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hsr-benelli S-series Service Manual

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ver.2009_03
Page 1/215

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Summary of Contents for hsr-benelli S-series

  • Page 1 ver.2009_03 Page 1/215...

  • Page 2: Table Of Contents

    1.2.4 Engine Break-In................13 1.2.5 Operating the engine on vehicle outside of water ......13 Unit identification………………….…………………….……………...… 14 1.3.1 HSR-BENELLI Personal Watercraft Identification Numbers…...… 14 1.3.2 VIN number………………….……………………….…………...…… 14 1.3.3 Engine number ………….……………………….…………………… 14 1.3.4 Three stars – ultra low emission ……………………………….…… 15 1.3.5 Safety instructions ……………………………………………….……...
  • Page 3 3. ENGINE......................32 Engine Removal and Installation............33 Engine Disassembly/Assembly............41 3.2.1 CYLINDER HEAD ................. 41 3.2.2 CYLINDER AND PISTONS ............58 3.2.3 ENGINE BOTTOM END ............... 66 3.2.4 Cooling system Thermostat and Water pump ......82 4. TRANSMISSION.................... 91 Transmission Dismantling..............
  • Page 4 8. COOLING SYSTEM..................147 Closed circuit cooling system ............148 Opened circuit cooling systems ............150 8.2.1 Exhaust cooling system ............... 153 8.2.2 Oil cooling system ............... 156 9. STEERING SYSTEM ................... 157 SERIES-R STEERING SYSTEM Steering Support Assembly ............158 Assembly of the Steering Support on the PWC ......
  • Page 5 11.2.7 Sector G ..................196 11.2.8 Sector H ..................196 12. HSR-BENELLI DIAGNOSTIC SYSTEM ............. 197 12.1 HSR-Benelli Utility Diagnostic System (HUDS) installation ..198 12.2 HSR Diagnostic Tool settings ............204 12.3 Vehicle registration process ............205 12.4 Periodic maintenance registration process ........208 13.
  • Page 6 ver.2009_03 Page 6/215...

  • Page 7: General Information

    1. General Information 1.1 Introduction This manual contains an introductory description of the HSR-Benelli Series-R and Series-S Personal Water Craft (PWC) together with the procedures for control/intervention and revision of the main components. It is designed primarily for use by trained mechanics in a properly equipped workshop. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily.
  • Page 8 ver.2009_03 Page 8/215...

  • Page 9: Service Quidelines

    Never reuse hose clamps when removed from fuel lines. Replace with small gear clamps. WARNING: Always use HSR-Benelli authorized lubricants, greases, and locking agents when assembling components. Failure to do so may cause severe engine or vehicle damage. Always disconnect the black (-) negative cable first from the battery when removing the battery.

  • Page 10: Service Tools

    Only run engine outdoors or in a well ventilated area. Never run the engine for more than 10 seconds without cooling water supply. 1.2.2 Service Tools HSR-BENELLI DIAGNOSTIC SYSTEM (Benelli engine version) IMPELLER TOOL FLYWHEEL PULLER ver.2009_03...
  • Page 11 T.D.C. MEASURER TRANSMISSION GEAR PULLER GEAR NUT REMOVAL TOOL COUPLER REMOVING TOOL VALVE OIL SEAL REMOVING TOOL OIL REMOVING TOOL ver.2009_03 Page 11/215...

  • Page 12: Operating Materials

    If used regularly, they cause decreases in performance and possibly damage to the engine. Recommended lubricants LUBRICANT SPECIFICATIONS Series-S Series-R Engine Oil HSR-Benelli engine oil 10w60, specification ACEA, A3/B3/B4, API SL Engine Oil 2,3 litres 2,7 litres Initial filling (completely dry system) Filling volumes...

  • Page 13: Engine Break-In

    Trim system liquid Brake fluid DOT4 1.2.4 Engine Brake-In WARNING: HSR-BENELLI recommends not to operate the engine over 6,000 r/min [RPM] during first five hours of operation. This protective braking-in has a positive effect on the engine„s lifespan. 1.2.5 Operating the engine on vehicle outside of water...

  • Page 14: Unit Identification

    1.3 Unit identification 1.3.1 HSR-BENELLI Personal Watercraft Identification Numbers The engine Serial number and VIN number are used to register the watercraft. They are unique numbers that distinguish each watercraft from others of the same model. If the watercraft is ever stolen these numbers will help identify it. The owner should keep a record of these numbers in a place other than the watercraft 1.3.2 VIN number...

  • Page 15: Three Stars - Ultra Low Emission

    1.3.4 Three stars – ultra low emission The three-star label identifies engines that meet the Air Resources Board’s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star – Low Emission Engines. 1.3.5 Safety instructions For Series-S ONLY Safety Instructions sticker is placed under the handle pole on...

  • Page 16: General Specifications

    Exhaust Manifold Overheat switch – engine limiter EXHAUST OVERHEATING WARNING activation Cooling manifold Sensor – 90° engine limiter activation COOLANT OVERHEATING WARNING ENGINE LUBRICATION SYSTEM Wet Sump ENGINE OIL SPECIFICATIONS HSR-BENELLI Engine oil 10w60, ACEA, A3/B3/B4, API SL ver.2009_03 Page 16/215...

  • Page 17: Standard Torque Specifications

    9200 – 9300 1/min – Determined by ECU RPM LIMITER EXHAUST SYSTEM Waterbox with water injector ENGINE MANAGEMENT SYSTEM FUEL DELIVERY WALBRO Multi-point fuel injection IDLE SPEED 1700 1/min +/- 50 MAGNETO GENERATOR OUTPUT 13.5V / 48A at 5000 rpm BATTERY Series-R: 12 Volts 20Ah Series-S: 12 Volts 14Ah...

  • Page 18: Convertion Chart

    1.4.3 Convertion Chart x 12 = in. lbs. ft. lbs. x 0,0833 = ft. lbs. in. lbs. x 1,356 = Nm ft. lbs. x 0,115 = kg-m in. lbs. x 0,7376 = ft. lbs. x 7,233 = ft. lbs. kg-m x 86,796 = in.
  • Page 19 ver.2009_03 Page 19/215...

  • Page 20: Maintenance

    The Maintenance intervals specified in the table should not be exceeded by more than 10%. All activities described in this manual must be carried out by trained service staff. In case of warranty repairs HSR-BENELLI reserves the right to request warranty approval documents for performed periodic maintenance of eligible PWC. ATTENTION: The vehicle owner or user is responsible adhering to the maintenance intervals.

  • Page 21: Flushing System Attachment

    2.1 Flushing system attachment For service purposes engine of vehicle could be started out of water using Flushing system to provide cooling by tap water. ATTENTION: Engine could be operated only at idle rpm even if flushing kit is attached. Do not run engine when flushing kit is attached continuously for a period over 5 miutes to prevent overheating.

  • Page 22: Periodic Maintenance Chart

    2.2 Periodic maintenance chart After the At 100 h Each Each first 10 At 25 h of At 50 h of At 75 h of Jobs to be performed additional additional hours of operation operation operation operation 25 h 100 h operation Visual Check of all hoses, pipes, hose clips,...

  • Page 23: Periodic Maintenance Procedures

    2.3 Periodic maintenance procedures 2.3.1 Oil level check NOTE: Use a clean, lint-free cloth PWC must be leveled to perform oil level verification. Check the oil level when engine is cold by pulling the oil dipstick out of the engine. The oil level must be within the minimum and maximum marks.

  • Page 24: Engine Oil And Filter Replacement

    Open oil filling cap on engine valve cover (shown by arrow). Refill the engine with new engine oil. ATTENTION: ALWAYS USE HSR-BENELLI ENGINE OIL. NOTE: FOR SERIES-S Volumes of oil in the engine: min 1,7 litres (without change of oil filter), max 2,0 litres (change of oil filter included).

