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Benelli 2009 TREK1130, Workshop Manual

The Benelli 2009 TREK1130 Workshop Manual is a valuable resource for every owner. This comprehensive manual covers all aspects of maintenance and repair, ensuring your bike's optimal performance. Download the free manual from manualshive.com, and gain access to step-by-step instructions and expert tips for a smooth ride.

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GEAR CHANGE

ENG

PRIMARY AND SECONDARY SHAFT 

GEARS REMOVAL

5

98

Engine Removal

Clutch Lid Removal

Clutch Removal

Oil Tank Removal

Oil Pump Removal

Clutch Command Removal

Water Pump Removal

Distribution Lid Removal

Phonic Wheel Removal

Alternator Removal

Female Collar Joint Removal

Z25 Gear/Splined Shaft Removal

Start-Up Motor Removal

Gear Change Removal

Shower Tube Removal

Intermediate Gear Small Shaft Removal

Satellite Gear Removal

Complete Free Wheel Removal

Primary Shaft Gears Removal

Bush

Primary Shaft

Shim

Needle Cage

Z24 5th Conductor Gear

Shim

Elastic Ring

3rd/4th Conductor Gear

Shim

Z25 6th Conductor Gear

Needle Cage

Z18 2nd Conductor Gear

Seeger

Shim

Seeger

Secondary Shaft Gears Removal

Elastic Ring

Shim

Z39 1st Conduct Gear

Needle Cage

Shim

Z28 5th Conduct Gear

Elastic Ring

Splined Shim

Z30 4th Conduct Gear

Broached Bush

Stop Ring

Splined Shim

Z32 3rd Conduct Gear

Broached Bush

Splined Shim

Elastic Ring

Z27 6th Conduct Gear

Elastic Ring

Shim

Z39 2nd Conduct Gear

Needle Cage

Secondary Shaft

O-Ring Gasket

SQ.

SYMBOLS

INTERVENTION/DESCRIPTION

Q.TY

OBSERVATIONS

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Remove the pieces in the given order.

NOTE:

Drain the engine oil and the cooling liquid before 

carrying out the operations.

See "FRAME 4.107" paragraph.

See paragraph "5.69".

See paragraph "5.71".

See paragraph "5.113".

See paragraph "5.116".

See paragraph "5.88".

See "COOLING PLANT 6.15" paragraph.

See paragraph "5.1".

See paragraph "5.18".

See paragraph "5.122".

See paragraph "5.128".

See paragraph "5.128".

See paragraph "5.125".

See paragraph "5.91".

See paragraph "5.131".

See paragraph "5.131".

See paragraph "5.131".

See paragraph "5.131".

Summary of Contents for 2009 TREK1130

Page 1: ...5 2 A 4 3 MANUALE OFFICINA WORKSHOP MANUAL MANUEL D ATELIER TECHNISCHES HANDBUCH MANUAL THE TALLER ver 01 June 2009 A V SSMT Code 0310294100000 ...

Page 2: ...Workshop Manual 2009 ...

Page 3: ......

Page 4: ...TRE 1130 K WORKSHOP MANUAL 2009 Benelli Q J s r l First Edition June 2009 All rights reserved Any reprinting or use without the written authorisation of Benelli Q J s r l is forbidden ...

Page 5: ...ontinuously improve all its models The important amendments and changes in the technical data or in the procedures will be communicated to all authorised Benelli dealers and will be published in the future editions of this manual NOTE The drawings and specifications are subject to amendment without prior notice PARTICULARLY IMPORTANT INFORMATION RELATING TO THE MANUAL The text in this manual conta...

Page 6: ... INSTALLAZIONE COPPA OLIO E FILTRO ASPIRAZIONE Installazione Filtro Aspirazione Guarnizione O Ring Filtro Aspirazione Vite Installazione Coppa Olio Guarnizione Coppa Olio Bussola Coppa Olio Vite Piastra Vite Fascetta Rondella Tappo Magnetico Avanti 3 108 Indietro Indice SQ SIMBOLI INTERVENTO DESCRIZIONE Q TÀ OSSERVAZIONI 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 1 2 1 10 1 2 1 1 1 Installare i pezzi nell o...

Page 7: ...SINTOFLON Copper Grease MOLYKOTE HSC PLUS Lithium Soap Based Grease TUTELA MR 2 Apply Some AREXONS SYSTEM Thread Brakes Apply TUTELA PROFESSIONAL IVORY SIL AC Sealing Paste Replace The Part Electric system 1 2 3 4 8 9 10 5 6 7 11 12 13 14 15 16 17 18 19 20 21 ENG GEN INFO 4 3 5 6 7 12 13 1 2 17 E G LS GR S NEW 52A43 Arexons SYSTEM 52A70 STRONG THREAD BREAKS AREXONS SYSTEM VARIATIONS The following ...

Page 8: ...INDICE 3 ROUTINE INSPECTIONS AND ADJUSTMENTS SPEC CHK ADJ 2 SPECIFICATIONS CHAS 4 FRAME GEN INFO 1 GENERAL INFORMATION ENG 5 ENGINE COOL 6 COOLING SYSTEM ELEC 7 ELECTRIC SYSTEM ...

Page 9: ......

Page 10: ...GEN INFO 1 ...

Page 11: ...SELECTION CLOCK ADJUSTMENT IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISMANTLING OPERATIONS SPARE PARTS GASKETS O RINGS OIL RETAINER AND BEARINGS SAFETY WASHERS SAFETY PLATES PINS AND THREAD BRAKES SAFETY ELASTIC RINGS CONNECTIONS CONTROL CONNECTIONS CONTROL SPECIAL TOOLS SPECIAL TOOLS FOR FRAME SPECIAL TOOLS FOR ENGINE 1 1 2 2 3 4 5 6 6 7 8 9 10 11 11 12 12 13 ...

Page 12: ...GEN INFO ...

Page 13: ...DENTIFICATION The identification data is Frame number on steering tube Engine number on lower base Homologation data on frame 1 1 GEN INFO 9 2 8 8 8 8 1 0 7 6 5 K T N B Z ZBN7856701888829 Benelli Q J s r l Pesaro Italy 97867023490 C A B C A B ...

Page 14: ...s soon as possible 1 2 GEN INFO 2 3 4 INSTRUMENTATION AND LIGHTS The instruments and warning lights are activated by turning the ignition key to ON position After an initial check up the information corresponds to the general conditions of the motorcycle at the moment The dashboard has following instruments INDICATOR LIGHTS 1 High beam warning light blue It comes on when the upper beams are activa...

Page 15: ...ade C or in Fahrenheit F The indication field is between 30 and 50 C or 22 and 122 F 1 3 GEN INFO 4 5 6 MULTIFUNCTION DISPLAY DISPLAY It indicates the speed The value can appear in kilometres Km h or in miles mph The value on the high full scale is of 320 Km h 198 8 mph TOTAL ODOMETER PARTIAL ODOMETER Trip It indicates the partial run from 0 to 999999 Km or Mi Lap In Chrono mode it indicates the a...

Page 16: ...st be carried out after three seconds from engine start up without subsequently activating the clutch lever a b c TOTAL TRIP CHRONO LAP CLOCK TRIP Start 2sec Start 2sec Start 2sec with chronometer at a stand still a a b c N NOTE The equipment has an integral memory preserving all parameters even with the engine off With the exception of the reset clock and of the Trip function all other parameters...

Page 17: ...eatedly press the START button to adjust the digit until the wanted digit is reached Press the START button 2 sec to adjust the next digit Repeat the procedure to adjust the second hour digit the first and second minutes digit Press the START button 2 sec to confirm the hour adjustment and to interrupt the selection the flashing c ...

Page 18: ...mmend always keeping the coupled parts together Amongst these there are gears cylinders pistons and other parts which surfaces through the normal work wear will have coupled The coupled pieces must always be reused or replaced together During dismantling operations clean all components and position them in a basin following the dismantling order This will facilitate the assembly operations and all...

Page 19: ...MATION SPARE PARTS Only use original Benelli spare parts To lubricate the components use oils and greases recommended by Benelli Other brands may be similar in aspect and function but of lower quality 1 1 1 7 GEN INFO ...

Page 20: ...and lubricate the oil retainers lips with engine oil 1 2 1 Install the bearings and the oil retainers so that the brand or manufacturer number facing the outside are visible To install the oil retainer lubricate the lips with a layer of engine oil When installing the bearings abundantly oil them Oil retainer 2 ATTENTION Do not use compressed air to dry the bearings making them rotate as this would...

Page 21: ... plates and the pins After having fastened the bolt or the nut according to specifications fold the locking flaps and the ends of the split pin against the bolt or nut surfaces 1 1 A 1 9 GEN INFO 2 Whenever applying thread brakes previously remove grease from both sides using solvent 2 Recommended solvent TUTELA MOTOR CLEAN A ...

Page 22: ...ic rings and replace the damaged or deformed ones Always replace the elastic rings of the piston pin after having used them once If installing an elastic ring ensure that the pointed angle is positioned on the other side compared to the push it receives Shaft 1 1 A B C D 1 10 GEN INFO A B C D ...

Page 23: ...rts various times 3 4 1 11 GEN INFO 3 Check all connections If there are loose connections Connect them correctly N NOTE If the foot of the terminal box is bent straighten it 4 C the wire the coupler the connector Connect N NOTE Check that all connections are securely installed 5 5 C Check continuity with a pocket tester N NOTE If there is no continuity clean the terminals To check the wiring foll...

Page 24: ...0 R300097146000 R300097147000 R180197033000 R180197036000 R300082003000 Steering Head Spanner This tool is used for the assembly and removal of the steering head cap Transmission Chain Regulator Spanner This tool is used to regulate the tensioning of the chain 20 Allen Spanner This tool is used to remove and install the swing arm pin Diagnosis Instrument This instrument is used as control check se...

Page 25: ... Cylinder Assembly Thicknesses These thicknesses are used to facilitate the correct insertion of the cylinder Clutch Dismantling Spanner This tool is used to block the clutch drum and loosen the nut Clutch Pressure Plate Adjustment Spanner This tool is used to regulate the clutch clearance BufferForDryClutchOilRetainer This tool is used to install the seal level Centring Ring This tool is used to ...

Page 26: ...SPEC 2 ...

Page 27: ...S GENERAL FASTENING SPECIFICATIONS FASTENING TORQUES AND RELATIVE PRELOADS FOR STANDARD CONNECTIONS ENGINE FASTENING TORQUES FRAME FASTENING TORQUES LUBRICATION POINTS AND TYPES OF LUBRICANT LUBRICATION POINTS AND TYPES OF ENGINE LUBRICANT LUBRICATION POINTS AND TYPES OF FRAME LUBRICANT COOLING SYSTEM LAYOUTS COOLING SYSTEM LAYOUTS 1 1 2 2 7 10 13 13 14 15 18 22 22 23 24 24 ...

Page 28: ...SPEC ...

Page 29: ... lb 240 Kg 529 lb Empty with empty oil and fuel tank Maximum technically admitted with driver and load Total width Total length 850 mm 33 4 in 2183 mm 85 9 in Seat height Total height 810 mm 31 8 in 1320 mm 51 9 in Interaxis 1514 mm 59 6 in 440 Kg 970 lb GENERAL SPECIFICATIONS SPEC 2 1 1514 810 2183 850 1320 ...

Page 30: ...5 min forced with humid carter Amount without oil filter cartridge replacement Amount with oil filter cartridge replacement Recommended oil By pass valve opening pressure STANDARD OIL FILTER Type of oil filter 1 6 bar with paper STANDARD STANDARD START UP Type of start up system electric start up STANDARD STANDARD OIL PUMP Type of oil pump with lobes 4 0 lt 0 25 mm 0 0098 in max Clearance between ...

Page 31: ... Tensioning system Maximum cam shaft eccentricity Inlet side cam shaft lobes sizes Maximum twist STANDARD CYLINDERS HEAD 0 1 mm Distance between the electrodes Model manufacturer x quantity 0 7 0 8 mm CHAMPION RG4HC NGK CR9EK 0 04 mm 0 0015 in 0 1 mm 0 0039 in max 35 3 mm 1 38 in 27 85 mm 1 096 in 35 3 mm 1 38 in 27 85 mm 1 096 in B A A B Measurement Drain side cam shaft lobes sizes B A A B TECHNI...

Page 32: ... 015 mm 0 0005 in Head diameter A Inlet Drain A A Valve stem eccentricity Valve stem diameter Inlet Drain Clearancebetweenvalve stemandvalveguide Inlet Drain Contact surface width B Inlet Drain B B Seat width C Inlet Drain C C VALVE SPRINGS STANDARD 37 0 mm 1 45 in 34 0 mm 1 33 in 186 Nm 18 96 Kgf m 92 5 Nm 9 43 Kgf m Inlet drain free length External Internal Inlet drain closed valve installed len...

Page 33: ...diameter C Pin seat diameter Piston height A B A B Type of band x elastic 3 72 x 0 97 mm 0 146 x 0 038 in 2 26 x 1 93 mm 0 088 x 0 075 in A B 2nd band B A A B x B A CONNECTING RODS STANDARD A Red B blue C yellow Connecting rod weight code K1 Black K2 Green K3 White K4 Brown K5 Orange A Red B Blu C Yellow Bearing colour code Width 0 050 mm 0 001 in 254 mm 10 in Maximum eccentricity Connecting rod h...

Page 34: ... springs free length Springs quantity 6 34 3 mm 1 35 in TRANSMISSION STANDARD Primary reduction ratio Type of transmission 44 79 straight teeth gears Secondary reduction system Secondary reduction ratio chain gears Transmission ratio 16 34 1ª 2ª 14 39 18 35 3ª 21 32 4ª 5ª 23 30 24 28 6ª 25 27 FUEL PUMP STANDARD Model manufacturer Type of pump 3 5 bar BITRON electric pump Output pressure GEARS COMM...

Page 35: ...e of tyre 120 70 ZR17 M C 58W tubeless Tyre pressure when cold Model manufacturer 222 kPa 2 22 bar roadsmart DUNLOP TECHNICAL DATA SPEC 2 7 17 M C x MT3 5 aluminium Rim Measurement Material 144 mm 5 66 in Type of wheel Wheel run Measurement STANDARD REAR TYRE Type of tyre 180 55 ZR17 M C 73W tubeless Tyre pressure when cold Model manufacturer 242 kPa 2 42 bar roadsmart DUNLOP STANDARD REAR WHEEL 1...

Page 36: ...MIT REAR BRAKE Type of brake Activation Single disk brake Recommended liquid DOT 4 STANDARD FRONT SUSPENSION Type of suspension with tilted stems telescopic fork with spiral spring hydraulic shock absorber Diameter x Thickness Minimum thickness 0 15 mm 0 006 in Maximum deformation 3 5 mm 0 13 in Worn brake pads thickness 262 mm 10 31 in 150 mm 5 9 in 175 mm 6 88 in Fork excursion Spring Free lengt...

Page 37: ...andard pressure Spring Free length Installed length 9 5 Nm 0 96 Kgf m Flexibility K1 61 mm 2 4 in Spring run K1 0 0 Spring pre load adjust ment positions Minimum Standard 10 mm 0 39 in Maximum 0 17 Bounce damping adjust ment positions Minimum Standard 30 Maximum from fully backward position Number of links STANDARD TRANSMISSION CHAIN Model manufacturer 108 REGINA 137 ORPB Loosening of transmission...

Page 38: ...CO Reel resistance 4 4 a 20 C Secondary reel inductance Primary reel inductance 23 5 mH 1kHz 2 5 mH 1 kHz 0 3V Max admitted current value 7 6 A Ω STANDARD BATTERY Battery capacity voltage Model manufacturer 12 V 14 A CTZ 14S BS UNIBAT STANDARD PROJECTOR Type of projector with halogen bulb Relative density 1 310 Direction indicators Rear position light brake light 12 V 21 W x 2 12 V 6 W x 2 LED x 1...

Page 39: ...e 285 empty 12 full STANDARD INLET STANDARD AIR TEMPERATURE SENSOR STANDARD SAFETY SWITCHES Neutral switch Trestle switch 20 00 057 MONT EL CE75A ASAHI DENSO Resistance Model manufacturer Tilt YE69A DENSO STANDARD FLASHING LIGHTS RELAY Model manufacturer Type of relay 355 E10 LEONELLI electric lasher Watt 10 W x4 Direction indicators flashing frequency 80 160 cycles min STANDARD OIL PRESSURE SENSO...

Page 40: ... 2 12 Model manufacturer SNVO21F0001 0 EUROSWITCH STANDARD LAMBDA Model manufacturer OPS 25324175 DELPHI STANDARD STEPPER Type of stepper Model manufacturer two phase 02SM001 JCI STANDARD RADIATOR VENT Model manufacturer VA31 A101 46A SPAL STANDARD INJECTOR Model manufacturer U9122 357 JCI STANDARD RELAY UNIT Model manufacturer CM1 NAIS Model manufacturer Phonic wheel sensor Pick Up ECU 1 O1VR002 ...

Page 41: ... fastening in a crossed manner in successive steps until the prescribed torque is reached Save different indication the fastening torques refer to the component with clean and dry threading The components must be at ambient temperature Key opening Threading external diameter 2 13 GEN INFO B B bolt FASTENING TORQUES IN GENERAL Nm kgf m 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 18 mm 2 3 4 5 10 25...

Page 42: ...CLASS 12 9 FASTENING TORQUE Nm M4 X 0 7 3 3 870 4 2 5 420 5 2 6 710 M5 X 0 8 6 6 350 7 5 7 930 9 9 520 Nm AXIAL PRE LOAD N N Nm N M6 X 1 10 8 860 13 11 520 16 14 180 M8 X 1 25 22 14 900 30 20 330 40 27 100 M8 X 1 25 17 280 36 24 890 45 31 110 M10 X 1 5 45 24 680 65 35 640 80 43 870 M10 X 1 25 50 27 870 70 39 013 85 47 380 M12 X 1 75 80 37 640 110 51 750 135 63 510 M12 X 1 5 85 40 547 120 57 250 14...

Page 43: ...lutch Lid Screws Blow By Lid Screws Counter shaft Lid Screw 25 M8 2 54 M8 10 1 01 25 M10 2 54 M24 By hand By stroke M40 M6 10 1 01 10 M6 1 01 M6 10 1 01 FASTENING TORQUES SPEC 2 15 LUBRICATION FASTENING TORQUES Nm Kgf m THREAD Oil Pump Fixing Screw Over Pressure Valve Exchanger Fixing Large Screw Head Oil Tube Nipple Head Oil Tube Hole Screw Oil Filter 8 3 M6 0 84 M12 25 2 54 60 M20 6 11 M10 16 1 ...

Page 44: ...l Sensor Screw 10 M6 1 01 M8 25 2 54 8 3 M6 0 84 Water Temperature Sensor 20 2 03 GEAR CHANGE FASTENING TORQUES Nm Kgf m THREAD GEAR CHANGE COMMAND FASTENING TORQUES Nm Kgf m THREAD Plate Fixing Screw Forks Pins Fixing Screw Forks Pins Fixing Screws Chain Cover Lid Fixing Screw Gear Change Command Lid Fixing Screws Gear Change Flange Fixing Screw 10 M6 1 01 M6 10 1 01 10 M6 1 01 M6 10 1 01 10 M6 1...

Page 45: ...Screw Petrol Tube Fitting 10 M6 1 01 M6 10 1 01 20 2 03 By hand M5 1 01 FASTENING TORQUES SPEC 2 17 Minimum Adjustment Cable Gas Cables Plate Fixing Screw M6 10 1 01 START UP FASTENING TORQUES Nm Kgf m THREAD Free Wheel Ring Fixing Screw Engine Collar Hexagonal Screw Satellite Gear Screw Engine Collar Hexagonal Nut M6 17 1 73 50 M10 5 09 M10 15 1 52 10 M6 1 01 ...

Page 46: ...1 1 01 M5 6 0 61 6 M5 0 61 M6 10 1 01 Arrow Fixing Nut By hand M6 Number Plate Light Fixing Screw M5 By hand Seat Stop Flap Fixing Screw By hand M6 Petrol Cap Fixing Screw On Tank Petrol Cap Fixing False Screw Fairing Fixing Small Heads Tank Fixing Bracket Screw 6 M5 0 61 M5 By hand By hand M6 M6 By hand Petrol Pump Set Fixing Screw 3 M5 0 30 Tank Fixing Screw On Seat Holder Small Frame By hand FA...

Page 47: ... Calliper Support Contrasting Pin Regulator Ring Nut 22 M8 2 24 22 By stroke By stroke Speed Sensor Small Plate Screw M3 By hand REAR SUSPENSION FASTENING TORQUES Nm Kgf m THREAD Articulated Connecting Rods Fixing Screw Balancing Device Fixing Special Screw On Frame Shock Absorber Upper Fixing Screw Shock Absorber Lower Fixing Screw 40 M10X1 25 4 07 60 6 11 By hand M10 M10 40 4 07 Handle Bar Clamp...

Page 48: ... FASTENING TORQUES SPEC 2 20 FOOTPEGS FASTENING TORQUES Nm Kgf m THREAD Rear Footpeg Rubber Pad Fixing Screw Passenger Footpeg Support Fixing Screw Front Footpeg Rubber Pad Fixing Screw Right Footpeg Support Fixing Screw Left Footpeg Support Fixing Screw Pump Pointer Fixing Screw By hand M4 M8 25 2 54 By hand M4 M8 25 2 54 30 M10 3 05 M6 10 1 01 Eccentric Fixing Screw Gear Change Rod Fixing Screw ...

Page 49: ... 8 10 M6 0 81 1 01 By hand 10 M10 1 01 M6 10 1 01 FASTENING TORQUES SPEC 2 21 DRAIN PLANT FASTENING TORQUES Nm Kgf m THREAD Primary Tubes Fixing Nut On Head Drain Valve Small Shaft Fixing Nut Valve Fixing Screw On Small Shaft Silencing Device Articulated Connecting Rods Fixing Screw Thermal Bulkheads Fixing Screw 15 M8 1 52 M8 By stroke 10 M8 1 01 M6 8 10 0 81 1 01 10 M6 1 01 INLET FASTENING TORQU...

Page 50: ...nsmission Chain Crown Wheel Pinion Cam Shafts Lobes Cam Shafts Supports Valve Stems Inlet And Drain Oil Pump Rotors Internal And External Valve Stems Ends Inlet And Drain Oil Pump Slot Oil Filtering Element Clutch Traction Rod LUBRICATION POINTS AND TYPES OF LUBRICANT SPEC 2 22 Primary And Secondary Shafts Gear Change Drum Gears Command Forks And Guide Bars Selector Gear Change Shaft Base Coupling...

Page 51: ...int And Metal Parts Subject To Contact In Motion Shock Absorber Fixing Screws Engine Support Bolts Upper Rear And Lower Rear Bearing And Swing Arm Oil Retainer Bearings And Shock Absorbers Link Oil Retainers Side Trestle Rotation Point And Metal Parts Subject To Contact In Motion Gears Command Shaft Joint Front Axis LUBRICATION POINTS AND TYPES OF LUBRICANT SPEC 2 23 LS LS LS LS LS LS LS LS LS LS ...

Page 52: ... Radiator Fan Radiator Water Pump Expansion Vessel Thermostat disk Water Oil Exchanger Oil Filter a b c d e f b a d e c g Radiator Connection Expansion Vessel Hot Water Outlet Tube Pump Flow Tube Pump Supply Tube Recovery Tub Vent 1 2 3 4 5 g f 1 2 3 4 5 5 ...

Page 53: ...Expansion Vessel Thermostat disk Water Oil Exchanger Oil Filter a b c d e f Radiator Connection Expansion Vessel Hot Water Outlet Tube Recovery Tub Vent Cold Water Inlet Tube On Exchanger Hot Water Outlet Tube From Exchanger 1 2 3 4 5 a b c d e f 1 2 3 4 5 ...

Page 54: ...CHK ADJ 3 ...

Page 55: ...ER REMOVAL STEPPER CONTROL STEPPER INSTALLATION VALVES CLEARANCE ADJUSTMENT AND CALIBRATED PADS ADJUSTMENT ENGINE MINIMUM POWER ADJUSTMENT ENGINE OIL LEVEL CONTROL ENGINE OIL CHANGE AND FILTER REPLACEMENT COOLING LIQUID CONTROL COOLING LIQUID CHANGE FUEL TUBE CONTROL AND REPLACEMENT DRAIN PLANT CONTROL AND REPLACEMENT COOLING SYSTEM CONTROL AND REPLACEMENT FRAME FRONT BRAKE ADJUSTMENT REAR BRAKE A...

Page 56: ...CATION SIDE TRESTLE LUBRICATION REAR SUSPENSION LUBRICATION ELECTRIC PLANT BATTERY CHARGE AND CONTROL FUSES CONTROL FRONT LIGHTS REPLACEMENT FRONT HEADLIGHT REMOVAL FRONT HEADLIGHT INSTALLATION FRONT HEADLIGHT ADJUSTMENT REAR HEADLIGHT REPLACEMENT NUMBER PLATE BRACKET HEADLIGHT REPLACEMENT FRONT INDICATORS REPLACEMENT FRONT INDICATORS LAMPS REPLACEMENT REAR INDICATORS LAMPS REPLACEMENT 64 65 67 68...

Page 57: ...CHK ADJ ...

Page 58: ...ied with guarantee a more reliable functioning longer lasting of the vehicle and will limit the need for expen sive revision operations This information is valid for both the already working vehicles and for the under construction vehicles for sale All persons in charge of maintenance must know all instructions contained in this chapter well INTRODUCTION 3 1 CHK ADJ ...

Page 59: ...g lubrication or replacement depending on requirements Replacement T Tighten Dealer Oil Filter 1 Petrol Filter Control Replacement R R R R R 3 Air Filter Control Replacement i Before every vehicle use R i R 4 Control Replacement R R However at every engine oil change R R R 2 Cooling Liquid Level restore control i i i Every 2 years or 20 000 Km i i i 5 i Transmission Chain Check the tensioning of t...

Page 60: ...m i i R 23 Distribution Mobile Slide Control Replacement i At every distribution chain replacement i i R 24 Distribution Chain Tensioner Control Replacement i At every distribution chain replacement i i R 25 T Steering Tube And Ring Nut Control Adjustment T T T Before every vehicle use T T T Every 20 000 Km lubricate with lithium soap based grease 26 T Steering Tube And Bearings Control Adjustment...

