Benelli ZAFFERAN 250 Service Manual
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Benelli ZAFFERAN 250 Service Manual

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ZAFFERANO
250
Service Manual
1

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Summary of Contents for Benelli ZAFFERAN 250

  • Page 1 ZAFFERANO Service Manual...

  • Page 2: Table Of Contents

    Contents Notice ..............................4 Preparing documents ........................5 General Safety ..........................5 Inspection / Adjustment ......................... 20 Inspection and maintenance of electrical system ................40 Battery/Charging System ......................41 1.1 Preparing documents ......................41 1.2 Failure diagnosis ........................42 1.3 Battery ............................. 42 1.4 Charging system ........................
  • Page 3 9. . Lubricating System .......................... 85 9.1 Preparing documents ........................ 85 9.2 Failure diagnosis........................85 9.3 Oil pump ............................ 86 10. Cooling System ..........................90 10.1 Preparing Documents ......................90 10.2 Failure Diagnosis ........................90 10.3 Water Pump ..........................90 11.

  • Page 4: Notice

    NOTICE This manual was produced by the Benelli Motor Company primarily for use by Benelli dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on a Benelli scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair.

  • Page 5: Preparing Documents

    Preparing documents General safety Maintenance rules Specification table Failure diagnosis General Safety Carbon monoxide Engine must be started up in a well-ventilated place, not in a closed area. Note Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even death of human.

  • Page 6: Important Information

    6. Keep all parts away from any source of fire. REPLACEMENT PARTS 1. Use only genuine Benelli parts for all re- placements. Use oil and grease recom- mended by Benelli for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
  • Page 7 LOCK WASHERS/ PLATES AND COTTER PINS 1. Replace all lock washers / plates and cotter pins after removal. Bend lock tabs along the bolt or nut flats after the bolt or nut has been tightened to specification. BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible.
  • Page 8 CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. • Disconnect Connect 3. Dry each terminal with an air blower. 4. Connect and disconnect the connector two or three times. 5. Pull the leads to check that it will not come off.

  • Page 9: How To Use The Conversion Table

    HOW TO USE THE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. METRIC MULTIPLIER × **mm 0.03937 ** in × 2 mm 0.03937 = 0.08 in CONVERSION TABLE...

  • Page 10: Special Tools

    SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool Usage Illustration Tool name...
  • Page 11 Tool name Tool Usage Illustration This tool is used for removing the Flywheel puller rotor. This tool is used when installing the Fork seal driver weight fork seal. Fork seal driver attachment (ø33) Oil seal guide This tool is used for protecting the oil seal lip when installing the secondary sliding sheave.
  • Page 12 Illustration Tool name Tool Usage This tool is needed for detecting Timing light ignition timing. This tool is used for removing and Valve lapper installing the lifter and for lapping the valve. Valve spring compressor These tools are used when removing Attachment or installing the valve and the valve spring.
  • Page 13 Specification (EFI Motorcycle ZAFFERANO) Engine Mo o del ZAFFERANO BJ169MM-5A type 91# unleaded Length inches 84.25 Fuel type petrol or above No. of Width inches 31.5 cylinder Height inches 56.45 ID × stroke 69×66.8 Total displacement Wheelbase inches 58.75 249.7ml Forward Engine Startup...
  • Page 14 Diameter of system spark ignition φ250mm Ignition rear brake disc (mm) capacitance...

  • Page 15: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- General torque ers with standard I.S.O. pitch threads. Torque specification (Nut) (Bolt) specifications for special components or as- • m kg semblies are included in the applicable sections 10 mm 6 mm of this book.
  • Page 16 LUBRICATION POINT AND GRADE OF LUBRICANT ENGINE Lubrication Point Symbol Oil seal lips O-ring (Except V-belt drive unit) Cylinder head tightening nut mounting surface Crankshaft pin outside Connecting rod big end thrust surface Rotary filter inner surface Drive gear inner surface Cam chain outside sprocket inner surface Piston pin Piston outside and ring groove...
  • Page 17 SPEC LUBRICATION POINT AND GRADE OF LUBRICANT CHASSIS Lubrication Point Symbol Front wheel oil seal lips (left / right) Swingarm oil seal lips (left / right) Steering head pipe bearing (upper / lower) Steering head pipe dust seal lips (upper / lower) Tube guide (throttle grip) inner surface Brake cable (brake lever) Brake lever and lever holder bolt sliding surface...
  • Page 18 Periodic Maintenance & Inspection Table Service cycle and 2000 4000 6000 8000 Tools time Inspection item Three Nine Twelve mont month months months months Air filter Ordinary tools Petrol filter Ordinary tools Fuel filter Ordinary tools Replacement of engine Replacement every 2000 MI Ordinary tools Tire pressure Tire pressure...
  • Page 19 Piston & cylinder—excessive abrasion; replace cylinder if it is blocked. Please have your motorcycle inspected and adjusted periodically at an authorized Benelli dealership to keep your vehicle in the best possible condition.

