Beta Motard M4 Service Manual
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Beta Motard M4 Service Manual

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Motard M4
Service Manual
Holtvej 8-10, Høruphav, 6470 Sydals
Telefon: +45 73 15 11 00
Fax: +45 73 15 11 01
info@scanmi.dk · www.scanmi.dk
CVR: 27 73 31 07
www.betamotor.dk
Juli 2011

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  • Page 1 Motard M4 Service Manual Holtvej 8-10, Høruphav, 6470 Sydals Telefon: +45 73 15 11 00 Fax: +45 73 15 11 01 info@scanmi.dk · www.scanmi.dk CVR: 27 73 31 07 www.betamotor.dk Juli 2011...
  • Page 2 ALP 4.0 - MOTARD M4 Thanks for you preference, and have a good time! This hand- book 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.
  • Page 3 IMPORTANT We recommend you to check all the tightenings after the first one or two hours’ ride over rough ground. Special attention should be paid to the following parts: • rear sprocket • footrest supports • front / rear brake caliper •...

  • Page 4: Table Of Contents

    Operating instructions ................85 Ecologic guide ..................85 Riding safety ..................86 CHAPTER 1 GENERAL INFORMATION .......... 87 Vehicle identification data ..............88 Delivery .................... 88 Load ....................89 Tyres ....................89 Familiarizing with your vehicle ............... 91 Keys and locks ................... 92 Ignition switch / Steering lock ...............
  • Page 5 Scheduled maintenance ..............141 Prolonged inactivity ................142 After prolonged inactivity ..............142 CHAPTER 4 ADJUSTMENTS ............143 Adjusting the brakes ................144 Adjusting the clutch ................144 Rear shock absorber regulation ............. 145 Adjusting the slow running ..............145 Adjusting the throttle play ..............

  • Page 6: Operating Instructions

    OPERATING INSTRUCTIONS • The vehicle must be accompanied by: number-plate, registration document, tax disc and insurance. • Do not carry any animals or objects which are not securely fastened to the vehicle, or exceed the vehicle’s overall dimensions or the maximum load specified by the manufacturer.

  • Page 7: Riding Safety

    RIDING SAFETY • Observe the Highway Code. • Always put on and fasten a homologated helmet. • 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. •...

  • Page 8: Chapter 1 General Information

    CONTENTS CHAPTER 1 GENERAL INFORMATION Vehicle identification data Delivery Load Tyres Familiarizing with your vehicle Keys and locks Ignition switch / Steering lock Crash helmet lock Instrument panel and controls Specifications Wiring diagram Electrical devices...

  • Page 9: Vehicle Identification Data

    VEHICLE IDENTIFICATION DATA FRAME IDENTIFICATION Frame identification data A are stamped on the right side of the steering head tube. ENGINE IDENTIFICATION Engine identification data B are stamped in the area shown in the figure. WARNING: Tampering with the identification numbers is severely punished by law.

  • Page 10: Load

    • Always measure the inflating pressures when the tyres are cold. pressure is correct TYRES ALP 4.0 TYRE FRONT REAR Size (90/90-21) (140/80-18) 70R or (130/80-18) 66R pressure is too high Pressure kg/cm TYRES MOTARD M4 TYRE FRONT REAR Size (120/70-17) (150/60-17) Pressure kg/cm...
  • Page 11 Note: The tyre (TUBE TYPE) tread depth must never be less than 2 mm. Failure to comply with this rule is punished under the regulations in force. • Before riding, check the tyres for cuts, cracks, abrasions, bulges, etc. If any defects are found, have the tyres checked by an expert as riding with a damaged tyre can be extremely dangerous.
  • Page 12 FAMILIARIZING WITH THE VEHICLE ALP 4.0 MOTARD M4 Main parts: 8- Rear light 17- Saddle 1- Air filter 9- Rear turn indicators 18- Engine 2- Fuel tank 10- Side stand 19- Front mudguard 3- Tank cap 11- Crash helmet lock...

