Tornado 903 Workshop Manual

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    04-Dec-2014

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Workshop Manual

Premise

This manual contains an introductory description of the Benelli Tornado Three 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.

WARNING 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.

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Introduction

SYMBOLSThe 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.

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CONTENTS

11.1 1.2 1.3

GENERAL INFORMATIONVEHICLE IDENTIFICATION IMPORTANT INFORMATION SPECIAL INSTRUMENTS 1.3.1 1.3.2 SPECIAL ENGINE INSTRUMENTS SPECIAL FRAME INSTRUMENTS

11 11 11 12 13 15 17 17 17 19 22 24 24 25 31 34 49 49 53 54 54 55 56 56 57 59 62 63 64 70 71 74 75 77 79 79 79 80 80 81 82 82 83 83 83 85 85 86

22.1 2.2 2.3 2.4 2.5

SPECIFICATIONSGENERAL SPECIFICATIONS ENGINE TECHNICAL CHARACTERISTICS FRAME CHARACTERISTICS ELECTRICAL COMPONENTS BOLT TORQUE 2.5.1 GENERAL BOLT TORQUE 2.5.2 2.5.3 FRAME BOLT TORQUE ENGINE BOLT TORQUE

2.6

POINTS TO OIL

33.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTION CHECK SPARK-PLUGS 3.2.1 INSTALLING SPARK-PLUGS CLEANING AIR BOX GAS CONTROL PLAY 3.4.1 CLUTCH ADJUSTING CLUTCH LEVER PLAY ADJUSTING CO ADJUSTING THROTTLE HOUSING CHECKING STEPPER ADJUSTING VALVE PLAY ENGINE DISTRIBUTION CHECKING ENGINE OIL LEVEL CHANGING ENGINE OIL AND FILTER CHECKING COOLING LIQUID LEVEL CHANGING REFRIGERANT LIQUID FILLING COOLING PLANT CHECKING EXHAUST TUBES CHECKING EXHAUST PLANT ADJUSTING FRONT BRAKE LEVER ADJUSTING REAR BRAKE LEVER CHECKING BRAKE LIQUID CHANGING FRONT AND REAR BRAKE PADS 3.21.1 3.21.2 CHANGING FRONT BRAKE PADS CHANGING REAR BRAKE PADS

3.22 3.23

CHECKING BRAKING PLANT TUBES PURGING FRONT/REAR BRAKING PLANT 3.23.1 3.23.2 PURGING REAR BRAKING PLANT PURGING FRONT BRAKING PLANT

3.24 3.25

ADJUSTING GEAR CONTROL PEDAL ADJUSTING CHAIN

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3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 3.34 3.35

OILING CHAIN CHECKING AND ADJUSTING STEERING BALL-BEARINGS CHECKING FORK ADJUSTING FORK CHECKING DAMPER ADJUSTING DAMPER CHECKING TIRE PRESSURE CHECKING WHEELS CHECKING AND OILING CLUTCH CABLE ELECTRICAL PLANT 3.35.1 3.35.2 CHECKING BATTERY BATTERY RECHARGING SYSTEM

87 88 89 90 92 92 94 95 96 96 96 98 101 102 102 103 103 104 104 104 105 106 106 106 107 107 108 109 110 112 113 114 114 115 116 116 117 117 118 120 121 121 121 123 124 125 125

3.36 3.37 3.38 3.39

CHANGING FUSES CHANGING FRONT LIGHTS ADJUSTING FRONT HEADLIGHT CHANGING REAR LIGHTS 3.39.1 3.39.2 3.39.3 CHANGING REAR HEADLIGHT CHANGING LICENCE-PLATE HOLDER LIGHT CHANGING FRONT AND REAR ARROWS 3.39.3.1 CHANGING FRONT ARROWS 3.39.3.2 CHANGING REAR ARROWS

