Benelli TRK 502 Service Station Manual
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Benelli TRK 502 Service Station Manual

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Table of Contents

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SERVICE STATION MANUAL
Pure Passion since 1911
code: B0000941950UK
Translation of the original instructions
Translation of the original instructions

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Summary of Contents for Benelli TRK 502

  • Page 1 SERVICE STATION MANUAL Pure Passion since 1911 code: B0000941950UK Translation of the original instructions Translation of the original instructions...
  • Page 2 WARNINGS: This manual has been produced by Benelli Q.J. s.r.l. for the main purpose of being used by Benelli dealers and their mechanics. It is not possible to provide a mechanic with all of the information they require in a single manual. The assumption is therefore that the people using this manual for the maintenance and repair of Benelli vehicles have a basic grounding in mechanics and the procedures inherent to the repair techniques for this type of vehicle.
  • Page 3 HOW TO USE THIS MANUAL This manual is a practical reference guide that is easy for mechanics to handle and use. The explanations of all of the installation, removal, disassembly, installation, repair and inspection procedures are organised into sequences of individual steps. Each chapter is divided into sections.

  • Page 4: General Information

    SYMBOLS SUBJECT SYMBOLS General Information Specifi cations Checks and periodic adjustments Frame Engine Cooling system Electrical system INDICATION SYMBOLS OL L S Wear/Clearance limits Thread locker application Special tool Recommended solvent Tightening torque Brake fl uid Grease application Sealant paste application I - III...
  • Page 5 INDEX CHAPTER 1 General information CHAPTER 2 Specifi cations CHAPTER 3 Checks and periodic adjustments ecks ks and d per periodic perio odic dic a ic ad adjustments adju CHAPTER 4 CHAP H H A A H H A Frame Frame CHAPTER 5 Engine...
  • Page 6 1 - 1...

  • Page 7: Table Of Contents

    CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................3 MOTORCYCLE IDENTIFICATION .............................3 FEATURES ..............................4 INSTRUMENTATION AND INDICATOR LIGHTS ........................4 MULTIFUNCTION DISPLAY ...............................5 IMPORTANT INFORMATION ........................6 GETTING READY FOR REMOVAL AND DISASSEMBLY OPERATIONS .................6 SPARE PARTS ..................................6 GASKETS, O-RING, OIL SEALS AND BEARINGS ........................7 SAFETY WASHERS/PLATES, COTTER PINS, AND THREAD SEALANT ................7 SAFETY SNAP RINGS ................................8 CHECKING CONNECTIONS ..............................8...

  • Page 8: Identification

    IDENTIFICATION MOTORCYCLE IDENTIFICATION Identifi cation data are as follows: Frame serial No. (on the steering sleeve) Engine serial No. (on the lower crankcase) Type-approval data (on the frame) 1 - 3...

  • Page 9: Features

    It indicates the vehicle speed in km/h or mph. Press the button function. In the event of serious problems, the control unit stops “Selection” 3 to pass from an indication to another. the injection/ignition function and it is necessary to contact an authorized service centre Benelli at soonest. 1 - 4...

  • Page 10: Multifunction Display

    FEATURES MULTIFUNCTION DISPLAY 15. FUEL TANK CAPACITY AND RESERVE FUEL GAUGE The digital fuel gauge shows the capacity of the fuel tank. As the fuel level drops, the lines on the gauge will become closer and closer to the "E" reserve area. From the moment in which the last line starts fl...

  • Page 11: Important Information

    Keep all components away from any heat source. SPARE PARTS Only use original Benelli spare parts. For part lubrication, use oils and greases recommended by Benelli. Other brands may be similar in appearance and function, but have a lower quality.

  • Page 12: Gaskets, O-Ring, Oil Seals And Bearings

    IMPORTANT INFORMATION GASKETS, O-RING, OIL SEALS, AND BEARINGS Always replace all gaskets, oil seals, and O-rings during the engine repairing interventions. olio The surfaces of gaskets, the oil seal lips, and the O-rings must motore labbro labbro be always cleaned. During installation, suitably oil all parts subjects to coupling and molla the bearings.

  • Page 13: Safety Snap Rings

    IMPORTANT INFORMATION SAFETY SNAP RINGS Before reassemble them, check all snap rings thoroughly and replace the damaged/deformed ones. Always replace the snap rings of the piston pin after having used them once. When installing a snap ring “A”, make sure the sharp edge “B”...
  • Page 14 IMPORTANT INFORMATION Connect: • the wire • the coupler • the connector NOTE:_________________________________ Make sure all connections are installed tightly. Check: • continuity (using a pocket tester) NOTE:_________________________________ If there is no continuity, clean the terminals. For checking wiring, follow the procedure of points from “1” to ”3”. As quick remedy, it is advisable to use a specifi...

  • Page 15: Special Tools

    SPECIAL TOOLS The special tools indicated herein serves for the complete and precise execution of the setting/assembly operations. Their use helps to prevent damages caused by unsuitable tools or improvised techniques. When placing an order, refer to the list below to avoid mistakes. ENGINE SPECIAL TOOLS Tool Code Tool Name-Function...
  • Page 16 SPECIAL TOOLS ENGINE SPECIAL TOOLS Tool Code Tool Name-Function Image Flywheel cover extractor This tool serves to extract the fl ywheel housing cover. 0320097045000 Engine phasing tool This tool serves to determine the position of the top dead centre. R180197022000 Oil fi...
  • Page 17 SPECIAL TOOLS ENGINE SPECIAL TOOLS Tool Code Tool Name-Function Image Measuring tool commonly found This tool is used to measure the outer di- mensions of parts. Standard tool commonly found Measuring tool commonly found This tool is used to measure thicknesses. Standard tool commonly found Flywheel assembly tool This tool serves to tighten the engine shaft...

  • Page 18: Special Frame Tools

    SPECIAL TOOLS SPECIAL FRAME TOOLS Tool Code Tool Name-Function Image Tool to tighten the steering sleeve lock This composed tool is used to tighten the steering sleeve lock nut. Standard tool commonly found Tool to tighten the front wheel pin This tool serves to tighten the front wheel pin.
  • Page 19 2 - 1...
  • Page 20 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ........................3 TECHNICAL DATA ............................4 ENGINE SPECIFICATIONS ...............................4 FRAME SPECIFICATIONS .................................9 ELECTRICAL SPECIFICATIONS .............................13 GENERAL TIGHTENING SPECIFICATIONS ...........................17 TIGHTENING TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS ..........18 TIGHTENING TORQUES .................................18 2 - 2...
  • Page 21 GENERAL SPECIFICATIONS SIZE STANDARD Total length (A) 2200 mm Total width (B) 915 mm Total height (C) 1450 mm Wheelbase (D) 1525 mm WEIGHT STANDARD Kerb weight (with full oil and 235 kg fuel tank) Empty (with no oil and empty fuel tank) 210 kg Max.
  • Page 22 TECHNICAL DATA ENGINE SPECIFICATIONS ENGINE STANDARD Type of engine 4 stroke, 2 cylinders in line, liquid cooling, 8 valves Cubic capacity 499.6 cc Number of cylinders Cylinder layout In line Inside diameter × stroke 69x66.8 mm Compression ratio 11.5:1 Idle speed 1400 Idle speed 1600...
  • Page 23 TECHNICAL DATA ENGINE SPECIFICATIONS SPARK PLUGS STANDARD Model (manufacturer) x quantity NGKCR8E Distance between electrodes 0.6 ÷ 0.7 mm CYLINDER HEAD STANDARD Head gasket maximum warp 0.03 mm CAMSHAFTS STANDARD Control system chain drive Camshaft diameter Ø 22.957-22.97 mm (Limit 22.94 mm) Clearance between support and camshaft 0.03-0.064 Clearance between camshaft and cam-...
  • Page 24 TECHNICAL DATA ENGINE SPECIFICATIONS VALVES, VALVE SEATS, VALVE GUIDES STANDARD Intake valve clearance (cold) 0.13 ~ 0.19 mm Exhaust valve clearance (cold) 0.19 ~ 0.25 mm VALVE SIZE Intake Ø 25 mm Exhaust Ø 22 mm Head ”A” diameter Intake 1.9 ~ 2.1 mm Exhaust 1.75 ~ 1.95 mm...
  • Page 25 TECHNICAL DATA ENGINE SPECIFICATIONS PISTON STANDARD Clearance between piston and cylinder 0.05 ~ 0.07 mm - 0.002 Piston diameter “A” Ø 65 - 0.003 Piston height “B” 25 mm - 0.002 Pin “C” seat Ø 16 - 0.003 diameter Piston pin outer diameter Ø...
  • Page 26 TECHNICAL DATA ENGINE SPECIFICATIONS CLUTCH STANDARD Clutch type wet clutch, multiple discs Clutch release cable with springs Operation for clutch release cable operation Operation with left handlebar lever Clutch cable clearance (on end 2 ~ 3 mm of the clutch lever) Clutch plate thickness 2.8 ±...
  • Page 27 TECHNICAL DATA FRAME SPECIFICATIONS STANDARD FRAME Modular trellis frame with the front module in stainless Frame type steel and the rear module in die-cast aluminium Steering head angle N.D. Trail N.D. FRONT WHEEL STANDARD Wheel type 6-spoke aluminium alloy Measure 17 M/C x MT3.
  • Page 28 TECHNICAL DATA FRAME SPECIFICATIONS FRONT BRAKE STANDARD LIMIT ual-disc brake Brake type semi-floating Activation use right hand Recommended fluid DOT4 Brake discs 320 x 4 mm (12.5 x 0.15 in) Diameter × thickness Minimum thickness 4.0 mm (0.15 in) Maximum deformation 0.1 mm (0.004 in) Thickness of 4 mm (0.15 in)
  • Page 29 TECHNICAL DATA FRAME SPECIFICATIONS FRONT SUSPENSION STANDARD Upside-down fork Suspension type with 50 mm diameter tubes Fork travel 150 mm Spring 295 mm Free Length Spacer length 137 mm Flexibility (K1) 8.6 N m 0 ~ 120 mm (0 ~ 4.72 in) Spring stroke (K1) Fork oil SAE 7.5...
  • Page 30 TECHNICAL DATA FRAME SPECIFICATIONS REAR SUSPENSION STANDARD Swing arm in aluminium alloy, gas-adjustable Suspension type shock absorber in hydraulics extended and spring preloaded Shock absorber fork travel 45 mm Spring 178+/- 1,5 mm Free Length Installed length 167+/- 1,5 mm Flexibility (K1) 16 Nm Spring stroke (K1)
  • Page 31 TECHNICAL DATA ELECTRICAL SPECIFICATIONS SYSTEM VOLTAGE STANDAR D 12 V System voltage IGNITION COILS STANDAR D Model (manufacturer) Primary coil resistance 0,65 ± 0,07 4 ± 0,5 kOhm Secondary coil resistance Primary coil inductance 1,8 mH Secondary coil inductance 4.7 H 10 A Max.
  • Page 32 TECHNICAL DATA ELECTRICAL SPECIFICATIONS License plate light LED x 1 Instrument board light LIGHTS (VOLTAGE WATT x QTY) STANDAR D Neutral indicator light LED x 1 High beam light LED x 1 Oil level alarm light LED x 1 Indicator light LED x 1 Faulty engine warning light LED x 1...
  • Page 33 TECHNICAL DATA ELECTRICAL SPECIFICATIONS FUSES (AMPERAGE x QTY) STANDARD Fuse CD1 (control unit) 15 A (Blue) Headlamp fuse 15 A (Blue) Service fuse 40 A (Red) Radiator fan fuse 15 A (Blue) Backup fuse 15 A (Blue) + 40 A (Red) Fuel pump fuse 15 A (Blue) THROTTLE VALVE SENSOR...
  • Page 34 TECHNICAL DATA ELECTRICAL SPECIFICATIONS LIQUID TEMPERATURE SENSOR STANDARD Model (manufacturer) WC -12A (QJ) Resistance 100 °C 178 Ohm VELOCITY SENSOR STANDARD Model (manufacturer)/distance GAP QJ / 1.1mm - 2.2 mm LAMBDA PROBE STANDARD Model (manufacturer) OSM (Delphi) INJECTOR STANDARD Model (manufacturer) Mini (Delphi) 12±1Ω...
  • Page 35 TECHNICAL DATA GENERAL TIGHTENING SPECIFICATIONS The tightening torques of the different special parts or assem- blies are provided in each chapter of this manual. As far as concerns assemblies with multiple fastenings, in order to prevent the risk of warping, cross tighten in successive stag- es, until you reach the required torque.
  • Page 36 TECHNICAL DATA TIGHTENING TORQUES TIGHTENING TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS The values provided in the following table refer to standard tightness, i.e. metric screws coupled with relevant nut or with lead screw in metal. The parts to be tightened together must be in metal or suffi ciently rigid not to need the insertion of bushing or shims. Coupling must always use lightly oiled or greased threads;...
  • Page 37 3 - 1...
  • Page 38 CHAPTER 3 PERIODIC MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ..............5 MAINTENANCE INTERVALS ..............................6 ENGINE/AIR BOX ............................9 REMOVAL/ASSEMBLY OF AIR BOX ............................9 ENGINE/THROTTLE CABLE CLEARANCE ....................11 ADJUSTMENT OF THROTTLE CABLE CLEARANCE ......................11 ADJUSTMENT OF IDLE SPEED ..............................14 ENGINE/CLUTCH CABLE ...........................15 ADJUSTMENT OF CLUTCH CABLE CLEARANCE ........................15 FRAME/HANDLEBAR ..........................16 REAR-VIEW MIRROR ADJUSTMENT .............................16 ENGINE/MOTOR OIL ..........................17...
  • Page 39 CHAPTER 3 ELECTRICAL SYSTEM ..........................40 BATTERY CHECK AND CHARGING ............................40 FUSES ......................................49 FUSE CHECK ...................................50 REPLACEMENT OF THE FRONT LIGHTS ..........................51 REMOVAL OF THE FRONT HEADLIGHT ..........................52 INSTALLATION OF THE HEADLIGHT .............................53 ADJUSTMENT OF HEADLIGHT ..............................54 SUBSTITUTION OF THE REAR LED LIGHT ...........................55 SUBSTITUTION OF THE REAR INDICATOR LIGHTS ......................56 SUBSTITUTION OF THE FRONT INDICATORS ........................57 SUBSTITUTION OF THE IGNITION BLOCK ...........................58...
  • Page 40 NOTES: ................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................

  • Page 41: Periodic Maintenance And Lubrication Intervals

    At 40,000 km (24,854 mi), repeat maintenance services from the one at 10,000 km (6,213 mi). For interventions relating the items marked, it is advisable to contact a Benelli dealer, given that it is necessary to have specifi c equipment, information, and technical skills.

  • Page 42: Maintenance Intervals

    PERIODIC MAINTENANCE AND LUBRICATION INTERVALS MAINTENANCE INTERVALS 1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km 0 Km Annual Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi) Part (0 mi) inspec- nance interventions Pre-delivery tion Service Service...
  • Page 43 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS MAINTENANCE INTERVALS 1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km 0 Km Annual Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi) Part (0 mi) inspec- nance interventions Pre-delivery tion Service Service...
  • Page 44 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS MAINTENANCE INTERVALS 1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km 0 Km Annual Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi) Part (0 mi) inspec- nance interventions Pre-delivery tion Service Service...

  • Page 45: Engine/Air Box

    ENGINE/AIR BOX REMOVAL/ASSEMBLY OF AIR BOX Position Description Quantity COMPLETE AIR FILTER BOX SCREW (M6X16) AIR TEMPERATURE SENSOR SCREW BAND SLEEVE Hose holder clip CANISTER FILTER SPRING BAND PIPE CHECK VALVE PIPE VALVE SPRING BAND PIPE PIPE PLATE SCREW (M6X16) AIR FILTER 3 - 9...
  • Page 46 ENGINE/AIR BOX REMOVAL/ASSEMBLY OF AIR BOX Park the motorcycle on a level surface. IMPORTANT NOTICE Prop the motorcycle on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...
  • Page 47 ENGINE/THROTTLE CABLE CLEARANCE ADJUSTMENT OF THROTTLE CABLE CLEARANCE CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION LEFT VIEW MIRROR RIGHT VIEW MIRROR HANDLEBAR SCREW GRIP CAP GRIP END THREADED INSERT LEFT HANDGRIP THREADED INSERT LEFT LIGHT SWITCH RIGHT LIGHT SWITCH ACCELERATOR CONTROL ACCELERATOR CONTROL PIPE FUEL OPEN CABLE FUEL CLOSE CABLE...
  • Page 48 ENGINE/THROTTLE CABLE CLEARANCE ADJUSTMENT OF THROTTLE CABLE CLEARANCE CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW BRAKE PEDAL CONTROL BALL JOINT ADJUSTMENT ROD SCREW RETURN SPRING THREADED PIN GEAR PEDAL SCREW TUBE GUIDE ABS SWITCH 3 - 12...