  • Page 25: Spark Plugs Replacement

    2.3.3 Spark plugs replacement ATTENTION: Replace spark plugs only when engine is COLD. In other case there is a risk to damage cylinder head thread. Use only spark plugs of recommended type in order to avoid engine damage. NOTE: RECOMMENDED SPARK PLUGS CHAMPION RG4HC Replace engine spark plugs every 100 hrs.

  • Page 26: Valve Clearance Inspection

    2.3.4 Valve clearance inspection ATTENTION: Valve clearance must be checked and adjusted when the engine is cold (room temperature) Remove cylinder head cover to access cylinder head (See Head cover Removal) Taking the engines cylinder 1 to the TDC verify that also the marks and of the Camshaft sprockets are aligned between them and with the head plain.

  • Page 27: Valve Clearance Adjustment

    SPECIFIC VALUE Intake = 0.30 ~ 0.35 mm Exhaust = 0.35 ~ 0.40 mm Note: Engine must be cold If the valve clearance is out of specifications take note about your current reading for adjustment. 2.3.5 Valve clearance adjustment ATTENTION: To prevent falling of removed parts into crankcase please use proper sealing material at timing chain drive casing.
  • Page 28 ATTENTION: Make sure that the distribution chain does not fall into the casing. Remove the chain tensioner. ATTENTION: Mark the removed elements for correct reassembling (cylinder number, camshaft IN/EX, etc). Remove mounting screws of camshaft holders (8) and remove them. Take care of removing metal bushings of each holder.
  • Page 29 Remove the cap (2) of the valve which requires adjustment using a magnet. To change the valve clearance, replace the shim with one of a different thickness. Measure the thickness of the removed shim. NOTE: Mark and record the locations of the valve caps and shims so that they can be reinstalled in their original positions.
  • Page 30 Installing Cylinder Head cover ATTENTION: Always use new gaskets. Position the gaskets of the head cover (1 and 2 ). ATTENTION: Make sure that gaskets (2) do not fall into the head during cover installation. *Apply THREEBOND® paste as shown on the drawing. Install the cylinder head cover and insert rubber bushings and the screws (3) and (4) as shown on the figure.

  • Page 31: Refilling Of Coolant

    2.3.6 Refilling of coolant WARNING: This process is a very sensitive and requires special attention. The risk is that air bubbles remain in the cooling system so that the heat of the engine cannot be transferred into the radiator of the Jet Pump. The total volume of coolant is: for SERIES-S 2,5 litres;...
  • Page 32 ver.2009_03 Page 32/215...

  • Page 33: Engine

    Engine 3.1 Engine Removal and Installation The installation of the engine and engine subsystems is the reverse to their removal. During engine installation, several important notes must be made. Always verify the correct number of engine mounting strap shims are installed on each engine mounting post.
  • Page 34 Engine installation into the PWC: (shown for Series-R Pro) Lift the engine into the PWC using a lifting device. Insure you hook on the exhaust hose and the and inline the Spider Couplers. Position the Engine into the 4 x engine supports on the hull. ver.2009_03 Page 34/215...
  • Page 35 Ensure the exhaust hose and the Spider Couplets are properly aligned. Take a metal ruler like shown on the picture and check the alignment of the Spider coupler to see if the engine is positioned properly according to propulsion system. If the engine position needs to be adjusted use special washer with 0,5 and 1 mm thickness to align the system.
  • Page 36 Tighten the exhaust hose with a screw driver. Plug in the cooling hose for the 3 in 1 hose. Plug in the water relieve hose for the 3 in 1 hose. Plug in the water relieve hose for the exhaust manifold Tighten the fuel hose to the fuel rail NOTE: Take care to install the sealing rings Plug in the cooling water supply lines as shown on the picture...
  • Page 37 Plug in the water relieve hoses from the oil cooler. Plug in the water supply hose for the waterpump. Plug in the coolant hose for the temperature thermostat. ver.2009_03 Page 37/215...
  • Page 38 Plug in the Ignition wires for the ignition coils. NOTE: Ignition wires are marked with numbers of corresponding cylinders. Plug in the wires for the injectors. NOTE: Injector wires are marked with numbers of corresponding cylinders. Plug in the connector for t he heat sensor. Plug in the TPS sensor.
  • Page 39 Plug in the oil pressure sensor. Plug in the SSSA connector. ö Tighten the ground wire. Connect the wires of the voltage regulator on the ignition cover. ver.2009_03 Page 39/215...
  • Page 40 Connect the positive wire from the starter to the starter relays. Connect the positive starter cable to the positive starter connector. Connect the acceleration wire to the throttle bodies. For adjustment of the acceleration wire insure the throttles are on open wide throttle position. ver.2009_03 Page 40/215...

  • Page 41: Engine Disassembly/Assembly

    Adjust the acceleration wire until specified free play on throttle lever is given. SPECIFIC VALUE CLEARANCE (A) = 2 - 3 mm NOTE: Insure that engine oil and coolant liquid are on proper level. NOTE: REMOVING THE ENGINE IS A REVERSE PROCEDURE TO DESCRIBED ABOVE 3.2 Engine Disassembly/Assembly 3.2.1 CYLINDER HEAD Head cover removal...
  • Page 42 NOTE: Replace 8 screws rubber bushings (5) during reassembling. Removing Camshafts Remove the head cover. Remove the chain pad (6), Unscrewing the two fixing screws (7). ATTENTION: Make sure that the distribution chain does not fall into the casing. Remove the chain tensioner. ATTENTION: Note the position of the elements for correct remounting.
  • Page 43 Check the deformation of the camshaft with a comparator, as shown on the picture. If the value does not enter within the specific measure, change the element. INTAKE AND EXHAUST SHAFT DIMENSIONS LIMIT: MAX. VALUE = 0.03 mm The maximum play between the distribution camshaft and seat is 0.1 mm.
  • Page 44 Visually check the timing chain guides: 1) Fixed guide (FRONT PART) 2) Mobile guide (REAR PART) 3) Upper guide (FIXED ON HEAD) If one or more elements are worn, change it/them. NOTE Always replace chain guides if timing chain is to be replaced.
  • Page 45 NOTE: Ensure that during assembling engine crankshaft is not moved from 1 cylinder TDC position and camshafts marks are aligned as shown on the picture. Position the exhaust shaft and the timing chain, position the holders in their original direction (written on the outside) and tighten the fixing screws according to the diagram in the figure.
  • Page 46 Position the timing chain on the camshaft sprockets. Position the bridge and the upper chain pad and tighten the fixing screws in two phases in shown sequence. Tightening torque: 1st phase: 6 N·m; 2nd phase: 13 N·m NOTE: Always oil the sliding parts with Teflon SINTOFLON paste. Position the chain tensioner (1) complete with O-ring (2) and tighten two screws (6).
  • Page 47 Check that cylinder 1 cams are turned towards each other as on the figure. Remove Cylinder Head Remove the chain tensioner, chain pads, camshafts (see above). Loosen and remove the eight nuts and washers (1) indicated in the figure according to the shown sequence and two screws on the right side of the engine (timing chain side).

  • Page 48: Cylinder Head Inspection

    Cylinder Head Inspection WARNING: Do not use a pointed instrument to avoid damaging or scatching: Spark plug hole threading Valve seats Check and eventually eliminate carbon deposits in the combustion chamber with a rounded-off scraper. If the surface is damaged or scratched, change the element.
  • Page 49 Position the head/cylinder gasket. Position the cylinder head. Position the fixing washers and nuts. Tighten to the specified torque following the shown sequence in following phases: 1st phase: 10 Nm; 2nd phase: 30 Nm; 3rd phase: 45 Nm; 4th phase: angle of 100°; 5th phase: tighten 2 bolts on timing chain side with 10.8 Nm NOTE:...
  • Page 50 To remove the valves use a valve dismantling instrument (2) with correct attachment (3), press the valve down and take off the two semi-cones. Loosen the clamp and remove the valve and its components as shown on picture. The following procedure is applied to the valves (4), the springs (5 and 6) and relative components (7, 8 and 9).
  • Page 51 Valves and Valve Guide Inspection The following procedure must be carried out on all valves and relative valve guides. Check that values (A) and (B) are within the tolerance of the specific values. If values (A) and (B) are not within the value limits, change the elements. INTAKE VALVE DIAMETER LIMIT A max.

