Benelli 900 Sei Workshop Manual Download Page 1 | Manualshive

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Summary of Contents for 900 Sei

Page 1: ...WI RII HIIP MIIIUII I H L L E t r F P P P P F I E I p a 7 a a a e ä a ä E e e a e e e ä 3 a e a 3 IE I F lliBenelli p 4 E Additionsandchangeto the workshopmanualfor 500ouattro 7s0 sei ...

Page 2: ...advance adjustment TOROUEWRENCH SETTINGS page 8 SPECIAL TOOLS page I ENGINE page 10 l Cylinder head cylinder blockandpistons 5 Clutch 9 Gearbox primarydriveanddesmodromic FRAME page i9 1 Front and rearbrake 3 Front and rearwheel 7 Front fork 8 Rearsuspensions I ELECTRICALEOUIPMENT page 28 1 Electronicignition 2 Alternator generator I WIRING DIAGRAM page31 ...

Page 3: ...ker clearance cold engine C A R B U R A T I O N carburettors I three Dell Orto typeVHB 24D LUBR ICATION normallubrication pressure by pump EATON type 3 5to 4 kg sqcm oil pressure sender unit for warniglight oil filter I replaceable cartridge GENERATO alternator 14V 12A IGNITION I electronic with magnetic control clearance betweenthe block on the rotating I sleeve andthe metalendsof each pick up 0 ...

Page 4: ...led fromthe L H sideof thevehicle 1 to 2 454 Z 111271 i to 1 666 Z 151251 1 to 1 211 Z 181231 1 t o 1 0 5 0 Z 2 0 2 1 i to 0 900 Z 2Ol18l 1 to 2 511 Z 21 54 double cradle tubular structure 100 90 v 1BMT29 120lso v 18MT28 2 kg sqcm 2 3kg sqcm withpasenger 2 5kg sqcm rockerpedal on thecentreR Hsideof thebike Discdia 260mm Cylinder dia 48 mm Master cyl dia 15 87 mm The rear brake is hydraulically con...

Page 5: ... D O I LC A P A C I T I E S fueltank 16 5 supergrade petrol98 100 NO RM 5 lt reserve included 3 AGIPSINT2000SAE10W 50oil 60 cc eachleS AGIPF 1 ATF Dexron AGIPF 1 Brake FluidSAEJ 1703C oilsump front fork oil brakingsystem ELECTRICAL EOUIPMENT BATTERY LIGHTS 12V 28 Ah headlight beam headlight town taiI light parking stop indicator lights speedometer Revcounter instrument panellights t2 v 404 5W 1 2V...

Page 6: ...incomplete disenga gement act on adjuster C afterslackening counternut D locatedon the dutch leverat the crankcase This operationcan be performedafter removingplug E I s I G G G G G F G G F lg tt tE 4 g La I gs t ra 4 g tsl s lgl F ülL ü F c t 2 15 CARBURATION Carburettors Dell Orto typeVHB 24D doublecontrols Carburettors settings Choke Throttle valve Qz qmm 40 Atomizer Need le Mainjet ldling jet ...

Page 7: ...s 8 2 16VALVEGEARING To carryout theadiustment operate asfollows Remove thefairing andfueltank Remove central hub from degree timing platecooe 69 90 78 52 704 087 0 799 validfor 750 Sei Fit on timingplate rhenewhub63 94 96 20 provided for model900 Sei pay attentionto havethe hub key traceturnedon rhe i 6 stamping side on the timing prate Removethe alternator from the crankshaftL H side and fit the...

Page 8: ...and if necessary restorethe valvetappetclearance operatingasfollows a remove the fairing close the fuel taps renrovef uel line from the fuel valve body disconnectthe rear fuel tank rubberand removethe fuel tank b remove the ignition breaker point cover and the twelvetappetadjustingholecaps A c rotate slowly the crankshaftclockwise till stamped trace G on rotating sleeveis alignedwith trace H stamp...

Page 9: ...tsin electricwirinqs should occur Suchinconveniences are easilydetecteddue to a poor working efficiency in cylinders To inspectand adjustthe ignitiontiming proceed as follows 1 Removethe coveron the right sideof the engine ur or rNw g 2 Makesurethat the mark A on the inspection hole rim isaligned with thecrankcase mark In caseit shouldbe necessary to adjustthese two marks undothe threescrews 8 and...

