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Benelli TnT1130, Workshop Manual

The Benelli TnT1130 Workshop Manual is a valuable resource for motorcycle enthusiasts. This comprehensive manual provides detailed instructions and guidance for servicing, maintaining, and repairing the Benelli TnT1130 model. Download this essential manual for free at manualshive.com, your go-to source for user manuals and guides.

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UK

382

MF13

Select the engine type and press ENTER to confirm..

Select the system to be tested from the list of available systems.
Select chassis code and system type.
The following can be selected:
- INJECTION (injection system auto-diagnostics)
- RE-PROGRAM (ECU re-mapping)

In this example, select the injection system and then the ECU
type/code. Press ENTER to confirm. The version and location
of the diagnostic socket will be provided.

DATABASE

POWERPLANT

898

BENELLI
Tornado Tre

DATABASE

SYSTEM TYPE

INJECTION

REPROGRAMMING

BENELLI
Tornado Tre
898
INJECTION

DATABASE

VERSION

(2002>) Not definite

BENELLI
Tornado Tre
898
INJECTION
Sagem

POSITION OF COMPONENTS

E.C.U.

Connector:

Left side
Right side

Left side
Right side

LOCATION OF ECU AND THE

DIAGNOSTICS SOCKET

Summary of Contents for TnT1130

Page 1: ......

Page 2: ...rcycle under review The illustrations in this manual are used to highlight the fundamental principles and procedures of basic interventions They may not show exactly the motorcycle in your possession This manual has been written for people who have the knowledge the technical skill and the instruments including the special for servicing Benelli motorcycles If you do not possess the necessary train...

Page 3: ...not observed WARNING Possibility of lesions in case the instructions are not observed NOTE The aim of this message is trying to avoid any damages to the vehicle things or environment OILING Indicates the type of oil to use TIGHTENING Indicates the correct tightness value to carry out SPECIFIC VALUE indicates the specific value using precision in struments SPECIFIC INSTRUMENTS indicates the specifi...

Page 4: ...NG SPARK PLUGS 57 3 3 CLEANINGAIRBOX 57 3 3 1 REMOVAL OFAIR BOX THROTTLE VALVE ANDAIR BOX DUCT 58 3 3 2 SOLENOID MOTOR REMOVAL 59 3 4 GASCONTROLPLAY 60 3 4 1 CLUTCH 61 3 5 ADJUSTINGCLUTCHLEVERPLAY 62 3 6 ADJUSTINGCO 62 3 7 ADJUSTINGTHROTTLEHOUSING 64 3 8 CHECKINGSTEPPER 65 3 9 ADJUSTINGVALVEPLAY 67 3 9 1 VALVE TABLET REPLACEMENT 68 3 10 ENGINEDISTRIBUTION 69 3 11 CHECKINGENGINEOILLEVEL 71 3 12 CHA...

Page 5: ...OVERDISASSEMBLY 114 4 2 PETROLTANKDISASSEMBLY 114 4 2 1 COVER PLATE DISASSEMBLY 115 4 2 2 PETROL PUMP REMOVAL 115 4 3 DISMANTLETANKFUELPUMP 116 4 4 COOLERFAIRINGDISASSEMBLY 116 4 4 1 FRONT SHIELD AND FRONT SHIELD SUPPORT DISASSEMBLY 117 4 5 COOLERSCONVEYORSDISASSEMBLY 117 4 6 MUDGUARDSDISASSEMBLY 119 4 6 1 FRONT MUDGUARD DISASSEMBLY 119 4 6 2 BACK MUDGUARD DISASSEMBLY 119 4 7 CHAINCARTERDISASSEMBL...

Page 6: ...2 MOUNTING DISTRIBUTION SENSOR 156 5 7 3 REMOVING PHONIC WHEEL 156 5 7 4 MOUNTING PHONIC WHEEL 156 5 8 CLUTCH 157 5 8 1 DISMANTLING CLUTCH CONTROL 157 5 8 2 REMOVING CLUTCH COVER 157 5 8 3 REMOVING CLUTCH 158 5 8 4 CHECKING THE EXTERNAL TEETH DISK CONDUCTOR 160 5 8 5 CHECKING INNER TOOTHED CONDUCTOR DISK 160 5 8 6 CHECKING CLUTCH SPRINGS 160 5 8 7 CHECKING CLUTCH BELL 161 5 8 8 CHECKING CLUTCH PRI...

Page 7: ...ING PLANT COOLING PLANT 220 REFRIGERANT LIQUID ENGINE REFRIGERANT LIQUID ENGINE REFRIGERANT LIQUID ENGINE REFRIGERANT LIQUID ENGINE REFRIGERANT LIQUID ENGINE 220 220 220 220 220 6 1 RADIATOR 221 6 1 1 DISMANTLING RADIATOR 221 6 1 1 1 LEFT COOLER DISASSEMBLY 222 6 1 2 COOLER CHECK AND CLEANING 224 6 1 3 RIGHT COOLERASSEMBLY 224 6 1 4 OIL RADIATOR DISASSEMBLY 225 6 1 5 OIL COOLER CHECK AND CLEANING ...

Page 8: ...3 13 CHECKING BRAKE CLAMPS 265 7 3 14 MOUNTING FRONT BRAKE CLAMPS 265 7 3 15 DISMANTLING REAR BRAKE CLAMP 266 7 4 FORK 267 7 4 1 REMOVING RIGHTAND LEFT STEM 267 7 4 2 CHECK FORK LEGS 268 7 4 3 INSTALLING FORK LININGS 268 7 5 HANDLEBAR 270 7 5 1 HANDLEBAR CONTROL 272 7 5 2 HANDLEBAR INSTALLATION 272 7 6 STEERINGHEAD 274 7 6 1 DISMANTLING LOWER STEERING PLATE 274 7 6 2 CHECKING LOWER STEERING PLATE ...

Page 9: ... BATTERY EFFICIENCY 323 9 5 FUSES 325 9 6 RELAYS 325 9 6 1 RELAY STARTER 325 9 6 2 RELAY SERVICES UNIT 326 9 7 STARTERENGINE 326 9 8 ALTERNATOR 327 9 9 STARTERDIAGNOSTICSYSTEM 328 9 10 CHECKINGSAFETYSYSTEMPARTS 330 9 11 GEAR SWITCH POSITION 330 9 12 LATERALSTAND SWITCH 331 9 13 CLUTCH SWITCH 331 9 14 SPEEDSENSOR 332 9 15 OILPRESSURESENSOR 332 9 16 SOLENOID 333 9 17 CHANGINGFRONTLIGHTS 334 9 17 1 F...

Page 10: ... TO USE AXONE2000 BENELLI 357 10 3 4 1 SERVICE MENU 357 10 3 5 UPGRADES 360 10 3 6 MEASURES 367 10 3 6 1 MULTIMETER VOLTMETER AMMETER OHMMETER CONTINUITY TEST 367 10 3 6 2 VOLTMETER 368 10 3 6 3 AMMETER 368 10 3 6 4 OHMEMETER 369 10 3 6 5 OSCILLOSCOPE 370 10 3 6 6 OPTIONS 371 10 3 6 7 SCALE SELECTIONS 374 10 3 6 8 AC DC READING SELECTION 376 10 3 6 9 TYPES OF SYNCHRONISM 377 10 3 7 AUTO DIAGNOSTIC...

Page 11: ...ty GENERAL PRECAUTIONS Correct maintenance and reparation procedures are important for the mechanic s safety and for the motorbikes safety and reliability In case more persons work together pay attention to the reciprocal safety In case it is necessary to start the motor inside a workshop take care that the exhaust gases are convoyed outside When you use toxic or inflammable materials take care th...

Page 12: ...diagonally starting from the centre and tighten to the indicated torque If you remove oil seals sealings O ring security washers self locking nuts cotters elastic rings and other specified parts be sure to replace them with new parts Moreover before assembling the new parts remove probable residual material of the contact surfaces The elastic rings must not be used a second time During the install...

Page 13: ...ed components including cylinders pistons gears and other parts that have become coupled during normal wear The coupled components must always be re used or changed without separating them 4 During dismantling clean all the components and place them in a bowl following the order of dismantling This will make the re mounting operation easier and allow a correct installation of all the components 5 ...

Page 14: ...nd the ends of the safety pins on a flat surface of bolts or nuts BALL BEARINGS AND OIL SEALS WARNING Do not rotate the compressed air ball bearings as this might damage their surfaces 1 Install the ball bearings and the oil seals so that the Producer brand or data are visible At the moment of installing the oil seal oil the lip with a slight layer of grease The ball bearings rotate freely if oile...

Page 15: ...2 R180197017000 INSTRUMENT FOR MOUNTING CLUTCH OIL SEAL CASING 3 R180197018000 CYLINDER MOUNTING SPACERS 4 R180197019000 SMALL CYLINDER COLUMN FIXING SPAN 5 R180197020000 FALSE SPARKING PLUG 6 R180197021000 PISTON THREAD MEASURER 1 3 1 SPECIAL ENGINE INSTRUMENTS ...

Page 16: ...180197023000 CLUTCH COVER OIL SEAL PAD 9 R180197024000 OIL SEAL PINION PAD 10 R180197025000 OIL SEAL VALVE PAD 11 R180197026000 INSTRUMENT FOR CHECKING VALVE LIFT 12 R180197027000 GONIOMETER INDICATOR 13 R180197028000 CLUTCH OIL SEAL PAD ON FLANGE ...

Page 17: ...80197030000 INSTRUUMENT FOR CHECKING ENGINE SHAFT AXIALPLAY 16 R180197036000 ENGINE MANAGEMENT DIAGNOSTIC INSTRUMENT 17 R180100143000 RAPID RELEASE PETROL TUBE KIT 18 R180297130000 CLUTCH REGULATION KEY 19 R180297048000 DISMANTLING PINION INSTRUMENT ...

Page 18: ...ISMANTLING CLUTCH INSTRUMENT 1 R180197033000 20 ALLEN WRENCH 2 R180197031000 STEERING RING NUT CLAMPS 3 R180197034000 EMGINE DISMANTLING INSTRU MENT 4 R180197032000 ENGINE SHOULDER ADJUST MENT CLAMPS 5 R180297049000 COWLING SUPPORT TROLLEY Compulsory instruments ...

Page 19: ...UK 19 MF13 6 R180297129000 RING NUT REGULATION KEY AND STEERING LOCK NUT 7 R300097147000 CHAIN REGULATION TOOL 8 R300097146000 DISASSEMBLY TOOL STEERING PLATE ...

Page 20: ...m Wheelbase 1443 mm Minimum light 100 mm Saddle height 780 mm Weight with oil and full tank 215 kg Weight without oil and full tank 205 kg Maximum load with pilot and load 400 kg 2 SPECIFICATIONS 2 1 GENERAL SPECIFICATIONS S S S S Specifications 2100 900 1443 1050 780 Dimensioni in mm Dimensions in mm ...

Page 21: ... Exhaust valve closing before P M S 21 Valve lift observation data with play of 0 mm Suction 0 75 mm Exhaust 8 75 mm The functioning play of the tappets with the engine cool must be Suction 0 30 0 35 mm Exhaust 0 35 0 40 mm Transmission Multiple disks oil bath friction commanded by a cable activated by a lever on the left side of the handlebar Transmission between engine and primary shaft of the g...

Page 22: ... 4 0 l about Without filter 3 8 l about Cooling Liquid closed pressured circuit with radiator thermostat and radiator oil air cooling A centrifugal pump commanded by gears on the primary gearbox shaft circulates the liquid and an expansion tank recovers the thermal expansion of the cooling liquid Water radiator capacity 3 0 l about Oil radiator capacity 300 cc ...

Page 23: ...S Type Cast Rim Dimensions 17 x MT3 50 Material aluminium Wheel span 120 mm FRONT TIRE STANDARD LIMITS Type Tubeless Dimensions 120 70 ZR17 58W Model D207 F RR Tire pressure cold 250 kPa 2 5 kg cm 2 5 bar Maximum pneumatic pressure 250 kPa 2 5 kg cm 2 5 bar Minimum depth tread 1 6 mm REARWHEEL STANDARD LIMITS Type Cast Rim Dimensions 17 x MT6 00 Material aluminium Wheel span 120 mm ...

Page 24: ...T 4 Brake disks Diameter x thickness 320 x 4 5 mm Min thickness 4 0 mm Max deformation 0 1 mm Thickness brake pads 4 5 mm 0 5 mm Internal cylinder pump diameter 15 mm Internal cylinder clamps diameter 34 mm REARBRAKES STANDARD LIMITS Type Single disk Brake liquid advised DOT 4 Brake disks Diameter x thickness 240 x 5 mm Min thickness 4 5 mm Max deformation 0 1 mm Thickness brake pads 4 3 mm 0 5 mm...

Page 25: ...Spring stroke K1 0 120 mm Oil advised SAE 7 5 Marzocchi 19 Quantity for stems 710 cc BAC K SUSPENSION STANDARD LIMITS Type Oscillating fork Back suspension type Helical spring damper gas Back stroke fork 115 mm Spring Spring rate K1 90 N mm Spring stroke K1 62 mm Optional spring available no Gas air pressure preload spring 1200 kPat 12 kgf cm2 Adjustment preload spring positions 18 mm ...

Page 26: ... Engine control system VALBRO TDD Relay group Safety relay CM1 NAIS 12V h o Dazzle anti dazzle light Ignition relay 01RA001 JCI h o Injector U9122 357 JCI type Pick up type O1VR001 JCI Engine stepper model 028M001 JCI Type bi phase Ignition coils Model 02IG001 JCI Primary coil resistance 0 6 Ù Secondary coil resistance 10 KÙ Primary coil inductance 2 5 mH 1 kHz 0 3V Secondary coil inductance 23 5 ...

Page 27: ... 4 Ù at 20 C Horn Model AB1242 262 O S C Max amperage 1 5A Direction indicator relay Model 70 016 70 001 4 Type Full transistor Flashing frequency 60 120 rpm Wattage 10W 10W 2W x2 Oil pressure sensor 285520 10 BITRON Fuel pump Model BITRON Max amperage 5A max at 13 5V Level sensor in the fuel pump Min resistance 285 Ù tank empty Max resistance 21 Ù tank full Stand switch model CE75A ASAHI DENSO Ra...

Page 28: ...with the relative special instructions if necessary If not otherwise specified the bolts are considered with greased thread created at environmental temperature A BOLT TORQUES Nm kgf m 1 4 mm 2 3 0 23 2 5 mm 4 5 0 45 3 6 mm 10 1 0 4 8 mm 25 2 5 5 10 mm 45 4 5 6 12 mm 80 8 0 7 14 mm 130 13 0 8 16 mm 200 30 0 9 18 mm 240 24 0 ...

Page 29: ...E WITHNUT LOWERCRANKPINHEADTORQUE M6 8 ENGINE ON LOWER FRAME CROSSBAR CLAMP ENGINE HEAD ON RIGHTHAND FRAMEWORK WITH NUT M12 40 RIGHTHANDENGINEFIXINGSCREW HEADTORQUEON M6 10 FRAMEWORK CLAMP RIGHTHANDENGINEHEADONLEFTHANDFRAMEWORK M12 40 WITHNUT FRAME GROUP STEERINGFERRULESTORQUEONLOWERANDUPPERSADDLE M8 25 POSTS ENGINEFRONTSUPPORTRODONSTEERINGSADDLEPOST M10 40 WITHNUT REARFORKFERRULESTORQUEONTHESADDL...

Page 30: ...GROUP COMMANDS PILOT FOOTBOARD ON FRAME SUPPORTS M8 22 GEAR TORQUE COMMAND ON SHAFT M6 10 DRIVING GEAR ROD ON GEAR COMMAND WITH NUT M6 10 DRIVING GEAR ROD ON GEAR PEDAL WITH NUT M6 10 PEDALBEATSPRING PIVOT M5 6 UPPERBRAKEPEDALSUPPORT M8 22 LOWER BRAKE PEDAL SUPPORT M6 10 GEAR COMMAND ON FOOTBOARD SUPPORT M8 22 BRAKE PUMP ROD GROUP ON BRAKE PEDAL M6 10 WITHNUT ...

Page 31: ...ION GROUP FERRULESTEMSONSTEERINGBASE M6 10 FERRULESTEMSONSTEERINGHEAD M8 22 FERRULEHUBSONFRONTWHEELCRANKPIN M8 30 FRONTMUDGUARDSUPPORTSONFORKS M5 6 BRAKE CLAMP SUPPORTS ON FORKS M10 50 REAR SUSPENSION GROUP DAMPERONFORKWITHNUT M10 35 UPPERMOUNT DAMPERONROCKERARMWITHNUT M10 35 LOWER MOUNT REAR SUPSENSION RODS ON REAR FORK WITH M10 35 NUT ROCKERARMONFRAME M10 45 FRONT WHEEL GROUP FRONTWHEELCRANKPINS...

