Benelli ZAFFERAN 250 User manual

1
ZAFFERANO
250
Service Manual

2
Contents
Notice.................................................................................................................................................... 4
Preparing documents......................................................................................................................5
General Safety................................................................................................................................5
Inspection /Adjustment.................................................................................................................20
Inspection and maintenance of electrical system ................................................................................40
1. Battery/Charging System............................................................................................................41
1.1 Preparing documents ..............................................................................................................41
1.2 Failure diagnosis .....................................................................................................................42
1.3 Battery .....................................................................................................................................42
1.4 Charging system......................................................................................................................43
1.5 Voltage/current regulator......................................................................................................... 44
1.6 Magneto charging coil .............................................................................................................45
1.7 Magneto disassembly..............................................................................................................45
2. Ignition System............................................................................................................................ 47
2.1 Preparing documents ..............................................................................................................47
2.2 Failure diagnosis .....................................................................................................................48
2.3 Ignition system check..............................................................................................................49
2.4 RELATED PARTS Group........................................................................................................51
2.5Ignition coil................................................................................................................................51
2.6 Trigger......................................................................................................................................52
3.. Startup System...............................................................................................................................54
3.1 Preparing documents ..............................................................................................................54
3.2 Failure diagnosis .....................................................................................................................55
3.3 Startup motor...........................................................................................................................55
3.4 Starter relay.............................................................................................................................56
4.. Bulbs/Switches/Meters................................................................................................................. 58
4.1 Preparing documents ..............................................................................................................58
4.2 Failure diagnosis .....................................................................................................................58
4.3 Replacement of headlamp bulbs.............................................................................................58
4.4 Replacement of front steering lamp bulbs...............................................................................58
4.5 Replacement of tail lamp bulbs...............................................................................................59
4.6 Meter........................................................................................................................................59
4.7 Main switch..............................................................................................................................59
4.8 Horn.........................................................................................................................................60
4.9 Handlebar switch.....................................................................................................................60
Inspection and maintenance of vehicle................................................................................................61
5.. Brake................................................................................................................................................63
5.1 Maintenance instruction...........................................................................................................63
5.2 Failure diagnosis .....................................................................................................................63
5.3 Front disc brake.......................................................................................................................64
5.4 Rear disc brake........................................................................................................................65
6. Body............................................................................................................................................65
7. Front Wheel/Front Suspension...................................................................................................67
7.1 Preparing documents ..............................................................................................................72
7.2 Failure diagnosis .....................................................................................................................72
7.3 Front wheel..............................................................................................................................73
7.4 Steering handle .......................................................................................................................75
7.5 Front fork .................................................................................................................................76
7.6 Radiator/expansion tank assembly.........................................................................................77
8.. Rear Wheel/Rear Suspension....................................................................................................... 80
8.1 Preparing documents ...............................................................................................................80
8.2 Failure diagnosis ......................................................................................................................80
8.3 Rear wheel................................................................................................................................80
8.4 Rear absorber/rear swing arm..................................................................................................82

