Benelli BN600R 2014 Service Station Manual

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SERVICE STATION MANUAL

Pure Passion since 1911

code:........................

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Page 1 All manuals and user guides at all-guides.com SERVICE STATION MANUAL Pure Passion since 1911 code:......
Page 2 WARNINGS: This manual has been written by Benelli Q.J. s.r.l., mainly for use by Benelli dealers and their specially trained mechanics. It is not possible to give a mechanic all of the information they require in a single manual. It is therefore presumed that the persons using this manual for the maintenance and repairs of Benelli bikes have a basic knowledge of mechanics and the procedures necessary for repairs and maintenance of this type of vehicle.
Page 3 All manuals and user guides at all-guides.com HOW TO USE THIS MANUAL This manual is a practical reference guide that is both easy to handle and use for mechanics. The explanations of all of the procedures for installing, removing, disassembling, ﬁ tting, repairing and checking, are organised in sequence, one step at a time. Each chapter is divided into sections.
Page 4 All manuals and user guides at all-guides.com SYMBOLS SUBJECT SYMBOLS General Information INFO SPEC Speciﬁ cations Inspections and Periodic Adjustments CHAS Frame Engine Engine Engine gine COOL Cooling system Cooling system Cooling ing syst system EXPLANATORY SYMBOLS Y SY SYMBOLS SYMB SYMB MBOL...
Page 5 All manuals and user guides at all-guides.com CONTENTS CHAPTER 1 General Information INFO CHAPTER 2 SPEC Speciﬁ cations CHAPTER 3 C C H H Inspections and Periodic Adjustments specti ections and tions and Periodic s an s an and Pe d Period d Peri Periodic...
Page 6 All manuals and user guides at all-guides.com INFO CHAPTER 1 General Information INFO - 5 -...
Page 7: Table Of Contents
All manuals and user guides at all-guides.com INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ....................7 MOTORCYCLE IDENTIFICATION ......................7 CHARACTERISTICS ..................... 8 INSTRUMENTS AND LIGHTS ........................8 MULTIPURPOSE DISPLAY ........................9 IMPORTANT INFORMATION ................10 PREPARATIONS FOR REMOVAL AND DISASSEMBLY OPERATIONS ..........10 REPLACEMENT PARTS ..........................10 GASKETS, O-RINGS, SEALS AND BEARINGS ..................
Page 8: Identification
All manuals and user guides at all-guides.com INFO IDENTIFICATION MOTORCYCLE IDENTIFICATION The identiﬁ cation data are: Serial number of the frame (on the steering head) Engine serial number (on the bottom base) Approval details (on frame) - 7 -...
Page 9: Characteristics
“ON”, or if the light stays on, have the electric circuit checked by an authorised Benelli service cen- tre. High beam light (blue) This switches on when the high beam is switched on.
Page 10: Multipurpose Display
All manuals and user guides at all-guides.com INFO CHARACTERISTICS MULTIPURPOSE DISPLAY The partial kilometre counter can be used to estimate the possi- COOLANT TEMPERATURE GAUGE ble distance to cover with a full tank of fuel. This information may Shows the coolant temperature in °F (Fahrenheit) or C°(Celsius) . make it possible to schedule future fuelling stops.
Page 11: Important Information
Keep all parts away from any source of heat. REPLACEMENT PARTS Only use original Benelli replacement parts. Only use oils and grease recommended by Benelli to lubricate parts. Other brands may look similar and operate in a similar manner, but will be of lower quality.
Page 12: Gaskets, O-Rings, Seals And Bearings
All manuals and user guides at all-guides.com INFO IMPORTANT INFORMATION GASKETS, O-RINGS, SEALS AND BEARINGS Always replace all gaskets, oil seals and O-rings when carrying out repairs to the engine. olio The gasket surfaces, oil seal lips and O-rings must always be motore labbro clean.
Page 13: Elastic Retaining Rings
All manuals and user guides at all-guides.com INFO IMPORTANT INFORMATION ELASTIC RETAINING RINGS Before reﬁ tting them, check all of the retaining rings and replace any that have become damaged or are out of shape. Always replace the retaining rings on the gudgeon pin after using them once.
Page 14 All manuals and user guides at all-guides.com INFO IMPORTANT INFORMATION Connect: • the wire • the coupler • the connector NOTE: Make sure all connections are ﬁ rmly installed. Check: • continuity (with a pocket tester) NOTE: • If there is no continuity, clean the terminals. •...
Page 15: Special Engine Equipment
All manuals and user guides at all-guides.com INFO SPECIAL EQUIPMENT The special equipment listed here serves for the complete, thorough performance of ﬁ ne tuning and assembly operations. The use of this equipment will help to prevent damage caused through using unsuitable tools or makeshift techniques. When completing an order, please check the list below to avoid any errors.
Page 16 All manuals and user guides at all-guides.com INFO SPECIAL EQUIPMENT SPECIAL ENGINE EQUIPMENT Tool Code Name-Tool Function Image Engine tuning tool This tool serves to establish the TDC po- sition Oil ﬁ lter tool This tool serves to tighten or remove the engine oil ﬁ...
Page 17 All manuals and user guides at all-guides.com INFO SPECIAL EQUIPMENT SPECIAL ENGINE EQUIPMENT Tool Code Name-Tool Function Image Measuring gauge This tool is used to measure thickness Flywheel tightening tool This tool serves to remove the ﬂ ywheel on the engine shaft - 16 -...
Page 18: Special Tools (Frame)
All manuals and user guides at all-guides.com INFO SPECIAL EQUIPMENT SPECIAL TOOLS (FRAME) Tool Code Name-Tool Function Image Tightening tool for steering head lock This assembled tool is used to tighten the lock nut securing the steering head. Front wheel steering arm tightening tool This tool is used to tighten the front wheel - 17 -...
Page 19 All manuals and user guides at all-guides.com SPEC CHAPTER 2 SPEC Speciﬁ cations - 18 -...
Page 20 All manuals and user guides at all-guides.com SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ................20 TECHNICAL DETAILS .................... 21 ENGINE SPECIFICATIONS ........................21 FRAME SPECIFICATIONS ........................26 ELECTRICAL SPECIFICATIONS ......................30 GENERAL TIGHTNESS SPECIFICATIONS .....................34 TIGHTNESS TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS ....35 TIGHTENING TORQUES ..........................35 - 19 -...
Page 21 All manuals and user guides at all-guides.com SPEC GENERAL SPECIFICATIONS DIMENSIONS STANDARD Overall length (A) 2160 mm Overall width (B) 800 mm Overall height (C) 1180 mm Distance between centres 1480 mm WEIGHT STANDARD Kerb weight (with oil and fuel 220 kg tank full) Empty (with no oil and empty tank)
Page 22 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ENGINE SPECIFICATIONS ENGINE STANDARD Engine Four-stroke inline four-cylinder liquid cooled, 4 valves per cylinder Double overhead camshaft (DOHC) Cubic capacity 600 c.c Number of cylinders Cylinder layout in line Stroke ratio 65x45.2 Compression ratio: 11.5:1...
Page 23 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ENGINE SPECIFICATIONS SPARK PLUGS STANDARD Model (make) x quantity NGN CR9E Distance between electrodes 0.6-0.7 mm CYLINDER HEAD STANDARD Head gasket maximum warping 0.03 mm CAMSHAFT STANDARD Control system chain transmission Camshaft support diameter Ø23 (0,+0.021) mm Clearance between support and camshaft...
Page 24 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ENGINE SPECIFICATIONS VALVES, VALVE SEATS, VALVE GUIDES STANDARD Aspirator valve clearance (cold) 0.13 ~ 0.19 mm Exhaust valve clearance (cold) 0.19 ~ 0.25 mm VALVE DIMENSIONS Intake Ø 25 mm Head diameter ”A”...
Page 25 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ENGINE SPECIFICATIONS PISTON STANDARD Clearance between piston and cylinder 0.05 ~ 007 mm 0.002 Piston diameter ”A” Ø 65 0.003 Piston height “B” 25 mm 0.002 Gudgeon pin seat Ø 16 0.003 diameter "C"...
Page 26 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ENGINE SPECIFICATIONS CLUTCH STANDARD Clutch: oil bath clutch, multiple discs Clutch release method wire cable and spring Clutch release action wire cable action action with left grip lever Clutch cable clearance (at the ends 2 ~ 3 mm of the clutch lever) Friction plate thickness...
Page 27 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS FRAME SPECIFICATIONS FRAME STANDARD Frame type: Dismountable truss-type, the rear one with steel tube truss, the front one of aluminium alloy Steering sleeve inclination N.A. Trail N.A. FRONT WHEEL STANDARD Wheel type 6-spoke alloy type Rim (Size)
Page 28 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS FRAME SPECIFICATIONS FRONT BRAKE STANDARD LIMIT Brake type Floating double-disc brake Activation With the right hand Recommended ﬂ uid DOT 4 Brake discs 320 x 4 mm (12.5 x 0.15 in) Diameter x thickness Minimum thickness 4.0 mm (0.15 in)
Page 29 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS FRAME SPECIFICATIONS FRONT SUSPENSION STANDARD Suspension type Upside-down fork with stems diameter 50mm Fork stroke 120 mm Spring Free length 295 mm Spacer length 137 mm Flexibility (K1) 8.6 Nm (0.96 Kgf-m) Spring stroke (K1) 0 ~ 120 mm (0 ~ 4.72 in) Fork oil...
Page 30 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS FRAME SPECIFICATIONS REAR SUSPENSION STANDARD Swinging fork in aluminium alloy, adjustable Suspension type gas shock absorber in spring extension and pre-load Fork travel 123 mm Spring Free length 178 +/- 1,5 mm Installed length 167 +/- 1,5 mm Flexibility (K1)
Page 31 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ELECTRICAL SPECIFICATIONS SYSTEM VOLTAGE STANDARD System voltage 12 V STARTING COILS STANDARD Model (brand) N.D. Primary coil resistance 0.6 O Secondary coil resistance 10 kO Primary coil choke 2.5 mH (1 kHz 0.3V) Secondary coil choke 23.5 mH (1kHz) Max.
Page 32 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ELECTRICAL SPECIFICATIONS Plate light 12 V 5 W x 1 Instrument cluster light LED x 1 LIGHTS (WATT x QTY.) STANDARD Neutral indicator light LED x 1 High beam light LED x 1 Oil level alarm light LED x 1...
