Beta RS4T USA Spécifications

WORKSHOP MANUAL01_Inghilterra_059311 27-12-2007 17:52 Pagina 1

10Workshop manual RR 4T - 400 - 450 - 525SAFETYCarbon monoxide• Exhaust gases contain carbon monoxide (CO), a poisonous gas that can cause loss of co

36Manuale di Officina RR 4T - 400 - 450 - 525Cylinder - Nikasil lining Nikasil is the trademark of a cylinder lining procedure developedby the piston

Checking the piston– Replace the piston if oil consumption is excessive or if the pi-ston skirt is scored. – If the piston is to be reused:1.Check the

38Manuale di Officina RR 4T - 400 - 450 - 52512233456677777788Lubrication systemOil line 1Ensure that the soldered joints present no capillary cracks.

396 - Motore Release 01 Date 09/2007211314456778991010Cylinder head top– Remove Seeger ring 1 and pull decompressor shaft 2 andspring 3 out of the hol

40Manuale di Officina RR 4T - 400 - 450 - 52512modelli 250modelli 250Cylinder head– Unscrew the three screws 1 and remove exhaust flange 2 to-gether w

416 - Motore Release 01 Date 09/2007– Remove spring caps 1 and valve springs 2 from the cylinderhead. – Remove the valve stem linings from the valve g

42Manuale di Officina RR 4T - 400 - 450 - 5251324885976101112Camshaft– Remove Seeger ring 1 and water pump impeller 2. – Pull out roller 3 from the sh

436 - Motore Release 01 Date 09/2007– Press oil seals 1 out of seal holding bush 2. – Fit the new oil seals with the gaps facing outward, pressingthem

44Manuale di Officina RR 4T - 400 - 450 - 525Automatic stretcher– Fully extract the automatic stretcher pressure pin and checkthat it can slide freely

456 - Motore Release 01 Date 09/2007Checking the clutch for wearThrust head 1Check the thrust head for signs of seizure and ensure thatit can slide fr

111 - General information Release 01 Date 09/2007Brake fluid• The brake fluid is highly corrosive. • Avoid contact with the eyes, the skin and the muc

46Manuale di Officina RR 4T - 400 - 450 - 525678951211101342Checking the kickstart for wearRemove all components from the kickstart shaft and clean th

476 - Motore Release 01 Date 09/2007F71168910Gearshift mechanismGearshift forks 1Check wear at ends A. When the forks are new, their thicknessranges f

48Manuale di Officina RR 4T - 400 - 450 - 5251678910114523GearboxClamp the driving shaft and the driven shaft in vices (using protective jaws). Remove

496 - Motore Release 01 Date 09/2007785643219101112131415161718GearboxClamp the driving shaft and the driven shaft in vices (using protective jaws). R

50Manuale di Officina RR 4T - 400 - 450 - 525Ignition systemGeneral informationThe measurements described below are only used to findeasily detectable

516 - Motore Release 01 Date 09/20071234567AElectric start gearsIdler gear 1Check the teeth and the bearing surface of the idler gear for signs of wea

Checking the operation of the free wheel– Fit free wheel gear 1 on free wheel device 2. – The free wheel gear should rotate clockwise.– Attempting to

ENGINE SECTION- REASSEMBLING THE ENGINE666_Inghilterra_059311 27-12-2007 18:32 Pagina 53

CONTENTSFitting the crankshaftand the countershaft . . . . . . . . . . . Chap. 6 - 55Fitting the gearboxand the gearshift mechanism . . . . . Chap.

