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Benelli ZAFFERAN 250 User Manual

Benelli ZAFFERAN 250
187 pages
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1
ZAFFERANO
250
Service Manual

Table of Contents

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Benelli ZAFFERAN 250 Specifications

General IconGeneral
BrandBenelli
ModelZAFFERAN 250
CategoryScooter
LanguageEnglish

Summary

NOTICE

IMPORTANT INFORMATION

Explains how important information is distinguished in the manual.

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCE DURES

Details steps for preparation before removal and disassembly.

REPLACEMENT PARTS

Specifies the use of genuine parts and recommended lubricants.

GASKETS, OIL SEALS AND O-RINGS

Covers replacement and proper oiling of gaskets, seals, and O-rings.

LOCK WASHERS/PLATES AND COTTER PINS

Instructions for replacing lock washers, plates, and cotter pins.

BEARINGS AND OIL SEALS

Guidelines for installing bearings and oil seals correctly.

CIRCLIPS

Instructions for checking and installing circlips.

CHECKING OF CONNECTIONS

HOW TO USE THE CONVERSION TABLE

SPECIAL TOOLS

Specification (EFI Motorcycle ZAFFERANO)

Model

Specifies the model as ZAFFERANO.

Engine

Provides specifications for the engine type, displacement, and cooling.

Tire Size

Lists the front and rear tire sizes.

Transmission Device

Covers clutch type and transmission type.

Electric Device

Details battery capacity, magneto type, and spark plug specifications.

Performance

Includes max speed, grade ability, and torque.

Braking

Mentions brake disc diameter.

GENERAL TORQUE SPECIFICATIONS

General Torque Specifications

Specifies torque for standard fasteners with ISO pitch threads.

LUBRICATION POINT AND GRADE OF LUBRICANT

ENGINE

Lists lubrication points for engine components and their symbols.

CHASSIS

Lists lubrication points for chassis components and their symbols.

Periodic Maintenance & Inspection Table

Anticipated Inspection

Ignition system

Describes symptoms related to ignition system abnormalities.

Carbon fouling elimination

Addresses symptoms of insufficient horsepower due to carbon fouling.

Piston & cylinder

Relates to excessive abrasion of piston and cylinder.

Inspection / Adjustment

Preparing information

Lists items that require preparation information for inspection.

Preparing Principles

Outlines general safety principles for inspection and adjustment.

THROTTLE CABLE ADJUSTMENT

Check

Details how to check the throttle cable free play.

Adjust

Provides adjustment steps for throttle cable free play.

ENGINE OIL LEVEL INSPECTION

Inspect

Steps for inspecting the engine oil level using the dipstick.

ENGINE OIL REPLACEMENT

Remove

Lists components to remove for oil replacement.

Install

Lists components to install during oil replacement.

ENGINE OIL PRESSURE INSPECTION

Inspect

Procedure for inspecting oil pressure.

Inspection steps

Step-by-step guide for checking oil pressure.

TRANSMISSION OIL REPLACEMENT

Remove

Lists parts to remove for transmission oil replacement.

Fill

Specifies the oil quantity and type for refilling.

Install

Lists components to install after oil replacement.

SPARK PLUG INSPECTION

Inspect

Instructions for inspecting the spark plug's electrode and insulator.

Measure

How to measure and adjust the spark plug gap.

EXHAUST SYSTEM INSPECTION

Inspect

Details inspection of nuts, bolts, and gaskets for leaks.

AIR FILTER CLEANING

Inspect

How to inspect the air filter element for damage.

Clean

Method for cleaning the air filter element.

CRANKCASE FILTER CLEANING

Inspect

How to inspect the crankcase filter element.

Clean

Method for cleaning the crankcase filter element.

COMPRESSION PRESSURE MEASUREMENT

Measure

Procedure for measuring compression pressure.

IGNITION TIMING CHECK

Attach

How to attach timing light and tachometer.

FRONT/ REAR BRAKE ADJUSTMENT

Check

How to check brake lever free play.

Adjust

Procedure for adjusting brake lever free play.

BRAKE FLUID LEVEL INSPECTION

Inspect

How to inspect the brake fluid level.

BRAKE PAD INSPECTION

Inspect

How to inspect front brake pads for wear.

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

Air bleeding steps

Detailed steps for bleeding the hydraulic brake system.

FRONT FORK INSPECTION

Check

How to check the fork's operation.

REAR SHOCK ABSORBER INSPECTION

Check

How to check the rear shock absorber mount for looseness.

REAR SHOCK ABSORBER ADJUSTMENT

Adjust

Detailed steps for adjusting spring preload using the adjuster ring.

TIRE INSPECTION

Measure

How to measure tire inflation pressure.

