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EVO 4T
Thanks for you preference, and have a good time! This handbook contains the information you need to properly operate and maintain your motorcycle.
The data and specifi cations provided in this manual does not constitute an engagement on the part of BETAMOTOR S.p.A. BETAMOTOR reserves the right to make any changes and improvements to its models at any moment and without notice.
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IMPORTANT
We recommend you to check all the tightenings after the fi rst one or two hours’ ride over rough ground. Special attention should be paid to the following parts:
• rear sprocket
• ensure that the footrests are properly fi xed
• front/rear brake levers/calipers/discs
• check that the plastics are properly fastened
• engine bolts
• shock absorber bolts/swingarm
• wheel hubs/spokes
• rear frame
• pipe connections
• tensioning the chain
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IMPORTANT
For any servicing requirements, please get in contact with Betamotor’s authorized service network.
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TABLE OF CONTENTS
Operating instructions ............................................................................. 5
Ecologic guide ....................................................................................... 5
Riding safety ......................................................................................... 6
CHAPTER 1 GENERAL INFORMATION .............................................. 7
Vehicle identifi cation data ....................................................................... 8
Familiarizing with the vehicle................................................................... 9
Specifi cations ...................................................................................... 10
Electrical system ................................................................................... 14
Recommended lubricants and liquids ...................................................... 18
CHAPTER 2 OPERATION .................................................................. 19
Main parts .......................................................................................... 20
Checks before and after use .................................................................. 24
Breaking in.......................................................................................... 24
Fuelling ............................................................................................... 25
Startup ................................................................................................ 26
Engine shut-down ................................................................................. 26
CHAPTER 3 ADJUSTMENTS .............................................................. 27
Brakes ................................................................................................ 28
Clutch ................................................................................................. 29
Adjustment of gas clearance .................................................................. 29
Accelerator ......................................................................................... 30
Handlebar .......................................................................................... 30
Adjusting fork ...................................................................................... 30
Shock absorber.................................................................................... 31
Suspension adjustment according to the motorcyclist’s weight .................... 32
CHAPTER 4 CHECKS AND MAINTENANCE ..................................... 33
Key to symbols..................................................................................... 34
Engine oil ............................................................................................ 34
Coolant .............................................................................................. 36
Air fi lter .............................................................................................. 38
Spark plug .......................................................................................... 40
Carburetor .......................................................................................... 41
Front Brake .......................................................................................... 42
Rear brake .......................................................................................... 44
Clutch control ...................................................................................... 45
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Steering gear....................................................................................... 47
Oil fork ............................................................................................... 48
Tyres................................................................................................... 52
Chain ................................................................................................. 53
Headlight ............................................................................................ 55
Rear tail light ....................................................................................... 56
Cleaning the vehicle ............................................................................. 57
Prolonged inactivity .............................................................................. 58
Scheduled maintenance vehicle ............................................................ 59
CHAPTER 5 TROUBLESHOOTING .................................................... 61
Troubleshooting ................................................................................... 62
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4
OPERATING INSTRUCTIONS
• The vehicle must be accompanied by: number-plate, registration document, tax disc and insurance.
• Do not carry animals, pets or loose objects that can stick out from the vehicle.
• Riding without a crash helmet is forbidden.
• Always ride with the low beam on.
• Any modifi cations of the engine or other parts resulting in a power and/or speed increase are punishable by severe sanctions including the confi scation of the vehicle.
• To protect your safety and that of others, always drive carefully and with your helmet on.
WARNING
Any modifi cations and tampering with the vehicle during the warranty period exempt the manufacturer from all responsibility and invalidate warranty.
ECOLOGIC GUIDE
• Every vehicle powered by an internal combustion engine produces an amount of noise (noise pollution) and gases (air pollution) which varies with the riding style.
• The abatement of noise and air pollution levels is the duty of everybody. Avoid full-throttle starts, sudden acceleration and abrupt braking. This will reduce noise emission as well as the wear and tear of the tyres and mechanical parts, and will also allow a considerable reduction in fuel consumption.
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RIDING SAFETY
• Observe the Highway Code.
• Always put on and fasten a homologated helmet.
• Always ride with the low beam on.
• Always keep the crash helmet visor clean.
• Avoid wearing garments with hanging ends.
• Do not keep sharp or brittle objects in your pockets while riding.
• Properly adjust the rearview mirrors.
• Always ride in a seated position, with both hands on the handlebars and both feet on the footrests.
• Always pay attention and do not allow anything to distract you while riding.
• Do not eat, drink, smoke, use a mobile phone, etc. while riding.
• Do not wear headphones to listen to music while riding.
• Never ride abreast with other vehicles.
• Do not tow and avoid being towed by other vehicles.
• Always keep a safe distance from other vehicles.
• Do not sit on the vehicle when it is on its stand.
• Do not start off while the vehicle is on its stand.
• Do not pull out the stand when the vehicle is facing downhill.
• Avoid swaying and wheelies as they are extremely dangerous for your own and other people’s safety as well as for your vehicle.
• Always apply both brakes on dry roads with no gravel and sand. Using one brake may be dangerous and cause uncontrolled skidding.
• To reduce the braking distance, always apply both brakes.
• On wet roads and in off-road riding, drive with care and at moderate speed. Take special care in applying the brakes.
• Do not start the engine in closed places.
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CHAPTER 1 GENERAL INFORMATION
CONTENTS
Vehicle identifi cation data ....................................................................... 8
Frame identifi cation ........................................................................... 8
Engine identifi cation .......................................................................... 8
Familiarizing with the vehicle................................................................... 9
Main parts ........................................................................................ 9
Specifi cations ...................................................................................... 10
Weight ........................................................................................... 10
Vehicle dimensions .......................................................................... 10
Tyres .............................................................................................. 10
Capacities ...................................................................................... 10
Front suspension .............................................................................. 11
Rear suspension .............................................................................. 11
Front brake ..................................................................................... 11
Rear brake ..................................................................................... 11
Engine ........................................................................................... 12
Carburetor ...................................................................................... 12
Gear box ....................................................................................... 13
Electrical system ................................................................................... 14
Electrical diagram for homologated version ........................................ 14
Legend electrical diagram for homologated version ............................. 15
Electrical diagram for race version .................................................... 16
Legend electrical diagram for race version ......................................... 17
Recommended lubricants and liquids ...................................................... 18
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1
A
B
VEHICLE IDENTIFICATION
DATA
FRAME IDENTIFICATION
Frame identifi cation data A are stamped on the right side of the steering head tube.
