Benelli 2009 TREK1130 Workshop Manual
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Benelli 2009 TREK1130 Workshop Manual

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Table of Contents

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ver. 01 June 2009
A
V
MANUALE OFFICINA • WORKSHOP MANUAL • MANUEL D'ATELIER •
TECHNISCHES HANDBUCH • MANUAL THE TALLER

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Summary of Contents for Benelli 2009 TREK1130

  • Page 1 ver. 01 June 2009 MANUALE OFFICINA • WORKSHOP MANUAL • MANUEL D’ATELIER • TECHNISCHES HANDBUCH • MANUAL THE TALLER...
  • Page 2 Workshop Manual 2009...
  • Page 4 TRE 1130 K WORKSHOP MANUAL 2009, Benelli Q.J. s.r.l. First Edition, June 2009 All rights reserved. Any reprinting or use without the written authorisation of Benelli Q.J. s.r.l. is forbidden.
  • Page 5 WARNING This manual has been edited by Benelli Q.J. s.r.l. mainly for use by Benelli dealers and their qualified mechanics. It is not possible to supply a mechanic with all the necessary information in a single manual. It is therefore assumed that the persons using this manual for maintenance and repair of Benelli vehicles have a basic knowledge of the mechanical principles and of the procedures concerning the repairing technique of this type of vehicle.

  • Page 6: How To Use This Manual

    HOW TO USE THIS MANUAL This manual is intended as a practical reference guide and easy to use for the mechanics. The explanations of all procedures of installation, removal, disassembly, assembly, repair and control are organized sequentially, taking one step at a time.

  • Page 7: General Information 1

    Arexons SYSTEM 52A70 STRONG THREAD BREAKS The following table refers to the sealing paste. The table shows the various specifications of AREXONS SYSTEM. Benelli recommends always using AREXONS SYSTEM Arexons SYSTEM 52A90 PENETRATING original products. Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER...
  • Page 8 INDICE GENERAL INFORMATION INFO SPECIFICATIONS SPEC ROUTINE INSPECTIONS AND ADJUSTMENTS FRAME CHAS ENGINE COOLING SYSTEM COOL ELECTRIC SYSTEM ELEC...

  • Page 11: Table Of Contents

    INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION OF MOTORCYCLE ..............MOTORCYCLE IDENTIFICATION....................FEATURES ......................INSTRUMENTATION AND LIGHTS....................MULTIFUNCTION DISPLAY ......................DISPLAY FUNCTIONS SELECTION ....................CLOCK ADJUSTMENT........................IMPORTANT INFORMATION ................PREPARATION FOR REMOVAL AND DISMANTLING OPERATIONS ........SPARE PARTS ............................GASKETS, O-RINGS, OIL RETAINER AND BEARINGS ............... SAFETY WASHERS/SAFETY PLATES, PINS AND THREAD BRAKES........
  • Page 12 INFO...

  • Page 13: Identification Of Motorcycle

    IDENTIFICATION OF MOTORCYCLE INFO MOTORCYCLE IDENTIFICATION The identification data is: • Frame number (on steering tube) • • Engine number (on lower base) • • Homologation data ( on frame) •...

  • Page 14: Features

    FEATURES INFO INSTRUMENTATION AND LIGHTS COOLING LIQUID TEMPERATURE INDICATOR It indicates the cooling liquid temperature in Celsius degrees (°C). The instruments and warning lights are activated by turning the ignition key to "ON" position. REVOLUTIONS COUNTER After an initial check-up, the information corresponds It indicates the number of engine revolutions per to the general conditions of the motorcycle at the minute expressed in miles.

  • Page 15: Multifunction Display

    FEATURES INFO MULTIFUNCTION DISPLAY SERVICE WARNING LIGHT It switches on for the first time after 1.000 Km (621 Mi) then every 10.000 Km (6.213 Mi). DISPLAY DISPLAY Every time it switches on, contact an authorised after It indicates the speed. -sales centre as soon as possible and carefully follow The value can appear in kilometres (Km/h) or in miles the indications in the maintenance and control tables...

  • Page 16: Display Functions Selection

    FEATURES INFO DISPLAY FUNCTIONS SELECTION "TOTAL"/ "TRIP" N OTE: The amendment or adjustment operations of the display functions must be carried out after three seconds from engine start-up, without subsequently activating the clutch lever (Start>2sec) The display is provided with 3 primary functions: “Total”/ ”Trip”...

  • Page 17: Clock Adjustment

    FEATURES INFO CLOCK ADJUSTMENT To switch from display. Press the START button (> 2 sec.); the first hour digit starts to flash. Repeatedly press the START button to adjust the digit until the wanted digit is reached. Press the START button (> 2 sec.) to adjust the next digit.

  • Page 18: Important Information

    IMPORTANT INFORMATION INFO PREPARATION FOR REMOVAL AND DISMANTLING OPERATIONS Before carrying out the dismantling operations, remove any dirt, mud, dust and foreign bodies. Only use appropriate cleaning tools and products. See the "SPECIAL TOOLS" paragraph. D D uring dismantling of the vehicle, we recommend always keeping the coupled parts together.

  • Page 19: Spare Parts

    IMPORTANT INFORMATION INFO SPARE PARTS Only use original Benelli spare parts. To lubricate the components, use oils and greases recommended by Benelli. Other brands may be similar in aspect and function, but of lower quality.

  • Page 20: Gaskets, O-Rings, Oil Retainer And Bearings

    IMPORTANT INFORMATION INFO GASKETS, O-RINGS, OIL RETAINER AND BEARINGS Engine Always replace all gaskets, oil retainers and the O-Rings during the engine repair interventions. The surfaces of the gaskets, the oil retainers lips and the O-Rings must always be kept clean. spring During installation, suitably oil all parts subject to coupling and the bearings, and lubricate the oil...

  • Page 21: Safety Washers/Safety Plates, Pins And Thread Brakes

    IMPORTANT INFORMATION INFO SAFETY WASHERS/SAFETY PLATES, PINS AND THREAD BRAKES After the removal, replace all safety washers/safety plates and the pins. After having fastened the bolt or the nut, according to specifications, fold the locking flaps and the ends of the split pin against the bolt or nut surfaces. Whenever applying thread brakes, previously remove grease from both sides using solvent.

  • Page 22: Safety Elastic Rings

    IMPORTANT INFORMATION INFO SAFETY ELASTIC RINGS Before assembling them, accurately check all elastic rings and replace the damaged or deformed ones. Always replace the elastic rings of the piston pin after having used them once. If installing an elastic ring , ensure that the pointed angle positioned on the other side compared to the push it receives.

  • Page 23: Connections Control

    CONNECTIONS CONTROL INFO CONNECTIONS CONTROL Check there are no stains, rust, humidity, etc. on the cables, the couplers and the connectors. Disconnect: • the wire • the coupler • the connector Check: • the wire • the coupler • the connector If there are traces of humidity Dry using a fan.

  • Page 24: Special Tools

    SPECIAL TOOLS INFO SPECIAL TOOLS The special tools shown here are used for the full and accurate execution of the set-up and assembly operations.Their use will help prevent damages caused by the use of unsuitable tools or improvised techniques.When filling in an order, consult the list below to avoid errors.
  • Page 25 SPECIAL TOOLS INFO ENGINE SPECIAL TOOLS Tool Code Name - Tool Function Illustration Phonic Wheel Removal R300097083000 This tool is used to block the phonic wheel, both during removal and during installation Buffer For Valves Oil Retainer R180197025000 This tool is used to install the valve oil retainer in the seat Cylinder Assembly Thicknesses R180197018000...
  • Page 27 SPEC CHAPTER 2 TECHNICAL DATA GENERAL SPECIFICATIONS ................... GENERAL SPECIFICATIONS ......................TECHNICAL DATA ....................ENGINE SPECIFICATIONS ....................... FRAME SPECIFICATIONS ......................... ELECTRIC SPECIFICATIONS......................FASTENING TORQUES ................... GENERAL FASTENING SPECIFICATIONS..................FASTENING TORQUES AND RELATIVE PRELOADS FOR STANDARD CONNECTIONS ..ENGINE FASTENING TORQUES ..................... FRAME FASTENING TORQUES .....................
  • Page 28 SPEC...

  • Page 29: General Specifications

    GENERAL SPECIFICATIONS SPEC GENERAL SPECIFICATIONS SIZES STANDARD Total length 2183 mm (85.9 in) Total width 850 mm (33.4 in) Total height 1320 mm (51.9 in) Seat height 810 mm (31.8 in) Interaxis 1514 mm (59.6 in) WEIGHT STANDARD In start order (with full oil and fuel tank) 240 Kg (529 lb) Empty (with empty oil and fuel tank) 215 Kg (473 lb)

  • Page 30: Technical Data

    TECHNICAL DATA SPEC ENGINE SPECIFICATIONS ENGINE STANDARD 3 cylinders in line, 4 stroke, Type of engine liquid cooling, 4 valves per cylinder, double cam axis on head with balancing counter shaft Engine displacement 1131 cc Number of cylinders in line, tilted forward by 15° Cylinders arrangement with anti-vibrations countershaft 88 x 62 mm (3.4 x 2.4 in)
  • Page 31 TECHNICAL DATA SPEC SPARK PLUGS STANDARD Model (manufacturer) x quantity CHAMPION RG4HC\NGK CR9EK Distance between the electrodes 0.7 ÷ 0.8 mm CYLINDERS HEAD STANDARD Maximum twist 0.1 mm CAM SHAFTS STANDARD Command system chain transmission Cam shafts supports diameter 22.459 ~ 22.472 mm (0.8842 ~ 0.8847 in) Clearance between support and cam shaft cap 0.1 mm (0.0039 in) max Inlet side cam shaft lobes sizes...
  • Page 32 TECHNICAL DATA SPEC VALVES, VALVE CONE, VALVE GUIDES STANDARD Inlet valves clearance (when cold) 0.25 ~ 0.30 mm (0.009 ~ 0.011 in) 0.30 ~ 0.35 mm (0.011 ~ 0.013 in) Drain valves clearance (when cold) Valves sizes Ø 33 mm (1.29 in) Inlet Drain Ø...
  • Page 33 TECHNICAL DATA SPEC PISTON STANDARD Clearance between piston and cylinder 0.05 ~ 0.07 mm (0.0019 ~ 0.0027 in) Piston diameter 88 mm (3.46 in) Piston height 10.5 mm (0.41 in) 19.01 mm (0.748 in) Pin seat diameter Piston pin external diameter 18.96 mm (0.746 in) Upper band elastic...
  • Page 34 TECHNICAL DATA SPEC CLUTCH STANDARD Type of clutch oil bath clutch, multiple disks Clutch release method cable with springs Activation for clutch release activation with cable Activation with left handle bar lever Clutch cable clearance (near 3 ~ 5 mm (0.11 ~ 0.19 in) clutch lever end) Friction disks thickness 3 mm (0.11 in)

  • Page 35: Frame Specifications

    TECHNICAL DATA SPEC FRAME SPECIFICATIONS FRAME STANDARD with steel-aluminium mixed structure trellis Type of frame Steering tube inclination 25° Forward run 103.5 mm (4.07 in) FRONT WHEEL STANDARD with 5 wires Type of wheel Measurement 17 M/C x MT3.5 aluminium Material Wheel run 150 mm (5.9 in)
  • Page 36 TECHNICAL DATA SPEC FRONT BRAKE STANDARD LIMIT Type of brake double disk brake Activation with right hand Recommended liquid DOT 4 Brake disks 320 x 4 mm (12.5 x 0.15 in) Diameter x Thickness Minimum thickness 4.0 mm (0.15 in) Maximum deformation 0.1 mm (0.004 in) Worn brake pads...
  • Page 37 TECHNICAL DATA SPEC REAR SUSPENSION STANDARD oscillating swing arm with Type of suspension spiral spring/gas shock absorber Fork excursion 145 mm (5.7 in) Spring 160 mm (6.29 in) Free length 137 mm (5.39 in) Installed length Flexibility (K1) 9.5 Nm (0.96 Kgf•m) 61 mm (2.4 in) Spring run (K1) Spring pre-load gas/air standard pressure...

  • Page 38: Electric Specifications

    TECHNICAL DATA SPEC ELECTRIC SPECIFICATIONS PLANT VOLTAGE STANDARD PLANT VOLTAGE 12 V IGNITION REELS STANDARD Model (manufacturer) 02IG001 (JCI) Primary real resistance Ω 10 kΩ Secondary reel resistance Primary reel inductance 2.5 mH (1 kHz 0.3V) Secondary reel inductance 23.5 mH (1kHz) 7.6 A Max.
  • Page 39 TECHNICAL DATA SPEC ELECTRIC START-UP SYSTEM STANDARD Model (manufacturer) 5-128-330 (DENSO) Supplied power 0.7 kw ACOUSTIC WARNING DEVICE STANDARD Type of acoustic warning device flat Model (manufacturer) DL 123 (LI XIANG CHINA) Maximum amperage Performances 105 ~ 118 db (A) FLASHING LIGHTS RELAY STANDARD Type of relay...
  • Page 40 TECHNICAL DATA SPEC LIQUID TEMPERATURE SENSOR STANDARD Model (manufacturer) 16TT001 (JCI) Resistance Ω Ω 2500 20 C°, 322.5 80 C° SPEED SENSOR STANDARD Model (manufacturer) SNVO21F0001/0 (EUROSWITCH) LAMBDA STANDARD Model (manufacturer) OPS + 25324175 (DELPHI) INJECTOR STANDARD Model (manufacturer) U9122-357 (JCI) RELAY UNIT STANDARD Model (manufacturer)

  • Page 41: Fastening Torques

    FASTENING TORQUES INFO GENERAL FASTENING SPECIFICA- TIONS The fastening torques of the components or of the special sets are shown in each chapter of this manual. With regard to the sets with multiple fixing elements, in order to avoid the risk of twisting, carry out fastening in a crossed manner, in successive steps, until the prescribed torque is reached.

  • Page 42: Fastening Torques And Relative Preloads For Standard Connections

    FASTENING TORQUES INFO FASTENING TORQUES AND RELATIVE PRE-LOADS FOR STANDARD CONNECTIONS The values shown in the following table refer to standard fastenings, meaning regarding the coupled metric screws with relative nut or with metal female screw. Furthermore, the bodies to be fastened must be made of metal or sufficiently stiff not to require bushes interpositions or spacers.

  • Page 43: Engine Fastening Torques

    FASTENING TORQUES SPEC ENGINE FASTENING TORQUES FASTENING TORQUES BASE THREAD Kgf•m Base Fixing TEF Screw 1.01 Base Fixing Screw 2.54 Base Benches Fixing TCEI Screw 4.58 Oil Conducts Closing Conical Grain 1.01 Bearings And Pin Fixing Screw 1.01 Plates And Tube Fixing Screw 1.01 Cylindrical Cap 2.54...
  • Page 44 FASTENING TORQUES SPEC FASTENING TORQUES DISTRIBUTION THREAD Kgf•m Distribution Gear Fixing Screw 1.52 Upper Slide Support Fixing Screw 1.52 Reel Fixing Distribution Lid Screw 1.01 Distribution Lid Screw 1.01 Mobile Slide Pin 1.32 FASTENING TORQUES CLUTCH THREAD Kgf•m Clutch Rod Adjustment Low Hexagonal Nut 1.63 Clutch Springs Fixing Screw 1.01...
  • Page 45 FASTENING TORQUES SPEC FASTENING TORQUES POWER SUPPLY THREAD Kgf•m Throttled Body Fixing Screw 1.01 Petrol Flute Fixing Screw 1.01 Pull Power Limit Device Plate Fix Screw Petrol Tube Fitting 2.03 Stepper Seat Fixing Screw By hand 1.01 Gas Cables Plate Fixing Screw 1.01 Minimum Adjustment Cable FASTENING TORQUES...

  • Page 46: Frame Fastening Torques

    FASTENING TORQUES SPEC FRAME FASTENING TORQUES FASTENING TORQUES BODY WORK THREAD Kgf•m Engine Protection Fixing Screw 8/10 0.81/1.01 Pinion Carter Upper Fixing Screw 1.01 Pinion Carter Lower Fixing Screw 2.24 Tank Lid Front Fixing Screw 8/10 0.81/1.01 Tank Lid Rear Fixing Screw 8/10 0.81/1.01 Fairing Support Bracket Fixing Screw...
  • Page 47 FASTENING TORQUES SPEC FASTENING TORQUES FRONT BRAKING PLANT THREAD Kgf•m Fitting Screw M10X1 1.52 Callipers Fixing Screw M10X1.25 4.07 Bleeding Screw By hand Pump Strap Fixing Screw 0.81 FASTENING TORQUES REAR SUSPENSION THREAD Kgf•m Articulated Connecting Rods Fixing Screw M10X1.25 4.07 Balancing Device Fixing Special Screw On Frame 6.11...
  • Page 48 FASTENING TORQUES SPEC FASTENING TORQUES FRAME THREAD Kgf•m Plates Closing Lower Pin On Engine M10X1.25 4.07 Plates Closing Upper Pin On Engine M10X1.25 4.07 Left Fixing Screw On Head M12X1.25 4.07 Right Register Screw On Head M12x1.25 4.07 Large Handle Fixing Screw By hand Small Frame Rear Fixing Screw 2.54...
  • Page 49 FASTENING TORQUES SPEC FASTENING TORQUES ELECTRIC PLANT THREAD Kgf•m Control Unit Fixing Screw By hand Front Pins Small Plate Fixing Nut 0.81 Remote Control Switch Small Plate Fixing Nut 1.01 Acoustic Warning Device Fixing Screw 8/10 0.81/1.01 Inertial Switch Small Plate Fixing Screw 8/10 0.81/1.01 Clutch Sensor...

  • Page 50: Lubrication Points And Types Of Lubricant

    LUBRICATION POINTS AND TYPES OF LUBRICANT SPEC LUBRICATION POINTS AND TYPES OF ENGINE LUBRICANT LUBRICATION POINT LUBRICANT Oil Retainers Lips O-Ring Bearings Connecting Rod Supports Pistons Surfaces Pistons Pins Cylinder Wall Bench Supports Cam Shafts Lobes Cam Shafts Supports Valve Stems (Inlet And Drain) Valve Stems Ends (Inlet And Drain) Oil Pump Rotors (Internal And External) Oil Pump Slot...

  • Page 51: Lubrication Points And Types Of Frame Lubricant

    LUBRICATION POINTS AND TYPES OF LUBRICANT SPEC LUBRICATION POINTS AND TYPES OF FRAME LUBRICANT LUBRICATION POINT LUBRICANT Steering Bearings And Bearings Tracks (Upper And Lower) Brake Lever Pivoting Point And Metal Parts Subject To Contact In Motion Clutch Lever Pivoting Point And Metal Parts Subject To Contact In Motion Engine Support Bolts (Upper Rear And Lower Rear) Shock Absorber Fixing Screws Bearing And Swing Arm Oil Retainer...

  • Page 52: Cooling System Layouts

    COOLING SYSTEM LAYOUTS SPEC COOLING SYSTEM LAYOUTS Radiator Fan Radiator Connection - Expansion Vessel Radiator Hot Water Outlet Tube Water Pump Pump Flow Tube Expansion Vessel Pump Supply Tube Thermostat disk Recovery Tub Vent Water/Oil Exchanger Oil Filter...
  • Page 53 COOLING SYSTEM LAYOUTS SPEC Radiator Fan Radiator Connection - Expansion Vessel Radiator Hot Water Outlet Tube Expansion Vessel Recovery Tub Vent Thermostat disk Cold Water Inlet Tube On Exchanger Water/Oil Exchanger Hot Water Outlet Tube From Exchanger Oil Filter...
  • Page 55 CHAPTER 3 ROUTINE INSPECTIONS AND ADJUSTMENTS INTRODUCTION...................... INTRODUCTION..........................ROUTINE MAINTENANCE AND LUBRICATION INTERVALS......... ROUTINE MAINTENANCE AND LUBRICATION INTERVALS ..........ENGINE ........................IGNITION SPARK PLUGS REMOVAL ..................... IGNITION SPARK PLUGS CONTROL ..................... IGNITION SPARK PLUGS INSTALLATION..................AIR BOX REMOVAL..........................AIR FILTERING ELEMENT REPLACEMENT................... AIR BOX INSTALLATION........................
  • Page 56 TRANSMISSION CHAIN LUBRICATION..................STEERING TUBE CONTROL AND ADJUSTMENT..............TRANSMISSION GEARS CONTROL AND REPLACEMENT............FRONT FORK CONTROL........................REAR SHOCK ABSORBER SET ADJUSTMENT................TYRES CONTROL..........................WHEELS CONTROL..........................CABLES CONTROL AND LUBRICATION..................LEVERS AND PEDALS LUBRICATION................... SIDE TRESTLE LUBRICATION......................REAR SUSPENSION LUBRICATION....................ELECTRIC PLANT....................BATTERY CHARGE AND CONTROL....................

  • Page 58: Introduction

    INTRODUCTION INTRODUCTION This chapter includes all information necessary to carry out recommended inspections and adjustments. These preventive maintenance procedures, if complied with, guarantee a more reliable functioning, longer lasting of the vehicle and will limit the need for expen- sive revision operations. This information is valid for both the already working vehicles, and for the under construction vehicles for sale.

  • Page 59: Routine Maintenance And Lubrication Intervals

    Reached 40.000 Km (24.854 mi), repeat the service voucher system starting from that of 10.000 Km (6.213 mi). For interventions relating to the marked items, we recommend contacting a Benelli dealer, given that it is necessary to use special tools, particular information and specific technical abilities.
  • Page 60 ROUTINE MAINTENANCE AND LUBRICATION INTERVALS 1000 Km 10000 Km 20000 Km 30000 Km 40000 Km 0 Km MAINTENANCE CONTROLS (621 mi) (6213 mi) (12427 mi) (18641 mi) (24854 mi) ANNUAL COMPONENT (0 mi) OR INTERVENTIONS CONTROL PRE-DELIVERY VOUCHER VOUCHER VOUCHER VOUCHER VOUCHER Control/Replacement...
  • Page 61 ROUTINE MAINTENANCE AND LUBRICATION INTERVALS 1000 Km 10000 Km 20000 Km 30000 Km 40000 Km 0 Km MAINTENANCE CONTROLS (621 mi) (6213 mi) (12427 mi) (18641 mi) (24854 mi) ANNUAL COMPONENT (0 mi) OR INTERVENTIONS CONTROL PRE-DELIVERY VOUCHER VOUCHER VOUCHER VOUCHER VOUCHER Control/Functioning...
  • Page 62 ROUTINE MAINTENANCE AND LUBRICATION INTERVALS N OTE: • AIR FILTER • The air filter must be replaced more often when the vehicle is used in particularly dusty and humid areas. • HYDRAULIC BRAKE MAINTENANCE • Regularly check the brakes liquid level and, if necessary, top-up. •...

