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Benelli ZAFFERAN 250, Service Manual

The Benelli ZAFFERAN 250 is an exceptional motorcycle that brings power and style to the ride. With its innovative design and advanced features, this bike is perfect for those seeking adventure and adrenaline. To ensure optimal performance, make sure to download the free Service Manual and user manuals from manualshive.com for all your maintenance and troubleshooting needs.

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145 

 

 

 

 

Gas mixture to thick

 

Fuel injector leakage       
rarefied air mixture 
Fuel pressure problem 
ECU data problem sensor failure 
Blocked airway 

 

17.2  Components of Electronic Fuel Injection System

 

 

 

17.2.1 

Engine Controller (MT05 ECU)

 

 

 

The  engine  controller  can  test  the  operation  conditions  of  the  engine  with  various  sensors  at  any 
time  and  guarantee  the  emission  and  economy  of  fuel  by  proper  computing  and  self-study  control 
output  mechanism  with  the  driving  performance  optimized.  Once  failures  are  found  within  the 
engine,  the  control  would  go  through  automatic  diagnosis.  The  normal  working  of  the  system 
requires two ECU. 

 

17.2.1.1  ECU Appearance

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

Above  is  the  label  of  th e  ECU  controller,  which  contains  the  type,  component  number,  client 
number,  hardware  number,  production  number,  software  edition  and  bar  code  of  the  ECU.  Such 
information shall not be erased or stained, or it will impact the guarantee of the product. 

 

17.2.1.2  ECU Definition of ECU Connector Pin

 

 

 

1) ECU 12

： 

J1-1

 

 

J2-1

 

Pin for activating 1-cylinder ignition coil

 

J1-2

 

Headlight control pin

 

J2-2

 

Pin for system grounding

 

J1-3

 

Pin for trouble light

 

J2-3

 

Pin for K line communication

 

J1-4

 

Pin for heating 2-cylinder oxygen

 

J2-4

 

Pin for crank signal high potential

 

Summary of Contents for ZAFFERAN 250

Page 1: ...1 ZAFFERANO 250 Service Manual ...

Page 2: ...p motor 55 3 4 Starter relay 56 4 Bulbs Switches Meters 58 4 1 Preparing documents 58 4 2 Failure diagnosis 58 4 3 Replacement of headlamp bulbs 58 4 4 Replacement of front steering lamp bulbs 58 4 5 Replacement of tail lamp bulbs 59 4 6 Meter 59 4 7 Main switch 59 4 8 Horn 60 4 9 Handlebar switch 60 Inspection and maintenance of vehicle 61 5 Brake 63 5 1 Maintenance instruction 63 5 2 Failure dia...

Page 3: ... 13 5 Clutch driven wheel 119 14 Transmission 126 14 1 Preparation documents 126 14 2 Failure diagnosis 126 15 Crankcase 131 15 1 Preparation documents 131 15 2 Failure diagnosis 131 Inspection and maintenance of Emission control system 142 16 Emission control system 137 16 1 Emission control system recognizance 137 16 2 Regular maintenance notes 138 16 3 Mechanic function of Emission control syst...

Page 4: ...ls Modifications and significant changes in specifications or procedures will be forwarded to all authorized Benelli dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol...

Page 5: ...ce not in a closed area Note Exhaust gas contains poisonous carbon monoxide which may cause unconsciousness or even death of human Start the engine in an open place An exhaust removal system shall be adopted if engine is started up in a closed area Petrol Ventilation is required for working places Fire is strictly forbidden in any working place or where petroleum is stored ...

Page 6: ... clean all parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 6 Keep all parts away from any source of fire REPLACEMENT PARTS 1 Use only genuine Benelli parts for all re placements Use oil and grease recom mended by Benelli for all lubrication jobs Other brands may be similar in function and appearance but infer...

Page 7: ...oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liberally when installing if appropri ate 1 Oil seal CAUTION Do not use compressed air to spin the bearings dry This will damage the bearing surfaces 1 Bearing CIRCLIPS 1 Check all circlips carefully before reas sembly Always replace piston pin clips af ter one use Replace distorted circlips When insta...

Page 8: ...not come off 6 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 7 Connect Connector NOTE The two connectors click together 8 Check for continuity with a tester NOTE If there is no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness For a field remedy use a contact revitalizer available on the market ...

Page 9: ...cc cm3 0 03527 0 06102 oz IMP liq Capacity lit liter 0 8799 qt IMP liq lit liter 0 2199 gal IMP liq Miscella neous kg mm 2 Centigrade 55 997 14 2 234 lb in 2 Fahrenheit F HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMP mm 0 03937 in 2 mm 0 03937 0 08 in ...

Page 10: ...o remove the flywheel magneto Ringnut wrench This tool is used to loosen and tighten the exhaust and steering ringnut Valve adjusting tool This tool is necessary for adjusting valve clearance Fuel level gauge This gauge is used to measure the fuel level in the float chamber Radiator cap tester Adaptor These tools are used for checking the cooling system T handle Damper rod holder These tool are us...

Page 11: ...ench This tool is used to loosen and tighten the steering ring nut Sheave holder This tool is used for holding the secondary sheave Cylinder cup installer set This tool is used for installing the cylinder cup to the master cylinder piston Thickness gauge This tool is used to measure the valve clearance Compression gauge These tools are used to measure the engine compression Pocket tester These ins...

Page 12: ...the valve Valve spring compressor Attachment These tools are used when removing or installing the valve and the valve spring Middle shaft bearing driver Mechanical seal installer These tools are used for installing mechanical seal Ignition checker This instrument is necessary for checking the ignition system components Sealant This sealant bond is used for crankcase mating surface etc ...

Page 13: ... feed and splash Tire Size Front wheel 120 70 14 Rear wheel Air filter Sponge 140 60 14 Transmission Device C Cl lu ut tc ch centrifugal Capacity of gasoline tank 2 95 gallons Performanc e Max speed 75 mph Transmission CVT Grade ability 20 degree Idle speed rpm 1400 100rpm min Drive Belt drive Max torque 17 3ft lb 5000rpm Electric Device Battery capacity typ e 12V 6Ah dry charged Max Hp 20 8hp 650...

Page 14: ...14 Ignition spark ignition DC capacitance system Diameter of rear brake disc mm φ250mm ...

Page 15: ...n ers with standard I S O pitch threads Torque specifications for special components or as semblies are included in the applicable sections of this book To avoid warpage tighten multi fastener assemblies in a crisscross fashion in progressive stages until full torque is reached Unless otherwise specified torque specifica tions call for clean dry threads Components should be at room temperature A D...

Page 16: ...nner surface Cam chain outside sprocket inner surface Piston pin Piston outside and ring groove Camshaft cam profile Valve stem IN EX Valve stem end lN EX Rocker shaft Valve rocker arm inner surface Shaft Shaft Oil pump assembly Gasket Oil pump assembly Holder Idle gear 1 thrust surfaces Shaft 1 Idle gear 2 thrust surfaces Idle gear 2 inner surface Main axle thrust surfaces Crankcase mating surfac...

Page 17: ...t right Steering head pipe bearing upper lower Steering head pipe dust seal lips upper lower Tube guide throttle grip inner surface Brake cable brake lever Brake lever and lever holder bolt sliding surface Sidestand sliding surface Centerstand sliding surface and mounting bolt Centerstand stopper pivot shaft Brake cam pivot shaft and cam surface ...

Page 18: ...ary tools Absorber working inspection I I I Ordinary tools Screw fastening inspection I I I I I I Torque spanner Oil leakage inspection for gearbox I I I I I I Ordinary tools Inspection or replacement of spark plug I I R R I Ordinary tools Replacement of gearbox oil I Replacement every 3000 MI Ordinary tools Lubrication of each part L L Lubricator Exhaust pipe I I I I I I Ordinary tools Ignition t...

