Beta EVO 4T 2011 Owner's Manual

CAUTION
It is important, after the first hour of break-in, to check
the tightness of all fasteners, paying particular attention
to the following:
• Footrest brackets
• Front and rear brake discs
• Wheel spokes
• Shock absorber bolt and rear linkage
• Engine bolts
• Rear sprocket
• Exhaust bolts
INDEX OF TOPICS
Main parts. .........................................................................................................................................................................................................................46
Vehicle identification details..................................................................................................................................................................................46
Engine identification details...................................................................................................................................................................................46
Console and controls...................................................................................................................................................................................................46
Technical details............................................................................................................................................................................................................. 47
Wiring scheme.................................................................................................................................................................................................................48
CHAPTER 2: Operation and Use
INDEX OF TOPICS
Filling the fuel tank...................................................................................................................................................................................................... 50
Start-up ............................................................................................................................................................................................................................... 50
Advance map change switch . ............................................................................................................................................................................... 51
Break-in .............................................................................................................................................................................................................................. 52
Checks and maintenance before and after off-road use ................................................................................................................... 52
Recommended lubricants and liquids............................................................................................................................................................. 53
CHAPTER 3: MAINTENANCE AND CHECKS
INDEX OF TOPICS
Lubrication circuit. ........................................................................................................................................................................................................ 55
Engine oil. ........................................................................................................................................................................................................................... 56
Brake master cylinder fluid.................................................................................................................................................................................... 59
Brakes circuit bleeding .............................................................................................................................................................................................60
Clutch master cylinder fluid...................................................................................................................................................................................62
Clutch circuit bleeding................................................................................................................................................................................................62
Fork oil ................................................................................................................................................................................................................................63
Sparkplug . .........................................................................................................................................................................................................................64
Air filter ..............................................................................................................................................................................................................................65
Ignition generator check .........................................................................................................................................................................................66
Front brake ....................................................................................................................................................................................................................... 67
Rear brake . .......................................................................................................................................................................................................................68
Coolant ................................................................................................................................................................................................................................69
Rear suspension linkage . ........................................................................................................................................................................................ 70
Checks after cleaning . ............................................................................................................................................................................................... 70
Scheduled maintenance .........................................................................................................................................71
CHAPTER 4: ADJUSTMENTS
INDEX OF TOPICS
Brake adjustment ......................................................................................................................................................................................................... 73
Clutch adjustment ........................................................................................................................................................................................................ 73
Carburettor ....................................................................................................................................................................................................................... 74
Tickover adjustment ................................................................................................................................................................................................... 74
Throttle free clearance adjustment .................................................................................................................................................................. 74
Checking and adjusting steering clearance ................................................................................................................................................ 74
Chain tension .................................................................................................................................................................................................................. 75
Front suspension adjustment ............................................................................................................................................................................... 76
Rear shockabsorber adjustment ........................................................................................................................................................................ 76
CHAPTER 5: WHAT TO DO IN AN EMERGENCY
INDEX OF TOPICS
Troubleshooting.............................................................................................................................................................................................................. 78
Index
Pag.
CHAPTER 1: GENERAL INFORMATION
ENGLISH
Index
Chapter 1
General information
INDEX OF TOPICS
Main parts
Vehicle identification details
Engine identification details
Console and controls
Technical details
Wiring scheme
betamotor.com
General information
1
ENGLISH
3
1
2
4
5
MAIN PARTS
1 - Filter box 2 - Fuel tank 3 - Fuel filler cap
4 - Silencer 5 - Kickstart lever
VEHICLE IDENTIFICATION DETAILS
Frame identification.
The frame identification details (A) are
stamped on the right-hand side of
the headstock.
A
ENGINE IDENTIFICATION DETAILS
B
1
4
2
3
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Engine identification data B is stamped in
the area shown in the figure. In order to
read it correctly, it is necessary to remove
the silencer and disconnect the regulator
connector.