  • Page 52: Valve Seat Inspection

    Check the deformation of the legs of the valve. If the concentricity value does not enter within the margin, change the element. VALVE REFORMATION VALUE LIMIT 0.01 mm Valve Seat Inspection The following procedure must be applied to all the valve seats. Eliminate eventual carbon deposits. Apply the tincture of bluing (b) on the face of the valve.
  • Page 53 smoothing operation on the face and the seat of the valve. Smooth: • the face of the valve • the seat of the valve NOTE: After having changed the cylinder head or the valve and the relative guide, it will be necessary to smooth the seat and face of the valve.
  • Page 54 Valve Spring Inspection The following procedure is valid for all valve springs. Measure the length (a) of the free valve. If the value does not enter within the envisaged limits, change the spring. FREE VALVE SPRING LENGTH External valve spring Tollerance limit: 37 mm Internal valve spring: Tollerance limit: 34.0 mm...
  • Page 55 Valve Caps Inspection The following procedure must be applied to all valve caps. Check that caps are not broken or scratched, in other case replace them. Mount Valve The following procedure must be applied to all the valves and relative components. Oil the valve stem with the recommended oil.
  • Page 56 WARNING: Always use new gaskets and oil seals. Mount the rubber valve seal (2) with the appropriate pad (3). ATTENTION: Intake valves are larger than the exhaust valves. Insert the valves (4). Position the internal (5) and external (6) springs as shown in the figure.
  • Page 57 Position the small cap as shown in the figure. Use the dismantling valve instrument making sure that the valve is correct. Position the calibrated pads (9) and valve caps (10). ATTENTION Make sure that the individual valve lifters and the valve guide are re-mounted in the original position.

  • Page 58: Cylinder And Pistons

    3.2.2 Cylinder and Pistons Dismantle Cylinder Body Remove the cylinder head (see "REMOVE CYLINDER HEAD"). Remove the gasket of the head, the cylinder body (1) and the base of the cylinders gasket beneath. Check that the walls do not present signs of seizure with the pistons.
  • Page 59 Dismantle Water Collector Unscrew and remove the three screws (1) and remove the collector (2). Check Water collector Check eventual breaks on the collector and if necessary change the piece. Mount Water Collector ATTENTION: Always use new gaskets. Position the gasket (1)and the collector (2) and tighten the screws (3).
  • Page 60 Piston Dismantle Piston Remove the cylinder (see "DISMANTLE CYLINDER BODY"). The following procedure must be applied to all 3 pistons. Remove the elastic ring (1). ATTENTION: Do not use hammers for the piston pin removal (2). Remove pin (2) and remove piston (3). ver.2009_03 Page 60/215...
  • Page 61 Check Piston The following procedure must also be applied to all the other pistons. Check eventual breaks on the piston. Use a micrometer, as shown in the figure, to check that the value (P) enters within the specific value. ATTENTION: In the case of changing one or more pistons: The piston is distinguished by a letter that indicates the class it belongs to.
  • Page 62 Piston Ring Play Measure the lateral play of the 1 and 2 segment using a feeler. If one of the two plays exceeds the limit specified, change both the piston and the segments. PISTON RING PLAY SERVICE LIMIT:(1 ): 0.20 mm ): 0.18 mm PISTON RING WIDTH ): 1.02 –...
  • Page 63 Check the value of (b). NOMINAL VALUE b = 19,002 ÷ 19,008 mm NOTE: If the play between the piston pin and the pin is more than 0.03 mm, change the piston. Mounting Piston Rings: Install the piston rings in the order: oil ring , 2 piston ring , 1st piston rings.
  • Page 64 Install the 2 piston ring (3) and the 1 piston ring (4). NOTE: The form and width of the 1st and 2nd piston ring are different. W4 = 3.1 ± 0.1 mm W3 = 3.7 ± 0.1 mm piston ringhave the letter “N” on the upper side. The 1 and 2 Make sure that the marked side is turned upwards when being...
  • Page 65 Position the piston (3), as shown in the figure, with the arrow on the piston pointing towards the exhaust. Insert the pin (4). ATTENTION: Always use new elastic rings for mounting the pistons. To avoid breaks that can take place with the rings bent. Position the two elastic rings (5), one for each side pay attention not to deform them.

  • Page 66: Engine Bottom End

    3.2.3 Engine Bottom end Crankcase Disassembling Remove the cylinder head (see “CYLINDER HEAD REMOVAL”) Remove the cylinder block (see “DISMANTLING CYLINDER BLOCK”) Remove the pistons (see “DISMANTLING PISTONS"). ATTENTION: Ensure that there is no oil left inside the engine before dismantling crankcase. Remove engine oil using oil pump tool if necessary.
  • Page 67 Remove the oil pump cover: Oil Pump and Oil Sump removal Rotate the engine 180° to access its bottom side. Remove the oil hose attachment from the oil sump cover. Remove the dipstick tube connection. Untighten and remove oil sump cover mounting screws. Remove the oil sump cover.
  • Page 68 Remove 2 balance shaft screws shown on the picture. Remove the lower crankcase part pulling it up. Use a soft hummer if necessary. NOTE: Pay attention to prevent crankshaft and balance shaft of falling down during casing removal. ver.2009_03 Page 68/215...
  • Page 69 Remove 2 large plastic lock nuts on both sides of balance shaft. (14). Remove the ring (15). Remove the balance shaft. Remove engine crankshaft. ATTENTION: Take note of crankshaft plain bearings position for correct reassembling. Remove the plain bearings. ver.2009_03 Page 69/215...
  • Page 70 Dismantling Balance Shaft Remove the circlip (1). Remove the ball-bearing (2) and the toothed wheel (3). Remove the ball-bearing (4). ver.2009_03 Page 70/215...
  • Page 71 Dismantling Crankshaft ATTENTION: Take note of crankshaft parts position for correct reassemling. The following procedure must be applied to all connecting rods mounted on the crankshaft shaft. Unscrew and remove bolts (1). Remove connecting rod (2) from the crankshaft (3). Check Engine Shaft and Connecting Rod Check eventual breaks or excessive wear on the whole engine shaft (1).
  • Page 72 Internal Diameter Connecting Rod Foot Using a caliber for small holes, measure the internal diameter of the connecting rod foot. INTERNAL DIAMETER CONNECTING ROD FOOT SERVICE LIMIT: 19.040 mm If the internal diameter of the connecting rod foot exceeds the specified limit, change the connecting rod.
  • Page 73 Crankcase Assembling Mounting Crankshaft NOTE: There are 3 different sizes of connecting rod plain bearings marked by colors mentioned in the chart. Position each con-rod plain bearings according to the marks on the rod flange (see picture). Take care the bearings are installed to relative slots. ATTENTION: Two marks shown on the figure must couple for connection rod body (1) and big end cap...
  • Page 74 NOTE: Apply MOLIKOTE® grease on the inner halves of con-rod plain bearings and ensure the outer halves and the con-rod bodies are cleaned with fuel to increase the friction between both parts. RECOMMENDED OIL MOLIKOTE® BR2 PLUS GREASE ATTENTION: Always change connecting rod bolts by new after each dismantling.
  • Page 75 Position the crankshaft on the upper part of crankcase. Tighten connecting rod bolts in three phases: Tightening torque: phase: 15 N·m (1,5 Kg-m) phase: 25 N·m (2,5 Kg-m) phase: + 50° NOTE: An angle torque control wrench is required to carry out the third tightening phase. Mounting Balance Shaft Position the ball-bearing (1) and fix with the circlip (2).
  • Page 76 Position the bushing (4). Position the ring(5). Position the roller bearing (3) on the balance shaft. Mounting Casting NOTE: There are 3 different sizes of crankshaft plain bearings marked by colors mentioned in the chart. ver.2009_03 Page 76/215...
  • Page 77 NOTE: Reading the letters must always be carried out starting from timing chain side. Position and center four semi-bronze plain bearings (25) each slotted with the correct color according to its letter stamped on the exhaust side of the crankcase (24). Position the crankshaft as shown on the figure.
  • Page 78 NOTE: Make sure that sprocket wheels marks of the balance shaft and the crankshaft are aligned as shown on the figure. Position balance shaft ring (28). Install 2 large plastic lock nuts on both sides of balance shaft. (29). ver.2009_03 Page 78/215...
  • Page 79 NOTE: Apply proper amount of recommended sealant to the contact surfaces of both crankcase parts. RECOMMENDED SEALANT LOCTITE 5699 FLANGE SEALANT Position the lower casing part on the upper. ATTENTION: Follow the mounting phases correctly. Position eight crankcase screws with washers, apply recommended grease for their threads and tighten to specified torque in three phases according to the sequence marked on engine carter.
  • Page 80 Tighten balance shaft M8 screws shown by arrows in two phases: Tightening torque: phase: 10 N·m (1,0 Kg-m) phase: 25 N·m (2,5 Kg-m) Tighten screws shown by circle marks with specified torque: Tightening torque: 10 N·m (1,0 Kg-m) ATTENTION: Always use new gaskets. Install Oil pump intake tube, Oil sump filter and oil sump cover.
  • Page 81 Rotate the engine 180° to be placed on its bottom side. Tighten the bolt under roll-over valve in two phases (shown in oval-mark) Tightening torque: phase: 10 N·m (1,0 Kg-m) phase: 25 N·m (2,5 Kg-m) Tighten five screws (shown in circle-marks) with specified torques: Tightening torque: 10 N·m (1,0 Kg-m) Install Oil pump cover and tighten its screws with specified torque:...

