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Beta RR 4T - 250, Workshop Manual

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Workshop manual RR 4T  - 400 - 450 - 525

CONTENTS

HOW TO CONSULT THE MANUAL . . . . . . . Chap. 1 - 7

GENERAL CONTENTS  . . . . . . . . . . . . . Chap. 1 - 7
Arrangement of subjects  . . . . . . . . . . . Chap. 1 - 7
Description of operations  . . . . . . . . . . . Chap. 1 - 7

PURPOSE OF THE MANUAL  . . . . . . . . . . . Chap. 1 - 7

Updates  . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 7

TERMS AND SYMBOLS   . . . . . . . . . . . . . . Chap. 1 - 8

CONVENTION   . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 9

SAFETY  . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10

Carbon monoxide  . . . . . . . . . . . . . . . . Chap. 1 - 10
Petrol  . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Engine oil  . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10
Coolant   . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 10

Brake fluid  . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 11
Threadlocking fluid  . . . . . . . . . . . . . . . Chap. 1 - 11
Shock absorber nitrogen  . . . . . . . . . . Chap. 1 - 11
Battery  . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 11
Hot parts  . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 11

NOTES  . . . . . . . . . . . . . . . . . . . . . . . . . . . Chap. 1 - 12

TABLES OF CONTENTS
TABLE OF CONTENTS OF EACH CHAPTER Chap. 1 - 12
CONTENTS OF EACH CHAPTER  . . . . . . . Chap. 1 - 12

OPERATING SPECIFICATIONS  . . . . . . . . Chap. 1 - 13

VEHICLE IDENTIFICATION  . . . . . . . . . Chap. 1 - 13

01_Inghilterra_059311  27-12-2007  17:52  Pagina 6

Summary of Contents for RR 4T - 250

Page 1: ...WORKSHOP MANUAL 01_Inghilterra_059311 27 12 2007 17 52 Pagina 1 ...

Page 2: ...01_Inghilterra_059311 27 12 2007 17 52 Pagina 2 ...

Page 3: ...s to avoid wasting time in obtaining spare parts preparing tools etc Gain access to the parts to be repaired by performing on ly the operations that are strictly necessary For best re sults always follow the removal procedures described in this manual Note Betamotor is committed to constantly improving its prod ucts For this reason there can be slight differences be tween the content of this manua...

Page 4: ...orques Specifications Recommended products 4 Maintenance 5 Bodywork and fittings 6 Engine 7 Carburettor 8 Front suspension wheel 9 Rear suspension wheel 10 Braking system 11 Electrical system Workshop manual RR 4T 400 450 525 01_Inghilterra_059311 27 12 2007 17 52 Pagina 4 ...

Page 5: ...Pag 5 GENERAL INFORMATION 1 01_Inghilterra_059311 27 12 2007 17 52 Pagina 5 ...

Page 6: ...Chap 1 9 SAFETY Chap 1 10 Carbon monoxide Chap 1 10 Petrol Chap 1 10 Engine oil Chap 1 10 Coolant Chap 1 10 Brake fluid Chap 1 11 Threadlocking fluid Chap 1 11 Shock absorber nitrogen Chap 1 11 Battery Chap 1 11 Hot parts Chap 1 11 NOTES Chap 1 12 TABLES OF CONTENTS TABLE OF CONTENTS OF EACH CHAPTER Chap 1 12 CONTENTS OF EACH CHAPTER Chap 1 12 OPERATING SPECIFICATIONS Chap 1 13 VEHICLE IDENTIFICAT...

Page 7: ...the part by a predetermined angle e g 30 PURPOSE OF THE MANUAL This manual is chiefly intended for qualified Betamotor dealers and mechanics A mechanic should not expect to find all the information he requires in a manual Anybody who uses this manual should have a working knowledge of the princi ples of mechanics and of motorcycle repairing techniques Performing repairs or maintenance operations w...

Page 8: ...ton rings and piston pins Valves valve springs valve cotters caps and thrust washers Valve guides with related valves springs caps valve cotters and thrust washers Crankshaft bearings Any part subject to even wear To keep the engine in perfect running order ensure that all fits are within the prescribed tolerances A close fit can lead to seizure as soon as the moving parts heat up on the other han...

Page 9: ...TION In order to clarify the left right convention used in this manual a diagram of the vehicle and engine are provided below with an indication of how the two sides are referred to in the manual Rh Rh Lh Lh 01_Inghilterra_059311 27 12 2007 17 52 Pagina 9 ...

Page 10: ... of spent oil in the environment Keep out of the reach of children Coolant Under certain circumstances the ethylene glycol contained in the coolant is flammable and its flame is invisible Should the ethylene glycol ignite its flame though invisible could cause serious burns Avoid bringing the coolant into contact with hot parts as these could ignite it The coolant ethylene glycol can irritate the ...

Page 11: ...valve Only use nitrogen to pressurize the shock absorber Un stable gases can explode and cause burns To prevent the risk of explosions and burns avoid keep ing the shock absorber close to flames or heat sources Keep out of the reach of children Battery The battery produces explosive gases Keep it away from sparks flames and cigarettes Only recharge it in well ventilated places The battery contains...

Page 12: ... glues sealants and lubricants as directed ob serving the indications about their specifications Always replace parts such as gaskets O rings and safety washers with new ones When loosening or tightening nuts or screws always start from the bigger ones or from the centre Always observe the prescribed tightening torques Only use genuine Betamotor spares TABLES OF CONTENTS TABLE OF CONTENTS OF EACH ...

Page 13: ...is stamped on the right side of the head tube The engine number is stamped on the upper crankcase half next to the swingarm ZD3 E1 XX XXXXXXXXXX Manufacturer s data Vehicle model Version 11 400 cc Euro 3 12 450 cc Euro 3 13 525 cc Euro 3 The following is an example of frame number format 1 frame number 01_Inghilterra_059311 27 12 2007 17 52 Pagina 13 ...

Page 14: ...14 Workshop manual RR 4T 400 450 525 01_Inghilterra_059311 27 12 2007 17 52 Pagina 14 ...

Page 15: ...SPECIAL TOOLS 2 02_Inghilterra_059311 27 12 2007 17 57 Pagina 1 ...

Page 16: ...BLING TOOL 3625200 WATER PUMP SEAL FITTING TOOL POMPA 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 ...

Page 17: ...25084 INNER BEARING PULLER 5 7MM 3625204 VALVE GUIDE CHECKING TOOL 3625207 INNER CLUTCH RING FITTING TOOL 3625208 SHAFT PROTECTING COVER 3625205 GEAR PULLER 3625201 VALVE SPRING TOOL 3625193 INNER RING FITTING TOOLS NJ206 3 2 Special tools Release 01 Date 09 2007 Code Description 02_Inghilterra_059311 27 12 2007 17 57 Pagina 3 ...

Page 18: ...CONE TUBE 3625098 TIMING CHAIN FITTING TOOL 3625209 SPARK PLUG SPANNER 13 16 3625090 CLUTCH BLEEDING OIL SYRINGE 3625194 LOCTITE 648 GREEN 24ML 3625199 CLUTCH PULLER Workshop manual RR 4T 400 450 525 Code Description 02_Inghilterra_059311 27 12 2007 17 57 Pagina 4 ...

Page 19: ...5 2 Special tools Release 01 Date 09 2007 Code Description 3625206 CARBURETTOR ADJUSTING SPANNER 02_Inghilterra_059311 27 12 2007 17 57 Pagina 5 ...

Page 20: ...6 Workshop manual RR 4T 400 450 525 02_Inghilterra_059311 27 12 2007 17 57 Pagina 6 ...

Page 21: ...TIGHTENING TORQUES SPECIFICATIONS RECOMMENDED PRODUCTS 3 03_Inghilterra_059311 27 12 2007 18 00 Pagina 1 ...

Page 22: ... FORK Chap 3 6 STANDARD ADJUSTMENTS SHOCK ABSORBER Chap 3 6 SPECIFICATIONS FRAME Chap 3 7 HOMOLOGATION E3 Chap 3 8 AIS valve Chap 3 8 The catalytic converter Chap 3 8 Soundproof shell Chap 3 8 USA HOMOLOGATION Chap 3 8 Canister RS4T USA filter system Chap 3 8 TIGHTENING TORQUES Chap 3 9 Workshop manual RR 4T 400 450 525 03_Inghilterra_059311 27 12 2007 18 00 Pagina 2 ...

Page 23: ... ring 1 scraper ring Lubrication 2 oil pumps Engine oil completely synthetic oil of known brands Bardahl XTM 15 W 50 Oil quantity 1 25 litres Primary drive cylindrical gears with straight teeth 33 76 teeth Clutch wet multiplate Transmission with front coupling 6 speed 6 speed 6 speed Gear ratios 1st 14 34 1st 14 34 1st 14 34 2nd 17 31 2nd 17 31 2nd 17 31 3rd 19 28 3rd 19 28 3rd 19 28 4th 22 26 4th...