Page 32: ...RADIATOR BOX RADIATOR ON SADDLE PILLAR M6 10 RADIATOR BOX COVER ON BASE M4 1 1 RADIATOR BOX FASTENINGS THREADS M6 4 UPPER COVER RADIATOR BOX FASTENINGS M4 1 LOWER COVER RADIATOR BOX FASTENNGS M4 1 EXPANSION TANK ON FRAME M6 3 COOLERFANWHEEL M6 3 RIGHTWATERCOOLERSUPPORTONFRAME M6 10 RIGHTWATERCOOLERSUPPORTONCOOLER M6 10 LEFTWATER COOLER SUPPORTON FRAME M6 10 LEFTWATERCOOLERSUPPORTONCOOLER M6 10 OIL...

Page 33: ...AKE CLIP ON SUPPORT M8 22 HYDRAULIC CONNECTION ON REAR BRAKE CLIP M10 15 HYDROSTOP ON REAR BRAKE PUMP M10 15 REAR BRAKE OILTANK ON EXPANSION VASE M5 4 EXHAUST PLANT GROUP EXHAUSTCOLLECTORSONENGINEHEAD M8 13 SILENCERSUPPORTONSADDLEPILLAR M8 25 SILENCERONSUPPORT M10 45 RIGHT 3 IN 1 TUBE SUPPORTPLATE ON FRAME M6 10 FIXING 3 IN 1 ON SUPPORT PLATE M10 45 SUPPLY PLANT GROUP COVER ON FILTER BOX M5 3 FILT...

Page 34: ...ROLPUMPONTANK M5 3 PETROLTUBEONTHROTTLEBODY M12 25 DISTRIBUTORONPLATE M5 4 GAS CABLES FIXING PLATE ON THROTTLE BODY M6 10 FRONT AND BACK BODYWORK GROUP USE STANDARDTIGHTENINGTORQUE WITH M6 THREAD FOR BODYWORK 8Nm 20 ...

Page 35: ...BALL BEARINGAND CRANKPIN FIXING SCREW M6 10 SMALLPLATESAND TUBE FIXING SCREW M6 10 CYLINDRICAL CAP M6 25 CYLINDRICAL CAP M6 10 OILDIAPHRAGM M10 25 NEUTRALPOSITIONSENSOR M8 10 MIN OILPRESSURESENSOR M10 25 OIL LOAD CLUTCH SUMP CAP M24 BY HAND CLUTCHSUMPPHASECAP M40 BY STRIKING CLUTCHSUMPCAPSCREW M6 10 SUMP BLOW BY SCREW M6 10 COUNTERSHAFTSUMPSCREW M6 10 OIL EXHAUST SUMP CAP M14 22 SUMPFILTERFIXINGSC...

Page 36: ...20 18 ENGINE GROUP CRANK MECHANISM PHONICWHEELFIXINGNUT M8 25 RODSCREW M9 25 50 ENGINE GROUP CYLINDER PISTON HEAD PRISONNERSCREW M8 12 CONICAL DOWEL M6 10 CONICAL CAP M14 30 CAPFIXINGSCREW M6 13 HEADFIXINGNUT M10 45 100 TIGHTENERFIXINGSCREW M6 10 CYLINDERCAPSCREW M6 10 CYLINDERFIXINGSCREW M6 10 ENGINE GROUP DISTRIBUTION DISTR ENTRYFIXINGSCREW M6 15 UPPERPADSUPPORTFIXINGSCREW M6 15 DISTR SUMPCOILFI...

Page 37: ... M6 10 GEARCOMMANDSUMPFIXINGSCREW M6 10 GEARCOMMANDSUMPFIXINGSCREW M6 10 CHAINCOVERSUMPFIXINGSCREW M6 10 GEAR FLANGE FIXING SCREW M8 20 ENGINE GROUP COOLING PUMPROTORBLINDFIXINGNUT M6 8 3 PUMPCOVERFIXINGSCREW M6 10 PURGESCREW M6 10 CRANKFIXINGSCREW M6 10 PUMPBODYFIXINGSCREW M6 10 COLLECTORFIXINGSCREW M6 10 THERMOSTATCAPFIXINGSCREW M6 10 SMALL COVER FIXING SCREW M6 10 ENGINE GROUP IGNITION SPARKING...

Page 38: ...crews Oil pump rotors Distribution bowl surfaces LOCTITE sustitute the element Clean and degrease the surfaces MOLYBDENUM BISULFIDE OIL Suction and discharge valve stems LITHIUM SOAP GREASE Sealing ring lips TEFLON SYNTOFLON PASTE Engine shaft pins Eccentric shaft pins Eccentric shaft u bolts MOLYCOTE COPPER GREASE Engine shaft fixing screws Gear flange Prisonner head fixing nuts THREE BOND 1215 S...

Page 39: ...UK 39 MF13 S S S Ls Ls DRY NEW NEW NEW NEW L ...

Page 40: ...UK 40 MF13 ...

Page 41: ...UK 41 MF13 ...

Page 42: ...UK 42 MF13 R L L E E E ...

Page 43: ...UK 43 MF13 ...

Page 44: ...UK 44 MF13 Ls L R E NEW L R E E E L E E L E ...

Page 45: ...UK 45 MF13 Ls L E L E Ls ...

Page 46: ...UK 46 MF13 E E T T T T T L Ls ...

Page 47: ...UK 47 MF13 E E E E E E ...

Page 48: ...UK 48 MF13 ...

Page 49: ...UK 49 MF13 ...

Page 50: ...UK 50 MF13 ...

Page 51: ...UK 51 MF13 L E E L L ...

Page 52: ...in 1st 2nd 3rd Service Service Service Engine oil Engine oil filter Cooling liquid Cooling plant Electrofans Valves Distribution chain Distribution mobile pad Distribution chain stretcher Sparking plugs i Before every use of the vehicle R i R Every year in any case R i R At every change of engine oil in any case i i i Every 2 years i i i i i i i i i i Every 40000 km 24900 mi i i Every 40000 km 249...

Page 53: ... Gear command Brakes Brake pads Accelerator command Clutch R i i i i i i i i i At every change of the transmission chain in any case i i R Clean and oil every 1000 km 625 mi i i R At every change of the transmission chain in any case i i i i i i i i i 16000 Km Every 3 years in any case i i i Every 25000 km 15000 mi Every 2 years in any case i i i i i i i i i i i i i i i i i i i Check Change Check ...

Page 54: ...ar damper Front fork oil Battery connections Electrical plant Instrumentation Vision Lights Signals Horn Front headlight Ignition switch i i i i i T i i i T i i Every 20000 km 12000 mi i i i i i i i i Every 50000 km 30000 mi i i i i i i i i Every 35000 km 21000 mi i i i i i i Every 20000 km 12000 mi i i i i i i i i i i i i i i i i i i i i i i i At every variation in the state of the vehicle i i i ...

Page 55: ...NTENANCEFREQUENCY 0 km 1000 km 6000 km 11000 km 0 mi 625 mi 3750 mi 6875 mi COMPONENT OPERATION before delivery running in 1st 2nd 3rd Service Service Service Locks Screws and nuts Tube clamp straps General oiling General test i i i i i T T T i i i i i i i i i i i i Check Functioning Check Tighten Check Tighten ...

Page 56: ...the nut 1 Remove the coil support rod 2 Slip off the coil Remove the sparking plugs beneath Sight check the state of the sparking plugs the isolator must not show any damage the electrodes must not be worn out the candles must not be burned or discoloured If the electrodes are contaminated with dirt deposits or rubble replace the candle Replace the candle if the central electrode is rounded Check ...

Page 57: ...ng on dusty roads the filtering element must be cleaned often Using the engine without filter or with a brokenfilteringelementisthesurestwayofaccelerating wearontheengineitself Makesurethattheairfilteris alwaysinagoodcondition Thedurationoftheengine depends in large part on this component ATTENTION To avoid the risk of fire or explosion do not use pet rol or inflammable solvents in cleaning the fi...

Page 58: ...is not dripping Reposition the filtering element inside the air box Position the air box cover 2 and fix it with the nine screws Mount the tank see MOUNT TANK 3 3 1 REMOVAL OF AIR BOX THROTTLE VALVE AND AIR BOX DUCT Remove the throttle valve fixing screw 1 Take off the recall cable 2 from the throttle Check visually the free run of the paddles 3 Loosen the screws of the clamps 1 on the throttle bo...

Page 59: ...ove the Air Box air duct 3 Check the state of the components visually if necessary replace them 3 3 2 SOLENOID MOTOR REMOVAL Remove the petrol tank Loosen and remove the fixing screws 1 Loosen the nut 1 and the lock nut 2 Take off the recall cables take off the connector remove the solenoid 3 1 ...

Page 60: ...the two rubber protections 1 Loosen the counter nut 2 Carry the adjusters to the bottom of the stroke 3 Remove the tank see tank disassembly Remove the air box see AIR box disassembly Remove the air box duct see AIR box disassembly Bigger adjustments are made with the lower adjustment screws Adjust the play on the nuts 4 and counter nuts 5 Adjust the play using the adjusters turning them clockwise...

Page 61: ...with the dedicated special tool Screw up the register in the clutch lever group completely until it touches Unscrew the locknut on the clutch bell plate and unscrew the registering screw two or three turns From this position slowly screw up the registering screw until resistance is felt From this position unscrew the registering screw of a turn and then tighten the locknut Register the clutch cabl...

Page 62: ...STRUMENTS Engine management diagnostic instruments R180197036000 ATTENTION The Axone connection must be carried out with the key on OFF Removing the driver saddle see saddle removal Remove the protective hood 1 of the diagnostic socket connect the Axone to the diagnostic socket 2 positioned under the passenger saddle Turn the key to ON Check that the arrest bike switch on the right command is on R...

Page 63: ...Stepper position and the strength of the mixture The position of the Stepper must maintain a value between 10 and 15 pitches If the value is not correct select fuel adjustment minimum on the Axone select icon adjustments hammer and screwdriver then take the Stepper to the values mentioned before Changing this parameter a CO reading will be obtained on the tester of about 1 MAX 1 5 lower values ind...

Page 64: ...dy to a vacuum gauge Start the engine and warm it up to 85 90 degrees Verify that the mercury columns 2 with the engine running at minimum are aligned otherwise balance them Adjust the values through the balancing screws 3 alignment of the body n 3 with the body n 2 the body n 1 with the body n 2 until you reach the alignment of the vacuum gauge s mercury columns 1 2 3 ...

Page 65: ...ne and warm it up to 85 90 degrees Verify visually the alignment of the mercury columns of the vacuum gauge If necessary adjust the values through the by pass screws 4 Once balanced the body tighten the by pass screws closing the passages completely 3 8 CHECK STEPPER Remove the petrol tank see petrol tank disassembly Remove the air box see AIR box disassembly Remove the air box duct see AIR box du...

Page 66: ...that there are no obstructions inside the valve body 5 otherwise replace it If required clean valve body and stepper Make sure that the piston A is moving free inside the valve body B If there is a hindered or forced movement replace the valve body B Check the conditions of the two O ring sealings C if required replace in couple Note In case of replacement of the Stepper verify the setup with the ...

Page 67: ...el inspection chap Turn the screw 1 using a compass key to align the two reference notches A and B taking the engine to the Upper dead point Taking the engine to the UDP verify that also the notches C and D of the Camshaft sprockets are aligned between them and with the head plain E Measure the clearance between camshaft and valve chap by a thickness gauge making sure that the clearance is in the ...

Page 68: ... the camshaft fixing bridges Raise the cam shaft paying attention to keep all teeth of the distribution chain in place allowing so the removal of the valve chap s 1 Raise the valve chap s 2 one at a time by aid of a magnet Remove the valve tablet 3 replace it with a new one 1 ...

Page 69: ...sassembly Remove the head carter see head carter disassembly Remove the phonic wheel CHAP see phonic wheel disassembly Mount the special tools Take the engine to the UDP see procedure NOTE The equipment for checking the valve lifter is to be mounted with the initials IN IN IN IN IN aspiration side and EX EX EX EX EX on the exhaust side Rotate the goniometer hold clockwise 1 until the first piston ...

Page 70: ...mm and check the goniometer value SPECIFIC VALUE Aspiration 21 opening 2 before the UDP Return piston one to the UDP Verify and reset the comparators and the goniometer Rotate the goniometer clockwise charging 1 mm on the comparator C exhaust Verify the specific value on the goniometer SPECIFIC VALUE Opening exhaust 42 2 before the LDP A B C D 21 2 ...

Page 71: ...case of swallowing en gine oil call a doctor immediately and in order to avoid sucking the product into the lungs do not pro voke vomiting It has been noted that continuous contact with engine oil provokes skin cancer in cav ies Brief contacts with engine oil can irritate the skin Keep new or used engine oil away from children and domestic animals Wear long sleeved clothing and gloves imperme able...

Page 72: ...il cap 1 with the engine off and pour a quantity of oil of the type advised until reaching half way up the spyhole between the MAX and MIN references Screw on the cap 1 again NOTE The engine contains around 3 8 litres of oil Use oil classified API SG or SH and viscosity SAE 15 W 50 3 12 CHANGE ENGINE OIL AND FILTER Let the engine run at minimum for 5 minutes then turn it off Place an adequate cont...

Page 73: ...s in vigour Remove the oil loading cap 1 Remove the magnetic oil discharge chap 2 Let all the used oil empty away Loosen the screw 1 and remove the security clamp 2 Unscrew and remove the oilfilter 3 Replace the filter with a new one tighten to the correct torque WORM DRIVE 15 N m 1 5 Kg m 20 N m 2 0 Kg m 1 2 3 2 1 ...

Page 74: ... magnetic CHAP is not damaged Replace it if necessary Re position the oil exhaust cap 2 and tighten it 22 N m 2 2 Kg m Fill the engine block with the recommended motor oil until the maximum reference level is reached on the inspection window Turn the engine on and let it run at minimum for about 5 minutes Switch off the engine and wait for 5 minutes Always check that the level in the spyhole is mi...

Page 75: ...id far from children and do mestic animals In the case of swallowing cooling liquid call a doc tor immediately and in order to avoid sucking the product into the lungs do not provoke vomiting In the case of contact of the engine cooling liquid with the eyes or the skin immediately rinse with water WARNING Sprays of refrigerant can damage painted surfaces Be careful not to spill the fluid when fill...

Page 76: ...f the radiators neck using recommended cooling liquid Verify the reference MIN and MAX on the recovery tank 3 14 CHANGE REFRIGERANT LIQUID NOTA Eseguire le seguenti operazioni a motore freddo e moto sul cavalletto laterale Remove the radiator cap 1 Prearrange near the motorcycle a container with a capacity higher than 4 litres for the exhausted liquid recovery 1 2 1 ...

Page 77: ...on both sides and press contemporaneously on the entry and exit rubber tubes of the radiator Remove the discharging bolt 1 on the cylinder 2 to discharge the residual liquid in the cylinder head body and cylinders Wait for the cooling liquid to empty itself completely TIGHTEN LIQUID DISCHARGE SCREWS ON PUMP ANDCYLINDERS 8 N m 0 8 Kg m ATTENTION In re mountng always substitute the copper washers of...

Page 78: ...ossible air sacks press the COOLER rubber pipes or incline the motorbike alternating to both sides Verify the liquid cooling level through the recovery cistern 3 Take the reference level between MIN and MAX Close the CHAP of the recovery 4 tank Start the engine and bring it to working temperature until the fans start about 103 Through the radiator pipe union switch off the engine Fill up through t...

Page 79: ...NG DUCT CHAP S DISTRIBUTION CHAIN VALVE CHAP S PISTONS PLUGS CONNECTING RODS BENCHES PRESSURE SWITCH MAIN DUCT OVERPRESSURE VALVE PUMP DISTRIBUTOR FILTER COOLER PAN PUMP ASPIRATION OIL CIRCUIT SCHEME GEAR BOX PRIMARY SHAFT CLUTCH SHOWER SECONDARY SHAFT ...

Page 80: ...ly worn or damaged replace it Remove the number plate holder see disassembly number plate holder Unscrew and remove the two screws 1 take off the spring 2 and slip off the muffler A Unscrew and remove the screw 3 take off the holding spring 4 slip off the second pipe union b Take off the spring 5 take off the valve cable 6 slip off the three in one pipe union c Unscrew and remove the nuts from the...

Page 81: ...F13 Loosen and remove the screw 3 Take off the holding spring 4 slip off the pipe union B Loosen the nut and the lock nut 5 Take off the valve recall cable 6 Slip off the three in one pipe union c 3 4 B 5 6 C ...

Page 82: ...LEVER ATTENTION Danger never carry out adjustment with the engine running Push on the lever 1 to neutralize the spring s push and simultaneously adjust the position rotating the ring nut 2 clockwise or counter clockwise setting the lever in one of the four possible positions Position 1 farer from the handlebar Position 2 nearer the handlebar 3 19 ADJUSTMENT REAR BRAKE PEDAL Loosen the nut and the ...

Page 83: ...Km and then every 5000 Km ATTENTION Brake liquid is harmful or mortal if swallowed and harmful if it comes into contact with the skin or the eyes Keep the brake liquid away from children and do mestic animals In the case of swallowing the brake liquid call a doctor immediately and in order to avoid sucking the liquid into the lungs do not provoke vomiting In the case of contact of the brake liquid...