  • Page 63: Engine

    ENGINE/IGNITION SPARK PLUGS IGNITION SPARK PLUGS REMOVAL The following procedure is applied to all ignition spark plugs. WARNING The replacement and check of the spark plugs must be carried out with the engine cold. Remove: • i • the right and left tank lids See "FRAME 4.112"...

  • Page 64: Ignition Spark Plugs Control

    ENGINE/IGNITION SPARK PLUGS IGNITION SPARK PLUGS CONTROL The following procedure is applied to all ignition spark plugs. Check: • the type of ignition spark plug Incorrect Change Type of ignition spark plug (manufacturer) RG4HC (CHAMPION) or CR9EK (NGK) Check: • the electrodes •...
  • Page 65 ENGINE/IGNITION SPARK PLUGS Clean: • the ignition spark plug ( (using a detergent for spark plugs or a metal brush) Measure: • the distance between the electrodes (using a feeler) If out of specification Restore the correct distance Distance between the electrodes 0.7 ~ 0.8 mm (0.02 ~ 0.03 in)

  • Page 66: Ignition Spark Plugs Installation

    ENGINE/IGNITION SPARK PLUGS IGNITION SPARK PLUGS INSTALLA- TION The following procedure is applied to all ignition spark plugs. WARNING Lubricate the spark plug threading. Recommended lubricant GRASSO AL RAME NOTE: Before installing the spark plug, clean it and the surface in contact with the gasket. 1 Install: •...

  • Page 67: Air Box Removal

    ENGINE/AIR BOX AIR BOX REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Seat Removal See "FRAME 4.130" paragraph. Tank Removal See "FRAME 4.118" paragraph. Air Box Removal Screw Filter Box Lid Gasket Check Net Filtering Element Check Net Screw Seeger...

  • Page 68: Air Filtering Element Replacement

    ENGINE/AIR BOX AIR FILTERING ELEMENT REPLACE- MENT Remove: • the seat See "FRAME 4.130" paragraph. • the tank See "FRAME 4.118" paragraph. Remove: • the 9 screws • the filter box lid • the filtering element See paragraph "3.10". ATTENTION Replace the air filter element every 20.000 Km (12.427 mi).
  • Page 69 ENGINE/AIR BOX Install: • the filter box lid • the 9 screws See paragraph "3.13" WARNING Never start the engine if the air filter is not installed. The unfiltered air causes rapid wearing of the engine parts and it may damage the engine. Furthermore, by running the engine without the air filter influences negatively on the setting up of the throttle bodies, and this entails a deterioration of...

  • Page 70: Air Box Installation

    ENGINE/AIR BOX AIR BOX INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Air Box Installation Conveyor Washer Inlet Conduct Rubber Pad Cable Gland Air Filter Box Screw Manually fasten. Blow By Tube Strip Tighten. Throttled Bodies Strip Tighten.

  • Page 71: Wired Actuator Control

    ENGINE/WIRED ACTUATOR WIRED ACTUATOR CONTROL Start: • the bike • and check with a few gas revolutions that the drain throttle works as shown in the illustration. If the inlet and drain throttles do not perform the correct closing cycle, it is necessary to remove the wired actuator.
  • Page 72 ENGINE/WIRED ACTUATOR CONTROL 2 If the control of the wired actuator is not sufficient for the correct throttle closing cycle, check the cables clearance adjustment. Loosen: • the nuts of the drain valve regulator (on 3 in 1 exhaust pipe) Adjust: •...

  • Page 73: Accelerator Cable Clearance Adjustment

    ENGINE/ACCELERATOR CABLE CLEARANCE ACCELERATOR CABLE CLEARANCE ADJUSTMENT N OTE: Before adjusting the accelerator cable clearance, adequately adjust the minimum power of the engine. Initially check at 1000 Km (621 mi) and subsequent- ly every 10.000 Km (6.213 mi). Check: • the accelerator cable clearance Check that the accelerator command grip works regularly and that it is possible to reach the maximum opening and automatic closing positions from all...

  • Page 74: Clutch Cable Clearance Adjustment

    ENGINE/CLUTCH CABLE CLEARANCE CLUTCH CABLE CLEARANCE ADJUSTMENT Check: • the clutch cable clearance If out of specification Adjust. Clutch cable clearance (at the end of the clutch lever) 3 ~ 5 mm (0.11 ~ 0.19 in) Adjust: • the clutch cable clearance Handle bar side Rotate the adjusting disk direction, until clearance of the specified clutch...

  • Page 75: Clutch Disks Adjustment

    ENGINE/CLUTCH DISKS CLUTCH DISKS ADJUSTMENT Position: • the bike on side trestle to avoid oil leaking. Remove: • the clutch lid See “ENGINE 5.69” paragraph. N OTE: Before adjusting the clutch disks, free the lower clutch command of the clutch cable. Check every 10000 Km.

  • Page 76: Exhaust Gas Adjustment

    ENGINE/EXHAUST GAS EXHAUST GAS ADJUSTMENT Remove: • the seat See "FRAME 4.130" paragraph. Remove: • the cap of the diagnostics socket Connect: • the diagnostics instrument to the socket positioned underneath the seat Special Tools: ENGINE INJECTION HANDLING DIAGNOSTICS INSTRUMENT - AXONE 2000 Code: R180197036000 Special Tools: ENGINE INJECTION HANDLING DIAGNOSTICS INSTRUMENT - BENDIA SCANTOOL...
  • Page 77 ENGINE/EXHAUST GAS Start: • the engine taking it to approx. 95°C. Check: • the lambda probe value Lambda Probe Value “1.00” VALUE GREATER THAN “1.00” VALUE LOWER THAN “1.00” If the lambda probe value shown on the display is greater than If the lambda probe value shown on the display is lower than "1.00", decrease the "CO%"...
  • Page 78 ENGINE/EXHAUST GAS Install: • the diagnostics socket cap Install: • the seat See "FRAME 4.131" paragraph.

  • Page 79: Throttled Body Adjustment

    ENGINE/THROTTLED BODY THROTTLED BODY ADJUSTMENT N OTE: Before synchronising the throttle bodies, suitably regulate the valves clearance and the engine minimum power. Engine Minimum Power 1250 ~ 1350 r/min. N OTE: Check and execute the alignment of the throttled body with engine temperature at approx. 90/95°C. Park: •...
  • Page 80 ENGINE/THROTTLED BODY Install: • the vacuum meter directly on to the fittings of the throttled body of the previously disconnected stepper air passages tubes. U L T I Special Tools: VACUUM METER Bil a ncia m en to fa rfall e giri/mi n 1250 Code: R300097170000...
  • Page 81 ENGINE/THROTTLED BODY C C orrect: • the alignment values using a screwdriver on the pair screws Align body 1 with body 2 by acting on the pair screw Align body 2 with body 3 by acting on the pair screw NOTE: Having reached an optimal alignment on the 3 bodies, it is possible to perfect the correction by...

  • Page 82: Stepper Removal

    ENGINE/STEPPER STEPPER REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Seat Removal See "FRAME 4.130" paragraph. Tank Removal See "FRAME 4.118" paragraph. Air Box Removal See paragraph "3.10". Stepper Removal Screw Click Strip Loosen. Minimum Air Tube Disconnect.

  • Page 83: Stepper Control

    ENGINE/STEPPER STEPPER CONTROL Check: • the stepper In the presence of breaks and/or deformations Replace. • the distributor In the presence of obstructions Replace. • the free sliding between the piston and the distributor In case of forced sliding Replace the distributor. •...

  • Page 84: Stepper Installation

    ENGINE/STEPPER STEPPER INSTALLATION Axerons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Stepper Installation O-Ring Gasket Distributor O-Ring Gasket Step-by-Step Motor Anti-vibration Rubber Pad Bush Special Plate Screw Manually fasten. Screw Manually fasten. Click Strip Tighten.
  • Page 85 ENGINE/VALVES CLEARANCE AND CALIBRATED PADS VALVES CLEARANCE ADJUSTMENT AND CALIBRATED PADS REPLACEMENT The following procedure is applied to all valves. N OTE: The adjusting of the valves clearance must be carried out with the engine cold, at ambient temperature and with the engine in PMS. Remove: •...
  • Page 86 ENGINE/VALVES CLEARANCE AND CALIBRATED PADS M M easure: • the valves clearance using a feeler positioning the cam as shown in the illustration. If out of specification Adjust. Valves Clearance Inlet Valve 0.25 ~ 0.30 mm (0.009 ~ 0.011 in) Drain Valve 0.30 ~ 0.35 mm (0.011 ~ 0.013 in) N OTE:...
  • Page 87 ENGINE/VALVES CLEARANCE AND CALIBRATED PADS NOTE: R R emove: During removal of the cam shafts, tighten a metal • the upper chain slide wire to the distribution chain to be able to recover • the drain/inlet/central headgears it in case it should fall in the base. •...
  • Page 88 ENGINE/VALVES CLEARANCE AND CALIBRATED PADS NOTE: Take note of the position of each valve lifter and of each calibrated pad to be able to re- assemble them correctly. DRAIN INLET M M easure: • the calibrated pad If out of specification Replace it until the correct clearance is reached.
  • Page 89 ENGINE/VALVES CLEARANCE AND CALIBRATED PADS Install: • the new drain/inlet calibrated pads • the new drain/inlet valves lifters See "ENGINE 5.33" paragraph. Check: • the valves clearances If out of specification Repeat the operations in the table. NOTE: • • Lubricate the calibrated pad using engine oil. •...
  • Page 90 ENGINE/VALVES CLEARANCE AND CALIBRATED PADS M M easure: • the valves clearance again If still out of specification Repeat the entire adjustment procedure until clearance is obtained. 14 Install: • the chain tensioner • the spring of the chain tensioner See “ENGINE 5.7”...

  • Page 91: Engine Minimum Power Adjustment

    ENGINE/ENGINE MINIMUM POWER ENGINE MINIMUM POWER ADJUST- MENT N OTE: Before adjusting the engine minimum power, adjust the throttled bodies and check that the engine has a suitable compression. Remove: • the seat See "FRAME 4.130" paragraph. 2 Remove: • the cap of the diagnostics socket Connect: •...
  • Page 92 ENGINE/ENGINE MINIMUM POWER 4 Check: • the engine minimum power If out of specification Adjust. Engine Minimum Power 1250 ~ 1350 r/min. Adjust: • the engine minimum power Rotate the minimum adjusting screw direction, until specified engine minimum power is obtained. DIRECTION The engine minimum power decreases DIRECTION...
  • Page 93 ENGINE/ENGINE MINIMUM POWER Install: • the diagnostics socket cap 10 Install: • the seat See "FRAME 4.131" paragraph.

  • Page 94: Engine Oil Level Control

    ENGINE/ENGINE OIL ENGINE OIL LEVEL CONTROL P P ark: • the bike levelled. NOTE: • • Place the bike on a suitable trestle. • Ensure that the bike is in straight position. Start: • the engine leave it to warm up for a few minutes, then turn it off. ATTENTION Do not start the engine if the oil is underneath MIN reference.
  • Page 95 ENGINE/ENGINE OIL To top-up with engine oil loosen: • the oil cap with the engine off Pour an amount of recommended oil until half the inspection hole between the MAX and MIN reference is reached. ATTENTION • Given that the engine oil also lubricates the clutch, if of unsuitable type or if containing additives, it may cause the sliding of the clutch.

  • Page 96: Engine Oil Change And Filter Replacement

    ENGINE/ENGINE OIL AND FILTER ENGINE OIL CHANGE AND FILTER REPLACEMENT Start: • the engine leave it to warm up for a few minutes, then turn it off. Remove: • the engine protection See "FRAME 4.120" paragraph. 3 Position: • a suitable container underneath the magnetic cap for the recovery of the engine oil.
  • Page 97 ATTENTION Only use the Benelli original oil filter (code R180107114000). Other brands of oil filters may differ with regard to the threading (diameter and step). The filtering performances and duration with consequent possible damages to the engine or oil leaks.
  • Page 98 ENGINE/ENGINE OIL AND FILTER Replace: • the gasket of the magnetic cap Install: • the new gasket • the magnetic cap Torque fasten: 22 N m - 2.24 Kgf•m Fill: • the base with recommended and specified amount of engine oil.

  • Page 99: Cooling Liquid Control

    ENGINE/COOLING LIQUID COOLING LIQUID CONTROL Park: • the bike levelled. NOTE: • • Place the bike on a suitable trestle. • Ensure that the bike is in straight position. Check: • the cooling liquid level the cooling liquid level must be between the maximum level reference (MAX) and that of the minimum level (MIN)
  • Page 100 ENGINE/COOLING LIQUID 5 Fill: • the cooling system (using the top-up nozzle up to the end of the same) ATTENTION • By adding water instead of cooling liquid, the percentage of anti-freeze contained in the cooling liquid decreases. If water is used instead of cooling liquid check, and eventually correct, the concentration of anti- freeze in the liquid.

  • Page 101: Cooling Liquid Change

    ENGINE/COOLING LIQUID COOLING LIQUID CHANGE Park: • the bike levelled. NOTE: • • Place the bike on a suitable trestle. • Ensure that the bike is in straight position. • Carry out the following operations with the engine cold. Remove: •...
  • Page 102 ENGINE/COOLING LIQUID Remove: • the liquid drain screw on the pump • the copper washer Drain: • the cooling liquid leave the liquid to flow completely 7 Install: • the copper washer • the liquid drain screw on the pump N OTE: Always replace the copper washer with a new one.
  • Page 103 ENGINE/COOLING LIQUID WARNING • The cooling liquid top-up must always be carried out with a cold engine. Never attempt to remove the radiator cap when the engine is hot to avoid the risk of burns. The circuit is pressurised. • If the cooling liquid should come into contact with the eyes, accurately rinse them with water and contact a doctor.
  • Page 104 ENGINE/COOLING LIQUID 11 Start: • the engine leave it to warm up for a few minutes, then turn it off. 12 Check: • the cooling liquid level See paragraph "3.42". N OTE: Before checking the cooling liquid level, wait a few minutes for it to gather inside the expansion vessel.

  • Page 105: Fuel Tube Control And Replacement

    ENGINE/FUEL TUBE FUEL TUBE CONTROL AND REPLACE- MENT Remove: • the seat See "FRAME 4.130" paragraph. • the tank See "FRAME 4.118" paragraph. • the air box See paragraph "3.10". 2 Check: • the fuel tube In the presence of cracks/damages Replace.
  • Page 106 ENGINE/FUEL TUBE 5 Replace: • the fuel tube Install: • the 2 washers • the screw Release: • the special tool Hook: • the new fuel tube Install: • the air box See paragraph "3.13". • the tank See "FRAME 4.119" paragraph. N OTE: To install the tank, check that the fuel tube is not bent or crushed by the same tank.

  • Page 107: Drain Plant Control And Replacement

    ENGINE/DRAIN PLANT DRAIN PLANT CONTROL AND REPLACEMENT The following procedure is applied to all drain tubes and gaskets. WARNING Do not touch the silencing device bracket until the drain plant has cooled down. 1 Check: • the exhaust pipes • the drain valve tube •...
  • Page 108 ENGINE/DRAIN PLANT Disconnect: • the lambda probe connector See "ELECTRIC PLANT 7.13" paragraph. • the drain valve cable See "FRAME 4.157" paragraph. Remove: • the entire drain unit See "FRAME 4.155" paragraph. Replace: • the interested component with a new one. 6 Install: •...

  • Page 109: Cooling System Control And Replacement

    ENGINE/COOLING SYSTEM COOLING SYSTEM CONTROL AND REPLACEMENT Remove: • the alternator lid See "FRAME 4.120" paragraph. • the right and left tank lids See "FRAME 4.112" paragraph. • the tank See "FRAME 4.118" paragraph. Check: • the radiator • the radiator inlet tube •...

  • Page 110: Frame

    FRAME/FRONT BRAKE ADJUSTMENT FRONT BRAKE ADJUSTMENT Adjust: • the position of the brake lever (distance between the accelerator knob and the brake lever). NOTE: Push the brake lever forward to neutralise the push of the spring and simultaneously adjust the posi- tion by turning the ring nut clockwise or anti- clockwise, until the brake lever is in the wanted...

  • Page 111: Rear Brake Adjustment

    FRAME/REAR BRAKE ADJUSTMENT REAR BRAKE ADJUSTMENT Adjust: • the position of the brake pedal Loosen the nut and lock nut Tighten or loosen the threaded pin to increase or decrease the rear brake command clearance. the clearance increases TIGHTENING the clearance decreases LOOSENING Tighten the nut Fasten the lock nut...

  • Page 112: Brakes Liquid Level Control

    FRAME/BRAKES LIQUID LEVEL CONTROL BRAKES LIQUID LEVEL CONTROL P P ark: • the bike levelled NOTE: • • Place the bike on a suitable trestle. • Ensure that the bike is in straight position. C C heck: • the brakes liquid level If below the minimum level notch Top-up to the correct level using the recommended brakes...

  • Page 113: Front And Rear Brake Pads Control

    FRAME/FRONT AND REAR BRAKE PADS CONTROL FRONT AND REAR BRAKE PADS CONTROL The following procedure is applied to all brakes pads. A A ctivate: • the brake Check: • the front brake pad • the rear brake pad • the wear limit of the front brake pads and rear Wear limit reached Replace all brake pads.

  • Page 114: Braking Plant Flexible Tubes Control

    FRAME/BRAKING PLANT FLEXIBLE TUBES CONTROL BRAKING PLANT FLEXIBLE TUBES CONTROL The following procedure is applied to all brakes flexible tubes and to the brakes tubes clamps. C C heck: • the brake flexible tube In the presence of cracks/damages/wear lines Replace.

  • Page 115: Hydraulic Braking System Bleeding

    FRAME/HYDRAULIC BRAKING SYSTEM BLEEDING HYDRAULIC BRAKING SYSTEM BLEEDING WARNING Bleed the hydraulic braking system every time that: • the system has been dismantled. • a flexible tube of the brake is loosened, disconnected or replaced. • the brakes liquid level is very low. •...
  • Page 116 FRAME/HYDRAULIC BRAKING SYSTEM BLEEDING Fill the brakes liquid tub to the correct level using the recommended brakes liquid. WARNING • Use only the prescribed brakes liquid. Other brakes liquids may be cause of deterioration of the rubber gaskets, causing leaks and unsuitable functioning of the braking system.
  • Page 117 FRAME/HYDRAULIC BRAKING SYSTEM BLEEDING Fill the brakes liquid tub to the correct level using the recommended brakes liquid. See paragraph "3.55". WARNING After having bled the hydraulic braking plant, check the functioning of the brakes. N OTE: After having bled the air, brake liquid may drip on the threaded section of the bleeding screw.

  • Page 118: Gear Change Pedal Adjustment

    FRAME/GEAR CHANGE PEDAL ADJUSTMENT ADJUSTMENT OF PEDAL OF THE GEAR CHANGE Adjust: • the position of the gear change pedal Remove the nut and the screw Loosen the two nuts of the rod Rotate the gears command rod clockwise or anti-clockwise. the gear change pedal is lowered CLOCKWISE the gear change pedal is lifted...

  • Page 119: Transmission Chain Loosening Regulating

    FRAME/TRANSMISSION CHAIN ADJUSTMENT TRANSMISSION CHAIN LOOSENING ADJUSTMENT N OTE: Do not inspect or adjust the transmission chain with the engine running. N OTE: Check the loosening of the transmission chain where it seems more tensed. WARNING If the transmission chain is too tense, the engine and other vital parts will be overloaded, whereas if it is too loose, it can come away and damage the suspension arm or cause an accident.
  • Page 120 FRAME/TRANSMISSION CHAIN ADJUSTMENT Adjust: • the loosening of the transmission chain Loosen the eccentric locking screws on both sides of the swing arm. Insert the specific tool inside the eccentric. Special Tools: TRANSMISSION CHAIN REGULATOR SPANNER Code: R300097147000 Rotate the eccentrics in direction until the specified loosening degree for the transmission chain is obtained.

  • Page 121: Transmission Chain Lubrication

    FRAME/TRANSMISSION CHAIN LUBRICATION TRANSMISSION CHAIN LUBRICA- TION The transmission chain is made of many parts interact- ing with each other. The chain must be subject to correct maintenance otherwise it will rapidly wear out. We therefore recommend subjecting the transmission chain to maintenance, in particular if using the bike in very dusty areas.

  • Page 122: Steering Tube Control And Adjustment

    FRAME/STEERING TUBE CONTROL AND ADJUSTMENT STEERING TUBE CONTROL AND ADJUSTMENT P P ark: • the bike levelled. N OTE: Place the bike on a trestle of adequate support so that the front wheel is lifted. Check: • the steering tube Make the front fork oscillate delicately grabbing it by the tubes' ends.
  • Page 123 FRAME/STEERING TUBE CONTROL AND ADJUSTMENT Adjust: • the steering tube Remove the kingpin ring nut Loosen the steering ring nut , therefore fasten it to the specified value using the appropriate spanner Special Tools: STEERING WHEEL RETURN RING SPANNER Code: R180297129000 Fastening torque of steering ring nut 60 N m - 6.11 Kgf•m WARNING...

  • Page 124: Transmission Gears Control And Replacement

    FRAME/TRANSMISSION GEARS CONTROL AND REPLACEMENT TRANSMISSION GEARS CONTROL AND REPLACEMENT Remove: • the clutch lid See “ENGINE 5.69” paragraph. • the transmission chain See "FRAME 4.97" paragraph. C C heck: • the teeth of the conducting and conducted gears In the presence of damages or wear Replace.

  • Page 125: Front Fork Control

    FRAME/FRONT FORK CONTROL FRONT FORK CONTROL Park: • the bike levelled. NOTE: Support the bike using suitable supports so that it cannot fall. C C heck: • the fork shank • the fork sleeve In the presence of damages/scratches Replace. •...

