Benelli TORNADO NAKED TRE R160 Owner's Manual

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Owner’s manual 2010
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Owner’s Manual 2010
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GENERAL INFORMATION
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INDEX
1 General information 7
1.1 Symbols 8
2.1 Safety 11
2.1.1 Motorcycle modification and trim personalization 11
2.1.2 General safety regulations 12
2.1.3 Vehicle load 14
2.1.4 Use of the vehicle in competitions 15
2.1.5 Advices for safe riding 15
2.1.6 Protective clothing 18
2.1.7 Suggestions against theft 19
2.2 Safety- Visual and acoustic signals 20
3 Controls and instruments 21
3.1 Location of controls and instruments 21
3.2 Sidestand 22
3.3 Handlebar controls, left side 23
3.4 Handlebar controls, right side 25
3.5 Ignition switch and steering lock 27
3.6 Gear lever 29
3.7 Instruments and warning lights 30
3.7.1 Multifunction display 31
4 Operation 32
4.1 Using the motorcycle 32
4.2 Preriding checks 33
4.3 Running-in 35
4.4 Selecting the display functions 36
4.5 Adjusting the clock 39
4.6 Parking the motorcycle 40
4.7 Saddle disassembly driver 41
4.8 Saddle disassembly passenger 41
4.9 Refuelling 42
4.10 Starting the engine 44
4.11 Improve our riding skills 45 5 Adjustments 46
5.1 List of adjustment 46
5.2 Recapitulatory table of adjustment 48
5.3 Adjustments that can be done by user 49
5.3.1 Front brake lever adjustment 49
5.3.2 Adjusting the rearview mirrors 49
5.3.3 Front projector regulation 49
5.3.4 Adjustment of minimum engine 50
5.3.5 Front projector lamps replacement 51
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GENERAL INFORMATIONS
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INDEX
5.4.1 Adjustment lever play 52
5.5 Adjusting the rear suspension 53
5.5 Adjusting the front suspension 53A
5.5.1 Adjusting rear suspension spring preload 55
5.5.1.1 Adjusting front suspension spring preload 55A
5.5.2 Adjusting rear suspension rebound damper hydraulic device 55
5.5.1.2 Adjusting front suspension rebound
damper hydraulic device 55A
5.5.1.2 Adjusting front susp. compression
damper hydraulic device 55B
5.5.3 Adjusting rear suspension compression damper hydraulic device 55
6 Maintenance 57
6.1 Tables of scheduled maintenance 57
6.3 Table of lubricants and fluids 67
6.4 Checking the engine oil level 68
6.5 Checking the coolant level 71
6.5.1 Topping up the coolant 72
6.6 Checking the wear of the brake pads 74
6.7 Checking the brake
6.7.1 Checking the clucth fluid level 76A
fluid level 75
6.8 Checking the tires and rims 77
6.8.1 Check of the rims and the wheel rims 79
6.9 Cleaning checking and lubricating the drive chain 80
6.9.1 Cleaning 81
6.9.2 Lubrification 81
6.10 Checking the idle speed 82
6.11 Replacing the fuses 83
6.12 Battery 85
6.13 Cleaning the motorcycle 86
6.14 Prolonged inactivity 88
6.15 Power control 89 7 Technical information 90
7.1 Specifications 90
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INFORMAZIONI GENERALI
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Dear Customer,
We invite you to read this Owner’s Manual before using your new TORNADO NAKED TRE R160.
It contains important information for a sefe use of the vehicle and to keep it in perfect working order. Keep it by putting it in the
special papers-case compartment.
We remain you, however, that TORNADO NAKED TRE 1130 is a higt performance vehicle thet needs tobe ride with attention and skill.
You better refrain from driving the vehicle out of bounds, if you are not sure of tour ability in managing it; however, when you ride on
public street or open to the public, you have to scrupulously observe the Highway Code.
Always remember to use a homologated helmet, of your size, and always correctly laced up. We recommend you, besides, always to wear
an appropriate protective wear.
1 • INFORMAZIONI GENERALI
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GENERAL INFORMATION
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In order to make more simple and readibly the most important information, we have used the following symbols:
Danger – Warns you that there is a serious instrinsic danger that could cause personal injuries and deadly accidents in case you don’t follow the supplied directions.
Warning – Warns you that there is a danger that could cause personal injuries and deadly accidents in case you don’t follow the supplied directions.
Caution – Reminds you a safety practice you better follow or an unsafety activity you better avoid if you don’t want to risk under go personal injuries or to damage your vehicle.
Reserves the right to make any changes, whenever deemed, to its products and to this manual. Wherever you will find any dissimilarity between what is written on this Owner’s Manual and the specific fitting-out of your vehicle, don’t hesitate to download from the web site Manual, or contact the Customer Service Benelli Q.J. calling +39 0721.41871 , which will arrange to send toyou the new update version.
1.1 • SYMBOLS
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INFORMAZIONI GENERALI
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1. vehicle identication number
2. engine serial number
3. homologation data We recommend writing down the main numbers in the spaces provided below. FRAME No. ZBN ___________________ ENGINE No. ____________________ COLOR CODE ____________________ KEY No. ____________________
1.2 • IDENTIFICATION DATA
2) engine serial number
3) homologation data
1) vehicle identication number
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GENERAL INFORMATION
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1.2 • IDENTIFICATION DATA
Identification motorcycle
The motorcycle is identified by the matriculation frame number.
Motorcycle key identification
The key, supplied in four copies, can be used both for starting the motorcycle and for operating all the locks. Keep the key copies in a safe place. Knowing the key identification number is essential in case you need to ask for a duplicate of the key.
Identification of motorcycle colour combination
The colour code must be mentioned when ordering bodyspares. This code can be read on the labels placed underthe saddle.
Spare parts order
If you need to order spare parts, beside the matriculation frame number, it can be necessary to mention the engine number, the colour code and the key identification number.
key identication number
labels
colour code
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
2.1Safety
2.1.1Motorcycle modification and trim personalization
WARNING It is strictly frobidden to intervent on the vehicle by modifying the mechanical components or by replacing them with non genuine spare parts. All this activities make the vehicle homologation forfait rendering it unusable for public street use, and can also cause serious damages for the user and for the vehicle itself. Benelli Q.J. is not responsable for any damage to persons or things caused by any modifications of the motorcycle original conditions.
It is possible to personalize the suspension trim by working on the special adjustments this activity is absolutely unwary unless the user is absolutely confident in his technical ability. The trim adjustment can compromise the motorcycle safe use and, therefore, it has to be done only by expert persons. Wherever you want to personalize the motorcycle trim in relation to your personal requirements, we suggest you to apply to a Benelli Q.J. Authorized Workshop. You can find the Benelli Q.J. Authorized Workshop list on Benelli Q.J. web site www.benelli.com or calling the Benelli Q.J. Customer Service dialling +39 0721.41871.
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INFORMAZIONI GENERALI
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2 • SAFETY INFORMATION
2.1.2 General safety regulations
Before you start riding make sure you keep in mind the controls, characteristics, working and limits of the motorcycle. In order to guarantee the vehicul maximum efficiency and reliability it is essential that your Benelli Q.J. Authorized workshop does all the maintenance operations written on the “Maintenance” section of this Owner’s Manual, following carefully all the directions and suggestions.We advise you against having the maintenance operations and the repairs done by persons or workshop that don’t belong to the Benelli Q.J. Authorized Workshop net. Especially we advise you against doing on your own themaintenance operations and the repairs on your TORNADO NAKED TRE R160! For any necessity or further information don’t hesitate to apply to your Benelli Q.J. Distributor or to the nearest BenelliQ.J. Authorized Workshop. You can find the Benelli Q.J. Distributor and the Benelli Q.J. Authorized Workshop list onthe web site www.benelli.com or calling the Benelli Q.J. Customer Service dialling +39 0721.41871. The full control of this motorcycle is basic for a safe riding. Therefore it is necessary to start riding with a good concentration and in perfect physical conditions, apare from always assessing the street and atmospheric conditions.In order to avoid compromising handling and stability of your motorcycle, you should obey the following warnings:
• do not attach any object to the vehicle;
• do not hook a sidecar, a tow or any other accessory to the motorcycle;
• do not remove any part and/or component;
• do not modify the vehicle in any way;
• do not wear garments that could adversely affect control and handling of the motorcycle.
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
Do not ride this motorcycle if you do not possess a regular driving licence. Failure to heed this warning constitutes a breach of the Highway Code, besides posing a serious hazard to the driver’s and other people’s safety.Always wear a helmet, even on short rides.Always wear suitable clothes, especially when travelling by night (e.g. garments with fluorescent bands). When refuelling, switch off the engine and refrain from smoking. Do not start the engine in closed places. Exhaust gases are toxic and can quickly saturate the air and cause faintingor even death.While riding, always keep both hands on the handlebars.Park the vehicle where it is unlikely to be bumped into or damaged. Even slight or involuntary bumps can cause thevehicle to topple over, with subsequent risk of serious harm to people or children. To prevent the vehicle from tipping over, never park it on soft or uneven ground, nor on asphalt strongly heated by the sun.Do not cover your motorcycle with a canvas soon afterwards riding. Before covering your motorcycle, wait until the engine and the exhaust pipes have thoroughly cooled. If your motorcycle has been involved in an accident, check all levers, wires, hoses, brake calipers and other mainparts for damage. Do not use the vehicle if you detect a damage that could adversely affect safety. As soon as possible and, kowever, before using your motorcycle after an accident, even if there are not any visible damages, it is necessary to have it inspected by a Benelli Q.J. Authorized Workshop, in order to erify the absence of defects and/or damages that the owner could not be able to detect.