ENGINE IDENTIFICATION
Engine identifi cation data B are stamped in the area shown in the picture.
In order to read it correctly, it is necessary to remove the silencer and disconnect the regulator connector.
WARNING:
Tampering with the identifi cation numbers is severely punished by law.
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FAMILIARIZING WITH THE VEHICLE
6
2
13
19
17
5
1
1
18
7 16
12
8
14
3
MAIN PARTS
1 Fuel tank
2 Tank cap
3 Silencer
4 Rear shock absorber
5 Headlight
6 Rear light
7 Side stand
8 Fork
9 Rider’s footrests
10 Lower bumper
11 10 15
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11 Engine
12 Front mudguard
13 Rear mudguard
14 Kick-start
15 Gear lever
16 Rear brake lever
17 Front brake lever
18 Clutch lever
19 Throttle
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1
SPECIFICATIONS
WEIGHT
Dry weight .....................................................................................72 kg
VEHICLE DIMENSIONS maximum length ........................................................................ 2005 mm maximum width .......................................................................... 850 mm wheelbase................................................................................ 1305 mm maximum height ....................................................................... 1115 mm ground clearance ........................................................................ 310 mm saddle height .............................................................................. 660 mm
TYRES
Dimensions
Front tyre
2,75 - 21
Rear tyre
4,00 - 18
Pressure [Bar]
Front tyre Rear tyre
0,4 ÷ 0,5 0,3 ÷ 0,4
CAPACITIES fuel tank ......................................................................................2,8 liters coolant circuit ................................................................................600 ml engine oil ......................................................................................900 ml
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FRONT SUSPENSION
Version
Wheel excursion [mm]
EVO 250
Right fork leg
166
Left fork leg
K spring
[N/mm]
Oil type
Oil level [mm]
(edge rod with fork compressed)
Register spring preload
X
65
X
7,65
125
Full open
X
65
X
EVO 300
Right fork leg
Shell Tellus S2 V32 SAE 6,1
166
Left fork leg
7,65
125
Full open
Click in extension Full open X Full open X
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REAR SUSPENSION
Version EVO 250 k spring 70N/mm
Length (spring in its seat) [mm]
Oil type
EVO 300
70N/mm
136 136 oil titan SAF 5045 Eu 137 RED
Click in extension Full open Full open
FRONT BRAKE disk-type with hydraulic control Ø 185 mm
REAR BRAKE disk-type with hydraulic control Ø 160 mm
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1
ENGINE
Version
Type
Bore x stroke
Displacement [cm 3 ]
Pressure ratio
Fuel system
EVO 250
Single-cylinder, 4-stroke
77 x 53,6
EVO 300
Single-cylinder, 4-stroke
84 x 53,6
249,6
11,5:1
297
11,4:1 carburetor carburetor
CARBURETOR
Version
Carburetor type
Main jet
Slow jet
Start jet
Needle
Needle position
(from top)
120
60
2°
EVO 250
Homologated Competition* Homologated Competition*
SE BSR33-79
17,5
5D132
127,5
27,5
60
5D132
3°
120
17,5
60
2°
EVO 300
SE BSR33-79
5D132
120
27,5
60
5D132
3°
Air screw turns
(from all closed)
3+1/2 2+1/2 3+1/2 2
Spacer YES NO YES NO
* Such modifi cation makes the vehicle non-compliant with the road regulations in force. Its use must be limited to the sole private circuits which are closed to circulation.
Cooling system ......................................... forced liquid circulation by pump
Spark plug ............................................................................ NGK CR7EB
Clutch .................................................................................. wet, multidisc
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GEAR BOX
Version
Primary drive
Gear ratio 1st gear
Gear ratio 2nd gear
Gear ratio 3rd gear
Gear ratio 4th gear
Gear ratio 5th gear
Secondary drive
EVO 250
18/63
13/36
15/36
16/30
24/27
28/21
EVO 300
18/63
13/36
15/36
16/30
24/27
28/21
Homologated Competition* Homologated Competition*
42/13 42/11 42/13 42/11
* Such modifi cation makes the vehicle non-compliant with the road regulations in force. Its use must be limited to the sole private circuits which are closed to circulation.
