hsr-benelli S-series Service Manual Download

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ver.2009_03

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3 Engine

3.1 Engine Removal and Installation

The installation of the engine and engine subsystems is the reverse to their removal. During

engine installation, several important notes must be made.

Always verify the correct number of engine mounting strap shims are installed on

each engine mounting post. Remove the pump to check driveshaft alignment, add

shims to move the engine up or down to align properly.

Always verify that the engine does not interfere with critical routings such as the

steering cable, cooling hoses, and main wiring harness.

Steering cable must be fixed on front left engine mounts to avoid damage from

engine.

Summary of Contents for S-series

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Page 2: ...ers 14 1 3 2 VIN number 14 1 3 3 Engine number 14 1 3 4 Three stars ultra low emission 15 1 3 5 Safety instructions 15 1 4 General specifications 16 1 4 1 General data 16 1 4 2 Standard Torque Specifications 17 1 4 3 Convertion Chart 18 2 MAINTENANCE 19 2 1 Flushing system attachment 21 2 2 Periodic maintenance chart 22 2 3 Periodic maintenance procedures 23 2 3 1 Oil level check 23 2 3 2 Engine o...

Page 3: ...UMP 109 5 1 Jet Pump overview 110 5 2 JET PUMP DISASSEMBLING 111 5 3 ASSEMBLING THE JET PUMP 116 5 4 Jet Pump Assembly into the PWC 127 5 5 Assembly of the Reverse Gear For Series R Pro Model only 129 5 6 Assembling riding plate 130 5 7 Steering cable setting 130 5 8 Trim system bleeding 131 6 FUEL SYSTEM 133 6 1 Fuel Tank and Fuel Pump 134 7 EXHAUST SYSTEM 138 7 1 Muffler and Hoses 139 7 2 Exhaus...

Page 4: ...YSTEM 9 4 Handle Pole Assembly 164 9 5 Handle Bar Assembly 170 9 6 Assembly of the Hanle Bar on the PWC 171 10 HULL 177 10 1 Dashboard cover 178 10 2 Drainagebox 180 10 3 Baggage Cover 181 10 4 Side Cover Assembling 184 10 5 Sponsons assembling 185 11 ELECTRICAL SYSTEM 186 11 1 General view SERIES S wiring diagram 187 11 1 1 Sector A 188 11 1 2 Sector B 188 11 1 3 Sector C 189 11 1 4 Sector D 189 ...

Page 5: ...95 11 2 7 Sector G 196 11 2 8 Sector H 196 12 HSR BENELLI DIAGNOSTIC SYSTEM 197 12 1 HSR Benelli Utility Diagnostic System HUDS installation 198 12 2 HSR Diagnostic Tool settings 204 12 3 Vehicle registration process 205 12 4 Periodic maintenance registration process 208 13 STORAGE 212 14 APPENDIX 214 ...

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Page 7: ...atisfactorily All adjustments maintenance and repair should be carried out only by qualified mechanics in accordance with this service manual The present manual has been prepared on the basis of state of the art specifications valid at the date of publication In the case of modifications carried out after this date differences may exist between the contents of the manual and the PWC under review T...

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Page 9: ...value and with specified locking agent Always use new gaskets o rings and seals clips cir clips and snap rings when assembling components Never reuse self locking nuts when assembling components Never reuse hose clamps when removed from fuel lines Replace with small gear clamps WARNING Always use HSR Benelli authorized lubricants greases and locking agents when assembling components Failure to do ...

Page 10: ...exercise extreme care when handling gasoline Do not smoke or allow open flames in or near the area where refuelling is performed or where gasoline is stored Always refuel the watercraft outdoors and in a well ventilated area Do not fill the tank to the fuel cap If you get gasoline or oil on your skin or clothing wash it off immediately with soap and water and change clothing The engine exhaust fro...

Page 11: ...ver 2009_03 Page 11 215 T D C MEASURER TRANSMISSION GEAR PULLER GEAR NUT REMOVAL TOOL COUPLER REMOVING TOOL VALVE OIL SEAL REMOVING TOOL OIL REMOVING TOOL ...

Page 12: ...1 ROZ RON or 82 5 MOZ MON may be used for a short time ATTENTION Lower quality fuels could only be used in case of emergency If used regularly they cause decreases in performance and possibly damage to the engine Recommended lubricants LUBRICANT SPECIFICATIONS Series S Series R Engine Oil specification HSR Benelli engine oil 10w60 ACEA A3 B3 B4 API SL Engine Oil Filling volumes Initial filling com...

Page 13: ...protective braking in has a positive effect on the engine s lifespan 1 2 5 Operating the engine on vehicle outside of water WARNING If PWC is outside of water its engine may be operated at idle speed only for maximum of 30 seconds Never run the engine for more than 30 seconds without cooling water supply If it is necessary to operate the engine longer than 30 seconds on vehicle out of water the fl...

Page 14: ...n these numbers will help identify it The owner should keep a record of these numbers in a place other than the watercraft 1 3 2 VIN number AT Manufacturing Country HSR HSR BENELLI A Model Code 1001 Sequential Serial Numbers Production Month C Month code Production Year 8 Model Year 08 Model year 8 2008 You will find the serial number at the right rear side of your PWC 1 3 3 Engine number Number i...

Page 15: ...utboard marine engine 2008 exhaust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission Engines 1 3 5 Safety instructions For Series S ONLY Safety Instructions sticker is placed under the handle pole on the Series S models For Series R ONLY Safety Instructions sticker is placed on the Luggage Cover on the Series R ...

Page 16: ... 92 93 Octane or 95 98 ROZ ISO 5146 SPARK PLUG CHAMPION RG4HC SPARK PLUG GAP 0 75 0 8 mm 0 0028 0 032 in ENGINE DISPLACEMENT 1130 cc NUMBER OF CYLINDER 3 CYLINDER LINING SURFACE Nicasil BORE x STROKE 88 x 62 mm COMPRESSION RATIO 12 13 1 CYLINDER COMPRESSION 9 6 1 bar 140 14 5 psi MAXIMUM HORSEPOWER Series S Pro Edition 142 hp Series S Race Edition 162 hp Series R Naked Edition 142 hp Series R Pro ...

Page 17: ... Race Edition 15 26 Series R Naked Edition 11 19 Series R Pro Edition 11 19 XL COUPLING TYPE Six piece coupler Damper MINIMUM DEPH FOR OPERATION 60cm 2 Ft HULL BODY HULL MATERIAL Fiberglass RTM Process 1 4 2 Standard Torque Specifications The following torque specifications are to be used as a general guideline Use standard torque values for the appropriate size fastener when torque values are not...

Page 18: ...bic centimeters cc x 0 061 Cubic inches cu in Imperial pints Imp pt x 0 568 liters l Liters l x 1 76 Imperial pints imp pt Imperial quarts Imp qt x 1 137 liters l Liters l x 0 88 Imperial quarts Imp qt Imperial quarts Imp qt x 1 201 US quarts US qt Liters l x 1 057 US quarts US qt US gallons US gal x 3 785 Liters l Liters l x 0 264 US gallons US gal Pounds force per square inch psi x 6 895 Kilopas...

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Page 20: ... The Maintenance intervals specified in the table should not be exceeded by more than 10 All activities described in this manual must be carried out by trained service staff In case of warranty repairs HSR BENELLI reserves the right to request warranty approval documents for performed periodic maintenance of eligible PWC ATTENTION The vehicle owner or user is responsible adhering to the maintenanc...

