Beta EVO 4T Owner'S Manual Download Page 65

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TROUBLESHOOTING

CHAPTER 5 TROUBLESHOOTING

CONTENTS

Troubleshooting ................................................................................... 66

Alphabetical index ............................................................................... 67

Summary of Contents for EVO 4T

Page 1: ...eed to properly operate and maintain your motorcycle The data specifications and images shown 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 mo ment and without notice Cod 008440090 000 ...

Page 2: ...llowing parts rear sprocket ensure that the footrests are properly fixed 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 IMPORTANT In the event of interventions on the vehicle contact Betamotor after sales service ...

Page 3: ...n parts 20 Checks before and after use 24 Breaking in 24 Fuelling 25 Startup 26 Engine shut down 26 CHAPTER 3 ADJUSTMENTS 27 Key to symbols 28 Brakes 28 Clutch 29 Adjustment of gas clearance 29 Accelerator 30 Handlebar adjustment 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...

Page 4: ...of steering gear 50 Oil fork 51 Tyres 55 Chain 55 Headlight 57 Rear tail light 58 Cleaning the vehicle 59 Prolonged inactivity 60 Scheduled maintenance vehicle 61 Tightening torque overview 62 CHAPTER 5 TROUBLESHOOTING 65 Troubleshooting 66 ...

Page 5: ...rmation marked with this symbol can entail a personal hazard INTEGRITY OF THE VEHICLE Failure to respect information marked with this symbol can entail serious dam age to the vehicle and termination of the warranty FLAMMABLE LIQUID HAZARD Read the use and maintenance manual carefully MANDATORY TO WEAR PROTECTIVE CLOTHING Use of the vehicle is subject to wearing specific protective clothing and saf...

Page 6: ...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 start off while the vehicle is on its stand 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 ...

Page 7: ...ns 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 CHAPTER 1 GENERAL INFORM...

Page 8: ... right side of the steering head tube ENGINE IDENTIFICATION Engine identification 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 identification numbers is severely punished by law A B ...

Page 9: ...encer 4 Rear shock absorber 5 Headlight 6 Rear light 7 Side stand 8 Fork 9 Rider s footrests 10 Lower bumper 14 3 12 4 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 7 2 1 16 6 5 13 8 19 17 18 11 10 15 9 ...

Page 10: ...S maximum length 2005 mm maximum width 850 mm wheelbase 1305 mm maximum height 1115 mm ground clearance 310 mm saddle height 660 mm TYRES CAPACITIES fuel tank 2 8 liters coolant circuit 600 ml engine oil 900 ml Dimensions Pressure Bar Front tyre Rear tyre Front tyre Rear tyre 2 75 21 4 00 18 0 4 0 5 0 3 0 4 ...

Page 11: ...l mm edge rod with fork compressed 65 125 65 125 Register spring preload X Full open X Full open Click in extension Full open X Full open X REAR SUSPENSION Version EVO 250 EVO 300 k spring 71N mm 71N mm Length spring in its seat mm 138 5 138 5 Oil type 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 wit...

Page 12: ...ion Carburetor type SE BSR33 79 SE BSR33 79 Main jet 120 127 5 120 120 Slow jet 17 5 27 5 17 5 27 5 Start jet 60 60 60 60 Needle 5D132 5D132 5D132 5D132 Needle position from top 2 3 2 3 Air screw turns from all closed 3 1 2 2 1 2 3 1 2 2 Spacer YES NO YES NO Such modification makes the vehicle non compliant with the road regulations in force Its use must be limited to the sole private circuits whi...

Page 13: ...r 16 30 16 30 Gear ratio 4th gear 24 27 24 27 Gear ratio 5th gear 28 21 28 21 Secondary drive Homologated Competition Homologated Competition 42 13 42 11 42 13 42 11 Such modification 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 Ignition electronic Hidria 12V 120W ...

Page 14: ...ERAL INFORMATION 14 GB ELECTRICAL SYSTEM ELECTRICAL DIAGRAM FOR HOMOLOGATED VERSION Key to colours Bi White Ve Green Ma Brown Vi Purple Bl Blue Ne Black Gi Yellow Rs Red Ar Orange Az Sky blue Ro Pink Gr Grey ...

Page 15: ... L H front turn signal with bulb 12V 10W 8 Engine stop button 9 Horn 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...

Page 16: ...1 GENERAL INFORMATION 16 GB ELECTRICAL DIAGRAM FOR RACE VERSION Key to colours Bi White Ve Green Ma Brown Vi Purple Bl Blue Ne Black Gi Yellow Rs Red Ar Orange Az Sky blue Ro Pink Gr Grey ...