Page 33 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ELECTRICAL SPECIFICATIONS FUSES (AMPS x QTY) STANDARD Fuse CD1(Control unit) 15 A (Blue) Fuse CD2(Control unit) 15 A (Blue) Headlight fuse 15 A (Blue) Service fuse 15 A (Blue) Radiator fan fuse 15 A (Blue) Spare fuse 15 A (Blu) + 40 A (Red)
Page 34 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS ELECTRICAL SPECIFICATIONS LIQUID TEMPERATURE SENSOR STANDARD Model (brand) N.A. Resistance N.A. SPEED SENSOR STANDARD Model (brand) N.A. LAMBDA STANDARD Model (brand) N.A. INJECTOR STANDARD Model (brand) N.A. RELAY UNIT STANDARD Model (brand) CM1 NAIS IGNITION SYSTEM...
Page 35 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS GENERAL TIGHTNESS SPECIFICATIONS The tightness torques for parts or special assemblies are provid- ed in each chapter of this manual. As far as concerns assemblies with multiple fastening elements, in order to avoid the risk of warping, cross-tighten the parts in successive stages until the required torque is achieved.
Page 36 All manuals and user guides at all-guides.com SPEC TECHNICAL DETAILS TIGHTENING TORQUES TIGHTNESS TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS The values given in the following table refer to standard tightness, i.e., for metric screws coupled with the relevant nut, or with screw nut in metal.
Page 37 All manuals and user guides at all-guides.com CHAPTER 3 Inspections and Periodic Adjustments - 36 -...
Page 38 All manuals and user guides at all-guides.com CHAPTER 3 REGULAR MAINTENANCE PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ......40 FREQUENCY ............................41 ENGINE/AIR FILTER ....................44 AIR FILTER REMOVAL/FITTING ......................44 ENGINE/ACCELERATOR CABLE CLEARANCE ..........46 ACCELERATOR CABLE CLEARANCE ADJUSTMENT ................46 ENGINE/CLUTCH CABLE ..................48 CLUTCH CABLE CLEARANCE ADJUSTMENT ..................48 FRAME/HANDLBAR ....................
Page 39 All manuals and user guides at all-guides.com ELECTRICAL SYSTEM/HEADLAMP ADJUSTMENT ........... 75 ADJUSTMENT ............................75 ELECTRICAL SYSTEM/REAR LAMP REPLACEMENT ........76 REPLACEMENT ............................76 ELECTRICAL SYSTEM/LICENCE PLATE LAMP REPLACEMENT ..... 76 REPLACEMENT ............................76 ELECTRICAL SYSTEM/REAR INDICATOR REPLACEMENT ......77 REPLACEMENT ............................77 ELECTRICAL SYSTEM/FRONT INDICATOR REPLACEMENT ......78 REPLACEMENT ............................78 - 38 -...
Page 40 All manuals and user guides at all-guides.com NOTES: ..........................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................................
Page 41: Periodic Maintenance And Lubrication Intervals
Some operations can be performed by the user as long as they have the necessary skills and in any case, as long as this is ex- pressly mentioned in this manual. In any case, carry out operations at an authorised Benelli workshop. A list of workshops is available on our website www.benelli. com or from our customer service (T_ +39 0721 41871).
Page 42: Frequency
All manuals and user guides at all-guides.com PERIODIC MAINTENANCE AND LUBRICATION INTERVALS FREQUENCY 1000 km 6,000 km 12,000 km 18,000 km 24,000 km 0 km Annual Maintenance interven- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi) Part (0 mi) inspec- tion or control 1°...
Page 43 All manuals and user guides at all-guides.com PERIODIC MAINTENANCE AND LUBRICATION INTERVALS FREQUENCY 1000 km 6,000 km 12,000 km 18,000 km 24,000 km 0 km Annual Maintenance interven- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi) Part (0 mi) inspec- tion or control 1°...
Page 44 All manuals and user guides at all-guides.com PERIODIC MAINTENANCE AND LUBRICATION INTERVALS FREQUENCY 1000 km 6,000 km 12,000 km 18,000 km 24,000 km 0 km Annual Maintenance interven- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi) Part (0 mi) inspec- tion or control 1°...
Page 45: Engine/Air Filter
All manuals and user guides at all-guides.com ENGINE/AIR FILTER AIR FILTER REMOVAL/FITTING Position Description Quantity SCREW ST4.8X25 AIR BOX COVER GASKET AIR FILTER SCREW M5X19 WASHER PLATE PLATE AIR TEMPERATURE SENSOR RUBBER TIP SCREW CLIP - 44 -...
Page 46 All manuals and user guides at all-guides.com ENGINE/AIR FILTER AIR FILTER REMOVAL/FITTING Removal: Remove the passenger seat, using the wrench provided and remove the rider's seat with the release knob (A) Fig, A. Remove the side fairings from the tank and fuel tank. Remove the two screws fastening the plates (7-8) securing the ﬁ...
Page 47: Engine/Accelerator Cable Clearance
All manuals and user guides at all-guides.com ENGINE/ACCELERATOR CABLE CLEARANCE ACCELERATOR CABLE CLEARANCE ADJUSTMENT 19 20 18 17 16 Position Description Quantity PAIR OF REAR VIEW MIRRORS ACCELERATION CONTROL BOTTOM ACCELERATION CONTROL TOP ACCELERATION CONTROL RIGHT SWITCH GRIP END HANDLEBAR LEFT SWITCH LH GRIP CLUTCH CONTROL...
Page 48 All manuals and user guides at all-guides.com ENGINE/ACCELERATOR CABLE CLEARANCE ACCELERATOR CABLE CLEARANCE ADJUSTMENT Position Description Quantity ROCKER ARM CABLE GLAND TUBE GUIDE CLUTCH CONTROL LEVER RUBBER CLAMP SCREW NUT M6 SPECIAL NUT SPECIAL SCREW CLUTCH SWITCH SCREW SCREW M6X14 U-BOLT LEVER SUPPORT NOTE:...
Page 49: Engine/Clutch Cable
All manuals and user guides at all-guides.com ENGINE/CLUTCH CABLE CLUTCH CABLE CLEARANCE ADJUSTMENT Check: • clutch cable clearance (A) If necessary, adjust. Clutch cable clearance Clearance distance Clutch lever 3 - 4 mm Adjust: • Clutch cable clearance Handlebar side Loosen the ring nut "C"...
Page 50: Frame/Handlbar
All manuals and user guides at all-guides.com FRAME/HANDLBAR REAR VIEW MIRROR ADJUSTMENT The following procedure applies to both rear view mirrors. • Installation Tighten the mirror (15) on the lever body (32). Tighten the nut "B" as far as it will go. Adjust the mirror position by turning it to the required posi- tion.
Page 51: Engine/Engine Oil
All manuals and user guides at all-guides.com ENGINE/ENGINE OIL ENGINE OIL LEVEL CHECK Park: • the bike on a level surface. NOTE: • Place the motorbike on suitable stands so that the tyres are at the same height from ground level. •...
Page 52: Engine Oil Check
All manuals and user guides at all-guides.com ENGINE/ENGINE OIL ENGINE OIL CHECK Start: • the engine and leave it to warm up for a few minutes before switching it off. Remove: • the sump plug Place: • a suitable container under the magnetic cap "A" to recover the engine oil.
Page 53: Engine/Spark Plugs
All manuals and user guides at all-guides.com ENGINE/SPARK PLUGS REMOVING THE SPARK PLUGS The following procedure applies to all spark plugs. WARNING: Spark pugs must be checked and replaced when the engine is cool. Remove: Carry out the removal procedure for the air ﬁ lter, as described previously in the "Engine/Air Filter"...
Page 54: Spark Plug Installation
All manuals and user guides at all-guides.com ENGINE/SPARK PLUGS CHECKING THE SPARK PLUGS The following section contains a table with the typical conditions of spark plugs with the different causes of damage and any remedies. SOILED OVERHEATED SPARK PLUG SPARK PLUG Cause Solutions Cause...
Page 55: Frame/Brake Adjustment
All manuals and user guides at all-guides.com FRAME/BRAKE ADJUSTMENT FRONT BRAKE ADJUSTMENT Adjust: • the position of the brake lever Fig. A (the distance”x” between the accelerator and the brake lever). NOTE: Push the brake lever forwards to neutralise the thrust of the spring and at the same time, adjust the position, turning the ring nut, "y"...
Page 56 All manuals and user guides at all-guides.com FRAME/BRAKE ADJUSTMENT FRONT BRAKE ADJUSTMENT Adjust: • the position of the brake pedal, using the eccentric pin Fig.A. • Loosen the lock nut ”A” . • Unscrew the threaded pin "B" • Take out the return spring (C) connecting the eccentric pin (D) to the frame Fig.
Page 57: Frame/Brake Fluid Check
All manuals and user guides at all-guides.com FRAME/BRAKE FLUID CHECK CHECK THE LEVEL OF THE REAR BRAKE FLUID / TOP UP Park: • the bike on a level surface. NOTE: Place the motorbike on a stand and make sure that it is in the upright position.
Page 58 All manuals and user guides at all-guides.com FRAME/BRAKE FLUID CHECK CHECK THE LEVEL OF THE REAR BRAKE FLUID / TOP UP Park: • the bike on a level surface. NOTE: Place the motorbike on a stand and make sure that it is in the upright position.
Page 59: Frame/Brake Pad Check
All manuals and user guides at all-guides.com FRAME/BRAKE PAD CHECK FRONT AND REAR BRAKE PAD CONTROL The following procedure applies to all brake pads. Enable: • the brake Check: • The front brake pads Fig. A • The rear brake pads Fig. A •...
Page 60: Frame/Brake System Hose Check
All manuals and user guides at all-guides.com FRAME/BRAKE SYSTEM HOSE CHECK BRAKE HOSE CHECK The following procedure serves for all brake hoses and brake hose clamps. Check: • The front and rear brake hose. If there are any cracks/signs of wear or damage, replace. Check: •...
Page 61: Frame/Transmission Chain Adjustment
All manuals and user guides at all-guides.com FRAME/TRANSMISSION CHAIN ADJUSTMENT ADJUSTMENT NOTE: Do not inspect or adjust the transmission chain while the engine is running. NOTE: Check the feed of the transmission chain in the point where it seems most taut. 10÷-15 mm WARNING: If the transmission chain is too taut, this will cause the engine...
Page 62: Lubrication
All manuals and user guides at all-guides.com FRAME/TRANSMISSION CHAIN ADJUSTMENT LUBRICATION IMPORTANT NOTICE: The transmission chain is comprised of many parts that interact with one another. The chain needs to be subjected to the correct maintenance to prevent its rapid deterioration. We therefore recommend that the transmission chain be subject to maintenance, especially when used in very dusty areas.
Page 63: Frame/Steering Head Check And Adjustment
All manuals and user guides at all-guides.com FRAME/STEERING HEAD CHECK AND ADJUSTMENT CHECK/ADJUSTMENT Park: • The bike on a level surface. NOTE: Place the bike on suitable supports so that the front wheel is raised. Check: • The steering head Allow the front fork swing gently, holding it by the ends of the tubes Fig.
