Benelli BN600R 2014 Guide

SERVICE STATION MANUAL

code:........................

Pure Passion since 1911

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- I -

WARNINGS:

This manual has been written by Benelli Q.J. s.r.l., mainly for use by Benelli dealers and their specially trained mechanics. It is not

possible to give a mechanic all of the information they require in a single manual. It is therefore presumed that the persons using this

manual for the maintenance and repairs of Benelli bikes have a basic knowledge of mechanics and the procedures necessary for

repairs and maintenance of this type of vehicle. Without this experience, any repairs or maintenance to this type of vehicle may be

dangerous or ineffective.

It is company policy at Benelli Q.J. s.r.l. to continuously upgrade and improve its models. Any changes or signi•cant modi•cations to

technical data or procedures will be made known to all authorised Benelli Dealers and will be published in future editions of the manual.

NOTE:

Drawings and speci•cations are subject to change without prior warning.

IMPORTANT INFORMATION ABOUT THE MANUAL

This manual contains the following important reminders:

WARNING:

IMPORTANT

NOTICE:

NOTE:

Failure to follow the instructions after this symbol may lead to serious injury or even death for the rider,

people in the vicinity, or people inspecting or repairing this bike.

"Important Notice" means that speci•c precautions are required to avoid causing damage to the bike.

A "Note" provides key information that will make the procedure either easier or clearer.

inders:

to follow the instructions after this symbol may lead to serious

e" provides key information that will make the procedure either ea

ollow the instructions after this symbol may lead to ser

the vicinity, or people inspecting or repairing this bike.

nt Notice" means that speci•c precautions are required to avo

e" provides key information that will make the procedure either

or people

ruct

or people

repairing

ol m

repairing th

er this

eans that speci•c precaut

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to s

w the

vicini

ser

ollow

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lead to

bike.

the

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is bik

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Not

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otic

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to avo

Not

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vides

rovide

eithe

recautio

that spec

means

equi

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formation that will make

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ion

atio

ion

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- II -

HOW TO USE THIS MANUAL

This manual is a practical reference guide that is both easy to handle and use for mechanics. The explanations of all of the procedures

for installing, removing, disassembling, •tting, repairing and checking, are organised in sequence, one step at a time.

1. Each chapter is divided into sections. The top part of each page contains the title of the current section.

2. To help with the identi•cation of parts and to make the different processes clearer, exploded drawings are provided at the start

of each section dealing with the removal or disassembly of parts.

3. The sequence of operations is listed on the exploded drawing, and numbered progressively. Each number refers to a step in the

disassembly process.

4. Parts needed lubricating or replacing are marked by symbols. See the "SYMBOLS" section.

5. The exploded drawing is accompanied by a table with instructions for the intervention. These state the order of operations, the

name of the parts, any notes for the job, etc.

6. Interventions requiring any other information (e.g., special tools and technical data) are described in sequence.

pecial tools and tec

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- III -

SYMBOLS

SUBJECT SYMBOLS

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

EXPLANATORY SYMBOLS

General Information

Speci!cations

Inspections and Periodic Adjustments

Frame

Engine

Cooling system

Wear limits, Backlash

Special tool

Tightening torque

Lubrication points

Grease application

YVORI SIL AC

Sealant paste

NEW

Part replacement

Thread locker application

Y SY

Bac

ackl

SYMBOLS

Engine

Cooling system

acklash

ing syst

gine

SYMB

MBOL

SYMB

klash

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- IV -

CONTENTS

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

COOL

General Information

Speci!cations

Inspections and Periodic Adjustments

Frame

Engine

Cooling system

CHAPTER 1

CHAPTER 2

CHAPTER 3

CHAPTER 4

CHAPTER 5

CHAPTER 6

specti

ons and Periodic Adjustmen

tions and Periodic Adjustmen

Engine

CHA

ame

s an

ic A

and Pe

ons

d Period

d Peri

ons

Engi

Frame

Engi

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GEN

INFO

- 5 -

GEN

INFO

General Information CHAPTER 1

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GEN

INFO

- 6 -

GENERAL INFORMATION

IDENTIFICATION ................................................................................................... 7

MOTORCYCLE IDENTIFICATION ............................................................................................................7