Page 17: ...20W 2 Horn 12V 3 Fuel cock 4 Horn 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 ...

Page 18: ... the products listed in the following chart PRODUCT TYPE SPECIFICATIONS ENGINE OIL Liqui Moly racing Synth 10W50 BRAKE OIL Liqui Moly brake fluid DOT 4 CLUTCH ACTUATOR OIL Liqui Moly brake fluid DOT 4 FORK OIL SHELL TELLUS S2 V32 SAE 6 1 TIE ROD GREASE Liqui Moly Schmierfix LIQUID COOLANT Liqui Moly Coolant ready mix RAF 12 PLUS ...

Page 19: ...s 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 ...

Page 20: ...witched off and the fuel cannot flow 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 STARTER The starter lever 1 is located on the car burettor To use pull it out HOT START The hot start 2 is located on the intake manifold To use pull it out 1 2 ...

Page 21: ...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 figure it is possible to select one of two possible mappings for the ignition advance With the switch in position soft map ping more suited to muddy terrain and for a gentler response of the bike...

Page 22: ...dlebar GEARCHANGE LEVER Gearchange lever is fitted to the left side of the engine The positions corresponding to the different gears are shown in the figure 2 BRAKE PEDAL Brake pedal is located in front of the right hand footrest KICK START The kick start pedal is located on the right side of the engine The upper part is rotatable 1 N 2 3 4 5 ...

Page 23: ...e 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 WARNING do not climb on the vehicle when the side stand is down ...

Page 24: ...he operation of the headlight the rear and brake lights the indicators the warning lights and the horn 9 Wash the motorcycle thoroughly after off road use page 59 BREAKING IN The breaking in period lasts approximately 10 hours during which it is advisable to Avoid travelling at constant speed For the first 3 hours of use the engine should only be used at up to 50 of its power The engine speed shou...

Page 25: ... open well ventilated area Pay special attention so that the fuel does not come into contact with hot parts of the vehicle Immediately clean up any spilled fuel WARNING Risk of poisoning Fuel is poisonous liquid and a health hazard Fuel must not come into contact with the skin eyes and clothing Do not breathe in the fuel vapours If contact occurs with the eyes rinse immediately with plenty of wate...

Page 26: ...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 ve hicle 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 float bowl may empty In this c...

Page 27: ...ustment of gas clearance 29 Accelerator 30 Adjusting the idle speed 30 Handlebar adjustment 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 ...

Page 28: ...earance WARNING reduced play causes brake overheating leading to sudden lockup 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 po sition 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 lock...

Page 29: ...llows Loosen ring 1 Rotate register 2 with respect to sheath 3 Tighten ring 1 3 1 2 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 The idle stroke of push rod must not be less than 0 9 mm ATTENTION reduced clearance leads to premature wear of the discs a...

Page 30: ...ion For standard calibration refer to page 11 1 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 ADJUSTMENT The handlebar can be adjusted by rotating it back...

Page 31: ...n 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 1 ADJUSTING THE SPRING PRELOAD Spring preload is adjusted by means of screw 2 Turning clockwise will increase the preload while rotating counter clock wise decreases the preloa...

Page 32: ...s against adjust ing ring 2 For standard calibration refer to page 11 NOTE for movement of the rings use a specific 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 2 1 w 70 Kg 70 Kg w 80 Kg 80 Kg w Adjustment Adjustment Adjustment Fork Sh...

Page 33: ...44 Front brake lining control 45 Rear brake 45 Check the level of the rear brake fluid 45 Restoring the level of the rear brake fluid 45 Bleeding the rear brake 46 Rear brake lining control 47 Clutch control 48 Check oil level 48 Bleeding clutch control 49 Check of steering gear 50 Oil fork 51 Removing legs 51 Oil replacement left leg 52 Oil replacement right leg 52 Legs assembly and parts 53 Link...

Page 34: ...k the oil level through the window 1 The level must be between the limits indi cated in the picture Otherwise restore the oil level through 2 Use the oil indicated on page 18 in the Recommended lubricants and liquids table REPLACEMENT Always perform the replacement when engine is hot Position the drive on a flat base ensuring stability Place a container under the engine WARNING Hot oil can cause s...

Page 35: ...w 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 Perform the 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 1 and then un screw 2 the cover 4 1 2 10Nm 15Nm ...

Page 36: ... cap 1 WARNING Hot oil can cause severe burns 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 load ing tube Where the liquid is not visible in the lower part of the loading tube position the...