Page 64: Frame/Front Fork Check
All manuals and user guides at all-guides.com FRAME/STEERING HEAD CHECK AND ADJUSTMENT CHECK/ADJUSTMENT Check: • Make sure that the steering head is not loose and that there are no sticking points by turning the front fork to the end of travel in both directions. If there are any sticking points, remove the bottom steering base and check the top and bottom bearings.
Page 65: Frame/Rear Shock Absorber Check
All manuals and user guides at all-guides.com FRAME/REAR SHOCK ABSORBER CHECK SHOCK ABSORBER ADJUSTMENT NOTE: Support the motorbike correctly, so that it cannot fall over. Adjustment • Adjust the spring preload Fig. A The rear shock absorber is ﬁ tted with an adjustment ring nut for the pre-load of spring *A and a return ring nut (D) * (**)Shock absorber ring nut adjustment tool Code:......
Page 66: Frame/Rear And Front Tyre Check
All manuals and user guides at all-guides.com FRAME/REAR AND FRONT TYRE CHECK CHECK The following procedure applies to both tyres. Check: • Tyre pressure and if it is not within the speciﬁ ed levels, adjust. Fig.A. WARNING: Tyre pressure must be checked and adjusted only when the wheel is at ambient temperature.
Page 67: Electric System/Check And Battery Charge
All manuals and user guides at all-guides.com ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE BATTERY WARNING: Batteries can generate explosive gas containing nitrogen and they contain electrolyte, comprised of sulphuric acid, which is a poisonous and highly caustic substance. Therefore, the following precautions are required: •...
Page 68 All manuals and user guides at all-guides.com ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE BATTERY Disconnect: • The cables from the terminal batteries Fig. B IMPORTANT NOTICE: Disconnect the negative cable from the battery "A" ﬁ rst, then the positive cable "B" Fig. B Disconnect: •...
Page 69 All manuals and user guides at all-guides.com ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE BATTERY stabilises within 30 minutes or so after the charge is com- plete, before measuring the open circuit voltage. recharge ricarica Check voltage at open Controllare la tensione circuit a circuito aperto.
Page 70 All manuals and user guides at all-guides.com ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE BATTERY CHARGE METHOD USING A CHARGER WITH VARIABLE CURRENT (VOLTAGE) NOTE: Measure the voltage 30 minutes after switching off the equipment. Set the charge voltage to 16 ~ 17 V. (A lower setting will not give sufﬁ...
Page 71 All manuals and user guides at all-guides.com ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE BATTERY CHARGE METHOD USING A CHARGER WITH CONSTANT VOLTAGE NOTE: Measure the voltage 30 minutes after switching off the equipment. Set the charge time to a maximum of 20 hours. NOTE: To guarantee maximum performance and duration for the battery, we advise using electronic chargers,...
Page 72: Electrical System/Fuse Check
All manuals and user guides at all-guides.com ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE BATTERY Install: • The battery • Tighten the 2 screws “C” fastening the battery bracket. Connect: • The cables from the battery (to the battery terminals) IMPORTANT NOTICE: First connect the positive cable "B"...
Page 73 All manuals and user guides at all-guides.com ELECTRICAL SYSTEM/FUSE CHECK FUSES KEY TO FUSES Refer to Fig. C A. Fuel Pump :15A (blue) B. Fan:15A (blue) C. CD2 (power unit):15A (blue) D. CD1(power unit):15A (blue) E. Services: 40 A(red) Headlamps: 15A(blue) G.
Page 74: Electrical System/Head Lamp Replacement
All manuals and user guides at all-guides.com ELECTRICAL SYSTEM/HEAD LAMP REPLACEMENT REPLACEMENT The following procedure applies to headlamps only. IMPORTANT NOTICE: Given that the lamp reaches very high temperatures inside the light, we recommend not touching it until it has cooled. Remove: •...
Page 75: Electrical System/Headlamp Adjustment
All manuals and user guides at all-guides.com ELECTRICAL SYSTEM/HEADLAMP ADJUSTMENT REMOVAL/INSTALLATION Remove: • The two screws "A" fastening the front lamp to the plate Fig.C. • Lower the lamp. • Remove the screw "B" fastening the headlamp to the hinge of the lamp support "C"...
Page 76: Electrical System/Headlamp Adjustment
All manuals and user guides at all-guides.com ELECTRICAL SYSTEM/HEADLAMP ADJUSTMENT ADJUSTMENT To adjust the beam from the headlight correctly: • Place the vehicle about 10 metres away from a vertical wall on a perfectly ﬂ at surface. Fig. A. • Sit on the bike in the rider's position.
Page 77: Electrical System/Rear Lamp Replacement
All manuals and user guides at all-guides.com ELECTRICAL SYSTEM/REAR LAMP REPLACEMENT REPLACEMENT Remove: • The passenger seat "A" at the back, using the tool provided Fig.A. • The two fastening screws of the plastic tail section "B" to the side tail sections "C" and "D" •...
Page 78: Electrical System/Rear Indicator Replacement
All manuals and user guides at all-guides.com ELECTRICAL SYSTEM/REAR INDICATOR REPLACEMENT REPLACEMENT The following procedure applies to both rear indicators. Remove: • The passenger seat at the back, using the tool provided Fig.A. • Remove the protective cap • Disconnect the electrical connections "A" of the indicators, orange-green and illustrated in Fig.
Page 79: Electrical System/Front Indicator Replacement
All manuals and user guides at all-guides.com ELECTRICAL SYSTEM/FRONT INDICATOR REPLACEMENT REPLACEMENT The following procedure applies to both front indicators. Remove: • The two screws "A" fastening the front lamp to the plate Fig.F. • Lower the lamp Fig. G. •...
Page 80 All manuals and user guides at all-guides.com CHAS CHAPTER 4 CHAS Frame - 79 -...
Page 81 All manuals and user guides at all-guides.com CHAS CHAPTER 4 FRAME FRONT WHEEL AND BRAKE DISCS ..............81 FRONT WHEEL REMOVAL ........................81 REMOVAL/INSTALLATION OF BRAKE DISCS ..................82 CHECK OF BRAKE DISCS ........................84 WHEEL AXLE CHECK ..........................85 CHECK/REPLACEMENT OF WHEEL BEARINGS ...................86 FRONT WHEEL INSTALLATION ......................87 REAR WHEEL AND BRAKE DISC ................
Page 82 All manuals and user guides at all-guides.com CHAS FRAME ........................138 FRAME FITTING ............................138 REAR FRAME FITTING ...........................141 LICENCE PLATE HOLDER FITTING .......................143 LICENCE PLATE HOLDER REMOVAL ....................144 CYCLING ........................ 145 STAND FITTING: ............................145 STAND REMOVAL ...........................146 REAR FOOTREST INSTALLATION ......................147 REAR FOOTREST REMOVAL .........................148 LEFT FRONT FOOTREST INSTALLATION .....................149 RIGHT FRONT FOOTREST FITTING ......................151...
Page 83: Front Wheel And Brake Discs
All manuals and user guides at all-guides.com CHAS 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: •...
Page 84 All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND BRAKE DISCS REMOVAL/INSTALLATION OF BRAKE DISCS Position Description Quantity COUNTERSUNK HEX-HEAD SCREW M8X16 8.8 ZB FRONT BRAKE DISC LEFT SHIM FRONT WHEEL RIM VALVE FRONT WHEEL PIN ADHESIVE - 83 -...
Page 85: Removal/Installation Of Brake Discs
All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND BRAKE DISCS REMOVAL/INSTALLATION OF BRAKE DISCS Removal: • Once the wheel has been removed from the fork, remove the 6 screws (1) fastening the two discs (2). Fig A In case of replacement of the two discs, proceed as described: Fitting: •...
Page 86: Check Of Brake Discs
All manuals and user guides at all-guides.com CHAS 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. If out of speciﬁ...
Page 87: Wheel Axle Check
All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND BRAKE DISCS CHECK OF BRAKE DISCS Measure: • Brake disc thickness. • Measure the brake disc thickness in several different points Fig.D. • If outside speciﬁ cations, replace. Brake disc Wear limits Front Rear...
Page 88: Check/Replacement Of Wheel Bearings
All manuals and user guides at all-guides.com CHAS 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 extrac- tor Fig.B.
Page 89: Front Wheel Installation
All manuals and user guides at all-guides.com CHAS FRONT WHEEL AND BRAKE DISCS FRONT WHEEL INSTALLATION Fitting: • Insert the full wheel, complete with discs, between the two front fork stems. • Insert the bushing(3) in the seat at base of the left stem •...
Page 90: Rear Wheel And Brake Disc
All manuals and user guides at all-guides.com CHAS REAR WHEEL AND BRAKE DISC REAR WHEEL REMOVAL 11 11 Position Description Quantity NUT M24 ELASTIC RING BEARING SHIM REAR WHEEL RIM (BLACK) SCREW SPROCKET CHAIN 137ZRPK 118 LINKS SPROCKET SUPPORT FLANGE SCREW (M10X41) FLEXIBLE COUPLING BUSHING...
Page 91 All manuals and user guides at all-guides.com CHAS 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: •...
Page 92: Sprocket And Rear Brake Disc Removal
All manuals and user guides at all-guides.com CHAS REAR WHEEL AND BRAKE DISC SPROCKET AND REAR BRAKE DISC REMOVAL Brake disc removal: • Once the rear wheel has been removed, take out the brake disc. • Unscrew the 6 fastening screws (6) and take out the brake disc (17) Fig.
Page 93: Wheel Axle Check
All manuals and user guides at all-guides.com CHAS REAR WHEEL AND BRAKE DISC WHEEL AXLE CHECK Check: • Wheel axle. • Roll the wheel axle “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 94: Check/Replacement Of Wheel Bearings
All manuals and user guides at all-guides.com CHAS 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.B.
Page 95: Sprocket Check And Replacement
All manuals and user guides at all-guides.com CHAS 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...
Page 96: Back Tyre Installation
All manuals and user guides at all-guides.com CHAS REAR WHEEL AND BRAKE DISC BACK TYRE INSTALLATION Fit: • Pre-assemble the bracket supporting the brake (11), inser- ting the parts (13) and (12). 13 12 • Insert the bushing (16) on the sprocket side and (4) on the brake disc FigB.
Page 97: Front And Rear Brakes
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REMOVAL AND INSTALLATION OF FRONT BRAKE PADS Removal: • Use a Philips screwdriver to remove the centering pin “A” of the pads Fig.A. NOTE During the extraction phase of the pin “A”, it is necessary to hold down the safety spring “B”...
Page 98: Removal And Installation Of Rear Brake Pads
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REMOVAL AND INSTALLATION OF REAR BRAKE PADS Removal: • Remove the two fastening screws “A” from the brake calli- per Fig. A. • Remove the centering pin “B” from the pads, freeing it from the safety O-ring “C”.
