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Beta RS 4T 400 Handbook

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RS 4T 400 - 450 - 520
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 specifi cations 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.
USA
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  • Page 1 RS 4T 400 - 450 - 520 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 specifi cations provided in this manual does not constitute an engagement on the part of BETAMOTOR S.p.A.
  • Page 2 • 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.

  • Page 3: Table Of Contents

    CONTENTS Operating instructions ................5 Ecologic guide ..................5 Riding safety ..................6 CHAPTER 1 GENERAL INFORMATION ..........7 Vehicle identifi cation data ............... 8 Tools kit ....................10 Steering lock ..................11 Familiarizing with the vehicle..............12 Moto-GPS “Voyager” (Trail Tech) ............16 Specifi...
  • Page 4 CHAPTER 4 ADJUSTMENTS .............. 55 Adjusting the home position of the front brake lever........56 Adjusting the home position of the brake pedal ........56 Adjusting the home position of the clutch lever ......... 56 Adjusting the handlebars ..............56 Gas control adjustment .................

  • Page 5: Operating Instructions

    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. •...

  • Page 6: Riding Safety

    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. •...

  • Page 7: Chapter 1 General Information

    CHAPTER 1 GENERAL INFORMATION CONTENTS Vehicle identifi cation data ............... 8 Frame identifi cation ................8 Engine identifi cation ................8 Label location ................... 9 Tools kit ....................10 Steering lock ..................11 Familiarizing with the vehicle..............12 Main parts: ..................12 Clutch lever ..................

  • Page 8: Vehicle Identifi Cation Data

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

  • Page 9: Label Location

    LABEL LOCATION This BETA exhaust system 2204185 meets U.S.EPA noise emission requirements of 80dBa for model specifi c code Beta 3867700497, 3867710497, 3867660497, 3867670497 and 3867680497 Installation of this exhaust system on motorcycles not specifi ed may violate U.S. federal law. USFS approved...

  • Page 10: Tools Kit

    TOOLS KIT The following items are supplied as stand- ard: operation and maintenance manual, tool kit (see photo). To take the tool kit, push the button 1 to get off the saddle. Pull back the saddle. Pull the rear side panel 2 to disassemble it. Get off the male end wrenches and hexa- gon socket 3.

  • Page 11: Steering Lock

    STEERING LOCK The vehicle is supplied with one key and a spare to be used for the steering lock. WARNING: Do not keep the spare keys in the vehicle. Keep the keys in a safe and easy-to-reach place. The code number stamped on the keys should be copied on this manual (or elsewhere) so it can be used to ask for duplicates should both keys be lost.

  • Page 12: Familiarizing With The Vehicle

    FAMILIARIZING WITH THE VEHICLE MAIN PARTS: 10 - Lower bumper 18 - Fork covers 1 - Fuel tank 19 - Rear mudguard (Bumper kit) 2 - Tank cap 11 - Saddle 20 - Cover air fi lter 3 - Silencer 12 - Engine 21 - Blinkers 4 - Rear shock absorber...

  • Page 13: Gearchange Lever

    CLUTCH LEVER Clutch lever 1 is fi tted to the left-hand side of the handlebars. Screw A can be used to alter the home position of the lever (see Adjustments). FRONT BRAKE LEVER Front brake lever 2 is fi tted to the right-hand side of the handlebars.

  • Page 14: Lights And Key-Switch

    LIGHTS AND KEY-SWITCH To switch on the engine, turn the the key- switch on 1 position. To switch off, turn on the 0 position. The A light is for the high beam light. The B light is for the blinker. RH SWITCH Starte button 1 is located on the right-hand side of the handlebars and operate the...

  • Page 15: Side Stand

    KICKSTART Kickstart 6 is fi tted to the right-hand side of the engine. The upper part of the kickstart can be oriented. SIDE STAND Press down side stand 7 with the foot and lean the vehicle against it. Ensure that the ground is solid and the vehicle stands steadily.

  • Page 16: Moto-Gps "Voyager" (Trail Tech)

    MOTO-GPS “VOYAGER” (TRAIL TECH) The dashboard user guide and the “RideLeader GPS File Editor” are available in the CD-ROM “TRAIL TECH” provided with the vehicle. NOTE The circumference of the front wheel is 219mm (8.62in). REMOVING THE LITHIUM BATTERY To remove the lithium battery on the dashboard (see the dashboard user guide available in the CD-ROM “TRAIL TECH”...

