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Workshop
Manual

Premise

This manual contains an introductory description of the Benelli Tornado Three together
with the procedures for control/intervention and revision of the main components.
Information considered generally noted is not included.
This manual will help you to understand the motorcycle better in order to provide the
client with a rapid and trustworthy service.

* The present manual has been prepared on the basis of state-of-the-art
specifications valid at the date of publication. In the case of modifications
carried out after this date, differences may exist between the contents of the
manual and the motorcycle under review.
* The illustrations in this manual are used to highlight the fundamental principles
and procedures of basic interventions. They may not show exactly the
motorcycle in your possession.
* This manual has been written for people who have the knowledge, the technical
skill and the instruments, including the special, for servicing Benelli motorcycles.
If you do not possess the necessary training and tools, have repairs made at
an authorised Benelli concessionaire.

WARNING
Inexpert mechanics or those lacking appropriate instruments and apparatuses
may not be able to carry out the operations described in this manual.
Incorrect repairs can cause damage to the mechanic and render the motorcycle
unsafe for the driver and passenger.

2

UK

MF10

Introduction

SYMBOLS
The symbols listed below are all present inside the manual and serve to show those
parts which need to be given special attention.
WARNING - indicates a grave danger for the safety of people and/or
the integrity of the vehicle.

OILING - Indicates the type of oil to use.

TIGHTENING - Indicates the correct tightness value to carry out.

SPECIFIC VALUE - indicates the specific value using precision
instruments.

SPECIFIC INSTRUMENTS - indicates the specific instruments to
use.

MF10

UK

3

CONTENTS

1

GENERAL INFORMATION

1.1

VEHICLE IDENTIFICATION

11
11

1.2
1.3

IMPORTANT INFORMATION
SPECIAL INSTRUMENTS

11
12

1.3.1
1.3.2

13
15

2

SPECIFICATIONS

17

2.1
2.2

GENERAL SPECIFICATIONS
ENGINE TECHNICAL CHARACTERISTICS

17
17

2.3
2.4

FRAME CHARACTERISTICS
ELECTRICAL COMPONENTS

19
22

2.5

BOLT TORQUE
2.5.1
GENERAL BOLT TORQUE

24
24

2.5.2
2.5.3

25
31

FRAME BOLT TORQUE
ENGINE BOLT TORQUE

2.6

POINTS TO OIL

34

3

PERIODIC CHECKS AND ADJUSTMENTS

3.1

INTRODUCTION

49
49

3.2

CHECK SPARK-PLUGS
3.2.1
INSTALLING SPARK-PLUGS

53
54

3.3
3.4

CLEANING AIR BOX
GAS CONTROL PLAY

54
55

3.5

3.4.1
CLUTCH
ADJUSTING CLUTCH LEVER PLAY

56
56

3.6
3.7

ADJUSTING CO
ADJUSTING THROTTLE HOUSING

57
59

3.8
3.9

CHECKING STEPPER
ADJUSTING VALVE PLAY

62
63

3.10
3.11

ENGINE DISTRIBUTION
CHECKING ENGINE OIL LEVEL

64
70

3.12
3.13

CHANGING ENGINE OIL AND FILTER
CHECKING COOLING LIQUID LEVEL

71
74

3.14
3.15

CHANGING REFRIGERANT LIQUID
FILLING COOLING PLANT

75
77

3.16
3.17

CHECKING EXHAUST TUBES
CHECKING EXHAUST PLANT

79
79

3.18
3.19

ADJUSTING FRONT BRAKE LEVER
ADJUSTING REAR BRAKE LEVER

79
80

3.20
3.21

CHECKING BRAKE LIQUID
CHANGING FRONT AND REAR BRAKE PADS

80
81

3.21.1
3.21.2

CHANGING FRONT BRAKE PADS
CHANGING REAR BRAKE PADS

82
82

CHECKING BRAKING PLANT TUBES
PURGING FRONT/REAR BRAKING PLANT

83
83

3.23.1
3.23.2

83
85

3.22
3.23

3.24
3.25

4

SPECIAL ENGINE INSTRUMENTS
SPECIAL FRAME INSTRUMENTS

PURGING REAR BRAKING PLANT
PURGING FRONT BRAKING PLANT

ADJUSTING GEAR CONTROL PEDAL
ADJUSTING CHAIN

UK

85
86

MF10

3.26
3.27

OILING CHAIN
CHECKING AND ADJUSTING STEERING BALL-BEARINGS

87
88

3.28
3.29

CHECKING FORK
ADJUSTING FORK

89
90

3.30
3.31

CHECKING DAMPER
ADJUSTING DAMPER

92
92

3.32
3.33

CHECKING TIRE PRESSURE
CHECKING WHEELS

94
95

3.34
3.35

CHECKING AND OILING CLUTCH CABLE
ELECTRICAL PLANT

96
96

3.35.1
3.35.2

96
98

CHECKING BATTERY
BATTERY RECHARGING SYSTEM

3.36
3.37

CHANGING FUSES
CHANGING FRONT LIGHTS

101
102

3.38
3.39

ADJUSTING FRONT HEADLIGHT
CHANGING REAR LIGHTS

102
103

3.39.1
3.39.2

CHANGING REAR HEADLIGHT
CHANGING LICENCE-PLATE HOLDER LIGHT

103
104

3.39.3

CHANGING FRONT AND REAR ARROWS
3.39.3.1 CHANGING FRONT ARROWS

104
104

3.39.3.2

105

CHANGING REAR ARROWS

4

COWLING

4.1

DISMANTLING COWLING

106
106

4.2
4.3

DISMANTLING LOWER SEMI-COWLING
DISMANTLING UPPER SEMI-COWLING

106
107

4.3.1 DISMANTLING LEFT AND RIGHT INTERNAL INSTRUMENT
BOARD FASTENINGS

107

4.4
4.5

DISMANTLING LEFT AND RIGHT REAR-VIEW MIRRORS
DISMANTLING LEFT AND RIGHT UPPER COWLING

108
109

4.6
4.7

DISMANTLING TAILPIECE
DISMANTLING WHEEL HOUSING

110
112

4.8

DISMANTLING COWLING BENEATH HEADLIGHT
4.8.1
DISMANTLING RADIATOR BOX

113
114

4.8.2
4.8.3

114
115

DISMANTLING AIR BOX CONDUIT
DISMANTLING RESONATOR

4.9
4.10
4.11
4.12
4.13
4.14

DISMANTLING FRONT MUDGUARD
DISMANTLING REAR MUDGUARD
DISMANTLING CABLE GROMMET COVER
DISMANTLING RIGHT AND LEFT FOOTRESTS
DISMANTLING TANK
DISMANTLING TANK FUEL PUMP