Page 84: ...locks Remove the brake blocks verifying that the thickness A is not under 3 5 mm It is necessary to replace the brake blocks when the contact surfaces between the block and the disc is down to brake lining A Besides the visual checking you can hear a particular noise while braking due to the dragging of the brake lining on the disc NOTE It is necessary to replace brake blocks always in couple to g...

Page 85: ... with the arrow up in march sense Position the two blocks insert the two plugs 2 insert the two elastic stoppers 3 Position the brake pliers on the fork stem so that the disc is between the two blocks Insert and tighten the two screws on the fork stem to the indicated torque 30 N m 3 0 Kg m WARNING After changing the brake pads work on the brake command with long but not intense braking for about ...

Page 86: ...ring 4 undo the pin 5 on the opposite side and remove the spring 6 Replace the couple of blocks 7 Re position spring 6 pin 5 and secure with ring 4 WARNING After changing the brake pads work on the brake command with long but not intense braking for about a hundred Km ...

Page 87: ...nge the tubes every 4 years 3 23 AIR DISCHARGE FRONT BRAKING SYSTEM WARNING Fill with the brake liquid using only the type of liq uid advised in the oils and liquids table of this manual Eventual mixing of fluids of a different type might cause a dangerous chemical reaction and a dimin ishing of braking efficiency with a consequent in crease in the risk of accidents WARNING During the purge of the...

Page 88: ... pipe to the pliers air discharge screw 3 Loosen the discharge valve Push and release the lever or the pedal repeatedly and in quick sequence Press fully and open the purge screw 2 Repeat the procedure until all the air bubbles have been com pletely removed Check the oil level in the tank during the operation Restore if necessary Close the discharge screw 3 25 N m 2 5 Kg m Reassemble the brake pli...

Page 89: ... automatic filling system add the brake liquid when the liquid level in the tank goes down Check the liquid level often during brake air discharge to avoid pumping air in the system When a brake discharge tool is used follow the user instructions of the manufacturer If a brake discharge tool is not available adopt the following procedure Connect a transparent discharge pipe to the discharge valve ...

Page 90: ... PEDAL Remove the fixing screws 3 of the gear pedal rod Loosen the two nuts 1 Adjust the angle of the gear command pedal by working on the rod 2 Rotating it clockwise the pedal will bend lower and vice versa if rotated anti clockwise 2 1 1 3 ...

Page 91: ...inary cleaning before lubrication it is mandatory to dissolve dirt deposits from the chain using kerosene such deposits must be subsequently removed with a clean cloth and or an air jet 3 26 CHAIN REPLACEMENT WARNING Using the motorcycle with the chain in a bad condi tion or badly adjusted may cause accidents WARNING If the chain shows flattened or scuffed links a correct oiling of the chain accor...

Page 92: ...f the main link and the O ring rubber tops Insert the main link from the inside of the transmission chain and install the plate with the identification sign turned towards the outside Be sure that the pivots of the main link are installed correctly Rivet the pivots of the principal stitch After riveting check that the hit areas of the main link are not cracked If there are cracks replace the main ...

Page 93: ... in neutral Loosen the eccentric blocking screws 1 on both sides of the fork Insert the specific tool in the eccentric rotate clockwise to pull the chain and counter clockwise to loosen the chain SPECIFIC EQUIPMENT Chain regulation tool R300097147000 Verify that there are about 15 mm between the fork and the lower chain shoe 15 mm 15 mm 15 mm 1 ...

Page 94: ...NG If the chain presents squashed or seized links lubrify correctly according to the instructions reported in the present chapter ATTENTION Do not inspect or adjust the transmission chain while the engine is on 3 28 CONTROL AND REPLACEMENT TRANSMISSION COG WHEELS Remove the cog wheel lid Remove the chain Check that the leading and conducted gear teeth are not damaged or worn replace them if necess...

Page 95: ...ing screws 1 Lower the handlebar on the tank Protect the tank with a cloth Remove the upper steering plate 1 see DISMANTLE FRONT FORK Remove the handlebar ATTENTION During the assembly phase never exceed the tightening torque to avoid steering malfunction Loosen the counter ring nut 2 and tighten the ring nut 3 us ing the specific instrument SPECIFIC EQUIPMENT Steering ring nut clamp R180297031000...

Page 96: ...e upper steering plate 1 see MOUNT FRONT FORK Check the free rotation of the steering 3 30 CHECK FORK Keeping the front brake drawn verify the state of the fork moving it Sight check the state of the splashguards If the fork needs maintenance refer directly to the supplier listed in the SPECIFICATIONS chapter ...

Page 97: ...MENT DAMPER Two adjustments are possible on the rear damper Preload spring adjustment 1 Braking in extension adjustment 2 REAR SUSPENSION NOTE The adjustment of the preload is carried out starting from the length of the damper equal to 140 mm Adjustment in compression and extension starts from all closed in direction Standard set up Spring length 140 mm Spring Preloaded 14 mm Brake in extension 12...

Page 98: ...d with ring nut 2 Clockwise the preload will be more rigid Anti clockwise the preload will be slacker Once the preload is adjusted tighten the ring nut 1 Adjusting the hydraulic braking device in compensation is car ried out in sudden steps Rotate the adjuster 3 clockwise to increase the braking ac tion or anti clockwise to diminish it 2 1 3 4 ...

Page 99: ...r its detachment with consequent deflation of the tire and loss of control of the vehicle Check the pressure of the tires with a manometer NOTE In the case of long continuous driving increase the value of nominal pressure by 0 2 bar Check the wear on the tires When the tread is at the same level as in A change the tire Pressure Front tire 250 kPa 2 5 bar Rear tire 250 kPa 2 5 bar A ...

Page 100: ... enter within the specific value SPECIFIC VALUE Axial veer 0 3 mm Work on the front wheel as on the back wheel SPECIFIC VALUE Axial veer 0 05 mm Excessive veering and eccentricity are generally caused by wear of the ball bearings Change the ball bearings If the problem persists change the rim of the wheel ...

Page 101: ...inse with a lot of water INTERNALCONTACT Drink great quantities of water or milk and immediately call a doctor EYES Rinse with water for 15 minutes and immediately see a doctor Moreover leakage of sulphuric acid leads to the formation of hydrogen that can provoke an explosion in the presence of a spark or a flame 3 35 ELECTRICAL PLANT 3 35 1 CHECK BATTERY This motorcycle is equipped with a sealed ...

Page 102: ...tal voltmeter to the battery terminals Positive tester probe positive battery terminal Negative tester probe negative battery terminal NOTE It is possible to check the state of the MF battery recharging by measuring the tension at empty i e the tension present with the positive terminal dfisconnected It is not necessary to recharge when the tension at empty is equal to or superior to 12 8V Check t...

Page 103: ... sure that the clips are well connected to the battery ter minals and are not short circuited Acorroded clip can provoke overheating at the contact point and a clip left behind can cause sparking If the battery heats up during recharging disconnect the battery charger and let the battery cool down before continuing This is necessary to avoid the battery exploding As illustrated in the figure the t...

Page 104: ...e battery charger and an ampere meter to the battery Begin the recharging operation Is the amperage higher than the standard charge indicated on the battery Wait more than 30 minutes before measuring the tension at empty of the battery 12 8 V recharge completed 12 0 12 7 V recharging needs to be carried out less than 12 0 V change the battery NOTE Set the recharge tension to 16 17V if the tension ...

Page 105: ...Wait more than 30 minutes before measuring the tension at empty of the battery 12 8 V recharge completed 12 0 12 7 V recharging needs to be carried out less than 12 0 V change the battery NOTE Set the recharge tension to 16 17V if the tension is lower the recharge will be insufficient If the tension is higher the battery will overload This kind of battery charger is not suitable for an MF battery ...

Page 106: ...of fire The fuses of the services 3 are in the glove box under the passengers saddle that must be removed to reach them Replace the burned fuse and close the lid NOTE Consult the information in the key to identify the function of the fuses Nine fuses are in the fuse box Alarm equipment fuse 2A 1 Petrol pump fuse 15A 2 Electric fan fuse 20A 3 Service fuse 10A 4 Light fuse 15A 5 Injection fuse 20 A ...

Page 107: ...ht and left inspection chap s of the parabolas unscrewing and removing the fixing screws 1 3 38 1 FRONT LIGHT DISASSEMBLY Remove the front shield carrier see Front shield disassembly Unscrew and remove the screws 2 from the framelet Take off the wiring connector front light 3 1 2 3 ...

Page 108: ...ion lids Unscrew the light fixing pivots 1 Unscrew and remove the central closing screw 2 from the framelet right and left Loosen and remove the screws 2 remove the speed indicator take off the connector 3 remove the light wiring 2 3 2 1 ...

Page 109: ...it on the vehicle in the driving position and check that the upper limit of the beam projected onto the vertical wall in less than about 1 10 with respect to the the horizontal axis of the lights For the setup of the front light adjust the two parabola adjustment screws 1 right and left positioned under the light There is the possibility to set the light parabola right and left separately loosenin...

Page 110: ...ING REAR HEADLIGHT This motorcycle is equipped with led lights Loosen the screws 2 of the muffler and lower it to allow to remove the lamp Cut the wiring blocking clamp 3 take off the connector 4 Loosen and remove the nuts 5 remove the light 6 2 3 4 6 5 ...

Page 111: ... 3 40 3 CHANGE FRONT AND REAR ARROWS 3 40 3 1 CHANGE FRONT ARROWS Cut the wiring fixing clamps Loosen and remove screw 1 Remove the arrow body Disconnect the connector Unscrew and remove the glass fixing screw Replace the damaged lamp 4 rotating it counter clockwise Position the arrow body the glass and fix it with the relative screw Work in an analogous way with the opposite arrow 1 1 4 ...

Page 112: ...UK 112 MF13 3 40 3 BACK ARROW LAMP REPLACEMENT Loosen and remove the screw 1 Remove the arrow glass 2 Remove and replace the lamp 3 Reposition the glass 2 tighten the screw 1 2 1 3 ...

Page 113: ...UK 113 MF13 ...

Page 114: ...off the cover pulling it towards away from the motorcycle Proceed the same way for the right cover 4 2 PETROL TANK DISASSEMBLY Remove the driver s saddle Loosen and remove the fixing screws 2 of the lock closing lid 3 Loosen and remove the front tank fixing screws 4 Loosen and remove the lateral right and left screws 5 Raise the tank take off the petrol pipe remove the tank from the motorcycle C C...

Page 115: ...fixing plate 2 4 2 2 PETROL PUMP REMOVAL Remove the petrol pipe see petrol pipe disassembly Disconnect the rapid unhooking petrol tube 8 from the pump using the specific equipment SPECIFIC EQUIPMENT QUICK PIPE REMOVAL KIT R180100143000 Insert the specific pump valve closure cap 10 to avoid oil spill ing out 1 2 ...

Page 116: ... proceed in the reverse way to dismantling NOTE Position the sealing O ring correctly in the apposite seat during remounting 4 4 COOLER FAIRING DISASSEMBLY Loosen and remove the screw 1 placed inside the flank cover Remove the arrow 2 Loosen and remove the fixing screw 3 fairing Take off the bottom from the cooler support Loosen and remove the screws 4 separating the internal fairing from the exte...

Page 117: ...eld support pulling it away from the motorcycle Loosen and remove the screws 2 remove the front shield from the front shield support 4 5 COOLERS CONVEYORS DISASSEMBLY Position the motorcycle on the side stand Remove the cooler covers see cover disassembly Unscrew and remove the screws 1 of the upper cooler fixing plate 2 1 ...

Page 118: ... right cooler support from the inlet fixing NOTE Replace the clamp when reassembling Take off the right cooler towards the outside from the supports allowing to slip from the ducts Slip off the right cooler 4 duct Proceed the same way for the left conveyor Proceed in inverse way to reassemble 2 3 4 ...

Page 119: ...il brake pipe blocking support from the mudguard 2 Unscrew and remove the screws 1 Slip off the mudguard 4 6 2 BACK MUDGUARD DISASSEMBLY Unscrew and remove the screws 1 Slip off the mudguard 3 4 7 CHAIN CARTER DISASSEMBLY Unscrew and remove the screws 4 Slip off the chain carter 5 2 3 4 5 ...

Page 120: ...13 4 8 NUMBER PLATE HOLDER DISASSEMBLY Cut the wiring blocking clips 1 Take off the connectors of the back lights Unscrew and remove the screws 2 on both sides of the exhaust Remove the number plate holder 2 1 1 ...

Page 121: ...UK 121 MF13 ...

Page 122: ...the radiator tube from the pump and blow off the liquid Disconnect the gas cables Disconnect the bobbins Disconnect three injectors connectors Disconnect the potentiometer connector Disconnect the phase sensor connector Disconnect the water sensor connector Disconnect the stepper sensor connector Disconnect the oil press sensor connector Disconnect the neutral sensor connector Disconnect the solen...

Page 123: ...per right and left without removing them Loosen the two security arm band screw s 5 of the lower motor fixing on the right side Loosen and remove the spindle 6 lower motor fixing Loosen the metal ring with the right tool 7 inside the frame of the upper motor spindle fixing SPECIFIC EQUIPMENT Registration key Motor shoulder code R180197032000 ...

Page 124: ...ing Place the motor ahead and put a suitable support to the motor remove definitively the two upper motor fixing screws lower the motor and pull it out of the frame 5 0 2 MOTOR ASSEMBLY ON THE FRAME Place the motor lift and fix it with the two upper fixing screws ...

Page 125: ...tor toward the frame back wall connect the lower and upper motor fixing spindles without closing Close the upper spindle 1 to the ledge loosen again the revolution spindle ritighten it to ledge Close the ledge inside metal ring 2 ...

Page 126: ...ge lower spindle 3 Close the two arm band security screws 4 Close the two upper fixing motor screws 5 and 6 close the arm band security screw 7 Install the small frame close the couple of the upper fixing screws 8 close the security screws ...

Page 127: ...34000 To support the engine use the specific equipment SPECIFIC EQUIPMENT Engine support R180197029000 Remove the access cover 1 to the phonic wheel Position the phonic wheel as shown in the figure The two signs Aand B Aon the cover B on the phonic wheel must coincide PMS Remove the three aluminium rods 2 that fix the relative coils using the fixing nuts 3 1 B A 2 3 ...

Page 128: ...ps 5 during reassembly Remove the head cover Remove the chain pad 6 unscrewing the two fixing screws 7 ATTENTION Make sure that the distribution chain does not fall into the casing Remove the chain stretcher ATTENTION Note the position of the elements for correct remounting Unscrew the fixing screws of the large caps 8 and remove them Remove the bridge 9 unscrewing the fixing screws Remove the cam...

Page 129: ...eck the deformation of the camshaft with a comparator as shown in the figure If the value does not enter within the specific measure change the element SUCTIONAND EXHAUST SHAFT DIMENSIONS LIMIT MAX VALUE 0 03 mm The maximum play between the distribution camshaft and seat is 0 1 mm If the value does enter within the specific value change the element VALUE LIMIT CAMSHAFTAND SEAT Max play 0 01 mm SPE...

Page 130: ...1 If the element has blocked links is excessively worn or has exceeded 40000 Km change it Sight check the distribution chain guides 1 Fixed guide FRONT PART 2 Mobile guide REAR PART 3 Upper guide FIXED ON HEAD If one or more elements are worn change it them NOTE REPLACE ALWAYS THE CHAIN SHOES WHEN REPLACING THE DISTRIBUTION CHAIN ...

Page 131: ...n position the fixed pad and then the mobile pad Position the exhaust shaft and the distribution chain position the caps in their original direction written on the outside and tighten the fixing screws according to the diagram in the figure 1st phase 6 N m 2nd phase 13 N m Position the aspiration shaft and the distribution chain position the caps in their original direction with the writing on the...

Page 132: ...tions Re position the fixed pad Position the body of the chain stretcher 1 complete with O ring 2 and tighten the two screws 6 as specified in the diagram 10 N m Position the rod pushing spring 3 and the washer 4 and tighten everything with a drive screw 5 as in the diagram 7 8 N m ATTENTION Always check that the chain stretcher is always in position 0 in exhaust before mounting it Align the signs...

Page 133: ...ion of the phonic wheel is as indicated in the figure A and B aligned Check the valve play with a feeler If the valve play is not within the specific value adjust the valve play see ADJUST VALVE PLAY Screw the phonic wheel cover onto the right side of the engine ASPIRATION SHAFT VALVE PLAY 0 30 0 35 EXHAUST SHAFT VALVE PLAY 0 35 0 40 ...

Page 134: ...nting that the gaskets 2 do not fall into the head Apply THREEBOND paste as in the drawing Position the cover of the head and insert the screws 3 and 4 where indicated in the figure Tighten the 8 fixing screws of the head with the appropriate rubber washers NOTE Replace the rubber tops of the screws 3 during reassembly 3 4 ...

Page 135: ...cated in the figure paying attention not to cut or damage the gaskets 10 N m 1 Kg m 5 2 CYLINDER HEAD 5 2 1 REMOVE CYLINDER Remove the canshaft see REMOVE CAMSHAFT Loosen and remove the eight nuts 1 indicated in the figure and the two screws on the right side of the engine distribution side NOTE Loosen for a moment the fixing screws and nuts according to the sequence indicated in the figure Then r...