  • Page 17: Specifi Cations

    SPECIFICATIONS WEIGHT Dry weight RR 400 ........113 kg (front 55 Kg; rear 58 Kg) Dry weight RR 450 - 520 ....113,5 kg (front 55 Kg; rear 58,5 Kg) DIMENSIONS maximum length ................. 2180 mm maximum width ................807 mm overall height ................
  • Page 18 FRONT SUSPENSION “SACHS” hydraulic upside-down fork (Ø48 mm shafts) spring ..................... K 4,8 oil type ..............Motul Factory Line 5wt oil quantity (from the top, without spring and with fork compressed) ... 110 mm REAR SUSPENSION Single shock absorber with compound lever spring .....................
  • Page 19 Carburetor RR 400 RR 450 RR 520 Carburator type Keihin FCR-MX 39 Keihin FCR-MX 39 Keihin FCR-MX 39 Main jet Idling jet Starter jet Needle OBDTS OBDVS OBDVS Needle position (from above) 5° 4° 4° Main air jet Idling air jet Mixture control screw 1 + 1/2 1 + 1/2...

  • Page 20: Electrical System

    ELECTRICAL SYSTEM ELECTRICAL DIAGRAM...

  • Page 21: Legend Electrical Diagram

    LEGEND ELECTRICAL DIAGRAM FRONT RIGHT TURNING LIGHT WITH 12V 10W LAMP FRONT STOP SWITCH ENGINE STOP STARTER SWITCH KEY SWITCH WHEEL RPM SENSOR JOYSTICK ENTER BUTTON TRAILTECH GPS 10) MENU/POWER BUTTON 11) BACK BUTTON 12) TEMPERATURE SENSOR 13) 4700 UF CAPACITOR 14) TURNING LIGHTS INDICATOR 15) HIGH BEAM INDICATOR 16) HORN BUTTON...
  • Page 22 BATTERY Battery 1 is located under the saddle and requires no maintenance. It is not necessary to check the level of the electrolyte or top up with water. Keep the battery terminals clean and, if necessary, protect them with a small quantity of vaseline technique.
  • Page 23 FUSE Fuse 3 is located in starting relay 4 placed under the saddle and front the battery. To gain access to the fuse remove the saddle. The fuse protects the following devices: •electric starter •horn •indicators •instrument panel The starting relay also contains spare fuse 5 (10 amperes).

  • Page 24: Recommended Lubricants And Liquid

    RECOMMENDED LUBRICANTS AND LIQUID To maximize the vehicle’s performance and ensure many years of trouble-free opera- tion, we recommend using the following products: Engine Oil: 850cc Motul 7100 10w40 (For Racing use Motul 300V 10w40) Transmission Oil 1000cc Motul Transoil Expert 10w40 Brake Fluid Motul RBF 600 Coolant/Antifreeze...

  • Page 25: Chapter 2 Operation

    CHAPTER 2 OPERATION CONTENTS Checks to be performed before each ride ..........26 Running-in ................... 27 Engine start ..................28 Cold starting ................... 28 Hot starting ..................28 What to do if the engine is “fl ooded” ..........28 Refuelling .................... 29 Fuel tank cap ..................

  • Page 26: Checks To Be Performed Before Each Ride

    CHECKS TO BE PERFORMED BEFORE EACH RIDE The vehicle can be used only if it is in perfect condition from a technical point of view. To ensure maximum safety, it is advisable to carry out a general inspection of the motorcycle before each ride. The checks to be performed are described below. 1 CHECK THE ENGINE OIL LEVEL Insuffi...

  • Page 27: Running-In

    RUNNING-IN The running-in period lasts approximately 15 hours, during which it is advisable to: 1 During the fi rst 3 hours of operation the engine should only be used to approxi- mately 50 percent of its power. In addition, the engine speed should not exceed 7,000 rpm.

  • Page 28: Engine Start

    ENGINE START COLD STARTING 1 Open fuel cock 1. 2 Take the vehicle off the stand. 3 Shift into neutral. 4 Operate choke 2 by pulling it until it stops. 5 WITHOUT opening the throttle, fi rmly and FULLY operate kickstart 3 or use the electric starter.