Page 99: Front Brake Pump Removal
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES FRONT BRAKE PUMP REMOVAL Position Description Quantity RADIAL PAD PAIR FRONT BRAKE HOSE RIGHT BRAKE CALLIPER (RADIAL) LEFT FRONT CALLIPER (RADIAL) GASKET SPECIAL SCREW RUBBER TIP SCREW SPECIAL SCREW SCREW FRONT BRAKE PUMP SELF-LOCKING NUT...
Page 100 All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES FRONT BRAKE PUMP REMOVAL Position Description Quantity DRAIN DRAIN PLUG Removal: NOTE Drain out the brake ﬂ uid before proceeding with these opera- tions. Follow the disassembly sequence shown below: •...
Page 101: Rear Brake Pump Removal
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REAR BRAKE PUMP REMOVAL Position Description Quantity REAR BRAKE HOSE SCREW SPECIAL SCREW REAR BRAKE CALLIPER REAR PAD PAIR REAR BRAKE PUMP GASKET REAR IDROSTOP - 100 -...
Page 102 All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REAR BRAKE PUMP REMOVAL Removal: NOTE Drain out the brake ﬂ uid before proceeding with these opera- tions. Follow the disassembly sequence shown below: • Remove the Idrostop (8) and the relevant gaskets (7). •...
Page 103: Front Brake Pump Installation
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES FRONT BRAKE PUMP INSTALLATION Position Description Quantity RADIAL PAD PAIR FRONT BRAKE HOSE RIGHT BRAKE CALLIPER (RADIAL) LEFT FRONT CALLIPER (RADIAL) GASKET SPECIAL SCREW RUBBER TIP SCREW SPECIAL SCREW SCREW FRONT BRAKE PUMP SELF-LOCKING NUT...
Page 104 All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES FRONT BRAKE PUMP INSTALLATION Position Description Quantity DRAIN DRAIN PLUG Fitting: Follow the assembly sequence shown below: WARNING Before installing, clean all of the internal parts of the brake, and lubricate them with clean or new brake ﬂ...
Page 105: Rear Brake Pump Installation
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REAR BRAKE PUMP INSTALLATION Position Description Quantity REAR BRAKE HOSE SCREW SPECIAL SCREW REAR BRAKE CALLIPER REAR PAD PAIR REAR BRAKE PUMP GASKET REAR IDROSTOP - 104 -...
Page 106 All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REAR BRAKE PUMP INSTALLATION Fitting: Follow the assembly sequence shown below: 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.
Page 107: Front Brake Calliper Tightness
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES FRONT BRAKE CALLIPER TIGHTNESS Removal: The following procedure is applied to both brake callipers. NOTE Before removing the brake calliper, drain the brake ﬂ uid from inside the brake circuit. Detach: •...
Page 108: Rear Brake Calliper
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REAR BRAKE CALLIPER Removal: NOTE Before removing the brake calliper, drain the brake ﬂ uid from inside the brake circuit. Detach: • the special screw (A) and gaskets (B) Fig.A. •...
Page 109: Check The Front And Rear Callipers
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES CHECK THE FRONT AND REAR CALLIPERS Check: • The brake calliper pistons. If there are any rust spots/lines/signs of wear, replace the brake calliper pistons. • The brake calliper cylinders. If there are any lines/signs of wear, replace the whole brake calliper.
Page 110: Front Brake Calliper Installation
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES FRONT BRAKE CALLIPER INSTALLATION Removal: The following procedure is applied to both brake callipers. 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, as the piston gaskets would tend to swell and warp.
Page 111 All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES FRONT BRAKE CALLIPER INSTALLATION IMPORTANT NOTICE Brake ﬂ uid can damage painted surfaces and plastic parts. Always clean up any brake ﬂ uid spills immediately. Bleed: • The brake circuit Check: •...
Page 112: Rear Brake Calliper Installation
All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REAR BRAKE CALLIPER INSTALLATION Fitting: 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, as the piston gaskets would tend to swell and warp.
Page 113 All manuals and user guides at all-guides.com CHAS FRONT AND REAR BRAKES REAR BRAKE CALLIPER INSTALLATION IMPORTANT NOTICE Brake ﬂ uid can damage painted surfaces and plastic parts. Always clean up any brake ﬂ uid spills immediately. Bleed: • The brake circuit Check: •...
Page 114: Front Fork
All manuals and user guides at all-guides.com CHAS FRONT FORK FRONT FORK STEM REMOVAL Position Description Quantity RIGHT RADIAL STEM ASSEMBLY LEFT RADIAL STEM ASSEMBLY COUNTERSUNK HEX-HEAD SCREW M8X25 ZB SPECIAL SCREW COUNTERSUNK HEX-HEAD SCREW M8X25 ZB HANDLEBAR BRACKET STEERING BASE OIL SEAL STEERING HEAD STEERING PIN RING NUT...
Page 115 All manuals and user guides at all-guides.com CHAS FRONT FORK FRONT FORK STEM REMOVAL Position Description Quantity COMPLETE FRONT FORK SCREW 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.
Page 116: Front Fork Stem Disassembly
All manuals and user guides at all-guides.com CHAS 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 •...
Page 117 All manuals and user guides at all-guides.com CHAS FRONT FORK FRONT FORK STEM DISASSEMBLY Slide out from inside the sleeve Fig. C: • The spring tip (2) • The fork spring (5) • The top spring guide bushing (6) • The shim(7) •...
Page 118 All manuals and user guides at all-guides.com CHAS 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 athead screw driver.
Page 119: Front Fork Stem Inspection
All manuals and user guides at all-guides.com CHAS 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 become weaker with time and could be dangerous.
Page 120: Front Fork Stem Assembly
All manuals and user guides at all-guides.com CHAS 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. Before reﬁ tting, check the condition of bushings and guides; check the guide bushings;...
Page 121 All manuals and user guides at all-guides.com CHAS FRONT FORK FRONT FORK STEM ASSEMBLY Fit: • The clip on the oil seal (13) using a small ﬂ athead screwdri- ver, making sure that it is perfectly inserted into the special raceway and taking care not to scratch the fork stem Fig.
Page 122 All manuals and user guides at all-guides.com CHAS 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. •...
Page 123: Front Fork Stem Fitting
All manuals and user guides at all-guides.com CHAS FRONT FORK FRONT FORK STEM FITTING The following procedure is applied to both front fork stems. Fit: • The front fork stems (A) Fig.A. tighten provisionally • The stop screws (B) on the bottom steering plate Fig. A. NOTE Check the assembly position “x”...
Page 124: Handlebar
All manuals and user guides at all-guides.com CHAS HANDLEBAR HANDLEBAR REMOVAL 19 20 18 17 16 Position Description Quantity PAIR OF REAR VIEW MIRRORS ACCELERATOR CONTROL BOTTOM ACCELERATOR CONTROL TOP ACCELERATOR CONTROL RIGHT SWITCH GRIP END HANDLEBAR LEFT SWITCH LH GRIP CLUTCH CONTROL CLUTCH CABLE ACCELERATOR OPENING CABLE...
Page 125 All manuals and user guides at all-guides.com CHAS HANDLEBAR HANDLEBAR REMOVAL Position Description Quantity ROCKER ARM CABLE GLAND TUBE GUIDE CLUTCH CONTROL LEVER RUBBER CLIP SCREW NUT M6 SPECIAL NUT SPECIAL SCREW CLUTCH SWITCH SCREW SCREW M6X14 BRACKET LEVER SUPPORT Park the bike on a level surface.
Page 126: Handlebar Inspection
All manuals and user guides at all-guides.com CHAS HANDLEBAR HANDLEBAR REMOVAL Take out the handlebar, loosening the four fastening screws (A) of the handlebar clevis (B) Fig.C. HANDLEBAR HANDLEBAR INSPECTION Check: • The handlebar (7) 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.
Page 127: Handlebar Installation
All manuals and user guides at all-guides.com CHAS HANDLEBAR HANDLEBAR INSTALLATION Proceed to install, following the steps for removal in reverse order, but taking care to observe the instructions below: Fit: • The switch on the right (5) and left (8) handlebars, taking care to align the projecting part “A”...
Page 128: Steering Head
All manuals and user guides at all-guides.com CHAS STEERING HEAD REMOVAL OF THE TOP AND BOTTOM STEERING BASE Park the bike on a level surface. IMPORTANT NOTICE Prop the bike on suitable supports so that it cannot fall. Remove: • The stop screws (3) on the top steering plate Fig.
Page 129 All manuals and user guides at all-guides.com CHAS STEERING HEAD REMOVAL OF THE TOP AND BOTTOM STEERING BASE Remove: • The cap (4) with the special tool Fig. B (**) steering head wrench Code:...... Loosen: • The steering pin ring nut •...
Page 130: Top And Bottom Steering Base Inspection
All manuals and user guides at all-guides.com CHAS STEERING HEAD TOP AND BOTTOM STEERING BASE INSPECTION Wash: • The bearings • The bearing tracks NOTE Use special washing solvent. Check: • The bearings(13) Fig. A • The dust seal rings (12) Fig. A ]If there is any spotting/damage, replace.
Page 131: Top And Bottom Steering Base Fitting
All manuals and user guides at all-guides.com CHAS STEERING HEAD TOP AND BOTTOM STEERING BASE FITTING Lubricate: • The bearings Fig. A. • The dust seal rings Fig. A. • The bearing tracks Fig. A. NOTE Use special grease. Fit: •...
Page 132: Rear Shock Absorber
All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVAL 13 12 Position Description Quantity TOP CHAIN SLIDE SCREW BOTTOM CHAIN SLIDE CHAIN COVER SCREW (M6X8) SCREW M6X25 GUIDE BUSHING REAR MUD GUARD WASHER BRACKET PLATE SHIM O-RING...
Page 133: Rear Shock Absorber Check
All manuals and user guides at all-guides.com CHAS 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: • the screws (16) and (18) Fig. A NOTE Hold the swinging arm to make sure it does not fall.
Page 134: Rear Shock Absorber Fitting
All manuals and user guides at all-guides.com CHAS REAR SHOCK ABSORBER REAR SHOCK ABSORBER FITTING Fit: • the screw (18) FigC and its respective washer (19) and tighten to the following torque: Torque 60 N*m • the screw (16) FigC and its respective washer (19) and tighten to the washer (15) and the following torque: Torque 60 N*m - 133 -...
Page 135: Transmission Chain And Swinging Arm
All manuals and user guides at all-guides.com CHAS TRANSMISSION CHAIN AND SWINGING ARM TRANSMISSION CHAIN REMOVAL Park the bike on a level surface. IMPORTANT NOTICE Place the bike on a suitable support stand so that it cannot fall and the rear wheel is raised. Detach: •...