  • Page 82: Cooling System Thermostat And Water Pump

    3.2.4 Cooling system Thermostat and Water pump Thermostat: Dismantling Thermostat: WARNING: Always use new gaskets and oil seals. Disconnect cooling system hose, loosen and remove mounting screws and remove the thermostat cover. Remove the thermostat (5). Verify that the by-pass hole (6) is not obstructed. Check Thermostat The thermostat begins and opens at around 75°C and reaches 7 mm minimum opening at 90°C, as shown in the diagram on...
  • Page 83 Check whether the thermostat pad is cracked. Pass a cord through the flange as indicated in the figure. Check the above-mentioned conditions by immerging the thermostat (1) in a container with water, maintaining it in suspension. Slowly heat the water and check the temperature with a thermometer (2).
  • Page 84 Dismantle Water Pump Loosen and remove the two screws (4) and the small plates (5). Remove the entry elbow (6). Loosen and remove the two screws (3) and remove the water pump from the engine. Remove O-Ring (7). Loosen and remove two screws (8). Remove the cover (9).
  • Page 85 Loosen and remove the nut (10) and remove the rotor (11). Remove the external circlip (12), the internal circlip (13) and the ball-bearing beneath. Remove the liner (14), the shaft (15), the ball-bearing (16) and oil seal beneath. Remove the mechanical seal (17). ver.2009_03 Page 85/215...
  • Page 86 Check the state of wear of the various components of the pump. Check that the various elements are not broken. Change worn or damaged elements if necessary. Water Pump Assembly Position the pump body (1) on a support. ATTENTION: The oil seal must be inserted downwards with the lip closed.
  • Page 87 Position the shaft (4) inside the pump body (1). Position the first ball-bearing (5), using a press to make it touch. Position the liner (6). Position the second ball-bearing (7), using a press to make it touch. Fix the ball-bearings with the external (8) and internal (9)circlips.
  • Page 88 ATTENTION: While mounting the counter-face and mechanical seal make sure that they are clean and bear no traces of grease. Position the counter face as in the figure (10). Position the mechanical seal (11) until it touches as shown in the figure.
  • Page 89 Position the cover and lock it tight with the two screws (15). Position the sealing washer (16) and tightly screw the purge screw (17) up. 10 N·m 1 Kg-m Always use LOCTITE 243® Position the O-Ring (18) on the pump body. Position the entry elbow (19) and fix with the two small plates (20) and the two screws (21) tightly.
  • Page 90 Position the pump (1) as in the figure and screw the two screws (2) up tightly. 10 N·m 1 Kg-m Always use LOCTITE 243® Reposition the entry and exit tubes (3) of the pump, tightening two hose clamps (4). ver.2009_03 Page 90/215...
  • Page 91 ver.2009_03 Page 91/215...

  • Page 92: Transmission

    Transmission 4.1 Transmission Dismantling Remove engine out of the PWC (see Engine Removal chapter). Remove the engine oil by opening the oil plug screw on the bottom of the engine (19 mm socket required). Use suitable equipment to collect the engine oil. Remove the following parts: Oil return line to the bottom of the engine Oil supply line...
  • Page 93 Remove 2 x short and 10 x long 5mm mounting screws Take note of short screw position (shown on figure) Remove transmission cover with a suitable tool. NOTE: do not damage the gasket surface of the casting. Remove the right hand thrust washer carefully and place beside.
  • Page 94 Remove carefully the left hand transmission gear assy and place beside. Remove carefully the second thrust washer and place beside. Remove carefully the 3 x needle cage bearings and place beside. Remove carefully the left had thrust bearing and place it beside.
  • Page 95 Remove Nut ( 41 mm) with an impact tool Remove transmission gear with the gear wheel remover. Tighten the screws of gear wheel remover in X-method, stopping the gear with a suitable tool. Remove the gear and place it beside. Remove 2 x transmission casing mounting screws and lower banjo bolt.
  • Page 96 Remove transmission gear box casing and place it beside. Disassembling transmission cover Support the transmission cover and use special tools to open the coupler. Loosen and remove the coupler. NOTE: The washer in between the bearing and the gear has a thickness of 4,5mm ver.2009_03 Page 96/215...
  • Page 97 Remove circlip and bearing NOTE: The washer in between the oil seal and the bearing has a thickness of 1,5mm. ver.2009_03 Page 97/215...

