Benelli Tornado Tre Novicento 903 Manuale di istruzioni

MF9_UK

LIMITED EDITION

COPERTINA

2MF9_UK

LIMITED EDITION

MF9_UK

LIMITED EDITION

SYMBOLS

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

those parts which need to be given special attention.

WARNING - indicates a grave danger for the safety of people and/

or the integrity of the vehicle.

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

instruments.

SPECIFIC INSTRUMENTS - indicates the specific instruments

to use.

Introduction

4MF9_UK

LIMITED EDITION

1 GENERAL INFORMATION 11

1.1 VEHICLE IDENTIFICATION 11

1.2 IMPORTANT INFORMATION 11

1.3 SPECIAL INSTRUMENTS 12

1.3.1 SPECIAL ENGINE INSTRUMENTS 13

1.3.2 SPECIAL FRAME INSTRUMENTS 16

2 SPECIFICATIONS 17

2.1 GENERAL SPECIFICATIONS 17

2.2 TECHNICAL CHARACTERISTICS ENGINE 17

2.3 FRAME CHARACTERISTICS 19

2.4 ELECTRICAL COMPONENTS 22

2.5 BOLT TORQUE 24

2.5.1 GENERAL BOLT TORQUE 24

2.5.2 BOLT TORQUE FRAME 25

2.5.3 BOLT TORQUE ENGINE 31

2.6 POINTS TO OIL 34

3 PERIODICAL CHECKS AND ADJUSTMENTS 49

3.1 INTRODUCTION 49

3.2 CHECK SPARKING-PLUGS 53

3.3 CLEAN AIR BOX 54

3.4 GAS COMMAND PLAY 55

3.5 ADJUSTMENT CO 56

3.6 ADJUSTMENT THROTTLE HOUSING 58

3.7 CHECK STEPPER 61

3.8 ADJUSTMENT CLUTCH LEVER PLAY 61

3.9 ADJUSTMENT VALVE PLAY 62

3.10 ENGINE DISTRIBUTION 63

3.11 CHECK ENGINE OIL LEVEL 69

3.12 CHANGE ENGINE OIL AND FILTER 70

3.13 CHECK COOLING LIQUID LEVEL 73

3.14 CHANGE REFRIGERANT LIQUID 74

3.15 FILL COOLING PLANT 76

3.16 CHECK FUEL TUBES 78

3.17 CHECK EXHAUST PLANT 78

3.18 ADJUSTMENT FRONT BRAKE LEVER 78

3.19 ADJUSTMENT REAR BRAKE PEDAL 79

3.20 CHECK BRAKE LIQUID 79

3.21 CHECK FRONT AND BACK BRAKE PADS 80

3.21.1 CHANGE FRONT BRAKE PADS 81

3.21.2 CHANGE REAR BRAKE PADS 81

3.22 CHECK BRAKING PLANT TUBES 82

3.23 PURGE FRONT/REAR BRAKING PLANT 82

3.23.1 PURGE REAR BRAKING PLANT 82

3.23.2 PURGE FRONT BRAKING PLANT 84

3.24 ADJUSTMENT GEAR COMMAND PEDAL 84

3.25 ADJUSTMENT CHAIN 85

CONTENTSCONTENTS

CONTENTS

MF9_UK

LIMITED EDITION

3.26 OIL CHAIN 85

3.27 CHECK AND ADJUST STEERING BALL-BEARINGS 87

3.28 CHECK FORK 88

3.29 ADJUST FORK 89

3.30 CHECK SHOCK ABSORBERS 91

3.31 ADJUST SHOCK ABSORBERS 91

3.32 CHECK TIRE PRESSURE 93

3.33 CHECK WHEELS 94

3.34 CHECK AND OIL CLUTCH CABLE 95

3.35 ELECTRICAL PLANT 95

3.35.1 CHECK BATTERY 95

3.35.2 BATTERY CHARGING SYSTEM 97

3.36 CHANGE FUSES 100

3.37 CHANGE FRONT LIGHTS 101

3.38 ADJUST FRONT HEADLIGHTS 101

3.39 CHANGE REAR LIGHTS 102

3.39.1 CHANGE REAR HEADLIGHTS 102

3.39.2 CHANGE LICENCE-PLATE HOLDER LIGHT 103

3.39.3 CHANGE FRONT AND REAR ARROWS 103

3.39.3.1 CHANGE FRONT ARROWS 103

3.39.3.2 CHANGE BACK ARROWS 104

4 COWLING 105

4.1 DISMANTLE COWLING 105