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
2.1.3 Vehicle load
The vehicle is designed for use by the rider with a passenger. To drive safely and under the highway code, never exceed the maximum allowed total gross weight of 400 kg (881.84 Lbs). That is the sum of the motorcycle, driver, passenger and load weight, according to the EEC 92/61 directive.
WARNING Since the load can strongly affect handling, braking, performance and safety characteristics of your motorcycle, you should always keep in mind the following warnings.NEVER OVER LOAD YOUR MOTORCYCLE! Driving an overloaded motorcycle can cause damage to the tyres, loss of control of the vehicle and serious injury. Check that the total of driver and passenger weight, the burden weight and the vehicle gross weight never exceed the granted values.Never carry any incorrectly fastened object on your motorcycle, because it could move from its position during riding. Steadily fasten the heaviest objects near the center of the motorcycle, and equally divide the load on both sides of the vehicle. Do not insert any object in the spaces on the frame trellis, in order to avoid interferring with the movable parts of the motorcycle. Before riding, always check the wear and the pressure of the tyres. Adjust the suspensions according to the load. Even if the motorcycle is correctly loaded, drive with caution and never exceed 130 km/h (80.6mph) when you carry a load.
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
Your TORNADO NAKED TRE R160 was projected for road use.However, making some modifications, considering the high performances that the motorcycle can reach, it is possible to use it also in competitions. However, you need to remember that once you transform the motorcycle for competitions use, it is nomore suitable for street traffic unless it is brought to its original conditions. To meet the passionate drivers numerous requests, Benelli Q.J. has designed a number of special components for use in competitions and/or sporting events. The use of such components is strictly limited to areas closed to traffic. Failure to observe this restriction constitutes a breach of the Highway Code for which Benelli Q.J. cannot be held responsible.For more information about Benelli Q.J. special components visit the web site www.benelli.com or call tgheBenelli Q.J. Customer Service dialling +39 0721.41871.
WARNING Riding the vehicle in competitions requires considerable skill and experience as well as an accurate setup of the motorcycle which was to be made only by perticularly prepared persons.
2.1.5 Advices for safe riding
Besides being a means of transport, your motorcycle is a source of recreation and excitement. (and this is true,especially, when we talk about a TORNADO NAKED TRE R160!).
2.1.4 Use the vehicle in competition
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
However the nature itself of the vehicle involves, a certain amount of risk. To ensure maximum safety, in addition toscrupulously observing the warnings and instructions provided in the previous paragraphs, it is essential to take a few additional precautions.
In particular: Before starting off Follow all the directions given in the section “PRE-RIDING CHECKS”. Conduct an overall check of all safety-related aspects of the motorcycle.
Familiarizing with the vehicle
The rider’s ability and his mechanical skills form the basis of riding safety. It is advisable to practise riding in areas without traffic until you have become familiar with the vehicle and its controls.
Being aware of one’s limits
When riding, never exceed your limits nor those imposed by law. Being aware of your limits and acting accordingly will help you avoid accidents.
Adverse weather conditions
Be very careful when riding in adverse weather conditions. On wet roads, for example, the braking distance increases as a result of reduced tyre traction. It is therefore necessary to travel at moderate speed and avoid a brupt braking and acceleration. Pay particular attention when riding on slippery surfaces such as road markings, manholes, level crossings, bridges, gratings,etc. Considering that a motorcycle cannot provide the same degree of shock protection as a motor vehicle, it is essential to adopt a “defensive” riding attitude, particularly in the adverse weather conditions described above.
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
When riding down long hills, reduce the speed of your motorcycle by closing the throttle and using a low gear ratio to take advantage of engine braking. Use the front and rear brakes as little as possible to maintain your speed, in order to prevent brake overheating and fade.Special attention should be given to the braking system, which plays a key role in ensuring safety. When braking, always take account of the speed of the vehicle and the condition of the road surface.The braking action should always be applied gently and gradually to both wheels. Performing this operation and, more in general, riding the vehicle always requires the utmost care. Therefore,caution should be exercised by all users, and in particular by inexperienced riders. When you make a turn, avoid sudden braking. Failure to observe this warning could lead to the sliding of the wheel sand the loss of control of the vehicle. Always operate the brakes before starting a turn. When you are laterally blown by a sudden gust of wind (as it may happen when you’re over taken by a vehicle ofgreat dimensions, when you come out of a tunnel or when you’re driving in a hilly zone), you could lose control of the vehicle. While driving under the above mentioned conditions, reduce your speed and be careful to avoid sideways gusts of wind. Maintain a safe distance behind vehicles in front of you and adjust your speed to the weather and traffic conditions. Remember that, as your bike picks up speed, stopping distances increase and the motorcycle becomes more difficult to control. In any case, never exceed the speed limits imposed by the Highway Code. It is strictly forbidden to drink alcoholic beverages or take drugs before riding. Even very small amounts of these substances adversely affect the rider’s ability to control the vehicle.
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
HELMET
Wearing the helmet when you ride a motorcycle in many countries, including Italy, is compulsory. However, wherever this obligation doesn’t exist, it is absolutely advisable to wear a helmet, taking care of choosing a homologated and of the right size one. If the helmet has no visor take care of wearing appropriate protective glasses during your riding.The helmet has to be always laced up. If you carry a passenger you better make sure that he wears correctly a homologated helmet. Never wear light helmet DGM (they can be used in Italy only for riding mopeds).
2.1.6 Protective clothing
Always wear suitable protective clothing. In particular, the following items should be worn:
• A close fitting jacket, made of tough material and easy to fasten.
• Supple, reinforced gloves providing both sensitivity and protection.
• Strong, close-fitting trousers covering the legs completely.
• Soft, reinforced boots providing both sensitivity and protection.
In any case, the clothes must allow complete freedom of movement and not hamper the rider in any way.In addition, they must have no loose parts capable of catching in the control levers, the foot rests, the wheels, the drive chain, etc., in order to avoid dangerous situations.
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
WARNING Protective clothes do not afford complete protection against the risk of personal injury in the event of an accident. It is therefore essential not be deceived by the false sense of security that you might perceive by wearing protective clothing. When riding, always adopt a cautious attitudeand follow the recommendations given in the previous paragraphs.
2.1.7 Suggestions against theft
Your TORNADO NAKED TRE R160 is a precious property and, like that, it has to be protected.
• Every time you park your motorcycle, operate the steering lock and remove the ignition key.
• Park your motorcycle in a closed garage every time it is possible.
• Install a good quality anti-theft device on your vehicle.
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GENERAL INFORMATION
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2 • SAFETY INFORMATION
2.2 Safety - Visual and acoustic signals
Before each ride, it is essential to verify the operation of the visual and acoustic signals.
thgilpots dna pmal liaT
thgil gnikrap dna maeb wol ,maeb hgiH
Number plate lamp
Rear turn indicators
Horn
Front turn indicators
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
3.1 Location of controls and instruments
Sidestand
Left side
Right side
Instruments and warning lights
Clutch lever
Left handlebar electrical controls
Ignition switch and steering lock
Fuel tank cap
Front brake lever
Throttle twist grip
Right handlebar electrical controls
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
3.2 Sidestand
The sidestand is equipped with a safety switch that prevents the motorcycle from moving off while the standis down. In case of working engine, with gear engaged and clutch lever pulled, the switch automatically turns off the engine by cutting the current supply. If the motorcycle is parked (sidestand down) and the gears are engaged, the switch prevents the engine from being started, there by avoiding the risk of accidentally toppling the vehicle.
Check in any way the sidestand position before riding.
Sidestand
Safety switch
Dual return spring
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
3.3 Handlebar controls, left
High beam flasher button Press the button repeatedly.
Control Lights
Lights on Low or high beam on
Control Turn indicator Shifting the lever to the left or right switches
on the left or right turn indicators. The switch then returns to the central position. Press to turn off the indicators.
Horn button Press to operate the warning horn.
Clutch lever Move towards/away from the handgrip to
release/engage the clutch.
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
Clutch lever
It is used to engage/disengage the clutch.
Control Lights
Pushing the switch you can turn the side lights into the headlights or dipped headlights.
Low/high beam button
When the light switch is in the position, the low beam is on. The high beam can be switched on by pressing the button when allowed by the traffic and road conditions.
Control Turn indicator
It is used to show the rider’s intention to change direction or lane.
WARNING: Failure to switch the turn indicators on or off at the right time may cause an accident. Always switch on the indicators before turning or changing lanes. Then be sure to switch off the indicators after completing the operation.
Horn button
It is used to attract the attention of other road users in case of danger.
High beam flasher button
It is used to attract the attention of other road users in case of danger. When the high beam is on, the function is inactive.
Start button
It is used to visualize all the functions of the LCD display.
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
3.4 Handlebar controls, right side
Front brake lever
Pull to the lever to apply the front brake.
Engine stop switch
Stops the engine and prevents it from being restarted.
Throttle twist grip
Rotate counterclockwise to increase engine speed.