116
116
117
117
118
120

5

ENGINE

5.1

CAMSHAFT

121
121

5.1.1
5.1.2

121
123

REMOVING CAMSHAFT
CHECKING CAMSHAFT

5.1.3 CHECKING CAMSHAFT CHAIN, SPROCKET WHEELS
AND CHAIN GUIDE
5.1.4
5.1.5

MF10

CHECKING CHAIN STRETCHER
MOUNTING CAMSHAFT

UK

124
125
125

5

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

6

CYLINDER HEAD
5.2.1
REMOVING CYLINDER HEAD

129
129

5.2.2
5.2.3

130
130

CHECKING CYLINDER HEAD
MOUNTING CYLINDER HEAD

VALVES AND VALVE SPRINGS
5.3.1
REMOVING VALVES

131
131

5.3.2
5.3.3

CHECKING VALVES AND VALVE GUIDES
CHECKING VALVE HOUSINGS

132
134

5.3.4
5.3.5

CHECKING VALVE SPRINGS
CHECKING BUCKET-TYPE TAPPETS

135
136

5.3.6
MOUNTING VALVES
CYLINDER

137
139

5.4.1
5.4.2

DISMANTLING CYLINDER CASING
CHECKING CYLINDER

139
140

5.4.3
5.4.4

DISMANTLING WATER COLLECTOR
CHECKING WATER COLLECTOR

140
141

5.4.5
5.4.6

MOUNTING WATER COLLECTOR
MOUNTING CYLINDERS

141
141

PISTONS
5.5.1
DISMANTLING PISTONS

142
142

5.5.2
5.5.3

CHECKING PISTONS
CHECKING SEGMENTS

143
143

5.5.4
5.5.5

SEGMENT SLOT PLAY
CHECKING PISTON PIN

144
144

5.5.6
5.5.7

MOUNTING SEGMENTS
MOUNTING PISTON

145
146

GENERATOR
5.6.1
REMOVING GENERATOR

147
147

5.6.2
MOUNTING GENERATOR
DISTRIBUTION SENSOR AND PHONIC WHEEL

148
148

5.7.1
5.7.2

REMOVING DISTRIBUTION SENSOR
MOUNTING DISTRIBUTION SENSOR

148
149

5.7.3
5.7.4

REMOVING PHONIC WHEEL
MOUNTING PHONIC WHEEL

149
149

CLUTCH
5.8.1
DISMANTLING CLUTCH CONTROL

150
150

5.8.2
5.8.3

REMOVING CLUTCH COVER
REMOVING CLUTCH

151
151

5.8.4
5.8.5

CHECKING NARROW TOOTHED CONDUCTOR DISK
CHECKING INNER TOOTHED CONDUCTOR DISK

154
154

5.8.6
5.8.7

CHECKING CLUTCH SPRINGS
CHECKING CLUTCH BELL

154
155

5.8.8
5.8.9

CHECKING CLUTCH PRIMARY BELL GROUP
MOUNTING CLUTCH GROUP

156
156

5.8.10
5.8.11

CHECKING CLUTCH DISKS
MOUNTING CLUTCH COVER

162
163

5.8.12 MOUNTING CLUTCH CONTROL
GEARS

164
165

5.9.1
5.9.2

165
165

REMOVING GEARS
DISMANTLING GEARS

UK

MF10

5.10

5.11

6

CHECKING GEAR FLANGE BALL-BEARINGS
CHECKING GEAR FORKS AND SLIDE RODS

168
168

5.9.5
5.9.6

CHECKING POSITIVE SHAFT
CHECKING PRIMARY AND SECONDARY SHAFT

170
170

5.9.7
5.9.8

ASSEMBLING GEARS
MOUNTING GEARS

171
178

OIL SUMP AND OIL PUMP
5.10.1 DISMANTLING OIL SUMP

179
179

5.10.2
5.10.3

DISMANTLING OVERPRESSURE OIL VALVE
REMOVING OIL PUMP

179
180

5.10.4
5.10.5

DISMANTLING OIL PUMP
CHECKING OIL SUMP

180
181

5.10.6
5.10.7

CHECKING OIL PUMP
ASSEMBLING OIL PUMP

181
182

5.10.8
5.10.9

MOUNTING OIL PUMP
MOUNTING OVERPRESSURE OIL VALVE

183
184

5.10.10 MOUNTING OIL SUMP
CASING

184
185

5.11.1
5.11.2

DISMANTLING CASING
DISMANTLING FREE WHEEL

185
192

5.11.3
5.11.4

DISMANTLING BALANCING COUNTER SHAFT
DISMANTLING ENGINE SHAFT

194
195

5.11.5
5.11.6

CHECKING CASING
CHECKING ENGINE SHAFT AND CONNECTING ROD

195
196

5.11.7
5.11.8

CONNECTING ROD INTERNAL FOOT DIAMETER
CONNECTING ROD HEAD LATERAL PLAY

197
197

5.11.9 CHECKING BALANCING COUNTER SHAFT
5.11.10 CHECKING FREE WHEEL

198
199

5.11.11 ASSEMBLING FREE WHEEL
5.11.12 MOUNTING ENGINE SHAFT

199
201

5.11.13 MOUNTING BALANCING COUNTER SHAFT
5.11.14 MOUNTING CASING

202
203

COOLING PLANT

214

REFRIGERANT LIQUID
6.1
RADIATOR

214
215

6.1.1
6.1.2

DISMANTLING RADIATOR
DISMANTLING RADIATOR BOX

215
218

6.1.3
6.1.4

CHECKING RADIATOR
MOUNTING RADIATOR

220
220

6.2

WATER OIL EXCHANGER
6.2.1
MOUNTING EXCHANGER

222
223

6.3

THERMOSTAT
6.3.1
DISMANTLING THERMOSTAT

224
224

6.3.2
6.3.3

225
226

6.4

MF10

5.9.3
5.9.4

CHECKING THERMOSTAT
MOUNTING THERMOSTAT

WATER PUMP
6.4.1
REMOVING WATER PUMP
6.4.2
DISMANTLING WATER PUMP
6.4.3
CHECKING WATER PUMP

UK

227
227
227
230

7

6.4.4
6.4.5

230
235

7

FRAME

238

7.1

FRONT WHEEL AND BRAKE DISK
7.1.1
REMOVING FRONT WHEEL

238
238

7.1.2
7.1.3

CHECKING FRONT BRAKE DISK
DISMANTLING FRONT WHEEL

239
239

7.1.4
7.1.5

CHECKING FRONT WHEEL
MOUNTING FRONT WHEEL

240
240

7.2

7.3

7.4

7.5

8

ASSEMBLING WATER PUMP
MOUNTING WATER PUMP

7.1.6
INSTALLING FRONT WHEEL
REAR WHEEL, BRAKE DISK AND CROWN

241
242

7.2.1
7.2.2

REMOVING REAR WHEEL
CHECKING REAR BRAKE DISK

242
243

7.2.3
7.2.4

DISMANTLING REAR WHEEL
CHECKING REAR WHEEL

244
246

7.2.5
7.2.6

