Benelli TnT1130 Manuel d'instructions

2MF13

This manual contains an introductory description of the Benelli TnT together with the

procedures for control/intervention and revision of the main components.

Information considered generally noted is not included.

This manual will help you to understand the motorcycle better in order to provide the

client with a rapid and trustworthy service.

* The present manual has been prepared on the basis of state-of-the-art

specifications valid at the date of publication. In the case of modifications

carried out after this date, differences may exist between the contents of the

manual and the motorcycle under review.

* The illustrations in this manual are used to highlight the fundamental principles

and procedures of basic interventions. They may not show exactly the motorcycle

in your possession.

* This manual has been written for people who have the knowledge, the technical

skill and the instruments, including the special, for servicing Benelli motorcycles.

If you do not possess the necessary training and tools, have repairs made at

an authorised Benelli concessionaire.

ATTENTIONTTENTION

TTENTIONTTENTION

TTENTION

Inexpert mechanics or those lacking appropriate instruments and apparatuses

may not be able to carry out the operations described in this manual.

Incorrect repairs can cause damage to the mechanic and render the motorcycle

unsafe for the driver and passenger.

Premise

MF13

SYMBOLS

The symbols listed below are all present inside the manual and serve to show those

parts which need to be given special attention.

ATTENTION - Be aware that you will find death or serious injury, in

case the instructions are not observed.

WARNING - Possibility of lesions in case the instructions are not

observed .

NOTE - The aim of this message is trying to avoid any damages to

the vehicle, things or environment.

OILING - Indicates the type of oil to use.

TIGHTENING - Indicates the correct tightness value to carry out.

SPECIFIC VALUE - indicates the specific value using precision in-

struments.

SPECIFIC INSTRUMENTS - indicates the specific instruments to

use.