  • Page 98: Transmission Assembling

    Disassembling transmission housing: Remove the oil seal and the O-ring. 4.2 Transmission Assembling Assembling the transmission cover Grease new oil seal on the seal lips and o the oil seal groove. Press in the oil seal by hand. ver.2009_03 Page 98/215...
  • Page 99 Press in the bearing and put in place the circlip to secure the bearing. Subassembly of the PTO gear. Press and glue the aluminum plug into the PTO gear with Loctite 648 as shown on the pictures below. Put the washer ( 4,5 mm ) in place. Install washer (1,5mm) in between the oil seal and the bearing using suitable tool.
  • Page 100 Assemble coupler into the PTO gear using grease and tighten the coupler with specified torque. Tightening torque: 80 N·m Assembling transmission housing Apply grease on the inside and sealing lips of the oil seal. Press in the oil seal. NOTE: The greased side of the oil seal needs to be on the same side like the painted side of the oil seal cover.
  • Page 101 Apply Loctite 5699 on the surface of the transmission cover Assembling transmission on the engine Put in place the transmission housing and tighten 3 x bolts. NOTE: Pay attention not to damage the oil seal by thread of the crankshaft NOTE: Insure that the oil delivery line will be placed in between the engine and the transmission housing.
  • Page 102 Tighten the 3 bolts with specified torque Tightening torque: 45 N·m Pressing in the transmission bolt During pressing in the transmission bolt ensure the lubrication holes are orientated to the right side ( 90 deg. to the right). Assembling the right hand side gear: NOTE: For correct Crankshaft gear installation apply Loctite 648 on the surface of the inner side of the cone.
  • Page 103 Assembling the right hand side gear tightening nut: NOTE: Apply on the thread of the tightening nut. RED Weicon Lock AN 305-86 Block the gear and tighten the nut with a specified torque. Tightening torque: 160 N·m Put in place transmission parts on the right hand side of the transmission: Put in place the thrust washer Put in place the 1 cageless needle bearing...
  • Page 104 Put in place the right hand gear assembly. Put in place the thrust washer of the right hand transmission gear. Put in place the thrust washer of the left hand transmission gear. Put in place the 3 x cage needle bearing Oil the bearing system Ensure the 2 x location pins are in place Apply Loctite 5699 on the transmission housing sealing surface.
  • Page 105 Put the Paper gasket for the transmission cover in place. Apply Loctite 5699 on the sealing surface of the transmission cover. NOTE: The short screws are to be used on the left hand side of the transmission like shown on the figure.
  • Page 106 Pay attention for amount of used Locking agent on the oil line banjo bolts thread. There is a risk of blocking oil passages. Tighten the oil plug screw with specified torque. Tightening torque: 30 N·m Refill the proper oil volume in the engine. ATTENTION: Use only original HSR-Benelli engine oil ver.2009_03 Page 106/215...

  • Page 107: Center Flange Bearing

    4.3 Center flange bearing Assembly of the flange bearing: Grease the oil seal lips with water resistance grease on both sides. RECOMMENDED LUBRICANT: FUCHS URETHYN E/M 2 Use new pre-coated screws or apply blue Loctite 243 Put in place the flange bearing and tight 4 screws with specified torque.
  • Page 108 Put in place the flange bearing cover apply blue Loctite 243 on the thread of the screws and tighten the screws with specified torque. Tightening torque: 10 N·m, in X-method ver.2009_03 Page 108/215...
  • Page 109 ver.2009_03 Page 109/215...

  • Page 110: Pump And Impeller

    5 PUMP AND IMPELLER 5.1 Jet Pump overview (Series-R Pro pump shown) ver.2009_03 Page 110/215...

  • Page 111: Jet Pump Disassembling

    NOTE: Series-S and Series-R engines have closed-loop cooling system. The radiator is integrated into jet pump housing which is connected to the cooling system lines. WARNING: Each time JET PUMP STATOR or JET PUMP assembly were removed from the hull, engine coolant could flow out.
  • Page 112 Remove cone. NOTE: Pay attention on the white O-ring in order not to lose it. Cleaning of the water sieve in the Jet Pump: NOTE: The water sieve protects the exhaust cooling system from sand and other particles to block the water supply. A heat sensor will warn you and slow down your personal PWC into the “limp home mode”...
  • Page 113 Removing of the Impeller: Remove the impeller from the impeller shaft by loosen the impeller with a Special Tool. Block the impeller shaft. (See Photo beside). NOTE: Remove the Impeller shaft with a soft tool in order to avoid damages on the thread.
  • Page 114 NOTE: Take care of bearings place for correct assembling. Disassembly of the Jet Pump Housing Disassembly of the Jet Pump Housing carrying the Liner for the engine Radiator. NOTE: The Jet Pump housing and the Liner cannot be taken apart and need to be replaced as one for repair. Remove the cooling water supply hose.
  • Page 115 Remove the spring located on the Nozzles. Remove the Steering nozzle. Remove plastic bushings from the steering nozzle with a soft tool carefully. Remove the allen screw (M 6 mm) from the trim nozzle. ver.2009_03 Page 115/215...

  • Page 116: Assembling The Jet Pump

    Remove the Trim Nozzle. Remove the plastic bushing with a soft tool carefully. NOTE: For Reverse Equipped PWC only: Remove the reverse support from the jet pump with an allen screw Driver (M 6mm) 5.3 ASSEMBLING THE JET PUMP NOTE: For Reverse Equipped PWC only Apply blue Loctite 243 on the threads of the screws ver.2009_03 Page 116/215...
  • Page 117 Tighten the reverse support on the Jet Pump Housing. Tightening torque: 20 N·m Reinstall the jet pump nozzles Press in the new plastic bushings into the trim nozzle Apply blue Loctite 243 on the threads of the screw tightening the Trim nozzle.
  • Page 118 Press in the new plastic bushings into the steering nozzle Apply blue Loctite 243 on the beginning of the threads of the screw and tighten the screws with specified torque. Tightening torque: 20 N·m Proceed the same process on both sides of the pump. Assembly of the Stator Housing of the Jet Pump Assembly of the Jet Pump Housing: Put in place the first (smaller in diameter) bearing.
  • Page 119 Press in the first bearing (smaller in diameter) bearing with a tool. Put in place the second (smaller in diameter) bearing with a tool. Press in the second bearing (smaller in diameter) bearing with a tool. ver.2009_03 Page 119/215...
  • Page 120 Put in place the distance sleeve. Put in place the third bearing (bigger diameter). Press in the third bearing (bigger diameter) with a special tool. Take a new oil seal and apply grease in the lips. Place the oil seal on the sleeve. RECOMMENDED LUBRICANT: FUCHS URETHYN E/M 2 ver.2009_03...
  • Page 121 Press in the new oil seal with a tool very carefully Apply grease on the remaining sleeve and put it in place. RECOMMENDED LUBRICANT: FUCHS URETHYN E/M 2 Put in place the sieve in the housing. Put in place the sieve housing and apply blue Loctite on the beginning of the thread ver.2009_03 Page 121/215...
  • Page 122 Tighten the screws for the sieve housing with specified torque. Tightening torque: 10 N·m, in X-method Apply grease on the impeller shaft all the way around. RECOMMENDED LUBRICANT: FUCHS URETHYN E/M 2 Press in the Impeller Shaft. Assembly of the Impeller: Screw carefully the Impeller on the Impeller Shaft and tighten it by hand.
  • Page 123 Use a special tool to tighten the impeller to the final torque. Tighten the Impeller to the specified torque. Tightening torque: 100 N·m Put in place the white plastic ring. ver.2009_03 Page 123/215...
  • Page 124 Apply blue Loctite 243 on the screws of the cone and tighten it with a specified torque. Tightening torque: 7 N·m Apply blue Loctite 243 in the thread of the water supply tube And tighten the tube on the housing. Put in place the O-Ring and apply slightly grease on the surface.
  • Page 125 Put in place the Stator Housing on the Impeller Housing Put in place the Nozzle assembly Apply blue Loctite 243 on the beginning of the threads of the screws. Tighten the screws with specified torque. Tightening torque: 25 N·m, in X-method ver.2009_03 Page 125/215...
  • Page 126 Put in place the O – Rings and the rubber cone and the rubber seal. Final assembly of the Jet Pump. ver.2009_03 Page 126/215...

  • Page 127: Jet Pump Assembly Into The Pwc

    5.4 Jet Pump Assembly into the PWC Grease the sealing lips of the jet pump. Assemble the Flange bearing with it`s 4 screws into the rear of jet pump tunnel. Apply blue Loctite 243 on the threads of the screws or take new micro coated screws. Support the Flange bearing during assembly with a hammer to pull it on the top position during tightening.
  • Page 128 In order to put the O - Rings on the jet pump housing grease the grooves for easy assembly. Apply blue Loctite 243 on the thread of the screws. Tighten the screws with specified torque. Tightening torque: 30 N·m, in X-method Put in place the impeller housing with the impeller on the jet pump housing.

