Benelli TNT125 - Special Tools

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Special Tools

Internal circlip plier:

Multimeter:

Jack:

Jack accessories:

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Main Page

Exhaust Emission Control Information4
Table of Contents6
Preface22
Chapter I Basic Information23
Notes before Maintenance24
Battery Grounding24
Sharp Edge of Part24
Solvent24
Cleaning Motorcycle before Disassembly25
Collecting and Cleaning Removed Part25
Storing Removed Part25
Check25
Replacement Part26
Assembly Order26
Fastening Order26
Tightening Torque26
Force27
Gasket and O-Ring Seal27
Mould Closing Glue and Threaded Fastening Glue27
Press Fitting27
Ball Bearing and Needle Bearing29
Oil Seal and Grease Oil Seal29
Circlip and Cotter Pin30
Lubrication30
Rotation Direction of Engine30
Wire30
Cable Connector Check31
Disconnection31
Check31
Check32
Cable Arrangement33
Tool33
Model Information34
China34
Europe36
Non-Europe38
Basic Specification41
General Technical Parameter43
Unit Conversion Table46
Chapter II Regular Maintenance47
Regular Maintenance Table49
Torque and Locking Agent51
Main Locking Torque Specifications51
Nut, Bolt, Screw Fastening Torque and Relative Parameters55
Technical Parameters56
Special Tools58
Regular Maintenance Procedures59
Electronic Fuel Injection System (EFI)59
Checking Throttle Control System59
Checking Idle Speed60
Checking Fuel Hose (Fuel Leakage, Hose Break and Hose Installation Situations)61
Checking Fuel Evaporation and Recovery System (Chinese, European and US Models)62
Engine Cylinder Head and Cylinder Head Cover64
Checking Valve Clearance64
Adjusting Valve Clearance66
Clutch67
Checking Whether Clutch Control System Is Normal67
Checking Free Travel of Clutch Handle67
Wheel/Tire68
Checking Tire Pressure68
Checking Whether Wheel/Tire Is Broken68
Checking Wear Situations of Thread69
Checking Whether Wheel Bearing Is Damaged69
Final Drive Mechanism71
Checking Lubrication State of Drive Chain71
Checking Whether Drive Chain Is Loose71
Adjusting Slackness of Drive Chain72
Checking Wheel Alignment73
Checking Wear of Drive Chain73
Checking Wear of Chain Guide74
Brake75
Check Whether Brake Hose and Brake Pipe Are Damaged and Their Installation States75
Free Travel of Front Brake75
Free Travel of Rear Brake75
Checking Brake76
Checking Brake Fluid Level76
Checking Wear of Brake Pad79
Checking Brake Light Switch79
Suspension System80
Checking Front Fork/Rear Shock Absorber80
Check for Oil Leakage of Front Fork Shock Absorber80
Check for Oil Leakage of Rear Shock Absorber81
Steering System82
Checking Steering Clearance82
Adjusting Tightness of Steering Seat82
Applying Lubricant to Steering Column Bearing84
Electrical System85
Checking Light and Switch85
Checking Accuracy of Headlight90
Checking Emergency Flameout Switch91
Others92
Applying Lubricant to Frame Parts92
Check Tightness of Bolt, Nut and Fastener95
Replacement Part97
Replacing Air Filter Element97
Replacing Fuel Pipe99
Replacing Oil101
Replacing Brake Hose and Brake Pipe103
Replacing Brake Fluid106
Replacing Rubber Parts of Master Cylinder110
Replacing Rubber Parts of Calipers112
Replacing Spark Plug120
Chapter III Electronic Fuel Injection System (EFI)121
Introduction to EFI125
EFI System126
EFI Part Position128
Technical Parameters134
Fuel Tank136
Exploded View of Fuel Tank136
Evaporative Emission Recovery System of Fuel138
Disassembly of Fuel Tank139
Check141
Installatation of Fuel Tank143
Notes for EFI Overhaul144
Ecu146
Engine Controller (MT05.2ECU)146
ECU Appearance146
ECU Disassembly146
ECU Installation147
Notes for ECU147
ECU Power Supply Requirements147
ECU Temperature Requirements148
Fuel Pump149
Working of Fuel Pump149
Appearance of Fuel Pump150
Composition of Fuel Pump151
Label and Mark of Fuel Pump151
Working Environment of Fuel Pump152
Fuel Pump Maintenance Process152
Safety Protection152
Fault Diagnosis of Fuel Pump Assembly153
Disassembly of Fuel Pump Assembly153
Installation of Fuel Pump Assembly154
Fuel Pressure Release Process154
Fuel Leakage Check Process155
Notes for Use155
Throttle Body157
Working Principle of Throttle Body157