Page 61: ...d the synchronisation i i i i 46 Fuelling CO Control Adjustment i However every 10 000 Km i i i 47 Frame Fixing Elements Check all nuts bolts and screws are adequately fastened T At every distribution chain replacement T T T 48 Air Box Valve Control Replacement i i Check the correct functioning replace if necessary i i i Check functioning clearance of the cable and the position of the pulley repla...

Page 62: ... is used in particularly dusty and humid areas HYDRAULIC BRAKE MAINTENANCE Regularly check the brakes liquid level and if necessary top up Replace the internal components of the brakes and callipers main cylinder and change the brakes liquid every two years Replace the brakes flexible tubes every 4 years or before if cracked or damaged ...

Page 63: ...e conveyor See paragraph 3 10 R the nut the bracket the rubber pad Remove 2 3 3 6 WARNING The replacement and check of the spark plugs must be carried out with the engine cold ATTENTION Before disconnecting the spark plugs remove the dirt eventually accumulated inside the seats using a jet of compressed air to avoid it falling inside the cylinders CHK ADJ A C 3 Disconnect the reel connector D 4 Re...

Page 64: ...fficiency of electric plant Incorrect connection of reels Particular driving conditions Extended periods at minimum Long distance travelled at low speed Spark plug too cold Remedies Carry out the setting up of the supply fuelling system Check the connections of the reels and relative impedance Every now and again it is necessary to reach a speed of approx 80 Km h Use a warmer spark plug as in the ...

Page 65: ...ark plug using a detergent for spark plugs or a metal brush 3 M the distance between the electrodes If out of specification Restore the correct distance Measure using a feeler 4 4 3 8 CHK ADJ C Distance between the electrodes 0 7 0 8 mm 0 02 0 03 in C ...

Page 66: ...all the reel 2 3 3 9 WARNING Lubricate the spark plug threading NOTE Before installing the spark plug clean it and the surface in contact with the gasket NOTE Before installing it apply sealing paste on the reel CHK ADJ 3 C the reel connector Connect A 4 Install Torque fasten the rubber pad the bracket the nut A GR Recommended lubricant GRASSO AL RAME GR Recommended paste TUTELA PROFESSIONAL IVORY...

Page 67: ...Gland Rubber Pad Inlet Conduct Washer Conveyor SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 9 1 1 1 1 1 1 2 2 1 1 3 1 2 1 2 1 3 3 1 Remove the pieces in the given order See FRAME 4 130 paragraph See FRAME 4 118 paragraph Disconnect Loosen Loosen ATTENTION Pay particular attention not to let foreign bodies fall inside the throttled bodies ...

Page 68: ...er element every 20 000 Km 12 427 mi If the vehicle is used during particular ly humid climates or in very dusty areas it will be necessary to intervene on the air filter at shorter intervals ATTENTION Before installing the filtering element inside the air box eliminate the excess oil checking it no longer drips CHK ADJ 4 Install the filtering element See paragraph 3 13 A Wash the filtering elemen...

Page 69: ... unfiltered air causes rapid wearing of the engine parts and it may damage the engine Furthermore by running the engine without the air filter influences negatively on the setting up of the throttle bodies and this entails a deterioration of the engine performances and eventually its overheating Therefore ensure that the air filter is always in good conditions The duration of the engine mainly dep...

Page 70: ...LS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 3 3 1 2 1 2 1 3 1 1 2 2 1 1 1 1 1 1 9 Install the pieces in the given order Manually fasten Tighten Tighten ATTENTION Pay particular attention to the phasing of the inlet valve flaps checking that with the valve completely open the resting oblique surfaces on support are identical Connect Manually fa...

Page 71: ...h a few gas revolutions that the drain throttle works as shown in the illustration If the inlet and drain throttles do not perform the correct closing cycle it is necessary to remove the wired actuator There are 2 types of controls to carry out 2 1 3 4 C R the seat See FRAME 4 130 paragraph the tank See FRAME 4 118 paragraph the filter box lid See paragraph 3 10 CONTROL 1 Remove Remove the 2 screw...

Page 72: ...the nuts of the drain valve regulator on 3 in 1 exhaust pipe CONTROL 2 7 6 8 Adjust ensuring it is always tensioned but keeping the stand by position of the drain valve the tensioning of the cable 3 15 CHK ADJ D 8 F Measurements of the regulator threads 9 8 mm 0 38 in 9 4 mm 0 37 in D 6 E F F E 9 10 Install the filter box lid See paragraph 3 13 the tank See FRAME 4 119 paragraph the seat See FRAME...

Page 73: ... and subsequent ly every 10 000 Km 6 213 mi Adjust the accelerator cable clearance Handle bar side 2 C the cables If damaged worn or tangled Replace Check 3 Accelerator cable clearance at accelerator knob flange 3 5 mm 0 11 0 19 in Loosen lock nut Rotate the adjusting nut in or direction until clearance of the specified accelerator cable is obtained Fasten the lock nut D a b c E DIRECTION DIRECTIO...

Page 74: ...e specified clearance of the clutch cable on handle bar side is not obtained act on the engine side adjusting nut Clutch cable clearance at the end of the clutch lever 3 5 mm 0 11 0 19 in Rotate the adjusting disk in or direction until clearance of the specified clutch cable is obtained C a D DIRECTION DIRECTION The clutch cable clearance increases The clutch cable clearance decreases B B C D C D ...

Page 75: ...e screw with relative cup and spring N NOTE Before adjusting the clutch disks free the lower clutch command of the clutch cable Check every 10000 Km A B C B C C CHK ADJ A Lock the flange Loosen the lock nut Tighten the regulator until contact with the internal reaction rod is heard and loosen it by of a turn Check the clearance on the clutch command positioned on the opposite side of the engine Re...

Page 76: ...ct the options choosing the wanted menu following the instructions regarding the diagnostics instrument Remove the cap of the diagnostics socket Connect the diagnostics instrument to the socket positioned underneath the seat 3 2 A Special Tools ENGINE INJECTION HANDLING DIAGNOSTICS INSTRUMENT AXONE 2000 Code R180197036000 Special Tools ENGINE INJECTION HANDLING DIAGNOSTICS INSTRUMENT BENDIA SCANTO...

Page 77: ...TER THAN 1 00 If the lambda probe value shown on the display is greater than 1 00 increase the CO value to minimum map 1 or 2 referred to used map lock so that the correction and relative lambda parameter work as close to 1 00 as possible If the lambda probe value shown on the display is lower than 1 00 decrease the CO value to minimum map 1 or 2 referred to used map lock so that the correction an...

Page 78: ...ENGINE EXHAUST GAS 3 21 Install the diagnostics socket cap 9 10 CHK ADJ Install the seat See FRAME 4 131 paragraph D 9 D ...

Page 79: ...m power N NOTE Check and execute the alignment of the throttled body with engine temperature at approx 90 95 C A 3 ENGINE THROTTLED BODY CHK ADJ R Remove the seat See FRAME 130 paragraph the tank See FRAME 4 118 paragraph the air filter box See paragraph 3 10 2 Disconnect the flexible tubes of the stepper air passages 3 Park the bike levelled A A A Engine Minimum Power 1250 1350 r min ...

Page 80: ...he tank directing it towards the rear part of the vehicle secure the tank with belt Install the vacuum meter directly on to the fittings of the throttled body of the previously disconnected stepper air passages tubes 4 Bil anciam ento farfall e RPM P1 mbar giri mi n 1250 425 P2 mbar 462 P3 mbar 505 Z o o m 1 2 3 M U L T IM A N esc off ok ON 4 B Special Tools VACUUM METER Code R300097170000 C C C C...

Page 81: ...acting on the previously closed by pass screws C ENGINE THROTTLED BODY CHK ADJ Carry out resetting of the throttle sensor using the diagnosis system 10 Install the air filter box See paragraph 3 13 the tank See FRAME 4 119 paragraph the seat See FRAME 4 131 paragraph 11 Turn off the engine Remove the measuring instrument Re connect the flexible tubes of the previously disconnected stepper air pass...

Page 82: ...er Pad Step by Step Motor Distributor Special Plate O Ring Gasket O Ring Gasket SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 2 3 3 1 4 2 2 2 1 1 1 1 2 Remove the pieces in the given order See FRAME 4 130 paragraph See FRAME 4 118 paragraph See paragraph 3 10 Loosen Disconnect Disconnect CHK ADJ 1 1 2 3 6 6 7 7 8 8 10 5 5 11 4 9 12 13 ...

Page 83: ...sliding between the piston and the distributor In case of forced sliding Replace the distributor the 2 O Ring gaskets In the presence of deformations Replace in pair A B 1 N NOTE Clean the distributor and the stepper before installation N In NOTE In case of replacing the stepper check the adjust ment of the diagnostics instrument reset the throttles 1 CHK ADJ A B C C D D B ...

Page 84: ... Screw Screw Click Strip Minimum Air Tube Connector SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 2 1 1 1 2 2 2 1 2 4 3 3 1 Install the pieces in the given order Manually fasten Manually fasten Tighten Connect Connect CHK ADJ 3 4 A 2 5 52 A4 3 Axerons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 9 9 11 12 7 7 6 6 5 5 2 10 10 11 13 4 3 1 ...

Page 85: ...ATED PADS CHK ADJ R Remove the phonic wheel cap 3 A Align the gear notches and Check that the notches are also aligned with the head plane 4 Remove the seat See FRAME 4 130 paragraph the tank See FRAME 4 118 paragraph the air filter box See paragraph 3 10 the radiator See COOLING PLANT 6 1 paragraph the stepper connector See paragraph 3 25 2 Remove the ignition reels the ignition spark plugs the d...

Page 86: ...E If the valves clearance is incorrect take note of the effectively detected value ENGINE VALVES CLEARANCE AND CALIBRATED PADS CHK ADJ 6 5 Remove the spring of the chain tensioner the chain tensioner See ENGINE 5 5 paragraph Valves Clearance Inlet Valve 0 25 0 30 mm 0 009 0 011 in Drain Valve 0 30 0 35 mm 0 011 0 013 in E F 5 E 6 G F G ...

Page 87: ...ral headgears the drain inlet Z34 gears the drain inlet cam shafts See ENGINE 5 8 paragraph 7 Remove the drain inlet valves lifters the drain inlet calibrated pads See ENGINE 5 30 paragraph 8 4 M L 7 J H I J J K K N NOTE Take note of the position of each headgear in order to be able to re assemble them in the correct position 8 L L M M N C NOTE Cover the opening of the distribution chain using a c...

Page 88: ... DRAIN INLET L M M L 28 N Valves Clearance Inlet Valve 0 25 0 30 mm 0 009 0 011 in Drain Valve 0 30 0 35 mm 0 011 0 013 in rule example example 1 Measure the thickness of the pad 5 The obtained value will be the measurement of the new pad 2 Measure the valve clearance 3 Sum the thickness of the pad with the measured valve clearance 4 Subtract from the obtained sum pad clearance the value of 0 30 m...

Page 89: ...clockwise a few times to adjust the parts in the relative seats Install the new drain inlet calibrated pads the new drain inlet valves lifters See ENGINE 5 33 paragraph Check the valves clearances If out of specification Repeat the operations in the table 11 4 P O Install the drain inlet cam shafts the drain inlet Z34 gears the distribution chain the drain inlet central headgears the upper chain s...

Page 90: ...of the chain tensioner See ENGINE 5 7 paragraph R Q R Q S 15 Install the phonic wheel cap 15 Install the stepper connector See paragraph 3 27 the radiator See COOLING PLANT 6 4 paragraph the air filter box See paragraph 3 13 the tank See FRAME 4 119 paragraph the seat See FRAME 4 131 paragraph Install the gasket of the distribution lid the distribution lid the ignition spark plugs the ignition ree...

Page 91: ... engine and leave it to warm up for a few minutes 3 Remove the seat See FRAME 4 130 paragraph 2 A B Remove the cap of the diagnostics socket Connect the diagnostics instrument to the socket positioned underneath the seat 2 A Special Tools DIAGNOSTICS INSTRUMENT ENGINE INJECTION HANDLING AXONE 2000 Code R180197036000 Special Tools DIAGNOSTICS INSTRUMENT ENGINE INJECTION HANDLING BENDIA SCANTOOL Cod...

Page 92: ...nimum power If out of specification Adjust 6 Adjust the accelerator cable clearance See paragraph 3 16 5 Engine Minimum Power 1250 1350 r min Rotate the minimum adjusting screw in or direction until specified engine minimum power is obtained a C C D E D E DIRECTION The engine minimum power decreases The engine minimum power increases D DIRECTION E Accelerator cable clearance near the flange of the...

Page 93: ...3 36 ENGINE ENGINE MINIMUM POWER CHK ADJ Install the diagnostics socket cap 9 10 Install the seat See FRAME 4 131 paragraph F 9 F ...

Page 94: ...maximum level MAX If below the minimum level notch Top up to the correct level using recommended engine oil 3 ATTENTION Do not start the engine if the oil is underneath MIN reference MIN MAX A B A 35 30 25 20 15 10 5 0 5 10 15 20 25 30 35 40 45 50 FOR RECOMMENDED ENGINE OILS COMPARED TO EXTERNAL TEMPERATURES SAE 10W SAE 20W SAE 30W SAE 40W SAE 10W 30 SAE 10W 40 SAE 10W 60 SAE 15W 40 mineral base S...

Page 95: ... Therefore we recommend not adding chemical additives and not using oil different to that shown in the technical specifications table of the engine See ROUTINE INSPECTIONS AND ADJUSTMENTS 2 2 paragraph Avoid the entering of foreign bodies inside the base The new or exhaust engine oil can be dangerous In fact swallowing it can be toxic for persons and domestic animals In case of swallowing immediat...

Page 96: ...Km 6213 mi ENGINE ENGINE OIL AND FILTER CHK ADJ Remove the engine protection See FRAME 4 120 paragraph 4 Remove the oil cap 3 Position a suitable container underneath the magnetic cap for the recovery of the engine oil 5 4 ATTENTION The used oils are damaging for the environment Dispose of the used oils according to the Standards in force A 5 Remove the magnetic cap together with the gasket B C A ...

Page 97: ...ne oil change ENGINE ENGINE OIL AND FILTER CHK ADJ Loosen the 2 screws Remove the strip the plate See COOLING PLANT 6 9 paragraph Remove the oil filter using tool for oil filter removal 8 ATTENTION Only use the Benelli original oil filter code R180107114000 Other brands of oil filters may differ with regard to the threading diameter and step The filtering performances and duration with consequent ...

Page 98: ...l level ENGINE ENGINE OIL AND FILTER CHK ADJ Fill the base with recommended and specified amount of engine oil Install the oil cap 12 J Install the engine protection See FRAME 4 121 paragraph 13 14 Start the engine leave it to warm up for a few minutes then turn it off I 22 N m 2 24 Kgf m T R 10 I H NEW Total quantity approx 3 5 l Amount without oil filter change approx 3 3 l Amount with oil filte...

Page 99: ... A 2 A MIN MAX B B 3 Remove the right tank lid See FRAME 4 112 paragraph the engine protection See FRAME 4 120 paragraph 4 Remove the radiator cap WARNING If the radiator is very hot the liquid inside will be pressurised Do not remove the radiator cap with the engine hot Boiling hot liquid may leak caus ing serious injuries When the engine has cooled down open the radiator cap as follows Position ...

Page 100: ...r can be used if distilled water is not available If the cooling liquid comes into contact with a painted surface immediately wash it using water 6 Check the cooling liquid level using the expansion vessel Bring the reference level between MIN and MAX 6 E 7 Install the radiator cap E N NOTE Before checking the cooling liquid level wait a few minutes for it to gather inside the expansion vessel 8 S...

Page 101: ...NG If the radiator is very hot the liquid inside will be pressurised Do not remove the radiator cap with the engine hot Boiling hot liquid may leak causing serious injuries When the engine has cooled down open the radiator cap as follows Position a towel on the radiator cap and slowly loosen the cap anti clockwise to drain any residue pressure When the usual hiss is no longer heard press on the ra...

Page 102: ...liquid drain screw on the pump Torque fasten B 8 Fill the cooling system using the top up nozzle up to the end of the same 5 8 B C C 10 N m 1 01 Kgf m T R Recommended Anti freeze High quality ethylene glycol based anti freeze liquid with organic inhibition In case of top up with inorganic inhibition products the benefits and features of the liquid decrease Mixing ratio 1 1 anti freeze water Total ...

Page 103: ...uid is flammable and its flame is invisible Avoid the cooling liquid coming into contact with hot parts in that the consequent fuelling of the ethylene glycol might expose the operator to risks of burns ATTENTION By adding water instead of cooling liquid the percentage of anti freeze contained in the cooling liquid decreases If water is used instead of cooling liquid check and eventually correct t...

Page 104: ...13 Install the engine protection See FRAME 4 121 paragraph the right tank lid See FRAME 4 113 paragraph N NOTE Before checking the cooling liquid level wait a few minutes for it to gather inside the expansion vessel 11 Start the engine leave it to warm up for a few minutes then turn it off ...

Page 105: ...pecial tool C to avoid petrol leaking However place cloths underneath the disconnecting point ENGINE FUEL TUBE CHK ADJ TO REPLACE THE FUEL TUBE Release the fuel tube using the specific tool and A 3 B C 4 Remove the screw the 2 washers from the injectors flute the fuel tube 4 RAPID RELEASE KIT Special Tools RAPID RELEASE KIT Code R180100143000 C B 2 Check the fuel tube In the presence of cracks dam...

Page 106: ... paragraph N NOTE To install the tank check that the fuel tube is not bent or crushed by the same tank ENGINE FUEL TUBE CHK ADJ Release the special tool Hook the new fuel tube 6 7 5 Replace the fuel tube Install the 2 washers the screw 5 N NOTE The fuel tube must be replaced every 20 000 Km or 12 427 mi ...

Page 107: ...ouch the silencing device bracket until the drain plant has cooled down A B C D Nuts of the exhaust pipe 15 N m 1 52 Kgf m Drain collector nut 10 N m 1 01 Kgf m Drain collector thermal protection screws 8 N m 0 81 Kgf m Drain collector nuts 10 N m 1 01 Kgf m E F G H B C D E F G H T R 2 TO REPLACE THE DRAIN PLANT Remove the number plate bracket See FRAME 4 128 paragraph the seat See FRAME 4 130 par...

Page 108: ...d component with a new one 6 Install the entire drain unit See FRAME 4 158 paragraph 7 Connect the drain valve cable See FRAME 4 157 paragraph the lambda probe connector See ELECTRIC PLANT 7 13 paragraph 8 Install the tank See FRAME 4 119 paragraph the right and left tank lids See FRAME 4 113 paragraph the heat shield lid See FRAME 4 133 paragraph the seat See FRAME 4 131 paragraph the number plat...

Page 109: ...the oil exchanger outlet tube the cylinder inflow fitting the water pump inlet sleeve the water pump outlet sleeve In the presence of cracks damages Replace E C 3 TO REPLACE THE COOLING SYSTEM Remove the cooling circuit See COOLING PLANT 6 6 paragraph Replace the interested component with a new one Install the cooling circuit See COOLING PLANT 6 7 paragraph F H A B C D F G H I Installa Install the...

Page 110: ...tem significantly reduces the system performances and may cause loss of control of the vehicle and possible accidents Therefore check and if required bleed the braking system ATTENTION After having adjusted the brake lever position check there is no dragging of the brake N NOTE Push the brake lever forward to neutralise the push of the spring and simultaneously adjust the posi tion by turning the ...

Page 111: ... touch this may mean that there is air inside the braking system Before using the vehicle remove the air by bleeding the braking system The presence of air inside the braking system significantly reduces the system performances and may cause loss of control of the vehicle and possible accidents Therefore check and if required bleed the braking system ATTENTION After having adjusted the brake pedal...

Page 112: ...nificantly lower the boiling point of the brakes liquid and may cause vapour bubbles BRAKES LIQUID LEVEL CONTROL P Park the bike levelled 1 ATTENTION The brakes liquid can damage the painted surfaces and the plastic parts Therefore always immediately clean all brakes liquid spills F F Front brake Rear brake A a b N NOTE Place the bike on a suitable trestle Ensure that the bike is in straight posit...

Page 113: ...eck the front brake pad the rear brake pad the wear limit of the front brake pads and rear Wear limit reached Replace all brake pads To replace the front brake pads see FRAME 4 32 paragraph and installation FRAME 4 36 for the rear brake pads see FRAME 4 34 paragraph and installa tion FRAME 4 38 2 2 2 a b CHK ADJ A B A Wear limit of the brake pads Front 0 5 mm 0 01 in Rear 1 0 mm 0 03 in B ...

Page 114: ...wing procedure is applied to all brakes flexible tubes and to the brakes tubes clamps C Check the brake flexible tube In the presence of cracks damages wear lines Replace 1 2 1 b CHK ADJ A B 2 Keep the bike in straight position Activate the brake repeatedly 3 Check the brake flexible tube In the presence of brakes liquid leaks Replace the damaged flexible tube 4 B A a ...

Page 115: ...liquid or excessively fill the tub until it overflows When bleeding the hydraulic braking system check there is always a sufficient amount of liquid before engaging the brake By ignoring this procedure air may penetrate inside the braking plant significantly extending the bleeding procedure Should the bleeding operation be difficult it may be necessary to let the brakes liquid rest for a few hours...

Page 116: ...he specified value e h i j h Insert the other end of the flexible tube inside a container Slowly activate the brake a few times Pull the brake lever completely or press the brake pedal to the end maintaining the reached position Loosen the bleeding screw d e f g 10 N m 1 01 Kgf m T R CHK ADJ A WARNING Use only the prescribed brakes liquid Other brakes liquids may be cause of deterioration of the r...

Page 117: ...ving bled the air brake liquid may drip on the threaded section of the bleeding screw This does not indicate the presence of leaks but of brake liquid accumulated on the threading of the screw during air bleeding Clean the interested parts Fill the brakes liquid tub to the correct level using the recommended brakes liquid See paragraph 3 55 CHK ADJ k ...

Page 118: ...the screw Loosen the two nuts of the rod Rotate the gears command rod clockwise or anti clockwise A a Once the gear change pedal adjustment is completed fasten the rod nuts and fix the rod to the support using the previously removed screw and nut d c b B C B A D C D ANTI CLOCKWISE CLOCKWISE the gear change pedal is lowered the gear change pedal is lifted ...

Page 119: ...here it seems more tensed N NOTE Do not inspect or adjust the transmission chain with the engine running Loosening of transmission chain 15 mm 0 59 in WARNING If the transmission chain is too tense the engine and other vital parts will be overloaded whereas if it is too loose it can come away and damage the suspension arm or cause an accident Therefore we recommend maintaining the loosening of the...

Page 120: ...ws on both sides of the swing arm Insert the specific tool inside the eccentric Rotate the eccentrics in or direction until the specified loosening degree for the transmission chain is obtained Fasten both eccentric locking screws to the specified value C a b D DIRECTION DIRECTION the transmission chain loosens the transmission chain tenses A C D B D 4 Special Tools TRANSMISSION CHAIN REGULATOR SP...

Page 121: ...e side plate and the other Do not use jets of vapour high pressure water jets aggressive solvents or brushes with very rough bristles or these O Rings will be damaged We therefore suggest cleaning the transmission chain with recommended products Dry the chain and accurately lubricate it using engine oil or specific lubricant for O Ring chains Do not use other types of lubricants on the transmissio...

Page 122: ...elicately grabbing it by the tubes ends In the presence of jamming loosening points Adjust the steering tube 2 1 N NOTE Place the bike on a trestle of adequate support so that the front wheel is lifted CHK ADJ 4 Loosen the stop screws of the upper steering wheel plate Remove the upper steering wheel plate 3 Remove the handle bar See FRAME 4 77 paragraph B 3 A B 2 A ...

Page 123: ...ering tube is not loose and that it does not have jamming points by turning the front fork to end run in both directions If detecting jamming points remove the lower steering wheel base and inspect the upper and lower bearings See FRAME 4 85 paragraph a b C D D c D C Special Tools STEERING WHEEL RETURN RING SPANNER Code R180297129000 T R Fastening torque of steering ring nut 60 N m 6 11 Kgf m G Ch...

Page 124: ...9 paragraph the transmission chain See FRAME 4 97 paragraph C Check the teeth of the conducting and conducted gears In the presence of damages or wear Replace 2 1 N In NOTE In case of replacing the transmission chain check that the conducting and conducted gears are in good state so as not to rapidly wear out the new chain CHK ADJ 2 ...

Page 125: ... the presence of leaks Replace 2 1 N S NOTE Support the bike using suitable supports so that it cannot fall CHK ADJ 4 Check the functioning of the fork Push a few times on the handle bar and check that the front fork smoothly returns backwards If the movement is not smooth Repair See FRAME 4 66 paragraph 3 Keep the bike in straight position Activate the front brake A 2 A B B ...

Page 126: ... phase return The regulator adjusts the spring pre load FRAME REAR SHOCK ABSORBER SET ADJUSTMENT 3 69 REAR SHOCK ABSORBER SET ADJUSTMENT N S NOTE Support the bike using suitable supports so that it cannot fall CHK ADJ 1 Adjust the spring pre load A B B A SPRING PRE LOAD Rotate the adjusting screw in or direction a C D 1 C D E D E D E DIRECTION DIRECTION the spring pre load increases the spring pre...

Page 127: ... Never overstep the minimum or maximum adjusting positions Rotate the adjusting screw in or direction a F G 1 H D H G H DIRECTION DIRECTION the extension damping increases suspension is stiffer the extension damping decreases suspension is more springy F G ADJUSTING POSITIONS Minimum 0 Standard 0 Maximum 10 mm ...

Page 128: ...RLOAD THE MOTORBIKE 2 C Check the tyres surface In the presence of damages wear Replace the tyre 2 TYRES CONTROL The following procedure is applied to both tyres C Check the tyres pressure If out of specification Adjust it 1 Net Weight with oil and fuel tank full Up to 90 kg of load Maximum Load TYRES PRESSURE WHEN COLD FRONT REAR 90 kg maximum load Including luggage driver passenger and accessori...

Page 129: ...perforation Use maximum care and replace the air chamber as soon as possible using an excellent quality spare part Wheel with air chamber Only tyre with air chamber Wheel without air chamber Tyre with or without air chamber WARNING After various tests the tyres shown below have been approved by Benelli Q J s r l for this model The front and rear tyres must be of the same drawing and the same brand...