  • Page 126: Rear Shock Absorber Set Adjustment

    FRAME/REAR SHOCK ABSORBER SET ADJUSTMENT REAR SHOCK ABSORBER SET ADJUSTMENT NOTE: Support the bike using suitable supports so that it cannot fall. The rear shock absorber is equipped with external regulators to adjust the motorbike asset at the load conditions. The regulator , placed below, in correspondence of the lower fixing of the shock absorber to the swing...
  • Page 127 FRAME/REAR SHOCK ABSORBER SET ADJUSTMENT EXPANSION DAMPING WARNING Never overstep the minimum or maximum adjusting positions. 1 Adjust: • the extension damping Rotate the adjusting screw direction the extension damping increases DIRECTION (suspension is sti er) the extension damping decreases DIRECTION (suspension is more springy) ADJUSTING POSITIONS...

  • Page 128: Tyres Control

    FRAME/TYRES CONTROL TYRES CONTROL The following procedure is applied to both tyres. C C heck: • the tyres pressure If out of specification Adjust it. WARNING • The tyres pressure must be checked and adjusted only when the temperature of the wheels is the same as the ambient temperature.
  • Page 129 WARNING After various tests, the tyres shown below have been approved by Benelli Q.J. s.r.l. for this model. The front and rear tyres must be of the same drawing and the same brand. No road behaviour guarantee can be given if a combination of tyres different to that approved by Benelli is used.
  • Page 130 FRAME/TYRES CONTROL WARNING If the tyres are new, they will have a relatively modest grip on the road until they have worn slightly. Therefore, we recommend driving the first 100 km at normal speed, before increasing speed. N OTE: Tyres with indication of rotary direction •...

  • Page 131: Wheels Control

    FRAME/WHEELS CONTROL WHEELS CONTROL The following procedure is applied to both wheels. Check: • the wheel See "FRAME 4.5" paragraph for the front wheel; the "FRAME 4.20" paragraph for the rear wheel. In case of damage/ovalisation Replace. WARNING Never attempt any kind of repairs on the wheel. N OTE: If a tyre or a wheel has been replaced or removed and re-assembled, it is always necessary to carry...

  • Page 132: Cables Control And Lubrication

    FRAME/CABLES CONTROL AND LUBRICATION CABLES CONTROL AND LUBRICA- TION The following procedure is applied to all cables and relative sheaths. WARNING If an external cable is damaged, it may corrode and cause interferences in the movement. Replace any damaged cables and sheaths as soon as possible.

  • Page 133: Levers And Pedals Lubrication

    FRAME/LEVERS AND PEDALS LUBRICATION LEVERS AND PEDALS LUBRICATION L L ubricate the rotary points and the levers and pedals metal parts subject to contact during movement. Recommended lubricant TUTELA MR2 GREASE...

  • Page 134: Side Trestle Lubrication

    FRAME/SIDE TRESTLE LUBRICATION SIDE TRESTLE LUBRICATION Lubricate the rotary points and the side trestle metal parts subject to contact during movement. Recommended lubricant TUTELA MR2 GREASE...
  • Page 135 FRAME/LUBRICATION OF THE REAR SUSPENSION LUBRICATION OF THE REAR SUSPEN- SION L L ubricate the rotary points and the rear suspension metal parts subject to contact during movement. Recommended grease SINTOFLON...

  • Page 136: Electric Plant

    ELECTRIC PLANT/BATTERY CHARGE AND CONTROL BATTERY CHARGE AND CONTROL WARNING The batteries generate a nitrogen based explosive gas and contain electrolyte, which is made of sulphuric acid, a poisonous and highly caustic substance. Therefore, the following precautions must always be complied with: •...
  • Page 137 ELECTRIC PLANT/BATTERY CHARGE AND CONTROL NOTE: Given that the battery is sealed, it is not possible to check the charge state by measuring the density of the electrolyte. Therefore, the battery charge must be controlled by measuring the voltage on the terminals of the same battery.
  • Page 138 ELECTRIC PLANT/BATTERY CHARGE AND CONTROL Check the battery charge as shown in the tables of the following example. Ratio between the voltage with open 12.5 NOTE: circuit and the charge time at 20°C • The charge state of a battery can be checked by measuring its voltage with open circuit (meaning the existing voltage when the positive terminal is 11.5...
  • Page 139 ELECTRIC PLANT/BATTERY CHARGE AND CONTROL Charging method with a battery charger of variable current (voltage) type Battery charger Measure the voltage with open NOTE: Measure the voltage 30 minutes after circuit before charging. having switched off the equipment. Ammeter NOTE: Connect a battery charger and Set the charging voltage on 16~17 V.
  • Page 140 ELECTRIC PLANT/BATTERY CHARGE AND CONTROL Charging method with a battery charger of constant voltage type Measure the voltage with open NOTE: Measure the voltage 30 minutes after having switched off the equipment. circuit before charging. Connect a battery charger and an ammeter to the battery and start charging.
  • Page 141 ELECTRIC PLANT/BATTERY CHARGE AND CONTROL 5 Install: • the battery Connect: • the battery cables (to the battery terminals) ATTENTION Firstly connect the battery positive cable therefore, the negative cable 6 Check: • the battery terminals In the presence of dirt Clean using a metal brush.

  • Page 142: Fuses Control

    ELECTRIC PLANT/FUSES CONTROL FUSES CONTROL The following procedure is applied to all fuses. ATTENTION If having to check or replace the fuses, to avoid a short circuit, always switch off the main switch by turning it to "OFF". 1 R R emove: •...
  • Page 143 ELECTRIC PLANT/FUSES CONTROL Fuses Amperage Quantity Services Electric fans Injection Petrol Pump Alarm Instrument Lights Alarm Instrument Petrol Pump 10 A Electric fan 15 A Services 15 A Injection 15 A Lights 20 A Spare 20 A Spare Spare Spare Spare 15 A Spare...

  • Page 144: Front Lights Replacement

    ELECTRIC PLANT/FRONT LIGHTS REPLACEMENT FRONT LIGHTS REPLACEMENT The following procedure is applied to both the front lights. ATTENTION Given that the projector bulb reaches very high temperatures, we recommend not touching it with the hands until it has cooled down. 1 R R emove: •...
  • Page 145 ELECTRIC PLANT/FRONT LIGHTS REPLACEMENT Install: • the new lamp and fix it using the fixing spring. Connect: • the connectors of the new lamp 6 Connect: • the right and left inspection lid • the fixing screws...

  • Page 146: Front Headlight Removal

    ELECTRIC PLANT/FRONT HEADLIGHT REMOVAL FRONT HEADLIGHT REMOVAL Remove: • the right and left tank lids See "FRAME 4.112" paragraph. • the mobile and fixed cap See "FRAME 4.110" paragraph. Remove: • the self-locking screws • the equipment lid 3 Remove: •...
  • Page 147 ELECTRIC PLANT/FRONT HEADLIGHT REMOVAL Release: • the headlight connectors 6 Remove: • the screws for headlight fixing on the frame • the nuts • the central screw for closing right and left frame • the nut...

  • Page 148: Front Headlight Installation

    ELECTRIC PLANT/FRONT HEADLIGHT INSTALLATION FRONT HEADLIGHT INSTALLATION Install: • the central screw for closing right and left frame • the screws for headlight fixing on the frame • the nuts Recommended thread brakes: AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES Torque fasten the screw 10 N m - 1.01 Kgf•m Torque fasten the screws 22 N m - 2.24 Kgf•m...
  • Page 149 ELECTRIC PLANT/FRONT HEADLIGHT INSTALLATION 4 Install: • the headlight fixing pins • the lamp inspection lids Torque fasten the pins 10 N m - 1.01 Kgf•m 5 Install: • the equipment lid • the self-locking screws 6 Install: • the mobile and fixed cap See "FRAME 4.111"...

  • Page 150: Front Headlight Adjustment

    ELECTRIC PLANT/FRONT HEADLIGHT ADJUSTMENT FRONT HEADLIGHT ADJUSTMENT To correctly adjust the luminous beam projected from the front headlight: • position the vehicle at approximately 10 meters from a vertical wall on a perfectly levelled ground; • sit on the vehicle in driving position; •...

  • Page 151: Rear Headlight Replacement

    ELECTRIC PLANT/REAR HEADLIGHT REPLACEMENT REAR HEADLIGHT REPLACEMENT Remove: • the seat See "FRAME 4.130" paragraph. • the heat shield lid See "FRAME 4.132" paragraph. • the number plate bracket See "FRAME 4.128" paragraph. • the silencing device See "FRAME 4.155" paragraph. Loosen: •...
  • Page 152 ELECTRIC PLANT/REAR HEADLIGHT REPLACEMENT 6 Hook: • the headlight connector Install: • a new wiring locking strip Install: • the silencing device screws Install: • the silencing device See "FRAME 4.158" paragraph. • the number plate bracket See "FRAME 4.129" paragraph. •...
  • Page 153 ELECTRIC PLANT/NUMBER PLATE BRACKET LIGHT REPLACEMENT NUMBER PLATE BRACKET LIGHT REPLACEMENT Remove: • the screw Remove: • the rubber lamp holder Replace: • the position bulb 4 Install: • the rubber lamp holder • the screw...

  • Page 154: Front Indicators Replacement

    ELECTRIC PLANT/FRONT INDICATORS REPLACEMENT FRONT INDICATORS REPLACEMENT The following procedure can be applied to both the front indicators. Remove: • the handle bar cable gland Release: • the indicator connector Loosen: • the lower nut Remove: • the rear-view mirror Install: •...

  • Page 155: Front Indicators Lamps Replacement

    ELECTRIC PLANT/FRONT INDICATORS LAMPS REPLACEMENT INDICATORS LAMPS REPLACEMENT FRONT The following procedure is applied to both the front indicators lamps. Remove: • the screw Remove: • the glass Remove: • the bulb to be changed Install: the new bulb Install: •...

  • Page 156: Rear Indicators Lamps Replacement

    ELECTRIC PLANT/REAR INDICATORS LAMPS REPLACEMENT REAR INDICATORS LAMPS REPLACEMENT The following procedure is applied to both the rear indicators lamps. Remove: • the screw Remove: • the glass • the bulb to be changed Install: • the new bulb • the glass Install: •...
  • Page 158 CHAS CHAPTER 4 FRAME FRONT WHEEL AND BRAKE DISKS................ FRONT WHEEL REMOVAL....................... FRONT BRAKE DISKS REMOVAL....................FRONT WHEEL DECOMPOSITION....................FRONT WHEEL CONTROL........................ BRAKE DISKS CONTROL........................FRONT BRAKE DISKS ASSEMBLY....................FRONT WHEEL INSTALLATION...................... FRONT WHEEL BALANCING......................REAR WHEEL AND BRAKE DISK................REAR WHEEL REMOVAL........................
  • Page 159 CHAS FRONT FORK......................FRONT FORK SHANKS REMOVAL....................FRONT FORK SHANKS DECOMPOSITION.................. FRONT FORK SHANKS INSPECTION..................... FRONT FORK SHANKS ASSEMBLY....................FRONT FORK SHANKS INSTALLATION..................HANDLE BAR......................HANDLE BAR REMOVAL........................HANDLE BAR INSPECTION......................HANDLE BAR INSTALLATION......................STEERING WHEEL HEAD..................UPPER AND LOWER STEERING WHEEL BASE REMOVAL............UPPER AND LOWER STEERING WHEEL BASE INSPECTION..........
  • Page 160 CHAS FAIRING........................MOBILE AND FIXED CAP REMOVAL.................... MOBILE AND FIXED CAP INSTALLATION.................. RIGHT AND LEFT TANK LIDS REMOVAL..................RIGHT AND LEFT TANK LIDS INSTALLATION................FAIRING SUPPORT BRACKET REMOVAL..................FAIRING SUPPORT BRACKET INSTALLATION................TANK CAP REMOVAL........................TANK CAP INSTALLATION......................TANK REMOVAL..........................TANK INSTALLATION........................
  • Page 161 CHAS CYCLING........................FRONT LEFT FOOTPEG UNIT REMOVAL..................FRONT LEFT FOOTPEG UNIT INSTALLATION................FRONT RIGHT FOOTPEG UNIT REMOVAL.................. FRONT RIGHT FOOTPEG UNIT INSTALLATION................ REAR FOOTPEGS UNIT REMOVAL....................REAR FOOTPEGS UNIT INSTALLATION..................TRESTLE REMOVAL........................... TRESTLE INSTALLATION........................CHAIN SLIDES REMOVAL........................ CHAIN SLIDES INSTALLATION....................... DRAIN PLANT......................
  • Page 162 CHAS...

  • Page 163: Front Wheel And Brake Disks

    FRONT WHEEL AND BRAKE DISKS CHAS FRONT WHEEL REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Front Wheel Removal NOTE: Place the bike on a trestle of adequate support so that the front wheel is lifted. Screw Front Brake Calliper (Right And Left) Stop Screw...
  • Page 164 FRONT WHEEL AND BRAKE DISKS CHAS FRONT WHEEL REMOVAL P P ark the bike levelled. N OTE: Place the bike on a trestle of adequate support so that the front wheel is lifted. 2 2 Remove: • the screws Disconnect: •...

  • Page 165: Front Brake Disks Removal

    FRONT WHEEL AND BRAKE DISKS CHAS FRONT BRAKE DISKS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Front Wheel Removal See paragraph "4.1". Front Brake Disks Removal Left Spacer Front Wheel Screw Front Brake Disk (Ø320)

  • Page 166: Front Wheel Decomposition

    FRONT WHEEL AND BRAKE DISKS CHAS FRONT WHEEL DECOMPOSITION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Decompose the pieces in the given order. Front Wheel Decomposition Bearing Inside Spacer NOTE: To install, invert the order of the removal operations.

  • Page 167: Front Wheel Control

    FRONT WHEEL AND BRAKE DISKS CHAS FRONT WHEEL CONTROL Check: • the wheel axis Roll the axis of the wheel on a flat surface. In the presence of deformations Replace. WARNING Do not attempt to straighten the axis of the wheel if it is deformed.
  • Page 168 FRONT WHEEL AND BRAKE DISKS CHAS ATTENTION Do not touch the internal track or the wheel bearings balls . Contact must only take place with the external track NOTE: Use a spanner that adapts to the diameter of the external track of the wheel bearing.

  • Page 169: Brake Disks Control

    FRONT WHEEL AND BRAKE DISKS CHAS BRAKE DISKS CONTROL The procedure below can be applied to all brake disks. Check: • the brake disk In the presence of damages/abrasions Replace. Measure: • the deformation of the brake disk If out of specification Correct the deformation or replace the brake disk.
  • Page 170 FRONT WHEEL AND BRAKE DISKS CHAS 3 M M easure: • the brake disk thickness Measure the thickness of the brake disk in different points. If out of specification Replace. Deformation limit of the brake disk (maximum) 0.1 mm (0.004 in) Front: 0.15 mm (0.006 in) Rear:...

  • Page 171: Front Brake Disks Assembly

    FRONT WHEEL AND BRAKE DISKS CHAS FRONT BRAKE DISKS ASSEMBLY 22 N m - 2.24 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Front Brake Disks Assembly Front Wheel Front Brake Disk (Ø320) Screw Left Spacer...
  • Page 172 FRONT WHEEL AND BRAKE DISKS CHAS FRONT BRAKE DISKS ASSEMBLY A A ssemble: • the inside spacer • the bearings Recommended lubricant TUTELA MR2 GREASE A A ssemble: • the left front brake disk • the screws NOTE: Repeat the above procedure for the right front brake disk.

  • Page 173: Front Wheel Installation

    FRONT WHEEL AND BRAKE DISKS CHAS FRONT WHEEL INSTALLATION 50 N m - 5.09 Kgf•m 8 N m - 0.81 Kgf•m 60 N m - 6.11 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Front Wheel Installation Front Wheel Front Wheel Pin Stop Screw...
  • Page 174 FRONT WHEEL AND BRAKE DISKS CHAS FRONT WHEEL INSTALLATION L L ubricate: • the wheel axis Lift the wheel between the two shanks of the fork. Insert the axis of the wheel. N OTE: Install the tyre and the wheel with the mark the rotary direction of the wheel.
  • Page 175 FRONT WHEEL AND BRAKE DISKS CHAS 3 Install: • the left brake calliper • the screws Torque fasten with: 50 N m - 5.09 Kgf•m Recommended lubricant TUTELA MR2 GREASE NOTE: Repeat the above procedure for the right brake calliper. N OTE: Ensure there is sufficient space between the brake pads before installing the callipers on the relative...

  • Page 176: Front Wheel Balancing

    FRONT WHEEL AND BRAKE DISKS CHAS FRONT WHEEL BALANCING N OTE: After having replaced the tyre, the wheel, or both, the front wheel needs balancing again. Adjust the balancing of the front wheel with the brake disk installed. Disconnect: • the balancing weight(s) Find: •...
  • Page 177 FRONT WHEEL AND BRAKE DISKS CHAS Turn the front wheel by 90° so that the unbalanced point (heavier) is positioned as shown in the illustration. If the unbalanced point does not remain in the given position, install a heavier weight. Repeat points until balancing of the front wheel is obtained.

  • Page 178: Rear Wheel And Brake Disk

    REAR WHEEL AND BRAKE DISK CHAS REAR WHEEL REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Wheel Removal NOTE: Place the bike on a trestle of adequate support so that the rear wheel is lifted. Screw Rear Brake Calliper Special Screw...
  • Page 179 REAR WHEEL AND BRAKE DISK CHAS REAR WHEEL REMOVAL P P ark the bike levelled. N OTE: Place the bike on a trestle of adequate support so that the rear wheel is lifted. 2 R R emove: • the screws Disconnect: •...

  • Page 180: Rear Brake Disk And Crown Wheel Removal

    REAR WHEEL AND BRAKE DISK CHAS REAR BRAKE DISK AND CROWN WHEEL REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Wheel Removal See paragraph "4.16. Rear Brake Disk And Crown Wheel Removal Screw Rear Brake Disk Spacer Self-locking Nut Crown Wheel...

  • Page 181: Rear Wheel Decomposition

    REAR WHEEL AND BRAKE DISK CHAS REAR WHEEL DECOMPOSITION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Decompose the pieces in the given order. Rear Wheel Decomposition Seeger Bearing Spacer NOTE: To install, invert the order of the operations for removal.

  • Page 182: Rear Wheel Control

    REAR WHEEL AND BRAKE DISK CHAS REAR WHEEL CONTROL C C heck: • the wheel axis Roll the axis of the wheel on a flat surface. In the presence of deformations Replace. WARNING Do not attempt to straighten the axis of the wheel if it is deformed.
  • Page 183 REAR WHEEL AND BRAKE DISK CHAS ATTENTION Do not touch the internal track or the wheel bearings balls . Contact must only take place with the external track NOTE: Use a spanner that adapts to the diameter of the external track of the wheel bearing.

  • Page 184: Rear Wheel Crown Wheel Holder Flange Inspection

    REAR WHEEL AND BRAKE DISK CHAS REAR WHEEL CROWN WHEEL HOLDER FLANGE INSPECTION C C heck: • the crown wheel holder flange In the presence of cracks/damages Replace. • the collar rubbers In the presence of damages/wear Replace.

  • Page 185: Crown Wheel Control And Replacement

    REAR WHEEL AND BRAKE DISK CHAS CROWN WHEEL CONTROL AND REPLACEMENT Check: • the crown wheel If more of a ¼ of each tooth is worn Replace the crown wheel. If the teeth are bent Replace the crown wheel. ¼ teeth Correct Distribution chain roller Crown Wheel...

  • Page 186: Rear Brake Disk And Crown Wheel Assembly

    REAR WHEEL AND BRAKE DISK CHAS REAR BRAKE DISK AND CROWN WHEEL ASSEMBLY 10 N m - 1.01 Kgf•m 45 N m - 4.58 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Rear Brake Disk And Crown Wheel Assembly Collar Rubber Spacer Crown Wheel Holder Flange...
  • Page 187 REAR WHEEL AND BRAKE DISK CHAS REAR BRAKE DISK AND CROWN WHEEL ASSEMBLY A A ssemble: • the spacer • the bearings Recommended lubricant TUTELA MR2 GREASE • the seegers A A ssemble: • the collar rubbers • the spacer •...

  • Page 188: Rear Wheel Installation

    REAR WHEEL AND BRAKE DISK CHAS REAR WHEEL INSTALLATION 22 N m - 2.24 Kgf•m 100 N m - 10.19 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Rear Wheel Installation O-Ring Gasket Bush Calliper Holder Plate Spacer Rear Wheel Plug...
  • Page 189 REAR WHEEL AND BRAKE DISK CHAS REAR WHEEL INSTALLATION Install: • the O-Ring gaskets • the bush • the calliper holder plate • the spacer Recommended lubricant TUTELA MR2 GREASE 2 Install • the rear wheel 3 Lubricate and install: •...

  • Page 190: Rear Wheel Balancing

    REAR WHEEL AND BRAKE DISK CHAS REAR WHEEL BALANCING NOTE: • • After having replaced the tyre, the wheel or both, the rear wheel needs balancing again. • Adjust the balancing of the rear wheel with the brake disk and the crown wheel holder flange. 1 Adjust: •...

  • Page 191: Front And Rear Brakes

    FRONT AND REAR BRAKES CHAS FRONT BRAKE PADS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Front Brake Pads Removal NOTE: The procedure below can be applied to both front brake callipers. Screw Left Brake Calliper Clip Safety Spring...

  • Page 192: Rear Brake Pads Removal

    FRONT AND REAR BRAKES CHAS REAR BRAKE PADS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Brake Pads Removal Screw Rear Brake Calliper Seeger Clip Thickness For Brake Pads...
  • Page 193 FRONT AND REAR BRAKES CHAS WARNING The need to dismantle the components of the brake disk is rare. Therefore, the following precautions must always be complied with: • Never dismantle the brake components unless absolutely necessary. • If one of the connections of the hydraulic braking plant disconnects, it is necessary to dismantle, empty, clean, adequately fill and bleed (after re- assembly) the entire braking system.

  • Page 194: Front Brake Pads Replacement

    FRONT AND REAR BRAKES CHAS FRONT BRAKE PADS REPLACEMENT The procedure below can be applied to both the brake callipers. NOTE: To replace the brake pads, always replace in pair to guarantee an even pressure. It is not necessary to disconnect the flexible tube. Disconnect: •...
  • Page 195 FRONT AND REAR BRAKES CHAS Clean: • the inside of the calliper • the pistons then dry everything Press: • the calliper pistons inwards to enable installation of the new brake pads.

  • Page 196: Rear Brake Pads Replacement

    FRONT AND REAR BRAKES CHAS REAR BRAKE PADS REPLACEMENT N OTE: To replace the brake pads, always replace in pair to guarantee an even pressure. It is not necessary to disconnect the flexible tube. Disconnect: • the screws • the brake calliper •...
  • Page 197 FRONT AND REAR BRAKES CHAS P P ress: • the calliper pistons inwards to enable installation of the new brake pads. A A ct: • on the brake command with long brakes but not intense for approximately one hundred kilometres.

