Page 1: Contents
COPERTINA MF9_UK...
Page 2 MF9_UK...
Page 3 I I I I I ntroduction SYMBOLS The symbols listed below are all present inside the manual and serve to show those parts which need to be given special attention. WARNING - indicates a grave danger for the safety of people and/ or the integrity of the vehicle.
Page 4: Table Of Contents
CONTENTS CONTENTS CONTENTS CONTENTS CONTENTS GENERAL INFORMATION VEHICLE IDENTIFICATION IMPORTANT INFORMATION SPECIAL INSTRUMENTS 1.3.1 SPECIAL ENGINE INSTRUMENTS 1.3.2 SPECIAL FRAME INSTRUMENTS SPECIFICATIONS GENERAL SPECIFICATIONS TECHNICAL CHARACTERISTICS ENGINE FRAME CHARACTERISTICS ELECTRICAL COMPONENTS BOLT TORQUE 2.5.1 GENERAL BOLT TORQUE 2.5.2 BOLT TORQUE FRAME 2.5.3 BOLT TORQUE ENGINE POINTS TO OIL...
Page 5 3.26 OIL CHAIN 3.27 CHECK AND ADJUST STEERING BALL-BEARINGS 3.28 CHECK FORK 3.29 ADJUST FORK 3.30 CHECK SHOCK ABSORBERS 3.31 ADJUST SHOCK ABSORBERS 3.32 CHECK TIRE PRESSURE 3.33 CHECK WHEELS 3.34 CHECK AND OIL CLUTCH CABLE 3.35 ELECTRICAL PLANT 3.35.1 CHECK BATTERY 3.35.2 BATTERY CHARGING SYSTEM 3.36 CHANGE FUSES...
Page 6 5.1.5 MOUNT CAMSHAFT CYLINDER HEAD 5.2.1 REMOVE CYLINDER HEAD 5.2.2 CHECK CYLINDERHEAD 5.2.3 MOUNT CYLINDER HEAD VALVES AND VALVE SPRINGS 5.3.1 REMOVE VALVES 5.3.2 CHECK VALVES AND VALVE GUIDES 5.3.3 CHECK VALVE HOUSING 5.3.4 CHECK VALVE SPRINGS 5.3.5 CHECK BUCKET-TYPE TAPPET 5.3.6 MOUNT VALVES CYLINDER...
Page 7 5.8.15 MOUNT CLUTCH COMMAND 5.8.16 ADJUSTMENT PHASE EARS 5.9.1 REMOVE GEARS 5.9.2 DISMANTLE GEARS 5.9.3 CHECK GEAR FLANGE BALL-BEARINGS 5.9.4 CHECK GEAR FORK AND SLIDE RODS 5.9.5 CHECK POSITIVE VALVE GEAR SHAFT 5.9.6 CHECK PRIMARY AND SECONDARY SHAFT 5.9.7 ASSEMBLE GEAR 5.9.8 MOUNT GEARS 5.10...
Page 8 WATER PUMP 6.4.1 REMOVE WATER PUMP 6.4.2 DISMANTLE WATER PUMP 6.4.3 CHECK WATER PUMP 6.4.4 ASSEMBLE WATER PUMP 6.4.5 MOUNT WATER PUMP FRAME FRONT WHEEL AND BRAKE DISKS 7.1.1 REMOVE FRONT WHEEL 7.1.2 CHECK FRONT BRAKE DISKS 7.1.3 DISMANTLE FRONT WHEEL 7.1.4 CHECK FRONT WHEEL 7.1.5...
Page 9 7.5.4 DISMANTLE LEFT SEMI-HANDLEBAR 7.5.5 CHECK RIGHT SEMI-HANDLEBAR 7.5.6 CHECK LEFT SEMI-HANDLEBAR 7.5.7 MOUNT RIGHT SEMI-HANDLEBAR 7.5.8 MOUNT LEFT SEMI-HANDLEBAR 7.5.9 INSTALL RIGHT SEMI-HANDLEBAR 7.5.10 INSTALL LEFT SEMI-HANDLEBAR STEERING DAMPER 7.6.1 DISMANTLE STEERING DAMPER 7.6.2 CHECK STEERING DAMPER 7.6.3 MOUNT STEERING DAMPER STEERING HEAD 7.7.1 DISMANTLE LOWER STEERING PLATE...
Page 10 SUPPLEMENTARY DIAGNOSIS ELECTRICAL PLANT CONNECTORS FUSES. SEMI-CONDUCTOR PARTS BATTERY 9.4.1 CHECK BATTERY EFFICIENCY FUSES RELAYS 9.6.1 RELAY STARTER 9.6.2 RELAY SERVICES GROUP ENGINE STARTER ALTERNATOR STARTER DIAGNOSTIC SYSTEM 9.10 CHECK SAFETY SYSTEM PARTS 9.11 DIODES 9.12 GEAR SWITCH POSITION 9.13 LATERAL SWITCH STAND 9.14 CLUTCH SWITCH...
Page 11: General Information
5. Keep all the components away from any source of heat. • SPARE PARTS Use original Benelli spare parts exclusively. Use oils and greases recommended by Benelli to oil the components. Other products might appear similar in look and function but are inferior in quality. MF9_UK...
Page 12: Special Instruments
1.3 SPECIAL INSTRUMENTS WARNING: To avoid errors in ordering the special instruments, refer exclusively to the inherent code. For correct maintenance and a perfect set-up use the BENELLI special instruments, avoiding damage as a result of inadequate or technically improvised instruments. MF9_UK...
Page 13: Special Engine Instruments
1.3.1 SPECIAL ENGINE INSTRUMENTS 1. R180197015000 GONIOMETER PLUG FOR DISTRIBUTION[*] 2. R180197017000 INSTRUMENT FOR MOUNTING CLUTCH OIL SEAL CASING [*] 3. R180197018000 CYLINDER MOUNTING SPACERS 4. R180197019000 SMALL CYLINDER COLUMN FIXING SPAN 5. R180197020000 FALSE SPARKING-PLUG 6. R180197021000 PISTON THREAD MEASURER MF9_UK...
Page 14 7. R180197022000 P.M.S. MEASURER 8. R180197023000 CLUTCH COVER OIL SEAL PAD [*] 9. R180197024000 OIL SEAL PINION PAD [*] 10. R180197025000 OIL SEAL VALVE PAD [*] 11. R180197026000 INSTRUMENT FOR CHECKING VALVE LIFT 12. R180197027000 GONIOMETER INDICATOR MF9_UK...
Page 15 13. R180197028000 CLUTCH OIL SEAL PAD ON FLANGE [*] 14. R180197029000 ENGINE SUPPORT 15. R180197030000 INSTRUUMENT FOR CHECKING ENGINE SHAFT AXIAL PLAY 16. R180197036000 ENGINE MANAGEMENT DIAGNOSTIC INSTRUMENT [*] 17. R180100143000 RAPID RELEASE PETROL TUBE KIT [*] MF9_UK...
Page 16: Special Frame Instruments
1.3.1 SPECIAL FRAME INSTRUMENTS 1. R180197033000 20 ALLEN WRENCH [*] 2. R180197031000 STEERING RING-NUT CLAMPS [*] 3. R180197034000 EMGINE DISMANTLING INSTRUMENT[*] 4. R180197032000 ENGINE SHOULDER ADJUSTMENT CLAMPS [*] (*) Compulsory instruments MF9_UK...
Page 17: Specifications
S S S S S pecifications SPECIFICATIONS 2.1 GENERAL SPECIFICATIONS DIMENSIONS STANDARD LIMITS Engine length 2040 mm — Engine width 780 mm — Maximum height 1160 mm — Wheelbase 1419 mm — Minimum light 100 mm — Saddle height 840 mm —...
Page 18 Valve lift [observation data with play of 0 mm] Suction: 9.2 mm Exhaust: 8.75 mm The functioning play of the tappets with the engine cool must be: Suction: 0.25-0.30 mm Exhaust: 0.30-0.35 mm Transmission Multiple disks dry friction: commanded by a cable activated by a lever on the left side of the handlebar.
Page 19: Frame Characteristics
2.3 FRAME CHARACTERISTICS FRAME STANDARD LIMITS Type Mixed steel-aluminium frame and structurre Angle of incidence 23.50° — Forward stroke 94.5 mm — FRONT WHEEL STANDARD LIMITS Type Cast — Dimensions: 17 x MT3.50 Material: aluminium Wheel span 120 mm — REAR WHEEL STANDARD LIMITS...
Page 20 REAR TIRE STANDARD LIMITS Type Tubeless — Dimensions 180/55 ZR17 (73W) — Model D207F RR (DUNLOP) — Tire pressure cold 250 kPa (2.5 kg/cm, 2.5 bar) — Maximum tire pressure 250 kPa (2.5 kg/cm, 2.5 bar) — Min. depth tread —...
Page 21 FRONT SUSPENSION STANDARD LIMITS Type Telescopic fork with — upturned stems Type of front fork Helical spring/damper — Front fork stroke 120 mm — Spring Spring rate (K1): 7.35 N/mm (0.75 kgf/mm) — Spring stroke (K1): 0 ~ 120 mm —...
Page 22: Electrical Components
OSCILLATING ARM STANDARD LIMITS Free play (at the end of the arm) Radial — 1 mm Axial — 1 mm TRANSMISSION CHAIN STANDARD LIMITS Model: 50ZVM (DAIDO) — Connection quantities — Play of the chain 40 ~ 50 mm — Max.
Page 23 COMPONENTS STANDARD Loading system Type: AC magnet Model: 5-101211-502-1 (DENSO) Nominal exit: 13.5V / 48A at 5000 rpm Tension adjustment (in the alternator) Type: Semiconductor, FIELD CONTROL Voltage adjustment: 14.5 ± 0.3V (at 5000 rpm, 10A and 25°C) Rectifier in the alternator Battery YT 12B-4 / 12V 10Ah Electrical start system...
Page 24: Bolt Torque
2.5 BOLT TORQUE 2.5.1 GENERAL BOLT TORQUE The bolt torques are inserted in the chapters of the manual together with the relative special instructions, if necessary. If not otherwise specified, the bolts are considered with greased thread, created at environmental temperature. BOLT TORQUES kgf·m 10 mm...
Page 25: Bolt Torque Frame
2.5.2 BOLT TORQUE FRAME DESCRIPTION THREAD NOMINAL INSTRUCTIONS TORQUE DETAILS (Nm) ENGINE GROUP: ENGINE ON BACK FUSION PLATE M12x1.25 GREASE RIGHTHAND FRAME WITH LEFTHAND NUT ENGINE SUPPORT ROD ON ENGINE M10x1.25 GREASE HEAD RIGHTHAND ENGINE ON LOWER CROSSBAR M12x1.25 GREASE LOWER ENGINE CRANKPIN THROUGH FRAME WITH NUT LOWER CRANKPIN HEAD TORQUE...
Page 26 SADDLE PILLAR GROUP: SADDLE PILLAR ON FRAMEWORK GREASE SADDLE PILLAR ON FRAME BACK PLATE GREASE WITH SPECIAL NUT HANDLEBAR GROUP COMMANDS: LEFT AND RIGHT SEMI-HANDLEBARS ON FORK STEM GREASE LEFT AND RIGHT SAFETY DOWELS LEFT AND RIGHT SEMI-HANDLEBARS SAFETY SCREWS FRONT OIL BRAKE TANK SUPPORT ROD ON FRONT BRAKE PUMP FRONT OIL BRAKE TANK ON SUPPORT ROD...
Page 27 REAR FORK GROUP: REAR FORK CRANKPIN SCREW ON REAR FORK CRANKPIN M18X1.5 GREASE CHAIN PAD ON REAR FORK FERRULES FOR ASSEMBLY STAND ON REAR FORK FRONT SUSPENSION GROUP: FERRULE STEMS ON STEERING BASE GREASE FERRULE STEMS ON STEERING HEAD GREASE FERRULE HUBS ON FRONT WHEEL CRANKPIN GREASE FRONT MUDGUARD SUPPORTS ON FORKS...
Page 28 REAR WHEELGROUP: REAR WHEEL CRANKPIN NUT M24x1.5 GREASE CROWN ON FLEXIBLE COUPLING FLANGE M10x1.25 GREASE REAR BRAKE DISK ON WHEEL LOCTITE 243 SPEED SENSOR ON CLIP SUPPORT LATERAL ASSEMBLY STAND GROUP: HANGER SUPPORT PLATE ON FRAME HANGER CRANKPIN ON FRAME M10x1.25 SPRING HOOK ON HANGER ELECTRIC PLANT GROUP:...
Page 29 FRONT BRAKING PLANT GROUP: FRONT BRAKE PUMP ON RIGHT SEMI-HANDLEBAR FIRST TORUE BOLT ARROW SIDE FRONT BRAKE CLIPS ON RELATIVE SUPPORTS M10x1.25 GREASE HYDRAULIC CONNECTIONS ON FRONT BRAKE PUMP AND CLIPS M10X1 RESTORE BOLT TORQUE TWICE AFTER HAVING LOOSENED REAR BRAKING PLANT GROUP: REAR BRAKE PUMP ON RIGHT FOOTBOARD SUPPORT GREASE WITH NUT...
