Benelli 900 Sei Instruction manual

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F.lli
Benelli
$.p.4.
-E----
Additions
andchange
to theworkshop
manual
for500ouattro
-7s0sei

INDEX
MAIN FEATURES :page 1
MAINTENANCEOPERATIONS ]I ,-
.
7 Clutch
lever
adjustment
15 Carburation
16 Valve
gearing
18 Valve tappetclearance
adjustment
20 lgnition advance
adjustment
TOROUEWRENCH
SETTINGS ,
page 8
SPECIAL
TOOLS page I
ENGINE , page..10
'l Cylinder
head,
cylinder
blockand
pistons
5 Clutch
9 Gearbox,
primary
drive
anddesmodromic
FRAME page
i9
1 Front and
rear
brake
3 Front and rearwheel
7 Front fork
8 Rear
suspensions
:I ELECTRICALEOUIPMENT page28
1 Electronicignition
2 Alternator-generator
!I WIRING
DIAGRAM page
31

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MAIN FEATURES
t
)
ENGINE I four
stroke
- number
ofcylinders I sixin
line
- bore
x stroke | 60x 53.4
mm
- displacement | 905.91
cc
- compressionratio | 9.53to 1
- revs
at maxenginespeed | 8400rPm
- horse
power | 80HP
VALVE
GEARING I camshaft
in
thecylinder
head,
chaindriven
- inlet I opens:11obefore
T.D.C.
-
closes:43o
after
B.D.C.
- exhaust I opens:43"
before
T.D.C.
-
closes:
11"afterB.D.C.
- rocker
clearance
for
valve
timing | 0.8
mm
ld engine)
| 0.13to0.l5mm
- normal rocker clearance (cold engine
CARBURATION
- carburettors I three
"Dell'Orto",
type
VHB
24D
LUBRICATION
- normallubrication
pressure
by
pump
"EATON"
type
3.5to
4 kg/sqcm;
oil
pressure
sender
unitfor
warnig
light
- oilfilter I replaceable
cartridge
GENERATO* |
- alternator | 14V -12A
IGNITION I electronic
withmagnetic
control
- clearance
betweentheblock
on the
rotating I
sleeveandthemetalends of each
"pick-up" | 0.20to0.30
mm
- max
ignition
advance | 35obefore
T.D.C.
at5000-5500 rpm
- sparkplugs I MarelliCXSL-BoschX260T2-LodgeHBL12
- plugpoints
gap | 0.5
mm
- igrrrition
coils I N.
3
- firing
order I 14-2-6-3-5
srARrNG I
I
- electric
starter
with electromagnetic ratchet I
control | 12V-0.4HP
E-----

TRANSMISSION
- clutch
- gear
oox
- gear
ratios
1st
gear
2nd
gear
3rd
gear
4thgear
5th
gear
- cardanshaft
-bevel
gear
ratio
FRAME
TI
RES
- front
- rear
- fronttire
pressure
- (ear
tlre
pressure
susPENSroN I
- front I telescopic
front fork with hydraulic
shock
absorbersand
I helicoidal
springs
I
- rcar I swinging
fork and
hydraulic
shockabsorbers
with helicoidal
spnngs
WHEELS
- front
and
rear
rims I light allovcastingswfvl
3/2.15
x 18"
multiple
discsdry type.
Hand
controlled
by lever ontheleft
sideof the
handlebar
five speed,constantmesh gears,
frontal engagement. Pedal
controlled
from
the
L/Hside
ofthe
vehicle
1
to2.454
(Z
:111271
i to 1.666
(Z
:151251
1
to 1.211
(Z
:181231
1to 1.050
(Z:20/21)
i to0.900
(Z
=2Ol18l
1to 2.511
(Z
= 21/54\
doublecradle,tubular
structure
100/90
v 1B
MT
29
120lso
v 18
MT
28
2kg/sqcm
2.3
kg/sqcm
(with
pasenger
2.5
kg/sqcm)
rocker
pedal
onthe
centre
R/H
side
ofthe
bike.
Disc
dia.260
mm
Cylinderdia.
48
mm
Master
cyl.dia.15.87mm
The rear
brake
ishydraulically
connectedto a second
front
brakeof same
type andsize
asthe hand
operated
front
ora
Ke.
BRAKES I
- front I disc
type with caliperhaving
2 cylinders. Levercontrolled
I Ig. Il. yf side
of
the
handlebar.
| ?,.,9
ora.ruu
mm
I Lyrrnoerora.Jö
mm
I tvtastercyl.
dia.
12.7mm
- rear I disctypewith caliper
having
2 cylinders.Controlled
by
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DIMENSIONS
AND
WEIGHT
- wheel
base
(loaded)
- maximum
length
- maximum
height
- width
- dryweight
1.46O
m
(57.4"1
2.110
m
(83.07")
1.130m
(M.48"1
0.690
m
(27.16"1
22O
ks
(485
lbs)
PER
FORMANCES
maximum
speed
fuel
consumption
(CUNA) 215
km/h
approx
(i
33
m.p.h.)
8
| x 100 km
(1.76g
x62mi.)
FUEL
AND
OIL
CAPACITIES
- fuel
tank 16.5
| (supergrade
petrol
98/1
00 NO-RM) 5 lt reserve
included
3 | (AGIP SINT
2000SAE
10W
50
oil)
60cceach
leS
(AGIP
F 1ATF Dexron)
AGIPF 1 Brake
Fluid
SAE
J 1703C
oilsump
front
fork
oil
braking
system
ELECTRICAL
EOUIPMENT
BATTERY
LIGHTS
12V -28
Ah
headlight
(beam)
headlight
(town)
tai
Ilight
(
parking-stop)
indicator
lights
speedometer
- Rev
counter
instrument
panel
lights
't2v-4045W
12V
-
4W
12V
-5121W
12V
-
21W
't2v-3w
12V
-1.2W
N.4 16
A
12V
FUSES
HORN
NB
-All data
herein
containedare
indicative
and
are
subiectto modificationwithout
orior
notice.