  • Page 129: Assembly Of The Reverse Gear (For Series - R Pro Model Only)

    5.5 Assembly of the Reverse Gear (For Series – R Pro Model only) Put in place the sleeves of the reverse shield. Apply blue Loctite 243 on the thread of the screws and put 2x per side the washer in place. Tightening torque: 10 Nm.

  • Page 130: Assembling Riding Plate

    5.6 Assembling riding plate Apply blue Loctite 243 on the thread of the screws. Put in place the Riding Plate and tighten 4 x screws with specified torque. Tightening torque: 12 Nm. 5.7 Steering cable setting Hold the steering in straight forward position. The distance of the jet nozzle to the jet drive outlet must be the same on the left and the right side.

  • Page 131: Trim System Bleeding

    5.8 Trim system bleeding NOTE: Put protection on the hull to avoid brake liquid contact with the paint of the hull! Fill an injector like shown in the picture with brake liquid half the way (10 cm ) and screw a bleeding nipple into the trim system.
  • Page 132 Keep the Injector pressurized and pump the nozzle up and down until no air bubbles are released to Injector. Put paper underneath the trim lever to collect remaining brake liquid. Remove the Injector, bleeding nipple, put in place O – Ring and screw the plug loosely into the Trim lever body.
  • Page 133 ver.2009_03 Page 133/215...

  • Page 134: Fuel System

    6 Fuel system 6.1 Fuel Tank and Fuel Pump Fuel tank disassembly out of the PWC: (Shown for Series-R Pro) Remove the 2 x screws of the fuel tank belts on the bottom of the hull. Unscrew the clamp of the fuel filling hose and remove the hose.
  • Page 135 Pull out the fuel pump carefully out of the fuel tank. Fuel pump filter and fuel pressure regulator are located on the fuel pump. Assembly of the fuel pump into the fuel tank: Put back in place the fuel pump for assembly. NOTE: It is EXTREMELY important to insure that THE FUEL FILTER IS NOT SQUECED INBETWEEN THE FUEL PUM AND THE TANK.
  • Page 136 Screw in the screws and tighten them with specified torque. Tightening torque: 5 N·m, in X-method Leak test of the subassembly of the Fuel Pump/Fuel Tank Note: Always perform a leak test during fuel tank disassembly/ fuel pump inspection. Apply a pressure of 0,3 bar into the tank system and check for loss of pressure with the help a spray test.
  • Page 137 Assembly of the Fuel tank into the PWC: Put back the fuel tank into the PWC as shown in the picture. Reinstall the fuel tank hose with the clam on the fuel tank. Apply blue Loctite 243 on the thread of the screw and tighten with specified torque.
  • Page 138 ver.2009_03 Page 138/215...

  • Page 139: Exhaust System

    7 Exhaust system 7.1 Muffler and Hoses: (Shown for Series-R Pro) Overview of the exhaust system in the Hull Inject 15 ml of engine oil into the exhaust muffler ensuring the temperature sensor will recognize the exhaust temperature in the exhaust system. Put in place the copper gasket and the temperature sensor Apply green Loctite 278 and tighten the sensor with specified torque.
  • Page 140 Apply Loctite on the thread of the screw tightening the exhaust mounting belt. Put the exhaust hose on the fitting in the Jet pump tunnel. Put in place the remaining hoses and tubes for the exhaust system shown on the pictures. Tighten the exhaust end flange with 6 x screws and apply Blue Loctite 243 on the threads and tighten in with 5 Nm ver.2009_03...

  • Page 141: Exhaust Manifold

    7.2 Exhaust Manifold: In order to assemble the Exhaust Maifold following parts have to be assembled. NOTE: There are two different injectors with different Inner diameters. Apply green Loctite 278 on the thread of the water injectors used on exhaust tubes of exhaust manifold.
  • Page 142 There are three different fittings for the 3 in 1 exhaust hose. Take the fitting with smaller inner diameter, apply green Loctite 278 on the thread and tighten the fitting as shown on the picture. Take the fitting with the bigger inner diameter apply green Loctite 278 and tighten it. Take the L - fitting and apply green Loctite 278 and tighten it to the position like shown on the photo.
  • Page 143 Apply gasket seal Loctite 5699 on both sides of the exhaust gasket. Put the applied gasket on the exhaust manifold as shown on the picture. NOTE: the cut edge of the gasket needs to be inline with the shape of the exhaust manifold.

  • Page 144: Assembling The Hoses On Exhaust Manifold

    Final assembly of the exhaust manifold and the 3 to 1 exhaust hose view: 7.3 Assembling the hoses on exhaust manifold There are two hoses of 135 mm length that need to be installed between the fittings of the exhaust manifold. Clamps are tightening the hoses. Install 2 x 80mm hoses like shown on the pictures.

  • Page 145: Leak Test Of The Exhaust Hose

    Assemble and clamp the big hose like shown on the picture. 7.4 Leak test of the Exhaust hose: The equipment of the leak test is shown bellow. 1. Manometer 2. Long hose 3. Short hose Link the test equipment in between the outlet of the manifold and the outlet of the 3 in 1 exhaust hose fitting.

  • Page 146: Assembling The Exhaust Manifold On The Engine

    Put the exhaust system into a water bath and check for air bubbles. 7.5 Assembling the exhaust manifold on the engine Apply blue Loctite 243 on the stainless steel nut and hand tight them on the stud screws of the cylinder head. Tighten the screws in the X - Method with a specified torque starting with the 2 cylinder continuing on 1...

  • Page 147: Cooling System

    ver.2009_03 Page 147/215...

  • Page 148: Closed Circuit Cooling System

    8 Cooling system 8.1 Closed circuit cooling system Series-S Pos. Part description Q-ty ASM COOLING PIPES ENGINE SCREW COOLING HOSE HOT 1 COOLING HOSE HOT 2 COOLING HOSE COLD HOSE CLAMP 38,1 HOSE CLAMP 25-40 SCREW CAP 1,4 BAR THREADED T-PIECE PADS ver.2009_03 Page 148/215...
  • Page 149 Series-R Pos. Part description Q-ty ASM COOLING ENGINE SCREW M5X10 COOLING HOSE COLD 3Z COOLING HOSE HOT SHORT 3Z COOLING HOSE HOT LONG 3Z HOSE CLAMP 38,1 HOSE CLAMP 25-40 THREADED T-PIECE PADS BRACKET COOLING HOSE SCREW CAP ver.2009_03 Page 149/215...

  • Page 150: Opened Circuit Cooling Systems

    8.2 Opened circuit systems: Series-S ver.2009_03 Page 150/215...
  • Page 151 Series-S cooling system components: Pos. Part description Q-ty OIL COOLER WATER MANIFOLD T-TYPE FITTING, M8 THREAD PLUG BLOT M8X10 EXHAUST MANIFOLD MAGNETIC VALVE IP67 T-TYPE FITTING INLINE FILTER INJECTOR EXHAUST REDUCTION FITTINGSLEEVE 4,5 MM BYPASS FITTING DN9 BLACK INTAKE LINE OIL COOLING HOSE, INNER D 13MM 120CM FLUSHING SYSTEM HOSE, INNER D 10MM 30 CM...
  • Page 152 Series-R Series-R cooling system components: Pos. Part description Q-ty OIL COOLER WATER MANIFOLD 3IN1 EXHAUST HOSE EXHAUST MANIFOLD MAGNETIC VALVE IP67 T-TYPE FITTING 5MM L-TYPE FITTING 5MM T-TYPE FITTING 3MM INLINE FILTER SPREDSERT M6 X 12,7 ELBOW SCREW-IN NOZZLE SCREW-IN HOSE NOZZLE BYPASS FITTING DN9 BLACK REDUCTION FITTINGSLEEVE 4,5 MM ver.2009_03...