CONSOLE AND CONTROLS
1 Clutch lever
2 Front brake lever
3 Throttle twistgrip
4 Hot start lever
General information
1
TECHNICAL DETAILS
ENGLISH
Vehicle weight
- in running order (dry) .......................................................................................................................... 72 kg
Dimensions
- overall length .................................................................................................................................. 2005 mm
- overall width ...................................................................................................................................... 850 mm
- overall height .................................................................................................................................. 1.115 mm
- wheelbase ........................................................................................................................................1.305 mm
- seat height ......................................................................................................................................... 660 mm
- ground clearance ............................................................................................................................. 310 mm
Tyres
- pressure kPa .........................................................................................................front 39-44 / rear 29-34
- tyre sizes .......................................................................................................... front 2.75- 21” (Tube Type)
rear 4.00 - 18” (X11Tubeless)
Capacities
- fuel tank .............................................................................................................................................. 2.5 litres
- cooling circuit ........................................................................................................................................ 600 cc
- engine oil ............................................................................................BARDAHL XT C60 15W50 - 900 cc
Front suspension
- hydraulic forks with 38 mm stanchions, rebound and spring preload adjustment
Fork oil capacities:
- right leg .....................................................................................................................................................370 cc
- left leg ....................................................................................................................................................... 350 cc
Rear suspension
- progressive hydraulic monoshock, with rebound and spring preload adjustment
Front and rear brake discs
- disc, with hydraulic control
Engine
- type .............................................................Single cylinder, 4-stroke, 4 valve head, SOHC. (ZD3E77)
- bore x stroke ...................................................................... 77x53,6 mm 250cc - 84x53,6 mm 300 cc
- displacement (cm3) ...................................................................................................................249.6 - 297
- compression ratio ..................................................................................................................11.5:1 - 11.4:1
- liquid cooling
- digital electronic ignition with magneto flywheel alternator and variable advance
- starting by kickstart
- sparkplug ....................................................................................................................................... NGK CR7EB
Fuel system
- carburettor ................................................................................................................MIKUNI SE BSR 33-79
- jet ......................................................................................................................................127.5-27.5 max-min
- runs on unleaded petrol
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General information
1
WIRING SCHEME
ENGLISH
CAUTION: Do not run the engine with the voltage regulator connected to the electrical generator without having connected the vehicle wiring harness (central system). Doing so could
cause damage to the regulator itself.
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Chapter 2
Operation and Use
INDEX OF TOPICS
Filling the fuel tank
Start-up
Advance map change switch
Break-in
Checks and maintenance before
and after off-road use
Recommended lubricants and liquids
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Operation and use
2
FILLING THE FUEL TANK
ENGLISH
A
Remove filler cap A. The capacity of the fuel
tank is approximately 2.5 litres.
START-UP
OFF ON
A
1 Put the gearbox in neutral.
2 WITHOUT opening the throttle, press the
kickstart lever progressively downwards,
avoiding violent strokes, to the bottom of
its travel.
Note
A long period with the engine out of use, such
as when the vehicle is on its side, can lead to a
lowering of the fuel level in the carburettor float
bowl, making the bike hard to start.
in this case open manually the fuel tap by turning the lever A clockwise (ON)
Once the engine has started, reclose the fuel
tap.
B
Starting the engine from cold
C
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1 Put the gearbox in neutral.
2 Operate the choke lever B (black knob)
by pulling it outwards.
3 WITHOUT opening the throttle, press the
kickstart lever progressively downwards,
avoiding violent strokes, to the bottom of
its travel.
4 Reclose the choke as soon as the engine has warmed up (the radiator will be
warm).
Operation and use
2
1 Put the gearbox in neutral.
2O
perate the hot start by pulling outward
the knob C (the red one)
3W
ITHOUT opening the throttle, press the
kickstart lever progressively downwards,
avoiding violent strokes, to the bottom of
its travel.
4R
elease the hot start after the engine has
run for some instants
ENGLISH
Starting the engine when hot
OFF ON
A
Starting when the bike has fallen
over
If the bike falls over, the carburettor float
bowl may empty.
1O
pen manually the fuel tap by turning the
lever A clockwise (ON)
2P
ut the gearbox in neutral.
