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Benelli BN600R 2014 User Manual

Benelli BN600R 2014
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SERVICE STATION MANUAL
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Pure Passion since 1911
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Table of Contents

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Benelli BN600R 2014 Specifications

General IconGeneral
Displacement600 cc
Compression Ratio11.5:1
Starting SystemElectric
Final DriveChain
Bore x Stroke65.0 x 45.2 mm
Maximum Power60 kW (82 hp) at 11, 500 rpm
Maximum Torque54 Nm @ 10, 500 rpm
Fuel SystemElectronic fuel injection
Transmission6-speed
Front SuspensionUpside-down telescopic fork
Front BrakeDual 320 mm discs, 4-piston calipers
Rear BrakeSingle 240 mm disc, single-piston caliper
Front Tire120/70 ZR17
Rear Tire180/55 ZR17
Width800 mm
Seat Height800 mm
Fuel Capacity15 L
Engine Type4-stroke, in-line 4-cylinder, liquid-cooled, DOHC

Summary

General Information

Motorcycle Identification

Locates serial number of frame, engine serial number, and approval details.

Instruments and Lights

Details status indicator lights and the rev counter on the dashboard.

Multipurpose Display

Explains coolant temperature, digital clock, fuel gauge, and speedometer functions.

Preparations for Removal and Disassembly

Provides essential guidelines before starting disassembly operations.

Replacement Parts

Recommends using only original Benelli parts and recommended lubricants.

Gaskets, O-rings, Seals and Bearings

Instructions for replacing and fitting gaskets, oil seals, O-rings, and bearings.

Safety Washers, Plates, Cotters, and Thread Blockers

Guidance on replacing safety washers and using thread blockers.

Elastic Retaining Rings

Details on checking and replacing elastic retaining rings.

Connection Checks

Procedure for checking wiring, couplers, and connectors for damage or moisture.

Special Equipment

Special Engine Equipment

Lists specialized tools required for engine maintenance and assembly operations.

Special Tools (Frame)

Details specialized tools for frame-related adjustments and tightening.

Specifications

General Specifications

Provides key dimensions, weight, and load capacity of the motorcycle.

Technical Details: Engine Specifications

Details engine capacity, power, torque, fuel, oil, and ignition system specifications.

Technical Details: Frame Specifications

Covers frame type, wheels, tires, and brake system specifications.

Technical Details: Front Suspension

Specifies fork stroke, spring details, fork oil, and steering bearing information.

Technical Details: Rear Suspension

Details rear suspension travel, spring pre-load, and bounce damping adjustments.

Technical Details: Electrical Specifications

Covers system voltage, starting coils, recharging, battery, and lighting specifications.

General Tightness Specifications

Provides general rules for tightening torque and cross-tightening procedures.

Tightness Torques and Preloads for Standard Connections

Lists specific tightening torques and axial preloads for various metric screw sizes.

Regular Maintenance

Periodic Maintenance and Lubrication Intervals

Provides a scheduled maintenance table with intervals and operations.

Engine/Air Filter

Details the removal and fitting procedure for the air filter.

Engine/Accelerator Cable Clearance

Explains how to adjust the accelerator cable clearance.

Engine/Clutch Cable

Provides the procedure for adjusting the clutch cable clearance.

Frame/Handlebar: Rear View Mirror Adjustment

Instructions on how to adjust the rear view mirrors.

Engine/Engine Oil: Engine Oil Level Check

Details how to check and top up the engine oil level.

Engine/Spark Plugs: Spark Plug Installation

Covers the procedure for removing, checking, and installing spark plugs.

Frame/Brake Adjustment: Front Brake Adjustment

Explains how to adjust the front brake lever position.

Frame/Brake Fluid Check: Rear Brake Fluid Level

Details how to check and top up the rear brake fluid level.

Frame/Brake Pad Check: Front and Rear Brake Pad Control

Procedure for checking front and rear brake pad wear limits.

Frame/Transmission Chain Adjustment

Covers chain tension adjustment and lubrication procedures.

Frame/Steering Head Check and Adjustment

Details how to check and adjust the steering head.

Frame/Front Fork Check

Instructions for checking the front fork for damage or leaks.