Page 30 PETROL PUMP ON TANK PETROL TUBE ON THROTTLE BODY M12X1.5 DISTRIBUTOR ON PLATE GAS CABLES FIXING PLATE ON THROTTLE BODY FRONT AND BACK BODYWORK GROUP: USE STANDARD TIGHTENING TORQUE WITH M6 THREAD FOR BODYWORK: 8Nm±20% MF9_UK...
Page 31: Bolt Torque Engine
2.5.3 BOLT TORQUE ENGINE DESCRIPTION THREAD NOMINAL BOLT SPECIAL TORQUE INSTRUCTIONS (Nm) ENGINE CRANKCASE GROUP: CRANKCASE TEF FIXING SCREW M6x1x35 CRANKCASE TEF FIXING SCREW M6x1x45 CRANKCASE TEF FIXING SCREW M6x1x60 CRANKCASE TEF FIXING SCREW M6x1x75 CRANKCASE TEF FIXING SCREW M6x1x120 CRANKCASE TEF FIXING SCREW M8x1.25x40 9.8+24.5...
Page 32 PRISONNER SCREW HEAD M10x1 BY STRIKING OIL THREAD VENT HEAD CONNECTION M18x1 14.7 LOCTITE 270 TCEI CRANKCASE FIXING SCREW M6x1X120 12.75 DOWEL M8x10 14.7 LOCTITE 270 ENGINE GROUP/OILING: TEF OIL PUMP FIXING SCREW M6x1x20 LOCTITE 243 OVERPRESSURE VALVE M12x1.5 24.5 LOCTITE 243 LARGE EXCHANGER FIXING SCREW M20x1.5...
Page 33 SPECIAL CLUTCH CUP FIXING SCREW M8x1x16 24.5 LOW CLUTCH ROD HEXAGONAL FIXING NUT M8x1.25 15.68 TEF CLUTCH SPRING FIXING SCREW M6x1x25 CLUTCH HEXAGONAL FIXING NUT M20x1 LOCTITE 243 TEF CYLINDER LEVER FIXING SCREW M6x1x20 LOCTITE 243 TCB CYLINDER FIXING SCREW M6x1x20 LOCTITE 243 ENGINE GROUP/GEARS:...
Page 34: Points To Oil
TCEI PHONIC WHEEL SENSOR SCREW M6x1x12 LOCTITE 243 ENGINE GROUP/ SUPPLY: TCEI THROTTLE BODY FIXING SCREW M6x1x25 ENGINE GROUP: SUPPLY: TSPEI FREE WHEEL RING FIXING SCREW M6x1x20 16.5 LOCTITE 270 ENGINE HEXAG. FLEXIBLE COUPLING SCREW M8x1,25x25 24.5 LOCTITE 270 LOW HEXAG. FLEXIBLE COUPLING NUT M10x1.25 29.4-49 SELF-BRAKING...
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Page 49: Periodical Checks And Adjustments
P P P P P eriodical PERIODICAL CHECKS AND C C C C C ADJUSTMENTS hecks 3.1 INTRODUCTION This chapter includes information about checks and adjustments for better maintanence of the bike's performance. MAINTENANCE FREQUENCY 0 km 1000 km 6000 km 11000 km (0 mi) (625 mi)
Page 50 MAINTENANCE FREQUENCY 0 km 1000 km 6000 km 11000 km (0 mi) (625 mi) (3750 mi) (6875 mi) COMPONENT OPERATION before delivery running-in Service Service Service Petrol filter Check/Change Throttle body Check/Change Air filter Check/Change Check/Change Pinion/Stop washer At every change of the transmission chain in any case Change Check/Adjust Transmission chain...
Page 51 MAINTENANCE FREQUENCY 0 km 1000 km 6000 km 11000 km (0 mi) (625 mi) (3750 mi) (6875 mi) COMPONENTS OPERATION before delivery running-in Service Service Service Transmissions and flexible Check/Adjust commands Steering crown saddle post Check/Adjust Steering saddlle post ball- Check/Adjust bearings Every 20000 km (12000 mi)
Page 52 MAINTENANCE FREQUENCY 0 km 1000 km 6000 km 11000 km (0 mi) (625 mi) (3750 mi) (6875 mi) COMPONENTS OPERATION before delivery running-in Service Service Service Locks Check/ Functioning Screws and nuts Check/Tighten Tube clamp straps Check/Tighten General oiling General test CODE: i = inspection and adjustment , cleaning, oiling or change according to need.
Page 53: Check Sparking-Plugs
3.2 CHECK SPARKING-PLUGS WARNING: Changing and checking the sparking-plugs must be carried out with the engine cold. Remove the internal instrument board fastenings (see “DISMANTLE INSTRUMENT BOARD FASTENINGS"). Remove the small cap (see “DISMANTLE SMALL CAP"). Remove the lower cowling (see "DISMANTLE LOWER COWLING").
Page 54: Clean Air Box
Oil the sparking-plug threading, position it in its proper seat and tighten it. 12 N·m 1.2 Kg-m Use the reverse procedure to dismantling. 3.3 CLEAN AIR BOX WARNING: To avoid the risk of fire or explosion do not use petrol or inflammable solvents in cleaning the filtering element inside the filter box.
Page 55: Gas Command Play
Remove the filtering element (3) situated inside the filter box. Wash the filtering element with solvents specific for this use and leave it to dry in the open air. Apply a specific oil to the entire surface of the filtering element. NOTE: Check that the filtering element is always positioned with its side of major density turned upwards.
Page 56: Adjustment Co
Adjust the play on the nuts (4) and counter-nuts (5). Adjust the play using the adjusters , turning them clockwise or anti-clockwise. Clockwise the play diminishes. Anti-clockwise the play increases. The value of the gas command play must come within the specific value.
Page 57 Select the engineering Parameters icon on Axone, then that on the Stepper position and start. Bring the engine water temperature to 90°. Connect a CO instrument tester to the exhaust plant. The operation of adjusting the CO at minimum is recursive and must take into consideration contemporaneously variations in the Stepper position and the strength of the mixture.
Page 58: Adjustment Throttle Housing
3.6 ADJUSTMENT THROTTLE HOUSING To be able to accede to the throttle body the following components need to be dismantled. Dismantle the mirrors (see "DISMANTLE MIRRORS"). Dismantle the internal instrumentation fastenings (see "DISMANTLE INTERNAL FASTENINGS"). Dismantle small cap (see “DISMANTLE SMALL CAP"). Dismantle lower semi-cowling (see "DISMANTLE SEMI- COWLING“).
Page 59 Disconnect the three tubes that connect the throttle body to the Stepper (1). Disconnect the three lips (2) that connect the throttle body. Connect, using the three T switches (3), the minimum air conduits of the throttle body to a mercury columned Vacuum meter.
Page 60 Start the engine, check that the mercury columns (4), with the engine at minimum, are alligned and then proceed to balancing. Tighten the upper by-pass screws (5) closing the passages completely. Work on the by-pass screws, loosening them until the columns are equal.
Page 61: Check Stepper
3.7 CHECK STEPPER Remove the internal instrument board fastenings (see “DISMANTLE INTERNAL INSTRUMENT BOARD FASTENINGS"). Remove the small cap (see "DISMANTLE SMALL CAP"). Remove the lower cowling (see“DISMANTLE LOWER COWLING"). Remove the upper left and right cowling (see "DISMANTLE LEFT AND RIGHT COWLING"). Remove the tank (see "DISMANTLE TANK").
Page 62: Adjustment Valve Play
3.9 ADJUSTMENT VALVE PLAY Remove the internal instrument board fastenings (see “DISMANTLE INTERNAL INSTRUMENT BOARD FASTENINGS"). Remove the small cap (see "DISMANTLE SMALL CAP"). Remove the lower cowling (see“DISMANTLE LOWER COWLING"). Remove the upper left and right cowling (see "DISMANTLE LEFT AND RIGHT COWLING").
Page 63: Engine Distribution
Remount the cams with the signs aligned, remount the chain, put the engine back into phase and check the distribution with the reference signs. 3.10 ENGINE DISTRIBUTION WARNING: Specific instruments are needed to set up the distribution: goniometer drive, upper dead centre Measurer and equipment for checking valve lifter.
Page 64 Carry the first piston to the upper dead centre, turning the screw (3) clockwise as indicated on it and align the two reference signs (A). WARNING: When mounting the goniometer indicator, check the presence of about 5 mm of space to avoid contact between the indicator and the goniometer.
Page 65 Position the goniometer indicator (5), using the nut (6) to adjust the indicator (A). SPECIFIC EQUIPMENT: Goniometer indicator (5): R180197027000 Position the upper dead centre measurer (7) in the place of the first piston sparking-plug. SPECIFIC EQUIPMENT U.p.c. Measurer (7): R180197022000 Position the equipment for checking the valve lifter (8) on the two suction and exhaust bridges at the height of the first piston,...
Page 66 Turn the goniomenter drive clockwise until finding the upper dead centre. The olives of the two eccentric shafts on the first piston should be turned towards each other. Once the u.d.c. (upper dead centre) is found, position the crown (12) at zero on the central test indicator. MF9_UK...
Page 67 Loosen the two screws (10) and turn the goniometer until the indicator (1) coincides with zero and tighten the screws again. Turn the test indicator crown (12) until it coincides with zero. Turn the goniometer drive from the upper dead centre clockwise until it reaches 1 mm on the test indicator (12).
Page 68 If the value does not correspond to the specific value, turn the goniometer twice and carry it to 21° before the UDC. Loosen the two screws (13). Load 1mm again on the test indicator (12). Lock the two worm screws with Loctite after having degreased them one at a time.
Page 69: Check Engine Oil Level
If the value found does not coincide with the specific value, tun the goniometer twice and bring it to 36° before the lower dead centre. Loosen the tow screws (16). Load 1 mm again. Tighten the two screws (16) with Loctite after having degreased them one at a time.
Page 70: Change Engine Oil And Filter
WARNING: Danger: Do not start the engine if the oil is below the MIN. reference. Carry out the check cold with the engine off. If carried out while warm, the engine must be off for at least ten minutes. This check is carried out placing the mortorbike on a horizontal surface and in an upright position (vertical position).
Page 71 WARNING: Used oils are harmful to the environment. Dispose of the used oils according to the regulations in vigour. Remove the oil loading cap (1). Remove the oil discharge cap (2). Let all the used oil empty away. Change the oil filter (3). MF9_UK...
Page 72 WARNING: To re-mount the oil filters (3), oil the surfaces of their contacts. NOTA: It is essential to use original Benelli filter oil Code: R180107101000. Re-position the oil exhaust cap (2) and tighten it. 22 N·m 2,2 Kg-m Engine oil quantity: - without substitution of oil filter: about 3.1 litres...
Page 73: Check Cooling Liquid Level
3.13 CHECK COOLING LIQUID LEVEL WARNING: Filling the cooling liquid must always be carried out with the engine cold. Never try to remove the radiator cap when the engine is hot to avoid the risk of burns. WARNING: In determined conditions the ethylene glycol contained in the cooling liquid is inflammable and its flame is invisible.
Page 74: Change Refrigerant Liquid
WARNING: Sprays of refrigerant can damage painted surfaces. Be careful not to spill the fluid when filling the cooling plant. Wipe any eventually spilt refrigerant with a clean cloth immediately. Remove the saddle to get to the cap Remove the cap and fill using the cooling fluid advised in the oils and liquids table.
Page 75 Remove the liquid discharge screw (2) on the pump (3) and recover the washer. NOTE: Let the cooling liquid empty away completely. NOTE: To facilitate the complete emptying of the cooling liquid contained in the cylinder blocks, lean the bike on both sides and press contemporaneously on the entry and exit rubber tubes of the radiator.
Page 76: Fill Cooling Plant
3.15 FILL COOLING PLANT NOTE: Carry out the following operations with the engine cold and the bike on the lateral assembly stand. Remove the radiator cap (1). Remove the expansion tank cap (2). Fill the circuit with about 3 litres of refrigerant liquid through the radiator cap (1).
Page 77 COOLING PLANT DIAGRAM MF9_UK...
Page 78: Check Fuel Tubes
3.16 CHECK FUEL TUBES Remove the tank (see "DISMANTLE TANK"). SPECIFIC EQUIPMENT Petrol tube rapid release kit: R180100143000 Sight check the state of the fuel tube (1). If the tube is damaged or excessively worn, change it. Mount the tank in the reverse way to dismantling. NOTE: The petrol tube must be changed every 16000 Km.
Page 79: Adjustment Rear Brake Pedal
3.19 ADJUSTMENT REAR BRAKE PEDAL Loosen the screw (1) and adjust the cam (2) at will. Loosen the nut (3). Adjust the play of the rear brake command, working on the threaded pin (4). The play increases by tightening. The play diminishes by loosening. 3.20 CHECK BRAKE LIQUID WARNING: An insufficient quantity of brake liquid may allow...
Page 80: Check Front And Back Brake Pads
WARNING: Brake liquid is harmful or mortal if swallowed and harmful if it comes into contact with the skin or the eyes. Keep the brake liquid away from children and domestic animals. In the case of swallowing the brake liquid call a doctor immediately and, in order to avoid sucking the liquid into the lungs, do not provoke vomiting.
Page 81: Change Front Brake Pads
The rear brake pads have to be changed when the pad-disk contact surfaces are coplanar witht the liner (B) present at the end of the steel casing of the pad. Apart from a sight check, a particular noise is noticeable during braking due to the rubbing of the liners on the disk.
