Benelli Tornado TNT600 Owner's Manual
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Benelli Tornado TNT600 Owner's Manual

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  • Page 2 OWNER’S MANUAL 2013...

  • Page 4: Table Of Contents

    CONTENTS DRIVING OF MOTORCYCLE PREFACE STARTING IMPORTANT NOTES USING GEAR SHIFTING MECHANISM SPECIAL ATTENTION DRIVING ON THE SLOPE SAFETY NOTES USING BRAKE AND STOPPING SAFETY RIDING RULES INSPECTION AND MAINTENANCE PROTECTIVE CLOTHES MAINTENANCE SCHEDULE PROTECTIVE HELMETS ENGINE OIL NOTES FOR RIDING IN RAINY DAYS SPARK PLUG SERIAL NUMBER ADJUSTMENT OF ACCELERATOR CABLE WIRE...

  • Page 5: Preface

    Benelli is equipped with professional technical service personnel and department, which is able to provide you with highest quality technical services. Insisting in the principle of “customer first”, Benelli makes great efforts to develop the products quality and performances so that the appearances and structures are always being innovated with advance structure.

  • Page 6: Important Notes

    The User Instruction should be considered as a permanent manual for the motorcycle. Please give it to the new owner if you transfer the motorcycle. No copy or reproduction of any part in this manual without written approval from Benelli.

  • Page 7: Special Attention

    SPECIAL ATTENTION The motorcycle must be equipped with a specify fuse only to avoid any serious damage or accident. • Fuse compartment is next to the storage battery. • Fuse specification: 20A for main power source fuse and 15A for ECU system fuse. •...

  • Page 8: Safety Notes

    SAFETY NOTES SAFETY RIDING RULES Have a complete inspection before starting the engine so as to prevent possible accidents or damages of spare parts. Never lend it to any people without a driving license. To avoid damages by other motor vehicles, the rider shall try his/her best to be visible at all time.

  • Page 9: Protective Clothes

    PROTECTIVE CLOTHES In order to assure personal safety, the rider should wear protective helmet, protective glasses, driving boots, gloves and protective clothes. The passenger should also wear the protective helmet. The exhaust system will be hot during running and still be hot for a while after the engine is stopped.

  • Page 10: Serial Number

    SERIAL NUMBER Vehicle Identification Number and the Serial Number are used for the registration of the motorcycle, including all necessary back up service. Remember the numbers for the possible uses in the future. The frame number is printed in the right side of head tube Product nameplate is riveted on the head tube.

  • Page 11: Configuration Of Parts

    CONFIGURATION OF PARTS BODY PARTS Clutch Lever Left Right Handle Switch Left Handle Switch Right Side Mirror Clutch Lever Front Brake Lever Fuel Tank Lock Throttle Meter Fuel Tank...
  • Page 12 Rear Brake Fuel Oil Observation Hole Side Stand Rear Foot Pedal Front Brake Front Foot Pedal Rear Brake Pedal...
  • Page 13 Front Brake Rear Foot Pedal Gear Shift Pedal Lever Front Foot Pedal Side Stand...

  • Page 14: Meter Panel

    METER PANEL Neutral Gear Indicator Light Temperature Engine Lubricant Time Display x1000rpm CL OCK High Beam Indicator Light Function Button km/h T R IP Right Signal Lamp Indicator Fuel Oil Level Indicator Light Left Signal Lamp Indicator Speedometer Light Tachometer Odometer...
  • Page 15 Left signal lamp indicator light Fuel oil level indicator When the turn signal lamp is turning left, the left Odometer steering lamp indicator light will flash. TRIP or ODO function on the odometer can be chosen as required. Right signal lamp indicator light TRIP: An odometer than can be zero cleared, recording When the turn signal lamp is turning right, the right the driving mileage within a period.

  • Page 16: Operation Procedures

    OPERATION PROCEDURES POWER LOCK When the key turns to “ ”position, the power gets through and the engine starts to run. The key can not be taken out. When the key turns to “ ”position, the power cuts off, and the engine can not run. The key can be taken out.

  • Page 17: Left Handle

    LEFT HANDLE Clutch Handle Headlamp High-Low Beam Turn Signal Lamp Switch Horn...
  • Page 18 Clutch handle When starting the engine or shifting the gear, operate the clutch handle to cut off the driving of rear wheel. Horn button Pressing the horn button, the horn will make sound. Headlamp high-low beams switch Press the headlamp high -low beams switch to position, the headlamp high beam will be on and high beam indicator light in the instrument panel lights up too;...