  • Page 13: Keys And Locks

    KEYS AND LOCKS The vehicle is supplied with two keys and the related spares for the ignition switch/ steering lock and the crash helmet lock. WARNING Do not keep the spare keys in the vehicle. Keep the keys in a safe and easy-to-reach place.

  • Page 14: Instrument Panel And Controls

    INSTRUMENT PANEL AND CONTROLS 1- LCD 10 - Engine start button 2- Ignition switch 11 - Engine stop button 3- Neutral warning light 12 - Turn indicator switch 4- Turn indicator warning light 13 - Horn button 5- High beam warning light 14 - Lights selector switch 6- Stand warning light 15 - High beam flash switch...
  • Page 15 LCD DISPLAY Operation and display of pages and icons ISTANT SPEED ODO – TOTAL COUNTER TRP – TRIP COUNTEER AVS – TRP AVERAGE SPEED LAP – STOPWATCH (FORMATS CLK – CLOCK FORMATS hh:mm:ss, con 12h e 24h, e mm:ss TACHOMETER BARS SPEED max –...
  • Page 16 Order of pages on LCD display The different pages can only be viewed in succession starting from the default page. Page 1 - TEST Turn the ignition switch to the ON posi- tion. General check of all the icons and bars on the LCD display and warning light test.
  • Page 17 While page 2 is displayed, briefly press Page 3 - TRP MODE if the vehicle is stationary or SCROLL while travelling to bring up page The new page is displayed as soon as the button is released. Displays: Instant speed at the top (max. 199 km/h or Mph) TRP Trip counter, displayed at the bot- tom (max.
  • Page 18 Pressing SCROLL for 1.5 seconds while page 5 is displayed brings up figure 21 for 1 sec- Page 6 - LAP – Stopwatch ond with the bars minutes:seconds:tenths of a second - - : - - :- - at the top. Holding down SCROLL brings up page 5 again.
  • Page 19 While page 7 is displayed, briefly press Page 8 - CLK - Clock minutes:seconds MODE if the vehicle is stationary or SCROLL while travelling to bring up page 8. The new page is displayed as soon as the button is released. Displayed information: Clock format MINUTES:SECONDS 00:00...
  • Page 20 Resetting the TRP, SPEED max and LAP parameters. The following parameters can be reset: - TRP, trip counter, and consequently AVS. - SPEED max, maximum speed reached by the vehicle. Times indicated by LAP in both configurations while either of the two pages is displayed. The parameters can be reset by pressing the MODE button while the vehicle is stationary or the SCROLL button at all time.
  • Page 21 MONITORING ICONS (engine oil and service icons) OIL ICON When 90 per cent of the hours making up the oil change interval have elapsed, the oil icon appears steadily on all pages. As soon as the preset value is reached, the icon starts to blink.
  • Page 22 BATTERY ICON - Vb LESS THAN 10.5 V When the vertical bar blinks and min is displayed, the battery voltage is less than 10.5 V. If the indication persists, the cause will have to be determined. IMPORTANT: If the battery is disconnect- ed or its voltage is nearly zero, the instru- ment loses its functionality.

  • Page 23: Specifications

    ............... (90/90-21) 54R rear cover ......... (140/80-18) 70R or (130/80-18) 66R front rim ..................1.85x21 rear rim ..................3.00x18 WHEEL DIMENSION - MOTARD M4 front cover ..............(120/70-17) 54R rear cover ..............(150/60-17) 66R front rim ..................3.50x17 rear rim ..................4.25x17...
  • Page 24 Ø 260 mm disc brake with hydraulic control FRONT BRAKE - MOTARD M4 Ø 310 mm disc brake with hydraulic control REAR BRAKE - ALP 4.0/MOTARD M4 Ø 220 mm disc brake with hydraulic control BRAKE OIL BARDAHL brake fluid DOT4...
  • Page 25 Clutch ..............multiple-disc in oil bath Transmission ......... 6-speed, with constant-mesh gears (350 cc) Valves ....................n. 4 Secondary transmission ............15/48 (ALP 4.0) 15/42 (MOTARD M4) Chain with OR ......REGINA DERVIO 5/8’-112link w/joint (ALP 4.0) REGINA DERVIO 5/8’ -110link w/joint (MOTARD M4)
  • Page 26 Tie rod grease ..............BARDAHL MPG2 Play of valves ............intake 0.05 - 0.10 mm exhaust 0.8 - 0.13 mm Starting ..................electric...

