SERVICE REPAIR MANUAL

Pure Passion since 1911

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 WARNINGS:

This manual has been produced by Benelli Q.J. s.r.l. for the main purpose of being used by Benelli dealers and their mechanics. It
is not possible to provide a mechanic with all of the information they require in a single manual. The assumption is therefore that the
people using this manual for the maintenance and repair of Benelli vehicles have a basic grounding in mechanics and the procedures
inherent to the repair techniques for this type of vehicle. Without this knowledge, repairs or maintenance of this type of vehicle may
be inefficient or dangerous.
The policy of Benelli Q.J. s.r.l. is the continued improvement of all its models. All authorised Benelli dealers will be informed of amend-
ments and important changes to technical details or procedures, which will be published in future editions of this manual.

NOTE:_________________________________
Designs, drawings and specifications will be subject to change without prior warning.

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IMPORTANT INFORMATION CONCERNING THIS MANUAL

20
The text in this manual contains the following important
ant warnings.
rtant w

WARNING Failure to abide

the rider,
e byy the
bide
r,, off persons
erso
pe o
he instructions
in
ns in the
ons he vicinity
vicinit
vic
ollowin
following
orr people S
thi symbol
ollowi this
peop intent
boll may
mbol ma
m ayy lead
nt on inspecting
ntent spec
sp ect
inspecti
le to
lea to serious injury to or even the death of
ng or repairing
cttin
in rrep
re the motorbike.
R
TO

An important
an
mportant
porta nt notice
ortant n
not di ess special
oti indicates
indica s ecial
spe au ns that
ecautio
pre
ial precautions hat
at need ob
nee to be
e complied
comp
com with to avoid damage to the
IMPORTANT bike.
NOTICE
O

A note pro
provides
es key
vides
rovi des
ovides ey information
in mation n to
ation to make
m processes
proces
proce easier
er or
or clearer.
cle
clea
c rer.
cleare
M

NOTE
A
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- Benelli TRK 502 - Page 1
 HOW TO USE THIS MANUAL
This manual is a practical reference guide that is easy for mechanics to handle and use. The explanations of all of the installation,
removal, disassembly, installation, repair and inspection procedures are organised into sequences of individual steps.

1. Each chapter is divided into sections. The title of the current section will be found at the top of every page.
2. To help with the identification of plants and make the different points of the various procedures clearer, the start of each section
about the removal or disassembly of parts will contain exploded drawings.
3. The parts to be lubricated or replaced are marked with symbols. See the section entitled “SYMBOLS”.
4. The exploded drawing is accompanied by a table with the instructions for the intervention, stating the order of operations, the
name of the parts, any notes about the job, etc.
5. Interventions requiring additional information (for example, special tools and technical information) will be described in se-

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quence.

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I - II
- Benelli TRK 502 - Page 2
 SYMBOLS

SUBJECT SYMBOLS

General Information

Specifications

Checks and periodic adjustments

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Frame

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Engine

S
R
Cooling system
TO

Electrical system
O
M
A

INDICATION SYMBOLS
OL
OL
LSS
D

Wear/Clearance limits Thread locker application

BA

Special tool Recommended solvent

T. R .
Tightening torque
Brake fluid

G Grease application

C
IL A Sealant paste application
IS
OR
YV

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- Benelli TRK 502 - Page 3
 INDEX

General information
CHAPTER 1

Specifications
CHAPTER 2

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Checks
hec
ecks d periodic
nd
ks and per odic
p
perio
oddic
ic adjustments
a
adju
ad j ent
nts
CHAPTER
CH
C H 3
S
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TO

Frame
Frame
HA P
CHAPTER
CHAP
C HA 4
O
M

Engine
Eng
En
ng
ng ine
gine
CHAPTER
C
CHHA
HA 5
A
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Cooling system
CHAPTER 6

Electrical system
CHAPTER 7

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 CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION ...........................................................................................................................................3
MOTORCYCLE IDENTIFICATION .............................................................................................................................................3
FEATURES ....................................................................................................................................................4
INSTRUMENTATION AND INDICATOR LIGHTS .......................................................................................................................4
MULTIFUNCTION DISPLAY .......................................................................................................................................................5
IMPORTANT INFORMATION ........................................................................................................................6
GETTING READY FOR REMOVAL AND DISASSEMBLY OPERATIONS .................................................................................6
SPARE PARTS ....................................................................................................................................................................... 6
GASKETS, O-RING, OIL SEALS AND BEARINGS ....................................................................................................................7
SAFETY WASHERS/PLATES, COTTER PINS, AND THREAD SEALANT ................................................................................7
SAFETY SNAP RINGS ...............................................................................................................................................................8
CHECKING CONNECTIONS .....................................................................................................................................................8

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SPECIAL ENGINE TOOLS .......................................................................................................................................................10
SPECIAL TOOLS .........................................................................................................................................10
SPECIAL FRAME TOOLS ........................................................................................................................................................13

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 IDENTIFICATION
MOTORCYCLE IDENTIFICATION

Identification data are as follows:

1. Frame serial No. (on the steering sleeve)
2. Engine serial No. (on the lower crankcase)
3 3. Type-approval data (on the frame)

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- Benelli TRK 502 - Page 7
 FEATURES
INSTRUMENTATION AND INDICATOR LIGHTS

The instrumentation and the lights go on by turning the ignition 6. LEFT DIRECTION INDICATOR LIGHT (GREEN)
key to "ON” position. It goes on when the left direction indicator light is activated.
After an initial check-up, the information correspond to the gen-
eral conditions of the motorcycle at that time. 7. HIGH BEAM INDICATOR LIGHT (BLUE)
The dashboard is equipped with the following instruments: It goes on when the high beam light is activated.

1. SPEEDOMETER 8. NEUTRAL POSITION INDICATOR LIGHT (GREEN)

It indicates the vehicle's speed in km/h or mph. It goes on when the gear is in “Neutral” position.

2. ADJUSTMENT BUTTON 9. OIL LEVEL WARNING LIGHT (RED)

Press the button shortly to switch over km/h and mph. The but- It goes on when the oil pressure value is too low. The elec-
ton serves to reset the “Trip” mileage. trical circuit of the light can be checked by turning the key
to "ON”.Once the engine is running, the light should switch
3. SELECTION BUTTON off. If the light does not switch on when the key is turned to
Press the button shortly to switch over the “Trip” function and the "ON" or if it stays on, have the electrical circuit checked by an
kilometre counter. Press the “Selection” button for some seconds authorised Benelli centre.

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to set the digital time.
Digital clock setting: 10. DIGITAL CLOCK
Keep pressed the switch of the menu “2” for 3 seconds to ac- It shows the time expressed in hours and minutes.

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cess the setting mode “TOTAL KM”.
Press and hold down the button ”2“ for three seconds until the 11. NEUTRAL GEAR INDICATOR LIGHT
hour digit begins to flash. It indicates the engaged gear.
Set the hour by pressing the button “3”.
12. TOTAL/PARTIAL KILOMETRE COUNTER
Press the button ”2“ to access minute setting. Set the required
minutes by pressing the button ”3“. Press the button “2” again to
exit. S
The total kilometre counter shows the total distance covered
in kilometres,. The partial kilometre counter (TRIP) shows the
R
distance covered after the latest reset.
4. COOLANT TEMPERATURE GAUGE The partial kilometre counter can be used to estimate the possi-
ble distance to cover with a full tank of fuel. This information may
TO

It shows the coolant temperature in °F (Fahrenheit) or C° (Cel-

sius). make it possible to schedule future fuelling stops.

5. SELF-DIAGNOSIS LIGHT 13. COOLANT TEMPERATURE GAUGE

The light warns the driver of failures of the power supply and The light goes on in yellow in case of engine overheating.
O

ignition systems, by switching on the engine yellow light (LED)

14. SPEEDOMETER
when their parts are faulty. Furthermore, it starts the protective
function. In the event of serious problems, the control unit stops It indicates the vehicle speed in km/h or mph. Press the button
M

the injection/ignition function and it is necessary to contact an “Selection” 3 to pass from an indication to another.
authorized service centre Benelli at soonest.
A

4 5 6 7 8 9
D
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17 10

11

16
1 13
14
15
2 12
3

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- Benelli TRK 502 - Page 8
 FEATURES
MULTIFUNCTION DISPLAY
15. FUEL TANK CAPACITY AND RESERVE FUEL GAUGE
The digital fuel gauge shows the capacity of the fuel tank. As the
fuel level drops, the lines on the gauge will become closer and
closer to the "E" reserve area.
From the moment in which the last line starts flashing, the vehi-
cle has a fuel range of about 3 litres.

16. LIGHT (ABS)

The anti-lock braking system of brakes goes on when starting to
check the system and turns off if the check outcome is positive.

17. RIGHT DIRECTION INDICATOR LIGHT (GREEN)

It goes on when the left direction indicator light is activated.

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17 10
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11
M

16
A

1 13
D

14
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15
2 12
3

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- Benelli TRK 502 - Page 9
 IMPORTANT INFORMATION

GETTING READY FOR REMOVAL AND DISAS-

SEMBLY OPERATIONS

• Before proceeding with disassembly, remove any dirt, mud,

dust, and foreign bodies.

• Only use suitable cleaning tools and agents.

See the paragraph “SPECIAL TOOLS”.

• During vehicle’s disassembly, it is advisable to always keep

the matching parts together, among which gears, cylinders,
pistons, and other parts, whose surface have been “cou-
pled” owing to the normal operating wear. The matching
parts must always be reused/replaced collectively. During

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the disassembly operations, clean all parts and position
them in a container following the disassembly order. This
will make the reassemble operations easier and allow a

20
correct installation of all parts.

• Keep all components away from any heat source.