WHEEL INSPECTION

Inspect

How to inspect wheels for damage or bends.

Inspection and Maintenance of Electrical System

Charging system

Focuses on the battery and charging system.

1. Battery/Charging System

1.1 Preparing documents

Notes and precautions for battery maintenance.

1.2 Failure diagnosis

Identifies potential issues and causes in the battery/charging system.

1.3 Battery

Details battery disassembly and handling.

1.4 Charging system

Covers charging system checks and tests.

1.5 Voltage/current regulator

Explains checks for the voltage/current regulator.

1.6 Magneto charging coil

Details how to check the magneto charging coil.

1.7 Magneto disassembly

Steps for magneto disassembly and installation.

2. Ignition System

2.1 Preparing documents

Notes and preparation for ignition system checks.

2.2 Failure diagnosis

Identifies ignition system failures and causes.

2.3 Ignition system check

Procedures for checking the ignition system.

2.4 RELATED PARTS Group

Checks components of the ignition system.

2.5 Ignition coil

Covers ignition coil disassembly and checks.

2.6 Trigger

Details trigger checks and measurements.

3. Starter System

3.1 Preparing documents

Notes and preparation for starter system checks.

3.2 Failure diagnosis

Lists starter system failures and causes.

3.3 Starter motor

Covers starter motor disassembly, breakdown, and assembly.

3.4 Starter relay

Details starter relay checks.

4. Bulbs/Switches/Meters

4.1 Preparing documents

Notes for preparing to measure switch conduction.

4.2 Failure diagnosis

Lists common causes for lights not working.

4.3 Replacement of the Headlamp Bulbs

Procedure for replacing headlamp bulbs.

4.4 Replacement of Front Steering Lamp Bulbs

Procedure for replacing front steering lamp bulbs.

4.5 Replacement of tail lamp bulbs

Procedure for replacing tail lamp bulbs.

Inspection and Maintenance of Vehicle

Front Disc Brake

Specifications for the front disc brake diameter and thickness.

Rear Disc Brake

Specifications for the rear disc brake diameter and thickness.

5. Brake

5.1 Maintenance instruction

General notes for brake maintenance.

5.2 Failure diagnosis

Common brake issues and their causes.

5.3 Front Brake Assy.

5.3.2Check

How to check brake pads and rotor for wear.

5.4 Rear Brake Rotor

5.4.2 Check

How to check rear brake pads and rotor for wear.

6. Body

Body Panel Components

Identification of various body panels and covers.

Front Wheel

Front Suspension

Handlebars

7. Front Wheel/Front Suspension

7.1 Preparing documents

Notes for preparing front wheel removal and suspension checks.

7.2 Failure diagnosis

Lists common issues with steering and wheel rolling.

7.3 Front wheel

Covers front wheel specifications and checks.

7.4 Steering handle

Details steering handle specifications.

7.5 Front fork

Covers front fork specifications and checks.

7.6 Radiator/Reserve Bottle Assembly

7.6.1 Disassembly

Steps for removing the radiator and reserve bottle.

7.6.2 Check

How to check the coolant level and radiator condition.

Rear Wheel/Rear Suspension

8. Rear Wheel/Rear Suspension

8.1 Preparing documents

Notes for preparing rear wheel and suspension checks.

8.2 Failure diagnosis

Lists common issues with rear wheel shimmy and absorber.

8.3 Rear wheel

Covers rear wheel specifications and disassembly.

8.4 Rear absorber/Rear Swing Arm

8.4.1 Disassembly of the rear absorber

Steps for disassembling the rear absorber.

8.4.2 Installation

Steps for installing the rear shock absorber.

Check and Maintenance of the Engine

Table of Torque Force of Engine Fasteners

Lists tightening torque values for engine fasteners.

Lubricating system diagram

9. Lubricating System

9.1 Preparing Documents

Notes and preparation for lubricating system checks.

9.2 Failure diagnosis

Lists lubrication system failures and causes.

9.3 Oil pump

Disassembly

Steps for disassembling the oil pump.

Check

How to check radial clearance of oil pump rotors.

Cooling System

10. Cooling System

10.1 Preparing Documents

Function and specific cooling circuit of the system.

10.2 Failure Diagnosis

Lists common cooling system failures.

10.3 Water Pump

Steps for water pump disassembly and installation.

Cylinder Head/Valves

11. Cylinder Head/Valve

11.1 Preparation documents

Function of the cylinder head and preparation notes.

11.2 Failure Diagnosis

Lists low and high compression pressure issues.

Cylinder Body and Piston

12. Cylinder Body and Piston

12.1 Preparation Documents

Function of cylinder body/piston and preparation notes.

12.2 Failure diagnosis

Lists low/high compression and white smoke issues.