Page 19: ... possible condition The above table is established under the presupposition of 600 mi month I Inspection A Adjustment R Replacement C Cleaning L Lubrication Note 1 Regulations on exhaust emission made by the State Environmental Protection Agency shall be complied with Maintenance must be carried out in accordance with the instruction manual supplied by the company We are not responsible for any lo...

Page 20: ...lug Headlamp Battery Clutch Ignition timing Front rear suspension system Rim tires Bolt nut fasteners Tire specifications Preparing Principles General Warning Make sure that it is well ventilated before starting the engine It is forbidden to start it in a closed area Exhaust gas which contains monoxide may cause unconsciousness or even death Petrol is liable to volatile or explode under certain co...

Page 21: ...gnition time BTDC12 degree 1 degree 1500 100rpm Frame Free play of front brake lever 10 20mm Free play of rear brake lever 10 20mm Pressure unit psi Specification Tire pressure EFI Motorcycle ZAFFERAN O Front wheel 120 70 14 36 psi Rear wheel 140 60 14 36 psi Torqu e value Locking nut for front wheel spindle 75 88N m Fixing nut for rear wheel 100 123N m ...

Page 22: ...grip flange Throttle cable free play Adjustment steps NOTE Never accelerate the throttle when stopping the engine Loosen the locknut 1 on the throttle cable Turn the adjuster 2 in or out until specified free play is obtained Turning in Free play is increased Turning out Free play is decreased Tighten the locknut After adjusting turn the handlebar to the right and to the left to ensure that this do...

Page 23: ...rk minimum mark filter 5 Start the engine and let it warm up for a few minutes 6 Turn off the engine NOTE Wait a few minutes until the oil settles before in specting the oil level ENGINE OIL REPLACEMENT 1 Start the engine and let it warm up for sev eral minutes 2 Turn off the engine and place an oil pan un der the engine 3 Remove Oil filler plug Drain plug 1 Compression spring 2 Oil strainer 3 O r...

Page 24: ...il check bolt If no oil comes out after one minute turn the engine off so it will not seize Check oil passages and oil pump for damage or leakage Start the engine after solving the problem s and recheck the oil pressure Tighten the oil check bolt to specification CAUTION Start the engine and check the oil pres sure with the oil check bolt loosened Do not apply at high speeds more than specified wh...

Page 25: ...t up and then stop 3 Place an oil pan under the crankcase 4 Remove Oil filler cap 2 2 Drain bolt 1 Drain the oil 5 Tighten 1 Drain bolt 6 Fill Crankcase Recommended oil SAE 10W30 motor oil Oil quantity 0 25 L CAUTION Wipe any spilled oil off the tire or the wheel 7 Install Oil filler cap 1 O ring 2 8 Start the engine for several minutes to warm it up and check for the oil leakage ...

Page 26: ...Spark plug type Incorrect Replace Standard spark plug CR8E NGK 2 Inspect Electrode 1 Wear damage Replace Insulator 2 Abnormal color Replace Normal color is a medium to light tan col or 2 Clean Spark plug with spark plug cleaner or wire brush 3 Measure Spark plug gap 3 with a plug gauge Out of specification Adjust gap Spark gap 6 Install 0 6 1 7 mm Spark plug NOTE Before installing a spark plug cle...

Page 27: ...se cover 2 Remove Air filter element 1 CAUTION Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the filter element will also affect the EFI tuning leading to poor engine performance and possible overheating 3 Inspect Air filter element Damaged Replace 4 Clean Air filter ele...

Page 28: ...sion 6 Install Air filter element Air filter case cover Side panels CRANKCASE FILTER CLEANING 1 R emove Crankcase filter cover 1 Crankcase filter cover seal Crankcase filter element 2 NOTE When installing the element in its case be sure its sealing surface matches the sealing surface of the case so there are no air leaks 2 Inspect Crankcase filter element Damaged Replace CAUTION This element is a ...

Page 29: ...utes 4 Turn off the engine 5 Remove Spark plug CAUTION Before removing the spark plug use com pressed air to blow away any dirt accumu lated in the spark plug well to prevent it from falling into the cylinder 6 Attach Compression gauge 1 7 Measure Compression pressure If it exceeds the maximum pressure al lowed Inspect the cylinder head valve surfaces and piston crown for carbon de posits If it is...

Page 30: ...ottle wide open until the reading on the compression gauge stabilizes Before cranking the engine ground all spark plug leads to prevent sparking 8 Install Spark plug 9 Install Side panels IGNITION TIMING CHECK NOTE Prior to checking the ignition timing check all electrical connections related to the ignition system Make sure all connections are tight and free of corrosion and that all ground conne...

Page 31: ...let it warm up for several minutes Let the engine run at the specified speed Engine speed 1 450 1 550 r min Visually check the stationary pointer a to verify it is within the required firing range b indicated on the flywheel Incorrect firing range Check the ignition system ...

Page 32: ...d Turning out Free play is increased Tighten the locknut CAUTION Make sure that there is no brake drag after adjusting the front brake lever free play A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system This air must be removed by bleed ing the brake system before the motorcycle is operated Air in the brake system will con siderably reduce braking perfo...

Page 33: ...brake fluid reservoir is horizontal If DOT 4 is not available DOT 3 can be used CAUTION Brake fluid may corrode painted surfaces or plastic parts Always clean up any split fluid im mediately Use only the designated brake fluid Other fluids may deteriorate the rubber seals causing leakage and poor brake perfor mance Refill with the same type of fluid Mixing fluids may result in a harmful chemical r...

Page 34: ...t properly bled 1 Bleed Brake system Air bleeding steps a Fill the reservoir with the proper brake fluid b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect a clear plastic hose 1 tightly to the caliper bleed screw 2 d Place the other end of the hose into a con tainer e Slowly apply the brake lever several times f Pull the lever in Hold the lever ...

Page 35: ...er the brake system considerably lengthen ing the bleeding procedure j Tighten the bleed screw Bleed screw NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the brake system have disappeared k Fill the brake fluid reservoir to the proper level Check brake operation after bleeding the brake system ...

Page 36: ...ont brake 3 Check Operation Push down hard on the handlebars sev eral times Unsmooth operation Repair REAR SHOCK ABSORBER INSPECTION 1 Remove Side panel Box Check Rear shock absorber mount Looseness Tighten Bolt upper 1 Bolt lower 2 REAR SHOCK ABSORBER ADJUSTMENT Always adjust each rear shock absorber preload to the same setting Uneven ad justment can cause poor handling and loss of stability Secu...

Page 37: ...ng Always adjust each shock absorber to the same setting TIRE INSPECTION 1 Measure Tire inflation pressure Out of specification Adjust Tire inflation pressure should only be checked and adjusted when the tire tem perature equals the ambient air tempera ture Tire inflation pressure and suspen sion must be adjusted according to the total weight of the cargo rider passenger and accessories fairing sa...

Page 38: ...y may result from sud den deflation Tube type wheel Tube type tire only Tubeless type wheel Tube type or tubeless tire Be sure to install the correct tube when using tube type tires After extensive tests the tires listed be low have been approved by Benelli Mo tor Co Ltd for this model No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Be...

Page 39: ... accident with possible injury to the rider or damage to the scooter 2 After a tire repair or replacement be sure to tighten the valve stem locknut 1 to specification WHEEL INSPECTION 1 Inspect Wheels Damage Bends Replace NOTE Always balance the wheel when a tire or wheel has been changed or replaced Never attempt to make any repairs to the wheel ...

Page 40: ...40 Inspection and Maintenance of Electrical System Charging system 1 Battery 2 Start Relay 3 Power lock assembly 4 Flash apparatus 5 Rectifier 6 Horn 7 ECU ...

Page 41: ...e detected voltage is very low Regulator failure overvoltage inside the battery will shorten its service life 3 The battery will be discharged if being stored for a long time which reduces its capacity It shall be charged about every three months when storing Check the charging system following the sequence listed on the failure diagnosis table 4 Do not remove the connector when there is current t...