Page 130: ...ntil they have worn slightly Therefore we recommend driving the first 100 km at normal speed before increasing speed F G F G N NOTE Tyres with indication of rotary direction Install the tyre with the mark facing the rotary direction of the wheel Align the mark with the installation point of the valve CHK ADJ ...

Page 131: ...ocedure is applied to both wheels C See FRAME 4 5 paragraph for the front wheel the FRAME 4 20 paragraph for the rear wheel In case of damage ovalisation Replace Check the wheel 1 N NOTE If a tyre or a wheel has been replaced or removed and re assembled it is always necessary to carry out wheel balancing CHK ADJ ...

Page 132: ...ng procedure is applied to all cables and relative sheaths CABLES CONTROL AND LUBRICA TION 1 N NOTE Keeping the end of the cable upwards pour a few drops of lubricant inside the sheath or use an appropriate lubrication device CHK ADJ C Check the external cable In the presence of damages Replace Recommended lubricant ENGINE OIL E 2 C Check the functioning of the cables If the movement is not smooth...

Page 133: ...S AND PEDALS LUBRICATION 3 76 LEVERS AND PEDALS LUBRICATION L Lubricate the rotary points and the levers and pedals metal parts subject to contact during movement CHK ADJ Recommended lubricant TUTELA MR2 GREASE LS ...

Page 134: ...ME SIDE TRESTLE LUBRICATION 3 77 SIDE TRESTLE LUBRICATION Lubricate the rotary points and the side trestle metal parts subject to contact during movement CHK ADJ Recommended lubricant TUTELA MR2 GREASE LS ...

Page 135: ...ICATION OF THE REAR SUSPENSION 3 78 LUBRICATION OF THE REAR SUSPEN SION L Lubricate the rotary points and the rear suspension metal parts subject to contact during movement CHK ADJ Recommended grease SINTOFLON S ...

Page 136: ...at it may cause serious burns or permanent injuries to the eyes FIRST AID IN CASE OF PHYSICAL CONTACT EXTERNAL CONTACT Skin wash with water Eyes Wash with running water for 15 minutes and immediately contact a doctor SWALLOWING Drink large amounts of water or milk therefore magnesium milk beaten eggs or vegetable oil Immediately contact a doctor BATTERY CHARGE AND CONTROL ATTENTION This battery is...

Page 137: ...he terminals of the same battery ATTENTION Firstly disconnect the battery negative cable therefore the positive cable CHK ADJ 1 Remove the seat See FRAME 4 130 paragraph 2 Disconnect the battery cables from the terminals 3 Disconnect the battery Check the battery charge A B A B 2 3 Connect a pocket tester to the battery terminals a Positive pointer of tester Positive terminal of the battery Negati...

Page 138: ...nsure that the cables clamps of the battery charger are in full contact with the battery terminals and are not in short circuit A corroded clamp can generate heat in the contact area and an inefficient clamp spring can cause sparks If the battery heats up during the charging process disconnect the battery charger and leave the battery to cool before continuing the operation The batteries that heat...

Page 139: ...ing left the battery unused for over 30 minutes 12 8 V or above Charging is completed 12 7 V or below Requires charging Below 12 0 V Replace the battery Measure the voltage with open circuit before charging Connect a battery charger and an ammeter to the battery and start charging Check that the current is higher than the standard value of the charge current shown on the battery Adjust the voltage...

Page 140: ...ry Charge the battery until the charge voltage reaches 15 V Measure the voltage with open circuit after having left the battery unused for over 30 minutes 12 8 V or above Charging is completed 12 7 V or below Requires charging Below 12 0 V Replace the battery NOTE Measure the voltage 30 minutes after having switched off the equipment NO SI NOTE Set the charge time at 20 hours maximum A V Voltmeter...

Page 141: ... ADJ 6 Check the battery terminals In the presence of dirt Clean using a metal brush If there are loose connections Connect them correctly 7 Lubricate the battery terminals 5 Install the battery Connect the battery cables to the battery terminals D D C 5 8 Install the seat See FRAME 4 131 paragraph Recommended grease ENGINE OIL E C ...

Page 142: ...S CONTROL The following procedure is applied to all fuses 2 Check the fuse CHK ADJ Connect a pocket tester to the fuse to check its continuity a 3 Replace the burnt fuse Turn the main switch to OFF Install a new fuse with correct amperage Switch on the switches to check that the electric circuit works If the fuse immediately burns check the electric circuit a b c d If the pocket tester indicates r...

Page 143: ... ignition system functioning and eventually cause a fire 4 Install the object compartment See FRAME 4 134 paragraph the seat See FRAME 4 131 paragraph CHK ADJ Fuses Amperage Quantity Alarm Instrument 5 A Petrol Pump 10 A Electric fan 15 A Services 15 A Injection 15 A Lights 20 A 1 1 1 1 1 1 Spare 20 A 1 Spare 15 A 1 Spare 5 A 1 20A 15A 20A 15A 15A 15A 5A 10A 5A 3 Lights Injection Services Alarm In...

Page 144: ...mp High beam Dipped beam a b ATTENTION Given that the projector bulb reaches very high temperatures we recommend not touching it with the hands until it has cooled down ATTENTION Avoid touching the glass part of the projector lamp to keep it clean from any oil trace On the contrary the glass transparency the duration of the bulb the luminosity of the projected light beam may be affected If the bul...

Page 145: ...IC PLANT FRONT LIGHTS REPLACEMENT 3 88 5 4 Connect the connectors of the new lamp Install the new lamp and fix it using the fixing spring 6 Connect the right and left inspection lid the fixing screws CHK ADJ ...

Page 146: ...MOVAL Remove the right and left tank lids See FRAME 4 112 paragraph the mobile and fixed cap See FRAME 4 110 paragraph 3 Remove the lamp inspection lids the headlight fixing pins CHK ADJ 4 Remove the side screws the nuts the bushes the equipment support the odometer instrument 2 3 A A A B B C C D E 4 D E F G H F G H ...

Page 147: ...FRONT HEADLIGHT REMOVAL 3 90 6 Remove the screws for headlight fixing on the frame the nuts the central screw for closing right and left frame the nut CHK ADJ 6 J Release the headlight connectors 5 I 5 I K J K L M L M ...

Page 148: ...e frame the nuts Recommended thread brakes CHK ADJ 3 Install the odometer instrument the equipment support the bushes the nuts the side screws A B C I H 3 E F G H G F E 1 B Connect the headlight connectors 2 D 2 D C A C AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 52A43 52A43 10 N m 1 01 Kgf m T R Torque fasten the screw A 22 N m 2 24 Kgf m T R Torque fasten the screws B I ...

Page 149: ...ipment lid the self locking screws 4 Install the headlight fixing pins the lamp inspection lids 5 4 L L K J 10 N m 1 01 Kgf m T R Torque fasten the pins J J K L 6 Install the mobile and fixed cap See FRAME 4 111 paragraph the right and left tank lids See FRAME 4 113 paragraph ...

Page 150: ...jected on the vertical wall is lower by approximately 1 10 compared to the horizontal axis of the headlights If the luminous beam is not compliant with this indication adjust until the luminous beam is in the correct position CHK ADJ 2 1 Adjust the projector light beam by acting on the two right and left dish regulator screws positioned underneath the headlight The headlight has the possibility of...

Page 151: ...2 paragraph the number plate bracket See FRAME 4 128 paragraph the silencing device See FRAME 4 155 paragraph CHK ADJ 4 Remove the nuts the headlight C 5 Install the new headlight the nuts Cut the wiring locking strip Release the headlight connector 4 3 Loosen the silencing device screws and lower it to enable the headlight to come out 2 A 2 A B B C B ...

Page 152: ...r Install a new wiring locking strip CHK ADJ Install the silencing device screws 7 D Install the silencing device See FRAME 4 158 paragraph the number plate bracket See FRAME 4 129 paragraph the heat shield lid See FRAME 4 135 paragraph the seat See FRAME 4 131 paragraph 8 7 D ...

Page 153: ...ER PLATE BRACKET LIGHT REPLACEMENT 3 96 1 NUMBER PLATE BRACKET LIGHT REPLACEMENT Remove the screw CHK ADJ 4 Install the rubber lamp holder the screw Replace the position bulb 2 3 Remove the rubber lamp holder 2 B 1 A B A ...

Page 154: ...to both the front indicators Remove the handle bar cable gland CHK ADJ A 1 B Release the indicator connector Loosen the lower nut Remove the rear view mirror 2 2 B A C D 4 H C D G Install the new rear view mirror Tighten the lower nut Hook the indicator connector 3 3 G F E F E Install the handle bar cable gland 4 H NEW ...

Page 155: ... INDICATORS LAMPS REPLACEMENT FRONT The following procedure is applied to both the front indicators lamps Remove the screw CHK ADJ A 1 Remove the glass Remove the bulb to be changed Install the new bulb 2 2 B A C D Install the glass the screw 3 B B C C D NEW ...

Page 156: ...MPS REPLACEMENT The following procedure is applied to both the rear indicators lamps Remove the screw CHK ADJ A 1 Remove the glass the bulb to be changed 2 2 B C D Install the new bulb the glass 3 D NEW A 4 F B 3 E C E F Install the screw 4 N NOTE Moderately fasten the screw ...

Page 157: ...CHAS 4 ...

Page 158: ...ND REAR BRAKES FRONT BRAKE PADS REMOVAL REAR BRAKE PADS REMOVAL FRONT BRAKE PADS REPLACEMENT REAR BRAKE PADS REPLACEMENT FRONT BRAKE PADS INSTALLATION REAR BRAKE PADS INSTALLATION FRONT BRAKE PUMP REMOVAL FRONT BRAKE PUMP DECOMPOSITION REAR BRAKE PUMP REMOVAL REAR BRAKE PUMP DECOMPOSITION FRONT AND REAR BRAKE PUMP CONTROL FRONT BRAKE PUMP INSTALLATION REAR BRAKE PUMP INSTALLATION FRONT BRAKE CALLI...

Page 159: ...N REAR SHOCK ABSORBER SET REAR SHOCK ABSORBER SET REMOVAL REAR SHOCK ABSORBER AND GAS CYLINDER TREATMENT REAR SHOCK ABSORBER SET CONTROL REAR SHOCK ABSORBER SET INSTALLATION TRANSMISSION CHAIN AND SWING ARM TRANSMISSION CHAIN AND SWING ARM REMOVAL TRANSMISSION CHAIN REMOVAL SWING ARM REMOVAL TRANSMISSION CHAIN INSPECTION SWING ARM INSPECTION TRANSMISSION CHAIN REPLACEMENT TRANSMISSION CHAIN AND SW...

Page 160: ...INSTALLATION FRONT MUDGUARD REMOVAL FRONT MUDGUARD INSTALLATION REAR MUDGUARD REMOVAL REAR MUDGUARD INSTALLATION NUMBER PLATE BRACKET REMOVAL NUMBER PLATE BRACKET INSTALLATION REAR FRAME SEAT REMOVAL SEAT INSTALLATION BATTERY BOX REMOVAL BATTERY BOX INSTALLATION LOCK REMOVAL LOCK INSTALLATION CODON REMOVAL CODON INSTALLATION REAR SMALL FRAME SET REMOVAL REAR SMALL FRAME SET DECOMPOSITION REAR SMAL...

Page 161: ...HT FOOTPEG UNIT INSTALLATION REAR FOOTPEGS UNIT REMOVAL REAR FOOTPEGS UNIT INSTALLATION TRESTLE REMOVAL TRESTLE INSTALLATION CHAIN SLIDES REMOVAL CHAIN SLIDES INSTALLATION DRAIN PLANT DRAIN UNIT REMOVAL DRAIN COLLECTOR DECOMPOSITION DRAIN UNIT INSTALLATION 145 145 146 147 148 149 150 151 152 153 154 155 155 157 158 CHAS ...

Page 162: ...CHAS ...

Page 163: ...rake Calliper Right And Left Stop Screw Front Wheel Pin Front Wheel SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 4 2 2 1 1 Remove the pieces in the given order NOTE Place the bike on a trestle of adequate support so that the front wheel is lifted Loosen 3 4 5 1 1 2 1 1 2 5 ...

Page 164: ...L REMOVAL P Park the bike levelled 1 2 2 Remove the screws Disconnect the left brake calliper 3 Loosen the stop screws N NOTE Do not pull the front brake lever whilst disconnecting the brake callipers N R NOTE Repeat the above procedure for the right brake calliper 3 2 4 A B C 4 Remove the front wheel pin the front wheel D E B A C 5 D E ...

Page 165: ...KS REMOVAL 4 3 Front Wheel Removal Front Brake Disks Removal Left Spacer Front Wheel Screw Front Brake Disk Ø320 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 1 1 12 2 Remove the pieces in the given order See paragraph 4 1 1 2 3 4 3 4 ...

Page 166: ...EL DECOMPOSITION 4 4 Front Wheel Decomposition Bearing Inside Spacer SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 2 1 Decompose the pieces in the given order NOTE To install invert the order of the removal operations 1 2 1 LS LS LS ...

Page 167: ...e of deformations Replace 1 A Check the tyre the front wheel In the presence of damages wear Replace 2 Measure the radial eccentricity of the wheel the side eccentricity of the wheel If the specified limit is exceeded Replace 3 Radial eccentricity limit of the wheel 0 05 mm 0 0019 in Side eccentricity limit of the wheel 0 05 mm 0 0019 in B C Replace the wheel bearings 5 Remove the bearings from th...

Page 168: ...TENTION Do not touch the internal track or the wheel bearings balls Contact must only take place with the external track CHAS N U NOTE Use a spanner that adapts to the diameter of the external track of the wheel bearing H E F G E F G H ...

Page 169: ...e brake disk 2 Deformation limit of the brake disk maximum Front 0 1 mm 0 004 in Rear 0 15 mm 0 006 in Place the bike on a trestle of adequate support so that the wheel is lifted Before measuring the front brake disk bending turn the handle bar to the right or to the left to ensure that the front wheel is still Remove the brake calliper Keep the comparator at a straight angle compared to the brake...

Page 170: ...olt Front 22 Nm 2 24 Kgf m Rear 10 Nm 1 01 Kgf m 4 N NOTE Fasten the brake disk bolts in successive steps and proceeding in a crossed manner Remove the brake disk Rotate the brake disk moving it one hole per bolt Install the brake a b c Measure the deformation of the brake disk If out of specification repeat the adjusting procedure until the deformation is within the specified values Should it not...

Page 171: ...Disks Assembly Front Wheel Front Brake Disk Ø320 Screw Left Spacer SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 1 2 12 1 Install the pieces in the given order 4 1 3 2 3 2 52A43 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 5 4 A 2 3 T R 22 N m 2 24 Kgf m 3 4 A 2 5 ...

Page 172: ...ews 2 The procedure below can be applied to both brake disks 3 4 C B Recommended lubricant TUTELA MR2 GREASE LS A B B LS C D N R NOTE Repeat the above procedure for the right front brake disk N NOTE Fasten the brake disk bolts in successive steps and proceeding in a crossed manner 3 22 N m 2 24 Kgf m T R Torque fasten AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 E 5 E 1 2 6 3 4 5 52A43 ...

Page 173: ...Front Wheel Front Wheel Pin Stop Screw Front Brake Calliper Right And Left Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 1 2 2 4 Install the pieces in the given order 3 2 5 5 5 4 5 5 4 1 T R 60 N m 6 11 Kgf m T R 8 N m 0 81 Kgf m T R 50 N m 5 09 Kgf m LS LS LS LS ...

Page 174: ...n the front wheel pin 60 N m 6 11 Kgf m T R 8 N m 0 81 Kgf m T R ATTENTION Before fastening the front wheel pin push on the handle bar and check that the front fork smoothly moves backwards Lift the wheel between the two shanks of the fork Insert the axis of the wheel a b 1 A A A Rest the front wheel on the ground c 2 C B B C Recommended lubricant TUTELA MR2 GREASE LS LS the stop screws ...

Page 175: ...is correct N NOTE Ensure there is sufficient space between the brake pads before installing the callipers on the relative brake disks Recommended lubricant TUTELA MR2 GREASE LS LS 3 Install the left brake calliper the screws Torque fasten with N R NOTE Repeat the above procedure for the right brake calliper 3 E D D E ...

Page 176: ... wheel turn quickly When the front wheel stops place an X on the part of the wheel facing downwards Turn the front wheel by 90 so that the X is positioned as shown in the illustration Let the front wheel go When the front wheel stops place an X on the part of the wheel facing downwards Repeat points to a few times until the applied marks always stop in the same point The point where all marks appl...

Page 177: ...n in the given position install a heavier weight Repeat points and until balancing of the front wheel is obtained FRONT WHEEL AND BRAKE DISKS 4 15 CHAS b 4 C Check the balancing of the front wheel b b c d c Have the front wheel turn and check that it remains still in each of the illustrated positions If it does not repeat balancing a X X X X X 4 ...

Page 178: ...pacer Calliper Holder Plate O Ring Gasket Bush SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 2 1 2 2 1 1 1 1 2 1 Remove the pieces in the given order NOTE Place the bike on a trestle of adequate support so that the rear wheel is lifted NOTE Loosen the regulator of the eccentrics 3 4 5 3 4 1 2 6 8 9 7 9 10 1 ...

Page 179: ...nect the brake calliper 2 1 3 R Remove the special screws the plugs the pin N NOTE Do not press on the brake pedal whilst removing the brake calliper 2 A B A A B 3 C D E C D C D 4 R Remove the rear wheel 4 F F N NOTE Push the rear wheel forward and remove the transmission chain from the rear cogwheel 5 R Remove the spacer the calliper holder plate the O Ring gaskets the bush 5 G H H G I J J E I ...

Page 180: ...r Brake Disk And Crown Wheel Removal Screw Rear Brake Disk Spacer Self locking Nut Crown Wheel Crown Wheel Holder Flange Spacer Collar Rubber SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 6 1 1 5 1 1 1 5 Remove the pieces in the given order See paragraph 4 16 1 2 3 6 8 7 5 4 ...

Page 181: ...POSITION 4 19 Rear Wheel Decomposition Seeger Bearing Spacer SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 2 2 1 Decompose the pieces in the given order NOTE To install invert the order of the operations for removal LS LS LS 2 1 2 3 1 ...

Page 182: ... of deformations Replace 1 A C Check the tyre the rear wheel In the presence of damages wear Replace 2 M Measure the radial eccentricity of the wheel the side eccentricity of the wheel If the specified limit is exceeded Replace 3 Radial eccentricity limit of the wheel 0 05 mm 0 0019 in Side eccentricity limit of the wheel 0 05 mm 0 0019 in C C Replace the wheel bearings 5 Remove the bearings from ...

Page 183: ...TENTION Do not touch the internal track or the wheel bearings balls Contact must only take place with the external track CHAS N U NOTE Use a spanner that adapts to the diameter of the external track of the wheel bearing H E F G E F G H ...

Page 184: ...RAKE DISK 4 22 1 CHAS REAR WHEEL CROWN WHEEL HOLDER FLANGE INSPECTION C Check the crown wheel holder flange In the presence of cracks damages Replace the collar rubbers In the presence of damages wear Replace 1 A B A B ...

Page 185: ...f the teeth are bent Replace the crown wheel 1 2 A D A B C A B C D 2 Replace the crown wheel Remove the self locking nuts and the crown wheel Using a clean cloth clean the crown wheel holder flange in particular the surfaces touching the crown wheel Install the new crown wheel a c b Crown wheel self locking nut 45 N m 4 58 Kgf m N NOTE Fasten the self locking nuts in more steps and proceed in cros...

Page 186: ...embly Collar Rubber Spacer Crown Wheel Holder Flange Crown Wheel Self locking Nut Spacer Rear Brake Disk Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 5 1 1 1 5 1 1 6 Install the pieces in the given order LS LS T R 45 N m 4 58 Kgf m LS T R 10 N m 1 01 Kgf m LS LS L S 8 7 6 3 1 2 4 5 ...

Page 187: ...t TUTELA MR2 GREASE LS Recommended lubricant TUTELA MR2 GREASE LS Recommended lubricant TUTELA MR2 GREASE LS A B LS E D E N NOTE Fasten the self locking nuts in successive steps and proceed in a crossed manner 45 N m 4 58 Kgf m T R Torque fasten 10 N m 1 01 Kgf m T R Torque fasten H H I J the seegers LS B C C C F G F G Recommended solvent TUTELA MOTOR CLEAN 4 3 L S 4 I J 5 1 2 6 3 4 5 N NOTE Faste...

Page 188: ...Spacer Rear Wheel Pin Plug Special Screw Rear Brake Calliper Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 2 1 1 1 1 1 2 2 1 2 Install the pieces in the given order NEW T R 22 N m 2 24 Kgf m LS LS LS LS LS LS LS LS LS NEW T R 100 N m 10 19 Kgf m LS LS 8 7 6 8 7 10 9 5 3 1 4 1 2 10 LS L S LS ...

Page 189: ...G H 4 Install the brake calliper the screws 2 E I 1 C D A Recommended lubricant TUTELA MR2 GREASE LS 100 N m 10 19 Kgf m T R LS LS NEW B LS A B C D LS LS L S Recommended lubricant TUTELA MR2 GREASE LS Recommended lubricant TUTELA MR2 GREASE LS LS J 22 N m 2 24 Kgf m T R ATTENTION Check that the path of the brake flexible tube is correct N NOTE Ensure there is sufficient space between the brake pad...

Page 190: ... replaced the tyre the wheel or both the rear wheel needs balancing again Adjust the balancing of the rear wheel with the brake disk and the crown wheel holder flange CHAS REAR WHEEL BALANCING 1 Adjust the balancing of the rear wheel See paragraph 4 14 ...

Page 191: ...ty Spring Pad SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 2 1 2 2 1 2 Remove the pieces in the given order NOTE The procedure below can be applied to both front brake callipers FRONT AND REAR BRAKES CHAS FRONT BRAKE PADS REMOVAL 1 1 2 3 3 4 4 5 6 6 ...

Page 192: ...ke Calliper Seeger Pin Clip Pad Thickness For Brake Pads SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 2 1 1 1 1 2 2 Remove the pieces in the given order FRONT AND REAR BRAKES CHAS REAR BRAKE PADS REMOVAL 1 1 2 3 4 5 6 7 7 ...

Page 193: ...uately fill and bleed after re assembly the entire braking system Do not use solvents on the internal components of the brake Only use clean or new brake liquid to clean the brake components The brake liquid can damage the painted surfaces and the plastic parts Therefore always immediately clean all brakes liquid spills Avoid bringing the brake liquid in contact with the eyes as it can cause serio...

Page 194: ...pplied to both the brake callipers A Disconnect the support of the brake flexible tube the brake calliper 1 Disconnect the clips the pins the safety spring 2 3 Disconnect the brake pads 3 NOTE To replace the brake pads always replace in pair to guarantee an even pressure It is not necessary to disconnect the flexible tube A B B E C D C F F F G G Wear limit of the brake pads 1 mm 0 04 in C D E ...

Page 195: ...FRONT AND REAR BRAKES 4 33 CHAS Press the calliper pistons inwards to enable installation of the new brake pads 6 Clean the inside of the calliper the pistons then dry everything 5 ...

Page 196: ... brake pads thicknesses 2 3 Measure the wear limit of the brake pads If out of specification Replace all brake pads 3 F G N NOTE To replace the brake pads always replace in pair to guarantee an even pressure It is not necessary to disconnect the flexible tube A B H G G Wear limit of the brake pads 1 0 mm 0 04 in C E B C D E F F H 4 Clean the inside of the calliper D ...

Page 197: ...D REAR BRAKES 4 35 CHAS A Act on the brake command with long brakes but not intense for approximately one hundred kilometres 6 P Press the calliper pistons inwards to enable installation of the new brake pads 5 ...

Page 198: ...YMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 2 1 2 2 1 2 Install the pieces in the given order NOTE The procedure below can be applied to both front brake callipers FRONT AND REAR BRAKES CHAS FRONT BRAKE PADS INSTALLATION 6 6 5 4 4 3 3 2 1 1 T R 50 N m 5 09 Kgf m LS NEW NEW LS ...

Page 199: ... 1 A Install the safety spring the pins the clips 2 Install the brake calliper Torque fasten the support of the flexible tube 3 4 C Check the brakes liquid level If below the minimum level notch Top up to the correct level using the recommended brake liquid See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 55 paragraph E F N NOTE Always install new brake pads 1 A A 2 3 F E B D C D B C D 50 N m 5 09 Kgf m ...

Page 200: ...Pin Seeger Rear Brake Calliper Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 2 2 1 1 1 1 2 Install the pieces in the given order FRONT AND REAR BRAKES CHAS PADS INSTALLATION REAR BRAKE NEW T R 22 N m 2 24 Kgf m LS NEW NEW LS 7 7 6 5 4 3 2 1 1 ...

Page 201: ...to the correct level using the recommended brakes liquid See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 55 paragraph 3 4 C Check the functioning of the brake pedal If the brake lever is soft or spongy to touch Bleed the braking system See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 58 paragraph 3 H G F A A D C F E D C B B N NOTE Always install new brake pads and thicknesses 22 N m 2 24 Kgf m T R H B A NEW L ...

Page 202: ... Washer Front Brake Tube Screw Front Brake Switch Connector Front Brake Light Switch SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 Remove the pieces in the given order NOTE Drainthebrakesliquidbeforecarryingouttheoperations See ROUTINEINSPECTIONSANDADJUSTMENTS3 58 paragraph ATTENTION Avoid trickeling of brake fluid 14 1...

Page 203: ...al Seeger Main Cylinder Kit Spring Body Main Cylinder Pin SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 1 1 1 1 1 1 Decompose the pieces in the given order NOTE To install invert the order of the removal operations 6 1 2 4 5 3 NEW NEW TOP 4 TOP 4 TOP 4 TOP 4 TOP 4 TOP 4 TOP 4 TOP 4 ...

Page 204: ...r Rod Hydrostop Gasket Brake Tube Gasket Screw Rear Brake Pump SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 Remove the pieces in the given order NOTE Drain the brakes liquid before carrying out the operations See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 58 paragraph Disconnect the central wiring pin 17 15 1...

Page 205: ...tion Dust Seal Rubber Seeger Main Cylinder Kit Rear Brake Pump SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 1 1 1 1 Decompose the pieces in the given order NOTE To install invert the order of the removal operations 4 2 1 NEW NEW NEW 3 NEW TO P 4 TOP 4 T O P 4 TOP 4 TOP 4 ...