3
9.. Lubricating System ..........................................................................................................................85
9.1 Preparing documents ................................................................................................................85
9.2 Failure diagnosis........................................................................................................................85
9.3 Oil pump ....................................................................................................................................86
10. Cooling System.................................................................................................................................90
10.1 Preparing Documents..............................................................................................................90
10.2 Failure Diagnosis.....................................................................................................................90
10.3 Water Pump .............................................................................................................................90
11. Cylinder head/valve...........................................................................................................................93
11.1 Preparation documents........................................................................................................... 93
11.2 Failure diagnosis.....................................................................................................................94
11.3 Cylinder head..........................................................................................................................94
12. Cylinder body and piston..............................................................................................................104
12.1 Preparation documents.........................................................................................................104
12.2 Failure diagnosis...................................................................................................................105
12.3 Cylinder body........................................................................................................................105
12.4 Piston....................................................................................................................................106
13. Driving disc/clutch/driven wheel....................................................................................................115
13.1 Preparation documents.........................................................................................................115
13.2 Failure diagnosis...................................................................................................................116
13.3 Left crankcase cover.............................................................................................................116
13.4 Driving disc ............................................................................................................................116
13.5 Clutch/driven wheel ..............................................................................................................119
14. Transmission................................................................................................................................126
14.1 Preparation documents.........................................................................................................126
14.2 Failure diagnosis...................................................................................................................126
15. Crankcase..................................................................................................................................... 131
15.1 Preparation documents.........................................................................................................131
15.2 Failure diagnosis...................................................................................................................131
Inspection and maintenance of Emission control system...................................................................142
16. Emission control system................................................................................................................137
16.1 Emission control system recognizance................................................................................137
16.2 Regular maintenance notes..................................................................................................138
16.3 Mechanic function of Emission control system.................................................................... 139
16.4 Catalytic transfer system...................................................................................................... 140
Inspection and Maintenance of Electronic Fuel Injection (EFI) System............................................. 142
17. Electronic Fuel Injection System................................................................................................... 143
17.1 Introduction of Electronic Fuel Injection System.................................................................. 143
17.2 Components of Electronic Fuel Injection System................................................................ 144
17.3 Methods for Fault Diagnosis and Maintenance ................................................................... 172
17.4 Common troubleshooting..................................................................................................... 181
Circuit Diagram...................................................................................................................................186

4
NOTICE
This manual was produced by the Benelli Motor Company primarily for use by Benelli dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
a Benelli scooter has a basic understanding of the mechanical ideas and the procedures of
scooter repair. Repairs attempted by anyone without this knowledge are likely to render the scooter
unsafe and unfit for use.
Benelli Motorcycles USA is continually striving to improve all its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Benelli
dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR
SAFETY IS INVOLVED!
FailuretofollowWARNINGinstructionscouldresultin severeinjuryordeath
to thescooteroperator,abystanderor apersoninspectingorrepairingthe
scooter.
CAUTION: CAUTION:indicatesspecialprecautionsthatmustbe takentoavoiddamage
to the scooter.
NOTE: NOTE: provides key information to make procedures easier or clearer.

5
Preparing documents
General safety Maintenance
rules Specification tableFailure
diagnosis General Safety
Carbon monoxide
Engine must be started up in a well-ventilated place, not in a closed area.
Note
Exhaust gas contains poisonous carbon monoxide, which may cause unconsciousness or even
death of human.
Start the engine in an open place. An exhaust removal system shall be adopted if engine
is started up in a closed area.
Petrol
Ventilation is required for working places. Fire is strictly forbidden in any working place or where
petroleum is stored.

6
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL PROCE-
DURES
1. Remove all dirt, mud, dust and foreign ma-
terial before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the “SPECIAL TOOLS” section.
4. When disassembling the machine, always
keep mated parts together. This includes
gears, cylinders, pistons and other parts
that have been “mated” through normal
wear. Mated parts must always be reused
or replaced as an assembly.
5. During machine disassembly, clean all
partsand place themin trays in the order of
disassembly. This will speed up assembly
and allow for the correct installation of all
parts.
6. Keepallparts awayfromanysource of fire.
REPLACEMENT PARTS
1. Use only genuine Benelli parts for all re-
placements. Use oil and grease recom-
mended by Benelli for all lubrication jobs.
Other brands may be similar in function
and appearance, but inferior in quality.
GASKETS, OIL SEALS AND O-RINGS
1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.