  • Page 198: Front Brake Pads Installation

    FRONT AND REAR BRAKES CHAS FRONT BRAKE PADS INSTALLATION 50 N m - 5.09 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Front Brake Pads Installation NOTE: The procedure below can be applied to both front brake callipers. Safety Spring Clip Left Brake Calliper...
  • Page 199 FRONT AND REAR BRAKES CHAS FRONT BRAKE PADS INSTALLATION Install: • the brake pads N OTE: Always install new brake pads. Install: • the safety spring • the pins • the clips Install: • the brake calliper Recommended lubricant TUTELA MR2 GREASE Torque fasten: 50 N m - 5.09 Kgf•m •...
  • Page 200 FRONT AND REAR BRAKES CHAS PADS INSTALLATION REAR BRAKE 22 N m - 2.24 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Rear Brake Pads Installation Thickness For Brake Pads Clip Seeger Rear Brake Calliper Screw...

  • Page 201: Rear Brake Pads Installation

    FRONT AND REAR BRAKES CHAS REAR BRAKE PADS INSTALLATION Install: • the brake pads thicknesses • the brake pads N OTE: Always install new brake pads and thicknesses. Install: • the clip • the pin • the seeger • the brake calliper •...

  • Page 202: Front Brake Pump Removal

    FRONT AND REAR BRAKES CHAS FRONT BRAKE PUMP REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Front Brake Pump Removal Screw Trestle Brakes Pump Body Screw NOTE: Drain the brakes liquid before carrying out the operations. See “ROUTINE INSPECTIONS AND ADJUSTMENTS 3.58”...

  • Page 203: Front Brake Pump Decomposition

    FRONT AND REAR BRAKES CHAS FRONT BRAKE PUMP DECOMPOSITION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Decompose the pieces in the given order. Front Brake Pump Decomposition Dust seal Seeger Main Cylinder Kit Spring Body Main Cylinder NOTE: To install, invert the order of the removal operations.

  • Page 204: Rear Brake Pump Removal

    FRONT AND REAR BRAKES CHAS REAR BRAKE PUMP REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Brake Pump Removal Brakes Liquid NOTE: Drain the brakes liquid before carrying out the operations. See “ROUTINE INSPECTIONS AND ADJUSTMENTS 3.58”...

  • Page 205: Rear Brake Pump Decomposition

    FRONT AND REAR BRAKES CHAS REAR BRAKE PUMP DECOMPOSITION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Decompose the pieces in the given order. Rear Brake Pump Decomposition Dust Seal Rubber Seeger Main Cylinder Kit Rear Brake Pump NOTE: To install, invert the order of the removal operations.

  • Page 206: Front And Rear Brake Pump Control

    FRONT AND REAR BRAKES CHAS FRONT AND REAR BRAKE PUMP CONTROL The following procedure is applied to both the brakes pumps. Check: • the brake main cylinder In the presence of damages/scratches/wear lines Replace. • the brakes liquid flow passages (brake pump body) In the presence of obstructions Clean using a...

  • Page 207: Front Brake Pump Installation

    FRONT AND REAR BRAKES CHAS FRONT BRAKE PUMP INSTALLATION 1.5 N m - 0.15 Kgf•m 8 N m - 0.81 Kgf•m 15 N m - 1.52 Kgf•m 7 N m - 0.71 Kgf•m 1.5 N m - 0.15 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS...
  • Page 208 FRONT AND REAR BRAKES CHAS FRONT BRAKE PUMP INSTALLATION WARNING • Before installation, clean all brake internal components, lubricating them using clean or new brakes liquid. • Do not use solvents on the internal components of the brake. Recommended brakes liquid TUTELA BRAKE FLUID TOP 4 - DOT 4 Install:...
  • Page 209 FRONT AND REAR BRAKES CHAS 4 Fill: • the brakes liquid tub (with the specified quality of recommended brakes liquid) Recommended brakes liquid TUTELA BRAKE FLUID TOP 4 - DOT 4 WARNING • Use only the prescribed brakes liquid. The use of other types of brakes liquid may damage the rubber gaskets, causing leaks and deteriorating the performances of the brakes.

  • Page 210: Rear Brake Pump Installation

    FRONT AND REAR BRAKES CHAS REAR BRAKE PUMP INSTALLATION 6 N m - 0.61 Kgf•m 10 N m - 1.01 Kgf•m 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Rear Brake Pump Installation Rear Brake Pump Screw Gasket...
  • Page 211 FRONT AND REAR BRAKES CHAS REAR BRAKE PUMP INSTALLATION WARNING • Before installation, clean all brake internal components, lubricating them using clean or new brakes liquid. • Do not use solvents on the internal components of the brake. Recommended brakes liquid TUTELA BRAKE FLUID TOP 4 - DOT 4 Install:...
  • Page 212 FRONT AND REAR BRAKES CHAS WARNING • Use only the prescribed brakes liquid. The use of other types of brakes liquid may damage the rubber gaskets, causing leaks and deteriorating the performances of the brakes. • Top-up using the same type of brakes liquid already present inside the system.

  • Page 213: Front Brake Callipers Removal

    FRONT AND REAR BRAKES CHAS FRONT BRAKE CALLIPERS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Front Brake Calliper Removal NOTE: The procedure below can be applied to both front brake callipers. Brakes Liquid NOTE: Drain the brakes liquid before carrying out the operations.

  • Page 214: Front Brake Callipers Decomposition

    FRONT AND REAR BRAKES CHAS FRONT BRAKE CALLIPERS DECOMPOSITION 10 N m - 1.01 Kgf•m 25 N m - 2.54 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Decompose the pieces in the given order. Front Brake Calliper Decomposition NOTE: The procedure below can be applied to both front brake callipers.

  • Page 215: Rear Brake Calliper Removal

    FRONT AND REAR BRAKES CHAS REAR BRAKE CALLIPER REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Brake Calliper Removal Brakes Liquid NOTE: Drain the brakes liquid before carrying out the operations. See paragraph "ROUTINE INSPECTIONS AND ADJUSTMENTS 3.58". Special Screw Washer Rear Brake Tube...

  • Page 216: Rear Brake Calliper Decomposition

    FRONT AND REAR BRAKES CHAS REAR BRAKE CALLIPER DECOMPOSITION 25 N m - 2.54 Kgf•m Arexons SYSTEM 52A43 10 N m - 1.01 Kgf•m MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Decompose the pieces in the given order. Rear Brake Calliper Decomposition Seeger Clip Brake Pads Thickness...
  • Page 217 FRONT AND REAR BRAKES CHAS FRONT BRAKE CALLIPERS REMOVAL The following procedure is applied to both the brake callipers. N OTE: Drain the brakes liquid from the entire braking plant before dismantling the brake calliper. See "ROUTINE INSPECTIONS AND ADJUSTMENTS 3.58"...
  • Page 218 FRONT AND REAR BRAKES CHAS RI REAR BRAKE CALLIPER REMOVAL N OTE: Drain the brakes liquid from the entire braking plant before dismantling the brake calliper. See "ROUTINE INSPECTIONS AND ADJUSTMENTS 3.58" paragraph. Disconnect: • the special screw • the washers •...

  • Page 219: Front Callipers And Rear Calliper Control

    FRONT AND REAR BRAKES CHAS FRONT CALLIPER AND REAR CALLIPER CONTROL RECOMMENDED REPLACEMENT PROGRAM FOR THE BRAKE COMPONENTS CHECK: After 1.000 Km BRAKES PADS Every 10.000 Km REPLACEMENT: If required CHECK: After 1.000 Km - BRAKE FLEXIBLE TUBES REPLACEMENT: Every 10.000 Km However, every 4 years.

  • Page 220: Front Brake Callipers Installation

    FRONT AND REAR BRAKES CHAS FRONT BRAKE CALLIPERS INSTALLATION 15 N m - 1.52 Kgf•m 50 N m - 5.09 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Front Brake Calliper Installation NOTE: The procedure below can be applied to both front brake callipers.
  • Page 221 FRONT AND REAR BRAKES CHAS FRONT BRAKE CALLIPERS INSTALLATION The following procedure is applied to both the brake callipers. WARNING • Before installation, clean all brake internal components, lubricating them using clean or new brakes liquid. • Never use solvents on the inside components of the brake as the gaskets of the pistons would inflate and deform.
  • Page 222 FRONT AND REAR BRAKES CHAS 3 Fill: • the brakes liquid tub (with the specified amount of recommended brakes liquid) Recommended brakes liquid TUTELA BRAKE FLUID TOP 4 - DOT 4 WARNING • Use only the prescribed brakes liquid. The use of other types of brakes liquid may damage the rubber gaskets, causing leaks and deteriorating the performances of the brakes.

  • Page 223: Rear Brake Calliper Installation

    FRONT AND REAR BRAKES CHAS REAR BRAKE CALLIPER INSTALLATION 22 N m - 2.24 Kgf•m 15 N m - 1.52 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Rear Brake Calliper Installation Rear Brake Calliper Screw Rear Brake Tube Washer Special Screw...
  • Page 224 FRONT AND REAR BRAKES CHAS REAR BRAKE CALLIPER INSTALLA- TION WARNING • Before installation, clean all brake internal components, lubricating them using clean or new brakes liquid. • Never use solvents on the inside components of the brake as the gaskets of the pistons would inflate and deform.
  • Page 225 FRONT AND REAR BRAKES CHAS 3 Fill: • the brakes liquid tub (with the specified amount of recommended brakes liquid). Recommended brakes liquid TUTELA BRAKE FLUID TOP 4 - DOT 4 WARNING • Use only the prescribed brakes liquid. The use of other types of brakes liquid may damage the rubber gaskets, causing leaks and deteriorating the performances of the brakes.

  • Page 226: Front Fork

    FRONT FORK CHAS FRONT FORK SHANKS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Front Brake Callipers Removal See paragraph "4.51". Front Wheel Removal See paragraph "4.1" Front Mudguard Removal See paragraph "4.124" Front Fork Shanks Removal ATTENTION: Before loosening the stop screws of the upper and lower brackets, install a support for the...
  • Page 227 FRONT FORK CHAS FRONT FORK SHANKS REMOVAL The following procedure is applied to both shanks of the front fork. Park the bike levelled. NOTE: Place the bike on a trestle of adequate support so that the front wheel is lifted. R R emove: •...

  • Page 228: Front Fork Shanks Decomposition

    FRONT FORK CHAS FRONT FORK SHANKS DECOMPOSITION 20 N m - 2.03 Kgf•m 20 N m - 2.03 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 50 N m - 5.09 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Decompose the pieces in the given order.
  • Page 229 FRONT FORK CHAS FRONT FORK SHANKS DECOMPOSI- TION The following procedure is applied to both shanks of the front fork. F F ix: • the stem in vice Completely loosen the closing cap unit from the supporting tube, using a 4 mm compass spanner Slowly lower the stem holder on the...
  • Page 230 FRONT FORK CHAS From inside the stem holder remove: • the spring pointer • the fork spring • the upper spring guide bush • the spacer • the lower spring guide bush • the spring pointer Release: • the stem from the vice Rotate the stem towards a container of adequate sizes so that the contained oil drains.
  • Page 231 FRONT FORK CHAS ATTENTION This operation must be carried out only after having completely drained the oil contained inside the sleeve. Remove: • the dust seal from the seat, using a small sharp screwdriver. Remove: • the oil retainer clip using the same screwdriver.

  • Page 232: Front Fork Shanks Inspection

    FRONT FORK CHAS FRONT FORK SHANKS INSPECTION The following procedure is applied to both shanks of the front fork. Check: • the fork shank • the fork sleeve In the presence of deformations/damages/scratches Replace. WARNING If deformed, do not attempt to straighten the internal fork shank in that, by weakening, it may become dangerous.

  • Page 233: Front Fork Shanks Assembly

    FRONT FORK CHAS FRONT FORK SHANKS ASSEMBLY ATTENTION The removed oil retainer and the dust seal must not be reused. Before re-assembling, check the conditions of the guide bushes; if scratches, ® replace them. Check that the Teflon coating of the guide bushes is intact.
  • Page 234 FRONT FORK CHAS Accompany: • the lower guide bush until it comes into contact with the fork sleeve • the seal ring • the oil retainer Subsequently introduce them in the seat. 5 Assemble: • the oil retainer clip using a small sharp screwdriver, checking that it is perfectly inserted in the appropriate groove and being careful not to scratch the fork shank.
  • Page 235 FRONT FORK CHAS Assemble the fork in vice by fixing it from the wheel holder foot. Lower the fork sleeve on to the fork shank. Insert: • the washer • the pumping unit fixing screw Fasten using an 8 mm Allen spanner: 50 N m - 5.09 Kgf•m AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES...
  • Page 236 FRONT FORK CHAS 10 Tighten: • the closing cap 11 Push downwards: • the spring • the preload spacer Insert a 17 mm spanner inside the nut Using a 4 mm compass spanner, keep the closing unit still and using a 17 mm spanner fasten the Fasten: 20 N m - 2.03 Kgf•m Lift the fork sleeve on to the fork shank.

  • Page 237: Front Fork Shanks Installation

    FRONT FORK CHAS FRONT FORK SHANKS INSTALLATION 22 N m - 2.24 Kgf•m 8 N m - 0.81 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Front Fork Shanks Installation Front Fork Shank Lower Plate Stop Screw Carry out a double passage.
  • Page 238 FRONT FORK CHAS FRONT FORK SHANKS INSTALLA- TION The following procedure is applied to both shanks of the front fork. Install: • the shanks of the front fork Temporarily fasten: • the stop screws of the lower steering plate Recommended lubricant TUTELA MR2 GREASE NOTE: Check the assembly quota.

  • Page 239: Handle Bar

    HANDLE BAR CHAS HANDLE BAR REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Handle Bar Removal Right Rear-view Mirror Disconnect indicator wire. Left Rear-view Mirror Disconnect indicator wire. Knob Terminal Left Knob Screw Left Switch Disconnect. Clutch Cable Screw Trestle...
  • Page 240 HANDLE BAR CHAS HANDLE BAR REMOVAL Park the bike levelled. WARNING Support the bike using suitable supports so that it cannot fall. Disconnect: • the knob of the handle bar NOTE: Direct a jet of compressed air between the left part of the handle bar and the relative knob, to gradually remove it from the handle bar.

  • Page 241: Handle Bar Inspection

    HANDLE BAR CHAS HANDLE BAR INSPECTION Check: • the handle bar In the presence of deformations/cracks/damages Replace. WARNING If deformed, do not attempt to straighten the handle bar in that, by weakening, it may become dangerous.

  • Page 242: Handle Bar Installation

    HANDLE BAR CHAS HANDLE BAR INSTALLATION 8 N m - 0.81 Kgf•m 8 N m - 0.81 Kgf•m 20 N m - 2.03 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Handle Bar Installation Handle Bar Screw Carry out a double passage.
  • Page 243 HANDLE BAR CHAS HANDLE BAR INSTALLATION Park the bike levelled. WARNING Support the bike using suitable supports so that it cannot fall. Install: • the right side handle bar switch NOTE: Align the protrusion of the switch with the hole on the right side handle bar.
  • Page 244 HANDLE BAR CHAS Install: • the trestle for the clutch lever NOTE: Align the slot of the retainer element of the clutch lever with the punching on the left side handle bar. Install: • the left side handle bar switch NOTE: Align the protrusion of the left side handle bar...

  • Page 245: Steering Wheel Head

    STEERING WHEEL HEAD CHAS UPPER AND LOWER STEERING WHEEL BASE REMOVAL Special Tools: STEERING HEAD SPANNER Code: R300097146000 Special Tools: STEERING RETURN RING SPANNER Code: R180297129000 SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Mobile and Fixed Cap Removal See paragraph "4,110"...
  • Page 246 STEERING WHEEL HEAD CHAS UPPER AND LOWER STEERING WHEEL BASE REMOVAL Park the bike levelled. WARNING Support the bike using suitable supports so that it cannot fall. Remove: • the stop screws of the steering plate upper Remove: • the cap (using the special tool Special Tools: STEERING HEAD SPANNER Code: R300097146000...

  • Page 247: Upper And Lower Steering Wheel Base Inspection

    STEERING WHEEL HEAD CHAS UPPER AND LOWER STEERING WHEEL BASE INSPECTION Wash: • the bearings • the bearings tracks Recommended solvent TUTELA MOTOR CLEAN Check: • the bearings • the dust seal rings In the presence of damages/pitting Replace. Replace: •...

  • Page 248: Upper And Lower Steering Wheel Base Installation

    STEERING WHEEL HEAD CHAS UPPER AND LOWER STEERING WHEEL BASE INSTALLATION 6 N m - 0.61 Kgf•m 60 N m - 6.11 Kgf•m Arexons SYSTEM 52A43 20 N m - 2.03 Kgf•m MEDIUM THREAD BRAKES 22 N m - 2.24 Kgf•m 60 N m - 6.11 Kgf•m 16 N m - 1.63 Kgf•m Special Tools: STEERING HEAD SPANNER...
  • Page 249 STEERING WHEEL HEAD CHAS UPPER AND LOWER STEERING WHEEL BASE INSTALLATION L L ubricate: • the bearings • the dust seal rings • the bearings tracks Recommended lubricant TUTELA MR2 GREASE Install: • the steering ring nut using the special tool Fasten: 16 N m - 1.63 Kgf•m ATTENTION...
  • Page 250 STEERING WHEEL HEAD CHAS Install: • the cap using the special tool Fasten with: 60 N m - 6.11 Kgf•m AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES Special Tools: STEERING HEAD SPANNER Code: R300097146000 • the stop screws of the upper steering plate Torque fasten: 22 N m - 2.24 Kgf•m Recommended lubricant...

  • Page 251: Rear Shock Absorber Set

    REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET REMOVAL...
  • Page 252 REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. REAR SHOCK ABSORBER SET REMOVAL Screw Screw Articulated Connecting Rod Spacer Seal Ring Rollers Bearing Screw Shock Absorber Screw Washer Bush Seal Ring...

  • Page 253: Rear Shock Absorber And Gas Cylinder Treatment

    REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER AND GAS CYLINDER TREATMENT WARNING This rear shock absorber and this gas cylinder contain a highly compressed gas (nitrogen). Carefully read and understand the following information before handling the rear shock absorber and gas cylinder. The manufacturer cannot be held responsible for any damages to property or personal injuries deriving from the improper use of the rear shock...
  • Page 254 REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET REMOVAL P P ark: • the bike levelled WARNING Support the bike using suitable supports so that it cannot fall. Disconnect: • the articulated connecting rods fixing screws • the relative nuts •...

  • Page 255: Rear Shock Absorber Set Control

    REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET CONTROL Check: • rear shock absorber rod In the presence of deformations/damages Replace the rear shock absorber set. • the rear shock absorber In the presence of gas/oil leaks Replace the rear shock absorber set.

  • Page 256: Rear Shock Absorber Set Installation

    REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 50 N m - 5.09 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 40 N m - 4.07 Kgf•m 60 N m - 6.11 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES...
  • Page 257 REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. REAR SHOCK ABSORBER SET INSTALLATION Balancing Device Rollers Bearing Spacer Seal Ring Bush Washer Screw Shock Absorber Screw Rollers Bearing Seal Ring Spacer Articulated Connecting Rod...
  • Page 258 REAR SHOCK ABSORBER SET CHAS REAR SHOCK ABSORBER SET INSTALLATION L L ubricate: • the spacers • the bearings Recommended lubricant TUTELA MR2 GREASE Clean: • the nut of the rear shock absorber set • the screw of the rear shock absorber set Recommended solvent TUTELA MOTOR CLEAN Install:...

  • Page 259: Transmission Chain And Swing Arm

    TRANSMISSION CHAIN AND SWING ARM CHAS TRANSMISSION CHAIN AND SWING ARM REMOVAL Special Tools: 20 ALLEN SPANNER Code: R180197033000 SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Brake Calliper Removal See paragraph "4.53". Disconnect Speed Sensor Connector See paragraph "ELECTRIC PLANT 7.11"...

  • Page 260: Transmission Chain Removal

    TRANSMISSION CHAIN AND SWING ARM CHAS TRANSMISSION CHAIN REMOVAL P P ark: • the bike levelled WARNING Place the bike on a trestle of adequate support so that the bike does not fall and the rear wheel is lifted. Disconnect: MASTER LINK •...

  • Page 261: Swing Arm Removal

    TRANSMISSION CHAIN AND SWING ARM CHAS SWING ARM REMOVAL Park: • the bike levelled WARNING Place the bike on a trestle of adequate support so that the bike does not fall and the rear wheel is lifted. Disconnect: • the nuts •...

  • Page 262: Transmission Chain Inspection

    TRANSMISSION CHAIN AND SWING ARM CHAS TRANSMISSION CHAIN INSPECTION Check: • the transmission chain Stiffness Clean and lubricate, or replace. Clean: • the transmission chain Clean the transmission chain using a clean cloth. Place the transmission chain in kerosene and remove all residue dirt.
  • Page 263 TRANSMISSION CHAIN AND SWING ARM CHAS L L ubricate: • the transmission chain Recommended grease SINTOFLON Check: • the conductor gear • the rear cogwheel If more of a ¼ of each tooth is worn Replace the gears of the transmission chain. If the teeth are bent Replace the gears of the transmission chain.

  • Page 264: Swing Arm Inspection

    TRANSMISSION CHAIN AND SWING ARM CHAS SWING ARM INSPECTION Check: • the swing arm In the presence of deformations/cracks/damages Replace. Check: • the swing arm pin Roll the swing arm pin on a flat surface. In the presence of deformations Replace.

  • Page 265: Transmission Chain Replacement

    TRANSMISSION CHAIN AND SWING ARM CHAS TRANSMISSION CHAIN REPLACE- MENT Loosen: • the transmission chain This chain uses a master link transmission chain with safety jump ring. Using the provided tool according to the chain manufacturer specifications. NOTE: Following the manufacturer instructions when using the special tool.
  • Page 266 TRANSMISSION CHAIN AND SWING ARM CHAS Check: • the surface interested by the pressing of the master link. This must not show cracks. If cracks are present, replace the master link, the seal rings and the jump ring. REPLACE ATTENTION Do not use a transmission chain with clip type master link.

