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Beta RR 4T-400 User Manual
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3625132
UNIVERSAL
ENGINE MOUNTING T
OOL
3625198
RACING ENGINE BRACKET
3625202
CHAIN LINK
ASSEMBLING TOOL
3625200
W
A
TER PUMP
SEAL
FITTING
TOOL
POMP
A
ACQUA
3625097
SPECIAL
RING PLIERS
3625203
PRIMARY
DRIVE PULLER
3625174
PISTON RING
∅
= 75 MM
3625175
PISTON RING
∅
= 89 MM
3625384
PISTON RING
∅
= 95 MM
2
Workshop manual RR 4T - 400 - 450 - 525
Code
Description
02_Inghilterra_059311 27-12-2007 17:57 Pagina 2
15
17
Table of Contents
1 General Information
6
General Information
5
Table of Contents
6
How to Consult the Manual
7
General Contents
7
Arrangement of Subjects
7
Description of Operations
7
Purpose of the Manual
7
Updates
7
Terms and Symbols
8
Convention
9
Safety
10
Carbon Monoxide
10
Petrol
10
Engine Oil
10
Coolant
10
3 Tightening Torques Specifications Recommended Products
22
Specifications
23
Specifications - Engine
23
Carburettor Tuning
24
Tightening Torques
25
Fits, Wear Limits
26
Standard Adjustments - Shock Absorber
26
Homologation E3
28
AIS Valve
28
The Catalytic Converter
28
Soundproof Shell
28
Usa Homologation
28
Canister RS4T USA Filter System
28
Tightening Torques
29
4 Maintenance
32
Planned Maintenance
33
Recommended Lubricants
33
How to Clean Parts
34
Fits
34
Part Fitting Guidelines
34
Oil Circuit
35
Checking the Engine Oil Level
35
Changing the Engine Oil and the Oil Filter
35
Cleaning the Short Oil Unit
36
Cleaning the Long Oil Unit
36
Replacing the Oil Filter
37
Checking the Front Brake Fluid Level
38
Restoring the Front Brake Fluid Level
38
Bleeding the Front Brake
38
Checking the Rear Brake Fluid Level
39
Restoring the Rear Brake Fluid Level
39
Bleeding the Rear Brake
39
Checking the Front Brake Pads
40
Checking the Rear Brake Pads
40
Checking the Level of the
41
Bleeding the Hydraulic Clutch
41
Fork Oil
44
Air Filter
45
Spark Plug
46
Fork
50
Adjusting the Rebound Damping
50
Shock Absorber
50
Adjusting the Hydraulic Compression Damping (High/Low Speeds)
50
Adjusting the Spring Preload
51
Rebound Damping
51
Charging the Battery
51
Scrolll Pushbutton
52
Warning Lights
52
Instrument Panel Operation
53
Speed RPM Indicator Functions
53
Clock CLK Functions
54
Conversion Procedure Km/H - Mph and Wheel
54
Odometer ODO Functions
54
Selection
54
STP Chronometer Function
54
TRIP Odometer TRIP Function
54
Button Functions
55
Current Speed Functions
55
Cycling through the Functions
55
Digital Speedometer (Rs4T Usa)
55
Automatic TRIP Functions (TD)
56
Sleep-Mode
56
WAKE-UP (from Sleep-Mode)
56
Changing the Wheel Circumference
57
5 Bodywork and Fittings
60
Removing the Plastics
61
Removing the Rear Mudguard
61
Removing the Saddle
61
Removing the Front Side Panels
62
Removing the Left-Hand Side Bumper
62
Removing the Rear Side Panels
62
Removing the Fork Covers
63
Removing the Front Mudguard
63
Removing the Headlight Grille
64
Section 5
68
Removing the Fuel Tank
69
Removing the Saddle
69
Draining the Cooling System
70
Removing the Right-Hand Side Panel
70
Removing the Silencer
70
Removing the Horn
71
Removing the Left-Hand Radiator
71
Right-Hand Radiator - Cylinder Connecting Pipe
71
Disconnecting the Electrical System
72
Disconnecting the Rear Brake Pump
72
Rear Frame
72
Removing the Intake Sleeve
72
Tipping over the Rear Frame
72
Disengaging the Exhaust Pipe
73
Releasing the Rear Shock Absorber
73
Removing the Drive Chain
73
Removing the Exhaust Pipe
73
Removing the Engine/Swingarm Pin
74
Section 6
78
Draining the Oil
79
Removing the Front Sprocket
79
Removing the Oil Filters