  • Page 49: Engine/Throttle Cable Clearance

    ENGINE/THROTTLE CABLE CLEARANCE ADJUSTMENT OF THROTTLE CABLE CLEARANCE NOTE:___________________________________________ The engine idle speed should be properly adjusted before adjusting the throttle cable clearance. Check at 10,000 km (6,213 mi) fi rst and then every 10,000 km (6,213 mi). Check: • the throttle cable clearance (A) Make sure the throttle grip works smoothly.

  • Page 50: Adjustment Of Idle Speed

    ENGINE/THROTTLE CABLE CLEARANCE ADJUSTMENT OF IDLE SPEED Check: • Start the engine and warm it up. • Extract the left, side guard by loosening the screw ”A” Fig. • Loosen lock nut “B” and rotate the adjusting screw ”C” to obtain the correct idle speed.

  • Page 51: Engine/Clutch Cable

    ENGINE/CLUTCH CABLE ADJUSTMENT OF CLUTCH CABLE CLEARANCE Check: • the clutch cable clearance (A) If outside specifi cations, adjust. Clutch cable clearance Gap (clearance) Clutch handle 3 - 4 mm Adjust: • the clutch cable clearance Handlebar side Move the clutch cable cowling. Loosen the ring nut “C”.

  • Page 52: Frame/Handlebar

    FRAME/HANDLEBAR REAR-VIEW MIRROR ADJUSTMENT The following procedure refer to both rear-view mirrors. Install: Screw the mirror (15) on the lever body (32). Move the nut “B” until it stops. Adjust the mirror position by rotating it. Tighten the lock nut “C”. NOTE:___________________________________________ Carry out the same procedure also with the right mirror.

  • Page 53: Engine/Motor Oil

    ENGINE/MOTOR OIL CHECKING ENGINE OIL LEVEL Park: • the motorcycle on a level surface. NOTE:___________________________________________ • Place the motorcycle on a suitable support. • Make sure it is in upright position. Start: • the engine allow it to warm up for some minutes and then turn it off. IMPORTANT NOTICE Do not start the engine if the oil level is below the MIN refer- ence indicated on the sight glass “B”.

  • Page 54: Engine Oil Change

    ENGINE/MOTOR OIL ENGINE OIL CHANGE Start: • the engine, warm it up for some minutes and then turn it off. Remove: • the oil drain cap “A” Fig. A. Position: • a suitable container underneath the drainage for oil recov- ery Fig.

  • Page 55: Oil Filter Removal/Installation

    Tighten the fi lter (2) to the following torque: Torque 22 N*m IMPORTANT NOTICE Always use original Benelli oil fi lters. Other brands of oil fi lters can be different in terms of thread (diameter and pitch). The use of other types of fi lter may affect the fi lter perfor- mance and duration, which will cause possible damage to the engine or oil leaks.

  • Page 56: Engine/Spark Plugs

    ENGINE/SPARK PLUGS REMOVAL OF SPARK PLUGS ON THE VEHICLE The following procedure applies to all of the spark plugs. WARNING Replace and check the spark plugs when the engine is cold. Park the motorcycle on a level surface. IMPORTANT NOTICE Prop the motorcycle on suitable supports so that it cannot fall.

  • Page 57: Spark Plug Check

    ENGINE/SPARK PLUGS SPARK PLUG CHECK The following procedure applies to all of the spark plugs. Check: • the type of spark plug Check: • the electrodes (A) Fig. E • If there is any damage, wear or rounding, Replace the spark plug. •...
  • Page 58 ENGINE/SPARK PLUGS SPARK PLUG CHECK In general, the table contains the typical conditions of spark plug with the various degeneration causes and corresponding solutions. SOILED OVERHEATED SPARK PLUG SPARK PLUG Cause Solutions Cause Solutions Over rich mix of air/fuel The fuel/carburettor system Ignition too advanced Adjust advanced ignition -Wrong setting of the carburetion.

  • Page 59: Assembly Of Spark Plugs

    ENGINE/SPARK PLUGS ASSEMBLY OF SPARK PLUGS The following procedure applies to all of the spark plugs Fig. D. WARNING Lubricate the spark plug threads with copper grease. NOTE:__________________________________________ Before installing it, clean the spark plug and the surface in contact with the seal. Install: •...
  • Page 60 ENGINE/COOLING SYSTEM CHECKING COOLANT LEVEL Park the motorcycle on a level surface. IMPORTANT NOTICE Prop the motorcycle on suitable supports so that it cannot fall. NOTE:__________________________________________ Make sure it is in upright position. Check the level when the engine is cold. Remove: •...

  • Page 61: Frame/Brake Adjustment

    FRAME/BRAKE ADJUSTMENT ADJUSTMENT OF THE FRONT BRAKE Adjust: • the brake lever position Fig. A (distance ”x” between the throttle grip and the brake lever). NOTE:__________________________________________ Push the brake lever forward to neutralise the spring thrust and at the same time adjust the position, by rotating the ring nut “y”...

  • Page 62: Adjustment Of The Rear Brake

    FRAME/BRAKE ADJUSTMENT ADJUSTMENT OF THE REAR BRAKE Adjust: • the brake pedal position Fig. A • Loosen the locknut “A”. • Screw off the lock nut “B”. • Screw up o screw off the threaded pin ”E” to increase or reduce the rear brake control clearance Fig.

  • Page 63: Frame/Checking Brake Fuid Level

    FRAME/CHECKING BRAKE FUID LEVEL CHECKING THE FRONT BRAKE LIQUID LEVEL/TOPPING UP Park: • The motorcycle on a level surface. NOTE:__________________________________________ Place the motorcycle on a stand and make sure it is in up- right position. Check: • the brake fl uid level If below the minimum notch “A”...

  • Page 64: Checking The Rear Brake Liquid Level/Topping Up

    FRAME/CHECKING BRAKE FUID LEVEL CHECKING THE REAR BRAKE LIQUID LEVEL/TOPPING UP Park: • The motorcycle on a level surface. NOTE:__________________________________________ Place the motorcycle on a stand and make sure it is in up- right position. Check: • the brake fl uid level If below the minimum notch “A”...

  • Page 65: Frame/Checking Abs Hoses

    FRAME/CHECKING ABS HOSES CHECK FOR ANY LEAKAGES OF ABS TUBES For the motorcycle models equipped with ABS, it is necessary to check for leakages in the braking system and especially in the ABS circuit. Remove: • The seat (See section Seat removal). •...

  • Page 66: Frame/Brake Pad Check

    FRAME/BRAKE PAD CHECK CHECKING WEAR OF FRONT/REAR BRAKE PADS The following procedure applies to brake pads. Activate: • the brake Check: • The front brake pads Fig. A. • The rear brake pads Fig. B. • The wear limit for the front/rear brake pads. If the wear reaches the limit, please replace all brake pads.

  • Page 67: Frame/Checking Hoses Of The Braking System

    FRAME/CHECKING HOSES OF THE BRAKING SYSTEM HOSE CHECK The following procedure applies to all brake hoses and brake hose clamps. Check: • the path of the hose of the front “A” and rear “B” brake. If there is any cracking/damage/wearing trace, replace. Check: •...

  • Page 68: Frame/Transmission Chain

    FRAME/TRANSMISSION CHAIN ADJUSTMENT OF THE TRANSMISSION CHAIN NOTE:__________________________________________ When the engine is running, do not check or adjust the trans- mission chain. NOTE:__________________________________________ Check the transmission chain slackness in the most taut point. 10-15 mm WARNING If the chain is too taut, there may be an overload of the en- gine or other vital parts, while , if it is too slack, it may jump out and damage the swing arm bracket or cause an accident.

  • Page 69: Lubrication Of Transmission Chain

    FRAME/TRANSMISSION CHAIN LUBRICATION OF TRANSMISSION CHAIN Introduction The transmission chain consists of several parts that interact with each other. The chain must be properly maintained to prevent its early wear. Therefore, it is advisable to maintain the transmission chain, especially if it is used in very dusty areas. This motorcycle is fi...

  • Page 70: Checking Wear Of Transmission Chain

    FRAME/TRANSMISSION CHAIN CHECKING WEAR OF TRANSMISSION CHAIN Check: • The transmission chain Rigidity. Clean and lubricate or replace. Clean: • The transmission chain Clean the transmission chain with a clean rag. Soak the transmission chain in kerosene and remove any re- maining dirt.

  • Page 71: Frame/Check And Adjustment Of Steering Sleeve

    FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE CHECK/ADJUSTMENT OF STEERING CLEARANCE Park: • The motorcycle on a level surface. NOTE:__________________________________________ Place the motorcycle on a suitable support so that the front wheel is raised. Check: • The steering sleeve Gently oscillate the front fork, holding it by the ends of the tubes Fig.
  • Page 72 FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE STEERING SLEEVE BEARING LUBRICATION • the steering ring nut (1), then using the apposite wrench (2) remove the steering ring nut (3). Fig. A-B. Tool to tighten the steering sleeve lock nut Code: R180297129000 Using a solvent with a high fl...

  • Page 73: Frame/Check Of Front Fork

    FRAME/CHECK OF FRONT FORK CHECK OF FRONT FORK Park: • The motorcycle on a level surface. NOTE:__________________________________________ Prop the motorcycle on suitable supports so that it cannot fall. Check: • The fork stem “A” Fig. A • The fork sleeve “B” Fig. A If there is any damage/line, replace.

  • Page 74: Frame/Check Of Rear Shock Absorber

    FRAME/CHECK OF REAR SHOCK ABSORBER SHOCK ABSORBER ADJUSTMENT NOTE:__________________________________________ Prop the motorcycle on suitable supports so that it cannot fall. Adjustment • Adjust the spring preload Fig. A. The rear shock absorber is equipped with an adjustment ring nut for the pre-load of spring “A" and a return ring nut "D”. •...

  • Page 75: Frame/Check Of Front/Rear Tyres

    FRAME/CHECK OF FRONT/REAR TYRES TYRE CHECK The following procedure is applied to both tyres. Check: • The tyre pressure. If outside specifi cations, adjust Fig. A. WARNING The tyre pressure must be checked and adjusted only when the wheel temperature corresponds to the ambient tempera- ture.

  • Page 76: Electrical System

    ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING WARNING The batteries produce a nitrogen-based explosive gas and contain electrolyte, which is composed of sulfuric acid, a poisonous substance and highly caustic. The following precautions should be always observed: Wear protective goggles when handling a battery or while working nearby.
  • Page 77 ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING • the battery cables from the terminals Fig. B IMPORTANT NOTICE Disconnect the negative cable of the battery “A” fi rst, and then the positive cable “B” Fig. B. Detach: • The battery • Remove the battery rubber tip and slide out the battery “D”.
  • Page 78 ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING Before removing the battery charger cable clamps from the terminals, turn the charger off. recharge ricarica Make sure the battery charger cable clamps are completely in contact with the battery terminals and are not short circuit- ed.A corroded clamp may generate heat in the contact area and an ineffective clamp spring may cause sparks.
  • Page 79 ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING CHARGING METHOD WITH A VARIABLE CURRENT (VOLTAGE) BATTERY CHARGER NOTE:__________________________________________ • Measure the voltage after 30 minutes from switching off of the appliance. • Set the charge voltage to 16 ~ 17 V. (Setting it on a lower value, the recharge would not be suffi cient. •...
  • Page 80 ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING CHARGING METHOD WITH A CONSTANT VOLTAGE BATTERY CHARGER NOTE:__________________________________________ • Measure the voltage after 30 minutes from switching off of the appliance. • Set the maximum charging time to max. 20 hours. NOTE:__________________________________________ • To ensure the highest performance and life of battery, it is advisable to use electronic battery chargers that can supply correct charging voltages and currents, according to the specifi...
  • Page 81 ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING Battery activation: Filling Electrolyte Make sure that the model [A] marked on the electrolyte bottle matches with the model [B] of the battery. The denominations must be the same. Battery model name: YTX9-BS WARNING Every battery is supplied with a bottle of its own electrolyte.
  • Page 82 ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING • Take the electrolyte bottle away from vinyl bag. • Detach the strip of caps [A] from the bottle and store it for seal the battery subsequently, Fig. A. NOTE:__________________________________________ Do not puncture or open the sealed cells [B] of the electro- lyte bottle.
  • Page 83 ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING • Place the strip of caps [A] on the fi lling ports and press strongly with both hands to insert them into the battery Fig. D (without tapping) Fig. E. If properly installed, the cap strip will be aligned with the battery top.
  • Page 84 ELECTRICAL SYSTEM BATTERY CHECK AND CHARGING IMPORTANT NOTICE Bring the start switch to the OFF position. Install: • The battery • Tighten 2 screws “A” fastening the battery bracket. Connect: • The battery cables to the terminals. IMPORTANT NOTICE Connect the positive cable of the battery “B” fi rst, and then the negative cable “B”...

  • Page 85: Fuses

    ELECTRICAL SYSTEM FUSES The following procedure applies to all fuses. IMPORTANT NOTICE Bring the start switch to the OFF position. Remove: • Rider and passenger seats, see chapter “Removal of rider and passenger seats, Chapter 4”. Check: • The fuse Connect the pocket tester to the fuse and check the continuity.

  • Page 86: Fuse Check

    ELECTRICAL SYSTEM FUSE CHECK FUSE LEGEND Refer to Fig. C 1. Petrol pump (15.00 A) 2. Fan (15.00 A) 3. ECU1 (15.00 A) 4. Services (10.00 A) 5. Lights (15.00 A) 3 - 50...

  • Page 87: Replacement Of The Front Lights

    ELECTRICAL SYSTEM REPLACEMENT OF THE FRONT LIGHTS The following procedure applies only to the front lights. IMPORTANT NOTICE Seeing that the projector lamp reaches very high tempera- tures, it is recommended to not touch it until it has cooled down. Remove: •...

  • Page 88: Removal Of The Front Headlight

    ELECTRICAL SYSTEM REMOVAL OF THE FRONT HEADLIGHT Place the motorcycle on a fl at, level fl oor. IMPORTANT NOTICE Prop the motorcycle on suitable supports so that it cannot fall. The vehicles’ front headlight is a LED light. If it needs to be replaced, carry out the following procedure: Remove: •...

  • Page 89: Installation Of The Headlight

    ELECTRICAL SYSTEM INSTALLATION OF THE HEADLIGHT Place the motorcycle on a fl at, level fl oor. IMPORTANT NOTICE Prop the motorcycle on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Install: • the side locking screws ”D” Fig. A. •...

  • Page 90: Adjustment Of Headlight

    ELECTRICAL SYSTEM ADJUSTMENT OF HEADLIGHT To carry out the correct adjustment of the two headlights’ lumi- nous beams: • Position the vehicle approx. 10 metres distance from a verti- cal wall on a perfectly fl at piece of ground Fig. A •...

  • Page 91: Substitution Of The Rear Led Light

    ELECTRICAL SYSTEM SUBSTITUTION OF THE REAR LED LIGHT Place the motorcycle on a fl at, level fl oor. IMPORTANT NOTICE Prop the motorcycle on suitable supports so that it cannot fall. To substitute the rear LED light, refer to “Chapter 4” Fair- ings, paragraph “Removal of the rear light”.

  • Page 92: Substitution Of The Rear Indicator Lights

    ELECTRICAL SYSTEM SUBSTITUTION OF THE REAR INDICATOR LIGHTS Place the motorcycle on a fl at, level fl oor. IMPORTANT NOTICE Prop the motorcycle on suitable supports so that it cannot fall. NOTE:_________________________________ The following procedure is applicable to both rear indicators. Remove: •...

  • Page 93: Substitution Of The Front Indicators

    ELECTRICAL SYSTEM SUBSTITUTION OF THE FRONT INDICATORS Place the motorcycle on a fl at, level fl oor. IMPORTANT NOTICE Prop the motorcycle on suitable supports so that it cannot fall. Remove: • Mobile windscreen, refer to chapter “Removal of mobile windscreen, Chapter 4”.

