Benelli Tornado TNT600, Owner'S Manual

Page 1: ......

Page 2: ...1 OWNER S MANUAL 2013 ...

Page 3: ...2 ...

Page 4: ...AD 24 USAGE INSTRUCTION 25 FUEL 25 ENGINE OIL 26 BREAKING IN 26 CHECK BEFORE RIDING 27 DRIVING OF MOTORCYCLE 29 STARTING 30 USING GEAR SHIFTING MECHANISM 30 DRIVING ON THE SLOPE 30 USING BRAKE AND STOPPING 30 INSPECTION AND MAINTENANCE 32 MAINTENANCE SCHEDULE 32 ENGINE OIL 34 SPARK PLUG 35 ADJUSTMENT OF ACCELERATOR CABLE WIRE 36 ADJUSTMENT OF CLUTCH 37 ADJUSTMENT OF IDLING SPEED 38 THROTTLE BODY 3...

Page 5: ... the maintenance procedures which would ensures the maximum performances and highest durability of your motorcycle service Benelli is equipped with professional technical service personnel and department which is able to provide you with highest quality technical services Insisting in the principle of customer first Benelli makes great efforts to develop the products quality and performances so th...

Page 6: ...on the following IMPORTANT NOTES Note This is for the maintenance or more important events explanations Caution This is for the operating specifications of the motorcycle Warning This is for the important procedures that may endanger safety of the rider or would bring injuries if ignored The User Instruction should be considered as a permanent manual for the motorcycle Please give it to the new ow...

Page 7: ...the motorcycle to our Authorised Service Center to have it check and repair SPECIAL ATTENTION The motorcycle must be equipped with a specify fuse only to avoid any serious damage or accident Always ensure the positive and negative lead of the battery are properly install Never install in reverse order When reversely installed please check the condition of the fuse Before replace the fuse please tu...

Page 8: ...not jump queues 5 Speeding is one the key reasons of the accidents So keep the speed within the limit 6 Turn on the signal lamp so as to be noticed by others when tuning the corner or changing a drive lane 7 Ride carefully on a crossway passageway of a parking lot and on highway 8 Any modification disassembly of the spare parts would affect the safety driving and maintenance 9 The installation of ...

Page 9: ...be trapped by the control lever foot pedal starting equipment pedals or wheels during driving Protective helmet that conforms to the safety quality standard is the primary protective gear in driving The most serious accident is head injury Please wear protective helmet and protective glasses as well Pay special attention in rainy days as the road is wet and the brake distance is two times as of th...

Page 10: ... numbers for the possible uses in the future 1 The frame number is printed in the right side of head tube 2 Product nameplate is riveted on the head tube 3 The engine number is printed on lower part of the right case of engine crank case SERIAL NUMBER VEHICLE IDENTIFICATIONS NUMBER VIN ENGINE NUMBER Please write down the numbers for your references 1 2 3 ...

Page 11: ...ATION OF PARTS BODY PARTS 1 Clutch Lever Left 2 Left Handle Switch 3 Clutch Lever 4 Fuel Tank Lock 5 Meter 1 2 3 4 5 6 7 8 9 10 6 Right Handle Switch 7 Right Side Mirror 8 Front Brake Lever 9 Throttle 10 Fuel Tank ...

Page 12: ...11 1 Rear Brake 2 Rear Foot Pedal 3 Front Foot Pedal 4 Rear Brake Pedal 5 Fuel Oil Observation Hole Side Stand 6 Front Brake 1 2 3 4 5 6 ...

Page 13: ...12 1 Front Brake 2 Gear Shift Pedal Lever 3 Front Foot Pedal 4 Side Stand 5 Rear Foot Pedal 1 2 3 4 5 ...

Page 14: ...gnal Lamp Indicator Light High Beam Indicator Light Engine Lubricant Neutral Gear Indicator Light Function Button Fuel Oil Level Indicator Tachometer Odometer Temperature Speedometer Time Display x1000rpm FI TRIP km h km C CLOCK E F N METER PANEL ...

Page 15: ...transmission is on neutral position the neutral gear indicator light will be on 6 Function button 7 Tachometer Tachometer indicates the revolution of engine 8 Temperature 9 Speedometer Speedometer indicates the driving speed km hour 10 Time display 11 Fuel oil level indicator 12 Odometer TRIP or ODO function on the odometer can be chosen as required TRIP An odometer than can be zero cleared record...

Page 16: ...ion when the vehicle parks at roadside at night the key turns to position the key can be taken out now the rear lamp parking lamp will be kept on Lock position turn the key counter clockwise to position the lock will extend out the lock core to lock OPERATION PROCEDURES POWER LOCK Lock the turn direction and take out the key to prevent from being stolen Turn and confirm the lock Do not park in the...