Page 82: Check Braking Plant Tubes
3.22 CHECK BRAKING PLANT TUBES Sight check the state of the front (1) and rear (2) braking plant tubes. If the tubing is broken, excessively worn or losing liquid, change 3.23 PURGE FRONT/REAR BRAKING PLANT 3.23.1 PURGE REAR BRAKING PLANT WARNING: Fill with the brake liquid using only the type of liquid advised in the oils and liquids table of this manual.
Page 83 Connect a possibly transparent tube of a suitable size to the purge screw (2), position the other end of the tube in a suitable recipient and place a liner similar to the disk between the brake pads. Open the tap of the rear plant oil tank . Operate and release the lever (3) repeatedly and in rapid succession.
Page 84: Purge Front Braking Plant
3.23.2 FRONT BRAKING PLANT PURGE Procede in the same way as for the rear plant without, however, having to remove the clamps. Purge the right as well as the left clamp. Procede in the same way as for the brake purge clamps also on the front brake pump.
Page 85: Adjustment Chain
3.25 CHAIN ADJUSTMENT To carry out the following operations, position the motorcycle on the supplied rear assembly stand horizontally and with the gears in neutral. WARNING: Using the motorcycle with the chain in a bad condition or badly adjusted may cause accidents. WARNING: If the chain shows flattened or scuffed links, a correct oiling of the chain according to the...
Page 86 3.26 OILING THE CHAIN WARNING: The chain is the O-ring type: to prevent damage do not clean it with jets of steam or water at high pressure nor use petrol or the detergent solvents on the market. Cleaning the chain must be carried out exclusively with kerosene.
Page 87: Check And Adjust Steering Ball-Bearings
3.27 CHECK AND ADJUSTMENT STEERING BALL-BEARINGS Check that the steering ball-bearings have no play. If necessary procede as follows. Remove the upper steering plate (1) (see "DISMANTLE FRONT FORK"). WARNING: Never exceed the bolt torque to avoid steering malfunction. Loosen the counter ring-nut (2) and tighten the ring-nut (3) using the specific instrument.
Page 88: Check Fork
Check the absence of play. If necesary, repeat the previous operations. Mount the upper steering plate (1) (see "MOUNT FRONT FORK") Check the free rotation of the steering. 3.28 CHECK FORK Keeping the front brake on, check the state of the fork as shown in the figure.
Page 89: Adjust Fork
If the fork needs maintenance, refer directly to the supplier listed in the "SPECIFICATIONS" chapter. 3.29 FORK ADJUSTMENT Three adjustments are possible on the front fork: - Preload spring adjustment (1) - Braking in extension adjustment (2) - Braking in compression adjustment (3) REAR SUSPENSION Standard Set-up Track...
Page 90 WARNING: It is essential that both stems of the fork are adjusted to the same position. Adjusting the preload spring is carried out counting the spins that are made clockwise or anti-clockwise with the adjuster (4). The preload will be rigid clockwise. The preload will be slack anti-clockwise.
Page 91: Check Shock Absorbers
3.30 CHECK DAMPER Check the state of the rear damper as shown in the figure. If the rear damper needs maintenance, refer directly to the supplier listed in the "SPECIFICATIONS" chapter. 3.31 ADJUSTMENT DAMPER Three adjustments are possible on the rear damper: : - Preload spring adjustment (1) - Braking in extension adjustment (2) - Braking in compression adjustment (3)
Page 92 Adjustment of the preload spring is carried out using the two ring-nuts (1) and (2) in the figure. Loosen ring-nut (1) and adjust the preload with ring-nut (2). Clockwise, the preload will be more rigid. Anti-clockwise, the preload will be slacker. Once the preload is adjusted, tighten the ring-nut (1).
Page 93: Check Tire Pressure
3.32 CHECK TIRE PRESSURE WARNING: Incorrect inflation of the tires causes serious danger in using the bike. Insufficient pressure can cause the the tire to slip on the rim or its detachment, with consequent deflation of the tire and loss of control of the vehicle.
Page 94: Check Wheels
3.33 CHECK WHEELS Check the radial and axial on the rear rim as in the figure. The value must enter within the specific value. SPECIFIC VALUE Axial veer = 0.3 mm Work on the front wheel as on the back wheel. SPECIFIC VALUE Axial veer = 0.05 mm Excessive veering and eccentricity are generally caused by...
Page 95: Check And Oil Clutch Cable
3.34 CHECK AND OIL CLUTCH CABLE Check the free run of the cable in its sheath. If necessary, oil it with the advised oil. If the cable sheath is damaged, change both the cable and sheath together. WARNING: If the external body of the battery is damaged, sulphuric acid, a poisonous and extremely corrosi- ve substance, may leak out.
Page 96 Check the state of charge of the battery (1) with a tester (2) functioning as a voltmeter. If necessary recharge the battery. SPECIFIC VALUE Battery charge = 12.5V WARNING: These values vary according to the temperature, the condition of the battery plates and the level of the electrolyte.
Page 97: Battery Charging System
WARNING: Pay attention never to remove the sealing fastenings of the MF battery. Recharge Environmental temperature Avoid the use of a nominal high potential battery charge because this forces the high amperage tension too quickly inside the battery, causing the battery to overheat with consequent damage to the plates.
Page 98 RECHARGING WITH A VARIABLE TENSION BATTERY CHARGER Measuring the NOTE: Recharge wait over 30 minutes tension at empty Ampere meter before measuring the tension at before recharging. empty of the battery Connect the battery NOTE: Set the recharge tension to 16 ~ charger and an ampere 17V.
Page 99 RECHARGING WITH A CONTINUOUS TENSION BATTERY CHARGER Measure the tension at NOTE: wait over 30 minutes empty before before measuring the tension at recharging. empty of the battery Connect the battery NOTE: Set the recharge tension to 16 ~ charger and an ampere 17V.
Page 100: Change Fuses
3.36 CHANGING FUSES The reload fuse (1) is on the left side of the engine in the position indicated. The spare fuse (2) is beside it. WARNING: Never use a fuse with a setting different to that specified to avoid damaging the electrical plant of the motorcycle with a consequent danger of fire.
Page 101: Change Front Lights
3.37 CHANGING FRONT LIGHTS Loosen and remove the four fixing screws (1). Remove the internal instrument board fastenings (see "DISMANTLE INTERNAL INSTRUMENT BOARD FASTENINGS"). Remove left mirror (see "DISMANTLE MIRRORS"). Remove the small cap (2) (see "DISMANTLE SMALL CAP"). Remove the lower left semi-cowling (see ("DISMANTLE LOWER COWLING").
Page 102: Change Rear Lights
Adjusting the front headlight allows carrying out the following adjustments: - Vertical headlight adjustment (1) - Oblique anti-dazzle light adjustment (2) - Horizontal headlight adjustment (3) - Oblique headlight adjustment (4) - Horizontal anti-dazzle light adjustment (5) - Vertical headlight adjustment (6) Positioning the lever (7) low, the light is set for driving to the right;...
Page 103: Change Licence-Plate Holder Light
3.39.2 CHANGING LICENCE-PLATE LIGHT Loosen and remove the screw (1). Remove the rubber lamp-holder. Change the position lamp. Position the rubber lamp-holder and tighten the screw (1). 3.39.3 CHANGE FRONT AND REAR ARROWS 3.39.3.1 CHANGE FRONT ARROWS Loosen and remove screw (1). Remove the glass cover (2).
Page 104: Change Back Arrows
3.39.3.2 CHANGE REAR ARROWS Loosen and remove the screw (1). Remove the glass cover (2) and change the bulb. Position the glass cover (2) and tighten the screw (1). Operate in the same way with the opposite arrow. MF9_UK...
Page 105: Cowling
C C C C C owling COWLING 4.1 DISMANTLE COWLING To remount proceed in the reverse way to dismantling, except for eventual specific notes. 4.2 DISMANTLE LOWER SEMI-COWLING WARNING: Do not damage the cowling while removing. WARNING: Take note of the position of the screws for correct remounting.
Page 106: Dismantle Upper Semi-Cowling
Unscrew and remove the two screws (1). Separate the right semi-cowling (2) from the left (3) as indicated in the figure. DISMANTLE UPPER SEMI-COWLING 4.3.1 DISMANTLE LEFT AND RIGHT INTERNAL INSTRUMENT BOARD FASTENINGS Unscrew and remove the screw (1). Remove the left instrument board fastenings (2). Procede in the same way with the right instrument board fastenings.
Page 107: Dismantle Left And Right Rearview Mirrors
Turn, as shown in ther figure, the left internal instrument board fastening (4) and remove it. Proceed in the same way with the right internal instrument board fastening (5). 4.4 DISMANTLE LEFT AND RIGHT REARVIEW MIRRORS Extract the internal rubber cap fastening. Support the left rearview mirror.
Page 108: Dismantle Tail-Piece
4.5 DISMANTLE UPPER LEFT AND RIGHT COWLING WARNING: Take note of the position of the screws for correct remounting. Remove the four screws (1). There are two high-speed nails in the area indicated by the arrows. Remove the two high-speed nails (2) under the front headlight to separte the cowlings from the wheel housing.
Page 109 4.6 DISMANTLE TAIL-PIECE WARNING: Note the position of the screws for correct remounting. Remove the saddle (1) using the supplied wrench. Unscrew and remove the centre fixing screw (2) of the license- plate holder support. Unscrew and remove the two lower license-plate holder support fixing screws (3).
Page 110: Dismantle Left And Right Upper Cowling
Loosen and remove screw (6), remove the glass cover of the tail-piece(7). Loosen screw (8) and extract the parabola (9). Detach the contacts to the tail-piece and remove the parabola (9). Loosen and remove the four screws (10). MF9_UK...
Page 111: Dismantle Wheel Housing
WARNING: During the following procedure do not force the elasticity of the rear tail-piece more than is necessary. Remove the rear tail-piece (11), enlarging its front part slightly and passing it towards the rear of the bike as indicated in the figure.
Page 112: Dismantle Cowling Beneath Headlight
4.8 DISMANTLE COWLING BENEATH THE HEADLIGHT WARNING: During the following operation support the cowling beneath the headlight. Remove the upper left and right cowlings (ss("DISMANTLE UPPER LEFT AND RIGHT COWLINGS"). Loosen and remove the two screws (1) and screw (2) on both sides.
Page 113: Dismantle Cable Grommet Cover
4.11 DISMANTLE CABLE GROMMET COVER Loosen and remove the two screws (1) and remove the cable grommet cover (2). 4.12 DISMANTLE RIGHT AND LEFT FOOTRESTS Loosen and remove the two screws (1) and remove the right footrest (2). Proceed in the same way with the left footrest (3). 4.13 DISMANTLE HOOD Remove the lower semi-cowlings (see ("DISMANTLE LOWER SEMI-COWLINGS").
Page 114: Dismantle Tank
4.14 DISMANTLE TANK Loosen and remove the two screws (1) and remove the steering block cover (2). Loosen and remove the two screws (3). Loosen and remove screw (4) and move the trigger box and the trigger box support as in the figure. MF9_UK...
Page 115 Loosen and remove the screw (5). Raise the fuel tank (6). Disconnect the petrol pump cabling (7). MF9_UK...
Page 116: Dismantle Tank Fuel Pump
Disconnect the rapid unhooking petrol tube (8) from the pump using the specific equipment. SPECIFIC EQUIPMENT INSTRUMENT: code R180100143000 Insert the specific pump valve closure cap (10) to avoid oil spilling out. 4.15 DISMANTLE TANK FUEL PUMP Remove the tank from the vehicle (see "DISMANTLE TANK"). Empty the tank, conserving the fuel in a dry place and far from the rays of the sun and open flames.
Page 117: Engine
E E E E E engine ENGINE CAMSHAFT 5.1.1 REMOVE CAMSHAFT To remove the engine from the frame use the specific equipment. SPECIFIC EQUIPMENT Engine dismantling instrument: R180197034000 To support the engine use the specific equipment. SPECIFIC EQUIPMENT Engine support: R180197029000 Remove the access cover (1) to the phonic wheel.
Page 118 Remove the coils (4) and the sparking-plugs beneath. WARNING: Take note of the position of the screws for correct remounting. Unscrew the eight head cover fixing screws (5). Remove the head cover. Remove the chain pad (6), unscrewing the two fixing screws (7).
Page 119: Check Camshaft
WARNING: Make sure that the distribution chain does not fall into the casing. Remove the chain stretcher. WARNING: Note the position of the elements for correct remounting. Unscrew the fixing screws of the large caps (8) and remove them. Remove the bridge (9), unscrewing the fixing screws. Remove the camshafts and the chain.
Page 120: Check Chain, Sprocket Wheels And Camshaft Chain Guide
The maximum play between the distribution camshaft and seat is 0.08 mm. If the value does enter within the specific value, change the element. VALUE LIMIT CAMSHAFT AND SEAT Max. play= 0.08 mm SPECIFIC EQUIPMENT Instrument for checking engine shaft axle: R180197030000 5.1.3 CHECK CHAIN, SPROCKET WHEELS AND CAMSHAFT CHAIN GUIDE...
Page 121: Check Chain Stretcher
5.1.4 CHECK CHAIN STRETCHER Check the free sliding of the chain stretcher rod. Check the state of the chain stretcher spring. Check the integrity of the chain stretcher. If an element or its components are damaged or ruined, change it/them. 5.1.5 MOUNT CAMSHAFT WARNING: To mount the camshafts correctly position the olives...
