workshop book engl

8/3/2019 Workshop Book Engl

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WI|RII$HIIPIIIUII

.F.lliBenelli .p.4.

Additions nd change o the workshopmanual or 500 ouattro- 7s0 sei


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I NDEX

MAIN FEATURES : page 1

MAINTENANCEOPERATIONS ]I , -7 Clutch ever djustment15 Carburat ion16 Valve ear ing18 Valve appetclearancedjustment20 lgni t ion dvancedjustment

TOROUEWRENCH ETTINGS ,page 8

SPECIAL OOLS page I

ENGINE , page..10' l Cyl inder ead, yl inder lockandpistons5 Clutch9 Gearbox, r imary r iveanddesmodromic

FRAME page 91 Front and rearbrake3 Front and rearwhee l7 Front fo rk8 Rearsuspensions

: I ELECTRICALEOUIPMENT page 281 Elect ron ic gn i t ion2 A l te rnator-genera tor

! I WIR INGDIAGRAM page31


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MAIN FEATURES

ENGINE I fou rs t roke- number f cyl inders I six n l ine- borex stroke | 60 x 53.4mm- displacement | 905.91cc- compressionatio | 9.53 o 1- revsat max enginespeed | 8400 rPm- horse ower | 80 HP

VALVE GEARING I camshaftn thecyl inder ead, hain r iven- inlet I opens: 1o efore .D.C. closes:3oafterB.D.C.- exhaust I opens: 3" before .D.C. closes: 1"af terB.D.C.- rocker learanceor valve iming | 0.8 mml d e n g i n e ) 0 . 1 3 t o 0 . l 5 m m normal rocker clearance (cold engine

C A R B U R A T I O N- carburet tors I three Del l 'Orto",ypeVHB 24D

LUBR CATION- normal ubr icat ion ressure

by pump EATON" ype3.5 o 4 kg/sqcm;i l pressureender n i t or warnig ight

- oi l f i l ter I replaceableartr idge

GENERATO* |- al ternator | 14 V - 12 A

IGNITION I electronic i th magnet icontrol- clearanceetween he block on the rotating I

sleeve nd he metalendsof each pick-up" | 0.20 o 0.30mm- max gnit ion dvance | 35o beforeT.D.C.at 5000-5500pm- s p a r k p l u g s I M a r e l l i C X S L - B o s c h X 2 6 0 T 2 - L o d g e H B L 1 2- plugpoints ap | 0 .5mm- igrrr i t ionoi ls I N. 3- f ir ingorder I 14-2-6-3-5

srARrNG II- electricstarterwith electromagneticatchet Ic o n t r o l | 1 2 V - 0 . 4 H P


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T R A N S M I S S I O N- clutch- gear ox- gear at ios

1 t gear2nd gear3r dgear4th gear5t h gear- cardan haft bevel ear atio

F R A M E

T IR E S- front- rear- front tire pressure- (ear lre pressure

susPENSroN I- f ront I te lescopic ront fork with hydraul ic hock absorbers ndI he l i co ida lp r ingsI- rcar I swinging ork and hydraul ic hockabsorbers i th hel icoidalspnngsW H E E L S- frontand ear ims I l ightal lovcast ingswfvl/2.15 18"

mult ip lediscs ry type.Handcontrol led y lever n the lef ts ide f the handlebarfive speed,constantmeshgears, rontal engagement.edalcontrol ledrom he L/H side f thevehicle1 to 2 .454 Z :111271i to 1 .666 Z :1512511 o 1 .211 Z :1812311 t o 1 . 0 5 0 Z : 2 0 / 2 1 )i t o 0 .900 Z =2O l18 l1 to 2.511 Z = 21/54\

double radle,ubular tructure

100/90 1BMT29120lso 18MT282 kg/sqcm2.3kg/sqcmwith asenger.5kg/sqcm)

rocker edal n thecentreR/Hside f thebike.Disc ia.260mmCyl inder i a . 8 mmMaste ry l .d ia .15 .87mmThe rear brake s hydraulicall y onnected o a second rontbrake of same type and sizeas the hand operated rontoraKe.