fl rvrarNrENANcE
oPERATtoNs
2.7 CLUTCHLEVER
ADJUSTMENT
Checkthat the free play at the handlebaris34 mm
(.12" to .16"),otherwise
acton screw
"4" to restore
the
correct
plav.
lf this adjustment
isnot sufficient
andclutchdoes
not
operate
correctly
(clutch
slipping
orincompletedisenga-
gement)
act
on adjuster
"C" after
slackening
counternut
"D" locatedon the dutch leverat the crankcase.
This
operationcan be performed
afterremoving
plug
"E".
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2.15
CARBURATION
Carburettors
Dell'Orto
type
VHB
24D,
double
controls
Carburettors
settings
:
Choke
Throttle
valve Qzqmm
40
Atomizer
Needle
Main
jet
ldling
jet
Starter
jet
F
loater
ZOUAtr
E
3(2nd
notch)
102
45
50
14
gr

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Synchronisation
of thecarburation
and
idling
speed
adjustment
For
the
aboveoperations
follow
whatis
indicatedin
the
workshop
manualfor 750/Sei
butbearing in mindthat
the
vacuometer
with three mercury
columnshas
to be
connected
to the connectors
purposelyprovided
after
removing
compensating
hose "
A" connecting
the
manifolds,
The threeconnectors
unused
have
to be temporarily
closed
by
means
of
rubber
plugs
"8".
2.16VALVE
GEARING
Tocarry
out
theadiustmentoperate
as
follows:
- Remove
the
fairing
and
fuel
tank.
- Remove
centralhubfromdegree
timing
plate
cooe
69.90.78.52
(704.087
0 799)validfor 750/Sei.
- Fit
ontiming
plate
rhenewhub
63.94.96.20
provided
for model
900 Sei;
payattention
to have
the hub key
trace
turned
on rhe i/6 stamping
sideon the timing
prate.
- Remove
the alternatorfrom the
crankshaft
L/H side
and
fit the timing plate
completewith
hub
and
lock
it
with
bolt
14
71.24.59.
- Secure
the arrow index for timing check code
63.94.75.20inthe
crankcase.
3
5
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- Rotatecrankshaftto bring
piston
of cylinder
n. 1 in
T.D.P.burst position. timing plate
will indicateT.D.P.
O" (ascertain
that this indicationis
correctby fitting a
dial gauge
in spark
plugholein orderthat the member
touching the upper part of the piston indicates
the
T D P.
position).
- Remove
taooetcover.
- Check that, with crankshaft
in the above
position,
a plateof 2.2 mm thickness
fits correctly
in the notch
on the L/H sideof camshaft
(thiscan be obtained
bv
reducing the thickness of plate 6190.79.00
(704.080.0.799)
placed againstthe rear part of the
cylinder
head.
It necessary,
undo the tlvo bolts
lockingthedistribution
gear
on camshaft,
removethe clrainstretcher and
rotate
thecamshaftto obtain
the
abovetiming
position.
- Lock the distribution
gear
on camshaft.
lf the screw
holesdo not correspond, rotate the gear
only till the
holesmatch.
Note: lt can be that to obtain a correct correspondence
of holesit is
necessary
to slipoff thegear
from camshaft
and to rotate it bv 1
80'
- Completethe assembly
paying
attention
to spread
with Loctite
the
gear
fixing
bolts
and
checkthevalve
tappetclearance.
2.18 VALVE TAPPET
CLEARANCE AOJUSTMENT
lmportant: thecyiindersare
