Page 1 TNT 25 Benelli Motorcycle Maintenance Manual...
Page 2 Benelli Motorcycle Maintenance Manual We have made every effort to ensure that this Manual is complete and accurate, but will not assume any responsibility for any inaccuracies or omissions that may appear in this Manual. We reserve the right to modify this Manual without prior notice and do not have the obligation to modify previous products accordingly.
Page 3 Abbreviations Ampere Pound ABDC After bottom dead center Meter Alternating current Minute ATDC After top dead center Newton BBDC Before bottom dead center Pascal Bottom dead center Horsepower BTDC Before top dead center Pound per square inch ℃ Degree celsius Revolution Direct current Revolutions per minute...
Page 4: Exhaust Emission Control Information
Exhaust Emission Control Information In order to protect our common environment, (1) and exhaust emission control system (2) which conform to the applicable regulations of the US Environmental Protection Agency and California Air Resources Board, and equipped the motorcycles sold in California only with fuel vapor recovery system (3) which conform to the applicable regulations of California Air Resources Board.
Page 5 Strictly Prohibiting the Modification of Noise Control System Federal law prohibit anyone from doing or instigating others to do the following: (1) Any person removes any part or make it inoperative before the final buyer purchases or receives any new motorcycle or in the course of the use of motorcycle, unless there is a need to repair, maintain or replace this part;...
Page 6: Table Of Contents
Contents EXHAUST EMISSION CONTROL INFORMATION ....................3 STRICTLY PROHIBITING THE MODIFICATION OF NOISE CONTROL SYSTEM ........4 CHAPTER I BASIC INFORMATION NOTES BEFORE MAINTENANCE ..........................1-2 BATTERY INSTALLATION ..........................1-2 SHARP EDGE OF PART ............................1-2 SOLVENT ................................1-2 CLEANING MOTORCYCLE BEFORE DISASSEMBLY ................1-3 COLLECTING AND CLEANING REMOVED PART ..................
Page 7 CHECKING IDLE SPEED ............................2-14 CHECKING FUEL HOSE (FUEL LEAKAGE, HOSE BREAK AND HOSE INSTALLATION SITUATIONS) ......................................2-14 CHECKING FUEL EVAPORATION AND RECOVERY SYSTEM (CHINESE, EUROPEAN AND US MODELS) ..................................2-15 COOLING SYSTEM ..............................2-17 CHECKING COOLANT LEVEL ..........................2-17 CHECK RADIATOR PIPE (COOLANT LEAKAGE, RADIATOR PIPE DAMAGE AND INSTALLATION STATE OF RADIATOR PIPE) ..........................
Page 8 CHECKING ENGINE STOP SWITCH ........................2-47 OTHERS ..................................2-48 ADDING LUBRICANT TO FRAME PARTS ......................2-48 CHECK TIGHTNESS OF BOLT, NUT AND FASTENER ................... 2-49 REPLACEMENT PART ............................2-51 REPLACING AIR FILTER ELEMENT ........................2-51 REPLACING FUEL HOSE ............................2-53 REPLACING COOLANT ............................
Page 9 CLEANING METHOD OF THROTTLE ........................ 3-29 INSTALLATION OF THROTTLE .......................... 3-29 PRECAUTIONS FOR INSTALLATION OF THROTTLE ..................3-29 NOTES FOR USE OF THROTTLE VALVE ......................3-29 WORKING PRINCIPLE OF FUEL INJECTOR ....................3-30 APPEARANCE OF FUEL INJECTOR ........................3-30 SEALING RING OF FUEL INJECTOR ......................... 3-30 OVERVOLTAGE IMPACT OF FUEL INJECTOR ....................
Page 10 INSTALLING RADIATOR AND RADIATOR FAN ....................4-12 CHECKING RADIATOR ............................4-12 CHECKING RADIATOR CAP ..........................4-13 CHECKING RADIATOR FILLER .......................... 4-14 THERMOSTAT ................................4-15 DISASSEMBLING THERMOSTAT ......................... 4-15 INSTALLING THERMOSTAT ..........................4-15 CHECKING THERMOSTAT ........................... 4-16 HOSE AND PIPELINE ............................... 4-17 INSTALLING HOSE ..............................
Page 11 SHIFT MECHANISM ............................... 5-45 SHIFT MECHANISM EXPLODED VIEW ......................5-45 DISASSEMBLING SHIFT MECHANISM ......................5-46 INSTALLING SHIFT MECHANISM ........................5-46 CHECKING SHIFT MECHANISM ......................... 5-47 DISASSEMBLING PRIMARY/SECONDARY SHAFT COMPONENT ............. 5-48 INSTALLING PRIMARY/SECONDARY SHAFT ....................5-49 CHECKING PRIMARY/SECONDARY SHAFT COMPONENT ................ 5-50 CHAPTER VI CHASSIS WHEEL / TIRE ..................................
Page 12 STEERING STEM ..............................6-78 HANDLEBAR................................6-83 FRAME ................................... 6-86 FRAME EXPLODED VIEW ............................ 6-86 LEFT PEDAL EXPLODED VIEW .......................... 6-88 RIGHT PEDAL EXPLODED VIEW ........................6-90 MUFFLER EXPLODED VIEW ..........................6-92 FENDER EXPLODED VIEW........................... 6-94 BODY COVERSFUEL TANK GARNISH PLATES EXPLODED VIEW ............6-96 SEAT CUSHION AND BODY COVERS EXPLODED VIEW ................
Page 13 STARTING SYSTEM CIRCUIT DIAGRAM ......................7-21 STARTER MOTOR ..............................7-22 STARTER RELAY ..............................7-24 STARTER RELAY DISASSEMBLY AND ACTION INSPECTION ..............7-24 LIGHTING SYSTEM ..............................7-25 HEADLIGHT ................................7-25 INSTRUMENT ................................7-27 INSTRUMENT DISASSEMBLY ..........................7-27 SWITCH, SENSOR AND OTHER PARTS ........................7-28 MAIN SWITCH................................
Page 14 SPECIAL TOOL LIST SUMMARY ......................... 8-35...
Page 15 • This sign indicates a certain step or a task to be  Use appropriate tools and original Benelli motorcycle completed. parts. This Maintenance Manual has described the ○ This sign indicates a certain substep or how to complete specific tools, instruments and test devices required in the work of this step.
Page 16: Chapter I Basic Information
CHAPTER I BASIC INFORMATION Notes before Maintenance ............................1-2 Battery Installation ............................... 1-2 Sharp Edge of Part ............................... 1-2 Solvent ................................... 1-2 Cleaning Motorcycle before Disassembly ......................1-3 Collecting and Cleaning Removed Part ......................1-3 Storing Removed Part ............................1-3 Check ..................................
Page 17: Notes Before Maintenance
Notes before Maintenance Please read the following precautions before checking, disassembling or assembling motorcycles. In order to facilitate the actual operation, the chapters are provided with notes, illustrations, pictures, precautions and detailed descriptions. This section describes the special precautions during the removal and reassembly or disassembly and reassembly of common parts.
Page 18: Cleaning Motorcycle Before Disassembly
Cleaning Motorcycle before Disassembly Thoroughly clean the motorcycle before disassembly. If dust or other foreign materials enter the sealing area in the disassembly process, the excessive wear will be caused and the performance of motorcycles will be reduced. Collecting and Cleaning Removed Part The removed parts are easily confused.
Page 19: Replacement Part
Replacement Part The replacement part must be an genuine part of Benelli or a part recommended by Benelli. Gaskets, O-ring seals, oil seals, grease seals, circlips or cotter pins and other parts must be replaced with new parts once they are removed.
Page 20: Force
Force The common sense and basic ability of judgement must be owned in the part removal and installation process to prevent excessive force from resulting in maintenance difficulties or high maintenance cost. If necessary, remove the screws with non-permanent locking agent by using a pneumatic wrench. If it is needed to beat the fastener, a rubber hammer must be used.
Page 21: Ball Bearing And Needle Bearing
Ball Bearing and Needle Bearing If not necessary, do not remove the ball or needle in the bearing. Once the ball or needle is removed, it must be replaced with a new one. When pressing the bearing, note that the manufacturer and size signs shall be placed outward.
Page 22: Circlip And Cotter Pin
Circlip and Cotter Pin Replace the removed circlip or cotter pin with a new one. In order to prevent deformation, the opening of circlip or cotter pin cannot be too large during installation. Lubrication In order to minimize the abrasion during running-in, the lubricant must be applied to the rotating parts or sliding parts.
Page 23: Wire
Wire Dual-color wire: the first is the base color, then the color of stripe. Unless noted otherwise, only the wires with the same color can be connected. Cable Connector Check Make sure that there are no corrosion, moisture and other foreign materials on the connector.
Page 24 3. Check All connectors If any joint is loose, conduct correct connection again. Note If the “A” pin on the terminal is flat, please bend it. 4. Check Wire Connector Joint Note Make sure that all joints are assembled firmly. 5.
Page 25: Cable Arrangement
Cable Arrangement Loose cable is a potential electrical safety hazard. Check the latter cable after the cable is clamped to ensure the electrical safety; It is not allowed to bend the cable clamp in the direction of welding spot; Bind the cables at the specific position; It is not allowed to arrange the cables at the end of frame or at the position of sharp corner;...
Page 26: Model Information
Model Information China Left view Right view 1-11...
Page 27 Left view Right view 1-12...
Page 28: Europe
Europe (Europe) Left view (Europe) Right view 1-13...
Page 29: Non-Europe
Non-Europe (Non-Europe) Left view (Non-Europe) Right view Frame No. Engine No. 1-14...
Page 30: Basic Specification
Basic Specification Dimension Standard Overall length 2080mm Overall width 810mm Overall height 1125mm Wheel base 1400mm 1-15...
Page 31: General Technical Parameter
General Technical Parameter Item Dimension Overall length 2080mm Overall width 810mm Overall height 1125mm Wheel base 1400mm Ground clearance Height of seat Curb weight : BJ250-15A (a1-1) 155kg BJ250-15A (a2-1) 155kg BJ250-15 (Europe) 155kg BJ250-15 (Non- Europe) 155kg Front wheel axle load BJ250-15A (a1-1) 100kg BJ250-15A (a2-1)
Page 32 General Technical Parameter BJ250-15A、BJ250-15 (Non-Europe), BJ250-15 (Europe Ⅳ) Item Spark plug NGK CR8E Valve timing : Air inlet : Open valve 41° Closed valve 71° Total time interval 292° Air exhaust: Open valve 64° Closed valve 34° 278° Total time interval Lubrication system Force lubrication and splash lubrication Oil :...
Page 33 General Technical Parameter BJ250-15A、BJ250-15 (Non-Europe)、BJ250-15 (Europe Ⅳ) Item Frame Type Steel Tube Trellis Frame Caster angle (angle) 23° 94 mm Tail Front tire : Type : Tubeless tire 110/70-17 Dimension : Tire pressure 220±10kPa Wheel type 12-spoke aluminium alloy 17×MT3.50 dimension Rim material Aluminium alloy...
Page 34: Unit Conversion Table
Unit Conversion Table Prefix of unit: Unit of length: Prefix Symbol Power km × 0.6214 = mile m × 3.281 =foot mega ×1000000 mm × 0.03937 = inch kilo ×1000 centi ×0.01 Unit of torque: milli ×0.001 μ N·m × 0.1020 = kgf·m micro ×0.000001 N·m ×...
Page 35: Chapter Ii Regular Maintenance
CHAPTER II REGULAR MAINTENANCE REGULAR MAINTENANCE TABLE .......................... 2-3 TORQUE AND LOCKING AGENT ..........................2-5 MAIN LOCKING TORQUE SPECIFICATIONS ....................2-5 NUT, BOLT, SCREW FASTENING TORQUE AND RELATIVE PARAMETERS..........2-9 REGULAR MAINTENANCE PROCEDURES ......................2-13 FUEL INJECTION SYSTEM (EFI) ......................... 2-13 CHECKING THROTTLE CONTROL SYSTEM ....................
Page 36 SUSPENSION SYSTEM ............................2-37 CHECKING FRONT /REAR SHOCK ABSORBER ..................2-37 CHECK FOR FRONT SHOCK ABSORBER OIL LEAKAGE ................ 2-37 CHECK FOR REAR SHOCK ABSORBER OIL LEAKAGE ................2-38 STEERING SYSTEM ..............................2-39 CHECKING STEERING CLEARANCE ......................2-39 ADJUSTING TIGHTNESS OF STEERING SEAT .................... 2-39 ADDING LUBRICANT TO STEERING STEM BEARING ................
Page 37: Regular Maintenance Table
Regular Maintenance Table To keep good running state of motorcycle, regular maintenance must be conducted according to the following table. The maintenance for the first time is very important, so it should not be neglected. Regular Check Table Frequency Whichever is the earlier Odometer reading Item Page...
Page 38 (Continued) Frequency Whichever is the earlier Odometer reading Page ×1000 km Item Interval Suspension system Front fork / rear Damper operation (damping and travel is • • • smooth)—check Oil leakage of front fork / rear Damper—check 1 year • •...
Page 39: Torque And Locking Agent
Torque and Locking Agent Main Locking Torque Specifications The following table shows the locking torque of the main fasteners that are to be used with screw fastening agent or silicone sealants. The letters in “Remarks” column have the following meanings: AL: Tighten the fastening bolts alternately twice in accordance with the higher locking torque.
Page 40 (Continued) Torque Fastener Remarks N·m kgf·m Clutch L⑴ Clutch cover bolt Clutch hub nut 12.0 Clutch spring bolt Engine lubrication system Oil drain bolt M12 Oil plug Tighten it with hands Oil pump bolt Oil pump cover bolt Crankshaft / transmission mechanism Balancer shaft fastening nut M14 L&R Crankcase bolt M6 Crankcase bolt...
Page 41 (Continued) Torque Fastener Remarks N·m kgf·m Rear caliper mounting bolt Rear brake master cylinder mounting bolt Rear brake master cylinder Tie-rod locking nut Suspension system Front axle fastening bolt Front Damper fastening bolt (upper) Front Damper fastening bolt (lower) Front Damper top plug Front damper piston rod nut Rear Damper bolt (upper) Rear shock absorber bolt (lower)
Page 42 (Continued) Torque Fastener Remarks N·m kgf·m Electrical system Alternator cover bolt Alternator wire fixing plate bolt Alternator Rotor Bolt 10.0 Crankshaft position sensor bolt Crankshaft sensor bolt 0.60 Crankshaft sensor cover bolt L⑴ Engine grounding terminal bolt Front brake lamp switch screw 0.12 Front steering lamp fixing nut Fuel level sensor bolt...
Page 43: Nut, Bolt, Screw Fastening Torque And Relative Parameters
Nut, Bolt, Screw Fastening Torque and Relative Parameters The following table shows the basic torques of bolt and nut (different thread diameters correspond to different tightening torques). This table is only applicable to the bolt and nut without the need for specific torque value. All the values in the following table are applicable to the thread cleaned using anhydrous solvent.
Page 44 Technical Parameters Item Standard Service limit Fuel injection system (EFI) Free play of throttle grip 3-5mm — Idle speed 1400 ±100 r/min — Negative pressure value of throttle valve body 50 ±3 kPa (under idle speed) — Air filter element Sponge filter —...
Page 45 (Continued) Item Standard Service Limit Brake Brake fluid: Level DOT4 — Thickness of brake lining Front brake lining 4.0 mm Rear brake lining 5.0 mm Brake lamp time setting: Front brake lamp It will be on after being pulled — Rear brake lamp It will be on after pressing about 10mm —...
Page 46 Special Tools The following special tools are needed for complete and correct adjustment and assembly; use the correct special tools to avoid the damages caused by improper tools or non-professional technology. In different countries, the specific tools which need to be used may vary. During ordering tools, please refer to the following information to prevent any errors. Inner circlip plier Vacuum meter BN-BN-43008-622steering special nut 4T wrench...
Page 47: Regular Maintenance Procedures
Regular Maintenance Procedures Fuel Injection System (EFI) Checking Throttle Control System • Check the free play of throttle grip ①. Free play of Throttle Grip Standard: 3-5mm ★If the free play is not accurate, please adjust the throttle cable. • Check whether the throttle grip can move smoothly from fully open to closed and whether the return spring can enable the throttle to be turned off completely at any steering position.
Page 48: Checking Idle Speed
Checking Idle Speed • Start the engine and make it hot thoroughly. • When the engine is idling, rotate the handlebar to both sides [A]. ★If the idle speed was changed when rotating the handlebar, it indicates that the throttle cable is not adjusted well or the winding method is incorrect or damaged.
Page 49: Checking Fuel Evaporation And Recovery System (Chinese, European And Us Models)
• Check whether the connection of hose joint is firm. 〇Push and pull the hose joint [A] for more than twice to ensure that the hose joint is fixed firmly. ★If the connection is not firm, install the hose joint again. Warning Slide the joint to ensure that the hose joint is properly installed on the fuel supply pipe, otherwise the fuel leakage may occur.
Page 50 • Check the carbon canister according to the following steps. 〇Remove the battery bracket A. 〇Remove the carbon canister [C] and the hose [1] used to connect carbon canister. 〇Check whether there are cracks or other damages on the carbon canister.
Page 51: Cooling System
Cooling System Checking Coolant Level Remark 〇Check the fluid level when the engine is cooled (to the indoor temperature or environment temperature). • Put the motorcycle vertically (do not use the side stand) and check the coolant level of the reserve tank [A]. ★If the coolant level is lower than the “LOWER”...