Appearance of Throttle Body157
Technical Parameters157
Throttle Body158
Throttle Position Sensor158
Air Control Valve of Idle Speed158
Working Environment of Throttle158
Disassembly of Throttle158
Cleaning Method of Throttle158
Installation of Throttle158
Precautions for Installation of Throttle158
Notes for Use of Throttle159
Idle Speed Stepper Motor159
Working Principle of Idle Speed Stepper Motor159
Appearance of Idle Speed Stepper Motor159
Definition of Pin160
Characteristic Parameter160
Fault Determination of Idle Speed Stepper Motor160
Circuit Inspection of Idle Speed Stepper Motor161
Cleaning161
Resetting of Idle Speed Stepper Motor161
Fuel Injector162
Working Principle of Fuel Injector162
Appearance of Fuel Injector162
Sealing Ring of Fuel Injector163
O-Ring Seal Connected to Oil Rail or Oil Injection Cap163
O-Ring Seal Connected to Intake Pipe End163
Recommended Lubricant163
Overvoltage Impact of Fuel Injector163
Temperature Range of Fuel Injector164
Fuel Contaminants of Fuel Injector164
Fuel Injector Harness Arrangement164
Notes for Use of Fuel Injector164
Requirements for Installation of Fuel Injector165
Replacement Method of Fuel Injector166
Fuel Injector Replaceability167
Blocking of Fuel Injector167
General Failure Mode and Prevention and Solving Measures in Using Process168
Intake Pressure Sensor169
Working Principle of Intake Pressure Sensor169
Appearance of Intake Pressure Sensor169
Working Environment169
Storage Environment169
Electric Environment169
Pin Definition170
Position170
Cleaning170
Fault Determination170
Oxygen Sensor171
Working Principle of Oxygen Sensor171
Appearance of Oxygen Sensor171
Technical Parameters171
Installation Requirements171
Oxygen Sensor Pin Definition172
Fault Determination172
Characteristic Curve173
Requirements for Fuel Quality173
Temperature Sensor of Engine Cylinder Head174
Working Principle of Temperature Sensor of Engine Cylinder Head174
Appearance of Temperature Sensor of Engine Cylinder Head174
Working Environment174
Electrical Environment174
Fault Determination and Characteristic of Output Resistance175
Canister Solenoid Valve (ECP)176
Overview of Working Principles176
Appearance176
ECP Pin176
Technical Parameters177
Installation Requirements177
Ignition Coil178
Appearance of Ignition Coil178
Fault Description178
Fault Maintenance Diagnosis Method of EFI System179
Diagnosis Directly Using the Flashing Fault Lamp at Instrument179
Diagnosing Fault Using Diagnostic Apparatus182
Common Troubleshooting Methods of Electronic Fuel Injection System184
Maintenance Tool184
Engine Working Data Flow Displayed by Diagnostic Apparatus185
Step I185
Simple Troubleshooting187
Daily Use and Maintenance187
Fault Phenomenon-Start Fault188
Fault Phenomenon-Start Failure with Tempering190
Fault Phenomenon-Instable Idle Speed190
Fault Phenomenon-Too High or too Low Idle Speed191
Target Idle Speed)191
Fault Phenomenon-Instable Idle Speed with Deceleration and Flameout192
Fault Phenomenon-Insufficient Power of Deceleration192
Fault Phenomenon-Slight Burning Phenomenon192
Fault Phenomenon-Fault Lamp Is On, but Fault Code Is Inconsistent with Fault192
Fault Phenomenon-Extremely High Fuel Consumption193
Fault Diagnosis Instructions for Delphi194
Main Parameters of Engine200
Lubrication System201
Diagram of Lubrication System201
Position of Fuel Pump203
Preparation Information205
Conventional Information205
Technical Parameters206
Torque Value206
Special Tools207
Troubleshooting208
Oil Level Is too Low208
Oil Pressure Is Low208
There Is no Oil Pressure208
Oil Pressure Is High208
Oil Is Polluted208
Oil Is Emulsified208
Checking Fuel Pump209
Cylinder Head / Distribution210
Exploded View of Cylinder Head / Distribution210
Preparation Information211
Technical Parameters211
Torque Value211
Fault Diagnosis212
Compression Pressure Is Low212
The Sound of Cylinder Head Is Abnormal212
Compression Pressure Is too High212
Special Tools213
Cylinder Head214
Disassembling Cylinder Head214
Checking Cylinder Head217
Replacing Valve Guide219
Finishing Valve Seat Ring221
Cylinder Block / Piston224