Page 42: ...2 Failure diagnosis Power supply dead Interrupted current Battery over Emission Poor contact of the charging wire Unconnected battery wiring Poor contact of the charging system Fuse blow Poor contact or short circuit of the lighting system Poor switch Low voltage Poor charging system Poor battery charging Poor contact short circuit or open circuit of wire terminals Poor contact Poor voltage curren...

Page 43: ...terminal of the charger with the negative terminal of the battery Warning The battery should be far away from a fire source Turn off the charger before or after charging to avoid explosive danger caused by spark which may exist in any connection Comply with the current and time requirements for charging as stated on the battery Note Except emergencies you should not use emergency charging Measure ...

Page 44: ...e and increase its speed gradually to measure the limiting voltage and current Limiting voltage speed 14 15V 5 000 rpm Check the voltage regulator if the limiting voltage is not within its required range Check the limiting voltage of the lighting system Note Set the multimeter to the AC voltage position Limiting voltage 13 1 0 5V 5 000 rpm Check the voltage current regulator if the limiting voltag...

Page 45: ...nector of the magneto Measure impedance between the white coil of the magneto and the body with multimeter Standard 0 6 1Ω 68F Replace the magneto coil when the measured value exceeds the standard value 1 7Magneto disassembly 1 7 1 Disassembly Remove the body guard Fix the flywheel using the universal spanner Remove fixing bolts of the flywheel Remove the flywheel using the puller tool Remove the ...

Page 46: ...46 Ignition system 1 Battery 2 Starter Relay 3 Power lock assembly 4 Flash apparatus 5 Rectifier 6 Horn 7 ECU ...

Page 47: ...y 5 Failure of the ignition system is mostly caused by poor contact of the socket Check whether each connector is in good condition 6 Check whether the heat value used for the spark plug is proper If not the engine may work abnormally or the spark plug may be burnt 7 Check in this chapter is based on the maximum voltage It also refers to check on the impedance of the ignition coil 8 Check the main...

Page 48: ... Poor terminal of high voltage wires Poor RELATED PARTS group when item is checked to be abnormal or there is no spark for spark plug Normal high voltage but no spark Poor spark plug or secondary leakage of the ignition coil Poor ignition coil Charging coil No high voltage The inner resistance is too small and it should be tested by required tester Low speed of the crankshaft Interfered tester It ...

Page 49: ... primary coil terminal black white and the GND Press the startup motor or step the actuating lever to measure the maximum primary voltage of the ignition coil Minimum voltage above 95V Note Never touch any metal part of the test rod with your finger to avoid electric shock 2 3 2 Charging coil Note Install the spark plug on the cylinder head and carry out measurement when the compression pressure i...

Page 50: ...50 B L B R BL W W G B BL W W G B ...

Page 51: ...p Connect the peak voltage shunt between the trigger with 6P connector blue white terminal and 6P connector black terminal Press the startup motor or step the actuating lever to measure the maximum voltage of the trigger Connection positive pole to blue white negative pole to black Minimum voltage above 1 7V Note Never touch any metal part of the test rod with your finger to avoid electric shock Ω...

Page 52: ...ard Remove the spark plug cap Remove the primary lead of the ignition coil Remove the fixing bolts and then the ignition coil Install the ignition coil in reverse order Note Install the primary coil with black white terminal ignition coil 2 5 2 Check the primary coil Measure impedance between terminals of the primary coil Standard 0 4Ω 10 20 It shows good if the impedance is within the range of st...

Page 53: ... and the negative terminal Standard 4 5 5 5KΩ 10 68F 2 6 Trigger Note Check the trigger on the engine Ω BL W Check Remove the body guard Remove the trigger terminal Measure the impedance between the blue white terminal of the side wire of the engine and the body GND Standard 100 200Ω 68F W G BL W W W W ...

Page 54: ...54 Starter System BATTERY G Y G Y M 1 Battery 2 Starter Relay 3 Power lock assembly 4 Flash apparatus 5 Rectifier 6 Horn 7 ECU ...

Page 55: ...lutch please comply with regulations Preparing principles Item Standard Limit for use Length of the brush of the startup motor 12 5mm 8 5mm Bushing of the startup idler shaft 8 3mm Outer diameter of the startup idler shaft 7 94mm Tightening torque force Bolts for the clutch cover of the startup motor 12 N m Fixing bolts for the clutch of the startup motor 95 N m Tools Spanner for fixing nuts Unive...

Page 56: ...d dismantle the terminal of the starter motor 3 3 2 Breakdown Remove screws in the shell front cover motor housing and other parts Check other components Replace any part with abraded damaged or burnt surfaces Clean the commutator surface if there is metal powder attached to it Check conduction between the surface of the other components Ensure non conduction between armature shafts of the commuta...

Page 57: ...re Press it gently for assembly 3 3 5 Installation Install the lead of the starter motor and the dustproof boot Then install the startup motor Install the wire clip for rear brake 3 4 Starter relay 3 4 1 Check Remove the body guard When the main switch is on check there is click sound at the time of pressing the starter motor With click sound it is normal check the GND loop of the starter relay ch...

Page 58: ...ction between the black wire of the terminal and the body ground connection Check conduction of the starter button and leads when it is not conducted Ω 3 4 4 Check Connect the starter relay to the battery and the terminal of the starter motor to the multimeter Connect fully charged battery between the black wire and the green yellow wire of the relay The relay shall sound click and the multimeter ...

Page 59: ...ailure diagnosis When the main switch ON is not light it is due to Poor bulbs Poor switch Bad contact or broken wires 4 3 Replacement of the Headlamp Bulbs 4 3 1Disassembly Remove the front shield Remove the fixing screws for dismantling the headlamp Disconnect the headlamp connector Remove the headlamp Remove the glass of the headlamp Fix the headlamp and rotate the socket clockwise to remove the...

Page 60: ... and the rear steering lamps are integrated 4 5 2 Installation Install the tail lamp in reverse order 4 5 3 Replacement of tail lamp bulbs 4 5 3 1 Disassembly Remove the fixing screws to dismantle the tail lamp bulbs Remove the bulbs from the socket 4 5 3 2 Installation Install the tail lamp bulbs in reverse order 4 6 Meter Remove the rearview mirror Remove the handlebar cowling and waterproof con...

Page 61: ...ng bolts and the fixing seat for the main switch Remove fixing bolts and replace the main switch 4 8 Horn Check Remove horn wires Connect the horn to a battery if it sounds the horn is in good condition 4 9 Handlebar Switch 1 Electric Start Switch 2 Hazard Light Switch 3 Headlamp Beam Passing Lamp Switch 4 Turn Signal Switch 5 Horn Switch ...

Page 62: ...orque of nut 1 5 9N m E Free stroke of front brake handle 10 20mm 1 Bolt 2 Master Cyl Strap 3 Handle bolt 4 Brake Lever 5 Nut M6 6 Front Brake Light Switch 7 Front Brake Line 8 Banjo Bolt 9 Front Brake Assembly 10 Washer 11 Bolt M8 35 12 Front Right Brake Caliper Assembly 13 Front fluid brake upper pump assembly 14 Front Brake Pads 15 Front Left Brake Caliper Assembly 16 Pipe Clamp 17 Bolt M6 35 1...

Page 63: ... disc diameter 250mm E Free stroke of front brake handle 10 20mm 1 Bolt M6 35 2 Master Cyl Strap 3 Handle Bolt 4 Rear Brake Lever 5 Nut M6 6 Rear Brake Light Switch 7 Banjo Bolt 8 Rear Brake Hose 9 Washer 10 Rear Brake Pads 11 Rear Brake Caliper Assembly 12 Rear Brake Master Cylinder Assembly 13 Rear Brake Assembly 14 Washer φ8 15 Bolt M8 35 16 Bolt M6 12 17 Pipe Clamp ...

