hsr-benelli S-series User manual

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SER
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Table of Content
1. GENERAL INFORMATION............................................................................. 6
1.1 Introduction…………………………………………………...……………. 7
1.2 Service quidelines……………………………………….………………… 9
1.2.1 Safety Warnings............................................................................... 9
1.2.2 Service Tools.................................................................................. 10
1.2.3 Operating materials........................................................................ 12
1.2.4 Engine Break-In.............................................................................. 13
1.2.5 Operating the engine on vehicle outside of water ......................... 13
1.3 Unit identification………………….…………………….……………...… 14
1.3.1 HSR-BENELLI Personal Watercraft Identification Numbers…...… 14
1.3.2 VIN number………………….……………………….…………...…… 14
1.3.3 Engine number ………….……………………….…………………… 14
1.3.4 Three stars –ultra low emission ……………………………….…… 15
1.3.5 Safety instructions ……………………………………………….…… 15
1.4 General specifications..........................................................................16
1.4.1 General data.................................................................................. 16
1.4.2 Standard Torque Specifications..................................................... 17
1.4.3 Convertion Chart ........................................................................... 18
2. MAINTENANCE ........................................................................................... 19
2.1 Flushing system attachment ............................................................. 21
2.2 Periodic maintenance chart ............................................................... 22
2.3 Periodic maintenance procedures .................................................... 23
2.3.1 Oil level check................................................................................ 23
2.3.2 Engine oil and filter replacement................................................... 24
2.3.3 Spark plugs replacement............................................................... 25
2.3.4 Valve clearance inspection............................................................ 26
2.3.5 Valve clearance adjustment........................................................... 27
2.3.6 Refilling of coolant.......................................................................... 31

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3. ENGINE.......................................................................................................... 32
3.1 Engine Removal and Installation........................................................ 33
3.2 Engine Disassembly/Assembly.......................................................... 41
3.2.1 CYLINDER HEAD ......................................................................... 41
3.2.2 CYLINDER AND PISTONS .......................................................... 58
3.2.3 ENGINE BOTTOM END ............................................................... 66
3.2.4 Cooling system Thermostat and Water pump .............................. 82
4. TRANSMISSION............................................................................................ 91
4.1 Transmission Dismantling.................................................................. 92
4.2 Transmission Assembling.................................................................. 98
4.3 Center flange bearing........................................................................ 107
5. PUMP........................................................................................................... 109
5.1 Jet Pump overview ............................................................................ 110
5.2 JET PUMP DISASSEMBLING ........................................................... 111
5.3 ASSEMBLING THE JET PUMP ......................................................... 116
5.4 Jet Pump Assembly into the PWC ................................................... 127
5.5 Assembly of the Reverse Gear (For Series –R Pro Model only)... 129
5.6 Assembling riding plate ................................................................... 130
5.7 Steering cable setting ...................................................................... 130
5.8 Trim system bleeding ....................................................................... 131
6. FUEL SYSTEM............................................................................................ 133
6.1 Fuel Tank and Fuel Pump ................................................................ 134
7. EXHAUST SYSTEM..................................................................................... 138
7.1 Muffler and Hoses ............................................................................. 139
7.2 Exhaust Manifold .............................................................................. 141
7.3 Assembling the hoses on exhaust manifold……………………….. 144
7.4 Leak test of the Exhaust hose ......................................................... 145
7.5 Assembling the exhaust manifold on the engine ……………….… 146