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SPARE PARTS
O

Only use original Benelli spare parts. For part lubrication, use
oils and greases recommended by Benelli. Other brands may be
similar in appearance and function, but have a lower quality.
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- Benelli TRK 502 - Page 10
 IMPORTANT INFORMATION

GASKETS, O-RING, OIL SEALS, AND BEARINGS

Always replace all gaskets, oil seals, and O-rings during the
engine repairing interventions.
olio E The surfaces of gaskets, the oil seal lips, and the O-rings must
labbro labbro motore be always cleaned.
During installation, suitably oil all parts subjects to coupling and
molla the bearings. Furthermore, lubricate the oil seal lips with engine
olio oil.

21
a Install the bearings and the oil seals so that the brand or the
manufacturer numbers facing outwards are clearly visible. To

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position the oil seals, lubricate the lips with a layer of engine oil.
During installation of the bearings, lubricate them thoroughly.

a. Oil seal
E
b.
S
Bearing
R
b
IMPORTANT NOTICE
TO

Do not use compressed air to dry the bearing whilst turning

them, since the surface might be damaged.
O

SAFETY WASHERS/PLATES, COTTER PINS, AND

M

THREAD SEALANT
A

After removal, replace all safety washers “A”, the safety plates,
and cotter pins.
D

After having tightened the bolt or the nut as per specifications,

bend the locking tab and the cotter pin ends against the surface
BA

of the bolt or nut.

A

Before applying the thread sealant, always degrease both parts

with solvent.

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- Benelli TRK 502 - Page 11
 IMPORTANT INFORMATION

SAFETY SNAP RINGS

A
Before reassemble them, check all snap rings thoroughly and
C replace the damaged/deformed ones.
Always replace the snap rings of the piston pin after having used
B them once. When installing a snap ring “A”, make sure the sharp
edge “B” is positioned on the other side compared to the thrust
“C” that it receives.

D Shaft “D”

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1 CHECKING CONNECTIONS

Make sure there are no stains, rust, humidity, etc. on wires,

20
couplers, and connectors.

1. Disconnect:
• the wire
• the coupler
•
S
the connector
R
TO

2 2. Check:
O

• the wire
• the coupler
M

• the connector

In presence of humidity → Dry using a fan.

In presence of rust/stains → Connect and disconnect the parts
A

several times.
D
BA

3 3. Check:
• all connections
In case of loose connections → Connect them properly.

NOTE:_________________________________
If the foot of the terminal “A” is bent, raise it.

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- Benelli TRK 502 - Page 12
 IMPORTANT INFORMATION

4. Connect:
4 • the wire
• the coupler
• the connector

NOTE:_________________________________
Make sure all connections are installed tightly.

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5. Check:
5 • continuity (using a pocket tester)

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NOTE:_________________________________
If there is no continuity, clean the terminals.
For checking wiring, follow the procedure of points from “1” to ”3”.
As quick remedy, it is advisable to use a specific product for the
contacts, which is available in the spare part shops.

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- Benelli TRK 502 - Page 13
 SPECIAL TOOLS

The special tools indicated herein serves for the complete and precise execution of the setting/assembly operations.
Their use helps to prevent damages caused by unsuitable tools or improvised techniques.
When placing an order, refer to the list below to avoid mistakes.

ENGINE SPECIAL TOOLS

Tool Code Tool Name-Function Image
Pad for valve oil seal
This tool serves to install the valve oil seal
in place.
R180197025000

21
Clutch disassembly wrench
This tool serves to lock the clutch drum
and tighten the nut.

20
0320097047000

Pad for piston pin removal

S
This tool serves to extract the piston pin.
R
Standard tool commonly found
TO

Tool for valve oil seal removal

This tool serves to extract the valve oil
O

seal.
Standard tool commonly found
M

Ring clamp tool

A

This tool serves to assemble the piston

O-rings and for the subsequent insertion
Standard tool commonly found into the cylinder.
D
BA

Gear selector drum assembly tool

This tool serves to assemble the gear se-
lection drum.

0320097051000

Flywheel extractor
This tool serves to extract the flywheel
from the engine shaft.
0320097045000

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- Benelli TRK 502 - Page 14
 SPECIAL TOOLS

ENGINE SPECIAL TOOLS

Tool Code Tool Name-Function Image
Flywheel cover extractor
This tool serves to extract the flywheel
housing cover.
0320097045000

Engine phasing tool

This tool serves to determine the position
of the top dead centre.
R180197022000

21
Oil filter tool
This tool serves to tighten or disassemble
the engine oil filter.
Standard tool commonly found

20
Chain tensioner lock tool
This tool serves to lock the tensioning pis-

S
ton during the assembly phase of the chain
tensioner.
R
0320097046001
TO

Tool to remove/assemble the clutch bell

O

ring nut
This tool is used to disassemble/assemble
M

of the notched ring nut, which clamps the

03200097052000 clutch bell.
A
D

Valve spring compressor tool

This tool is used to remove the valve
BA

springs.

0320097050000

Measuring tool commonly found

This tool is used to measure the hole inner
dimensions.
Standard tool commonly found

1 - 11
- Benelli TRK 502 - Page 15
 SPECIAL TOOLS

ENGINE SPECIAL TOOLS

Tool Code Tool Name-Function Image
Measuring tool commonly found
This tool is used to measure the outer di-
mensions of parts.
Standard tool commonly found

Measuring tool commonly found

This tool is used to measure thicknesses.
Standard tool commonly found

21
Flywheel assembly tool
This tool serves to tighten the engine shaft

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flywheel.

0320097044000

S
R
TO

Tool to remove the magnetic cap from

the alternator cover
This tool serves to unscrew the magnetic
O

cap of the alternator cover.

0320097043000
M
A
D

Toothed wrench for clutch bell lock

This tool is used to disassemble the clutch
BA

bell.

03200097053000

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- Benelli TRK 502 - Page 16
 SPECIAL TOOLS

SPECIAL FRAME TOOLS

Tool Code Tool Name-Function Image
Tool to tighten the steering sleeve lock
nut
This composed tool is used to tighten the
steering sleeve lock nut.

Standard tool commonly found

Tool to tighten the front wheel pin

21
This tool serves to tighten the front wheel
pin.
Standard tool commonly found

20
Tool to extract the rear swing arm bear-
ings

Standard tool commonly found S

This tool serves to extract bearings.
R
TO

Lifting jack
It allows to lift the frame and the engine.
O
M

Standard tool commonly found

A
D
BA

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 CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .......................................................................................................................3
TECHNICAL DATA ........................................................................................................................................4
ENGINE SPECIFICATIONS .......................................................................................................................................................4
FRAME SPECIFICATIONS.........................................................................................................................................................9
ELECTRICAL SPECIFICATIONS .............................................................................................................................................13
GENERAL TIGHTENING SPECIFICATIONS ...........................................................................................................................17
TIGHTENING TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS ................................................18
TIGHTENING TORQUES .........................................................................................................................................................18

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- Benelli TRK 502 - Page 19
 GENERAL SPECIFICATIONS

SIZE STANDARD
Total length (A) 2200 mm
Total width (B) 915 mm
Total height (C) 1450 mm
Wheelbase (D) 1525 mm

WEIGHT STANDARD
Kerb weight (with full oil and 235 kg
fuel tank)
Empty (with no oil and empty fuel tank) 210 kg
Max. technical capacity 217 kg

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(with rider and load)

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D

D
A
BAB

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- Benelli TRK 502 - Page 20
 TECHNICAL DATA
ENGINE SPECIFICATIONS

ENGINE STANDARD
Type of engine 4 stroke, 2 cylinders in line,
liquid cooling, 8 valves
Cubic capacity 499.6 cc
Number of cylinders 2
Cylinder layout In line
Inside diameter × stroke 69x66.8 mm
Compression ratio 11.5:1
Idle speed 1400

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Idle speed 1600
Distribution Double overhead camshaft, chain-con-
trolled, and four-valves for each cylinder

20
Maximum net power 28 kW/1100 rpm (38.06 hp)
Maximum net torque 52 N.m/10500 rpm

FUEL STANDARD
Recommended fuel
S
premium unleaded petrol RON 95 min
R
ENGINE OIL STANDARD
Forced lubrication system with wet sump design
TO

Total amount 3.2 l

Quantity without oil filter cartridge re-
3l
placement
O

Quantity with oil filter cartridge replace-

3.2 l
ment
Recommended oil
M

API SH 15W50 (synthetic)

Jaso -MACCMC g4
10W50
A

OIL FILTER STANDARD

D

Type of oil filter Cartridge

BA

OIL PUMP STANDARD

Oil pump type lobe
Clearance between inner rotor tip and
0.25 mm max
rotor tip
Clearance between outer rotor tip and oil
0.2 mm max
pump housing

STARTING STANDARD
Starting system type electrical

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- Benelli TRK 502 - Page 21
 TECHNICAL DATA
ENGINE SPECIFICATIONS

SPARK PLUGS STANDARD

Model (manufacturer) x quantity NGKCR8E
Distance between electrodes 0.6 ÷ 0.7 mm

CYLINDER HEAD STANDARD

Head gasket maximum warp
0.03 mm

CAMSHAFTS STANDARD
Control system chain drive
Camshaft diameter Ø 22.957-22.97 mm (Limit 22.94 mm)
Clearance between support and camshaft
0.03-0.064

21
cap
Clearance between camshaft and cam-
0.02-0.054mm
shaft seat

20
Camshaft radial clearance 0.01mm (Limit 0.02mm)
Camshaft lobe dimensions on intake side
B

A
S Size “A”= 32.2 mm
Size “B”= 24,8 mm
R
TO

Camshaft lobe dimensions on exhaust

side
B
O

Size “A”= 31.9 mm

Size “B”= 24,92 mm
A
M

Maximum camshaft eccentricity

A

0.04 mm (0.00015 in.)

