
functions
T≥ 3” resets LAP and TD - T<3” cycles through
3 - TOD
T≥ 3” and Vel=0 enables setting of circumference, unit and number of pulses for each wheel turn - T<3” or
Vel>0 cycles through functions
4 - TD
functions
T≥ 3” resets LAP and TD - T<3” cycles through
5 - COUNTDOWN
T≥ 3” and Vel=0 enables setting of
countdown - T<3” or Vel>0 cycles through functions.
T = Time during which button is pressed down
Vel = Speed of vehicle
CURRENT SPEED FUNCTION
This information is constantly displayed together with an indication provided by a graphic bar. The default unit is Mph. To
change the unit, press the button to access the Setup menu and
select km/h. When Mph is selected, no indication is provided as
to which unit is currently displayed.
AUTOMATIC LAP FUNCTION (LAP)
T≥ 3” resets LAP and TD
T<3” cycles through functions
This information represents the actual riding time associated with the TD parameter. It is an automatic
counter which is activated by the first pulse generated
by the speed sensor and stops 3 seconds after receiving the last pulse from the sensor. The counter for
this parameter can be reset while in LAP mode by
pressing the A button for about 3 seconds until 00’00”
is displayed. The LAP function can be reset while the
vehicle is stationary or in motion and also causes the
reset of the TD parameter.
MILEOMETER FUNCTION (TOD)
T≥ 3” and Vel=0 enables setting of circumference, unit
and number of pulses for each wheel turn
T<3” or Vel>0 cycles through functions
The information is displayed together with the TOD
caption. Depending on the selected unit, the informat
is displayed in Mph (default) or Km/h and is permanently stored in non-volatile memory. It is not possible
to reset this information during normal operation of
the instruments.
TIME FUNCTION (TIME)
T≥ 3” and Vel=0 activates time setting mode
T<3” or Vel>0 cycles through functions
The time can only be set while the vehicle is stationary.
Press and hold button C or D for more than 3 seconds to enter
the time setting mode.
Once the time has been set, press the button for about 3 seconds to go back to the standard operating mode. The Time parameter is displayed in the 0-12 format if Mph has been selected, and in the 0-24 format if Km/h has been chosen. When in the
setting menu, if no buttons are pressed for 20 seconds the system will automatically return to the standard operating mode.
Moving off (Vel > 0) while the setting mode is activated causes
the system to automatically return to the standard operating
mode.
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AUTOMATIC TRIP FUNCTION (TD)
T≥ 3” resets LAP and TD
T<3” cycles through functions
A
This function is always accompanied by the TD caption. The information displayed represents the total distance covered by the
vehicle in kilometres or miles (according to the selected unit). It
is an automatic counter which is activated by the first pulse generated by the speed sensor.
The counter for this parameter can be reset while in TD mode
by pressing the button for about 3 seconds until 000.0 is displayed. The TD function can be reset while the vehicle is stationary or in motion and also causes the reset of the LAP parameter.
COUNTDOWN TRIP FUNCTION (COUNTDOWN)
T≥ 3” and Vel=0 enables setting of countdown
T<3” or Vel>0 cycles through functions
This function is always accompanied by a flashing TD caption.
The counter is always active and is automatically decreased by
0.1 kilometres or miles according to the selected unit. The value
for this parameter can be changed in TD decrease mode by
pressing the button for about 3 seconds while the vehicle is stationary.
The different figures that make up the counter can be altered
starting from the most significant figure and shifting in successive steps to the least significant figure.
Pressing the button for a short time decreases the value by one
step; pressing it for a longer time allows a different parameter to
be selected. After setting the least significant figure, press the
button for about three seconds to go back to the standard operating mode. If the parameter reaches 000.0, the system automatically sets it to 999.9.
While in the setting menu, if no buttons are pressed for 20 seconds the system will automatically return to the standard operating mode.
Moving off (Vel > 0) while the setting mode is activated causes
the system to automatically return to the standard operating
mode
SLEEP-MODE
One minute after the last pulse from the speed sensor has been
received, or after the button was last depressed, the microcontroller switches to a power-saving status named Sleep Mode. In
order to save power, all standard instrument activity is suspended, the display and the backlighting are turned off (if the vehicle
has no battery the backlighting is automatically turned off as
soon as the engine is switched off) and only the clock remains
in operation. The system can go into Sleep Mode regardless of
the selected function.
WAKE UP (from Sleep Mode)
The system wakes up from Sleep Mode whenever:
•The instrument receives a signal from the speed sensor.
•The button is depressed.
As soon as the microcontroller wakes up the following happens:
• The display and the warning lights are checked (all the warning lights come up providing that power is supplied by the vehicle) for about 2 seconds.
• The selected wheel circumference and number of wheel pulses are displayed for about 2 seconds.
• The last function in use when the system went into Sleep Mode
is activated. If the waking up takes place through the electronic transmission (i.e. without pressing the button), the instruments immediately switch to the standard operating mode
without checking the display and the warning lights and without showing the selected wheel circumference and number of
wheel pulses.
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CHANGING THE WHEEL CIRCUMFERENCE,
UNIT AND NUMBER OF PULSES
The wheel circumference, the unit and the number of wheel
pulses can be altered only when the vehicle is stationary.
Hold down the button while the TOD function is active until the only information displayed is the circumference and all the other segments are switched off. The different digits that make up the wheel
circumference figure can be altered in succession from the most
significant digit to the least significant digit. To shift the selection
from one digit to the next (the selected digit will blink with f = 1 Hz,
Duty = 50%), press the button for a short time.
NOTE: The wheel circumference can range from 1000 to 2500
mm in 1 mm steps. If the selected wheel circumference is
greater than 2500 mm, the system automatically selects the default value (2154 mm).
Once the wheel circumference has been adjusted, the unit can
be changed by holding the button down for about 3 seconds
while the least significant digit is active. This will bring up the two
abbreviations km/h and Mph and the selected unit will blink for
a few seconds (f = 1 Hz, Duty = 50%). The parameter is
changed as described above. When the unit is changed, the TD
and LAP parameters are both irreversibly deleted.
Pressing the mode button for about 3 seconds when the selected unit is active (the unit will blink with f = 1Hz, Duty = 50%),
makes it possible to alter the number of wheel pulses.
This parameter indicates the number of pulses that the electronic transmission sends to the instruments for each wheel
turn, with a maximum of 6+ pulses for each wheel turn.
NOTE: The pulses may NOT be equally spaced.
Pressing the mode button for about 3 seconds while the corresponding value is selected will return the system to the standard
operating mode.
Installing the instrument panel
The default circumference value is 2154 mm, the units for
speeds and distances are km/h and km respectively. The default
setting for the number of pulses is 1 pulse per wheel turn. To
change any one of these parameters, use the procedure described in the previous paragraphs. When the instruments are
first installed, the software version and production date are displayed for about 2 seconds. Immediately after the display has
been checked and the preset wheel circumference and number
of pulses per wheel turn have been displayed, the system goes
into standard operating mode.
High power consumption functions Given its high power consumption, the backlight unit and the warning lights are operated
only by the power supplied by the vehicle. When no power is
supplied (and the backup battery is activated) the backlighting is
turned off and the warning lights disabled. This, however, does
not prevent the instruments from working properly.
E2 prom erasing procedure When testing and checking an instrument, it is sometimes useful to erase the E2prom memory. This is a
procedure which, in principle, is not intended for the user.
To gain access to the procedure, follow these steps:
• Disconnect the instrument panel from the main battery and the
backup battery.
• Connect pin 5 of the input connector (unwired) to 12 V.
• Press the button.
• Restore the connection with the backup battery or the main
battery (if present).
The system will then erase all the data contained in the E2prom
and activate the default values (wheel circumference 2154 mm,
speeds measured in km/h, distances measured km, 1 pulse per
wheel turn). There is no way to retrieve the erased data.
4 - Maintenance
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Pagina 1
BODYWORK AND FITTINGS
5
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Pagina 2
CONTENTS
Removing the plastics . . . . . . . . . . . . . Chap. 5 - 3
Removing the saddle . . . . . . . . . . . . . . Chap. 5 - 3
Removing the rear mudguard . . . . . . . . Chap. 5 - 3
Removing
Removing
Removing
Removing
the
the
the
the
front side panels . . . . . .
rear side panels . . . . . . .
right-hand side bumper
left-hand side bumper . .
Chap.
Chap.
Chap.
Chap.
5
5
5
5
-
4
4
4
4
Removing the front mudguard . . . . . . . Chap. 5 - 5
Removing the fork covers . . . . . . . . . . Chap. 5 - 5
Removing the headlight grille . . . . . . . Chap. 5 - 6
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Removing the plastics
To make some areas of the vehicle easier to check and service,
it is first necessary to remove parts of the bodywork as described below.
A
Removing the saddle
Remove the two fixing screws A (one on each side), lift the saddle as shown in the figure and pull it back and off the vehicle.
Removing the rear mudguard
Remove the two fixing screws B and then the two screws C and
D from under the rear mudguard.
B
C
5 - Bodywork and fittings
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Removing the front side panels
Unscrew the eight fixing screws E (four on each side) and take
off the front side panels.
E
Removing the rear side panels
Unscrew the four fixing screws F (two on each side) and take off
the rear side panels. In addition to fastening the rear side panel, the upper screw also fixes the saddle.
F
Removing the right-hand side bumper
Unscrew the six fixing screws G, remove the plastic clamp and
take off the right-hand side bumper (if present).
G
Removing the left-hand side bumper
Unscrew the four fixing screws H, remove the two plastic clamps
and take off the left-hand side bumper (if present).
H
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Removing the front mudguard
Remove the four screws L from under the front mudguard.
L
Also remove mudguard brace fixing screw M from under the
mudguard.
M
Finally remove the two brace fixing screws N from the top of the
brace.
M
Removing the fork covers
Unscrew the eight fixing screws P (five on the left side and three
on the right side) and remove the fork covers.
P
5 - Bodywork and fittings
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Removing the headlight grille
Release the two rubber bands Q as shown in the figure, pull out
the headlight and remove grille R.
Q
R
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Pagina 1
ENGINE SECTION
- REMOVING THE ENGINE FROM THE VEHICLE
- DISASSEMBLING THE ENGINE
- OVERHAULING THE ENGINE
- REASSEMBLING THE ENGINE
- INSTALLING THE ENGINE ON THE VEHICLE
6
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Pagina 3
ENGINE SECTION
- REMOVING THE ENGINE FROM THE VEHICLE
6
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Pagina 4
CONTENTS
Removing the saddle . . . . . . . . . . . . . . . Chap. 6 - 5
Removing the fuel tank . . . . . . . . . . . . . Chap. 6 - 5
Removing the right-hand side panel . . Chap. 6 - 6
Removing the silencer . . . . . . . . . . . . . Chap. 6 - 6
Draining the cooling system . . . . . . . . . . Chap. 6 - 6
Removing the left-hand radiator . . . . . . Chap. 6 - 7
Removing the horn . . . . . . . . . . . . . . . . . Chap. 6 - 7
Right-hand radiator cylinder connecting pipe . . . . . . . . . . Chap. 6 - 7
Removing the intake sleeve . . . . . . . . . . Chap. 6 - 8
Rear frame . . . . . . . . . . . . . . . . . . . . . . . . Chap. 6 - 8
Disconnecting the electrical system . . Chap. 6 - 8
Tipping over the rear frame . . . . . . . . . . Chap. 6 - 8
Disconnecting the rear brake pump . . . . Chap. 6 - 8
Disengaging the exhaust pipe . . . . . . . . Chap.
Releasing the rear shock absorber . . . . Chap.
Removing the exhaust pipe . . . . . . . . . . Chap.
Removing the drive chain . . . . . . . . . . . Chap.
Removing the engine/swingarm pin . . Chap.
Removing the rear suspension linkage Chap.
Removing the rear end . . . . . . . . . . . . . Chap.
Removing the throttle
twist grip assembly . . . . . . . . . . . . Chap.
Removing the carburettor . . . . . . . . . . Chap.
4
6
6
6
6
-
9
9
9
9
6 - 10
6 - 10
6 - 10
6 - 10
6 - 10
Removing the brake pedal
pull-off spring . . . . . . . . . . . . . . . . . Chap.
Removing the spark plug cap . . . . . . . Chap.
Removing the water delivery
pipe from the pump . . . . . . . . . . . . Chap.
Removing the front sprocket casing . Chap.
Removing the clutch pump assembly Chap.
6 - 11
6 - 11
6 - 11
Releasing the decompressor cable . . Chap.
Removing the engine . . . . . . . . . . . . . . Chap.
Removing the kickstart . . . . . . . . . . . . Chap.
Removing the engine from the frame . Chap.
6
6
6
6
6 - 11
6 - 11
-
12
12
12
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Place the vehicle on a central stand. Drain the engine oil (see
Chapter 4 Maintenance).
Removing the saddle
Remove the left-hand and right-hand saddle screws. Remove
the saddle by pulling it towards the back of the vehicle.
Removing the fuel tank
To remove the tank together with the deflectors, unscrew the
left-hand and right-hand screws fixing it to the radiator.
Remove the central screw as shown in the figure and disengage
the tank.
Close the fuel cock, remove the fuel line and take off the reservoir.
6 - Engine
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Removing the right-hand side panel
To gain access to the silencer fixing screws, it is first necessary
to remove the right-hand side panel.
Pay attention to the plastic catches between the side panel and the mudguard.
Removing the silencer
Loosen the two screws shown in the figure.
Remove the spring that fastens the silencer to the exhaust pipe.
Be careful to avoid injury from the spring.
Draining the cooling system
Place a container as shown in the figure to collect the coolant.
Unscrew drain screw 1 on the cylinder front.
1
Remove the radiator cap in the upper part of the system and allow the coolant to drain completely.
Refit the drain screw using, if necessary, a new seal.
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Removing the left-hand radiator
To remove the left-hand radiator, it is first necessary to disconnect the upper pipe after removing the clamp as shown in the
figure.
Subsequently remove the clamp as shown in the figure and remove the lower pipe.
Removing the horn
Remove the horn and the related bracket so as to facilitate the
removal of the plastic bumper.
Loosen the two screws 1 and remove the left-hand radiator.
1
Right-hand radiator - cylinder connecting pipe
Remove the clamp shown in the figure and disconnect the righthand radiator lower pipe from the cylinder.
6 - Engine
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Removing the intake sleeve
Disconnect the carburettor intake sleeve.
Rear frame
Remove the two screws 1 to the left and right of the rear frame
and loosen the two screws 2.
2
1
Disconnecting the electrical system
Disconnect all the electrical connections, cutting the wire clamps
where necessary.
Tipping over the rear frame
It is now possible to overturn the rear frame towards the front of
the vehicle.
To avoid scratching the rear mudguard, place a soft cloth
over the handlebars.
Disconnecting the rear
brake pump
Unscrew the two screws 1 to
disengage the rear brake
pump from the frame.
1
8
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Disengaging the exhaust pipe
Release the two springs that support the exhaust pipe with the
cylinder
Take care to avoid hand injury.
Remove the screw that fixes the exhaust pipe to the frame.
Releasing the rear shock absorber
Disengage the shock absorber from the frame as shown in the
figure.
Removing the exhaust pipe
It is now possible to remove the exhaust pipe by pulling it towards the front of the vehicle.
Removing the drive chain
Find the split link, move it onto the sprocket and remove the retainer as shown in the figure. Undo the chain and remove it.
6 - Engine
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Pagina 10
Removing the engine/swingarm pin
Remove the engine/swingarm pin. For safety reasons, it is advisable to unscrew the left side while holding the pin in position
on the right side.
Removing the rear suspension linkage
Remove the linkage pin as previously described.
Removing the rear end
The swingarm assembly can now be removed from the vehicle.
Removing the throttle twist grip assembly
When the carburettor needs to be removed, it is advisable to remove the throttle twist assembly from the handlebars.
Removing the carburettor
Detach the sleeve that connects the cylinder to the carburettor
and remove the carburettor together with the cables and the
previously removed twist grip.
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Removing the brake pedal pull-off spring
Removing the spark plug cap
Removing the water delivery pipe from the pump
Removing the front sprocket casing
Unscrew screw 1 and screw 2 on the opposite side.
1
2
Removing the clutch pump assembly
Remove the clutch assembly without disconnecting the pipe so
as to avoid having to fill and bleed the system again.