  • Page 153: Exhaust Cooling System

    INTAKE LINE OIL COOLING HOSE, INNER D 13MM 85CM INTAKE LINE OIL COOLING HOSE, INNER D 10MM 50/45/40 CM EXIT LINE OIL COOLING HOSE, INNER D 10MM 50/45/40 CM EXIT LINE OIL COOLING HOSE, INNER D 13MM 105CM INTAKE LINE EXHAUST COOLING HOSE, INNER D 10MM 115CM FLUSHING SYSTEM HOSE, INNER D 10MM 50 CM...
  • Page 154 The flow of the cooling liquid: The water enters the system through wards the Jet Pump tunnel. The T – Fitting splits the water flow into the exhaust manifold and the Flushing system hose. The hose for the exhaust manifold cooling system feeds first the end of the manifolds ver.2009_03 Page 154/215...
  • Page 155 and goes through wards the tubes up to the end where the headed liquid is collected. It leaves the system on the left hand side of the manifold and returns to the 3 to 1 hose on order to cool it. It leaves the 3 in 1 hose through wards a fitting to exit the system via a hose to left rear part of the PWC.

  • Page 156: Oil Cooling System

    8.2.2 Oil cooling system The coolant for the oil cooler is supplied with hose from the Jet Pump at the rear of the PWC. The coolant is split into the oil cooler through wards the coolant water manifold. It passes the oil cooler and enters a second water manifold And goes through the hull to be released through wards a fitting in the jet pump tunnel.
  • Page 157 ver.2009_03 Page 157/215...

  • Page 158: Steering System

    9 Steering system SERIES-R STEERING SYSTEM 9.1 Steering Support Assembly (For Series-R model only) Take the steering support and press in the bearing inside the steering support by hand. Put the steering tube in place Put in place the second bearing and press it in by hand. Use a tool to install bearing circlip in place.
  • Page 159 Grease the oil seal and press it in by hand. Oil seal needs to be in line with Steering support. Put in place steering axle and put it in carefully with a soft hammer. NOTE: Ensure the parts are in line and are sliding carefully. Put in place the ring.

  • Page 160: Assembly Of The Steering Support On The Pwc

    Assemble and tighten SSSA sensor support with 2 x screws (Apply BLUE Weicon Lock AN 302-43 on screws thread) NOTE: SSSA sensor needs to be flattened to the support before tightening screws. After final assembly please perform a check. Steering shaft should move easily.

  • Page 161: Handle Bar Assembly

    Tighten the screws with specified torque. Tightening torque: 20 N·m, in X-method 9.3 Handle Bar assembly (For Series-R model only) Assembly of the handelbar: Assembling grips on the handle bar. Apply Loctite 435 to insure the grips will not become loose. Press by hand the grips on the handle bar after the Loctite has been applied.
  • Page 162 Final assembly of the handle bar. Assembly of the handlebar on the PWC: Ensure you put in place Start-Stop switch wire first. Put in place the handle bar cover. Apply BLUE Weicon Lock AN 302-43 on the threads of handlebar cover screws. Tighten screws with specified torque.
  • Page 163 Tightening torque: 25 N·m, in X-method Put throttle cable end in the throttle lever hole. Assemble Trim oil line with the banjo-bolt. Tighten trim lever on the handlebar. ver.2009_03 Page 163/215...

  • Page 164: Series-S Steering System

    Tighten the Start-Stop switch on the handle bar. SERIES-S STEERING SYSTEM Handle Pole Assembly: Parts for the Handle Pole assembly: ver.2009_03 Page 164/215...
  • Page 165 Assemble the red protection bar and tighten the screws for the extension Stick two aluminum profiles into the Handle Pole plate as shown in the picture Apply Loctite 243 on the thread of the 8 screws ( M5 x 35) as shown on the photo. Tighten the screws into the handle bar and tighten them with specified torque.
  • Page 166 Apply Loctite 243 on the thread of the screws and tighten them with specified torque. Tightening torque: 5 N·m Put the bushings in place and press them in with your fingers. Put the rubber protector of the lower handle plate in place and ensure the flatten side will be in position as shown on the photos.
  • Page 167 Put the rubber protector of the lower handling plate in place. Ensure the flatten side will show to the upper side as shown on the photos. Tighten the screws. Assemble the springs of the handle bar. Warm the hose if needed and pull it on the spring. Cut the remaining hose 3- 5 mm from the end of the spring with a knife.
  • Page 168 Press down the spring and screw in the bold with a tool. NOTE: Do not use hammer to install the bolt. This will lead to destroy the thread on the handle bar support. Tighten the bolt with a torque meter. Tightening torque: 25 N·m Assembly of the dashboard in the handle bar: Put in place the bracket for the dashboard.
  • Page 169 Put in place the dashboard into the handle bar. Tighten the dash board on the handle bar with 3 NM. Assembly of the locking pin for the handle bar: Put in place the location pin into the handle bar support. Put in place the locking pin ball by hand Put in place the location pin holder and tighten it Clean the aluminum part of the handle bar and put the safety stickers on it.

  • Page 170: Handle Bar Assembly

    9.5 Handle Bar Assembly Apply Loctite 243 on the Screw for the steering control bushing. Put the bearing in place and press it on the steering control bushing. Put the steering control lever in place. Put the subassembly of the steering control bushing in place. Put in place the second ball bearing and press it in.

  • Page 171: Assembly Of The Hanle Bar On The Pwc

    Apply Loctite 243 on the thread of the second steering control bushing and put it in place. Tighten the system with a torque meter. Tightening torque: 20 N·m Take the ball joint screw and apply Loctite 243 on the thread of the screw. Tighten the ball joint.
  • Page 172 Take the other 3 cables for Trim system, Dashboard and from Start-Stop switch (two wires) and put it through the handle bar . Apply Loctite 243 on the 4 screws for the fixation of the handle bar. Tighten screws with specified torque in x Method Tightening torque: 30 N·m Connect the dashboard wire and place it into the handle bar.
  • Page 173 Put in place wiring protection clamp. Tighten the screws on the handle bar. Fix cable with a tie rap. NOTE: for initial adjustment of the steering cable install the fastener on steering cable thread (steering plate side) with 12 full turns. Do the same for cable end on Jet pump side.
  • Page 174 Assembly of the Trim lever: Put the O – Ring in place Put banjo-bolt into the fitting of trim system line, put second O-ring in place and Tighten the bolt. Trim system bleeding Bleed the system: See in PUMP chapter. Assemble the hand grips Put Loctite 435 in the hand grips and distribute it internally.
  • Page 175 Put in place rubber grommet for the wires/cables of the handle pole NOTE: Please check that cables are moving freely WARNING: If throttle cable is not moving freely PWC could suddenly accelerate on its own while steering. Put in place handle bar protector with two tie raps and cut the extending tie rap ends. ver.2009_03 Page 175/215...
  • Page 176 Install the Throttle cable and insure there is free play of 2-3 mm on the throttle lever. Do a final test on Start-Stop switch buttons to check electrical system operation. ver.2009_03 Page 176/215...
  • Page 177 ver.2009_03 Page 177/215...

  • Page 178: Hull

    10 Hull 10.1 Dashboard cover (For Series-R model only) Disassembly of dashboard cover Remove the support plate screw from the dashboard and carefully remove the dashboard equipment by hand. NOTE: Take care not to damage the gasket. Reassembly of the dashboard cover NOTE: Take care not to damage dashboard gasket.
  • Page 179 Apply BLUE Weicon Lock AN 302-43 on the screws like shown on the photo. NOTE: It is very important to tighten the dashboard screws with the proper torque of 2 Nm. The other two screws need to be tightened with 5 Nm. Assembly on the PWC Put in place the dashboard cover on the PWC Apply BLUE Weicon Lock AN 302-43 on thread of the screws (2 types of screws: Top M6 x...