D
BA

FUEL STANDARD
Recommended fuel lead free petrol RON 93 min.

TIMING STANDARD
CHAIN
Tensioning system Automatic

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- Benelli TRK 502 - Page 22
 TECHNICAL DATA
ENGINE SPECIFICATIONS

VALVES, VALVE SEATS, VALVE GUIDES STANDARD

Intake valve clearance (cold) 0.13 ~ 0.19 mm
Exhaust valve clearance (cold) 0.19 ~ 0.25 mm

VALVE SIZE
Intake Ø 25 mm

A Exhaust Ø 22 mm
Head ”A” diameter

Intake 1.9 ~ 2.1 mm

B

21
Exhaust 1.75 ~ 1.95 mm
Contact ”B” specific length

20
Intake 1 ~ 1.1 mm
C
Seat ”C” width Exhaust
S 1 ~ 1.1 mm
R
Intake 1.9 ~ 2.1 mm
B
TO

Contact surface length Exhaust 1.75 ~ 1.95 mm

Intake 3.965 ~ 3.98 mm

O

Valve stem diameter

Exhaust 3.965 ~ 3.98 mm
Clearance between valve stem and valve guide Intake 0.05 ~ 0.075 mm
M

Exhaust 0.04 ~ 0.065 mm

A

Valve stem eccentricity

0.05 mm
D
BA

VALVE SPRING STANDARD

Outer 38.8 mm
Intake/exhaust free length
Inner 41.6 mm

Intake 1.2 mm

Exhaust 1.2 mm

CYLINDERS STANDARD
Cylinder layout perpendicular line
Bore 69.00-69.01mm (limit 69.02mm)
Compression ratio 11.5:1
Max. ovalization 0.008
0.006

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- Benelli TRK 502 - Page 23
 TECHNICAL DATA
ENGINE SPECIFICATIONS

PISTON STANDARD
Clearance between piston and cylinder 0.05 ~ 0.07 mm
- 0.002
Piston diameter “A” Ø 65 - 0.003 mm
C
Piston height “B” 25 mm
B
A Pin “C” seat - 0.002
Ø 16 - 0.003 mm
diameter
Piston pin outer diameter 0
Ø 16 0.008. mm

Top ring

21
B Type of ring elastic

A Size “A” X ”B” 2.3 x 0.8 mm

20
2nd ring

B Type of ring elastic

A Size “A” X ”B”

S 2.3 x 0.8 mm
R
Oil scraper ring

B
TO

Size “A” X ”B” 2.26 x 1.93 mm

A

CONNECTING RODS STANDARD

O

Bearing colour code A = Red B = Blue C = Yellow

M

Connecting rod code K1 = Black K2 = Green K3 = White

K4 = Brown K5 = Orange

DRIVE SHAFT STANDARD

A
D

B B B
BA

C
A

Width “A” 269.5 mm

Maximum eccentricity “B” 22.6 ± 0.01 mm
Connecting rod head side clearance “C” 0.1 - 0.25
Main bearing colour code A = red B = blue C = yellow

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- Benelli TRK 502 - Page 24
 TECHNICAL DATA
ENGINE SPECIFICATIONS

CLUTCH STANDARD
Clutch type wet clutch, multiple discs
Clutch release cable with springs
Operation for clutch release cable operation
Operation with left handlebar lever
Clutch cable clearance (on end
2 ~ 3 mm
of the clutch lever)
Clutch plate thickness 2.8 ± 0.05 mm - 3 (0, - 0.1) mm
Clutch plate quantity 7
Steel plate thickness 1.6 (0, -0.05) mm

21
Steel plate quantity 7
Plate pack thickness 11.2 mm
Maximum warp 0.05 mm

20
Clutch spring free length 40 ± 0.01 mm
Spring quantity 4

TRANSMISSION STANDARD
Transmission type
Main reduction ratio S straight-toothed gearbox
44/82
R
Second reduction system
TO

Transmission ratio Chain, ratio 14:46

1st 13-37
2nd 19-37
3rd 18-28
O

4th 24-32
5th 21-25
M

6th 24-26

GEAR SHIFT MECHANISM STANDARD

A

Gear shift mechanism type sequential with Desmodromic valve and prese-
lector
D

Maximum deformation of shift fork guide bar Straightness 0.02

Roundness 0.005
BA

AIR FILTER STANDARD

Air filter type SPONGE

FUEL PUMP STANDARD

Pump type electric pump
Model (manufacturer) Delphi
Output pressure 250 KPa

THROTTLE BODY STANDARD

Diameter 37 mm
Accelerator cable clearance Rotating type
(at accelerator handle flange)

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- Benelli TRK 502 - Page 25
 TECHNICAL DATA
FRAME SPECIFICATIONS

FRAME STANDARD
Modular trellis frame with the front module in stainless
Frame type steel and the rear module in die-cast aluminium
Steering head angle N.D.
Trail N.D.

FRONT WHEEL STANDARD

Wheel type 6-spoke aluminium alloy
Measure 17 M/C x MT3.50 DOT-D

21
Rim
Material aluminium
Wheel travel 120 mm

20
REAR WHEEL STANDARD
Wheel type 6-spoke aluminium alloy

Rim
Measure S 17 M/C x MT4.50 Dot -D
R
Material aluminium
TO

Wheel travel 122 mm

FRONT TYRE STANDARD

O

Tyre type tubeless

Measure 120/70 ZR17 M/C(58W)
M

Model (manufacturer) N.D.

Tyre pressure (when the tyre is being cooled) 2.4 Bar.
A

REAR TYRE STANDARD

D

REAR TYRE tubeless

BA

Measure 160/60 ZR17 M/C (73) W

Model (manufacturer) N.D.
Tyre pressure (when the tyre is being cooled) 2.4 Bar.

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- Benelli TRK 502 - Page 26
 TECHNICAL DATA
FRAME SPECIFICATIONS

FRONT BRAKE STANDARD LIMIT

Brake type dual-disc brake
semi-floating
Activation use right hand
Recommended fluid DOT4
Brake discs

Diameter × thickness 320 x 4 mm (12.5 x 0.15 in)

Minimum thickness 4.0 mm (0.15in)
Maximum deformation 0.1 mm (0.004in)

21
Thickness of
4 mm (0.15 in)
worn brake pads

20
Inner diameter of pump cylinder 16 mm (0.62in)
Inner diameter of caliper cylinder 34 e 30 mm (1.33 e 1.18 in)

REAR
F BRAKE
S
STANDARD LIMIT
R
Brake type single-disc brake
Activation
A use right foot
TO

Recommended
F fluid DOT4
Brake discs
O

Diameter × thickness 260 x 5 mm

M

Minimum thickness 4.5 mm (0.17in)

Maximum deformation 0.15mm (0.006in)
A

Thickness of
4 mm
worn brake pads
D

Inner diameter of pump cylinder 12 mm (0.47in)

BA

Inner diameter of caliper cylinder 32 mm (1.25 in)

2 - 10
- Benelli TRK 502 - Page 27
 TECHNICAL DATA
FRAME SPECIFICATIONS

FRONT SUSPENSION STANDARD

Upside-down fork
Suspension type with 50 mm diameter tubes

Fork travel 150 mm

Spring

Free Length 295 mm

Spacer length 137 mm

21
Flexibility (K1) 8.6 Nm
Spring stroke (K1) 0 ~ 120mm (0 ~ 4.72 in)

20
Fork oil

Recommended oil SAE 7.5 Marzocchi 19

Quantity per stem S 770 cc.
R
Level (from the top of the outer
side, with the outer side
TO

95 mm
completely compressed and
without the fork spring)

STEERING STANDARD
O

Bearing type for steering ball bearing

M

Angle from one end of stroke to the other (left) 30°

Angle from one end of stroke to the other (right) 30°
A
D
BA

2 - 11
- Benelli TRK 502 - Page 28
 TECHNICAL DATA
FRAME SPECIFICATIONS

REAR SUSPENSION STANDARD

Swing arm in aluminium alloy, gas-adjustable
Suspension type shock absorber in hydraulics extended
and spring preloaded
Shock absorber fork travel 45 mm
Spring

Free Length 178+/- 1,5 mm

21
Installed length 167+/- 1,5 mm
Flexibility (K1) 16 Nm

20
Spring stroke (K1) 42+/- 1 mm

Spring preload gas/air standard pressure 1200 kPa (12 bar)

Spring preload adjustment S

R
positions Minimum 0
TO

Standard 0
Maximum 10 mm (0.39in)
O

Rebound damping adjust-

M

ment positions Minimum* 0

Standard* -17
A

Maximum* - 30
* from the fully retracted position
D

TRANSMISSION CHAIN STANDARD

BA

Model (manufacturer) N.D

Quantity of chains N.D
Slackness of transmission chain N.D

2 - 12
- Benelli TRK 502 - Page 29
 TECHNICAL DATA
ELECTRICAL SPECIFICATIONS

SYSTEM VOLTAGE STANDAR D

System voltage 12 V

IGNITION COILS STANDAR D

Model (manufacturer) QJ
Primary coil resistance 0,65 ± 0,07 Ohm
Secondary coil resistance 4 ± 0,5 kOhm
Primary coil inductance 1,8 mH

21
Secondary coil inductance 4.7 H
Max. allowable current value 10 A

20
RECHARGE SYSTEM STANDAR D
System type Magnetic AC
Model (manufacturer)
S QJ
R
Rated output 12.8 V a 1400 rpm 14A
TO

Voltage regulation 13.5 + 0.5 V (3000 rpm 25 C°)