6 - Engine
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Releasing the decompressor cable
Removing the engine
Remove the lower engine/frame pivot pin.
Remove the upper engine/frame pivot pin.
Removing the kickstart
Loosen the screw shown in the figure and remove the kickstart.
Removing the engine from the frame
Remove the engine from the frame, extracting it from the left
side. Place the engine on special tool 3625132.
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6
ENGINE SECTION
- DISASSEMBLING THE ENGINE
Pag. 13
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CONTENTS
Draining the oil . . . . . . . . . . . . . . . . . . Chap. 6 - 15
Removing the oil filters . . . . . . . . . . . . Chap. 6 - 15
Removing the front sprocket . . . . . . . Chap. 6 - 15
Removing the clutch . . . . . . . . . . . . . . Chap. 6 - 16
Pulling out the flywheel . . . . . . . . . . . Chap. 6 - 17
Removing the clutch hub and drum . . Chap. 6 - 17
Removing the oil pump . . . . . . . . . . . . Chap. 6 - 18
Removing the cylinder head top . . . . Chap. 6 - 19
Removing the cylinder head,
the cylinder and the piston . . . . . . Chap. 6 - 19
Removing the timing chain and gear . Chap. 6 - 21
Removing the electric start
and kickstart gears . . . . . . . . . . . . Chap. 6 - 22
Removing the primary torque gear
and the free wheel . . . . . . . . . . . . Chap. 6 - 23
Removing the gearshift mechanism
and the gear shafts . . . . . . . . . . . . Chap. 6 - 24
Removing the countershaft
and the crankshaft . . . . . . . . . . . . Chap. 6 - 25
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Draining the oil
– Remove screws 1, 2 e 3 and drain the engine oil into a container.
– Remove the kickstart and the gearchange lever.
2
NOTE: Dispose of spent oil without polluting the environment.
3
Should the engine oil come into contact with the skin,
wash with plenty of soap and water.
1
Removing the oil filters
– Unscrew the four screws and remove the two oil filter covers
4.
4
4
– Pull the two oil filters out of the crankcase.
NOTE: We recommend using a pair of Seeger ring pliers (see
figure) to pull out the oil filters.
WARNING: There may be an outflow of residual oil during this operation.
Removing the front sprocket
– Remove flange screw 5 together with the spring.
– Remove the rear sprocket from the driven shaft.
– Remove the distance ring from the driven shaft.
5
NOTE: If the transmission and the clutch are in working order, it
is possible to shift into gear to lock the driven shaft. If, on the
other hand, the driven shaft cannot be locked in this way, hold
the front sprocket in position with a suitable retaining spanner
and unscrew the flange screw.
7
6
– Remove thrust rod 6 from the driving shaft.
– Unscrew the two screws 7 and remove the starter motor.
6 - Engine
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Removing the clutch
– Unscrew all clutch cover screws and remove the cover with its
gasket.
– Remove the two centring bushes from the crankcase.
– To prevent the clutch plates from jamming when the clutch
springs are released, loosen the screws following a crosswise
pattern.
– Remove the pressure plate with the screws, spring bracket
and clutch springs.
– Remove thrust head 1.
– Remove all the lined and steel plates from the clutch drum.
– Remove all twelve dragging bushes 2.
– Using a flat chisel, bend up safety plate 4, fit clutch retainer 5
with six dragging bushes as
shown in the figure and unscrew
nut 6.
4
NOTE: Do not remove the
clutch retainer as it will be
used later to unscrew the
flywheel nut.
5
6
– Unscrew the four screws 4 and remove the ignition cover with
the related gasket from the crankcase.
– The stator will stay fitted to the cover.
4
4
– Push with the clutch retainer removed previously and unscrew
nut 5.
– Remove the clutch retainer.
5
WARNING: SINCE THE 250 CC MODELS FIT A
LONGER CRANKSHAFT FIXING SCREW, IT IS ESSENTIAL TO PUSH WITH THE CLUTCH RETAINER
WHEN UNSCREWING NUT 5, OTHERWISE THE FIXING
SCREW COULD BE BENT AND CAUSE DAMAGE TO THE
CRANKCASE.
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– Position the special tool as shown in the figure, unscrew the
primary torque gear flange nut and remove it.
– Remove the special tool.
THERE ARE FLANGE NUTS WITH LEFT-HAND AND
RIGHT-HAND THREADS. THE FLANGE NUTS BEARING THE CAPTION “LEFT” HAVE A LEFT-HAND
THREAD. THOSE WITH NO INSCRIPTION HAVE A RIGHTHAND THREAD.
– Bring the crankshaft to the top dead centre.
– Unscrew crankshaft fixing screw 1 and remove retaining ring
2.
– Manually screw in the crankshaft fixing screw.
– When resistance is felt, slightly move the flywheel to and fro
until the crankshaft screw is inserted in the related opening in
the crankshaft.
– Tighten the crankshaft fixing screw to 10 N·m.
1
2
Pulling out the flywheel
– Unscrew the two screws 3 and remove the pick-up from the
crankcase.
– Fit the puller and pull out the flywheel using the protective cap.
– Remove the key from the crankshaft.
3
NEVER HIT THE FLYWHEEL WITH A HAMMER OR ANOTHER TOOL AS THIS COULD CAUSE THE FLYWHEEL MAGNETS TO COME OFF AND DAMAGE THE
CRANKSHAFT. PUSH WITH THE PULLER TO AVOID BENDING THE FIXING SCREW (250 CC MODELS).
Removing the clutch hub and drum
– Fit the protective cap to the driving shaft and then fit the puller.
– Remove the hub from the driving shaft.
– Remove from the driving shaft clutch drum 4 with the support
bush and the two thrust washers.
6 - Engine
Release 01 Date 09/2007
4
5
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– Remove clutch drum 1 together with stepped washer 2 and
the two half washers 3 from the driving shaft.
3
3
– Remove the two needle roller bearings 4 and the support
washer.
2
1
3
4
Removing the oil pump
– Unscrew the two screws 5 and remove the oil pump cover.
4
– Remove roller 6, inner rotor 7 and outer rotor 8 from the oil
pump casing.
8
7
6
– Remove oilway screws 9 e 10 with the related seal rings and
then remove the oil line.
10
9
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Removing the cylinder head top
– Unscrew all six screws with the related seal rings and remove
the two valve covers 1 with their gaskets.
– Unscrew the spark plug.
1
– Unscrew the four screws and remove water pump cover 2 with
the related gasket.
2
– Unscrew all screws 3 on the cylinder head top.
3
3
3
3
3
– Using a plastic mallet, carefully hit area A in an upward direction and remove the cylinder head top.
A
Removing the cylinder head, the cylinder and the piston
– Remove screw 4 with the seal ring and the compression
spring.
– Unscrew the two screws and pull the chain stretcher out of the
cylinder.
6 - Engine
Release 01 Date 09/2007
4
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– Position the timing chain separating tool and undo the chain
(see figure).
– ENSURE THAT THE EJECTED NAILS DO NOT FALL
INTO THE ENGINE.
– HOLD THE TIMING CHAIN IN POSITION SO THAT IT
DOES NOT FALL DOWN TOWARDS THE CHAIN CASING.
– REMOVE THE OPEN CHAIN LINK AND REPLACE IT WITH
A NEW ONE.
Any link of the timing chain can be opened.
– To prevent the timing chain from falling down to the chain casing, insert a wire clamp into each chain end.
– Remove the camshaft from the cylinder head.
– Remove the three screws 1.
NOTE:
– There is no need to remove these three screws if the cylinder
and the cylinder head require no servicing. The cylinder and
the cylinder head can be removed together without having to
replace the cylinder head gasket.
– The screw on the timing chain side is fitted with a copper seal
ring (6x10x1).
When refitting the parts, replace the copper washer with
a new one.
1
1
– Remove the four cylinder head screws 2 with the related
washers and remove the cylinder head together with the gasket.
2
– Pull up the cylinder while holding the piston in position.
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– Remove the Seeger ring and push the piston pin out of the
piston. Remove the piston.
Removing the timing chain and gear
– Loosen the two screws 1 and remove chain guard 2.
– Remove the timing chain.
1
1
2
– Remove screws 3 and 4, pull the chain stretcher and the chain
guide up and out of the crankcase.
3
4
– Remove Seeger ring 5.
5
– Fit the puller and remove the timing gear from the crankshaft.
6 - Engine
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Removing the electric start and kickstart gears
– Remove the two Seeger rings 1 and the thrust washers. Remove kickstart idler gear 2 and electric start idler gear 3 from
their support pins.
1
2
3
1
– Remove the double gear and the needle roller cage from the
support pin. Remove the support pin from the crankcase.
– Carefully unscrew flange screw 4 while holding the kickstart
spring in position. Decompress the kickstart spring and unfasten it.
4
WARNING: TAKE CARE TO AVOID INJURY DUE TO THE RELEASE OF THE KICKSTART SPRING.
– Remove the kickstart shaft, the starter coupling, the spring
and the washer from the crankcase.
– Push back the guide plate and pull out the gear shaft and
thrust washer 5 from the crankcase.
– Remove screw 6 and the gear selector.
– Unscrew screw 7 and remove the selector lever together with
the bushing and the spring.
6
8
5
NOTE: Remove the selector lever only if the crankcase is to be
replaced.
– Remove safety washer 8. Remove the thrust washer, the oil
pump gear and the needle roller from the oil pump shaft.
22
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Removing the primary torque gear and the free wheel
– Remove flange nut 1.
NOTE: THERE ARE FLANGE NUTS WITH LEFT-HAND AND
RIGHT-HAND THREADS. THE FLANGE NUTS BEARING THE
CAPTION “LEFT” HAVE A LEFT-HAND THREAD. THOSE
WITH NO INSCRIPTION HAVE A RIGHT-HAND THREAD.
– Pull out from the crankcase the oil pump shaft complete with
the roller, inner rotor 3 and outer rotor 4.
1
2
3
4
– Remove the two opposed screws 5.
5
– Fit the puller and remove the primary torque gear from the
crankshaft.
– Loosen the crankshaft fixing screw.
– Unscrew all thirteen crankcase screws.
6 - Engine
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Removing the gearshift mechanism and the gear shafts
– Lay down the engine on one side.
– Release the engine fastening on the stand.
– Detach the left-hand crankcase half using suitable tools positioned on the specially designed supports. Alternatively, gently tap the driven shaft with a plastic mallet.
TO PREVENT DAMAGE TO THE SEALING SURFACES,
AVOID SEPARATING THE CRANKCASE WITH A
SCREWDRIVER OR A SIMILAR TOOL.
– Remove the left-hand crankcase half with its gasket.
– Remove the two centring bushes from the crankcase and fix
the right-hand crankcase half in the stand.
– Remove thrust washer 1, O-ring 2 and inner ring nut 3.
– Remove the two fork guide rods 4 with the four springs from
the crankcase and turn the gearshift forks to one side.
3
2
1
4
– Remove desmodromic mechanism 5.
– Remove gearshift forks 6.
4
5
6
During the removal, ensure that gearshift bushes A on
the fork dragging pins are not left in the desmodromic
mechanism.
6
A
– Jointly remove the driving shaft and the driven shaft from their
seats.
– Remove 1st speed idler gear 7 from the crankcase together
with the needle roller cage and the two thrust washers.
7
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Removing the countershaft and the crankshaft
– Turn the crankshaft until the marks on the countershaft and
the crankshaft are aligned.
– In this position the crankshaft can be removed from its seat.
– Remove the crankshaft.
– Clean all the parts, check them for wear and replace as necessary.
NOTE: When the engine is overhauled, it is advisable to
replace all gaskets, oil seals, O-rings and bearings.
6 - Engine
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Pagina 27
6
ENGINE SECTION
- OVERHAULING THE ENGINE
Pag. 27
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Pagina 28
CONTENTS
IMPORTANT NOTE ABOUT
CRANKCASE SERVICING
. . . . . . . . . Chap. 6 - 29
Left-hand crankcase half . . . . . . . . . . Chap. 6 - 30
Right-hand crankcase half . . . . . . . . . Chap. 6 - 31
Desmodromic mechanism ball bearing 3 Chap. 6 - 32
“60” oil jet 8 . . . . . . . . . . . . . . . . . . . . Chap. 6 - 32
“100” oil jet 1 . . . . . .
By-pass valve . . . . .
Clutch cover . . . . . .
Crankshaft oil seal 4
Oil channel 5 . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
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. . Chap. 6 - 33
. . Chap. 6 - 33
. . Chap. 6 - 33
. . Chap. 6 - 33
. . Chap. 6 - 33
Crankshaft . . . . . . . . . . . . . . . . . . . . . . Chap. 6 - 34
Countershaft gear . . . . . . . . . . . . . . . . Chap. 6 - 35
Compensating for the
crankshaft axial play . . . . . . . . . . . Chap. 6 - 35
Cylinder - Nikasil lining . . . . . . . . . . . . Chap. 6 - 36
Measuring the piston and the cylinder Determining the piston fit . . . . . . . Chap. 6 - 36
Checking the piston . . . . . . . . . . . . . . Chap. 6 - 37
Checking the piston rings
and their gaps . . . . . . . . . . . . . . . . Chap. 6 - 37
Checking the oil pumps for wear . . . . Chap. 6 - 37
Lubrication system . . . . . . . . . . . . . . . Chap. 6 - 38
Cylinder head top . . . . .
Rocker arm pins 5 and 6
Rocker arm rollers 8 . . .
Adjusting screws 9 . . . .
Decompressor shaft 2 . .
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Chap. 6 - 39
Chap. 6 - 39
Chap. 6 - 39
Chap. 6 - 39
Chap. 6 - 39
Cylinder head . . . . . . . . . . . . . . . . . . . Chap. 6 - 40
28
Sealing surface . . . . . . . . . . . . . . . . . . Chap. 6 - 41
Valve guides . . . . . . . . . . . . . . . . . . . . Chap. 6 - 41
Valve seats . . . . . . . . . . . . . . . . . . . . . Chap. 6 - 41
Valves . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 6 - 41
Valve springs . . . . . . . . . . . . . . . . . . . Chap. 6 - 41
Valve springs for the 250 cc model . . Chap. 6 - 41
Valve stem linings . . . . . . . . . . . . . . . . Chap. 6 - 41
Camshaft . . . . . . . . . . . . . . . . . . . . . . . Chap. 6 - 42
Preassembling the camshaft . . . . . . . Chap. 6 - 43
Automatic stretcher . . . . . . . . . . . . . . Chap. 6 - 44
Valve gear control . . . . . . . . . . . . . . . . Chap. 6 - 44
Checking the clutch for wear . . . . . . . Chap. 6 - 45
Checking the kickstart for wear . . . . . Chap. 6 - 46
Preassembling the kickstart shaft . . . Chap. 6 - 46
Gearshift mechanism . . . . . . . . . . . . . Chap. 6 - 47
Preassembling the shaft
of the gearshift mechanism . . . . . . Chap. 6 - 47
Gearbox . . . . . . . . . . . . . . . . . . . . . . . Chap. 6 - 48
Assembling the driving shaft . . . . . . . Chap. 6 - 48
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . Chap. 6 - 49
Assembling the driven shaft . . . . . . . . Chap. 6 - 49
Ignition system . . . . . . . . . . . . . . . . . . Chap. 6 - 50
Checking the stator and the pick-up . Chap. 6 - 50
Replacing the stator . . . . . . . . . . . . . . Chap. 6 - 50
Electric start gears . . . . . . . . . . . . . . . Chap. 6 - 51
Checking the operation
of the free wheel . . . . . . . . . . . . . . Chap. 6 - 52
Replacing the free wheel hub . . . . . . . Chap. 6 - 52
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IMPORTANT NOTE ABOUT CRANKCASE SERVICING
NOTE: Read through this paragraph before beginning work, then determine the reassembly sequence
so that the crankcase halves can undergo a single
heat treatment for the replacement of the bearings.
If necessary, use drifts of suitable diameter to remove the
bearings. Remove the reference bushings and place the
crankcase halves on a flat surface. The prevent damage to
the crankshaft sealing surfaces, the support surface should
be large enough to allow the crankcase sealing surfaces to
rest completely on it. A wooden surface is recommended
for the purpose. If a suitable press is unavailable, fit the
bearings and the seal rings with the greatest care using
suitable tools. Cold-working bearings fall almost spontaneously into their respective seats when the crankcase halves reach a temperature of 150° C.
