Benelli TRK 502 Manuals

Manuals and User Guides for Benelli TRK 502. We have 4 Benelli TRK 502 manuals available for free PDF download: Service Station Manual, Owner's Manual, User Manual

Benelli TRK 502 Service Station Manual (408 pages)

Brand: Benelli | Category: Motorcycle | Size: 22 MB

Chapter 1 General Information

7
- Table of Contents
  7
- Identification
  8
  - Motorcycle Identification
    8
- Features
  9
  - Instrumentation and Indicator Lights
    9
  - Multifunction Display
    10
- Important Information
  11
- Special Tools
  15
  - Special Frame Tools
    18
Chapter 3 Periodic Maintenance

38
- Periodic Maintenance and Lubrication Intervals
  41
- Engine/Air Box
  45
  - Removal/Assembly of Air Box
    45
- Engine/Throttle Cable Clearance
  49
  - Adjustment of Throttle Cable Clearance
    49
  - Adjustment of Idle Speed
    50
- Engine/Clutch Cable
  51
  - Adjustment of Clutch Cable Clearance
    51
- Frame/Handlebar
  52
  - Rear-View Mirror Adjustment
    52
- Engine/Motor Oil
  53
  - Checking Engine Oil Level
    53
  - Engine Oil Change
    54
  - Oil Filter Removal/Installation
    55
- Engine/Spark Plugs
  56
- Frame/Brake Adjustment
  61
  - Adjustment of the Front Brake
    61
  - Adjustment of the Rear Brake
    62
- Frame/Checking Brake Fuid Level
  63
  - Checking the Front Brake Liquid Level/Topping up
    63
  - Checking the Rear Brake Liquid Level/Topping up
    64
- Frame/Checking Abs Hoses
  65
  - Check for any Leakages of Abs Tubes
    65
- Frame/Brake Pad Check
  66
  - Checking Wear of Front/Rear Brake Pads
    66
- Frame/Checking Hoses of the Braking System
  67
  - Hose Check
    67
- Frame/Transmission Chain
  68
- Frame/Check and Adjustment of Steering Sleeve
  71
  - Check/Adjustment of Steering Clearance
    71
- Frame/Check of Front Fork
  73
  - Check of Front Fork
    73
- Frame/Check of Rear Shock Absorber
  74
  - Shock Absorber Adjustment
    74
- Frame/Check of Front/Rear Tyres
  75
  - Tyre Check
    75
- Electrical System
  76
  - Battery Check and Charging
    76
  - Fuses
    85
  - Fuse Check
    86
  - Replacement of the Front Lights
    87
  - Removal of the Front Headlight
    88
  - Installation of the Headlight
    89
  - Adjustment of Headlight
    90
  - Substitution of the Rear Led Light
    91
  - Substitution of the Rear Indicator Lights
    92
  - Substitution of the Front Indicators
    93
  - Substitution of the Ignition Block
    94
Chapter 4 Frame