Introduction

4MF13

1GENERAL INFORMATIONGENERAL INFORMATION

GENERAL INFORMATIONGENERAL INFORMATION

GENERAL INFORMATION 11

1.1 VEHICLE IDENTIFICATION 13

1.2 IMPORTANT INFORMATION 13

1.3 SPECIAL INSTRUMENTS 14

1.3.1 SPECIAL ENGINE INSTRUMENTS 15

1.3.2 SPECIAL FRAME INSTRUMENTS 18

2SPECIFICATIONSSPECIFICATIONS

SPECIFICATIONSSPECIFICATIONS

SPECIFICATIONS 20

2.1 GENERAL SPECIFICATIONS 20

2.2 ENGINE TECHNICAL CHARACTERISTICS 21

2.3 FRAME CHARACTERISTICS 23

2.4 ELECTRICAL COMPONENTS 26

2.5 BOLT TORQUE 28

2.5.1 GENERAL BOLT TORQUE 28

2.5.2 FRAME BOLT TORQUE 29

2.5.3 ENGINE BOLT TORQUE 35

2.6 POINTS TO OIL 38

3PERIODIC CHECKS AND ADJUSTMENTSPERIODIC CHECKS AND ADJUSTMENTS

PERIODIC CHECKS AND ADJUSTMENTSPERIODIC CHECKS AND ADJUSTMENTS

PERIODIC CHECKS AND ADJUSTMENTS 52

3.1 INTRODUCTION 52

3.2 CHECK SPARK-PLUGS 56

3.2.1 INSTALLING SPARK-PLUGS 57

3.3 CLEANING AIR BOX 57

3.3.1 REMOVAL OF AIR BOX THROTTLE VALVE AND AIR BOX DUCT 58

3.3.2 SOLENOID MOTOR REMOVAL 59

3.4 GAS CONTROL PLAY 60

3.4.1 CLUTCH 61

3.5 ADJUSTING CLUTCH LEVER PLAY 62

3.6 ADJUSTING CO 62

3.7 ADJUSTING THROTTLE HOUSING 64

3.8 CHECKING STEPPER 65

3.9 ADJUSTING VALVE PLAY 67

3.9.1 VALVE TABLET REPLACEMENT 68

3.10 ENGINE DISTRIBUTION 69

3.11 CHECKING ENGINE OIL LEVEL 71

3.12 CHANGING ENGINE OIL AND FILTER 72

3.13 CHECKING COOLING LIQUID LEVEL 75

3.14 CHANGING REFRIGERANT LIQUID 76

3.15 FILLING COOLING PLANT 78

3.16 CHECKING EXHAUST TUBES 80

3.17 CONTROL AND REPLACEMENT EXHAUST PLANT 80

3.18 ADJUSTING FRONT BRAKE LEVER 82

3.19 ADJUSTING REAR BRAKE LEVER 82

3.20 CHECKING BRAKE LIQUID 83

3.21 CHANGING FRONT AND REAR BRAKE PADS 84

3.21.1 HANGING REAR BRAKE PADS 86

3.22 CHECKING BRAKING PLANT TUBES 87

3.23 AIR DISCHARGE FRONT BRAKING SYSTEM 87

3.23.1 AIR DISCHARGE BACK BRAKE SYSTEM 89

3.23.2 FILLING UP BRAKE LIQUID 89

3.24 ADJUSTING GEAR CONTROL PEDAL 90

3.25 LUBRICATIONAND CHAIN CLEANING 91

3.26 CHAIN REPLACEMENT 91

3.27 CHAIN REGULATION 93

CONTENTS

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3.28 CONTROL AND REPLACEMENT TRANSMISSION COG-WHEELS 94

3.29 CHECKING AND ADJUSTING STEERING BALL-BEARINGS 95

3.30 CHECKINGFORK 96

3.31 CHECKING DAMPER 97

3.32 ADJUSTING DAMPER 97

3.33 CHECKING TIRE PRESSURE 99

3.34 CHECKING WHEELS 100

3.35 CHECKING AND OILING CLUTCH CABLE 101

3.36 ELECTRICAL PLANT 101

3.36.1 CHECKING BATTERY 101

3.36.2 BATTERY RECHARGING SYSTEM 103

3.37 CHANGING FUSES 106

3.38 CHANGING FRONT LIGHTS 107

3.38.1 FRONT LIGHTH DISASSEMBLY 107

