Benelli TRK502 2013 User manual

TRK502

TRK 502 2
CONTENTS
CONTENTS ...........................................................................................................................................................................................................
Special Reminding ...........................................................................................................................................................................................
Preface ..................................................................................................................................................................................................................
Safety Notes ........................................................................................................................................................................................................
Safety Driving Rules ...................................................................................................................................................................................
Protection Clothes .....................................................................................................................................................................................
Serial Number ....................................................................................................................................................................................................
Location of Parts ...............................................................................................................................................................................................
Meter & Indicator ........................................................................................................................................................................................
Primary Parts ......................................................................................................................................................................................................
Key switch ......................................................................................................................................................................................................
Left Handle ....................................................................................................................................................................................................
Right Handle .................................................................................................................................................................................................
Fuel Tank ........................................................................................................................................................................................................
Rear Shock Absorber ..................................................................................................................................................................................
Rear Brake Pedal ..........................................................................................................................................................................................
256779
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15
15
16
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22
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24

CONTENTS
3TRK 502
Shift Pedal ...................................................................................................................................................................................................
Tool Bag .......................................................................................................................................................................................................
Notice of Use of Fuel and Engine Oil ......................................................................................................................................................
Running In .......................................................................................................................................................................................................
Inspection before Driving ..........................................................................................................................................................................
How to start the engine ........................................................................................................................................................................
Smooth launching ..................................................................................................................................................................................
To change gear ........................................................................................................................................................................................
Inspection& Maintenance ..........................................................................................................................................................................
Maintenance Schedule .........................................................................................................................................................................
Oil Level & Oil Change ...........................................................................................................................................................................
Spark plug ..................................................................................................................................................................................................
Catalytic Converter...................................................................................................................................................................................
Battery ..........................................................................................................................................................................................................
Throttle Cable Adjustment ...................................................................................................................................................................
Clutch Adjustment ...................................................................................................................................................................................
Chain Adjustment ....................................................................................................................................................................................
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25
25
26
27
28
29
30
30
30
34
35
35
36
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40
40

CONTENTS
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TRK 502
Brake ...............................................................................................................................................................................................................
Maintenance of Air Filter..........................................................................................................................................................................
Bulb Replacement ......................................................................................................................................................................................
Fuse Replacement ......................................................................................................................................................................................
Lubrication points ......................................................................................................................................................................................
Adjustment of Valve Clearance .............................................................................................................................................................
Tire ...................................................................................................................................................................................................................
Storage Guideline .............................................................................................................................................................................................
Specication & Technical Parameter .........................................................................................................................................................
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44
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46
46
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48
50

SPECIAL REMINDING
5TRK 502
Warning: The motorcycle must be equipped with the qualied fuse for a safe driving, any other unqualied
specications of fuses are not allowed to use, especially the electric wires which would result severe damages to
other parts, even re accidents.
Location of fuse: beside the battery;
Fuse specication: 40A for main power fuse.
Burnt fuse is usually caused by the internal circuit fault of the motorcycle. Simply estimate the whole situation of
the motorcycle before changing the spare fuse and if the fuse still burn after changing, send the motorcycle to the
maintenance service center as soon as possible. It can only be driven after the fault is resolved.
Notes:
Before changing the fuse, switch the key to " " in case of short circuit;
* Make sure the contact point of fuse is not broken while changing the fuse, which would result bad contact, parts
damage, and even re.
No reconguration: Do not recongure the motorcycle or change the places of the parts and accessories at will,
which would have a strong impact on the stability and safety of the motorcycle, probably operation faults. All the
recongurations of the electric system, emission control system, canister and any other systems or parts are against
the driving safety and other relative trac administration regulations. And all the quality problems and
consequences resulted by the user's reconguration or changing of the parts without authorizations would be
taken by the user himself. The user shall obey the specic regulations and rules of the trac administrative
department.

PREFACE
6
TRK 502
Notes
Running in of Motorcycle
The very beginning 1,000km driving-way of the motorcycle is the most important part of its service life.
If the running in is carried normally, a longest service life can be assured and the performances of the new
motorcycle can be fully fullled.
PREFACE
Thanks for choosing Benelli motorcycle, which is combined with international advanced technologies and would
bring you happy and safe driving experience.
Please fully understand the rules and requirements stated in this manual.
This instruction manual covers the maintenance procedures, which would ensure the maximum performances
and highest durability of your motorcycle if appropriately operated.
Our company is equipped with professional technical maintenance personnel and department, which is able to
provide you with high quality technical maintenance services. We make great eorts to develop the products
quality and performances so that the appearances and structures can be improved and may have dierence than
the data in this manual. The picture information here is only for reference, subject to our products.