Frame/Rear Shock Absorber Check

Explains how to adjust the rear shock absorber spring preload.

Frame/Rear and Front Tyre Check

Procedure for checking tyre pressure, surface, and tread depth.

Electric System/Check and Battery Charge

Provides guidance on checking and charging the motorcycle's battery.

Electrical System/Fuse Check

Details how to check and replace fuses.

Electrical System/Head Lamp Replacement

Procedure for replacing the motorcycle's headlamp.

Electrical System/Headlamp Adjustment

Instructions on how to adjust the headlamp beam.

Electrical System/Rear Lamp Replacement

Procedure for replacing the rear lamp unit.

Electrical System/Front Indicator Replacement

Details how to replace the motorcycle's front indicators.

Frame

Front Wheel and Brake Discs: Front Wheel Removal

Step-by-step guide for removing the front wheel.

Front Wheel and Brake Discs: Removal/Installation of Brake Discs

Procedure for removing and installing the front brake discs.

Front Wheel and Brake Discs: Check of Brake Discs

Instructions for checking brake disc deformation and wear limits.

Front Wheel and Brake Discs: Wheel Axle Check

Procedure for checking the front wheel axle for warping.

Front Wheel and Brake Discs: Check/Replacement of Wheel Bearings

Details how to check and replace front wheel bearings.

Front Wheel and Brake Discs: Front Wheel Installation

Step-by-step guide for installing the front wheel.

Rear Wheel and Brake Disc: Rear Wheel Removal

Procedure for removing the rear wheel.

Rear Wheel and Brake Disc: Sprocket and Rear Brake Disc Removal

Instructions for removing the sprocket and rear brake disc.

Rear Wheel and Brake Disc: Wheel Axle Check

Procedure for checking the rear wheel axle for warping.

Rear Wheel and Brake Disc: Check/Replacement of Wheel Bearings

Details how to check and replace rear wheel bearings.

Rear Wheel and Brake Disc: Sprocket Check and Replacement

Procedure for checking and replacing the rear sprocket.

Front and Rear Brakes: Removal and Installation of Front Brake Pads

Step-by-step guide for removing and installing front brake pads.

Front and Rear Brakes: Removal and Installation of Rear Brake Pads

Procedure for removing and installing rear brake pads.

Front and Rear Brakes: Front Brake Pump Removal

Details the process for removing the front brake pump.

Front and Rear Brakes: Rear Brake Pump Removal

Procedure for removing the rear brake pump.

Front and Rear Brakes: Front Brake Pump Installation

Step-by-step guide for installing the front brake pump.

Front and Rear Brakes: Rear Brake Pump Installation

Procedure for installing the rear brake pump.

Front and Rear Brakes: Front Brake Caliper Tightness

Instructions on tightening the front brake caliper.

Front and Rear Brakes: Rear Brake Caliper

Details the removal and disassembly of the rear brake caliper.

Front and Rear Brakes: Check the Front and Rear Callipers

Guidance on checking front and rear brake caliper pistons and cylinders.

Front and Rear Brakes: Front Brake Caliper Installation

Step-by-step guide for installing the front brake caliper.

Front and Rear Brakes: Rear Brake Caliper Installation

Procedure for installing the rear brake caliper.

Front Fork: Front Fork Stem Removal

Details the process for removing front fork stems.

Front Fork: Front Fork Stem Disassembly

Step-by-step guide for disassembling the front fork stem.

Front Fork: Front Fork Stem Inspection

Instructions for inspecting fork stems, sleeves, springs, and damper shafts.

Front Fork: Front Fork Stem Assembly

Procedure for assembling the front fork stem components.

Front Fork: Front Fork Stem Fitting

Details on fitting the front fork stems and related components.

Handlebar: Handlebar Removal

Step-by-step guide for removing the handlebar.

Handlebar: Handlebar Inspection

Procedure for inspecting the handlebar for damage or warping.

Handlebar: Handlebar Installation

Instructions on how to install the handlebar.

Steering Head: Removal of the Top and Bottom Steering Base

Details the process for removing steering head components.

Steering Head: Top and Bottom Steering Base Inspection

Procedure for inspecting steering head bearings and bases.