BRAKES I- f ront I disc type with cal iperhaving2 cyl inders. evercontrol ledI Ig. I l . y f side f thehandlebar.| ?,. ,9 ra. uummI Lyrrnoerra. mm

I tvtasteryl .dia.12.7mm- rear I disc type with cal iper aving cyl inders. ontrol led y

dddd4dddddddddddddddtddd&d*

#*tI


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DIMENSIONSNDWEIGHT- wheelbase loaded)- maximumength- maximum eight- width- dry weight

1.46O (57.4"12 . 1 1 0 ( 8 3 . 0 7 " )1 .130 (M.48"10.690m (27.16"122O s(485 bs)

PER ORMANCESmaximum peedfuelconsumptionCUNA) 215 km/happrox i 33 m.p .h . )8 | x 1 0 0 m ( 1 . 7 6 g 6 2 m i . )

F U E LA N D O I L C A P A C I T I E S- fuel ank 16.5 (supergradeetrol98/100 NO-RM)5 lt reserveincluded

3 | (AGIPSINT2000SAE10W 50o i l )60 cc each eS AGIPF 1 ATF Dexron)AGIPF 1 Brake lu idSAE 1703C

o i l sumpfront ork oi lbraking ystem

E L E C T R I C A LO U I P M E N TBATTERYLIGHTS

12V -28 Ah

headl ightbeam)headlighttown)ta i l ight parking-stop)indicatorightsspeedometerRevcounterinstrument anel ights

' t 2 v - 4 0 4 5 W1 2 V 4 W1 2 V - 5 1 2 1 W1 2 V 2 1 W' t 2 v - 3 w1 2 V - 1 . 2 WN . 4 1 6A1 2 V

FUSES

H O R N

NB - All dataherein ontained re ndicative ndar esubiect o modification ithout oriornotice.


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fl rvrarNrENANcEPERATtoNs2. 7 CLUTCHLEVER ADJUSTMENTCheck that the free play at the handlebars 34 mm(.12" to .16"), otherwiseac t on screw 4" to restorethe correctplav.lf this adjustments not suffici ent nd clutchdoesno toperate orrectly clutchslipping r incomple te isenga-gement)ac t on adjuster C" afterslackeningounternut"D" locatedon the dutch leverat the crankcase.hi soperation can b e performedafter removing lu g "E".

Is IGGGGGFGGFlg*tt |

Otlser0 3 mm ( .01 8" )Concen t r i c i r y i0 3 m m ( . 0 1 1 8 " )

IIIC o n c e n t r i c r t y0 . 3 m m ( . 0 1 8 " )Qf f5et. 0 .3mm t .0118" );

Ij Concen t r i c i t y0 .3mm ( .01 8" )

Th eadmissibleerror son th isax s

WHEELSNSPECTION

REMOVINGND RE-F ITT ING YRESON RIMSThis motorcyclei ts l ight al loy r ims which of fer veryhigh mechanical esistance ut might suffer damagef om a functional an d aestetic aspect if impropertooling is used or removing nd assembly perations.Under th ese circustances.ever use tools that haveribbingsor sharp edgeson the sides contacting her ims: the contact ing urface f such tool ing has tobe very wide, smooth an d with rounded edges; heuse of any lubr icants vai lable n the market forthesepurposes i l l great ly aci l i tate yre sl id ingandsettling on the rim, preventing ls o overloads n thetools. lt is also very important fo r the tyre beads obe properly entered into the center ri m groove.Tyres that have an arrow on their side have o bef t ted n the ol lowing ay:

- rea(wheel,with arrow urned n the ridingdirection;- front wheel. with arrow turned against he ridingdirect ion.