numberedfrom 1to 6 f
rom
the left hand
side
of therider's
position.
Check
and if necessaryrestore the
valve
tappetclearance
operating
as
follows.
a remove
the fairing, closethe fuel taps,
renrove
f
uel
line from the fuel valve
body, disconnectthe rearfuel
tank rubber
and
remove
thefuel tank.
b remove the ignition breaker point cover and the
twelvetappetad
justing
hole
caps
"A".
c rotate slowly the crankshaftclockwisetill stamped
trace "G" on rotating
sleeve
is aligned with trace
"H"
stampedon "Pick-up"
centre.
Note: to make easythis operation it is advisableto
remove
thespark
plugs.
At this
point piston
1 or 6 is in position
T.D.C.
if the
trace "E" is aligned with trace "F" stamped
on the
crankcase.The compression
stroke of the one or the
other piston is indicated
by the posirion of the valves
(botlr
closed
).
d check the clearance
of both valvesirr compression
stroke by inserting a thickness
llauge.
lf the clearance
is correct
there
\..rll
be a sliglrt clragof resistance
as
the
gaLrge
is
inserted;aüjrist|'eirtisrrecessary
if the clearance
is
too srlallor excess
ve.
Note: the clrecking
6rrCthe adjustnrentis better
carried
out by fitting a ciial
grairge
togetherwith the special
support
"N".
The starrrpecitappret
cleararrce
is; 0.13 to 0.15 mm
(0.0051
1to000565")
e adJustment is
made by loosening
the tappet scre,/v
nut "F" and turnrnqthe adjustingscrew
"E" till the
correctclearance
is
obtained.
Lock
screw
nut arrdchecktheclearance.
I
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f check
and adjust
the valve
clearance
of the other
cylinders
after having rotated
the crankshaft
aligning
the trace "G" on rotating
sleevewith the traceon
"Pick-up"
centre
of theother
rylinders.
2.20 IGNITIONADVANCE ADJUSTMENT
The electronic
ignition unit doesnot require
any
maintenance
operation
as it is made of parts which
are
not
subjectto mechanical wear.
Therefore
after inspecting
and if necessary
ad.justing
the ignition timing no periodical
adjustments
or
maintenance
operations
are needed, except in case
troublesin the electronic
components
(pick-up
and
electronic
set)or defective
contactsin electricwirinqs
shouldoccur.
Such
inconveniences
areeasilydetected
dueto a poor
working
efficiency
incylinders.
To inspect
andadjustthe ignition
timingproceed
as
follows:
1 Remove
the coveron the right
sideof the engine
ur or rNw)g.
2 Make
surethatthemark
"A" on the
inspection
hole
rim
is
alignedwith
thecrankcase
mark.
Incase it shouldbe
necessary
to adjustthesetwo marks,
undo
the
threescrews
"8" andsuitablyrotate
the
pick-
upholding
plate.
3 Usinga feeler
gauge
check
thattheclearance
between
theblock
"C" on the
rotating
sleeveandthe
metal
ends
ofeach
pick-up
is
0.20
-
0.30
mm(0.0078"
-
0.0118").
To
get
this
value
undo
thescrews
"D" andsuitably
shift
the
pick-up
bodv.
Following
the adjustments
accordingto paragraphs
2
and3,
the
max
ignition
advance
rate
will
be:
35o
before
T.D.C.
at
5000-5500rpm.
The ignition
advancecurveis shown in the diagram.
2d
JOOO