44.1 4.2 4.3

COWLINGDISMANTLING COWLING DISMANTLING LOWER SEMI-COWLING DISMANTLING UPPER SEMI-COWLING

4.3.1 DISMANTLING LEFT AND RIGHT INTERNAL INSTRUMENT BOARD FASTENINGS 4.4 4.5 4.6 4.7 4.8 DISMANTLING LEFT AND RIGHT REAR-VIEW MIRRORS DISMANTLING LEFT AND RIGHT UPPER COWLING DISMANTLING TAILPIECE DISMANTLING WHEEL HOUSING DISMANTLING COWLING BENEATH HEADLIGHT 4.8.1 DISMANTLING RADIATOR BOX 4.8.2 4.8.3 4.9 4.10 4.11 4.12 4.13 4.14 DISMANTLING AIR BOX CONDUIT DISMANTLING RESONATOR

DISMANTLING FRONT MUDGUARD DISMANTLING REAR MUDGUARD DISMANTLING CABLE GROMMET COVER DISMANTLING RIGHT AND LEFT FOOTRESTS DISMANTLING TANK DISMANTLING TANK FUEL PUMP

55.1

ENGINECAMSHAFT 5.1.1 5.1.2 REMOVING CAMSHAFT CHECKING CAMSHAFT

5.1.3 CHECKING CAMSHAFT CHAIN, SPROCKET WHEELS AND CHAIN GUIDE 5.1.4 5.1.5 CHECKING CHAIN STRETCHER MOUNTING CAMSHAFT

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5.2

CYLINDER HEAD 5.2.1 REMOVING CYLINDER HEAD 5.2.2 5.2.3 CHECKING CYLINDER HEAD MOUNTING CYLINDER HEAD

129 129 130 130 131 131 132 134 135 136 137 139 139 140 140 141 141 141 142 142 143 143 144 144 145 146 147 147 148 148 148 149 149 149 150 150 151 151 154 154 154 155 156 156 162 163 164 165 165 165

5.3

VALVES AND VALVE SPRINGS 5.3.1 REMOVING VALVES 5.3.2 5.3.3 5.3.4 5.3.5 CHECKING VALVES AND VALVE GUIDES CHECKING VALVE HOUSINGS CHECKING VALVE SPRINGS CHECKING BUCKET-TYPE TAPPETS

5.4

5.3.6 MOUNTING VALVES CYLINDER 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6 DISMANTLING CYLINDER CASING CHECKING CYLINDER DISMANTLING WATER COLLECTOR CHECKING WATER COLLECTOR MOUNTING WATER COLLECTOR MOUNTING CYLINDERS

5.5

PISTONS 5.5.1 DISMANTLING PISTONS 5.5.2 5.5.3 5.5.4 5.5.5 5.5.6 5.5.7 CHECKING PISTONS CHECKING SEGMENTS SEGMENT SLOT PLAY CHECKING PISTON PIN MOUNTING SEGMENTS MOUNTING PISTON

5.6

GENERATOR 5.6.1 REMOVING GENERATOR 5.6.2 MOUNTING GENERATOR DISTRIBUTION SENSOR AND PHONIC WHEEL 5.7.1 5.7.2 5.7.3 5.7.4 REMOVING DISTRIBUTION SENSOR MOUNTING DISTRIBUTION SENSOR REMOVING PHONIC WHEEL MOUNTING PHONIC WHEEL

5.7

5.8

CLUTCH 5.8.1 DISMANTLING CLUTCH CONTROL 5.8.2 5.8.3 5.8.4 5.8.5 5.8.6 5.8.7 5.8.8 5.8.9 5.8.10 5.8.11 REMOVING CLUTCH COVER REMOVING CLUTCH CHECKING NARROW TOOTHED CONDUCTOR DISK CHECKING INNER TOOTHED CONDUCTOR DISK CHECKING CLUTCH SPRINGS CHECKING CLUTCH BELL CHECKING CLUTCH PRIMARY BELL GROUP MOUNTING CLUTCH GROUP CHECKING CLUTCH DISKS MOUNTING CLUTCH COVER