  • Page 94: Substitution Of The Ignition Block

    ELECTRICAL SYSTEM SUBSTITUTION OF THE IGNITION BLOCK Remove: • Using a jointed hexagonal spanner, remove the ignition block “A” positioned in front of the steering head Fig. A • Remove the ignition block and disconnect the connector “B” Fig. B Install: •...
  • Page 95 4 - 1...
  • Page 96 CHAPTER 4 FRAME FRONT WHEEL AND BRAKE DISCS ......................5 FRONT WHEEL REMOVAL ................................5 REMOVAL/INSTALLATION OF BRAKE DISCS .........................6 CHECK OF BRAKE DISCS ................................8 WHEEL AXLE CHECK ................................9 CHECK/REPLACEMENT OF WHEEL BEARINGS ........................10 FRONT WHEEL INSTALLATION ..............................11 REAR WHEEL AND BRAKE DISC ......................12 REAR WHEEL REMOVAL ................................12 REMOVAL OF THE REAR DISC BRAKE, CROWN WHEEL AND PHONIC WHEEL ..............15 WHEEL AXLE CHECK ................................16...
  • Page 97 CHAPTER 4 TRANSMISSION CHAIN AND SWINGING ARM ..................71 TRANSMISSION CHAIN REMOVAL ............................71 REMOVAL OF THE SWINGING ARM ............................73 FRAME .................................74 INSTALLATION/REMOVAL OF THE FRAME PARTS ......................74 LEFT/RIGHT ENGINE PROTECTION INSTALLATION ......................76 REMOVAL OF THE LEFT/RIGHT ENGINE PROTECTION .....................77 REMOVAL OF THE FRONT FRAME/WINDSCREEN SUPPORT ....................78 INSTALLATION OF THE FRONT FRAME/WINDSCREEN SUPPORT ..................79 REMOVAL/INSTALLATION OF REAR FRAME PARTS ......................80 REMOVAL OF THE REAR FRAME ............................82...
  • Page 98 CHAPTER 4 TANK ................................134 TANK PARTS ..................................134 REMOVAL OF THE TANK CAP SUPPORT ..........................135 INSTALLATION OF THE TANK CAP SUPPORT ........................136 REMOVAL OF THE TANK PUMP ............................137 INSTALLATION OF THE TANK PUMP ...........................138 REMOVAL OF THE TANK FUEL LEVEL SENSOR ........................139 INSTALLATION OF THE TANK FUEL LEVEL SENSOR ......................140 AIR FILTER ..............................141 AIR FILTER PARTS ................................141...

  • Page 99: Front Wheel And Brake Discs

    FRONT WHEEL AND BRAKE DISCS FRONT WHEEL REMOVAL Park: • The bike on a level surface NOTE:_________________________________ Place the bike on a suitable support so that the front wheel is raised. Remove: • The screw (E) • the ABS sensor “A” •...
  • Page 100 FRONT WHEEL AND BRAKE DISCS REMOVAL/INSTALLATION OF BRAKE DISCS CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW FRONT BRAKE DISC LEFT SHIM BEARING FRONT WHEEL RIM (GREY) FRONT WHEEL AXLE VALVE SHIM INTERNAL SHIM OIL SEAL FRONT WHEEL ABS SENSOR SCREW FRONT TIRE 4 - 6...
  • Page 101 FRONT WHEEL AND BRAKE DISCS REMOVAL/INSTALLATION OF BRAKE DISCS Remove: • front wheel, refer to chapter “Removal of the front wheel” • brake callipers, refer to chapter “Removal of the front brake callipers” • screws (12*) • brake disc (2*) Install: •...

  • Page 102: Check Of Brake Discs

    FRONT WHEEL AND BRAKE DISCS CHECK OF BRAKE DISCS The procedure below applies to all brake discs. Check: • the brake disc If there is any damage/abrasion, replace. Measure: • The deformation of the brake disc. Substitute the brake disc if it is outside the specifi cation. •...

  • Page 103: Wheel Axle Check

    FRONT WHEEL AND BRAKE DISCS WHEEL AXLE CHECK Carry out a visual check of the front wheel and rear wheel axle bolt to check for damage. Substitute the wheel axle bolt if it is damaged or bent. Check: • Wheel axle. •...

  • Page 104: Check/Replacement Of Wheel Bearings

    FRONT WHEEL AND BRAKE DISCS CHECK/REPLACEMENT OF WHEEL BEARINGS Check: • Wheel bearings If the front wheel turns irregularly or is loose, replace the wheel bearings. Replace: • Wheel bearings Remove the wheel bearings “A” using a general bearing ex- tractor Fig.

  • Page 105: Front Wheel Installation

    FRONT WHEEL AND BRAKE DISCS FRONT WHEEL INSTALLATION Install: • the wheel between the two tubes of the fork Fig. A • the bush (8*) – left side Fig. A • the bush (3*) – right side Fig. A Tighten the torque: •...
  • Page 106 REAR WHEEL AND BRAKE DISC REAR WHEEL REMOVAL 10 10 whit ABS sensor CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION REAR WHEEL AXLE BUSHING SCREW REAR BRAKE DISC VALVE REAR WHEEL RIM (BLACK) INTERNAL SHIM DUST COVER FLEXIBLE COUPLING SHIM O-RING BEARING OIL SEAL SCREW...
  • Page 107 REAR WHEEL AND BRAKE DISC REAR WHEEL REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION BEARING ELASTIC RING TRANSMISSION CHAIN REAR TYRE (160/60-R17) CALLIPER HOLDER PLATE REAR WHEEL ABS SENSOR SCREW 4 - 13...

  • Page 108: Rear Wheel And Brake Disc

    REAR WHEEL AND BRAKE DISC REAR WHEEL REMOVAL Park: • The bike on a level surface NOTE:_________________________________ Place the bike on a suitable support so that the rear wheel is raised. Remove: • the fi xing screws (A) of the brake calliper Fig. A Detach: •...

  • Page 109: Removal Of The Rear Disc Brake, Crown Wheel And Phonic Wheel

    REAR WHEEL AND BRAKE DISC REMOVAL OF THE REAR DISC BRAKE, CROWN WHEEL AND PHONIC WHEEL Remove: • the screws (26*) Fig. A • the brake disc (4*) Fig. A Removal of the phonic wheel: • the phonic wheel (25*) Fig. A •...

  • Page 110: Wheel Axle Check

    REAR WHEEL AND BRAKE DISC WHEEL AXLE CHECK Check: • Wheel axle. • Rotate the axle of wheel “A” on a fl at surface Fig. A. If there is any warping, replace. WARNING Do not try to straighten the wheel axle if it is warped. Check: •...

  • Page 111: Check/Replacement Of Wheel Bearings

    REAR WHEEL AND BRAKE DISC CHECK/REPLACEMENT OF WHEEL BEARINGS Check: • Wheel bearings If the front wheel turns irregularly or is loose, replace the wheel bearings. Replace: • Wheel bearings Remove the bearings from the wheel ”A” with a generic bearing extractor Fig.

  • Page 112: Sprocket Check And Replacement

    REAR WHEEL AND BRAKE DISC SPROCKET CHECK AND REPLACEMENT Check: • The sprocket If more than 1/4 of each tooth is worn, replace the sprocket. If the teeth are bent, replace the sprocket. 1/4 teeth Correct Transmission chain roller Chain wheel Replace: •...

  • Page 113: Installation Of The Disc Brake

    REAR WHEEL AND BRAKE DISC INSTALLATION OF THE DISC BRAKE Install: • brake disc (4*) Fig. A • lubricate screws (26) Fig. A. MR2 TUTELA grease • tighten to the following torque: Torque 10 N*m Use Loctite thread locker to secure. Loctite 243 NOTE:_________________________________ Tighten the self-locking nuts in several stages, proceeding...

  • Page 114: Back Tyre Installation

    REAR WHEEL AND BRAKE DISC BACK TYRE INSTALLATION Install: • Position brake calliper support bracket (23*) Fig. A. • Insert the bushes (2*) right side and (20*) left side Fig. B. • Position the register slide (A) and (B) Fig. C. •...

  • Page 115: Front And Rear Brakes

    FRONT AND REAR BRAKES REMOVAL AND INSTALLATION OF FRONT BRAKE PADS The procedure that follows is applicable to both front brake callipers. NOTE:_________________________________ Substitute the brake pads always together to ensure a uni- form pressure. Remove: • pin springs (B) Fig. A •...

  • Page 116: Removal And Installation Of Rear Brake Pads

    FRONT AND REAR BRAKES REMOVAL AND INSTALLATION OF REAR BRAKE PADS Remove: • the screw “A” Fig. A. • the calliper body “B” Fig. B. Take out: • The brake pads “C” Fig. B. Measure: • The wear limit for the brake pads. If outside specifi...
  • Page 117 FRONT AND REAR BRAKES FRONT BRAKE PUMP REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION PIPE BRACKET REAR BRAKE HOSE REAR BRAKE CALLIPER HOSE – ABS CEN- TRAL UNIT FRONT BRAKE PUMP REAR BRAKE CALLIPER REAR BRAKE PADS (A PAIR) REAR IDROSTOP GASKET FRONT BRAKE CALLIPER HOSE –...
  • Page 118 FRONT AND REAR BRAKES FRONT BRAKE PUMP REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION RIGHT BRAKE CALLIPER (RADIAL) ABS CENTRAL UNIT SCREW FRONT BRAKE PADS (A PAIR) SPECIAL SCREW SPECIAL SCREW SCREW SPECIAL SCREW SPECIAL SCREW SPECIAL SCREW FRONT BRAKE LEVER SELF-LOCKING NUT SCREW MICROSWITCH...
  • Page 119 FRONT AND REAR BRAKES FRONT BRAKE PUMP REMOVAL NOTE:_________________________________ Drain out the brake fl uid before proceeding with these oper- ations. Refer to Chapter 3: Periodic maintenance, paragraph “Check- ing and topping up the front brake fl uid level”. IMPORTANT NOTICE When removing the pump, avoid spilling onto the surfaces of the motorcycle brake fl...

  • Page 120: Rear Brake Pump Removal

    FRONT AND REAR BRAKES REAR BRAKE PUMP REMOVAL 21 29 NOTE:_________________________________ The above exploded view is part of the spare parts table of the chapter “Front and rear brakes”, paragraph “Removal of the front brake pump”. 4 - 26...
  • Page 121 FRONT AND REAR BRAKES REAR BRAKE PUMP REMOVAL NOTE:_________________________________ Drain out the brake fl uid before proceeding with these oper- ations. Refer to Chapter 3: Periodic maintenance, paragraph “Check- ing and topping up the front brake fl uid level”. Remove: •...

  • Page 122: Front Brake Pump Installation

    FRONT AND REAR BRAKES FRONT BRAKE PUMP INSTALLATION WARNING Before installing, clean all of the internal parts of the brake, and lubricate them with clean or new brake fl uid. Never use solvents on the internal parts of the brake. Recommended brake fl...

  • Page 123: Rear Brake Pump Installation

    FRONT AND REAR BRAKES REAR BRAKE PUMP INSTALLATION Install: • Connect the brake fl uid reservoir hose (1*) to the brake pump (5) Fig. B • Connect the main brake hose (3*). • Position the Idrostop (8*) Fig. B and tighten to the following torque pressure: Torque 12 N*m •...

  • Page 124: Abs Anti-Lock Braking System

    ABS ANTI-LOCK BRAKING SYSTEM LOCATION OF THE COMPONENTS The components that compose the anti-lock braking system are: • phonic wheel sensor (A) – front wheel Fig. A • phonic wheel (B) – front wheel Fig. A • phonic wheel sensor (C) – rear wheel Fig. B •...
  • Page 125 ABS ANTI-LOCK BRAKING SYSTEM POSITION OF THE COMPONENTS • Fuse box “1” Fig. E • Connector of the ABS diagnostic system “2” Fig. F 4 - 31...

  • Page 126: Rotation Sensor Check

    ABS ANTI-LOCK BRAKING SYSTEM ROTATION SENSOR CHECK IMPORTANT NOTICE The wheel rotation sensor must be handled with caution, must not receive knocks, e.g., with a hammer, or dropped on a hard surface. It is a precision instrument. Do not soak the rotation sensor in water or mud Do not attempt to repair or remove the wheel rotation sensor.

  • Page 127: Check Of The Phonic Wheel And Abs Of The Front And Rear Wheel

    ABS ANTI-LOCK BRAKING SYSTEM CHECK OF THE PHONIC WHEEL AND ABS OF THE FRONT AND REAR WHEEL Check: Carry out a visual check of the phonic wheel of the wheel. Substitute the phonic wheel if it is deformed or damaged, such as damaged teeth.

  • Page 128: Precautions

    ABS ANTI-LOCK BRAKING SYSTEM PRECAUTIONS PRECAUTIONS DURING THE MAINTENANCE OF THE ABS A series of important precautions must be adopted during the maintenance of the ABS system. • The ABS system has been designed to be fed by a 12V sealed battery. Do not use any other type of battery, only sealed 12V. •...
  • Page 129 ABS ANTI-LOCK BRAKING SYSTEM PRECAUTIONS IMPORTANT NOTICE The LED yellow warning light of the ABS “E” Fig. A could come on if the tyre pressures are not correct, if tyre not rec- ommended has been fi tted, or if the wheel is deformed. If the warning light comes on, solve the problem by cancelling the maintenance code.

  • Page 130: Removal Of The Abs Hydraulic Unit

    ABS ANTI-LOCK BRAKING SYSTEM REMOVAL OF THE ABS HYDRAULIC UNIT IMPORTANT NOTICE The ABS hydraulic unit “A” has been adjusted and set with precision by the manufacturer. Therefore it must be handled very carefully, must never by hit for example by a hammer, or dropped on a hard surface.

  • Page 131: Installation Of The Abs Hydraulic Unit

    ABS ANTI-LOCK BRAKING SYSTEM INSTALLATION OF THE ABS HYDRAULIC UNIT Install: • Position the ABS hydraulic unit on the frame. • Install the rigid tubes of the brakes onto the ABS hydraulic unit and manually screw in the fl are nuts without tightening. •...

  • Page 132: Removal Of The Abs Rotation Sensors - Front/Rear Wheel

    ABS ANTI-LOCK BRAKING SYSTEM REMOVAL OF THE ABS ROTATION SENSORS – FRONT/REAR WHEEL IMPORTANT NOTICE The wheel rotation sensor must be handled with caution, must not receive knocks, e.g., with a hammer, or dropped on a hard surface. It is a precision instrument. Do not soak the wheel rotation sensor in water or mud Do not attempt to repair or remove the wheel rotation sensor.

  • Page 133: Front Brake Calliper Tightness

    FRONT AND REAR BRAKES FRONT BRAKE CALLIPER TIGHTNESS The following procedure is applied to both brake callipers. NOTE:_________________________________ Before disassembling the brake calliper, discharge the brake fl uid from the complete braking system: refer to “Frame/ brake fl uid level check, Chapter 3”. Remove: •...

  • Page 134: Rear Brake Calliper

    FRONT AND REAR BRAKES REAR BRAKE CALLIPER NOTE:_________________________________ Before disassembling the brake calliper, discharge the brake fl uid from the complete braking system: refer to “Frame/ brake fl uid level check, Chapter 3”. 21 29 Remove: • the screw (20*) Fig. A •...

  • Page 135: Check The Front And Rear Callipers

    FRONT AND REAR BRAKES CHECK THE FRONT AND REAR CALLIPERS Check: • the pistons (1) of the brake callipers Fig. A Substitute the brake calliper pistons if there are signs of rust/ scoring/traces of wear. • The cylinders of the brake callipers. If there are any lines/signs of wear, replace the whole brake calliper.

  • Page 136: Front Brake Calliper Installation

    FRONT AND REAR BRAKES FRONT BRAKE CALLIPER INSTALLATION NOTE:_________________________________ The procedure mentioned below is applicable to both calli- pers of the front brake. IMPORTANT NOTICE Before installing, clean all of the internal parts of the brake, and lubricate them with clean or new brake fl uid. Never use solvents on internal components of the brake, in- asmuch that the seals of the pistons would tend to swell and deform.

  • Page 137: Rear Brake Calliper Installation

    FRONT AND REAR BRAKES REAR BRAKE CALLIPER INSTALLATION IMPORTANT NOTICE Before installing, clean all of the internal parts of the brake, and lubricate them with clean or new brake fl uid. Never use solvents on internal components of the brake, inasmuch that the seals of the pistons would tend to swell and deform.
  • Page 138 FRONT AND REAR BRAKES REAR BRAKE CALLIPER INSTALLATION Install: • The brake hose (4) Fig. E 21 29 • the sealing washers (9*) Fig. E • the special screw (20*) Fig. E Tighten to the previous set torque pressure twice after having been slackened: Torque 15 N*m Check:...
  • Page 139 FRONT FORK FRONT FORK STEM REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW UPPER U-CLAMP LOWER U-CLAMP BUSHING HANDLEBAR FIXING PIN WASHER SCREW STEERING HEAD SPECIAL SCREW STEERING PIN RING NUT STEERING RING NUT DUST SEAL BEARING WASHER 4 - 45...
  • Page 140 FRONT FORK FRONT FORK STEM REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW SEEGER RING STEERING BASE SCREW LEFT RADIAL STEM ASSEMBLY RIGHT RADIAL STEM ASSEMBLY SCREW SCREW SCREW COVER ABS SPEED SENSOR – REAR WHEEL SCREW 4 - 46...
  • Page 141 FRONT FORK FRONT FORK STEM REMOVAL The following procedure is applied to both front fork stems. Park: • The bike on a level surface NOTE:_________________________________ Place the bike on a suitable support so that the front wheel is raised. Remove: •...

