Benelli BN600R 2014 Guide

SERVICE STATION MANUAL
code:........................
Pure Passion since 1911
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- I -
WARNINGS:
This manual has been written by Benelli Q.J. s.r.l., mainly for use by Benelli dealers and their specially trained mechanics. It is not
possible to give a mechanic all of the information they require in a single manual. It is therefore presumed that the persons using this
manual for the maintenance and repairs of Benelli bikes have a basic knowledge of mechanics and the procedures necessary for
repairs and maintenance of this type of vehicle. Without this experience, any repairs or maintenance to this type of vehicle may be
dangerous or ineffective.
It is company policy at Benelli Q.J. s.r.l. to continuously upgrade and improve its models. Any changes or signi•cant modi•cations to
technical data or procedures will be made known to all authorised Benelli Dealers and will be published in future editions of the manual.
NOTE:
Drawings and speci•cations are subject to change without prior warning.
IMPORTANT INFORMATION ABOUT THE MANUAL
This manual contains the following important reminders:
WARNING:
IMPORTANT
NOTICE:
NOTE:
Failure to follow the instructions after this symbol may lead to serious injury or even death for the rider,
people in the vicinity, or people inspecting or repairing this bike.
"Important Notice" means that speci•c precautions are required to avoid causing damage to the bike.
A "Note" provides key information that will make the procedure either easier or clearer.
id
inders:
to follow the instructions after this symbol may lead to serious
in
or
e" provides key information that will make the procedure either ea
de
de
rs
rs
:
:
to
f
ollow the instructions after this symbol may lead to ser
io
io
us
n
n
the vicinity, or people inspecting or repairing this bike.
or
or
ta
ta
nt Notice" means that speci•c precautions are required to avo
id
id
e" provides key information that will make the procedure either
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- II -
HOW TO USE THIS MANUAL
This manual is a practical reference guide that is both easy to handle and use for mechanics. The explanations of all of the procedures
for installing, removing, disassembling, •tting, repairing and checking, are organised in sequence, one step at a time.
1. Each chapter is divided into sections. The top part of each page contains the title of the current section.
2. To help with the identi•cation of parts and to make the different processes clearer, exploded drawings are provided at the start
of each section dealing with the removal or disassembly of parts.
3. The sequence of operations is listed on the exploded drawing, and numbered progressively. Each number refers to a step in the
disassembly process.
4. Parts needed lubricating or replacing are marked by symbols. See the "SYMBOLS" section.
5. The exploded drawing is accompanied by a table with instructions for the intervention. These state the order of operations, the
name of the parts, any notes for the job, etc.
6. Interventions requiring any other information (e.g., special tools and technical data) are described in sequence.
pecial tools and tec
pecial tools and tec
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- III -
SYMBOLS
SUBJECT SYMBOLS
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
COOL
EXPLANATORY SYMBOLS
T
.
R
.
General Information
Speci!cations
Inspections and Periodic Adjustments
Frame
Engine
Cooling system
Wear limits, Backlash
Special tool
Tightening torque
E
Lubrication points
G
Grease application
YVORI SIL AC
Sealant paste
NEW
Part replacement
Thread locker application
Y SY
Bac
kl
ackl
SYMBOLS
Engine
En
gi
ne
Cooling system
Cooling system
acklash
acklash
in
ing syst
gine
ne
SYMB
MBOL
MBOL
SYMB
klash
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- IV -
CONTENTS
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG
COOL
General Information
Speci!cations
Inspections and Periodic Adjustments
Frame
Engine
Cooling system
CHAPTER 1
CHAPTER 2
CHAPTER 3
CHAPTER 4
CHAPTER 5
CHAPTER 6
P
specti
ec
CH
HA
ec
ti
ons and Periodic Adjustmen
ts
tions and Periodic Adjustmen
Fr
Engine
Engine
C
C
H
H
A
CHA
P
P
CHA
us
us
us
us
ame
s an
s an
ic A
and Pe
an
C
ons
on
ts
d Period
d Peri
ons
ons
C
CH
H
A
A
A
HA
A
A
HA
AP
En
En
En
En
Engi
Engi
C
H
En
En
gi
ne
gi
ne
C
C
C
Frame
Fr
C
C
Engi
ne
ne
ne
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GEN
INFO
- 5 -
GEN
INFO
General Information CHAPTER 1
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GEN
INFO
- 6 -
GENERAL INFORMATION
IDENTIFICATION ................................................................................................... 7
MOTORCYCLE IDENTIFICATION ............................................................................................................7
CHARACTERISTICS ............................................................................................. 8
INSTRUMENTS AND LIGHTS...................................................................................................................8
MULTIPURPOSE DISPLAY.......................................................................................................................9
IMPORTANT INFORMATION ............................................................................... 10
PREPARATIONS FOR REMOVAL AND DISASSEMBLY OPERATIONS ...............................................10
REPLACEMENT PARTS ..........................................................................................................................10
GASKETS, O-RINGS, SEALS AND BEARINGS .....................................................................................11
SAFETY WASHERS/SAFETY PLATES, COTTERS AND THREAD BLOCKERS ..................................11
ELASTIC RETAINING RINGS ..................................................................................................................12
CONNECTION CHECKS ..........................................................................................................................12
SPECIAL ENGINE EQUIPMENT..............................................................................................................14
SPECIAL EQUIPMENT......................................................................................... 14
SPECIAL TOOLS (FRAME) .....................................................................................................................17
CHAPTER 1
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GEN
INFO
2
1
3
- 7 -
MOTORCYCLE IDENTIFICATION
The identification data are:
1. Serial number of the frame (on the steering head)
2. Engine serial number (on the bottom base)
3. Approval details (on frame)
IDENTIFICATION
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GEN
INFO
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CHARACTERISTICS
INSTRUMENTS AND LIGHTS
The instruments and lights will switch on when the ignition key is
turned to "ON".
