Benelli 2014 BN600 Service Manual

SERVICE STATION MANUAL

Pure Passion since 1911

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

WARNINGS:

rs

:

ollow the instructions after this symbol may lead to serious

the vicinity, or people inspecting or repairing this bike.

ta

nt Notice" means that speci• c precautions are required to avo

id

in

tyvoto

it

re

th

This manual has been written by Benelli Q.J. s.r.l., mainly for use by Benelli dealers and their specially trained mechanics. It is not possible to give a mechanic all of the information they require in a single manual. It is therefore presumed that the persons using this manual for the maintenance and repairs of Benelli bikes have a basic knowledge of mechanics and the procedures necessary for repairs and maintenance of this type of vehicle. Without this experience, any repairs or maintenance to this type of vehicle may be dangerous or ineffective. It is company policy at Benelli Q.J. s.r.l. to continuously upgrade and improve its models. Any changes or signi• cant modi• cations to technical data or procedures will be made known to all authorised Benelli Dealers and will be published in future editions of the manual.

NOTE:

Drawings and speci• cations are subject to change without prior warning.

IMPORT

This manual contains the following important reminders:

WARNING:

Failure to follow the instructions after this symbol may lead to serious injury or even death for the rider, people in the vicinity, or people inspecting or repairing this bike.

"Important Notice" means that speci• c precautions are required to avoid causing damage to the bike.

ANT INFORMATION ABOUT THE MANUAL

IMPOR TA NT

NOTICE:

NOTE:

A "Note" provides key information that will make the procedure either easier or clearer.

- I -

HOW TO USE THIS MANUAL

This manual is a practical reference guide that is both easy to handle and use for mechanics. The explanations of all of the procedures for installing, removing, disassembling, • tting, repairing and checking, are organised in sequence, one step at a time.

1. Each chapter is divided into sections. The top part of each page contains the title of the current section.

2. To help with the identi• cation of parts and to make the different processes clearer, exploded drawings are provided at the start of each section dealing with the removal or disassembly of parts.

3. The sequence of operations is listed on the exploded drawing, and numbered progressively. Each number refers to a step in the disassembly process.

4. Parts needed lubricating or replacing are marked by symbols. See the "SYMBOLS" section.

5. The exploded drawing is accompanied by a table with instructions for the intervention. These state the order of operations, the name of the parts, any notes for the job, etc.

6. Interventions requiring any other information (e.g., special tools and technical data) are described in sequence.

- II -

SUBJECT SYMBOLS

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

T

.

R

.

E

G

YV

ORI SIL AC

NEW

kl

SYMBOLS

gi

ne

Cooling system

SYMBOLS

General Information

Speci! cations

Inspections and Periodic Adjustments

Frame

Engine

EXPLANATORY SYMBOLS

Wear limits, Backlash

Special tool

Tightening torque

Lubrication points

Cooling system

Thread locker application

Grease application

Sealant paste

Part replacement

- III -

CONTENTS

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

ti

ons and Periodic Adjustmen

ts

tions and Periodic Adjustmen

A

ne

General Information

Speci! cations

Inspections and Periodic Adjustments

Frame

CHAPTER 1

CHAPTER 2

CHAPTER 3

CHAPTER 4

Engine

Cooling system

CHAPTER 5

CHAPTER 6

- IV -

GEN

INFO

GEN

INFO

General Information

CHAPTER 1

- 5 -

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

IDENTIFICATION ................................................................................................... 7

MOTORCYCLE IDENTIFICATION ............................................................................................................7

CHARACTERISTICS ............................................................................................. 8

INSTRUMENTS AND LIGHTS ...................................................................................................................8

MULTIPURPOSE DISPLAY ....................................................................................................................... 9

IMPORTANT INFORMATION ............................................................................... 10

PREPARATIONS FOR REMOVAL AND DISASSEMBLY OPERATIONS ...............................................10

REPLACEMENT PARTS ..........................................................................................................................10

GASKETS, O-RINGS, SEALS AND BEARINGS .....................................................................................11

SAFETY WASHERS/SAFETY PLATES, COTTERS AND THREAD BLOCKERS .................................. 11

ELASTIC RETAINING RINGS ..................................................................................................................12

CONNECTION CHECKS ..........................................................................................................................12

SPECIAL ENGINE EQUIPMENT ..............................................................................................................14

SPECIAL EQUIPMENT ......................................................................................... 14

SPECIAL TOOLS (FRAME) .....................................................................................................................17

- 6 -

GEN

INFO

IDENTIFICATION

MOTORCYCLE IDENTIFICATION

The identiﬁ cation data are:

1. Serial number of the frame (on the steering head)

2. Engine serial number (on the bottom base)

3. Approval details (on frame)

3

1

2

- 7 -

GEN

INFO

CHARACTERISTICS

INSTRUMENTS AND LIGHTS

The instruments and lights will switch on when the ignition key is turned to "ON". After an initial check-up, the information will correspond to the overall condition of the bike at that time. The dashboard has the following instruments.

1 STATUS INDICATOR LIGHTS

1A. Neutral gear light (green)

This switches on when the gear is in "Neutral".

1B. Oil level warning light (red)

This switches on when the oil pressure is insuf! cient. It is

possible to check the electrical circuit of the light by turning the key to “ON”. Once the engine is running, the light should switch off. if the light does not switch on at the start, when the key is turned to “ON”, or if the light stays on, have the electric circuit checked by an authorised Benelli service centre.

1C. High beam light (blue)

This switches on when the high beam is switched on.

1D. Indicator light (green)

This switches on when the indicators are working.

1E. "FI" Injection diagnostic light

When the vehicle is started, the light will switch on orange for

a few seconds to show that the injection system is operating correctly.

2 REV COUNTER

This shows the number of engine revs per minute, expressed in

thousands.

1A.

1B.

1C.

1D.

2

1E.

- 8 -

GEN

INFO

CHARACTERISTICS

MULTIPURPOSE DISPLAY

3 COOLANT TEMPERATURE GAUGE

Shows the coolant temperature in °F (Fahrenheit) or C°(Celsius) .

4 DIGITAL CLOCK

Shows the time in hours, minutes and seconds

5 SELECT BUTTON 6 RESET BUTTON

Digital clock setting Hold down the ”Select“button for 5 seconds until the reading

begins to ! ash. Adjust the hour by pressing the ”Select“ button. Press the "Reset" button to pass on to the minutes adjustment. Adjust the minutes by pressing the ”Select“button. Press the "Reset" button to pass on to the seconds adjustment. Reset the seconds to zero by pressing the "Reset" button.

7 FUEL TANK CAPACITY AND RESERVE FUEL GAUGE

The digital fuel gauge shows the capacity of the fuel tank. As the fuel level drops, the lines on the gauge will become closer and closer to the "E" reserve area. As soon as the # about 2 litres of fuel.

8 TOTAL/PARTIAL KILOMETRE COUNTER

The total kilometre counter shows the total distance covered in kilometres,. The partial kilometre counter ( TRIP) shows the distance covered since the last reset in kilometres.

nal line starts to ! ash, there is an autonomy of

The partial kilometre counter can be used to estimate the possible distance to cover with a full tank of fuel. This information may make it possible to schedule future fuelling stops.

9 SPEEDOMETER

Indicates the vehicle's speed in km/h or mph. To pass from km to mph and vice versa, press and hold down the “Select” button 5 for at least one second.

3

4

5

9

6

8

- 9 -

7

GEN

INFO

IMPORTANT INFORMATION

PREPARATIONS FOR REMOVAL AND DISAS-

SEMBLY OPERATIONS

• Before carrying out any removal and disassembly operations, remove any dirt, mud, dust or foreign bodies.

• Only use suitable cleaning tools and products.

See the "SPECIAL EQUIPMENT" section.

• While disassembling the vehicle, we recommend keeping coupled parts together at all times. These parts include gears, cylinders, pistons and other parts, whose surfaces will be "coupled" during the normal wear and tear of work. Coupled pieces must always be re-used or replaced in groups. During the disassembly operation, clean all parts and place them in a bowl, using the same order as for disassembly. This will make reassembly operations easier and allows for the correct installation of all parts.

• Keep all parts away from any source of heat.

REPLACEMENT PARTS

Only use original Benelli replacement parts. Only use oils and grease recommended by Benelli to lubricate parts. Other brands may look similar and operate in a similar manner, but will be of lower quality.

- 10 -

GEN

INFO

IMPORTANT INFORMATION

labbro

molla

olio

motore

a

b

E

A

GASKETS, O-RINGS, SEALS AND BEARINGS

Always replace all gaskets, oil seals and O-rings when carrying out repairs to the engine. The gasket surfaces, oil seal lips and O-rings must always be clean. During installation, always oil the coupled parts and bearings, and lubricate the oil seal lips with engine oil.

Fit the bearings and oil seals so that the brand or manufacturer's number is facing outwards and visible. To • t the oil seal, lubricate the lips with a • ne layer of engine oil. Always apply plenty of oil to bearings when • tting them.

a. Oil seal b. Bearing

IMPORTANT NOTICE:

Never use compressed air to dry bearings, allowing them to turn, as this will damage the surfaces.

SAFETY WASHERS/SAFETY PLATES, COTTERS

AND THREAD BLOCKERS

After removing, replace all of the safety washers "A", and the safety plates and cotters. After tightening the bolt or nut according to speci• cation, bend

the locking tabs and the ends of the cotter against the ! at sides of the nut.

Whenever applying thread blocker, always • rst degrease both sides, with solvent.

- 11 -

GEN

INFO

IMPORTANT INFORMATION

A

B

C

D

A

ELASTIC RETAINING RINGS

Before re• tting them, check all of the retaining rings and replace any that have become damaged or are out of shape. Always replace the retaining rings on the gudgeon pin after using them once. If • tting a retaining ring "A", make sure that the sharp edge "B" is positioned on the other side to the thrust, "C" that it receives.

"D" Shaft

1

Make sure that there are no marks, rust, moisture, etc. on wiring, couplers, or connectors.

1. Disconnect:

• the wire

• the coupler

• the connector

2

2. Check:

• the wire

• the coupler

• the connector

If there are traces of moisture → Use a fan to dry. If there is any rust/marks → Connect and disconnect the parts several times.

CONNECTION CHECKS

3. Check:

3

• all connections

If there are any loose connections → Reconnect them properly.

NOTE:

If the foot of terminal "A" is bent, raise it.

- 12 -

GEN

INFO

IMPORTANT INFORMATION

4. Connect:

4

• the wire

• the coupler

• the connector

NOTE:

Make sure all connections are ! rmly installed.

5

5. Check:

• continuity (with a pocket tester)

NOTE:

• If there is no continuity, clean the terminals.

To control the wiring, follow the steps from "1" through to "3"

•

• For a quick ! x, we recommend using a speci! c product for contacts, which can be found on sale in spare parts stores.

- 13 -

GEN

INFO

SPECIAL EQUIPMENT

The special equipment listed here serves for the complete, thorough performance of • ne tuning and assembly operations. The use of this equipment will help to prevent damage caused through using unsuitable tools or makeshift techniques. When completing an order, please check the list below to avoid any errors.

SPECIAL ENGINE EQUIPMENT

Tool Code Name-Tool Function Image

1

This serves to insert the valve oil seal in situ.

Valve stem seal tool

1

This serves to block the clutch drum and loosen the nut

This tool serves to take out the gudgeon pin

This tool serves to take out the oil seal from valves

This tool serves to • t retaining rings on the

piston and to insert this into the cylinder

This tool serves to • t the gear selector

Clutch removal tool

Gudgeon pin removal tool

Valve stem seal removal tool

Ring clamp tool

Gear selector drum ﬁ tting tool

drum

1

This tool serves to remove the ! ywheel

This tool serves to remove the cover hous-

Flywheel extractor

from the engine shaft

Flywheel cover extractor

ing the ! ywheel

- 14 -

GEN

INFO

SPECIAL EQUIPMENT

SPECIAL ENGINE EQUIPMENT

Tool Code Name-Tool Function Image

1

This tool serves to establish the TDC po-

Engine tuning tool

sition

1

This tool serves to tighten or remove the

Chain tensioner locking tool

This tool serves to lock the tensioner pis-

ton while ! tting the chain tensioner

This tool is used to ! t the oil seal on the

Tool to remove/ﬁ t the clutch bell hous-

This tool is used to remove and ! t the notched ring nut that holds the clutch bell

Valve spring compressor tool

This tool is used to remove springs from

Oil ﬁ lter tool

engine oil ! lter

Oil seal insertion tool

engine casing near the gear

ing ring nut

housing

valves

1

This tool is used to measure the inner di-

1

This tool is used to measure the external

Valve removal adaptor

This tool is used to remove valves

Measuring gauge

mensions of bores

Measuring gauge

dimensions of parts

- 15 -

GEN

INFO

SPECIAL EQUIPMENT

SPECIAL ENGINE EQUIPMENT

Tool Code Name-Tool Function Image

1

This tool is used to measure thickness

Measuring gauge

1

This tool serves to remove the ! ywheel on

Flywheel tightening tool

the engine shaft

- 16 -

GEN

INFO

SPECIAL EQUIPMENT

SPECIAL TOOLS (FRAME)

Tool Code Name-Tool Function Image

1

Tightening tool for steering head lock

nut

This assembled tool is used to tighten the

lock nut securing the steering head.

