EVO 4T Thanks for you preference, and have a good time! This handbook 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.
IMPORTANT We recommend you to check all the tightenings after the first one or two hours’ ride over rough ground.
TABLE OF CONTENTS Operating instructions............................................................................. 5 Ecologic guide ....................................................................................... 5 Riding safety ......................................................................................... 6 CHAPTER 2 OPERATION .................................................................. 19 Main parts ...............................................................................
Steering gear....................................................................................... 47 Oil fork ............................................................................................... 48 Tyres................................................................................................... 52 Chain ................................................................................................. 53 Headlight ...........................................................................
OPERATING INSTRUCTIONS • The vehicle must be accompanied by: number-plate, registration document, tax disc and insurance. • Do not carry animals, pets or loose objects that can stick out from the vehicle. • Riding without a crash helmet is forbidden. • Always ride with the low beam on. • Any modifications of the engine or other parts resulting in a power and/or speed increase are punishable by severe sanctions including the confiscation of the vehicle.
RIDING SAFETY • Observe the Highway Code. • Always put on and fasten a homologated helmet. • Always ride with the low beam on. • Always keep the crash helmet visor clean. • Avoid wearing garments with hanging ends. • Do not keep sharp or brittle objects in your pockets while riding. • Properly adjust the rearview mirrors. • Always ride in a seated position, with both hands on the handlebars and both feet on the footrests. • Always pay attention and do not allow anything to distract you while riding.
CONTENTS Vehicle identification data ....................................................................... 8 Frame identification ........................................................................... 8 Engine identification .......................................................................... 8 Familiarizing with the vehicle................................................................... 9 Main parts........................................................................................
1 VEHICLE IDENTIFICATION DATA FRAME IDENTIFICATION Frame identification data A are stamped on the right side of the steering head tube. GENERAL INFORMATION A GB B ENGINE IDENTIFICATION Engine identification data B are stamped in the area shown in the picture. In order to read it correctly, it is necessary to remove the silencer and disconnect the regulator connector. WARNING: Tampering with the identification numbers is severely punished by law.
FAMILIARIZING WITH THE VEHICLE 1 19 6 17 2 13 5 14 7 16 18 12 8 3 11 10 15 4 MAIN PARTS 1 2 3 4 5 6 7 8 9 10 Fuel tank Tank cap Silencer Rear shock absorber Headlight Rear light Side stand Fork Rider’s footrests Lower bumper 9 GENERAL INFORMATION 1 11 12 13 14 15 16 17 18 19 9 Engine Front mudguard Rear mudguard Kick-start Gear lever Rear brake lever Front brake lever Clutch lever Throttle GB
1 SPECIFICATIONS WEIGHT Dry weight ..................................................................................... 72 kg Front .......................................................................................... 36 kg Rear ........................................................................................... 36 kg GENERAL INFORMATION VEHICLE DIMENSIONS GB maximum length........................................................................ 2005 maximum width ..........................
1 FRONT SUSPENSION Version EVO 250 EVO 300 166 166 Wheel excursion [mm] Right fork leg Left fork leg Right fork leg Left fork leg X 7,65 X 7,65 K spring [N/mm] Shell Tellus S2 V32 SAE 6,1 Oil level [mm] (edge rod with fork compressed) Register spring preload Click in extension 65 125 65 125 X Full open X Full open Full open X Full open X REAR SUSPENSION Version EVO 250 EVO 300 k spring 70N/mm 70N/mm 136 136 Length (spring in its seat) [mm] Oil type oil titan SAF 5045 E
1 ENGINE Version EVO 250 EVO 300 Single-cylinder, 4-stroke Single-cylinder, 4-stroke 77 x 53,6 84 x 53,6 Displacement [cm3] 249,6 297 Pressure ratio 11,5:1 11,4:1 carburetor carburetor EVO 250 EVO 300 Type Bore x stroke GENERAL INFORMATION Fuel system CARBURETOR Version Carburetor type Homologated Competition* Homologated SE BSR33-79 Competition* SE BSR33-79 Main jet 120 127,5 120 120 Slow jet 17,5 27,5 17,5 27,5 Start jet 60 60 60 60 Needle 5D132 5D132 5D132 5D1
GEAR BOX Secondary drive EVO 250 18/63 13/36 15/36 16/30 24/27 28/21 EVO 300 18/63 13/36 15/36 16/30 24/27 28/21 Homologated Competition* Homologated Competition* 42/13 42/11 42/13 42/11 * Such modification makes the vehicle non-compliant with the road regulations in force. Its use must be limited to the sole private circuits which are closed to circulation. Ignition ...........................................................