  • Page 27: Wiring Diagrams

    WIRING DIAGRAM...

  • Page 28: Wiring Diagram

    WIRING DIAGRAM RIGHT-HAND FRONT TURN INDICATOR (12V-10W BULB) FRONT BRAKE LIGHT BUTTON RIGHT-HAND CONTROL SET ENGINE STOP BUTTON START BUTTON WHEEL REVOLUTION SENSOR HIGH BEAM WARNING LIGHT TURN INDICATOR WARNING LIGHT DISPLAY NEUTRAL WARNING LIGHT STAND WARNING LIGHT SCROLL BUTTON HORN BUTTON LIGHTS SELECTOR SWITCH HIGH-BEAM FLASH...

  • Page 29: Electrical Devices

    ELECTRICAL DEVICES Remove the saddle by sliding it backwards after turning the fixing screw 1/4 of a turn anticlockwise. WARNING To avoid damage to the electrical equipment, never disconnect the cables while the engine is running. STAND RELAY A FUSE B - two 20A WARNING Before you replace the blown fuse, trace and eliminate the failure that caused the...
  • Page 30 NOTES ON THE BATTERY G Insert the new battery in the specially designed compartment under the saddle (see photo) tightening it with the H equipment elastic H. Connect the black cable terminal to the negative (-) and the red cable to the positive (+) inserting the red cap protection.
  • Page 32 CONTENTS CHAPTER 2 OPERATION Checks and maintenance before and after off-road use Recommended lubricants Running-in Starting the engine Shutting off the engine Refuelling...

  • Page 33: Recommended Lubricants

    CHECKS AND MAINTENANCE OPERATIONS BEFORE AND AFTER OFF-ROAD To avoid trouble during operation, it is advisable to perform a few checks and maintenance operations before and after riding. In addition in order to make your vehicle safer, a few minutes spent carrying out these operations will enable you to save time and money.

  • Page 34: Running-In

    RUNNING-IN The running-in period lasts approximately 10 hours, during which it is advisable to: • Warm up the engine well before starting off. • Avoid riding at constant speed (chang- ing the speed allows the different com- ponents to bed in uniformly and in a shorter time).

  • Page 35: Starting The Engine

    STARTING THE ENGINE • Rotate the ignition key clockwise and en- sure that the neutral warning light (N) on the instrument panel is lit. IMPORTANT: Remember, before turning the key, to posi- tion the light- switch knob in headlight po- sition (see page 93), so as to reduce bat- tery consumption as much as possible.

  • Page 36: Shutting Off The Engine

    Note: The vehicle can be started while the stand is down providing the neutral warning light (N) is lit. Note: In an emergency, the vehicle can also be operated without a battery. SHUTTING OFF THE ENGINE • While the vehicle is stationary and in neutral gear, rotate the ignition key to the “OFF”...

  • Page 37: Refuelling

    REFUELLING • Switch off the engine. • Remove cap A. Note: The fuel tank capacity is approximately 10.5 litres, including 3 litres reserve. ATTENTION: Any spills of petrol on the bodywork or other parts of the motorcycle must be dried immediately.