Engine start button The push button must be released as soon as the motor
is switched on. Pressing the button 3 seconds after the motor starting, you can use the display functions.
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
Engine stop switch
It is used to switch off the engine in an emergency. The ignition circuit is disabled, preventing the engine from being restarted. To be able to restart the engine, return the switch to the “ON” position.
Under normal conditions, do not use this switch to shut off the engine.
Front brake lever
It controls a hydraulic circuit that operates the front wheel braking system.
Throttle twist grip
It controls the fuel-air mixture supplied to the engine, which regulates engine speed. To increase engine speed,rotate the hand grip from its idle position counterclockwise.
Engine start button
This device permits the motor starting, pushing the steering clutch , if it is used 3 seconds after the motor starting, you can use the display functions.
To avoid damaging the electrical equipment, be sure not to hold down the button for longer than 5 consecutive seconds. If, after some attempts, the engine does not start, contact your authorized Benelli Q.J. service center.
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
3.5 Ignition switch and steering lock
WARNING Do not attach a ring or any other object to the ignition key as they may hinder the steering action. Never attempt to change the switch functions while riding,as you may lose control of the vehicle. Alwa ys check the absen ce o f an y restriction in the steering action befero you ride.
The ignition switch enables and disables the electrical circuit and the steering lock. The four positions of the switch are described below.
OFF position
All electrical circuits are deactivated. The key can be removed.
ON position
All electrical circuits are activated. The instruments and warning lights perform the self-diagnostic cycle. The engine can be started. The key cannot be removed.
ON
OFF
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
“LOCK” Position
Turn the handlebar to the left. Press the key in gently while rotating it to the LOCK position.All electrical circuits are deactivated and the steering is locked. The key can be removed.
“P” Position
CAUTION Do not leave the key on the P position fora long time, in order to avoid dischargingthe battery of your motorcycle.
Turn the key from the LOCK position to the P position(parking). All electrical circuits are deactivated except the parking lights (position lights). The steering is locked.The key can be removed.
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
3.6 Gear lever
WARNING Only operate the change gear with the clutch lever fully pulled.6
TheN (neutral) position is indicated by the warning light on the instrument panel.To change into first gear, push the lever down.To change into second gear, lift the lever up. Lifting the lever up repeatedly engages all the other gears in succession up to the sixth speed.
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
3.7 Instruments and warning lights
The instruments and warning lights are activated by turning the ignition switch to the ON position. After a preliminary check the displayed information reflects the current general condition of the motorcycle.
High beam warning light (blue)
Lights up when the high beam is activated.
Warning lights
Turn indicator light (green)
Lights up when the turn indicators are activated.
Reserve fuel indicator (amber)
Comes on when approximately 5 litres of fuel are left; in this case, ll up the tank as soon as possible.
Multifunction display
Water temperature indicator
Indicates the cooling water temperature expressed in Celsius degrees (°C).
Tachometer
Indicates the engine rpm expressed in thousands.
Neutral indicator (green)
Lights up when the gears are in neutral.
Injection warning light (orange)
Lights up in case of the injectors failure; in this case, contact an authorized service center as soon as possible.
Alarm led
Lights up when the oil pressure or the coo ling water tempeare not correct (more than one anomalies may occur simultaneously); at th e s ame time, the writings “OIL”,“H2O” ,“BAT” start ashing on the tachometer in place of the speed indication. If the a la rm led light s up, i m­mediately stop the vehicle, allows it cool down for a few minutes, check the oil level rature or the battery voltage and top up if necessary. If the problem persists, contact an authorized service center as soon as possible.
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CONTROLS AND INSTRUMENTS
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3 • CONTROLS AND INSTRUMENTS
3.7.1 Multifuction display
Speedometer Measures the speed of the vehicle. The speed can be displayed in kilometres per hour (km/h) temperatuor miles per hour (mph). The full-scale value is 320 km/h (199 mph).
“Total” mileage counter Displays the total distance covered
from 0 to 999999 (km or mi). “Chrono” chronometer Displays the distance covered time expressed in minutes, seconds and
hundredths.
“Clock” Displays the time (0÷12)
and the minutes.
“Trip” mileage counter Displays the partial distance covered, from 0 to 99999.9 (km or mi).
“Lap” trip With the chrono mode it displays the intermediate time; once the chronometer is stopped, it displays the total time.
Fuel level Displays the amount of fuel in the tank
using an 8-bar chart.
Thermometer
Displays the ambient temperature in centigrade degrees (°C) or Farenheit (°F). The range is between
-30 and +50 (°C) or -22 and +122 (°F).
NOTE : when a °F value greater than 99°F is
displayed, the hundreds are not indicated although they are understood.
Service Warning Light
It comes on the first time after 1000 km (600 mi), and then every 5000 km (3100 mi). Whenever it lights up, contact an authorized service center as soon as possible and
carefully follow the indications provided in the maintenance and control tables in this manual. When the warning light goes on, also the writing “Service” starts flashing for 10 seconds every time the vehicle is started, in place of the trip odometer “Trip” writing.
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OPERATION
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4 • OPERATION
4.1 Using the motorcycle
This section provides the basic information needed to correctly operate the motorcycle:
•Preriding checks
•Running-in
•Selecting the display functions
•Adjusting the clock
• Parking the motorcycle
•Saddle disassembly
•Refuelling
•Starting the engine
•Improve our riding skills
PROTECT THE ENVIRONMENT Benelli Q.J., in order to protect the interests of the community, awakens the Customers and the Technical Assistance operators to use the vehicle and dispose of its replaced parts respecting the laws in force concerning environmental pollution and waste disposal and recycling.
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OPERATION
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4 • OPERATION
4.2 Preriding checks
A motorcycle can be in good running order and then become unexpectedly unreliable even if unused (e.g. deflation of the tyres, battery discarge, and so on…). It is therefore important tocarry out the checks described in the table below before each ride. A few moments taken tocarry out these checks will help you maintain your motorcycle safe and in perfect working order.If any of the above-mentioned parts shows a failure during its operation, have it controlled andrepaired by a Benelli Q.J. Authorized workshop before using the motorcycle.
Brakes
Gear lever
Clutch lever
Engine start button/ stop switch
Throttle twist grip
Check fluid level. Check for fluid leakage. Pull lever and press pedal to check brake operation.
Press pedal to check gear operation.
Pull lever and check that it moves smoothly and gradually.
Check operation.
Check that grip rotates smoothly and returns to closed position when released.
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OPERATION
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4 • OPERATION
4.2 Preriding checks
Steering system
Lights, visual and acoustic signals
Tyres
Suspensions
Frame fasteners
Drive chain
Fuel
Coolant
Engine oil
Verify that the operation is smooth and uniform. Check for play and loosening.
Check operation.
Check inating pressure and wear.
Verify that the operation is smooth and uniform.
Check clearance or slackening.
Check clearance absence and lubrication presence.
Check level. Refuel, if necessary. Check for fuel leakage.
Check level. Check for leakage.
Check level. Check for leakage.
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OPERATION
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4 • OPERATION
4.3 Running-in
Failure to observe the indications provided below can reduce performance and shorten the lifeof the motorcycle.
Running-in is generally considered to apply only to the engine. In fact, it should be regarded as an essential phase for other important parts such as the tyres, the brakes and the drive chain. During the very first miles, adopt a relaxed riding style.
In particular, observe for the first 2500 km (1600 mi) the max revolutions number indicated in the table. After the running-in period, above 2500 km (1600 mi), the engine is “hot” and can be run to its maximum speed.
km
0 to 500 Km
500 to 1000
Km
1000 to 2500
Km
rpm max.
5000 rpm
7500 rpm
9000 rpm
ATTENZIONE
New tyres must undergo a proper running-in period to reach their complete efficiency. Avoid abrupt acceleration, turning and braking during the first 100 km (62,5 mi). Failure to observe these prescriptions can lead to the sliding of the wheels and the loss of control of the vehicle with subsequent risk of accidents
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OPERATION
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4 • OPERATION
4.4 Selecting the display function
ATTENTION The display modification or regulationoperations, must be made 3 seconds after the motor starting.
The display is provided with 3 main functions:
1) “TOTAL”/“TRIP”
2) “CHRONO“/”LAP”
3) “CLOCK“/”TRIP”
To move from the visualisation 1 “Total”/”Trip” to the button for more than 2 seconds. To move from the visualisation 2 “Chrono”/”Lap” to the visualisation 3 press the“Start” button for more than two seconds (when the chronometer is switched off). To switch from function 3 to function 1, keep pressed the“Start” button for less than two seconds.
(Start>2sec)
(Start>2sec with chronometer o)
(Start<2sec)
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OPERATION
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4 • OPERATION
Resetting the trip mileage counters The value of the“Trip” function can be reset pressing two times the START button.
NOTE:The instrument panel has an integrated memory which retains all the parameters even when the engine is not running. Except for the clock, which is reset, all the parameters are retained even when the battery is disconnected.
Set “Chrono” / “Lap” Move to the visualisation 2 To set the “Chrono” press the START button for less than one second. To see the “Lap” from the “Chrono” position, press the START button for less than one second. Each time the START button will be pressed for less than one second , the “Lap” function will indicate the “Chrono time, in the specific moment. To stop the “Chrono” press the START button for less than one second. To stop the “Chrono” press the START button for 3 seconds at least. To leave the “Chrono” position, press the START button for 3 seconds at least, moving to the 3 “Clock” /“Trip”visualisation.