7TRK 502
Please carefully read this manual and stand by the key rules. The words of "Alarm", "Caution" and "Note" are used
here to indicate the importance degrees, please make sure that you have fully understand the meanings as
following:
Alarm------------ This is for the important procedures that may endanger safety of the driver and would bring
injuries if ignored.
Caution------------ This is for the relative operation specications of the motorcycle in case of damages to the
motorcycle.
Note------------ This is for the maintenance
This instruction manual is a daily care issues document of this motorcycle, which should be together transferred
to a second owner if this motorcycle is to be transferred.
SAFETY NOTES
Alarm:
For the safety purpose, the driver should be specically careful with understanding on the safety notes
before driving.
SAFETY NOTES

8
TRK 502
1. Have a complete inspection before starting the engine so as to prevent possible accidents or damages of parts.
2. Many accidents happen due to inexperienced driver. Make sure the driver is qualied before driving the
motorcycle. Never give it to any people without a driving license.
3. Most of the crashes between cars and motorcycles are caused by the car drivers' "not seeing" the motorcycle
drivers. In order to avoid accidents, the driver shall expose himself/herself by:
Wearing bright colored and reective clothes;
Don't drive into the invisible corner of rear-view mirror of the other car drivers.
4. The driver shall obey the national and local laws and rules.
Speeding is one of the key reasons of the accidents. So keep the speed in the limit stated.
Use signals lights before turning or braking/accelerating to prevent accidents
5. In the driving, the driver should hold the handles and keep both feet on the pedals and the passenger should
grab somewhere on the vehicle or the driver with feet on the passenger pedals.
6. Any reconguration or disassembly of the parts is illegal, which would aect the safety driving and
maintenance.
7. The after-market accessories shall not aect the safety driving and operation performances of the motorcycle.
Overloading of the electrical systems would result dangers to the vehicle.
8. Do not operate the engine within conned space as the exhaust gas would cause damage to the body.
SAFETY NOTES

9TRK 502
SAFETY NOTES
1. Fatal accidents of motorcycle drivers are mostly caused by head injuries. For the purpose of personal safety, the
driver should wear a safety helmet, and also motorcycle boots, gloves and protection clothes. The passenger shall
also wear the same.
2. The exhaust pipe will be very hot during driving and the heat will last after turning o the engine. Never touch
the muer and wear those clothes that can totally cover the legs.
3. Don't wear those loose clothes that may interfere with the control levers, pedals or wheels.
PROTECTION CLOTHES

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TRK 502
Vehicle identication number (VIN) and the serial number are used for the registration of the motorcycle, which
can also make sure that the dealer would provide you better services involving accessories purchasing or other
services.
Record the numbers for the possible use in the future.
Vehicle identication number (VIN) is printed on the right side of the head tube.
The engine number is printed on lower part of the right case of engine crank case
Please write down the numbers for your reference.
SERIAL NUMBER
VIN:
Engine Number:

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LOCATION OF PARTS
1 Clutch lever
2 Left handle switch
3 Meter
4 Right handle switch
6 Front brake lever
5 Throttle grip
1 542 63

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LOCATION OF PARTS
7. Rear shock absorber
8. Rear brake pedal
9. Shift pedal
10. Side stand
11. Tank
7
8910
11

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13
LOCATION OF PARTS
Meter & Indicator 54 6 7 8 9
16
11
10
13
14
15
12
2
1
3

