TNT300 Owner`s Manual

EDITION: TNT300-8-2014
TNT300 USER’S MANUAL
256779
CONTENTS ...........................................................................................................................................................................................................
Special Reminding ...........................................................................................................................................................................................
Preface ..................................................................................................................................................................................................................
Safety Notes ........................................................................................................................................................................................................
Safety Driving Rules ...................................................................................................................................................................................
Protection Clothes .....................................................................................................................................................................................
Serial Number .................................................................................................................................................................................................... 10
Location of Parts ............................................................................................................................................................................................... 11
Meter & Indicator ........................................................................................................................................................................................ 13
Primary Parts ...................................................................................................................................................................................................... 15
Key switch ...................................................................................................................................................................................................... 15
Left Handle .................................................................................................................................................................................................... 16
Right Handle ................................................................................................................................................................................................. 17
Fuel Tank ........................................................................................................................................................................................................ 18
Rear Shock Absorber .................................................................................................................................................................................. 19
Rear Brake Pedal .......................................................................................................................................................................................... 21
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Shift Pedal ................................................................................................................................................................................................... 21
Tool Bag ....................................................................................................................................................................................................... 22
Notice of Use of Fuel and Engine Oil ...................................................................................................................................................... 22
Running In ....................................................................................................................................................................................................... 23
Inspection before Driving .......................................................................................................................................................................... 24
How to start the engine ........................................................................................................................................................................ 25
Smooth launching .................................................................................................................................................................................. 26
To change gear ........................................................................................................................................................................................ 27
Inspection& Maintenance .......................................................................................................................................................................... 27
Maintenance Schedule ......................................................................................................................................................................... 27
Oil Level & Oil Change ........................................................................................................................................................................... 31
Spark plug .................................................................................................................................................................................................. 32
Catalytic Converter................................................................................................................................................................................... 32
Battery .......................................................................................................................................................................................................... 33
Throttle Cable Adjustment ................................................................................................................................................................... 36
Clutch Adjustment ................................................................................................................................................................................... 37
Chain Adjustment .................................................................................................................................................................................... 37
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Brake ............................................................................................................................................................................................................... 39
Maintenance of Air Filter.......................................................................................................................................................................... 41
Bulb Replacement ...................................................................................................................................................................................... 41
Fuse Replacement ...................................................................................................................................................................................... 42
Lubrication points ...................................................................................................................................................................................... 43
Adjustment of Valve Clearance ............................................................................................................................................................. 43
Tire ................................................................................................................................................................................................................... 43
Storage Guideline ............................................................................................................................................................................................. 45
Speci£cation & Technical Parameter ......................................................................................................................................................... 47
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4
Warning: The motorcycle must be equipped with the quali£ed fuse for a safe driving, any other unquali£ed
speci£cations of fuses are not allowed to use, especially the electric wires which would result severe damages to
other parts, even £re accidents.
Location of fuse: beside the battery;
Fuse speci£cation: 40A for main power fuse.
Burnt fuse is usually caused by the internal circuit fault of the motorcycle. Simply estimate the whole situation of
the motorcycle before changing the spare fuse and if the fuse still burn after changing, send the motorcycle to the
maintenance service center as soon as possible. It can only be driven after the fault is resolved.
Notes:
Before changing the fuse, switch the key to "
" in case of short circuit;
* Make sure the contact point of fuse is not broken while changing the fuse, which would result bad contact, parts
damage, and even £re.
No recon£guration: Do not recon£gure the motorcycle or change the places of the parts and accessories at will,
which would have a strong impact on the stability and safety of the motorcycle, probably operation faults. All the
recon£gurations of the electric system, emission control system, canister and any other systems or parts are against
the driving safety and other relative tra£c administration regulations. And all the quality problems and
consequences resulted by the user's recon£guration or changing of the parts without authorizations would be taken
by the user himself. The user shall obey the speci£c regulations and rules of the tra£c administrative
department.
5
Notes
Running in of Motorcycle
The very beginning 1,000km driving-way of the motorcycle is the most important part of its service life.
If the running in is carried normally, a longest service life can be assured and the performances of the new
motorcycle can be fully ful£lled.
PREFACE
Thanks for choosing Benelli motorcycle, which is combined with international advanced technologies and would
bring you happy and safe driving experience.
Please fully understand the rules and requirements stated in this manual.
This instruction manual covers the maintenance procedures, which would ensure the maximum performances
and highest durability of your motorcycle if appropriately operated.