Page 136 All manuals and user guides at all-guides.com CHAS TRANSMISSION CHAIN AND SWINGING ARM TRANSMISSION CHAIN INSPECTION Lubricate: • The transmission chain NOTE Use speciﬁ c grease Check: • Driving gear • Rear toothed sprocket If more than 1/4 of each tooth (4) is worn, replace the transmis- sion chain sprockets all together.
Page 137 All manuals and user guides at all-guides.com CHAS TRANSMISSION CHAIN AND SWINGING ARM TRANSMISSION CHAIN REPLACEMENT Loosen: • The transmission chain This chain uses a transmission chain with master link with safety side plate. • Use the special tool, according to the chain manufacturer’s speciﬁ...
Page 138: Swinging Arm Fitting
All manuals and user guides at all-guides.com CHAS TRANSMISSION CHAIN AND SWINGING ARM SWINGING ARM FITTING Position Description Quantity SPECIAL SCREW BUSHING BEARING INTERNAL SHIM SHIM SCREW M8X92 BUSHING NUT M8 HALF SWINGER ARM (RIGHT) HALF SWINGER ARM (LEFT) SPECIAL PLATE SCREW M5X10 NUT M8 SCREW M8...
Page 139 All manuals and user guides at all-guides.com CHAS TRANSMISSION CHAIN AND SWINGING ARM SWINGING ARM FITTING Fit: • Swinging arm assembly (A) • Swinging arm pin (5) NOTE Use speciﬁ c grease during assembly. • Line up the swinging arm pin seats (A) on both sides of the pin (5) Fig.
Page 140: Frame
All manuals and user guides at all-guides.com CHAS FRAME FRAME FITTING Position Description Quantity FRAME TEF SCREW M6X14 8.8 ZB SCREW M6X16 SCREW BOTTOM COVER RUBBER TIP FRONT RIGHT HALF FRAME SCREW (M10X45) WASHER FRONT LEFT HALF FRAME SCREW (M10X75) NUT M10 BUSHING SCREW...
Page 141 All manuals and user guides at all-guides.com CHAS FRAME FRAME FITTING Position Description Quantity PLATE RIVET SCREW M10X22 TOP FRAME BRACKET SCREW M6X20 FRAME BRACKET SCREW M6X25 LEFT BRACKET BRACKET RIGHT BRACKET SCREW M6X60 SCREW (M6×10) WASHER VIBRATION DAMPING PAD IMPORTANT NOTICE Place the engine on a suitable support, so that all frame parts can be ﬁ...
Page 142 All manuals and user guides at all-guides.com CHAS FRAME FRAME FITTING Apply: • Insert the pin (X) of the swinging arm Fig. C. Fit: • The frame (1) to the two front half frames, right and left, applying the shims and screws (34), and (18) on both sides Fig.
Page 143: Rear Frame Fitting
All manuals and user guides at all-guides.com CHAS FRAME REAR FRAME FITTING Position Description Quantity SCREW M8X35 WASHER COLUMN SCREW M8X40 RUBBER TIP BATTERY SUPPORT COLUMN RUBBER BUSHING BUSHING REAR FRAME THERMAL PROTECTION THERMAL PROTECTION FAIRING CLOSURE LEFT INSULATING PLATE PLATE SCREW RIGHT INSULATING PLATE...
Page 144 All manuals and user guides at all-guides.com CHAS FRAME REAR FRAME FITTING Position Description Quantity SCREW M8X55 SCREW (M6X8) CABLE GLAND RIGHT HEAT REFLECTIVE SHIELD LEFT HEAT REFLECTIVE SHIELD SADDLE OPENING CABLE SADDLE OPENING CABLE ELASTIC CLIP HEAT REFLECTIVE SHIELD Fit: •...
Page 145: Licence Plate Holder Fitting
All manuals and user guides at all-guides.com CHAS FRAME LICENCE PLATE HOLDER FITTING Position Description Quantity LH LICENCE PLATE HOLDER RH LICENCE PLATE HOLDER SCREW (M6X12) SCREW M6X25 LICENCE PLATE HOLDER SUPPORT PLATE LICENCE PLATE HOLDER REFLECTOR BAND SCREW TBEI M5X16 8.8 ZB RUBBER TIP BUSHING SPECIAL SCREW...
Page 146: Licence Plate Holder Removal
All manuals and user guides at all-guides.com CHAS FRAME LICENCE PLATE HOLDER FITTING Fit: • The licence plate holder assembly (6) screwing in the two special screws (15) complete with bushing (14) and rubber tip (13) through the two exhaust pipe shells to the silencer Fig.
Page 147: Cycling
All manuals and user guides at all-guides.com CHAS CYCLING STAND FITTING: Position Description Quantity SIDE STAND SPECIAL SCREW SCREW (M6X8) STAND SUPPORT PLATE SIDE SCREW M10X35 INTERNAL SCREW EXTERNAL SCREW NUT M12 WASHER SIDE STAND SENSOR SCREW BELLEVILLE WASHER - 146 -...
Page 148: Stand Removal
All manuals and user guides at all-guides.com CHAS CYCLING STAND FITTING: Fit: • The stand support plate (4) to the left front semi-frame, using the two fastening screws (X) (5) Fig. A NOTE Apply thread locker to each of the screws. •...
Page 149: Rear Footrest Installation
All manuals and user guides at all-guides.com CHAS CYCLING REAR FOOTREST INSTALLATION Position Description Quantity REAR FOOTREST SUPPORT PLATE LH ELASTIC RING PLATE BALL SPRING LH REAR FOOTREST SCREW M4X10 LH FOOTREST RUBBER STOP PIN FOR ZB FOOTREST LH RUBBER FOOTREST COVER COUNTERSUNK HEX-HEAD SCREW M8X25 ZB RH FOOTREST RUBBER STOP RH RUBBER FOOTREST COVER...
Page 150: Rear Footrest Removal
All manuals and user guides at all-guides.com CHAS CYCLING REAR FOOTREST INSTALLATION Fit: • The left (1) and right (15) footrest plates. NOTE Apply thread locker to each of the screws. • Tighten the two screws (11) with the following torque: Torque 25 N*m NOTE If the rubber footrest cover (13) is worn, replace.
Page 151: Left Front Footrest Installation
All manuals and user guides at all-guides.com CHAS CYCLING LEFT FRONT FOOTREST INSTALLATION Position Description Quantity LH FRONT FOOTREST SPRING LH FRONT FOOTREST SUPPORT PLATE ELASTIC RING COUNTERSUNK HEX-HEAD SCREW M8X25 ZB ELASTIC WASHER BUSHING SCREW SCREW M6X20 GEAR PEDAL SCREW M6X42 NUT M6 BALL JOINT...
Page 152 All manuals and user guides at all-guides.com CHAS CYCLING LEFT FRONT FOOTREST INSTALLATION Fit: • The left front footrest plate (4) Fig. A NOTE Apply thread locker to each of the fastening screws (6). • Tighten the two screws (6) with the following torque: 210 mm Torque 25 N*m NOTE...
Page 153: Right Front Footrest Fitting
All manuals and user guides at all-guides.com CHAS CYCLING RIGHT FRONT FOOTREST FITTING Position Description Quantity SCREW BUSHING ELASTIC WASHER ELASTIC RING ECCENTRIC BALL JOINT THREADED PIN SPRING THREADED PIN WASHER SCREW M4X10 RH FOOTREST RUBBER STOP RIGHT RUBBER FOOTREST COVER RH FRONT FOOTREST SUPPORT PLATE RH FRONT FOOTREST SPRING...
Page 154: Right Front Footrest Removal
All manuals and user guides at all-guides.com CHAS CYCLING RIGHT FRONT FOOTREST FITTING Fit: • The right front footrest support plate (16) Fig. A. NOTE Apply thread locker to each of the fastening screws (21). • Tighten the two screws (21) with the following torque: Torque 25 N*m NOTE If the right rubber footrest cover (15) is worn, replace it.
Page 155: Exhaust
All manuals and user guides at all-guides.com CHAS EXHAUST EXHAUST INSTALLATION Position Description Quantity EXHAUST GASKET NUT M8 EXHAUST MANIFOLD GRAPHITE GASKET SCREW M8X45 SCREW M8X20 MANIFOLD FITTING (EXHAUST) SILENCER WASHER WASHER SCREW M10X22 SCREW M6X25 RUBBER TIP BRACKET TOP BUSHING LAMBDA PROBE ELASTIC WASHER WASHER...
Page 156 All manuals and user guides at all-guides.com CHAS EXHAUST EXHAUST INSTALLATION Position Description Quantity LH THERMAL PROTECTION SCREW M6x10 LH EXHAUST PIPE PROTECTION LH EXHAUST PIPE END PIECE WASHER SCREW M6X40 RH EXHAUST PIPE END PIECE RH EXHAUST PIPE PROTECTION RH THERMAL PROTECTION SNAP-ON CLIP (M6) SCREW (M6×19.2)
Page 157: Exhaust Assembly Removal
All manuals and user guides at all-guides.com CHAS EXHAUST EXHAUST INSTALLATION Assemble: • The silencer (8) with the bracket (14) Fig. D • Apply thread locker to the screws (11) and tighten to the following torque: Torque 13 N*m Fit: •...
Page 158: Fairing
All manuals and user guides at all-guides.com CHAS FAIRING EXHAUST PIPE PROTECTION INSTALLATION Fit: • The two exhaust pipe protections (23) and (28), complete with internal thermal protections, Fig. A, inserting them into the silencer. • Tighten the two screws (22) Fig. A into the top section. •...
Page 159: Front Mud Guard Installation
All manuals and user guides at all-guides.com CHAS FAIRING FRONT MUD GUARD INSTALLATION Position Description Quantity FRONT MUD GUARD SCREW SCREW BRACKET NYLON WASHER “T” BUSHING NUT M5 BOTTOM MUD GUARD RIGHT BRACKET LEFT BRACKET SCREW M5X12 WASHER ELASTIC WASHER WASHER SNAP-ON CLIP (M5) TUBE CLAMP...
Page 160: Front Mud Guard Removal
All manuals and user guides at all-guides.com CHAS FAIRING FRONT MUD GUARD INSTALLATION Assemble: • The brackets (4) and the respective screws (3) at the base of the two front forks’ feet. Fit: • The front mud guard (1) with the respective fastening screws (2) on both sides Fig.
Page 161: Rear Mud Guard Installation
All manuals and user guides at all-guides.com CHAS FAIRING REAR MUD GUARD INSTALLATION 13 12 Position Description Quantity BOTTOM CHAIN SLIDE SCREW TOP CHAIN SLIDE CHAIN COVER SCREW (M6X8) SCREW M6X25 GUIDE BUSHING REAR MUD GUARD WASHER BRACKET PLATE SHIM O-RING BUSHING SCREW M10X70...
