Benelli TNT 25 - Clutch Cable Routing

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Clutch Cable Routing:

Run the clutch cable

through the gap between

the meter and upper

bridge

Run the clutch cable

through the frame as

shown. Do not interfere

with the throttle cable.

8-9

Main Page

Exhaust Emission Control Information4
Table of Contents6
Chapter I Basic Information16
Notes before Maintenance17
Battery Installation17
Sharp Edge of Part17
Solvent17
Cleaning Motorcycle before Disassembly18
Collecting and Cleaning Removed Part18
Storing Removed Part18
Check18
Replacement Part19
Assembly Order19
Fastening Order19
Tightening Torque19
Force20
Gasket and O-Ring Seal20
Silicone Sealant and Non-Permanent Locking Agent20
Press Fitting20
Ball Bearing and Needle Bearing21
Oil Seal and Grease Oil Seal21
Circlip and Cotter Pin22
Lubrication22
Rotation Direction of Engine22
Wire23
Cable Connector Check23
Cable Arrangement25
Tool25
Model Information26
China26
Europe28
Non-Europe29
Basic Specification30
General Technical Parameter31
Unit Conversion Table34
Chapter II Regular Maintenance35
Regular Maintenance Table37
Torque and Locking Agent39
Main Locking Torque Specifications39
Nut, Bolt, Screw Fastening Torque and Relative Parameters43
Regular Maintenance Procedures47
Fuel Injection System (Efi)47
Checking Throttle Control System47
Checking Idle Speed48
Checking Fuel Hose (Fuel Leakage, Hose Break and Hose Installation Situations)48
Checking Fuel Evaporation and Recovery System (Chinese, European and Us Models)49
Cooling System51
Checking Coolant Level51
Check Radiator Pipe (Coolant Leakage, Radiator Pipe Damage and Installation State of Radiator Pipe)51
Engine Cylinder Head and Cylinder Head Cover52
Check Valve Clearance52
Adjusting Valve Clearance54
Check Whether Air Inlet Device Is Damaged58
Clutch59
Check Whether Clutch Control System Is Normal59
Check Free Play of Clutch Handle59
Wheel/Tire60
Checking Tire Pressure60
Checking Whether Rim/Tire Is Broken60
Checking Wear Situations of Thread61
Checking Whether Wheel Bearing Is Damaged62
Final Drive Mechanism63
Checking Lubrication State of Drive Chain63
Checking Whether Drive Chain Is Loose63
Adjusting Slackness of Drive Chain64
Checking Wheel Alignment65
Checking Wear of Drive Chain65
Brake67
Check Whether Brake Hose and Brake Pipe Are Damaged and Their Installation States67
Free Play of Front Brake67
Free Play of Rear Brake67
Checking Brake68
Checking Brake Fluid Level68
Checking Wear of Brake Pad69
Checking Brake Lamp Switch70
Suspension System71
Checking Front /Rear Shock Absorber71
Check for Front Shock Absorber Oil Leakage71
Check for Rear Shock Absorber Oil Leakage72
Steering System73
Checking Steering Clearance73
Adjusting Tightness of Steering Seat73
Adding Lubricant to Steering Stem Bearing74
Electrical System75
Checking Lamp and Switch75
Checking Accuracy of Head Lamp79
Check Side Stand Switch80
Checking Engine Stop Switch81
Others82
Adding Lubricant to Frame Parts82
Check Tightness of Bolt, Nut and Fastener83
Replacement Part85
Replacing Air Filter Element85
Replacing Fuel Hose87
Replacing Coolant88
Replacing Radiator Hose91
Replacing Oil92
Replacing Brake Hose93
Replacing Rear Brake Fluid Pipe95
Replacing Brake Fluid96
Replacing Rubber Parts of Brake Master Cylinder98
Replacing Rubber Parts of Calipers101
Replacing Spark Plug105
Chapter III Fuel Injection System106
Introduction to Efi108
Efi System109
Efi Part Position111