  • Page 20: Inspection / Adjustment

    Inspection / Adjustment Cylinder Preparing information Periodic Maintenance & Inspection pressure Gear Table Engine oil/ Oil filter Fixing steering stem bearing & Replacement of gear oil handlebar Inspection & adjustment of Drive belt throttle cable Free play of the front/rear brake Air filter Inspection of brake fluid level...
  • Page 21 Specification Engine Idle speed 1400±100rpm/mi Spark plug gap 0.6-0.7mm Spec. of spark plug NGK CR8E Cylinder compression 1.25Mpa/1500rp pressure BTDC12 degree ±1 degree 1500±100rpm Ignition time Frame 10-20mm Free play of front brake lever Free play of rear brake 10-20mm lever Specification Tire pressure...
  • Page 22 THROTTLE CABLE ADJUSTMENT NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. Check: • Throttle cable free play 1 Out of specification → Adjust. Free (throttle cable): play 3 to 5 mm at throttle grip flange Adjust: •...
  • Page 23 ENGINE OIL LEVEL INSPECTION 1. Stand the scooter on a level surface. NOTE: Make sure the scooter is upright when inspect- ing the oil level. 2. Start the engine and let it warm up for a few minutes. 3. Turn off the engine. Inspect: ④...
  • Page 24 Fill: Crankcase • Oil quantity: 1.4L Check: Engine oil level • ************************************* ENGINE OIL PRESSURE INSPECTION Remove: Side Panels • Inspect: Oil Pressure • ***************************************************** Inspection steps: Slightly loosen the oil check bolt 1 . • Start the engine and keep it idling until the oil begins to seep from the oil check bolt.
  • Page 25 TRANSMISSION OIL REPLACEMENT NOTE: Make sure the scooter is upright when replacing the oil. 1. Stand the scooter on a level surface. 2. Start the engine for several minutes to warm it up and then stop. 3. Place an oil pan under the crankcase. Remove: •...
  • Page 26 SPARK PLUG INSPECTION Remove: • Spark plug cap • Spark plug CAUTION: Before removing the spark plug, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinder. Check: •...
  • Page 27 EXHAUST SYSTEM INSPECTION Remove: • Side panels Inspect: • Nut 1 (exhaust pipe) Loose / Damage → Tighten / replace. • Gasket (exhaust pipe) Exhaust gas leaks → Tighten / replace. Inspect: • Bolt 2 (muffler) • Connecting bolt 3 (muffler) Loose/Damage →...
  • Page 28 CAUTION: Do not twist the element when squeezing the element. 5. Apply the recommended oil to the entire surface of the filter and squeeze out the ex- cess oil. The element should be wet but not dripping. Recommended oil: Foam Air Filter Oil Never use low flash point solvents such as gasoline to clean the air filter element.
  • Page 29 Install: • Crankcase filter element • Crankcase filter cover seal • Crankcase filter cover COMPRESSION PRESSURE MEASUREMENT NOTE: Insufficient compression pressure will result in performance loss. Remove: • Side panels Check: • Valve clearance Out of specification → Adjust. 3. Start the engine and let it warm up for sev- eral minutes.
  • Page 30 Compression (With oil applied into cylinder) Diagnosis Reading Higher than Worn or damaged pistons without oil Possible defective ring(s), valves, Same as without oil Cylinder, head gasket or piston → Repair. Compression pressure (at sea level): Standard: 1.25Mpa/1500rpm ***************************************************** easurement steps: •...
  • Page 31 Check: • Ignition timing ***************************************************** hecking steps: • Start the engine and let it warm up for several minutes. Let the engine run at the specified speed. Engine speed: idling 1,450 1,550 r / min ． Visually check the stationary pointer a to verify it is within the required firing range b indicated on the flywheel.
  • Page 32 FRONT/ REAR BRAKE ADJUSTMENT Check: • Brake lever free play 1 Out of specification → Adjust. Free play (brake lever): 5 mm (at brake lever end) Adjust: • Brake lever free play ***************************************************** djustment steps: • Loosen the locknut 2 . •...
  • Page 33 BRAKE FLUID LEVEL INSPECTION 1. Stand the scooter on a level surface. NOTE: Make sure the scooter is upright when inspect- ing the brake fluid level. 2. Stand the scooter on its centerstand. Inspect: • Brake fluid level Brake fluid level is below the “LOWER” level line 1 →...
  • Page 34 BRAKE PAD INSPECTION ② 1. Operate the brake lever. Inspect: • Brake pad (front) Wear indicators 1 almost touch the brake disc → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKE” in ① CHAPTER 7. AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) leed the brake system whenever:...
  • Page 35 NOTE: When bleeding the brake system, make sure that there is always enough brake fluid in the brake fluid reservoir before applying the brake lever. Ignoring this precaution could allow air to enter the brake system, considerably lengthen- ing the bleeding procedure. Tighten the bleed screw.
  • Page 36 FRONT FORK INSPECTION Securely support the scooter so that there is no danger of it falling over. 1. Stand the scooter on a level surface. Check: • Inner tube Scratches / damage → Replace. • Oil seal Excessive oil leakage → Replace. Hold the scooter upright and apply the front brake.
  • Page 37 Adjust: • Spring preload Turn the adjuster ring 1 to direction a or b . NOTE: Use the special wrench included in the owner’s tool kit to adjust the spring preload. ***************************************************** Adju stment steps: • Turn the adjuster ring in or out. Turning toward a →...
  • Page 38 Co., Ltd. for this model. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Benelli is used on this scooter. The front and rear tires should always be by the same manufacturer and of the same design.
  • Page 39 After mounting a tire, ride conservatively for a while to give the tire time to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or damage to the scooter. 2.

  • Page 40: Inspection And Maintenance Of Electrical System

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

  • Page 41: Battery/Charging System

    1. Battery/Charging System 2. Preparing documents -------------1.1 Failure diagnosis------------ 1.2 3. Battery -----------------------------1.3 Charging system ------------ 1.4 4. Voltage/current regulator --------1.5 Charging coil of magneto - 1.6 5. Disassembly of magneto ---- 1.7 1.1 Preparing documents Note of work: *Note 1.

  • Page 42: Failure Diagnosis

    Preparing principles Item Specifications Capacity/Type 12V-6AH/ dry-charged Voltage Fully charged 13.1V （68F） Necessa 12.3V (not working for 1h) Battery charging Charging current Standard: 0.6A, quick: 6A Charging time Standard: 10-15 hours, quick: 30 mins Capacit 200W/8500rp Alternator Between white-black 3.3-3.5Ω Coil impedance（68F）...

  • Page 43: Charging System

    Install the battery in reversal order. * Note First positive terminal and then negative terminal to prevent short circuit. Check the charging situation (open circuit voltage). Open the battery cover and remove the fixing plate assembly of the battery. Remove the lead of the battery connector. Measure voltage between terminals.

  • Page 44: Voltage/Current Regulator

    * Note Connect the positive terminal of the multimeter with the negative terminal of the battery. Check whether there is a short-circuit in the main switch or in the main wire in the case of any abnormality. 1.4.2 Charging check Use a multimeter to check the charging status of the battery when it is being fully charged.

  • Page 45: Magneto Charging Coil

    3. The red probe connects the black terminal of the stabilizer and the black probe connects white terminals of the stabilizer (white1, white2, white3). Pointers indicate values. If not, the stabilizer is damaged and needs replacement. * Note • Do not touch any metal part of the test rod of the multimeter with your finger for check.

  • Page 46: Ignition System

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

  • Page 47: Preparing Documents

    2. Ignition System Preparing documents--------------2.1 RELATED PARTS Group ----------------2.4 Failure diagnosis ------------------2.2 Ignition coil --------------------------------- 2.5 Ignition system check-------------2.3 Trigger ----------------------------- 2.6 2.1 Preparing documents Note of Work: 1. Check the ignition system following the sequence listed in the table of failure diagnosis. 2.

  • Page 48: Failure Diagnosis

    2.2 Failure Diagnosis No Spark Abnormality Cause (confirm it sequentially as follows) ①The inner resistance is too small and it should be tested by required tester. ②Low speed of the crankshaft. ③Interfered tester (It is normal that voltage is Ignition always beyond the required value upon coil Too low high-voltage...

  • Page 49: Ignition System Check

    2.3 Ignition system multimeter check * Note • When there is no spark, check whether there is loose wiring or poor contact, and make sure all voltage values are normal. • There are kinds of multimeters with different impedances and different test values.
  • Page 51 When the maximum voltage measured at the terminal of RELATED PARTS Group is abnormal, dismantle the body guard and the magneto terminal. Connect the charging coil (black/red) to the shunt. If the voltage of RELATED PARTS is measured to be abnormal while the voltage at the magneto terminal is normal, it is caused by poor contact or disconnected wiring.

  • Page 52: Related Parts Group

    2.4 RELATED PARTS GROUP 2.4.1 System check Check the system. Remove the RELATED PARTS Group, and check components of the ignition system at the terminal. 2.4.2 Check Remove RELATED PARTS Group and check whether the terminal is loose. Item Test terminal Standard (68F) Main switch Red--red/white...

  • Page 53: Trigger

    Remove the spark plug cap. Measure the impedance between the primary side wire of the ignition coil and the negative terminal. Standard: 4.5-5.5KΩ±10％（68F） 2.6 Trigger Ω * Note BL/W Check the trigger on the engine. Check: Remove the body guard. Remove the trigger terminal.

