Benelli BJ500-6A User Manual Download Page 24 | Manualshive

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BJ500-6A

24

PRIMARY PARTS

REAR BRAKE PEDAL

Step the rear brake pedal to slow down
the rear wheel. Brake light will turn on
while rear brake is in use.

SHIFT PEDAL

This motorcycle is equipped with six-speed
constant mesh gearbox.

Caution:

When the transmission is on neutral position, the indicator lamp would turn
on. Slowly release the clutch lever to make sure the transmission is on the
neutral position.

SHIFT PEDAL

REAR BRAKE PEDAL

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Summary of Contents for BJ500-6A

Page 1: ...BJ500 6A USER S MANUAL ...

Page 2: ... Preface Safety Notes Safety Driving Rules Protection Clothes Serial Number Location of Parts Meter Indicator Primary Parts Key switch Left Handle Right Handle Fuel Tank Rear Shock Absorber Rear Brake Pedal 2 5 6 7 7 8 9 10 11 15 15 16 21 22 23 24 ...

Page 3: ...pection before Driving How to start the engine Smooth launching To change gear Inspection Maintenance Maintenance Schedule Oil Level Oil Change Spark plug Catalytic Converter Battery Throttle Cable Adjustment Clutch Adjustment Chain Adjustment 24 25 25 26 26 28 29 30 31 31 34 35 35 36 39 40 40 ...

Page 4: ... 4 BJ500 6A Brake Maintenance of Air Filter Bulb Replacement Fuse Replacement Lubrication points Adjustment of Valve Clearance Tire Storage Guideline Specification Technical Parameter 42 44 44 45 46 46 47 48 50 ...

Page 5: ...ng the fuse switch the key to in case of short circuit Make sure the contact point of fuse is not broken while changing the fuse which would result bad contact parts damage and even fire No reconfiguration Do not reconfigure the motorcycle or change the places of the parts and accessories at will which would have a strong impact on the stability and safety of the motorcycle probably operation faul...

Page 6: ...enance procedures which would ensure the maximum performances and highest durability of your motorcycle if appropriately operated Our company is equipped with professional technical maintenance personnel and department which is able to provide you with high quality technical maintenance services We make great efforts to develop the products quality and performances so that the appearances and stru...

Page 7: ...ose the driver should be specifically careful with understanding on the safety notes before driving 1 Have a complete inspection before starting the engine so as to prevent possible accidents or damages of parts 2 Many accidents happen due to inexperienced driver Make sure the driver is qualified before driving the motorcycle Never give it to any people without a driving license 3 Most of the cras...

Page 8: ...hall not affect the safety driving and operation performances of the motorcycle Overloading of the electrical systems would result dangers to the vehicle 8 Do not operate the engine within confined space as the exhaust gas would cause damage to the body 1 Fatal accidents of motorcycle drivers are mostly caused by head injuries For the purpose of personal safety the driver should wear a safety helm...

Page 9: ...de you better services involving accessories purchasing or other services Record the numbers for the possible use in the future Vehicle identification number VIN is printed on the right side of the head tube The engine number is printed on lower part of the right case of engine crank case Please write down the numbers for your reference SERIALNUMBER VIN Engine Number ...

Page 10: ...t handle switch 3 ABS switch if equipped 4 Meter 6 Right handle switch 5 Meter function button 8 Front brake lever 7 Throttle grip Rear shock absorber Rear brake pedal Shift pedal 12 9 10 11 Fuel tank Left view Right view 4 5 7 6 8 1 2 3 C 11 12 9 10 ...

Page 11: ...BJ500 6A 11 LOCATIONOFPARTS Meter Indicator Daytime mode 11 10 1 12 3 4 2 5 6 9 7 8 13 14 16 15 17 ...

Page 12: ...BJ500 6A 12 LOCATIONOFPARTS Night mode 11 1 12 3 4 2 5 13 14 16 6 10 9 7 8 17 15 ...

Page 13: ...hows the time 8 WATER TEMPERATURE INDICATOR This indicator indicates the temperature of cooling liquid When the pointer is in between C and H the temperature is normal It should stop to check the water tank if the pointer is higher than H level 9 GEAR INDICATOR LAMP Numbers on the meter indicate the gear positions of the vehicle including 1 2 3 4 5 and6 10 SPEEDOMETER Speedometer shows the running...