5.9

5.8.12 MOUNTING CLUTCH CONTROL GEARS 5.9.1 5.9.2 REMOVING GEARS DISMANTLING GEARS

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5.9.3 5.9.4 5.9.5 5.9.6 5.9.7 5.9.8 5.10

CHECKING GEAR FLANGE BALL-BEARINGS CHECKING GEAR FORKS AND SLIDE RODS CHECKING POSITIVE SHAFT CHECKING PRIMARY AND SECONDARY SHAFT ASSEMBLING GEARS MOUNTING GEARS

168 168 170 170 171 178 179 179 179 180 180 181 181 182 183 184 184 185 185 192 194 195 195 196 197 197 198 199 199 201 202 203 214 214 215 215 218 220 220 222 223 224 224 225 226 227 227 227 230

OIL SUMP AND OIL PUMP 5.10.1 DISMANTLING OIL SUMP 5.10.2 5.10.3 5.10.4 5.10.5 5.10.6 5.10.7 5.10.8 5.10.9 DISMANTLING OVERPRESSURE OIL VALVE REMOVING OIL PUMP DISMANTLING OIL PUMP CHECKING OIL SUMP CHECKING OIL PUMP ASSEMBLING OIL PUMP MOUNTING OIL PUMP MOUNTING OVERPRESSURE OIL VALVE

5.11

5.10.10 MOUNTING OIL SUMP CASING 5.11.1 5.11.2 5.11.3 5.11.4 5.11.5 5.11.6 5.11.7 5.11.8 DISMANTLING CASING DISMANTLING FREE WHEEL DISMANTLING BALANCING COUNTER SHAFT DISMANTLING ENGINE SHAFT CHECKING CASING CHECKING ENGINE SHAFT AND CONNECTING ROD CONNECTING ROD INTERNAL FOOT DIAMETER CONNECTING ROD HEAD LATERAL PLAY

5.11.9 CHECKING BALANCING COUNTER SHAFT 5.11.10 CHECKING FREE WHEEL 5.11.11 ASSEMBLING FREE WHEEL 5.11.12 MOUNTING ENGINE SHAFT 5.11.13 MOUNTING BALANCING COUNTER SHAFT 5.11.14 MOUNTING CASING

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COOLING PLANTREFRIGERANT LIQUID 6.1 RADIATOR 6.1.1 6.1.2 6.1.3 6.1.4 DISMANTLING RADIATOR DISMANTLING RADIATOR BOX CHECKING RADIATOR MOUNTING RADIATOR

6.2 6.3

WATER OIL EXCHANGER 6.2.1 MOUNTING EXCHANGER THERMOSTAT 6.3.1 DISMANTLING THERMOSTAT 6.3.2 6.3.3 CHECKING THERMOSTAT MOUNTING THERMOSTAT

6.4

WATER PUMP 6.4.1 REMOVING WATER PUMP 6.4.2 DISMANTLING WATER PUMP 6.4.3 CHECKING WATER PUMP

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6.4.4 6.4.5

ASSEMBLING WATER PUMP MOUNTING WATER PUMP

230 235 238 238 238 239 239 240 240 241 242 242 243 244 246 246 247 247 249 250 250 251 252 253 253 254 255 256 256 257 257 258 259 259 260 261 261 262 262 264 264 265 266 267 267 268 268 268 269 270MF10

77.1

FRAMEFRONT WHEEL AND BRAKE DISK 7.1.1 REMOVING FRONT WHEEL 7.1.2 7.1.3 7.1.4 7.1.5 CHECKING FRONT BRAKE DISK DISMANTLING FRONT WHEEL CHECKING FRONT WHEEL MOUNTING FRONT WHEEL

7.2

7.1.6 INSTALLING FRONT WHEEL REAR WHEEL, BRAKE DISK AND CROWN 7.2.1 7.2.2 7.2.3 7.2.4 7.2.5 7.2.6 7.2.7 7.2.8 REMOVING REAR WHEEL CHECKING REAR BRAKE DISK DISMANTLING REAR WHEEL CHECKING REAR WHEEL CHECKING HUB CHECKING CROWN MOUNTING REAR WHEEL INSTALLING REAR WHEEL