4.2 DISMANTLE LOWER SEMI-COWLING 105

4.3 DISMANTLE UPPER SEMI-COWLING 106

4.3.1 DISMANTLE LEFT AND RIGHT INSTRUMENT BOARD INTERNAL

FASTENINGS 106

4.4 DISMANTLE LEFT AND RIGHT REAR-VIEW MIRRORS 107

4.5 DISMANTLE TAIL-PIECE 108

4.6 DISMANTLE LEFT AND RIGHT UPPER COWLING 110

4.7 DISMANTLE WHEEL HOUSING 111

4.8 DISMANTLE COWLING BENEATH HEADLIGHT 112

4.9 DISMANTLE FRONT MUDGUARD 112

4.10 DISMANTLE REAR MUDGUARD 112

4.11 DISMANTLE CABLE GROMMET COVER 113

4.12 DISMANTLE RIGHT AND LEFT FOOTRESTS 113

4.13 DISMANTLE HOOD 113

4.14 DISMANTLE TANK 114

4.15 DISMANTLE TANK FUEL PUMP 116

5 ENGINE 117

5.1 CAMSHAFT 117

5.1.1 REMOVE CAMSHAFT 117

5.1.2 CHECK CAMSHAFT 119

5.1.3 CHECK CHAIN, SPROCKET WHEELS AND CAMSHAFT

CHAIN GUIDE 120

5.1.4 CHECK CHAIN STRETCHER 121

6MF9_UK

LIMITED EDITION

5.1.5 MOUNT CAMSHAFT 121

5.2 CYLINDER HEAD 125

5.2.1 REMOVE CYLINDER HEAD 125

5.2.2 CHECK CYLINDERHEAD 126

5.2.3 MOUNT CYLINDER HEAD 126

5.3 VALVES AND VALVE SPRINGS 127

5.3.1 REMOVE VALVES 127

5.3.2 CHECK VALVES AND VALVE GUIDES 128

5.3.3 CHECK VALVE HOUSING 130

5.3.4 CHECK VALVE SPRINGS 131

5.3.5 CHECK BUCKET-TYPE TAPPET 132

5.3.6 MOUNT VALVES 133

5.4 CYLINDER 135

5.4.1 DISMANTLE CYLINDER CASING 135

5.4.2 CHECK CYLINDER 136

5.4.3 DISMANTLE WATER COLLECTOR 136

5.4.4 CHECK WATER COLLECTOR 137

5.4.5 MOUNT WATER COLLECTOR 137

5.4.6 MOUNT CYLINDERS 137

5.5 PISTONS 138

5.5.1 DISMANTLE PISTONS 138

5.5.2 CHECK PISTONS 139

5.5.3 CHECK SEGMENTS 139

5.5.4 CHECK PISTON PIN 140

5.5.5 MOUNT PISTONS 140

5.6 GENERATOR 141

5.6.1 REMOVE GENERATOR 141

5.6.2 MOUNT GENERATOR 142

5.7 DISTRIBUTION SENSOR AND PHONIC WHEEL 142

5.7.1 REMOVE DISTRIBUTION SENSOR 142

5.7.2 MOUNT DISTRIBUTION SENSOR 143

5.7.3 REMOVE PHONIC WHEEL 143

5.7.4 MOUNT PHONIC WHEEL 143

5.8 CLUTCH 144

5.8.1 DISMANTLE CLUTCH COMMAND 144

5.8.2 REMOVE CLUTCH 144

5.8.3 REMOVE CLUTCH COVER 146

5.8.4 REMOVE PRIMARY TRANSMISSION 147

5.8.5 DISMANTLE CLUTCH GROUP 147

5.8.6 CHECK EXTERNAL EQUIPPED DISK 149

5.8.7 CHECK INTERNAL DISK 149

5.8.8 CHECK CLUTCH SPRINGS 149

5.8.9 CHECK CLUTCU COVER 150

5.8.10 CHECK PRIMARY ASSEMBLY 151

5.8.11 MOUNT CLUTCH GROUP 151

5.8.12 MOUNT PRIMARY ASSEMBLY 153

5.8.13 MOUNT CLUTCH COVER 153

5.8.14 MOUNT CLUTCH 154

MF9_UK

LIMITED EDITION

5.8.15 MOUNT CLUTCH COMMAND 155

5.8.16 ADJUSTMENT PHASE 156

5.9 EARS 156

5.9.1 REMOVE GEARS 156

5.9.2 DISMANTLE GEARS 156

5.9.3 CHECK GEAR FLANGE BALL-BEARINGS 159

5.9.4 CHECK GEAR FORK AND SLIDE RODS 159

5.9.5 CHECK POSITIVE VALVE GEAR SHAFT 160

5.9.6 CHECK PRIMARY AND SECONDARY SHAFT 160

5.9.7 ASSEMBLE GEAR 161

5.9.8 MOUNT GEARS 168

5.10 OIL SUMP AND OIL PUMP 169

5.10.1 DISMANTLE OIL SUMP 169