ELECTRICAL SYSTEM ELECTRICAL DIAGRAM FOR HOMOLOGATED VERSION GENERAL INFORMATION 1 GB 14
LEGEND ELECTRICAL DIAGRAM FOR HOMOLOGATED VERSION R.H. front turn signal with bulb 12V - 10W Headlamp (double filament bulb) 12V-35/35W Position light with bulb 12V - 5W High beam indicator light with bulb 12V 1,2W Dashboard indicator light with bulb 12V 1,2W Turn signal indicator light with bulb 12V 1,2W L.H. front turn signal with bulb 12V - 10W Engine stop button Horn button Light switch Turn signal switch Blinker Rear brake stop button L.H.
ELECTRICAL DIAGRAM FOR RACE VERSION GENERAL INFORMATION 1 GB 16
1 LEGEND ELECTRICAL DIAGRAM FOR RACE VERSION Headlamp with bulb 12V-20W Horn 12V Fuel cock Horn button Engine stop button Condenser 4700µF - 25V Light switch (black) Switch for change mapping (yellow) Tail light with bulb 12V - 3W Generator Pick-up H.T.
1 RECOMMENDED LUBRICANTS AND LIQUIDS For better operation and longer vehicle life, we advise you to use the products listed in the following chart: GENERAL INFORMATION Engine Oil: GB 850cc Motul 7100 10w40 (For Competition use Motul 300V 10w40) Brake Fluid Motul RBF 600 Coolant/Antifreeze Motul Motocool Expert Fork Oil Motul Factory Line 5 wt.
CONTENTS Main parts .......................................................................................... 20 Fuel cock ........................................................................................ 20 Starter ............................................................................................ 20 Hot start ......................................................................................... 20 Clutch lever ............................................................................
2 MAIN PARTS FUEL COCK Fuel valve has two positions: OPERATION C : OFF Automatic. If the engine is shut off, the fuel supply is switched off and the fuel cannot flow from the tank to the carburetor. A: fuel supply always enabled. The fuel passes from the tank to the carburetor even with the engine off. STARTER 1 2 The starter lever 1 is located on the carburettor. To use, pull it out. HOT START The hot start 2 is located on the intake manifold. To use, pull it out.
2 CLUTCH LEVER Clutch lever 1 is fitted to the left-hand side of the handlebars. Screw A can be used to alter the home position of the lever (see Adjustments). 1 A LH SWITCH OPERATION The off switch is positioned on the left-hand side of the handlebar and consists of the following: shutdowns engine: it is necessary to hold it until the engine stops.
2 FRONT BRAKE LEVER AND GAS CONTROL 1 The front brake lever 1 and the gas throttle 2 are located on the right side of the handlebar. 2 OPERATION 4 3 2 N 5 GEARCHANGE LEVER Gearchange lever is fitted to the left side of the engine. The positions corresponding to the different gears are shown in the figure. 1 BRAKE PEDAL Brake pedal is located in front of the righthand footrest. KICK-START The kick-start pedal is located on the right side of the engine.
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. 2 OPERATION WARNING! The kickstand has an automatic closing device. When the vehicle weight on the kickstand is reduced, it closes automatically.