96
- Front Wheel and Brake Discs
  99
- Front Wheel Removal
  99
- Check of Brake Discs
  102
- Wheel Axle Check
  103
- Check/Replacement of Wheel Bearings
  104
- Front Wheel Installation
  105
- Rear Wheel and Brake Disc
  108
  - Rear Wheel Removal
    108
  - Removal of the Rear Disc Brake, Crown Wheel and Phonic Wheel
    109
  - Wheel Axle Check
    110
  - Check/Replacement of Wheel Bearings
    111
  - Sprocket Check and Replacement
    112
  - Installation of the Disc Brake
    113
  - Back Tyre Installation
    114
- Front and Rear Brakes
  115
- Abs Anti-Lock Braking System
  124
  - Location of the Components
    124
  - Rotation Sensor Check
    126
  - Check of the Phonic Wheel and Abs of the Front and Rear Wheel
    127
  - Precautions
    128
  - Removal of the Abs Hydraulic Unit
    130
  - Installation of the Abs Hydraulic Unit
    131
  - Removal of the Abs Rotation Sensors - Front/Rear Wheel
    132
  - Front Brake Calliper Tightness
    133
  - Rear Brake Calliper
    134
  - Check the Front and Rear Callipers
    135
  - Front Brake Calliper Installation
    136
  - Rear Brake Calliper Installation
    137
  - Front Fork Stem Disassembly
    142
  - Front Fork Stem Inspection
    145
  - Front Fork Stem Assembly
    146
  - Front Fork Stem Fitting
    149
- Handlebar
  150
  - Handlebar Removal
    150
  - Handlebar Inspection
    154
  - Handlebar Installation
    155
- Steering Head
  156
- Rear Shock Absorber
  160
  - Rear Shock Absorber Removal
    160
  - Rear Shock Absorber Check
    163
  - Rear Shock Absorber Fitting
    164
- Transmission Chain and Swinging Arm
  165
- Cycling
  183
  - Installation of the Stand / Footrests
    183
  - Removal of the Side Stand
    185
  - Installation of the Side Stand
    186
  - Removal of the Rear Footrest Support
    187
  - Installation of the Rear Footrest Support
    188
  - Removal of the Right/Left Rear Footrest
    189
  - Installation of the Left/Right Rear Footrests
    190
  - Right Front Footrest Removal
    191
  - Right Front Footrest Fitting
    192
  - Left Front Footrest Removal
    193
  - Left Front Footrest Installation
    194
  - Removal of the Gear Lever
    195
  - Installation of the Gearchange Lever
    196
  - Exhaust Assembly Removal
    198
  - Exhaust Installation
    200
  - Front Mud Guard Removal
    202
  - Rear Mud Guard Removal
    205
  - Rear Mud Guard Installation
    206
  - Removal of the Rider Seat and Passenger Seat
    209
  - Installation of the Rider Seat and Passenger Seat
    210
  - Front Fairing
    211
  - Removal of the Front Fairing
    212
  - Front Headlight and Windscreen
    214
  - Removal of Movable Windscreen
    216
  - Installation of the Mobile Headlight Fairing
    217
  - Removal of the Headlight Unit
    220
  - Installation of the Headlight Unit
    221
  - Tank Cover
    222
  - Removal of the Fuel Tank Cover
    223
  - Installation of the Fuel Tank Cover
    224
  - Removal of Fuel Tank
    225
  - Tank Fitting
    227
  - Removal of the Tank Cap Support
    229
  - Installation of the Tank Cap Support
    230
  - Removal of the Tank Pump
    231
  - Installation of the Tank Pump
    232
  - Removal of the Tank Fuel Level Sensor
    233
  - Installation of the Tank Fuel Level Sensor
    234
- Air Filter
  236
  - Removal of the Air Filter
    236
  - Installation of the Air Filter
    237
  - Installation of the Air Filter Box
    239
  - Removal of the Side Fairings
    241
  - Installation of the Side Fairings
    242
  - Upper Tail Fairing
    243
  - Tailpiece Removal
    244
  - Removal of the Rear Passenger Handles
    246
  - Installation of the Rear Handles
    247
  - Removal of the Rear Light
    248
  - Installation of the Rear Lights
    250
  - Removal of the Chain Pinion Cover
    252
  - Installation of the Chain Pinion Cover
    253
Chapter 5 Engine