Page 21: ... system to provide cooling by tap water ATTENTION Engine could be operated only at idle rpm even if flushing kit is attached Do not run engine when flushing kit is attached continuously for a period over 5 miutes to prevent overheating Flushing system hose Series R LEFT SIDE Flushing system fitting Flushing system hose Series S RIGHT SIDE ...

Page 22: ... x x x x x x Check tighten engine mount bolts x x x x x x x Check valve for fuel ventilation x x x x x x x Check throttle operation system x x x x x x Check and clean jet pump including cooling system sieve x x x x x x Check renew drive damper x x x x x x Check steering and lanyard operation x x x x x x Replace rubber duckbills if necessary Series S only x x x x x x Check and grease Battery clamps...

Page 23: ...l must be within the minimum and maximum marks When engine is warm proceed the same way but insure your check is done five minutes after engine is stopped to enable the remaining oil to go back to the bottom of the engine Oil level may be higher than at cold engine since the oil volume increases in warm condition WARNING Engine oil may be hot Note Engine must be cold If the valve clearance is out ...

Page 24: ...TE FOR SERIES S Volumes of oil in the engine min 1 7 litres without change of oil filter max 2 0 litres change of oil filter included In case of completely dry engine 2 3 litres Required torque for oil filter cover 24 Nm Required torque for ignition coils 10 Nm Required torque for spark plugs 12 Nm WARNING Never fill with more than 2 3 l of oil into the engine oil filter included NOTE FOR SERIES R...

Page 25: ...NOTE RECOMMENDED SPARK PLUGS CHAMPION RG4HC Replace engine spark plugs every 100 hrs Check electrode gap and spark plug condition after the break in period 10 12hrs 1 Unscrew nut A 2 Remove ignition plate B 3 Remove ignition coil C 4 Unscrew spark plug To reinstall Follow the procedure exactly in the opposite way WARNING Do not tighten spark plugs with torque over 12Nm not to damage cylinder head ...

Page 26: ...them and with the head plain Measure the clearance between camshaft and valve cap by a thickness gauge making sure that the clearance is in the specific range Start from measuring clearance on Cylinder 2 EXHAUST valves Cylinder 3 INTAKE valves Proceed the measurement for other valves rotating the engine using a wrench on a special nut of camshaft measure the clearance when the cams corresponding t...

Page 27: ...he valve clearance is out of specifications take note about your current reading for adjustment 2 3 5 Valve clearance adjustment ATTENTION To prevent falling of removed parts into crankcase please use proper sealing material at timing chain drive casing Remove the chain pad 6 unscrewing the two fixing screws 7 ...

Page 28: ...d elements for correct reassembling cylinder number camshaft IN EX etc Remove mounting screws of camshaft holders 8 and remove them Take care of removing metal bushings of each holder Remove the bridge 9 unscrewing the fixing screws Raise the camshaft paying attention to keep all teeth of the timing chain in place allowing the removal of the valve caps 1 ...

Page 29: ...ze 3 Calculate the thickness of the replacement shim Example your reading on the intake valve is 0 27mm spec 0 30 0 35mm Clearance is less than specified The shims are available in 0 025 mm steps of thickness Present shim gives 0 27mm clearance with its thickness 2 350 mm Shim size calculation Present clearance 0 27mm 0 30 0 35mm needs to be achieved by reducing shim size Using of 2 size thinner s...

Page 30: ...ead during cover installation Apply THREEBOND paste as shown on the drawing Install the cylinder head cover and insert rubber bushings and the screws 3 and 4 as shown on the figure NOTE Replace the rubber bushings of the screws 3 and 4 during reassembly Tighten the head cover mounting screws to the specific torque take care not to cut or damage rubber bushings Tightening torque 10 N m 1 Kg m ...

Page 31: ...ximum of air bubbles out of it Add more coolant 3 Repeat this process 2 3 times until no more coolant can be added 4 Do a test run in the water to heat the engine Stop the engine couple of times and check the anti freeze coolant level Add coolant if necessary 5 Repeat this process couple of times until the thermostat has opened and the entire amount of coolant circulates in the cooling system WARN...

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Page 33: ... verify the correct number of engine mounting strap shims are installed on each engine mounting post Remove the pump to check driveshaft alignment add shims to move the engine up or down to align properly Always verify that the engine does not interfere with critical routings such as the steering cable cooling hoses and main wiring harness Steering cable must be fixed on front left engine mounts t...

Page 34: ...stallation into the PWC shown for Series R Pro Lift the engine into the PWC using a lifting device Insure you hook on the exhaust hose and the and inline the Spider Couplers Position the Engine into the 4 x engine supports on the hull ...

Page 35: ... the engine is positioned properly according to propulsion system If the engine position needs to be adjusted use special washer with 0 5 and 1 mm thickness to align the system NOTE If the engine needs to be heightened you have to use washers on all four engine supports Apply blue Loctite on the screws and tighten the screws of the engine support with specified torque Tightening torque 30 N m ...

Page 36: ...e for the 3 in 1 hose Plug in the water relieve hose for the 3 in 1 hose Plug in the water relieve hose for the exhaust manifold Tighten the fuel hose to the fuel rail NOTE Take care to install the sealing rings Plug in the cooling water supply lines as shown on the picture into the oil cooler ...

Page 37: ...ver 2009_03 Page 37 215 Plug in the water relieve hoses from the oil cooler Plug in the water supply hose for the waterpump Plug in the coolant hose for the temperature thermostat ...

Page 38: ... NOTE Ignition wires are marked with numbers of corresponding cylinders Plug in the wires for the injectors NOTE Injector wires are marked with numbers of corresponding cylinders Plug in the connector for the heat sensor Plug in the TPS sensor Plug in the pick up coil sensor ...

Page 39: ...ver 2009_03 Page 39 215 Plug in the oil pressure sensor Plug in the SSSA connector ö Tighten the ground wire Connect the wires of the voltage regulator on the ignition cover ...

Page 40: ...om the starter to the starter relays Connect the positive starter cable to the positive starter connector Connect the acceleration wire to the throttle bodies For adjustment of the acceleration wire insure the throttles are on open wide throttle position ...

Page 41: ...r level NOTE REMOVING THE ENGINE IS A REVERSE PROCEDURE TO DESCRIBED ABOVE 3 2 Engine Disassembly Assembly 3 2 1 CYLINDER HEAD Head cover removal Loosen and remove self locking nuts 3 and coil support rods 2 Slip off ignition coils 4 Remove the spark plugs using 16mm spark plug wrench Unscrew 8 valve cover mounting screws 5 ATTENTION Take note of the position of the screws for correct reassembling...

Page 42: ...he chain tensioner 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 camshafts and the chain Camshafts Inspection Check that camshafts with a micrometer as shown on the picture If the value does not enter within the specific measure change the element INTAKE SH...

Page 43: ...T 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 CAMSHAFT AND SEAT Max play 0 01 mm Chain Sprocket Wheels and Camshaft Chain Guide Inspection Check the state of wear of the camshaft distribution chain 1 If the element has blocked links is excessively worn chang...