Our company is equipped with professional technical maintenance personnel and department, which is able to
provide you with high quality technical maintenance services. We make great eForts to develop the products
quality and performances so that the appearances and structures can be improved and may have diFerence than
the data in this manual. The picture information here is only for reference, subject to our products.
6
Please carefully read this manual and stand by the key rules. The words of "Alarm", "Caution" and "Note" are used
here to indicate the importance degrees, please make sure that you have fully understand the meanings as
following:
Alarm------------ This is for the important procedures that may endanger safety of the driver and would bring
injuries if ignored.
Caution------------ This is for the relative operation speci£cations of the motorcycle in case of damages to the
motorcycle.
Note------------ This is for the maintenance
This instruction manual is a daily care issues document of this motorcycle, which should be together transferred
to a second owner if this motorcycle is to be transferred.
SAFETY NOTES
Alarm:
For the safety purpose, the driver should be speci£cally careful with understanding on the safety notes
before driving.
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1. Have a complete inspection before starting the engine so as to prevent possible accidents or damages of parts.
2. Many accidents happen due to inexperienced driver. Make sure the driver is quali£ed before driving the
motorcycle. Never give it to any people without a driving license.
3. Most of the crashes between cars and motorcycles are caused by the car drivers' "not seeing" the motorcycle
drivers. In order to avoid accidents, the driver shall expose himself/herself by:
Wearing bright colored and re£ective clothes;
Don't drive into the invisible corner of rear-view mirror of the other car drivers.
4. The driver shall obey the national and local laws and rules.
Speeding is one of the key reasons of the accidents. So keep the speed in the limit stated.
Use signals lights before turning or braking/accelerating to prevent accidents
5. In the driving, the driver should hold the handles and keep both feet on the pedals and the passenger should
grab somewhere on the vehicle or the driver with feet on the passenger pedals.
6. Any recon£guration or disassembly of the parts is illegal, which would aFect the safety driving and
maintenance.
7. The after-market accessories shall not aFect the safety driving and operation performances of the motorcycle.
Overloading of the electrical systems would result dangers to the vehicle.
8. Do not operate the engine within con£ned space as the exhaust gas would cause damage to the body.
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PROTECTION CLOTHES
1. Fatal accidents of motorcycle drivers are mostly caused by head injuries. For the purpose of personal safety, the
driver should wear a safety helmet, and also motorcycle boots, gloves and protection clothes. The passenger shall
also wear the same.
2. The exhaust pipe will be very hot during driving and the heat will last after turning oF the engine. Never touch
the mu£er and wear those clothes that can totally cover the legs.
3. Don't wear those loose clothes that may interfere with the control levers, pedals or wheels.
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Vehicle identi£cation number (VIN) and the serial number are used for the registration of the motorcycle, which
can also make sure that the dealer would provide you better services involving accessories purchasing or other
services.
Record the numbers for the possible use in the future.
Vehicle identi£cation number (VIN) is printed on the right side of the head tube.
The engine number is printed on lower part of the right case of engine crank case
Please write down the numbers for your reference.
Vehicle Identi£cation Number(VIN):
Engine Number:
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10
4
3
1
7
2
1. Clutch lever
2. Left switch handle
3. Meter
4. Key switch
5. Right switch handle
6. Throttle grip
7. Front brake lever
5
6
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8. Rear shock absorber
9. Rear brake pedal
10. Shift pedal
11. Side stand
12. Tank
12
8
10
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12
11
9
1
10
2
11
5
3
4
14
6
7
8
13
METER & INDICATOR
1. TURNING INDICATOR
The indication lamps would £ash with the turning signals.
2. TURNING INDICATOR
The indication lamps would £ash with the turning signals.
3. HIGH BEAM INDICATOR LAMP
This gauge shows the temperature of coolant
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When the high beam lamp of the headlamp turns on, the high beam indicator lamp would be on.
4. ENGINE OIL PRESSURE WARNING LAMP
When this indicator light up, that means the bike has the risk of insu£cient lubrication and should be checked/
repaired immediately.
5. NEUTRAL INDICATOR LAMP
When the transmission is in the neutral, the green indicator lamp would be on.
6. FUNCTION BUTTON A
Short press the button to switch between trip and odometer functions on the meter. Long press the button A to
reset the "Trip" mileage.