Page 52: Engine Cylinder Head And Cylinder Head Cover
Engine Cylinder Head and Cylinder Head Cover Check Valve Clearance Remark ○Valve clearance can be checked and adjusted only when the engine is cooled (to the indoor temperature). ●Removal: Remove the seat (see “Disassembling Seat” in “Frame” chapter), Remove the fuel tank (see “Disassembling Fuel Tank” in “Fuel Tank” chapter), ●Disassemble the mounting bolt [A] and remove the cylinder cover Note...
Page 53 ●Place the crankshaft on the piston TDC ○TDC sign of flywheel is [A] ○Timing sign: [A] (Half meshing surface of crankcase) ●Use the thickness gauge [A] to measure the valve clearance between cam and valve lifter at the TDC position. Note Please keep the thickness gauge level to prevent that the misjudgement gets stuck.
Page 54: Adjusting Valve Clearance
Adjusting Valve Clearance ●To change the valve clearance, remove the camshaft chain tightener, camshaft and valve lifter. Replace the valve shim used currently with that with different thickness. Remark In order to install the valve lifter and valve shim at the original positions, mark their positions before removal.
Page 55 ●Clean the dust or oil stain on the valve shim. ●Measure the thickness of the removed valve shim [A]. 2-21...
Page 56 Valve Clearance Adjustment Table of Exhaust Valve Examples of current valve shim Thickness (mm) Valve clearance/without adjustment Thickness of valve shim to be installed (mm) 1. Measure the valve clearance (the engine has been cooled). 2. Check the current valve shim dimension. 3.
Page 57 Valve Clearance Adjustment Table of Inlet Valve Examples of current valve shim Thickness (mm) Valve clearance/without adjustment Thickness of valve shim to be installed (mm) 1. Measure the valve clearance (the engine has been cooled). 2. Check the current valve shim dimension. 3.
Page 58: Check Whether Air Inlet Device Is Damaged
Note After selecting other valve Shims according to the table above, please measure the valve clearance again. If the valve clearance exceeds the specified scope, use the supplement shim. ○If there is no valve clearance, use the valve shim which is several times smaller and then measure the valve clearance again.
Page 59: Clutch
Clutch Check Whether Clutch Control System is Normal ●Start the engine to ensure that the clutch cannot slip and can be separated normally. ★If the clutch is abnormal, check the clutch system. Warning If the motorcycle needs to be run in the checking process, ensure to run it at the place where the traffic conditions are normal.
Page 60: Wheel/Tire
Wheel/Tire Checking Tire Pressure ●Remove the valve cap. ●Measure the tire pressure with an air pressure gauge [A] when the tire is cooled (i.e., the travelled mileage of motorcycle within 3 hours before the measurement does not exceed 2 km). ●Install the valve cap back.
Page 61: Checking Wear Situations Of Thread
Checking Wear Situations of Thread As the tread wear is more and more serious, it is more likely to cause tire blowout. It is estimated that 90% of tires will be damaged in the last 10% of service life of tire (90% wear). If the tire is used until it is grinded smoothly, the money cannot be saved and safety issues may be caused.
Page 62: Checking Whether Wheel Bearing Is Damaged
Checking Whether Wheel Bearing is Damaged ●Use the jack to lift the front wheel up from the floor (see “Disassembling/ Installing Tire” in the “Wheel/Tire” chapter). ●Rotate the handle to the rightmost or leftmost side. ●Shake the wheel frame to both sides [A] with both hands to check whether there is axial clearance in the front wheel bearing.
Page 63: Final Drive Mechanism
Final Drive Mechanism Checking Lubrication State of Drive Chain ●If there is no special lubricant, the priority can be given to the heavy oil (e.g.: SAE 90), not light oil, because the heavy oil can be attached to the drive chain for longer time with better lubrication effect. ●If the drive chain looks dirty, it must be cleaned before adding the lubricant.
Page 64: Adjusting Slackness Of Drive Chain
Adjusting Slackness of Drive Chain ●Lift the rear wheel up from the ground with a bracket (see “Disassembling Rear Wheel” in the “Wheel/Tire” chapter). ●Unscrew the rear wheel axle nut [A]. ●Screw off the locknuts [C] of two chain adjusters on the left and right.
Page 65: Checking Wheel Alignment
Checking Wheel Alignment ●Check whether the position of the concave scale line [B] on the right chain adjuster [A] on the rear swing arm [C] is the same as that of concave scale line on the left chain adjuster. ★If they are not aligned, adjust the slackness of drive chain and align the wheel alignment (see “Adjusting Slackness of Drive Chain”).
Page 66 Checking Wear of Chain Guide ●Remove the rear swing arm (see “Disassembling Rear Swing Arm” in “Suspension System”). ●Visually checking the chain guide [A]. ★If there is abnormal wear or damage in the chain guide, it must be replaced. 2-32...
Page 67: Brake
Brake Check Whether Brake Hose and Brake Pipe are Damaged and Their Installation States ●For the motorcycle models which are equipped with ABS, there are the following precautions: ●Removing: Fuel tank (see “Disassembling Fuel Tank” in “Fuel Injection System (EFI)”) and battery (see “Disassembling Battery” in “Electrical System”).
Page 68: Checking Brake
★If the measured value does not meet the specified valve, the adjustment shall be carried out. ○Adjust the free play of brake pedal. 1. Loosen the nut A above the connecting rod C. 2. Screw up or screw off the brake push rod B to adjust the free play of brake pedal.
Page 69: Checking Wear Of Brake Pad
●Check whether the level of the brake fluid in the rear brake fluid cup [A] is between the upper limit [B] and the lower limit [C]. ★If the level is below the lower limit, add the brake fluid to the cup until the level reaches the high fluid level line [C].
Page 70: Checking Brake Lamp Switch
Checking Brake Lamp Switch ●Turn on the main switch.. ●After the brake handle is applied for 20mm or the brake pedal is depressed for about 25mm, the brake lamp shall be on. ★If the brake lamp is not on, check or replace the following parts: Battery (see “Checking Charging Situation”...
Page 71: Suspension System
Suspension System Checking Front /Rear Shock Absorber ●Shake the front fork up and down for four or five times to check whether the travel of shock absorber is smooth. ★If the front fork cannot be moved smoothly or there is noise, check the oil level or fork clamp of front shock absorber oil (see “Replacing Front Shock Absorber Oil”...
Page 72: Check For Rear Shock Absorber Oil Leakage
Check for Rear Shock Absorber Oil Leakage ●Visually check for rear shock absorber [A] oil leakage. ★If oil leakage is found, replace the shock absorber. 2-38...
Page 73: Steering System
Steering System Checking Steering Clearance ●Lift the front wheel up from the ground with a jack. Special Tool—Jack: ●When the front wheel faces ahead straightly and the front wheel is off the ground, the whole handle shall be able to slide freely to the left and right steering upper limits by the gravity action after the left or right handle is pushed slightly.
Page 74: Adding Lubricant To Steering Stem Bearing
●Check the tightness of steering seat: ★Make sure that the support is not loose and rotate the front fork left and right to the end of travel to ensure that there is no block point. If there is any block point, remove the lower bracket components and check the upper and lower steering bearings.
Page 75: Electrical System
Electrical System Checking Lamp and Switch Step 1 ●Turn on the main switch. ●All motorcycle lamps will be on according to the order shown in the table below. Position lamp [A] Position lamp (a1-1) (LED) [A] Tail lamp (LED) [B] License plate lamp [C] Tachometer lamp (LED) [D] Liquid crystal meter panel (LCD) [E]...
Page 76 Step 2 ●Turn on the Main switch. ●Turn on the turn signal switch [A] (left or right). ●Left turn signal or right turn signal (LED) (position of corresponding switch) (front and rear) will flash. 2-42...
Page 77 ●Left/right turning indicator (LED) [B] in the meter panel will flash. ★If the left turn signal or right turn signal is not on, check or replace the following parts: Turn signal (LED) (see “Replacing Turn Signal” in the “Electrical System” chapter); Header parts of turning indicator (LED) (see “Checking Header Parts”...
Page 78 ●Press the passing lamp switch [D] (models with passing lamp switches) or turn the dimmer switch to the position of high beam [A]. ●The low beam head lamp [A] and high beam head lamp [B] shall be on. ●The high beam indicator (LED) [C] shall be on. ★If the high beam head lamp and/or high beam indicator (LED) are/is not on, check or replace the following parts: Head lamp high beam bulb (see “Replacing Head Lamp Bulb”...
Page 79: Checking Accuracy Of Head Lamp
Checking Accuracy of Head Lamp ●Check the accuracy of head lamp beam. ★If the headlight beam lights up one side instead of straight front, adjust the beam. Adjust the beam of front head lamp correctly according to the following steps: Park the motorcycle about 10 meters away from the upright wall on the completely flat ground.
Page 80: Check Side Stand Switch
Check Side Stand Switch ●Check the side stand switch [A] according to the table below. Side Stand Switch Side stand Gear position Clutch lever Engine startup switch Engine Run Neutral Release Start Continuous running Neutral Tighten Start Continuous running 1-6 Gear Position Release Not start Continuous running...
Page 81: Checking Engine Stop Switch
Checking Engine Stop Switch Step 1 ●Turn on the main switch. ●Set the gear as neutral. ●Turn the engine stop switch to the stop position [A]. ●Press the starter button. ●At this time, the engine shall have not started. ★If the engine has started, check or replace the following parts: Engine stop switch (see “Checking Switch”...
Page 82: Others
Others Adding Lubricant to Frame Parts ●The rust must be removed with rust remover before any parts are lubricated and the grease, oil, stain or dirt shall be removed. ●Lubricate the following positions with the specified lubricant. Remark ○If the motorcycles are used in humid environment or on rainy days, especially when the motorcycles are sprayed and washed with high-pressure water, the relevant parts must be lubricated in accordance with the following specifications.
Page 83: Check Tightness Of Bolt, Nut And Fastener
●After the connection between two ends of throttle cable steel cable, the steel cable shall be able to move freely [A]. ★If the steel cable cannot move smoothly after the lubricant is applied, the cable has been worn [B] or the throttle cable jacket is broken [C], the throttle cable must be replaced.
Page 84 Bolts, Nuts and Fasteners to Be Checked Engine: Clutch lever fulcrum shaft bolt locknuts, Engine mounting bolts and nuts, Engine fixing bracket fastening bolts, Engine fixing plate fastening bolts, Exhaust pipe flange fastening bolts, Muffler cavity fastening bolts, Muffler cylinder mounting bolts Shift rocker arm fastening bolts, Wheel: Front wheel axle,...
Page 85: Replacement Part
Replacement Part Replacing Air Filter Element Remark ○If the motorcycle is used in a dusty environment, the replacement interval of air filter element shall be shorter than the recommended replacement interval. ○After riding in rainy days or on muddy roads, replace the air filter element immediately.
Page 86 ●Install a new filter element [5]. Note The recommended air filter element (Benelli part number: 49202N220002) must be used. If other air filter elements are used, the engine will be worn prematurely or the performance of engine will be reduced.
Page 87: Replacing Fuel Hose
Replacing Fuel hose ●Disassemble the fuel tank [see “Fuel Tank Disassembly” in the “Fuel Tank” chapter]. ●Make sure to plug the hose joint [A] with a piece of cloth. ●Press the joint lock claws [A]. ●Pull the joint [C] of [B] according to the direction shown in the figure.
Page 88: Replacing Coolant
Replacing Coolant Warning When the engine is still hot, do not remove the radiator cap or replace the coolant to avoid scalding. Carry out the above operation until the engine is cooled. If the coolant splashes on the tire, the tire slip will be caused, which may cause traffic accidents or personal injury.
Page 89 ●Pour the coolant until the level reaches the full level of fluid storage tank and then close the cover. Note Use the recommended coolant (Benelli part No.: 06109P250000) preferentially. If other coolant is used, the engine may be damaged or the performance of engine may be reduced.
Page 90 ●Exhaust the air in the radiator according to the following steps: ○Start the engine (the radiator cap has been removed) and make the engine run at the speed of 3000 RPM to 4000 RPM until no bubble can be seen in the coolant [A]. ○Lightly pat the radiator hose to discharge the bubbles in the hose.
Page 91: Replacing Radiator Hose
Replacing Radiator Hose ●Drain the coolant (see “Replacing Coolant”). ●Removing: Engine fairing (see “Disassembling Engine Fairing” in the “Frame” chapter), Side cover (see “Disassembling middle side cover” in the “Frame” chapter), Clamp [A] Water pipe [B] ●Install the new hose and then tighten the pipe clamp. Locking torque of radiator hose (water pipe) clamping screw: 2.0 N·m ●Add the coolant (see “Replacing Coolant”).
Page 92: Replacing Oil
Replacing Oil ●After the engine becomes hot, place the motorcycle vertically and make it be perpendicular to the ground. ●Remove the oil drain bolt [A] to discharge the oil. ○Place an appropriate container under the oil drain bolt [A] to collect the oil.
Page 93: Replacing Brake Hose
Replacing Brake Hose Note The brake fluid will quickly corrode the surfaces of painted parts, therefore, if the brake fluid splashes on any plastic part, it must be thoroughly rinsed immediately. ●Remove the banjo bolt [A] of brake hose. ●When the brake hose is removed, do not splash the brake fluid on any painted parts.
Page 94 ●Each side of brake pipe accessory is equipped with gasket. The gasket shall be replaced with a new one during installation. ●Tightening: Locking torque of brake hose banjo bolt: 25 N·m ●When the brake hose is installed, avoid significant bending, kinking, extrusion or twisting and arrange it according to the section in the “Appendix”...
Page 95: Replacing Rear Brake Fluid Pipe
Replacing Rear Brake Fluid Pipe Note The brake fluid will quickly corrode the surfaces of painted parts, therefore, if the brake fluid splashes on any plastic part, it must be thoroughly rinsed immediately. ●Remove the rear brake fluid pipe clamp [A]. ●When the rear brake fluid pipe is removed, do not splash the brake fluid on any painted parts.
Page 96: Replacing Brake Fluid
Replacing Brake Fluid ●Park the motorcycle on the flat ground Remark ○Support the motorcycle with center stand and ensure that the motorcycle is vertical ●Check the brake fluid level ★If the level is lower than the lowest sign (the position of oil lens [A]), add the recommended brake fluid to the correct level ●Remove the brake fluid cylinder cover [B] from the brake pump ○Check the brake fluid cylinder diaphragm on the cylinder.
Page 97 Remark ○The replacement steps of front brake fluid are as follows. The replacement steps of rear brake fluid are the same as that of front brake fluid. ●Replacing Brake Fluid 1. Keep the main oil cylinder in the horizontal state and disassemble the brake fluid cylinder cover.
Page 98: Replacing Rubber Parts Of Brake Master Cylinder
Replacing Rubber Parts of Brake master cylinder Disassembling Front Brake master cylinder ●Remove the front brake master cylinder (see “Disassembling Front Brake master cylinder” in the “Brake” chapter). ●Remove the fluid reservoir can fixing screw [F], fluid reservoir can [E], connector [C] and O-ring seal. ●Screw off the locknut [E] and fulcrum shaft bolt [F] and then remove the brake handle.
Page 99 Disassembling Rear Brake Master Cylinder ●Remove the rear brake master cylinder (see “Disassembling Rear Brake master cylinder” in the “Brake” chapter). ●Remove the connector [H] and O-ring seal [H]. ●Slide out the dust cover [A] ●Remove the snap spring [B]. Special tool—inside circlip plier: ●Take the piston assembly [D] and reset spring [F].
Page 100 Assembling Brake master cylinder ●Before assembly, use the brake fluid or ethnaol to clean all parts, including the brake master cylinder. Note Except for the brake pad and disc brake, other brake parts can only be cleaned by disc brake fluid, isopropyl alcohol or ethanol. Do not use any other fluid to clean above parts.
Page 101: Replacing Rubber Parts Of Calipers
Replacing Rubber Parts of Calipers Disassembling Front Calipers ●Before the front calipers are disassembled, drain the front brake fluid. ●Loosen the front calipers mounting bolt [A] and banjo bolt [B], and then gently unscrew them. ●Removing: Front calipers [C] (see “Disassembling Front Calipers” in the “Brake” chapter), Front brake pad (see “Disassembling Front Brake Pad”...
Page 102 Assembling Front Calipers ●Clean the calipers parts (except for the brake pad). Note The parts must be cleaned by using the disc brake fluid, isopropyl alcohol or ethanol! ●Replacing the new oil seal [A]. ○Add the silicone grease to the oil seal, and then install it into the brake caliper with hands.
Page 103 Disassembling Rear Calipers ●Loose the rear calipers banjo bolt [A] and then tighten it gently (do not screw it too tightly). ●Removing: Rear calipers [B] (see “Disassembling Rear Calipers” in the “Brake” chapter), Brake pad (see “Disassembling Rear Brake Pad” in the “Brake” chapter), Rear calipers assembling bolt, O-ring seal...
Page 104 Assembling Rear Calipers ●Clean the calipers parts (except for the brake pad). Note The parts must be cleaned by using the disc brake fluid, isopropyl alcohol or ethanol! ●Install the deflating screw and deflating valve dust cover. Locking torque of deflating screw: 7.8 N·m ●Apply the brake fluid to the inner wall of brake caliper.
Page 105: Replacing Spark Plug
Replacing Spark Plug ●Remove the ignition coil (see “Disassembling Ignition Coil” in the “Electrical System” chapter). ●Remove the spark plug [A] vertically with the wrench for spark plug. ●Replace a new spark plug. Standard Spark Plug Model: NGK CR8E ●Insert a new spark plug into the spark plug hole and press the spark plug tightly with your finger.