Exploded View of Cylinder Block / Piston224
Exploded View of Crankshaft225
Preparation Information226
Technical Parameters227
Torque Value227
Fault Diagnosis228
Compression Pressure Is Low228
Compression Pressure Is High228
Exhaust Pipe Is Emitting White Smoke228
The Sound of Piston Is Abnormal228
Special Tools229
Cylinder Block231
Disassembling231
Check231
Piston231
Check232
Installation234
Installation of Cylinder Block235
Crankshaft235
Check235
Sub-Assembly of Crankcase237
Exploded View of Crankcase237
Dismounting and Mounting Diagram of Crankcase Bearing238
Preparation Information239
Overview239
Technical Parameters239
Torque Value239
Crankcase240
Disassembling Crankcase240
Checking Crankcase240
Assembling Crankcase242
Clutch244
Exploded View of Left Cover244
Exploded View of Clutch245
Preparation Information246
Conventional Information246
Technical Parameters247
Torque Value247
Special Tools248
Troubleshooting249
Clutch Lever Is too Hard to Pull249
Clutch Is Slipping When Accelerating249
Clutch Does Not Disengage or Clutch Disengages Suddenly During the Running of Motorcycle249
Right Cover250
Disassembing Right Cover250
Assembling Right Cover250
Clutch251
Disassembling Clutch251
Assembling Clutch252
Check253
Subassembly of Cylinder Head Cover255
Exploded View of Cylinder Head Cover255
Preparation Information256
Overview256
Technical Parameters256
Torque Valve256
Cylinder Head Cover256
Disassembling Cylinder Head Cover256
Checking Cylinder Head Cover257
Installing Cylinder Head Cover257
Kickstarter Component258
Exploded View of Kickstarter Component258
Preparation Information259
Overview259
Technical Parameters259
Torque Value259
Kickstarter Mechnism259
Disassembling Kickstarter Mechanism259
Installing Kickstarter Mechanism260
Gearshift Mechanism261
Exploded View of Gearshift Mechanism261
Technical Parameters262
Torque Value262
Troubleshooting262
It Is Difficult to Shift Gears262
Shift Pedal Is Not Returned262
Gearshift Mechanism263
Disassembling Gearshift Mechanism263
Checking Gearshift Mechanism264
Installing Gearshift Mechanism264
Drive System265
Exploded View of Drive System265
Technical Parameters266
Troubleshooting267
Drive System Trips over Stop or Is out of Gear267
The Noise of Engine Is too Large267
Primary Shaft Component268
Auxiliary Shaft Component268
Check269
Installing Drive System271
Assembling Primary Shaft Component and Aauxiliary Shaft Component271
Installng Drive System272
Starter Mechanism274
Exploded View of Starter Mechanism274
Technical Parameters275
Torque Value275
Troubleshooting275
Engine Cannot Start275
Starter Mechanism276
Disassembling Starter Mechanism276
Installing Starter Mechanism278
Chapter V Finished Motorcycle279
Wheel / Tire284
Exploded View of Front Wheel / Tire284
Technical Parameters287
Special Tools288
Wheel (Rim)289
Disassembling Front Wheel289
Installing Front Wheel290
Disassembling Rear Wheel291
Installing Rear Wheel293
Checking Wheels294
Checking Wheel Axle294
Checking Dynamic Balance295
Adjusting Dynamic Balance295
Disassembling Grip End295
Installing Grip End296
Checking / Adjusting Tire Pressure297
Checking Tire297
Disassembling Tire298
Installing Tire299
Hub Bearing301
Disassembling Hub Bearing301
Installing Hub Bearing301
Checking Hub Bearing302
Hub Bearing Lubrication302
Drive Mechanism303
Exploded View of Drive Mechanism303
Technical Parameters305
Special Tools306
Drive Chain307
Checking the Slackness of Drive Chain307
Checking / Adjusting Wheel Alignment307
Checking the Wear of Drive Chain307
Lubrication of Drive Chain307
Disassembling Drive Chain307
Installing Drive Chain308
Sprocket, Shaft Sleeve, Shaft Sleeve Bearing309
Disassembling Rear Sprocket309
Installing Rear Sprocket309
Disassembling Shaft Sleeve Bearing310
Installing Shaft Sleeve Bearing310
Checking Shaft Sleeve Bearing310
Lubrication of Shaft Sleeve Bearing310
Checking the Damper of Shaft Sleeve311
Checking the Wear of Sprocket311
Checking the Deformation of Rear Sprocket311
Brake312
Exploded View of Front Brake312
Exploded View of Rear Brake314
CBS of Hydraulic Brake316
Technical Parameters319
Special Tools320
Brake Lever, Brake Pedal321