Page 122 Position the transmission chain on the toothed wheels of the distribution shafts. Position the bridge and the upper chain pad and tighten the fixing screws in two phases as in the diagram in the figure. 1st phase: 6 N·m; 2nd phase: 13 N·m NOTE: Always oil with Teflon SINTOFLON paste.
Page 123 Check that the posiiton of the cylinder 1 olives are turned towards each other as in the figure. Check that the position of the phonic wheel is as indicated in the figure (“A” and “B” aligned). Check the valve play with a feeler. If the valve play is not within the specific value, adjust the valve play (see "ADJUST VALVE PLAY").
Page 124 WARNING: Always use new gaskets. Position the gaskets of the head cover (1 and 2 ). WARNING: Make sure during mounting that the gaskets (2) do not fall into the head. *Apply THREEBOND® paste as in the drawing. Position the head cover and tighten screws (3) and (4) where indicated in the figure.
Page 125: Cylinder Head
Tighten the head cover fixing screws to the specific worm drive according to the order indjcated in the figure, paying attention not to cut or damage the gaskets. 10 N·m 1 Kg-m SUCTION CYLINDER HEAD 5.2.1 REMOVE CYLINDER Remove the canshaft (see "REMOVE CAMSHAFT"). Loosen and remove the eight nuts (1) indicated in the figure and the two screws on the right side of the engine (distribution side).
Page 126: Check Cylinderhead
5.2.2 CHECK CYLINDER HEAD WARNING: Do not use a pointed instrument to avoid damaging or scatching: Sparking-plug hole threading Valve seat Check and eventually eliminate carbon deposits in the combustion chamber with a rounded-off scraper. If the surface is damaged or scratched, change the element. Check the distortion of the cylinder head as indicated in the figure.
Page 127: Valves And Valve Springs
VALVES AND VALVE SPRINGS 5.3.1 REMOVE VALVES Remove the cylinder head (see ("REMOVE CYLINDER HEAD"). Position the head on a support (1) slightly inclined so that the valve to be removed is perpendicular to the surface. To remove the valve use the apposite instrument (3) with the correct mount (3), compressing the valve and undo the two lock cones.
Page 128: Check Valves And Valve Guides
The following procedure is applied to the valves (4), the springs (5) and relative components (7, 8 and 9). NOTE: Make sure that valve (4) has a perfect seal by pouring petrol into the conduits and making sure that there are no losses through the valves.
Page 129 Check the state of the surfaces of the valves. Eliminate eventual carbon deposits. If the surface is excessively ruined, change the element. Check thickness (A) indicated in the figure. VALVE THICKNESS VALUE LIMIT A= 0.9 ÷ 1.1 mm Check the concentricity of the valve stem. If the concentricity value does not enter within the margin, change the element.
Page 130: Check Valve Housing
5.3.3 CHECK VALVE SEATS The following procedure must be applied to all the valve seats. Eliminate eventual carbon deposits. Apply the (Dykem) Workshop (b) tincture of bluing onto the face of the valve. Install the valve in the cylinder head. Press the valve through the valve guide and on the valve seat to leave a clear trace.
Page 131: Check Valve Springs
Apply disulfide of molybdenum to the stem of the valve. Insert the valve into the cylinder head. Rotate the valve until its face and seat shine uniformly, then remove the smoothing paste. NOTE: To obtain optimum smoothing results, strike the seat of the valve lightly while turning it forwards and backwards in your hands.
Page 132: Check Bucket-Type Tappet
Bring the spring to a value length (c) and check the value of the load: VALUE LIMIT External spring length: 23.2 mm Load value limit: 537 N Internal spring length: 21.2 mm Load value limit: 298 N Check the inclination (a) of the valve spring as illustrated in the figure.
Page 133: Mount Valves
5.3.6 MOUNT VALVES The follwing procedure must be applied to all the valves and relative components. Oil the valve stem with the recommended oil. RECOMMENED OIL Disulfide of molybdenum oil Mount the lower small cup (1). Check the thickness of the small cup. If the thickness is 1.5 mm add a clearance adjustment of 0.6 mm.
Page 134 WARNING: The suction valves are larger than the exhaust valves. Insert the valves (4). Position the internal (5) and external (6) springs as shown in the figure. Insert the two lock cones (7) into the upper small cup (8). MF9_UK...
Page 135: Cylinder
Position the small cup as shown in the figure. Ensure the fixing of the valve using the specific instrument. Position the calibrated pads (9) and the bucket-type tappets (10). NOTE: · Check that the buckets turn easily by rotating them with a finger.
Page 136: Check Cylinder
5.4.2 CHECK CYLINDER Check that the walls do not present signs of seizure with the pistons. Check the ovalisation of the cylinders as indicated in the figu- WARNING: In the case of changing the cylinder block also change the pistons and the elastic straps, if necessary.
Page 137: Check Water Collector
5.4.4 CHECK WATER COLLECTOR Check eventual breaks on the collector and if necessary change the piece. 5.4.5 MOUNT WATER COLLECTOR WARNING: Always use new gaskets. Position the gasket (1)and the collector (2) and tighten the screws (3). 10 N·m 1 Kg-m 5.4.6 MOUNT CYLINDERS WARNING: Always use new gaskets.
Page 138: Pistons
PISTON 5.5.1 DISMANTLE PISTON Remove the cylinder (see "DISMANTLE CYLINDER BODY"). The following procedure must be applied to all the pistons. Remove the elastic ring (1). WARNING: Do not use a hammer to remove the pins (2). Remove pin (2) and remove piston (3). MF9_UK...
Page 139: Check Pistons
5.5.2 CHECK PISTON The following procedure must also be applied to all the other pistons. Check eventual breaks on the piston. Use a micrometer, as shown in the figure, to check that the value (P) enters within the specific value. CLASS ø...
Page 140: Check Piston Pin
5.5.4 CHECK PISTON PIN The following procedure must be applied to all the piston pins. Check that value (a) enters within the specific value. NOMINAL VALUE a = 18.995 ÷ 19.000 mm Check the value of (b). NOMINAL VALUE b = 19.002 ÷ 19.008 mm NOTE: If the play between the piston pin and the piston is greater than 0.03 mm, change the piston.
Page 141: Generator
Position the piston (3), as shown in the figure, with the arrow on the piston pointing towards the exhaust. Insert the pin (4). WARINING: Always use new elastic rings for mounting the pistons. Position the two elastic rings (5), one for each side. GENERATOR 5.6.1 REMOVAL GENERATOR WARNING:...
Page 142: Remove Generator
Remove the generator (2). Check the state of the flexible couplings of the tires. If they are worn or damaged, change them. 5.6.2 MOUNT GENERATOR To mount the generator, grease the O-ring and work in the reverse way to dismantling, tightening screws (1) to the specific worm drive after having applied LOCTITE ®...
Page 143: Mount Distribution Sensor
5.7.2 MOUNT PHASE SENSOR Position the sensor in its housing and fix with screw (2), and tighten. 10 N·m 1 Kg-m + LOCTITE 243 ® 5.7.3 REMOVE PHONIC WHEEL Remove the clutch cover (see "REMOVE CLUTCH COVER"). Unscrew and remove screw (3) and remove the phonic wheel (4).
Page 144: Clutch
CLUTCH 5.8.1 DISMANTLE CLUTCH COMMAND Remove the clutch command cable and unscrew the three screws (1). Remove the clutch body command and the cable support plate (3). Remove the ferrule (4) and the clutch command rod (5). 5.8.2 REMOVE THE CLUTCH Remove the four screws (1) and the clutch hood (2).
Page 145 Remove the circlip (3). WARNING: Do not allow the ball to come out during the following dismantling operation. Remove the ball-bearing group, the pin and the nut (4). Unscrew and remove the clutch fixing nut (5). Remove the clutch group (6). MF9_UK...
Page 146: Remove Clutch Cover
Remove the spacer (7), the O-ring beneath and the cover (8). 5.8.3 REMOVE CLUTCH COVER Place a container under the oil sump to allow the oil to empty. Remove the discharge screw cap. NOTE: Be careful not to lose the sealing washer beneath. WARNING: Note the position of the screws for correct re- mounting.
Page 147: Remove Primary Transmission
5.8.4 REMOVE PRIMARY TRANSMISSION Remove the clutch cover (see "REMOVE CLUTCH GROUP"). Remove the primary group (1), the two roller-cages and the spacer beneath. 5.8.5 DISMANTLE CLUTCH GROUP WARNING: Take note, while dismantling the clutch, of the position of the elements for correct re-mounting. Remove the clutch (see "DISMANTLE CLUTCH GROUP").
Page 148 Remove the eight external disks (6), the nine internal disks (7) and the load modulation spring beneath. Remove the drag hub (8). Separate the coupling (9) from the sliding flange (10). MF9_UK...
Page 149: Check External Equipped Disk
5.8.6 CHECK EXTERNAL EQUIPPED DISK The following operations must be carried out on all the external equipped disks. Check the external equipped disk liner. If it does not enter within the specific value, change the entire set of disks. VALUE LIMIT DISK LINER = 2.6 mm 5.8.7 CHECK INTERNAL DISK The following operations must be carried out on all the internal...
Page 150: Check Clutcu Cover
Bring the spring to a value length (c) and check the value of the load. VALUE LIMIT CLUTCH SPRING LENGTH c = 22 mm LOAD VALUE LIMIT 180 N Check the incline (d) of the clutch spring as illustrated in the figure.
Page 151: Check Primary Assembly
5.8.10 CHECK PRIMARY ASSEMBLY Check that the components of the primary assembly are not excessivly worn, rough or broken. If necessary, change the component or components or the entire primary assembly. 5.8.11 MOUNT CLUTCH GROUP Position the coupling (1) in the sliding flange (2) as indicated in the figure.
Page 152 WARNING: During the following phase, position the Belleville spring (4) with the convex face turned upwards. Position the Belleville spring (4). WARNING: During the following phase position the Belleville spring (5) with the concave face turned upwards. WARNNG: During the following phase make sure to insert the internal disk with the bigger liner (2 mm) first with respect to the others (1.6 mm).
Page 153: Mount Primary Assembly
5.8.12 MOUNT PRIMARY ASSEMBLY Position the spacer (1) making sure that the two oil passages are turned outwards. Position the two roller cages (2) and the spacer (3). Position the primary assembly (4). 5.8.13 MOUNT CLUTCH COVER WARNING: Aways use new gaskets. Put “THREEBOND 1215”...
Page 154: Mount Clutch
Tighten the screws according to the order indicated in the figu- 10 N·m 1 Kg-m 5.8.14 MOUNT CLUTCH WARNING: The spacer should be inserted with its smaller diameter facing outwards. Position the clutch cover (1), the O-ring (2) and the spacer (3) on the primary shaft (4).
Page 155: Mount Clutch Command
Position the ball in the primary shaft. Position the disk pusher pin (7) complete with ball-bearing (8). Fix with elastic ring (9). 5.8.15 MOUNT CLUTCH COMMAND Insert the clutch command rod (1). Insert the ferrule (2). Position the cable support rod (3) and the clutch command body (4).
Page 156: Adjustment Phase
5.8.16 ADJUSTMENT PHASE Unscrew the locknut (1). Use an Allen wrench to make the disk pusher touch the clutch lever pin. Then unscrew 1/4 of a turn (check that there is a minimum of play in the clutch lever). At this point block the nut (1), and check, tapping slightly on the disk pusher pin with a rubber hammer, whether play remains between the elastic ring and the ball-bearing.
Page 157 Remove the shaft command selector (5). WARNING: While removing pin (6), resist the reaction of the spring placed under the pawls (7). WARNING: Take note of the position of the forks before removing them for correct re-mounting. Remove the pin (6). Loosen and remove the two screws (8).
Page 158 WARNING: The toothed wheels of the gear are free. Rotate the gears on the support (the external side below). Remove the two shafts contemporaneously. WARNING: During the dismantling of the drum fixing pin, support the positive valve gear (17) (see previous figure) to avoid it falling.
Page 159: Check Gear Flange Ball-Bearings
5.9.3 CHECK GEAR FLANGE BALL-BEARINGS Check the free rotation of the ball-bearings (1) and (2). If necessary, change them. NOTE: It is necessary to remove plate (3), working on screws (4), to change the ball-bearings (1) and (2). 5.9.4 CHECK FORK GEAR AND SLIDE RODS The following procedure must be carried out on all the fork gears.
Page 160: Check Positive Valve Gear Shaft
WARNING: Do not attempt to straighten the rod. Check the presence of curvature on the slide rod. If necessary, change the element. 5.9.5 CHECK POSITIVE GEAR SHAFT VALVE Check the state of the positive gear shaft valve guide. If necessary, change it. 5.9.6 CHECK PRIMARY AND SECONDARY SHAFT Check wear and eventual breaks on the primary shaft (1) and...
Page 161: Assemble Gear
5.9.7 ASSEMBLE GEAR WARNING: Always use new gaskets and oil seals. Position the gear flange on the apposite support (external side above). Position the gear fixing spring (i) in the appropriate hole. Position the washer (2) and the gear fixing spring (3) and fix with the threaded pin (4).
Page 162 Position the positive valve gear shaft as in the figure, supporting it with a suitable support. NOTE: Check, while mounting the gear selector drum, that the two elements shown coincide. Fix the drum (7) with the threaded pin (8) and tighten. NOTE: Once pin (8) is tightened it is possible to remove the support previously positioned under the positi-...