  • Page 29: Refuelling

    REFUELLING FUEL TANK CAP Open: Turn tank cap 1 anticlockwise. Close: Replace the tank cap and turn it clockwise. Arrange tank breather pipe 2 so that it forms no kinks. FUEL COCK OFF Fuel cock 3 is closed. ON Before using the vehicle, turn the knob to ON.

  • Page 31: Chapter 3 Checks And Maintenance

    CHAPTER 3 CHECKS AND MAINTENANCE CONTENTS Oil circuit .................... 32 Checking the engine oil level ............32 Changing the engine oil and fi lters extraction ........33 Changing the gear and clutch oil ............35 Brakes ....................36 Check the level of the front brake fl uid ..........36 Restoring the level of the front brake fl...

  • Page 32: Oil Circuit

    OIL CIRCUIT The pump 1 (high pressure) push oil to crank mechanism 4, to piston oil jet 5, to stretcher 6, to head jet 7. The valve 2 control the pressure and the paper fi lter 3 scrubs the oil from subtle impurity. When oil has lubricated the head and has pushed the chain stretcher, the oil goes in generator room A.

  • Page 33: Changing The Engine Oil And Fi Lters Extraction

    CHANGING THE ENGINE OIL AND FILTERS EXTRACTION Before performing this operation, remove the lower bumper A, after underscrewing the three screws B as shown in the fi gure. Whenever the oil is changed, is necessary to change the paper fi lter and to clean the wire netting fi...
  • Page 34 To change the paper fi lter, remove the oil tap form engine unscrewing the two screws E. Using special seeger ring pliers, pull the paper oil fi lter. Mount the new paper fi lter, close the oil tap to engine, tighten the screws at 6 Nm. Remove screw fastener from left carter and pour in 800 ml engine oil PANOLIN OFF ROAD 4T RACE 10W/50.

  • Page 35: Changing The Gear And Clutch Oil

    CHANGING THE GEAR AND CLUTCH OIL Before performing this operation, remove the lower bumper A after unscrewing the three screws B as shown in the picture. The oil must be changed when the engine is at operating temperature. Park the motorcycle on level ground, remove the screw C and let oil drain in a container.

  • Page 36: Brakes

    BRAKES CHECK THE LEVEL OF THE FRONT BRAKE FLUID Check the level of the brake fl uid through sight A. The level of the fl uid should never fall below the mark in the sight. RESTORING THE LEVEL OF THE FRONT BRAKE FLUID To restore the level of the brake fl...

  • Page 37: Check The Level Of The Rear Brake Fl Uid

    CHECK THE LEVEL OF THE REAR BRAKE FLUID Check the level of the brake fl uid through sight D. The level of the fl uid should never fall below the mark in the sight. RESTORING THE LEVEL OF THE REAR BRAKE FLUID To restore the level of the brake fl...

  • Page 38: Front Brake Lining Control

    FRONT BRAKE LINING CONTROL In order to verify the wear condition of front brake is enough to view the pincer from the bottom, 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.

  • Page 39: Tyres

    TYRES Only fi t tyres approved by BETAMOTOR. Unsuitable tyres can adversely affect the road holding of the vehicle. • To protect your safety, immediately re- place any damaged tyres. • Slick tyres adversely affect the road holding of the vehicle, especially on wet roads and in off-road riding.

  • Page 40: Hydraulic Clutch

    HYDRAULIC CLUTCH CHECK OIL LEVEL To check the oil level in the clutch pump, fi rst remove cover 2. Remove the two screws 1 and take off cover 2 together with the rubber bellows. With the clutch pump in a horizontal posi- tion, the level of the oil should be 5 mm below the upper rim.

  • Page 41: 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 performed by a BETAMOTOR authorized workshop. • Rest the motor on a central stand, lift it making sure that it is stable. •...
  • Page 42 • Loosen the counter-nut 2 and remove cap 1. • Extract the spring 3 and overturn the pipe, making the oil escape. • Move the pumping unit and drain the remaining oil. When the oil has been drained completely, introduce the amount of new oil described in chapter 1.
  • Page 43 • Tighten the cap to the completely ex- tended leg. • Insert the legs into the plates. Once the leg has been positioned at the desired extension, tighten screws E at 17Nm and F at 12Nm, after the screws have been greased.