7. FUNCTION BUTTON B
Long press the button to enter time adjusting mode. Shortly press the button B to select a digit for clock adjustment. Within time adjusting mode, short press function button A to adjust the value of clock; If function button A is
long pressed, the value of clock will swiftly change, to reach the desired value easily. If both Function A and Function B are short pressed simultaneously, displaying units of coolant temperature, mileage and speed can be
switched between the metric and imperial units.
8. TACHOMETER
Tachometer indicates the revolution per minute of engine
9. COOLANT TEMPERATURE GAUGE
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10. SPEEDOMETER
Speedometer shows the running speed, hours/kilometers.
11. CLOCK
It shows the time
12. FUEL LEVEL INDICATOR:
It indicates the fuel level in the fuel tank
13. ODOMETER/ TRIP METER
Odometer records the total mileage driven, and Trip meter can be reset, which
records the mileages driven in a speci£c period.
14. FI INDICATOR
It £ashes when EFI system trouble happens and it shows up when it does
self-diagnosis
PRIMARY PARTS
KEY SWITCH
“
”(OF)position: All the circuits are oF.
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“ ”(On) position: The circuits are on
“ ” Position: turn left to the maximum, press the key to the position of “ ”. Take out the key. In this condition, the
vehicle has been locked. If you want to unlock the vehicle, insert the key and turn clockwise.
5
1
2
LEFT HANDLE
1. CLUTCH LEVER
When starting the engine or shifting, pull the clutch lever to cut oF driving on the rear wheels.
2. HIGH & LOW BEAM SWITCH
Turn the switch to "
" position, the high beam of headlamp turn on and the indicator lamp on the meter would
also turn on; turn the switch to "
" position, the low beam of headlamp turn on.
3. DIRECTION INDICATOR LAMP SWITCH
Turn the switch to "
" position, the left direction signal lamp £ashes; turn the switch to "
right direction signal lamp £ashes. And the indicator lamps would turn on accordingly.
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" position, the
Alarm:
Turn on the direction signal lamps in time when changing the driveway or turning a direction and turn oF
the lamps.
4. HORN BUTTON
Press down on the button, to activate the horn.
5. PASSING SWITCH
When passing other vehicles, press this button so the high beams of the headlamp would £ash to alarm the
vehicles in front of you.
RIGHT HANDLE
1. ENGINE STOP SWITCH
When the switch is on "
When the switch is on "
" position and the power is on, the engine runs.
" position and the power is oF, the engine will not run.
Note:
Under normal conditions, this switch shall be on "Operate" (
) position. Use this switch under
emergency situation, for example accident or key switch problems.
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2. HAZARD SWITCH
Push the switch and the four direction signal lamps would £ash to warn for emergency situation
3. ELECTRIC STARTER BUTTON
Pull the clutch lever or put in Neutral gear and press the button to run the electric motor and start the engine.
4. FRONT BRAKE LEVER
Pull the brake lever properly to use the front brake.
5. THROTTLE GRIP
Throttle grip is to control the speed of engine. Twist the grip toward yourself when revving up or turn it in
opposite way to slow down.
FUEL TANK
The capacity of fuel tank (including reserve) is about 16L.
To open fuel tank cap, please insert the key and turn it clockwise and open the cover. To close the fuel tank,
please recap and then press it. Take away the key when you hear the sound of locking.
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Alarm:
Do not over £ll the fuel tank. Do not make fuel splashes on hot engine.
Please stop the engine and turn the ignition key to "
" (OF) position when you need to refuel.
Do not forget to lock the fuel tank cover after adding the fuel in case of evaporation to the air, which is
waste of energy and would pollute the environment. Don't use £re when refueling.
REAR SHOCK ABSORBER
The motorcycle is equipped with one rear shock absorber on the right
side of bike.
Spring pre-load adjustment.
The rear shock absorber is equipped with adjustment ring nuts for
preload adjustment.
Adjust the spring preload as follows:
To increase the preload setting of the spring, turn the adjustment
ring nut with special wrench as illustrated, to make the suspension stiFer.
Please rotate opposite direction to achieve a softer setting. After
adjustment, please make sure the lock nut tightened to ensure safety
of riding.
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Rebound damping adjustment
The rear suspension rebound damping can be adjusted by the
adjusting knob in the lower end of rear suspension. To adjust the
rebound damping, please follow the procedure:
1. Turn the adjust knob as illustrated until feeling tight and no click
sound heard, this is the zeroing point with maximum rebound damping
eFect (rebound extremely slow).