3O
perate the Hot Start knob (C).
4W
ITHOUT opening the throttle, press the
kickstart lever progressively downwards,
avoiding violent strokes, to the bottom of
its travel.
5 Close the fuel tap.
ADVANCE MAP CHANGE SWITCH
Using the switch shown in the figure, it is
possible to choose between two different
map for spark advance.
With the switch in position 1, “soft” map is
selected, more suitable for slippery terrain
and for a softer engine response.
With the switch in position 2, “hard” map
is selected, for a more aggressive engine response: more suitable for dry conditions.
1
2
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Operation and use
2
ENGLISH
BREAK-IN
The break-in period lasts for about 10 hours of use. During this period,
please observe the following recommendations:
1 F or the first 3 hours of use, the engine should only be used at up to 50% of its power. The
engine speed should not exceed 7000 rpm.
2 F or the next 7 hours of use, the engine should only be used at up to 75% of its power.
3 Warm the engine up well before using the bike.
4A
void travelling at a constant speed: varying the speed makes the components bed in uniformly and in less time.
CAUTION:
After the first three hours (or two fills of petrol), change the engine oil.
• Always use super unleaded petrol.
• After the first trip off-road, check all the nuts and bolts.
CHECKS AND MAINTENANCE BEFORE AND AFTER OFF-ROAD USE
To avoid unpleasant surprises while operating the vehicle, we recommend that you perform
a series of checks and maintenance jobs both before and after use. In fact, dedicating just a
few minutes to these checks and jobs will not only make riding safer, but can save you time
and money. Proceed as follows:
Tyres
Check the pressure, general condition and tread depth.
Spokes
Check that the tension is correct.
Nuts and bolts
Check the tight of all the nuts and bolts.
Chain
Check the tension (clearance 20 mm) and, if necessary, grease it.
Air filter
Clean the filter and soak it in air filter oil.
Note
Check that you have the vehicle’s identification documents. On cold days, before setting off we advise that you
run the engine, as a minimum, for the time required to reach the correct operating temperature. Every time the
vehicle is used off-road it needs to be cleaned carefully.
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Operation and use
2
ENGLISH
RECOMMENDED LUBRICANTS AND LIQUIDS
To promote better operation and longer life, we recommend that you preferably use the
products listed in the table:
TYPE OF PRODUCT
TECHNICAL SPECIFICATIONS
Engine oil
Bardahl XT C60 15W50
Brake and clutch fluid
Bardahl brake fluid dot 4
Fork oil
Idemitsu oj-racing-01
Bel ray “mc 10sae 5”
Grease for linkages
Bardahl outboard grease
Coolant
Bardahl permanent
Filter oil
Bardahl oil filter
Note
When changing the fluids, we recommend that you adhere strictly to the table shown.
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Chapter 3
Maintenance and checks
index of topics
Lubrication Circuit
Engine Oil
Brake master cylinder fluid
Brakes circuit bleeding
Clutch master cylinder fluid
Clutch circuit bleeding
Fork oil
Air filter
Ignition generator check
Sparkplug
Front brake
Rear brake
Rear suspension linkage
Coolant
Checks after cleaning
Scheduled maintenance
betamotor.com
Maintenance and checks
LUBRICATION CIRCUIT
ENGLISH
The output oil pump (1) draws in oil from
the area at the base of the gearbox through
its own mesh oil filter (2) and then sends it
to the paper oil filter (3). From here the oil,
starting from the bypass valve (4), is directed in three different directions: by means
of a jet (5) it lubricates the piston pin and
takes heat from the crown of the piston;
and it passes through two pipes, one of
which (6) takes it to the crankshaft to lubricate the roller bearing on the crankpin; the
other (7), whose flow is regulated by a calibrated hole on the cylinder base gasket (8),
feeds the valvegear (9). The oil then returns
to the base of the crank chamber from the
piston, the conrod assembly and the cylinder walls, and is drawn in by the scavenge
pump (10) through the mesh filter (11). It is
pumped through special jets (12) and lubricates the transmission gears. The oil in the
cylinder head, however, returns to the base
of the gearbox passing through the timing
case and the inner clutch casing.
