Benelli TnT1130 Instruction manual

UK
2MF13
This manual contains an introductory description of the Benelli TnT together with the
procedures for control/intervention and revision of the main components.
Information considered generally noted is not included.
This manual will help you to understand the motorcycle better in order to provide the
client with a rapid and trustworthy service.
* The present manual has been prepared on the basis of state-of-the-art
specifications valid at the date of publication. In the case of modifications
carried out after this date, differences may exist between the contents of the
manual and the motorcycle under review.
* The illustrations in this manual are used to highlight the fundamental principles
and procedures of basic interventions. They may not show exactly the motorcycle
in your possession.
* This manual has been written for people who have the knowledge, the technical
skill and the instruments, including the special, for servicing Benelli motorcycles.
If you do not possess the necessary training and tools, have repairs made at
an authorised Benelli concessionaire.
AA
AA
ATTENTIONTTENTION
TTENTIONTTENTION
TTENTION
Inexpert mechanics or those lacking appropriate instruments and apparatuses
may not be able to carry out the operations described in this manual.
Incorrect repairs can cause damage to the mechanic and render the motorcycle
unsafe for the driver and passenger.
PP
PP
Premise

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SYMBOLS
The symbols listed below are all present inside the manual and serve to show those
parts which need to be given special attention.
ATTENTION - Be aware that you will find death or serious injury, in
case the instructions are not observed.
WARNING - Possibility of lesions in case the instructions are not
observed .
NOTE - The aim of this message is trying to avoid any damages to
the vehicle, things or environment.
OILING - Indicates the type of oil to use.
TIGHTENING - Indicates the correct tightness value to carry out.
SPECIFIC VALUE - indicates the specific value using precision in-
struments.
SPECIFIC INSTRUMENTS - indicates the specific instruments to
use.
II
II
Introduction

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1GENERAL INFORMATIONGENERAL INFORMATION
GENERAL INFORMATIONGENERAL INFORMATION
GENERAL INFORMATION 11
1.1 VEHICLE IDENTIFICATION 13
1.2 IMPORTANT INFORMATION 13
1.3 SPECIAL INSTRUMENTS 14
1.3.1 SPECIAL ENGINE INSTRUMENTS 15
1.3.2 SPECIAL FRAME INSTRUMENTS 18
22
22
2SPECIFICATIONSSPECIFICATIONS
SPECIFICATIONSSPECIFICATIONS
SPECIFICATIONS 20
2.1 GENERAL SPECIFICATIONS 20
2.2 ENGINE TECHNICAL CHARACTERISTICS 21
2.3 FRAME CHARACTERISTICS 23
2.4 ELECTRICAL COMPONENTS 26
2.5 BOLT TORQUE 28
2.5.1 GENERAL BOLT TORQUE 28
2.5.2 FRAME BOLT TORQUE 29
2.5.3 ENGINE BOLT TORQUE 35
2.6 POINTS TO OIL 38
33
33
3PERIODIC CHECKS AND ADJUSTMENTSPERIODIC CHECKS AND ADJUSTMENTS
PERIODIC CHECKS AND ADJUSTMENTSPERIODIC CHECKS AND ADJUSTMENTS
PERIODIC CHECKS AND ADJUSTMENTS 52
3.1 INTRODUCTION 52
3.2 CHECK SPARK-PLUGS 56
3.2.1 INSTALLING SPARK-PLUGS 57
3.3 CLEANING AIR BOX 57
3.3.1 REMOVAL OF AIR BOX THROTTLE VALVE AND AIR BOX DUCT 58
3.3.2 SOLENOID MOTOR REMOVAL 59
3.4 GAS CONTROL PLAY 60
3.4.1 CLUTCH 61
3.5 ADJUSTING CLUTCH LEVER PLAY 62
3.6 ADJUSTING CO 62
3.7 ADJUSTING THROTTLE HOUSING 64
3.8 CHECKING STEPPER 65
3.9 ADJUSTING VALVE PLAY 67
3.9.1 VALVE TABLET REPLACEMENT 68
3.10 ENGINE DISTRIBUTION 69
3.11 CHECKING ENGINE OIL LEVEL 71
3.12 CHANGING ENGINE OIL AND FILTER 72
3.13 CHECKING COOLING LIQUID LEVEL 75
3.14 CHANGING REFRIGERANT LIQUID 76
3.15 FILLING COOLING PLANT 78
3.16 CHECKING EXHAUST TUBES 80
3.17 CONTROL AND REPLACEMENT EXHAUST PLANT 80
3.18 ADJUSTING FRONT BRAKE LEVER 82
3.19 ADJUSTING REAR BRAKE LEVER 82
3.20 CHECKING BRAKE LIQUID 83
3.21 CHANGING FRONT AND REAR BRAKE PADS 84
3.21.1 HANGING REAR BRAKE PADS 86
3.22 CHECKING BRAKING PLANT TUBES 87
3.23 AIR DISCHARGE FRONT BRAKING SYSTEM 87
3.23.1 AIR DISCHARGE BACK BRAKE SYSTEM 89
3.23.2 FILLING UP BRAKE LIQUID 89
3.24 ADJUSTING GEAR CONTROL PEDAL 90
3.25 LUBRICATIONAND CHAIN CLEANING 91
3.26 CHAIN REPLACEMENT 91
3.27 CHAIN REGULATION 93
CC
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CONTENTS