OPERATION 2 CHECKS BEFORE AND AFTER USE For safe driving and long vehicle life you should: • Check all fluid levels. • Check the correct operation of the brakes and brake pad wear (page 43). • Check pressure, general condition and thickness of tread (page 10). • Check that the spokes are properly tightened. • Check the chain tension (page 54). • Check the adjustment and the operation of all the cable controls. • Inspect all the nuts and bolts.
2 FUELLING Use unleaded gasoline. Fuel tank capacity is shown on page 10. To open the fuel tank’s cap, turn it anticlockwise. OPERATION To close the fuel tank’s cap, set it on the tank and crew it clockwise.
2 STARTUP Set the fuel tank tap to A (see page 20). - Check that the gears are in neutral (page 22). - Pull the clutch lever (page 21). KICKSTART (page 22): depress the kick-starter with a sharp movement of the foot. OPERATION 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 20), start the vehicle, wait a few seconds, then move the starter back to its starting position.
CONTENTS Brakes ................................................................................................ 28 Front brake ..................................................................................... 28 Rear Brake...................................................................................... 28 Clutch ................................................................................................. 29 Adjustment of gas clearance............................................................
3 BRAKES 1 FRONT BRAKE 2 The front brake is disk type with hydraulic control. The position of the lever is controlled through the use of register 1. Once the position of the lever has been changed, register 2 must be changed to restore the initial correct clearance. ADJUSTMENTS WARNING: reduced play causes brake overheating leading to sudden lockup. REAR BRAKE 1 2 The rear brake is disk type with hydraulic control. You may adjust pedal height by means of register 1.
CLUTCH 2 The idle stroke of push rod must not be less than 0.9 mm 0,9 mm ATTENTION: reduced clearance leads to premature wear of the discs and overheating of the entire clutch group. ADJUSTMENT OF GAS CLEARANCE 2 The throttle control cable should always have a 3-5 mm play. In addition, the idle speed should not change when the handlebars are fully rotated to the left or right. 3 1 ADJUSTMENTS The position of the lever is controlled through the use of register 1.
3 ACCELERATOR ADJUSTING THE IDLE SPEED A In order to perform this operation correctly, we advise you to do it when the engine is hot, connecting an electric revolution counter to the spark plug wire. Then use a screwdriver on register screw A to calibrate the minimum with 1.100÷1.200 rpm. ADJUSTMENTS HANDLEBAR The handlebar can be adjusted by rotating it back and forth. - To adjust the handlebar loosen screws 1. - Position the handlebar according to requirements. - Tighten to the torque indicated.
3 ADJUSTING THE SPRING PRELOAD Spring preload is adjusted by means of screw 2. Turning clockwise will increase the preload, while rotating counter- clockwise decreases the preload. 2 ADJUSTMENTS For standard calibration, refer to page 11. SHOCK ABSORBER ADJUSTING THE REBOUND DAMPER The hydraulic brake unit in extension determines the behaviour in the extension phase of the shock absorber and can be adjusted using screw 1.
3 ADJUSTING THE SPRING PRELOAD To adjust the spring preload, use the procedure described below. Loosen counter-ring 1, rotate ring 2 clockwise to increase the spring preload (and consequently the shock absorber preload) or anticlockwise to decrease it. After obtaining the desired preload, turn counter-ring 1 until it stops against adjusting ring 2. 2 1 ADJUSTMENTS For standard calibration, refer to page 11.
CONTENTS Key to symbols..................................................................................... 34 Engine oil............................................................................................ 34 Check the level................................................................................ 34 Replacement ................................................................................... 34 Coolant ........................................................................................
4 KEY TO SYMBOLS Tightening torque Threadlocker medium intensity CHECKS AND MAINTENANCE ENGINE OIL CHECK THE LEVEL 1 MAX MIN 2 Let the engine run for a few minutes then turn it off. Keep the vehicle in vertical position relative to the ground. Wait a few minutes and check the oil level through the window 1. The level must be between the limits indicated in the picture. Otherwise restore the oil level through 2. Use the oil indicated on page 18 in the “Recommended lubricants and liquids” table.