Page 24: ...B Main jet 178 178 Jet needle OBDVR OBDVT Idling jet 42 42 Main air jet 200 200 Idling air jet 100 100 Needle valve position 3 3 Starting jet 85 85 Fuel mixture adj screw open by 1 25 turns 1 25 turns Throttle valve 15 15 Power reduction throttle valve stop throttle valve stop Pump diaphragm stop 858 2 15 mm 858 2 15 mm 03_Inghilterra_059311 27 12 2007 18 00 Pagina 4 ...

Page 25: ...t head screw M6 Loctite 646 16 N m Primary drive gear hexagonal nut M20x1 5 Loctite 243 150 N m Countershaft gear socket head screws M6 Loctite 243 8 N m Clutch hub hexagonal nut M18x1 5 Loctite 243 150 N m Clutch spring flange screws M6 8 N m Gear selector socket head screw M6 Loctite 243 10 N m Selector lever flange screw M5 Loctite 243 6 N m Timing chain stretcher chain guide chain guard flange...

Page 26: ...mpression ring max 0 80 mm scraper ring max 1 00 mm Valves width of sealing surface intake max 1 50 mm width of sealing surface exhaust max 2 00 mm head floating max 0 05 mm valve guide diameter max 6 2 mm spring cup min 0 4 mm mm when new 0 5 mm Valve springs 450 525 400 minimum outer spring length 39 20 mm minimum inner spring length 36 45 mm Oil pump play btw outer rotor and pump casing max 0 2...

Page 27: ...5 front cover 90 90 21 54R o 54M rear cover 140 80 18 70R o 70M or 130 90 18 70R only Pirelli MT 21 Rallycross Tube Type front rim 21x1 6 rear rim 18 x2 15 WHEEL DIMENSION MOTARD secondary clutch gear 15 43 front cover 120 70 17 58W o 58H rear cover 150 60 17 66W o 66H front rim 17x3 5 rear rim 17x4 25 Fuel tank capacity 8 5 litres including 1 litre reserve Chain 135 ZRDK 007 Bulbs Headlight 12V 2...

Page 28: ...is part of the muffler fixed to the exhaust pipe by spot welding in two places Its function is to reduce the harmful substances present in the exhaust fumes specifically CO carbon monoxide the HC unburned fuel and the Nox nitrogen oxide Soundproof shell This last device 2 located above the ai filter has the function of reducing the emission of polluting gases and sound thus minimising noise pollut...

Page 29: ...flange nut M20x1 5 CH27 90 N m Swingarm pin hexagonal nut M16x1 5 CH19 100 N m Handlebar clamp screws M8 CH10 20 N m Handlebar support screws M10 TCEI Loctite 243 40 N m Upper shock absorber screw M10x1 25 Loctite 243 80 N m Lower shock absorber screw M12 Loctite 243 80 N m Chain sprocket screws special screw M8 10 9 Loctite 243 25 30 N m Brake pedal screw M8 CH10 Brake pedal ball joint screw M6 L...

Page 30: ...10 Workshop manual RR 4T 400 450 525 03_Inghilterra_059311 27 12 2007 18 00 Pagina 10 ...

Page 31: ...MAINTENANCE 4 04_Inghilterra_059311 27 12 2007 18 10 Pagina 1 ...

Page 32: ...ap 4 18 Coolant Chap 4 18 Chain maintenance Chap 4 19 Chain wear Chap 4 19 Chain tensioning Chap 4 19 SUSPENSIONS Chap 4 20 Fork Adjusting the rebound damping Chap 4 20 Adjusting the compression damping Chap 4 20 Shock absorber Adjusting the hydraulic compression damping high low speeds Chap 4 20 Adjusting the spring preload Chap 4 21 Adjusting the hydraulic rebound damping Chap 4 21 Charging the ...

Page 33: ...teering K K Fork K Rear suspension K Frame bolts nuts and oil line T T Chain tensioning K K K Check and adjust clean lubricate or replace as necessary C Clean R Replace renew T Tighten RECOMMENDED LUBRICANTS To keep the vehicle in perfect running order and prolong its life we recommend using the products listed in the table be low PRODUCT TYPE SPECIFICATIONS ENGINE OIL BARDAHL XTM 15W 50 BRAKE FLU...

Page 34: ...ven number of hours It is therefore advisable to periodically replace them all the more so that their wear is difficult to verify This approach is recommended in addition to the dimensional checks of the various components mentioned in the related para graphs It is essential to thoroughly clean all components Bearings and other wear prone parts should be lubricated with en gine oil before they are...

Page 35: ...ld the oil should reach the lower edge of sight A When the engine is hot the oil should reach the upper edge of the sight If necessary top up with engine oil WARNING An insufficient quantity of engine oil or the use low quality oil lead to early engine wear Changing the engine oil and the oil filter Before performing this operation remove if present lower bumper A after unscrewing the three screws...

Page 36: ... head screw 3 next to the engine number Remove the screw with the oil unit thoroughly clean the components and blow them with low pressure com pressed air Check the O rings for damage and if necessary re place them Fit long oil unit 4 using a 300 mm spanner as shown in the fig ure then insert the spanner through the opening in the hole on the opposite side of the crankcase Push the oil unit into t...

Page 37: ...with engine oil Fit the long filter unit in the front and the short filter unit in the back of the crankcase Grease the oil filter cover O rings and fit covers 4 Fit screws 2 and tighten them to 6 N m Tighten screw 1 to 8 N m Lift up the vehicle Remove screw fastening 5 from the clutch cover and pour in 1 25 litres of the recommended engine oil see table in Chapter 3 WARNING Before actually starti...

Page 38: ... Take care not to drip it onto the paintwork Bleeding the front brake To bleed air from the front brake circuit follow these steps Remove rubber cap B from valve C Open the brake fluid reservoir cap Insert one end of a small tube into valve C and place the oth er end in a container Unscrew valve C while pulling the lever and repeatedly pull the brake lever until the oil comes out in an uninterrupt...

Page 39: ... onto the paintwork Bleeding the rear brake To bleed air from the rear brake circuit follow these steps Remove rubber cap E from valve F Unscrew the brake fluid reservoir cap Insert one end of a small tube into valve F and place the oth er end in a container Unscrew valve F while operating the pedal and repeatedly actuate the brake pedal until the oil comes out in an uninter rupted flow with no ai...

Page 40: ...pads can result in poor braking and lead to brake disc damage Checking the rear brake pads To check the wear of the rear brake pads visually inspect the caliper from behind The lining on the visible ends of the two brake pads should be at least 2 mm thick Should the lining be thinner immediately replace the brake pads NOTE Perform the check at the intervals specified in the Main tenance table in C...

Page 41: ...essary to remove the clutch pump cover Remove the two screws 1 and take off cov er 2 together with the rubber bellows Remove the breather valve from clutch pump cylinder 3 and replace it with the bleed ing syringe filled with SAE 10 hydraulic fluid Inject fluid until it comes out with no air bubbles from clutch pump hole 4 Ensure that no fluid flows over After completing the bleeding check the lev...

Page 42: ...ning LH switch Dip switch 4 has three positions lights off low beam on high beam on Button 5 operates the horn Switch 6 is used to stop the engine Press the button until the engine stops Gearchange lever Gearchange lever 7 is fitted to the left side of the engine The positions corresponding to the different gears are shown in the figure The neutral position is between the 1st and 2nd gears Brake p...

Page 43: ...he lights CONTROLS RS4T USA RH switch Starte button 13 is located on the right hand side of the handle bars and operate the electri engine starter Push the button un til the engine sterts Do not press the button 13 while the engine is running While button 14 turns off the engine Caution Before turning it on make sure the switch 14 is on ON LH switch Dip switch 4 has three positions lights off low ...

Page 44: ...Remove lower plug F and upper plug A pay attention to the spring Allow the oil to drain completely from the fork leg Screw on lower plug F again Pour in fresh oil of the type specified in the table in Chapter 3 Screw on upper plug A again Tighten screw D then screw E and then screw D again Workshop manual RR 4T 400 450 525 D E F A B C 04_Inghilterra_059311 27 12 2007 18 10 Pagina 14 ...

Page 45: ...il so as to prevent dripping WARNING Do not clean the filter in foam containing petrol or petroleum as these substances may corrode it Do not clean the filter with hot water Do not start the engine if the air filter is not in place dust and dirt getting into the engine could cause damage and excessive wear If necessary also clean the inside of the filter casing When refitting make sure of the seal...

Page 46: ...park plug cap and un screw the spark plug using the spanner provided Carefully clean the electrodes using a wire brush Blow the spark plug with compressed air to prevent any residues from getting into to engine Using a thickness gauge check that the spark gap is 0 6 0 7 mm If necessary correct the distance by bending the earth electrode Also check that the insulator is not cracked and the electrod...