Page 206: ...uctions Clean using a jet of compressed air 1 C Check the brake pump kit In the presence of damages scratches wear lines Replace 2 3 Check the brakes liquid tub In the presence of cracks damages Replace diaphragm of the brakes liquid tub In the presence of cracks damages Replace A B Front Rear a b Front Rear a b Front Rear a b a b 2 3 a b a b A B B A 4 C Check the brake flexible tubes In the prese...

Page 207: ...s Liquid Tub Support For Brakes Liquid Tub Diaphragm Lid Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 1 1 1 2 1 1 1 1 1 1 2 1 1 1 2 Install the pieces in the given order NOTE Once operations have been completed top up with brakes liquid NEW T R 1 5 N m 0 15 Kgf m NEW NEW LS T R 8 N m 0 81 Kgf m T R 7 N m 0 71 Kgf m T R 1 5 N m 0 15 Kgf m T R ...

Page 208: ...ew Torque fasten the connector of the front brake switch 2 A WARNING Before installation clean all brake internal components lubricating them using clean or new brakes liquid Do not use solvents on the internal components of the brake UP 8 N m 0 81 Kgf m T R A B 15 N m 1 52 Kgf m T R B WARNING To guarantee bike safety it is essential that the path of the brake flexible tube is correct N NOTE Faste...

Page 209: ...uid already present inside the system The brakes liquid must never be mixed with liquids of other brands in that it may cause a dangerous chemical reaction with the consequent deterioration of the performances of the brakes During top up be careful not to let water flow inside the tub The presence of water will significantly reduce the boiling point of the brakes liquid and may cause vapour to for...

Page 210: ...quid Tub Diaphragm Brakes Liquid Tub Cap SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 Install the pieces in the given order Connect the central wiring pin NOTE Once operations have been completed top up with brakes liquid 3 5 6 4 17 16 14 19 15 12 13 1 2 2 7 8 11 9 10 18 NEW NEW NEW LS T R 6 N m 0 61 Kgf...

Page 211: ...sential that the path of the brake flexible tube is correct 3 Fill the brakes liquid tub up to the maximum level mark 3 A A Recommended lubricant TUTELA MR2 GREASE LS WARNING Before installation clean all brake internal components lubricating them using clean or new brakes liquid Do not use solvents on the internal components of the brake Recommended brakes liquid TUTELA BRAKE FLUID TOP 4 DOT 4 TO...

Page 212: ...iquid spills WARNING Use only the prescribed brakes liquid The use of other types of brakes liquid may damage the rubber gaskets causing leaks and deteriorating the performances of the brakes Top up using the same type of brakes liquid already present inside the system The brakes liquid must never be mixed with liquids of other brands in that it may cause a dangerous chemical reaction with the con...

Page 213: ...RIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 2 1 2 1 Remove the pieces in the given order NOTE The procedure below can be applied to both front brake callipers NOTE Drain the brakes liquid before carrying out the operations See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 58 paragraph FRONT AND REAR BRAKES CHAS FRONT BRAKE CALLIPERS REMOVAL 4 4 5 1 2 2 3 ...

Page 214: ...14 2 2 1 2 4 1 1 1 2 2 4 4 1 1 Decompose the pieces in the given order NOTE The procedure below can be applied to both front brake callipers NOTE To install invert the order of the removal operations FRONT AND REAR BRAKES CHAS FRONT BRAKE CALLIPERS DECOMPOSITION 1 1 2 2 3 4 4 5 5 5 8 9 9 10 10 11 11 12 11 12 12 11 12 13 14 3 4 A 2 5 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 52A43 T R 25 N m ...

Page 215: ...lliper SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 2 1 2 1 Remove the pieces in the given order NOTE Drain the brakes liquid before carrying out the operations See paragraph ROUTINE INSPECTIONS AND ADJUSTMENTS 3 58 FRONT AND REAR BRAKES CHAS REAR BRAKE CALLIPER REMOVAL 4 4 5 1 2 2 3 ...

Page 216: ...ATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 1 1 2 2 2 1 1 2 2 2 2 2 1 1 Decompose the pieces in the given order NOTE To install invert the order of the removal operations FRONT AND REAR BRAKES CHAS REAR BRAKE CALLIPER DECOMPOSITION 1 NEW Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 5 2 A 4 3 2 3 4 5 5 6 6 7 8 9 10 11 12 13 10 11 12 13 14 15 NEW 3 4 A 2 5 NEW NEW NEW NEW NEW T R 10 N m 1 01 Kgf...

Page 217: ...Ø 30 mm the gaskets of the brake calliper pistons first the oil retainers smaller gaskets then the seal rings larger gaskets See paragraph 4 52 2 D N NOTE Drain the brakes liquid from the entire braking plant before dismantling the brake calliper See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 58 paragraph N Inse NOTE Insert the end of the brake flexible tube in a container and slowly drain the brakes l...

Page 218: ...iners smaller gaskets then the seal rings larger gaskets See paragraph 4 54 2 D N NOTE Drain the brakes liquid from the entire braking plant before dismantling the brake calliper See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 58 paragraph N Inse NOTE Insert the end of the brake flexible tube in a container and slowly drain the brakes liquid by pumping it A B F 1 B C a b G H Remove the gaskets of the br...

Page 219: ...rakes liquid flow passages brake calliper body In the presence of obstructions Clean using a jet of compressed air the insulators In the presence of rust scratches wear lines Replace the insulators of the brake calliper 1 A B 2 ATTENTION Every time the brake calliper is dismantled replace the gaskets of the pistons C RECOMMENDED REPLACEMENT PROGRAM FOR THE BRAKE COMPONENTS BRAKES PADS CHECK After ...

Page 220: ...5 1 2 1 2 1 Install the pieces in the given order NOTE The procedure below can be applied to both front brake callipers Restore the torque twice after having loosened NOTE Once operations have been completed top up with brakes liquid FRONT AND REAR BRAKES CHAS FRONT BRAKE CALLIPERS INSTALLATION 2 2 1 5 4 4 3 LS LS NEW T R 50 N m 5 09 Kgf m T R 15 N m 1 52 Kgf m NEW ...

Page 221: ...mponents of the brake as the gaskets of the pistons would inflate and deform Every time the brake calliper is dismantled replace the gaskets of the pistons 15 N m 1 52 Kgf m T R 50 N m 5 09 Kgf m T R WARNING To guarantee bike safety it is essential that the path of the brake flexible tube is correct 1 E Install the gaskets of the brake calliper pistons firstly the seal rings larger gaskets then th...

Page 222: ...nt deterioration of the performances of the brakes During top up be careful not to let water flow inside the tub The presence of water will significantly reduce the boiling point of the brakes liquid and may cause vapour to form ATTENTION The brakes liquid can damage the painted surfaces and the plastic parts Therefore always immediately clean all brakes liquid spills Check the functioning of the ...

Page 223: ...CRIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 2 1 2 1 Install the pieces in the given order Restore the torque twice after having loosened NOTE Once operations have been completed top up with brakes liquid FRONT AND REAR BRAKES CHAS REAR BRAKE CALLIPER INSTALLATION LS LS NEW NEW T R 22 N m 2 24 Kgf m T R 15 N m 1 52 Kgf m 2 2 1 5 4 4 3 ...

Page 224: ...calliper pistons firstly the seal rings larger gaskets then the oil retainers smaller gaskets the insulators the brake calliper pistons See paragraph 4 54 1 A B C 1 G 2 F F E C B A D 2 Install the brake calliper Torque fasten the front brake tube the copper washers the special screw Torque fasten by restoring twice after having loosened 15 N m 1 52 Kgf m T R 22 N m 2 24 Kgf m T R WARNING To guaran...

Page 225: ...nt deterioration of the performances of the brakes During top up be careful not to let water flow inside the tub The presence of water will significantly reduce the boiling point of the brakes liquid and may cause vapour to form ATTENTION The brakes liquid can damage the painted surfaces and the plastic parts Therefore always immediately clean all brakes liquid spills Check the functioning of the ...

Page 226: ...ork Shank SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 2 6 2 Remove the pieces in the given order See paragraph 4 51 See paragraph 4 1 See paragraph 4 124 ATTENTION Before loosening the stop screws of the upper and lower brackets install a support for the shank of the front fork Loosen Loosen FRONT FORK CHAS FRONT FORK SHANKS REMOVAL 1 2 2 3 ...

Page 227: ...eering plate lower R Remove the front brake calliper See paragraph 4 51 the front wheel See paragraph 4 1 the front mudguard See paragraph 4 124 1 1 2 A B 4 Remove the shanks of the front fork C 4 NOTE Place the bike on a trestle of adequate support so that the front wheel is lifted ATTENTION Before loosening the stop screws of the upper and lower brackets install a support for the shank of the fr...

Page 228: ... 14 15 16 17 18 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Decompose the pieces in the given order NOTE The procedure below can be applied to both shanks of the front fork NOTE To install invert the order of the removal operations FRONT FORK CHAS FRONT FORK SHANKS DECOMPOSITION 3 4 A 2 5 3 4 A 2 5 LS NEW 52A43 LS NEW 1 3 4 5 6 7 8 9 11 12 13 14 16 10 17 18 15 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A...

Page 229: ...tely loosen the closing cap unit from the supporting tube using a 4 mm compass spanner Slowly lower the stem holder on the supporting tube a b C C E Using a 4 mm compass spanner keep the cap unit still and using a 17 mm spanner loosen the nut Loosen and remove the upper cap unit 2 Push downwards the fork spring the preload spacer so that a 17 mm spanner can be inserted in the nut G F H c d H F D E...

Page 230: ...hat the contained oil drains J K L M N K L M N I J Release the stem from the vice NOTE To favour the draining it is necessary to perform a few pumps repeatedly pushing the pumping rod forward backwards O O ATTENTION This operation must be carried out only after having drained the oil contained inside the stem Remove the pumping unit fixing screw the washer the pumping unit Lock the wheel holder fo...

Page 231: ...e the oil retainer clip using the same screwdriver NOTE To separate these two elements it is necessary to energetically pull them ATTENTION This operation must be carried out only after having completely drained the oil contained inside the sleeve Manually remove the upper guide bush the lower guide bush the seal ring oil retainer the dust seal clip the dust seal 9 7 V Remove the fork shank from t...

Page 232: ...he pumping unit contains elements particularly sensitive to foreign bodies During dismantling and re assembling of the front fork shaft do not allow foreign bodies to enter the front fork 1 1 B 2 Measure the free length of the spring If out of specification Replace C 1 A B 2 C Free length of the spring 262 mm 10 31 in 3 Check the dampener rod In the presence of damages wear Replace In the presence...

Page 233: ...tainer the seal ring the lower guide bush 1 A Apply at the end of the supporting tube adhesive tape so that the seat of the upper bush is covered C 3 Manually insert the upper guide bush Slightly lubricate the dust seal and oil retainer with grease a Remove the adhesive tape applied on the end of the fork shank eliminating any traces of adhesive b Delicately introduce the fork shank inside the for...

Page 234: ... groove and being careful not to scratch the fork shank Accompany the lower guide bush until it comes into contact with the fork sleeve the seal ring the oil retainer G 6 Insert in the seat the dust seal by manually pressing Subsequently introduce them in the seat d H 6 4 F F 5 G H 7 Insert the full pumping unit inside the stem holder I 7 J I J ...

Page 235: ...ed beaker prepare the quantity of oil to pour into the stem Pour inside the fork sleeve approximately 2 3 of the required oil therefore pump a few times to eliminate the air Proceed until the required amount is poured Lower the fork sleeve on to the fork shank to the stroke of the dust seal on the wheel holder foot Wait a few minutes and check the air volume and eventually restore the level h 130 ...

Page 236: ...ten the closing cap on to the fork sleeve using a 4 mm compass spanner Insert a 17 mm spanner inside the nut Using a 4 mm compass spanner keep the closing unit still and using a 17 mm spanner fasten the nut Fasten m n T W 12 10 V 11 U V U T T V 20 N m 2 03 Kgf m T R 20 N m 2 03 Kgf m T R Lift the fork sleeve on to the fork shank o X W X T ...

Page 237: ... Screw Upper Plate Stop Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 2 6 2 Install the pieces in the given order Carry out a double passage FRONT FORK CHAS FRONT FORK SHANKS INSTALLATION LS LS LS T R 22 N m 2 24 Kgf m T R 8 N m 0 81 Kgf m L S 3 2 2 1 ...

Page 238: ...1 1 A 1 NOTE Check the assembly quota Figure B B A 2 3 Fasten the stop screws of the lower steering plate Fasten by carrying out a double passage the stop screws of the upper steering plate Fasten B C ATTENTION Check that the path of the brake flexible tubes is correct 3 B 227 5 mm 2 8 N m 0 81 Kgf m T R 22 N m 2 24 Kgf m T R LS Recommended lubricant TUTELA MR2 GREASE LS Recommended lubricant TUTE...

Page 239: ...rake Pump Screw Handle Bar SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 1 1 1 1 2 1 1 2 1 1 2 1 1 1 1 2 1 2 1 2 2 1 Remove the pieces in the given order Disconnect indicator wire Disconnect indicator wire Disconnect Disconnect indicator wire Disconnect clutch switch Disconnect Disconnect switch HANDLE BAR CHAS HANDLE BAR REMOVA...

Page 240: ...tor cable the accelerator knob WARNING Support the bike using suitable supports so that it cannot fall NOTE Direct a jet of compressed air between the left part of the handle bar and the relative knob to gradually remove it from the handle bar Disconnect the knob of the handle bar 2 1 A B C 3 2 A B C ...

Page 241: ...AS HANDLE BAR INSPECTION Check the handle bar In the presence of deformations cracks damages Replace WARNING If deformed do not attempt to straighten the handle bar in that by weakening it may become dangerous 1 1 A 1 A ...

Page 242: ...r view Mirror SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 1 2 2 2 1 1 1 2 1 2 1 1 1 1 2 1 2 1 1 1 1 2 1 Install the pieces in the given order Carry out a double passage Manually fasten Manually fasten HANDLE BAR CHAS HANDLE BAR INSTALLATION LS LS LS LS LS LS LS T R 20 N m 2 03 Kgf m LS LS LS T R 8 N m 0 81 Kgf m T R 8 N m 0 81 K...

Page 243: ...he switch with the hole on the right side handle bar Install the right side handle bar switch 2 1 A D 3 B C Install the accelerator knob the slot of the accelerator cable the accelerator cables 4 F 4 NOTE Align the coupling surfaces of the retainer element of the brake pump trestle with THE punching on the right side handle bar There must be a 2 mm 0 07 in space between the switch on the right sid...

Page 244: ...switch with the hole on the left side handle bar K J Adjust the clutch cable clearance See paragraph ROUTINE INSPECTIONS AND ADJUSTMENTS 3 17 8 G H I K J Apply a thin layer of rubber adhesive on the end of the left side handle bar Make the knob slide on the end of the left side handle bar knob Remove any trace of excess rubber adhesive using a clean cloth a b c Clearance of clutch cable at the end...

Page 245: ...n SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 2 1 2 1 1 1 2 2 1 6 2 1 1 1 1 1 1 Remove the pieces in the given order See paragraph 4 110 See paragraph 4 1 See paragraph 4 64 See paragraph 4 77 NOTE Remove cap using the special tool NOTE Remove cap using the special tool STEERING WHEEL HEAD CHAS UPPER AND LOWER STEERING WHEEL BASE REMOVAL 15 3 1 1...

Page 246: ...crews of the steering plate upper 2 1 A 2 3 Remove the cap using the special tool 3 B Special Tools STEERING HEAD SPANNER Code R300097146000 C A 4 WARNING Firmly support the lower steering base so that it cannot fall Loosen the kingpin ring nut the steering ring nut using the spanner for the steering ring nut 4 Special Tools STEERING WHEEL RETURN RING SPANNER Code R180297129000 D C B D ...

Page 247: ...bearings the bearings tracks 3 Check the upper steering base the lower steering base together with the steering tube In the presence of deformations cracks damages Replace 4 3 Remove the bearings tracks from the column tube of the steering wheel using a long rod and a hammer Remove the bearing track from the lower bracket using a scalpel and a hammer Install a new rubber seal and new bearings trac...

Page 248: ...rry out a double passage NOTE Install both ring nuts using the special tool Carry out a double passage STEERING WHEEL HEAD CHAS UPPER AND LOWER STEERING WHEEL BASE INSTALLATION 3 4 A 2 5 LS LS LS LS LS LS LS LS LS T R 20 N m 2 03 Kgf m T R 60 N m 6 11 Kgf m T R 6 N m 0 61 Kgf m LS T R 22 N m 2 24 Kgf m LS LS LS LS T R 16 N m 1 63 Kgf m T R 60 N m 6 11 Kgf m LS LS T R 8 N m 0 81 Kgf m T R 8 N m 0 8...

Page 249: ...ering ring nut Install the steering ring nut using the special tool Fasten the kingpin ring nut using the special tool Fasten 2 1 A 2 B Install the front fork shanks See paragraph 4 75 3 16 N m 1 63 Kgf m T R 60 N m 6 11 Kgf m T R B A Recommended lubricant TUTELA MR2 GREASE LS Recommended lubricant TUTELA MR2 GREASE LS LS LS Special Tools STEERING RETURN RING SPANNER Code R180297129000 ...

Page 250: ...ening points Adjust the steering tube 5 C Install the cap using the special tool Fasten with 4 60 N m 6 11 Kgf m T R 22 N m 2 24 Kgf m T R 4 C Recommended lubricant TUTELA MR2 GREASE LS LS 52A43 D D AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 the stop screws of the upper steering plate Torque fasten Special Tools STEERING HEAD SPANNER Code R300097146000 ...

Page 251: ...4 89 REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET REMOVAL 18 16 15 14 13 12 4 7 5 4 7 8 19 8 7 3 5 7 3 17 18 16 15 14 12 11 2 1 9 10 6 ...

Page 252: ...t Shock Absorber Screw Pin Washer Bush Seal Ring Spacer Rollers Bearing Balancing Device SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 1 2 2 2 1 4 2 1 1 1 2 1 2 2 2 1 2 1 Remove the pieces in the given order REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET REMOVAL ...

Page 253: ... personal injuries deriving from the improper use of the rear shock absorber and the gas cylinder Do not tamper with do not attempt to open the rear shock absorber or the gas cylinder Do not submit the rear shock absorber or the gas cylinder to naked flames or other sources of high heat A high overheating may cause an explosion due to the excessive gas pressure Do not deform do not damage the rear...

Page 254: ... set hold the swing arm to avoid it falling NOTE Lift the swing arm and remove the rear shock absorber set from the connecting point on the swing arm 1 Disconnect the articulated connecting rods fixing screws the relative nuts the two articulated connecting rods the lower screw of the rear shock absorber set the relative nut 2 A A C A C Disconnect the fixing screw of the rear shock absorber set th...

Page 255: ...sorber set the rear shock absorber In the presence of gas oil leaks Replace the rear shock absorber set the spring In the presence of damages wear Replace the rear shock absorber set the bushes In the presence of damages wear Replace the dust seals In the presence of damages wear Replace the screws In the presence of deformations damages wear lines Replace 1 1 ...

Page 256: ...17 15 13 17 3 2 4 5 6 8 9 18 19 11 10 LS T R 60 N m 6 11 Kgf m 52A43 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 52A43 52A43 LS LS T R 40 N m 4 07 Kgf m LS LS LS LS LS LS LS LS LS Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 LS 14 T R 50 N m 5 09 Kgf m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 5 4 A 2 3 ...

Page 257: ...al Ring Spacer Articulated Connecting Rod Nut Screw Nut Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 2 1 2 2 2 1 2 1 1 1 2 4 1 2 2 2 1 1 Install the pieces in the given order REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET INSTALLATION LS LS LS LS LS LS LS LS 3 4 A 2 5 3 4 A 2 5 3 4 A 2 5 ...

Page 258: ...ck absorber set 3 Clean the nut of the rear shock absorber set the screw of the rear shock absorber set 2 Fasten the nut of the rear shock absorber set Fasten with the lower fixing nut of the rear shock absorber set the fixing screws of the articulated connecting rods Fasten 4 Recommended lubricant TUTELA MR2 GREASE LS 50 N m 5 09 Kgf m T R 40 N m 4 07 Kgf m T R Recommended solvent TUTELA MOTOR CL...

Page 259: ...lers Bearing Bearing Inside Spacer Screw Welnut Upper Chain Slide SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 4 2 1 1 1 1 1 2 2 1 1 2 1 2 2 1 Remove the pieces in the given order See paragraph 4 53 See paragraph ELECTRIC PLANT 7 11 See paragraph 4 16 See paragraph 4 126 See paragraph 4 122 See paragraph 4 89 NOTE Support the bike using suitable...

Page 260: ...upport so that the bike does not fall and the rear wheel is lifted NOTE Cut the transmission chain only if it or the swing arm has to be replaced 1 Disconnect the transmission chain using a transmission chain cutter or the provided tool according to the transmission chain manufacturer specifications 2 MASTER LINK TRANSMISSION CHAIN TOOLS SET 2 ...

Page 261: ...er set hold the swing arm to avoid it falling NOTE The shock absorber must be dismantled 1 Disconnect the nuts the articulated connecting rods fixing screws the two articulated connecting rods the washers the lower screw of the rear shock absorber set the relative nut 2 B B C A C Check the swing arm vertical movement by moving it up and down If the vertical movement of the swing arm is not smooth ...

Page 262: ...ace the transmission chain in kerosene and remove all residue dirt Remove the transmission chain from the kerosene and leave it to dry completely a b c C D ATTENTION This bike is equipped with a transmission chain with small rubber O Rings placed between one side plate and the other To clean the transmission chain we recommend not using high pressure jets of air or water not to use vapour petrol a...

Page 263: ... more of a of each tooth is worn Replace the gears of the transmission chain If the teeth are bent Replace the gears of the transmission chain Correct Distribution chain roller Transmission chain gears E F G H E F G H NOTE Never use a new chain with worn cogwheels Both the chain and the cogwheels must be in good conditions or the new chain will rapidly wear out ...

Page 264: ...ng arm pin the bushes the seal rings the spacer the bearings 3 2 1 B Check the bushes the seal rings the seeger In the presence of damages wear Replace the bearings the inside spacer In the presence of damages pitting Replace 4 4 C D F C C D D E E F F G Check the articulated connecting rods the balancing device In the presence of damages wear Replace the roller bearings the seal rings In the prese...

Page 265: ...the special tool 2 TRANSMISSION CHAIN TOOLS SET TRANSMISSION CHAIN TOOLS SET JUMP RING O RING MASTER LINK 108 LINKS MASTER LINK LINK WARNING Do not reuse the old transmission chain the master link the jump ring of the master link and the O Rings ATTENTION Insert the master link from inside the transmission chain therefore apply the jump ring with the identification mark facing outwards Assemble an...

Page 266: ...he surface interested by the pressing of the master link This must not show cracks If cracks are present replace the master link the seal rings and the jump ring 4 4 ATTENTION Do not use a transmission chain with clip type master link OK REPLACE CRACKS ...

Page 267: ...IPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 2 1 1 2 2 1 2 2 1 1 1 1 1 2 4 1 Install the pieces in the given order NOTE Install using the special tool 17 16 16 15 15 14 12 11 13 10 6 5 4 2 1 5 3 6 52A43 T R 60 N m 6 11 Kgf m LS Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 LS L S L S LS LS LS T R 22 N m 2 24 Kgf m LS LS 3 4 A 2 5 3 4 A 2 5 LS LS LS LS LS LS LS LS 9 8 7 9 ...

Page 268: ...R2 GREASE LS A A C D E 3 Adjust the loosening of the transmission chain See paragraph ROUTINE INSPECTIONS AND ADJUSTMENTS 3 62 4 Install the rear shock absorber set See paragraph 4 94 the rear wheel See paragraph 4 26 Check there are approximately 15 mm 0 59 in between the swing arm and the lower chain slide Recommended solvent TUTELA MOTOR CLEAN the ring nut the regulator the special screw C D E ...

Page 269: ...4 107 ENGINE CHAS ENGINE REMOVAL 1 2 3 4 5 6 8 10 11 9 7 12 ...

Page 270: ...te Engine SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 1 1 1 1 1 1 1 1 1 1 1 1 Remove the pieces in the given order NOTE Place a suitable trestle underneath frame and engine See paragraph 4 122 NOTE Drain the cooling liquid before carrying out the operations See paragraph ROUTINE INSPECTIONS AND ADJUSTMENTS 3 44 See paragraph 4 112 See paragraph 4 118 See paragr...

Page 271: ...ON Careful not to damage frame and engine when installing the engine NOTE Place a suitable trestle underneath frame and engine Torque fasten Torque fasten Near to the engine without fastening and near the regulator ring nut to the frame without fastening Lock the screw using the spanner Torque fasten Fasten by hand Lock screw using the spanner Fasten by hand Fasten by hand NOTE Insert the cooling ...

Page 272: ...t Lid Left Headlight lid Fixed Cap Anti vibration Nut Screw Bush Split pin Knob Pin Small Plate Mobile Cap SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 1 2 2 2 1 1 1 2 2 2 2 2 2 2 2 1 Remove the pieces in the given order 14 15 17 16 13 11 12 10 10 11 1 2 8 4 3 6 5 3 5 7 4 9 9 14 15 16 13 12 ...

Page 273: ...rew Benelli Decalcomania SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 1 2 2 2 2 2 2 2 2 1 1 2 2 2 1 1 Install the pieces in the given order Manually fasten 5 4 1 3 6 8 7 9 9 8 17 16 2 14 15 12 13 15 13 11 14 10 10 5 4 3 6 LS LS T R 6 N m 0 61 Kgf m T R 8 N m 0 81 Kgf m LS T R 8 N m 0 81 Kgf m LS 5 2 A 7 0 Arexons SYSTEM 52A70 STRONG THREAD BREAK...

Page 274: ...w Bush Steering Lock Lid Special Screw Bush Special Screw Left Tank Lid Quick Fixing Clip SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 2 2 1 1 1 1 1 1 Remove the pieces in the given order NOTE The procedure below can be applied to both tank lids 1 1 2 2 3 5 4 6 7 8 ...

