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TROUBLESHOOTING

CHARTER 5 TROUBLESHOOTING

CONTENTS

Troubleshooting ................................................................................... 58

Содержание ENDURO SPORT

Страница 1: ...contains the information you need to properly operate and maintain your motorcycle The data and specifications provided in this manual does not constitute an engagement on the part of BETAMOTOR S p A BETAMOTOR reserves the right to make any changes and improvements to its models at any moment and without notice Code 024440080 000 ...

Страница 2: ... 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 For any servicing requirements please get in contact with Beta motor s authorized service network ...

Страница 3: ...uelling 32 Oil mixer refuelling 33 Starting the engine 33 Engine shut down 33 CHAPTER 3 ADJUSTMENTS 35 Adjustment of brakes 36 Adjustment of clutch lever 36 Adjustment of idling speed 36 Adjustment of gas clearance 37 Adjusting the fork Factory 37 Adjusting the spring preload Factory 37 Adjusting the shock absorber Enduro Motard Motard Sport Track 38 Adjusting the compression and extension brake F...

Страница 4: ...ng play 48 Chain 49 Headlight 50 Replacing the headlight bulbs 50 Tail light 50 Cleaning the vehicle 51 Prolonged inactivity 52 Maintenance schedule 53 CHAPTER 5 REMOVING AND INSTALLING SUPERSTRUCTURES 55 Removing and installing of the saddle 56 CHARTER 5 TROUBLESHOOTING 57 Troubleshooting 58 ...

Страница 5: ...te warranty SYMBOLS SAFETY ATTENTION Failure to respect information 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 vehicl...

Страница 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 ...

Страница 7: ...ntification 8 Familiarizing with the vehicle 9 Main parts 9 Technical data 10 Vehicle dimensions 10 Tyres 10 Filling capacity 11 Front suspension 11 Rear suspension 12 Front brake 12 Rear brake 12 Engine 12 Fuel system 13 Electrical system 14 Electrical diagram 14 Legend electrical diagram 15 Recommended lubricants and liquids 16 ...

Страница 8: ...FICATION Frame identification data A are stamped on the right side of the steering head tube ENGINE IDENTIFICATION Engine identification data B are stamped on the l h side half crankcase WARNING Tampering with the identification numbers is severely punished by law B A ...

Страница 9: ...k cap 3 Silencer 4 Rear shock absorber 5 Headlight 6 Rear light 7 Side stand 8 Fork 9 Rider s footrests 10 Kickstarter 11 Saddle 12 Engine 13 Front mudguard 14 Number plate holder 15 Side panel air filter cover 16 Front side panel 17 Rear side panel 18 Fork covers 19 Rear mudguard 4 5 6 9 14 13 16 17 19 2 18 ...

Страница 10: ...t from ground mm 1225 1155 1225 1190 1155 Clearance from ground mm 350 315 350 345 315 Saddle height mm 935 900 935 930 900 Footrest height mm 405 365 405 395 365 Dimensions mm 1415 1390 1415 1385 1390 FRAME steel double cradle frame TYRES ENDURO SPORT ENDURO Front tyre Rear tyre Dimension Pressure Bar Dimension Pressure Bar 80 90 21 1 110 80 18 1 FACTORY Front tyre Rear tyre Dimension Pressure Ba...

Страница 11: ...l the models 500cc FACTORY 850cc crank case transmission oil 10W 30 820cc FRONT SUSPENSION Version ENDURO SPORT MOTARD SPORT ENDURO MOTARD FACTORY TRACK Fork leg diameter mm 40 37 41 41 Wheel stroke mm 245 205 6 265 210 Right fork leg Left fork leg Right fork leg Left fork leg Oil type SAE 15 SAE 10 SAE 15 SAE 15 Oil quantity ml 360ml 300ml 450ml 450ml 370ml 370ml Register spring preload X X 10 fr...

Страница 12: ...x FRONT BRAKE disk type with hydraulic control Ø 260 mm REAR BRAKE disk type with hydraulic control Ø 210 mm ENGINE type single cylinder two stroke bore x stroke 40 3x39 mm displacement cm3 49 7 cm3 compression ratio 12 1 liquid cooled ignition electronic MORIC 120W kick starter spark plug NGK BR9 ES clutch wet multidisc gearchange 6 speed primary drive Z 20 71 final drive MOTARD MOTARD SPORT TRAC...