Page 106: Chapter Iii Fuel Injection System
CHAPTER III FUEL INJECTION SYSTEM INTRODUCTION TO EFI .............................. 3-3 EFI SYSTEM ..................................3-4 EFI PART POSITION ..............................3-6 TECHNICAL PARAMETERS ............................3-10 FUEL TANK ..................................3-12 FUEL TANK EXPLODED VIEW ..........................3-12 FUEL EVAPORATIVE RECOVERY SYSTEM ..................... 3-15 DISASSEMBLY OF FUEL TANK ..........................3-16 NOTES FOR EFI SERVICE .............................
Page 107 ENGINE TEMPERATURE SENSOR .......................... 3-36 INTAKE AIR TEMPERATURE SENSOR ........................3-37 MANIFOLD ABSOLUTE PRESSURE SENSOR ....................... 3-39 OXYGEN SENSOR ................................ 3-41 IDLE SPEED STEPPER MOTOR ..........................3-43 CARBON CANISTER SOLENOID VALVE (ECP) ....................3-45 FAULT MAINTENANCE DIAGNOSIS METHOD OF EFI SYSTEM ..............3-47 DIRECTLY MAKING THE FAULT LAMP AT INSTRUMENT FLASH FOR DIAGNOSIS ......
Page 108: Introduction To Efi
Introduction to EFI This motorcycle adopts the small engine EFI (electronic fuel injection) system of Delphi Corporation. This system achieves closed-loop control, fuel injection and ignition control through oxygen sensor. Three-way catalytic converter is used to treat the gas after the combustion of engine, to convert it into harmless gas and discharge it to the atmosphere. This system uses closed-loop control self-learning system, which can effectively eliminate the manufacturing differences of system and related mechanical parts, improve the overall consistency of the motorcycle, and eliminate the error of motorcycle caused due to wear and other causes after actual use.
Page 109: Efi System
EFI System...
Page 110 No. of ECU connector J2 Black (Black) J1 Grey (Grey) Function description J1-1 Idle speed control valve A high J1-2 J1-3 Fault lamp J1-4 J1-5 J1-6 Revolution meter J1-7 CAN line signal low J1-8 CAN line signal high J1-9 Power (system) grounding J1-10 J1-11 Idle speed control valve A low...
Page 111: Efi Part Position
EFI Part Position ECU [A] Throttle body [A] Throttle position sensor [A] Fuel injector [B]...
Page 112 Starting relay [A] Igniter [A] Ignition coil [A] Fuse [A]...
Page 113 Oxygen sensor [A] Carbon canister solenoid valve [A] Side stand switch [A] Gear position sensor [B] Speed sensor [A]...
Page 114 Main switch key [A] Main switch [B] Coolant temperature switch sensor [A] Fuel pump [A]...
Page 115: Technical Parameters
Technical Parameters Item Standard EFI system Idle speed 1400 ±100 r/min (rpm) Throttle valve assembly: Type Cylinder type Φ34 mm Diameter Negative value of throttle valve 2.7 kPa Bypass screw — ECU: Manufacturer Delphi Type Electronic memory type, equipped with IC ignitor, sealed using resin Avaliable engine rotation speed scope 100 -11 200 r/min (rpm)
Page 116 (Continued) Item Standard Throttle handle and throttle line 3-5 mm Free clearance of throttle handle Air filter Wet type sponge filter Filter element material 3-11...
Page 117: Fuel Tank
Fuel tank Fuel tank Exploded View 3-12...
Page 118 Parts and specifications Fuel tank components Rubber sleeve Fuel tank installing sleeve Fuel tank installing washer Bolt M6×35 Front fender installing seat of fuel tank Bolt M6×10 Fuel tank cover supporting components Tank cover sealing washer Socket head cap screw M5×30 Socket head cap screw M5×14 Fuel pump components 13 ' fuel pump screw...
Page 119 Fuel Tank Exploded View Torque Tightener Remarks N·m kgf·m ft·lb Fuel tank mounting bolt 88.5 in·lb Front fender installing seat of fuel tank 88.5 in·lb Fuel tank lock mounting bolt 70.8 in·lb Fuel tank lock decoration screw 53.1 in·lb Fuel pump mounting bolt 88.5 in·lb Fuel level sensor tightening nut 88.5 in·lb...
Page 120: Fuel Evaporative Recovery System
Fuel Evaporative Recovery System Name and specifications Fuel tank components One way valve components Connecting pipe between fuel tank and One way valve Clamp Carbon canister Connecting pipe between carbon canister and solenoid valve Connecting pipe between one way valve and carbon canister Carbon canister solenoid valve Connecting pipe between carbon canister solenoid valve and engine intake air port...
Page 121: Disassembly Of Fuel Tank
Disassembly of Fuel Tank  Disassemble rear seat (see “replacement of air filter element”)  Disassemble front seat (see “replacement of air filter element”)  Disassemble fuel tank fender  Disassemble front mounting bolt of fuel tank  Disassemble rear mounting bolt of fuel tank ...
Page 122: Notes For Efi Service
Notes for EFI service There are many notes for service of EFI system. ○This EFI system must be powered by a 12V battery. Do not use any other battery as a power source for EFI system. ○Do not connect the wrong battery cable, or ECU may be damaged. ○To avoid damage to EFI parts, do not disconnect the battery cable or any other electrical connectors while the main switch is on or the engine is running.
Page 123 ○In order to maintain a correct mix of fuel and air (F / A), intake air leakage shall not occur in EFI system. Screw up oil filler plug [A] after adding oil. The locking torque of oil filler plug: tighten it with hands. 3-18...
Page 124: Ecu
Engine controller (MT05 ECU) The ECU can detect the running state of engine in real time through various kinds of sensors. Through reasonable calculation and self-learning control output device, it can ensure original vehicle emissions and fuel economy at the same time of optimizing the steering performance of vehicles under different conditions.
Page 125: Ecu Disassembly
ECU Disassembly •Disassemble front seat • Disassemble ECU [A] Bolt [B] ECU Installation •Assemble it in reverse order of disassembly Tightening bolt torque of ECU: 3.9N·m Warning The installation surface must be flat, to prevent causing external stress to ECU, which may result in bending of ECU circuit board: Notes for ECU Notes...
Page 126: Fuel Pump
Fuel pump Fuel pump Working Fuel pump assembly provides the fuel to engine with 250Kpa gasoline pressure to meet system requirements. It is installed at the bottom of tank to provide the required fuel to engine through the connecting pipes. Fuel pump: The electrical principle of electric fuel pump is that: when DC motor is driving the fuel pump with turbine-type structure to run, the fuel in the circumferential grooves of turbine rotor will move at a high speed with the turbine motor.
Page 127: Fuel Pump Label And Mark
Fuel pump Composition 1. Fuel pump body 2. Filter 3. Sealing washer and fuel pump bracket 4. Pressure adjustor 5. Fuel pump harness Fuel pump Label and Mark Fuel pump assembly: make it at fuel pump assembly installing plate in the form of label. Fuel pump: make engraved mark at fuel pump.
Page 128: Fuel Pump Maintenance Process
Fuel pump Maintenance Process: Safety Protection: When conducting maintenance operation for fuel system, care should be taken to ensure personal safety  Disconnect the negative electrode of battery of motorcycle.  Smoking is prohibited and a “no smoking” sign should be placed near the operating area. ...
Page 129 face the rear of fuel tank, and ensure that the installing surface of fuel tank is clean and flat.  Install mounting bolts on the fuel pump assembly cover and tighten them evenly in the order indicated in the following figure. Installing torque of screw: 3- 4 Nm. The fuel pump assembly should be secured with special bolts.
Page 130: Notes For Use
Notes for Use: Notes Cause Do not: throw or knock fuel pump It may cause damage to the internal of fuel pump Do not: fuel pump is “running in dry state” (there is no fuel at fuel pump inlet and filter) It may cause damage to the internal of fuel pump Please ensure that there is sufficient fuel in the tank Impurities may go into the fuel pump from damaged filter...
Page 131 Warning:  Because there is no gasoline in the fuel tank of new motorcycle at the beginning, a lot of air is generated at fuel hose, so it needs to start it for several times to bleed the air in the fuel line, and then the engine can work properly, which is normal.
Page 132: Throttle Body
Throttle Body Working Principle of Throttle Body Throttle body assembly mainly consists of the following components: main casting valve, bearing, shaft and valve plate, return spring, throttle wire part, throttle position sensor system, and bypass screws control system. All of the above subsystems work together to meet the requirements for following functions: ...
Page 133: Technical Parameters
Technical Parameters Throttle Body: 34mm inner diameter: maximum flow: ≥50g/s@2.7kPa vacuum degree   Breakaway torque of throttle body: Idle speed state: 0.12±0.03Nm Full opening: 0.32±0.05Nm Throttle Position Sensor:  Reference voltage: 5±0.1VDC  Resistance between T1 and T2: 3k-12kΩ Idle Air Control Valve: ...
Page 134: Cleaning Method Of Throttle
Cleaning Method of Throttle Clean throttle body using carburetor cleaner (3M product is recommended). Spray cleaner at the inner wall of throttle body, and gently remove dust and carbon deposit and other items using a brush. Be careful to prevent the bypass screws from being blocked by dirt.
Page 135: Working Principle Of Fuel Injector
Fuel injector Additional resistor Various sensors Crankshaft position sensor Air flow meter Coolant temperature sensor Throttle position sensor Ignition switch Oxygen sensor Vehicle speed sensor Battery voltage Working Principle of Fuel Injector Injector is an actuator. It can inject appropriate fuel into the intake air of engine through ECU and then suck it into combustion chamber and then mix it with the oxygen in the fresh air filled for combustion.
Page 136 O-ring Seal Connected to fuel Rail or fuel Injection Cap •Dimensions: •Inner diameter: 6.35 mm •Outer diameter: 14.85 mm •Section thickness: 4.25 mm •Material •Viton□GLT (blue): application at low temperature •Viton□A(black): except the application at low temperature O-ring Seal Connected to Intake Air Pipe End •Dimensions: •Inner diameter: 9.61mm •Outer diameter: 14.49 mm...
Page 137: Overvoltage Impact Of Fuel Injector
Overvoltage Impact of Fuel Injector The fuel injector can run at the voltage of 26V and the working conditions of 100ms (pulse) and 200ms (one cycle time) for 1 minute at most (run with oil). It will not affect the flow rate, cause permanent damage to the solenoid coil or weaken the electromagnetic performance.
Page 138: Notes For Use Of Fuel Injector
Notes for Use of Fuel Injector Notes Cause Do not: resuse the seal; if it needs to reuse it in special conditions, please carefully check whether the sealing ring is damaged before Avoid leakage use. Do not: immerse the end of nozzle in the lubricant. It may block spray hole.
Page 139: Requirements For Installation Of Fuel Injector
Requirements for Installation of Fuel Injector During the installation and removal process, please strictly observe the following methods to avoid damage to the fuel injector body and electronic components.  Lubrication: Apply a small amount of lubricant to the underside of the sealing ring. ISO 10 light mineral fuel or equivalent product is recommended.
Page 140: Blocking Of Fue Injector
Blocking of Fue Injector The accumulation of fuel impurities may cause flow offset and shorten fuel injector life. When the engine is standing, the heat of engine may produce fuel precipitation through the head of fuel injector, and the precipitation gathered in the injection hole may cause flow offset.
Page 141: Engine Temperature Sensor
Engine Temperature Sensor  Working principle of engine temperature sensor This sensor is used for coolant-cooled engine to measure the temperature at coolant passage of engine, installed at engine cylinder. Within the temperature range of this sensor, its resistance may vary with engine temperature. Its characteristic is the negative temperature coefficient resistance characteristic.
Page 142: Intake Air Temperature Sensor
Intake Air Temperature Sensor  Working principle of intake air temperature sensor Within the temperature range of the sensor, its resistance may vary with the engine temperature, its characteristic is negative temperature coefficient resistance characteristic. It is a non-serviceable part. ...
Page 143 •Pin definition and function drawing Measure the resistance between two pins of sensor using multimeter. The specific temperature and resistance correspondence table is as follows: Measured temperature Resistance value (Ohm） (degree centigrade) 9,399 7,263 5,658 4,441 3,511 2,795 2,240 Intake air temperature sensor is at air filter, and it can be removed after wearing gloves. ...
Page 144: Manifold Absolute Pressure Sensor
Manifold Absolute Pressure Sensor •Working principle of manifold absolute pressure sensor This sensor is used to measure the absolute pressure of air intake manifold, reflect the intake air pressure according to the difference of resistance, and then calculate the intake air volume in engine combustion chamber through indirect conversion, and it is also a non-serviceable part.
Page 145 •Pin definition •Position Manifold absolute pressure sensor is integrated at throttle body •Cleaning If necessary, the sensor can be cleaned with isopropyl alcohol and then air dried. It should be soaked in isopropyl alcohol for not more than 1 minute, and sealing connector should be installed during cleaning to prevent cleaner from intruding into the inside of sensor.
Page 146: Oxygen Sensor
Oxygen Sensor •Working principle of oxygen sensor Oxygen sensor can be used to detect the oxygen content in the waste gas of engine exhaust pipe for internal fuel closed loop control of ECU, thus maintaining engine combustion at the most reasonable state of air and fuel ratio. •Appearance of oxygen sensor •Technical parameters ...
Page 147 •Oxygen sensor pin definition •Characteristic curve Oxygen sensor is at exhaust manifold. Please first pull up oxygen sensor plug-in, and then remove the oxygen sensor with 13# open spanner, and pay attention to not knot or clinch the harness. •Requirements for fuel quality ...
Page 148: Idle Speed Stepper Motor
Idle Speed Stepper Motor 1. Valve plate; 2. Intake air manifold; 4. Idle speed stepper motor; 5. By-pass port •Working principle of idle speed stepper motor The function of idle speed control valve is to control the flow area of bypass air passage of throttle body, so as to adjust the air volume of engine and control the idle speed of engine.
Page 149 •Characteristic parameter: Rated voltage: 12Vdc Maximum / minimum working voltage 7.5Vdc/14Vdc 53Ω±5.3 Resistance per coil (@27°C): 35Ω Maximum resistance(@-40°C): Inductance per coil (@25°C): 33.5mH±6(1kHz) Stepped distance (stepped frequency): 0.04167mm Maximum travel: 8.5mm (204 steps) Operating temperature range: -40°C -125°C (150°C peak value) Minimum storage temperature: -40°C Weight:...
Page 150: Carbon Canister Solenoid Valve (Ecp)
Carbon Canister Solenoid Valve (ECP) •Overview of working principles Carbon canister solenoid valve controls the fuel vapor in the carbon canister into engine intake system from carbon canister, and make it burn in the engine. Thus, reduce fuel evaporation emission. •Appearance The appearance of carbon canister solenoid valve is shown below: •The ECP solenoid valve pins do not have positive and negative electrodes, and the connection method is as shown below...
Page 151 •Technical parameters  Normal operating voltage: 8-16V VDC  Operating temperature: -40-120°C  Operating frequency: 16 Hz  Maximum flow: 25-35L/min Flow curve is as shown below: Duty cycle (%) • Installation requirements  Carbon canister solenoid valve should be horizontally installed at motorcycle. ...
Page 152: Fault Maintenance Diagnosis Method Of Efi System
Fault Maintenance Diagnosis Method of EFI System Directly Making the Fault Lamp at Instrument Flash for Diagnosis Fault lamp [A] is located on the meter panel and has a mark below it. Under normal circumstances, open the key, the fault lamps will be on normally, indicating that the EFI system is a state with power supply, and it can work; fault lamp is off, indicating that there is no power supply in EFI circuit, it will not work, and check should be conducted for the connection of positive and negative electrodes of fuse and battery.
Page 153 •MT05 Trouble Code Table DTC Number System or Component DTC Description (Diagnostic (software instrument display） display ) MAP Circuit Low Voltage or Manifold Absolute Open Pressure Sensor (MAP) MAP Circuit High Voltage —_108 IAT Circuit Low Voltage Intake Air Temperature IAT Circuit High Voltage or Sensor (IAT) Open...
Page 154 Park Neutral Switch Diag Park Neutral Switch Error 2128 CCP short to high 1093 CCP short to low/open 1092 Rollover Sensor Rollover Sensor 1500 5376 Diagnostic malfunction/Triggered BLM_MaxAdapt Several BLM value hit maximum BLM_MinAdapt Several BLM value hit minimum PE mode burned AFR keeps PESystLean lean 3-49...
Page 155: Diagnosing Fault Using Diagnostic Tool
Diagnosing Fault Using Diagnostic Tool • Diagnostic Tool •Operation Method: a) Find the 6-hole diagnose interface at motorcycle; b) Connect connecting wire and diagnostic tool interface; c) Open the key for diagnosis. Warning  XCM-PT100X diagnostic tool is a high-precision instrument, so it should be protected from shock and vibration;...
Page 156: Checking Fault Using Diagnostic Software Pchud
Checking Fault Using Diagnostic Software PCHUD PCHUD software used to detect and record engine operating data, laptop should be connected to 6-hole diagnostic port of motorcycle through K line before use, and diagnosis port should be below rear seat. Please note that PCHUD system only supports 16Bit Microsoft Windows operating system or a very small number of 32bit Windows operating system, does not support 64bit systems such as Win7, Win8 or iOS, etc.
Page 157 (5) If the software interface cannot display the real-time communications data, it needs to conduct the following work: check whether there is problem in COM port connection setting, generally set COM Port: 4. Baud Rate:10400, and do not select DTR High at startup And then conduct normal communications, display the current trouble code at MALFCURR, and display historical trouble code at MALFHIST.