Page 162: Rear Mud Guard Removal
All manuals and user guides at all-guides.com CHAS FAIRING REAR MUD GUARD INSTALLATION Assemble: • The rear mud guard (8) with the respective fastening screws (2) Fig. A NOTE Apply thread locker to the respective screws. FAIRING REAR MUD GUARD REMOVAL Removal: •...
Page 163: Tank Cap Fitting
All manuals and user guides at all-guides.com CHAS FAIRING TANK CAP FITTING Position Description Quantity SCREW SCREW OPENING RUBBER GASKET FUEL TANK SCREW M6X70 PLATE BUSHING RUBBER TIP WASHER SCREW SPRING PIPE FUEL TANK LEVEL PROBE O-RING SCREW FUEL PUMP FUEL FILTER HOSES - 162 -...
Page 164 All manuals and user guides at all-guides.com CHAS FAIRING TANK CAP FITTING Assemble: • The rubber gasket (4) to the fuel tank (5) • Apply the opening (3) over the gasket (4) • Tighten the safety screw (1) and lock the opening. •...
Page 165: Tank Fitting
All manuals and user guides at all-guides.com CHAS FAIRING TANK FITTING Assemble: • The hoses (19) correctly, as shown in Fig. B • The tank (5) to the frame, fastening the screw (6) ﬁ rst Fig. C • The level gauge in the tank (A) •...
Page 166: Tank Cover Fitting
FUEL TANK CAP LEFT PANEL BOTTOM LEFT PANEL FRONT TANK PAD SCREW ST4.2X13 WASHER RUBBER TIP STEERING BLOCK COVER LOCK CAP BRACKET SCREW SNAP-ON CLIP (M6) RIGHT PANEL RIGHT BOTTOM PANEL SCREW (ST4.2×13) SCREW (M6×19.2) BENELLI EMBLEM SCREW - 165 -...
Page 167: Tank Cover Removal
All manuals and user guides at all-guides.com CHAS FAIRING TANK COVER FITTING Apply: • The two snap-on clips (12) to the frame Fig. A Secure: • The front pad of the tank (4) to the tank cap (1), securing with the two screws (5) Fig. B Pre-assemble: •...
Page 168: Fairing Fitting
All manuals and user guides at all-guides.com CHAS FAIRING FAIRING FITTING Position Description Quantity SCREW RH EXTERNAL TOP FAIRING FAIR. RH EXTERNAL BOTTOM TANK CAP FUEL RIGHT RIGHT BRACKET RH COVER LH COVER LEFT BRACKET TANK CAP FUEL LEFT FAIR. LH EXTERNAL BOTTOM LH EXTERNAL TOP FAIRING SCREW M6X14 SNAP-ON CLIP (M6)
Page 169: Fairing Removal
All manuals and user guides at all-guides.com CHAS FAIRING FAIRING FITTING Pre-assemble: • The top right external fairing (2) with the bottom right exter- nal fairing (3) and apply the right cover (6). • The top left external fairing (11) with the bottom left external fairing (10) and apply the left cover (7).
Page 170: Cowl Fitting
SCREW ST4,2X9,5 SNAP-ON CLIP (M5) SCREW M5X10 FAIRING CLOSURE SCREW ST4,2X12 "BENELLI ø 40” DECAL Pre-assemble: • The right side (1) and the left side (3) to the cowl (2). • Secure the assembled dome to the front light group, with the ﬁ...
Page 171: Complete Headlamp Fitting
All manuals and user guides at all-guides.com CHAS FAIRING COMPLETE HEADLAMP FITTING Position Description Quantity HEADLAMP SCREW HEADLAMP SUPPORT SCREW M6X60 WASHER SHIM BUSHING SCREW LAMP BUSHING VIBRATION DAMPING RUBBER SCREW M6X20 DIRECTION INDICATORS FRONT LH WASHER LH PLATE DIRECTION INDICATORS FRONT RH BUSHING SCREW M6X25 SNAP-ON CLIP...
Page 172: Full Rear Light Removal
All manuals and user guides at all-guides.com CHAS FAIRING COMPLETE HEADLAMP FITTING Position Description Quantity WASHER ELASTIC WASHER LICENCE PLATE LIGHT SCREW ST4,2X9,5 DIRECTION INDICATORS REAR RH RH PLATE Pre-assemble: • The cowl to the assembled headlamp. Secure: • The cowl to the frame with the screw (4) of the headlamp support (3) Fig.
Page 173 All manuals and user guides at all-guides.com CHAS FAIRING TAILPIECE FITTING Position Description Quantity BOTTOM LEFT PANEL BATTERY BOX RIGHT BOTTOM PANEL RIGHT TAILPIECE (WHITE) CENTRAL TAILPIECE (WHITE) LEFT TAILPIECE (WHITE) SCREW M8X25 SNAP-ON CLIP (M6) SCREW TBEI M6X14 8.8 ZB SCREW (M6×15.2) NYLON WASHER SCREW ST4,2X9,5...
Page 174: Tailpiece Fitting
PASSENGER SEAT RH REAR HANDLE LH REAR HANDLE HEAT REFLECTIVE SHIELD VIBRATION DAMPING RUBBER THERMAL PROTECTION "BENELLI” LOGO ADHESIVE RH TAILPIECE ADHESIVE BN600i BW SCREW LH TAILPIECE ADHESIVE BN600i BW Assembly • Assemble the left tailpiece (6) and the right piece (4) with the fastening screws (10) at the bottom and (14) and the interme- diate part of the frame.
Page 175 All manuals and user guides at all-guides.com CHAPTER 5 Engine - 174 -...
Page 176 All manuals and user guides at all-guides.com CHAPTER 5 ENGINE HEAD TIMING GEAR ..................... 176 HEAD TIMING GEAR COVER REMOVAL ....................177 REMOVAL OF THE DISTRIBUTION CHAIN TENSIONER ..............178 INLET CAMSHAFT REMOVAL ........................179 REMOVAL OF CAMSHAFT, OUTLET SIDE ....................179 CAMSHAFT CHECK ..........................180 OUTLET CAMSHAFT FITTING ........................181 INLET CAMSHAFT FITTING ........................182 CHAIN SLIDE REMOVAL .........................183...
Page 177 All manuals and user guides at all-guides.com CHAPTER 5 OIL PUMP REMOVAL ..........................219 OIL PUMP ASSEMBLY ..........................220 OIL FILTER REMOVAL/INSTALLATION ....................220 STARTING ......................221 STARTER MOTOR REMOVAL/INSTALLATION ..................222 FLYWHEEL REMOVAL ..........................223 FLYWHEEL FITTING ..........................224 PHASE SENSOR INSTALLATION/ADJUSTMENT ..................226 SUPPLY........................227 THROTTLE VALVE REMOVAL ........................228 THROTTLE VALVE FITTING ........................229 - 176 -...
Page 178: Head Timing Gear
All manuals and user guides at all-guides.com HEAD TIMING GEAR HEAD TIMING GEAR COVER REMOVAL Position Description Quantity DISTRIBUTION GEAR RUBBER TIP O-RING SCREW RUBBER TIP SCREW (M6X16) WASHER M.6 BRACKET PLUG DISTRIBUTION GEAR COVER DIAPHRAGM DIAPHRAGM SCREW (M6X14) DISTRIBUTION GEAR COVER GASKET PLUG TOP CHAIN SLIDES DISTRIBUTION CHAIN...
Page 179 All manuals and user guides at all-guides.com HEAD TIMING GEAR HEAD TIMING GEAR COVER REMOVAL Position Description Quantity SCREW (M7) PIN (3X6) BOTTOM CHAIN SLIDE GASKET CHAIN SLIDE CHAIN TENSIONER SCREW (M6X25) COVER COIL SPARK PLUG Once the engine has been moved to the relevant support, disas- semble the parts as described below: Remove the bracket (8) by loosening the screw (6) and washer (7) Fig.
Page 180: Head Timing Gear Cover Removal
All manuals and user guides at all-guides.com HEAD TIMING GEAR HEAD TIMING GEAR COVER REMOVAL As soon as the timing gear cover (10) has been lifted, take care with the removal of the cover seal (14) Fig.E. NOTE If the timing gear cover seal (10) should be broken, it must be replaced with an original When the cover is being reﬁ...
Page 181: Inlet Camshaft Removal
All manuals and user guides at all-guides.com HEAD TIMING GEAR INLET CAMSHAFT REMOVAL Remove the 2 fastening screws (20) of the distribution gears (18) Fig.A. Proceed to take out 10 fastening screws from the underframes supporting the inlet camshaft Fig. B. Take out the inlet camshaft NOTE During this stage of disassembly, take care to mark the positions...
Page 182: Camshaft Check
All manuals and user guides at all-guides.com HEAD TIMING GEAR CAMSHAFT CHECK Make a visual check of the camshaft lobes and if there is any blue discolouration/blotching or lines, replace. • Measure the size of the lobes. If the measurements taken (Fig. E) are not within the speciﬁ ca- tions, proceed with shaft replacement.
Page 183: Outlet Camshaft Fitting
All manuals and user guides at all-guides.com HEAD TIMING GEAR OUTLET CAMSHAFT FITTING Insert the relevant tool* inside the spark plug hole, as described previously, to check the TDC Fig. A. (*) Engine tuning tool Code:...... Once the TDC has been established, proceed to assemble the outlet camshaft.
Page 184: Inlet Camshaft Fitting
All manuals and user guides at all-guides.com HEAD TIMING GEAR INLET CAMSHAFT FITTING Keep the relevant tool* inside the spark plug hole, as described previously, to check the TDC Fig. A. (*) Engine tuning tool Code:...... Once the TDC for the cylinder 1 has been established, proceed to assemble the inlet camshaft.
Page 185: Chain Slide Removal
All manuals and user guides at all-guides.com HEAD TIMING GEAR CHAIN SLIDE REMOVAL Open the chain tensioner housing cover Fig.A, removing the 7 tightening screws. • Remove The pin (27) of the mobile chain slide (24) Fig.B and take out the slide. •...
Page 186: Distribution Chain Installation
All manuals and user guides at all-guides.com HEAD TIMING GEAR DISTRIBUTION CHAIN INSTALLATION Pass the distribution chain (17) on the drive shaft pinion, as shown in Fig. A Insert the ﬁ xed and mobile chain tensioner slides as shown in the previous section and then the two distribution gear cams, making sure that both are ﬁ...