Page 47: ...n Now slow ly turn the mixture adjusting screw anticlockwise until the en gine speed starts to decrease again Choose the point be tween these two positions where the idle speed is higher Should the engine speed increase considerably reduce it to the standard level and repeat the above procedure NOTE Failure to successfully complete the above procedure may be due to an idling jet of unsuitable size...

Page 48: ...th a rag Materials soaked in fuel are also highly flammable In case of ingestion or contact with sensitive body parts immediately seek medical attention Dispose of fuel in accordance with the law Coolant Check the coolant level when the engine is cold Follow these steps Unscrew cap A and visually check the level of the coolant When the engine is cold the liquid should be about 10 mm above the radi...

Page 49: ... both fork arms Tighten nut 1 Chain wear Carefully follow the procedure described below to check the wear of the chain Change into neutral pull up the upper chain stretch with a force of 10 15 kg see figure Now measure the length of 18 links on the lower chain stretch If the measurement is equal to or greater than 272 mm replace the chain Chains do not always wear out evenly For this reason the me...

Page 50: ...Adjusting the hydraulic compression damping high low speeds The shock absorber can be adjusted for both high and low speeds The expressions high speed and low speed refer to the move ment of the shock absorber not to the speed of the vehicle The low and high speed adjustments affect the behaviour of the shock absorber during slow and fast compression respectively Low speed adjustment Using a screw...

Page 51: ...ter the activation check that the volt age is greater than 12 6 V If it is lower recharge the battery Depending on the recharger that is available recharge the bat tery using one of the following procedures Constant voltage charge the battery with a voltage of 14 4 15 V for about 12 hours 10 12 hours after the charging is com plete measure the voltage as previously described Constant current charg...

Page 52: ...ent panel has three warning lights Warning light B GREEN indicates turn indicators have been activated Warning light C BLUE indicates when the high beam light is ON Warning light D YELLOW indicates the reserve not activated Important When cleaning operation using a high pressure water jet cleaner avoid aiming the jet to the digital instrument panel B A C D 04_Inghilterra_059311 27 12 2007 18 10 Pa...

Page 53: ...nt information If the SCROLL pushbutton is pushed repeatedly the functions are displayed in sequenced screens in the following order 1st screen SPEED rpm indicator Odometer ODO 2nd screen SPEED rpm indicator Clock CLK 3rd screen SPEED rpm indicator Trip odometer TRIP 4th screen SPEED rpm indicator STP chronometer 1st screen SPEED rpm indicator Odometer ODO and so on SPEED RPM INDICATOR FUNCTIONS I...

Page 54: ...the SCROLL pushbutton for ap proximately three seconds After this time has elapsed the desired hour can be selected by pressing the SCROLL key When the pushbutton is released after three seconds the instrument panel will automatically shift to the min utes Select the minutes by pressing repeatedly the SCROLL pushbutton TRIP ODOMETER TRIP FUNCTION It indicates the distance travelled from the last r...

Page 55: ...e than 3 seconds to enter the time setting mode Once the time has been set press the button for about 3 sec onds to go back to the standard operating mode The Time pa rameter is displayed in the 0 12 format if Mph has been select ed and in the 0 24 format if Km h has been chosen When in the setting menu if no buttons are pressed for 20 seconds the sys tem will automatically return to the standard ...

Page 56: ...ameter reaches 000 0 the system auto matically sets it to 999 9 While in the setting menu if no buttons are pressed for 20 sec onds the system will automatically return to the standard oper ating mode Moving off Vel 0 while the setting mode is activated causes the system to automatically return to the standard operating mode SLEEP MODE One minute after the last pulse from the speed sensor has been...

Page 57: ...d Pressing the mode button for about 3 seconds while the corre sponding value is selected will return the system to the standard operating mode Installing the instrument panel The default circumference value is 2154 mm the units for speeds and distances are km h and km respectively The default setting for the number of pulses is 1 pulse per wheel turn To change any one of these parameters use the ...

Page 58: ...28 Workshop manual RR 4T 400 450 525 04_Inghilterra_059311 27 12 2007 18 10 Pagina 28 ...

Page 59: ...BODYWORK AND FITTINGS 5 05_Inghilterra_059311 27 12 2007 18 14 Pagina 1 ...

Page 60: ...anels Chap 5 4 Removing the rear side panels Chap 5 4 Removing the right hand side bumper Chap 5 4 Removing the left hand side bumper Chap 5 4 Removing the front mudguard Chap 5 5 Removing the fork covers Chap 5 5 Removing the headlight grille Chap 5 6 Workshop manual RR 4T 400 450 525 05_Inghilterra_059311 27 12 2007 18 14 Pagina 2 ...

Page 61: ...oving the saddle Remove the two fixing screws A one on each side lift the sad dle as shown in the figure and pull it back and off the vehicle Removing the rear mudguard Remove the two fixing screws B and then the two screws C and D from under the rear mudguard 5 Bodywork and fittings Release 01 Date 09 2007 A B C C 05_Inghilterra_059311 27 12 2007 18 14 Pagina 3 ...

Page 62: ...fastening the rear side pan el the upper screw also fixes the saddle Removing the right hand side bumper Unscrew the six fixing screws G remove the plastic clamp and take off the right hand side bumper if present Removing the left hand side bumper Unscrew the four fixing screws H remove the two plastic clamps and take off the left hand side bumper if present Workshop manual RR 4T 400 450 525 G H F...

Page 63: ...m under the mudguard Finally remove the two brace fixing screws N from the top of the brace Removing the fork covers Unscrew the eight fixing screws P five on the left side and three on the right side and remove the fork covers 5 Bodywork and fittings Release 01 Date 09 2007 L M M P 05_Inghilterra_059311 27 12 2007 18 14 Pagina 5 ...

Page 64: ...ving the headlight grille Release the two rubber bands Q as shown in the figure pull out the headlight and remove grille R Workshop manual RR 4T 400 450 525 Q R 05_Inghilterra_059311 27 12 2007 18 14 Pagina 6 ...

Page 65: ...NE SECTION REMOVING THE ENGINE FROM THE VEHICLE DISASSEMBLING THE ENGINE OVERHAULING THE ENGINE REASSEMBLING THE ENGINE INSTALLING THE ENGINE ON THE VEHICLE 6 63_Inghilterra_059311 27 12 2007 18 17 Pagina 1 ...

Page 66: ...2 Workshop manual RR 4T 400 450 525 63_Inghilterra_059311 27 12 2007 18 17 Pagina 2 ...

Page 67: ...ENGINE SECTION REMOVING THE ENGINE FROM THE VEHICLE 6 63_Inghilterra_059311 27 12 2007 18 17 Pagina 3 ...

Page 68: ... Chap 6 9 Removing the exhaust pipe Chap 6 9 Removing the drive chain Chap 6 9 Removing the engine swingarm pin Chap 6 10 Removing the rear suspension linkage Chap 6 10 Removing the rear end Chap 6 10 Removing the throttle twist grip assembly Chap 6 10 Removing the carburettor Chap 6 10 Removing the brake pedal pull off spring Chap 6 11 Removing the spark plug cap Chap 6 11 Removing the water deli...

Page 69: ...rds the back of the vehicle Removing the fuel tank To remove the tank together with the deflectors unscrew the left hand and right hand screws fixing it to the radiator Remove the central screw as shown in the figure and disengage the tank Close the fuel cock remove the fuel line and take off the reser voir 5 6 Engine Release 01 Date 09 2007 63_Inghilterra_059311 27 12 2007 18 17 Pagina 5 ...

Page 70: ... Remove the spring that fastens the silencer to the exhaust pipe Be careful to avoid injury from the spring Draining the cooling system Place a container as shown in the figure to collect the coolant Unscrew drain screw 1 on the cylinder front Remove the radiator cap in the upper part of the system and al low the coolant to drain completely Refit the drain screw using if necessary a new seal 6 Wor...

Page 71: ... move the lower pipe Removing the horn Remove the horn and the related bracket so as to facilitate the removal of the plastic bumper Loosen the two screws 1 and remove the left hand radiator Right hand radiator cylinder connecting pipe Remove the clamp shown in the figure and disconnect the right hand radiator lower pipe from the cylinder 7 6 Engine Release 01 Date 09 2007 1 63_Inghilterra_059311 ...

Page 72: ...al connections cutting the wire clamps where necessary Tipping over the rear frame It is now possible to overturn the rear frame towards the front of the vehicle To avoid scratching the rear mudguard place a soft cloth over the handlebars Disconnecting the rear brake pump Unscrew the two screws 1 to disengage the rear brake pump from the frame 8 Workshop manual RR 4T 400 450 525 1 2 1 63_Inghilter...

Page 73: ...ber Disengage the shock absorber from the frame as shown in the figure Removing the exhaust pipe It is now possible to remove the exhaust pipe by pulling it to wards the front of the vehicle Removing the drive chain Find the split link move it onto the sprocket and remove the re tainer as shown in the figure Undo the chain and remove it 9 6 Engine Release 01 Date 09 2007 63_Inghilterra_059311 27 1...