Page 158 And then query the corresponding fault according to trouble code table. •PCHUD Software Parameter Interpretation: VRPM engine speed VTHROT throttle position VBARO ATMOSPHERIC PRESSURE VMAP manifold absolute pressure VMAPEXP expect manifold absolute pressure VIGN battery voltage VCLTS cylinder temperature or coolant temperature VIAT intake air temperature STATUSBYTE5...
Page 159 VMAPRANG MAP read angle AFFNLAFR target air fuel ratio SAESTA cylinder 1 Advanced ignition angle SAIDLDYN idle dynamic Spark Advance SPDWELL dwell time IAINTEGOFST airflow integral of idle air control valve IACVDSMP desired position of idld air control valve STATUSBYTE2 STATUSBYTE2 FCLCEN1 cylinder 1 close loop correction enable...
Page 160 □Norm fuel cut-off enable, the normal flag is white, FUELCOFF None □Abnormal if not blue □Norm Rollover sensor enable, normal is white, if VRLVENBL None □Abnormal not blue 3. The parameters can be checked 1 min for idle speed after vehicle starting. And then check the stability of EFI parameter after 3 minutes of long idle.
Page 161 □Norm VCLTS degC □Abnormal cylinder temperature or coolant temperature □Norm VIGN battery voltage volt □Abnormal □Norm vehicle speed vehicle speed Km/h □Abnormal □Norm FBLMCOR1 0.75 1.15 cylinder 1 block learn memory factor □Abnormal □Norm FBLMCOR2 0.75 1.15 cylinder 2 block learn memory factor □Abnormal □Norm...
Page 162: Common Troubleshooting Methods Of Electronic Fuel Injection System
Common Troubleshooting Methods of electronic Fuel Injection System Maintenance Tool a) Disassembly and assembly of electronic control system components - common automotive mechanical parts removal tool b) Electronic control system circuit and system electrical signal - digital multimeter (with buzzer) c) Electric control system fault diagnosis and engine working condition detection ■...
Page 163: Engine Working Data Flow Displayed By Diagnostic Tool
Engine Working Data Flow Displayed by Diagnostic Tool Analyze and determine engine fault using the engine working data flow displayed by the diagnostic tool. Step I a) Engine harness and the vacuum pipeline—may affect the system to control air flow and fuel supply b) Whether oxygen sensor is assembled in place—may affect the system to determine the air to fuel ratio c) Engine fault indicator—may affect the system to give an alarm for fault d) Battery voltage—determine whether the power of battery is sufficient...
Page 164  Check and repair bulb and its line  Connect diagnostic tool to system diagnosis interface It is be able to be on: b) Whether diagnostic tool can be connected to system for communications  Check fuse and grounding line If not: ...
Page 165  Check fuel quantity in fuel tank, fuel filter, fuel line pressure and nozzle Too low idle speed:  One way valve clearance and confirm whether it is too small Fault Phenomenon—Instable Idle Speed with Deceleration and Flameout One way valve clearance Check whether idle speed bypass hole and throttle body are too dirty Fault Phenomenon—Insufficient Power of Deceleration Check whether the parameters are normal at idle speed and high idle speed;...
Page 166 Sample of Diagnosis Table Registration number (license Name of rider: Year of first registration: number): Model: Engine No.: Frame No.: Date in the event of a fault: Mileage: Environment in the event of a fault: □Clear □ Cloudy □Rain □Snow □Fair □Others: Weather □...
Page 167: Chapter Iv Cooling System
CHAPTER IV COOLING SYSTEM EXPLOSIVE VIEW ................................. 4-2 COOLANT FLOW DIAGRAM ............................4-4 TECHNICAL PARAMETERS ............................4-6 COOLANT ..................................4-7 CHECKING WHETHER COOLANT DETERIORATES ..................4-7 CHECKING COOLANT LEVEL ..........................4-7 DISCHARGING COOLANT ............................4-7 ADDING COOLANT ..............................4-7 DETECTING PRESSURE ............................4-7 CLEANING COOLING SYSTEM ..........................
Page 168: Explosive View
Explosive View...
Page 169 Torque Chinese name and specification Remarks N·m kgf·m ft·lb Inlet hose Stainless steel clamp radiator fan switch Bolt M6×12 88.5 in·lb radiator fan Radiator Clamp (diameter : 10) Reserve tank Bolt M6×12 88.5 in·lb Reserve tank cover radiator overflow hose radiator cap Radiator overflow hose Bolt M6×20...
Page 170: Coolant Flow Diagram
Coolant Flow Diagram The permanent antifreeze is used to prevent the cooling system from rusting or being corroded as coolant. Once the engine starts, the pump begins to rotate and the coolant begins to circulate. Using the paraffin base thermostat, the cooling system is on or off with the temperature changes of coolant. In order to keep the coolant in the proper temperature, the thermostat constantly changes the valve opening.
Page 171 expand. The redundant coolant will flow through the radiator cap and hose, then flow to the reserve tank and be stored in the reserve tank temporarily. Conversely, with the decrease of engine temperature, the coolant in the radiator and water jacket will shrink and the coolant stored in the reserve tank will return to the radiator.
Page 172: Technical Parameters
Technical Parameters Item Standard Prepared coolant in delivery (Recommended) Type Permanent antifreeze Color Green Mixing ratio 50% soft water, 50% coolant Freezing point -35℃ Amount 3.4L (Full fluid level of reserve tank, radiator and engine are included) Radiator cap Release pressure 93-123kPa Thermostat Opening valve temperature...
Page 173: Coolant
Coolant Checking Whether Coolant Deteriorates ●Visually check the coolant in the fluid storage tank. ★If white cotton-wool flotages are observed, it indicates that the aluminum parts inside the cooling system have been corroded. If the coolant is brown, it indicates that the iron parts or steel parts rust. When any one of above situations occurs, please clean the cooling system.
Page 174: Cleaning Cooling System
Cleaning Cooling System Sometimes, the rust, scale and calcium oxide will be deposited inside the pipeline cavity in the cooling system and radiator. Once rust, scale and calcium oxide are found, please clean the cooling system! Otherwise the above sediment will block the coolant passage, which will greatly reduce the efficiency of cooling system.
Page 175: Coolant Pump
coolant Pump Disassembling coolant pump ●Remove the bottom cover (see “Disassembling Bottom Cover” in the “Frame” chapter), ●Drain the coolant (see “Replacing Coolant” in the “Regular Maintenance” chapter); ●Darin the oil (see “Replacing Oil” in the “Regular Maintenance” chapter); ●Removing: coolant Pump Cover Bolt [A] ooolant Pump Cover [B] coolant hose [C]...
Page 176: Checking Coolant Pump Impeller
Checking coolant Pump Impeller ●Visually check the coolant pump impeller. ★If the surface of impeller has been corroded or the blade has been broken, replace the coolant pump assembly. 4-10...
Page 177: Radiator
Radiator Disassembling Radiator and Radiator Fan ●Remove the radiator fairing (see “Disassembling Radiator Fairing” in the “Frame” chapter), ●Drain the coolant (see “Replacing Coolant” in the “Regular Maintenance” chapter), ●Removing: Radiator lock bolt [A] at the lower side, Outlet hose clamp of engine [B], Outlet hose of engine [C], Radiator mounting bolt [D] at the upper side, Reserve tank hose [E]...
Page 178: Installing Radiator And Radiator Fan
Installing Radiator and Radiator Fan ●Arrange the radiator fan leads properly (see the section in the “Appendix” chapter: Winding Method of Cable, Wire and Hose”). ●Install the radiator bracket sleeve [A], buffer sleeve [B] and bolt as shown in the figure. ●Install the parts disassembled previously (see the corresponding chapters) Locking torque of radiator mounting bolt (upper side): 10 N·m Locking torque of radiator mounting bolt (lower side): 10 N·m...
Page 179: Checking Radiator Cap
Checking Radiator Cap ●Removing: Radiator cap [A] ●Check the base [A], top [B] valve sealing and valve spring [C]. ★If any one of above parts is broken, replace with a new radiator cap. ●Install the cap [A] on the pressure meter [B] of cooling system. Remark ○Wet the sealing surface of radiator cap with water or coolant to prevent pressure leakage.
Page 180: Checking Radiator Filler
Checking Radiator Filler ●Removing: Radiator Cap ●Check whether the radiator filler is damaged. ●Check the top seal sleeve and bottom seal sleeve [A] inside the filler. The top seal sleeve base and bottom seal sleeve base must be smooth and clean so as to ensure the normal operation of radiator cap.
Page 181: Thermostat
Thermostat Disassembling Thermostat ●Drain the coolant (see “Replacing Coolant” in the “Regular Maintenance” chapter); ●Remove the radiator fairing (see “Disassembling Radiator Fairing” in the “Frame” chapter), ●Remove the radiator (see “Disassembling Radiator” in the “Radiator” chapter), ●Removing Bolt [A], Thermostat [B], ●Removing: Thermostat Note...
Page 182: Checking Thermostat
Checking Thermostat ●Remove the thermostat (see “Disassembling Thermostat”) and check the thermostatic control valve [A] in indoor temperature. ★If the valve is open, a new thermostat is required. ●To measure the valve opening temperature, the thermostat [A] shall be hung in a container filled with water, and then raise the water temperature.
Page 183: Hose And Pipeline
Hose and Pipeline Installing Hose ●Install the hose and pipeline and pay attention to the bending direction of hose and pipeline. Avoid over bending, kinking, squeezing or twisting. ●Arrange the hose (see the section in the “Appendix” chapter: Winding Method of Cable, Wire and Hose”). ●The clamp [A] shall be as close to the hose as possible to protect the end of hose from tilting and prevent the hose from loosening.
Page 184: Coolant Temperature Sensor
coolant Temperature Sensor Note Do not drop the coolant temperature sensor on a hard surface, otherwise the coolant temperature sensor will be damaged. Disassembling/Installing coolant Temperature Sensor ●Disassemble the radiator (see “Radiator”—“Disassembling Radiator”). ●Disassemble the coolant temperature sensor [A] ●Install the parts disassembled previously (see the corresponding chapters). Locking torque: 20-25 N·m Checking coolant Temperature Sensor ●See “Engine coolant Temperature Sensor”...
Page 185: Chapter V Engine
CHAPTER V ENGINE LUBRICATION SYSTEM ..................................... 5-2 PREPARATION INFORMATION ................................5-2 OIL PASSAGE DIAGRAM ..................................5-2 TECHNICAL PARAMETERS.................................. 5-3 OIL PUMP ........................................5-4 CYLINDER HEAD ......................................5-7 CYLINDER HEAD EXPLODED VIEW ..............................5-7 CAMSHAFT AND VALVE EXPLODED VIEW ............................. 5-8 PREPARATION INFORMATION ................................
Page 186: Lubrication System
Lubrication System Preparation Information Function of lubrication system: The function of engine lubrication system is to supply lubricant to the friction surface of parts to make the dry friction of surface become the liquid friction among the particles of the lubricant so as to reduce the wear of parts; cool the parts with higher thermal load;...
Page 187: Technical Parameters
Technical Parameters Item Standard Use limit Oil capacity : ＿ When replacing oil 1.2±0.05L ＿ When disassembling 1.5±0.05L Oil pump rotor: Radial clearance between inner and outer rotors 0.05-0.13mm 0.15mm Clearance between outer rotor and oil pump body 0.10-0.16mm 0.2mm...
Page 188: Oil Pump
Oil Pump Oil Pump Disassembly ●Loose the oil pump mounting bolt [D] and remove the roller sprocket [D] on the oil pump, oil pump chain [B] and clutch shell component [A] ●Remove the screw [A]. ●Remove the oil pump [B]. ●Disassemble the screw [A], remove the oil pump cover and decomposition the oil pump [B].
Page 189 Checking Oil Pump ●Check the radial clearance between outer rotor [A] and inner rotor [B]. Service limit: 0.15mm. ●Check the clearance between outer rotor [A] and oil pump cover [B]. Service limit: 0.20mm.
Page 190 Installing Oil Pump ●The assembly of oil pump is shown below Screw [A] Chain [B] Screw [C] Gasket [D] Roller sprocket [E] Oil pump body [F] Oil pump shaft [G] Innerrotor[H] Outer rotor[I] Oil pump cover [J] Note: After the assembly, the inner and outer rotors shall rotate flexibly without clamping stagnation.
Page 191: Cylinder Head
Cylinder Head Cylinder Head Exploded View...
Page 192: Camshaft And Valve Exploded View
Camshaft and Valve Exploded View...
Page 193: Preparation Information
Preparation Information Function of Cylinder Head: Cylinder head is used to seal the cylinder and it forms a combustion chamber with the piston to withstand the high temperature and high pressure gas. And it can also complete the intake and exhaust through the valve mechanism. Operation Precautions: In order to ensure the sealing of cylinder head and crankcase, the cylinder head withstands great bolt tightening torque.
Page 194: Technical Parameters
Technical Parameters Item Standard Use limit Planeness of cylinder head 0.03mm 0.05mm Valve and valve guide Valve clearance: ＿ Intake 0.13-0.15 mm ＿ Exhaust 0.13-0.15 mm Outer diameter of valve guide : Intake 4.465-4.475 mm 4.455 mm Exhaust 4.465-4.475 mm 4.455 mm Inner diameter of valve guide : Intake...
Page 195: Special Tools And Sealant
Special Tools and Sealant Pressure meter 20 kgf/cm Valve seat cutter 60°: Valve spring compressor assembly: Valve seat cutter fixer rod: Valve seat cutter 45°: Valve seat cutter 45°: Valve seat cutter 32°: Valve guide mandrel: Valve seat cutter 32°: Valve guide reamer: 5-11...
Page 196 Valve seat cutter fixer: Pressure meter adaptor: Valve seat cutter 60°: L-hose: Valve guide driver: Valve guide driver Attachment E: Valve spring compressor adaptor: Adhesive: Valve oil seal compressing fixture: 5-12...
Page 197: Cylinder Head
Cylinder Head Disassembling Cylinder Head ●Remove the ignition coil. ●Loosen the fastening bolts [A], take the gasket and remove the cylinder head cover [B]. ●Loosen the fastening bolt [A] and remove the chain tensioner [B]. ●Measure the fit clearance between cylinder head [A] and camshaft [B] with a thickness gauge.
Page 198 ●Loosen the camshaft support lock screw [A] and remove the camshaft support [B] and camshaft stopper collar. ●Remove the chain guide and chain ●Remove the camshaft. 5-14...
Page 199 ●Loosen the cylinder head bolt [A]. ●Remove the cylinder head [B]. ●Remove the Valve lifter, compress the valve spring with the valve spring compression tools and remove the valve cotter. ●Take the valveshim, valve spring, upper and lower valve spring seats and valve. Valve Decomposition Valve [A] Lower valve spring seat [B]...
Page 200 Checking Combustion Chamber ●Check the combustion chamber and clear the carbon deposits in the combustion chamber. Checking Cylinder Head Joint Surface ●Measure the planeness of cylinder head joint surface [C] with a thickness gauge [A] and straightedge [B]. Service limit: 0.05mm. ★When the planeness of cylinder cover joint surface exceeds the use limit, put the fine sandpaper on the plate so that the cylinder head joint surface fits the sandpaper, and then push and grind them...
Page 201 Checking Valve Guide ●Check the valve guide and remove the carbon deposits in the valve guide with a reamer before check. Note Rotate the reamer clockwise and do not rotate the reamer secondaryclockwise. ●Measure the inner diameter of valve guide with a measurement meter [A].
Page 202 ●After the valve guide is embedded, carry out the finishing by using the valve guide reamer [A]. Note Add an appropriate amount of cutting oil during cutting with a reamer. The reamer shall be rotated clockwise. ● Clean the carbon deposits in the combustion chamber and valve, and thoroughly rinse the intake and exhaust valves.
Page 203 ●Remove 1/4 of outer end of valve seat ring with a 25° cutter. ●Remove 1/4 of bottom of valve seat ring with a 60° cutter. Take the cutter and check the positions which have been disposed. ●Grind the valve seat ring with a 45° finishing cutter to reach an appropriate width.
Page 204 ●If the contacted position is in the too high part of valve, please Contact surface is high lower the valve seat ring with a 25° flat cutter. ●If the contacted position is in the too low part of valve, raise the valve seat ring with a 60°...
Page 205: Cylinder And Piston
Cylinder and Piston Cylinder Exploded View 5-21...
Page 206: Piston, Crankshaft Connecting Rod Exploded View
Piston, Crankshaft Connecting Rod Exploded View 5-22...
Page 207: Preparation Information
Preparation Information Function of Cylinder Block: The cylinder provides a space to compression, combustion and expansion of gas and plays a guiding role in the piston movement. It also transfers a portion of heat in the cylinder to the surrounding cooling mediums. Function of Piston: 1.
Page 208: Technical Parameters
Technical Parameters Item Standard value Use limit Cylinder: Inner diameter 72.000-72.015 mm 72.02 mm Cylindricity 0.015 mm Roundness 0.015 mm Planeness 0.02 mm 0.08 mm Piston: Outer diameter of piston (measurement point) 71.94-71.955 mm 71.93 mm (8-11mm at the bottom of piston skirt) Inner diameter of piston pin hole 16.002-16.008 mm 16.02 mm...
Page 209: Cylinder Checking And Replacement
Cylinder Checking and Replacement Disassembling Cylinder ●Remove the parts above the cylinder head and loosen the cylinder mounting bolt [A]. ●Remove the cylinder [B] vertically. ●Removing Gasket [A] Dowel pins [B] Installing Cylinder ●Install the gasket [A] and dowel pin [B] on the crankcase. ★The wrinkle and unevenness are not allowed to appear on the gasket ★Dislocation is not allowed;...