Steering Head: Top and Bottom Steering Base Fitting

Instructions on how to fit the steering head base components.

Rear Shock Absorber: Rear Shock Absorber Removal

Step-by-step guide for removing the rear shock absorber.

Rear Shock Absorber: Rear Shock Absorber Check

Details on checking the rear shock absorber rod, spring, and bushing.

Rear Shock Absorber: Rear Shock Absorber Fitting

Instructions on how to fit the rear shock absorber.

Transmission Chain and Swinging Arm: Transmission Chain Removal

Procedure for removing the transmission chain.

Transmission Chain and Swinging Arm: Transmission Chain Inspection

Guidance on checking the transmission chain for wear and lubrication.

Transmission Chain and Swinging Arm: Transmission Chain Replacement

Step-by-step guide for replacing the transmission chain.

Transmission Chain and Swinging Arm: Swinging Arm Fitting

Instructions on how to fit the swinging arm assembly and related parts.

Frame: Frame Fitting

Details on fitting the main frame components.

Frame: Rear Frame Fitting

Procedure for fitting the rear frame components.

Frame: Licence Plate Holder Fitting

Instructions on how to fit the licence plate holder assembly.

Frame: Licence Plate Holder Removal

Procedure for removing the licence plate holder.

Cycling: Stand Fitting

Details on fitting the side stand and its sensor.

Cycling: Rear Footrest Installation

Step-by-step guide for installing rear footrests.

Cycling: Left Front Footrest Installation

Instructions on how to install the left front footrest.

Cycling: Right Front Footrest Fitting

Procedure for fitting the right front footrest and brake pedal.

Exhaust: Exhaust Installation

Details on installing exhaust components like manifold and silencer.

Fairing: Exhaust Pipe Protection Installation

Procedure for installing exhaust pipe protections and end pieces.

Fairing: Front Mud Guard Installation

Instructions on how to install the front mud guard.

Fairing: Rear Mud Guard Installation

Details on installing the rear mud guard.

Fairing: Top Chain Slide and Chain Cover Fitting

Procedure for fitting the chain cover and top chain slide.

Fairing: Tank Cap Fitting

Instructions on how to fit the fuel tank cap assembly.

Fairing: Tank Fitting

Procedure for fitting the fuel tank and related hoses.

Fairing: Tank Cover Fitting

Details on fitting the fuel tank cover components.

Fairing: Fairing Fitting

Instructions on fitting the external fairing panels and covers.

Fairing: Cowl Fitting

Procedure for fitting the cowl and securing it to the front light group.

Fairing: Complete Headlamp Fitting

Details on fitting the complete headlamp assembly.

Fairing: Tailpiece Fitting

Instructions on fitting the tailpiece components and passenger seat.

Engine

Head Timing Gear: Head Timing Gear Cover Removal

Procedure for removing the head timing gear cover.

Head Timing Gear: Removal of the Distribution Chain Tensioner

Details on removing the distribution chain tensioner.

Head Timing Gear: Inlet Camshaft Removal

Step-by-step guide for removing the inlet camshaft.

Head Timing Gear: Removal of Camshaft, Outlet Side

Procedure for removing the outlet camshaft.

Head Timing Gear: Camshaft Check

Instructions for checking camshaft lobes, eccentricity, and clearances.

Head Timing Gear: Outlet Camshaft Fitting

Procedure for fitting the outlet camshaft.

Head Timing Gear: Inlet Camshaft Fitting

Details on fitting the inlet camshaft.

Head Timing Gear: Chain Slide Removal

Procedure for removing chain slides.

Head Timing Gear: Distribution Chain Installation

Instructions on installing the distribution chain.

Head Timing Gear: Valve Clearance Adjustment

Guidance on checking and adjusting valve clearance.

Head Timing Gear: Valve Flap and Calibrated Pad Removal

Procedure for removing valve flaps and calibrated pads.

Head Timing Gear: Head Removal

Details on removing the cylinder head.

Head Timing Gear: Valve Flap and Spring Removal

Instructions for removing valve flaps and springs.