7
LOCK WASHERS/PLATES AND COTTER
PINS
1. Replace all lock washers/plates and cotter
OR pinsafterremoval.Bendlocktabsalongthe
boltornutflatsaftertheboltor nuthasbeen
tightened to specification.
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
Wheninstallingoilseals,applyalightcoatingof
lightweight lithium base grease to the seal lips.
Oilbearingsliberallywheninstalling,ifappropri-
ate.
1 Oil seal
CAUTION:
Do not use compressed air tospin the bearings
dry. This will damage the bearing surfaces.
1 Bearing
CIRCLIPS
1. Check all circlips carefully before reas-
sembly. Always replace piston pin clips af-
ter one use. Replace distorted circlips.
When installing a circlip 1 , make sure that
the sharp-edged corner 2 is positionedop-
posite the thrust 3 it receives. See section-
al view.
4 Shaft

8
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
•
1. Disconnect
2. Connect
3. Dry each terminal with an air blower.
4. Connect and disconnect the connector two
or three times.
5. Pull the leads to check that it will not
come off.
6. Iftheterminalcomesoff,bendupthepin 1
andreinserttheterminalintotheconnector.
7.
•
Connect: Connector
NOTE:
The two connectors “click” together.
8. Check for continuity with a tester.
NOTE:
•
If there is no continuity, clean the terminals.
Be sure to perform the steps 1 to 7 listed
•
above when checking the wire harness.
For a field remedy, use a contact revitalizer
•
available on the market.
Use the tester on the connectors as shown.

9
METRIC TO IMP
Known
Multiplier
Result
Torque
mkg
cm.kg
7.233
86.794
0.0723
0.8679
ft
•
lb
ft
•
lb
Weight
kg
g
2.205
0.03527
lb
oz
Distance
km/hr
0.6214
mph
km
0.6214
mi
m
m
3.281
1.094
ft
yd
cm
0.3937
in
mm
0.03937
in
Volume/
cc (cm3)
cc (cm3)
0.03527
0.06102
oz
•
(IMPliq.)
Capacity
lit (liter)
0.8799
qt (IMP liq.)
lit (liter)
0.2199
gal (IMP liq.)
Miscella-
neous
kg/mm
2
Centigrade
55.997
14.2
°
234
lb/in 2
Fahrenheit ( F)
HOW TO USE THE CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL unit data.
Ex.METRIC MULTIPLIER IMP
**mm ×0.03937 = ** in
2 mm ×0.03937 = 0.08 in
CONVERSION TABLE
••
kg/cm psi (lb/in )
°

10
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools; this will help prevent damage caused bythe use of inappropri-
ate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Illustration
Tool name
Tool Usage
Weight
Rocker arm shaft puller bolt
These tools are used when removing
or installing the rocker arm shafts.
Rotor holding tool
This tool is used to remove the
flywheel magneto.
Ringnut wrench
This tool is used to loosen and tighten
the exhaust and steering ringnut.
Valve adjusting
tool
This tool is necessary for adjusting
valve clearance.
Fuel level gauge
This gauge is used to measure the fuel
level in the float chamber.
Radiator cap tester
Adaptor
These tools are used for checking the
cooling system.
T-handle
Damper rod holder
These tool are used for holding the
damper rod holder when removing or
installing the damper rod holder.
Clutch spring compressor
Clutch spring holder arm
These tools are used for removing the
nut with holding the compression spring.
Locknut wrench
This tool is used when removing or
installing the secondary sheave nut.

11
Illustration
Tool name
Tool Usage
Flywheel puller
This tool is used for removing the
rotor.
Fork seal driver weight
Fork seal driver attachment (ø33)
This tool is used when installing the
fork seal.
Oil seal guide
This tool is used for protecting the oil
seal lip when installing the secondary
sliding sheave.
Ring nut wrench
This tool is used to loosen and tighten
the steering ring nut.
Sheave holder
This tool is used for holding the
secondary sheave.
Cylinder cup installer set
This tool is used for installing the
cylinder cup to the master cylinder
piston.
Thickness gauge
This tool is used to measure the valve
clearance.
Compression gauge
These tools are used to measure the
engine compression.
Pocket tester
These instruments are invaluable for
checking the electrical system.
Engine tachometer
This tool is needed for detecting
engine rpm.

12
Tool name
Tool Usage
Illustration
Timing light
This tool is needed for detecting
ignition timing.
Valve lapper
This tool is used for removing and
installing the lifter and for lapping the
valve.
Valve spring compressor
Attachment
These tools are used when removing
or installing the valve and the valve
spring.
Middle shaft bearing driver
Mechanical seal installer
These tools are used for installing
mechanical seal.
Ignition checker
This instrument is necessary for checking
the ignition system components.
Sealant
This sealant (bond) is used for crankcase
mating surface, etc.