4 - Unscrew the plug 4 in the left-hand casing and use pliers to extract the filter. Clean it carefully and blow it through with compressed air. Check for damage to the O-rings, and replace them if necessary. Refit all the parts and tighten the plug to 15 Nm. CHECKS AND MAINTENANCE 4 - Perform the same procedure for the filter located on the right side of crankcase. - Put a drawn pan under the engine closer to the paper filter cover 1 and then unscrew 2 the cover.
4 - Extract the paper filter using pliers. Check the condition of the O-ring too, and replace it if necessary. Change the filter and refit the cover, tightening the three M6x20 bolts to 10 Nm. CHECKS AND MAINTENANCE - Pour in the quantity of oil indicated on page 10. - Use the oil indicated on page 18 in the “Recommended lubricants and liquids” table. - Close the filler cap 1. WARNING: Hot oil can cause severe burns! COOLANT CHECK THE LEVEL Keep the vehicle in vertical position relative to the ground.
4 REPLACEMENT Position the vehicle on a flat base and in a stable manner. Replacement of the coolant must take place when the engine is cold. 1) Unscrew cap 1. 2) Unscrew screw 2, collecting the liquid in a container. 10Nm 2 3) Drain the liquid. 4) Tighten screw 2 applying the specific washer. 5) Unscrew drain screw 3 and fill until the liquid starts to overflow the screw. 6) Tighten screw 3. 3 10Nm CHECKS AND MAINTENANCE 1 7) Place the vehicle as shown and proceed to filling.
4 RADIATOR GRILL Should the grill be obstructed proceed as follows: Remove the grill by pulling it towards the front of the vehicle. Shake and wash the grill. CHECKS AND MAINTENANCE Reapply the grill pushing it towards the radiator. GB AIR FILTER 1 Check after every ride. REMOVING AND FITTING AIR FILTER To access the filter: - Loosen the fastening screw 1 of the rear cover. 2 - Remove the filter frame and the filter by unscrewing the screw 2.
CLEANING AIR FILTER - Thoroughly wash the filter with water and soap. 4 - Dry the filter. - If necessary also clean the interior of the filter box. WARNING: Do not clean the filter with gasoline or petrol. NOTE: If the filter is damaged, replace it immediately. Verify the integrity of water proofing gaskets on air box shown in the picture. Change them if these are damaged. To replace, contact authorised Betamotor customer service. WARNING: Never use the vehicle if the air filter is not in place.
4 SPARK PLUG CHECKS AND MAINTENANCE 0,5÷0,6 mm GB Keeping the spark plug in good condition will reduce fuel consumption and increase engine performance. To perform the check, simply slide off the electrical connection tube and unscrew the spark plug. Examine the distance between the electrodes with a feeler. This distance should be from 0.5÷0.6 mm. If it is not, it may be corrected by bending the earth electrode. Check as well that there are no cracks in the insulation or corroded electrodes.
4 CARBURETOR DRAINING THE CARBURETOR FLOAT CHAMBER If the carburetor tank needs to be emptied, proceed as described. Perform the operation once the engine is cold. Turn the fuel cock to the “C” position (see page 20) Place tube 1 in a container to gather the fuel that fl ows out. Loosen screw 1 and drain the fuel until complete emptying of the tank. Tighten screw 1. 41 1 CHECKS AND MAINTENANCE WARNING Fuel is flammable and toxic and must be handled with great care.
4 FRONT BRAKE A CHECK THE LEVEL OF THE FRONT BRAKE FLUID CHECKS AND MAINTENANCE Check the level of the brake fluid through sight A. The level of the fluid should never fall below the mark in the sight. GB 1 RESTORING THE LEVEL OF THE FRONT BRAKE FLUID To restore the level of the brake fluid, loosen the two screws 1, lift cap 2 and add brake fluid until its level is 5 mm below the upper rim of the reservoir. 2 Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table.