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LOCATION OF PARTS
1. TACHOMETER
Tachometer indicates the revolution per minute of engine.
2. ADJUST BUTTON
Short press the button to switch between km/h and mph.Long press
the button to reset the "Trip" mileage.
3. SELECT BUTTON
Short press the button to switch between trip and odometer func-
tions on the meter.Press button “SELECT” for several seconds,
there will appear the interface for time adjustment: “SELECT” for
selection of digits of time display and “ADJUST” for adjustment of
each value.
4. WATER TEMPERATURE INDICATOR
This indicator indicates the temperature of cooling liquid. When the
pointer is in between C and H, the temperature is normal. It should
stop to check the water tank if the pointer is higher than H level.
5.ENGINE CONTROL SYSTEM TROUBLE INDICA-
TOR
Return to authorized dealer if this indicator is activated during
riding.
6.TURNING INDICATOR
The indication lamps would flash with the turning signals.
7. HIGH BEAM INDICATOR LAMP
When the high beam lamp of the headlamp turns on, the high
beam indicator lamp would be on.
8. NEUTRAL INDICATOR LAMP
When the transmission is in the neutral, the indicator lamp
would be on.
9.ENGINE OIL PRESSURE WARNING LAMP
When this indicator light up, that means the bike has the risk of
insufficient lubrication and should be checked/
repaired immediately.
10. CLOCK
It shows the time.
11. GEAR INDICATOR LAMP
Numbers on the meter indicate the gear positions of the
vehicle including 1, 2, 3, 4 ,5,and6.
12.ODOMETER & TRIP METER
Relative mileage (TRIP): it records the mileage the vehicle
covers in a period of time.Odometer (TOTAL): it records
the total mileage the vehicle has covered in km.

TRK 502
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13. WATER TEMPERATURE INDICATOR
It should stop to check the water tank if the INDICATOR is light .
14.SPEEDOMETER
Speedometer shows the running speed, hours/kilometers.
15. FUEL LEVEL INDICATOR
It indicates the fuel level in the fuel tank.
16. ABS INDICATOR LIGHT
1. ABS failure -- If any type of ABS failure is detected and stored, ABS
indicator light is lit and stays on after repaired, then ABS indicator
light will be unlit after the next Power switch ON/OFF and when
vehicle speed exceeds 5km/h.
2. ABS is under OFF mode --ABS indicator light Blink 1 time/1.27s
(Slow Blink)
3. When press the the ABS switch within 3s ~30s --ABS indicator
light Blink 1 time/0.32s(Quick Blink)
4. ABS is under ON mode -- When keyswitch turned on, the ABS
indicator lamp lit and stays activated, until the motorcycle drive o,
reaching about 3~5KM/H will the ABS indicator lamp be unlit.
PRIMARY PARTS
Normally the ABS indicator light comes on when
the ignition switch is turned on and goes o
shortly after the vehicle starts moving. If the indi-
cator light shows any of the following, a fault or
faults may have occurred in the ABS. You should
have the vehicle checked by an authorized Benelli
dealer.
a. The light does not come on when the ignition
switch is turned on.
b. The light remains lit after the vehicle moving
over 5km/h.
Remember that the ABS does not function when
the indicator light is on, but if only the ABS system
fails (without any other malfunctions in mechanical
parts, for example, brake hoses, master cylinders,
brake calipers), the conventional brake system
should still work normally.

TRK 502 16
“ ”（On）position: The circuits are on
“ ” Position: turn left to the maximum, press the key to the position
of “ ”. Take out the key. In this condition, the vehicle has been locked.
If you want to unlock the vehicle, insert the key and turn clockwise.
“ ”（O）position: All the circuits are o.
1. HORN BUTTON
Press down on the button,to activate the horn.
2. HIGH & LOW BEAM SWITCH
Turn the switch to " " position, the high beam of headlamp turn
on and the indicator lamp on the meter would also turn on; turn
the switch to " " position, the low beam of headlamp turn on.
3. DIRECTION INDICATOR LAMP SWITCH
Turn the switch to " " position, the left direction signal lamp ashes; turn the switch to " " position, the
right direction signal lamp ashes. And the indicator lamps would turn on accordingly.
4. PASSING SWITCH
When passing other vehicles, press this button so the high beams of the headlamp would ash to alarm the
vehicles in front of you.
PRIMARY PARTS
P
U
S
H
KEY SWITCH
2
4
3
1
2
4
3
1
7. HIGH BEAM INDICATOR LAMP
When the high beam lamp of the headlamp turns on, the high
beam indicator lamp would be on.
8. NEUTRAL INDICATOR LAMP
When the transmission is in the neutral, the indicator lamp
would be on.
9.ENGINE OIL PRESSURE WARNING LAMP
When this indicator light up, that means the bike has the risk of
insufficient lubrication and should be checked/
repaired immediately.
10. CLOCK
It shows the time.
11. GEAR INDICATOR LAMP
Numbers on the meter indicate the gear positions of the
vehicle including 1, 2, 3, 4 ,5,and6.
12.ODOMETER & TRIP METER
Relative mileage (TRIP): it records the mileage the vehicle
covers in a period of time.Odometer (TOTAL): it records
the total mileage the vehicle has covered in km.
or
LEFT HANDLE HAZARD SWITCH