Страница 13: ...S Main jet 76 115 Slow jet 34 34 Start jet 45 45 Needle A39 A39 Needle position from top 2 2 Air screw turns from fully closed 1 1 2 1 1 2 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 ...

Страница 14: ...1 GENERAL INFORMATION 14 GB ELECTRICAL SYSTEM ELECTRICAL DIAGRAM ...

Страница 15: ...OUBLE FILAMENT BULB 8 SIDE TAILLIGHT BULB 12V 5W 9 ENGINE STOP BUTTON 10 HORN BUTTON 11 HEADLIGHT SELECTOR 12 TURN SIGNAL LAMPS SWITCH 13 L H FRONT TURN INDICATOR 14 REGULATOR 15 ENGINE STOP BUTTON 16 OIL LEVEL SENSOR NOT FITTED ON FACTORY 17 L H REAR TURN INDICATOR 18 R H REAR TURN INDICATOR 19 REAR LIGHT LIT BY LED 20 PLATE ILLUMINATION 21 NEUTRAL SENSOR 22 GENERATOR 23 ELECTRONIC CONTROL UNIT 2...

Страница 16: ...BRAKE OIL DOT 4 OLIO PER FORCELLE RR50 Enduro Sport FORC Ø 40 SAE 10W Motard Sport RR50 Enduro FORC Ø 37 SAE 7 5W Motard RR50 Factory FORC Ø 41 RR50 Track FORC Ø 41 GREASE FOR JOINTS AND RODS LIQUI MOLY SCHMIERFIXIX LIQUID COOLANT LIQUI MOLY COOLANT READY MIX RAF12 PLUS RECOMMENDED LUBRICANTS AND LIQUIDS For better operation and longer vehicle life we advise you to use the products listed in the f...

Страница 17: ... pedal 21 Kickstart 21 Side stand 21 Keys 22 Steering Lock 22 Digital rpm indicator operating instructions 23 Main parts 23 Warning lights 24 Battery replacement 24 Adjust button function instruction 25 Select button function instruction 26 To enter the setting mode 27 Checks before and after use 31 Breaking in 31 Refuelling 32 Oil mixer refuelling 33 Starting the engine 33 Engine shut down 33 ...

Страница 18: ...e cap B A B ON RES OFF FUEL COCK Fuel cock has three positions OFF fuel supply closed Fuel cannot pass from the tank to the carburettor ON fuel supply enabled Fuel flows from the tank to the carburettor The tank empties until it reaches the reserve level RES reserve fuel supply Fuel flows from the tank to the carburettor and the tank empties completely ...

Страница 19: ...nk cap set it on the tank and screw it clockwise WARNING The model Factory has no mixer therefore in the fuel tank must be introduced directly gasoline oil mixture to 1 5 Use the oil indicated on page 16 in the Recommended lubricants and liquids table STARTER The starter lever is located on the left side of the handlebar To operate the starter rotate the lever coun terclockwise ...

Страница 20: ...follows 1 Horn button 2 Dip switch parking lights and high beam parking lights and low beam 3 Shut down 4 Turn signal light switch 1 2 FRONT BRAKE LEVER AND GAS CONTROL The front brake lever 1 and the gas throt tle 2 are located on the right side of the handlebar 1 2 3 4 5 6 GEAR CHANGE LEVER Gear change lever is fitted to the left side of the engine The positions corresponding to the different ge...

Страница 21: ...nd with a quick movement down ward The pedal will automatically return upwards After starting manually fold the pedal in the rest position SIDE STAND Press down side stand with the foot and lean the vehicle against it Ensure that the ground is solid and the vehicle stands steadily Warning Once you lift the vehicle off the side stand the stand auto matically returns to its rest position Do not sit ...

Страница 22: ...ng lock is on To activate the steering lock turn the handlebar counter clockwise push the key and turn counter clockwise Remove the key from this position The engine cannot be started To deactivate the steering lock turn the key clockwise turn the handlebar clockwise From this position the handlebar is free to move the key can be removed and the engine cannot be started WARNING do not keep the spa...