556 - Motor Release 01 Date 09/2007Fitting the crankshaft and the countershaft– Fasten the right-hand crankcase half to the assembly stand.– Carefully

NOTESThe information contained in this paragraph is designedto prevent damage to the vehicle. • Thoroughly clean the vehicle before removing parts. •

– Oil the ends of the gearshift forks and attach them to the slid-ing gears.– Insert the desmodromic mechanism into its bearing.– Attach the gearshift

576 - Motor Release 01 Date 09/2007M6x...45454530454545306060756060Assembling the crankcase– Remove the engine retainer from the stand. – Apply a thin

Fitting the oil pumps– Using a cloth, carefully clean the rest surface of the oil pumpcover. – Insert the roller into the oil pump shaft.– Fit the inn

Fitting the gear selector– Fit screw 1 (M5x20) with washer 2, selector lever 3, springholding bush 4 and selector lever spring 5. – Apply Loctite 243

60Workshop manual RR 4T - 400 - 450 - 525– Insert the support pins into the crankcase holes. Fit needleroller cage 1 and double gear 2.– Insert the pr

4321Fitting the clutch drum and hub– Insert the support washer and needle roller bearings 1. – Fit the driving shaft with clutch drum 2, half washers

Fitting the timing gear – Ensure that the key is properly seated in the crankshaft. – Heat timing pinion 1 and fit it to the crankshaft with the highe

636 - Motor Release 01 Date 09/2007Fitting the piston and the cylinder– Fit a new cylinder base gasket.– Oil the piston pin bearing in the connecting

Ensure that drain hole A is facing upwards.– Insert the camshaft in the cylinder head so that marks B onthe camshaft gear are aligned with the upper e

656 - Motor Release 01 Date 09/2007Fitting the cylinder head top– Clean or degrease the sealing surfaces of the cylinder headtop and the cylinder head

131 - General information Release 01 Date 09/20072) engine number3) type-approval dataOPERATING SPECIFICATIONSVEHICLE IDENTIFICATIONThe frame number i

Fitting the automatic stretcher– Fit the preassembled automatic stretcher 1 with a new gasket. – Fit the two screws (M6x20) with the 6x10x1 copper rin

676 - Motor Release 01 Date 09/2007Fitting the flywheel– Unscrew the crankshaft fixing screw, fit seal ring 1 and tightenthe crankshaft fixing screw t

68Workshop manual RR 4T - 400 - 450 - 525Fitting the clutch– Before fitting the clutch, carefully oil the lined plates.Clutch plates– Place the twelve

Fitting the oil line- Position oil line 3 and fasten it with the two oilway screws 1and 2, using new seal rings. Tightening torque: 10 N·m.Position th

70Workshop manual RR 4T - 400 - 450 - 525Fitting the oil filter– Pour engine oil into the oil filter casings until they are about1/4 full.– Insert the

ENGINE SECTION- INSTALLING THE ENGINE ON THE VEHICLE667_Inghilterra_059311 27-12-2007 18:38 Pagina 71

To mount the engine on the vehicle, follow theprocedures described for its removal in rever-se order, taking care to apply the tighteningtorques and u

CARBURETTOR707_Inghilterra_059311 27-12-2007 18:44 Pagina 1

CONTENTSCARBURETTOR - KEIHIN FCR M X 39 . . . Chap. 7 - 3Removing and reinstallinthe carburettor . . . . . . . . . . . . . . . . Chap. 7 - 4Disass

37 - Carburettor Release 01 Date 09/2007CARBURETTOR - KEIHIN FCR M X 39 07_Inghilterra_059311 27-12-2007 18:44 Pagina 3

14Workshop manual RR 4T - 400 - 450 - 52501_Inghilterra_059311 27-12-2007 17:52 Pagina 14

4Workshop manual RR 4T - 400 - 450 - 525Removing and reinstalling the carburettor NOTE: Before starting work on the carburettor, thoroughly cleanthe v

57 - Carburettor Release 01 Date 09/2007Disassembling the carburettorNOTE: The disassembly should be carried out in a clean work-place with sufficient

– Rotate the carburettor, loosen the three screws and removethe accelerating pump cover. NOTE: When removing the cover, ensure that the springand the