Page 64: ...0 Thickness of rear brake pad 6 0 3 0 EFI Motorcycle ZAFFERANO Diameter of front disc brake φ250mm Diameter of rear disc brake φ250mm 5 1 2 Torque force Fixing bolts for front rear brake disc 22 29 N m Mounting bolts for front brake cylinder assembly 22 29 N m Mounting bolts for rear brake cylinder assembly 22 29 N m 5 2Failure diagnosis Brake Poor brake performance Slow reaction or tight lever 1 ...

Page 65: ... performance Loosen fixing bolts for the brake cylinder assembly Remove the brake cylinder assembly from the front absorber Remove the front wheel spindle Remove the front wheel Remove the brake disc from the front wheel 5 3 2Check Check whether brake pads are abraded Replace it if necessary Measure the brake pad and the brake rotor Record maximum values Specification Diameter of the front brake r...

Page 66: ...stain brake pads with oil spots Use brake cleaning agent to clean brake pads with oil spots brake pad brake cylinder Note Any oil spots on brake pads will reduce brake performance 5 4 Rear Brake Rotor 5 4 1Disassembly Remove the body guard Remove the rear brake cylinder assembly Remove the rear wheel Remove the brake rotor from the rim of the rear wheel Note Replace the brake pad assembly If the b...

Page 67: ...ds in pairs Diameter of the rear brake rotor φ240mm Thickness of the rear brake rotor 4 0mm Limit for use brake pads 3 0 mm brake rotor 4 0mm 5 4 3 Installation Install the rear brake rotor Install the rear wheel Install the rear brake cylinder assembly Note Any grease on brake pads will reduce the brake performance and even lead to failure Tighten bolts and nuts to the required torque force brake...

Page 68: ...t rubber foot 22 spark plug cover 23 rear fender installation assembly 24 Right guard 25 protecting net 26 protecting net 27 Front left guard 28 Left guard 29 rear connecting bracket of the left right guard 30 decorating cover plate of the guard 31 rear fender installation assembly 32 rear fender 33 rear license plate bracket 34 rear reflector assembly 35 rear fender bracket 36 rear fender install...

Page 69: ...handrail seat Helmet box left right rear guard left right front guard rear fender rear inner fender rear inner fender rubber rear lower fender pedal front fender Note Do not damage any body parts during disassembly Do not damage any hook or claw in the body during disassembly Align panels for the body at each corresponding groove Ensure correct installation of each hook or claw part during assembl...

Page 70: ... 2 0mm Horizontal 2 0mm D Front wheel camber limit 0 2mm E Front wheel certificate number 1 Front wheel axle 2 Brake rotor bolt 3 Brake rotor 4 Left front wheel spacer 5 Oil seal 6 Bearing 7 Valve stem cap 8 Valve stem 9 Tire 120 70 14 10 Front wheel 11 Bearing spacer sleeve 12 Speedometer drive unit 13 Washer 14 Nut ...

Page 71: ...al 6 Bushing 7 Bearing 8 Tapered roller bearing 9 Dust seal 10 Bolt M6 12 11 Socket head cap screw M8 30 12 Upper handlebar clamp 13 Lower handlebar clamp 14 Key 15 Steering stem 16 Bolt M8 35 17 Bolt M5 10 18 Front right fork assy 19 Socket head cap screw M6 25 20 Front left fork assy 21 Three way front brake hose clamp 22 Rubber gasket 23 Clamp 24 Right brake hose clamp 25 Left brake hose clamp ...

Page 72: ...roke of throttle controlling handle 5 10mm E Installation torque of nut 16 5 9N m 1 Right rearview mirror assembly 2 Left rearview mirror assembly 3 Handlebar weight assembly 4 Right handlebar grip w tube 5 Right combination switch 6 Throttle cable 7 Bolt M5 10 8 Handlebar assembly 9 Left combination switch 10 Left handlebar grip 11 Seat latch cable ...

Page 73: ...m Limit for use mm Front wheel spindle Bend 0 2 Front wheel Rim shimm y Vertically 2 0 Horizontally Within 1 0 2 0 Torque force Tools Fixing bolts for the steering handle 22 29 N m Bearing puller Locking nut for the front wheel spindle 75 88 N m Locking nut spanner 7 2Failure diagnosis 7 2 1Difficulty in steering Failure of the steering handle bearing Damaged steering handle bearing Low tire press...

Page 74: ... front fender and odometer cable wheel axle Remove the front brake hose Remove the oil seal and the bearings respectively with oil seal remover and bearing puller 7 3 2 Check 7 3 2 1 Check the bending of the wheel axle Place the wheel spindle on the V base and measure the eccentricity ratio with a dial indicator Limit for use replacement when beyond 0 2mm 7 3 2 2 Check for rim shimmy Place the rim...

Page 75: ...pressed in horizontally The oil seal side of the bearings shall be pressed in from the outside 7 3 4 Installation Lubricate the oil seal of the front wheel with grease Lubricate gear engagement parts and moving parts with grease Install the middle bearing sleeve bearings and oil seal Align the gear housing assembly and then install the front wheel Note If the gear housing assembly of the odometer ...

Page 76: ...ront brake handle and the rear brake handle Remove the decorating cover of the grip the throttle cable assembly and the right grip assembly Remove the left handlebar sleeve Remove fixing bolts for the handlebars Remove the handlebars 7 4 2 Installation Install it in reverse order Fixing bolts Torque force 40 60 N m ...

Page 77: ...pper and the lower bearing cups Remove the front forks Tools Fixing bolt spanner for the steering handle Fixing nut spanner Special disassembly tool for bearing cups Note The opening of the body guard shall be cleaned with cloth 7 5 3 Installation Tools Fixing nut spanner Ensure the front fork is not loose by left and right movement Steps Install the steering handle Install the front absorber Inst...

Page 78: ...it approaches the lower limit Broken or twisted heat sinks will reduce the cooling capability of the radiator Repair the radiator with a small screwdriver when over 1 3 of heat sinks are damaged or twisted Replacement Check the liquid level of the radiator Remove the radiator cover after the liquid has fully cooled Completely remove the coolant Add the prepared coolant slowly through the filling h...

Page 79: ...led Apply the required pressure to the cooling system with the radiator pressure tester lower than pressure for opening the valve of the cap and ensure that it can keep for at least 6s under the required pressure In the case of pressure leakage check the hoses all connections pump position and inspection hole 7 6 3Installation Install it in reverse order radiator pressure tester ...

Page 80: ...80 Rear Wheel Rear Suspension ...

Page 81: ... Fixing nut for the rear wheel 100 123 N m Top nuts for the rear absorber 37 44 N m Bottom nuts for the rear absorber 22 29 N m 8 2Failure diagnosis 8 2 1Rear wheel shimmy Deformed rim Tire failure Rear wheel not fixed Low tire pressure 8 2 2 Too soft absorber Elastic fatigue of spring 8 3Rear wheel 8 3 1Disassembly Remove the body guard and the muffler Remove the rear brake cylinder assembly rear...

Page 82: ...ly replacement when beyond 2 0mm Horizontally replacement when beyond 2 0mm When the rear wheel shimmy exceeds the limit the rear wheel bearing is loose which causes a shimmy Check and replace the rear wheel bearings 8 3 3 Installation Install the rear wheel in reverse order and lock nuts Fixing nuts for the rear wheel Torque force 100 113 N m ...

Page 83: ...cleaner assembly Remove the fixing bolts for the rear absorber Remove the rear absorber 8 4 2 Installation Install the rear shock absorber Torque force Upper fixing nut 37 44 N m Lower fixing nut 22 29 N m Install the rear absorber Install the air cleaner Install the muffler Install the rear handrail and the rear fender Install the seat and the rear left right guard bolt rear absorber assembly bol...

Page 84: ... 12 Drain bolts of the crankcase 20 25 Spark plug 17 25 Closing bolts 9 12 Blots for the transmission chamber 9 12 cover Fixing bolts for the motor 9 12 Fixing bolts for the oil pump 9 12 Locking nuts for the flywheel 190 210 Right cover bolt 9 12 Fixing screws of the impeller 9 12 Fixing screws of chain guide 9 12 Connecting bolts of the sprocket 50 60 Locking nuts of the clutch 107 123 Fixing sc...