If the bearings are not firmly in place after the crankcase
has cooled down, the subsequent heating would probably
cause them to turn in their seats. In that case the crankcase will have to be replaced.
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Left-hand crankcase half
Remove all the oil seals and heat the crankcase half in an oven
at a temperature of approximately 150° C.
6
3
2
Crankshaft roller bearing 1
Using a suitable drift, push in the bearing from the outside. Fit
the new bearing, pushing it from the inside to its abutting end.
8
Driving shaft ball bearing 2
Using a suitable drift, push in the bearing from the outside. Fit
the new bearing, pushing it from the inside to its abutting end.
1
Driven shaft roller bearing 3
Using a suitable drift, push in the bearing from the outside. Fit
the new bearing, pushing it from the inside to its abutting end.
7
Gear shaft oil seal 4
Fit the new oil seal pushing it from the outside to the correct level, with the open side facing inward.
5
Driven shaft oil seal 5
Fit the new oil seal pushing it from the outside to the correct level, with the open side facing inward.
Countershaft ball bearing 6
Using a bearing puller, extract the bearing from the crankcase
half.
Insert the new bearing and push it to its abutting end.
Desmodromic mechanism ball bearing 7
At a temperature of approximately 150° C the ball bearing comes out of its seat almost spontaneously.
If necessary, hit the crankcase half against a flat wooden board.
Insert the new bearing and push it to the correct level.
Gear shaft needle roller bearing 8
Push in the bearing from the outside.
Insert the new bearing, pushing it from the inside to the correct
level.
4
8
– When the crankcase is cold, ensure that the bearings are
firmly seated.
7
WARNING: To avoid burns, be sure to wear protective
clothes when using the oven.
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The oil pump casing should show no signs of scoring or seizure.
Blow all the oil channels with compressed air and ensure that
they are clear.
Check that the two steady pins 1 are firmly seated. If necessary
lock with Loctite 243.
Right-hand crankcase half
Remove all the oil seals and heat the crankcase half in an oven
to a temperature of approximately 150° C.
Crankshaft roller bearing 2
Using a suitable drift, push in the bearing from the outside. Fit
the new bearing, pushing it from the inside to its abutting end.
Driving shaft ball bearing 3
Using a suitable drift, push in the bearing from the outside. Fit
the new bearing, pushing it from the inside to its abutting end.
NOTE: Driving shaft ball bearing 3 is fastened by a screw. Apply Loctite 243 to the screw thread and tighten to 5 N·m.
Driven shaft ball bearing 4
Using a suitable drift, push in the bearing from the outside. Fit
the new bearing, pushing it from the inside to its abutting end.
Crankshaft oil seal 5
Insert the new oil seal and push it with is open side facing inward
until it is flush.
Kickstart idler gear support pin 6. Electric start idler gear support
pin 7. As a rule, support pins are not subject to wear. Replacement of the support pins should be carefully evaluated, since in
most cases the operation causes damage to the crankcase.
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Countershaft ball bearing 1 and oil seal 2
Using a suitable puller, extract the ball bearing from the crankcase half and remove the oil seal.
Press in the new oil seal with the open side facing downwards
until it is flush.
Press in the new ball bearing to its abutting end.
1
2
Desmodromic mechanism ball bearing 3
Remove screw A.
At a temperature of approximately 150° C the ball bearing comes out of its seat almost spontaneously.
If necessary, hit the crankcase half against a flat wooden board.
Insert the new bearing and push it to its abutting end. Apply Loctite 243 to the thread of screw A and tighten to 5 N·m.
Gear shaft needle roller bearing 4
Push in the needle roller bearing from the outside.
Insert the new bearing, pushing it in from the outside until it is
flush.
4
3
A
– When the crankcase half has cooled down, ensure that the
bearing is securely seated.
Kickstart release plate 5
When replacing the release plate, apply Loctite 243 to the two
screws and tighten to 8 N·m.
5
Oil pump casing 6 should bear no signs of scoring or seizure.
6
Ensure that the passages of all oil channels 7 are clear.
To clean all the oil channels and check that their passages are clear, it is advisable to remove the two jets and
the by-pass valve (see below).
7
“60” oil jet 8
Remove the oil jet and blow the oil channel with compressed air.
Degrease the oil jet thread, apply Loctite 243 and refit the oil jet.
8
NOTE: This jet cools down the piston by spraying engine oil onto its lower side.
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“100” oil jet 1
Remove the oil jet and blow the oil channel with compressed air.
Degrease the oil jet thread, apply Loctite 243 and refit the oil jet.
NOTE: : This jet provides the right quantity of oil for the connecting rod bearing.
1
By-pass valve
Check that the valve piston, the sealing surface and the compression spring are not damaged.
2
Minimum length of compression spring 2: 23.5 mm
If the spring is shorter than 23.5 mm, the by-pass valve
opening pressure is reduced. This entails a decrease in
the oil pressure and thereby greater wear.
Blow all the oil channels with compressed air and check that the
passages are clear.
Clutch cover
Kickstart shaft oil seal 3
Remove the old oil seal with a screwdriver.
Fit the new oil seal and push it to its abutting end.
Crankshaft oil seal 4
Remove the old oil seal with a screwdriver.
Fit the new oil seal and push it to its abutting end, with its open
side facing downwards.
3
5
Oil channel 5
Blow with compressed air and check that the passage is clear.
4
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A
B
Crankshaft
If the connecting rod bearing is replaced, take care to properly
position the coupling shaft. The holes in the shaft section A and
in the coupling shaft B must be aligned.
IF THE COUPLING SHAFT IS FORCED IN OUT OF POSITION, THE CONNECTING ROD BEARING WILL RECEIVE LITTLE OR NO OIL AND WILL CONSEQUENTLY
BE DAMAGED.
If the crankshaft is to be reused, be sure to check the offset of
the shaft sections. Place the crankshaft on a roller equalizer or
similar equipment and use a comparator to measure the offset
at the ends of the shaft sections.
Offset of shaft sections: ≤ 0.08 mm
Check the radial and axial plays of the connecting rod bearing.
Radial play: ≤ 0.05 mm
Axial play: ≤ 1.10 mm
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Measuring the outside diameter of the handwheels
Using a vernier caliper, measure the outside diameter of the
handwheels as shown in the figure.
Outside diameter of handwheels = 65 mm ± 0.05 mm
Countershaft gear
– To remove the countershaft gear from the crankshaft, it is first
necessary to remove the inner ring nut of the cylindrical roller
bearing (see below).
– Whenever the cylindrical roller bearings are replaced, the inner collars on the crankshaft also need to be replaced.
– To this end, clamp the crankshaft in a vice by the shaft section
fitting the inner collar to be replaced.
– Heat special tool Part No. 3625193 on an electric hotplate to
approximately 150° C and immediately push it onto the inner
collar. Squeeze the special tool hard to obtain good heat transmission and remove the inner collar from the crankshaft.
– Remove the two screws from the countershaft gear.
– Insert the two screws 1 into M6 threaded holes 2.
– Remove the countershaft gear from the crankshaft and evenly
tighten the two screws.
– Before fitting the countershaft gear, heat it to approximately
100° C.
– Degrease the two countershaft gear fixing screws and apply
Loctite 243 to their threads.
– Fit the countershaft gear to the crankshaft so that mark C is in
the coupling shaft area.
– Fit the fixing screws and tighten to 8 N·m.
– Before fitting a new inner collar, heat the special tool again to
about 150° C, fit it with the inner collar and immediately push
it onto the shaft section.
– Allow the inner collar to cool down for about 30 seconds and
then, using a suitable tube, hit the inner collar until it is seated
properly.
– After replacing the inner collars, measure the crankshaft axial
play.
NEVER ATTEMPT TO INSERT AN INNER COLLAR BY
HITTING IT WHILE THE CRANKSHAFT IS HELD IN A VICE BY A SHAFT SECTION. THIS WOULD RISK COMPRESSING THE SHAFT SECTIONS, MAKING THE CRANKSHAFT UNUSABLE.
1
1
C
2
2
Compensating for the crankshaft axial play
– Insert the crankshaft in the right-hand crankcase half and fit
the crankcase gasket.
– Fit the crankcase screws in the engine base area and tighten them.
– Fit the comparator on the crankcase and measure the crankshaft axial play.
Axial play: 0.1 - 0.2 mm
– If the measurement does not correspond to the nominal value,
proceed to rectify the axial play.
– To this end, remove the crankshaft and then remove the inner
collar from the crankshaft on the ignition side using the specially designed tool. Then add or remove thrust washers as
necessary.
Add thrust washers if the axial play is excessive and remove them if the axial play is too small. Thrust washers
can only be added on the ignition side.
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Cylinder - Nikasil lining
Nikasil is the trademark of a cylinder lining procedure developed
by the piston manufacturer Mahle. The name is derived from the
two materials used in the procedure – nickel containing silicon
carbide to make a particularly hard substance. The principal advantages of Nikasil are excellent heat dissipation, making for an
increased power supply, and reduced cylinder weight and wear.
When worn down, the lining can be restored (replaced) at a low
cost providing the cylinder sliding surface is not damaged.
1
Measuring the piston and the cylinder - Determining the
piston fit
– To determine how worn a cylinder is, measure it at the centre
of the sliding surface with a comparator.
– Measure the diameter along axes X and Y to determine
whether any ovalization is present.
Cylinder diameter 250
size I cylinder: 75,000 - 75,012 mm
size II cylinder: 75,013 - 75,025 mm
Cylinder diameter 400 - 450
size I cylinder: 89,000 - 89,012 mm
size II cylinder: 89,013 - 89,025 mm
Cylinder diameter 525
size I cylinder: 95,000 - 95,012 mm
size II cylinder: 95,013 - 95,025 mm
x
y
Cylinder size 1 is stamped on the cylinder side in front of
the chain tunnel; piston size 2 is stamped on the piston
top.
- The piston is measured on the skirt transversally to the piston
pin as shown in the figure.
Piston diameter 250
size I piston: 74,960 - 74,970 mm
size II piston: 74,971 - 74,980 mm
Piston diameter 400
size I piston: 88,930 - 88,940 mm
size II pistonI: 88,941 - 88,950 mm
Piston diameter 450
size I piston: 88,916 - 88,946 mm
size II pistonI: 88,926 - 88,956 mm
Piston diameter 525
size I piston: 94,942 - 94,950 mm
size II pistonI: 94,951 - 94,958 mm
2
- The piston fit is obtained by subtracting the piston diameter
from the minimum cylinder diameter.
Piston fit 250
size I pistonI: 0,030 - 0,052 mm
size I piston: 0,032 - 0,055 mm
wear limit: 0,12 mm
Piston fit 400
size I pistonI: 0,060 - 0,082 mm
size I pistonI: 0,062 - 0,085 mm
wear limit: 0,12 mm
Piston fit 450
size I piston: 0,054 - 0,096 mm
size I pistonI: 0,056 - 0,099 mm
wear limit: 0,12 mm
Piston fit 525
size I pistonI: 0,050 - 0,070 mm
size I pistonI: 0,054 - 0,075 mm
wear limit: 0,12 mm
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Checking the piston
– Replace the piston if oil consumption is excessive or if the piston skirt is scored.
– If the piston is to be reused:
1.Check the wear of the piston sliding surface.
2.Check that the piston rings can move freely in their grooves.
Clean the grooves with an old piston ring or with emery paper
(400 grain).
3.Check the piston ring wear and gaps (see below).
4.When installed, the piston pin should float in its hole. Replace
the piston pin if it shows signs of colour alteration or sliding.
Checking the piston rings and their gaps
– Insert the piston ring in the cylinder and align it with the piston
(approx. 10 mm under the upper edge of the cylinder).
– Using a thickness gauge, measure ring gap A.
Compression ring: max. 0.80 mm
Scraper ring: max. 1.00 mm
A
If the measurements exceeds the above values, check the wear
of the cylinder and piston. If wear is within the allowable limits,
replace the piston ring.
Checking the oil pumps for wear
– Insert the inner and outer rotors into the crankcase so that the
marks are positioned next to each other.
– Using thickness gauge B, perform the following wear measurements:
B
Outer rotor – oil pump casing: max. 0.20 mm
Outer rotor – inner rotor: max. 0.20 mm
B
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2
2
5
1
7
3
8
4
6
7
7
7
6
8
7
7
3
Lubrication system
Oil line 1
Ensure that the soldered joints present no capillary cracks. Blow the oil line with compressed air to check whether the passage is clear. Also check that there are no friction points on the oil line. Always replace the seal rings with new ones
(8x12x1).
O-ring 2
At each oil change, also replace the O-rings.
Oil pump cover 3
Check the inside for signs of seizure caused by the oil pump rotors and if necessary replace.
Oil pump shaft 4
Place the shaft on a flat surface and check its offset.
Oil pump gear 5
Check the teeth for wear. The roller seat should not be damaged.
Oil units 6
Clean the two oil units with low-pressure compressed air.
O-rings 7
Check their porosity and if necessary replace them.
Oil pump rotors 8
Insert the oil pump rotors in the crankcase and check them as shown in the figure on the previous page. No particles
should stick to the rotors.
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10
4
10
6
4
5
2
11
3
1
7
7
9
9
8
Cylinder head top
– Remove Seeger ring 1 and pull decompressor shaft 2 and
spring 3 out of the hole.
– Remove the two terminals 4 from the cylinder head top together with rocker arm pivots 5 and 6. Remove rocker arms 7.
– Clean all the components and check them for wear.
Rocker arm pins 5 and 6
The rocker arm pivots should show no signs of scoring and
should rotate freely in rocker arms 7.
Rocker arm rollers 8
Check that the rocker arm rollers can slide freely. If any radial
play is found, replace the rocker arm.
Adjusting screws 9
The contact surfaces of the adjusting screws should be flat.
Decompressor shaft 2
Check the sliding of the decompressor shaft and its play in the
support hole.
Replace O-ring 11.
Replacing O-rings 10.
– Before reassembly, carefully oil all the components.
– Position the rocker arms in the cylinder head top and then fit
the rocker arm pins.
Shorter rocker arm 6 is to be fitted at the back.
– Fit terminals 4 and turn them so as to allow the cylinder
head top screws to be fitted at a later stage.
– Fit decompressor shaft 2 and preload the spring.
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modelli 250
modelli 250
2
1
Cylinder head
– Unscrew the three screws 1 and remove exhaust flange 2 together with its gasket.
– Using the specially designed tool, remove the four valves.
– The 250 cc model fits conical valves.
– Used valves are to be reinserted in the same valve guide. To ensure this, we recommend inserting the valves in
a piece of cardboard in the same way they are fitted in the cylinder head (see figure).
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– Remove spring caps 1 and valve springs 2 from the cylinder
head.
– Remove the valve stem linings from the valve guides and remove spring holders 3.
The 250 cc model fits conical springs.
Sealing surface
Check the spark thread and the valve seats for damage or
cracks. Using a straightedge and a thickness gauge, check to
see if any distortion is present. Maximum allowable distortion:
0.10 mm.
1
3
2
Valve guides
Check the valve guides with limit gauge 4 (Ø 6.05 mm). If the
gauge can be easily inserted into the valve guide, the latter will
have to be replaced.
Valve seats
The valve seats should show no signs of hammering-in. Width
of sealing surface: intake valve max. 1.50 mm; exhaust valve
max. 2.00 mm. If necessary, grind the valves.
4
Valves
Check the valve heads for signs of wear and floating. Maximum
allowable valve head floating: 0.03 mm. The valve seat should
show no signs of hammering-in. The sealing surface should be
at the centre of the valve seat. The valve stem is chromium-plated; wear generally occurs on the valve guide.
Valve springs
Visually check that the valve springs are not broken or worn.
Measure their length with a vernier caliper. The minimum allowable valve length is 39.20 mm for the outer valve springs and
36.45 mm for the inner valve springs. Replace as necessary.
Valve springs for the 250 cc model
Visually check that the valve springs are not broken or worn.
Measure their length with a vernier caliper. The minimum allowable length for the valve springs is 37.70 mm. Shorter
springs will have to be replaced.
Valve stems linings
Always replace the valve stem linings when the valves are removed.
– Insert the four spring holders 3 into the cylinder head.
– Fit the valve stem linings on the valve guides and lubricate.
– Carefully oil the valve stems and insert the valves into the valve guides. When refitting, ensure that the valves are properly
positioned.
– Fit valve springs 2 and insert spring caps 1 into the valve
springs.