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Ignition ...........................................................electronic Hidria 12V-120W
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ELECTRICAL SYSTEM
ELECTRICAL DIAGRAM FOR HOMOLOGATED VERSION
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LEGEND ELECTRICAL DIAGRAM FOR HOMOLOGATED VERSION
1) R.H. front turn signal with bulb 12V - 10W
2) Headlamp (double fi lament bulb) 12V-35/35W
3) Position light with bulb 12V - 5W
4) High beam indicator light with bulb 12V 1,2W
5) Dashboard indicator light with bulb 12V 1,2W
6) Turn signal indicator light with bulb 12V 1,2W
7) L.H. front turn signal with bulb 12V - 10W
8) Engine stop button button
10) Light switch
11) Turn signal switch
12) Blinker
13) Rear brake stop button
14) L.H. rear turn signal with bulb 12V - 10W
15) Tail light with bulb 12V - 5/21W
16) R.H. rear turn signal with bulb 12V - 10W
17) Connector connected to the fuel cock
18) Condenser 4700µF - 25V
19) Switch for change mapping
20) Pick-up
21) Generator
22) H.T. coil
23) Electronic control unit
24) Regulator 12V
25) Thermal switch
26) Electrofan
27) Frame earth
28) Horn 12V
29) Frame earth
30) Front brake stop button
1
Key to colours
Bi = White
Ve = Green
Ma = Brown
Vi = Purple
Bl = Blue
Ne = Black
Gi = Yellow
Rs = Red
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Ar = Orange
Az = Sky-blue
Ro = Pink
Gr = Grey
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ELECTRICAL DIAGRAM FOR RACE VERSION
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LEGEND ELECTRICAL DIAGRAM FOR RACE VERSION
1) Headlamp with bulb 12V-20W
12V cock button
5) Engine stop button
6) Condenser 4700µF - 25V
7) Light switch (black)
8) Switch for change mapping (yellow)
9) Tail light with bulb 12V - 3W
10) Generator
11) Pick-up
12) H.T. coil
13) Electronic control unit
14) Regulator 12V
15) Thermal switch
16) Electrofan
17) Frame earth
1
Key to colours
Bi = White
Ve = Green
Ma = Brown
Vi = Purple
Bl = Blue
Ne = Black
Gi = Yellow
Rs = Red
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Ar = Orange
Az = Sky-blue
Ro = Pink
Gr = Grey
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1
RECOMMENDED LUBRICANTS AND LIQUIDS
For better operation and longer vehicle life, we advise you to use the products listed in the following chart:
Engine Oil: 850cc
Brake Fluid
Coolant/Antifreeze
Fork Oil
Air Filter Oil
Air Filter Cleaner
Grease
Motul 7100 10w40
(For Competition use Motul 300V 10w40)
Motul RBF 600
Motul Motocool Expert
Motul Factory Line 5 wt.
Motul Air Filter Oil
Motul Air Filter Clean
Motul Tech 300
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CHAPTER 2 OPERATION
CONTENTS
Main parts .......................................................................................... 20
Fuel cock ........................................................................................ 20
Starter ............................................................................................ 20
Hot start ......................................................................................... 20
Clutch lever .................................................................................... 21
LH switch ........................................................................................ 21
RH switch ....................................................................................... 21
Front brake lever and gas control ...................................................... 22
Gearchange lever............................................................................ 22
Brake pedal .................................................................................... 22
Kick-start ........................................................................................ 22
Checks before and after use .................................................................. 24
Breaking in.......................................................................................... 24
Fuelling ............................................................................................... 25
Startup ................................................................................................ 26
Engine shut-down ................................................................................. 26
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2
MAIN PARTS
FUEL COCK
Fuel valve has two positions:
C : OFF Automatic. If the engine is shut off, the fuel supply is switched off and the fuel cannot fl ow from the tank to the carburetor.
A: fuel supply always enabled. The fuel passes from the tank to the carburetor even with the engine off.
2
1
STARTER
The starter lever 1 is located on the carburettor.
To use, pull it out.
HOT START
The hot start 2 is located on the intake manifold.
To use, pull it out.
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CLUTCH LEVER
Clutch lever 1 is fi tted to the left-hand side of the handlebars. Screw A can be used to alter the home position of the lever (see
Adjustments).
1
A
LH SWITCH
The off switch is positioned on the left-hand side of the handlebar and consists of the following: shutdowns engine: it is necessary to hold it until the engine stops.
RH SWITCH
The lights and services switch is located on the right-hand side of the radiator and consists of the following:
1 Rear light power on/off
2 Mapping change switch
By acting on the switch shown in the fi gure, it is possible to select one of two possible mappings for the ignition advance.
With the switch in position A, “soft” mapping more suited to muddy terrain and for a gentler response of the bike is selected.
With the switch in position B “hard” mapping that is more suitable for dry land and for a more aggressive response of the bike is selected.
A
1
21
2
B
2
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2
1
FRONT BRAKE LEVER AND GAS
CONTROL
The front brake lever 1 and the gas throttle 2 are located on the right side of the handlebar.
2
3
N
4
1
5
2
GEARCHANGE LEVER
Gearchange lever is fi tted to the left side of the engine.
The positions corresponding to the different gears are shown in the fi gure.
BRAKE PEDAL
Brake pedal is located in front of the righthand footrest.
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KICK-START
The kick-start pedal is located on the right side of the engine. The upper part is rotatable
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SIDE STAND
Press down side stand with the foot and lean the vehicle against it.
Ensure that the ground is solid and the vehicle stands steadily.
WARNING! The kickstand has an automatic closing device. When the vehicle weight on the kickstand is reduced, it closes automatically.
2
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2
CHECKS BEFORE AND AFTER USE
For safe driving and long vehicle life you should:
• Check all fl uid levels.
• Check the correct operation of the brakes and brake pad wear (page 43).
• Check pressure, general condition and thickness of tread (page 10).
• Check that the spokes are properly tightened.
• Check the chain tension (page 54).
• Check the adjustment and the operation of all the cable controls.
• Inspect all the nuts and bolts.
• With the engine running, check the operation of the headlight, the rear and brake lights, the indicators, the warning lights and the horn.
• Wash the motorcycle thoroughly after off-road use (page 58).
BREAKING IN
The breaking-in period lasts approximately 10 hours, during which it is advisable to:
•
The engine speed should not exceed 7000 rpm.
power.
WARNING:
After the fi rst 3 hours to replace the engine oil.
This procedure should be followed each time piston, piston rings, cylinder, crankshaft or crankshaft bearings are replaced.
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FUELLING
Use unleaded gasoline.
Fuel tank capacity is shown on page
10.
To open the fuel tank’s cap, turn it anticlockwise.
To close the fuel tank’s cap, set it on the tank and crew it clockwise.
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STARTUP
Set the fuel tank tap to A (see page 20).
- Check that the gears are in neutral (page
22).
- Pull the clutch lever (page 21).
KICKSTART (page 22): depress the kick-starter with a sharp movement of the foot.
ATTENTION
Once the pedal has been depressed, release it immediately. This avoids jolts to the entire ignition group and to the foot.