Page 85: ...85 Lubricating system diagram 1 camshaft 2 oil pump 3 crank 4 fuel filter ...

Page 86: ...cools components with high thermal load absorbs shock from bearings and other parts reduces noise increases sealing between the piston rings and the cylinder wall and cleans and removes particles in the surface Basic item standard and use limit Item Standard Limit for use Fuel capacity when replacing fuel 1 4L when disassembly 1 5L Oil pump rotor radial clearance between inner and outer rotors 0 0...

Page 87: ...sen the fixing bolt and remove the cover plate Loosen the screw and remove the oil pump oil pump bolt Remove the screw and the oil pump assembly Remove the screw and the oil pump cover oil pump cover screw Check the radial clearance between the inner and outer rotors Limit for use 0 17mm gauge ...

Page 88: ...88 Check the clearance between the outer rotor and the oil pump housing Limit for use 0 23mm Check clearance between rotor surface Limit for use 0 11mm gauge flat plate ...

Page 89: ... picture screw outer rotor inner rotor oil pump oil pump shaft pin spacer split washer oil pump cover cotter pin oil pump screw Note After assembly the inner and outer rotors shall rotate flexibly without being seized 9 3 3 Installation Install it in reverse order ...

Page 90: ...90 Cooling System Connects to radiator Flows back to radiator Water pump ...

Page 91: ...rature Specific cooling circuit The cooling water entering from the crankcase goes to the cylinder water jacket through the water channel of the crankcase then goes upward through the cylinder cover finally enters into the radiator through the pipe to dissipate heat and transfers heat to the outside air with the help of the radiator s fins 10 2 Failure Diagnosis Water leakage Damaged seals Broken ...

Page 92: ... the blade Note Don t damage the spacer and the joint surface of the housing during disassembly dowel pin impeller assembly gasket water inlet Check Check the abrasion of the blade assembly If it is serious replace it Installation Install it in reverse order ...

Page 93: ...93 Cylinder Head Valves ...

Page 94: ...eaned and blown by high pressure air before inspection Preparation standard Unit mm Item Standard value Usage limit Cylinder pressure 1 2Mpa Flatness of cylinder cover 0 03 0 05 Valve guide Valve clearance Inlet 0 08 0 1 0 09 Exhaust 0 1 0 15 0 10 ID of valve guide pipe Inlet Exhaust 4 5 4 512 4 532 Clearance between valve lever and valve guide pipe Inlet 0 015 0 037 0 07 Exhaust 0 03 0 052 0 08 W...

Page 95: ...s damaged air tightness of valve seat is not good camshaft worn or damaged gasket cylinder head is gas leaking camshaft and valve rocker is worn the spark plug is installed improperly High compression pressure Excessive carbon deposit in combustion chamber 11 3 Cylinder Head Removal Remove the nut cylinder cover nut Remove the bolt and take off the chain tensioner and gasket chain tensioner bolt ...

Page 96: ...emove the bolt and cam sprocket cover and take off the chain Remove the cylinder cover Notice The chain should be hung by a metal wire in case it falls into the crankcase cam sprocket chain bolt Remove the bolt and take down pressure plate Remove rocker and camshaft assembly rocker assembly pressure plate camshaft assembly bolt ...

Page 97: ...mshaft if there is dot like corrosion scratches or bluing please replace it Measure the height of the cam at the same time check whether it is worn or damaged If not conforming to the specified value please replace it Usage limit height of cam inlet 33 14mm exhaust 33 mm cam bearing Measure the OD of rocker shaft Usage limit 11 94mm micrometer Measure the ID of rocker hole Usage limit 12 07mm Clea...

Page 98: ...to compress the valve spring remove the valve collets Then take down the spring seat outer valve spring and inner valve spring and valves Valve Disassembly valve inner spring outer spring valve collet spring lower seat spring upper seat ...

Page 99: ...mm outer 34 4mm vernier calliper Measure the OD of valve lever Usage limit 4 43mm Inspect the valve guide please use a reamer before inspection Clear out the carbon deposits in the valve guide pipe Notice please turn the reamer clockwise Do not turn the reamer counter clockwise valve reamer ...

Page 100: ...he replacement of valve guide the surface of valve seat ring has to be refinished Put the valve guide into a freezer to cool for one hour Heat the cylinder head to 212 302F with electric furnace or hot oven Fix the cylinder head use the valve guide removing tools to remove the valve guide from the upper side of the cylinder head Place a new O ring on the new valve guide Install the valve guide fro...

Page 101: ...er to cut please add the proper amount of cutting lubricant The rotation direction of the reamer is clockwise Clear out the carbon deposits in the combustion chamber and valve tracts and clean the inlet valve and exhaust valve thoroughly Inspect the contacting surface width of the valve seat width of valve seat ring ...

Page 102: ...lve seat Note Coat the valve seat ring with a transparent or Prussian blue coating to see more clearly Use a 32 milling cutter to clear out the 1 4 of the outer end of valve seat rough 32 Use a 60 milling cutter to clear out the 1 4 of the bottom of valve seat Take down the milling cutter and inspect the treated parts 60 ...

Page 103: ...e a 45 finishing milling cutter to cut the valve seat to its appropriate specification After the cutting of the valve seat please coat polishing agent onto the surface of valve and polish the valve slightly high contacting surface low contacting surface 0 8mm Installation The installation sequence shall be in reversed sequence of removal Note When installing the valve spring put the spring pitch s...

Page 104: ...104 Cylinder Body and Piston cam chain sliders piston cylinder body piston pin piston ring assembly base gasket ...

Page 105: ...d Item Standard value Usage limit Cylinder Inside Diameter 69 69 01 69 5 Cylindricity 0 005 0 05 Circular degree 0 05 Flatness 0 02 0 05 Piston Piston ring Piston pin Piston mark direction IN against the inlet valve Measuring point of piston outer diameter 68 96 68 97 at the bottom of piston skirt 12mm 68 91 Piston pin housing bore Inside Diameter 17 002 17 008 17 04 Outer diameter of piston pin 1...

Page 106: ... piston Excessive carbon deposit in the damage in the cylinder the piston or combustion chamber the piston ring wear in the piston pinhole and piston pin 12 3 Cylinder Body Removal of the cylinder body Remove the cylinder head then take off the cylinder cap gasket and locating pin Remove the main link plate Remove the cylinder cylinder locating pin gasket main link plate Check Check abrasion of in...

Page 107: ...ston piston bead flange and piston pin Examine the piston the piston pin and the piston rings Remove the piston rings Note Don t break or damage the piston rings Clear the carbon deposits from the piston ring grooves Load the piston ring Measure the clearance between the piston ring and the piston ring groove Usage limit first ring 0 08mm second ring 0 08mm piston piston ring push ...

Page 108: ...press piston rings into the cylinder with the piston head Measure clearance of piston ring gap Usage limit 0 70mm piston ring Measure ID of piston pin hole Usage limit 17 04mm Measure OD of piston pin Usage limit 16 96mm Clearance between piston pin hole and piston pin Usage limit 0 02mm 1 2 3 ...

Page 109: ...easured at the upper middle and lower locations Usage limit 69 5mm Measure the clearance between cylinder and piston Take the maximum value Usage limit 0 1mm Measure circular degree of inner wall of cylinder difference in ID between X orientation and Y orientation Usage limit 0 05mm Measure cylindricity of inner wall of cylinder difference in ID along the upper middle and lower locations between X...

Page 110: ...d of the connecting rod Installation of the Piston Install piston pin Lubricate piston ring and piston with machine oil and install with the piston ring marking facing upwards Note Piston shall not be scratched and piston rings shall not be broken After installation of piston rings it shall move easily Inside the piston ring groove top ring second ring oil ring ...