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12
10
11
8
6
5
9
7
4
8
2
3
1
Camshaft
– Remove Seeger ring 1 and water pump impeller 2.
– Pull out roller 3 from the shaft hole and remove lining holder 4
from the camshaft.
– Remove ball bearing 5 from the camshaft with a suitable puller (see figure).
NEVER CLAMP THE CAMSHAFT IN A VICE.
– Release spring 6 from decompressor shaft 7 while extracting
the latter from the camshaft.
– Unscrew the two screws 8 and remove camshaft gear 9.
– Using the puller, remove ball bearing 10 from the camshaft.
Clean and check all components and if necessary replace them.
Camshaft
Check the support points and the cams for signs of wear.
Replace ball bearings 5 and 10.
Decompressor shaft 7
Check the play of the shaft in the support and the wear of its
contact surface with the rocker arm.
Camshaft gear 9
Check the wear of the teeth.
Ensure that screw 11 is firmly seated.
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– Press oil seals 1 out of seal holding bush 2.
– Fit the new oil seals with the gaps facing outward, pressing
them in until they are flush. Carefully grease the sealing lips.
– Remove the two O-rings 3 from the seal holding bush and remove any residues with a wire brush.
– Fit two new O-rings.
– The seal holder can be removed from the cylinder head with
the aid of the two M3 threaded holes 4 without removing the
cylinder head top.
1
4
2
6
9
5
7
1
8
1
6
10
2
3
3
12
Preassembling the camshaft
– Apply Loctite 243 on the threads of the two screws 6 and fit
camshaft gear 7. Tighten the screws to 28 N·m.
– Key ball bearing 5 with a socket punch.
– Fit decompressor shaft 8 and spring 9. Preload the spring by
approximately 1/2 turn and insert the spring end into slot B.
Check if the decompressor shaft returns automatically to the
starting position. If that is not the case, increase the spring
preload.
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14
9
B
8
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Automatic stretcher
– Fully extract the automatic stretcher pressure pin and check
that it can slide freely.
– Check the wear of the pressure pin teeth and the dog.
➙
➙
– When refitting, push the dog in the direction indicated by the
arrow so that the pressure pin no longer jams and then fully
insert the pressure pin into the stretcher body.
➦
Valve gear control
Thoroughly clean all the components and check them for wear.
Timing pinion 1
Check the teeth for nicks or signs of wear.
Chain stretcher shoe 2
Check for signs of sliding on the contact surface.
3
Chain guide 3
Check for signs of sliding on the contact surfaces.
4
Chain coupling 4
Replace the open link of the timing chain.
2
1
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Checking the clutch for wear
Thrust head 1
Check the thrust head for signs of seizure and ensure that
it can slide freely.
Axial bearing 2
Ensure that the bearing is not damaged.
Push rod 3
Place the push rod on a flat surface and check its offset.
Clutch springs 4
Minimum length 41.5 mm (43 mm when new). If necessary, replace all six springs.
Clutch hub 8
Check for damage and signs of wear.
Pressure plate 9
Check for signs of damage on contact surface A with the
steel plate.
Clutch drum 10
Check the wear of thrust surfaces B of the lined plates
and the clutch drum. If the combined recesses exceed 0.5
mm, replace the lined plates and the clutch drum.
Needle roller bearings 11
Check for signs of wear or damage.
Seven cork discs 5
Minimum allowable thickness 1.7 mm (1.8 mm when
new). The cork discs must be flat.
Four 1.0-mm middle discs 6
Ensure that the discs are flat and free from mechanical
damage. Replace as necessary.
Four 1,4-mm middle discs 6A
Ensure that the discs are flat and free from mechanical
damage. Replace as necessary.
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3
11
10
12
9
8
1
7
2
6
5
4
Checking the kickstart for wear
Remove all components from the kickstart shaft and clean them.
Starter gear 1
Check the wear of the teeth and the play of the support.
Starter idler gear 2
Check to see if there is any play or any sign of seizure on the support. Check the wear of the teeth, which are in constant mesh with
the clutch drum.
Starter coupling 3
Check the inclined surface and the teeth for signs of wear.
Kickstart shaft 4
Check the support points and the teeth for signs of wear or damage and ensure that the starter gear oil hole is clear.
Preassembling the kickstart shaft
– Clamp kickstart shaft 4 in a vice (using protective jaws), with
its toothed end facing upwards.
– Fit thrust washer 5, needle roller cage 6 and starter gear 1
with the stop teeth facing downwards.
– Fit thrust washer 7 and Seeger ring 8 with the sharp edge facing upwards.
– Fit dragging hub 9 taking care to align its groove with the hole in the kickstart shaft.
– Fit kickstart spring 10, inserting its inside end into the hub
groove and the kickstart shaft hole.
– Remove the kickstart shaft from the vice.
– Fit starter coupling 3 on the kickstart shaft taking care to align
mark A on the starter coupling with oil hole B in the kickstart
shaft.
– Fit the kickstart shaft with starter coupling spring 11 and thrust washer 12.
46
B
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Gearshift mechanism
Gearshift forks 1
Check wear at ends A. When the forks are new, their thickness
ranges from 4.8 to 4.9 mm. The wear limit is 4.6 mm.
Desmodromic mechanism 2
Check the wear of profiled grooves B.
Check the desmodromic mechanism support in ball bearing 3.
Ball bearing 3
Check that it can turn smoothly.
Bushes 4
Ensure that the bushes present no dents or cracks.
Fork guide rods 5
Check the offset of the rods on a flat surface. Check for signs of
scoring or seizure. The gearshift forks should slide freely on the
guide rods.
F
Selector 6
Check wear at return points C.
Check the wear of selector return surface D (if the surface is
deeply worn, replace the selector).
Check that guide pin E is firmly seated and not worn.
Gearshift mechanism
Preassemble the shaft of the gearshift mechanism and measure clearance F between selector 6 and the guide plate. The play
should be 0.40 - 0.80 mm.
9
7
8
10
D
6
C
E
Preassembling the shaft of the gearshift mechanism
– Clamp the short end of the shaft of the gearshift
mechanism in a vice (use protective jaws).
– Fit selector 6 with the guide pin facing downwards
and then attach the guide pin to the guide plate.
– Fit compression spring 7.
– Fit spring holding bush 8, top it with return spring
9 with the bent end facing upwards and then attach it to pin 11 (see figure).
– Fit thrust washer 10.
1
4
5
1
4
11
B
3
2
5
6
A
7
9
4
1
8
10
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1
2
3
4
5
6
7
8
9
10
11
Gearbox
Clamp the driving shaft and the driven shaft in vices (using protective jaws). Remove
the gears and check if the following parts show signs of wear or seizure:
• Needle roller cages.
• Bearing surfaces of the driving shaft, driven shaft and idler gears.
• Gear couplings.
• Sides of all gear teeth.
• Tooth profile of the driving and driven shafts and of the related gears.
• Check that the profiles of all the gears can move smoothly.
Thoroughly clean all the parts and replace any faulty components.
Always fit new Seeger rings whenever the transmission is repaired.
Assembling the driving shaft
– Clamp the driving shaft in a vice with its grooved end facing downwards (use protective jaws).
– Carefully oil all the components before assembling them.
– Fit needle roller cage 2, top it with 5th-speed idler gear 1 with the front couplings facing upwards.
– Insert thrust washer 3 (25.2x32x1.5 mm) and Seeger ring 4 with the sharp edge facing upwards.
– Fit 3rd-/4th-speed double sliding gear 5 with the smaller gear at the bottom and then
fit Seeger ring 6.
– Fit toothed washer 7 (25.2x32x1.5 mm) and needle roller cage 8.
– Fit 6th-speed idler gear 9 with the slot facing upwards.
– Fit 2nd-speed fixed gear 10 with the shoulder at the bottom and thrust washer 11
(17.2x30x1 mm).
– Finally check that all the gears can move smoothly.
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17
18
16
15
14
13
12
11
10
9
7
8
6
5
4
3
2
1
Gearbox
Clamp the driving shaft and the driven shaft in vices (using protective jaws). Remove
the gears and check if the following parts show signs of wear or seizure:
• Needle roller cages.
• Bearing surfaces of the driving shaft, driven shaft and idler gears.
• Gear couplings.
• Sides of all gear teeth.
• Tooth profile of the driving and driven shafts and of the related gears.
• Check that the profiles of all the gears can move smoothly.
Thoroughly clean all the parts and replace any faulty components.
Always fit new Seeger rings whenever the gearbox is repaired.
Assembling the driven shaft
– Clamp the driving shaft in a vice with its grooved end facing downwards (use protective jaws).
– Carefully oil all components before assembling them.
– Fit needle roller cage 2 and 2nd-speed idler gear 1 on the driven shaft with the slot
for the front couplings facing upwards.
– Insert thrust washer 3 (25.2x32x1.5 mm) and Seeger ring 4 with the sharp edge facing upwards.
– Fit 6th-speed sliding gear 5 with the fork slot facing upwards.
– Fit Seeger ring 6 and toothed washer 7 (25.2x32x1.5 mm).
– Fit two-piece needle roller cage 9 + 11 and 4th-speed idler gear 8 with the slot for
the front couplings facing downwards.
– Fit 3rd-speed idler gear 10 with the slot for the front couplings facing upwards.
– Fit toothed washer 12 (25.2x32x1.5 mm) and Seeger ring 13.
– Fit 5th-speed sliding gear 14 with the fork slot facing downwards and thrust washer
15 (20x32x1 mm).
– Fit needle roller cage 16, 1st-speed idler gear 17 with the slot facing downwards and
thrust washer 18 (17.2x30x1.5 mm).
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Ignition system
General information
The measurements described below are only used to find
easily detectable faults. Inside short circuits, which produce feeble sparks with a low ignition power, can only be
discovered with a specially designed ignition test bench.
In case of problems first check the wires and connectors
of the ignition system.
When taking a measurement, be sure to use a suitable
measuring range. The CDI unit can only be checked on a
specially designed ignition test bench.
Checking the stator and the pick-up
Using an ohmmeter, take the following measurements:
NOTE: The following measurements correspond to the
nominal values only at a temperature of 20° C. If the
measured values differ considerably from the nominal values, replace the stator.
Acc.
Measurement
Colour
Resistance
4K-3B
Pick-up
Stator
Charged coil
red – green
black/red – red/white
ground – yellow
bianco – yellow
100 Ω ± 20%
12,6 Ω ± 20%
0,65 Ω ± 20%
0,16 Ω ± 20%
Replacing the stator
– Loosen screw 4 and remove the fixing plate.
– Unscrew the two screws 5 and remove the stator from the
ignition cover.
– Position the new stator in the ignition cover. Degrease the threads of the three screws and then apply Loctite 243 to them.
– Fit the screws and tighten them to 8 N·m.
– Arrange the wires without stretching them and then fasten
them with the fixing plate.
50
4
5
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7
6
1
2
3
5
A
4
Electric start gears
Idler gear 1
Check the teeth and the bearing surface of the idler gear for signs of wear. Also check the idler gear support pin for signs
of seizure.
Double gear 2
Check the teeth and the bearing surface of the double gear for signs of wear. Also check the double gear support pin for
signs of seizure. Fit the double gear together with the needle roller cage on the support pin and check the play.
Free wheel hub 3
Remove the free wheel from the hub and check to see if there are any dents on contact surface A. Thoroughly clean the
free wheel hub.
Free wheel 4
Thoroughly clean the free wheel with petroleum and compressed air. Check the free wheel segments for wear and oil it
generously.
Free wheel gear 5
Fit the free wheel gear on the crankshaft and check the play. If necessary, replace the needle bushing. Check for the presence of dents on the contact surface with the free wheel.
NOTE: If double gear 2 or toothed free wheel 5 show signs of damage that warrant their replacement, remember that the
two parts (2 and 5) can only be replaced together.
Starter motor 6
Replace O-ring 7 on the flange.
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Checking the operation of the free wheel
– Fit free wheel gear 1 on free wheel device 2.
– The free wheel gear should rotate clockwise.
– Attempting to rotate the free wheel gear anticlockwise should
lock the gear with no idle travel.
1
2
Replacing the free wheel hub
– Squeeze expansion ring 3 with a pair of Seeger pliers and remove it together with free wheel 2.
3
2
– Remove the six screws 4.
– Using a plastic mallet, hit hub 5 laterally to detach it from the
primary gear.
– Fit a new free wheel hub on the primary gear.
– Degrease the screw threads, apply Loctite 648 to them and tighten the screws to 16 N·m following a crosswise pattern.
A
4
5
– Carefully oil free wheel 2 and insert it into hub 5.
– Using a pair of Seeger ring pliers, insert the expansion ring into the groove and ensure that it is properly seated. Once the
expansion ring is in place, we recommend hitting it carefully
with a punch.
2
NOTE: “Notches” A on the expansion ring should mesh with the
free wheel hub slot.
5
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ENGINE SECTION
- REASSEMBLING THE ENGINE
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CONTENTS
Fitting the crankshaft
and the countershaft . . . . . . . . . . . Chap. 6 - 55
Fitting the gearbox
and the gearshift mechanism . . . . . Chap. 6 - 55
Assembling the crankcase . . . . . . . . . Chap. 6 - 57
Fitting the oil pumps . . . . . . . . . . . . . . Chap. 6 - 58
Fitting the gear selector . . . . . . . . . . . . Chap. 6 - 59
Fitting the electric start
and kickstart gears . . . . . . . . . . . . Chap. 6 - 59
Fitting the clutch drum and hub . . . . . Chap. 6 - 61
Fitting the primary pinion nut . . . . . . . Chap. 6 - 61
Fitting the timing gear . . . . . . . . . . . . . Chap. 6 - 62
Fitting the piston and the cylinder . . . Chap. 6 - 63
Fitting the cylinder head . . . . . . . . . . . Chap. 6 - 63
Fitting the cylinder head top . . . . . . . . Chap. 6 - 65
Fitting the automatic stretcher . . . . . . Chap. 6 - 66
Adjusting the play of the valves . . . . . Chap. 6 - 66
Fitting the flywheel . . . . . . . . . . . . . . . Chap. 6 - 67
Fitting the pick-up
and the ignition cover . . . . . . . . . . Chap. 6 - 67
Fitting the clutch . . . . . . . . . . . . . . . . . Chap. 6 - 68
Clutch plates . . . . . . . . . . . . . . . . . . . . Chap. 6 - 68
Fitting the oil line . . . . . . . . . . . . . . . . Chap. 6 - 69
Installing the starter motor . . . . . . . . . Chap. 6 - 69
Fitting the oil filter . . . . . . . . . . . . . . . . Chap. 6 - 70
Adding engine oil . . . . . . . . . . . . . . . . Chap. 6 - 70
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Fitting the crankshaft and the countershaft
– Fasten the right-hand crankcase half to the assembly stand.
– Carefully oil the crankshaft roller bearing and grease the oil
seal.
– Carefully insert the crankshaft into the bearing.
– Turn the crankshaft until mark A is at the front and then insert
the countershaft into its bearing. Ensure that crankshaft mark
A is between the two countershaft marks B.
A
B
B
Fitting the gearbox and the gearshift mechanism
– Turn the engine onto one side.
– Simultaneously insert driving shaft 1 and driven shaft 2 into
their respective bearings.
1
2
– Attach bushes 3 to the gearchange forks with a little grease.
3
– Attach the four springs 4 to the fork guide rods with a little
grease.
4
4
4
4
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– Oil the ends of the gearshift forks and attach them to the sliding gears.
1
– Insert the desmodromic mechanism into its bearing.
A
– Attach the gearshift forks to the desmodromic mechanism and
fit the two fork guide rods 2 along with the springs.
– Ensure that the following parts are fitted:
inner race of bearing 3
O-ring 4
thrust washer 5
2 centring bushes in the crankcase
4
3
5
2
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30
M6x...
30
45
45
60
45
75
60
45
45
NOTE: This diagram shows all the
lengths of the carter fixing screws.
45
Assembling the crankcase
– Remove the engine retainer from the stand.
– Apply a thin film of grease to the crankcase sealing surface
and fit a new gasket.
– Lay down the left-hand crankcase half and tap it with a plastic
mallet until it is properly positioned.
– Ensure that the crankcase gasket is properly seated.
– Grease the crankcase screws, their threads and the cylinder
head resting surface. Fit the screws and tighten them (for the
lengths of the screws, refer to the diagram).