Page 17: ...16 LEFT HANDLE Clutch Handle Headlamp High Low Beam Turn Signal Lamp Switch Horn ...

Page 18: ... low beam will be on Use low beam light when driving in the downtown or in front of vehicles so as not to influence the vision of other people Turn signal lamp switch Press the left turn signal lamp switch the left turn signal light will flash At the same time the green turn indicator light in the instrument panel will flash too Turn the turn signal lamp switch to the middle position to cancel the...

Page 19: ...18 RIGHT HANDLE Front Brake Handle Hazard Warning Lamp Button Engine Off Switch Accelerator Control Handle Electric Starting Switch ...

Page 20: ...and the engine can not start Hazard warning lamp button Electric starting switch Press the electric starting switch the electric motor will run and the engine can start Accelerator control handle The accelerator control handle is used to control the speed of engine Turn the handle facing the driver to accelerate turn the handle reversely to decelerate Front brake handle Grasp the right brake handl...

Page 21: ...f position Do not forget to lock the fuel tank cover after filling to prevent the fuel evaporating into the air which will waste the energy and pollute the environment No smoking or naked lights when filling If the fuel overflow and enter into the canister or other parts please see your authorised Service Center soon to clean or replace the canister because too much fuel entering into the canister...

Page 22: ...ween the low speed gear and two speed gear step down the gear shifting lever from the neutral position to select the low speed gear use the tiptoe to move the gear shifting pedal upward or use the heel to step down to change into the next high gear use the tiptoe to step the gear shifting lever to change into the next low gear GEAR SHIFTING PEDAL LEVER ...

Page 23: ...22 Step down the rear brake pedal as shown in the Figure to put into gear of rear brake when operating the rear brake the brake lamp will be on REAR BRAKE PEDAL ...

Page 24: ...nd is located at the left side of the vehicle please use your foot to shift the stand into proper position when stopping SIDE STAND Do not put the vehicle at the declinational slope otherwise the vehicle may overturn ...

Page 25: ...o bear different situations and road conditions as required by the driver There are five positions for adjustment available Use the kick stand to support the motorcycle properly and turn the spring adjusting ring to the needed position REAR SUSPENSION PRELOAD ...

Page 26: ...fuel of common grade may be used which should be replaced USAGE INSTRUCTION Using lead free fuel or low lead fuel can extend the service life of the spark plug When the transmission is on neutral position the indicator light will be on the rider should loose the clutch lever slowly to confirm if the transmission is at the neutral position FUEL ...

Page 27: ...g the first 1 000km driving period do not operate the throttle when it is fully open at the same time change the gear appropriately to prevent the engine being over pressurized Careful operation of the new motorcycle during the breaking in period will be greatly useful to extend the service life of the motorcycle Special attention In the first 500km of breaking in is important to replace the engin...

Page 28: ... Revolve smoothly 3 No axial float and loose 1 proper air pressure 2 proper lug depth 3 no fissure or cut 1 Enough fuel storage to drive the planned distance 1 Operate all the lamps headlamp rearlamp brake lamp instrument panel lamp and steering lamp etc 1 proper clearance between the handle and brake pedal 2 no feeling of braking ineffective braking 3 no oil leaking CHECK BEFORE RIDING ...

Page 29: ...ht gear indicator light turn signal indicator light Function normally The oil level is proper 1 Proper accelerator cable clearance 2 Smooth fueling and quick fuel cut off 1 Proper cable wire clearance 2 Smooth operation 1 Proper degree of tightness 2 Properly lubricating Check the electrolyte level and add the electrolyte as needed ...

Page 30: ...ide the fuel necessary to start the engine in accordance with the ambient temperature and the engine condition Grasp the clutch handle and start the engine when the transmission is on the neutral position Do not over run the engine when not driving for it will make the engine overheated and may damage the internal parts of the engine Do not start engine in poorly ventilated places Do not leave the...

Page 31: ...e rider should decelerate and make the engine to run within the normal running range When climbing steep slope the motorcycle will begin to decelerate and seem to be underpowered the rider should change into the lower gear then the engine can operate within its normal power range Please shift the gear quickly to prevent the motorcycle to lose speed When on downhill please shift the engine into low...

Page 32: ... please put the motorcycle into first gear to prevent skidding and shift the gear back into the neutral position before starting the engine Turn the ignition switch to off position to stop the engine and take down the ignition key from the switch Using only the front brake or the rear brake is dangerous which will cause slid or lose of control Use the brake carefully and slightly when riding on th...

Page 33: ...ns The steering gear system support and wheel system are key components which require carful maintenance of specialized technical personnel For the sake of safety we recommend you to contact your authorised Service Centre to perform these job I Inspection cleaning adjustment lubricating or replacement C Cleaning R Replacement A Adjustment L Lubricating INSPECTION AND MAINTENANCE MAINTENANCE SCHEDU...