  • Page 54: Starter System

    Starter System BATTERY 1.)Battery 2.) Starter Relay 3.) Power lock assembly 4.) Flash apparatus 5.) Rectifier 6.) Horn 7.) ECU...

  • Page 55: Preparing Documents

    3. Starter System Preparing documents ----------- 3.1 Failure diagnosis ----------------- 3.2 Starter motor ---------------------- 3.3 Starter relay ----------------------- 3.4 3.1 Preparing documents Note of Work Disassemble the starter motor on the engine. For the disassembly of the starter clutch, please comply with regulations. Preparing principles Item Standard...

  • Page 56: Failure Diagnosis

    3.2 Failure diagnosis Startup failure Weak rotation No rotation of RE rotary of the starter motor engine of the starter motor • Fuse blown • Low battery • Poor startup clutch • Low battery • Poor wiring contact • Reversal rotation of the startup motor •...

  • Page 57: Starter Relay

    3.3.4 Assembly Lubricate the oil seal inside the front cover with grease. Install the brush on the bracket. Lubricate moving parts at two ends of the brush shaft with grease. Press each brush into the bracket. * Note • Pay special attention that...
  • Page 58 3.4.3 Check GND Loop of the Starter Relay Remove the starter relay connector Check conduction between the black wire of the lead terminal and the body ground connection. When the starter button is pressed, it shall show good conduction between the black wire of the terminal and the body ground connection.

  • Page 59: Bulbs/Switches/Meters

    4. Bulbs/Switches/Meters Preparing documents ---------------------------4.1 Meters ------------------- 4.6 Failure diagnosis---------------------------------4.2 Main switch ------------ 4.7 Replacement of headlamp bulbs -------------4.3 Horn ---------------------- 4.8 Replacement of front steering lamp bulbs---4.4 Handlebar switch ------ 4.9 Replacement of tail lamp bulbs --------- ------4.5 4.1 Preparing documents Note of Work Remove the switch from the vehicle to measure its conduction.

  • Page 60: Replacement Of Tail Lamp Bulbs

    Loosen fixing screws of steering lamps. Remove the bulb socket from the lamps. ② ① 4.4.2 Installation Install the bulb in reverse order. ①：front right steering lamp ②：front left steering lamp 4.5 Replacement of tail lamp bulbs 4.5.1 Disassembly Remove the cushion assembly and body guard.

  • Page 61: Horn

    O /BL R/W Y （R：red R/W：red/white Y：yellow O/BL：orange/blue） 4.7.2 Replacement of the Main Switch Remove the front guard. Remove the fixing bolts and the fixing seat for the main switch. Remove fixing bolts and replace the main switch. 4.8 Horn Check Remove horn wires.

  • Page 62: Inspection And Maintenance Of Vehicle

    Inspection and Maintenance of Vehicle Front Disc Brake A Diameter of front brake disc： 250mm Thickness of front brake disc: 4.0mm Wear limit: 3.0 Brake block thickness:6.0mm Wear limit: 5.0mm D Installation torque of nut 1 :5-9N·m Free stroke front brake handle:10-20mm 1.) Bolt 2.) Master Cyl.

  • Page 63: Rear Disc Brake

    Rear Disc Brake Installation torque of nut 1:5-9N·m Thickness of rear brake disc4.0mm Wear limit:3.0mm Brake Block thickness:6.0mm Wear limit:5.0mm Rear brake disc diameter: 250mm Free stroke front brake handle:10-20mm 1.) Bolt M6×35 2.) Master Cyl. Strap 3.) Handle Bolt 4.) Rear Brake Lever 5.) Nut M6 6.) Rear Brake Light Switch 7.) Banjo Bolt 8.) Rear Brake Hose 9.) Washer 10.) Rear Brake Pads 11.) Rear Brake Caliper Assembly 12.) Rear Brake Master Cylinder Assembly 13.) Rear Brake Assembly 14.) Washer φ8 15.) Bolt M8×35 16.) Bolt M6×12 17.) Pipe Clamp...
  • Page 64 5. Brake Maintenance instruction --------------------- 5.1 Failure diagnosis ------------------------------ 5.2 Front disc brake ------------------------------ 5.3 Rear disc brake -------------------------------- 5.4 5.1 Maintenance instruction Note of Work * Note • Do not stain the brake assembly with oil spots during installation or disassembly. •...
  • Page 65 5.3 Front Brake Assy. 5.3.1 Disassembly * Note • Replace the brake pad assembly. • If the brake pads will be used again, mark it before disassembly so as to reinstall it in the original place. Remove the following assemblies from the front absorber.
  • Page 66 5.3.3 Installation Install the brake rotor and the front wheel. Install the front brake hose assembly and the brake cylinder assembly. Do not stain the brake pads and the brake rotor with grease. * Note Any grease on brake pads will reduce the brake performance and even lead to failure.
  • Page 67 5.4.2 Check Check whether the brake rotor and the brake shoes are abraded. Replace them if necessary. Measure the brake pads and the brake rotor. Record maximum values. * Note • Scrub the rusty brake rotor with sandpaper #120. • Measurement with micrometer. Measure the thickness of the brake rotor and the brake pads.

  • Page 68: Body

    6. Body *Note Do not damage the body when removing it. Do not damage the hook of the body. Do match the grooves for the panels. Correctly install the hooks of each part. 1.) front fender 2.) front fender 3.) front shield panel 4.) decorating plate of the front shield 5.) front shield baseplate 6.) windshield 7.) handlebar front shield 8.) handlebar rear shield 9.) left baffle plate 10.) decorating cover of the handlebar front shield 11.) right baffle plate 12.) left rubber foot 13.) pedal cover plate 14.) inspection cover 15.) left rubber foot 16.) Left pedal 17.) Lower connecting plate 18.) Right pedal 19.) right rubber foot 20.) fuel tank guard...
  • Page 69 Dismantle the body in following order: Handlebar front shield →windshield →handlebar rear shield →meter →front shield →front inner fender →foot guard → ↓ Battery box cover →left/right pedal cover →left/right pedal rubber → left/right pedal guard →rear handrail →seat → ↓...
  • Page 70 Front Wheel Front wheel spec: 120/70-14 tire Installation torque of N·m nut 14: 75-88 Rim run-out limit: Vertical: 2.0mm Horizontal: 2.0mm Front wheel camber limit：0.2mm Front wheel certificate number: 1.) Front wheel axle 2.) Brake rotor bolt 3.) Brake rotor 4.) Left front wheel spacer 5.) Oil seal 6.) Bearing 7.) Valve stem cap 8.) Valve stem 9.) Tire 120/70-14 10.) Front wheel 11.) Bearing spacer sleeve 12.) Speedometer drive unit 13.) Washer 14.) Nut...

  • Page 71: Front Suspension

    Front Suspension Installation torque of nut N·m 22-29 Installation torque of nut N·m 16: 22-29 Upper steel ball number: 16 Lower steel ball number: 16 1.) Nut 2.) Lock washer 3.) Nut 4.) Lock washer 5.) Dust seal 6.) Bushing 7.) Bearing 8.) Tapered roller bearing 9.) Dust seal 10.) Bolt M6×12 11.) Socket head cap screw M8×30 12.) Upper handlebar clamp 13.) Lower handlebar clamp 14.) Key 15.) Steering stem 16.) Bolt M8×35 17.) Bolt M5×10 18.) Front right fork assy.
  • Page 72 Handlebars Installation torque of nut N·m 13：55-62 Free stroke of front brake handle:10-20mm Free stroke of rear brake handle: 10-20mm Free stroke throttle controlling handle: 5-10mm Installation torque of nut N·m 16: 5-9 1.) Right rearview mirror assembly 2.) Left rearview mirror assembly 3.) Handlebar weight assembly 4.) Right handlebar grip w/ tube 5.) Right combination switch 6.) Throttle cable 7.) Bolt M5×10 8.) Handlebar assembly 9.) Left combination switch 10.) Left handlebar grip 11.) Seat latch cable...