Страница 23: ...edometer record topwatch and MAX record Time Clock 12 24 MODE Stopwatch According to setup distance to record the testing time Speed Log Average speed and max speed record Battery Inner Battery Level Display range 4 levels Adjust Button Press the Adjust button in the main screen to switch between ODO Trip A B Total Hour meter Hour meter A B Press and hold the Adjust button for 3 seconds in Trip A ...

Страница 24: ...ing this procedure could result in permanent damage to the meter 1 WARNING LIGHTS 1 Headlight indicator The system activates the indicator in synchrony with the activation of the mains beams 2 Direction indicator lights The system activates the indicator in synchrony with the activation of the direction indicators 3 Neutral indicator light The system activates the indicator in synchrony with the e...

Страница 25: ...A to trip B When the trip A is selected hold pressing the Adjustbutton for 3 seconds to reset the trip A Press the Adjust button to switch from trip B to total hour meter Hold pressing the Adjust button for 3 seconds to reset the trip B Press the Adjust button to switch from total hour meter to hour meter A Press the Adjust button to switch from hour meter A to hour meter B When the hour meter A i...

Страница 26: ... to change between 12 24 hour mode NOTE If 24hour mode is chosen then the AM PM symbol will not be displayed Press the Select button to switch from Stopwatch to Speed Record Press and hold the Select button for 1 second to reset the Stopwatch Press the Select button to switch from Speed Record back to main screen Press and hold the Select button for 3 seconds to reset the Speed Record NOTE If Engi...

Страница 27: ...djust button and then the Select button to change the setting NOTE Default 2250mm Enduro 2000mm Motard EX The tire circumference setting is changed from 2 100 mm to 2 400 mm Press Adjust button to go back to tire circumferences value setting screen From switch to screen by pressing the Select button Press the Adjust button to enter the clock Hour setting Press the Select button to set the time hou...

Страница 28: ...o change the setting to 14 05 Press the Select button to choose the minute you want to set NOTE Setting range 0 59 minutes EX Now the minute is changed from 14 00 to 14 05 Press the Adjust button to get back to Clock setting screen Switch from to Press Select button to switch to Stopwatch distance setup entering screen Press Adjust button to enter the distance setup for Stopwatch Distance setup fo...

Страница 29: ...r to the digit that would like to set To set the digit press the Select button Once programmed press the Adjust but ton to return to the main menu Note the limit is set to 5000km If OFF is chosen then press the Adjust but ton to exit the maintenance mileage setting Press Select button to switch the screen from to Press the Adjust button to enter the Back light Brightness setting Press the Adjust b...

Страница 30: ...s Adjust button to enter the mileage setting ODO setting Press the Adjust button to enter the actual ODO viewing display Press the Select button to enter the User ODO setting Press Adjust button to enter the User ODO setting Press the Adjust button to back to ODO adjust function Press Select Button to switch to ODO viewing adjusting function In Setting Screen press and hold the both Adjust and Sel...

Страница 31: ...cable controls 7 Inspect all the nuts and bolts 8 With the engine running check the 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 51 BREAKING IN Breaking in takes approximately 500 km 350 miles During this time Avoid travel at high speeds Change speed often so that the parts will break in...

Страница 32: ...obile phone Refuel in an 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 immedia...

Страница 33: ...Close the side stand page 21 WITH KICK STARTER page 21 Depress the kick starter with a sharp movement of the foot ATTENTION Once the pedal has been depressed release it immediately This avoids jolts to the entire ignition group and to the foot COLD STARTING Operate the starter page 19 start the vehicle wait a few seconds then move the starter back to its starting position ENGINE SHUT DOWN To shut ...

Страница 34: ...34 GB ...

Страница 35: ...f clutch lever 36 Adjustment of idling speed 36 Adjustment of gas clearance 37 Adjusting the fork Factory 37 Adjusting the spring preload Factory 37 Adjusting the shock absorber Enduro Motard Motard Sport Track 38 Adjusting the compression and extension brake Factory 38 Adjusting the spring preload Enduro Factory 38 ...