4 BLEEDING THE FRONT BRAKE 1 2 CHECKS AND MAINTENANCE To bleed air from the front brake circuit, proceed as follows: •Remove the rubber cap 1 from the valve 2. •Open the sump cap. •Insert one end of a transparent tube into a container. •Pump with the brake lever 2/3 times and keep the lever pressed. •Unscrew the valve and let the oil drain. •If are still visible in the tube repeat above operation until obtaining a continuous outflow of oil within no air bubbles. •Close the valve and release the lever.
4 REAR BRAKE CHECK THE LEVEL OF THE REAR BRAKE FLUID Check the level of the brake fluid through sight A. The level of the fluid should never fall below the mark in the sight. 1 CHECKS AND MAINTENANCE 2 GB RESTORING THE LEVEL OF THE REAR BRAKE FLUID To restore the level of the brake fluid, loosen the two screws 1, lift cap 2 and add brake fluid until its level is 5 mm below the upper rim of the reservoir. A Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table.
4 NOTE: During this procedure, continuously top up the brake pump thank to replace the oil that is out flowing. •Remove the tube. •Replace the rubber cap. REAR BRAKE LINING CONTROL CHECKS AND MAINTENANCE Close the oil reservoir cap. 2 mm In order to verify the wear condition of rear brake is enough to view the caliper from the back side, where is possible to glimpse the brake lining tails which will have to show a brake of 2 mm in thickness. If the stratum is lesser let’s start replacing them.
4 If the level is lower than indicated proceed with refilling. Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table. CHECKS AND MAINTENANCE WARNING: The fluid is extremely corrosive. Take care not to spill it on the paintwork. BLEEDING CLUTCH CONTROL 1 2 • Remove the rubber cap 1 from the valve 2. • Open the sump cap. • Insert one end of a trasparent tube into a container. • Pump with the brake lever 2/3 times and keep the lever pressed.
4 STEERING GEAR CHECK OF STEERING GEAR CHECKS AND MAINTENANCE Periodically check the play in the steering sleeve by moving the fork back and forth as shown in the figure. Whenever you feel play, adjust as described below: Loosen the screws 1. 1 10Nm Loosen the screw 2. 3 Take up the play by means of nut 3. Tighten the screws to the specified torque values.
4 OIL FORK CHECKS AND MAINTENANCE The procedure for changing the oil in the forks is provided only for information. We recommend having the operation performed by a BETAMOTOR authorized workshop. REMOVING LEGS To replace, proceed as follows: Position the vehicle on the central bike stand. 1 Remove the front wheel. Remove the mudguard, the brake caliper and brake disc cover. Loosen the screws 1 and pull off the stems. 2 OIL REPLACEMENT RIGHT LEG Unscrew upper plug 2.
Empty the fork leg and the cartridge, draining all the oil inside. 3 4 Reassemble the cartridge on the fork leg tightening the fixing screw, then refill oil in the cartridge. Use the liquid indicated on page 18 in the “Recommended lubricants and liquids” table. Reassemble the plug on the rod, tighten the lock nut and, extending the fork leg. OIL REPLACEMENT LEFT LEG Unscrew upper plug 3. Remove the spring and totally empty the oil. Pour in the quantity of liquid indicated on page 11.
4 LEGS ASSEMBLY AND PARTS Apply the legs to the vehicle and tighten the screws 1 to the torque indicated. CHECKS AND MAINTENANCE 1 Grease the wheel bolt. Apply wheel and wheel bolt. Apply brake caliper, disc cover and fender. Tighten to the torque indicated. 10Nm Place the vehicle on the ground. Compress and release the fork 3-4 times. Tighten the wheel bolt and the screws of the foot.
LINKAGE REAR SUSPENSION To guarantee an optimal operation and the longest lifetime of the progressive linkage of the rear suspension, it is recommended to check after every race/run the correct tightening of the bolt. 45Nm 4 30Nm 45Nm To check the upper shock absorber fastening proceed as follow: Remove screws 1 and 2 (two per side). Remove the mudguard. 10Nm 2 At the end refit the screws 1 and 2. Tighten to the torque indicated.
