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Benelli IMPERIALE 400 User Manual

Benelli IMPERIALE 400
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Maintenance Manual of
Two-wheeled Motorcycle
IMPERIALE 400(BJ400-8)
COPY - MOTOWAY GEORGE KABRANIS S.A - Dimitrios Kabranis - dkabranis@motoway.gr
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Benelli IMPERIALE 400 Specifications

General IconGeneral
Displacement374 cc
Max Torque29 Nm @ 3500 rpm
Transmission5-speed
ABSDual channel ABS
Fuel SystemElectronic Fuel Injection
Bore x Stroke72.7 mm x 90 mm
Compression Ratio8.5:1
StarterElectric
Final DriveChain
Front Tire100/90 - 19
Rear Tire130/80 - 18
Length2170 mm
Height1120 mm
Seat Height780 mm
Wheelbase1440 mm
Kerb Weight205 kg
Engine TypeSingle cylinder, 4 stroke, air cooled, SOHC
Fuel Tank Capacity12.5 liters
Front BrakeDisc
Rear Brake240 mm disc
Front SuspensionTelescopic forks
Rear SuspensionDual shock absorbers
FrameDouble cradle
Fuel Capacity12.5 liters

Summary

Introduction

Preparatory Information

General safety

Safety precautions for carbon monoxide, gasoline, and accumulator handling.

Maintenance rules

General precautions for checking, disassembling, or assembling the motorcycle.

Model information

Motorcycle identification

Important Note

Special tools

Tools for maintenance of engine

Lists special tools for engine disassembly and assembly.

Tools for chassis maintenance

Lists common and special tools for chassis maintenance.

Tools for electrical parts

Lists special tools for testing electrical parts.

Specification table (BJ400-8)

Unit conversion table

Winding method of cables, wires and hoses

Troubleshooting Guide

Diagnostic procedure for the fault that engine cannot be started or it is difficult to start the engine

Procedures for diagnosing starting issues like starter motor not working.

The starter motor is rotating, but the engine does not work

Troubleshooting steps when the starter motor rotates but the engine fails to start.

The engine does not run

Potential causes for the engine not running.

Fuel does not flow

Common issues related to fuel flow problems.

No sparks; sparks are weak

Troubleshooting ignition system issues leading to weak or no spark.

There is a problem with the fuel/air mixture

Issues related to incorrect fuel or air mixture.

Too low cylinder pressure

Causes of low cylinder pressure affecting engine performance.

It cannot run properly at a low speed

Troubleshooting low-speed running problems.

Ignition is abnormal

Issues causing abnormal ignition performance.

The muffler is overheated

Potential causes and remedies for muffler overheating.

The temperature is too high

Troubleshooting engine overheating issues.

The output force of engine is insufficient

Reasons for reduced engine power output.

Not properly lubricated

Problems arising from insufficient or improper lubrication.

The clutch is not working properly

Diagnosing and fixing clutch malfunctions.

The clutch cannot be separated properly

Issues preventing proper clutch disengagement.

There is a problem with shifting

Troubleshooting gear shifting difficulties.

Jump

Problems related to gear jumping or dislodging.

Excessive speed change

Issues causing abrupt or incorrect speed changes.

The engine makes an unusual noise

Identifying and resolving unusual engine noises.

The frame makes an unusual noise

Diagnosing and fixing frame-related noises.

The front fork makes a noise

Addressing noises originating from the front fork.

The rear shock absorber makes a noise

Troubleshooting noises from the rear shock absorber.

The brake disc makes a noise

Causes and solutions for noises from the brake disc.

Excessive exhaust gas

Identifying and addressing excessive exhaust gas.

Poor performance and / or stability

Diagnosing and rectifying poor performance or stability issues.

It is difficult to rotate the handlebar

Troubleshooting handlebar rotation difficulties.

The handlebars vibrate or shake severely

Addressing severe handlebar vibration or shaking.