  • Page 38: Chapter 3 Checks And Maintenance

    CONTENTS CHAPTER 3 CHECKS AND MAINTENANCE Motor oil level check Motor oil and oil filter substitution Fume collecting tube Brake pump oil - Bleeding the brakes Fork oil Air filter Spark plug Front and rear brakes Carburetor Battery Removing the plastics Notes for cross-country Final transmission group substitution Cleaning and checking the vehicle...

  • Page 39: Motor Oil Level Check

    MOTOR OIL LEVEL CHECK Motor oil level On this vehicle oil check must be carried out while the motor is hot, since the oil tank is positioned higher than the motor (see scheme). Fig. B Fig. A Procedure for oil level check •...
  • Page 40 Oil level check To be carried out only after having verified the presence of oil in the motor (see page 118). • Start the motor running and let it run on minimum for 3 minutes. • Turn the motor off and wait one minute. •...
  • Page 41 MOTOR OIL AND FILTER OIL SUBSTITU- TION Always renew the oil when the engine is hot. To avoid burns, take care not to touch the engine and the oil. • The oil filter should be renewed at the same time as the oil. •...
  • Page 42 Emptying oil from the tank • Remove the four carter clamping screws at the back of the motor. • Unloosen the Q screw and let all of the oil flow out of the tank. • The first time you change the oil (see page 113), we suggest that you also clean the metal filter which is positioned on the fi- nal end of the oil tank.
  • Page 43 • For completely emptying the oil even from the tank, remove the saddle, the front sides and the tank. • Tilt the motor-bike to the left and unscrew the H screw positioned on the frame. • Apply a rubber tube I. •...
  • Page 44 Assembly • Proceed by carrying out the inverse pro- cedure to that of disassembling the metal filter and net of the oil tank • Insert a new oil filter. • Apply a thin film of engine oil to the filter cover O-ring before insertion.

  • Page 45: Fume Collecting Tube

    FUME COLLECTING TUBE Fume collecting tube A is located on the left side of the vehicle, next to the shock absorber, and comes out of the lower part of the filter box. It is designed to collect the fumes produced by the engine oil. Should you find some oil in the tube, re- move the cap at the lower end of the tube and drain the oil, or the mixture of oil and...
  • Page 46 Rear brake Check that oil is present by looking through reservoir E. The oil level must never be below the minimum level line in relief on container F. For restoring the oil level pro- ceed as follows: • Unscrew the oil container clamping screw G.
  • Page 47 Bleeding the front brake Follow these steps to bleed the front brake circuit: • Remove rubber cap A from valve B. • Remove the oil reservoir cap. • Insert one end of a small tube into valve B and place the other end in a container. MOTARD •...
  • Page 48 Bleeding the rear brake Follow these steps to bleed the rear brake circuit: • Remove rubber cap C. • Remove the oil reservoir cap. • Insert one end of a small tube into valve D and place the other end in a container. •...

  • Page 49: Fork Oil

    FORK OIL Right/left-hand rod The procedure for changing the oil in the forks is provided only for information. We recommend having the operation per- formed by a BETAMOTOR authorized workshop. Follow these steps to renew the oil: 1) Remove the handle-bar by unscrewing the four C clamping screws of the two D stand screws.

  • Page 50: Air Filter

    AIR FILTER Follow these steps to gain access to the air filter. • Slightly raise the carter tank A as in fig- ure. • Remove plastic cover E and unscrewing the three fixing screws B. • Remove filter C after loosening the filter retaining cover fixing screw D.

  • Page 51: Spark Plug

    SPARK PLUG Keeping the spark plug in good condition makes for reduced consumption and opti- mum engine performance. It is advisable to remove the spark plug when the engine is hot (and naturally off) because the carbon formation and the colour of the insulator provide important information on carburetion, lubrication, and the general condition of the engine.

  • Page 52: Brakes

    FRONT BRAKE Check To check the wear of the front brake, visu- ally inspect the brake pad ends by look- ing at the brake caliper from the front. The brake linings should be at least 2 mm thick. If the linings are thinner, replace the pads immediately.