1

Front wheel steering arm tightening

tool

This tool is used to tighten the front wheel

- 17 -

SPEC

Speci• cations

CHAPTER 2

- 18 -

SPEC

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ................................................................................ 20

TECHNICAL DETAILS ............................................................................................ 21

ENGINE SPECIFICATIONS ......................................................................................................................21

FRAME SPECIFICATIONS .......................................................................................................................26

ELECTRICAL SPECIFICATIONS ..............................................................................................................30

GENERAL TIGHTNESS SPECIFICATIONS .............................................................................................34

TIGHTNESS TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS ..................35

TIGHTENING TORQUES ..........................................................................................................................35

- 19 -

SPEC

GENERAL SPECIFICATIONS

DIMENSIONS STANDARD

Overall length (A)

Overall width (B)

Overall height (C) 1180 mm Distance between centres

2160 mm

800 mm

1480 mm

WEIGHT STANDARD

Kerb weight (with oil and fuel tank full)

Empty (with no oil and empty tank) 208 kg Maximum permissible load capacity

(with rider and load)

C

220 kg

410 kg

D

A

B

- 20 -

SPEC

TECHNICAL DETAILS

ENGINE SPECIFICATIONS

ENGINE STANDARD

Engine Four-stroke inline four-cylinder

liquid cooled, 4 valves per cylinder

Double overhead camshaft (DOHC)

Cubic capacity

Number of cylinders 4 Cylinder layout

Stroke ratio Compression ratio: Low idling speed High idling speed Distribution Double overhead camshaft, chain control,

with 4 valves per cylinder

Maximum net power Max. net torque

60 kW/11500rpm(82CV)

600 c.c

in line

65x45.2

11.5:1

52 N.m/10500rpm

FUEL STANDARD

Recommended fuel Lead-free RON95

ENGINE OIL STANDARD

Lubrication system forced, wet sump Total amount 3.2 l Amount without oil ! lter cartridge replace-

ment Amount with oil ! lter cartridge replace-

ment Recommended oil: API SJ 15W50 (synthetic)

3.2 l

Jaso -MACCMC g4

OIL FILTER STANDARD

Oil ! lter type Paper

OIL PUMP STANDARD

Oil pump type Lobe Clearance between the inner and outer

rotor tips Clearance between outer rotor and oil

pump

0.25 mm max.

0.2 mm max

IGNITION STANDARD

Ignition system type electrical

- 21 -

SPEC

B

A

B

A

TECHNICAL DETAILS

ENGINE SPECIFICATIONS

SPARK PLUGS STANDARD

Model (make) x quantity

Distance between electrodes

NGN CR9E

0.6-0.7 mm

CYLINDER HEAD STANDARD

Head gasket maximum warping

CAMSHAFT STANDARD

Control system Camshaft support diameter Clearance between support and camshaft

follower Cam lobe dimensions, intake side

Cam lobe dimensions, exhaust side

chain transmission

Ø23 (0,+0.021) mm

0.03 - 0.064

Measurement “A”= 32.495 mm

Measurement “B”= 25 mm

Measurement “A”= 32.495 mm

Measurement “B”= 25 mm

0.03 mm

Maximum camshaft eccentricity

0.02 mm

FUEL STANDARD

Recommended fuel Lead-free RON95

CHAIN

STANDARD

DISTRIBUTION

Model/number of links 120 Automatic tensioning system

- 22 -

SPEC

A

B

C

B

TECHNICAL DETAILS

ENGINE SPECIFICATIONS

VALVES, VALVE SEATS, VALVE GUIDES STANDARD

Aspirator valve clearance (cold)

Exhaust valve clearance (cold)

VALVE DIMENSIONS

Head diameter ”A”

Contact surface length ”B”

Seat width ”C”

Contact surface length "B"

0.13 ~ 0.19 mm

0.19 ~ 0.25 mm

Intake Ø 25 mm

Exhaust Ø 22 mm

Intake 1.9-2.1 mm

Exhaust 1.75 ~ 1.95 mm

Intake 1 ~ 1.1 mm

Exhaust 1 ~ 1.1 mm

Intake 1.9 ~ 2.1 mm

Exhaust 1.75 ~ 1.95 mm

Valve stem diameter

Clearance between valve stem and valve guide Intake 0.05 ~ 0.075 mm

Valve stem eccentricity

Intake 3.965 ~ 3.98 mm

Exhaust 3.965 ~ 3.98 mm

Exhaust 0.04 ~ 0.065 mm

0.05 mm

VALVE SPRINGS STANDARD

Intake/exhaust effective length

Intake/exhaust installed length (valve closed)

External

Internal 41.6 mm

External 152.8 N m / 15.58 Kgf•m

Internal 143 N m / 15.58 Kgf•m

Intake 1.2 mm

Exhaust 1.2 mm

38.8 mm

CYLINDERS STANDARD

Cylinder layout perpendicular inline Stroke ratio 65.0:45.2 Compression ratio: 11.5x1 Stroke 65 Maximum ovalisation /O/ 0.008

/o/ 0.006

- 23 -

SPEC

TECHNICAL DETAILS

A

B

C

A

B

A

B

A

B

C

B

A

ENGINE SPECIFICATIONS

PISTON STANDARD

Clearance between piston and cylinder

Piston diameter ”A” Ø 65

Piston height “B” 25 mm

Gudgeon pin seat

diameter "C"

Gudgeon pin external diameter

Top band

Band type elastic

Dimensions “A” X ”B” 2.3 x 0.8 mm

2nd band

Band type elastic

Dimensions “A” X

”B”

Oil scraper ring

Dimensions “A” X

”B”

0.05 ~ 007 mm

0.002

0.003

0.002

Ø 16

0.003

0

Ø 16

0.008

2.3 x 0.8 mm

2.3 x 1.93 mm

mm

PISTON ROD STANDARD

Bearing colour codes Rod weight code K1 = Black K2 = Green K3 = White

A = Red B = Blue C = Yellow

K4 = Brown K5 = Orange

ENGINE SHAFT STANDARD

Width “A” 269.5 mm Maximum eccentricity "B" 22.6 ± 0.01 mm Side clearance at connecting rod big end

"C" Main bearing colour code A = Red B = Blue C = Yellow

0.1 - 0.25

- 24 -

SPEC

TECHNICAL DETAILS

ENGINE SPECIFICATIONS

CLUTCH STANDARD

Clutch:

Clutch release method

Clutch release action wire cable action action

Clutch cable clearance (at the ends of the clutch lever)

Friction plate thickness Number of • ction plates Steel disc thickness Steel disc thickness Disc pack thickness 11.2 mm

Max. warping 0.05 mm Friction spring effective length 40 ± 0.01 mm Spring quantity 4

oil bath clutch, multiple discs

wire cable and spring

with left grip lever

2 ~ 3 mm

2.8 ± 0.05 mm - 3 (0. - 0.1) mm 7

1.6 (0. -0.05) mm 7

TRANSMISSION STANDARD

Transmission type Straight tooth gear Primary reduction ratio 44:82 Secondary reduction system Transmission ratio Chain, ratio 14:46

1st 13-37

2nd 19-37

3rd 18:-28 4th 24-32 5th 21-25 6th 24-26

GEAR CONTROL MECHANISM STANDARD

Type of gear control mechanism sequential with desmodronic drive and prese-

lector

Maximum warp on gear shift guide bar Straightness 0.02

Roundness 0.005

AIR FILTER STANDARD

Air • lter type SPONGE

FUEL PUMP STANDARD

Pump type electric pump Model (make) Delphi Outgoing pressure 250 KPa

THROTTLE BODIES STANDARD

Diameter 37 mm Accelerator cable clearance (at the accelerator grip

! ange)

Rotary

- 25 -

SPEC

TECHNICAL DETAILS

FRAME SPECIFICATIONS

FRAME STANDARD

Frame type: Dismountable truss-type, the rear one with

steel tube truss, the front one of aluminium

alloy

Steering sleeve inclination

Trail N.A.

N.A.

FRONT WHEEL STANDARD

Wheel type Rim (Size) Rim (Material) Wheel travel

6-spoke alloy type

17 M/C x MT3.50 DOT-D

Aluminium

120 mm

REAR WHEEL STANDARD

Wheel type 6-spoke alloy type Rim (Size)

Rim (Material) Aluminium Wheel travel 122 mm

17 M/C x MT5.50 Dot -D

FRONT TYRE STANDARD

Tyre type tubeless Size 120/70 ZR17 M/C (58W)

Model (brand) N.A. Tyre pressure (cold) 2.4 Bar.

REAR TYRE STANDARD

Tyre type tubeless Size 180/55 ZR17 M/C (73W) Model (brand) N.A. Tyre pressure (cold) 2.4 Bar.

- 26 -

SPEC

TECHNICAL DETAILS

FRAME SPECIFICATIONS

FRONT BRAKE STANDARD LIMIT

Brake type Floating double-disc

brake

Activation

Recommended ﬂ uid DOT 4

Brake discs

Diameter x thickness

Minimum thickness

Max. deformation

Worn brake pad thickness

Pump cylinder ID 16 mm (0.62 in)

Caliper cylinder ID 34 and 30 mm (1.33

With the right hand

320 x 4 mm (12.5 x

0.15 in)

4 mm (0.15 in)

and 1.18 in)

4.0 mm (0.15 in)

0.1 mm (0.004 in)

REAR BRAKE STANDARD LIMIT

Brake type Single-disc brake

Activation With the right foot

Recommended ﬂ uid DOT 4

Brake discs

Diameter x thickness

Minimum thickness 4.5 mm (0.17 in)

Max. deformation 0.15 mm (0.006 in)

Worn brake pad thickness 4 mm

Pump cylinder ID 12 mm (0.47 in)

Caliper cylinder ID 32 mm (1.25 in)

260 x 5 mm

- 27 -

SPEC

TECHNICAL DETAILS

FRAME SPECIFICATIONS

FRONT SUSPENSION STANDARD

Suspension type

Fork stroke

Spring Free length Spacer length Flexibility (K1)

Spring stroke (K1) 0 ~ 120 mm (0 ~ 4.72 in)

Fork oil

Recommended oil SAE 7.5 Marzocchi 19 Amount for each stem 770 cc. Level (from the top of the outside pipe, with the pipe com-

pletely compressed without the fork spring) 95 mm

Upside-down fork with stems diameter 50mm

120 mm

295 mm 137 mm

8.6 Nm (0.96 Kgf-m)

STEERING STANDARD

Steering bearing type Ball bearings Angle from end-of-stroke to end-of stroke (lh) 30° Angle from end-of-stroke to end-of stroke (rh) 30°

- 28 -

SPEC

TECHNICAL DETAILS

FRAME SPECIFICATIONS

REAR SUSPENSION STANDARD

Suspension type

Fork travel

Spring Free length Installed length Flexibility (K1)

Spring stroke (K1) 42+/- 1 mm

Spring pre-load gas/air standard pressure 1200 kPa (12 bar)

Spring pre-load adjustment positions

Minimum 0

Standard 0 Maximum 10 mm (0.39 in)

Bounce damping adjustment positions Minimum* 0 Standard* -17 Maximum* -30

* from the completely returned position

Swinging fork in aluminium alloy, adjustable gas shock absorber in spring extension and pre-load

123 mm

178 +/- 1,5 mm 167 +/- 1,5 mm

16 Nm

DRIVE CHAIN STANDARD

Model (brand) REGINA Link number 118 Drive chain loosening 15 mm (0.59 in) from skid

137-ORPB

- 29 -

SPEC

TECHNICAL DETAILS

ELECTRICAL SPECIFICATIONS

SYSTEM VOLTAGE STANDARD

System voltage

12 V

STARTING COILS STANDARD

Model (brand) N.D. Primary coil resistance 0.6 O Secondary coil resistance 10 kO Primary coil choke 2.5 mH (1 kHz 0.3V) Secondary coil choke 23.5 mH (1kHz) Max. current withstand value 7.6 A

RECHARGING SYSTEM STANDARD

System type Magnetic AC Model (brand) 5-101211-502-1 (DENSO) Nominal output 13.5 V 48 A at 5000 rpm Voltage regulator (inside the alternator) semiconductor, FieldControl Voltage setting 14.5 + 0.3 V (5000 rpm 10 A 25 C°)

STARTING RELAY STANDARD

Model (brand) N.A. Amps 100 A Coil resistance 4.4 O at 20 C°

BATTERY STANDARD

Model (brand) YTX9-BS Battery capacity voltage 12 V / 14 A Relative density 1.310

HEADLIGHT STANDARD

Headlight type Halogen bulb

BULBS (WATT x QTY) STANDARD

Headlight Front position indicator 12 V 5 W x 2

Rear position indicator/brake light A LED Turn indicators

12 V 55 W x 2

- 30 -

SPEC

TECHNICAL DETAILS

ELECTRICAL SPECIFICATIONS

Plate light 12 V 5 W x 1 Instrument cluster light LED x 1

LIGHTS (WATT x QTY.) STANDARD

Neutral indicator light LED x 1 High beam light LED x 1 Oil level alarm light LED x 1 Turn indicator lights LED x 1 Engine failure alarm light LED x 1

ELECTRIC START SYSTEM STANDARD

Model (brand) 5-128-330 Power output 0.7 kw

HORN STANDARD

Horn type low Model (brand) N.D. Max. amps 3 A Performance 105 ~ 118 db (A)

FLASHER RELAY STANDARD

Relay type elettro lasher Model (brand) 355 E10

Turn indicators ! ashing frequency 80 ~160 cycles/min

Watt 10W x4

OIL PRESSURE SENSOR STANDARD

Model (brand)

N.A.