3
9
8
12
5
7
3
6
2
1
8
12
11
4
10
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Maintenance and checks
3
ENGINE OIL
ENGLISH
Use only fully synthetic oils of a reliable
brand (BARDAHL XTC60 15W50).
CHECKING THE ENGINE OIL LEVEL
MAX
MIN
The engine oil level must be checked when
the engine is warm. Run the engine for several minutes and then switch it off. Place
the bike on a flat surface in such a way that
it is perfectly vertical.
Wait a few minutes and then check the oil
level in the sightglass located in the clutch
casing (right-hand side of the engine). The
level must be between the limits indicated
in the picture.
If necessary, remove the oil filler plug and
top up the level.
N.B. Running the engine with too little oil causes
excessive wear to the engine components.
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Maintenance and checks
3
CHANGING THE ENGINE OIL
ENGLISH
N.B. At each oil change, the mesh filters must be
cleaned and the paper filter replaced.
N.B. The oil change must be carried out when
the engine is at working temperature. Be careful
not to scald yourself with the hot oil.
After the engine has reached operating
temperature, switch the bike off and stand
it upright.
Unscrew the oil drainplug and let all the oil
flow out into a drain pan. Thoroughly clean
the magnet on the drainplug to get rid of
the metallic impurities that it has collected.
Unscrew the plug in the left-hand casing
and use pliers to extract the filter. Clean it
carefully and blow it through with compressed air. Check for damage to the O-rings,
and replace them if necessary. Refit all the
parts and tighten the plug to 15 Nm.
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Maintenance and checks
3
ENGLISH
Execute same procedure for the filter located on the right side of crankcase.
Put a drawn pan under the engine closer
to the paper filter cover and then unscrew
the cover.
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Maintenance and checks
3
ENGLISH
Extract the paper filter using pliers. Check
the condition of the O-ring too, and replace
it if necessary.
Change the filter and refit the cover, tightening the three M6x20 bolts to 10 Nm.
Refit the oil drainplug, tightening it to 20
Nm, and refill with 0.9 litres of engine oil
(BARDHAL XTC60 15W50). Finally, tighten
the oil filler plug (A) to 10 Nm.
A
BRAKE MASTER CYLINDER FLUID
C
Front brake
Use the sight-glass (A) to check the brake
fluid level. There must always be enough
brake fluid for the level to be visible in the
sight-glass. If there is not enough, the fluid
must be brought up to the correct level. To
do this, refill the reservoir by unscrewing
the two screws (B), removing the filler cap
(C) and topping up the fluid.
A
B
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Maintenance and checks
3
Rear brake
ENGLISH
Check the level of the brake fluid through
sightA. The level of the fluid should never
fall below the mark in the sight.
To restore the level of the brake fluid,
unscrew cap B and pour in brake fluid
(BARDAHL BRAKE FLUID DOT 4) until the
level reaches the mark in sight A.
Note
For replacements, refer to the table on page 71,
using the lubricants recommended on page 53.
Warning
If you notice softness in the lever, there
could be an air bubble in the system. In
this case, bleed the rear brake system.
Alternatively, contact your dealer imme diately.
B
A
BLEEDINGTHE FRONT BRAKE
To bleed the air from the front brake sy stem, follow the steps below:
- Remove the rubber cap (A) from the ble ed-nipple (B).
Take off the clutch fluid reservoir cover.
- Fit one end of a small transparent tube
over the bleed-nipple (B), and insert the
other end into a container.
- Pump 2/3 times with the lever and hold
the lever in.
- Unscrew the bleed-nipple, allowing the
fluid to flow through the tube.
- Reclose the bleed-nipple and release the
lever.
- If you can see air bubbles through the
tube, repeat the above operations until
the fluid that comes out is free of air.
Note
During this operation it is important that you top
up the master-cylinder reservoir continually, to
compensate for the fluid which has been pum ped out.
- Remove the small tube.
- Refit the rubber cap.
