Benelli TRK 502 Service Station Manual

4 - 2
CHAPTER 4
FRAME
FRONT WHEEL AND BRAKE DISCS ...........................................................................................................5
FRONT WHEEL REMOVAL ........................................................................................................................................................5
REMOVAL/INSTALLATION OF BRAKE DISCS .........................................................................................................................6
CHECK OF BRAKE DISCS ........................................................................................................................................................8
WHEEL AXLE CHECK ................................................................................................................................................................9
CHECK/REPLACEMENT OF WHEEL BEARINGS ..................................................................................................................10
FRONT WHEEL INSTALLATION ..............................................................................................................................................11
REAR WHEEL AND BRAKE DISC .............................................................................................................12
REAR WHEEL REMOVAL ........................................................................................................................................................12
REMOVAL OF THE REAR DISC BRAKE, CROWN WHEEL AND PHONIC WHEEL ..............................................................15
WHEEL AXLE CHECK ..............................................................................................................................................................16
CHECK/REPLACEMENT OF WHEEL BEARINGS ..................................................................................................................17
SPROCKET CHECK AND REPLACEMENT ............................................................................................................................18
INSTALLATION OF THE DISC BRAKE ....................................................................................................................................19
BACK TYRE INSTALLATION....................................................................................................................................................20
FRONT AND REAR BRAKES .....................................................................................................................21
REMOVAL AND INSTALLATION OF FRONT BRAKE PADS ...................................................................................................21
REMOVAL AND INSTALLATION OF REAR BRAKE PADS......................................................................................................22
FRONT BRAKE PUMP REMOVAL ...........................................................................................................................................23
REAR BRAKE PUMP REMOVAL .............................................................................................................................................26
FRONT BRAKE PUMP INSTALLATION ...................................................................................................................................28
REAR BRAKE PUMP INSTALLATION .....................................................................................................................................29
ABS ANTI-LOCK BRAKING SYSTEM ........................................................................................................30
LOCATION OF THE COMPONENTS .......................................................................................................................................30
ROTATION SENSOR CHECK ..................................................................................................................................................32
CHECK OF THE PHONIC WHEEL AND ABS OF THE FRONT AND REAR WHEEL ..............................................................33
PRECAUTIONS ........................................................................................................................................................................34
REMOVAL OF THE ABS HYDRAULIC UNIT ...........................................................................................................................36
INSTALLATION OF THE ABS HYDRAULIC UNIT ....................................................................................................................37
REMOVAL OF THE ABS ROTATION SENSORS – FRONT/REAR WHEEL ............................................................................38
FRONT BRAKE CALLIPER TIGHTNESS ................................................................................................................................39
REAR BRAKE CALLIPER ........................................................................................................................................................40
CHECK THE FRONT AND REAR CALLIPERS ........................................................................................................................41
FRONT BRAKE CALLIPER INSTALLATION ............................................................................................................................42
REAR BRAKE CALLIPER INSTALLATION ..............................................................................................................................44
FRONT FORK ..............................................................................................................................................45
FRONT FORK STEM REMOVAL .............................................................................................................................................45
FRONT FORK STEM DISASSEMBLY ......................................................................................................................................48
FRONT FORK STEM INSPECTION .........................................................................................................................................51
FRONT FORK STEM ASSEMBLY ............................................................................................................................................52
FRONT FORK STEM FITTING .................................................................................................................................................55
HANDLEBAR ...............................................................................................................................................56
HANDLEBAR REMOVAL ..........................................................................................................................................................56
HANDLEBAR INSPECTION .....................................................................................................................................................60
HANDLEBAR INSTALLATION ..................................................................................................................................................61
STEERING HEAD ........................................................................................................................................62
REMOVAL OF THE TOP AND BOTTOM STEERING BASE ....................................................................................................62
TOP AND BOTTOM STEERING BASE INSPECTION .............................................................................................................64
TOP AND BOTTOM STEERING BASE FITTING .....................................................................................................................65
REAR SHOCK ABSORBER ........................................................................................................................66
REAR SHOCK ABSORBER REMOVAL ...................................................................................................................................66
REAR SHOCK ABSORBER CHECK ........................................................................................................................................69
REAR SHOCK ABSORBER FITTING ......................................................................................................................................70
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