Page 44: ...NOTE Always replace chain guides if timing chain is to be replaced Chain Tensioner Inspection Check the free sliding of the chain stretcher rod Check the state of the chain stretcher spring Check the integrity of the chain stretcher If an element or its components are damaged or ruined change it them Camshafts installation Using a special tool set the piston of cylinder 1 to TDC position ...

Page 45: ...inal direction written on the outside and tighten the fixing screws according to the diagram in the figure Tightening torque 1st phase 6 N m 2nd phase 13 N m Position the intake shaft and the timing chain position the holders in their original mark on the outside of holder should match the number engraved on inside of cylinder head and tighten the fixing screws according to the diagram in the figu...

Page 46: ...ts with Teflon SINTOFLON paste Position the chain tensioner 1 complete with O ring 2 and tighten two screws 6 Tightening torque 10 N m Position the rod pushing spring 3 and the washer 4 and tighten tensoiner cap nut 5 Tightening torque 7 8 N m ATTENTION Always check that chain tensioner is in position 0 before mounting it Align the marks on the camshaft sprockets as shown on the figure Count 30 ch...

Page 47: ...ach other as on the figure Remove Cylinder Head Remove the chain tensioner chain pads camshafts see above Loosen and remove the eight nuts and washers 1 indicated in the figure according to the shown sequence and two screws on the right side of the engine timing chain side ...

Page 48: ... deposits in the combustion 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 Mounting Cylinder Head NOTE Always use new gaskets Clean and degrease the head surface and the cylinders ...

Page 49: ...t phase 10 Nm 2nd phase 30 Nm 3rd phase 45 Nm 4th phase angle of 100 5th phase tighten 2 bolts on timing chain side with 10 8 Nm NOTE Apply grease to the fixing nuts to oil the threading MOLIKOTE BR2 PLUS grease Valves and Valve Spring Remove Valves Remove the cylinder head see REMOVE CYLINDER HEAD Position the head on a slightly inclined surface to show the valves to remove perpendicular to the s...

Page 50: ... and relative components 7 8 and 9 NOTE Make sure that valve 4 has a perfect seal by pouring 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 tw...

Page 51: ...c values If values A and B are not within the value limits change the elements INTAKE 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 condition 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...

Page 52: ...pplied to all the valve seats Eliminate eventual carbon deposits Apply the tincture of bluing b on the face of the valve Install the valve into the appropriate seat Press it using the guide on the seat to leave an evident impression Measure the width of the seat of the valve NOTE It will be necessary to remove the bluing at the point at which the seat and the face of the valve touch NOTE If the tr...

Page 53: ...of molybdenum to the stem of the valve Insert the valve into the cylinder head Rotate the valve until its face and seat shine uniformly Then remove the smoothing paste NOTE To obtain optimum smoothing results strike the seat of the valve lightly while turning it forwards and backwards in your hands Apply a fine grained paste to the face of the valve and repeat the above operations Completely elimi...

Page 54: ...ollerance limit 37 mm Internal valve spring Tollerance limit 34 0 mm Bring the spring to a value length c and check the value of the load VALUE LIMIT External spring length 23 2 mm Load value limit 565 N Internal spring length 21 2 mm Load value limit 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 I...

Page 55: ...ps are not broken or scratched in other case replace them Mount Valve The following procedure must be applied to all the valves and relative components 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 ...

Page 56: ...eals Mount the rubber valve seal 2 with the appropriate pad 3 ATTENTION Intake 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 57: ...g valve instrument making sure that the valve is correct Position the calibrated pads 9 and valve caps 10 ATTENTION Make sure that the individual valve lifters and the valve guide are re mounted in the original position NOTE Check that valve caps turn easily by rotating them with a finger ...

Page 58: ...signs of seizure with the pistons Check the ovalisation of the cylinders as indicated in the figure ATTENTION In the case of changing the cylinder block also change the pistons and the elastic straps if necessary 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 ar...

Page 59: ...ove the three screws 1 and remove the collector 2 Check Water collector Check eventual breaks on the collector and if necessary change the piece Mount Water Collector ATTENTION Always use new gaskets Position the gasket 1 and the collector 2 and tighten the screws 3 ...

Page 60: ...mantle 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 piston pin removal 2 Remove pin 2 and remove piston 3 ...

Page 61: ...d 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 NOTE The maximum play of the piston is of 0 1 mm Change the piston if necessary Check Piston Rings The following procedure must be applied to all the piston rings Check the absence of scuffing and traces of shrinkage on every Piston ring Check that the ed...

Page 62: ...n and the segments PISTON RING PLAY SERVICE LIMIT 1st 0 20 mm 2nd 0 18 mm PISTON RING WIDTH STANDARD 1st 1 02 1 04 mm 2nd 1 01 1 03 mm OIL RING 2 01 2 03 PISTON RING THICKNESS STANDARD 1st 0 97 0 99 mm 2nd 0 97 0 99 mm 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 63: ...gs in the order oil ring 2 nd piston ring 1st piston rings The first element to insert into the slot of the oil ring 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 superimpos...

Page 64: ...on ring are different W4 3 1 0 1 mm W3 3 7 0 1 mm The 1st and 2nd piston ringhave the letter N on the upper side Make sure that the marked side is turned upwards when being installed on the piston Piston Installation Position the two piston rings 1 and the oil ring 2 on the piston positioning the opening at 120 from each other ...

Page 65: ... the arrow on the piston pointing towards the exhaust Insert the pin 4 ATTENTION Always use 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 attention not to deform them ...

Page 66: ...p tool if necessary ATTENTION After reassembling ensure to rotate the engine with its electric starter without spark plugs but with transmission installed on it and filled with engine oil for 60 seconds before installing the engine into the PWC to ensure that all bearings are sufficiently lubricated with oil before the first test run in the PWC Remove the roll over valve block unscrewing 6 mountin...

Page 67: ...rom the oil sump cover Remove the dipstick tube connection Untighten and remove oil sump cover mounting screws Remove the oil sump cover Dismantle Oil Pump intake tube and Oil Sump filter assy ATTENTION Note the position of the screws for correct remounting Remove the screws shown by circle marks on the figure Then remove 8 crankcase bolts shown by oval marks ...

Page 68: ... Remove 2 balance shaft screws shown on the picture Remove the lower crankcase part pulling it up Use a soft hummer if necessary NOTE Pay attention to prevent crankshaft and balance shaft of falling down during casing removal ...

Page 69: ...large plastic lock nuts on both sides of balance shaft 14 Remove the ring 15 Remove the balance shaft Remove engine crankshaft ATTENTION Take note of crankshaft plain bearings position for correct reassembling Remove the plain bearings ...

Page 70: ...ver 2009_03 Page 70 215 Dismantling Balance Shaft Remove the circlip 1 Remove the ball bearing 2 and the toothed wheel 3 Remove the ball bearing 4 ...

Page 71: ...hole 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 Check eventual br...

Page 72: ...ed limit change the connecting rod 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 PLAY SERVICE LIMIT 0 40 mm CONNECTING...

Page 73: ... in the chart Position each con rod plain bearings according to the marks on the rod flange see picture Take care the bearings are installed to relative slots ATTENTION Two marks shown on the figure must couple for connection rod body 1 and big end cap 2 Assemble the connecting rod on the crankshaft so that the marks 1 and 2 are aligned as shown on picture ...