Page 39
OPERATION
38
4 • OPERATION
Set “Clock” / “Trip”
Move to the visualisation 3. To set the timer, push the START button for two seconds at least. The first number starts flashing.
Press continuously the START button for the number regulation until reaching the number you desire. Repeat the same operation to set the second timer number, the first and the second minutes number. Press the START button for three seconds at least, to stop the selection and the flashing. To reset the “Trip” from the visualisation 3 press two times the start START button.
Set “Km” / “Mi”
From the 1 “Total” / “Trip” visualisation, when the motor is switched on, press the START button for at least ten seconds. The Km or Mi symbol will start flashing, press the START button to move to Km or Mi, press for at least two seconds theSTART button, to select the measure unit you desire, moving automatically to the °C o °F selection, press the START button for less than one second to select the temperature unit you desire. Press the START button for at least three seconds, to confirm and exit from the Set “Km” / “Mi” visualisation.
Page 40
OPERATION
39
4 • OPERATION
Set “Service”
When the first 1000 Km (600Mi) will be reached and every 5000Km (3100Mi) you will see the flashing Service pilot light on the display, instead of the partial “Trip”rip” for 10 seconds during the vehicle starting. To reset the Service pilot light, press the START button for at least ten seconds until the pilot light is switched off.
4.5 Adjusting the clock
Switch to function 3 Press the “Start” button (> 2 sec.); the first figure will start flashing. Repeatedly press the “Start” button until the desired figure has been entered. Press the “Start” button (> 2 sec.) to enter the following figure. Repeat the above procedure to enter the second figure of the “hours”, the first and second figure of the “minutes”. Press the “Start” button (> 2 sec.) to confirm the time adjustment and to stop the selection (the flashing).
Page 41
OPERATION
40
4 • OPERATION
4.6 Parking the motorcycle
TORNADO NAKED TRE R160 is equipped with the sidestand. It is possible to separately buy the central backstand.
Using the sidestand
Park the motorcycle safely on solid ground. On slopes, engage the first gearand park the vehicle so that the front wheel faces up hill. Remember to put the gear lever in the neutral position before restarting the engine.
Using your foot, lower the sidestand as far as it will go,and then slowly tip the motorcycle toward you to bring the stand supporting foot into contact with the ground’ssurface.
WARNING Do not sit on the vehicle when it is parked on the sidestand, as your full weight would rest on the vehicle’s only support.
Page 42
OPERATION
41
4 • OPERATION
4.7 Saddle disassembly driver
Insert the key. Press the end part of the saddle and, at the same time,turn the key counterclockwise.Slightly lift the saddle from the rear, slide it backwards and remove it.
4.8 Saddle disassembly passenger
Insert the key. Remove the pilot saddle. Slightly lift the saddle from the rear, slide it backwards and remove it.
1
2
2
1
key supplied
Page 43
OPERATION
42
4 • OPERATION
4.9 Refuelling
Lift the dust cover. Insert the key into the lock, rotate it clockwise and lift the tank cap. After refuelling, press down the tank cap while rotating the key clockwise to facilitate the locking. Then release the key and remove it.
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OPERATION
43
4 • OPERATION
WARNING Petrol and its fumes are highly toxic and flammable. Avoid contact and inhalation. When refuelling,switch off the engine, avoid smoking, and keep away from flames, sparks and heat sources. Perform refuelling in the open air or in a well ventilated area. Overfilling the tank may cause the fuel to overflow as a result of the expansion due to the heat from the engine or to exposure to sunlight. Fuel spills can catch fire. The level of the fuel in the tank must never be higher than the base of the filler. Verify that the tank filler cap is correctly closed before using the motorcycle.
Only use unleaded fuel with a R.O.N. octane rating of 95 or higher. Immediately wipe the overflown fuel with a clean cloth, to avoid damage to the painted or plastic surfaces.
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OPERATION
44
4 • OPERATION
4.10 Starting the engine
As you turn the ignition switch to the ON position, the instruments and the warning lights will go through the self-diagnostic cycle; during this phase, make sure that all the warning lights on the dashboard come on. One of the following conditions must be verified, in order thatthe ignition switch system allows engine starting: The gears are in neutral. The gears are engaged, the clutch lever is pulled and the side stand is up. Press the start button without turning the throttle twist grip. As soon as the engine starts, release the button.
• Do not press the start button for longer than 5 consecutive seconds.
• Avoid warming up the engine while thevehicle is stationary. It is advisable to bring the engine to the
working temperature by riding at reduced speed.
• To ensure the maximum life of the engine, never speed up at full throttle when the engine is cold.
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OPERATION
45
4 • OPERATION
4.11 Improve our riding skills
Riding a motorcycle requires experience and concentration. In experienced riders should under go a period of training and attend an introductory course consisting of theoretical lessons as well as practical riding sessions in areas closed to traffic. The instructor’s advice will help the novice rider become familiar with the basics of riding safety. Relying on the advice of persons other than a qualified riding instructor, even if possessing specific knowledge, may prove to be useless or even dangerous, especially if the practical training takes place in an area open to traffic.
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ADJUSTMENT
46
5 • ADJUSTMENT
5.1 List of adjustment
There are many adjustments that can significantly improve the ergonomics, geometry and safety of the motorcycle.
WARNING To avoid losing control of the vehicle while riding, be sure to always keep both hands on the handlebars. All adjustments must be performed when the vehicle is stationary and, where not otherwise provided in this manual, they have to be done only by Benelli Q.J. Authorized Workshop; in fact, some of these operations can cause a danger for the user’s safety if they are not properly done or if they are unappropriate.
Page 48
ADJUSTMENT
47
5 • ADJUSTMENT
Rearview mirrors adjustment
Gear lever adjustment
Headlight adjustment
Front suspension
adjustment
Clutch lever adjustment
Drive chain
adjustment
Rear suspension adjustment
Back foot brake pedal regulation
Front brake lever
adjustment
Page 49
REGOLAZIONI
48
5 • REGOLAZIONI
5.2 Recapitulatory table of adjustment
TYPE OF ADJUSTMENT
Front brake lever adjustment
Clutch lever adjustment
Rearview mirrors adjustment
Front suspension spring preload
Front suspension adjustment
adjustment
Front projector regulation
Back foot brake pedal regulation
COMPETENCE
User
User
User
User
User
Authorized Dealer
Authorized Dealer
Adjusting rear suspension spring preload
Adjustment of minimum engine rpm
Adjusting rear suspension compression
damper hydraulic device
Drive chain adjustment
Gear lever adjustment
Authorized Dealer
User
Authorized Dealer
Authorized Dealer
Authorized Dealer
and extension
Page 50
ADJUSTMENT
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5 • ADJUSTMENT
5.3 Adjustment that can be done by user
WARNING Never perform the adjustment while rid-ing.
5.3.1 Front brake lever adjustment
Push the lever forward to neutralize the spring thrust and,at the same time, adjust its position in one of the four possible directions by turning the ring nut clockwise oranticlockwise.
5.3.2 Adjusting the rearview mirrors
Move the wing mirror to regulate the position.
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ADJUSTMENT
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5 • ADJUSTMENT
5.3.3 Front projector regulation
For the front projector regulation use the 2 right and left register screws under the projector. The projector can regulate the right and left parable separately, unscrew to lower the light beam, screw to raise the light beam.
5.3.4 Adjustment of minimum engine rpm
Use the screw to adjust the minimum engine rpm. Tightening it will increase the minimum rpm. Loosening it will decrease the minimum rpm.
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ADJUSTMENT
51
5 • ADJUSTMENT
5.3.5 Front projector lamps replacement
For the front projector lamps replacement, remove the right and left inspection covers, of the parable, unscrewing the 3 fixing screws.Remove the burned lamps.
Page 53
ADJUSTMENT
52
5 • ADJUSTMENT
WARNING – The following adjustmentsare reserved to the Benelli Q.J. Authorized Workshops. Never
perform the adjustment while riding.
5.4.1 Clutch lever adjustment
Turn the knob on the lever clockwise and counterclockwise. Turn the knob counterclockwise will move the lever. Clockwise, the lever will move away.
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ADJUSTMENT
53
5 • ADJUSTMENT
5.5 Rear suspension adjustment
Spring preload
Rebound damper hydraulic device
Extension damper hydraulic device
Page 55
ADJUSTMENT
53a
5 • ADJUSTMENT
5.5 Front suspension adjustment
Spring preload
Rebound damper hydraulic device
Extension damper hydraulic device
Page 56
ADJUSTMENT
54
5 • ADJUSTMENT
WARNING The high temperature of the exhaust pipes can cause burns. Before adjusting the rear suspension, shut off the engine and wait until the exhaust pipes have thoroughly cooled. The rear shock absorber contains highly compressed gas. Do not try to open or disassemble it in any way
When you estimate the rear suspension settings, never push or pull in any wayon the exhaust muffler and on the tail.They would be certainly damaged.
Check the rear suspension settings in the position indicated by the arrow. NOTE: At the moment of delivery of the motorcycle, the rear suspension is adjusted in the standard configuration, with damper spring length of 140 mm (5.55 in) [14 mm (0.55 in) of preload].