- 31 -

SPEC

TECHNICAL DETAILS

ELECTRICAL SPECIFICATIONS

FUSES (AMPS x QTY) STANDARD

Fuse CD1(Control unit)

Fuse CD2(Control unit) 15 A (Blue) Headlight fuse 15 A (Blue) Service fuse 15 A (Blue) Radiator fan fuse 15 A (Blue) Spare fuse 15 A (Blu) + 40 A (Red) Fuel pump fuse 15 A (Blue)

15 A (Blue)

THROTTLE VALVE SENSOR STANDARD

Model (brand) 6PX 008476-11 Resistance 4.0 KO ± 20%

FUEL PUMP STANDARD

Model N.A. Max. amps N.A. Level sensor inside Min.Max. resistance

285 O (empty) - 12 O (full)

SAFETY SWITCHES STANDARD

Stand switch CE75A Idle switch 20.00.057 (MONT.EL ) Tilt YE69A (DENSO)

AIRBOX AIR TEMPERATURE SEN-

STANDARD

SOR

Model (brand) Resistance 23.75 O 20 C°, 16.7 O 30 C°

THROTTLE BODY AIR PRESSURE

15TT001 (JCI)

STANDARD

SENSOR

Model (brand) N.A.

- 32 -

SPEC

TECHNICAL DETAILS

ELECTRICAL SPECIFICATIONS

LIQUID TEMPERATURE SENSOR STANDARD

Model (brand)

Resistance N.A.

N.A.

SPEED SENSOR STANDARD

Model (brand) N.A.

LAMBDA STANDARD

Model (brand) N.A.

INJECTOR STANDARD

Model (brand) N.A.

RELAY UNIT STANDARD

Model (brand) CM1 NAIS

IGNITION SYSTEM STANDARD

Start system type DELPHI MT05 Ignition timing 5° before TDC from 900 to 1800 r/min Tone wheel sensor (Pick-Up) O1VR002 (JCI) Model (brand) DELPHI

STEPPER STANDARD

Model (brand) N.A. Stepper type two phases

RADIATOR FAN STANDARD

Model (brand) N.A.

- 33 -

SPEC

TECHNICAL DETAILS

A

B

GENERAL TIGHTNESS SPECIFICATIONS

The tightness torques for parts or special assemblies are provided in each chapter of this manual. As far as concerns assemblies with multiple fastening elements, in order to avoid the risk of warping, cross-tighten the parts in successive stages until the required torque is achieved. Unless otherwise stated, tightness torques refer to parts with clean, dry threads. Parts must be at ambient temperature.

"B"

NUT

4mm

5mm 4.5 0.45 6mm

8mm 10mm 12mm 14mm 16mm 18mm

GENERAL TIGHTNESS

TORQUES

N.m Kgf.m

2.3 0.23

10 1.01 25 2.54 45 4.58

80 8.15 130 13.25 200 20.39 240 24.47

- 34 -

SPEC

TECHNICAL DETAILS

TIGHTENING TORQUES

TIGHTNESS TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS

The values given in the following table refer to standard tightness, i.e., for metric screws coupled with the relevant nut, or with screw nut in metal. The bodies to be tightened must be metal or suf• ciently rigid not to required the insertion of bushing or shims. Coupling is always made with the thread slightly oiled or greased; alternatively, the type of thread blocker required must be stated. Axial preloads related to tightening torque have increased by 10% compared to the value calculated, to take into account the tolerance on the nominal torque and the variation that the friction coef• cient may undergo from tightening to tightening.

8.8 CLASS 10.9 CLASS 12.9 CLASS

SCREW

M4 X 0.7

M5 X 0.8

M6 X 1

M8 X 1.25

M8 X 1 (*)

M10 X 1.5

M10 X 1.25 (*)

M12 X 1.75

M12 X 1.5 (*)

M12 X 1.25 (*)

M14 X 2

M14 X 1.5 (*)

M16 X 2

M16 X 1.5 (*)

M18 X 2.5

M18 X 1.5 (*)

M20 X 2.5

M20 X 1.5 (*) 440 130.620 630 187.020 750 222.650

M22 X 2.5 540 141.950 750 197.150 900 236.580

M22 X 1.5 (*) 600 162.750 850 230.560 1.000 271.240

M24 X 3 670 160.238 950 227.203 1.130 270.252

M24 X 2 (*) 750 184.566 1.050 258.392 1.250 307.610

TIGHTNESS

TORQUES

[Nm]

3 3.870 4.2 5.420 5.2 6.710

6 6.350 7.5 7.930 9 9.520 10 8.860 13 11.520 16 14.180 22 14.900 30 20.330 40 27.100 25 17.280 36 24.890 45 31.110 45 24.680 65 35.640 80 43.870 50 27.870 70 39.013 85 47.380 80 37.640 110 51.750 135 63.510 85 40.547 120 57.250 145 69.170 90 43.550 130 62.900 150 72.580

130 52.670 185 74.800 220 88.950 150 62.900 205 85.960 245 102.780 200 74.070 280 103.690 335 124.060 225 86.140 310 118.680 360 137.820 265 83.650 370 116.790 450 142.040 320 104.900 450 147.520 550 180.300 390 111.870 550 257.770 650 186.450

AXIAL

PRELOAD

[Nm]

TIGHTNESS

TORQUES

N.m

AXIAL

PRELOAD

[Nm]

TIGHTNESS

TORQUES

N.m

AXIAL

PRELOAD

[Nm]

(*) The metric screw named has a • ne pitch.

- 35 -

CHK

ADJ

CHK

ADJ

Inspections and Periodic Adjustments

CHAPTER 3

- 36 -

CHK

ADJ

CHAPTER 3

REGULAR MAINTENANCE

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ............................ 40

FREQUENCY ............................................................................................................................................41

ENGINE/AIR FILTER .............................................................................................. 44

AIR FILTER REMOVAL/FITTING ..............................................................................................................44

ENGINE/ACCELERATOR CABLE CLEARANCE ................................................. 46

ACCELERATOR CABLE CLEARANCE ADJUSTMENT ...........................................................................46

ENGINE/CLUTCH CABLE ...................................................................................... 48

CLUTCH CABLE CLEARANCE ADJUSTMENT .......................................................................................48

FRAME/HANDLBAR .............................................................................................. 49

REAR VIEW MIRROR ADJUSTMENT ......................................................................................................49

ENGINE/ENGINE OIL ............................................................................................. 50

ENGINE OIL LEVEL CHECK ....................................................................................................................50

ENGINE OIL CHECK ................................................................................................................................51

ENGINE/SPARK PLUGS ........................................................................................ 52

REMOVING THE SPARK PLUGS .............................................................................................................52

CHECKING THE SPARK PLUGS .............................................................................................................52

SPARK PLUG INSTALLATION ..................................................................................................................53

FRAME/BRAKE ADJUSTMENT ............................................................................ 54

FRONT BRAKE ADJUSTMENT ................................................................................................................54

FRONT BRAKE ADJUSTMENT ................................................................................................................55

FRAME/BRAKE FLUID CHECK ............................................................................. 56

CHECK THE LEVEL OF THE REAR BRAKE FLUID / TOP UP ................................................................56

CHECK THE LEVEL OF THE REAR BRAKE FLUID / TOP UP ................................................................57

FRAME/BRAKE PAD CHECK ................................................................................ 58

FRONT AND REAR BRAKE PAD CONTROL ...........................................................................................58

FRAME/BRAKE SYSTEM HOSE CHECK ............................................................. 59

BRAKE HOSE CHECK..............................................................................................................................59

FRAME/TRANSMISSION CHAIN ADJUSTMENT ................................................. 60

ADJUSTMENT ..........................................................................................................................................60

LUBRICATION ...........................................................................................................................................61

FRAME/STEERING HEAD CHECK AND ADJUSTMENT ..................................... 62

CHECK/ADJUSTMENT .............................................................................................................................62

FRAME/FRONT FORK CHECK ............................................................................. 63

CHECK ......................................................................................................................................................63

FRAME/REAR SHOCK ABSORBER CHECK ....................................................... 64

SHOCK ABSORBER ADJUSTMENT ........................................................................................................64

FRAME/REAR AND FRONT TYRE CHECK .......................................................... 65

CHECK ......................................................................................................................................................65

ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE ...................................... 66

BATTERY ..................................................................................................................................................66

ELECTRICAL SYSTEM/FUSE CHECK .................................................................. 71

FUSES.......................................................................................................................................................71

ELECTRICAL SYSTEM/HEAD LAMP REPLACEMENT ....................................... 73

REPLACEMENT ........................................................................................................................................73

ELECTRICAL SYSTEM/HEADLAMP ADJUSTMENT ........................................... 74

REMOVAL/INSTALLATION .......................................................................................................................74

- 37 -

CHK

ADJ

ELECTRICAL SYSTEM/HEADLAMP ADJUSTMENT ........................................... 75

ADJUSTMENT ..........................................................................................................................................75

ELECTRICAL SYSTEM/REAR LAMP REPLACEMENT ....................................... 76

REPLACEMENT ........................................................................................................................................76

ELECTRICAL SYSTEM/LICENCE PLATE LAMP REPLACEMENT ..................... 76

REPLACEMENT ........................................................................................................................................76

ELECTRICAL SYSTEM/REAR INDICATOR REPLACEMENT .............................. 77

REPLACEMENT ........................................................................................................................................77

ELECTRICAL SYSTEM/FRONT INDICATOR REPLACEMENT ............................ 78

REPLACEMENT ........................................................................................................................................78

- 38 -

CHK

ADJ

NOTES:

..................................................................................................................................................................................................................

- 39 -

CHK

ADJ

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

Intervals given in the scheduled maintenance table must be considered as a general guideline for conditions of normal use only. It may be necessary to reduce these intervals according to weather conditions, terrain, geographical situation and individual use. Some operations can be performed by the user as long as they have the necessary skills and in any case, as long as this is expressly mentioned in this manual. In any case, carry out operations at an authorised Benelli workshop. A list of workshops is available on our website www.benelli. com or from our customer service (T_ +39 0721 41871). In general, maintenance needs to be carried out with the motorbike on the rear stand, engine off and switch set to OFF:

While checking ﬂ uid levels, it is preferable to keep the motorbike upright without using the rear stand.

NOTE:

• Annual checks need to be carried out every year unless maintenance is carried out on the base of servicing at set distance intervals (or in the case of the UK, mileage).

At 36,000 km, repeat maintenance services as begun at 12,000 km.

•

• For intervals for those items marked“ ”, we recommend contacting a Benelli dealer, given that it is necessary to have special

equipment, speci! c information and speci! c technical experience-

The following section shows all of the maintenance operations-

NOTE:

AIR FILTER

•

The air ! lter needs to be replaced more often if the vehicle is used in particularly damp or dusty environments.

HYDRAULIC BRAKE MAINTENANCE

• Check brake ﬂ uid levels on a regular basis and top up as necessary.

• Replace the parts inside the brake pump and callipers every two years. Also change the brake ﬂ uid.

• Replace brake hoses every 4 years, or before if cracked or damaged.

KEY

I Inspection and adjustment, cleaning, lubrication or replacement, as needed R Replacement T Tighten

Dealer

- 40 -

CHK

ADJ

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

FREQUENCY

NO.

1

2

• Fuel • lter

3

• Air Filter

4

• Cooling Fluid

5

•

6

• Spark plugs

7

•

8

• Crown

9

•

10

•

11

•

12

•

13

• Brake pads

14

•

15

•

16

•

17

Part

Engine oil:

Oil • lter

Cooling system:

Transmission

Chain

Pinion/Re-

taining

washer

Circuit hoses

fuel

Brake ! uid Check/Top up/ I I I I I I I

*clutch Replace Replace every 18000 km or in any case, every 2 years

Front brake/ Rear brake:

Fork chain

slide

Fork chain

slide

Accelerator

grip

Maintenance interven-

tion or control

Check/Top up/Replace-

ment

Replacement R R R R R

Check/Replacement I I R I

Check/Replacement I R I R

Check/Top up/Replace-

ment

Replace Every 2 years or 18.000 km

Check the level of the

cooling ! uid

and make sure there

are no leaks

of ! uid from the vehicle

Check/Replacement I R I R I

Check chain tension

Make sure that the

rear wheel is correctly

aligned Clean and

lubricate

Check /Lubricate I I I I I I

Check/Replacement

Check for faults/leaks

Check operation and

! uid

level, and make sure

that there are no

leaks of ! uid from the

vehicle

Check/Replacement I I I I I

Check operation and

if necessary, adjust

the accelerator cable

backlash Lubricate the

accelerator grip housing

and cable

0 km

(0 mi)

Pre-delivery

I R R R R R R

I I I I I I I

Every 500 km and after every wash or if the motorcycle has been used in the rain.

I I I I I I I

1000 km

(621 mi)

1°

Service

Check the conditions, clean and restore the distance between electrodes

I I I I I I

Replace every 24000 km or in any case, every 3 years

6,000 km

(3,726 mi)

2°

Service

Before every use of the vehicle

Or at any engine oil replacement

Replace every time the chain is replaced

I I R I

Replace if worn to the limit

12,000 km

(7,452 mi)

3°

Service

18,000 km

(11,178 mi)

4°

Service

24,000 km

(14,904 mi)

5°

Service

Annual inspec-

tion

- 41 -

CHK

ADJ

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

FREQUENCY

NO.