CHARACTERISTICS ............................................................................................. 8

INSTRUMENTS AND LIGHTS...................................................................................................................8

MULTIPURPOSE DISPLAY.......................................................................................................................9

IMPORTANT INFORMATION ............................................................................... 10

PREPARATIONS FOR REMOVAL AND DISASSEMBLY OPERATIONS ...............................................10

REPLACEMENT PARTS ..........................................................................................................................10

GASKETS, O-RINGS, SEALS AND BEARINGS .....................................................................................11

SAFETY WASHERS/SAFETY PLATES, COTTERS AND THREAD BLOCKERS ..................................11

ELASTIC RETAINING RINGS ..................................................................................................................12

CONNECTION CHECKS ..........................................................................................................................12

SPECIAL ENGINE EQUIPMENT..............................................................................................................14

SPECIAL EQUIPMENT......................................................................................... 14

SPECIAL TOOLS (FRAME) .....................................................................................................................17

CHAPTER 1

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GEN

INFO

- 7 -

MOTORCYCLE IDENTIFICATION

The identiﬁcation data are:

1. Serial number of the frame (on the steering head)

2. Engine serial number (on the bottom base)

3. Approval details (on frame)

IDENTIFICATION

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GEN

INFO

- 8 -

CHARACTERISTICS

INSTRUMENTS AND LIGHTS

The instruments and lights will switch on when the ignition key is

turned to "ON".

After an initial check-up, the information will correspond to the

overall condition of the bike at that time.

The dashboard has the following instruments.

1 STATUS INDICATOR LIGHTS

1A. Neutral gear light (green)

This switches on when the gear is in "Neutral".

1B. Oil level warning light (red)

This switches on when the oil pressure is insuf!cient. It is

possible to check the electrical circuit of the light by turning

the key to “ON”. Once the engine is running, the light should

switch off. if the light does not switch on at the start, when

the key is turned to “ON”, or if the light stays on, have the

electric circuit checked by an authorised Benelli service cen-

tre.

1C. High beam light (blue)

This switches on when the high beam is switched on.

1D. Indicator light (green)

This switches on when the indicators are working.

1E. "FI" Injection diagnostic light

When the vehicle is started, the light will switch on orange for

a few seconds to show that the injection system is operating

correctly.

1A.

1B.

1C.

1D.

1E.

2 REV COUNTER

This shows the number of engine revs per minute, expressed in

thousands.

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GEN

INFO

- 9 -

CHARACTERISTICS

MULTIPURPOSE DISPLAY

3 COOLANT TEMPERATURE GAUGE

Shows the coolant temperature in °F (Fahrenheit) or C°(Celsius) .

4 DIGITAL CLOCK

Shows the time in hours, minutes and seconds

5 SELECT BUTTON

6 RESET BUTTON

Digital clock setting

Hold down the ”Select“button for 5 seconds until the reading

begins to !ash.

Adjust the hour by pressing the ”Select“ button.

Press the "Reset" button to pass on to the minutes adjustment.

Adjust the minutes by pressing the ”Select“button.

Press the "Reset" button to pass on to the seconds adjustment.

Reset the seconds to zero by pressing the "Reset" button.

7 FUEL TANK CAPACITY AND RESERVE FUEL GAUGE

The digital fuel gauge shows the capacity of the fuel tank. As

the fuel level drops, the lines on the gauge will become closer

and closer to the "E" reserve area.

As soon as the #

nal line starts to !ash, there is an autonomy of

about 2 litres of fuel.

8 TOTAL/PARTIAL KILOMETRE COUNTER

The total kilometre counter shows the total distance covered

in kilometres,. The partial kilometre counter ( TRIP) shows the

distance covered since the last reset in kilometres.

The partial kilometre counter can be used to estimate the possi-

ble distance to cover with a full tank of fuel. This information may

make it possible to schedule future fuelling stops.

9 SPEEDOMETER

Indicates the vehicle's speed in km/h or mph. To pass from km to

mph and vice versa, press and hold down the “Select” button 5

for at least one second.

345

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