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d
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d
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fl to*ouE
wRENcH
sErrtNG
Distribution
gear
fixing
bolts.
.
Cylinder
head
bolts
Crankcase
upperbolts
@
8 mm.
Crankcase
upperbolts
0 6 mm.
Crankcase
lower
bolts
@
8 mm
Crankcase
lower
bolts
@
6 mm
Con-rodsecuring
nuts.
. .
Oil
pressure
switch.
Clutch
assy
fixingnuts
Spark
plug
Oildrain
plug
. .
Oilcartridgecover
fixing
bolt . .
Clutch
housing
retaining
plare
. .
Plate
securing
todrive shaft
clutch
plate
drum
Standard
settings
Screws
and
nuts
f, 6 mm.
Screws
and
nuts
Ö8 ^m.
kgm ftllbs
1.8-2
z.ö-3
2.3 - 2.5
0.8
- 1.2
l.J - l.c
0.8
- 1.2
z.z
- z.c
0.8
- 1.2
l.t - t.o
a
A
0.8
- 1.2
2 -2.4
11.5-14.5
20.2
-
21.7
to.o-tö
5.7
- 8.8
't6.6
-
18
67- R6
15.9-18
10.8
-
14.5
5.7
- 8.6
ö.o
- |t.o
25.3
- 28.9
'18 -21.7
58
5.7-8.6
14.5
-17.3
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)
)SPECIAL
TOOLS
) tnaddition
to those
indicated
in theworkshop
manual
for 500
Ouattro
and75O
Sei
alsothefollowing
tools
are
needed.
Pos. Code Description
1
2
A
5
6
7
8
I
10
tl
12
62.90.93.00
62.91.28.00
62.92.67.11
62.92.67.10
02.9Z.O/ .II
63.90.30.20
63.94.96.20
63.94.75.20
65.90.66.00
65.91.19.00
14.71.24.59
61.90.i9.00
Puller,
male
pin
oncable
connection
Wrench.holding
clutchdrum
Punch,
layshaft
securing
nut
Punch,
layshaft
securing
nut
Tool,
forassembling
securingnut on layshaft
Tool.l
holding
clutch
gear
crown
Hub,
timing
plate
Arrow,index
for
timingcheck
Puller,
flywheel
Tool.holding
flywheel
Nut,
securing
hub
timing
plate
oncrankshaft
Wrench,
spark
plug
)
)
)
)
)
)
)
)
)
)
)
)
)
)
)
I
)4
a
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,d
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!l errrcrrue
6.1CYLINDERHEAD,CYLINDERBLOCK,
PISTON
ANDCON.RODS
10

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)
Notice
The cylinder head gasket
is made of rolled sectron
klingerite
with the interposition
of six soft copper
seal
r
in
gs.
On re-assembly
pay attention that rings
are praced
as
indicated
in the drawing,
rhatis,
with thecentral
part in
relief
turned
upside
(towards
the
cylinderhead).
ln the area
around the timing chain slit apply some
sealingmaterial
HYLON4AR
PL 32 MEDIUM or equi-
valent.
To avoid
oil leaks
apply
some
retaining
tapeTEFLON
on threadings
on thelower
studs
fixing
the
cyl
inderhead
to crankcase.
tl
COPPER
SEALRING
lz ll
tl
il
t9

?
3 coNTRoLs
a Measure
the cylinderbore at threedifferentheights,
:' top, centreand bottom on both axis (longitudinal
ä and transversal).
Should the measurements
taken
I exceedthe use
limits it will be necessary
to re-ream
the cylinder bearing
in mind that pistons
and piston
a rings
areavailable
with 0.40 mm (0.0157")
oversize.
7 Cylinderdiameter:
7
3
3
e
Standard
value ClassA: d OO.OtO
to 60.020 mm
Q.3625"
to 2.3629")
Class
B:
0 60.000to60.010
mm
(2.3622"
to2.3625")
Takethe measurement
of the piston ring ends
gap.
Place
the piston ring in the cylinderbore andcheck
with
a
thickness
gauge:
Piston
ring.
top
and
center; 0.25to 0.45 mm
(0.0098"
to0.0177")
Oil
scraper: 0.20to 0.35mm
(0.0078"
to0.0137")
Wearlimit: 0.8
mm
(0.0314")
++ N.B. Letters
"A" and "8" indicating
theclass
selection
J are
marked
on top of thepiston
and
on theupper
part
ofthe
cylinder
block
near
the
lining.
7
Da Using
a micrometer
takethe measurements
of thedia-
{ meter
at 1
'l mm (0.043")from piston
baseat g0o of
ä, pistonaxis. lf the measurement
exceeds
the indicated
I limits
or if the cylinder
is
deformed
orscoredthis
has
rä to be
replaced.
4Piston
diameter:
Normalvalue Oversize
Class
"A"
0 59.980to 59.990
mm
(2.36141"
to
2.36iB")
Class
"8"
0 59.970
to 59.980
mm
(2.3610"
to2.3614")
0 60.370to60.390
mm
(2.3767"
to 2.3775"1
14.
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-
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7
v
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Check
theside
play
of piston
rings.
When
the
rings
have
been
fitted over
the piston
check
theclearance
oerween
rings
and
slots
onpiston.
,z
IJ