2. Turn the adjust knob in opposite direction, and count for clicking sound. The total adjustable range is 36 clicks
from the zero point, in normal riding, the setting should be 5~10 clicks according to the road condition and rider's
preference.
Generally speaking, when the spring preload is increased, the rebound damping should also be increased
accordingly. If you are not sure how to adjust the rear suspension correctly, please refer to the authorized dealers
for technical advice.
Alarm:
Rotate this adjusting knob with hand only, and never use too much force, or the rear suspension will be
damaged. This will be deemed as abnormal usage, will not be covered by warranty.
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REAR BRAKE PEDAL
Step the rear brake pedal to slow down the rear wheel.
Brake light will turn on while rear brake is in use.
SHIFT PEDAL
This motorcycle is equipped with six-speed constant mesh gearbox.
Caution:
When the transmission is on neutral position, the indicator lamp would turn on. Slowly release the clutch
lever to make sure the transmission is on the neutral position.
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Slow down the motorcycle when turning to the low gear. Revving up the engine slightly to shift gears in more
smooth way to avoid damaging gears
TOOL BAG
The tool bag is in the seat cushion. By using tools in the bag, you can do basic repair and adjustment and change
some parts when needed.
NOTICE OF USE OF FUEL AND ENGINE OIL
Fuel
It is a must to use lead free gasoline. Use gasoline contains octane number more than 93.
Notice: Use lead free gasoline can extend the working life of spark plug.
Engine Oil
Please use four-stroke engine oil it should be equal or higher than API SAE service grade SF. The speci£cation
is SJ10W/50.
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For driving a new motorcycle in its £rst 1,000km way, the engine should not be over revved and all the gears shall
not be over 80% of red zone engine rpm; don't operate the throttle under a fully open position; change the gears
in time to keep the engine rpm in reasonable range. It is strongly suggested to use the motorcycle very carefully
during its running in period; also the rider has to be familiar to the performance.
Note:In the £rst 300km of break in, you should examine the cleanliness of the engine oil frequently. Check the
oil level of engine oil before driving.
INSPECTION BEFORE DRIVING
Please check on the following contents which are very important before driving,
Content
Comments
Handlebar
1) Stable
2) Turn smoothly
3) No sliding or loose
Braking
1)Right clearance of the lever and brake pedal
2)No sponge feeling
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Tire
Fuel Level
1)Appropriate air pressure
2)Appropriate tire treads depth
3)No crack or cut
Su£cient fuel for the driving
Light
Operate all the lamps – headlight, taillight, stoplight, instrument-panel
light and city light.
Indicator Lamp
High beams indicator lamp, gear Indicator light, and turning indicator.
Horn & Brake Switch
Engine Oil
Throttle
Clutch
Driving Chain
Horn & Brake Switch
Correct oil level
1)Appropriate free play in clutch lever
2)Smooth operation
1)Appropriate free play in throttle cable
2)Smooth operation, no stuck when returning to full close position
1)Appropriate tightness
2)Appropriate lubrication
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DRIVING TIPS
HOW TO START THE ENGINE
Insert the ignition key into the ignition lock and to " ". Step on the shift pedal to the neutral. The neutral
indicator light lightens up if the gear box is in neutral position. Start the engine by pushing the start switch.
Caution:
Do not run the engine in high speed when you do not drive the motorcycle, or it will become overheating
and damage its inner parts.
Warning:
Do not start the engine indoor with bad ventilation or without ventilation. Do not leave a starting
motorcycle when no one else is around.
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SMOOTH LAUNCHING
Hold the clutch lever, paused for an instant and step on the shift pedal to the £rst gear. Twist the throttle grip
towards yourself and release the clutch lever slowly and smoothly at the same time. Then the motorcycle will begin
to move forward smoothly.
Warning:
Put the stands back to retracted position before driving.
Gear box usage
Gear box can ensure a smooth running of engine within normal engine rpm Driver should choose a proper gear
according to driving speed. It is dangerous to drive with clutch disengaged. Lower the gear when you slow down
the motorcycle to make engine run within normal rpm range.
Drive on slope way
When drive on uphill road, motorcycle will slow down and seem to be lack of power. Switch to low gears so that
engine can generate normal power. Shift the gear swiftly to prevent motorcycle from losing speed.
Turn to low speed gears in order to brake when driving on downhill slope.
Don't over rev the engine.