Page 275: ...ank Lid Special Screw Bush Special Screw Steering Lock Lid Bush Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 1 1 1 1 1 1 2 2 Install the pieces in the given order NOTE The procedure below can be applied to both tank lids Manually fasten 8 8 7 7 6 4 5 3 2 1 LS LS T R 8 N m 0 81 Kgf m LS LS ...

Page 276: ...t Tank Lids Removal Fairing Support Bracket Removal Screw Nut Washer Bush Fairing Support Bracket Quick Fixing Clip SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 1 1 2 1 1 2 Remove the pieces in the given order See paragraph 4 112 1 3 2 3 4 5 6 6 ...

Page 277: ...airing Support Bracket Installation Quick Fixing Clip Fairing Support Bracket Bush Washer Screw Nut SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 2 1 1 2 1 1 Install the pieces in the given order 5 4 6 4 3 2 1 1 LS T R 12 N m 1 22 Kgf m LS ...

Page 278: ... 4 116 Tank Cap Removal Screw Screw Tank Cap Seal For Ring Nut Collector Gasket SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 1 3 1 1 1 1 Remove the pieces in the given order Insert key Open cap 1 2 2 2 3 4 5 6 ...

Page 279: ...tallation Gasket Collector Screw Seal For Ring Nut Tank Cap Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 1 1 1 1 1 3 Install the pieces in the given order 3 6 6 6 5 4 2 1 NEW T R 6 N m 0 61 Kgf m NEW NEW NEW T R 6 N m 0 61 Kgf m ...

Page 280: ...2 1 1 2 1 Remove the pieces in the given order See paragraph 4 112 See paragraph 4 112 See paragraph 4 130 Lift the tank slightly Disconnect Disconnect Disconnect the petrol fitting tube using the special tool ATTENTION When using the special tool the two flaps of the petrol pump must be pressed Once the petrol tube is removed insert the special tool B to avoid petrol leaking 1 2 3 3 2 1 4 6 5 7 S...

Page 281: ...BOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 1 2 1 1 2 2 2 Install the pieces in the given order ATTENTION Remove special tool B using special tool A rapidly connecting the petrol tube fitting LS T R 12 N m 1 22 Kgf m LS T R 12 N m 1 22 Kgf m LS 7 6 5 5 6 7 4 2 3 1 Special Tools RAPID RELEASE KIT Code R180100143000 2 RAPID RELEASE KIT A B ...

Page 282: ...Screw Nylon Washer Engine Protection Left Front Small Plate Left Rear Small Plate Right Rear Small Plate Right Front Small Plate Quick Fixing Clip SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 1 1 2 1 1 1 4 4 1 1 1 1 1 4 Remove the pieces in the given order 1 2 3 4 4 5 6 7 8 9 8 8 15 9 15 9 11 10 15 15 13 12 14 ...

Page 283: ...ylon Washer Special Screw Pinion Lid Quick Fixing Clip Small Plate Screw Alternator Lid Nylon Washer Special Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 4 1 1 1 1 1 4 4 1 1 1 2 1 1 1 Install the pieces in the given order Manually fasten NEW T R 8 N m 0 81 Kgf m NEW NEW NEW T R 8 N m 0 81 Kgf m 15 14 13 12 12 11 10 9 8 7 8 8 1 7 1 7 5 6 1 1 3 4 2 ...

Page 284: ... CHAIN CARTER REMOVAL 4 122 Chain Carter Removal Screw Washer Chain Carter Quick Fixing Clip SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 2 2 1 2 Remove the pieces in the given order 4 4 3 1 2 1 2 ...

Page 285: ...stallation Quick Fixing Clip Chain Carter Washer Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 2 1 2 2 Install the pieces in the given order 1 1 2 4 3 4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 3 4 A 2 5 52A43 T R 8 N m 0 81 Kgf m ...

Page 286: ...land Nut Screw Bracket SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 1 4 4 1 2 2 2 2 4 2 Remove the pieces in the given order NOTE It is not necessary to remove the brake flexible tube to remove the front mudguard just unhook it from the pipe gland as shown in figure 1 2 2 2 3 3 3 3 2 5 4 6 7 8 5 6 7 8 9 9 9 9 10 A A ...

Page 287: ...2 3 4 5 6 7 8 9 10 2 4 2 2 2 2 1 4 4 1 Install the pieces in the given order NOTE To install the front mudguard hook the brake flexible tube in the pipe gland as shown in figure 10 9 9 9 8 8 8 8 9 6 7 5 4 3 6 5 4 3 2 2 2 2 1 A A NEW T R 8 N m 0 81 Kgf m LS NEW LS 3 4 A 2 5 3 4 A 2 5 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 5 2 A 4 3 52A43 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 T R ...

Page 288: ...HAS REAR MUDGUARD REMOVAL 4 126 Rear Mudguard Removal Special Screw Nylon Washer Rear Mudguard SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 3 3 1 Remove the pieces in the given order 1 2 2 2 1 3 1 ...

Page 289: ...allation Rear Mudguard Nylon Washer Special Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 1 3 3 Install the pieces in the given order NEW T R 8 N m 0 81 Kgf m NEW 3 4 A 2 5 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 5 4 A 2 3 52 A 43 3 2 2 2 3 1 3 ...

Page 290: ...ator Screw Bush Rubber Pad Screw Nut Left Number Plate Bracket Right Number Plate Bracket SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 1 1 1 1 2 1 1 1 2 2 1 2 1 1 4 4 4 1 1 1 1 Remove the pieces in the given order Disconnect the indicators wiring and number plate light 16 16 17 18 22 17 18 20 4 1 6 6 7 13 13 14 15 21 2 19 3 5 8 9 ...

Page 291: ...SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 1 1 1 4 4 4 1 1 2 1 2 2 1 1 1 2 1 1 1 1 1 Install the pieces in the given order Manually fasten Pressure push Connect the indicators wiring and number plate light 7 7 6 5 1 6 5 3 19 22 17 17 16 10 10 9 8 2 21 4 20 18 15 14 13 13 12 12 11 7 6 6 5 5 T R 8 N m 0 81 Kgf m T R 8 N m 0 81 Kgf...

Page 292: ... 4 130 1 3 Remove the seat by lifting it slightly from the rear end and sliding it backwards CHAS SEAT REMOVAL Insert the key 1 Press the seat in the end part and simultaneously turn the key anti clockwise 2 2 3 ...

Page 293: ...REAR FRAME 4 131 2 Press the seat in the end part and hook it closed CHAS SEAT INSTALLATION Install the seat by resting the front hook on the appropriate slot of the tank 1 2 1 B B ...

Page 294: ...Box Removal Screw Left Bracket Right Bracket Object Compartment Battery Wiring SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 2 2 1 4 1 1 1 1 Remove the pieces in the given order See paragraph 4 130 See paragraph 4 155 See paragraph 4 112 See paragraph 4 118 Disconnect ATTENTION Disconnect the negative cable first then the positive one 1 2 3 2 4 4 4 6 5 4 7 8 ...

Page 295: ...ew Bush Screw Bush Rear Wiring Screw Rear Small Frame Set Battery Box SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 1 1 4 1 1 1 2 2 1 4 1 1 Remove the pieces in the given order Disconnect 9 10 11 10 12 13 14 15 16 17 17 18 18 21 22 20 20 20 20 19 ...

Page 296: ...ESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 1 4 1 2 2 1 1 1 4 1 1 2 1 Install the pieces in the given order ATTENTION Before installing it check that the threaded registers of the tie rod are intact Connect 14 13 12 13 11 10 9 8 7 6 6 5 5 2 1 3 3 3 3 4 3 4 A 2 5 3 4 A 2 5 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 52A43 T R 25 N m 2 54 Kgf m 52 A4 3 Arexons SYSTEM 52A43 ME...

Page 297: ...ld Lid Anti vibration Rubber Pad Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 15 16 17 18 19 20 21 22 1 1 1 1 4 Install the pieces in the given order Connect ATTENTION Connect the positive cable first then the negative one See paragraph 4 119 See paragraph 4 113 See paragraph 4 158 22 21 20 21 3 4 A 2 5 52A4 3 T R 10 N m 1 01 Kgf m NEW NEW LS LS 19 19 17 18 19 16 15 Arexons SYSTEM 5...

Page 298: ...Bracket Object Compartment Screw Bush Screw Screw Flexible Command Lock Seat Opening Lever SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2 2 1 4 1 1 1 1 1 1 2 1 1 1 Remove the pieces in the given order See paragraph 4 130 See paragraph 4 112 See paragraph 4 118 NOTE Slightly move the battery box 1 2 3 2 4 4 4 6 5 4 7 10 10 11 12 13 14 8 9 ...

Page 299: ...t Heat Shield Lid Anti vibration Rubber Pad Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 1 1 2 Install the pieces in the given order NOTE Reposition the battery box in the initial position See paragraph 4 119 See paragraph 4 113 14 13 12 13 3 4 A 2 5 T R 10 N m 1 01 Kgf m NEW NEW LS 52A4 3 11 11 11 9 10 11 8 5 5 4 3 2 1 7 6 Arexons SYSTEM 52A43 MED...

Page 300: ...ve the seat See paragraph 4 130 the heat shield lid See paragraph 4 132 the silencing device See paragraph 4 155 1 Disconnect the right and left headlight connectors 2 3 C C B D Remove the screws the nuts the bushes the complete codon 3 B C D ...

Page 301: ...F K Remove the nuts the bushes the anti vibrations the washers the right rear headlight the left rear headlight 4 F E G H I Remove the screws the washers the screws the codon the handle 5 L K M N O F F G G G H H H I J K L M M L N O J ...

Page 302: ...on the screws the washers the screws 1 Connect the right and left headlight connectors 2 3 K K K J Install the left rear headlight the right rear headlight the washers the anti vibrations the bushes the nuts 3 F H I J K J J I I I H H H G F 1 E B A C D E E D C C D B A G ...

Page 303: ... 4 141 CHAS Install the silencing device See paragraph 4 158 the heat shield lid See paragraph 4 135 the seat See paragraph 4 131 5 4 M M N L Install the complete codon the bushes the nuts the screws 4 M O O L N ...

Page 304: ... Codon Removal Rear Small Frame Set Removal Object Compartment Screw Left Bracket Right Bracket Screw Rear Small Frame Set SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 2 2 1 1 4 1 1 6 1 Remove the pieces in the given order See paragraph 4 130 See paragraph 4 155 See paragraph 4 138 1 2 3 2 5 5 5 7 6 5 4 8 8 9 ...

Page 305: ...Special Screw Left Special Screw Left Rear Small Frame Right Rear Small Frame SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 4 2 1 1 1 1 1 1 1 Decompose the pieces in the given order NOTE To install invert the order of the removal parts 3 4 A 2 5 52 A4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 1 9 8 1 1 1 2 2 3 4 5 6 7 ...

Page 306: ...llation Silencing Device Installation Heat Shield Lid Anti vibration Rubber Pad Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 1 6 1 1 4 1 1 2 2 Install the pieces in the given order See paragraph 4 140 See paragraph 4 158 9 8 7 8 3 4 A 2 5 T R 10 N m 1 01 Kgf m NEW NEW LS 52A4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 5 4 A 2 3 LS 5 5 5 3 4 5 6 2 2 1 ...

Page 307: ...ar Change Rod Screw Left Front Footpeg Holder Plate Screw Fork Gear Change Command Lever Bush Elastic Washer Screw Gear Change Command Small Lever SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 1 1 1 1 Remove the pieces in the given order 1 2 3 4 5 7 8 6 9 17 17 18 14 10 11 ...

Page 308: ... 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 Install the pieces in the given order NOTE If the rubber pads are worn replace them Delicately fasten by hand Manually fasten 15 14 13 12 11 9 18 10 17 21 21 22 26 16 24 27 23 25 20 20 19 4 8 7 5 3 6 2 1 T R 10 N m 1 01 Kgf m LS LS LS LS LS 3 4 A 2 5 3 4 A 2 5 3 4 A 2 5 5 2 A ...

Page 309: ...peg Spring Rubber Pad Screw Pointer Eccentric Screw Screw Fork Brake Command Lever Bush Spring Elastic Washer Right Front Footpeg Holder Plate SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 Remove the pieces in the given order See paragraph 4 42 1 3 2 4 5 6 7 8 10 9 11 12 13 14 16 17 15 18 ...

Page 310: ...ON Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Install the pieces in the given order NOTE If the rubber pads are worn replace them NOTE Ensure that the braking plant functions correctly once installation is complete 5 2 A 4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 LS T R 8 N m 0 81 Kgf m LS Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52...

Page 311: ...ber Cover Seeger Pin Right Rear Footpeg Small Plate Ball Spring Screw Right Footboard Holder Plate SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 1 1 1 1 1 1 1 1 1 2 1 Remove the pieces in the given order NOTE The procedure below can be applied to both rear footpegs 7 6 3 1 2 9 8 4 5 10 10 11 ...

Page 312: ... INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 1 2 1 1 1 1 1 1 1 1 1 Install the pieces in the given order NOTE If the rubber pads are worn replace them Manually fasten NOTE The procedure below can be applied to both rear brake callipers LS T R 22 N m 2 24 Kgf m LS 52A43 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 52A43 LS LS 3 4 A 2 5 3 4 A 2 5 Arexons SYSTEM 52A43 MEDIUM...

Page 313: ...l Spring Nut Special Screw Washer Side Trestle Washer Screw Side Trestle Sensor Screw Plate SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 1 1 1 1 1 1 1 2 1 2 1 Remove the pieces in the given order Disconnect connector 2 1 3 4 8 5 6 7 9 10 11 ...

Page 314: ...MBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 1 2 1 2 1 1 1 1 1 1 1 Install the pieces in the given order Connect connector 10 11 9 8 4 7 6 5 3 2 1 LS 5 2 A 4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 LS 3 4 A 2 5 3 4 A 2 5 5 2 A 4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 T R 8 N m 0 81 Kgf m T R 22 N m 2 24 Kgf m T R 45 N m 4 58 Kgf m ...

Page 315: ...ower Chain Slide Screw Welnut Chain Slide Screw Welnut Chain Slide SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 1 1 2 2 1 2 2 1 Remove the pieces in the given order NOTE To remove the upper chain slide see paragraph 4 97 3 4 5 3 4 1 2 7 6 7 6 8 ...

Page 316: ...Welnut Screw Lower Chain Slide Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 1 2 2 1 2 2 1 1 Install the pieces in the given order NOTE To install the upper chain slide see paragraph 4 105 6 5 4 6 5 8 7 2 3 2 3 1 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 5 2 A 4 3 3 4 A 2 5 ...

Page 317: ...k Fixing Clip Screw Nut Screw Thermal Protection Screw Catalyst Thermal Protection Spring Nut SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 2 1 1 2 2 2 2 2 1 6 2 1 2 1 1 1 Remove the pieces in the given order See paragraph 4 128 See paragraph 4 130 See paragraph 4 136 See paragraph 4 136 See paragraph 4 118 See ELECTRIC PLANT 7 13 paragraph See paragr...

Page 318: ...d Bush Drain Collector Fitting Spring Three In One Drain Collector Drain Collector Drain Gasket SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 17 18 19 20 21 22 23 24 25 2 1 1 1 1 1 1 3 3 1 4 5 6 7 8 7 8 6 1 2 3 4 5 9 16 17 11 18 19 20 12 13 14 21 15 23 22 24 24 24 25 25 25 10 10 10 CHAS ...

Page 319: ...TION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 2 1 1 1 Remove the pieces in the given order Spread the wings of plate n 8 to free the heads of screws n 7 NOTE To install invert the order of the removal operations ATTENTION To install after having installed screws n 7 tighten the wings of plate n 8 on the hexagonal sides of the screws Manually fasten nut n 4 2 CHAS 3 10 1 9 8 7 7 4 5 6 T R...

Page 320: ...Silencing Device Articulated Connecting Rod Bush Silencing Device Spring Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 3 3 6 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 2 2 2 2 1 1 2 Install the pieces in the given order Manually fasten Manually fasten 25 22 21 20 19 18 19 18 20 25 24 23 22 21 10 12 9 17 8 7 6 16 15 14 11 13 CHAS GR...

Page 321: ...ENG 5 ...

Page 322: ...ION CHAIN REMOVAL DISTRIBUTION CHAIN CONTROL DISTRIBUTION CHAIN INSTALLATION DISTRIBUTION CHAIN INSTALLATION AND ENGINE PHASING VALVES CLEARANCE ADJUSTMENT VALVES CLEARANCE CONTROL AND ADJUSTMENT VALVES LIFTERS AND CALIBRATED PADS REMOVAL VALVES LIFTERS CONTROL VALVES LIFTERS AND CALIBRATED PADS INSTALLATION HEAD REMOVAL VALVES AND VALVES SPRINGS REMOVAL VALVES AND RELATIVE GUIDES CONTROL VALVES S...

Page 323: ...L CLUTCH PRESSURE PLATE PIN CONTROL CLUTCH INSTALLATION CLUTCH DISKS ADJUSTMENT CLUTCH COMMAND REMOVAL CLUTCH COMMAND CONTROL CLUTCH COMMAND INSTALLATION GEAR CHANGE GEAR CHANGE REMOVAL PRIMARY AND SECONDARY SHAFT GEARS REMOVAL GEARS CONTROL GEAR CHANGE FLANGE BEARINGS CONTROL GEARS COMMAND FORKS CONTROL DESMODROMIC SHAFT CONTROL PRIMARY AND SECONDARY SHAFT GEARS INSTALLATION GEAR CHANGE INSTALLAT...

Page 324: ... START UP MOTOR REMOVAL START UP MOTOR CONTROL START UP MOTOR INSTALLATION Z25 GEAR SPLINED SHAFT FEMALE COLLAR JOINT REMOVAL Z25 GEAR SPLINED SHAFT FEMALE COLLAR JOINT CONTROL Z25 GEAR SPLINED SHAFT FEMALE COLLAR JOINT INSTALLATION SATELLITE GEAR AND FREE WHEEL REMOVAL SATELLITE GEAR AND FREE WHEEL CONTROL SATELLITE GEAR AND FREE WHEEL INSTALLATION HANDLING BASE LOWER BASE REMOVAL LOWER BASE CONT...

Page 325: ...NCING COUNTER SHAFT CONTROL CONNECTING ROD HALF BEARINGS AND CONNECTING RODS CONTROL CONNECTING ROD HALF BEARINGS AND CONNECTING RODS INSTALLATION BALANCING COUNTER SHAFT ENGINE SHAFT AND BENCH HALF BEARINGS INSTALLATION POWER SUPPLY THROTTLED BODY REMOVAL THROTTLED BODY ADJUSTMENT THROTTLED BODY INSTALLATION 138 138 140 141 142 143 146 154 154 155 156 ENG ...

Page 326: ...ENG ...

Page 327: ... Pad Washer Special Screw Rubber Pad Reel Spark Plug Rubber Pad Special Screw Rubber Pad Distribution Lid Lid Gasket O Ring Gasket Quick Fitting Seal Ring SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 3 3 3 3 3 3 3 3 3 5 5 1 1 3 1 1 Remove the pieces in the given order Champion RG4HC NGK CR9E ...

Page 328: ...HEAD DISTRIBUTION ENG 5 2 C C GASKETS CONTROL Check the lid gasket the O Ring gaskets the rubber pad In the presence of damages wear Replace the faulty parts 1 1 A B C A B C ...

Page 329: ...3 NEW T R 12 N m 1 22 Kgf m 2 14 13 12 11 10 9 5 4 8 7 6 3 16 15 2 2 1 T R 15 N m 1 52 Kgf m T R 8 N m 0 81 Kgf m T R 10 N m 1 01 Kgf m NEW T R 10 N m 1 01 Kgf m NEW LS 52A70 YVORI SIL AC Arexons SYSTEM 52A70 STRONG THREAD BREAKS 5 7 A 2 0 YVORI SIL AC GR ...

Page 330: ...acket Nut Seal Ring Quick Fitting SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 3 1 5 5 3 3 3 3 3 3 3 3 3 1 1 Install the pieces in the given order NOTE The Yvori Sil Ac sealing paste must only be applied on the highlighted surface as shown in the figure Champion RG4HC NGK CR9E NOTE Do not exceed with the Copper Grease NEW NEW NEW NEW YVORI SIL AC Y...

Page 331: ...Seal Ring Spring Screw Chain Tensioner O Ring Gasket SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 1 1 1 2 1 1 Remove the pieces in the given order Operations to be carried out with the engine in PMS DISTRIBUTION CHAIN TENSIONER REMOVAL 1 2 3 4 4 5 6 ...

Page 332: ...HEAD DISTRIBUTION ENG 5 6 DISTRIBUTION CHAIN TENSIONER CONTROL Check the chain tensioner the spring the seal ring In the presence of damages wear Replace 1 A B C 1 A B C ...

Page 333: ...sioner Screw Spring Seal Ring Screw 5 7 SQ INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 1 2 3 4 5 6 1 1 2 1 1 1 Install the pieces in the given order NOTE Bring the tensioner from position to position before installing it on the head A B 6 5 4 3 3 2 1 NEW T R 10 N m 1 01 Kgf m A B SYMBOLS T R 10 N m 1 01 Kgf m NEW LS LS ...

Page 334: ...rence Plug 5 8 SQ INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 4 1 1 2 2 1 6 3 6 Remove the pieces in the given order See paragraph 5 1 See paragraph 5 5 NOTE During removal the reference plugs may still be attached to the cam shafts lids Operations to be carried out with the engine in PMS Slightly rotate the inlet cams clockwise using a 24 spanner loosening the distribution chain ...

Page 335: ...D DISTRIBUTION ENG INLET CAM SHAFT REMOVAL Inlet Z34 Gear Inlet Distribution Shaft 5 9 SQ INTERVENTION DESCRIPTION Q TY OBSERVATIONS 10 11 1 1 Remove the pieces in the given order 10 11 DRAIN INLET SYMBOLS ...

Page 336: ... Drain Distribution Shaft SQ INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 2 1 1 6 3 6 1 Remove the pieces in the given order Operations to be carried out with the engine in PMS See paragraph 5 1 See paragraph 5 5 See paragraph 5 8 NOTE Fasten the distribution chain with a wire to avoid it falling in the base NOTE During removal the reference plugs may still be attached to the cam shaft...

Page 337: ...on Replace the cam shaft 0 90 80 70 60 50 40 30 20 10 0 01mm 0 30mm 2 3 1 2 Measure the sizes of the cam shaft lobes and If out of specification Replace the cam shaft Size limit of the cam shaft lobes Inlet side cam shaft Limit 35 3 mm 1 38 in Limit 27 85 mm 2 77 cm Drain side cam shaft Limit 35 3 mm 1 38 in Limit 27 85 mm 2 77 cm A B A B 3 Eccentricity limit of the cam shaft 0 04 mm 0 001 in A B ...

Page 338: ...in specification Replace the cam shaft head and lids Measure the clearance between cam shaft support and cam shaft lid If out of specification Measure the diameter of the cam shaft support Clearance between cam shaft support and cap Limit 0 1 mm 0 076 mm 5 4 4 5 Cam shaft supports diameter 22 459 22 472 mm 0 8842 0 8847 in C C ...

Page 339: ...Install the pieces in the given order Operations to be carried out with the engine in PMS NOTE We recommend removing all grease from threads for the plate fixing screws Slightly rotate the drain cams anti clockwise using a 24 spanner completely hooking the distribution chain on the gear 5 6 6 6 7 7 5 7 5 DRAIN 4 3 2 1 T R 6 13 N m 0 61 1 32 Kgf m T R 15 N m 1 52 Kgf m SYMBOLS 2 4 NEW GA 3 4 A 2 5 ...

Page 340: ... 1 1 2 1 2 1 2 6 3 6 Install the pieces in the given order NOTE We recommend removing all grease from threads for the plate fixing screws Slightly rotate the inlet cams anti clockwise using a 24 spanner completely hooking the distribution chain on the gear 7 9 8 6 5 5 12 12 11 10 10 12 11 11 10 2 1 3 4 INLET DRAIN T R 6 13 N m 0 61 1 32 Kgf m 24 T R 15 N m 1 52 Kgf m SYMBOLS NEW NEW 5 2 A 4 3 S GR...

Page 341: ...ides Removal Mobile Chain Slide Pin Mobile Slide Fixed Slide SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 1 1 1 Remove the pieces in the given order Operations to be carried out with the engine in PMS See paragraph 5 1 See paragraph 5 5 See paragraph 5 8 See paragraph 5 10 NOTE Always replace the chain slides together with the distribution chain 2 3 1 ...

Page 342: ...16 CHAIN SLIDES CONTROL Check the contact surface of the fixed slide the contact surface of the mobile slide the contact surface of the upper chain slide In the presence of damages wear Replace the faulty parts 1 1 A B A B C C ...

Page 343: ...n Slides Installation Mobile Slide Mobile Chain Slide Pin Fixed Slide SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 1 1 1 Install the pieces in the given order Operations to be carried out with the engine in PMS 1 3 2 T R 12 N m 1 22 Kgf m GR GR ...

Page 344: ...l Screw Nut Washer Phonic Wheel 5 18 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 1 1 1 1 Remove the pieces in the given order See paragraph 5 69 NOTE Lock the phonic wheel using the appropriate tool Special Tools PHONIC WHEEL REMOVAL Code R300097083000 3 PM S 4 2 1 ...

Page 345: ...HEAD DISTRIBUTION ENG 5 19 PHONIC WHEEL CONTROL Check the gear of the phonic wheel In the presence of damages cracks wear Replace the faulty parts 1 1 A PM S T I A ...

Page 346: ...BOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 1 1 1 1 Install the pieces in the given order NOTE Lock the phonic wheel using the appropriate tool PM S 1 2 3 4 Special Tools PHONIC WHEEL REMOVAL Code R300097083000 L O C T IT E T R 45 N m 4 58 Kgf m 8 4 A 6 5 56A48 Arexons SYSTEM 56A48 HIGH TEMPERATURE 56A48 ...

Page 347: ...lide Removal Inlet Z34 Gear Removal Drain Z34 Gear Removal Distribution Chain Removal Distribution Chain 5 21 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 1 Remove the pieces in the given order See paragraph 5 1 See paragraph 5 69 See paragraph 5 8 See paragraph 5 5 See paragraph 5 18 See paragraph 5 15 See paragraph 5 8 See paragraph 5 10 NOTE Remove the chain from the engine 1 ...