Page 14: ...uick Blink 4 ABS is under ON mode When keyswitch turned on the ABS indicator lamp lit and stays activated until the motorcycle drive off reaching about 3 5KM H will the ABS indicator lamp be unlit Normally the ABS indicator light comes on when the ignition switch is turned on and goes off shortly after the vehicle starts moving If the indicator light shows any of the following a fault or faults ma...

Page 15: ...key In this condition the vehicle has been locked If you want to unlock the vehicle insert the key and turn clockwise Off position All the circuits are off 17 PHOTOSENSITIVE SWITCH There are two modes in this meter They switch automatically depending on the intensity of the light Please follow below steps to switch manually Cover the switch with your hand for 3 5 seconds to switch daytime mode to ...

Page 16: ...n the switch to position the left direction signal lamp flashes turn the switch to position the right direction signal lamp flashes And the indicator lamps would turn on accordingly 4 PASSING SWITCH When passing other vehicles press this button so the high beams of the headlamp would flash to alarm the vehicles in front of you PRIMARYPARTS Alarm Turn on the direction signal lamps in time when chan...

Page 17: ... 3 5 sec onds the ABS indicator light should be changed from lit to blink as per 1 27s Slow Blink when you release the switch Now the ABS was turned OFF and the brake will work as conventional system From ABS OFF mode ON mode Please keep pressing the ABS switch precisely within the range of 3 5 sec onds the ABS indicator light should be changed from blink as per 1 27s Slow Blink to constant lit wh...

Page 18: ...ulates brake force Intermittently gaining gripping force and braking force helps prevent wheel lock up and allows stable steering control while stopping Brake control function is identical to that of a conventional vehicle The brake lever is used for the front brake and the brake pedal for the rear brake Although the ABS provides stability while stopping by preventing wheel lock up remember the fo...

Page 19: ...s ABS will help prevent wheel lock up when braking in a straight line but it cannot control wheel slip which may be caused by braking during cornering When leaning in corners it is better to limit braking to gentle application of both brakes or not to brake at all Reduce your speed before you enter the corner Same as conventional brake system an excessive sudden braking may cause wheel lock up and...

Page 20: ...toppie or burn out rear wheel drifting or any maneuvers may cause the front and rear wheel to have different rotation status In this case first turn the ignition key to OFF and then back to ON ABS indicator light goes off by this operation but if ABS indicator light remains lit after the vehicle runs at the speed of approximately 5 km h or above you should have the bike checked by an authorized Be...

Page 21: ... SWITCH Turn switch to position of to light up the front lamp Turn to to light up meter lamp city light and tail lamp turn to for daytime driving 5 METER FUNCTION BUTTON In ODO mode turn off the key To adjust the clock turn on the key switch and immediately long press the set button when released the hour digit will start flashing on the meter Short press the set button to change the number or lon...

Page 22: ...witch and wait for over 10 secs then long press the set button to realize the unit switches Under any modes ODO TRIP A and TRIP B short press the set button to switch between three modes while in TRIP A and TRIP B modes long press the set button to reset the trip mileage Alarm Gasoline is extremely flammable and can be explosive under certain conditions creating the potential for serious burns Tur...

Page 23: ...he adjustment ring nut with special wrench to make the suspension stiffer Please rotate opposite direction to achieve a softer setting After adjustment please make sure the lock nut tightened to ensure safety of riding Preload Note Never fill the tank so the fuel level rises into the filler neck If the tank is overfilled heat may cause the fuel to expand and flow into the Evaporative Emission Cont...

Page 24: ...turn on while rear brake is in use SHIFT PEDAL This motorcycle is equipped with six speed constant mesh gearbox Caution When the transmission is on neutral position the indicator lamp would turn on Slowly release the clutch lever to make sure the transmission is on the neutral position SHIFT PEDAL REAR BRAKE PEDAL ...

Page 25: ... and change some parts when needed NOTICE OF USE OF FUEL AND ENGINE OIL Fuel It is a must to use lead free gasoline Use gasoline contains octane number more than 92 Notice Use lead free gasoline can extend the working life of spark plug Engine Oil Please use four stroke engine oil it should be equal or higher than API SAE service grade SF The specification is SJ10W 50 NOTICEOFUSEOFFUELANDENGINEOIL...

Page 26: ...he motorcycle very carefully during its running in period also the rider has to be familiar to the performance Note In the first 300km of break in you should examine the cleanliness of the engine oil frequently Check the oil level of engine oil before driving INSPECTION BEFORE DRIVING Please check on the following contents which are very important before driving RUNNINGIN Content Handlebar Braking...