5.10.2 DISMANTLE OVERPRESSURE OIL VALVE 169

5.10.3 REMOVE OIL PUMP 170

5.10.4 DISMANTLE OIL PUMP 170

5.10.5 CHECK OIL SUMP 171

5.10.6 CHECK OIL PUMP 171

5.10.7 ASSEMBLE OIL PUMP 172

5.10.8 MOUNT OIL PUMP 173

5.10.9 MOUNT OVERPRESSURE VALVE 174

5.10.10MOUNT OIL SUMP 174

5.11. CASING 175

5.11.1 DISMANTLE CASING 175

5.11.2 DISMANTLE FREE WHEEL 182

5.11.3 DISMANTLE BALANCING COUNTER SHAFT 184

5.11.4 DISMANTLE ENGINE SHAFT 185

5.11.5 CHECK CASING 185

5.11.6 CHECK ENGINE SHAFT AND CONNECTING ROD 186

5.11.7 CHECK BALANCING COUNTER SHAFT 187

5.11.8 CHECK FREE WHEEL 188

5.11.9 ASSEMBLE FREE WHEEL 188

5.11.10 MOUNT ENGINE SHAFT 190

5.11.11 MOUNT BALANCING COUNTER SHAFT 191

5.11.12 MOUNT CASING 192

6 COOLING PLANT 203

6.1 RADIATOR 203

6.1.1 DISMANTLE RADIATOR 203

6.1.2 DISMANTLE RADIATOR BOX 206

6.1.3 CHECK RADIATOR 208

6.1.4 MOUNT RADIATOR 208

6.2 WATER OIL EXCHANGER 209

6.2.1 MOUNT EXCHANGER 210

6.3 THERMOSTAT 211

6.3.1 DISMANTLE THERMOSTAT 211

6.3.2 CHECK THERMOSTAT 212

6.3.3 MOUNT THERMOSTAT 213

8MF9_UK

LIMITED EDITION

6.4 WATER PUMP 214

6.4.1 REMOVE WATER PUMP 214

6.4.2 DISMANTLE WATER PUMP 214

6.4.3 CHECK WATER PUMP 217

6.4.4 ASSEMBLE WATER PUMP 217

6.4.5 MOUNT WATER PUMP 222

7 FRAME 225

7.1 FRONT WHEEL AND BRAKE DISKS 225

7.1.1 REMOVE FRONT WHEEL 225

7.1.2 CHECK FRONT BRAKE DISKS 226

7.1.3 DISMANTLE FRONT WHEEL 226

7.1.4 CHECK FRONT WHEEL 227

7.1.5 MOUNT FRONT WHEEL 227

7.1.6 INSTALL FRONT WHEEL 228

7.2 REAR WHEEL, BRAKE DISK AND CROWN 229

7.2.1 REMOVE REAR WHEEL 229

7.2.2 CHECK REAR BRAKE DISK 230

7.2.3 DISMANTLE REAR WHEEL 231

7.2.4 CHECK REAR WHEEL 233

7.2.5 CHECK HUB 233

7.2.6 CHECK CROWN 234

7.2.7 MOUNT REAR WHEEL 234

7.2.8 INSTALL REAR WHEEL 236

7.3 FRONT AND REAR BRAKES 237

7.3.1 REMOVE FRONT BRAKE PUMP 237

7.3.2 REMOVE REAR BRAKE PUMP 238

7.3.3 CHECK FRONT AND REAR BRAKE PUMPS 239

7.3.4 INSTALL FRONT BRAKE PUMP 240

7.3.5 INSTALL REAR BRAKE PUMP 240

7.3.6 DISMANTLE FRONT PLANT BRAKE TUBES 241

7.3.7 DISMANTLE REAR PLANT BRAKE TUBES 242

7.3.8 CHECK FRONT AND REAR BRAKE TUBING 243

7.3.9 MOUNT FRONT BRAKE TUBES PLANT 243

7.3.10 MOUNT REAR BRAKE TUBES PLANT 244

7.3.11 DISMANTLE FRONT BRAKE CLAMPS 244

7.3.12 DISMANTLE REAR BRAKE CLAMPS 245

7.3.13 CHECK BRAKE CLAMPS 246

7.3.14 MOUNT FRONT BRAKE CLAMPS 246

7.3.15 MOUNT REAR BRAKE CLAMPS 247

7.4 FORK 248

7.4.1 REMOVE RIGHT AND LEFT STEM 248

7.4.2 CHECK FORK LEGS 249

7.4.3 INSTALL FORK LININGS 249

7.5 SEMI- HANDLEBARS 251

7.5.1 REMOVE RIGHT SEMI-HANDLEBAR 251

7.5.2 REMOVE LEFT SEMI-HANDLEBAR 252

7.5.3 DISMANTLE RIGHT SEMI-HANDLEBAR 253

MF9_UK

LIMITED EDITION

7.5.4 DISMANTLE LEFT SEMI-HANDLEBAR 254

7.5.5 CHECK RIGHT SEMI-HANDLEBAR 254