OK
NO
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ADJUSTMENT
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5 • ADJUSTMENT
5.5.1 Adjusting rear suspension spring preload
Adjust the spring preload by means of the two ring nuts(AandB) shown in the figure. Unloose the ring nut (A)and adjust the preload using the ring nut (B).Turn clockwise for a stiffer preload.Turn anticlockwise for a softer preload.Once the adjustment is over, tighten the ring nut (A).
5.5.2 Adjusting rear suspension rebound damper hydraulic device
Adjusting of the rebound damper hydraulic device is madein jerks. Turn the rule (C) clockwise to increase thebraking action, or turn anticlockwise to decrease it.
5.5.3 Adjusting device hydraulic braking the rear suspension compression.
The setting of the hydraulic braking compression is done in increments. Turn control clockwise (D) to increase the braking action, or turn it counterclockwise to decrease.
5.5.1
5.5.2 5.5.3
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ADJUSTMENT
55a
5 • ADJUSTMENT
5.5.1.1 Adjusting front suspension spring preload
Adjusting of the spring preload is performed by countingthe rule turns (A), either clockwise and anticlockwise.Turn clockwise for stiffer preload adjustment.Turn anticlockwise for softer preload adjustment.
WARNING It is essential that the adjusters of bothfork rods are adjusted to the same position.
5.5.1.2 Adjusting front suspension rebound damper hydraulic device
Adjusting of the rebound damper hydraulic device is madein jerks. Turn the rule (B) clockwise to increase the braking action, or turn anticlockwise to decrease it.
5.5.3
+
-
Giri
A
+
-
Scatti
B
Page 59
ADJUSTMENT
55b
5 • ADJUSTMENT
5.5.1.3 Adjusting front suspension compression damper hydraulic device
Adjusting of the compression damper hydraulic deviceis made in jerks. Turn the rule (C) clockwise to increase the braking action, or turn anticlockwise to decrease it. NOTE:Start adjusting the preload from the “all open” position (direction - ).The compression and rebound adjusting starts rom the “all close” position (direction +).
+
-
CLICKS
c
Spring preload Rebound damper Compression damper
7 turns 1 turn 1/2 turn
FRONT SUSPENSION
Sport
Spring preload Rebound damper Compression damper
7 turns 3 turns 2 turns
FRONT SUSPENSION Standard
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ADJUSTMENT
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5 • ADJUSTMENT
Rear suspension
NOTE:Adjusting of the preload starts from the damper spring length of 140 mm (5.55 in). The compression and rebound adjustment
starts from the “all close” position (direction +).
140 mm
Spring length Rebound damper Spring Preloading
Standard conguration
140 mm (5.55 in) 12 clicks 14 mm (0.55 in)
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MAINTENANCE
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6 • MAINTENANCE
6.1 Tables of scheduled maintenance and checks
WARNING
• Impropriety or lack of recommended maintenance operations can lead to an increase of the risk of
accidents and damage to the motorcycle.
• Always use genuine Benelli Q.J. spare parts. Using non-genuine spare parts can acceleratethe wear of
your motorcycle and shorten its life.
• Failure to perform the recommended operations, as well as using non-genuine spare parts,can cause the
unoperativeness of the legal guaranty. To replace or top up the lubricants and fluids of your motorcycle, use only the suitable products.
PROTECT THE ENVIRONMENT Benelli Q.J., in order to protect the interests of the community, awakens the Customers and the Technical Assistance operators to use the vehicle and dispose of its replaced parts respecting the laws in force concerning environmental pollution and waste disposal and recycling.
The main periodic checks and maintenance operations are shown in the following tables. These operations are necessary to keep the motorcycle safe and in perfect running order.
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MAINTENANCE
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6 • MAINTENANCE
The intervals indicated in the periodic maintenance and lubrication tables must be intended as a general guide under normal riding conditions. It could be necessary to reduce these intervals according to the climate, the ground conditions, the geographic position and the conditions of use. Some of the operations can be carried out by the user, providing he or she possesses the requisite skills and, however, only when explicitly scheduled in this Owner’s Manual. In any other case have the operations performed by a Benelli Authorized Workshop, whose list is available on the web site www.benelli.com or calling the Benelli Coustomer Service dialling +39 0721.41871.
As a rule maintenance operations must be performed while the motorcycle is on the rear stand after switching off the engine and setting the start switch to OFF. On the contrary, while checking the fluid levels it is advisable to keep the motorcycle in an upright position without using the rear stand.
Tables of scheduled maintenance
NOTE:
• The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
• From 40.000 Km, repeat the maintenance intervals starting from 10.000 Km.
• Items marked with an " " should be performed by a Benelli dealer as they require special tools, data and technicalskills.
Code:
I =inspection and adjustment,cleaning,oiling, or change according to need. R =change T =tighten =dealer
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6 • MAINTENANCE
Maintenance Frequency
NO.
Component Chek or maintenance job
0 Km
(0 mi)
Before delivery
1000 Km (621 mi)
1° Running-in
1st
Service
11.000 Km (6.836 mi)
2nd
Service
21.000 Km
(13.051 mi)
3rd
Service
31.000 Km
(19.266 mi)
4rd
Service
41.000 Km
(25.481 mi)
5rd
Service
Annual
Check
1
Engine oil
Check/Change
I R R R R R R
Before every use of the vehicle.
2
Engine oil filter
Check/Change
R R R R R
At every change of engine oil in any case.
3
Petrol filter
Check/Change
R R R R
4
Air filter
Check/Change
I R I R
5
Cooling liquid
Check/Restore level
I I I I I I I
Change
21.000 km every 2 Years in any case.
6
Cooling plant
Check coolant level and vehicle for
coolant leakage
I I I I I I I
7
Sparking-plugs
Check/Change
I R I R
Check condition. Clean and regap.
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MAINTENANCE
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6 • MAINTENANCE
NO.
Component Chek or maintenance job
0 Km
(0 mi)
Before delivery
1000 Km (621 mi)
1° Running-in
1st
Service
11.000 Km (6.836 mi)
2nd
Service
21.000 Km
(13.051 mi)
3rd
Service
31.000 Km
(19.266 mi)
4rd
Service
41.000 Km
(25.481 mi)
5rd
Service
Annual
Check
8
Transmission chain
Chack chain slack. Make sure that the rear wheel is property aligned.
Clean and lubricate
I I I I I I I
Every 500 Km and after washing the motorcycle or rinding in the rain.
9
Crown
Check/Lubricate
I I I I I I I
At every change of the distribution chain in any case
10
Pinion/Stop washer
Check/Lubricate
I I I I I I I
At every change of the distribution chain in any case
11
Oil circulating tubes
Check defects and losses
I R I R I
20.000 Km Every 3 years in any case
12
Brake liquid
Check/Change
I I I I I I I
20.000 Km Every 2 years in any case
13
Front brake/ Rear
brake
Chek operation,fluid level and
vehicle for fluid leakage.
I I I I I I I
14
Brake pads
Check/Change
I I I I I I
Whenever worn to the limit
15
Rear fork pads chain
Check/Change
I I I I I I
Whenever worn to the limit
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MAINTENANCE
61
6 • MAINTENANCE
NO.
Component Chek or maintenance job
0 Km
(0 mi)
Before delivery
1000 Km (621 mi)
1° Running-in
1st
Service
11.000 Km (6.836 mi)
2nd
Service
21.000 Km
(13.051 mi)
3rd
Service
31.000 Km
(19.266 mi)
4rd
Service
41.000 Km
(25.481 mi)
5rd
Service
Annual
Check
17
Fork chain guide
slide
Check/Change
I I I I I I
Whenever worn to the limit
18
Lower frame chain
slide
Check/Change
I I I I I I
Whenever worn to the limit
19
Accellerator
command
Check peration and free play. Adjust
the throttle cable free play if
necessary. Lubricate thr throttle
grip housing and cable.
I I I I I I I
20
Clutch
Check/Adjust play
I I I I I
21
Clutch command
Check/Adjust
I I I I I I I
22
Throttle body
Check/Adjust
I I I I I
23
Valves
Check/Adjust
I I I I
24
Distribuition chain
Check/Change
R
Every 40.000 Km (24900 mi)
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MAINTENANCE
62
6 • MAINTENANCE
NO.
Component Chek or maintenance job
0 Km
(0 mi)
Before delivery
1000 Km (621 mi)
1° Running-in
1st
Service
11.000 Km (6.836 mi)
2nd
Service
21.000 Km
(13.051 mi)
3rd
Service
31.000 Km
(19.266 mi)
4rd
Service
41.000 Km
(25.481 mi)
5rd
Service
Annual
Check
25
Distribuition mobile
pad
Check/Change
R
At every change of the distribution chain in any case
26
Distribuition chain
stretcher
Check/Change
I I I R
At every change of the distribution chain in any case
27
Steering crown
saddle post
Check/Adjust
T T T T T T T
Before every use of the vehicle.
28
Steerin g saddle post
ball-bearings
Check/Adjust
T T T T T T T
Every 20.000 Km (12000 mi).Lubricate with lithium-soap-based grease.
29
Rear/Front wheel
ball-bearing
Check/Change
I I I I R
Every 40.000 Km (24900 mi)
30
Large fork ball-
bearings
Check/Change
I I I I R
Every 40.000 Km (24900 mi)
31
Swingarm
Check operation and for excessive
play. Lubricate with lithium-soap-
based grease.
I I I I
32
Fork
Check operation and for oil leakage.