The handlebar is placed on one side

Diagnosing and fixing handlebar misalignment.

The damping effect is not ideal

Adjusting or repairing damping systems for optimal effect.

Brake is unable to work properly

Troubleshooting brake system malfunctions.

Battery has failed

Identifying and resolving battery failure issues.

Battery has run out

Addressing a depleted battery condition.

Battery is overcharged

Diagnosing and rectifying battery overcharging.

Torque and locking agent

Locking torques and related parameters of nuts

Basic torques for nuts, with thread diameters and locking torque details.

Locking torque and related parameters of bolts and screws

Torques for bolts and screws based on grade and thread diameter.

Main locking torque specifications

Inspection / adjustment

Preparation standard

Defines satisfactory conditions and warnings for inspection preparation.

Specifications

Engine

Technical specifications for the engine.

Motorcycle body

Technical specifications for the motorcycle body components.

Relevant component certifications

Certifications for various motorcycle components.

Regular maintenance checklist

Expected inspection

Engine Oil/Filter

Inspection of engine oil level

Procedure for checking and maintaining the engine oil level.

Replacement of engine oil level gauge

Steps for replacing the engine oil level gauge.

Inspection/adjustment of throttle cable

Air filter

Filter element replacement

Steps for replacing the air filter element.

Spark plug

Check the gap of spark plug

Procedure for checking and adjusting the spark plug gap.

Accumulator

Battery disassembly

Steps for safely removing the motorcycle battery.

Charging System

1.1 Preparatory Information

Pre-operation notes and cautions for the battery and charging system.

1.2 Fault Diagnosis

Common faults and troubleshooting steps for the battery and charging system.

1.3 Battery

Procedures for battery maintenance, charging, and replacement.

1.4 Charging System

Procedures for inspecting the charging system's performance.

1.5 Disassembly of Voltage and Current Regulator

Steps to remove and inspect the voltage and current regulator.

1.6 Alternator

Procedures for disassembling, inspecting, and installing the alternator.

Inspection and Maintenance of Electrical System

Torque Table of Fastener of Electrical System

Tightening torques for various electrical system fasteners.

Precautions

Important safety and handling precautions for electrical system work.

II. Ignition System

2.1 Preparatory Information

Precautions and preparation for ignition system inspection.

2.2 Fault Diagnosis

Diagnosing common faults in the ignition system.

2.3 Trigger

Notes on trigger disassembly and inspection.

2.4 Ignition Coil

Steps to remove and inspect the ignition coil.

2.5 Spark Plug

Visual inspection, gap measurement, and replacement of spark plugs.

2.6 ECU

Information regarding the Engine Control Unit (ECU).

III. Starter System

3.1 Preparatory Information

Precautions for starter motor and clutch operation.

3.2 Fault Diagnosis

Troubleshooting common starter system faults.

3.3 Starter Motor

Steps for disassembling and installing the starter motor.

3.4 Starter Relay

Procedures for inspecting the starter relay's operation and voltage.

IV. Bulbs /Switches/Meters

4.1 Preparatory Information

Precautions for switch inspection and lock torque values.

4.2 Fault Diagnosis

Troubleshooting the "ON" light of the main switch being off.

4.3 Replacement of headlight bulb

Steps for removing and installing the headlight bulb.

4.4 Replacement of Turn Signal Light Bulb

Steps for replacing turn signal light bulbs.

4.5 Replacement of Taillight Bulb

Procedure for replacing the taillight bulb.

4.6 Replacement of License Plate Light Bulb

Steps for replacing the license plate light bulb.

4.7 Meters

Disassembly and installation procedures for the meter assembly.

4.8 Ignition Switch

Steps for removing and replacing the ignition switch.

4.9 Electric horn

Disassembly, installation, and inspection of the electric horn.

4.10 Handlebar Switch

Diagrams and information for left and right handlebar switches.