• Throttle valve

18

•

19

• Throttle valve

20

•

21

•

22

•

23

•

24

•

25

•

26

•

27

•

28

• Swing arm

29

•

30

•

31

•

32

• Wheels

33

• Tyres

34

• Side stand

35

Part

Clutch control

Valve clear-

ance

Distribution

chain

Distribution

chain slides

Chain ten-

sioner

distribution

Steering

ring nut and

sleeve

Steering bearings

Wheel bear-

ings

front / back

Fork bear-

ings

Front sus-

pension

Front sus-

pension oil

Rear suspen-

sion

Maintenance interven-

tion or control

Check operation/Adjust

backlash

Check/Adjustment I I I I I I I

Check/Adjustment I I I I I

Check operation/Adjust

clearance

Check/Replacement R

Check/Adjustment T T T T T T T

Check/Replacement T T

Check/Replacement I I

Check/Replacement I I I R

Check operation and

make sure there is no

excessive

clearance. Lubricate. Check operation and

make sure there are no

leaks

Replacement

Check/adjustment make

sure that

there are no leaks

Make sure they are not

off centre

or damaged

Check the depth of

tread and make sure

they are not damaged.

Replace if necessary Check in• ation pres-

sure.

Replace if necessary

Check operation I I I I I I I

0 km

(0 mi)

Pre-delivery

1000 km

(621 mi)

1°

Service

I I I I I

Every 18000 km lubricate with lithium soap-based grease

I I I I I I

Every 18000 km lubricate with lithium soap-based grease

I I I I I I

6,000 km

(3,726 mi)

2°

Service

Check clearance every 24000 km (14904 mi)

Every 24000 km (14904 mi)

Every time the distribution chain is replaced

Before every use of the vehicle

Every 24000 km (24900 mi)

Every 24000 km (14904 mi)

I I I I

Every 24000 km (11178 mi)

I I I I

Before every use of the vehicle

Replace if worn to the limit

12,000 km

(7,452 mi)

3°

Service

I I I

18,000 km

(11,178 mi)

4°

Service

R

24,000 km

(14,904 mi)

5°

Service

I

Annual inspec-

tion

36

Switch Check operation I I I I I I I

• Side stand

- 42 -

CHK

ADJ

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

FREQUENCY

NO.

•

37

• Head light

38

•

39

• Instruments

40

•

41

•

42

•

43

• Electric fans

44

•

45

• Fuel /CO*

46

•

47

•

48

•

49

•

50

•

51

•

52

Part

Instruments,

lights, signals

and switches

Acoustic

warning

Connections

Battery

Electrical

System

Ignition

switch

Electronic

injection fuel consumption

Cyclist part

fastening

Oil sump

screws

Lid screws

clutch

Catalytic

converter

USA canister

version

Brake/clutch

hoses

Maintenance interven-

tion or control

Check operation I I I I I I I

Check operation I I I I I I

Adjustment At every change in vehicle set-up

Check operation I I I I I I I

Set the minimum run-

ning speed for

engine and synchroni-

sation

Check/Adjustment I I I I I I I

Make sure all nuts, bolts and screws are correctly

tightened,

Replacement T T T T T

Replacement

Check for faults/leaks

0 km

(0 mi)

Pre-delivery

I I I I I I I

1000 km

(621 mi)

1°

Service

T T T T T T

T T T T T

I I I I R

No maintenance required. In case of malfunction replace.

I I I I R

No maintenance required. In case of malfunction replace.

6,000 km

(3,726 mi)

2°

Service

Every 12000 km (7452 mi)

12,000 km

(7,452 mi)

3°

Service

Every 4 years

18,000 km

(11,178 mi)

4°

Service

24,000 km

(14,904 mi)

5°

Service

Annual

inspec-

tion

53

54

Parts and

•

wires subject to movement

Oil suction

•

Check/Replacement I I I I I I I

Before every use of the vehicle

Check/Replacement I I I I

• lter

- 43 -

CHK

ADJ

ENGINE/AIR FILTER

11

5

6

7

4

10

9

2

3

1

5

6

8

1

9

10

1

AIR FILTER REMOVAL/FITTING

Position Description Quantity

1 SCREW ST4.8X25 8

2 AIR BOX COVER 1

3 GASKET 1

4 AIR FILTER 1

5 SCREW M5X19 2

6 WASHER 2

7 PLATE 1

8 PLATE 1

9 AIR TEMPERATURE SENSOR 2

10 RUBBER TIP 2

11 SCREW CLIP 4

- 44 -

CHK

ADJ

ENGINE/AIR FILTER

AIR FILTER REMOVAL/FITTING

Removal:

1. Remove the passenger seat, using the wrench provided and remove the rider's seat with the release knob (A) Fig, A.

2. Remove the side fairings from the tank and fuel tank.

3. Remove the two screws fastening the plates (7-8) securing the • lter body to the frame. Fig.B

4. Loosen the two screw clips (11) and separate the • lter body from the throttle valves.

5. Place the • lter on a • at surface.

6. Remove the 11 screws (1) fastening the cover (2) Fig. B.

7. Take out the • lter element (4) Fig, C.

NOTE:

Replace the air • lter element every 12,000 km. If the vehicle is used in particularly damp or dusty climates, it will be necessary to change the air •

Check:

To make sure there is no damage to the air • lter. If damaged, it will need to be replaced and if intact, proceed to wash:

1. Wash the • lter element with speci• c solvents for this purpose.

2. Air dry.

3. Apply a speci• c oil to the whole surface of the • lter element.

lter more often.

A

B

NOTE:

Before • tting the • lter element into the air box., be sure to drain off any excess oil and make sure that it is no longer dripping.

Installation:

1. During the installation stage, follow the steps for removing the • lter, as described above, only this time in reverse order.

IMPORTANT NOTICE:

Never start the engine without the air • lter installed. If not

• ltered, air will cause engine parts to wear out quickly and may

even damage the engine. Using the engine without air • lter will also have a negative effect on the • ne tuning of the throttle valves and this in turn will cause the engine's performance to suffer and even to eventually overheat. Make sure that the air • lter is always in good working order. The lifetime of the engine depends mainly on this part.

7 8

2

1

C

4

- 45 -

CHK

ADJ

ENGINE/ACCELERATOR CABLE CLEARANCE

1

10

32

14

13

25

4

19

18

16

5

21

11

24

22

30

15

12

3

6

2

26

28

33

31

27

29

23

19

20

18 17

16

6

9

8

7

20

17

ACCELERATOR CABLE CLEARANCE ADJUSTMENT

Position Description Quantity

1 PAIR OF REAR VIEW MIRRORS 1

2 ACCELERATION CONTROL 1

3 BOTTOM ACCELERATION CONTROL 1

4 TOP ACCELERATION CONTROL 1

5 RIGHT SWITCH 1

6 GRIP END 2

7 HANDLEBAR 1

8 LEFT SWITCH 1

9 LH GRIP 1

10 CLUTCH CONTROL 1

11 CLUTCH CABLE 1

12 THROTTLE OPENING CABLE 1

13 THROTTLE CLOSING CABLE 1

14 REAR VIEW MIRROR (RIGHT) 1

15 REAR VIEW MIRROR (LEFT) 1

16 SCREW M6X35 2

17 ELASTIC WASHER 2

18 WASHER 2

19 GRIP CAP 2

- 46 -

CHK

ADJ

ENGINE/ACCELERATOR CABLE CLEARANCE

ACCELERATOR CABLE CLEARANCE ADJUSTMENT

Position Description Quantity

20 ROCKER ARM 2

21 CABLE GLAND 1

22 TUBE GUIDE 3

23 CLUTCH CONTROL LEVER 1

24 RUBBER CLAMP 2

25 SCREW 2

26 NUT M6 1

27 SPECIAL NUT 1

28 SPECIAL SCREW 1

29 CLUTCH SWITCH 1

30 SCREW 1

31 SCREW M6X14 2

32 U-BOLT 1

33 LEVER SUPPORT 1

NOTE:

Before adjusting accelerator cable clearance, it is necessary to set the minimum idle speed of the engine. First check at 1000 km (621 mi) and then every 6,000 km (3.726 mi).

Check:

• accelerator cable clearance (A)

Make sure that the accelerator control grip (2) is working normally and that it is possible to reach the maximum open position and automatic closure position in all steering positions. If necessary, adjust. Fig.A

Accelerator cable clear-

ance (A)

Accelerator cable

Adjust:

• accelerator cable clearance

Handlebar side

1. Loosen the nut support "D"

2. Turn the adjustment nut "C" clockwise or anticlockwise to

set the accelerator cable clearance as speci! ed. Fig.B

Accelerator cable clear-

ance

Clockwise Anticlockwise Reduces clearance

Increases clearance

Size

3 - 5 mm

Clearance

A

B

CD

3. Tighten the support nut "D"

Make the adjustment to both acceleration controls.

IMPORTANT NOTICE:

After adjusting the clearance of the accelerator, start the engine and turn the handlebars to the right and left, making sure that the minimum idle speed of the engine does not change.

- 47 -

CHK

ADJ

ENGINE/CLUTCH CABLE

CLUTCH CABLE CLEARANCE ADJUSTMENT

Check:

• clutch cable clearance (A)

If necessary, adjust.

Clutch cable clearance Clearance distance

Clutch lever

Adjust:

• Clutch cable clearance

Handlebar side

1. Loosen the ring nut "C"

2. Turn the adjustment device "B" clockwise or anticlockwise

to set the clutch cable clearance as speci! ed. Fig.B

Clutch cable clearance Clearance

Clockwise Anticlockwise Reduces clearance

3. Tighten the ring nut "C"

3 - 4 mm

Increases clearance

NOTE:

If it is not possible to achieve the speci! ed clearance for the clutch cable from the handlebar side, use the adjustment nut on the engine side "E". Fig.C

A

B

C

E

C

- 48 -

CHK

ADJ

FRAME/HANDLBAR

REAR VIEW MIRROR ADJUSTMENT

The following procedure applies to both rear view mirrors.

• Installation

1. Tighten the mirror (15) on the lever body (32).

2. Tighten the nut "B" as far as it will go.

3. Adjust the mirror position by turning it to the required position.

4. Tighten the support nut "C"

NOTE:

Perform the same procedure on the right-hand mirror.

A

C

B

- 49 -

CHK

ADJ

ENGINE/ENGINE OIL

ENGINE OIL LEVEL CHECK

Park:

• the bike on a level surface.

NOTE:

• Place the motorbike on suitable stands so that the tyres are at the same height from ground level.

• Make sure that the bike is upright.

Start:

• the engine.

leave it to warm up for a few minutes before switching it off.

IMPORTANT NOTICE:

Do not start the engine if the oil is under the MIN reference of the rod "B" Fig. A,

Check:

• the engine oil level

the oil level must be between the minimum level (MIN) and maximum level (MAX) marks on the dipstick. If it is below the minimum level mark, top up to the correct level with the recommended engine oil.

To top up the engine oil:

1. unscrew the oil cap with the engine switched off

2. Pour in enough of a suitable type of oil between the MAX and MIN levels, Fig. A,

NOTE:

A

B

MAX

MIN

The engine oil level must be checked without screwing in the dipstick cap

IMPORTANT NOTICE:

Given that engine oil also lubricates the clutch, if it is not the right type or if it contains additives, it could cause the clutch to slip. Therefore, we recommend not adding any chemical additives or using oils of other types than the one listed in the

technical speci! cations for the engine. Engine oil, whether new or spent, can be dangerous. If ingested, engine oil may be poisonous to people or pets. In the event of ingestion, seek medical attention immediately; do not provoke vomiting to avoid breathing the product into the lungs. Brief contact with engine oil may irritate the skin.

• Keep the engine oil out of reach of children and pets.

• Wear long-sleeved clothing and waterproof gloves every time you top up the engine oil.

• Wash off any oil that has come into contact with the skin with soap and water.

• Recycle or correctly dispose of spent engine oil.

3. Screw the ! ller cap back in place.

NOTE:

When checking the engine oil level, restart the engine, leave it to warm up for a few minutes and then switch it off. Wait a few moments to give the oil enough time to # ow down.

- 50 -

CHK

ADJ

ENGINE/ENGINE OIL

T

.

R

.

ENGINE OIL CHECK

Start:

• the engine and leave it to warm up for a few minutes before switching it off.

Remove:

• the sump plug

Place:

• a suitable container under the magnetic cap "A" to recover the engine oil. Fig. A

Remove:

• the magnetic cap "A" (together with the copper gasket).

Drain:

• the engine oil out of the crankcase.

NOTE:

Replace the oil ! lter cartridge if necessary.

Replace:

the seal on the magnetic cap.

•

Install:

• the new seal

• the magnetic cap

Tighten the magnetic cap with the following torque:

Torque 24 N*m

Fill:

• the crankcase with the recommended engine oil in the amount speci! ed.

Install:

• the oil cap "B" Fig, B

A

B

MAX

MIN

Start:

• the engine.

leave it to warm up for a few minutes before switching it off.

NOTE:

Always make sure that the level is midway between the MIN and MAX marks on the dipstick Fig.B.

op up the engine oil level if needed.

T

- 51 -

CHK

ADJ

ENGINE/SPARK PLUGS

3

8

7

6

4

5

2

29

30

REMOVING THE SPARK PLUGS

The following procedure applies to all spark plugs.

WARNING:

Spark pugs must be checked and replaced when the engine is cool.

Remove:

Carry out the removal procedure for the air ! lter, as described previously in the "Engine/Air Filter" chapter, in the paragraph "Air ! lter removal/installation."

IMPORTANT NOTICE:

Before removing the spark plugs, remove any build up of dirt from the seat with a jet of compressed air, to prevent it from dropping down into the cylinders.