– Remove screws 1 and throttle sensor 2. Remove the throttle sensor only if it is defective. Thethrottle speed sensor needs to be readjusted every tim

Choke valvesEnsure that choke knob piston 1 presents no deep scoring orresidues. Checking the accelerating pumpCheck that the diaphragm is not cracked

Reassembling the carburettor– Fit choke idling jet 1 and choke main jet 2. – Fit O-ring 3 in the groove and fasten the suction pump to thecarburettor

– Position the float and the needle valve and fit float pin 1. – Check the float level (see page 14).– Fit the carburettor float chamber complete with

– Apply Loctite 243 to screw 1 and tighten it.– Fit the jet needle and fasten it with screw 2.– Position the throttle valve cover with the related gas

Checking the throttle sensorNOTE: The following measurement should be taken when thetemperature of the part is approximately 20° C. – Unplug the throt

137 - Carburettor Release 01 Date 09/2007Carburettor - Idle speed adjustmentThe adjustment of the idle speed strongly affects engine starting.In other

SPECIAL TOOLS202_Inghilterra_059311 27-12-2007 17:57 Pagina 1

14Workshop manual RR 4T - 400 - 450 - 52507_Inghilterra_059311 27-12-2007 18:44 Pagina 14

Pag. 1FRONT SUSPENSION / WHEEL808_Inghilterra_059311 27-12-2007 18:49 Pagina 1

CONTENTSFork components . . . . . . . . . . . . . . . . . Chap. 8 - 4Taking down the wheel . . . . . . . . . . . . . Chap. 8 - 5Checking the head tu

38 - Front suspension / wheel Release 01 Date 09/200708_Inghilterra_059311 27-12-2007 18:49 Pagina 3

4Workshop manual RR 4T - 400 - 450 - 5259 12 3348 39 24 30 31 72 51333 70 41 7134 3610 3719 21 25 73 8322843 45 46Fork components5) Supporting tube8)

Taking down the wheelNOTE: Place the vehicle on a specially designed central standand keep the front wheel off the ground. – Remove wheel holder cap 1

If necessary, follow these steps to overhaul the steering seats: – Unscrew the four screws as shown in the figure and removethe handlebars.– Unscrew s

78 - Front suspension / wheel Release 01 Date 09/200713126Cleaning the wiper sealNOTE: This operation can be performed with the fork installedon the v

8Workshop manual RR 4T - 400 - 450 - 52548Draining the oilNOTE: This operation cannot be performed while the fork is in-stalled on the vehicle.NOTE:

98 - Front suspension / wheel Release 01 Date 09/200741Removing the pump assembly and the foot valvePerform this operation only after completely drai

3625132 UNIVERSAL ENGINE MOUNTING TOOL3625198 RACING ENGINE BRACKET3625202 CHAIN LINK ASSEMBLING TOOL3625200 WATER PUMP SEAL FITTING TOOLPOMPA ACQUA36

10Workshop manual RR 4T - 400 - 450 - 5253032– Push rod 32 towards the inside of case 30 to allow the pumpassembly to be removed from below. NOTE: T

118 - Front suspension / wheel Release 01 Date 09/20071369108– Remove fork leg 6 from sheath 13. Pull hard to obtain the sep-aration. This operat

12Workshop manual RR 4T - 400 - 450 - 525InstallationNOTE: Fins 37 and piston 36 determine the rebound dampingaction. If necessary, the behaviour of t

138 - Front suspension / wheel Release 01 Date 09/20073345464344InstallationNOTE: Fins 46 and piston 45 determine the compression damp-ing. If ne

14Workshop manual RR 4T - 400 - 450 - 52539– Remove the adhesive tape from the end of the fork leg, clean-ing it of any traces of adhesive.– Manually

158 - Front suspension / wheel Release 01 Date 09/20073032Reassembling the pump assembly and the foot valve– Insert pump rod 32 into case 30.Each pump