Page 74: ...d The swingarm assembly can now be removed from the vehicle Removing the throttle twist grip assembly When the carburettor needs to be removed it is advisable to re move the throttle twist assembly from the handlebars Removing the carburettor Detach the sleeve that connects the cylinder to the carburettor and remove the carburettor together with the cables and the previously removed twist grip 10 ...

Page 75: ...moving the front sprocket casing Unscrew screw 1 and screw 2 on the opposite side Removing the clutch pump assembly Remove the clutch assembly without disconnecting the pipe so as to avoid having to fill and bleed the system again 11 6 Engine Release 01 Date 09 2007 2 1 63_Inghilterra_059311 27 12 2007 18 18 Pagina 11 ...

Page 76: ... pivot pin Removing the kickstart Loosen the screw shown in the figure and remove the kickstart Removing the engine from the frame Remove the engine from the frame extracting it from the left side Place the engine on special tool 3625132 12 Workshop manual RR 4T 400 450 525 63_Inghilterra_059311 27 12 2007 18 18 Pagina 12 ...

Page 77: ...Pag 13 ENGINE SECTION DISASSEMBLING THE ENGINE 6 64_Inghilterra_059311 27 12 2007 18 22 Pagina 13 ...

Page 78: ... cylinder head top Chap 6 19 Removing the cylinder head the cylinder and the piston Chap 6 19 Removing the timing chain and gear Chap 6 21 Removing the electric start and kickstart gears Chap 6 22 Removing the primary torque gear and the free wheel Chap 6 23 Removing the gearshift mechanism and the gear shafts Chap 6 24 Removing the countershaft and the crankshaft Chap 6 25 14 Workshop manual RR 4...

Page 79: ...o pull out the oil filters WARNING There may be an outflow of residual oil dur ing this operation Removing the front sprocket Remove flange screw 5 together with the spring Remove the rear sprocket from the driven shaft Remove the distance ring from the driven shaft NOTE If the transmission and the clutch are in working order it is possible to shift into gear to lock the driven shaft If on the oth...

Page 80: ... all clutch cover screws and remove the cover with its gasket Remove the two centring bushes from the crankcase To prevent the clutch plates from jamming when the clutch springs are released loosen the screws following a crosswise pattern Remove the pressure plate with the screws spring bracket and clutch springs Remove thrust head 1 Remove all the lined and steel plates from the clutch drum Remov...

Page 81: ...is inserted in the related opening in the crankshaft Tighten the crankshaft fixing screw to 10 N m Pulling out the flywheel Unscrew the two screws 3 and remove the pick up from the crankcase Fit the puller and pull out the flywheel using the protective cap Remove the key from the crankshaft NEVER HIT THE FLYWHEEL WITH A HAMMER OR AN OTHER TOOL AS THIS COULD CAUSE THE FLY WHEEL MAGNETS TO COME OFF ...

Page 82: ...the two needle roller bearings 4 and the support washer Removing the oil pump Unscrew the two screws 5 and remove the oil pump cover Remove roller 6 inner rotor 7 and outer rotor 8 from the oil pump casing Remove oilway screws 9 e 10 with the related seal rings and then remove the oil line 3 3 4 6 7 8 9 10 64_Inghilterra_059311 27 12 2007 18 22 Pagina 18 ...

Page 83: ...ump cover 2 with the related gasket Unscrew all screws 3 on the cylinder head top Using a plastic mallet carefully hit area A in an upward direc tion and remove the cylinder head top Removing the cylinder head the cylinder and the piston Remove screw 4 with the seal ring and the compression spring Unscrew the two screws and pull the chain stretcher out of the cylinder 1 2 3 3 3 3 3 A 4 64_Inghilte...

Page 84: ... Remove the camshaft from the cylinder head Remove the three screws 1 NOTE There is no need to remove these three screws if the cylinder and the cylinder head require no servicing The cylinder and the cylinder head can be removed together without having to replace the cylinder head gasket The screw on the timing chain side is fitted with a copper seal ring 6x10x1 When refitting the parts replace t...

Page 85: ...timing chain and gear Loosen the two screws 1 and remove chain guard 2 Remove the timing chain Remove screws 3 and 4 pull the chain stretcher and the chain guide up and out of the crankcase Remove Seeger ring 5 Fit the puller and remove the timing gear from the crankshaft 1 2 4 3 5 1 64_Inghilterra_059311 27 12 2007 18 22 Pagina 21 ...

Page 86: ...nd unfas ten it WARNING TAKE CARE TO AVOID INJURY DUE TO THE RE LEASE OF THE KICKSTART SPRING Remove the kickstart shaft the starter coupling the spring and the washer from the crankcase Push back the guide plate and pull out the gear shaft and thrust washer 5 from the crankcase Remove screw 6 and the gear selector Unscrew screw 7 and remove the selector lever together with the bushing and the spr...

Page 87: ...T HAVE A LEFT HAND THREAD THOSE WITH NO INSCRIPTION HAVE A RIGHT HAND THREAD Pull out from the crankcase the oil pump shaft complete with the roller inner rotor 3 and outer rotor 4 Remove the two opposed screws 5 Fit the puller and remove the primary torque gear from the crankshaft Loosen the crankshaft fixing screw Unscrew all thirteen crankcase screws 1 4 3 5 2 64_Inghilterra_059311 27 12 2007 1...

Page 88: ... Remove the two centring bushes from the crankcase and fix the right hand crankcase half in the stand Remove thrust washer 1 O ring 2 and inner ring nut 3 Remove the two fork guide rods 4 with the four springs from the crankcase and turn the gearshift forks to one side Remove desmodromic mechanism 5 Remove gearshift forks 6 During the removal ensure that gearshift bushes A on the fork dragging pin...

Page 89: ...ft and the crankshaft are aligned In this position the crankshaft can be removed from its seat Remove the crankshaft Clean all the parts check them for wear and replace as nec essary NOTE When the engine is overhauled it is advisable to replace all gaskets oil seals O rings and bearings 64_Inghilterra_059311 27 12 2007 18 22 Pagina 25 ...

Page 90: ...26 Workshop manual RR 4T 400 450 525 64_Inghilterra_059311 27 12 2007 18 22 Pagina 26 ...

Page 91: ...Pag 27 ENGINE SECTION OVERHAULING THE ENGINE 6 65_Inghilterra_059311 27 12 2007 18 28 Pagina 27 ...

Page 92: ...ap 6 39 Decompressor shaft 2 Chap 6 39 Cylinder head Chap 6 40 Sealing surface Chap 6 41 Valve guides Chap 6 41 Valve seats Chap 6 41 Valves Chap 6 41 Valve springs Chap 6 41 Valve springs for the 250 cc model Chap 6 41 Valve stem linings Chap 6 41 Camshaft Chap 6 42 Preassembling the camshaft Chap 6 43 Automatic stretcher Chap 6 44 Valve gear control Chap 6 44 Checking the clutch for wear Chap 6 ...

Page 93: ...d be large enough to allow the crankcase sealing surfaces to rest completely on it A wooden surface is recommended for the purpose If a suitable press is unavailable fit the bearings and the seal rings with the greatest care using suitable tools Cold working bearings fall almost sponta neously into their respective seats when the crankcase hal ves reach a temperature of 150 C If the bearings are n...

Page 94: ...l with the open side facing inward Driven shaft oil seal 5 Fit the new oil seal pushing it from the outside to the correct le vel with the open side facing inward Countershaft ball bearing 6 Using a bearing puller extract the bearing from the crankcase half Insert the new bearing and push it to its abutting end Desmodromic mechanism ball bearing 7 At a temperature of approximately 150 C the ball b...

Page 95: ...ble drift push in the bearing from the outside Fit the new bearing pushing it from the inside to its abutting end NOTE Driving shaft ball bearing 3 is fastened by a screw Ap ply Loctite 243 to the screw thread and tighten to 5 N m Driven shaft ball bearing 4 Using a suitable drift push in the bearing from the outside Fit the new bearing pushing it from the inside to its abutting end Crankshaft oil...

Page 96: ...rom the outside Insert the new bearing pushing it in from the outside until it is flush When the crankcase half has cooled down ensure that the bearing is securely seated Kickstart release plate 5 When replacing the release plate apply Loctite 243 to the two screws and tighten to 8 N m Oil pump casing 6 should bear no signs of scoring or seizure Ensure that the passages of all oil channels 7 are c...

Page 97: ...pening pressure is reduced This entails a decrease in the oil pressure and thereby greater wear Blow all the oil channels with compressed air and check that the passages are clear Clutch cover Kickstart shaft oil seal 3 Remove the old oil seal with a screwdriver Fit the new oil seal and push it to its abutting end Crankshaft oil seal 4 Remove the old oil seal with a screwdriver Fit the new oil sea...