I I I I
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MAINTENANCE
63
6 • MAINTENANCE
NO.
Component Chek or maintenance job
0 Km
(0 mi)
Before delivery
1000 Km (621 mi)
1° Running-in
1st
Service
11.000 Km (6.836 mi)
2nd
Service
21.000 Km
(13.051 mi)
3rd
Service
31.000 Km
(19.266 mi)
4rd
Service
41.000 Km
(25.481 mi)
5rd
Service
Annual
Check
33
Fork Oil
Change
Every 20.000 Km (12000 mi)
34
Rear damper
Check operation and for oil leakage.
I I I I
35
Wheels
Check ronout and for damage.
I I I I
36
Tires
Check tread depth and for damage.
Replace if necessary. Check air pressure. Correct if necessary.
I I I I I I I
Whenever worn to the limit
37
Sidestend
Check/functioning
I I I I I I I
38
Lateral assemby
stand switch
Check/functioning
I I I I I I I
39
Vision lights/Signals
Check/functioning
I I I I I I I
40
Front headlight
Check/functioning
I I I I I I I
Adjust
At every variation in the state of the vehicle
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MAINTENANCE
64
6 • MAINTENANCE
NO.
Component Chek or maintenance job
0 Km
(0 mi)
Before delivery
1000 Km (621 mi)
1° Running-in
1st
Service
11.000 Km (6.836 mi)
2nd
Service
21.000 Km
(13.051 mi)
3rd
Service
31.000 Km
(19.266 mi)
4rd
Service
41.000 Km
(25.481 mi)
5rd
Service
Annual
Check
41
Horn
Check/functioning
I I I I I I I
42
Instrumentation
Check/functioning
I I I I I I I
43
Battery connections
Check/functioning
I I I I I I I
44
Electical plant
Check/functioning
I I I I I I I
45
Ignition switch
Check/functioning
I I I I I I I
46
Electrofans
Check/functioning
I I I I I I I
47
Electronic fuel
injection
Adjust engine idling speed and
synchronization
I I I I I
48
Carburation / CO°
Check/Adjust
I I I I I
Every 10.000 Km (62500 mi)
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MAINTENANCE
65
6 • MAINTENANCE
NO.
Component Chek or maintenance job
0 Km
(0 mi)
Before delivery
1000 Km (621 mi)
1° Running-in
1st
Service
11.000 Km (6.836 mi)
2nd
Service
21.000 Km
(13.051 mi)
3rd
Service
31.000 Km
(19.266 mi)
4rd
Service
41.000 Km
(25.481 mi)
5rd
Service
Annual
Check
49
Chassis fasteners
Make sure that all nuts, bolts and
screws are properly tightened.
T T T T T
50
Air Box Valve
Check/Change
I I I I I
Check operation.
51
Exhaust plant valve
Check/Change
I I I I I
Check operation, cable free play and pulley position. Replace
52
Inlet outlet valve
actuator
Check/Change
I I I I I
Check operation, cable free play and pulley position. Replace
53
Valve actuator cable
Check/Change
I I I I I
Check operation, cable free. Replace
54
Oil basin screws
Check
T T T T T
55
Clutch cover screws
Check
T T T T T
56
Alternator rubber
even tension device
Change
R R R R
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MAINTENANCE
66
6 • MAINTENANCE
• The air filter element needs to be replaced more frequently when riding in unusually wet dusty areas.
HYDRAULIC BRAKE SERVICE
• Regularly check and,if necessary,correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and change the
brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
NO.
Component Chek or maintenance job
0 Km
(0 mi)
Before delivery
1000 Km (621 mi)
1° Running-in
1st
Service
11.000 Km (6.836 mi)
2nd
Service
21.000 Km
(13.051 mi)
3rd
Service
31.000 Km
(19.266 mi)
4rd
Service
41.000 Km
(25.481 mi)
5rd
Service
Annual
Check
57
Catalyser
Check defects and losses
I I I I R
Maintenance is not envisioned, replace in the case of malfunctioning
58
Cannister USA
version
Check defects and losses
I I R I R
Maintenance is envisioned, replace in case of leaks.
59
Brake hoses
Check/Change
I I I I I I I
Every 4 years
60
Moving parts and
cables
Check/Change
I I I I I I I
Before every use of the vehicle.
Intake oil filter
61
Check/Change
I I I I I I I
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MAINTENANCE
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6 • MAINTENANCE
6.3 Tabella lubrificanti e liquidi
For the availability of the suggested product, Benelli Q.J. suggests to directly apply to the Authorized Dealers or Workshops. If the above described lubricant is not available, Benelli Q.J. suggests to use a fully synthetic engine oil having characteristics equal or better than the ones prescribed in the following standards:
• API SJ • ACEA A3 • JASO - MA
Olio Motore Engine Oil Huile Moteur Motorenöl Aceite Motor
PRO-ACTION 4T
Impianto di Rareddamento Cooling System Sistème de Refroidissement Kühlkreislauf Sistema de Refrigeración
PARAFLU MOTO RIDER
Comando Freni Brake System Circuit Freins Bremsbedienung Sistema de Mando Frenos
Olio Filtro Aria Air Filter Oil Huile de Filtre à Air Luftlteröl Aceite del Filtro de Aire
TOP 4
AIR FILTER OIL
POLES PROTECTION GREASE
Grasso Protezione Poli Batteria Protection Battery Poles Grease Graisse de Poteaux de Batterie Schutzbatterie-Pfostenfett Grasa de los postes de la batería
Grasso Lubricazione Catena Grease for Lubricating Chains Graisse pour Lubrier des Chaînes Fett für das Schmieren der Ketten Grasa para lubricar cadenas
Lubricante Spray Multiuso Multipurpose Spray Lubricant Lubriant Universel Spray Mehrzwecksprayschmiermittel Lubricante Multipropósito Spray
TP 2
6 IN 1
RECCOMENDS
Page 72
MAINTENANCE
68
6 • MAINTENANCE
6.4 Checking the engine level oil
Check the oil level while the engine is not running, andhas been allowed to cool down for at least ten minute safter a ride. Th e check must be perfo rmed after plac ing the motorcycle in an upright position on a horizontal surface.The level must be between the MAX and MIN marks on the crankcase.If the oil level is below the MIN mark, top up.
Do not start the engine if the oil level isbelow the MIN mark.
MAX
MIN
Oil sight glass
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MAINTENANCE
69
6 • MAINTENANCE
6.4.1 Topping up the engine oil level
To top up the engine oil level, remove the oil filler plugand pour an appropriate amount of engine oil of the recommended type. Never exceed the MAX level mark. At the end of the operation, place back the oil filler plug.
To avoid clutch sliding and damage to the engine, never add chemical additives to the engine oil, nor use an engine oil different from the one specified in the table lubricants and fluids. Make sure that no foreign body gets inthe crankcase while topping up the engine oil.
Oil filler plug
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WARNING New or exhaust engine oil can be dangerous. Engine oil is highly toxic for people and domestic animals. In the event of an engine oil ingestion, immediately call a doctor and do not cause vomiting, in order to avoid inhalation of engine oil in lungs. It has been proved that prolonged contact with engine oil can cause skin cancer on guinea pigs. Even a brief contact with engine oil can cause skin irritation.
• Keep new or exhaust engine oil out of reach of children and domestic animals.
• While topping up the engine oil, wear a long-sleeved shirt and a pair of water-proof gloves to protect your
skin.
• If the engine oil comes in touch with your skin, wash it away with soap and water.
• Correctly recycle or dispose of the exhaust engine oil, in order to avoid environmental pollution.
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6.5 Checking the coolant level
Check the coolant level while the engine is off and cold. The check must be performed after placing the motorcycle in an upright position on a horizontal surface. The level in the cup must be included between the MAX and MIN references. In the case the cooling liquid level is under the MIN reference, remove the cup plug and make a topping up, or bring the motorbike in the closest Benelli Q.J. authorized machine shop.
Do not start the engine if the coolant level is below the MIN mark.
Coolant sight glass
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6.5.1 Topping up the coolant level
WARNING This operation has to be performed only by a Benelli Q.J. Authorized Workshop. Perform the topping up of the coolant when the engine is off and cold. Never attempt to remove the coolant filler cap when the engine is hot, in order to avoid the risk of burns. The cooling system is under pressure! Under certain conditions, ethylene glycol contained in the coolant can become flammable. When it is lighted, it produces an invisible flame. Avoid spilling coolant on hot parts of the motorcycle, because the subsequent combustion of ethylene glycol could cause serious burns. Coolant is a highly toxic fluid. Avoid contact and ingestion. Keep coolant out of reach of children and domestic animals. In the event of a coolant ingestion, immediately call a doctor and do not cause vomiting, in order to avoid inhalation of coolant in lungs. If the coolant comes in touch with your skin or eyes, immediately wash it away with water.
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To gain access to the coolant filler cap, remove the passenger saddle.Remove the filler cap and top up using the coolant recommended in the lubricants and liquids table.After the reset time, reassemble carefully the radiator cap and the closing cover.
Coolant can damage painted and plastic parts.When you top up the coolant level, be careful not to spill coolant on any part of the motorcycle. If you do spill coolant on your motorcycle, immediately wipe it away using a clean cloth.