Page 27: ... indicator Horn Brake Switch Horn Brake Switch Engine Oil Correct oil level Correct oil level Throttle 1 Appropriate free play in clutch lever 2 Smooth operation Clutch 1 Appropriate free play in throttle cable 2 Smooth operation no stuck when returning to full close position Driving Chain 1 Appropriate tightness 2 Appropriate lubrication Light Operate all the lamps headlight taillight stoplight i...

Page 28: ...the gear box is in neutral position Start the engine by pushing the start switch Warning Do not start the engine indoor with bad ventilation or without ventilation Do not leave a starting motorcycle when no one else is around Caution Do not run the engine in high speed when you do not drive the motorcycle or it will become overheating and damage its inner parts INSPECTIONBEFOREDRIVING ...

Page 29: ...r according to driving speed It is dangerous to drive with clutch disengaged Lower the gear when you slow down the motorcycle to make engine run within normal rpm range Drive on slope way When drive on uphill road motorcycle will slow down and seem to be lack of power Switch to low gears so that engine can generate normal power Shift the gear swiftly to prevent motorcycle from losing speed Turn to...

Page 30: ... side stand please shift to the first gear to prevent slipping Shift to neutral position before starting the engine Turn the power key to the position to stop the engine Remove ignition key from the switch after locking for security reason BJ500 6A 30 Warning It is dangerous only to use either the front brake or rear brake which may causes the motorcycle to skid or lose control Be careful and use ...

Page 31: ...aken according to the following chart the inspection and maintenance of the key components are required to be made by professionals Better to consult authorized dealers to do inspection and maintenance for safety s sake MAINTENANCE SCHEDULE I Inspection cleaning adjustment replacement C Cleaning R Replacement A Adjustment L Lubrication INSPECTION MAINTENANCE ...

Page 32: ...ilter Spark Plug Valve Clearance Engine Oil Oil Filter Fuel Injection Drive Chain 4000km 7000km Per 24000km I Per 6000km R Per 6000km R Per 1000km I L A Per 6000km I or R 10000km 13000km 16000km ODOMETER READING 1 3 4 5 6 7 8 9 Battery 10 2 I I I I I I I I R R I I I I I I I I I ...

Page 33: ... Braking Hydraulic Fluid Clutch Hanger Bracket Nut Bolt Fastener Wheel Rim Spoke Steering Bearing 4000km 7000km Replace every two years Replace every two years 10000km 13000km 16000km ODOMETER READING 11 13 14 15 16 17 18 19 Cooling System 20 21 22 12 I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I I ...

Page 34: ...the odometer reading exceeds the fixed value 3 Take more maintenance to keep good performance for frequent driving in heavy conditions as rugged roads OIL LEVEL OIL CHANGE Check the oil level before starting the engine Put the motorcycle on side stand Pull the handle bar and let the bike stand vertical to the flat ground Check if the oil level is between the maximum and minimum level If not fill t...

Page 35: ...ng inspection period noted in the maintenance schedule Readjust the electrode gap of spark plug with feeler gauge and keep the gap between 0 7 0 8mm Replace the sparking plug for each 6000km Type of Spark Plug NGK CR8E CATALYTIC CONVERTER In order to meet the requirements of environmental emission the muffler of the motorcycle is equipped with catalytic converter INSPECTION MAINTENANCE Do not Scre...

Page 36: ...ment is needed please use the genuine parts or entrust the distributors to replace BATTERY Battery is under the seat cushion The battery for the motorcycle is maintenance free type For the new motorcycle please ask the dealer of the company to fill electrolyte into the battery for you It is not necessary to refill electrolyte in the future If you have to take out the battery for inspection please ...

Page 37: ...ur local dealers Connect the wire polarities correctly Positive wire red shall be connected with the positive terminal and negative wire black to the negative terminal Tighten terminal bolts Clean frequently the erosive substances on the terminals with a wire brush while in use Please operate according to the following requirements while filling electrolyte into the maintenance free battery INSPEC...

Page 38: ...g begins normally Attention Please be sure not to tilt the container or electrolyte filling may be interrupted d When you are sure that there is at least one pipe that has bubbles coming out on each side three pipes on each side leave it there and keep the filling process over 20minutes If there is no pipe that has bubbles coming out on each side tap slightly two to three times the bottom of the e...

Page 39: ...of the same type During motorcycle design the battery specifications are considered as the best choice If a battery of a different model is used it may affect performance and life time of the motorcycle and possibly causes electrical failure If the motorcycle will not be used for a long time please remove the battery and charge it once a month THROTTLE CABLE ADJUSTMENT 1 Screw off the lock nut 2 T...

