Benelli 900 Sei Manuel d'instructions

WI|RII$HIIP

MIIIUII

L-.

F.lli

Benelli

$.p.4.

-E----

Additions

andchange

to theworkshop

manual

for500ouattro

-7s0sei

INDEX

MAIN FEATURES :page 1

MAINTENANCEOPERATIONS ]I ,-

7 Clutch

lever

adjustment

15 Carburation

16 Valve

gearing

18 Valve

tappetclearance

adjustment

20 lgnition

advance

adjustment

TOROUEWRENCH

SETTINGS ,

page 8

SPECIAL

TOOLS page I

ENGINE ,

page..10

'l Cylinder

head,

cylinder

blockand

pistons

5 Clutch

9 Gearbox,

primary

drive

anddesmodromic

FRAME page

1 Front and

rear

brake

3 Front and

rearwheel

7 Front fork

8 Rear

suspensions

:I ELECTRICALEOUIPMENT page28

1 Electronicignition

2 Alternator-generator

!I WIRING

DIAGRAM page

{

MAIN FEATURES

)

ENGINE I four

stroke

- number

ofcylinders I sixin

line

- bore

x stroke | 60x 53.4

- displacement | 905.91

- compressionratio | 9.53to 1

- revs

at maxenginespeed | 8400rPm

- horse

power | 80HP

VALVE

GEARING I camshaft

thecylinder

head,

chaindriven

- inlet I opens:11obefore

T.D.C.

closes:43o

after

B.D.C.

- exhaust I opens:43"

before

T.D.C.

closes:

11"afterB.D.C.

- rocker

clearance

for

valve

timing | 0.8

ld engine)

| 0.13to0.l5mm

- normal rocker clearance (cold engine

CARBURATION

- carburettors I three

"Dell'Orto",

type

VHB

24D

LUBRICATION

- normallubrication

pressure

pump

"EATON"

type

3.5to

4 kg/sqcm;

oil

pressure

sender

unitfor

warnig

light

- oilfilter I replaceable

cartridge

GENERATO* |

- alternator | 14V -12A

IGNITION I electronic

withmagnetic

control

- clearance

betweentheblock

on the

rotating I

sleeveandthemetalends

of each

"pick-up" | 0.20to0.30

- max

ignition

advance | 35obefore

T.D.C.

at5000-5500

rpm

- sparkplugs I MarelliCXSL-BoschX260T2-LodgeHBL12

- plugpoints

gap | 0.5

- igrrrition

coils I N.

- firing

order I 14-2-6-3-5

srARrNG I

- electric

starter

with electromagnetic

ratchet I

control | 12V-0.4HP

E-----

TRANSMISSION

- clutch

- gear

oox

- gear

ratios

1st

gear

2nd

gear

3rd

gear

4thgear

5th

gear

- cardanshaft

-bevel

gear

ratio

FRAME

RES

- front

- rear

- fronttire

pressure

- (ear

tlre

pressure

susPENSroN I

- front I telescopic

front fork with hydraulic

shock

absorbersand

I helicoidal

springs

- rcar I swinging

fork and

hydraulic

shockabsorbers

with helicoidal

spnngs

WHEELS

- front

and

rear

rims I light

allovcastingswfvl

3/2.15

x 18"

multiple

discsdry type.

Hand

controlled

by lever

ontheleft

sideof the

handlebar

five speed,constantmesh

gears,

frontal engagement.

Pedal

controlled

from

the

L/Hside

ofthe

vehicle

to2.454

:111271

i to 1.666

:151251

to 1.211

:181231

1to 1.050

(Z:20/21)

i to0.900

=2Ol18l

1to 2.511

= 21/54\

doublecradle,tubular

structure

100/90

v 1B

120lso

v 18

2kg/sqcm

2.3

kg/sqcm

(with

pasenger

2.5

kg/sqcm)

rocker

pedal

onthe

centre

R/H

side

ofthe

bike.

Disc

dia.260

Cylinderdia.

Master

cyl.dia.15.87mm

The rear

brake

ishydraulically

connectedto a second

front

brakeof same

type andsize

asthe hand

operated

front

ora

Ke.

BRAKES I

- front I disc

type with caliperhaving

2 cylinders.

Levercontrolled

I Ig. Il. yf side

the

handlebar.

| ?,.,9

ora.ruu

I Lyrrnoerora.Jö

I tvtastercyl.

dia.

12.7mm

- rear I disctypewith caliper

having

2 cylinders.Controlled

E-

DIMENSIONS

AND

WEIGHT

- wheel

base

(loaded)

- maximum

length

- maximum

height

- width

- dryweight

1.46O

(57.4"1

2.110

(83.07")

1.130m

(M.48"1

0.690

(27.16"1

22O

(485

lbs)

PER

FORMANCES

maximum

speed

fuel

consumption

(CUNA) 215

km/h

approx

m.p.h.)

| x 100

(1.76g

x62mi.)