Brake usage and stopping
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26
Twist the throttle grip in the direction away from yourself to close the throttle. Use front and rear brake evenly.
Shift to low speed gear to slow down.
Before stopping the motorcycle, hold the clutch and shift to neutral position. Check the neutral position indicator
light to check whether it is in neutral position.
Notice:
Inexperienced drivers usually use rear brake only, which will accelerate abrasion of the brake and result
in longer stopping distance.
Warning:
It is dangerous only to use either the front brake or rear brake which may causes the motorcycle to skid or
lose control. Be careful and use brakes properly when you drive on wet road or curved road.
The motorcycle should be parked on £rm and £at road. If you have to park the motorcycle on a slope by the side
stand, please shift to the £rst gear to prevent slipping. Shift to neutral position before starting the engine.
Turn the power key to the position " " to stop the engine.
Remove ignition key from the switch after locking for security reason.
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MAINTENANCE SCHEDULE
Listed below is the scheduled maintenance time table. Inspection, examination, lubrication and speci£ed
maintenance should be taken according to the following chart the inspection and maintenance of the key
components, are required to be made by professionals. Better to consult authorized dealers to do inspection and
maintenance for safety's sake.
MAINTENANCE SCHEDULE:
I: Inspection, cleaning, adjustment, replacement
C: Cleaning R: Replacement
A: Adjustment L: Lubrication
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ODOMETER READING
NO
1
2
ITEM
1000km
Fuel system
4000km
7000km
10000km
I
13000km
I
16000km
I
Throttle
I
Operation
3
Air Filter
I
4
Spark Plug
I
I
I
I
I
Per 6000km: I or R
R
R
Valve
5
Per 24000km: I
Clearance
6
Engine Oil
I
Per 6000km: R
7
Oil Filter
I
Per 6000km: R
8
Fuel Injection
I
9
Drive Chain
10
Battery
I
I
Per 1000km: I / L /A
I
29
I
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ODOMETER READING
NO
ITEM
1000km
4000km
7000km
10000km
11
Wear of Brake pads
I
12
Brake System
I
13
Braking Hydraulic
Tube
I
I
16
Braking Hydraulic
Fluid
17
Clutch
I
I
I
18
Hanger Bracket
I
I
I
19
Nut Bolt Fastener
I
I
I
20
Wheel/Rim
I
I
I
21
Steering Bearing
I
I
22
Cooling System
I
I
14
15
I
13000km
I
I
I
I
I
I
I
Replace every two years
I
I
Replace every two years
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30
16000km
I
Be repaired by authorized dealers: with quali£ed tools and inspection materials provided by the owner; by
persons with mechanical repair certi£cation; required to be followed the maintenance manual for self-inspection.
Examination and repair are suggested to be taken by authorized dealers for the sake of safety, in cases of these
items
Notes:
1. Make more inspections for driving in dusty areas.
2. Repeat the shown regular inspection, if the odometer reading exceeds the £xed value.
3. Take more maintenance to keep good performance for frequent driving in heavy conditions as rugged roads.
OIL LEVEL & OIL CHANGE
Check the oil level before starting the engine.
Put the motorcycle on side stand. Pull the handle bar and let the bike stand
vertical to the £at ground. Check if the oil level is between the maximum
and minimum level. If not, £ll the quali£ed engine oil to the proper amount.
Oil Change & Oil Filter Replacing
1. Take down the oil £lter with the special tool and oil drain bolt before oil
draining.
2. Replace the oil £lter with a new one if needed.
31
2
3
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3. Install the oil £lter with the special tool and oil drain bolt.
4. Fill the engine with quali£ed engine oil
5. Make the engine runs in idling for several minutes and turn oF.
6. Make sure the oil reaches the upper limit mark without any oil leakage.
SPARK PLUG
Clear away carbon deposit on the spark plug with small metal wire brush or spark plug cleaner during inspection
period noted in the maintenance schedule. Readjust the electrode gap of spark plug with feeler gauge and keep the
gap between 0.6~0.7mm.
0.6-0.7mm
6-0.7mm
Replace the sparking plug for each 6000km.
Type of Spark Plug: NGK CR8E
Do not Screw the spark plug too tight to avoid damaging the threads of cylinder cover.
Don't let the foreign objects fall into the engine through spark plug hole during
dismounting.
CATALYTIC CONVERTER
In order to meet the requirements of environmental emission, the mu£er of the motorcycle is equipped with
catalytic converter.
