Benelli TRK 502 Owner's Manual
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Benelli TRK 502 Owner's Manual

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Owner's Manual
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

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Summary of Contents for Benelli TRK 502

  • Page 1 Owner’s Manual Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 The Benelli team wishes you many safe and pleasant rides. So, remember to put safety first! Benelli continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product informa- tion available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If there is any question concer- ning this manual, please consult a Benelli dealer.
  • Page 4 Introduction Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all DANGER safety messages that follow this symbol to avoid possible injury or death. A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious WARNING injury.
  • Page 5 Introduction TRK502 OWNER’S MANUAL Benelli Q.J. s.r.l. 4th edition, June 2017 All rights reserved. Any reprinting or unauthorized use without the written permission of Benelli Q.J. s.r.l. is expressly prohibited. Printed in Italia.

  • Page 6: Table Of Contents

    Table of contents Safety information ........1-1 For your safety – • Brake light switches....... 6-19 pre-operation checks ......4-1 • Checking the front and rear brake pads........6-20 Description..........2-1 • Checking the brake • Left view............2-1 Operation and important fluid level ...........6-20 •...
  • Page 7 Table of contents Specifications.......... 8-1 • Electric System........... 8-4 Consumer information......9-1 • Identification numbers......9-1 • Diagnostic connector......9-2 • Vehicle data recording......9-2 Regular maintenance coupons....10-1...
  • Page 8 Table of contents...

  • Page 9: Safety Information

    Safety information Be a Responsible Owner Safe Riding • Many accidents involve inexperienced As the vehicle’s owner, you are responsible for Perform the pre-operation checks each time operators. In fact, many operators who the safe and proper operation of your motor- you use the vehicle to make sure it is in safe have been involved in accidents do not cycle.
  • Page 10 Safety information • onto the operator, the seat strap burns. Loading • A passenger should also observe the or grab bar, if equipped, with both Adding accessories or cargo to your motor- hands and keep both feet on the above precautions. cycle can adversely affect stability and han- passenger footrests.
  • Page 11 Benelli vehicles. other modifications performed to your vehi- or front fender. These items, inclu- Benelli is not in a position to test the products cle that change any of the vehicle’s design ding such cargo as sleeping bags, that these aftermarket companies produce.
  • Page 12 Safety information • and should be kept to a minimum. Aftermarket Tires and Rims somewhat by the tie-downs, if possible, Bulky or large accessories may se- The tires and rims that came with your motor- so that the motorcycle will not bounce riously affect the stability of the cycle were designed to match the performan- excessively during transport.

  • Page 13: Description

    Description Left view 1. Shock absorber assembly rebound damping force adjusting knob (3-15) 2. Battery (6-28) 3. Fuse box (6-29) 4. Seat lock (3-14) 5. Shock absorber assembly spring preload adjusting ring (3-15) 6. Shift pedal (3-8) 7. Engine oil drain bolt (6-11) 8.

  • Page 14: Right View

    Description Right view 1. Rear brake fluid reservoir (6-21) 2. Fuel tank cap (3-10) 3. Headlight (6-31) 4. Radiator cap (6-14) 5. Coolant reservoir (6-13) 6. Engine oil level check window (6-10) 7. Engine oil filler cap (6-10) 8. Brake pedal (3-9) 2 - 2...

  • Page 15: Controls And Instruments

    Description Controls and instruments 1. Clutch lever (3-8) 2. Left handlebar switches (3-6) 3. Multi-function meter unit (3-3) 4. Right handlebar switches (3-6) 5. Throttle grip (6-17) 6. Brake lever (3-8) 7. Front brake fluid reservoir (6-20) 8. Main switch/steering lock (3-1) 9.
  • Page 16 Description NOTE ........................................................................................................................................................................................................................................................................................................................................2 - 4...

  • Page 17: Instrument And Control Functions

    Instrument and control functions Main switch/steering lock (off) All electrical systems are off. The bike is supplied with 3 keys for: The key can be removed. - Opening the fuel cap - Steering lock - Ignition - Opening the saddle WARNING Never turn the key to “...
  • Page 18 Instrument and control functions To lock the steering: To unlock the steering: 1) Turn the handlebar completely to the left. 1) Insert the key in the steering lock. 2) Insert the key in the ignition. 2) Turn the key clockwise. 3) Turn the key anticlockwise, in the “...