16Workshop manual RR 4T - 400 - 450 - 525235– Push preassembled pump 23 until it comes into contact withfork leg 5. – Manually screw in the foot valve

178 - Front suspension / wheel Release 01 Date 09/20074823R– Open the adjuster by completely unscrewing adjusting screwR. – Using two 19-mm spanner

18Workshop manual RR 4T - 400 - 450 - 52508_Inghilterra_059311 27-12-2007 18:49 Pagina 18

Pag. 1REAR SUSPENSION / WHEEL909_Inghilterra_059311 27-12-2007 18:53 Pagina 1

3625001 LOCTITE 243 BLUE 6CCM3625081 BUSH PULLER3625082 INNER BEARING PULLER 12-16MM3625083 INNER BEARING PULLER 18-23MM3625084 INNER BEARING PULLER 5

CONTENTSRemoving the chain . . . . . . . . . . . . . . . Chap. 9 - 4Taking down the rear wheel . . . . . . . . . Chap. 9 - 4Removing the rear sprock

Before attempting to remove the rear suspension, placethe vehicle on a central stand with the rear wheel off theground.39 - Rear suspension / wheel Re

Removing the chainFind the split link and position it on the rear sprocket. Removethe link with a pair of pliers and undo the chain.When refitting, it

Verificare che l’errore massimo di planarità sui 360° non sia su-periore a 0,04 mm.When refitting the parts, tighten them to the prescribed torques(s

6Workshop manual RR 4T - 400 - 450 - 52509_Inghilterra_059311 27-12-2007 18:53 Pagina 6

Pag. 1BRAKING SYSTEM1010_Inghilterra_059311 27-12-2007 18:56 Pagina 1

CONTENTSFront brake pumpOverhauling the front brake pump . Chap. 10 - 4Replacing the front brake pads . . . . . . Chap. 10 - 5Replacing the front bra

Special attention should be given to the braking system. Nospecial maintenance is required, but frequent checks andthorough inspections are necessary,

Front brake pumpOverhauling the front brake pump– Empty the system.– Unscrew front brake lever screw 1.The replacement can only be performed after emp

510 - Braking system Release 01 Date 09/2007Replacing the front brake padsTo replace the brake pads, follow these steps: – Push the brake caliper towa

43625238 CHECKING SPANNER 3625173 FLYWHEEL PULLER 3625000 SILICONE (TUBE)3625098 TIMING CHAIN FITTING TOOL3625209 SPARK PLUG SPANNER 13/163625090 CLUT

6Workshop manual RR 4T - 400 - 450 - 525Replacing the rear brake pumpThe replacement can only be performed after emptyingthe system.Avoid disposing of

WARNING: Always keep the brake disc free from oil andgrease as these substances greatly reduce the brakingaction.Every time the braking system is serv

8Workshop manual RR 4T - 400 - 450 - 52510_Inghilterra_059311 27-12-2007 18:56 Pagina 8

Pag. 1ELECTRICAL SYSTEM1111_Inghilterra_059311 27-12-2007 18:59 Pagina 1

2Workshop manual RR 4T - 400 - 450 - 525123456789101112131415161718192021222324252627282930313233343536373811_Inghilterra_059311 27-12-2007 18:59 P

311 - Electrical system Release 01 Date 09/2007WIRING DIAGRAM Euro 31) RIGHT-HAND FRONT TURN INDICATOR (12V-10W BULB)2) FRONT BRAKE LIGHT BUTTON3) STA

4Workshop manual RR 4T - 400 - 450 - 52511_Inghilterra_059311 27-12-2007 18:59 Pagina 4

511 - Electrical system Release 01 Date 09/2007WIRING DIAGRAM RR4T USA1) WHEEL SENSOR2) STARTING BUTTON3) PUSHBUTTON SCROLL4) NO CONNECT TELL TALE LAM