Page 74: ...ASE ATTENTION Always change connecting rod bolts by new after each dismantling Oil the thread and the diameter under the flanging of the fixing bolts 3 with the recommended grease Tighten the fixing bolts 3 slightly RECOMMENDED OIL MOLIKOTE BR2 PLUS GREASE NOTE Apply MOLIKOTE grease on the inner halves of crankshaft plain bearings and ensure the outer halves and their crankcase seats are cleaned w...

Page 75: ...n connecting rod bolts in three phases Tightening torque 1st phase 15 N m 1 5 Kg m 2nd phase 25 N m 2 5 Kg m 3rd phase 50 NOTE An angle torque control wrench is required to carry out the third tightening phase Mounting Balance Shaft Position the ball bearing 1 and fix with the circlip 2 ...

Page 76: ...76 215 Position the bushing 4 Position the ring 5 Position the roller bearing 3 on the balance shaft Mounting Casting NOTE There are 3 different sizes of crankshaft plain bearings marked by colors mentioned in the chart ...

Page 77: ... out starting from timing chain side Position and center four semi bronze plain bearings 25 each slotted with the correct color according to its letter stamped on the exhaust side of the crankcase 24 Position the crankshaft as shown on the figure Position the balance shaft ...

Page 78: ... 215 NOTE Make sure that sprocket wheels marks of the balance shaft and the crankshaft are aligned as shown on the figure Position balance shaft ring 28 Install 2 large plastic lock nuts on both sides of balance shaft 29 ...

Page 79: ...ing part on the upper ATTENTION Follow the mounting phases correctly Position eight crankcase screws with washers apply recommended grease for their threads and tighten to specified torque in three phases according to the sequence marked on engine carter RECOMMENDED OIL MOLIKOTE BR2 PLUS GREASE Tightening torque 1st phase 13 N m 1 3 Kg m 2nd phase 25 N m 2 5 Kg m 3rd phase 45 N m 4 5 Kg m ...

Page 80: ...5 N m 2 5 Kg m Tighten screws shown by circle marks with specified torque Tightening torque 10 N m 1 0 Kg m ATTENTION Always use new gaskets Install Oil pump intake tube Oil sump filter and oil sump cover Tighten cover screws with a specified torque Oil sump filter mounting screws 10 N M 1 0 Kg m LOCTITE 243 Tightening torque 10 N m 1 0 Kg m ...

Page 81: ...1st phase 10 N m 1 0 Kg m 2nd phase 25 N m 2 5 Kg m Tighten five screws shown in circle marks with specified torques Tightening torque 10 N m 1 0 Kg m Install Oil pump cover and tighten its screws with specified torque Tightening torque 10 N m 1 0 Kg m Install roll over valve assembly and tighten its fasteners with a specified torque Tightening torque 10 N m 1 0 Kg m ...

Page 82: ...skets and oil seals Disconnect cooling system hose loosen and remove mounting screws and remove the thermostat cover Remove the thermostat 5 Verify that the by pass hole 6 is not obstructed Check Thermostat The thermostat begins and opens at around 75 C and reaches 7 mm minimum opening at 90 C as shown in the diagram on the figure ...

Page 83: ... 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 thermostat if necessary Check that the thermostat cover and the tubes connected to it are not broken otherwise change the damaged element Mounting the Thermostat WARNING The thermostat must be mounted with the by pass hole 2 turned upwards as shown on the figure...

Page 84: ...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 O Ring 7 Loosen and remove two screws 8 Remove the cover 9 ...

Page 85: ...and remove the nut 10 and remove the rotor 11 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 oil seal beneath Remove the mechanical seal 17 ...

Page 86: ...e various elements are not broken Change worn or damaged elements if necessary Water Pump Assembly Position the pump body 1 on a support ATTENTION The oil seal must be inserted downwards with the lip closed Position oil seal until it touches 2 Grease the shaft 4 at the points indicated on the figure ...

Page 87: ... 4 inside the pump body 1 Position the first ball bearing 5 using a press to make it touch 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 88: ... are clean and bear no traces of grease Position the counter face 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 Position the sealing washer 13 and fix it tight with the nut 14 8 N m 0 8 Kg m Always use LOCTITE 243 ...

Page 89: ... two screws 15 Position the sealing washer 16 and tightly screw the purge screw 17 up 10 N m 1 Kg m Always use LOCTITE 243 Position the O Ring 18 on the pump 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 ...

Page 90: ...09_03 Page 90 215 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 Reposition the entry and exit tubes 3 of the pump tightening two hose clamps 4 ...

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Page 92: ...see Engine Removal chapter Remove the engine oil by opening the oil plug screw on the bottom of the engine 19 mm socket required Use suitable equipment to collect the engine oil Remove the following parts Oil return line to the bottom of the engine Oil supply line Rear engine Support Coupler cover ...

Page 93: ...d 10 x long 5mm mounting screws Take note of short screw position shown on figure Remove transmission cover with a suitable tool NOTE do not damage the gasket surface of the casting Remove the right hand thrust washer carefully and place beside ...

Page 94: ... the left hand transmission gear assy and place beside Remove carefully the second thrust washer and place beside Remove carefully the 3 x needle cage bearings and place beside Remove carefully the left had thrust bearing and place it beside ...

Page 95: ...n gear with the gear wheel remover Tighten the screws of gear wheel remover in X method stopping the gear with a suitable tool Remove the gear and place it beside Remove 2 x transmission casing mounting screws and lower banjo bolt NOTE Remove the copper washer of lower banjo bolt ...

Page 96: ...ear box casing and place it beside Disassembling transmission cover Support the transmission cover and use special tools to open the coupler Loosen and remove the coupler NOTE The washer in between the bearing and the gear has a thickness of 4 5mm ...

Page 97: ...ver 2009_03 Page 97 215 Remove circlip and bearing NOTE The washer in between the oil seal and the bearing has a thickness of 1 5mm ...

Page 98: ... Disassembling transmission housing Remove the oil seal and the O ring 4 2 Transmission Assembling Assembling the transmission cover Grease new oil seal on the seal lips and o the oil seal groove Press in the oil seal by hand ...

Page 99: ...circlip to secure the bearing Subassembly of the PTO gear Press and glue the aluminum plug into the PTO gear with Loctite 648 as shown on the pictures below Put the washer 4 5 mm in place Install washer 1 5mm in between the oil seal and the bearing using suitable tool ...

Page 100: ...torque Tightening torque 80 N m Assembling transmission housing Apply grease on the inside and sealing lips of the oil seal Press in the oil seal NOTE The greased side of the oil seal needs to be on the same side like the painted side of the oil seal cover Put in place the O ring Apply Loctite 5699 on the O Ring ...

Page 101: ...the transmission housing and tighten 3 x bolts NOTE Pay attention not to damage the oil seal by thread of the crankshaft NOTE Insure that the oil delivery line will be placed in between the engine and the transmission housing Apply RED Weicon Lock AN 305 86 on the thread of all 3 screws Ensure the copper gasket is used on the bigger one ...

Page 102: ...sing in the transmission bolt During pressing in the transmission bolt ensure the lubrication holes are orientated to the right side 90 deg to the right Assembling the right hand side gear NOTE For correct Crankshaft gear installation apply Loctite 648 on the surface of the inner side of the cone ...

Page 103: ...ut with a specified torque Tightening torque 160 N m Put in place transmission parts on the right hand side of the transmission Put in place the thrust washer Put in place the 1st cageless needle bearing Put in place the 1st thrust ring Put in place the 2nd cageless needle bearing Put in place the 2nd thrust ring Put in place the 3rd cageless needle bearing Oil the bearing system ...

