Benelli TRK 502 Service Station Manual

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CHAPTER 3
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ...................................................................5
MAINTENANCE INTERVALS .....................................................................................................................................................6
ENGINE/AIR BOX ..........................................................................................................................................9
REMOVAL/ASSEMBLY OF AIR BOX .........................................................................................................................................9
ENGINE/THROTTLE CABLE CLEARANCE ...............................................................................................11
ADJUSTMENT OF THROTTLE CABLE CLEARANCE ............................................................................................................11
ADJUSTMENT OF IDLE SPEED ..............................................................................................................................................14
ENGINE/CLUTCH CABLE ...........................................................................................................................15
ADJUSTMENT OF CLUTCH CABLE CLEARANCE ................................................................................................................15
FRAME/HANDLEBAR .................................................................................................................................16
REAR-VIEW MIRROR ADJUSTMENT .....................................................................................................................................16
ENGINE/MOTOR OIL ..................................................................................................................................17
CHECKING ENGINE OIL LEVEL .............................................................................................................................................17
ENGINE OIL CHANGE .............................................................................................................................................................18
OIL FILTER REMOVAL/INSTALLATION ...................................................................................................................................19
ENGINE/SPARK PLUGS .............................................................................................................................20
REMOVAL OF SPARK PLUGS ON THE VEHICLE ..................................................................................................................20
SPARK PLUG CHECK ..............................................................................................................................................................21
ASSEMBLY OF SPARK PLUGS ...............................................................................................................................................23
FRAME/BRAKE ADJUSTMENT .................................................................................................................25
ADJUSTMENT OF THE FRONT BRAKE .................................................................................................................................25
ADJUSTMENT OF THE REAR BRAKE ...................................................................................................................................26
FRAME/CHECKING BRAKE FUID LEVEL .................................................................................................27
CHECKING THE FRONT BRAKE LIQUID LEVEL/TOPPING UP ............................................................................................27
CHECKING THE REAR BRAKE LIQUID LEVEL/TOPPING UP ..............................................................................................28
FRAME/CHECKING ABS HOSES ..............................................................................................................29
CHECK FOR ANY LEAKAGES OF ABS TUBES .....................................................................................................................29
FRAME/BRAKE PAD CHECK .....................................................................................................................30
CHECKING WEAR OF FRONT/REAR BRAKE PADS .............................................................................................................30
FRAME/CHECKING HOSES OF THE BRAKING SYSTEM .......................................................................31
HOSE CHECK ..........................................................................................................................................................................31
FRAME/TRANSMISSION CHAIN ................................................................................................................32
ADJUSTMENT OF THE TRANSMISSION CHAIN ...................................................................................................................32
LUBRICATION OF TRANSMISSION CHAIN ...........................................................................................................................33
CHAIN GUIDE CHECK .............................................................................................................................................................33
CHECKING WEAR OF TRANSMISSION CHAIN .....................................................................................................................34
FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE ................................................................35
CHECK/ADJUSTMENT OF STEERING CLEARANCE ............................................................................................................35
FRAME/CHECK OF FRONT FORK ............................................................................................................37
CHECK OF FRONT FORK .......................................................................................................................................................37
FRAME/CHECK OF REAR SHOCK ABSORBER ......................................................................................38
SHOCK ABSORBER ADJUSTMENT .......................................................................................................................................38
FRAME/CHECK OF FRONT/REAR TYRES ...............................................................................................39
TYRE CHECK ...........................................................................................................................................................................39
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