  • Page 142: Front Fork Stem Disassembly

    FRONT FORK FRONT FORK STEM DISASSEMBLY Disassemble the pieces in the order listed. NOTE:_________________________________ The following procedure is applied to both front fork stems. Secure: • The fork sleeve (10) in a clamp Fig. A • Completely unscrew the cap assembly (1) from the support tube, using a 4 mm pin and hook wrench(B).
  • Page 143 FRONT FORK FRONT FORK STEM DISASSEMBLY Slide out from inside the sleeve Fig. C: • The tip (2) • The spring (5) • The bush (6) • Shim (7) • The lower bush (8) • The tip (9). Release: • The rod from the clamp •...
  • Page 144 FRONT FORK FRONT FORK STEM DISASSEMBLY IMPORTANT NOTICE This operation is only necessary after completely draining the oil from inside the sleeve. Remove: • The dust seal (14) from the seat using a small fl at-blade screwdriver Fig. F Remove: •...

  • Page 145: Front Fork Stem Inspection

    FRONT FORK FRONT FORK STEM INSPECTION The following procedure is applied to both front fork stems. Check: • Fork stem “A” Fig. A • The fork sleeve (10). If there is any deformation/damage/wear, replace. WARNING Do not try to straighten the inner fork if bent, since it will be- come weaker with time and could be dangerous.

  • Page 146: Front Fork Stem Assembly

    FRONT FORK FRONT FORK STEM ASSEMBLY The following procedure is applied to both front fork stems. IMPORTANT NOTICE The oil and dust seals must not be reused after removal. Be- fore refi tting, check the condition of bushings and guides; check the guide bushings;...
  • Page 147 FRONT FORK FRONT FORK STEM ASSEMBLY Assemble: • The clip on the oil seal (13) using a small fl athead screw- driver, making sure that it is perfectly inserted into the special raceway and taking care not to scratch the fork stem Fig.
  • Page 148 FRONT FORK FRONT FORK STEM ASSEMBLY • Lift the fork sleeve completely Fig. I • Using a graduated measuring container, prepare the correct amount of oil to be poured into the stem Fig. I. • Pour about 2/3 of the oil into the fork sleeve (A), then pump the fork to eliminate any air.

  • Page 149: Front Fork Stem Fitting

    FRONT FORK FRONT FORK STEM FITTING The following procedure is applied to both front fork stems. Install: • The stems of the front fork (A) Fig. A. tighten provisionally: • The stop screws (19*) of the lower steering plate Fig. A. NOTE:________________________________ Check the assembly quota “x”...

  • Page 150: Handlebar

    HANDLEBAR HANDLEBAR REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION REAR VIEW MIRROR (LEFT) REAR VIEW MIRROR (RIGHT) HANDLEBAR SCREW GRIP CAP GRIP END THREADED INSERT LEFT HANDGRIP THREADED INSERT LEFT LIGHT COMMUTATOR SWITCH RIGHT LIGHT COMMUTATOR SWITCH ACCELERATOR CONTROL ACCELERATOR CONTROL HOSE FUEL OPEN CABLE FUEL CLOSE CABLE 4 - 56...
  • Page 151 HANDLEBAR HANDLEBAR REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION CLUTCH CABLE CLUTCH CONTROL RUBBER CLIP SCREW BUSHING ELASTIC WASHER BRAKE PEDAL SCREW SCREW BRAKE PEDAL BALL JOINT REGISTER ROD SCREW RETURN SPRING THREADED PIN GEAR PEDAL SCREW TUBE GUIDE ABS SWITCH 4 - 57...
  • Page 152 HANDLEBAR HANDLEBAR REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. NOTE:________________________________ Direct a jet of compressed air between the left of the handle- bar and the relevant grip, so that it can be slid off the handle- bar gradually.
  • Page 153 HANDLEBAR HANDLEBAR REMOVAL • screws (1) handlebar u-clamp (2) Fig. C Detach: • the handlebar (3*) NOTE:________________________________ The numbers marked (*) are a part of the spare parts table chapter “Handlebar”. 4 - 59...

  • Page 154: Handlebar Inspection

    HANDLEBAR HANDLEBAR INSPECTION Check: • Handlebar (3) Fig. D ]If there is any warping/cracking/damage, replace. WARNING Do not try to straighten the handlebar if bent, since it will become weaker and could be dangerous. 4 - 60...

  • Page 155: Handlebar Installation

    HANDLEBAR HANDLEBAR INSTALLATION IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Proceed to install, following the steps for removal in reverse order, but taking care to observe the instructions below: Install: • Right commutator switch (11*) NOTE:________________________________ Align the projections (A) of the switch with the hole (B) on the right side of the handlebar.

  • Page 156: Steering Head

    STEERING HEAD REMOVAL OF THE TOP AND BOTTOM STEERING BASE IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove the parts in the indicated order. • Removal of the mobile and fi xed head light fairing (Re- fer to paragraph) •...
  • Page 157 STEERING HEAD REMOVAL OF THE TOP AND BOTTOM STEERING BASE Remove: • The cap (10) using the special tool (A) Fig. B (**) steering head wrench Code:R300097146000 Pull out the upper steering base. Loosen: • the steering pin ring nut (B) •...

  • Page 158: Top And Bottom Steering Base Inspection

    STEERING HEAD TOP AND BOTTOM STEERING BASE INSPECTION Wash: • The bearings • The bearing tracks RECOMMENDED SOLVENT TUTELA MOTOR CLEAN Check: • The bearings (14) Fig. A • Dust seal rings (13) Fig. A ]If there is any spotting/damage, replace. Replace: •...

  • Page 159: Top And Bottom Steering Base Fitting

    STEERING HEAD TOP AND BOTTOM STEERING BASE FITTING Lubricate: • The bearings Fig. A. • The dust seal rings Fig. A. • The races of the bearings Fig. A. RECOMMENDED LUBRICANT MR2 TUTELA GREASE Install: • The steering ring nut (2) Fig. C using the special tool to the following torque: Torque 16 N*m (**) Tool to tighten the steering sleeve lock nut...

  • Page 160: Rear Shock Absorber

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SWINGING ARM PIN BUSHING OIL SEAL SEEGER RING BEARING BEARING INTERNAL SHIM SWINGING ARM CHAIN SLIDE SCREW SHIM VIBRATION DAMPING RUBBER SCREW GUIDE BUSHING SCREW SCREW REAR SHOCK ABSORBER 4 - 66...
  • Page 161 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVAL CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW SCREW CHAIN TENSIONER SLIDE PLATE ABS PHONIC WHEEL SENSOR – REAR WHEEL SCREW CHAIN COVER WASHER 4 - 67...
  • Page 162 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter “Removal of the rider and passenger seat, Chapter 4”. •...

  • Page 163: Rear Shock Absorber Check

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER CHECK Check: • Rear shock absorber rod ]If there is any warping/damage, replace the rear shock absorber assembly. • Rear shock absorber ]If there is any gas/oil leak, replace the rear shock absorber as- sembly.

  • Page 164: Rear Shock Absorber Fitting

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER FITTING Lubricate: • the spacers of the shock absorber unit • the xing screws RECOMMENDED LUBRICANT MR2 TUTELA GREASE Clean: • the nuts of the rear shock absorber unit • the screws of the rear shock absorber unit RECOMMENDED SOLVENT TUTELA MOTOR CLEAN Install:...

  • Page 165: Transmission Chain And Swinging Arm

    TRANSMISSION CHAIN AND SWINGING ARM TRANSMISSION CHAIN REMOVAL NOTE:________________________________ Prop the bike on suitable supports so that it cannot fall. Remove the parts in the indicated order. • Chain pinion cover, refer to chapter “Removal of the chain pinion cover, Chapter 4”. Detach: •...
  • Page 166 TRANSMISSION CHAIN AND SWINGING ARM TRANSMISSION CHAIN REPLACEMENT Loosen: • The transmission chain This chain uses a transmission chain with master link with safety clip link. • Use the special tool, according to the chain manufacturer’s specifi cations and the type of use required. NOTE:________________________________ Follow the instructions of the manufacturer when using the special tool.

  • Page 167: Removal Of The Swinging Arm

    TRANSMISSION CHAIN AND SWINGING ARM REMOVAL OF THE SWINGING ARM Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove the parts in the indicated order. • Rear mudguard, refer to chapter “Removal of the rear mudguard, Chapter 4”.
  • Page 168 FRAME INSTALLATION/REMOVAL OF THE FRAME PARTS CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION FRAME SCREW SCREW LEFT ENGINE PROTECTION SCREW SCREW SCREW RUBBER BUSHING SHIM SHIM SCREW RIGHT ENGINE PROTECTION SCREW SCREW PLATE LEFT RADIATOR BRACKET RIGHT RADIATOR BRACKET HOMOLOGATION PLATE 4 - 74...
  • Page 169 FRAME INSTALLATION/REMOVAL OF THE FRAME PARTS CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION RIVET FRONT FRAME METRIC RAPID FIXING CLIP SCREW BRACKET SCREW HEADLIGHT FAIRING SUPPORT SCREW ELASTIC WASHER SCREW SCREW WASHER SCREW 4 - 75...

  • Page 170: Left/Right Engine Protection Installation

    FRAME LEFT/RIGHT ENGINE PROTECTION INSTALLATION Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: • The left engine protection (5*) to the following torque pres- sure: Torque (M10 screw) 45 N*m •...

  • Page 171: Removal Of The Left/Right Engine Protection

    FRAME REMOVAL OF THE LEFT/RIGHT ENGINE PROTECTION Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: Proceed using the opposite order to removal. 4 - 77...

  • Page 172: Removal Of The Front Frame/Windscreen Support

    FRAME REMOVAL OF THE FRONT FRAME/WINDSCREEN SUPPORT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Movable windscreen, see chapter entitled “Removal of movable windscreen, Chapter 4”. •...

  • Page 173: Installation Of The Front Frame/Windscreen Support

    FRAME INSTALLATION OF THE FRONT FRAME/WINDSCREEN SUPPORT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: proceed using the opposite order to removal. 4 - 79...

  • Page 174: Removal/Installation Of Rear Frame Parts

    FRAME REMOVAL/INSTALLATION OF REAR FRAME PARTS 11 12 CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION REAR FRAME SCREW SCREW LEFT BAG SUPPORT FRAME RIGHT BAG SUPPORT FRAME SCREW BUSHING RUBBER TIP SCREW PLATE CASE RELEASE SCREW SCREW SCREW SCREW PLATE 4 - 80...
  • Page 175 FRAME REMOVAL/INSTALLATION OF REAR FRAME PARTS CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW ELASTIC CLIP SCREW SCREW REAR TOP BOX RACK TWO REAR SIDE BAGS REAR TOP BOX BRACKET REAR TOP BOX SUPPORT PLATE 4 - 81...

  • Page 176: Removal Of The Rear Frame

    FRAME REMOVAL OF THE REAR FRAME Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rear footrests, refer to chapter “Removal of the rear foot- rests’ support, chapter 4”. •...

  • Page 177: Rear Frame Fitting

    FRAME REAR FRAME FITTING Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Install: • the rear frame (1*) Fig. A. •...

  • Page 178: Removal Of Side Bag Frame

    FRAME REMOVAL OF SIDE BAG FRAME Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the screws (14*) Fig. A • the nut (17*) Fig. A • the screw (15*) Fig.

  • Page 179: Installation Of The Side Bags Support Frame

    FRAME INSTALLATION OF THE SIDE BAGS SUPPORT FRAME Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 85...

  • Page 180: Number Plate Holder

    FRAME NUMBER PLATE HOLDER CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION UPPER FAIRING METRIC RAPID FIXING CLIP SCREW SNAP-ON CLIP SCREW SCREW PLATE LICENCE PLATE HOLDER SUPPORT VIBRATION DAMPING RUBBER REFLECTOR REFLECTOR BRACKET NUMBER PLATE HOLDER SCREW REAR MUD GUARD SCREW SCREW COVER 4 - 86...

  • Page 181: Removal Of The Number Plate Holder

    FRAME REMOVAL OF THE NUMBER PLATE HOLDER Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the screws (6*) Fig. A • The complete number plate holder support (8*) Fig. A NOTE:_________________________________ The numbers marked (*) are a part of the spare parts table, chapter “Frame”, paragraph “Number plate holder”.

  • Page 182: Installation Of The Number Plate Holder

    FRAME INSTALLATION OF THE NUMBER PLATE HOLDER Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 88...

  • Page 183: Cycling

    CYCLING INSTALLATION OF THE STAND / FOOTRESTS CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION LEFT FRONT FOOTREST SUPPORT PLATE LEFT FRONT FOOTREST ANTI-SLIP RUBBER ELASTIC RING COTTER PIN SCREW RIGHT FRONT FOOTREST SUPPORT RIGHT FRONT FOOTREST LEFT REAR FOOTREST SUPPORT SCREW PEDANA POSTERIORE SINISTRA SPRING 4 - 89...
  • Page 184 CYCLING STAND/FOOTRESTS CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SPRING BALL PLATE SCREW LH FOOTREST RUBBER STOP LEFT RUBBER FOOTREST COVER RIGHT REAR FOOTREST SUPPORT RIGHT REAR FOOTREST RH FOOTREST RUBBER STOP RIGHT RUBBER FOOTREST COVER SPECIAL SCREW WASHER SIDE STAND SCREW SIDE STAND SUPPORT PLATE SCREW...

  • Page 185: Removal Of The Side Stand

    CYCLING REMOVAL OF THE SIDE STAND Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Disconnect: • the connector of the side stand sensor (32*) Fig. A Remove: • the internal spring (36*) Fig.

  • Page 186: Installation Of The Side Stand

    CYCLING INSTALLATION OF THE SIDE STAND Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screw (37*) Fig. B-C •...

  • Page 187: Removal Of The Rear Footrest Support

    CYCLING REMOVAL OF THE REAR FOOTREST SUPPORT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the screws (12*) Fig. A • The right rear footrest support (22*) Fig. A •...

  • Page 188: Installation Of The Rear Footrest Support

    CYCLING INSTALLATION OF THE REAR FOOTREST SUPPORT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (12*) Fig. B to the following torque: Torque 25 N*m Use Loctite thread locker to secure.

  • Page 189: Removal Of The Right/Left Rear Footrest

    CYCLING REMOVAL OF THE RIGHT/LEFT REAR FOOTREST Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the O-ring (7*) Fig. A • the pin (13*) Fig. A •...

  • Page 190: Installation Of The Left/Right Rear Footrests

    CYCLING INSTALLATION OF THE LEFT/RIGHT REAR FOOTRESTS Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 96...

  • Page 191: Right Front Footrest Removal

    CYCLING RIGHT FRONT FOOTREST REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • The spring (1) Fig. A • the screw (2) Fig. A • the ball joint (3) Fig. A •...

  • Page 192: Right Front Footrest Fitting

    CYCLING RIGHT FRONT FOOTREST FITTING Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (8*) Fig. A to the following torque: Torque 25 N*m Use Loctite thread locker to secure.

  • Page 193: Left Front Footrest Removal

    CYCLING LEFT FRONT FOOTREST REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the screws (8*) Fig. A • the left front footrest holder plate (1*) Fig. A NOTE:_________________________________ Substitute the left anti-slip rubber cover (5*) if it is worn.

  • Page 194: Left Front Footrest Installation

    CYCLING LEFT FRONT FOOTREST INSTALLATION Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (8*) Fig. A to the following torque: Torque 25 N*m Use Loctite thread locker to secure.

  • Page 195: Removal Of The Gear Lever

    CYCLING REMOVAL OF THE GEAR LEVER Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • The left front footrest, refer to chapter “Removal of the left front footrest, Chapter 4”. •...