  • Page 267: Transmission Chain And Swing Arm Installation

    TRANSMISSION CHAIN AND SWING ARM CHAS TRANSMISSION CHAIN AND SWING ARM INSTALLATION 22 N m - 2.24 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 10 N m -1.01 Kgf•m 60 N m - 6.11 Kgf•m Special Tools: 20 ALLEN SPANNER Code: R180197033000 SYMBOLS...

  • Page 268: Swing Arm Installation

    TRANSMISSION CHAIN AND SWING ARM CHAS SWING ARM INSTALLATION L L ubricate and clean: • the bearings • the spacer • the seal rings • the bushes • the swing arm pin Recommended lubricant TUTELA MR2 GREASE Recommended solvent TUTELA MOTOR CLEAN Install: •...

  • Page 269: Engine

    ENGINE CHAS ENGINE REMOVAL...
  • Page 270 ENGINE CHAS ENGINE REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Place a suitable trestle underneath frame and engine Engine Protection Removal See paragraph "4,122" Empty Cooling Liquid NOTE: Drain the cooling liquid before carrying out the operations.

  • Page 271: Engine Installation

    ENGINE CHAS ENGINE INSTALLATION 45 N m - 4.58 Kgf•m 40 N m - 4.07 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Engine Installation ATTENTION: Careful not to damage frame and engine when installing the engine. NOTE: Place a suitable trestle underneath frame and engine.
  • Page 272 FAIRING CHAS MOBILE AND FIXED CAP REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Mobile And Fixed Cap Removal Benelli Decalcomania Screw Special Screw Screw Right Headlight Lid Left Headlight lid Fixed Cap Anti-vibration Screw Bush...

  • Page 273: Fairing

    Q.TY OBSERVATIONS Install the pieces in the given order. Mobile And Fixed Cap Installation Mobile Cap Fixed Cap Small Plate Knob Manually fasten. Split pin Bush Screw Anti-vibration Left Headlight lid Right Headlight Lid Screw Special Screw Screw Benelli Decalcomania...

  • Page 274: Right And Left Tank Lids Removal

    FAIRING CHAS RIGHT AND LEFT TANK LIDS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Right And Left Tank Lids Removal Screw Bush Steering Lock Lid NOTE: The procedure below can be applied to both tank lids. Special Screw Bush Special Screw...

  • Page 275: Right And Left Tank Lids Installation

    FAIRING CHAS RIGHT AND LEFT TANK LIDS INSTALLATION 8 N m - 0.81 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Right And Left Tank Lids Installation NOTE: The procedure below can be applied to both tank lids.

  • Page 276: Fairing Support Bracket Removal

    FAIRING CHAS FAIRING SUPPORT BRACKET REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Right And Left Tank Lids Removal See paragraph "4.112". Fairing Support Bracket Removal Screw Washer Bush Fairing Support Bracket Quick Fixing Clip...

  • Page 277: Fairing Support Bracket Installation

    FAIRING CHAS FAIRING SUPPORT BRACKET INSTALLATION 12 N m - 1.22 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Fairing Support Bracket Installation Quick Fixing Clip Fairing Support Bracket Bush Washer Screw...

  • Page 278: Tank Cap Removal

    FAIRING CHAS TANK CAP REMOVAL Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. Tank Cap Removal Insert key. Open cap. Screw Screw Tank Cap Seal For Ring Nut Collector Gasket...

  • Page 279: Tank Cap Installation

    FAIRING CHAS TANK CAP INSTALLATION 6 N m - 0.61 Kgf•m 6 N m - 0.61 Kgf•m Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Install the pieces in the given order. Tank Cap Installation Gasket Collector Screw Seal For Ring Nut Tank Cap Screw...

  • Page 280: Tank Removal

    FAIRING CHAS TANK REMOVAL Special Tools: RAPID RELEASE KIT SPECIAL TOOL Code: R180100143000 RAPID RELEASE KIT SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Steering Lock Lid Removal See paragraph "4.112". Right And Left Tank Lids Removal See paragraph "4.112".

  • Page 281: Tank Installation

    FAIRING CHAS TANK INSTALLATION Special Tools: RAPID RELEASE KIT Code: R180100143000 RAPID RELEASE KIT 12 N m - 1.22 Kgf•m 12 N m - 1.22 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Tank Installation ATTENTION: Remove special tool (B) using special tool (A) rapidly connecting the petrol tube fitting.

  • Page 282: Engine Lids Removal

    FAIRING CHAS ENGINE LIDS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Engine Lids Removal Special Screw Nylon Washer Alternator Lid Screw Small Plate Quick Fixing Clip Pinion Lid Special Screw Nylon Washer Engine Protection Left Front Small Plate Left Rear Small Plate Right Rear Small Plate Right Front Small Plate...

  • Page 283: Engine Lids Installation

    FAIRING CHAS ENGINE LIDS INSTALLATION 8 N m - 0.81 Kgf•m 8 N m - 0.81 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Engine Lids Installation Quick Fixing Clip Right Front Small Plate Right Rear Small Plate Left Rear Small Plate Left Front Small Plate Engine Protection...

  • Page 284: Chain Carter Removal

    FAIRING CHAS CHAIN CARTER REMOVAL Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. Chain Carter Removal Screw Washer Chain Carter Quick Fixing Clip...

  • Page 285: Chain Carter Installation

    FAIRING CHAS CHAIN CARTER INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 8 N m - 0.81 Kgf•m Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Install the pieces in the given order. Chain Carter Installation Quick Fixing Clip Chain Carter Washer Screw...

  • Page 286: Front Mudguard Removal

    FAIRING CHAS FRONT MUDGUARD REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Front Mudguard Removal NOTE: It is not necessary to remove the brake flexible tube to remove the front mudguard, just unhook it from the pipe gland as shown in figure Brake Flexible Tube Special Screw...

  • Page 287: Front Mudguard Installation

    FAIRING CHAS FRONT MUDGUARD INSTALLATION 8 N m - 0.81 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 8 N m - 0.81 Kgf•m 8 N m - 0.81 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Front Mudguard Installation Bracket Screw...

  • Page 288: Rear Mudguard Removal

    FAIRING CHAS REAR MUDGUARD REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Mudguard Removal Special Screw Nylon Washer Rear Mudguard...

  • Page 289: Rear Mudguard Installation

    FAIRING CHAS REAR MUDGUARD INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 8 N m - 0.81 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Rear Mudguard Installation Rear Mudguard Nylon Washer Special Screw...

  • Page 290: Number Plate Bracket Removal

    FAIRING CHAS NUMBER PLATE BRACKET REMOVAL Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. Number Plate Bracket Removal Screw Screw Number Plate Bracket Cover Disconnect the indicators wiring and number plate light. Washer Reflector Screw Number plate light Screw Small Plate Left Rear Indicator...

  • Page 291: Number Plate Bracket Installation

    FAIRING CHAS NUMBER PLATE BRACKET INSTALLATION 8 N m - 0.81 Kgf•m 8 N m - 0.81 Kgf•m 8 N m - 0.81 Kgf•m 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 6 N m - 0.61 Kgf•m Q.TY SYMBOLS INTERVENTION/DESCRIPTION...

  • Page 292: Rear Frame

    REAR FRAME CHAS SEAT REMOVAL Insert: • the key Press: • the seat in the end part and simultaneously turn the key anti-clockwise. 3 Remove: • the seat by lifting it slightly from the rear end and sliding it backwards.

  • Page 293: Seat Installation

    REAR FRAME CHAS SEAT INSTALLATION Install: • the seat by resting the front hook on the appropriate slot of the tank 2 Press: • the seat in the end part and hook it closed.

  • Page 294: Battery Box Removal

    REAR FRAME CHAS BATTERY BOX REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Seat Removal See paragraph "4.130". Screw Anti-vibration Rubber Pad Heat Shield Lid Silencing Device Removal See paragraph "4.155". Right And Left Tank Lids Removal See paragraph "4.112".
  • Page 295 REAR FRAME CHAS BATTERY BOX REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Battery Screw Relay Box Fuses Box Screw Control Unit Screw Bush Screw Bush Rear Wiring Disconnect. Screw Rear Small Frame Set Battery Box...

  • Page 296: Battery Box Installation

    REAR FRAME CHAS BATTERY BOX INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 25 N m - 2.54 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Battery Box Installation Install the pieces in the given order. Battery Box Rear Small Frame Set ATTENTION: Before installing it, check that the threaded...
  • Page 297 REAR FRAME CHAS BATTERY BOX INSTALLATION 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Battery Box Installation Install the pieces in the given order. Battery Wiring Connect. ATTENTION: Connect the positive cable first then the negative one.

  • Page 298: Lock Removal

    REAR FRAME CHAS LOCK REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Seat Removal See paragraph "4.130". Screw Anti-vibration Rubber Pad Heat Shield Lid Right And Left Tank Lids Removal See paragraph "4.112". Tank Removal See paragraph "4.118". Lock Removal Screw Left Bracket...

  • Page 299: Lock Installation

    REAR FRAME CHAS LOCK INSTALLATION 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Lock Installation Seat Opening Lever Lock Flexible Command Screw NOTE: Reposition the battery box in the initial position.

  • Page 300: Codon Removal

    REAR FRAME CHAS CODON REMOVAL Remove: • the seat See paragraph "4.130". • the heat shield lid See paragraph "4.132". • the silencing device See paragraph "4.155". Disconnect: • the right and left headlight connectors Remove: • the screws • the nuts •...
  • Page 301 REAR FRAME CHAS Remove: • the nuts • the bushes • the anti-vibrations • the washers • the right rear headlight • the left rear headlight Remove: • the screws • the washers • the screws • the codon • the handle...

  • Page 302: Codon Installation

    REAR FRAME CHAS CODON INSTALLATION Install: • the handle • the codon • the screws • the washers • the screws Connect: • the right and left headlight connectors Install: • the left rear headlight • the right rear headlight •...
  • Page 303 REAR FRAME CHAS Install: • the complete codon • the bushes • the nuts • the screws Install: • the silencing device See paragraph "4.158". • the heat shield lid See paragraph "4.135". • the seat See paragraph "4.131".

  • Page 304: Rear Small Frame Set Removal

    REAR FRAME CHAS REAR SMALL FRAME SET REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Seat Removal See paragraph "4.130". Screw Anti-vibration Rubber Pad Heat Shield Lid Silencing Device Removal See paragraph "4.155". Codon Removal See paragraph "4.138". Rear Small Frame Set Removal Object Compartment Screw...

  • Page 305: Rear Small Frame Set Decomposition

    REAR FRAME CHAS REAR SMALL FRAME SET DECOMPOSITION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Decompose the pieces in the given order. Rear Small Frame Set Decomposition Screw Rubber Strip Rear Beam Special Nut Small Column Right Special Screw Left Special Screw Left Rear Small Frame Right Rear Small Frame...

  • Page 306: Rear Small Frame Set Installation

    REAR FRAME CHAS REAR SMALL FRAME SET INSTALLATION 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Complete Rear Small Frame Installation Rear Small Frame Set Screw Right Bracket Left Bracket...
  • Page 307 CYCLING CHAS FRONT LEFT FOOTPEG UNIT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Front Left Footpeg Unit Removal Screw Left Fixing Rubber Pad Rubber Pad Seeger Left Front Footpeg Spring Rubber Pad Screw Pointer Eccentric Screw Screw Spacer...

  • Page 308: Cycling

    CYCLING CHAS FRONT LEFT FOOTPEG UNIT INSTALLATION 35 N m - 3.56 Kgf•m 8 N m - 0.81 Kgf•m 10 N m - 1.01 Kgf•m 8 N m - 0.81 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 25 N m - 2.54 Kgf•m 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES...

  • Page 309: Front Right Footpeg Unit Removal

    CYCLING CHAS FRONT RIGHT FOOTPEG UNIT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Brake Pump Removal See paragraph “4.42”. Front Right Footpeg Unit Removal Screw Right Fixing Rubber Pad Rubber Pad Seeger Right Front Footpeg Spring Rubber Pad Screw...

  • Page 310: Front Right Footpeg Unit Installation

    CYCLING CHAS FRONT RIGHT FOOTPEG UNIT INSTALLATION 8 N m - 0.81 Kgf•m 35 N m - 3.56 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 25 N m - 2.54 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order.

  • Page 311: Rear Footpegs Unit Removal

    CYCLING CHAS REAR FOOTPEGS UNIT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Rear Footpegs Unit Removal Screw Right Footpeg Rubber Stop Right Footpeg Rubber Cover Seeger Right Rear Footpeg Small Plate Ball Spring Screw Right Footboard Holder Plate NOTE: The procedure below can be applied to both rear footpegs.
  • Page 312 CYCLING CHAS REAR FOOTBOARDS UNIT INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 22 N m - 2.24 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Rear Footboards Unit Installation NOTE: If the rubber pads are worn, replace them.

  • Page 313: Trestle Removal

    CYCLING CHAS TRESTLE REMOVAL Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. Trestle Removal Inside Spring External Spring Special Screw Washer Side Trestle Washer Screw Side Trestle Sensor Disconnect connector. Screw Plate...

  • Page 314: Trestle Installation

    CYCLING CHAS TRESTLE INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 45 N m - 4.58 Kgf•m 8 N m - 0.81 Kgf•m 22 N m - 2.24 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Install the pieces in the given order. Trestle Installation Plate Screw...

  • Page 315: Chain Slides Removal

    CYCLING CHAS CHAIN SLIDES REMOVAL Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. Chain Slides Removal Screw Lower Chain Slide Screw Welnut Chain Slide Screw Welnut Chain Slide NOTE: To remove the upper chain slide see paragraph "4.97".

  • Page 316: Chain Slides Installation

    CYCLING CHAS CHAIN SLIDES INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Install the pieces in the given order. Chain Slides Installation Chain Slide Welnut Screw Chain Slide Welnut Screw Lower Chain Slide Screw NOTE: To install the upper chain slide see paragraph "4.105".

  • Page 317: Drain Plant

    DRAIN PLANT CHAS DRAIN UNIT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Number Plate Bracket Removal See paragraph "4.128". Seat Removal See paragraph "4.130". Heat Seal Lid Removal See paragraph "4.136". Lock Removal See paragraph "4.136". Tank Removal See paragraph "4.118".
  • Page 318 DRAIN PLANT CHAS DRAIN UNIT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Bush Rubber Pad Drain Collector Articulated Connecting Rod Bush Drain Collector Fitting Spring Three-In-One Drain Collector Drain Collector Drain Gasket...

  • Page 319: Drain Collector Decomposition

    DRAIN PLANT CHAS DRAIN COLLECTOR DECOMPOSITION 12 N m - 1.22 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Drain Collector Decomposition Elastic Ring Drain Valve Cap Spring Drain Valve Flange Washer Spread the wings of plate n. 8 to free the heads of screws n.

  • Page 320: Drain Unit Installation

    DRAIN PLANT CHAS DRAIN UNIT INSTALLATION 19 18 8 N m - 0.81 Kgf•m 10 N m - 1.01 Kgf•m 15 N m - 1.52 Kgf•m 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Drain Unit Installation Drain Gasket Drain Collector...
  • Page 322 CHAPTER 5 ENGINE HEAD DISTRIBUTION....................DISTRIBUTION LID REMOVAL......................GASKETS CONTROL..........................DISTRIBUTION LID INSTALLATION....................DISTRIBUTION CHAIN TENSIONER REMOVAL................DISTRIBUTION CHAIN TENSIONER CONTROL................DISTRIBUTION CHAIN TENSIONER INSTALLATION..............INLET CAM SHAFT REMOVAL......................DRAIN CAM SHAFT REMOVAL....................... CAM SHAFTS CONTROL........................DRAIN CAM SHAFT INSTALLATION..................... INLET CAM SHAFT INSTALLATION....................
  • Page 323 PISTONS........................PISTONS REMOVAL..........................PISTONS CONTROL..........................ELASTIC BANDS CONTROL......................PINS CONTROL............................ PISTONS INSTALLATION........................CLUTCH........................CLUTCH LID REMOVAL........................CLUTCH LID INSTALLATION......................CLUTCH REMOVAL..........................FRICTION DISKS CONTROL......................STEEL DISKS CONTROL........................COMPRESSION SPRINGS CONTROL..................... CLUTCH BELL CONTROL........................CLUTCH DRUM INSPECTION......................CLUTCH PRESSURE PLATE CONTROL..................CLUTCH PRESSURE PLATE PIN CONTROL.................
  • Page 324 LUBRICATION PLANT..................OIL TANK AND INLET FILTER REMOVAL................. OIL TANK AND INLET FILTER CONTROL................. OIL TANK AND INLET FILTER INSTALLATION............... OIL PUMP REMOVAL........................OIL PUMP CONTROL........................OIL PUMP INSTALLATION......................OVER PRESSURE VALVE REMOVAL..................OVERPRESSURE VALVE CONTROL................... OVERPRESSURE VALVE INSTALLATION................. START-UP......................ALTERNATOR REMOVAL......................
  • Page 325 HANDLING......................BENCH HALF-BEARINGS, ENGINE SHAFT AND BALANCING COUNTER-SHAFT REMOVAL............................CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS REMOVAL....ENGINE SHAFT AND BALANCING COUNTER-SHAFT CONTROL....CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS CONTROL....CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS INSTALLATION..BALANCING COUNTER-SHAFT, ENGINE SHAFT AND BENCH HALF-BEARINGS INSTALLATION..........................

  • Page 327: Head Distribution

    HEAD DISTRIBUTION DISTRIBUTION LID REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Distribution Lid Removal Bracket Rubber Pad Washer Special Screw Rubber Pad Reel Spark Plug Champion RG4HC - NGK CR9E Rubber Pad Special Screw Rubber Pad Distribution Lid Lid Gasket O-Ring Gasket...

  • Page 328: Gaskets Control

    HEAD DISTRIBUTION GASKETS CONTROL Check: • the lid gasket • the O-Ring gaskets • the rubber pad In the presence of damages/wear Replace the faulty parts.

  • Page 329: Distribution Lid Installation

    HEAD DISTRIBUTION DISTRIBUTION LID INSTALLATION Arexons SYSTEM 52A70 12 N m - 1.22 Kgf•m STRONG THREAD BREAKS 15 N m - 1.52 Kgf•m 10 N m - 1.01 Kgf•m 8 N m - 0.81 Kgf•m 10 N m - 1.01 Kgf•m...
  • Page 330 HEAD DISTRIBUTION DISTRIBUTION LID INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Distribution Lid Installation Lid Gasket NOTE: The Yvori Sil Ac sealing paste must only be applied on the highlighted surface, as shown in the figure. O-Ring Gasket Distribution Lid Rubber Pad...

  • Page 331: Distribution Chain Tensioner Removal

    HEAD DISTRIBUTION DISTRIBUTION CHAIN TENSIONER REMOVAL SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Q.TY Remove the pieces in the given order. Operations to be carried out with the engine in Distribution Chain Tensioner Removal PMS. Screw Seal Ring Spring Screw Chain Tensioner O-Ring Gasket...

  • Page 332: Distribution Chain Tensioner Control

    HEAD DISTRIBUTION DISTRIBUTION CHAIN TENSIONER CONTROL Check: • the chain tensioner • the spring • the seal ring In the presence of damages/wear Replace.

  • Page 333: Distribution Chain Tensioner Installation

    HEAD DISTRIBUTION DISTRIBUTION CHAIN TENSIONER INSTALLATION 10 N m - 1.01 Kgf•m 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Distribution Chain Tensioner Installation NOTE: Bring the tensioner from position to position before installing it on the head.

  • Page 334: Inlet Cam Shaft Removal

    HEAD DISTRIBUTION INLET CAM SHAFT REMOVAL INLET DRAIN SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Distribution Lid Removal See paragraph "5.1" Distribution Chain Tensioner Removal See paragraph "5.5" Inlet Cam Shaft Removal Screw Upper Chain Slide Central Headgear NOTE: During removal the reference plugs may still be...
  • Page 335 HEAD DISTRIBUTION INLET CAM SHAFT REMOVAL INLET DRAIN SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Inlet Z34 Gear Inlet Distribution Shaft...

  • Page 336: Drain Cam Shaft Removal

    HEAD DISTRIBUTION DRAIN CAM SHAFT REMOVAL DRAIN SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Q.TY Remove the pieces in the given order. Operations to be carried out with the engine in PMS. Distribution Lid Removal See paragraph “5.1”. Distribution Chain Tensioner Removal See paragraph “5.5”. Inlet Cam Shaft Removal See paragraph “5.8”.

  • Page 337: Cam Shafts Control

    HEAD DISTRIBUTION CAM SHAFTS CONTROL C C heck: • the cam shaft lobes In the presence of blue fading/pittings/scratches Replace the cam shaft. 2 Measure: • the sizes of the cam shaft lobes If out of specification Replace the cam shaft. Size limit of the cam shaft lobes Inlet side cam shaft <Limit>: 35.3 mm (1.38 in)
  • Page 338 HEAD DISTRIBUTION Measure: • the clearance between cam shaft support and cam shaft lid If out of specification Measure the diameter of the cam shaft support. Clearance between cam shaft support and cap <Limit>: 0.1 mm (0.076 mm) Measure: • the diameter of the cam shaft support If out of specification Replace the cam shaft.

  • Page 339: Drain Cam Shaft Installation

    HEAD DISTRIBUTION DRAIN CAM SHAFT INSTALLATION 6 + 13 N m - 0.61 +1.32 Kgf•m 15 N m - 1.52 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Operations to be carried out with the engine in PMS. Drain Cam Shaft Installation Drain Z34 Gear Small Plate...

  • Page 340: Inlet Cam Shaft Installation

    HEAD DISTRIBUTION INLET CAM SHAFT INSTALLATION 6 + 13 N m - 0.61 + 1.32 Kgf•m 6 + 13 N m - 0.61 + 1.32 Kgf•m 6 + 13 N m - 0.61 + 1.32 Kgf•m INLET DRAIN Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 15 N m - 1.52 Kgf•m SYMBOLS...

  • Page 341: Chain Slides Removal

    HEAD DISTRIBUTION CHAIN SLIDES REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Operations to be carried out with the engine in PMS. Distribution Lid Removal See paragraph "5.1" Distribution Chain Tensioner Removal See paragraph "5.5" Inlet Cam Shaft Removal See paragraph "5.8"...

  • Page 342: Chain Slides Control

    HEAD DISTRIBUTION CHAIN SLIDES CONTROL Check: • the contact surface of the fixed slide • the contact surface of the mobile slide • the contact surface of the upper chain slide In the presence of damages/wear Replace the faulty parts.