Page 34: ... Passage I I I Spark Plug I R I 35 Air Throttle Operation I I I 36 Engine Oil R at 1st 500KM 1000KM and then every 5000KM Per 1000KM I L A Oil Filter C C C Valve Clearance I I I I 34 Air Filter Note 1 C C C 49 Oil Filter Screen Wearing of Brake Disc Suspension System Drive Chain Clutch Equipment Brake Switch Wheel Wheel Rim Note 3 Note 3 C I I C I I I I I C I I I I I C I I I I I 45 40 37 Engine Id...

Page 35: ...to watch if the oil level is within the scale range When the oil level is below the lower scale mark please open the upper oil filler cap and add the oil to the upper scale mark ENGINE OIL Replacing the engine oil when the temperature of the engine is warmed Fix the frame with the central support bar to ensure the engine oil is drained quickly and completely ...

Page 36: ... gap measuring plate to readjust the spark plug electrode gap and keep it within 0 6 0 7mm Replace the spark plug after every 8000km driving SPARK PLUG The spark plug shouldn t be screwed too tight to make the thread damage in case of damaging the thread of cylinder cover Don t let any other subjects to fall into the engine when disassembling the spark plug ...

Page 37: ...osition to fully closed position 2 Measure the free play of throttle control pull button at the air throttlemanually operated pull button flange The standard free play should be 10 15 Unscrew the locking nut 1 and turn the regulator 2 to adjust the free stroke ADJUSTMENT OF ACCELERATOR CABLE WIRE ...

Page 38: ...the free play should be 10 20mm If the free play is improper please adjust it in accordance with the following procedures 1 Loose the locking nut 2 Screw in or screw out the adjusting screw adjusting nut making the free play of clutch meet with the specified requirement 3 Screw up the locking nut ADJUSTMENT OF CLUTCH ...

Page 39: ...do not over screw the adjusting screw counter clockwise otherwise the idling speed will decrease instead and be unstable 3 Please cut off the engine after adjustment and restart after three 3 seconds after two minutes stable operation please confirm the idling running again Start the engine to warm up it during the idling After that close the accelerator and adjust the idling screw knob to keep th...

Page 40: ...g the throttle body remove the accelerator stay and the hose connected with air filter and intake manifold then remove the throttle body Open the cover at the bottom of throttle body spray the detergents onto the inner wall of throttle body and brush away the dirt and carbon deposit After cleaning please operate in reverse order to install the throttle body and ensure the proper installation of al...

Page 41: ...ting conditions frequent maintenance must be given Adjustment of drive chain After each 1000km s driving please adjust the drive chain and make the chain free play be 10 20mm The chain needs to be adjusted frequently according to your driving conditions DRIVE CHAIN The recommendation above is the maximum adjustment time interval actually the chain should be checked and adjusted before each riding ...

Page 42: ...the tightness of the chain The front and rear chain wheel should be kept aligned when adjusting the chain There are reference marks on the swinging arm and each chain adjustor to help you to carry out the adjustment These reference marks can be aligned mutually and be the reference from one end to the other end After aligning and adjusting the tightness of chain to 10 20mm please retighten the rea...

Page 43: ... replacing the new chain please check if the two chain wheels are worn Please replace if necessary The chain connector is clipped between the open end please install against the moving direction Chain Connector ...

Page 44: ...chain link 5 Excessive damage 6 Adjustment of loose chain Please check the following conditions of the chain wheel 1 Over worn wheel tooth 2 Broken or damaged wheel tooth 3 Loose chain wheel retaining nut Lubrication of Drive Chain Apply chain lube or soak all the chain links and make the lubricant go through the chain plate pin bushing and roller ...

Page 45: ...fe driving Please remember to check the braking system regularly and this check should be carried out by qualified distributors Adjustment of Brake 1 The free play of front brake handle ends should be 10 20mm 2 Measure the moving distance of brake pedal before and after the brake works The free play should be 20 30mm BRAKE 10 20mm ...

Page 46: ...ck if the disc is worn to the limit mark Please replace it with a new brake disc if worn to this mark Brake fluid If the liquid level is lower than the LOWER mark the recommended brake fluid should be added Adding brake fluid is one of the important items in regular maintenance ...

Page 47: ...ced together The motorcycle use DOT3 or DOT4 brake fluid Take care not to allow brake fluid to get into with paint surface or plastic surface because these surfaces will be corroded If the braking system or brake disc of your motorcycle needs to be repaired we recommend that the repair should be carried out by authorised distributors They are equipped with complete tools and proficient skills whic...

Page 48: ...n may cause tire skidding Driving motorcycle when the tires are over worn is very dangerous the over worn tires are unsuitable for ground adhesion and driving The proper tire pressure will ensure the maximum stability comfortable driving and durability of tire Please check the tire pressure regularly and adjust it as needed Please change a new tire when the tread depth of the central tire thread i...