4.11 Inspection of switch

Wiring connections for rear brake light and sidestand switches.

4.12 Speed sensor

Disassembly, inspection, and installation of the speed sensor.

4.13 Oxygen sensor

Disassembly, inspection, and installation of the oxygen sensor.

4.14 Fuel Level Sensor

Disassembly, inspection, and installation of the fuel level sensor.

4.15 Relay and fuse box

Disassembly, inspection, and internal circuits of relays and fuse box.

4.16 Fuse

Disassembly, installation, and inspection of fuses.

V. Brake

5.1 Preparatory Information

Operation precautions and technical parameters for the brake system.

5.2 Fault Diagnosis

Common brake system faults and their causes.

5.3 Front Brake Disc

Disassembly, installation, and inspection of the front brake disc.

5.4 Rear Brake Disc

Disassembly, installation, and inspection of the rear brake disc.

5.5 Fluid Brake and ABS

Information and procedures for the fluid brake and ABS systems.

VI. Body Cover

VII. Front Wheel/Front Suspension

7.1 Preparatory Information

Operation precautions and technical parameters for front wheel and suspension.

7.2 Fault Diagnosis

Troubleshooting common front wheel and suspension issues.

7.3 Front Wheel

Disassembly, inspection, and installation of the front wheel.

7.4 Handlebar

Disassembly, inspection, and installation of handlebar components.

7.5 Front Fork

Disassembly, inspection, and installation of the front fork assembly.

7.6 Front Shock Absorber

Disassembly, inspection, and installation of the front shock absorber.

VIII. Rear wheel/rear suspension

8.1 Preparation of Information

Precautions and technical parameters for rear wheel and suspension.

8.2 Fault Diagnosis

Troubleshooting rear wheel and suspension issues.

8.3 Rear wheel

Disassembly, inspection, and bearing replacement for the rear wheel.

8.4 Rear Shock Absorber

Disassembly, inspection, and installation of the rear shock absorber.

8.5 Rear Rocker Arm

Disassembly, inspection, and installation of the rear rocker arm.

8.6 Chain Drive

Disassembly, inspection, and installation of the drive chain and sprockets.

IX. Fuel Tank/Seat

9.1 Preparatory Information

Precautions for fuel tank and seat work, and locking torques.

9.2 Fault Diagnosis

Troubleshooting reduction in gasoline quantity.

9.3 Seat

Disassembly, inspection, and installation of the seat assembly.

9.4 Fuel Tank

Warnings and steps for fuel tank disassembly, inspection, and installation.

X. Frame

10.1 Preparatory Information

Precautions for frame work and engine oil capacity.

10.2 Fault Diagnosis

Troubleshooting common frame and engine issues.

10.3 Frame

Steps for frame disassembly, installation, and inspection.

10.4 Sidestand

Steps to remove and install the sidestand.

10.5 Center stand

Steps to remove and install the center stand.

10.6 Footpeg

Disassembly and installation of front and rear footpegs.

10.7 Muffler

Warnings and steps for muffler disassembly and installation.

10.8 Disassembly / installation of engine

Exploded views and procedures for engine removal and installation.

XI. Lubrication System

11.1 Preparatory Information

Function and precautions for the lubrication system.

11.2 Troubleshooting

Diagnosing common oil level and pressure issues.

11.3 Fuel Pump

Disassembly, inspection, assembly, and installation of the fuel pump.

XII. Cylinder Head Cover

12.1 Preparatory Information

Precautions and locking torque for cylinder head cover work.

12.2 Fault Diagnosis

Troubleshooting oil leakage from the cylinder head cover.

12.3 Cylinder head cover

Steps to remove, inspect, and install the cylinder head covers.

XIII. Cylinder Head

13.1 Preparatory Information

Function, precautions, and technical parameters of the cylinder head.

13.2 Fault Diagnosis

Troubleshooting common cylinder head issues like low compression.