  • Page 19: Multi-Function Meter Unit And Indicator Lights And Warning Lights

    Instrument and control functions Multi-function meter unit and Indica- tor lights and warning lights 1. Tachometer (3-4) 2. “SELECT” button (3-5) 3. “RESET” button (3-5) 4. Coolant temperature (3-4) 5. Engine trouble warning light “ “(3-4) 6. Left turn signal indicator light ” “...
  • Page 20 This indicator light comes on when the tran- Digital clock trol system. If this occurs, have a Benelli dealer smission is in the neutral position. check the on-board diagnostic system. Shows the time in hours and minutes.
  • Page 21 ABS system. In which event, take the The transmission gear display shows the se- lected gear. motorcycle to an authorized Benelli servi- ce centre. This model is equipped with 6 gears. Anti-lock Brake System (ABS) warning light 1.

  • Page 22: Handlebar Switches

    Instrument and control functions Handlebar switches Righ Passing button Press this button (daytime) to enable lashing lights. Left Run/Start switch “ ” To crank the engine with the starter, set this switch to “ ”, See page 5-1 for starting in- structions prior to starting the engine.
  • Page 23 Instrument and control functions ABS button Enabling ABS: B: The ABS will be active again from any other Do not try to adjust settings of ABS while the Make sure the motorcycle is stationary and previous setting when the button is pressed motorcycle running.

  • Page 24: Clutch Lever

    Instrument and control functions Clutch lever Shift pedal Brake lever The clutch lever is located on the left side of The shift pedal is located on the left side of The brake lever is located on the right side of the handlebar.

  • Page 25: Abs

    5 km/h, contact an authorized the rear wheel from raising form the Benelli service centre for checking. ground. • When the ABS is working, a pulsation • The ABS control unit always uses the...

  • Page 26: Fuel Tank Cap

    Instrument and control functions below or equal to about 5 km/h. Fuel tank cap • The ABS does not work in case of low battery. NOTICE Be careful not to damage the wheel sensor or wheel sensor rotor; otherwise, improper performance of the ABS will result.

  • Page 27: Fuel

    Instrument and control functions Fuel Make sure there is sufficient gasoline in The fuel tank cap cannot be closed unless the the tank. key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked.
  • Page 28 Premium unleaded gasoline (Gasohol [E10] acceptable) Fuel tank capacity: Your Benelli engine has been designed to use 20 L ± 0.5 L (5.3 US gal, 4.4 Imp gal) premium unleaded gasoline with a research octane number of 95 or higher. If knocking (or...

  • Page 29: Catalytic Converter

    Instrument and control functions Catalytic converter This model is equipped with a catalytic con- verter in the exhaust system. WARNING The exhaust system is hot after operation. To prevent a fire hazard or burns: • Do not park the vehicle near possible fire hazards such as grass or other ma- terials that easily burn.

  • Page 30: Seats

    Instrument and control functions Seats Rider seat Adjusting the headlight beams To remove the rider seat Passenger seat The headlight beam adjusting knobs are used 1. Remove the passenger seat. To remove the passenger seat to raise or lower the height of the headlight beams.

  • Page 31: Adjusting The Shock Absorber Assembly

    • Do not dispose of a damaged or worn- out shock absorber assembly your- self. Take the shock absorber assem- 1. Adjusting knob. bly to a Benelli dealer for any service. 2. Increase braking action. 3. Decrease braking action. NOTICE...

  • Page 32: Sidestand

    • It prevents starting when the transmis- Benelli’s ignition circuit cut-off system has sion is in gear and the clutch lever is pul- been designed to assist the operator in led, but the sidestand is still down.
  • Page 33 2. Make sure that the start/engine stop switch is set to “ ”. ring this inspection. 3. Turn the key on. • If a malfunction is noted, have a Benelli dealer check 4. Shift the transmission into the neutral position. the system before riding. 5. Press the electric start button.