Page 210 Checking Cylinder ●Check the wear situation of inner wall of cylinder. Check whether there are obvious scratches and obviously shining irregularities ★If the wear is serious, please replace it. 5-26...
Page 211: Piston
Piston Disassembling Piston ●Remove the piston pin clip[A], remove the piston pin [B] and take the piston [C]. Note During disassembly, do not drop the clip into the crankcase. ●Remove the piston ring. Installing Piston ●When replacing the piston, select the cylinder and piston of matching group for assembly and detect the cylinder matching clearance and other size requirements ●Apply engine oil to the piston ring and piston evenly, make the...
Page 212 ●Scale the gasket attached to the crankcase before installing the piston. Note Foreign materials shall not fall into the crankcase. ●Install the piston, piston pin and piston pin snap ring. ★When assembling with a new piston pin snap ring, the snap ring open end should not overlap the piston ring hole gap.
Page 213 Checking Piston, Piston Pin and Piston Ring ●Check the piston, piston pin and piston ring. ★Clear the carbon deposits inside the piston ring groove. Note Do not break or damage the piston ring. ●Install the piston ring after the clearing. Press one side of piston ring with hands and measure the clearance between piston ring [A] and piston ring groove [B] with a thickness gauge [C].
Page 214 Service limit: 0.4mm. 5-30...
Page 215 ●Measure the inner diameter of piston pin hole with a measurement meter ●Inner diameter of piston pin hole Service limit: 16.02mm. ●Measure the outer diameter of piston pin. Service limit: 15.99mm. ●Clearance between piston pin hole and piston pin. Service limit: 0.025mm. ●Measure the outer diameter of piston.
Page 216 ●Measure the roundness of inner wall of cylinder (inner diameter difference between X and Y directions). Service limit: 0.015mm. ●Measure the cylindricity of inner wall of cylinder (inner diameter difference between X and Y directions in upper, middle and lower positions).
Page 217: Crankshaft Connecting Rod
Crankshaft Connecting Rod Crankshaft Connecting RodExploded View Crankshaft component Right crankcase Left crankcase crankcase bolt 5-33...
Page 218: Preparation Information
Preparation Information Function of Crankshaft: It can change the reciprocating motion of piston into rotary motion, generate torque and drive the valve mechanism and other auxiliary mechanisms simultaneously, and it is the installation carrier and power source of timing sprocket, drive gear, bearing, crank pin and other parts.
Page 219: Technical Parameters
Technical Parameters Item Standard value Service limit Horizontal clearance between connecting rod big 0.10-0.35mm 0.5mm ends Crankshaft Radial clearance between connecting rod big ends 0.012-0.024mm 0.035mm connecting rod components Run-out 0.03mm 0.1mm -0.2mm Crankshaft deflection 61.9-62mm 5-35...
Page 220: Crankshaft Connecting Rod
Crankshaft Connecting Rod Disassembling Crankshaft Connecting Rod ●Loosen the crankcase bolts, remove the right crankcase and other accessories on the crankshaft and crankcase, and remove the crankshaft connecting rod combination [A] from the left crankcase [B]. Note Do not damage the joint surface. Do not remove the crankshaft by violent force, and use the same force to knock the crankshaft slowly.
Page 221 ●Measure the radial clearance of connecting rod big end: ★Fix a dial indicator on the connecting rod to measure the clearance between connecting rod big ends in X-Y direction. In addition, use the inner diameter dial gauge to check the inner diameter of connecting rod small end.
Page 222: Balance Shaft
Balance Shaft Preparation Information Function of Balance Shaft: The balance shaft is used to balance the unbalanced force of engine, improve the stability of engine and improve the shock comfort of engine. Disassembling Balance Shaft ●Loosen the mounting bolt, remove the right crankcase, remove the crankshaft from the left crankcase and take the balance shaft Assembling Balance Shaft: ●The assembly of balance shaft shall be carried out in the order...
Page 223: Tensioner
Tensioner Function of Tensioner: As a common holding device on the chain drive system, it can maintain the appropriate tension of chain in the driving process so as to prevent belt from skidding, or to protect the synchronous belt from being dragged out due to the occurrence of tooth jumping and disengaging, or to prevent the chain from loosening and falling off or to reduce the wear of sprocket and chain.
Page 224: Clutch
Clutch Clutch Exploded View Clutch housing [A] Slotted adjusting screw [B] Bolt [C] Clutch spring [D] Nut [E] Pressure plate [F] Bearing block [G] Locknut [H] Friction plates Clutch hub [J] 5-40...
Page 225: Special Tool
Special Tool Clutch locking tool: 5-41...
Page 226: Disassembling Clutch
Disassembling Clutch ●Disassemble the bolt [A] and open the clutch cover [B] on the right crankcase ●Loosen the five bolts [A] of pressure plate [B] in the diagonal crossover way. ●Remove the pressure plate, clutch spring and bearing block. ●Remove the slotted adjusting screw [A] and nut [B]. ●For the special tool [C] locking clutch, remove the locknut and washer[B].
Page 227 ●Remove the clutch disc and friction plates. ●Remove the clutch hub. ●Remove the spline gasket. ●Remove the oil pump lock screw [A]. ●Remove the oil pump sprocket, clutch shell component and chain. 5-43...
Page 228: Installing Clutch
Installing Clutch ●The assembly shall be carried out in the order contrary to the disassembly order. Checking Clutch ●Check whether there are burrs or damaged marks on the clutch shell groove; repair it with a file if any, and replace it if the number of parts to be repaired is too large.
Page 229: Shift Mechanism
Shift Mechanism Shift Mechanism Exploded View Shift lever [A] Return spring [B] Star wheel pressure plate [C] Shift positioning roller arm shaft [D] Shift locating roller arm component [E] Return spring [F] Star locating plate [G] Separating seat [H] 5-45...
Page 230: Disassembling Shift Mechanism
Disassembling Shift Mechanism ●Remove the shift lever [A] and return spring ●Remove the bolt and star wheel pressure plate ●Remove the shift locating roller arm shaft, shift locating roller arm shaft component and return spring ●Remove the star locating plate fixing pin, separating seat and star locating plate ●The disassembled parts are shown in the Exploded View Installing Shift Mechanism ●The assembly shall be carried out in the order contrary to the disassembly order.
Page 231: Checking Shift Mechanism
Checking Shift Mechanism ●Before the decomposition, the shift lever shall be able to rotate flexibly without clamping stagnation; ●Check the wear of shift lever component and replace the component if the wear is serious; ●Check whether the shift lever is bent and replace it if it is bent overly; ●Check whether the elastic force of return spring is reduced and replace it if necessary;...
Page 232: Disassembling Primary/Secondary Shaft Component
Disassembling primary/secondary Shaft Component ●Loosen the closing bolt ●Separate the crankcase Note Do not damage the spacer and closing surface ●Remove the left crankcase Main shaft [A] Main shaft fork [B] SecondarySecondary shaft five-gear fork [C] Shift drum [D] SecondarySecondary shaft six-gear fork [E] SecondarySecondary shaft [F] 5-48...
Page 233: Installing Primary/Secondary Shaft
●Pull out the fork shaft ●Remove the fork ●Pull shift drum, main shaft component secondarysecondary shaft ●The disassembled parts are shown in theExploded View Primary shaft [A] Secondary shaft [B] Fork drum [C] Shift drum [D] Fork [E] Output sprocket [F] Installing primary/secondary Shaft ●The assembly shall be carried out in the order contrary to the disassembly order.
Page 234: Checking Primary/Secondary Shaft Component
Checking primary/secondary Shaft Component ●Measure the outer diameter of fork shaft [B] with a micrometer [A] Service limit: 9.97mm ●Measure the inner diameter of fork hole [B] with a measurement meter [A] Service limit: 10.03mm ●Measure the thickness of fork [B] with calipers [A] Service limit: 4.7mm ●Measure the diameter of shift drum [B] with a micrometer [A] Service limit: 41.5mm...
Page 235: Chapter Vi Chassis
CHAPTER VI CHASSIS WHEEL / TIRE ................................. 6-3 EXPLODED VIEW OF FRONT WHEEL / TIRE ....................6-3 EXPLODED VIEW OF REAR WHEEL / TIRE ....................... 6-5 TECHNICAL PARAMETERS............................ 6-7 SPECIAL TOOLS ................................ 6-8 WHEEL (RIM) ................................6-9 HUB BEARING ................................6-21 DRIVE MECHANISM ..............................
Page 236 SEAT CUSHION AND BODY COVERS EXPLODED VIEW ................6-98 BOTTOM COVER AND ENGINE EXPLODED VIEW ..................6-100 SEAT CUSHION ..............................6-102 BODY COVERS ............................... 6-103 REAR HANDRAIL AND TAIL COVER ....................... 6-105 REAR FENDER ............................... 6-107 FRONT FENDER ..............................6-108 BODY COVERSFUEL TANK GARNISH PLATES AND FAIRING ..............
Page 237: Wheel / Tire
Wheel / Tire Exploded View of Front Wheel / Tire...
Page 238 Torque Parts and specifications Remark N·m kgf·m Front Wheel Axle 10.7 Right sleeve of front wheel Dust ring components Si R Radial Ball Bearing 6204-2RS Intermediate sleeve of front wheel Bolt M8×16 Trim cover of front rim Front rim Valve Z2-01-1/straight 10 Front brake disc/O280 11 Tubeless Tire 110/70-17 12 Left sleeve of front wheel...
Page 239: Exploded View Of Rear Wheel / Tire
Exploded View of Rear Wheel / Tire...
Page 240 Torque Parts and specifications Remark N·m kgf·m Rear Wheel Axle M14×1.5×292 15.0 Gasket 16 Left sleeve of rear wheel Dust ring components Si R Radial Ball Bearing 6204-2RS Chain drive sleeve Self-locking nut M10×1.25 Spring washer φ10 Gasket 10 sprocket /43 teeth 11 Chain 520HO-1×108 12 Sprocket hub 13 Sprocket installing bolt...
Page 241: Technical Parameters
Technical Parameters Item Standard Service Limit Wheel (rim) Wheel runout: ≤TIR 0.5 mm Axial TIR 1.0 mm ≤TIR 0.8 mm Radial TIR 1.0 mm ≤TIR 0.03 mm Wheel shaft runout /100 mm TIR 0.2 mm ≤10 g Wheel balancing — Balance weight 10 g, 20 g, 30 g —...
Page 242: Special Tools
Special Tools Complete set of tools for installing bearing Bearing remover shaft Jack: Jack accessories: Bearing remover head...
Page 243: Wheel (Rim)
Wheel (Rim) Disassembling Front Wheel •Disassemble: Front calipers mounting bolt [A] Front calipers •Loosen: Shaft tightening bolt [B] (right side), Front shaft [A], • Disassemble the fairing at the lower part (see “frame”—“disassembling fairing”). • Lift the front wheel from the ground using a jack. Special tools—jack and jack accessories: •...
Page 244 Installing Front Wheel Remarks ○Rotating direction of wheel [A]. • Check the rotation of front wheel, and then install front wheel. •Apply high-temperature lubricating grease to the edge of the oil seal [E]. •Put the left shaft sleeve of front wheel [A] over the left side of the hub.
Page 245 Disassembling Rear Wheel •Lift rear wheel from the ground using bracket [A]. •Disassemble: Rear calipers mounting bolt [A], rear calipers [B] •Disassemble rear wheel speed sensor [A] from the calipers •Loosen: Left chain adjuster [A], Chain adjuster locking nut [B], 6-11...
Page 246 •Loosen: Right chain adjuster [A], Chain adjuster locking nut [B], •Disassemble: Rear Wheel Axle nut [A], •Disassemble: Rear Wheel Axle [A], •Remove the drive chain of rear sprocket to the left •Rotate rear wheel backwards to remove it. Note Do not place the wheel on the ground horizontally and make the brake disc towards, otherwise, brake disc may be damaged or deformed.
Page 247 Installing Rear Wheel •Apply high temperature grease to the edge of oil seal. •Put shaft sleeve at two sides of hub. Shaft sleeve at right side [A] Shaft sleeve at left side [B] •Install drive chain at the rear sprocket. •Install calipers bracket [A] to the swing arm stop block [B].
Page 248 Checking Wheels •Lift the front wheel / rear wheel from the ground. Special tools: jack and jack accessories •Gently rotate the wheel to check whether the wheels are able to rotate smoothly. ★If the wheels do not rotate smoothly, replace the hub bearings (see “Removing / Installing Wheel Bearings”).
Page 249 Adjustment of Static Balance of Rim Note After replacing outer tire or rim or both of them, adjust the static balance of rim. When adjusting the static balance of rim, brake disc should be installed in place. •Disassemble front and rear wheels (see “Disassembling Front / Rear Wheel”).
Page 250 c. Rotate the front wheel by 90°, and make a “X ” mark at the place shown in the figure below: d. Release rim: e. When rim stops rotating, make a “X ” mark at the bottom of front wheel; f.
Page 251 Note Start from the lightest weight. Remark ○Benelli dealers sell the balance weights of 10, 20 and 30 g respectively. The imbalance within 10g will not affect the driving stability of the motorcycle. ○Please do not use more than 4 weights (including 4, total weight of more than 90 g).
Page 252 Checking / Adjusting Tire Pressure •See “Regular Maintenance”—“Checking Tire Pressure”. Checking Tire •See “Regular Maintenance”—“Checking Whether Wheel / Tire Is Damaged”. Disassembling Tire •Disassemble: Tire (see “Disassembling Front Wheel / Rear Wheel), Air valve (deflate) •To keep tires balanced, make a mark at the place of air valve rod using a chalk, so as to install the tires at the original places later.
Page 253 Installing Tire Warning Front and rear wheels must be the products of the same manufacturer! •Check rims and tires and replace them if necessary. •Clean the sealing surfaces of rims and tires, and make the sealing surface of rim smooth using a fine abrasive cloth if necessary. •Remove and discard the air valve.
Page 254 In addition, permanent (internal) maintenance has another benefit: associated damage that cannot be found in external examination can be identified in a thorough examination. In view of this, Benelli does not recommend the use of temporary (external) maintenance, only recommend the use of reasonable permanent (internal) maintenance.
Page 255: Hub Bearing
Hub Bearing Disassembling Hub Bearing •Remove the wheel (see “Disassembling Front Wheel / Rear Wheel”), and remove the following parts: shaft collar, shaft sleeve (removed from rear hub), oil seal •Remove the hub bearing [A] with the bearing puller. Note Do not place the wheels horizontally on the floor and make the brake disc face down, or the brake disc may be damaged or deformed.
Page 256 Checking Hub Bearing Because the error of hub bearing is very small, generally it is unable to measure the clearance. Remark ○Do not remove any bearing for check, because the bearing must be replaced with one after removal. •If it needs to check whether there is an axial clearance in the bearing, it is jammed or blocked during the rotation, please rotate each bearing in the hub back and forth [A]! ★If the bearing cannot rotate smoothly, please replace the bearing!
Page 257: Drive Mechanism
Drive Mechanism Exploded View of Drive Mechanism 6-23...
Page 258 Torque Parts and specifications Remark N·m kgf·m Rear Wheel Axle M14×1.5×292 15.0 Gasket 16 Left sleeve of rear wheel Dust ring components Si R Radial Ball Bearing 6204-2RS Chain drive shaft sleeve Self-locking nut M10×1.25 Spring gasket φ10 Gasket 10 Sprocket/43 teeth Chain 520HO-1×108 Sprocket hub...
Page 259: Technical Parameters
Technical Parameters Item Standard Lower Service Limit Drive chain Slackness of drive chain 32-38 mm —— Wearing capacity of drive chain (with a length of 20 links) 317.5-318.2 mm 323 mm Standard drive chain: Manufacturer —— Model 520HO —— Quantity of chains 108 links ——...
Page 260: Special Tools
Special Tools Tools for disassembling and assembling chain: Complete set of tools for installing bearing: 6-26...
Page 261: Drive Chain
Drive Chain Checking the Slackness of Drive Chain •See “Regular Maintenance”—“Checking the Slackness of Drive Chain”. Checking the Slackness of Drive Chain •See “Regular Maintenance”—“Adjusting the Slackness of Drive Chain”. Checking / Adjusting Wheel Alignment •See “Regular Maintenance”—“Checking Wheel Alignment”. Checking the Wear of Drive Chain •See “Regular Maintenance”—“Checking the Wear of Drive Chain”.
Page 262 •Drive Chain Main chain plate [A], Rubber O-ring [B], Side plate of main chain plate [C], Remark ○Insert the main chain plate from the inside of drive chain, and then assemble side plate, make ID sign towards the outside. Warning Do not use old chain, main chain plate, side plate of main chain plate or rubber O-ring.
Page 263: Sprocket, Shaft Sleeve, Shaft Sleeve Bearing
Sprocket, Shaft Sleeve, Shaft Sleeve Bearing Disassembling Rear Sprocket •Disassembling rear wheel (see “Wheel / Tire”—“Disassembling Rear Wheel”). Note Do not place the wheel on the ground horizontally and make the brake disc towards, otherwise, brake disc may be damaged or deformed.
Page 264 Disassembling Shaft Sleeve Bearing •Knock out the bearing [A] from one side of wheel. Special Tools—Complete Set of Tools for Installing Bearing: Installing Shaft Sleeve Bearing •Replace one new bearing. •Press bearing [A] towards the inside, until it reaches the top. Special Tools—Complete Set of Tools for Installing Bearing [B]: •Apply high-temperature grease to the bearing.