Page 111: ...alling into the crankcase Install piston piston pin and piston pin clips Installation of cylinder Install gasket and locating pin onto the crankcase Lubricate machine oil on inner wall of cylinder piston and piston rings Be careful when installing piston rings into the cylinder Note Do not damage piston rings locating pin gasket ...

Page 112: ...112 Driving Disc Clutch Driven Wheel ...

Page 113: ...113 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE CRANKCASE FILTER COVER AND CRANKCASE COVER LEFT ...

Page 114: ...114 V BELT CLUTCH AND SECONDARY PRIMARY SHEAVE ...

Page 115: ...115 SECONDARY SHEAVE ...

Page 116: ... possibility of sliding between triangular belt and the wheel Preparation standard unit mm Item Standard value Usage limit OD of right semi driving wheel shaft sleeve 27 959 27 98 27 93 ID of right semi driving wheel bushing 28 28 021 28 04 Width of triangular belt 22 23 21 Thickness of clutch abrasion piece 4 1 5 ID of clutch outer bushing 134 875 135 125 135 5 Free length of clutch compression s...

Page 117: ...n ball bearing Broken clutch compression spring dirty driving belt wheel surface 13 3 Left crankcase cover Removal Remove cover standing bolt and remove gasket as well as standing pin Note Remove standing bolt and loosen in a crisscross pattern left cover standing bolt 13 4 Driving disc Removal Remove the driving disc standing nut and remove the left semi part of driving disc Remove triangular bel...

Page 118: ...racks or whether the rubber or cotton yarn has failed or is worn Measure width of triangular belt Usage limit 21mm Note Please choose original factory parts when changing Remove driving wheel right semi part right semi part of driving disc width ...

Page 119: ...hing Check abrasion of the ball bearing Measure OD of the ball bearing Usage limit 19 5mm Measure the right semi ID of driving wheel shaft Sleeve Usage limit 28 04mm Measure the OD of the slide bushing Usage limit 27 93mm slide bushing right semi of driving wheel ...

Page 120: ...remove standing nut Remove clutch bushing and clutch driven wheel driven wheel retainer clutch bushing sleeve spanner Disassemble Clutch Remove retaining ring and disassemble clutch Note While disassembling no oil shall stick to clutch abrasion piece retaining ring abrasion piece ...

Page 121: ...the abrasion of clutch abrasion piece Measure the thickness of abrasion piece Usage limit 1 5mm Disassemble clutch and driven wheel Note Use spring compressor in removal in case spring is damaged Fix spring compressor and remove clutch standing nut Loose compressor and detach clutch and driven wheel ...

Page 122: ...g Remove directing pin Remove left semi weld of driven wheel Remove the oil seal on the left semi part of driven wheel left semi weld of driven wheel directing pin oil seal Check the free length of clutch spring Usage limit 104mm free length ...

Page 123: ...eel Remove needle bearing from right semi driven wheel Remove elastic retaining ring and outer roller bearing Note The removed bearing is non reusable needle bearing roller bearing elastic retaining ring Grease the outer rolling bearing evenly and put it into the bushing Note Press the outer roller bearing into the bushing face the marked side outward and then fill the shaft cavity with 8 9g greas...

Page 124: ... the driven wheel surface Install oil seal of driven left semi slide bushing Install greased O ring onto the slider bushing of the driven wheel s left semi part Lubricating grease Oil seal O ring Assemble the left and right parts of the driven wheel together Install greased directing pin into directing groove directing pin directing groove ...

Page 125: ...ng and clutch on driven wheel Use clutch spring compression assembly after compression install the locking nut Note Compress the spring moderately Do not damage it spanner locking nut clutch spring compressor Installation Install driving disc clutch driven wheel in reversed sequence of removal ...

Page 126: ...126 input shaft middle shaft output shaft ...

Page 127: ... 2 Gear box 14 3 14 1 Preparation documents Function transfer torsion and decide final output torsion and rotation speed 14 2 Failure diagnosis Motor fails to make motorcycle run Broken driving gear Burnt driving gear Leaked gear oil Too much gear oil Damaged oil seal ...

Page 128: ...e gasket and locating pin bolt gear room cover Remove output shaft assembly Remove middle shaft assembly Remove input shaft Check abrasion of input shaft output shaft and each gear Replace if the abrasion is serious input shaft output shaft assembly middle shaft assembly ...

Page 129: ... should be replaced with a new one Use special tools to disassemble bearing and oil seal bearing bearing oil seal Installation The installation sequence shall be in reverse sequence of removal Add 0 35L gear lubricant after installation Note Use special tools to install bearings and oil seals in case they are damaged ...

Page 130: ...130 left crankcase crankshaft right crankcase ...

Page 131: ...131 magneto start the main gear gasket ...

Page 132: ...nkcase connecting the engine to other parts of the body through the connection with suspension holes in the car circuit Notes The crankcase is thin section casting thus has to avoid shock on operation in case of deformation and fracture All components must be cleaned and dried with high pressure air before testing The lubricant in the crankcase should be drained before operation Preparation standa...

Page 133: ...ng Remove the bolt remove the cover and remove magneto magneto cover bolt Loose the bolt and remove the right crankcase cover Take off the gasket Use special tool to loosen locking nut and remove the one way clutch assembly Take off the starting idle gear and shaft Take off the starting motor starting idle gear one way clutch assembly right crankcase cover ...

Page 134: ...and water pump gear water pump gear oil pump gear Remove the bolt Remove the oil pump Remove the water pump bolt and closing bolt Remove the water pump Put the left crankcase under the water and remove the right crankcase water pump ...

Page 135: ...ake off the timing chain crankshaft assembly timing chain bolt Inspection Measure the right left clearance of connecting rod big end Usage limit 0 9mm Measure clearance between X Y orientation of connecting rod big end Usage limit 0 05mm connecting rod ...

Page 136: ... loose condition replace the crankshaft assembly crankshaft bearing Remove the oil seal of left crankcase Note The removed oil seal is non reusable Use special tools to remove oil seal oil seal Installation Assemble crankcase according to reversed sequence of removal Note Install oil seal with special tools in case the oil seal is damaged ...

Page 137: ... and Maintenance of Emission Control System Muffler 1 Heat shield 2 Bolt M6 16 3 Rubber damper 4 Lock washer φ6 5 Screw M6 12 6 Washer φ6 7 Muffler end cap 8 Bolt M10 95 9 Muffler assembly 10 Nut M8 11 Muffler gasket ...

Page 138: ...or or service center at each province and municipality of our Company will provide the best service to customers with reasonable prices 1 Those without periodic maintenance within the time or kilometer specified by our Company 2 Those without the periodic inspection adjustment or maintenance by the distributor or service center of our company or those who cannot submit the maintenance records 3 Ov...

Page 139: ...receive regular maintenance according to Benelli distributors or Benelli service center Please do the necessary check frequently so as to keep a good motorcycle condition Note Increase frequency of washing air filter if your motorcycle runs on sandy gravel roads or under heavily polluted environments so as to extend its service life Motorcycles which often run at high speed or with high mileage sh...

Page 140: ...ombustor compression ratio ignition time Emission system etc in order to meet high intake and Emission efficiency and try for enhance combustion efficiency Gas intake device Intake gas into gas Emission tube make incompletely burnt CO and HC react to form harmless gas Division Device Component Purpose Exhaust system Catalytic device Catalytic transfer Canister oxidation catalyst in the center of g...

Page 141: ...he motor is running or just shut down it shall not be touched because of high temperature 2 Motorcycle with transfer catalyst shall not be near flammable material 3 There is CO inside gas Emissions which is harmful to health So do not run the motor in a closed space 4 Motorcycle with transfer catalyst shall not use lead gasoline prevention for catalytic poison 5 Do not push motorcycle to run motor...