  • Page 34: Auxiliary Usb Jack

    Instrument and control functions Auxiliary USB jack WARNING To prevent electrical shock or short-circu- iting, make sure that the cap is installed when the auxiliary (USB) jack is not being used. NOTICE 1. Auxiliary USB jack cap The accessory connected to the auxiliary 3.

  • Page 35: For Your Safety - Pre-Operation Checks

    If necessary, add recommended coolant to specified level. • Check cooling system for leakage. Front brake • Check operation. • If soft or spongy, have Benelli dealer bleed hydraulic system. • Check brake pads for wear. • Replace if necessary. • Check fluid level in reservoir.

  • Page 36: Throttle Grip

    Make sure that operation is smooth. Throttle grip • Check throttle grip free play. • If necessary, have Benelli dealer adjust throttle grip free play and lubricate cable and grip housing. Control cables • Make sure that operation is smooth. •...
  • Page 37 Tighten if necessary. Instruments, lights, • Check operation. • Correct if necessary. signals and switches Sidestand switch • Check operation of ignition circuit cut-off system. • If system is not working correctly, have Benelli dealer check vehicle. 4 - 3...
  • Page 38 For your safety – pre-operation checks NOTE ........................................................................................................................................................................................................................................................................................................................................4 - 4...

  • Page 39: Operation And Important Riding Points

    The neutral indicator light should come If there is a control or function you do not un- on. If not, ask a Benelli dealer to check the In order for the ignition circuit cut-off system derstand, ask your Benelli dealer.

  • Page 40: Shifting

    Operation and important riding points Shifting Tips for reducing fuel consumption NOTICE Fuel consumption depends largely on your • Even with the transmission in the neu- riding style. Consider the following tips to re- tral position, do not coast for long pe- duce fuel consumption: riods of time with the engine off, and •...

  • Page 41: Engine Break-In

    Since the engine is brand new, do not put an mediately have a Benelli dealer check excessive load on it for the first 1600 km (1000 WARNING the vehicle.
  • Page 42 Operation and important riding points NOTE ........................................................................................................................................................................................................................................................................................................................................5 - 4...

  • Page 43: Periodic Maintenance And Adjustment

    (if applicable). WARNING use, the maintenance intervals may need to Benelli dealers are trained and equipped to be shortened. perform these particular services. Brake discs, calipers, drums, and linings can become very hot during use. To avoid...

  • Page 44: Owner's Tool Kit

    Replacement If you do not have the tools or experience re- quired for a particular job, have a Benelli dea- Dealer ler perform it for you. A list of workshops is available on our website...

  • Page 45: General Maintenance And Lubrication Chart

    Periodic maintenance and adjustment General maintenance and lubrication chart 1000 Km 4000 Km 7000 Km 10.000 Km 13.000 Km 0 Km Maintenance (621mi) (2.486 mi) (4.350 mi) (6.214 mi) (8.078mi) Annual Part (0 mi) intervention inspection 1° 2° 3° 4° 5°...
  • Page 46 Periodic maintenance and adjustment 1000 Km 4,000 Km 7,000 Km 10,000 Km 13,000 Km 0 Km Annual Maintenance interven- (621 mi) (2,486 mi) (4,350 mi) (6,214 mi) (8,078 mi) Part (0 mi) inspec- tion or control 1° 2° 3° 4° 5°...
  • Page 47 Periodic maintenance and adjustment 1000 Km 4,000 Km 7,000 Km 10,000 Km 13,000 Km 0 Km Annual Maintenance interven- (621 mi) (2,486 mi) (4,350 mi) (6,214 mi) (8,078 mi) Part (0 mi) inspec- tion or control 1° 2° 3° 4° 5°...
  • Page 48 Periodic maintenance and adjustment 1000 Km 4,000 Km 7,000 Km 10,000 Km 13,000 Km 0 Km Annual Maintenance interven- (621 mi) (2,486 mi) (4,350 mi) (6,214 mi) (8,078 mi) Part (0 mi) inspec- tion or control 1° 2° 3° 4° 5°...
  • Page 49 Periodic maintenance and adjustment 1000 Km 4,000 Km 7,000 Km 10,000 Km 13,000 Km 0 Km Annual Maintenance interven- (621 mi) (2,486 mi) (4,350 mi) (6,214 mi) (8,078 mi) Part (0 mi) inspec- tion or control 1° 2° 3° 4° 5°...
  • Page 50 Periodic maintenance and adjustment 1000 Km 4,000 Km 7,000 Km 10,000 Km 13,000 Km 0 Km Annual Maintenance interven- (621 mi) (2,486 mi) (4,350 mi) (6,214 mi) (8,078 mi) Part (0 mi) inspec- tion or control 1° 2° 3° 4° 5°...