Page 163 Mount springs (10) and push rods (11) onto the flange (9). Position the pawls (12). Position the stop plate (13). Position the pre-mounted pin complete with sprocket wheel and pawl (15). MF9_UK...
Page 164 Fix the plate with the two screws (14) and tighten (+ LOCTITE 243). Position the pre-mounted pin (15). 10 N·m 1 Kg-m + LOCTITE 243 ® Rotate the flange on the support (internal side above). Couple the primary and secondary shafts Position them as shown in the figure.
Page 165 Position the O-Ring (16) on the secondary shaft. Position the spacer (17) with its minor dimension outwards. Position the pinion (18), the safety washer (19) and the nut (20). Tighten the nut. 140 N·m 14 Kg-m MF9_UK...
Page 166 WARNING: Do not force the spring (21) too much while mounting the command shaft (22). Mount the spring (21) on the command shaft selector (22), as indicated in the figure. Position the two forks (23) on the secondary shaft and fork (24) on the primary shaft.
Page 167 Position the command shaft selector (29), already pre-mounted, as shown in the figure. Insert the oil seal (31) onto the gear command cover with the appropriate instrument. Insert the two centering dowels and the specific instrument (32). Mount the gasket (33). Mount the cover (30) and push it down until the instrument (32) has completed emerged.
Page 168: Mount Gears
Insert the fixing screws (34) and tighten. 10 N·m 1 Kg-m 5.9.8 MOUNT GEARS WARNING: While mounting the gears make sure that they are in fourth gear to avoid breaking the neutral sensor. Otherwise, remove the neutral sensor before re- mounting the gears.
Page 169: Oil Sump And Oil Pump
5.10 OIL SUMP AND OIL PUMP 5.10.1 DISMANTLE OIL SUMP Unscrew and remove the oil discharge cap (1) and the copper gasket beneath. Unscrew and remove the twelve screws (2) and remove the oil sump (3). 5.10.2 DISMANTLE OVERPRESSURE OIL VALVE Remove the oil sump (see "DISMANTLE OIL SUMP").
Page 170: Remove Oil Pump
5.10.3 REMOV OIL PUMP Remove the primary asembly (see "REMOVE PRIMARY ASSEMBLY"). Remove the safety ring (1) and the toothed wheel (2) Unscrew and remove the three screws (3) and extract the oil pump (4). 5.10.4 DISMANTLE OIL PUMP Remove the oil pump shaft (1) complete with internal rotor (2). Remove the external rotor.
Page 171: Check Oil Sump
If necessary, remove the safety ring (4) and the internal rotor (5). Take off the pin (6). 5.10.5 CHECK OIL SUMP Check for breaks on the oil sump, eventually changing it. Check the presence of foreign bodies on the suction filter (2), eventually cleaning it.
Page 172: Assemble Oil Pump
The internal and external rotors should not be serrated. Check that the measurements (a) and (b) enter within the specific value, otherwise change the oil pump. 1: Internal rotor 2: External rotor 3: Pump body VALUE LIMIT a = 0.25 mm max. b = 0.2 mm max.
Page 173: Mount Oil Pump
Insert the external rotor (6) as in the figure. Oil the two rotors abundantly. 5.10.8 MOUNT OIL PUMP Insert the oil pump from the right with the specific instrument until it touches, as in the figure. Insert the centering dowel. Fix with the three screws (7) and tighten.
Page 174: Mount Overpressure Valve
5.10.9 MOUNT OVERPRESSURE VALVE Position the overpressure valve (1) and valve (2). Tighten. 25 N·m 2.5 Kg-m + LOCTITE 243 ® 5.10.10 MOUNT OIL SUMP WARNING: Aways use new gaskets. Apply THREEBOND 1215 sealing paste to the casing surface and oil sump. Position the O-Ring (1) on the casing.
Page 175: Casing
5.11 CASING 5.11.1 DISMANTLE CASING Remove the head. Remove the pistons (see “DISMANTLE PISTONS"). Remove the oil sump (see "DISMANTLE OIL SUMP"). Remove the oil pump (see "DISMANTLE OIL PUMP"). Remove the water pump (see "DISMANTLE WATER PUMP"). Remove the gears (see "ADJUSTMENT PHASE"). Remove the exchanger (see "WATER OIL EXCHANGER").
Page 176 Remove the five screws (6). Remove screw (7). Remove the two screws (8). MF9_UK...
Page 177 Remove screw (9). Remove the two screws (10). Loosen and remove screw (11). MF9_UK...
Page 178 WARNING: Take note of the position of the screws for correct re-mounting. Remove the nine screws (12) indicated in the figure (lower part of the engine). Remove the lower base (13). Remove the large plastic lock nut (14). MF9_UK...
Page 179 Remove the ring (15). Remove the balancing counter-shaft (16). Remove the engine shaft (17). WARNING: Take note of the position of the bronze bearings for correct re-mounting. Remove the four semi-bronze bearings (18). MF9_UK...
Page 180 Remove the drainage tube stop plate (19.) Remove the drainage tube (20). Remove the ball-bearings (21) and (22). Remove screw (23) and plate (24), freeing the pin (25). MF9_UK...
Page 181 Support the satellite gear (27) and take off the pin (26) as shown in the figure. Unscrew and remove screw (28), washer (29) and the female flexible coupling (30). Support the toothed wheel (31) and remove pin (32). Remove the toothed wheel (31). MF9_UK...
Page 182: Dismantle Free Wheel
Remove the spacer (33). Remove the free wheel (34). 5.11.2 DISMANTLE FREE WHEEL Remove the elastic safety ring. Remove the washer (1). MF9_UK...
Page 183 Remove the toothed wheel (2). Remove the roller cage (3). Remove the screws (4). MF9_UK...
Page 184: Dismantle Balancing Counter Shaft
Dismantle the free wheel. 5.11.3 DISMANTLE BALANCING COUNTER SHAFT Remove the circlip (1). Remove the ball-bearing (2) and the toothed wheel (3). Remove the ball-bearing (4). MF9_UK...
Page 185: Dismantle Engine Shaft
5.11.4 DISMANTLE ENGINE SHAFT WARNING: Take note of the position of the elements for correct re-mounting. The following procedure must be applied to all the connecting rods mounted on the engine shaft. Unscrew and remove screws (1). Remove the connecting rod (2) from the engine shaft (3). 5.11.5 CHECK CASING Check the presence of any breaks on the upper and lower casing, eventually changing the casings, always coupled.
Page 186: Check Engine Shaft And Connecting Rod
Check that the toothed wheels are not broken or excessively worn. Change them if necessary. 5.11.6 CHECK ENGINE SHAFT AND CONNECTING ROD Check eventual breaks or excessive wear on the whole engine shaft (1). Change the piece if necessary. Check the eccentricity of the engine shaft at the points indicated in the figure.
Page 187: Check Balancing Counter Shaft
Check eventual breaks or excessive play on the connecting rod (2) and on the two semi-bronze bearings. 5.11.7 CHECK BALANCING COUNTER SHAFT Check the eventual presence of breaks on the balancing counter shaft. Check the free rotation of the ball-bearings. Check eventual breaks or excessive wear on the toothed wheel.
Page 188: Check Free Wheel
5.11.8 CHECK FREE WHEEL Check eventual breaks, wear and slippage on the free wheel. Change the element if necessary. 5.11.9 ASSEMBLE FREE WHEEL Assemble the two elements as shown in the figure. Tighten screws (1). 17 N·m 1.7 Kg-m + LOCTITE 270 ®...
Page 189 Position the roller cages (2). Positon the toothed wheel (3). Position the washer (4) and fix with the circlip. MF9_UK...
Page 190: Mount Engine Shaft
5.11.10 MOUNT ENGINE SHAFT CONNECTING ROD BRONZE BEARINGS SELECTION TABLE WARNING: TYPE COLOUR Ø CONNECTING ROD HEAD Various semi-bronze bearings liners exist 40.395/40.401 distinguished by different colours (see table). Blue 40.401/40.407 Yellow 40.407/40.413 CONNECTING ROD SELECTION TABLE TYPE COLOUR WEIGHT (g) Black 408/412 Green...
Page 191: Mount Balancing Counter Shaft
Position the engine shaft on the upper semi-casing. Tighten screws (3) in three phases. 1st 15 N·m 1.5 Kg-m 2nd 25 N·m 2.5 Kg-m 3°rd + 50° 5.11.11 MOUNTAGGIO BALANCING COUNTER SHAFT Position the ball-bearing (1) and fix with the circlip (2). Position the roller ball-bearing (3) on the counter shaft (4).
Page 192: Mount Casing
5.11.12 MOUNT CASING Position the roller cage (1), block it with washer (2) and fix with screw (3) tightly. 10 N·m 1 Kg-m + LOCTITE 243 ® Position the ball-bearing (4) with the apposite pad and fix with the circlip (5). Position the liner (6) as indicated in the figure.
Page 193 Position the free wheel (7) as shown in the figure. Position the toothed wheel (8) and insert pin (9) until touching, in the direction in the figure.. Position the washer (11) in the female flexible coupling housing and fix with screw (12) tightly. 25 N·m 2.5 Kg-m + LOCTITE 270 ®...
Page 194 Position the toothed wheel (13) as shown in the figure. Position pin (14) until touching, as indicated in the figure. Position plate (15) and fix with screw (16) tightly. 10 N·m 1 Kg-m + LOCTITE 243 ® MF9_UK...
Page 195 WARNING: Position the two elements shown, as in the figure. Position ball-bearings (17) and (18). WARNING: Position element (19) as shown in the figure. Position the drainage tube until touching (19). Position the tube retaining plate and ball-bearing (20) and fix with screws (21) tightly.
Page 196 Position and tighten the copper washer and the cap (22). WARNING: A type of semi-bronze bearing exists: Various liners of this semi-bronze bearing exist distinguished by different colours (see table). BENCH SEMI-BALL-BEARING CONNECTING ROD SEMI-BALL-BEARING COLOUR SELECTION COLOUR SELECTION 1.918 - 1.922 1.660 - 1.684 Blue 1.922 - 1.926...
Page 197 WARNING: The reading of the letters must always be carried out starting from the transmission chain side. Position the four semi-bronze bearings (25) each slotted with the correct colour associated with its letter stamped on the outside of the casing (24), centering them with the tooth in the cable.
Page 198 Make sure that the toothed wheels of the balancing counter shaft and the engine shaft are as shown in the figure. Position ring (28). Position the large cap (29), one per side, in the apposite seats. Put THREEBOND 1215 on the contact surfaces of the two casings.
Page 199 Position the lower casing (30) on the upper. WARNING: Follow the mounting phases correctly. Position screws (31) and tighten in three phases, according to the order stamped on the casing. 1st 10 N·m 1 Kg-m 2nd 20 N·m 2 Kg-m 3rd 37 N·m 3.7 Kg-m Tighten screws (32) in two phases.
Page 200 Tighten screws (33) according to the order in the figure. 10 N·m 1 Kg-m Tighten screw (34). 10 N·m 1 Kg-m Tighten the two screws (35). 10 N·m 1 Kg-m MF9_UK...
Page 201 Tighten screw (36). 10 N·m 1 Kg-m Tighten the two screws (37) in two phases. 1st 10 N·m 1 Kg-m 2nd 25 N·m 2.5 Kg-m Tighten screw (38) in two phases. 1° 10 N·m 1 Kg-m 2° 25 N·m 2.5 Kg-m MF9_UK...
Page 202 Tighten the four screws (39). 1° 10 N·m 1 Kg-m Position balancing counter shaft ball-bearing stop plate (40) and fix with the two screws (41) tightly. 10 N·m 1 Kg-m WARNING: Always use new gaskets. Apply THREEBOND 1215 sealing paste on the surfaces of the casing and the cover.
Page 203: Cooling Plant
C C C C C P P P P P ooling lant COOLING PLANT RADIATOR 6.1.1 DISMANTLE RADIATOR Remove rearview mirrors (see "DISMANTLE REARVIEW MIRRORS"). Remove the small cap (see "DISMANTLE SMALL CAP"). Remove the internal instrument board fastenings (see "DISMANTLE INTERNAL INSTRUMENT...
Page 204 Unscrew the two small bands (8) and (9) of the send and return radiator tubes (10) and (11). Remove the expansion tank, unscrewing the two fixing screws (13) and (14). Remove the relay support rod (15), unscrewing the two fixing screws (16) and (17).
Page 205 Remove the fixing screw of the expansion tank support plate (19) and the radiator box. Remove the rear brake oil tank (20) unscrewing screw (21), taking care not to upset it. Remove the radiator box fixing screw (22) (right side). MF9_UK...
Page 206: Dismantle Radiator Box
Remove the central radiator box fixing screw (23). Press lightly on the radiator box in the engine forward direction to unhook it. Take the radiator box off. 6.1.2 DISMANTLE RADIATOR BOX Position the radiator box on a surface with the cap upwards. Unscrew the seven screws (1).
Page 207 Rotate the radiator box and unscrew the screws (2). Unscrew the last four screws (2). Unhook the fan body (3) and extract the radiator (4). MF9_UK...
Page 208: Check Radiator
6.1.3 CHECK RADIATOR Check the state of the radiator fins. Repair or change the radiator if necessary. Check the state of the radiator entry and exit tubes. Change the elements if necessary. Check the radiator tap seal (1), checking that it is not damaged. 6.1.4 MOUNT RADIATOR Reverse the operations described in the dismantling procedu- Pour the refrigerant liquid into the the cooling plant (see...