7.3

FRONT AND REAR BRAKES 7.3.1 REMOVING FRONT BRAKE PUMP 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11 7.3.12 7.3.13 7.3.14 7.3.15 REMOVING REAR BRAKE PUMP CHECKING FRONT AND BACK BRAKE PUMPS INSTALLING FRONT BRAKE PUMP INSTALLING REAR BRAKE PUMP DISMANTLING FRONT BRAKING PLANT TUBES DISMANTLING REAR BRAKING PLANT TUBES CHECKING FRONT AND REAR BRAKE TUBING MOUNTING FRONT BRAKING PLANT TUBES MOUNTING REAR BRAKING PLANT TUBES DISMANTLING FRONT BRAKE CLAMP DISMANTLING REAR BRAKE CLAMP CHECKING BRAKE CLAMPS MOUNTING FRONT BRAKE CLAMPS DISMANTLING REAR BRAKE CLAMP REMOVING RIGHT AND LEFT STEM CHECK FORK LEGS INSTALLING FORK LININGS

7.4

FORK 7.4.1 7.4.2 7.4.3

7.5

SEMI-HANDLEBARS 7.5.1 REMOVING RIGHT SEMI-HANDLEBAR 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6 7.5.7 7.5.8 7.5.9 7.5.10 REMOVING LEFT SEMI-HANDLEBAR DISMANTLING RIGHT SEMI-HANDLEBAR DISMANTLING LEFT SEMI-HANDLEBAR CHECKING RIGHT SEMI-HANDLEBAR CHECKING LEFT SEMI-HANDLEBAR MOUNTING RIGHT SEMI-HANDLEBAR MOUNTING LEFT SEMI-HANDLEBAR INSTALLING RIGHT SEMI-HANDLEBAR INSTALLING LEFT SEMI-HANDLEBAR

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7.6

REAR DAMPER 7.6.1 DISMANTLING STEERING DAMPER 7.6.2 7.6.3 CHECKING STEERING DAMPER MOUNTING STEERING DAMPER

271 271 271 272 272 272 274 274 275 275 277 277 279 279 281 282 283 284 285 285 285 286 286 286 290 290 291 291 291 292 293 293 293 293 294 295 296 296 296 298 299 317 320 320 321 321 322 324

7.7

STEERING HEAD 7.7.1 DISMANTLING LOWER STEERING PLATE 7.7.2 7.7.3 CHECKING LOWER STEERING PLATE MOUNTING LOWER STEERING PLATE

7.8

REAR DAMPER 7.8.1 REMOVING REAR DAMPER 7.8.2 7.8.3 CHECKING REAR DAMPER MOUNTING REAR DAMPER

7.9

REAR FORK 7.9.1 REMOVING REAR FORK 7.9.2 7.9.3 7.9.4 7.9.5 DISMANTLING REAR FORK COMPONENTS CHECKING REAR FORK MOUNTING REAR FORK INSTALLING REAR FORK

7.10

FRONT FRAME 7.10.1 REMOVING FRONT FRAME 7.10.2 7.10.3 CHECKING FRONT FRAME INSTALLING FRONT FRAME

7.11

REAR FRAME 7.11.1 DISMANTLING REAR FRAME 7.11.2 7.11.3 CHECKING REAR INSTALLING REAR FRAME

7.12

TRANSMISSION CHAIN 7.12.1 REMOVING TRANSMISSION CHAIN 7.12.2 7.12.3 CHECKING TRANSMISSION CHAIN INSTALLING TRANSMISSION CHAIN

88.1

INJECTION PLANT ENGINEENGINE MANAGEMENT SYSTEM 8.1.1 DESCRIPTION OF THE SYSTEM 8.1.2 8.1.3 SYSTEM SENSORS POSITION OF THE SENSORS

8.2

SYSTEM ACTIVATING DEVICES 8.2.1 ENGINE SUPPLY PLANT 8.2.2 IGNITION AND INJECTION DIAGNOSTIC SYSTEM NUMBERING THE ECM CONNECTORS FUEL PUMP CHECKING SYSTEM SUPPLEMENTARY DIAGNOSES