  • Page 51: Checking The Spark Plugs

    Do not attempt to diagnose such problems Spark plug gap: yourself. Instead, have a Benelli dealer check the vehicle. 0.7~0.8 mm (0.027~0.031 in) If a spark plug shows signs of electrode ero-...

  • Page 52: Canister

    Periodic maintenance and adjustment Canister Engine oil and oil filter cartridge Engine oil filler cap The engine oil level should be checked before each ride. In addition, the oil must be chan- ged and the oil filter cartridge replaced at the intervals specified in the periodic maintenan- ce and lubrication chart.
  • Page 53 7. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the speci- fied torque with a torque wrench. An oil filter wrench is available at a Benelli de- 1. Engine oil drain bolt aler.
  • Page 54 8. Install the engine oil drain bolt and its new mediately turn the engine off and have a NOTICE Benelli dealer check the vehicle. gasket, and then tighten the bolt to the spe- cified torque. • In order to prevent clutch slippage (since the engine oil also lubricates 11.

  • Page 55: Coolant

    If water has been added to the coolant, 4. Coolant reservoir cap engine temperature. have a Benelli dealer check the antifreeze • Make sure that the vehicle is positioned content of the coolant as soon as possible, straight up when checking the coolant otherwise the effectiveness of the coolant 3.
  • Page 56 Periodic maintenance and adjustment 7. Pour the specified amount of the recom- WARNING mended coolant into the radiator and reser- voir. Never attempt to remove the radiator cap when the engine is hot. Antifreeze/water mixture ratio: Recommended antifreeze: High-quality ethylene glycol antifreeze 1.

  • Page 57: Air Filter Element

    Check the engine idling speed and, if neces- intervals specified in the periodic maintenan- sary, have it corrected by a Benelli dealer. ce and lubrication chart. Have a Benelli dealer replace the air filter ele- ment. Engine idling speed: 1400-1600 r/min...

  • Page 58: Checking The Throttle Grip Free Play

    Safety in all conditions of riding ne noise. To prevent this from occurring, the depends on a relatively small area of road valve clearance must be adjusted by a Benelli contact. dealer at the intervals specified in the periodic Therefore, it is essential to maintain the tires maintenance and lubrication chart.
  • Page 59 “broken in” for it to develop its it, or if the sidewall is cracked, have a Benelli- dealer replace the tire immediately. optimal characteristics.

  • Page 60: Adjusting The Clutch Lever Free Play

    Periodic maintenance and adjustment • fore, it is advisable before doing any Adjusting the clutch lever free play WARNING high-speed riding to ride conservati- vely for approximately 100 km (60 mi) Measure the clutch lever free play as shown. • The front and rear tires should be of after installing a new tire.

  • Page 61: Checking The Brake Lever Free Play

    There should be no free play at the brake lever The brake light, which is activated by the bra- end. If there is free play, have a Benelli dealer ke pedal and brake lever, should come on just inspect the brake system.

  • Page 62: Checking The Front And Rear Brake Pads

    To check the brake pad wear, check the wear indicator grooves. If a brake pad has worn to the point that a wear indicator groove almost appears, have a Benelli dealer replace the bra- 1. Brake pad wear indicator ke pads as a set.