Checking the Position of Brake Pedal321
Adjusting the Position of Brake Pedal321
Removing the Brake Pedal322
Installing the Brake Pedal322
Calipers324
Disassembling Front Calipers324
Disassembling Rear Calipers325
Installing Calipers326
Disassembling Front Calipers326
Assembling Front Calipers326
Disassembling Rear Calipers326
Assembling Rear Calipers326
Checking the Liquid Seal of Calipers for Damage326
Checking Dust Seal of the Calipers for Damage327
Checking the Calipers Piston and Brake Cylinder for Damage329
Brake Pad330
Disassembling Front Brake Pad330
Installing Front Brake Pad331
Disassembling Rearbrake Pad331
Installing Rear Brake Pad332
Checking the Wear of Brake Pad332
Master Cylinder332
Disassembling Front Master Cylinder332
Installing Front Master Cylinder333
Disassembling Rear Master Cylinder334
Installing Rear Master Cylinder334
Disassembling Rear Master Cylinder335
Disassembling Front Master Cylinder335
Assembling Master Cylinder335
Checking Master Cylinder (Visual Check)335
Brake Discs336
Disassembling Brake Discs336
Installing Brake Disc336
Checking the Wear of Brake Disc336
Checking the Deformation of Brake Disc337
Brake Fluid338
Checking the Level of Brake Fluid338
Replacing Brake Fluid338
Exhausting Air from Brake Pipe338
Brake Hose340
Disassembling / Installing Brake Hose and Brake Pipe340
Checking Brake Hose and Brake Pipe340
Suspension System341
Exploded View of Front Suspension System341
Exploded View of Rear Suspension System343
Technical Parameters344
Special Tools345
Front Shock Absorber346
Disassembling Front Shock Absorber346
Installing Front Shock Absorber347
Replacing Front Shock Absorber Oil347
Disassembling Front Shock Absorber351
Checking Inner Pipe and Outer Pipe353
Checking Dust Seal353
Checking Spring Tension353
Rear Shock Absorber354
Adjusting Spring Pre-Tightening Force354
Disassembling Rear Shock Absorber355
Installing Rear Shock Absorber356
Checking Rear Shock Absorber356
Rear Swing Arm357
Disassembling Swing Arm357
Installing Swing Arm357
Disassembling Swing Arm Bushing358
Checking Damper358
Control System359
Exploded View of Control System359
Special Tools361
Control System362
Checking Control System362
Adjusting Control System362
Steering Lever363
Disassembling Steering Lever and Steering Lever Bearing363
Installing Steering Lever and Steering Lever Bearing364
Steering Lever Bearing Lubrication367
Checking Deformation of Steering Lever367
Handlebar368
Disassembling Handlebar368
Installing Handlebar369
Frame371
Exploded View of Frame371
Exploded View of Left Pedal373
Exploded View of Right Pedal375
Exploded View of Muffler377
Exploded View of Front Fender379
Exploded View of Rear Fender381
Exploded View of Cowling383
Exploded View of Fuel Tank Guard385
Exploded View of Seat Cushion and Guard387
Exploded View of Engine389
Seat Cushion391
Disassembling Seat Cushion391
Installing Seat Cushion391
Cowling392
Disassembling Cowling392
Installing Cowling393
Guard394
Disassembling Left Guard394
Installing Left Guard394
Disassembling Right Guard395
Installing Right Guard395
Rear Tail Cover396
Disassembling Tail Cover396
Installing Tail Cover396
Rear Fender397
Disassembling Rear Fender397
Installing Rear Fender397
Front Fender398
Disassembling Front Fender398
Installing Front Fender398
Fuel Tank Guard and Fairing399
Disassembling Fuel Tank Guard399
Installing Fuel Tank Guard399
Frame400
Disassembling Frame400
Installing Frame400
Checking Frame400
Side Stand401
Disassembling Side Stand401
Installing Side Stand401
Left Front Pedal402
Disassembling Left Front Pedal402
Installing Left Front Pedal403
Left Rear Pedal404
Disassembling Left Rear Pedal404
Installing Left Rear Pedal404
Front Right Pedal405
Disassembling Front Right Pedal405
Installing Front Right Pedal405
Rear Right Pedal406
Disassembling Rear Right Pedal406
Installing Rear Right Pedal406
Muffler407
Disassembling Muffler407
Installing Muffler409
Disassembling/Installing Engine410
Exploded View of Engine Disassembly and Installation410
Disassembling Engine412
Installing Engine418
Precautions424
Technical Parameters425
Special Tools426