  • Page 73: Front Wheel/Front Suspension

    7. Front Wheel/Front Suspension 8. Preparing documents-----------------------7.1 9. Failure diagnosis-----------------------------7.2 10. Front wheel----------------------------------7.3 11. Steering handle ---------------------------- 7.4 12. Front fork -------------------------------------7.5 7.1 Preparing documents Note of Work Before removing the front wheel, you should use jack to support the body bottom and suspend the front wheel which shall not be reversely rotated.

  • Page 74: Front Wheel

    Failure of wheel bearing or gear housing. 7.2.5 Abnormal noise from the front absorber Fricative sound of the absorber guard. Loose bolts in the absorber 7.3 Front wheel 7.3.1 Disassembly Support the body bottom to suspend the front wheel ① Remove the cotter pin and locking nuts for the front wheel spindle.

  • Page 75: Bearing Replacement

    7.3.2.3 Check the front wheel bearing Remove the left bushing and the oil seal of the front wheel. Check rolling of the bearings. The bearings will not roll if abraded or loosened. Replace it. ① ① ① clearance ②axially ③ radially 7.3.3 Bearing replacement Remove the front wheel axle, front wheel, middle bearing sleeve and left axle spacer;...
  • Page 76 7.4 Handlebars 7.4.1 Disassembly Remove the front and rear shield and the rearview mirror assembly. Remove the front brake handle and the rear brake handle. Remove the decorating cover of the grip, the throttle cable assembly and the right grip assembly.

  • Page 77: Front Fork

    7.5 Front fork 7.5.1 Disassembly Remove the front wheel. Remove the front shield, front inner fender and front fender. Remove the brake hose and the odometer cable. Loosen the gland nut and the lock washer. Remove the upper and the lower bearing cups.
  • Page 78 7.6 Radiator/Reserve Bottle Assembly 7.6.1 Disassembly Remove the body guard. ② Remove the headlamp. Loosen four fixing bolts for the radiator assembly. Loosen the hose clamps for the inlet/outlet hoses of the radiator. Remove the power cord of the cooling fan. Remove the radiator assembly and the reserve bottle assembly.
  • Page 79 Check the fan switch. Replace it when the switch doesn’t work normally. ① ①：cooling fan ②：fan switch ② Pressure test the radiator. Remove the radiator cover after the coolant has fully cooled. Apply the required pressure to the cooling system with the radiator pressure tester (lower than pressure for opening the valve of the cap) and ensure that it can keep for at least 6s under the required pressure;...

  • Page 80: Rear Wheel/Rear Suspension

    Rear Wheel/Rear Suspension...

  • Page 81: Preparing Documents

    Rear Wheel/Rear Suspension Preparing documents ------------ 8.1 Failure diagnosis ------------------ 8.2 Rear wheel -------------------------- 8.3 Rear absorber/rear swing arm--- 8.4 8.1 Preparing documents Note of Work The surface of the brake rotors and brake pads shall not be stained with oil spots. Preparing Principles Item Standard (mm)
  • Page 82 8.3.2 Check 8.3.2.1 Check rim shimmy Rotate the wheel by h a n d and measure the eccentricity ratio with a dial indicator. Limit for use: Vertically: replacement when beyond 2.0mm. Horizontally: replacement when beyond 2.0mm. When the rear wheel shimmy exceeds the limit, the rear wheel bearing is loose, which causes a shimmy.

  • Page 83: Rear Absorber/Rear Swing Arm

    8.4 Rear absorber/Rear Swing Arm 8.4.1 Disassembly of the rear absorber Remove the seat and the left/right rear guard. Remove the rear handrail and the rear fender. Remove the muffler. Remove the air cleaner assembly. Remove the fixing bolts for the rear absorber.
  • Page 84 Check and Maintenance of the Engine Table of Torque Force of Engine Fasteners Tightening torque（N·m） Name of fastening parts and fasteners Cylinder cover bolts 27～30 32～35 Double end studs 9～12 Drain bolts of the gearbox 20～25 Drain bolts of the crankcase 17～25 Spark plug 9～12...
  • Page 85 Lubricating system diagram 1 camshaft 2 oil pump 3 crank 4 fuel filter...

  • Page 86: Lubricating System

    9. Lubricating System Preparing documents--------9.1 Failure diagnosis-------------9.2 Oil pump-------------------------9.3 9.1 Preparing Documents Note of Work After the oil pump is disassembled, carefully clean each part and its surface with high flash point contact cleaner. When the oil pump is disassembled, do not allow any impurities to fall into the crankcase.

  • Page 87: Oil Pump

    9.3 Oil pump Disassembly ① Remove the right cover, flywheel assembly and start gearwheel. Loosen the fixing bolt and remove the cover plate. Loosen the screw and remove the oil pump ①：oil pump ②：bolt ② Remove the screw and the oil pump assembly. Remove the screw and the oil pump cover.
  • Page 88 Check the clearance between the outer rotor and the oil pump housing. Limit for use: 0.23mm. ① Check clearance between rotor surface. Limit for use: 0.11mm. ① ①：gauge ②: flat plate ②...
  • Page 89 Breakdown Break down the oil pump according to the following picture. ⑦ ⑧ ⑥ ⑤ ④ ③ ② ① ⑪ ⑩ ⑨ ① screw ②outer rotor ③inner rotor ④ oil pump ⑤ oil pump shaft ⑥ pin ⑦ spacer ⑧ split washer ⑨ oil pump cover ⑩ cotter pin ⑪ oil pump screw Note: After assembly, the inner and outer rotors shall rotate flexibly without being seized.

  • Page 90: Cooling System

    Cooling System Connects radiator Flows back to radiator Water pump...

  • Page 91: Cooling System

    10. Cooling System Preparing Documents ---------------------- 10.1 Failure Diagnosis ---------------------------- 10.2 Water Pump ---------------------------------- 10.3 Preparing Documents 10.1 Function of the cooling system: The cooling method of the engine is water cooling. Water cooling, in which the water is used as the heat conductor, is a method of cooling high-temperature components and then transferring heat to the outside air, thus keeping the engine working under the optimum temperature.
  • Page 92 Loosen the bolt, and remove the water pump cover. Remove the blade. Note: Don’t damage the spacer and the joint surface of ① the housing during disassembly. ② ①: dowel pin ②: impeller assembly ③: gasket ④: water inlet ④ ③...
  • Page 93 Cylinder Head/Valves...

  • Page 94: Cylinder Head/Valve

    11. Cylinder Head/Valve Preparation documents -------------- 11.1 Failure diagnosis-----------------------11.2 Cylinder head---------------------------11.3 Preparation documents 11.1 Function of the cylinder head: The cylinder head is used to seal the cylinder and forms a combustion chamber with piston to bear the high temperature and high pressure combustible gas, and to intake and exhaust gas through the valve actuating mechanism.