Note
Handle brake fluid with care: being corrosive,
it can damage painted or plastic parts irrepa
rably.
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-
Maintenance and checks
3
To bleed the air from the rear brake system,
follow the steps below:
- Remove the rubber cap C.
- Take off the clutch fluid reservoir cover.
- Fit one end of a small transparent tube
over the bleed-nipple D, and insert the
other end into a container.
- Pump 2/3 times with the brake pedal and
hold the pedal down.
- Unscrew the bleed-nipple, allowing the
fluid to flow through the tube.
- Reclose the bleed-nipple and release the
pedal.
- If bubbles of air are visible through the
tube, repeat the above operations until
the fluid that comes out is free of air.
ENGLISH
Bleeding the rear brake
D
C
Note
During this operation it is important to top up the
master-cylinder reservoir continually, to compensate for the fluid which has been pumped out.
- Remove the small tube.
- Refit the rubber cap.
Note
Handle brake fluid with care: being corrosive, it
can damage painted or plastic parts irreparably.
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Maintenance and checks
ENGLISH
3
CLUTCH MASTER CYLINDER FLUID
Check the fluid in the reservoir. The level
must never be below half-way up the reservoir. To bring the clutch fluid up to the correct level, refill the reservoir by unscrewing
the two screws A, removing the filler cap B
and topping up the fluid.
A
B
Note
Change the fluids in accordance with the intervals in the table on page 71, using the lubricants
recommended on page 53.
Bleeding the clutch system
D
C
To bleed the air from the clutch system, follow the steps below:
- Remove the rubber cap from the bleednipple C.
- Take off the clutch fluid reservoir cover.
- Fit one end of a small transparent tube
over the bleed-nipple D, and insert the
other end into a container.
- Pump 2/3 times with the lever and hold
the lever down.
- Unscrew the bleed-nipple, allowing the
fluid to flow through the tube.
- Reclose the bleed-nipple and release the
lever.
- If you can see air bubbles through the
tube, repeat the above operations until
the fluid that comes out is free of air.
Note
During this operation it is important that you top
up the master-cylinder reservoir continually, to
compensate for the fluid which has been pumped out.
- Remove the small tube.
- Refit the rubber cap.
Note
Handle brake fluid with care: since it is corrosive,
it can cause irreparable damage to painted or
plastic parts
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Maintenance and checks
3
FORK OIL
A
70 mm
To change the fork oil, follow the steps below:
1 Take out the front wheel.
2 Remove the front mudguard.
3 Slack off the fork stanchion pinch bolts
(A) and slide out the complete fork leg.
4 Unscrew the upper cap.
5Unscrew the locknut securing the cap
and remove it.
6Undo the screw retaining the cartridge
(located under the fork leg) and extract
the cartridge.
7Drain the fork leg and cartridge completely of oil.
8Refit the cartridge to the fork leg, tightening the retaining bolt, then refill with oil
(OJ01), thus charging the cartridge, up
to the level shown in the diagram (with
fork leg fully compressed).
9Refit the cap to the damper rod, tighten
the locknut, and screw the cap onto the
stanchion, with the fork leg fully extended.
9Replace everything, tightening the 5
screws (A) to 0.85 kgm.
ENGLISH
Right fork leg
oil level
Note
Recommended tightening torque 7.8: 9.1 Nm.
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Maintenance and checks
3
LEFT SHAFT
ENGLISH
To replace the oil, proceed as follows:
1.Remove the front wheel.
2.Remove the front mudguard.
3.Loosen the shaft locking screws (A).
4.Unscrew the slider plug.
5.Remove the spacer and the spring, compress the fork to the end of the stroke,
then empty out all the oil.
6.Add oil (OJ01), up to the level shown in
the figure.
7. Reinsert the spring and the spacer then
replace cap.
8.Put the shaft back on the fork triple
clamps, tightening the screws (A) to 0.85
kgm.
oil level
130 mm
A
Note
Change the fluids in accordance with the intervals in the table on page 71, using the lubricants
recommended on page 53.