Page 348: ... CHAIN REMOVAL R Remove the screws the small plates the Inlet Z34 gear the Drain Z34 gear the fixed slide the distribution chain 1 N NOTE To remove the screws rotate the inlet cam clockwise using a 24 spanner 1 24 E F D C B B A A B C D E F A ...

Page 349: ...nd to all distribution chain guides HEAD DISTRIBUTION ENG 5 23 1 N NOTE However the distribution chain must be replaced when it exceeds 40 000 km Check the distribution chain In the presence of damages no flexibility locked links Replace the distribution chain together with the cam shaft gears 1 A A ...

Page 350: ...N CHAIN INSTALLATION 5 24 Distribution Chain Installation Distribution Chain SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 1 Install the pieces in the given order Operations to be carried out with the engine in PMS PM S 1 E E ...

Page 351: ... P Position the distribution chain on the engine shaft gear the phonic wheel See paragraph 5 20 ATTENTION This operation must be carried out with the distribution chain tensioned A A B A C D E A C D E N L NOTE Lubricate the chain using engine oil ATTENTION Carefully follow the instructions given in the various assembly phases Install the distribution chain the fixed slide Recommended lubricant ENG...

Page 352: ...ly rotate the cam anti clockwise using a 24 spanner in order to hook and tension the distribution chain positioning the reference as shown in figure a the Z34 gear see paragraph 5 14 on the inlet shaft hooking the chain on to the already positioned gear as shown in figure therefore rotate the inlet cam reaching the stop point and relative insertion in the seat G b P M S 24 NEW NEW a F b G N NOTE E...

Page 353: ...UTION ENG 5 27 N R NOTE Rotate the cam shafts using a spanner performing a full turn and bringing the engine in PMS 5 Install the chain tensioner See paragraph 5 7 the upper chain slide See paragraph 5 14 5 H H I I ...

Page 354: ...RANCE ADJUSTMENT 5 28 Distribution Lid Removal Valves Clearance Adjustment SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS Remove the pieces in the given order Operations to be carried out with the engine in PMS See paragraph 5 1 ...

Page 355: ... cams and cup using a feeler Position the cam as shown in the figure If out of specification Replace the pad See paragraph 5 30 1 1 N NOTE Measurement must be carried out on all shafts and cups Clearance between cup and shafts Inlet 0 28 0 32 mm 0 028 0 032 in Drain 0 34 0 38 mm 0 034 0 038 in A A ...

Page 356: ... Cam Shaft Removal Valves Lifters And Calibrated Pads Removal Inlet Valve Lifter Inlet Valve Calibrated Pad Drain Valve Lifter Drain Valve Calibrated Pad 5 30 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 6 6 6 6 Remove the pieces in the given order See paragraph 5 1 See paragraph 5 5 See paragraph 5 8 See paragraph 5 10 DRAIN INLET 1 2 3 4 ...

Page 357: ...efore removing the internal parts of the head for example valves valves springs valves seats check that the valves are adequately sealed NOTE Remove the valves lifters the calibrated pad NOTE Take note of the position of each valve lifter and of each pad in order to be able to re assemble them in the correct position 1 1 A A 1 2 3 DRAIN INLET A B B ...

Page 358: ...AD DISTRIBUTION ENG 5 32 VALVES LIFTERS CONTROL The following procedure is applied to all valves lifters C Check the valves lifters In the presence of damages scratches Replace the valves lifters 1 1 A A ...

Page 359: ...ted Pads Installation Inlet Valve Calibrated Pad Inlet Valve Lifter Drain Valve Calibrated Pad 5 33 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 6 6 6 6 Install the pieces in the given order NOTE Always check the valves clearance See paragraph 5 29 DRAIN INLET 2 1 4 3 GR GR GR GR ...

Page 360: ...HEAD DISTRIBUTION ENG HEAD REMOVAL 5 34 8 9 9 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3 7 3 5 4 6 ...

Page 361: ...r Screw Special Screw Seal Washer Tube Head Head Gasket Reference Plug 5 35 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 8 8 2 1 2 1 1 1 2 Remove the pieces in the given order See FRAME 4 107 paragraph See paragraph 5 1 See paragraph 5 5 See paragraph 5 8 See paragraph 5 10 See paragraph 5 69 See paragraph 5 15 See paragraph 5 18 See paragraph 5 21 NOTE Loosen each nut b...

Page 362: ...HEAD DISTRIBUTION ENG VALVES AND VALVES SPRINGS REMOVAL 5 36 DRAIN INLET 12 8 9 10 11 13 14 5 8 1 2 3 4 6 7 1 ...

Page 363: ...ower Spring Plate Drain Valve Split Pin Drain Valve Upper Spring Plate Drain Valve Internal Spring Drain Valve External Spring Drain Valve Drain Valve Oil Retainer Drain Valve Lower Spring Plate 5 37 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 12 6 6 6 6 6 6 12 6 6 6 6 6 6 Remove the pieces in the given order See FRAME 4 107 paragraph See paragraph 5 1 Se...

Page 364: ...resence of leaks of the valves seats Check the contact surface the seat and the width of the valve seat See paragraph 5 41 Pour clean solvent inside the inlet doors Check that the valves are adequately sealed Clearance between valve stem and valve guide Inlet 0 0010 0 0037 mm 0 000039 0 00014 in Drain 0 025 0 052 mm 0 00098 0 0020 in 0 90 80 70 6 0 50 40 30 20 10 0 01mm 0 30mm 2 2 Measure the clea...

Page 365: ...having installed the valve guide bore it using a borer to obtain the correct clearance between the stem and valve guide N NOTE After having re assembled the valve guide trim the seat E C Eliminate the carbonaceous deposits from the contact surface and from the valve seat Check the contact surface of the valve In the presence of pittings wear Rectify the contact surface of the valve the end of the ...

Page 366: ...installed always replace the relative guide If the valve is disconnected or re assembled always replace the oil retainer M Measure the eccentricity of the valve stem If out of specification Replace the valve Valve stem eccentricity 0 015 mm 0 0005 in 6 6 ...

Page 367: ...alve seat If out of specification Replace the head 2 1 3 3 N NOTE Where the valve seat and the valve face touch each other the Prussian blue will result removed Valve seat width Inlet 0 9 1 1 mm 0 035 0 043 in Drain 0 9 1 1 mm 0 035 0 043 in Apply some blue colouring Dykem for mechanics on the contact surface of the valve Install the valve in the head Push the valve inside the guide and against it...

Page 368: ...it forwards and backwards Figure Apply a thin lapping paste on the surface contact of the valve and repeat the above procedure After every lapping operation it is important to remove every trace of lapping paste from the contact surface and from the valve seat Apply blue colouring Dykem for mechanics on the contact surface of the valve Install the valve in the head Push the valve inside the guide ...

Page 369: ...nlet 35 mm 1 377 in drain 33 mm 1 299 in Measure the force of the compressed valve spring If out of specification Replace the valve spring Installed length Spring inclination limit Inlet valve spring 1 7 mm 0 06 in Drain valve spring 1 7 mm 0 06 in 2 Force of the compressed valve spring installed External valve spring 186 N m 18 96 Kgf m a 32 8 mm 1 29 in Drain valve spring 32 5 N m 3 31 Kgf m a 3...

Page 370: ...HEAD DISTRIBUTION ENG VALVES AND VALVES SPRINGS INSTALLATION 5 44 DRAIN INLET 10 14 13 12 11 9 8 3 14 7 6 5 4 2 1 7 E E E E E E ...

Page 371: ...rnal Spring Inlet Valve Upper Spring Plate Inlet Valve Split Pin Drain Valve Lower Spring Plate Drain Valve Oil Retainer Drain Valve Drain Valve External Spring Drain Valve Internal Spring Drain Valve Upper Spring Plate Drain Valve Split Pin 5 45 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 6 6 6 6 6 6 12 6 6 6 6 6 6 12 Install the pieces in the given orde...

Page 372: ...alve spring the upper spring plate 1 N L NOTE Lubricate the valve stem and the valve oil retainer N NOTE Trim the end of the valve stem using a stone to thinly sharpen see figure 1 Special Tools BUFFER FOR VALVES OIL RETAINER Code R180197025000 N NOTE Ensure that every valve has been re assembled in its original position A B A C D E F B a C E F b c a b c E E E E Recommended lubricant ENGINE OIL E ...

Page 373: ...n tool 2 2 ATTENTION Hitting the point of the valve with excessive force may damage the same valve Install the calibrated pad the valves lifters N NOTE Lubricate the valve lifter using copper grease MOLYKOTE HSC PLUS By manually rotating the valve lifter it must move smoothly Re assemble each valve lifter and pad in the original position 4 This procedure is applied to all valves and relative compo...

Page 374: ...TRIBUTION ENG HEAD INSTALLATION 5 48 2 1 1 9 8 9 8 9 8 9 8 9 8 9 8 9 8 9 8 7 3 7 4 6 5 NEW T R 15 N m 1 52 Kgf m T R 10 N m 1 01 Kgf m 5 2 A 7 0 Arexons SYSTEM 52A70 STRONG THREAD BREAKS 5 4 A 6 8 GR GR GR NEW ...

Page 375: ...tallation Reference Plug Head Gasket Head Seal Washer Tube Special Screw Screw Washer Nut 5 49 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 2 1 1 2 1 1 2 8 8 Install the pieces in the given order NEW NEW 0 7 A 2 5 GR GR GR ...

Page 376: ... 1st phase 25 N m 2 54 Kgf m 2nd phase 45 N m 4 58 Kgf m 3rd phase 50 angle pair 4th phase 50 angle pair 5th phase fasten the screws 10 N m 1 01 Kgf m N NOTE Using copper grease lubricate the threading of the head fixing nuts 1 8 5 7 INLET DRAIN 1 4 8 2 6 3 A A GR Recommended lubricant COPPER GREASE GR ...

Page 377: ...CYLINDERS ENG CYLINDERS REMOVAL 5 51 1 1 2 3 4 4 ...

Page 378: ...stribution Chain Removal Head Removal Cylinders Removal Screw Carter Cylinder Carter Cylinder Gasket Reference Plug 5 52 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 2 1 1 2 Remove the pieces in the given order See FRAME 4 107 paragraph See paragraph 5 1 See paragraph 5 5 See paragraph 5 8 See paragraph 5 10 See paragraph 5 69 See paragraph 5 15 See paragraph 5 18 See paragraph 5 ...

Page 379: ... CYLINDERS CONTROL The following procedure is applied to the entire cylinder unit Check the cylinder wall In the presence of vertical scratches Replace the cylinder and the piston together with the relative bands 1 1 A A ...

Page 380: ... Cylinder Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 2 1 1 2 Install the pieces in the given order NOTE Apply engine oil on the bands and on the pistons wall before installing the carter cylinder Do not exceed with the engine oil 4 4 3 2 1 1 T R 10 N m 1 01 Kgf m E GR E GR E E NEW NEW ...

Page 381: ...cylinder gasket CYLINDERS INSTALLATION 1 A Apply the thickness in the central piston the thickness in the side piston the thickness in the side piston 2 Special Tools CYLINDER ASSEMBLY THICKNESSES Code R180197018000 NEW A A A B C D B C D ...

Page 382: ...tially remove the thicknesses and 5 3 P Position the cylinder unit 4 4 N NOTE By compressing the piston bands using one hand with the other install the cylinder set subsequently removing the thickness E E E F F G H I G H I E E Recommended lubricant ENGINE OIL E ...

Page 383: ...DERS ENG 5 57 6 6 Install the two cylinder fixing screws ATTENTION Completely fasten the cylinder fixing screws after having fixed the head J J T R 10 N m 1 01 Kgf m GR Recommended lubricant COPPER GREASE GR ...

Page 384: ...l Removal Distribution Chain Removal Head Removal Cylinders Removal Pistons Removal Pistons 5 58 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 3 Remove the pieces in the given order See FRAME 4 107 paragraph See paragraph 5 1 See paragraph 5 5 See paragraph 5 8 See paragraph 5 10 See paragraph 5 69 See paragraph 5 15 See paragraph 5 18 See paragraph 5 21 See paragraph 5 34 See paragraph ...

Page 385: ... the pin the piston the internal elastic ring the external elastic ring the pin the piston the internal elastic ring the elastic ring the pin the piston the elastic ring 1 1 A A B 1 C F 3 E D I 2 H G B C D E F G 2 I N NOTE Do not use hammers to remove the pins 1 3 H ...

Page 386: ...50 87 960 B B 87 961 87 971 87 961 87 971 C C 87 972 87 982 87 972 87 982 CLASS P P Measure the diameter of skirt of piston P using the micrometer 10 5 mm 0 413 in from the lower edge of the piston 1 1 2 2 If out of specification Replace the piston and the relative bands together ATTENTION The piston is distinguished by a letter indicating its class The coupling cylinder piston must be carried out...

Page 387: ...ny carbonaceous deposits from the piston bands and from the relative grooves Side clearance between the piston bands Upper band Limit 0 20 mm 0 0078 in Second band Limit 0 18 mm 0 0070 in Measure the side clearance between one piston band and the other If out of specification Replace the piston and the relative bands together 1 2 3 Measure the upper band thickness the second band thickness Elastic...

Page 388: ... 9 002 19 008 mm 0 7481 0 7483 in Measure the external diameter of the piston pin If out of specification Replace the piston pin PINS CONTROL The following procedure is applied to all pins Check the piston pin In the presence of blue fading grooves Replace the piston pin and check the lubricating system 1 2 Piston pin external diameter 18 995 19 000 mm 0 747 0 748 in 3 A A B B ...

Page 389: ...PISTONS ENG PISTONS INSTALLATION Pistons Installation Pistons 5 63 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 3 Install the pieces in the given order 1 ...

Page 390: ...the upper band 1 2 N The first and second rings have the letter N on the upper side Remember to install the piston bands so that the letter N is facing upwards NOTE N NOTE The spacer and the side rings do not have a particular upper or lower side they can be inserted in any way 1 C N A B C A B D E E E E D E E 3 Incorrect Correct ATTENTION When installing the spacer careful that its ends do not ove...

Page 391: ...NS ENG 5 65 4 The two bands have a different thickness The upper band has a lower thickness than the 2nd band 4 Piston bands thickness Upper band 3 1 0 1 mm Second band 3 7 0 1 mm Upper band 2nd band F G G F ...

Page 392: ...ISTONS ENG 5 66 Install the central piston the piston pin the piston pin stop rings 5 5 2 NEW H I 2 I NEW N L NOTE Lubricate the piston pin before installing it H I E Recommended lubricant ENGINE OIL E H ...

Page 393: ...e internal rings then the piston pins and finally the external rings Lubricate the pistons well before installing them ATTENTION Match the piston class to the letter on the cylinder A B C Face the arrow on the piston crown towards the drain Figure 7 K 3 J J 3 K L L K 1 J L 1 7 E E E Recommended lubricant ENGINE OIL E ...

Page 394: ...PISTONS ENG 5 68 8 8 P Position in an alternative manner the light between the two ends of each piston band at 120 compared to the other ...

Page 395: ...ket 5 69 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 1 2 3 6 1 1 Remove the pieces in the given order NOTE Loosen each screw by of a turn at a time repeatedly and proceeding in a crossed sequence After having completely loosened all the screws remove them PM S 3 3 4 4 4 2 1 6 5 ...

Page 396: ...crew Screw Screw 5 70 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 1 1 6 3 2 1 Install the pieces in the given order NOTE Accurately clean the support surfaces of the gasket NEW PM S 4 4 3 3 3 5 6 1 2 T R 10 N m 1 01 Kgf m NEW T R 10 N m 1 01 Kgf m LS LS LS L S LS LS LS LS LS ...

Page 397: ...ENG CLUTCH REMOVAL 5 71 5 8 9 10 11 12 13 13 14 1 2 3 7 CLUTCH 6 4 15 PM S ...

Page 398: ...late Clutch Disks Series Friction Steel Disk Disk Hexagonal Nut Disk Spring Clutch Drum High Shim Clutch Bell Needle Cage Spacer Low Shim SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 6 6 6 1 1 1 1 1 1 1 1 1 2 1 1 Remove the pieces in the given order See paragraph 5 69 ...

Page 399: ...h pressure plate 2 R Remove the clutch disks series the friction steel disk the disk 3 2 PM S Loosen the clutch drum nut 4 N NOTE By keeping the clutch drum still using the retainer tool specific for the clutch loosen the relative nut Special Tools CLUTCH DISMANTLING SPANNER Code R180297047000 2 4 I L PM S PM S 1 PM S B A G F E D C J 3 G I J A B C D E F H I H ...

Page 400: ...74 R Remove the high shim the clutch bell 6 R Remove the needle cage the spacer the low shim 7 PM S PM S 7 6 R Remove the clutch drum nut the disk spring the clutch drum set 5 PM S 5 K L M N O P Q R K L M N O P Q R ...

Page 401: ...tion disks Check the friction disk In the presence of damages wear Replace all friction disks Measure the thickness of the friction disks If out of specification Replace all friction disks 2 N M NOTE Measure the friction disk in four points 2 Friction disk thickness Limit 2 8 mm 0 110 in ...

Page 402: ...ed to all steel disks Check the steel disk In the presence of damages wear Replace all steel disks Measure the twisting of the steel disk using a surface plate and a feeler If out of specification Replace all steel disks 2 2 Steel disk twisting limit 0 1 mm 0 0039 in A A ...

Page 403: ...gs Check the compression springs In the presence of damages Replace all compression springs COMPRESSION SPRINGS CONTROL Measure the free length of the compression springs If out of specification Replace all compression springs 2 2 Compression spring free height 34 3 mm 1 35 in A A ...

Page 404: ...utch jaws of the clutch bell In the presence of damages pittings wear lines Trim the clutch jaws of the clutch bell or replace the clutch bell 1 N NOTE The presence of pittings on the clutch jaws of the clutch bell will make the clutch malfunction A A ...

Page 405: ...UM INSPECTION Check the grooved part of the clutch drum In the presence of damages pittings wear lines Replace the clutch drum 1 N NOTE The presence of pittings on the grooved part of the drum will make the clutch malfunction A A ...

Page 406: ...CLUTCH ENG 5 80 1 CLUTCH PRESSURE PLATE CONTROL Check the clutch pressure plate In the presence of cracks damages Replace the bearing In the presence of damages wear Replace 1 A B A B ...

Page 407: ...age In the presence of damages wear Replace CLUTCH PRESSURE PLATE PIN CONTROL Check the pressure plate pin the bush In the presence of damages wear Replace the clutch pressure plate pin together with the traction lever shaft pinion B A A C B C ...

Page 408: ...G CLUTCH INSTALLATION 5 82 11 8 7 6 5 4 3 2 15 14 13 9 CLUTCH 10 12 1 PM S 3 T R 100 N m 10 19 Kgf m T R 10 N m 1 01 Kgf m 56A48 E E E E E Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER 56A48 E E E E E E LS ...

Page 409: ... Steel Disk Clutch Disks Series Clutch Pressure Plate Compression Spring Cup Screw SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 1 2 1 1 1 1 1 1 1 1 1 6 6 6 Install the pieces in the given order NOTE To assemble the clutch unit gather shims 1 and 5 Always check the relief thickness LS E E E E E E E E E 8 4 A 6 5 ...

Page 410: ...with the lowest relief towards the inside of the engine Insert the spacer the needle cage 2 Insert the clutch bell 3 N NOTE Before inserting the needle cages lubricate their sliding area well PM S 5 PM S 2 PM S 3 PM S 4 PM S 1 A A B C D E F B C D E F A E E E E E E Recommended lubricant ENGINE OIL E Recommended lubricant ENGINE OIL E Recommended lubricant ENGINE OIL E Recommended lubricant ENGINE O...

Page 411: ...7000 100 N m 10 9 Kgf m T R Torque fasten with DISK SPRING INSERTION DIRECTION 8 9 Insert sequentially and alternatively the friction disks the steel disks DISK INSERTION DIRECTION N NOTE The friction steel disk must be inserted with the friction band towards the inside of the engine N L NOTE Lubricate all disks one by one using engine oil before inserting them in the clutch drum 2 7 I L PM S 6 PM...

Page 412: ...the pressure plate the compression springs the cups the screws PM S 10 N m 1 01 Kgf m T R Torque fasten N L NOTE Lubricate the screws threads 10 N O P Q N O P Q LS T R 10 N m 1 01 Kgf m Recommended lubricant TUTELA MR2 GREASE LS ...

Page 413: ...rd and loosen it by of a turn Check the clearance on the clutch command positioned on the opposite side of the engine 1 2 Fasten the lock nut using special tool keeping the regulator still 2 Special Tools CLUTCH PRESSURE PLATE ADJUSTING SPANNER Code R180297130000 1 N NOTE To use the special tool remove one screw with relative cup and spring A A B C B C B C B C ...

Page 414: ...mand Body Plug Small Plate O Ring Gasket Bush Clutch Command Rod Ball Needle Cage Needle Cage Spring Clutch Command SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 1 3 1 1 1 1 1 1 1 1 1 1 1 Remove the pieces in the given order See paragraph 5 69 See paragraph 5 71 9 2 2 2 3 5 6 7 8 10 11 12 13 1 4 ENG ...

Page 415: ...CLUTCH 5 89 CLUTCH COMMAND CONTROL Check the clutch command In the presence of deformations damages wear lines Replace the clutch command spring In the presence of damages wear Replace 1 ENG 1 A A B B ...

Page 416: ...te Plug Clutch Command Body Screw Clutch Cable SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 1 1 1 1 1 1 1 1 1 1 1 3 1 Install the pieces in the given order 5 12 12 12 11 9 8 7 6 4 3 2 1 13 10 ENG T R 10 N m 1 01 Kgf m NEW NEW LS 52A43 E LS LS LS L S E Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 LS LS LS LS LS E E 3 4 A 2 5 ...

Page 417: ...MBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 8 1 1 Remove the pieces in the given order NOTE Remove the neutral sensor located in the rear part of the engine before removing the gear change NOTE Drain the engine oil before carrying out the operations See paragraph 5 69 See paragraph 5 71 See paragraph 5 88 See COOLING PLANT 6 15 paragraph ENG 1 1 1 1 1 1 3 2 1 ...

Page 418: ...R CHANGE REMOVAL R Remove the nut keeping the pinion still with the special tool 1 ENG 1 R Remove the washer the pinion the spacer 2 2 Special Tools PINION DISMANTLING TOOL Code R180297048000 A 3 8 3 8 A B B C A C D E D E ...

Page 419: ...GEAR CHANGE 5 93 ENG 3 Remove the washer the pin the spring the spacer the washer 4 4 Remove the screws the selector lid the selector lid gasket 3 F F F F G H G H I J K L M I J K L M ...

Page 420: ...hind the gear change flange to avoid it falling Remove the bush the desmodromic sprocket the jumpers the pegs the springs the peg the complete gear change drum 6 R S T N N N O O P Q R S T U V W P U W NOTE During removal of the desmodromic sprocket contrast the reaction of the springs located underneath the jumpers W T R Q R S T V U ...

Page 421: ...emoval of the pins pay attention to the desmodromic and to the forks and 8 Remove the threaded pin the gears fixing jumper the washer the spring 8 ATTENTION Ensure that the peg is correctly inserted in its seat NOTE Take note of the position of the forks before removing them for a correct re assembly X Z X X Y Y Z Z A A B C D E E Y Z A B C D E C A B F G H I J F G H I J ...

Page 422: ...GEAR CHANGE 5 96 ENG 9 Remove the primary shaft the secondary shaft 9 ATTENTION The gears are free Remove the shafts and simultaneously K K K L L L ...

Page 423: ...GEAR CHANGE PRIMARY AND SECONDARY SHAFT GEARS REMOVAL 5 97 ENG 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 PRIMARY SHAFT SECONDARY SHAFT 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 ...

Page 424: ...ear Elastic Ring Splined Shim Z30 4th Conduct Gear Broached Bush Stop Ring Splined Shim Z32 3rd Conduct Gear Broached Bush Splined Shim Elastic Ring Z27 6th Conduct Gear Elastic Ring Shim Z39 2nd Conduct Gear Needle Cage Secondary Shaft O Ring Gasket SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35...

Page 425: ...RS CONTROL Check the gears of the two shafts In the presence of blue fading pittings wear lines Replace the faulty gears the gears clutch jaws In the presence of cracks damages round edges Replace the faulty gears 1 ENG 1 ...

Page 426: ...GS CONTROL 1 ENG 1 Check the free rotation of the bearings If out of specification Replace To replace the bearings remove the screws the small plate the bearing the seal ring the bearing the shims the bearing A A B C E D G F F B C D E F G C E G ...

Page 427: ...or both The clearance of each fork is important for the smoothness and precision of the speed gear change Fork slot clearance Limit 0 50 mm 0 019 in 3 4 3 M Measure the width of the slot of the gear change fork using a cursor gauge Slot fork width Standard value 5 0 5 1 mm 0 19 0 20 in 4 M Measure the thickness of the gear change fork using a cursor gauge Fork gear change thickness Standard value ...

Page 428: ...GEAR CHANGE 5 102 Check the movement of the gears command fork on the relative guide bar If the movement is not smooth Replace the gears command forks together with the relative bar guide 6 ENG 6 ...

Page 429: ... Check the grooves of the desmodromic shaft In the presence of damages scratches wear lines Replace the desmodromic shaft set the segment of the desmodromic shaft In the presence of damages wear Replace the desmodromic shaft set 1 ENG 1 A A B B ...

Page 430: ...ION 5 104 ENG 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 PRIMARY SHAFT SECONDARY SHAFT 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 NEW NEW NEW NEW NEW NEW NEW E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E E 16 ...

Page 431: ... Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Install the pieces in the given order NOTE Never use a used elastic ring When installing a new elastic ring careful not to stretch its ends more than necessary for it to be inserted on the shaft Once ...

Page 432: ... the neutral sensor before installing the gear change NOTE Check the presence of the oil conduct tube inside the carter ATTENTION Apply Ivori Sil Ac sealing paste on the gear change flange coupling plate being careful not to obstruct the oil passage hole NOTE Install the neutral sensor located in the rear part of the engine once the gear change has been installed NOTE Insert the engine oil once op...

Page 433: ...the two thicknesses of 0 2 mm each 1 Install the primary shaft the secondary shaft the spacer 1 A B D F E C E A B C E E D E F 56A48 Recommended lubricant ENGINE OIL E AREXONS SYSTEM 56A48 HIGH TEMPERATURE THREAD BRAKES 56A48 ATTENTION The gears are free Remove the shafts and simultaneously A B ...