255
- Head Distribution
  257
- Coils and Spark Plugs Removal
  258
- Coils and Spark Plugs Assembly
  259
- Timing Gear Cover Assembly
  261
- Distribution Chain Tensioner Removal
  262
- Timing Chain Tensioner Assembly
  263
- Intake and Exhaust Camshaft Removal
  264
- Camshaft Check
  265
- Exhaust Camshaft Installation
  266
- Intake Camshaft Assembly
  267
- Timing Chain Slide Removal
  268
- Timing Chain Slide Assembly
  269
- Timing Chain Removal
  270
- Distribution Chain Installation
  271
- Valve Clearance Adjustment
  272
- Camshaft and Valve Pad Removal
  273
- Camshaft and Valve Pad Removal
  275
- Head Removal
  276
- Valve Flap and Spring Removal
  277
- Check of Valves and Guides
  278
- Valve Seat Check
  280
- Valve Oil Seal Removal- Installation
  281
- Valve Spring Test
  282
- Valve and Valve Spring Installation
  283
- Cylinder Check
  284
- Head Installation
  285
- Pistons
  286
  - Piston Removal
    288
  - Piston Pin Check
    289
  - Piston Rings Check
    290
  - Piston Check
    291
  - Piston Assembly
    292
  - Piston Installation
    293
  - Removal of Connecting Rods
    294
- Crankcase
  294
- Clutch
  304
  - Clutch and Disc Removal
    305
  - Friction Disc Check
    307
  - Steel Disc Check
    308
  - Disc Assembly
    308
  - Clutch Assembly
    309
- Lubrication System
  310
  - Oil Sump and Intake Filter Removal
    311
  - Oil Sump and Intake Filter Installation
    312
  - Pressure-Relief Valve Installation
    313
  - Pressure-Relief Valve Removal
    314
  - Oil Pump Removal
    315
  - Oil Pump Assembly
    317
  - Neutral Position/Gear Indicator Sensor Removal
    318
- Gear Box
  318
  - Neutral Position/Gear Indicator Sensor Assembly
    319
  - Gear Box Assembly
    323
  - Gear Shift Control
    325
  - Starter
    329
- Starting
  329
  - Starter Removal
    330
  - Starter Installation
    331
  - Flywheel Removal
    332
  - Flywheel Installation
    335
  - Starter Gear Removal
    336
  - Starter Gear Assembly
    337
  - Phase Sensor
    338
  - Phase Sensor Removal
    339
  - Phase Sensor Installation
    340
- Power System
  341
  - Throttle Body
    341
  - Throttle Valve Removal
    343
  - Throttle Valve Installation
    344
Chapter 6 Cooling System

346
- Water Pump
  348
- Water Pump Removal
  348
- Water Pump Installation
  349
- Thermostat
  350
  - Thermostat Removal
    350
  - Thermostat Installation
    351
- Water Manifold
  352
  - Water Manifold Removal
    352
  - Water Manifold Installation
    353
- Heat Exchanger
  354
  - Heat Exchanger Removal
    354
  - Heat Exchanger Installation
    355
- Radiator
  356
  - Disassemble the Radiator
    357
  - Radiator Installation
    359
Electrical System

361
- Sensors
  362
  - Description of the Engine Management System
    362
  - Coolant Temperature Sensor
    363
  - Gear Position Sensor
    364
  - Phase Sensor
    365
  - Air Temperature Sensor
    366
  - Side Stand Switch
    367
  - Lambda Probe
    368
  - Oil Pressure Sensor
    369
  - Front Brake Microswitch
    370
  - Idrostop
    371
  - Clutch Switch
    372
  - Map Sensor (Manifold Absolute Pressure)
    373
  - Position Sensor of the Throttle Body Unit (Potentiometer)
    374
- Devices
  375
  - Devices Position
    375
  - Right Electric Device
    376
  - Starting Relay (Remote Control Switch)
    377
  - Horn
    378
  - Instrumentation Dashboard
    379
  - Master Switch
    380
  - Voltage Regulator
    381
  - Left Electric Device
    382
  - Converter of Can Bus Signals
    383
  - Injection Ecu
    384
  - Injection Ecu Connections
    386
  - Indicator Light Intermittence
    387
  - Abs Button
    388
  - Services Relay
    389
  - Stator
    390
- Actuators
  391
  - Position of Actuators
    391
  - Idle Air Control System (Stepper)
    392
  - Injectors
    393
  - Ignition Coils
    394
  - Cooling Fan
    395
  - Fuel Pump
    396
  - Fuel Level Sensor
    397
  - Starter
    398
  - Abs Ecu
    400
- Battery
  403
  - Vehicle Battery
    403
  - Battery Efficiency Control
    404
- Diagnostics
  405
  - Vehicle Diagnostics
    405
- Electrical System
  406
  - Wiring Diagram of Trk502 Electrical System
    406
  - Colour Key
    407

Benelli TRK 502 Owner's Manual (128 pages)

