TNT300

0TNT300ServiceManual1PrefaceThismaintenancemanualwhichispreparedbytheBenelliCompanyisintendedfortheusebyBenellidealersandprofessionalmaintenancepersonnel.Notalltheserviceinformationrelatedtomotorcyclesisincludedinthismanual,soitisusedonlyforrepairingandmaintainingBenellimotorcycles,tolearntheprinciples,maintenanceproceduresandmaintenancetechnologiesofthesemotorcycles.WehopethatthepersonwhousesthismanualforrepairingandmaintainingaBenellimotorcyclehasabasicknowledgeofmotorcyclemachineryandthenecessaryproceduresforrepairandmaintenanceofmotorcycles.Theassemblymaybeconductedimproperlywhenrepairingmotorcyclesanddangersmaybecausedafterassemblywithoutthisknowledge.ThismanualisonlyforreferenceduringrepairandmaintenanceoftheTNT300motorcycle.TheBenelliCompanywillcontinuetoredesignandimprovethistypeofmotorcycle.ModificationsormajorchangesinproductspecificationswillbeannouncedtoallBenelliauthorizeddealers,andcompiledinthelaterversionofthismaintenancemanual.Note:Designsandspecificationsaresubjecttochangewithoutpriornotice.2ImportantInformationinThisMaintenanceManualThefollowingimportantitemsareincludedinthismanual:Warning:Ifthissymbolispresent,failuretofollowtheinstructionsmaycausesevereinjuriesandevendeathtomotorcyclists,peoplenearbyortheonewhoisrepairingthemotorcycle.Important:“Important”meansspecificpreventivemeasurestoavoiddamagingthemotorcycle.Note:“Note”meansimportantinformationwhichcanmakeproceduresmuchsimplerandeasiertocomplete.3UserGuideThismanualisapracticalreferenceguidewhichiseasytooperateandusebytechnicians.Instructionsfor:assembly,removal,disassembly,repairandcheckofallofthecomponentsareinsequence,onestepatatime.1.Eachchapterisdividedintoseveralsections,theheadlineincludedonthetopofeachpageexplainswhatsectionofthevehicleisbeingrepaired.2.Inordertobetteridentifypartsandmakedifferentprocessesclearer,breakdowndrawingsareofferedatthestartofeachsectioninvolvingallpartsinthedisassembly.3.Operatingsequencesarelistedonbreakdowndrawings,andthesequencesarenumberedonebyone.Eachnumberreferstoeachstepduringthedisassembly.4.Partsthatneedtobelubricatedwhenchangedaresymbolized.Pleaserefertothe“Symbol”section.5.BreakdowndrawingsareequippedwithatablewithIDnumbers,includingoperatingsequence,partname,precautionforwork,etc.6.Describeanyotherrequiredinformation(suchasspecialtoolsandtechnicaldata)insequence.4ExhaustEmissionControlInformationInordertoprotectourenvironment,BenelliCompanyhasintroducedprovisionsthatconformtoenvironmentalprotectionregulationsofChina,EuropeandtheUnitedStates.Thismotorcycleisequippedwith(1)crankcaseblow-bygasfilteringsystem,(2)exhaustemissioncontrolsystemand(3)fuelevaporationrecoverysystem.1.Crankcaseblow-bygasfilteringsystemThissystemcanpreventgasinthecrankcasefrombeingdischargedintotheenvironment.Thegasinthecrankcaseispumpedintoairinletsonbothsidesoftheenginebyanoilseparator.Whentheengineisrunning,thegasispumpedintothecombustionchamber,andthencombustswithairandfuelpumpedoutofthefuelinjectionsystem.2.ExhaustemissioncontrolsystemThissystemcanreducethenumberofpollutantsfromexhaustgasfromthistypeofmotorcycleintotheenvironment.Fuelinjectionsystem,ignitionsystemandexhaustsystemofthistypeofmotorcyclehavebeencarefullydesignedandassembledtohavefuelefficientenginesandlowquantityofpollutantsdischarged.Acatalyticconvertersystemisincludedonthistypeofmotorcycle.3.FuelevaporationrecoverysystemFuelvaporinthefuelinjectionsystemwillnotbedischargedintotheenvironment,ratherispumpedintotherunningenginetobecombusted.Iftheengineisnotstarted,thevaporwillbestoredinacharcoalcanister.Ifitisliquidfuel,itwillbepumpedintoseparators,andthenbackintothefueltank.Warning1.Beforefinalbuyerspurchaseorreceiveanymotorcycleormotorcycleengine,nooneshalldisassembleordestroyanypartsmountedonthemotorcycleormotorcycleenginebasedontheprovisionsofthismanual;anymanufacturerordealershallnotdeliberatelydisassembleordestroyanypartsafteranymotorcycleormotorcycleengineissoldordeliveredtothefinalbuyer.2.Afteranymotorcycleormotorcycleengineissoldordeliveredtothefinalbuyer,anyonewhoisengagedinrepairing,maintaining,selling,leasingortradingmotorcyclesormotorcycleengines,ormanagingmotorcycleteamsshallnotdisassembleordestroyanypartsmountedonthemotorcyclesormotorcycleenginesbasedontheprovisionsofthismanual…”Remarks“Disassemblingordestroyinganyparts”isgenerallydefinedasfollows:1.Temporarilydisassemblinganypartsorthesituationinwhichthepartscannottemporarilyrunfortherepairingpurposedoesnotbelongto“refit”.2.Thefollowingsituationsbelongto“refit”:a)Improperlyadjustmotorcyclepartstomakeitsexhaustgasdischargedexceedemissionstandards.b)Useofreplacementpartsoraccessoriesthatimpacttheperformanceordurabilityofthemotorcycle.c)Addpartsoraccessoriestomakemotorcyclesexceedemissionstandards.d)Permanentlydisassemble,separateordestroyanypartsonexhaustemissioncontrolsystems.Itissuggestedthatalldealersshouldabidebytheabovementionedprovisionsforconformitywithlocallaws.5SymbolsSpecificSymbolsGeneralInformationSpecificationsCheckandRegularAdjustmentChassisEngineCoolingSystemFuelSystem