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3.28 CONTROL AND REPLACEMENT TRANSMISSION COG-WHEELS 94
3.29 CHECKING AND ADJUSTING STEERING BALL-BEARINGS 95
3.30 CHECKINGFORK 96
3.31 CHECKING DAMPER 97
3.32 ADJUSTING DAMPER 97
3.33 CHECKING TIRE PRESSURE 99
3.34 CHECKING WHEELS 100
3.35 CHECKING AND OILING CLUTCH CABLE 101
3.36 ELECTRICAL PLANT 101
3.36.1 CHECKING BATTERY 101
3.36.2 BATTERY RECHARGING SYSTEM 103
3.37 CHANGING FUSES 106
3.38 CHANGING FRONT LIGHTS 107
3.38.1 FRONT LIGHTH DISASSEMBLY 107
3.39 ADJUSTING FRONT HEADLIGHT 109
3.40 BACK LIGHTH DISASSEMBLY 110
3.40.1 CHANGING REAR HEADLIGHT 110
3.40.2 CHANGING LICENCE-PLATE HOLDER LIGHT 111
3.40.3 BACK ARROW LAMP REPLACEMENT 111
3.40.3.1 CHANGING FRONT ARROWS 111
3.40.3.2 BACK ARROW LAMP REPLACEMENT 112
44
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4COWLINGCOWLING
COWLINGCOWLING
COWLING 114
4.1 TANK COVER DISASSEMBLY 114
4.2 PETROL TANK DISASSEMBLY 114
4.2.1 COVER PLATE DISASSEMBLY 115
4.2.2 PETROL PUMP REMOVAL 115
4.3 DISMANTLE TANK FUEL PUMP 116
4.4 COOLER FAIRING DISASSEMBLY 116
4.4.1 FRONT SHIELD AND FRONT SHIELD SUPPORT DISASSEMBLY 117
4.5 COOLERS CONVEYORS DISASSEMBLY 117
4.6 MUDGUARDS DISASSEMBLY 119
4.6.1 FRONT MUDGUARD DISASSEMBLY 119
4.6.2 BACK MUDGUARD DISASSEMBLY 119
4.7 CHAIN CARTER DISASSEMBLY 119
4.8 NUMBER PLATE HOLDER DISASSEMBLY 120
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5ENGINEENGINE
ENGINEENGINE
ENGINE 122
5.0 MOTOR REMOVAL 122
5.0.1 MOTOR DISASSEMBLY FROM THE FRAME 122
5.0.2 MOTOR ASSEMBLY ON THE FRAME 124
5.1 CAMSHAFT 127
5.1.1 REMOVING CAMSHAFT 127
5.1.2 CHECKING CAMSHAFT 129
5.1.3 CHECKING CAMSHAFT CHAIN, SPROCKET WHEELS
AND CHAIN GUIDE 130
5.1.4 CHECKING CHAIN STRETCHER 131
5.1.5 MOUNTING CAMSHAFT 131
5.2 CYLINDER HEAD 135
5.2.1 REMOVING CYLINDER HEAD 135
5.2.2 CHECKING CYLINDER HEAD 136
5.2.3 MOUNTING CYLINDER HEAD 137
5.3 VALVES AND VALVE SPRINGS 137
5.3.1 REMOVING VALVES 137