13.3 Cylinder head

Disassembly, inspection, and replacement of cylinder head components.

XIV. Cylinder Block and Piston

14.1 Preparatory Information

Function and precautions for cylinder block and piston.

14.2 Fault Diagnosis

Troubleshooting common cylinder block and piston issues.

14.3 Cylinder Block

Disassembly, inspection, and installation of the cylinder block.

14.4 Piston

Disassembly, inspection, and installation of the piston assembly.

14.5 Crankshaft connecting rod

Inspection of connecting rod and crankshaft components.

XV. Crankcase

15.1 Preparatory Information

Function, precautions, and locking torques for the crankcase.

15.2 Disassembly and Installation of Crankcase Bearing

Procedures for removing and installing crankcase bearings.

15.3 Crankcase

Disassembly and inspection procedures for the crankcase.

XVI. Clutch

16.1 Preparatory Information

Operation precautions, technical parameters, and locking torques for the clutch.

16.2 Fault Diagnosis

Troubleshooting common clutch operation issues.

16.3 Right Cover

Steps to remove and install the right engine cover.

16.4 Clutch

Disassembly, inspection, and installation of the clutch assembly.

XVII. Gearshift Mechanism

17.1 Preparatory Information

Locking torque specifications for gearshift mechanism components.

17.2 Fault Diagnosis

Troubleshooting common gearshift mechanism problems.

17.3 Gearshift Mechanism

Disassembly, inspection, and installation of the gearshift mechanism.

XVIII. Drive System

18.1 Preparatory Information

Function and technical parameters of the drive system.

18.2 Fault Diagnosis

Troubleshooting common drive system faults.

18.3 Drive system

Exploded views and inspection of drive system components.

18.4 Installation

Assembly and installation procedures for drive system components.

XIX. Electric Starter Mechanism

19.1 Preparatory Information

Technical parameters and locking torque for the electric starter.

19.2 Troubleshooting

Diagnosing engine start failures related to the starter system.

19.3 Electric starter mechanism

Disassembly and installation procedures for the electric starter mechanism.

XX. Exhaust Emission Control System

20.1 Guarantee of Exhaust Emission Control System

Guarantee provisions for the exhaust emission control system.

20.2 Regular Maintenance Notice

Guidelines for regular maintenance related to emissions.

20.3 Mechanical Function of Exhaust Control System

Summary of the exhaust control system's mechanical function.

20.4 Catalyst Conversion System

Structure and description of the catalyst conversion system.

XXI. Fuel injection system (EFI)

21.1 Introduction to EFI

Overview of the EFI system's function and benefits.

21.2 EFI system

Diagram and pin definitions for the EFI system.

21.3 EFI part position

Identifies the location of EFI system components on the motorcycle.

21.4 Technical parameters

Detailed technical specifications for EFI system components.

21.5 Precautions for EFI Overhaul

Important safety and handling precautions for EFI system overhaul.

21.6 ECU

Function, appearance, disassembly, installation, and precautions for the ECU.

21.7 Fuel Pump

Working principle, appearance, composition, and maintenance of the fuel pump.

21.8 Throttle Body

Working principle, parameters, disassembly, cleaning, installation, and notes for the throttle body.

21.9 Oxygen sensor

Working principle, appearance, parameters, and installation of the oxygen sensor.

21.10 Intake pressure and temperature sensor

Working principle, appearance, environment, and fault determination of the intake sensor.

21.11 Canister solenoid valve (ECP)

Working principle, appearance, pin definition, parameters, and installation of the canister solenoid valve.

21.12 Ignition coil

Appearance and fault description of the ignition coil.

21.13 Fault maintenance and diagnosis method of EFI system

Methods for maintaining and diagnosing EFI system faults using diagnostic tools.

21.14 Circuit Diagram of BJ400-8 (electronic injection version, exported)

Wiring diagram for the electronic injection system.

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