Check periodically and, if necessary, remove
any residues of dirt that may remain between
the fork seal and the dust cover, by removing the
dust cover.
Note
Recommended tightening torque 7.8: 9.1 Nm.
Sparkplug
Keeping the sparkplug in good condition helps
to reduce fuel consumption and keep the engine running optimally.
To check it, just pull off the plug cap and unscrew the sparkplug.
Check the gap between the electrodes with a
feeler gauge: it should be 0.6-0.7 mm. If it is
not within this range, you can adjust it by bending the negative electrode. Take care not to
damage the central electrode.
Check also that there are no cracks in the in-
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sulation or corroded electrodes. If you find
either of these faults, replace the sparkplug
immediately.
Check the sparkplug at the intervals given
in the table on page ......
The best way to fit the sparkplug is to screw
it in by hand until it will go no further, then
lock it with a spanner.
Note
We recommend that you always use NGK CR7EB
sparkplugs.
Maintenance and checks
3
AIR FILTER
A
ENGLISH
To access the filter, simply unscrew the 5
locking screws (A) of the rear mudguard,
then proceed as follows:
1.Remove the mudguard by disconnecting
the tail light cable.
2.Remove the filter frame and the filter by
unscrewing the 2 screws (B).
3.Wash it with soap and water.
4.Dry it.
5.Moisten it with filter oil, removing any excess so that it does not drip.
6.If necessary, clean the inside of the filter
box as well.
7.Proceed with reassembly. We recommend
first assembling the frame on the filter.
B
Note
If the filter is very dirty, wash it first with petrol,
then with shampoo and water.
If the filter is damaged, replace it immediately.
Caution
After every intervention, check that nothing
has been left inside the filter box.
Clean the filter every time the vehicle is
used off-road.
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Maintenance and checks
3
IGNITION GENERATOR CHECK
ENGLISH
To check that the current generator is
operating correctly, proceed as follows:
The check in question must be performed while the temperature of the component is approximately 20°C.
The check may also be performed with
the generator mounted on the motorbike
or on the engine.
Disconnect the black, 12-way connector
between the generator and the CDI.
Disconnect the white, 2-way connector
between the generator and the wiring.
Use a multimeter to check that the resistances read between the terminals
shown below fall within the prescribed
range:
BLACK-WHITE (Pick-Up)
320 ohm ±15%
RED-BLUE 15 ohm ±15 %
(condenser charging)
YELLOW-YELLOW 0.6 ohm ±30%
(service power supply)
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Maintenance and checks
3
FRONT BRAKE
ENGLISH
Check
To check the front brake wear, simply observe the caliper from the front, where it is
possible to see the ends of the two pads
where there should be a layer of lining
which is at least 2 mm thick. If the layer is
thinner, replace the pads immediately.
Note
Observe the times shown in the table on page 71.
when performing the check.
Pad replacement
To replace the pads, proceed as follows:
1.Remove the disc cover and the caliper by
unscrewing the two screws (A) and loosening screw B.
2.Take off split pin C.
3.Unscrew screw B.
4.Remove the pads (D) and replace them.
5.For reassembly, proceed in reverse order.
On the screws (A), it is advisable to use
an appropriate medium resistance locking agent.
C
B
A
Note
Pay particular attention to the correct reassembly of the split pin in order to prevent braking
problems.
If the brake disc is removed, apply the appropriate locking agent to the screws when reassembling.
D
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Maintenance and checks
3
ENGLISH
REAR BRAKE
Checking
To check the rear brake wear, simply observe the caliper from above, where it is possible to see the ends of the two pads where
there should be a layer of lining which is at
least 2 mm thick. If it is thinner than this,
replace the pads immediately.
Note
Check the brakepads at the intervals given in the
table on page 71.
A
Replacing the brakepads
To replace the pads, proceed as follows:
- Remove the wheel.
- Remove the caliper from the swingarm.
- Unscrew screw A.
- Remove the pads and replace them.
- For reassembly, proceed in reverse order.
On screw A, it is advisable to use an appropriate medium resistance locking agent.
If the brake disc is removed, apply the appropriate locking agent to the screws when
reassembling.