Page 187: Valve Flap And Calibrated Pad Removal
All manuals and user guides at all-guides.com HEAD TIMING GEAR VALVE FLAP AND CALIBRATED PAD REMOVAL Position Description Quantity HYDRAULIC CUP SCREW BUSHING WASHER VALVE PAD MM 1,600 VALVE PAD MM 1,625 VALVE PAD MM 1,650 VALVE PAD MM 1,675 VALVE PAD MM 1,700 VALVE PAD MM 1,725 VALVE PAD MM 1,750...
Page 188 All manuals and user guides at all-guides.com HEAD TIMING GEAR VALVE FLAP AND CALIBRATED PAD REMOVAL Position Description Quantity VALVE PAD MM 1,975 VALVE PAD MM 2,000 VALVE PAD MM 2,025 VALVE PAD MM 2,050 VALVE PAD MM 2,075 VALVE PAD MM 2,100 VALVE PAD MM 2,125 VALVE PAD MM 2,150 VALVE PAD MM 2,175...
Page 189: Head Removal
All manuals and user guides at all-guides.com HEAD TIMING GEAR VALVE FLAP AND CALIBRATED PAD REMOVAL Once the distribution cover, chain tensioner and camshafts have been removed, it is possible to remove the inlet and outlet valve ﬂ aps, proceeding as follows: •...
Page 190: Valve Flap And Spring Removal
All manuals and user guides at all-guides.com HEAD TIMING GEAR VALVE FLAP AND SPRING REMOVAL Use a special combined tool to remove the valves (27-28) and springs (29-25) Fig. A. (*) Valve spring compressor tool Code:...... (**) Valve disassembly adaptor Code:......
Page 191: Valve Check
All manuals and user guides at all-guides.com HEAD TIMING GEAR VALVE CHECK Replace the valves one at a time, taking care not to mix the parts. Each valve needs to be inserted into its own seat, as mar- ked before it was removed. NOTE The seat (A) on the valve head cannot be ground;...
Page 192: Valve Seat Check
All manuals and user guides at all-guides.com HEAD TIMING GEAR VALVE SEAT CHECK The following procedure applies to all valves and valve seats Fig. C. 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.
Page 193: Valve Spring Test
All manuals and user guides at all-guides.com HEAD TIMING GEAR VALVE SPRING TEST The following procedure applies to all valve springs Fig. A. Carry out a measuring check and visual inspection of springs to make sure there are no breakages, warping, or loss of tension. Valve spring Dimension (A) Inlet...
Page 194: Cylinder Check
All manuals and user guides at all-guides.com HEAD TIMING GEAR CYLINDER CHECK The following procedure applies the whole cylinder group. Check: • the walls of the cylinder Fig.A If there are any vertical lines, replace the cylinder and the piston all together and the relevant clips.
Page 195 All manuals and user guides at all-guides.com PISTONS Position Description Quantity PISTON SEGMENT SERIES PIN RETAINING RING PISTON PISTON PIN SCREW (M7) NUT M7 HALF BEARING (YELLOW) HALF BEARING (BLUE) HALF BEARING (GREEN) SCREW FULL DRIVE SHAFT DISTRIBUTION CHAIN PINION DRIVE SHAFT SPLINE FLYWHEEL KEY...
Page 196: Pistons
All manuals and user guides at all-guides.com PISTONS PISTON PIN REMOVAL The following removal procedure applies to all piston pins (4). Once the pin retaining ring (2) has been removed from both sides of the cylinder (3), proceed to remove the pins from each piston with the special tool (*) Fig.
Page 197: Pin Assembly
All manuals and user guides at all-guides.com PISTONS PIN ASSEMBLY The following reﬁ tting procedure applies to all piston pins (4). • Before lubricating, insert the pin (4) into the piston (3), ma- king it pass by the fork foot (8) Fig. C. •...
Page 198: Elastic Clip Control
All manuals and user guides at all-guides.com PISTONS ELASTIC CLIP CONTROL The following procedure applies to all elastic clips (1) Check: • for the absence of lines and stress traces on each clip Fig. If outside speciﬁ cation, replace the relevant clips and pistons. NOTE Before measuring side clearance between the piston clips, re- move any carbon deposits from the piston clips and grooves.
Page 199: Clip Fitting
All manuals and user guides at all-guides.com PISTONS CLIP FITTING The following procedure applies to all pistons. During the clip assembly process, install them in the following order: Oil scraper clip Clips Top clips See Fig.A NOTE The ﬁ rst and second ring are marked D on the top side and PVD Fig.
Page 200: Crank Gear
All manuals and user guides at all-guides.com CRANK GEAR CHECK OF CONNECTING ROD AND CONNECTING ROD HALF BEARINGS Check: • For any breakages or excessive clearance on the connec- ting rod (5) and connecting rod head half bearings (8) Fig. If replacing the connecting rod, check the class of origin marked on the head.
Page 201 All manuals and user guides at all-guides.com CRANK GEAR CONNECTING ROD AND CONNECTING ROD HALF BEARING INSTALLATION Fit: • The connecting rod half bearings: Clean the steering head, connecting rod supports and the inner half of each rod. Fit the top bearing of the steering head in the connecting rod and the bottom bearing in the steering in the connecting rod cap.
Page 202: Main Half Bearing And Drive Shaft Installation
All manuals and user guides at all-guides.com CRANK GEAR MAIN HALF BEARING AND DRIVE SHAFT INSTALLATION Position Description Quantity BOTTOM CASING CASING (GREY) RIVET SPECIAL SCREW SPECIAL SCREW BALL ROLLER BEARING (YELLOW) ROLLER BEARING (RED) ROLLER BEARING (GREEN) ROLLER BEARING (BLUE) COVER SCREW (M6X12) SCREW (M6X45)
Page 203 All manuals and user guides at all-guides.com CRANK GEAR MAIN HALF BEARING AND DRIVE SHAFT INSTALLATION Position Description Quantity WASHER RETAINING WASHER SCREW (M8X100) OIL SEAL ROLLER BEARING SCREW (M6X40) SCREW (M8X115) WASHER SCREW (M10X100) SCREW (M8X85) SCREW (M8X75) SCREW (M8X45) SCREW (M8X55) SCREW (M10X60) BUSHING...
Page 204 All manuals and user guides at all-guides.com CRANK GEAR MAIN HALF BEARING AND DRIVE SHAFT INSTALLATION Fit: • connecting rod main half bearings: Clean the main half bearings (6), the main supports and the crankcase sections in contact with the half bearings Fig. A. Rest the bottom crankcase on the work bench, Fig.
Page 205 All manuals and user guides at all-guides.com CRANK GEAR MAIN HALF BEARING AND DRIVE SHAFT INSTALLATION • Assemble the half casings on the bottom crank case, pre- viously ﬁ xed to the support and turned 180° Fig.D. • Insert the 4 fastening screws for the two half casings (25- 23-27-28) and proceed with the following torque: Torque 120~130 N*m Measure:...
Page 206: Drive Shaft Check
All manuals and user guides at all-guides.com CRANK GEAR 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 32 (-0.028, -0.042) mm B: Ø 32 (-0.034, -0.048) mm Check: •...
Page 207: Clutch
All manuals and user guides at all-guides.com CLUTCH Position Description Quantity ROLLER BEARING GUIDE BUSHING WASHER CLUTCH BELL CLUTCH DRUM DRIVEN CLUTCH DISC STEEL CLUTCH DISC BELLEVILLE WASHER GASKET PRESSURE PLATE CLUTCH SPRING FLANGE SCREW (M6X25) BEARING COMPLETE CLUTCH BUSHING GASKET GUIDE BUSHING - 206 -...
Page 208: Clutch And Disc Removal
All manuals and user guides at all-guides.com CLUTCH Position Description Quantity CLUTCH CONTROL SHAFT SPRING WASHER OIL SEAL ROLLER BEARING OIL FILLER CAP O-RING (18X3.5) CLUTCH COVER PLATE SCREW (M6X30) SCREW (M6X25) CLUTCH AND DISC REMOVAL Removal: • Remove the clutch cover, unscrewing the 12 screws (29) fastening the cover to the engine casing Fig.
Page 209: Friction Disc Check
All manuals and user guides at all-guides.com 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 discs Fig. A If not within speciﬁ...
Page 210: Clutch Assembly
All manuals and user guides at all-guides.com CLUTCH CLUTCH ASSEMBLY Assembly During the assembly process, follow the order below: Oil pump pinion (complete with chain) Guide bushing (2) Clutch bell (4) Scraper washer (3) Friction drum (5) complete with discs Pressure plate (10) Use the speciﬁ...
Page 211: Gear Assembly
All manuals and user guides at all-guides.com GEAR ASSEMBLY Position Description Quantity SELECTOR SHAFT SHIM STOP SPRING BUSHING GEAR STOP DEVICE SCRAPING ELASTIC RING COMPLETE GEAR STOP DEVICE SPRING PLUG SPRING DESMODROMIC BEARING PLATE SCREW (M6X14) GEAR DRUM WASHER SCREW (M6X15) - 210 -...
Page 212 All manuals and user guides at all-guides.com GEAR ASSEMBLY Position Description Quantity SPRING GEAR SELECTION FORK 1ST/4TH - 2ND/3RD GEAR SELECTION FORK 5TH/6TH GEAR SELECTION FORK 5TH/6TH WASHER PINION OIL SEAL BROACHED BUSHING O-RING GASKET BEARING BEARING RETAINER SECONDARY SHAFT BROACHED BUSHING DRIVEN GEARS 2ND Z39 SCRAPING...
Page 213 All manuals and user guides at all-guides.com GEAR ASSEMBLY Position Description Quantity NOTCHED WASHER NOTCHED WASHER DRIVING GEAR 2ND ZI8 COMPLETE MAIN SHAFT GEAR ASSEMBLY Measurement: Use the speciﬁ c measuring device to check the size of the hole (B) inside the bottom casing of the neutral sensor assembly Fig. A, which is also the support for the desmodronic extremities (12).
Page 214 All manuals and user guides at all-guides.com GEAR ASSEMBLY GEAR ASSEMBLY Assembly Use the speciﬁ c tool (*) to assemble the gear drum (17) Fig.D (**) Gear selector drum assembly tool Code:...... Tighten the drum via the washer (19) and screw (18) in Fig.D, to the following torque: Torque 12 N*m NOTE...
Page 215: Gear Fork Check
All manuals and user guides at all-guides.com GEAR ASSEMBLY GEAR FORK CHECK Measurement: The following procedure applies to all gear forks (1) Fig. G. Check: • the transfer part of the gear fork cam (A). • The tooth on the gear fork cam (B). If there is warping/damage/lines/traces of wear, replace the gear fork.
Page 216 All manuals and user guides at all-guides.com GEAR ASSEMBLY GEAR ASSEMBLY Assemble the forks and gear pin, complete with springs (20), following the sequence illustrated in Fig. I. Spring Gear selection fork 5th/6th Gear selection fork 5th/6th Gear selection fork 1st/4th - 2nd/3rd Spring Check: •...