Page 98: ...TING ROD BEARING WILL RE CEIVE LITTLE OR NO OIL AND WILL CONSEQUENTLY BE DAMAGED If the crankshaft is to be reused be sure to check the offset of the shaft sections Place the crankshaft on a roller equalizer or similar equipment and use a comparator to measure the offset at the ends of the shaft sections Offset of shaft sections 0 08 mm Check the radial and axial plays of the connecting rod bearin...

Page 99: ...aft so that mark C is in the coupling shaft area Fit the fixing screws and tighten to 8 N m Before fitting a new inner collar heat the special tool again to about 150 C fit it with the inner collar and immediately push it onto the shaft section Allow the inner collar to cool down for about 30 seconds and then using a suitable tube hit the inner collar until it is seated properly After replacing th...

Page 100: ...inder 89 013 89 025 mm Cylinder diameter 525 size I cylinder 95 000 95 012 mm size II cylinder 95 013 95 025 mm Cylinder size 1 is stamped on the cylinder side in front of the chain tunnel piston size 2 is stamped on the piston top The piston is measured on the skirt transversally to the piston pin as shown in the figure Piston diameter 250 size I piston 74 960 74 970 mm size II piston 74 971 74 9...

Page 101: ...s Insert the piston ring in the cylinder and align it with the piston approx 10 mm under the upper edge of the cylinder Using a thickness gauge measure ring gap A Compression ring max 0 80 mm Scraper ring max 1 00 mm If the measurements exceeds the above values check the wear of the cylinder and piston If wear is within the allowable limits replace the piston ring Checking the oil pumps for wear I...

Page 102: ...ngs Oil pump cover 3 Check the inside for signs of seizure caused by the oil pump rotors and if necessary replace Oil pump shaft 4 Place the shaft on a flat surface and check its offset Oil pump gear 5 Check the teeth for wear The roller seat should not be damaged Oil units 6 Clean the two oil units with low pressure compressed air O rings 7 Check their porosity and if necessary replace them Oil p...

Page 103: ...e rocker arm rollers can slide freely If any radial play is found replace the rocker arm Adjusting screws 9 The contact surfaces of the adjusting screws should be flat Decompressor shaft 2 Check the sliding of the decompressor shaft and its play in the support hole Replace O ring 11 Replacing O rings 10 Before reassembly carefully oil all the components Position the rocker arms in the cylinder hea...

Page 104: ...th its gasket Using the specially designed tool remove the four valves The 250 cc model fits conical valves Used valves are to be reinserted in the same valve gui de To ensure this we recommend inserting the valves in a piece of cardboard in the same way they are fitted in the cy linder head see figure 65_Inghilterra_059311 27 12 2007 18 28 Pagina 40 ...

Page 105: ...n The sealing surface should be at the centre of the valve seat The valve stem is chromium pla ted wear generally occurs on the valve guide Valve springs Visually check that the valve springs are not broken or worn Measure their length with a vernier caliper The minimum al lowable valve length is 39 20 mm for the outer valve springs and 36 45 mm for the inner valve springs Replace as necessary Val...

Page 106: ...while extracting the latter from the camshaft Unscrew the two screws 8 and remove camshaft gear 9 Using the puller remove ball bearing 10 from the camshaft Clean and check all components and if necessary replace them Camshaft Check the support points and the cams for signs of wear Replace ball bearings 5 and 10 Decompressor shaft 7 Check the play of the shaft in the support and the wear of its con...

Page 107: ...of the two M3 threaded holes 4 without removing the cylinder head top 1 1 3 3 2 8 5 9 7 6 6 10 13 14 12 Preassembling the camshaft Apply Loctite 243 on the threads of the two screws 6 and fit camshaft gear 7 Tighten the screws to 28 N m Key ball bearing 5 with a socket punch Fit decompressor shaft 8 and spring 9 Preload the spring by approximately 1 2 turn and insert the spring end into slot B Che...

Page 108: ...pressure pin no longer jams and then fully insert the pressure pin into the stretcher body 1 3 4 2 Valve gear control Thoroughly clean all the components and check them for wear Timing pinion 1 Check the teeth for nicks or signs of wear Chain stretcher shoe 2 Check for signs of sliding on the contact surface Chain guide 3 Check for signs of sliding on the contact surfaces Chain coupling 4 Replace ...

Page 109: ...iscs must be flat Four 1 0 mm middle discs 6 Ensure that the discs are flat and free from mechanical damage Replace as necessary Four 1 4 mm middle discs 6A Ensure that the discs are flat and free from mechanical damage Replace as necessary Clutch hub 8 Check for damage and signs of wear Pressure plate 9 Check for signs of damage on contact surface A with the steel plate Clutch drum 10 Check the w...

Page 110: ...hole is clear Preassembling the kickstart shaft Clamp kickstart shaft 4 in a vice using protective jaws with its toothed end facing upwards Fit thrust washer 5 needle roller cage 6 and starter gear 1 with the stop teeth facing downwards Fit thrust washer 7 and Seeger ring 8 with the sharp edge fa cing upwards Fit dragging hub 9 taking care to align its groove with the ho le in the kickstart shaft ...

Page 111: ...nts C Check the wear of selector return surface D if the surface is deeply worn replace the selector Check that guide pin E is firmly seated and not worn Gearshift mechanism Preassemble the shaft of the gearshift mechanism and measu re clearance F between selector 6 and the guide plate The play should be 0 40 0 80 mm Preassembling the shaft of the gearshift mecha nism Clamp the short end of the sh...

Page 112: ...sion is repaired Assembling the driving shaft Clamp the driving shaft in a vice with its grooved end facing downwards use pro tective jaws Carefully oil all the components before assembling them Fit needle roller cage 2 top it with 5th speed idler gear 1 with the front couplings fa cing upwards Insert thrust washer 3 25 2x32x1 5 mm and Seeger ring 4 with the sharp edge fa cing upwards Fit 3rd 4th ...

Page 113: ... use pro tective jaws Carefully oil all components before assembling them Fit needle roller cage 2 and 2nd speed idler gear 1 on the driven shaft with the slot for the front couplings facing upwards Insert thrust washer 3 25 2x32x1 5 mm and Seeger ring 4 with the sharp edge fa cing upwards Fit 6th speed sliding gear 5 with the fork slot facing upwards Fit Seeger ring 6 and toothed washer 7 25 2x32...

Page 114: ...g measurements NOTE The following measurements correspond to the nominal values only at a temperature of 20 C If the measured values differ considerably from the nominal va lues replace the stator Replacing the stator Loosen screw 4 and remove the fixing plate Unscrew the two screws 5 and remove the stator from the ignition cover Position the new stator in the ignition cover Degrease the th reads ...

Page 115: ...l from the hub and check to see if there are any dents on contact surface A Thoroughly clean the free wheel hub Free wheel 4 Thoroughly clean the free wheel with petroleum and compressed air Check the free wheel segments for wear and oil it generously Free wheel gear 5 Fit the free wheel gear on the crankshaft and check the play If necessary replace the needle bushing Check for the pre sence of de...

Page 116: ...ch it from the primary gear Fit a new free wheel hub on the primary gear Degrease the screw threads apply Loctite 648 to them and ti ghten the screws to 16 N m following a crosswise pattern Carefully oil free wheel 2 and insert it into hub 5 Using a pair of Seeger ring pliers insert the expansion ring in to the groove and ensure that it is properly seated Once the expansion ring is in place we rec...

Page 117: ...ENGINE SECTION REASSEMBLING THE ENGINE 6 66_Inghilterra_059311 27 12 2007 18 32 Pagina 53 ...

Page 118: ...ming gear Chap 6 62 Fitting the piston and the cylinder Chap 6 63 Fitting the cylinder head Chap 6 63 Fitting the cylinder head top Chap 6 65 Fitting the automatic stretcher Chap 6 66 Adjusting the play of the valves Chap 6 66 Fitting the flywheel Chap 6 67 Fitting the pick up and the ignition cover Chap 6 67 Fitting the clutch Chap 6 68 Clutch plates Chap 6 68 Fitting the oil line Chap 6 69 Insta...

Page 119: ...the front and then insert the countershaft into its bearing Ensure that crankshaft mark A is between the two countershaft marks B Fitting the gearbox and the gearshift mechanism Turn the engine onto one side Simultaneously insert driving shaft 1 and driven shaft 2 into their respective bearings Attach bushes 3 to the gearchange forks with a little grease Attach the four springs 4 to the fork guide...

Page 120: ... the gearshift forks to the desmodromic mechanism and fit the two fork guide rods 2 along with the springs Ensure that the following parts are fitted inner race of bearing 3 O ring 4 thrust washer 5 2 centring bushes in the crankcase 56 Workshop manual RR 4T 400 450 525 1 A 4 5 2 2 3 66_Inghilterra_059311 27 12 2007 18 32 Pagina 56 ...

Page 121: ...m for the lengths of the screws refer to the diagram Check that all the shafts can move smoothly before and after tightening the crankcase screws to 10 N m Clamp the engine in the stand Accurately cut off the gasket that protrudes from the cylinder base and the sealing surfaces Check to see if the key is fitted to the crankshaft Carefully oil the free wheel and the needle roller cage in the free w...