Page 136: ...alve seat Check and eventually eliminate carbon deposits in the combus tion chamber with a rounded off scraper If the surface is damaged or scratched change the element Check the distortion of the cylinder head as indicated in the figure If is is outside the specific value rectify the head VALUE LIMIT HEAD DISTORTION max distortion 0 2 mm ...

Page 137: ...hase final tightening with an angle of 50 50 NOTE Apply grease to the fixing nuts to oil the threading MOLIKOTE CU7439 PLUS copper grease Mount the oil tube head 20 connection to the crankcase Tighten to the prescribed worm drive N B This tightening requires a worm drive angle wrench Drilled screw 20 N m 2 Kg m LOCTITE 270 Joining element on crankcase 20 N m 2 Kg m 5 3 VALVES AND VALVE SPRINGS 5 3...

Page 138: ... components 7 8 and 9 NOTE Make sure that valve 4 has a perfect seal by pour ing petrol into the conduits and making sure that there are no losses through the valves Make sure that the valves are perfectly sealed Remove the small bowls taking note of the position on each valve and coupling them to their pads Free the pusher spring plate 7 using the specified instrument to remove the two lock cones...

Page 139: ...s If values A and B are not within the value limits change the elements ASPIRATION VALVE DIAMETER LIMIT A max 5 05 mm B min 4 965 mm EXHAUST DIMENSION LIMITS A max 5 05 mm B min 4 955 mm Check the state of the surfaces of the valves Eliminate eventual carbon deposits If the surface is excessively ruined change the element Check thickness A indicated in the figure VALVE THICKNESS VALUE LIMIT A 1 0 ...

Page 140: ...UK 140 MF13 Check the deformation of the legs of the valve If the concentricity value does not enter within the margin change the element VALVE REFORMATION VALUE LIMIT 0 01 mm ...

Page 141: ...o remove the bluing at the point at which the seat and the face of the valve touch NOTE If the trace is not partial or not uniform carry out a smoothing operation on the face and the seat of the valve Smooth the face of the valve the seat of the valve NOTE After having changed the cylinder head or the valve and the relative guide it will be necessary to smooth the seat and face of the valve Apply ...

Page 142: ...ns Completely eliminate the smoothing paste from the face and the seat of the valve at the end of each operation Apply the tincture of bluing b on the face of the valve Install the valve in the cylinder head Press the valve through the valve guide and on the valve seat to leave a clear trace 5 3 4 CHECK THE VALVE SPRING The following procedure is valid for all the valve springs Measure the length ...

Page 143: ...314 N Check the inclination a of the valve spring as illustrated in the figure If a does not enter within the specific value change it VALUE LIMIT INCLINATION SUCTION SPRING A 2 mm VALUE LIMIT INCLINATION EXHAUST SPRING A 2 mm 5 3 5 CHECK BUCKET TYPE TAPPET The follwing procedure must be applied to all the bucket type tappets Check that the buckets are not broken or scratched if so change them ...

Page 144: ...Oil the valve stem with the recommended oil RECOMMENED OIL Disulfide of molybdenum oil Mount the lower small cup 1 Check that the thickness of the small cap is 1 5 mm WARNING Always use new gaskets and oil seals Mount the rubber valve seal 2 with the appropriate pad 3 SPECIFIC EQUIPMENT INSTRUMENT 3 R180197025000 ...

Page 145: ...13 ATTENTION The suction valves are larger than the exhaust valves Insert the valves 4 Position the internal 5 and external 6 springs as shown in the figure Insert the two lock cones 7 into the upper small cup 8 ...

Page 146: ...e tappets 10 ATTENTION Make sure that the individual valve lifters and the valve guide are re mounted in the original position NOTE Check that the buckets turn easily by rotating them with a finger 5 4 CYLINDER 5 4 1 DISMANTLE CYLINDER BODY Remove the cylinder head see REMOVE CYLINDER HEAD Remove the gasket of the head the cylinder body 1 and the base of the cylinders gasket beneath ...

Page 147: ...e ATTENTION In the case of changing the cylinder block also changethepistonsandtheelasticstraps ifnecessary The cylinder is distinguished by a letter that indicates the class it belongs to The cylinder piston coupling must be carried out among the same classes that they belong to The letters are on the external front part exhaust side of the cylinder 5 4 3 DISMANTLE WATER COLLECTOR Unscrew and rem...

Page 148: ...ts Position the gasket 1 and the collector 2 and tighten the screws 3 10 N m 1 Kg m 5 4 6 MOUNT CYLINDERS WARNING Always use new gaskets Position the gasket 1 and the liners 2 3 and 4 as shown in the figure and check the correct position of the centering dowels Position the cylinder pistons 5 6 and 7 enter them in order SPECIFIC EQUIPMENT CYLINDER MOUNTING LINERS R180197018000 ...

Page 149: ...SMANTLE PISTON Remove the cylinder see DISMANTLE CYLINDER BODY The following procedure must be applied to all 3 pistons Remove the elastic ring 1 ATTENTION Do not use hammers for the spindle removal 2 Remove pin 2 and remove piston 3 ...

Page 150: ... procedure must be applied to all the segments Check the absence of scuffing and traces of shrinkage on every segment Check that the edge of the section is well defined and free in the housings Whenever wear in the segments is found change the pistons as well 10 5 mm CLASS P A ø 87 950 87 960 B ø 87 961 87 971 C ø 87 972 87 982 5 5 2 CHECK PISTON The following procedure must also be applied to all...

Page 151: ...he segments SEGMENT CABLEPLAY SERVICE LIMIT 1st 0 20 mm 2nd 0 18 mm SEGMENT CABLE WIDTH STANDARD 1st 1 02 1 04 mm 2nd 1 01 1 03 mm SCRAPER RING 2 01 2 03 SEGMENT THICKNESS STANDARD 1st 0 97 0 99 mm 2nd 0 97 0 99 mm 5 5 5 CHECK PISTON PIN The following procedure must be applied to all the piston pins Check that value a enters within the specific value NOMINAL VALUE a 18 995 19 000 mm ...

Page 152: ... ring segment 2nd segment 1st segment The first element to insert into the slot of the scraper ring segment is the spacer 1 After having positioned the spacer insert its lateral rings 2 NOTE The spacer and the lateral rings do not possess a particular upper or lower side so they can be inserted in any way WARNING When installing the spacer pay attention so that its ends are not superimposed in the...

Page 153: ...W4 3 1 0 1 mm W3 3 7 0 1 mm The 1st and 2nd segment have the letter N on the upper side Make sure that the marked side is turned upwards when being installed on the piston 5 5 7 MOUNT PISTON Position the two segments 1 and the scrapper ring 2 on the piston positioning the opening at 120 from each other 1st segment 2nd segment ...

Page 154: ...e new elastic rings for mounting the pistons To avoid breaks that can take place with the rings bent Position the two elastic rings 5 one for each side pay atten tion not to deform them 5 6 GENERATOR 5 6 1 REMOVAL GENERATOR ATTENTION Support the generator during the mounting phase Remove the electrical connections Loosen and remove the three screws 1 ...

Page 155: ...erator grease the O ring and work in the re verse way to dismantling tightening screws 1 to the specific worm drive after having applied LOCTITE NOTE To ease mounting the generator position the en gine if possible horizontally 27 N m 2 7 Kg m LOCTITE 243 5 7 PHASE SENSOR AND PHONIC WHEEL 5 7 1 REMOVE PHASE SENSOR Remove the phase sensor 1 by unscrewing the fixing screw 2 ...

Page 156: ...w and remove the screw and the washer 3 and remove the phonic wheel 4 5 7 4 MOUNT PHONIC WHEEL ATTENTION During the phonic wheel mounting phase position it with the writing towards the outside of the engine Position the phonic wheel 4 and tighten the fixing screw to the specified worm drive Check the liner a between the phonic wheel and the phase sensor VALUE LIMIT a from 0 8 to 1 0 mm 26 N m 2 6 ...

Page 157: ...1 Remove the clutch body command 2 and the cable support plate 3 Remove the ferrule 4 and the clutch command rod 5 5 8 2 REMOVE CLUTCH COVER Place a container under the oil sump to allow the oil to empty Remove the discharge screw cap 1 NOTE Be careful not to lose the sealing washer beneath If damaged replace it 1 2 3 ...

Page 158: ...H Remove the clutch cover loosening the two centring screws 1 first then the rest of the screws 2 Remove the six clutch disk pushing plate fixing screws 1 Extract the clutch plate 2 Extract the external teeth and internal teeth disk unit conductor 3 ...

Page 159: ...leville spring 4 Unscrew and remove the clutch fixing nut 5 Extract the sphere from inside the gear shaft with a magnetic tool 6 Remove the clearance adjustor 7 with the 4 mm thick projecting stop Undo the drum 8 Undo the bell 9 5 6 4 ...

Page 160: ... following operations must be carried out on all the internal disks Check the distortion of the disk as shown in the figure If the disk is broken or does not enter within the specific value change the entire set of disks VALUE LIMIT MAX DISTORTION 0 1 mm 5 8 6 CHECK CLUTCH SPRINGS The following operations must be carried out on all the clutch springs Measure the lengths a of the free spring If the...

Page 161: ...UE LIMIT 170 N Check the incline d of the clutch spring as illustrated in the figure If d does not enter within the specific value change the entire set of springs VALUE LIMIT YELLOWANDBLACKCLUTCHSPRINGINCLINATION d 2 mm 5 8 7 CHECK CLUTCH COVER Check that the cover 1 is not broken otherwise change it Check the state of the roller ball bearings 2 and change them if necessary ...

Page 162: ...e the clutch bell unit and primary 5 8 9 MOUNTING CLUTCH UNIT NOTE There are two clearance elements for assembling the clutch unit Always check the thickness of the projection Internal engine thickness 3 5 mm External engine thickness 4 0 mm Position the clearance element 1 with the lowest projection 1 3 5 mm turned towards the inside of the engine Insert the spacer 2 ...

Page 163: ...UK 163 MF13 2 5 4 Oil the ball bearing slide area well Insert the clutch bell unit 2 complete with roller bearings Engage in sequence Primary gear 4 Gear control alternator 5 ...

Page 164: ...mp gear 1 Insert the second 2 clearance element with the projection thickness 4 0 mm towards the outside of the engine Insert the clutch drum 3 Insert the slide plate 4 and relative 6 return springs 5 into the appropriate columns ...

Page 165: ...utside of the engine Insert the clutch bell unit fixing nut 1 Block the clutch bell unit with the specific instrument Screw and tighten the nut with loctite Worm drive 80 N M 8 Kgm Loctite 648 SPECIFIC INSTRUMENT Dismantling clutch instrument R180297047000 SIDE TO INSERT ...

Page 166: ...of the engine Insert in sequence alternating the conductor disks with external teeth A and conducted disks with internal teeth B NOTE Oil the disks with engine oil one by one before inserting them into the clutch drum CLUTCH PACK N 5 conducted disks thickness 2 mm N 5 conducted disks thickness 1 5 mm N 1 conducted disk thickness 2 5 mm N 10 conducting disks thickness 3 mm Total thickness clutch pa...

Page 167: ... 167 MF13 1 2 Reinsert the sphere 1 Insert the disk pushing plate 2 insert the springs and the screws alternated between them tighten to indicated torque Worm drive 10N M 1 Kg m NOTE Oil the screw threads ...

Page 168: ... 1 loosen the locknut 2 and screw up the adjuster 3 until it makes contact with the internal reaction rod unscrew a turn Check the play on the clutch control positioned on the opposite side of the engine SPECIFIC INSTRUMENT Regulation clutch equipment R180297130000 ...

Page 169: ...lutch cover clean the contact surface with the engine 1 accurately without damaging it change the clutch casing cover gasket ATTENTION Aways use new gaskets Position the gasket and the clutch cover 1 and tighten with the centering screws 2 and then with screws 2 10 N m 1 Kg m ...

Page 170: ...COMMAND Insert the clutch command rod 1 Insert the ferrule 2 Position the cable support rod 3 and the clutch command body 4 Fix the clutch command with the three screws 5 and tighten Insert the clutch command cable 10 N m 1 Kg m LOCTITE 243 ...

Page 171: ...ore removing the gears remove the neutral sen sor at the back of the engine Loosen and remove the nine fixing screws 1 and remove the gears 2 5 9 2 DISMANTLE GEARS Position the gears on a support Loosen and remove the three screws 3 and remove the gear command cover 4 Remove the shaft command selector 5 ...

Page 172: ... Loosen and remove the two screws 8 Remove the stop plate 9 Free and remove the two fork pins 10 from the washers 11 working on the screws 12 Remove the forks Remove the nut 13 holding the pinion firm 14 with the instru ment 15 Remove the safety washer the pinion and the spacer WARNING The toothed wheels of the gear are free Rotate the gears on the support the external side below Remove the two sh...

Page 173: ... the gear flange external side above Unscrew and remove the drum fixing pin 18 Remove the posiive valve gear 17 see previous figure and the gear selector drum 19 ATTENTION Make sure that the peg 20 is well inserted into its seat Unscrew and remove the threaded pin 21 and the the gear fixing assembly 22 the washer beneath and the gear fixing spring 23 ...

Page 174: ...ollowing procedure must be carried out on all the fork gears Check the state of elements 1 and 2 shown in the figure and if necessary change them FORK SLOT PLAY Check the play of the gears in the fork slot Using a feeler check the play of the gear fork in its gear slot The play of each fork is important for the sliding and precision of the speed gears Fork slot play Value Limit 0 50 mm If the play...

Page 175: ...e fork gear slot using a cursor gauge Fork slot length Standard value 5 0 5 1 mm FORK GEAR THICKNESS Measure the THICKNESS of the fork gear slot using a cursor gauge Fork gear thickness Standard 4 8 4 9 mm Check the free movement of the fork on the slide rod ...

Page 176: ...HAFT Check wear and eventual breaks on the primary shaft 1 and the secondary shaft 2 and their components If necessary change the entire 1 or 2 unit ATTENTION Never use a used elastic ring After having removed the elastic ring of the shaft throw it away and install a new elastic ring When installing a new elastic ring make sure not to enlarge its ends more than is necessary to insert it onto the s...

Page 177: ...upport external side uppermost Position the gear fixing spring i in the appropriate hole Position the washer 2 and the gear fixing spring 3 and fix with the threaded pin 4 Tighten 10 N m 1 Kg m Position pin 5 onto the positive valve gear shaft with the appro priate instrument and the two liners 6 of 0 2 mm each ...

Page 178: ...e support NOTE Check while mounting the gear selector drum that the two elements shown coincide Fix the drum 7 with the threaded pin 8 and tighten NOTE Once pin 8 is tightened it is possible to remove the support previously positioned under the positive val ve gear shaft 10 N m 1 Kg m LOCTITE 270 ...

Page 179: ...UK 179 MF13 Mount springs 10 and push rods 11 onto the flange 9 Position the pawls 12 Position the stop plate 13 Position the pre mounted pin complete with sprocket wheel and pawl 15 ...

Page 180: ...ounted pin 15 10 N m 1 Kg m LOCTITE 243 Rotate the flange on the support internal side above Couple the primary and secondary shafts Position them as shown in the figure Rotate the flange external side above ATTENTION Support the primary and secondary shafts because they are loose ...

Page 181: ...n the O Ring 16 on the secondary shaft Position the spacer 17 with its minor dimension outwards Position the pinion 18 the safety washer 19 and the nut 20 Tighten the nut Bend the washer tongue 140 N m 14 Kg m LOCTITE 648 ...

Page 182: ...e spring Insert the 1 mm thick clearance element 22B on the selector shaft Position the two forks 23 on the secondary shaft and fork 24 on the primary shaft NOTE Forks 23 are greater in diameter than fork 24 Insert the two slide rods 25 Insert the two washers 26 into the hole of the rod and fix them with screws 27 and tighten Position the ferrule onto the sprocket wheel pin 28 10 N m 1 Kg m LOCTIT...

Page 183: ... thickness Insert the oil seal 31 onto the gear command cover 30 with the appropriate instrument Grease the internal lip see chapter 2 specifications Insert the two centring dowels Mount the gasket 33 Protect the teeth of the shaft with a hood 32 Mount the cover 30 and push it down until it emerges completely from the protective hood 32 29A ...

Page 184: ...the neutral sensor Otherwise remove the neutral sensor before re mounting the gears ATTENTION Verify the presence of the oil pipe inside the carter NOTE Apply Treebond paste onto the gear flange coupling surface paying attention not to obstruct the oil passage hole Insert the gear unit 1 and lock the screws 2 tightly according to the order indicated 20 N m 2 0 Kg m Copper fat ...

Page 185: ... oil sump 3 5 10 2 DISMANTLE OVERPRESSURE OIL VALVE Remove the oil sump see DISMANTLE OIL SUMP Remove the overpressure oil valve 1 Check the functioning of the overpressure oil valve pushing the piston with a plug of adequate dimensions from the threaded side If the piston does not move freely change it Remove the oil drip filter and if necessary clean the net or change the riser if damaged ...