3.39 ADJUSTING FRONT HEADLIGHT 109

3.40 BACK LIGHTH DISASSEMBLY 110

3.40.1 CHANGING REAR HEADLIGHT 110

3.40.2 CHANGING LICENCE-PLATE HOLDER LIGHT 111

3.40.3 BACK ARROW LAMP REPLACEMENT 111

3.40.3.1 CHANGING FRONT ARROWS 111

3.40.3.2 BACK ARROW LAMP REPLACEMENT 112

4COWLINGCOWLING

COWLINGCOWLING

COWLING 114

4.1 TANK COVER DISASSEMBLY 114

4.2 PETROL TANK DISASSEMBLY 114

4.2.1 COVER PLATE DISASSEMBLY 115

4.2.2 PETROL PUMP REMOVAL 115

4.3 DISMANTLE TANK FUEL PUMP 116

4.4 COOLER FAIRING DISASSEMBLY 116

4.4.1 FRONT SHIELD AND FRONT SHIELD SUPPORT DISASSEMBLY 117

4.5 COOLERS CONVEYORS DISASSEMBLY 117

4.6 MUDGUARDS DISASSEMBLY 119

4.6.1 FRONT MUDGUARD DISASSEMBLY 119

4.6.2 BACK MUDGUARD DISASSEMBLY 119

4.7 CHAIN CARTER DISASSEMBLY 119

4.8 NUMBER PLATE HOLDER DISASSEMBLY 120

5ENGINEENGINE

ENGINEENGINE

ENGINE 122

5.0 MOTOR REMOVAL 122

5.0.1 MOTOR DISASSEMBLY FROM THE FRAME 122

5.0.2 MOTOR ASSEMBLY ON THE FRAME 124

5.1 CAMSHAFT 127

5.1.1 REMOVING CAMSHAFT 127

5.1.2 CHECKING CAMSHAFT 129

5.1.3 CHECKING CAMSHAFT CHAIN, SPROCKET WHEELS

AND CHAIN GUIDE 130

5.1.4 CHECKING CHAIN STRETCHER 131

5.1.5 MOUNTING CAMSHAFT 131

5.2 CYLINDER HEAD 135

5.2.1 REMOVING CYLINDER HEAD 135

5.2.2 CHECKING CYLINDER HEAD 136

5.2.3 MOUNTING CYLINDER HEAD 137

5.3 VALVES AND VALVE SPRINGS 137

5.3.1 REMOVING VALVES 137

6MF13

5.3.2 CHECKING VALVES AND VALVE GUIDES 139

5.3.3 CHECKING VALVE HOUSINGS 141

5.3.4 CHECKING VALVE SPRINGS 142

5.3.5 CHECKING BUCKET-TYPE TAPPETS 143

5.3.6 MOUNTING VALVES 144

5.4 CYLINDER 146

5.4.1 DISMANTLING CYLINDER CASING 146

5.4.2 CHECKING CYLINDER 147

5.4.3 DISMANTLING WATER COLLECTOR 147

5.4.4 CHECKING WATER COLLECTOR 148

5.4.5 MOUNTING WATER COLLECTOR 148

5.4.6 MOUNTING CYLINDERS 148

5.5 PISTONS 149

5.5.1 DISMANTLING PISTONS 148

5.5.2 CHECKING PISTONS 150

5.5.3 CHECKING SEGMENTS 150

5.5.4 SEGMENT SLOT PLAY 151

5.5.5 CHECKING PISTON PIN 151

5.5.6 MOUNTING SEGMENTS 152

5.5.7 MOUNTING PISTON 153

5.6 GENERATOR 15 4

5.6.1 REMOVING GENERATOR 154

5.6.2 MOUNTING GENERATOR 155

5.7 DISTRIBUTION SENSOR AND PHONIC WHEEL 155

5.7.1 REMOVING DISTRIBUTION SENSOR 155

5.7.2 MOUNTING DISTRIBUTION SENSOR 156

5.7.3 REMOVING PHONIC WHEEL 156

5.7.4 MOUNTING PHONIC WHEEL 156

5.8 CLUTCH 157

5.8.1 DISMANTLING CLUTCH CONTROL 157

5.8.2 REMOVING CLUTCH COVER 157

5.8.3 REMOVING CLUTCH 158

5.8.4 CHECKING THE EXTERNAL TEETH DISK CONDUCTOR 160

5.8.5 CHECKING INNER TOOTHED CONDUCTOR DISK 160

5.8.6 CHECKING CLUTCH SPRINGS 160