CHECKS AND MAINTENANCE 4 GB 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 wear and overheating of the tyres. • The front and rear tyres must have the same tread design.
4 CHAIN Checking the drive chain periodically to ensure longer chain life. Always keep it lubricated and clean of deposited dirt. CHECKS AND MAINTENANCE Take special care in preventing the lubricant from coming into contact with the rear tyre or brake disc, otherwise the tyre grip and the action of the brake would be greatly reduced, making it very difficult to control the vehicle. CHECK AND ADJUST TIGHTENING CHAIN Position the vehicle on the central bike stand.
4 Rotate register 3 into the same position as register 2. Ensure the distance between chain and swingarm is that recommended. If the distance between chain and swingarm is not that recommended proceed to readjustment. CHECKS AND MAINTENANCE 3 GB Tighten the pin to the torque indicated.
Keep the headlight glass clean at all times (page 57). REPLACING THE HEADLIGHT BULBS 1 Dismantle the headlight mask removing the two retaining screws 1 indicated in the figure. Remove the screws 2 indicated in the figure. 2 CHECKS AND MAINTENANCE 4 HEADLIGHT Take out the bulb assembly from the bulb holder. Remove the bulb from the connectors and carry out replacement. To reassemble, proceed inversely as described above.
4 REAR TAIL LIGHT Keep the tail light glass clean at all times (see page 57). CHECKS AND MAINTENANCE Remove the screws indicated in the figure. GB Remove the bulb holder from its place. Remove the bulb. To reassemble, proceed inversely as described above.
CLEANING THE VEHICLE WARNING: Do not clean your vehicle with a high-pressure device with a strong jet of water. Excessive pressure can reach electrical components, connectors, flexible cables, bearings, etc and can damage or destroy them. 4 When cleaning, avoid direct exposure to sunlight. Close off the exhaust system to prevent water from entering. Avoid directing the jet of water onto the air filter box cover.
CHECKS AND MAINTENANCE 4 GB PROLONGED INACTIVITY A few simple operations should be performed to keep the vehicle in good condition whenever it is to remain inactive for a long period (e.g. during the winter): • Thoroughly clean the vehicle. • Reduce the tyre pressures by approximately 30 percent, and if possible raise the tyres off the ground. • Remove the spark plug and pour a few drops of engine oil into the spark plug hole.
Coupon 9 360 hours or 9.000 Km Coupon 8 320 hours or 8.000 Km Coupon 7 280 hours or 7.000 Km Coupon 6 240 hours or 6.000 Km Coupon 5 200 hours or 5.000 Km Coupon 4 160 hours or 4.000 Km Coupon 3 120 hours or 3.000 Km Coupon 2 80 hours or 2.000 Km Coupon 1 40 hours or 1.
GB 60
CHAPTER 5 TROUBLESHOOTING TROUBLESHOOTING CONTENTS Troubleshooting ................................................................................... 62 Alphabetical index ...............................................................................
5 TROUBLESHOOTING PROBLEM CAUSE The engine turns over but Fuel cock in C position will not start Dirty carburettor jets Spark plug dirty Spark gap wrongly adjusted Fault in the ignition system TROUBLESHOOTING The power delivered by the engine is insufficient Tank vent obstructed Fuel system dirty Defective ignition system Lack of fuel Loose or oxidized connector or ignition coil Radiator grill blocked Radiator (air side) blocked Forced ventilation absent Low coolant Silencer partly clogged Carburati
ALPHABETICAL INDEX Accelerator ......................................................................................... 30 Adjusting fork ...................................................................................... 30 Adjustment of gas clearance.................................................................. 29 Air filter .............................................................................................. 38 Brakes ......................................................................
Rear brake .......................................................................................... 44 Rear tail light ....................................................................................... 56 Recommended lubricants and liquids ...................................................... 18 Riding safety ......................................................................................... 6 Scheduled maintenance vehicle ............................................................