Page 265 Checking Shaft Sleeve Bearing •As the shaft sleeve bearing error is very small, generally it is unable to measure the clearance. Remark ○Do not remove any bearing for check, because the bearing must be replaced with one after removal. •If it needs to check whether there is an axial clearance in the bearing, it is jammed or blocked during the rotation, please rotate each bearing in the hub back and forth [A]! ★If the bearing cannot rotate smoothly, please replace the bearing!
Page 266 Check the Deformation of Rear Sprocket •Lift the rear wheel from the grounding using a bracket, so that it can rotate smoothly. •As shown in the figure, place a dial indicator [A] near the gear teeth [B] of the rear sprocket. Turn the rear wheel [C] and measure the runout (deformation) of sprocket.
Page 267: Brake
Brake Exploded View of Front Brake 6-33...
Page 268 Torque Parts and specifications Remark N·m kgf·m Front hydraulic brake components Master Cylinder components Gasket Brake hose installing bolt Front hydraulic brake hose assembly Brake Caliper components Brake Pads components Bolt M×23 Fixing cover Hydraulic brake handle/pedal components Self-locking nut M6 Screw M4×l2 Gasket 4 Lightened spring gasket 4...
Page 269: Exploded View Of Rear Brake
Exploded View of Rear Brake 6-35...
Page 270 Torque Parts and specifications Remark N·m kgf·m Rear hydraulic brake components Self-locking nut M6 Joint M6 Thin nut M6 Foot mounted pump plunger screw Bolt M6×l×20 Screw M6×25-8.8-ZG Screw M6×15.2 Bolt M8×l.25×20 Spring gasket φ8 Brake hose mounting bolt Gasket Brake Pads components Brake Caliper components Rear brake hose assembly...
Page 271: Technical Parameters
Technical Parameters Item Standard Lower Service Limit Brake handle/pedal, brake pedal 4-way adjustable (for the selection by —— Brake handle/pedal position rider） Brake handle/pedal free clearance Not adjustable —— Pedal free clearance Adjustable —— Pedal position About 45 mm below the top of pedal ——...
Page 272: Special Tools
Special Tools Inside circlip plier Multimeter Jack: Jack accessories: 6-38...
Page 273: Brake Handle/Pedal, Brake Pedal
Brake handle/pedal, Brake Pedal Adjusting the Position of Brake handle/pedal •There are 4 positions at brake handle/pedal adjuster, so that the rider can adjust the position of brake handle/pedal according to the Front size of their hands. •Push the brake handle/pedal forward and turn the adjuster [A], so that the number is aligned with the arrow mark [B] at brake handle/pedal.
Page 274 Removing the Brake Pedal •Disassemble: Rear Master Cylinder mounting bolt [A], Right Front Pedal Bracket Bolt [B] Section Locking Screw [C] •Disassemble: Brake pedal return spring [D] Eccentric push rod [B], Lower spring pin [C], •Disassemble the rear brake pedal installing screw [E], and remove the brake pedal [A].
Page 275 •Install the right front pedal bracket. Locking Torque of Front Pedal Bracket Screw [A]: 40N•m •Install Brake Master Cylinder mounting bolt [B]. Locking Torque of Rear Master Cylinder Fixing Screw [A]: 10N•m •Press the brake pedal [A], align the joint hole of the Brake Master Cylinder, and install the mounting bolt [C] and nut.
Page 276: Calipers
Calipers Disassembling Front Calipers •Loosen the banjo bolt [C] at the bottom of the brake hose, and then tighten it slightly. •Remove the calipers mounting bolt [B], the separation calipers [A] and the brake disc. Note Do not remove the calipers mounting bolts. To remove calipers, simply remove the calipers mounting bolt, because brake fluid may leak after removing calipers mounting bolt.
Page 277 Installing the Calipers •Install the caliper and the lower end of brake hose. ○Replace the gaskets on both sides of the hose joint with new ones •Locking torque: Locking Torque of Calipers Mounting bolt: Front calipers: 34 N•m Rear calipers: 25 N•m Brake hose banjo bolt: 25 N•m •Check the fluid level in the brake fluid cup.
Page 278 Checking Dust Seal of the Calipers for Damage •Check dust seal [B] for cracks, abrasion, expansion or other damages. ★If the dust seal is damaged, please replace it with a new one! Piston [C], Oil seal [A] Checking the Calipers Piston and Brake Caliper for Damage •Visually inspect the piston [A] and the Brake Caliper surface [B].
Page 279: Brake Pads
Brake Pads Disassembling Front Brake Pads •Disassemble front calipers •Disassemble the fixed pin of Brake Pads[A]. •Disassemble: Fixing pin of Brake Pads [A], Spring plate of Brake Pads [B], Fixing pin clip of Brake Pads [C] Note When pulling out pin A, please press safety spring B •Disassemble: Front Brake Pads Installing Front Brake Pads...
Page 280 Disassembling Rear Brake Pads •Disassemble calipers mounting bolt [A]. •Disassemble bolt [B] from brake calipers, and rotate rear calipers [E] in the direction of C. •Disassemble: Brake Pads [D] Installing Rear Brake Pads •Push the calipers inward as far as possible. •Install: The operations should be conducted in reverse order of disassembly.
Page 281: Brake Master Cylinder
Brake Master Cylinder Disassembling Front Brake Master Cylinder •Disassemble the mounting bolt of front Brake Master Cylinder [A]. •Disconnect the connector of front brake lamp switch [E]. Note If brake fluid spills out, please rinse immediately! •Disassemble: Brake handle/pedal pivot bolt [B] and locking nut [C] Brake handle/pedal [A], front brake lamp switch mounting bolt [B], flat washer [F] and spring washer [G]...
Page 282 Disassembling Rear Brake Master Cylinder •Disassemble: Rear Brake Master Cylinder tightening bolts [A] Bolt [B] Rear brake lamp switch sensor [D], Brake hose [B], Rear Brake Master Cylinder [G] •Slide out the clamp [F]. •Pull out the lower end of the oil cup hose [E] and drain the brake fluid into a container.
Page 283: Brake Discs
Brake Discs Disassembling Brake Discs •Disassemble the wheels (see “Wheels / Tires”—“Removing Front Wheels / Rear Wheels”). •Disassemble mounting bolts and remove the brake disc. ○Disassemble the sensor rotor (models equipped with ABS). •Disassemble the gasket. Installing Brake Disc •Replace the gasket. •Install the brake disc onto the wheels with the marked side facing out.
Page 284: Brake Fluid
Brake Fluid Checking the Level of Brake Fluid •See “Regular Maintenance”—“Checking the Level of Brake Fluid”. Replace Brake Fluid •See “Regular Maintenance”—“Replacing Brake Fluid”. Air Bleeding from Brake Pipe Brake fluid compression coefficient is very small, so almost all the work of the brake handle/pedal or brake pedal will be transmitted directly to the calipers, thus generating braking effect.
Page 285 Warning The following precautions should be taken when handling disc brakes: 1. Do not reuse the brake fluid! 2. If the container containing of the brake fluid is not sealed or opened for a long time, do not use the brake fluid inside the container! 3.
Page 286: Brake Hose
Brake Hose Disassembling / Installing Brake Hose and Brake Pipe •See “Regular Maintenance”—“Replacing Brake Hose and Brake Pipe”. Checking Brake Hose and Brake Pipe •See “Regular Maintenance”—“Checking the Damage and Installation of Brake Hose and Brake Pipe”. 6-52...
Page 287: Suspension System
Suspension System Front Suspension System Exploded View 6-53...
Page 288 Torque Parts and specification Remark Kgf.m Bolt M8×1.25×30 Handlebar upper seat Handlebar lower seat Handle locating stud Sound reduction plug Upper bridge fastening screw Stainless screw M6×25 Body Covers bush Body Covers rubber pad Bolt M8×1.25×25 Upper bridge Handle locating spacer Self-locking nut M10×1.25 Upper bridge fastening nut Special nut...
Page 289: Rear Suspension System Exploded View
Rear Suspension System Exploded View 6-55...
Page 290 Torque Parts and specification Remark N·m kgf·m 1 Rear swing arm installing shaft M14x1.5x280 10.8 2 Dustproof ring component G, R 3 Needle bearing HK2020 4 Bearing oil seal G, R 5 Rear swing arm shaft sleeve 6 Self-locking nut M14X1.5 10.8 7 Rear swing arm assembly 8 Rear shock absorber component...
Page 291: Technical Parameters
Technical Parameters Item Standard Front shock absorber (each one) Diameter of front shock absorber inner pipe 41mm Pressure Atmospheric pressure (unadjustable) Front shock absorber oil: 32# shock absorber oil Viscosity 28.8-35.2 Oil quantity 440±5ml (after the disassembly, the oil has been drained completely) Front shock absorber oil level 80±2ml (fully compressed, without front shock absorber spring: at the top of inner pipe)
Page 292: Special Tool
Special Tool Internal calipers: Front shock absorber piston rod puller Oil seal and bearing puller: Front shock absorber oil level gauge: Complete set of tools used for bearing assembly: Hook wrench T=3.2: Jack: Jack accessories: 6-58...
Page 293: Front Shock Absorber
Front Shock Absorber Disassembling Front Shock Absorber ●Removing: Front wheel (see “Wheel/Tire”—“Disassembling Front Wheel”), Front fender (see “Frame”—“Disassembling Front Fender”) Front calipers (see “Brake”—“Disassembling Front Calipers”) ★Before removing the front shock absorber installing seat, remove the upper front fork clamping bolt [A] Remark ○Remove the head cover after the front fork clamping bolt is disassembled.
Page 294 Installing Front Shock Absorber ●Keep the direction and position of top of outer pipe [A] as shown in the figure on the right before installing the front shock absorber. 1 mm [B] ●Locking torque: Front shock absorber clamping bolt (at the lower side): 22 N·m Front shock absorber head cover: 15-20 N·m Front shock absorber clamping bolt (at the upper side): 22 N·m Remark...
Page 295 ●Install the fixing tool [A], as shown in the figure. Remark ○The upper part protecting device shall not touch the inner pipe when installing the fixing tool; pull up the outer pipe, clamp the outer pipe with the tool, and then lock the two bolts. The outer pipe plays a guiding role.
Page 296 ●Removing: Shock absorber spring [A] Spring seat [B] Adjusting sleeve Buffer block and adjusting sleeve seat [D] ●Pour the shock absorber oil into a suitable container. ○Pull the piston rod up and down for at least ten times and pour out the shock absorber oil in the front shock absorber.
Page 297 ○Remove the piston rod puller. ○Wait until the oil level is stable. ○When the shock absorber is compressed to the bottom and the piston rod is pushed to the bottom, insert the tape or ruler into the inner pipe to measure the distance between the top of inner pipe and shock absorber oil level. Oil level (when the shock absorber is compressed to the bottom and the shock absorber spring is removed) Standard: 80±2mm (Away from the top of inner pipe)
Page 298 ●Installing: Adjusting sleeve, Buffer block and other parts Please replace with new parts! ●Fix the bolt at the top with a wrench and lock the piston rod nut [A]. Locking torque of piston rod nut: 18-20 N·m ●Clamp the gasket by using the holder and loosen the front shock absorber spring compressor nut.
Page 299 ●Separate the outer pipe and inner pipe. ●Pull out the dustproof ring. ●Remove the clamp ring [A] of outer pipe. ●Remove the oil seal [B] and gasket [C]. ●Replace the following parts with new ones: Oil seal, Locking torque of hexagon bolt at the bottom of front shock absorber: 23 N·m ●Install the following parts on the inner pipe [A].
Page 300 Checking Inner Pipe and Outer Pipe ●Visually check the inner pipe [A] and replace it if there is any damage. ●If there are cracks or rust on the inner pipe, the sharp edge and tilted part can be worn with a millstone. The sharp edges or raised parts will damage the oil seal.
Page 301: Rear Shock Absorber
Rear Shock Absorber Adjusting Spring Preload ●Remove the rear shock absorber from the frame (see “Disassembling Rear Shock Absorber”). ●Loosen the locknut [A], rotate the adjusting nut [B] and loosen the spring. Special Tool—Hook Wrench: ●Adjust the spring Preload, rotate the adjusting nut [B] to the suitable position and tighten the locknut [A].
Page 302 ●In order to adjust the spring Preload, rotate the adjusting nut to the suitable position and tighten the locknut with a hook wrench [A] (the rear shock absorber is fixed on the frame). Special Tool—Hook Wrench ★If you feel that the spring is too soft or hard, please adjust it! Adjusting Spring Spring Damping...
Page 303 Installing Rear Shock Absorber ●Locking torque: Fastening bolt above rear shock absorber: 45 N·m Fastening bolt below rear shock absorber: 45 N·m Checking Rear Shock Absorber ●Remove the rear shock absorber (see “Disassembling Rear Shock Absorber”). ●Visually checking: Whether the travel is smooth; Whether there is oil leakage;...
Page 304: Rear Swing Arm
Rear Swing Arm Disassembling Swing Arm ●Lift the rear wheel above the ground with a jack. Special Tool—Jack: Jack Accessories: ●Removing: Rear wheel (see “Wheel/Tire”—“Disassembling Rear Wheel”), ●Removing: Fastening bolt [A] at the lower side of rear shock absorber [B] (see “Disassembling Rear Shock Absorber”) ●Remove the swing arm installing shaft nut [A].
Page 305 Installing Swing Arm ●Apply sufficient grease on the edge of oil seal [A]. ●Install the bush [B]. ●Put the installing shaft [A] into the frame from the left side. ●Lock the swing arm installing shaft nut [A]. Locking torque of swing arm installing shaft nut: 108 N·m ●Install the parts disassembled previously (see the corresponding chapters).
Page 306 Disassembling Swing Arm Bearing ●Removing: Rear swing arm (see “Disassembling Rear Swing Arm”), Dustproof ring [A], Oil seal [B], Casing [C], ●Remove the needle bearing. Special Tool—Oil Seal and Bearing Puller [A]: Installing Swing Arm Bearing ●Replace the needle bearing [A] with a new one. ●Enable the manufacturer sign to face outward when installing the needle bearing.
Page 307 Checking Swing Arm Bearing Note Do not remove the bearing for check, otherwise the bearing may be damaged. ●Check the needle bearing [A] installed inside the swing arm. ○The wear of roller in bearing is small generally and it is difficult to measure the wear extent.
Page 308: Steering System
Steering system Steering system Exploded View 6-74...
Page 309 Torque Parts and specification Remark N·m kgf·m Allen bolt M6x35 Handlebar weight Handlebar weight installing seat Right grip component Right combination switch Right rearview mirror component Throttle cable component Handlebar Left rearview mirror component Left combination switch Left handlebar grip Clutch handle component Clutch cable jacket Clutch cable component...
Page 310: Special Tool
Special Tool Complete set of tools used for bearing assembly Outer ring screwdriver of head pipe : Steering pipe bearing installing tool (diameter: 35.5): 6-76...
Page 311: Steering System
Steering system Checking Steering system ●See “Regular Maintenance”—“Checking Steering system Clearance”. Adjusting Steering system ●See “Regular Maintenance”—“Adjusting Steering system Clearance”. 6-77...
Page 312: Steering Stem
Steering Stem Disassembling Steering Stem and Steering Stem Bearing ●Removing: Handlebar (see “Disassembling Handlebar”), Fairing (see “Frame”—“Disassembling Fairing”), Front wheel (see “Wheel/Tire”—“Disassembling Front Wheel”), Front fender (see “Frame”—“Disassembling Front Fender”), Front shock absorber (see “Suspension System”—“Disassembling Front Shock Absorber”), ●Removing: Upper bridge locknut [A] Upper bridge [B], ●Remove the Steering Stem locknut [A].
Page 313 ●To remove the ball bearing outer ring [A] which is pressed into the head pipe, insert a rod [C] into the inner cavity [D] of head pipe [B], and then knock both sides of ball bearing alternately to remove the outer ring.
Page 314 ●Replace the bearing inner ring and oil seal with new ones. ●Apply grease to oil seals. ●Cover the Steering Stem with oil seal [A], then install the ball bearing inner ring at the lower side and apply grease to the Steering Stem [D].
Page 315 ●Install the bearing at the corresponding position according to the following method. ○Lock the Steering Stem nut with a locking torque of 55 N·m first and then loosen it for a small circle (less than one circle) to enable the nut to rotate slightly. And then lock it with a Steering Stem nut wrench [A] in accordance with the specified locking torque.
Page 316 Steering Stem Bearing Lubrication ●See “Regular Maintenance”—“Steering Stem Bearing Lubrication”. Checking Deformation of Steering Stem ●If the Steering Stem is disassembled or the Steering Stem cannot be adjusted for smooth rotation, please check the straightness of Steering Stem! ★If the Steering Stem [A] is bent, please replace it! 6-82...
Page 317: Handlebar
Handlebar Disassembling Handlebar ●Removing: Handlebar weightHandlebar weight [A] Left rearview mirror [D] Clutch handle lock bolt [E], Left combination switch [C], Left handle grip [B], ●Removing: Handlebar weightHandlebar weight [A] Right rearview mirror [D] Front Brake Master Cylinder lock bolt [E] Right combination switch [C] Throttle handle [B] ●Remove the bolt [A] of handlebar installing seat.
Page 318 Installing Handlebar ●Install the handlebar installing seat and handlebar on the Upper bridge. ●Tighten the bolt of handlebar installing seat. Remark ○Lock the front handlebar installing seat bolt [A] and then lock the other one [B]. ○Lock two handlebar installing seat bolts twice alternately to ensure that the locking torque is even.