Remove:

• The two screws (6*)

• The two brackets (8*)

• The four rubber pads (2*) and four OR gaskets (3*) Fig. A

Disconnect:

• The connectors (X) from the coils (29*) Fig. A

Slide out:

• The coil (29*)

• The spark plug (30*) underneath it Fig. B

29*

3*

A

X

8*

2*

6*

B

NOTE:

The numbers marked with (*) are part of the table of replacement parts in Chapter 5 "Engine", "Removing the timing belt cover" paragraph

CHECKING THE SPARK PLUGS

The following procedure applies to all spark plugs.

Check:

• The type of spark plug

Check:

1. the electrodes (A) Fig. C

If there is any damage/wear/rounding Replace the spark plugs.

2. the insulation section (B) Fig. C

Abnormal colour Replace the spark plug. The usual colour is a mid- to light-brown

C

B

A

- 52 -

CHK

ADJ

ENGINE/SPARK PLUGS

T

.

R

.

T

.

R

.

3

8

7

6

4

5

2

29

30

CHECKING THE SPARK PLUGS

The following section contains a table with the typical conditions of spark plugs with the different causes of damage and any remedies.

SOILED

SPARK PLUG

Cause

Over rich mix of air/fuel

Carburettor incorrectly calibrated

Electrical system fault

-Imperfect coil connection

Speciﬁ c riding conditions

-Prolonged periods at “minimum”

-Long sections at low speed

Spark plug too cold

The fuel/carburettor system

needs to be ! ne tuned

Check the coil connections and relevant impedance

Èvery so often, the bike needs to be taken to speeds of about 80 km/h

Use a warmer spark plug, as per speci! cations

The following procedure applies to all spark plugs. Fig. D/

Solutions Cause Solutions

SPARK PLUG INSTALLATION

WARNING:

Lubricate the plug threads with copper grease.

Ignition too advanced

Insufﬁ cient air/fuel mix

Insufﬁ cient coolant and/or lubricant

Spark plug torque too low

The spark plug used is too hot

OVERHEATED

SPARK PLUG

Adjust advanced ignition

Adjust air/fuel ratio

Add coolant and/or lubricant

Tighten to the correct torque

Use cooler spark plugs as per speci! cations

D

NOTE:

Before installing the spark plug, clean it and also the surfaces in contact with the gasket.

Install:

• the spark plug on the head, tightening it by hand until you can feel it come into contact with the base of the head. Tighten to the correct torque.

Torque 12 N*m

Install:

• The coil (29*)

• The rubber tips (2*) and the OR gasket (3*) Fig.D

Connect:

• the coil connector

Install:

• The coil (6*)

• The bracket (8*)

Tighten to the correct torque.

Torque 8 N*m

- 53 -

CHK

ADJ

FRAME/BRAKE ADJUSTMENT

FRONT BRAKE ADJUSTMENT

Adjust:

• the position of the brake lever Fig. A (the distance”x” between the accelerator and the brake lever).

NOTE:

Push the brake lever forwards to neutralise the thrust of the spring and at the same time, adjust the position, turning the ring nut, "y" clockwise or anticlockwise until the brake lever is where it should be.

Ring nut Position Distance

Position 1 the distance is further from

the handlebar.

Position 4 The distance is nearer to the

handlebars

WARNING:

If the brake lever is soft or spongy to the touch, this may be a symptom of air in the brake system. Before using the motorbike, it is necessary to bleed out the air by emptying out the brake circuit. Air in the brake circuit will considerably reduce the performance of the system and may even lead to a loss of vehicle control and possible accidents Therefore, check the system and if necessary, bleed it.

A

Y

X

IMPORTANT NOTICE:

After adjusting the position of the brake lever, make sure that there is no brake drag of any kind.

- 54 -

CHK

ADJ

FRAME/BRAKE ADJUSTMENT

FRONT BRAKE ADJUSTMENT

Adjust:

• the position of the brake pedal, using the eccentric pin Fig.A.

• Loosen the lock nut ”A” .

• Unscrew the threaded pin "B"

• Take out the return spring (C) connecting the eccentric pin (D) to the frame Fig. B

• Use an open wrench to adjust the position of the eccentric (D) compared to the stop screw (E)

Eccentric position Brake pedal position

Clockwise

Anticlockwise The pedal lowers

The pedal lifts

NOTE:

We recommend leaving a gap of about 5/10 mm between the stop head and eccentric pin Fig. B

• Tighten the lock nut ”A” .

A

B

A

B

0.5 mm

E

• Insert the spring "C".

WARNING:

If the brake lever is soft or spongy to the touch, this may be a symptom of air in the brake system. Before using the motorbike, it is necessary to bleed out the air by emptying out the brake circuit. Air in the brake circuit will considerably reduce the performance of the system and may even lead to a loss of vehicle control and possible accidents Therefore, check the system and if necessary, bleed it.

IMPORTANT NOTICE:

After adjusting the position of the brake pedal, make sure that there is no brake drag of any kind.

C

D

- 55 -

CHK

ADJ

FRAME/BRAKE FLUID CHECK

CHECK THE LEVEL OF THE REAR BRAKE FLUID / TOP UP

Park:

• the bike on a level surface.

NOTE:

Place the motorbike on a stand and make sure that it is in the upright position.

Check:

• Brake ! uid levels If it is below the minimum level mark "A" Fig. A, top up to the correct level with the recommended engine oil.

Fluid top up procedure:

• Once the motorbike is level, unscrew the top cap "B" from the brake pump Fig. A

Check:

the seal on the cap. If there is any damage/wear Replace the gasket

IMPORTANT NOTICE:

Brake ! uid can damage painted surfaces or plastic parts. Therefore, apply absorbent paper around the pump and always clean up any break ! uid spills immediately.

A

B

A

B

C

• Apply the vacuum device "B" to the bleeding screw "C".

• Top up the ! uid as far as the level in the peep hole on the pump Fig. C.

• Pump the brake ! uid until the brake lever moves.

• Once the top up process is complete, # t the cap and tighten the two fastening screws to the cover:

WARNING:

Only use the prescribed brake ! uid. Other brake ! uids may be the cause of deterioration to rubber gaskets, causing leaks and an unsuitable operation of the braking system. Top up with the same brake ! uid already in the system. The mix of different brake ! uids may lead to a harmful chemical reaction, able to cause incorrect operation of the braking system. While topping up, take care not to let any water into the tray. Water would signi# cantly lower the boiling point of the brake ! uid and could cause steam bubbles.

C

- 56 -

CHK

ADJ

FRAME/BRAKE FLUID CHECK

T

.

R

.

CHECK THE LEVEL OF THE REAR BRAKE FLUID / TOP UP

Park:

• the bike on a level surface.

NOTE:

Place the motorbike on a stand and make sure that it is in the upright position.

Check:

• Brake ! uid levels If it is below the minimum level mark "A" Fig. A, top up to the correct level with the recommended engine oil.

Fluid top up procedure:

• Once the motorbike is level, unscrew the top cap "B" from the brake pump Fig. B

Check:

the seal on the cap "C " If there is any damage/wear Replace the gasket

IMPORTANT NOTICE:

Brake ! uid can damage painted surfaces or plastic parts. Therefore, apply absorbent paper around the pump and always clean up any break ! uid spills immediately.

A

B

C

B

• Remove the screw fastening the rear brake outer calliper and loosen the internal fastening screw Fig. C so as to lift the brake calliper. This will completely bleed the circuit, removing all air bubbles.

• Apply the vacuum device "D" to the bleeding screw and loosen the screw.

• Top up the ! uid as far as the level in the peephole on the pump.

• Pump the brake ! uid until the brake lever moves.

• Once the top up process is complete, lower the calliper and tighten the two fastening screws to the following torque:

Torque 22 N*m

• Close the pump cover.

WARNING:

Only use the prescribed brake ! uid. Other brake ! uids may be the cause of deterioration to rubber gaskets, causing leaks and an unsuitable operation of the braking system. Top up with the same brake ! uid already in the system. The mix of different brake ! uids may lead to a harmful chemical reaction, able to cause incorrect operation of the braking system. While topping up, take care not to let any water into the tray. Water would signi# cantly lower the boiling point of the brake ! uid and could cause vapour bubbles.

C

D

- 57 -

CHK

ADJ

FRAME/BRAKE PAD CHECK

A

FRONT AND REAR BRAKE PAD CONTROL

The following procedure applies to all brake pads.

Enable:

• the brake

Check:

• The front brake pads Fig. A

• The rear brake pads Fig. A

• Wear limit for the front and rear brake pads

If the wear limit has been reached, replace the brake pads in block.

Pads Wear limit (A)

Front

Rear 1 mm

1 mm

NOTE:

To replace the pads, please see the "Frame" chapter, in the section "Front brake pad removal and installation."

A

- 58 -

CHK

ADJ

FRAME/BRAKE SYSTEM HOSE CHECK

BRAKE HOSE CHECK

The following procedure serves for all brake hoses and brake hose clamps.

Check:

• The front and rear brake hose.

If there are any cracks/signs of wear or damage, replace.

Check:

• The hose clamp for the front brake "A" Fig. A. If loose, tighten the clamp screw.

Check:

• The hose clamp "B" for the rear brake Fig. A. If loose, tighten the clamp screw.

A

B

- 59 -

CHK

ADJ

FRAME/TRANSMISSION CHAIN ADJUSTMENT

T

.

R

.

ADJUSTMENT

NOTE:

Do not inspect or adjust the transmission chain while the engine is running.

NOTE:

Check the feed of the transmission chain in the point where it seems most taut.

WARNING:

If the transmission chain is too taut, this will cause the engine to overload, as well as other vital parts, while if too slack, it may come off and damage the fork arm or cause an accident. We

recommend keeping the chain slack to within speci! ed limits.

Park:

• the bike on a level surface.

WARNING:

Support the motorbike correctly, so that it cannot fall over and so that the rear wheel is raised.

• Allow the rear wheel to turn several time and identify the position where the transmission chain is at its most taut.

Adjustment screw

Lock nut

A

10÷-15 mm

B

Wheel pin

Check:

• the slackness of the transmission chain, if not within speci! cations, adjust Fig. A.

Transmission belt slackening

Adjust:

• the slackness of the transmission chain Fig. B.

If the chain tension is not correct, adjust it as follows.

• Loosen the wheel pin nut on the left side of the swinging arm.

• To tension the transmission chain, turn the tension adjustment screw on each side of the swinging arm (anti-clockwise).

• To loosen the transmission chain, turn the tension adjustment bolt on the left side of the swinging arm (clockwise) and push the rear wheel forwards.

• At the end of adjustment, tighten the wheel pin nut to the following torque:

10-15 mm

C

D E

slot on the swinging arm “D”, while on the left side (LH), it is at the

ﬁ fth slot on the swinging arm ”E” Fig.C.

Torque 80 N*m

IMPORTANT NOTICE:

Incorrect transmission chain tension will overload the engine and other vital parts of the motorcycle, and it may cause the chain to slip or break/ To stop this from happening, keep the transmission chain tension within the speci! ed limits. Make sure that the distance for the right side (RH) is at the eighth

- 60 -

CHK

ADJ

FRAME/TRANSMISSION CHAIN ADJUSTMENT

LUBRICATION

IMPORTANT NOTICE:

The transmission chain is comprised of many parts that interact with one another. The chain needs to be subjected to the correct maintenance to prevent its rapid deterioration. We therefore recommend that the transmission chain be subject to maintenance, especially when used in very dusty areas. This motorbike is • tted with a transmission chain • tted with small rubber O-rings inserted between a side plate and the other. Never use steam jets or jets of highly pressurized water, aggressive solvents or brushes with overly stiff bristles, as they could damage the O-rings. We recommend using only those products recommended for cleaning transmission chains. Dry the chain and lubricate it carefully using engine oil or another lubricant speci• cally for chains with O-ring. Do not use other types of lubricant on the transmission chain, as they may contain solvents that would damage the O-rings.

Apply:

• A • ne, even layer of lubricant to the whole chain, taking care not to reach the parts around it, especially the pneumatic parts.

- 61 -

CHK

ADJ

FRAME/STEERING HEAD CHECK AND ADJUSTMENT

T

.

R

.

T

.

R

.

CHECK/ADJUSTMENT

Park:

• The bike on a level surface.

NOTE:

Place the bike on suitable supports so that the front wheel is raised.

Check:

• The steering head

Allow the front fork swing gently, holding it by the ends of the tubes Fig. A. If there are any sticking/slackening points, adjust the steering head.

Remove:

• the handlebar (see the speci! c paragraph)

Loosen:

• The screws securing the upper steering plate "A" Fig. B.

Remove:

• The upper steering plate "B" Fig. B.

Adjust:

• The steering head

• Remove the ring nut from the steering pin "D" Fig. C.

• Loosen the steering ring nut "E" and tighten it to the speci! ed value using the relevant wrench.

A

B

.

(**) Tightening tool for steering head lock nut

Code:......................

Torque 16 N*m

• Tighten the ring nut "D" with the speci! c tool, to the following torque:

Torque 60 N*m

WARNING:

Do not overly tighten the steering ring nut.

Remove:

• The cap "F" with the special tool "G" Fig. D

.

(**)steering head wrench tool

Code:......................

A

C

D

E

D

F

G

- 62 -

CHK

ADJ

FRAME/STEERING HEAD CHECK AND ADJUSTMENT

CHECK/ADJUSTMENT

Check:

• Make sure that the steering head is not loose and that there are no sticking points by turning the front fork to the end of travel in both directions. If there are any sticking points, remove the bottom steering base and check the top and bottom bearings.