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The catalytic converter contains precious metals as the catalyst, which will transform the hazardous substances in
the exhaust gas, including carbon monoxide, hydrocarbon and nitrogen oxide into non-toxic carbon dioxide, water
and nitrogen through chemical reaction.
Since the catalytic converter is very important, the defective catalytic converter will pollute the air and damage
the performance of the engine, if the replacement is needed, please use the genuine parts or entrust the
distributors to replace.
Caution:
The catalytic converter is at high temperature area, please do not touch.
BATTERY
Battery is under the seat cushion. The battery for the motorcycle is maintenance
free type. For the new motorcycle, please ask the dealer of the company to £ll
electrolyte into the battery for you. It is not necessary to re£ll electrolyte in the future.
If you have to take out the battery for inspection, please follow these steps:
a. Shut oF power switch of the motorcycle;
b. Remove the seat cushion;
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d. Take down the negative terminal (—) £rst, and then the positive terminal(+);
e. Take out the battery gently.
Install the battery in the reverse order of removal.
Attention:
Connect correctly the battery wires when the battery is re-installed. The red wire shall be connected with
the positive terminal (+); and black wire shall be connected to the negative terminal(—). If the wires
are wrongly connected, it may damage the electrical system and the battery.
Power switch (key) shall be shut oF while inspecting or replacing battery.
Please operate on the following requirements for the £rst use:
Remove the sealing paper on the battery. Inject specially supplied electrolyte into the battery and put on the
battery sealing plug. Leave it for 30 minutes for full chemical reaction and then you can use the battery.
For the new battery, initial charge after electrolyte £lling will extend its service life. This operation shall be
performed by your local dealers.
Connect the wire polarities correctly. Positive wire (red) shall be connected with the positive terminal(+); and
negative wire(black)to the negative terminal(—). Tighten terminal bolts. Clean frequently the erosive
substances on the terminals with a wire brush while in use.
Please operate according to the following requirements while £lling electrolyte into the maintenance-free battery:
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34
a. Place vertically the battery on a horizontal plane and remove the sealing tape.
b. Take out the electrolyte from the plastic bag. Open its cover strip and use it as £lling plug for the battery.
Attention: Please do not tear or puncture the sealing tape on the £lling port.
The cover strip can be kept as £lling plug for the battery.
c. Lift the electrolyte container upside down vertically and align the six £lling ports of the container with the six
£lling ports on the battery. Pull downward hard the electrolyte container so as to puncture the sealing tape on the
£lling ports of electrolyte container. Electrolyte thus £ows from the container to the battery. Check the three £lling
pipes on both sides. At least there is one pipe that has bubbles coming out on each side, which means that
electrolyte £lling begins normally. Attention: Please be sure not to tilt the container, or electrolyte £lling may be
interrupted.
d. When you are sure that there is at least one pipe that has bubbles coming out on each side (three pipes on
each side), leave it there and keep the £lling process over 20minutes.
If there is no pipe that has bubbles coming out on each side, tap slightly two to three times the bottom of the
electrolyte container and check again if there is at least one pipe that has bubbles coming out on each side (The
electrolyte cannot be taken down now).
e. When the electrolyte has completely £owed through, tap the container bottom several times to drain residual
electrolyte; and then slowly pull out the electrolyte container.
35
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f. The six sealing plugs on the cover strip align respectively to the six £lling ports on the battery. Make sure the
ends of the six sealing plug has inserted into the £lling ports on the battery; press them hard into the ports till the
cover strip makes a plane with the top surface of the upper part of the battery.
After completion of electrolyte £lling, please do not pull out the cover strip or £ll water, electrolyte or other liquid.
Pay attention to the following matters while replacing the battery.
Before replacing the battery, please £rst determine the model of motorcycle and check if both batteries are of the
same type. During motorcycle design, the battery speci£cations are considered as the best choice. If a battery of a
diFerent model is used, it may aFect performance and life time of the motorcycle, and possibly causes
electrical failure.
If the motorcycle will not be used for a long time, please remove the battery and charge it once a month.
Warning:Battery will produce explosive gases when chemical reaction occurs in the battery.
Keep the battery away from £re, spark and high temperature places.
The battery is £lled with sulfuric acid (electrolyte). Electrolyte is poisonous substance.
Please keep it out of reach of children.