5.8.7 CHECKING CLUTCH BELL 161

5.8.8 CHECKING CLUTCH PRIMARY BELL GROUP 162

5.8.9 MOUNTING CLUTCH GROUP 162

5.8.10 CHECKING CLUTCH DISKS 168

5.8.11 MOUNTING CLUTCH COVER 169

5.8.12 MOUNTING CLUTCH CONTROL 170

5.9 GEARS 17 1

5.9.1 REMOVING GEARS 171

5.9.2 DISMANTLING GEARS 171

5.9.3 CHECKING GEAR FLANGE BALL-BEARINGS 174

5.9.4 CHECKING GEAR FORKS AND SLIDE RODS 174

5.9.5 CHECKING POSITIVE SHAFT 176

5.9.6 CHECKING PRIMARY AND SECONDARY SHAFT 176

5.9.7 ASSEMBLING GEARS 177

5.9.8 MOUNTING GEARS 184

5.10 OIL SUMP AND OIL PUMP 185

5.10.1 DISMANTLING OIL SUMP 185

5.10.2 DISMANTLING OVERPRESSURE OIL VALVE 185

5.10.3 REMOVING OIL PUMP 186

MF13

5.10.4 DISMANTLING OIL PUMP 186

5.10.5 CHECKING OIL SUMP 187

5.10.6 CHECKING OIL PUMP 187

5.10.7 ASSEMBLING OIL PUMP 188

5.10.8 MOUNTING OIL PUMP 189

5.10.9 MOUNTING OVERPRESSURE OIL VALVE 190

5.10.10 MOUNTING OIL SUMP 190

5.11 CASING 191

5.11.1 DISMANTLING CASING 191

5.11.2 DISMANTLING FREE WHEEL 198

5.11.3 DISMANTLING BALANCING COUNTER SHAFT 200

5.11.4 DISMANTLING ENGINE SHAFT 201

5.11.5 CHECKING CASING 201

5.11.6 CHECKING ENGINE SHAFT AND CONNECTING ROD 202

5.11.7 CONNECTING ROD INTERNAL FOOT DIAMETER 203

5.11.8 CONNECTING ROD HEAD LATERAL PLAY 203

5.11.9 CHECKING BALANCING COUNTER SHAFT 204

5.11.10 CHECKING FREE WHEEL 205

5.11.11 ASSEMBLING FREE WHEEL 205

5.11.12 MOUNTING ENGINE SHAFT 207

5.11.13 MOUNTING BALANCING COUNTER SHAFT 208

5.11.14 MOUNTING CASING 209

6COOLING PLANTCOOLING PLANT

COOLING PLANTCOOLING PLANT

COOLING PLANT 220

REFRIGERANT LIQUID ENGINEREFRIGERANT LIQUID ENGINE

REFRIGERANT LIQUID ENGINE 220220

220220

220

6.1 RADIATOR 221

6.1.1 DISMANTLING RADIATOR 221

6.1.1.1 LEFT COOLER DISASSEMBLY 222

6.1.2 COOLER CHECK AND CLEANING 224

6.1.3 RIGHT COOLER ASSEMBLY 224

6.1.4 OIL RADIATOR DISASSEMBLY 225

6.1.5 OIL COOLER CHECK AND CLEANING 226

6.1.6 OIL COOLER ASSEMBLY 226

6.2 OIL DISTRIBUTOR 228

6.2.1 OIL DISTRIBUTOR ASSEMBLY 229

6.3 THERMOSTAT 230

6.3.1 DISMANTLING THERMOSTAT 230

6.3.2 CHECKING THERMOSTAT 231

6.3.3 MOUNTING THERMOSTAT 232

6.4 WATER PUMP 233

6.4.1 REMOVING WATER PUMP 233

6.4.2 DISMANTLING WATER PUMP 233

6.4.3 CHECKING WATER PUMP 236

6.4.4 WATER PUMP ASSEMBLY 236

6.4.5 MOUNTING WATER PUMP 241

7FRAMEFRAME

FRAMEFRAME

FRAME 244

7.1 FRONT WHEEL AND BRAKE DISK 244

7.1.1 REMOVING FRONT WHEEL 244

7.1.2 CHECKING FRONT BRAKE DISK 245

7.1.3 DISMANTLING FRONT WHEEL 245

7.1.4 CHECKING FRONT WHEEL 246

7.1.5 MOUNTING FRONT WHEEL 246

