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TRK 502
Benelli TRK 502 Service Station Manual
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3 - 55
ELECTRICAL
SYSTEM
SUBSTITUTION OF THE REAR LED LIGHT
Place the motorcycle on a
fl
at,
level
fl
oor
.
IMPORT
ANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.
T
o substitute the rear LED light, refer to “Chapter 4” Fair-
ings, paragraph “Removal of the rear light”.
COPY - Moto GB - Grant Martland - grantmartland@motogb.co.uk
90
92
Table of Contents
Chapter 1 General Information
7
Table of Contents
7
Identification
8
Motorcycle Identification
8
Features
9
Instrumentation and Indicator Lights
9
Multifunction Display
10
Important Information
11
Getting Ready for Removal and Disassembly Operations
11
Spare Parts
11
Gaskets, O-Ring, Oil Seals and Bearings
12
Safety Washers/Plates, Cotter Pins, and Thread Sealant
12
Safety Snap Rings
13
Checking Connections
13
Special Tools
15
Special Frame Tools
18
Chapter 3 Periodic Maintenance
38
Periodic Maintenance and Lubrication Intervals
41
Engine/Air Box
45
Removal/Assembly of Air Box
45
Engine/Throttle Cable Clearance
49
Adjustment of Throttle Cable Clearance
49
Adjustment of Idle Speed
50
Engine/Clutch Cable
51
Adjustment of Clutch Cable Clearance
51
Frame/Handlebar
52
Rear-View Mirror Adjustment
52
Engine/Motor Oil
53
Checking Engine Oil Level
53
Engine Oil Change
54
Oil Filter Removal/Installation
55
Engine/Spark Plugs
56
Removal of Spark Plugs on the Vehicle
56
Spark Plug Check
57
Assembly of Spark Plugs
59
Frame/Brake Adjustment
61
Adjustment of the Front Brake
61
Adjustment of the Rear Brake
62
Frame/Checking Brake Fuid Level
63
Checking the Front Brake Liquid Level/Topping up
63
Checking the Rear Brake Liquid Level/Topping up
64
Frame/Checking Abs Hoses
65
Check for any Leakages of Abs Tubes
65
Frame/Brake Pad Check
66
Checking Wear of Front/Rear Brake Pads
66
Frame/Checking Hoses of the Braking System
67
Hose Check
67
Frame/Transmission Chain
68
Adjustment of the Transmission Chain
68
Lubrication of Transmission Chain
69
Chain Guide Check
69
Checking Wear of Transmission Chain
70
Frame/Check and Adjustment of Steering Sleeve
71
Check/Adjustment of Steering Clearance
71
Frame/Check of Front Fork
73
Check of Front Fork
73
Frame/Check of Rear Shock Absorber
74
Shock Absorber Adjustment
74
Frame/Check of Front/Rear Tyres
75
Tyre Check
75
Electrical System
76
Battery Check and Charging
76
Fuses
85
Fuse Check
86
Replacement of the Front Lights
87
Removal of the Front Headlight
88
Installation of the Headlight
89
Adjustment of Headlight
90
Substitution of the Rear Led Light
91
Substitution of the Rear Indicator Lights
92
Substitution of the Front Indicators
93
Substitution of the Ignition Block
94
Chapter 4 Frame
96
Front Wheel and Brake Discs
99
Front Wheel Removal
99
Check of Brake Discs
102
Wheel Axle Check
103
Check/Replacement of Wheel Bearings
104
Front Wheel Installation
105
Rear Wheel and Brake Disc
108
Rear Wheel Removal
108
Removal of the Rear Disc Brake, Crown Wheel and Phonic Wheel
109
Wheel Axle Check
110
Check/Replacement of Wheel Bearings
111
Sprocket Check and Replacement
112
Installation of the Disc Brake
113
Back Tyre Installation
114
Front and Rear Brakes
115
Removal and Installation of Front Brake Pads
115
Removal and Installation of Rear Brake Pads
116
Rear Brake Pump Removal
120
Front Brake Pump Installation
122
Rear Brake Pump Installation
123
Abs Anti-Lock Braking System
124
Location of the Components
124
Rotation Sensor Check
126