  • Page 196: Installation Of The Gearchange Lever

    CYCLING INSTALLATION OF THE GEARCHANGE LEVER Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screw (1) Fig. A to the following torque: Torque 10 N*m NOTE:_________________________________...
  • Page 197 EXHAUST SYSTEM EXHAUST ASSEMBLY CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION EXHAUST GASKET LAMBDA PROBE EXHAUST MANIFOLD GRAPHITE GASKET SILENCER RUBBER TIP SCREW SCREW BUSHING RUBBER TIP LEFT FLANGE RIGHT FLANGE SCREW CLIP 4 - 103...

  • Page 198: Exhaust Assembly Removal

    EXHAUST SYSTEM EXHAUST ASSEMBLY REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Disconnect: • the Lambda sensor (2*) Fig. A. Remove: • the screws (8*) Fig. B. •...
  • Page 199 EXHAUST SYSTEM EXHAUST ASSEMBLY REMOVAL Disconnect: • the exhaust system, removing it from inside to outside Fig. NOTE:_________________________________ To make extraction easier, it is advisable to loosen the silenc- er joint band (A) to the exhaust manifold Fig. E NOTE:_________________________________ The numbers marked (*) are a part of the spare parts table, chapter “Exhaust system”, paragraph “exhaust system”.

  • Page 200: Exhaust Installation

    EXHAUST SYSTEM EXHAUST INSTALLATION Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the nuts (2*) Fig. A to the following torque: Torque 22 N*m NOTE:_________________________________ Lubricate the nuts with copper grease during the assembly...
  • Page 201 FAIRING FRONT MUD GUARD CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION FRONT MUD GUARD SCREW NYLON WASHER MUDGUARD SUPPORT PLATE SCREW SCREW ELASTIC WASHER WASHER SNAP-ON CLIP LOWER MUD GUARD SCREW “T” BUSHING REFLECTOR LEFT RUBBER PROTECTION RIGHT RUBBER PROTECTION LEFT BRACKET RIGHT BRACKET INTERNAL SHIELD ABS STICKER...

  • Page 202: Front Mud Guard Removal

    FAIRING FRONT MUD GUARD REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the screw (6*) Fig. A • the screw (2*) from both sides Fig. A •...
  • Page 203 FAIRING FRONT MUD GUARD REMOVAL Remove: • the screws (11*) Fig. E • the mud guard support plates (4*) Fig. E NOTE:_________________________________ The numbers marked (*) are a part of the spare parts table, chapter “Fairing”, paragraph “Front mud guard”. 4 - 109...
  • Page 204 FAIRING FRONT MUD GUARD INSTALLATION Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 110...

  • Page 205: Rear Mud Guard Removal

    FAIRING REAR MUD GUARD REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the screws (1) Fig. A • The fl ap guard (2) Fig. A •...

  • Page 206: Rear Mud Guard Installation

    FAIRING REAR MUD GUARD INSTALLATION Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (8*) Fig. A to the following torque: Torque 10 N*m 4 - 112...
  • Page 207 FAIRING REMOVAL OF THE UPPER CHAIN GUARD Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the screws (11*) Fig. A • The chain guard (10*) Fig. A NOTE:_________________________________ The numbers marked (*) are shown in the replacement parts table in the “Rear shock absorber”...
  • Page 208 FAIRING INSTALLATION OF THE UPPER CHAIN GUARD Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (11*) Fig. A to the following torque: Torque 10 N*m Use Loctite thread locker to secure.

  • Page 209: Removal Of The Rider Seat And Passenger Seat

    FAIRING REMOVAL OF THE RIDER SEAT AND PASSENGER SEAT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the passenger seat (1) using the supplied spanner (2) Fig. •...

  • Page 210: Installation Of The Rider Seat And Passenger Seat

    FAIRING INSTALLATION OF THE RIDER SEAT AND PASSENGER SEAT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (3) Fig. A to the following torque: Torque 10 N*m 4 - 116...

  • Page 211: Front Fairing

    FAIRING FRONT FAIRING CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION FRONT FAIRING SCREW TOP BUSHING RUBBER TIP SCREW METRIC RAPID FIXING CLIP LEFT AIR DUCT RIGHT AIR DUCT SCREW LEFT RETINA RIGHT RETINA LEFT SIDE (WHITE) RIGHT SIDE (WHITE) WASHER DIRECTION INDICATOR (FRONT LEFT) DIRECTION INDICATOR (FRONT RIGHT) LEFT AIR INTAKE RIGHT AIR INTAKE...

  • Page 212: Removal Of The Front Fairing

    FAIRING REMOVAL OF THE FRONT FAIRING IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, refer to chapter “Removal of the rider and passenger seat, Chapter 4”. • the screws (1) Fig. B. •...
  • Page 213 FAIRING INSTALLATION OF THE FRONT FAIRING IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 119...

  • Page 214: Front Headlight And Windscreen

    FAIRING FRONT HEADLIGHT AND WINDSCREEN CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION HEADLIGHT FAIRING SCREW SHIM VIBRATION DAMPING PAD COMPLETE INSTRUMENT LEFT HEADLIGHT FAIRING RIGHT HEADLIGHT FAIRING SPECIAL SCREW LEFT HAND GUARD LEFT SUPPORT BRACKET SCREW BUSHING METRIC RAPID FIXING CLIP RIGHT HAND GUARD RIGHT SUPPORT BRACKET FIXED HEADLIGHT FAIRING...
  • Page 215 FAIRING FRONT HEADLIGHT AND WINDSCREEN CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW TOP BUSHING RUBBER TIP INSTRUMENTATION PLATE LAMP ADHESIVE 4 - 121...

  • Page 216: Removal Of Movable Windscreen

    FAIRING REMOVAL OF MOVABLE WINDSCREEN Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • the screws (9*) • the screws (2*) • The movable windscreen (1*) together with the left/right headlight fairing 4 - 122...

  • Page 217: Installation Of The Mobile Headlight Fairing

    FAIRING INSTALLATION OF THE MOBILE HEADLIGHT FAIRING Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 123...
  • Page 218 FAIRING REMOVAL OF THE INSTRUMENTATION PLATE Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Movable windscreen, see chapter entitled “Removal of movable windscreen, Chapter 4”. • Front fairing, see chapter entitled “Removal of front fair- ing, Chapter 4”.
  • Page 219 FAIRING INSTALLATION OF THE INSTRUMENTATION PLATE Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 125...

  • Page 220: Removal Of The Headlight Unit

    FAIRING REMOVAL OF THE HEADLIGHT UNIT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Movable windscreen, see chapter entitled “Removal of movable windscreen, Chapter 4”. • Front fairing, see chapter entitled “Removal of front fair- ing, Chapter 4”.

  • Page 221: Installation Of The Headlight Unit

    FAIRING INSTALLATION OF THE HEADLIGHT UNIT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 127...

  • Page 222: Tank Cover

    TOP BUSHING RUBBER TIP SCREW SCREW METRIC RAPID FIXING CLIP LEFT FUEL TANK CAP RIGHT FUEL TANK CAP LEFT PANEL RIGHT PANEL SCREW LEFT COVER RIGHT COVER SCREW NYLON WASHER STICKER (BENELLI BLACK) STICKER (BENELLI WHITE) WINDSCREEN HEADLAMP 4 - 128...

  • Page 223: Removal Of The Fuel Tank Cover

    FAIRING REMOVAL OF THE FUEL TANK COVER Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...

  • Page 224: Installation Of The Fuel Tank Cover

    FAIRING INSTALLATION OF THE FUEL TANK COVER Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 130...

  • Page 225: Removal Of Fuel Tank

    FAIRING REMOVAL OF FUEL TANK Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...
  • Page 226 FAIRING REMOVAL OF FUEL TANK Disconnect: • the tube of the non-return valve (10*) Fig. D. • the connector of the level sensor (1) Fig. E. Disconnect: • The tubing of the valve (12*) of the fuel pump. NOTE:_________________________________ The numbers marked (*) are a part of the spare parts table, chapter “Tank”, paragraph “Tank parts”.

  • Page 227: Tank Fitting

    FAIRING TANK FITTING Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (10*) Fig. A to the following torque: Torque 10 N*m •...
  • Page 228 TANK TANK PARTS CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW PLATE BUSHING BUSHING VIBRATION DAMPING RUBBER FUEL TANK FUEL TUBE/HOSE CENTRAL FAIRING CLOSURE SCREW SCREW PLATE BUSHING RUBBER TIP WASHER SCREW FUEL TANK LEVEL PROBE O-RING SCREW FUEL PUMP SCREW FUEL FILTER FILTER SUPPORT FUEL TUBE/HOSE...

  • Page 229: Removal Of The Tank Cap Support

    TANK REMOVAL OF THE TANK CAP SUPPORT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...

  • Page 230: Installation Of The Tank Cap Support

    TANK INSTALLATION OF THE TANK CAP SUPPORT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 136...

  • Page 231: Removal Of The Tank Pump

    TANK REMOVAL OF THE TANK PUMP Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...

  • Page 232: Installation Of The Tank Pump

    TANK INSTALLATION OF THE TANK PUMP Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (20*) Fig. A to the following torque: Torque 10 N*m Use Loctite thread locker to secure.

  • Page 233: Removal Of The Tank Fuel Level Sensor

    TANK REMOVAL OF THE TANK FUEL LEVEL SENSOR Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...

  • Page 234: Installation Of The Tank Fuel Level Sensor

    TANK INSTALLATION OF THE TANK FUEL LEVEL SENSOR Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (18*) Fig. A to the following torque: Torque 10 N*m Use Loctite thread locker to secure.
  • Page 235 AIR FILTER AIR FILTER PARTS CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION COMPLETE AIR FILTER BOX SCREW AIR TEMPERATURE SENSOR SCREW CLIP SLEEVE HOSE HOLDER CLIP CARTRIDGE FILTER SPRING BAND PIPE NON-RETURN VALVE PIPE VALVE SPRING BAND PIPE PIPE PLATE SCREW AIR FILTER 4 - 141...

  • Page 236: Air Filter

    AIR FILTER REMOVAL OF THE AIR FILTER Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...

  • Page 237: Installation Of The Air Filter

    AIR FILTER INSTALLATION OF THE AIR FILTER Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 143...
  • Page 238 AIR FILTER REMOVAL OF THE AIR FILTER BOX Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...

  • Page 239: Installation Of The Air Filter Box

    AIR FILTER INSTALLATION OF THE AIR FILTER BOX Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 145...
  • Page 240 FAIRING SIDE FAIRINGS 30 30 CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION LEFT PANEL FAIRING CLOSURE SCREW METRIC RAPID FIXING CLIP VIBRATION DAMPING RUBBER LEFT TAIL FAIRING (WHITE) RIGHT TAIL FAIRING (WHITE) TOP BUSHING RUBBER TIP LEFT LOWER SIDE RIGHT LOWER SIDE WASHER LEFT REAR DIRECTION INDICATORS RIGHT REAR DIRECTION INDICATORS...

  • Page 241: Removal Of The Side Fairings

    FAIRING REMOVAL OF THE SIDE FAIRINGS Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...

  • Page 242: Installation Of The Side Fairings

    FAIRING INSTALLATION OF THE SIDE FAIRINGS Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 148...

  • Page 243: Upper Tail Fairing

    FAIRING UPPER TAIL FAIRING CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION UPPER FAIRING METRIC RAPID FIXING CLIP SCREW SNAP-ON CLIP SCREW SCREW PLATE LICENCE PLATE HOLDER SUPPORT VIBRATION DAMPING RUBBER REFLECTOR REFLECTOR BRACKET NUMBER PLATE HOLDER SCREW REAR MUD GUARD SCREW SCREW COVER 4 - 149...

  • Page 244: Tailpiece Removal

    FAIRING TAILPIECE REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...
  • Page 245 FAIRING TAILPIECE REMOVAL Remove: • the fi xing screws (3*) • the upper fairing (1*) Fig. G Remove: • the fi xing screws (17*) Fig. H • the upper fairing (1*) Fig. I NOTE:_________________________________ The numbers marked (*) are a part of the spare parts table, chapter “Fairings”, paragraph “Upper fairings / tail fairing”.

  • Page 246: Removal Of The Rear Passenger Handles

    FAIRING REMOVAL OF THE REAR PASSENGER HANDLES Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...

  • Page 247: Installation Of The Rear Handles

    FAIRING INSTALLATION OF THE REAR HANDLES Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. Tighten: • the screws (1) Fig. A to the following torque: Torque 10 N*m 4 - 153...

  • Page 248: Removal Of The Rear Light

    FAIRING REMOVAL OF THE REAR LIGHT Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. •...
  • Page 249 FAIRING REMOVAL OF THE REAR LIGHT • the screws (2) Fig. D • the headlight support bracket (3) Fig. C Remove: • the rear light (18*) Fig. E. NOTE:_________________________________ The numbers marked (*) are a part of the spare parts table, chapter “Fairings”, paragraph “Side fairings”.

  • Page 250: Installation Of The Rear Lights

    FAIRING INSTALLATION OF THE REAR LIGHTS Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Install: Proceed using the opposite order to removal. 4 - 156...
  • Page 251 FAIRING CHAIN PINION COVER 11 12 CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION BUSHING O-RING THREADED CAP MAGNETIC CAP O-RING SCREW PHASE SENSOR SCREW ALTERNATOR COVER PINION COVER PLATE SCREW FLY-WHEEL COVER GASKET SCREW SCREW 4 - 157...

  • Page 252: Removal Of The Chain Pinion Cover

    FAIRING REMOVAL OF THE CHAIN PINION COVER Remove: • the screws (15*) Fig. A. • The pinion cover (10*) Fig. A NOTE:________________________________ The numbers marked (*) are a part of the spare parts table, chapter “Fairings”, paragraph “Removal of the chain pinion cover”.

  • Page 253: Installation Of The Chain Pinion Cover

    FAIRING INSTALLATION OF THE CHAIN PINION COVER Install: • The pinion cover (10*) Fig. A. • the screws (15*) Tighten to the following torque: Torque 8 N*m NOTE:________________________________ The numbers marked (*) are a part of the spare parts table, chapter “Fairings”, paragraph “Removal of the chain pinion cover”.
  • Page 254 5 - 1...
  • Page 255 CHAPTER 5 ENGINE HEAD DISTRIBUTION ...........................4 COILS AND SPARK PLUGS REMOVAL ............................5 COILS AND SPARK PLUGS ASSEMBLY ...........................6 TIMING GEAR COVER ASSEMBLY ............................8 DISTRIBUTION CHAIN TENSIONER REMOVAL ........................9 TIMING CHAIN TENSIONER ASSEMBLY ..........................10 INTAKE AND EXHAUST CAMSHAFT REMOVAL ........................11 CAMSHAFT CHECK .................................12 EXHAUST CAMSHAFT INSTALLATION ..........................13 INTAKE CAMSHAFT ASSEMBLY .............................14 TIMING CHAIN SLIDE REMOVAL ............................15...
  • Page 256 CHAPTER 5 GEAR BOX ..............................65 NEUTRAL POSITION/GEAR INDICATOR SENSOR ASSEMBLY ...................66 GEAR BOX ASSEMBLY ................................70 GEAR SHIFT CONTROL ................................72 STARTER ....................................76 STARTING ..............................76 STARTER REMOVAL ................................77 STARTER INSTALLATION ...............................78 FLYWHEEL REMOVAL ................................79 FLYWHEEL INSTALLATION ..............................82 STARTER GEAR REMOVAL ..............................83 STARTER GEAR ASSEMBLY ..............................84 PHASE SENSOR..................................85 PHASE SENSOR REMOVAL ..............................86 PHASE SENSOR INSTALLATION ............................87...

  • Page 257: Head Distribution

    HEAD DISTRIBUTION DISTRIBUTION COVER REMOVAL COIL RUBBER TIP O-RING SCREW BUSHING SCREW SPECIAL WASHER BRACKET TIMING GEAR COVER TIMING GEAR COVER GASKET 5 - 4...

  • Page 258: Coils And Spark Plugs Removal

    HEAD DISTRIBUTION COILS AND SPARK PLUGS REMOVAL Remove: • the screw (6*) Fig. A • washer (7*) Fig. A • bracket (8*) Fig. A • the coils (1*) Fig. B • the spark plugs, using a special wrench. NOTE:_________________________________ Numbers marked (*) are part of the spare parts table in Chapter 5 “Engine”, section entitled “Timing gear cover removal ”.

  • Page 259: Coils And Spark Plugs Assembly

    HEAD DISTRIBUTION COILS AND SPARK PLUGS ASSEMBLY The procedure applies to all of the spark plugs Fig.C. WARNING Lubricate the spark plug threads with copper grease. Grease NOTE:__________________________________________ Before installing it, clean the spark plug and surface in contact with the seal. Install: •...
  • Page 260 HEAD DISTRIBUTION TIMING GEAR COVER REMOVAL Take care with the seal on the timing gear cover (10*) Fig. E. during removal. NOTE:_________________________________ In case of seal breakage on the timing gear cover (10), replace. During the assembly of the cover, install sealing paste on the surface as shown in Fig.