8.3 8.4 8.5

99.1 9.2 9.3 9.4 9.5

ELECTRICAL PLANTCONNECTORS FUSES SEMI-CONDUCTOR PARTS BATTERY 9.4.1 CHECKING BATTERY EFFICIENCY FUSES

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9.6

RELAYS 9.6.1 RELAY STARTER 9.6.2 RELAY SERVICES UNIT STARTER ENGINE ALTERNATOR STARTER DIAGNOSTIC SYSTEM CHECKING SAFETY SYSTEM PARTS DIODES GEAR SWITCH POSITION LATERAL STAND SWITCH CLUTCH SWITCH SPEED SENSOR OIL PRESSURE SENSOR FRONT LIGHTS REAR LIGHTS 9.18.1 REAR HEADLIGHT 9.18.2 9.18.3 LICENCE-PLATE HOLDER LIGHT FRONT AND REAR ARROWS 9.18.3.1 FRONT ARROWS 9.18.3.2 REAR ARROWS

324 324 325 325 326 327 328 328 328 329 329 330 330 331 331 331 332 332 332 333 335 335 339 342 342 342 343 345 345 345 345 346 347 347 347 348 348

9.7 9.8 9.9 9.10 9.11 9.12 9.13 9.14 9.15 9.16 9.17 9.18

1010.1 10.2 10.3 10.4 10.5 10.6

DIAGNOSTICSELECTRICAL PART FRAME PRELIMINARY OPERATIONS SELF-DIAGNOSIS RESETTING THROTTLE ADJUSTING STEPPER / CO

1111.1 11.2 11.3 11.4 11.5 11.6 11.7 11.8 11.9

USA VERSIONE.V.A.P CANISTER CANISTER POSITION REMOVING CANISTER CANISTER CONNECTION EXHAUST LIGHTS CONTROL REAR CATADIOPTRICS FRONT CATADIOPTRICS REAR ARROWS

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Information

General

1

GENERAL INFORMATION

1.1 VEHICLE IDENTIFICATIONThe identification data are: 1) Frame number [on steering casing]. 2) Number of engine on lower crankcase 3) Homologation data [on frame].

1.2 IMPORTANT INFORMATION REMOVAL AND DISMANTLING 1. Before carrying out dismantling operations, remove eventual dirt, mud, dust and foreign bodies. 2. Use appropriate instruments and cleaning products exclusively. Refer to the SPECIAL INSTRUMENTS paragraph. 3. During dismantling, avoid separating the coupled components, including cylinders, pistons, gears and other parts that have become coupled during normal wear. The coupled components must always be re-used or changed without separating them. 4. During dismantling, clean all the components and place them in a bowl, following the order of dismantling. This will make the re-mounting operation easier and allow a correct installation of all the components. 5. Keep all the components away from any source of heat. SPARE PARTS Use original Benelli spare parts exclusively. Use oils and greases recommended by Benelli to oil the components. Other products might appear similar in look and function but are inferior in quality.

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WASHERS, O-RINGS AND OIL SEAL 1. During the revision of the engine, change all the washers, O-rings and seals. The surfaces of the washers and O-rings, and the lips of the oil seals must be cleaned. 2. Oil all the coupled components and the ball-bearings and grease the lips of the seals, when remounting. ELASTIC SAFETY WASHERS/PLATES AND SAFETY PINS After removing, change all the elastic safety washers and safety pins. After tightening the bolts or nuts, bend the tongues of the safety washers/plates and the ends of the safety pins on a flat surface of bolts or nuts. BALL-BEARINGS AND OIL SEALS WARNING: Do not rotate the compressed air ball-bearings as this might damage their surfaces.

1. Install the ball-bearings and the oil seals so that the Producer brand or data are visible. At the moment of installing the oil seal, oil the lip with a slight layer of grease. The ball-bearings rotate freely if oiled in an appropriate way.

1.3 SPECI...

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