IGNITION RELAY STANDAR D

O

Model (manufacturer) QJ
Amperage 100 A
M

Coil resistance 4.4 Ohm a 20°C

A

BATTERY STANDAR D
D

Model (manufacturer) YTX9-BS

Voltage of battery capacity 12 V / 8 Ah
BA

Inrush current CCA 120A

HEADLAMP STANDAR D
Headlamp type halogen lamp

BULBS (VOLTAGE WATT x QTY) STANDAR D

Headlamp (High beam/low beam light) 12 V 55 W x 2
Front position indicator light LED
Rear position indicator light/brake light LED
Direction indicators LED
License plate light 12 V 5 W x 1

2 - 13
- Benelli TRK 502 - Page 30
 TECHNICAL DATA
ELECTRICAL SPECIFICATIONS
License plate light
Instrument board light LED x 1

LIGHTS (VOLTAGE WATT x QTY) STANDAR D

Neutral indicator light LED x 1
High beam light LED x 1
Oil level alarm light LED x 1
Indicator light LED x 1
Faulty engine warning light LED x 1

21
20
ELECTRIC IGNITION SYSTEM STANDARD
Model (manufacturer) S QJ
R
Power output 0.7 kw
TO

HORN STANDARD
Horn type low
O

Model (manufacturer) QJ
M

Maximum amperage 3A
Performance 105 ~ 118 db (A)
A

FLASHER RELAY STANDARD

D

Relay type Electronic Flasher

BA

Model (manufacturer) QJ 600 45 Flasher

Blinking frequency of direction indicators 80 ~160 cicli/min

Watt 130mA x4

OIL PRESSURE SENSOR STANDARD

Model (manufacturer)/Calibration 0,05 ± 0,015MPa

2 - 14
- Benelli TRK 502 - Page 31
 TECHNICAL DATA
ELECTRICAL SPECIFICATIONS

FUSES (AMPERAGE x QTY) STANDARD

Fuse CD1 (control unit) 15 A (Blue)
Headlamp fuse 15 A (Blue)
Service fuse 40 A (Red)
Radiator fan fuse 15 A (Blue)
Backup fuse 15 A (Blue) + 40 A (Red)
Fuel pump fuse 15 A (Blue)

21
THROTTLE VALVE SENSOR STANDARD

20
Model (manufacturer) TGKEYAIR
Resistance 2 KOhm ± 20%

FUEL PUMP
S STANDARD
R
Model N.D
Max. amperage N.D.
TO

Level sensor external

Min. Max. resistance 90-95 Ω (empty) - (full) 0-18Ω
O

SAFETY SWITCHES STANDARD

M

Stand switch N.D

Neutral switch QJ
A

Tilt QJ 250T-3(QJ)
D

AIRBOX AIR TEMPERATURE SENSOR STANDARD

BA

Model (manufacturer) 12160244 (PACKARD)

Resistance 181±8 Ohm 100°C
THROTTLE BODY AIR PRESSURE SENSOR
STANDARD
Model (manufacturer)/Power supply voltage 240600695(DELPHI) /5V

2 - 15
- Benelli TRK 502 - Page 32
 TECHNICAL DATA
ELECTRICAL SPECIFICATIONS

LIQUID TEMPERATURE SENSOR STANDARD

Model (manufacturer) WC -12A (QJ)
Resistance 100 °C 178 Ohm

VELOCITY SENSOR STANDARD

Model (manufacturer)/distance GAP QJ / 1.1mm - 2.2 mm

LAMBDA PROBE STANDARD

21
Model (manufacturer) OSM (Delphi)

INJECTOR STANDARD

20
Model (manufacturer) Mini (Delphi) 12±1Ω

RELAY UNIT STANDARD

Model (manufacturer) S CM1 NAIS
R
IGNITION SYSTEM STANDARD
TO

Type of ignition system BOSCH MSE6.0

Ignition system phasing 10° before the TDC from 900 to 1800 rpm
O

Phonic wheel sensor (pick-up) 550±50Ω

Model (manufacturer) DELPHI
M

STEPPER STANDARD
A

Model (manufacturer) LOREADA

D

Model (manufacturer) two-phase

RADIATOR FAN STANDARD

BA

Model (manufacturer)/Power consumption Panasonic SSW7109/ 2,76A @ 12V

2 - 16
- Benelli TRK 502 - Page 33
 TECHNICAL DATA
GENERAL TIGHTENING SPECIFICATIONS

The tightening torques of the different special parts or assem-

blies are provided in each chapter of this manual.
As far as concerns assemblies with multiple fastenings, in order
to prevent the risk of warping, cross tighten in successive stag-
es, until you reach the required torque.
Unless otherwise stated, the tightness torques refer to parts with
B clean, dry threads.
A Parts must be at ambient temperature.

21
“B” GENERAL TIGHTENING
NUT TORQUES

20
N.m Kgf.m
4 mm 2.3 0.23
5 mm 4.5 0.45
6 mm
8 mm
10
25
1.01
2.54 S
R
10 mm 45 4.58
12 mm 80 8.15
TO

14 mm 130 13.25
16 mm 200 20.39
18 mm 240 24.47
O
M
A
D
BA

2 - 17
- Benelli TRK 502 - Page 34
 TECHNICAL DATA
TIGHTENING TORQUES

TIGHTENING TORQUES AND RELEVANT PRELOADS FOR STANDARD CONNECTIONS

The values provided in the following table refer to standard tightness, i.e. metric screws coupled with relevant nut or with lead screw
in metal.
The parts to be tightened together must be in metal or sufficiently rigid not to need the insertion of bushing or shims.
Coupling must always use lightly oiled or greased threads; alternatively, the type of thread lock paste required will be indicated
Axial preloads, related to tightness torques, have been increased by 10% on the calculated value to take into account the tolerance
on the nominal torque and the changes that the friction coefficient may undergo between tightening operations.

CLASS 8.8 CLASS 10.9 CLASS 12.9

21
SCREW TIGHTENING AXIAL TIGHTENING AXIAL TIGHTENING AXIAL
TORQUE PRELOAD TORQUE PRELOAD TORQUE PRELOAD
[Nm] [N] [Nm] [N] [Nm] [N]
M4 X 0.7 3 3.870 4.2 5.420 5.2 6.710

20
M5 X 0.8 6 6.350 7.5 7.930 9 9.520
M6 X 1 10 8.860 13 11.520 16 14.180
M8 X 1.25 22 14.900 30 20.330 40 27.100
M8 X 1 (*) 25 17.280 36 24.890 45 31.110
M10 X 1.5 45 24.680 65
S 35.640 80 43.870
R
M10 X 1.25 (*) 50 27.870 70 39.013 85 47.380
M12 X 1.75 80 37.640 110 51.750 135 63.510
TO

M12 X 1.5 (*) 85 40.547 120 57.250 145 69.170

M12 X 1.25 (*) 90 43.550 130 62.900 150 72.580
M14 X 2 130 52.670 185 74.800 220 88.950
M14 X 1.5 (*) 150 62.900 205 85.960 245 102.780
O

M16 X 2 200 74.070 280 103.690 335 124.060

M

M16 X 1.5 (*) 225 86.140 310 118.680 360 137.820

M18 X 2.5 265 83.650 370 116.790 450 142.040
M18 X 1.5 (*) 320 104.900 450 147.520 550 180.300
A

M20 X 2.5 390 111.870 550 257.770 650 186.450

M20 X 1.5 (*) 440 130.620 630 187.020 750 222.650
D

M22 X 2.5 540 141.950 750 197.150 900 236.580

M22 X 1.5 (*) 600 162.750 850 230.560 1.000 271.240
BA

M24 X 3 670 160.238 950 227.203 1.130 270.252

M24 X 2 (*) 750 184.566 1.050 258.392 1.250 307.610

(*) The metric screw indicated has a fine pitch.

2 - 18
- Benelli TRK 502 - Page 35
 21
20
S
R
TO
3
O
M
A
D
BA

3-1
- Benelli TRK 502 - Page 36
 CHAPTER 3
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ...................................................................5
MAINTENANCE INTERVALS .....................................................................................................................................................6
ENGINE/AIR BOX ..........................................................................................................................................9
REMOVAL/ASSEMBLY OF AIR BOX .........................................................................................................................................9
ENGINE/THROTTLE CABLE CLEARANCE...............................................................................................11
ADJUSTMENT OF THROTTLE CABLE CLEARANCE ............................................................................................................11
ADJUSTMENT OF IDLE SPEED..............................................................................................................................................14
ENGINE/CLUTCH CABLE...........................................................................................................................15
ADJUSTMENT OF CLUTCH CABLE CLEARANCE ................................................................................................................15
FRAME/HANDLEBAR .................................................................................................................................16
REAR-VIEW MIRROR ADJUSTMENT .....................................................................................................................................16
ENGINE/MOTOR OIL ..................................................................................................................................17

21
CHECKING ENGINE OIL LEVEL .............................................................................................................................................17
ENGINE OIL CHANGE .............................................................................................................................................................18
OIL FILTER REMOVAL/INSTALLATION ...................................................................................................................................19

20
ENGINE/SPARK PLUGS .............................................................................................................................20
REMOVAL OF SPARK PLUGS ON THE VEHICLE ..................................................................................................................20
SPARK PLUG CHECK..............................................................................................................................................................21
ASSEMBLY OF SPARK PLUGS ...............................................................................................................................................23
S
FRAME/BRAKE ADJUSTMENT .................................................................................................................25
R
ADJUSTMENT OF THE FRONT BRAKE .................................................................................................................................25
ADJUSTMENT OF THE REAR BRAKE ...................................................................................................................................26
TO

FRAME/CHECKING BRAKE FUID LEVEL .................................................................................................27

CHECKING THE FRONT BRAKE LIQUID LEVEL/TOPPING UP ............................................................................................27
CHECKING THE REAR BRAKE LIQUID LEVEL/TOPPING UP ..............................................................................................28
FRAME/CHECKING ABS HOSES ..............................................................................................................29
O

CHECK FOR ANY LEAKAGES OF ABS TUBES .....................................................................................................................29