13
Specification (EFI Motorcycle ZAFFERANO)
Moodel
ZAFFERANO
Engine
Engine
type
BJ169MM-5A
Length inches
84.25
Fuel type
91# unleaded
petrol or above
Width inches
31.5
No. of
cylinder
1
Height inches
56.45
ID × stroke
69×66.8
Wheelbase inches
58.75
Total
displacement
249.7ml
Weight lbs.
(Curb weight)
Forward
shaft
165
Startup
Electric
Backshaft
265
CCoooling
Water cooling
Total
430
Lubrication
Force-feed and
splash
Tire
Size
Front wheel
120/70-14
Rear wheel
Air filter
Sponge
140/60-14
Transmission
Device
CClluuttcch
centrifugal
Capacity of
gasoline
tank
2.95 gallons
Performanc
e
Max. speed
75 mph
Transmission
CVT
Grade ability
≥20 degree
Idle speed
-rpm
1400±100rpm/min
Drive
Belt drive
Max. torque
17.3ft.lb /5000rpm
Electric
Device
Battery
capacity/typ
e
12V-6Ah/
dry-charged
Max. Hp
20.8hp /6500 rpm
Magneto
type
QJ（153-2）12V
200W/8500 rpm
Compression
ratio
10.5 : 1
Spark plug
NGK CR8E
Cylinder
pressure
1.25MPa/1500rp
m
Spark plug
gap
0.6-0.7mm
Braking
Diameter
of front
brake disc
(mm)
φ250mm

14
Ignition
spark ignition
DC
capacitance
system
Diameter of
rear brake
disc (mm)
φ250mm

15
A
(Nut)
B
(Bolt)
General torque
specification
•
s
Nm
m kg
10 mm
6 mm
6
0.6
12 mm
8 mm
15
1.5
14 mm
10 mm
30
3.0
17 mm
12 mm
55
5.5
19 mm
14 mm
85
8.5
22 mm
16 mm
130
13.0
GENERAL TORQUE
SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads. Torque
specifications for special components or as-
sembliesareincludedintheapplicablesections
of this book. To avoid warpage, tighten multi-
fastener assemblies in a crisscross fashion, in
progressive stages, until full torque is reached.
Unless otherwise specified, torque specifica-
tions call for clean, dry threads. Components
should be at room temperature.
A: Distance across flats
B: Outside thread diameter

16
LUBRICATION POINT AND GRADE OF LUBRICANT
ENGINE
Lubrication Point
Symbol
Oil seal lips
O-ring (Except V-belt drive unit)
Cylinder head tightening nut mounting surface
Crankshaft pin outside
Connecting rod big end thrust surface
Rotary filter inner surface
Drive gear inner surface
Cam chain outside sprocket inner surface
Piston pin
Piston outside and ring groove
Camshaft cam profile
Valve stem (IN, EX)
Valve stem end (lN, EX)
Rocker shaft
Valve rocker arm inner surface
Shaft
Shaft (Oil pump assembly)
Gasket (Oil pump assembly)
Holder
Idle gear 1 thrust surfaces
Shaft 1
Idle gear 2 thrust surfaces
Idle gear 2 inner surface
Main axle thrust surfaces
Crankcase mating surfaces
Sealant
Crankcase breather plug
Stator grommet
Sealant
Suction pipe

17
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
CHASSIS
Lubrication Point
Symbol
Front wheel oil seal lips (left/right)
Swingarm oil seal lips (left/right)
Steering head pipe bearing (upper/lower)
Steering head pipe dust seal lips (upper/lower)
Tube guide (throttle grip) inner surface
Brake cable (brake lever)
Brake lever and lever holder bolt sliding surface
Sidestand sliding surface
Centerstand sliding surface and mounting bolt
Centerstand stopper pivot shaft
Brake cam pivot shaft and cam surface