  • Page 95: Failure Diagnosis

    Failure Diagnosis 11.2 Low compression pressure Noise in the cylinder head valve clearance is not adjusted properly valve clearance is not adjusted properly valve is burnt or bent valve spring is damaged air tightness of valve seat is not good camshaft worn or damaged gasket cylinder head is gas-leaking camshaft and valve rocker is worn...
  • Page 96 ① Remove the bolt, and take off the adjusting cover ② And the cap sprocket cover cap . ①：cam sprocket cover cap ②：adjusting cover ③ ③：bolt Remove the bolt and cam sprocket cover, and take ① off the chain. Remove the cylinder cover. Notice: The chain should be hung by a metal wire ②...
  • Page 97 Inspection of the Cylinder Head Check the outer ring of bearing, if the bearing doesn’t rotate stably and easily, please replace the outer ring. Check the inner ring of the bearing, if the inner ring doesn’t ① fasten onto the camshaft, please replace it. corrosion, Check the nose of camshaft, if there is dot-like scratches or bluing, please replace it.
  • Page 98 Use the valve spring compressor to compress the valve spring, remove the valve collets. Then take down the spring seat, outer valve spring and inner valve spring and valves. ④ Valve Disassembly ④ ③ ② ① ⑥ ⑤ ①：valve ②：inner spring ③：outer spring ④：valve collet ⑤：spring lower seat ⑥：spring upper seat...

  • Page 99: Valve Inspection

    Valve Inspection Measure the free length of valve spring. Usage limit：spring：inner 29.92mm ① outer 34.4mm ①：vernier calliper Measure the OD of valve lever. Usage limit：4.43mm Inspect the valve guide, please use a reamer before inspection. ① Clear out the carbon deposits in the valve guide pipe.
  • Page 100 Measure the ID of every valve guide. Usage limit: inlet/exhaust：4.532mm Usage limit of clearance between valve and valve guide pipe: Inlet valve：0.07mm Exhaust valve：0.08mm Replacement of Valve Guide Note: When the clearance between the valve and valve guide pipe exceeds the usage limit, please replace the valve guide.
  • Page 101 After inserting the valve guides, use the valve guide reamer to refinish the guide hole. Note: when using the reamer to cut, please add the proper amount of cutting lubricant. The rotation direction of the reamer is clockwise. Clear out the carbon deposits in the combustion chamber and valve tracts, and clean the inlet valve and exhaust valve thoroughly.
  • Page 102 Refinishing of the Valve Seat Use a 45° milling cutter to clear out the rough or uneven parts on the surface of the valve seat. Note: Coat the valve seat ring with a transparent or rough Prussian blue coating to see more clearly. Use a 32°...
  • Page 103 0.8mm Use a 45° milling cutter to cut the valve seat to its appropriate width. All the indentation and uneven parts have to be eliminated. Standard width of valve seat ring：Inlet：0.8mm Exhaust：0.8mm If the contacting part is the place where the valve is too high, please use a 32°...

  • Page 104: Cylinder Body And Piston

    Cylinder Body and Piston ①：cam chain sliders ②：piston ③：piston ring assembly ⑥：base gasket ④：cylinder body ⑤：piston pin...

  • Page 105: Preparation Documents

    Cylinder Body and Piston Preparation documents------------12.1 Failure diagnosis--------------------12.2 Cylinder body------------------------12.3 Piston----------------------------------12.4 Preparation Documents 12.1 Function of the cylinder body: cylinder body provides space for gas compression, combustion and expansion. It also transfers part of its heat energy to the cooling medium inside the cylider. Function of piston: 1.

  • Page 106: Failure Diagnosis

    12.2 Failure diagnosis Low compression pressure white smoke from the exhaust pipe wear, burning or snap in the piston wear and damage in the piston ring wear or damage in the cylinder or the piston wear or damage in the piston or the cylinder damaged gasket,gas leak between the crankcase and the gas Higher compression pressure abnormal sound from the piston...

  • Page 107: Piston

    12.4 Piston Removal Remove the retaining clip of the piston pin. ① Note: Don’t allow the retaining ring fall into the crankcase during removal. Remove the piston pin and unload the piston. ①: piston ② ②: bead flange and piston pin Examine the piston, the piston pin and the piston rings.
  • Page 108 Remove the piston rings and install the piston rings at the bottom of the cylinder. Note: press piston rings into the cylinder with the piston head. Measure clearance of piston ring gap. Usage limit: 0.70mm. ①：piston ring ① Measure ID of piston pin hole. Usage limit：...
  • Page 109 Measure OD of piston Note: measured place shall be perpendicular to the piston pin, at about 11mm bellow piston skirt. 90° Usage limit：68.91mm. Check scratch and abrasion of inner wall of the cylinder. Note: It shall be perpendicular to the piston pin, and the cylinder ID shall be measured at the upper, middle and lower locations...
  • Page 110 ① Check the flatness of cylinder surface. Usage limit: 0.05mm ①：feeler gauge ②：tester ② Measure the wrist-pin end of the connecting rod. Usage limit: 17.06mm. ①：wrist-pin end of the connecting rod ① Installation of the Piston Install piston pin. ① Lubricate piston ring and piston with machine oil and install with the piston ring marking facing upwards.
  • Page 111 Open the right cap, take off the actuation level assembly. Clean gasket on crankcase. Note: There should be no foreign material falling into ① the crankcase. Install piston, piston pin, and piston pin clips. Installation of cylinder Install gasket and locating pin onto the crankcase. Lubricate machine oil on inner wall of cylinder, piston and piston rings.

  • Page 112: Driving Disc/Clutch/Driven Wheel

    Driving Disc / Clutch / Driven Wheel...
  • Page 113 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE CRANKCASE FILTER COVER AND CRANKCASE COVER (LEFT)
  • Page 114 V-BELT, CLUTCH AND SECONDARY/PRIMARY SHEAVE...
  • Page 115 SECONDARY SHEAVE...

  • Page 116: Preparation Documents

    Driving Disc / Clutch / Driven Wheel Preparation documents--------------------13.1 Failure diagnosis----------------------------13.2 Clutch/driven wheel------------------------13.3 Preparation documents 13.1 Function: driving disc/clutch/driven wheel form step less speed variator. Driving disc and driven wheel transfer torsion through a triangular belt. Notes In operation, keep the drive belt free of oil or grease to minimize possibility of sliding between triangular belt and the wheel.

  • Page 117: Failure Diagnosis

    13.2 Failure diagnosis Motor fails not make cycle run low horsepower shaking driving Worn triangular belt Worn triangular belt broken clutch abrasion piece spring Broken driven wheel deformed clutch compression spring Broken or damaged clutch abrasion piece worn ball bearing Broken clutch compression spring dirty driving belt wheel surface 13.3 Left crankcase cover...
  • Page 118 Check whether the triangular belt has cracks, or whether the rubber or cotton yarn has failed or is worn. Measure width of triangular belt. width Usage limit: 21mm Note: Please choose original factory parts when changing. Remove driving wheel right semi part. ①: right semi part of driving disc ①...
  • Page 119 Disassemble driving wheel right semi part ② ① ①：shaft sleeve ②：bushing Check abrasion of the ball bearing. Measure OD of the ball bearing. Usage limit：19. 5mm Measure the right semi ID of driving wheel shaft Sleeve. Usage limit: 28.04mm. ② Measure the OD of the slide bushing.