Page 40: ...d free play 3 Tighten locknut CHAIN ADJUSTMENT Adjust the tightness of drive chain for driving each 1000km s in following methods to reach the free play of 10 20mm Make regular adjustment of the chain according to your driving condition INSPECTIONBEFOREDRIVING Warning Suggestions here are for regular maintenance schedule it s recommended for inspection and adjustment of the chain before each drivi...

Page 41: ...t after adjust the chain tightness to 10 20mm and confirm again During regular maintenance check the following conditions of the chain 1 Loose pin 2 Damaged roller 3 Rusty chain link 4 Twisted or snarled link 5 Excessive free play 6 Loose chain The sprocket is probably damaged if any above mentioned problems on the chain are found Check the following items for sprocket INSPECTION MAINTENANCE Notic...

Page 42: ...OT4 brake fluid Please replace it every two years Don t forget to check the amount level in the front brake fluid reservoir Add appropriate brake fluid if necessary Brake pads Check the front and rear wheel brake pads whether have been worn to limits Change the pads if over the limit INSPECTIONBEFOREDRIVING Warning In case of drinking the brake fluid by mistake or contacting with eye or skin wash ...

Page 43: ...wheel brake pads Rear Brake To adjust the stroke of rear brake pedal screw or turn the adjusting bolt of rear brake the free play be adjusted to 20 30mm INSPECTION MAINTENANCE Warning Maintenance of braking system or brake pads should be taken by the authorized dealer which is equipped with necessary tools and can assure the quality of the service Caution The disk braking system has high pressure ...

Page 44: ...ake out after cleaning for complete drying 4 Immerse the filter element in clean engine oil again after saturation take out and squeeze off excessive oil 5 Install the components back in the reverse order of dismount BULB REPLACEMENT Replacing of Head Lamp Bulb Take off the cover replace the old bulb with the same specification one and finally set up in the reversed orders INSPECTIONBEFOREDRIVING ...

Page 45: ...ation as indicated INSPECTION MAINTENANCE Notice The new bulb installed must in the same specification with the old one High power bulb will increase load to circuit system which will cause faults such like battery power shortage Warning It s dangerous to use other specifications of fuse which would result severe failures like burning firing 15A 15A POWER LOCK ECU 15A 15A 15A 15A 15A FUEL PUMP FAN...

Page 46: ...the vehicle is wet due to raining or washing Detail lubrication points are shown in the figure below Motorcycle lubricant Lubricant grease 1 Rear brake pedal shaft 2 Side stand and its spring 3 Throttle cable 4 Pivot of front brake lever 5 Pivot of clutch lever ADJUSTMENT OF VALVE CLEARANCE Check and adjust the valve clearance when the engine is cold The Standard Valve Clearance Intake Valve 0 15 ...

Page 47: ...causing slipping or even getting out of control Tire pressure should be kept in the standard range Adjust the tire pressure under a cold condition INSPECTION MAINTENANCE Notice Adjustment of valve clearance will have direct influence on the performance of engine thus requiring strict accordance with the time interval required in Maintenance Schedule Adjustment should be done with professional tech...

Page 48: ...bricate drive chain 3 Detach the spark plug and add one teaspoon of 15 20cm3 clean engine oil to cylinder Pushing the starting switch for several times to distribute oil in the cylinder and install the spark plug again 4 Remove the battery Keep the battery in proper place which can avoid freezing and the direct sunlight 5 Clean and dry the motorcycle Wax the surface of the paint 6 Inflate tire to ...

Page 49: ...r storage 1 Take off the cover and clean the motorcycle Change engine oil if you keep your motorcycle for more than four months 2 Install the battery and do charging as needed 3 Wash away the anti rust agent in fuel tank and add new petrol into fuel tank ...

Page 50: ...e Electric Starting Transmission System Chain Clutch Wet multi plate Front Brake Type Dual discs Rear Brake Type Disc brake Front tire Specification 120 70ZR17 Rear tire Specification 160 60ZR17 ELECTRICAL SYSTEM Battery 12V 8Ah YTX9 BS Magneto Fly wheel Magneto Headlamp LED12V 11 3 11 3W Tail Brake Lamp LED 12V1 5 1 0W Front City Lamp LED 12V6 3W Turn Signal Lamp LED 12V 3 6W Meter Lamp 12V 2W Ne...

Page 51: ...www benelli com Benelli Q J S r l Strada della Fornace Vecchia 3 61122 Pesaro Italy ...

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