Page 434: ... m T R T R 10 N m 1 01 Kgf m 4 Install the spring the washer the gears fixing jumper the threaded pin Torque fasten with 4 T R 10 N m 1 01 Kgf m 10 N m 1 01 Kgf m T R G G J H J H E LS E E E K K L L 52A43 I E E E H I J K L M N O P 52A43 P O N M Recommended lubricant ENGINE OIL E AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 ...

Page 435: ...tall the springs the pegs the jumpers the desmodromic sprocket the bush 6 6 NOTE During INSTALLATION of the desmodromic sprocket contrast the reaction of the springs located underneath the jumpers 5 2 A 4 3 R Q Q R S T U S T U V W E E E E E S T U V W S U Recommended lubricant ENGINE OIL E AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 V ...

Page 436: ...e washer the spacer the spring the pin the washer 8 8 N NOTE Do not force the spring cap too much during installation on the command shaft 52A43 X X Y Y Y Z A B D Z A B C D E E E E E E E B N NOTE Ensure that the washers and remain in position Z D Recommended lubricant ENGINE OIL E AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 C ...

Page 437: ...1 01 Kgf m T R T R 10 N m 1 01 Kgf m T R 10 N m 1 01 Kgf m Install the pinion the washer 10 10 E E F G G G GR E NOTE Before installing remove the grease from the broached using solvent F G H H I Recommended solvent TUTELA MOTOR CLEAN Recommended lubricant ENGINE OIL E Recommended lubricant COPPER GREASE GR I ...

Page 438: ...4 2 Kgf m T R 11 Install the nut keeping the pinion still with the special tool Special Tools PINION DISMANTLING TOOL Code R180297048000 3 8 3 8 J K J K 56A48 Torque fasten with AREXONS SYSTEM 56A48 HIGH TEMPERATURE THREAD BRAKES 56A48 ...

Page 439: ... Bush Oil Tank Gasket Inlet Filter Removal Screw Inlet Filter O Ring Gasket 5 113 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 1 1 1 2 1 10 1 2 1 2 1 1 Remove the pieces in the given order NOTE Drain the engine oil before carrying out the operations 6 8 7 8 1 2 11 9 12 3 4 5 10 10 ENG ...

Page 440: ...he oil tank In the presence of clinks damages Replace 1 1 Check the inlet filter In the presence of clinks damages Replace In the presence of deposits residues Accurately clean the filtering area using solvent 2 2 ENG A A A B B Recommended solvent TUTELA MOTOR CLEAN ...

Page 441: ...ERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 1 1 2 1 2 1 10 1 2 1 1 1 Install the pieces in the given order NOTE Insert the engine oil once operations have been completed 7 5 6 5 12 11 2 4 1 10 9 8 3 3 ENG T R 22 N m 2 24 Kgf m T R 10 N m 1 01 Kgf m T R 10 N m 1 01 Kgf m T R 10 N m 1 01 Kgf m NEW NEW NEW LS 5 2 A 4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 NEW NEW GR ...

Page 442: ...p Shaft 5 116 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 A 7 8 9 10 11 1 1 3 1 1 1 1 1 1 1 1 1 Remove the pieces in the given order NOTE Drain the engine oil before carrying out the operations See paragraph 5 69 See paragraph 5 71 See paragraph COOLING PLANT 6 15 NOTE To remove the pump hit the oil pump shaft on the water pump side with a rubber hammer 1 3 3 3 2 4 5 6 9 11 1...

Page 443: ...pump slot 2 1 2 Clearance between the internal rotor point and the rotor point 0 25 mm 0 0098 in Clearance between the external rotor and the oil pump slot 0 2 mm 0 0078 in Check the oil pump functioning Rotate gear Z34 as shown in the figure If the movement is not smooth Check the internal external rotor seat again In the presence of scratches damages Replace the faulty part s 3 3 NOTE This contr...

Page 444: ...18 Back Index SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 A 7 8 9 10 11 1 1 1 1 1 1 1 1 1 3 1 1 Install the pieces in the given order NOTE Insert the engine oil once having completed the operations 11 9 9 9 10 8 7 6 3 1 2 5 4 A PM S ENG T R 10 N m 1 01 Kgf m T R 10 N m 1 01 Kgf m 5 2 A 4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 E E E GR GR GR GR E E 3 4 A 2 5 ...

Page 445: ...Removal Over Pressure Valve Removal Over Pressure Valve Washer 5 119 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 1 1 Remove the pieces in the given order See paragraph 5 113 NOTE Drain the engine oil before carrying out the operations 1 2 ENG ...

Page 446: ...eck the pressure valve body the pressure valve the spring the washer In the presence of damages wear Replace the fault parts 1 1 N NOTE Abundantly and accurately lubricate the pressure valve ENG A B C D A A A B A C A D E Recommended lubricant ENGINE OIL E ...

Page 447: ...Over Pressure Valve 5 121 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 1 1 Install the pieces in the given order NOTE Insert the engine oil once operations have been completed 2 1 ENG NEW T R 25 N m 2 54 Kgf m 52 A 43 NEW 3 4 A 2 5 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 ...

Page 448: ... O Ring Gasket Male Joint Washer Nut Collar Rubber SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 3 1 1 1 1 1 4 Remove the pieces in the given order NOTE Drain the engine oil before carrying out the operations See paragraph 5 69 See paragraph 5 71 See paragraph 5 88 See paragraph COOLING PLANT 6 15 1 1 2 3 4 5 6 7 7 7 7 ENG ...

Page 449: ...P 5 123 ALTERNATOR CONTROL Check the clearance between the male joint and the alternator If out of specification Replace the part 1 1 2 Check the collar rubber In the presence of damages wear Replace 2 ENG A A ...

Page 450: ...SERVATIONS 1 2 3 4 5 6 7 4 1 1 1 1 1 3 Install the pieces in the given order 7 7 6 5 4 3 2 1 1 1 1 T R 45 N m 4 58 Kgf m ENG 5 6 A 4 8 Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER 56A48 LS LS NEW LS LS NEW 56A48 5 2 A 4 3 5 6 A 4 8 Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER 5 4 A 6 8 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 8 4 A 6 5 8 4 A 6 5 8 4 A 6 5 3 4 A 2 5 ...

Page 451: ...t Up Motor Removal Screw Complete Start up Motor Nut SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 2 1 1 Remove the pieces in the given order NOTE Drain the engine oil before carrying out the operations See paragraph 5 69 See paragraph 5 71 See paragraph 5 88 See paragraph COOLING PLANT 6 15 See paragraph 5 122 1 1 3 2 ENG ...

Page 452: ...TART UP MOTOR CONTROL Check the start up motor functioning If the start up motor turns with force Replace the part the O Ring gasket In the presence of damages pittings wear lines Replace the O Ring gasket 1 1 ENG A A ...

Page 453: ... INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 1 1 1 2 Install the pieces in the given order NOTE Lubricate the O Ring being careful not to damage it NOTE Insert the engine oil once operations have been completed 4 4 3 2 1 T R 10 N m 1 01 Kgf m ENG Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 NEW LS NEW LS 52A43 3 4 A 2 5 ...

Page 454: ...lined Shaft Removal Splined Shaft Z25 Gear SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 1 1 1 1 Remove the pieces in the given order NOTE Drain the engine oil before carrying out the operations See paragraph 5 69 See paragraph 5 71 See paragraph 5 88 See paragraph COOLING PLANT 6 15 See paragraph 5 122 NOTE Remove it using the special tool 1 2 3 4 5 ENG Special Tools ALTERNATO...

Page 455: ...INT CONTROL Check the female collar joint In the presence of damages wear Replace the splined shaft In the presence of torsions clinks wear lines Replace the Z25 gear In the presence of cracks damages round edges Replace the faulty gear 1 1 ENG A A B C B C ...

Page 456: ...TIONS 1 2 3 4 5 1 1 1 1 1 Install the pieces in the given order NOTE Insert the splined shaft respecting the phasing on the relative Z25 gear as shown in the figure NOTE Install it using the special tool NOTE Insert the engine oil once operations have been carried out 5 4 3 2 1 ENG 56A48 T R 50 N m 5 09 Kgf m Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER 56A48 8 4 A 6 5 8 4 A 6 5 56A48 Special Tool...

Page 457: ...aft Satellite Gear Female Collar Joint Removal Z25 Gear Splined Shaft Removal Free Wheel Unit Removal Complete Free Wheel SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 2 1 1 1 1 1 1 1 Remove the pieces in the given order NOTE Drain the engine oil before carrying out the operations See paragraph 5 69 See paragraph 5 71 See paragraph 5 88 See COOLING PLANT 6 15 paragraph See ...

Page 458: ...ear the needle cage the screws the flange the free wheel the free wheel hub 1 3 1 Check any breakages wear and slidings of the components of the free wheel If out of specification Replace the part 2 Check the satellite gear In the presence of damages lines wear Replace 2 A A B C D E F G H B C D E F G H I I ...

Page 459: ...RIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 1 1 6 1 1 1 1 1 1 1 1 1 2 1 Install the pieces in the given order NOTE Insert the engine oil once operations have been completed ENG 14 14 13 12 11 10 9 15 2 3 4 4 4 5 4 4 4 6 7 8 1 E 52A43 E E 52A70 0 7 A 2 5 3 4 A 2 5 0 7 A 2 5 E E E E E E E E Arexons SYSTEM 52A70 STRONG THREAD BRAKES 5 7 A 2 0 Arexons SYSTEM 52A43 MEDIUM THREAD BRA...

Page 460: ...HANDLING BASE LOWER BASE REMOVAL 5 134 ENG 2 3 1 3 5 4 15 15 15 15 15 12 12 17 8 8 8 8 18 14 9 10 13 13 17 10 11 17 15 15 15 6 7 6 16 ...

Page 461: ...OLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 1 2 1 1 2 1 8 1 2 1 2 2 1 8 1 3 1 Remove the pieces in the given order NOTE Drain the engine oil and the cooling liquid before carrying out the operations NOTE Operations to be carried out with the engine overturned See FRAME 4 107 paragraph See paragraph 5 69 See paragraph 5 71 See paragraph 5 113 See pa...

Page 462: ...der the sequence shown in the figure After having completely loosened all screws remove them the lower base 4 ATTENTION Hit one side of the base with a rubber hammer Only hit the reinforced parts of the base not the coupling surfaces Work slowly and carefully to ensure that the two halves of the base evenly separate Overturn the engine 2 Remove the screws the plate A B C C D E B D E F G F F G 6 2 ...

Page 463: ...NG 1 3 Scrupulously clean all coupling surfaces destined to welcome the sealing paste and the coupling surfaces of the base Check the lower base In the presence of cracks damages Replace the oil flow passages In the presence of obstructions Clean with a jet of compressed air Recommended solvent TUTELA MOTOR CLEAN ...

Page 464: ...HANDLING BENCH HALF BEARINGS ENGINE SHAFT AND BALANCING COUNTER SHAFT REMOVAL 5 138 ENG 1 4 2 UPPER BASE LOWER BASE 10 10 10 10 6 5 3 7 7 8 9 10 10 10 10 ...

Page 465: ...val Cap Engine Shaft Rollers Bearing Screw Plate Bearing Bench Half Bearings Removal Bench Half Bearing SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 1 1 1 1 1 1 2 1 1 8 Remove the pieces in the given order NOTE Drain the engine oil and the cooling liquid before carrying out the operations See FRAME 4 107 paragraph See paragraph 5 69 See paragraph 5 71 See paragraph 5 ...

Page 466: ...Bearings Removal Connecting Rods Removal Screw Connecting Rod Connecting Rod Half Bearings Removal Connecting Rod Half Bearing 5 140 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 6 3 6 Remove the pieces in the given order See FRAME 4 107 paragraph See paragraph 5 69 See paragraph 5 71 See paragraph 5 113 See paragraph 5 116 See COOLING PLANT 6 15 paragraph See paragraph 5 91 See para...

Page 467: ...vement is not correct Replace the Z34 command gear In the presence of damages wear lines Replace Measure the engine shaft eccentricity If out of specification Replace the engine shaft 3 4 Engine shaft eccentricity Lower than 0 03 mm 0 0011 in Check the bench supports surfaces the connecting rod supports surfaces In the presence of scratches wear lines Replace the engine shaft 4 0 90 80 70 60 50 40...

Page 468: ...ternal diameter Limit 19 040 mm 0 749 in Check the internal diameter of the connecting rod foot If out of specification Replace the connecting rod 2 Check the side clearance of the connecting rod using a feeler If out of specification Replace the connecting rod 3 3 Check the connecting rod head width the connecting rod pin width If out of specification Replace the connecting rod or the shaft engin...

Page 469: ...alf Bearing Connecting Rods Installation Connecting Rod Screw 5 143 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 6 3 6 Install the pieces in the given order NOTE Do not exceed with the copper grease ENG 3 3 3 3 3 3 2 2 2 2 2 2 1 1 1 1 1 1 T R 15 25 N m 50 1 52 2 54 Kg m 50 GR E GR GR NEW GR NEW GR GR GR GR GR GR E ...

Page 470: ...NGS AND CONNECTING RODS INSTALLATION Install the connecting rod half bearings Clean the bearings of the connecting rod heads the connecting rod supports and the internal part of half of each connecting rod Install the upper bearing of the connecting rod head inside the connecting rod and the lower bearing of the connecting rod head inside the connecting rod cap 1 Select the connecting rod half bea...

Page 471: ...d head S Select the class marked on the connecting rod head 3 K4 C 102600 SELECTION TABLE TYPE K1 K2 K3 K4 K5 COLOUR Black Green White Brown Orange WEIGHT g 412 416 396 400 400 404 404 408 408 412 Install the screws 4 C T R 15 25 N m 50 1 52 2 54 Kgf m 50 C C 15 25 N m 50 1 52 2 54 Kgf m 50 T R Torque fasten GR NEW ...

Page 472: ...HAFT AND BENCH HALF BEARINGS INSTALLATION 5 146 ENG 10 7 9 UPPER BASE LOWER BASE 1 5 6 8 4 4 3 2 1 1 1 1 1 1 1 10 N m 1 01 Kgf m T R GR GR E Arexons SYSTEM 52A70 STRONG THREAD BREAKS 52A70 5 2 A 7 0 YVORI SIL AC YVORI SIL AC E GR GR E E GR GR ...

Page 473: ...ine Shaft Installation Engine Shaft Cap Balancing Counter Shaft Installation Balancing Counter Shaft Seal Ring Cap SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 8 1 1 2 1 1 1 1 1 1 Install the pieces in the given order NOTE Insert the engine oil and the cooling liquid once the operations have been completed GR GR E E E 0 7 A 2 5 YVORI SIL AC YVORI SIL AC ...

Page 474: ...e half bearings Rest the upper base overturned on to the work bench Install the bench half bearings in the bench supports seats and the engine shaft in the upper base HANDLING 5 148 ENG 1 Install the lower half bearings of the bench supports in the lower base 1 2 2 ATTENTION Do not exchange the bench half bearings between them To obtain the correct clearance between the bench support surface and t...

Page 475: ...l plate the screws the roller bearings BENCH HALF BEARING ST THICKNESS COLOUR 41 830 41 836 41 836 41 843 41 843 41 849 37 960 37 970 A B C Red Blue Yellow 1 918 1 922 1 922 1 926 1 926 1 930 Ø std A seat red Ø std B seat blue Ø std C seat yellow Ø std single seat 1 2 3 4 A C C B E G H 10 N m 1 01 Kgf m T R Torque fasten with G F E H T R 10 N m 1 01 Kgf m E 5 2 A 7 0 E Recommended lubricant ENGINE...

Page 476: ...gwheels of the balancing counter shaft and of the engine shaft are in phase as shown in figure J J K K L L 8 7 E E YVORI SIL AC YVORI SIL AC 5 Install the engine shaft I I 5 GR GR GR GR Recommended lubricant ENGINE OIL E Recommended lubricant COPPER GREASE GR Recommended paste TUTELA PROFESSIONAL IVORY SIL AC YVORI SIL AC L ...

Page 477: ...ENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 1 3 1 8 1 2 1 2 2 1 8 Install the pieces in the given order NOTE Apply copper grease on all screws NOTE Install the respective washers first NOTE Install the respective washer first NOTE Insert the engine oil and the cooling liquid once the operations have been completed 3 2 9 GR GR GR GR GR GR GR GR GR YVORI SIL AC YVORI SIL AC GR GR GR...

Page 478: ...holes A the sealing paste on to the contact surface as shown in the figure Apply 2 N NOTE Hit the reinforced parts of the base with a rubber hammer perfectly coupling the two half carter as shown in figure A A B B B 3 YVORI SIL AC YVORI SIL AC YVORI SIL AC YVORI SIL AC YVORI SIL AC YVORI SIL AC YVORI SIL AC YVORI SIL AC YVORI SIL AC YVORI SIL AC Recommended paste TUTELA PROFESSIONAL IVORY SIL AC Y...

Page 479: ...HASE 10 N m 1 01 Kgf m 2nd PHASE 24 5 N m 2 49 Kgf m 17 25 1st PHASE 10 N m 1 01 Kgf m 1 3 7 22 8 4 9 10 16 25 23 24 11 13 12 2 6 5 14 15 17 18 19 21 20 Install the counter shaft lid gasket the counter shaft lid the screws the screw the screw 6 6 5 5 Install the plate the screws C B B 10 N m 1 01 Kgf m T R Torque fasten with T R 10 N m 1 01 Kgf m C C G F H F E D D E G 10 N m 1 01 Kgf m T R Torque ...

Page 480: ...PPLY THROTTLED BODY REMOVAL Throttled Body Removal Screw Throttled Body O Ring Gasket 5 154 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 6 1 3 Remove the pieces in the given order ENG 2 3 3 3 1 1 ...

Page 481: ...h the balancing 2 Correct the alignment values by acting on the pair screws and with a screwdriver Align body 1 with body 2 by acting on the pair screw Align body 2 with body 3 by acting on the pair screw 3 A 2 N NOTE Ensure that the bypass screws of bodies 1 2 3 are completely closed B A A A B B B 3 C D C D C D 3 2 1 2 1 3 4 1 N NOTE Having reached an optimal alignment on the 3 bodies it is possi...

Page 482: ...LLATION Throttled Body Installation O Ring Gasket Throttled Body Screw 5 156 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 3 1 6 Install the pieces in the given order ENG 2 1 1 1 3 3 NEW LS E T R 10 N m 1 0 Kgf m E LS NEW ...

Page 483: ...COOL 6 ...

Page 484: ...L DISTRIBUTOR REMOVAL OIL DISTRIBUTOR CONTROL OIL DISTRIBUTOR INSTALLATION THERMOSTAT THERMOSTAT REMOVAL THERMOSTAT CONTROL THERMOSTAT INSTALLATION WATER PUMP WATER PUMP REMOVAL WATER PUMP CONTROL WATER PUMP INSTALLATION WATER COLLECTOR WATER COLLECTOR REMOVAL WATER COLLECTOR CONTROL WATER COLLECTOR INSTALLATION 1 1 3 4 6 6 7 9 9 10 11 12 12 13 14 15 15 17 18 21 21 22 23 COOL ...

Page 485: ...COOL ...

Page 486: ...eeve Screw Strip Deformable Strip Radiator Sleeve Right Engine Sleeve SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1 Remove the pieces in the given order NOTE Drain the cooling liquid before carrying out the operations See FRAME 4 120 paragraph See FRAME 4 112 paragraph See FRAME 4 120 paragraph 1 3 3 4 6 2 5 7 8 9 10 10 11 1...

Page 487: ...SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 2 2 2 1 6 6 2 8 2 2 2 1 1 2 1 Disconnect the electric fans n 22 NOTE Careful when removing the spacers when installing place them in the correct sequence COOL 1 3 3 4 6 2 5 7 8 9 10 10 11 12 13 14 15 16 16 17 18 17 18 19 20 20 21 21 21 21 23 30 23 22 22 23 23 23 24 27 26 25 29 24 28 26 25 29 ...

Page 488: ...diator flexible tubes the radiator piping In the presence of cracks damages Replace 3 N NOTE Straighten the eventually crushed flaps using a flat head thin screwdriver 1 COOL RADIATOR CONTROL Check the radiator flaps In the presence of obstructions Clean Apply a jet of compressed air on the rear part of the radiator In the presence of damages Repair or replace ...

Page 489: ...OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 1 1 2 2 2 6 8 2 6 1 2 2 2 1 1 2 Install the pieces in the given order NOTE Carefully place them in the correct sequence carry out the operations in reverse order to removal Manually fasten Connect the electric fans 10 NOTE Change them only if worn 30 28 28 27 25 29 26 24 23 22 19 19 16 20 21 17 18 15 15 14 13 14 13 12 11 11 8 8 8 8 9 1 ...

Page 490: ...BOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 19 20 21 22 23 24 25 26 27 28 29 30 2 1 1 1 1 1 1 1 1 2 1 1 Install the pieces in the given order NOTE Insert the cooling liquid once operations have been completed 30 28 28 27 25 29 26 24 23 22 19 19 16 20 21 17 18 15 15 14 13 14 13 12 11 11 8 8 8 8 9 1 9 10 10 9 9 9 5 4 6 7 2 5 3 6 7 2 COOL LS LS NEW NEW NEW T R 10 N m 1 01 Kgf m T R 10 N m 1 01 Kg...

Page 491: ...Strip Water Tube Exchanger Input Tube SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 1 1 2 2 1 1 1 2 2 1 Remove the pieces in the given order NOTE Drain the cooling liquid before carrying out the operations NOTE The click strips can be re used for the installation being careful during the dismantling phase 1 4 3 5 3 4 2 6 9 8 10 8 9 7 COOL ...

Page 492: ...Outlet Tube Water Tube Click Strip Click Strip Click Strip SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 1 2 2 1 1 1 2 2 1 1 Install the pieces in the given order NOTE Unless worn re use the removal click strips otherwise change them NOTE Insert the cooling liquid once operations have been completed 10 7 8 6 8 7 9 5 2 3 1 3 2 4 COOL ...

Page 493: ...ing system In the presence of leaks Repair or replace the faulty parts COOL COOLING CIRCUIT INSTALLATION Fill the cooling system with the specified amount of recommended cooling liquid See paragraph ROUTINE INSPECTIONS AND ADJUSTMENTS 3 44 ...

Page 494: ...Seal Ring 6 9 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 8 9 10 11 1 2 1 1 1 1 2 1 1 1 1 Remove the pieces in the given order See FRAME 4 120 paragraph See FRAME 4 155 paragraph NOTE Drain the engine oil and the cooling liquid before carrying out the operations NOTE Remove the oil filter using the tool specific for the removal and installation of oil filters 2 3 1 4 5 6 10...

Page 495: ...RIBUTOR 6 10 OIL DISTRIBUTOR CONTROL Check the oil distributor In the presence of clinks damages Replace the flow and outlet flexible tubes In the presence of cracks damages wear lines Replace 1 1 A A B B COOL ...

Page 496: ...s in the given order NOTE Accurately remove grease from the thread of the special screw NOTE Install the oil filter using the tool specific for the removal and installation of oil filters NOTE Insert the engine oil and the cooling liquid once the operations have been completed 10 9 11 8 7 6 2 1 4 3 5 T R 10 N m 1 01 Kgf m T R 30 60 N m 3 05 6 11 Kgf m L O C T I T E T R 20 N m 2 03 Kgf m Arexons SY...

Page 497: ...r Outlet Tube Screw Thermostat disk O Ring Gasket Thermostat 6 12 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 2 1 1 1 Remove the pieces in the given order NOTE Drain the cooling liquid before carrying out the operations 2 1 4 5 2 3 COOL ...

Page 498: ...r Place a thermometer in the water Mixing the water keep an eye on the thermostat and the temperature shown on the thermometer When the temperature of 75 C is reached the thermostat valve starts to open reaching a temperature of 90 C The thermostat valve reaches an opening of at least 7 mm A B N NOTE If in doubt on the precision of the thermostat replace it A faulty thermostat can cause significan...

Page 499: ...TERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 1 1 2 1 Install the pieces in the given order NOTE Install the thermostat with the vent hole facing upwards NOTE Insert the cooling liquid once operations have been completed 4 5 2 1 4 3 A T R 10 N m 1 01 Kgf m NEW NEW 52A43 3 4 A 2 5 LS Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 LS A COOL ...

Page 500: ...rip Water Flow Tube Water Return Tube Screw Water Pump 6 15 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 1 1 2 1 1 2 1 Remove the pieces in the given order NOTE Drain the cooling liquid before carrying out the operations 6 6 7 3 3 4 1 5 2 COOL ...

Page 501: ... O Ring gasket the centring bushes 5 Remove the internal seeger the external seeger the bearing the spacer the bearing the seal ring 2 2 Remove the cap nut the seal washer the water pump impeller the O Ring gasket 3 3 4 4 Remove the mechanical seal the back the water pump shaft A A B D C B C E F G I J K L M N O P Q R T V E G F H I I J K L M N O P Q R S T U V COOL D H S U ...

Page 502: ...anical seal the back In the presence of damages cracks wear lines Replace 1 1 Check the gaskets the seal washer the spacer the seegers the seal ring In the presence of damages cracks wear lines Replace 2 2 Check the bearings If the movement is not smooth Replace 3 3 A A B C D E F G H I J K B C D E F G H I J K COOL ...

Page 503: ...Q SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 6 7 1 2 1 1 2 1 1 Install the pieces in the given order NOTE Insert the cooling liquid in the circuit once operations have been completed 3 4 A 2 5 3 4 A 2 5 E 2 2 1 5 5 4 7 3 6 T R 10 N m 1 01 Kgf m 5 2 A 4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 5 2 A 4 3 E COOL ...

Page 504: ...3 N NOTE Lubricate the water pump shaft as shown in the figure before installing it N D NOTE During installation of the back and of the mechanica seal ensure they are clean and that there are no traces of grease 8 N m 0 81 Kgf m T R B A E A B C D E F G E E LS D F G H I J K L T R 8 N m 0 81 Kgf m 3 4 A 2 5 L K J I H COOL Recommended lubricant ENGINE OIL E Recommended lubricant ENGINE OIL E AREXONS ...