Check of the Phonic Wheel and Abs of the Front and Rear Wheel
127
Precautions
128
Removal of the Abs Hydraulic Unit
130
Installation of the Abs Hydraulic Unit
131
Removal of the Abs Rotation Sensors - Front/Rear Wheel
132
Front Brake Calliper Tightness
133
Rear Brake Calliper
134
Check the Front and Rear Callipers
135
Front Brake Calliper Installation
136
Rear Brake Calliper Installation
137
Front Fork Stem Disassembly
142
Front Fork Stem Inspection
145
Front Fork Stem Assembly
146
Front Fork Stem Fitting
149
Handlebar
150
Handlebar Removal
150
Handlebar Inspection
154
Handlebar Installation
155
Steering Head
156
Removal of the Top and Bottom Steering Base
156
Top and Bottom Steering Base Inspection
158
Top and Bottom Steering Base Fitting
159
Rear Shock Absorber
160
Rear Shock Absorber Removal
160
Rear Shock Absorber Check
163
Rear Shock Absorber Fitting
164
Transmission Chain and Swinging Arm
165
Transmission Chain Removal
165
Removal of the Swinging Arm
167
Left/Right Engine Protection Installation
170
Removal of the Left/Right Engine Protection
171
Removal of the Front Frame/Windscreen Support
172
Installation of the Front Frame/Windscreen Support
173
Removal/Installation of Rear Frame Parts
174
Removal of the Rear Frame
176
Rear Frame Fitting
177
Removal of Side Bag Frame
178
Installation of the Side Bags Support Frame
179
Number Plate Holder
180
Removal of the Number Plate Holder
181
Installation of the Number Plate Holder
182
Cycling
183
Installation of the Stand / Footrests
183
Removal of the Side Stand
185
Installation of the Side Stand
186
Removal of the Rear Footrest Support
187
Installation of the Rear Footrest Support
188
Removal of the Right/Left Rear Footrest
189
Installation of the Left/Right Rear Footrests
190
Right Front Footrest Removal
191
Right Front Footrest Fitting
192
Left Front Footrest Removal
193
Left Front Footrest Installation
194
Removal of the Gear Lever
195
Installation of the Gearchange Lever
196
Exhaust Assembly Removal
198
Exhaust Installation
200
Front Mud Guard Removal
202
Rear Mud Guard Removal
205
Rear Mud Guard Installation
206
Removal of the Rider Seat and Passenger Seat
209
Installation of the Rider Seat and Passenger Seat
210
Front Fairing
211
Removal of the Front Fairing
212
Front Headlight and Windscreen
214
Removal of Movable Windscreen
216
Installation of the Mobile Headlight Fairing
217
Removal of the Headlight Unit
220
Installation of the Headlight Unit
221
Tank Cover
222
Removal of the Fuel Tank Cover
223
Installation of the Fuel Tank Cover
224
Removal of Fuel Tank
225
Tank Fitting
227
Removal of the Tank Cap Support
229
Installation of the Tank Cap Support
230
Removal of the Tank Pump
231
Installation of the Tank Pump
232
Removal of the Tank Fuel Level Sensor
233
Installation of the Tank Fuel Level Sensor
234
Air Filter
236
Removal of the Air Filter
236
Installation of the Air Filter
237
Installation of the Air Filter Box
239
Removal of the Side Fairings
241
Installation of the Side Fairings
242
Upper Tail Fairing
243
Tailpiece Removal
244
Removal of the Rear Passenger Handles
246
Installation of the Rear Handles
247
Removal of the Rear Light
248
Installation of the Rear Lights
250
Removal of the Chain Pinion Cover
252
Installation of the Chain Pinion Cover
253
Chapter 5 Engine
255
Head Distribution
257
Coils and Spark Plugs Removal
258
Coils and Spark Plugs Assembly
259
Timing Gear Cover Assembly
261
Distribution Chain Tensioner Removal
262
Timing Chain Tensioner Assembly
263
Intake and Exhaust Camshaft Removal
264
Camshaft Check
265