  • Page 343: Chain Slides Installation

    HEAD DISTRIBUTION CHAIN SLIDES INSTALLATION 12 N m - 1.22 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Operations to be carried out with the engine in PMS. Chain Slides Installation Mobile Slide Mobile Chain Slide Pin Fixed Slide...

  • Page 344: Phonic Wheel Removal

    HEAD DISTRIBUTION PHONIC WHEEL REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Clutch Lid Removal See paragraph "5.69" Phonic Wheel Removal Screw Washer Phonic Wheel NOTE: Lock the phonic wheel using the appropriate tool. Special Tools: PHONIC WHEEL REMOVAL Code: R300097083000...

  • Page 345: Phonic Wheel Control

    HEAD DISTRIBUTION PHONIC WHEEL CONTROL Check: • the gear of the phonic wheel In the presence of damages/cracks/wear Replace the faulty parts.

  • Page 346: Phonic Wheel Installation

    HEAD DISTRIBUTION PHONIC WHEEL INSTALLATION 45 N m - 4.58 Kgf•m Arexons SYSTEM 56A48 HIGH TEMPERATURE SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Phonic Wheel Installation Phonic Wheel NOTE: Lock the phonic wheel using the appropriate tool.

  • Page 347: Distribution Chain Removal

    HEAD DISTRIBUTION DISTRIBUTION CHAIN REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Distribution Lid Removal See paragraph "5.1". Clutch Lid Removal See paragraph "5.69". Upper Chain Slide Removal See paragraph "5.8". Distribution Chain Tensioner Removal See paragraph "5.5". Phonic Wheel Removal See paragraph “5.18”.
  • Page 348 HEAD DISTRIBUTION DISTRIBUTION CHAIN REMOVAL N OTE: R R emove: • the screws To remove the screws rotate the inlet cam • the small plates clockwise using a 24 spanner. • the Inlet Z34 gear • the Drain Z34 gear •...

  • Page 349: Distribution Chain Control

    HEAD DISTRIBUTION DISTRIBUTION CHAIN CONTROL The following procedure is applied to all cogwheels of the cam shafts and to all distribution chain guides. Check: • the distribution chain In the presence of damages/no flexibility/locked links Replace the distribution chain together with the cam shaft gears.

  • Page 350: Distribution Chain Installation

    HEAD DISTRIBUTION DISTRIBUTION CHAIN INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Operations to be carried out with the engine in PMS. Distribution Chain Installation Distribution Chain...

  • Page 351: Distribution Chain Installation And Engine Phasing

    HEAD DISTRIBUTION DISTRIBUTION CHAIN INSTALLA- TION AND ENGINE PHASING ATTENTION Carefully follow the instructions given in the various assembly phases. Install: • the distribution chain • the fixed slide NOTE: Lubricate the chain using engine oil. Recommended lubricant ENGINE OIL P P osition: •...
  • Page 352 HEAD DISTRIBUTION R R otate: • the drain and inlet cam shaft in phase anti-clockwise using a 24 spanner, bringing the olives in cylinder 1, facing each other. N OTE: Engine phasing tolerance: 3°. Install: • • the Z34 gear (see paragraph “5.14”).
  • Page 353 HEAD DISTRIBUTION 5 Install: • the chain tensioner See paragraph “5.7”. • the upper chain slide See paragraph “5.14”. NOTE: Rotate the cam shafts using a spanner performing a full turn and bringing the engine in PMS.

  • Page 354: Valves Clearance Adjustment

    HEAD DISTRIBUTION VALVES CLEARANCE ADJUSTMENT SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Operations to be carried out with the engine in PMS. Distribution Lid Removal See paragraph "5.1" Valves Clearance Adjustment...

  • Page 355: Valves Clearance Control And Adjustment

    HEAD DISTRIBUTION VALVES CLEARANCE CONTROL AND ADJUSTMENT Measure: • the clearance between cams and cup using a feeler Position the cam as shown in the figure. If out of specification Replace the pad. See paragraph “5.30”. N OTE: Measurement must be carried out on all shafts and cups.

  • Page 356: Valves Lifters And Calibrated Pads Removal

    HEAD DISTRIBUTION VALVES LIFTERS AND CALIBRATED PADS REMOVAL INLET DRAIN SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Distribution Lid Removal See paragraph "5.1". Distribution Chain Tensioner Removal See paragraph "5.5". Inlet Cam Shaft Removal See paragraph "5.8". Drain Cam Shaft Removal See paragraph “5.10”.
  • Page 357 HEAD DISTRIBUTION VALVES LIFTERS AND CALIBRATED PADS REMOVAL The following procedure is applied to all valve lifters and calibrated pads. NOTE: Before removing the internal parts of the head (for example: valves, valves springs, valves seats), check that the valves are adequately sealed. Remove: •...

  • Page 358: Valves Lifters Control

    HEAD DISTRIBUTION VALVES LIFTERS CONTROL The following procedure is applied to all valves lifters. C C heck: • the valves lifters In the presence of damages/scratches Replace the valves lifters.

  • Page 359: Valves Lifters And Calibrated Pads Installation

    HEAD DISTRIBUTION VALVES LIFTERS AND CALIBRATED PADS INSTALLATION INLET DRAIN SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Valves Lifters And Calibrated Pads Installation Inlet Valve Calibrated Pad Inlet Valve Lifter Drain Valve Calibrated Pad NOTE: Always check the valves clearance. See paragraph “5.29”.

  • Page 360: Head Removal

    HEAD DISTRIBUTION HEAD REMOVAL...
  • Page 361 HEAD DISTRIBUTION HEAD REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Engine Removal See "FRAME 4.107" paragraph. Distribution Lid Removal See paragraph "5.1". Distribution Chain Tensioner Removal See paragraph "5.5". Inlet Cam Shaft Removal See paragraph "5.8". Drain Cam Shaft Removal See paragraph "5.10".

  • Page 362: Valves And Valves Springs Removal

    HEAD DISTRIBUTION VALVES AND VALVES SPRINGS REMOVAL DRAIN INLET...
  • Page 363 HEAD DISTRIBUTION VALVES AND VALVES SPRINGS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Engine Removal See "FRAME 4.107" paragraph. Distribution Lid Removal See paragraph "5.1". Distribution Chain Tensioner Removal See paragraph "5.5". Inlet Cam Shaft Removal See paragraph "5.8".

  • Page 364: Valves And Relative Guides Control

    HEAD DISTRIBUTION VALVES AND RELATIVE GUIDES CONTROL The following procedure is applied to all valves and valves guides. Check: • the valves seal In the presence of leaks of the valves seats Check the contact surface, the seat and the width of the valve seat.
  • Page 365 HEAD DISTRIBUTION Replace: • the valve guide N OTE: To facilitate the removal and installation of the valve guide operations and to maintain assembly correct, heat the head in an oven bringing it to 100° C (212° F). Remove the valve guide using an appropriate extractor Install the new valve guide using an appropriate installer...
  • Page 366 HEAD DISTRIBUTION M M easure: • the eccentricity of the valve stem If out of specification Replace the valve. NOTE: • • If a new valve is installed, always replace the relative guide. • If the valve is disconnected or re-assembled, always replace the oil retainer.

  • Page 367: Valves Seats Control

    HEAD DISTRIBUTION VALVES SEATS CONTROL The following procedure is applied to all valves and valves seats. E E liminate: • the carbonaceous deposits (from the contact surface and from the valve seat Check: • the valve seat In the presence of pittings/wear Replace the head.
  • Page 368 HEAD DISTRIBUTION 4 Lappa Lap: • the contact surface of the valve • the valve seat N OTE: After having replaced the head or the valve and the relative guide, the seat and the contact surface of the valve must be lapped. Apply a rough lapping paste on the contact surface of the valve.

  • Page 369: Internal And External Valves Springs Control

    HEAD DISTRIBUTION INTERNAL AND EXTERNAL VALVES SPRINGS CONTROL The following procedure is applied to all valves springs. Measure: • the free length of the valves springs If out of specification Replace the valve spring. Valves springs free length External spring 38.5 mm (1.515 in) inlet: 36 mm (1.417 in)

  • Page 370: Valves And Valves Springs Installation

    HEAD DISTRIBUTION VALVES AND VALVES SPRINGS INSTALLATION DRAIN INLET...
  • Page 371 HEAD DISTRIBUTION VALVES AND VALVES SPRINGS INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Valves And Valves Springs Installation Inlet Valve Lower Spring Plate Inlet Valve Oil Retainer Inlet Valve Inlet Valve External Spring Inlet Valve Internal Spring Inlet Valve Upper Spring Plate Inlet Valve Split Pin Drain Valve Lower Spring Plate...
  • Page 372 HEAD DISTRIBUTION VALVES AND VALVES SPRINGS INSTALLATION NOTE: Install in the head: • the valve lower spring plate Lubricate the valve stem and the valve oil retainer • the valve oil retainer (see figure • the valve Recommended lubricant • the external valve spring ENGINE OIL •...
  • Page 373 HEAD DISTRIBUTION Install: • the valve pins NOTE: Re-assemble the valves' pins by compressing the spring of each valve using the appropriate compression tool F F ix: • the pins on to the valves stems Delicately hit the point of the valve using a soft hammer.

  • Page 374: Head Installation

    HEAD DISTRIBUTION HEAD INSTALLATION Arexons SYSTEM 52A70 STRONG THREAD BREAKS 15 N m - 1.52 Kgf•m 10 N m - 1.01 Kgf•m...
  • Page 375 HEAD DISTRIBUTION HEAD INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Head Installation Reference Plug Head Gasket Head Seal Washer Tube Special Screw Screw Washer...
  • Page 376 HEAD DISTRIBUTION HEAD INSTALLATION INLET DRAIN 1 Fasten the nuts (1 ~ 8) respecting the fastening sequence: 1st phase: 25 N m - 2.54 Kgf•m 2nd phase: 45 N m - 4.58 Kgf•m 3rd phase: 50° angle pair 4th phase: 50° angle pair 5th phase: fasten the screws 10 N m - 1.01 Kgf•m N OTE:...

  • Page 377: Cylinders

    CYLINDERS CYLINDERS REMOVAL...
  • Page 378 CYLINDERS CYLINDERS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Engine Removal See "FRAME 4.107" paragraph. Distribution Lid Removal See paragraph "5.1". Distribution Chain Tensioner Removal See paragraph "5.5". Inlet Cam Shaft Removal See paragraph "5.8". Drain Cam Shaft Removal See paragraph "5.10".

  • Page 379: Cylinders Control

    CYLINDERS CYLINDERS CONTROL The following procedure is applied to the entire cylinder unit. Check: • the cylinder wall In the presence of vertical scratches Replace the cylinder and the piston together with the relative bands.

  • Page 380: Cylinders Installation

    CYLINDERS CYLINDERS INSTALLATION 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Cylinders Installation NOTE: Apply engine oil on the bands and on the pistons' wall before installing the carter cylinder. Do not exceed with the engine oil. Reference Plug Carter Cylinder Gasket Carter Cylinder...
  • Page 381 CYLINDERS CYLINDERS INSTALLATION Install: • the cylinder gasket A A pply: Special Tools: CYLINDER ASSEMBLY THICKNESSES • the thickness in the central piston • the thickness in the side piston Code: R180197018000 • the thickness in the side piston...
  • Page 382 CYLINDERS Install: P P osition: • the 2 reference plugs •the cylinder unit Recommended lubricant ENGINE OIL N OTE: Sequentially remove: By compressing the piston bands using one hand, • the thicknesses with the other, install the cylinder set, subsequently removing the thickness.
  • Page 383 CYLINDERS 10 N m - 1.01 Kgf•m 6 Install: • the two cylinder fixing screws ATTENTION Completely fasten the cylinder fixing screws after having fixed the head. Recommended lubricant COPPER GREASE...

  • Page 384: Pistons

    PISTONS PISTONS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Engine Removal See "FRAME 4.107" paragraph. Distribution Lid Removal See paragraph "5.1". Distribution Chain Tensioner Removal See paragraph "5.5". Inlet Cam Shaft Removal See paragraph "5.8". Drain Cam Shaft Removal See paragraph “5.10”.
  • Page 385 PISTONS PISTONS REMOVAL Remove: N OTE: • the external elastic ring Do not use hammers to remove the pins. • the pin • the piston • the internal elastic ring • the external elastic ring • the pin • the piston •...

  • Page 386: Pistons Control

    PISTONS PISTONS CONTROL The following procedure is applied to all three pistons. C C heck: • the piston wall In the presence of vertical scratches Replace the piston together with the relative bands and the cylinder. Measure: • the diameter of skirt of piston P using the micrometer.

  • Page 387: Elastic Bands Control

    PISTONI ELASTIC BANDS CONTROL The following procedure is applied to all elastic bands. Check: • there are no scratches and signs of forcing on every band If out of specification Replace the relative bands and the pistons. Measure: • the side clearance between one piston band and the other If out of specification Replace the piston and...

  • Page 388: Pins Control

    PISTONS PINS CONTROL The following procedure is applied to all pins. Check: • the piston pin In the presence of blue fading/grooves Replace the piston pin and check the lubricating system. Measure: • the external diameter of the piston pin If out of specification Replace the piston pin.

  • Page 389: Pistons Installation

    PISTONS PISTONS INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Pistons Installation Pistons...
  • Page 390 PISTONS PISTONS INSTALLATION The following procedure is applied to all pistons. Install: • the oil scraper band • the 2nd band • the upper band NOTE: The first and second rings have the letter N on the upper side. Remember to install the piston bands so that the letter N is facing upwards.
  • Page 391 PISTONS The two bands have a different thickness. The upper band has a lower thickness than the 2nd band 2nd band Piston bands thickness Upper band 3.1 ~ 0.1 mm Upper band Second band 3.7 ~ 0.1 mm...
  • Page 392 PISTONS Install: • the central piston • the piston pin • the piston pin stop rings NOTE: Lubricate the piston pin before installing it. Recommended lubricant ENGINE OIL...
  • Page 393 PISTONS N OTE: Install: To assemble the two side pistons insert • the side piston first the internal rings , then the piston pins • the side piston and finally the external rings Lubricate the pistons well before installing them. Recommended lubricant ENGINE OIL ATTENTION...
  • Page 394 PISTONS 8 P P osition in an alternative manner: • the light between the two ends of each piston band at 120° compared to the other.

  • Page 395: Clutch

    CLUTCH CLUTCH LID REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Clutch Lid Removal NOTE: Loosen each screw by ¼ of a turn at a time, repeatedly and proceeding in a crossed sequence. After having completely loosened all the screws, remove them.

  • Page 396: Clutch Lid Installation

    CLUTCH CLUTCH LID INSTALLATION 10 N m - 1.01 Kgf•m 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Clutch Lid Installation Clutch Lid Gasket NOTE: Accurately clean the support surfaces of the gasket.

  • Page 397: Clutch Removal

    CLUTCH CLUTCH REMOVAL...
  • Page 398 CLUTCH CLUTCH REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Clutch Lid Removal See paragraph "5.69" Clutch Removal Screw Compression Spring Clutch Pressure Plate Clutch Disks Series Friction Steel Disk Disk Hexagonal Nut Disk Spring Clutch Drum High Shim Clutch Bell Needle Cage...
  • Page 399 CLUTCH CLUTCH REMOVAL R R emove: • the clutch lid • the clutch lid gasket See paragraph "5.69". R R emove: • the screws • the cups • the compression springs • the clutch pressure plate R R emove: • the clutch disks series •...
  • Page 400 CLUTCH R R emove: • the clutch drum nut • the disk spring • the clutch drum set R R emove: • the high shim • the clutch bell R R emove: • the needle cage • the spacer • the low shim...

  • Page 401: Friction Disks Control

    CLUTCH FRICTION DISKS CONTROL The following procedure is applied to all friction disks. Check: • the friction disk In the presence of damages/wear Replace all friction disks. Measure: • the thickness of the friction disks If out of specification Replace all friction disks. NOTE: Measure the friction disk in four points.

  • Page 402: Steel Disks Control

    CLUTCH STEEL DISKS CONTROL The following procedure is applied to all steel disks. Check: • the steel disk In the presence of damages/wear Replace all steel disks. Measure: • the twisting of the steel disk (using a surface plate and a feeler If out of specification Replace all steel disks.

  • Page 403: Compression Springs Control

    CLUTCH COMPRESSION SPRINGS CONTROL The following procedure is applied to all compression springs. Check: • the compression springs In the presence of damages Replace all compression springs. Measure: • the free length of the compression springs If out of specification Replace all compression springs.

  • Page 404: Clutch Bell Control

    CLUTCH CLUTCH BELL CONTROL Check: • the clutch jaws of the clutch bell In the presence of damages/pittings/wear lines Trim the clutch jaws of the clutch bell, or replace the clutch bell. N OTE: The presence of pittings on the clutch jaws of the clutch bell will make the clutch malfunction.

  • Page 405: Clutch Drum Inspection

    CLUTCH CLUTCH DRUM INSPECTION Check: • the grooved part of the clutch drum In the presence of damages/pittings/wear lines Replace the clutch drum. N OTE: The presence of pittings on the grooved part of the drum will make the clutch malfunction.

  • Page 406: Clutch Pressure Plate Control

    CLUTCH CLUTCH PRESSURE PLATE CONTROL Check: • the clutch pressure plate In the presence of cracks/damages Replace. • the bearing In the presence of damages/wear Replace.

  • Page 407: Clutch Pressure Plate Pin Control

    CLUTCH CLUTCH PRESSURE PLATE PIN CONTROL Check: • the pressure plate pin • the bush In the presence of damages/wear Replace the clutch pressure plate pin together with the traction lever shaft pinion. 2 Check: • the needle cage In the presence of damages/wear Replace.

  • Page 408: Clutch Installation

    CLUTCH CLUTCH INSTALLATION 100 N m - 10.19 Kgf•m Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER 10 N m - 1.01 Kgf•m...
  • Page 409 CLUTCH CLUTCH INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Clutch Installation Low Shim Spacer Needle Cage Clutch Bell High Shim Clutch Drum Disk Spring Hexagonal Nut Disk Friction Steel Disk Clutch Disks Series Clutch Pressure Plate Compression Spring Screw NOTE:...
  • Page 410 CLUTCH CLUTCH INSTALLATION Position: • the low shim with the lowest relief towards the inside of the engine. Thickness 3.5 mm. Recommended lubricant ENGINE OIL Insert: • the spacer • the needle cage N OTE: Before inserting the needle cages, lubricate their sliding area well.
  • Page 411 CLUTCH 6 Insert: • the convex disk spring towards the outside of the engine • the fixing nut DISK SPRING INSERTION DIRECTION Tighten: • the clutch drum nut 100 N m - 10.19 Kgf•m N OTE: By keeping the clutch drum still using the retainer tool specific for the clutch , tighten the relative nut.
  • Page 412 CLUTCH 10 Insert: • the pressure plate 10 N m - 1.01 Kgf•m • the compression springs • the cups • the screws Torque fasten. 10 N m - 1.01 Kgf•m NOTE: Lubricate the screws' threads. Recommended lubricant TUTELA MR2 GREASE...

  • Page 413: Clutch Disks Adjustment

    CLUTCH CLUTCH DISKS ADJUSTMENT Lock: • the flange ((IMG)) Loosen: • the lock nut ((IMG)) Tighten: • the regulator ((IMG)) until contact with the internal reaction rod is heard and loosen it by ¼ of a turn. Check the clearance on the clutch command positioned on the opposite side of the engine.

  • Page 414: Clutch Command Removal

    CLUTCH CLUTCH COMMAND REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Clutch Lid Removal See paragraph "5.69" Clutch Pressure Plate Removal See paragraph "5.71" Clutch Command Removal Clutch Cable Screw Clutch Command Body Plug Small Plate O-Ring Gasket Bush Clutch Command Rod...

  • Page 415: Clutch Command Control

    CLUTCH CLUTCH COMMAND CONTROL Check: • the clutch command In the presence of deformations/damages/wear lines Replace. • the clutch command spring In the presence of damages/wear Replace.

  • Page 416: Clutch Command Installation

    CLUTCH CLUTCH COMMAND INSTALLATION 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Clutch Command Installation Clutch Command Spring Needle Cage Needle Cage Ball Clutch Command Rod Bush O-Ring Gasket Small Plate...

  • Page 417: Gear Change

    GEAR CHANGE GEAR CHANGE REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Remove the neutral sensor located in the rear part of the engine before removing the gear change. NOTE: Drain the engine oil before carrying out the operations.
  • Page 418 GEAR CHANGE GEAR CHANGE REMOVAL R R emove: • the nut keeping the pinion still with the special tool Special Tools: PINION DISMANTLING TOOL Code: R180297048000 R R emove: • the washer • the pinion • the spacer...
  • Page 419 GEAR CHANGE Remove: • the screws • the selector lid • the selector lid gasket Remove: • the washer • the pin • the spring • the spacer • the washer...
  • Page 420 GEAR CHANGE R R emove: • the screws • the flange Remove: ATTENTION • the bush During removal of the peg support the • the desmodromic sprocket desmodromic positioned behind the gear • the jumpers change flange to avoid it falling. •...
  • Page 421 GEAR CHANGE NOTE: Remove: During removal of the pins pay attention to • the screws the desmodromic and to the forks • the washers • the pins • the clutch forks 1st/4th - 2nd/3rd • the clutch fork 5th/6th NOTE: •...
  • Page 422 GEAR CHANGE Remove: ATTENTION • the primary shaft The gears are free. • the secondary shaft Remove the shafts simultaneously.

  • Page 423: Primary And Secondary Shaft Gears Removal

    GEAR CHANGE PRIMARY AND SECONDARY SHAFT GEARS REMOVAL PRIMARY SHAFT SECONDARY SHAFT...
  • Page 424 GEAR CHANGE PRIMARY AND SECONDARY SHAFT GEARS REMOVAL Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the engine oil and the cooling liquid before carrying out the operations. Engine Removal See "FRAME 4.107" paragraph. Clutch Lid Removal See paragraph "5.69".

  • Page 425: Gears Control

    GEAR CHANGE GEARS CONTROL Check: • the gears of the two shafts In the presence of blue fading/pittings/wear lines Replace the faulty gears. • the gears clutch jaws In the presence of cracks/damages/round edges Replace the faulty gears.

  • Page 426: Gear Change Flange Bearings Control

    GEAR CHANGE GEAR CHANGE FLANGE BEARINGS CONTROL Check: • the free rotation of the bearings If out of specification Replace. To replace the bearings remove: • the screws • the small plate • the bearing • the seal ring • the bearing •...