79
Removing the Clutch
80
Pulling out the Flywheel
81
Removing the Clutch Hub and Drum
81
Removing the Oil Pump
82
Removing the Cylinder Head Top
83
Removing the Cylinder Head, the Cylinder and the Piston
83
Removing the Timing Chain and Gear . Chap
85
Removing the Electric Start and Kickstart Gears
86
Removing the Primary Torque Gear and the Free Wheel
87
Removing the Gearshift Mechanism and the Gear Shafts
88
Removing the Countershaft and the Crankshaft
89
Section 7
92
Important Note about Crankcase Servicing
93
Left-Hand Crankcase Half
94
Right-Hand Crankcase Half
95
60" Oil Jet 8
96
By-Pass Valve
97
Clutch Cover
97
Crankshaft Oil Seal 4
97
Crankshaft
98
Compensating for the
99
Countershaft Gear
99
Cylinder - Nikasil Lining
100
Measuring the Piston and the Cylinder - Determining the Piston Fit
100
Checking the Oil Pumps for Wear
101
Checking the Piston
101
Checking the Piston Rings
101
Lubrication System
102
Decompressor Shaft 2
103
Rocker Arm Pins 5 and 6
103
Cylinder Head
104
Sealing Surface
105
Valve Guides
105
Valve Seats
105
Valve Springs
105
Valve Springs for the 250 CC Model
105
Valve Stem Linings
105
Valves
105
Camshaft
106
Preassembling the Camshaft
107
Automatic Stretcher
108
Checking the Clutch for Wear
109
Checking the Kickstart for Wear
110
Preassembling the Kickstart Shaft
110
Gearshift Mechanism
111
Preassembling the Shaft of the Gearshift Mechanism
111
Assembling the Driving Shaft
112
Gearbox
112
Assembling the Driven Shaft
113
Gearbox
113
Ignition System
114
Replacing the Stator
114
Electric Start Gears
115
Checking the Operation
116
Replacing the Free Wheel Hub
116
Section 8
118
Fitting the Crankshaft and the Countershaft
119
Fitting the Gearbox and the Gearshift Mechanism
119
Assembling the Crankcase
121
Fitting the Oil Pumps
122
Fitting the Electric Start and Kickstart Gears
123
Fitting the Gear Selector
123
Fitting the Clutch Drum and Hub
125
Fitting the Primary Pinion Nut
125
Fitting the Timing Gear
126
Fitting the Cylinder Head
127
Fitting the Piston and the Cylinder
127
Fitting the Cylinder Head Top
129
Adjusting the Play of the Valves
130
Fitting the Automatic Stretcher
130
Fitting the Flywheel
131
Fitting the Pick-Up
131
Fitting the Clutch
132
Fitting the Oil Line
133
Installing the Starter Motor
133
Fitting the Oil Filter
134
7 Carburettor
138
Carburettor - Keihin Fcr M X 39
139
Disassembling the Carburettor
141
The Carburettor
141
Checking the Accelerating Pump
144
Checking the Float Needle Valve
144
Checking the Jet Needle
144
Checking the Throttle Valve
144
Choke Valves
144
Reassembling the Carburettor
145
8 Front Suspension / Wheel
152
Fork Components
154
Taking down the Wheel
155
Checking the Head Tube Seats
156
Air Bleed Screw
157
Cleaning the Wiper Seal
157
Removal
157
Installation
157
Draining the Oil
158
Removing the Pump Assembly and the Foot Valve
159
Braking System
175
10 Braking System
176
Front Brake Pump
178
Replacing the Front Brake Caliper Pistons
179
Replacing the Front Brake Pads
179
Replacing the Rear Brake Pump
180
Replacing the Caliper Pistons
181
Checking for Leakage Currents
191
Charging the Battery
191
Filling the Battery
192
Checking the Voltage Regulators
193
Checking the Charging Voltage
193
CDI Unit
194
Checking the Ignition Coil
194
Main Fuse
195
Checking the Starting Relay
195
Checking the Starter Motor
196
Replacing the Rear Brake Pads
181
5
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Beta RR 4T-400 Specifications
General
Brand
Beta
Model
RR 4T-400
Category
Motorcycle
Language
English
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