– Check that all the shafts can move smoothly before and after
tightening the crankcase screws to 10 N·m.
– Clamp the engine in the stand.
– Accurately cut off the gasket that protrudes from the cylinder
base and the sealing surfaces.
– Check to see if the key is fitted to the crankshaft.
– Carefully oil the free wheel and the needle roller cage in the
free wheel gear.
– Insert free wheel gear 1 into the free wheel hub and fit all the
components together on the crankshaft.
60
60
1
The primary pinion flange nut will be fitted at a later stage.
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Fitting the oil pumps
– Using a cloth, carefully clean the rest surface of the oil pump
cover.
– Insert the roller into the oil pump shaft.
– Fit the inner and outer rotors to the oil pump shaft so that the
two centres A and B are placed next to each other, and then
insert all the part into the crankcase.
A
The inner and outer rotors should be fitted so that their
centres face the crankcase.
– Fill the oil pump casing with engine oil.
– Degrease the threads of the two screws 1 (M5x12), apply Loctite 222, fit the oil pump cover and tighten the screws to 6 N·m.
– Insert roller 2 into the oil pump shaft hole.
2
1
If the selector plate has been removed, it can now be easily refitted.
– Fit oil pump gear 3, thrust washer 4 and safety washer
5
3
5.
– Check the smoothness of the oil pump shaft by turning the oil
pump gear.
4
– Using a cloth, carefully clean the rest surface of the oil pump
cover.
– Position the inner and outer rotors in the crankcase so that the
two centres A and B are placed next to each other.
A
The inner and outer rotors should be fitted so that their
centres face the crankcase.
B
– Fit roller 6.
– Degrease the thread of the two screws (M5x16) and apply
Loctite 222.
– Fill the oil pump casing with oil.
– Fasten the oil pump cover with the two screws and tighten
them to 6 N·m.
– After fitting the oil pumps, check their smoothness by turning
the oil pump gear.
6
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Fitting the gear selector
– Fit screw 1 (M5x20) with washer 2, selector lever 3, spring
holding bush 4 and selector lever spring 5.
– Apply Loctite 243 to the screw thread and tighten the screw to
6 N·m.
1
3
2
1
4
5
– Move the selector lever away from the desmodromic mechanism and fit the latter with the gear selector. Ensure that the
flat points are off-centre.
– Apply Loctite 243 to the thread of the screw 7 (M6x30) and
tighten to 10 N·m.
6
– Grease the preassembled shaft of the gearshift mechanism
and insert it in the bearings together with the thrust washer until the selector comes into contact with the gear selector.
– Push back the selector and push in the gear control shaft until it stops.
– Check that spring ends A touch crankcase dog B on the left
and right sides.
– Fit the gearchange lever and then insert all the gears in succession. When changing gears, turn the driving shaft, then remove the gearchange lever again.
Fitting the electric start and kickstart gears
– Oil the support surfaces of the kickstart gear 8 and of electric
start gear 9. Fit the gears to their respective support pins.
– Fit the thrust washers and the Seeger rings with the sharp
edge facing outward.
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B
A
A
8
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– Insert the support pins into the crankcase holes. Fit needle
roller cage 1 and double gear 2.
1
2
– Insert the preassembled kickstart shaft into the bearing hole
so that the starter coupling is located behind the release plate.
– Attach the spring link to the starter spring, apply Loctite 243 to
the thread of screw 3 (M6x12), preload the starter spring by
turning it about 45 degrees clockwise, fasten the spring link
with the screw and tighten to 10 N·m.
– Position the starter spring so that the distance from the kickstart shaft does not change.
Exercise extreme caution when fitting the spring as it could
come off and cause personal injury.
60
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Fitting the clutch drum and hub
– Insert the support washer and needle roller bearings 1.
– Fit the driving shaft with clutch drum 2, half washers 3 and
stepped washer 4.
2
3
4
1
– Heat the clutch hub to approx. 150° C and key it on the driving
shaft.
– Fit a new safety plate.
– Degrease the driving shaft thread and apply Loctite 243 to it.
– Position the special tool (see removal procedure), fit flange
nut 5 and tighten it to 150 N·m.
– Secure the flange nut with safety plate 6 as shown in the figure.
As a rule, there is no need to heat a used clutch hub before fitting it.
6
5
Fitting the primary pinion nut
– Position the special tool as shown in the figure.
– Degrease the crankshaft thread and apply Loctite 243 to it.
– Fit flange nut 7 and tighten it to 150 N·m.
7
– Bring the crankshaft to the top dead centre and fit the crankshaft fixing screw without fitting the seal ring.
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Fitting the timing gear
– Ensure that the key is properly seated in the crankshaft.
– Heat timing pinion 1 and fit it to the crankshaft with the high
end facing inward. If necessary, gently tap with a suitable
tube.
– Fit Seeger ring 2 with the sharp edge facing outward.
1
2
– Degrease the threads of the two screws (M6x25) and apply
Loctite 243. Fasten chain guide 3 and chain stretcher shoe 4
with the two screws 5 (8 N·m) without forgetting the two bushes.
4
3
5
5
Fit the chain stretcher shoe, locking the screw in the seat
in the crankcase B.
B
NOTE: AFTER TIGHTENING THE CHAIN STRETCHER
SHOE, ENSURE THAT IT CAN SLIDE FREELY.
– Fit the timing chain so that the two stretches have the same
length.
7
NOTA: The timing chain can also be fitted after fitting the cylinder and the cylinder head.
– Degrease the threads of the two screws 7 (M5x16) and apply
Loctite 243. Fit chain guard 6 and tighten the screws to 6 N·m.
– Fit a wire clamp in the two ends of the timing chain (see figure).
7
6
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Fitting the piston and the cylinder
– Fit a new cylinder base gasket.
– Oil the piston pin bearing in the connecting rod and the piston
pin itself.
– Fit the piston and fasten the piston pin with two new retaining
rings.
NOTE: THE ARROW ON THE PISTON TOP MUST POINT IN
THE DIRECTION OF TRAVEL.
- Oil the piston and fit the piston rings.
The scraper ring gap should face the back of the vehicle.
The compression ring gap should form an angle of 90° with the
scraper ring gap.
– Pull up the timing chain through the chain tunnel.
– Push the cylinder onto the piston and remove the mounting
ring.
WHEN FITTING THE CYLINDER, TAKE CARE NOT TO
BREAK THE OIL SCRAPER RING!
Fitting the cylinder head
– Check that the two centring bushes are properly seated in the
cylinder.
– Fit a new cylinder gasket (with the inscription “ALTO” facing
upwards) and fit the cylinder head and the timing chain.
– Oil the threads and the contact surfaces of the four flange
screws and fit them along with the related washers.
– Tighten the flange screws in three steps following a crosswise
pattern:
1st step – tighten until a slight resistance is felt.
2nd step – tighten to 40 N·m.
3rd step – tighten to 50 N·m.
– Fit and tighten the three screws 1 (M6x45) and 2 (M6x40) to
10 N·m.
1
Screw 2 must be fitted laterally on the timing chain guard
with a new copper retaining ring (6x10x1).
2
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Ensure that drain hole A is facing upwards.
A
– Insert the camshaft in the cylinder head so that marks B on
the camshaft gear are aligned with the upper edge of the cylinder (see figure). The automatic decompressor stop screw
must be positioned at the top.
Before fitting the camshaft, lock the crankshaft at the top
dead centre using the crankshaft fixing screw.
– Fit the timing chain on the camshaft gear and then fit a new
chain joint 1.
– First fit the insert of the special tool as shown in the figure and
then press the chain joint.
B
B
1
– Fit the insert of the special tool as shown in the figure and rivet the chain joint.
The nailing of the chain coupling should be so strong that
the cross section of the coupling piece ends is trapezoidal
in shape (see sketch).
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Fitting the cylinder head top
– Clean or degrease the sealing surfaces of the cylinder head
top and the cylinder head itself.
– Insert the centring bushes in the cylinder head.
– Apply a thin film of sealant (Three Bond) over the cylinder
head sealing surface.
– Carefully position the cylinder head top and tighten the screws
to 10 N·m. For the screw lengths, refer to the diagram.
NOTE:
– Fit the M6x75 screw with a new copper ring 6x10x1.
M6x...
NOTE: The diagram shows the
lengths of the
cylinder
head
c l a m p i n g
screws.
– Before tightening the screws, check and if necessary adjust
the axial play of the rocker arms.
– To this end, insert a thickness gauge 1 (≠0.05 mm) between
the terminal and the rocker arm. Push in the terminal and
tighten the screw next to the terminal.
– Tighten the other screws to 10 N·m following a crosswise pattern.
55
55
45
30
75
30
45
50
1
Rocker arm axial play: 0.02 - 0.10 mm
Fit the fitting cap, grease the O-rings and fit the seal holder so
that its abutting end faces the camshaft gear.
TO AVOID DAMAGING THE OIL SEALS, BE SURE TO
USE THE FITTING CAP.
The seal holder has a drain hole. Fit the seal holder with the hole
facing upwards.
– Remove the fitting cap, insert the roller into the camshaft and
fit the water pump impeller with the Seeger ring.
– Fit the water pump cover with a new seal. Tighten the screws
(M8x20) to 8 N·m following a crosswise pattern.
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Fitting the automatic stretcher
– Fit the preassembled automatic stretcher 1 with a new gasket.
– Fit the two screws (M6x20) with the 6x10x1 copper rings and
tighten them to 8 N·m.
1
– Using a screwdriver, push in the pressure pin until a slight resistance is felt, then push it in one further notch.
– Fit the compression spring and the clamp screw with a new retaining ring and then tighten to 10 N·m.
Adjusting the play of the valves
- Valve play A is measured between the valve stem and the adjusting screw when the engine is cold.
Cold valve play: 0.12 mm
NOTE: IF THE PISTON IS NOT AT THE TOP DEAD CENTRE,
THE VALVES ARE ACTUATED BY THE ROCKER ARMS AND
THE PLAY OF THE VALVES CANNOT BE PROPERLY ADJUSTED. IN THAT CASE, ROTATE THE CRANKSHAFT ONE
MORE TURN AND THEN LOCK IT AGAIN.
A
– After completing the adjustment, tighten the counternuts to 11
N·m.
– Fit the two valve covers 2 with new gaskets and with screws
(M6x20) complete with retaining rings (6x10x1). Tighten the
screws to 8 N·m.
– Screw in the spark plug and tighten it to 12 N·m.
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Fitting the flywheel
– Unscrew the crankshaft fixing screw, fit seal ring 1 and tighten
the crankshaft fixing screw to 25 N·m (see above).
– Ensure that the key is properly seated in the crankshaft and
then fit the flywheel on the crankshaft.
– Fit the wave washer and the flange nut. Pushing with the
clutch retainer, tighten the flange nut to 60 N·m.
Fitting the pick-up and the ignition cover
– Position the pick-up in the crankcase and insert cable guide 2
in the specially designed opening in the crankcase.
– Degrease the thread of the two screws 3 (M5x16), apply Loctite 243 and tighten the screws to 6 N·m.
2
3
– Fit a new gasket and fasten the ignition cover with the four
screws (4 and 5). Tightening torque: 10 N·m.
4
5
NOTE: Fit the two longer screws 4 (M6x35) in the holes with the
centring bushes.
5
5
6 - Motor
Release 01 Date 09/2007
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Fitting the clutch
– Before fitting the clutch, carefully oil the lined plates.
Clutch plates
– Place the twelve dragging bushes 3 in the hub. If
necessary fix them with a little grease.
– Starting with a middle plate 6 and 6A, alternate eight
middle plates with seven lined plates 5, ending with
a thin middle plate 6 at the top. (see figure to side)
– Fit the thrust head.
– Position the pressure plate, fit the clutch springs, the spring
cups and the flange screws.
– Tighten screws 7 to 10 N·m following a crosswise pattern.
7
– Ensure that the centring bushes are fitted in the crankcase.
– Grease all the oil seals in the clutch cover and fix the clutch
cover gasket with a little grease.
– Take special care in ensuring that oil jet 8 in the crankcase is
not blocked by the gasket.
– Pour approximately 30 ml of engine oil in the crankshaft hole.
– Carefully position the preassembled clutch cover, pressing it
slightly.
– Fit the screws (screw length M6x30 or M6x35 – see figure)
and tighten them to 10 N·m.
NOTE: If you have difficulty fitting the clutch cover, check the
position of the starter spring.
8
M6x30
M6x30
M6x35
M6x35
M6x30
68
M6x30
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Fitting the oil line
- Position oil line 3 and fasten it with the two oilway screws 1
and 2, using new seal rings. Tightening torque: 10 N·m.
1
2
Position the oil line so that it does not come into contact
with the engine. Also, when tightening, ensure that the oil
line is not taut.
3
Installing the starter motor
– Carefully oil the O-ring on the starter motor and insert the motor in the crankcase. Fit the two screws 4 (M6x20) and tighten
them to 8 N·m.
4
– Oil distance ring 5 and slide it onto the driven shaft with the
groove for the O-ring facing inward.
– Fit the chain sprocket with the high collar facing inward.
– Degrease the flange nut thread, apply Loctite 243 to it and
tighten the screw with the spring washer to 60 N·m.
5
NOTE: Before tightening the screw, lock the crankshaft and shift
into first gear.
6 - Engine
Release 01 Date 09/2007
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Fitting the oil filter
– Pour engine oil into the oil filter casings until they are about
1/4 full.
– Insert the two oil filters 1 in the crankcase.
1
– Oil the O-rings on the oil filter covers and fix covers 2 with the
four screws (M5x16), applying a tightening torque of 6 N·m.
– Fit the kickstart and the gearshift lever.
2
Adding engine oil
– Fit clamping screws 3 and 4 and oil drain screw 5 and then
tighten them.
4
NOTE: Tightening torques: 3 10 N·m, 4 15 N·m, 5 20 N·m.
3
5
– Remove the clamping screw from the clutch cover and pour in
1.20 litres of 10W-50 engine oil (see table in Chapter 3 Tightening torques - Specifications - Recommended products).
– Replace the clamping screw and check the seal of the engine.
API: SG, SH
NOTE: Check the engine oil level after reinstalling the engine on
the vehicle.
TEMPERATUR
- WE RECOMMEND USING ONLY SYNTHETIC OILS
OF KNOWN BRANDS HAVING OR EXCEEDING THE
QUALITY REQUIREMENTS OF API CLASSES SG OR
SH (CHECK THE INFORMATION PROVIDED ON THE CONTAINERS).
- AN INSUFFICIENT QUANTITY OF OIL, OR AN OIL OF INFERIOR QUALITY, LEADS TO PREMATURE WEAR OF THE
ENGINE.
70
–
10W 40
10W 50
0°C
32°F
+
15W 40
15W 50
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ENGINE SECTION
- INSTALLING THE ENGINE ON THE VEHICLE
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To mount the engine on the vehicle, follow the
procedures described for its removal in reverse order, taking care to apply the tightening
torques and use the products specified in
Chapter 3 Tightening torques - Specifications Recommended products.
72
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Pagina 1
CARBURETTOR
7
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Pagina 2
CONTENTS
CARBURETTOR - KEIHIN FCR M X 39 . . . Chap. 7 - 3
Removing and reinstallin
the carburettor . . . . . . . . . . . . . . . . Chap. 7 - 4
Disassembling the carburettor
. . . . . . Chap. 7 - 5
Choke valves . . . . . . . . . . . . . . . .
Checking the accelerating pump
Checking the jet needle . . . . . . .
Checking the float needle valve .
Checking the throttle valve . . . . .
.
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Chap.
Chap.
Chap.
Chap.
Chap.
7
7
7
7
7
-
8
8
8
8
8
Reassembling the carburettor . . . . . . . Chap. 7 - 9
Adjusting the position
of the throttle sensor . . . . . . . . . . . Chap. 7 - 12
Checking the throttle sensor . . . . . . . Chap. 7 - 13
Removing and refitting
the throttle sensor . . . . . . . . . . . . . Chap. 7 - 13
Carburettor - Idle speed adjustment
Basic information about
carburettor wear . . . . . . . . . . . . .
Mixture adjusting screw . . . . . . . . .
Checking the float level . . . . . . . . .