COLD STARTING: operate the starter (page 20), start the vehicle, wait a few seconds, then move the starter back to its starting position.
HOT STARTING: operate the hot start (page 20), WITH-
OUT stepping on the gas to start the vehicle, wait a few seconds, then return the hot start to the initial position.
Once you start the engine, turn the fuel cock to the “C” position.
STARTING WHEN THE BIKE HAS FALLEN
OVER:
If the bike falls over, the carburettor fl oat bowl may empty. In this case, follow the procedure for starting a warm engine.
ENGINE SHUT-DOWN
To shut-down the engine:
- press the button on the left switch unit
(see page 21).
NOTE:
With the engine off, make sure the fuel cock is set to C (page 20).
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CHAPTER 3 ADJUSTMENTS
CONTENTS
Brakes ................................................................................................ 28
Front brake ..................................................................................... 28
Rear Brake...................................................................................... 28
Clutch ................................................................................................. 29
Adjustment of gas clearance .................................................................. 29
Accelerator ......................................................................................... 30
Adjusting the idle speed ................................................................... 30
Handlebar .......................................................................................... 30
Adjusting fork ...................................................................................... 30
Adjusting the rebound damper .......................................................... 30
Adjusting the spring preload ............................................................. 31
Shock absorber.................................................................................... 31
Adjusting the rebound damper .......................................................... 31
Adjusting the spring preload ............................................................. 32
Suspension adjustment according to the motorcyclist’s weight .................... 32
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3
1
2
BRAKES
FRONT BRAKE
The front brake is disk type with hydraulic control.
The position of the lever is controlled through the use of register 1.
Once the position of the lever has been changed, register 2 must be changed to restore the initial correct clearance.
WARNING: reduced play causes brake overheating leading to sudden lockup.
2
1
REAR BRAKE
The rear brake is disk type with hydraulic control. You may adjust pedal height by means of register 1.
Once you change the original pedal position you need to modify regulator 2 on the brake pump to allow you to reset the correct pump travel.
WARNING: reduced play causes brake overheating leading to sudden lockup.
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CLUTCH
The position of the lever is controlled through the use of register 1.
Once the position of the lever has been changed, register 2 must be changed to restore the initial correct clearance.
2
The idle stroke of push rod must not be less than 0.9 mm
ATTENTION: reduced clearance leads to premature wear of the discs and overheating of the entire clutch group.
0,9 mm
1
3
ADJUSTMENT OF GAS
CLEARANCE
The throttle control cable should always have a 3-5 mm play. In addition, the idle speed should not change when the handlebars are fully rotated to the left or right.
To adjust the clearance proceed as follows:
- Loosen ring 1.
- Rotate register 2 with respect to sheath 3.
- Tighten ring 1.
3
2 1
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29
3
1
20Nm
A
ACCELERATOR
ADJUSTING THE IDLE SPEED
In order to perform this operation correctly, we advise you to do it when the engine is hot, connecting an electric revolution counter to the spark plug wire. Then use a screwdriver on register screw A to calibrate the minimum with 1.100÷1.200 rpm.
HANDLEBAR
The handlebar can be adjusted by rotating it back and forth.
- To adjust the handlebar loosen screws 1.
- Position the handlebar according to requirements.
- Tighten to the torque indicated.
1
ADJUSTING FORK
ADJUSTING THE REBOUND
DAMPER
The hydraulic brake unit in extension determines the behaviour in the extension phase of the fork and can be adjusted using screw 1. Turning clockwise increases the action of the brake in extension, while rotating counter-clockwise decreases the action of the brake in extension.
For standard calibration, refer to page
11 .
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ADJUSTING THE SPRING
PRELOAD
Spring preload is adjusted by means of screw 2. Turning clockwise will increase the preload, while rotating counter- clockwise decreases the preload.
For standard calibration, refer to page
11.
2
3
SHOCK ABSORBER
ADJUSTING THE REBOUND
DAMPER
The hydraulic brake unit in extension determines the behaviour in the extension phase of the shock absorber and can be adjusted using screw 1. Turning clockwise increases the action of the brake in extension, while rotating counter-clockwise decreases the action of the brake in extension.
For standard calibration, refer to page
11.
NOTE: for adjustment use a T-handle wrenches with jointed hexagonal socket.
31
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3
1
2
ADJUSTING THE SPRING
PRELOAD
To adjust the spring preload, use the procedure described below.
Loosen counter-ring 1, rotate ring 2 clockwise to increase the spring preload (and consequently the shock absorber preload) or anticlockwise to decrease it.
After obtaining the desired preload, turn counter-ring 1 until it stops against adjusting ring 2.
For standard calibration, refer to page
11.
NOTE: for movement of the rings use a specifi c sector key with square pin
SUSPENSION ADJUSTMENT
ACCORDING TO THE
MOTORCYCLIST’S WEIGHT
The following table shows the approximate calibration of the suspension adjustment according to the motorcyclist’s weight.