  • Page 19: Right Handle

    RIGHT HANDLE Front Brake Handle Accelerator Control Handle Engine Off Switch Hazard Warning Lamp Button Electric Starting Switch...
  • Page 20 Engine off switch When the switch is pressing at position, the power of the complete vehicle will be on and the engine can start. When the switch is pressing at position the power of the complete vehicle will be cut off and the engine can not start.

  • Page 21: Fuel Tank

    FUEL TANK Insert the fuel tank key and turn the key clockwise to open the fuel tank cover, the fuel tank cover can be opened with the key. Guide pin against the fuel tank and then press down to close the fuel tank cover, take it out until the locking sound is heard. The fuel tank can not be over-filled.

  • Page 22: Gear Shifting Pedal Lever

    GEAR SHIFTING PEDAL LEVER This motorcycle comes with the constant mesh six-speed non cyclical gear shifting, the operation is shown as in the figure. The neutral position is between the low-speed gear and two-speed gear, step down the gear shifting lever from the neutral position to select the low-speed gear;...

  • Page 23: Rear Brake Pedal

    REAR BRAKE PEDAL Step down the rear brake pedal (as shown in the Figure) to put into gear of rear brake, when operating the rear brake, the brake lamp will be on.

  • Page 24: Side Stand

    SIDE STAND The kick stand is located at the left side of the vehicle, please use your foot to shift the stand into proper position when stopping. Do not put the vehicle at the declinational slope, otherwise the vehicle may overturn.

  • Page 25: Rear Suspension Preload

    REAR SUSPENSION PRELOAD The spring on the rear shock absorber can be adjusted to bear different situations and road conditions as required by the driver. There are five positions for adjustment available. Use the kick stand to support the motorcycle properly and turn the spring adjusting ring to the needed position.

  • Page 26: Usage Instruction

    USAGE INSTRUCTION FUEL It is better to use lead-freefuel or low-lead fuel. The octane value of the fuel should be above 90. If the engine makes slight knocking sound, fuel of common grade may be used, which should be replaced. When the transmission is on neutral position, the indicator light will be on, the rider should loose the clutch lever slowly to confirm if the transmission is at the neutral position.

  • Page 27: Engine Oil

    ENGINE OIL Please use the high clarity and high quality engine oil which conforms to or above SF level. Always insist on recommended fully synthetic motorcycle engine oil. BREAKING IN The engine of the new motorcycle shall not be over-run and theRPM speed on any gear shall not exceed 80% of its maximum rotating speed during the first 1,000km driving period;...

  • Page 28: Check Before Riding

    CHECK BEFORE RIDING Please check the following items before driving. The importance of these checks shall not be ignored. Scope of Checking Focus of Checking 1) Stable Handle 2) Revolve smoothly 3) No axial float and loose 1) proper clearance between the handle and brake pedal Brake 2) no feeling of braking ineffective braking 3) no oil leaking...
  • Page 29 High beam indicator light, gear indicator light, turn signal Indicator Light indicator light Horn & Brake Switch Function normally. Engine Oil The oil level is proper. 1) Proper accelerator cable clearance Accelerator 2) Smooth fueling and quick fuel cut-off 1) Proper cable wire clearance. Clutch 2) Smooth operation.

  • Page 30: Driving Of Motorcycle

    DRIVING OF MOTORCYCLE STARTING OF ENGINE Turn the power lock clockwise to the contact of “ ”position, if the transmission is on neutral position, the neutral position indicator light will be on. Grasp the clutch handle and start the engine when the transmission is on the neutral position. Start the engine by electric starting, ECU will provide the fuel necessary to start the engine in accordance with the ambient temperature and the engine condition.

  • Page 31: Starting

    STARTING Grasp the clutch handle for a short moment, then step down the speed shifting lever to put into first gear. Turn the accelerator control handle facing the driver, at the same time, loose the clutch handle slowly and stably, now the motorcycle will move forward. USING GEAR SHIFTING MECHANISM The gear shifting mechanism can ensure the stable running of the engine under normal operation range.
  • Page 32 The inexperienced rider often uses the rear brake only, which will accelerate the wearing of brake and make the braking distance too long. Using only the front brake or the rear brake is dangerous, which will cause slid or lose of control. Use the brake carefully and slightly when riding on the wet highroads, slippery road surface and all the roads with a curve.

  • Page 33: Inspection And Maintenance

    INSPECTION AND MAINTENANCE The following table is the periodic service interval. After each time limit, inspection, verification, lubricating and stipulated maintenance must be carried out in accordance with the stated instructions. The steering gear system, support and wheel system are key components, which require carful maintenance of specialized technical personnel.
  • Page 34 CYCLE MAINTENANCE MILEAGE ODOMETER READING (NOTE2) REFERENCED MAINTENANCE COMMENT 1000KM 4000KM 8000KM 12000KM ITEMS PAGE Fuel Passage Oil Filter Air Throttle Operation Air Filter Note 1 Spark Plug Valve Clearance Engine Oil R at 1st 500KM - 1000KM and then every 5000KM Oil Filter Screen Engine Idle Speed Drive Chain...