6Workshop manual RR 4T - 400 - 450 - 52511_Inghilterra_059311 27-12-2007 18:59 Pagina 6

711 - Electrical system Release 01 Date 09/2007WIRING DIAGRAM RS4T USA1) RIGHT-HAND FRONT TURN INDICATOR (12V-10W BULB)2) FRONT BRAKE LIGHT BUTTON3) S

52 - Special tools Release 01 Date 09/2007Code Description3625206 CARBURETTOR ADJUSTING SPANNER02_Inghilterra_059311 27-12-2007 17:57 Pagina 5

CONTENTSChecking for leakage currents . . . . . . Chap. 11 - 5Removing and reinstalling the battery Chap. 11 - 5Charging the battery . . . . . . . .

Checking for leakage currentsCheck for leakage currents before inspecting the regulator-rec-tifier.– Disconnect the ignition and remove the earth cabl

Filling the battery– Remove the battery and the electrolyte container from thepackage.Before starting to fill the battery, read through the enclosed i

Checking the voltage regulatorsIf a regulator is suspected of being defective, it should be repla-ced, if possible, with one that is known to be in wo

CDI unitCheck the wires and connectors of the CDI unit.The operation of the CDI unit can only be checked on a speciallydesigned test bench for ignitio

Main fuseFuse 3 is installed in starting relay 4 under right-hand side pa-nel 5.To gain access to the fuse, remove the saddle and lift swingingsupport

Checking the starter motor– Disconnect the battery negative terminal and remove the star-ter motor.– Connect the negative terminal of a 12 V battery t

01_Inghilterra_059311 27-12-2007 17:52 Pagina 2

6Workshop manual RR 4T - 400 - 450 - 52502_Inghilterra_059311 27-12-2007 17:57 Pagina 6

TIGHTENING TORQUESSPECIFICATIONSRECOMMENDED PRODUCTS303_Inghilterra_059311 27-12-2007 18:00 Pagina 1

2CONTENTSSPECIFICATIONS - ENGINE . . . . . . . . . . . . Chap. 3 - 3SPECIFICATIONS . . . . . . . . . . . . . . . . . Chap. 3 - 3CARBURETTOR TUNING

3SPECIFICATIONS - ENGINESPECIFICATIONSEngine 400 450 525Type single-cylinder, 4-stroke, liquid-cooled, with countershaft and electric startDisplacemen

4Workshop manual RR 4T - 400 - 450 - 525SPECIFICATIONS - ENGINECARBURETTOR TUNING400/450 525 Carburettor type Keihin FCR-MX 39 Keihin FCR-MX 39Carbure

53 - Tighening torques, specifications, recommended products, Homologation E3 Release 01 Date 09/2007SPECIFICATIONS - ENGINETIGHTENING TORQUESDescript

6Workshop manual RR 4T - 400 - 450 - 525SPECIFICATIONS - ENGINEFITS, WEAR LIMITSCrankshaft axial play . . . . . . . . . . . . . . . . . . . . . . . .

73 - Tighening torques, specifications, recommended products, Homologation E3 Release 01 Date 09/2007SPECIFICATIONS - CYCLE PARTS400/450/525Frame Sin

8Workshop manual RR 4T - 400 - 450 - 525HOMOLOGATION E3The latest models are E3 type-approved andthey differ from prior approvals in that three de-vic

93 - Tighening torques, specifications, recommended products, Homologation E3 Release 01 Date 09/2007SPECIFICATIONS - FRAMETIGHTENING TORQUES4 fork fo

3INTRODUCTIONThis publication has been designed to assist authorizedservice personnel of Betamotor Workshops in maintainingand repairing the vehicle r

10Workshop manual RR 4T - 400 - 450 - 52503_Inghilterra_059311 27-12-2007 18:00 Pagina 10

MAINTENANCE404_Inghilterra_059311 27-12-2007 18:10 Pagina 1

2CONTENTSPLANNED MAINTENANCE . . . . . . . . . . . . Chap. 4 - 3RECOMMENDED LUBRICANTS . . . . . . . . Chap. 4 - 3How to clean parts . . . . . .