w < 70 Kg 70 Kg < w < 80 Kg 80 Kg < w
Fork
Adjustment
Standard
Shock absorber
Standard
Fork
Adjustment
+ 5 turns preload
Shock absorber
+ 1,5 turns preload
Fork
Adjustment
+ 10 turns preload
Shock absorber
+ 3 turns preload
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CHAPTER 4 CHECKS AND MAINTENANCE
CONTENTS
Key to symbols..................................................................................... 34
Engine oil ............................................................................................ 34
Check the level ................................................................................ 34
Replacement ................................................................................... 34
Coolant .............................................................................................. 36
Check the level ................................................................................ 36
Replacement ................................................................................... 37
Radiator grill ................................................................................... 38
Air fi lter .............................................................................................. 38
Removing and fi tting air fi lter ............................................................ 38
Cleaning air fi lter ............................................................................ 39
Spark plug .......................................................................................... 40
Carburetor .......................................................................................... 41
Draining the carburetor fl oat chamber ................................................ 41
Front Brake .......................................................................................... 42
Check the level of the front brake fl uid ............................................... 42
Restoring the level of the front brake fl uid ........................................... 42
Bleeding the front brake ................................................................... 43
Front brake lining control .................................................................. 43
Rear brake .......................................................................................... 44
Check the level of the rear brake fl uid ................................................ 44
Restoring the level of the rear brake fl uid ............................................ 44
Bleeding the rear brake .................................................................... 44
Rear brake lining control .................................................................. 45
Clutch control ...................................................................................... 45
Check oil level ................................................................................ 45
Bleeding clutch control ..................................................................... 46
Steering gear....................................................................................... 47
Check of steering gear ..................................................................... 47
Oil fork ............................................................................................... 48
Removing legs ................................................................................. 48
Oil replacement right leg .................................................................. 48
Oil replacement left leg .................................................................... 49
Legs assembly and parts ................................................................... 50
Linkage rear suspension ................................................................... 51
Tyres................................................................................................... 52
Chain ................................................................................................. 53
Check and adjust tightening chain ..................................................... 53
Headlight ............................................................................................ 55
Replacing the headlight bulbs ........................................................... 55
Rear tail light ....................................................................................... 56
Cleaning the vehicle ............................................................................. 57
Prolonged inactivity .............................................................................. 58
Scheduled maintenance vehicle ............................................................ 59
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4
MAX
MIN
2
1
KEY TO SYMBOLS
Threadlocker medium intensity
ENGINE OIL
CHECK THE LEVEL
The engine oil level must be checked when the engine is warm.
Let the engine run for a few minutes then turn it off.
Keep the vehicle in vertical position relative to the ground.
Wait a few minutes and check the oil level through the window 1.
The level must be between the limits indicated in the picture.
Otherwise restore the oil level through 2.
Use the oil indicated on page 18 in the “Recommended lubricants and liquids” table.
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REPLACEMENT
Always perform the replacement when engine is hot:
- Position the drive on a fl at base ensuring stability.
- Place a container under the engine.
- Unscrew the fi ller cap 2 and the drain plug 3.
- Completely empty the crankcase.
- Close the cap 3.
34
- Unscrew the plug 4 in the left-hand casing and use pliers to extract the fi lter.
Clean it carefully and blow it through with compressed air. Check for damage to the
O-rings, and replace them if necessary.
Refi t all the parts and tighten the plug to
15 Nm.
4
4
- Perform the same procedure for the fi lter located on the right side of crankcase.
- Put a drawn pan under the engine closer to the paper fi lter cover 1 and then unscrew 2 the cover.
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35
2
10Nm
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- Extract the paper fi lter using pliers. Check the condition of the O-ring too, and replace it if necessary.
Change the fi lter and refi t the cover, tightening the three M6x20 bolts to 10
Nm.
- Pour in the quantity of oil indicated on page 10.
- Use the oil indicated on page 18 in the “Recommended lubricants and liquids” table.
- Close the fi ller cap 1.
WARNING:
Hot oil can cause severe burns!
1
COOLANT
CHECK THE LEVEL
Keep the vehicle in vertical position relative to the ground.
The level of the coolant must be checked when the engine is cold. Use the following procedure:
Unscrew cap 1 and ensure that the liquid is visible in the lower portion of the loading tube.
Where the liquid is not visible in the lower part of the loading tube position the vehicle as in the fi gure and then top up.
Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table.
36
REPLACEMENT
Position the vehicle on a fl at base and in a stable manner.
Replacement of the coolant must take place when the engine is cold.
1) Unscrew cap 1.
in a container.
3) Drain the liquid.
washer.
5) Unscrew drain screw 3 and fi ll until the liquid starts to overfl ow the screw.
6) Tighten screw 3.
1
2 10Nm
3 10Nm
4
7) Place the vehicle as shown and proceed to fi lling.
8) Reapply the loading cap 1.
The amounts of liquid are shown on page
10.
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1
2
RADIATOR GRILL
Should the grill be obstructed proceed as follows:
Remove the grill by pulling it towards the front of the vehicle.
Shake and wash the grill.
Reapply the grill pushing it towards the radiator.
AIR FILTER
Check after every ride.
REMOVING AND FITTING AIR
FILTER
To access the fi lter:
- Loosen the fastening screw 1 of the rear cover.
- Remove the fi lter frame and the fi lter by unscrewing the screw 2.
WARNING:
After every intervention, check that nothing has been left inside the fi lter box.
- Reassemble by performing the operations in reverse order.
GB
38
CLEANING AIR FILTER
- Thoroughly wash the fi lter with water and soap.
- Dry the fi lter.
- Wet the fi lter with specifi c oil and then remove the excess oil to prevent it from dripping.
- If necessary also clean the interior of the fi lter box.
WARNING:
Do not clean the fi lter with gasoline or petrol.
NOTE:
If the fi lter is damaged, replace it immediately.
Verify the integrity of water proofing gaskets on air box shown in the picture.
Change them if these are damaged.
To replace, contact authorised Betamotor customer service.
WARNING:
Never use the vehicle if the air fi lter is not in place. The infi ltration of dust and dirt can cause damage and considerable wear.
WARNING:
After each operation check that no object is left in the fi lter box.
39
4
GB
4
0,5÷0,6 mm
SPARK PLUG
Keeping the spark plug in good condition will reduce fuel consumption and increase engine performance.
To perform the check, simply slide off the electrical connection tube and unscrew the spark plug. Examine the distance between the electrodes with a feeler. This distance should be from 0.5÷0.6 mm. If it is not, it may be corrected by bending the earth electrode.
Check as well that there are no cracks in the insulation or corroded electrodes. If so, replace immediately.
When replacing the spark plug, screw it in by hand until it stops, then tighten with a wrench.
WARNING:
Do not check while the engine is hot.
GB
40
CARBURETOR
DRAINING THE CARBURETOR
FLOAT CHAMBER
If the carburetor tank needs to be emptied, proceed as described. Perform the operation once the engine is cold.