18
Periodic Maintenance & Inspection Table
Service cycle and
time Inspection item
Per
600
MI
600
MI
2000
MI
4000
MI
6000
MI
8000
MI
Tools
New
One
mont
h
Three
month
s
Six
months
Nine
months
Twelve
months
*
Air filter
I
C
C
R
C
Ordinary tools
*
Petrol filter
I
I
R
Ordinary tools
*
Fuel filter
C
C
C
Ordinary tools
Replacement of engine
oil
R
Replacement every 2000 MI
Ordinary tools
Tire pressure
I
I
I
I
I
I
Tire pressure
gauge, inflator
Battery inspection
I
I
I
I
I
I
Densimete
r,
multimete
r
Actuation gap
inspection
I
I
I
I
I
I
Ordinary tools
Inspection of steering
handle fastening
I
I
I
Ordinary tools
Absorber working
inspection
I
I
I
Ordinary tools
Screw fastening
inspection
I
I
I
I
I
I
Torque spanner
Oil leakage inspection
for gearbox
I
I
I
I
I
I
Ordinary tools
*
Inspection or
replacement of
spark plug
I
I
R
R
I
Ordinary tools
*
Replacement of
gearbox oil
I
Replacement every 3000 MI
Ordinary tools
Lubrication of each part
L
L
Lubricator
Exhaust pipe
I
I
I
I
I
I
Ordinary tools
*
Ignition timing
I
I
I
I
I
I
Timing lamp
*
Exhaust gas inspection
at idle speed
A
I
A
A
A
A
Tachometer, CO
HC analyzer
*
Throttle inspection
I
I
I
I
I
Ordinary tools
Fuel pipeline inspection
I
I
I
I
I
Ordinary tools
Lighting/metering/electric
devices
I
I
I
I
I
I
Visual multimeter
Main stand bracket
I
I
I
Ordinary tools
Absorber
I
I
I
I
Ordinary tools
*
Torque force of engine
bolts
I
I
I
I
I
Torque spanner

19
AnticipatedInspection
1
Ignition system—obviously continuous ignition abnormality, engine fire or overheating, which
requires inspection and maintenance.
2
Carbon fouling elimination—obviously insufficient horsepower, which requires carbon fouling
removal from cylinder head, piston head and exhaust system.
3
Piston & cylinder—excessive abrasion; replace cylinder if it is blocked.
Please have your motorcycle inspected and adjusted periodically at an authorized Benelli dealership to keep
your vehicle in the best possible condition.
The above table is established under the presupposition of 600 mi/month.
I—Inspection A—Adjustment R—Replacement C—Cleaning L—Lubrication
Note: 1. “*” Regulations on exhaust emission made by the State Environmental Protection Agency
shall be complied with. Maintenance must be carried out in accordance with the instruction
manual supplied by the company. We are not responsible for any loss rising from private adjustment
or maintenance.
2. Increase frequency of washing air filter if your motorcycle runs on sandy/gravel roads or
under heavily polluted environments so as to extend its service life.
3. Motorcycles which often run at high speed or with high mileage shall be maintained more
frequently.

20
Inspection / Adjustment
Preparing information
Periodic Maintenance & Inspection
Table Engine oil/ Oil filter
Fixing steering stem bearing &
handlebar Inspection & adjustment of
throttle cable
Cylinder
pressure Gear
oil
Replacement of gear oil
Drive belt
Free play of the front/rear
brake
Air filter Inspection of brake fluid level
Spark plug Headlamp
Battery Clutch
Ignition timing Front/rear suspension system
Rim/tires Bolt/nut/fasteners
Tire specifications
Preparing Principles
General
Warning!
•Make sure that it is well ventilated before starting the engine. It is forbidden to start it in a
closed area. Exhaust gas, which contains monoxide, may cause unconsciousness or even death.
•Petrol is liable to volatile or explode under certain conditions. Ventilation is required and no fire in
any working places. Fire is strictly forbidden in working areas or where oil is stored.