After an initial check-up, the information will correspond to the
overall condition of the bike at that time.
The dashboard has the following instruments.
1 STATUS INDICATOR LIGHTS
1A. Neutral gear light (green)
This switches on when the gear is in "Neutral".
1B. Oil level warning light (red)
This switches on when the oil pressure is insuf!cient. It is
possible to check the electrical circuit of the light by turning
the key to “ON”. Once the engine is running, the light should
switch off. if the light does not switch on at the start, when
the key is turned to “ON”, or if the light stays on, have the
electric circuit checked by an authorised Benelli service cen-
tre.
1C. High beam light (blue)
This switches on when the high beam is switched on.
1D. Indicator light (green)
This switches on when the indicators are working.
1E. "FI" Injection diagnostic light
When the vehicle is started, the light will switch on orange for
a few seconds to show that the injection system is operating
correctly.
1A.
1B.
1C.
1D.
1E.
2 REV COUNTER
This shows the number of engine revs per minute, expressed in
thousands.
2
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GEN
INFO
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CHARACTERISTICS
MULTIPURPOSE DISPLAY
3 COOLANT TEMPERATURE GAUGE
Shows the coolant temperature in °F (Fahrenheit) or C°(Celsius) .
4 DIGITAL CLOCK
Shows the time in hours, minutes and seconds
5 SELECT BUTTON
6 RESET BUTTON
Digital clock setting
Hold down the ”Select“button for 5 seconds until the reading
begins to !ash.
Adjust the hour by pressing the ”Select“ button.
Press the "Reset" button to pass on to the minutes adjustment.
Adjust the minutes by pressing the ”Select“button.
Press the "Reset" button to pass on to the seconds adjustment.
Reset the seconds to zero by pressing the "Reset" button.
7 FUEL TANK CAPACITY AND RESERVE FUEL GAUGE
The digital fuel gauge shows the capacity of the fuel tank. As
the fuel level drops, the lines on the gauge will become closer
and closer to the "E" reserve area.
As soon as the #
nal line starts to !ash, there is an autonomy of
about 2 litres of fuel.
8 TOTAL/PARTIAL KILOMETRE COUNTER
The total kilometre counter shows the total distance covered
in kilometres,. The partial kilometre counter ( TRIP) shows the
distance covered since the last reset in kilometres.
The partial kilometre counter can be used to estimate the possi-
ble distance to cover with a full tank of fuel. This information may
make it possible to schedule future fuelling stops.
9 SPEEDOMETER
Indicates the vehicle's speed in km/h or mph. To pass from km to
mph and vice versa, press and hold down the “Select” button 5
for at least one second.
345
6
7
8
9
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GEN
INFO
- 10 -
IMPORTANT INFORMATION
PREPARATIONS FOR REMOVAL AND DISAS-
SEMBLY OPERATIONS
• Before carrying out any removal and disassembly opera-
tions, remove any dirt, mud, dust or foreign bodies.
• Only use suitable cleaning tools and products.
See the "SPECIAL EQUIPMENT" section.
• While disassembling the vehicle, we recommend keeping
coupled parts together at all times. These parts include
gears, cylinders, pistons and other parts, whose surfaces
will be "coupled" during the normal wear and tear of work.
Coupled pieces must always be re-used or replaced in
groups. During the disassembly operation, clean all parts
and place them in a bowl, using the same order as for dis-
assembly. This will make reassembly operations easier and
allows for the correct installation of all parts.
• Keep all parts away from any source of heat.
REPLACEMENT PARTS
Only use original Benelli replacement parts. Only use oils and
grease recommended by Benelli to lubricate parts. Other brands
may look similar and operate in a similar manner, but will be of
lower quality.
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GEN
INFO
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IMPORTANT INFORMATION
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a
b
GASKETS, O-RINGS, SEALS AND BEARINGS
Always replace all gaskets, oil seals and O-rings when carrying
out repairs to the engine.
The gasket surfaces, oil seal lips and O-rings must always be
clean.
During installation, always oil the coupled parts and bearings,
and lubricate the oil seal lips with engine oil.
Fit the bearings and oil seals so that the brand or manufacturer's
number is facing outwards and visible. To •t the oil seal, lubri-
cate the lips with a •ne layer of engine oil.