7.1.6 INSTALLING FRONT WHEEL 247

8MF13

7.2 REAR WHEEL, BRAKE DISK AND CROWN 248

7.2.1 REMOVING REAR WHEEL 248

7.2.2 CHECKING REAR BRAKE DISK 249

7.2.3 DISMANTLING REAR WHEEL 250

7.2.4 CHECKING REAR WHEEL 252

7.2.5 CHECKING HUB 252

7.2.6 CHECKING CROWN 253

7.2.7 MOUNTING REAR WHEEL 253

7.2.8 INSTALLING REAR WHEEL 255

7.3 FRONT AND REAR BRAKES 256

7.3.1 REMOVING FRONT BRAKE PUMP 256

7.3.2 REMOVING REAR BRAKE PUMP 257

7.3.3 CHECKING FRONT AND BACK BRAKE PUMPS 258

7.3.4 INSTALLING FRONT BRAKE PUMP 259

7.3.5 INSTALLING REAR BRAKE PUMP 259

7.3.6 DISMANTLING FRONT BRAKING PLANT TUBES 260

7.3.7 DISMANTLING REAR BRAKING PLANT TUBES 261

7.3.8 CHECKING FRONT AND REAR BRAKE TUBING 262

7.3.9 MOUNTING FRONT BRAKING PLANT TUBES 262

7.3.10 MOUNTING REAR BRAKING PLANT TUBES 263

7.3.11 DISMANTLING FRONT BRAKE CLAMP 263

7.3.12 DISMANTLING REAR BRAKE CLAMP 264

7.3.13 CHECKING BRAKE CLAMPS 265

7.3.14 MOUNTING FRONT BRAKE CLAMPS 265

7.3.15 DISMANTLING REAR BRAKE CLAMP 266

7 .4 FORK 2 6 7

7.4.1 REMOVING RIGHT AND LEFT STEM 267

7.4.2 CHECK FORK LEGS 268

7.4.3 INSTALLING FORK LININGS 268

7.5 HANDLEBAR 270

7.5.1 HANDLEBAR CONTROL 272

7.5.2 HANDLEBAR INSTALLATION 272

7.6 STEERING HEAD 274

7.6.1 DISMANTLING LOWER STEERING PLATE 274

7.6.2 CHECKING LOWER STEERING PLATE 287

7.6.3 MOUNTING LOWER STEERING PLATE 287

7.7 REAR DAMPER 278

7.7.1 REMOVING REAR DAMPER 278

7.7.2 CHECKING REAR DAMPER 278

7.7.3 MOUNTING REAR DAMPER 279

7.8 REAR FORK 281

7.8.1 REMOVING REAR FORK 281

7.8.2 CHECKING REAR FORK 285

7.8.3 MOUNTING REAR FORK 286

7.8.4 BACK FORK INSTALLATION ON FRAME 287

7.9 SUPPORT FRAME 288

7.9.1 LIGHT SUPPORT FRAME REMOVAL 288

7.9.2 TEST FRONT LIGHT SUPPORT FRAME 289

7.9.3 FRONT LIGHT SUPPORT FRAME INSTALLATION 290

7.10 BACK FRAME 290

7.10.1 BACK RIGHT FRAME DISASSEMBLY 290

7.10.2 BACK RIGHT FRAME ASSEMBLY 292

7.10.3 LEFT BACK FRAME DISASSEMBLY 293

7.10.4 LEFT BACK FRAME ASSEMBLY 295

MF13

7.10.5 STIRRUP REMOVAL PASSENGER FOOTBOARDS 297

7.11 TRANSMISSION CHAIN 298

7.11.1 REMOVING TRANSMISSION CHAIN 298

7.11.2 CHECKING TRANSMISSION CHAIN 298

7.11.3 INSTALLING TRANSMISSION CHAIN 299

8INJECTION PLANT ENGINEINJECTION PLANT ENGINE

INJECTION PLANT ENGINEINJECTION PLANT ENGINE

INJECTION PLANT ENGINE 300

8.1 ENGINE MANAGEMENT SYSTEM 300

8.1.1 DESCRIPTION OF THE SYSTEM 300

8.1.2 SYSTEM SENSORS 300

8.1.3 POSITION OF THE SENSORS 301

8.2 SYSTEM ACTIVATING DEVICES 301

8.2.1 ENGINE SUPPLY PLANT 303