34 - Maintenance Release 01 Date 09/2007PLANNED MAINTENANCEInterval hours (h) 3 after/every 15Item fuel (litres) 20 100Air filter (after each off-road

4How to clean partsClean all parts with suitable biodegradable solvents andthen dry them with compressed air.Clean the assemblies before disassembling

5Oil circuitOil pump 3 sucks the engine oil from the gearbox oil sumpthrough long oil unit 4. The oil flows through oil line 5 into thecylinder head t

6Cleaning the short oil unitShort oil unit 1 is fitted into socket-head screw 2 on the lowerside of the engine. Insert an Allen key into the socket an

7Replacing the oil filterRemove screw 1 and place a container under the engine to col-lect the drained oil. Remove the four screws 2 and take off thet

8Checking the front brake fluid levelCheck the brake fluid level by looking through sight A. The lev-el should never fall below the mark in the sight.

9Checking the rear brake fluid levelEnsure the brake fluid level by looking through sight D. The lev-el should never fall below the mark in the sight.

4GENERAL CONTENTS1 General information2 Specific tools3 Tightening torques - Specifications -Recommended products 4 Maintenance5 Bodywork and fittin

10Checking the front brake padsTo check the wear of the front brake pads, visually inspect thecaliper from below. The lining on the visible ends of th

11Checking the level of the hydraulic clutch fluidTo check the level of the fluid in the clutch pump, it is first nec-essary to remove cover 2. Remove

12Workshop manual RR 4T - 400 - 450 - 525CONTROLSClutch leverClutch lever 1 is fitted to the left-hand side of the handlebars.Screw A can be used to a

134 - Maintenance Release 01 Date 09/2007CONTROLS (RR4t USA)Starter buttonStarte button 3 is located on the right-hand side of the handle-bars and ope

14Fork oilLeft/right fork leg To renew the oil, follow these steps: – Unscrew the four screws B fastening handlebar clamp C andremove the handlebars.–

15Air filterA dirty air filter blocks the passage of air, reduces engine powerand increases fuel consumption. For these reasons, it is essen-tial to m

16Spark plugMaintaining the spark plug in good condition makes for reducedfuel consumption and optimum engine performance. It is prefer-able to remove

17Carburettor - Idle speed adjustmentThe adjustment of the idle speed strongly affects engine start-ing, i.e. an engine whose idle speed is properly a

18Emptying the float chamberShould the float chamber need to be emptied, use the followingprocedure when the engine is cold. Close the fuel cock andpl

19Chain maintenanceThe life of the chain mainly depends on its maintenance. Chain without X-rings should be regularly cleaned in petroleumand then imm

Pag. 5GENERAL INFORMATION101_Inghilterra_059311 27-12-2007 17:52 Pagina 5

20SUSPENSIONSForkAdjusting the rebound damping The hydraulic rebound damping unit determines the behaviourof the fork during the rebound phase and is

21Adjusting the spring preloadUse the following procedure to adjust the spring preload.Loosen locknut 1, turn ring nut 2 clockwise to increase thespri

22Workshop manual RR 4T - 400 - 450 - 525DIGITAL RPM INDICATOR (RR4T Euro 3 version)SCROLL PUSHBUTTONThe instrument panel has a pushbutton A which cha

234 - Maintenance Release 01 Date 09/2007INSTRUMENT PANEL OPERATIONEvery time the battery is connected, the instrument panelchecks all the functions.O

24Workshop manual RR 4T - 400 - 450 - 525CONVERSION PROCEDURE Km/h - Mph and wheelselectionIn order to convert km/h to mph, proceed as follows:- Set

254 - Maintenance Release 01 Date 09/2007DIGITAL SPEEDOMETER(RR4T USA RS4T USA version)CYCLING THROUGH THE FUNCTIONSIt is always possible to cycle thr