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17
PRIMARY PARTS
Alarm：
Turn on the direction signal lamps in time when changing the
driveway or turning a direction and turn o the lamps.
5. ABS SWITCH
If you want to enable/disable the ABS , please keep you motorcycle slower than5km/h
or stop, because the ABS switch only works when vehicle speed is lower than 5km/h.
5
ABS
From ABS ON mode → OFF mode
Please Keep pressing the ABS switch precisely within the range of 3~5 sec-
onds, the ABS indicator light should be changed from lit to blink as per 1.27s
(Slow Blink) when you release the switch,Now the ABS was turned OFF and
the brake will work as conventional system.
From ABS OFF mode → ON mode
Please keep pressing the ABS switch precisely within the range of 3~5 sec-
onds, the ABS indicator light should be changed from blink as per 1.27s(Slow
Blink) to constant lit when you release the switch.
Or you can turn the power switch o and on to reset the ABS system to On
mode
ABS
ABS ~
~

BN302
18
PRIMARY PARTS
ABS
ABS
The operation will be ignored by the
system If you keep pressing the ABS
switch within 5s~30s. ABS will keep the
current mode.
The ABS will be changed to ON mode
from any other mode if the switch was
stuck or pressed more than 30s.
ABS is designed to help prevent the wheels from locking up when the brakes are applied hard while running
straight. The ABS automatically regulates brake force Intermittently, gaining gripping force and braking force
helps prevent wheel lock-up and allows stable steering control while stopping. Brake control function is identical
to that of a conventional vehicle. The brake lever is used for the front brake and the brake pedal for the rear brake.
Although the ABS provides stability while stopping by preventing wheel lock-up, remember the following
characteristics:
~
NOTICE
The ABS switch does
not work If you press
the ABS switch as
whichever of the front
and rear wheel speed
is over 5km/h.
Anti-lock Brake System (ABS) for models equipped with ABS

BN302
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PRIMARY PARTS
• To apply the brake effectively, use the front brake lever and rear brake pedal simultaneously in the same
manner as conventional vehicle brake system.
• ABS cannot compensate for adverse road conditions, misjudgment or improper application of brakes. You
must take the same care as with vehicles not equipped with ABS.
• ABS is not designed to shorten the braking distance. On unpaved, uneven, or downhill surfaces, the stopping
distance of a vehicle with ABS may be longer than that of an equivalent vehicle without ABS. Use special caution
in such areas.
• ABS will help prevent wheel lock-up when braking in a straight line, but it cannot control wheel slip which may
be caused by braking during cornering. When leaning in corners, it is better to limit braking to gentle application
of both brakes or not to brake at all. Reduce your speed before you enter the corner. Same as conventional brake
system, an excessive sudden braking may cause wheel lock up and lose control.
• During braking, ABS will not prevent the rear wheel from lifting.
ABS cannot protect the rider from all possible hazards and is not a substitute for safe riding practices. Be
aware of how the ABS operates and its limitations. It is the rider’ s responsibility to ride at appropriate speeds and
manner for weather, road surface and trac conditions.
WARNING
!

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PRIMARY PARTS
The computers integrated in the ABS compare vehicle speed with wheel speed. Since non-recommended tires
can aect wheel speed, they may confuse the computers, which can extend braking distance.
Use of non-recommended tires may cause malfunctioning of ABS and can lead to extended braking distance.
The rider could have an accident as a result. Always use recommended standard tires for this vehicle.
WARNING
!
○ ABS indicator light may come on under certain extreme riding condition. For example, wheelie, stoppie,
or burn-out, rear-wheel drifting, or any maneuvers may cause the front and rear wheel to have dierent rotation
status. In this case, rst turn the ignition key to “OFF” , and then back to “ON” . ABS indicator light goes o by
this operation, but if ABS indicator light remains lit after the vehicle runs at the speed of approximately 5 km/h or
above, you should have the bike checked by an authorized Benelli dealer.
○ When the ABS is functioning, you may feel a pulsing in the brake lever or pedal. This is normal. You don’ t
need and should not stop applying brakes when this specic pulsing feeling appears.
○ ABS does not function at speeds of approximate 5 km/h or below.
○ ABS does not function if the battery is discharged.
!
NOTICE