THROTTLE CABLE ADJUSTMENT
1. Screw oF the lock nut. 2. Turn the adjustor to make the cable clearance within10-20mm.
3. Retighten the lock nut after adjustment of cable clearance.
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36
CLUTCH ADJUSTMENT
The free play of clutch is measured from the free status of the lever, to
the engagement point of the clutch the standard should be 10-20mm.
Adjust in following methods, if anything abnormal.
(1) Loose the locknut.
(2) Screw in or out adjusting bolt and adjusting screw to make required free play.
(3) Tighten locknut
10-20mm
CHAIN ADJUSTMENT
Adjust the tightness of drive chain for driving each 1000km's in following methods to reach the free play of
10~20mm. Make regular adjustment of the chain according to your driving condition.
Warning:Suggestions here are for regular maintenance schedule it's recommended for inspection
and adjustment of the chain before each driving. Accident as chain detaching or serious damage on
engine can be caused by excessively slack chain.
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Adjust the chain in following methods:
1. Support the motorcycle with side stand.
2. Loosen rear axle nut.
3. Loosen locknut.
4. Turn adjusting nut to adjust the tightness of the chain. Reference marks are adopted on left and right swing
arm and should reach the same grid after adjustment. Retighten the rear axle nut after adjust the chain
tightness to 10~20mm and con£rm again
Notice:
When use new chain, check both front and rear sprockets if they are still in service limit and replace them,
if necessary
During regular maintenance, check the following conditions of the chain:
(1) Loose pin
(2) Damaged roller
(3) Rusty chain link
(4) Twisted or snarled link
(5) Excessive free play
(6) Loose chain
The sprocket is probably damaged, if any above-mentioned problems on the chain are found.
Check the following items for sprocket:
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(1) Over worn sprocket tooth (2) Broken or damaged sprocket tooth (3) Loosened sprocket £xing nuts
BRAKE
The motorcycle uses disc brake as both the front brake and the rear brake. Adjustment is £nished before delivery.
Contact dealer if any problem.
Brake Fluid
The motorcycle uses DOT4 brake £uid. Please replace it every two years.
Warning:
In case of drinking the brake £uid by mistake or contacting with eye or skin, wash with a large amount
of water, and seek medical advice immediately if in a serious condition.
Don't forget to check the amount level in the front brake £uid reservoir. Add appropriate brake £uid if
necessary.
Brake pads
Check the front and rear wheel brake pads whether have been worn to limits. Change the pads if over the limit.
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Warning:
Maintenance of braking system or brake pads should be taken by the authorized dealer which is
equipped with necessary tools and can assure the quality of the service.
Caution:
The disk braking system has high pressure in the pipe require periodical maintenance in the manual.
Check the braking system everyday as follows:
1. Whether leak on the front and rear wheel braking system;
2. Whether leak, crack on the brake £uid tubes;
3. Check the feedback feeling on brake lever
4. Check abrasion condition of the front and rear wheel brake pads
Rear Brake
To adjust the stroke of rear brake pedal, screw or turn the adjusting bolt of rear brake, the free play be
adjusted to 20~30mm.
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MAINTENANCE OF AIR FILTER
Air £lter should be regularly maintained, especially when driving in areas full of dust and sand.
1. Dismount the seat, fuel tank and the side cover.
2. Remove the screw, open the cover of air £lter and take out the £lter element.
3. Immerse the £lter element in clean solution and take out after cleaning for complete drying.
4. Immerse the £lter element in clean engine oil again, after saturation, take out and squeeze oF excessive oil.
5. Install the components back in the reverse order of dismount.
Caution:
Those highly £ammable liquid like gasoline and organic solvent cannot be used for cleaning
the £lter element.
BULB REPLACEMENT
Replacing of Head Lamp Bulb
Take oF the cover, replace the old bulb with the same speci£cation one, and £nally set up in the reversed orders.
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Notice:
The new bulb installed must in the same speci£cation with the old one. High-power bulb will increase
load to circuit system which will cause faults such like battery power shortage.
FUSE REPLACEMENT
The fuse is beside the battery. Frequent blowing
of fuse indicates short circuit or over loading. Contact
with the authorized dealer for proper repairing.
Use the fuses for the same speci£cation as indicated.
Warning:
It's dangerous to use other speci£cations of fuse, which would result severe failures like burning, £ring.