26Workshop manual RR 4T - 400 - 450 - 525AUTOMATIC TRIP FUNCTION (TD)T≥ 3” resets LAP and TDT<3” cycles through functionsThis function is always ac

274 - Maintenance Release 01 Date 09/2007CHANGING THE WHEEL CIRCUMFERENCE,UNIT AND NUMBER OF PULSESThe wheel circumference, the unit and the number of

28Workshop manual RR 4T - 400 - 450 - 52504_Inghilterra_059311 27-12-2007 18:10 Pagina 28

BODYWORK AND FITTINGS505_Inghilterra_059311 27-12-2007 18:14 Pagina 1

6Workshop manual RR 4T - 400 - 450 - 525CONTENTSHOW TO CONSULT THE MANUAL . . . . . . . Chap. 1 - 7GENERAL CONTENTS . . . . . . . . . . . . . Chap.

2CONTENTS Removing the plastics . . . . . . . . . . . . . Chap. 5 - 3Removing the saddle . . . . . . . . . . . . . . Chap. 5 - 3Removing the rear mu

3Removing the plasticsTo make some areas of the vehicle easier to check and service,it is first necessary to remove parts of the bodywork as de-scribe

4Removing the front side panelsUnscrew the eight fixing screws E (four on each side) and takeoff the front side panels. Removing the rear side panelsU

5Removing the front mudguardRemove the four screws L from under the front mudguard.Also remove mudguard brace fixing screw M from under themudguard.F

6Removing the headlight grilleRelease the two rubber bands Q as shown in the figure, pull outthe headlight and remove grille R.Workshop manual RR 4T -

ENGINE SECTION- REMOVING THE ENGINE FROM THE VEHICLE- DISASSEMBLING THE ENGINE- OVERHAULING THE ENGINE- REASSEMBLING THE ENGINE- INSTALLING THE ENGINE

2Workshop manual RR 4T- 400 - 450 - 52563_Inghilterra_059311 27-12-2007 18:17 Pagina 2

ENGINE SECTION- REMOVING THE ENGINE FROM THE VEHICLE663_Inghilterra_059311 27-12-2007 18:17 Pagina 3

CONTENTSRemoving the saddle . . . . . . . . . . . . . . . Chap. 6 - 5Removing the fuel tank . . . . . . . . . . . . . Chap. 6 - 5Removing the right-

Place the vehicle on a central stand. Drain the engine oil (seeChapter 4 Maintenance). Removing the saddleRemove the left-hand and right-hand saddle s

71 - General information Release 01 Date 09/2007HOW TO CONSULT THE MANUALArrangement of subjectsThe manual is divided into chapters that cover the mai

Removing the right-hand side panelTo gain access to the silencer fixing screws, it is first necessaryto remove the right-hand side panel.Pay attention

Removing the left-hand radiatorTo remove the left-hand radiator, it is first necessary to discon-nect the upper pipe after removing the clamp as shown

Removing the intake sleeve Disconnect the carburettor intake sleeve.Rear frameRemove the two screws 1 to the left and right of the rear frameand loose

Disengaging the exhaust pipeRelease the two springs that support the exhaust pipe with thecylinderTake care to avoid hand injury.Remove the screw that

Removing the engine/swingarm pin Remove the engine/swingarm pin. For safety reasons, it is ad-visable to unscrew the left side while holding the pin i

Removing the brake pedal pull-off spring Removing the spark plug capRemoving the water delivery pipe from the pump Removing the front sprocket casingU

Releasing the decompressor cableRemoving the engineRemove the lower engine/frame pivot pin.Remove the upper engine/frame pivot pin.Removing the kickst

Pag. 13ENGINE SECTION- DISASSEMBLING THE ENGINE664_Inghilterra_059311 27-12-2007 18:22 Pagina 13