  • Page 180: Drainagebox

    10.2 Drainage box Those are the products you need to assemble a drainage box. Note: The Method of gluing requires 2 components: The Primer and the glue Apply Primer on the surface that need to be glued. Apply liquid Loctite on the surface that need to be glued. Ensure you are putting primer and glue on the latches connecting both halfs of the drainage box.

  • Page 181: Baggage Cover

    Tighten the screw for the drainage box. Put in place the Hose sucking the water out of the hull into the Jet Pump tunnel to be released. 10.3 Baggage Cover: Assemly of baggage cover (electric Reverse button for Sereis-R Pro only) Those are the parts involved in the assembly of the Baggage Cover.
  • Page 182 Put in place the circlips with a suitable tool in order to lock the springs. Insure the system is working easily and properly. Note: For Series – R Pro only (Reverse Switch). Put in place the reverse switch and wire. Apply BLUE Weicon Lock AN 302-43 on the thread as shown on the picture.
  • Page 183 Final view of baggage hood Assembly of the luggage on the PWC deck. Put in place the baggage cover on the PWC by hooking in the levers with the spring under plastic covers. NOTE: for Models with electric reverse only. Put the electric cable through the hole of the dashboard.

  • Page 184: Side Cover Assembling

    Tighten the screws with a specified torque in x – method. Tightening torque: 5 Nm, in X-method 10.4 Side Cover Assembling Apply BLUE Weicon Lock AN 302-43 on the thread of the base stud. Screw in the base stud by hand and let the Loctite dry out. Put in place the side cover.

  • Page 185: Sponsons Assembling

    10.5 Sponsons assembling Apply BLUE Weicon Lock AN 302-43 on the thread of the screws Put in place the sponsons ground plate. Tighten it with specified torque. Tightening torque: 15 N·m Put in place the sponsons and tighten it with5 Nm ver.2009_03 Page 185/215...
  • Page 186 ver.2009_03 Page 186/215...

  • Page 187: Electrical System

    11 Electrical System 11.1 General view (SERIES-S wiring diagram) ver.2009_03 Page 187/215...

  • Page 188: Sector A

    11.1.1 Sector A 11.1.2 Sector B ver.2009_03 Page 188/215...

  • Page 189: Sector C

    11.1.3 Sector C 11.1.4 Sector D ver.2009_03 Page 189/215...

  • Page 190: Sector E

    11.1.5 Sector E 11.1.6 Sector F ver.2009_03 Page 190/215...

  • Page 191: Sector G

    11.1.7 Sector G 11.1.8 Sector H ver.2009_03 Page 191/215...

  • Page 192: General View (Series-R Wiring Diagram)

    11.2 General view (SERIES-R wiring diagram) ver.2009_03 Page 192/215...

  • Page 193: Sector A

    11.2.1 Sector A 11.2.2 Sector B ver.2009_03 Page 193/215...

  • Page 194: Sector C

    11.2.3 Sector C 11.2.4 Sector D ver.2009_03 Page 194/215...

  • Page 195: Sector E

    11.2.5 Sector E 11.2.6 Sector F ver.2009_03 Page 195/215...

  • Page 196: Sector G

    11.2.5 Sector G 11.2.5 Sector H ver.2009_03 Page 196/215...
  • Page 197 ver.2009_03 Page 197/215...

  • Page 198: Hsr-Benelli Diagnostic System

    12 HSR-Benelli diagnostic system 12.1 HSR-Benelli Utility Diagnostic System (HUDS) installation (Benelli engine version) 1. Save provided file “HUDS_Series R and S.rar” to the hard disk of your computer. 2. Open this file from location where you’ve saved it (WinRAR or analog software is required): 3.
  • Page 199 4. Click OK to Extract folder to the directory were your RAR-file was saved. (To change destination folder use right explorer panel to choose it, then press OK). 5. Close WinRAR window. Go to the location folder of RAR-file. Folder “HUDS_Series R and S” should appear: ver.2009_03 Page 199/215...
  • Page 200 6. Open folder “HUDS_Series R and S” and start the file “ServiceHSR564.exe”: 7. The following window should appear: ver.2009_03 Page 200/215...
  • Page 201 8. Click “OK" and choose language file (English or Italian are currently available), press “Open” button: ver.2009_03 Page 201/215...
  • Page 202 9. Next window “Select device” will open. Choose file “CNS_B1HSR_07$US_NEW.dcn” and click “Open”: ver.2009_03 Page 202/215...
  • Page 203 10. Program start view: NOTE: If your computer isn‟t equipped with a COM port, see “using USB-to- COM adapter” chapter below: Using USB-to-COM adapter If direct COM (RS-232) connection is not possible for your computer USB-to-COM adapter should be used to complete Diagnostic or Registration process. USB-to-COM adapters are after-market available .

  • Page 204: Hsr Diagnostic Tool Settings

    Adapter settings. NOTE: For a perfect operation the adapter should be configured in a range COM1-COM4 of your system. Please contact your IT administrator if required to complete this setting. 12.2 HSR Diagnostic Tool settings Start Diagnostic software as described above. Press “COM” button of the upper panel.

  • Page 205: Vehicle Registration Process

    12.3 Vehicle registration process NOTE: ECU of each new vehicle is limited to maximum 2500 rpm before registration process is completed. Warranty period starts from date of registration. WARNING: ECU could be registered only ONCE. Do not attempt to register ECU for troubleshooting purposes.
  • Page 206 Starting Registration process. Start program by “ServiceHSR564.exe” file. Click “End Of Line” button on the upper panel. The “Line End Parameters” window should appear: This window should be used to complete vehicle warranty registration (put VIN (Chassis number), *1, Engine number, *2) To get the activation code for releasing ECU to full power mode please copy ECU code from field “ECU_CODE”...
  • Page 207 Registration in B2B system. Use the following link to access B2B system: http://hsrtest.xpml.at/ Fill in your Login and Password and click “Login” buton. Fill in corresponding fields with unit’s data: VIN number (=CHASSIS NUMBER, to be copied from field *1 of Line End paraneters, see above)

  • Page 208: Periodic Maintenance Registration Process

    Activation Code will appear in next window: Copy the activation key and go back to Diagnostic system. Finalizing Registration process. Once received from B2B the Activation code should be copied and pasted to the field “UNLOCK_CODE” (*4) of End Line Parameters window.
  • Page 209 To start Maintenance registration click “Unit History” button on the upper panel: Click here Next window view: Click for unit search Click to open registered units list ver.2009_03 Page 209/215...
  • Page 210 Registered Unit window example: Click to select unit Scroll Unit History page to reach Maintenance field. Example of Maintenance field: Click to register new maintenance ver.2009_03 Page 210/215...
  • Page 211 Maintenance Entry window will open. To register performed maintenance fill the following fields: • Maintenance Interval – Select performed maintenanace (10 hours, 25 hours, 50 hours, 75 hours, etc.) • Hours – Enter vehicle current Motor Hours value • Comment – Add your comments if necessary •...
  • Page 212 ver.2009_03 Page 212/215...

  • Page 213: Storage

    13 Storage The decommissioning of the vehicle is necessary ... at the end of the season if the vehicle will be decommissioned during the winter months. if the vehicle will not be used for more than 30 days. In addition to the maintenance work described in the maintenance interval table under end of the season, various other service work is also required.
  • Page 214 ver.2009_03 Page 214/215...

  • Page 215: Appendix

    E-Mail office@hsr-benelli.com Directives HSR-Benelli thus confirms that the construction of the engine corresponds to the following pertinent conditions: – EU directive about sport boats 94/25/EG with addendum 2003/44/EG – USA EPA Federal Register 40 CFR Part 91 – USA CARB 13 California Code of Regulation Article 4.7 Spark Ignition Marine Engines ver.2009_03...

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