  • Page 120: Clutch/Driven Wheel

    13.5 Clutch/Driven Wheel Removal Use retainer to fix the clutch bushing and remove standing nut. Remove clutch bushing and clutch/driven wheel. ① ② ①: driven wheel ②: retainer ③ ③ : clutch bushing ④: sleeve spanner ④ Disassemble Clutch Remove retaining ring and disassemble clutch. Note: While disassembling, no oil shall stick to clutch abrasion piece.
  • Page 121 Check the abrasion of clutch bushing. Measure ID of clutch bushing. Usage limit: 135.145mm Check the abrasion of clutch abrasion piece. Measure the thickness of abrasion 1.5mm piece Usage limit: Disassemble clutch and driven wheel Note: Use spring compressor in removal in case spring is damaged.
  • Page 122 Remove spring bushing. ①: spring bushing ① Remove directing pin. ① ③ Remove left semi weld of driven wheel. Remove the oil seal on the left semi part of driven wheel. ①：left semi weld of driven wheel ②：directing pin ③：oil seal ②...
  • Page 123 Check abrasion of driven wheel. ① ② Measure right semi shaft sleeve OD of driven wheel. Usage limit: 40.90mm Measure left semi slide bushing ID of driven wheel. Usage limit: 41.06mm ① right semi part of driven wheel ② left semi part of driven wheel Replacement of right semi bearing ①...
  • Page 124 Install needle bearing. ① Press needle bearing with the tool in the figure. ①：bearing screwdriver ② ① Assemble clutch/driven wheel Clean grease on the driven wheel surface. Install oil seal of driven left semi slide bushing. Install greased O-ring onto the slider bushing of the driven wheel’s left semi part.
  • Page 125 Install spring bushing. ① Clean leaked grease. ①: spring bushing Install clutch compression spring and clutch on driven wheel. Use clutch spring compression assembly, after ① compression install the locking nut Note: Compress the spring moderately. Do not damage it ①：...
  • Page 126 ① ③ ② ①：input shaft ②：middle shaft ③：output shaft...

  • Page 127: Transmission

    Transmission Preparation documents----------------14.1 Failure diagnosis------------------------14.2 Gear box----------------------------------14.3 Preparation documents 14.1 Function: transfer torsion and decide final output torsion and rotation speed. Failure diagnosis 14.2 Motor fails to make motorcycle run Broken driving gear Burnt driving gear Leaked gear oil Too much gear oil Damaged oil seal...
  • Page 128 14.3 Gear box Removal Loosen bolts and remove gear box cover. Remove gasket and locating pin. ①：bolt ②：gear room cover ② ① Remove output shaft assembly. Remove middle shaft assembly. Remove input shaft. ① Check abrasion of input shaft, output shaft and each gear.
  • Page 129 Remove oil seal on the gear box cover and remove bearing. Note: Bearing knocked out shall not be used any more, and should ① be replaced with a new one Use special tools to disassemble bearing and oil seal ①：bearing ②：bearing oil seal ②...
  • Page 130 ① ② ③ ①: left crankcase ②: crankshaft ③: right crankcase...
  • Page 131 ①：magneto ②：start the main gear ③：gasket ① ② ③...

  • Page 132: Crankcase

    Crankcase Preparation documents-------------------15.1 Failure diagnosis---------------------------15.2 Crankcase-----------------------------------15.3 Preparation Documents 15.1 Function of the crankcase: The crankcase is the force-bearing part of the engine. Its main function is bearing crankshaft, clutch, transmission case, cylinder body and cylinder head, bearing the inertia force from combustion shock and the movement of crankshaft connecting rod system, and forming a closed space (oil sealing, gas sealing).
  • Page 133 15.3 Crankcase Removal of crankcase ① Loosen the fan casing standing bolt, remove the fan casing and take off the starter motor. ①：starter motor ②：bolt ③：fan ② casing ③ Remove the bolt, remove the cover and remove magneto. ① ①：magneto ②：cover ③：bolt ②...
  • Page 134 Take off the oil pump gear and water pump gear. ① ①：water pump gear ②：oil pump gear ② ② Remove the bolt ①. Remove the oil pump ②. ① Remove the water pump bolt and closing bolt. ① Remove the water pump. Put the left crankcase under the water and remove the right crankcase.
  • Page 135 ① Remove the crankshaft connecting rod assembly. ③ Take off the timing chain. ①：crankshaft assembly ②：timing chain ② ③：bolt Inspection Measure the right-left clearance of connecting rod big end. Usage limit：0.9mm Measure clearance between X-Y orientation of connecting rod big end Usage limit：0.05mm ①...
  • Page 136 Shimmy measurement Usage limit: 0.1mm Check whether the crankshaft bearing revolution has noise or loose condition. If there is noise or loose condition, replace the crankshaft assembly. ①：crankshaft bearing ① Remove the oil seal of left crankcase. Note: The removed oil seal is non-reusable. ①...

  • Page 137: Inspection And Maintenance Of Emission Control System

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

  • Page 138: Emission Control System

    16. Emission control system Emission control system recognizance----------------------------------16.1 Regular maintenance notes/guarantee of Emission standards----16.2 Mechanical function of exhaust gas control system------------------16.3 Catalytic transfer system----------------------------------------------------16.4 Measures for idle Emission value over defined value---------------16.5 16.1 Emission Control System Recognizance 1. The Emission system of this motorcycle is in conformity with the revision of EC/97/24/5/I and 2002/81/EC B stage by EU.

  • Page 139: Regular Maintenance Notes

    The use is requested to carry out regular checks, adjustments or maintenance according to the scheduled time to ensure normal emission.  If other problems occur, please contact Benelli distributors or a Benelli service center for help.  Relevant Emission provisions are shown as follows: Emission provision ≤2.0g/km...
  • Page 140 16.3 Mechanical Function of the Emission Control System In general Solution for exhaust gas is based on two-stroke single-cylinder motor and carburetor, which adopts gas-intake device to maintain qualified exhaust gas standard, meanwhile the fuel evaporative exhaust gas adopts active carbon canister. * Engine improvement Improve the engine elements such as spark plug, combustor, compression ratio, ignition time, Emission system, etc.

  • Page 141: Catalytic Transfer System

    16.4 Catalytic transfer system 16.4.1 Structure: 1: Primary Catalyst Location 2: Secondary Catalyst Location 16.4.2 Instruction： 1. Function of transfer catalyst is to transfer completely burnt HC, CO and NO to harmless gas such as H O, CO for Emission. 、...
  • Page 142 Measures When the Idle Speed Emission Value Exceeds the Standard Qualified Periodic inspection (maintenance plan Qualified Measure idle emission (note 1) Qualified Adjust Carburetor (note2) Qualified Qualified Remove and clean the carburetor delivery Qualified Replace the carburetor Dismantle repair engine Qualified •Valve（leakage）...

  • Page 143: Inspection And Maintenance Of Electronic Fuel Injection (Efi) System

    Inspection and Maintenance of Electronic Fuel Injection (EFI) System...