CONTENTSDraining the oil . . . . . . . . . . . . . . . . . . Chap. 6 - 15Removing the oil filters . . . . . . . . . . . . Chap. 6 - 15Removing the fr

156 - Engine Release 01 Date 09/2007Draining the oil– Remove screws 1, 2 e 3 and drain the engine oil into a con-tainer. – Remove the kickstart and th

8TERMS AND SYMBOLSWorkshop manual RR 4T - 400 - 450 - 525When performing these oper-ations, flammable vapourscan be released and metalparts can be ej

16Workshop manual RR 4T - 400 - 450 - 525– Unscrew the four screws 4 and remove the ignition cover withthe related gasket from the crankcase. – The st

176 - Engine Release 01 Date 09/2007– Position the special tool as shown in the figure, unscrew theprimary torque gear flange nut and remove it.– Remo

18Workshop manual RR 4T - 400 - 450 - 525– Remove clutch drum 1 together with stepped washer 2 andthe two half washers 3 from the driving shaft.2143–

196 - Engine Release 01 Date 09/2007Removing the cylinder head top– Unscrew all six screws with the related seal rings and removethe two valve covers

20Workshop manual RR 4T - 400 - 450 - 525– Position the timing chain separating tool and undo the chain(see figure). – ENSURE THAT THE EJECTED NAILS D

216 - Engine Release 01 Date 09/2007– Remove the Seeger ring and push the piston pin out of thepiston. Remove the piston.Removing the timing chain and

22Workshop manual RR 4T - 400 - 450 - 525Removing the electric start and kickstart gears– Remove the two Seeger rings 1 and the thrust washers. Re-mov

236 - Engine Release 01 Date 09/2007Removing the primary torque gear and the free wheel – Remove flange nut 1. NOTE: THERE ARE FLANGE NUTS WITH LEFT-H

24Workshop manual RR 4T - 400 - 450 - 525Removing the gearshift mechanism and the gear shafts – Lay down the engine on one side.– Release the engine f

256 - Engine Release 01 Date 09/2007Removing the countershaft and the crankshaft– Turn the crankshaft until the marks on the countershaft andthe crank

91 - General information Release 01 Date 09/2007CONVENTIONIn order to clarify the left/right convention used in this manual, a diagram of the vehicle

26Workshop manual RR 4T - 400 - 450 - 52564_Inghilterra_059311 27-12-2007 18:22 Pagina 26

Pag. 27ENGINE SECTION- OVERHAULING THE ENGINE665_Inghilterra_059311 27-12-2007 18:28 Pagina 27

CONTENTSIMPORTANT NOTE ABOUTCRANKCASE SERVICING . . . . . . . . . Chap. 6 - 29Left-hand crankcase half . . . . . . . . . . Chap. 6 - 30Right-hand c

IMPORTANT NOTE ABOUT CRANKCASE SERVICINGNOTE: Read through this paragraph before begin-ning work, then determine the reassembly sequenceso that the cr

30Manuale di Officina RR 4T - 400 - 450 - 525Left-hand crankcase half Remove all the oil seals and heat the crankcase half in an ovenat a temperature

316 - Motore Release 01 Date 09/2007The oil pump casing should show no signs of scoring or seizu-re.Blow all the oil channels with compressed air and

Countershaft ball bearing 1 and oil seal 2Using a suitable puller, extract the ball bearing from the crank-case half and remove the oil seal. Press in

“100” oil jet 1Remove the oil jet and blow the oil channel with compressed air.Degrease the oil jet thread, apply Loctite 243 and refit the oil jet. N

34Manuale di Officina RR 4T - 400 - 450 - 525ABCrankshaftIf the connecting rod bearing is replaced, take care to properlyposition the coupling shaft.

356 - Motore Release 01 Date 09/2007Measuring the outside diameter of the handwheelsUsing a vernier caliper, measure the outside diameter of thehandwh