Page 142: ...etor note2 Qualified Remove and clean the carburetor Qualified Qualified for delivery Replace the carburetor Qualified Note Dismantle and repair engine Valve leakage Piston abrasive Combustor cleaning Qualified 1 Measure it with the idle speed measurement program 2 Adjust the engine speed with stop screws to live up to requirements and measure CO HC at the idle speed ...

Page 143: ...143 Inspection and Maintenance of Electronic Fuel Injection EFI System ...

Page 144: ...lute the electronic component due to fuel spills Gasoline is a flammable and combustible liquid so the operation shall be carried out in such a place with good ventilation Cut off the power switch before removing the sensor plug The operation shall be carried out in a place with good ventilation so that the electronic component may not be corroded by water After the removal of throttle certain mea...

Page 145: ...the engine the control would go through automatic diagnosis The normal working of the system requires two ECU 17 2 1 1 ECU Appearance Above is the label of the ECU controller which contains the type component number client number hardware number production number software edition and bar code of the ECU Such information shall not be erased or stained or it will impact the guarantee of the product ...

Page 146: ...l J2 10 Pin for 5V system reference voltage grounding J1 11 J2 11 Pin for intake pressure sensor signal J1 12 J2 12 Pin for throttle position sensor signal J1 13 J2 13 Pin for crank signal low potential J1 14 Dump switch efficient at low J2 14 Signal pin for water temperature sensor J1 15 J2 15 Ignition power 12V positive voltage after key J1 16 J2 16 J1 17 J2 17 Pin for signal 1 cylinder oxygen s...

Page 147: ... would affect the heat dissipation function of ECU d Connect with M8 bolts and make sure the tightening torque is around 3 9Nm keep the surface neat to prevent outside force to ECU in case of circuit board bending e The DC power supply voltage of ECU of normal working is between 9V and 16V W hen it s working under a voltage not over 26V for one minute permanent damage would not happen to ECU neith...

Page 148: ...148 17 2 1 4 Installation requirements The installation requirements for ECU controller are shown in the figure below the tightening torque force for fixing bolts M6 is 5 Nm ...

Page 149: ...e pipe and ensure no leakage Clamps and air intake pressure hoses shall match with the vehicle type Maintain vehicle performance DO Keep the air intake hose always connect ECU and intake manifold Prevent dust from entering into the engine to ensure safety DO When the air intake hose is pulled out from ECU loosen the clamp at the joint and then pull the hose carefully from the ECU Prevent joints in...

Page 150: ...any controller hardware fails or is damaged during the warranty period the controller must be sent back to the factory attached with detailed controller component number serial number vehicle type date of production accumulated miles where used and date of return 17 2 2 Fuel injectors 17 2 2 1 General working principle The fuel injector is designed with an electromagnetic coil around an iron core ...

Page 151: ...accumulated impurities in the fuel pipe between the fuel filter and the fuel injector Impurities will cause failure such as bonding flow deviation and leakage Therefore the fuel filter is very important Replace it only with a new fuel injector of the same part number 17 2 2 3 O ring O ring for connecting the fuel rail or the fuel injector cap O ring for connecting the end of the air intake pipe O ...

Page 152: ...cture r Viscosity cSt 40 Spindura1 0 Equilon 10 Spindura2 2 Equilon 21 DTE 24 Mobil 32 DTE 25 Mobil 46 DTE 26 Mobil 68 Norpar15 Exxon Mobil 1 Drawsol60 DAStewart 1 2 NocoLubeAW46 NOCOEnerg y 46 NocoLubeAW32 NOCOEnerg y 32 AdvantageSpindleOil AdvantageLubricationSpecialties 10 17 2 2 6 Over voltage effect The fuel injector can work under the voltage of 26V and pulse width of 100ms 200ms for a cycle...

Page 153: ... failure such as bonding flow deviation and leakage Therefore the fuel filter is very important 17 2 2 9 Cable arrangement Cables of the fuel injector shall be deployed far away from heat source and protected from any external abrasion or damage Do not insert pull the fuel injector connector it is not necessary ...

Page 154: ...when it is installed on the intake pipe Damage the fuel injector and o ring DON T impose tensile force on the connector Cause interrupted power supply DON T use a fuel injector which has been thrown Possible damage DON T store fuel injector fuel rail or engine with fuel injector installed under non protective environment Possible damage to electronic and mechanical components of the fuel injector ...

Page 155: ... comply with following instructions for installation and disassembly to avoid damage to fuel injectors and electronic components Lubrication apply a little lubricant to the lower part of the o ring Do not use ISO 10 light mineral oil or equivalent product If it is possible it is better to apply lubricant to the fuel injector seat other than the o ring Thus it can minimize pollution to the fuel inj...

Page 156: ... 2 14 Fuel Injector Blocked Accumulated impurities in the fuel can cause flow deviation and reduction of service life When the engine stops working deposits may be generated in fuel as heat from the engine runs through the fuel injector head Deposits accumulated around the fuel injection holes lead to flow deviation If the fuel injector is blocked it may cause reduced flow increased friction and a...

Page 157: ...e to control the idle speed and its stability It reduces the bypass flow clockwise and lowers the idle speed while increasing the bypass flow counterclockwise will raise the idle speed Normally it should be fastened by two turns All above subsystems work together to achieve the following functions Control the air intake flow Control the air flow at idle speed Check the throttle position provide th...

Page 158: ... of the battery Turn off the switch of the fuel pipe Loosen the clamp fixing the air cleaner Remove the throttle cable from the throttle cable wheel Loosen the clamp fixing the throttle valve body with the air intake pipe Remove the air cleaner and then remove the throttle valve assembly Loosen the clamp fixing the fuel injection rail with the fuel injector cap and then remove the fuel injection r...

Page 159: ...t periodically Check whether the valve channel is filthy or blocked by fouling clean it with detergent periodically Check whether the slide rheostat of the throttle position sensor is damaged if yes replace the throttle position sensor A special diagnosis device is required for check A special adjustment and test device shall be used for replacement of the throttle position sensor to determine whe...

Page 160: ...stall all necessary parts 17 2 3 8 Precautions Do not spray any cleaner into the TPS throttle position sensor Use the throttle cable to open the throttle valve block Do not insert any tool or stick into the throttle valve hole to keep the valve block open It causes deformation of the valve block and damage to the inner wall of the throttle valve Remove carbon deposits around the valve block to mai...

Page 161: ...age DON T hammer the fuel injector for troubleshooting when there is an error Damage to the fuel injector DON T components bump into each other when being unpacked Possible impact on the minimum air leakage or other damage DON T completely release the throttle at any position Possible damage DON T block the bypass hole with dirt or sand Possible impact on the stability of idle speed DON T take sto...

Page 162: ...d on water cooled engines Normal working temperature 40 266 F continuous working Relative humidity of working 0 100 Typical working pressure under the minimum installation torque the sensor can seal the engine coolant when the actual pressure is 206 8kPa 30psi and the temperature is 275 F Limit working environment 1 hour at the highest temperature of 302 F 17 2 4 5 Storage Environment Storage temp...

Page 163: ... Within the temperature scope of the sensor the electric resistance would vary with different temperatures of the engine which is a negative temperature coefficient resister The intake air temperature sensor is not a repairable part 17 2 5 2 Appearance of Intake Air Temperature Sensor 17 2 5 3 Technical parameters Working voltage 5DVC Response time 15S Working temperature 40 302 F Relative humidit...

Page 164: ...the absolute pressure of the intake bend tube which in compliance with the change between the resistance value and the intake pressure can measure the air input of the engine s combustion chamber indirectly 17 2 6 1Appearance 17 2 7 Oxygen Sensor 17 2 7 1 Working Principles Oxygen sensor is mainly used for measuring the oxygen content within the exhaust pipe of combustion engine and for the fuel c...

Page 165: ...165 17 2 7 2 Appearance of the oxygen sensor ...