  • Page 261: Timing Gear Cover Assembly

    HEAD DISTRIBUTION TIMING GEAR COVER ASSEMBLY Assemble: Proceed in the opposite direction to removal. NOTE:_________________________________ During the assembly stage of the timing gear cover, repla- cement of the rubber tips (5*) is recommended. Tighten: Tighten the screws (4*) to the following torque: Torque 12 N*m NOTE:_________________________________ Numbers marked (*) are part of the spare parts table in...

  • Page 262: Distribution Chain Tensioner Removal

    HEAD DISTRIBUTION DISTRIBUTION CHAIN TENSIONER REMOVAL Remove: the screws (C) the screw (B) the washer the seal NOTE:_________________________________ Operation to perform with the engine in TDC. Using the special tool during the removal stage, keep the tensioner retracted, Fig. I., then remove the two screws “C” Fig.

  • Page 263: Timing Chain Tensioner Assembly

    HEAD DISTRIBUTION TIMING CHAIN TENSIONER ASSEMBLY During the assembly stage, take care to ensure that the seal (D) Fig. H is undamaged and unworn. Replace if necessary. Move: The tensioner to the retracted position and insert it into its hou- sing using the special tool (*) (*) Tool: Chain tensioner lock tool Code: 0320097046001...

  • Page 264: Intake And Exhaust Camshaft Removal

    HEAD DISTRIBUTION INTAKE AND EXHAUST CAMSHAFT REMOVAL Remove: • Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. • Head timing gear, see section entitled “Head timing gear cover removal”. NOTE:_________________________________ During the removal stage, use a marker pen to mark the position of the holders since, when reinstalling, they need to be in their original positions, Fig.

  • Page 265: Camshaft Check

    HEAD DISTRIBUTION CAMSHAFT CHECK Make a visual check of the camshaft lobes and if there is any blue discolouration/pitting or lines, replace. • Measure the size of the lobes. If the measures taken (Fig. E) are not compliant with specifi ca- tions, replace the shaft.

  • Page 266: Exhaust Camshaft Installation

    HEAD DISTRIBUTION EXHAUST CAMSHAFT INSTALLATION Insert: Install the special tool (*) into the spark plug seat to check the top dead centre Fig. A. (*) Tool: Engine phasing tool Code:R180197022000 Once the TDC has been identifi ed, proceed to assemble the camshaft, exhaust side.

  • Page 267: Intake Camshaft Assembly

    HEAD DISTRIBUTION INTAKE CAMSHAFT ASSEMBLY Install the relevant tool (*) into the spark plug seat to check the top dead centre Fig. A. (*) Tool: Engine phasing tool Code:R180197022000 Once the TDC has been identifi ed, proceed to assemble the camshaft, exhaust side.

  • Page 268: Timing Chain Slide Removal

    HEAD DISTRIBUTION TIMING CHAIN SLIDE REMOVAL Remove: • Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear, see section entitled “Head timing gear cover removal”. Chain tensioner, see chapter entitled “Chain tensioner removal”. Exhaust camshaft, see chapter entitled “Exhaust camshaft removal”.

  • Page 269: Timing Chain Slide Assembly

    HEAD DISTRIBUTION TIMING CHAIN SLIDE ASSEMBLY To assemble the chain slides, follow the removal process in the opposite order. NOTE:_________________________________ Operation to perform with the engine in TDC. At the end of assembly, proceed to load the timing chain tensio- ner.

  • Page 270: Timing Chain Removal

    HEAD DISTRIBUTION TIMING CHAIN REMOVAL Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see the chapter entitled “Head timing gear cover removal”. Chain tensioner, see chapter entitled “Chain tensioner removal”. Exhaust camshaft, see chapter entitled “Exhaust camshaft removal”.

  • Page 271: Distribution Chain Installation

    HEAD DISTRIBUTION DISTRIBUTION CHAIN INSTALLATION Insert: • the timing chain (1) in to the camshaft pinion, as in Fig. A • Insert the fi xed and mobile chain tensioner slides, see chapter“Timing chain assembly”. • The two camshafts, making sure that both are installed with the phasing references “aligned”...

  • Page 272: Valve Clearance Adjustment

    HEAD DISTRIBUTION VALVE CLEARANCE ADJUSTMENT Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see chapter entitled “Head timing gear cover removal” NOTE:_________________________________ Valve clearance must be checked and adjusted when the engine is cool (ambient temperature).

  • Page 273: Camshaft And Valve Pad Removal

    HEAD DISTRIBUTION CAMSHAFT AND VALVE PAD REMOVAL INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION BUSHING (M20) SCREW BUSHING WASHER VALVE RUBBER TIP CYLINDER HEAD STUD BOLT SCREW THERMOSTAT CUP THERMOSTAT GRUB SCREW HEAD GASKET WATER TEMPERATURE SENSOR COUPLING RETAINING WASHER SCREW O-RING SUCTION PIPE...
  • Page 274 HEAD DISTRIBUTION CAMSHAFT AND VALVE PAD REMOVAL INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION PLUG TAPPET VALVE VALVE PAD VALVE RUBBER TIP TOP SHIELDED BULB EXTERNAL VALVE SPRING BOTTOM SHIELDED BULB EXHAUST VALVE INTAKE VALVE INTERNAL VALVE SPRING 5 - 21...

  • Page 275: Camshaft And Valve Pad Removal

    HEAD DISTRIBUTION CAMSHAFT AND VALVE PAD REMOVAL Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see the chapter entitled “Head timing gear cover removal”. To remove the intake and exhaust valve lifter, proceed as fol- lows: •...

  • Page 276: Head Removal

    HEAD DISTRIBUTION HEAD REMOVAL Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see the chapter entitled “Head timing gear cover removal”. Chain tensioner, see chapter entitled “Chain tensioner removal”. Exhaust camshaft, see chapter entitled “Intake and exhaust camshaft removal”.

  • Page 277: Valve Flap And Spring Removal

    HEAD DISTRIBUTION VALVE FLAP AND SPRING REMOVAL Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see the chapter entitled “Head timing gear cover removal”. Chain tensioner, see chapter entitled “Chain tensioner removal”.

  • Page 278: Check Of Valves And Guides

    HEAD DISTRIBUTION CHECK OF VALVES AND GUIDES The following process applies to all of the valves and valve guides. Check: • the valve seals. If there are leaks from the valve seats, check the contact surfa- ce, the seat and the width of the valve seat. See the section .....
  • Page 279 HEAD DISTRIBUTION CHECK OF VALVES AND GUIDES Eliminate: • The carbon deposits (5) (from the contact surface and valve seat) Fig. E. Check: • the contact surface of the valve (7) Fig. F If there is any pitting/wear, grind the contact surface of the valve. •...

  • Page 280: Valve Seat Check

    HEAD DISTRIBUTION VALVE SEAT CHECK The following process is applied to all valves and valve seats Fig. H Eliminate: • carbon deposits (from the contact surfaces and valve seat (A) Check: • the valve seat (A) If there are marks/signs of wear, replace the head. Measure: •...

  • Page 281: Valve Oil Seal Removal- Installation

    HEAD DISTRIBUTION VALVE OIL SEAL REMOVAL- INSTALLATION Remove: Once the valve has been removed, using the special tool (*) to take out the oil seal (AA) Fig. B. (*) Tool for valve oil seal removal Install: Proceed to install the oil seal (AA) Fig. D using the special tool ** Fig.

  • Page 282: Valve Spring Test

    HEAD DISTRIBUTION VALVE SPRING TEST The following process is applied to all valve springs. Measure: • the free length of the valve springs (A) Fig. A. If not compliant with specifi cations, replace the valve spring. Valve spring Dimension (A) Intake 38.8 mm - 37.3 mm Exhaust...

  • Page 283: Valve And Valve Spring Installation

    HEAD DISTRIBUTION VALVE AND VALVE SPRING INSTALLATION Install the head: NOTE:________________________________ Lubricate the valve stem and oil seal. Engine oil • Valve bottom spring plate (4), • valve oil seal (3) Fig. A1 see section entitled “Valve oil seal installation/removal”. •...

  • Page 284: Cylinder Check

    HEAD DISTRIBUTION CYLINDER CHECK Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see chapter entitled “Head timing gear cover removal” Head see chapter entitled “Head removal” The following procedure applies the whole cylinder group. Check: •...

  • Page 285: Head Installation

    HEAD DISTRIBUTION HEAD INSTALLATION Before assembling the head, replace the seals (2). Make sure that the alignment dowels (1) are in position Fig. C. • Position the head and tighten the screws (3), following the sequence stated in Fig. D. •...

  • Page 286: Pistons

    PISTONS INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION PISTON SEGMENT SERIES PIN RETAINING RING PISTON PIN PISTON COMPLETE CONNECTION ROD PLUG SCREW GUIDE BUSHING CONNECTING ROD MAIN BEARING SHELL COUNTERSHAFT WASHER FULL DRIVE SHAFT SPLINE PLUG GEAR DRIVE SHAFT GEAR 5 - 33...
  • Page 287 PISTONS INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION WASHER BEARING COUNTERSHAFT GEAR GUIDE BUSHING BEARING BEARING RETAINER 5 - 34...

  • Page 288: Piston Removal

    PISTONS PISTON REMOVAL The following removal process applies to all pistons. Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see the chapter entitled “Head timing gear cover removal”. Head see chapter entitled “Head removal”. Top base, see chapter entitled “Connecting rod remo- val”.

  • Page 289: Piston Pin Check

    PISTONS PISTON PIN CHECK The following procedure applies to all piston pins. Check: • piston pin If there is blue discolouration or grooves, replace the piston pin and check the lubrication system. Measure: • the outer diameter of the piston pin Fig. B. If not compliant with specifi...

  • Page 290: Piston Rings Check

    PISTONS PISTON RINGS CHECK The following procedure is applied to all elastic clips (1). Check: • the absence of lines and traces of forcing on each clip Fig. If outside specifi cation, replace the relevant clips and pistons. NOTE:_________________________________ Before measuring side clearance between the piston clips, remove any carbon deposits from the piston clips and grooves.

  • Page 291: Piston Check

    PISTONS PISTON CHECK The following procedure applies to both pistons. Check: • The sides of the piston (B) Fig. D. If there are any vertical lines, replace the piston all together with the relevant clips. Measure: • The diameter of the piston skirt (B) with a micrometer, considering a distance from the bottom edge of around 10.5 mm Fig.

  • Page 292: Piston Assembly

    PISTONS PISTON ASSEMBLY The following procedure applies to all pistons. Install: in the following order: oil scraper clip second clip top clip See Fig. A NOTE:_________________________________ The fi rst and second ring are marked with the letter D on the top side and PVD Fig.

  • Page 293: Piston Installation

    PISTONS PISTON INSTALLATION NOTE:_________________________________ To install the pistons (1), fi rst insert the inner rings (2), then the pins (4) and fi nally the outer rings (3) Fig. C To insert the pistons inside the cylinders, it is necessary to use a specifi...

  • Page 294: Removal Of Connecting Rods

    CRANKCASE REMOVAL OF CONNECTING RODS Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see the chapter entitled “Head timing gear cover removal”. Chain tensioner, see chapter entitled “Chain tensioner removal”. Exhaust camshaft, see chapter entitled “Exhaust camshaft removal”.
  • Page 295 CRANKCASE REMOVAL OF CONNECTING RODS Remove: • Take out the drive shaft, and slide out the connecting rod, including the pistons, from the cylinder group. • Remove the pistons, see the chapter entitled “PISTON REMOVAL”. 5 - 42...

  • Page 296: Check Of Connecting Rod And Connecting Rod Bearing Shells

    CRANKCASE CHECK OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS Check: • Any breakages or excessive clearance on the connecting rod (5) and the big end bearing shells (8) Fig. A. If replacing the connecting rod, check the class of origin marked on the head.

  • Page 297: Installation Of Connecting Rod And Connecting Rod Bearing Shells

    CRANKCASE INSTALLATION OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS Install: • The connecting rod bearing shells: Install the top and bottom bearing shells and bottom bearing of the big and and connecting rod cap. NOTE:_________________________________ Align the projections “A” on the bearing shells of the big end with the slots “B”...
  • Page 298 CRANKCASE INSTALLATION OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS NOTE:_________________________________ Do not mix up the connecting rod bushings and the con- necting rods. To achieve the correct clearance between the connecting rod support and the big end main bearing shells and to prevent engine damage, the big end bearing shells must be installed in their original positions Fig.

  • Page 299: Main Bearing Shell And Drive Shaft Installation

    CRANKCASE MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION 40 40 40 40 INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION ENGINE CASING O-RING IDLE SENSOR SCREW OIL SEAL PLATE SCREW SCREW PLATE PLUG SPECIAL SCREW RETAINING WASHER COUPLING O-RING SPECIAL SCREW RUBBER TIP CENTERING BUSHING BUSHING...
  • Page 300 CRANKCASE MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION OIL FILTER JOINT OIL PRESSURE SENSOR WASHER BEARING BEARING BEARING BEARING DISTRIBUTOR SCREW FLANGE GASKET OIL PRESSURE VALVE SPECIAL SCREW SCREW JOINT SCREW WASHER SCREW SCREW SCREW SCREW...
  • Page 301 CRANKCASE MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION Install: • clean the main bearing shells (6) • connecting rod main bearing shells: • install the connecting rod main bearing shells in the relevant seats in the top and bottom base. NOTE:_________________________________ Align the projections of the main bearing shells with the slots in the top base Fig.

  • Page 302: Drive Shaft Check

    CRANKCASE DRIVE SHAFT CHECK Measure: • the eccentricity of the camshaft If outside specifi cations, replace the drive shaft. Drive shaft eccentricity Size Drive shaft A: Ø 30 (-0.005, -0.017) mm B: Ø 32 (-0.028, -0.042) mm Check: • The surfaces of the shaft supports (A) Fig. A. •...

  • Page 303: Drive Shaft Installation

    CRANKCASE DRIVE SHAFT INSTALLATION Once the drive shaft has been inserted, proceed to assemble the big end Fig. B. Tighten the nuts to the following torque: Torque 25 N*m NOTE:_________________________________ Lubricate the big end pins with copper grease Measure: Once the big end has been assembled, use a thickness gauge to measure the drive shaft-big end collar Fig.

  • Page 304: Clutch

    CLUTCH INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION RING NUT SCREW FLANGE SPRING PUSHER DISC PLATE CLUTCH DISCS BELLEVILLE WASHER RING CLUTCH DRUM WASHER BEARING CLUTCH BELL GUIDE BUSHING ROLLER BEARING PINION SHIM 5 - 51...

  • Page 305: Clutch And Disc Removal

    CLUTCH CLUTCH AND DISC REMOVAL Remove: • the clutch cover screws Fig. A. • clutch cover • the gasket. NOTE:_________________________________ In case of gasket anomalies, install a new gasket. Remove: • the guide bushing (1) Fig. B • clutch control shaft (2) Fig. B •...
  • Page 306 CLUTCH CLUTCH AND DISC REMOVAL Take out the disc pack (6*), washer and clutch drum (9*) and the guide shim (13*). NOTE:_________________________________ Numbers marked (*) are part of the spare parts table in Chapter 5 “Clutch”. 5 - 53...

  • Page 307: Friction Disc Check

    CLUTCH FRICTION DISC CHECK The following procedure applies to all friction discs. Check: • Friction disc If there is any damage/wear, replace the friction discs. Measure: • The thickness of the friction disc Fig. A. If not within specifi cations, replace the friction discs together. Disc Size Friction disc...

  • Page 308: Steel Disc Check

    CLUTCH STEEL DISC CHECK The following procedure applies to all steel discs. Check: • The steel disc. If there is any damage/wear, replace the steel discs all together. Measure: • The warping of the steel discs Fig. B. If not within specifi cations, replace the steel discs together. Disc Twist limit Disc...

  • Page 309: Clutch Assembly

    CLUTCH CLUTCH ASSEMBLY Assemble: • oil pump pinion (complete with chain) (A) • guide shim (4*) • clutch bell (8*) • washer (6*) • clutch drum complete with discs (8*) • disc pusher plate (11*) • using a specifi c tool (**) assemble the fastening ring nut (18) and washer (6) as shown in the fi...