CHECKING HUB
CHECKING CROWN

246
247

7.2.7
7.2.8

MOUNTING REAR WHEEL
INSTALLING REAR WHEEL

247
249

FRONT AND REAR BRAKES
7.3.1
REMOVING FRONT BRAKE PUMP

250
250

7.3.2
7.3.3

REMOVING REAR BRAKE PUMP
CHECKING FRONT AND BACK BRAKE PUMPS

251
252

7.3.4
7.3.5

INSTALLING FRONT BRAKE PUMP
INSTALLING REAR BRAKE PUMP

253
253

7.3.6
7.3.7

DISMANTLING FRONT BRAKING PLANT TUBES
DISMANTLING REAR BRAKING PLANT TUBES

254
255

7.3.8
7.3.9

CHECKING FRONT AND REAR BRAKE TUBING
MOUNTING FRONT BRAKING PLANT TUBES

256
256

7.3.10
7.3.11

MOUNTING REAR BRAKING PLANT TUBES
DISMANTLING FRONT BRAKE CLAMP

257
257

7.3.12
7.3.13

DISMANTLING REAR BRAKE CLAMP
CHECKING BRAKE CLAMPS

258
259

7.3.14
7.3.15

MOUNTING FRONT BRAKE CLAMPS
DISMANTLING REAR BRAKE CLAMP

259
260

FORK
7.4.1

REMOVING RIGHT AND LEFT STEM

261
261

7.4.2
7.4.3

CHECK FORK LEGS
INSTALLING FORK LININGS

262
262

SEMI-HANDLEBARS
7.5.1
REMOVING RIGHT SEMI-HANDLEBAR

264
264

7.5.2
7.5.3

REMOVING LEFT SEMI-HANDLEBAR
DISMANTLING RIGHT SEMI-HANDLEBAR

265
266

7.5.4
7.5.5

DISMANTLING LEFT SEMI-HANDLEBAR
CHECKING RIGHT SEMI-HANDLEBAR

267
267

7.5.6
7.5.7

CHECKING LEFT SEMI-HANDLEBAR
MOUNTING RIGHT SEMI-HANDLEBAR

268
268

7.5.8
7.5.9

MOUNTING LEFT SEMI-HANDLEBAR
INSTALLING RIGHT SEMI-HANDLEBAR

268
269

7.5.10

INSTALLING LEFT SEMI-HANDLEBAR

270

UK

MF10

7.6

7.7

7.8

7.9

7.10

7.11

7.12

271
271

7.6.2
7.6.3

CHECKING STEERING DAMPER
MOUNTING STEERING DAMPER

271
272

STEERING HEAD
7.7.1
DISMANTLING LOWER STEERING PLATE

272
272

7.7.2
7.7.3

274
274

CHECKING LOWER STEERING PLATE
MOUNTING LOWER STEERING PLATE

REAR DAMPER
7.8.1
REMOVING REAR DAMPER

275
275

7.8.2
7.8.3

277
277

CHECKING REAR DAMPER
MOUNTING REAR DAMPER

REAR FORK
7.9.1
REMOVING REAR FORK

279
279

7.9.2
7.9.3

DISMANTLING REAR FORK COMPONENTS
CHECKING REAR FORK

281
282

7.9.4
7.9.5

MOUNTING REAR FORK
INSTALLING REAR FORK

283
284

FRONT FRAME
7.10.1 REMOVING FRONT FRAME

285
285

7.10.2
7.10.3

285
286

CHECKING FRONT FRAME
INSTALLING FRONT FRAME

REAR FRAME
7.11.1 DISMANTLING REAR FRAME

286
286

7.11.2
7.11.3

CHECKING REAR
INSTALLING REAR FRAME

290
290

TRANSMISSION CHAIN
7.12.1 REMOVING TRANSMISSION CHAIN

291
291

7.12.2
7.12.3

291
292

CHECKING TRANSMISSION CHAIN
INSTALLING TRANSMISSION CHAIN

8

INJECTION PLANT ENGINE

293

8.1

ENGINE MANAGEMENT SYSTEM
8.1.1
DESCRIPTION OF THE SYSTEM

293
293

8.1.2
8.1.3

293
294

8.2

MF10

REAR DAMPER
7.6.1
DISMANTLING STEERING DAMPER

SYSTEM SENSORS
POSITION OF THE SENSORS

SYSTEM ACTIVATING DEVICES
8.2.1
ENGINE SUPPLY PLANT

295
296

8.3

8.2.2
IGNITION AND INJECTION DIAGNOSTIC SYSTEM
NUMBERING THE ECM CONNECTORS

296
296

8.4
8.5

FUEL PUMP CHECKING SYSTEM
SUPPLEMENTARY DIAGNOSES

298
299

9

ELECTRICAL PLANT

317

9.1
9.2

CONNECTORS
FUSES

320
320

9.3
9.4

SEMI-CONDUCTOR PARTS
BATTERY

321
321

9.5

9.4.1
CHECKING BATTERY EFFICIENCY
FUSES

322
324

UK

9

9.6

10

RELAYS
9.6.1
RELAY STARTER

324
324

9.7

9.6.2
RELAY SERVICES UNIT
STARTER ENGINE

325
325

9.8
9.9

ALTERNATOR
STARTER DIAGNOSTIC SYSTEM

326
327

9.10
9.11

CHECKING SAFETY SYSTEM PARTS
DIODES

328
328

9.12
9.13

GEAR SWITCH POSITION
LATERAL STAND SWITCH

328
329

9.14
9.15

CLUTCH SWITCH
SPEED SENSOR

329
330

9.16
9.17

OIL PRESSURE SENSOR
FRONT LIGHTS

330
331

9.18

REAR LIGHTS
9.18.1 REAR HEADLIGHT

331
331

9.18.2
9.18.3

LICENCE-PLATE HOLDER LIGHT
FRONT AND REAR ARROWS

332
332

9.18.3.1 FRONT ARROWS
9.18.3.2 REAR ARROWS

332
333

10

DIAGNOSTICS

335

10.1
10.2

ELECTRICAL PART
FRAME

335
339

10.3
10.4

PRELIMINARY OPERATIONS
SELF-DIAGNOSIS

342
342

10.5
10.6

RESETTING THROTTLE
ADJUSTING STEPPER / CO

342
343

11

USA VERSION

345

11.1
11.2

E.V.A.P CANISTER
CANISTER POSITION

345
345

11.3
11.4

REMOVING CANISTER
CANISTER CONNECTION

345
346

11.5
11.6

EXHAUST
LIGHTS CONTROL

347
347

11.7
11.8

REAR CATADIOPTRICS
FRONT CATADIOPTRICS

347
348

11.9

REAR ARROWS

348

UK

MF10

General

Information

1

GENERAL INFORMATION

1.1 VEHICLE IDENTIFICATION
The identification data are:
1) Frame number [on steering casing].
2) Number of engine on lower crankcase
3) Homologation data [on frame].

1.2 IMPORTANT INFORMATION