  • Page 63: Changing The Brake Fluid

    Changing the brake fluid otherwise, the rubber seals may dete- riorate, causing leakage. Have a Benelli dealer change the brake fluid at • Refill with the same type of brake flu- the intervals specified in the periodic mainte- id. Adding a brake fluid other than nance and lubrication chart.

  • Page 64: Drive Chain Slack

    Benelli workshop. If you suspect that there is a serious mal- function with the chain, stop the bike im- mediately and call your nearest Benelli au- thorised workshop. 1. Axle nut 2. Locknut Drive chain slack: 3.

  • Page 65: Cleaning And Lubricating The Drive Chain

    Periodic maintenance and adjustment Cleaning and lubricating the drive 3. Thoroughly lubricate the drive chain with a NOTICE special O-ring chain lubricant. chain Incorrect transmission chain tension will The drive chain must be cleaned and lubrica- overload the engine and other vital parts ted at the intervals specified in the periodic of the motorcycle, and it may cause the maintenance and lubrication chart, otherwise...

  • Page 66: Checking And Lubricating The Cables

    If a cable is damaged or does not move smo- at the intervals specified in the periodic main- othly, have a Benelli dealer check or replace it. tenance chart. Brake pedal The throttle cable is equipped with a rubber cover.

  • Page 67: Checking And Lubricating The Brake And Clutch Levers

    Periodic maintenance and adjustment Shift pedal Checking and lubricating the brake Clutch lever and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary. Brake lever Recommended lubricant: Recommended lubricants: Lithium-soap-based grease...

  • Page 68: Checking And Lubricating The Sidestand

    Therefore, we ask that you check this system regularly, as described below, To check the operation and have it repaired by a Benelli dealer if it 1. Place the vehicle on a lat surface and keep does not operate correctly.

  • Page 69: Checking The Steering

    2. Hold the lower ends of the front fork legs and try to move them forward and backward. If any free play can be felt, have a Benelli dea- Worn or loose steering bearings may cause ler check or repair the steering.

  • Page 70: Checking The Wheel Bearings

    If there is play in the wheel hub or if the wheel This model is equipped with a VRLA (Valve Re- does not turn smoothly, have a Benelli dealer To charge the battery gulated Lead Acid) battery.

  • Page 71: Replacing The Fuses

    Periodic maintenance and adjustment Using a conventional battery charger will 4. After installation, make sure that the bat- Replacing the fuses damage the battery. tery leads are properly connected to the bat- tery terminals. The fuse boxes and individual fuses are loca- ted under the rider seat.

  • Page 72: Brake/Tail Light And The Turn Signal Light

    3. Turn the key to “ ” and turn on the electri- cal circuit in question to check if the device operates. 4. If the fuse immediately blows again, have a Benelli dealer check the electrical system. 1. Fuel Pump 2. Fan 1. Brake/tail light 3.

  • Page 73: Auxiliary Lights

    Periodic maintenance and adjustment Auxiliary lights 1. Remove the right and left inspection lids 5. Installthe new lamp and fix it using the fixing spring. 6. Connect the connectors of the new lamp. If an auxiliary light does not come on, replace 7.

  • Page 74: Troubleshooting

    However, should your motorcycle require any repair, take it to a Benelli dealer, whose skilled technicians have the necessary tools, expe- rience, and know-how to service the motor- cycle properly.

  • Page 75: Troubleshooting Charts

    Remove the spark plugs and check the electrodes. The engine does not start. Have a Benelli dealer check the vehicle. Check the compression. 4. Compression The engine does not start. There is compression.
  • Page 76 The coolant level Benelli dealer check and repair the cooling system. is OK. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

  • Page 77: Motorcycle Care And Storage

    Be sure to consult a such products are used on hard-to-re- car, however, it detracts from the overall ap- Benelli dealer for advice on what products move dirt, do not leave the cleaner pearance of a motorcycle.
  • Page 78 Motorcycle care and storage • Do not use high-pressure washers or After riding in the rain, near the sea or on salt- dampened with a mild detergent, and then steam-jet cleaners since they cause sprayed roads wash it off thoroughly with water. water seepage and deterioration in Since sea salt or salt sprayed on roads during Some cleaning compounds for plastics may...