  • Page 427: Gears Command Forks Control

    GEAR CHANGE GEARS COMMAND FORKS CONTROL The following procedure is applied to all gears command forks. Check: • the gears command fork cam follower • the gears command fork jaw In the presence of deformations/damages/scratches /wear lines Replace the gears command fork. Check: •...
  • Page 428 GEAR CHANGE Check: • the movement of the gears command fork on the relative guide bar If the movement is not smooth Replace the gears command forks together with the relative bar guide.

  • Page 429: Desmodromic Shaft Control

    GEAR CHANGE DESMODROMIC SHAFT CONTROL Check: • the grooves of the desmodromic shaft In the presence of damages/scratches/wear lines Replace the desmodromic shaft set • the segment of the desmodromic shaft In the presence of damages/wear Replace the desmodromic shaft set...

  • Page 430: Primary And Secondary Shaft Gears Installation

    GEAR CHANGE PRIMARY AND SECONDARY SHAFT GEARS INSTALLATION PRIMARY SHAFT SECONDARY SHAFT...
  • Page 431 GEAR CHANGE PRIMARY AND SECONDARY SHAFT GEARS INSTALLATION Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Install the pieces in the given order. NOTE: Never use a used elastic ring. When installing a new elastic ring careful not to stretch its ends more than necessary for it to be inserted on the shaft.

  • Page 432: Gear Change Installation

    GEAR CHANGE GEAR CHANGE INSTALLATION 20 N m - 2.03 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. ATTENTION: During installation of the gear change, ensure it is in fourth gear to avoid breaking the neutral sensor or, remove the neutral sensor before installing the gear change.
  • Page 433 GEAR CHANGE GEAR CHANGE INSTALLATION Install: ATTENTION • the primary shaft The gears are free. • the secondary shaft Remove the shafts simultaneously. • the spacer Recommended lubricant ENGINE OIL 2 Install: • the plug on the desmodromic shaft • the two thicknesses (of 0.2 mm each) AREXONS SYSTEM 56A48 HIGH TEMPERATURE THREAD BRAKES...
  • Page 434 GEAR CHANGE 10 N m - 1.01 Kgf•m Install: AREXONS SYSTEM 52A43 • the desmodromic MEDIUM THREAD BRAKES • the clutch forks 1st/4th - 2nd/3rd • the clutch fork 5th/6th • the pins • the washers Recommended lubricant • the screws ENGINE OIL Torque fasten with: 10 N m - 1.01 Kgf•m...
  • Page 435 GEAR CHANGE Install: • the complete gear change drum • the peg Torque fasten with: 10 N m - 1.01 Kgf•m AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 10 N m - 1.01 Kgf•m NOTE: During INSTALLATION of the desmodromic sprocket contrast the reaction of the springs located underneath the jumpers Install:...
  • Page 436 GEAR CHANGE Install: • the flange • the screws Torque fasten with: 10 N m - 1.01 Kgf•m AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES 10 N m - 1.01 Kgf•m Install: • the washer • the spacer • the spring •...
  • Page 437 GEAR CHANGE Install: • the selector lid gasket • the selector lid • the screws Torque fasten. 10 N m - 1.01 Kgf•m Recommended lubricant ENGINE OIL 10 N m - 1.01 Kgf•m Recommended lubricant COPPER GREASE 10 N m - 1.01 Kgf•m Install: •...
  • Page 438 GEAR CHANGE Install: • the nut keeping the pinion still with the special tool Special Tools: PINION DISMANTLING TOOL Code: R180297048000 Torque fasten with: 140 N m - 14.2 Kgf•m AREXONS SYSTEM 56A48 HIGH TEMPERATURE THREAD BRAKES...

  • Page 439: Lubrication Plant

    LUBRICATION PLANT OIL TANK AND INLET FILTER REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Oil Tank Removal Magnet Cap NOTE: Drain the engine oil before carrying out the operations. Washer Strip Screw Plate Screw Oil Tank Bush Oil Tank Gasket Inlet Filter Removal...

  • Page 440: Oil Tank And Inlet Filter Control

    LUBRICATION PLANT OIL TANK AND INLET FILTER CONTROL Check: • the oil tank In the presence of clinks/damages Replace. Check: • the inlet filter In the presence of clinks/damages Replace. In the presence of deposits/residues Accurately clean the filtering area using solvent. Recommended solvent TUTELA MOTOR CLEAN...

  • Page 441: Oil Tank And Inlet Filter Installation

    LUBRICATION PLANT OIL TANK AND INLET FILTER INSTALLATION 10 N m - 1.01 Kgf•m 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 10 N m - 1.01 Kgf•m 22 N m - 2.24 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order.

  • Page 442: Oil Pump Removal

    LUBRICATION PLANT OIL PUMP REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the engine oil before carrying out the operations. Clutch Lid Removal See paragraph "5.69" Clutch Removal See paragraph "5.71" Water Pump Removal See paragraph "COOLING PLANT 6.15"...

  • Page 443: Oil Pump Control

    LUBRICATION PLANT OIL PUMP CONTROL Check: • the pump body In the presence of scratches/damages/wear Replace. • the cogwheel In the presence of gear damages/wear Replace. Measure: • the tolerance between the internal rotor and the external rotor • the tolerance between the external rotor and the oil pump slot Internal rotor External rotor...

  • Page 444: Oil Pump Installation

    LUBRICATION PLANT OIL PUMP INSTALLATION 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Oil Pump Installation Oil Pump Shaft Roller Internal Rotor Shim...

  • Page 445: Over Pressure Valve Removal

    LUBRICATION PLANT OVER PRESSURE VALVE REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Oil Tank Removal See paragraph "5,113" NOTE: Drain the engine oil before carrying out the operations. Over Pressure Valve Removal Over Pressure Valve Washer...

  • Page 446: Overpressure Valve Control

    LUBRICATION PLANT OVERPRESSURE VALVE CONTROL Check: • the pressure valve body • the pressure valve • the spring • the washer In the presence of damages/wear Replace the fault parts. N OTE: Abundantly and accurately lubricate the pressure valve. Recommended lubricant ENGINE OIL...

  • Page 447: Overpressure Valve Installation

    LUBRICATION PLANT OVERPRESSURE VALVE INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 25 N m - 2.54 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Over Pressure Valve Installation Washer Over Pressure Valve NOTE: Insert the engine oil once operations have been completed.
  • Page 448 START-UP ALTERNATOR REMOVAL Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the engine oil before carrying out the operations. Clutch Lid Removal See paragraph "5.69" Clutch Removal See paragraph "5.71" Clutch Command Removal See paragraph "5.88" Water Pump Removal See paragraph "COOLING PLANT 6.15"...

  • Page 449: Start-Up

    START-UP ALTERNATOR CONTROL Check: • the clearance between the male joint and the alternator If out of specification Replace the part. Check: • the collar rubber In the presence of damages/wear Replace.

  • Page 450: Alternator Installation

    START-UP ALTERNATOR INSTALLATION Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER 45 N m - 4.58 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Install the pieces in the given order. Alternator Installation Collar Rubber Washer Male Joint...

  • Page 451: Start-Up Motor Removal

    START-UP START-UP MOTOR REMOVAL Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the engine oil before carrying out the operations. Clutch Lid Removal See paragraph "5.69" Clutch Removal See paragraph "5.71" Clutch Command Removal See paragraph "5.88" Water Pump Removal See paragraph "COOLING PLANT 6.15"...

  • Page 452: Start-Up Motor Control

    START-UP START-UP MOTOR CONTROL Check: • the start-up motor functioning If the start-up motor turns with force Replace the part. • the O-Ring gasket In the presence of damages/pittings/wear lines Replace the O-Ring gasket.

  • Page 453: Start-Up Motor Installation

    START-UP START-UP MOTOR INSTALLATION 10 N m - 1.01 Kgf•m Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Install the pieces in the given order. Start-Up Motor Installation O-Ring Gasket NOTE: Lubricate the O-Ring being careful not to damage it.

  • Page 454: Z25 Gear/Splined Shaft, Female Collar Joint Removal

    START-UP Z25 GEAR/SPLINED SHAFT, FEMALE COLLAR JOINT REMOVAL Special Tools: ALTERNATOR SPANNER Code: R300097161000 Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the engine oil before carrying out the operations. Clutch Lid Removal See paragraph "5.69" Clutch Removal See paragraph "5.71"...

  • Page 455: Z25 Gear/Splined Shaft, Female Collar Joint Control

    START-UP Z25 GEAR/SPLINED SHAFT, FEMALE COLLAR JOINT CONTROL Check: • the female collar joint In the presence of damages/wear Replace. • the splined shaft In the presence of torsions/clinks/wear lines Replace. • the Z25 gear In the presence of cracks/damages/round edges Replace the faulty gear.

  • Page 456: Z25 Gear/Splined Shaft, Female Collar Joint Installation

    START-UP Z25 GEAR/SPLINED SHAFT, FEMALE COLLAR JOINT INSTALLATION 50 N m - 5.09 Kgf•m Arexons SYSTEM 56A48 HIGH TEMPERATURE SEALER Special Tools: ALTERNATOR SPANNER Cod e: R300097161000 Q.TY SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Install the pieces in the given order. Z25 Gear/Splined Shaft Installation Z25 Gear NOTE: Insert the splined shaft respecting the phasing...
  • Page 457 START-UP SATELLITE GEAR AND FREE WHEEL UNIT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the engine oil before carrying out the operations. Clutch Lid Removal See paragraph "5.69". Clutch Removal See paragraph "5.71". Clutch Command Removal See paragraph "5.88".

  • Page 458: Satellite Gear And Free Wheel Control

    START-UP SATELLITE GEAR AND FREE WHEEL CONTROL Remove: • the seeger • the washer • the Z60 free wheel gear • the needle cage • the screws • the flange • the free wheel • the free wheel hub 2 Check: •...

  • Page 459: Satellite Gear And Free Wheel Installation

    START-UP SATELLITE GEAR AND FREE WHEEL UNIT INSTALLATION Arexons SYSTEM 52A43 Arexons SYSTEM 52A70 MEDIUM THREAD BRAKES STRONG THREAD BRAKES Arexons SYSTEM 52A70 STRONG THREAD BRAKES 10 N m - 1.01 Kgf•m 16 N m - 1.63 Kgf•m 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY...

  • Page 460: Handling Base

    HANDLING BASE LOWER BASE REMOVAL...
  • Page 461 HANDLING BASE LOWER BASE REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the engine oil and the cooling liquid before carrying out the operations. NOTE: Operations to be carried out with the engine overturned. Engine Removal See "FRAME 4.107"...
  • Page 462 HANDLING BASE LOWER BASE REMOVAL Remove: • the screw • the screw • the screws • the counter-shaft lid • the counter-shaft lid gasket 2 Remove: • the screws • the plate Overturn: • the engine Remove: • the screws Loosen each screw by ¼...

  • Page 463: Lower Base Control

    HANDLING BASE LOWER BASE CONTROL Scrupulously wash: • the lower base by dipping it in a neutral solvent. Recommended solvent TUTELA MOTOR CLEAN Scrupulously clean: • all coupling surfaces destined to welcome the sealing paste and the coupling surfaces of the base. Check: •...

  • Page 464: Lower Base Installation

    HANDLING BENCH HALF-BEARINGS, ENGINE SHAFT AND BALANCING COUNTER-SHAFT REMOVAL UPPER BASE LOWER BASE...
  • Page 465 HANDLING BENCH HALF-BEARINGS, ENGINE SHAFT AND BALANCING COUNTER-SHAFT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the engine oil and the cooling liquid before carrying out the operations. Engine Removal See "FRAME 4.107" paragraph. Clutch Lid Removal See paragraph "5.69".

  • Page 466: Connecting Rod Half-Bearings And Connecting Rods Removal

    HANDLING CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Engine Removal See "FRAME 4.107" paragraph. Clutch Lid Removal See paragraph "5.69". Clutch Removal See paragraph "5.71". Oil Tank Removal See paragraph "5.113". Oil Pump Removal See paragraph "5.116".
  • Page 467 HANDLING BALANCING COUNTER-SHAFT CONTROL AND ENGINE SHAFT Remove from the balancing counter-shaft: • the seeger • the bearing • the Z34 command gear • the bearing Check: • the bearings Clean the bearings, therefore rotate the internal track with a finger. If the movement is not correct Replace.

  • Page 468: Connecting Rod Half-Bearings And Connecting Rods Control

    HANDLING CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS CONTROL Check: • any breakages or excessive clearance on the connecting rod and on the connecting rod half-bearings In case of replacing the connecting rod, check the class marked on the connecting rod head. Check: •...

  • Page 469: Connecting Rod Half-Bearings And Connecting Rods Installation

    HANDLING CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS INSTALLATION 15 + 25 N m + 50° - 1.52 + 2.54 Kg•m + 50° SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Connecting Rod Half-Bearings Installation Connecting Rod Half-Bearing Connecting Rods Installation Connecting Rod NOTE:...
  • Page 470 HANDLING CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS INSTALLATION Install: • the connecting rod half-bearings Clean the bearings of the connecting rod heads, the connecting rod supports and the internal part of half of each connecting rod. Install the upper bearing of the connecting rod head inside the connecting rod, and the lower bearing of the connecting rod head inside the connecting rod cap.
  • Page 471 HANDLING S S elect: • the class marked on the connecting rod head SELECTION TABLE TYPE COLOUR WEIGHT (g) Black 412/416 Green 396/400 White 400/404 Brown 404/408 Orange 408/412 ATTENTION Associate the connecting rod types following the class marked on the connecting rod head. Install: •...

  • Page 472: Balancing Counter-Shaft, Engine Shaft And Bench Half-Bearings Installation

    HANDLING BALANCING COUNTER-SHAFT, ENGINE SHAFT AND BENCH HALF-BEARINGS INSTALLATION 10 N m - 1.01 Kgf•m UPPER BASE Arexons SYSTEM 52A70 STRONG THREAD BREAKS LOWER BASE...
  • Page 473 HANDLING BALANCING COUNTER-SHAFT, ENGINE SHAFT AND BENCH HALF-BEARINGS INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Bench Half-Bearings Installation Bench Half-Bearing Bearing Plate Screw Rollers Bearing Engine Shaft Installation Engine Shaft Balancing Counter-Shaft Installation Balancing Counter-Shaft Seal Ring NOTE: Insert the engine oil and the cooling liquid once...
  • Page 474 HANDLING BALANCING COUNTER-SHAFT, ENGINE SHAFT AND BENCH HALF- BEARINGS INSTALLATION Install: • the bench half-bearings Clean the bench half-bearings, the bench supports and the base parts in contact with the half-bearings. Rest the upper base overturned on to the work bench.
  • Page 475 HANDLING The bench half-bearings have various thicknesses distinguished by different letters and colours as shown in the table. BENCH HALF-BEARING COLOUR THICKNESS 1.918 ~ 1.922 Blue 1.922 ~ 1.926 Yellow 1.926 ~ 1.930 Ø std A seat red 41.830 - 41.836 Ø...
  • Page 476 HANDLING 5 Install: • the engine shaft Recommended lubricant COPPER GREASE Install: • the balancing counter-shaft Recommended lubricant ENGINE OIL WARNING Ensure that the cogwheels of the balancing counter-shaft and of the engine shaft are in phase as shown in figure Install: •...
  • Page 477 HANDLING BASE LOWER BASE INSTALLATION 11 11 SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. NOTE: Apply copper grease on all screws. Lower Base Installation Bush Bush Lower Base Screw NOTE: Install the respective washers first. Screw Screw Screw NOTE:...
  • Page 478 HANDLING BASE LOWER BASE INSTALLATION Install: • the centring bush • the centring bushes N OTE: Accurately clean the contact surfaces of the upper and lower base with solvent. Recommended solvent TUTELA MOTOR CLEAN Apply: • the sealing paste on to the contact surface as shown in the figure.
  • Page 479 HANDLING BASE Install: • the screws 23 24 HALF-CARTER CLOSING FASTENING TORQUES SEQUENCE FASTENING TORQUES 1st PHASE: 12.7 N m - 1.22 Kgf•m 1 ~ 8 2nd PHASE: 24.5 N m - 2.49 Kgf•m 3rd PHASE: 45.0 N m - 4.58 Kgf•m 1st PHASE: 12.7 N m - 1.22 Kgf•m 9 ~ 12 2nd PHASE: 30 N m - 3.05 Kgf•m...

  • Page 480: Power Supply

    POWER SUPPLY THROTTLED BODY REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Throttled Body Removal Screw Throttled Body O-Ring Gasket...

  • Page 481: Throttled Body Adjustment

    POWER SUPPLY THROTTLED BODY ADJUSTMENT C C onnect: • the vacuum meter tubes directly to the fittings Start: • the engine and bring it to a temperature of approx. 90°/95°C. Check: • the alignment of the mercury columns with engine power to the minimum. Eventually proceed with the balancing.

  • Page 482: Throttled Body Installation

    POWER SUPPLY THROTTLED BODY INSTALLATION 10 N m - 1.0 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Throttled Body Installation O-Ring Gasket Throttled Body Screw...
  • Page 484 COOL CHAPTER 6 COOLING PLANT RADIATOR........................ RADIATOR REMOVAL......................... RADIATOR CONTROL......................... RADIATOR INSTALLATION........................ COOLING CIRCUIT....................COOLING CIRCUIT REMOVAL......................COOLING CIRCUIT INSTALLATION....................OIL DISTRIBUTOR..................... OIL DISTRIBUTOR REMOVAL......................OIL DISTRIBUTOR CONTROL......................OIL DISTRIBUTOR INSTALLATION....................THERMOSTAT......................THERMOSTAT REMOVAL........................THERMOSTAT CONTROL........................THERMOSTAT INSTALLATION......................WATER PUMP......................WATER PUMP REMOVAL........................
  • Page 485 COOL...
  • Page 486 RADIATOR COOL RADIATOR REMOVAL 24 28 SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the cooling liquid before carrying out the operations. Alternator Lid Removal See "FRAME 4.120" paragraph. Right And Left Tank Lids Removal See "FRAME 4.112"...
  • Page 487 RADIATOR COOL RADIATOR REMOVAL 24 28 SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Screw Upper Bush Rubber Pad Disconnect the electric fans n. 22. Water Radiator Screw Special Fixing Pin Electric fan Spacer NOTE: Careful when removing the spacers, when installing place them in the correct sequence. Screw Lower Bush Left Support...
  • Page 488 RADIATOR COOL RADIATOR CONTROL Check: • the radiator flaps In the presence of obstructions Clean. Apply a jet of compressed air on the rear part of the radiator. In the presence of damages Repair or replace. N OTE: Straighten the eventually crushed flaps using a flat head thin screwdriver.
  • Page 489 RADIATOR COOL RADIATOR INSTALLATION 10 N m - 1.01 Kgf•m 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Radiator Installation Radiator Cap Rubber Pad Right Support Left Support Screw Lower Bush Special Fixing Pin Spacer NOTE:...
  • Page 490 RADIATOR COOL RADIATOR INSTALLATION 10 N m - 1.01 Kgf•m 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Deformable Strip Screw Strip Deformable Strip Sleeve Screw Strip Deformable Strip Right Radiator Sleeve Left Radiator Sleeve Radiator Sleeve Deformable Strip...
  • Page 491 COOLING CIRCUIT COOL COOLING CIRCUIT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Cooling Circuit Removal NOTE: Drain the cooling liquid before carrying out the operations. Click Strip NOTE: The click strips can be re-used for the installation being careful during the dismantling phase.
  • Page 492 COOLING INSTALLATION COOL COOLING CIRCUIT INSTALLATION SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Cooling Circuit Installation Exchanger Input Tube Water Tube Click Strip NOTE: Unless worn, re-use the removal click strips, otherwise change them. Click Strip Screw Strip Exchanger Outlet Tube Water Tube...
  • Page 493 COOLING CIRCUIT COOL COOLING CIRCUIT INSTALLATION Fill: • the cooling system (with the specified amount of recommended cooling liquid) See paragraph "ROUTINE INSPECTIONS AND ADJUSTMENTS 3.44". 2 Check: • the cooling system In the presence of leaks Repair or replace the faulty parts.
  • Page 494 OIL DISTRIBUTOR COOL OIL DISTRIBUTOR REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. Engine Protection Removal See "FRAME 4.120" paragraph. Drain Collectors Removal See "FRAME 4.155" paragraph. NOTE: Drain the engine oil and the cooling liquid before carrying out the operations.
  • Page 495 OIL DISTRIBUTOR COOL OIL DISTRIBUTOR CONTROL Check: • the oil distributor In the presence of clinks/damages Replace. • the flow and outlet flexible tubes In the presence of cracks/damages/wear lines Replace.
  • Page 496 OIL DISTRIBUTOR COOL OIL DISTRIBUTOR INSTALLATION 30 + 60 N m - 3.05 + 6.11 Kgf•m 20 N m - 2.03 Kgf•m Arexons SYSTEM 52A43 10 N m - 1.01 Kgf•m MEDIUM THREAD BRAKES SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Oil Distribution Installation Seal Ring Oil Distributor...
  • Page 497 THERMOSTAT COOL THERMOSTAT REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the cooling liquid before carrying out the operations. Thermostat Removal Exchanger Outlet Tube Screw Thermostat disk O-Ring Gasket Thermostat...
  • Page 498 THERMOSTAT COOL THERMOSTAT CONTROL Check: • the by-pass hole In the presence of clogging Replace. • the thermostat If it does not open at 75° ~ 90° C (167~ 194° F) Replace. Place the thermostat in a container full of water. Slowly heat the water.
  • Page 499 THERMOSTAT COOL THERMOSTAT INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION OBSERVATIONS Q.TY Install the pieces in the given order Thermostat Installation NOTE: Thermostat Install the thermostat with the vent hole facing upwards. O-Ring Gasket Thermostat disk Screw...
  • Page 500 WATER PUMP COOL WATER PUMP REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the cooling liquid before carrying out the operations. Water Pump Removal Screw Washer Strip Water Flow Tube Water Return Tube Screw Water Pump...
  • Page 501 WATER PUMP COOL WATER PUMP REMOVAL R R emove: • the screws • the plates • the water input elbow • the O-Ring gasket Remove: • the screws • the water pump lid • the water pump body • the O-Ring gasket •...
  • Page 502 WATER PUMP COOL WATER PUMP CONTROL Check: • the water pump lid • the water pump body • the water pump impeller • the mechanical seal • the back In the presence of damages/cracks/wear lines Replace Check: • the gaskets •...
  • Page 503 WATER PUMP COOL WATER PUMP INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Water Pump Installation Water Pump Screw Water Return Tube Water Flow Tube Strip Washer Screw...