Install:

• The upper steering plate "B" Fig. B.

• The screws securing the upper steering plate "A" Fig. B.

Check again:

• The steering head

• Make the front fork swing gently, holding it by the ends of the tubes Fig. A.

• If there are any sticking/slackening points, repeat the operations to adjust the steering head.

FRAME/FRONT FORK CHECK

CHECK

Park:

• The bike on a level surface.

NOTE:

Support the motorbike correctly, so that it cannot fall over.

Check:

• The fork stem "A" Fig. A.

• The fork sleeve "B" Fig. A. If there is any damage/lines, replace

• Oil seal If there are any leaks, replace

Keep:

• The bike upright.

Enable:

• The front brake

Check:

• Fork operation.

Push hard on the handlebars several times and make sure that the front fork slides easily back into place.

• If the movement is not smooth, repair.

A

B

- 63 -

CHK

ADJ

FRAME/REAR SHOCK ABSORBER CHECK

SHOCK ABSORBER ADJUSTMENT

NOTE:

Support the motorbike correctly, so that it cannot fall over.

Adjustment

• Adjust the spring preload Fig. A

The rear shock absorber is ! tted with an adjustment ring nut for the pre-load of spring *A and a return ring nut (D) *

.

(**)Shock absorber ring nut adjustment tool

Code:......................

• To increase the spring's preload and therefore make the suspension more rigid, turn the adjustment ring nut “A” in direction (B).

• To reduce the spring's preload and therefore make the suspension softer, turn the adjustment ring nut “A” in direction (C). At the end of the adjustment, tighten the return ring nut (D).

IMPORTANT NOTICE:

To avoid damaging the mechanism, do not try turning over the maximum or minimum setting.

D

A

C

B

A

B

+

E

-

Position Distance

Min. Max. 10 mm

Adjustment

• Adjustment of the hydraulic brake action in extension Fig. B

It is possible to adjust the hydraulic brake device using the adjustment screw "E" using a screwdriver

• Turn it clockwise to increase the brake action and anticlockwise to reduce it.

0 mm

.

IMPORTANT NOTICE:

To avoid damaging the mechanism, do not try turning over the maximum or minimum setting.

- 64 -

CHK

ADJ

FRAME/REAR AND FRONT TYRE CHECK

0

1

2

3

CHECK

The following procedure applies to both tyres.

Check:

• Tyre pressure and if it is not within the speci! ed levels, adjust. Fig.A.

WARNING:

Tyre pressure must be checked and adjusted only when the wheel is at ambient temperature. Tyre pressure and suspensions need to be adjusted according to total weight (including baggage, rider, passenger and accessories) taking into account the riding speed envisaged. Riding the bike when overloaded may cause damage to the tyres, with the risk of accident or injury.

NEVER OVERLOAD THE BIKE UNDER ANY CIRCUMSTANCES.

Position Wear limit (A)

Net weight (with oil and full fuel tank)

Maximum load* See general speci! cations COLD TYRE PRES-

SURE

Up to 90 kg load*

90 kg ~ maximum load*

See general speci! cations

FRONT REAR

2.4 bar 2.4 bar

2.4 bar 2.6 bar

A

B

C

B

*Including baggage, rider, passenger and accessories.

WARNING:

It is dangerous to ride with worn treads. If the tread reaches wear limits, replace the tyre immediately

Check:

• The tyre surface Fig.B.

If there is any damage/wear, replace the tyre.

Minimum tread depth "A"

A. Tread depth B. Side C. Signs of wear

.

WARNING:

If tyres are new, their grip on the road will not be as good as when they are slightly worn. Therefore, we recommend riding at normal speeds for the ! rst 100 km, before going at speed.

- 65 -

CHK

ADJ

ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE

BATTERY

WARNING:

Batteries can generate explosive gas containing nitrogen and they contain electrolyte, comprised of sulphuric acid, which is a poisonous and highly caustic substance. Therefore, the following precautions are required:

• Wear protective goggles when handling the battery or working near it.

• Batteries must be charged in suitably ventilated areas.

• Keep batteries away from • re, sparks or naked • ame (for

example: welding accessories, lit cigarettes).

• NEVER SMOKE while charging or handling batteries.

• KEEP BATTERIES AND ELECTROLYTE WELL OUT OF REACH OF CHILDREN.

• Do not allow electrolyte to come into contact with any are of the body as it can cause serious burns or permanent injury to eyes.

FIRST AID IN CASE OF CONTACT:

EXTERNAL CONTACT

• Skin: wash with water.

• Eyes: Wash with plenty of running water for 15 minutes and seek immediate medical attention.

INGESTION

• Drink large amounts of water or milk, then milk of magnesium, beaten egg or vegetable oil. Seek immediate medical attention.

IMPORTANT NOTICE:

This battery is sealed. Never remove the sealed caps under any circumstances, as this will damage the balance between the cells and affect battery performance. Charge time, amperage and voltages for this battery are different from those of conventional batteries. Charge the battery as illustrated in the • gures. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take the utmost care while the battery is charging.

NOTE:

Given that the battery is sealed, it is necessary to check the charge by measuring the density of the electrolyte. Therefore, the battery charge is checked by measuring the voltage on the battery terminals.

Removal:

Remove the passenger seat, using the wrench provided

• and remove the rider's seat with the release knob (A) Fig, A.

A

- 66 -

CHK

ADJ

ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE

Relazione tra la tensione a circuito aperto e il tempo di ricarica a 20°C

Tempo ricarica (ore)

Questi valori variano col variare della temperatura, della condizione delle piastre della batteria e del livello di elettrolito.

Tensione a circuito aperto (V)

11.5

12

12.5

13

5 6.5 10

Tensione a circuito aperto (V)

Stato di ricarica della batteria (%)

100 75 50 30 25 0

20

10

11

12

13

14

Temperatura ambiente 20 °C

BATTERY

Disconnect:

• The cables from the terminal batteries Fig. B

IMPORTANT NOTICE:

Disconnect the negative cable from the battery "A" ! rst, then the positive cable "B" Fig. B

Disconnect:

• The battery

• Remove the 2 screws "C" fastening the battery lock bracket and remove the battery "D".

Check:

• Battery charge

Connect a pocket tester to the battery terminals Fig. C

Check the battery charge as shown in the tables below Fig.D.

NOTE:

A battery charge can be checked measuring the voltage in an open circuit (the voltage when the positive terminal is disconnected). If the open-circuit voltage is equal to or over 12.8 V required.

EXAMPLE:

- Open circuit voltage = 12.0 V

- Charge time = 6.5 hours

- Battery charge = 20 ~ 30 %

-

Charge:

• Battery (see ! gure with the appropriate charge method).

, no charge is

B

D

A

B

C

IMPORTANT NOTICE:

Do not subject the battery to rapid charging.

WARNING:

- Never remove the caps sealing the battery.

- Never use fast chargers as they emit a high amp current into the battery at high speed; this can overheat and damage the battery.

- If it is not possible to adjust the charge current of the battery charger, take care not to overcharge the battery.

- The battery must be removed from the bike for charging. (If it is necessary to charge the battery with it ! tted on to the bike, disconnect the negative cable from the battery terminal).

- To reduce the possibility of sparks, connect the battery charger to the power supply only after connecting the cables to the battery.

- Before removing the clips from the battery terminals, remember to switch off the charger.

- Make sure that the clips on the battery charger cables are completely in contact with the battery terminals and that there are no short circuits. A corroded terminal may generate heat in the contact area, while an inef! cient terminal spring may cause sparks.

- If the battery overheats at any time during charging, disconnect the charger and leave the battery to cool before

continuing. Overheated batteries can explode#

- As illustrated in Fig. F, the open circuit voltage of a battery

D

Relation between the open circuit voltage and the charge time at 20°C

Voltage at open circuit (V)

Charge time (hours)

These values change according to modi! cations of temperature, battery plates conditions and electrolyte level

E

Room temperature 20 °C

Voltage at open circuit (V)

Battery charge status (%)

- 67 -

CHK

ADJ

ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE

Tensione a circuito aperto (V)

Controllare la tensione

a circuito aperto.

0 10 20 30 40 50 60

10

11

12

13

14

15

16

17

18

ricarica

BATTERY

stabilises within 30 minutes or so after the charge is complete, before measuring the open circuit voltage.

recharge

Voltage at open circuit (V)

F

Check voltage at open circuit

- 68 -

CHK

ADJ

ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE

Ruotando la rotella di

regolazione

della tensione di ricarica,

impostare

la tensione di ricarica

su 20 ~ 24 V.

Tenere sotto controllo

l’amperaggio

per 3 ~ 5 minuti

per verificare

se la corrente di carica

standard viene raggiunta.

Se la corrente non supera

la corrente di

carica standard

una volta trascorsi

5 minuti, sostituire la

batteria.

Se per la ricarica sono necessarie più di 5 ore, è consigliabile controllare la corrente di carica dopo 5 ore. Se si verificano variazioni dell’amperaggio,regolare nuovamente la tensione per ottenere la corrente di carica standard.

Misurare la tensione a circuito aperto della batteria dopo averla lasciata per più di 30 minuti inutilizzata.

12.8 V o superiore La ricarica è completa

12.7 V o inferiore Ricarica necessaria. Inferiore a 12.0 V Sostituire la batteria.

Misurare la tensione a circuito aperto

prima di procedere con la ricarica.

Collegare alla batteria un

caricabatterie e un amperometro

e iniziare la ricarica.

Verificare che la corrente sia più elevata

del valore standard della corrente di

ricarica riportato sulla batteria.

Regolare la tensione in modo

tale che la corrente sia al livello

di carica standard.

Impostare il tempo in base

al tempo di ricarica adatto

per la tensione a circuito

aperto.

Vedere le istruzioni

incluse alla batteria.

NO

SI

A

Caricabatterie

Amperometro

BATTERY

CHARGE METHOD USING A CHARGER WITH VARIABLE CURRENT (VOLTAGE)

NOTE:

- Measure the voltage 30 minutes after switching off the equipment.

- Set the charge voltage to 16 ~ 17 V. (A lower setting will not give suf• cient charge.

- A setting that is too high will overload the battery).

Battery charger

Ammeter

Measure the voltage at open circuit before

charging

YES

Set the voltage so that the current is equal to

In case it takes more than 5 hours for charge, it is recommended to check the charge current after 5 hours. In the event of amps changes, set again the voltage to obtain the standard charge current

standard charge level

Set time according to charge time suitable for the voltage in an open circuit. Refer to instructions supplied with the battery

Connect a battery charger and an ammeter

to the battery and start charging

Check the current is higher than the standard value of the charge one indicated on

the battery

YES

By rotating a charge voltage

setting roller, set the charge

voltage to 20 ~ 24 V

Monitor the amps for 3 ~ 5

minutes to check if the standard

charge current is reached

Should current not exceed the standard charge current after 5 minutes, replace the battery

Measure the battery open circuit voltage after a downtime of 30 minutes.

12.8 V or higher > Charge is complete

12.7 V or lower >Charge necessary Lower than 12.0V > Replace the battery

- 69 -

CHK

ADJ

ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE

Questo tipo di caricabat-

terie non può essere

utilizzato per ricaricare

queste batterie. Si consiglia

l’uso di un caricabatterie a

tensione variabile.

Misurare la tensione a circuito aperto

prima di procedere con la ricarica.

Collegare alla batteria un

caricabatterie e un amperometro

e iniziare la ricarica.

Verificare che la corrente sia più elevata

del valore standard della corrente di

ricarica riportato sulla batteria.

Caricare la batteria finché la

tensione di carica

non arriva a 15 V.

Misurare la tensione a circuito

aperto dopo aver lasciato la batteria per più di 30 minuti

inutilizzata.

12.8 V o superiore La ricarica è completa.

12.7 V o inferiore Ricarica necessaria.

Inferiore a 12.0 V Sostituire la batteria.

NOSI

A

V

Voltometro

Caricabatterie

Amperometro

BATTERY

CHARGE METHOD USING A CHARGER WITH CONSTANT VOLTAGE

NOTE:

- Measure the voltage 30 minutes after switching off the equipment.

- Set the charge time to a maximum of 20 hours.

NOTE:

- To guarantee maximum performance and duration for the battery which are able to provided the correct charging voltage and current, based on the speci! cations required

for sealed battery technology.

, we advise using electronic chargers,

Charge the battery until charge voltage

Measure the voltage in an open circuit

YES

Connect a battery charger and an ammeter

to the battery and start charging

Check the current is higher than the standard value of the charge one indicated on

reaches 15 V

before charging

the battery

Voltage

This kind of charger cannot be used for charge these batteries. It is recommended to use a charger with varia-

ble voltage

Battery charger

Ammeter

Measure the open circuit voltage after a battery downtime of 30 minutes.

12.8 V or higher. Charge is complete.

12.7 V or lower. Charge necessary.

Lower than 12.0V. C. Change the battery

- 70 -

CHK

ADJ

ELECTRIC SYSTEM/CHECK AND BATTERY CHARGE

BATTERY

Install:

• The battery

• Tighten the 2 screws “C” fastening the battery bracket.

Connect:

• The cables from the battery (to the battery terminals)

IMPORTANT NOTICE:

First connect the positive cable "B" of the battery, then the negative cable "A" Fig. G.

Check:

• The battery terminals If dirty, clean with a metal brush.

If there are any loose connections → Reconnect them properly.

ELECTRICAL SYSTEM/FUSE CHECK

FUSES

The following procedure applies to all fuses.