  • Page 35: Engine Oil

    ENGINE OIL Please check the engine oil level before staring the engine. When checking the oil level, place the motorcycle on vertical flat ground and use the oil gauge to watch if the oil level is within the scale range. When the oil level is below the lower scale mark, please open the upper oil filler cap and add the oil to the upper scale mark.

  • Page 36: Spark Plug

    SPARK PLUG In the initial 1000km driving and every 4000km interval, use the small metal wire or spark plug cleaner to clear the carbon deposit on it. Use the spark plug gap-measuring plate to readjust the spark plug electrode gap and keep it within 0.6-0.7mm. Replace the spark plug after every 8000km driving.

  • Page 37: Adjustment Of Accelerator Cable Wire

    ADJUSTMENT OF ACCELERATOR CABLE WIRE Check if the throttle manually-operated pull button revolves smoothly from the fully open position to fully closed position. Measure the free play of throttle control pull button at the air throttlemanually-operated pull button flange. The standard free play should be 10°~15°. Unscrew the locking nut (1) and turn the regulator (2) to adjust the free stroke.

  • Page 38: Adjustment Of Clutch

    ADJUSTMENT OF CLUTCH The free play of the clutch takes the endpoint position of clutch lever as standard before the loosing of clutch, the free play should be 10—20mm. If the free play is improper, please adjust it in accordance with the following procedures: Loose the locking nut Screw in or screw out the adjusting screw, adjusting nut, making the free play of clutch meet with the specified requirement.

  • Page 39: Adjustment Of Idling Speed

    ADJUSTMENT OF IDLING SPEED The engine should be at normal operation temperature to accurately adjust the idling speed. Place the motorcycle aat vertical position and start the engine to heat-up. Use the throttle stop screw to adjust the idling speed to 1400-1600r/min Turn the adjusting screw clockwise to the decrease the rotating speed, while screw the adjusting screw counter clockwise to increase the rotating speed.

  • Page 40: Throttle Body

    THROTTLE BODY The idling speed of the motorcycle will decrease because of the throttle body pollution; please clean the throttle body after each 5000km’s driving. Please disconnect the negative electrode lead connection of battery and disconnect the sensor connector installed on the throttle when cleaning the throttle body; remove the accelerator stay and the hose connected with air filter and intake manifold, then remove the throttle body.

  • Page 41: Drive Chain

    DRIVE CHAIN The service life of drive chain depends on the proper lubrication and adjustment. The improper maintenance many cause the abnormal early wear of the drive chain and chain wheel. If under extreme sevior operating conditions, frequent maintenance must be given. Adjustment of drive chain: After each 1000km’s driving, please adjust the drive chain and make the chain free play be 10 - 20mm.
  • Page 42 Please adjust the chain in accordance with the following procedures: Use the central support to lift up the motorcycle. Loose the rear axle nut. Loose the locking nut. Turn the adjusting bolt to the right or to the left to adjust the tightness of the chain. The front and rear chain wheel should be kept aligned when adjusting the chain.
  • Page 43 After replacing the new chain, please check if the two chain wheels are worn. Please replace if necessary. The chain connector is clipped between the open end, please install against the moving direction Chain Connector...
  • Page 44 Please check the following conditions of the chain regularly: Loose pin Damaged idler wheel Dried and rusted chain link Knotted or seized chain link Excessive damage Adjustment of loose chain Please check the following conditions of the chain wheel: Over-worn wheel tooth Broken or damaged wheel tooth Loose chain wheel retaining nut.

  • Page 45: Brake

    BRAKE Both the front and rear wheel of the motorcycle is fitted with disc brake. The proper brake operation is very important to the safe driving. Please remember to check the braking system regularly, and this check should be carried out by qualified distributors. Adjustment of Brake (1) The free play of front brake handle ends should be 10-20mm.
  • Page 46 Brake Disc The essential of checking the front wheel brake disc is to check if the disc is worn to the limit mark. Please replace it with a new brake disc if worn to this mark. Brake fluid If the liquid level is lower than the LOWER mark, the recommended brake fluid should be added.

  • Page 47: Braking System

    Braking system Please check the following conditions of the braking system every day: Check if there is leakage of the front and rear wheel braking system. The brake lever and the brake pedal should have a certain amount of support resistance.