Page 505: ...entring bushes the O Ring gasket the water pump body the water pump lid the O Ring gasket the screws Torque fasten the 2 screws with 10 N m 1 01 Kgf m T R T R 10 N m 1 01 Kgf m NEW LS 52A43 NEW LS M N O P Q R P N M M O Q R COOL AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 Recommended lubricant TUTELA MR2 GREASE LS AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 Recommended lubricant TUTELA MR2 ...

Page 506: ...rip Water Tube Screw Water Collector Water Collector Gasket 6 21 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 1 3 1 1 Remove the pieces in the given order NOTE Drain the cooling liquid before carrying out the operations See ENGINE 5 122 paragraph 3 3 3 4 1 2 5 COOL ...

Page 507: ...WATER COLLECTOR 6 22 WATER COLLECTOR CONTROL Check the water collector In the presence of damages breaks Replace 1 1 A A COOL ...

Page 508: ...ater Tube Strip 6 23 SQ SYMBOLS INTERVENTION DESCRIPTION Q TY OBSERVATIONS 1 2 3 4 5 1 1 3 1 1 Install the pieces in the given order NOTE Insert the cooling liquid once operations have been completed 3 3 3 2 5 4 1 T R 10 N m 1 01 Kgf m NEW LS 5 2 A 4 3 Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 52A43 NEW 3 4 A 2 5 LS COOL ...

Page 509: ...ELEC 7 ...

Page 510: ...BODIES UNIT POTENTIOMETER NEUTRAL SWITCH SIDE TRESTLE SENSOR CLUTCH SWITCH FRONT BRAKE SENSOR SPEED SENSOR BAROMETRIC PRESSURE SENSOR LAMBDA PROBE FALL SENSOR HYDROSTOP OIL PRESSURE SENSOR AMBIENT TEMPERATURE SENSOR DEVICES DEVICES POSITION SYSTEM DEVICES HORN EQUIPMENT IGNITION SWITCH MAP BUTTON RIGHT ELECTRIC DEVICE LEFT ELECTRIC DEVICE DIODE 1 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 18 1...

Page 511: ...THE THROTTLE UNIT POTENTIOMETER WALBRO ECU 1 IGNITION REEL WALBRO ECU 1 TEMPERATURE SENSOR OF THE COOLING LIQUID WALBRO ECU 1 AIR TEMPERATURE SENSOR WALBRO ECU 1 FUEL PUMP WALBRO ECU 1 SENSOR POWER SUPPLY VOLTAGE WALBRO ECU 1 BAD FUNCTIONING OF THE ENGINE DIAGNOSIS WARNING LIGHT LAMP MIL WALBRO ECU 1 COOLING VENT WALBRO ECU 1 START UP SYSTEM DIAGNOSTICS ELECTRIC PART FRAME ELECTRIC PLANT ELECTRIC ...

Page 512: ...ELEC ...

Page 513: ...or all engine speeds and loads Furthermore the system has hardware diagnostics functions compliant with the requirements of the State of California USA for on board diagnostics This function assures that in case of a fault in the system the type of fault and engine data at the time of the fault are stored in the ECM memory This stored data can be recovered by a Benelli dealer using an appropriate ...

Page 514: ...ensor Potentiometer Fall Sensor a c e b d Phase Sensor Hydrostop Neutral Switch Oil Pressure Sensor Speed Sensor f h j g i Ambient Temperature Probe Air Temperature Sensor Barometric Pressure Sensor Clutch Switch Cooling Liquid Temperature Sensor k m o l n a e f g h i j k l n o m ELEC ...

Page 515: ...mpliant with the clean combustion and low emissions Remove the fixed cap See FRAME 4 110 paragraph the equipment support See paragraph ROUTINE INSPECTIONS AND ADJUSTMENTS 3 89 Disconnect the inlet air temperature sensor Loosen the nut Check the resistance using the multitester Placed underneath the on board equipment dashboard SENSORS 7 3 ELEC 1 2 3 DATA OF RESISTANCE TO THE TYPICAL CONDITIONS 30 ...

Page 516: ...8 teeth equally distant next to a space of three times the length The reading interpretation is used by the ECM to determine the position of the engine shaft compared to the point where the fuel is injected and to the need for fuel ignition Remove the screw Check the distance between phase sensor and phonic wheel ELEC 1 2 1 A A Distance between phase sensor and phonic wheel 1 mm 0 039 in Check the...

Page 517: ...ID P The information of the cooling liquid temperature received by the ECM is used to optimise the power supply at all engine temperatures and to calculate the power supply requirement upon cold and hot start ups Placed on the right side of the cylinder head ELEC 1 RESISTANCE DATA TO THE TYPICAL CONDITIONS 20 C 10 C 0 C 2 35 a 2 65 KΩ 3 60 a 4 00 KΩ 5 60 a 6 25 KΩ AMBIENT TEMPERATURE RESISTANCE VA...

Page 518: ...ultitester positioned on symbol Ω between PIN 1 and PIN 3 the more external PINs 2 POSITION SENSOR OF THE THROTTLE BODIES UNIT POTENTIOMETER Placed on the right end of the small shaft of the throttle bodies unit The throttle bodies unit position sensor potentiometer managed and powered directly by ECM supplies a signal that identifies the throttle opening position used by the same ECM to determine...

Page 519: ... box The neutral switch indicates when the gear change is in neutral Furthermore the neutral switch supplies a signal relating to the safety device that prevents start up with the trestle lowered and the gear engaged IF a gear is engaged with the trestle lowered power supply to the ECM is interrupted causing the engine to switch off In case of no continuity between the wire of the neutral sensor a...

Page 520: ...placed in neutral or the stand in closed position Placed at the top of the side trestle shank Disconnect the connector of the side trestle switch Measure the continuity using a multitester If the above conditions are satisfied the stand switch functions otherwise replace the component 2 3 PIN 2 PIN 1 STAND Lifted Lowered ...

Page 521: ... otherwise replace the component CLUTCH SWITCH Placed on the clutch lever The engine will not start until the lever is pulled up to the handle bar U Use the tester and check on the clutch switch pins the table Disconnect the clutch switch cables 2 1 PIN 2 PIN 1 CLUTCH Pulled Released ...

Page 522: ...ntinuity diode trial function and check the functioning as shown in the table Disconnect the contacts of the electric plant on the sensor proceed as shown for the control 2 1 PIN 2 PIN 1 SENSOR Pulled Brake Lever Brake Lever Released FRONT BRAKE SENSOR Placed on the front brake pump It is a switch in contact with the brake lever used for switching on the stop lights ...

Page 523: ...ctor of the speed sensor wire 1 Remove the two screws the speed sensor 2 Connect a 12V battery between pin1 and pin2 a 10kΩ resistance between pin2 and pin3 the multitester probe with pin2 and probe with pin3 as shown in the figure If a screwdriver touching the speed sensor surface is moved when in the above specified conditions the voltage indicated by the tester changes 0V 12V or 12V 0V If the v...

Page 524: ...ce the part 1 2 BAROMETRIC PRESSURE SENSOR Inside the control unit The atmospheric pressure is detected by means of a sensor placed inside the injection module This sensor enables the detection of the air density in different environmental conditions which for example the use of the vehicle in areas having different heights With this information the amount of fuel for the injector is calibrated ad...

Page 525: ...the ratio between air and petrol where Value 1 when combustion is stoichiometric of 1 when petrol is in excess of 1 when air is in excess The probe then transmits as electric signal to the control unit that adjusts the inflow of fuel and air inside the combustion chamber C Check the resistance with the multitester positioned on symbol Ω between PIN 1 and PIN 5 the more external PINs 1 Resistance 9...

Page 526: ...S AND ADJUSTMENTS 3 10 paragraph 1 Disconnect the connector of the fall sensor 2 FALL SENSOR Placed in the centre of the bike in correspondence with the expansion vessel In case of fall it interrupts the flow of petrol to the injection system If the above conditions are satisfied the fall sensor functions otherwise replace the component PIN 2 PIN 1 FALL SENSOR Position Horizontal Position Vertical...

Page 527: ... the above conditions are satisfied the hydrostop functions otherwise replace the component PIN 2 PIN 1 BRAKE Calibrated Released HYDROSTOP Placed on the rear brake pump It is a switch that works by reading the oil pressure exercised on the pump It is used to switch on the stop lights MULTIMETER 0 1 0 2 0 3 0 1 2 1 ...

Page 528: ...e regulator with inflow on the detection hole Calibrate the air pressure regulator at 2 bar Progressively lower the pressure until 0 4 0 7 bar are reached In case of no continuity between PIN1 and engine mass replace the component 2 OIL PRESSURE SENSOR Placed on the lower half carter It measures the oil pressure in ball bearing gallery Continuity between PIN1 and mass 0 4 0 7 bar ...

Page 529: ... 2 3 AMBIENT TEMPERATURE SENSOR Placed near the equipment It reads the ambient temperature and sends the value to the equipment Check the continuity with the multitester positioned on PIN 1 and PIN 2 and check the table If the above conditions are satisfied the lambda probe functions otherwise replace the component TOLLERANCE Ω C 5 10 25 40 21 K 19 K 10 K 6 K 0 5 K 0 5 K 0 5 K 0 5 K ...

Page 530: ...DEVICES 7 18 DEVICES POSITION b c Right Electric Device Left Electric Device a b Ignition Switch Map Button c d Horn Equipment Diode e f g e d a ELEC g f ...

Page 531: ...he right tank fairing The horn is an electric mechanic device used as acoustic warning device R Disconnect the wires of the acoustic warning device Connect PIN1 and PIN2 to the battery and check functioning Remove the fixing screw on the frame DEVICES 7 19 ELEC 1 2 3 ...

Page 532: ...revs counter It indicates the number of engine revolutions per minute alarm LED It switches on when the oil pressure value or that of the cooling temperature or that of the battery voltage is incorrect possibility of more anomalies occurring simultaneously In case it switches on check with reference to the type of alarm communicated H O BAT OIL the cause or nature of the relative signalling Remove...

Page 533: ...e the seat See FRAME 4 130 paragraph the right and left tank lids See FRAME 4 112 paragraph the tank See FRAME 4 118 paragraph the steering lock lid See FRAME 4 112 paragraph the air filter box See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 10 paragraph the conveyor See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 10 paragraph Disconnect the key lock wiring Remove the two fixing pull screws on the trellis DEV...

Page 534: ...be removed Key at OFF position All electric circuits are deactivated The key can be removed Key at LOCK position All electric circuits are deactivated and the steering wheel is locked The key can be removed Key at PARKING position All electric circuits are deactivated except for the parking lights position lights and the steering wheel is locked The key can be removed PIN 4 PIN 3 PIN 2 PIN 1 Key O...

Page 535: ... pressed the map loaded on block 2 button state 1 contact closed is selected Remove the cap See FRAME 4 110 paragraph the equipment support See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 89 paragraph Disconnect the map button wiring Check the continuity between n 4 and n 5 between n 1 and n 6 with button pressed Check the continuity between n 4 and n 2 between n 1 and n 3 with button released DEVICES 7...

Page 536: ...Check the connections must be reported as shown in the table Brown Red Purple Black Purple Green Black Brown Red Brown Red DEVICES 7 24 ELEC 4 4 1 8 5 4 JUMPER 3 7 1 4 5 8 3 7 ...

Page 537: ... with the multitester position on RUN OFF button placed at ON Check the continuity with the multitester positioned on the start up button at ON Check the continuity with the multitester positioned on the emergency lights switch at ON DEVICES 7 25 ELEC 1 2 3 A B C A B C If the above conditions are satisfied the emergency lights switch the Run Off button and the start up button function otherwise re...

Page 538: ... button pressed Check the continuity with the multitester positioned on the relative terminals with the flash button pressed Check the continuity with the multitester positioned on the relative terminals with reference to the selection right left Check the continuity with the multitester positioned on the relative terminals with reference to the selection high beam dipped beam DEVICES 7 26 ELEC 1 ...

Page 539: ...ion with terminal positive on PIN2 and with terminal negative on PIN1 and then on PIN3 DEVICES 7 27 ELEC 1 1 2 MULTIMETER 0 1 0 2 0 3 0 1 2 3 1 2 3 2 MULTIMETER 0 1 0 2 0 3 0 1 2 NEUTRAL SENSOR DIODE MODULE The device can be identified by the number of insertions present on the relative connector 2 PIN Check the continuity with the multitester positioned on symbol continuity diode trial function w...

Page 540: ...TORS 7 28 ACTUATORS POSITION b e Fuel Pump Stepper Alternator Remote Control Switch a b Ignition Reels Injectors Start up Motor e f f f g Injection Relay Cooling Vent Solenoid h i ij h f a i ELEC c d c d g j ...

Page 541: ...ibutor the stepper AIR AT MINIMUM CONTROL SYSTEM STEPPER Located inside the air filter box The system includes a valve for controlling the air passage underneath the throttles of the throttled body and equipped with a step by step engine stepper The system controls the following parameters Functioning at minimum Air supply in case of engine overrevving Correction of the air fuel ratio working at m...

Page 542: ...ACTUATORS 7 30 ELEC Check the resistance with the multitester positioned on symbol Ω between PIN1 and PIN4 and then between PIN2 and PIN3 2 Resistance 50 5 Ω 1 3 2 4 2 ...

Page 543: ...le The duration of each injection is calculated by the ECM according to the data received by the various system sensors Remove the seat See FRAME 4 130 paragraph the right and left tank lids See FRAME 4 112 paragraph the tank See FRAME 4 118 paragraph the air filter box See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 10 paragraph the 2 flute screws the flute the injectors retainer clips the injectors A ...

Page 544: ...ACTUATORS 7 32 ELEC Check the resistance with the multitester positioned on symbol Ω between PIN1 and PIN2 2 Resistance 12 2 Ω 2 MULTIMETER 0 1 0 2 0 3 0 1 2 ...

Page 545: ...ector is inside the head BERU the connector is wired C Check the resistance with the multitester positioned on symbol Ω between PIN1 and PIN2 This check is valid for both types of reels 2 Resistance 0 6 0 1 Ω Remove the seat See FRAME 4 130 paragraph the right and left tank lids See FRAME 4 112 paragraph the tank See FRAME 4 118 paragraph the air filter box See ROUTINE INSPECTIONS AND ADJUSTMENTS ...

Page 546: ...e 2 COOLING VENTS Placed on the radiator body The ECM activates and deactivates the cooling vents according to a signal received from the cooling liquid temperature sensor When the cooling liquid temperature reaches the upper threshold temperature the cooling vents activate by means of a command from the ECM When the cooling liquid temperature drops sufficiently lower threshold temperature the coo...

Page 547: ...uaranteeing from the first activation of the board with a timed function the correct fuel pressure necessary for engine start up and with a continuous functioning for the subsequent normal use of the vehicle Place the outlet tube inside a container to drain the petrol Connect the battery 12 V to the petrol pump PIN1 positive cable PIN2 negative cable a b c Check the resistance with the multitester...

Page 548: ... to the relative conditions which ignition switch off and relative use of the vehicle through this management it is possible to guarantee a stable power supply to the ECM allowing it to carry out the correct memorising and setting of the parameters procedures during the stop phases continuing to self power for a few seconds after board switch off the services All under lock and key devices like th...

Page 549: ...Green REEL Yellow White POWER Yellow White POWER Orange White HIGH BEAMS RELAY POWER Red Black INJECTION RELAY ELECTRIC FANS RELAY PETROL PUMP RELAY POWER Red White REEL Red Black REEL Brown Purple POWER Orange Green POWER White Black REEL Brown REEL White Black POWER Orange POWER Orange Black REEL Brown REEL Orange Black ...

Page 550: ...nnector Remove the start up relay 1 2 Check the winding if it is open or at mass and if there is resistance The winding is in good conditions if the resistance is 4 Start up relay resistance 3 6 Ω Apply 12 volt to the terminals and Check the continuity between the power terminals as shown in the figure If there is continuity the start up relay is in good conditions 3 WARNING Do not apply the batte...

Page 551: ...2 paragraph the tank See FRAME 4 118 paragraph the air filter box See ROUTINE INSPECTIONS AND ADJUSTMENTS 3 10 paragraph Disconnect the cable connected to the drain valve Remove the two screws 1 2 Reel resistance 3 6 Ω Absorbed Current 8 7 1 A Measure the reel impedance with the multitester positioned on symbol between PIN1 PIN 2 as shown in the figure Measure the current absorbed by the solenoid ...

Page 552: ...k that it is correctly positioned as shown in the figure Even if only one control results negative replace the part 4 ATTENTION At every inspection of the solenoid device check the integrity of the contacts and the functioning of the diode 4 ...

Page 553: ...echarging of the battery Switch on the bike Measure the voltage with the multitester positioned on symbol at the ends of the battery 1 2 With bike switched off 12 7 0 5 V With bike revving up at 3 000 rpm 13 5 0 5 V 2 MULTIMETER 0 1 0 2 0 3 0 If the above conditions are satisfied the alternator functions otherwise replace the component ...

Page 554: ...rt check the right electric block See paragraph 7 25 the clutch switch See paragraph 7 9 If the motor still does not start carry out the following check Remove the start up motor See ENGINE 5 125 paragraph Lock the start up motor in a vice Carry out the connections as shown in the figure and check the correct functioning 1 2 3 3 ...

Page 555: ... Code R180197036000 AXONE Code R300082003000 BENDIA A Diagnostic software able to identify the faults present or that have occurred on the bike is included in the special equipment This Software has a guide manual for using the same program in order to perform the control on every individual system component DIAGNOSTICS 7 43 S C A N T O O L ELEC ...

Page 556: ...connector has 24 pins arranged on three rows numbered A B and C and on eight columns as shown at the side The first column is called 1 and the eighth column 8 The position of each ECM connector is described through this manual through the identification of connector 1 black or 2 grey followed by the row number and the column number where it is situated In the example at the side pin 6 B is shown b...

Page 557: ...s in short circuit pin 1 BI of ECM to the mass pin 1 CI of ECM to the mass pin 2 B8 of ECM to the mass Ok Proceed with test 7 Short circuit Locate and repair the wiring fault proceed with test 7 Proceed with test 4 2 Check the value of the safety relay white red resistance pin 1 RO BI of ECM to pin 1 C1 of ECM injector 2 pin 1 RO BI of ECM to pin 1 B1 of ECM injector 1 pin 1 RO BI of ECM to pin 2 ...

Page 558: ...engine to check the fault has been eliminated Ok Activity Performed end the test The fault remains Contact Benelli after sales assistance Locate and repair the cables fault proceed with test 7 5 Check the continuity of the cable for short circuit pin 1 RO BI of ECM to pin 1 B1 of ECM injector 1 pin 1 RO BI of ECM to pin 1 C1 of ECM injector 2 pin 1 RO BI of ECM to pin 2 B8 of ECM injector 3 Ok Pro...

Page 559: ...able is in short circuit pin 1 B7 of ECM to pin 1 B5 of ECM pin 1 B7 of ECM to pin 1 B3 of ECM Ok Replace the position sensor of the throttle bodies unit proceed with test 5 Short circuit Locate and repair the wiring fault proceed with test 5 3 Check the continuity of the cable pin 1 B3 of ECM to pin 3 of sensor pin 1 B7 of ECM to pin 2 of sensor pin 1 B5 of ECM to pin 1 of sensor Ok Proceed with ...

Page 560: ...eel 1 pin 2 A1 of ECM ignition reel 3 0 8 Ω Disconnect the relative reel and proceed with test 3 Open circuit Disconnect the relative reel and proceed with test 5 Short circuit RESULT PRECAUTION LOCATION TEST FAULT CODE P1351 52 53 Open or short circuit 2 1 3 ignition reel Ensure that the connector of the relative ignition reels is inserted correctly Disconnect the ECM and proceed with the locatio...

Page 561: ... Ok Proceed with test 5 Short circuit Locate and restore the wiring fault proceed with test 7 5 Check the cable for short circuit pin 1 C6 to mass Ok Proceed with test 7 Short circuit Locate and repair the wiring fault proceed with test 7 3 Check the continuity of the cable pin 1 C6 of ECM to pin 2 of sensor pin 1 B2 of ECM to pin 1 of sensor Ok Proceed with test 5 Ok Disconnect the temperature se...

Page 562: ...B2 of ECM Ok Proceed with test 5 Short circuit Locate and restore the wiring fault proceed with test 7 6 Check the cable for short circuit pin 1 C5 of ECM to the mass Ok Proceed with test 7 Short circuit Locate and repair the wiring fault proceed with test 7 3 Check the continuity of the cable pin 1 C5 of ECM to pin 2 of sensor pin 1 B2 of ECM to pin 1 of sensor Ok Proceed with test 5 Ok Disconnec...

Page 563: ...1 H1 to pin 2 of fuel pump pin 1 of fuel pump 12 vDC with ignition key in position on Ok Proceed with test 4 Open circuit RESULT PRECAUTION LOCATION TEST FAULT CODE P1231 Open or short circuit to the mass Check if the pump activates briefly when ignition is activated Ensure that the pump connector is inserted correctly Disconnect the ECM and proceed with the location 1 test P1232 Short circuit to ...

Page 564: ... P1601 Open or short circuit to the mass Ensure that the warning light lamp connector is correctly inserted and that the bulb is operational Replace if faulty Disconnect the ECM and proceed with the location 1 test P1602 Short circuit to positive pole battery Disconnect the warning light lamp and proceed with test 4 POSSIBLE CAUSE PRECAUTION BAD FUNCTIONING OF THE ENGINE DIAGNOSIS WARNING LIGHT LA...

Page 565: ...es fault proceed with test 5 4 Check the cable for short circuit pin 2 A4 of ECM to pin 1 RO BI injection relay of ECM Ok Proceed with test 5 Short circuit Locate and repair the cables fault proceed with test 5 3 Check the continuity of the cable Vent cable with electric fans of ECM Ok Proceed with test 4 Open circuit RESULT PRECAUTION LOCATION TEST FAULT CODE P1552 Open or short circuit to the ma...

Page 566: ...h Faulty connector contact Open circuit in wiring Faulty fuse Faulty start up motor Battery discharged Faulty start up relay Start up motor wire loose disconnected or interrupted Check the presence of 12V on the relay connector when the start up button is pressed Check the start up relay Faulty start up relay Faulty start up relay contact no voltage The click is heard the motor turns The click can...

Page 567: ...S NOT START Check the neutral sensor Faulty neutral sensor Open circuit in wiring Faulty connector contact Faulty diode module Faulty side trestle switch Open circuit in wiring Faulty connector contact Check the side trestle switch incorrect correct incorrect correct ...

Page 568: ...ty key switch connection Burnt lamps Faulty lamps connections Faulty lights switch Faulty lights switch connection Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore HIGH BEAMS DIPPED BEAMS LIGHTS INDICATORS Front rear position lights do not work High beams dipped beams lights do not work Rear stop light does not work Rear stop light remains on ...

Page 569: ...g light Faulty dashboard Faulty dashboard connection Faulty dashboard Faulty dashboard connection Burnt warning light Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore Replace dashboard Replace Deoxidise Restore Replace dashboard Deoxidise Re...

Page 570: ...injection relay connection Faulty injector Faulty injector connection Faulty injection ECU Faulty side stand injector Faulty engine pick up Phonic wheel pick up light incorrect Faulty petrol pump Faulty neutral sensor Replace Deoxidise Restore Replace Deoxidise Restore Replace Deoxidise Restore Replace Replace Replace Replace Replace Replace DIAGNOSTICS 7 58 IGNITION PLANT No spark plugs spark Bur...

Page 571: ...ension too soft Rear suspension too stiff Insufficient spring pre load Insufficiently extended hydraulic brake Low tyre pressure Damaged shock absorber Excessive spring pre load Excessive extended hydraulic brake High tyre pressure Damaged swing arm bearings Damaged suspension balancing device bearings Damaged shock absorber joints Damaged suspension connecting rod joints Bent swing arm pin Adjust...

Page 572: ...eplace Replace Check Top up Replace Replace Clean Bleed Repair Replace Replace Check Top up Replace Replace Replace Check Adjust Replace DIAGNOSTICS 7 60 DRAIN PLANT Excessive exhaust noise Poor engine performances Damaged exhaust pipe Loosened tube fixings Damaged exhaust pipe Loosened tube fixings Replace Fasten Replace Fasten COOLING PLANT Engine temperature too high Engine temperature too low ...

Page 573: ...ELECTRIC LAYOUT ELECTRIC PLANT 7 61 ELEC ...

Page 574: ...Injection Alarm 4 Right Indicator 5 Left Indicator 6 Neutral 7 High beams 8 Position Light 9 GND Petrol Level 10 Petrol Level COLOURS CONTACTS Yellow Grey Grey Red Blue Blue Black Black Black Red Red Brown Red 11 Set Reset Switch 12 Revolutions 13 Speed Sensor Output 14 15 Speed Sensor Mass 16 Mass 17 Ambient Temperature Sensor Mass 18 Ambient Temperature Sensor 19 Permanent Positive 20 Under lock...

Page 575: ...se When checking the parts carefully follow the control instructions The non compliance with the correct procedure can cause serious damages COUPLERS With a lock type coupler release the lock before disconnecting it and push all the way when connecting it When connecting the coupler ensure to grip the coupler body and not to pull the wires Check whether the terminals of the coupler are loose or be...

Page 576: ... following the method indications shown on the battery packaging however see ROUTINE INSPECTIONS AND ADJUSTMENTS 3 79 paragraph Should the terminals be corroded remove the battery pour hot water over them and clean using a metal brush Once connection is completed grease slightly Install a cap on the positive terminal ELEC ATTENTION Do not use batteries different from those specified ATTENTION Hydr...

Page 577: ...sconnecting the connectors of every individual powered utility Bring the ignition switch to OFF position Disconnect the battery negative cable ELEC 1 2 3 ATTENTION As the current leaks during malfunctioning may be high firstly use a high range of multitester to avoid damages Do not bring the ignition switch to ON when measuring the current With the control board switched off the current leaks must...

Page 578: ...y using a multitester If the tester indicates less than 13 0V or more than 15 0V the cause to be identified is in the generator Start the engine and make it rev at 2000 r min with the lights switch at ON and the selector on HI headlights position ELEC 1 2 3 N NOTE When carrying out this test ensure that the battery is fully charged Output for charge 13 0 V 14 5 V a 2000 g min ...

Page 579: ......

Page 580: ...of Benelli Q J s r l The total or partial reproduction is forbidden VersionJune2009 01 BENELLI Q J s r l Strada della Fornace Vecchia 61100 Pesaro Italy Benelli recommends original accessories Benelli recommends original products ...

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