Page 104: ... thrust washer of the right hand transmission gear Put in place the thrust washer of the left hand transmission gear Put in place the 3 x cage needle bearing Oil the bearing system Ensure the 2 x location pins are in place Apply Loctite 5699 on the transmission housing sealing surface ...

Page 105: ... be used on the left hand side of the transmission like shown on the figure Tighten using the other 10 screws Tighten all 12 screws according to the tightening procedure and with specified torque Tightening torque 10 N m Install the oil lines in the order your removed them Apply RED Weicon Lock AN 305 86 and tighten the banjo bolt with specified torque Tightening torque 25 N m ...

Page 106: ...que Tightening torque 20 N m WARNING Pay attention for amount of used Locking agent on the oil line banjo bolts thread There is a risk of blocking oil passages Tighten the oil plug screw with specified torque Tightening torque 30 N m Refill the proper oil volume in the engine ATTENTION Use only original HSR Benelli engine oil ...

Page 107: ... with water resistance grease on both sides RECOMMENDED LUBRICANT FUCHS URETHYN E M 2 Use new pre coated screws or apply blue Loctite 243 Put in place the flange bearing and tight 4 screws with specified torque Support the bearing with a hammer to put the bearing on the top position Tightening torque 30 N m ...

Page 108: ...ver 2009_03 Page 108 215 Put in place the flange bearing cover apply blue Loctite 243 on the thread of the screws and tighten the screws with specified torque Tightening torque 10 N m in X method ...

Page 109: ...ver 2009_03 Page 109 215 ...

Page 110: ...ver 2009_03 Page 110 215 5 PUMP AND IMPELLER 5 1 Jet Pump overview Series R Pro pump shown ...

Page 111: ...JET PUMP assembly were removed from the hull engine coolant could flow out After reassembling jet pump to the vehicle always perform engine coolant level check and refill to specified volume if necessary 5 2 JET PUMP DISASSEMBLING Remove the O rings from the jet pump and place it beside Remove 4 x Allen screws m5 locking the Nozzle Remove Jet Pump housing Impeller housing with the Stator Remove 3 ...

Page 112: ...he water sieve protects the exhaust cooling system from sand and other particles to block the water supply A heat sensor will warn you and slow down your personal PWC into the limp home mode of 4000 rpm This requires regular maintenance There is a second one in the water injection of the exhaust system Remove the sieve out of the housing with a tool ...

Page 113: ...oosen the impeller with a Special Tool Block the impeller shaft See Photo beside NOTE Remove the Impeller shaft with a soft tool in order to avoid damages on the thread Remove the impeller shaft Disassembly of the Stator Housing of the Jet Pump Remove the bearings out of the housing with a soft tool ...

Page 114: ...et Pump Housing carrying the Liner for the engine Radiator NOTE The Jet Pump housing and the Liner cannot be taken apart and need to be replaced as one for repair Remove the cooling water supply hose Disassembly of the Jet Pump nozzles Open with an allen screw driver M 6mm the screws on the left and right hand side of the steering nozzle ...

Page 115: ...03 Page 115 215 Remove the spring located on the Nozzles Remove the Steering nozzle Remove plastic bushings from the steering nozzle with a soft tool carefully Remove the allen screw M 6 mm from the trim nozzle ...

Page 116: ...ic bushing with a soft tool carefully NOTE For Reverse Equipped PWC only Remove the reverse support from the jet pump with an allen screw Driver M 6mm 5 3 ASSEMBLING THE JET PUMP NOTE For Reverse Equipped PWC only Apply blue Loctite 243 on the threads of the screws ...

Page 117: ...Pump Housing Tightening torque 20 N m Reinstall the jet pump nozzles Press in the new plastic bushings into the trim nozzle Apply blue Loctite 243 on the threads of the screw tightening the Trim nozzle Tighten the screw with specified torque Tightening torque 20 N m ...

Page 118: ...e 243 on the beginning of the threads of the screw and tighten the screws with specified torque Tightening torque 20 N m Proceed the same process on both sides of the pump Assembly of the Stator Housing of the Jet Pump Assembly of the Jet Pump Housing Put in place the first smaller in diameter bearing ...

Page 119: ... Page 119 215 Press in the first bearing smaller in diameter bearing with a tool Put in place the second smaller in diameter bearing with a tool Press in the second bearing smaller in diameter bearing with a tool ...

Page 120: ...tance sleeve Put in place the third bearing bigger diameter Press in the third bearing bigger diameter with a special tool Take a new oil seal and apply grease in the lips Place the oil seal on the sleeve RECOMMENDED LUBRICANT FUCHS URETHYN E M 2 ...

Page 121: ...l with a tool very carefully Apply grease on the remaining sleeve and put it in place RECOMMENDED LUBRICANT FUCHS URETHYN E M 2 Put in place the sieve in the housing Put in place the sieve housing and apply blue Loctite on the beginning of the thread ...

Page 122: ...ecified torque Tightening torque 10 N m in X method Apply grease on the impeller shaft all the way around RECOMMENDED LUBRICANT FUCHS URETHYN E M 2 Press in the Impeller Shaft Assembly of the Impeller Screw carefully the Impeller on the Impeller Shaft and tighten it by hand ...

Page 123: ...ver 2009_03 Page 123 215 Use a special tool to tighten the impeller to the final torque Tighten the Impeller to the specified torque Tightening torque 100 N m Put in place the white plastic ring ...

Page 124: ...nd tighten it with a specified torque Tightening torque 7 N m Apply blue Loctite 243 in the thread of the water supply tube And tighten the tube on the housing Put in place the O Ring and apply slightly grease on the surface Apply grease on the sockets of the Impeller housing ...

Page 125: ...in place the Stator Housing on the Impeller Housing Put in place the Nozzle assembly Apply blue Loctite 243 on the beginning of the threads of the screws Tighten the screws with specified torque Tightening torque 25 N m in X method ...

Page 126: ...ver 2009_03 Page 126 215 Put in place the O Rings and the rubber cone and the rubber seal Final assembly of the Jet Pump ...

Page 127: ...ring with it s 4 screws into the rear of jet pump tunnel Apply blue Loctite 243 on the threads of the screws or take new micro coated screws Support the Flange bearing during assembly with a hammer to pull it on the top position during tightening Tighten the screws with specified torque Tightening torque 30 N m in X method ...

Page 128: ...Loctite 243 on the thread of the screws Tighten the screws with specified torque Tightening torque 30 N m in X method Put in place the impeller housing with the impeller on the jet pump housing Apply blue Loctite 243 on the threads of the screws and tighten with Tighten the screws with specified torque Tightening torque 20 Nm ...

Page 129: ...Reverse Gear For Series R Pro Model only Put in place the sleeves of the reverse shield Apply blue Loctite 243 on the thread of the screws and put 2x per side the washer in place Tightening torque 10 Nm NOTE Ensure the reverse shield moves easily ...

Page 130: ...le to the jet drive outlet must be the same on the left and the right side Otherwise adjust the steering cable accordingly To disconnect the steering cable from the jet nozzle at the ball joint you must first pull the steering cable back Then pull up on the connection The cable will be free from the connection The distance should be the same on both sides x WARNING Pay special attention when assem...