Coolant filler cap
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6.6 Checking the wear of the brake pads
WARNING If the brake pads are excessively worn out, the effectiveness of the braking system decreases,increasing the risk of accidents. Check frequently, from a Benelli Q.J. Authorized Workshop, the wear and tear of the linings and, wherever need, make them replaced. Ensure that the new pads are suitably broken in.
Limit of the wear and tear of the linings A: 3,5 mm (0.14 in).
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6.7 Checking the brake fluid level
WARNING Lack of maintenance of the braking system can increase the risk of accidents. If you notice any anomaly in the working of the braking system, go immediately to a Benelli Q.J. AuthorizedWorkshop. Wherever you suspect that can exsist a serious failure of the braking system, stop immediately the motorcycle and call the nearest Benelli Q.J. Authorized Workshop. Never use your motorcycle if the fluid level is below the MIN mark. The brakes may fail to properly operate, which could lead to an accident. If the brake fluid level is below the MIN mark, you musthave it topped up by an authorized Benelli Q.J. dealer.
Rear brake uid rese rvoir
Front brake uid reservoir
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The level of the brake fluid decreases as the brake pads wear down. Ensure that the fluid level is always between the MAX and MIN marks. If the level falls below the MIN mark, contact a Benelli Q.J. authorized service center and have the brake system over hauled. Have the topping up of the brake fluid performed only by Benelli Q.J. authorized service center. Brake fluid is highly toxic. Avoid contact and ingestion. Keep brake fluid out of reach of children and domestic animals. In the event of a brake fluid ingestion, immediately call a doctor and do not cause vomiting, in order to avoid inhalation of brake fluid in lungs. If the brake fluid comes in touch with your skin or eyes, immediately wash with water. Use only the brake fluid specified in the table lubricants and fluids of this manual. Mixing different brake fluids can cause a dangerous chemical reaction, as well as the decrease of the braking efficiency, with subsequent increase of the risk of accidents. An insufficient amount of brake fluid may allow the introduction of air in the braking system. This could compromise the effectiveness of the braking system, with subsequent increase of the risk of accidents. Presence of air in the braking system can be identified in the moment you feel a characteristic “spongy effect” while pushing the brake pedal. In this case, have a braking system bleeding performed by an authorized Benelli Q.J.dealer before riding your motorcycle again.
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6.7.1 Fluid Clutch
The wear of the friction causes a change in the normal fluid level. In any case, the level should always be included between the MAX and MIN present on the pan, in case apply only to Authorized Workshop Benelli QJ for overall supervision of the facility and a topping up. The clutch fluid is harmful if it comes into contact with skin or eyes and can even be fatal if swallowed. Hold the clutch fluid away from children and pets. If swallowed, call a doctor immediately and do not induce vomiting to prevent aspiration of product into the lungs. If fluid contact with eyes or skin, rinse immediately with plenty of water. Make topping up using only the type of fluid lubricants shown in Table and liquids of this manual. Any mixing between fluids of different types can cause a dangerous chemical reaction and decrease the efficiency of the system. The presence of air in the hydraulic system could be highlighted by a feeling of excessive pliability of the ineffectiveness of command and clutch bleed if done by a dealer Benelli QJ before each ride.
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6.8 Checking the tires and rims
WARNING Before using the motorcycle, alwayscheck the pressure and wear of the tyres. An incorrect inflating pressure can lead to dangerous situations during riding. An insufficiently inflated tyre can cause the sliding of the tyre on the wheel rim orits detachment; this may lead to the deflation of the tyre with subsequent loss of control of the vehicle.
Checking the inflating pressure of the tyres is an essential requirement to ensure driving safety. Insufficiently inflated tyres can reduce the handling of the motorcycle and wear themselves out very quickly.On the other hand, an excessively high inflating pressure reduces the wideness of the surface in contact with the ground, and it can compromise the grip of the vehicle. Before riding your motorcycle, it is therefore necessary to measure the tyre pressure at room temperature.The vehicle must be parked since three hours at least.
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Check the pressure according to the values indicated in the table below:
In the event of long travels, you can increase the face value of the tyre pressure of 0.2 bar. It is extremely important to check the wear of the tyres before riding. In fact, a worn out tyre can be punctured more easily than a new one, and it can adversely affect handling and stability of the motorcycle. Check that the depth of the tyre tread is not below the values prescribed by the Highway Code.Verify the absence of crevices at the bottom of the tread design and fissures on the tyre sidewall. Moreover, verify the absence of nails and glass splinters in the tyre. If these conditions are not verified, have the tyre replaced by anauthorized Benelli Q.J. dealer.
If a tyre is punctured it must be replaced, not repaired. A repaired tyre provides a restricted performance and lower safety levels than a new one. If you make a provisional or emergency repair to a tyre, you must ride at very low speed until you reach the nearest Benelli Q.J.authorized service center and have the tyre replaced. With a provisionally repaired tyre, never exceed 60 km/h (37.2 Mph). Tyre repairing must never be performed if the tyre is punctured onits sidewall, or if the diameter of the puncture on the tread is greater than 6 mm (0.23 in).
Front cool tyre
Back cool tyre
Pressure
250 kPa (2,5 bar)
250 kPa (2,2 bar)
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When it is necessary to replace the tyres, use only the type specified in the technical data table.Moreover, avoid using tyres of a different brand or type on the front and on the rear wheel at the same time. Using tyres different from those specified can adversely affect the handling andstability of the motorcycle, increasing the risk of accidents.
• The wheel rims of your motorcycle have been designed for use with tubeless tyres only. Do not assemble an air tube tyre on rims designed for tubeless tyres. Otherwise, the tyre bead could not properly settle down on the wheel rim, leading to the deflation of the tyre and the loss of control of the vehicle.
• Have the tyres replaced according to their direction of spin, which is high lighted by a small arrow on the tyre sidewall.
• New tyres should be run in for a short period before demanding their full performance.In fact, during this period the tyres could have a reduced grip on some kind of roads. We suggest to ride at reduced speed and exercise extreme caution during the first 100 km (62.5 mi) after there placement of a tyre.
6.8.1 Checking of the rims and the wheel rims Before riding, always verify the absence of cracks, bending or buckling on the wheel rims.
WARNING If you find that the wheel rim is damaged, have it replaced by a Benelli Q.J. authorized service center. Never attempt to repair the wheel rim, even in case of slight damage.Every time you replace a tyre or a rim, you must have a wheel balancing performed. Wheel unbalance can adversely affect performance and handling of the motorcycle, as well asshorten the life of the tyres.
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6.9 Cleaning checking and lubricating the drive chain
To perform this operation, you must put the motorcycle on the rear stand, upright on a horizontal surface and with the gear in neutral.
WARNING Riding your motorcycle when the drive chain is in poor condition or improperly adjusted can lead to accidents. If you notice any anomaly in the working of the drive chain, like suspected noises or excessive loose of the chain, go immediately a Benelli Q.J. authorized service center. Wherever you suspect that can exist a serious failure of the drive chain, stop immediately the motorcycle and call the nearest Benelli Q.J. authorized service center.Every time the chain is replaced, you must always replace the front and rear sprockets too.
Never try to repair or replace a drive chain. It is a complex and particularly dangerous operation and, therefore,it has to be performed by the Benelli Q.J. authorized service centers.
15 mm15 mm
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6.9.1 Cleaning
The chain of TORNADO NAKED TRE R160 is of the O-ring type. To prevent it from damaging, never clean the chain with a steam or high pressure water jet, nor using gasoline or other solvents. The chain must be cleaned using kerosene only. Kerosene is highly toxic and flammable. Avoid contact and inhalation. Keep kerosene away from sparks and flames. Keep kerosene out of reach of children and domestic animals. Correctly dispose of exhaust kerosene, in order to avoid environmental pollution. If you are not sure that you can use kerosene in complete safety, don’t use it and, when you can go to a Benelli Q.J.authorized service center ask for the drive chain cleaning.
6.9.2 Lubrication
Chain lubrication has to be performed only by a Benelli Q.J. authorized service center according to the intervals specified in the tables of scheduled maintenance.It is also necessary to perform this operation after riding under the rain and after cleaning the motorcycle. Riding your motorcycle when the drive chain is in poor condition or improperly adjusted can lead to accidents. To ensure proper operation, the drive chain needs to be properly lubricated.
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6.10 Checking the idle speed
The idle speed should range from 1200 to 1300 rpm. If a tune-up is necessary, contact an authorized service centre.
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6. 11 Replacing the fuses
The replacement of the fuses has to be performed only by a Benelli Q.J. authorized service center. Only in case of extreme urgency and if it is not possible to have a specialized technical assistance, the operation can be carried out by the owner according to the indications provided below.
Turn the ignition key on the “OFF” position before checking or replacing the fuses, in order to avoid a short circuit with subsequent damage to other electric parts of the motorcycle.
The recharge fuse is located on the left side of the motorcycle, in the position shown in the figure.The service fuses are found under the passenger saddle; remove the saddle to gain access to the fuses. Remove the glovebox. Replace the blown fuse and refit the cover. The functions of the various fuses are given in the following legend.
Spare fuse
Recharge fuse
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WARNING Never replace a fuse with a rating other than that precribed, in order to avoid damage to the electrical equipment of the motorcycle which could lead to a fire.