Head Timing Gear: Valve Oil Seal Removal - Insertion

Procedure for removing and inserting valve oil seals.

Head Timing Gear: Valve Check

Guidance on checking valves, seats, and stem-guide clearance.

Head Timing Gear: Valve Seat Check

Procedure for checking valve seats for wear or damage.

Head Timing Gear: Valve Spring Test

Instructions for testing valve springs for tension and condition.

Head Timing Gear: Valve and Valve Spring Fitting

Procedure for fitting valves and valve springs.

Head Timing Gear: Cylinder Check

Details on checking cylinder walls, cooling cavities, and stroke.

Head Timing Gear: Head Fitting

Instructions on fitting the cylinder head.

Pistons: Piston Pin Removal

Procedure for removing piston pins.

Pistons: Pin Check

Guidance on checking piston pins for wear or damage.

Pistons: Pin Assembly

Procedure for assembling piston pins into pistons.

Pistons: Piston Check

Details on checking piston diameter and cylinder-piston coupling.

Pistons: Elastic Clip Control

Instructions for checking piston clips for wear and measuring side clearance.

Pistons: Clip Fitting

Procedure for fitting piston clips.

Pistons: Piston Fitting

Details on fitting pistons into cylinders using special tools.

Crank Gear: Check of Connecting Rod and Connecting Rod Half Bearings

Guidance on checking connecting rods and their half bearings.

Crank Gear: Connecting Rod and Connecting Rod Half Bearing Installation

Procedure for installing connecting rod half bearings.

Crank Gear: Main Half Bearing and Drive Shaft Installation

Details on installing main half bearings and drive shaft.

Crank Gear: Drive Shaft Check

Instructions for checking drive shaft eccentricity and support surfaces.

Crank Gear: Drive Shaft Installation

Procedure for installing the drive shaft.

Clutch: Friction Disc Check

Guidance on checking friction discs for wear and thickness.

Clutch: Steel Disc Check

Procedure for checking steel discs for warpage.

Clutch: Disc Assembly

Instructions on assembling clutch discs with washers and gaskets.

Clutch: Clutch Assembly

Step-by-step guide for assembling the clutch.

Gear Assembly: Gear Assembly

Details on assembling gear components, including measurement and checks.

Gear Assembly: Gear Fork Check

Instructions for checking gear forks and gear fork pins.

Gear Assembly: Gear Assembly

Procedure for assembling gear forks, gear pins, and bearings.

Gear Assembly: Gear Assembly

Details on assembling half casings and neutral sensor.

Lubrication System: Oil Sump and Inlet Filter Removal

Procedure for removing the oil sump and inlet filter.

Lubrication System: Oil Sump and Inlet Filter Installation

Instructions on installing the oil sump and inlet filter.

Lubrication System: Oil Pump Removal

Details on removing the oil pump.

Lubrication System: Pressure-Relief Valve Installation

Procedure for installing the pressure-relief valve.

Lubrication System: Oil Pump Assembly

Instructions on assembling the oil pump.

Lubrication System: Oil Filter Removal/Installation

Procedure for removing and installing the engine oil filter.

Starting: Starter Motor Removal/Installation

Details on removing and installing the starter motor.

Starting: Flywheel Removal

Procedure for removing the flywheel.

Starting: Flywheel Fitting

Instructions on fitting the flywheel assembly.

Starting: Phase Sensor Installation/Adjustment

Details on installing and adjusting the phase sensor.

Supply: Throttle Valve Removal

Procedure for removing throttle valves.

Supply: Throttle Valve Fitting

Instructions on fitting and balancing throttle valves.

Cooling System

Water Pump: Water Pump Removal/Fitting

Step-by-step guide for removing and fitting the water pump.

Thermostat: Thermostat Removal/Fitting

Procedure for removing, checking, and fitting the thermostat.

Manifold: Manifold Removal/Fitting

Details on removing and fitting the manifold.

Heat Exchanger: Heat Exchanger Removal/Fitting

Procedure for removing and fitting the heat exchanger.

Radiator: Radiator Removal/Fitting

Step-by-step guide for removing and fitting the radiator.

Radiator: Pipes

Details on removing and fitting radiator pipes and hoses.

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