Page 131: ...id half the way 10 cm3 and screw a bleeding nipple into the trim system Put covering material on the PWC in order to protect the paint of the deck Attach the Injector with a hose and tighten it with a plastic clamp Press the injector 10 times Put the nozzle in top position and repeat the injector pump process 10 times Put the nozzle in bottom position and repeat the injector pump process 10 times ...

Page 132: ... collect remaining brake liquid Remove the Injector bleeding nipple put in place O Ring and screw the plug loosely into the Trim lever body Tilt the nozzle to the top position and ensure the excessive brake fluid will be released of the trim lever Tighten the plug screw Clean the trim leaver with a cleaner in order to avoid brake liquid contact with the paint of the hull ...

Page 133: ...ver 2009_03 Page 133 215 ...

Page 134: ...ro Remove the 2 x screws of the fuel tank belts on the bottom of the hull Unscrew the clamp of the fuel filling hose and remove the hose NOTE Pump out any remaining fuel out of the tank if required Remove the fuel tank out of the hull Disassembly of the fuel pump out of the fuel tank Unscrew the 6 x screw from the fuel pump ...

Page 135: ... on the fuel pump Assembly of the fuel pump into the fuel tank Put back in place the fuel pump for assembly NOTE It is EXTREMELY important to insure that THE FUEL FILTER IS NOT SQUECED INBETWEEN THE FUEL PUM AND THE TANK There is the risk of leaking fuel into the hull Apply blue Loctite 243 on the thread of the screws of the fuel tank ...

Page 136: ...st of the subassembly of the Fuel Pump Fuel Tank Note Always perform a leak test during fuel tank disassembly fuel pump inspection Apply a pressure of 0 3 bar into the tank system and check for loss of pressure with the help a spray test see picture Release the pressure carefully by opening the fuel cap as shown in the picture ...

Page 137: ... tank into the PWC Put back the fuel tank into the PWC as shownin the picture Reinstall the fuel tank hose with the clam on the fuel tank Apply blue Loctite 243 on the thread of the screw and tighten with specified torque Tightening torque 10 N m ...

Page 138: ...ver 2009_03 Page 138 215 ...

Page 139: ...ystem in the Hull Inject 15 ml of engine oil into the exhaust muffler ensuring the temperature sensor will recognize the exhaust temperature in the exhaust system Put in place the copper gasket and the temperature sensor Apply green Loctite 278 and tighten the sensor with specified torque Tightening torque 20 N m ...

Page 140: ...exhaust mounting belt Put the exhaust hose on the fitting in the Jet pump tunnel Put in place the remaining hoses and tubes for the exhaust system shown on the pictures Tighten the exhaust end flange with 6 x screws and apply Blue Loctite 243 on the threads and tighten in with 5 Nm ...

Page 141: ...ifferent injectors with different Inner diameters Apply green Loctite 278 on the thread of the water injectors used on exhaust tubes of exhaust manifold Tighten the water injectors on its predefined position on the exhaust manifold to be in line Apply Green Loctite 278 on the thread of the fitting tighten it and turn it into the final position ...

Page 142: ...inner diameter apply green Loctite 278 on the thread and tighten the fitting as shown on the picture Take the fitting with the bigger inner diameter apply green Loctite 278 and tighten it Take the L fitting and apply green Loctite 278 and tighten it to the position like shown on the photo The view of the final assembly ...

Page 143: ...t gasket Put the applied gasket on the exhaust manifold as shown on the picture NOTE the cut edge of the gasket needs to be inline with the shape of the exhaust manifold Apply blue Loctite 243 on the thread of the screws and tighten them with specified torque Tightening torque 30 N m ...

Page 144: ...ust hose view 7 3 Assembling the hoses on exhaust manifold There are two hoses of 135 mm length that need to be installed between the fittings of the exhaust manifold Clamps are tightening the hoses Install 2 x 80mm hoses like shown on the pictures Clamp in the same way as shown above ...

Page 145: ...equipment of the leak test is shown bellow 1 Manometer 2 Long hose 3 Short hose Link the test equipment in between the outlet of the manifold and the outlet of the 3 in 1 exhaust hose fitting The circle of the water jacket should be closed by the mentioned equipment for the test Apply air pressure of 3 bar into the system ...

Page 146: ... on the engine Apply blue Loctite 243 on the stainless steel nut and hand tight them on the stud screws of the cylinder head Tighten the screws in the X Method with a specified torque starting with the 2nd cylinder continuing on 1st or 3rd cylinder and finalizing respectively on the 3rd or 1st cylinder Tightening torque 10 N m ...

Page 147: ...ver 2009_03 Page 147 215 ...

Page 148: ...rcuit cooling system Series S Pos Part description Q ty 1 ASM COOLING PIPES ENGINE 1 2 SCREW 1 3 COOLING HOSE HOT 1 1 4 COOLING HOSE HOT 2 1 5 COOLING HOSE COLD 1 6 HOSE CLAMP 38 1 2 7 HOSE CLAMP 25 40 4 8 SCREW CAP 1 4 BAR 1 9 THREADED T PIECE 1 10 PADS 2 ...

Page 149: ...cription Q ty 1 ASM COOLING ENGINE 1 2 SCREW M5X10 1 3 COOLING HOSE COLD 3Z 1 4 COOLING HOSE HOT SHORT 3Z 1 5 COOLING HOSE HOT LONG 3Z 1 6 HOSE CLAMP 38 1 2 7 HOSE CLAMP 25 40 4 8 THREADED T PIECE 1 9 PADS 3 10 BRACKET COOLING HOSE 1 11 SCREW CAP 1 ...

Page 150: ...ver 2009_03 Page 150 215 8 2 Opened circuit systems Series S ...

Page 151: ...E INNER D 10MM 30 CM 3 INTAKE LINE OIL COOLING HOSE INNER D 10MM 10 10 10 CM 3 EXIT LINE OIL COOLING HOSE INNER D 10MM 50 45 40 CM 4 EXIT LINE OIL COOLING HOSE INNER D 10MM 33CM 5 EXIT LINE OIL COOLING HOSE INNER D 10MM 35CM 6 EXIT LINE EXHAUST COOLING HOSE INNER D 13MM 36CM 7 INTAKE LINE EXHAUST COOLING HOSE INNER D 10MM 80CM 8 EXHAUST MANIFOLD COOLING HOSE INNER D 10MM 10CM 9 EXHAUST MANIFOLD CO...

Page 152: ...B WATER MANIFOLD 2 C 3IN1 EXHAUST HOSE 1 D EXHAUST MANIFOLD 1 E MAGNETIC VALVE IP67 1 F T TYPE FITTING 5MM 2 G L TYPE FITTING 5MM 1 H T TYPE FITTING 3MM 3 I INLINE FILTER 1 J SPREDSERT M6 X 12 7 1 K ELBOW SCREW IN NOZZLE 1 L SCREW IN HOSE NOZZLE 1 M BYPASS FITTING DN9 BLACK 1 N REDUCTION FITTINGSLEEVE 4 5 MM 1 ...