• REMOVAL AND DISMANTLING
1. Before carrying out dismantling operations, remove eventual dirt, mud, dust and
foreign bodies.
2. Use appropriate instruments and cleaning products exclusively. Refer to the
“SPECIAL INSTRUMENTS” paragraph.
3. During dismantling, avoid separating the coupled components, including cylinders,
pistons, gears and other parts that have become “coupled” during normal wear. The
coupled components must always be re-used or changed without separating them.
4. During dismantling, clean all the components and place them in a bowl, following
the order of dismantling.
This will make the re-mounting operation easier and allow a correct installation of
all the components.
5. Keep all the components away from any source of heat.
•

SPARE PARTS
Use original Benelli spare parts exclusively.
Use oils and greases recommended by Benelli to oil the components.
Other products might appear similar in look and function but are inferior in quality.

2

1

3

MF10

UK

11

• WASHERS, O-RINGS AND OIL SEAL
1. During the revision of the engine, change all the washers, O-rings and seals.
The surfaces of the washers and O-rings, and the lips of the oil seals must be
cleaned.
2. Oil all the coupled components and the ball-bearings and grease the lips of the
seals, when remounting.
• ELASTIC SAFETY WASHERS/PLATES AND SAFETY PINS
After removing, change all the elastic safety washers and safety pins. After tightening the bolts or nuts, bend the tongues of the safety washers/plates and the ends of
the safety pins on a flat surface of bolts or nuts.
•

BALL-BEARINGS AND OIL SEALS
WARNING:
Do not rotate the compressed air ball-bearings as this might damage
their surfaces.

1. Install the ball-bearings and the oil seals so that the Producer brand or data are
visible. At the moment of installing the oil seal, oil the lip with a slight layer of
grease. The ball-bearings rotate freely if oiled in an appropriate way.

1.3 SPECIAL INSTRUMENTS
WARNING:
To avoid errors in ordering the special instruments, refer exclusively to
the inherent code.
For correct maintenance and a perfect set-up use the BENELLI special instruments,
avoiding damage as a result of inadequate or technically improvised instruments.

12

UK

MF10

1.3.1

SPECIAL ENGINE INSTRUMENTS

1. R180197015000
GONIOMETER PLUG FOR
DISTRIBUTION[*]

2. R180197017000
INSTRUMENT FOR MOUNTING
CLUTCH OIL SEAL CASING [*]

3. R180197018000
CYLINDER MOUNTING SPACERS
[*]

4. R180197019000
SMALL CYLINDER COLUMN
FIXING SPAN

5. R180197020000
FALSE SPARKING-PLUG

6. R180197021000
PISTON THREAD MEASURER

MF10

UK

13

7. R180197022000
P.M.S. MEASURER

8. R180197023000
CLUTCH COVER OIL SEAL PAD [*]

9. R180197024000
OIL SEAL PINION PAD [*]

10. R180197025000
OIL SEAL VALVE PAD [*]

11. R180197026000
INSTRUMENT FOR CHECKING
VALVE LIFT

12. R180197027000
GONIOMETER INDICATOR

13. R180197028000
CLUTCH OIL SEAL PAD ON
FLANGE [*]

14

UK

MF10

14. R180197029000
ENGINE SUPPORT

15. R180197030000
INSTRUUMENT FOR CHECKING
ENGINE SHAFT
AXIAL PLAY

16. R180197036000
ENGINE MANAGEMENT
DIAGNOSTIC
INSTRUMENT [*]

17. R180100143000
RAPID RELEASE PETROL TUBE
KIT [*]

1.3.2

SPECIAL FRAME INSTRUMENTS

1. R180197033000
20 ALLEN WRENCH [*]

2. R180197031000
STEERING RING-NUT CLAMPS [*]

MF10

UK

15

3. R180197034000
EMGINE DISMANTLING INSTRUMENT[*]

4. R180197032000
ENGINE SHOULDER ADJUSTMENT CLAMPS [*]

5. R180297049000
COWLING SUPPORT TROLLEY

6. R180297048000
DISMANTLING PINION
INSTRUMENT

7. R180297047000
DISMANTLING CLUTCH
INSTRUMENT

16

UK

(*) Compulsory instruments

MF10

Specifications

2

SPECIFICATIONS

2.1 GENERAL SPECIFICATIONS
DIMENSIONS

STANDARD

LIMITS

Engine length

2040 mm

—

Engine width

780 mm

—

Maximum height

1160 mm

—

Wheelbase

1419 mm

—

Minimum light

100 mm

—

Saddle height

840 mm

—

Weight with oil and full tank

220 kg

—

Weight without oil and full tank

200 kg

—

Maximum load with pilot and load

400 kg

—

2.2 TECHNICAL CHARACTERISTICS: ENGINE
ENGINE
Type

Three four-stroke cylinders in line

Bore

88 mm

Stroke

49.2 mm

Total displacement

898 cm³

Compression ratio

11±05:1

Max. power at shaft [95/1/EC]