Exhaust Camshaft Installation
266
Intake Camshaft Assembly
267
Timing Chain Slide Removal
268
Timing Chain Slide Assembly
269
Timing Chain Removal
270
Distribution Chain Installation
271
Valve Clearance Adjustment
272
Camshaft and Valve Pad Removal
273
Camshaft and Valve Pad Removal
275
Head Removal
276
Valve Flap and Spring Removal
277
Check of Valves and Guides
278
Valve Seat Check
280
Valve Oil Seal Removal- Installation
281
Valve Spring Test
282
Valve and Valve Spring Installation
283
Cylinder Check
284
Head Installation
285
Pistons
286
Piston Removal
288
Piston Pin Check
289
Piston Rings Check
290
Piston Check
291
Piston Assembly
292
Piston Installation
293
Removal of Connecting Rods
294
Crankcase
294
Check of Connecting Rod and Connecting Rod Bearing Shells
296
Installation of Connecting Rod and Connecting Rod Bearing Shells
297
Main Bearing Shell and Drive Shaft Installation
299
Drive Shaft Check
302
Drive Shaft Installation
303
Clutch
304
Clutch and Disc Removal
305
Friction Disc Check
307
Steel Disc Check
308
Disc Assembly
308
Clutch Assembly
309
Lubrication System
310
Oil Sump and Intake Filter Removal
311
Oil Sump and Intake Filter Installation
312
Pressure-Relief Valve Installation
313
Pressure-Relief Valve Removal
314
Oil Pump Removal
315
Oil Pump Assembly
317
Neutral Position/Gear Indicator Sensor Removal
318
Gear Box
318
Neutral Position/Gear Indicator Sensor Assembly
319
Gear Box Assembly
323
Gear Shift Control
325
Starter
329
Starting
329
Starter Removal
330
Starter Installation
331
Flywheel Removal
332
Flywheel Installation
335
Starter Gear Removal
336
Starter Gear Assembly
337
Phase Sensor
338
Phase Sensor Removal
339
Phase Sensor Installation
340
Power System
341
Throttle Body
341
Throttle Valve Removal
343
Throttle Valve Installation
344
Chapter 6 Cooling System
346
Water Pump
348
Water Pump Removal
348
Water Pump Installation
349
Thermostat
350
Thermostat Removal
350
Thermostat Installation
351
Water Manifold
352
Water Manifold Removal
352
Water Manifold Installation
353
Heat Exchanger
354
Heat Exchanger Removal
354
Heat Exchanger Installation
355
Radiator
356
Disassemble the Radiator
357
Radiator Installation
359
Electrical System
361
Sensors
362
Description of the Engine Management System
362
Coolant Temperature Sensor
363
Gear Position Sensor
364
Phase Sensor
365
Air Temperature Sensor
366
Side Stand Switch
367
Lambda Probe
368
Oil Pressure Sensor
369
Front Brake Microswitch
370
Idrostop
371
Clutch Switch
372
Map Sensor (Manifold Absolute Pressure)
373
Position Sensor of the Throttle Body Unit (Potentiometer)
374
Devices
375
Devices Position
375
Right Electric Device
376
Starting Relay (Remote Control Switch)
377
Horn
378
Instrumentation Dashboard
379
Master Switch
380
Voltage Regulator
381
Left Electric Device
382
Converter of Can Bus Signals
383
Injection Ecu
384
Injection Ecu Connections
386
Indicator Light Intermittence
387
Abs Button
388
Services Relay
389
Stator
390
Actuators
391
Position of Actuators
391
Idle Air Control System (Stepper)
392
Injectors
393
Ignition Coils
394
Cooling Fan
395
Fuel Pump
396
Fuel Level Sensor
397
Starter
398
Abs Ecu
400
Battery
403
Vehicle Battery
403
Battery Efficiency Control
404
Diagnostics
405
Vehicle Diagnostics
405
Electrical System
406
Wiring Diagram of Trk502 Electrical System
406
Colour Key
407
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Benelli TRK 502 Specifications
General
Brand
Benelli
Model
TRK 502
Category
Motorcycle
Language
English
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