FRAME/BRAKE PAD CHECK .....................................................................................................................30
M

CHECKING WEAR OF FRONT/REAR BRAKE PADS .............................................................................................................30

FRAME/CHECKING HOSES OF THE BRAKING SYSTEM .......................................................................31
HOSE CHECK ..........................................................................................................................................................................31
A

FRAME/TRANSMISSION CHAIN ................................................................................................................32

ADJUSTMENT OF THE TRANSMISSION CHAIN ...................................................................................................................32
D

LUBRICATION OF TRANSMISSION CHAIN ...........................................................................................................................33

CHAIN GUIDE CHECK .............................................................................................................................................................33
BA

CHECKING WEAR OF TRANSMISSION CHAIN.....................................................................................................................34

FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE ................................................................35
CHECK/ADJUSTMENT OF STEERING CLEARANCE ............................................................................................................35
FRAME/CHECK OF FRONT FORK ............................................................................................................37
CHECK OF FRONT FORK .......................................................................................................................................................37
FRAME/CHECK OF REAR SHOCK ABSORBER ......................................................................................38
SHOCK ABSORBER ADJUSTMENT .......................................................................................................................................38
FRAME/CHECK OF FRONT/REAR TYRES ...............................................................................................39
TYRE CHECK ...........................................................................................................................................................................39

3-2
- Benelli TRK 502 - Page 37
 CHAPTER 3
ELECTRICAL SYSTEM ...............................................................................................................................40
BATTERY CHECK AND CHARGING .......................................................................................................................................40
FUSES ......................................................................................................................................................................................49
FUSE CHECK ...........................................................................................................................................................................50
REPLACEMENT OF THE FRONT LIGHTS..............................................................................................................................51
REMOVAL OF THE FRONT HEADLIGHT ................................................................................................................................52
INSTALLATION OF THE HEADLIGHT .....................................................................................................................................53
ADJUSTMENT OF HEADLIGHT ..............................................................................................................................................54
SUBSTITUTION OF THE REAR LED LIGHT ...........................................................................................................................55
SUBSTITUTION OF THE REAR INDICATOR LIGHTS ............................................................................................................56
SUBSTITUTION OF THE FRONT INDICATORS .....................................................................................................................57
SUBSTITUTION OF THE IGNITION BLOCK ...........................................................................................................................58

21
20
S
R
TO
O
M
A
D
BA

3-3
- Benelli TRK 502 - Page 38
NOTES:
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................

21
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................

20
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................

S
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
R
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
TO

..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
O

..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
M

..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
A

..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
D

..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
BA

..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................
..................................................................................................................................................................................................................

3-4
- Benelli TRK 502 - Page 39
 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

NOTE:___________________________________________
In general, maintenance needs to be carried out with the motorcycle on the rear stand, engine off and switch in “OFF” posi-
tion.
While checking fluid levels, it is preferable to keep the motorcycle upright without using the rear stand.
Annual checks are to be carried out every year unless maintenance is carried out basing on the maintenance service system
according to the mileage travelled.
At 40,000 km (24,854 mi), repeat maintenance services from the one at 10,000 km (6,213 mi). For interventions relating the
items marked, it is advisable to contact a Benelli dealer, given that it is necessary to have specific equipment, information,
and technical skills.

The following section shows all maintenance operations.

21
NOTE:___________________________________________

20
AIR FILTER
• Replace the air filter more frequently when the vehicle is used in particularly damp or dusty environments.

HYDRAUILC BRAKE MAINTENANCE

• Check brake fluid levels on a regular basis and top up, if necessary.

S
• Replace the inner parts of the brake/calliper pump every two years and change the brake fluid.
• Replace the brake hoses every 4 years, or before if cracked or damaged.
R
TO

KEY
I Checking, adjustment, cleaning, lubrication or replacement as required
R Replacement
O

T Tighten
Dealer
M
A
D
BA

3-5
- Benelli TRK 502 - Page 40
 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
MAINTENANCE INTERVALS

1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km

0 Km Annual
Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi)
NO. Part
nance interventions
(0 mi)
1ST 2ND 3RD 4TH 5TH
inspec-
Pre-delivery tion
Service Service Service Service Service

Check/Level top up/

I R R R R R R
1 Engine oil Change
Check every 500 km (310 mi)
Replacement R R R R R
2 Oil filter
In any case at every engine oil change
Check/Replacement I I R I
3 ◙ Fuel filter

Check/Replacement R R R R
4 ◙ Air filter

21
Coolant Check/Top up I I I I R I I
5 ◙
liquid Replace Every 2 years or 13,000 km (8,078 mi)
Check the coolant level
Cooling and make sure there I I I I I I I

20
6 ◙
system are no leakages
of fluid from the vehicle
Check/Replacement I I R R I
7 ◙ Spark plugs
Check the status, clean and adjust the distance between electrodes.

◙
Transmission
Measure chain tension.
Check whether the
I
S I I I I I
R
8 chain
rear wheel is properly
aligned. Clean and Every 500 km (310 mi) and after every wash or if the motorcycle was used in the rain.
grease.
TO

Check/Lubricate I I I I I I
9 ◙ Chain wheel
Replace in any case at every chain change.
Pinion/ I I I I I I
10 ◙ Clamping Check/Replacement
Replace in any case at every chain change.
O

washer
Fuel line Check for faults and I I I R
11 ◙
circuit leakages. Replace in any case every 3 years.
M

Brake fluid Check/Top up I I I I I I I

12 ◙
* clutch Replace Replace every 2 years.

Check the fluid

A

level and make sure I I I I I I I

Front brake/
13 ◙ there are
Rear brake
D

no leakages form the

vehicle.
BA

Check/Replacement I I I I I
14 ◙ Brake pads
Replace if worn up to limit.
Swing arm Check/Replacement I I I I I
15 ◙
chain slide Replace if worn up to limit.
Swing arm Check/Replacement I I I I I
16 ◙ chain guide
slide Replace if worn up to limit.
Check operation and I I I I I I I
adjust throttle cable
Throttle
17 ◙ clearance, if necessary.
grip
Lubricate throttle grip
housing and the cable.
Check operation/Adjust
I I I I I
18 ◙ Throttle body clearance

Clutch Check/Adjustment I I I I I I I
19 ◙
control
Check/Adjustment I I I I I
20 ◙ Throttle body

Check operation/Adjust
Valve clear- I
21 ◙ clearance
ance
Check clearance every 22,000 km (13,670 mi)

3-6
- Benelli TRK 502 - Page 41
 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
MAINTENANCE INTERVALS

1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km

0 Km Annual
Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi)
NO. Part
nance interventions
(0 mi)
1ST 2ND 3RD 4TH 5TH
inspec-
Pre-delivery tion
Service Service Service Service Service

Distribution Check/Replacement R
22 ◙
chain Every 21,000 km (13048 mi)
Distribution Check/Replacement R
23 ◙
chain slides When replacing the timing chain and every 22,000 km (13671 mi)
Timing chain Check/Replacement R
24 ◙
tensioner When replacing the timing chain and every 22,000 km (13671 mi)
Check/Adjustment T T T T T T T
Steering nut
25 ◙
and sleeve

21
Steering Check/Replacement T T
26 ◙
bearings Every 19,000 km (11,806 mi) lubricate using lithium soap grease
Front/rear Check/Replacement I I
27 ◙ wheel bear-
Every 40,000 km (24900 mi)

20
ings
Swing arm Check/Replacement I I I R
28 ◙
bearings Every 25,000 km (14904 mi)
Check operation and I I I I
make sure the clear-
29 ◙ Swing arm
ance is not
excessive.Lubricate. S
R
Check operation and I I I I I I
Front sus-
30 ◙ make sure there are no
pension
leakages.
TO

Front sus- R R
31 ◙ Replacement
pension oil

Checking/adjustment, I I I I
Rear suspen- I I
32 ◙ make sure
O

sion
there are no leakages.
Before each use
Check they are not I I I
M

33 ◙ Wheels off-centred
or damaged. Every 18,000 km (11,184 mi)
Check the depth of I I I I I I
tread and make sure
A

they are not damaged.

34 ◙ Tyres Replace, if necessary.
D

Check in ation pres- Replace if worn up to limit.

sure.
Correct, if necessary.
BA

Check/Operation I I I I I I I
35 ◙ Side stand

Switch Check/Operation I I I I I I I
36 ◙
side stand
Equipment, Check/Operation I I I I I I I
lights, indica-
37 ◙
tor lights, and
switches
Check/Operation I I I I I I
38 ◙ Headlamp
Adjustment At every change in vehicle set-up
Check/Operation I I I I I I I
39 ◙ Horn

Instrumen- Check/Operation I I I I I I I
40 ◙
tation
Battery Check/Operation I I I I I I I
41 ◙
connections
Electrical Check/Operation I I I I I I I
42 ◙
System
Ignition Check/Operation I I I I I I I
43 ◙
switch

3-7
- Benelli TRK 502 - Page 42
 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
MAINTENANCE INTERVALS

1000 Km 7,000 Km 13,000 Km 19,000 Km 25,000 Km

0 Km Annual
Checks or mainte- (621 mi) (3,726 mi) (7,452 mi) (11,178 mi) (14,904 mi)
NO. Part
nance interventions
(0 mi)
1ST 2ND 3RD 4TH 5TH
inspec-
Pre-delivery tion
Service Service Service Service Service

Check/Operation I I I I I I I
44 ◙ Electric fans

Carburation / Check/Adjustment I I I I I I I
45 ◙
CO° Every 13,000 km (8,077 mi)
Ensure all nuts, bolts T T T T T T
Chassis part
46 ◙ and screws have been
fixing
accurately tightened.
Oil sump Replacement T T T T T
47 ◙
screws
T T T T T

21
Clutch cover
48 ◙ Replacement
screws
Catalytic Check for faults and I I I I R
49 ◙
converter leakages. No maintenance required. In case of malfunction, replace.