Page 10: ...ssyfixingnuts Sparkplug Oildrainplug Oil cartridge coverfixingbolt Clutchhousing retaining plare Plate securing to driveshaftclutchplatedrum Standard settings Screws andnutsf 6 mm Screws and nutsÖ 8 m kgm ftll bs 1 8 2 z ö 3 2 3 2 5 0 8 1 2 l J l c 0 8 1 2 z z z c 0 8 1 2 l t t o a A 0 8 1 2 2 2 4 11 5 1 4 5 20 2 21 7 t o o t ö 5 7 8 8 t 6 6 1 8 6 7 R 6 1 5 9 1 8 1 0 8 1 4 5 5 7 8 6 ö o t o 25 3 2...

Page 11: ... I I 63 90 30 20 63 94 96 20 63 94 75 20 65 90 66 00 65 91 19 00 14 71 24 59 61 90 i9 00 Puller malepin on cableconnection Wrench holding clutchdrum Punch layshaft securing nut Punch layshaft securing nut Tool for assembling securing nut on layshaft Tool lholding clutchgear crown Hub timingplate Arrow indexfor timingcheck Puller flywheel Tool holding flywheel Nut securing hubtimingplateon cranksha...

Page 12: ...5 g d d d d d d d d d d d d d d t d ä d d d d d d d d E d g I l errrcrrue 6 1 CYLINDER HEAD CYLINDERBLOCK PISTON AND CON RODS 10 ...

Page 13: ...s are pracedas indicatedin the drawing rhat is with the centralpart in reliefturned upside towardsthe cylinderhead ln the area around the timing chain slit apply some s ea lin gma teria lHYL ON4 ARPL 32 MEDIUM o r equi valent To avo id o il lea ksa pp ly some re tain in g ta pe T EFLON on threadings on the lowerstudsfixing the cylinder head to crankcase t l C O P P E R S E A LR I N G lz ll tl il t...

Page 14: ......

Page 15: ... 45mm 0 0098 to 0 0177 Oil scraper 0 20to 0 35mm 0 0078 to 0 0137 Wear limit 0 8 mm 0 0314 N B Letters A and 8 indicating theclass selection J are markedon top of the pistonand on the upperpart of thecylinder blocknearthe lining 7 Da Usinga micrometertake the measurements of the dia meter at 1 l mm 0 043 from pistonbaseat g0oof ä piston axis lf the measurement exceeds the indicated I limitsor if t...

Page 16: ...e r Check the couplingplay betweenpistonpin and big end beari ng Che ck the pa ralleiism of b oth small an d b ig en d a x is Ma ximu m va lue 0 1 00 mm o n 2 00 mm 0 00 39 on 7 8 7 Q hole A Colour selectron 1 2 bla ck wh ite 15 000 to 14 997 mm 05905 ro0 5904 15 003 to 15 000 mm 0 5906 to0 5905 18 805 18 905 G r t ct q 18805i18 r Dopo alesatura Er i ilq 2IW2 t t t T l 0 piston pin 8 Colour 0 sele...

Page 17: ...6 5 CLUTCH 4 il t 3 v e 3 7 7 t e 7 3 7 7 a 4 7 3 E a 7 ü 4 t t 7 t t t t I t d t c ...

Page 18: ...esand isbelowthewearlimit 3 1 5t o 3 3 5 m m l O 2 4 t o 0 1 3 1 wea rlimit 2 9 mm 0 1 1 Placethe driven plateson a plane and usinga compara tor check their distortion if this is over 0 1 mm l n n n r o n l e r e t h e m v v v v Checkand if necessary replace the two retaining rings oR Check the efficiencyof the two clutch housingsprings Re assembly Reversethe dismantlingoperationspaying attentron ...

Page 19: ... l t t I 6 9 GEAR BoX t t t 7 7 t 7 t I I 7 I 17 ...