2
. . Chap. 7 - 14
. . Chap. 7 - 14
. . Chap. 7 - 14
. . Chap. 7 - 14
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CARBURETTOR - KEIHIN FCR M X 39
7 - Carburettor
Release 01 Date 09/2007
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Removing and reinstalling the carburettor
NOTE: Before starting work on the carburettor, thoroughly clean
the vehicle.
– Remove the saddle and the fuel tank with the deflectors.
– Unscrew the throttle twist grip.
– Loosen the clamp screw on the float chamber, drain the fuel
into a suitable container, then tighten the screw again.
– Unplug the valve sensor connector.
– Disconnect the sleeve.
– Remove the carburettor from the frame top.
Collect the petrol in a suitable container and remove any
spills. Petrol is highly flammable and, in certain conditions, explosive. Keep sparks, flames and heat sources
away from the working area. Always work in a well ventilated
area. Never use petrol as a cleaning solvent. Handle petrol only if absolutely necessary. Do not use petrol to clean components that need to be blown with compressed air. Keep out of
the reach of children.
– When refitting, fit the carburettor to the sleeves and fasten it
with the two hose clamps. Ensure that the carburettor is fitted
vertically in relation to the vehicle.
– Refit the throttle twist grip and check that the cables can slide
freely.
– Attach the valve sensor plug.
– Fit the tank and the saddle.
– Properly arrange the carburettor breather pipes.
– Start the engine and check the operation of the carburettor.
The engine speed should not change when the handlebars
are fully turned to the left or right. If the engine speed
changes, check the arrangement of the throttle cables.
4
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Disassembling the carburettor
NOTE: The disassembly should be carried out in a clean workplace with sufficient space to properly arrange all carburettor
components.
– Remove the carburettor and clean it of coarse dirt.
– Loosen the two screws 1 and remove all breather pipes from
the carburettor.
1
1
– Remove the two screws 2 and remove the throttle valve cover from the carburettor with the related gasket.
2
2
– Remove screw 3 and pull the jet needle out of the throttle
valve.
– Remove screw 4.
3
4
– Pull up the throttle valve lever and remove the throttle valve
complete with roller 5 and the throttle valve plate from the carburettor.
7 - Carburettor
Release 01 Date 09/2007
5
5
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– Rotate the carburettor, loosen the three screws and remove
the accelerating pump cover.
NOTE: When removing the cover, ensure that the spring
and the seal rings are not lost.
– Remove the two seal rings, the spring and the diaphragm from
the pump casing.
– Remove the float chamber screws and detach the float chamber.
– Remove float pin 1 and remove the float together with the needle valve.
– Remove main jet 2.
2
1
– Loosen screw 3 and, using a pair of pliers, carefully remove
the float needle valve support from the carburettor.
– Unscrew idling jet 4, starting jet 5 and nozzle 6.
– Tighten mixture adjusting screw 7 until it stops, taking note of
the screw turns.
– Unscrew the mixture adjusting screw and remove it together
with the spring, washer and O-ring.
NOTE: As a rule, the spring, the washer and the O-ring remain
in the hole. These parts can be removed with a jet of compressed air.
6
7
4
6
5
3
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– Remove screws 1 and throttle sensor 2.
1
Remove the throttle sensor only if it is defective. The
throttle speed sensor needs to be readjusted every time
screws 1 are loosened.
2
– Remove screw 3 and pull the connecting piece out of the carburettor.
3
– Loosen the two screws and remove the suction pump and Oring 4 from the carburettor.
– Unscrew choke idling jet 5 and choke main jet 6.
4
– Clean all the jets and the other components and blow them
with compressed air.
– Clean the carburettor body and blow all the ducts inside it.
– Check the condition of all the gaskets and replace any damaged ones.
7 - Carburettor
Release 01 Date 09/2007
6
6
7
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Choke valves
Ensure that choke knob piston 1 presents no deep scoring or
residues.
1
Checking the accelerating pump
Check that the diaphragm is not cracked or porous.
Check that the gaskets are not damaged.
Ensure that holes 2 are clear.
2
2
Checking the jet needle
Ensure that the jet needle is not bent or worn.
Checking the float needle valve
Check to see if the sealing surface of the needle valve presents
any dimples. There should be no dirt between the valve seat
and the float needle.
Checking the throttle valve
Throttle valve rollers 3 should rotate easily and have no flat areas. Check that throttle valve plate 4 is not damaged.
8
3
4
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Reassembling the carburettor
– Fit choke idling jet 1 and choke main jet 2.
– Fit O-ring 3 in the groove and fasten the suction pump to the
carburettor with the two screws.
3
1
2
– Insert the fuel connection into the carburettor and fasten it with
screw 4.
NOTE: When fitted, the connection should turn easily and
smoothly.
4
– Fit choke knob 5 and operate it a few times to make sure it
slides properly. Also check if the knob engages properly.
– Fit the spring, the washer and the O-ring on mixture adjusting
screw 7 and tighten the screw until it stops.
– Unscrew the mixture adjusting screw by the number of turns
that was taken note of during disassembly.
5
7
8
Original carburettor adjustment: see table in Chapter 3
Specifications.
– Fit idling jet 8, starting jet 9 and the nozzle complete with main
jet 10.
10
9
– Insert needle valve seat 11 in the related hole and fasten it
with screw 12.
12
11
7 - Carburettor
Release 01 Date 09/2007
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– Position the float and the needle valve and fit float pin 1.
– Check the float level (see page 14).
1
– Fit the carburettor float chamber complete with its gasket, position adjusting screw support 2 and fasten the float chamber
by means of screws 3.
2
When fitting the carburettor float chamber, ensure that
accelerating pump push rod 4 slides into the hole.
3
4
– Fit diaphragm 5 with the inscription facing upwards and the
spring in the pump casing.
– Fit O-ring 6 in the groove. Fix seal ring 7 in the cover with a little grease and fasten the cover with the three screws.
5
7
6
– Fit the throttle sensor so that the flat area on the carburettor
engages the throttle sensor slot and fasten it by means of
screws 10.
10
10
– Pull up the throttle valve lever and insert the throttle valve
along with roller 8 and the plate in the carburettor, ensuring
that rollers 9 engage the throttle valve (see figure).
– Check the smoothness of the throttle valve.
10
9
8
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– Apply Loctite 243 to screw 1 and tighten it.
– Fit the jet needle and fasten it with screw 2.
2
1
– Position the throttle valve cover with the related gasket and
fasten it with the two screws 3.
3
3
– Fasten the breather pipes with the two float chamber screws
4.
4
7 - Carburettor
Release 01 Date 09/2007
4
11
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Pagina 12
Checking the throttle sensor
NOTE: The following measurement should be taken when the
temperature of the part is approximately 20° C.
– Unplug the throttle sensor.
– Connect a multimeter (measuring range Ωx 1k) to the blue (+)
and black (–) wires of the throttle sensor.
THROTTLE SENSOR RESISTANCE: 4 – 6 kΩ
– Now connect the multimeter to the yellow (+) and black (–)
wires of the throttle sensor.
– When the throttle twist grip is rotated slowly, the resistance
should vary evenly.
Bl
Bl
Gi
THROTTLE SENSOR RESISTANCE: 0-5 kΩ ±1 kΩ
(WHEN THROTTLE TWIST GRIP IS ROTATED)
Gi
Ne
Bl = blue
Gi = yellow
Ne = black
Removing and refitting the throttle sensor
– Unplug the throttle sensor and loosen screws 1.
– Remove the throttle sensor from the carburettor.
Ne
1
1
– When fitting the throttle sensor, ensure that the flat section of
the throttle pin engages the throttle sensor slot.
– Fit the two screws without tightening them and adjust the position of the throttle sensor.
12
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Carburettor - Idle speed adjustment
The adjustment of the idle speed strongly affects engine starting.
In other words, an engine whose idle speed is properly adjusted
is easier to start than an improperly tuned engine. The idle speed
is adjusted by means of adjusting roller 1 and mixture adjusting
screw 2. The adjusting roller is used to alter the basic position of
the throttle valve; the mixture adjusting screw is used to adjust the
idle speed mixture, which comes to the engine through the idle
speed system. Turning the screw clockwise decreases the quantity of fuel (lean mixture); turning it anticlockwise increases the
quantity of fuel (rich mixture).
TO PROPERLY ADJUST THE IDLE SPEED, FOLLOW THESE
STEPS:
1 Screw in mixture adjusting screw 2 until it stops and then screw
it out until the basic adjustment specified by Betamotor is obtained (see Chapter 3 Tightening torques - Specifications - Recommended products).
2 Warm up the engine.
3 Using adjusting roller 1, adjust the standard idle speed (1400 1500 rpm).
4 Slowly turn mixture adjusting screw 2 clockwise until the idle
speed begins to lower. Memorize this position and then slowly
turn the mixture adjusting screw anticlockwise until the idle
speed begins to lower again. Choose the point between the two
settings where the idle speed is highest. Should the engine
speed increase excessively, decrease the speed to the standard level and go through step 4 again. Anybody using the vehicle intensively for sporting purposes should choose a leaner
mixture by approximately 1/4 of a turn (clockwise) relative to this
ideal value. This is because, in these conditions, the engine
heats more than in standard use.
NOTE: If the above procedure should prove unsuccessful, the
problem may be due to an idling jet of unsuitable size.
a) If the mixture adjusting screw is turned until it stops and the idle
speed does not change, a smaller idling jet is needed.
b) If the engine stalls while the mixture adjusting screws is still
open by two turns, a larger idling jet is required.
It goes without saying that, after replacing the jet, the adjustment will have to be restarted from the beginning.
5 Turn the adjusting roller until the desired engine speed is obtained.
6 The idle speed will have to be readjusted in case of marked
changes in the outside temperature and the riding altitude.
1
2
3
Basic information about carburettor wear
The throttle valve, the jet needle and the nozzle are subject to
heavy wear and tear caused by engine vibration. This may result
in carburettor malfunctions (e.g. enrichment of the mixture). The
above-mentioned parts should consequently be replaced after
200 hours.
Mixture adjusting screw
The mixture adjusting screw is difficult to reach. For this reason a
special tool is provided to facilitate the task. Place the special tool
on mixture adjusting screw 2 on the lower side of the carburettor.
Slightly press the tool upwards and turn adjusting roller 3 until the
tool snaps into the slot of the mixture adjusting screw. Now it is
possible to perform the adjustment. The roller has reference
marks for the turns.
Checking the float level
Remove the carburettor and the float chamber. Tilt the carburettor
so that the float rests on the float needle valve without crushing it.
In this position the float edge should be parallel with the sealing
surface of the carburettor float chamber (see figure). If the float
level differs from the nominal value, check the float needle valve
and if necessary replace it. If the needle valve is in working order,
the float level can be adjusted by bending float lever 4. Fit the carburettor float chamber and the carburettor and then adjust the idle
speed.
7 - Carburettor
Release 01 Date 09/2007
//
4
13
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Pagina 1
8
FRONT SUSPENSION / WHEEL
Pag. 1
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Pagina 2
CONTENTS
Fork components . . . . . . . . . . . . . . . . . Chap. 8 - 4
Taking down the wheel . . . . . . . . . . . . . Chap. 8 - 5
Checking the head tube seats . . . . . . . Chap. 8 - 6
Cleaning the wiper seal
Removal . . . . . . . . . .
Installation . . . . . . . .
Air bleed screw . . . . . . .
Removal . . . . . . . . . .
Installation . . . . . . . .
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Chap. 8 - 7
Chap. 8 - 7
Chap. 8 - 7
Chap. 8 - 7
Chap. 8 - 7
Chap. 8 - 7
Draining the oil . . . . . . . . . . . . . . . . . . . Chap. 8 - 8
Removing the pump assembly
and the foot valve . . . . . . . . . . . . . . Chap. 8 - 9
Separating leg from the leg holder
and removing the seal rings . . . . . Chap. 8 - 10
Overhauling and changing the adjustment
of the cartridge and the foot valve Chap. 8 - 11
Overhauling the cartridge
(rebound damping) . . . . . . . . . . . . . Chap. 8 - 11
Removal . . . . . . . . . . . . . . . . . . . . . Chap. 8 - 11
Installation . . . . . . . . . . . . . . . . . . . Chap. 8 - 12
Overhauling the foot valve
(compression damping) . . . . . . . . Chap. 8 - 12
Removal . . . . . . . . . . . . . . . . . . . . . Chap. 8 - 12
Installation . . . . . . . . . . . . . . . . . . . Chap. 8 - 13
Reassembling the fork leg and the sheath Fitting the seal rings . . . . . . . . . . . Chap. 8 - 13
Reassembling the pump assembly
and the foot valve . . . . . . . . . . . . . Chap. 8 - 15
Adding oil . . . . . . . . . . . . . . . . . . . . . . Chap. 8 - 16
Reinstalling the fork on the vehicle . . Chap. 8 - 17
Removing the fork from the vehicle . . Chap. 8 - 18
2
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18:49
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Release 01 Date 09/2007
3
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Pagina 4
9
10
48
19
39
24
21
Fork components
5) Supporting tube
8) Lower sliding bush
9) Cup
10) Seal ring
12) Wiper seal
13) Outer leg holder
19) Compression adjusting screw
21) Spring
24) Spring guide
25) Preload tube
4
13
25
34
33
36
37
43
30 31 72
73
28)
30)
31)
32)
33)
34)
36)
37)
39)
41)
43)
12 33
28
32
Foot pad
Cartridge case
Inside rod
Pump rod
Fin pull-off spring
Rebound piston fin
Pump piston
Rebound damping piston reeds
Upper sliding bush
Foot valve
Compression valve fin
70
45
41
71
46
5
8
45) Foot valve piston
46) Compression damping valve
reeds
48) Cap
70) Wheel holder
71) Rebound adjusting screw
72) Jet needle
73) Case cover
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Pagina 5
Taking down the wheel
NOTE: Place the vehicle on a specially designed central stand
and keep the front wheel off the ground.
– Remove wheel holder cap 1.
– Loosen the two screws 2 on the left-hand fork foot.
1
2
–
–
–
–
Remove the two screws 3 from the right-hand fork foot.
Pull out the fork pin on the right side.
Remove the wheel assembly.
If the disc is replaced, refer to the table of tightening torques
in Chapter 3 Tightening torques - Specifications - Recommended products.
– Remove the leg protections, the front mudguard and the mudguard grille (see Chapter 5 Bodywork and fittings).
3
Unscrew the two screws 1, disconnect the caliper assembly, remove the pipe from the fork and disconnect the speed sensor
cable.
1
Unscrew the four screws on the left side and the four screws on
the right side and then remove the fork from the brackets.
8 - Front suspension / wheel
Release 01 Date 09/2007
5
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Pagina 6
If necessary, follow these steps to overhaul the steering seats:
– Unscrew the four screws as shown in the figure and remove
the handlebars.
– Unscrew screws 1 and 2 and remove the two brackets from
the head tube.
1
2
Checking the head tube seats
Check the seats for wear. If necessary, remove them using a
suitable drift.
– For each seat, use a drift and a hammer to alternately hit the
grooves in the head tube to the left and right of the seat.
– Use the drift from above to remove the lower seat.
– Use the drift from below to remove the upper seat.
6
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Pagina 7
Cleaning the wiper seal
NOTE: This operation can be performed with the fork installed
on the vehicle.
13
Removal
– Before performing this operation, thoroughly clean leg 6.
– Using a small screwdriver, pry dust scraper 12 off sheath 13
taking care not to score the fork leg.
– Push down the wiper seal along the leg and, using a jet of
compressed air, clean the wiper seal inside and its seat on the
sheath.
12
6
Do not on any account use metal tools to remove dirt particles.
– Make the legs complete a short travel and remove any dirt
from the supporting tubes.
– Lubricate the wiper seal and the visible surface of the seal ring
with silicone grease.
Installation
- Manually press wiper seal 12 back into its seat.
12
Air bleed screw
NOTE: This operation is to be performed with the fork installed
on the vehicle and the fork legs fully extended (front wheel off
the ground). Owing to the particular shape of the seal rings, air
getting into the fork legs during use may remain trapped and
cause fork malfunctions.
Removal
– Using a cross-tip screwdriver, unscrew air bleed screw 14 on
each fork leg, in the upper part of the leg holder, to release the
pressure that may have built up inside. Perform this operation
on a monthly basis in case of standard road use, or after each
competition.
– Check the condition of seal ring 50 and if necessary replace
it.
14
50
Installation
- Tighten air bleed screw 14 to the prescribed torque (see table
in Cap. 3 Tightening torques - Specifications - Recommended
products), taking care not to damage seal ring 50.