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8. COOLING SYSTEM..................................................................................... 147
8.1 Closed circuit cooling system ......................................................... 148
8.2 Opened circuit cooling systems ...................................................... 150
8.2.1 Exhaust cooling system ............................................................... 153
8.2.2 Oil cooling system ....................................................................... 156
9. STEERING SYSTEM ................................................................................... 157
SERIES-R STEERING SYSTEM
9.1 Steering Support Assembly ............................................................ 158
9.2 Assembly of the Steering Support on the PWC ............................. 160
9.3 Handle Bar assembly ........................................................................ 161
SERIES-S STEERING SYSTEM
9.4 Handle Pole Assembly ..................................................................... 164
9.5 Handle Bar Assembly ....................................................................... 170
9.6 Assembly of the Hanle Bar on the PWC ......................................... 171
10.HULL ........................................................................................................... 177
10.1 Dashboard cover ............................................................................... 178
10.2 Drainagebox ...................................................................................... 180
10.3 Baggage Cover .................................................................................. 181
10.4 Side Cover Assembling .................................................................... 184
10.5 Sponsons assembling ...................................................................... 185
11.ELECTRICAL SYSTEM .............................................................................. 186
11.1 General view (SERIES-S wiring diagram) ....................................... 187
11.1.1 Sector A ....................................................................................... 188
11.1.2 Sector B ....................................................................................... 188
11.1.3 Sector C ....................................................................................... 189
11.1.4 Sector D ....................................................................................... 189
11.1.5 Sector E ....................................................................................... 190
11.1.6 Sector F ....................................................................................... 190
11.1.7 Sector G ...................................................................................... 191
11.1.8 Sector H ....................................................................................... 191
11.2 General view (SERIES-R wiring diagram) ....................................... 192
11.2.1 Sector A ....................................................................................... 193
11.2.2 Sector B ....................................................................................... 193

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11.2.3 Sector C ....................................................................................... 194
11.2.4 Sector D ....................................................................................... 194
11.2.5 Sector E ....................................................................................... 195
11.2.6 Sector F ....................................................................................... 195
11.2.7 Sector G ...................................................................................... 196
11.2.8 Sector H ....................................................................................... 196
12.HSR-BENELLI DIAGNOSTIC SYSTEM ..................................................... 197
12.1 HSR-Benelli Utility Diagnostic System (HUDS) installation .......... 198
12.2 HSR Diagnostic Tool settings .......................................................... 204
12.3 Vehicle registration process ............................................................ 205
12.4 Periodic maintenance registration process ................................... 208
13.STORAGE ................................................................................................... 212
14.APPENDIX .................................................................................................. 214

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1.General Information
1.1 Introduction
This manual contains an introductory description of the HSR-Benelli Series-R and
Series-S Personal Water Craft (PWC) together with the procedures for
control/intervention and revision of the main components. It is designed primarily for
use by trained mechanics in a properly equipped workshop. A basic knowledge of
mechanics, the proper use of tools, and workshop procedures must be understood in
order to carry out maintenance and repair satisfactorily. All adjustments,
maintenance, and repair should be carried out only by qualified mechanics in
accordance with this service manual.
* 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 PWC 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 PWC in your possession.
SYMBOLS
Whenever you see these ATTENTION symbols, heed their instructions!
Always follow safe operating and maintenance practices.

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1.2 Service guidelines
1.2.1 Safety Warnings
ATTENTION:
Clean inside and outside of watercraft prior to servicing.
Clean all parts before installing.
Always use a service apron to prevent damage to foot well and top-deck fiberglass.
Watch for sharp edges which can cause personal injury.
Protect hands and arms when working with sharp components.
Always use a soft-faced hammer and extreme care when removing difficult or stuck
components.
Some fasteners are installed with locking agents or lubricants. Use of impact drivers will aid
in fastener removal.
Always follow torques specifications located throughout manual.
Fasteners secured with either too little or too much torque may fail and cause severe
property damage, injury or death.
Always follow torque sequence patterns when founding this manual.
Tighten each fastener evenly and to the specified torque value, and with specified locking
agent.
Always use new gaskets, o- rings and seals, clips, cir- clips, and snap rings when
assembling components.
Never reuse self-locking nuts when assembling components.
Never reuse hose clamps when removed from fuel lines. Replace with small gear clamps.
WARNING:
Always use HSR-Benelli authorized lubricants, greases, and locking agents when
assembling components. Failure to do so may cause severe engine or vehicle damage.
Always disconnect the black (-) negative cable first from the battery when removing the
battery. When installing the battery, attach the red (+) positive cable first, then the black (-)
negative cable.
Wear appropriate clothing, eye protection, and rubber gloves when working with batteries.
Battery acid contains sulphuric acid and is extremely poisonous. Serious burns can result
when in contact with skin, clothing, eyes or internal body components. If battery acid is
ingested, drink large quantities of water or milk. Follow with milk of magnesia, beaten egg or
vegetable oil. Call a physician immediately. Flush eyes for 15 minutes with water and seek

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prompt medical attention if acid comes in contact with eyes. Thoroughly wash affected
external body parts that come in contact with battery acid with water.
Keep hands, arms, legs, feet and hair away from rotating parts, hot engine and exhaust
components, drive pump and impeller and engine induction when engine is running.
Never attempt engine or driveline inspections and/or repairs without first removing lanyard
and battery cables.
Gasoline is highly flammable and explosive under certain conditions.
Always exercise extreme care when handling gasoline.
Do not smoke or allow open flames in or near the area where refuelling is performed or
where gasoline is stored.
Always refuel the watercraft outdoors and in a well ventilated area.
Do not fill the tank to the fuel cap.
If you get gasoline or oil on your skin or clothing, wash it off immediately with soap and water
and change clothing.
The engine exhaust from this product contains chemicals known to cause cancer, birth
defects or other reproductive harm.
Only run engine outdoors or in a well ventilated area.
Never run the engine for more than 10 seconds without cooling water supply.
1.2.2 Service Tools
HSR-BENELLI DIAGNOSTIC SYSTEM
(Benelli engine version)
IMPELLER TOOL
FLYWHEEL PULLER

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T.D.C. MEASURER
TRANSMISSION GEAR PULLER
GEAR NUT REMOVAL TOOL
COUPLER REMOVING TOOL
VALVE OIL SEAL REMOVING TOOL
OIL REMOVING TOOL

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1.2.3 Operating materials
WARNING:
Using of not recommended operating materials causes
damage to the engine and voiding of the warranty.
Fuel
-Super petrol unleaded DIN 51607, Octane between 95 and 98 ROZ/85 MOZ.
-US premium Unleaded gasoline (91/92/93 Octane) or 95/98 ROZ ISO 5146.
In case of emergency, unleaded fuel with 91 ROZ [RON] or 82.5 MOZ [MON] may be used
for a short time.
ATTENTION:
Lower-quality fuels could only be used in case of
emergency. If used regularly, they cause decreases in
performance and possibly damage to the engine.
Recommended lubricants
LUBRICANT
SPECIFICATIONS
Series-S
Series-R
Engine Oil
specification
HSR-Benelli engine oil 10w60,
ACEA, A3/B3/B4, API SL
Engine Oil
Filling volumes
Initial filling (completely dry system)
Oil change without changing filter
Oil change with filter
2,3 litres
1,7 litres
2,0 litres
2,7 litres
2,1 litres
2,4 litres

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LUBRICANT
SPECIFICATIONS
Series-S
Series-R
Transmission oil
Lubricated by Engine oil
system - HSR-Benelli engine oil
10w60, ACEA, A3/B3/B4, API
SL
see engine
oil volumes
see engine
oil volumes
Coolant
Permanent type of antifreeze
based on monoethylene glycol,
GREEN, freezing point < -38°C
Total
amount:
2,5 litres
Total
amount:
3,0 litres
Trim system liquid
Brake fluid DOT4
1.2.4 Engine Brake-In
WARNING:
HSR-BENELLI recommends not to operate the engine over
6,000 r/min [RPM] during first five hours of operation. This
protective braking-in has a positive effect on the engine„s
lifespan.
1.2.5 Operating the engine on vehicle outside of water
WARNING:
If PWC is outside of water its engine may be operated at idle
speed only for maximum of 30 seconds. Never run the
engine for more than 30 seconds without cooling water
supply.
If it is necessary to operate the engine longer than 30 seconds on vehicle out of water, the
flushing equipment must be used.
Use flushing system to operate vehicle out of water
An auxiliary cooling supply may be used if the watercraft cannot be operated in water during
adjustments.
If possible, always operate the watercraft in water rather than use an auxiliary cooling supply.
See chapter Maintenance –Flushing system connection.

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1.3 Unit identification
1.3.1 HSR-BENELLI Personal Watercraft Identification
Numbers
The engine Serial number and VIN number are used to register the watercraft. They are
unique numbers that distinguish each watercraft from others of the same model.
If the watercraft is ever stolen these numbers will help identify it. The owner should keep a
record of these numbers in a place other than the watercraft
1.3.2 VIN number
AT : Manufacturing Country
HSR : HSR-BENELLI
A: Model Code
1001: Sequential Serial Numbers
Production Month: C (Month code)
Production Year : 8
Model Year : 08 (Model year : 8= 2008)
You will find the serial number at the right rear side of your PWC
1.3.3 Engine number
Number is beside the starter motor.
Engine Number:
BH33 Engine Type
000001 Serial Number
JJ808 Model and Year Code

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1.3.4 Three stars –ultra low emission
The three-star label identifies engines that meet the Air Resources
Board’s Personal Watercraft and Outboard marine engine 2008
exhaust emission standards. Engines meeting these standards have
65% lower emissions than One Star –Low Emission Engines.
1.3.5 Safety instructions
For Series-S ONLY
Safety Instructions sticker is placed under the handle pole on
the Series-S models.
For Series-R ONLY
Safety Instructions sticker is placed on the Luggage Cover on
the Series-R

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1.4 General specifications
1.4.1 General data
2009 HSR-BENELLI
Series –S Series - R
Length: ..........…………….. 2,32 m Length: ..........………. 3,23m
Width:…………………….. 0,70 m Width:………………… 1,20 m
Height:……………………. 0,67 m Height:……………….. 1,03 m
Dry Weight:………………. 168kg Dry Weight:………….. 263 kg
Category: …………………. Stand-up Category: ……………. Runabout
Riders:…………………….. 1 person Riders:………………….1 –3 persons
Fuel Capacity: 18 litres 4, 75 US Gal Fuel Capacity: 70 litres 18,47 US Gal
Emission Certification: Three Star - Ultra Low Emission
ENGINE
EMISSION CONTROL SYSTEM
SFI ( Sequential Fuel Injection )
FUEL
Recommended fuel:
- Super petrol unleaded DIN 51607, Octane between 95
and 98 ROZ/85 MOZ.
- US premium Unleaded gasoline (91/92/93 Octane) or
95/98 ROZ ISO 5146.
SPARK PLUG
CHAMPION RG4HC
SPARK PLUG GAP
0,75 –0,8 mm ( 0.0028 –0.032 in.)
ENGINE DISPLACEMENT
1130 cc
NUMBER OF CYLINDER
3
CYLINDER LINING SURFACE
Nicasil
BORE x STROKE
88 x 62 mm
COMPRESSION RATIO
12 -13:1
CYLINDER COMPRESSION
9,6 +/- 1 bar ( 140 +/- 14,5 psi )
MAXIMUM HORSEPOWER
Series-S Pro Edition - 142 hp,
Series-S Race Edition - 162 hp,
Series-R Naked Edition - 142 hp,
Series-R Pro Edition - 172 hp
COOLING SYSTEM
- closed loop with thermostat;
- auxiliary opened loop oil & exhaust cooling systems
THERMOSTAT
70°C
EXHAUST OVERHEATING WARNING
Exhaust Manifold Overheat switch –engine limiter
activation
COOLANT OVERHEATING WARNING
Cooling manifold Sensor –90° engine limiter activation
ENGINE LUBRICATION SYSTEM
Wet Sump
ENGINE OIL SPECIFICATIONS
HSR-BENELLI Engine oil 10w60,
ACEA, A3/B3/B4, API SL