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5.3.2 CHECKING VALVES AND VALVE GUIDES 139
5.3.3 CHECKING VALVE HOUSINGS 141
5.3.4 CHECKING VALVE SPRINGS 142
5.3.5 CHECKING BUCKET-TYPE TAPPETS 143
5.3.6 MOUNTING VALVES 144
5.4 CYLINDER 146
5.4.1 DISMANTLING CYLINDER CASING 146
5.4.2 CHECKING CYLINDER 147
5.4.3 DISMANTLING WATER COLLECTOR 147
5.4.4 CHECKING WATER COLLECTOR 148
5.4.5 MOUNTING WATER COLLECTOR 148
5.4.6 MOUNTING CYLINDERS 148
5.5 PISTONS 149
5.5.1 DISMANTLING PISTONS 148
5.5.2 CHECKING PISTONS 150
5.5.3 CHECKING SEGMENTS 150
5.5.4 SEGMENT SLOT PLAY 151
5.5.5 CHECKING PISTON PIN 151
5.5.6 MOUNTING SEGMENTS 152
5.5.7 MOUNTING PISTON 153
5.6 GENERATOR 15 4
5.6.1 REMOVING GENERATOR 154
5.6.2 MOUNTING GENERATOR 155
5.7 DISTRIBUTION SENSOR AND PHONIC WHEEL 155
5.7.1 REMOVING DISTRIBUTION SENSOR 155
5.7.2 MOUNTING DISTRIBUTION SENSOR 156
5.7.3 REMOVING PHONIC WHEEL 156
5.7.4 MOUNTING PHONIC WHEEL 156
5.8 CLUTCH 157
5.8.1 DISMANTLING CLUTCH CONTROL 157
5.8.2 REMOVING CLUTCH COVER 157
5.8.3 REMOVING CLUTCH 158
5.8.4 CHECKING THE EXTERNAL TEETH DISK CONDUCTOR 160
5.8.5 CHECKING INNER TOOTHED CONDUCTOR DISK 160
5.8.6 CHECKING CLUTCH SPRINGS 160
5.8.7 CHECKING CLUTCH BELL 161
5.8.8 CHECKING CLUTCH PRIMARY BELL GROUP 162
5.8.9 MOUNTING CLUTCH GROUP 162
5.8.10 CHECKING CLUTCH DISKS 168
5.8.11 MOUNTING CLUTCH COVER 169
5.8.12 MOUNTING CLUTCH CONTROL 170
5.9 GEARS 17 1
5.9.1 REMOVING GEARS 171
5.9.2 DISMANTLING GEARS 171
5.9.3 CHECKING GEAR FLANGE BALL-BEARINGS 174
5.9.4 CHECKING GEAR FORKS AND SLIDE RODS 174
5.9.5 CHECKING POSITIVE SHAFT 176
5.9.6 CHECKING PRIMARY AND SECONDARY SHAFT 176
5.9.7 ASSEMBLING GEARS 177
5.9.8 MOUNTING GEARS 184
5.10 OIL SUMP AND OIL PUMP 185
5.10.1 DISMANTLING OIL SUMP 185
5.10.2 DISMANTLING OVERPRESSURE OIL VALVE 185
5.10.3 REMOVING OIL PUMP 186