Page 122: ...as been removed it can now be eas ily refitted Fit oil pump gear 3 thrust washer 4 and safety washer 5 Check the smoothness of the oil pump shaft by turning the oil pump gear Using a cloth carefully clean the rest surface of the oil pump cover Position the inner and outer rotors in the crankcase so that the two centres A and B are placed next to each other The inner and outer rotors should be fitt...

Page 123: ...washer un til the selector comes into contact with the gear selector Push back the selector and push in the gear control shaft un til it stops Check that spring ends A touch crankcase dog B on the left and right sides Fit the gearchange lever and then insert all the gears in suc cession When changing gears turn the driving shaft then re move the gearchange lever again Fitting the electric start an...

Page 124: ...ach the spring link to the starter spring apply Loctite 243 to the thread of screw 3 M6x12 preload the starter spring by turning it about 45 degrees clockwise fasten the spring link with the screw and tighten to 10 N m Position the starter spring so that the distance from the kick start shaft does not change Exercise extreme caution when fitting the spring as it could come off and cause personal i...

Page 125: ...dure fit flange nut 5 and tighten it to 150 N m Secure the flange nut with safety plate 6 as shown in the fig ure As a rule there is no need to heat a used clutch hub be fore fitting it Fitting the primary pinion nut Position the special tool as shown in the figure Degrease the crankshaft thread and apply Loctite 243 to it Fit flange nut 7 and tighten it to 150 N m Bring the crankshaft to the top ...

Page 126: ...g the two bush es Fit the chain stretcher shoe locking the screw in the seat in the crankcase B NOTE AFTER TIGHTENING THE CHAIN STRETCHER SHOE ENSURE THAT IT CAN SLIDE FREELY Fit the timing chain so that the two stretches have the same length NOTA The timing chain can also be fitted after fitting the cylin der and the cylinder head Degrease the threads of the two screws 7 M5x16 and apply Loctite 2...

Page 127: ...unting ring WHEN FITTING THE CYLINDER TAKE CARE NOT TO BREAK THE OIL SCRAPER RING Fitting the cylinder head Check that the two centring bushes are properly seated in the cylinder Fit a new cylinder gasket with the inscription ALTO facing upwards and fit the cylinder head and the timing chain Oil the threads and the contact surfaces of the four flange screws and fit them along with the related wash...

Page 128: ...using the crankshaft fixing screw Fit the timing chain on the camshaft gear and then fit a new chain joint 1 First fit the insert of the special tool as shown in the figure and then press the chain joint Fit the insert of the special tool as shown in the figure and riv et the chain joint The nailing of the chain coupling should be so strong that the cross section of the coupling piece ends is trap...

Page 129: ... adjust the axial play of the rocker arms To this end insert a thickness gauge 1 0 05 mm between the terminal and the rocker arm Push in the terminal and tighten the screw next to the terminal Tighten the other screws to 10 N m following a crosswise pat tern Rocker arm axial play 0 02 0 10 mm Fit the fitting cap grease the O rings and fit the seal holder so that its abutting end faces the camshaft...

Page 130: ...etween the valve stem and the ad justing screw when the engine is cold Cold valve play 0 12 mm NOTE IF THE PISTON IS NOT AT THE TOP DEAD CENTRE THE VALVES ARE ACTUATED BY THE ROCKER ARMS AND THE PLAY OF THE VALVES CANNOT BE PROPERLY AD JUSTED IN THAT CASE ROTATE THE CRANKSHAFT ONE MORE TURN AND THEN LOCK IT AGAIN After completing the adjustment tighten the counternuts to 11 N m Fit the two valve c...

Page 131: ...retainer tighten the flange nut to 60 N m Fitting the pick up and the ignition cover Position the pick up in the crankcase and insert cable guide 2 in the specially designed opening in the crankcase Degrease the thread of the two screws 3 M5x16 apply Loc tite 243 and tighten the screws to 6 N m Fit a new gasket and fasten the ignition cover with the four screws 4 and 5 Tightening torque 10 N m NOT...

Page 132: ...screws 7 to 10 N m following a crosswise pattern Ensure that the centring bushes are fitted in the crankcase Grease all the oil seals in the clutch cover and fix the clutch cover gasket with a little grease Take special care in ensuring that oil jet 8 in the crankcase is not blocked by the gasket Pour approximately 30 ml of engine oil in the crankshaft hole M6x35 M6x30 M6x30 M6x30 M6x30 M6x35 Care...

Page 133: ... motor and insert the mo tor in the crankcase Fit the two screws 4 M6x20 and tighten them to 8 N m Oil distance ring 5 and slide it onto the driven shaft with the groove for the O ring facing inward Fit the chain sprocket with the high collar facing inward Degrease the flange nut thread apply Loctite 243 to it and tighten the screw with the spring washer to 60 N m NOTE Before tightening the screw ...

Page 134: ... F 15W 40 15W 50 10W 40 10W 50 API SG SH TEMPERATUR Remove the clamping screw from the clutch cover and pour in 1 20 litres of 10W 50 engine oil see table in Chapter 3 Tight ening torques Specifications Recommended products Replace the clamping screw and check the seal of the engine NOTE Check the engine oil level after reinstalling the engine on the vehicle WE RECOMMEND USING ONLY SYNTHETIC OILS ...

Page 135: ...ENGINE SECTION INSTALLING THE ENGINE ON THE VEHICLE 6 67_Inghilterra_059311 27 12 2007 18 38 Pagina 71 ...

Page 136: ...ed for its removal in rever se order taking care to apply the tightening torques and use the products specified in Chapter 3 Tightening torques Specifications Recommended products 72 Workshop manual RR 4T 400 450 525 67_Inghilterra_059311 27 12 2007 18 38 Pagina 72 ...

Page 137: ...CARBURETTOR 7 07_Inghilterra_059311 27 12 2007 18 44 Pagina 1 ...

Page 138: ...8 Checking the throttle valve Chap 7 8 Reassembling the carburettor Chap 7 9 Adjusting the position of the throttle sensor Chap 7 12 Checking the throttle sensor Chap 7 13 Removing and refitting the throttle sensor Chap 7 13 Carburettor Idle speed adjustment Chap 7 14 Basic information about carburettor wear Chap 7 14 Mixture adjusting screw Chap 7 14 Checking the float level Chap 7 14 2 Workshop ...

Page 139: ...3 7 Carburettor Release 01 Date 09 2007 CARBURETTOR KEIHIN FCR M X 39 07_Inghilterra_059311 27 12 2007 18 44 Pagina 3 ...

Page 140: ...ays work in a well ventilated area Never use petrol as a cleaning solvent Handle petrol on ly if absolutely necessary Do not use petrol to clean compo nents that need to be blown with compressed air Keep out of the reach of children When refitting fit the carburettor to the sleeves and fasten it with the two hose clamps Ensure that the carburettor is fitted vertically in relation to the vehicle Re...

Page 141: ...oosen the two screws 1 and remove all breather pipes from the carburettor Remove the two screws 2 and remove the throttle valve cov er from the carburettor with the related gasket Remove screw 3 and pull the jet needle out of the throttle valve Remove screw 4 Pull up the throttle valve lever and remove the throttle valve complete with roller 5 and the throttle valve plate from the car burettor 1 1...

Page 142: ...ve Remove main jet 2 Loosen screw 3 and using a pair of pliers carefully remove the float needle valve support from the carburettor Unscrew idling jet 4 starting jet 5 and nozzle 6 Tighten mixture adjusting screw 7 until it stops taking note of the screw turns Unscrew the mixture adjusting screw and remove it together with the spring washer and O ring NOTE As a rule the spring the washer and the O...

Page 143: ...r Loosen the two screws and remove the suction pump and O ring 4 from the carburettor Unscrew choke idling jet 5 and choke main jet 6 Clean all the jets and the other components and blow them with compressed air Clean the carburettor body and blow all the ducts inside it Check the condition of all the gaskets and replace any dam aged ones 7 7 Carburettor Release 01 Date 09 2007 2 3 6 6 4 1 07_Ingh...

Page 144: ...ure that the jet needle is not bent or worn Checking the float needle valve Check to see if the sealing surface of the needle valve presents any dimples There should be no dirt between the valve seat and the float needle Checking the throttle valve Throttle valve rollers 3 should rotate easily and have no flat ar eas Check that throttle valve plate 4 is not damaged 1 2 2 3 4 8 Workshop manual RR 4...

Page 145: ...y Also check if the knob engages properly Fit the spring the washer and the O ring on mixture adjusting screw 7 and tighten the screw until it stops Unscrew the mixture adjusting screw by the number of turns that was taken note of during disassembly Original carburettor adjustment see table in Chapter 3 Specifications Fit idling jet 8 starting jet 9 and the nozzle complete with main jet 10 Insert ...