  • Page 144: Electronic Fuel Injection System

    17. Electronic Fuel Injection System Electronic Fuel Injection System------------------------------------17.1 Components of Electronic Fuel Injection System--------------17.2 Failure Diagnosis-------------------------------------------------------17.3 Common Troubleshooting--------------------------------------------17.4 17.1 Introduction of Electronic Fuel Injection System ZAFFERANO adopts the small-scale engine electronic fuel injection system manufactured by Delphi Company, which is controlled with oxygen sensors within a closed loop. The three-way catalytic converter would go through treatment with the gas after combustion in the engine, turn it into harmless gas and release it into the air.

  • Page 145: Components Of Electronic Fuel Injection System

    Gas mixture to thick Fuel injector leakage rarefied air mixture Fuel pressure problem ECU data problem sensor failure Blocked airway 17.2 Components of Electronic Fuel Injection System 17.2.1 Engine Controller (MT05 ECU) The engine controller can test the operation conditions of the engine with various sensors at any time and guarantee the emission and economy of fuel by proper computing and self-study control output mechanism with the driving performance optimized.
  • Page 146 sensor Pin for activating 1-cylinder fuel injector Pin for signal 2- J1-5 J2-5 cylinder oxygen sensor J1-6 Connector pin for tachometer J2-6 Pin for activating 2-cylinder fuel injector J1-7 CAN line low signal 1 pin J2-7 Pin for heating 1-cylinder oxygen sensor J1-8 CAN line high signal 1 pin J2-8...
  • Page 147 17.2.1.3 Circuit Diagram of Electronic Injection System Notes: Keep ECU away from places of high temperature, like muffler or engine; Keep ECU away from water, engine oil or any places of liquid; Keep ECU away from mud or other dirt that would affect the heat dissipation function of ECU; Connect with M8 bolts and make sure the tightening torque is around 3.9Nm, keep the surface neat to prevent outside force to ECU in case of circuit board bending;...
  • Page 148 Installation requirements 17.2.1.4 The installation requirements for ECU controller are shown in the figure below (the tightening torque force for fixing bolts (M6) is 5 Nm).

  • Page 149: Maintenance Instructions

    17.2.1.5 Maintenance Instructions Instructions on ECU controller Instruction Cause DON’T: Place ECU beside the engine or the exhaust The service life of ECU is affected by pipe during transfer. high temperature which also easily damages the plastic shell of the ECU. DON’T: Place ECU in water, oil or liquid environment.

  • Page 150: Maintenance And Repair

    ● Reset mode: When the ECU receives a reset command or faces a serious problem, the system enters into the reset mode. All I/O interface is reset to the predefined state and enters into normal working conditions after the reset is finished. ●...
  • Page 151 Check Check whether the fuel injector is blocked; clean it with special equipment (such as ultrasonic) or special detergent; Check whether there is fuel leakage from the fuel injector; if yes, replace it with a new fuel injector of the same part number; Check whether the electromagnetic oil of the fuel injector is damaged: measure resistance of the electromagnetic coil with a voltmeter;...
  • Page 152 ·Outer diameter: 14.49mm ·Section thickness: 2.44mm 17.2.2.4 O-ring replacement ● Use the suggested lubricating oil to lubricate the o-ring. Do not contact the orifice plate with lubricating oil, otherwise it affects fuel injection. ● We suggest that an o-ring can be used only once. If replacement is impossible, please check whether it is damaged before repeated use.
  • Page 153 accumulated impurities in the fuel pipe between the fuel filter and the fuel injector. Impurities will cause failure such as bonding, flow deviation and leakage. Therefore, the fuel filter is very important. 17.2.2.9 Cable arrangement ● Cables of the fuel injector shall be deployed far away from heat source and protected from any external abrasion or damage.
  • Page 154 17.2.2.10 Instructions Instructions on the fuel injector Instruction Cause DON’T: use o-ring repeatedly. If it has to Avoid leakage. used repeatedly, please check whether it is damaged before use. DON’T: immerse the injector mouth Block the injection hole. in lubricant. Forbidden: dry run under no fuel pressure.
  • Page 155 By the installation seat during the installation of the fuel injector. DO: install it into the hole after being Protect the o-ring and reduce pollution. applied with correct lubricant. DO: test the fuel injector adhered to Confirm the invalidation of the fuel injector. the needle valve or whose needle valve fails in seating.
  • Page 156 Note: High temperature in the fuel injector and its surrounding parts. ● The motorcycle flames out. ● Disconnect the negative pole of the battery to avoid any accidental startup of the engine. ● Remove the fuel injector connector. ● Release fuel pressure. ●...
  • Page 157 17.2.3 Throttle Valve 17.2.3.1 General Working Principles: The throttle valve mainly consists of the main cast valve body, return spring, throttle cable, throttle position sensor and idle adjustment screw. The throttle position sensor provides the movement of the throttle to ECU; the idle adjustment screw is able to control the idle speed and its stability.
  • Page 158 17.2.3.3 Technical Parameters Throttle valve (inner diameter: 26mm): ● Maximum flow: 19.29±1.0g/s@0.75kPa vacuum degree ● Torque for opening the throttle valve: ● At idle speed: 0.19±0.05Nm ● When fully open: 0.37±0.10Nm Throttle position sensor: ● Reference voltage: 5±0.1VDC ● Resistance between T1 and T2: 3k～12kΩ 17.2.3.4 Working Environment Normal working environment: -40～257°F...
  • Page 159 Note: Do not disassemble the throttle position sensor if unnecessary. A special adjustment and test device shall be used during the assembly of the throttle position sensor to determine whether its assembly position satisfies technical condition requirements. Check ● Check whether the throttle cable wheel turns flexibly and returns normally; adjust the return spring to be within a reasonable range.
  • Page 160 17.2.3.6 Cleaning Remove the cover at the bottom of the throttle valve and clean the body with carburetor cleaner (3M product suggested). Spray cleaner on the inner wall of the throttle valve and remove dust and carbon deposit lightly with a brush. Do not block the bypass with impurities. Note: Do not block the bypass with impurities.
  • Page 161 DO: clean bypass when the seat is Ensure stable idle speed. removed. DO: if idle screws are removed, replace Ensure no air leakage from the o-ring. the o-ring. DON’T: use any fallen or defective Possible inner damage. component. Forbidden: no protective cap for storage Possible impact on normal work due parts.
  • Page 162 17.2.4.2 Appearance 17.2.4.3 Installation Requirements Dynamic torque requirement: start the threads by hand and torque it to the required torque with a dynamoelectric spanner of a speed over 400r/m. You can also screw it down to the required torque with a spanner by hand. The recommended torques are as follows: 20N·m~25N·m Static torque requirement:...
  • Page 163 17.2.4.7. Sample cleaning If necessary, the sensor can be cleaned with isopropanol first for not over 1 minute and then air dried. It is required to install a sealed joint in cleaning in case the fluid penetrates into inside of the sensor.
  • Page 164 17.2.5.5 Sample Cleaning If necessary, the sensor can be cleaned with isopropanol first for not over 1 minute and then air dried. It is required to install a sealed joint in cleaning in case the fluid penetrates into inside of the sensor.
  • Page 165 17.2.7.2 Appearance of the oxygen sensor...
  • Page 166 17.2.7.3 Technical Parameters ● Air-fuel ratio strong threshold value:＞750VDC ● Air-fuel ratio rare threshold value:＜120Mvdc ● Heater power of sensor: 7.0W （the above parameters are received from the measuring stand; working condition: exhaust temperature: 842°F; air-fuel ratio: 70%; voltage: 10Hz, 13.5V.） ●...