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5.10.4 DISMANTLING OIL PUMP 186
5.10.5 CHECKING OIL SUMP 187
5.10.6 CHECKING OIL PUMP 187
5.10.7 ASSEMBLING OIL PUMP 188
5.10.8 MOUNTING OIL PUMP 189
5.10.9 MOUNTING OVERPRESSURE OIL VALVE 190
5.10.10 MOUNTING OIL SUMP 190
5.11 CASING 191
5.11.1 DISMANTLING CASING 191
5.11.2 DISMANTLING FREE WHEEL 198
5.11.3 DISMANTLING BALANCING COUNTER SHAFT 200
5.11.4 DISMANTLING ENGINE SHAFT 201
5.11.5 CHECKING CASING 201
5.11.6 CHECKING ENGINE SHAFT AND CONNECTING ROD 202
5.11.7 CONNECTING ROD INTERNAL FOOT DIAMETER 203
5.11.8 CONNECTING ROD HEAD LATERAL PLAY 203
5.11.9 CHECKING BALANCING COUNTER SHAFT 204
5.11.10 CHECKING FREE WHEEL 205
5.11.11 ASSEMBLING FREE WHEEL 205
5.11.12 MOUNTING ENGINE SHAFT 207
5.11.13 MOUNTING BALANCING COUNTER SHAFT 208
5.11.14 MOUNTING CASING 209
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6COOLING PLANTCOOLING PLANT
COOLING PLANTCOOLING PLANT
COOLING PLANT 220
REFRIGERANT LIQUID ENGINEREFRIGERANT LIQUID ENGINE
REFRIGERANT LIQUID ENGINEREFRIGERANT LIQUID ENGINE
REFRIGERANT LIQUID ENGINE 220220
220220
220
6.1 RADIATOR 221
6.1.1 DISMANTLING RADIATOR 221
6.1.1.1 LEFT COOLER DISASSEMBLY 222
6.1.2 COOLER CHECK AND CLEANING 224
6.1.3 RIGHT COOLER ASSEMBLY 224
6.1.4 OIL RADIATOR DISASSEMBLY 225
6.1.5 OIL COOLER CHECK AND CLEANING 226
6.1.6 OIL COOLER ASSEMBLY 226
6.2 OIL DISTRIBUTOR 228
6.2.1 OIL DISTRIBUTOR ASSEMBLY 229
6.3 THERMOSTAT 230
6.3.1 DISMANTLING THERMOSTAT 230
6.3.2 CHECKING THERMOSTAT 231
6.3.3 MOUNTING THERMOSTAT 232
6.4 WATER PUMP 233
6.4.1 REMOVING WATER PUMP 233
6.4.2 DISMANTLING WATER PUMP 233
6.4.3 CHECKING WATER PUMP 236
6.4.4 WATER PUMP ASSEMBLY 236
6.4.5 MOUNTING WATER PUMP 241
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7FRAMEFRAME
FRAMEFRAME
FRAME 244
7.1 FRONT WHEEL AND BRAKE DISK 244
7.1.1 REMOVING FRONT WHEEL 244
7.1.2 CHECKING FRONT BRAKE DISK 245
7.1.3 DISMANTLING FRONT WHEEL 245
7.1.4 CHECKING FRONT WHEEL 246
7.1.5 MOUNTING FRONT WHEEL 246
7.1.6 INSTALLING FRONT WHEEL 247