Page 153: ...SYSTEM HOSE INNER D 10MM 50 CM 7 INTAKE LINE EXHAUST COOLING HOSE INNER D 10MM 25CM 8 MAGNETIC VALVE HOSE INNER D 6 MM 27CM 9 INLINE FILTER HOSE INNER D 10 MM 15CM 10 EXIT LINE EXHAUST COOLING HOSE INNER D 10MM 150CM 11 EXHAUST MANIFOLD COOLING HOSE INNER D 10MM 85CM 12 INLINE FILTER HOSE INNER D 10 MM 10CM 13 EXHAUST MANIFOLD COOLING HOSE INNER D 10MM 8CM 14 EXHAUST MANIFOLD COOLING HOSE INNER D ...

Page 154: ...ng liquid The water enters the system through wards the Jet Pump tunnel The T Fitting splits the water flow into the exhaust manifold and the Flushing system hose The hose for the exhaust manifold cooling system feeds first the end of the manifolds ...

Page 155: ... the end where the headed liquid is collected It leaves the system on the left hand side of the manifold and returns to the 3 to 1 hose on order to cool it It leaves the 3 in 1 hose through wards a fitting to exit the system via a hose to left rear part of the PWC ...

Page 156: ...pplied with hose from the Jet Pump at the rear of the PWC The coolant is split into the oil cooler through wards the coolant water manifold It passes the oil cooler and enters a second water manifold And goes through the hull to be released through wards a fitting in the jet pump tunnel ...

Page 157: ...ver 2009_03 Page 157 215 ...

Page 158: ...1 Steering Support Assembly For Series R model only Take the steering support and press in the bearing inside the steering support by hand Put the steering tube in place Put in place the second bearing and press it in by hand Use a tool to install bearing circlip in place ...

Page 159: ...t in place steering axle and put it in carefully with a soft hammer NOTE Ensure the parts are in line and are sliding carefully Put in place the ring Put in place the steering lever Put in place the indicator disc Apply BLUE Weicon Lock AN 302 43 on the thread and tighten nut with specified torque Tightening torque 25 N m ...

Page 160: ...thread NOTE SSSA sensor needs to be flattened to the support before tightening screws After final assembly please perform a check Steering shaft should move easily 9 2 Assembly of the Steering Support on the PWC For Series R model only Put in place steering support by tilting it Apply blue Loctite on thread of 6 mount screws ...

Page 161: ...ing torque 20 N m in X method 9 3 Handle Bar assembly For Series R model only Assembly of the handelbar Assembling grips on the handle bar Apply Loctite 435 to insure the grips will not become loose Press by hand the grips on the handle bar after the Loctite has been applied ...

Page 162: ...e handle bar Assembly of the handlebar on the PWC Ensure you put in place Start Stop switch wire first Put in place the handle bar cover Apply BLUE Weicon Lock AN 302 43 on the threads of handlebar cover screws Tighten screws with specified torque ...

Page 163: ...ver 2009_03 Page 163 215 Tightening torque 25 N m in X method Put throttle cable end in the throttle lever hole Assemble Trim oil line with the banjo bolt Tighten trim lever on the handlebar ...

Page 164: ...ver 2009_03 Page 164 215 Tighten the Start Stop switch on the handle bar SERIES S STEERING SYSTEM 9 4 Handle Pole Assembly Parts for the Handle Pole assembly ...

Page 165: ...e Handle Pole plate as shown in the picture Apply Loctite 243 on the thread of the 8 screws M5 x 35 as shown on the photo Tighten the screws into the handle bar and tighten them with specified torque Tightening torque 5 N m X method Apply Loctite 3425 A B on the top end of the handle bar and stick it together like shown on the photo ...

Page 166: ...nd tighten them with specified torque Tightening torque 5 N m Put the bushings in place and press them in with your fingers Put the rubber protector of the lower handle plate in place and ensure the flatten side will be in position as shown on the photos Tighten the screws ...

Page 167: ... the photos Tighten the screws Assemble the springs of the handle bar Warm the hose if needed and pull it on the spring Cut the remaining hose 3 5 mm from the end of the spring with a knife Grease the Handle bar shaft and put it in place as shown on the photos Put in place the spring for the Handle bar and push carefully the bolt through the pushing ...

Page 168: ...stroy the thread on the handle bar support Tighten the bolt with a torque meter Tightening torque 25 N m Assembly of the dashboard in the handle bar Put in place the bracket for the dashboard And assemble it according to the pictures Assemble the dashboard like shown on the photos bellow Put 2 washers on the screws to insure the proper distance ...

Page 169: ...ssembly of the locking pin for the handle bar Put in place the location pin into the handle bar support Put in place the locking pin ball by hand Put in place the location pin holder and tighten it Clean the aluminum part of the handle bar and put the safety stickers on it Put in place the sticker for the load of the vehicle ...

Page 170: ...on the Screw for the steering control bushing Put the bearing in place and press it on the steering control bushing Put the steering control lever in place Put the subassembly of the steering control bushing in place Put in place the second ball bearing and press it in ...

Page 171: ... on the thread of the screw Tighten the ball joint Put the Handle bar clamp and mounting screws in place Tighten the screws with a torque meter Tightening torque 20 N m 9 6 Assembly of the Handle Bar on the PWC Place on the RIGHT SIDE of PWC Trim Dashboard and the Start Stop switch wire Place on the LEFT SIDE of PWC Throttle and Steering cables Take left two cables for Throttle and Steering and pu...

Page 172: ... the 4 screws for the fixation of the handle bar Tighten screws with specified torque in x Method Tightening torque 30 N m Connect the dashboard wire and place it into the handle bar Put in place the Start Stop Switch and connect the wires Put in place throttle cable on the throttle lever and put assemblies throttle lever and Start Stop switch on the steering system ...

Page 173: ...eering plate side with 12 full turns Do the same for cable end on Jet pump side This should lead to a proper balanced adjustment of the steering system Connect steering cable with the Steering lever and Jet pump steering nozzle Do a control measurement as follows Take a ruler and aline it on the nozzle of the jet pump Take a measurement tool and measure the adjustment for the jet pump on both side...

Page 174: ...trim system line put second O ring in place and Tighten the bolt Bleed the system See Trim system bleeding in PUMP chapter Assemble the hand grips Put Loctite 435 in the hand grips and distribute it internally Pull hand grips on the handle bar Tighten Throttle lever assembly Trim lever and Start Stop switch body ...

Page 175: ...es cables of the handle pole NOTE Please check that cables are moving freely WARNING If throttle cable is not moving freely PWC could suddenly accelerate on its own while steering Put in place handle bar protector with two tie raps and cut the extending tie rap ends ...

Page 176: ...ver 2009_03 Page 176 215 Install the Throttle cable and insure there is free play of 2 3 mm on the throttle lever Do a final test on Start Stop switch buttons to check electrical system operation ...

Page 177: ...ver 2009_03 Page 177 215 ...

Page 178: ...R model only Disassembly of dashboard cover Remove the support plate screw from the dashboard and carefully remove the dashboard equipment by hand NOTE Take care not to damage the gasket Reassembly of the dashboard cover NOTE Take care not to damage dashboard gasket ...

Page 179: ...shboard screws with the proper torque of 2 Nm The other two screws need to be tightened with 5 Nm Assembly on the PWC Put in place the dashboard cover on the PWC Apply BLUE Weicon Lock AN 302 43 on thread of the screws 2 types of screws Top M6 x 12 below M6 x 20 Tighten the 6 screws with specified torque Tightening torque 3 N m in X method ...