Brand: Benelli | Category: Motorcycle | Size: 2 MB

Table of Contents
6
Safety Information
8
Description
12
Left View
12
Right View
13
Controls and Instruments
14
Instrument and Control Functions
16
Key
16
Main Switch/Steering Lock
16
Multi-Function Meter Unit and Indicator Lights and Warning Lights
18
Handlebar Switches
21
Clutch Lever
23
Shift Pedal
23
Brake Lever
23
Brake Pedal
24
Abs
24
Fuel Tank Cap
25
Fuel
26
Catalytic Converter
28
Seats
28
Adjusting the Headlight Beams
29
Adjusting the Shock Absorber Assembly
29
Sidestand
31
Ignition Circuit Cut-O System
31
Central Stand (Only for TRK502X)
32
Auxiliary USB Jack
34
For Your Safety - Pre-Operation Checks
35
Operation and Important Riding Points
38
Starting the Engine
38
Shifting
39
Tips for Reducing Fuel Consumption
39
Engine Break-In
40
Parking
40
Periodic Maintenance and Adjustment
42
Owner's Tool Kit
43
General Maintenance and Lubrication Chart
44
Checking the Spark Plugs
50
Canister
51
Engine Oil and Oil Lter Cartridge
51
Coolant
54
Air Lter Element
56
Checking the Engine Idling Speed
56
Checking the Throttle Grip Free Play
57
Valve Clearance
57
Tires
57
Adjusting the Clutch Lever Free Play
59
Checking the Brake Lever Free Play
60
Brake Light Switches
60
Checking the Front and Rear Brake Pads
61
Checking the Brake Uid Level
61
Changing the Brake Uid
62
Drive Chain Slack
63
Cleaning and Lubricating the Drive Chain
64
Checking and Lubricating the Cables
65
Checking and Lubricating the Throttle Grip and Cable
65
Checking and Lubricating the Brake and Shift Pedals
65
Checking and Lubricating the Brake and Clutch Levers
66
Checking and Lubricating the Central and Side Stand
67
Checking the Front Fork
67
Checking the Steering
68
Checking the Wheel Bearings
69
Battery
69
Replacing the Fuses
70
Brake/Tail Light and the Turn Signal Light
71
Auxiliary Lights
72
Troubleshooting
73
Troubleshooting Charts
74
Motorcycle Care and Storage
76
Matte Color Caution
76
Care
76
Storage
78
Speci Cations
80
Front Suspension
82
Electrical System
82
Consumer Information
84
Identi Cation Numbers
84
Diagnostic Connector
85
Vehicle Data Recording
85
Regular Maintenance Coupons
86
Manuel du Propriétaire
92
Consignes de Sécurité
98
Commandes et Instruments
99
Réglage du Combiné Ressort-Amortisseur
101
Pour la Sécurité - Contrôles Avant Utilisation
102
Utilisation et Conseils Importants Concernant le Pilotage
103
Entretien Périodique et Réglage
104
Nettoyage et Graissage de la Chaîne de Transmission
107
Soin et Remisage de la Moto
109
Remarque Concernant les Pièces de Couleur Mate
109
Partie Électrique
110
Caractéristiques
110
Coupons D'entretien Periodique
111
Funktionen der Instrumente und Bedienungselemente
115
Multifunktionsmesser-Einheit und Kontrollleuchten und Warnleuchten
115
Zu Ihrer Sicherheit - Routinekontrolle vor Fahrtbeginn
118
Wichtige Fahr- und Bedienungshinweise
119
Regelmäßige Wartung und Einstellung
120
Zündkerzen Prüfen
121
Leerlaufdrehzahl Prüfen
122
Kundendienst Regelmässige Wartung
127

Benelli TRK 502 Owner's Manual (92 pages)