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LUBRICATION POINTS
Appropriate lubrication is important to keep every part of your motorcycle in normal running and lengthen its
working life and to ensure safe driving. Lubricate your motorcycle after you have driven it for a long mileage or the
vehicle is wet due to raining or washing. Detail lubrication points are shown in the £gure below:
Motorcycle lubricant
Lubricant grease
1. Rear brake pedal shaft
2. Side stand and its spring
3. Throttle cable
4. Pivot of front brake lever
5. Pivot of clutch lever
ADJUSTMENT OF VALVE CLEARANCE
Check and adjust the valve clearance when the engine is cold.
The Standard Valve Clearance: Intake Valve: 0.13-0.19mm, Exhaust Valve: 0.19-0.25mm
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Notice:
Adjustment of valve clearance will have direct in£uence on the performance of engine, thus requiring
strict accordance with the time interval required in "Maintenance Schedule". Adjustment should be done
with professional technicians corresponding tools. In order to keep the valve clearance in good condition,
we strongly recommend you to leave it up to consult to authorized dealers about this maintenance.
TIRE
In£aztion pressure and tire tread should be regularly checked. In order to ensure maximum safety and longer
service life, in£ation pressure requires more frequent routine check.
Tire Pressure
Insu£cient tire pressure will not only accelerate wearing, but also have bad impact on driving stability such as
making turning di£cult. However, too high pressure will reduce the contact area between tire and ground, thus
causing slipping or even getting out of control. Tire pressure should be kept in the standard range. Adjust the tire
Front Wheel
230kpa
Rear Wheel
250kpa
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Tire Tread
Driving a motorcycle with wheels excessively worn will reduce driving stability or even get out of control. When
the tire tread of front wheel is less than 1.6mm, and the rear wheel's tread is less than 2mm or even less,
replacement is strongly recommended.
STORAGE GUIDELINE
Storage
If you need to keep your motorcycle for a long time without using, it's suggested tofollowing these instructions:
1. Change engine oil.
2. Lubricate drive chain
3. Detach the spark plug and add one teaspoon of (15~20cm3) clean engine oil to cylinder. Pushing the
starting switch for several times to distribute oil in the cylinder, and install the spark plug again.
4. Remove the battery. Keep the battery in proper place which can avoid freezing and the direct sunlight.
5. Clean and dry the motorcycle. Wax the surface of the paint.
6. In£ate tire to the required pressure. Put the motorcycle on a block to make two tires oF the ground.
7. Cover the motorcycle (no plastic or coating material) and keep it in the place with consistent temperature
and low humidity. Do not keep your motorcycle under direct sunlight.
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Use the motorcycle after storage
1. Take oF the cover and clean the motorcycle. Change engine oil if you keep your motorcycle for more than four
months.
2. Install the battery and do charging as needed.
3. Wash away the anti-rust agent in fuel tank, and add new petrol into fuel tank.
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Front Brake Type ...................................................... disc brake
Rear Brake Type ........................................................ disc brake
Front tire Speci£cation............................................ 110/70-17
Rear tire Speci£cation.............................................. 140/60-17
SIZE AND WEIGHT
Length............................................................................... 2115mm
Width................................................................................... 800mm
Height................................................................................1120mm
Wheelbase........................................................................1405mm
Dry Weight.............................................................................180kg
ELECTRICAL SYSTEM
Battery...............................................................................12V 8Ah
Magneto..................................................... Fly-wheel Magneto
Headlamp..................................................................12V 55/55W
Tail/Brake Lamp............................................................. 12V LED
Turn Signal Lamp.......................................................... 12V LED
Meter Lamp.......................................................................12V 2W
Neutral Position Indicator Lamp................................12V 2W
High beam indicator lamp...........................................12V 2W
Turning indicator ............................................................12V 3W
Horn Speci£cation............................................................12V 3A
ENGINE
Type.......Parallel two-cylinder, Four-stroke, liquid-cooled
Model............................................................................. KW265MN
Bore × Stroke..........................................................ø65×45.2mm
Displacement................................................................... 299.8ml
Maximum Power........................................ 28KW/11000r/min
Maximum Torque........................................27N.m/9000r/min
Ignition System Type................................................................TLI
Compression Ratio..................................................................12:1
Start Type............................................................Electric Starting
Transmission System
Clutch.................................................................... Wet, Multi-disc
CAPACITY
Fuel Tank (include reserve tank)...............................16±0.5L
Fuel Type.................................................................... 93 & above
SIX SPEED TRANSMISSIONS
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www.benelli.com
Benelli Q.J. S.r.l.
Strada della Fornace Vecchia 3, 61122 Pesaro - Italy