100 kw / 136 cv at 11500 rpm
reduced for foreign countries: 72 kw / 98 cv

Minimum rotation at full speed

1350 rpm

Maximum at full speed

11800 rpm

Distribution

At 4 valves per 00HC cylinder

Valves

Suction valve diameter: 33 mm
Exhaust valve: 29 mm

Distribution diagram
[observed data with 1 mm play]

MF10

Suction valve opening before P.M.S.: 21°
Suction valve opening after P.M.I.: 57°
Exhaust valve opening before P.M.I.: 36°
Exhaust valve opening before P.M.S.: 26°

UK

17

Valve lift [observation data with play of 0 mm]

Suction: 9.2 mm
Exhaust: 8.75 mm
The functioning play of the tappets
with the engine cool must be:
Suction: 0.25-0.30 mm
Exhaust: 0.30-0.35 mm

Transmission

Multiple disks dry friction:
commanded by a cable activated by a lever on the
left side of the handlebar. Transmission between
engine and primary shaft of the gear-box by straighttoothed gears. Mechanisms of selecting the gears with
drum and forks. An articulated lever commands the
rotation of the drum. 6 gear gearbox.
Primary ratio: 44/79 [1:1.795
Ratio pinion/crown: 15/41 [1:2.563]

Total ratios:

First gear: 14/39
Second gear: 18/35
Third gear: 21/32
Fourth gear: 223/30
Fifth gear: 24/28
Sixth gear: 25/27

OILING/COOLING
Oiling

Humid housing with trochoidal circulation pump,
opening pressure of the oil
circuit valve, 6.5 bar.

Engine oil quantity
Cooling

With filter: 3.8 l about
Without filter: 3.5 l about
Closed circuit pressurised liquid with radiator, thermostat
and water-oil heat exchanger.
A centrifugal pump
commanded by gears on the primary gearbox shaft
circulates the liquid and an expansion tank
recovers the thermal expansion of the cooling liquid.

Radiator capacity

18

3.0 l about

UK

MF10

2.3 FRAME CHARACTERISTICS
FRAME
Type

STANDARD

LIMITS

Mixed steel-aluminium
frame and structurre

Angle of incidence

23.50°

—

Forward stroke

94.5 mm

—

FRONT WHEEL

STANDARD

LIMITS

Type

Cast

—

Rim

Dimensions: 17 x MT3.50
Material: aluminium

Wheel span

120 mm

—

STANDARD

LIMITS

Type

Cast

—

Rim

Dimensions: 17 x MT6.00
Material: aluminium

REAR WHEEL

Wheel span

120 mm

—

FRONT TIRE

STANDARD

LIMITS

Tubeless

—

120/70 ZR17 (58W)

—

D207F RR (DUNLOP)

—

Type
Dimensions
Model
Tire pressure cold

250 kPa (2.5 kg/cm, 2.5 bar)

Maximum pneumatic pressure

250 kPa (2.5 kg/cm2.2.5 bar)

—

—

1.6 mm

Minimum depth tread

MF10

UK

19

REAR TIRE

STANDARD

LIMITS

Tubeless

—

190/55 ZR17 (73W)

—

D207F RR (DUNLOP)

—

Tire pressure cold

250 kPa (2.5 kg/cm, 2.5 bar)

—

Maximum tire pressure

250 kPa (2.5 kg/cm, 2.5 bar)

—

Min. depth tread

—

2.0 mm

FRONT BRAKES

STANDARD

LIMITS

Type

Double disk

—

DOT 4

—

Brake disks
Diameter x thickness:
Min. thickness:
Max. deformation:

320 x 4.5 mm
—
—

—
4.0 mm
0.1 mm

Thickness brake pads

4.5 mm

0.5 mm

Internal cylinder pump diameter

15 mm

—

Internal cylinder clamps diameter

34 mm

—

REAR BRAKES

STANDARD

LIMITS

Type

Single disk

—

DOT 4

—

Brake disks
Diameter x thickness:
Min. thickness:
Max. deformation:

240 x 5 mm
—
—

—
4.5 mm
0.1 mm

Thickness brake pads

4.3 mm

0.5 mm

Internal cylinder pump diameter

12 mm

—

Internal cylinder clamps diameter

32 mm

—

Type
Dimensions
Model

Brake liquid advised

Brake liquid advised

20

UK

MF10

FRONT SUSPENSION

STANDARD

LIMITS

Telescopic fork with
upturned stems

—

Type of front fork

Helical spring/damper
oil

—

Front fork stroke

120 mm

—

9.5 N/mm
0 ~ 120 mm

—
—

SAE 7,5 Marzocchi 19

—

Adjustment positions in extension (*)

2,5 rotations
from all closed

—
—

Adjustment positions in compression (*)

1,5 rotations
from all closed

—
—

Type

Spring
Spring rate (K1):
Spring stroke (K1):
Oil advised

Quantity for stems

480 cc.

BAC K SUSPENSION

STANDARD

LIMITS

Oscillating fork

—

Type of rear fork

Helical spring/damper
gas

—

Rear fork stroke

62 mm

—

85 N/mm
62 mm

—
—

no

—

1200 kPat (12 kgf/cm2)

—

Adjustment preload spring positions

14 mm

—

Adjustment positions in extension (*)

Road: 11 clicks
from all closed

—
—

Adjustment positions in compression(*)

Road: 8 clicks
from all closed

—
—

Type

Spring
Spring rate (K1):
Spring stroke (K1):
Optional spring available
Gas/air pressure preload spring

(*) Unscrew from completely closed (screwed).

MF10

UK

21

OSCILLATING ARM
Free play (at the end of the arm)
Radial
Axial

TRANSMISSION CHAIN
Model:
Connection quantities
Play of the chain
Max. section of ten connections

STANDARD

LIMITS

—
—

1 mm
1 mm

STANDARD

LIMITS

50ZVM (DAIDO)

—

114

—

40 ~ 50 mm

—

150.1 mm

—

2.4 ELECTRICAL CONNECTIONS
COMPONENTS

STANDARD

Plant tension

12V

Cooling liquid temperature sensor
Model:
Resistance:

16 TT (SAGEM)
2500 Ù at 20°C / 322.5 Ù at 80°C

Engine control system

SAGEM MC 1000

Relay group
Safety relay
Dazzle/anti-dazzle light:
Ignition relay:

CM1 (NAIS) 12V h.o.
01RA001 (SAGEM) h.o.