Page 186: ...e the clutch unit Remove the safety ring 1 and the toothed wheel 2 Unscrew and remove the three screws 3 and extract the oil pump 4 5 10 4 DISMANTLE OIL PUMP Remove the oil pump shaft 1 complete with internal rotor 2 Remove the external rotor ...

Page 187: ... SUMP Check for breaks on the oil sump 1 eventually changing it Check the presence of foreign bodies eventually cleaning the drip filter Eliminate the residues 5 10 6 CHECK OIL PUMP Check that the pump body 1 and the toothed wheel 2 are not damaged or excessively worn If necessary change the element or elements ...

Page 188: ...alue otherwise change the oil pump 1 Internal rotor 2 External rotor 3 Pump body VALUE LIMIT a 0 25 mm max b 0 2 mm max 5 10 7 ASSEMBLE OIL PUMP Position the pin 2 in the shaft 1 Insert the internal rotor 3 and the 1 mm liner clearance and block with the safety ring 4 Position the shaft inside the body 5 as indicated in the figure ...

Page 189: ...rument until it touches as in the figure Insert the centering dowel Fix with the three screws 7 and tighten 8 5 N m 0 85 Kg m LOCTITE 243 Insert the toothed wheel check the free movement of the oil pump 8 and fix with the elastic ring 9 ATTENTION Cover the sump drainage hole with paper or rags in order to avoid the elastic ring accidentally falling inside the engine ...

Page 190: ... gaskets or O rings Position the two centering dowels on the base Position the O Ring 1 on the casing Apply the gasket onto the casing surface Remount the oil drip filter fixing the two screws 2 and tightening them 10 N M 1Kg m LOCTITE 243 Position the sump 2 and tighten the magnetic screw cap 3 22 N m 2 2 Kg m Tighten according to the order indicated in the figure 10 N m 1 Kg m ...

Page 191: ...UMP Remove the water pump see DISMANTLE WATER PUMP Remove the gears see ADJUSTMENT PHASE Remove the oil distributor see OIL DISTRIBUTOR Remove the counter shaft cover 1 unscrewing the four screws 2 Remove the stop plate 3 unscrewing the two screws 4 ATTENTION Note the position of the screws for correct re mounting Remove the five screws 5 indicated in the figure upper part of the engine ...

Page 192: ...UK 192 MF13 Remove the five screws 6 Remove screw 7 Remove the two screws 8 ...

Page 193: ...UK 193 MF13 Remove screw 9 Remove the two screws 10 Loosen and remove screw 11 ...

Page 194: ...3 ATTENTION Take note of the position of the screws for correct re mounting Remove the nine screws 12 indicated in the figure lower part of the engine Remove the lower base 13 Remove the large plastic lock nut 14 ...

Page 195: ...F13 Remove the ring 15 Remove the balancing counter shaft 16 Remove the engine shaft 17 ATTENTION Take note of the position of the bronze bearings for correct re mounting Remove the four semi bronze bearings 18 ...

Page 196: ...UK 196 MF13 Remove the drainage tube stop plate 19 Remove the drainage tube 20 Remove the ball bearings 21 and 22 Remove screw 23 and plate 24 freeing the pin 25 ...

Page 197: ...ellite gear 27 and take off the pin 26 as shown in the figure Unscrew and remove the screw 28 the washer 29 the retaining plate and the female flexible coupling 30 Support the toothed wheel 31 and remove pin 32 Remove the toothed wheel 31 ...

Page 198: ...UK 198 MF13 Remove the spacer 33 Remove the free wheel 34 5 11 2 DISMANTLE FREE WHEEL Remove the elastic safety ring Remove the washer 1 ...

Page 199: ...UK 199 MF13 Remove the toothed wheel 2 Remove the roller cage 3 Remove the screws 4 ...

Page 200: ...UK 200 MF13 Dismantle the free wheel 5 11 3 DISMANTLE BALANCING COUNTER SHAFT Remove the circlip 1 Remove the ball bearing 2 and the toothed wheel 3 Remove the ball bearing 4 ...

Page 201: ...ft Unscrew and remove screws 1 Remove the connecting rod 2 from the engine shaft 3 5 11 5 CHECK CASING Check the presence of any breaks on the upper and lower cas ing eventually changing the casings always coupled NOTE Checkthattheoilpassagechannelsarenotobstructed otherwise clean them with an appropriate piece of wire and compressed air Check the free rotation of the ball bearings changing them i...

Page 202: ...n the whole engine shaft 1 Change the piece if necessary Support the engine shaft with two V blocks and with the two ends resting upon the blocks install a comparator and turn the engine shaft slowly Check the deformation of the engine shaft at the points indicated in the figure If the deformation does not enter within the specific value change the piece DEFORMATION VALUE LIMIT 0 040 mm ...

Page 203: ...g rod foot exceeds the specified limit change the connecting rod 5 11 8 CONNECTING ROD HEAD LATERAL PLAY Check the lateral play of the connecting rod with a feeler If the play exceeds the specified limit remove the connecting rod and check the width of the connecting rod head and pin If the width exceeds the specified limit change the connecting rod or the engine shaft CONNECTING ROD HEAD LATERAL ...

Page 204: ...2 0 22 05 mm 5 11 9 CHECK BALANCING COUNTER SHAFT Check the eventual presence of breaks on the balancing coun ter shaft Check the free rotation of the ball bearings Check eventual breaks or excessive wear on the toothed wheel If necessary change the elements or the entire balancing coun ter shaft ...

Page 205: ...CK FREE WHEEL Check eventual breaks wear and slippage on the free wheel Change the element if necessary 5 11 11 ASSEMBLE FREE WHEEL Assemble the two elements as shown in the figure Tighten screws 1 17 N m 1 7 Kg m LOCTITE 270 ...

Page 206: ...UK 206 MF13 Position the roller cage 2 oiling it See Chapter 2 SPECIFI CATIONS Positon the toothed wheel 3 Position the washer 4 and fix with the circlip ...

Page 207: ... connecting rod on the engine shaft so that the refer ent writing for the coupling is turned towards the front of the engine ATTENTION Always change the connecting rod screws after each dismantling Oil the thread and the diameter under the flanging of the fixing screws 3 with the recommended oil Tighten the fixing screws 3 slightly RECOMMENDED OIL MOLIKOTE CU7439 PLUS copper grease CONNECTINGRODSE...

Page 208: ... m 1 5 Kg m 2nd 25 N m 2 5 Kg m 3rd 50 NOTE An angle torque control wrench is needed to carry out the third tightening phase 5 11 13 MOUNTAGGIO BALANCING COUNTER SHAFT Position the ball bearing 1 and fix with the circlip 2 Position the bush 4 Position the seeger ring 5 Position the roller ball bearing 3 on the counter shaft ...

Page 209: ...G Position the roller cage 1 block it with washer 2 and fix with screw 3 tightly 10 N m 1 Kg m LOCTITE 243 Position the ball bearing 4 with the apposite pad and fix with the circlip 5 Position the spacer 6 as indicated in the figure ...

Page 210: ... the toothed wheel 8 and insert pin 9 until touching in the direction in the figure Position the flexible coupling the washer retaining plate and tightened screw in the housing Bend the retaining plate to avoid it protruding from the head of the screw 50 N m 5 0 Kg m LOCTITE 648 ...

Page 211: ...UK 211 MF13 Position the toothed wheel 13 as shown in the figure Position pin 14 until touching as indicated in the figure Position plate 15 and fix with screw 16 tightly 10 N m 1 Kg m LOCTITE 243 ...

Page 212: ...on ball bearings 17 and 18 ATTENTION Position element 19 as shown in the figure Insert the shower pipe 19 completely verifying the phase on the bearing sealing plate A Position the tube retaining plate and ball bearing 20 and fix with screws 21 tightly 10 N m 1 Kg m LOCTITE 648 ...

Page 213: ...ts Various liners of this semi bronze bearing exist distinguished by different colours see table BENCHSEMI BALL BEARING STD COLOUR SELECTION A Red 1 918 1 922 B Blue 1 922 1 926 C Yellow 1 926 1 930 Ø seat std A red 41 830 41 836 Ø seat std B blue 41 836 41 843 Ø seat std C yellow 41 843 41 849 Ø single std shaft 37 960 37 970 ...

Page 214: ...ain Position the four semi bronze bearings 25 each slotted with the correct colour associated with its letter stamped on the outside of the casing 24 centering them with the tooth in the cable Position the engine shaft 26 as in the figure Position the balancing counter shaft 27 LETTER COLOUR A Red B Blue C Yellow ...

Page 215: ...toothed wheels of the balancing counter shaft and the engine shaft are as shown in the figure Position ring 28 Position the large cap 29 one per side in the apposite seats Put THREEBOND 1215 on the contact surfaces of the two casings ...

Page 216: ...phases correctly Position the eight screws 31 with washers and copper fat and tighten to torque in three phases according to the order printed on the carter 1st 13 N m 1 3 Kg m 2nd 25 N m 2 5 Kg m 3rd 45 N m 4 5 Kg m Tighten screws 32 in two phases 1st 10 N m 1 Kg m 2nd 25 N m 2 5 Kg m ...

Page 217: ...K 217 MF13 Tighten screws 33 according to the order in the figure 10 N m 1 Kg m Tighten screw 34 10 N m 1 Kg m Tighten the two screws 35 With M8 screws the worm drive is 1 13 N m 1 3 Kg m 2 30 N m 3 Kg m ...

Page 218: ... M8 screws the worm drive is 1 13 N m 1 3 Kg m 2 30 N m 3 Kg m Tighten the two screws 37 in two phases With M8 screws the worm drive is 1 10 N m 1 Kg m 2 25 N m 2 5 Kg m Tighten screw 38 in two phases 1 10 N m 1 Kg m 2 25 N m 2 5 Kg m ...

Page 219: ... 1 10 N m 1 Kg m Position balancing counter shaft ball bearing stop plate 40 and fix with the two screws 41 tightly 10 N m 1 Kg m ATTENTION Always use new gaskets Position the gasket and the counter shaft cover 42 Tighten the screws 43 10 N m 1 Kg m ...

Page 220: ...tank capacity Antifreeze Water 1500 ml 1500 ml ATTENTION Boiling water or steam can cause grave burns if the radiator tap is removed while the engine is still hot After having let the engine cool down wrap a thick cloth around the tap and remove it cautiously rotating it a quarter of a turn to release the pressure and then unscrew it completely The engine must be cold when carrying out maintenance...

Page 221: ...F13 6 1 RADIATOR 6 1 1 DISMANTLE RADIATOR Removecoolerfairings see COOLERFAIRINGDISASSEMBLY Take off the elastic clamp 1 on the right side cooler pipe union Take off the lower elastic clamp 2 on the cooler 1 2 ...

Page 222: ...g screws 1 Take off the cooler disconnect the fan connector Unscrew the screws 2 Remove the fan from the cooler 3 6 1 1 1 LEFT COOLER DISASSEMBLY Remove the cooler fairings see fairing disassembly Take off the upper elastic clamp 1 1 1 3 2 2 2 1 ...

Page 223: ...UK 223 MF13 Take off the lower elastic clamp 2 on the cooler Remove the upper and lower fixing screws 3 Take off the cooler Disconnect the fan connector 3 2 3 ...

Page 224: ...be is cracked or flattened it must be removed Check the state of the radiator entry and exit tubes If any water carrying tube is cracked or flattened it must be removed Change the elements if necessary Verify the tightness of the radiator chap 1 checking that it is not damaged or deformed 6 1 3 RIGHT RADIATOR ASSEMBLY Reverse the operations described in the dismantling procedure Pour the refrigera...

Page 225: ...l filter to impound the oil to blow off Remove the two pipes fittings A and B on the oil distributor Blow off the oil in the container Loosen and remove the two pipe unions A and B on the oil cooler Loosen and remove the oil cooler pipe fixing screw 1 on the engine A B A B 1 ...

Page 226: ... the foreign materials must be removed For the cleaning we suggest you to use compressed air If necessary repair or replace the radiator If one of the two delivery and recovery oil tubes are damaged squashed or cracked replace them 6 1 6 OIL COOLER ASSEMBLY To install the radiator again on the frame use the inverse procedure instead of the disassembly Put the two oil delivery and recovery tubes on...

Page 227: ... Put the two oil delivery and recovery tubes A and B on the distributor Close in couple the two connectors 5 6 on the distributor 30 Nm 3 Kg m WARNING Fit the oil with about 400cc make the starting motor rotate without switching on the motor favouring in this way the lubrication system reintegration ...

Page 228: ...he oil distributor NOTE Take care not to lose the clearance Loosen and remove the screw 2 and remove the distributor Loosen and remove the two underlying screws Be sure that the distributor is not damaged or clogged otherwise replace the particular Verify that the delivery and recovery oil tubes are not broken Change the damaged element if necessary 1 2 ...

Page 229: ... with the phase plaque without closing the two screws A Close in couple in two phases the connector screw 2 1 phase 30 N m 3 Kg m 2 phase 60 N m 6 Kg m Close in couple the two screws A of the phase plaque Remount the oil filter 6 N m 0 6 Kg m Reintroduce the lacking oil into the engine Remount the exhaust plant ...

Page 230: ...kets and oil seals Remove the refrigerant liquid from the cooling circuit see CHANGE REFRIGENRANT LIQUID Remove the tube 1 loosening the clamp 2 Loosen and remove the two screws 3 and remove the thermo stat cover 4 Remove the thermostat 5 Verify that the by pass hole 6 is not obstructed 6 ...

Page 231: ...bove mentioned conditions by immerging the thermostat 1 in a container with water maintaining it in suspension Slowly heat the water and check the temperature with a ther mometer 2 When a temperature of 75 C is reached the thermostat valve begins to open and arrives at a temperature of 90 C The thermostat valve reaches an opening of at least 7 mm Change the thermostat if necessary Check that the t...

Page 232: ... the figure Position ithe thermostat 1 as indicated in the figure Position the thermostat cover 3 and tighten with the two screws 4 il coperchio termostato 3 e fissare con le due viti 4 10 N m 1 Kg m Place the tube 5 and tighten the clamp 6 Reinsert the refrigerant liquid into the cooling circuit see CHANGE REFRIGERANT LIQUID ...

Page 233: ...ng circuIt CHANGE RERIGERANT LIQUID Remove the inlet and outlet pipes 1 from the pump 2 6 4 2 DISMANTLE WATER PUMP Loosen and remove the two screws 4 and the small plates 5 Remove the entry elbow 6 Loosen and remove the two screws 3 and remove the water pump from the engine Remove the l O Ring 7 ...

Page 234: ...UK 234 MF13 Loosen and remove the two screws 8 Remove the cover 9 Loosen and remove the nut 10 and remove the rotor 11 ...

Page 235: ...K 235 MF13 Remove the external circlip 12 the internal circlip 13 and the ball bearing beneath Remove the liner 14 the shaft 15 the ball bearing 16 and the oil seal beneath Remove the mechanical seal 17 ...

Page 236: ...nts of the pump Check that the various elements are not broken Change worn or damaged elements if necessary 6 4 4 WATER PUMP ASSEMBLY Position the pump body 1 on a support ATTENTION The oil seal must be inserted downwards with the lip closed Position the oil seal until it touches 2 ...

Page 237: ...UK 237 MF13 Grease the shaft 4 at the points indicated in the figure Position the shaft 4 inside the pump body 1 Position the first ball bearing 5 using a press to make it touch ...

Page 238: ...UK 238 MF13 Position the liner 6 Position the second ball bearing 7 using a press to make it touch Fix the ball bearings with the external 8 and internal 9 circlips ...

Page 239: ...ace and the mechanical seal make sure that they are clean and bear no traces of grease Position the counterface as in the figure 10 Position the mechanical seal 11 until it touches as shown in the figure Position the rotor 12 making it meets clutch A ...

Page 240: ...fix it tight with the nut 14 8 N m 0 8 Kg m Always use LOCTITE 243 Position the cover and lock it tight with the two screws 15 10 N m 1 Kg m Position the sealing washer 16 and tightly screw the purge screw 17 up 10 N m 1 Kg m Always use LOCTITE 243 ...

Page 241: ...body Position the entry elbow 19 and fix with the two small plates 20 and the two screws 21 tightly 10 N m 1 Kg m 6 4 5 MOUNT WATER PUMP Position the pump 1 as in the figure and screw the two screws 2 up tightly 10 N m 1 Kg m Always use LOCTITE 243 ...

Page 242: ...UK 242 MF13 Reposition the entry and exit tubes 3 of the pump tightening the two bands 4 Restore the level of the liquid in the circuit see CHANGE COOLING LIQUID ...

Page 243: ...UK 243 MF13 ...

Page 244: ...ike without the front wheel Loosen the two fork clamp locking screws 1 on the right stem Loosen and remove the two brake clamp fixing screws 2 on both sides WARNING Note the position of the elements for correct re mount ing WARNING During the following operation prevent the left spacer falling Loosen and remove the pin 3 Remove the front wheel F F F F Frame ...