IMPORTANT NOTICE:

To avoid short circuits, always switch off the main switch by setting it to "OFF" when checking or replacing fuses.

• Remove the passenger seat, using the wrench provided and remove the rider's seat with the release knob (A) Fig, A.

• Open the fuse box "B" Fig. B

G

D

A

B

C

A

Check:

• the fuse

Connect a pocket tester to the fuse and check continuity.

NOTE:

Set the tester selector to “Ω x 1”

If the pocket tester reads “∞”, replace the fuse.

•

Replace:

• Burnt fuses.

- Turn the main switch to "OFF".

- Fit a new fuse with the correct amperage.

- Switch on the switches to make sure that the electrical circuit is working,

- If the fuse burns out immediately, check the power circuit.

WARNING:

Never use a fuse with amperage other than the one speciﬁ ed. The use of makeshift techniques or of fuses with the incorrect amperage may cause irreversible damage to the electrical system, causing operating defects in the lights and ignition, or even cause ﬁ re.

A

- 71 -

CHK

ADJ

ELECTRICAL SYSTEM/FUSE CHECK

FUSES

KEY TO FUSES

Refer to Fig. C

A. Fuel Pump :15A (blue)

B. Fan:15A (blue)

C. CD2 (power unit):15A (blue)

D. CD1(power unit):15A (blue)

E. Services: 40 A(red)

F. Headlamps: 15A(blue)

G. Spare fuse 40A (red)

H. Spare fuse 15A (blue)

I. Spare fuse 15A (blue)

B

C

B A

D E F

I

H

G

- 72 -

CHK

ADJ

ELECTRICAL SYSTEM/HEAD LAMP REPLACEMENT

REPLACEMENT

The following procedure applies to headlamps only.

IMPORTANT NOTICE:

Given that the lamp reaches very high temperatures inside the light, we recommend not touching it until it has cooled.

Remove:

• The two screws "A" fastening the front lamp to the plate Fig.A.

• Lower the headlight and remove the protective cap "B" Fig. B

• Disconnect the lamp.

Install:

• Insert the new lamp

Connect:

• Connect the new lamp to the connectors.

• Fit the cap.

• Raise the headlamp and fasten the two screws removed previously.

A

B

- 73 -

CHK

ADJ

ELECTRICAL SYSTEM/HEADLAMP ADJUSTMENT

T

.

R

.

REMOVAL/INSTALLATION

Remove:

• The two screws "A" fastening the front lamp to the plate Fig.C.

• Lower the lamp.

• Remove the screw "B" fastening the headlamp to the hinge of the lamp support "C" Fig. D

• Disconnect the connector to the headlamp "D" and the four cables connecting the two indicators "E".

Install:

• To install the headlamp, follow the same steps for its removal, this time in reverse order.

• Secure the fastening screws "A" with Loctite and with the following torque

Torque 10 N*m

C

A

D

E

C

B

- 74 -

CHK

ADJ

ELECTRICAL SYSTEM/HEADLAMP ADJUSTMENT

ADJUSTMENT

To adjust the beam from the headlight correctly:

• Place the vehicle about 10 metres away from a vertical wall

on a perfectly ﬂ at surface. Fig. A.

• Sit on the bike in the rider's position.

• Make sure that the upper limit of the beam as shining on the wall, is lower than 1/10 of the horizontal axis of the headlamp.

• If the beam does not fall within these limits, make the adjustments to set it to the correct position,

Adjust:

• The headlamp beam using the adjustment screw "A" in the bottom right of the light, at the back. Fig. B

Turn the screw anticlockwise to raise the beam. Turn the screw clockwise to lower the beam.

A

h

9:10

10 m

B

A

- 75 -

CHK

ADJ

ELECTRICAL SYSTEM/REAR LAMP REPLACEMENT

REPLACEMENT

Remove:

• The passenger seat "A" at the back, using the tool provided Fig.A.

• The two fastening screws of the plastic tail section "B" to the side tail sections "C" and "D"

• The three fastening screws "E" Fig.B>

• Remove the cap protecting the connector

• Disconnect the connector

Replace:

• Remove the rear light and replace with a new one.

Install:

• To install the rear light, follow the same steps for its removal, this time in reverse order.

B

A

D

C

B

E

ELECTRICAL SYSTEM/LICENCE PLATE LAMP REPLACEMENT

REPLACEMENT

Remove:

• The screw "A" Fig.C.

• The rubber lamp holder "B" Fig.C.

• The park light

•

Install:

• To install the licence plate light, follow the same steps for its removal, this time in reverse order.

C

B

A

- 76 -

CHK

ADJ

ELECTRICAL SYSTEM/REAR INDICATOR REPLACEMENT

REPLACEMENT

The following procedure applies to both rear indicators.

Remove:

• The passenger seat at the back, using the tool provided Fig.A.

• Remove the protective cap

• Disconnect the electrical connections "A" of the indicators, orange-green and illustrated in Fig. D.

• Remove the clips fastening the cables on the licence plate holder.

• Remove the support nuts for the rear indicators "B" Fig, E

• Remove the indicators and replace with new ones.

Install:

• To install the new indicators, follow the same steps for their removal, this time in reverse order.

D

A

E

B

- 77 -

CHK

ADJ

ELECTRICAL SYSTEM/FRONT INDICATOR REPLACEMENT

REPLACEMENT

The following procedure applies to both front indicators.

Remove:

• The two screws "A" fastening the front lamp to the plate Fig.F.

• Lower the lamp Fig. G.

• Disconnect the electrical connections "B" of the indicators, orange and green/black Fig. H.

• Remove the support nuts for the indicators "C" Fig.H

• Remove the indicators and replace with new ones.

Install:

• To install the new indicators, follow the same steps for their removal, this time in reverse order.

F

A

G

B

H

C

- 78 -

CHAS

Frame

CHAS

CHAPTER 4

- 79 -

CHAS

CHAPTER 4

FRAME

FRONT WHEEL AND BRAKE DISCS .................................................................... 81

FRONT WHEEL REMOVAL ......................................................................................................................81

REMOVAL/INSTALLATION OF BRAKE DISCS ........................................................................................82

CHECK OF BRAKE DISCS .......................................................................................................................84

WHEEL AXLE CHECK ..............................................................................................................................85

CHECK/REPLACEMENT OF WHEEL BEARINGS ...................................................................................86

FRONT WHEEL INSTALLATION ..............................................................................................................87

REAR WHEEL AND BRAKE DISC ........................................................................ 88

REAR WHEEL REMOVAL .........................................................................................................................88

SPROCKET AND REAR BRAKE DISC REMOVAL ..................................................................................90

WHEEL AXLE CHECK ..............................................................................................................................91

CHECK/REPLACEMENT OF WHEEL BEARINGS ...................................................................................92

SPROCKET CHECK AND REPLACEMENT .............................................................................................93

BRAKE DISC ASSEMBLY .........................................................................................................................93

BACK TYRE INSTALLATION ....................................................................................................................94

FRONT AND REAR BRAKES ................................................................................ 95

REMOVAL AND INSTALLATION OF FRONT BRAKE PADS ....................................................................95

REMOVAL AND INSTALLATION OF REAR BRAKE PADS ......................................................................96

FRONT BRAKE PUMP REMOVAL ...........................................................................................................97

REAR BRAKE PUMP REMOVAL ..............................................................................................................99

FRONT BRAKE PUMP INSTALLATION ...................................................................................................101

REAR BRAKE PUMP INSTALLATION .....................................................................................................103

FRONT BRAKE CALLIPER TIGHTNESS ................................................................................................105

REAR BRAKE CALLIPER ........................................................................................................................106

CHECK THE FRONT AND REAR CALLIPERS .......................................................................................107

FRONT BRAKE CALLIPER INSTALLATION............................................................................................108

REAR BRAKE CALLIPER INSTALLATION ..............................................................................................110

FRONT FORK ......................................................................................................... 112

FRONT FORK STEM REMOVAL .............................................................................................................112

FRONT FORK STEM DISASSEMBLY .....................................................................................................114

FRONT FORK STEM INSPECTION ........................................................................................................117

FRONT FORK STEM ASSEMBLY ...........................................................................................................118

FRONT FORK STEM FITTING ................................................................................................................121

HANDLEBAR .......................................................................................................... 122

HANDLEBAR REMOVAL .........................................................................................................................122

HANDLEBAR INSPECTION.....................................................................................................................124

HANDLEBAR INSTALLATION .................................................................................................................125

STEERING HEAD ................................................................................................... 126

REMOVAL OF THE TOP AND BOTTOM STEERING BASE ...................................................................126

TOP AND BOTTOM STEERING BASE INSPECTION.............................................................................128

TOP AND BOTTOM STEERING BASE FITTING .....................................................................................129

REAR SHOCK ABSORBER ................................................................................... 130

REAR SHOCK ABSORBER REMOVAL ...................................................................................................130

REAR SHOCK ABSORBER CHECK .......................................................................................................131

REAR SHOCK ABSORBER FITTING ......................................................................................................132

TRANSMISSION CHAIN AND SWINGING ARM ................................................... 133

TRANSMISSION CHAIN REMOVAL ........................................................................................................133

TRANSMISSION CHAIN INSPECTION ...................................................................................................133

SWINGING ARM FITTING .......................................................................................................................136

- 80 -

CHAS

FRAME .................................................................................................................... 138

FRAME FITTING ......................................................................................................................................138

REAR FRAME FITTING ...........................................................................................................................141

LICENCE PLATE HOLDER FITTING .......................................................................................................143

LICENCE PLATE HOLDER REMOVAL ....................................................................................................144

CYCLING ................................................................................................................ 145

STAND FITTING: ......................................................................................................................................145

STAND REMOVAL ...................................................................................................................................146

REAR FOOTREST INSTALLATION .........................................................................................................147

REAR FOOTREST REMOVAL .................................................................................................................148

LEFT FRONT FOOTREST INSTALLATION .............................................................................................149

RIGHT FRONT FOOTREST FITTING ......................................................................................................151

RIGHT FRONT FOOTREST REMOVAL ..................................................................................................152

EXHAUST ............................................................................................................... 153

EXHAUST INSTALLATION.......................................................................................................................153

EXHAUST ASSEMBLY REMOVAL...........................................................................................................155

FAIRING .................................................................................................................. 156

EXHAUST PIPE PROTECTION INSTALLATION .....................................................................................156

EXHAUST PIPE PROTECTION REMOVAL .............................................................................................156

FRONT MUD GUARD INSTALLATION ....................................................................................................157

FRONT MUD GUARD REMOVAL ............................................................................................................158

REAR MUD GUARD INSTALLATION ......................................................................................................159

REAR MUD GUARD REMOVAL ..............................................................................................................160

TANK CAP FITTING .................................................................................................................................161

TANK FITTING .........................................................................................................................................163

TANK REMOVAL ......................................................................................................................................163

TANK COVER FITTING ...........................................................................................................................164

TANK COVER REMOVAL ........................................................................................................................165

FAIRING FITTING ....................................................................................................................................166

FAIRING REMOVAL .................................................................................................................................167

COWL FITTING ........................................................................................................................................168

COWL REMOVAL .....................................................................................................................................168

COMPLETE HEADLAMP FITTING ..........................................................................................................169

FULL REAR LIGHT REMOVAL ................................................................................................................170

TAILPIECE FITTING ................................................................................................................................171

TAILPIECE REMOVAL .............................................................................................................................172

- 81 -

CHAS

FRONT WHEEL AND BRAKE DISCS

FRONT WHEEL REMOVAL

Park:

• The bike on a level surface

NOTE

Place the bike on a suitable support so that the front wheel is raised.

Remove:

• the fastening screws “A” from both brake callipers Fig. A

Detach:

• the left front calliper

NOTE

Repeat the above procedure for the right brake calliper.

NOTE

Do not pull the front brake lever while removing the callipers.

Loosen:

the setscrews “B” Fig.B

•

Remove:

• the front wheel pin “C” Fig. C

• front wheel

• The left shim “D” Fig.C

A

B

C

D

- 82 -

CHAS

FRONT WHEEL AND BRAKE DISCS

5

3

4

1

2

1

2

6

7

REMOVAL/INSTALLATION OF BRAKE DISCS

Position Description Quantity

1 COUNTERSUNK HEX-HEAD SCREW M8X16 8.8 ZB 12

2 FRONT BRAKE DISC 2

3 LEFT SHIM 1

4 FRONT WHEEL RIM 1

5 VALVE 1

6 FRONT WHEEL PIN 1

7 ADHESIVE 2

- 83 -

CHAS

FRONT WHEEL AND BRAKE DISCS

T

.

R

.

1

2

6

3

4

5

REMOVAL/INSTALLATION OF BRAKE DISCS

Removal:

• Once the wheel has been removed from the fork, remove the 6 screws (1) fastening the two discs (2). Fig A

In case of replacement of the two discs, proceed as described:

Fitting:

• Insert the front brake disc (2) on the edge of the rim (4)

• Insert the 6 fastening screws (1) after putting a drop of thread locker (medium type) on the end of the thread.

NOTE

Repeat the above procedure for the front right brake disc. The procedure below applies to both brake discs. Tighten the bolts on the brake disc in successive steps and proceeding in a crossover fashion Fig A.

• Tighten the 6 screws with the following torque:

Torque 22N*m

A

- 84 -

CHAS

FRONT WHEEL AND BRAKE DISCS

T

.

R

.

1

2

6

3

4

5

CHECK OF BRAKE DISCS

The procedure below applies to all brake discs. Check:

• the brake disc If there is any damage/abrasion, replace.

Measure:

• The deformation of the brake disc.