Always apply plenty of oil to bearings when •tting them.
a. Oil seal
b. Bearing
IMPORTANT NOTICE:
Never use compressed air to dry bearings, allowing them to turn,
as this will damage the surfaces.
SAFETY WASHERS/SAFETY PLATES, COTTERS
AND THREAD BLOCKERS
After removing, replace all of the safety washers "A", and the
safety plates and cotters.
After tightening the bolt or nut according to speci•cation, bend
the locking tabs and the ends of the cotter against the !at sides
of the nut.
Whenever applying thread blocker, always •rst degrease
both sides, with solvent.
E
E
A
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GEN
INFO
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IMPORTANT INFORMATION
ELASTIC RETAINING RINGS
Before re•tting them, check all of the retaining rings and replace
any that have become damaged or are out of shape.
Always replace the retaining rings on the gudgeon pin after
using them once. If •tting a retaining ring "A", make sure that the
sharp edge "B" is positioned on the other side to the thrust, "C"
that it receives.
"D" Shaft
CONNECTION CHECKS
Make sure that there are no marks, rust, moisture, etc. on wiring,
couplers, or connectors.
1. Disconnect:
• the wire
• the coupler
• the connector
2. Check:
• the wire
• the coupler
• the connector
If there are traces of moisture → Use a fan to dry.
If there is any rust/marks → Connect and disconnect the parts
several times.
3. Check:
• all connections
If there are any loose connections → Reconnect them properly.
NOTE:
If the foot of terminal "A" is bent, raise it.
A
B
C
D
A
1
2
3
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GEN
INFO
- 13 -
IMPORTANT INFORMATION
4. Connect:
• the wire
• the coupler
• the connector
NOTE:
Make sure all connections are !rmly installed.
5. Check:
• continuity (with a pocket tester)
NOTE:
• If there is no continuity, clean the terminals.
•To control the wiring, follow the steps from "1" through to "3"
• For a quick !x, we recommend using a speci!c product for
contacts, which can be found on sale in spare parts stores.
4
5
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GEN
INFO
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SPECIAL EQUIPMENT
The special equipment listed here serves for the complete, thorough performance of •ne tuning and assembly operations.
The use of this equipment will help to prevent damage caused through using unsuitable tools or makeshift techniques.
When completing an order, please check the list below to avoid any errors.
SPECIAL ENGINE EQUIPMENT
Tool Code Name-Tool Function Image
1Valve stem seal tool
This serves to insert the valve oil seal in
situ.
1Clutch removal tool
This serves to block the clutch drum and
loosen the nut
1Gudgeon pin removal tool
This tool serves to take out the gudgeon
pin
1Valve stem seal removal tool
This tool serves to take out the oil seal
from valves
1Ring clamp tool
This tool serves to •t retaining rings on the
piston and to insert this into the cylinder
1Gear selector drum fitting tool
This tool serves to •t the gear selector
drum
1Flywheel extractor
This tool serves to remove the !ywheel
from the engine shaft
1
Flywheel cover extractor
This tool serves to remove the cover hous-
ing the !ywheel
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GEN
INFO
- 15 -
SPECIAL EQUIPMENT
SPECIAL ENGINE EQUIPMENT
Tool Code Name-Tool Function Image
1Engine tuning tool
This tool serves to establish the TDC po-
sition
1Oil filter tool
This tool serves to tighten or remove the
engine oil !lter
1Chain tensioner locking tool
This tool serves to lock the tensioner pis-
ton while !tting the chain tensioner
1Oil seal insertion tool
This tool is used to !t the oil seal on the
engine casing near the gear
1
Tool to remove/fit the clutch bell hous-
ing ring nut
This tool is used to remove and !t the
notched ring nut that holds the clutch bell
housing
1Valve spring compressor tool
This tool is used to remove springs from
valves
1Valve removal adaptor
This tool is used to remove valves
1Measuring gauge
This tool is used to measure the inner di-
mensions of bores
1Measuring gauge
This tool is used to measure the external
dimensions of parts
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GEN
INFO
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SPECIAL EQUIPMENT
SPECIAL ENGINE EQUIPMENT
Tool Code Name-Tool Function Image
1Measuring gauge
This tool is used to measure thickness
1Flywheel tightening tool
This tool serves to remove the !ywheel on
the engine shaft
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GEN
INFO
- 17 -
SPECIAL EQUIPMENT
SPECIAL TOOLS (FRAME)
Tool Code Name-Tool Function Image
1Tightening tool for steering head lock
nut
This assembled tool is used to tighten the
lock nut securing the steering head.
1Front wheel steering arm tightening
tool
This tool is used to tighten the front wheel
pin
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SPEC
- 18 -
SPEC
Speci•cations CHAPTER 2
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SPEC
- 19 -
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ................................................................................ 20
TECHNICAL DETAILS............................................................................................ 21
ENGINE SPECIFICATIONS ......................................................................................................................21
FRAME SPECIFICATIONS .......................................................................................................................26
ELECTRICAL SPECIFICATIONS..............................................................................................................30
GENERAL TIGHTNESS SPECIFICATIONS .............................................................................................34
TIGHTNESS TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS..................35
TIGHTENING TORQUES..........................................................................................................................35
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