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7.2 REAR WHEEL, BRAKE DISK AND CROWN 248
7.2.1 REMOVING REAR WHEEL 248
7.2.2 CHECKING REAR BRAKE DISK 249
7.2.3 DISMANTLING REAR WHEEL 250
7.2.4 CHECKING REAR WHEEL 252
7.2.5 CHECKING HUB 252
7.2.6 CHECKING CROWN 253
7.2.7 MOUNTING REAR WHEEL 253
7.2.8 INSTALLING REAR WHEEL 255
7.3 FRONT AND REAR BRAKES 256
7.3.1 REMOVING FRONT BRAKE PUMP 256
7.3.2 REMOVING REAR BRAKE PUMP 257
7.3.3 CHECKING FRONT AND BACK BRAKE PUMPS 258
7.3.4 INSTALLING FRONT BRAKE PUMP 259
7.3.5 INSTALLING REAR BRAKE PUMP 259
7.3.6 DISMANTLING FRONT BRAKING PLANT TUBES 260
7.3.7 DISMANTLING REAR BRAKING PLANT TUBES 261
7.3.8 CHECKING FRONT AND REAR BRAKE TUBING 262
7.3.9 MOUNTING FRONT BRAKING PLANT TUBES 262
7.3.10 MOUNTING REAR BRAKING PLANT TUBES 263
7.3.11 DISMANTLING FRONT BRAKE CLAMP 263
7.3.12 DISMANTLING REAR BRAKE CLAMP 264
7.3.13 CHECKING BRAKE CLAMPS 265
7.3.14 MOUNTING FRONT BRAKE CLAMPS 265
7.3.15 DISMANTLING REAR BRAKE CLAMP 266
7 .4 FORK 2 6 7
7.4.1 REMOVING RIGHT AND LEFT STEM 267
7.4.2 CHECK FORK LEGS 268
7.4.3 INSTALLING FORK LININGS 268
7.5 HANDLEBAR 270
7.5.1 HANDLEBAR CONTROL 272
7.5.2 HANDLEBAR INSTALLATION 272
7.6 STEERING HEAD 274
7.6.1 DISMANTLING LOWER STEERING PLATE 274
7.6.2 CHECKING LOWER STEERING PLATE 287
7.6.3 MOUNTING LOWER STEERING PLATE 287
7.7 REAR DAMPER 278
7.7.1 REMOVING REAR DAMPER 278
7.7.2 CHECKING REAR DAMPER 278
7.7.3 MOUNTING REAR DAMPER 279
7.8 REAR FORK 281
7.8.1 REMOVING REAR FORK 281
7.8.2 CHECKING REAR FORK 285
7.8.3 MOUNTING REAR FORK 286
7.8.4 BACK FORK INSTALLATION ON FRAME 287
7.9 SUPPORT FRAME 288
7.9.1 LIGHT SUPPORT FRAME REMOVAL 288
7.9.2 TEST FRONT LIGHT SUPPORT FRAME 289
7.9.3 FRONT LIGHT SUPPORT FRAME INSTALLATION 290
7.10 BACK FRAME 290
7.10.1 BACK RIGHT FRAME DISASSEMBLY 290
7.10.2 BACK RIGHT FRAME ASSEMBLY 292
7.10.3 LEFT BACK FRAME DISASSEMBLY 293
7.10.4 LEFT BACK FRAME ASSEMBLY 295

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7.10.5 STIRRUP REMOVAL PASSENGER FOOTBOARDS 297
7.11 TRANSMISSION CHAIN 298
7.11.1 REMOVING TRANSMISSION CHAIN 298
7.11.2 CHECKING TRANSMISSION CHAIN 298
7.11.3 INSTALLING TRANSMISSION CHAIN 299
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8INJECTION PLANT ENGINEINJECTION PLANT ENGINE
INJECTION PLANT ENGINEINJECTION PLANT ENGINE
INJECTION PLANT ENGINE 300
8.1 ENGINE MANAGEMENT SYSTEM 300
8.1.1 DESCRIPTION OF THE SYSTEM 300
8.1.2 SYSTEM SENSORS 300
8.1.3 POSITION OF THE SENSORS 301
8.2 SYSTEM ACTIVATING DEVICES 301
8.2.1 ENGINE SUPPLY PLANT 303
8.2.2 IGNITION AND INJECTION DIAGNOSTIC SYSTEM 303
8.3 NUMBERING THE ECM CONNECTORS 303
8.4 SUPPLEMENTARY DIAGNOSES 305
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9ELECTRICAL PLANTELECTRICAL PLANT
ELECTRICAL PLANTELECTRICAL PLANT
ELECTRICAL PLANT 318
9.1 CONNECTORS 321
9.2 FUSES 321
9.3 SEMI-CONDUCTOR PARTS 322
9.4 BATTERY 322
9.4.1 CHECKING BATTERY EFFICIENCY 323
9.5 FUSES 325
9.6 RELAYS 325
9.6.1 RELAY STARTER 325
9.6.2 RELAY SERVICES UNIT 326
9.7 STARTER ENGINE 326
9.8 ALTERNATOR 327
9.9 STARTER DIAGNOSTIC SYSTEM 328
9.10 CHECKING SAFETY SYSTEM PARTS 330
9.11 GEAR SWITCH POSITION 330
9.12 LATERAL STAND SWITCH 331
9.13 CLUTCH SWITCH 331
9.14 SPEED SENSOR 332
9.15 OIL PRESSURE SENSOR 332
9.16 SOLENOID 333
9.17 CHANGING FRONT LIGHTS 334
9.17.1 FRONT LIGHTH DISASSEMBLY 334
9.17.2 ADJUSTING FRONT HEADLIGHT 336
9.18 BACK LIGHTH DISASSEMBLY 336
9.18.1 CHANGING REAR HEADLIGHT 336
9.18.2 CHANGING LICENCE-PLATE HOLDER LIGHT 337
9.18.3 CHANGING FRONT AND REAR ARROWS 337
9.18.3.1 CHANGING FRONT ARROWS 337
9.18.3.2 BACK ARROW LAMP REPLACEMENT 338
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10 DIAGNOSTICSDIAGNOSTICS
DIAGNOSTICSDIAGNOSTICS
DIAGNOSTICS 340
10.1 ELECTRICAL PART 340
10.2 FRAME 34 4
10.3 AXONE2000 BENELLI INSTRUCTION MANUAL 347
10.3.1 GENERAL SAFETY PRECAUTIONS FOR OPERATORS 347
10.3.2 HOW TO USE AXONE2000 BENELLI CORECTLY 348
10.3.3 DESCRIPTION OF AXONE2000 BENELLI 349
10.3.3.1 KEYPAD 349