Page 319 ●Installing: Left handle [A] Left combination switch [B] ●Apply the Loctite to the thread of handlebar Handlebar weight bolt and then tighten the bolt. ●Installing: Handlebar weight [C] Left rearview mirror [D] Locking torque of combination switch fastening screw: 3.5 N·m 6-85...
Page 320: Frame
Frame Frame Exploded View 6-86...
Page 321 Torque Parts and specification Remark N·m kgf·m Frame assembly Bolt M8×35 Left upper hanging plate component of engine Nut M10×1.25 AL, S Clip component Nut M10×1.25 Allen bolt M10×40 Front left fixing bracket component of engine Side stand assembly 10 Side stand spring 11 Allen bolt M6×16 12 Engine stop switch installing plate component 13 Screw M6×10...
Page 322: Left Pedal Exploded View
Left Pedal Exploded View 6-88...
Page 323 Torque Parts and specification Remark N·m kgf·m Left rear pedal bracket Check ringφ5 Allen bolt M8×40 Pedal installing plate Pedal ball Left pedal rubber Pedal spring Left rear pedal Left pedal rubber pad 10 Screw M4×10 11 Pedal installing pin 12 Combination screw M6×10 13 Bolt M6×10 14 assemblyShift pedal installation bracket...
Page 324: Right Pedal Exploded View
Right Pedal Exploded View 6-90...
Page 325 Torque Parts and specification Remark N·m kgf·m Right rear pedal bracket Check ringφ5 Right pedal rubber Pedal installing plate Pedal ball Pedal spring Right rear pedal Pedal installing pin Right pedal rubber pad 10 Screw M4×10 11 Cotter pin 2×18 12 Gasketφ6 13 Upper spring pin 14 Brake pedal reset spring...
Page 326: Muffler Exploded View
Muffler Exploded View 6-92...
Page 327 Torque No. Parts and specification Remark N·m kgf·m Bolt M8×16 Exhaust pipe gasket component Bolt M8×25 Thermal insulation spacer Combination screw M6×16 Muffler decorating cover Allen bolt M8×50 Self-locking nut M8 Muffler assembly Oxygen sensor Spring gasket φ8 Body Covers bush Rubber sleeve II L: apply Loctite.
Page 328: Fender Exploded View
Fender Exploded View 6-94...
Page 329 Torque Parts and specification Remark N·m kgf·m Front part of rear fender Screw M6×15.2 Screw M6×14 Bolt M6×30 Grey nylon gasket Front fender installing plate Tapping screw ST4.2×13 Bolt M5×0.8×14 T-shape bush 5×7×6×10×0.8 10 Fender 11 Nut M5 12 Body Covers installing clamping nut M5 13 Front small fender 14 Gasketφ5 15 Spring gasketφ5...
Page 330: Body Coversfuel Tank Garnish Plates Exploded View
Body CoversFuel Tank Garnish Plates Exploded View 6-96...
Page 331 Torque Parts and specification Remark N·m kgf·m Oil tank front Body Covers Screw M6×15.2 Right fuel tank decorating plate Right Body CoversFuel Tank Garnish Plates Card ST4.2 Tapping screw ST4.2×13 Fuel tank upper Body Covers Left fuel tank decorating plate Left Body CoversFuel Tank Garnish Plates 10 Front right decorating cover 11 Bolt M6×12...
Page 332: Seat Cushion And Body Covers Exploded View
Seat Cushion and Body Covers Exploded View 6-98...
Page 333 Torque Parts and specification Remark N·m kgf·m Front seat component Rubber sleeve T-shape bush Bolt M6×25 Rear seat component Rear luggage carrier screw I Rear handrail Right upper tail cover Combination screw M6×16 Right lower tail cover Tapping screw ST4.2×13 Left lower tail cover Left upper tail cover Card ST4.2...
Page 334: Bottom Cover And Engine Exploded View
Bottom Cover and Engine Exploded View 6-100...
Page 335 Torque Parts and specification Remark N·m kgf·m 1 Tapping screw ST4.2×13 2 Bottom cover mesh 3 Card ST4.2 4 Right bottom cover 5 Stainless screw M6×25 6 Screw M6×15.2 7 Engine 8 Injector 9 Injector seat 10 Allen bolt M6×15 11 Throttle valve body subassembly 12 Clamp component 13 Clamp...
Page 336: Seat Cushion
Seat Cushion Disassembling Seat Cushion ●Insert the key [A] into the seat lock, turn the key counterclockwise, open the seat [B] and lift up to remove the rear seat. ●Removing: Screw [A] Front seat [C] Installing Seat Cushion ●Install the parts disassembled previously. ●Press down the rear part of seat until the click sound is generated by the seat lock.
Page 337: Body Covers
Body Covers Disassembling Left Body Covers ●Disassemble the seat (see “Seat”—“Disassembling Seat”) ●Disassembling: Screw [A] Tapping screw [B] Left Body Covers [C] Installing Left Body Covers ●Install the parts disassembled previously. 6-103...
Page 338 Disassembling Right Body Covers ●Disassemble the seat (see “Seat”—“Disassembling Seat”) ●Disassembling: Screw [A] Tapping screw [B] Left Body Covers [C] Installing Right Body Covers ●Install the parts disassembled previously. 6-104...
Page 339: Rear Handrail And Tail Cover
Rear Handrail and Tail Cover Disassembling Rear Handrail ●Disassemble the rear seat (see “Seat”—“Disassembling Seat”) ●Disassembling: Screw [B] Rear handrail [A] Installing Rear Handrail ●Install the parts disassembled previously. Fastening torque of rear handrail mounting bolt: 25 N·m 6-105...
Page 340 Disassembling Tail Cover ●Disassemble the seat (see “Seat”—“Disassembling Seat”) ●Disassemble the left Body Covers (see “Body Covers”—“Disassembling Left Body Covers”) ●Disassemble the right Body Covers (see “Body Covers”—“Disassembling Right Body Covers”) ●Disassemble the rear handrail (see “Rear Handrail and Tail Cover”—“Disassembling Rear Handrail”) ●Disassembling: Screw [E]...
Page 341: Rear Fender
Rear Fender Disassembling Rear Fender ●Disassemble the screw [A] and then remove the rear fender bracket from the frame ●Unplug the rear turn signal and rear license plate lamp connectors ●Removing: Rear fender left part [A] Rear fender right part [B] Rear fender bracket [C] Rear turn signal [D] Rear license plate lamp [E]...
Page 342: Front Fender
Front Fender Disassembling Front Fender ●Disassemble the screw [A] and remove the front fender [B] from the front shock absorber ●Removing: Screw [A] Screw [B] Front small fender [C] Front fender [D] Installing Front Fender ●Install the parts disassembled previously. 6-108...
Page 343: Body Coversfuel Tank Garnish Plates And Fairing
Body CoversFuel Tank Garnish Plates and Fairing Disassembling Body CoversFuel Tank Garnish Plates ●Disassemble the seat (see “Seat”—“Disassembling Seat”) ●Disassemble the fuel tank (see “Fuel Tank”—“Disassembling Fuel Tank”) ●Decompose the Body CoversFuel Tank Garnish Plates Installing Body CoversFuel Tank Garnish Plates ●Install the parts disassembled previously.
Page 344: Radiator Fairing
Radiator Fairing Disassembling Radiator Fairing ●Disassembling Bolt [A] Front right decorating cover [B] Front decorating cover [C] Front left decorating cover [D] Installing Radiator Fairing ●Install the parts disassembled previously. 6-110...
Page 345: Bottom Cover
Bottom Cover Disassembling Bottom Cover ●Disassemble the fastening bolt [A] of left bottom cover [B]. ●Disassemble the fastening bolt [A] of right bottom cover [B]. ●Unfasten the buckle inside the plastic part combination. ●Separate the left bottom cover [B], right bottom cover [A] and bottom cover mesh [C].
Page 346: Frame
Frame Disassembling Frame ●Removing: Seat (see “Seat”—“Disassembling Seat”) Fuel tank (see “Fuel Tank”—“Disassembling Fuel Tank”) Body Covers (see “Body Covers”—“Disassembling Body Covers”) Tail cover (see “Tail Cover”— “Disassembling Tail Cover”) Rear fender (see “Rear Fender” — “Disassembling Rear Fender”) Rear wheel (see “Rear Wheel” — “Disassembling Rear Wheel”) Front wheel (see “Front Wheel”...
Page 347: Side Stand
Side Stand Disassembling Side Stand ●Lift the rear wheel above the ground by using the bike stand. ●Removing: Side stand spring [D], Nut [B], Side stand bolt [A], Side stand [C], Installing Side Stand ●Apply the grease to the moving part of side stand [C]. ●Apply the Loctite to the thread of side stand bolt [A].
Page 348: Left Front Pedal
Left Front Pedal Disassembling Left Front Pedal ●Disassembling: Screw [A] Left front pedal bracket [B] ●Disassembling Shift foot bar component [A] Shift foot bar installing seat assembly [C] Pedal installing pin [B] Left front pedal bracket [D] Left front pedal component [E] Pedal installing bush [F] Front pedal spring [G] Steel ball [H]...
Page 349: Left Rear Pedal
Left Rear Pedal Disassembling Left Rear Pedal ●Disassembling: Screw [A] Left rear pedal bracket [B] ●Disassembling Left rear pedal bracket [A] Check ring [B] Pedal installing plate [C] Pedal ball [D] Pedal Spring [E] Left rear pedal [F] Left pedal rubber pad [G] Screw [H] Pedal installing pin [J] Left pedal rubber [K]...
Page 350: Front Right Pedal
Front Right Pedal Disassembling Front Right Pedal ●Disassemble the right front pedal bracket (see “Brake”—“Disassembling Brake Pedal”) ●Disassembling Right front pedal bracket [A] Pedal installing pin [B] Right front pedal component [C] Front pedal spring [D] Pedal installing plate [E] Pedal installing bush [F] Steel ball [G] Gasket [H]...
Page 351: Rear Right Pedal
Rear Right Pedal Disassembling Rear Right Pedal ●Disassembling: Screw [A] Right rear pedal bracket [B] ●Disassembling Right rear pedal bracket [A] Check ring [B] Pedal installing plate [C] Pedal ball [D] Pedal spring [E] Right rear pedal [F] Right pedal rubber pad [G] Screw [H] Pedal installing pin [J] Left pedal rubber [K]...
Page 352 Muffler Warning Do not disassemble the muffler when the engine is heated to avoid burn. Disassemble the muffler when it is cooled. Disassembling Muffler ●Removing: Bottom cover (see “Bottom Cover”—“Disassembling Bottom Cover”), Oxygen sensor (see “Electrical System”—“Disassembling Oxygen Sensor”) Right rear pedal (see “Right Rear Pedal”—“Disassembling Right Rear Pedal”) ●Remove the exhaust front pipe fixer screw [A].
Page 353 Installing Muffler ●Replace the exhaust pipe gasket[A] with a new one. Locking torque: Exhaust front pipe fixing screw: 22N·m Muffler lower mounting bolt: 22N·m Muffler rear fixing screw: 22N·m ●Install the parts disassembled previously (see the corresponding chapters). 6-119...
Page 354: Disassembling/Installing Engine
Disassembling/Installing Engine Engine Disassembly and Installation Exploded View 6-120...
Page 355 Torque Parts and specification Remark N·m kgf·m ft·lb Frame assembly Bolt M8×35 Left upper hanging plate component of engine Nut M10×1.25 Nut M10×1.25 Allen bolt M10×40 Front left fixing bracket component of engine Rear swing arm shaft Front right fixing bracket component of engine Bolt M10×1.25×170 S, M Bolt M10×1.25×130...
Page 356 Disassembling Engine ●Support the rear part of swing arm with a bracket. ●Grasp the brake handle/pedal slowly and bind it with a tape. Warning The brake handle/pedal must be grasped when disassembling the engine, otherwise the motorcycle will topple, which will cause accidents and personal injury.
Page 357 ●Loosen the clamp [C] at the connection position of throttle [A] and engine [B] ●Remove the shift lever swing arm ●Disconnect the various cable connectors ●Loosening: Upper mounting bolt of engine [A], 6-123...
Page 358 ●Removing: Upper hanging plate mounting bolt of engine [A], ●Loosening: Front mounting bolt of engine [A], ●Removing: Front left fixing bracket component mounting bolt of engine [A] 6-124...
Page 359 ●Removing: Front right fixing bracket component mounting bolt of engine [A] ●Removing: Remove the rear lower fixing nut of engine [A] ●Removing Rear swing arm shaft [A] ●Remove the engine by using the bike stand or hoist 6-125...
Page 360 Installing Engine ●Support the engine with a suitable stand or hoist. ●Install the front left fixing bracket component of engine [B] and do not tighten the screw [A] ●Install the front right fixing bracket component of engine [B] and do not tighten the screw [A] ●Install the left upper hanging plate component [B] and right upper hanging plate component [C] of engine and do not tighten the bolt 6-126...
Page 361 ●Install the rear swing arm shaft [A] and do not tighten it; ●Install the rear lower fixing nut of engine [A] and do not tighten it; ●Install the front mounting bolt of engine [A] and do not tighten it; ●Fasten the bolt, screw or nut according to the following steps: ○Step 1: lock the rear swing arm shaft ○Step 2: lock the rear lower mounting bolt of engine ○Step 3: lock the front mounting bolt of engine...
Page 362 Remark ○Fasten the engine mounting bolt, screw or nut in order by three times ○Locking torque: Rear swing arm shaft: 108N·m Rear lower mounting bolt of engine: 50N·m Upper mounting bolt of engine: 50N·m Front mounting bolt of engine: 50N·m Front bracket fixing screw of engine: 45N·m Upper hanging plate mounting bolt of engine: 25N·m ●Arrange the lead, cable and hose properly (see “Appendix”—“Winding Method of Cable, Wire and Hose”).
Page 363: Chapter Vii Electrical System
CHAPTER VII ELECTRICAL SYSTEM PRECAUTIONS ................................7-2 TECHNICAL PARAMETERS ............................7-3 SPECIAL TOOL ................................7-4 ELECTRICAL WIRING ..............................7-5 WIRING INSPECTION .............................. 7-5 CHARGING SYSTEM ..............................7-6 CHARGING SYSTEM CIRCUIT DIAGRAM ......................7-6 BATTERY ..................................7-7 MAGNETO ................................. 7-11 VOLTAGE REGULATOR/RECTIFIER ......................... 7-14 IGNITION SYSTEM ..............................
Page 364: Precautions
Precautions Many important precautions must be understood when maintaining the electrical system. Learn and follow all of the following rules.  Do not reverse the positive and negative electrodes of storage battery, otherwise the diode of electrical components will be burnt. ...
Page 365: Technical Parameters
Technical Parameters Item Standard Battery Type Maintenance-free storage battery Model YTX7L-BS Capacity 12 V 6 Ah Voltage Charging system Type Three-phase AC AC generator output voltage 55V or above when it is 5000 r/min (rpm) 0.05-0.5Ω (at normal temperature 20℃) Stator coil resistance Charging voltage 14.2 -15.2 V...
Page 366: Special Tool
Special Tool Multimeter: tester probe:...
Page 367: Electrical Wiring
Electrical Wiring Wiring Inspection ●Visually check the melting, wear and other phenomena of wires. ★If the wire is broken, replace the damaged wire. ●Pull out each connector [A] to check whether there is any corrosion, dirt and damage. ★If the connectors are corroded or soiled, carefully clean them. If the connectors are damaged, replace them.
Page 368: Charging System
Charging System Charging System Circuit Diagram Charging System...
Page 369: Battery
Battery Disassembling Battery ● Switch off the power lock ●Disassemble the seat (see “Finished Motorcycle—Seat” chapter) ●Disassemble the right safety guard (see “Finished Motorcycle—Safety Guard” chapter) ●Disconnect the negative terminal of battery * Note ○Make sure to disconnect the negative (-) lead first ●...
Page 370 Battery Activation ●Filling Electrolyte ○Make sure that the model [A] marked on the electrolyte bottle matches with the model [B] of the battery. These models must be the same. Storage battery model: YTX7L-BS Warning Make sure to use the electrolyte of the model same as that marked on the storage battery, because the volume and density of used electrolyte are different if the storage battery models are different.
Page 371 ●Check the electrolyte flow ★If there are no rising bubbles in the filling port [A], or if the electrolyte is not completely injected into the storage battery, slightly tap the electrolyte bottle [B] several times. ●Keep the electrolyte bottle at this position for 20 minutes or above. Do not remove the container from the battery before it becomes empty, because all the electrolyte in the container is required for normal operation of battery.
Page 372 ●After the charging is completed, vigorously press the strap cover [A] with both hands to make it enter into the battery (do not thump or beat it). After it is installed properly, the strap cover and the top of battery will be parallel. Warning Once the strip cover is inserted into the battery, do not remove the cover and do not add water or electrolyte to the battery.
Page 373: Magneto
●Check the voltage regulator if the limiting voltage is not within the range of specified value. Magneto *Note ○The charging coil of magneto can be checked on the engine. Magneto Disassembly ●Disconnect the magneto lead couplers ●Put a suitable container below the magneto cover ●Loosen the magneto cover mounting bolt and remove the magneto cover and coil ●Pull out the magneto lead between the engine and bracket...
Page 374 ●Remove the flywheel Magneto Inspection ●There are three types of magneto faults: short circuit, open circuit ( the coil is burnt) or magnetic loss of rotor. A short or open circuit of coil will result in low output or even no output. The magnetic loss of rotor will result in low output, this loss may be caused by the dropping or beating suffered of the AC generator, or it may also caused by placing it near the electromagnetic field, or due to the aging only.