Turn the fuel cock to the “C” position (see page 20)
Place tube 1 in a container to gather the fuel that fl ows out.
Loosen screw 1 and drain the fuel until complete emptying of the tank.
Tighten screw 1.
WARNING
Fuel is fl ammable and toxic and must be handled with great care. Never work on the fuel system near heat sources or open fl ames. Always allow the engine to cool down before working on the fuel system.
Wipe off any excess fuel with a rag. Materials soaked in fuel are also fl ammable. In case of ingestion or contact with sensitive parts of the body immediately seek medical attention. Fuel is to be disposed of as prescribed by law.
1
2
4
41
GB
4
A
2
1
FRONT BRAKE
CHECK THE LEVEL OF THE FRONT
BRAKE FLUID
Check the level of the brake fl uid through sight A. The level of the fl uid should never fall below the mark in the sight.
RESTORING THE LEVEL OF THE
FRONT BRAKE FLUID
To restore the level of the brake fl uid, loosen the two screws 1, lift cap 2 and add brake fl uid until its level is 5 mm below the upper rim of the reservoir.
Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table.
WARNING:
The brake fl uid is extremely corrosive. Take care not to spill it on the paintwork.
GB
42
BLEEDING THE FRONT BRAKE
To bleed air from the front brake circuit, proceed as follows:
•Remove the rubber cap 1 from the valve
2.
•Open the sump cap.
•Insert one end of a transparent tube into a container.
•Pump with the brake lever 2/3 times and keep the lever pressed.
•Unscrew the valve and let the oil drain.
•If are still visible in the tube repeat above operation until obtaining a continuous outfl ow of oil within no air bubbles.
•Close the valve and release the lever.
NOTE:
During this procedure, continuously top up the brake pump thank to replace the oil that is out fl owing.
•Remove the tube.
•Replace the rubber cap.
Close the oil reservoir cap.
2
1
FRONT BRAKE LINING CONTROL
In order to verify the wear condition of front brake is enough to view the caliper from the bottom, where is possible to glimpse the brake lining tails which will have to show a brake of 2 mm in thickness. If the stratum is lesser let’s start replacing them.
NOTE:
Perform the check according to the times shown in the table on page 59.
To replace, contact authorised Betamotor customer service.
43
2 mm
4
GB
4
A
1
2
2
1
REAR BRAKE
CHECK THE LEVEL OF THE REAR
BRAKE FLUID
Check the level of the brake fl uid through sight A. The level of the fl uid should never fall below the mark in the sight.
RESTORING THE LEVEL OF THE
REAR BRAKE FLUID
To restore the level of the brake fl uid, loosen the two screws 1, lift cap 2 and add brake fl uid until its level is 5 mm below the upper rim of the reservoir.
Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table.
WARNING
The fl uid is extremely corrosive. Take care not to spill it on the paintwork.
BLEEDING THE REAR BRAKE
To bleed air from the rear brake circuit, proceed as follows:
• Remove the rubber cap 1 from the valve
2.
• Open the sump cap.
• Insert one end of a transparent tube into a container.
• Pump with the brake lever 2/3 times and keep the lever pressed.
• Unscrew the valve and let the oil drain.
• If are still visible in the tube repeat above operation until obtaining a continuous outfl ow of oil within no air bubbles.
• Close the valve and release the lever.
GB
44
NOTE:
During this procedure, continuously top up the brake pump thank to replace the oil that is out fl owing.
•Remove the tube.
•Replace the rubber cap.
Close the oil reservoir cap.
REAR BRAKE LINING CONTROL
In order to verify the wear condition of rear brake is enough to view the caliper from the back side, where is possible to glimpse the brake lining tails which will have to show a brake of 2 mm in thickness. If the stratum is lesser let’s start replacing them.
NOTE:
Perform the check according to the times shown in the table on page 59.
To replace, contact authorised Betamotor customer service.
2 mm
4
CLUTCH CONTROL
CHECK OIL LEVEL
To check the oil level in the clutch pump, fi rst remove cover 1.
Remove the two screws 2 and take off cover 1 together with the rubber bellows.
With the clutch pump in a horizontal position, the level of the oil should be 5 mm below the upper rim.
45
1
2
GB
4
If the level is lower than indicated proceed with refi lling.
Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table.
WARNING:
The fl uid is extremely corrosive. Take care not to spill it on the paintwork.
GB
2
1
BLEEDING CLUTCH CONTROL
• Remove the rubber cap 1 from the valve 2.
• Open the sump cap.
• Insert one end of a trasparent tube into a container.
• Pump with the brake lever 2/3 times and keep the lever pressed.
• Unscrew the valve and let the oil drain.
• If are still visible in the tube repeat above operation until obtaining a continuous outfl ow of oil within no air bubles.
• Close the valve and release the lever.
NOTE:
During this procedure, continuosly top up the brake pump thank to replace the oil that is out fl owing.
• Remove the tube.
• Replace the rubber cap.
46
STEERING GEAR
CHECK OF STEERING GEAR
Periodically check the play in the steering sleeve by moving the fork back and forth as shown in the fi gure. Whenever you feel play, adjust as described below:
4
Loosen the screws 1.
Loosen the screw 2.
Take up the play by means of nut 3.
Tighten the screws to the specifi ed torque values .
47
1
10Nm
3
2
10Nm
GB
4
1
OIL FORK
The procedure for changing the oil in the forks is provided only for information.
We recommend having the operation performed by a BETAMOTOR authorized workshop.
REMOVING LEGS
To replace, proceed as follows:
Position the vehicle on the central bike stand.
Remove the front wheel.
Remove the mudguard, the brake caliper and brake disc cover.
Loosen the screws 1 and pull off the stems.
GB
2
OIL REPLACEMENT RIGHT LEG
Unscrew upper plug 2.
Unscrew fi xing lock nut and take off the plug.
Unscrew the fi xing screw of the cartridge positioned under the fork leg, and extract the cartridge.