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10.3.3.2 INTERFACE MODULE 350
10.3.3.3 READ/WRITE UNIT 350
10.3.3.4 INPUT/OUTPUT CONNECTORS 351
10.3.3.5 HOW TO POWER THE AXONE2000 BENELLI 352
10.3.3.6 RECHARGING THE BATTERY 352
10.3.3.7 REPLACING THE BATTERY 353
10.3.3.8 NOTES FOR CORRECT USE 353
10.3.3.9 TECHNICAL SPECIFICATIONS 354
10.3.3.10 SPARE PARTS 355
10.3.3.11 GLOSSARY 355
10.3.3.12 GETTING STARTED 356
10.3.3.13 STARTING PROGRAMS 355
10.3.4 HOW TO USE AXONE2000 BENELLI 357
10.3.4.1 SERVICE MENU 357
10.3.5 UPGRADES 360
10.3.6 MEASURES 367
10.3.6.1 MULTIMETER
(VOLTMETER, AMMETER, OHMMETER, CONTINUITY TEST) 367
10.3.6.2 VOLTMETER 368
10.3.6.3 AMMETER 368
10.3.6.4 OHMEMETER 369
10.3.6.5 OSCILLOSCOPE 370
10.3.6.6 OPTIONS 371
10.3.6.7 SCALE SELECTIONS 374
10.3.6.8 AC/DC READING SELECTION 376
10.3.6.9 TYPES OF SYNCHRONISM 377
10.3.7 AUTO-DIAGNOSTICS 379
10.3.7.1 TESTING 380
10.4 MAINTENANCE OPERATIONS WITH DIAGNOSTICS TOOL 388
10.5 SELF-DIAGNOSIS 388
10.6 RESETTING THROTTLE 388
10.7 ADJUSTING STEPPER / CO 389
10.8 INSTRUCTIONS TO ADJOURN THE GEARCASE
SOFTWARE WITH THE AXONE 390