  • Page 53: Carburetor

    CARBURETOR To ensure optimum carburetion, it is essen- tial to carefully clean the carburetor. Remove the carburetor from the vehicle. Unscrew the two fixing screws A and re- move the float chamber. Check that the float is properly positioned by verifying that float holder plate is parallel with the carburetor body surface as shown in the figure.

  • Page 54: Removing The Plastics

    REMOVING THE PLASTICS FOR ALP To facilitate checks and operations in cer- tain areas of the vehicle, it is essential to remove the bodywork sections as de- scribed below. Removing the saddle • Unloosen the clamping screw A and then remove the saddle by pushing it towards the rear of the vehicle so as to disengage it from the hook on the fuel tank.
  • Page 55 Disassembling rear sides • Unscrew the clamping screws N, after having removed the rear handles and thus slide the sides out. Removing the fuel tank • Remove screw I fixing the fuel tank to the frame, detach the fuel cock line and then remove the tank by pulling it towards the rear of the vehicle.

  • Page 56: Removing The Plastics

    REMOVING THE PLASTICS FOR MOTARD M4 To facilitate checks and operations in cer- tain areas of the vehicle, it is essential to remove the bodywork sections as de- scribed below. Removing the saddle • Unloosen the clamping screw A and then...
  • Page 57 Disassembling rear sides • After removing the front side panels and the grab handles, unscrew the two side fasteners N and remove rear fairings M. Subsequently remove the three screws O and take off the side panels, disengaging them from their catches. Disassembling rear tail •...

  • Page 58: Notes For Cross-Country

    NOTES FOR CROSS-COUNTRY In order to use the vehicle cross-country, it is possible to disassemble those parts which are bulky: licence-plate carrier, stand, di- rection indicators and passenger foot- board. Removing the stand • Remove the stand switch by unscrewing the only fixing screw C.

  • Page 59: Final Transmission Group Substitution

    FINAL TRANSMISSION GROUP SUBSTI- TUTION In case one of the three final transmission components must be substituted because of wear (pinion, chain and crown), it is recommended to substitute the entire group. Substituting the chain • Use a screwdriver as shown in the fig- ure.
  • Page 60 Replacing the front sprocket • Loosen the rear wheel. • Loosen the chain adjusters. • Move the wheel forward to the end of its travel to allow the slackening of the chain. •Remove the two chain guard fixing screws F. •...

  • Page 61: Cleaning And Checking The Vehicle

    CLEANING AND CHECKING THE VEHICLE 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 (2-4 percent shampoo in water). Subsequently rinse well with water, and dry with air and cloth or suede leather.

  • Page 62: Scheduled Maintenance

    SCHEDULED MAINTENANCE 4-Stroke Motorcycles Alp 4.0 Motard M4 spark plug engine oil filter clutch engine play of valves engine oil and oil filter idle speed adjustment engine oil lines rear shock absorber battery nuts and bolts* steering bearings and steering play...

  • Page 63: Prolonged Inactivity

    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.

  • Page 64: Chapter 4 Adjustments

    CONTENTS CHAPTER 4 ADJUSTMENTS Adjusting the brakes Adjusting the clutch Rear shock absorber regulation Adjusting the slow running Adjusting the throttle play Checking and adjusting the steering play Tensioning the chain Adjusting the headlight...

  • Page 65: Adjusting The Brakes

    ADJUSTING THE BRAKES Front brake The front brake is a hydraulically operated disc brake, and therefore requires no ad- justment. Rear brake The rear brake is a hydraulically operated disc brake. The brake pedal can be adjusted for height by means of adjusters A and B. The brake lever play should never be less than 5 mm.

  • Page 66: Rear Shock Absorber Regulation

    For the ALP 4.0 rear shock absorber regu- lation, consider that the length of the spring with standard pre-loading is of 194 mm, while the length of the MOTARD M4 rear shock absorber spring with standard pre- load is of 235 mm.