Page 180: ...omponents The Primer and the glue Apply Primer on the surface that need to be glued Apply liquid Loctite on the surface that need to be glued Ensure you are putting primer and glue on the latches connecting both halfs of the drainage box Apply BLUE Weicon Lock AN 302 43 on the thread of the screw to put in place the drainage box in the hull ...

Page 181: ...ater out of the hull into the Jet Pump tunnel to be released 10 3 Baggage Cover Assemly of baggage cover electric Reverse button for Sereis R Pro only Those are the parts involved in the assembly of the Baggage Cover Assemble the axles with the springs and put it into the baggage cover on both sides ...

Page 182: ...d properly Note For Series R Pro only Reverse Switch Put in place the reverse switch and wire Apply BLUE Weicon Lock AN 302 43 on the thread as shown on the picture Put in place the connectors for the electric reverse cable Assembly of the hood latch Install the axel into the latch through wards the spring Tighten the latch with 2 x screws ...

Page 183: ... Put in place the baggage cover on the PWC by hooking in the levers with the spring under plastic covers NOTE for Models with electric reverse only Put the electric cable through the hole of the dashboard Apply BLUE Weicon Lock AN 302 43 on the thread of the screws of the baggage latch cover ...

Page 184: ...ening torque 5 Nm in X method 10 4 Side Cover Assembling Apply BLUE Weicon Lock AN 302 43 on the thread of the base stud Screw in the base stud by hand and let the Loctite dry out Put in place the side cover Put in place the rubber washers and tighten self locking nut carefully by hand ...

Page 185: ...5 Sponsons assembling Apply BLUE Weicon Lock AN 302 43 on the thread of the screws Put in place the sponsons ground plate Tighten it with specified torque Tightening torque 15 N m Put in place the sponsons and tighten it with5 Nm ...

Page 186: ...ver 2009_03 Page 186 215 ...

Page 187: ...ver 2009_03 Page 187 215 11 Electrical System 11 1 General view SERIES S wiring diagram ...

Page 188: ...ver 2009_03 Page 188 215 11 1 1 Sector A 11 1 2 Sector B ...

Page 189: ...ver 2009_03 Page 189 215 11 1 3 Sector C 11 1 4 Sector D ...

Page 190: ...ver 2009_03 Page 190 215 11 1 5 Sector E 11 1 6 Sector F ...

Page 191: ...ver 2009_03 Page 191 215 11 1 7 Sector G 11 1 8 Sector H ...

Page 192: ...ver 2009_03 Page 192 215 11 2 General view SERIES R wiring diagram ...

Page 193: ...ver 2009_03 Page 193 215 11 2 1 Sector A 11 2 2 Sector B ...

Page 194: ...ver 2009_03 Page 194 215 11 2 3 Sector C 11 2 4 Sector D ...

Page 195: ...ver 2009_03 Page 195 215 11 2 5 Sector E 11 2 6 Sector F ...

Page 196: ...ver 2009_03 Page 196 215 11 2 5 Sector G 11 2 5 Sector H ...

Page 197: ...ver 2009_03 Page 197 215 ...

Page 198: ...ystem HUDS installation Benelli engine version 1 Save provided file HUDS_Series R and S rar to the hard disk of your computer 2 Open this file from location where you ve saved it WinRAR or analog software is required 3 Select folder HUDS_Series R and S and press button Extract To on the upper bar ...

Page 199: ...xtract folder to the directory were your RAR file was saved To change destination folder use right explorer panel to choose it then press OK 5 Close WinRAR window Go to the location folder of RAR file Folder HUDS_Series R and S should appear ...

Page 200: ...ver 2009_03 Page 200 215 6 Open folder HUDS_Series R and S and start the file ServiceHSR564 exe 7 The following window should appear ...

Page 201: ...ver 2009_03 Page 201 215 8 Click OK and choose language file English or Italian are currently available press Open button ...

Page 202: ...ver 2009_03 Page 202 215 9 Next window Select device will open Choose file CNS_B1HSR_07 US_NEW dcn and click Open ...

Page 203: ...ing USB to COM adapter chapter below Using USB to COM adapter If direct COM RS 232 connection is not possible for your computer USB to COM adapter should be used to complete Diagnostic or Registration process USB to COM adapters are after market available The general view of adapter is shown on the picture ...

Page 204: ...if required to complete this setting 12 2 HSR Diagnostic Tool settings Start Diagnostic software as described above Press COM button of the upper panel The window will appear Select the COM port equal to your Adapter system settings see above and click Close button Now the HSR Diagnostic Tool should work correctly If there are any problems please contact your IT Administrator ...

Page 205: ... HUDS software as described above NOTE Check that Diagnostic cable is attached to a proper connector of vehicle with its one end and to the COM port of your computer with other end see using USB to COM adapter if necessary Attachment of Diagnostic cable to Series R connector Placed at rear left side of vehicle engine compartment close to battery Corresponding connector of wire harness is to be dis...

Page 206: ...hould appear This window should be used to complete vehicle warranty registration put VIN Chassis number 1 Engine number 2 To get the activation code for releasing ECU to full power mode please copy ECU code from field ECU_CODE 3 and insert this number during vehicle warranty registration procedure using on line B2B system see B2B 2nd generation features below 3 1 2 4 5 ...

Page 207: ...uton Fill in corresponding fields with unit s data VIN number CHASSIS NUMBER to be copied from field 1 of Line End paraneters see above Engine number to be copied from field 2 ECU number ECU CODE to be copied from field 3 Select Usage Type Enter Customer Information fields Attach invoice scanned copy proving unit s sale Click Register button to complete Registration ...

Page 208: ...s window To complete the ECU Unlocking procedure press Set Line End Parameters button 5 ECU is unlocked now vehicle could be operated in full power mode 12 4 Periodic maintenance registration process Periodic Maintenance registration NOTE In order to maintain Warranty during the warranty period it is absolutely necessary to record the maintenance based on periodic maintenance schedule in time in t...

Page 209: ...ver 2009_03 Page 209 215 To start Maintenance registration click Unit History button on the upper panel Next window view Click here Click for unit search Click to open registered units list ...

Page 210: ...ver 2009_03 Page 210 215 Registered Unit window example Scroll Unit History page to reach Maintenance field Example of Maintenance field Click to select unit Click to register new maintenance ...

Page 211: ...hours 25 hours 50 hours 75 hours etc Hours Enter vehicle current Motor Hours value Comment Add your comments if necessary ECU File Ensure the filled in HUDS file screenshot is attached ECU File Ensure the invoice for performed service scanned copy is attached Click Add maintenance entry button to save Maintenance Entry in Unit s history Maintenance Registration is complete ...

Page 212: ...ver 2009_03 Page 212 215 ...

Page 213: ...k spark plugs See Chapter Checking the spark plugs Fill approx 10 ml 0 34 oz US of clean motor oil directly through the spark plug holes Before you replace the spark plugs crank up the motor briefly with the starter Replace the spark plugs ATTENTION Never fill more motor oil than specified into the spark plug holes Too much motor oil can cause engine damage Fill the fuel tank all the way Full fuel...

Page 214: ...ver 2009_03 Page 214 215 ...

Page 215: ... Mail office hsr benelli com Directives HSR Benelli thus confirms that the construction of the engine corresponds to the following pertinent conditions EU directive about sport boats 94 25 EG with addendum 2003 44 EG USA EPA Federal Register 40 CFR Part 91 USA CARB 13 California Code of Regulation Article 4 7 Spark Ignition Marine Engines ...

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