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General
II
II
Information
1 GENERAL INFORMATION
ATTENTION/WARNING/NOTE
Read carefully the manual and follow the instructions. To underline special
information, the symbols and the words ATTENTION, WARNING and NOTE have
specific meanings. Pay particular attention to the messages underlined with the
following words and the corresponding signal.
Shows a possible danger which could cause death
or injury.
NOTE:
Show a particular information which simplifies the maintenance or
makes the instructions clearer.
Please note, that in any case the warnings contained in this manual can not cover
all the possible risks concerning the reparation or the missed maintenance of the
motorbike. Exceeding the mentioned ATTENTIONS it is necessary to apply the
personal judgment and the fundamental principles of safety.
GENERAL PRECAUTIONS
* Correct maintenance and reparation procedures are important for the mechanic’s
safety and for the motorbikes safety and reliability .
* In case more persons work together, pay attention to the reciprocal safety.
* In case it is necessary to start the motor inside a workshop, take care that the
exhaust gases are convoyed outside.
* When you use toxic or inflammable materials, take care that the working area
is well ventilated and follow all the instructions of the material’s manufacturer.
* Never use petrol as a solvent for cleaning
* To avoid burns, do not touch the motor, the motor oil, the COOLER and the
exhaust system before they are completely cold.
* After an intervention on the fuel system, the oil-cirquit, the refrigerant liquid
circuit, the exhaust system and the brake system, verify the absence of
losses in all the circuits and the accessories connected with the system.
ATTENZIONE
AA
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ATTENTIONTTENTION
TTENTIONTTENTION
TTENTION
ATTENZIONE
AA
AA
ATTENTIONTTENTION
TTENTIONTTENTION
TTENTION

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* In case it will be necessary to replace parts, only use Benelli original spare
parts or their equivalents
* In case of disassembly of parts to be used again, dispose them in a tidy way
in order to reassemble them in the right way and in the correct position.
* Be sure to use special tools, when it is required.
* Be sure that all the parts to be reassembled are clean. Lubrificate at the
indicated points.
* Use the suggested lubricants, adhesives and sealings.
* In case of battery disassembly, first disconnect the positive clamp and then
the negative one and replace the CHAP. on the positive clamp.
* In case of intervention on the electric parts, if the procedures do not require the
use of battery energy, disconnect the negative clamp.
* When tightening the bolts and nuts of the cylinder head and the carter, start
from the biggest ones. Always screw bolts and nuts diagonally starting from
the centre and tighten to the indicated torque.
* If you remove oil seals, sealings, O-ring, security washers, self-locking nuts,
cotters, elastic rings, and other specified parts, be sure to replace them with
new parts. Moreover, before assembling the new parts, remove probable residual
material of the contact surfaces.
* The elastic rings must not be used a second time. During the installation of a
new ring, pay attention to avoid opening the extremities more than necessary
to make it sliding on the shaft. After the assembly, always verify it is well fitted
in the groove and properly assembled.
* Use a torque key to tighten the fixing elements to the mentioned torque.
Clean dirty threads from oil and grease.
* After assembling verify the tightness and function of the parts.
* To respect the environment do not dispose used motor oil and other polluting
liquids, batteries and pneumatics illegally.
* To protect the environment and natural resources, dispose the motorbike
and spare parts in a proper way.
AVVERTENZA
WARNINGWARNING
WARNINGWARNING
WARNING

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1.1 VEHICLE IDENTIFICATION
The identification data are:
1) Frame number [on steering casing].
2) Number of engine on lower crankcase
3) Homologation data [on frame].
1.2 IMPORTANT INFORMATION
• REMOVAL AND DISMANTLING
1. Before carrying out dismantling operations, remove eventual dirt, mud, dust and
foreign bodies.
2. Use appropriate instruments and cleaning products exclusively. Refer to the
“SPECIAL INSTRUMENTS” paragraph.
3. During dismantling, avoid separating the coupled components, including cylinders,
pistons, gears and other parts that have become “coupled” during normal wear. The
coupled components must always be re-used or changed without separating them.
4. During dismantling, clean all the components and place them in a bowl, following
the order of dismantling.
This will make the re-mounting operation easier and allow a correct installation of
all the components.
5. Keep all the components away from any source of heat.
• SPARE PARTS
Use original Benelli spare parts exclusively.
Use oils and greases recommended by Benelli to oil the components.
Other products might appear similar in look and function but are inferior in quality.
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1