  • Page 504: Water Pump Installation

    WATER PUMP COOL WATER PUMP INSTALLATION Install: • the water pump shaft N OTE: Lubricate the water pump shaft as shown in the figure before installing it. Recommended lubricant ENGINE OIL Install: • the seal ring • the bearing • the spacer •...
  • Page 505 WATER PUMP COOL 4 Install: • the centring bushes • the O-Ring gasket • the water pump body • the water pump lid • the O-Ring gasket • the screws Torque fasten the 2 screws with: 10 N m - 1.01 Kgf•m 10 N m - 1.01 Kgf•m AREXONS SYSTEM 52A43 MEDIUM THREAD BRAKES...
  • Page 506 WATER COLLECTOR COOL WATER COLLECTOR REMOVAL SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Remove the pieces in the given order. NOTE: Drain the cooling liquid before carrying out the operations. Alternator Removal See “ENGINE 5.122” paragraph. Water Collector Removal Strip Water Tube Screw Water Collector Water Collector Gasket...
  • Page 507 WATER COLLECTOR COOL WATER COLLECTOR CONTROL Check: • the water collector In the presence of damages/breaks Replace.
  • Page 508 WATER COLLECTOR COOL WATER COLLECTOR INSTALLATION Arexons SYSTEM 52A43 MEDIUM THREAD BRAKES 10 N m - 1.01 Kgf•m SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS Install the pieces in the given order. Water Collector Installation Water Collector Gasket Water Collector Screw Water Tube Strip NOTE: Insert the cooling liquid once operations have...
  • Page 510 ELEC CHAPTER 7 ELECTRIC PLANT SENSORS........................DESCRIPTION OF THE ENGINE MANAGEMENT SYSTEM............SENSORS POSITION........................... SYSTEM SENSORS..........................INLET AIR TEMPERATURE SENSOR....................PHASE SENSORS..........................TEMPERATURE SENSOR OF THE COOLING LIQUID..............POSITION SENSOR OF THE THROTTLE BODIES UNIT (POTENTIOMETER)....... NEUTRAL SWITCH..........................SIDE TRESTLE SENSOR........................CLUTCH SWITCH..........................
  • Page 511 ELEC ACTUATORS......................ACTUATORS POSITION........................SYSTEM ACTIVATING ACTUATORS....................AIR AT MINIMUM CONTROL SYSTEM (STEPPER)..............INJECTORS............................. IGNITION REELS........................... COOLING VENTS..........................FUEL PUMP............................RELAY UNIT............................REMOTE CONTROL SWITCH......................SOLENOID.............................. ALTERNATOR............................START-UP MOTOR ..........................DIAGNOSTICS......................IGNITION AND INJECTION SYSTEM DIAGNOSTICS..............NUMBERING OF ECM CONNECTORS.................... ADDITIONAL DIAGNOSIS........................
  • Page 512 ELEC...
  • Page 513 ECM memory. This stored data can be recovered by a Benelli dealer using an appropriate service equipment provided to all Benelli dealers (see Axone/Benida instruction manual).
  • Page 514 SENSORS ELEC SENSORS POSITION S S ide Trestle Sensor Phase Sensor Ambient Temperature Probe Lambda Probe Hydrostop Air Temperature Sensor Front Brake Sensor Neutral Switch Barometric Pressure Sensor Potentiometer Oil Pressure Sensor Clutch Switch Fall Sensor Speed Sensor Cooling Liquid Temperature Sensor •...
  • Page 515 SENSORS ELEC SYSTEM SENSORS INLET AIR TEMPERATURE SENSOR Placed underneath the on board equipment (dashboard) Considering that the air density (and, therefore, the amount of oxygen available to burn the fuel) varies with the temperature, an inlet air temperature sensor has been arranged.
  • Page 516 SENSORS ELEC PHASE SENSORS Placed in the right part of the engine near the engine shaft The position sensor of the elbow shaft detects the movement of a cogwheel fixed at the right end of the engine shaft through reading of a particular wheel made of 28 teeth, equally distant, next to a space of three times the length.
  • Page 517 SENSORS ELEC TEMPERATURE SENSOR OF THE COOLING LIQUID Placed on the right side of the cylinder head The information of the cooling liquid temperature received by the ECM is used to optimise the power supply at all engine temperatures, and to calculate the power supply requirement upon cold and hot start-ups.
  • Page 518 SENSORS ELEC POSITION SENSOR OF THE THROTTLE BODIES UNIT (POTENTIOMETER) Placed on the right end of the small shaft of the throttle bodies unit The throttle bodies unit position sensor (potentiometer), managed and powered directly by ECM, supplies a signal that identifies the throttle opening position used by the same ECM to determine the fuel dosing and the ignition advance.

  • Page 519: Neutral Switch

    SENSORS ELEC NEUTRAL SWITCH Located inside the gear change box The neutral switch indicates when the gear change is in neutral. Furthermore, the neutral switch supplies a signal relating to the safety device that prevents start-up with the trestle lowered and the gear engaged. IF a gear is engaged with the trestle lowered, power supply to the ECM is interrupted causing the engine to switch off.
  • Page 520 SENSORS ELEC SIDE TRESTLE SENSOR Placed at the top of the side trestle shank If the side trestle is lowered, the engine will not start until the gear change is placed in neutral or the stand in closed position. Disconnect: •...
  • Page 521 SENSORS ELEC CLUTCH SWITCH Placed on the clutch lever The engine will not start until the lever is pulled up to the handle bar. Disconnect: • the clutch switch cables U U se: • the tester and check on the clutch switch pins the table CLUTCH PIN 1 PIN 2...
  • Page 522 SENSORS ELEC FRONT BRAKE SENSOR Placed on the front brake pump It is a switch in contact with the brake lever used for switching on the stop lights. Disconnect: • the contacts of the electric plant on the sensor proceed as shown for the control Use: •...

  • Page 523: Speed Sensor

    SENSORS ELEC SPEED SENSOR Placed on the rear calliper support Reads the fixing screws of the rear brake disk. If the speed is not indicated on the dashboard or it does not function correctly, check the speed sensor and the electric connections with reference to the cable paths on the electric layout.
  • Page 524 SENSORS ELEC BAROMETRIC PRESSURE SENSOR Inside the control unit The atmospheric pressure is detected by means of a sensor placed inside the injection module. This sensor enables the detection of the air density in different environmental conditions (which, for example, the use of the vehicle in areas having different heights).
  • Page 525 SENSORS ELEC LAMBDA PROBE Placed on the drain collector near the catalyst The Lambda probe is able to detect the concentration of oxygen inside the exhaust gas; precisely the lambda value indicating the ratio between air and petrol, where: • Value 1, when combustion is stoichiometric •...
  • Page 526 SENSORS ELEC FALL SENSOR Placed in the centre of the bike in correspondence with the expansion vessel In case of fall, it interrupts the flow of petrol to the injection system. Remove: • the seat See "FRAME 4.130" paragraph. • the tank See "FRAME 4.118"...
  • Page 527 SENSORS ELEC HYDROSTOP Placed on the rear brake pump It is a switch that works by reading the oil pressure exercised on the pump. It is used to switch on the stop lights. Check: • the continuity with the multitester positioned on PIN 1 and PIN 2 and check the table.
  • Page 528 SENSORS ELEC OIL PRESSURE SENSOR Placed on the lower half carter It measures the oil pressure in ball bearing gallery. Disconnect: • the electric coupling Remove: • the oil pressure sensor from the half-carter Check: • the continuity between PIN1 and the sensor mass using an air pressure regulator with inflow on the detection hole.
  • Page 529 SENSORS ELEC AMBIENT TEMPERATURE SENSOR Placed near the equipment It reads the ambient temperature and sends the value to the equipment. Remove: • the fixed cap See "FRAME 4.110" paragraph. • the equipment support See "ROUTINE INSPECTIONS AND ADJUSTMENTS 3.89” paragraph. Disconnect: •...
  • Page 530 DEVICES ELEC DEVICES POSITION Right Electric Device Ignition Switch Horn Left Electric Device Map Button Equipment Diode • • • • • •...
  • Page 531 DEVICES ELEC SYSTEM DEVICES HORN Placed on the right side trellis underneath the right tank fairing The horn is an electric-mechanic device used as acoustic warning device. Remove: • the fixing screw on the frame Disconnect: • the wires of the acoustic warning device Connect: •...
  • Page 532 DEVICES ELEC EQUIPMENT Placed on the headlight equipment support small frame The equipment supplies the driver all information regarding the functioning of the bike: • indicator luminous warning lights: high beams warning light indicators warning light fuel reserve warning light gear change in neutral warning light injection malfunctioning warning light •...

  • Page 533: Ignition Switch

    DEVICES ELEC IGNITION SWITCH Placed behind the steering tube The ignition switch is used for: • giving the main contact to the electric plant • closing the steering lock • keep the parking lights switched on during all requested conditions Remove: •...
  • Page 534 DEVICES ELEC Check: • the continuity with the multitester and check the table. PIN 1 PIN 2 PIN 3 PIN 4 Key ON Key OFF Lock Parking If the above conditions are satisfied, the ignition switch functions, otherwise replace the component. Key at "ON"...
  • Page 535 DEVICES ELEC MAP BUTTON Placed on the dashboard support small frame The map button is used to change the mapping of the control unit. 1) With the button released the map loaded on block 1 (button state 0, contact open) is selected 2) With the button pressed the map loaded on block 2 (button state 1, contact closed) is selected Remove:...
  • Page 536 DEVICES ELEC Check: • the connections must be reported as shown in the table. Brown/Red Purple/Black Purple/Green Black Brown/Red Brown/Red JUMPER...
  • Page 537 DEVICES ELEC RIGHT ELECTRIC DEVICE Placed on the right side of the handle bar The right electric device is made of: • RUN/OFF button it is used to close the contact of the electric plant in case of an emergency •...
  • Page 538 DEVICES ELEC LEFT ELECTRIC DEVICE Placed on the left side of the handle bar The left electric device is made of: • lights switch command high beam/dipped beam shunting switch • indicators command by moving the command to the left or to the right, the relative indicators will be activated.
  • Page 539 DEVICES ELEC DIODE MODULES Placed underneath the on board equipment INDICATORS DIODE MODULE The device can be identified by the number of insertions present on the relative connector (3 PIN). Check: • the continuity with the multitester positioned on symbol (continuity/diode trial function), with terminal + (positive) on PIN2 and with terminal - (negative) on PIN1 and then on PIN3.
  • Page 540 ACTUATORS ELEC ACTUATORS POSITION Fuel Pump Ignition Reels Injection Relay Stepper Injectors Cooling Vent Alternator Start-up Motor Solenoid Remote Control Switch • • • • • • • • • •...
  • Page 541 ACTUATORS ELEC SYSTEM ACTIVATING ACTUATORS In reply to the signal received by the sensors, the ECM adjusts a series of electronic and electric-mechanic actuators. The function and position of the actuators is shown below. AIR AT MINIMUM CONTROL SYSTEM (STEPPER) Located inside the air filter box The system includes a valve for controlling the air passage underneath the throttles of the throttled body...
  • Page 542 ACTUATORS ELEC Check: • the resistance with the multitester positioned on symbol Ω between PIN1 and PIN4 and then between PIN2 and PIN3 Resistance 50 ± 5 Ω...
  • Page 543 ACTUATORS ELEC INJECTORS Positioned on the throttle bodies unit The engine is equipped with three quadruple jet injectors. The jet quantity of the injectors is constant, but the opening duration of every injector is variable. The duration of each injection is calculated by the ECM according to the data received by the various system sensors.
  • Page 544 ACTUATORS ELEC Check: • the resistance with the multitester positioned on symbol Ω between PIN1 and PIN2 Resistance 12 ± 2 Ω...
  • Page 545 ACTUATORS ELEC IGNITION REELS Placed directly on the head of every spark plug The ignition reel gives the necessary high voltage and ignition energy to produce high voltage sparks between the ignition spark plug electrodes. The ECM, through the reading of the various system sensors, determines the relative ignition and advance times.
  • Page 546 ACTUATORS ELEC COOLING VENTS Placed on the radiator body The ECM activates and deactivates the cooling vents according to a signal received from the cooling liquid temperature sensor. When the cooling liquid temperature reaches the upper threshold temperature, the cooling vents activate by means of a command from the ECM.

  • Page 547: Fuel Pump

    ACTUATORS ELEC FUEL PUMP Placed inside the fuel tank The electric pump distributes the fuel inside the supply circuit, by means of a pressure regulator, at a constant pressure of 3.5 bar. The ECM directly manages the functioning of the pump guaranteeing, from the first activation of the board with a timed function, the correct fuel pressure necessary for engine start-up and with a continuous...
  • Page 548 ACTUATORS ELEC SERVICES RELAY UNIT Placed inside the object compartment below the vehicle seat The relay unit is managed by the ECM to drive every load in an optimum manner like: • the lighting system The ECM ensures that all lights switch on in certain conditions, also allowing an energy saving when in discharged battery condition.
  • Page 549 ACTUATORS ELEC POWER REEL Orange/White Yellow/Red DIPPED BEAMS RELAY POWER REEL Yellow/Red Yellow/Green POWER REEL Orange/White Yellow/White HIGH BEAMS RELAY REEL POWER Yellow/Green Yellow/White POWER REEL Red/Black Red/Black INJECTION RELAY POWER REEL Red/White Brown/Purple REEL POWER Brown Orange/Green ELECTRIC FANS RELAY POWER REEL White/Black...
  • Page 550 ACTUATORS ELEC REMOTE CONTROL SWITCH Placed on the left side of the bike near the pinion carter The remote control switch closes the power contact on the start-up motor. Remove: • the alternator lid See "FRAME 4.120" paragraph. Disconnect: • the battery cable - •...
  • Page 551 ACTUATORS ELEC SOLENOID Placed on left side underneath the injectors flute The opening and closing is managed through the ECM to improve the torque/power supply in different use conditions of the vehicle. Remove: • the seat See "FRAME 4.130" paragraph. •...
  • Page 552 ACTUATORS ELEC Check: • the diode Check that it is correctly positioned as shown in the figure. Even if only one control results negative, replace the part. ATTENTION At every inspection of the solenoid device, check the integrity of the contacts and the functioning of the diode.
  • Page 553 ACTUATORS ELEC ALTERNATOR Placed on the left side of the vehicle It allows the balancing of the electric consumptions through the recharging of the battery. Switch on: • the bike Measure: • the voltage with the multitester positioned on symbol at the ends of the battery With bike switched off...
  • Page 554 ACTUATORS ELEC START-UP MOTOR Placed on the left side of the vehicle It is used to start the bike. If the motor does not start, check: • the right electric block See paragraph “7.25”. • the clutch switch See paragraph "7.9". If the motor still does not start, carry out the following check: Remove:...
  • Page 555 DIAGNOSTICS ELEC SYSTEM DIAGNOSTICS IGNITION AND INJECTION There are two special tools for the injection and ignition system diagnosis. there are two special tools. (Code R180197036000) AXONE S C A N T O O L (Code R300082003000) BENDIA A Diagnostic software, able to identify the faults present or that have occurred on the bike, is included in the special equipment.
  • Page 556 DIAGNOSTICS ELEC NUMBERING OF CONNECTORS ECM The diagram at the side shows the sequence of the two ECM connectors. These pin numbers correspond directly to the pin numbers supplied during the diagnostics procedures and to the layout drawing of the wiring used in this manual.
  • Page 557 DIAGNOSTICS ELEC ADDITIONAL DIAGNOSIS The following tables, if used correctly, will help identify the fault in the system, once the diagnostics problem code has been stored. NOTE 1) Black Connector 2) Grey Connector INJECTORS -WALBRO ECU 1 FAULT CODE POSSIBLE CAUSE PRECAUTION P1201/02/03 The flooding indicates short circuit...
  • Page 558 Replace the relative injector and proceed with Faulty test 7 7) Connect the wiring, reset the fault Activity Performed - end the test code and activate the engine to check the fault has been eliminated. Contact Benelli after-sales assistance The fault remains...
  • Page 559 - pin 1/B7 of ECM to pin 1/B3 of ECM with test 5 5) Connect the wiring, reset the fault Activity Performed - end the test code and activate the engine to check the fault has been eliminated. Contact Benelli after-sales assistance The fault remains...
  • Page 560 Replace the relative ignition reel, proceed Faulty ignition reel with test 7 7) Connect the wiring, reset the fault Activity Performed - end the test code and activate the engine to check the fault has been eliminated. The fault remains Contact Benelli after-sales assistance...
  • Page 561 - pin 1/C6 to mass Short circuit with test 7 6) Connect the wiring, reset the fault Activity Performed - end the test code and activate the engine to check the fault has been eliminated. Contact Benelli after-sales assistance The fault remains...
  • Page 562 - pin 1/C5 of ECM to the mass Short circuit with test 7 7) Connect the wiring, reset the fault Activity Performed - end the test code and activate the engine to check the fault has been eliminated. Contact Benelli after-sales assistance The fault remains...
  • Page 563 The fault remains Contact Benelli after-sales assistance N OTE Another possible cause of the malfunctioning of the TPS/AIR TEMPERATURE/H O TEMPERATURE sensors may be the absence of 5 Vdc power supply.
  • Page 564 DIAGNOSTICS ELEC SENSOR POWER SUPPLY VOLTAGE -WALBRO ECU 1 FAULT CODE POSSIBLE CAUSE PRECAUTION P0562 Faulty battery/alternator - low Check and take note of the sensor data of the diagnostics tool (see Axone or Bendia instruction voltage manual). Ensure that the voltage through the battery is acceptable, take note of the voltage.
  • Page 565 Locate and repair the cables fault, proceed Short circuit with test 5 5) Connect the wiring, reset the fault Activity Performed - end the test code and activate the engine to check the fault has been eliminated. Contact Benelli after-sales assistance The fault remains...
  • Page 566 DIAGNOSTICS ELEC START-UP SYSTEM DIAGNOSTICS THE START-UP MOTOR DOES NOT TURN Check if the start-up motor turns The click by connecting the start-up motor terminal directly to terminal + Bring the ignition switch at "ON", with is heard the engine switch off switch at "RUN". of the battery.
  • Page 567 DIAGNOSTICS ELEC THE START-UP MOTOR TURNS BUT THE ENGINE DOES NOT START incorrect Faulty neutral sensor Check the neutral sensor correct Open circuit in wiring Faulty connector contact Faulty diode module incorrect Faulty side trestle switch Check the side trestle switch correct Open circuit in wiring Faulty connector contact...
  • Page 568 DIAGNOSTICS ELEC ELECTRIC PART COMPONENT ANOMALY INTERVENTION GEAR SYSTEM • Faulty alternator Replace • Faulty alternator connection Check Battery warning light on • Faulty battery Replace MAIN • Fuse 30A Replace • Burnt remote control switch Replace No function • Oxidised battery connections Deoxidise/Restore POWER SUPPLY PLANT •...
  • Page 569 DIAGNOSTICS ELEC COMPONENT ANOMALY INTERVENTION Acoustic warning device • Burnt bike fuse 10A Replace does not work • Faulty bike fuse 10A connection Deoxidise/Restore • Faulty warning device Replace • Faulty switch Replace • Faulty acoustic warning device Deoxidise/Restore connection •...
  • Page 570 DIAGNOSTICS ELEC COMPONENT ANOMALY INTERVENTION INJECTION • H O Bulb Replace • Burnt 10A fuse Replace H O temperature • Faulty 10A fuse connection Deoxidise/Restore indicator does not work • Faulty dashboard Replace • Faulty dashboard connection Deoxidise/Restore • Faulty ECU connection Deoxidise/Restore Throttled body •...
  • Page 571 DIAGNOSTICS ELEC FRAME COMPONENT ANOMALY INTERVENTION STEERING WHEEL • Damaged steering bearings Replace • Excessively fastened steering Hard steering wheel bearings Adjust • Bent kingpin Replace • Excessively brakes steering shock absorber Adjust • Damaged steering shock absorber joints Replace •...
  • Page 572 DIAGNOSTICS ELEC COMPONENT ANOMALY INTERVENTION BRAKES • Air bubbles inside the hydraulic circuit Bleed Brakes lever and pedal • Leaks inside hydraulic circuit Repair too soft or "spongy" • Damaged callipers seals Replace • Damaged pump seals Replace • Callipers pistons do not slide smoothly Check •...
  • Page 573 ELECTRIC PLANT ELEC ELECTRIC LAYOUT...
  • Page 574 ELECTRIC PLANT ELEC To identify the contacts of the various components refer to the layout below. 17 18 19 20 CONTACTS COLOURS CONTACTS COLOURS 1) Oil Pressure Purple 11) Set/Reset Switch Yellow/Grey 2) H O Temperature Brown/Purple 12) Revolutions Grey/Red 3) Injection Alarm Red/Black 13) Speed Sensor Output...
  • Page 575 ELECTRIC PLANT ELEC MAINTENANCE WARNINGS CONNECTORS Trigger • When connecting a connector, push until a trigger is heard. • Check whether the connector is corroded or dirty and if its cover is broken. COUPLERS • With a lock type coupler, release the lock before disconnecting it and push all the way when connecting it.
  • Page 576 ELECTRIC PLANT ELEC BATTERY ATTENTION Do not use batteries different from those specified. The MF battery (without maintenance) assembled in this vehicle does not require maintenance operations like the electrolyte level control and the distilled water top-up. Note that the charge system for an MF battery is different to that for a normal battery.
  • Page 577 ELECTRIC PLANT ELEC BATTERY EFFICIENCY CONTROL BATTERY CURRENT LEAKS CONTROL Remove: • the seat See "FRAME 4.130" paragraph. Bring: • the ignition switch to OFF position. Disconnect: • the battery negative cable Connect: • the multitester between the negative terminal and the negative cable of the battery, in function of the ammeter in continuous current ATTENTION...
  • Page 578 ELECTRIC PLANT ELEC CHARGE OUTPUT CONTROL R R emove: • the alternator lid See "FRAME 4.120" paragraph. Start: • the engine and make it rev at 2000 r/min with the lights switch at ON and the selector on HI headlights position. Measure: •...
  • Page 580 This manual is the property of Benelli Q.J. s.r.l.. The total or partial reproduction is forbidden. Benelli recommends original accessories Benelli recommends original products Version June 2009/01 BENELLI Q.J. s.r.l. Strada della Fornace Vecchia 61100 - Pesaro - Italy...

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