Electrical Wiring427
Wiring Inspection427
Charging System428
Circuit Diagram of Charging System428
Battery429
Disassembling Battery429
Battery Installation430
Battery Activation430
Initial Charge432
Charging State Inspection433
Magneto433
Disassembling Magneto434
Checking Magneto435
Installing Magneto437
Rectifier438
Disassebling Rectifier438
Main Wiring Terminal Circuit Inspection438
Rectifier Inspection438
Rectifier Installation439
Ignition System440
Circuit Diagram of Ignition System440
Operation Precautions441
Crankshaft Sensor442
Disassembling Crankshaft Position Sensor442
Check442
Ignition Coil442
Disassembling Ignition Coil442
Checking Ignition Coil443
Installing Ignition Coil443
Spark Plug443
Checking Spark Plug443
Check444
IC Igniter Inspection444
ECU Group445
Ignition System Troubleshooting446
Starter System447
Circuit Diagram of Starter System447
Starter Motor448
Disassembling Starter Motor448
Checking Starter Motor448
Carbon Brush Inspection449
Commutator Cleaning and Inspection449
Carbon Brush Lead Inspection450
Right-Hand End Cover Assembly Inspection450
Starter Relay451
Disassembling Starter Relay451
Checking Starter Relay451
Installing Starter Relay452
Lighting System453
Headlight453
Tail Light453
Turn Signal Light454
License Plate Light454
Instrument455
Disassembling Instrument455
Instrument and Indicator Light455
Status Indicator Light456
Function Buttons456
Tachometer457
All / Part of Kilometer Counters457
Speedometer457
Digital Clock (8)457
Fuel Gauge (9)457
Switch, Sensor and Other Parts458
Power Lock Switch458
Disassembling Power Lock458
Power Lock Inspection458
Handle Switch459
Switch State (Non-Europe)459
Switch State (Europe)460
Checking the Time to Turn on Brake Lamp462
Adjsuting the Time to Turn on Brake Lamp462
Switch Inspection462
Rear Brake Lamp Switch Connection462
Side Stand Switch Connection462
Oil Level Sensor463
Disassemble Oil Level Sensor463
Checking Oil Level Sensor463
Installing Oil Level Sensor464
Horn465
Disassembling Horn465
Checking Horn465
Installing Horn465
Fuse466
Disassmbling Fuse466
Installing Fuse466
Checking Fuse466
Winding Method of Cable, Wire and Hose470
Main Cable470
Throttle Cable473
Clutch Cable474
Oil Pipe475
Troubleshooting Guide476
The Engine Cannot Start or Is Difficult to Start476
Starter Motor Does Not Run476
Starter Motor Is Running, but the Engine Does Not Run476
Engine Does Not Run476
There Is no Fuel Flow476
There Is no Spark; Spark Is Weak476
There Is Problem with Fuel / Air Mixture477
Cylinder Pressure Is too Low477
The Running Is Abnormal During Low-Speed Driving477
Spark Is Weak477
Others478
Motorcycle Cannot Run Properly or Do Not Have Sufficient Power at High Speed478
Ignition Is Abnormal478
There Is Problem with Fuel / Air Mixture478
Cylinder Pressure Is too Low478
There Is a "Click" to Give an Alarm for Fault479
Others479
Temperature Is too High479
Ignition Is Abnormal479
Muffler Is Overheated479
There Is Problem with Fuel / Air Mixture479
Cylinder Pressure Is too High480
Insufficient Engine Output Power480
Improperly Adding Lubrication Oil480
Oil Cooler Is Abnormal480
Clutch Is Abnormal480
Clutch Is Slipping480
Clutch Cannot be Properly Separated480
There Is a Problem with Shifting480
It Is Unable to Engage the Gear; Control Pedal Cannot be Reset480
Trip Stop480
Excessive Speed Change481
Engine Gives an Abnormal Noise481
There Is a "Click" to Give an Alarm for Fault481
There Is Knocking Noise at Piston481
Valve Gives a Noise481
The Drive System Makes an Unusual Noise481
Clutch Noise481
Transmission Device Makes a Noise482
Drive System Makes a Noise482
The Frame Gives an Unusual Noise482
Front Fork Gives a Noise482
Rear Shock Absorber Gives a Noise482
Brake Disc Gives a Noise482
Other Noises482
Oil Perssure Warning Light Is on482
Too Much Exhaust482
White Exhaust482
The Handlebar Shakes or Vibrates Severely483
Handlebar Is Swinging to One Side483
Shock Absorption Effect Is Not Ideal483
Brake Cannot Work483
Battery Fault483
Battery Power Runs out483
Battery Overcharging484
Circuit Diagram485

Benelli TNT125 - Special Tools

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