Page 146: ...ring in the pump casing Fit O ring 6 in the groove Fix seal ring 7 in the cover with a lit tle grease and fasten the cover with the three screws Fit the throttle sensor so that the flat area on the carburettor engages the throttle sensor slot and fasten it by means of screws 10 Pull up the throttle valve lever and insert the throttle valve along with roller 8 and the plate in the carburettor ensur...

Page 147: ...n it with screw 2 Position the throttle valve cover with the related gasket and fasten it with the two screws 3 Fasten the breather pipes with the two float chamber screws 4 11 7 Carburettor Release 01 Date 09 2007 2 1 3 3 4 4 07_Inghilterra_059311 27 12 2007 18 44 Pagina 11 ...

Page 148: ...d vary evenly Removing and refitting the throttle sensor Unplug the throttle sensor and loosen screws 1 Remove the throttle sensor from the carburettor THROTTLE SENSOR RESISTANCE 4 6 kΩ 12 Workshop manual RR 4T 400 450 525 When fitting the throttle sensor ensure that the flat section of the throttle pin engages the throttle sensor slot Fit the two screws without tightening them and adjust the po s...

Page 149: ...e due to an idling jet of unsuitable size a If the mixture adjusting screw is turned until it stops and the idle speed does not change a smaller idling jet is needed b If the engine stalls while the mixture adjusting screws is still open by two turns a larger idling jet is required It goes without saying that after replacing the jet the adjust ment will have to be restarted from the beginning 5 Tu...

Page 150: ...14 Workshop manual RR 4T 400 450 525 07_Inghilterra_059311 27 12 2007 18 44 Pagina 14 ...

Page 151: ...Pag 1 FRONT SUSPENSION WHEEL 8 08_Inghilterra_059311 27 12 2007 18 49 Pagina 1 ...

Page 152: ...uling and changing the adjustment of the cartridge and the foot valve Chap 8 11 Overhauling the cartridge rebound damping Chap 8 11 Removal Chap 8 11 Installation Chap 8 12 Overhauling the foot valve compression damping Chap 8 12 Removal Chap 8 12 Installation Chap 8 13 Reassembling the fork leg and the sheath Fitting the seal rings Chap 8 13 Reassembling the pump assembly and the foot valve Chap ...

Page 153: ...3 8 Front suspension wheel Release 01 Date 09 2007 08_Inghilterra_059311 27 12 2007 18 49 Pagina 3 ...

Page 154: ...justing screw 21 Spring 24 Spring guide 25 Preload tube 28 Foot pad 30 Cartridge case 31 Inside rod 32 Pump rod 33 Fin pull off spring 34 Rebound piston fin 36 Pump piston 37 Rebound damping piston reeds 39 Upper sliding bush 41 Foot valve 43 Compression valve fin 45 Foot valve piston 46 Compression damping valve reeds 48 Cap 70 Wheel holder 71 Rebound adjusting screw 72 Jet needle 73 Case cover 0...

Page 155: ...table of tightening torques in Chapter 3 Tightening torques Specifications Recom mended products Remove the leg protections the front mudguard and the mud guard grille see Chapter 5 Bodywork and fittings Unscrew the two screws 1 disconnect the caliper assembly re move the pipe from the fork and disconnect the speed sensor cable Unscrew the four screws on the left side and the four screws on the ri...

Page 156: ...hecking the head tube seats Check the seats for wear If necessary remove them using a suitable drift For each seat use a drift and a hammer to alternately hit the grooves in the head tube to the left and right of the seat Use the drift from above to remove the lower seat Use the drift from below to remove the upper seat 6 Workshop manual RR 4T 400 450 525 1 2 08_Inghilterra_059311 27 12 2007 18 49...

Page 157: ...ally press wiper seal 12 back into its seat 12 50 14 Air bleed screw NOTE This operation is to be performed with the fork installed on the vehicle and the fork legs fully extended front wheel off the ground Owing to the particular shape of the seal rings air getting into the fork legs during use may remain trapped and cause fork malfunctions Removal Using a cross tip screwdriver unscrew air bleed ...

Page 158: ...anner to be inserted in counternut 23 While holding counternut 23 in position with the 19 mm span ner use another 19 mm spanner to completely unscrew plug 48 48 31 20 21 32 25 Remove plug 48 spring guide cup 20 spring 21 and preload tube 25 Remove adjuster inside transmission rod 32 from the end of rod 31 Release fork leg 5 from the vice and turn it upside down over a suitable container to collect...

Page 159: ...he tool must on no account be turned but should only be used to hold the fork leg inside components in place Using the 21 mm socket wrench unscrew foot valve 41 Remove foot valve assembly 41 Remove shock absorber assembly 21 from fork leg 5 21 5 23 24 Unscrew and remove counternut 23 and remove spring guide 24 To be able to work on the pump it is first necessary to remove the components of the sto...

Page 160: ... below NOTE The pump can be completely overhauled and adjusted Check ring 35 for wear 35 12 Separating the fork leg from the leg holder and removing the seal rings Using a small flat blade screwdriver remove wiper seal 12 Using the same screwdriver remove metal retaining ring 11 11 08_Inghilterra_059311 27 12 2007 18 49 Pagina 10 ...

Page 161: ...r guide bush 8 cup 9 seal ring 10 retaining ring 11 and dust scraper 12 from the fork leg Do not reuse the removed seal rings and wiper seals 39 8 10 11 9 12 32 38 Overhauling and changing the adjustment of the cartridge and the foot valve Overhauling the cartridge rebound damping Removal Clamp the milled portion of rod 32 in a vice Depending on the type of nut used unscrew nut 38 with a 12 mm or ...

Page 162: ...d end The piston should be oriented so that the smaller holes face adjusting fins 37 Manually screw in nut 38 Clamp the milled part of damping rod 32 in a vice Using a suitable spanner 12 mm or 13 mm based on the nut used tighten nut 38 to the prescribed torque see table in Chapter 3 Tightening torques Specifications Recommend ed products 35 37 36 34 33 32 38 42 47 Overhauling the foot valve compr...

Page 163: ...hrough spanner slot 47 Using a 13 mm spanner tighten nut 42 to the prescribed torque see table in Chapter 3 Tightening torques Specifica tions Recommended products 42 47 Reassembling the fork leg and the sheath Fitting the seal rings Never reuse any removed seal rings and wiper seals Be fore reassembly check the condition of the guide bush es If they are scored or scratched replace them Ensure tha...

Page 164: ...e to ensure that the upper guide bush does not receive damage Move the lower guide bush until it comes into contact with the sheath the cup and the seal ring Fit the specially designed inserter on fork leg 5 and use it to push seal ring 10 until the lower guide bush the cup and the seal ring are properly seated 10 5 11 Using a small flat blade screwdriver fit retaining ring 11 en suring that it is...

Page 165: ...that the side with the spanner slot faces case 30 and the tip goes past wire groove F Fit wire 27 into groove F Bring tip 29 into contact with the retaining ring Insert foot pad 28 so that slotted holes for the passage of oil face the tip Insert upper nut 26 and screw it on tip 29 26 32 28 27 F 29 26 29 Holding nut 26 with an 18 mm spanner tighten tip 29 to the prescribed torque see table in Chapt...

Page 166: ...eath all the way up along the fork leg Prepare the oil to be poured into the fork leg in a measuring cup see table in Chapter 3 Tightening torques Specifications Recommended products Pour approximately 2 3 of the oil into sheath 13 then pump a few times to remove the air Pour in the rest of the oil Lower the leg holder on the fork leg until the wiper seal comes into contact with the wheel holding ...

Page 167: ...ng adjusting screw R see table in Chapter 3 Tightening torques Specifications Recommended products 48 Reinstalling the fork on the vehicle Follow the reverse procedure to the removal observing the tightening torques specified in the table in Chapter 3 Tightening torques Specifications Recommended products To ensure proper operation of the fork fit the wheel on the fork by following these steps Ins...

Page 168: ...18 Workshop manual RR 4T 400 450 525 08_Inghilterra_059311 27 12 2007 18 49 Pagina 18 ...

Page 169: ...Pag 1 REAR SUSPENSION WHEEL 9 09_Inghilterra_059311 27 12 2007 18 53 Pagina 1 ...

Page 170: ... the rear wheel Chap 9 4 Removing the rear sprocket Chap 9 4 Removing the rear brake disc Chap 9 4 Removing the swingarm Chap 9 5 Removing the shock absorber Chap 9 5 2 Workshop manual RR 4T 400 450 525 09_Inghilterra_059311 27 12 2007 18 53 Pagina 2 ...

Page 171: ...ttempting to remove the rear suspension place the vehicle on a central stand with the rear wheel off the ground 3 9 Rear suspension wheel Release 01 Date 09 2007 09_Inghilterra_059311 27 12 2007 18 53 Pagina 3 ...