8 - Front suspension / wheel
Release 01 Date 09/2007
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Draining the oil
NOTE: This operation cannot be performed while the fork is installed on the vehicle.
48
NOTE: It is advisable to slightly loosen the plug before removing the fork leg from the steering plates.
– Remove the fork leg from the steering plates as directed by
the manufacturer.
– Clamp the fork leg in a vice.
– Using a 19-mm spanner, completely unscrew plug 48.
– Slowly lower the sheath along the fork leg.
– Push down spring guide cup 20 and spring 21 to allow a 19mm spanner to be inserted in counternut 23.
– While holding counternut 23 in position with the 19-mm spanner, use another 19-mm spanner to completely unscrew plug
48.
48
23
20
21
– Remove plug 48, spring guide cup 20, spring 21 and preload
tube 25.
– Remove adjuster inside transmission rod 32 from the end of
rod 31.
– Release fork leg 5 from the vice and turn it upside down over
a suitable container to collect the oil it contains. Pump a few
times to facilitate the outflow.
NOTE: The appearance, density and quality of the spent oil is a
clue to the condition of the seals and guides. If the oil is dense
and dark and contains solid particles, replace the guide bushes
and the seals.
48
20
31
21
25
32
5
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Removing the pump assembly and the foot valve
Perform this operation only after completely draining the
oil from the fork leg.
– Clamp the wheel holding foot of the fork leg in a vice.
– Stop the rotation of the case by accurately inserting the hexagon on the case into the slotted hole at the lower end of the
tool.
In the upper part of the tool there are two diametrically
opposite holes where a pin can be inserted to facilitate its
locking. However, the tool must on no account be turned
but should only be used to hold the fork leg inside components
in place.
41
– Using the 21-mm socket wrench, unscrew foot valve 41.
– Remove foot valve assembly 41.
– Remove shock absorber assembly 21 from fork leg 5.
21
5
– Unscrew and remove counternut 23 and remove spring guide
24.
– To be able to work on the pump, it is first necessary to remove
the components of the stop pad. Hold foot pad nut 26 with an
18-mm spanner and unscrew tip 29 with a 17-mm hexagonal
spanner.
23
24
– Remove upper nut 26 and foot pad 28.
– Using a small screwdriver, pry retaining ring 27 off the rod.
– Remove retaining ring 27 and tip 29 from the rod.
26
28
29
27
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– Push rod 32 towards the inside of case 30 to allow the pump
assembly to be removed from below.
30
NOTE: The pump can be completely overhauled and adjusted.
– Check ring 35 for wear.
32
35
Separating the fork leg from the leg holder and removing the
seal rings
– Using a small flat blade screwdriver, remove wiper seal 12.
– Using the same screwdriver, remove metal retaining ring 11.
12
11
10
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– Remove fork leg 6 from sheath 13. Pull hard to obtain the separation. This operation will remove from the sheath seal ring
10, cup 9 and lower guide bush 8.
– Manually remove upper guide bush 39. If the bush is difficult
to remove by hand, the operation can be facilitated by inserting a flat blade screwdriver in the bush slot.
– Remove lower guide bush 8, cup 9, seal ring 10, retaining ring
11 and dust scraper 12 from the fork leg.
8
10
13
6
9
Do not reuse the removed seal rings and wiper seals.
9
11
39
8
10
12
Overhauling and changing the adjustment of the cartridge
and the foot valve
Overhauling the cartridge (rebound damping)
32
Removal
– Clamp the milled portion of rod 32 in a vice.
– Depending on the type of nut used, unscrew nut 38 with a 12mm or a 13-mm spanner.
– Remove in succession nut 38, rebound adjusting reed or
reeds 37, piston 36 complete with ring 35, fin 34 and spring
33.
38
35
33
34
36
37
38
8 - Front suspension / wheel
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Pagina 12
Installation
35
NOTE: Fins 37 and piston 36 determine the rebound damping
action. If necessary, the behaviour of the fork during the rebound
phase can be altered by replacing fins 37 and piston 36 with other parts having different characteristics.
37
Only use genuine Betamotor fins and pistons. Do not
modify the components.
36
– If necessary replace piston ring 35.
– Fit in succession spring 33, fin 34, piston 36 complete with
ring 35, rebound adjusting fin or fins 37 in the rod end.
33
34
The piston should be oriented so that the smaller holes
face adjusting fins 37.
– Manually screw in nut 38.
– Clamp the milled part of damping rod 32 in a vice.
– Using a suitable spanner (12-mm or 13-mm based on the nut
used), tighten nut 38 to the prescribed torque (see table in
Chapter 3 Tightening torques - Specifications - Recommended products).
32
38
Overhauling the foot valve (compression damping)
Removal
– Clamp in a vice the foot screw through spanner slot 47.
– Unscrew nut 42 with a 13-mm spanner.
– Remove in succession nut 42, spring 33, fin 43, piston 45
complete with O-ring 44, compression adjusting reed or reeds
46.
42
47
42
33
44
43
45
46
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Installation
33
NOTE: Fins 46 and piston 45 determine the compression damping. If necessary, the behaviour of the fork during the compression phase can be altered by replacing fins 46 and piston 45
with other parts having different characteristics.
44
43
45
46
Only use genuine Betamotor fins and pistons. Do not
modify the components.
– If necessary replace piston O-ring 44.
– Insert in succession compression fin or fin stack 46, piston 45
complete with O-ring 44, fin 43 and spring 33 in the foot valve.
The piston should be oriented so that the smaller holes
face adjusting fins 45.
42
– Manually screw in nut 42.
– Clamp in a vice the foot screw through spanner slot 47.
– Using a 13-mm spanner, tighten nut 42 to the prescribed
torque (see table in Chapter 3 Tightening torques - Specifications - Recommended products).
47
Reassembling the fork leg and the sheath - Fitting the seal
rings
Never reuse any removed seal rings and wiper seals. Before reassembly, check the condition of the guide bushes. If they are scored or scratched, replace them. Ensure
that the Teflon lining of the guide bushes is intact.
– Cover the seat of the upper bush by applying adhesive tape to
the end of the fork leg.
– Apply a thin film of grease to the wiper seal and the seal ring.
– Insert the following parts in succession into the fork leg: wiper
seal 12, retaining ring 11, seal ring 10, cup 9 and lower guide
bush 8.
Pay attention to the orientation of seal ring 10: fit it so that
its hollow side faces cup 9.
8
9
10
11
12
8 - Front suspension / wheel
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– Remove the adhesive tape from the end of the fork leg, cleaning it of any traces of adhesive.
– Manually insert upper guide bush 39.
NOTE: If the guide bush is difficult to insert by hand, the operation can be facilitated by inserting a flat blade screwdriver in the
bush slot.
39
– Gently insert the fork leg into the sheath, taking care to ensure
that the upper guide bush does not receive damage.
– Move the lower guide bush until it comes into contact with the
sheath, the cup and the seal ring.
– Fit the specially designed inserter on fork leg 5 and use it to
push seal ring 10 until the lower guide bush, the cup and the
seal ring are properly seated.
10
5
– Using a small flat blade screwdriver, fit retaining ring 11, ensuring that it is perfectly seated in the groove and taking care
not to score the fork leg.
11
– Fit wiper seal 12 by pressing it by hand.
12
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Reassembling the pump assembly and the foot valve
– Insert pump rod 32 into case 30.
30
Each pump contains a seal ring. Before reassembly,
check that the seal rings are not worn or damaged and if
necessary replace them. Be very careful and if necessary
use a small flat blade screwdriver to facilitate the insertion of the
pump piston into the tube-case. The piston should go unimpeded.
32
– Insert stop pad tip 29 into rod 32 so that the side with the
spanner slot faces case 30 and the tip goes past wire groove
F.
– Fit wire 27 into groove F.
– Bring tip 29 into contact with the retaining ring.
26
– Insert foot pad 28 so that slotted holes for the passage of oil
face the tip.
28
32
– Insert upper nut 26 and screw it on tip 29.
F
27
29
– Holding nut 26 with an 18-mm spanner, tighten tip 29 to the
prescribed torque (see table in Chapter 3 Tightening torques
- Specifications - Recommended products) using a 17-mm
spanner.
– Fit spring guide 24 on pump rod 32 so that smaller side of the
guide faces the foot pad.
26
29
– Fully screw in counternut 23 without tightening.
23
24
32
8 - Front suspension / wheel
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– Push preassembled pump 23 until it comes into contact with
fork leg 5.
– Manually screw in the foot valve.
– Stop the rotation of the case by carefully inserting the hexagon on the case into the slotted hole at the lower end of the
tool.
23
In the upper part of the tool there are two diametrically opposite holes where a pin can be inserted to facilitate its
locking. However, the tool must on no account be turned
but should only be used to hold the fork leg inside components
in place.
5
– Using a 21-mm socket wrench, tighten foot valve 41 to the
prescribed torque (see table in Chapter 3 Tightening torques
- Specifications - Recommended products).
41
Adding oil
h
– Push the sheath all the way up along the fork leg.
– Prepare the oil to be poured into the fork leg in a measuring
cup (see table in Chapter 3 Tightening torques - Specifications
- Recommended products).
– Pour approximately 2/3 of the oil into sheath 13, then pump a
few times to remove the air.
– Pour in the rest of the oil.
– Lower the leg holder on the fork leg until the wiper seal comes
into contact with the wheel holding foot.
– Wait a few minutes and then measure the volume of the air
(see table in Chapter 3 Tightening torques - Specifications Recommended products) and if necessary restore the level.
13
NOTE: A smaller or greater volume of air, or the use of unsuitable oil, can completely change the behaviour the fork.
–
–
–
–
Push sheath 13 up fork leg 5.
Insert adjuster inside transmission rod 31.
Insert preload tube 21, spring 25 and spring guide cup 20.
Fully tighten plug 48.
48
20
25
31
21
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– Open the adjuster by completely unscrewing adjusting screw
R.
48
– Using two 19-mm spanners, tighten counternut 23 on plug 48
to the prescribed torque (see table in Chapter 3 Tightening
torques - Specifications - Recommended products).
R
23
– Push up the sheath along the fork leg.
– Using the 19-mm spanner, screw plug 48 on the leg holder to
the prescribed torque (see table in Chapter 3 Tightening
torques - Specifications - Recommended products).
– Restore the proper adjustment by turning adjusting screw R
(see table in Chapter 3 Tightening torques - Specifications Recommended products).
48
Reinstalling the fork on the vehicle
Follow the reverse procedure to the removal, observing the
tightening torques specified in the table in Chapter 3 Tightening
torques - Specifications - Recommended products.
To ensure proper operation of the fork, fit the wheel on the fork
by following these steps:
– Insert the pin through the right-hand wheel holder, the wheel
and the left-hand wheel holder.
– Screw tight the pin nut on the left side.
– Push the fork legs completely and then release them a few
times.
– Tighten the two screws on the right-hand wheel holder in the
sequence 1-2-1.
8 - Front suspension / wheel
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Pagina 1
9
REAR SUSPENSION / WHEEL
Pag. 1
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Pagina 2
CONTENTS
Removing the chain . . . . . . . .
Taking down the rear wheel . .
Removing the rear sprocket . .
Removing the rear brake disc
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Chap.
Chap.
Chap.
Chap.
9
9
9
9
-
4
4
4
4
Removing the swingarm . . . . . . . . . . . . Chap. 9 - 5
Removing the shock absorber . . . . . . . Chap. 9 - 5
2
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Before attempting to remove the rear suspension, place
the vehicle on a central stand with the rear wheel off the
ground.
9 - Rear suspension / wheel
Release 01 Date 09/2007
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Removing the chain
Find the split link and position it on the rear sprocket. Remove
the link with a pair of pliers and undo the chain.
When refitting, it is important that the link should be fitted
in the opposite direction to the rotation of the chain (see
figure).
Taking down the rear wheel
Loosen the chain stretchers on the left and right sides.
Unscrew wheel spindle nut 1.
Pull out the wheel spindle from the left side and take down the
wheel assembly..
1
Removing the rear sprocket
Unscrew the six screws and remove the rear sprocket from the
wheel hub.
WARNING
Important! Follow these steps to properly tighten the rear
sprocket:
– Apply medium-resistance threadlocking Loctite to the
screw threads.
– Using a torque spanner, tighten the six sprocket locknuts to
25-30 N·m.
– Check the tightening by turning the six inside nuts with a
hexagonal long-arm CH13 spanner (400-500 mm).
All the nuts should be securely locked.
Removing the rear brake disc
If necessary unscrew the four screws 1 and remove the brake
disc.
- When refitting the disc, check the tightening torques against
those specified in the table in Chapter 3 Tightening torques Specifications - Recommended products.
4
1
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Verificare che l’errore massimo di planarità sui 360° non sia superiore a 0,04 mm.
When refitting the parts, tighten them to the prescribed torques
(see Chapter 3 Tightening torques - Specifications - Recommended products).
Removing the swingarm
Disengage the swingarm from the rear brake line and from the
caliper with its support bracket.
Unscrew the swingarm/frame pin and the swingarm/linkage pin.
Remove the swingarm.
.
1
2
Removing the shock absorber
– Unscrew pins 1 and 2 and unfasten the rear suspension linkage.
2
1
– Remove the upper shock absorber fastener.
9 - Rear suspension / wheel
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Pagina 1
10
BRAKING SYSTEM
Pag. 1
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Pagina 2
CONTENTS
Front brake pump
Overhauling the front brake pump . Chap. 10 - 4
Replacing the front brake pads . . . . . . Chap. 10 - 5
Replacing the front brake
caliper pistons . . . . . . . . . . . . . . . Chap. 10 - 5
Replacing the rear brake pump . . . . . . . Chap. 10 - 6
Replacing the rear brake pads . . . . . . . Chap. 10 - 7
Replacing the caliper pistons . . . . . . . Chap. 10 - 7
2
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Pagina 3
Special attention should be given to the braking system. No
special maintenance is required, but frequent checks and
thorough inspections are necessary, especially if the vehicle is used in competitions.
10 - Braking system
Release 01 Date 09/2007
Visually check all the components and in particular the
pump, the pipes and the caliper. Ensure that there are no
leakages and that all the components are in good condition.
3
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Front brake pump
Overhauling the front brake pump
– Empty the system.
– Unscrew front brake lever screw 1.
The replacement can only be performed after emptying
the system.
Avoid disposing of the fluid in the environment. Dispose
in accordance with the law.
1
– Remove the pump and replace it with a new spare kit.
Subsequently replenish and bleed the system (see Chapter 4 Maintenance). Only use DOT 4 or DOT 5.1 oil.
4
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Replacing the front brake pads
To replace the brake pads, follow these steps:
– Push the brake caliper towards the disc so that the pistons
can reach their base position.
– Loosen grub screw A.
– Pull out pin B while supporting the two brake pads as shown
in the figure.
– Remove the pads taking care not to drop the leaf spring located underneath.
– To refit the parts, follow the reverse procedure. When fitting
the brake pads, ensure that the leaf spring is properly positioned.
WARNING: Always keep the brake disc free from oil and
grease as these substances greatly reduce the braking
action.
Every time the braking system is serviced, operate the brake
lever to bring the pads into contact with the disc, restore the correct pressure point and ensure proper operation of the braking
system.
A
C
B
Replacing the front brake caliper pistons
Loosen the two screws C and remove the brake caliper. Repeatedly pull the brake lever. In these conditions, without the
brake pads in place, the pistons will come out of their seats, allowing the pistons and the related oil seals to be removed. Replace the parts with those contained in the spare kit.
Subsequently replenish and bleed the system (see Chapter 4 Maintenance). Only use DOT 4 or DOT 5.1 oil.
10 - Braking system
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Replacing the rear brake pump
1
The replacement can only be performed after emptying
the system.
Avoid disposing of the fluid in the environment. Dispose
in accordance with the law.
– Remove right-hand guard 1 (if present).
– Unscrew nut 2 to disengage the brake lever pump.
– Remove the pump from below and replace it with a new one
from the spare kit.
2
Subsequently replenish and bleed the system (see Chapter 4 Maintenance). Only use DOT 4 or DOT 5.1 oil.
6
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Replacing the rear brake pads
To replace the brake pads, follow these steps:
– Push the brake caliper towards the disc so that the pistons
can reach their base position.
– Loosen grub screw A.