7.5.6 CHECK LEFT SEMI-HANDLEBAR 255

7.5.7 MOUNT RIGHT SEMI-HANDLEBAR 255

7.5.8 MOUNT LEFT SEMI-HANDLEBAR 255

7.5.9 INSTALL RIGHT SEMI-HANDLEBAR 256

7.5.10 INSTALL LEFT SEMI-HANDLEBAR 257

7.6 STEERING DAMPER 258

7.6.1 DISMANTLE STEERING DAMPER 258

7.6.2 CHECK STEERING DAMPER 258

7.6.3 MOUNT STEERING DAMPER 259

7.7 STEERING HEAD 259

7.7.1 DISMANTLE LOWER STEERING PLATE 259

7.7.2 CHECK LOWER STEERING PLATE 261

7.7.3 MOUNT STEERING PLATE 261

7.8 REAR DAMPER 262

7.8.1 REMOVE REAR DAMPER 262

7.8.2 CHECK REAR DAMPER 264

7.8.3 MOUNT REAR DAMPER 264

7.9 REAR FORK 266

7.9.1 REMOVE REAR FORK 266

7.9.2 DISMANTLE REAR FORK COMPONENTS 268

7.9.3 CHECK REAR FORK 269

7.9.4 MOUNT REAR FORK 270

7.9.5 INSTALL REAR FORK 271

7.10 FRONT FRAME 272

7.10.1 REMOVE FRONT FRAME 272

7.10.2 CHECK FRONT FRAME 272

7.10.3 INSTALL FRONT FRAME 273

7.11 REAR FRAME 273

7.11.1 DISMANTLE REAR FRAME 273

7.11.2 CHECK REAR FRAME 274

7.11.3 INSTALL REAR FRAME 274

7.12 TRANSMISSION CHAIN 275

7.12.1 REMOVE TRANSMISSION CHAIN 275

7.12.2 CHECK TRANSMISSION CHAIN 275

7.12.3 INSTALL TRANSMISSION CHAIN 276

8 INJECTION PLANT 277

8.1 ENGINE MANAGEMENT SYSTEM 277

8.1.1 DESCRIPTION OF THE SYSTEM 277

8.1.2 SYSTEM SENSORS 277

8.1.3 POSITION OF THE SENSORS 278

8.2 SYSTEM ACTIVATING DEVICES 278

8.2.1 ENGINE SUPPLY PLANT 280

8.2.2 IGNITION AND INJECTION DIAGNOSTIC SYSTEM 280

8.3 NUMBERING THE ECM CONNECTORS 280

8.4 FUEL PUMP CHECKING SYSTEM 282

10 MF9_UK

LIMITED EDITION

8.5 SUPPLEMENTARY DIAGNOSIS 283

9 ELECTRICAL PLANT 301

9.1 CONNECTORS 304

9.2 FUSES. 304

9.3 SEMI-CONDUCTOR PARTS 305

9.4 BATTERY 305

9.4.1 CHECK BATTERY EFFICIENCY 306

9.5 FUSES 308

9.6 RELAYS 308

9.6.1 RELAY STARTER 308

9.6.2 RELAY SERVICES GROUP 309

9.7 ENGINE STARTER 309

9.8 ALTERNATOR 310

9.9 STARTER DIAGNOSTIC SYSTEM 311

9.10 CHECK SAFETY SYSTEM PARTS 312

9.11 DIODES 312

9.12 GEAR SWITCH POSITION 312

9.13 LATERAL SWITCH STAND 313

9.14 CLUTCH SWITCH 313

9.15 SPEED SENSOR 314

9.16 OIL PRESSURE SENSOR 314

9.17 FRONT LIGHTS 315

9.18 REAR LIGHTS 315

9.18.1 REAR HEADLIGHT 315

9.18.2 LICENCE PLATE LIGHT SUPPORT 316

9.18.3 FRONT AND REAR ARROWS 316

9.18.3.1FRONT ARROWS 316

9.18.3.2REAR ARROWS 317

10 DIAGNOSTICS 319

10.1 ELECTRICAL PART 319

10.2 FRAME 323

10.3 PRELIMINARY OPERATIONS 326

10.4 SELF-DIAGNOSIS 326

10.5 RESET THROTTLE 326

10.6 ADJUST STEPPER/CD 327

11 USA VERSION 329

11.1 E.V.A.P. CANNISTER 329

11.2 CANNISTER POSITION 329

11.3 REMOVE CANNISTER 329

11.4 CANNISTER CONNECTION 330

11.5 EXHAUST 331

11.6 LIGHT COMMANDS331

11.7 REAR CATADIOPTRICS 331

11.8 FRONT CATADIOPTRICS 332

11.9 REAR ARROWS 332

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