Page 209: Water Oil Exchanger
6.2 WATER OIL EXCHANGER Remove the semi-cowling (see "DISMANTLE SEMI- COWLING"). Remove the wheel housing (see "DISMANTLE WHEEL HOUSING"). Remove the exhaust plant. Discharge the liquid refrigerant circuit (see "CHANGE LIQUID REFRIGERANT"). Remove the engine oil filter (1) (see "REMOVE OIL FILTER"). Disconnect the entry and exit connectors (A) and (B).
Page 210: Mount Exchanger
6.2.1 MOUNT EXCHANGER Oil the O-Ring on the exchanger (1). Position the exchanger (1) as in the figure. WARNING: Always re-mount the clearance element. Insert the clearance element (2) before the connector to screw (3). Tighten screw (3) in two phases. 1st phase: 30 N·m 3 Kg-m 2nd phase: 60 N·m 6 Kg-m Use LOCTITE 243...
Page 211: Thermostat
Reintroduce the liquid advised into the cooling circuit (see "CHANGE REFRIGERANT LIQUID"). Remount the oil filter(see "CHANGE OIL FILTER"). Reintroduce the lacking oil into the engine. Remount the exhaust plant. Remount the wheel housing. Remount the semi-cowling. THERMOSTAT 6.3.1 DISMANTLE THERMOSTAT WARNING: Always use new gaskets and oil seals.
Page 212: Check Thermostat
Remove the thermostat (5). 6.3.2 CHECK THERMOSTAT The thermostat begins to open at 75°C and reaches the maximum opening of 7 mm at 90°C, as shown in the diagram in the figure. TEMPERATURE Check the above conditions by immersing the thermostat (1) in a container with water.
Page 213: Mount Thermostat
6.3.3 MOUNT THERMOSTAT WARNING: The thermostat must be mounted with the by-pass hole (2) turned upwards, as in the figure. Position ithe thermostat (1) as indicated in the figure. Position the thermostat cover (3) and tighten with the two screws (4) il coperchio termostato (3) e fissare con le due viti (4).
Page 214: Water Pump
WATER PUMP 6.4.1 REMOVE WATER PUMP Remove the refrigerant liquid from the cooling circuIt ("CHANGE RERIGERANT LIQUID"). Remove the two entry and exit tubes (1) in the pump (2). 6.4.2 DISMANTLE WATER PUMP Loosen and remove the two screws (4) and the small plates (5).
Page 215 Loosen and remove the two screws (8). Remove the cover (9). Loosen and remove the nut (10) and remove the rotor (11). MF9_UK...
Page 216 Remove the external circlip (12), the internal circlip (13) and the ball-bearing beneath. Remove the liner (14), the shaft (15), the ball-bearing (16) and the oil seal beneath. Remove the mechanical seal (17). MF9_UK...
Page 217: Check Water Pump
6.4.3 CHECK WATER PUMP Check the state of wear of the various components of the pump. Check that the various elements are not broken. Change worn or damaged elements if necessary. 6.4.4 ASSEMBLE WATER PUMP Position the pump body (1) on a support. WARNING: The oil seal must be inserted downwards with the lip closed.
Page 218 Grease the shaft (4) at the points indicated in the figure. Position the shaft (4) inside the pump body (1). Position the first ball-bearing (5), using a press to make it touch. MF9_UK...
Page 219 Position the liner (6). Position the second ball-bearing (7), using a press to make it touch. Fix the ball-bearings with the external (8) and internal (9)circlips. MF9_UK...
Page 220 WARNING: While mounting the counterface and the mechanical seal make sure that they are clean and bear no traces of grease. Position the counterface as in the figure (10). Position the mechanical seal (11) until it touches as shown in the figure.
Page 221 Position the sealing washer (13) and fix it tight with the nut (14). 8 N·m 0.8 Kg-m Always use LOCTITE 243 ® Position the cover and lock it tight with the two screws (15). 10 N·m 1 Kg-m Position the sealing washer (16) and tightly screw the purge screw (17) up.
Page 222: Mount Water Pump
Position the O-Ring (18) on the pump body. Position the entry elbow (19) and fix with the two small plates (20) and the two screws (21) tightly. 10 N·m 1 Kg-m 6.4.5 MOUNT WATER PUMP Position the pump (1) as in the figure and screw the two screws (2) up tightly.
Page 223 Reposition the entry and exit tubes (3) of the pump, tightening the two bands (4). Restore the level of the liquid in the circuit (see "CHANGE COOLING LIQUID"). MF9_UK...
Page 224 MF9_UK...
Page 225: Frame
F F F F F rame 7 7 7 7 7 FRAME FRAME FRAME FRAME FRAME FRONT WHEEL AND BRAKE DISKS 7.1.1 REMOVE FRONT WHEEL Prepare a support suitable to sustain the bike without the front wheel. Loosen the four fork clamp screws (1). Loosen and remove the brake clamp fixing screws (2) on both sides.
Page 226: Check Front Brake Disks
7.1.2 CHECK FRONT BRAKE DISKS WARNING: The following procedures must also be applied to the opposite disk. WARNING: The following procedures must be applied with the disk mounted on the wheel. Check the lateral displacement of the brake disk with a comparator.
Page 227: Check Front Wheel
7.1.4 CHECK FRONT WHEEL WARNING: Change the brake disk fixing screws. The ball- bearings must be changed if removed. Carry out the radial and axial check on the front rim (see "CHECK WHEEL"), using a comparator. If the value of displacement does not enter within the specific value, change the piece.
Page 228: Install Front Wheel
Tighten the disk fixing screws in the order indicated in the figu- Do the same for the opposite disk. 22 N·m 2.2 Kg-m Grease thread 7.1.6 INSTALL FRONT WHEEL WARNING: After each operation on the bike it is advisable to balance it.
Page 229: Rear Wheel, Brake Disk And Crown
Tighten screw (2). 60 N·m 6 Kg-m Grease thread Tighten the four screws (3) of the fork clamps. Mount the brake clamps. 30 N·m 3 Kg-m Grease the thread Clamp screws 50 N·m 5 Kg-m Grease the thread Brake clamp screws. REAR WHEEL, BRAKE DISK AND CROWN 7.2.1 REMOVE REAR WHEEL...
Page 230: Check Rear Brake Disk
Loosen and remove nut (2). Undo the pin and push the wheel forward. Disengage the chain (3) from the crown. Remove nut (4) and the chain stretcher plate (5). Remove the wheel. 7.2.2 CHECK REAR BRAKE DISK WARNING: The following procedure must be carried out with the disk mounted on the wheel.
Page 231: Dismantle Rear Wheel
Check the state of wear of the disk with a gauge. If the value of the liner (A) does not enter within the specific value, change the piece. SPECIFIC VALUE A = 4.5 mm 7.2.3 DISMANTLE REAR WHEEL Loosen and remove the five brake disk fixing screws (1). Remove the brake disk (2).
Page 232 Remove the flange (4) complete with crown (5), extracting it from the wheel. Loosen and remove the five nuts (6) and remove the crown (5) from the flange. WARNING: During the following operation prevent the internal spacer falling if dismantling the ball-bearings is envisaged.
Page 233: Check Rear Wheel
7.2.4 CHECK REAR WHEEL WARNING: Change the fixing screws on the brake disk. If the ball-bearings are dismantled, they must be changed. Carry out the radial and axial check on the rear rim (see CHECK WHEEL"), using a comparator. If the value of displacement does not enter within the specific value, change the piece.
Page 234: Check Crown
Check that the flexible couplings (2) are not broken. If necessary, change them. 7.2.6 CHECK CROWN Sight check that the crown (1) is not broken and that the teeth are not excessively worn. Change the crown, the pinion and the chain if necessary. 7.2.7 MOUNT REAR WHEEL WARNING: Identify correctly the left and right of the wheel based...
Page 235 Push the left side ball-bearing in first until it touches and fix it with the circlip (2). Insert the internal spacer from the right side and push the right side ball-bearing in until it touches. Position the five flexible couplings in the correct seats (3). Position the crown (4) on the flange (5) and fix it with the nuts (6) tightening then according to the order indicated.
Page 236: Install Rear Wheel
Position the disk holder flange (8) on the wheel and tighten the five screws (10) according to the order in the figure. Insert the right spacer (9) in the ball-bearing. 22 N·m 2.2 Kg-m with LOCTITE 243 Positiona the disk (11) and tighten the five screws (10) according to the order in the figure.
Page 237: Front And Rear Brakes
Position the chain (4). Position the nut (5) without tightening it. Adjust the chain (see "ADJUST CHAIN"). Tighten the nut (5). 80 N·m 8 Kg-m Grease thread FRONT AND REAR BRAKES 7.3.1 REMOVE FRONT BRAKE PUMP The oil in the braking plant needs to be emptied before proceeding to remove the pump.
Page 238: Remove Rear Brake Pump
Loosen and remove the two screws (4). Remove the complete brake pump (5). 7.3.2 REMOVE REAR BRAKE PUMP Remove the rear brake pump from the clamp support and position it under the brake pump. Position the end of a tube of suitable diameter at the purge screw (1) and the other end in a suitable recipient.
Page 239: Check Front And Rear Brake Pumps
Loosen and remove screw (5) and the ferrule (6). Rotate the pump (7) keeping the idrostop (2) steady until the latter is completely unscrewed. Remove the idrostop. Remove the entire tank pump. 7.3.3 CHECK FRONT AND REAR BRAKE PUMP Check that the front and rear brake pumps are not damaged. If necessary, change the damaged pump.
Page 240: Install Front Brake Pump
7.3.4 INSTALL FRONT BRAKE PUMP WARNING: First tighten the arrow side screw. WARNING: Always change the braking plant sealing gaskets. Position the front brake pump (1), and the assembly stand (2) and fix tightly with the two screws (3). 10 N·m 1 Kg-m Position the brake (4) and fix it tightly with screw (5) on the connector.
Page 241: Dismantle Front Plant Brake Tubes
Position the rear brake pump (2) and fix with the two screws (5) and the relative nuts (7) tightly. 10 N·m 1 Kg-m Fix the tank pump (8) and the ferrule (9) with screw (10). Mount the footrest (see "MOUNT FOOTREST"). 4 N·m 0.4 Kg-m 7.3.6 DISMANTLE FRONT BRAKE PLANT TUBES...
Page 242: Dismantle Rear Plant Brake Tubes
WARNING: Always change the sealing gaskets at every dismantling. Loosen and remove the connecting screws (2), one fixed to the right brake clamp and the other to the left brake clamp. Loosen and remove connecting screw (3) of the front brake pump.
Page 243: Check Front And Rear Brake Tubing
7.3.8 CHECK FRONT AND REAR BRAKE TUBING Check that the front (1) and rear (2) tubing is not broken. Change the damaged element if necessary. 7.3.9 MOUNT FRONT BRAKE TUBES PLANT WARNING: Always change the sealing gaskets at every dismantling. Position the brake plant tubes with the "T"...
Page 244: Mount Rear Brake Tubes Plant
7.3.10 MOUNT REAR BRAKE TUBES PLANT WARNING: Always change the sealing gaskets at every dismantling. Position tube (1) on the clamp (2) and on the pump. Position the connector screw (3) and tighten it with the associated sealing gasket. 15 N·m 1.5 Kg-m Restore the level of the braking liquid and purge the plant (see "PURGE BRAKING PLANT").
Page 245: Dismantle Rear Brake Clamps
Remove the connector screws (2). Loosen and remove the two brake clamp fixing screws (3). Remove the brake clamps (4). 7.3.12 DISMANTLE REAR BRAKE CLAMP WARNING: Always change the sealing gaskets at every dismantling. Remove the rear brake clamp from the clamp support unscrewing the two screws and position it under the brake pump.
Page 246: Check Brake Clamps
7.3.13 CHECK BRAKE CLAMP Check that the front and rear brake clamps are not broken or show losses. If necessary, change the damaged element. 7.3.14 MOUNT FRONT BRAKE CLAMP Position the right (1) and left (2) brake clamps. Tighten screws (3). Position the brake tubing on the two clamps and on the pump.
Page 247: Mount Rear Brake Clamps
7.3.15 MOUNT REAR BRAKE CLAMP Tighten the connector screw (1) on the clamp (2). 15 N·m 1.5 Kg-m Restore the level of the braking liquid and purge the rear plant (see "PURGE BRAKING PLANT"). Position the clamp (2) on the clamp support (3). Tighten the two screws (4).
Page 248: Fork
FORK 7.4.1 REMOVE RIGHT AND LEFT STEM WARNING: After removing the stem clamps do not leave them hanging up but provide an adequate support. Remove the front mudguard (1) (see "DISMANTLE FRONT MUDGUARD"). Remove the right and left upper cowlings (2) (see "REMOVE UPPER COWLINGS").
Page 249: Check Fork Legs
7.4.2 CHECK FORK LEGS Turn directly to the supplier listed in the "SPECIFICATIONS" chapter with regard to checking the stems and linings. 7.4.3 INSTALL FORK LININGS WARNING: Do not damage the surfaces of the linings. WARNING: The stem must be mounted with the brake clamp holder support towards the inside of the vehicle.