– Pull out pin B while supporting the two pads (see figure).
– Remove the pads taking care not to drop the leaf spring above
them.
– To refit the parts, follow the reverse procedure. When fitting
the brake pads, ensure that the leaf spring is properly positioned.
WARNING: Always keep the brake disc free from oil and
grease as these substances greatly reduce the braking
action.
Every time the braking system is serviced, operate the brake
lever to bring the pads into contact with the disc, restore the correct pressure point and ensure proper operation of the braking
system.
A
B
Replacing the caliper pistons
After removing the caliper and the brake pads, repeatedly actuate the brake lever until the piston comes out of its seat, then remove the piston and the oil seal and replace them with new
parts from a spare kit.
Subsequently replenish and bleed the system (see Chapter 4 Maintenance). Only use DOT 4 or DOT 5.1 oil.
10 - Braking system
Release 01 Date 09/2007
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Pagina 1
11
ELECTRICAL SYSTEM
Pag. 1
18:59
Pagina 2
21
27-12-2007
23
25
20
29
35
2
14
13
12
11
10
9
8
7
6
5
4
3
2
1
15
38
16
36
37
17
34
27
26
18
32
33
28
30
19
31
24
22
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Pagina 3
WIRING DIAGRAM Euro 3
1) RIGHT-HAND FRONT TURN INDICATOR (12V-10W BULB)
2) FRONT BRAKE LIGHT BUTTON
3) START BUTTON
4) WHEEL REVOLUTION SENSOR
5) SCROLL BUTTON
6) TELL TALE LAMP (NO CONECT)
7) HEADLIGHT TELL TALE LAMP
8) TRAFFICATOR LIGHTS TELL TALE LAMP
9) DISPLAY
10) ENGINE STOP BUTTON
11) HORN BUTTON
12) HEADLIGHT SELECTOR
13) TURN SIGNAL LAMPS SWITCH
14) L.H. SWITCH
15) LH FRONT TURN SIGNAL (BULB 12V-10W)
16) UNIT TURN SIGNAL LAMPS
17) REGULATOR 12V
18) ELECTRIC FAN KIT (option)
19) LEFT-HAND REAR TURN INDICATOR (12V-10W BULB)
20) NUMBER-PLATE LIGHT (12V-5W BULB)
21) REAR LIGHT (12V-5/21W BULB)
22) RIGHT-HAND REAR TURN INDICATOR (12V-10W BULB)
23) BATTERY POSITIVE TERMINAL
24) BATTERY 12V-5Ah
25) GENERATOR
26) 10A FUSE
27) EARTH BRAID
28) STARTER RELAY
29) STARTER MOTOR
30) BATTERY NEGATIVE TERMINAL
31) ELECTRONIC CONTROL UNIT
32) SPARK.PLUG
33) AT COIL
34) REAR BRAKE LIGHT BUTTON
35) FRAME EARTH
36) PARKING LIGHT BULB, 12V-3W
37) HEADLIGHT WITH 12V-25/25W
38) 12V HORN
Key to colours
Bl = Blue
Ne = Black
Gi = Yellow
Rs = Red
Ar = Orange
Bi = White
Ve = Green
Ma= Brown
Vi = Purple
11 - Electrical system
Release 01 Date 09/2007
Az = Sky-blue
Ro = Pink
Gr = Grey
3
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Pagina 5
WIRING DIAGRAM RR4T USA
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
27)
WHEEL SENSOR
STARTING BUTTON
PUSHBUTTON SCROLL
NO CONNECT TELL TALE LAMP
NO CONNECT TELL TALE LAMP
NO CONNECT TELL TALE LAMP
DISPLAY
ENGINE STOP BUTTON
LIGHTS SWICH
CONTROL GROUP
REGULATOR
ELECTROVALVE KIT (OPTIONAL)
TAIL LAMP (LED)
FUSE 10 A
EARTH BRAID
POSITIVE BATTERY
STARTER RELAY
STARTER MOTOR
NEGATIVE BATTERY
BATTERY 12V-4AH
PICK-UP
ELECTRONIC CONTROL UNIT
AT COIL
SPARK PLUG
EARTH CONNECTION FRAME
POSITION LAMP 12V-5W
HEADLAMP 12V-35/35W
KEY TO COLOURS
BI
VE
MA
VI
BL
NE
GI
RS
AR
AZ
RO
GR
=
=
=
=
=
=
=
=
=
=
=
=
WHITE
GREEN
BROWN
PURPLE
BLUE
BLACK
YELLOW
RED
ORANGE
SKY-BLUE
PINK
GREY
11 - Electrical system
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Pagina 7
WIRING DIAGRAM RS4T USA
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
27)
28)
29)
30)
31)
32)
33)
34)
35)
36)
37)
38)
39)
40)
RIGHT-HAND FRONT TURN INDICATOR (12V-10W BULB)
FRONT BRAKE LIGHT BUTTON
START BUTTON
WHEEL REVOLUTION SENSOR
HIGH BEAM WARNING LIGHT
TURN INDICATOR WARNING LIGHT
DISPLAY
LOW BEAM WARNING LIGHT
NOT CONNECTED
MODE BUTTON
ENGINE STOP BUTTON
HORN BUTTON
LIGHTS SELECTOR SWITCH
TURN INDICATOR SWITCH
LEFT-HAND CONTROL SET
LEFT-HAND FRONT TURN INDICATOR (12V-10W BULB)
FLASHER UNIT
12V REGULATOR
LEFT-HAND REAR TURN INDICATOR (12V-10W BULB)
NUMBER-PLATE LIGHT (12V-5W BULB)
REAR LIGHT (12V-5/21W BULB)
RIGHT-HAND REAR TURN INDICATOR (12V-10W BULB)
BATTERY POSITIVE TERMINAL
BATTERY 12V-4AH
GENERATOR
10A FUSE
EARTH BRAID
STARTER RELAY
STARTER MOTOR
BATTERY NEGATIVE TERMINAL
REAR STOP LAMP RELAY
ELECTRONIC CONTROL UNIT
HV COIL
SPARK PLUG
CONDENSER
REAR BRAKE LIGHT BUTTON
FRAME EARTH
PARKING LIGHT BULB 12V-3W
HEADLIGHT WITH 12V-25/25W
12V HORN
KEY TO COLOURS
BI
VE
MA
VI
BL
=
=
=
=
=
WHITE
GREEN
BROWN
PURPLE
BLUE
11 - Electrical system
Release 01 Date 09/2007
NE
GI
RS
AR
AZ
=
=
=
=
=
BLACK
YELLOW
RED
ORANGE
SKY-BLUE
RO
GR
=
=
PINK
GREY
7
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Pagina 8
CONTENTS
Checking for leakage currents . . . . . . Chap. 11 - 5
Removing and reinstalling the battery Chap. 11 - 5
Charging the battery . . . . . . . . . . . . . . Chap. 11 - 5
Filling the battery . . . . . . . . . . . . . . . . Chap. 11 - 6
Checking the voltage regulators . . . . . Chap. 11 - 7
Checking the charging voltage . . . . . . Chap. 11 - 7
CDI unit . . . . . . . . . . . . . . . . . . . . . . . . Chap. 11 - 8
Checking the ignition coil . . . . . . . . . . Chap. 11 - 8
Troubleshooting the ignition system . Chap. 11 - 8
Main fuse . . . . . . . . . . . . . . . . . . . . . . . Chap. 11 - 9
Checking the starting relay . . . . . . . . . Chap. 11 - 9
Checking the starter motor . . . . . . . . Chap. 11 - 10
Instrument panel . . . . . . . . . . . . . . . . Chap. 11 - 10
8
Workshop manual RR 4T - 400 - 450 - 525
11_Inghilterra_059311
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Pagina 9
Checking for leakage currents
Check for leakage currents before inspecting the regulator-rectifier.
– Disconnect the ignition and remove the earth cable from the
battery.
– Connect and ampere meter between the earth cable and the
negative terminal of the battery.
Nominal value: max. 1 mA
– If the actual value exceeds the nominal value, proceed to
check the various users.
Possible malfunctions include:
• A faulty regulator-rectifier.
• A faulty capacitor.
• Leakage currents in the connectors, the ignition switch or the
starting relay.
0,00
Removing and reinstalling the battery
– Remove the saddle.
– Disconnect the negative terminal first and then the positive
terminal from the battery.
– Release elastic band 1 and remove the battery from the battery holder.
– When reinstalling the battery, first connect the positive terminal and then the negative terminal.
WARNING: TO PREVENT POSSIBLE LEAKAGE OF ACID, BE
SURE TO POSITION THE BATTERY TERMINALS AT THE
FRONT.
1
Charging the battery
– Remove the battery and measure its charge. Use a voltmeter
to measure the voltage between the battery terminals (voltage
at rest). Maximum tolerance of measuring instrument: 1 per
cent.
– To obtain a correct measurement, do not charge or discharge
the battery for at least 30 minutes before performing the operation.
– If the battery charge cannot be determined, the battery can be
charged for a maximum of 10 hours with 0.5 amperes and a
maximum of 14.4 volts.
IMPORTANT:
– NEVER REMOVE THE BATTERY PLUGS.
– TO RECHARGE THE BATTERY, FIRST CONNECT THE
BATTERY TO THE CHARGER AND THEN TURN ON THE
CHARGER.
– IF THE BATTERY IS CHARGED INDOORS, TAKE CARE TO
ENSURE PROPER VENTILATION. DURING THE CHARGE
THE BATTERY PRODUCES EXPLOSIVE GASES.
– IF THE BATTERY IS OVERCHARGED, OR IF THE CHARGING VOLTAGE IS EXCESSIVE, THERE MAY BE AN OUTFLOW OF ELECTROLYTE THROUGH THE SAFETY VALVES, WHICH WOULD CAUSE THE BATTERY TO LOSE
PART OF ITS CAPACITY.
11 - Electrical system
Release 01 Date 09/2007
Batterydicahrge
Voltage di
at rest
Tensione
riposo Stato
carica
%
Volts
Volt
%
>12,7
~12,5
~12,2
~12,0
~11,8
<11,5
100
75
50
25
0
0
Charge duration
Durata
di carica
0,5 AA
aat 0,5
––
4h
7h
11 h
14 h
20 h
Charge
voltage
Tensione
di
carica
Max.
14,4 V
9
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Pagina 10
Filling the battery
– Remove the battery and the electrolyte container from the
package.
Before starting to fill the battery, read through the enclosed instruction slip.
– Open the electrolyte container.
– Insert the electrolyte container in the battery filler openings
and push it down hard.
– When all container compartments are empty, remove the container from the battery.
– Carefully close the filler openings with the cover.
NOTE: After filling the battery, allow it to rest for at least half an
hour without charging it.
IMPORTANT: WHEN FILLING A NEW BATTERY, BE SURE TO
FOLLOW THE DIRECTIONS PROVIDED IN THE ENCLOSED
INSTRUCTION SLIP, WHICH ALSO PROVIDES THE SAFETY
RULES TO BE FOLLOWED. FAILURE TO OBSERVE THESE
RULES MAY LEAD TO SERIOUS PERSONAL INJURY.
10
Workshop manual RR 4T - 400 - 450 - 525
11_Inghilterra_059311
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Pagina 11
Checking the voltage regulators
If a regulator is suspected of being defective, it should be replaced, if possible, with one that is known to be in working order.
Alternatively, take a few measurements to determine whether it
is operating properly:
– While the engine is off, disconnect the regulator connector located on the frame under the tank.
– Use a digital multimeter designed for measurements of up to
20,000 Ω.
Checking the charging voltage
NOTE: The following values should be regarded as valid only
when the battery is charged (minimum charge 90 per cent).
– Start the engine and turn on the low beam.
– Connect a voltmeter to the two battery connections.
– Rev the engine to 5000 rpm and read the voltage.
Nominal value: 14.0 - 15.0 V
If the measured value differs considerably from the nominal value, follow these step:
– Check the plug between the stator and the regulator-rectifier
and the plug between the regulator-rectifier and the wiring
harness.
– Check the stator.
– Replace the regulator-rectifier.
Puntale NERO
BLACK
probe
Puntale
ROSSO
RED probe
1
2
3
4
∞
1
/
∞
∞
∞
2
3
4
∞
∞
∞
∞
∞
∞
/
∞
∞
/
∞
/
∞ ==Corresponds
the multimeter reading
when
Corrispontetoall’indicazione
che fornisce
RED quando
and BLACK
terminalsROSSO
are note in
contact
ilthe
tester
i terminali
NERO
non
with one
another. tra di loro.
sono
in contatto
11 - Electrical system
Release 01 Date 09/2007
1
2
3
4
Red
Yellow
Black
White
1
2
4
3
11
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Pagina 12
CDI unit
Check the wires and connectors of the CDI unit.
The operation of the CDI unit can only be checked on a specially
designed test bench for ignitions.
IMPORTANT: NEVER CHECK THE CDI UNIT WITH STANDARD MEASURING EQUIPMENT AS THIS COULD IRREPARABLY DAMAGE HIGHLY SENSITIVE ELECTRONIC COMPONENTS.
It is also possible to replace the control unit with one that is
known to be in working order to determine whether it is operating properly.
Checking the ignition coil
– Disconnect all the cables and unplug the spark plug.
– Using an ohmmeter, take the following measurements:
NOTE: The following measurements correspond to the nominal
values only at a temperature of 20° C.
If the measured values differ considerably from the nominal value, replace the ignition coil.
12
1
2
3
RED ROSSO
probe
Puntale
BLACK NERO
probe
Puntale
Troubleshooting the ignition system
Before checking the ignition system, verify the following:
• Emergency switch in on position.
• Battery charge.
• Main fuse.
Check if a spark is produced when the engine is started by following these steps:
– Remove the spark plug cap.
– Separate the spark plug cap from the ignition cable.
– Keep the free end of the ignition cable about 5 mm for an
earth connection.
– When the starter motor is operated, a bright electrical spark
should be produced. If the battery charge is very low, use the
kickstart.
– If a spark is produced, refit the spark plug cap.
– Unscrew the spark plug and insert it into the spark plug cap.
– Keep the spark plug connected to earth. When the electric
start is operated, a bright spark should be produced at the
electrode. If that is not the case, either the spark plug cap or
the spark plug is defective.
– If a spark is not produced at the first attempt, check the ignition switch and the wiring harness components.
– If the ignition system is correctly powered but no spark is produced, check the following:
• Earth connection of the CDI unit and the ignition coil.
• Wire connecting the CDI unit to the ignition coil.
• Stator.
• Ignition coil.
1
1
2
3
/
0,8
6150
2
0,8
/
6150
3
6150
6150
/
Tolerance ± 10 %
Tolleranza ± 10%
Tester for measurements up to 20.000 Ω
Tester per misure fino a 20.000 Ω
Workshop manual RR 4T - 400 - 450 - 525
11_Inghilterra_059311
27-12-2007
18:59
Pagina 13
Main fuse
Fuse 3 is installed in starting relay 4 under right-hand side panel 5.
To gain access to the fuse, remove the saddle and lift swinging
support 6 to expose the battery.
5
The fuse protects the following users:
– Electric start system.
– Horn.
– Indicators.
– Instrument panel.
The starting relay also contains spare fuse 7 (10 A).
A blown fuse should only be replaced with another of the same
type.
Should the new fuse also burn out when fitted, proceed to check
the electrical system.
The fuse has a capacity of 10 amperes.
WARNING:
Do not on any account fit a fuse of greater power or attempt to
“fix” the damaged fuse. Unsuitable servicing could cause damage to the entire electrical system.
6
4
3
Checking the starting relay
– Disconnect the starting relay multiple plug.
– Disconnect the negative terminal from the battery and the two
wires from the starting relay.
– Connect the starting relay to a 12 V battery.
– Using an ohmmeter, check continuity between terminals C
and D.
7
C
Note: 0 Ω in working order
Note: ∞ Ω defective
NOTE: A slight click can be heard when the starting relay trips.
D
11 - Electrical system
Release 01 Date 09/2007
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Pagina 14
Checking the starter motor
– Disconnect the battery negative terminal and remove the starter motor.
– Connect the negative terminal of a 12 V battery to the starter
motor casing and momentarily connect the battery positive
terminal with starter motor connector 3 (use thick cables).
– When the electrical circuit is closed, the starter motor should
begin to turn.
– If that is not the case, replace the starter motor.
14
Workshop manual RR 4T - 400 - 450 - 525