Page 217 All manuals and user guides at all-guides.com GEAR ASSEMBLY GEAR ASSEMBLY Check: Make sure that the end of the gear retainer spring (3) does not come away from the selector plate (1) and that when idle, the two ends of the spring and strike pin is “0”, Fig. O. Measure: •...
Page 218: Neutral Sensor Assembly
All manuals and user guides at all-guides.com GEAR ASSEMBLY NEUTRAL SENSOR ASSEMBLY Assembly Fit the neutral sensor (37*) taking care to insert ﬁ rst the spring (11) and then the pin (10) Fig. A. NOTE Before assembly, check the sensor continuity (see speciﬁ c section).
Page 219: Lubrication System
All manuals and user guides at all-guides.com LUBRICATION SYSTEM Position Description Quantity SCREW OIL FILTER DISTRIBUTOR GASKET SCREW M14 O-RING GUIDE BUSHING OIL PUMP COVER GUIDE BUSHING SCREW WASHER OUTER ROTOR INNER ROTOR OIL PUMP OIL PUMP SHAFT SCREW (M6×35) OIL PUMP CHAIN - 218 -...
Page 220: Oil Sump And Inlet Filter Removal
All manuals and user guides at all-guides.com LUBRICATION SYSTEM Position Description Quantity PUMP GEARS WASHER SCREW (M5X10) OIL PRESSURE VALVE INLET FILTER INLET FILTER FITTING COMPLETE OIL PUMP OIL PUMP GASKET OIL SUMP AND INLET FILTER REMOVAL Removal: NOTE Before carrying out disassembly of the oil sump, it is necessary to remove the oil from the engine, removing the magnetic seal cap.
Page 221: Pressure-Relief Valve Installation
All manuals and user guides at all-guides.com LUBRICATION SYSTEM PRESSURE-RELIEF VALVE INSTALLATION Check: Before ﬁ tting the valve, make sure that all of its component parts are free from anomalies Fig. A. If there is any damage or wear, replace. Fitting: Insert the pressure-relief valve (22) complete with O-ring inside the bottom casing, by simply ﬁ...
Page 222: Oil Pump Assembly
Fitting: IMPORTANT NOTICE NOTE Always use original Benelli oil ﬁ lters. Other brands of oil ﬁ lter can be different in terms of thread (dia- meter and pitch). Before ﬁ tting a new oil ﬁ lter, apply a ﬁ ne layer of engine oil to the The use of other types of ﬁ...
Page 223: Starting
All manuals and user guides at all-guides.com STARTING Position Description Quantity STARTER MOTOR O-RING SCREW (M6X40) IGNITION SHAFT DOUBLE GEAR START GEAR SCREW (M6X32) MAGNET FLYWHEEL COMPLETE FREEWHEEL FLYWHEEL SCREW (M6X16) - 222 -...
Page 224: Starter Motor Removal/Installation
All manuals and user guides at all-guides.com STARTING STARTER MOTOR REMOVAL/INSTALLATION Removal: Remove the two screws (3) locking the motor-casing Fig. A. Take out the motor from the clutch side. Check: • Starter motor operation. If the starter motor turns over with effort, replace the part. •...
Page 225: Flywheel Removal
All manuals and user guides at all-guides.com STARTING FLYWHEEL REMOVAL Removal: Remove the caps (3*) and (5*) and the relevant gaskets from the left casing cover (10*) Fig. A. Remove the 9 fastening screws (1*) Use the speciﬁ c tools (**) to remove the cover (10*) (**) tool to remove the ﬂ...
Page 226: Flywheel Fitting
All manuals and user guides at all-guides.com STARTING FLYWHEEL FITTING Fitting: Assemble the parts of the whole freewheel (9) and tighten the 6 fastening screws (11) Fig. A. to the following torque: Torque 24 N*m Insert the double gear (5), shaft (4) and starter gear (6) Fig. IMPORTANT NOTICE During the insertion of the ﬂ...
Page 227 All manuals and user guides at all-guides.com STARTING Position Description Quantity SCREW (M6X25) PINION COVER MAGNETIC CAP O-RING MAGNETIC CAP SCREW (M6X12) PHASE SENSOR RETAINING WASHER LEFT CASING GASKET PLATE SCREW (M6X10) BUSHING GASKET COVER SCREW (M6X22) SCREW (M6X30) - 226 -...
Page 228: Phase Sensor Installation/Adjustment
All manuals and user guides at all-guides.com STARTING PHASE SENSOR INSTALLATION/ADJUSTMENT Position Description Quantity OIL SUMP GASKET OIL SUMP MAGNETIC CAP Fitting: Apply a suitably thick copper scraper shim (x) to keep the distance for the phase sensor compared to a suitable pickup for reading the number of revolutions Fig.
Page 229: Supply
All manuals and user guides at all-guides.com SUPPLY Position Description Quantity BRACKET INJECTOR INJECTOR SUPPORT SCREW (M5X16) SCREW (M5×10) SCREW (M4X10) O-RING POTENTIOMETER SCREW PLATE THROTTLE VALVE NUT M5 STEPPER MOTOR DISTRIBUTOR PLATE CLIP MINIMUM AIR PIPE 4 MINIMUM AIR PIPE 3 - 228 -...
Page 230: Throttle Valve Removal
All manuals and user guides at all-guides.com SUPPLY Position Description Quantity MINIMUM AIR PIPE 2 MINIMUM AIR PIPE 1 SCREW (M5×25) BUSHING VIBRATION DAMPING RUBBER SPECIAL PLATE WASHER THROTTLE VALVE REMOVAL Removal: Remove the 4 suction pipes (19*) and the relevant gaskets (18*), loosening the 8 screws (21*) Fig.A.
Page 231: Throttle Valve Fitting
All manuals and user guides at all-guides.com SUPPLY THROTTLE VALVE REMOVAL Correct: • Alignment values via the 2 screws (D) using a screw driver. • Align valve 1 with valve 2, using the screw (C) Fig. D. • Align valve 3 with valve 4, using the screw (C) Fig. D. •...
Page 232 All manuals and user guides at all-guides.com COOL CHAPTER 6 COOL Cooling system - 231 -...
Page 233 All manuals and user guides at all-guides.com COOL CHAPTER 6 - COOLING SYSTEM WATER PUMP ......................233 WATER PUMP REMOVAL/FITTING ......................234 THERMOSTAT ......................235 THERMOSTAT REMOVAL/FITTING ......................235 MANIFOLD ......................236 MANIFOLD REMOVAL/FITTING ......................236 HEAT EXCHANGER ....................237 HEAT EXCHANGER REMOVAL/FITTING ....................237 RADIATOR ......................
Page 234 All manuals and user guides at all-guides.com COOL WATER PUMP Position Description Quantity WATER PUMP ROTOR RETAINING RING OIL SEAL WATER PUMP COVER O-RING BEARING ELASTIC RING WATER PUMP SHAFT SCREW (M6X40) COMPLETE WATER PUMP “L” FITTING SCREW (M6X20) WASHER WATER PUMP BODY RETAINING RING BUSHING...
Page 235: Water Pump
All manuals and user guides at all-guides.com COOL WATER PUMP WATER PUMP REMOVAL/FITTING Removal: NOTE Remove coolant before removing parts. Remove the two pump delivery and return hoses (17*-18*), taking off the clamps (19*) Fig.A. Remove the 4 fastening screws (9) and take out the pump Fig.B Take out all of the parts in the order shown in the exploded drawings and check to ensure each part is intact.
Page 236: Thermostat
All manuals and user guides at all-guides.com COOL THERMOSTAT THERMOSTAT REMOVAL/FITTING Removal: Remove the two screws (15*) fastening the thermostat cup (14*) Fig. A Take out the thermostat (13*) NOTE Remove coolant before carrying out these steps. Check: • The by-pass hole (A) If there is any clogging, replace.
Page 237: Manifold
All manuals and user guides at all-guides.com COOL MANIFOLD MANIFOLD REMOVAL/FITTING Removal: Remove the two screws (11*) fastening the water ﬁ tting (12*) Fig. A Check: • The water ﬁ tting (12*) If there is any damage/breakage, replace. • The seal (39*). If there is any damage/breakage, replace.
Page 238: Heat Exchanger
All manuals and user guides at all-guides.com COOL HEAT EXCHANGER HEAT EXCHANGER REMOVAL/FITTING Removal: Remove the connection pipes (10*) and (13*) of the distribu- tor (3*), loosening the clips (9*) Fig. A NOTE The numbers marked (*) are shown in the replacement parts table in Chapter 5 “Cooling circuit”...
Page 239: Radiator
All manuals and user guides at all-guides.com COOL RADIATOR RADIATOR REMOVAL/FITTING RADIATOR (**) Position Description Quantity SCREW BUSHING RUBBER TIP WATER RADIATOR SCREW LH RADIATOR GUARD RH RADIATOR GUARD WATER DELIVERY OPENING CLIP HOSE RADIATOR BULB SCREW (M6X30) RIGHT BRACKET LEFT BRACKET BUSHING SNAP-ON CLIP (M6)
Page 240 All manuals and user guides at all-guides.com COOL RADIATOR RADIATOR REMOVAL/FITTING PIPES(*) Position Description Quantity SUCTION PIPE WATER TANK CAP PIPE TEF SCREW M6X14 8.8 ZB WATER TANK CLIP PIPE PIPE CLIP HOSE CLIP HOSE HOSE “T” FITTING CLIP HOSE HOSE HOSE SCREW CLIP...
Page 241 All manuals and user guides at all-guides.com COOL RADIATOR RADIATOR REMOVAL/FITTING Position Description Quantity RUBBER VIBRATION DAMPING PAD PIPE THERMAL PROTECTION CLIP IMPORTANT NOTICE Remove coolant before carrying out these steps. Removal: Remove the connecting pipe (18*) , loosening the clip (19*) Fig.A NOTE The numbers marked (*) are shown in the replacement parts...
Page 242 All manuals and user guides at all-guides.com COOL RADIATOR RADIATOR REMOVAL/FITTING Fitting: Once each part has been checked, proceed to assemble the radiator, following the procedure for removal described above, this time in reverse order. Tighten the fastening screws of the radiator (1**-12**) to the following torque: Torque 10 N*m The clips (“clik”...
Page 243 All manuals and user guides at all-guides.com Pure Passion since 1911 SERVICE STATION MANUAL 2013, Benelli Q.J. s.r.l. First Edition, DECEMBER 2013. All rights reserved. Reprints or unauthorised use without the written permission of Benelli Q.J. s.r.l. are expressly prohibited.

Benelli BN600R 2014 Service Station Manual

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