  • Page 310: Lubrication System

    LUBRICATION SYSTEM INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION OIL PUMP CHAIN COMPLETE OIL PUMP SCREW WASHER OIL PUMP PINION OIL PUMP COVER OIL PUMP SHAFT ROLLER SCREW OUTER ROTOR INNER ROTOR WASHER OIL PUMP BUSHING SCREW INTAKE FILTER FITTING INTAKE FILTER THREADED CAP PLUG...

  • Page 311: Oil Sump And Intake Filter Removal

    LUBRICATION SYSTEM OIL SUMP AND INTAKE FILTER REMOVAL Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see the chapter entitled “Head timing gear cover removal”. Chain tensioner, see chapter entitled “Chain tensioner removal”.

  • Page 312: Oil Sump And Intake Filter Installation

    LUBRICATION SYSTEM OIL SUMP AND INTAKE FILTER INSTALLATION Install: Proceed using the opposite order to removal. • Tighten the screws fastening the oil sump (E) to the fol- lowing torque: Torque 0.6 N*m Tighten: • the magnetic cap, complete with copper washer, to the following torque: Torque 25 N*m NOTE:_________________________________...

  • Page 313: Pressure-Relief Valve Installation

    LUBRICATION SYSTEM PRESSURE-RELIEF VALVE INSTALLATION Remove: • Oil sump, see section entitled “Oil sump and intake fi lter removal”. Check: Before installing the valve, make sure all the parts are free from anomalies Fig. A. If there is any damage or wear, replace the faulty parts. Installation: Install the pressure relief valve (A) with O-ring inside the bottom casing, by slotting it in Fig.

  • Page 314: Pressure-Relief Valve Removal

    LUBRICATION SYSTEM PRESSURE-RELIEF VALVE REMOVAL Remove: • Oil sump, see section entitled “Oil sump and intake fi lter removal”. • The pressure relief valve (A): 5 - 61...

  • Page 315: Oil Pump Removal

    LUBRICATION SYSTEM OIL PUMP REMOVAL Remove: Clutch, see chapter entitled “Clutch removal”. • Use a wrench to block the pump control gear (5*) • unscrew the screw (3*) • take out the washer (4*) Fig. A. • take out the pump pinion (5*) Oil sump, see chapter entitled “Oil sump removal”.
  • Page 316 LUBRICATION SYSTEM OIL PUMP REMOVAL Remove: • the screws (9*) • the pump cover (6*) • outer rotor (10*) • inner rotor (11*) • roller (8*) • oil pump shaft (7*) Check: • the pump body (13*) Fig. D If there are any lines/damage/wear, replace. •...

  • Page 317: Oil Pump Assembly

    LUBRICATION SYSTEM OIL PUMP ASSEMBLY Install: Proceed using the opposite order to removal. Tighten the assembly screws (1) to the following torque: Torque 12 N*m Tighten the assembly screws (3*) with the pump pinion (5*) to the following torque: Torque 7 N*m NOTE:_________________________________ Add engine oil once these steps have been completed.

  • Page 318: Neutral Position/Gear Indicator Sensor Removal

    GEAR BOX NEUTRAL POSITION/GEAR INDICATOR SENSOR REMOVAL Remove: • the screws (5) Take out: • the pin (3) Fig. A. • the spring (2) Fig. A. • the neutral position/gear indicator sensor (1) Fig. A. • the gasket (4) Fig. B. 5 - 65...

  • Page 319: Neutral Position/Gear Indicator Sensor Assembly

    GEAR BOX NEUTRAL POSITION/GEAR INDICATOR SENSOR ASSEMBLY Assemble: • insert the spring (2) Fig. A • the pin (3) Fig. A • the gasket (4) Fig. B • the neutral position/gear indicator sensor (1). NOTE:_________________________________ Before assembly, check the continuity of the sensor (see the chapter entitled “Electrical system”) Tighten the two screws (5) of the sensor to the following torque: Torque 0.6 N*m...
  • Page 320 GEAR BOX 34 36 INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION SELECTOR SHAFT STOP SPRING SHIM BUSHING SEEGER RING SCRAPING PLUG SPRING DESMODROMIC BEARING PLATE SCREW GEAR DRUM WASHER SCREW SCREW GEAR FIXING CLICK ASSEMBLY 5 - 67...
  • Page 321 GEAR BOX INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION WASHER HAIRSPRING SPRING GEAR SELECTION FORK 5TH/6TH GEAR SELECTION FORK 5TH/6TH GEAR SELECTION FORK 1ST/4TH - 2ND/3RD NUT (M18) WASHER PINION OIL SEAL BROACHED BUSHING O-RING BEARING BEARING RETAINER COMPLETE MAIN SHAFT BEARING ELASTIC RING SCRAPING...
  • Page 322 GEAR BOX GEAR BOX DISASSEMBLY Remove: Coils and Spark plugs, see the section entitled “Coil and spark plug removal”. Head timing gear cover, see the chapter entitled “Head timing gear cover removal”. Chain tensioner, see chapter entitled “Chain tensioner removal”. Exhaust camshaft, see chapter entitled “Exhaust camshaft removal”.

  • Page 323: Gear Box Assembly

    GEAR BOX GEAR BOX ASSEMBLY Measure: Use a specifi c gauge to check the size of the hole (1) in the top right casing Fig. A. Housing port size: Ø 47 (0,+0.022) mm desmodronic If outside specifi cations, replace the bottom casing. Check: •...
  • Page 324 GEAR BOX GEAR BOX ASSEMBLY Assemble: • the plate (12*) • the 2 screws (13*) Fig. F to the following torque: Torque 12 N*m NOTE:_________________________________ Numbers marked (*) are part of the spare parts table in Chapter 5 “Gears”. 5 - 71...

  • Page 325: Gear Shift Control

    GEAR BOX GEAR SHIFT CONTROL Measure: The following procedure is applied to all gear shift control rods (1). G. Check: • the follower of the gear shift control rod cam (A) • The tooth of the gear shift control rod (B) If there is warping/damage/lines/traces of wear, replace the gear shift control rod .
  • Page 326 GEAR BOX GEAR BOX ASSEMBLY Assemble: spring (21*). gear selection fork 5th/6th (25*). gear selection fork 5th/6th (24*). gear selection fork 1st/4th - 2nd/3rd (23*). spring NOTE:_________________________________ see the sequence in Fig. I Check: • the two bearing stops (33) Fig. L If there is any warping/damage/lines/signs of wear, replace.
  • Page 327 GEAR BOX GEAR BOX ASSEMBLY Check: that the end of the gear lock spring (2*) is in its seat on the selector (*1) plate. Check: that in the neutral position, the clearance between the two ends of the spring and the strike pin is “0” Fig. O Assemble: •...
  • Page 328 GEAR BOX GEAR BOX ASSEMBLY Install: • washer • the counter shaft gear nut (6) Torque 90-100 N*m Install: • washer • drive shaft gear nut (2) (**) Torque 115-125 N*m NOTE:________________________________ To keep the two drive shafts still, it is necessary to use the tool (**) in Fig.

  • Page 329: Starter

    STARTING STARTER INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION STARTER MOTOR O-RING SCREW IGNITION SHAFT DOUBLE GEAR START GEAR FLYWHEEL ROTOR SCREW MAGNET FLYWHEEL COMPLETE FREEWHEEL 5 - 76...

  • Page 330: Starter Removal

    STARTING STARTER REMOVAL Remove: the screws (3*) Fig. A the starter motor (1*) from the clutch Fig. B. Check: • starter motor operation. NOTE:_________________________________ If the starter motor turns with force, replace the part. • The O-ring gasket. If there is any damage/spotting/traces of wear, replace the O- ring gasket.

  • Page 331: Starter Installation

    STARTING STARTER INSTALLATION Install: Proceed using the opposite order to removal. Assemble: • the screws (3*) Fig. A to the following torque: Torque 12 N*m Use Loctite thread sealant to secure. Loctite 243 NOTE:_________________________________ Once the starter motor is assembled, proceed with the cur- rent wire connection.

  • Page 332: Flywheel Removal

    STARTING FLYWHEEL REMOVAL Remove: • the cap (1). Use the tool (2*) for this operation Fig. A (*) Tool to remove the magnetic cap from the alternator cover Code: 0320097043000. Remove: • the screws (3) Fig. B • take out the magnet fl ywheel cover Fig. B. Use the tool (4*) for this operation Fig.
  • Page 333 STARTING FREEWHEEL REMOVAL Remove: the assembled freewheel elements (6*) Fig. D • the 6 screws (8*). Check: • the roller cage and support. If there are any anomalies or signs of wear, replace the whole freewheel (6*). NOTE:_________________________________ Numbers marked (*) are part of the spare parts table in Chapter 5 “Starting”.
  • Page 334 STARTING FREEWHEEL INSTALLATION Installation: Proceed in the opposite order to removal. Assemble: • the screws (8*) Fig. A to the following torque. Torque 35 N*m Use Loctite thread sealant to secure. Loctite 243 5 - 81...

  • Page 335: Flywheel Installation

    STARTING FLYWHEEL INSTALLATION Installation: proceed in the opposite order to removal. Assemble: • the nut (5) Fig. A • the washer (6) Fig. A. Tighten the nut (5) to the following torque. Torque 90 N*m Assemble: • the fl ywheel magnet cover •...

  • Page 336: Starter Gear Removal

    STARTING STARTER GEAR REMOVAL Remove: Flywheel, see chapter entitled “Flywheel removal”. Remove: • the satellite starter gear (1) Fig. E • the freewheel starter gear (2) Fig. F • the spline (3) Fig. F 5 - 83...

  • Page 337: Starter Gear Assembly

    STARTING STARTER GEAR ASSEMBLY To assemble the chain slides, follow the removal process in the opposite order. 5 - 84...

  • Page 338: Phase Sensor

    STARTING PHASE SENSOR 11 12 INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION BUSHING O-RING THREADED CAP MAGNETIC CAP O-RING SCREW PHASE SENSOR SCREW ALTERNATOR COVER PINION COVER PLATE SCREW THE FLYWHEEL COVER GASKET SCREW SCREW 5 - 85...

  • Page 339: Phase Sensor Removal

    STARTING PHASE SENSOR REMOVAL Disconnect: • The connector for the phase sensor (7*): Remove: • the screw (6*) Fig. A • the phase sensor (7*) Fig. A Check: the integrity of the phase sensor. 5 - 86...

  • Page 340: Phase Sensor Installation

    STARTING PHASE SENSOR INSTALLATION Assemble: • the phase sensor (7*) • the fastening screws (6*) to the following torque: B: Torque 12 N*m Measure: • the distance (A) between the phase sensor (7*) and the pick-up on the fl ywheel magnet Fig. B. NOTE:_________________________________ Use a thickness gauge to take this measurement 5 - 87...

  • Page 341: Power System

    POWER SYSTEM THROTTLE BODY INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION SCRAPING FLANGE WASHER WASHER OIL SEAL SHAFT THROTTLE VALVE FLANGE SCREW BUSHING SPRING SCREW BRACKET STEERING RING NUT SCREW INSERT INJECTOR BRACKET MAP SENSOR SCREW PIPE PIPE GLAND CLIP INSERT 5 - 88...
  • Page 342 POWER SYSTEM INTERVENTION Pos. Description Qty. SYMBOLS REMARKS DESCRIPTION SEALING RING PLATE SCREW ROLLER BEARING SEEGER PLATE SCREW POTENTIOMETER WASHER SCREW SCREW THROTTLE VALVE PIPE CLIP PIPE PIPE SPECIAL PLATE O-RING STEPPER MOTOR SPECIAL WASHER BUSHING PIPE DISTRIBUTOR VIBRATION DAMPING RUBBER SCREW O-RING SCREW...

  • Page 343: Throttle Valve Removal

    POWER SYSTEM THROTTLE VALVE REMOVAL Remove: • Rider and passenger seats, see chapter entitled “Removal of rider and passenger seats, Chapter 4”. • Fuel tank, see chapter entitled “Fuel tank removal , Chap- ter 4”. • Air fi lter, see chapter entitled “Air fi lter removal, Chapter 4”.

  • Page 344: Throttle Valve Installation

    POWER SYSTEM THROTTLE VALVE INSTALLATION Installation: Proceed using the opposite order to removal. IMPORTANT NOTICE During assembly of the accelerator cables, take care to insert the hood (9) on the control line (10) Fig. E. 5 - 91...
  • Page 345 6 - 1...
  • Page 346 CHAPTER 6 COOLING SYSTEM WATER PUMP ...............................3 WATER PUMP REMOVAL ................................4 WATER PUMP INSTALLATION ..............................5 THERMOSTAT ...............................6 THERMOSTAT REMOVAL ................................6 THERMOSTAT INSTALLATION ..............................7 WATER MANIFOLD ............................8 WATER MANIFOLD REMOVAL ..............................8 WATER MANIFOLD INSTALLATION ............................9 HEAT EXCHANGER ............................10 HEAT EXCHANGER REMOVAL ...............................10 HEAT EXCHANGER INSTALLATION ............................11 RADIATOR ..............................12 DISASSEMBLE THE RADIATOR .............................13...
  • Page 347 WATER PUMP 12 13 CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION WATER PUMP IMPELLER SEALING RING OIL SEAL WATER PUMP COVER O-RING BEARING SEEGER RING WATER PUMP SHAFT SCREW COMPLETE WATER PUMP L-SHAPED JOINT SCREW WASHER WATER PUMP BODY SCREW BUSHING SEEGER RING SLEEVE SCREW CLIP...

  • Page 348: Water Pump

    WATER PUMP WATER PUMP REMOVAL Remove: • Gear lever, see the section entitled “Gear lever installation” in Chapter 4 • the bands (19*) Fig. A • the water inlet manifold (2) Fig. A • the water return manifold (3) Fig. A •...

  • Page 349: Water Pump Installation

    WATER PUMP WATER PUMP INSTALLATION Install: Proceed to assemble the pump, lubricating it with engine oil: • the pump shaft (8*) • the bushing (16*) • the bearings (6*) NOTE:_________________________________ When inserting the pump, take care to ensure that the groove on the water pump shaft (8*) is facing in the direc- tion shown in Fig.

  • Page 350: Thermostat

    THERMOSTAT THERMOSTAT REMOVAL Remove: • Right-side bodywork, see the section in Chapter 4 entitled “front bodywork”. • screws (3) Fig. A • thermostat (4) Fig. B NOTE:_________________________________ Drain out the coolant before proceeding with these opera- tions. Check: • The by-pass port (A) If clogged, replace.

  • Page 351: Thermostat Installation

    THERMOSTAT THERMOSTAT INSTALLATION Install: • Install the thermostat so that the bypass port (A) is facing upwards. • the screws (3) and tighten to the following torque: Torque 12 N*m Use Loctite thread locker to secure the screws. Loctite 242 NOTE:_________________________________ Fill with coolant after completing these operations.

  • Page 352: Water Manifold

    WATER MANIFOLD WATER MANIFOLD REMOVAL Remove: • Coolant • Manifolds drain, see the section entitled “Exhaust assem- bly removal” in Chapter 4. • the bands (1) Fig. A • the screws (3) Fig. A • the water manifold (2) Fig. A •...

  • Page 353: Water Manifold Installation

    WATER MANIFOLD WATER MANIFOLD INSTALLATION Install: Carry out the removal steps in reverse order • the screws (3) and tighten to the following torque: Torque 12 N*m Use Loctite thread locker to secure the screws. Loctite 242 NOTE:________________________________ Fill with coolant after completing these operations. 6 - 9...

  • Page 354: Heat Exchanger

    HEAT EXCHANGER HEAT EXCHANGER REMOVAL Remove: • Coolant • Manifolds drain, see the section entitled “Exhaust assem- bly removal” in Chapter 4. • the bands (1) Fig. A • the hose (2) Fig. A • the hose (3) Fig. A •...

  • Page 355: Heat Exchanger Installation

    HEAT EXCHANGER HEAT EXCHANGER INSTALLATION Install: Proceed to install the distributor following the removal steps in reverse order. • the special screw (7) to the following torque: Torque 60 N*m • the distributor cap to the following torque: Torque 25 N*m NOTE:________________________________ If not worn, re-use the previously removed bands;...

  • Page 356: Radiator

    RADIATOR CONTENTS Pos. Description SYMBOLS REMARKS DESCRIPTION SCREW BUSHING RUBBER TIP WATER RADIATOR BUSHING INTAKE HOSE WATER TANK CAP WATER TANK SCREW VIBRATION DAMPING RUBBER PIPE PIPE CLIP PIPE SCREW CLIP SLEEVE SLEEVE CLIP PINION COVER SCREW ELECTRIC FAN 6 - 12...