8.2.2 IGNITION AND INJECTION DIAGNOSTIC SYSTEM 303

8.3 NUMBERING THE ECM CONNECTORS 303

8.4 SUPPLEMENTARY DIAGNOSES 305

9ELECTRICAL PLANTELECTRICAL PLANT

ELECTRICAL PLANTELECTRICAL PLANT

ELECTRICAL PLANT 318

9.1 CONNECTORS 321

9.2 FUSES 321

9.3 SEMI-CONDUCTOR PARTS 322

9.4 BATTERY 322

9.4.1 CHECKING BATTERY EFFICIENCY 323

9.5 FUSES 325

9.6 RELAYS 325

9.6.1 RELAY STARTER 325

9.6.2 RELAY SERVICES UNIT 326

9.7 STARTER ENGINE 326

9.8 ALTERNATOR 327

9.9 STARTER DIAGNOSTIC SYSTEM 328

9.10 CHECKING SAFETY SYSTEM PARTS 330

9.11 GEAR SWITCH POSITION 330

9.12 LATERAL STAND SWITCH 331

9.13 CLUTCH SWITCH 331

9.14 SPEED SENSOR 332

9.15 OIL PRESSURE SENSOR 332

9.16 SOLENOID 333

9.17 CHANGING FRONT LIGHTS 334

9.17.1 FRONT LIGHTH DISASSEMBLY 334

9.17.2 ADJUSTING FRONT HEADLIGHT 336

9.18 BACK LIGHTH DISASSEMBLY 336

9.18.1 CHANGING REAR HEADLIGHT 336

9.18.2 CHANGING LICENCE-PLATE HOLDER LIGHT 337

9.18.3 CHANGING FRONT AND REAR ARROWS 337

9.18.3.1 CHANGING FRONT ARROWS 337

9.18.3.2 BACK ARROW LAMP REPLACEMENT 338

1010

10 DIAGNOSTICSDIAGNOSTICS

DIAGNOSTICSDIAGNOSTICS

DIAGNOSTICS 340

10.1 ELECTRICAL PART 340

10.2 FRAME 34 4

10.3 AXONE2000 BENELLI INSTRUCTION MANUAL 347

10.3.1 GENERAL SAFETY PRECAUTIONS FOR OPERATORS 347

10.3.2 HOW TO USE AXONE2000 BENELLI CORECTLY 348

10.3.3 DESCRIPTION OF AXONE2000 BENELLI 349

10.3.3.1 KEYPAD 349

10 MF13

10.3.3.2 INTERFACE MODULE 350

10.3.3.3 READ/WRITE UNIT 350

10.3.3.4 INPUT/OUTPUT CONNECTORS 351

10.3.3.5 HOW TO POWER THE AXONE2000 BENELLI 352

10.3.3.6 RECHARGING THE BATTERY 352

10.3.3.7 REPLACING THE BATTERY 353

10.3.3.8 NOTES FOR CORRECT USE 353

10.3.3.9 TECHNICAL SPECIFICATIONS 354

10.3.3.10 SPARE PARTS 355

10.3.3.11 GLOSSARY 355

10.3.3.12 GETTING STARTED 356

10.3.3.13 STARTING PROGRAMS 355

10.3.4 HOW TO USE AXONE2000 BENELLI 357

10.3.4.1 SERVICE MENU 357

10.3.5 UPGRADES 360

10.3.6 MEASURES 367

10.3.6.1 MULTIMETER

(VOLTMETER, AMMETER, OHMMETER, CONTINUITY TEST) 367

10.3.6.2 VOLTMETER 368

10.3.6.3 AMMETER 368

10.3.6.4 OHMEMETER 369

10.3.6.5 OSCILLOSCOPE 370

10.3.6.6 OPTIONS 371

10.3.6.7 SCALE SELECTIONS 374

10.3.6.8 AC/DC READING SELECTION 376

10.3.6.9 TYPES OF SYNCHRONISM 377

10.3.7 AUTO-DIAGNOSTICS 379

10.3.7.1 TESTING 380

10.4 MAINTENANCE OPERATIONS WITH DIAGNOSTICS TOOL 388

10.5 SELF-DIAGNOSIS 388

10.6 RESETTING THROTTLE 388

10.7 ADJUSTING STEPPER / CO 389

10.8 INSTRUCTIONS TO ADJOURN THE GEARCASE

SOFTWARE WITH THE AXONE 390

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