Injector
type:

U9122-357 (SAGEM)

Pick-up
type:

O1VR001 (SAGEM)

Engine stepper
model:
Type:

028M001 (SAGEM)
bi-phase

Ignition coils
Model:
Primary coil resistance:
Secondary coil resistance:
Primary coil inductance:
Secondary coil inductance:
Max. admissible current value:

02IG001 (SAGEM)
0.6 Ù
10 KÙ
2.5 mH (1 kHz 0.3V)
23.5 mH (1 kHz)
7.6 A

Throttle valve sensor
Standard resistance:

22

1.2 kÙ ± 20%

UK

MF10

COMPONENTS

STANDARD

Loading system
Type:
Model:
Nominal exit:

AC magnet
5-101211-502-1 (DENSO)
13.5V / 48A at 5000 rpm

Tension adjustment (in the alternator)
Type:
Voltage adjustment:

Semiconductor, FIELD CONTROL
14.5 ± 0.3V (at 5000 rpm, 10A and 25°C)

Rectifier
Battery

in the alternator
YT 12B-4 / 12V 10Ah

Electrical start system
Model:
Power:

5-128-330 (DENSO)
0.7 kw

Starter relay
Model:
Amperage:
Coil resistance:

MS5F - 421 (JIDECO)
100A
4.4 Ù at 20°C

Horn
Model:
Max. amperage:

AB1242/262 O.S.C.
1.5A

Direction indicator relay:
Model:
Type:
Flashing frequency:
Wattage:

70.016.70.001.4
Full-transistor
60 ~ 120 rpm
(10W+10W+2W) x2

Oil level switch (model)

285520-10 (BITRON)

Fuel pump
Model:
Max. amperage:
Level sensor:
Min. resistance:
Max. resistance:

BITRON
5A max. at 13.5V
in the fuel pump
285 Ù (tank empty)
21 Ù (tank full)

Stand switch (model)

CE75A (ASAHI DENSO)

Radiator fan (model)

VA46-A101-46 S (SPAL)

Neutral switch (model)

11720.3 (F.M.D.I.)

Commutator switch (model)

23-038/1 (EUROSWITCH)

Air temperature sensor
Model:
Resistance:

MF10

ISTT (SAGEM)
23.75 Ù at 20°C
19.48 Ù at 25°C
16.07 Ù at 30°C

UK

23

2.5

BOLT TORQUE

2.5.1

GENERAL BOLT TORQUE

The bolt torques are inserted in the chapters of the manual together with the relative
special instructions, if necessary.
If not otherwise specified, the bolts are considered with greased thread, created at
environmental temperature.

A

A

24

BOLT TORQUES
Nm

kgf·m

1

4 mm

2,3

0,23

2

5 mm

4,5

0,45

3

6 mm

10

1,0

4

8 mm

25

2,5

5

10 mm

45

4,5

6

12 mm

80

8,0

7

14 mm

130

13,0

8

16 mm

200

30,0

9

18 mm

240

24,0

UK

MF10

2.5.2

BOLT TORQUE FRAME

DESCRIPTION

THREAD

TORQUE
(Nm)

ENGINE GROUP:
ENGINE ON BACK FUSION PLATE
RIGHTHAND FRAME WITH LEFTHAND NUT

M12

40

ENGINE SUPPORT ROD ON ENGINE
HEAD

M10

40

RIGHTHAND ENGINE ON LOWER CROSSBAR
LOWER ENGINE CRANKPIN THROUGH FRAME
WITH NUT

M12

40

LOWER CRANKPIN HEAD TORQUE
ENGINE ON LOWER FRAME CROSSBAR

M6

8

ENGINE HEAD ON RIGHTHAND FRAMEWORK WITH NUT

M12

40

RIGHTHAND ENGINE FIXING SCREW HEAD TORQUE ON
FRAMEWORK

M6

10

RIGHTHAND ENGINE HEAD ON LEFTHAND FRAMEWORK
WITH NUT

M12

40

STEERING FERRULES TORQUE ON LOWER AND UPPER SADDLE
POSTS

M8

25

ENGINE FRONT SUPPORT ROD ON STEERING SADDLE POST
WITH NUT

M10

1.25

FORK DAMPER SUPPORT ON CROSSBAR

M16

50

REAR FORK FERRULES TORQUE ON THE SADDLE
POSTS

M8

10

M6

10

RIGHT COWLING MOUNT UNDER HEADLIGHT ON FRONT
ENGINE SUPPORT ROD

M6

10

FIXING STEERING WHEEL BLOCK ON FRAME

M6

FRAME GROUP:

LEFT COWLING MOUNT UNDER HEADLIGHT ON FRONT
ENGINE SUPPORT ROD

MF10

UK

25

SADDLE PILLAR GROUP:
SADDLE PILLAR ON FRAMEWORK

M8

25

SADDLE PILLAR ON FRAME BACK PLATE
WITH SPECIAL NUT

M8

25

LEFT AND RIGHT SEMI-HANDLEBARS ON FORK STEM

M10

45

LEFT AND RIGHT SAFETY DOWELS

M6

7

LEFT AND RIGHT SEMI-HANDLEBARS SAFETY SCREWS

M5

6

FRONT OIL BRAKE TANK SUPPORT ROD ON FRONT
BRAKE PUMP

M5

10

FRONT OIL BRAKE TANK ON SUPPORT ROD

M5

5

CLUTCH LEVER ON LEFT SEMI-HANDLEBAR

M6

5

PILOT FOOTBOARD ON FRAME SUPPORTS

M8

22

GEAR TORQUE COMMAND ON SHAFT

M6

10

DRIVING GEAR ROD ON GEAR COMMAND WITH NUT

M6

10

DRIVING GEAR ROD ON GEAR PEDAL WITH NUT

M6

10

FORK LEVER ON LEFT AND RIGHT FOOTREST SUPPORTS

M8

22

LOWER SPRING CRANKPIN ON RIGHT FOOTREST SUPPORT

M5

6

UPPER SPRING CRANKPIN ON RIGHT FOOTREST SUPPORT

M5

6

BRAKE PUMP ROD GROUP ON BRAKE PEDAL
WITH NUT

M6

10

HANDLEBAR GROUP COMMANDS:

PEDAL GROUP COMMANDS:

26

UK

MF10

REAR FORK GROUP:
REAR FORK CRANKPIN SCREW ON REAR FORK CRANKPIN

M18

65

CHAIN PAD ON REAR FORK

M6

8

FERRULES FOR ASSEMBLY STAND ON REAR FORK

M8

25

FERRULE STEMS ON STEERING BASE

M6

10

FERRULE STEMS ON STEERING HEAD

M8

22

FERRULE HUBS ON FRONT WHEEL CRANKPIN

M8

30

FRONT MUDGUARD SUPPORTS ON FORKS

M5

6

BRAKE CLAMP SUPPORTS ON FORKS

M10

50

STRAP TORQUE STEERING DAMPER ON DAMPER
BODY

M6

10

STEERING DAMPER ON STEERING HEAD

M6

10

STEERING DAMPER ON FRAME

M6

10

DAMPER ON FORK WITH NUT
(UPPER MOUNT)

M10

35

DAMPER ON ROCKER ARM WITH NUT
(LOWER MOUNT)

M10

35

REAR SUPSENSION RODS ON REAR FORK WITH
NUT

M10

35

ROCKER ARM ON FRAME

M10

45

FRONT WHEEL CRANKPIN SCREW

M18

60

FRONT BRAKE DISKS ON WHEEL

M8

25

FRONT SUSPENSION GROUP:

REAR SUSPENSION GROUP:

FRONT WHEEL GROUP:

MF10

UK

27

REAR WHEELGROUP:
REAR WHEEL CRANKPIN NUT

M24

80

CROWN ON FLEXIBLE COUPLING FLANGE

M10

45

REAR BRAKE DISK ON WHEEL

M8

25

SPEED SENSOR ON CLIP SUPPORT

M6

6

HANGER SUPPORT PLATE ON FRAME

M10

35

HANGER CRANKPIN ON FRAME

M10

35

SPRING HOOK ON HANGER

M6

10

IINERTIAL SWITCH ON FILTER BOX

M6

1.5

AIR SENSOR ON FILTER BOX

M10

8

LATERAL ASSEMBLY STAND GROUP:

ELECTRIC PLANT GROUP:

COOLING PLANT GROUP:
LATERAL RADIATOR BOX ON SADDLE PILLAR

M6

3

UPPER FRONT RADIATOR BOX RADIATOR ON SADDLE PILLAR

M6

10

RADIATOR BOX COVER ON BASE

M4

1
1

RADIATOR BOX FASTENINGS THREADS

M6

4

UPPER COVER RADIATOR BOX FASTENINGS

M4

1

LOWER COVER RADIATOR BOX FASTENNGS

M4

1

EXPANSION TANK ON FRAME

M6

3

FANS ON SUPPORT

M6

3

FANS SUPPORT ON RADIATOR BOX

Autofil. 4

1

28

UK

MF10

FRONT BRAKING PLANT GROUP:
FRONT BRAKE PUMP ON RIGHT SEMI-HANDLEBAR

M6

10

FRONT BRAKE CLIPS ON RELATIVE SUPPORTS

M10

50

HYDRAULIC CONNECTIONS ON FRONT BRAKE PUMP AND CLIPS

M10

15

REAR BRAKE PUMP ON RIGHT FOOTBOARD SUPPORT
WITH NUT

M6

10

REAR BRAKE CLIP ON SUPPORT

M8

22

HYDRAULIC CONNECTION ON REAR BRAKE CLIP

M10

15

HYDROSTOP ON REAR BRAKE PUMP

M10

15

REAR BRAKE OIL TANK ON RADIATOR BOX WITH WELL NUT

M5

4

EXHAUST COLLECTORS ON ENGINE HEAD

M8

13

SILENCER SUPPORT ON SADDLE PILLAR

M8

25

SILENCER ON SUPPORT

M10

45

RIGHT "3 IN 1" TUBE SUPPORT PLATE ON FRAME

M6

10

FIXING "3 IN 1" ON SUPPORT PLATE

M10

45

COVER ON FILTER BOX

M5

3

FILTER BOX ON STEERING SADDLE POST

M6

10

AIR CONDUIT BOX ON FILTER BOX

M5

5

REAR BRAKING PLANT GROUP:

EXHAUST PLANT GROUP:

SUPPLY PLANT GROUP:

MF10

UK

29

PETROL PUMP ON TANK

M5

3

PETROL TUBE ON THROTTLE BODY

M12

25

DISTRIBUTOR ON PLATE

M5

4

GAS CABLES FIXING PLATE ON THROTTLE BODY

M6

10

FRONT AND BACK BODYWORK GROUP:
USE STANDARD TIGHTENING TORQUE WITH M6 THREAD FOR BODYWORK: 8Nm±20%

30

UK

MF10

2.5.3

BOLT TORQUE ENGINE

DESCRIPTION

THREAD

BOLT
TORQUE
(Nm)

CRANKCASE TEF FIXING SCREW

M6

10

CRANKCASE FIXING SCREW

M8

2.5

CRANKCASE BANKS TCEI FIXING SCREW

M8

37

OIL CONDUIT CLOSURE CONICAL DOWEL

M8

10

BALL-BEARING AND CRANKPIN FIXING SCREW

M6

10

SMALL PLATES AND TUBE FIXING SCREW

M6

10

CYLINDRICAL CAP

M6

25

CYLINDRICAL CAP

M6

10

OIL DIAPHRAGM

M10

25

NEUTRAL POSITION SENSOR

M8

10

MIN. OIL PRESSURE SENSOR

M10

25

OIL LOAD CLUTCH SUMP CAP

M24

BY HAND

CLUTCH SUMP PHASE CAP

M40

BY STRIKING

CLUTCH SUMP CAP SCREW

M6

10

CLUTCH SCREW

M6

10

SUMP SCREW

M6

10

COP. CLUTCH CENTRING SCREW

M6

10

SUMP BLOW-BY SCREW

M6

10

COUNTERSHAFT SUMP SCREW

M6

10

OIL EXHAUST SUMP CAP

M18

22

SUMP FILTER FIXING SCREW

M6

10

SUMP FIXING SCREW

M6

10

ENGINE CRANKCASE GROUP:

MF10

UK

31

PRISONNER SCREW HEAD

M10

BY STRIKING

VENT HEAD CONNECTION

M18

15

DOWEL

M8

15

OIL PUMP FIXING SCREW

M6

8.3

OVERPRESSURE VALVE

M12

25

LARGE EXCHANGER FIXING SCREW

M20

60

OIL TUBE HEAD BORED SCREW

M10

16

OIL HEAD NIPPLE TUBE

M10

33

15÷20

25+50°

PHONIC WHEEL FIXING NUT

M8

26

ROD SCREW

M9

25+50°

PRISONNER SCREW

M8

25

CONICAL DOWEL

M6

10

CONICAL CAP

M14

10

CAP FIXING SCREW

M6

13

HEAD FIXING NUT

M10

45+100°

TIGHTENER FIXING SCREW

M6

10

CYLINDER CAP SCREW

M6

10

CYLINDER FIXING SCREW

M6

10

DISTR. ENTRY FIXING SCREW

M6

15

UPPER PAD SUPPORT FIXING SCREW .

M6

10

DISTR. SUMP COIL FIXING SCREW

M6

10

DISTR. SUMP SCREW

M6

10

-

12

ENGINE GROUP/OILING:

FILTER

ENGINE GROUP/CRANK MECHANISM:

ENGINE GROUP/CYLINDER-PISTON-HEAD:

ENGINE GROUP/DISTRIBUTION:

MOBILE PAD PIN

ENGINE GROUP/CLUTCH:

32

UK

MF10

LOW CLUTCH ROD HEXAGONAL FIXING NUT

M8

16

CLUTCH SPRING FIXING SCREW

M6

10

CLUTCH HEXAGONAL FIXING NUT

M20

80

CLUTCH CONTROL FIXING SCREW

M6

10

M24

140

PLATE FIXING SCREW

M6

10

FORK PINS FIXING SCREW

M6

10

FORK PINS FIXING SCREW

M6

10

SELLET DRUM FIXING SCREW

M6

10

GEAR COMMAND SUMP FIXING SCREW

M6

10

GEAR COMMAND SUMP FIXING SCREW

M6

10

CHAIN COVER SUMP FIXING SCREW

M6

10

GEAR FLANGE FIXING SCREW

M8

20

PUMP ROTOR BLIND FIXING NUT

M6

8.3

PUMP COVER FIXING SCREW

M6

10

PURGE SCREW

M6

10

CRANK FIXING SCREW

M6

10

PUMP BODY FIXING SCREW

M6

10

COLLECTOR FIXING SCREW

M6

10

THERMOSTAT CAP FIXING SCREW

M6

10

SMALL COVER FIXING SCREW

M6

10

ENGINE GROUP/GEARS:
ENGINE PINION FIXING NUT

ENGINE GROUP/ GEAR COMMAND:

ENGINE GROUP/COOLING:

ENGINE GROUP/IGNITION:
SPARKING-PLUG

10

COIL ROD FIXING NUT

10

ENGINE GROUP/ELECTRICAL PLANT:
ELECT. ENGINE FIXING SCREW .

M6

10

ALTERNATOR FIXING SCREW

M8

27

MF10

UK

33

PHONIC WHEEL SENSOR SCREW

M6

8.3

M6

10

FREE WHEEL RING FIXING SCREW

M6

17

ENGINE HEXAG. FLEXIBLE COUPLING SCREW

M8

37

ENGINE HEXAG. FLEXIBLE COUPLING SCREW

M10

37

TEF INGR. SATELLITE SCREW

M6

10

ENGINE GROUP/ SUPPLY:
THROTTLE BODY FIXING SCREW

ENGINE GROUP: SUPPLY:

2.6 POINTS TO OIL
ENGINE OIL

-

Ball-bearings
Piston surface
Piston segments
Piston pin
Shafts, nuts and screws
Oil pump rotors
Distribution bowl surfaces

LOCTITE®
sustitute the element
Clean and degrease the surfaces

34

MOLYBDENUM BISULFIDE OIL

- Suction and discharge valve stems

LITHIUM SOAP GREASE

- Sealing ring lips

TEFLON® SYNTOFLON® PASTE

- Engine shaft pins
- Eccentric shaft pins
- Eccentric shaft u-bolts

MOLYCOTE® COPPER GREASE

- Engine shaft fixing screws
- Gear flange
- Prisonner head fixing nuts

THREE BOND 1215 SEALING PASTE

-

UK

Casing coupling surfaces
Casing-cover-gear coupling surfaces
Casing-oil sump surfaces
Casing-cover-countershaft surfaces
Water chamber caps

MF10

NEW
DRY
S

L

S
NEW
NEW

Ls

NEW

Ls

MF10

S

S

UK

35

36

UK

MF10

MF10

UK

37

R

E

E

L

L

E
38

UK

MF10

MF10

UK

39

40

UK

MF10

MF10

UK

41

E

L

Ls

Ls

L

E

L

42

UK

MF10

E

L

Ls

E
T

T

T

T

T

E
E

E

E

E
E
MF10

UK

43

44

UK

MF10

MF10

UK

45

46

UK

MF10

MF10

UK

47

48

UK

MF10

Periodical
Checks

3

PERIODICAL CHECKS AND
ADJUSTMENTS

3.1 INTRODUCTION
This chapter includes information about checks and adjustments for better
maintanence of the bike's performance.
MAINTENANCE FREQUENCY

COMPONENT

OPERATION

0 km

1000 km

6000 km

11000 km

(0 mi)

(625 mi)

(3750 mi)

(6875 mi)

before delivery

running-in
1st

2nd

3rd

Service

Service

Service

Level check

Before every use of the vehicle

Engine oil

R

R

R

Change
Every year in any case
R
Engine oil filter

R

R

Change
At every change of engine oil in any case
Check/Restore level

i

i

i

Cooling liquid
Change

Every 2 years

Cooling plant

Check losses

i

i

i

Electrofans

Check functioning

i

i

i

Valves

Check/Adjust

i

i

Check

i

i

Distribution chain
Change

Every 25000 km (15000 mi)

Check/Change

i

i

Every 25000 km (15000 mi)
Distribution mobile pad

Change
At every change of the distribution chain in any case

Distribution chain stretcher

Check/Change

i

Check/Change

i

i

i

Sparking-plugs
Change

R

CODE:
i = inspection and adjustment , cleaning, oiling or change according to need.
R = change
T = tighten

MF10

UK

49