- Top
ring:
Normalvalue 0.03
to
0.052
mm
(0.001
1"to0.0020")
Wear
limit 0.18 mm
(0.0070")
- Centre
ring:
Normalvalue 0.03to0.052
mm
(0.001
1"to
0.0020")
Wearlimit 0.15
mm
(0.0059")
- Bottom
ring:
Normal
value 0.03to 0.052
mm
(0
001
I
" to0.0020")
Wear
limit 0.11
mm
t0.0043")
d
d
d
d
d
d
d
d
d
GI
d
d
GI
d
d
d
d
d
d
d
d
d
d
d
d
d
d
d
d
d
d
d
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Using
a micrometer checktheholeinthe
piston
and
the
piston
pin
diameter.
Dimensions
ofpiston
pin
hole
"A" in
piston
Dimensions
of pistonpin"8" diameter
Checkthe coupling
playbetween
pistonpin
and
bigend
beari
ng.
Checkthe paralleiism
of both small andbig end axis.
Maximumvalue:
*0.100 mm on 200 mm (0.0039"
on
7 87"\.
Q hole "A"
Colour @ selectron
1
2
black
white
1
5.000
to 14.997
mm
(0
5905"ro0.5904")
15.003
to15.000
mm
(0.5906"
to
05905")
18,805
+ 18.905
-=|- G
@
(r'
.t.
ct
'q
18805i18.
r Dopo alesatura
Er
i ilq
2IW2
.t.-t--t-T.l'
0 piston
pin
"8"
Colour 0 selection
2
black
white
14.991to 14.994
mm
(0.5904"
to0.5903")
15.000to 14.997
mm
(0.5905"
to
0.5904")
Selection
of small
end
bushinq
diameter
CLASS
"A"
Bluemark
on
stem
\-LAJJ D
Blue
mark
on
stem
38.103
to38.109
mm
(1.5001"
to
1.5003") 38.109
to
38.1
15
mm
(1.5003"
to 1.5005")
14

6.5 CLUTCH
4
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3
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3
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4
7
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Removal
of clutchassembly
1 Undo the two fixing bolts and remove R/H cover.
2 Undo the 4 bolts f
ixing
pressure
plate,
takeout the
springs
and spacing
washersand removepressureplate
together
with other
plates.
3 Remove
the pressure
capand
straightenthe
retaining
washerflaps.
4 Set up the special
wrench
drum and with tool "8" undo
e
t
G
G
d
d
d
d
d
d
d
d
d
d
a
d
d
d
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ä
4
4
1
4
4
4
d
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i
"4" to hold the clutch
thecentrallockingbolt.
!F
5 Take off the bolt, stop washers,
remove
the clutch
drum and thetwo half
-washers.
6 Straighten
retainingwasher
flaps
and
with thespecial
tool "C" undo the clutch housing
centrai lock ring.
7 SIip
off clutch
housing.
Checking
operations
Usinga gauge
checkthe wear
replace
them if theirthickness
new
plate
thickness.
of thedrive
plates
and
is
belowthe
wear
limit:
3.15to335
mm
lO]24"
to0131")
wearlimit: 2.9
mm
(0.11")
Place
the driven
plates
on a plane
and using a compara-
tor check their distortion; if this is over 0.1 mm
ln nn?"\ ronlere them
\v,vvv
Checkand
if necessary
replace
thetwo retaining
rings
(oR).
Checkthe efficiencyof the two clutch housing
springs.
Re-assembly
Reversethe dismantling
operations
paying
attentron
to
eliminate
f
rom clutch
plates
the presence
of oil or other
lub
rican
t.
To lock the bolts follorv the torque wrench settings
ind
icated.
Assemblethe pressure
plate,
washers,
springs
and fix
everything with the 4 bolts. Before locking ensure
and if necessaryadjustto obtain
the value
"A" 21.5 to
28 mm (108" to 'i
.10") in the drawing.
Check this
measurementafter having {ixed and locked trio bolts
only.
After the pressure
plate has
been
assembled
check that
acting
on clutch
lever
the
plate
turns
with a maximum
complanation
of 0.2 to 0.3 mm (0.078" to 0.011").
16

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GEARBoX
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17

N.B. On assembly
pay attention
to carefully
space
the
chain
sprocket
acting
on thrust
washers
"A" available
as
spare
parts wirh 0.10 0.15 0'5 mm thicknesses
(0.003
0.005
-
0.019"1
Check
that the gearshift
forks
fully engage
the gears
with
no
dif
f
iculties.
To adjust
act
on thrust
washers
"8" available as
spare
purt.
*ith the
following
thicknesses
1I -2 -21 -23'
2.4 2.5mm (0.070 0.078 0'082
- 0'090 0'094
0098").
L
lö