If out of speci! ed values, correct the deformation or replace the brake disc.

Brake disc Deformation limit

Front 0.1 mm Rear 0.15 mm

• Place the bike on a suitable support so that the wheel is raised.

• Before measuring the bending of the front brake disc, turn the handlebar right and then left to make sure that the front wheel stops.

• Remove the brake calliper.

• Keep the gauge at a right angle to the surface of the brake disc.

• Measure the bending 1.5 mm (0.05 in) under the edge of the brake disc Fig.A.

Adjust:

• The deformation of the brake disc.

• Remove the brake disc.

• Turn the brake disc, moving it one hole per bolt Fig.B.

• Fit the brake.

A

B

NOTE

Tighten the bolts on the brake disc in successive steps and proceeding in a crossover fashion Fig.C.

Tightness torque:

Brake disc Tightness torque

Front 22 N.m Rear 10 N.m

C

- 85 -

CHAS

3

FRONT WHEEL AND BRAKE DISCS

CHECK OF BRAKE DISCS

Measure:

• Brake disc thickness.

• Measure the brake disc thickness in several different points Fig.D.

• If outside speci• cations, replace.

Brake disc Wear limits

Front A

Rear A

FRONT WHEEL AND BRAKE DISCS

WHEEL AXLE CHECK

Check:

• Wheel axle.

• Roll the wheel axle “A” on a ! at surface Fig.A.

If there is any warping, replace.

WARNING

Do not try to straighten the wheel axle if it is warped.

Check:

• Tyre

• Front wheel

If there is any warping, replace.

D

A

Measure:

• The radial eccentricity of the wheel “B” Fig.B.

• The side eccentricity of the wheel “C” Fig.B.

If the speci• ed limit is exceeded, replace.

Eccentricity Limit

Radial(B)

Side(C) 1 mm

0.05 mm

B

C

B

- 86 -

CHAS

FRONT WHEEL AND BRAKE DISCS

CHECK/REPLACEMENT OF WHEEL BEARINGS

Check:

• Wheel bearings

If the front wheel turns irregularly or is loose, replace the wheel bearings.

Replace:

• Wheel bearings

Remove the wheel bearings “A” using a general bearing extractor Fig.B. Fit the new wheel bearing, following the removal steps in reverse order.

IMPORTANT NOTICE

During the bearing insertion, do not touch the inner seat “B” or the ball bearings of the wheel “C”. Contact must only occur with the outer seat of bearing “D” Fig. C.

NOTE

Use a wrench that is adapted to the diameter of the outer edge “E” of the wheel bearing, Fig.C.

A

B

A

E

D

C

B

C

- 87 -

CHAS

FRONT WHEEL AND BRAKE DISCS

T

.

R

.

T

.

R

.

T

.

R

.

FRONT WHEEL INSTALLATION

Fitting:

• Insert the full wheel, complete with discs, between the two front fork stems.

• Insert the bushing(3) in the seat at base of the left stem

• insert the wheel pin (6) after greasing it.

• Tighten the wheel pin using the speci• c tool.

(**) tool to tighten the front wheel column.

Code:......................

Tightness torque:

Torque 60 N*m

• Insert the two screws “B”, and tighten by hand.

• compress the fork two-three times so as to settle the wheel pin (6) Fig.B

• Tighten the two screws “B” with the following torque:

Torque 8 N*m

Fit:

• the right brake calliper, inserting the fastening screws “A”, after greasing them with the special copper grease Fig. C.

• Tighten the two screws “A” with the following torque:

A

6

3

B

Torque 45 N*m

NOTE

Repeat the above procedure for the left brake calliper. Make sure that there is enough space between the brake pads before • Check that the path of the brake hose is correct.

tting the callipers to the brake discs.

C

A

- 88 -

CHAS

REAR WHEEL AND BRAKE DISC

1

2

3

4

5

8

10

17

6

14

11

12

9

7

13

16

15

18

REAR WHEEL REMOVAL

Position Description Quantity

1 NUT M24 1

2 ELASTIC RING 1

3 BEARING 1

4 SHIM 1

5 REAR WHEEL RIM (BLACK) 1

6 SCREW 6

7 NUT 5

8 SPROCKET 1

9 CHAIN 137ZRPK 118 LINKS 1

10 SPROCKET SUPPORT FLANGE 2

11 SCREW (M10X41) 5

12 FLEXIBLE COUPLING 5

13 BUSHING 1

14 REAR WHEEL PIN 1

15 VALVE 1

16 BUSHING 1

17 REAR BRAKE DISC 1

18 ADHESIVE 2

- 89 -

CHAS

REAR WHEEL AND BRAKE DISC

REAR WHEEL REMOVAL

Park:

• The bike on a level surface

NOTE

Place the bike on a suitable support so that the rear wheel is raised.

Remove:

• the fastening screws “A” from the brake calliper Fig. A

Detach:

• the brake calliper.

• Completely slacken the transmission chain tension.

• Move the wheel forwards and free the transmission chain from the sprocket Fig. B.

Remove:

• The nut(1) and pin (14).

NOTE

During this stage, take care as the following parts will also be separated: chain tensioner “B” adjustments Fig B sprocket side and brake disc side, and the brake calliper support plate “C“ Fig.A.

Remove:

The bushing (16) brake disc side (FigC) e the shim (4)

• sprocket side (FigD).

A

C

B

DC

- 90 -

CHAS

REAR WHEEL AND BRAKE DISC

17

6

8

10

11

12

7

SPROCKET AND REAR BRAKE DISC REMOVAL

Brake disc removal:

• Once the rear wheel has been removed, take out the brake disc.

• Unscrew the 6 fastening screws (6) and take out the brake disc (17) Fig. A

Sprocket removal:

• Once the rear wheel has been removed, take out the sprocket (8) Fig.B.

• Take out the 5 fastening nuts (7) and separate the sprocket from the ! ange (10).

• Separate the ! ange (10) from the screws (11) and the ! exible couplings (12).

Check:

• Sprocket support ! ange.

If there is any cracking/damage, replace.

• Flexible couplings.

]If there is any damage or wear, replace.

A

B

- 91 -

CHAS

REAR WHEEL AND BRAKE DISC

WHEEL AXLE CHECK

Check:

• Wheel axle.

• Roll the wheel axle “A” on a ﬂ at surface Fig.A.

If there is any warping, replace.

WARNING

Do not try to straighten the wheel axle if it is warped.

Check:

• Tyre

• Front wheel If there is any warping, replace.

Measure:

• The radial eccentricity of the wheel “B” Fig.B.

• The side eccentricity of the wheel “C” Fig.B.

If the speci! ed limit is exceeded, replace.

Eccentricity Limit

Radial(B) Side(C) 0.05 mm

0.05 mm

A

B

C

B

- 92 -

CHAS

REAR WHEEL AND BRAKE DISC

CHECK/REPLACEMENT OF WHEEL BEARINGS

Check:

• Wheel bearings If the front wheel turns irregularly or is loose, replace the wheel bearings.

Replace:

• Wheel bearings Remove the bearings from the wheel ”A” with a generic bearing extractor Fig.B. Fit the new wheel bearing, following the removal steps in reverse order.

IMPORTANT NOTICE

During the bearing insertion, do not touch the inner seat “B” or the ball bearings of the wheel “C”. Contact must only occur with the outer seat of bearing “D” Fig. C.

NOTE

Use a wrench that is adapted to the diameter of the outer edge “E” of the wheel bearing, Fig.C.

A

B

A

E

D

C

B

C

- 93 -

CHAS

REAR WHEEL AND BRAKE DISC

T

.

R

.

8

10

11

12

7

T

.

R

.

17

6

SPROCKET CHECK AND REPLACEMENT

Check:

• The sprocket If more than 1/4 of each tooth is worn, replace the sprocket. If the teeth are bent, replace the sprocket.

1. 1/4 teeth

2. Correct

3. Transmission chain roller

4. Sprocket

Sprocket replacement:

• Once the rear wheel has been removed, take out the sprocket, as described in the previous section.

Replace:

• Clean the sprocket ! ange (10) with a clean rag, especially the surfaces touching the sprocket.

• Insert the 5 fastening nuts (7) and tighten to the following torque.

Torque 45 N*m

NOTE

1

A

3

2

4

B

Tighten the self-locking nuts in several stages, proceeding with a crossover sequence.

REAR WHEEL AND BRAKE DISC

BRAKE DISC ASSEMBLY

Brake disc assembly:

• Once the rear wheel has been removed, take out the brake disc, as described in the previous paragraph.

• Clean the sprocket ! ange with a clean rag, especially the surfaces touching the disc.

Fit:

• The brake disc (17) and the 6 screws (6) Fig. A

• Use thread locker (medium type) on the end of the thread.

Tighten the fastening screws to the following torque:

Torque 10 N*m

NOTE

Tighten the self-locking nuts in several stages, proceeding with a crossover sequence.

A

- 94 -

CHAS

REAR WHEEL AND BRAKE DISC

T

.

R

.

T

.

R

.

12

13

9

11

13

12

BACK TYRE INSTALLATION

Fit:

• Pre-assemble the bracket supporting the brake (11), inserting the parts (13) and (12).

• Insert the bushing (16) on the sprocket side and (4) on the brake disc FigB.

• Insert the chain tensioner adjustment devices “A” on the sprocket side and “B” on the disc brake side Fig.C

Fit:

• The rear wheel

Lubricate and install:

• The pin (14)

• Tighten the nut (1) to the following torque FigC:

Torque 80 N*m Fit:

• The brake callipers and respective fastening screws to the following torque:

Torque 25 N*m

NOTE

Apply copper grease the fastening screws of the brake calliper before tightening. Make sure that there is enough space between the brake pads

before ! tting the calliper to the relevant brake discs.

A

B

4

16

IMPORTANT NOTICE

Check that the path of the brake hose is correct.

A B

C

1

D

- 95 -

CHAS

FRONT AND REAR BRAKES

REMOVAL AND INSTALLATION OF FRONT BRAKE PADS

Removal:

• Use a Philips screwdriver to remove the centering pin “A” of the pads Fig.A.

NOTE

During the extraction phase of the pin “A”, it is necessary to hold down the safety spring “B” Fig.A

• Remove the worn pad Fig.B

Measure:

• The wear limit for the brake pads.

If outside speci! cations, replace the brake pads as a block.

Pads Wear limits

Front

Fitting:

• Proceed to install, following the steps for removal in reverse order.

Check:

• The brake " uid level “B” Fig.C

If below the minimum notch, top up with the recommended brake " uid until it is at the correct level.

Check:

• Brake lever operation.

If the brake lever is soft or spongy to the touch, bleed the brake circuit.

1 mm

A

B

C

- 96 -

CHAS

FRONT AND REAR BRAKES

REMOVAL AND INSTALLATION OF REAR BRAKE PADS

Removal:

• Remove the two fastening screws “A” from the brake calliper Fig. A.

• Remove the centering pin “B” from the pads, freeing it from the safety O-ring “C”.

NOTE

During the extraction phase of the pin “B”, it is necessary to hold down the safety spring “X” Fig.A

Take out:

• The brake pads “D” and shims “E” Fig.B.

Measure:

• The wear limit for the brake pads.

If outside speci! cations, replace the brake pads as a block.

Pads Wear limits

Rear

Fitting:

• Proceed to install, following the steps for removal in reverse order.

Check:

• The brake " uid level “B” Fig.C

If below the minimum notch, top up with the recommended brake " uid until it is at the correct level.

Check:

• Brake pedal operation.

If the brake lever is soft or spongy to the touch, bleed the brake circuit.

1 mm

E

C

X

A

B

A

B

D

E

C

B

- 97 -

CHAS

FRONT AND REAR BRAKES

15

12

13

14

16

17

11

8

10

5

9

6

5

7

3

1

5

4

7

2

18

20

19

21

5

FRONT BRAKE PUMP REMOVAL

Position Description Quantity

1 RADIAL PAD PAIR 8

2 FRONT BRAKE HOSE 1

3 RIGHT BRAKE CALLIPER (RADIAL) 1

4 LEFT FRONT CALLIPER (RADIAL) 1

5 GASKET 7

6 SPECIAL SCREW 1

7 RUBBER TIP 1

8 SCREW 2

9 SPECIAL SCREW 1

10 SCREW 1

11 FRONT BRAKE PUMP 1

12 SELF-LOCKING NUT 1

13 SCREW (M6X12) 1

14 WASHER 1

15 FRONT BRAKE LEVER 1

16 MICROSWITCH 1

17 BRACKET 1

18 FRONT BRAKE HOSE 1

19 SPECIAL SCREW 1

- 98 -

CHAS

FRONT AND REAR BRAKES

FRONT BRAKE PUMP REMOVAL

Position Description Quantity

20 DRAIN 1

21 DRAIN PLUG 1

Removal:

NOTE

Drain out the brake ! uid before proceeding with these operations.

Follow the disassembly sequence shown below:

Remove the special screw (9) and the relevant gaskets (5).

•

• Take out the front brake hose (2).

• Remove the “X” connection of the front brake microswitch (16) Fig.A.

• Remove the microswitch (16) by unscrewing the screw (13) and the washer (14).

• Remove the nut (12) and the fastening screw (10).

• Take out the front brake disc lever (15).

• Unscrew the screws (8) fastening the bracket (17).

• Take out the pump.

IMPORTANT NOTICE

during the disassembly stage, do not allow any brake ! uid remaining in the circuit to drip onto the vehicle.

A

X

- 99 -

Benelli 2014 BN600 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual