WSManual TreK1130 PDF

ver.
01 June 2009
25
34A
A
V
Code 0310294100000
MANUALE OFFICINA • WORKSHOP MANUAL • MANUEL D’ATELIER •

TECHNISCHES HANDBUCH • MANUAL THE TALLER
SSMT
Workshop
Manual
2009
TRE 1130 K
WORKSHOP MANUAL
2009, Benelli Q.J. s.r.l.
First Edition, June 2009
All rights reserved.
Any reprinting or use without the
written authorisation of Benelli Q.J. s.r.l.
is forbidden.
WARNING
This manual has been edited by Benelli Q.J. s.r.l. mainly for use by Benelli dealers and their qualified mechanics. It is not
possible to supply a mechanic with all the necessary information in a single manual. It is therefore assumed that the persons
using this manual for maintenance and repair of Benelli vehicles have a basic knowledge of the mechanical principles and of
the procedures concerning the repairing technique of this type of vehicle. Without this knowledge, the repair or the
maintenance of this type of vehicle can be dangerous and ineffective.
The Benelli Q.J. s.r.l. policy is to continuously improve all its models. The important amendments and changes in the
technical data or in the procedures will be communicated to all authorised Benelli dealers and will be published in the future
editions of this manual.
NOTE
The drawings and specifications are subject to amendment without
. prior notice.
PARTICULARLY IMPORTANT INFORMATION RELATING TO

THE MANUAL
The text in this manual contains following important references.
Failure to follow the instructions under this symbol may cause serious injury or even
WARNING death of the driver, the person near-by, or the person who intents to inspect or repair
the bike.
Attention indicates the precautions that should be complied with to to avoid

ATTENTION damage to the bike.
NOTE A note supplies key information to facilitate or clarify procedures.

HOW TO USE THIS MANUAL
This manual is intended as a practical reference guide and easy to use for the mechanics. The explanations of all
procedures of installation, removal, disassembly, assembly, repair and control are organized sequentially, taking one step
at a time.
1 Each chapter is divided into sections. At the top of each page shows the title of current section.
2 To help identify parts and clarify the points of the various procedures, at the beginning of each section, exploded drawings are
shown the removal and disassembly of the components.
3 The sequence of the operations is shown on the exploded drawing using progressive numbering.The number indicates
the stage of dismantling.
4 The parts to be lubricated or replaced are marked by symbols. See the "SYMBOLS" paragraph.
5 The exploded drawing is accompanied by a table with the intervention instructions, indicating the order of the ope-
rations, the name of the pieces, the notes relating to the work, etc.
6 The interventions requiring additional information (for example, special tools and technical data), are described
sequentially.
IMPIANTO DI LUBRIFICAZIONE IMPIANTO DI LUBRIFICAZIONE

ENG ENG
INSTALLAZIONE COPPA OLIO

E FILTRO ASPIRAZIONE
A
CONTROLLO COPPA OLIO E FILTRO
ASPIRAZIONE
1 Controllare:
• la coppa dell’olio A
In presenza di lesioni/danni Sostituire.
2 Controllare:
• il filtro aspirazione B
6
In presenza di lesioni/danni Sostituire.
4 NEW 4 8
In presenza di sedimenti/residui
tamente la zona filtrante con solvente.
Pulire accura-
1 NEW
10
TE
EN
LV
SO
3 5
3
52
A4
3
3
B
9 10.8 N m - 1.1 Kg m 2
R.
2
T.
6 9.8 N m - 1 Kg m
R.
T.
NEW 11
7 10.8 N m - 1.1 Kg m
R.
T.
21 N m - 2.1 Kg m 12
R.
GR
T.
5 SQ. SIMBOLI INTERVENTO/DESCRIZIONE Q.TÀ OSSERVAZIONI
Installare i pezzi nell’ordine indicato.

Installazione Filtro Aspirazione
1 NEW
Guarnizione O-Ring 1
2 Filtro Aspirazione 1
3 52A43
Vite 2
Installazione Coppa Olio
4 NEW
Guarnizione Coppa Olio 1
5 Bussola 2
6 Coppa Olio 1
7 Vite 10
8 Piastra 1
9 Vite 2
10 Fascetta 1
11 NEW
Rondella 1
12 GR
Tappo Magnetico 1
NOTA:
Immettere l’olio motore una volta completate
le operazioni.
3 108 <<Indietro Indice Avanti>> 3 107 <<Indietro Indice Avanti>>

SYMBOLS
SYMBOLS
1 GEN SPEC 2
INFO These symbols do not refer to all vehicles:
the symbols from 1 to 7 indicate the subject of each
chapter.
3 CHK CHAS 4 1 General Information
ADJ
2 Specifications
3 Routine Inspections and Adjustments
4 Frame
5 ENG COOL 6 5 Engine
6 Cooling system
7 Electric system
7 ELEC The symbols from 8 to 10 indicate the following:
8 Wear, Clearance Limit

9 Special Tool
10 Fastening Torque
8 9
The symbols from 11 to 21 in the exploded drawings

T. R . indicate the type of lubricant and the point of lubrication:
10 TOP 11
4 11 Brakes Liquid TUTELA BRAKE FLUID TOP 4 - DOT 4
12 Engine Oil SELENIA MOTO RIDER PRO-ACTION 4T
13 Oil for Gears TUTELA MATRYX MOTO RIDER
14 Solvent For Fairing TUTELA THE SHAMPOO
12 13 15 Solvent For Engine TUTELA MOTOR CLEAN
E G
16 Molybdenum Disulphide Grease SINTOFLON
17 Copper Grease MOLYKOTE HSC PLUS
18 Lithium Soap Based Grease TUTELA MR 2
14 15 19 Apply Some AREXONS SYSTEM Thread Brakes
20 Apply TUTELA PROFESSIONAL IVORY SIL AC
Sealing Paste
21 Replace The Part
16 S 17 GR 18 LS
19 20 IS
IL A
C
21 NEW
OR
52A43 YV
AREXONS-SYSTEM VARIATIONS
Arexons SYSTEM 52A70
STRONG THREAD BREAKS 52A70 The following table refers to the sealing paste.
The table shows the various specifications of
AREXONS SYSTEM.
Arexons SYSTEM 52A90 Benelli recommends always using AREXONS SYSTEM
PENETRATING 52A90
original products.

HIGH TEMPERATURE SEALER 56A48

MEDIUM THREAD BRAKES 52A43

HIGH RESISTANCE SEALER 56A01
INDICE
GENERAL INFORMATION
1 GEN
INFO
SPECIFICATIONS
2 SPEC
ROUTINE INSPECTIONS AND ADJUSTMENTS

3 CHK
ADJ
FRAME
4 CHAS
ENGINE
5 ENG
COOLING SYSTEM
6 COOL
ELECTRIC SYSTEM
7 ELEC
GEN
INFO
1
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION OF MOTORCYCLE ...................................................................... 1

MOTORCYCLE IDENTIFICATION................................................................................................... 1
FEATURES .............................................................................................................. 2
INSTRUMENTATION AND LIGHTS................................................................................................ 2
MULTIFUNCTION DISPLAY ............................................................................................................ 3
DISPLAY FUNCTIONS SELECTION . ................................................................................................ 4
CLOCK ADJUSTMENT....................................................................................................................... 5
IMPORTANT INFORMATION ................................................................................ 6

PREPARATION FOR REMOVAL AND DISMANTLING OPERATIONS ................................... 6
SPARE PARTS ...................................................................................................................................... 7
GASKETS, O-RINGS, OIL RETAINER AND BEARINGS ............................................................... 8
SAFETY WASHERS/SAFETY PLATES, PINS AND THREAD BRAKES..................................... 9
SAFETY ELASTIC RINGS .................................................................................................................... 10
CONNECTIONS CONTROL ...................................................................................... 11

CONNECTIONS CONTROL ............................................................................................................... 11
SPECIAL TOOLS ...................................................................................................... 12

SPECIAL TOOLS FOR FRAME ......................................................................................................... 12
SPECIAL TOOLS FOR ENGINE ....................................................................................................... 13
GEN
INFO
GEN IDENTIFICATION OF MOTORCYCLE
INFO
MOTORCYCLE IDENTIFICATION
The identification data is:
• Frame number (on steering tube) A
• Engine number (on lower base) B
• Homologation data ( on frame) C
ZBN
TK5
670
188
882
9
saro
.l. Pe
Q.J. s.r
Benelli Italy
88 29
01 88 0
85 67 49
ZB N7 8 6 7 0 2 3
#97
1 1
GEN FEATURES
INFO
INSTRUMENTATION AND LIGHTS 2 COOLING LIQUID TEMPERATURE INDICATOR

It indicates the cooling liquid temperature in Celsius
degrees (°C).
The instruments and warning lights are activated by
turning the ignition key to "ON" position. 3 REVOLUTIONS COUNTER
After an initial check-up, the information corresponds It indicates the number of engine revolutions per
to the general conditions of the motorcycle at the minute expressed in miles.
moment. The dashboard has following instruments:
4 ALARM LED
1 INDICATOR LIGHTS It comes on when the oil pressure value, or that of the
a High beam warning light (blue) cooling temperature or of the battery voltage is incorrect
It comes on when the upper beams are activated. (also possible is the verifying of more anomalies
b Turn direction warning light (green) simultaneously) and it is accompanied by the flashing of
It comes on when flip the switch of turn direction. the relative wording "OIL", "H O", "BAT" appearing on the
c Fuel reserve warning light (orange)
speedometer instead of the speed value.
It comes on when the fuel tank contains about 5 If it switches on, immediately stop, leave the vehicle to
litres of fuel; in this case refuel as soon as possible. cool down for a few minutes and, if necessary, check the
d Neutral gear warning light (green) oil level and top-up.
It comes on when the gear is in “Neutral” position. If the problem persists, contact an authorised after-sales
e Injection malfunctioning warning light (orange) centre as soon as possible.
It remains on when a malfunctioning of the injection
plant verifies; in this case, contact an authorised
after-sales centre as soon as possible.
c d
b e
1
a
3
2
1 2
GEN FEATURES
INFO
MULTIFUNCTION DISPLAY 4 S
SERVICE WARNING LIGHT
It switches on for the first time after 1.000 Km (621 Mi)
1 DISPLAY then every 10.000 Km (6.213 Mi).
It indicates the speed. Every time it switches on, contact an authorised after
-sales centre as soon as possible and carefully follow
The value can appear in kilometres (Km/h) or in miles the indications in the maintenance and control tables
(mph).The value on the high full scale is of 320 Km/h in this manual.
(198.8 mph). Together with the warning light the flashing wording
2 TOTAL ODOMETER "Service" is displayed instead of the partial odometer
“Total” "Trip" for 10 seconds at every vehicle ignition.
It indicates the total run from 0 to 999999 Km or Mi.
"Chrono" Chronometer 5 T
THERMOMETER
It indicates the ambient temperature.
It indicates the run time expressed in minutes, The value can appear in degrees Centigrade (°C) or in
seconds an hundredths. Fahrenheit (°F).
“Clock” The indication field is between -30 and +50 °C or -22
It indicates the hour (0-12) and the minutes. and +122 °F.
3 PARTIAL ODOMETER
NOTE:
N
“Trip” D
During displaying of °F with values above 99°F, the
It indicates the partial run from 0 to 999999 Km or Mi. value of the hundredths is not present, but it is,
“Lap” however, understood.
In "Chrono" mode, it indicates the average time and
once the chronometer is stopped, it indicates the 6 FUEL LEVEL
It indicates the amount of fuel inside the tankwith an
real time.
eight bar diagram.
1
6
3 5
1 3
GEN FEATURES
INFO
DISPLAY FUNCTIONS SELECTION a "TOTAL"/ "TRIP"
NOTE:
The amendment or adjustment operations of the
display functions must be carried out after three
seconds from engine start-up, without subsequently
activating the clutch lever
(Start>2sec)
The display is provided with 3 primary functions:
a “Total”/ ”Trip” b "CHRONO"/ "LAP"
b “Chrono”/ ”Lap”
c “Clock”/ ”Trip”
(Start>2sec with
To switch from a "Total"/"Trip" to b "Chrono"/ "Lap", chronometer
press the START button for more than two seconds. at a stand still)
To switch from b "Chrono"/"Lap" to c "Clock"/"Trip", c "CLOCK"/ "TRIP"

press the START button for more than two seconds (with
chronometer at a stand still).
To switch from a "Clock"/"Trip" to c "Total"/"Trip",

press the START button for more than two seconds. (Start>2sec)
Partial odometer resetting a

The value of the "Trip" function is reset by pressing the
START key twice consecutively (with engine running and
without pulling the clutch).
Press the START button for at least two seconds and

NOTE: adjust the next digit.
The equipment has an integral memory preserving Repeat the procedure to adjust the second hour
digit, the first and second minutes digit.
all parameters even with the engine off. With the Press the START button for at least three seconds to
exception of the reset clock and of the "Trip" function, interrupt the selection and the flashing.
all other parameters remain in the memory even in To reset the "Trip" from the display c press
case of disconnection from the battery. the START button twice consecutively.
Set "Chrono"/"Lap" Set "Km"/"Mi"

Switch to b display. From the display a "Total"/"Trip" with engine
To start the "Chrono" press the START button for less running, keep the START button pressed for at
than one second. least ten seconds.
To view "Lap" from the "Chrono" position, press the The "Km" or "Mi" symbol will start to flash, press the
START button for less than one second. START button to switch to "Km" or "Mi".
Every time the START key is pressed for less than one Press the START button for at least two seconds to
second, the "Lap" function will display the time on the select the wanted unit of measure, automatically
"Chrono" at that moment (lap time). switching to the °C or °F selection.
To stop the "Chrono" press the START button for less Press the START button for less than one second to
than one second. select the wanted unit of temperature.
To reset the "Chrono" press the START button for at Press the START button for at least three seconds to
least three seconds. confirm and exit from the Set "Km"/"Mi" display.
To exit from the "Chrono" position press the START
button for at least two seconds moving to the c Set "Service"
"Clock"/"Trip" display. Upon reaching the first 1.000 Km (621 Mi) and every
10.000 Km (6.213 Mi), the flashing "Service" warning
Set "Clock"/"Trip" light will be displayed instead of the partial "Trip" for
Switch to c display. 10 seconds upon every vehicle ignition.
To adjust the clock, press the START button for at least To reset the "Service" warning light, keep the START
two seconds. button pressed for at least ten seconds until the
The first hour digit starts to flash. warning light switches off.
Repeatedly press the START button to adjust the digit
until the wanted digit is reached.
1 4
GEN FEATURES
INFO
CLOCK ADJUSTMENT
To switch from c display.
Press the START button (> 2 sec.); the first hour digit
starts to flash.
Repeatedly press the START button to adjust the digit
until the wanted digit is reached.
Press the START button (> 2 sec.) to adjust the next
digit.
Repeat the procedure to adjust the second hour digit,
the first and second minutes digit.
Press the START button (> 2 sec.) to confirm the hour
adjustment and to interrupt the selection (the
flashing).
1 5
GEN IMPORTANT INFORMATION
INFO
PREPARATION FOR REMOVAL AND

PRE
DISMANTLING OPERATIONS
1 Before carrying out the dismantling operations,
remove any dirt, mud, dust and foreign bodies.
Only use appropriate cleaning tools and products.
See the "SPECIAL TOOLS" paragraph.
2 During dismantling of the vehicle, we recommend

always keeping the coupled parts together.
Amongst these there are gears, cylinders, pistons and
other parts, which surfaces, through the normal work
wear, will have "coupled". The coupled pieces must
always be reused or replaced together.
During dismantling operations, clean all components
and position them in a basin following the dismantling
order. This will facilitate the assembly operations and
allow correct installation of all components.
3 Keep all components away from any source of heat.
1 6
INFO
SPARE PARTS
1 Only use original Benelli spare parts. To lubricate the
components, use oils and greases recommended by
Benelli. Other brands may be similar in aspect and
function, but of lower quality.
1 7
INFO
GASKETS, O-RINGS, OIL RETAINER

AND BEARINGS
Engine
lip oil 1 Always replace all gaskets, oil retainers and the
lip O-Rings during the engine repair interventions.
The surfaces of the gaskets, the oil retainers lips and
spring the O-Rings must always be kept clean.
oil During installation, suitably oil all parts subject to
coupling and the bearings, and lubricate the oil
retainers lips with engine oil.
1
Recommended lubricant
E ENGINE OIL
2 Install the bearings and the oil retainers so that the

brand or manufacturer number facing the outside
a are visible. To install the oil retainer, lubricate the lips
with a layer of engine oil.
When installing the bearings, abundantly oil them.
a Oil retainer
ATTENTION
Do not use compressed air to dry the bearings
making them rotate, as this would damage their
surface.
b Bearing
E ENGINE OIL
b
1 8
INFO
SAFETY WASHERS/SAFETY PLATES,

PINS AND THREAD BRAKES
1 After the removal, replace all safety washers/safety

plates A and the pins.
After having fastened the bolt or the nut, according
to specifications, fold the locking flaps and the ends
A of the split pin against the bolt or nut surfaces.
2 Whenever applying thread brakes, previously remove

grease from both sides using solvent.
Recommended solvent
TUTELA MOTOR CLEAN
1 9
INFO
SAFETY ELASTIC RINGS

A
1 Before assembling them, accurately check all elastic
C rings and replace the damaged or deformed ones.
Always replace the elastic rings of the piston pin after
B having used them once. If installing an elastic ring
A , ensure that the pointed angle B is
positioned on the other side compared to the push
D C it receives.
1 D Shaft
1 10
GEN CONNECTIONS CONTROL
INFO
C
CONNECTIONS CONTROL
Check there are no stains, rust, humidity, etc. on the
cables, the couplers and the connectors.
1 Disconnect:
• the wire
• the coupler
• the connector
2 Check:
• the wire
• the coupler
• the connector
If there are traces of humidity Dry using a fan.
In the presence of rust/stains Connect and
disconnect the parts various times.
3 Check:
• all connections
If there are loose connections Connect them
correctly.
NOTE:
If the foot A of the terminal box is bent, straighten
it.
A
4 C
Connect:
• the wire
• the coupler
• the connector
NOTE:
Check that all connections are securely installed.
5 C
Check:
• continuity
(
(with a pocket tester)
NOTE:
N
• If there is no continuity, clean the terminals.
• To check the wiring, follow the procedure from
point 1 to 3 .
• As quick remedy, we recommend using a specific
product for the contacts, found in spare parts
shops.
5
1 11
GEN SPECIAL TOOLS
INFO
SPECIAL TOOLS
The special tools shown here are used for the full and accurate execution of the set-up and assembly operations.Their use
will help prevent damages caused by the use of unsuitable tools or improvised techniques.When filling in an order, consult
the list below to avoid errors.
FRAME SPECIAL TOOLS

Tool Code Name - Tool Function Illustration
Steering Return Ring Spanner

R180297129000
This tool is used to remove and install
the ring nut from the steering wheel
Quick Release Kit

R180100143000 a
This kit is divided into two tools. Tool A is used to b
remove the petrol tube, tool B works as cap to
avoid petrol leaks.
Steering Head Spanner

R300097146000
This tool is used for the assembly and removal
of the steering head cap.
Transmission Chain Regulator Spanner

R300097147000
This tool is used to regulate the tensioning of
the chain.
20 Allen Spanner
R180197033000
This tool is used to remove and install the swing
arm pin
Diagnosis Instrument
R180197036000 This instrument is used as control, check, setting

and managing parameters in the injection plant
Diagnosis Instrument S CANTO O L
R300082003000 This instrument is used as control, check, setting

and managing parameters in the injection plant
Vacuum meter
M U L T IM A N
ON
Bil a nciam ent o f a rf a ll e

1
Z oom
R300097170000
3
This instrument is used to synchronise the

ok
P3 mbar
P2 mbar
P1 mbar
RPM
- 505
- 462
- 425
1250
carburettors or the throtless bodies as control

giri/mi n
esc
off
instrument
1 12
GEN SPECIALTOOLS
INFO
ENGINESPECIALTOOLS
Tool Code Name - Tool Function Illustration
Phonic Wheel Removal

R300097083000
This tool is used to block the phonic wheel,
both during removal and during installation
Buffer For Valves Oil Retainer

R180197025000
This tool is used to install the valve oil retainer
in the seat
Cylinder Assembly Thicknesses

R180197018000
These thicknesses are used to facilitate the
correct insertion of the cylinder
Clutch Dismantling Spanner

R180297047000
This tool is used to block the clutch
drum and loosen the nut
Clutch Pressure Plate Adjustment Spanner

R180297130000
This tool is used to regulate the clutch clearance
Buffer For Dry Clutch Oil Retainer

R180197023000
This tool is used to install the seal level
Centring Ring
R300197151000
This tool is used to install the dry clutch carter
Pinion Dismantling Tool

R180297048000
This tool is used to block the pinion and
remove the nut
Alternator Spanner
R300097161000
This tool is used to remove and install the
female joint
1 13
2 SPEC
SPEC
CHAPTER 2
TECHNICAL DATA
GENERAL SPECIFICATIONS ................................................................................... 1

GENERAL SPECIFICATIONS ............................................................................................................. 1
TECHNICAL DATA ................................................................................................. 2

ENGINE SPECIFICATIONS ............................................................................................................... 2
FRAME SPECIFICATIONS ................................................................................................................. 7
ELECTRIC SPECIFICATIONS............................................................................................................. 10
FASTENING TORQUES ........................................................................................... 13

GENERAL FASTENING SPECIFICATIONS.................................................................................... 13
FASTENING TORQUES AND RELATIVE PRELOADS FOR STANDARD CONNECTIONS ..... 14
ENGINE FASTENING TORQUES ..................................................................................................... 15
FRAME FASTENING TORQUES ..................................................................................................... 18
LUBRICATION POINTS AND TYPES OF LUBRICANT ........................................... 22

LUBRICATION POINTS AND TYPES OF ENGINE LUBRICANT ............................................ 22
LUBRICATION POINTS AND TYPES OF FRAME LUBRICANT ............................................... 23
COOLING SYSTEM LAYOUTS ............................................................................... 24

COOLING SYSTEM LAYOUTS ......................................................................................................... 24
SPEC
GENERAL SPECIFICATIONS
SPEC
GENERAL SPECIFICATIONS
SIZES STANDARD
Total length 2183 mm (85.9 in)
Total width 850 mm (33.4 in)
Total height 1320 mm (51.9 in)
Seat height 810 mm (31.8 in)
Interaxis 1514 mm (59.6 in)
WEIGHT STANDARD
In start order (with full oil and fuel tank) 240 Kg (529 lb)
Empty (with empty oil and fuel tank) 215 Kg (473 lb)
Maximum technically admitted 440 Kg (970 lb)
(with driver and load)
2183 850
1320
810
1514
2 1
TECHNICAL DATA
SPEC
ENGINE SPECIFICATIONS
ENGINE STANDARD
Type of engine 3 cylinders in line, 4 stroke,
liquid cooling, 4 valves per cylinder,
double cam axis on head with
balancing counter shaft
Engine displacement 1131 cc
Number of cylinders 3
Cylinders arrangement in line, tilted forward by 15°
with anti-vibrations countershaft
Bore x stroke 88 x 62 mm (3.4 x 2.4 in)
Compression ratio 11.6 : 1
Minimum power 1250 rpm
Maximum power 9500 rpm
Distribution chain driven double head cam shaft,

with 4 valves per cylinder
Maximum net power 92 kW (123 cv) at 9000 rpm
Maximum net torque 112 N m (11.4 kgf•m) at 5000 rpm
STANDARD FUEL STANDARD

Recommended fuel super unleaded petrol RON 95 min
ENGINE OIL STANDARD

Lubrication system forced, with humid carter
Total quantity 3.5 lt
Amount without oil filter 3.3 lt
cartridge replacement
Amount with oil filter cartridge
replacement 4.0 lt
Recommended oil
SAE DEGREES
FOR RECOMMENDED ENGINE OILS COMPARED TO EXTERNAL TEMPERATURES
-35 -30 -25 -20 -15 -10 -5 0 +5 +10 +15 +20 +25 +30 +35 +40 +45 +50
SAE 10W
SAE 20W
SAE 30W SAE 10 W-50
SAE 40W API SJ - JASO MA
SAE 10W - 30
SAE 10W - 40
SAE 10W - 60
SAE 15W - 40 mineral base
SAE 15W - 40 semisynthetic base
SAE 5W - 30 synthetic base
OIL FILTER STANDARD

Type of oil filter with paper
By-pass valve opening pressure 1.6 bar
STANDARD OIL PUMP STANDARD

Type of oil pump with lobes
Clearance between the internal rotor point 0.25 mm (0.0098 in) max
0.25 mm (0.0098 in) max and the rotor point
Clearance between the external rotor and the
0.2 mm (0.0078 in) max
oil pump slot
STANDARD START-UP STANDARD

Type of start-up system electric start-up
2 2
TECHNICAL DATA
SPEC
SPARK PLUGS STANDARD

Model (manufacturer) x quantity CHAMPION RG4HC\NGK CR9EK
Distance between the electrodes 0.7 ÷ 0.8 mm
CYLINDERS HEAD STANDARD

Maximum twist
0.1 mm
CAM SHAFTS STANDARD

Command system chain transmission
Cam shafts supports diameter 22.459 ~ 22.472 mm (0.8842 ~ 0.8847 in)
Clearance between support and cam shaft cap 0.1 mm (0.0039 in) max
Inlet side cam shaft lobes sizes
B
Measurement A 35.3 mm (1.38 in)
Measurement B 27.85 mm (1.096 in)
A
Drain side cam shaft lobes sizes
B
Measurement A 35.3 mm (1.38 in)
Measurement B 27.85 mm (1.096 in)
A
Maximum cam shaft eccentricity
0.04 mm (0.0015 in)
DISTRIBUTION CHAIN STANDARD

Model/number of links BF49C/118
Tensioning system automatic
2 3
TECHNICAL DATA
SPEC
VALVES, VALVE CONE, VALVE GUIDES STANDARD

Inlet valves clearance (when cold) 0.25 ~ 0.30 mm (0.009 ~ 0.011 in)
Drain valves clearance (when cold) 0.30 ~ 0.35 mm (0.011 ~ 0.013 in)
Valves sizes
Inlet A Ø 33 mm (1.29 in)
A Drain A Ø 29 mm (1.14 in)

Head diameter
B Inlet B 1 ~ 1.3 mm (0.039 ~ 0.051 in)

Drain B 1 ~ 1.3 mm (0.039 ~ 0.051 in)
Contact surface
width
C Inlet C 0.9 ~ 1.1 mm (0.035 ~ 0.043 in)

Drain C 0.9 ~ 1.1 mm (0.035 ~ 0.043 in)
Seat width
Valve stem Inlet 4.965 ~ 5.05 mm (0.195 ~ 0.198 in)

diameter Drain 4.955 ~ 5.05 mm (0.195 ~ 0.198 in)
Clearance between valve Inlet 0.0010 ~ 0.0037 mm (0.000039 ~ 0.00014 in)

stem and valve guide Drain 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)
Valve stem eccentricity
0.015 mm (0.0005 in)
VALVE SPRINGS STANDARD

Inlet/drain free External 37.0 mm (1.45 in )
length Internal 34.0 mm (1.33 in )
Inlet/drain (closed External 186 N m 18.96 Kgf•m
valve) installed
length Internal 92.5 N m 9.43 Kgf•m
Spring inclination
Inlet 1.7 mm (0.066 in)

Drain 1.7 mm (0.066 in)
CYLINDERS STANDARD
Cylinders arrangement in line tilted forward 15°
Bore x stroke 88 x 62
Compression ratio 11.6 ± 0.5 : 1
Bore 88 mm (3.46 in)
Maximum ovalisation 0.005 mm (0.00019 in)
2 4
TECHNICAL DATA
SPEC
PISTON STANDARD
Clearance between piston and cylinder 0.05 ~ 0.07 mm (0.0019 ~ 0.0027 in)
Piston diameter A 88 mm (3.46 in)

C
Piston height B 10.5 mm (0.41 in)
B
Pin seat diameter C 19.01 mm (0.748 in)
A
Piston pin external diameter 18.96 mm (0.746 in)
Upper band
Type of band elastic

B
Sizes A x B) 3.15 x 0.96 mm (0.124 x 0.037 in)
A
2nd band
Type of band elastic

B
Sizes ( A x B) 3.72 x 0.97 mm (0.146 x 0.038 in)
A
Oil scraper ring
B Sizes ( A x B) 2.26 x 1.93 mm (0.088 x 0.075 in)
A
CONNECTING RODS STANDARD
Bearing colour code A = Red B = Blu C = Yellow
Connecting rod weight code K1 = Black K2 =Green K3 = White

K4 = Brown K5 = Orange
ENGINE SHAFT STANDARD
B B
C
A
Width A 254 mm (10 in)
Maximum eccentricity B 0.050 mm (0.001 in)
Connecting rod head side clearance C 0.15 mm (0.0059 in)
Bench bearing colour code A = Red B = blue C = yellow
2 5
TECHNICAL DATA
SPEC
CLUTCH STANDARD
Type of clutch oil bath clutch, multiple disks
Clutch release method cable with springs
Activation for clutch release activation with cable
Activation with left handle bar lever
Clutch cable clearance (near
3 ~ 5 mm (0.11 ~ 0.19 in)
clutch lever end)
Friction disks thickness 3 mm (0.11 in)
Friction disks quantity 11
Steel disks thickness 2 mm (0.078 in)
Steel disks quantity 5
Steel disks thickness 1.5 mm (0.059 in)
Steel disks quantity 5
Disks pack thickness 50.25 mm (1.97 in)
Maximum twist 0.05 (0.0019 in)
Clutch springs free length 34.3 mm (1.35 in)
Springs quantity 6
TRANSMISSION STANDARD
Type of transmission straight teeth gears
Primary reduction ratio 44/79
Secondary reduction system chain/gears
Secondary reduction ratio 16/34
Transmission ratio
1ª 14/39
2ª 18/35
3ª 21/32
4ª 23/30
5ª 24/28
6ª 25/27
GEARS COMMAND MECHANISM STANDARD

Type of gears command mechanism sequential with desmodromic and preselector
Gears command fork guide bar maximum
0.05 mm (0.0019 in)
deformation
STANDARD AIR FILTER STANDARD

Type of air filter with sponge
FUEL PUMP STANDARD

Type of pump electric pump
Model (manufacturer) BITRON
Output pressure 3.5 bar
THROTTLE BODIES STANDARD

Diameter 53 mm (2.08 in)
Accelerator cable clearance (at accelerator
1 mm (0.039 in)
knob flange)
2 6
TECHNICAL DATA
SPEC
FRAME SPECIFICATIONS
FRAME STANDARD
Type of frame with steel-aluminium mixed structure trellis
Steering tube inclination 25°

Forward run 103.5 mm (4.07 in)
FRONT WHEEL STANDARD

Type of wheel with 5 wires
Measurement 17 M/C x MT3.5
Rim
Material aluminium
Wheel run 150 mm (5.9 in)
REAR WHEEL STANDARD

Type of wheel with 5 wires
Measurement 17 M/C x MT6.00
Rim
Material aluminium
Wheel run 144 mm (5.66 in)
FRONT TYRE STANDARD

Type of tyre tubeless
Measurement 120/70 ZR17 M/C (58W)
Model (manufacturer) roadsmart (DUNLOP)
Tyre pressure (when cold) 222 kPa (2.22 bar)
REAR TYRE STANDARD

Type of tyre tubeless
Measurement 180/55 ZR17 M/C (73W)
Model (manufacturer) roadsmart (DUNLOP)
Tyre pressure (when cold) 242 kPa (2.42 bar)
2 7
TECHNICAL DATA
SPEC
FRONT BRAKE STANDARD LIMIT

Type of brake double disk brake
Activation with right hand
Recommended liquid DOT 4
Brake disks
Diameter x Thickness 320 x 4 mm (12.5 x 0.15 in)

Minimum thickness 4.0 mm (0.15 in)
Maximum deformation 0.1 mm (0.004 in)
Worn brake pads
thickness 4 mm (0.15 in)
Pump cylinder internal diameter 16 mm (0.62 in)

Calliper cylinder internal diameter 34 e 30 mm (1.33 e 1.18 in)
F
REAR BRAKE STANDARD LIMIT
T
Type of brake Single disk brake
A
Activation with right foot
F
Recommended liquid DOT 4
Brake disks
Diameter x Thickness 240 x 5 mm (9.44 x 0.19 in)

Minimum thickness 4.5 mm (0.17 in)
Maximum deformation 0.15 mm (0.006 in)
Worn brake pads
thickness 3.5 mm (0.13 in)
Pump cylinder internal diameter 12 mm (0.47 in)

Calliper cylinder internal diameter 32 mm (1.25 in)
FRONT SUSPENSION STANDARD

with tilted stems telescopic fork with spiral
Type of suspension
spring/hydraulic shock absorber
Fork excursion 150 mm (5.9 in)

Spring
Free length 262 mm (10.31 in)

Spacer length 175 mm (6.88 in)
Flexibility (K1) 9.5 Nm (0.96 Kgf•m)
Spring run (K1) 0 ~ 120 mm (0 ~ 4.72 in)
Oil for fork
Recommended oil SAE 7.5 Marzocchi 19

Quantity for stem 710 cc.
Level (from end of external tube,
with external tube fully compress-
130 mm (0 ~ 5.11 in)
ed, and without fork spring)
STEERING WHEEL STANDARD

Type of bearings for steering wheel ball bearing
Angle from end run to end run (left) 30°
Angle from end run to end run (right) 30°
2 8
TECHNICAL DATA
SPEC
REAR SUSPENSION STANDARD

oscillating swing arm with
Type of suspension spiral spring/gas shock absorber
Fork excursion 145 mm (5.7 in)

Spring
Free length 160 mm (6.29 in)

Installed length 137 mm (5.39 in)
Flexibility (K1) 9.5 Nm (0.96 Kgf•m)
Spring run (K1) 61 mm (2.4 in)
Spring pre-load gas/air standard pressure 1200 kPa (12 bar)
Spring
pre-load Minimum 0
adjust- Standard 0
ment
positions Maximum 10 mm (0.39 in)
Bounce
damping Minimum* 0
adjust- Standard* -17
ment
positions Maximum * - 30
* from fully backward position
TRANSMISSION CHAIN STANDARD

Model (manufacturer) REGINA 137-ORPB
Number of links 108
Loosening of transmission chain 15 mm (0.59 in) from slide
2 9
TECHNICAL DATA
SPEC
ELECTRIC SPECIFICATIONS
PLANT VOLTAGE STANDARD

PLANT VOLTAGE 12 V
IGNITION REELS STANDARD

Model (manufacturer) 02IG001 (JCI)
Primary real resistance 0.6 Ω
Secondary reel resistance 10 kΩ
Primary reel inductance 2.5 mH (1 kHz 0.3V)
Secondary reel inductance 23.5 mH (1kHz)
Max. admitted current value 7.6 A
RECHARGE SYSTEM STANDARD

Type of system AC Magnetic
Model (manufacturer) 5-101211-502-1 (DENSO)
Nominal output 13.5 V 48 A a 5000 rpm
Voltage regulator (inside alternator) semi-conductor, FieldControl
Voltage adjustment 14.5 + 0.3 V (5000 rpm 10 A 25 C°)
START-UP RELAY STANDARD

Model (manufacturer) MS5F-421 (JIDECO)
Amperage 100 A
Reel resistance 4.4 Ω a 20 C°
BATTERY STANDARD
Model (manufacturer) CTZ 14S -BS (UNIBAT)
Battery capacity voltage 12 V / 14 A
Relative density 1.310
PROJECTOR STANDARD
Type of projector with halogen bulb
BULBS (VOLTAGE WATT x Q.TY) STANDARD

Projectors 12 V 55 W x 4
Front position light 12 V 5 W x 2
Rear position light/brake light LED x 1
Direction indicators 12 V 21 W x 2 + 12 V 6 W x 2
Number plate light 12 V 5 W x 1
Instruments control board light LED x 1
WARNING LIGHTS (VOLTAGE WATT x Q.TY) STANDARD

Neutral warning light LED x 1
High-beam warning light LED x 1
Oil level alarm warning light LED x 1
Direction indicators warning light LED x 1
Fuel level alarm warning light LED x 1
Cooling temperature warning light LED x 1
Faulty engine signal warning light LED x 1
Gears change warning light LED x 1
2 10
TECHNICAL DATA
SPEC
ELECTRIC START-UP SYSTEM STANDARD

Model (manufacturer) 5-128-330 (DENSO)
Supplied power 0.7 kw
ACOUSTIC WARNING DEVICE STANDARD

Type of acoustic warning device flat
Model (manufacturer) DL 123 (LI XIANG CHINA)
Maximum amperage 3A
Performances 105 ~ 118 db (A)
FLASHING LIGHTS RELAY STANDARD

Type of relay electric lasher
Model (manufacturer) 355 E10 (LEONELLI)
Direction indicators flashing frequency 80 ~160 cycles/min
Watt 10 W x4
OIL PRESSURE SENSOR STANDARD

Model (manufacturer) 11717.61 (F.M.D.I.)
FUSES (AMPERAGE x Q.TY) STANDARD

Main fuse 30 A x 1
Fuel injection system fuse 15A x 1
Projector fuse 20 A x 1
Services fuse 15 A x 1
Radiator fan motor fuse 15 A x 1
Back-up fuse (odometer and clock) 5Ax1
Reserve fuse 20A x 1 15A x 1 5A x 1
Petrol pump fuse 10 A x 1
THROTTLE VALVE SENSOR STANDARD

Model (manufacturer) 6PX 008476-11 (Hella)
Resistance 4.0 KΩ ± 20%
FUEL PUMP STANDARD

Model BITRON
Max. amperage 5 A a 13.5 V
Level sensor internal
Min. Max. resistance 285 Ω (empty) - 12 Ω(full)
SAFETY SWITCHES STANDARD

Trestle switch CE75A (ASAHI DENSO)
Neutral switch 20.00.057 (MONT.EL )
Tilt YE69A (DENSO)
INLET STANDARD AIR TEMPERATURE STANDARD

SENSOR
Model (manufacturer) 15TT001 (JCI)
Resistance 23.75 Ω 20 C°, 16.7Ω 30 C°
ENVIRONMENTAL AIR TEMPERATURE STANDARD

SENSOR
Model (manufacturer) FACOMSA 2211-1002
2 11
TECHNICAL DATA
SPEC
LIQUID TEMPERATURE SENSOR STANDARD

Model (manufacturer) 16TT001 (JCI)
Resistance 2500 Ω 20 C°, 322.5 Ω 80 C°
SPEED SENSOR STANDARD

Model (manufacturer) SNVO21F0001/0 (EUROSWITCH)
LAMBDA STANDARD
Model (manufacturer) OPS + 25324175 (DELPHI)
INJECTOR STANDARD
Model (manufacturer) U9122-357 (JCI)
RELAY UNIT STANDARD

Model (manufacturer) CM1 NAIS
IGNITION SYSTEM STANDARD

Type of ignition system WALBRO
Ignition setting 5° before PMS from 900 to 1800 r/min
Phonic wheel sensor (Pick-Up) O1VR002 (JCI)
Model (manufacturer) ECU - 1
STEPPER STANDARD
Model (manufacturer) 02SM001 (JCI)
Type of stepper two-phase
RADIATOR VENT STANDARD

Model (manufacturer) VA31-A101-46A (SPAL)
2 12
GEN FASTENING TORQUES
INFO
GENERAL FASTENING SPECIFICA-

TIONS
The fastening torques of the components or of the
special sets are shown in each chapter of this manual.
With regard to the sets with multiple fixing elements,
in order to avoid the risk of twisting, carry out
fastening in a crossed manner, in successive steps,
until the prescribed torque is reached.
Save different indication, the fastening torques refer
to the component with clean and dry threading.
The components must be at ambient temperature.
A Key opening
A B
B Threading external diameter
B FASTENING TORQUES IN GENERAL
bolt Nm kgf•m
4 mm 2.3 0.23
5 mm 4.5 0.45
6 mm 10 1.01
8 mm 25 2.54
10 mm 45 4.58
12 mm 80 8.15
14 mm 130 13.25
16 mm 200 20.39
18 mm 240 24.47
2 13
GEN FASTENING TORQUES
INFO
FASTENING TORQUES AND RELATIVE PRE-LOADS FOR STANDARD CONNECTIONS

The values shown in the following table refer to standard fastenings, meaning regarding the coupled metric screws with
relative nut or with metal female screw.
Furthermore, the bodies to be fastened must be made of metal or sufficiently stiff not to require bushes interpositions or
spacers.
The coupling is always with lightly oiled or greased thread; alternatively, the type of requested thread brakes paste must
be shown.
The axial pre-loads, correlated to the fastening torque, are increased by 10% compared to the calculated value, to take into
account of the tolerance on the nominal moment of the torque and of the variation that the friction coefficient can suffer
from, from fastening to fastening.
CLASS 8.8 CLASS 10.9 CLASS 12.9

SCREWS FASTENING AXIAL FASTENING AXIAL FASTENING AXIAL
TORQUE PRE-LOAD TORQUE PRE-LOAD TORQUE PRE-LOAD
[Nm] [N] [Nm] [N] [Nm] [N]
M4 X 0.7 3 3.870 4.2 5.420 5.2 6.710
M5 X 0.8 6 6.350 7.5 7.930 9 9.520
M6 X 1 10 8.860 13 11.520 16 14.180
M8 X 1.25 22 14.900 30 20.330 40 27.100
M8 X 1 (*) 25 17.280 36 24.890 45 31.110
M10 X 1.5 45 24.680 65 35.640 80 43.870
M10 X 1.25 (*) 50 27.870 70 39.013 85 47.380
M12 X 1.75 80 37.640 110 51.750 135 63.510
M12 X 1.5 (*) 85 40.547 120 57.250 145 69.170
M12 X 1.25 (*) 90 43.550 130 62.900 150 72.580
M14 X 2 130 52.670 185 74.800 220 88.950
M14 X 1.5 (*) 150 62.900 205 85.960 245 102.780
M16 X 2 200 74.070 280 103.690 335 124.060
M16 X 1.5 (*) 225 86.140 310 118.680 360 137.820
M18 X 2.5 265 83.650 370 116.790 450 142.040
M18 X 1.5 (*) 320 104.900 450 147.520 550 180.300
M20 X 2.5 390 111.870 550 257.770 650 186.450
M20 X 1.5 (*) 440 130.620 630 187.020 750 222.650
M22 X 2.5 540 141.950 750 197.150 900 236.580
M22 X 1.5 (*) 600 162.750 850 230.560 1.000 271.240
M24 X 3 670 160.238 950 227.203 1.130 270.252
M24 X 2 (*) 750 184.566 1.050 258.392 1.250 307.610
(*) The shown metric screw is fine step.
2 14
FASTENING TORQUES
SPEC
ENGINE FASTENING TORQUES
FASTENING TORQUES
BASE THREAD
Nm Kgf•m
Base Fixing TEF Screw M6 10 1.01
Base Fixing Screw M8 25 2.54
Base Benches Fixing TCEI Screw M10 45 4.58
Oil Conducts Closing Conical Grain M6 10 1.01
Bearings And Pin Fixing Screw M6 10 1.01
Plates And Tube Fixing Screw M6 10 1.01
Cylindrical Cap M16 25 2.54
Conical Cap M10 10 1.01
Oil Diaphragm M8 25 2.54
Neutral Position Sensor M8 10 1.01
Oil Pressure Minimum Sensor M10 25 2.54
Clutch Lid Oil Load Cap M24 By hand ~
Clutch Lid Phase Cap M40 By stroke ~
Clutch Lid Screws M6 10 1.01
Blow-By Lid Screws M6 10 1.01
Counter-shaft Lid Screw M6 10 1.01
Tank Oil Drain Cap M14 22 2.24
Tank Filter Fixing Screw M6 10 1.01
Tank Fixing Screw M6 10 1.01
Head Prisoner M10 By stroke ~
Head Vent Fitting M18 15 1.52
Grain M8 25 2.54
FASTENING TORQUES
LUBRICATION THREAD
Nm Kgf•m
Oil Pump Fixing Screw M6 8.3 0.84
Over Pressure Valve M12 25 2.54
Exchanger Fixing Large Screw M20 60 6.11
Head Oil Tube Hole Screw M10 16 1.63
Head Oil Tube Nipple M10 20 2.03
Oil Filter M20 18 1.83
FASTENING TORQUES
HANDLING THREAD
Nm Kgf•m
Phonic Wheel Fixing Nut M8 25 2.54
Connecting Rod Screw M9 25 + 50° 2.54 + 5.09
FASTENING TORQUES
PISTON CYLINDER HEAD THREAD
Nm Kgf•m
Prisoner M8 12 1.22
Conical Grain M6 10 1.01
Conical Cap M14 30 3.05
Lids Fixing Screw M6 13 1.32
Head Fixing Nut M10 45 + 100° 4.58 + 10.19
Tensioner Fixing Screw M6 10 1.01
Cylinder Cap Screw M6 10 1.01
Cylinder Fixing Screw M6 10 1.01
2 15
FASTENING TORQUES
SPEC
FASTENING TORQUES
DISTRIBUTION THREAD
Nm Kgf•m
Distribution Gear Fixing Screw M6 15 1.52
Upper Slide Support Fixing Screw M6 15 1.52
Reel Fixing Distribution Lid Screw M6 10 1.01
Distribution Lid Screw M6 10 1.01
Mobile Slide Pin ~ 13 1.32
FASTENING TORQUES
CLUTCH THREAD
Nm Kgf•m
Clutch Rod Adjustment Low Hexagonal Nut M8 16 1.63
Clutch Springs Fixing Screw M6 10 1.01
Clutch Fixing Hexagonal Nut M20 100 10.19
Clutch Command Fixing Screw M6 10 1.01
FASTENING TORQUES
GEAR CHANGE THREAD
Nm Kgf•m
Engine Pinion Fixing Nut M24 140 14.27
FASTENING TORQUES
GEAR CHANGE COMMAND THREAD
Nm Kgf•m
Plate Fixing Screw M6 10 1.01
Forks Pins Fixing Screw M6 10 1.01
Forks Pins Fixing Screws M6 10 1.01
Gear Change Command Lid Fixing Screws M6 10 1.01
Chain Cover Lid Fixing Screw M6 10 1.01
Gear Change Flange Fixing Screw M8 20 2.03
FASTENING TORQUES
COOLING THREAD
Nm Kgf•m
Pump Impeller Fixing Cap Nut M6 8.03 0.81
Pump Lids Fixing Screw M6 10 1.01
Bleeding Screw M6 10 1.01
Elbow Fixing Screw M6 10 1.01
Pump Body Fixing Screw M6 10 1.01
Collector Fixing Screw M6 10 1.01
Thermostat Disk Fixing Screw M6 10 1.01
Small Lid Fixing Screw M6 10 1.01
FASTENING TORQUES
IGNITION THREAD
Nm Kgf•m
Spark Plug M10 12 1.22
Reel Bracket Fixing Nut M6 8 0.81
FASTENING TORQUES
ELECTRIC PLANT THREAD
Nm Kgf•m
Start-up Motor Fixing Screw M6 10 1.01
Alternator Fixing Screw M8 25 2.54
Phonic Wheel Sensor Screw M6 8.3 0.84
Water Temperature Sensor / 20 2.03
2 16
FASTENING TORQUES
SPEC
FASTENING TORQUES
POWER SUPPLY THREAD
Nm Kgf•m
Throttled Body Fixing Screw M6 10 1.01
Petrol Flute Fixing Screw M6 10 1.01
Pull Power Limit Device Plate Fix Screw / / /
Petrol Tube Fitting / 20 2.03
Stepper Seat Fixing Screw M5 By hand 1.01
Gas Cables Plate Fixing Screw M6 10 1.01
Minimum Adjustment Cable / / /
FASTENING TORQUES
START-UP THREAD
Nm Kgf•m
Free Wheel Ring Fixing Screw M6 17 1.73
Engine Collar Hexagonal Screw M10 50 5.09
Engine Collar Hexagonal Nut M10 15 1.52
Satellite Gear Screw M6 10 1.01
2 17
FASTENING TORQUES
SPEC
FRAME FASTENING TORQUES
FASTENING TORQUES
BODY WORK THREAD
Nm Kgf•m
Engine Protection Fixing Screw M6 8/10 0.81/1.01
Pinion Carter Upper Fixing Screw M6 10 1.01
Pinion Carter Lower Fixing Screw M8 22 2.24
Tank Lid Front Fixing Screw M6 8/10 0.81/1.01
Tank Lid Rear Fixing Screw M6 8/10 0.81/1.01
Fairing Support Bracket Fixing Screw M6 10 1.01
Steering Lock Lid Fixing Screw M6 8/10 0.81/1.01
Right/Left Bearing Frames Fixing Screw / A mano ~
Cap Fixing Screw M6 8/10 0.81/1.01
Small Glass Support Small Frame Fixing Screw M5 6 0.61
Small Glass Adjustment Fixing Knob / A mano ~
Front Mudguard Fixing M6 8/10 0.81/1.01
Rear Mudguard Fixing M6 8/10 0.81/1.01
Tube Stop Eye Fixing Screw M5 6 0.61
Front Mudguard Small Brackets Fixing Screw M5 6 0.61
Number Plate Support Closing Screw M6 10 1.01
Number Plate Support Fixing Screw On Drain M6 10 1.01
Number Plate Light Fixing Screw M5 By hand ~
Arrow Fixing Nut M6 By hand ~
Petrol Cap Fixing Screw On Tank M5 6 0.61
Petrol Cap Fixing False Screw M5 By hand ~
Fairing Fixing Small Heads M6 By hand ~
Tank Fixing Bracket Screw M6 By hand ~
Seat Stop Flap Fixing Screw M6 By hand ~
Tank Fixing Screw On Seat Holder Small Frame / By hand ~
Petrol Pump Set Fixing Screw M5 3 0.30
Vent Fitting / By hand ~
FASTENING TORQUES
REAR WHEEL THREAD
Nm Kgf•m
Rear Wheel Pin / 100 10.19
Brake Disks Screw On Wheel M6 10 1.01
Crown Wheel Holder Flange Screw M10X1.25 45 4.58
FASTENING TORQUES
FRONT WHEEL THREAD
Nm Kgf•m
Front Wheel Pin / 50 5.09
Brake Disks Screw On Wheel M8 22 2.24
FASTENING TORQUES
REAR BRAKING PLANT THREAD
Nm Kgf•m
Fitting Screw M10X1 15 1.52
Calliper Fixing Screw M8 22 2.24
Bleeding Screw / By hand ~
Rear Pin Pump Fixing Screw M6 10 1.01
Spherical Joint Fixing Screw M6 10 1.01
Brake Liquid Small Tank Fixing Screw M5 By hand ~
Hydrostop Screw M10X1 15 1.52
2 18
FASTENING TORQUES
SPEC
FASTENING TORQUES
FRONT BRAKING PLANT THREAD
Nm Kgf•m
Fitting Screw M10X1 15 1.52
Callipers Fixing Screw M10X1.25 40 4.07
Bleeding Screw / By hand ~
Pump Strap Fixing Screw M6 8 0.81
FASTENING TORQUES
REAR SUSPENSION THREAD
Nm Kgf•m
Articulated Connecting Rods Fixing Screw M10X1.25 40 4.07
Balancing Device Fixing Special Screw On Frame / 60 6.11
Shock Absorber Upper Fixing Screw M10 By hand ~
Shock Absorber Lower Fixing Screw M10 40 4.07
FASTENING TORQUES
FRONT SUSPENSION THREAD
Nm Kgf•m
Lower Plate Clamp Closing Screw M6 8 0.81
Upper Plate Clamp Closing Screw M8 15/18 1.52/1.83
Handle Bar Clamp Closing Screw M8 18 1.83
Steering Wheel Upper Plate Fixing Central Screw / 60 6.11
Steering Wheel Bearing Fastening Ring Nut / 15 1.52
Steering Column Return Ring / 60 6.11
Steering Wheel Strokes Screw M6 10 1.01
Front Wheel Pin Clamp Closing Screw M6 8 0.81
Handle Bar Clamp Fulcrum Stop Grain M3 By hand ~
Clutch Lever Clamp Fixing Screw M6 8 0.81
Handle Bar Counter Weight / 15 1.52
Gas Command Fixing Screw M5 By hand ~
GPS Support Screw M6 8 0.81
FASTENING TORQUES
TRESTLE THREAD
Nm Kgf•m
Trestle Plate Fixing Screw M10 35 3.56
Hanger Sensor Screw M5 6 0.61
Hanger Fixing Special Screw On Plate / By stroke ~
Special Screw Lock Nut M10X1.25 40 4.07
FASTENING TORQUES
SWING ARM THREAD
Nm Kgf•m
Swing Arm Pin Screw / 60 6.11
Lower Chain Slide Fixing TSPEI Screw M6 8/10 0.81/1.01
External Upper Chain Slide Fixing Screw M5 By hand ~
Internal Upper Chain Slide Fixing Screw M5 By hand ~
Central Chain Slide Fixing Screw M6 8/10 0.81/1.01
Chain Carter Fixing Screw M6 8/10 0.81/1.01
Eccentric Clamp Closing Screw M8 22 2.24
Rear Calliper Support Contrasting Pin / 22 ~
Swing Arm Regulator / By stroke ~
Regulator Ring Nut / By stroke ~
Speed Sensor Small Plate Screw M3 By hand ~
2 19
FASTENING TORQUES
SPEC
FASTENING TORQUES
FRAME THREAD
Nm Kgf•m
Plates Closing Lower Pin On Engine M10X1.25 40 4.07
Plates Closing Upper Pin On Engine M10X1.25 40 4.07
Left Fixing Screw On Head M12X1.25 40 4.07
Right Register Screw On Head M12x1.25 40 4.07
Large Handle Fixing Screw M6 By hand ~
Small Frame Rear Fixing Screw M8 25 2.54
Seat Holder Small Frame Front Fixing Screw M8 25 2.54
Seat Holder Central Triangle Fixing Screw M6 10 1.01
Lock Fixing Screw M6 10 1.01
Seat Holder Central Tie Rod M6 By hand ~
Regulator Screw / 8/10 0.81/1.01
Headlights Support Fixing Screw M5 By hand ~
Seat Release Fixing Screw M6 8/10 0.81/1.01
Battery Box Rear Fixing Screw M6 8 0.81
Battery Box Front Fixing Screw M6 8 0.81
Battery Box Support Small Plates Fixing Screw M8 22 2.24
Rear Insulating Bulkhead Hooking Small Heads M6 10 1.01
Rear Headlights Fixing Nut M6 By hand ~

Pull Key Switch Fixing Screws M6 With pull ~
FASTENING TORQUES
FOOTPEGS THREAD
Nm Kgf•m
Rear Footpeg Rubber Pad Fixing Screw M4 By hand ~
Passenger Footpeg Support Fixing Screw M8 25 2.54
Front Footpeg Rubber Pad Fixing Screw M4 By hand ~
Left Footpeg Support Fixing Screw M8 25 2.54
Right Footpeg Support Fixing Screw M10 30 3.05
Pump Pointer Fixing Screw M6 10 1.01
Gear Change Rod Fixing Screw On Gear Change Command M5 6 0.61
Eccentric Fixing Screw M6 10 1.01
Gear Change Rod Fixing Screw On Gear Change Lever M6 10 1.01
Footpeg Fixing Screw On Footpeg Support M10 40 4.07
FASTENING TORQUES
FRONT HEADLIGHT THREAD
Nm Kgf•m
Equipment Small Frame Support Screw M6 By hand ~
Selfbraking Dashboard Lid Fixing Screw / By hand ~
Instrument Support Fixing Screw On Frame M8 22 2.24
Closing Screw On Instrument Support M6 10 1.01
Front Headlight Fixing Lower Screw M6 By hand ~
Headlight Support Fixing Special Screw / By hand ~
FASTENING TORQUES
COOLING PLANT THREAD
Nm Kgf•m
Radiator Upper Fixing Screw M6 10 1.01
Radiator Lower Connection Small Plates Fixing Screw M6 10 1.01
Vent Fixing Selfbraking Screw / By hand ~
2 20
FASTENING TORQUES
SPEC
FASTENING TORQUES
ELECTRIC PLANT THREAD
Nm Kgf•m
Control Unit Fixing Screw M4 By hand ~
Front Pins Small Plate Fixing Nut M6 8 0.81
Remote Control Switch Small Plate Fixing Nut M6 10 1.01
Acoustic Warning Device Fixing Screw M6 8/10 0.81/1.01
Inertial Switch Small Plate Fixing Screw M6 8/10 0.81/1.01
Clutch Sensor / By hand ~
Air Temperature Sensor M10 10 1.01
Solenoid Fixing Screw M6 10 1.01
FASTENING TORQUES
DRAIN PLANT THREAD
Nm Kgf•m
Primary Tubes Fixing Nut On Head M8 15 1.52
Silencing Device Articulated Connecting Rods Fixing Screw M8 By stroke ~
Valve Fixing Screw On Small Shaft M8 10 1.01
Thermal Bulkheads Fixing Screw M6 8/10 0.81/1.01
Drain Valve Small Shaft Fixing Nut M6 10 1.01
FASTENING TORQUES
INLET THREAD
Nm Kgf•m
Filter Box Lid Closing Screw M5 By hand ~
Air Box Fixing Screw On Frame M6 8 0.81
Inlet Flap Fixing Screw Special M6 By hand ~
2 21
LUBRICATION POINTS AND TYPES OF LUBRICANT
SPEC
LUBRICATION POINTS AND TYPES

OF ENGINE LUBRICANT
LUBRICATION POINT LUBRICANT
Oil Retainers Lips E
O-Ring LS
Bearings LS
S
Connecting Rod Supports
Pistons Surfaces E
Pistons Pins E
Cylinder Wall E
Bench Supports S
S
Cam Shafts Lobes
Cam Shafts Supports S
Valve Stems (Inlet And Drain) E
Valve Stems Ends (Inlet And Drain) E
Oil Pump Rotors (Internal And External) E
Oil Pump Slot E
Oil Filtering Element E
Clutch (Traction Rod) E
Oil Pump/Water And Washer Conductor Gear E
Clutch (Push Plate) E
Start-Up Clutch Return Gear Internal Surface E
Start-Up Clutch Set E
Primary Conduct Gear E
Final Transmission (Chain, Crown Wheel, Pinion) GR
Primary And Secondary Shafts E
Gear Change Drum E
Gears Command Forks And Guide Bars LS
Gear Change Shaft LS
Selector LS
Base Coupling Surface YVORI SIL AC
E ENGINE OIL
LS
LITHIUM SOAP
BASED GREASE
YVORI SIL AC
SEALING PASTE
2 22
LUBRICATION POINTS AND TYPES OF LUBRICANT
SPEC
LUBRICATION POINTS AND TYPES

OF FRAME LUBRICANT
LUBRICATION POINT LUBRICANT
Steering Bearings And Bearings Tracks (Upper And Lower) LS
Brake Lever Pivoting Point And Metal Parts Subject To Contact In Motion LS
Clutch Lever Pivoting Point And Metal Parts Subject To Contact In Motion LS
LS
Engine Support Bolts (Upper Rear And Lower Rear)
Shock Absorber Fixing Screws LS
Bearing And Swing Arm Oil Retainer LS
LS
Bearings And Shock Absorbers Link Oil Retainers
Side Trestle Rotation Point And Metal Parts Subject To Contact In Motion LS
LS
Gears Command Shaft Joint
Front Axis LS
LS
LITHIUM SOAP
BASED GREASE
2 23
COOLING SYSTEM LAYOUTS
SPEC

a Radiator Fan 1 Radiator Connection - Expansion Vessel
b Radiator 2 Hot Water Outlet Tube
c Water Pump 3 Pump Flow Tube
d Expansion Vessel 4 Pump Supply Tube
e Thermostat disk 5 Recovery Tub Vent
f Water/Oil Exchanger
g Oil Filter
e
1
b 5
4 3
d
g
f c
5
2 24
SPEC
a Radiator Fan 1 Radiator Connection - Expansion Vessel

b Radiator 2 Hot Water Outlet Tube
c Expansion Vessel 3 Recovery Tub Vent
d Thermostat disk 4 Cold Water Inlet Tube On Exchanger
e Water/Oil Exchanger 5 Hot Water Outlet Tube From Exchanger
f Oil Filter
2 a
d
1
3
c
5 b
4
f
e
2 25
3 CHK
ADJ
CHK
ADJ
CHAPTER 3
ROUTINE INSPECTIONS AND ADJUSTMENTS
INTRODUCTION...................................................................................................... 1
INTRODUCTION.................................................................................................................................. 1
ROUTINE MAINTENANCE AND LUBRICATION INTERVALS................................. 2

ROUTINE MAINTENANCE AND LUBRICATION INTERVALS ................................................ 2
ENGINE .................................................................................................................. 6
IGNITION SPARK PLUGS REMOVAL ............................................................................................. 6
IGNITION SPARK PLUGS CONTROL ............................................................................................. 7
IGNITION SPARK PLUGS INSTALLATION.................................................................................... 9
AIR BOX REMOVAL............................................................................................................................. 10
AIR FILTERING ELEMENT REPLACEMENT................................................................................... 11
AIR BOX INSTALLATION................................................................................................................... 13
WIRED ACTUATOR CONTROL........................................................................................................ 14
ACCELERATOR CABLE CLEARANCE ADJUSTMENT................................................................ 16
CLUTCH CABLE CLEARANCE ADJUSTMENT ............................................................................. 17
CLUTCH DISKS ADJUSTMENT ....................................................................................................... 18
EXHAUST GAS ADJUSTMENT ........................................................................................................ 19
THROTTLED BODY ADJUSTMENT ................................................................................................ 22
STEPPER REMOVAL............................................................................................................................ 25
STEPPER CONTROL............................................................................................................................ 26
STEPPER INSTALLATION .................................................................................................................. 27
VALVES CLEARANCE ADJUSTMENT AND CALIBRATED PADS ADJUSTMENT............... 28
ENGINE MINIMUM POWER ADJUSTMENT................................................................................. 34
ENGINE OIL LEVEL CONTROL ........................................................................................................ 37
ENGINE OIL CHANGE AND FILTER REPLACEMENT................................................................. 39
COOLING LIQUID CONTROL.......................................................................................................... 42
COOLING LIQUID CHANGE ............................................................................................................ 44
FUEL TUBE CONTROL AND REPLACEMENT.............................................................................. 48
DRAIN PLANT CONTROL AND REPLACEMENT........................................................................ 50
COOLING SYSTEM CONTROL AND REPLACEMENT ............................................................... 52
FRAME.................................................................................................................... 53
FRONT BRAKE ADJUSTMENT........................................................................................................ 53
REAR BRAKE ADJUSTMENT............................................................................................................ 54
BRAKES LIQUID LEVEL CONTROL................................................................................................. 55
FRONT AND REAR BRAKE PADS CONTROL.............................................................................. 56
BRAKING PLANT FLEXIBLE TUBES CONTROL.......................................................................... 57
HYDRAULIC BRAKING SYSTEM BLEEDING................................................................................ 58
GEAR CHANGE PEDAL ADJUSTMENT........................................................................................ 61
TRANSMISSION CHAIN LOOSENING REGULATING............................................................... 62
CHK
ADJ
TRANSMISSION CHAIN LUBRICATION....................................................................................... 64

STEERING TUBE CONTROL AND ADJUSTMENT...................................................................... 65
TRANSMISSION GEARS CONTROL AND REPLACEMENT...................................................... 67
FRONT FORK CONTROL................................................................................................................... 68
REAR SHOCK ABSORBER SET ADJUSTMENT............................................................................ 69
TYRES CONTROL................................................................................................................................ 71
WHEELS CONTROL............................................................................................................................ 74
CABLES CONTROL AND LUBRICATION...................................................................................... 75
LEVERS AND PEDALS LUBRICATION........................................................................................... 76
SIDE TRESTLE LUBRICATION.......................................................................................................... 77
REAR SUSPENSION LUBRICATION............................................................................................... 78
ELECTRIC PLANT.................................................................................................... 79
BATTERY CHARGE AND CONTROL.............................................................................................. 79
FUSES CONTROL................................................................................................................................ 85
FRONT LIGHTS REPLACEMENT..................................................................................................... 87
FRONT HEADLIGHT REMOVAL...................................................................................................... 89
FRONT HEADLIGHT INSTALLATION............................................................................................ 91
FRONT HEADLIGHT ADJUSTMENT.............................................................................................. 93
REAR HEADLIGHT REPLACEMENT................................................................................................ 94
NUMBER PLATE BRACKET HEADLIGHT REPLACEMENT....................................................... 96
FRONT INDICATORS REPLACEMENT........................................................................................... 97
FRONT INDICATORS LAMPS REPLACEMENT............................................................................ 98
REAR INDICATORS LAMPS REPLACEMENT............................................................................... 99
CHK
ADJ
CHK INTRODUCTION
ADJ
INT
INTRODUCTION
This chapter includes all information necessary to carry
out recommended inspections and adjustments.
These preventive maintenance procedures, if complied
with, guarantee a more reliable functioning, longer
lasting of the vehicle and will limit the need for expen-
sive revision operations.
This information is valid for both the already working
vehicles, and for the under construction vehicles for
sale.
All persons in charge of maintenance must know all
instructions contained in this chapter well.
3 1
CHK ROUTINE MAINTENANCE AND LUBRICATION INTERVALS
ADJ
ROUTINE MAINTENANCE AND

LUBRICATION INTERVALS
NOTE
N
In general, the maintenance operations must be carried out with the motorbike positioned on rear trestle, with
engine off and switch in "OFF" position.
Whereas, during the liquid level control, we recommend placing the bike in vertical position, without using the rear
trestle.
The annual controls must be carried out every year, except for when a service control based on a voucher system
connected to the kilometres covered is already carried out.
Reached 40.000 Km (24.854 mi), repeat the service voucher system starting from that of 10.000 Km (6.213 mi). For
interventions relating to the marked items, we recommend contacting a Benelli dealer, given that it is necessary to
use special tools, particular information and specific technical abilities.
The following tables show all maintenance operations.
i Inspection and adjustment, cleaning, lubrication or replacement depending on requirements

R Replacement
T Tighten
Dealer
0 Km 1000 Km 10000 Km 20000 Km 30000 Km 40000 Km

NO. COMPONENT MAINTENANCE CONTROLS (0 mi) (621 mi) (6213 mi) (12427 mi) (18641 mi) (24854 mi) ANNUAL
OR INTERVENTIONS PRE-DELIVERY 1st 2nd 3rd 4th 5th CONTROL
VOUCHER VOUCHER VOUCHER VOUCHER VOUCHER
Control/Replacement i R R R R R R
1 Engine Oil
Before every vehicle use
Control/Replacement R R R R R
2 Oil Filter
However, at every engine oil change
Control/Replacement R R R R R
3 Petrol Filter
Control/Replacement i R i R
4 Air Filter
Before every vehicle use
Level restore control i i i i i i i

5 Cooling Liquid
Every 2 years or 20.000 Km
Check the cooling liquid level and i i i i i i i

6 Cooling Plant that there are no leaks from
the vehicle.
Control/Replacement i R i R
7 Spark Plugs
Check the condition, clean and restore the distance between the electrodes
Check the tensioning of the chain i i i i i i i

8 and that the rear wheel is
Transmission Chain correctly aligned.
Clean and lubricate Every 500 km and after every bike washing, or if the bike has worn under the rain
Control/Lubrication i i i i i i i
9 Crown Wheel
However, replace at every chain replacement
Control i i i i i i i
10 Stop Pinion
/Washer However, replace at every chain replacement
Faults and leaks control i R i R i

11 Fuel Circuit Tubes
Replace every 20.000 Km and, however, every 3 years
Control/Replacement i i i i i i i
12 Brakes Liquid
Replace every 20.000 Km and, however, every 2 years
Check the functioning, the liquid i i i i i i i

13 Front Brake/ level and that there are no liquid
Rear Brake leaks from the vehicle.
Control/Replacement i i i i i i
14 Brake Pads
Replace if worn to the limit
3 2
ADJ
0 Km 1000 Km 10000 Km 20000 Km 30000 Km 40000 Km

15 Swing Arm Chain
Flow Slide Replace if worn to the limit
16 Swing Arm Chain
Guide Slide Replace if worn to the limit
17 Lower Frame
Chain Slide Replace if worn to the limit
Check functioning and if necessary, i i i i i i i

Accelerator adjust the clearance of the
18 accelerator cable. Lubricate the slot
Command of the accelerator knob and of the cable
Clearance check/adjustment i i i i i
19 Clutch
Control/Adjustment i i i i i i i
20 Clutch Command
Control/Adjustment i i i i i
21 Throttled Body
Control/Adjustment i i i i
22 Valves
Control/Replacement i i i R
23 Distribution Chain
Every 40.000 Km
24 Distribution
Mobile Slide At every distribution chain replacement
25 Distribution
Chain Tensioner At every distribution chain replacement
Steering Tube Control/Adjustment T T T T T T T

26
And Ring Nut Before every vehicle use
Control/Adjustment T T T T T T T
27 Steering Tube
And Bearings Every 20.000 Km lubricate with lithium soap based grease
Front/Rear Control/Replacement i i i i R
28 Wheel Bearings
Every 40.000 Km
Control/Replacement i i i i R
29 Swing Arm Bearings
Every 40.000 Km
Check the functioning and that i i i i

30 Oscillating Swing Arm it does not have an
excessive clearance
Check the functioning and i i i i

31 Fork that there are no leaks
Replacement
32 Fork Oil
Every 20.000 Km
Control/Adjustment i i i i
33 Rear Shock Absorber Check there are no leaks
Check they are aligned i i i i

34 Wheels or not damaged
Check the depth of the tread and

that there are no damages. Replace T i i i i i i
35 Tyres if necessary. Check the blowing
pressure. Correct if necessary Replace if worn to the limit
Control/Functioning i i i i i i i
36 Side Trestle
37 Side Trestle Switch
3 3
ADJ
0 Km 1000 Km 10000 Km 20000 Km 30000 Km 40000 Km

38 Lights/Visual Signs
39 Front Light
Adjustment At every vehicle asset variation
Acoustic Warning Control/Functioning i i i i i i i

40
Device
41 Equipment
42 Battery Connections
Control/Adjustment i i i i i i i
43 Electric Plant
44 Ignition Switch
45 Electric fans
Fuel Electronic i i i i i
46 Adjust the minimum power of
Injection the engine and the synchronisation
Control/Adjustment i i i i i i
47 Fuelling/CO°
However, every 10.000 Km
Frame Fixing Check all nuts, bolts and screws T T T T T T T

48 are adequately fastened
Elements At every distribution chain replacement
Control/Replacement i i i i i
49 Air Box Valve
Check the correct functioning, replace if necessary
50 Drain Plant Valve
Check functioning, clearance of the cable and the position of the pulley, replace if necessary
Inlet Drain Control/Replacement i i i i i

51
Valve Actuator Check functioning, clearance of the cable and the position of the pulley, replace if necessary
52 Valves Actuator
Cables Check the correct sliding of the cables, replace if damaged
Control T T T T T T
53 Oil Tank Screws
Control T T T T T T
54 Clutch Lid Screws
Alternator Collar Replacement R R R R

55
Rubber
Faults and leaks control i i i i R

56 Catalyst
Maintenance not envisioned, replace if malfunctioning
Faults and leaks control i i R i R

57 USA Cannister
Version
Control/Replacement i i i i i i i
58 Brake Flexible
Tubes Every 4 years
Parts And Cables Control/Replacement i i i i i i i

59
Subject To Movement Before every vehicle use
3 4
ADJ
NOTE:
• AIR FILTER
• The air filter must be replaced more often when the vehicle is used in particularly dusty and humid areas.
• HYDRAULIC BRAKE MAINTENANCE
• Regularly check the brakes liquid level and, if necessary, top-up.
• Replace the internal components of the brakes and callipers main cylinder, and change the brakes liquid every
two years.
• Replace the brakes flexible tubes every 4 years, or before if cracked or damaged.
3 5
CHK ENGINE/IGNITION SPARK PLUGS
ADJ
IGNITION SPARK PLUGS REMOVAL
The following procedure is applied to all ignition spark

plugs.
WARNING
The replacement and check of the spark plugs
must be carried out with the engine cold.
1 R
Remove:
• the
i right and left tank lids
See "FRAME 4.112" paragraph.
• the tank
• the air box
See paragraph "3.10".
• the conveyor
ATTENTION
Before disconnecting the spark plugs, remove the
dirt eventually accumulated inside the seats using
a jet of compressed air, to avoid it falling inside the
cylinders.
2 R
Remove:
B • the nut A
A • the bracket B
• the rubber pad C
3 Disconnect:
• the reel connector D
D
4 Remove:
E • the reel E
• the spark plug underneath F
F
3 6
ADJ
IGNITION SPARK PLUGS CONTROL

plugs.
1 C
Check:
• the type of ignition spark plug
Incorrect Change
Type of ignition spark plug (manufacturer)

RG4HC (CHAMPION)
or CR9EK (NGK)
2 C
Check:
• the electrodes A
In the presence of damages/wear/rounding
Replace the ignition spark plug.
• the insulating part B
Anomalous colour Replace the ignition spark
plug.
The colour is usually light brown.
B
A
2
DIRTY SPARK PLUG OVERHEATED

SPARK PLUG
Causes Remedies Causes Remedies
• Mix air/petrol too rich Carry out the setting up of the supply • Ignition too advanced Adjust the ignition advance
-Incorrect carburettor calibration /fuelling system
• Air/petrol mix too poor Adjust the air/petrol ratio
• Inefficiency of electric plant Check the connections of the reels and
-Incorrect connection of reels relative impedance • Insufficient cooling and/or lubricant Add cooling and/or lubricating liquid
liquid
• Particular driving conditions Every now and again, it is necessary to
-Extended periods "at minimum" reach a speed of approx. 80 Km/h • Fastening torque of the spark plugs Tighten up to correct torque
-Long distance travelled at low speed too low
• Spark plug too cold Use a warmer spark plug as in the • Use of a spark plug too hot Use a colder spark plug as in the
specification specification
3 7
ADJ
3 Clean:
• the ignition spark plug
((using a detergent for spark plugs or a metal brush)
4 M
Measure:
• the distance between the electrodes C
(
(using a feeler)
If out of specification Restore the correct
distance
Distance between the electrodes

0.7 ~ 0.8 mm (0.02 ~ 0.03 in)
C
3 8
ADJ
IGNITION SPARK PLUGS INSTALLA-

GR
TION
plugs.
WARNING
Lubricate the spark plug threading.
GR
GRASSO AL RAME
NOTE:
Before installing the spark plug, clean it and the
surface in contact with the gasket.
1 Install:
• the ignition spark plug
on the head manually tightening it until a contact on
the base of the head is heard, therefore, torque
fasten.
12 N m - 1.22 Kgf•m
R.
T.
2 Install:
• the reel
NOTE:
YVO
RI S
Before installing it, apply sealing paste on the reel.
IL A
C
YVO
Recommended paste
RI S
IL A
C TUTELA PROFESSIONAL
IVORY SIL AC
2
3 C
Connect:
• the reel connector A
A
4 Install:
• the rubber pad
• the bracket
• the nut
Torque fasten: 8 N m - 0.81 Kgf•m

R.
T.
3 9
CHK ENGINE/AIR BOX
ADJ
AIR BOX REMOVAL
10
18
1
7
13
2 11
19
9
15 14
4
16
17
12
5
20
SQ. SYMBOLS INTERVENTION/DESCRIPTION Q.TY OBSERVATIONS
Remove the pieces in the given order.

Seat Removal See "FRAME 4.130" paragraph.
Tank Removal See "FRAME 4.118" paragraph.
Air Box Removal
1 Screw 9
2 Filter Box Lid 1
3 Gasket 1
4 Check Net 1
5 Filtering Element 1
6 Check Net 1
7 Screw 1
8 Seeger 2
9 Pin 2
10 Throttle Cable 1 Disconnect.
11 Inlet Valve 1
12 Throttled Bodies Strip 3 Loosen.
13 Blow By Tube Strip 1 Loosen.
14 Screw 2
15 Air Filter Box 1
16 Cable Gland 2
17 Rubber Pad 1
18 Inlet Conduct 3
19 Washer 3
20 Conveyor 1
ATTENTION:
Pay particular attention not to let foreign bodies
fall inside the throttled bodies.
3 10
CHK ENGINE/AIR BOX
ADJ
AIR FILTERING ELEMENT REPLACE-

MENT
1 R
Remove:
• the seat
• the tank
2 R
Remove:
• the 9 screws
• the filter box lid
• the filtering element
ATTENTION
Replace the air filter element every 20.000 Km
(12.427 mi). If the vehicle is used during particular-
ly humid climates or in very dusty areas, it will be
necessary to intervene on the air filter at shorter
intervals.
3 C
Check:
• the air filter element A
In the presence of damages Replace.
A
a Wash the filtering element using solvents for
specific use.
b Dry in the air.
c Apply specific oil on the entire surface of the

filtering element.
3
4 Install:
• the filtering element
ATTENTION
Before installing the filtering element inside the air
box, eliminate the excess oil checking it no longer
drips.
3 11
CHK ENGINE/AIR BOX
ADJ
5 Install:
• the 9 screws
See paragraph "3.13"
WARNING
Never start the engine if the air filter is not
installed. The unfiltered air causes rapid wearing of
the engine parts and it may damage the engine.
Furthermore, by running the engine without the air
filter influences negatively on the setting up of the
throttle bodies, and this entails a deterioration of
the engine performances, and eventually its
overheating.
Therefore, ensure that the air filter is always in
good conditions.
The duration of the engine mainly depends from
this component.
6 Install:
• the tank
• the seat
3 12
CHK ENGINE/AIR BOX
ADJ
AIR BOX INSTALLATION
11
3
20
LS
14
8
LS
13
19 10
2
12
6 7
LS
18
17
5
4
9
16
1
15
Install the pieces in the given order.

Air Box Installation
1 Conveyor 1
2 Washer 3
3 Inlet Conduct 3
4 Rubber Pad 1
5 Cable Gland 2
6 Air Filter Box 1
7 LS
Screw 2 Manually fasten.
8 Blow By Tube Strip 1 Tighten.
9 Throttled Bodies Strip 3 Tighten.
10 Inlet Valve 1 ATTENTION:
Pay particular attention to the phasing of the
inlet valve flaps checking that, with the valve
completely open, the resting oblique surfaces
on support are identical.
11 Throttle Cable 1 Connect.
12 Pin 2
13 Seeger 2
14 LS
Screw 1 Manually fasten
15 Check Net 1
16 Filtering Element 1
17 Check Net 1
18 Gasket 1
19 Filter Box Lid 1
20 LS
Screw 9 Manually fasten
3 13
CHK ENGINE/WIRED ACTUATOR
ADJ
WIRED ACTUATOR CONTROL

1 Start:
• the bike
and check with a few gas revolutions that the drain
throttle works as shown in the illustration.
If the inlet and drain throttles do not perform the

correct closing cycle, it is necessary to remove the
wired actuator.
There are 2 types of controls to carry out.
1
C
CONTROL 1
2 R
Remove:
• the seat
• the tank
3 Remove:
• the 2 screws A
4 Measure:
• the distance
between the balancing device B , in orthogonal
position compared to the piston axis, and the screw
head C
Distance between balancing device and screw head
14 mm (0.55 in)
14 C
B STROKE ADJUSTMENT
On the contrary, regulate the screw C
MEASUREMENT 4
5 Should this not be sufficient for the correct closing

cycle of the throttles, check the drain valves.
3 14
CHK ENGINE/WIRED ACTUATOR
ADJ
C
CONTROL 2
D
If the control of the wired actuator is not sufficient for
the correct throttle closing cycle, check the cables
clearance adjustment.
6 Loosen:
• the nuts of the drain valve regulator D
(on 3 in 1 exhaust pipe)
7 Adjust:
• the tensioning of the cable
ensuring it is always tensioned but keeping the
stand-by position of the drain valve.
8 Adjust:
• the thread of regulator E and of regulator F
up to the specified measurement.
E
Measurements of the regulator threads
E 9.8 mm (0.38 in)
F 9.4 mm (0.37 in)
F
8
9 Install:
• the 2 screws G
10 Install:
• the tank
• the seat
3 15
CHK ENGINE/ACCELERATOR CABLE CLEARANCE
ADJ
ACCELERATOR CABLE CLEARANCE

ADJUSTMENT
NOTE:
Before adjusting the accelerator cable clearance,
adequately adjust the minimum power of the
engine.
Initially check at 1000 Km (621 mi) and subsequent-
ly every 10.000 Km (6.213 mi).
1 C
Check:
• the accelerator cable clearance A
Check that the accelerator command grip works
regularly and that it is possible to reach the maximum
opening and automatic closing positions from all
steering positions.
A If out of specification Adjust.
Accelerator cable clearance

(at accelerator knob flange)
3 ~ 5 mm (0.11 ~ 0.19 in)
1
2 Adjust:
• the accelerator cable clearance
Handle bar side

E C
B a Loosen lock nut B
D b Rotate the adjusting nut C in D or E

2 direction, until clearance of the specified
accelerator cable is obtained.
DIRECTION D The clearance increases
DIRECTION E The clearance decreases
c Fasten the lock nut.
WARNING
After adjustment of the accelerator cable clearance,
start the engine and turn the handle bar to the
right and to the left, ensuring that the minimum
engine power does not change.
3 C
Check:
• the cables
If damaged, worn, or tangled Replace.
3 16
CHK ENGINE/CLUTCH CABLE CLEARANCE
ADJ
CLUTCH CABLE CLEARANCE

C ADJUSTMENT
1 Check:
D • the clutch cable clearance A
If out of specification Adjust.
B
A Clutch cable clearance
(at the end of the clutch lever)
3 ~ 5 mm (0.11 ~ 0.19 in)
1
2 Adjust:
• the clutch cable clearance
Handle bar side
a Rotate the adjusting disk B in C or D

direction, until clearance of the specified clutch
cable is obtained.
DIRECTION C The clutch cable clearance increases
DIRECTION D The clutch cable clearance decreases
NOTE:
If the specified clearance of the clutch cable on
handle bar side is not obtained, act on the engine
side adjusting nut.
3 17
CHK ENGINE/CLUTCH DISKS
ADJ
CLUTCH DISKS ADJUSTMENT

1 Position:
• the bike
on side trestle to avoid oil leaking.
2 Remove:
• the clutch lid
See “ENGINE 5.69” paragraph.
NOTE:
Before adjusting the clutch disks, free the lower
clutch command of the clutch cable. Check every
10000 Km.
3 Lock:
• the flange A
Loosen:
• the lock nut B
B A Tighten:
• the regulator C
until contact with the internal reaction rod is heard
C and loosen it by ¼ of a turn.
Check the clearance on the clutch command positioned

on the opposite side of the engine.
3
Clutch lever clearance: 3 ~ 5 mm (0.11 ~ 0.19 in)
Clutch disengagement screw: ¼ of a turn outwards
4 Fasten:
• the lock nut B
using special tool keeping the regulator still C .
Special Tools: CLUTCH PRESSURE PLATE ADJUSTMENT SPANNER

Code : R180297130000
B C
NOTE:
To use the special tool, remove one screw with
relative cup and spring.
5 Install:
• the clutch lid
4 See “ENGINE 5.70” paragraph.
3 18
CHK ENGINE/EXHAUST GAS
ADJ
EXHAUST GAS ADJUSTMENT

1 R
Remove:
• the seat
2 Remove:
• the cap of the diagnostics socket A
Connect:
B • the diagnostics instrument
to the socket positioned underneath the seat B .
Special Tools: ENGINE INJECTION HANDLING

DIAGNOSTICS INSTRUMENT - AXONE 2000
A Code: R180197036000
2 Special Tools: ENGINE INJECTION HANDLING

DIAGNOSTICS INSTRUMENT - BENDIA SCANTOOL
Code: R300082003000
3 Check:
• the bike stop switch on right command
the switch must be on “RUN” (switched on). C
• the vehicle
C no gear must be engaged.
4 Select:
• the options
choosing the wanted menu, following the instructions
regarding the diagnostics instrument.
3 19
ADJ
5 Start:
• the engine
taking it to approx. 95°C.
6 Check:
• the lambda probe value
Lambda Probe Value

“1.00”
VALUE GREATER THAN “1.00” VALUE LOWER THAN “1.00”

If the lambda probe value shown on the display is greater than If the lambda probe value shown on the display is lower than
"1.00", increase the "CO%" value to minimum map 1 or 2 (referred "1.00", decrease the "CO%" value to minimum map 1 or 2 (referred
to used map lock) so that the correction and relative lambda to used map lock) so that the correction and relative lambda
parameter work as close to "1.00" as possible. parameter work as close to "1.00" as possible.
7 Turn-off:
• the diagnostics instrument
following the instructions relating to the bike.
8 Disconnect:
• the diagnostics connector
from the socket.
3 20
ADJ
9 Install:
• the diagnostics socket cap D
10 Install:
• the seat
3 21
CHK ENGINE/THROTTLED BODY
ADJ
THROTTLED BODY ADJUSTMENT

NOTE:
Before synchronising the throttle bodies, suitably
regulate the valves clearance and the engine
minimum power.
Engine Minimum Power

1250 ~ 1350 r/min.
NOTE:
Check and execute the alignment of the throttled
body with engine temperature at approx. 90/95°C.
1 Park:
• the bike levelled.
NOTE:
Place the bike on a suitable trestle.
2 Remove:
• the seat
See "FRAME 130" paragraph.
• the tank
• the air filter box
3 Disconnect:
A A A • the flexible tubes of the stepper air passages A
3 22
ADJ
4 Install:
B • the vacuum meter
directly on to the fittings of the throttled body of the
previously disconnected stepper air passages tubes.
M U L T IM A N
Bila ncia m en to fa rfall

e
RPM 3 giri/min
Special Tools: VACUUM METER
1 2
1250
P1 mbar
Code: R300097170000
- 425
P2 mbar
- 462
P3 mbar
Zoom
- 505
esc
ON off
ok
5 Install:
• the tank
directing it towards the rear part of the vehicle
(secure the tank with belt).
6 Start:
• the engine
and leave it to warm up for a few minutes until the
temperature reaches 95°C.
7 Fasten:
C C C
• the by-pass screws C
Tighten them completely.
3 23
ADJ
8 Correct:
• the alignment values
using a screwdriver on the pair screws D and E .
Align body 1 with body 2 by acting on the pair screw
1 D .
3 2 Align body 2 with body 3 by acting on the pair screw
E .
E N
NOTE:
D Having reached an optimal alignment on the 3
8 bodies, it is possible to perfect the correction by
individually acting on the previously closed by-pass
screws C .
9 Turn-off:
• the engine
Remove:
• the measuring instrument
Re-connect:
• the flexible tubes of the previously disconnected
stepper air passages.
10 Carry out:
• resetting of the throttle sensor
using the diagnosis system:
a Adjust the engine minimum power

b Adjust the exhaust gas emissions
11 Install:
• the tank
• the seat
3 24
CHK ENGINE/STEPPER
ADJ
STEPPER REMOVAL
13
1 1
10
12
9
4
11
8 8
7 7
5
6 6
5

Seat Removal See "FRAME 4.130" paragraph.
Tank Removal See "FRAME 4.118" paragraph.
Air Box Removal See paragraph "3.10".
Stepper Removal
1 Screw 2
2 Click Strip 3 Loosen.
3 Minimum Air Tube 3 Disconnect.
4 Connector 1 Disconnect.
5 Screw 4
6 Nut 2
7 Bush 2
8 Anti-vibration Rubber Pad 2
9 Step-by-Step Motor 1
10 Distributor 1
11 Special Plate 1
12 O-Ring Gasket 1
13 O-Ring Gasket 2
3 25
CHK ENGINE/STEPPER
ADJ
STEPPER CONTROL
D B
1 Check:
• the stepper A
In the presence of breaks and/or deformations
Replace.
• the distributor B
In the presence of obstructions Replace.
• the free sliding between the piston C and the
distributor B
In case of forced sliding Replace the distributor.
• the 2 O-Ring gaskets D
In the presence of deformations Replace in
C A pair.
NOTE:
Clean the distributor and the stepper before
installation.
NOTE:
N
In case of replacing the stepper, check the adjust-
ment of the diagnostics instrument, reset the
throttles.
1
3 26
CHK ENGINE/STEPPER
ADJ
STEPPER INSTALLATION
1
9 9
11
12
4
13
11
Axerons SYSTEM 52A43
52A43
52A43
MEDIUM THREAD BRAKES
5 5
6 6
10
7 7
10

Stepper Installation
1 O-Ring Gasket 2
2 Distributor 1
3 O-Ring Gasket 1
4 Step-by-Step Motor 1
6 Bush 2
7 Nut 2
8 Special Plate 1
9 Screw 2 Manually fasten.
52A43
11 Click Strip 3 Tighten.

12 Minimum Air Tube 3 Connect.
13 Connector 1 Connect.
3 27
CHK ENGINE/VALVES CLEARANCE AND CALIBRATED PADS
ADJ
VALVES CLEARANCE ADJUSTMENT

AND CALIBRATED PADS
REPLACEMENT
The following procedure is applied to all valves.
NOTE:
The adjusting of the valves clearance must be
carried out with the engine cold, at ambient
temperature and with the engine in PMS.
1 Remove:
• the seat
• the tank
• the radiator
See "COOLING PLANT 6.1" paragraph.
• the stepper connector
2 Remove:
• the ignition reels
• the ignition spark plugs
• the distribution lid
• the gasket of the distribution lid
3 Remove:
• the phonic wheel cap A
A
3
4 Align:
• the gear notches B and C
Check that the notches are also aligned with the
B C head plane D .
D
4
3 28
ADJ
5 Measure:
• the valves clearance
using a feeler E positioning the cam as shown in
the illustration.
E Valves Clearance
Inlet Valve
0.25 ~ 0.30 mm (0.009 ~ 0.011 in)
Drain Valve
0.30 ~ 0.35 mm (0.011 ~ 0.013 in)
NOTE:
If the valves clearance is incorrect, take note of the
effectively detected value.
6 Remove:
• the spring of the chain tensioner F
• the chain tensioner G
F
3 29
ADJ
K
J
7 Remove: NOTE:
N
• the upper chain slide H D
During removal of the cam shafts, tighten a metal
• the drain/inlet/central headgears I wire to the distribution chain to be able to recover
• the drain/inlet Z34 gears J it in case it should fall in the base.
• the drain/inlet cam shafts K
NOTE:
Take note of the position of each headgear in order
to be able to re-assemble them in the correct
position.
8 Remove:
• the drain/inlet valves lifters L
L • the drain/inlet calibrated pads M
See "ENGINE 5.30" paragraph.
M
NOTE:
N
L C
Cover the opening of the distribution chain using a
cloth to avoid the calibrated pad from falling in the
M base.
84
3 30
ADJ
NOTE:
Take note of the position of each valve lifter L
1 2 3 and of each calibrated pad M to be able to re-
assemble them correctly.
DRAIN
INLET
L
M 9
10 Measure:
• the calibrated pad
If out of specification Replace it until the correct
clearance is reached.
28 The thickness N of every calibrated pad is shown
N in hundredths of millimetre.
Valves Clearance
Inlet Valve
0.25 ~ 0.30 mm (0.009 ~ 0.011 in)
10
Drain Valve
0.30 ~ 0.35 mm (0.011 ~ 0.013 in)
HOW TO FIND THE VALUE OF THE NEW PAD INLET DRAIN
rule example example

1) Measure the thickness of the pad 0.35 0.37
2) Measure the valve clearance 0.22 0.31
3) Sum the thickness of the pad with the measured valve 0.35 + 0.22 = 0.37 + 0.31 =
clearance 0.57 0.68
4) Subtract from the obtained sum (pad + clearance)
the value of 0.30 mm (for inlet) 0.57 - 0.30 0.68 - 0.35
the value of 0.35 mm (for drain)
5) The obtained value will be the measurement of the new pad 0.27 0.33
3 31
ADJ
11 Install:
• the new drain/inlet calibrated pads O
O • the new drain/inlet valves lifters P
P Check:
S • the valves clearances
E
O If out of specification Repeat the operations in

the table.
P
NOTE:
N
11
4 • Lubricate the calibrated pad using engine oil.
• Lubricate the valve lifter using molybdenum
disulphide grease.
• By manually rotating the valve lifter, it must turn
smoothly.
E ENGINE OIL
S
SINTOFLON
NOTE:
Before installing, ensure that the engine shaft is in
PMS of cylinder 1.
12 Install:
• the drain/inlet cam shafts
• the drain/inlet Z34 gears
• the distribution chain
• the drain/inlet/central headgears
• the upper chain slide
Torque fasten the screws of the small plates on the

drain/inlet Z34 gears 15 N m - 1.52 Kgf•m
R.
T.
Torque fasten the screws of the drain/inlet/central

headgears 6 + 13 N m - 0.61 + 1.32 Kgf•m
R.
T.
NOTE:
N
• Lubricate the bearings of the cam shafts, the lobes
and the supports of the cam shafts.
• Firstly install the drain shaft.
• Align the marks on the cam shafts with the marks
on the relative headgears.
• Have the engine shaft turn clockwise a few times
to adjust the parts in the relative seats.
S
SINTOFLON
3 32
ADJ
13 Measure:
• the valves clearance again
If still out of specification Repeat the entire
adjustment procedure until clearance is obtained.
14 Install:
• the chain tensioner Q
• the spring of the chain tensioner R
R
14
15 Install:
• the phonic wheel cap S
S
15
16 Install:
• the gasket of the distribution lid
• the distribution lid
• the ignition spark plugs
• the ignition reels
17 Install:
• the stepper connector
• the radiator
• the tank
• the seat
3 33
CHK ENGINE/ENGINE MINIMUM POWER
ADJ
ENGINE MINIMUM POWER ADJUST-

MENT
NOTE:
Before adjusting the engine minimum power,
adjust the throttled bodies and check that the
engine has a suitable compression.
1 Remove:
• the seat
2 Remove:
• the cap of the diagnostics socket A
Connect:
B • the diagnostics instrument
to the socket positioned underneath the seat B
Special Tools: DIAGNOSTICS INSTRUMENT

ENGINE INJECTION HANDLING - AXONE 2000
A Code: R180197036000
2 Special Tools: DIAGNOSTICS INSTRUMENT

ENGINE INJECTION HANDLING - BENDIA SCANTOOL
Code: R300082003000
3 Start:
• the engine
and leave it to warm up for a few minutes.
3 34
ADJ
4 Check:
• the engine minimum power
Engine Minimum Power

1250 ~ 1350 r/min.
5 Adjust:
• the engine minimum power
a Rotate the minimum adjusting screw C in D
or E direction, until specified engine minimum
power is obtained.
DIRECTION D The engine minimum power decreases

C
D E 5 DIRECTION E The engine minimum power increases
6 Adjust:

(near the flange of the accelerator knob)
3 ~ 5 mm (0.11 ~ 0.19 in)
7 Turn-off:
• the diagnosis instrument
following the instructions relating to the bike.
8 Disconnect:
• the diagnostics connector
from the socket.
3 35
ADJ
9 Install:
• the diagnostics socket cap F
10 Install:
• the seat
3 36
CHK ENGINE/ENGINE OIL
ADJ
ENGINE OIL LEVEL CONTROL
1 Park:
NOTE:
N
• Place the bike on a suitable trestle.
• Ensure that the bike is in straight position.
2 Start:
• the engine
leave it to warm up for a few minutes, then turn it off.
ATTENTION
Do not start the engine if the oil is underneath MIN
reference.
3 Check:
• the engine oil level
B the engine oil level must be between the minimum
level reference (MIN) A and that of the maximum
level (MAX) B .
MAX If below the minimum level notch Top-up to
the correct level using recommended engine oil.
MIN
A Recommended Oil
3 SAE 10 W-50 API SJ - JASO MA
SAE DEGREES
FOR RECOMMENDED ENGINE OILS COMPARED TO EXTERNAL TEMPERATURES
-35 -30 -25 -20 -15 -10 -5 0 +5 +10 +15 +20 +25 +30 +35 +40 +45 +50
SAE 10W
SAE 20W
SAE 30W
SAE 40W
SAE 10W - 30
SAE 10W - 40
SAE 10W - 60
SAE 15W - 40 mineral base
3 37
CHK ENGINE/ENGINE OIL
ADJ
4 To top-up with engine oil loosen:

• the oil cap with the engine off
Pour an amount of recommended oil until half the
inspection hole between the MAX and MIN reference
is reached.
ATTENTION
• Given that the engine oil also lubricates the clutch,
if of unsuitable type or if containing additives, it
may cause the sliding of the clutch.
Therefore, we recommend not adding chemical
4 additives and not using oil different to that shown
in the technical specifications table of the engine.
See "ROUTINE INSPECTIONS AND ADJUSTMENTS
2.2" paragraph.
• Avoid the entering of foreign bodies inside the
base.
• The new or exhaust engine oil can be dangerous.
In fact, swallowing it can be toxic for persons and
domestic animals. In case of swallowing,
immediately call the doctor and do not force
vomiting in order to avoid inhaling the product in
the lungs. Brief contact with the engine oil can
irritate the skin.
• Keep the engine oil away from the reach of
children and domestic animals.
• Wear clothing with long sleeves and waterproof
gloves every time engine oil top-up is carried out.
• If the engine oil comes into contact with the skin
wash with soap and water.
• Recycle or dispose of the exhaust engine oil
correctly.
NOTE:
The engine contains approx. 3.5 litres of oil.
Use oil with API-SJ classification and SAE 10W/50
viscosity.
5 Tighten:
• the oil cap
NOTE:
To check the engine oil level again, start the
engine, leave it to warm up for a few minutes then
turn it off.
Wait a few minutes for the oil to flow downwards.
3 38
CHK ENGINE/ENGINE OIL AND FILTER
ADJ
ENGINE OIL CHANGE AND FILTER

REPLACEMENT
1 Start:
• the engine
2 Remove:
• the engine protection
3 Position:
• a suitable container
underneath the magnetic cap for the recovery of the
engine oil.
NOTE:
Initially replace the engine oil at 1000 Km (621 mi)
and then every 10000 Km (6213 mi).
ATTENTION
The used oils are damaging for the environment.
Dispose of the used oils according to the Standards
in force.
4 Remove:
• the oil cap A
A
4
5 Remove:
• the magnetic cap B
(together with the gasket C )
C
B
5
3 39
ADJ
6 Drain:
• the engine oil
making it all flow from the base.
In case of having to also replace the cartridge of the

oil filter, proceed as follows.
NOTE:
Initially replace the oil filter at 1000 Km (621 mi)
and then every 10000 Km (6213 mi) and, however,
at every engine oil change.
7 Loosen:
• the 2 screws D
Remove:
• the strip E
E • the plate F
G F Remove:
• the oil filter G
using tool for oil filter removal.
D 7
8 NOTE:
Before installing the new oil filter, apply a thin
layer of engine oil on the contact surfaces of the
same to lubricate it.
E
ATTENTION
Only use the Benelli original oil filter (code
R180107114000).
Other brands of oil filters may differ with regard to
the threading (diameter and step). The filtering
8 performances and duration with consequent
possible damages to the engine or oil leaks.
E ENGINE OIL
9 Fasten:
• the oil filter
using a suitable spanner.
Torque fasten: 18 + 20 N m - 1.83 + 2.03 Kgf•m

R.
T.
3 40
ADJ
10 Replace:
• the gasket of the magnetic cap
Install:
• the new gasket H
• the magnetic cap I
R.
T.
H NEW
I
10
11 Fill:
• the base
with recommended and specified amount of engine
oil.
Total quantity
approx. 3.5 l
Amount without oil filter change
approx. 3.3 l
Amount with oil filter change
approx. 4.0 l
12 Install:
• the oil cap J
J
12
13 Install:
14 Start:
• the engine
NOTE:
Always check that the level on the inspection hole
is halfway between MIN and MAX.
If required, restore the engine oil level.
3 41
CHK ENGINE/COOLING LIQUID
ADJ
C
COOLING LIQUID CONTROL
1 P
Park:
NOTE:
N
2 Check:
• the cooling liquid level
A the cooling liquid level must be between the
maximum level reference (MAX) A and that of the
minimum level (MIN) B .
MAX If below the minimum level notch top-up to the
correct level using recommended cooling liquid.
MIN
B
2
3 Remove:
• the right tank lid
4 Remove:
• the radiator cap C
C WARNING
If the radiator is very hot, the liquid inside will be
pressurised. Do not remove the radiator cap with
the engine hot. Boiling hot liquid may leak, caus-
ing serious injuries. When the engine has cooled
down, open the radiator cap as follows:
Position a towel on the radiator cap and slowly
4
loosen the cap anti-clockwise to drain any residue
pressure.
When the usual hiss is no longer heard, press on
the radiator cap and loosen it anti-clockwise to
remove it.
3 42
ADJ
5 Fill:
D • the cooling system
(using the top-up nozzle D up to the end of the
same)
ATTENTION
• By adding water instead of cooling liquid, the
percentage of anti-freeze contained in the cooling
liquid decreases.
If water is used instead of cooling liquid check,
and eventually correct, the concentration of anti-
5 freeze in the liquid.
• Add only distilled water. However, soft water can
be used if distilled water is not available.
• If the cooling liquid comes into contact with a
painted surface, immediately wash it using water.
6 Check:
using the expansion vessel E .
Bring the reference level between MIN and MAX.
E 6
7 Install:
• the radiator cap
8 Start:
• the engine
Check:
NOTE:
Before checking the cooling liquid level, wait a few
minutes for it to gather inside the expansion vessel.
9 Install:
3 43
ADJ
COOLING LIQUID CHANGE
1 Park:
NOTE:
N
• Carry out the following operations with the
engine cold.
2 Remove:
3 Remove:
• the radiator cap A
A WARNING
If the radiator is very hot, the liquid inside will be
pressurised. Do not remove the radiator cap with
the engine hot. Boiling hot liquid may leak, causing
serious injuries. When the engine has cooled down,
open the radiator cap as follows:
Position a towel on the radiator cap and slowly
3
loosen the cap anti-clockwise to drain any residue
pressure.
When the usual hiss is no longer heard, press on
the radiator cap and loosen it anti-clockwise to
remove it.
4 Arrange besides the bike:

• a container
with capacity above 4 l for the recovery of the
exhausted liquid.
3 44
ADJ
5 Remove:
• the liquid drain screw on the pump B
• the copper washer C
B C
6 Drain:
• the cooling liquid
leave the liquid to flow completely
7 Install:
• the copper washer
• the liquid drain screw on the pump
NOTE:
Always replace the copper washer with a new one.
Torque fasten: R.
T.
10 N m - 1.01 Kgf•m
8 Fill:
D • the cooling system
(using the top-up nozzle D up to the end of the
same)
NOTE:
Eventually press on the rubber tubes of the
radiator or tilt the bike to both sides to eliminate
air bubbles.
8 Recommended Anti-freeze
High quality, ethylene glycol based
anti-freeze liquid with organic
inhibition. In case of top-up with inorganic
inhibition products, the benefits and features
of the liquid decrease.
Mixing ratio
1:1 (anti-freeze: water)
Total quantity
2.50 l
Cooling liquid tub capacity
120 cc
Cooling liquid treatment
The cooling liquid is potentially toxic and must
be handled with particular attention.
3 45
ADJ
WARNING
• The cooling liquid top-up must always be carried
out with a cold engine. Never attempt to remove
the radiator cap when the engine is hot to avoid
the risk of burns.
The circuit is pressurised.
• If the cooling liquid should come into contact with
the eyes, accurately rinse them with water and
contact a doctor.
• If the cooling liquid comes into contact with
clothing, immediately remove the liquid using
water and soap.
• In case of swallowing the cooling liquid, force
vomiting and immediately contact a doctor.
• In certain conditions, the ethylene glycol
contained in the cooling liquid is flammable and
its flame is invisible.
Avoid the cooling liquid coming into contact with
hot parts, in that the consequent fuelling of the
ethylene glycol might expose the operator to risks
of burns.
ATTENTION
• By adding water instead of cooling liquid, the
percentage of anti-freeze contained in the cooling
liquid decreases.
If water is used instead of cooling liquid check,
and eventually correct, the concentration of anti-
freeze in the liquid.
• Add only distilled water. However, soft water can
be used if distilled water is not available.
• If the cooling liquid comes into contact with a
painted surface, immediately wash it using water.
• Never mix different types of anti-freeze.
9 Check:
using the expansion vessel E .
Bring the reference level between MIN and MAX.
E 9
10 Install:
• the radiator cap
3 46
ADJ
11 Start:
• the engine
12 Check:
NOTE:
Before checking the cooling liquid level, wait a few
minutes for it to gather inside the expansion vessel.
13 Install:
3 47
CHK ENGINE/FUEL TUBE
ADJ
FUEL TUBE CONTROL AND REPLACE-

MENT
1 Remove:
• the seat
• the tank
• the air box
2 Check:
• the fuel tube A
A In the presence of cracks/damages Replace.
correctly.
TO REPLACE THE FUEL TUBE
3 Release:
• the fuel tube
using the specific tool B and C .
Special Tools: RAPID RELEASE KIT

Code: R180100143000
NOTE:
When using the special tool, the two flaps of the
petrol pump must be pressed. Once the fuel tube is
removed, insert the special tool (C) to avoid petrol
RAPID RELEASE KIT leaking.
However, place cloths underneath the disconnecting
point.
B
3
4 Remove:
• the screw D
• the 2 washers E
E from the injectors flute.
• the fuel tube
D
3 48
CHK ENGINE/FUEL TUBE
ADJ
5 Replace:
• the fuel tube
Install:
• the 2 washers
• the screw
6 Release:
• the special tool
Hook:
• the new fuel tube
7 Install:
• the air box
• the tank
NOTE:
To install the tank, check that the fuel tube is not bent
or crushed by the same tank.
• the seat
NOTE:
The fuel tube must be replaced every 20.000 Km or
(12.427 mi).
3 49
CHK ENGINE/DRAIN PLANT
ADJ
DRAIN PLANT CONTROL AND

REPLACEMENT
The following procedure is applied to all drain tubes
and gaskets.
WARNING
Do not touch the silencing device bracket until the
drain plant has cooled down.
1 Check:
• the exhaust pipes A
• the drain valve tube B
• the silencing device C
In the presence of cracks/damages Replace.
• the gaskets D
C In the presence of gas leaks Replace.
Check:
• the fastening torques
G
Nuts of the exhaust pipe E
R.
T.
15 N m - 1.52 Kgf•m
F D Drain collector nut F
10 N m - 1.01 Kgf•m
Drain collector thermal protection screws G
8 N m - 0.81 Kgf•m
H Drain collector nuts H
E 10 N m - 1.01 Kgf•m
B
A
1
TO REPLACE THE DRAIN PLANT
2 Remove:
• the number plate bracket
• the seat
• the heat shield lid
• the right and left tank lids
• the tank
3 50
CHK ENGINE/DRAIN PLANT
ADJ
3 Disconnect:
• the lambda probe connector
See "ELECTRIC PLANT 7.13" paragraph.
• the drain valve cable
4 Remove:
• the entire drain unit
5 Replace:
• the interested component
with a new one.
6 Install:
• the entire drain unit
7 Connect:
• the drain valve cable
• the lambda probe connector
See "ELECTRIC PLANT 7.13" paragraph.
8 Install:
• the tank
• the seat
3 51
CHK ENGINE/COOLING SYSTEM
ADJ
COOLING SYSTEM CONTROL AND

REPLACEMENT
1 Remove:
• the alternator lid
• the tank
2 Check:
• the radiator A
B • the radiator inlet tube B
• the radiator outlet tube C
• the water/oil exchanger D
• the oil exchanger inlet tube E
G • the oil exchanger outlet tube F
• the cylinder inflow fitting G
I • the water pump inlet sleeve H
• the water pump outlet sleeve I
TO REPLACE THE COOLING SYSTEM
A 3 Remove:
• the cooling circuit
C
H
F 4 Replace:
• the interested component
with a new one.
E D
5 Install:
• the cooling circuit
6 Install:
Installa
• the tank
3 52
CHK FRAME/FRONT BRAKE ADJUSTMENT
ADJ
FRONT BRAKE ADJUSTMENT
1 Adjust:
• the position of the brake lever
(distance A between the accelerator knob and the
brake lever).
N
NOTE:
Push the brake lever forward to neutralise the push
of the spring and simultaneously adjust the posi-
tion by turning the ring nut B clockwise or anti-
clockwise, until the brake lever is in the wanted
position.
A
POSITION 1 the distance is further away from the
handle bar
B POSITION 4 the distance is closer to the handle bar
WARNING
If the brake lever is soft or spongy to the touch,
this may mean that there is air inside the braking
1 system. Before using the vehicle, remove the air by
bleeding the braking system. The presence of air
inside the braking system significantly reduces the
system performances and may cause loss of
control of the vehicle and possible accidents.
Therefore, check and, if required, bleed the
braking system.
ATTENTION
After having adjusted the brake lever position,
check there is no dragging of the brake.
3 53
CHK FRAME/REAR BRAKE ADJUSTMENT
ADJ
R
REAR BRAKE ADJUSTMENT
A 1 Adjust:
• the position of the brake pedal
a Loosen the nut A and lock nut B .

b Tighten or loosen the threaded pin C to increase
or decrease the rear brake command clearance.
B TIGHTENING the clearance increases
C LOOSENING the clearance decreases
c Tighten the nut A
d Fasten the lock nut B

A to the specified value.
16 N m - 1.63 Kgf•m
R.
T.
WARNING
1 If the brake pedal is soft or spongy to the touch,
this may mean that there is air inside the braking
system. Before using the vehicle, remove the air by
bleeding the braking system. The presence of air
inside the braking system significantly reduces the
system performances and may cause loss of control
of the vehicle and possible accidents.
Therefore, check and, if required, bleed the
braking system.
ATTENTION
After having adjusted the brake pedal position,
ensure there is no sticking of the brakes.
3 54
CHK FRAME/BRAKES LIQUID LEVEL CONTROL
ADJ
BRAKES LIQUID LEVEL CONTROL
1 Park:
• the bike levelled
NOTE:
N
2 Check:
a • the brakes liquid level
If below the minimum level notch A Top-up
to the correct level using the recommended brakes
liquid.
Recommended brakes liquid

TOP
4
TUTELA BRAKE FLUID
A TOP 4 - DOT 4
2 a FFront brake
b F
Rear brake
b WARNING
• Use only the prescribed brakes liquid. Other
brakes liquids may be cause of deterioration of
the rubber gaskets, causing leaks and unsuitable
functioning of the braking system.
• Top-up using the same type of brakes liquid
A already present inside the plant. The mixing of
different brakes liquids can cause a dangerous
chemical reaction, able to determine a bad func-
tioning of the braking system.
2 • During top-up, be careful not to let water flow in-
side the tub. Water would significantly lower the
boiling point of the brakes liquid and may cause
vapour bubbles.
ATTENTION
The brakes liquid can damage the painted surfaces
and the plastic parts. Therefore, always
immediately clean all brakes liquid spills.
NOTE:
To assure the correct reading of the brakes liquid
level, the end of the tub must be horizontal.
3 55
CHK FRAME/FRONT AND REAR BRAKE PADS CONTROL
ADJ
FRONT AND REAR BRAKE PADS

CONTROL
The following procedure is applied to all brakes pads.
1 Activate:
• the brake
2 Check:
a • the front brake pad
• the rear brake pad
• the wear limit of the front brake pads A and rear
B
Wear limit reached Replace all brake pads.
A To replace the front brake pads see "FRAME 4.32"
paragraph and installation "FRAME 4.36"; for the rear
brake pads see "FRAME 4.34" paragraph and installa-
tion "FRAME 4.38".
Wear limit of the brake pads

b
Front 0.5 mm (0.01 in)
Rear 1.0 mm (0.03 in)
a FFront brake
B b F
Rear brake
3 56
CHK FRAME/BRAKING PLANT FLEXIBLE TUBES CONTROL
ADJ
a BRAKING PLANT FLEXIBLE TUBES

CONTROL
The following procedure is applied to all brakes
A flexible tubes and to the brakes tubes clamps.
1 Check:
• the brake flexible tube A
In the presence of cracks/damages/wear lines
Replace.
1
2 Check:
b • the clamp of the brake flexible tube B
B If loose Fasten the clamp bolt.
3 Keep:
• the bike in straight position
Activate:
• the brake repeatedly
4 Check:
• the brake flexible tube
In the presence of brakes liquid leaks Replace
the damaged flexible tube.
3 57
CHK FRAME/HYDRAULIC BRAKING SYSTEM BLEEDING
ADJ
HYDRAULIC BRAKING SYSTEM

BLEEDING
WARNING
Bleed the hydraulic braking system every time
that:
• the system has been dismantled.
• a flexible tube of the brake is loosened,
disconnected or replaced.
• the brakes liquid level is very low.
• the brake is faulty.
NOTE:
N
• Careful not to spill the brakes liquid or excessively
fill the tub until it overflows.
• When bleeding the hydraulic braking system,
check there is always a sufficient amount of liquid
before engaging the brake. By ignoring this
procedure, air may penetrate inside the braking
plant, significantly extending the bleeding
procedure.
• Should the bleeding operation be difficult, it may
be necessary to let the brakes liquid rest for a few
hours. Repeat the bleeding procedure when the
bubbles inside the flexible have disappeared.
1 B
S leed:
• the hydraulic braking system
3 58
ADJ
a Fill the brakes liquid tub to the correct level using

the recommended brakes liquid.
WARNING
• Use only the prescribed brakes liquid. Other
brakes liquids may be cause of deterioration of
the rubber gaskets, causing leaks and unsuitable
already present inside the plant. The mixing of
different brakes liquids can cause a dangerous
chemical reaction, able to determine a bad

TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4
ATTENTION
The brakes liquid may damage the painted
surfaces and the plastic parts. Therefore,
b Install the brakes liquid tub diaphragm.
A c Connect a transparent plastic tube A by securely

B inserting it on the bleeding screw B
2 P
Front brake calliper
3 Rear brake calliper
d Insert the other end of the flexible tube inside a

container.
2
e Slowly activate the brake a few times.
f Pull the brake lever completely, or press the brake

pedal to the end, maintaining the reached position.
g Loosen the bleeding screw.
NOTE:
By loosening the bleeding screw the pressure is
released allowing the brake lever to reach the
A
B accelerator knob, or allowing the brake pedal to
3 reach end run.
h Fasten the bleeding screw and release the brake

lever or pedal.
i Repeat points e to h until the air bubbles
have definitely disappeared from the brakes liquid
visible in the plastic tube.
j Fasten the bleeding screws to the specified value.

10 N m - 1.01 Kgf•m
R.
T.
3 59
ADJ
k Fill the brakes liquid tub to the correct level using

the recommended brakes liquid.
WARNING
After having bled the hydraulic braking plant,
check the functioning of the brakes.
NOTE:
After having bled the air, brake liquid may drip on
the threaded section of the bleeding screw.
This does not indicate the presence of leaks but of
brake liquid accumulated on the threading of the
screw during air bleeding. Clean the interested
parts.
3 60
CHK FRAME/GEAR CHANGE PEDAL ADJUSTMENT
ADJ
ADJUSTMENT OF PEDAL OF THE

GEAR CHANGE
1 Adjust:
D C • the position of the gear change pedal
a Remove the nut A and the screw B .

A b Loosen the two nuts of the rod C .
B
1 c Rotate the gears command rod D clockwise
or anti-clockwise.
CLOCKWISE the gear change pedal is lowered
ANTI-CLOCKWISE the gear change pedal is lifted
d Once the gear change pedal adjustment is

completed, fasten the rod nuts and fix the rod to
the support using the previously removed screw
and nut.
3 61
CHK FRAME/TRANSMISSION CHAIN ADJUSTMENT
ADJ
TRANSMISSION CHAIN LOOSENING

ADJUSTMENT
NOTE:
Do not inspect or adjust the transmission chain
with the engine running.
NOTE:
Check the loosening of the transmission chain
where it seems more tensed.
WARNING
If the transmission chain is too tense, the engine
and other vital parts will be overloaded, whereas
if it is too loose, it can come away and damage the
suspension arm or cause an accident. Therefore,
we recommend maintaining the loosening of the
chain within the specified limits.
1 Park:
WARNING
Support the bike with adequate supports, so that
it cannot fall and so that the rear wheel is lifted.
2 Have the rear wheel turn repeatedly and identify the

position in which the transmission chain is more
tensioned.
3 Check:
• the loosening of the transmission chain
Loosening of transmission chain

15 mm (0.59 in)
15 m
m
3 62
CHK FRAME/TRANSMISSION CHAIN ADJUSTMENT
ADJ
4 Adjust:
a Loosen the eccentric locking screws A on both

sides of the swing arm.
b Insert the specific tool B inside the eccentric.
D
Special Tools: TRANSMISSION CHAIN

REGULATOR SPANNER
A Code: R300097147000
A 4
c Rotate the eccentrics in C or D direction until

the specified loosening degree for the transmission
chain is obtained.
B DIRECTION C the transmission chain loosens
DIRECTION D the transmission chain tenses
NOTE:
To maintain the correct alignment of the wheel,
4 evenly adjust on both sides.
d Fasten both eccentric locking screws to the

C specified value.
Eccentric locking screws

22 N m (2.24 Kgf•m)
D
3 63
CHK FRAME/TRANSMISSION CHAIN LUBRICATION
ADJ
TRANSMISSION CHAIN LUBRICA-

TION
The transmission chain is made of many parts interact-
ing with each other.
The chain must be subject to correct maintenance
otherwise it will rapidly wear out.
We therefore recommend subjecting the transmission
chain to maintenance, in particular if using the bike in
very dusty areas.
This bike is equipped with a transmission chain with
small rubber O-Rings placed between one side plate
and the other.
Do not use jets of vapour, high pressure water jets,
aggressive solvents or brushes with very rough
bristles, or these O-Rings will be damaged.
We therefore suggest cleaning the transmission chain
with recommended products.
Dry the chain and accurately lubricate it using engine
oil or specific lubricant for O-Ring chains.
Do not use other types of lubricants on the
transmission chain,
in that they might contain solvents that will damage
the O-Rings.
S
SINTOFLON
1 Apply:
• a thin and even layer of lubricant
on the entire chain being careful not to reach the
surrounding parts, in particular tyres.
3 64
CHK FRAME/STEERING TUBE CONTROL AND ADJUSTMENT
ADJ
STEERING TUBE CONTROL AND

ADJUSTMENT
1 Park:
NOTE:
Place the bike on a trestle of adequate support so
that the front wheel is lifted.
2 Check:
• the steering tube
Make the front fork oscillate delicately grabbing it by
the tubes' ends.
In the presence of jamming/loosening points
Adjust the steering tube.
3 Remove:
• the handle bar
4 Loosen:
• the stop screws of the upper steering wheel
B plate A
Remove:
• the upper steering wheel plate B
A
3
3 65
CHK FRAME/STEERING TUBE CONTROL AND ADJUSTMENT
ADJ
5 Adjust:
a Remove the kingpin ring nut C .

D C
b Loosen the steering ring nut D , therefore fasten it
to the specified value using the appropriate spanner
Special Tools: STEERING WHEEL RETURN RING SPANNER

Code: R180297129000
5
Fastening torque of steering ring nut
R.
T.
60 N m - 6.11 Kgf•m
WARNING
Do not excessively fasten the steering ring nut.
c Check that the steering tube is not loose and that it

does not have jamming points, by turning the front
fork to end run in both directions. If detecting
jamming points, remove the lower steering wheel
base and inspect the upper and lower bearings.
6 Install:
• the upper steering wheel plate F
F • the stop screws of the upper steering wheel
plate G
G
6
7 Check:
the tubes' ends.
Repeat the operations to adjust the steering tube.
3 66
CHK FRAME/TRANSMISSION GEARS CONTROL AND REPLACEMENT
ADJ
TRANSMISSION GEARS CONTROL

AND REPLACEMENT
1 Remove:
• the clutch lid
• the transmission chain
2 Check:
• the teeth of the conducting and conducted gears
In the presence of damages or wear Replace.
NOTE:
N
In case of replacing the transmission chain, check
that the conducting and conducted gears are in
good state so as not to rapidly wear out the new
chain.
3 67
CHK FRAME/FRONT FORK CONTROL
ADJ
FRONT FORK CONTROL
1 Park:
NOTE:
N
S
Support the bike using suitable supports so that it
cannot fall.
2 Check:
B • the fork shank A
• the fork sleeve B
In the presence of damages/scratches Replace.
• the oil retainer
In the presence of leaks Replace.
A
3 Keep:
• the bike in straight position.
Activate:
• the front brake
4 Check:
• the functioning of the fork
Push a few times on the handle bar and check that
the front fork smoothly returns backwards.
If the movement is not smooth Repair.
3 68
CHK FRAME/REAR SHOCK ABSORBER SET ADJUSTMENT
ADJ
REAR SHOCK ABSORBER SET

ADJUSTMENT
NOTE:
N
S
cannot fall.
The rear shock absorber is equipped with external

regulators to adjust the motorbike asset at the load
conditions.
The regulator A , placed below, in correspondence
B of the lower fixing of the shock absorber to the swing
arm, adjusts the hydraulic brake during the
extending phase (return).
The regulator B adjusts the spring pre-load.
SPRING PRE-LOAD
D 1 Adjust:
• the spring pre-load
C a Rotate the adjusting screw C in D or D
E
direction
E
DIRECTION D the spring pre-load increases
1 DIRECTION E the spring pre-load decreases
ADJUSTING POSITIONS
Minimum: 0
Standard: -17
Maximum: -30
3 69
CHK FRAME/REAR SHOCK ABSORBER SET ADJUSTMENT
ADJ
EXPANSION DAMPING
WARNING
Never overstep the minimum or maximum
G adjusting positions.
1 Adjust:
F • the extension damping
H
a Rotate the adjusting screw F in G or D
H direction
1
DIRECTION G the extension damping increases

(suspension is stiffer)
DIRECTION H the extension damping decreases

(suspension is more springy)
ADJUSTING POSITIONS
Minimum: 0
Standard: 0
Maximum: 10 mm
3 70
CHK FRAME/TYRES CONTROL
ADJ
TYRES CONTROL
The following procedure is applied to both tyres.
1 Check:
• the tyres pressure
If out of specification Adjust it.
3
0
WARNING
2 1
1 • The tyres pressure must be checked and adjusted

only when the temperature of the wheels is the
same as the ambient temperature.
• The tyres pressure and the suspension must be
adjusted according to the total weight (including
luggage, driver, passenger and accessories) and
bearing in mind the envisioned gear speed.
• The use of the overloaded bike may cause
damages to the tyres, with the risk of an accident
or injuries to persons.
NEVER OVERLOAD THE MOTORBIKE.
Net Weight
(with oil and fuel 240 Kg
tank full)
Maximum Load* 440 Kg
TYRES PRESSURE FRONT REAR
WHEN COLD
Up to 90 kg of load* 2.2 bar 2.4 bar
90 kg ~
maximum load* 2.3 bar 2.6 bar
* Including luggage, driver, passenger and accessories.
WARNING
It is dangerous to ride with the tread worn.
If the tread reaches wear limit, immediately
replace the tyre.
2 Check:
• the tyres surface
A In the presence of damages/wear Replace the
tyre.
C Minimum tread depth

B 45 N m - 4.58 Kgf•m
A Tread depth
2 B Side wall
C Wear signal device
3 71
ADJ
WARNING
• Do not use "tubeless" type tyres on rims designed
only for tyres with air chamber, so as to avoid the
risk of tyre braking with consequent injuries to
persons caused by the sudden deflating.
• If using tyres with air chamber, remember that
the correct type of air chamber must be installed.
• Always replace both the tyre and the air chamber
together.
• To avoid nipping the air chamber, ensure that the
rim band and the air chamber are correctly
centred on the wheel groove.
• We recommend patching the air chamber in case
of perforation. Use maximum care and replace
the air chamber as soon as possible using an
excellent quality spare part.
D E D Tyre
E Wheel
E
ESS TIR
TUBEL
LE FOR
S U I TA B Wheel with air Only tyre with air
chamber chamber
Wheel without air Tyre with or without
chamber air chamber
WARNING
After various tests, the tyres shown below have
been approved by Benelli Q.J.
s.r.l. for this model. The front and rear tyres must
be of the same drawing and the same brand. No
road behaviour guarantee can be given if a
combination of tyres different to that approved
by Benelli is used.
Front tyre
MANUFACTURER MEASURE MODEL
Dunlop 120/70 SPORT MAX

ZR17 58W ROADSMART
Rear tyre
MANUFACTURER MEASURE MODEL
Dunlop 180/55 SPORT MAX

ZR17 73W ROADSMART
3 72
ADJ
WARNING
If the tyres are new, they will have a relatively
modest grip on the road until they have worn
slightly. Therefore, we recommend driving the
first 100 km at normal speed, before increasing
speed.
NOTE:
Tyres with indication of rotary direction F :
• Install the tyre with the mark facing the rotary
G F direction of the wheel.
• Align the mark G with the installation point
of the valve.
3 73
CHK FRAME/WHEELS CONTROL
ADJ
WHEELS CONTROL
The following procedure is applied to both wheels.
1 C
Check:
• the wheel
See "FRAME 4.5" paragraph for the front wheel; the
"FRAME 4.20" paragraph for the rear wheel.
In case of damage/ovalisation Replace.
WARNING
Never attempt any kind of repairs on the wheel.
NOTE:
If a tyre or a wheel has been replaced or removed
and re-assembled, it is always necessary to carry
out wheel balancing.
3 74
CHK FRAME/CABLES CONTROL AND LUBRICATION
ADJ
CABLES CONTROL AND LUBRICA-

C
TION
The following procedure is applied to all cables and
relative sheaths.
WARNING
If an external cable is damaged, it may corrode
and cause interferences in the movement.
Replace any damaged cables and sheaths as soon
as possible.
1 Check:
• the external cable
2 Check:
• the functioning of the cables
If the movement is not smooth Lubricate.
E ENGINE OIL
NOTE:
Keeping the end of the cable upwards, pour a few
drops of lubricant inside the sheath or use an
appropriate lubrication device.
3 75
CHK FRAME/LEVERS AND PEDALS LUBRICATION
ADJ
LEVERS AND PEDALS LUBRICATION
Lubricate the rotary points and the levers and pedals

metal parts subject to contact during movement.
LS
TUTELA MR2 GREASE
3 76
CHK FRAME/SIDE TRESTLE LUBRICATION
ADJ
SIDE TRESTLE LUBRICATION
Lubricate the rotary points and the side trestle metal

parts subject to contact during movement.
LS
TUTELA MR2 GREASE
3 77
CHK FRAME/LUBRICATION OF THE REAR SUSPENSION
ADJ
LUBRICATION OF THE REAR SUSPEN-

SION
Lubricate the rotary points and the rear suspension
metal parts subject to contact during movement.
S
Recommended grease
SINTOFLON
3 78
CHK ELECTRIC PLANT/BATTERY CHARGE AND CONTROL
ADJ
BATTERY CHARGE AND CONTROL
WARNING
The batteries generate a nitrogen based explosive
gas and contain electrolyte, which is made of
sulphuric acid, a poisonous and highly caustic
substance.
Therefore, the following precautions must always
be complied with:
• Wear the protection glasses when handling the
battery or working near it.
• Recharge the battery in an adequately aired area.
• Keep the batteries away from fire, sparks or
naked flames (for example: welding tools, lit
cigarettes).
• DO NOT SMOKE when recharging or handling a
battery.
• KEEP THE BATTERIES AND THE ELECTROLYTE
AWAY FROM CHILDRENS REACH.
• Avoid the electrolyte coming into contact with
body parts, in that it may cause serious burns or
permanent injuries to the eyes.
FIRST AID IN CASE OF PHYSICAL CONTACT:
EXTERNAL CONTACT
• Skin: wash with water.
• Eyes: Wash with running water for 15 minutes
and immediately contact a doctor.
SWALLOWING
• Drink large amounts of water or milk, therefore
magnesium milk, beaten eggs or vegetable oil.
Immediately contact a doctor.
ATTENTION
• This battery is sealed. Do not remove the sealing
caps, as the balance between the cells would not
be maintained and the battery performances
would suffer the consequences.
• The time, amperage and voltage for charging the
above battery are different to those of
conventional batteries. Charge the battery as
shown in the explanatory illustrations. If the
battery is overcharged, the level of the
electrolyte decreases significantly. Therefore,
pay maximum attention during battery charging.
3 79
ADJ
NOTE:
Given that the battery is sealed, it is not possible
to check the charge state by measuring the density
of the electrolyte.
Therefore, the battery charge must be controlled
by measuring the voltage on the terminals of the
same battery.
1 Remove:
• the seat
2 Disconnect:
• the battery cables
from the terminals.
B
ATTENTION
Firstly disconnect the battery negative cable A ,
therefore, the positive cable B .
A
2
3 Disconnect:
• the battery
Check:
• the battery charge
a Connect a pocket tester to the battery terminals.
Positive pointer of tester Positive

terminal of the battery
3 Negative pointer of tester Negative
terminal of the battery
3 80
ADJ
b Check the battery charge as shown in the tables of

13 the following example.
Voltage with open circuit (V)
12.5 Ratio between the voltage with open

circuit and the charge time at 20°C NOTE:
12 • The charge state of a battery can be checked by
measuring its voltage with open circuit (meaning
11.5 the existing voltage when the positive terminal is
disconnected).
• If the voltage with open circuit is the same or
5 6.5 10 above 12.8 V, no charging is required.
Charge time (hours)
These values vary with the varying of the temperature, of the condition of the battery plates and of the Example
level of the electrolyte.
c Voltage with open circuit = 12.0 V

14
13
d Charge time = 6.5 hours
12
e Battery charge =20 ~ 30%
11
10
Ambient tem-
perature 20°C
100 75 5030 25 0 4 Charge:
20 • the battery (see the illustration with the appropriate
Battery charge state (%) charging method).
ATTENTION
Do not submit the battery to rapid charge.
WARNING
• Never remove the caps sealing the battery.
• Do not use rapid battery chargers as these insert
the battery with high amperage current at high
speed, therefore the battery may overheat and its
elements be damaged.
• Should it be impossible to adjust the charge
current of the battery charger, pay attention not
to overcharge the battery.
• For charging, the battery must be disconnected
from the bike. (Should it be necessary to charge
the battery when connected to the bike,
disconnect the negative cable from the battery
terminal).
• To reduce the possibility of sparks being produc-
ed, connect the battery charger to the power
supply network only after having connected the
battery cables.
• Before disconnecting the cables clamps of the
battery charger from the battery terminals,
remember to switch off the battery charger.
• Ensure that the cables clamps of the battery
charger are in full contact with the battery
terminals and are not in short circuit. A corroded
clamp can generate heat in the contact area and
charge an inefficient clamp spring can cause sparks.
18 • If the battery heats up during the charging
17 process, disconnect the battery charger and

16 leave the battery to cool before continuing the
15 operation. The batteries that heat up can
14 explode!!
13 • As shown in the following illustrations, the
12 voltage with open circuit of a battery stabilises
11 approximately 30 minutes after charging has
10 completed, before measuring the voltage with
0 10 20 30 40 50 60
open circuit.
Check the voltage
with open circuit.
3 81
ADJ
Charging method with a battery charger of variable current (voltage) type
Battery charger
Measure the voltage with open NOTE:
Measure the voltage 30 minutes after
Ammeter circuit before charging. having switched off the equipment.
A
NOTE:
Connect a battery charger and Set the charging voltage on 16~17 V.
(By setting it on a lower value, the
an ammeter to the battery charge would be insufficient.
Whereas, if it is set on a value too
and start charging. high, the battery would be
overcharged).
Check that the current is higher than

the standard value of the charge
SI current shown on the battery.
NO
By rotating the adjusting

washer of the charge
voltage, set the charge
voltage on 20 ~ 24 V.
Keep amperage under

Adjust the voltage so that the SI control for 3 ~ 5 minutes
current is at standard charge level. to check if the standard
charge current is reached.
NO
Set the time according to If the current does not

the charge time suitable exceed the standard
for voltage with open circuit. charge current once 5
See the instructions with minutes have passed,
replace the battery.
the battery.
If charging requires more than 5 hours, we recommend checking the charge current after 5 hours.
If amperage variations occur, adjust the voltage again to obtain the standard charge current.
Measure the battery voltage with open circuit after having left the battery unused for over 30 minutes.
12.8 V or above Charging is completed
12.7 V or below Requires charging.
Below 12.0 V Replace the battery.
3 82
ADJ
Charging method with a battery charger of constant voltage type
Measure the voltage with open NOTE:

Measure the voltage 30 minutes after
having switched off the equipment.
circuit before charging.
Connect a battery charger and

an ammeter to the battery
and start charging.
Check that the current is higher than

the standard value of the charge
SI current shown on the battery.
NO
This type of battery

charger cannot be used
to charge these batteries.
We recommend using a
battery charger with
variable voltage.
Battery charger
Charge the battery until the
charge voltage reaches 15 V.
Ammeter
Voltmeter
A
NOTE:
Set the charge time at 20 hours V
maximum.
Measure the voltage with open

circuit after having left the battery
unused for over 30 minutes.
12.8 V or above Charging is NOTE:

completed. To assure maximum performances and duration of the battery,
we recommend using electronic battery chargers able to supply
12.7 V or below Requires correct charging voltages and currents, according to the
charging. specifications requested from the technology of the sealed
batteries.
Below 12.0 V Replace the
battery.
3 83
ADJ
5 Install:
• the battery
Connect:
• the battery cables
C (to the battery terminals)
ATTENTION
Firstly connect the battery positive cable C ,
therefore, the negative cable D .
D
5
6 Check:
• the battery terminals
In the presence of dirt Clean using a metal
brush.
correctly.
7 Lubricate:
• the battery terminals
Recommended grease
E ENGINE OIL
8 Install:
• the seat
3 84
CHK ELECTRIC PLANT/FUSES CONTROL
ADJ
FUSES CONTROL
The following procedure is applied to all fuses.
ATTENTION
If having to check or replace the fuses, to avoid a
short circuit, always switch off the main switch by
turning it to "OFF".
1 Remove:
• the seat
• the object compartment
2 Check:
• the fuse
a Connect a pocket tester to the fuse to check its

continuity.
NOTE:
Set the pocket tester selector on “ Ω x 1”.
b If the pocket tester indicates “ ”, replace the fuse.

8
3 Replace:
• the burnt fuse
a Turn the main switch to "OFF".

b Install a new fuse with correct amperage.
c Switch on the switches to check that the electric

circuit works.
d If the fuse immediately burns, check the electric

circuit.
3 85
CHK ELECTRIC PLANT/FUSES CONTROL
ADJ
Services Electric fans

Fuses Amperage Quantity
Injection Petrol Pump
Alarm Instrument 5A 1
Lights Alarm
Instrument
Petrol Pump 10 A 1
Electric fan 15 A 1
15A
15A
15A
10A
20A
5A
Services 15 A 1
Injection 15 A 1
20A 15A Lights 20 A 1
5A
Spare 20 A 1
Spare
Spare Spare 3 Spare 15 A 1
Spare 5A 1
WARNING
Never use a fuse with amperage different to that
specified. The use of improvised techniques or
fuses with different amperage can cause
irreversible damages to the electric plant, cause
faults in the lights and ignition system
functioning, and eventually cause a fire.
4 Install:
• the object compartment
• the seat
3 86
CHK ELECTRIC PLANT/FRONT LIGHTS REPLACEMENT
ADJ
FRONT LIGHTS REPLACEMENT

The following procedure is applied to both the front
lights.
ATTENTION
Given that the projector bulb reaches very high
temperatures, we recommend not touching it with
the hands until it has cooled down.
1 Remove:
• the fixing screws
• the right and left inspection lids
2 Disconnect:
• the connectors
of the lamp to be replaced
a High beam
b Dipped beam
a
b 2
3 Release:
A • the fixing spring
Extract:
• the lamp A
ATTENTION
Avoid touching the glass part of the projector
lamp to keep it clean from any oil trace. On the
contrary, the glass transparency, the duration of
the bulb, the luminosity of the projected light
beam may be affected. If the bulb becomes dirty,
3 accurately clean it using a cloth wet with alcohol
or thinner for enamel.
3 87
CHK ELECTRIC PLANT/FRONT LIGHTS REPLACEMENT
ADJ
4 Install:
• the new lamp
and fix it using the fixing spring.
5 Connect:
• the connectors of the new lamp
6 Connect:
• the right and left inspection lid
• the fixing screws
3 88
CHK ELECTRIC PLANT/FRONT HEADLIGHT REMOVAL
ADJ
FRONT HEADLIGHT REMOVAL

1 Remove:
• the mobile and fixed cap
2 Remove:
A • the self-locking screws A
• the equipment lid B
B
3 Remove:
• the lamp inspection lids
• the headlight fixing pins C
4 Remove:
H • the side screws D
D • the nuts E
• the bushes F
• the equipment support G
• the odometer instrument H
E
4
3 89
CHK ELECTRIC PLANT/FRONT HEADLIGHT REMOVAL
ADJ
5 Release:
• the headlight connectors I
6 Remove:
• the screws
for headlight fixing on the frame J
• the nuts K
• the central screw L
for closing right and left frame
• the nut M
M L K J
3 90
CHK ELECTRIC PLANT/FRONT HEADLIGHT INSTALLATION
ADJ
FRONT HEADLIGHT INSTALLATION

1 Install:
52A43 52A43
• the central screw A
for closing right and left frame
• the screws B
for headlight fixing on the frame
C A C B • the nuts C
Recommended thread brakes:

1
AREXONS SYSTEM 52A43
52A43 MEDIUM THREAD BRAKES
Torque fasten the screw A 10 N m - 1.01 Kgf•m
R.
T.
Torque fasten the screws B 22 N m - 2.24 Kgf•m
R.
T.
2 Connect:
• the headlight connectors D
3 Install:
E • the odometer instrument E
I • the equipment support F
• the bushes G
• the nuts H
• the side screws I
H
3
3 91
CHK ELECTRIC PLANT/FRONT HEADLIGHT INSTALLATION
ADJ
4 Install:
• the headlight fixing pins J
• the lamp inspection lids
Torque fasten the pins J 10 N m - 1.01 Kgf•m
R.
T.
5 Install:
L • the equipment lid K
• the self-locking screws L
K
6 Install:
• the mobile and fixed cap
3 92
CHK ELECTRIC PLANT/FRONT HEADLIGHT ADJUSTMENT
ADJ
FRONT HEADLIGHT ADJUSTMENT

1 To correctly adjust the luminous beam projected from
the front headlight:
• position the vehicle at approximately 10 meters from
a vertical wall on a perfectly levelled ground;
• sit on the vehicle in driving position;
• check that the upper limit of the luminous beam
projected on the vertical wall is lower by
approximately 1/10 compared to the horizontal axis
of the headlights.
If the luminous beam is not compliant with this

indication, adjust until the luminous beam is in the
correct position.
9/10 h
10 m
1
2 Adjust:
• the projector light beam
by acting on the two right and left dish regulator
screws positioned underneath the headlight.
The headlight has the possibility of adjusting the right

and left dishes separately; by loosening the luminous
beam lifts, by tightening the luminous beam lowers.
3 93
CHK ELECTRIC PLANT/REAR HEADLIGHT REPLACEMENT
ADJ
REAR HEADLIGHT REPLACEMENT
1 Remove:
• the seat
• the silencing device
2 Loosen:
• the silencing device screws A
and lower it to enable the headlight to come out.
A
2
3 Cut:
• the wiring locking strip
Release:
• the headlight connector
4 Remove:
• the nuts B
• the headlight C
B
C
4
5 Install:
• the new headlight
• the nuts
3 94
CHK ELECTRIC PLANT/REAR HEADLIGHT REPLACEMENT
ADJ
6 Hook:
• the headlight connector
Install:
• a new wiring locking strip
7 Install:
• the silencing device screws D
D
7
8 Install:
• the seat
3 95
CHK ELECTRIC PLANT/NUMBER PLATE BRACKET LIGHT REPLACEMENT
ADJ
NUMBER PLATE BRACKET LIGHT

REPLACEMENT
1 Remove:
A • the screw A
2 Remove:
B • the rubber lamp holder B
3 Replace:
• the position bulb
4 Install:
• the rubber lamp holder
• the screw
3 96
CHK ELECTRIC PLANT/FRONT INDICATORS REPLACEMENT
ADJ
FRONT INDICATORS REPLACEMENT

A The following procedure can be applied to both the
front indicators.
1 Remove:
• the handle bar cable gland A
2 Release:
D • the indicator connector B
Loosen:
B • the lower nut C
Remove:
C • the rear-view mirror D
3 Install:
E • the new rear-view mirror E
Tighten:
G • the lower nut F
Hook:
F • the indicator connector G
NEW
4 Install:
• the handle bar cable gland H
H
3 97
CHK ELECTRIC PLANT/FRONT INDICATORS LAMPS REPLACEMENT
ADJ
INDICATORS LAMPS REPLACEMENT

FRONT
The following procedure is applied to both the front
indicators lamps.
A 1 Remove:
• the screw A
2 Remove:
D NEW • the glass B
C C Remove:
• the bulb to be changed C
Install:
the new bulb D
B B 2
3 Install:
• the glass
• the screw
3 98
CHK ELECTRIC PLANT/REAR INDICATORS LAMPS REPLACEMENT
ADJ
REAR INDICATORS LAMPS

REPLACEMENT
The following procedure is applied to both the rear
indicators lamps.
1 Remove:
• the screw A
A
2 Remove:
• the glass B
• the bulb to be changed C
B C 2
3 Install:
• the new bulb D
• the glass E
NEW
E D
3
4 Install:
• the screw F
NOTE:
Moderately fasten the screw.
3 99
4 CHAS
CHAS
CHAPTER 4
FRAME
FRONT WHEEL AND BRAKE DISKS........................................................................ 1

FRONT WHEEL REMOVAL............................................................................................................... 1
FRONT BRAKE DISKS REMOVAL.................................................................................................... 3
FRONT WHEEL DECOMPOSITION................................................................................................. 4
FRONT WHEEL CONTROL................................................................................................................ 5
BRAKE DISKS CONTROL................................................................................................................... 7
FRONT BRAKE DISKS ASSEMBLY.................................................................................................. 9
FRONT WHEEL INSTALLATION...................................................................................................... 11
FRONT WHEEL BALANCING........................................................................................................... 14
REAR WHEEL AND BRAKE DISK............................................................................. 16

REAR WHEEL REMOVAL................................................................................................................... 16
REAR BRAKE DISK AND CROWN WHEEL REMOVAL............................................................... 18
REAR WHEEL DECOMPOSITION.................................................................................................... 19
REAR WHEEL CONTROL................................................................................................................... 20
REAR WHEEL CROWN WHEEL HOLDER FLANGE INSPECTION........................................... 22
CROWN WHEEL CONTROL AND REPLACEMENT.................................................................... 23
REAR BRAKE DISK AND CROWN WHEEL ASSEMBLY............................................................. 24
REAR WHEEL INSTALLATION......................................................................................................... 26
REAR WHEEL BALANCING............................................................................................................... 28
FRONT AND REAR BRAKES.................................................................................... 29

FRONT BRAKE PADS REMOVAL.................................................................................................... 29
REAR BRAKE PADS REMOVAL....................................................................................................... 30
FRONT BRAKE PADS REPLACEMENT.......................................................................................... 32
REAR BRAKE PADS REPLACEMENT.............................................................................................. 34
FRONT BRAKE PADS INSTALLATION.......................................................................................... 36
REAR BRAKE PADS INSTALLATION.............................................................................................. 38
FRONT BRAKE PUMP REMOVAL................................................................................................... 40
FRONT BRAKE PUMP DECOMPOSITION.................................................................................... 41
REAR BRAKE PUMP REMOVAL...................................................................................................... 42
REAR BRAKE PUMP DECOMPOSITION....................................................................................... 43
FRONT AND REAR BRAKE PUMP CONTROL............................................................................. 44
FRONT BRAKE PUMP INSTALLATION.......................................................................................... 45
REAR BRAKE PUMP INSTALLATION............................................................................................. 48
FRONT BRAKE CALLIPERS REMOVAL.......................................................................................... 51
FRONT BRAKE CALLIPERS DECOMPOSITION........................................................................... 52
REAR BRAKE CALLIPER REMOVAL................................................................................................ 53
REAR BRAKE CALLIPER DECOMPOSITION................................................................................. 54
FRONT CALLIPERS AND REAR CALLIPER CONTROL.............................................................. 57
FRONT BRAKE CALLIPERS INSTALLATION................................................................................ 58
REAR BRAKE CALLIPER INSTALLATION...................................................................................... 61
CHAS
FRONT FORK........................................................................................................... 64
FRONT FORK SHANKS REMOVAL................................................................................................. 64
FRONT FORK SHANKS DECOMPOSITION.................................................................................. 66
FRONT FORK SHANKS INSPECTION............................................................................................. 70
FRONT FORK SHANKS ASSEMBLY................................................................................................ 71
FRONT FORK SHANKS INSTALLATION........................................................................................ 75
HANDLE BAR........................................................................................................... 77
HANDLE BAR REMOVAL................................................................................................................... 77
HANDLE BAR INSPECTION.............................................................................................................. 79
HANDLE BAR INSTALLATION......................................................................................................... 80
STEERING WHEEL HEAD........................................................................................ 83

UPPER AND LOWER STEERING WHEEL BASE REMOVAL...................................................... 83
UPPER AND LOWER STEERING WHEEL BASE INSPECTION................................................. 85
UPPER AND LOWER STEERING WHEEL BASE INSTALLATION............................................ 86
REAR SHOCK ABSORBER SET................................................................................ 89

REAR SHOCK ABSORBER SET REMOVAL.................................................................................... 89
REAR SHOCK ABSORBER AND GAS CYLINDER TREATMENT.............................................. 91
REAR SHOCK ABSORBER SET CONTROL.................................................................................... 93
REAR SHOCK ABSORBER SET INSTALLATION.......................................................................... 94
TRANSMISSION CHAIN AND SWING ARM............................................................ 97

TRANSMISSION CHAIN AND SWING ARM REMOVAL........................................................... 97
TRANSMISSION CHAIN REMOVAL............................................................................................... 98
SWING ARM REMOVAL.................................................................................................................... 99
TRANSMISSION CHAIN INSPECTION........................................................................................... 100
SWING ARM INSPECTION................................................................................................................ 102
TRANSMISSION CHAIN REPLACEMENT...................................................................................... 103
TRANSMISSION CHAIN AND SWING ARM INSTALLATION.................................................. 105
SWING ARM INSTALLATION........................................................................................................... 106
ENGINE.................................................................................................................... 107
ENGINE REMOVAL.............................................................................................................................. 107
ENGINE INSTALLATION.................................................................................................................... 109
CHAS
FAIRING.................................................................................................................. 110
MOBILE AND FIXED CAP REMOVAL............................................................................................ 110
MOBILE AND FIXED CAP INSTALLATION.................................................................................. 111
RIGHT AND LEFT TANK LIDS REMOVAL.................................................................................... 112
RIGHT AND LEFT TANK LIDS INSTALLATION........................................................................... 113
FAIRING SUPPORT BRACKET REMOVAL.................................................................................... 114
FAIRING SUPPORT BRACKET INSTALLATION.......................................................................... 115
TANK CAP REMOVAL....................................................................................................................... 116
TANK CAP INSTALLATION............................................................................................................. 117
TANK REMOVAL................................................................................................................................ 118
TANK INSTALLATION....................................................................................................................... 119
ENGINE LIDS REMOVAL.................................................................................................................. 120
ENGINE LIDS INSTALLATION........................................................................................................ 121
CHAIN CARTER REMOVAL............................................................................................................. 122
CHAIN CARTER INSTALLATION.................................................................................................... 123
FRONT MUDGUARD REMOVAL................................................................................................... 124
FRONT MUDGUARD INSTALLATION.......................................................................................... 125
REAR MUDGUARD REMOVAL...................................................................................................... 126
REAR MUDGUARD INSTALLATION............................................................................................. 127
NUMBER PLATE BRACKET REMOVAL........................................................................................ 128
NUMBER PLATE BRACKET INSTALLATION............................................................................... 129
REAR FRAME.......................................................................................................... 130

SEAT REMOVAL................................................................................................................................. 130
SEAT INSTALLATION........................................................................................................................ 131
BATTERY BOX REMOVAL................................................................................................................ 132
BATTERY BOX INSTALLATION...................................................................................................... 134
LOCK REMOVAL................................................................................................................................. 136
LOCK INSTALLATION....................................................................................................................... 137
CODON REMOVAL............................................................................................................................ 138
CODON INSTALLATION.................................................................................................................. 140
REAR SMALL FRAME SET REMOVAL........................................................................................... 142
REAR SMALL FRAME SET DECOMPOSITION............................................................................ 143
REAR SMALL FRAME SET INSTALLATION................................................................................. 144
CHAS
CYCLING.................................................................................................................. 145
FRONT LEFT FOOTPEG UNIT REMOVAL..................................................................................... 145
FRONT LEFT FOOTPEG UNIT INSTALLATION........................................................................... 146
FRONT RIGHT FOOTPEG UNIT REMOVAL.................................................................................. 147
FRONT RIGHT FOOTPEG UNIT INSTALLATION........................................................................ 148
REAR FOOTPEGS UNIT REMOVAL................................................................................................ 149
REAR FOOTPEGS UNIT INSTALLATION...................................................................................... 150
TRESTLE REMOVAL........................................................................................................................... 151
TRESTLE INSTALLATION.................................................................................................................. 152
CHAIN SLIDES REMOVAL................................................................................................................ 153
CHAIN SLIDES INSTALLATION....................................................................................................... 154
DRAIN PLANT......................................................................................................... 155

DRAIN UNIT REMOVAL.................................................................................................................... 155
DRAIN COLLECTOR DECOMPOSITION....................................................................................... 157
DRAIN UNIT INSTALLATION........................................................................................................... 158
CHAS
FRONT WHEEL AND BRAKE DISKS
CHAS
FRONT WHEEL REMOVAL
2
1
1
4
2
1
5
5

Front Wheel Removal
NOTE:
Place the bike on a trestle of adequate support
so that the front wheel is lifted.
1 Screw 4
2 Front Brake Calliper (Right And Left) 2
3 Stop Screw 2 Loosen.
4 Front Wheel Pin 1
5 Front Wheel 1
4 1
CHAS
FRONT WHEEL REMOVAL

1 Park the bike levelled.
NOTE:
2 Remove:
• the screws A
Disconnect:
• the left brake calliper B
B
NOTE:
N
R
Repeat the above procedure for the right brake
calliper.
A NOTE:
Do not pull the front brake lever whilst
2 disconnecting the brake callipers.
3 Loosen:
• the stop screws C
4 Remove:
D • the front wheel pin D
• the front wheel E
E
5 4
4 2
CHAS
FRONT BRAKE DISKS REMOVAL
2
3
1
4

Front Wheel Removal See paragraph "4.1".
Front Brake Disks Removal
1 Left Spacer 1
2 Front Wheel 1
3 Screw 12
4 Front Brake Disk (Ø320) 2
4 3
CHAS
FRONT WHEEL DECOMPOSITION
LS
LS
2
1
Decompose the pieces in the given order.

Front Wheel Decomposition
1 LS
Bearing 2
2 Inside Spacer 1
NOTE:
To install, invert the order of the removal
operations.
4 4
CHAS
FRONT WHEEL CONTROL

A
1 Check:
• the wheel axis A
Roll the axis of the wheel on a flat surface.
In the presence of deformations Replace.
WARNING
Do not attempt to straighten the axis of the wheel
if it is deformed.
1
2 Check:
• the tyre
• the front wheel
In the presence of damages/wear Replace.
3 Measure:
• the radial eccentricity of the wheel B
C • the side eccentricity of the wheel C
If the specified limit is exceeded Replace.
B
Radial eccentricity limit of the wheel

0.05 mm (0.0019 in)
Side eccentricity limit of the wheel
3 0.05 mm (0.0019 in)
4 Check:
• the wheel bearings
If the front wheel turns irregularly or is loose
Replace the wheel bearings.
5 Replace:
a Remove the bearings from the wheel D using an

extractor for bearings.
b Install the new wheel bearings inverting the order
of the removal operations.
D
5
4 5
CHAS
ATTENTION
Do not touch the internal track E or the wheel
bearings balls F . Contact must only take place
with the external track G .
H
NOTE:
N
U a spanner H that adapts to the diameter of the
Use
G external track of the wheel bearing.
E F
4 6
CHAS
BRAKE DISKS CONTROL

The procedure below can be applied to all brake disks.
1 Check:
• the brake disk
In the presence of damages/abrasions Replace.
2 Measure:
• the deformation of the brake disk
If out of specification Correct the deformation
or replace the brake disk.
Deformation limit of the brake disk

(maximum)
Front: 0.1 mm (0.004 in)

Rear: 0.15 mm (0.006 in)
a Place the bike on a trestle of adequate support so

that the wheel is lifted.
b Before measuring the front brake disk bending,
turn the handle bar to the right or to the left, to
ensure that the front wheel is still.
c Remove the brake calliper.
d Keep the comparator at a straight angle compared

to the brake disk surface.
e Measure the bending of 1.5 mm (0.5 in) below the

brake disk edge.
4 7
CHAS
3 Measure:
• the brake disk thickness
Measure the thickness of the brake disk in different points.
If out of specification Replace.
Deformation limit of the brake disk

(maximum)
Front: 0.1 mm (0.004 in)
3 Rear: 0.15 mm (0.006 in)
4 Adjust:
• the deformation of the brake disk
a Remove the brake disk.

b Rotate the brake disk moving it one hole per bolt.
c Install the brake.
NOTE:
Fasten the brake disk bolts in successive steps and
1 proceeding in a crossed manner.
6
3
Brake disk bolt
4
Front: 22 Nm (2.24 Kgf•m)

5 Rear:10 Nm (1.01 Kgf•m)
2
d Measure the deformation of the brake disk.

e If out of specification, repeat the adjusting
procedure until the deformation is within the
specified values.
f Should it not be possible to bring the bending of

the brake disk within the specified values, replace
it.
4 8
CHAS
FRONT BRAKE DISKS ASSEMBLY
22 N m - 2.24 Kgf•m
R.
T.
52A43
52A43
1
3
4
2

Front Brake Disks Assembly
1 Front Wheel 1
2 Front Brake Disk (Ø320) 2
3 Screw 12
52A43
4 Left Spacer 1
4 9
CHAS
B
FRONT BRAKE DISKS ASSEMBLY
LS
1 Assemble:
• the inside spacer A
• the bearings B
A
B
LS
TUTELA MR2 GREASE
1
2 Assemble:
• the left front brake disk C
C • the screws D
NOTE:
N
D R
Repeat the above procedure for the right front
brake disk.

52A43
2
3 The procedure below can be applied to both brake

disks.
1 6
NOTE:
3 proceeding in a crossed manner.
4

R.
T.
5
2
4 Assemble:
• the left spacer E
4
5
4 10
CHAS
FRONT WHEEL INSTALLATION
50 N m - 5.09 Kgf•m
R.
T.
8 N m - 0.81 Kgf•m
R.
T.
5 4
5
60 N m - 6.11 Kgf•m 2
R.
T.
LS
4 LS
5
1

Front Wheel Installation
1 Front Wheel 1
2 LS
Front Wheel Pin 1
3 Stop Screw 2
4 Front Brake Calliper (Right And Left) 2
5 LS
Screw 4
4 11
CHAS
FRONT WHEEL INSTALLATION

1 Lubricate:
A • the wheel axis
A a Lift the wheel between the two shanks of the fork.

b Insert the axis of the wheel.
NOTE:
Install the tyre and the wheel with the mark A in
1 the rotary direction of the wheel.
c Rest the front wheel on the ground.
2 Fasten:
• the front wheel pin B 60 N m - 6.11 Kgf•m
R.
T.
C
B LS
TUTELA MR2 GREASE
• the stop screws C R.

T.
8 N m - 0.81 Kgf•m
LS
2 ATTENTION
Before fastening the front wheel pin, push on the
handle bar and check that the front fork smoothly
moves backwards.
4 12
CHAS
3 Install:
• the left brake calliper D
• the screws E
D Torque fasten with: 50 N m - 5.09 Kgf•m
R.
T.
LS
E TUTELA MR2 GREASE
LS
3 NOTE:
N
R
Repeat the above procedure for the right brake
calliper.
NOTE:
Ensure there is sufficient space between the brake
pads before installing the callipers on the relative
brake disks.
ATTENTION
Check that the path of the brake flexible tube is
correct.
4 13
CHAS
FRONT WHEEL BALANCING

NOTE:
After having replaced the tyre, the wheel, or both,
the front wheel needs balancing again.
Adjust the balancing of the front wheel with the
brake disk installed.
1 Disconnect:
• the balancing weight(s)
2 Find:
• the unbalanced point (heavier)
of the front wheel.
NOTE:
Place the front wheel on a suitable balancing
bench.
a Have the front wheel turn quickly.

b When the front wheel stops, place an "X" on the
part of the wheel facing downwards.
c Turn the front wheel by 90° so that the "X" is
positioned as shown in the illustration.
d Let the front wheel go.

e When the front wheel stops, place an "X²" on the
part of the wheel facing downwards.
f Repeat points d to f a few times, until the

applied marks always stop in the same point.
g The point where all marks applied stop represent

the "X" unbalanced point (heavier) of the wheel.
3 Adjust:
• the balancing of the front wheel
A
a Install a balancing weight A on the rim in the
point diametrically opposed to the unbalanced
point (heavier).
NOTE:
Start with the lightest weight.
X 3
4 14
CHAS
b Turn the front wheel by 90° so that the unbalanced

point (heavier) is positioned as shown in the
illustration.
c If the unbalanced point does not remain in the
X given position, install a heavier weight.
d Repeat points b and c until balancing of the
front wheel is obtained.
4 Check:
X • the balancing of the front wheel
a Have the front wheel turn and check that it

remains still in each of the illustrated positions.
X X b If it does not, repeat balancing.
X 4
4 15
REAR WHEEL AND BRAKE DISK
CHAS
REAR WHEEL REMOVAL
8
9
1
10
2 7
4
3

Rear Wheel Removal
NOTE:
Place the bike on a trestle of adequate support
so that the rear wheel is lifted.
1 Screw 2
2 Rear Brake Calliper 1
3 Special Screw 2
4 Plug 2
5 Pin 1
NOTE:
Loosen the regulator of the eccentrics.
6 Rear Wheel 1
7 Spacer 1
8 Calliper Holder Plate 1
9 O-Ring Gasket 2
10 Bush 1
4 16
CHAS
REAR WHEEL REMOVAL

NOTE:
that the rear wheel is lifted.
2 Remove:
• the screws A
Disconnect:
• the brake calliper B
NOTE:
A Do not press on the brake pedal whilst removing
the brake calliper.
B
A
2
3 Remove:
• the special screws C
• the plugs D
D • the pin E
E D
C
C
3
4 Remove:
F • the rear wheel F
NOTE:
Push the rear wheel forward and remove the
transmission chain from the rear cogwheel.
5 Remove:
I • the spacer G
• the calliper holder plate H
• the O-Ring gaskets I
• the bush J
J
H G
5
4 17
CHAS
REAR BRAKE DISK AND CROWN WHEEL REMOVAL
1 2
8
7 6
5

Rear Wheel Removal See paragraph "4.16.
Rear Brake Disk And Crown Wheel Removal
1 Screw 6
2 Rear Brake Disk 1
3 Spacer 1
4 Self-locking Nut 5
5 Crown Wheel 1
6 Crown Wheel Holder Flange 1
7 Spacer 1
8 Collar Rubber 5
4 18
CHAS
REAR WHEEL DECOMPOSITION
1
2
LS
LS

Rear Wheel Decomposition
1 Seeger 2
2 LS
Bearing 2
3 Spacer 1
NOTE:
To install, invert the order of the operations
for removal.
4 19
CHAS
REAR WHEEL CONTROL

A
1 Check:
• the wheel axis A
Roll the axis of the wheel on a flat surface.
WARNING
Do not attempt to straighten the axis of the wheel
if it is deformed.
1
2 Check:
• the tyre
• the rear wheel
3 Measure:
• the radial eccentricity of the wheel B
C • the side eccentricity of the wheel C
If the specified limit is exceeded Replace.
B
Radial eccentricity limit of the wheel

0.05 mm (0.0019 in)
Side eccentricity limit of the wheel
3 0.05 mm (0.0019 in)
4 Check:
If the rear wheel turns irregularly or is loose
Replace the wheel bearings.
5 Replace:
a Remove the bearings from the wheel D using

an extractor for bearings.
b Install the new wheel bearings inverting the order
of the removal operations.
D
5
4 20
CHAS
ATTENTION
Do not touch the internal track E or the wheel
bearings balls F . Contact must only take place
with the external track G .
H
NOTE:
N
U a spanner H that adapts to the diameter of the
Use
G external track of the wheel bearing.
E F
4 21
CHAS
REAR WHEEL CROWN WHEEL

A HOLDER FLANGE INSPECTION
B
1 Check:
• the crown wheel holder flange A
• the collar rubbers B
4 22
CHAS
CROWN WHEEL CONTROL AND

C A REPLACEMENT
1 C
Check:
• the crown wheel
B If more of a ¼ of each tooth A is worn
Replace the crown wheel.
If the teeth are bent Replace the crown wheel.
A ¼ teeth
D B Correct
1 C Distribution chain roller
D Crown Wheel
2 Replace:
• the crown wheel
a Remove the self-locking nuts and the crown wheel.
b Using a clean cloth clean the crown wheel holder

flange, in particular the surfaces touching the
crown wheel.
c Install the new crown wheel.
2 Crown wheel self-locking nut

45 N m - 4.58 Kgf•m
NOTE:
Fasten the self-locking nuts in more steps and
proceed in crossed sequence.
4 23
CHAS
REAR BRAKE DISK AND CROWN WHEEL ASSEMBLY
8 7
LS
1
2 3 4
5
10 N m - 1.01 Kgf•m
R.
T.
LS
LS
45 N m - 4.58 Kgf•m
R.
T.

Rear Brake Disk And Crown Wheel Assembly
1 Collar Rubber 5
2 Spacer 1
3 Crown Wheel Holder Flange 1
4 LS
Crown Wheel 1
5 Self-locking Nut 5
6 Spacer 1
7 LS
Rear Brake Disk 1
8 Screw 6
LS
4 24
CHAS
C REAR BRAKE DISK AND CROWN

WHEEL ASSEMBLY
1 Assemble:
A • the spacer A
LS
B C • the bearings B
B
LS
LS TUTELA MR2 GREASE
1
• the seegers C
2 Assemble:
• the collar rubbers D
D • the spacer E
• the crown wheel holder flange F
E • the crown wheel G
G
Recommended solvent
LS
TUTELA MOTOR CLEAN
LS
F 2 TUTELA MR2 GREASE
3 Install:
Installa
• the self-locking nuts
NOTE:
Fasten the self-locking nuts in successive steps and
proceed in a crossed manner.
4
LS
TUTELA MR2 GREASE
3
R.
T.
4 Install:
I • the spacer H
• the rear brake disk I
• the screws J
LS
J TUTELA MR2 GREASE
LS
H
4
1
NOTE:
proceeding in a crossed manner.
6
3 Torque fasten: 10 N m - 1.01 Kgf•m

R.
T.
2 5
4 25
CHAS
REAR WHEEL INSTALLATION
NEW 5
3
LS 1
10
2
LS
LS
10
9 4
22 N m - 2.24 Kgf•m
R.
T.
LS
7
LS
LS
7
8
LS
100 N m - 10.19 Kgf•m

R.
T.

Rear Wheel Installation
1 NEW
O-Ring Gasket 2
2 Bush 1
3 Calliper Holder Plate 1
4 LS
Spacer 1
5 LS
Rear Wheel 1
6 LS
Pin 1
7 Plug 2
8 LS
Special Screw 2
9 LS
Rear Brake Calliper 1
10 LS
Screw 2
LS
4 26
CHAS
REAR WHEEL INSTALLATION

A NEW
1 Install:
• the O-Ring gaskets A
LS • the bush B
LS • the calliper holder plate C
• the spacer D
LS
B C D LS
1 TUTELA MR2 GREASE
2 Install
E • the rear wheel E
3 Lubricate and install:

• the pin F
• the plugs G
G • the special screws H
G
LS
F
LS LS
H TUTELA MR2 GREASE
LS
H
3 Torque fasten: 100 N m - 10.19 Kgf•m
R.
T.
4 Install:
• the brake calliper I
• the screws J 22 N m - 2.24 Kgf•m
R.
T.
LS
J TUTELA MR2 GREASE
I
J NOTE:
LS Ensure there is sufficient space between the brake
4 pads before installing the calliper on the relative
brake disk.
ATTENTION
Check that the path of the brake flexible tube is
correct.
4 27
CHAS
REAR WHEEL BALANCING
NOTE:
N
• After having replaced the tyre, the wheel or both,
the rear wheel needs balancing again.
• Adjust the balancing of the rear wheel with the
brake disk and the crown wheel holder flange.
1 Adjust:
• the balancing of the rear wheel
See paragraph ”4.14”.
4 28
FRONT AND REAR BRAKES
CHAS
FRONT BRAKE PADS REMOVAL
3
5
2
4
6 6

Front Brake Pads Removal
NOTE:
The procedure below can be applied to both
front brake callipers.
1 Screw 2
2 Left Brake Calliper 1
3 Clip 2
4 Pin 2
5 Safety Spring 1
6 Pad 2
4 29
CHAS
REAR BRAKE PADS REMOVAL
7 6 7
4
2
5

Rear Brake Pads Removal
1 Screw 2
3 Seeger 1
4 Pin 1
5 Clip 1
6 Pad 2
7 Thickness For Brake Pads 2
4 30
CHAS
WARNING
The need to dismantle the components of the
brake disk is rare. Therefore, the following
precautions must always be complied with:
• Never dismantle the brake components unless
absolutely necessary.
• If one of the connections of the hydraulic braking
plant disconnects, it is necessary to dismantle,
empty, clean, adequately fill and bleed (after re-
assembly) the entire braking system.
• Do not use solvents on the internal components of
the brake.
• Only use clean or new brake liquid to clean the
brake components.
• The brake liquid can damage the painted surfaces
and the plastic parts. Therefore, always
• Avoid bringing the brake liquid in contact with
the eyes, as it can cause serious injuries.
FIRST AID IN CASE OF BRAKE LIQUID SPLASHING

IN THE EYES:
• Wash with running water for 15 minutes and
immediately contact a doctor.
4 31
CHAS
FRONT BRAKE PADS REPLACEMENT
The procedure below can be applied to both the

brake callipers.
NOTE:
To replace the brake pads, always replace in pair to
guarantee an even pressure.
It is not necessary to disconnect the flexible tube.
1 Disconnect:
A • the support of the brake flexible tube A
2 Disconnect:
C • the clips C
• the pins D
C • the safety spring E
3 Disconnect:
• the brake pads F
F
F
3
4 Measure:
• the wear limit of the brake pads G
If out of specification Replace the brake
pads together.
G Wear limit of the brake pads

1 mm (0.04 in)
4 32
CHAS
5 Clean:
• the inside of the calliper
• the pistons
then dry everything
6 Press:
• the calliper pistons
inwards to enable installation of the new brake pads.
4 33
CHAS
REAR BRAKE PADS REPLACEMENT
NOTE:
To replace the brake pads, always replace in pair to
guarantee an even pressure.
It is not necessary to disconnect the flexible tube.
1 Disconnect:
• the screws A
• the seeger C
• the pin D
C • the clip E
A
B
D
E 1
2 Disconnect:
• the brake pads F
G • the brake pads thicknesses G
G
F F
3 Measure:
• the wear limit of the brake pads H
If out of specification Replace all brake pads.
H Wear limit of the brake pads

1.0 mm (0.04 in)
4 Clean:
• the inside of the calliper
4 34
CHAS
5 Press:
• the calliper pistons
inwards to enable installation of the new brake pads.
6 Act:
• on the brake command
with long brakes but not intense for approximately
one hundred kilometres.
4 35
CHAS
FRONT BRAKE PADS INSTALLATION
50 N m - 5.09 Kgf•m
R.
T.
4
2
5
3
6
LS
1 1
NEW

Front Brake Pads Installation
NOTE:
1 NEW
Pad 2
2 Safety Spring 1
3 Pin 2
4 Clip 2
5 Left Brake Calliper 1
6 LS
Screw 2
4 36
CHAS
FRONT BRAKE PADS INSTALLATION

A
1 Install:
NEW • the brake pads A
NOTE:
Always install new brake pads.
A
1
2 Install:
D • the safety spring B
• the pins C
D • the clips D
3 Install:
F • the brake calliper E
LS
TUTELA MR2 GREASE
E
Torque fasten: R.
T.
50 N m - 5.09 Kgf•m
• the support of the flexible tube F

3
4 Check:
• the brakes liquid level
If below the minimum level notch G Top-up
to the correct level using the recommended brake
G liquid.
3.55" paragraph.
5 Check:
• the functioning of the brake lever
If the brake lever is soft or spongy to touch
Bleed the braking plant.
3.58" paragraph.
4 37
CHAS
PADS INSTALLATION REAR BRAKE
NEW
1 2 1
22 N m - 2.24 Kgf•m
R.
T.
LS
4
6
3

Rear Brake Pads Installation
1 NEW
Thickness For Brake Pads 2
2 NEW
Pad 2
3 Clip 1
4 Pin 1
5 Seeger 1
7 LS
Screw 2
4 38
CHAS
REAR BRAKE PADS INSTALLATION

A
A
1 Install:
NEW • the brake pads thicknesses A
B B • the brake pads B
NOTE:
Always install new brake pads and thicknesses.
2 Install:
• the clip C
• the pin D
• the seeger E
• the brake calliper F
LS
E • the screws G
G
LS
F TUTELA MR2 GREASE
D
C 2 Torque fasten: 22 N m - 2.24 Kgf•m
R.
T.
3 Check:
If below the minimum level notch H Top-up to
the correct level using the recommended brakes
liquid.
See "ROUTINE INSPECTIONS AND ADJUSTMENTS 3.55"
paragraph.
H
4 Check:
• the functioning of the brake pedal
If the brake lever is soft or spongy to touch Bleed
the braking system.
See "ROUTINE INSPECTIONS AND ADJUSTMENTS 3.58"
paragraph.
4 39
CHAS
FRONT BRAKE PUMP REMOVAL
1 1
14 2
14
12
15
6
5
13
16
10 8 7
9
11

Front Brake Pump Removal
1 Screw 2
2 Trestle 1
3 Brakes Pump Body 1
4 Screw 1
NOTE:
Drain the brakes liquid before carrying out the operations.
See “ROUTINE INSPECTIONS AND ADJUSTMENTS 3.58”
paragraph.
5 Brakes Command Lever 1
6 Nut 2
7 Screw 1 ATTENTION:
Avoid trickeling of brake fluid.
8 Lid 1
9 Support For Brakes Liquid Tub Diaphragm 1
10 Diaphragm of Brakes Liquid Tub 1
11 Special Screw 1
12 Washer 1
13 Front Brake Tube 1
14 Screw 2
15 Front Brake Switch Connector 1
16 Front Brake Light Switch 1
4 40
CHAS
FRONT BRAKE PUMP DECOMPOSITION
1
2 NEW
TO
4 P 3
TO
4 P
TO
4 P

Front Brake Pump Decomposition
1 TOP
4 Dust seal 1
2 TOP
4
NEW
Seeger 1
3 TOP
4 Main Cylinder Kit 1
4 TOP
4 Spring 1
5 Body Main Cylinder 1
6 TOP
4 Pin 1
NOTE:
operations.
4 41
CHAS
REAR BRAKE PUMP REMOVAL
4
3 5
7
10
19
17 15
11 12 13
16
18
18
9 14

Rear Brake Pump Removal
Brakes Liquid NOTE:
Drain the brakes liquid before carrying out the
operations. See “ROUTINE INSPECTIONS AND
ADJUSTMENTS 3.58” paragraph.
1 Brakes Liquid Tub Cap 1
2 Brakes Liquid Tub Diaphragm 1
3 Screw 1
4 Bush 1
5 Spring Strip 1
6 Brakes Liquid Tub 1
7 Spring Strip 1
8 Tub Tube 1
9 Screw 1
10 Nut 1
11 Ball Joint 1
12 Nut 1
13 Regulator Rod 1
Disconnect the central wiring pin.
14 Hydrostop 1
15 Gasket 1
16 Brake Tube 1
17 Gasket 1
18 Screw 2
19 Rear Brake Pump 1
4 42
CHAS
REAR BRAKE PUMP DECOMPOSITION
3
NEW
TO
4 P
NEW
TO
4 P 2
1 NEW
TO 4
P

Rear Brake Pump Decomposition
1 NEW
Dust Seal Rubber 1
2 TOP
4
Seeger 1
3 TOP
4
Main Cylinder Kit 1
4 Rear Brake Pump 1
NOTE:
operations.
4 43
CHAS
a FRONT AND REAR BRAKE PUMP

CONTROL
The following procedure is applied to both the brakes
pumps.
1 Check:
• the brake main cylinder
In the presence of damages/scratches/wear lines
Replace.
• the brakes liquid flow passages
1 (brake pump body)
In the presence of obstructions Clean using a
jet of compressed air.
b
a Front
b Rear
2 Check:
a • the brake pump kit
Replace.
a Front
b Rear
b
3 Check:
a b • the brakes liquid tub A
B In the presence of cracks/damages Replace.
B • diaphragm of the brakes liquid tub B
a Front
b Rear
A
A 3
4 Check:
• the brake flexible tubes
Replace.
• the hydrostop cables
If disconnected Connect them.
4 44
CHAS
FRONT BRAKE PUMP INSTALLATION
1.5 N m - 0.15 Kgf•m 16 16
R.
T.
12
15
8 N m - 0.81 Kgf•m 12
R.
T.
14
LS
13 NEW
8
11
5 NEW
6 15 N m - 1.52 Kgf•m
R.
T.
7 LS
7 N m - 0.71 Kgf•m
R.
T.
10
1 3 4
2
1.5 N m - 0.15 Kgf•m
R.
9
T.

Front Brake Pump Installation
1 Front Brake Light Switch 1
2 Screw 1
3 Front Brake Switch Connector 1
5 NEW
Washer 2
6 Special Screw 1
7 LS
Brakes Command Lever 1
8 Screw 1
9 Nut 1
10 Brakes Pump Body 1
11 Trestle 1
12 Screw 2
13 NEW
Diaphragm of Brakes Liquid Tub 1
14 Support For Brakes Liquid Tub Diaphragm 1
15 Lid 1
16 Screw 2
NOTE:
Once operations have been completed, top-up
with brakes liquid.
4 45
CHAS
FRONT BRAKE PUMP INSTALLATION
WARNING
• Before installation, clean all brake internal
components, lubricating them using clean or new
brakes liquid.
• Do not use solvents on the internal components
of the brake.

TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4
1 Install:
• the pin
in the main cylinder body
• the spring
• the main cylinder kit
• the seeger
• the dust seal
2 Install:
• the front brake pump
R.
B
T.
A UP
LS
TUTELA MR2 GREASE
NOTE:
2 • Install the main cylinder support of the brake with
the “UP” mark A facing upwards.
• Align the end of the retainer element of the main
cylinder of the brake with the punching B on
the right knob of the handle bar.
• Firstly, fasten the upper bolt, then the lower bolt.
3 Install:
• the copper washers
• the front brake tube
• the special screw

R.
T.
• the connector of the front brake switch
WARNING
To guarantee bike safety, it is essential that the
path of the brake flexible tube is correct.
NOTE:
N
• Fasten the fitting bolt by keeping the brake
flexible tube still.
• Turn the handle bar to the right and left to check
that the brake flexible tube does not touch other
parts (for example, the cables band, the metal
cables, the electric wires). Correct if necessary.
4 46
CHAS
4 Fill:
• the brakes liquid tub
(with the specified quality of recommended brakes
liquid)
TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4
WARNING
• Use only the prescribed brakes liquid. The use of
other types of brakes liquid may damage the
rubber gaskets, causing leaks and deteriorating
the performances of the brakes.
already present inside the system. The brakes
liquid must never be mixed with liquids of other
brands, in that it may cause a dangerous
chemical reaction, with the consequent
deterioration of the performances of the brakes.
• During top-up, be careful not to let water flow
inside the tub. The presence of water will
significantly reduce the boiling point of the
brakes liquid and may cause vapour to form.
ATTENTION
• The brakes liquid can damage the painted
surfaces and the plastic parts. Therefore, always
5 Bleed:
• the braking plant
3.58" paragraph.
6 Check:
If below the minimum level notch C Top-up
liquid.
3.55" paragraph.
7 Check:
Bleed the braking plant. .
3.58" paragraph.
4 47
CHAS
REAR BRAKE PUMP INSTALLATION
19
18 NEW
6 N m - 0.61 Kgf•m
R.
T.
14
16
17 15
12
NEW
13
10
10 N m - 1.01 Kgf•m 1
R.
T.
3 5
4
9 8 7
2 LS
2
11 6
10 N m - 1.01 Kgf•m
R.
T.

Rear Brake Pump Installation
1 Rear Brake Pump 1
2 Screw 2
3 NEW
Gasket 1
4 LS
Brake Tube 1
5 NEW
Gasket 1
6 Hydrostop 1
Connect the central wiring pin.
7 Regulator Rod 1
8 Nut 1
9 Ball Joint 1
10 Nut 1
11 Screw 1
12 Tube 1
13 Spring Strip 1
14 Brakes Liquid Tub 1
15 Spring Strip 1
16 Bush 1
17 Screw 1
18 NEW
Brakes Liquid Tub Diaphragm 2
19 Brakes Liquid Tub Cap 1
NOTE:
with brakes liquid.
4 48
CHAS
REAR BRAKE PUMP INSTALLATION
WARNING
brakes liquid.
• Do not use solvents on the internal components
of the brake.

TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4
1 Install:
• the main cylinder kit
• the seeger
• the dust seal rubber
2 Install:
• the brake pump
LS
TUTELA MR2 GREASE
Torque fasten: R.
T.
10 N m - 1.01 Kgf•m
WARNING
3 Fill:
(up to the maximum level mark A )

A TOP TUTELA BRAKE FLUID
4
TOP 4 - DOT 4
4 49
CHAS
WARNING
ATTENTION
4 Bleed:
3.58" paragraph.
5 Check:
If below the minimum level notch B Top-up
liquid.
3.55" paragraph.
B
4 50
CHAS
FRONT BRAKE CALLIPERS REMOVAL

Front Brake Calliper Removal
NOTE:
Brakes Liquid NOTE:
operations. See “ROUTINE INSPECTIONS AND
ADJUSTMENTS 3.58” paragraph.
1 Special Screw 1
2 Washer 2
4 Screw 2
5 Front Brake Calliper 1
4 51
CHAS
FRONT BRAKE CALLIPERS DECOMPOSITION
10 N m - 1.01 Kgf•m
R.
T.
1
13
3 2
1
NEW
8 14
2
7 25 N m - 2.54 Kgf•m
R.
T.
5
5
6
5
52
A4
3 5
NEW
9
11 Arexons SYSTEM 52A43
52A43
12 MEDIUM THREAD BRAKES
NEW
12
11
9
10
11
12
4
4
NEW
TOP
4 12
11
10

Front Brake Calliper Decomposition
NOTE:
1 Clip 2
2 Pin 2
3 Safety Spring 1
4 NEW
Pad 2
5 Screw 4
52A43
6 Left Half-bearing 1
7 Right Half-bearing 1
8 NEW
O-Ring Gasket 1
9 Ø 34 mm Piston 2
10 TOP
4
Ø 30 mm Piston 2
11 NEW TOP
4 Oil retainer 4
12 NEW TOP
4 Seal Ring 4
13 Bleed Screw Cap 1
14 Bleeding Screw 1
NOTE:
operations.
4 52
CHAS
REAR BRAKE CALLIPER REMOVAL
2 3 2 1
5

Rear Brake Calliper Removal
Brakes Liquid NOTE:
operations. See paragraph "ROUTINE
INSPECTIONS AND ADJUSTMENTS 3.58".
1 Special Screw 1
2 Washer 2
3 Rear Brake Tube 1
4 Screw 2
4 53
CHAS
REAR BRAKE CALLIPER DECOMPOSITION
13
12 P
11 TO 4
10
4 NEW
NEW
1
10
11
12
13
25 N m - 2.54 Kgf•m
R.
T.
3
9
52
A4
3
NEW 2
7
6
52A43
10 N m - 1.01 Kgf•m 15 6
R.

T.
14

Rear Brake Calliper Decomposition
1 TOP
Seeger 1
2 Pin 1
4
3 Clip 1
4 NEW
Pad 2
5 NEW
Brake Pads Thickness 2
6 Screw 2
52A43
TOP
7 Right Half-bearing 1
4
TOP
8 Left Half-bearing 1
4
TOP
9 O-Ring Gasket 2
4
NEW
TOP
10 Oil retainer 2
4
NEW
11 NEW
Seal Ring 2
12 Insulator 2
13 Ø 32 mm Piston 2
14 Bleed Screw Cap 1
15 Bleeding Screw 1
NOTE:
operations.
4 54
CHAS
FRONT BRAKE CALLIPERS REMOVAL
The following procedure is applied to both the brake

callipers.
NOTE:
Drain the brakes liquid from the entire braking
plant before dismantling the brake calliper.
3.58" paragraph.
1 Disconnect:
A • the special screw A
B • the washers B
• the front brake tube C
NOTE:
N
Inse the end of the brake flexible tube in a
Insert
C container and slowly drain the brakes liquid by
pumping it.
2 Disconnect:
• the brake calliper pistons D
(2 Ø 34 mm and 2 Ø 30 mm)
• the gaskets of the brake calliper pistons E
(first the oil retainers - smaller gaskets, then the seal
rings - larger gaskets)
E 2
a Fix the pistons of the brake calliper with a wedge

of wood F
G
b Blow compressed air inside the attachment for the
F flexible tube of the brake G to force the left side
pistons out from the brake calliper.
WARNING
Never attempt to remove the pistons from the
calliper with force.
c Remove the gaskets of the brake calliper pistons.
d Repeat the above procedure to force the right side

pistons out from the brake calliper.
4 55
CHAS
REAR BRAKE CALLIPER REMOVAL

RI
NOTE:
Drain the brakes liquid from the entire braking
plant before dismantling the brake calliper.
3.58" paragraph.
1 Disconnect:
• the special screw A
• the washers B
• the front brake tube C
See paragraph “4.53”.
C B
NOTE:
N
A Inse the end of the brake flexible tube in a
Insert
container and slowly drain the brakes liquid by
pumping it.
B 1
2 Disconnect:
• the brake calliper pistons D
• the insulators E
• the gaskets of the brake calliper pistons F
(first the oil retainers - smaller gaskets, then the seal
rings - larger gaskets)
D See paragraph "4.54".
E
F
a Fix the pistons of the brake calliper with a wedge

of wood G
G
b Blow compressed air inside the attachment for the
flexible tube of the brake H to force the pistons
H out from the brake calliper.
WARNING
• Cover the pistons of the brake calliper with a
cloth. Careful not to injure yourself when the
pistons are expelled from the brake calliper.
• Never attempt to remove the pistons from the
calliper with force.
c Remove the gaskets of the brake calliper pistons.
4 56
CHAS
FRONT CALLIPER AND REAR

CALLIPER CONTROL
RECOMMENDED REPLACEMENT PROGRAM
FOR THE BRAKE COMPONENTS
CHECK: After 1.000 Km
BRAKES PADS
Every 10.000 Km
REPLACEMENT: If required
CHECK: After 1.000 Km -
BRAKE FLEXIBLE TUBES REPLACEMENT: Every 10.000 Km
However,
every 4 years.
CHECK: Before every use
REPLACEMENT: Every 20,000 Km
BRAKES LIQUID However,
every 2 years
1 Check:
a • the brake calliper pistons A
C C In the presence of rust/scratches/wear lines
B Replace the pistons of the brake calliper.
• the brake calliper cylinders B
In the presence of scratches/wear lines Replace
the brake calliper set.
• the brake calliper body C
In the presence of cracks/damages Replace
the brake calliper set.
A • the brakes liquid flow passages (brake calliper body)
A In the presence of obstructions Clean using a
1
jet of compressed air.
• the insulators D
In the presence of rust/scratches/wear lines
b Replace the insulators of the brake calliper.
B C
C
ATTENTION
Every time the brake calliper is dismantled,
replace the gaskets of the pistons.
a Front
A A b Rear
D
1
2 Check:
• the brake calliper bracket E
4 57
CHAS
FRONT BRAKE CALLIPERS INSTALLATION
5 15 N m - 1.52 Kgf•m
R.
T.
4
NEW
50 N m - 5.09 Kgf•m
R.
T.
LS

Front Brake Calliper Installation
NOTE:
1 Front Brake Calliper 1
2 LS
Screw 2
4 NEW
Washer 2
5 Special Screw 1 Restore the torque twice after having loosened.
NOTE:
with brakes liquid.
4 58
CHAS
FRONT BRAKE CALLIPERS

INSTALLATION
The following procedure is applied to both the brake
callipers.
WARNING
brakes liquid.
• Never use solvents on the inside components of
the brake as the gaskets of the pistons would
inflate and deform.
• Every time the brake calliper is dismantled,

TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4
1 Install:
• the gaskets of the brake calliper pistons A
(firstly the seal rings - larger gaskets, then the oil
retainers - smaller gaskets)
• the brake calliper pistons B
(2 Ø 34 mm and 2 Ø 30 mm)
A NEW 1
2 Install:
F • the brake calliper C
E NEW

R.
T.
C LS
TUTELA MR2 GREASE

D
• the front brake tube D
2 • the copper washers E
• the special screw F
Fasten by restoring the torque twice after having

loosened: 15 N m - 1.52 Kgf•m
R.
T.
WARNING
4 59
CHAS
3 Fill:
(with the specified amount of recommended brakes
liquid)
TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4
WARNING
ATTENTION
4 Bleed:
3.58" paragraph.
5 Check:
If below the minimum level notch G Top-up
liquid.
3.55" paragraph.
6 Check:
3.58" paragraph.
4 60
CHAS
REAR BRAKE CALLIPER INSTALLATION
22 N m - 2.24 Kgf•m
R.
T.
LS
2
4 3 4 5
1
NEW
15 N m - 1.52 Kgf•m
R.
T.

Rear Brake Calliper Installation
2 LS
Screw 2
3 Rear Brake Tube 1
4 NEW
Washer 2
5 Special Screw 1 Restore the torque twice after having loosened.
NOTE:
with brakes liquid.
4 61
CHAS
REAR BRAKE CALLIPER INSTALLA-

TION
WARNING
brakes liquid.
• Never use solvents on the inside components of
the brake as the gaskets of the pistons would
inflate and deform.
• Every time the brake calliper is dismantled,

TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4
1 Install:
• the gaskets of the brake calliper pistons A
(firstly the seal rings - larger gaskets
then the oil retainers - smaller gaskets)
• the insulators B
• the brake calliper pistons C
C See paragraph "4.54".
B
A NEW
2 Install:
• the brake calliper D
D
NEW
R.
T.
E F
G LS
TUTELA MR2 GREASE
• the front brake tube E

F 2 • the copper washers F
• the special screw G
Torque fasten by restoring twice after having

loosened:
15 N m - 1.52 Kgf•m
R.
T.
WARNING
4 62
CHAS
3 Fill:
(with the specified amount of recommended brakes
liquid).
TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4
WARNING
ATTENTION
4 Bleed:
3.58" paragraph.
5 Check:
If below the minimum level notch H Top-up
liquid.
3.55" paragraph.
H
6 Check:
• the functioning of the brake pedal
3.58" paragraph.
4 63
FRONT FORK
CHAS
FRONT FORK SHANKS REMOVAL
2
2

Front Brake Callipers Removal See paragraph "4.51".
Front Wheel Removal See paragraph "4.1"
Front Mudguard Removal See paragraph "4.124"
Front Fork Shanks Removal
ATTENTION:
Before loosening the stop screws of the upper
and lower brackets, install a support for the
shank of the front fork.
1 Upper Plate Stop Screw 2 Loosen.
2 Lower Plate Stop Screw 6 Loosen.
3 Front Fork Shank 2
4 64
FRONT FORK
CHAS
FRONT FORK SHANKS REMOVAL
The following procedure is applied to both shanks of

the front fork.
NOTE:
2 Remove:
• the front brake calliper
• the front wheel
• the front mudguard
3 Loosen:
• the stop screws of the steering plate
upper A
lower B
ATTENTION
Before loosening the stop screws of the upper and
lower brackets, install a support for the shank of
the front fork.
A
3
4 Remove:
• the shanks of the front fork C
4 65
FRONT FORK
CHAS
FRONT FORK SHANKS DECOMPOSITION
20 N m - 2.03 Kgf•m
R.
T.
2
NEW
LS
52A43 3
20 N m - 2.03 Kgf•m 4
R.
T.
52A43 Arexons SYSTEM 52A43

16 5
10
15
11
NEW
12 NEW
17
18 13 8
9
52A43
52A43
14 NEW
50 N m - 5.09 Kgf•m
R.
T.

Front fork shanks decomposition NOTE:
shanks of the front fork.
1 Cap 1
2 Spring Pointer 1
3 NEW LS
O-Ring Gasket 1
4 Nut 1
5 Fork Spring 1
6 Upper Spring Guide Bush 1
7 Spacer 1
8 Lower Spring Guide Bush 1
9 Spring Pointer 1
10 Fork Sleeve 1
11 Seal Ring 1
12 NEW
Oil retainer 1
13 Oil Retainer Clip 1
14 NEW
Dust seal 1
15 Dampener Rod Set 1
52A43
16 Fork Shank 1
17 NEW
Copper Washer 1
18 Screw 1 NOTE:
52A43

operations.
4 66
FRONT FORK
CHAS
C FRONT FORK SHANKS DECOMPOSI-

E TION
the front fork.
B
1 Fix:
• the stem A in vice B
a Completely loosen the closing cap unit C from

the supporting tube, using a 4 mm compass
spanner D .
A
b Slowly lower the stem holder E on the
supporting tube.
ATTENTION
The fork spring is compressed.
H 2 Push downwards:
G • the fork spring F
H • the preload spacer
so that a 17 mm spanner can be inserted in the nut.
F c Using a 4 mm compass spanner, keep the cap unit

H still and using a 17 mm spanner loosen the nut
G .
d Loosen and remove the upper cap unit H .
4 67
FRONT FORK
CHAS
3 From inside the stem holder remove:

• the spring pointer I
I • the fork spring J
• the upper spring guide bush K
K • the spacer L
M • the lower spring guide bush M
• the spring pointer N
N L J
4 Release:
• the stem from the vice
e Rotate the stem towards a container of adequate

sizes so that the contained oil drains.
NOTE:
To favour the draining, it is necessary to perform a
few pumps, repeatedly pushing the pumping rod
forward-backwards O .
ATTENTION
This operation must be carried out only after
having drained the oil contained inside the stem.
P
f Lock the wheel holder foot P in vice.
5 Remove:
• the pumping unit fixing screw Q
• the washer R
• the pumping unit S
4 68
FRONT FORK
CHAS
ATTENTION
This operation must be carried out only after
having completely drained the oil contained
T inside the sleeve.
6 Remove:
• the dust seal T from the seat, using a small sharp
screwdriver.
7 Remove:
• the oil retainer clip U using the same screwdriver.
U
8 Remove:
W • the fork shank V from the fork sleeve W
NOTE:
V Z To separate these two elements it is necessary to
Y energetically pull them.
X
• oil retainer X
• the seal ring Y
• the lower guide bush Z
9 Manually remove:
• the upper guide bush A
NOTE:
Should this operation result difficult to carry out
D manually, help yourself by inserting a sharp
A E screwdriver inside the slot of the bush.
B • the lower guide bush B
C
• the seal ring C
F • oil retainer D
9 • the dust seal clip E
• the dust seal F
NOTE:
The removed oil retainers and the dust seals must
not be reused.
4 69
FRONT FORK
CHAS
FRONT FORK SHANKS INSPECTION

A

the front fork.
1 Check:
• the fork shank A
• the fork sleeve B
In the presence of deformations/damages/scratches
B Replace.
1
WARNING
If deformed, do not attempt to straighten the
internal fork shank in that, by weakening, it may
become dangerous.
2 Measure:
• the free length of the spring C
C Free length of the spring

262 mm (10.31 in)
3 Check:
• the dampener rod D
D In the presence of damages/wear Replace.
In the presence of obstructions Clear all oil
passages using compressed air.
ATTENTION
• The pumping unit contains elements particularly
sensitive to foreign bodies.
• During dismantling and re-assembling of the
front fork shaft, do not allow foreign bodies to
3 enter the front fork.
4 Check:
• the O-Ring of the cap E
E
4
4 70
FRONT FORK
CHAS
FRONT FORK SHANKS ASSEMBLY
ATTENTION
The removed oil retainer and the dust seal must
not be reused. Before re-assembling, check the
conditions of the guide bushes; if scratches,
replace them. Check that the Teflon ® coating of
the guide bushes is intact.
1 Apply at the end of the supporting tube:

• adhesive tape so that the seat of the upper bush is
covered.
a Slightly lubricate the dust seal and oil retainer

with grease.
LS
TUTELA MR2 GREASE
1
2 Insert
Inse in the supporting tube:
• the dust seal A
• the dust seal clip B
• the oil retainer C
• the seal ring D
• the lower guide bush E
E D ATTENTION
C B Pay attention to the direction of the oil retainer
A C , it must be inserted so that the hollow part is
2 facing the seal ring D .
b Remove the adhesive tape applied on the end of

the fork shank, eliminating any traces of adhesive.
3 Manually insert:
• the upper guide bush E
NOTE:
Should the insertion of the guide bush result
difficult to carry out manually, help yourself by
inserting a sharp screwdriver inside the slot of the
bush.
E
c Delicately introduce the fork shank inside the fork
sleeve, being careful not to damage the upper
3 guide bush.
4 71
FRONT FORK
CHAS
4 Accompany:
• the lower guide bush until it comes into contact
with the fork sleeve
F • the seal ring
• the oil retainer F
d Subsequently introduce them in the seat.
5 Assemble:
• the oil retainer clip G using a small sharp
G screwdriver, checking that it is perfectly inserted in
the appropriate groove and being careful not to
scratch the fork shank.
6 Insert in the seat:

• the dust seal H by manually pressing.
7 Insert:
• the full pumping unit I inside the stem holder J .
I
4 72
FRONT FORK
CHAS
e Assemble the fork in vice by fixing it from the wheel

holder foot.
f Lower the fork sleeve on to the fork shank.
8 Insert:
• the washer K
• the pumping unit fixing screw L
Fasten using an 8 mm Allen spanner:

50 N m - 5.09 Kgf•m
R.
T.
NEW
K 52A43 MEDIUM THREAD BRAKES
52A43
L
g Completely lift the fork sleeve.
h
e In a graduated beaker prepare the quantity of oil to
pour into the stem.
h
TYPE: SAE 7.5

Quantity: 710 cc
i Pour inside the fork sleeve M approximately

2/3 of the required oil, therefore pump a few times
to eliminate the air.
j Proceed until the required amount is poured.
k Lower the fork sleeve on to the fork shank to the

stroke of the dust seal on the wheel holder foot.
M
l Wait a few minutes and check the air volume and
eventually restore the level.
h: 130 mm.
ATTENTION
A lower or higher air volume, or a type of oil
different to that prescribed, may change the
behaviour of the fork in its every phase.
9 Insert inside the fork sleeve:

• the spring pointer N
S • the lower spring guide bush O
• the spacer P
Q • the upper spring guide bush Q
O • the fork spring R
• the spring pointer S
N P R
ATTENTION
ATTENTION to the introduction direction of the
9 spring. The tighter part must face upwards.
4 73
FRONT FORK
CHAS
10 Tighten:
• the closing cap T
T
10
11 Push downwards:
T • the spring U
V • the preload spacer
m Insert a 17 mm spanner inside the nut V .

U n Using a 4 mm compass spanner, keep the closing
unit T still and using a 17 mm spanner fasten the
nut V .
Fasten: 20 N m - 2.03 Kgf•m
R.
T.
11
o Lift the fork sleeve on to the fork shank.
12 FFix:
X • the fork sleeve W in vice
W Fasten:
• the closing cap X on to the fork sleeve using a
4 mm compass spanner.

R.
T.
12
4 74
FRONT FORK
CHAS
FRONT FORK SHANKS INSTALLATION
22 N m - 2.24 Kgf•m
R.
T.
LS
2 LS 2
8 N m - 0.81 Kgf•m
R.
T.

Front Fork Shanks Installation
1 Front Fork Shank 2
2 LS
Lower Plate Stop Screw 6 Carry out a double passage.
3 LS
Upper Plate Stop Screw 2
4 75
FRONT FORK
CHAS
FRONT FORK SHANKS INSTALLA-

TION
the front fork.
1 Install:
B • the shanks of the front fork A
LS Temporarily fasten:
• the stop screws of the lower steering plate B
B
LS
TUTELA MR2 GREASE
NOTE:
Check the assembly quota. Figure 2
227.5 mm
3 Fasten:
• the stop screws of the lower steering plate B
Fasten by carrying out a double passage.

8 N m - 0.81 Kgf•m
R.
T.
• the stop screws of the upper steering plate C
LS
C
3 Fasten: 22 N m - 2.24 Kgf•m
R.
T.
LS
TUTELA MR2 GREASE
ATTENTION
Check that the path of the brake flexible tubes is
correct.
4 76
HANDLE BAR
CHAS
HANDLE BAR REMOVAL
12
13
1
14
15
2
17
16
18 21 20
19
19
9
19
20 3
4 10
22
23
11
8
5
7
6
6

Handle Bar Removal
1 Right Rear-view Mirror 1 Disconnect indicator wire.
2 Left Rear-view Mirror 1 Disconnect indicator wire.
3 Cap 1
4 Knob Terminal 1
5 Left Knob 1
6 Screw 2
7 Left Switch 1 Disconnect.
8 Clutch Cable 1
9 Screw 2
10 Trestle 1 Disconnect indicator wire.
11 Clutch Command Lever 1 Disconnect clutch switch.
12 Screw 2
13 Trestle 1
14 Accelerator Knob 1
15 Gas Opening Cable 1
16 Gas Closing Cable 1
17 Screw 2
18 Right Switch 1 Disconnect.
19 Screw 2
20 Trestle 1
21 Front Brake Pump 2 Disconnect switch.
22 Screw 2
23 Handle Bar 1
4 77
HANDLE BAR
CHAS
HANDLE BAR REMOVAL

WARNING
cannot fall.
2 Disconnect:
• the knob of the handle bar A
NOTE:
Direct a jet of compressed air between the left part
of the handle bar and the relative knob, to
gradually remove it from the handle bar.
A
2
3 Disconnect:
• the slot of the accelerator cable B
• the accelerator knob C
B
C
4 78
HANDLE BAR
CHAS
HANDLE BAR INSPECTION

1 Check:
A • the handle bar A
In the presence of deformations/cracks/damages
Replace.
WARNING
If deformed, do not attempt to straighten the
handle bar in that, by weakening, it may become
1 dangerous.
4 79
HANDLE BAR
CHAS
HANDLE BAR INSTALLATION
22
LS
21 8 N m - 0.81 Kgf•m
R.
T.
23
20
19 LS
12
8 N m - 0.81 Kgf•m
R.
T.
17
18
LS
16 13 14
15
15
8
LS
4
LS
3 20 N m - 2.03 Kgf•m 4
R.
LS T.
3 7
2
1 LS
6
5
LS
11
9
10
10

Handle Bar Installation
1 Handle Bar 1
2 LS
Screw 2 Carry out a double passage.
3 LS
Knob Terminal 2
4 Cap 2
5 Clutch Cable 1
6 Clutch Command Lever 1
7 Trestle 1
8 LS
Screw 2
9 Left Switch 1
11 Left Knob 1
12 Left Rear-view Mirror 1
13 Front Brake Pump 1
14 Trestle 1
15 LS
Screw 2
16 Right Switch 1
18 LS
Gas Closing Cable 1
19 LS
Gas Opening Cable 1
20 Accelerator Knob 1
21 Trestle 1
22 LS
Screw 2
23 Right Rear-view Mirror 1
4 80
HANDLE BAR
CHAS
HANDLE BAR INSTALLATION

WARNING
cannot fall.
2 Install:
B • the right side handle bar switch A
NOTE:
C Align the protrusion B of the switch with the hole
C on the right side handle bar.
3 Install:
• the brake trestle D
LS
TUTELA MR2 GREASE
D E
Fasten: R.
T.
8 N m - 0.81 Kgf•m
3 NOTE:
• Install the trestle of the brake pump with the
mark “UP” facing upwards.
• Firstly, fasten the upper screw, then the lower
screw.
NOTE:
• Align the coupling surfaces of the retainer
element of the brake pump trestle with THE
punching E on the right side handle bar.
• There must be a 2 mm (0.07 in) space between the
switch on the right side handle bar and the brake
pump trestle.
4 Install:
• the accelerator knob
• the slot of the accelerator cable F
• the accelerator cables
4 81
HANDLE BAR
CHAS
5 Install:
• the trestle for the clutch lever G
H NOTE:
Align the slot of the retainer element of the clutch
lever with the punching H on the left side handle
bar.
6 Install:
I • the left side handle bar switch I
K NOTE:
Align the protrusion J of the left side handle bar
switch with the hole K on the left side handle
bar.
J
6
7 Install:
• the knob of the handle bar
a Apply a thin layer of rubber adhesive on the end of

the left side handle bar.
b Make the knob slide on the end of the left side
handle bar knob.
c Remove any trace of excess rubber adhesive using
a clean cloth.
ATTENTION
Do not touch the handle bar knob until the rubber
adhesive has completely dried.
8 Adjust:
• the clutch cable clearance
See paragraph "ROUTINE INSPECTIONS AND
ADJUSTMENTS 3.17".
Clearance of clutch cable

(at the end of the clutch lever)
3 ~ 5 mm (0.11 ~ 0.19 in)
9 Adjust:
ADJUSTMENTS 3.16".

(at accelerator knob flange)
3 ~ 5 mm (0.11 ~ 0.19 in)
4 82
STEERING WHEEL HEAD
CHAS
UPPER AND LOWER STEERING

WHEEL BASE REMOVAL
14
16 2
15 1
Special Tools: STEERING HEAD SPANNER

17 Code: R300097146000
4
3 3
5
6
7
Special Tools: STEERING RETURN RING SPANNER
8 Code: R180297129000
8
7
9
10
10
12 11
13 11

Mobile and Fixed Cap Removal See paragraph "4,110"
Front Wheel Removal See paragraph "4.1"
Front Fork Shanks Removal See paragraph "4.64"
Handle Bar Removal See paragraph "4.77"
Upper And Lower Steering Wheel Base Removal
1 Screw 2
2 Cap 1 NOTE:
Remove cap using the special tool.
3 Screw 2
4 Upper Steering Head 1
5 Kingpin Ring Nut 1
6 Steering Ring Nut 1 NOTE:
Remove cap using the special tool.
7 Dust Seal Ring 2
8 Bearing 2
9 Lower Steering Base 1
10 Screw 6
11 Screw 2
12 Front Brake Tube Guide Support Small Plate 1
13 Front Brake Tube Guide 1
14 Screw 1
15 GPS Support 1
16 Grain 1
17 Pin 1
4 83
STEERING WHEEL HEAD
CHAS

WHEEL BASE REMOVAL
WARNING
cannot fall.
2 Remove:
upper A
A
2
3 Remove:
C • the cap B
(using the special tool C )

Code: R300097146000
4 Loosen:
• the kingpin ring nut
• the steering ring nut
(using the spanner for the steering ring nut D )
Special Tools: STEERING WHEEL RETURN RING SPANNER

Code: R180297129000
D
4 WARNING
Firmly support the lower steering base so that it
cannot fall.
4 84
STEERING WHEEL HEAD
CHAS

WHEEL BASE INSPECTION
1 Wash:
• the bearings
• the bearings tracks
Recommended solvent
TUTELA MOTOR CLEAN
2 Check:
• the bearings A
B • the dust seal rings B
In the presence of damages/pitting Replace.
A
B
2
3 Replace:
• the bearings
D • the bearings tracks
a Remove the bearings tracks C from the column

tube of the steering wheel using a long rod D
and a hammer.
b Remove the bearing track E from the lower
C bracket using a scalpel F and a hammer.
c Install a new rubber seal and new bearings tracks.
ATTENTION
If a track for bearings is not installed correctly, the
F tube for the steering head may be damaged.
E NOTE:
• The bearings and the relative tracks must always
be replaced together.
• Every time the steering tube is dismantled, the
rubber seal must be replaced.
3
4 Check:
• the upper steering base
• the lower steering base
(together with the steering tube)
Replace.
4 85
STEERING WHEEL HEAD
CHAS

WHEEL BASE INSTALLATION
6 N m - 0.61 Kgf•m 4
16
R.
T.
60 N m - 6.11 Kgf•m
R.
2
T.
3 17
52A43
52
MEDIUM THREAD BRAKES A4
20 N m - 2.03 Kgf•m
R.
3 T.
1 LS
14
LS
22 N m - 2.24 Kgf•m 15 15
R.
T.
13 60 N m - 6.11 Kgf•m
R.
LS LS T.
12 16 N m - 1.63 Kgf•m
R.
T.
LS 10
LS
11

8 N m - 0.81 Kgf•m Code: R300097146000
R.
T.
11 Special Tools: STEERING RETURN RING SPANNER

LS
Code: R180297129000
10
LS
9
8 LS
LS
6 7
5 7 8 N m - 0.81 Kgf•m
R.
T.

Upper And Lower Steering Wheel Base Installation
1 Pin 1
2 Grain 1
3 GPS Support 1
4 Screw 1
5 Front Brake Tube Guide 1
6 Front Brake Tube Guide Support Small Plate 1
7 Screw 2
8 Screw 6 Carry out a double passage.
9 LS
Lower Steering Base 1
10 LS
Bearing 2
11 Dust Seal Ring 2
12 LS
Steering Ring Nut 1
13 LS
Kingpin Ring Nut 1 NOTE:
LS
Install both ring nuts using the special tool.
LS
14 Steering Head 1
15 Screw 2
16 Cap 1
52A43
17 LS
Screw 2 Carry out a double passage.
LS
4 86
STEERING WHEEL HEAD
CHAS

WHEEL BASE INSTALLATION
1 Lubricate:
• the bearings
• the dust seal rings
• the bearings tracks
LS
TUTELA MR2 GREASE
2 Install:
• the steering ring nut A using the special tool
R.
T.
LS
LS
ATTENTION
B Do not excessively fasten the steering ring nut.
A
• the kingpin ring nut B using the special tool
2 Fasten: 60 N m - 6.11 Kgf•m
R.
T.
LS
TUTELA MR2 GREASE
Special Tools: STEERING RETURN RING SPANNER

Code: R180297129000
3 Install:
• the front fork shanks
4 87
STEERING WHEEL HEAD
CHAS
4 Install:
• the cap C using the special tool
C
Fasten with: 60 N m - 6.11 Kgf•m
R.
T.
52A43

LS
D
4
Code: R300097146000
• the stop screws of the upper steering plate D
R.
T.
LS
TUTELA MR2 GREASE
5 Check:
the tubes' ends.
Adjust the steering tube.
4 88
CHAS
REAR SHOCK ABSORBER SET REMOVAL
2
1
11
7
4
5
7
10
3
4
19 9
7
8
8
5
12
7
13
6
14 3
15
16
18
17
18
16
15
14 12
4 89
CHAS


1 Screw 1
2 Nut 1
3 Screw 2
4 Nut 2
5 Articulated Connecting Rod 2
6 Spacer 1
7 Seal Ring 4
8 Rollers Bearing 2
9 Screw 1
10 Nut 1
11 Shock Absorber 1
12 Screw 2
13 Pin 1
14 Washer 2
15 Bush 2
16 Seal Ring 2
17 Spacer 1
18 Rollers Bearing 2
19 Balancing Device 1
4 90
CHAS
REAR SHOCK ABSORBER AND GAS

CYLINDER TREATMENT
WARNING
This rear shock absorber and this gas cylinder
contain a highly compressed gas (nitrogen).
Carefully read and understand the following
information before handling the rear shock
absorber and gas cylinder.
The manufacturer cannot be held responsible
for any damages to property or personal injuries
deriving from the improper use of the rear shock
absorber and the gas cylinder.
• Do not tamper with, do not attempt to open the
rear shock absorber or the gas cylinder.
• Do not submit the rear shock absorber or the gas
cylinder to naked flames or other sources of high
heat.
A high overheating may cause an explosion due
to the excessive gas pressure.
• Do not deform, do not damage the rear shock
absorber or the gas cylinder in any way.
In case of damages to the rear shock absorber, to
the gas cylinder or both, the damping
performances will be jeopardised.
4 91
CHAS

REMOVAL
1 Park:
WARNING
cannot fall.
2 Disconnect:
A • the articulated connecting rods fixing screws A
• the relative nuts B
• the two articulated connecting rods C
E • the lower screw of the rear shock absorber set D
D • the relative nut E
C
A NOTE:
B To remove the articulated connecting rods fixing
screws and the lower screw of the rear shock
2 absorber set hold the swing arm to avoid it falling.
3 Disconnect:
• the fixing screw of the rear shock absorber set F
• the relative nut G
• the rear shock absorber set H
F G
NOTE:
Lift the swing arm and remove the rear shock
absorber set from the connecting point on the
H swing arm.
4 92
CHAS

CONTROL
1 Check:
• rear shock absorber rod
In the presence of deformations/damages
Replace the rear shock absorber set.
• the rear shock absorber
In the presence of gas/oil leaks Replace the
rear shock absorber set.
• the spring
1 In the presence of damages/wear Replace
the rear shock absorber set.
• the bushes
• the dust seals
• the screws
In the presence of deformations/damages/wear
lines Replace.
4 93
CHAS
REAR SHOCK ABSORBER SET INSTALLATION
52A43
50 N m - 5.09 Kgf•m
R.
T.
52A
43
18
52A43
19

52A43
LS
13
16
15
13
10
LS LS LS
17
16 1 11
13
12 LS LS
12 40 N m - 4.07 Kgf•m
R.
T.
8 15
LS 13
7 LS
LS 14
6 LS
17
60 N m - 6.11 Kgf•m 5
R.
T.

52A43
2 LS
LS
LS
3
52A
43
2
4
5
6 8
4 94
CHAS


1 Balancing Device 1
2 LS
Rollers Bearing 2
3 LS
Spacer 1
4 Seal Ring 2
5 LS
Bush 2
6 Washer 2
7 Pin 1
8 Screw 2
52A43
9 Shock Absorber 1
10 LS
Nut 1
11 LS
Screw 1
12 LS
Rollers Bearing 2
13 Seal Ring 4
14 Spacer 1
15 Articulated Connecting Rod 2
16 LS
Nut 2
17 LS
Screw 2
18 Nut 1
52A43
19 Screw 1
52A43
4 95
CHAS

INSTALLATION
1 Lubricate:
• the spacers
• the bearings
LS
TUTELA MR2 GREASE
2 Clean:
• the nut of the rear shock absorber set
• the screw of the rear shock absorber set
Recommended solvent
TUTELA MOTOR CLEAN
3 Install:
• the rear shock absorber set
NOTE:
• Lift the swing arm to install the rear shock
absorber set.
• Install the fixing screw of the rear shock absorber
set.
4 Fasten:
• the nut of the rear shock absorber set
Fasten with: 50 N m - 5.09 Kgf•m

R.
T.

• the lower fixing nut of the rear shock absorber set

• the fixing screws of the articulated connecting
rods

R.
T.
4 96
TRANSMISSION CHAIN AND SWING ARM
CHAS
TRANSMISSION CHAIN AND SWING

ARM REMOVAL
2
2
8
3
1 17
16
9 15
11 16 15
14
10
10
13
12 9
5
Special Tools: 20 ALLEN SPANNER
Code: R180197033000
4
6

Rear Brake Calliper Removal See paragraph "4.53".
Disconnect Speed Sensor Connector See paragraph "ELECTRIC PLANT 7.11"
Rear Wheel Removal See paragraph "4.16".
Rear Mudguard Removal See paragraph "4,126"
Chain Carter Removal See paragraph "4,122"
Set Removal
Rear Shock Absorber See paragraph "4.89"
Transmission Chain And Swing Arm Removal
NOTE:
Support the bike using suitable supports so that
it cannot fall.
1 Transmission Chain 1
2 Screw 4
3 Eccentric 2
4 Special Screw 1
5 Ring Nut 1 Loosen.
6 Register 1 Loosen.
7 Pin 1 NOTE:
Remove using the special tool.
8 Swing Arm 1
9 Bush 2
10 Seal Ring 2
11 Seeger 1
12 Rollers Bearing 1
13 Bearing 2
14 Inside Spacer 1
15 Screw 2
16 Welnut 2
17 Upper Chain Slide 1
4 97
CHAS
TRANSMISSION CHAIN REMOVAL

1 Park:
WARNING
that the bike does not fall and the rear wheel is
lifted.
2 Disconnect:
MASTER LINK • the transmission chain
(using a transmission chain cutter or the provided
tool, according to the transmission chain
manufacturer specifications.)
NOTE:
Cut the transmission chain only if it, or the swing
arm, has to be replaced.
TRANSMISSION CHAIN
TOOLS SET 2
4 98
CHAS
SWING ARM REMOVAL

1 Park:
WARNING
that the bike does not fall and the rear wheel is
lifted.
2 Disconnect:
B • the nuts A
D • the articulated connecting rods fixing screws B
• the two articulated connecting rods C
F • the washers D
E • the lower screw of the rear shock absorber set E
C
• the relative nut F
B NOTE:
A
To remove the articulated connecting rods fixing
D screws and the lower screw of the rear shock
2
absorber set hold the swing arm to avoid it falling.
3 Check:
• the swing arm vertical movement F
by moving it up and down.
If the vertical movement of the swing arm is not
smooth or is blocked, check the spacers, the bearings,
F the washers and the dust seal lids.
NOTE:
The shock absorber must be dismantled.
4 99
CHAS
TRANSMISSION CHAIN INSPECTION

A
1 Check:
• the transmission chain A
Stiffness Clean and lubricate, or replace.
2 Clean:
a Clean the transmission chain using a clean cloth.
b Place the transmission chain in kerosene and

remove all residue dirt.
c Remove the transmission chain from the kerosene

and leave it to dry completely.
2
ATTENTION:
This bike is equipped with a transmission chain
with small rubber O-Rings B placed between
one side plate and the other.
To clean the transmission chain we recommend
not using high pressure jets of air or water, not to
use vapour, petrol, aggressive solvents (for
example petrol oil), or brushes with very hard
bristles.
The use of high pressure objects may force dirt or
water inside the internal cavities of the
transmission chain whereas, the use of solvents
may deteriorate the O-Rings.
Furthermore, the O-Rings may also be damaged
by using a brush with very hard bristles.
We therefore suggest cleaning the transmission
chain with kerosene.
Do not place the transmission chain in the
kerosene for more than ten minutes.
Kerosene damages the O-Rings.
3 Check:
• the O-Rings B
In the presence of damages Replace the
transmission chain.
• the transmission chain rollers C
B In the presence of damages/wear Replace the
transmission chain.
• the transmission chain side plates D
C In the presence of damages/wear Replace the
transmission chain.
In the presence of cracks Replace the
transmission chain and ensure that the path of the
battery vent tube is correct and sufficiently distant
D 3 from the transmission chain and below the swing
arm.
4 100
CHAS
4 Lubricate:
S
Recommended grease
SINTOFLON
5 Check:
• the conductor gear
G E • the rear cogwheel
If more of a ¼ of each tooth E is worn
Replace the gears of the transmission chain.
F If the teeth are bent Replace the gears of the
transmission chain.
F Correct
G Distribution chain roller
H H Transmission chain gears
5
NOTE:
Never use a new chain with worn cogwheels.
Both the chain and the cogwheels must be in good
conditions or the new chain will rapidly wear out.
4 101
CHAS
SWING ARM INSPECTION

1 Check:
A • the swing arm A
Replace.
2 Check:
• the swing arm pin B
Roll the swing arm pin on a flat surface.
B In the presence of deformations Replace.
WARNING
Do not attempt to straighten the swing arm pin
and the balancing axis if they are deformed.
3 Wash:
• the swing arm pin
• the bushes
• the seal rings
• the spacer
• the bearings
Recommended solvent
TUTELA MOTOR CLEAN
4 Check:
• the bushes C
• the seal rings D
• the seeger E
• the bearings F
• the inside spacer G
In the presence of damages/pitting Replace.
C D
E F
G
F D
C 4
4 Check:
• the articulated connecting rods H
• the balancing device I
H In the presence of damages/wear Replace.
L • the roller bearings J
J J K • the seal rings K
H In the presence of damages/pitting Replace.
K • the spacers L
In the presence of damages/scratches Replace.
L J
I K
K J 4
4 102
CHAS
TRANSMISSION CHAIN REPLACE-

MENT
1 Loosen:
This chain uses a master link transmission chain with
safety jump ring.
Using the provided tool according to the chain
manufacturer specifications.
NOTE:
Following the manufacturer instructions when
using the special tool.
TRANSMISSION
CHAIN TOOLS SET
1
2 STANDARD NUMBER OF LINKS: 108

MASTER
LINK LINK
108 LINKS 2
TRANSMISSION CHAIN TOOLS SET WARNING

Do not reuse the old transmission chain, the
master link, the jump ring of the master link and
the O-Rings.
3 Insert:
• the master link
• the O-Rings
• the jump ring
ATTENTION
Insert the master link from inside the transmission
chain, therefore apply the jump ring with the
JUMP RING identification mark facing outwards.
a Assemble and fix the tools set for the transmission

chain.
b Ensure that the pins of the master link are correctly
assembled.
c Clinch the master link pins sideways.

O-RING
MASTER LINK 3 d Ensure that the pins are correctly spotted.
4 103
CHAS
4 Check:
OK • the surface interested by the pressing of the master
link.
This must not show cracks.
If cracks are present, replace the master link, the seal
rings and the jump ring.
REPLACE
ATTENTION
Do not use a transmission chain with clip type
master link.
CRACKS 4
4 104
CHAS
TRANSMISSION CHAIN AND SWING

ARM INSTALLATION
16
LS 16 22 N m - 2.24 Kgf•m
R.
T.
15
10
52A43
17 7
52
A4
3
6 9
LS
4 8 9
1 LS
5 3
52A43
LS
2 LS
5
6
LS
52A
43
13
LS LS
10 N m -1.01 Kgf•m
R.
T.
14
12
60 N m - 6.11 Kgf•m
R.
T.
LS
Special Tools: 20 ALLEN SPANNER 11

Code: R180197033000

Transmission Chain And Swing Arm Installation
1 LS
Inside Spacer 1
2 LS
Bearing 2
3 LS
Rollers Bearing 1
4 Seeger 1
5 LS
Seal Ring 2
6 LS
Bush 2
8 Welnut 2
9 Screw 2
52A43
10 Swing Arm 1
11 LS
Pin 1 NOTE:
Install using the special tool.
12 LS
Register 1
13 LS
Ring Nut 1
14 Special Screw 1
52A43
15 Eccentric 2
16 LS
Screw 4
17 Transmission Chain 1
4 105
CHAS
SWING ARM INSTALLATION

1 Lubricate and clean:
• the bearings
• the spacer
• the seal rings
• the bushes
• the swing arm pin
LS
TUTELA MR2 GREASE
Recommended solvent
TUTELA MOTOR CLEAN
2 Install:
• the swing arm
• the swing arm pin A using the special tool B

Code: R300097146000
E D A
C • the ring nut C
• the regulator D
• the special screw E
3 Install:
• the rear shock absorber set
B See paragraph "4.94".
• the rear wheel
4 Adjust:
ADJUSTMENTS 3.62”.
Check there are approximately

15 mm (0.59 in) between the swing
arm and the lower chain slide
4 106
ENGINE
CHAS
ENGINE REMOVAL
11
10
9
7
4
8
6
1
12
4 107
ENGINE
CHAS
ENGINE REMOVAL

NOTE:
Place a suitable trestle underneath frame and
engine
Engine Protection Removal See paragraph "4,122"
Empty Cooling Liquid NOTE:
Drain the cooling liquid before carrying out the
operations. See paragraph "ROUTINE
INSPECTIONS AND ADJUSTMENTS 3.44".
Right And Left Tank Lids Removal See paragraph "4.112"
Tank Removal See paragraph "4.118"
Air Box Removal See paragraph "ROUTINE INSPECTIONS AND
ADJUSTMENTS 3.10".
Actuator Cables Removal See paragraph "ELECTRIC PLANT 7.28"
Disconnect Lambda Probe Connector See "ELECTRIC PLANT 7.13" paragraph.
Drain Fitting and Collectors Removal See paragraph "4.155"
Radiator Removal See "COOLING PLANT 6.1" paragraph.
Disconnect Battery See paragraph "ROUTINE INSPECTIONS AND
ADJUSTMENTS 3.79”
Disconnect Remote Control Switch See paragraph "ELECTRIC PLANT 7.38"
Start-Up Motor Removal See “ENGINE 5.125” paragraph.
Disconnect Gas Cables See paragraph "4.77"
Clutch Cable Removal See “ENGINE 5.88” paragraph.
Disconnect Reels See “ENGINE 5.1” paragraph.
Disconnect Injectors See paragraph "ELECTRIC PLANT 7.31"
Disconnect Potentiometer Connector See paragraph "ELECTRIC PLANT 7.6"
Disconnect Phase Sensor Connector See paragraph "ELECTRIC PLANT 7.4"
Disconnect Sensor Connector
Cooling Liquid Temperature See paragraph "ELECTRIC PLANT 7.5"
Disconnect Stepper Sensor Connector See paragraph "ROUTINE INSPECTIONS AND
ADJUSTMENTS 3.25".
Disconnect Oil Pressure Sensor Connector See paragraph "ELECTRIC PLANT 7.16"
Disconnect Sensor Connector
Side Trestle See paragraph "4.151"
Disconnect Neutral Sensor Connector See paragraph "ELECTRIC PLANT 7.7"
Transmission Chain Removal See paragraph "4.97"
Gear Change Removal See “ENGINE 5.91” paragraph.
Right Front Footboard Holder Plate Removal See paragraph "4.147"
Engine Removal
1 Engine Support Screw 1
2 Nut 1
3 Engine Screw 1
4 Regulator Ring Nut 1
5 Engine Register 1
6 Adjustment Grain 1
7 Nut 1
8 Engine Right Front Screw 1
9 Nut 1
10 Left Engine Screw 1
11 Small Plate 1
12 Engine 1
4 108
ENGINE
CHAS
ENGINE INSTALLATION
8 LS
4
45 N m - 4.58 Kgf•m 2
R.
T.
5
LS
LS
LS 11 LS
9
10
LS
12
LS
1
LS
40 N m - 4.07 Kgf•m
R.
T.
LS
LS 3

Engine Installation
ATTENTION:
Careful not to damage frame and engine when
installing the engine.
NOTE:
Place a suitable trestle underneath frame and
engine.
1 LS
Engine Support Screw (222.5 mm) 1 Torque fasten
2 LS
Left Engine Screw 1
3 LS
Engine 1
4 Small Plate 1
5 LS
Nut 1 Torque fasten
6 LS
Engine Register 1 Near to the engine without fastening and near the
LS
regulator ring nut to the frame without fastening
7 LS
Engine Screw 1 Lock the screw using the spanner
8 LS
Nut 1 Torque fasten
9 LS
Regulator Ring Nut 1 Fasten by hand
10 LS
Engine Right Front Screw 1 Lock screw using the spanner
11 LS
Nut 1 Fasten by hand
12 Adjustment Grain 1 Fasten by hand
NOTE:
Insert the cooling liquid once operations have
been completed.
4 109
FAIRING
CHAS
MOBILE AND FIXED CAP REMOVAL
17
14
15
5
3
6
4 5
16 14
15
13 4 7
16
9
13 3
9
11 12
10 12 11
10
1 8

Mobile And Fixed Cap Removal
1 Benelli Decalcomania 1
2 Screw 1
3 Special Screw 2
4 Cap 2
5 Screw 2
6 Right Headlight Lid 1
7 Left Headlight lid 1
8 Fixed Cap 1
9 Anti-vibration 2
10 Nut 2
11 Screw 2
12 Bush 2
13 Split pin 2
14 Knob 2
15 Pin 2
16 Small Plate 2
17 Mobile Cap 1
4 110
FAIRING
CHAS
MOBILE AND FIXED CAP INSTALLATION
1
5
4
70
52A
52A70
LS STRONG THREAD BREAKS
13
15
12
14 13
3 5
4 11
6 14
LS
3
10 15
6
10
8 7 8 N m - 0.81 Kgf•m
R.
T.
LS
9 7 8
9
17 2
LS
6 N m - 0.61 Kgf•m 16
R.
T.
8 N m - 0.81 Kgf•m
R.
T.

Mobile And Fixed Cap Installation
1 Mobile Cap 1
2 Fixed Cap 1
3 Small Plate 2
4 LS
Pin 2
5 Knob 2 Manually fasten.
52A70
6 Split pin 2
7 Bush 2
8 LS
Screw 2
9 Nut 2
10 Anti-vibration 2
11 Left Headlight lid 1
12 Right Headlight Lid 1
13 Screw 2
14 Cap 2
15 LS
Special Screw 2
16 LS
Screw 1
17 Benelli Decalcomania 1
4 111
FAIRING
CHAS
RIGHT AND LEFT TANK LIDS REMOVAL
1
2 1
2
5
4
8

Right And Left Tank Lids Removal
1 Screw 2
2 Bush 2
3 Steering Lock Lid 1
NOTE:
tank lids.
4 Special Screw 1
5 Bush 1
6 Special Screw 1
7 Left Tank Lid 1
8 Quick Fixing Clip 1
4 112
FAIRING
CHAS
RIGHT AND LEFT TANK LIDS INSTALLATION
8
7 LS 8
7
8 N m - 0.81 Kgf•m
R.
T.
4
5
1
LS

Right And Left Tank Lids Installation
NOTE:
tank lids.
2 Left Tank Lid 1
3 Special Screw 1 Manually fasten.
4 Bush 1
5 LS
Special Screw 1
6 Steering Lock Lid 1
7 Bush 2
8 LS
Screw 2
4 113
FAIRING
CHAS
FAIRING SUPPORT BRACKET REMOVAL
2
3
4
3
6 1

Right And Left Tank Lids Removal See paragraph "4.112".
Fairing Support Bracket Removal
1 Screw 1
2 Nut 1
3 Washer 2
4 Bush 1
5 Fairing Support Bracket 1
4 114
FAIRING
CHAS
FAIRING SUPPORT BRACKET INSTALLATION
12 N m - 1.22 Kgf•m
R.
T.
6
4
3
4
1 5
LS
2
1

Fairing Support Bracket Installation
2 Fairing Support Bracket 1
3 Bush 1
4 Washer 2
5 LS
Screw 1
6 Nut 1
4 115
FAIRING
CHAS
TANK CAP REMOVAL
2
2

Tank Cap Removal
Insert key.
Open cap.
1 Screw 1
2 Screw 3
3 Tank Cap 1
4 Seal For Ring Nut 1
5 Collector 1
6 Gasket 1
4 116
FAIRING
CHAS
TANK CAP INSTALLATION
3 6 N m - 0.61 Kgf•m
R.
T.
6
6 N m - 0.61 Kgf•m 6
R.
T.
NEW
4
NEW
1

Tank Cap Installation
1 NEW
Gasket 1
2 Collector 1
3 Screw 1
4 NEW
Seal For Ring Nut 1
5 Tank Cap 1
6 Screw 3
4 117
FAIRING
CHAS
TANK REMOVAL
Special Tools: RAPID RELEASE KIT

SPECIAL TOOL Code: R180100143000
A B 3
RAPID RELEASE KIT
6 7 6
1 2

Steering Lock Lid Removal See paragraph "4.112".
Seat Removal See paragraph "4.130".
Tank Removal
1 Special Screw 2
2 Bush 2
3 Rubber Buffer 2
4 Tank 1 Lift the tank slightly.
5 Petrol Pump Connector 1 Disconnect.
6 Tank Vent Tube 2 Disconnect.
7 Petrol Tube Fitting 1 Disconnect the petrol fitting tube using the special
tool.
ATTENTION:
When using the special tool, the two flaps of the
petrol pump must be pressed. Once the petrol
tube is removed, insert the special tool (B) to
avoid petrol leaking.
4 118
FAIRING
CHAS
TANK INSTALLATION
A B Special Tools: RAPID RELEASE KIT

Code: R180100143000
RAPID RELEASE KIT

LS
4
12 N m - 1.22 Kgf•m
R.
T.
2 1 2
7 6
6 7
LS
12 N m - 1.22 Kgf•m
R.
T.

Tank Installation
ATTENTION:
Remove special tool (B) using special tool (A)
rapidly connecting the petrol tube fitting.
1 Petrol Tube Fitting 1
2 Tank Vent Tube 2
3 Petrol Pump Connector 1
4 Tank 1
5 Rubber Buffer 2
6 Bush 2
7 LS
Special Screw 2
4 119
FAIRING
CHAS
ENGINE LIDS REMOVAL
5
3
6
1
2
15
14
8 9
11
15 13
15 8
9
12 15
9 8
10

Engine Lids Removal
1 Special Screw 1
2 Nylon Washer 1
3 Alternator Lid 1
4 Screw 2
5 Small Plate 1
7 Pinion Lid 1
8 Special Screw 4
9 Nylon Washer 4
10 Engine Protection 1
11 Left Front Small Plate 1
12 Left Rear Small Plate 1
13 Right Rear Small Plate 1
14 Right Front Small Plate 1
4 120
FAIRING
CHAS
ENGINE LIDS INSTALLATION
12 NEW
11
13
10
15
14
12
1 8 N m - 0.81 Kgf•m
R.
T.
2
8 7
NEW
5
1 3
1 8
7
4 1
7 8 8 N m - 0.81 Kgf•m
R.
T.

Engine Lids Installation
2 Right Front Small Plate 1
3 Right Rear Small Plate 1
4 Left Rear Small Plate 1
5 Left Front Small Plate 1
6 Engine Protection 1
7 NEW
Nylon Washer 4
8 Special Screw 4
9 Pinion Lid 1
11 Small Plate 1
13 Alternator Lid 1
14 NEW
Nylon Washer 1
15 Special Screw 1
4 121
FAIRING
CHAS
CHAIN CARTER REMOVAL
3
4
2
1
4
1 2

Chain Carter Removal
1 Screw 2
2 Washer 2
3 Chain Carter 1
4 122
FAIRING
CHAS
CHAIN CARTER INSTALLATION

52A43
2
1
3
4
1
52A43
4 3
8 N m - 0.81 Kgf•m
R.
T.

Chain Carter Installation
2 Chain Carter 1
3 Washer 2
4 Screw 2
52A43
4 123
FAIRING
CHAS
FRONT MUDGUARD REMOVAL
6 4
5 8
2 7
2 8
6
3 2 7
5
3
2
3
9 10
9
9
9
1 A

Front Mudguard Removal
NOTE:
It is not necessary to remove the brake flexible
tube to remove the front mudguard, just
unhook it from the pipe gland as shown in
figure A .
1 Brake Flexible Tube 1
2 Special Screw 4
3 Nylon Washer 4
4 Front Mudguard 1
5 Screw 2
6 "T" Bush 2
7 Pipe Gland 2
8 Nut 2
9 Screw 4
10 Bracket 2
4 124
FAIRING
CHAS
FRONT MUDGUARD INSTALLATION
8 N m - 0.81 Kgf•m 5 7
R.
T.
6 3
9 4
9 3
Arexons SYSTEM 52A43 5 6
52A43
52
9 4
A4
3
8 LS
9
8
8 N m - 0.81 Kgf•m
R.
T.
NEW
2 1 8 N m - 0.81 Kgf•m
R.
T.
2
2
52
A4
3

52A43
10 A

Front Mudguard Installation
1 Bracket 2
2 Screw 4
52A43
3 Nut 2
4 Pipe Gland 2
5 "T" Bush 2
6 LS
Screw 2
7 Front Mudguard 1
8 NEW
Nylon Washer 4
9 Special Screw 4
52A43
10 Brake Flexible Tube 1

NOTE:
To install the front mudguard, hook the brake
flexible tube in the pipe gland, as shown in
figure A .
4 125
FAIRING
CHAS
REAR MUDGUARD REMOVAL
1
2
2 1

Rear Mudguard Removal
1 Special Screw 3
2 Nylon Washer 3
3 Rear Mudguard 1
4 126
FAIRING
CHAS
REAR MUDGUARD INSTALLATION
52A43
2
52A43
1
8 N m - 0.81 Kgf•m
R.
T.
NEW 2 3

Rear Mudguard Installation
1 Rear Mudguard 1
2 NEW
Nylon Washer 3
3 Special Screw 3
52A43
4 127
FAIRING
CHAS
NUMBER PLATE BRACKET REMOVAL
19
14 20
3 15
18
4
13 16
18 18 17
17 13
17
21
22
16 18 17
16
1 2
6
6
9 11
11
8
12
10
10

Number Plate Bracket Removal
1 Screw 1
2 Nut 1
3 Screw 1
4 Nut 1
5 Number Plate Bracket Cover 1
Disconnect the indicators wiring and number plate
light.
6 Washer 2
7 Reflector 1
8 Screw 1
9 Number plate light 1
10 Screw 2
11 Nut 2
12 Small Plate 1
13 Nut 2
14 Left Rear Indicator 1
15 Right Rear Indicator 1
16 Screw 4
17 Bush 4
18 Rubber Pad 4
19 Screw 1
20 Nut 1
21 Left Number Plate Bracket 1
22 Right Number Plate Bracket 1
4 128
FAIRING
CHAS
NUMBER PLATE BRACKET INSTALLATION
8 N m - 0.81 Kgf•m
R.
T.
4 8 N m - 0.81 Kgf•m
R.
T.
9 3
20 8
5
10 19
7
5 5 6
6 10
6
2
1
7 5 6
52A43
7
21
22 17
8 N m - 0.81 Kgf•m 17
R.
T.
10 N m - 1.01 Kgf•m
R.
T.
18
14 12
52A43
12
15
11
13
13 6 N m - 0.61 Kgf•m
R.
T.
16

Number Plate Bracket Installation
1 Right Number Plate Bracket 1
2 Left Number Plate Bracket 1
3 Nut 1
4 Screw 1
5 Rubber Pad 4
6 Bush 4
7 Screw 4
52A43
8 Right Rear Indicator 1

9 Left Rear Indicator 1
10 Nut 2
11 Small Plate 1
12 Nut 2
13 Screw 2
14 Number plate light 1
16 Reflector 1
17 Washer 2 Pressure push.
Connect the indicators wiring and number plate
light.
18 Number Plate Bracket Cover 1
19 Nut 1
20 Screw 1
21 Nut 1
22 Screw 1
4 129
REAR FRAME
CHAS
SEAT REMOVAL
1 Insert:
• the key
2 Press:
• the seat in the end part
and simultaneously turn the key anti-clockwise.
3 Remove:
• the seat by lifting it slightly from the rear end and
sliding it backwards.
4 130
REAR FRAME
CHAS
SEAT INSTALLATION
1 Install:
• the seat
by resting the front hook on the appropriate
slot of the tank B .
2 Press:
• the seat in the end part
and hook it closed.
4 131
REAR FRAME
CHAS
BATTERY BOX REMOVAL
3 1
7 2

1 Screw 2
3 Heat Shield Lid 1
Silencing Device Removal See paragraph "4.155".
Tank Removal See paragraph "4.118".
Battery Box Removal
4 Screw 4
5 Left Bracket 1
6 Right Bracket 1
7 Object Compartment 1
8 Battery Wiring 1 Disconnect.
ATTENTION:
Disconnect the negative cable first then the
positive one.
4 132
REAR FRAME
CHAS
BATTERY BOX REMOVAL
18
22
12
19
10
11 10
18
13 15 17
14
16
17
21
20
20
20
20

9 Battery 1
10 Screw 2
11 Relay Box 1
12 Fuses Box 1
13 Screw 4
14 Control Unit 1
15 Screw 1
16 Bush 1
17 Screw 2
18 Bush 2
19 Rear Wiring 1 Disconnect.
20 Screw 4
21 Rear Small Frame Set 1
22 Battery Box 1
4 133
REAR FRAME
CHAS
BATTERY BOX INSTALLATION
14
1
11
4
13
12 13
10 8 6
9
7
6

52A43

52A43
2
3
52A43
3 25 N m - 2.54 Kgf•m
3
R.
T.
3
52A43
Battery Box Installation Install the pieces in the given order.

1 Battery Box 1
2 Rear Small Frame Set 1 ATTENTION:
52A43
Before installing it, check that the threaded

registers of the tie rod are intact.
3 Screw 4
52A43
4 Rear Wiring 1 Connect.

5 Bush 2
6 Screw 2
7 Bush 1
8 Screw 1
9 Control Unit 1
10 Screw 4
11 Fuses Box 1
12 Relay Box 1
13 Screw 2
14 Battery 1
4 134
REAR FRAME
CHAS
BATTERY BOX INSTALLATION
NEW 22 10 N m - 1.01 Kgf•m
R.
20
T.
52A43
16 21
52A43
21
17
19
19
LS
19
18
15
Battery Box Installation Install the pieces in the given order.

15 Battery Wiring 1 Connect.
ATTENTION:
Connect the positive cable first then the
negative one.
17 Right Bracket 1
18 Left Bracket 1
19 LS
Screw 4
Tank Installation See paragraph "4.119".
Right And Left Tank Lids Installation See paragraph "4.113".
Silencing Device Installation See paragraph "4.158".
20 Heat Shield Lid
21 NEW Anti-vibration Rubber Pad
22 Screw
52A43
4 135
REAR FRAME
CHAS
LOCK REMOVAL
3 1
7 2
6
14
4 12
8 13
9
11
4
10 10

1 Screw 2
3 Heat Shield Lid 1
Lock Removal
4 Screw 4
5 Left Bracket 1
6 Right Bracket 1
8 Screw 1
9 Bush 1
10 Screw 1
NOTE:
Slightly move the battery box.
11 Screw 2
12 Flexible Command 1
13 Lock 1
14 Seat Opening Lever 1
4 136
REAR FRAME
CHAS
LOCK INSTALLATION
NEW
12 14 10 N m - 1.01 Kgf•m
R.
T.
52A43
8 13
52A43
13
9
1
11
11 3
7 2
6
4
11
LS
11
10
5 5

Lock Installation
1 Seat Opening Lever 1
2 Lock 1
3 Flexible Command 1
4 Screw 2
NOTE:
Reposition the battery box in the initial
position.
5 Screw
6 Bush
7 Screw
8 Object Compartment
9 Right Bracket
10 Left Bracket
11 LS
Screw
Tank Installation See paragraph "4.119".
Tank Lids Installation Right And Left See paragraph "4.113".
12 Heat Shield Lid
13 NEW
Anti-vibration Rubber Pad
14 Screw
52A43
4 137
REAR FRAME
CHAS
CODON REMOVAL
1 Remove:
• the seat
2 Disconnect:
• the right and left headlight connectors
3 Remove:
• the screws
D • the nuts B
• the bushes C
• the complete codon D
C
B
3
4 138
REAR FRAME
CHAS
4 Remove:
• the nuts E
• the bushes F
• the anti-vibrations G
• the washers H
• the right rear headlight I
• the left rear headlight J
E
H E
G H E
F G H
F G
F
5 Remove:
• the screws K
• the washers L
O • the screws M
• the codon N
• the handle O
L N
M
K
L
K
5
4 139
REAR FRAME
CHAS
CODON INSTALLATION
1 Install:
A • the handle A
• the codon B
• the screws C
• the washers D
• the screws E
D B
C
E
D
E
1
2 Connect:
• the right and left headlight connectors
3 Install:
• the left rear headlight F
• the right rear headlight G
• the washers H
• the anti-vibrations I
• the bushes J
• the nuts K
K
H K
I H K
J I H
J I
J
4 140
REAR FRAME
CHAS
4 Install:
O • the complete codon L
L • the bushes M
• the nuts N
• the screws O
M
N
4
5 Install:
• the seat
4 141
REAR FRAME
CHAS
REAR SMALL FRAME SET REMOVAL
3 1
4 2
8 9

1 Screw 2
3 Heat Shield Lid 1
Silencing Device Removal See paragraph "4.155".
Codon Removal See paragraph "4.138".
Rear Small Frame Set Removal
5 Screw 4
6 Left Bracket 1
7 Right Bracket 1
8 Screw 6
4 142
REAR FRAME
CHAS
REAR SMALL FRAME SET DECOMPOSITION
3
52A43
4 1
6
1
5
Arexons SYSTEM 52A43 7
52A43
2
1

Rear Small Frame Set Decomposition
1 Screw 4
2 Rubber Strip 2
3 Rear Beam 1
4 Special Nut 1
52A43
5 Small Column 1
6 Right Special Screw 1
7 Left Special Screw 1
8 Left Rear Small Frame 1
9 Right Rear Small Frame 1
NOTE:
To install, invert the order of the removal parts.
4 143
REAR FRAME
CHAS
REAR SMALL FRAME SET INSTALLATION
NEW
7 9 10 N m - 1.01 Kgf•m
R.
T.
52A43
6 8
52A43
2 1
5
LS

Complete Rear Small Frame Installation
2 Screw 6
3 Right Bracket 1
4 Left Bracket 1
5 LS
Screw 4
Codon Installation See paragraph "4.140".
Silencing Device Installation See paragraph "4.158".
7 Heat Shield Lid 1
8 NEW
Anti-vibration Rubber Pad 2
9 Screw 2
52A43
4 144
CYCLING
CHAS
FRONT LEFT FOOTPEG UNIT REMOVAL
26
13
27
21
16
15
14
17 25
9
18
8 10 17
20
24 19
5 11
22 16
7 23
3 4 12
6 2
1

Front Left Footpeg Unit Removal
1 Screw 1
2 Left Fixing Rubber Pad 1
3 Rubber Pad 1
4 Seeger 1
5 Pin 1
6 Left Front Footpeg 1
7 Spring 1
8 Rubber Pad 1
9 Screw 1
10 Pointer Eccentric 1
11 Nut 1
12 Screw 1
13 Nut 1
14 Screw 1
15 Spacer 1
16 Ball Joint 2
17 Nut 2
18 Gear Change Rod 1
19 Screw 2
20 Left Front Footpeg Holder Plate 1
21 Screw 1
22 Fork 1
23 Gear Change Command Lever 1
24 Bush 1
25 Elastic Washer 1
26 Screw 1
27 Gear Change Command Small Lever 1
4 145
CYCLING
CHAS
FRONT LEFT FOOTPEG UNIT INSTALLATION
R.
T.
35 N m - 3.56 Kgf•m
R.
T.
8 N m - 0.81 Kgf•m
27
LS
10 N m - 1.01 Kgf•m
R.
4
T.
20 1 LS
25
LS 3
LS A4
52
26 21 5
LS 17
8 N m - 0.81 Kgf•m 22
R.
T.
18 16 21
52
A4
3
3
7 19
LS LS
11 24
52A43
LS
6 20
LS
13 12 23
25 N m - 2.54 Kgf•m
R.
T.
10 N m - 1.01 Kgf•m
R.
T.
10 14
52A43
52A

43

Front Left Footpeg Unit Installation
NOTE:
If the rubber pads are worn, replace them.
1 Gear Change Command Small Lever 1
2 LS
Screw 1
3 Left Front Footpeg Holder Plate 1
4 Screw 1
52A43
5 Elastic Washer 1
6 Gear Change Command Lever 1
7 Bush 1
8 Fork 1
9 Spring 1
10 Left Front Footpeg 1
11 LS
Pin 1
12 Seeger 1
13 Rubber Pad 1
14 Left Fixing Rubber Pad 1
15 Screw 1 Delicately fasten by hand.
52A43
17 LS
Screw 1
18 Rubber Pad 1
52A43
20 LS
Ball Joint 2
21 Nut 2
22 Gear Change Rod 1
23 LS
Screw 1
24 LS
Nut 1
25 Spacer 1
26 LS
Screw 1
27 LS
Nut 1
4 146
CYCLING
CHAS
FRONT RIGHT FOOTPEG UNIT REMOVAL
12
18 11
9
14
17
16
5
15
13 10
2
4 8
7 6
3

Rear Brake Pump Removal See paragraph “4.42”.
Front Right Footpeg Unit Removal
1 Screw 1
2 Right Fixing Rubber Pad 1
3 Rubber Pad 1
4 Seeger 1
5 Pin 1
6 Right Front Footpeg 1
7 Spring 1
8 Rubber Pad 1
9 Screw 1
11 Screw 2
12 Screw 1
13 Fork 1
14 Brake Command Lever 1
15 Bush 1
16 Spring 1
17 Elastic Washer 1
18 Right Front Footpeg Holder Plate 1
4 147
CYCLING
CHAS
FRONT RIGHT FOOTPEG UNIT INSTALLATION
8 N m - 0.81 Kgf•m
R.
52A T.
43
35 N m - 3.56 Kgf•m
R.
T.
5 52A
43
10

52A43
MEDIUM THREAD BRAKES 8

LS
25 N m - 2.54 Kgf•m 2
R.
T.
4
14 3
LS 1
13 7
16
15 9
11 12
17
Arexons SYSTEM 52A43 18

52A
52A43

43

Front Right Footpeg Unit Installation
NOTE:
1 Bush 1
2 Brake Command Lever 1
3 Spring 1
4 Elastic Washer 1
5 Right Front Footpeg Holder Plate 1
6 Screw 1
52A43
8 LS
Screw 1
9 Rubber Pad 1
10 Screw 2
52A43
11 Spring 1
12 Right Front Footpeg 1
13 Fork 1
14 LS
Pin 1
15 Seeger 1
16 Right Fixing Rubber Pad 1
17 Rubber Pad 1
18 Screw 1
52A43
NOTE:
Ensure that the braking plant functions
correctly once installation is complete.
4 148
CYCLING
CHAS
REAR FOOTPEGS UNIT REMOVAL
10
4
11
10
6
8
9
7
2
1

Rear Footpegs Unit Removal
1 Screw 1
2 Right Footpeg Rubber Stop 1
3 Right Footpeg Rubber Cover 1
4 Seeger 1
5 Pin 1
6 Right Rear Footpeg 1
7 Small Plate 1
8 Ball 1
9 Spring 1
10 Screw 2
11 Right Footboard Holder Plate 1
NOTE:
rear footpegs.
4 149
CYCLING
CHAS
REAR FOOTBOARDS UNIT

INSTALLATION

52A43
LS
2
8
52A43
2 22 N m - 2.24 Kgf•m
R.
T.
4
6 LS
5
3

52A43

11 52A43

Rear Footboards Unit Installation
NOTE:
1 Right Footboard Holder Plate 1
2 Screw 2
52A43
3 Small Plate 1
4 Right Rear Footpeg 1
5 LS
Spring 1
6 Ball 1
7 LS
Pin 1
8 Seeger 1
9 Right Footpeg Rubber Cover 1
10 Right Footpeg Rubber Stop 1
52A43
NOTE:
rear brake callipers.
4 150
CYCLING
CHAS
TRESTLE REMOVAL
10
11
4 3
5
7
6
2

Trestle Removal
1 Inside Spring 1
2 External Spring 1
3 Nut 1
4 Special Screw 1
5 Washer 1
6 Side Trestle 1
7 Washer 1
8 Screw 2
9 Side Trestle Sensor 1 Disconnect connector.
10 Screw 2
11 Plate 1
4 151
CYCLING
CHAS
TRESTLE INSTALLATION

52A43
45 N m - 4.58 Kgf•m
R.
T.
52
A4
3
4
1
52
A4
3
8 N m - 0.81 Kgf•m
R.
T.
LS
8 9
7
22 N m - 2.24 Kgf•m
R.
5
T.

52A43

10
6
11

Trestle Installation
1 Plate 1
2 Screw 2
52A43
3 Side Trestle Sensor 1 Connect connector.

4 Screw 2
52A43
5 Washer 1
6 Side Trestle 1
7 Washer 1
8 LS
Special Screw 1
9 Nut 1
10 External Spring 1
11 Inside Spring 1
4 152
CYCLING
CHAS
CHAIN SLIDES REMOVAL
4
3
5 1
3 4
7 6
7 6

Chain Slides Removal
1 Screw 1
2 Lower Chain Slide 1
3 Screw 2
4 Welnut 2
5 Chain Slide 1
6 Screw 2
7 Welnut 2
8 Chain Slide 1
NOTE:
To remove the upper chain slide see paragraph
"4.97".
4 153
CYCLING
CHAS
CHAIN SLIDES INSTALLATION
5
6
52A
4 8
43
6 5

52A43
2 3
2 3

Chain Slides Installation
1 Chain Slide 1
2 Welnut 2
3 Screw 2
4 Chain Slide 1
5 Welnut 2
6 Screw 2
7 Lower Chain Slide 1
8 Screw 1
52A43
NOTE:
To install the upper chain slide see paragraph
"4.105".
4 154
DRAIN PLANT
CHAS
DRAIN UNIT REMOVAL
7 6 5 4
8
7 8
6
4
5
1
12
2
11
20 25
18 16 21 25
17 25
13
9 19 15 24
24
24
10 10
10
14 23
22

Number Plate Bracket Removal See paragraph "4.128".
Heat Seal Lid Removal See paragraph "4.136".
Lock Removal See paragraph "4.136".
Disconnect Lambda Probe Connector See "ELECTRIC PLANT 7.13" paragraph.
Disconnect Drain Valve Cable See paragraph "4.157".
Drain Unit Removal
1 Screw 2
2 Spring 1
3 Silencing Device 1
4 Bush 2
5 Silencing Device Articulated Connecting Rod 2
6 Rubber Pad 2
7 Bush 2
9 Screw 1
10 Nut 6
11 Screw 2
12 Thermal Protection 1
13 Screw 2
14 Catalyst Thermal Protection 1
15 Spring 1
16 Nut 1
4 155
DRAIN PLANT
CHAS
DRAIN UNIT REMOVAL
7 6 5 4
8
7 8
6
4
5
1
12
2
11
20 25
18 16 21 25
17 25
13
9 19 15 24
24
24
10 10
10
14 23
22
17 Bush 2
18 Rubber Pad 1
19 Drain Collector Articulated Connecting Rod 1
20 Bush 1
21 Drain Collector Fitting 1
22 Spring 1
23 Three-In-One Drain Collector 1
24 Drain Collector 3
25 Drain Gasket 3
4 156
DRAIN PLANT
CHAS
DRAIN COLLECTOR DECOMPOSITION
12 N m - 1.22 Kgf•m
R.
T.
7
7
1
8
10 3 2
6
4 5

Drain Collector Decomposition
1 Elastic Ring 1
2 Drain Valve Cap 1
3 Spring 1
4 Nut 1
5 Drain Valve Flange 1
6 Washer 1
Spread the wings of plate n. 8 to free the heads of
screws n. 7.
7 Screw 2
8 Plate 1
9 Drain Valve 1
10 Drain Valve Shaft 1
NOTE:
operations.
ATTENTION:
To install, after having installed screws n. 7,
tighten the wings of plate n. 8 on the hexagonal
sides of the screws.
Manually fasten nut n. 4.
4 157
DRAIN PLANT
CHAS
DRAIN UNIT INSTALLATION
25
20 21
22
18
19
20 19 18
22
21
25
23
8 N m - 0.81 Kgf•m
R.
T.
16
24
17 10 N m - 1.01 Kgf•m 1
R.
1
T.
LS
1 NEW
6
8 12 2
9 11 2 GR
15 7 2
10 13 3 3
3
4
15 N m - 1.52 Kgf•m
R.
5
T.
10 N m - 1.01 Kgf•m
R.
T.
14

Drain Unit Installation
1 NEW
Drain Gasket 3
2 Drain Collector 3
3 Nut 6
4 Drain Collector 1
5 GR
Spring 1
6 Bush 1
7 Drain Collector Articulated Connecting Rod 1
8 Rubber Pad 1
9 Bush 1
11 Drain Collector Fitting 1
12 Nut 1
13 Spring 1
14 LS
Three-In-One Thermal Protection 1
15 Screw 2
16 Thermal Protection 1
17 Screw 2
19 Bush 2
20 Rubber Pad 2
21 Silencing Device Articulated Connecting Rod 2
22 Bush 2
23 Silencing Device 1
24 Spring 1
4 158
5 ENG
ENG
CHAPTER 5
ENGINE
HEAD DISTRIBUTION............................................................................................... 1
DISTRIBUTION LID REMOVAL.......................................................................................................... 1
GASKETS CONTROL............................................................................................................................ 2
DISTRIBUTION LID INSTALLATION................................................................................................ 3
DISTRIBUTION CHAIN TENSIONER REMOVAL........................................................................... 5
DISTRIBUTION CHAIN TENSIONER CONTROL........................................................................... 6
DISTRIBUTION CHAIN TENSIONER INSTALLATION................................................................. 7
INLET CAM SHAFT REMOVAL......................................................................................................... 8
DRAIN CAM SHAFT REMOVAL....................................................................................................... 10
CAM SHAFTS CONTROL................................................................................................................... 11
DRAIN CAM SHAFT INSTALLATION............................................................................................. 13
INLET CAM SHAFT INSTALLATION............................................................................................... 14
CHAIN SLIDES REMOVAL................................................................................................................. 15
CHAIN SLIDES CONTROL................................................................................................................. 16
CHAIN SLIDES INSTALLATION....................................................................................................... 17
PHONIC WHEEL REMOVAL............................................................................................................. 18
PHONIC WHEEL CONTROL............................................................................................................. 19
PHONIC WHEEL INSTALLATION.................................................................................................... 20
DISTRIBUTION CHAIN REMOVAL.................................................................................................. 21
DISTRIBUTION CHAIN CONTROL.................................................................................................. 23
DISTRIBUTION CHAIN INSTALLATION........................................................................................ 24
DISTRIBUTION CHAIN INSTALLATION AND ENGINE PHASING.......................................... 25
VALVES CLEARANCE ADJUSTMENT............................................................................................. 28
VALVES CLEARANCE CONTROL AND ADJUSTMENT............................................................. 29
VALVES LIFTERS AND CALIBRATED PADS REMOVAL............................................................ 30
VALVES LIFTERS CONTROL............................................................................................................. 32
VALVES LIFTERS AND CALIBRATED PADS INSTALLATION.................................................. 33
HEAD REMOVAL................................................................................................................................. 34
VALVES AND VALVES SPRINGS REMOVAL................................................................................ 36
VALVES AND RELATIVE GUIDES CONTROL............................................................................... 38
VALVES SEATS CONTROL................................................................................................................ 41
INTERNAL AND EXTERNAL VALVES SPRINGS CONTROL...................................................... 43
VALVES AND VALVES SPRINGS INSTALLATION....................................................................... 44
HEAD INSTALLATION........................................................................................................................ 48
CYLINDERS............................................................................................................. 51
CYLINDERS REMOVAL...................................................................................................................... 51
CYLINDERS CONTROL..................................................................................................................... . 53
CYLINDERS INSTALLATION............................................................................................................. 54
ENG
PISTONS.................................................................................................................. 58
PISTONS REMOVAL............................................................................................................................ 58
PISTONS CONTROL............................................................................................................................ 60
ELASTIC BANDS CONTROL.............................................................................................................. 61
PINS CONTROL.................................................................................................................................... 62
PISTONS INSTALLATION.................................................................................................................. 63
CLUTCH................................................................................................................... 69
CLUTCH LID REMOVAL.................................................................................................................... 69
CLUTCH LID INSTALLATION........................................................................................................... 70
CLUTCH REMOVAL............................................................................................................................ 71
FRICTION DISKS CONTROL............................................................................................................. 75
STEEL DISKS CONTROL..................................................................................................................... 76
COMPRESSION SPRINGS CONTROL............................................................................................. 77
CLUTCH BELL CONTROL.................................................................................................................. 78
CLUTCH DRUM INSPECTION.......................................................................................................... 79
CLUTCH PRESSURE PLATE CONTROL......................................................................................... 80
CLUTCH PRESSURE PLATE PIN CONTROL................................................................................. 81
CLUTCH INSTALLATION.................................................................................................................. 82
CLUTCH DISKS ADJUSTMENT....................................................................................................... 87
CLUTCH COMMAND REMOVAL................................................................................................... 88
CLUTCH COMMAND CONTROL................................................................................................... 89
CLUTCH COMMAND INSTALLATION.......................................................................................... 90
GEAR CHANGE....................................................................................................... 91
GEAR CHANGE REMOVAL.............................................................................................................. 91
PRIMARY AND SECONDARY SHAFT GEARS REMOVAL........................................................ 97
GEARS CONTROL.............................................................................................................................. 99
GEAR CHANGE FLANGE BEARINGS CONTROL........................................................................ 100
GEARS COMMAND FORKS CONTROL........................................................................................ 101
DESMODROMIC SHAFT CONTROL.............................................................................................. 103
PRIMARY AND SECONDARY SHAFT GEARS INSTALLATION.............................................. 104
GEAR CHANGE INSTALLATION..................................................................................................... 106
ENG
LUBRICATION PLANT.......................................................................................... 113

OIL TANK AND INLET FILTER REMOVAL................................................................................. 113
OIL TANK AND INLET FILTER CONTROL................................................................................. 114
OIL TANK AND INLET FILTER INSTALLATION....................................................................... 115
OIL PUMP REMOVAL..................................................................................................................... 116
OIL PUMP CONTROL..................................................................................................................... 117
OIL PUMP INSTALLATION........................................................................................................... 118
OVER PRESSURE VALVE REMOVAL.......................................................................................... 119
OVERPRESSURE VALVE CONTROL........................................................................................... 120
OVERPRESSURE VALVE INSTALLATION................................................................................. 121
START-UP............................................................................................................. 122
ALTERNATOR REMOVAL.............................................................................................................. 122
ALTERNATOR CONTROL............................................................................................................... 123
ALTERNATOR INSTALLATION..................................................................................................... 124
START-UP MOTOR REMOVAL..................................................................................................... 125
START-UP MOTOR CONTROL..................................................................................................... 126
START-UP MOTOR INSTALLATION........................................................................................... 127
Z25 GEAR/SPLINED SHAFT, FEMALE COLLAR JOINT REMOVAL ................................... 128
Z25 GEAR/SPLINED SHAFT, FEMALE COLLAR JOINT CONTROL ................................... 129
Z25 GEAR/SPLINED SHAFT, FEMALE COLLAR JOINT INSTALLATION........................... 130
SATELLITE GEAR AND FREE WHEEL REMOVAL..................................................................... 131
SATELLITE GEAR AND FREE WHEEL CONTROL..................................................................... 132
SATELLITE GEAR AND FREE WHEEL INSTALLATION........................................................... 133
HANDLING BASE.................................................................................................. 134

LOWER BASE REMOVAL................................................................................................................ 134
LOWER BASE CONTROL................................................................................................................ 137
LOWER BASE INSTALLATION....................................................................................................... 151
ENG
HANDLING............................................................................................................ 138
BENCH HALF-BEARINGS, ENGINE SHAFT AND BALANCING COUNTER-SHAFT
REMOVAL........................................................................................................................................... 138
CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS REMOVAL............... 140
ENGINE SHAFT AND BALANCING COUNTER-SHAFT CONTROL................... 141
CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS CONTROL................ 142
CONNECTING ROD HALF-BEARINGS AND CONNECTING RODS INSTALLATION...... 143
BALANCING COUNTER-SHAFT, ENGINE SHAFT AND BENCH HALF-BEARINGS
INSTALLATION................................................................................................................................. 146
POWER SUPPLY.................................................................................................... 154

THROTTLED BODY REMOVAL.............................................................................. 154
THROTTLED BODY ADJUSTMENT....................................................................... 155
THROTTLED BODY INSTALLATION..................................................................... 156
ENG
HEAD DISTRIBUTION
ENG
DISTRIBUTION LID REMOVAL
9
15
16
10
11 1
3 2
4
5
12
6
14
14
13 14

Distribution Lid Removal
1 Nut 3
2 Bracket 3
3 Rubber Pad 3
4 Washer 3
5 Special Screw 3
6 Rubber Pad 3
7 Reel 3
8 Spark Plug 3 Champion RG4HC - NGK CR9E
9 Rubber Pad 3
10 Special Screw 5
11 Rubber Pad 5
12 Distribution Lid 1
13 Lid Gasket 1
14 O-Ring Gasket 3
15 Quick Fitting 1
16 Seal Ring 1
5 1
HEAD DISTRIBUTION
ENG
C C
GASKETS CONTROL
1 C
Check:
• the lid gasket A
• the O-Ring gaskets B
• the rubber pad C
In the presence of damages/wear Replace
B the faulty parts.
A
1
5 2
HEAD DISTRIBUTION
ENG
DISTRIBUTION LID INSTALLATION
YVO
RI S
IL A
C
8
GR
52A70
7 12 N m - 1.22 Kgf•m
R.
T.
STRONG THREAD BREAKS
6
16 15 N m - 1.52 Kgf•m
R.
T.
52A70
15 NEW
10 N m - 1.01 Kgf•m 5
R.
T.
NEW 4 14 8 N m - 0.81 Kgf•m
R.
T.
12 13
11
10 10 N m - 1.01 Kgf•m
R.
T.
3
9 NEW
2
2
LS
1 2
C
LA
I SI
OR
YV
5 3
HEAD DISTRIBUTION
ENG
DISTRIBUTION LID INSTALLATION

Distribution Lid Installation
1 YVORI SIL AC
Lid Gasket 1 NOTE:
The Yvori Sil Ac sealing paste must only be
applied on the highlighted surface, as shown
in the figure.
2 LS
O-Ring Gasket 3
3 Distribution Lid 1
4 NEW
Rubber Pad 5
5 Special Screw 5
6 Rubber Pad 3
7 GR
Spark Plug 3 Champion RG4HC - NGK CR9E
NOTE:
NEW
Do not exceed with the Copper Grease.
8 YVORI SIL AC
Reel 3
9 NEW
Rubber Pad 3
10 Special Screw 3
11 Washer 3
12 Rubber Pad 3
13 Bracket 3
14 Nut 3
15 NEW
Seal Ring 1
16 Quick Fitting 1
52A70
5 4
HEAD DISTRIBUTION
ENG
DISTRIBUTION CHAIN TENSIONER REMOVAL
5
1
2
3

Operations to be carried out with the engine in
Distribution Chain Tensioner Removal PMS.
1 Screw 1
2 Seal Ring 1
3 Spring 1
4 Screw 2
5 Chain Tensioner 1
6 O-Ring Gasket 1
5 5
HEAD DISTRIBUTION
ENG
DISTRIBUTION CHAIN TENSIONER

CONTROL
1 Check:
• the chain tensioner A
B • the spring B
C • the seal ring C
A
1
5 6
HEAD DISTRIBUTION
ENG
DISTRIBUTION CHAIN TENSIONER

INSTALLATION
A B
10 N m - 1.01 Kgf•m 3
R.
T.
2
6
5
4
LS
3 NEW 1
10 N m - 1.01 Kgf•m
R.
T.

Distribution Chain Tensioner Installation
NOTE:
Bring the tensioner from position A to position
B before installing it on the head.
1 LS NEW
O-Ring Gasket 1
2 Chain Tensioner 1
3 Screw 2
4 Spring 1
5 Seal Ring 1
6 Screw 1
5 7
HEAD DISTRIBUTION
ENG
INLET CAM SHAFT REMOVAL
2
7
7 9 8
1
9 8 INLET
9 8
4 24 DRAIN
3
4

Distribution Lid Removal See paragraph "5.1"
Distribution Chain Tensioner Removal See paragraph "5.5"
Inlet Cam Shaft Removal
1 Screw 4
3 Central Headgear 1 NOTE:
During removal the reference plugs may still be
attached to the cam shafts lids.
4 Reference Plug 2
5 Screw 2
Operations to be carried out with the engine in PMS.
Slightly rotate the inlet cams clockwise using a 24
spanner, loosening the distribution chain.
6 Small Plate 1
7 Screw 6
8 Inlet Side Cam Shaft Headgear 3 NOTE:
9 Reference Plug 6
5 8
HEAD DISTRIBUTION
ENG
INLET CAM SHAFT REMOVAL
INLET 11
DRAIN
10

10 Inlet Z34 Gear 1
11 Inlet Distribution Shaft 1
5 9
HEAD DISTRIBUTION
ENG
DRAIN CAM SHAFT REMOVAL
DRAIN
4 5
4
5 6
7
5
6

Distribution Lid Removal See paragraph “5.1”.
Distribution Chain Tensioner Removal See paragraph “5.5”.
Inlet Cam Shaft Removal See paragraph “5.8”.
Drain Cam Shaft Removal
1 Screw 2
2 Small Plate 1
3 Drain Z34 Gear 1
NOTE:
Fasten the distribution chain with a wire to
avoid it falling in the base.
4 Screw 6
5 Drain Side Cam Shaft Headgear 3 NOTE:
6 Reference Plug 6
7 Drain Distribution Shaft 1
5 10
HEAD DISTRIBUTION
ENG
CAM SHAFTS CONTROL

1 Check:
• the cam shaft lobes
In the presence of blue fading/pittings/scratches
Replace the cam shaft.
2 Measure:
A • the sizes of the cam shaft lobes A and B
If out of specification Replace the cam shaft.
Size limit of the cam shaft lobes
Inlet side cam shaft

A <Limit>: 35.3 mm (1.38 in)
B <Limit>: 27.85 mm (2.77 cm)
B Drain side cam shaft
A <Limit>: 35.3 mm (1.38 in)

B <Limit>: 27.85 mm (2.77 cm)
3 Measure:
• the cam shaft eccentricity
If out of specification Replace the cam shaft.
80
70
90
Eccentricity limit of the cam shaft

60
0
50
0.01m
m 0-3
10
0mm
0.04 mm (0.001 in)

40
20
30
5 11
HEAD DISTRIBUTION
ENG
4 Measure:
• the clearance between cam shaft support and cam
shaft lid
If out of specification Measure the diameter of
the cam shaft support.
Clearance between cam shaft

support and cap
<Limit>: 0.1 mm (0.076 mm)
5 Measure:
• the diameter of the cam shaft support C
C If out of specification Replace the cam shaft.
If within specification Replace the cam shaft
head and lids.
Cam shaft supports diameter

22.459 ~ 22.472 mm
(0.8842 ~ 0.8847 in)
5 12
HEAD DISTRIBUTION
ENG
DRAIN CAM SHAFT INSTALLATION
6 + 13 N m - 0.61 +1.32 Kgf•m 7
R.
T.
GR
7 6 DRAIN
7
6 5
4
6
5
15 N m - 1.52 Kgf•m
R.
T.
24
GA
3
3
A4
52
NEW

52A43

Drain Cam Shaft Installation
1 Drain Z34 Gear 2
2 Small Plate 1
3 Screw 2 NOTE:
52A43
NEW
We recommend removing all grease from

threads for the plate fixing screws.
4 GA
Drain Distribution Shaft 1 Slightly rotate the drain cams anti-clockwise using
a 24 spanner, completely hooking the distribution
chain on the gear.
5 Reference Plug 6
6 Drain Side Cam Shaft Headgear 3
7 GR
Screw 6
5 13
HEAD DISTRIBUTION
ENG
INLET CAM SHAFT INSTALLATION
9 6 + 13 N m - 0.61 + 1.32 Kgf•m
R.
T.
GR 12
8 6 + 13 N m - 0.61 + 1.32 Kgf•m
R.
T.
GR
12
6 + 13 N m - 0.61 + 1.32 Kgf•m

12
7 11
R.
10
T.
GR 10 11 INLET
10
5 11
24
4
6
5
S DRAIN
3
1
3

A4
52A43
52
NEW MEDIUM THREAD BRAKES
15 N m - 1.52 Kgf•m
R.
T.

Inlet Cam Shaft Installation
1 Screw 2 NOTE:
52A43
NEW
We recommend removing all grease from

threads for the plate fixing screws.
2 Small Plate 1
3 Inlet Z34 Gear 1
4 S
Inlet Distribution Shaft 1
5 Reference Plug 2
6 Central Headgear 1
7 GR
Screw 2
9 GR
Screw 2
10 Reference Plug 6
11 Inlet Side Cam Shaft Headgear 3
12 GR
Screw 6
Slightly rotate the inlet cams anti-clockwise using
a 24 spanner, completely hooking the distribution
chain on the gear.
5 14
HEAD DISTRIBUTION
ENG
CHAIN SLIDES REMOVAL

Distribution Chain Tensioner Removal See paragraph "5.5"
Inlet Cam Shaft Removal See paragraph "5.8"
Drain Cam Shaft Removal See paragraph “5.10”
Chain Slides Removal
1 Mobile Chain Slide Pin 1
2 Mobile Slide 1
3 Fixed Slide 1
NOTE:
Always replace the chain slides together with
the distribution chain.
5 15
HEAD DISTRIBUTION
ENG
CHAIN SLIDES CONTROL

C
1 Check:
• the contact surface of the fixed slide A
B • the contact surface of the mobile slide B
• the contact surface of the upper chain slide C
A In the presence of damages/wear Replace
the faulty parts.
5 16
HEAD DISTRIBUTION
ENG
CHAIN SLIDES INSTALLATION
2
GR
12 N m - 1.22 Kgf•m
R.
T.

Chain Slides Installation
1 Mobile Slide 1
2 GR
Mobile Chain Slide Pin 1
3 Fixed Slide 1
5 17
HEAD DISTRIBUTION
ENG
PHONIC WHEEL REMOVAL
PM
S
2 3
1 4

Clutch Lid Removal See paragraph "5.69"
Phonic Wheel Removal
1 Screw 1
2 Nut 1
3 Washer 1
4 Phonic Wheel 1 NOTE:
Lock the phonic wheel using the appropriate
tool.
Special Tools: PHONIC WHEEL REMOVAL

Code: R300097083000
5 18
HEAD DISTRIBUTION
ENG
PHONIC WHEEL CONTROL

S T
1 Check:
PM • the gear of the phonic wheel A
I
In the presence of damages/cracks/wear
Replace the faulty parts.
A 1
5 19
HEAD DISTRIBUTION
ENG
PHONIC WHEEL INSTALLATION
PM
S
2
LO
45 N m - 4.58 Kgf•m
CT
8
1
R.
T.
A4
3
ITE

56A48
HIGH TEMPERATURE

Phonic Wheel Installation
1 Phonic Wheel 1 NOTE:
Lock the phonic wheel using the appropriate
tool.
2 Washer 1
3 Nut 1
4 Screw 1
56A48
Special Tools: PHONIC WHEEL REMOVAL

Code: R300097083000
5 20
HEAD DISTRIBUTION
ENG
DISTRIBUTION CHAIN REMOVAL

Distribution Lid Removal See paragraph "5.1".
Clutch Lid Removal See paragraph "5.69".
Upper Chain Slide Removal See paragraph "5.8".
Distribution Chain Tensioner Removal See paragraph "5.5".
Phonic Wheel Removal See paragraph “5.18”.
Fixed Chain Slide Removal See paragraph “5.15”.
Inlet Z34 Gear Removal See paragraph "5.8".
Drain Z34 Gear Removal See paragraph “5.10”.
Distribution Chain Removal
1 Distribution Chain 1 NOTE:
Remove the chain from the engine.
5 21
HEAD DISTRIBUTION
ENG
DISTRIBUTION CHAIN REMOVAL
F
E
24
B
A
1 Remove: NOTE:
• the screws A To remove the screws A rotate the inlet cam
• the small plates B clockwise using a 24 spanner.
• the Inlet Z34 gear C
• the Drain Z34 gear D
• the fixed slide E
• the distribution chain F
5 22
HEAD DISTRIBUTION
ENG
DISTRIBUTION CHAIN CONTROL
The following procedure is applied to all cogwheels of

the cam shafts and to all distribution chain guides.
1 Check:
• the distribution chain A
In the presence of damages/no flexibility/locked links
Replace the distribution chain together with
the cam shaft gears.
NOTE:
However, the distribution chain must be replaced
when it exceeds 40.000 km.
A
1
5 23
HEAD DISTRIBUTION
ENG
DISTRIBUTION CHAIN INSTALLATION
1 E
PM
S

Distribution Chain Installation
1 E
Distribution Chain 1
5 24
HEAD DISTRIBUTION
ENG
DISTRIBUTION CHAIN INSTALLA-

TION AND ENGINE PHASING
B
ATTENTION
Carefully follow the instructions given in the
various assembly phases.
1 Install:
E
• the fixed slide B
A NOTE:
N
L
Lubricate the chain using engine oil.
E ENGINE OIL
2 Position:
E on the engine shaft gear.
• the phonic wheel C
D
NOTE:
N
R
Rotate the phonic wheel clockwise by acting on the
nut, bringing the PMS D aligned with the carter
reference E .
ATTENTION
This operation must be carried out with the
distribution chain tensioned.
PMS
C
A
2
5 25
HEAD DISTRIBUTION
ENG
3 Rotate:
• the drain and inlet cam shaft
in phase anti-clockwise using a 24 spanner, bringing
the olives in cylinder 1, facing each other.
24 24
NOTE:
Engine phasing tolerance: 3°.
24
G b
NEW
NEW
PMS
a
4
4 Install: • the Z34 gear G (see paragraph “5.14”).

• the Z34 gear F (see paragraph “5.13”). on the inlet shaft hooking the chain on to the already
Partially rotate the cam anti-clockwise using a 24 positioned gear as shown in figure b ; therefore
spanner in order to hook and tension the rotate the inlet cam reaching the stop point and
distribution chain, positioning the reference as relative insertion in the seat.
shown in figure a .
5 26
HEAD DISTRIBUTION
ENG
5 Install:
I • the chain tensioner H
• the upper chain slide I
H
NOTE:
N
R
Rotate the cam shafts using a spanner performing
a full turn and bringing the engine in PMS.
5 27
HEAD DISTRIBUTION
ENG
VALVES CLEARANCE ADJUSTMENT

Valves Clearance Adjustment
5 28
HEAD DISTRIBUTION
ENG
VALVES CLEARANCE CONTROL AND

ADJUSTMENT
1 Measure:
• the clearance between cams and cup
using a feeler A .
Position the cam as shown in the figure.
A If out of specification Replace the pad.
NOTE:
Measurement must be carried out on all shafts and
cups.
Clearance between cup and shafts
Inlet
0.28 ~ 0.32 mm (0.028 ~ 0.032 in)
Drain
0.34 ~ 0.38 mm (0.034 ~ 0.038 in)
1
5 29
HEAD DISTRIBUTION
ENG
VALVES LIFTERS AND CALIBRATED

PADS REMOVAL
INLET
DRAIN
1
2
3
4

Inlet Cam Shaft Removal See paragraph "5.8".
Drain Cam Shaft Removal See paragraph “5.10”.
Valves Lifters And Calibrated Pads Removal
1 Inlet Valve Lifter 6
2 Inlet Valve Calibrated Pad 6
3 Drain Valve Lifter 6
4 Drain Valve Calibrated Pad 6
5 30
HEAD DISTRIBUTION
ENG

PADS REMOVAL
The following procedure is applied to all valve lifters
and calibrated pads.
NOTE:
N
Before removing the internal parts of the head (for
example: valves, valves springs, valves seats),
check that the valves are adequately sealed.
1 Remove:
• the valves lifters A
1 2 3 • the calibrated pad B
DRAIN NOTE:
Take note of the position of each valve lifter and of
each pad in order to be able to re-assemble them in
INLET the correct position.
A
B 1
5 31
HEAD DISTRIBUTION
ENG
VALVES LIFTERS CONTROL

The following procedure is applied to all valves lifters.
1 Check:
A • the valves lifters A
In the presence of damages/scratches Replace
the valves lifters.
5 32
HEAD DISTRIBUTION
ENG

PADS INSTALLATION
INLET
DRAIN
2 GR
1
4 GR

Valves Lifters And Calibrated Pads Installation
1 Inlet Valve Calibrated Pad 6
2 GR
Inlet Valve Lifter 6
3 Drain Valve Calibrated Pad 6
4 GR
6
NOTE:
Always check the valves clearance.
5 33
HEAD DISTRIBUTION
ENG
HEAD REMOVAL
1 2
1 1
2 2
1
1 2 2
1
2
1 7
2
1
2
5
9
3
5 34
HEAD DISTRIBUTION
ENG
HEAD REMOVAL

Engine Removal See "FRAME 4.107" paragraph.
Drain Cam Shaft Removal See paragraph "5.10".
Chain Slides Removal See paragraph "5.15".
Phonic Wheel Removal See paragraph "5.18".
Distribution Chain Removal See paragraph "5.21".
Head Removal
1 Nut 8 NOTE:
Loosen each nut by ½ a turn at a time. After
having completely loosened all nuts, remove
them.
2 Washer 8
3 Screw 2
4 Special Screw 1
5 Seal Washer 2
6 Tube 1
7 Head 1
8 Head Gasket 1
9 Reference Plug 2
5 35
HEAD DISTRIBUTION
ENG
VALVES AND VALVES SPRINGS REMOVAL
1 1
2
4
8 8
9
6
7 10
11
13
14
5
12 DRAIN
INLET
5 36
HEAD DISTRIBUTION
ENG
VALVES AND VALVES SPRINGS REMOVAL

Valves Lifters And Calibrated Pads Removal See paragraph "5.30".
Head Removal See paragraph "5.34".
Valves And Valves Springs Removal
1 Inlet Valve Split Pin 12
2 Inlet Valve Upper Spring Plate 6
3 Inlet Valve Internal Spring 6
4 Inlet Valve External Spring 6
5 Inlet Valve 6
6 Inlet Valve Oil Retainer 6 NOTE:
7 Inlet Valve Lower Spring Plate 6 Carefully identify the position of each part in
8 Drain Valve Split Pin 12 order to be able to re-assemble it correctly.
9 Drain Valve Upper Spring Plate 6
10 Drain Valve Internal Spring 6
11 Drain Valve External Spring 6
12 Drain Valve 6
13 Drain Valve Oil Retainer 6
14 Drain Valve Lower Spring Plate 6
NOTE:
The valves removal initial procedure is
irrelevant.
5 37
HEAD DISTRIBUTION
ENG
VALVES AND RELATIVE GUIDES

CONTROL
A The following procedure is applied to all valves and
valves guides.
1 Check:
• the valves seal
In the presence of leaks of the valves seats
Check the contact surface, the seat and the width of
the valve seat.
B 1 See paragraph "5.41".
a Pour clean solvent A inside the inlet doors.
b Check that the valves are adequately sealed.
NOTE:
There must be no leaks from the valve seat B .
2 Measure:
• the clearance between stem and valve guide
70
80
60
Clearance between stem and valve guide =

90
50
0.0
0
1m
C valve guide internal diameter

m
0-3
0m
40
m
10
30
20
- D valve stem diameter
C If out of specification Replace the valve guide.
Clearance between valve stem

and valve guide
Inlet
0.0010 ~ 0.0037 mm
(0.000039 ~ 0.00014 in)
D
Drain
0.025 ~ 0.052 mm
(0.00098 ~ 0.0020 in)
5 38
HEAD DISTRIBUTION
ENG
3 Replace:
• the valve guide
NOTE:
To facilitate the removal and installation of the
valve guide operations and to maintain assembly
correct, heat the head in an oven bringing it to
E 100° C (212° F).
a Remove the valve guide using an appropriate

extractor E .
b Install the new valve guide using an appropriate
installer F and extractor E .
c After having installed the valve guide, bore it using
a borer G to obtain the correct clearance
between the stem and valve guide.
F NOTE:
After having re-assembled the valve guide, trim
the seat.
4 EEliminate:
• the carbonaceous deposits H
(from the contact surface and from the valve seat)
5 C
Check:
J • the contact surface of the valve I
In the presence of pittings/wear Rectify the
contact surface of the valve.
• the end of the valve stem J
In the presence of a template or diameter of the head
greater than the body of the valve stem
Replace the valve.
I
5 39
HEAD DISTRIBUTION
ENG
6 Measure:
• the eccentricity of the valve stem
If out of specification Replace the valve.
NOTE:
N
• If a new valve is installed, always replace the
relative guide.
• If the valve is disconnected or re-assembled,
always replace the oil retainer.
Valve stem eccentricity

6
0.015 mm (0.0005 in)
5 40
HEAD DISTRIBUTION
ENG
VALVES SEATS CONTROL

The following procedure is applied to all valves and
valves seats.
1 Eliminate:
• the carbonaceous deposits
(from the contact surface and from the valve seat A )
2 Check:
• the valve seat A
In the presence of pittings/wear Replace the
head.
3 Measure:
• the width of the valve seat A
If out of specification Replace the head.
B
Valve seat width
A A
Inlet
0.9 ~ 1.1 mm (0.035 ~ 0.043 in)
3 Drain
0.9 ~ 1.1 mm (0.035 ~ 0.043 in)
a Apply some blue colouring (Dykem) for mechanics

B on the contact surface of the valve.
b Install the valve in the head.
c Push the valve inside the guide and against its seat
to leave a well-defined impression.
d Measure the width of the valve seat.
NOTE:
Where the valve seat and the valve face touch each
other, the Prussian blue will result removed.
5 41
HEAD DISTRIBUTION
ENG
4 Lap:
Lappa
• the contact surface of the valve
• the valve seat
NOTE:
After having replaced the head or the valve and the
relative guide, the seat and the contact surface of
C the valve must be lapped.
a Apply a rough lapping paste C on the contact

surface of the valve.
4
ATTENTION
Avoid the lapping paste penetrating in the space
between the valve stem and the guide.
b Apply molybdenum disulphide oil on the valve
stem.
c Install the valve in the head.
d Rotate the valve until the contact surface and its
seat are evenly polished, then remove all lapping
paste.
NOTA:
To obtain the best lapping results, slightly spot the
valve seat whilst manually rotating it forwards and
backwards. Figure 5
e Apply a thin lapping paste on the surface contact

of the valve and repeat the above procedure.
f After every lapping operation, it is important to

5 remove every trace of lapping paste from the
contact surface and from the valve seat.
g Apply blue colouring (Dykem) for mechanics on
the contact surface of the valve.
h Install the valve in the head.

i Push the valve inside the guide and against its seat
to leave a well-defined impression.
5 42
HEAD DISTRIBUTION
ENG
INTERNAL AND EXTERNAL VALVES

SPRINGS CONTROL
The following procedure is applied to all valves
springs.
1 Measure:
• the free length of the valves springs A
If out of specification Replace the valve spring.
A 1
Valves springs free length
External spring
inlet: 38.5 mm (1.515 in)
drain: 36 mm (1.417 in)
Inside spring
inlet: 35 mm (1.377 in)
drain: 33 mm (1.299 in)
2 Measure:
• the force of the compressed valve spring B
C
C Installed length
B Force of the compressed

valve spring (installed)
External valve spring
2 186 N m (18.96 Kgf•m)
a 32.8 mm (1.29 in)
Drain valve spring
32.5 N m (3.31 Kgf•m)
a 30.8 mm (1.21 in)
3 Measure:
• the inclination of the valves springs D
D
Spring inclination limit

Inlet valve spring
1.7 mm (0.06 in)
Drain valve spring
1.7 mm (0.06 in)
3
5 43
HEAD DISTRIBUTION
ENG
VALVES AND VALVES SPRINGS INSTALLATION
7 7
6
E
4
14 14
E
13
2
E
1 12
11
9
8
3
E
10 DRAIN
INLET
5 44
HEAD DISTRIBUTION
ENG

Valves And Valves Springs Installation
1 Inlet Valve Lower Spring Plate 6
2 E
Inlet Valve Oil Retainer 6
3 E
Inlet Valve 6
4 Inlet Valve External Spring 6
5 Inlet Valve Internal Spring 6
6 E
Inlet Valve Upper Spring Plate 6
7 Inlet Valve Split Pin 12
8 Drain Valve Lower Spring Plate 6
9 E
Drain Valve Oil Retainer 6
10 E
Drain Valve 6
11 Drain Valve External Spring 6
12 Drain Valve Internal Spring 6
13 E
Drain Valve Upper Spring Plate 6
14 Drain Valve Split Pin 12
5 45
HEAD DISTRIBUTION
ENG
F
E
D
E
B
A
a
c
1
1 Install in the head: NOTE:

N
• the valve lower spring plate A L
Lubricate the valve stem and the valve oil retainer
• the valve oil retainer B (see figure a ) c .
• the valve C
• the external valve spring D Recommended lubricant
• the internal valve spring E E ENGINE OIL
• the upper spring plate F
NOTE:
Trim the end of the valve stem using a stone to Special Tools: BUFFER FOR VALVES OIL RETAINER
thinly sharpen (see figure b ). Code: R180197025000
NOTE:
Ensure that every valve has been re-assembled in
its original position.
5 46
HEAD DISTRIBUTION
ENG
2 Install:
• the valve pins G
NOTE:
N
R
Re-assemble the valves' pins by compressing the
H spring of each valve using the appropriate
compression tool H .
3 Fix:
• the pins on to the valves stems
Delicately hit the point of the valve using a soft
hammer.
ATTENTION
Hitting the point of the valve with excessive force
may damage the same valve.
4 Install:
• the calibrated pad I
• the valves lifters J
J NOTE:
N
• Lubricate the valve lifter using copper grease
GR MOLYKOTE HSC PLUS.
I • By manually rotating the valve lifter, it must move
smoothly.
• Re-assemble each valve lifter and pad in the
original position.
4
This procedure is applied to all valves and relative
components.
GR
COPPER GREASE
5 47
HEAD DISTRIBUTION
ENG
HEAD INSTALLATION
9 8
56A48
9 9
STRONG THREAD BREAKS
8 8
9
9 8 8
9
8
9 3
GR 8
9
8
GR 4 NEW
0
A7
52
6
GR
15 N m - 1.52 Kgf•m
R.
T.
1
7
10 N m - 1.01 Kgf•m
R.
T.
NEW 2
5 48
HEAD DISTRIBUTION
ENG
HEAD INSTALLATION

Head Installation
1 Reference Plug 2
2 NEW
Head Gasket 1
3 Head 1
4 NEW
Seal Washer 2
5 Tube 1
6 Special Screw 1
52A70
7 GR
Screw 2
8 GR
Washer 8
9 GR
Nut 8
5 49
HEAD DISTRIBUTION
ENG
HEAD INSTALLATION
INLET
6 2 3 7
GR
5 1 4 8
DRAIN 1
1 Fasten the nuts (1 ~ 8) respecting the fastening sequence:

1st phase: 25 N m - 2.54 Kgf•m
2nd phase: 45 N m - 4.58 Kgf•m
3rd phase: 50° angle pair
4th phase: 50° angle pair
5th phase: fasten the screws A 10 N m - 1.01 Kgf•m
NOTE:
Using copper grease lubricate the threading of the head fixing nuts (1~8).
GR
COPPER GREASE
5 50
CYLINDERS
ENG
CYLINDERS REMOVAL
1
3
1
5 51
CYLINDERS
ENG
CYLINDERS REMOVAL

Cylinders Removal
1 Screw 2
2 Carter Cylinder 1
3 Carter Cylinder Gasket 1
4 Reference Plug 2
5 52
CYLINDERS
ENG
CYLINDERS CONTROL
The following procedure is applied to the entire
cylinder unit.
A 1 Check:
• the cylinder wall A
In the presence of vertical scratches Replace
the cylinder and the piston together with the relative
bands.
5 53
CYLINDERS
ENG
CYLINDERS INSTALLATION
4
2 NEW
4
GR
10 N m - 1.01 Kgf•m
R.
T.

Cylinders Installation
NOTE:
Apply engine oil on the bands and on the
pistons' wall before installing the carter
cylinder. Do not exceed with the engine oil.
1 Reference Plug 2
2 NEW
Carter Cylinder Gasket 1
3 E
Carter Cylinder 1
4 GR
Screw 2
5 54
CYLINDERS
ENG
CYLINDERS INSTALLATION
A NEW
1 Install:
• the cylinder gasket A
2 Apply:
• the thickness B in the central piston Special Tools: CYLINDER ASSEMBLY THICKNESSES
• the thickness C in the side piston Code: R180197018000
• the thickness D in the side piston
5 55
CYLINDERS
ENG
E E
3 4
3 Install: 4 Position:
• the 2 reference plugs E •the cylinder unit F
E ENGINE OIL
H
5
NOTE: 5 Sequentially remove:

By compressing the piston bands using one hand, • the thicknesses G , H and I .
with the other, install the cylinder set,
subsequently removing the thickness.
5 56
CYLINDERS
ENG
J GR
10 N m - 1.01 Kgf•m
R.
T.
6 Install:
• the two cylinder fixing screws J
ATTENTION
Completely fasten the cylinder fixing screws after having fixed the head.
GR
COPPER GREASE
5 57
PISTONS
ENG
PISTONS REMOVAL

Drain Cam Shaft Removal See paragraph “5.10”.
Chain Slides Removal See paragraph “5.15”.
Phonic Wheel Removal See paragraph “5.18”.
Distribution Chain Removal See paragraph “5.21”.
Head Removal See paragraph “5.34”.
Cylinders Removal See paragraph “5.51”.
Pistons Removal
1 Pistons 3
5 58
PISTONS
ENG
PISTONS REMOVAL
C I
1 2
B H D
A G
E
F 3
1 Remove: NOTE:
• the external elastic ring A Do not use hammers to remove the pins.
• the pin B
• the piston 1
• the internal elastic ring C
• the external elastic ring D

• the pin E
• the piston 3
• the internal elastic ring F
• the elastic ring G

• the pin H
• the piston 2
• the elastic ring I
5 59
PISTONS
ENG
PISTONS CONTROL
The following procedure is applied to all three pistons.
1 Check:
• the piston wall A
In the presence of vertical scratches Replace
the piston together with the relative bands and the
cylinder.
A
1
2 Measure:
P • the diameter of skirt of piston P using the
micrometer.
B
B 10.5 mm (0.413 in) from the lower edge of the piston.
CLASS P P
A 87.950 ~ 87.960
2
B 87.961 ~ 87.971
C 87.972 ~ 87.982
If out of specification Replace the piston and

the relative bands together.
ATTENTION
The piston is distinguished by a letter indicating
its class. The coupling cylinder piston must be
carried out between equal classes. Figure 3 .
5 60
PISTONI
ENG
ELASTIC BANDS CONTROL

The following procedure is applied to all elastic bands.
1 Check:
• there are no scratches and signs of forcing on
every band
If out of specification Replace the relative
bands and the pistons.
1
2 Measure:
• the side clearance between one piston band and
the other
If out of specification Replace the piston and
the relative bands together.
NOTE:
Before measuring the side clearance between the
piston bands, eliminate any carbonaceous deposits
from the piston bands and from the relative
grooves.
Side clearance between
2 the piston bands
Upper band
<Limit> : 0.20 mm (0.0078 in)
Second band
<Limit> : 0.18 mm (0.0070 in)
3 Measure:
• the upper band thickness
• the second band thickness
Elastic bands thicknesses
Upper band
0.97 ~ 0.99 mm
(0.0381 ~ 0.0389 in)
3 Second band
0.97 ~ 0.99 mm
(0.0381 ~ 0.0389 in)
5 61
PISTONS
ENG
PINS CONTROL
The following procedure is applied to all pins.
1 Check:
• the piston pin
In the presence of blue fading/grooves Replace
the piston pin and check the lubricating system.
2 Measure:
• the external diameter of the piston pin A
If out of specification Replace the piston pin.
Piston pin external diameter

18.995 ~ 19.000 mm
(0.747 ~ 0.748 in)
A 2
3 Measure:
• the internal diameter of the bore of the piston pin
B
If out of specification Replace the piston.
The internal diameter of the bore

of the piston pin
9.002 ~ 19.008 mm
B (0.7481 ~ 0.7483 in)
3
5 62
PISTONS
ENG
PISTONS INSTALLATION

Pistons Installation
1 Pistons 3
5 63
PISTONS
ENG
PISTONS INSTALLATION
C The following procedure is applied to all pistons.
N
1 Install:
• the oil scraper band A
• the 2nd band B
E
• the upper band C
B NOTE:
N
E The first and second rings have the letter N on the
upper side. Remember to install the piston bands
so that the letter N is facing upwards.
A
E
E ENGINE OIL
2 The first element to insert in the oil scraper segment

slot is the spacer D .
After having positioned the spacer, insert its side rings
E .
E
NOTE:
D The spacer and the side rings do not have a
particular upper or lower side: they can be inserted
E in any way.
ATTENTION
When installing the spacer, careful that its ends
Incorrect do not overlap inside the slot. Figure 3 .
Correct
5 64
PISTONS
ENG
4 The two bands have a different thickness.

The upper band G has a lower thickness than the
2nd band F .
2nd band Piston bands thickness

F
Upper band
Upper band 3.1 ~ 0.1 mm
G Second band
4 3.7 ~ 0.1 mm
5 65
PISTONS
ENG
I
E NEW
H 2
I
NEW
5 Install:
• the central piston 2
• the piston pin H
• the piston pin stop rings I
NOTE:
N
L
Lubricate the piston pin before installing it.
E ENGINE OIL
5 66
PISTONS
ENG
L
E
K
J
K 1 J 3
L
E
E
6
NOTE: 6 Install:
To assemble the two side pistons insert • the side piston 1
first the internal rings J , then the piston pins • the side piston 3
K and finally the external rings L .
Lubricate the pistons well before installing them.
E ENGINE OIL
ATTENTION
Match the piston class to the letter on the cylinder
(A, B, C).
Face the arrow on the piston crown towards the
drain. Figure 7 .
5 67
PISTONS
ENG
8 Position in an alternative manner:

• the light between the two ends of each piston band at 120° compared to the other.
5 68
CLUTCH
ENG
CLUTCH LID REMOVAL
PM
S
4
3 1
6
4 5

Clutch Lid Removal
NOTE:
Loosen each screw by ¼ of a turn at a time,
repeatedly and proceeding in a crossed
sequence. After having completely loosened
all the screws, remove them.
1 Screw 1
2 Screw 2
3 Screw 3
4 Screw 6
5 Clutch Lid 1
6 Clutch Lid Gasket 1
5 69
CLUTCH
ENG
CLUTCH LID INSTALLATION
10 N m - 1.01 Kgf•m
R.
T.
PM
S
LS
3
LS
3
4 LS
6
1 NEW
3 2
LS
LS
5
10 N m - 1.01 Kgf•m
R.
4
T.

Clutch Lid Installation
1 NEW
Clutch Lid Gasket 1 NOTE:
Accurately clean the support surfaces of the
gasket.
2 Clutch Lid 1
3 LS
Screw 6
4 LS
Screw 3
5 LS
Screw 2
6 LS
Screw 1
5 70
CLUTCH
ENG
CLUTCH REMOVAL
12 15
14 PM
13
S
13
11
9
8
10
7
6
3
2
1
5 71
CLUTCH
ENG
CLUTCH REMOVAL

Clutch Removal
1 Screw 6
2 Cup 6
3 Compression Spring 6
4 Clutch Pressure Plate 1
5 Clutch Disks Series 1
6 Friction Steel Disk 1
7 Disk 1
8 Hexagonal Nut 1
9 Disk Spring 1
10 Clutch Drum 1
11 High Shim 1
12 Clutch Bell 1
13 Needle Cage 2
14 Spacer 1
15 Low Shim 1
5 72
CLUTCH
ENG
CLUTCH REMOVAL
PM 1 Remove:
• the clutch lid A
S
• the clutch lid gasket B
B
A
1
2 Remove:
• the screws C
• the cups D
F • the compression springs E
• the clutch pressure plate F
E
D
C PM
S
3 Remove:
• the clutch disks series G
• the friction steel disk H
• the disk I
PM
S
I
H
3
4 Loosen:
• the clutch drum nut
I NOTE:
By keeping the clutch drum still using the retainer
L tool specific for the clutch J , loosen the relative
nut.
PM
S
Special Tools: CLUTCH DISMANTLING SPANNER

Code: R180297047000
J 42
5 73
CLUTCH
ENG
5 Remove:
• the clutch drum nut K
• the disk spring L
M • the clutch drum set M
L PM
6 Remove:
O • the high shim N
• the clutch bell O
PM
N
S
7 Remove:
R • the needle cage P
• the spacer Q
• the low shim R
Q
P PM
S
5 74
CLUTCH
ENG
FRICTION DISKS CONTROL

The following procedure is applied to all friction disks.
1 Check:
• the friction disk
In the presence of damages/wear Replace all
friction disks.
2 Measure:
• the thickness of the friction disks
If out of specification Replace all friction disks.
NOTE:
N
M
Measure the friction disk in four points.
Friction disk thickness

<Limit> : 2.8 mm (0.110 in)
2
5 75
CLUTCH
ENG
STEEL DISKS CONTROL

The following procedure is applied to all steel disks.
1 Check:
• the steel disk
In the presence of damages/wear Replace all
steel disks.
2 Measure:
• the twisting of the steel disk
(using a surface plate and a feeler A ).
If out of specification Replace all steel disks.
Steel disk twisting limit

0.1 mm (0. 0039 in)
A 2
5 76
CLUTCH
ENG
C
COMPRESSION SPRINGS CONTROL
The following procedure is applied to all compression

springs.
1 Check:
• the compression springs
In the presence of damages Replace all
compression springs.
2 Measure:
• the free length of the compression springs A
If out of specification Replace all compression
springs.
Compression spring free height

34.3 mm (1. 35 in)
A 2
5 77
CLUTCH
ENG
CLUTCH BELL CONTROL

1 Check:
• the clutch jaws of the clutch bell A
In the presence of damages/pittings/wear lines
Trim the clutch jaws of the clutch bell, or replace the
clutch bell.
NOTE:
The presence of pittings on the clutch jaws of the
clutch bell will make the clutch malfunction.
A 1
5 78
CLUTCH
ENG
CLUTCH DRUM INSPECTION

1 Check:
• the grooved part of the clutch drum A
Replace the clutch drum.
NOTE:
The presence of pittings on the grooved part of the
A drum will make the clutch malfunction.
1
5 79
CLUTCH
ENG
CLUTCH PRESSURE PLATE CONTROL

A
1 Check:
• the clutch pressure plate A
• the bearing B
B
1
5 80
CLUTCH
ENG
CLUTCH PRESSURE PLATE PIN

CONTROL
1 Check:
• the pressure plate pin A
B • the bush B
In the presence of damages/wear Replace the
clutch pressure plate pin together with the traction
lever shaft pinion.
A
1
2 Check:
C • the needle cage C
5 81
CLUTCH
ENG
CLUTCH INSTALLATION
4 1
2 PM
S
E
E
E
100 N m - 10.19 Kgf•m
R.
T.
5 3
7
8 E
E
8
A4
56
6
E
E

56A48
HIGH TEMPERATURE SEALER
9
10
11
13
14 E
15 E
LS
10 N m - 1.01 Kgf•m 12
R.
T.
5 82
CLUTCH
ENG
CLUTCH INSTALLATION

Clutch Installation
1 E
Low Shim 1
2 E
Spacer 1
3 E
Needle Cage 2
4 E
Clutch Bell 1
5 E
High Shim 1
6 Clutch Drum 1
7 Disk Spring 1
8 Hexagonal Nut 1
56A48
9 E
Disk 1
10 E
Friction Steel Disk 1
11 E
Clutch Disks Series 1
12 E
Clutch Pressure Plate 1
13 Compression Spring 6
14 Cup 6
15 LS
Screw 6
NOTE:
To assemble the clutch unit, gather shims 1 and
5. Always check the relief thickness.
5 83
CLUTCH
ENG
CLUTCH INSTALLATION
E
A 1 P
Position:
• the low shim A
with the lowest relief towards the inside of the
engine.
A Thickness 3.5 mm.
PM
S
1 E ENGINE OIL
2 Insert:
• the spacer B
E • the needle cage C
B
NOTE:
Before inserting the needle cages, lubricate their
sliding area well.
E
PM
S
C E ENGINE OIL
2
3 Insert:
• the clutch bell D
E
E ENGINE OIL
PM
S
D 3
4 Position:
• the high shim E
with the lowest relief towards the outside of the
engine.
E
E Thickness 4.0 mm.
PM
ENGINE OIL
S
E
4
5 Insert:
• the clutch drum F
PM
S
F 5
5 84
CLUTCH
ENG
6 Insert:
• the convex disk spring G
towards the outside of the engine
G • the fixing nut H
H
PM
S
DISK
SPRING INSERTION DIRECTION 6
7 Tighten:
100 N m - 10.19 Kgf•m • the clutch drum nut
R.
T.
I NOTE:
By keeping the clutch drum still using the retainer
L tool specific for the clutch I , tighten the relative
nut.
PM
8
A4
S
56
Special Tools: CLUTCH DISMANTLING SPANNER

Code: R180297047000
I 72
Torque fasten with: 100 N m - 10.9 Kgf•m
R.
T.

56A48 HIGH TEMPERATURE SEALER
8 Insert:
J • the disk with convex side J
towards the outside of the engine
K • the friction steel disk K
NOTE:
The friction steel disk K must be inserted with the
friction band towards the inside of the engine.
E Recommended lubricant
DISK
INSERTION DIRECTION
E
8 E ENGINE OIL
9 Insert sequentially and alternatively:

• the friction disks L
• the steel disks M
L M NOTE:
N
L
Lubricate all disks, one by one, using engine oil,
before inserting them in the clutch drum.
E
E
E ENGINE OIL
9
5 85
CLUTCH
ENG
10 Insert:
10 N m - 1.01 Kgf•m
N • the pressure plate N
R.
T.
• the compression springs O

P O • the cups P
Q • the screws Q
PM
Torque fasten. 10 N m - 1.01 Kgf•m
R.
T.
S
LS NOTE:
N
L
Lubricate the screws' threads.
10
LS
TUTELA MR2 GREASE
5 86
CLUTCH
ENG
A
CLUTCH DISKS ADJUSTMENT
B
1 Lock:
A • the flange ((IMG)) C
Loosen:
B • the lock nut ((IMG))
C Tighten:
• the regulator ((IMG))
until contact with the internal reaction rod is heard
and loosen it by ¼ of a turn.
1 Check the clearance on the clutch command
positioned on the opposite side of the engine.
2 Fasten:
• the lock nut B
using special tool keeping the regulator still C
B C Special Tools: CLUTCH PRESSURE PLATE
ADJUSTING SPANNER
Code: R180297130000
NOTE:
To use the special tool, remove one screw with
2 relative cup and spring.
5 87
CLUTCH
ENG
CLUTCH COMMAND REMOVAL
13
1
12
11
10 9
8
4
2 7
2 6
5
3
2

Clutch Pressure Plate Removal See paragraph "5.71"
Clutch Command Removal
1 Clutch Cable 1
2 Screw 3
3 Clutch Command Body 1
4 Plug 1
5 Small Plate 1
6 O-Ring Gasket 1
7 Bush 1
8 Clutch Command Rod 1
9 Ball 1
10 Needle Cage 1
11 Needle Cage 1
12 Spring 1
13 Clutch Command 1
5 88
CLUTCH
ENG
CLUTCH COMMAND CONTROL

1 Check:
• the clutch command A
In the presence of deformations/damages/wear
B lines Replace.
A • the clutch command spring B
5 89
CLUTCH
ENG
CLUTCH COMMAND INSTALLATION
10 N m - 1.01 Kgf•m
R.
T.
LS
13
2
LS
E
3
4 5
LS
6
LS 10 E
12 12
8 7
LS
9
NEW
12
11
3
A4 Arexons SYSTEM 52A43
52
52A43

Clutch Command Installation
1 LS
Clutch Command 1
2 Spring 1
3 LS
Needle Cage 1
4 Needle Cage 1
5 E
Ball 1
6 E
Clutch Command Rod 1
7 Bush 1
8 LS NEW
O-Ring Gasket 1
9 Small Plate 1
10 LS
Plug 1
11 LS
Clutch Command Body 1
12 Screw 3
52A43
13 Clutch Cable 1
5 90
GEAR CHANGE
ENG
GEAR CHANGE REMOVAL
2
1
1 1
1 3
1
1

NOTE:
Remove the neutral sensor located in the rear
part of the engine before removing the gear
change.
NOTE:
Drain the engine oil before carrying out the
operations.
Clutch Removal See paragraph "5.71".
Clutch Command Removal See paragraph "5.88".
Water Pump Removal See "COOLING PLANT 6.15" paragraph.
Gear Change Removal
1 Screw 8
2 Special Screw 1
3 Gear change 1
5 91
GEAR CHANGE
ENG
GEAR CHANGE REMOVAL

1 Remove:
• the nut A
A keeping the pinion still with the special tool B
Special Tools: PINION DISMANTLING TOOL

Code: R180297048000
33
88
2 Remove:
• the washer C
• the pinion E
• the spacer D
D
C
A
5 92
GEAR CHANGE
ENG
3 Remove:
• the screws F
• the selector lid G
• the selector lid gasket H
H
F G
F 3
4 Remove:
• the washer I
• the pin J
• the spring K
• the spacer L
• the washer M
M
L
K
J
I 4
5 93
GEAR CHANGE
ENG
5 Remove:
• the screws N
• the flange O
N
O
N
5
W
R
V
S U
T
Q
T
S
R 6
ATTENTION 6 Remove:
During removal of the peg U support the • the bush P
desmodromic W positioned behind the gear • the desmodromic sprocket Q
change flange to avoid it falling. • the jumpers R
• the pegs S
• the springs T
NOTE: • the peg U
During removal of the desmodromic sprocket W • the complete gear change drum V
contrast the reaction of the springs T located
underneath the jumpers R .
5 94
GEAR CHANGE
ENG
D
E
C
E
Y
X
B
Y
X A
A 7
NOTE: 7 Remove:
During removal of the pins Z pay attention to • the screws X
the desmodromic C and to the forks A and B . • the washers Y
• the pins Z
• the clutch forks 1st/4th - 2nd/3rd A
NOTE: • the clutch fork 5th/6th B
Take note of the position of the forks before • the desmodromic C
removing them for a correct re-assembly. • the plug D
• the shims E
ATTENTION
Ensure that the peg F is correctly inserted in
its seat.
8 Remove:
• the threaded pin G
• the gears fixing jumper H
• the washer I
• the spring J
J
I
H
G 8
5 95
GEAR CHANGE
ENG
ATTENTION 9 Remove:
The gears are free. • the primary shaft K
Remove the shafts K and L simultaneously. • the secondary shaft L
5 96
GEAR CHANGE
ENG
PRIMARY AND SECONDARY SHAFT

GEARS REMOVAL
PRIMARY
SHAFT 2
3
4
6 5
7
8
9
10
11
18 16
12
13 17
14
15
19
21
20
22
24 23
25
26
28 27
29
30
31
32
33
34
36 35 37
SECONDARY
SHAFT
38
5 97
GEAR CHANGE
ENG

GEARS REMOVAL

NOTE:
Drain the engine oil and the cooling liquid before
carrying out the operations.
Oil Tank Removal See paragraph "5.113".
Oil Pump Removal See paragraph "5.116".
Alternator Removal See paragraph "5.122".
Female Collar Joint Removal See paragraph "5.128".
Z25 Gear/Splined Shaft Removal See paragraph "5.128".
Start-Up Motor Removal See paragraph "5.125".
Gear Change Removal See paragraph "5.91".
Shower Tube Removal See paragraph "5.131".
Intermediate Gear Small Shaft Removal See paragraph "5.131".
Satellite Gear Removal See paragraph "5.131".
Complete Free Wheel Removal See paragraph "5.131".
Primary Shaft Gears Removal
1 Bush 1
2 Primary Shaft 1
3 Shim 1
4 Needle Cage 1
5 Z24 5th Conductor Gear 1
6 Shim 1
7 Elastic Ring 1
8 3rd/4th Conductor Gear 1
9 Shim 1
10 Z25 6th Conductor Gear 1
11 Needle Cage 1
12 Z18 2nd Conductor Gear 1
13 Seeger 1
14 Shim 1
15 Seeger 1
Secondary Shaft Gears Removal
16 Elastic Ring 1
17 Shim 1
18 Z39 1st Conduct Gear 1
19 Needle Cage 1
20 Shim 1
21 Z28 5th Conduct Gear 1
22 Elastic Ring 1
23 Splined Shim 1
25 Broached Bush 1
26 Stop Ring 1
27 Splined Shim 1
28 Z32 3rd Conduct Gear 1
29 Broached Bush 1
30 Splined Shim 1
31 Elastic Ring 1
33 Elastic Ring 1
34 Shim 1
35 Z39 2nd Conduct Gear 1
36 Needle Cage 1
37 Secondary Shaft 1
38 O-Ring Gasket 1
5 98
GEAR CHANGE
ENG
GEARS CONTROL
1 Check:
• the gears of the two shafts
In the presence of blue fading/pittings/wear lines
Replace the faulty gears.
• the gears clutch jaws
In the presence of cracks/damages/round edges
Replace the faulty gears.
5 99
GEAR CHANGE
ENG
GEAR CHANGE FLANGE BEARINGS

CONTROL
1 Check:
• the free rotation of the bearings C E G
To replace the bearings remove:

• the screws A
C • the small plate B
B • the bearing C
• the seal ring D
• the bearing E
• the shims F
• the bearing G
A
D E
G
F
F
5 100
GEAR CHANGE
ENG
GEARS COMMAND FORKS CONTROL
1 The following procedure is applied to all gears

command forks.
Check:
B • the gears command fork cam follower A
• the gears command fork jaw B
In the presence of deformations/damages/scratches
A /wear lines Replace the gears command fork.
1
2 Check:
• the clearance of the gear change fork inside the
slot of its gear using a feeler.
If the clearance is out of specification Replace
the fork or the relative gear or both.
The clearance of each fork is important for the

smoothness and precision of the speed gear change.
Fork-slot clearance
2 <Limit> : 0.50 mm (0.019 in)
3 Measure:
• the width of the slot of the gear change fork using
a cursor gauge
Slot-fork width
Standard value: 5.0 - 5.1 mm
(0.19 - 0.20 in)
4 Measure:
• the thickness of the gear change fork using a
cursor gauge
Fork-gear change thickness

Standard value: 4.8 - 4.9 mm
(0.18 - 0.19 in)
5 Check:
• the gears command fork guide pin
Roll the guide pin of the gears command fork on a
flat surface
NOTE:
Do not attempt to straighten the fork guide bar if
it is deformed.
5 101
GEAR CHANGE
ENG
6 Check:
• the movement of the gears command fork on the
relative guide bar
If the movement is not smooth Replace the
gears command forks together with the relative bar
guide.
5 102
GEAR CHANGE
ENG
DESMODROMIC SHAFT CONTROL
1 Check:
• the grooves of the desmodromic shaft A
Replace the desmodromic shaft set
• the segment of the desmodromic shaft B
B In the presence of damages/wear Replace the
desmodromic shaft set
A
1
5 103
GEAR CHANGE
ENG

GEARS INSTALLATION
E
15
PRIMARY E
E
SHAFT 14
E E
E
E E
13
12
E
E
10 11
E 9
E
NEW
8
E
7
E
E 5 6 NEW
36
4 38
3
2 37
1 NEW
E
NEW 35
33 E
34 E E
NEW
E
32
30 31 E
E
29 E
28 E E
26 27 E
NEW
E
E
NEW
E
25
E
E
E
24
E
23
22
E
21
20 E
E
19
18 17
E
SECONDARY
SHAFT
16
5 104
GEAR CHANGE
ENG

GEARS INSTALLATION

NOTE:
Never use a used elastic ring.
When installing a new elastic ring careful not to
stretch its ends more than necessary for it to be
inserted on the shaft.
Once the elastic ring has been installed, always
ensure it is compltely and firmly inserted in its
slot.
NOTE:
Accurately oil each gear, shaft and bearing but
not excessively in order to avoid jeopardising the
sealing paste hold with oil leaks.
Primary Shaft Gears Installation
1 NEW E
Seeger 1
2 E
Shim 1
3 NEW E
Seeger 1
4 E
Z18 2nd Conductor Gear 1
5 E
Needle Cage 1
6 E
Z25 6th Conductor Gear 1
7 E
Shim 1
8 E
3rd/4th Conductor Gear 1
9 NEW E
Elastic Ring 1
10 E
Shim 1
11 E
Z24 5th Conductor Gear 1
12 E
Needle Cage 1
13 E
Shim 1
14 E
Primary Shaft 1
15 E
Bush 1
Secondary Shaft Gears Installation
16 NEW E
O-Ring Gasket 1
17 E
Secondary Shaft 1
18 E
Needle Cage 1
19 E
Z39 2nd Conduct Gear 1
20 E
Shim 1
21 NEW E
Elastic Ring 1
22 E
Z27 6th Conduct Gear 1
23 NEW E
Elastic Ring 1
24 E
Splined Shim 1
25 E
Broached Bush 1
26 E
Z32 3rd Conduct Gear 1
27 E
Splined Shim 1
28 E
Stop Ring 1
29 E
Broached Bush 1
30 E
31 E
Splined Shim 1
32 NEW E
Elastic Ring 1
33 E
34 E
Shim 1
35 E
Needle Cage 1
36 E
Z39 1st Conduct Gear 1
37 E
Shim 1
38 NEW E
Elastic Ring 1
NOTE:
Insert the engine oil and the cooling liquid once
the operations have been completed.
NOTE:
Check that the seegers are in their seats.
5 105
GEAR CHANGE
ENG
GEAR CHANGE INSTALLATION
C
LA
I SI
OR
YV
C
LA
I SI
OR
YV
C
LA
I SI
OR
YV
20 N m - 2.03 Kgf•m
R.
T.
C
LA
I SI
OR
YV
2
3
3
3
3 1
GR

ATTENTION:
During installation of the gear change, ensure it
is in fourth gear to avoid breaking the neutral
sensor or, remove the neutral sensor before
installing the gear change.
NOTE:
Check the presence of the oil conduct tube
inside the carter.
ATTENTION:
Apply Ivori Sil Ac sealing paste on the gear
change flange coupling plate being careful not
to obstruct the oil passage hole.
Gear Change Installation
1 Gear change 1
2 Special Screw 1
3 GR
Screw 8
NOTE:
Install the neutral sensor located in the rear
part of the engine once the gear change has
been installed.
NOTE:
Insert the engine oil once operations have been
completed.
5 106
GEAR CHANGE
ENG
GEAR CHANGE INSTALLATION
A
E
ATTENTION 1 Install:
The gears are free. • the primary shaft A
• the secondary shaft B
Remove the shafts A and B simultaneously. • the spacer C
E ENGINE OIL
2 Install:
• the plug D on the desmodromic shaft E
• the two thicknesses F (of 0.2 mm each)
D AREXONS SYSTEM 56A48

56A48 HIGH TEMPERATURE THREAD BRAKES
56
A4
8
E
F
2
5 107
GEAR CHANGE
ENG
E
J
LS
E
J
E
I E
E
K
L
52
A4
3
K
L E
H
10 N m - 1.01 Kgf•m H 3
R.
T.
3 Install:
• the desmodromic G AREXONS SYSTEM 52A43
• the clutch forks 1st/4th - 2nd/3rd H 52A43 MEDIUM THREAD BRAKES
• the clutch fork 5th/6th I
• the pins J
• the washers K Recommended lubricant
• the screws L
E ENGINE OIL
R.
T.
4 Install:
• the spring M
• the washer N
• the gears fixing jumper O
• the threaded pin P

R.
T.

10 N m - 1.01 Kgf•m
R.
T.
M
N
O
52A43
P 4
5 108
GEAR CHANGE
ENG
5 Install:
• the complete gear change drum Q
• the peg R
R.
T.

10 N m - 1.01 Kgf•m
R.
T.
Q
3
A4
52
NOTE:
During INSTALLATION of the desmodromic
sprocket V contrast the reaction of the springs
S located underneath the jumpers U .
6 Install:
• the springs S
• the pegs T
• the jumpers U
• the desmodromic sprocket V
E
• the bush W
U E
T Recommended lubricant
S E ENGINE OIL
W V
E
E
S
T
E
U 6
5 109
GEAR CHANGE
ENG
7 Install:
• the flange X
• the screws Y
R.
T.

X
Y 10 N m - 1.01 Kgf•m
R.
T.
43
52A
8 Install:
• the washer Z
• the spacer A
• the spring B
• the pin C
• the washer D
NOTE:
Do not force the spring cap too much B during
installation on the command shaft.
NOTE:
Ensure that the washers Z and D remain in
position.
E
E
E E Recommended lubricant
E
E ENGINE OIL
Z
A
E
E
B
C
D 8
5 110
GEAR CHANGE
ENG
9 Install:
• the selector lid gasket E
• the selector lid F
• the screws G
Torque fasten. 10 N m - 1.01 Kgf•m
R.
T.
E ENGINE OIL
10 N m - 1.01 Kgf•m
R.
T.
GR
COPPER GREASE
E
F
GR
G
E
G 10 N m - 1.01 Kgf•m 9
R.
T.
10 Install:
• the pinion H
• the washer I
NOTE:
Before installing remove the grease from the
broached using solvent.
Recommended solvent
TUTELA MOTOR CLEAN
H
I
10
5 111
GEAR CHANGE
ENG
11 Install:
J • the nut J
keeping the pinion still with the special tool K
Special Tools: PINION DISMANTLING TOOL

Code: R180297048000
33
88 Torque fasten with: 140 N m - 14.2 Kgf•m
R.
T.
56
A4
8
K 11
56A48 HIGH TEMPERATURE THREAD BRAKES
5 112
LUBRICATION PLANT
ENG
OIL TANK AND INLET FILTER REMOVAL
9 5
12
3
10
8
10
11 4
7
8
2
6
1

Oil Tank Removal
1 Magnet Cap 1 NOTE:
operations.
2 Washer 1
3 Strip 1
4 Screw 2
5 Plate 1
6 Screw 10
7 Oil Tank 1
8 Bush 2
9 Oil Tank Gasket 1
Inlet Filter Removal
10 Screw 2
11 Inlet Filter 1
12 O-Ring Gasket 1
5 113
LUBRICATION PLANT
ENG
A
OIL TANK AND INLET FILTER
CONTROL
1 Check:
• the oil tank A
In the presence of clinks/damages Replace.
2 Check:
• the inlet filter B
In the presence of deposits/residues Accurately
clean the filtering area using solvent.
Recommended solvent
TUTELA MOTOR CLEAN
B
2
5 114
LUBRICATION PLANT
ENG
OIL TANK AND INLET FILTER INSTALLATION
NEW 4 8
LS
1 NEW
10
GR
3
52
A4
5
3
3
9 10 N m - 1.01 Kgf•m
R.
T.
GR 6 10 N m - 1.01 Kgf•m
R.
T.

NEW 11
7 10 N m - 1.01 Kgf•m
R.
T.
22 N m - 2.24 Kgf•m 12
R.
T.
LS

Inlet Filter Installation
1 NEW
O-Ring Gasket 1
2 LS
Inlet Filter 1
3 Screw 2
52A43
Oil Tank Installation

4 NEW
Oil Tank Gasket 1
5 Bush 2
6 Oil Tank 1
7 Screw 10
8 GR Plate 1
9 Screw 2
10 GR Strip 1
11 NEW
Washer 1
12 Magnet Cap 1
LS NOTE:
completed.
5 115
LUBRICATION PLANT
ENG
OIL PUMP REMOVAL
PM
S
A
6
7
4 9
8
3 10
3
11
3
1 2

NOTE:
operations.
Clutch Removal See paragraph "5.71"
Water Pump Removal See paragraph "COOLING PLANT 6.15"
Oil Pump Removal NOTE:
To remove the pump, hit the oil pump shaft on
the water pump side with a rubber hammer.
1 Seeger 1
2 Z34 Command Gear 1
3 Screw 3
4 Oil Pump 1
5 Bush 1
6 External Rotor 1
A Rotor Set 1
7 Seeger 1
8 Shim 1
9 Internal Rotor 1
10 Roller 1
11 Oil Pump Shaft 1
5 116
LUBRICATION PLANT
ENG
OIL PUMP CONTROL

A 1 Check:
• the pump body A
In the presence of scratches/damages/wear
Replace.
• the cogwheel B
In the presence of gear damages/wear
Replace.
2 Measure:
D • the tolerance between the internal rotor and the
external rotor C
E • the tolerance between the external rotor and the
oil pump slot D
E Internal rotor
F External rotor
F C G Oil pump slot
G Clearance between the internal

2
rotor point and the rotor point
0.25 mm (0.0098 in)
Clearance between the external
rotor and the oil pump slot
0.2 mm (0.0078 in)
3 Check:
• the oil pump functioning
Rotate gear Z34 as shown in the figure.
If the movement is not smooth Check the
internal/external rotor seat again.
In the presence of scratches/damages Replace
the faulty part(s).
NOTE:
This control is carried out after having fixed the oil
pump in the engine body and having inserted gear
3 Z34 in its seat.
5 117
LUBRICATION PLANT
ENG
OIL PUMP INSTALLATION
PM
S
A
6 5
GR
10 N m - 1.01 Kgf•m
R.
T.
8 GR 3
4
9 2
E 9
1
E
E
7
52A43
3
A4

52
9 10 N m - 1.01 Kgf•m
R.
T.
11 10

Oil Pump Installation
1 Oil Pump Shaft 1
2 Roller 1
3 GR
Internal Rotor 1
4 Shim 1
5 Seeger 1
6 GR
Rotor Set 1
A External Rotor 1
7 Bush 1
8 Oil Pump 1
E
9 Screw 3
52A43
10 Z34 Command Gear 1

E
11 Seeger 1
NOTE:
Insert the engine oil once having completed the
operations.
5 118 <<Back Index Forward>>

LUBRICATION PLANT
ENG
OVER PRESSURE VALVE REMOVAL

Oil Tank Removal See paragraph "5,113"
NOTE:
operations.
Over Pressure Valve Removal
1 Over Pressure Valve 1
2 Washer 1
5 119
LUBRICATION PLANT
ENG
OVERPRESSURE VALVE CONTROL

E
1 Check:
• the pressure valve body A
• the pressure valve B
A
C • the spring C
A
B • the washer D
A In the presence of damages/wear Replace the
fault parts.
A
D
1 NOTE:
Abundantly and accurately lubricate the pressure
valve.
E ENGINE OIL
5 120
LUBRICATION PLANT
ENG
OVERPRESSURE VALVE INSTALLATION
52A43
1 NEW
3
52A4
2 25 N m - 2.54 Kgf•m
R.
T.

Over Pressure Valve Installation
1 NEW
Washer 1
2 Over Pressure Valve 1
52A43
NOTE:
completed.
5 121
START-UP
ENG
ALTERNATOR REMOVAL
7
7
1 7
6 7
5

NOTE:
operations.
Clutch Command Removal See paragraph "5.88"
Alternator Removal
1 Screw 3
2 Alternator 1
3 O-Ring Gasket 1
4 Male Joint 1
5 Washer 1
6 Nut 1
7 Collar Rubber 4
5 122
START-UP
ENG
ALTERNATOR CONTROL
1 Check:
• the clearance between the male joint and the
alternator
If out of specification Replace the part.
2 Check:
• the collar rubber A
A
2
5 123
START-UP
ENG
ALTERNATOR INSTALLATION

56A48
1
1
LS
8
A4
56
7 LS
1
2 1
3
56A48
4
8
A4
56
5 NEW
6
56A48
43
52A
7 45 N m - 4.58 Kgf•m
R.
T.

52A43

Alternator Installation
1 LS
Collar Rubber 4
2 Nut 1
56A48
3 Washer 1
4 Male Joint 1
56A48
5 NEW LS
O-Ring Gasket 1
6 Alternator 1
56A48
7 Screw 3
52A43
5 124
START-UP
ENG
START-UP MOTOR REMOVAL
1
2

NOTE:
operations.
Alternator Removal See paragraph "5.122"
Start-Up Motor Removal
1 Screw 2
2 Complete Start-up Motor 1
3 Nut 1
5 125
START-UP
ENG
START-UP MOTOR CONTROL
A 1 Check:
• the start-up motor functioning
If the start-up motor turns with force Replace
the part.
• the O-Ring gasket A
Replace the O-Ring gasket.
1
5 126
START-UP
ENG
START-UP MOTOR INSTALLATION
10 N m - 1.01 Kgf•m
R.
T.
3
LS
4 1
2 NEW
43
52A
4

52A43

Start-Up Motor Installation
1 NEW LS
O-Ring Gasket 1 NOTE:
Lubricate the O-Ring being careful not to
damage it.
2 Complete Start-up Motor 1
3 Nut 1
4 Screw 2
52A43
NOTE:
completed.
5 127
START-UP
ENG
Z25 GEAR/SPLINED SHAFT, FEMALE

COLLAR JOINT REMOVAL
1 2 3
Special Tools: ALTERNATOR SPANNER

Code: R300097161000

NOTE:
operations.
Alternator Removal See paragraph "5.122"
Female Collar Joint Removal
1 Screw 1
2 Washer 1
3 Female Joint 1 NOTE:
Remove it using the special tool.
Z25 Gear/Splined Shaft Removal
4 Splined Shaft 1
5 Z25 Gear 1
5 128
START-UP
ENG

B A COLLAR JOINT CONTROL
1 Check:
C • the female collar joint A
• the splined shaft B
In the presence of torsions/clinks/wear lines
Replace.
1 • the Z25 gear C
In the presence of cracks/damages/round edges
Replace the faulty gear.
5 129
START-UP
ENG

COLLAR JOINT INSTALLATION
50 N m - 5.09 Kgf•m
R.
T.
4
5
56A48
3
48
56A

56A48
Special Tools: ALTERNATOR SPANNER

Cod e: R300097161000

Z25 Gear/Splined Shaft Installation
1 Z25 Gear 1 NOTE:
Insert the splined shaft respecting the phasing
on the relative Z25 gear, as shown in the figure.
2 Splined Shaft 1
Female Collar Joint Installation
3 Female Joint 1 NOTE:
56A48
Install it using the special tool.

4 Washer 1
5 Screw 1
56A48
NOTE:
carried out.
5 130
START-UP
ENG
SATELLITE GEAR AND FREE

WHEEL UNIT REMOVAL
4 1
5
6
2
3

NOTE:
operations.
Alternator Removal See paragraph "5.122".
Satellite Gear Removal
1 Screw 2
2 Bearing Retainer Small Plate 1
3 Shower Tube 1
4 Screw 1
5 Small Plate 1
6 Intermediate Gear Small Shaft 1
7 Satellite Gear 1
Female Collar Joint Removal See paragraph "5.128".
Z25 Gear/Splined Shaft Removal See paragraph "5.128".
Free Wheel Unit Removal
8 Complete Free Wheel 1
5 131
START-UP
ENG
SATELLITE GEAR AND FREE WHEEL

CONTROL
B
A F
1 Remove:
• the seeger A
• the washer B
E • the Z60 free wheel gear C
• the needle cage D
• the screws E
• the flange F
• the free wheel G
• the free wheel hub H
D
G
1
2 Check:
• the satellite gear I
In the presence of damages, lines, wear
Replace.
I
3 Check:
• any breakages, wear and slidings of the
components of the free wheel
If out of specification Replace the part.
5 132
START-UP
ENG
SATELLITE GEAR AND FREE

WHEEL UNIT INSTALLATION
11 14
10 14
9
A 43
52
52A70
13
12
52A43
Arexons SYSTEM 52A70 MEDIUM THREAD BRAKES
52A70
STRONG THREAD BRAKES
52A70
STRONG THREAD BRAKES
10 N m - 1.01 Kgf•m
R.
T.
1
16 N m - 1.63 Kgf•m
R.
T.
2
10 N m - 1.01 Kgf•m
R.
T.
3 E
0
A7
4 52
4
E
4 E
5
4
E
4 4
E
E
6 15
7
8

Free Wheel Unit Installation
1 Free Wheel Hub 1
E
2 Free Wheel 1
E
3 Flange 1
E
4 Screw 6
52A70
5 Needle Cage 1
E
6 Z60 Free Wheel Gear 1

E
7 Washer 1
E
8 Seeger 1
9 Intermediate Gear Small Shaft 1
E
10 Small Plate 1
11 Screw 1
52A43
12 Shower Tube 1
13 Bearing Retainer Small Plate 1
14 Screw 2
52A70
Satellite Gear Installation

15 Satellite Gear 1
E
NOTE:
completed.
5 133
HANDLING BASE
ENG
LOWER BASE REMOVAL
16
2
3
1
3
6
4
6 5
7
15 15 15
17
11
10
10 17
13 13
9
17
8 8
8 8
18
12 14
12
15 15 15 15 15
5 134
HANDLING BASE
ENG
LOWER BASE REMOVAL

NOTE:
Drain the engine oil and the cooling liquid
before carrying out the operations.
NOTE:
Operations to be carried out with the engine
overturned.
Lower Base Removal
1 Screw 1
2 Screw 1
3 Screw 2
4 Counter-shaft Lid 1
5 Counter-Shaft Lid Gasket 1
6 Screw 2
7 Plate 1
8 Screw 8 NOTE:
Remove the respective washers.
9 Screw 1
10 Screw 2
11 Screw 1 NOTE:
Remove the respective washer.
12 Screw 2
13 Screw 2
14 Screw 1
15 Screw 8
16 Lower Base 1
17 Bush 3
18 Bush 1
5 135
HANDLING BASE
ENG
B LOWER BASE REMOVAL

C
A 1 Remove:
• the screw A
C • the screw B
• the screws C
• the counter-shaft lid D
• the counter-shaft lid gasket E
D
E 1
2 Remove:
• the screws F
F • the plate G
G F
3 Overturn:
• the engine
4 Remove:
• the screws
Loosen each screw by ¼ of a turn at a time,
I repeatedly following, in decreasing numerical order,
the sequence shown in the figure.
H After having completely loosened all screws, remove
them.
• the lower base H
ATTENTION
I Hit one side of the base with a rubber hammer.
Only hit the reinforced parts of the base, not the
coupling surfaces.
I Work slowly and carefully to ensure that the two
6 2 4 8 halves of the base evenly separate.
5 1 3 7 • the centring bushes I

I
5 136
HANDLING BASE
ENG
LOWER BASE CONTROL
1 Scrupulously wash:
• the lower base
by dipping it in a neutral solvent.
Recommended solvent
TUTELA MOTOR CLEAN
1
2 Scrupulously clean:
• all coupling surfaces
destined to welcome the sealing paste and the
coupling surfaces of the base.
3 Check:
• the lower base
• the oil flow passages
In the presence of obstructions Clean with a jet
of compressed air.
5 137
HANDLING
ENG
BENCH HALF-BEARINGS, ENGINE SHAFT AND

BALANCING COUNTER-SHAFT REMOVAL
3
10
10
10
10
2
6
7
9
UPPER BASE
8
7 10
10
10
10
LOWER BASE
5 138
HANDLING
ENG
BENCH HALF-BEARINGS, ENGINE SHAFT AND

BALANCING COUNTER-SHAFT REMOVAL

NOTE:
Cylinders Removal See paragraph "5.51".
Pistons Removal See paragraph "5.58".
NOTE:
Operations to be carried out with the engine
overturned.
Lower Base Removal See paragraph "5.134".
Balancing Counter-Shaft Removal
1 Cap 1
2 Seal Ring 1
3 Balancing Counter-Shaft 1
Engine Shaft Removal
4 Cap 1
5 Engine Shaft 1
6 Rollers Bearing 1
7 Screw 2
8 Plate 1
9 Bearing 1
Bench Half-Bearings Removal
10 Bench Half-Bearing 8
5 139
HANDLING
ENG
CONNECTING ROD HALF-BEARINGS AND

CONNECTING RODS REMOVAL
1
1
1 2
1
2
1
1
2 3
3 2

Cylinders Removal See paragraph "5.51".
Pistons Removal See paragraph "5.58".
Lower Base Removal See paragraph "5.134".
Balancing Counter-Shaft Removal See paragraph "5.138".
Engine Shaft Removal See paragraph "5.138".
Bench Half-Bearings Removal See paragraph "5.138".
Connecting Rods Removal
1 Screw 6
2 Connecting Rod 3
Connecting Rod Half-Bearings Removal
3 Connecting Rod Half-Bearing 6
5 140
HANDLING
ENG
BALANCING COUNTER-SHAFT
CONTROL AND ENGINE SHAFT
1 Remove from the balancing counter-shaft:
A • the seeger A
B • the bearing B
• the Z34 command gear C
C • the bearing D
D
1
2 Check:
• the bearings B D
Clean the bearings, therefore rotate the internal track
with a finger.
If the movement is not correct Replace.
• the Z34 command gear C
In the presence of damages/wear lines Replace.
D C 2
3 Measure:
• the engine shaft eccentricity
If out of specification Replace the engine shaft.
80
70
90
Engine shaft eccentricity

60
0
50
0.01m
Lower than: 0.03 mm (0.0011 in)

m 0-3
10
0mm
40
20
30
4 Check:
• the bench supports surfaces E
E F E • the connecting rod supports surfaces F
In the presence of scratches/wear lines
Replace the engine shaft.
F E E F
4
5 141
HANDLING
ENG
CONNECTING ROD HALF-BEARINGS

AND CONNECTING RODS CONTROL
1 Check:
B • any breakages or excessive clearance on the
connecting rod A and on the connecting rod
half-bearings B
In case of replacing the connecting rod, check the
class marked on the connecting rod head.
A
1
2 Check:
• the internal diameter of the connecting rod
foot C
If out of specification Replace the connecting
rod.
C
Connecting rod foot internal diameter
Limit > : 19.040 mm (0.749 in)
3 Check:
• the side clearance of the connecting rod using a
feeler D
D If out of specification Replace the connecting
rod.
Connecting rod head side clearance

Limit > : 0.40 mm (0.015 in)
4 Check:
• the connecting rod head width E
• the connecting rod pin width F
If out of specification Replace the connecting
rod or the shaft engine.
E F Connecting rod head width

Standard: 21.8 mm ~ 21.9 mm
(0.85 ~ 0.86 in)
4 Connecting rod pin width

Standard: 22.0 mm ~ 22.05 mm
(0.866 ~ 0.868 in)
5 142
HANDLING
ENG

CONNECTING RODS INSTALLATION
3
3
GR
3 2
3
2
NEW 3
3
1
2
GR
GR
15 + 25 N m + 50° - 1.52 + 2.54 Kg•m + 50°

R.
T.
GR
GR
1
GR
GR
2
1
2
E

Connecting Rod Half-Bearings Installation
1 GR
Connecting Rod Half-Bearing 6
Connecting Rods Installation
2 GR
Connecting Rod 3 NOTE:
E
Do not exceed with the copper grease.

3 NEW GR
Screw 6
5 143
HANDLING
ENG

B A CONNECTING RODS INSTALLATION
1 Install:
• the connecting rod half-bearings
GR
a Clean the bearings of the connecting rod heads,
the connecting rod supports and the internal part
GR
of half of each connecting rod.
b Install the upper bearing of the connecting rod
1 head inside the connecting rod, and the lower
bearing of the connecting rod head inside the
connecting rod cap.
N
NOTE:
A
Align the protrusions A of the head half-bearings
with the notches B inside the connecting rod and
in the relative cap.
ATTENTION
Do not swap the half-bearings of the connecting
rod heads and the connecting rods. To obtain the
correct clearance between connecting rod
support and connecting rod head half-bearing,
and to prevent damages to the engine, the half-
bearings of the connecting rod heads must be
re-assembled in the original position.
2 Select:
• the connecting rod half-bearings as shown in the
table
CONNECTING ROD HALF-BEARING
K4/C
10260
0 STD COLOUR THICKNESS
A Red 1.680 ~ 1.684

B Blue 1.684 ~ 1.688
2
C Yellow 1.688 ~ 1.692
Ø std A seat red 40.395 - 40.401
Ø std B seat blue 40.401 - 40.407
Ø std C seat yellow 40.407 - 40.413
Ø std single seat 36.976 - 36.986
5 144
HANDLING
ENG
3 Select:
• the class marked on the connecting rod head
K4/C SELECTION TABLE

10260
0 TYPE COLOUR WEIGHT (g)
K1 Black 412/416
K2 Green 396/400
K3 White 400/404
K4 Brown 404/408
3
K5 Orange 408/412
ATTENTION
Associate the connecting rod types following the
class marked on the connecting rod head.
4 Install:
• the screws C
Torque fasten:
15 + 25 N m + 50° - 1.52 + 2.54 Kgf•m + 50°
R.
T.
NEW C
GR
15 + 25 N m + 50° - 1.52 + 2.54 Kgf•m + 50°

R.
T.
5 145
HANDLING
ENG
BALANCING COUNTER-SHAFT, ENGINE

SHAFT AND BENCH HALF-BEARINGS INSTALLATION
8
GR GR
GR
GR
7
C
LA
I SI
OR
YV
1
1
1
1 GR
9
5
YV
OR
I SI
10 LA
C
3
4
E 2
10 N m - 1.01 Kgf•m
UPPER BASE
R.
T.
0
A7
52
4 1
52A70
1 STRONG THREAD BREAKS
GR
LOWER BASE
5 146
HANDLING
ENG
BALANCING COUNTER-SHAFT, ENGINE

SHAFT AND BENCH HALF-BEARINGS INSTALLATION

Bench Half-Bearings Installation
1 GR
Bench Half-Bearing 8
2 Bearing 1
E
3 Plate 1
4 Screw 2
52A70
5 Rollers Bearing 1
E
Engine Shaft Installation

6 GR
Engine Shaft 1
7 YVORI SIL AC
Cap 1
Balancing Counter-Shaft Installation
8 Balancing Counter-Shaft 1
E
9 Seal Ring 1
10 YVORI SIL AC
Cap 1
NOTE:
5 147
HANDLING
ENG
BALANCING COUNTER-SHAFT,
ENGINE SHAFT AND BENCH HALF-
A BEARINGS INSTALLATION
C 1 Install:
GR
D • the bench half-bearings A
a Clean the bench half-bearings, the bench supports
and the base parts in contact with the half-bearings.
B 1 b Rest the upper base overturned on to the work

bench.
c Install the bench half-bearings A in the bench
supports seats B and the engine shaft in the
upper base.
NOTE:
N
A
Align the protrusions C of the bench half-bearings
with the notches D of the upper base.
d Install the lower half-bearings of the bench supports

A in the lower base.
NOTE:
N
• Align
A the protrusions C of the bench supports
lower half-bearings with the notches D of the
lower base.
• Do not move the engine shaft until the clearance
measuring operations have been completed.
GR
COPPER GREASE
4 2 N
I umber 1 refers to the bench half-bearing seat on the
3
distribution side.
2 ATTENTION
1 Do not exchange the bench half-bearings
between them.
To obtain the correct clearance between the
bench support surface and the bench half-
bearing, and to prevent damages to the engine,
the bench half-bearings must be re-assembled in
the original position.
2
5 148
HANDLING
ENG
3 The bench half-bearings have various thicknesses

distinguished by different letters and colours as shown
in the table.
BENCH HALF-BEARING
ST COLOUR THICKNESS
1
A
A Red 1.918 ~ 1.922

2
C
B Blue 1.922 ~ 1.926

3
C
C Yellow 1.926 ~ 1.930

B
Ø std A seat red 41.830 - 41.836
Ø std B seat blue 41.836 - 41.843
Ø std C seat yellow 41.843 - 41.849
Ø std single seat 37.960 - 37.970
NOTE:
If replacing the engine shaft, always replace the
bench half-bearings.
4 Install:
H • the bearing E
E
• the small plate F
• the screws G
• the roller bearings H

R.
T.
E
F
E AREXONS SYSTEM 52A70
52A70 THREAD BRAKES
70
G 4
52A
10 N m - 1.01 Kgf•m
R.
T.
E ENGINE OIL
5 149
HANDLING
ENG
5 Install:
• the engine shaft I
GR
GR
GR GR I GR
COPPER GREASE
6 Install:
• the balancing counter-shaft J
J
E
E ENGINE OIL
WARNING
Ensure that the cogwheels of the balancing
counter-shaft and of the engine shaft are in phase
as shown in figure 7 .
8 Install:
L • the seal ring K
C
• the two caps L
LA
I SI
OR
YV
YVO
Recommended paste
RI S
IL A
IVORY SIL AC
YVO
RI S
IL A
C
K
L 8
5 150
HANDLING BASE
ENG
LOWER BASE INSTALLATION
11 11 11
YVO GR
RI S
IL A
C
7
GR
6
GR
6 2
9 9
GR
5 GR
2
4 4
GR
4 4
1
8 10
GR
8
GR
GR
11 11 11 11 11

NOTE:
Apply copper grease on all screws.
Lower Base Installation
1 Bush 1
2 Bush 3
3 YVORI SIL AC
Lower Base 1
4 GR
Screw 8 NOTE:
Install the respective washers first.
5 GR
Screw 1
6 GR
Screw 2
7 GR
Screw 1 NOTE:
Install the respective washer first.
8 GR
Screw 2
9 GR
Screw 2
10 GR
Screw 1
11 GR
Screw 8
NOTE:
5 151
HANDLING BASE
ENG
LOWER BASE INSTALLATION

B
1 Install:
• the centring bush A
• the centring bushes B
NOTE:
Accurately clean the contact surfaces of the upper
and lower base with solvent.
B
Recommended solvent
B
TUTELA MOTOR CLEAN
2 A
Apply:
• the sealing paste on to the contact surface
IS
IL
AC as shown in the figure.
OR
YV
C
WARNING
I SIL A
YVOR
Do not apply the sealing paste in the engine oil
flow holes.
YVO
Recommended paste
YVO YVOR
I SIL AC
RI S
IL A
RI S
IL A
C IVORY SIL AC
YVO
RI S
IL A
C
YV YV
OR OR
IS IS
IL IL
AC AC
C
I SIL A
YVOR YVO
RI S
IL A
C
YVO
RI S
IL A
C
NOTE:
Hit the reinforced parts of the base with a rubber
hammer, perfectly coupling the two half-carter as
shown in figure 3
5 152
HANDLING BASE
ENG
4 Install:
25 23 24 • the screws
12 HALF-CARTER CLOSING FASTENING TORQUES

SEQUENCE FASTENING TORQUES
11
1st PHASE: 12.7 N m - 1.22 Kgf•m
1~8 2nd PHASE: 24.5 N m - 2.49 Kgf•m
3rd PHASE: 45.0 N m - 4.58 Kgf•m
16 13 1st PHASE: 12.7 N m - 1.22 Kgf•m
10 9 ~ 12
2nd PHASE: 30 N m - 3.05 Kgf•m
9
6 2 4 8 13 ~ 15
1st PHASE: 10 N m - 1.01 Kgf•m
2nd PHASE: 24.5 N m - 2.49 Kgf•m
5 1 3 7 1st PHASE: 10 N m - 1.01 Kgf•m

16
2nd PHASE: 24.5 N m - 2.49 Kgf•m
14 22
17 ~25 1st PHASE: 10 N m - 1.01 Kgf•m
15
19 18 17 20 21
5 Install:
10 N m - 1.01 Kgf•m • the plate B
R.
T.
• the screws C
B C
R.
T.
C
70
52A

52A70 STRONG THREAD BREAKS
6 Install:
10 N m - 1.01 Kgf•m
G • the counter-shaft lid gasket D
R.
T.
F • the counter-shaft lid E

• the screws F
NEW H • the screw G
• the screw H
F
Torque fasten all screws. 10 N m - 1.01 Kgf•m
R.
T.
GR
E
D 6 GR
COPPER GREASE
5 153
POWER SUPPLY
ENG
THROTTLED BODY REMOVAL
3
3
3

Throttled Body Removal
1 Screw 6
2 Throttled Body 1
3 O-Ring Gasket 3
5 154
POWER SUPPLY
ENG
THROTTLED BODY ADJUSTMENT

A A
A 1 Connect:
• the vacuum meter tubes A
directly to the fittings
2 Start:
• the engine
4
and bring it to a temperature of approx. 90°/95°C.
3 Check:
• the alignment of the mercury columns
2 with engine power to the minimum.
Eventually proceed with the balancing.
1
NOTE:
Ensure that the bypass screws B of bodies 1-2-3
are completely closed.
B B B
3 Correct:
• the alignment values
by acting on the pair screws C and D with a
screwdriver.
1 Align body 1 with body 2 by acting on the pair screw
3 2 C .
Align body 2 with body 3 by acting on the pair screw
D .
D NOTE:
C Having reached an optimal alignment on the 3
3 bodies, it is possible to perfect the correction by
individually acting on the by-pass screws B .
5 155
POWER SUPPLY
ENG
THROTTLED BODY INSTALLATION
LS 10 N m - 1.0 Kgf•m
R.
T.
1
1
1
NEW

Throttled Body Installation
1 NEW LS
O-Ring Gasket 3
2 Throttled Body 1
3 Screw 6
E
5 156
6 COOL
COOL
CHAPTER 6
COOLING PLANT
RADIATOR................................................................................................................ 1
RADIATOR REMOVAL......................................................................................................................... 1
RADIATOR CONTROL......................................................................................................................... 3
RADIATOR INSTALLATION................................................................................................................ 4
COOLING CIRCUIT.................................................................................................... 6
COOLING CIRCUIT REMOVAL.......................................................................................................... 6
COOLING CIRCUIT INSTALLATION................................................................................................. 7
OIL DISTRIBUTOR..................................................................................................... 9
OIL DISTRIBUTOR REMOVAL............................................................................................................ 9
OIL DISTRIBUTOR CONTROL............................................................................................................ 10
OIL DISTRIBUTOR INSTALLATION.................................................................................................. 11
THERMOSTAT.......................................................................................................... 12
THERMOSTAT REMOVAL.................................................................................................................. 12
THERMOSTAT CONTROL.................................................................................................................. 13
THERMOSTAT INSTALLATION........................................................................................................ 14
WATER PUMP.......................................................................................................... 15
WATER PUMP REMOVAL.................................................................................................................. 15
WATER PUMP CONTROL.................................................................................................................. 17
WATER PUMP INSTALLATION........................................................................................................ 18
WATER COLLECTOR................................................................................................ 21
WATER COLLECTOR REMOVAL...................................................................................................... 21
WATER COLLECTOR CONTROL...................................................................................................... 22
WATER COLLECTOR INSTALLATION............................................................................................. 23
COOL
RADIATOR
COOL
RADIATOR REMOVAL
14 10 11
13 10
15
8
9
12
7
20 6
1 4 3
22 3
16
30 23
24 28 5
26
17 23
18 23
25 20
23 2
29
21 16
21 18 17
21 23
22
25
26
24
21 27
19 29

NOTE:
operations.
Alternator Lid Removal See "FRAME 4.120" paragraph.
Right And Left Tank Lids Removal See "FRAME 4.112" paragraph.
Engine Protection Removal See "FRAME 4.120" paragraph.
Radiator Removal
1 Deformable Strip 1
4 Radiator Sleeve 1
5 Left Engine Sleeve 1
6 Left radiator Sleeve 1
8 Screw Strip 1
9 Sleeve 1
11 Right Radiator Sleeve 1
12 Screw Strip 1
14 Radiator Sleeve 1
15 Right Engine Sleeve 1
6 1
RADIATOR
COOL
RADIATOR REMOVAL
14 10 11
13 10
15
8
9
12
7
20 6
1 4 3
22 3
16
30 23
24 28 5
26
17 23
18 23
25 20
23 2
29
21 16
21 18 17
21 23
22
25
26
24
21 27
19 29
16 Screw 2
17 Upper Bush 2
18 Rubber Pad 2
Disconnect the electric fans n. 22.
19 Water Radiator 1
20 Screw 6
21 Special Fixing Pin 6
22 Electric fan 2
23 Spacer 8 NOTE:
Careful when removing the spacers, when
installing place them in the correct sequence.
24 Screw 2
25 Nut 2
26 Lower Bush 2
27 Left Support 1
28 Right Support 1
29 Rubber Pad 2
30 Radiator Cap 1
6 2
RADIATOR
COOL
RADIATOR CONTROL
1 Check:
• the radiator flaps
In the presence of obstructions Clean.
Apply a jet of compressed air on the rear part of the
radiator.
In the presence of damages Repair or replace.
NOTE:
Straighten the eventually crushed flaps using a flat
1 head thin screwdriver.
2 Check:
• the radiator flexible tubes
• the radiator piping
3 Check:
• the radiator fan
If functioning is faulty Check and repair.
See "ELECTRIC PLANT 7.34" chapter.
6 3
RADIATOR
COOL
RADIATOR INSTALLATION
17 19 NEW 16
21 19
NEW 18
23
22
20
10 N m - 1.01 Kgf•m
R.
T.
24
11 25
NEW 30 27 28
10 28 NEW
15 LS
1 9
5 NEW
26
6
14 9
3 13 9
7 11 29
9
2
8 15
8 13 14
8 9
10
7 6 LS
5 10 N m - 1.01 Kgf•m
4
R.
T.
8
12 2

Radiator Installation
1 Radiator Cap 1
2 Rubber Pad 2
3 Right Support 1
4 Left Support 1
5 LS
Screw 2
6 Lower Bush 2
7 Nut 2
8 Special Fixing Pin 6
9 Spacer 8 NOTE:
Carefully place them in the correct sequence,
carry out the operations in reverse order to
removal.
10 Electric fan 2
12 Water Radiator 1
Connect the electric fans 10.
13 Rubber Pad 2 NOTE:
14 Upper Bush 2 Change them only if worn.
15 LS
Screw 2
17 NEW Radiator Sleeve 1
18 Right Engine Sleeve 2
6 4
RADIATOR
COOL
RADIATOR INSTALLATION
17 19 NEW 16
21 19
NEW 18
23
22
20
10 N m - 1.01 Kgf•m 24
R.
T.
11 25
NEW 30 27 28
10 28 NEW
15
1 9
5 LS
NEW
26
6
14 9
3 13 9
7 11 29
9
2
8 15
8 13 14
8 9
10
7 6 LS
5 10 N m - 1.01 Kgf•m
4
R.
T.
8
12 2

19 NEW
Deformable Strip 2
20 Screw Strip 1
21 NEW Deformable Strip 1
22 Sleeve 1
23 Screw Strip 1
26 Left Radiator Sleeve 1
27 Radiator Sleeve 1
NOTE:
been completed.
6 5
COOLING CIRCUIT
COOL
COOLING CIRCUIT REMOVAL
6
8
1
3 10
8
4 7
5 9
3 4 2

Cooling Circuit Removal
NOTE:
operations.
1 Click Strip 1 NOTE:
The click strips can be re-used for the
installation being careful during the
dismantling phase.
2 Click Strip 1
3 Click Strip 2
4 Water Tube 2
5 Exchanger Outlet Tube 1
6 Screw Strip 1
7 Click Strip 1
8 Click Strip 2
9 Water Tube 2
10 Exchanger Input Tube 1
6 6
COOLING INSTALLATION
COOL
COOLING CIRCUIT INSTALLATION
5
3
10
8 1
3
7 4
6 2
8 7 9

Cooling Circuit Installation
1 Exchanger Input Tube 1
2 Water Tube 2
3 Click Strip 2 NOTE:
Unless worn, re-use the removal click strips,
otherwise change them.
4 Click Strip 1
5 Screw Strip 1
7 Water Tube 2
8 Click Strip 2
9 Click Strip 1
10 Click Strip 1
NOTE:
been completed.
6 7
COOLING CIRCUIT
COOL
COOLING CIRCUIT INSTALLATION
1 Fill:
• the cooling system (with the specified amount of
recommended cooling liquid)
ADJUSTMENTS 3.44".
2 Check:
• the cooling system
In the presence of leaks Repair or replace the
faulty parts.
6 8
OIL DISTRIBUTOR
COOL
OIL DISTRIBUTOR REMOVAL
11
10
8
6
9 5
1
3

Engine Protection Removal See "FRAME 4.120" paragraph.
Drain Collectors Removal See "FRAME 4.155" paragraph.
NOTE:
Oil Distributor Removal
1 Strip 1
2 Screw 2
3 Plate 1
4 Oil Filter 1 NOTE:
Remove the oil filter using the tool specific for
the removal and installation of oil filters.
5 Special Screw 1
6 Shim 1
7 Click Strip 2
8 Flow Tube 1
9 Outlet Tube 1
10 Oil Distributor 1
11 Seal Ring 1
6 9
OIL DISTRIBUTOR
COOL
OIL DISTRIBUTOR CONTROL

A
1 Check:
• the oil distributor A
• the flow and outlet flexible tubes B
B Replace.
6 10
OIL DISTRIBUTOR
COOL
OIL DISTRIBUTOR INSTALLATION
LS 1 NEW
4 2
NEW
5 30 + 60 N m - 3.05 + 6.11 Kgf•m
R.
T.
6
52A
E
3
IT 43
CT
7
LO
NEW 8
11
20 N m - 2.03 Kgf•m
R.
9
T.
GR
52A43
10 10 N m - 1.01 Kgf•m MEDIUM THREAD BRAKES

R.
T.

Oil Distribution Installation
1 NEW LS
Seal Ring 1
2 Oil Distributor 1
3 Outlet Tube 1
4 Flow Tube 1
5 NEW
Click Strip 2
6 Shim 1
7 Special Screw 1 NOTE:
52A43
Accurately remove grease from the thread of

the special screw.
8 NEW
Oil Filter 1 NOTE:
E
Install the oil filter using the tool specific for the
removal and installation of oil filters.
9 Plate 1
10 GR
Screw 2
11 Strip 1
NOTE:
6 11
THERMOSTAT
COOL
THERMOSTAT REMOVAL
1 5
4
2 3

NOTE:
operations.
Thermostat Removal
2 Screw 2
3 Thermostat disk 1
4 O-Ring Gasket 1
5 Thermostat 1
6 12
THERMOSTAT
COOL
THERMOSTAT CONTROL
A
1 Check:
• the by-pass hole A
In the presence of clogging Replace.
• the thermostat B
B If it does not open at 75° ~ 90° C (167~ 194° F)
Replace.
a Place the thermostat in a container full of water.
C
b Slowly heat the water.
c Place a thermometer in the water.

D d Mixing the water, keep an eye on the thermostat
E and the temperature shown on the thermometer.
F e When the temperature of 75°C is reached, the
thermostat valve starts to open reaching a
temperature of 90°C. The thermostat valve reaches
an opening of at least 7 mm.
B C Thermometer
7 D Water
opening (mm, in)
E Thermostat
F Container
A Completely closed
A B Completely open
0
NOTE:
75°C (167°F) 90°C (194°F) If in doubt on the precision of the thermostat,
temperature replace it. A faulty thermostat can cause significant
overheating or undercooling.
2 Check:
• the thermostat disk G
G • the tubes connected to it H
In the presence of breaks Replace.
H
2
6 13
THERMOSTAT
COOL
THERMOSTAT INSTALLATION

52A43

A
5 1
2
LS
52A
43
4
3
10 N m - 1.01 Kgf•m
R.
T.
NEW
Install the pieces in the given order

Thermostat Installation
1 Thermostat 1 NOTE:
Install the thermostat with the vent hole A
facing upwards.
2 NEW LS
O-Ring Gasket 1
3 Thermostat disk 1
4 Screw 2
52A43

NOTE:
been completed.
6 14
WATER PUMP
COOL
WATER PUMP REMOVAL
6
3
2
1
7

NOTE:
operations.
Water Pump Removal
1 Screw 1
2 Washer 1
3 Strip 2
4 Water Flow Tube 1
5 Water Return Tube 1
6 Screw 2
7 Water Pump 1
6 15
WATER PUMP
COOL
WATER PUMP REMOVAL

1 Remove:
D • the screws A
• the plates B
• the water input elbow C
• the O-Ring gasket D
B
A
C
1
2 Remove:
• the screws E
E • the water pump lid F
I • the water pump body G
• the O-Ring gasket H
• the centring bushes I
G
I
H
F 2
3 Remove:
M • the cap nut J
• the seal washer K
• the water pump impeller L
• the O-Ring gasket M
L
J 3
4 Remove:
• the mechanical seal N
• the back O
• the water pump shaft P
P
O
N
5 Remove:
• the internal seeger Q
• the external seeger R
• the bearing S
Q • the spacer T
R
S • the bearing U
T • the seal ring V
U
V
6 16
WATER PUMP
COOL
WATER PUMP CONTROL

D
A E
1 Check:
• the water pump lid A
• the water pump body B
• the water pump impeller C
• the mechanical seal D
• the back E
C In the presence of damages/cracks/wear lines
Replace
B
1
2 Check:
I • the gaskets F
• the seal washer G
F • the spacer H
J • the seegers I
• the seal ring J
In the presence of damages/cracks/wear lines
Replace.
H
G 2
3 Check:
K • the bearings K
If the movement is not smooth Replace
6 17
WATER PUMP
COOL
WATER PUMP INSTALLATION
E
6
7
1
43
52A
43
52A

52A43
10 N m - 1.01 Kgf•m
R.
T.

Water Pump Installation
1 Water Pump 1
E
2 Screw 2
52A43
3 Water Return Tube 1

4 Water Flow Tube 1
5 Strip 2
6 Washer 1
7 Screw 1
52A43
NOTE:
Insert the cooling liquid in the circuit once
operations have been completed.
6 18
WATER PUMP
COOL
WATER PUMP INSTALLATION

1 Install:
• the water pump shaft A
NOTE:
A Lubricate the water pump shaft as shown in the
figure before installing it.
E Recommended lubricant
1 E ENGINE OIL
2 Install:
E • the seal ring B
E
• the bearing C
• the spacer D
F G
LS
• the bearing E
• the external seeger F
D E • the internal seeger G
C
B
E ENGINE OIL
2
LS
TUTELA MR2 GREASE
3 Install:
• the back H
8 N m - 0.81 Kgf•m
• the mechanical seal I
R.
T.
• the water pump impeller J

H • the seal washer K
J I
• the cap nut L
K Torque fasten with: 8 N m - 0.81 Kgf•m

R.
T.
52A43
L
3 52A43 MEDIUM THREAD BRAKES
NOTE:
N
D
During installation of the back and of the
mechanica seal, ensure they are clean and that
there are no traces of grease.
6 19
WATER PUMP
COOL
4 Install:
Q • the centring bushes M
LS
R • the O-Ring gasket N
• the water pump body O
NEW M • the water pump lid P
52A43
• the O-Ring gasket Q
LS
NEW • the screws R
O Torque fasten the 2 screws with: 10 N m - 1.01 Kgf•m
R.
M
T.
N
P 10 N m - 1.01 Kgf•m
R.
T.
4 AREXONS SYSTEM 52A43

LS
TUTELA MR2 GREASE
5 Install:
10 N m - 1.01 Kgf•m • the O-Ring gasket S
R.
T.
• the water input elbow T

S • the plates U
• the screws V
LS
Torque fasten the 2 screws. 10 N m - 1.01 Kgf•m
R.
T.
U
V NEW AREXONS SYSTEM 52A43
T 52A43 MEDIUM THREAD BRAKES
52A43
LS
TUTELA MR2 GREASE
6 20
WATER COLLECTOR
COOL
WATER COLLECTOR REMOVAL
5
4
3
1 3
3
2

NOTE:
operations.
Alternator Removal See “ENGINE 5.122” paragraph.
Water Collector Removal
1 Strip 1
2 Water Tube 1
3 Screw 3
4 Water Collector 1
5 Water Collector Gasket 1
6 21
WATER COLLECTOR
COOL
WATER COLLECTOR CONTROL

1 Check:
• the water collector A
In the presence of damages/breaks Replace.
6 22
WATER COLLECTOR
COOL
WATER COLLECTOR INSTALLATION
52A43
LS 1 NEW
52
A4
3
3
5 3
3 10 N m - 1.01 Kgf•m
R.
T.

Water Collector Installation
1 NEW LS
Water Collector Gasket 1
2 Water Collector 1
3 Screw 3
52A43
4 Water Tube 1
5 Strip 1
NOTE:
been completed.
6 23
7 ELEC
ELEC
CHAPTER 7
ELECTRIC PLANT
SENSORS.................................................................................................................. 1
DESCRIPTION OF THE ENGINE MANAGEMENT SYSTEM....................................................... 1
SENSORS POSITION........................................................................................................................... 2
SYSTEM SENSORS.............................................................................................................................. 3
INLET AIR TEMPERATURE SENSOR............................................................................................... 3
PHASE SENSORS................................................................................................................................. 4
TEMPERATURE SENSOR OF THE COOLING LIQUID................................................................ 5
POSITION SENSOR OF THE THROTTLE BODIES UNIT (POTENTIOMETER)....................... 6
NEUTRAL SWITCH............................................................................................................................... 7
SIDE TRESTLE SENSOR...................................................................................................................... 8
CLUTCH SWITCH................................................................................................................................. 9
FRONT BRAKE SENSOR..................................................................................................................... 10
SPEED SENSOR.................................................................................................................................... 11
BAROMETRIC PRESSURE SENSOR................................................................................................. 12
LAMBDA PROBE.................................................................................................................................. 13
FALL SENSOR....................................................................................................................................... 14
HYDROSTOP......................................................................................................................................... 15
OIL PRESSURE SENSOR..................................................................................................................... 16
AMBIENT TEMPERATURE SENSOR................................................................................................ 17
DEVICES................................................................................................................... 18
DEVICES POSITION............................................................................................................................. 18
SYSTEM DEVICES................................................................................................................................ 19
HORN...................................................................................................................................................... 19
EQUIPMENT.......................................................................................................................................... 20
IGNITION SWITCH............................................................................................................................... 21
MAP BUTTON....................................................................................................................................... 23
RIGHT ELECTRIC DEVICE................................................................................................................... 25
LEFT ELECTRIC DEVICE...................................................................................................................... 26
DIODE...................................................................................................................................................... 27
ELEC
ACTUATORS............................................................................................................ 28
ACTUATORS POSITION..................................................................................................................... 28
SYSTEM ACTIVATING ACTUATORS............................................................................................... 29
AIR AT MINIMUM CONTROL SYSTEM (STEPPER)..................................................................... 29
INJECTORS............................................................................................................................................. 31
IGNITION REELS................................................................................................................................... 33
COOLING VENTS.................................................................................................................................. 34
FUEL PUMP............................................................................................................................................ 35
RELAY UNIT........................................................................................................................................... 36
REMOTE CONTROL SWITCH............................................................................................................ 38
SOLENOID.............................................................................................................................................. 39
ALTERNATOR........................................................................................................................................ 41
START-UP MOTOR .............................................................................................................................. 42
DIAGNOSTICS.......................................................................................................... 43
IGNITION AND INJECTION SYSTEM DIAGNOSTICS................................................................. 43
NUMBERING OF ECM CONNECTORS............................................................................................ 44
ADDITIONAL DIAGNOSIS.................................................................................................................. 45
INJECTORS -WALBRO ECU - 1.......................................................................................................... 45
POSITION SENSOR OF THE THROTTLE UNIT (POTENTIOMETER)
-WALBRO ECU - 1................................................................................................................................. 47
IGNITION REEL -WALBRO ECU - 1................................................................................................... 48
TEMPERATURE SENSOR OF THE COOLING LIQUID
-WALBRO ECU - 1................................................................................................................................. 49
AIR TEMPERATURE SENSOR -WALBRO ECU - 1......................................................................... 50
FUEL PUMP -WALBRO ECU - 1........................................................................................................ 51
SENSOR POWER SUPPLY VOLTAGE -WALBRO ECU - 1.......................................................... 52
BAD FUNCTIONING OF THE ENGINE DIAGNOSIS WARNING LIGHT LAMP (MIL)
-WALBRO ECU - 1................................................................................................................................. 52
COOLING VENT -WALBRO ECU - 1................................................................................................. 53
START-UP SYSTEM DIAGNOSTICS................................................................................................. 54
ELECTRIC PART..................................................................................................................................... 56
FRAME..................................................................................................................................................... 59
ELECTRIC PLANT..................................................................................................... 61
ELECTRIC LAYOUT.............................................................................................................................. 61
MAINTENANCE WARNINGS............................................................................................................. 63
BATTERY EFFICIENCY CONTROL.................................................................................................... 65
ELEC
SENSORS
ELEC
DESCRIPTION OF SYSTEM FOR

ENGINE MANAGEMENT
Each model is equipped with an electronic engine

management system with a control that includes
both fuel ignition and distribution.
The electronic control module (ECM) obtains
information from the sensors placed around the
engine, from the cooling and inlet systems and
calculates, with precision, the ignition advance and
the fuel requirement for all engine speeds and loads.
Furthermore, the system has hardware diagnostics
functions compliant with the requirements of the
State of California, USA, for on board diagnostics.
This function assures that, in case of a fault in the
system, the type of fault and engine data at the time
of the fault are stored in the ECM memory.
This stored data can be recovered by a Benelli dealer
using an appropriate service equipment provided to
all Benelli dealers (see Axone/Benida instruction
manual).
In this way, a precise diagnosis of the fault and defect,
timely repaired, can be made.
7 1
SENSORS
ELEC
SENSORS POSITION
a Side Trestle Sensor f Phase Sensor k Ambient Temperature Probe
b Lambda Probe g Hydrostop l Air Temperature Sensor
c Front Brake Sensor h Neutral Switch m Barometric Pressure Sensor
d Potentiometer i Oil Pressure Sensor n Clutch Switch
e Fall Sensor j Speed Sensor o Cooling Liquid Temperature
Sensor
k l
•
• a
•
• •
•
n
i
b
h m
c
• d
• •
•
•
• • ••
j e
o
g f
7 2
SENSORS
ELEC
SYSTEM SENSORS
INLET AIR TEMPERATURE SENSOR
Placed underneath the on board equipment
P
(dashboard)
Considering that the air density (and, therefore, the
amount of oxygen available to burn the fuel) varies
with the temperature, an inlet air temperature sensor
has been arranged.
Variations in the air temperature (and, therefore, in
the air density) are compensated by adjusting the
amount of fuel injected to a level compliant with the
clean combustion and low emissions.
1 Remove:
• the fixed cap
• the equipment support
ADJUSTMENTS 3.89”
2 Disconnect:
• the inlet air temperature sensor
Loosen:
• the nut
3 Check:
• the resistance
using the multitester
DATA OF RESISTANCE TO THE TYPICAL CONDITIONS
AMBIENT TEMPERATURE RESISTANCE VALUE

30 °C 1.6 a 1.8 KΩ
25 °C 1.9 a 2.2 KΩ
20 °C 2.3 a 2.7 KΩ
15 °C 2.9 a 3.3 KΩ
10 °C 3.5 a 4.0 KΩ
5 °C 4.4 a 4.9 KΩ
0 °C 5.5 a 6.1 KΩ
7 3
SENSORS
ELEC
PHASE SENSORS
Placed in the right part of the engine near the
engine shaft
The position sensor of the elbow shaft detects the
movement of a cogwheel fixed at the right end of the
engine shaft through reading of a particular wheel
made of 28 teeth, equally distant, next to a space of
three times the length.
The reading interpretation is used by the ECM to
determine the position of the engine shaft compared
to the point where the fuel is injected and to the need
for fuel ignition.
1 Remove:
• the screw A
2 Check:
• the distance
between phase sensor and phonic wheel
Distance between phase sensor

and phonic wheel
1 mm (0.039 in)
3 Check:
• the resistance
with a multitester
Resistance
500 ± 100 Ω
7 4
SENSORS
ELEC
TEMPERATURE SENSOR OF THE

COOLING LIQUID
Placed on the right side of the cylinder head
P
The information of the cooling liquid temperature
received by the ECM is used to optimise the power
supply at all engine temperatures, and to calculate
the power supply requirement upon cold and hot
start-ups.
1 Remove:
• the seat
• the tank
3.10” paragraph.
RESISTANCE DATA TO THE TYPICAL CONDITIONS
AMBIENT TEMPERATURE RESISTANCE VALUE

20 °C 2.35 a 2.65 KΩ
10 °C 3.60 a 4.00 KΩ
0 °C 5.60 a 6.25 KΩ
7 5
SENSORS
ELEC
POSITION SENSOR OF THE

THROTTLE BODIES UNIT
(POTENTIOMETER)
Placed on the right end of the small shaft of the
throttle bodies unit
The throttle bodies unit position sensor
(potentiometer), managed and powered directly by
ECM, supplies a signal that identifies the throttle
opening position used by the same ECM to determine
the fuel dosing and the ignition advance.
1 Remove:
• the seat
• the tank
3.10" paragraph.
A • the throttled body
• the two screws A
1
2 Check:
• the resistance
with the multitester positioned on symbol Ω
between PIN 1 and PIN 3 (the more external PINs).
Resistance
4000 Ω ± 20 %
7 6
SENSORS
ELEC
NEUTRAL SWITCH
Located inside the gear change box
The neutral switch indicates when the gear change is
in neutral.
Furthermore, the neutral switch supplies a signal
relating to the safety device that prevents start-up with
the trestle lowered and the gear engaged.
IF a gear is engaged with the trestle lowered, power
supply to the ECM is interrupted causing the engine to
switch off.
1 Remove:
• the seat
• the tank
• the shock absorber
• the rear wheel
See paragraph "FRAME 4.16”.
• the swing arm
1
2 Check:
• the continuity
with the multitester positioned on symbol
(continuity/diode trial function), position one
terminal on the sensor point and the other on the
PIN.
ENGINE MASS
ON (neutral)
OFF (neutral excluded)
WARNING
When connecting and disconnecting the gear
change switch wire, ensure to place the ignition
switch on OFF, to avoid damages to the electronic
parts.
In case of no continuity between the wire of the

neutral sensor and the mass, replace the component.
7 7
SENSORS
ELEC
SIDE TRESTLE SENSOR

Placed at the top of the side trestle shank
P
If the side trestle is lowered, the engine will not start
until the gear change is placed in neutral or the stand
in closed position.
2 Disconnect:
• the connector of the side trestle switch
3 Measure:
• the continuity
using a multitester.
STAND PIN 1 PIN 2
Lifted
Lowered
If the above conditions are satisfied, the stand switch

functions, otherwise replace the component.
7 8
SENSORS
ELEC
CLUTCH SWITCH
Placed on the clutch lever
The engine will not start until the lever is pulled up to
the handle bar.
1 Disconnect:
• the clutch switch cables
2 Use:
• the tester
and check on the clutch switch pins the table
CLUTCH PIN 1 PIN 2
Pulled
Released
If the above conditions are satisfied, the clutch switch

7 9
SENSORS
ELEC
FRONT BRAKE SENSOR

Placed on the front brake pump
It is a switch in contact with the brake lever used for
switching on the stop lights.
1 Disconnect:
• the contacts of the electric plant on the sensor
proceed as shown for the control
2 Use:
• the multitester
position on the symbol (continuity/diode trial
function), and check the functioning as shown in the
table
SENSOR PIN 1 PIN 2
Pulled Brake Lever
Brake Lever
Released
If the above conditions are satisfied, the front brake

sensor functions, otherwise replace the component.
7 10
SENSORS
ELEC
SPEED SENSOR
Placed on the rear calliper support
P
Reads the fixing screws of the rear brake disk.
If the speed is not indicated on the dashboard or it

does not function correctly, check the speed sensor
and the electric connections with reference to the
cable paths on the electric layout.
If the sensor and the connection are correct, check the
functioning of the speedometer.
1 Disconnect:
• the connector
of the speed sensor wire
2 Remove:
A • the two screws A
• the speed sensor
3 Connect:
• a 12V battery (between pin1 and pin2)
• a 10kΩ resistance (between pin2 and pin3)
10 kΩ 12 V • the multitester (probe + with pin2 and probe – with
pin3) as shown in the figure.
PIN1
If a screwdriver touching the speed sensor surface is
PIN3 PIN2 moved when in the above specified conditions, the
voltage indicated by the tester changes (0V
12V or 12V 0V).
Speed sensor
If the voltage indicated by the tester does not change,
3 replace the speed sensor with a new one.
NOTE:
The highest voltage indicated by the tester (12V) is
the battery voltage.
7 11
SENSORS
ELEC
BAROMETRIC PRESSURE SENSOR

Inside the control unit
The atmospheric pressure is detected by means of a
sensor placed inside the injection module.
This sensor enables the detection of the air density in
different environmental conditions (which, for
example, the use of the vehicle in areas having
different heights).
With this information, the amount of fuel for the
injector is calibrated adjusting to the prevailing
conditions.
1 Remove:
• the control unit
2 If the sensor detects conflicting barometric pressure

references from the real ones, check there is not dust
or debris obstructing the air passage hole, otherwise
replace the part.
7 12
SENSORS
ELEC
LAMBDA PROBE
Placed on the drain collector near the catalyst
The Lambda probe is able to detect the concentration

of oxygen inside the exhaust gas; precisely the
lambda value indicating the ratio between air and
petrol, where:
• Value 1, when combustion is stoichiometric

• < of 1, when petrol is in excess
• > of 1, when air is in excess
The probe then transmits as electric signal to the

control unit that adjusts the inflow of fuel and air inside
the combustion chamber.
1 Check:
• the resistance
between PIN 1 and PIN 5 (the more external PINs).
Resistance
9±2 Ω
7 13
SENSORS
ELEC
FALL SENSOR
Placed in the centre of the bike in correspondence
with the expansion vessel
In case of fall, it interrupts the flow of petrol to the
injection system.
1 Remove:
• the seat
• the tank
3.10" paragraph.
2 Disconnect:
• the connector of the fall sensor
3 Check:
• the continuity
MULTIMETER
with the multitester positioned on PIN 1 and PIN 2
and check the table.
20 30
0 10
FALL SENSOR PIN 1 PIN 2
Position
Horizontal
Position
- + Vertical
If the above conditions are satisfied, the fall sensor

1 2
7 14
SENSORS
ELEC
HYDROSTOP
Placed on the rear brake pump
It is a switch that works by reading the oil pressure
exercised on the pump.
It is used to switch on the stop lights.
1 Check:
• the continuity
MULTIMETER
20 30
0 10
BRAKE PIN 1 PIN 2
Calibrated
Released
- +
If the above conditions are satisfied, the hydrostop
1 2
7 15
SENSORS
ELEC
OIL PRESSURE SENSOR

Placed on the lower half carter
It measures the oil pressure in ball bearing gallery.
1 Disconnect:
• the electric coupling
2 Remove:
• the oil pressure sensor
from the half-carter
2 Check:
• the continuity
between PIN1 and the sensor mass using an air
pressure regulator with inflow on the detection hole.
• Calibrate the air pressure regulator at 2 bar
• Progressively lower the pressure until 0.4 - 0.7 bar are
reached.
Continuity between PIN1 and mass

0.4 - 0.7 bar
In case of no continuity between PIN1 and engine

mass, replace the component.
7 16
SENSORS
ELEC
AMBIENT TEMPERATURE SENSOR

Placed near the equipment
It reads the ambient temperature and sends the value
to the equipment.
1 Remove:
• the fixed cap
3.89” paragraph.
2 Disconnect:
• the ambient temperature probe
3 Check:
• the continuity
°C Ω TOLLERANCE
5 21 K ± 0.5 K
10 19 K ± 0.5 K
25 10 K ± 0.5 K
40 6K ± 0.5 K
If the above conditions are satisfied, the lambda probe
7 17
DEVICES
ELEC
DEVICES POSITION
a Right Electric Device c Ignition Switch e Horn
b Left Electric Device d Map Button f Equipment
g Diode
e
a •
•
b
g
•
••
7 18
DEVICES
ELEC
SYSTEM DEVICES
HORN
Placed on the right side trellis underneath the
right tank fairing
The horn is an electric-mechanic device used as
acoustic warning device.
1 R
Remove:
• the fixing screw on the frame
2 Disconnect:
• the wires of the acoustic warning device
3 Connect:
• PIN1 and PIN2
to the battery and check functioning.
7 19
DEVICES
ELEC
EQUIPMENT
Placed on the headlight equipment support small
frame
The equipment supplies the driver all information
regarding the functioning of the bike:
• indicator luminous warning lights:
high beams warning light
indicators warning light
fuel reserve warning light
gear change in neutral warning light
injection malfunctioning warning light
• cooling liquid temperature indicator
It indicates the cooling liquid temperature
• revs counter
It indicates the number of engine revolutions per
minute
• alarm LED
It switches on when the oil pressure value
or that of the cooling temperature or that of the
battery voltage is incorrect (possibility of more
anomalies occurring simultaneously).
In case it switches on check, with reference to the
type of alarm communicated (H, O, BAT, OIL) the
cause or nature of the relative signalling.
1 Remove:
• the fixed cap
3.89” paragraph.
2 Disconnect:
• the equipment pin
3 Loosen:
• the two fixing nuts
4 Take out:
• the equipment
7 20
DEVICES
ELEC
IGNITION SWITCH
Placed behind the steering tube
The ignition switch is used for:
• giving the main contact to the electric plant
• closing the steering lock
• keep the parking lights switched on during all
requested conditions
1 Remove:
• the seat
• the tank
• the steering lock lid
3.10" paragraph.
• the conveyor
3.10" paragraph.
2 Disconnect:
• the key lock wiring
3 Remove:
• the two fixing pull screws on the trellis A
A 3
7 21
DEVICES
ELEC
4 Check:
• the continuity
with the multitester and check the table.
PIN 1 PIN 2 PIN 3 PIN 4
Key ON
Key OFF
4
Lock
Parking
If the above conditions are satisfied, the ignition switch

Key at "ON" position

All electric circuits are active, the equipment and
warning lights carry out the self-diagnosis; the
engine can be started.
The key cannot be removed.
Key at "OFF" position

All electric circuits are deactivated
The key can be removed.
Key at "LOCK" position

All electric circuits are deactivated and the
steering wheel is locked.
Key at "PARKING" position

All electric circuits are deactivated except for the
parking lights (position lights) and the steering
wheel is locked.
NOTE:
Do not leave the key in "PARKING" position for a
long time in order to avoid discharging the battery
of the bike.
7 22
DEVICES
ELEC
MAP BUTTON
Placed on the dashboard support small frame
The map button is used to change the mapping of the
control unit.
1) With the button released the map loaded on block 1
(button state 0, contact open) is selected
2) With the button pressed the map loaded on block 2
(button state 1, contact closed) is selected
1 Remove:
• the cap
3.89” paragraph.
2 Disconnect:
• the map button wiring
3 Check:
• the continuity
2 3 between n. 4 and n. 5
between n. 1 and n. 6
with button pressed
7 8 Check:
5 6 • the continuity
4 1 with button released
3
7 23
DEVICES
ELEC
4 Check:
• the connections
must be reported as shown in the table.
4 1 Brown/Red
5 4 Purple/Black
5 Purple/Green
8 8 Black
3 Brown/Red
1
7 Brown/Red
3 7
JUMPER
7 24
DEVICES
ELEC
RIGHT ELECTRIC DEVICE

A
Placed on the right side of the handle bar
The right electric device is made of:
• RUN/OFF button A
C it is used to close the contact of the electric plant in
case of an emergency
• start-up button B
it is used to start the engine
B • emergency lights switch C
it is used to activate the 4 indicators in case of an
emergency
1 Check:
• the continuity
with the multitester position on RUN/OFF button
placed at ON
2 Check:
• the continuity
with the multitester positioned on the start-up
button at ON
3 Check:
• the continuity
with the multitester positioned on the emergency
lights switch at ON
Check the table.
PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6
Emergency lights
switch
Run/Off Button
Start-up Button
If the above conditions are satisfied, the emergency lights switch, the
Run/Off button and the start-up button function, otherwise replace the
components.
7 25
DEVICES
ELEC
D LEFT ELECTRIC DEVICE

A
Placed on the left side of the handle bar
The left electric device is made of:
• lights switch command A
high beam/dipped beam shunting switch
B • indicators command B
by moving the command to the left or to the right,
the relative indicators will be activated.
The command returns to the centre; press to
C deactivate the indicators
• acoustic warning device button C
press to activate the acoustic warning device.
• high beams flash button D
used to signal ones presence in conditions of scarce
visibility
1 Check:
• the continuity
with the multitester positioned on the relative
terminals with the horn button pressed.
2 Check:
• the continuity
terminals with the flash button pressed.
3 Check:
• the continuity
terminals with reference to the selection (right/left).
4 Check:
• the continuity
terminals with reference to the selection (high
beam/dipped beam).
Check the table.
PIN 1 PIN 2 PIN 3 PIN 4 PIN 5 PIN 6 PIN 7 PIN 8 PIN 9 PIN 10
Acoustic Warning
Device
High Beam Light
Dipped Beam Light
Flash Button
High Beams
Right indicator
Left Indicator
If the above conditions are satisfied, the acoustic warning device, the lights switch command, the high
beams flash button function, otherwise replace the components.
7 26
DEVICES
ELEC
DIODE MODULES
Placed underneath the on board equipment
INDICATORS DIODE MODULE

The device can be identified by the number of
insertions present on the relative connector (3 PIN).
1 Check:
• the continuity
MULTIMETER

(continuity/diode trial function), with terminal +
0 10 20 30
(positive) on PIN2 and with terminal - (negative) on
PIN1 and then on PIN3.
- +
1 2 3
123
NEUTRAL SENSOR DIODE MODULE

The device can be identified by the number of
MULTIMETER
insertions present on the relative connector (2 PIN).
20 30
0 10
2 Check:
• the continuity
(continuity/diode trial function), with terminal +
(positive) on PIN1 and with terminal - (negative)
- + on PIN2.
1 2
1 2
7 27
ACTUATORS
ELEC
ACTUATORS POSITION
a Fuel Pump e Ignition Reels h Injection Relay
b Stepper f Injectors i Cooling Vent
c Alternator fg Start-up Motor ij Solenoid
d Remote Control Switch
f h
a
•• •
•
••
•
c
d
j
• • e
•
7 28
ACTUATORS
ELEC
SYSTEM ACTIVATING ACTUATORS
In reply to the signal received by the sensors, the ECM

adjusts a series of electronic and electric-mechanic
actuators.
The function and position of the actuators is shown
below.
AIR AT MINIMUM CONTROL SYSTEM

(STEPPER)
Located inside the air filter box
The system includes a valve for controlling the air
passage underneath the throttles of the throttled body
and equipped with a step-by-step engine (stepper).
The system controls the following parameters:
• Functioning at minimum
• Air supply in case of engine overrevving.
• Correction of the air/fuel ratio working at
minimum speeds at heights above sea level.
• Correction of the air/fuel ratio in cold and hot
start-ups.
When the step-by-step engine (stepper) is activated,
it more or less opens the air passage control valve
and allows a certain flow of air along a series of tubes
in the throttle bodies unit.
1 Remove:
• the seat
C F • the right and left tank lids
See paragraph “FRAME 4.112“.
• the tank
See paragraph "FRAME 4.118"
A • the air filter box
3.10” paragraph.
B • the 4 plate screws A
A • the plate B
• the 2 screws C
• the two nuts D
Disconnect:
• the 3 air tubes E
E Remove:
• the distributor F
G • the stepper G
D 1
7 29
ACTUATORS
ELEC
2 Check:
• the resistance
with the multitester positioned on symbol Ω between
PIN1 and PIN4 and then between PIN2 and PIN3
1
2 Resistance
3
4 50 ± 5 Ω
7 30
ACTUATORS
ELEC
INJECTORS
Positioned on the throttle bodies unit
The engine is equipped with three quadruple jet
injectors.
The jet quantity of the injectors is constant, but the
opening duration of every injector is variable.
The duration of each injection is calculated by the ECM
according to the data received by the various system
sensors.
1 Remove:
• the seat
• the tank
3.10" paragraph.
• the 2 flute screws A
• the flute B
• the injectors retainer clips C
• the injectors D
C C
A
A
B
D
7 31
ACTUATORS
ELEC
2 Check:
MULTIMETER
• the resistance
20 30
between PIN1 and PIN2
0 10
Resistance
12 ± 2 Ω
- +
1 2
7 32
ACTUATORS
ELEC
IGNITION REELS
Placed directly on the head of every spark plug
The ignition reel gives the necessary high voltage and
ignition energy to produce high voltage sparks between
the ignition spark plug electrodes.
The ECM, through the reading of the various system
sensors, determines the relative ignition and advance
times.
There are 2 types of reels:
SAGEM: the connector is inside the head
BERU: the connector is wired.
1 Remove:
• the seat
• the tank
3.10” paragraph.
• the conveyor
3.10" paragraph.
• the reels
3.6” paragraph.
2 Check:
• the resistance
MULTIMETER
PIN1 and PIN2
20 30
0 10
Resistance
0.6 ± 0.1 Ω
This check is valid for both types of reels.
- +
1 2
7 33
ACTUATORS
ELEC
COOLING VENTS
Placed on the radiator body
The ECM activates and deactivates the cooling vents
according to a signal received from the cooling liquid
temperature sensor.
When the cooling liquid temperature reaches the
upper threshold temperature, the cooling vents
activate by means of a command from the ECM.
When the cooling liquid temperature drops
sufficiently, lower threshold temperature, the cooling
vents deactivate by means of a command from the
ECM.
1 Remove:
• the coupler
of the cooling vent wire.
2 Check:
A
• the charge current of the vent motor
with an ammeter connected as shown in the figure.
Motor Vent Ammeter
The voltmeter is used to check that the battery powers
the motor at 12 volt.
When the vent turns at full speed, the ammeter must
show no more than 5 amp.
If the motor does not turn, replace the vent motor unit
with a new one.
2
NOTE:
It is not necessary to remove the cooling vent from
the radiator to carry out the above trial.
7 34
ACTUATORS
ELEC
FUEL PUMP
Placed inside the fuel tank
The electric pump distributes the fuel inside the
supply circuit, by means of a pressure regulator, at a
constant pressure of 3.5 bar.
The ECM directly manages the functioning of the
pump guaranteeing, from the first activation of the
board with a timed function, the correct fuel pressure
necessary for engine start-up and with a continuous
functioning for the subsequent normal use of the
vehicle.
1 Remove:
• the seat
• the tank
2 Check:
• the fuel pump
a Place the outlet tube inside a container to drain

the petrol.
b Connect the battery (12 V) to the petrol pump.

PIN1 positive cable +
PIN2 negative cable -
3 Check:
• the resistance
PIN3 and PIN4
Resistance with full tank

12 ± 2 Ω
- +
Resistance with empty tank
285 ± 2 Ω
2
c If the above conditions are satisfied, the fuel pump

functions, otherwise replace the part.
7 35
ACTUATORS
ELEC
SERVICES RELAY UNIT

Placed inside the object compartment below the
vehicle seat
The relay unit is managed by the ECM to drive
every load in an optimum manner like:
• the lighting system
The ECM ensures that all lights switch on in certain
conditions, also allowing an energy saving when in
discharged battery condition.
• the fuel pump
The fuel pump is activated only when the start-up
motor starts to make the engine rev.
• the electric fans
• the injection
The ECM autonomously manages the excitement
of the injection relay according to the relative
conditions which ignition, switch off and relative
use of the vehicle; through this management, it is
possible to guarantee a stable power supply to the
ECM allowing it to carry out the correct memorising
and setting of the parameters procedures during
the stop phases, continuing to self-power for a few
seconds after board switch off.
• the services
All "under lock and key" devices like the dashboard,
the various safety devices and the lighting system,
are connected to the services relay.
1 Remove:
MULTIMETER
• the seat
20 30
0 10
2 Check:
• the resistance
PIN1 and PIN2
- + Resistance
12 ± 2 Ω
3 Use:
• the tester
and check on the pins of the relay the table powering
PIN 85 and PIN 86 from the battery
RELAY PIN 87 PIN 30 PIN 87A
2 Powered by
the battery
Not powered by
the battery
If the above conditions are satisfied, the relay function,

otherwise replace the components.
NOTE:
This procedure must be applied to all the above
relay.
7 36
ACTUATORS
ELEC
POWER REEL
Orange/White Yellow/Red
DIPPED BEAMS RELAY

POWER REEL
Yellow/Red Yellow/Green
POWER REEL
Orange/White Yellow/White
HIGH BEAMS RELAY

POWER REEL
Yellow/White Yellow/Green
POWER REEL
Red/Black Red/Black
INJECTION RELAY
POWER REEL
Red/White Brown/Purple
POWER REEL
Orange/Green Brown
ELECTRIC FANS RELAY

POWER REEL
White/Black White/Black
POWER REEL
Orange Brown
PETROL PUMP RELAY

POWER REEL
Orange/Black Orange/Black
7 37
ACTUATORS
ELEC
REMOTE CONTROL SWITCH

Placed on the left side of the bike near the pinion
carter
The remote control switch closes the power contact
on the start-up motor.
1 Remove:
2 Disconnect:
• the battery cable -
• the start-up motor cable
• the battery cable
• the start-up relay connector
Remove:
• the start-up relay
3 Apply:
• 12 volt to the terminals A and B
Check:
• the continuity
between the power terminals as shown in the figure.
If there is continuity, the start-up relay is in good
conditions.
A B
WARNING
Do not apply the battery voltage to the start-up
relay for more than 5 seconds as it may overheat
suffering damages to the winding.
3
4 Check:
• the winding
if it is "open" or "at mass" and if there is resistance.
The winding is in good conditions if the resistance is:
Start-up relay resistance

3-6Ω
7 38
ACTUATORS
ELEC
SOLENOID
Placed on left side underneath the injectors flute
The opening and closing is managed through the ECM
to improve the torque/power supply in different use
conditions of the vehicle.
1 Remove:
• the seat
• the tank
3.10" paragraph.
2 Disconnect:
• the cable connected to the drain valve
Remove:
• the two screws A
3 Measure:
MULTIMETER
• the reel impedance
0 10 20 30
between PIN1 PIN 2 as shown in the figure.
- + Reel resistance
1 2
3-6Ω
4 Measure:
MULTIMETER
• the current absorbed by the solenoid
using the multitester
- +
20 30
0 10
Absorbed Current
- +
8.7 ± 1 A
1 2
7 39
ACTUATORS
ELEC
4 Check:
• the diode
Check that it is correctly positioned as shown in the
figure.
Even if only one control results negative, replace the

part.
4
ATTENTION
At every inspection of the solenoid device, check
the integrity of the contacts and the functioning
of the diode.
7 40
ACTUATORS
ELEC
ALTERNATOR
Placed on the left side of the vehicle
It allows the balancing of the electric consumptions
through the recharging of the battery.
1 Switch on:
• the bike
2 Measure:
• the voltage
MULTIMETER
with the multitester positioned on symbol at the

ends of the battery
20 30
0 10
With bike switched off

12.7 ± 0.5 V
- + With bike revving up at 3.000 rpm

13.5 ± 0.5 V
If the above conditions are satisfied, the alternator

- +
7 41
ACTUATORS
ELEC
START-UP MOTOR
Placed on the left side of the vehicle
It is used to start the bike.
1 If the motor does not start, check:

• the right electric block
• the clutch switch
If the motor still does not start, carry out the following
check:
2 Remove:
• the start-up motor
3 Lock:
• the start-up motor
in a vice.
Carry out:
• the connections
as shown in the figure and check the correct
functioning.
- +
7 42
DIAGNOSTICS
ELEC
SYSTEM DIAGNOSTICS IGNITION

AND INJECTION
There are two special tools for the injection and
ignition system diagnosis.
there are two special tools.
S CANTO O L
(Code R180197036000) AXONE
(Code R300082003000) BENDIA
A Diagnostic software, able to identify the faults
present or that have occurred on the bike, is included
in the special equipment.
This Software has a guide manual for using the same
program, in order to perform the control on every
individual system component.
7 43
DIAGNOSTICS
ELEC
NUMBERING OF CONNECTORS ECM
The diagram at the side shows the sequence of the two

ECM connectors.
These pin numbers correspond directly to the pin
numbers supplied during the diagnostics procedures
and to the layout drawing of the wiring used in this
manual.
Each connector has 24 pins arranged on three rows
numbered A, B, and C and on eight columns as shown
GREY BLACK at the side.
The first column is called 1 and the eighth column 8.
The position of each ECM connector is described

through this manual, through the identification of
connector 1 (black) or 2 (grey), followed by the row
number and the column number where it is situated.
In the example at the side, pin 6/B is shown by the
intersection of the lines.
7 44
DIAGNOSTICS
ELEC
ADDITIONAL DIAGNOSIS
The following tables, if used correctly, will help identify the fault in the system, once the diagnostics problem code has been
stored.
NOTE
N
1) Black Connector
2) Grey Connector
INJECTORS -WALBRO ECU 1

FAULT CODE POSSIBLE CAUSE PRECAUTION
P1201/02/03 The flooding indicates short circuit Ensure that the injectors’ relative connectors
Open or short circuit - are inserted correctly.
injectors 2/1/3 Disconnect the ECM and proceed with the
location 1 test.
NOTE
N
1) ECU Black Connector
2) ECU Grey Connector
LOCATION TEST
TEST RESULT PRECAUTION
1) Check the integrity of the terminal
and the cable: Ok Proceed with test 2
- pin ECM 1/BI
- pin ECM 1/CI
- pin ECM 1/B2 Faulty Repair the fault, proceed with test 6
2) Check the value of the safety relay Disconnect the relative injector and proceed
white/red resistance: from 15.5 to 16.3 with test 3
- pin 1/RO/BI of ECM to pin 1/C1 of
ECM (injector 2)
Open circuit Proceed with test 4
- pin 1/RO/BI of ECM to pin 1/B1 of
ECM (injector 1)
- pin 1/RO/BI of ECM to pin 2/B8 of Disconnect the relative injector and proceed
ECM (injector 3) Short circuit with test 3
3) Check if the cable is in short circuit:

Ok Proceed with test 7
- pin 1/BI of ECM to the mass
- pin 1/CI of ECM to the mass
- pin 2/B8 of ECM to the mass Locate and repair the wiring fault, proceed
Short circuit with test 7
4) Check the continuity of the cable:

- pin 1/AB of ECM to injection relay Ok Proceed with test 6
- pin 1/BI of ECM to pin 2 of
connector (injector 2)
- pin 1/CI of ECM to pin 2 of
connector (injector 1)
- pin 2/B8 of ECM to pin 2 of Open circuit Locate and repair the wiring fault, proceed
connector (injector 3) with test 7
7 45
DIAGNOSTICS
ELEC

5) Check the continuity of the cable
for short circuit:
- pin 1/RO/BI of ECM to pin 1/B1
of ECM (injector 1)
- pin 1/RO/BI of ECM to pin 1/C1
of ECM (injector 2) Locate and repair the cables fault, proceed
Short circuit
- pin 1/RO/BI of ECM to pin 2/B8 with test 7
of ECM (injector 3)
6) Check the resistance of the relative

injector: from 15.5 to 16.3 Proceed with test 7
- between pin 1 and pin 2 Replace the relative injector and proceed with
Faulty
test 7
7) Connect the wiring, reset the fault Ok Activity Performed - end the test
code and activate the engine to
check the fault has been eliminated. The fault remains Contact Benelli after-sales assistance
7 46
DIAGNOSTICS
ELEC
POSITION SENSOR OF THE THROTTLE BODIES UNIT (POTENTIOMETER) - WALBRO

ECU 1

P0122 Low sensor input voltage Check and take note of the sensor data of the
diagnostics tool (see Axone or Bendia instruction
manual)
P0123 High sensor input voltage Ensure that the sensor connector is inserted
correctly. Disconnect the ECM and proceed with
the location 1 test.
LOCATION TEST
and the cable: Ok Disconnect the sensor and proceed with test 2
- pin ECM 1/B5
- pin ECM 1/B7
- pin ECM 1/B3 Faulty Repair the fault, proceed with test 5
2) Check if the cable is in short circuit:

- pin 1/B7 of ECM to the mass
Short circuit Locate and repair the wiring fault, proceed
with test 5

- pin 1/B3 of ECM to pin 3 of sensor
- pin 1/B7 of ECM to pin 2 of sensor
- pin 1/B5 of ECM to pin 1 of sensor Locate and repair the wiring fault, proceed
Open circuit
with test 5
4) Check if the cable is in short circuit: Replace the position sensor of the throttle
Ok
bodies unit, proceed with test 5
- pin 1/B7 of ECM to pin 1/B5 of ECM
Locate and repair the wiring fault and proceed
- pin 1/B7 of ECM to pin 1/B3 of ECM Short circuit
with test 5
7 47
DIAGNOSTICS
ELEC
IGNITION REEL - WALBRO ECU 1

P1351/52/53 Open or short circuit - 2/1/3 ignition Ensure that the connector of the relative ignition
reel reels is inserted correctly.
Disconnect the ECM and proceed with the
location 1 test.
LOCATION TEST
and the cable: Ok Proceed with test 2
- pin ECM 1/A8 (BOB1)

- pin ECM 1/B8 (BOB2) Faulty Repair the fault, proceed with test 7
- pin ECM 1/A1 (BOB3)
2) Check the value of the safety relay Disconnect the relative reel and proceed
white/red resistance: 0.8 Ω
with test 3
pin 1/RO/BI of ECM at:
- pin 1/B8 of ECM (ignition reel 2) Open circuit Proceed with test 4
- pin 1/A8 of ECM (ignition reel 1)
- pin 2/A1 of ECM (ignition reel 3) Short circuit Disconnect the relative reel and proceed
with test 5
3) Check the cable for short circuit:

- pin 1/B8 of ECM to the mass
- pin 1/A8 of ECM to the mass
- pin 2/A1 of ECM to the mass Locate and repair the cables fault, proceed
Short circuit
with test 7
4) Check the continuity of cable

P1/RO/BI with each pin 2 of the
ignition reels:
Power pin 8 of the lock relay with Ok Proceed with test 6
each pin of the ignition reels.
- pin 1/B8 of ECM to pin 1 of
ignition reel 2
- pin 1/A8 of ECM to pin 1 of
ignition reel 1 Locate and repair the cables fault, proceed
Open circuit
with test 7
- pin 2/A1 of ECM to pin 1 of
ignition reel 3
5) Check the cable for short circuit

RO/BI from safety relay with: Ok Proceed with test 6
Power pin 8 of lock relay at:
- pin 1/B8 of ECM (ignition reel 2)
- pin 1/A8 of ECM (ignition reel 1) Locate and repair the cables fault, proceed
- pin 2/a1 of ECM (ignition reel 3) Short circuit
with test 7
6) Check the resistance of the relative

ignition reel: 0.8 Ω Proceed with test 7
- pin 1 of ignition reel to pin 2 of Replace the relative ignition reel, proceed
ignition reel Faulty
with test 7
7 48
DIAGNOSTICS
ELEC
COOLING LIQUID TEMPERATURE SENSOR -WALBRO ECU 1

P0118 C.C. engine temperature sensor Ensure that the connector is inserted correctly.
location 1 test
Disconnect the sensor and proceed with the
location 1 test.
P0119 C.A. engine temperature sensor Proceed with location test 1
LOCATION TEST
1) Check the integrity of the terminal Ok Proceed with test 2
and the cable:
- pin ECM 1/B2
- pin ECM 1/C6 Faulty Repair the fault, proceed with test 7
2) Check the resistance value Disconnect the temperature sensor and

Ok
proceed to 6
- pin 1/B2 of ECM to pin 1/E4 of ECM
Open circuit Proceed with test 3
(dependant on temperature, see Disconnect the temperature sensor and
below) Short circuit
proceed to 4

- pin 1/C6 of ECM to pin 2 of sensor
Open circuit
with test 7
4) Check the wiring for short circuit Ok Proceed with test 5
- pin 1/C6 to pin 1/B2 of ECM Locate and repair the cables fault and proceed
Short circuit
with test 7
5) Check the cable for short circuit Ok Proceed with test 7
- pin 1/C6 to mass Locate and restore the wiring fault, proceed
Short circuit
with test 7
7 49
DIAGNOSTICS
ELEC
AIR TEMPERATURE SENSOR -WALBRO ECU 1

P1502 Open or short circuit to positive (+) Check and take note of the display data of the
pole battery diagnostics tool (see Axone instruction manual)
if available.
Check and take note of the sensor data of the
diagnostics tool (see Bendia instruction manual).
Ensure that the sensor connector is inserted
correctly.
location 1 test.
P1501 Short circuit to mass Disconnect the sensor and proceed with the
location test
LOCATION TEST
1) Check
C the integrity of the terminal Ok P
Proceed with test 2
and the cable:
- pin ECM 1/B2
- pin ECM 1/E5 Faulty R
Repair the fault, proceed with test 7
2) Check the resistance value Disconnect the temperature sensor and

Ok
proceed to test 6
- pin 1/B2 of ECM to pin 1/C5 of
ECM Open circuit Proceed with test 3
(dependant on temperature, see Disconnect the temperature sensor and
below) Short circuit
proceed to test 4

- pin 1/C5 of ECM to pin 2 of sensor
Open circuit
with test 7
4) Check the wiring for short circuit Ok Proceed with test 5
- pin 1/E5 to pin 1/B2 of ECM Locate and repair the cables fault and proceed
Short circuit
with test 7
5) Check the resistance of the sensor:

- pin 1 of sensor at pin 2 of sensor
(dependant on temperature, see Replace the temperature sensor and proceed

Faulty
below) to test 7
- pin 1/C5 of ECM to the mass Locate and restore the wiring fault, proceed
Short circuit
with test 7
7 50
DIAGNOSTICS
ELEC
FUEL PUMP -WALBRO ECU 1

P1231 Open or short circuit to the mass Check if the pump activates briefly when ignition
is activated.
Ensure that the pump connector is inserted
correctly.
location 1 test.
P1232 Short circuit to positive (+) pole Disconnect the fuel pump and proceed with
battery the location 4 test.
LOCATION TEST
1) Check the integrity of the terminal Disconnect the fuel pump and proceed with
Ok
and the cable: test 2.
- pin ECM 2/A2 Faulty Repair the fault, proceed with test 5

with test 5

blue/green from petrol pump relay: Ok Proceed with test 4
- pin 1/H1 to pin 2 of fuel pump
- pin 1 of fuel pump + 12 vDC with
ignition key in position on Locate and repair the cables fault, proceed
Open circuit
with test 5

RO/BI safety relay:
- pin 2/A2 of ECM to pin 2/E1 of Locate and repair the cables fault, proceed
ECM Short circuit
with test 5
NOTE
Another possible cause of the malfunctioning of the TPS/AIR TEMPERATURE/H2O TEMPERATURE sensors may be the
absence of 5 Vdc power supply.
Check as follows:
Disconnect AIR TEMPERATURE/H O TEMPERATURE/TPS according to the anomaly encountered and check by turning
the board and using the volthmmeter
2 that:
• on pin 2 of AIR TEMPERATURE connector (or on Pin 1/C5 of ECU) there is a voltage of between 4.5 ~ 5.5 Vdc
• on pin 2 of ENGINE TEMPERATURE (or on pin 1/C6 of ECU)
• on pin 1 of TPS command (or on pin 1/B5 of ECU)
7 51
DIAGNOSTICS
ELEC
SENSOR POWER SUPPLY VOLTAGE -WALBRO ECU 1

P0562 Faulty battery/alternator - low Check and take note of the sensor data of the
voltage diagnostics tool (see Axone or Bendia instruction
manual).
Ensure that the voltage through the battery is
acceptable, take note of the voltage.
location 1 test.
P0563 Faulty alternator - high voltage Ensure that the output voltage of the alternator
is acceptable, take note of the voltage.
N
NOTE
1) Using a volthmmeter ensure that the battery is charged
2) Check that there are 12 Vdc on the brown cable (alternator) once the board is switched on.
3) Start the bike and go to 3.500 rpm and, using a volthmmeter, then connecting the battery, check the voltage is
between 13.5/ 14.5 Vdc
BAD FUNCTIONING OF THE ENGINE DIAGNOSIS WARNING LIGHT LAMP (MIL)

-WALBRO ECU 1
P1601 Open or short circuit to the mass Ensure that the warning light lamp connector is
correctly inserted and that the bulb is
operational.
Replace if faulty.
location 1 test.
P1602 Short circuit to positive (+) pole Disconnect the warning light lamp and proceed
battery with test 4.
7 52
DIAGNOSTICS
ELEC
COOLING VENT -WALBRO ECU 1

P1552 Open or short circuit to the mass Check and take note of the sensor data of the
diagnostics tool (see Axone or Bendia instruction
manual).
Ensure that the vent connector is inserted
correctly.
location 1 test.
P1553 Short circuit to positive (+) pole Disconnect the vent and proceed with test 4.
battery
LOCATION TEST
1) Check the integrity of the terminal Ok Disconnect the vent and proceed with test 2
and the cable:
- pin ECM 2/A4 Faulty Repair the fault, proceed with test 5

with test 5
3) Check the continuity of the cable: Ok Proceed with test 4

- Vent cable with electric fans of
ECM Locate and repair the cables fault, proceed
Open circuit
with test 5
4) Check the cable for short circuit: Ok Proceed with test 5

- pin 2/A4 of ECM to pin 1/RO/BI
injection relay of ECM Locate and repair the cables fault, proceed
Short circuit
with test 5
7 53
DIAGNOSTICS
ELEC
START-UP SYSTEM DIAGNOSTICS
THE START-UP MOTOR DOES

NOT TURN
Check if the start-up motor turns

The click by connecting the start-up motor
Bring the ignition switch at "ON", with terminal directly to terminal +
the engine switch off switch at "RUN". is heard of the battery.
Engage neutral gear (the relative (Do not use a thin wire as the
warning light on the dashboard will current flow is high)
switch on).
Pull the clutch.
Check if a click of the ignition relay is the motor the motor
heard when the start-up button is pressed. turns does not turn
Faulty start-up Faulty start-up

relay. motor.
Battery
Start-up motor discharged.
wire loose,
disconnected
The click cannot be heard or interrupted.
Faulty ignition switch.

Faulty engine switch off switch.
Faulty main relay.
Check the presence of 12V on the no voltage Faulty start-up button.
relay connector when the start-up Faulty clutch lever position switch.
Faulty connector contact.
button is pressed Open circuit in wiring.
Faulty fuse.
voltage present
Faulty start-up relay

incorrect
Check the start-up relay
correct
Faulty start-up relay contact
NOTE
The safety conditions upon bike start-up are managed by the ECU (control unit) as described below:
• with gear engaged and trestle stand lowered, the start-up motor turns but it does not start the engine.
• with neutral gear engaged and trestle stand lowered, the start-up motor turns and starts the engine.
7 54
DIAGNOSTICS
ELEC
THE START-UP MOTOR TURNS

BUT THE ENGINE DOES NOT START
incorrect
Check the neutral sensor Faulty neutral sensor
correct
Open circuit in wiring
Faulty connector contact
Faulty diode module
incorrect Faulty side trestle switch

Check the side trestle switch
correct Open circuit in wiring

Faulty connector contact
7 55
DIAGNOSTICS
ELEC
ELECTRIC PART
COMPONENT ANOMALY INTERVENTION

GEAR SYSTEM • Faulty alternator Replace
Battery warning light on • Faulty alternator connection Check
• Faulty battery Replace
MAIN • Fuse 30A Replace

No function • Burnt remote control switch Replace
• Oxidised battery connections Deoxidise/Restore
POWER SUPPLY PLANT • Faulty key switch Replace

Services 12V • Faulty key switch connection Deoxidise/Restore
No function enabled • Faulty main relay Replace
• Faulty main relay connection Deoxidise/Restore
ELECTRIC START-UP • Burnt bike fuse 10A Replace

• Faulty bike fuse 10A connection Deoxidise/Restore
Start-up motor does • Faulty clutch switch Replace
not work • Faulty start-up motor Replace
• Faulty start-up button Replace
• Faulty right electric block
connection Deoxidise/Restore
• Faulty start-up remote control
switch Replace
• Faulty power cables connections Deoxidise/Restore
COOLING PLANT • Burnt electric fans fuse Replace

• Faulty electric fans fuse connection Deoxidise/Restore
Electric fans do not work • Faulty ECU Replace
• H²O Bulb Replace
• Faulty H²O bulb connection Deoxidise/Restore
• Faulty electric fan Deoxidise/Restore
INDICATORS/LIGHTS • Burnt lights fuse Replace

PLANT • Faulty lights fuse connection Deoxidise/Restore
Front/rear position • Faulty key switch Replace
lights do not work • Faulty key switch connection Deoxidise/Restore
• Burnt lamps Replace
• Faulty lamps connections Deoxidise/Restore
• Faulty lights switch Replace
• Faulty lights switch connection Deoxidise/Restore
HIGH BEAMS/DIPPED • Burnt lights fuse Replace

BEAMS LIGHTS • Faulty lights fuse connection Deoxidise/Restore
INDICATORS • Faulty key switch Replace
Front/rear position • Faulty key switch connection Deoxidise/Restore
lights do not work • Burnt lamps Replace
High beams/dipped • Burnt lights fuse Replace

beams lights do not work • Faulty lights fuse connection Deoxidise/Restore
• Faulty high beam + dipped beam
lights relay Replace
• Faulty high beam dipped beam
lights relay connection Deoxidise/Restore
Rear stop light does • Burnt 10A fuse Replace

not work • Faulty 10A fuse connection Deoxidise/Restore
• Burnt lamp Replace
• Faulty front brake lever switch Replace
• Faulty front brake lever switch
connection Deoxidise/Restore
• Faulty rear brake lever switch Replace
• Rear brake lever switch connection Deoxidise/Restore
Rear stop light • Blocked front brake lever switch Replace/Repair

remains on • Blocked rear brake lever switch Replace/Repair
7 56
DIAGNOSTICS
ELEC

Acoustic warning device • Burnt bike fuse 10A Replace
does not work • Faulty bike fuse 10A connection Deoxidise/Restore
• Faulty warning device Replace
• Faulty switch Replace
• Faulty acoustic warning device Deoxidise/Restore
connection
• Faulty switch connection Deoxidise/Restore
Indicators do not work • Burnt bike fuse 10A Replace

• Faulty bike fuse 10A connection Deoxidise/Restore
• Fault intermittence Replace
• Faulty intermittence connection Deoxidise/Restore
• Faulty indicators switch Replace
• Faulty indicators switch connection Deoxidise/Restore
Indicator remains on • The lamp of the other indicator,

same side, is burnt Replace
• the connection of the other
indicator is faulty Deoxidise/Restore
DASHBOARD PLANT • Burnt 2A fuse Replace

• Faulty 2A fuse connections Deoxidise/Restore
Dashboard does not • Faulty dashboard Replace
light up • Faulty dashboard connection Deoxidise/Restore
Dashboard does not • Burnt 2A fuse Replace
work • Faulty 2A fuse connections Deoxidise/Restore
Speedometer does • Faulty speed sensor Replace
not work • Faulty speed sensor connection Deoxidise/Restore
• Burnt 10A fuse Replace
• Faulty 10A fuse connection Deoxidise/Restore
• Faulty dashboard Replace
• Faulty dashboard connection Deoxidise/Restore
Oil warning light does • Faulty oil pressure sensor Replace

not light up • Fault oil pressure sensor connection Deoxidise/Restore
• Burnt warning light Replace dashboard
Neutral warning light • Faulty neutral sensor Replace

does not light up • Faulty neutral sensor connection Deoxidise/Restore
Battery state warning • Faulty alternator connection Deoxidise/Restore

light on • Faulty dashboard Replace
• Faulty battery Replace
• Faulty alternator Replace
Fuel reserve warning • Faulty fuel level sensor Replace
light does not light up • Faulty fuel level sensor connection Deoxidise/Restore
Indicators warning light • Fault intermittence Replace

does not light up • Faulty intermittence connection Deoxidise/Restore
Position lights warning • Faulty dashboard Replace

light does not light up • Faulty dashboard connection Deoxidise/Restore
Head lights warning • Faulty dashboard Replace
light does not light up • Faulty dashboard connection Deoxidise/Restore
7 57
DIAGNOSTICS
ELEC

INJECTION • H2O Bulb Replace
H2O temperature • Burnt 10A fuse Replace
indicator does not work • Faulty 10A fuse connection Deoxidise/Restore
• Faulty ECU connection Deoxidise/Restore
Throttled body • Faulty potentiometer Replace
potentiometer • Faulty potentiometer connection Deoxidise/Restore
Air temperature sensor • Faulty sensor Replace

signals error • Faulty sensor connection Deoxidise/Restore
FUEL INJECTION PLANT • Burnt 25A fuse Replace

• Faulty 25A fuse connection Deoxidise/Restore
Injector does not inject • Faulty injection relay Replace
fuel • Faulty injection relay connection Deoxidise/Restore
• Faulty injector Replace
• Faulty injector connection Deoxidise/Restore
• Faulty injection ECU Replace
• Faulty side stand injector Replace
• Faulty engine pick up Replace
• Phonic wheel/pick up light incorrect Replace
• Faulty petrol pump Replace
• Faulty neutral sensor Replace
IGNITION PLANT • Burnt 25A fuse Replace

• Faulty fuse 25A connection Deoxidise/Restore
No spark plugs spark • Faulty injection relay connection Deoxidise/Restore
• Faulty reels Replace
• Reels connections Deoxidise/Restore
• Faulty injection ECU Replace
• Faulty spark plug Replace
• Faulty motor mass connection Replace
• Faulty side stand switch Replace
• Faulty engine pick up Replace
• Phonic wheel/pick up light incorrect Replace
• Faulty neutral sensor Replace
7 58
DIAGNOSTICS
ELEC
FRAME

STEERING WHEEL • Damaged steering bearings Replace
Hard steering wheel • Excessively fastened steering
bearings Adjust
• Bent kingpin Replace
• Excessively brakes steering shock
absorber Adjust
• Damaged steering shock absorber
joints Replace
• Low tyre pressure Adjust
The bike tends to steer • Bent fork Replace

or does not proceed in • Bent frame Replace
a straight line • Bent swing arm Replace
• Damaged steering bearings Replace
• Bent wheel pin Replace
• Damaged swing arm bearings Replace
FRONT WHEEL • Bent wheel rim Replace

Front wheel • Wheel not balanced Balancing Device
oscillates/vibrates • Faulty tyre Replace
• Tyre not suitable Replace
• Damaged wheel bearings Fasten
• Pin fixing screws not fastened Fasten
• Pin fixing ring nut not fastened Fasten
Front wheel hardly turns • Damaged bearings Replace

• Bent wheel pin Replace
• Brakes pads rub excessively against
the disks (see brakes) Check
• Bent brake disks Replace
• Wheel pin ring nut excessively
fastened Torque fasten
FRONT SUSPENSION • Deteriorated fork oil Replace

• Low forks oil level Top-up
Front suspension too soft • Low tyre pressure Adjust
• Damaged fork Adjust
Front suspension too stiff • High fork oil level Adjust
• High tyre pressure Adjust
REAR WHEEL • Bent wheel rim Replace

Front wheel • Wheel not balanced Balancing Device
oscillates/vibrates • Faulty tyre Replace
• Tyre not suitable Replace
• Damaged wheel bearings Fasten
• Fixing nut not fastened Fasten
• Suspension screws not fastened Fasten
• Damaged suspension bearings Replace
Rear wheel hardly turns • Damaged bearings Replace

• Wheel hub seal ring out of seat Check
• Brakes pads rub excessively against
the disk Check
• Bent brake disk Replace
• Damaged transmission chain Replace
REAR SUSPENSION • Insufficient spring pre-load Adjust

• Insufficiently extended hydraulic
Rear suspension too soft brake Adjust
• Low tyre pressure Adjust
• Damaged shock absorber Replace
Rear suspension too stiff • Excessive spring pre-load Adjust
• Excessive extended hydraulic brake Adjust
• High tyre pressure Adjust
• Damaged swing arm bearings Replace
• Damaged suspension balancing
device bearings Replace
• Damaged shock absorber joints Replace
• Damaged suspension connecting
rod joints Repair
• Bent swing arm pin Replace
7 59
DIAGNOSTICS
ELEC

BRAKES • Air bubbles inside the hydraulic
Brakes lever and pedal circuit Bleed
too soft or "spongy" • Leaks inside hydraulic circuit Repair
• Damaged callipers seals Replace
• Damaged pump seals Replace
• Callipers pistons do not slide
smoothly Check
• Low hydraulic liquid level Top-up
• Deformed brake disks Replace
Brakes lever and pedal • Bent brake lever and pedal Replace
too hard
Insufficient braking • Dirty disks Clean
power • Air bubbles inside the hydraulic
circuit Bleed
• Leaks inside hydraulic circuit Repair
• Damaged callipers seals Replace
• Damaged pumps seals Replace
• Calliper pistons do not slide
smoothly Check
• Low hydraulic liquid level Top-up
• Deformed brake disks Replace
Pads rub against brake • Damaged pads springs Replace
disks • Deformed brake disks Replace
• Callipers pistons do not slide
smoothly Check
• Hydraulic liquid level too high Adjust
• Brakes pads worn out over
the limit Replace
DRAIN PLANT • Damaged exhaust pipe Replace
• Loosened tube fixings Fasten
Excessive exhaust noise
Poor engine • Damaged exhaust pipe Replace

performances • Loosened tube fixings Fasten
COOLING PLANT • Cooling liquid level too low Top-up

• Faulty cooling vents Replace
Engine temperature • Liquid expansion vessel cap Replace
too high • Faulty cooling Replace
• Faulty electric fan thermal switch Replace
• Faulty instrument temperature
sensor Replace
• Thermostat locked closed Replace
• Bent or obstructed radiator flaps Repair/Clean
• Scaled radiators Clean
• Damaged water pump Replace
• Faulty ignition/injection plant Check
• Fuel not suitable Replace
• Faulty engine cooling circuit Check
• Spark plug thermal degree not
suitable Replace
• Carbonaceous residues storage
inside head/piston Clean
Engine temperature • Thermostat locked open Replace

too low
7 60
ELECTRIC PLANT
ELEC
ELECTRIC LAYOUT
7 61
ELECTRIC PLANT
ELEC
To identify the contacts of the various components

refer to the layout below.
13 14 15 16 17 18 19 20
12 11 10 9 8 7 6 5 4 3 2 1
CONTACTS COLOURS CONTACTS COLOURS
1) Oil Pressure Purple 11) Set/Reset Switch Yellow/Grey

2) H2O Temperature Brown/Purple 12) Revolutions Grey/Red
3) Injection Alarm Red/Black 13) Speed Sensor Output Blue
4) Right Indicator Pink 14)
5) Left Indicator Blue 15) Speed Sensor Mass Blue/Black
6) Neutral White/Purple 16) Mass Black
7) High beams Yellow/White 17) Ambient Temperature
Sensor Mass Black
8) Position Light Yellow/Black
18) Ambient Temperature
9) GND Petrol Level Yellow/Purple Sensor Red
10) Petrol Level Brown/Yellow 19) Permanent Positive Red
20) Under lock and key Brown/Red
7 62
ELECTRIC PLANT
ELEC
MAINTENANCE WARNINGS
Trigger CONNECTORS
• When connecting a connector, push until a trigger is
heard.
• Check whether the connector is corroded or dirty
and if its cover is broken.
COUPLERS
• With a lock type coupler, release the lock before
disconnecting it and push all the way when
connecting it.
• When connecting the coupler, ensure to grip the
coupler body and not to pull the wires.
• Check whether the terminals of the coupler are loose
or bent.
• Check whether the terminals are corroded or dirty.
FUSES
• When a fuse triggers, investigate the cause, repair
and, therefore, replace the fuse.
• Do not use a fuse with a different capacity from the
original.
• Do not use a wire or another replaced for the fuse.
PARTS TO SEMI-CONDUCTORS
Incorrect ATTENTION
Careful not to drop the parts with an ECU type
incorporated semi-conductor.
When checking the parts, carefully follow the control

instructions.
The non compliance with the correct procedure can
cause serious damages.
7 63
ELECTRIC PLANT
ELEC
BATTERY
ATTENTION
Do not use batteries different from those
specified.
The MF battery (without maintenance) assembled in

this vehicle does not require maintenance operations
like the electrolyte level control and the distilled water
top-up.
Note that the charge system for an MF battery is
different to that for a normal battery.
Therefore, do not replace an MF battery with a normal
one.
The recommended battery is:
YUASA YTZ 14 S
Charge following the method indications shown on

the battery packaging, however, see "ROUTINE
INSPECTIONS AND ADJUSTMENTS 3.79" paragraph.
ATTENTION
Hydrogen is not produced during the normal
charging of the battery but it may be produced
when the battery is excessively charged.
Therefore, do not go near the battery with flames
during charging.
Should the terminals be corroded, remove the battery,

pour hot water over them and clean using a metal
brush.
Once connection is completed, grease slightly.
Install a cap on the positive terminal.
7 64
ELECTRIC PLANT
ELEC
BATTERY EFFICIENCY CONTROL

BATTERY CURRENT LEAKS CONTROL
1 Remove:
• the seat
2 Bring:
• the ignition switch
to OFF position.
Disconnect:
• the battery negative cable
3 Connect:
• the multitester
mA between the negative terminal and the negative
cable of the battery, in function of the ammeter in
+
continuous current
ATTENTION
As the current leaks during malfunctioning may
be high, firstly use a high range of multitester to
avoid damages.
- +
3
Do not bring the ignition switch to ON when
measuring the current.
With the control board switched off, the current
leaks must be >/- Ã 2~2.5 mA.
On the contrary, identify the source of such absorption

by disconnecting the connectors of every individual
powered utility
NOTE:
N
In case of installing antitheft devices, disconnect
the latter before carrying out the checks.
7 65
ELECTRIC PLANT
ELEC
CHARGE OUTPUT CONTROL

1 Remove:
2 Start:
• the engine
and make it rev at 2000 r/min with the lights switch
at ON and the selector on HI headlights position.
3 Measure:
• the DC voltage
between the positive and negative terminals of the
battery using a multitester.
If the tester indicates less than 13.0V or more than
15.0V, the cause to be identified is in the generator.
NOTE:
When carrying out this test, ensure that the battery
is fully charged.
Output for charge

13.0 V - 14.5 V a 2000 g/min
7 66
This manual is the property of Benelli Q.J. s.r.l..
The total or partial reproduction is forbidden.
Benelli recommends original accessories
Benelli recommends original products
Version June 2009/01

BENELLI Q.J. s.r.l.
Strada della Fornace Vecchia
61100 - Pesaro - Italy

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MANUALE OFFICINA • WORKSHOP MANUAL • MANUEL D’ATELIER •

PARTICULARLY IMPORTANT INFORMATION RELATING TO

Attention indicates the precautions that should be complied with to to avoid

NOTE A note supplies key information to facilitate or clarify procedures.

IMPIANTO DI LUBRIFICAZIONE IMPIANTO DI LUBRIFICAZIONE

INSTALLAZIONE COPPA OLIO

5 SQ. SIMBOLI INTERVENTO/DESCRIZIONE Q.TÀ OSSERVAZIONI

Installare i pezzi nell’ordine indicato.

3 108 <<Indietro Indice Avanti>> 3 107 <<Indietro Indice Avanti>>

7 ELEC The symbols from 8 to 10 indicate the following:

8 Wear, Clearance Limit

The symbols from 11 to 21 in the exploded drawings

Arexons SYSTEM 56A48

Arexons SYSTEM 52A43

Arexons SYSTEM 56A01

ROUTINE INSPECTIONS AND ADJUSTMENTS

IDENTIFICATION OF MOTORCYCLE ...................................................................... 1

IMPORTANT INFORMATION ................................................................................ 6

CONNECTIONS CONTROL ...................................................................................... 11

SPECIAL TOOLS ...................................................................................................... 12

• Engine number (on lower base) B

• Homologation data ( on frame) C

INSTRUMENTATION AND LIGHTS 2 COOLING LIQUID TEMPERATURE INDICATOR

DISPLAY FUNCTIONS SELECTION a "TOTAL"/ "TRIP"

To switch from b "Chrono"/"Lap" to c "Clock"/"Trip", c "CLOCK"/ "TRIP"

To switch from a "Clock"/"Trip" to c "Total"/"Trip",

Partial odometer resetting a

Press the START button for at least two seconds and

Set "Chrono"/"Lap" Set "Km"/"Mi"

PREPARATION FOR REMOVAL AND

2 During dismantling of the vehicle, we recommend

3 Keep all components away from any source of heat.

GASKETS, O-RINGS, OIL RETAINER

2 Install the bearings and the oil retainers so that the

SAFETY WASHERS/SAFETY PLATES,

1 After the removal, replace all safety washers/safety

2 Whenever applying thread brakes, previously remove

SAFETY ELASTIC RINGS

FRAME SPECIAL TOOLS

Steering Return Ring Spanner

Quick Release Kit

Steering Head Spanner

Transmission Chain Regulator Spanner

R180197036000 This instrument is used as control, check, setting

Diagnosis Instrument S CANTO O L

R300082003000 This instrument is used as control, check, setting

Bil a nciam ent o f a rf a ll e

This instrument is used to synchronise the

carburettors or the throtless bodies as control

Phonic Wheel Removal

Buffer For Valves Oil Retainer

Cylinder Assembly Thicknesses

Clutch Dismantling Spanner

Clutch Pressure Plate Adjustment Spanner

Buffer For Dry Clutch Oil Retainer

Pinion Dismantling Tool

GENERAL SPECIFICATIONS ................................................................................... 1

TECHNICAL DATA ................................................................................................. 2