Page 37: ...G Never unscrew the filler cap of the radiator when the engine is hot Danger of burning WARNING Wear appropriate protective clothing and protection gloves Keep coolant out of reach of children Avoid any direct contact of the coolant with skin eyes or clothing If this hap pens with the eyes rinse immediately with plenty of water and seek medical advice with skin Immediately clean contaminated areas...

Page 38: ... table WARNING Never unscrew the filler cap of the radiator when the engine is hot Danger of burning WARNING Wear appropriate protective cloth ing and protection gloves Keep coolant out of reach of chil dren Avoid any direct contact of the cool ant with skin eyes or clothing If this happens with the eyes rinse immediately with plenty of water and seek medical advice with skin Immediately clean con...

Page 39: ...ly the grill pushing it towards the radiator AIR FILTER Check after every ride REMOVING AND FITTING AIR FILTER To access the filter Loosen the fastening screw 1 of the rear cover Remove the filter frame and the filter by unscrewing the screw 2 WARNING After every intervention check that nothing has been left inside the filter box Reassemble by performing the operations in reverse order 1 2 ...

Page 40: ... clean the filter with gasoline or petrol NOTE If the filter 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 filter is not in place The infiltration of dust and dirt can cause damage and considerable wear...

Page 41: ...e 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 ...

Page 42: ...mes and lighted cigarettes away Refuel in an open well ventilated area Immediately clean up any spilled fuel WARNING Risk of poisoning Fuel is poisonous liquid and a health hazard Wear appropriate protective clothing and protection gloves Fuel must not come into contact with the skin eyes and clothing Do not breathe in the fuel vapours If contact occurs with the eyes rinse immediately with plenty ...

Page 43: ...ir Use the liquid indicated on page 18 in the Recommended lubricants and liquids table WARNING The clutch fluid is extremely corrosive Take care not to spill it on the paintwork Wear appropriate protective clothing and protection gloves Keep coolant out of reach of children WARNING Avoid any direct contact of the liquid with skin eyes or clothing If this happens with the eyes rinse immediately wit...

Page 44: ...TE During this procedure continuously top up the brake pump thank to replace the oil that is out flowing Remove the tube Replace the rubber cap Close the oil reservoir cap 1 2 WARNING The brake fluid is extremely corrosive Take care not to spill it on the paintwork Wear appropriate protective clothing and protection gloves Keep coolant out of reach of children WARNING Avoid any direct contact of t...

Page 45: ... replace contact authorised Betamotor customer service 2 1 A REAR BRAKE CHECK THE LEVEL OF THE REAR BRAKE FLUID Check the level of the brake fluid through sight A The level of the fluid should never fall below the mark in the sight RESTORING THE LEVEL OF THE REAR BRAKE FLUID To restore the level of the brake fluid loosen the two screws 1 lift cap 2 and add brake fluid until its level is 5 mm below...

Page 46: ...a continuous outflow of oil within no air bubbles Close the valve and release the lever WARNING The brake fluid is extremely corrosive Take care not to spill it on the paintwork Wear appropriate protective clothing and protection gloves Keep coolant out of reach of children WARNING Avoid any direct contact of the liquid with skin eyes or clothing If this happens with the eyes rinse immediately wit...

Page 47: ...start replacing them NOTE Perform the check according to the times shown in the table on page 61 To replace contact authorised Betamotor customer service WARNING The brake fluid is extremely corrosive Take care not to spill it on the paintwork Wear appropriate protective clothing and protection gloves Keep coolant out of reach of children WARNING Avoid any direct contact of the liquid with skin ey...

Page 48: ...i tion the level of the oil should be 5 mm below the upper rim 2 1 WARNING The clutch fluid is extremely corrosive Take care not to spill it on the paintwork Wear appropriate protective clothing and protection gloves Keep coolant out of reach of children WARNING Avoid any direct contact of the liquid with skin eyes or clothing If this happens with the eyes rinse immediately with plenty of water an...

Page 49: ... procedure continuously top up the brake pump thank to replace the oil that is out flowing Remove the tube Replace the rubber cap WARNING The clutch fluid is extremely corrosive Take care not to spill it on the paintwork Wear appropriate protective clothing and protection gloves Keep coolant out of reach of children WARNING Avoid any direct contact of the liquid with skin eyes or clothing If this ...

Page 50: ...odically check the play in the steering sleeve by moving the fork back and forth as shown in the figure Whenever you feel play adjust as described below Loosen the screws 1 Loosen the screw 2 Take up the play by means of nut 3 Tighten the screws to the specified torque values ...

Page 51: ... 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 1 ...

Page 52: ... lubricants and liquids table Reassemble the plug on the rod tighten the lock nut and extending the fork leg 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 3 OIL REPLACEMENT RIGHT LEG Unscrew upper plug 2 Unscrew fixing lock nut and take o...