FUEL

AND

OIL

CAPACITIES

- fuel

tank 16.5

| (supergrade

petrol

98/1

00 NO-RM)

5 lt reserve

included

3 | (AGIP

SINT

2000SAE

10W

oil)

60cceach

leS

(AGIP

F 1ATF Dexron)

AGIPF 1

Brake

Fluid

SAE

J 1703C

oilsump

front

fork

oil

braking

system

ELECTRICAL

EOUIPMENT

BATTERY

LIGHTS

12V -28

headlight

(beam)

headlight

(town)

tai

Ilight

(

parking-stop)

indicator

lights

speedometer

- Rev

counter

instrument

panel

lights

't2v-4045W

12V

-5121W

12V

21W

't2v-3w

12V

-1.2W

N.4 16

12V

FUSES

HORN

-All data

herein

containedare

indicative

and

are

subiectto modificationwithout

orior

notice.

fl rvrarNrENANcE

oPERATtoNs

2.7 CLUTCHLEVER

ADJUSTMENT

Checkthat the free play at the handlebaris34 mm

(.12" to .16"),otherwise

acton screw

"4" to restore

the

correct

plav.

lf this adjustment

isnot sufficient

andclutchdoes

not

operate

correctly

(clutch

slipping

orincompletedisenga-

gement)

act

on adjuster

"C" after

slackening

counternut

"D" locatedon the dutch leverat the crankcase.

This

operationcan be performed

afterremoving

plug

"E".

€

€I

€

lg*

tt<

tE-

,4,

t-ra

tsl-

lgl

.*-

ülL'

ü,

€

2.15

CARBURATION

Carburettors

Dell'Orto

type

VHB

24D,

double

controls

Carburettors

settings

Choke

Throttle

valve Qzqmm

Atomizer

Needle

Main

jet

ldling

jet

Starter

jet

loater

ZOUAtr

3(2nd

notch)

102

I=L

{

Synchronisation

of thecarburation

and

idling

speed

adjustment

For

the

aboveoperations

whatis

indicatedin

the

workshop

manualfor 750/Sei

butbearing

in mindthat

the

vacuometer

with three

mercury

columnshas

to be

connected

to the connectors

purposelyprovided

after

removing

compensating

hose "

A" connecting

the

manifolds,

The threeconnectors

unused

have

to be temporarily

closed

means

rubber

plugs

"8".

2.16VALVE

GEARING

Tocarry

out

theadiustmentoperate

follows:

- Remove

the

fairing

and

fuel

tank.

- Remove

centralhubfromdegree

timing

plate

cooe

69.90.78.52

(704.087

0 799)validfor

750/Sei.

- Fit

ontiming

plate

rhenewhub

63.94.96.20

provided

for model

900 Sei;

payattention

to have

the hub key

trace

turned

on rhe i/6 stamping

sideon the timing

prate.

- Remove

the alternatorfrom the

crankshaft

L/H side

and

fit the timing

plate

completewith

hub

and

lock

with

bolt

71.24.59.

- Secure

the arrow index for timing check code

63.94.75.20inthe

crankcase.

ESr

lEL

!t)

{

t,t;7*"

t ,iJr

,=\\,@-

\ ,-/

^<-

Z--i\-A

(l ,

lilit

4q! I

tr'9-

\+=

*_l.li\

- Rotatecrankshaftto bring

piston

of cylinder

n. 1 in

T.D.P.burst position.

timing plate

will indicateT.D.P.

O" (ascertain

that this indicationis

correctby fitting a

dial gauge

in spark

plugholein orderthat the member

touching the upper part of the piston indicates

the

T D P.

position).

- Remove

taooetcover.

- Check that, with crankshaft

in the above

position,

a plateof 2.2 mm thickness

fits correctly

in the notch

on the L/H sideof camshaft

(thiscan be obtained

reducing the thickness of plate 6190.79.00

(704.080.0.799)

placed againstthe rear part of the

cylinder

head.

It necessary,

undo the tlvo bolts

lockingthedistribution

gear

on camshaft,

removethe clrainstretcher

and

rotate

thecamshaftto obtain

the

abovetiming

position.

- Lock the distribution

gear

on camshaft.

lf the screw

holesdo not correspond,

rotate the gear

only till the

holesmatch.

Note: lt can be that to obtain a correct correspondence

of holesit is

necessary

to slipoff thegear

from camshaft

and to rotate it bv 1

80'

- Completethe assembly

paying

attention

to spread

with Loctite

the

gear

fixing

bolts

and

checkthevalve

tappetclearance.