Страница 36: ...se 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 1900 R P M ADJUSTMENT OF BRAKES FRONT BRAKE The front brake is disk type with hydraulic control You can adjust lever height by means of the register A REAR BRAKE The rear brake is disk type with hydraulic control You may ad...

Страница 37: ...the telescopic fork during extension and can be adjusted by means of screw 1 Turning the screw clockwise in creases the action of the rebound damper turning it anticlockwise decreases the ac tion of the rebound damper For standard calibration refer to page 11 ADJUSTING THE SPRING PRELOAD FACTORY Spring preload is adjusted by means of screw 2 Turning clockwise will increase the preload while rotati...

Страница 38: ... is used to adjust the hydraulic damping during the rebound return phase Knob C located on the expansion tank of the shock absorber adjusts the hydraulic damping during the compression phase Turning knobs D and C clockwise in creases the damping action conversely turning them anticlockwise decreases it For standard setting refer to page 12 ADJUSTING THE SPRING PRELOAD ENDURO FACTORY To adjust the ...

Страница 39: ...ke lining control 43 Rear brake 43 Check the level of the rear brake fluid 43 Rear brake lining control 44 Air filter 45 Spark plug 46 Carburettor 47 Draining the carburettor float chamber 47 Tyres 48 Check and adjusting of steering play 48 Chain 49 Check and adjust tightening chain 49 Headlight 50 Replacing the headlight bulbs 50 Tail light 50 Cleaning the vehicle 51 Prolonged inactivity 52 Maint...

Страница 40: ...w the oil while the engine is hot Place a container under the engine Unscrew filler cap 1 and drain plug 3 Empty the crankcase completely Close plug 3 Pour in 850 gr 820 cc of oil Verify the level as described above Screw on filler cap 1 again WARNING Hot oil can cause severe burns WARNING Dispose of used oil in compliance with local regulations NOTE Change the gear box oil after the first 500 km ...

Страница 41: ...ry version is 850cc while for all other versions it is 500 cc Use the fluids specified in the table on page 16 WARNING Never unscrew the filler cap of the radiator when the engine is hot Danger of burning A B 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 wi...

Страница 42: ...mediately NOTE Use the liquid indicated on page 16 in the Recommended lubricants and liquids table 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 imme...

Страница 43: ...ntact authorised Betamotor authorised service immediately NOTE Use the liquid indicated on page 16 in the Recommended lubricants and liquids table 2 mm FRONT BRAKE LINING CONTROL To check the wear of the front brake pads visually inspect the caliper from below The lining on the visible ends of the two brake pads should be at least 2 mm thick If this layer is thinner than 2 mm replace the pads imme...

Страница 44: ...eek medical advice with skin immediately clean contaminated areas with soap and water Change clothing that is contaminated with liquid If liquid is swallowed contact a doctor immediately REAR BRAKE LINING CONTROL To check the wear of the rear brake pads visually inspect the caliper from below The lining on the visible ends of the two brake pads should be at least 2 mm thick Should the lining be th...

Страница 45: ...g we suggest to grease the side that touches the filter box Paper filter Motard Track En duro Blow the filter with compressed air If necessary also clean the interior of the filter box Reassemble proceeding in the reverse order NOTE If the filter is damaged replace it imme diately WARNING After every intervention check that nothing has been left inside the filter box Clean the filter every time th...

Страница 46: ... the engine Examine the distance between the elec trodes 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 The spark plug may appear black fat carburation light brown appropriate carburation white thin carburation Check as well that there are no cracks in the insulation or corroded electrodes If so replace immediately Lubricate th...

Страница 47: ...ner under the carburettor pipe so that you can collect the running out fuel Open the drain screw to drain the fuel Close the drain screw WARNING Follow action on a cold engine WARNING Fire hazard Fuel is highly flam mable Always stop the engine when refuelling and keep open flames and lighted cigarettes away Refuel in an open well ventilated area Immediately clean up any spilled fuel ...