20
Cannister I I I I R
Check for faults and
50 ◙ USA
leakages. No maintenance required. In case of malfunction, replace.
version
I I I I I I I

51 ◙
Brake hoses
/clutch
Check for faults and
leakages.
S Over 4 years
R
Check/Replacement I I I I I I I
Moving parts
52 ◙
TO

and cables Before each use

Oil intake Check/Replacement I I I I

53 ◙
filter
O
M
A
D
BA

3-8
- Benelli TRK 502 - Page 43
 ENGINE/AIR BOX
REMOVAL/ASSEMBLY OF AIR BOX

18

21
20
S
R
TO
O
M

Position Description Quantity

A

1 COMPLETE AIR FILTER BOX 1

D

2 SCREW (M6X16) 2
3 AIR TEMPERATURE SENSOR 2
BA

4 SCREW BAND 2
5 SLEEVE 1
6 Hose holder clip 2
7 CANISTER FILTER 1
8 SPRING BAND 4
9 PIPE 1
10 CHECK VALVE 1
11 PIPE 1
12 VALVE 1
13 SPRING BAND 4
14 PIPE 1
15 PIPE 1
16 PLATE 1
17 SCREW (M6X16) 2
18 AIR FILTER 1

3-9
- Benelli TRK 502 - Page 44
 ENGINE/AIR BOX
REMOVAL/ASSEMBLY OF AIR BOX

Park the motorcycle on a level surface.

A
IMPORTANT NOTICE 2
Prop the motorcycle on suitable supports so that it cannot
fall.

Remove:
• Rider and passenger seats, see chapter entitled “Removal 1
of rider and passenger seats, Chapter 4”.
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• Tank fairing, see chapter entitled “Removal of tank fairing,
Chapter 4”.

21
• Tank, see chapter “Fuel tank removal, Chapter 4”.
• the screws (1) Fig. A
• the cover (2) Fig. A 3

20
Disconnect:
• the connector (3) from the cover Fig. A
Remove:
• the protective mesh (4) Fig. B
•
1.
the air filter element (5) Fig. B
S
R
B
TO

IMPORTANT NOTICE
Replace the air filter element every 12,000 km (7,456 mi)
When using the vehicle in particularly humid climates or in
O

very dusty areas, it is necessary to maintain the air filter ele-

ment more frequently.
4
M

Check:
If the air filter element is faulty, replace or wash it:
5
1. Wash the element using specific solvents.
A

2. Air dry.
3. Apply a specific oil on the whole surface of the air filter
D

element.
BA

IMPORTANT NOTICE
Before installing the air filter element of the air box, remove WARNING
the excess oil, making sure it does not drip any longer.
Never start the engine without having installed the air filter
Install: element first. The unfiltered air causes a quick wear of the
1. During the installation stage, proceed in the opposite direc- engine parts and might damage the engine. Furthermore, us-
tion to above described removal. ing the engine without air filter, setting of the throttle bodies
is affected, causing a worsening of engine performance, as
well as its overheating.
Therefore, make sure the air filter is always in good working
order.
The engine life depends mainly on this part.

3 - 10
- Benelli TRK 502 - Page 45
 ENGINE/THROTTLE CABLE CLEARANCE
ADJUSTMENT OF THROTTLE CABLE CLEARANCE

21
20
ABS

37

S
R
TO

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
1 LEFT VIEW MIRROR
O

2 RIGHT VIEW MIRROR

M

3 HANDLEBAR
4 SCREW
5 GRIP CAP
A

6 GRIP END
7 THREADED INSERT
D

8 LEFT HANDGRIP
BA

9 THREADED INSERT
10 LEFT LIGHT SWITCH
11 RIGHT LIGHT SWITCH
12 ACCELERATOR CONTROL
13 ACCELERATOR CONTROL PIPE
14 FUEL OPEN CABLE
15 FUEL CLOSE CABLE
16 CLUTCH CABLE
17 CLUTCH CONTROL
18 RUBBER BAND
19 SCREW
20 BUSHING
21 ELASTIC WASHER
22 BRAKE PEDAL CONTROL
23 SCREW
24 NUT

3 - 11
- Benelli TRK 502 - Page 46
 ENGINE/THROTTLE CABLE CLEARANCE
ADJUSTMENT OF THROTTLE CABLE CLEARANCE

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
25 SCREW
26 BRAKE PEDAL CONTROL
27 NUT
28 BALL JOINT
29 NUT
30 ADJUSTMENT ROD
31 SCREW
32 RETURN SPRING
33 THREADED PIN

21
34 GEAR PEDAL
35 SCREW
36 TUBE GUIDE

20
37 ABS SWITCH

S
R
TO
O
M
A
D
BA

3 - 12
- Benelli TRK 502 - Page 47
 ENGINE/THROTTLE CABLE CLEARANCE
ADJUSTMENT OF THROTTLE CABLE CLEARANCE

NOTE:___________________________________________
The engine idle speed should be properly adjusted before
A
adjusting the throttle cable clearance.
Check at 10,000 km (6,213 mi) first and then every 10,000 km
(6,213 mi).

Check:
• the throttle cable clearance (A)
Make sure the throttle grip works smoothly. Furthermore, check A
that the max opening position and the automatic closing one can
be reached in any steering position. If outside specifications,
adjust. Fig. A

21
Throttle cable clearance
Dimensions
(A) B
Throttle cable 2 - 3 mm

20
Adjust:
• the throttle cable clearance
Handlebar side
D C
1. Loosen the locknut “D”.
2. Rotate the adjusting nut “C” clockwise or counter-clockwise
S
R
up to the specified throttle cable clearance. Fig. B
Throttle cable clearance Clearance
TO

Clockwise The gap is increased

Anticlockwise The gap is decreased

3. Tighten the lock nut “D”.

O

Carry out the adjustment on both accelerator controls.

M

WARNING
After having adjusted the throttle cable clearance, start the
engine and turn the handlebar to the right and to the left,
A

making sure the engine idle speed does not change.

D
BA

3 - 13
- Benelli TRK 502 - Page 48
 ENGINE/THROTTLE CABLE CLEARANCE
ADJUSTMENT OF IDLE SPEED

Check:
• Start the engine and warm it up.
A
• Extract the left, side guard by loosening the screw ”A” Fig.
A.
• Loosen lock nut “B” and rotate the adjusting screw ”C” to
obtain the correct idle speed. Fig. B
• Accelerate and decelerate a few times to make sure the idle
speed is within the indicated range. Adjust again, if neces-
sary.

Throttle cable clearance mm

Throttle cable clearance on
3 ~ 5 mm (0.11 ~ 0.19 in)

21
the accelerator grip)

20
Idle speed rpm
STANDARD 1,400 -1,600
S C
R
B
TO

WARNING
If the handlebar movement leads to variations in the idle
speed, the throttle cables may be adjusted or routed improp-
O

erly or be damaged.
Correct these anomalies before use.
M

IMPORTANT NOTICE
A

The use of the vehicle with damaged cables or improperly

adjusted/routed may jeopardize
the driving safety.
D
BA

3 - 14
- Benelli TRK 502 - Page 49
 ENGINE/CLUTCH CABLE
ADJUSTMENT OF CLUTCH CABLE CLEARANCE

Check: A
• the clutch cable clearance (A)
If outside specifications, adjust.

Clutch cable clearance Gap (clearance)

Clutch handle 3 - 4 mm
A
Adjust:
• the clutch cable clearance
Handlebar side
1. Move the clutch cable cowling.
2. Loosen the ring nut “C”.

21
3. Rotate the adjuster “C” clockwise or counter-clockwise up to
the specified clutch cable clearance. Fig. B B
Clutch cable clearance Clearance

20
Clockwise The gap is increased
Anticlockwise The gap is decreased

4. Tighten the ring nut “C”.

NOTE:___________________________________________ S
R
If the specified clearance of the clutch cable cannot be ob- B
tained on the handlebar side, use the adjusting nut on the
engine side ”E”. Fig. C C
TO

1. Prise the dust seal in the middle of the clutch cable.

2. Loosen the lock nut “F” in the middle of the clutch cable.
3. Rotate the adjusting nut “E” to obtain the correct clearance.
O

C
M
A
D

F E
BA

3 - 15
- Benelli TRK 502 - Page 50
 FRAME/HANDLEBAR
REAR-VIEW MIRROR ADJUSTMENT

The following procedure refer to both rear-view mirrors. A

Install:
1. Screw the mirror (15) on the lever body (32).
2. Move the nut “B” until it stops.
3. Adjust the mirror position by rotating it.
4. Tighten the lock nut “C”.
C

NOTE:___________________________________________
Carry out the same procedure also with the right mirror. B

21
20
S
R
TO
O
M
A
D
BA

3 - 16
- Benelli TRK 502 - Page 51
 ENGINE/MOTOR OIL
CHECKING ENGINE OIL LEVEL

Park: A
• the motorcycle on a level surface.

NOTE:___________________________________________
• Place the motorcycle on a suitable support.
• Make sure it is in upright position.
MAX
Start:
• the engine MIN
allow it to warm up for some minutes and then turn it off. B
IMPORTANT NOTICE

Do not start the engine if the oil level is below the MIN refer-
ence indicated on the sight glass “B”.

21
• Keep the engine oil out of reach of children and pets.
Check: • Wear long-sleeve clothing and waterproof gloves when
• the engine oil level topping up the engine oil.

20
the engine oil level must be within the references of the mini- • Wash with water and soap in the event the engine oil
mum (MIN) and maximum (MAX) level. comes into contact with skin.
If below the minimum notch, top up with the recommended en- • Recycle or dispose the waste oil properly.
gine oil up to the correct level.
3. Turn the oil cover back to its original position.