Page 245: ...the state of wear of the disk with a gauge If the value of the liner A does not enter within the specific value change the piece SPECIFIC VALUE A 4 5 mm 7 1 3 DISMANTLE FRONT WHEEL ATTENTION During the following procedure prevent the internal spacer falling if dismantling the ball bearings is en visaged Remove the six disk 2 fixing screws 1 Remove the disk 2 end the ball bearing 3 The operation of...

Page 246: ...of the two cylindrical zones A and B with respect to one another with a comparator The lateral displacement cylindricity error must enter within the specific value If the lateral displacement value does not enter within the spe cific value change the piece SPECIFIC VALUE 0 05 mm 7 1 5 MOUNT FRONT WHEEL ATTENTION Before mounting the ball bearings identify correctly the right and left sides of the w...

Page 247: ...TALL FRONT WHEEL WARNING After each operation on the bike it is advisable to balance it ATTENTION While installing the wheel pay attention to the direc tion of mounting Position the front wheel and the left spacer 1 coaxial with respect to the respective housing holes on the fork and insert the wheel pin from the right side tightening it 60 Nm 6 Kgm grease the thread ...

Page 248: ...ead Clamp screws 50 N m 5 Kg m Grease the thread Brake clamp screws 7 2 REAR WHEEL BRAKE DISK AND CROWN 7 2 1 REMOVE REAR WHEEL Loosen the fork screws 4 Loosen and remove the nuts 5 of the wheel pivot Remove the two grains 6 through a M4 metrical screw Rotate the eccentrics loosening the chain Remove the chain from the cog wheel 2 5 4 ...

Page 249: ...t of the brake disk with a compa rator The lateral displacement must enter within the specific value If the value of the displacement does not enter within the specific value change the piece SPECIFIC VALUE Lateral displacement 0 3 mm Check the state of wear of the disk with a gauge If the value of the liner A does not enter within the specific value change the piece SPECIFIC VALUE A 4 5 mm 7 A ...

Page 250: ...ix disk fixing screws 1 Remove the brake disk 2 Change the brake disk fixing screws Remove the right spacer 3 extracting it from the wheel Remove the flange 4 complete with crown 5 extracting it from the wheel Loosen and remove the five nuts 6 and remove the crown 5 from the flange ...

Page 251: ...g if dismantling the ball bearings is en visaged Remove the five flexible couplings 7 Remove the circlip 9 Extract the ball bearings 8 on both sides This operation is to be carried out exclusively if required by the maintenance plan or if the ball bearing could be the source of malfunctioning Once dismantled the ball bearings must be changed ...

Page 252: ...nge the piece Check the cylindricity of the rear wheel pin SPECIFIC VALUE A 0 05 mm ATTENTION Do not try to straighten a bent pin Check the lateral displacement of the cylinder zone A with a comparator This lateral displacement cylindricity error must enter within the specific value If the value of the displacement does not enter within the spe cific value change the piece SPECIFIC VALUE A 0 05 mm...

Page 253: ... 1 is not broken and that the teeth are not excessively worn Change the crown the pinion and the chain if necessary 7 2 7 MOUNT REAR WHEEL ATTENTION Before mounting the ball bearings identify the right and left sides of the wheel correctly basing yourself upon the direction of rotation shown on the circle with the drawing of an arrow ...

Page 254: ... Insert the internal spacer from the right side and push the right side ball bearing in until it touches Position the five flexible couplings in the correct seats 3 Position the crown 4 on the flange 5 and fix it with the nuts 6 tightening then according to the order indicated 45 N m 4 5 Kg m Grease thread Position the flange complete with crown on the wheel ...

Page 255: ...e wheel after every opera tion on the wheel Position the wheel 1 Insertthepivot 2 payingattentiontothesenseofassembly thepart with the left side punching must be positioned on the chain side Insert the two grains tighten the nuts of the pivot to the indicated torque 65 N m 6 5 Kg m Grease thread Position the chain 3 Regulate the chain through the eccentrics Tighten the fork screws 80 N m 8 Kg m Gr...

Page 256: ...mp and the other end in a suitable recipient Open the purge screw 1 and empty the braking liquid Do the same thing with the opposite clamp NOTE To help the liquid discharge open the liquid tank lid and drive the front brake lever repeatedly ATTENTION Place a rag under the connector because of the prob able leakage of braking liquid Remove the screw 2 and the connector 3 Loosen and remove the two s...

Page 257: ...he same thing with the opposite clamp NOTE To help empty the liquid open the liquid tank cap and work on the rear brake lever repeatedly First loosen the idrostop 2 making sure not to twist the wires of the relative cabling excessively Loosen and remove the two screws 3 Remove the elastic clip 4 Remove the oil pipe from the pump Rotate the pump 7 keeping the idrostop 2 steady until the latter is c...

Page 258: ...AR BRAKE PUMP Check that the front and rear brake pumps are not damaged If necessary change the damaged pump Check that the front and rear brake pumps are not obstructed If necessary eliminate the obstruction with a jet of compressed air ...

Page 259: ... 15 N m 1 5 Kg m 7 3 5 INSTALL REAR BRAKE PUMP Connect the cap 1 of the brake pedal pump 2 and tighten the screw 3 10 N m 1 Kg m ATTENTION Always change the braking plant sealing gaskets Fix the connector 5 of the brake pipe to the pump through idrostop 4 and the two gaskets 6 Rotate the pump to tighten the idrostop 4 Tighten the idrostop keeping the brake tube in the correct an gular position 15 ...

Page 260: ...otrest see MOUNT FOOTREST 4 N m 0 4 Kg m 7 3 6 DISMANTLE FRONT BRAKE PLANT TUBES Position the end of a tube of suitable diameter at the purge screw 1 of a brake clamp and the other end in a suitable re cipient Open the purge screw 1 and empty the braking liquid NOTE To help empty the liquid open the liquid tank cap and work on the rear brake lever repeatedly 8 10 1 2 5 ...

Page 261: ...osi tion it under the brake pump Position the end of a tube of suitable diameter at the purge screw 1 of a brake clamp and the other end in a suitable re cipient Open the purge screw 1 and empty the braking liquid Remove the brake tube 2 from the clamp 3 unscrewing screw 4 NOTE To help empty the liquid open the liquid tank cap and work on the rear brake lever repeatedly Loosen the idrostop 1 takin...

Page 262: ...TUBES PLANT ATTENTION Always change the sealing gaskets at every disman tling Position the brake plant tubes with the T 1 connector on the right side of the vehicle Fix the tubes with the connector screws and the sealing gas kets tightly two on the clamp and one on the pump 15 N m 1 5 Kg m Restore the level of the braking liquid and purge the plant see PURGE BRAKING PLANT ...

Page 263: ...m Restore the level of the braking liquid and purge the plant see PURGE BRAKING PLANT 7 3 11 DISMANTLE FRONT BRAKE CLAMPS ATTENTION Always change the sealing gaskets at every disman tling Position the end of a tube of suitable diameter at the purge screw 1 of a brake clamp and the other end in a suitable re cipient Open the purge screw 1 and empty the braking liquid NOTE To help empty the liquid o...

Page 264: ...ke clamp from the clamp support unscrew ing the two screws and position it under the brake pump Position the end of a tube of suitable diameter at the purge screw 1 of a brake clamp and the other end in a suitable re cipient Open the purge screw 1 and empty the braking liquid NOTE To help empty the liquid open the liquid tank cap and work on the rear brake lever repeatedly Loosen and remove the co...

Page 265: ...cessary change the damaged element 7 3 14 MOUNT FRONT BRAKE CLAMP Position the right and left 2 brake clamps Tighten screws 3 Position the brake tubing on the two clamps and on the pump 50 N m 5 Kg m Tighten screws 4 15 N m 1 5 Kg m Restore the level of the braking liquid and purge the front plant see PURGE BRAKING PLANT ...

Page 266: ...E CLAMP Tighten the connector screw 1 on the clamp 2 15 N m 1 5 Kg m Restore the level of the braking liquid and purge the rear plant see PURGE BRAKING PLANT Position the clamp 2 on the clamp support 3 Tighten the two screws 4 22 N m 2 2 Kg m ...

Page 267: ...guard see DISMANTLE FRONT MUD GUARD Remove the front wheel see REMOVE FRONT WHEEL Remove the handlebar Remove the front pliers Remove the upper steering plate see DISMANTLE STEER ING PLATE SPECIFIC INSTRUMENTS Wrench with male hexagonal insert R180197033000 Remove the handlebar Loosen the three screws 6 Take the lining 7 off downwards Repeat the operation for the opposite lining ...

Page 268: ...with regard to checking the stems and linings 7 4 3 INSTALL FORK LININGS WARNING Do not damage the surfaces of the linings WARNING The stem must be mounted with the brake clamp holder support towards the inside of the vehicle Insert from under the lining right and left without tightening the screws 3 3 ...

Page 269: ...hten the screws 5 one for each stem 25 N m 2 5 Kg m Tighten the steering plate central screw 6 60 N m 6 Kg m Tighten the six screws 3 three for each stem Position the front wheel see MOUNT FRONT WHEEL 12 N m 1 2 Kg m Position the front brake clamp 7 and tighten the two screws 8 Do the same with the opposite brake clamp 50 N m 5 Kg m ...

Page 270: ... two screws 1 and free the front brake pump 2 Remove the gas command using the two screws beneath Loosen and remove the two screws 4 Disconnect the connector Remove right light command 5 Disconnect the micro switch connector 1 brake lights 1 1 5 3 4 2 ...

Page 271: ...off first Loosen and remove the two screws 2 and free the clutch command 3 Disconnect the left light command connector Loosen and remove the screws 4 Remove the left light command 5 Slip off the handlebar grip Loosen and remove the screws of the steering plate bridge 5 Remove the handlebar ...

Page 272: ...y replace it 7 5 2 HANDLEBAR INSTALLATION Position the handlebar on the steering plate seat Verify the correct inclination with the reference notches tighten the two screws 1 of the U bolt to the indicated torque 22 N m 2 2 Kg m Position the gas command 2 fix it with the two screws 3 Position the front brake pump and fix it with the two screws 4 2 3 4 1 REFERENCE NOTCHES ...

Page 273: ... Position the front brake pump 4 and fix it with the two screws 5 to the indicated torque 22 N m 2 2 Kg m Position right light command block and fix it with the two screws 6 Connect the brake light micro switch connector 7 ...

Page 274: ...n the left light command block 1 Connect the connector 6 N m 0 6 Kg m Position the clutch command and tighten the two fixing screws 3 10 N m 1 Kg m Connect the micro clutch connector 4 on the lever Insert the handle 5 4 3 5 ...

Page 275: ...e the two bridge fixing screws 2 Remove the fixing screw steering plate 3 Remove the upper plate ATTENTION Support the lower steering plate during the folllowing operation Loosen and remove the counter ring nut 6 Loosen and remove the ring nut 7 SPECIFIC EQUIPMENT Steering ring nut wrench R180197031000 Remove the dust cover 8 ...

Page 276: ...pin 9 and the lower steering plate complete with pin 10 Remove the ball cage 11 and the upper and lower coupling pins inside the chassis Remove the ball cage 12 Remove the upper coupling pin 13 and the dust cover 14 from the steering plate ...

Page 277: ...k that the steering roller cages are not excessively worn or broken Change the elements damaged or worn if necessary 7 6 3 MOUNT LOWER STEERING PLATE Carry out in reverse order to dismantling Tighten the ring nut 1 40 N m 4 Kg m Tighten the counter ring nut 2 Manual 90 Tighten the steering fixing screw 3 60 N m 6 Kg m ...

Page 278: ... damper 7 7 2 REMOVE REAR DAMPER Lift the vehicle adequately with some supports under the driver s footboards keeping the back wheel raised from earth Loosen and remove the upper fixing screw 3 from the engine setting the shock absorber free laying the wheel to ground Loosen and remove the nuts and the related screws 4 Remove the two connecting rods 140 mm ...

Page 279: ...er totally free slip the shock absorber off from the left side 7 3 3 MOUNT REAR DAMPER Operate in the reverse sense to dismantling Tighten the upper shock absorber fixing nut 1 to the indicated torque 50 N m 5 Kg m Tighten the lower shock absorber fixing nut 2 to the indicated torque 50 N m 5 Kg m 1 ...

Page 280: ...UK 280 MF13 Tighten the connecting rod fixing nuts 1 to the indicated torque 50 N m 5 Kg m 65 N m 6 5 Kg m 1 ...

Page 281: ...wheel see REMOVE REAR WHEEL l Remove the chain see DISMANTLE CHAIN Remove the mudguard Remove the chain carter Remove the brake pliers Disconnect the connector of the speed sensor wiring 4 Disconnect the cable 5 on the exhaust valve Remove the muffler A the pipe union b and the pipe union c 4 5 A ...

Page 282: ...n ring nut 7 inside the frame loosen the register 8 Loosen the nut 9 and the relative upper fixing screw of the shock absorber Loosen and remove the lower fixing screw shock absorber Set the back brake pump body free 11 9 8 7 10 11 ...

Page 283: ...UK 283 MF13 11 Loosen and remove the upper fixing screw 2 of the right footboard setting the brake oil tank free Slip off the fork from the frame Slip off the pivot 11 Extract the fork 3 2 ...

Page 284: ... screws 3 and remove the chain pad 4 Remove the ferrule 5 and the oil seal 6 Repeat the operation on the opposite part of the rear fork as well Remove the oil seal 7 Repeat the operation on the opposite part of the rear fork as well 3 4 5 6 ...

Page 285: ... the state of the rear fork change it if there are breaks Check the free rotation of the ball bearings 1 If necessary change them Check the state of wear of the chain pad If necessary change it Verify the eccentrics state if necessary replace them ...

Page 286: ...ys use new oil seals Proceed in the reverse manner to dismantling Tighten the screws 1 of the lower chain shoe Tighten the screws 2 of the upper chain shoe to the indicated torque 10 N m 1 Kg m Tighten the screws 3 of the internal chain shoes 1 2 3 3 ...

Page 287: ...oval Bring the adjustor 1 to touch and tighten 90 40 N m 4 Kg m Tighten the ring nut 2 placed inside the frame Insert the pin from the left side Tighten the rear fork pin fixing screw 3 65 N m 6 5 Kg m Tighten the two connecting rod nuts 4 to the indicated torque 50 N m 5 Kg m 1 2 4 3 4 ...

Page 288: ...o screws 1 Disconnect the front light wiring connector 2 Remove the light support frame Remove the front shield see front shield disassembly Remove the light from the light support frame see LIGHT DISASSEMBLY Loosen and remove the central closing screw 3 on right and left framelet 1 1 2 3 ...

Page 289: ...upport frame 7 9 2 7 9 2 7 9 2 7 9 2 7 9 2 TEST FRONT LIGHT SUPPORT TEST FRONT LIGHT SUPPORT TEST FRONT LIGHT SUPPORT TEST FRONT LIGHT SUPPORT TEST FRONT LIGHT SUPPORT FRAME FRAME FRAME FRAME FRAME Check the state of the two parts of the light support frame visually If necessary replace the damaged piece Do not try to straighten 1 ...

Page 290: ...e frame to the indicated torque Connect the front wiring connector 12 N m 1 2 Kg m 7 10 REAR FRAME 7 10 1 BACK RIGHT FRAME DISASSEMBLY Loosen and remove the heat shield screws 2 under the saddle Remove the number plate holder Remove the muffler Remove the saddles Loosen and remove the screws 3 Remove the rear frame cross bar 1 2 3 3 ...

Page 291: ...e the screw 2 Remove the internal wiring fixing clip NOTE Verify always before dismantling the passage of the wiring Loosen the lock nut 3 of the joint pivot Loosen the pivot 4 making the side of the frame come out from its seat Remove the right side of the frame 1 2 1 1 4 3 ...

Page 292: ... Screw the joint pivot up to reach the contact of the two parts Block the pivot with the lock nut 1 Position and tighten the frame right side fixing screws 2 to the frame with the indicated torque 22 N m 2 2 Kg m Position and fix the wiring on the inner side of the frame with tie wraps 3 1 2 2 2 3 ...

Page 293: ... under the saddle and tighten the screws 2 Assemble the number plate holder see NUMBER PLATE HOLDER assembly Assemble the muffler 7 10 3 LEFT BACK FRAME DISASSEMBLY Remove the saddles Remove the number plate holder Remove the muffler Loosen and remove the screws of the heat shield under the saddle 1 3 4 2 ...

Page 294: ...he screws 1 Remove the back frame cross bar Loosen and remove the lateral fixing screws 2 Loosen and remove the screw 3 Remove the internal wiring fixing tie wrap NOTE Verify always before dismantling the passage of the wiring 2 3 1 ...

Page 295: ...the joint pivot Loosen the pivot 1 making the side of the frame coming out of its seat Remove the left side from the frame 7 10 4 LEFT BACK FRAME ASSEMBLY Position the left side of the back frame on the motorcycle Position the saddle opening lock hook on the opening cable and fix it by the screws 1 1 1 3 2 1 2 3 ...

Page 296: ...es of the frame up to reach the contact of the two parts Block with the lock nut 2 Position and tighten the left frame side fixing screws 3 to the indicated torque 22 N m 2 2 Kg m Position and fix the wiring on the inner side of the frame by a tie wrap 4 2 3 4 ...

