Benelli TRK 502 Service Station Manual

5 - 2
CHAPTER 5
ENGINE
HEAD DISTRIBUTION ...................................................................................................................................4
COILS AND SPARK PLUGS REMOVAL ....................................................................................................................................5
COILS AND SPARK PLUGS ASSEMBLY ...................................................................................................................................6
TIMING GEAR COVER ASSEMBLY ..........................................................................................................................................8
DISTRIBUTION CHAIN TENSIONER REMOVAL ......................................................................................................................9
TIMING CHAIN TENSIONER ASSEMBLY ...............................................................................................................................10
INTAKE AND EXHAUST CAMSHAFT REMOVAL ....................................................................................................................11
CAMSHAFT CHECK .................................................................................................................................................................12
EXHAUST CAMSHAFT INSTALLATION ..................................................................................................................................13
INTAKE CAMSHAFT ASSEMBLY .............................................................................................................................................14
TIMING CHAIN SLIDE REMOVAL ............................................................................................................................................15
TIMING CHAIN SLIDE ASSEMBLY ..........................................................................................................................................16
TIMING CHAIN REMOVAL .......................................................................................................................................................17
DISTRIBUTION CHAIN INSTALLATION ..................................................................................................................................18
VALVE CLEARANCE ADJUSTMENT .......................................................................................................................................19
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................20
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................21
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................22
HEAD REMOVAL ......................................................................................................................................................................23
VALVE FLAP AND SPRING REMOVAL....................................................................................................................................24
CHECK OF VALVES AND GUIDES ..........................................................................................................................................25
VALVE SEAT CHECK ...............................................................................................................................................................27
VALVE OIL SEAL REMOVAL- INSTALLATION ........................................................................................................................28
VALVE SPRING TEST ..............................................................................................................................................................29
VALVE AND VALVE SPRING INSTALLATION..........................................................................................................................30
CYLINDER CHECK ..................................................................................................................................................................31
HEAD INSTALLATION ..............................................................................................................................................................32
PISTONS ......................................................................................................................................................33
PISTON REMOVAL ..................................................................................................................................................................35
PISTON PIN CHECK ................................................................................................................................................................36
PISTON RINGS CHECK ...........................................................................................................................................................37
PISTON CHECK .......................................................................................................................................................................38
PISTON ASSEMBLY .................................................................................................................................................................39
PISTON INSTALLATION ...........................................................................................................................................................40
REMOVAL OF CONNECTING RODS ......................................................................................................................................41
CRANKCASE ...............................................................................................................................................41
CHECK OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS ...................................................................43
INSTALLATION OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS ......................................................44
MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION ................................................................................................46
DRIVE SHAFT CHECK .............................................................................................................................................................49
DRIVE SHAFT INSTALLATION ................................................................................................................................................50
CLUTCH .......................................................................................................................................................51
CLUTCH AND DISC REMOVAL ...............................................................................................................................................52
FRICTION DISC CHECK ..........................................................................................................................................................54
STEEL DISC CHECK ...............................................................................................................................................................55
DISC ASSEMBLY .....................................................................................................................................................................55
CLUTCH ASSEMBLY ...............................................................................................................................................................56
LUBRICATION SYSTEM .............................................................................................................................57
OIL SUMP AND INTAKE FILTER REMOVAL ...........................................................................................................................58
OIL SUMP AND INTAKE FILTER INSTALLATION ....................................................................................................................59
PRESSURE-RELIEF VALVE INSTALLATION ..........................................................................................................................60
PRESSURE-RELIEF VALVE REMOVAL ..................................................................................................................................61
OIL PUMP REMOVAL ...............................................................................................................................................................62
OIL PUMP ASSEMBLY .............................................................................................................................................................64
NEUTRAL POSITION/GEAR INDICATOR SENSOR REMOVAL .............................................................................................65
COPY - Moto GB - Grant Martland - grantmartland@motogb.co.uk

Benelli TRK 502 Specifications

General

Brand	Benelli
Model	TRK 502
Category	Motorcycle
Language	English