S
NOTE:___________________________________________
R
To check the engine oil level again, restart the engine, warm
Recommended oil
it up for some minutes and then turn it off. Wait some min-
TO

SAE 10 W-50 API SJ - JASO MA utes to allow the oil to flow downwards.

Adjust:

To top up with engine oil:

O

1. unscrew the oil cover with the engine switched off.

2. Pour an amount of oil of the recommended type within the
M

reference of the maximum (MAX) and the minimum (MIN)

level (Fig. A).

NOTE:___________________________________________
A

The engine contains approx.ly 3.5 l of oil.

Use oil rated API-SJ SAE 10W/50.
D

IMPORTANT NOTICE
BA

Owing to the fact that the engine oil lubricates also the
clutch, it may cause the clutch slipping if it is not suitable
or contains additives. Therefore, it is advisable not to add
chemical additives and not to use types of oil other than the
one indicated in the table of the engine technical specifica-
tions.
The engine oil, whether new or waste, can be hazardous.
In case of swallowing, it can be noxious for people and
pets. In the event of swallowing, seek medical aid imme-
diately; do not induce vomiting to avoid aspiration of the
product into the lungs. Short contacts with the engine oil
may irritate skin.

3 - 17
- Benelli TRK 502 - Page 52
 ENGINE/MOTOR OIL
ENGINE OIL CHANGE

Start:
• the engine, warm it up for some minutes and then turn it off.
A
Remove:
• the oil drain cap “A” Fig. A.
Position:
• a suitable container underneath the drainage for oil recov-
ery Fig. B
NOTE:___________________________________________
Change the engine oil at 1000 Km (621 mi) first and then ev-
ery 6000 km (3728 mi).
A
IMPORTANT NOTICE

Waste oil are environmentally unfriendly.

Dispose waste oil according to applicable law.

21
Remove: B

20
• the magnetic cap “B” (together with the copper seal)
Drain:
• the engine oil from the crankcase. B
NOTE:___________________________________________ B
Replace also the oil filter cartridge.
S
R
Replace:
• the magnetic cap seal.
TO

Install:
• the new seal
• the magnetic cap
Tighten the magnetic cap to the following torque:
O

T. R .

C
M

Torque 22 N*m

Fill:
• the crankcase with the recommended engine oil with the
A

specified amount. MAX

Install:
D

• the oil cap “A” Fig. A.

MIN
B
BA

Start:
• the engine
allow it to warm up for some minutes and then turn it off.

NOTE:___________________________________________
Always check the level is in the middle between the refer-
ence MIN and MAX of the sight glass “B” Fig. C.
Top up, if necessary.
D

Recommended engine oil:

Rating: API SJ-JASO MA2
Viscosity: 10W50
Capacity: 3 l (without filter removal)
3.2 l (with filter removal)

3 - 18
- Benelli TRK 502 - Page 53
 ENGINE/MOTOR OIL
OIL FILTER REMOVAL/INSTALLATION

Removal: A
NOTE:___________________________________________
Before removing the oil filter, it is necessary to drain the oil
from the engine.

1. Place a suitable container underneath the engine.

2. Use the specific tool (**) to turn counter-clockwise the oil
filter (2) and remove it Fig. A.

Install:

21
NOTE:___________________________________________
Before fitting a new oil filter, apply a fine layer of engine oil to
the contact surfaces of the filter to lubricate it Fig. A.

20
1. Proceed using the opposite order to removal.
Tighten the filter (2) to the following torque:
T. R .

Torque 22 N*m
S
R
IMPORTANT NOTICE
Always use original Benelli oil filters.
TO

Other brands of oil filters can be different in terms of thread

(diameter and pitch).
The use of other types of filter may affect the filter perfor-
mance and duration, which will cause possible damage to
O

the engine or oil leaks.

M
A
D
BA

3 - 19
- Benelli TRK 502 - Page 54
 ENGINE/SPARK PLUGS
REMOVAL OF SPARK PLUGS ON THE VEHICLE

The following procedure applies to all of the spark plugs.

A
WARNING
Replace and check the spark plugs when the engine is cold.
Park the motorcycle on a level surface.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot A
fall.

Remove:
• Rider and passenger seats, see chapter “Removal of rider
and passenger seats, Chapter 4”.
• Movable windscreen, see chapter “Removal of movable

21
windscreen, Chapter 4”.
• Front fairing, see chapter “Removal of front fairing, Chap-
ter 4”. B
• Tank fairing, see chapter “Removal of tank fairing, Chap-

20
ter 4”.
• Tank, see chapter “Fuel tank removal, Chapter 4”.
• The two side guards “A” (left and right) Fig. A.
• Loosen the claps of the two rubber sleeves “B” Fig. B.
•
•
Disconnect the breather hose “C” from the filter casing.
Release the filter box “D”. S B
C
R
D
IMPORTANT NOTICE
TO

Before disassembly of spark plug, remove any dirt from the

groove of the seats with a stream of compressed air to pre-
vent it from falling into cylinders.
O

Remove: C
M

• The screw (E)

• The bracket (F)
Disconnect:
• The coil connectors (G) Fig. C
A

• The two rubber tips and the O-rings. E

D

Slide out: F
• The coil and the spark plug underneath Fig. D
BA

3 - 20
- Benelli TRK 502 - Page 55
 ENGINE/SPARK PLUGS
SPARK PLUG CHECK

The following procedure applies to all of the spark plugs. E

Check:
• the type of spark plug
Check:
• the electrodes (A) Fig. E
• If there is any damage, wear or rounding,
Replace the spark plug.
• the insulating part (B) Fig. E
Abnormal colour B
Replace the spark plug. A
Generally, the colour is a light, medium brown.

Clean:
the spark plug using a cleaner for spark plugs or a metal brush.

21
Check: F
Measure the distance between electrodes [D] using a thickness
gauge.

20
If the distance between electrodes is not correct, replace the
spark plug.

Distance between spark

plug electrodes
(mm)
S D
R
D 0.8-0.9
TO

Spark plug type

O

NGK CR8E
M
A
D
BA

3 - 21
- Benelli TRK 502 - Page 56
 ENGINE/SPARK PLUGS
SPARK PLUG CHECK

In general, the table contains the typical conditions of spark

plug with the various degeneration causes and corresponding
solutions.

SOILED OVERHEATED
SPARK PLUG SPARK PLUG
Cause Solutions Cause Solutions
Over rich mix of air/fuel The fuel/carburettor system Ignition too advanced Adjust advanced ignition
-Wrong setting of the carburetion. needs to be fine tuned
Insufficient air/fuel mix Adjust air/fuel ratio
Electrical system fault Check the coil connections
-Imperfect coil connection and relevant impedance Insufficient coolant and/or Add coolant and/or lubricant
lubricant

21
Specific riding conditions Èvery so often, the bike
-Prolonged periods at “minimum” needs to be taken to speeds Spark plug torque too low Tighten to the correct torque
-Long sections at low speed of about 80 km/h
The spark plug used is too Use cooler spark plugs as per

20
Spark plug too cold Use a warmer spark plug, as hot specifications
per specifications

S
R
TO
O
M
A
D
BA

3 - 22
- Benelli TRK 502 - Page 57
 ENGINE/SPARK PLUGS
ASSEMBLY OF SPARK PLUGS

The following procedure applies to all of the spark plugs Fig. D. D

WARNING 6
Lubricate the spark plug threads with copper grease. 7
8
G

NOTE:__________________________________________ 1
Before installing it, clean the spark plug and the surface in
contact with the seal.

Install:
2
• the spark plug to the head, tightening it by hand until it
3

21
comes into contact with the base of the head. Tighten to
torque. 4
T. R .
5

20
Torque 12 N*m 9
Install:
•
•
the coil (1*)
The rubber tips (2*) and the O-rings (3*) Fig. D
S 10
R
Connect:
TO

• the coil connector

Install:
• The screw (6*)
• The bracket (8*)
O

Tighten the torque.

M

T. R .

Torque 10 N*m
A
D

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in Chap-
BA

ter 5 “Engine”, paragraph “Timing gear cover removal ”.

3 - 23
- Benelli TRK 502 - Page 58
 ENGINE/COOLING SYSTEM
CHECKING COOLANT LEVEL

Park the motorcycle on a level surface. A

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot A
fall.

NOTE:__________________________________________
Make sure it is in upright position.
Check the level when the engine is cold.

Remove:
• Rider and passenger seats, see chapter “Removal of rider
and passenger seats, Chapter 4”.

21
• Movable windscreen, see chapter “Removal of movable
windscreen, Chapter 4”.
• Front fairing, see chapter “Removal of front fairing, Chap- B
ter 4”.

20
B

Check:
• the coolant level

The coolant level must be within the maximum level reference S

R
(MAX) and the minimum one (MIN). If below the minimum notch,
top up with the recommended coolant up to the correct level. Fig.
TO

Remove:
• the expansion tank cap
• add coolant liquid up to the level line (MAX) Fig. C.
O

C
M

Press the hose “B” (from the water pump to the expansion tank)
to remove any air bubbles Fig. B.
A

D
D
BA

3 - 24
- Benelli TRK 502 - Page 59
 FRAME/BRAKE ADJUSTMENT
ADJUSTMENT OF THE FRONT BRAKE

Adjust:
• the brake lever position Fig. A
A
(distance ”x” between the throttle grip and the brake lever). Y
NOTE:__________________________________________
Push the brake lever forward to neutralise the spring thrust
and at the same time adjust the position, by rotating the ring
nut “y” clockwise or counter-clockwise until the brake lever
reaches the required position.