Page 20: ...e parts wi rh 0 10 0 15 0 5 mm thi ckne sses 0 0030 005 0 019 1 Checkthat the gearshift forks fully engage the gears with nodifficulties To adjustact on thrustwashers 8 available asspare p u r t i t h t h ef o l l o w i n g t h i c k n e s s e s 1 I 2 2 1 2 3 2 4 2 5 mm 0 070 0 078 0 082 0 090 0 094 0 0 9 8 l ö ...

Page 21: ...vrs u u Lr u u üf l u üN t u t tt ll u ü u l tt U U U t U t U t 462 Q 139 5 o o t o 156 t I tzs l zg o ...

Page 22: ...I e G G G G G e e 4 E l a_ 3 4 g L trs 4 tss 4 H s 1 ttr 1 Its 4 5 1 3r A ttllb 1 e3 1 s ä 4 r s d 7 1 BRAKES Handcontrolled front brake 20 ...

Page 23: ...I lntegralbrake I G ä a t I 3 7 7 3 3 7 3 7 7 v 7 7 a I 7 b E t b t ü 7 t 7 L 7 3 7 7 3 1 1 L I ...

Page 24: ...inders When revisioningthe master cylinders check the inner diameter ol the cyiinder and the outer diameterof the f loater Master cylinder for left front and rear brakes integral Ma x ad mis sible cy li nderdi a 15 9 l8mm 626 Min a dmis sible f loaterd ia 1 5 832mm 622 Mastercylinder for right f ront brake Max admissible cylinder dia 12 843 mm 50 M in a dmiss ible loat erdi a 12 5 67mm 498 22 Brak...

Page 25: ...tance it may occur that the master cylinderscraper with contactwith gasoline or diesel oil will melt and gluesto the Jloater affectingits sliding action The caliper gasketsare subject to sticking to the piston It is sometimes possible that Curingstorageof the calipers beforeassembly or when the machineitself is left unused for long periods of time in a relatively short period for instance 2 4 mont...

Page 26: ...7 3 WHEELS 1i l I zl 11 r 24 ...

Page 27: ...der these circustances never use tools that have ribbingsor sharp edgeson the sidescontactingthe rims the contacting surfaceof such tooling has to be very wide smooth and with rounded edges the use of any lubricants available on the market for thesepurposes will greatlyfacilitate tyre slidingand settlingon the rim preventing also overloads on the tools lt is also very important for the tyre beadst...

Page 28: ...h 95 mmt 1 Solo 3 14 1 5 B compressed to 91 5mm 3 60 shouldgivea load of 9 3 kg 30 o 20lbs C compressed to 60 9mm 2 39 shouldgivea load of 90 7 kQ 3o o 199lbs Ensure the fork longspring hasthe followingsizes and load ings A freelength 336mm 1 5 13 14 1 5 B compressed to 328 mm 12 14 1 shouldgivea load of 9 3 kg 30Ä 20lbs C compressed to 257 mm 10 i1 shouldgivea load o 90 7kg 3 199lbs give a load z...

Page 29: ...31mm 9 33 Lengthundera load of 103 kg 226 lbs shouldbe 1 9 7m m 7 7 5 1 Lengthundera load of 145 kg 320 lbs shouldbe 1 6 8 m m 6 6 1 Lengthundera load of 232 kg 510 lbs shouldbe 1 3 5m m 5 3 1 N B lf any springhasdeformedor is not within the above limits replace Position 2 i 229 5 Position3 222 open320 t l C l o s e d L C Z l l t Closed F C 235 E E o t N 27 ...

Page 30: ...otation of the rotor when the metal block on the rotor is approaching positionwell defined the metal ends of the pick up an electricimpulseis genera ted in the pick up that reachesthe electronic switch 28 transistor inside theelectronic set ln this way a breakof the coil maincircuitis obtained as a consequence in the secondary circuit of the same coil the highvoltage needed for the ignition isgene...

Page 31: ... a current regulatorand rectifier Thegenerator iscomposed of rotatingpart inductor fitted directlyon crankshaft fix part induced Removing the alternator enerator 1 Remove the L H sidecover 2 it on the outer part of the generator the special tool A 3 Undocentralbolt 8 spacer andwasher With engineat standstill do not forgetto disconnect the ignition switch to avoid battery dischargeand damage the co...

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