Page 172: ... sprocket from the wheel hub WARNING Important Follow these steps to properly tighten the rear sprocket Apply medium resistance threadlocking Loctite to the screw threads Using a torque spanner tighten the six sprocket locknuts to 25 30 N m Check the tightening by turning the six inside nuts with a hexagonal long arm CH13 spanner 400 500 mm All the nuts should be securely locked Removing the rear ...

Page 173: ... the swingarm Disengage the swingarm from the rear brake line and from the caliper with its support bracket Unscrew the swingarm frame pin and the swingarm linkage pin Remove the swingarm Removing the shock absorber Unscrew pins 1 and 2 and unfasten the rear suspension link age Remove the upper shock absorber fastener 5 9 Rear suspension wheel Release 01 Date 09 2007 2 1 2 1 09_Inghilterra_059311 ...

Page 174: ...6 Workshop manual RR 4T 400 450 525 09_Inghilterra_059311 27 12 2007 18 53 Pagina 6 ...

Page 175: ...Pag 1 BRAKING SYSTEM 10 10_Inghilterra_059311 27 12 2007 18 56 Pagina 1 ...

Page 176: ... front brake pads Chap 10 5 Replacing the front brake caliper pistons Chap 10 5 Replacing the rear brake pump Chap 10 6 Replacing the rear brake pads Chap 10 7 Replacing the caliper pistons Chap 10 7 2 Workshop manual RR 4T 400 450 525 10_Inghilterra_059311 27 12 2007 18 56 Pagina 2 ...

Page 177: ...ions are necessary especially if the vehi cle is used in competitions Visually check all the components and in particular the pump the pipes and the caliper Ensure that there are no leakages and that all the components are in good condi tion 3 10 Braking system Release 01 Date 09 2007 10_Inghilterra_059311 27 12 2007 18 56 Pagina 3 ...

Page 178: ...er emptying the system Avoid disposing of the fluid in the environment Dispose in accordance with the law Remove the pump and replace it with a new spare kit Subsequently replenish and bleed the system see Chap ter 4 Maintenance Only use DOT 4 or DOT 5 1 oil 4 Workshop manual RR 4T 400 450 525 1 10_Inghilterra_059311 27 12 2007 18 56 Pagina 4 ...

Page 179: ... and grease as these substances greatly reduce the braking action Every time the braking system is serviced operate the brake lever to bring the pads into contact with the disc restore the cor rect pressure point and ensure proper operation of the braking system Replacing the front brake caliper pistons Loosen the two screws C and remove the brake caliper Re peatedly pull the brake lever In these ...

Page 180: ...the environment Dispose in accordance with the law Remove right hand guard 1 if present Unscrew nut 2 to disengage the brake lever pump Remove the pump from below and replace it with a new one from the spare kit Subsequently replenish and bleed the system see Chap ter 4 Maintenance Only use DOT 4 or DOT 5 1 oil 1 2 10_Inghilterra_059311 27 12 2007 18 56 Pagina 6 ...

Page 181: ...an reach their base position Loosen grub screw A Pull out pin B while supporting the two pads see figure Remove the pads taking care not to drop the leaf spring above them To refit the parts follow the reverse procedure When fitting the brake pads ensure that the leaf spring is properly posi tioned Replacing the caliper pistons After removing the caliper and the brake pads repeatedly actu ate the ...

Page 182: ...8 Workshop manual RR 4T 400 450 525 10_Inghilterra_059311 27 12 2007 18 56 Pagina 8 ...

Page 183: ...Pag 1 ELECTRICAL SYSTEM 11 11_Inghilterra_059311 27 12 2007 18 59 Pagina 1 ...

Page 184: ...2 Workshop manual RR 4T 400 450 525 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 11_Inghilterra_059311 27 12 2007 18 59 Pagina 2 ...

Page 185: ...OR 12V 18 ELECTRIC FAN KIT option 19 LEFT HAND REAR TURN INDICATOR 12V 10W BULB 20 NUMBER PLATE LIGHT 12V 5W BULB 21 REAR LIGHT 12V 5 21W BULB 22 RIGHT HAND REAR TURN INDICATOR 12V 10W BULB 23 BATTERY POSITIVE TERMINAL 24 BATTERY 12V 5Ah 25 GENERATOR 26 10A FUSE 27 EARTH BRAID 28 STARTER RELAY 29 STARTER MOTOR 30 BATTERY NEGATIVE TERMINAL 31 ELECTRONIC CONTROL UNIT 32 SPARK PLUG 33 AT COIL 34 REAR...

Page 186: ...4 Workshop manual RR 4T 400 450 525 11_Inghilterra_059311 27 12 2007 18 59 Pagina 4 ...

Page 187: ...LATOR 12 ELECTROVALVE KIT OPTIONAL 13 TAIL LAMP LED 14 FUSE 10 A 15 EARTH BRAID 16 POSITIVE BATTERY 17 STARTER RELAY 18 STARTER MOTOR 19 NEGATIVE BATTERY 20 BATTERY 12V 4AH 21 PICK UP 22 ELECTRONIC CONTROL UNIT 23 AT COIL 24 SPARK PLUG 25 EARTH CONNECTION FRAME 26 POSITION LAMP 12V 5W 27 HEADLAMP 12V 35 35W KEY TO COLOURS BI WHITE VE GREEN MA BROWN VI PURPLE BL BLUE NE BLACK GI YELLOW RS RED AR OR...

Page 188: ...6 Workshop manual RR 4T 400 450 525 11_Inghilterra_059311 27 12 2007 18 59 Pagina 6 ...

Page 189: ...V REGULATOR 19 LEFT HAND REAR TURN INDICATOR 12V 10W BULB 20 NUMBER PLATE LIGHT 12V 5W BULB 21 REAR LIGHT 12V 5 21W BULB 22 RIGHT HAND REAR TURN INDICATOR 12V 10W BULB 23 BATTERY POSITIVE TERMINAL 24 BATTERY 12V 4AH 25 GENERATOR 26 10A FUSE 27 EARTH BRAID 28 STARTER RELAY 29 STARTER MOTOR 30 BATTERY NEGATIVE TERMINAL 31 REAR STOP LAMP RELAY 32 ELECTRONIC CONTROL UNIT 33 HV COIL 34 SPARK PLUG 35 CO...

Page 190: ...tage regulators Chap 11 7 Checking the charging voltage Chap 11 7 CDI unit Chap 11 8 Checking the ignition coil Chap 11 8 Troubleshooting the ignition system Chap 11 8 Main fuse Chap 11 9 Checking the starting relay Chap 11 9 Checking the starter motor Chap 11 10 Instrument panel Chap 11 10 8 Workshop manual RR 4T 400 450 525 11_Inghilterra_059311 27 12 2007 18 59 Pagina 8 ...

Page 191: ...a voltmeter to measure the voltage between the battery terminals voltage at rest Maximum tolerance of measuring instrument 1 per cent To obtain a correct measurement do not charge or discharge the battery for at least 30 minutes before performing the ope ration If the battery charge cannot be determined the battery can be charged for a maximum of 10 hours with 0 5 amperes and a maximum of 14 4 vol...

Page 192: ...ts are empty remove the con tainer from the battery Carefully close the filler openings with the cover NOTE After filling the battery allow it to rest for at least half an hour without charging it IMPORTANT WHEN FILLING A NEW BATTERY BE SURE TO FOLLOW THE DIRECTIONS PROVIDED IN THE ENCLOSED INSTRUCTION SLIP WHICH ALSO PROVIDES THE SAFETY RULES TO BE FOLLOWED FAILURE TO OBSERVE THESE RULES MAY LEAD...

Page 193: ...a voltmeter to the two battery connections Rev the engine to 5000 rpm and read the voltage Nominal value 14 0 15 0 V If the measured value differs considerably from the nominal va lue follow these step Check the plug between the stator and the regulator rectifier and the plug between the regulator rectifier and the wiring harness Check the stator Replace the regulator rectifier 1 2 3 4 1 2 3 4 Pun...

Page 194: ...ition Battery charge Main fuse Check if a spark is produced when the engine is started by fol lowing these steps Remove the spark plug cap Separate the spark plug cap from the ignition cable Keep the free end of the ignition cable about 5 mm for an earth connection When the starter motor is operated a bright electrical spark should be produced If the battery charge is very low use the kickstart If...

Page 195: ... has a capacity of 10 amperes WARNING Do not on any account fit a fuse of greater power or attempt to fix the damaged fuse Unsuitable servicing could cause dama ge to the entire electrical system Checking the starting relay Disconnect the starting relay multiple plug Disconnect the negative terminal from the battery and the two wires from the starting relay C D Connect the starting relay to a 12 V...

Page 196: ...ry to the starter motor casing and momentarily connect the battery positive terminal with starter motor connector 3 use thick cables When the electrical circuit is closed the starter motor should begin to turn If that is not the case replace the starter motor 14 Workshop manual RR 4T 400 450 525 11_Inghilterra_059311 27 12 2007 18 59 Pagina 14 ...

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