  • Page 167: Fuel Pump Assembly

    17.2.8.1 Appearance 17.2.9 Fuel Pump Assembly 17.2.9.1 Working Principles The electric pump works together with the pressure regulator to provide 250Kpa fuel pressure for the engine. It is installed under the gasoline tank. Fuel pump assembly: provide pressure for the engine and fuel for the system required. It is installed on the bottom and provides fuel via the connection pipe.
  • Page 168 ppearance 17.2.9.2 Fuel Pump Assembly A 1：pressure regulator 2：Pressure regulator clamp 3：high pressure fuel hose 4: pump installation bracket 5: fuel pump 6: filter screen 7：Fuel Pump harness 8: Fuel Pump bracket 9：Fuel Pump harness...

  • Page 169: Maintenance Procedures

    17.2.9.3 Label and Identification Fuel pump assembly:  Fuel pump assembly, fuel pump set and the pressure regulator are all equipped with production batches and dates.  Fuel pump assembly: identified with a label on the installation plate. Fuel pump: ...
  • Page 170 Procedures" after maintenance. ● Check and make sure there is enough fuel within the fuel tank when the pump is running after maintenance. 17.2.9.6 Failure Diagnosis of Fuel Pump Assembly Step Procedure Start the ignition key and run the fuel If the fuel pump starts If the fuel pump fails pump...
  • Page 171 33. installation torque of screws: 3～4Nm. The fuel assembly shall be fixed with specific bolts and installed according to the specific orders and torques required. The wrong torques and orders would cause deformation and leakage at the washers. ● install the fuel tank onto the motorcycle; ●...
  • Page 172 inlet and filter screen of the fuel pump) Make sure sufficient fuel in the fuel tank Do not: damage the filter screen during foreign matters would come into the fuel pump through the damaged filter to destroy the fuel pump maintenance Do not: disassemble the internal parts of the no guarantee...

  • Page 173: Methods For Fault Diagnosis And Maintenance

    regulator and fuel pump Do: make sure correct fuel pipe layout, without improper layout may damage the fuel pipe any interference with other components Do: make sure sufficient fuel in the fuel tank avoid the fuel pump being "dry running' (close over the filter screen of the fuel pump) Do: replace two O-rings during the maintenance ensure correct pressure adjustment curve of the...
  • Page 174 the trouble light will flash in corresponding fault code. Then check the fault code list for the breakdown in correspondence. In case of reading faults with the trouble light, the rules of flash codes are illustrated as below. Take the open circuit of intake pressure sensor or short circuit of signal end pin to the negative electrode of the battery as an example, after the key has been switched for three times, the trouble light will flash 10 times standing for 0, flash once after 1.2 seconds standing for 1, flash 10 times after another 1.2 seconds standing for 0 and flash 7 times after another 1.2 seconds standing...
  • Page 175 P0563 over tension of electronic control injection system P0560 fault of trouble light (damage of filament or plug-in device) short circuit of tachometer line to the negative electrode of P1693 the battery short circuit of tachometer line to the positive electrode of P1694 the battery short circuit of signal end pin of the rear cylinder oxygen...
  • Page 176 17.3.2 Fault Diagnosis by Diagnostic Apparatus Operation Steps： a) Find the 6-hole diagnostic port on the motorcycle. b) Connect the harness line to the port on the diagnostic apparatus. c) Turn on the key to diagnose the faults. 17.3.3 Fault Diagnosis with the Diagnostic Software PCHUD PCHUD software is used to inspect and record the operating data of the engine.
  • Page 177 Instructions of PCHUD Software: （1）Connect a notebook computer to the 6-hole diagnostic port of the motorcycle with the K line and turn on the key. （2）Click the icon "HUD.EXE" to start PCHUD software （3）Select "File" on the software interface, click "Open", choose "PCHUD.HAD" and select OK. （4）Select "Parameter File"...
  • Page 178 （5）If the real-time communication data fail to display on the soft ware interface when the power is on, check whether the connection setting of COM port in "Setup". Under the normal circumstance, set COM Port: 4 and Baud Rate: 10400, instead of DTR High at startup. Normal communication is ready to make then.
  • Page 179 Then check the corresponding fault according to the fault code list...
  • Page 180 PCHUD： VRPM engine speed VTHROT throtle position VBARO BARO VMAP manifold air pressure VMAPEXP expect manifold air pressure VIGN ignition key voltage VCLTS cylinder temperature or coolant temperature VIAT intake air temperature STATUSBYTE5 STATUSBYTE5 VAFCMET airflow correction met VBAROCMET Baro update met VCSINSYNSPRK sequential spark enable SATITRIG...
  • Page 181 SAESTA cylinder 1 Spark Advance SAIDLDYN idle dynamic Spark Advance SPDWELL dwell time IAINTEGOFST airflow integral of idle air control valve IACVDSMP desired position of idld air control valve STATUSBYTE2 STATUSBYTE2 FCLCEN1 cylinder 1 close loop correction enable PPDSEBL prime pulse disable FPENABL fuel pump enable FTRNSAES...

  • Page 182: Common Troubleshooting

    17.4 Common Troubleshooting 17.4.1 Repair Tools Disassembling the parts of the electronic control system- common disassembly tools for auto machinery parts Circuit of the electronic control system and its electrical signal- digital multimeter (with beep) Diagnosing the faults in the electronic control system and checking the engine's operation ...
  • Page 183 Engine trouble light- influences the system in fault warning. Storage battery voltage- judges whether the battery power is adequate. According to the experience, judge whether the readings of coolant temperature sensor, air intake temperature sensor, manifold absolute pressure sensor and oxygen sensor are normal.
  • Page 184 17.4.3.2 Fault Description- Startup Failure Turn the ignition lock to "ON" to check whether the trouble light turns on.  Check the fuse and the ground wire. If no：  Check whether ECU's plug is tightly connected.  Check whether the light and circuit are normal through the inspection function of the diagnostic apparatus's actuator.
  • Page 185 Whether the clearance of crankshaft position sensor is too large 17.4.3.3 Fault Description- Startup Failure Accompanied with Backfire Check whether the high-tension cable of ignition coil is loose Whether the timing gear is loose. 17.4.3.4 Fault Description- Unstable Idle Speed Idle speed Check whether the idle speed by-pass bolt is too loose or tight.
  • Page 186 17.4.3.8 Fault Description- Little Misfire Check whether the spark plug gap meets the standard between 0.7-1mm. 17.4.3.9 Fault Description- Non-conformity between Fault Code and Fault When Trouble Light is On The ground wire of the system may be not connected well. Reconnect the ground wire, turn off the storage battery power line for 3 minutes and turn it on, then start the engine.
  • Page 187 S P E E D M E T E R S P E E D S E N S O R F U E L M E T E R R E L A Y P U M P R E L A Y B A T T E R Y O I L P U M P I A C...

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