Page 250 Position the right semi-handlebar (see "MOUNT RIGHT SEMI- HANDLEBAR"). Position the left semi-handlebar (see "MOUNT LEFT SEMI- HANDLEBAR"). Position the upper steering plate (4) and adjust the stems according to specific value A. SPECIFIC VALUE A = 1 mm Tighten the screws (5), one for each stem. 25 N·m 2.5 Kg-m Tighten the steering plate central screw (6).
Page 251: Semi-Handlebars
Position the front brake clamp (7) and tighten the two screws (8). Do the same with the opposite brake clamp. 50 N·m 5 Kg-m SEMI-HANDLEBARS 7.5.1 REMOVE RIGHT SEMI-HANDLEBAR Remove the upper steering plate (see "DISMANTLE STEERING HEAD"). Loosen and remove the two screws (2) and free the front brake pump (3).
Page 252: Remove Left Semi-Handlebar
Loosen and remove screw (5), disconnect the ignition command cabling and take the right semi-handlebar off, upwards. 7.5.2 REMOVE LEFT SEMI-HANDLEBAR Disconnect the micro clutch connector (1), taking the rubber cap off first. Loosen and remove the two screws (2) and free the clutch command (3).
Page 253: Dismantle Right Semi-Handlebar
Remove the upper steering plate (5) (see "MOUNT STEERING HEAD"). 7.5.3 DISMANTLE RIGHT SEMI-HANDLEBAR Remove the right semi-handlebar (see "REMOVE RIGHT SEMI-HANDLEBAR"). Remove the start command block (1) using the two screws beneath it. Separate the semi-handlebar rod (2) from the support (3), unscrewing screw (4).
Page 254: Dismantle Left Semi-Handlebar
7.5.4 DISMANTLE LEFT SEMI-HANDLEBAR Remove the left semi-handelbar (see "REMOVE LEFT SEMI- HANDLEBAR"). Remove the handle. Remove the block (1), unscrewing the two fixing screws under Separate the semi-handlebar rod (2) from the support (3), unscrewing screw (4). 7.5.5 CHECK RIGHT SEMI-HANDLEBAR WARNING: Do not try to straighten the semi-handlebar rod.
Page 255: Check Left Semi-Handlebar
7.5.6 CHECK LEFT SEMI-HANDLEBAR WARNING: Do not try to straighten the semi-handlebar rod. Check that the rod (1) and the support (2) are not damaged or bent. Change the damaged element if necessary. 7.5.7 MOUNT RIGHT SEMI-HANDLEBAR WARNING: Do not try to straighten the semi-handlebar rod. WARNING: During the assembly of the semi-handlebar make the two signs coincide as shown in figure (A).
Page 256: Install Right Semi-Handlebar
7.5.9 INSTALL RIGHT SEMI-HANDLE Position the ignition block (1) and tighten the two fixing screws. Position the gas command (2) and fix with the two fixing screws. Position the right semi-handlebar (3). Position the front pump brake (4) and fix it with the two screws (5).
Page 257: Install Left Semi-Handlebar
Position the upper plate (6). Tighten screw (7). 6 N·m 0.6 Kg-m Tighten the plate-lining assembly screw (8). 30 N·m 3 Kg-m 7.5.10 INSTALL LEFT SEMI-HANDLEBAR Position the lights block (1) on the semi-handlebar (2). WARNING: The longest screw must be positioned at the back of the block.
Page 258: Steering Damper
Tighten the safety screw under the upper plate (3). 6 N·m 0.6 Kg-m Position the clutch command and tighten the two fixing screws (4). 10 N·m 1 Kg-m Connect the micro clutch connector (5) on the lever. Tighten the semi-handlebar screw (6). 30 N·m 3 Kg-m Insert the handle (7).
Page 259: Mount Steering Damper
7.6.3 MOUNT STEERING DAMPER Position the steering damper (1) and tighten the two fixing screws (2). 10 N·m 1 Kg-m STEERING HEAD 7.7.1 DISMANTLE LOWER STEERING PLATE Remove the steering damper (1) (see "DISMANTLE STEERING"). Remove the two semi-handlebar fixing screws (2). Remove the steering fixing screw (3).
Page 260 Remove the dust cover (8). Remove the upper cowling pin (9) and the lower steering plate complete with pin (10). Remove the ball cage (11) and the upper and lower coupling pins inside the chassis. Remove the ball cage (12). MF9_UK...
Page 261: Check Lower Steering Plate
Remove the upper coupling pin (13) and the dust cover (14) from the steering plate. 7.7.2 CHECK LOWER STEERING PLATE Check that none of the components of the steering plate are broken. Check that the steering roller cages are not excessively worn or broken.
Page 262: Rear Damper
Tighten the steering fixing screw (3). 60 N·m 6 Kg-m REAR DAMPER 7.8.1 REMOVE REAR DAMPER Support the vehicle adequately. Remove the rear wheel (1) (see "REMOVE REAR WHEEL"). Remove the lower semi-cowling (2) (see "DISMANTLE SEMI- COWLING"). Loosen and remove the right side rear fork fixing pin (3) of the bike.
Page 263 Loosen the reaction ring-nut (4) inside the chassis with the apposite instrument and loosen the adjustor (5). SPECIFIC EQUIPMENT Engine shoulder adjustment wrench: R180197032000 Loosen and remove nuts (6) and relative screws. Remove the rear fork pin (7) from the left side and lower the rear fork as far as possible, extracting it from the damper and rotating it downwards.
Page 264: Check Rear Damper
Loosen and remove nut (8) and remove screw (9). Remove the rear damper (10). 7.8.2 CHECK REAR DAMPER Apply to the direct supplier listed in the "SPECIFICATIONS" chapter with regard to checking the rear damper. 7.8.3 MOUNT REAR DAMPER Operate in the reverse sense to dismantling. Tighten the nut (1).
Page 265 Tighten the two nuts (2). 50 N·m 5 Kg-m Bring the adjuster to touch (3) and tighten it. + 90° Tighten the ring-nut inside the frame. 40 N·m 4 Kg-m Insert the pin from the left side. Tighten the rear fork fixing pin screw (4). Re-mount the rear wheel (see "MOUNT REAR WHEEL").
Page 266: Rear Fork
REAR FORK 7.9.1 REMOVE REAR FORK Support the vehicle adequately. Remove the lower semi-cowling (1) (see "DISMANTLE SEMI- COWLING"). Remove the rear wheel (2) (see "REMOVE REAR WHEEL"). Remove the chain (3) (see "DISMANTLE CHAIN"). Disconnect the mileage counter cabling connector. Remove the brake clamp, unscrewing the two fixing screws (4).
Page 267 Loosen the reaction ring-nut (7) inside the chassis and loosen the adjustor (8). Loosen and remove nuts (9) and relative screws. Undo pin (10) and remove the rear fork. MF9_UK...
Page 268: Dismantle Rear Fork Components
7.9.2 DISMANTLE REAR FORK COMPONENTS Loosen and remove the two screws Remove the chain casing (2). Loosen and remove the two screws (3) and remove the chain pad (4). Remove the ferrule (5) and the oil seal (6). Repeat the operation on the opposite part of the rear fork as well.
Page 269: Check Rear Fork
Remove the oil seal (7). Repeat the operation on the opposite part of the rear fork as well. Loosen and remove screw (8) and the assembly stand ferule (9), the chain adjustment screw (10) and the locknut (11). Repeat the operation on the opposite part of the rear fork as well.
Page 270: Mount Rear Fork
7.9.4 MOUNT REAR FORK WARNING: Always use new oil seals. Proceed in the reverse manner to dismantling. Tighten the assembly stand support screw (1). 20 N·m 2 Kg-m Tighten the chain pad screws (2). 10 N·m 1 Kg-m Tighten the chain casing screws (3). 10 N·m 1 Kg-m MF9_UK...
Page 271: Install Rear Fork
7.9.5 INSTALL REAR FORK Operate in the reverse manner to removal. Bring the adjustor (1) to touch and tighten. + 90° Tighten the ring-nut (2) inside the chassis. 40 N·m 4 Kg-m Insert the pin from the left side. Tighten the rear fork pin fixing screw (3). 65 N·m 6.5 Kg-m Tighten the two nuts (4).
Page 272: Front Frame
7.10 FRONT FRAME 7.10.1 REMOVE FRONT FRAME Remove the internal instrument board fastenings (see "REMOVE INSTRUMENT BOARD"). Remove the cap (see "REMOVE CAP"). Remove right and left upper cowlings (see "REMOVE UPPER COWLINGS"). Remove the lower cowlings (see "REMOVE LOWER COWLINGS").
Page 273: Install Front Frame
7.10.3 INSTALL FRONT FRAME Operate in the reverse manner to removal. Tighten the two fixing nuts (1). 12 N·m 1.2 Kg-m 7.11 REAR FRAME 7.11.1 DISMANTLE REAR FRAME Remove the internal instrument board fastenings (see "REMOVE INSTRUMENT BOARD"). Remove the cap (see "REMOVE CAP"). Remove right and left upper cowlings (see "REMOVE UPPER COWLINGS").
Page 274: Check Rear Frame
Loosen and remove the two lateral screws (7). Loosen and remove the centre screw (8). Remove the rear frame, freeing it from the electrical plant and the radiator cap tubes. NOTE: Always check the passage of the electrical plant and the radiator cap tubes before dismantling.
Page 275: Transmission Chain
Tighten the two exhaust support rod screws (3). 25 N·m 2.5 Kg-m Tighten the exhaust support screw (4) 25 N·m 2.5 Kg-m Operate in the reverse manner to remove the remaining elements. 7.12 TRANSMISSION CHAIN 7.12.1 REMOVE TRANSMISSION CHAIN Remove the transmission chain (1) with a link cutter. 7.12.2 CHECK TRANSMISSION CHAIN Check that the chain is not excessively worn or excessively loose.
Page 276: Install Transmission Chain
WARNING: This is a chain with an O-ring. Respect the cleaning phases. If necessary, disolve the dirt deposits on the chain using kerosene. These deposits must be later removed with a clean rag or a jet of air. Then oil the chain. 7.12.3 INSTALL TRANSMISSION CHAIN Position the chain on the crown and on the pinion.
Page 277: Injection Plant
These functions ensure that, in the case of faults in the system, the type of fault and the engine data at the moment of fault are stored in the ECM memory. The stored data can be retrieved by a Benelli dealer using the apposite service equipment supplied to all Benelli dealers (see Axone imstruction manual).
Page 278: Position Of The Sensors
Throttle body group position sensor - placed at the right end of the small throttle body group shaft. The throttle body group position sensor gives a completely closed position reading and all the other opening angles are calculated taking the completely closed position as basis. The throttle body group angle is used by the ECM to determine the supply needs of all the throttle body group positions.
Page 279 The system controls the following parameters: • Minimum functioning. • Supply of air in the case of the engine missing. • Correction of the air/fuel relation operating at minimum speeds at heights above sea-level. • Correction of the air/fuel relation in cold and hot starts. When the stepper is activated it opens the valve more or less to allow a determined flow of air to flow along a series of tubes in the throttle body group.
Page 280: Engine Supply Plant
8.2.1 ENGINE SUPPLY PLANT Location of actuators 1 Oil pump (on the base of the oil tank) 2 Ignition coils (upper part of the cover of the cams) 3 Canister breather valve (only USA version) 4 Minimum air control system (on the lower part of the air box filter) 5 Injectors (behind the throttle bodies) 6 Cooling fan (behind the radiator).
Page 281 NOTE: Note that the first column is not marke A because of the restricted space on the face of the connector. The diagram to the side shows the numbering of the pins as they appear on the connector. The position of the ECM connectors is described in this manual through the identification of the connector, 1 (black) or 2 (grey), followed by the row number and the column number in which it is situated.
Page 282: Fuel Pump Checking System
8.4 FUEL PUMP CHECKING SYSTEM Key: Orange Azure White Services/ injection Black connection Cooling fan BLU Blue sectioning Yellow Grey Oil pressure Cooling fan sensor Brown Green Violet Sky blue Petrol pump Engine shaft sensor Injector 2 Liquid thermistor Injector 1 Injector 3 thermistor Coil...
Page 283: L I M I T E D E D I T I On
8.5 SUPPLEMENTARY DIAGNOSIS The following tables, if used correctly, help to identify a fault in the system once the diagnostic code of the problem has been stored. PHASE SENSOR (ENGINE SHAFT) – MC 1000 ECM Fault code Possible cause Instruction P0335 Damage to the phase sensor Check and note the data on the...
Page 284 Activity carried out – terminate the test fault code and start the engine to check that the fault has disappeared The fault persists Contact the Benelli assistance CHECK AIR AT MINIMUM – MC 1000 ECM Fault code Possible cause Instruction...
Page 285 7 - Re-connect the cabling, cancel the Activity carried out – terminate the test fault code and activate the functional test of the diagnostic equipment (see Axone manual) to Fault Contact the Benelli assistance view the checking operations of the stepper engine MF9_UK...
Page 286 INJECTORS – MC 1000 ECM Fault code Possible cause Instruction P0201/02/03 Injection plant damaged– 2/ Check and note the data on the display of the diagnostic instrument (see Axone Failure to ignite indicates instruction manual) if available. open circuit Make sure that the relative injector Flooding indicates short connectors are correctly inserted.
Page 287 Change the relative injector, proceed to test 7 - Reconnect the cabling, cancel the Activity carried out - terminate test fault code and activate the engine to check the elimination of the fault The fault persists Contact the Benelli assistance MF9_UK...