Page 166: ... ratio 70 voltage 10Hz 13 5V Resistance of heater 9 6 1 5Ω measured lower than 70 F Working temperature scope 500 1562 F 17 2 7 4 Installation Requirements Installation angle to the level 10 Tightening torque 40 60Nm 17 2 7 5 Fuel requirement Pb 0 005g L P 0 0002g L S 0 04 Si 4ppm 17 2 8 Ignition Coil 17 2 8 1 Working Principles The ignition coil can provide energy to the spark plug The high volta...

Page 167: ...nder the gasoline tank Fuel pump assembly provide pressure for the engine and fuel for the system required It is installed on the bottom and provides fuel via the connection pipe Fuel Pump electrical It gets the pressure and fuel from the fuel tank bythe driving impeller of the engine Pressure adjuster mechanical film type which can adjust the pressure of the fuel pump fuel to receive what is requ...

Page 168: ...el Pump Assembly Appearance 1 pressure regulator 2 Pressure regulator clamp 3 high pressure fuel hose 4 pump installation bracket 5 fuel pump 6 filter screen 7 Fuel Pump harness 8 Fuel Pump bracket 9 Fuel Pump harness ...

Page 169: ...l flow layout of the motorcycle 17 2 9 5 Maintenance Procedures Safety Protection Guarantee personal safety in maintenance procedures of the fuel system Disconnect positive terminal of the battery Do not smoke and set up a No Smoking symbol nearby the operation area Make sure the fire extinguishing apparatus are equipped Guarantee good ventilation and keep it away from open fires Wear safety glass...

Page 170: ... on the fuel pipe 2 check the fuel pump set 3 check the pressure adjuster 1 fuel filter is blocked 2 the fuel pipe is kinked 3 check the pressure regulator 17 2 9 7 Removing the Fuel Pump Assembly refer to the chapter Fuel Pressure Release Procedures and release the fuel pressure disconnect the negative terminal of the battery cut off the connecter of the fuel pump assembly harness remove the resi...

Page 171: ...ssure regulator one with larger diameter and the other smaller install the pressure regulator onto the seat of the fuel pump assembly bracket it is strictly prohibited to strike the pressure regulator which would damage the device install the fuel pressure regulator clamp replace with a new fuel pump assembly seal 17 2 9 10 Fuel Leakage Inspection Procedures Notice do not go through this procedure...

Page 172: ...with the fuel pump not designed towards this end Do not fix other components with mounting screws to the fuel pump assembly influence on installation of the fuel pump assembly Do not damage fuel pump wiring harness during maintenance of the fuel pump damaged terminal may lead to poor contact power supply disconnection Do not make the manual pump to touch the fuel pump assembly during defueling fro...

Page 173: ...er for several times to dissipate all the air in the fuel line so that the engine can operate normally This is a normal process which will avoid the engine from taking a long time to start but still in failure in the later startup 2 The gasoline can cool down the fuel pump so do no run the pump with little or no fuel or the fuel pump will be overheated and damaged 17 3Methods for Fault Diagnosis a...

Page 174: ... pressure sensor to the positive electrode of the battery 264 P0112 short circuit of signal end pin of the intake temperature sensor to the negative electrode of the battery 274 P0113 open circuit of intake temperature sensor or short circuit of signal end pin to the positive electrode of the battery 275 P0117 short circuit of signal end pin of the cylinder end temperature sensor to the negative e...

Page 175: ...of the battery 578 0 P0137 short circuit of signal end pin of the rear cylinder oxygen sensor to the negative electrode of the battery 311 P0138 short circuit of signal end pin of the rear cylinder oxygen sensor to the positive electrode of the battery 312 P0038 short circuit of heating end pin of the rear cylinder oxygen sensor to the positive electrode of the battery 56 P0037 short circuit of he...

Page 176: ...aratus c Turn on the key to diagnose the faults 17 3 3 Fault Diagnosis with the Diagnostic Software PCHUD PCHUD software is used to inspect and record the operating data of the engine Before using the software connect a notebook computer to the 6 hole diagnostic port of the motorcycle with the K line The notebook computer needs to install the K line driver software before using ...

Page 177: ...ine and turn on the key 2 Click the icon HUD EXE to start PCHUD software 3 Select File on the software interface click Open choose PCHUD HAD and select OK 4 Select Parameter File within Setup click the file MT05COMMON par choose Comm protocol within Setup then select Keywork2000 and click OK meanwhile choose 17 in Device Code ...

Page 178: ...n check whether the connection setting of COM port in Setup Under the normal circumstance set COM Port 4 and Baud Rate 10400 instead of DTR High at startup Normal communication is ready to make then Current fault code is displayed in the position of MALFCURR and historical fault code displayed on MALFHIST ...

Page 179: ...179 Then check the corresponding fault according to the fault code list ...

Page 180: ...EDY2 O2 ready FCNO block learn memory cell FBLMCOR1 cylinder 1 block learn memory FCLCINT1 intergral of close loop correction FCLCMUL1 close loop correction IARDRPM desired idle rpm IARPMERR idle rpm error FPWVC1 base pulse width of cylinder 1 VO2 Oxygen sensor signal STATUSBYTE3 STATUSBYTE3 FO2STAT1 cylinder 1 oxygen sensor signal rich lean state FCLREST1 cylinder 1 close loop correction reset FO...

Page 181: ...ired position of idld air control valve STATUSBYTE2 STATUSBYTE2 FCLCEN1 cylinder 1 close loop correction enable PPDSEBL prime pulse disable FPENABL fuel pump enable FTRNSAES acceleration enrich enter FTRNSDES deceleration enlean enter FTRNSAEDCLOAD acceleration enrich exit FTRNSDEINLOAD deceleration enlean exit FCLCEN2 cylinder 2 close loop correction enable ...

Page 182: ...ronic control system recommended Fault diagnosis software PCHUD and port wire if available d Fault code list of the electronic control system for emergency e Fuel pressure gauge range 0 300kPa 17 4 2 Operation Data Flow of the Engine Shown on the Diagnostic Apparatus Analyze and check the faults in engine through the operation data flow of the engine shown on the diagnostic apparatus 17 4 2 1 Step...

Page 183: ...arly the increased temperature of the exhausted air will significantly reduce the service lives of oxygen sensor and ternary catalytic converter The air valve clearance is too large may cause the manifold air pressure become low thus influencing the system in judging the engine s operation and leading to abnormal idling in the engine s warming up Besides the clogged exhaust system e g foreign mate...

Page 184: ...epair the light and its circuit Make the judgment with another ECU If yes Connect the diagnostic apparatus to the system s diagnostic port b Whether the diagnostic apparatus can be connected to the system for communication If no Check the fuse and the ground wire Check whether ECU s plug is tightly connected Check whether the diagnostic apparatus works normally on another normal motorcycle Make th...

Page 185: ...dle air bypass hole is too large Check whether the air valve clearance especially the exhaust valve clearance is too large Idle speed Check the oil amount in the fuel tank the fuel filter the oil line pressure and the oil is too low nozzle Check whether the idle air bypass hole is too tiny Check whether the air valve clearance is too small 17 4 3 6 Fault Description Unstable Idle Speed Slowing Dow...

Page 186: ...rt is damaged usually it needs to be replaced When starting the engine do not run any other organs of the engine including the throttle do not push the throttle in the startup If the engine trouble light turns on when the engine is operating it is necessary to check the reason and remove the fault as early as possible Do not use leaded gasoline for lead will do harm to the oxygen sensor and ternar...

Page 187: ... L I G H T 3 W W A T E R T E M P E R A T U R E S I G N A L L I G H T M A L F U N C T I O N I N D I C A T O R L I G H T O I L S I G N A L I N D I C A T O R L I G H T A I R T E M P E R A T U R E S E N S O R SPEED METER FUELMETER TACHOMETER BATTERY RELAY PUMP RELAY OIL PUMP INJ IAC TPS IAT CLT OXYGEN SENSOR IMPS SPEED SENSOR AIR TEMPERATURE DIAGNOSTIC APPARATUS RECTIFIER FLASHER SPARK PLUG POWER LOCK...

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