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• WASHERS, O-RINGS AND OIL SEAL
1. During the revision of the engine, change all the washers, O-rings and seals.
The surfaces of the washers and O-rings, and the lips of the oil seals must be
cleaned.
2. Oil all the coupled components and the ball-bearings and grease the lips of the
seals, when remounting.
• ELASTIC SAFETY WASHERS/PLATES AND SAFETY PINS
After removing, change all the elastic safety washers and safety pins. After tighten-
ing the bolts or nuts, bend the tongues of the safety washers/plates and the ends of
the safety pins on a flat surface of bolts or nuts.
• BALL-BEARINGS AND OIL SEALS
WARNING:
Do not rotate the compressed air ball-bearings as this might damage
their surfaces.
1. Install the ball-bearings and the oil seals so that the Producer brand or data are
visible. At the moment of installing the oil seal, oil the lip with a slight layer of
grease. The ball-bearings rotate freely if oiled in an appropriate way.
1.3 SPECIAL INSTRUMENTS
WARNING:
To avoid errors in ordering the special instruments, refer exclusively to
the inherent code.
For correct maintenance and a perfect set-up use the BENELLI special instruments,
avoiding damage as a result of inadequate or technically improvised instruments.

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1. R180197015000
GONIOMETER PLUG FOR
DISTRIBUTION[*]
2. R180197017000
INSTRUMENT FOR MOUNTING
CLUTCH OIL SEAL CASING [*]
3. R180197018000
CYLINDER MOUNTING SPACERS
[*]
4. R180197019000
SMALL CYLINDER COLUMN
FIXING SPAN
5. R180197020000
FALSE SPARKING-PLUG
6. R180197021000
PISTON THREAD MEASURER
1.3.1 SPECIAL ENGINE INSTRUMENTS

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7. R180197022000
P.M.S. MEASURER
8. R180197023000
CLUTCH COVER OIL SEAL PAD [*]
9. R180197024000
OIL SEAL PINION PAD [*]
10. R180197025000
OIL SEAL VALVE PAD [*]
11. R180197026000
INSTRUMENT FOR CHECKING
VALVE LIFT
12. R180197027000
GONIOMETER INDICATOR
13. R180197028000
CLUTCH OIL SEAL PAD ON
FLANGE [*]

UK
17
MF13
14. R180197029000
ENGINE SUPPORT
15. R180197030000
INSTRUUMENT FOR CHECKING
ENGINE SHAFT
AXIAL PLAY
16. R180197036000
ENGINE MANAGEMENT
DIAGNOSTIC
INSTRUMENT [*]
17. R180100143000
RAPID RELEASE PETROL TUBE
KIT [*]
18. R180297130000
CLUTCH REGULATION KEY
19. R180297048000
DISMANTLING PINION
INSTRUMENT

UK
18 MF13
1.3.2 SPECIAL FRAME INSTRUMENTS
20. R180297047000
DISMANTLING CLUTCH
INSTRUMENT
1. R180197033000
20 ALLEN WRENCH [*]
2. R180197031000
STEERING RING-NUT CLAMPS [*]
3. R180197034000
EMGINE DISMANTLING INSTRU-
MENT[*]
4. R180197032000
ENGINE SHOULDER ADJUST-
MENT CLAMPS [*]
5. R180297049000
COWLING SUPPORT TROLLEY
(*) Compulsory instruments

UK
19
MF13
6. R180297129000
RING NUT REGULATION KEY
AND STEERING LOCK NUT
7. R300097147000
CHAIN REGULATION TOOL
8. R300097146000
DISASSEMBLY TOOL
STEERING PLATE

UK
20 MF13
DIMENSIONS STANDARD LIMITS
Engine length 2100 mm —
Engine width 900 mm —
Maximum height 1050 mm —
Wheelbase 1443 mm —
Minimum light 100 mm —
Saddle height 780 mm —
Weight with oil and full tank 215 kg —
Weight without oil and full tank 205 kg —
Maximum load with pilot and load 400 kg —
2 SPECIFICATIONS
2.1 GENERAL SPECIFICATIONS
SS
SS
Specifications
2100 900
1443
1050
780
Dimensioni in mm
Dimensions in mm