  • Page 44: Air Filter

    AIR FILTER A dirty air fi lter hinders the passage of air, reduces engine power and increases fuel consumption. For these reasons it is essen- tial to clean the air fi lter on a regular basis. Follow these steps to gain access to the air fi...

  • Page 45: Spark Plug

    SPARK PLUG To accede to spark plug, is necessary to take off saddle and the fuel tank. To remove the fuel tank proceed as follows. Unscrew the two screws A, unscrew the screw B (both side). Close the fuel tap (OFF position) and disconnect the pipe fuel C from the fuel tap.
  • Page 46 Measure the spark gap with a thickness gauge. The gap should be 0.8÷0.9 mm. If the gap is not as specifi ed, restore the proper gap by bending the earth elec- trode. Check that the insulator is not cracked and that the electrodes are not corroded, in which case the spark plug should be immediately replaced.

  • Page 47: Carburettor

    CARBURETTOR CARBURETTOR WEAR GUIDELINES The throttle valve, the needle valve and the needle jet are subject to heavy wear due to engine vibrations. This can result in carburettor malfunctions (e.g. mixture enrichment). DRAINING THE CARBURETTOR FLOAT CHAMBER The carburettor float chamber can be drained by following the procedure de- scribed below while the engine is cold.

  • Page 48: Coolant

    CHECKING THE FLOAT LEVEL (FLOAT HEIGHT) Remove the carburettor and the float chamber. Tilt the carburettor so that the fl oat touches the fl oat needle valve without pressing it too hard. In this position the fl oat edge should be parallel with the fl...

  • Page 49: Chain

    CHAIN DRIVE CHAIN MAINTENANCE The life of the drive chain largely depends on its maintenance. Chains without X- rings must be periodically cleaned in petroleum and then immersed in hot chain oil or treated with a chain spray. X-ring chains require very little maintenance. The best way to clean them is rinsing them generously with water.

  • Page 50: Battery

    BATTERY CHARGING THE BATTERY Remove the battery and check its charge. Using an open-circuit multimeter (10-12 hours after the activation), check that the voltage is greater than 12.6 V. If it is lower, it is advisable to recharge the battery. Based on the type of charger available, charge the battery using either of the fol- lowing procedures:...

  • Page 51: Cleaning The Vehicle

    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, fl exible cables, bearings, etc and can damage or destroy them. WARNING: Wash motorbikes frequently that are used near the sea (salty air) and on roads subject to salt spreading in winter.

  • Page 52: Scheduled Maintenance Vehicle

    SCHEDULED MAINTENANCE VEHICLE Engine Engine oil Paper fi lter oil Wire netting fi lter oil Gear and clutch oil Engine clamping screws Kick start and gearchange lever screws Spark plug cap Spark plug Breather pipe Countershaft bearings Crankshaft bearings Connecting rod Piston and segments Cylinder Cylinder head bolt torque...
  • Page 53 Carburetor Tightness Idling setting Fuel pipe Breather pipe Assembling Coolant system tightness and coolant level groups Exhaust manifold tightness Drives sliding and regulation Liquid level clutch pump Airbox and air fi lter Chain, plate wheel and pinion Brake Liquid level, pads thickness Disc thickness Pipe tightness Idle travel levers and drives sliding...

  • Page 54: 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 55 CHAPTER 4 ADJUSTMENTS CONTENTS Adjusting the home position of the front brake lever........56 Adjusting the home position of the brake pedal ........56 Adjusting the home position of the clutch lever ......... 56 Adjusting the handlebars ..............56 Gas control adjustment ................. 57 Checking and adjusting the steering play ..........

  • Page 56: Adjusting The Home Position Of The Front Brake Lever

    ADJUSTING THE HOME POSITION OF THE FRONT BRAKE LEVER The home position of brake lever 2 can be adjusted by means of screw 1. ADJUSTING THE HOME POSITION OF THE BRAKE PEDAL The home position of brake pedal 3 can be altered by turning adjusting screw 5 af- ter loosening the counternut located under dust cap 4.

  • Page 57: Gas Control Adjustment

    GAS CONTROL ADJUSTMENT The throttle control cable should always have a 3-5 mm play. In addition, the idle speed should not change when the handle- bars are fully rotated to the left or right. Push back protective cap 10. Loosen counternut 11 and turn adjusting screw 12.