Brand: Benelli | Category: Motorcycle | Size: 1 MB

Table of Contents
6
Safety Information
9
Description
13
- Left View
  13
- Right View
  14
- Controls and Instruments
  15
Instrument and Control Functions
17
- Key
  17
- Main Switch/Steering Lock
  17
- Multi-Function Meter Unit and Indicator Lights and Warning Lights
  19
- Handlebar Switches
  22
- Clutch Lever
  24
- Shift Pedal
  24
- Brake Lever
  24
- Abs
  25
- Brake Pedal
  25
- Fuel Tank Cap
  26
- Fuel
  27
- Catalytic Converter
  29
- Seats
  30
- Adjusting the Headlight Beams
  30
- Adjusting the Shock Absorber Assembly
  31
- Sidestand
  32
- Ignition Circuit Cut-Off System
  32
- Auxiliary USB Jack
  34
For Your Safety - Pre-Operation Checks
35
Throttle Grip
36
Operation and Important Riding Points
39
- Starting the Engine
  39
- Shifting
  40
- Tips for Reducing Fuel Consumption
  40
- Engine Break-In
  41
- Parking
  41
Periodic Maintenance and Adjustment
43
- Owner's Tool Kit
  44
- General Maintenance and Lubrication Chart
  45
- Checking the Spark Plugs
  51
- Canister
  52
- Engine Oil and Oil Filter Cartridge
  52
- Coolant
  55
- Air Filter Element
  57
- Checking the Engine Idling Speed
  57
- Checking the Throttle Grip Free Play
  58
- Valve Clearance
  58
- Tires
  58
- Adjusting the Clutch Lever Free Play
  60
- Checking the Brake Lever Free Play
  61
Brake Light Switches
61
Checking the Front and Rear Brake Pads
62
Checking the Brake Fluid Level
62
Changing the Brake Fluid
63
Drive Chain Slack
64
Cleaning and Lubricating the Drive Chain
65
Checking and Lubricating the Cables
66
Checking and Lubricating the Throttle Grip and Cable
66
Checking and Lubricating the Brake and Shift Pedals
66
Checking and Lubricating the Brake and Clutch Levers
67
Checking and Lubricating the Sidestand
68
Checking the Front Fork
68
Checking the Steering
69
Checking the Wheel Bearings
70
Battery
70
Replacing the Fuses
71
Brake/Tail Light and the Turn Signal Light
72
Auxiliary Lights
73
Troubleshooting
74
Troubleshooting Charts
75
Motorcycle Care and Storage
77
Matte Color Caution
77
Care
77
Storage
79
Specifications
81
- Air Filter
  81
- Electric System
  84
Consumer Information
85
- Identification Numbers
  85
- Diagnostic Connector
  86
- Vehicle Data Recording
  86
Regular Maintenance Coupons
87

Benelli TRK 502 User Manual (55 pages)

Brand: Benelli | Category: Motorcycle | Size: 12 MB

Table of Contents
2
Protection Clothes
9
Serial Number
10
Location of Parts
11
- Meter & Indicator
  15
Primary Parts
18
- Key Switch
  18
- Left Handle (A)
  18
- Right Handle (A)
  23
- Left Handle (B)
  24
- Right Handle (B)
  25
- Fuel Tank
  26
- Rear Shock Absorber
  27
- Rear Brake Pedal
  28
  - Shift Pedal
    28
  - Tool Bag
    29
Notice of Use of Fuel and Engine Oil
29
Inspection before Driving
30
- How to Start the Engine
  32
- Smooth Launching
  33
- To Change Gear
  34
Running in
30
Inspection& Maintenance
35
- Maintenance Schedule
  35
- Oil Level & Oil Change
  38
- Spark Plug
  39
- Catalytic Converter
  39
- Battery
  40
- Throttle Cable Adjustment
  43
- Clutch Adjustment
  44
- Chain Adjustment
  44
- Brake
  46
- Maintenance of Air Filter
  48
- Bulb Replacement
  48
- Fuse Replacement
  49
- Lubrication Points
  50
- Adjustment of Valve Clearance
  50
- Tire
  51
Storage Guideline
52
Speci Cation & Technical Parameter
54

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Benelli TRK 502 Service Station Manual (408 pages)

Table of Contents

Chapter 1 General Information

Chapter 3 Periodic Maintenance

Chapter 4 Frame

Chapter 5 Engine

Chapter 6 Cooling System

Electrical System

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Benelli TRK 502 User Manual (55 pages)

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