  • Page 357: Disassemble The Radiator

    RADIATOR DISASSEMBLE THE RADIATOR Remove: • Side bodywork, see the section in Chapter 4 entitled “front bodywork”. NOTE:_________________________________ Drain out all coolant by taking out the screw (12*) before proceeding with removal operations, as shown in Fig. A. • the bands (19*) Fig. A •...
  • Page 358 RADIATOR DISASSEMBLE THE RADIATOR Check: • the radiator fi ns. If clogged, clean. Use a jet of compressed air on the back of the radiator. NOTE:________________________________ Straighten any bent fi ns using a fi ne fl athead screwdriver Check: • the radiator hoses.

  • Page 359: Radiator Installation

    RADIATOR RADIATOR INSTALLATION Install: Once each individual part has been checked, proceed to install the radiator following the removal steps in reverse order. • the screws to fasten the radiator to the bracket on the frame, tightening to the following torque: Torque 10 N*m •...
  • Page 360 ELE. - 16...
  • Page 361 ELECTRICAL SYSTEM SENSORS ..............................3 DESCRIPTION OF THE ENGINE MANAGEMENT SYSTEM ....................3 COOLANT TEMPERATURE SENSOR ............................4 GEAR POSITION SENSOR ...............................5 PHASE SENSOR..................................6 AIR TEMPERATURE SENSOR ..............................7 SIDE STAND SWITCH ................................8 LAMBDA PROBE ..................................9 OIL PRESSURE SENSOR ...............................10 FRONT BRAKE MICROSWITCH .............................11 IDROSTOP ....................................12 CLUTCH SWITCH ..................................13 MAP SENSOR (MANIFOLD ABSOLUTE PRESSURE) ......................14...

  • Page 362: Sensors

    In the event of a system failure, this function ensures that the type of fault and the engine data at the time of fault are stored in the ECM memory. The stored data can be recovered by means of an apposite service equipment available at any Benelli’s Dealer (see Texa instruction manual), thus allowing a precise fault diagnostic and the immediate solving of the defect.

  • Page 363: Coolant Temperature Sensor

    SENSORS COOLANT TEMPERATURE SENSOR It is situated close to the cylinder head (A), Fig. A, and calculates the information of temperature and coolant re- ceived from the ECM that are used to optimize the supply to all engine temperatures and to calculate the supply requirements in the heat and cold setting off.

  • Page 364: Gear Position Sensor

    SENSORS GEAR POSITION SENSOR It is situated on the left side of the engine, close to the pinion, and detects the position of the gear. Disconnect: • The electrical coupling. Remove: • The gear position sensor from the half casing. Check: •...

  • Page 365: Phase Sensor

    SENSORS PHASE SENSOR It is situated close to the left engine casing (1), Fig. A. The position sensor of the crankshaft shows the movement of a sprocket fixed to the right end of the drive shaft by reading a particular wheel consisting of 28 equidistant teeth near to a triple length space. The interpretation of such reading is used by the ECM to fix the position of the drive shaft in relation to the point in which fuel is injected and to the requirements of fuel ignition.

  • Page 366: Air Temperature Sensor

    SENSORS AIR TEMPERATURE SENSOR Working principle of intake air temperature sensor Within the sensor temperature range, the resistance varies according to the various temperature. It is distinguished by the negative temperature coefficient resistor. It is a part that can not be maintained. Appearance of intake air temperature sensor (see Fig. A): Measured temperature Resistance value (°C)

  • Page 367: Side Stand Switch

    SENSORS SIDE STAND SWITCH It is situated near the supporting plate of the side stand (A), Fig. If the gear is engaged and the stand is open, and therefore the circuit is open, the ECU prevents starting or shuts off the engine (if rotating).

  • Page 368: Lambda Probe

    SENSORS LAMBDA PROBE They are situated on the exhaust manifold (A), Fig. L. The lambda probe serves to detect the oxygen concentration in the exhaust gases. More precisely, the lambda value indicates the air/petrol ratio, in which: • Value 1, when combustion is stoichiometric •...

  • Page 369: Oil Pressure Sensor

    SENSORS OIL PRESSURE SENSOR It is situated on the lower half casing and measures oil pressure in the bushing gallery (A), Fig. M. It indicates the presence of sufficient oil pressure to the dash- board. Disconnect: • The electrical coupling. Remove: • The oil pressure sensor from the half casing. Check: •...

  • Page 370: Front Brake Microswitch

    SENSORS FRONT BRAKE MICROSWITCH It is a switch in contact with the brake lever, situated on the front brake pump, which serves to switch on the stop lights (A), Fig. Check: • The continuity by positioning the multitester on the symbol →|- (function diode/ continuity test) to check operation, as shown in the table. SENSOR PIN 1 PIN 2...

  • Page 371: Idrostop

    SENSORS IDROSTOP It is a switch situated on the rear brake pump, which reads the oil pressure exerted on the pump. It serves to switch the stop lights on (A), Fig. O. Check: • The continuity by positioning the multitester on PIN 1 and PIN 2 and checking the table.

  • Page 372: Clutch Switch

    SENSORS CLUTCH SWITCH It is situated on the clutch lever and serves to prevent the engine from starting before the lever is completely pulled (A) Fig. P. Disconnect: • The clutch switch cables. Use: • The tester and check the clutch switch pins referring to the table.

  • Page 373: Map Sensor (Manifold Absolute Pressure)

    SENSORS MAP SENSOR (MANIFOLD ABSOLUTE PRESSURE) It is situated close to the throttle body and serves to detect the absolute pressure on the intake manifold. It reflects the size of inlet pressure, which can be converted to air intake volume accessing the combustion chamber of the engine. ELE. - 29...

  • Page 374: Position Sensor Of The Throttle Body Unit (Potentiometer)

    SENSORS POSITION SENSOR OF THE THROTTLE BODY UNIT (POTENTIOMETER) It is situated on the right end of the shaft of the throttle body unit. The position sensor of the throttle body unit (potentiometer), controlled and supplied directly by the ECM, gives out a signal, which identifies the throttle opening position used by the ECM to determine fuel dosage and ignition advance (A), Fig.

  • Page 375: Devices

    DEVICES DEVICES POSITION Ω Position Device RIGHT ELECTRIC DEVICE STARTING RELAY HORN INSTRUMENTATION IGNITION SWITCH REGULATOR LEFT ELECTRIC DEVICE INJECTION ECU LIGHT CONTROL RELAY SERVICES RELAY STATOR CONVERTER OF CAN BUS SIGNALS ELE. - 31...

  • Page 376: Right Electric Device

    DEVICES RIGHT ELECTRIC DEVICE It is situated on the right side of the handlebar Fig. 1. The right electric device consists of: RUN/OFF button (A) • it serves to break contact to the electric device in case of emergency. Ignition button (C) •...

  • Page 377: Starting Relay (Remote Control Switch)

    DEVICES STARTING RELAY (REMOTE CONTROL SWITCH) It is situated close to the fuse block and breaks power contact on the starter (1) Fig. A. Apply: • 12 volt to terminals (2) and (3) Fig. B Check: • The continuity between power terminals. In presence of continuity, the starter relay works properly.

  • Page 378: Horn

    DEVICES HORN It is situated on the left side of the frame close to the radiator (1) Fig. A. The horn is an electromechanical device, which serves as acoustic warning device. Connect: • PIN1 and PIN2 to the battery and check. Check: •...

  • Page 379: Instrumentation Dashboard

    DEVICES INSTRUMENTATION DASHBOARD It is situated on the headlight instrumentation support frame. The instrumentation provides all information concerning the motorcycle operation to the driver: INDICATOR LIGHTS: • high beam light • left indicator light • right indicator light • neutral position indicator light •...

  • Page 380: Master Switch

    DEVICES MASTER SWITCH The ignition switch (1), Fig. A, is positioned behind the steering sleeve and serves to: • Provide the main contact to the electrical system • Close the steering block. • Keep the parking lights on for all conditions required. Check: •...

  • Page 381: Voltage Regulator

    DEVICES VOLTAGE REGULATOR It is situated on the left side of the vehicle close to the water radiator and allows balancing of electrical consumption via the battery recharge (A), Fig. 6. Multimeter selection: diode test. Connect the black probe to the red line terminal of voltage regulator.

  • Page 382: Left Electric Device

    DEVICES LEFT ELECTRIC DEVICE It is situated on the left side of the handlebar Fig. 7. The left electric device consists of: Light switch control (A) • for switching-over the high/low beam. Indicator lights control (B) • by moving the control to the right or to the left, the relevant indi- cator lights are activated.

  • Page 383: Converter Of Can Bus Signals

    DEVICES CONVERTER OF CAN BUS SIGNALS It is situated on the left, front side of the vehicle and serves to collect and convert the digital/analogue signals into CAM-BUS for the instrument panel (Fig. A). ELE. - 39...

  • Page 384: Injection Ecu

    DEVICES INJECTION ECU Check the various utilities, situated close to the passenger’s under-seat, according to the diagram below. Hereunder is a table indicating the meaning corresponding to the error code detected. ERROR TABLE Code error Error description 1st lambda heater cylinder - open/short circ. 1st lambda heater cylinder - ground open/short circ.
  • Page 385 DEVICES INJECTION ECU ERROR TABLE Code error Error description 2nd injector - open circuit 2nd injector - short circuit to ground 2nd injector - positive short circuit Drive shaft position sensor - failure (out of range) Drive shaft position sensor - failure (open circuit) 1092 Vapour exhaust checking valve - open circuit 1112...

  • Page 386: Injection Ecu Connections

    DEVICES INJECTION ECU CONNECTIONS 线束内接 线束内接 68K电阻 68K电阻 LAMBDA SENSOR LAMBDA SENSOR GND TO GND TO Zyl.1 Zyl.2 ENGINE ENGINE IGNITION IGNITION UPSTREAM 1 UPSTREAM 2 COIL 1 COIL 2 INTAKE TEMP. ZS-K1 ZS-K1 THROTTLE INTAKE ENGINE COOLANT SENSOR 氧传感器2 INJECTOR 1 POSITION 氧传感器1...

  • Page 387: Indicator Light Intermittence

    DEVICES INDICATOR LIGHT INTERMITTENCE It is situated inside the storage compartment, underneath the vehicle seat, and allows to control the indicator flashers. ELE. - 43...

  • Page 388: Abs Button

    DEVICES ABS BUTTON It is situated on the left side of the control handlebar (3), Fig. A, and allows to manage the insertion/release of ABS control. Disconnect: • The electrical coupling. Check: The resistance using the multitester on symbol Ω between • pin 1 and pin 2. Resistance: 0 Ω...

  • Page 389: Services Relay

    DEVICES SERVICES RELAY It is situated inside the storage compartment, underneath the ve- hicle seat (Fig. A). The relay assembly is managed by the ECM to control each load at best, such as: • The lighting system The ECM ensures that the lights turn on in certain conditions. •...

  • Page 390: Stator

    DEVICES STATOR There are three types of failures of magnetoelectric generator (stator): • Short circuit Line break (wire burnt) • • Rotor Magnetic Disappear. Ω Short circuit or open circuit of coil wires that cause low output or even no output. Disappearing of rotor magnetism will lead to low output, which may be caused by AC electric generator or striving.

  • Page 391: Actuators

    ACTUATORS POSITION OF ACTUATORS Position Device STEPPER INJECTORS IGNITION COILS COOLING FAN FUEL PUMP STARTER ABS ECU ELE. - 47...

  • Page 392: Idle Air Control System (Stepper)

    ACTUATORS IDLE AIR CONTROL SYSTEM (STEPPER) The system is situated inside the air filter case, contains a valve for checking air flow underneath the throttled body throttles and is equipped with a stepper motor. The system controls the following parameters: • Idle speed • Air supply in case of engine overspeed • Adjustment of air/fuel ratio by working at idle speed at altitudes above sea level.

  • Page 393: Injectors

    ACTUATORS INJECTORS They are positioned on the throttle body unit. The engine is equipped with three four-jet injectors (1), Fig. A. The amount of jet of the injectors is constant, but the duration of time during which each injector remains open is variable. The duration of each injection is calculated via ECM according to the data received from the various system sensors.

  • Page 394: Ignition Coils

    ACTUATORS IGNITION COILS The ignition coil is situated directly on the head of each spark plug (1), Fig. A, and provides high voltage and ignition energy necessary to produce high-voltage sparks between the elec- trodes of the spark plug. Check: •...

  • Page 395: Cooling Fan

    ACTUATORS COOLING FAN It is situated on the radiator body (1) Fig. A. The ECM enables and disables the cooling fan according to a signal received by the coolant temperature sensor. When the coolant temperature reaches the upper-tier tempera- ture, the cooling fans are activated via command. When the coolant temperature lowers enough (lower-tier tem- perature), the coolant fans are activated via command by the ECM.

  • Page 396: Fuel Pump

    ACTUATORS FUEL PUMP The electric pump is situated in the fuel tank (1), Fig. A, and provides fuel in the supply circuit via a pressure regulator at a constant pressure of 3.5 bar. The ECM controls the pump operation directly, by ensuring the correct fuel pressure necessary for starting the engine from the first activation of the instrument panel via a timed function, and a continuous operation for the normal use of the vehicle.

  • Page 397: Fuel Level Sensor

    ACTUATORS FUEL LEVEL SENSOR It is situated close to the fuel pump (1), Fig. A, and provides an outlet value of variable resistance according to the fuel level. Check: • The resistance depending on fuel level (Fig. B) by position- ing the multitester on symbol Ω between the PIN1 - PIN2.

  • Page 398: Starter

    ACTUATORS STARTER The starter (1), Fig. A, is a part that can be replaced totally. If the starter is damaged, replace it. Remove: • Release the coiled spring of brushes. • Remove the casing framework. • Use an ohmmeter to measure the resistance between the wire terminal and the insulated brush.
  • Page 399 ACTUATORS STARTER Measure: • The resistance between each segment of the switch and the framework shaft (Fig. D). Reading should be infinite (no continuity). Insulation check Ω infinite 20°C (68°F) Check: • The switch segments for discoloration. NOTE:________________________________ The presence of discoloured segments in pairs refers to short circuits of coils that require the replacement of the starter.

  • Page 400: Abs Ecu

    ACTUATORS ABS ECU It is situated underneath the fuel tank Fig. A. Precautions There are several precautions to follow concerning the ABS system. • The power supply of the ABS system must be equipped with a 12 V sealed battery. Do not use other types of batteries. •...
  • Page 401 ACTUATORS ABS ECU Please refer to the features on the Texa diagnostic device for managing the diagnostics. Hereunder are the main fault codes and the necessary corrective actions. DTC (Hex) Fault codes Solutions 5055 5019 5017 Replace ABS unit 5013 5018 5014 5053...
  • Page 402 ACTUATORS ABS ECU Diagram Position Code GND_ECU CAN1P WSS_F WAU_IN1 DIAGK BLS - input_PD -SW2H_NO DIAGL WSO_F UB_VR GND_MR CAN1M WSP_F WSP_R WSS_R ABS_OFF -input_PU - SW2L_NO WSO_R NABS_SLAMP UB_MR ELE. - 58...

  • Page 403: Battery

    BATTERY VEHICLE BATTERY IMPORTANT NOTICE Do not use batteries other than the indicated ones (A), Fig. 1. The MF battery (maintenance-free) mounted on this vehicle does not require maintenance operations, as electrolyte level control and topping up of distilled water. Please note that the charging system of the MF battery differs from the one of a standard one.

  • Page 404: Battery Efficiency Control

    BATTERY BATTERY EFFICIENCY CONTROL CHECKING BATTERY CURRENT LOSSES Connect: • The multitester between the negative terminal and the negative wire of the battery as ammeter in direct current (B) Fig. 2. IMPORTANT NOTICE Since the current losses may be high in case of malfunctioning, use a high range of the multitester first to prevent damages.

  • Page 405: Diagnostics

    DIAGNOSTICS VEHICLE DIAGNOSTICS Refer to the Texa diagnostic instructions. ELE. - 61...

  • Page 406: Electrical System

    ELECTRICAL SYSTEM WIRING DIAGRAM OF TRK502 ELECTRICAL SYSTEM 7 - 62...

  • Page 407: Colour Key

    ELECTRICAL SYSTEM COLOUR KEY CODE COLOUR Black Blue Green White Yellow Orange Dark grey Purple Brown Grey Pink ELE. - 63...
  • Page 408 Pure Passion since 1911 SERVICE STATION MANUAL 2013, Benelli Q.J. s.r.l. 1st edition, April 2017 All rights reserved. Reprinting or unauthorised use are expressly prohibited without the written consent of Benelli Q.J. s.r.l.

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