48
Empty the fork leg and the cartridge, draining all the oil inside.
Reassemble the cartridge on the fork leg tightening the fi xing screw, then refi ll oil in the cartridge.
Pour in the quantity of liquid indicated on page 11.
Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table.
Reassemble the plug on the rod, tighten the lock nut and, extending the fork leg.
3
OIL REPLACEMENT LEFT LEG
Unscrew upper plug 3.
Remove the spring and totally empty the oil.
Pour in the quantity of liquid indicated on page 11.
Reassemble the spring and extend fork leg.
Apply and tighten cap 3.
4
GB
49
4
10Nm
50Nm
1 10Nm
25Nm
LEGS ASSEMBLY AND PARTS
Apply the legs to the vehicle and tighten the screws 1 to the torque indicated.
ATTENTION: Tightening of the screws should be carried out by adjusting the torque wrench to to the stability torque with repeated tightening until stability torque has been achieved.
Grease the wheel bolt.
Apply wheel and wheel bolt.
Apply brake caliper, disc cover and fender.
Tighten to the torque indicated.
Place the vehicle on the ground.
Compress and release the fork 3-4 times.
Tighten the wheel bolt and the screws of the foot.
ATTENTION: Tightening of the screws should be carried out by adjusting the torque wrench to to the stability torque with repeated tightening until stability torque has been achieved.
Tighten to the torque indicated.
10Nm
GB
50
LINKAGE REAR SUSPENSION
To guarantee an optimal operation and the longest lifetime of the progressive linkage of the rear suspension, it is recommended to check after every race/run the correct tightening of the bolt.
Verify that the result of the suspension bolts to specifi ed torque.
30Nm
45Nm
To check the upper shock absorber fastening proceed as follow:
Remove screws 1 and 2 (two per side).
Remove the mudguard.
At the end refi t the screws 1 and 2.
Tighten to the torque indicated.
NOTE: It is recommended not to wash with water jets at high pressure in the zone of the linkage.
Perform the check according to the times indicated in the table on page 59.
To verify device, contact authorised Betamotor customer service.
10Nm
2
51
45Nm
4
1
10Nm
GB
4
TYRES
Only fi t tyres approved by BETAMOTOR.
Unsuitable tyres can adversely affect the road holding of the vehicle.
• To protect your safety, immediately replace any damaged tyres.
• Slick tyres adversely affect the road holding of the vehicle, especially on wet roads and in off-road riding.
• Insuffi cient pressure results in abnormal wear and overheating of the tyres.
• The front and rear tyres must have the same tread design.
• Always measure the infl ating pressures when the tyres are cold.
• Keep the tyre pressures within the prescribed range.
GB
52
CHAIN
Checking the drive chain periodically to ensure longer chain life. Always keep it lubricated and clean of deposited dirt.
Take special care in preventing the lubricant from coming into contact with the rear tyre or brake disc, otherwise the tyre grip and the action of the brake would be greatly reduced, making it very diffi cult to control the vehicle.
4
CHECK AND ADJUST
TIGHTENING CHAIN
Position the vehicle on the central bike stand.
If the distance between chain and swingarm is less than 20 mm proceed with adjustment.
Loosen the pin 1.
Rotate register 2 until the distance between chain and swingarm is that recommended.
20mm
53
2
1
GB
4
3
80Nm
Rotate register 3 into the same position as register 2.
Ensure the distance between chain and swingarm is that recommended.
If the distance between chain and swingarm is not that recommended proceed to readjustment.
Tighten the pin to the torque indicated.
GB
54
HEADLIGHT
Keep the headlight glass clean at all times
(page 57).
REPLACING THE HEADLIGHT
BULBS
Dismantle the headlight mask removing the two retaining screws 1 indicated in the fi gure.
1
Remove the screws 2 indicated in the fi gure.
Take out the bulb assembly from the bulb holder.
Remove the bulb from the connectors and carry out replacement.
To reassemble, proceed inversely as described above.
55
2
4
GB
4
REAR TAIL LIGHT
Keep the tail light glass clean at all times
(see page 57).
Remove the screws indicated in the fi gure.
Remove the bulb holder from its place.
Remove the bulb.
To reassemble, proceed inversely as described above.
GB
56
CLEANING THE VEHICLE
WARNING: Do not clean your vehicle with a high-pressure device with a strong jet of water. Excessive pressure can reach electrical components, connectors, fl exible
4 cables, bearings, etc and can damage or destroy them.
WARNING: Wash motorbikes frequently that are used near the sea (salty air) and on roads subject to salt spreading in winter. Cover with a fi lm of oil or silicone spray unpainted parts and the most exposed parts such as wheels, forks and swingarm.
Do not treat rubber parts and brakes.
When cleaning, avoid direct exposure to sunlight.
Close off the exhaust system to prevent water from entering.
Avoid directing the jet of water onto the air fi lter box cover.
Use water jet to soften the dirt and mud accumulated on the paintwork, then remove them with a soft bodywork sponge soaked in water and shampoo. Subsequently rinse well with water, and dry with air and cloth or suede leather.
Proceed to the emptying of the fi lter box using the appropriate ventilation and drying.
Detergents pollute water. Always wash the vehicle in areas equipped for collection and purifi cation of the washing liquids.
After cleaning, ride a short distance until the engine reaches operating temperature.
WARNING: braking effect is reduced with wet brakes. Operate the brakes cautiously to allow them to dry.
Push back the handlebar control covers, so that water can evaporate.
When the bike is completely dry and cooled down, lubricate all moving parts.
Treat all plastic and painted components with non-aggressive detergents or products that are specifi c for the care of the motorcycle.
To prevent malfunction of the electrical system, treat electric contacts and switches with electrical contact spray.
GB
57
4
PROLONGED INACTIVITY
A few simple operations should be performed to keep the vehicle in good condition whenever it is to remain inactive for a long period (e.g. during the winter):
• Thoroughly clean the vehicle.