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Maintenance and checks
3
Check the level (this must be done with
cold engine) as follows:
- Unscrew the filler cap (A) and visually
check the fluid level.
- If the level is close to the bottom of the
tube, add fluid as follows:
- Add the coolant to the system through the
radiator.
- Undo screw (F) located on the left-hand
side of the cylinder head until the coolant
comes out of the bleed hole.
- Tighten the bleed screw and continue
pouring the liquid into the radiator until it
reaches the flared section in proximity to
the filler cap.
ENGLISH
COOLANT
A
F
The capacity of the circuit is given in the
table on page 47. Use the fluids recommended in the table on page 53.
Caution
To prevent scalding, never unscrew the radiator filler cap when the engine is hot.
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Maintenance and checks
3
REAR SUSPENSION LINKAGE
ENGLISH
A
B
C
E
D
To guarantee optimum operation and working life of the rear suspension progressive linkage, it is advisable to check that the
nuts and bolts A, B, C, D and E are correctly
tightened after every journey. Proceed as
follows:
--Remove the linkage by unscrewing screws
A, B, C, and D.
--Remove the bushings.
--Clean all the parts with a dry cloth.
--Lubricate the bearings and the bushings
with lithium grease.
--Reassemble the unit, starting by securing
the connecting-rods to the frame, using
the bushings with an inner diameter of 8
mm and the special M screws.
--Secure the relay-arm to the swingarm,
using the bushings with heads which are
2.5 mm thick and the M 10x75 screw, and
to the shock absorber (M10x45 screw).
--Then mount the connecting rods on the
relay arm using the remaining bushings
and the M10x125 screw.
Note
The prescribed tightening torques are 4.5 kgm for
screws A, B, C and E and 3.0 kgm for screw D.
CHECKS AFTER CLEANING
A
After cleaning the motorcycle, it is good
practice to:
- Clean the air filter (proceed as described
on page 65).
- Grease the drive chain.
- Remove any water inside the carburettor tank by unscrewing the screw positioned on the bottom of the carburettor float
chamber
Note
This operation must be performed with the reserve valve closed.
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Maintenance and checks
3
Item
end of running in (3h)
after the first 10h
every 30h
every 60h
I-P
I-P
I-P
I-P
Spark plug
I
I
S
S
Petrol filter
I
I
I
Engine oil
S
S
S
Engine oil main filter
S
S
S
Engine oil mesh filters
P
P
P
Coolant
I
I
I
I
Brakes
I
I
I
S
Steering gear
I
I
I
I
Vehicle nuts and bolts*
I
I
I
I
Cilinder-Head nuts and bolts
I
I
I
Valve clearance
I
Air filter
Piston rings
Piston
I
ENGLISH
SCHEDULED MAINTENANCE EVO 250 E 300 CC 4T
I
S
I-S
I - Inspection, checking tightening, replacement as required
P - Cleaning
S - Replacement
* pay particular attention to the nuts and bolts securing the progressive leverage to the rear suspension.
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Chapter 4
Adjustments
INDEX OF TOPICS
Brake adjustment
Clutch adjustment
Tickover adjustment
Throttle free clearance adjustment
Steering play check and adjstment
Chain tension
Front suspension adjustment
Rear shockabsorber adjustment
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Adjustment
4
ENGLISH
BRAKE ADJUSTMENT
Front brake
The front brake is disc type with hydraulic
control, and for this reason it requires only
ordinary maintenance. If you wish to adjust
the position of the lever, use adjuster screw
A. It is advisable to leave a minimum of
play.
A
Rear brake
The rear brake is disc type with hydraulic
control.
You can adjust the pedal height using adjusters B and C.
We recommend that you leave a minimum
of free clearance.
C
B
CLUTCH ADJUSTMENT
D
The only adjustment that can be made on
the clutch adjusting the position of the
clutch lever E.
To make this adjustment, use adjuster D.
E
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Adjustment
4
ENGLISH
CARBURETTOR
Tickover adjustment
Tickover adjustment has a major influence
on starting the engine. That is to say, an engine with a correctly adjusted tickover will
be easier to start than an engine with incorrect tickover adjustment.