Страница 48: ... play should not cause diffi culty or irregularity in turning the handlebar TYRES Only fit tyres approved by BETAMOTOR Unsuitable tyres can adversely affect the road holding of the vehicle To protect your safety immediately replace any damaged tyres Slick tyres adversely affect the road holding of the vehicle especially on wet roads and in off road riding Insufficient pressure results in abnormal ...

Страница 49: ...greatly reduced making it very difficult to control the vehicle CHECK AND ADJUST TIGHTENING CHAIN Checking the drive chain periodically to ensure longer chain life Always keep it lubricated and clean of deposited dirt If play exceeds 20 mm tighten the chain as follows Loosen the pin 1 Loosen counternuts A on either side of the fork Turn adjusting screws B on either side until the desired chain ten...

Страница 50: ...over 2 release connector push on the spring 3 and remove the lamp holder and replace the light bulb with a new one Be careful not to touch the bulb so as not to compromise its efficiency To refit follow the procedure above but in reverse order Fasten the lamp holder front cowl to the supporting pins and fix it with the two elastics TAIL LIGHT Keep the tail light glass clean at all times see page 5...

Страница 51: ...cover and the throttle body WASHING MODE Use water jet to soften the dirt and mud accumulated on the paintwork then remove them with a soft bodywork sponge soaked in water and shampoo Subsequently rinse well with water and dry with air and cloth or suede leather Detergents pollute water Always wash the vehicle in areas equipped for collection and purification of the washing liquids AFTER WASHING P...

Страница 52: ...s by approximately 30 percent and if possible raise the tyres off the ground Cover the unpainted parts excepting the brakes and the rubber parts with a film of oil or spray silicone Remove the battery and keep it in a dry place Charge the battery every 15 days Protect the vehicle with a dust cover AFTER PROLONGED INACTIVITY Reinstall the battery Restore the tyre inflating pressures Check the tight...

Страница 53: ...ing bearings and steering play c c c c c c c c c c wheel bearings c c c c c c c c c air filter c p p s p p s p p s general vehicle operation c c c c c c c c c c braking system c c c c c c c c c c lights c c c c c c c c c c general greasing c c c c c c c c c c brake fluid silencer p p p p p p p p p fork oil and oil seals s s s headlight c c c c c c c c c adjustment operation tyre condition and pres...

Страница 54: ...54 GB ...

Страница 55: ...REMOVING AND INSTALLING SUPERSTRUCTURES 5 55 GB CHAPTER 5 REMOVING AND INSTALLING SUPERSTRUCTURES CONTENTS Removing and installing of the saddle 56 ...

Страница 56: ...5 REMOVING AND INSTALLING SUPERSTRUCTURES 56 GB REMOVING AND INSTALLING OF THE SADDLE Remove screw A Remove the saddle in the direction B indi cated in the figure B A ...

Страница 57: ...6 TROUBLESHOOTING 57 GB CHARTER 5 TROUBLESHOOTING CONTENTS Troubleshooting 58 ...

Страница 58: ... adjusted Spark plug dirty Restore the spark gap Clean or replace the spark plug Engine overheats and loses power Silencer partly clogged Exhaust clearance partially obstructed Mix too lean Ignition delayed Contact authorised Betamotor cus tomer service Contact authorised Betamotor cus tomer service Contact authorised Betamotor cus tomer service Contact authorised Betamotor cus tomer service Front...

Страница 59: ...justment of brakes 36 Adjustment of clutch lever 36 Adjustment of gas clearance 37 Adjustment of idling speed 36 Air filter 45 Breaking in 31 Carburettor 47 Chain 49 Check and adjusting of steering play 48 Checks before and after use 31 Cleaning the vehicle 51 Digital rpm indicator operating instructions 23 Electrical system 14 Engine shut down 33 Front brake 42 Gearbox oil 40 Headlight 50 Keys 22...

Страница 60: ...43 Recommended lubricants and liquids 16 Refuelling 32 Removing and installing of the saddle 56 Replacing the headlight bulbs 50 Riding safety 6 Spark plug 46 Starting the engine 33 Steering Lock 22 Symbols 5 Tail light 50 Technical data 10 Troubleshooting 58 Tyres 48 Vehicle identification data 8 ...

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