• Reduce the tyre pressures by approximately 30 percent, and if possible raise the tyres off the ground.
• Remove the spark plug and pour a few drops of engine oil into the spark plug hole.
Make the engine turn a few times by operating the kick-start (where available) and then replace the spark plug.
• Cover the unpainted parts, excepting the brakes and the rubber parts, with a fi lm of oil or spray silicone.
• Protect the vehicle with a dust cover.
•Drain the carburetor tank as described at page 41.
AFTER PROLONGED INACTIVITY
• Restore the tyre infl ating pressures.
• Check the tightening of all the screws having an important mechanical function.
GB
58
SCHEDULED MAINTENANCE VEHICLE
4
Engine Spark plug
Clutch
Cylinder
Piston sealing rings
Piston
Water pump shaft
Oil seal water pump shaft
Coolant
Gear oil
Oil net fi lters
Paper fi lter
Connecting rod
Crankshaft bearings
Gear
Vehicle Rear shock absorber
Linkage rear suspension
Fork oil
Steering bearings and steering clearance
Wheel bearings
Spokes
Air fi lter
Throttle control
Braking system
Oil pumps brakes
Oil clutch actuator
Transmission chain
State and tyre pressure
Electrical system
Key
C Check (Clean, adjust, lubricate, replace as necessary)
S Replace/renew
R Adjust
59
P S S S S
C C C C C
C C
C C
C C
C C
C C
C C
C C
T T
S
C C
C C
C C
P P
C C
C
C
S S
S C S
C
C
C
C C
S S
S
S
S
C
S
S
S
S
P P
S S
P
S
P
S
P
S
S
S
C
C C C
C T
S
C
C C C
C C C
C C C
S P S
C C C
C C C
C C C
C C C
C C C
C C C
C C C
S S S S
C C C C
C
C
S S
C S C S
C
C
S S
C S C S
S S S S
P P P P
S S S S
S
S
C
C C C C
T C T C
S S
C C C C
C C C C
C C C C
P S P S
C C C C
C C C C
C C C C
C C C C
C C C C
C C C C
C C C C
S
C
C
P
S
C
S
C
C
C
C
C
C
P
C
C
C
S
C
C
T
P Clean
T Tighten
GB
GB
60
CHAPTER 5 TROUBLESHOOTING
CONTENTS
Troubleshooting ................................................................................... 62
Alphabetical index ............................................................................... 63
5
61
GB
5
TROUBLESHOOTING
PROBLEM CAUSE
Fuel cock in C position The engine turns over but will not start
Dirty carburettor jets
Spark plug dirty
Spark gap wrongly adjusted
Fault in the ignition system
The power delivered by the engine is insuffi cient
Tank vent obstructed
Fuel system dirty
Air fi lter dirty
Defective ignition system
The motor stops or splutters
Lack of fuel
Poor carburettor seal
Engine overheats
(liquid fl ows out/vapor from the vent radiator)
Loose or oxidized connector or ignition coil
Radiator grill blocked
Radiator (air side) blocked
Forced ventilation absent
Front braking poor
Rear braking poor
Low coolant
Silencer partly clogged
Carburation too lean
Brake pads worn
Air or humidity in the hydraulic circuit
Brake pads worn
Air or humidity in the hydraulic circuit
REMEDY
Turn the fuel cock in A position
Contact authorised BETAMOTOR customer service
Clean or replace the spark plug
Restore the spark gap
(page 40)
Contact authorised BETAMOTOR customer service
Check the tank vent
Contact authorised BETAMOTOR customer service
Clean the air fi lter
Contact authorised BETAMOTOR customer service
Move the fuel cock to A
Refuel
Make sure that the sleeve between carburetor and engine is intact
Check the connector. Clean and treat with specifi c spray
Remove and clean the grill (page
38)
Clean the radiator
Check that the cooling fan is working correctly
Check the coolant level (page 36)
Contact authorised BETAMOTOR customer service
Contact authorised BETAMOTOR customer service
Contact authorised BETAMOTOR customer service
Contact authorised BETAMOTOR customer service
Contact authorised BETAMOTOR customer service
Contact authorised BETAMOTOR customer service
GB
62
ALPHABETICAL INDEX
Accelerator ......................................................................................... 30
Adjusting fork ...................................................................................... 30
Adjustment of gas clearance .................................................................. 29
Air fi lter .............................................................................................. 38
Brakes ................................................................................................ 28
Breaking in.......................................................................................... 24
Carburetor .......................................................................................... 41
Chain ................................................................................................. 53
Checks before and after use .................................................................. 24
Cleaning the vehicle ............................................................................. 57
Clutch ................................................................................................. 29
Clutch control ...................................................................................... 45
Coolant .............................................................................................. 36
Ecologic guide ....................................................................................... 5
Electrical system ................................................................................... 14
Engine oil ............................................................................................ 34
Engine shut-down ................................................................................. 26
Familiarizing with the vehicle................................................................... 9
Front Brake .......................................................................................... 42
Fuelling ............................................................................................... 25
Handlebar .......................................................................................... 30
Headlight ............................................................................................ 55
Key to symbols..................................................................................... 34
Main parts .......................................................................................... 20
Oil fork ............................................................................................... 48
Operating instructions ............................................................................. 5
Prolonged inactivity .............................................................................. 58
63
GB
Rear brake .......................................................................................... 44
Rear tail light ....................................................................................... 56
Recommended lubricants and liquids ...................................................... 18
Riding safety ......................................................................................... 6
Scheduled maintenance vehicle ............................................................ 59
Shock absorber.................................................................................... 31
Spark plug .......................................................................................... 40
Specifi cations ...................................................................................... 10
Startup ................................................................................................ 26
Steering gear....................................................................................... 47
Suspension adjustment according to the motorcyclist’s weight .................... 32
Troubleshooting ................................................................................... 62
Tyres................................................................................................... 52
Vehicle identifi cation data ....................................................................... 8
GB
64
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