  • Page 67: Checking And Adjusting The Steering Play

    CHECKING AND ADJUSTING THE STEERING PLAY Periodically check the play of the steering head tube by moving the forks backwards and forwards as shown in the figure. If any play is felt, carry out the adjustment by following these steps: •...

  • Page 68: Tensioning The Chain

    TENSIONING THE CHAIN To ensure the drive chain a longer life, it is advisable to periodically check its tension. Always maintain the chain clean and lu- bricated. If the chain play exceeds 20 mm, tension the chain by following these steps: •...

  • Page 69: Adjusting The Headlight

    ADJUSTING THE HEADLIGHT • The headlight beam is adjusted manually after loosening the screws on either side of the headlight with an Allen key. • Periodically check the direction of the beam. The beam can only be adjusted vertically. • Place the vehicle on level ground (but not on the stand) 10 metres from a vertical wall.

  • Page 70: Chapter 5 Replacements

    CONTENTS CHAPTER 5 REPLACEMENTS Replacing the front brake pads Replacing the rear brake pads Replacing the bulbs ALP Replacing the bulbs MOTARD Replacing the turn indicator bulbs...

  • Page 71: Replacing The Front Brake Pads

    REPLACING THE FRONT BRAKE PADS The procedure for replacing the brake pads is provided only for information. We rec- ommend having the operation performed by a BETAMOTOR authorized workshop. ALP 4.0 FRONT BRAKE Follow these steps to replace the pads: •...
  • Page 72 MOTARD M4 FRONT BRAKE Follow these steps to replace the pads: •Disassemble the pincers from the spe- cial support C by unscrewing the two screws A. • Loosen the two screws B. • Extract the brake pads. WARNING: When removing the front brake caliper, take care not to damage sensor C.

  • Page 73: Replacing The Rear Brake Pads

    REPLACING THE REAR BRAKE PADS The procedure for replacing the brake pads is provided only for information. We rec- ommend having the operation performed by a BETAMOTOR authorized workshop. Follow these steps to replace the pads: • Position the motor-bike on a central stand, with the rear tire raised above the ground.

  • Page 74: Replacing The Bulbs Alp

    REPLACING THE BULBS ALP FRONT Remove the headlight rim after unscrew- ing the three fixing screws. Remove the three reflector fixing screws A and pull out the reflector. Detach the bulb connector. Rotate the bulb holder anticlockwise and extract the burnt-out bulb. Fit a new bulb taking care not to touch the bulb to avoid impairing its function.

  • Page 75: Replacing The Bulbs Motard

    C in senso orario fino a battuta. Note: In the MOTARD M4 version the rear light and the indicators require no special main- tenance as their light is produced by LEDs.

  • Page 76: Replacing The Turn Indicator Bulbs

    REPLACING THE TURN INDICATOR BULBS Loosen screw A and remove the lens. Replace the defective bulb. The bulbs have bayonet bases. To remove them, press them lightly, rotate them 30° anticlockwise and then extract them. Headlight bulb 12V-55/60W Parking light bulb 12V-5W Right/left, front/rear 12V-10W...

  • Page 78: Chapter 6 Troubleshooting

    CONTENTS CHARTER 6 TROUBLESHOOTING INDEX...
  • Page 79 PROBLEM CAUSE REMEDY - Fuel system clogged (fuel lines, Clean the system. Engine does not start fuel tank, fuel cock). - Air filter dirty. Proceed as described on page 129. - No current supplied to spark Clean or replace the spark plug. If the plug.
  • Page 80 Air filter ................... 129 Brake pump oil ................. 124 Brakes, adjustment ................144 Brakes, bleeding ................124 Bulbs, replacement ................153 Carburettor ..................132 Chain, tensioning ................147 Checks after cleaning ................ 140 Checks and maintenance operation before and after off-road use ....112 Clutch, adjustment ................
  • Page 81 ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

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