2.18 VALVE TAPPET

CLEARANCE AOJUSTMENT

lmportant: thecyiindersare

numberedfrom 1to 6 f

rom

the left

hand

side

of therider's

position.

Check

and if necessaryrestore

the

valve

tappetclearance

operating

follows.

a remove

the fairing,

closethe fuel taps,

renrove

uel

line from the fuel valve

body, disconnectthe rearfuel

tank rubber

and

remove

thefuel

tank.

b remove the ignition breaker point cover and the

twelvetappetad

justing

hole

caps

"A".

c rotate slowly the crankshaftclockwisetill stamped

trace "G" on rotating

sleeve

is aligned

with trace

"H"

stampedon "Pick-up"

centre.

Note: to make easythis operation it is advisableto

remove

thespark

plugs.

At this

point piston

1 or 6 is

in position

T.D.C.

if the

trace "E" is aligned

with trace "F" stamped

on the

crankcase.The compression

stroke of the one or the

other piston is indicated

by the posirion

of the valves

(botlr

closed

d check the clearance

of both valvesirr compression

stroke by inserting

a thickness

llauge.

lf the clearance

is correct

there

\..rll

be a sliglrt

clragof resistance

the

gaLrge

inserted;aüjrist|'eirtisrrecessary

if the

clearance

too srlallor excess

ve.

Note: the clrecking

6rrCthe adjustnrentis better

carried

out by fitting a ciial

grairge

togetherwith the special

support

"N".

The starrrpecitappret

cleararrce

is; 0.13 to 0.15 mm

(0.0051

1to000565")

e adJustment

made by loosening

the tappet scre,/v

nut "F" and turnrnqthe adjustingscrew

"E" till the

correctclearance

obtained.

Lock

screw

nut arrdchecktheclearance.

{

f check

and adjust

the valve

clearance

of the other

cylinders

after having

rotated

the crankshaft

aligning

the trace "G" on rotating

sleevewith the traceon

"Pick-up"

centre

of theother

rylinders.

2.20 IGNITIONADVANCE

ADJUSTMENT

The electronic

ignition unit doesnot require

any

maintenance

operation

as it is made

of parts

which

are

not

subjectto mechanical

wear.

Therefore

after inspecting

and if necessary

ad.justing

the ignition timing no periodical

adjustments

maintenance

operations

are needed,

except in case

troublesin the electronic

components

(pick-up

and

electronic

set)or defective

contactsin electricwirinqs

shouldoccur.

Such

inconveniences

areeasilydetected

dueto a poor

working

efficiency

incylinders.

To inspect

andadjustthe ignition

timingproceed

follows:

1 Remove

the coveron the right

sideof the engine

ur or rNw)g.

2 Make

surethatthemark

"A" on the

inspection

hole

rim

alignedwith

thecrankcase

mark.

Incase

it shouldbe

necessary

to adjustthesetwo marks,

undo

the

threescrews

"8" andsuitablyrotate

the

pick-

upholding

plate.

3 Usinga feeler

gauge

check

thattheclearance

between

theblock

"C" on the

rotating

sleeveandthe

metal

ends

ofeach

pick-up

0.20

0.30

mm(0.0078"

0.0118").

get

this

value

undo

thescrews

"D" andsuitably

shift

the

pick-up

bodv.

Following

the adjustments

accordingto paragraphs

and3,

the

max

ignition

advance

rate

will

be:

35o

before

T.D.C.

5000-5500rpm.

The ignition

advancecurveis shown

in the diagram.

JOOO

€

fl to*ouE

wRENcH

sErrtNG

Distribution

gear

fixing

bolts.

Cylinder

head

bolts

Crankcase

upperbolts

8 mm.

Crankcase

upperbolts

0 6 mm.

Crankcase

lower

bolts

8 mm

Crankcase

lower

bolts

6 mm

Con-rodsecuring

nuts.

. .

Oil

pressure

switch.

Clutch

assy

fixingnuts

Spark

plug

Oildrain

plug

. .

Oilcartridgecover

fixing

bolt . .

Clutch

housing

retaining

plare

. .

Plate

securing

todrive

shaft

clutch

plate

drum

Standard

settings

Screws

and

nuts

f, 6 mm.

Screws

and

nuts

Ö8 ^m.

kgm ftllbs

1.8-2

z.ö-3

2.3 - 2.5

0.8

- 1.2

l.J - l.c

0.8

- 1.2

z.z

- z.c

0.8

- 1.2

l.t - t.o

0.8

- 1.2

2 -2.4

11.5-14.5

20.2

21.7

to.o-tö

5.7

- 8.8

't6.6

67- R6

15.9-18

10.8

14.5

5.7

- 8.6

ö.o

- |t.o

25.3

- 28.9

'18 -21.7

5.7-8.6

14.5

-17.3

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