Benelli TRK 502 Service Station Manual

5 - 2
CHAPTER 5
ENGINE
HEAD DISTRIBUTION ...................................................................................................................................4
COILS AND SPARK PLUGS REMOVAL ....................................................................................................................................5
COILS AND SPARK PLUGS ASSEMBLY ...................................................................................................................................6
TIMING GEAR COVER ASSEMBLY ..........................................................................................................................................8
DISTRIBUTION CHAIN TENSIONER REMOVAL ......................................................................................................................9
TIMING CHAIN TENSIONER ASSEMBLY ...............................................................................................................................10
INTAKE AND EXHAUST CAMSHAFT REMOVAL ....................................................................................................................11
CAMSHAFT CHECK .................................................................................................................................................................12
EXHAUST CAMSHAFT INSTALLATION ..................................................................................................................................13
INTAKE CAMSHAFT ASSEMBLY .............................................................................................................................................14
TIMING CHAIN SLIDE REMOVAL ............................................................................................................................................15
TIMING CHAIN SLIDE ASSEMBLY ..........................................................................................................................................16
TIMING CHAIN REMOVAL .......................................................................................................................................................17
DISTRIBUTION CHAIN INSTALLATION ..................................................................................................................................18
VALVE CLEARANCE ADJUSTMENT .......................................................................................................................................19
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................20
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................21
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................22
HEAD REMOVAL ......................................................................................................................................................................23
VALVE FLAP AND SPRING REMOVAL....................................................................................................................................24
CHECK OF VALVES AND GUIDES ..........................................................................................................................................25
VALVE SEAT CHECK ...............................................................................................................................................................27
VALVE OIL SEAL REMOVAL- INSTALLATION ........................................................................................................................28
VALVE SPRING TEST ..............................................................................................................................................................29
VALVE AND VALVE SPRING INSTALLATION..........................................................................................................................30
CYLINDER CHECK ..................................................................................................................................................................31
HEAD INSTALLATION ..............................................................................................................................................................32
PISTONS ......................................................................................................................................................33
PISTON REMOVAL ..................................................................................................................................................................35
PISTON PIN CHECK ................................................................................................................................................................36
PISTON RINGS CHECK ...........................................................................................................................................................37
PISTON CHECK .......................................................................................................................................................................38
PISTON ASSEMBLY .................................................................................................................................................................39
PISTON INSTALLATION ...........................................................................................................................................................40
REMOVAL OF CONNECTING RODS ......................................................................................................................................41
CRANKCASE ...............................................................................................................................................41
CHECK OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS ...................................................................43
INSTALLATION OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS ......................................................44
MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION ................................................................................................46
DRIVE SHAFT CHECK .............................................................................................................................................................49
DRIVE SHAFT INSTALLATION ................................................................................................................................................50
CLUTCH .......................................................................................................................................................51
CLUTCH AND DISC REMOVAL ...............................................................................................................................................52
FRICTION DISC CHECK ..........................................................................................................................................................54
STEEL DISC CHECK ...............................................................................................................................................................55
DISC ASSEMBLY .....................................................................................................................................................................55
CLUTCH ASSEMBLY ...............................................................................................................................................................56
LUBRICATION SYSTEM .............................................................................................................................57
OIL SUMP AND INTAKE FILTER REMOVAL ...........................................................................................................................58
OIL SUMP AND INTAKE FILTER INSTALLATION ....................................................................................................................59
PRESSURE-RELIEF VALVE INSTALLATION ..........................................................................................................................60
PRESSURE-RELIEF VALVE REMOVAL ..................................................................................................................................61
OIL PUMP REMOVAL ...............................................................................................................................................................62
OIL PUMP ASSEMBLY .............................................................................................................................................................64
NEUTRAL POSITION/GEAR INDICATOR SENSOR REMOVAL .............................................................................................65
COPY - Moto GB - Grant Martland - grantmartland@motogb.co.uk

Benelli TRK 502 Specifications

General

Displacement	500 cc
Transmission	6-speed
Fuel Tank Capacity	20 liters
Seat Height	800 mm
Wet Weight	235 kg
Bore x Stroke	69 mm x 66.8 mm
Compression Ratio	11.5:1
Clutch	Wet multi-plate
Frame	Steel trellis
Wheelbase	1505 mm
Ground Clearance	190 mm
Max Power	47.6 hp (35 kW) @ 8500 rpm
Max Torque	46 Nm @ 6000 rpm
Front Suspension	50 mm upside-down fork
Front Brake	Double floating discs, 320mm, 4-piston calipers
Rear Brake	Single 260 mm disc
Fuel System	Electronic Fuel Injection (EFI)
ABS	Dual-channel ABS
Front Tire	120/70 R17
Rear Tire	160/60 R17
Engine Type	Liquid-cooled, four-stroke, parallel twin cylinder, DOHC, 4 valves per cylinder