Page 49: ...s some in the oil accumulation pipe Discharge approach loosen the clamp and move upward take out the drain plug from the pipe and discharge all the oil stored in the pipe and then plug in the drain end and finally loosen the clamp move downward and clamp the drain end tightly OIL ACCUMULATION PIPE ...

Page 50: ...e right front of the motorcycle 2 Remove the air filter side cover and take out the filter cartridge of air filter 3 Wash the air filter cartridge in the clean washing oil and make it fully dry 4 Fully immerse the filter cartridge into the clean gear oil and then squeeze out the excess oil 5 Install every part in the reverse order of dismantling SERVICING OF AIR FILTER ...

Page 51: ...ail gas of motorcycle including carbon monoxide hydrocarbon and nitrogen oxide etc into non toxic carbon dioxide water and nitrogen through chemical reaction Since the catalytic converter is very important the defective catalytic converter will pollute the air and damage the performance of the engine if the replacement is needed please use the genuine parts CATALYTIC CONVERTER The catalytic conver...

Page 52: ...to the air and be fuel saving and environment friendly at the same time There is a port on the fuel pump and the fuel goes through the fuel filter and reaches fuel injector and finally the fuel will be injected into the inlet air pipe The connection method of fuel inlet and fuel return pipe is shown in the graph as below The port in the upper end of fuel pump is connected to the port in the top of...

Page 53: ...ey points of lubrication maintenance are seen as bellows Lubricating oil for motorcycle Y Lubricating Grease Z 1 rear brake pedal shaft Z 2 speedometer flexible Y 3 Speedometer gear and gear shaft bearing Z 4 Kick stand support joint and spring hook Z 5 Gear shifting pedal lever pin shaft Z 6 Accelerator Y 7 Front brake handle pin shaft Z 8 Clutch handle pin shaft Y LUBRICATION OF PARTS The lubric...

Page 54: ...ded When the new storage battery is used for the first time it should be initially charged after filling electrolyte This should be operated by the distributors Please connect the wire poles correctly positive lead red wire must be connected to the positive terminal while negative lead black wire to negative terminal and tighten the terminal bolt Please use the wire brush to clear away the corrosi...

Page 55: ... of insufficient storage battery electrolyte will lead to sulfurization and damage the storage battery plate Please make sure that the vent pipe is connected to the storage battery vent when checking the storage battery plate and filling distilled water Please do not squeeze bend or twist the vent pipe or place the vent pipe port against the parts so as not to erode the parts Only used distilled w...

Page 56: ...ding cap cover and use a small plastic funnel to add the distilled water into the upper level mark UPPER LEVEL Please make sure that the vent pipe is connected to the storage battery vent when checking the storage battery plate and filling distilled water Please do not bend or twist the vent pipe Make sure the vent pipe port is facing the ground not facing the parts otherwise the storage battery e...

Page 57: ... The electrolyte is toxic so keep it away from children Take down the storage battery to check or to add electrolyte based on the steps as below a Turn off the motorcycle power switch b Remove the cushion first c Remove the install screw d Remove the negative terminal and remove the positive terminal e Take out the storage battery gently Install the storage battery in the reverse order of dismantl...

Page 58: ...e storage battery There should be short circuit or circuit overload if the blowout of fuse happens frequently Please entrust the Sales Distributor to repair as soon as possible Replacement of bulbs When replacing the bulbs the bulbs of the same rated power and specification must be used If a bulb of different rated power is used the circuitry may be overloaded and the bulb damaged ...

Page 59: ... the fuel tank and the fuel injection unit 4 Remove the spark plug and inject one spoon 15 20cm3 of clean engine oil into the cylinder then install the spark plug again The gasoline will deteriorate if stored in the fuel tank for a long time the deteriorated fuel will cause difficult starting The gasoline is extremely inflammable and may explode under certain conditions Please do not smoke or make...

Page 60: ...he place with no heat and moisture and having the minimum temperature variation Please do not keep the motorcycle in the environment of direct sunlight Use after storage Take off the covered materials and clean the motorcycle If the motorcycle is stored for more than 4 months please replace the engine oil Check the storage battery electrolyte level and charge and install properly as required Pleas...

Page 61: ...bing ability Carrying capacity Fuel injection unit 800mm Hydraulic Spring Type fly wheel permanent magnet 1 4L 1 4L 1 4L 12V Engine Size Frame Electric System Capacity Key Properties Wheel Base Rear Braking Type Rear lamp brake lamp 1480mm Pedal Braking 12V LED Cylinder Bore x Stroke Sparking Mode Primary Reduction Ratio Maximum Power Clutch Starting Mode First Gear Transmission Ratio Third Gear T...

Page 62: ...61 NOTES ...

Page 63: ...62 NOTES ...

Page 64: ......