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RPM LIMITER
9200 –9300 1/min –Determined by ECU
EXHAUST SYSTEM
Waterbox with water injector
ENGINE MANAGEMENT SYSTEM
FUEL DELIVERY
WALBRO Multi-point fuel injection
IDLE SPEED
1700 1/min +/- 50
MAGNETO GENERATOR OUTPUT
13.5V / 48A at 5000 rpm
BATTERY
Series-R: 12 Volts 20Ah
Series-S: 12 Volts 14Ah
FUSES
30A –Alternator, 15A –Fuel Pump, 7,5A –Stop switch,
30A - Main
STARTER
Electric Motor 12V –850 W
PROPULSION
JET PUMP TYPE
SOLAS –Axial Flow –12 Veins –Steel stator
IMPELLER
Stainless steel –3 blade
Series-S Pro Edition –14/25,
Series-S Race Edition –15/26,
Series-R Naked Edition –11/19,
Series-R Pro Edition –11/19 XL
COUPLING TYPE
Six piece coupler + Damper
MINIMUM DEPH FOR OPERATION
60cm (2 Ft)
HULL / BODY
HULL MATERIAL
Fiberglass, RTM Process
1.4.2 Standard Torque Specifications
The following torque specifications are to be used as a general guideline.
Use standard torque values for the appropriate size fastener when torque values are not
specified.
Always consult the specific manual section for torque values of fasteners and use of
locking agent.
RECOMMENDED TORQUE SPECIFICATION
STAINLESS STEEL FASTENERS (METRIC)
4 mm
3 -3,5 NM (40–42 in.lbs.)
5 mm
4 –4,5 NM (45-52 in.lbs.)
6 mm
5,5 –6,5 NM (66-78 in.lbs.)
7 mm
17 –23 NM (13-16 ft.lbs.)
10 mm
35 –40 NM (26-30 ft.lbs.)
12 mm
54 –60 NM (40-44 ft.lbs.)

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1.4.3 Convertion Chart
ft. lbs.
x 12
= in. lbs.
in. lbs.
x 0,0833
= ft. lbs.
ft. lbs.
x 1,356
= Nm
in. lbs.
x 0,115
= kg-m
Nm
x 0,7376
= ft. lbs.
kg-m
x 7,233
= ft. lbs.
kg-m
x 86,796
= in. lbs.
kg-m
x 10
= Nm
in.
x 25,4
= mm
mm
x 0,03937
= in.
in.
x 2,54
= cm
mile (mi.)
x 1,6
= km
Km
x 0,6214
= mile (mi.)
Ounces (oz.)
x 28,35
= Grams (g)
Grams (g)
x 0,035
= Ounces (oz.)
lb.
x 0,454
= kg
kg
x 2,2046
= lb.
Cubic inches (cu in)
x 16,387
= Cubic centimeters (cc)
Cubic centimeters (cc)
x 0,061
= Cubic inches ( cu in)
Imperial pints (Imp pt)
x 0,568
= liters (l)
Liters (l)
x 1,76
= Imperial pints (imp pt)
Imperial quarts (Imp qt.)
x 1,137
= liters (l)
Liters (l)
x 0,88
= Imperial quarts (Imp qt)
Imperial quarts (Imp qt.)
x 1,201
= US quarts (US qt)
Liters (l)
x 1,057
= US quarts ( US qt)
US gallons (US gal)
x 3,785
= Liters (l)
Liters (l)
x 0,264
= US gallons (US gal)
Pounds –force per square inch
(psi)
x 6,895
= Kilopascals (kPa)
Kilopascals (kPa)
x 0,145
= Pounds –force per square inch (psi)
Kilopascals (kPa)
x 0,01
= Kilograms- force per square cm
Kilograms- force per square cm
x 98,1
= Kilopascals (kPa)
C to F: 9 ( C + 40) 5 - 40 = F F to C: 5 ( F + 40) 9 - 40 = C

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2 Maintenance
The table in chapter Periodic maintenance table provides the manufacturer’s
recommended intervals for maintenance work. Following the maintenance recommendations,
a long life span of the vehicle can be achieved and unnecessary environmental damage
prevented. The Maintenance intervals specified in the table should not be exceeded by more
than 10%.
All activities described in this manual must be carried out by trained service staff.
In case of warranty repairs HSR-BENELLI reserves the right to request warranty approval
documents for performed periodic maintenance of eligible PWC.
ATTENTION:
The vehicle owner or user is responsible adhering to the
maintenance intervals. HSR assumes no liability for damage
that arises due to maintenance not carried out.