Page 288 Locate and repair the cable fault, proceed to test 5 5 - Reconnect the cabling, cancel the Activity carried out – terminate the test fault code and activate the engine to check the elimination of the fault. The fault persists Contact the Benelli assistance MF9_UK...
Page 289 IGNITION COIL – MC 1000 ECM Fault Code Possible cause Instruction P0351/52/53 Ignition system damaged – Check and note the data on the display of ignition coil 2/1/3 the diagnostic instrument (see Axone instruction manual) if available. P1351/52/53 Open or short circuit – Make sure that the connector of the relati- ignition coil 2/1/3 ve ignition coil is inserted correctly.
Page 290 7 - Reconnect the cabling, cancel the Activity carried out - terminate test fault code and activate the engine to check the elimination of the fault The fault persists Contact the Benelli assistance COOLING LIQUID TEMPERATURE SENSOR – MC 1000 ECM Fault Code Possible cause Instruction...
Page 291 7 - Reconnect the cabling, cancel the Attività svolta – terminare il test fault code and activate the engine to check the elimination of the fault Fault Contact the Benelli assistance Resistance data in typical conditions: Engine warm: Environmental temperature Resistance value 20°C...
Page 292 AIR ENTRANCE TEMPERATURE SENSOR – MC 1000 ECM Fault code Possible cause Instruction P0110 Air entrance temperature Check and note the data on the display of system damaged the diagnostic instrument (see Axone instruction manual) if available. P0113 Open or short circuit at posi- Check and note the data on the diagnostic tive battery pole (+) instrument sensor (see Axone instruction...
Page 293 Activity carried out - temoinate test fault code and activate the engine to check the elimination of the fault Fault Contact Benelli assitance If the engine is hot, remove the sensor and let it cool down beofre carrying out the test Resistance data:...
Page 294 Locate and rectify the cable fault, proceed to test 5 5 - Reconnect the cabling, cancel the Activity carried out – terminate the test fault code and activate the engine to check the elimination of the fault Fault Contact the Benelli assistance MF9_UK...
Page 295 ECM. Proceed to test 4 4 - Reconnect the cabling, cancel the Activity carried – terminate the test fault code and activate the engine to check the elimination of the fault Fault Contact the Benelli assistance MF9_UK...
Page 296 Locate and repair the cable fault, proceed voltage to test 3 3 - Reconnect the cabling, cancel the Activity carried out – terminate the test fault code and activate the engine to check the elimination of the fault F ault Contact the Benelli assistance MF9_UK...
Page 297 - Instrument pin 5 to instrument pin to test 5 5 - Reconnect the cabling, cancel the Activity carried out – terminate the test fault code and activate the engine to check the elimination of the fault Fault persists Contact the Benelli assistance MF9_UK...
Page 298 - ECM pin 2/G1 & 2/G2 to ECM pin to test 5 1/H4 Activity carried out – terminate ithe test 5 - Reconnect the cabling, cancel the fault code and activate the engine Fault Contact the Benelli l’assistance to check the elimination of the fault. MF9_UK...
Page 299 Activity carried – terminate the test 5 - Reconnect the cabling, cancel the fault code and activate the function Fault Contact the Benelli assistance test of the diagnostic instrument (see Axone instruction manual) to check the operation of the tempe- rature indicator.
Page 300 6 - Reconnect the cabling, cancel the Activity carried out – terminate the test fault code and activate the function Fault test of the diagnostic instrument Contact the Benelli assistance (see Axone instruction manual) to check the operation of the rev counter. MF9_UK...
Page 301: Electrical Plant
E E E E E lectrical ELECTRICAL PLANT P P P P P lant MF9_UK...
Page 302 KEY: Orange Azure White Black BLU Blue Yellow Pink Grey Brown Violet Green Sky blue MF9_UK...
Page 303 Consult the table below to identify the contacts of the various components: COLOURS COLOURS 1) Main switch Green / White 11) Level spyhole Brown/ Yellow 2) Battery 12) GND level spyhole Yellow/ Violet 3) Env. temp. sensor 13) Oil pressure sensor Violet 4) GND environmental temperature 14) Water Temperature...
Page 304: Connectors
9.1 CONNEC TORS When connecting a connector make sure to press until hearing a click. Check whether the connector is corroded or dirty and whether its cover is broken. CLICK With a block type connector make sure to release the block CLICK before disconnecting it and to press down completely when connecting.
Page 305: Semi-Conductor Parts
9.3 SEMI-CONDUCTOR PARTS INCORRECT WARNING: Be careful not the let the parts fall with an incorporated semi-conductor like the ECU. When controlling such parts follow the checking instructions to the letter. Failure to respect the correct procedure can cause grave damage.
Page 306: Check Battery Efficiency
Loading method It is preferable to use the constant tension method of loading so as not to overload the batteries. Follow this rule: NORMAL: 1.0A x 5 ~ 10h SLOW: 0.5A x 8 ~ 16h Check the voltage after ~ 30 minutes from loading the voltage at the battery heads.
Page 307 Battery current losses WARNING: Since current losses in the case of malfunctioning can be high, use a high range of the multitester first when using the ammeter. Do not put the ignition switch on "ON" when measuring the current. With the switchboard off, the losses of current should be >/- Ã...
Page 308: Fuses
9.5 FUSES General fuse: The general fuse (1) is on the left side of the engine. To remove it undo the plastic protective cover. Fuse (2) is the spare. Service fuses: Electric fan Injection Red/White Orange/Green Orange Services Petro pump Lights The service fuses box is under the saddle.
Page 309: Relay Services Group
9.6.2 RELAY SERVICES GROUP Positioned under the saddle are the: 1) dazzle lights relay 2) dazzle lights relay 3) safety relay 4) injection relay. 9.7 ENGINE STARTER Remove left semi-cowling (see "DISMANTLE COWLING)"). Disconnect the supply cables on the battery. Remove the starter relay (see "DISMANTLE RELAY").
Page 310: Alternator
9.8 ALTERNATOR Unscrew the three clutch command fixing screws (1), unhook the clutch cable and remove the clutch command to allow the removal of the alternator. Disconnect the battery supply cables. Disconnect the connector (2), lift the protective cap and unscrew the starter supply fixing nut(3).
Page 311: Starter Diagnostic System
9.9 STARTER DIAGNOSTIC SYSTEM The starter does not rotate Put the ignition switch on "ON" with the engine shut-off switch on "RUN". Put the gears into neutral (the Check whether the starter engine relative warning lamp on the The click rotates by connecting the starter instrument board lights up).
Page 312: Check Safety System Parts
9.10 CHECK SAFETY SYSTEM PARTS If the safety system does not function properly, check each component. If anomalies are found, substitute the component (1) with a new one. 9.11 DIODES The diodes (1) are under the saddle inside the fuse box. Disconnect the diode module and check what follows: +Tester prod + Tester prod...
Page 313: Lateral Switch Stand
9.13 LATERAL STAND SWITCH The connector of the lateral stand switch is under the petrol tank. Remove the petrol tank. Disconnect the lateral stand switch and measure the continuity as described below. Check the continuity with a multitester as indicated in the table. Stand PIN 1 PIN 2...
Page 314: Speed Sensor
9.15 SPEED SENSOR When the speed is not indicated on the instrument board, proceed as follows: Check the integrity of the fuse. If the fuse in question is intact, check the speed sensor (1): 1) Remove the vehicle sensor as described in the "ENGINE" chapter.
Page 315: Front Lights
9.17 FRONT LIGHTS Loosen and remove the four fixing screws (1). Remove the internal instrument board fastenings (see "DISMANTLE INTERNAL INSTRUMENT BOARD FASTENINGS"). Remove the left mirror (see "DISMANTLE MIRRORS"). Remove the cap (2) (see "DISMANTLE CAP"). Remove the lower left semi-cowling (see "DISMANTLE LOWER COWLING").
Page 316: Licence Plate Light Support
Change the lamp (3). Position the glass cover (2), reversing the dismantling proce- dure. Tighten screw (1). 9.18.2 LICENCE PLATE LIGHT HOLDER Loosen and remove screw (1). Remove the rubber lamp holder. Change the position lamp. Position the lampholder and tighten screw (1). 9.18.3 FRONT AND REAR ARROWS 9.18.3.1 FRONT ARROWS...
Page 317: 2Rear Arrows
Remove the arrow body (3). Change the damaged led, rotating it anti-clockwise. Position the arrow body (3) and the glass cover (2) and fix with screw (1). Operate in the same way with the opposite arrow. 9.18.3.2 REAR ARROWS Loosen and remove screw (1). Remove the glass cover (2) and change the lamp.
Page 318 MF9_UK...
Page 319: Diagnostics
D D D D D iagnostic 10 DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS 10.1 ELECTRICAL PART LOADING SYSTEM Battery warning light lit Alternator damaged Change Alternator connection defective Check Battery damaged Change GENERAL No function 30A Fuse Change Relay switch burnt Change Battery connections oxidised Deoxidise/Restore...
Page 320 Dazzle/dimmer lights not functioning Light fuses burnt Change Light fuses connection defective Deoxidise/Restore Lamps burnt Change Lamp connections defective Deoxidise/Restore Lights switch damaged Change Lights switch connection defective Deoxidise/Restore Dazzle + dimmer lights relay damaged Change Dazzle light and dimmers relay connection defective Deoxidise/Restore Rear light stop not functioning...
Page 321 Tachymeter not functioning Speed sensor damaged Change Speed sensor connection defective Deoxidise/Restore 10A fuse burnt Change 10A fuse connection defective Deoxidise/Restore Instrument board damaged Change Instrument board connection defective Deoxidise/Restore H2O temperature indicator not functioning Speed sensor connection defective Deoxidise/Restore 10A fuse burnt Change 10A fuse connection defective...
Page 322 INJECTION Air pressure /temperature sensor signal error Sensor damaged Change Sensor connection defective Deoxidise/Restore Potentiometer throttle valve signal error Potentiometer damaged Change Potentiometer connection defective Deoxidise/Restore Engine temperature sensor signal error Engine temperature sensor damaged Change Sensor connection defective Deoxidise/Restore FUEL INJECTION PLANT Injector does not inject fuel 25A fuse burnt...
Page 323: Frame
10.2 FRAME STEERING Steering hard Steering ball-bearings damaged Change Steerring ball-bearings tightened excessively Adjust Steering pin bent Change Sterring damper braked excessively Adjust Steering damper joints damaged Change Low tire pressure Adjust The engine tends to swerve or not proceed in a direct line Fork bent Change Frame bent...
Page 324 REAR WHEEL Rear wheel oscilates/vibrates Wheel rim bent Change Wheel not balanced Balance Tire defective Change Tire unsuitable Change Wheel ball-bearings damaged Tighten Fixing nut not tight Tighten Suspension screws not tight Tighten Suspension ball-bearings damaged Change Rear wheel rotates with difficulty Ball-bearings damaged Change Wheel hub sealing ring out of place...
Page 325 Braking power insufficient Disks dirty Clean Air bubble in hydraulic circuit Purge Losses in the hydraulic circuit Repair Clamp seals damaged Change Pump seals damaged Change Clamp pistons do not run freely Check Hydraulic liquid low Refill Brake disks distorted Change Pads dragging on brake disks Pad springs damaged...
Page 326: Preliminary Operations
1. Carry out the procedure described in "Preliminary operations", selecting "self- diagnosis" and pressing "ENTER". 2. Select "DATABASE" with the horizontal arrows 3. Press “ENTER” 4. From the "SELECT TRADEMARK" menu select “Benelli” 5. Press “ENTER” 6. From the "SELECT MODEL" menu select “Tornado Three” 7. Press “ENTER”...
Page 327: Adjust Stepper/Cd
10.6 ADJUST STEPPER / CO This operation must be carried out also using an exhaust gases analyser. The process is repetitive, arriving at the CO wanted by repeating the procedure described below. 1. Carry out the procedure described for self-diagnosis. 2.
Page 328 MF9_UK...
Page 329: Usa Version
U U U U U V V V V V 11 11 11 11 11 USA VERSION USA VERSION ersion USA VERSION USA VERSION USA VERSION WARNING: If on any changed component an adhesive recomendations label is applied, this must necessarily be re-integrated.
Page 330: Cannister Connection
Disconnect the tube (3) connected to the gas tank. Disconnect the tube (4) connected to the Stepper. 11.4 CANNISTER CONNECTION Tube (1) connects the gas tank to the Cannister. T connector (2) with connection tube (3) between the Cannister and the Stepper. MF9_UK...
Page 331: Exhaust
11.5 EXHAUST The exhaust is distinguished by bossing on the lower part of the silencer. To remove it, use the same procedure as the European version.. 11.6 LIGHT COMMANDS The left light command is not equipped with an ON/OFF switch. To remove it, use the same procedure as the European version.
Page 332: Front Catadioptrics
11.8 FRONT CATADIOPTRICS Two catadioptrics (1) are positioned at the front, one on the left and one on the right. In the case of removal, change the element because it is fixed with double adhesive. 11.9 REAR ARROWS The rear arrows (1) are not in carbon. To remove them, use the same procedure as in the European version.
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Benelli Tornado Tre Novicento 903 Workshop Manual

Contents

2 Specifications

3 Periodical Checks and Adjustments

4 Cowling

5 Engine

6 Cooling Plant

7 Frame

8 Injection Plant

9 Electrical Plant

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Summary of Contents for Benelli Tornado Tre Novicento 903