  • Page 79: Storage

    Storage WARNING Short-term Contaminants on the brakes or tires can • Consult a Benelli dealer for advice on Always store your motorcycle in a cool, dry cause loss of control. what products to use. place and, if necessary, protect it against dust •...
  • Page 80 Motorcycle care and storage Long-term • Remove the spark plug caps from Before storing your motorcycle for several the spark plugs, and then install months: the spark plugs and the spark plug • Follow all the instructions in the “Care” caps.

  • Page 81: Specifications

    Specifications Dimensions: Fuel: Starting system: Electric starter Overall length: Recommended fuel: Lubrication system: 2200 mm (86.6 in) Premium unleaded gasoline (Gasohol [E10] Wet sump Overall width: acceptable) 915 mm (36 in) Fuel tank capacity: Overall height: 20 L ± 0.5 L (5.3 US gal, 4.4 Imp gal) Engine oil: Fuel reserve amount: 1450 mm (57 in)
  • Page 82 Specifications Chassis: Front wheel: Front suspension: Frame type: Wheel type: Type: Trellis pipes with steel plates Alluminium alloy Fork upside- down Rim size: Shock absorber: 17 x MT 3.50 Hydraulic damper Front tire: Wheel travel: 150 mm (5.90 in) Type: Rear wheel: Tubeless Size:...
  • Page 83 Specifications Bulb wattage: Fuse(s): Headlight: Main fuse: H7 55W 40.0 A Brake/tail light: Light fuse: 15 A Front turn signal light: Signaling system fuse: 7.5 A Rear turn signal light: Ignition fuse: 10.0 A Meter lighting: Parking lighting fuse: 7.5 A Neutral indicator light: Radiator fan motor fuse: 15.0 A...

  • Page 84: Electric System

    Specifications Electric System 8 - 4...

  • Page 85: Consumer Information

    These identification numbers are needed when registering the vehicle with the autho- rities in your area and when ordering spare parts from a Benelli dealer. VEHICLE IDENTIFICATION NUMBER: The identification number of the vehicle is The engine serial number is punched on the punched on the steering head;...

  • Page 86: Diagnostic Connector

    Diagnostic Connector The label of the model is applied to the left The diagnostic connector is located as shown. Benelli will not disclose this data to a third side of the steering head. party except: Record the information on this label in the •...

  • Page 87: Regular Maintenance Coupons

    Regular maintenance coupons COUPON N. 1 - ....Model/Cubic capacity Dealer’s stamp Frame number, in full Km travelled SERVICE CARRIED OUT USING REMOTE MEANS Responsibility of the dealer The vehicle has been inspected, following all of the operations envisaged in the maintenance plan.
  • Page 88 Regular maintenance coupons COUPON N. 2 - ....Model/Cubic capacity Dealer’s stamp Frame number, in full Km travelled SERVICE CARRIED OUT USING REMOTE MEANS Responsibility of the dealer The vehicle has been inspected, following all of the operations envisaged in the maintenance plan.
  • Page 89 Regular maintenance coupons COUPON N. 3 - ....Model/Cubic capacity Dealer’s stamp Frame number, in full Km travelled SERVICE CARRIED OUT USING REMOTE MEANS Responsibility of the dealer The vehicle has been inspected, following all of the operations envisaged in the maintenance plan.
  • Page 90 Regular maintenance coupons COUPON N. 4 - ....Model/Cubic capacity Dealer’s stamp Frame number, in full Km travelled SERVICE CARRIED OUT USING REMOTE MEANS Responsibility of the dealer The vehicle has been inspected, following all of the operations envisaged in the maintenance plan.
  • Page 91 Regular maintenance coupons COUPON N. 5 - ....Model/Cubic capacity Dealer’s stamp Frame number, in full Km travelled SERVICE CARRIED OUT USING REMOTE MEANS Responsibility of the dealer The vehicle has been inspected, following all of the operations envisaged in the maintenance plan.
  • Page 92 Regular maintenance coupons NOTE ........................................................................................................................................................................................................................................................................................................................................10 - 6...

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