  • Page 48: Tire

    TIRE The proper tire pressure will ensure the maximum stability, comfortable driving and durability of tire. Please check the tire pressure regularly and adjust it as needed. Please change a new tire when the tread depth of the central tire thread is at the level as below: MINIMUM THICKNESS OF TIRE TREAD FRONT TIRE 1.6mm...

  • Page 49: Oil Accumulation Pipe

    OIL ACCUMULATION PIPE The air filter oil accumulation pipe should be often checked, and discharge the oil if there is some in the oil accumulation pipe. Discharge approach: loosen the clamp and move upward take out the drain plug from the pipe, and discharge all the oil stored in the pipe, and then plug in the drain end, and finally loosen the clamp, move downward and clamp the drain end tightly.

  • Page 50: Servicing Of Air Filter

    SERVICING OF AIR FILTER The air filter should be maintained regularly, and more frequent service should be given if driven under dusty or sandy areas. Take down the air filter installed on the right front of the motorcycle. Remove the air filter side cover and take out the filter cartridge of air filter. Wash the air filter cartridge in the clean washing oil and make it fully dry.

  • Page 51: Catalytic Converter

    CATALYTIC CONVERTER In order to meet the requirements of environmental emission, the muffler of the motorcycle is equipped with catalytic converter. The catalytic converter contains precious metals as the catalyst, which will transform the hazardous substances in the tail gas of motorcycle, including carbon monoxide, hydrocarbon and nitrogen oxide etc into non-toxic carbon dioxide, water and nitrogen through chemical reaction.

  • Page 52: Canister

    CANISTER The motorcycle is equipped with a fuel evaporation control device: canister. The canister is installed under the storage battery cell, the inside of the canister is filled with vapor-absorbing active carbon particles which can effectively prevent the residue fuel vapor evaporating into the air, and be fuel-saving and environment friendly at the same time.

  • Page 53: Lubrication Of Parts

    LUBRICATION OF PARTS Appropriate lubrication is quite important to ensure the normal operation of every part in the motorcycle, extend the service life of motorcycle and guarantee the safe driving. We suggest that the lubrication maintenance should be made after long-time riding or cleaning or exposure in the rain.

  • Page 54: Storage Battery

    STORAGE BATTERY When the storage battery is used for the first time, please operate based on the steps below: Remove the vent gum cap, fill the storage battery electrolyte into the position between upper limit (UPPER) and lower limit (LOWER), stand for 30 minutes and use after the chemical reaction is complete.
  • Page 55 Please pay attention to the following details Please check the electrolyte level of storage battery frequently and keep it next to the (UPPER) mark, which is the perfect position. Power shortage of storage battery will cause difficult starting, dim lights and harsh sound of horn, under these circumstances, please check the storage battery timely and add electrolyte or charge accordingly.
  • Page 56 Battery electrolyte: The storage battery is located inside the storage battery cell below the cushion. The electrolyte level should be kept between the upper level mark(UPPER LEVEL) and lower level mark(LOWER LEVER) on the side of storage battery. If the electrolyte level is lower than the lower level mark(LOWER LEVER), please take down the fluid feeding cap cover and use a small plastic funnel to add the distilled water into the upper level mark (UPPER LEVEL).
  • Page 57 The storage battery will bring about explosive gas, so be cautious of spark and flame. The storage battery contains vitriol (electrolyte), and any contact with it in eye or skin might lead to severe burn. The electrolyte is toxic so keep it away from children. Take down the storage battery to check or to add electrolyte based on the steps as below: a.
  • Page 58 Replacement of the Fuse Fuse compartment is located near the storage battery. There should be short-circuit or circuit overload if the blowout of fuse happens frequently, Please entrust the Sales Distributor to repair as soon as possible. Don’t use the fuse out of the designated specification, or it will bring serious negative effects to the electric system.

  • Page 59: Storage Guidance

    STORAGE GUIDANCE Storage: If the vehicle is to be kept for a long time, certain maintenance measures should be taken to reduce the effect of long-time storage on the quality of the motorcycle. 1. Replace the engine oil. 2. Lubricate the drive chain. 3.
  • Page 60 When the engine runs, the ignition switch should be placed at off position. 5. Remove the storage battery, and keep it in the place free from freezing and direct sunlight 6. Clean and dry the motorcycle. Wax all the painting surfaces. 7.

  • Page 61: Specifications And Technical Parameters

    SPECIFICATIONS AND TECHNICAL PARAMETERS Size Frame Length 2120mm Front Shock Absorber Sleeve, Oil Damping Type Width 800mm Rear Shock Absorber Hydraulic Spring Type Height 1100mm Front Braking Type Manually-Operated Braking Wheel Base 1480mm Rear Braking Type Pedal Braking Electric System Curb Weight 220kg Engine...
  • Page 62 NOTES:...
  • Page 63 NOTES:...

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