You adjust the tickover using the adjuster
knob (A), which regulates the base position
of the throttle valve.
A
B
Throttle free clearance adjustment
To adjust the tension of the throttle cable,
use adjuster B. If this amount of adjustment
is insufficient, use adjuster C (on the throttle cable itself).
C
CHECKING AND ADJUSTING STEERING
CLEARANCE
Check the steering head tube clearance
on a periodic basis, moving the forks backwards and forwards as shown in the figure.
If a clearance is felt, adjust as follows:
- Remove the handlebar protection.
- Unscrew the two screws (C).
- Remove handlebar D.
- Loosen nut E.
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Adjustment
4
C
D
ENGLISH
- Loosen the screws (G) on the upper plate.
- Recover the clearance by intervening on
ring nut F.
- Check that the rotation of the steering
gear takes place in a fluent way. Excessive
tightening of the steering gear bearings
may jeopardise operation.
- Tighten nut E.
E
F
To re-secure, proceed in reverse order.
G
CHAIN TENSION
20mm
For a longer life of the final drive chain,
we suggest you to check its tension periodically.
Always clean off dirt deposits and lubricate it.
If the free clearance in the chain exceeds
20 mm, it needs tensioning as follows:
- Slack off nut A.
- Adjust with lever B.
- Adjust with the same lever on the opposite side, taking it to the same position.
B
- Check the wheel alignment.
- Re-tighten nut A.
A
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Adjustment
ENGLISH
4
RIDER’S WEIGHT (Kg)
SPRING PRELOAD
peso > 80
+ 10 giri
75 < peso < 80
+ 5 giri
peso < 70
0
B
FRONT SUSPENSION ADJUSTMENT
Forks
A
- For a more reactive ride, unscrew adjuster
knob B completely, with respect to the
standard position.
- For a more controlled ride, preload the
spring by about 4-5 turns, using screw
A, and lock knob B 15 clicks from fully
open (about mid-point in the range of
adjustment).
- Rider’s weight. Adjust to compensate for
the rider’s weight as follows.
In the event of any abnormality in operation, please contact our authorised service
centres.
REAR SHOCKABSORBER ADJUSTMENT
Information on adjustment
- For a more reactive ride, back off the compression adjustment screw (A).
- For a more controlled ride, tighten the
compression adjustment screw (A).
A
Note
For the standard adjustment, position the screw
at +12 clicks from fully open.
Periodically clean the working area of thebuffer as follows:
- Lower/remove the buffer, using a small
screwdriver, and blow compressed air by
means of the milling on the spring spacer.
- Always ensure that the progressive linkage
bolts and the upper and lower shock absorber fixing bolts are correctly tightened.
Note
For correct tightening, refer to the “Rear Suspension Linkage” paragraph on page 70.
In the event of any abnormality in operation, please contact our authorised service
centres.
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Chapter 5
What to do in an emergency
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What to do in an emergency
5
ENGLISH
PROBLEM
The engine
will not start
The engine
misfires
CAUSE
CURE
Fuel feed system obstructed (pipes,
fuel tank, tap)
Clean out the system
Air filter excessively dirty
Follow procedure on page 65
No current getting to the sparkplug
Clean or replace the sparkplug.
If the problem persists, contact one
of our dealers
Engine flooded
With the throttle closed, active the
Hot Start knob and operate the kickstart lever repeatedly
Drained floatbowl
Operate the manual tap as described
on page 50
Sparkplug with incorrect
electrode gap
Set the electrode gap correctly.
See note on page 64
Sparkplug dirty
Clean or replace the sparkplug
Earthing fault
Check insulation at kill switch
Pads worn, greasy or vitrified
Follow procedure on page 67
Air or moisture in hydraulic circuit
Follow procedure on page 60
Pads worn, greasy or vitrified
Follow procedure on page 68
Air or moisture in hydraulic circuit
Follow procedure on page 61
Poor front
braking
Poor rear braking
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