Driving Disc / Clutch / Driven Wheel

13. Driving Disc / Clutch / Driven Wheel

13.1 Preparation documents

Function and notes for the driving disc/clutch system.

13.2 Failure diagnosis

Lists common issues with the driving disc/clutch system.

Transmission

14. Transmission

14.1 Preparation documents

Function of the transmission system.

14.2 Failure diagnosis

Lists common transmission failures.

15. Crankcase

15.1 Preparation Documents

Function and notes for the crankcase.

15.2 Failure diagnosis

Lists common crankcase noises.

Inspection and Maintenance of Emission Control System

Muffler

Lists components of the muffler assembly.

16. Emission control system

16.1 Emission Control System Recognizance

Conformance to EU emission standards and warranty.

16.2 Regular Maintenance Notes

Notes on maintaining emission standards, fuel, and maintenance schedule.

16.3 Mechanical Function of the Exhaust Gas Control System

How the exhaust gas control system functions.

16.4 Catalytic Transfer System

Description of the catalytic converter system.

Measures When the Idle Speed Emission Value Exceeds the Standard

Inspection and Maintenance of Electronic Fuel Injection (EFI) System

17.Electronic Fuel Injection System

Electronic Fuel Injection System

Introduction to the EFI system.

Components of Electronic Fuel Injection System

Lists components of the EFI system.

Failure Diagnosis

Common EFI system failures.

Common Troubleshooting

General troubleshooting advice for EFI.

17.2.1 Engine Controller (MT05 ECU)

17.2.1.1 ECU Appearance

Shows the appearance and label of the ECU controller.

17.2.1.2 ECU Definition of ECU Connector Pin

Defines the function of each connector pin on the ECU.

17.2.1.3 Circuit Diagram of Electronic Injection System

17.2.1.4 Installation requirements

17.2.1.5 Maintenance Instructions

17.2.2 Fuel injectors

17.2.2.1 General working principle

Explains how a fuel injector works.

17.2.2.2 Appearance of the fuel injector

Shows the appearance of a fuel injector.

Check

Procedures for checking fuel injector blockage, leakage, and coil resistance.

17.2.2.3 O-ring

Details O-ring specifications for fuel injectors.

17.2.2.11 Installation Requirements

17.2.2.14 Fuel Injector Blocked

17.2.2.15 Cleaning

17.2.3 Throttle Valve

17.2.3.1 General Working Principles

Explains the function of the throttle valve system.

17.2.3.2 Appearance

Shows the appearance of the throttle valve assembly.

17.2.3.5 Disassembly of the Throttle Valve

Check

17.2.3.6 Cleaning

17.2.3.7 Installation of the Throttle Valve

17.2.3.8 Precautions

17.2.4 Water Temperature Sensor

17.2.4.1 General Working Principle

Explains how the water temperature sensor works.

17.2.5 Intake Air Temperature Sensor

17.2.5.1 Working Principle

Explains how the intake air temperature sensor works.

17.2.6 Intake Pressure Sensor

17.2.6.1 Working Principle

Explains how the intake pressure sensor works.

17.2.7 Oxygen Sensor

17.2.7.1 Working Principles

Explains how the oxygen sensor works.

17.2.8 Ignition Coil

17.2.8.1 Working Principles

Explains the function of the ignition coil.

17.2.9 Fuel Pump Assembly

17.2.9.1 Working Principles

Explains how the fuel pump assembly works.

17.2.9.6 Failure Diagnosis of Fuel Pump Assembly

17.2.9.9 Replacing the Pressure Regulator

17.2.9.10 Fuel Leakage Inspection Procedures

17.3Methods for Fault Diagnosis and Maintenance

MT05 Fault Code List

17.3.2 Fault Diagnosis by Diagnostic Apparatus

17.3.3 Fault Diagnosis with the Diagnostic Software PCHUD

Instructions of PCHUD Software

17.4 Common Troubleshooting

17.4.1 Repair Tools

Lists essential tools for electronic control system repair.

17.4.3 Concise Fault Removal Techniques

17.4.3.1 Daily Use and Maintenance

Recommendations for daily use and maintenance.

17.4.3.2 Fault Description- Startup Failure

Troubleshooting steps for startup failures.

17.4.3.4 Fault Description- Unstable Idle Speed

Checks for idle speed bypass bolt and oil pipeline leaks.

17.4.3.5 Fault Description- Too High/Low Idle Speed

Troubleshooting for abnormal idle speeds.

17.4.3.7 Fault Description-Poor Acceleration

Checks parameters, fuel, exhaust system, and trouble lights.

17.4.3.10 Fault Description- Abnormally High Oil Consumption

Checks oxygen sensor and oil leakage for high oil consumption.

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