20 A
15 A
20 A
10 A
15 A
15 A
10 A
5A
Lights
Injection
Services
Instrument
Petrol pump
Electric fans
FUSES
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6.12 Battery
The battery is of the maintenance-free type and is installed under the saddles, between the driver saddle and the passenger saddle.This battery does not require checking of the fluid level or adding of distilled water. If the battery seems to be run-down (causing electrical problems or a difficult starting), have it recharged by an authorized Benelli Q.J. dealer as soon as possible. Remember that the battery runs down more quickly if your motorcycle is equipped with additive electrical accessories. Always have the battery replaced by a Benelli Q.J. authorized service center.
WARNING If the battery casing is damaged, there may be a leakage of sulphuric acid, a highly toxic and corrosive substance. Avoid any contact with your eyes, skin and clothes.Always wear protective glasses when you have to work near the battery. In the event of a contact with sulphuric acid, give the FIRST AID as described below:
• CONTACT WITH SKIN: Wash away with a great amount of water.
• INGESTION: Drink great amounts of water or milk, and immediately call a doctor.
• CONTACT WITH EYES: Wash away with water for about 15 minutes, and immediately call a
doctor. Furthermore, leakage of sulphuric acid can result in the formation of hydrogen gas which, ifignited by a spark or a flame, would cause an explosion.
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The inversion of the battery wires can damage the battery and the recharging system. The red wires must be connected to the positive terminal (+), while the black wires must be connected to the negative terminal (-).
If the motorcycle is to remain unused for a long time (a month or longer), it is advisable to disconnect the battery cables or have the battery removed by skilled personnel. In case of prolonged inactivity, to avoid shortening the life of the battery, it is essential to have it recharged by a Benelli Q.J. authorized service center every 4-5 months, in order to guarantee its life in time.
6.13 Cleaning the motorcycle
Periodic careful cleaning is a key factor in preserving the value of the motorcycle, protecting its surface finish and checking for damages, wear and leakage of corrosive fluids.Wash the motorcycle with water, a mild detergent and a sponge. Wipe the vehicle with a soft cloth. Use an air jet todry difficult to reach areas. Periodically treat the paint work with high quality wax. After riding on roads treated with corrosive substances (salt),wash the vehicle as soon as possible with cold water. Do not use hot water as it enhances the corrosive action.
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Do not wash your motorcycle soon afterwards riding. Attend a few minutes to allow the engine and the exhaust pipes to thoroughly cool.
Before washing the vehicle, stop up the exhaust pipes and protect the electrical parts. Never use washing systems involving steam or high pressure water jets. These systems could cause water infiltration and damage the internal parts of your motorcycle. Avoid cleaning the rims with fuel or solvents. Avoid using clothes or sponges that have been in contact with strong or abrasive detergents,solvents or gasoline.To avoid irreparable damage to the front fairing, never use alkaline or strongly acid detergents,petrol, brake fluid or other solvents. Clean the front fairing only with a soft cloth, warm water and a neutral detergent.
WARNING Avoid smearing brakes or tyres with oil or wax. The presence of water on the brakes can lead to a decrease of the braking effectiveness with subsequent risk of accidents. After completing the washing, run the engine for a few minutes and start off at reduced speed. Carefully apply the brakes a few times so as to dry the brake pads and discs.
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6.14 Prolonged inactivity
If the motorcycle is not to be used for a long period, contact a Benelli Q.J. authorized service center to have the following operations carried out:
- Empty the fuel tank.
- Remove the battery and store it in a suitable place.
- Remove the spark plug caps and the spark plugs.
Pour a teaspoonful of engine oil in every spark plug hole, thenplace back the spark plugs and the corresponding caps. Make the engine run idle for a few times.
- Lubricate all control cables and the joints of all pedals and levers.
- Clean the motorcycle and treat the paintwork with high quality wax.
- Park your motorcycle in a fresh, dry and dark place, with a temperature relatively constant and lower than 25° C(77°F).
Avoid direct contact of the tyres with heating pipes or radiators, and prolonged contact with oil or gasoline.Avoid parking with the tyres near to electrical motors or devices capable to produce sparks or electric discharge. During the period of inactivity, place your motorcycle on the rear stand.
- Cover the vehicle with an adequate canvas cover Benelli Q.J. that can be bought as optional.
When the motorcycle is used the first time, carry out a general check and have it serviced at anauthorized service center.
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6.15 Power control
This system allows to select two different settings of the tune:
STANDARD:
With botton in OFF position (light on) the engine performs 137hp (101 KW * )
ECONOMY:
With button in ON position (light off) the engine performs 112 hp (82 KW*) allowing a more linear distribution, a decreased fuel consumption included between 10% and 20 % depending on the road. In particular way it allows an easier control of the bike in low grip condition of the road.
WARNING: Do not activate the Power Control System when the bike is running.
* For counries having power limits standard tune 72 kW.
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Benelli Q.J. reserves the right to make any changes to its models on the purpose of constantly conform them to the technological advance. Therefore the technical data that are shown below, can be different from those that can be checked on the vehicle. Moreover some data, like the performance, are susceptible of alteration in function of the specific recording conditions besides, of course, in function of the typical performance of every vehicle.
7.1 Specification
2100
900
1443
1050
780
Dimensions in mm
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Overall length Max. width Max. height Seat height Wheelbase
DIMENSIONS
2100 mm (82.7 in)
900 mm (35.4 in)
1200 mm (41.4 in)
780 mm (30.7 in)
1443 mm (56.8 in)
Empty weight (without fuel) Weight with fuel
Maximum weight techni­cally acceptable with pilot, passenger and loading.
WEIGHT
205 kg (451.9 Lbs)
215 kg (474 Lbs)
400 kg (882 Lbs)
Type
Displacement Number of cylinders Cylinders position
Bore stroke
Compression ratio Idle speed Distribution
Starting Clutch Lubrication Cooling
Filter oil
ENGINE
four-stroke 12 valves
DOHC
1130 cc
3
aligned inclined by 15°
forward
88 x 62 mm
(3.5 X 1.94 in)
Double-overhead
camshaft
Electric starter
Dry clucth Wet sump
With liquid heat
exchanger water / oil
Polyurethan dry sponge
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Maximum net power
Maximum net torque
116 KW (135CV)
to 10200 rpm
120 Nm to
8400 rpm
Recommended fuel
Fuel tank capacity
Reserve fuel
FUEL
Lead-free premium
petrol
16.5 lt (4.4 Gal)
5 lt (1.3 Gal)
Type
Spark plug
Spark gap
IGNITION - POWER SUPPLY
“WALBRO TDD“
integrated
ignition-injection
system.Inductive
discharge electronic
ignition, “Multipoint”
electronic injection.
CHAMPION RG4HC\
NGK CR9E
0,7 ÷ 0,8 mm
(0.028 ÷ 0.032 in)
Recommended oil
Total
Quantity without oil lter cartridge replacement
ENGINE OIL
API SJ 15W/50
(Synthetic)
JASO - MA CC MC G4
4 lt (1 Gal)
3.8 lt (0.8 Gal)
Primary Number of teeth on crankshaft gear Number of teeth on clutch gear Transmission ratio
TRASMISSIN
Z = 44
Z = 79
1.795
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SUSPENSIONS
Front
Secondary Number of teeth on front
sprocket Number of teeth on rear
sprocket Transmission ratio
Z = 16
Z = 36
2.25
Type
Gear ratio in rst (overall ratio)
Gear ratio in second (overall ratio)
Gear ratio in third (overall ratio)
GEAR SPEED
Removable, six-speed
gearbox with
constantmesh gears
2.786 (11.252)
1.994 (7.851)
1.524 (6.155)
Gear ratio in fourth (overall ratio)
Gear ratio in fth (overall ratio)
Gear ratio in sixth (overall ratio)
1.304 (5.267)
1.167 (4.713)
0.926 (4.362)
Type
FRAME
Steel-aluminium mixed
solution
Type
“Upside down”
telescopic hydraulic fork
50 mm
120 mm (4.7 in)
Rod diameter Travel range
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Type
Swingarm Wheel travel range
Progressive, with mono
shock absorber which
can be in extension
regulated,
spring-loaded.
Steel trestle
120 mm (4.5 in)
Rear
Type
Disc diameter Disc ange Pincers
BRAKES
Double steel oating
wave disc
320 mm (12.6 in)
Aluminium alloy
4-piston
Front
Type Disc diameter Caliper Calipers, piston diameters
Single steel disc
240 mm (9.5 in)
2-piston
32 mm (1.3 in)
Rear
Type Material Dimensions
RIMS
Five spokes
Alluminium alloy
3,50” x 17”
Front
Rear Type Material Dimensions
Five spokes
Alluminium alloy
6,00” x 17”
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Type Dimensions Maximum inating pressure
Type Dimensions Maximum inating pressure
TYRES
Tubeless
120/70 - ZR 17 (58 W) *
250 kPa
2,8 bar
Tubeless
190/55 - ZR 17 (73 W) **
2,8 bar
Front
Rear
Equipment voltage Low beam High beam Front light Rear light - Brake light Front turn indicators Battery Alternator
ELECTRICAL EQUIPMENT
12V 12V - 55W 12V - 55W
12V - 5W
12V - 21W
12V - 3 x 5W
12V - 12 Ah
480W to 5000 rpm
* 120/65-ZR 17 56W
** 180/55-zr 17 (73W) 190/55-zr 17 (73W) 200/55-zr 17 (73W)
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