Page 53: ...lt Apply brake caliper disc cover and fender Tighten to the torque indicated ATTENTION Tightening of the screws should be carried out by adjusting the torque wrench to the stability torque with repeated tighten ing until stability torque has been achieved 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 o...

Page 54: ...ension bolts to specified torque To check the upper shock absorber fasten ing proceed as follow Remove screws 1 and 2 two per side Remove the mudguard At the end refit 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 61 To verify d...

Page 55: ...ar and overheating of the tyres The front and rear tyres must have the same tread design Always measure the inflating pressures when the tyres are cold Keep the tyre pressures within the prescribed range 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 lubri cant from coming into contac...

Page 56: ...proceed with adjustment Loosen the pin 1 Rotate register 2 until the distance between chain and swingarm is that recommended 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 pro ceed to readjustment Tighten the pin to the torque indicated ...

Page 57: ...BULBS Dismantle the headlight mask removing the two retaining screws 1 indicated in the figure Remove the screws 2 indicated in the figure Take out the bulb assembly from the bulb holder Remove the bulb from the connectors and carry out replacement To reassemble proceed inversely as de scribed above 1 2 1Nm 1Nm 0 5Nm ...

Page 58: ...GB REAR TAIL LIGHT Keep the tail light glass clean at all times see page 59 Remove the screws indicated in the figure Remove the bulb holder from its place Remove the bulb To reassemble proceed inversely as de scribed above 0 5Nm ...

Page 59: ...aintwork 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 Detergents pollute water Always wash the vehicle in areas equipped for collection and purification of the washing liquids AFTER WASHING Proceed to the emptying of the filter box using the appropriate ventilation and drying After cleaning r...

Page 60: ...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 film of oil or spray silicone Protect the vehicle with a dust cover Drain the carburetor tank as described at page 42 AFTER PRO...

Page 61: ... C S C S C S C S C Gear oil S S S S S S S S S S Oil net filters P P P P P P P P P P Paper filter S S S S S S S S S S Connecting rod S S Crankshaft bearings S S Gear C C Vehicle Rear shock absorber C C C C C C C C C C Linkage rear suspension T T C T C T C T C T Fork oil S S S S S Steering bearings and steering clearance C C C C C C C C C C Wheel bearings C C C C C C C C C C Spokes C C C C C C C C C...

Page 62: ...s 10 Stem pin on steering head 10 Upper handlebar u bolt 20 Rear axle Tightening torque Nm Threadlock Wheel pin 80 Rear shock absorber frame 45 Rear shock absorber rocker arm 45 Connecting rod frame 30 Connecting rod rocker arm 45 Rocker arm swinging arm 45 Engine Tightening torque Nm Threadlock Gearbox oil drain plug 20 Oil filter plug left side 15 Oil filter plug right side 10 Draining screw coo...

Page 63: ...ck Headlight mask 1 Headlight bulb socket 0 5 Tail light glass 0 5 M Medium strength threadlock WARNING Tightening of the screws should be carried out by adjusting the torque wrench to the stability torque with repeated tightening until stability torque has been achieved ...

Page 64: ...64 GB ...

Page 65: ...5 TROUBLESHOOTING 65 GB CHAPTER 5 TROUBLESHOOTING CONTENTS Troubleshooting 66 Alphabetical index 67 ...

Page 66: ...or seal Make sure that the sleeve between carburetor and engine is intact Loose or oxidized connector or ignition coil Check the connector Clean and treat with specific spray Engine overheats liquid flows out vapor from the vent radiator Radiator grill blocked Remove and clean the grill page 39 Radiator air side blocked Clean the radiator Forced ventilation absent Check that the cooling fan is wor...

Page 67: ...ering gear 50 Checks before and after use 24 Cleaning the vehicle 59 Clutch 29 Clutch control 48 Coolant 36 Electrical system 14 Engine oil 34 Engine shut down 26 Familiarizing with the vehicle 9 Front Brake 43 Fuelling 25 Handlebar adjustment 30 Headlight 57 Key to symbols 28 Key to symbols 34 Main parts 20 Oil fork 51 Operating instructions 5 Prolonged inactivity 60 ...

Page 68: ...ids 18 Riding safety 6 Scheduled maintenance vehicle 61 Shock absorber 31 Spark plug 41 Specifications 10 Startup 26 Suspension adjustment according to the motorcyclist s weight 32 Symbols 5 Tightening torque overview 62 Troubleshooting 66 Tyres 55 Vehicle identification data 8 ...

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