Technical Parameters115
Fuel Tank117
Fuel Tank Exploded View117
Fuel Evaporative Recovery System120
Disassembly of Fuel Tank121
Notes for Efi Service122
Ecu124
Engine Controller (Mt05 Ecu)124
Ecu Disassembly125
Ecu Installation125
Notes for Ecu125
Ecu Power Supply Requirements125
Ecu Temperature Requirements125
Fuel Pump126
Fuel Pump Working126
Fuel Pump Appearance126
Fuel Pump Label and Mark127
Working Environment of Fuel Pump127
Fuel Pump Maintenance Process128
Safety Protection128
Notes for Use130
Throttle Body132
Working Principle of Throttle Body132
Appearance of Throttle Body132
Technical Parameters133
Working Environment of Throttle133
Disassembly of Throttle133
Cleaning Method of Throttle134
Installation of Throttle134
Precautions for Installation of Throttle134
Notes for Use of Throttle Valve134
Working Principle of Fuel Injector135
Appearance of Fuel Injector135
Sealing Ring of Fuel Injector135
Overvoltage Impact of Fuel Injector137
Temperature Range of Fuel Injector137
Fuel Contaminants of Fuel Injector137
Fuel Injector Harness Arrangement137
Notes for Use of Fuel Injector138
Requirements for Installation of Fuel Injector139
Injector Replaceability139
Blocking of Fue Injector140
Engine Temperature Sensor141
Intake Air Temperature Sensor142
Manifold Absolute Pressure Sensor144
Oxygen Sensor146
Idle Speed Stepper Motor148
Carbon Canister Solenoid Valve (Ecp)150
Fault Maintenance Diagnosis Method of Efi System152
Directly Making the Fault Lamp at Instrument Flash for Diagnosis152
Diagnosing Fault Using Diagnostic Tool155
Checking Fault Using Diagnostic Software Pchud156
Common Troubleshooting Methods of Electronic Fuel Injection System162
Maintenance Tool162
Engine Working Data Flow Displayed by Diagnostic Tool163
Concise Troubleshooting163
Chapter IV Cooling System167
Explosive View168
Coolant Flow Diagram170
Technical Parameters172
Coolant173
Checking Whether Coolant Deteriorates173
Checking Coolant Level173
Discharging Coolant173
Adding Coolant173
Detecting Pressure173
Cleaning Cooling System174
Disassembling/Installing Reserve Tank174
Coolant Pump175
Disassembling Coolant Pump175
Installing Coolant Pump175
Checking Coolant Pump Impeller176
Radiator177
Disassembling Radiator and Radiator Fan177
Installing Radiator and Radiator Fan178
Checking Radiator178
Checking Radiator Cap179
Checking Radiator Filler180
Thermostat181
Disassembling Thermostat181
Installing Thermostat181
Checking Thermostat182
Hose and Pipeline183
Installing Hose183
Checking Hose183
Coolant Temperature Sensor184
Disassembling/Installing Coolant Temperature Sensor184
Checking Coolant Temperature Sensor184
Chapter V Engine185
Lubrication System186
Preparation Information186
Oil Passage Diagram186
Technical Parameters187
Oil Pump188
Cylinder Head191
Cylinder Head Exploded View191
Camshaft and Valve Exploded View192
Preparation Information193
Technical Parameters194
Special Tools and Sealant195
Cylinder Head197
Cylinder and Piston205
Cylinder Exploded View205
Piston, Crankshaft Connecting Rod Exploded View206
Preparation Information207
Technical Parameters208
Cylinder Checking and Replacement209
Piston211
Crankshaft Connecting Rod217
Crankshaft Connecting Rodexploded View217
Preparation Information218
Technical Parameters219
Crankshaft Connecting Rod220
Balance Shaft222
Tensioner223
Clutch224
Clutch Exploded View224
Special Tool225
Disassembling Clutch226
Installing Clutch228
Checking Clutch228
Shift Mechanism229