  • Page 58: Adjusting Fork

    ADJUSTING FORK ADJUSTING THE REBOUND DAMPER The hydraulic rebound damper determines the behaviour of the telescopic fork during extension and can be adjusted by means of screw A. Turning the screw clockwise (towards the + sign) increases the action of the rebound damper; turning it anticlock- wise (towards the –...

  • Page 59: Shock Absorber

    SHOCK ABSORBER ADJUSTING THE HYDRAULIC COMPRESSION DAMPER (HIGH AND LOW SPEEDS) The shock absorber can be adjusted for both high and low speeds. The terms ‘high’ and ‘low’ refer to the compression speed of the shock absorber, not to the speed of the vehicle.

  • Page 60: Tensioning The Chain

    ADJUSTING THE HYDRAULIC REBOUND DAMPER Turn screw G to adjust the hydraulic re- bound damper. Turning the screw anticlockwise (out) de- creases the damping effect. Standard adjustment: 18 clicks from the completely closed position TENSIONING THE CHAIN To ensure the drive chain a longer life, it is advisable to periodically check its tension.

  • Page 61: Adjusting The Idle Speed

    ADJUSTING THE IDLE SPEED Engine starting is strongly affected by the idle speed adjustment. In other words, an engine whose slow running is properly adjusted is easier to start than an engine with an unsuitably tuned up engine. The idle speed is adjusted by means of adjusting knob 1 and mixture adjusting screw 2.
  • Page 62 NOTE Failure to successfully complete the above procedure can be the result of an improp- erly sized idling jet. a) If the mixture adjusting screw is turned until it stops and no changes in the idle speed are observed, a smaller idling jet is required. b) If the engine stalls when the adjusting screw is still two turns open, a larger idling jet is needed.

  • Page 63: Chapter 5 Replacements

    CHAPTER 5 REPLACEMENTS CONTENTS Replacing the brake pads ..............64 Front ....................64 Rear....................65 Replacing the headlight bulbs ..............66 Tail light ....................66...

  • Page 64: Replacing The Brake Pads

    REPLACING THE BRAKE PADS The procedure for replacing the brake pads is provided only for information. We recommend having the operation performed by a BETAMOTOR authorized workshop. FRONT Follow these steps to replace the pads: •Push the brake caliper towards the disc so that the pistons reach their home positions.
  • Page 65 REAR Follow these steps to replace the pads: •Push the brake caliper towards the disc so that the pistons reach their home positions. •Unscrew dowel A. •Pull out pin B, while supporting the two pads as shown in the fi gure. •Remove the brake pads taking care not to drop the leaf spring located above the two pads.

  • Page 66: Replacing The Headlight Bulbs

    REPLACING THE HEADLIGHT BULBS Release both spring washers and move forward the lamp holder front cowl. Carefully remove the headlight bulb 1 together with lamp holder. To replace the high beam / low beam, lift the rubber cover 2, release connector, push on the spring 3 and remove the lamp holder and replace the light bulb with a new one.

  • Page 67: Chapter 6 Troubleshooting

    CHAPTER 6 TROUBLESHOOTING INDICE ARGOMENTI Troubleshooting ................... 68 Alphabetical index ................69...

  • Page 68: Troubleshooting

    - Air fi lter dirty. Proceed as described on page 44 - No current supplied to spark plug. Clean or replace the spark plug. If the problem persists, contact a BETA- MOTOR dealer. - Engine fl ooded. Operate the start-up pedal 5-10 times or the electrical starter pushbutton 2 times every 5 seconds.
  • Page 69 ALPHABETICAL INDEX Adjusting fork ..................58 Adjusting the handlebars ..............56 Adjusting the home position of the brake pedal ........56 Adjusting the home position of the clutch lever ......... 56 Adjusting the home position of the front brake lever........56 Adjusting the idle speed ................
  • Page 70 Recommended lubricants and liquid ............24 Refuelling .................... 29 Replacing the brake pads ..............64 Replacing the headlight bulbs ..............66 Riding safety ..................6 Running-in ................... 27 Scheduled maintenance vehicle ............. 52 Shock absorber..................59 Spark plug ..................45 Specifi...

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