Page 297: ...le and tighten the screws 6 Assemble the exhaust muffler see muffler assembly Assemble the saddles 7 10 5 STIRRUP REMOVAL PASSENGER FOOTBOARDS Loosen and remove the screws 1 right footboard stirrup 2 Check visually the state of the stirrup if necessary replace the piece Proceed in the same for the opposite footboard stirrup 1 2 5 6 ...

Page 298: ...chain is not excessively worn or excessively loose Change the chain if necesary Check that the chain does not have crushed or seized up links ATTENTION This is a chain with an O ring Respect the cleaning phases If necessary disolve the dirt deposits on the chain using kerosene These deposits must be later removed with a clean rag or a jet of air Then oil the chain 1 ...

Page 299: ...UK 299 MF13 7 11 3 INSTALL TRANSMISSION CHAIN Position the chain on the crown and on the pinion Unite the two ends of the chain 1 and 2 with the specific equipment Adjust the chain see ADJUST CHAIN ...

Page 300: ...e density of the air are compensated by adjusting the quantity of fuel injected at a level conforming to clean combustion and low emissions Barometric pressure sensor the barometric pressure sensor is incorporated within the ECM and is connected to the air filter box by a flexible tube The barometric pressure sensor measures the pressure of the air in the air filter box The density of the air is c...

Page 301: ... speed gear is in the neutral position or the stand is closed Clutch switch placed on the clutch lever The engine will not start until the lever is pulled up to the handle 8 1 3 POSITION OF THE SENSORS 1 Barometric pressure sensor Engine control module under the saddle 2 Clutch lever on the clutch lever 3 Suction air temperature sensor low in the air filter box 4 Cooling liquid temperature sensor ...

Page 302: ... saddle and the glove box The main power relay is encouraged to supply a stable voltage to the ECM When turned off the ECM maintains the main power relay in such a way as to be able to accomplish the turning off procedure that includes Inserting the data in the ECM memory Supplying data about the position of the stepper engine of the air control valve Activating the cooling fans until the engine i...

Page 303: ...self on the bike This Software is supplied with a manual guide to the use of the programme in order to be able to carry out a check on every single component of the system The system can also be checked observing the operations desribed as follows NOTE See Axone user instructions in chapter 10 diagnostics 8 3 NUMBERING THE ECM CONNECTORS The diagram on the side shows the sequence of the two ECM co...

Page 304: ...ws the numbering of the pins as they appear on the connector The position of the ECM connectors is described in this manual through the identification of the connector 1 black or 2 grey followed by the row number and the column number in which it is situated In the example to the side pin 1 F2 is shown from the intersection of the lines GREY BLACK ...

Page 305: ...t 6 Disconnect the relative injector and proceed to test 3 Proceed to test 4 Disconnect the relative injector and proceed to test 5 Proceed to test 7 Locate and repair the cable fault proceed to test 7 Result Ok Fault from15 5 a 16 3 Open circuit Short circuit Ok Short circuit Test 1 Check the integrity of the terminal and the cable ECM 1 BI pin ECM 1 CI pin ECM 1 B2 pin 2 Check the value of the r...

Page 306: ...njector 1 ECM Pin 1 RO BI at ECM pin 1 C1 injector 2 ECM Pin 1 RO BI atECM pin 2 B8 injector 3 6 Check the resistance of the relative injector between Pin 1 and Pin 2 7 Reconnect the cabling cancel the fault code and activate the engine to check the elimination of the fault Proceed to test 6 Locate and repair the cable fault and proceed to test 7 Ok Open circuit 4 Check the continuity of the cable...

Page 307: ...t proceed to test 5 Change the position sensor of the throttle body group proceed to test 5 Locate and repair the cable fault proceed to test 5 Activity carried out terminate the test Contact the Benelli assistance Result OK Fault OK Short circuit OK Open circuit OK Short circuit OK The fault persists Test 1 Check the integrity of the terminal and the cable ECM pin 1 B5 ECM pin 1 B7 ECM pin 1 B3 2...

Page 308: ...fault proceed to test 7 Result OK Fault 0 8 Ù Open circuit Short circuit OK Short circuit OK Open circuit Test 1 Check the integrity of the terminal and the cable ECM pin 1 A8 BOB1 ECM pin 1 B8 BOB2 ECM pin 1 A1 BOB3 2 Check the resistance value red white safety relay ECM pin 1 RO B at ECM pin 1 B8 ignition coil 2 ECM pin 1 A8 ignition coil 1 ECM pin 2 A1 ignition coil 3 3 Check the cable for shor...

Page 309: ...relays with Supply blocking relay pin 8 to ECM pin 1 B8 ignition coil 2 ECM pin 1 A8 ignition coil 1 ECM pin 2 A1 ignition coil 3 6 Check the resistance of the relative ignition coil Pin 1 of the ignition coil at pin 2 of the ignition coil 7 Reconnect the cabling cancel the fault code and activate the engine to check the elimination of the fault Proceed to test 6 Locate and repair the cable fault ...

Page 310: ...Open circuit OK Short circuit OK Short circuit OK Fault Test 1 Check the integrity of the terminal and the cable ECM pin 1 B2 ECM pin1 C6 2 Check the resistance value ECM pin 1 B2 to ECM pin 1 E4 depending on the temperature see below 3 Check the continuity of the cable ECM pin 1 C6 to sensor pin 2 ECM pin 1 B2 to sensor pin 1 4 Check the cabling for short circuiting pin 1 C6 tol ECM B2 1 E4 5 Che...

Page 311: ...ion Proceed to test 2 Rectify the fault proceed to test 7 Disconnect the temperature sensor and proceed to test 6 Proceed to test 3 Disconnect the temperature sensor proceed to test 4 Proceed to test 5 Locate and rectify cable fault proceed to test 7 Proceed to test 5 Locate and rectify cable fault proceed to test 7 Result OK Fault OK Open circuit Short circuit OK Open circuit OK Short circuit Tes...

Page 312: ...nsor pin 2 depending on the temperature see below 6 Check the cabling for short circuiting EXM pin 1 C5 to the chassis 7 Reconnect the cabling cancel the fault code and activate the engine to check the elimination of the fault If the engine is hot remove the sensor and let it cool down beofre carrying out the test Resistancedata Resistance value 1 6 a 1 8 KÙ 1 9 a 2 2 KÙ 2 3 a 2 7 KÙ 2 9 a 3 3 KÙ ...

Page 313: ...cate and rectify the cable fault proceed to test 5 Proceed to test 5 Locate and rectify the cable fault proceed to test 5 Activity carried out terminate the test Contact the Benelli assistance Result OK Fault OK Short circuit OK Open circuit OK Short circuit OK Fault Test 1 Check the integrity of the terminal and the cable ECM pin 2 A2 2 Check the cable for short circuiting pin dell ECM 2 A2 to th...

Page 314: ...ed 2 Check that on the brown cable alternator there are 12 Vdc once the switchboard is turned on 3 Switch on the engine reach 3500 RPM and verify by voltmeter connecting it to the battery poles that there is a voltage in the range 13 5 14 5 dc NOTE Another possible cause for non correct working of the sensors TPS TEMP Air TEMP H2 O could be due to the missing of the 5 Vdc supply Check as follows D...

Page 315: ... that the bulb works Disconnect the ECM and proceed to location test 1 Disconnect the warning lamp proceed to test 4 Possible cause Open or short circuit to the chassis Short circuit at the positive battery pole Fault code P1601 P1602 BAD FUNCTIONING OF THE ENGINE DIAGNOSIS WARNING LAMP MIL WALBRO ECUA 1 ...

Page 316: ...t proceed to test 5 Proceed to test 4 Locate and rectify the cable fault proceed to test 5 Proceed to test 5 Locate and repair the cable fault proceed to test 5 Activity carried out terminate ithe test Contact the Benelli l assistance Result Ok Fault Ok Short circuit Ok Open circuit Ok Short circuit Ok Fault Test 1 Check the integrity of the terminal and the cable ECM pin 2 A4 2 Check the cable fo...

Page 317: ...UK 317 MF13 ...

Page 318: ...UK 318 MF13 E E E E Electrical P P P P Plant 9 ELECTRICAL PLANT ...

Page 319: ... POSIT NUMBER PLATE LIGHT FALL SENSOR KEY BLOCK GA BLOCK DR ELECTRIC SCHEME KEY POSITION KEY COLOUR HORN CLUTCH SWITCH N C INJECTION RELAYS RELAYS LOWER LIGHTS RELAYS DRIVE BEAM RELAYS SECURITY RELAYS PETROL PUMP RELAYS SINOID FANS SENS NEUTRAL SIDE STAND IDROSTOP BLINKER OIL PRESSURE SENSOR ALTERNATOR BATTERY FRAME GND ELECTROMAGNETIC SWITCH PETROL PUMP STARTER MOTOR INJECTION FUSE 25A SERVICE FU...

Page 320: ...w Blue 6 Neutral White Violet 7 Driving beams Yellow White 8 Position light Yellow Black 9 Fuel level GND Yellow Violet 10 Fuel level Brown Yellow A COLOURS 11 Set Reset Switch Yellow Grey 12 Gears Grey Red 13 Speed sensor exit Blue 14 15 Speed sensor mass Blue Black 16 Mass Black 17 Mass sensor environment temp Black 18 Mass sensor environment temp Red 19 Feeding control position Red 20 Lower key...

Page 321: ...nd to press down completely when connecting On disconnecting the connector make sure to hold the body of the connector and not pull the wires Check whether the connector terminals are loose or bent Check whether the terminals are corroded or dirty 9 2 FUSES Always investigate the cause of a fuse burning out repair and then change the fuse Do not use a fuse with a capacity different to the original...

Page 322: ...ructions to the letter Failure to respect the correct procedure can cause grave damage 9 4 BATTERY ATTENTION Do not use batteries other that those specified The battery 1 mounted on this vehicle is the hermetic type There is no need therefore for maintenance The batteries advised are the following YUASA YTZ 14S Proceed to reload following the indications in the battery packaging or as indicated ...

Page 323: ... after 30 minutes from loading the voltage at the battery heads Voltage à 12 5 Volt 9 4 1 CHECK BATTERY EFFICIENCY Check battery current losses Bring the ignition switch to the OFF position Disconnect the cables of the negative pole of the battery Connect thel multitester between the negative pole and the negative cable of the battery in function of a continuous current ammeter red wire black wire...

Page 324: ...tricity diagram NOTE In the case of eventually installing anti theft devices disconnect the latter before carrying out the checks Check load exit Dismantle the semi cowlings to get to the alterrnator zone Start the engine and make it spin at 2000 rev min with the lights switch ON and the selector on the dazzle position Hl Measure the DC voltage between the positive and negative terminals of the ba...

Page 325: ... general fuse 1 is on the left side of the engine To remove it undo the plastic protective cover Fuse 2 is the spare GENERAL FUSE 40 Ah Service fuses The service fuses box is under the saddle Open the fusebox cover to identify the position of the burned out fuse read the key placed under the cover and consult the electricity diagram 9 6 RELAYS 9 6 1 RELAY STARTER The relay starter 1 is on the left...

Page 326: ... RO GI RED YELLOW AR ORANGE VI MA VIOLET BROWN GI RO YELLOW RED BL VE BLUE GREEN GI BI YELLOW WHITE AR NE ORANGE BLACK 9 7 ENGINE STARTER Disconnect the supply cables on the battery Remove the starter relay see DISMANTLE RELAY Disconnect the suppy cables 1 on the engine starter 2 un screw the engine starter fixing screws 3 and extract the com ponent Check that the engine rotates freely without eff...

Page 327: ...pply cables Disconnect the connector 2 lift the protective cap and unscrew the starter supply fixing nut 3 Unscrew the three fixing screws 4 and extract the alternator moving the water pump tube slightly and paying attention not to let the flexible rubber couplings fall To re mount it use the reverse procedure oiling the flexible couplings and the O rings Tighten the three screws 25 N m 2 5 Kg m ...

Page 328: ...ose disconnected or interupted Starter defective Battery discharged Check the presence of the 12V on the connector relay between YE GR and black when the starter button is pressed Ignition switch defective Shut off engine switch defective General relay defective Starter button defective Clutch lever position switch defective Contact connector defective Open circuit on the cabling Fuse damaged Volt...

Page 329: ...n circuit on the cabling Contact connector defective Incorrect Correct Check the lateral assembly stand switch Lateral assembly stand switch defective Open circuit on the cabling Contact connector defective The engine does not rotate even if the starter engine rotates Starter clutch defective Incorrect Correct Incorrect ...

Page 330: ...new one 9 11 GEAR POSITION SWITCH The connector of the neutral switch wire is in the rear zone of the engine Disconnect the neutral switch wire and check the continuity between the NEUTRAL sensor wire and the chassis In the cae in which there is no continuity between the neutral sensor wire and the chassis change the component Engine frame ON neutral OFF neutral excluded ...

Page 331: ...itch and measure the continuity as described below Check the continuity with a multitester as indicated in the table Stand PIN 1 PIN 2 Raised Lowered If the above conditions are satisfied the stand switch is functioning 9 13 CLUTCH SWITCH Disconnect the clutch switch cables Use a tester to check the following on the clutch switch pins Clutch PIN 1 PIN 2 Pulled Released ...

Page 332: ...emove the vehicle sensor as described in the ENGINE chapter 2 Disconnect the connector 2 and check that the connector measures 10K betwen terminal A brown wire and B blue wire 9 15 OIL PRESSURE SENSOR To check the good functioning of this component the continuity between the contact on the sensor 1 and the chassis of the vehicle must be ascertained with the vehicle not running as shown in the figu...

Page 333: ...lenoid disassembly Remove the Seeger ring 1 remove the cable fixing plate set the piston free Loosen and remove the screws 2 remove the solenoid 3 Verify the free movement of the piston 4 if it moves hard remove it and lubricate the sliding zone 4 3 2 1 ...

Page 334: ...t remove the parabolas right and left inspection lids unscrewing and removing the fixing screws 1 9 17 1 FRONT LIGHT DISASSEMBLY Remove the wind shield see wind shield disassembly Unscrew and remove the frame screws 2 Take off the front LIGHT wiring connector 3 1 2 3 ...

Page 335: ...ection lids Unscrew the LIGHT fixing pivots 1 Unscrew and remove the central closing screw 2 of the right and left frame Loosen and remove the screws 2 remove the speed indicator remove the connector 3 remove the LIGHT wiring 2 3 2 1 ...

Page 336: ...rtical wall in less than about 1 10 with respect to the the horizontal axis of the lights For the regulation of the front light act on the two adjustment screws 1 of parabola right and left positioned under the light The right and left parabola can be set separately loosening will raise the light beam Tightening will lower the light beam 9 18 BACK LIGHTh DISASSEMBLY 9 18 1 CHANGING REAR HEADLIGHT ...

Page 337: ...crew 1 Remove the rubber lamp holder Change the position lamp Position the rubber lamp holder and tighten the screw 1 9 18 3 CHANGE FRONT AND REAR ARROWS 9 18 3 1 CHANGE FRONT ARROWS Cut the wiring fixing tie wraps Loosen and remove screw 1 Remove the arrow body Disconnect the connector Unscrew and remove the glass fixing screw ...

Page 338: ...se Position the arrow body the glass and fix with the dedicated screw Work the same way with the opposite arrow 9 18 3 2 BACK ARROW LAMP REPLACEMENT Loosen and remove the screw 1 Remove the glass arrow 2 Remove and replace the lamp 3 Reposition the glass 2 tighten the screw 1 ...

Page 339: ...UK 339 MF13 ...

Page 340: ...n damaged Change Right electrical connection block Deoxidise Restore Relay starter damaged Change Power cable connections defective Deoxidise Restore COOLING PLANT Electric fan not functioning Electric fan fuse burnt Change Electric fan fuse connection defective Deoxidise Restore ECU defective Change H2 O bulb Change H2 O bulb connection defective Deoxidise Restore Electric fan damaged Deoxidise R...

Page 341: ...unctioning 10A engine fuse burnt Change 10A engine fuse connection defective Deoxidise Restore Horn damaged Change Switch damaged Change Horn connection defective Deoxidise Restore Switch connection defective Deoxidise Restore Direction indicators not functioning 10A engine fuse burnt Change 10A engine fuse connection defective Deoxidise Restore Intermittent light damaged Change Intermittent light...

Page 342: ...light burnt Change instrument board Pilot lamp battery switched on Alternator connection defective Deoxidise Restore Instrument board damaged Change Defective battery Change Defective generator Change Fuel reserve warning light does not light up Fuel level sensor damaged Change Fuel level sensor connection defective Deoxidise Restore Instrument board damaged Change Instrument board connection defe...

Page 343: ...efective Deoxidise Restore Injection relay damaged Change Injection relay connection defective Deoxidise Restore Injector damaged Change Injector connection defective Deoxidise Restore ECU injection damaged Change Lateral injection hanger damaged Change Pick up engine damaged Change Pick up light phonic wheel not exact Change Petrol pump damaged Change Neutral sensor fault Change IGNITION PLANT Sp...