Paral lel ism0. 3mm (.0118") I Paral lel ism0. 3mm (.0118")+

Olfset0. 3mm (.0118") Cocentricity0.3 mm (.0118")

The admissibleerror ison th i s ax i s

ftHril

.1C


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7 .7 FRONT ORKdddddddddddddddddddddddd

^ A \-'w


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7.8 REARSUSPENSIONS

The free lengthof the spr ing s 280 mm (11.023") .Lengthunder a load of 52 kg (114 lbs) shouldbe23 1mm (9 .33" ) .Lengthundera load of 103 kg (226 lbs) shouldbe1 9 7m m ( 7 7 5 " 1 .Lengthundera load of 145 kg (320 lbs) shouldbe' 1 6 8m m ( 6 . 6 1 " ) .Lengthundera load of 232 kg (510 lbs) shouldbe1 3 5m m ( 5 . 3 1 " ) .N.B. - lf an y springhas deformedor is not within theaboveimits, eplace.

Posit ion 2 i 229.5 Posit ion3 : 22 2" open 320 t l C l o s e d L . C Z l l t ) Closed F.C 23 5

EEo.t .N

27


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N(I

r-| '--\IleI$y= r ffI'tl +/ \rtn$

f l er-ecrRrcALeurPMENr8 .1 ELECTRONICGNIT ION

ELECTRONICGNIT ION EVICES

O batteryO rotorO switchO H.V. o i le electronicetO spark lug

With ign i t ion swi tch in c losed posi t ion , t he bat te rycurrent th rough the e lect ron ic swi tch ( t ransis tor )s i tua ted ins ide the e lect ron ic se t reaches the matnc i r c u i to { t h e g n i t i o n o i l .Dur ing the ro ta t ion of the ro tor when the meta l b lockon the ro tor is approach ing posi t ionwel l de f ined) hemeta l ends of the p ick-up an e lect r ic mpulse s genera-ted in the p ick-up that reaches he e lect ron ic swi tch28

( t ransistor)ns ideheelectronicet .ln this way a breakof the coi l maincircui t s obtainedas a consequencen the secondary ircuit of th e samecoi l the highvol tage eededor the gnit ion sgeneratedand by meansof a high voltage able s transmittedothe spark lug.The impulse eneratedn the pick up that reachesheelectronic et is indipendent f the batterycurrent.


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Cautions- Th e reversal f th e polarityof th e batterycandamagethe electronic et.- Shouldyou need o charge he battery t is advisableto disconnect t from the electrical ystem o avoiddamageso the electronic et; he same n case f electr icweldings n the motorcycle.- H.V.coi ls ndelectronicets ave een ocatedn airvplaceshus to al low a correct ool ing.Avoid to makemodif icat ions hat might change he cool ingof thecomponents.

8 .2 ALTERNATOR ENERATOBThegeneratoras powerof 14 V - 12A and upply hecurrent to al l the electr ical quipmentdirect ly orthrough he battery.The battery scharged y thesamealternator hrough a current regulator nd rect i f ier .Th egeneratorscomposed f :- rotat ingpart ( inductor) i t ted direct ly n crankshaft- f i x pa r t i nduced) .

Removinghe alternatorenera tor1 Remove he L/H side over2 | it on th e outer part of the generator he specialtool "A"3 Undo centralbolt "8", spacer ndwasher

- With engineat standsti l l o no t forget o disconnectthe ignit ion switch to avoid battery dischargean ddamagehe components f the gnit ion part icular lyheH .V . o i l ) .Values or the electrical hecking f pick,up.ln case f igni t ion rregular i t iesheck he eff ic iencv fpick-up.- Resistencef thecircui twi th pickup at a temperatureof about20" C.22Oohm+ 15.To checkusea tester ohmmeter) onnectinghe cableends o the wo pick-up ables.

4 Lock again crew 8"5 Screw n th e outer part ofcentral ut o f the pul ler , l ip puller "C". Actingon theof f rotor from crankshaft.

workshop book engl

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