Shift Mechanism Exploded View229
Disassembling Shift Mechanism230
Installing Shift Mechanism230
Checking Shift Mechanism231
Disassembling Primary/Secondary Shaft Component232
Installing Primary/Secondary Shaft233
Checking Primary/Secondary Shaft Component234
Chapter VI Chassis235
Wheel / Tire237
Exploded View of Front Wheel / Tire237
Exploded View of Rear Wheel / Tire239
Technical Parameters241
Special Tools242
Wheel (Rim)243
Hub Bearing255
Drive Mechanism257
Exploded View of Drive Mechanism257
Technical Parameters259
Special Tools260
Drive Chain261
Sprocket, Shaft Sleeve, Shaft Sleeve Bearing263
Brake267
Exploded View of Front Brake267
Exploded View of Rear Brake269
Technical Parameters271
Special Tools272
Brake Handle/Pedal, Brake Pedal273
Calipers276
Brake Pads279
Brake Master Cylinder281
Brake Discs283
Brake Fluid284
Brake Hose286
Suspension System287
Front Suspension System Exploded View287
Rear Suspension System Exploded View289
Technical Parameters291
Special Tool292
Front Shock Absorber293
Rear Shock Absorber301
Rear Swing Arm304
Steering System308
Steering System Exploded View308
Special Tool310
Steering System311
Steering Stem312
Handlebar317
Frame320
Frame Exploded View320
Left Pedal Exploded View322
Right Pedal Exploded View324
Muffler Exploded View326
Fender Exploded View328
Body Coversfuel Tank Garnish Plates Exploded View330
Seat Cushion and Body Covers Exploded View332
Bottom Cover and Engine Exploded View334
Seat Cushion336
Body Covers337
Rear Handrail and Tail Cover339
Rear Fender341
Front Fender342
Body Coversfuel Tank Garnish Plates and Fairing343
Radiator Fairing344
Bottom Cover345
Frame346
Side Stand347
Left Front Pedal348
Left Rear Pedal349
Front Right Pedal350
Rear Right Pedal351
Disassembling/Installing Engine354
Chapter VII Electrical System363
Precautions364
Technical Parameters365
Special Tool366
Electrical Wiring367
Wiring Inspection367
Charging System368
Charging System Circuit Diagram368
Battery369
Magneto373
Voltage Regulator/Rectifier376
Ignition System377
Ignition System Circuit Diagram377
Operation Precautions377
Crankshaft Sensor378
Ignition Coil379
Spark Plug380
Ecu381
Ignition System Troubleshooting382
Starting System383
Starting System Circuit Diagram383
Starter Motor384
Starter Relay386
Starter Relay Disassembly and Action Inspection386
Lighting System387
Headlight387
Instrument389
Instrument Disassembly389
Switch, Sensor and Other Parts390
Main Switch390
Handle Switch391
Brake Lamp Lightingtime Inspection393
Brake Lamp Lighting Time Adjustment393
Switch Inspection393
Side Stand Switch Connection393
Color393
Speed Sensor394
Oxygen Sensor395
Fuel Level Sensor396
Horn397
Fan398
Fan Switch399
Relay and Fuse Box400
Fuse403
Chapter VIII Appendix405
Routing of Cable, Wire and Hose406
Main Harness Routing407
Throttle Cable Routing411
Clutch Cable Routing413
Other Matters415
Troubleshooting Guide429
The Engine Cannot Start or Is Difficult to Start429
Abnormal Running During Low-Speed Driving430
Abnormal Running or Poor Power During High-Speed Driving430
Temperature Is too High431
Overcooling431
Clutch Is Abnormal431
Problem with Shifting433
Engine Makes Abnormal Noise433
The Drive System Makes Abnormal Noise434
The Frame Noise434
Too Much Exhaust Smoke435
Poor Performance and / or Stability436
Battery Fault436
Circuit Diagram437
Special Tool List Summary439

Benelli TNT 25 - Clutch Cable Routing

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