Page 344: ... damaged Change FRONT WHEEL Front wheel oscilates vibrates Wheel rim bent Change Wheel not balanced Balance Tire defective Change Wheel ball bearings damaged Tighten Pin fixing screws not tight Tighten Pin fixing ring nut not tight Tighten Front wheel rotates with difficulty Ball bearings damaged Change Wheel pin damaged Change Brake pads drag excessively on the disks see brakes Check Brake disks ...

Page 345: ...djust Hydraulic brake in extension insufficient Adjust Tire pressure low Adjust Damper damaged Change Rear suspension too rigid Preload spring excessive Adjust Hydraulic brake in extension insufficient Adjust Tire pressure high Adjust Rear wheel ball bearings damaged Change Suspension balancer ball bearings damaged Change Damper joints damaged Change Suspension joints connecting rod damaged Repair...

Page 346: ...e loosened Tighten Poor engine performance Exhaust pipe damaged Change Fixing pipe loosened Tighten COOLING PLANT Engine temperature too high Cooling liquid level too low Refill Defective cooling fanwheels Change Expansion tank cooling liquid cap defective Change Electric fan therrmo switch defective Change Sensor temperature instrument defective Change Thermostat blocked closed Change Cooler fins...

Page 347: ... engine Keep away from the fan Then cooling fan is controled by a temperature switch operates according to the temperature of the coolant disconnect the fan cable whenever operating on a warm engine so that the fan does not suddenly start up after the engine has been turned off Do not pour fuel directly into the carburettor to start the engine quickly Do not open the radiator cap before both the t...

Page 348: ... equipment must be used in a dry area Do not expose it or use it near heat sources Turn the device on and off using only th ON OFF switch Do not subject hte AXONE2000 BENELLI CPU to heavy shocks Do not expose the AXONE2000 BENELLI CPU to water or the liquids Do not lay objects on the power cable and do not kink the cable For frequent use store the equipment with the power charge cable connected Di...

Page 349: ...play an on line help guide when provided by the program 7 Store delete key to store test data or to delete the data from the memory according to the selected program 8 AUX 2 key to access auxiliary functions 9 AUX 1 key to access auxiliary functions 10 Up down keys 11 ON OFF key to turn the instrument on and off 12 Number keys to enter codes numeric data and select tests according to the selected ...

Page 350: ...c group of programs Tje module is clipped into the dedicated housing in the base of the AXONE2000 BENELLI The OBD module can be replaced whenAXONE2000 BENELLI is working but is recommended to replace the module when theAXONE2000 BENELLI is off 10 3 3 3 READ WRITE UNIT The read write unit 1 includes a memory card 2 containing various diagnostic programs NOTE Always insert the memory card before swi...

Page 351: ...attery using only the charger supplied 2 Lower parallel serial connection This connector acts as an interface between theAXONE2000 BENELLI and external units such as printers remote terminals serial devices etc This connector is also used to power theAXONE2000 BENELLI 3 Upper connector Depending on the interface module inserted in the AXONE2000 BENELLI the connector is used to carry out special te...

Page 352: ...powered externally ATTENTION The battery charger may be used as an external power source but only if the label carries one of the following captions Sec 12V 1000mA 12 0 VA OUTPUT 12Vdc 1A 10 3 3 6 RECHARGING THE BATTERY To recharge theAXONE2000 BENELLI internal battery Insert the plug 1 in the POWER connector 2 Connect the power unit 3 to the 220 V mains The fully charged instrument battery effici...

Page 353: ...recharge the battery completely for 12 18 hours before normal use 10 3 3 8 NOTES FOR CORRECT USE RECHARGING PRECAUTIONS Always use AXONE2000 BENELLI with charged battery In order to maximise the performance a slow charge should always be preferred For the efficient battery operation just follow the simple rules below The first two charge cycles must be performed with the instrument under charge fo...

Page 354: ...the reset is not immediate and it may be necessary to wait for a few minutes 10 3 3 9 TECHNICAL SPECIFICATIONS The following technical characteristics refer to the use of the AXONE2000 BENELLI CPU those relating to the various programs and the associated interface modules are available in the specific section of each kit Self powered portable computer Graphic display with adjustable brightness and...

Page 355: ...al results are recorded and stored MEMORY CARD data card which can be inserted into AXONE2000 BENELLI drive data can be read and written on the card PARALLEL execution of several tasks at the same time e g transmission of several data at the same time PERIPHERAL external device connected to the instrument SERIAL execution of operations one after the other e g transmission of data in sequence OPERA...

Page 356: ...ludes the instrument control program an interface module to be arranged in the base AXONE2000 BENELLI the sensors the cables for the connection to the engine the adapters the manual and all what is required by the tools and the specific tests Contact your area BENELLI dealer for information on available kits 10 3 3 13 STARTING PROGRAMS An introductory screen where to select the required language w...

Page 357: ...uctory page you can access the diagnosis and service programs using the scroll arrows as described in the previous paragraph To select SERVICE move to the corresponding icon and press ENTER to select The following functions can be accessed KEYPAD DISALE INSTRUMENT RESET SERIAL INSTRUMENT BIOS UPGRADE WORKSHOP BATTERY PARALLEL SERIAL KEYPAD This function is used to test the correct operation of eac...

Page 358: ...ious interface modules PARALLEL This function is used to test transmission reception and check correct operation of the parallel port SERIAL This function is used to test transmission reception and check correct operation of the serial ports Update firmware Service Parallel Service Serial Service ...

Page 359: ... is switched on BATTERY The function is used to discharge the battery The discharge curve is stored on the memory card to be displayed at a later time The remaining functions BIOS UPGRADE RESET INSTRUMENT and DISABLE INSTRUMENT are reserved to technical assistance and must not be used by the end user Workshop data Service Battery Service ...

Page 360: ...The upgrade file can be loaded to the PC in various ways By means of a CD ROM or a diskette provided by the technical assistance service Downloading from the internet or by modem link to by the technical assistance service server Receving it directly on the PC as an e mail attachment BENELLI will inform you on the relevant upgrade method INTERNET CONNECTION Information regarding the availability o...

Page 361: ...TERNET CONNECTION Accede to the menu Service Accede to the program internet Configuration CALLING COUNTRY CONFIGURATION Select page MODEM Service Internet Configuration Service Upgrading Mail ISP access Modem Test Modem CONFIGURATION OUT ...

Page 362: ...call frequency Calling from Italy MODEM OUT pulse Wait for line tone disabled enabled Volume Serial connection timeout 10 OFF FWD BACK SELECT CANCEL Type of call frequency Calling from Italy Italy MODEM OUT pulse Wait for line tone disabled enabled Volume Serial connection timeout 10 OFF Save changes Calling from MODEM OUT pulse enabled Volume Serial connection timeout 10 OFF SELECT CONFIRM CANCEL...

Page 363: ... ARROW key UP DOWN RIGHT LEFT 3 In the map to move for selecting the required character use ARROW keys UP DOWN RIGHT LEFT press ENTER to write the selected one 4 To cancel the last character point on to DEL key in the map and press ENTER 5 To terminate the Username insertion go to END in the map and press ENTER Proceed by the same mode for inserting the Password External line access number Telepho...

Page 364: ...ogramme indicates the potential criticality of the connection In this case the battery charger supplied with the system can be used to power the AXONE2000 BENELLI Sec 12V 1000mA 12 0 VA OUTPUT 12Vdc 1A Select Via internet in the following submenu to go to the connection wizard page Update Internet not availablel External line access number Telephone number 123456 XXX YYY 0 2 11 95 200 212 DNS ISP ...

Page 365: ...dow with the connection speed which depends on the communication line The first steps ends once the available programs on the BENELLI server have been detected and after comparing the versions on the BENELLI server with those installed on the AXONE2000 OPTIONS OUT Restore memory Internet connection Connecting OPTIONS OUT Restore memory Internet connection OPTIONS OUT Connected at 49333 b s Checkin...

Page 366: ...sis 24 Kb Self diagnosis 1407 Kb Lamp reset 77 Kb Gas 6 Kb Measurs 12 Kb OBD 209 Kb Internet 317 Kb Select Exit OPTIONS OUT Connected at 49333 b s Connecting to file transfer service OPTIONS OUT Connected at 49333 b s Authenticating Service 121 Kb Engine diagnosis 24 Kb Self diagnosis 1407 Kb Lamp reset 77 Kb Gas 6 Kb Measurs 12 Kb OBD 209 Kb Internet 317 Kb OPTIONS OUT Connected at 49333 b s Upgr...

Page 367: ...rminal The function can be accessed from the main menu Go to the corresponding icon and press ENTER to access the function NOTE The multimeter function can be used to measure voltage current and resistance Particularly current can be measured on different scales The original kit cables can be used to measure capacity up to 2A full scale Capacity from 20A to 600A require the use of an ammeter clamp...

Page 368: ...le ABICOR ammeter clamp optional is required for tests from 20A to 600A Set the required full scale value manually following the indications in the selection menu This menu will provide all the indications required for connecting the BICOR clamp This will ensure that the instrument in set correctly in this example the full scale value is set to 20A mV 000 0 MAX mV 000 0 MED mV 000 0 MIN OPTIONS OU...

Page 369: ...istance tests are performed during the red probe and the black earth clamp Connect the component to be measured between the two terminals The main characteristics of the ohmmeter are Automatic scale change Stored values minimum medium maximum Graphic view of resistance in time Concurrent analogue and digital display A 000 0 MAX A 000 0 MED A 000 0 MIN OPTIONS OUT A mA Ù 1000 MAX Ù 1000 MED Ù 1000 ...

Page 370: ...ursor in the Options submenu to activate the reading 4 Navigation window to quit the program and go back to main menu 5 Readings window to set two different reading modes alternate AC or direct DC 6 Scale window to set the voltage V and time T scales according to the signal to be displayed 7 Channel window to indicate the selected channel 1 2 3 or 4 and the red yellow green and blue wires all refe...

Page 371: ...displaying the input channel on the display Select the required channel highlighted in bold print by means of the scroll arrows and press ENTER IMPORTANT The function can be selected directly by means of the number keypad by recalling the corresponding channel number OPTIONS CH1 8 6 4 v T DC AC MAN EXT Va 10 0mV Vb 10 0mV Dv 0 0 Dt 5mS A B INT TIPO SINC CH1 8 6 4 v T DC AC Input Cursors Zoom Grid ...

Page 372: ...he two points where the cursors crosses the curve The difference in voltage Dv and the time that separates them Dt will be shown in absolute values Note that the colour of the intersection point will be inverted by moving the two cursors on the curve at the point corresponding to where the signal was read This allows an easier more accurate reading The original line will be cancelled whereby confi...

Page 373: ...function is used to hide and show grid lines on the display Go to the corresponding function and press ENTER to select SCREEN RESET To select the Screen reset function go to the required option by means of the scroll buttons and press ENTER The signal or signals stored on the display will be cancelled and the initial page will appear OPTIONS CH1 EXIT v T DC AC MAN EXT Va 10 0mV Vb 10 0mV Dv 0 0 Dt...

Page 374: ...he windows identified by letters V and T are used to select the voltage and time scale A grid will appear in the signal display window dividing the display into square Squares of the same side may indicate different units and values These functions must be set according to the signal to be measured in Manual mode so that the best resolution is used for displaying the curve or part of it In this wa...

Page 375: ...t of a single square Fig 2 SCALE SELECTION T To select T div scale select the window with the letter T bold and blinking and press ENTER A drop down menu will apper containing the values which can be set on the time scale Use the scroll arrows to select the required time division value and press ENTER The new scale with the selected scale will be displayed the time value axis will change automatic...

Page 376: ...with the alternative component if AC is selected This option is extremely useful to highlight the disturbance overlaying a direct signal Atypical example is testing the voltage of a battery If the test is executed inAC hte reading shows the residual signal generated by the rectifier diodes of the alternator The measurement with the oscilloscope inAC mode alternate allows the selection of small vol...

Page 377: ...enerator signal before the voltage regulator 10 3 6 9 TYPES OF SYNCHRONISM Synchronism means the way of stabilising the display of the wave form signal on the screen an auxiliary signal is used It may be generated from yxz itself INT it may be input from the outside EXT or it may be generated by the operator MAN The type of synchronism is shown in the window in the right of the screen Three are th...

Page 378: ...is represents the starting point of the synchronism in the display Use the arrow keys to move it left or right in order to improve the display of the signal by centring it in the screem MANUAL SYNCHRONISM To select the Manual sybchronism select the window with the MAN letters Press ENTER to start measuring of the signal Manual trigger offers new diagnostic possibilities While internal or external ...

Page 379: ...s twice any of the scroll arrows EXTERNAL SYNCHRONISM Not available 10 3 7 AUTO DIAGNOSTICS The AUTO DIAGNOSTICS program is used to connect the AXONE2000 BENELLI to various injection ECUs with different characteristics according to the make and the specific injection system The auto diagnostics with the motorcycle ECU Possible procedures Read functional parameters of all systems connected to the E...

Page 380: ...The auto diagnostics interface cable cannot be powered by the yxz internal battery An external power source must be used as shown below connector 1 to the motorcycle connector 2 to the motorcycle battery power cable 3 never to an external battery 10 3 7 1 TESTING To start a program insert the OBD module with the instrument off selectAUTO DIAGNOSTICS and press ENTER to confirm Details on the page w...

Page 381: ...to enable or disable tones HOW TO SELECT MAKE AND MODEL Use the scroll arrows to select the available manufacturers and press ENTER to confirm Select the motorcycle model and press ENTER to confirm Systemselectionwindow showing information on the system Functionwindow showingthefunctioninuseandthekeys for selecting other functions and and for quitting auto diagnostics Diagnostics window showing in...

Page 382: ...example select the injection system and then the ECU type code Press ENTER to confirm The version and location of the diagnostic socket will be provided DATABASE POWERPLANT 898 BENELLI Tornado Tre DATABASE SYSTEM TYPE INJECTION REPROGRAMMING BENELLI Tornado Tre 898 INJECTION DATABASE VERSION 2002 Not definite BENELLI Tornado Tre 898 INJECTION Sagem POSITION OF COMPONENTS E C U Connector Left side ...

Page 383: ...interface between the motorcycle cable interface and the main cable Connect the adapter cable to the ECU auto diagnostic socket as shown in the figure using the suggested sonnection cable STARTING DIAGNOSTICS Select the motorcycle system to be tested and start the test ATTENTION Make sure the ignition key is off before starting the test Set up the connection DATABASE Sagem BENELLI Tornado Tre 898 ...

Page 384: ...ay them instead of those shown Press ENTER to confirm To view a parameter value Select the required parameter Press ENTER Press ENTER again to display parameter view NOTE The selected data refresher speed and the number of available items depends on the ECU CURRENT AND SAVED ERRORS Use the keys and on the keypad to view the errors icon intop right to access to ERRORS function The yxz picture will ...

Page 385: ...or deletion will be confirmed by the message STO which will appearnexttotheerrrormessage Theautomaticstoragefunction is used to temporary store the errors deleted from the ECU memory in the yxz memory and display them STOP will appear next to the items on the display All stored errors will be cleared by deletion ATT MEM and STO error status management depends on the selected system and may vary DA...

Page 386: ... press keys to view the ACTUATORS function Go to the required actuator with the scroll arrows Press ENTER to activate the selected component The list may not be comprehensive Use the left right scroll arrows to select missing items and display them instead of those shown Press ENTER to confirm NOTE In most cases the engine must be off before accessing the ACTUATORS functions Follow the instruction...

Page 387: ...wed the second figure appeares Press ESC repeatedly until MAIN MENU appears Select another model to resume auto dianostics Press the ON OFF button to switch the device off ATTENTION Always use the ESC key to quit procedures in a sale correct way DATABASE BENELLI Tornado Tre 898 INJECTION Sagem Error clearing DATABASE BENELLI Tornado Tre 898 INJECTION Sagem Press ENTER to confirm EXIT RPM Températu...

Page 388: ...1 Press ENTER 12 The FRAME CODE menu is not defined press ENTER 13 From the PLANT TYPE menu select Walbro 14 Press ENTER 15 The VERSION Il menu is not defined press ENTER 16 Follow the instructions seen on the instrument and press ENTER 17 At this point the instrument is in communication with the console With the and keys it is possible to scroll the following menus identified by icons 1 ENGINEERI...

Page 389: ...ows 10 Increase or diminish this procedure according to whether you want to thin or thicken the fuel 11 Go to the ENGINEERING PARAMETERS page icon C NOTE it is important in order to have a correct reading of the CO that the position of the stepper is at a value of about 10 15 steps as acting on the FUEL ADJUST MENTAT MINIMUM value this parameter is modified automatically this parameter with the en...

Page 390: ...sition screen Press Enter Gearcase data screen Press Plus or Minus With the symbol o go in the selection Gearcase Selection gearcase screen Select Select with the Up and Down arrows the gearcase type Selected gearcase screen Press Enter Starting the gearcase reprogramming waiting time about 6 min the temperature needle moves until reaching the lower scale on the Axone display you will read a value...

Page 391: ...UK 391 MF13 ...

Page 392: ...Produced and Printed SERIART Fabriano AN ITALY ...

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