Page 375 ●Start the engine ○Operate the engine according to the revolutions per minute (rpm) given by the Table 1 ○Record the voltage readings (3 measurement values in total) Table 1 Magneto Output Voltage Range of tester Wiring Readings when it is 5000rpm Connect tester (+) to Connect tester (-) to 750 V AC...
Page 376: Voltage Regulator/Rectifier
Voltage Regulator/Rectifier Rectifier Disassembly: ●Disassembling: coupler Bolt Voltage regulator/rectifier Main Wiring Terminal Circuit Inspection ●Remove the motorcycle body safety guard. ●Remove the 3 pins plug of the regulator/rectifier and check the breakover among main wiring terminals in the following method. Rectifier Inspection 1.
Page 377: Ignition System
Ignition System Ignition System Circuit Diagram Black/Red 1 Black/White1 White blue Green white Trigger probe Ignition power Ignition system Operation Precautions 1. Check the ignition system in accordance with the order of fault diagnosis table step by step. 2. The ignition system is the electronic automatic angle feeding device and has been cured in the ECU group, so the ignition time does not need to be adjusted.
Page 378: Crankshaft Sensor
Crankshaft Sensor Crankshaft Position Sensor Disassembly ●Integrated with the magneto, it cannot be disassembled separately ●Use the tester *Note The trigger can be checked on the engine. Blue direction Green Checking Tinned brass Black nylon ● Disconnect the trigger lead coupler. ●Measure the resistance of red and yellow engine leads.
Page 379: Ignition Coil
Ignition Coil Ignition Coil Disassembly: ●Remove the ignition coil [A] mounting bolts [B] which under the fuel tank and disconnect the connector. Ignition Coil Inspection *Note • If the spark plug does not generate sparks, check whether the wiring parts are loose or poor contact, •...
Page 380: Spark Plug
Spark Plug Spark Plug condition Inspection ●Disassemble the spark plug (see the spark plug disassembly section) ●Visually check the spark plug ○If the central electrode [A] and/or side electrode [B] of spark plug is/are corroded or damaged, or the insulator terminal [C] is broken, replace the spark plug ★If the spark plug is dirty or there are carbon deposits on the spark plug, replace the spark plug...
Page 381: Ecu
IC Igniter Inspection ○IC igniter is put inside the electronic control unit. ●Refer to the following items Electrical start-up safety circuit-related components operation inspection (see the electrical start-up safety circuit-related components operation checking section) Ignition system troubleshooting (see the ignition system section) Electronic control unit voltage inspection (see the electronic control unit power inspection section in the chapter of electronic fuel injection system (ECU)) ●System inspection...
Page 382: Ignition System Troubleshooting
Ignition System Troubleshooting Ignition error (no spark) Not good Battery inspection Battery charging or battery replacement Good Not good Ignition system circuit and connector inspection Repair or replace the damaged part Good Not good Spark plug inspection Replace the spark plug Good Not good Primary side coil peak voltage inspection...
Page 383: Starting System
Starting System Starting System Circuit Diagram Side stand Flameout Clutch switch switch switch Battery Relay motor Start switch Main relay Neutral switch starting schematic Diagram 7-21...
Page 384: Starter Motor
Starter Motor *Note Before the starter motor is disassembled, turn “OFF” the main switch, remove the bond strap of battery, and then turn on the power to see whether the motor runs to confirm safety. *Note Do not pat the starter motor shaft or body, otherwise the motor body may be damaged Starter Motor Disassembly ●Disassemble the starter motor lead terminal nut...
Page 385 Commutator Cleaning and Inspection ●If necessary, polish the surface [A] of commutator with a crocus cloth [B] and clean the groove ●Measure the diameter [A] of commutator [B] ★If the diameter of commutator is shorter than the service limit, replace the starter motor with a new one Commutator Diameter Standard: 28mm Service limit: 27mm...
Page 386: Starter Relay
Starter Relay Starter Relay Disassembly and Action Inspection ●Disconnect the starter motor lead and battery negative electrode (-) lead end terminal [C] from the starter relay ●Disconnect the starter motor lead and battery positive electrode (+) lead end terminal [D] from the starter relay ●...
Page 387: Lighting System
Lighting System Headlight Disassemble the headlight (see “Frame-Fairing Disassembly”) Headlight Bulb Replacement ●Disassemble the rear housing and remove 4 fixing screws [A] ●Disconnect the headlight bulb connector [A] ●Loosen the headlight bulb fixing circlip [A] ●Remove the bulb from its mounting position after the bulb is cooled [A] Warning When managing the quartz-halogen bulb, do not touch the...
Page 388 ●Connect the headlight bulb joint and install the rear fixing housing ●After the installation, adjust the head lamp concentration (see the head lamp concentration inspection section in the chapter of regular maintenance) ○Other bulbs: repeat the above operations Front City Light Bulb Replacement ●...
Page 389: Instrument
Instrument Instrument Disassembly ●Remove the fixing nut at the top of headlight by using a Allen wrench ●Remove the instrument fixing bracket mounting plate (inside the head cover) by using a socket wrench ●Separate the instrument bracket and mounting plate by using a socket wrench ●Remove the fairing in the front of instrument by using a screwdriver...
Page 390: Switch, Sensor And Other Parts
Switch, Sensor and Other Parts Main Switch Main Switch Disassembly ●Remove the fairing. ● Disconnect the main switch lead connector. Main Switch Inspection ●Check the breakover of connector terminal. ★If the breakover does not consistent with the breakover table, please replace the main switch Wiring principle diagram Wire color Red/White...
Page 391: Handle Switch
Handle Switch Switch State 1 1. Dimmer switch 2. Turn signal switch 3. Horn switch 4. headlight control switch 5. Engine stop switch 6. Start switch 7. Passing button Red/ Orange/ Yellow/ Dark Green/ Dark White Blue green Yellow green Dimmer switch Steering Turn signal switch Horn switch...
Page 392 Switch State 2 (Automatic Headlight On) 1. Dimmer switch 2. Turn signal switch 3. Horn switch 4. Warning indicator switch 5. Emergency off switch 6. Start switch 7. Passing button Green Orange Green Flameout Emergency white black off switch Dark Start switch green Green...
Page 393: Brake Lamp Lightingtime Inspection
Brake Lamp LightingTime Inspection • See the brake lamp switch operation inspection section in the chapter of regular maintenance Brake Lamp Lighting Time Adjustment • See the brake lamp switch operation inspection section in the chapter of regular maintenance Switch Inspection •...
Page 394: Speed Sensor
Speed Sensor Speed Sensor Disassembly Warning Do not make the sensor drop especially on the hard surface. The impact shock may damage the sensor ●Loosen the bolt ●Disconnect the speed sensor coupler Speed Sensor Inspection ●Disassemble the speed sensor (see the speed sensor disassembly section) ●Connect the speed sensor coupler [A], battery [B], 10kΩ...
Page 395: Oxygen Sensor
Oxygen Sensor Oxygen Sensor Disassembly Warning Do not make the sensor drop especially on the hard surface. The impact shock may damage the sensor ●Disassembling: Right lower fairing (see the lower fairing disassembly section in the chapter of frame) Oxygen sensor coupler [A] (disconnected) Clamp [B] (open) Oxygen sensor [C] Oxygen Sensor Installation...
Page 396: Fuel Level Sensor
Fuel Level Sensor Fuel Level Sensor Disassembly • Disassembling: Fuel tank (see the fuel tank disassembly section in the chapter of fuel system (EFI) Disassembling: Nuts [D] Fuel level sensor [C] • Check whether the fuel sensor floater moves smoothly without clamping stagnation.
Page 397: Horn
Horn Horn Disassembly ●Remove the horn leads. Horn Inspection ● Connect a battery (12V) to the horn, if the horn sounds well, it means the horn is OK, otherwise, adjust or replace it.. Resistance 1.4Ω 7-35...
Page 398: Fan
Fan Disassembly ●Disassemble the radiator fan (see the “Disassembling Radiator and Radiator Fan” in the “Radiator” chapter) Fan Inspection ●Check the fan blades [A], ★If the fan blades are damaged, replace the fan component ●Confirm whether the copper terminal in the fan coupler are loose first ★If they are not loose, connect the fan to the positive and negative electrodes of battery directly, as shown in the figure on the right...
Page 399: Fan Switch
Fan Switch Fan Switch Disassembly ● Disconnect the fan switch coupler ●Disassemble the fan switch Checking Fan Switch Breakover temperature 98±4℃, 9℃≥breakover temperature—turn-off temperature≥3℃ 7-37...
Page 400: Relay And Fuse Box
Relay and Fuse Box Relay and Fuse Box Disassembly ●The relay is manufactured on the wire harness directly, ●The position is in the rear tail cover area on the right side of the motorcycle ●Pull the upper cover during disassembly, ●Pull out the No.
Page 401 Internal Circuit of Relay Box 1 Fuel pump relay 2 Main relay 3 Headlight relay ●State 1: relay(Headlight always on) 7-39...
Page 402 ●State 2: relay ●The headlight is not always on; the relays of this type do not include the No. 3 relay in the state 1 and the inspection method is the same as state 1 relay 7-40...
Page 403: Fuse
Fuse Fuse Disassembly ●Disassemble the seat (see the seat disassembly section in the chapter of frame) ●Disassemble the safety guard on the right side ● Squeeze the latches [A] and open the cover ●Use sharp-nose pliers to pull the fuse up and out of the fuse box Fuse Installation ★If the fuse break down during operation, check the electrical system to figure out the cause, and then replace the fuse with a new one with suitable ampere...
Page 404 Fuse Inspection ●Disassemble the fuse (see the fuse disassembly section) ●Check the fuse parts ★If the fuse is blown out, replace the fuse. Before replacing the blown fuse, check the amperage of the affected circuit. If the amperage is equal to or greater than the rated current of the fuse, check the circuit and related parts to figure out whether they are short-circuited Shell [A]...
Page 405: Chapter Viii Appendix
CHAPTER VIII APPENDIX ROUTING OF CABLE, WIRE AND HOSE ......................8-2 MAIN HARNESS ROUTING: ............................ 8-3 THROTTLE CABLE ROUTING ..........................8-7 CLUTCH CABLE ROUTING: ..........................8-9 OTHER MATTERS: ..............................8-11 TROUBLESHOOTING GUIDE ........................... 8-25 THE ENGINE CANNOT START OR IS DIFFICULT TO START: ..............8-25 ABNORMAL RUNNING DURING LOW-SPEED DRIVING: ................
Page 406: Routing Of Cable, Wire And Hose
Routing of Cable, Wire and Hose...
Page 407: Main Harness Routing
Main Harness Routing: . Make the main harness across the frame from right side of steering tube. Hook the harness with the clamp...
Page 408 Hook the harness with the clamp and make the main harness pass through the upper side of frame Run the main harness through the upper side of frame and hook it with the clamp...
Page 409 Run the main harness through the outer side of the air filter installing bracket Run the main harness through the lower side of the frame bracket as illustrate...
Page 410 Hook the rubber sheath of the main harness end coupler...
Page 411: Throttle Cable Routing
Throttle Cable Routing Run the throttle cable through the hole of the upper bridge and connect it with the right handlebar switch Run the throttle cable through the frame as shown, do not interfere with the clutch cable...
Page 412 Run the throttle cable through the lower side of frame , as shown Hook the throttle cable with the clamp. Do not interfere with main harness and clutch cable.
Page 413: Clutch Cable Routing
Clutch Cable Routing: Run the clutch cable through the gap between the meter and upper bridge Run the clutch cable through the frame as shown. Do not interfere with the throttle cable.
Page 414 Run the clutch cable as shown and hook it with the clamp Make clutch line go through the inside of frame, and pay attention to Run the clutch cable through the frame. Do not interfere with throttle cable. 8-10...
Page 415: Other Matters
Other Matters: Clamp the throttle cable, front brake hose and right handlebar switch lead together with a rubber clamp Clamp the clutch cable and left handlebar switch lead together with a rubber clamp 8-11...
Page 416 Run the brake hose through left side of steering tube Run the front brake hose through the rear side of the lower bridge. 8-12...
Page 417 Routing of the radiator inlet hose as shown Clamp the fan switch lead and engine temperature senser lead with the frame with a cable tie as shown. Clamp the engine temperature senser with the front frame bracket with a cable tie as shown.
Page 418 Hook the alternator lead with the clamp. Clamp the sidestand switch lead with a cable clip Clamp the sidestand switch lead with a cable 8-14...
Page 419 Routing of the sidestand switch lead as shown Gear position switch lead as shown Clamp the branch of the main harness, engine power output wire and gear position switch lead together with a cable tie 8-15...
Page 420 Hook the branch of the main harness as shown Clamp the start motor lead with a cable clip as shown 8-16...
Page 421 Run the start motor lead through the frame as shown Clamp the start motor lead and the branch of the main harness with a cable tie 8-17...
Page 422 Route the main harness, throttle cable and clutch cable as shown Route the main harness, throttle cable and clutch cable as shown Hook the main harness, throttle cable and clutch cable with the clamp. Hook the branch of the main harness and the main relay positive lead with the clamp.
Page 423 Hook the main harness, relay positive lead and Oxygen sensor cable with the clamp. Hook the branch of the main harness and sidestand switch lead with the clamp. 8-19...
Page 424 Hook the main harness as shown ECU installation As shown Route the igniter lead as shown, 8-20...
Page 425 Route the coolant reservoir hose as shown Clamp the clutch cable and speed sensor with a clamp The position of motorcycle bond strap as shown 8-21...
Page 426 Fuse location as shown Clamp the rear brake hose and speed sensor cable together with clamp. 8-22...
Page 427 Run the rear brake hose and the speed sensor cable through the inner side of the rear swing arm and cable guide as shown Route the fuel hose as shown 8-23...
Page 428 The installation direction of fuel level sensor as shown Canister c –to- canister solenoid valve hose 5×9×150 Canister –to –roll over valve hose 4.5×8.5×300 Canister solenoid valve –to-engine intake pipe 5×9×100 MAP hose 4.5×8.5×100 Fuel tank –to- rollover valve hose 4.5×8.5×220 Coolant reservoir hose 7×11×240...
Page 429: Troubleshooting Guide
Troubleshooting Guide Remarks ○For most of EFI faults, refer to the chapter “EFI”. ○This table is not exhaustive and it is unable to list the possible causes of each issue and can only be used as a basic guide to help solve some common problems. Short circuit or poor contact of ignition coil ;...
Page 430: Abnormal Running During Low-Speed Driving
Abnormal running during low-speed Abnormal running or poor power driving: during high-speed driving: Spark is weak: Ignition is abnormal: Battery voltage is low; Spark plug is dirty, damaged or abnormal; Alarming system fault; Spark plug is unsuitable; Ignition coil fault; Short circuit or poor contact of ignition coil ;...
Page 431: Temperature Is Too High
Cooling system components are abnormal: Muffler is overheated: Thermostat fault; For Benelli emission control systems, if the cylinder is Clutch is abnormal: not ignited or the running is abnormal, do not start the engine (go the nearest service center for maintenance);...
Page 432 Oil level is too low; Oil is poor or unsuitable Instrument is abnormal: Thermostat is broken; Water Engine temperature sensor is broken Coolant is abnormal: Coolant level too low; Coolant deterioration; Coolant mixing ratio is incorrect Cooling system components are abnormal: The radiator fins is broken;...
Page 433: Problem With Shifting
Timing chain tensioner fault; Timing chain, sprocket or guide plate is worn; The breathe valve is broken; Secondary air inlet valve is broken; Alternator rotor is loosened; Overheating of muffler causes melting of catalytic converter (Benelli emission control system) 8-29...
Page 434: The Drive System Makes Abnormal Noise
The drive system makes abnormal noise: The frame noise: Clutch noise: Front fork noise: The clearance between clutch housing and friction plate is Lack of lubricating oil or too thin oil film; too large; Spring has poor elasticity or is damaged Rear shock absorber noise: Clutch housing is worn;...
Page 435: Too Much Exhaust Smoke
Too much exhaust smoke: White exhaust smoke: Piston oil ring is worn; Cylinder is worn; Valve seal is damaged; Valve guide is worn; Oil level is too high Black exhaust smoke: Air filter is blocked Brown exhaust smoke: Vent pipe clamp is loosened; Air filter has poor sealing or not assembled 8-31...
Page 436: Poor Performance And / Or Stability
Poor performance and / or stability: Battery fault: The handlebar is difficult to turn: Battery power runs out: Routing of cable is incorrect; Not enough power; Routing of hose is incorrect; There is problem with battery (voltage too low); Routing of wire is incorrect; Poor battery cable contact;...
Page 437: Circuit Diagram
Circuit Diagram 8-33...
Page 438 8-34...
Page 439: Special Tool List Summary
Special Tool list Summary gear shift oil seal installer & gear shift oil seal guide ACG crankshaft puller+ crankshaft installation guide rod (2PCs in 1 set) plate (2PCs as 1 set) Complete Code:BN-20000-515-0 Complete Code:BN-17901-515-0 ACG flywheel puller+flywheel/ one-way clutch stopper NEEDLE BEARING 12×16×10 (clutch lever needle (2PCs as 1 set) bearing tool)
Page 440 300cc steering special nut 4T wrench 300cc steering special nut 7T wrench Complete Code:BN43008-622-0 Complete Code:BN43009-622 Front steering bracket support RR swingarm support Complete Code:BN-43011-622-0 Complete Code:BN53021-622-0 Footrest bracket C ring tool Footrest bracket bush installer Complete Code：BN-58222-515-0 Complete Code：BN-58244-622-0 8-36...

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