Ring nut position Gap X

Position 1 there is more gap from the
handlebar
Position 4 there is less gap from the

21
handlebar

WARNING

20
If the brake lever is soft or spongy to the touch, there might
be air in the braking system. Before using the vehicle, it is
necessary to exhaust air by bleeding the braking system.
The presence of air in the braking system significantly re-
duces the system performance and ultimately may cause a
loss of control of the motorcycle and accidents. Therefore, S
R
check and exhaust air in the braking system, if necessary.
TO

IMPORTANT NOTICE
After adjusting position of the brake handle, make sure that
there is no brake drag.
O
M
A
D
BA

3 - 25
- Benelli TRK 502 - Page 60
 FRAME/BRAKE ADJUSTMENT
ADJUSTMENT OF THE REAR BRAKE

Adjust:
• the brake pedal position Fig. A
A

• Loosen the locknut “A”.

• Screw off the lock nut “B”.
• Screw up o screw off the threaded pin ”E” to increase or
reduce the rear brake control clearance Fig. A.
B
Tighten: E
• the nut “A”
• Tighten the lock nut “B”.
A
WARNING
If the brake lever is soft or spongy to the touch, there might
be air in the braking system. Before using the vehicle, it is

21
necessary to exhaust air by bleeding the braking system.
The presence of air in the braking system significantly re-
duces the system performance and ultimately may cause a B

20
loss of control of the motorcycle and accidents.
Therefore, check and exhaust air in the braking system, if
necessary.
B
IMPORTANT NOTICE
After adjusting position of the brake pedal, make sure that
S
R
there is no brake sticking.
TO
O
M
A
D
BA

3 - 26
- Benelli TRK 502 - Page 61
 FRAME/CHECKING BRAKE FUID LEVEL
CHECKING THE FRONT BRAKE LIQUID LEVEL/TOPPING UP

Park: A
• The motorcycle on a level surface. B
NOTE:__________________________________________
Place the motorcycle on a stand and make sure it is in up-
right position.

Check:
• the brake fluid level
If below the minimum notch “A” Fig. A, top up with the recom-
mended brake fluid until it is at the correct level. A
Fluid topping up procedure:
• Once having positioned the motorcycle on a level surface,
loosen the two fastening screws “B” of the brake pump

21
cover Fig. A.

Check:
B
the cap gasket

20
If there is any damage/wear, C
replace the gasket.

IMPORTANT NOTICE
Brake fluid can damage painted surfaces and plastic parts.
Therefore, wrap the absorbent paper around the pump and S
R
always clean up any brake fluid spills immediately.
TO

• Apply the vacuum device to the drain screw ”C” Fig. B.

• Top the liquid up to the level indicated on the pump sight
glass Fig. C.
• Pump the brake fluid by moving the brake lever.
• After topping up, place the cap and tighten the two fasten-
O

ing screws. C
M

WARNING
Only use the prescribed fluid. Other brake fluids may cause
the deterioration of the rubber seals, causing leakages and
A

malfunctioning of the braking system.

Top up with the same type of brake fluid already in the sys-
D

tem. Mixing different types of brake fluid may cause a nox-

ious chemical reaction, which may affect the braking system
operation.
BA

While topping up brake fluid, take care not to let any water
enter the container. Water would lower the boiling point of
the brake fluid significantly, causing steam bubbles.

Fluido f reni consigli ato

TOP
4
TUTELA BRAKE FLUID
TOP 4 - DOT 4

3 - 27
- Benelli TRK 502 - Page 62
 FRAME/CHECKING BRAKE FUID LEVEL
CHECKING THE REAR BRAKE LIQUID LEVEL/TOPPING UP

Park: A
• The motorcycle on a level surface.

NOTE:__________________________________________
Place the motorcycle on a stand and make sure it is in up-
right position.

Check:
• the brake fluid level A
If below the minimum notch “A” Fig. A, top up with the recom- MAX
mended brake fluid until it is at the correct level.

Fluid topping up procedure: MIN

• Once having positioned the motorcycle on a level surface,
loosen the top cover “A” of the brake pump Fig. A.

21
IMPORTANT NOTICE B

20
Brake fluid can damage painted surfaces and plastic parts. E
Therefore, wrap the absorbent paper around the pump and
always clean up any brake fluid spills immediately.

• Remove the fastening screw of the outer rear brake caliper

and loosen the inner fastening screw “D” Fig. B in order to
raise the caliper and carry out a complete exhaust, without D S
R
air bubbles.
• Apply the vacuum device to the drain screw ”E” and loosen
TO

the latter.
• Top the liquid up to the MAX level indicated on the graduat-
ed container “F”. Pump the brake fluid by moving the brake
lever.
F
• After topping up, lower the caliper and tighten the two fas-
O

tening screws to the following torque:

M

T. R .

Torque 22 N*m
A

• Close the pump cover.

D

WARNING
Only use the prescribed fluid. Other brake fluids may cause
BA

the deterioration of the rubber seals, causing leakages and

malfunctioning of the braking system.
Top up with the same type of brake fluid already in the sys-
tem. Mixing different types of brake fluid may cause a nox-
ious chemical reaction, which may affect the braking system
operation.
While topping up brake fluid, take care not to let any water
enter the container. Water would lower the boiling point of
the brake fluid significantly, causing steam bubbles.

3 - 28
- Benelli TRK 502 - Page 63
 FRAME/CHECKING ABS HOSES
CHECK FOR ANY LEAKAGES OF ABS TUBES

For the motorcycle models equipped with ABS, it is necessary to

check for leakages in the braking system and especially in the
A
ABS circuit.
Remove: C
• The seat (See section Seat removal).
• Disassemble the passenger’s seat (see section Passen-
ger’s seat removal).
• Remove the fuel tank (see section Fuel tank removal). A
• By means of the brake lever/pedal check for brake fluid
leakages from the hoses “A”, the tubes (models equipped
with ABS) “B” and the fittings “C”.
• In case of fluid leakage in any point, check or replace the
faulty component. B
A

21
20
C

S C
C
R
A
TO
O
M

D
A
A

C
D
BA

E
C

3 - 29
- Benelli TRK 502 - Page 64
 FRAME/BRAKE PAD CHECK
CHECKING WEAR OF FRONT/REAR BRAKE PADS

The following procedure applies to brake pads. A

Activate:
• the brake

Check:

•
•
The front brake pads Fig. A.
The rear brake pads Fig. B.
A
• The wear limit for the front/rear brake pads.

If the wear reaches the limit, please replace all brake

pads.

21
Pads Wear limit (A)
Front 1 mm
B

20
Rear 1 mm

NOTE:__________________________________________
For replacing the pads, refer to the chapter “Frame”, section
“Removal/installation of front brake pads”.
S B
R
TO
O
M
A
D
BA

3 - 30
- Benelli TRK 502 - Page 65
 FRAME/CHECKING HOSES OF THE BRAKING SYSTEM
HOSE CHECK

The following procedure applies to all brake hoses and brake

hose clamps.
A

Check:
• the path of the hose of the front “A” and rear “B” brake.
If there is any cracking/damage/wearing trace, replace.

Check: A
• The hose clamp of the front brake ”C” Fig. A. If loosened,
tighten the clamp bolt.

Check: C
• The hose clamp “D” of the rear brake Fig. B. If loosened,
tighten the clamp bolt.

21
T. R .

B
Torque 25 N*m

20
Keep:
• The motorcycle in a upright position.
Activate: B
• The brake several times.
Recheck: S
R
• The brake hose. If there is any brake fluid leakage, replace
the damaged hose.
TO

D
O
M
A
D
BA

3 - 31
- Benelli TRK 502 - Page 66
 FRAME/TRANSMISSION CHAIN
ADJUSTMENT OF THE TRANSMISSION CHAIN

NOTE:__________________________________________
When the engine is running, do not check or adjust the trans-
A
mission chain.

NOTE:__________________________________________
Check the transmission chain slackness in the most taut
point.
10-15 mm
WARNING
If the chain is too taut, there may be an overload of the en-
gine or other vital parts, while , if it is too slack, it may jump
out and damage the swing arm bracket or cause an accident.
Therefore, it is advisable to keep the chain slackness within
the specified range.

21
Park:
• the motorcycle on a level surface.
B
Adjusting screw

20
WARNING
Prop the motorcycle on suitable supports so that it cannot Wheel pin
fall and the rear wheel is raised. Lock nut

• Rotate the rear wheel several times and determine its tight-
est position. S
R
Check:
• the slackness of transmission chain. If outside specifica-
TO

tions, adjust Fig. A.

O

Transmission chain slack-

10-15 mm
ness C
M

Adjust:
• slackness of transmission chain Fig. B
A

If the chain tension is not correct, adjust it as follows.

D

• Loosen the wheel axle nut on the left side of the swing arm.
• To tension the transmission chain, turn the tension adjust-
BA

ment bolt on each side of the swing arm (counter-clockwise).

“D”
• To loosen the transmission chain, turn the tension adjust-
E
ment bolt clockwise and push the rear wheel forwards.
• After adjustment, tighten the wheel axle nut to the following
torque: Right side Left side

T. R .

Torque 80 N*m

WARNING
If the chain is too taut, there may be an overload of the en-
gine or other vital parts, while , if it is too slack, it may jump
out and damage the suspension arm or cause an accident.
Therefore, it is advisable to keep the chain slackness within
the specified range.
The gap on the right side must correspond to the 8th notch
on the swing arm “D”, while for the left side, to the 5th notch
on the swing arm “E” Fig. C.

3 - 32
- Benelli TRK 502 - Page 67
 FRAME/TRANSMISSION CHAIN
LUBRICATION OF TRANSMISSION CHAIN

Introduction

The transmission chain consists of several parts that interact

with each other.
The chain must be properly maintained to prevent its early wear.
Therefore, it is advisable to maintain the transmission chain,
especially if it is used in very dusty areas.
This motorcycle is fitted with a transmission chain complete
with small rubber O-rings inserted between one side plate and
another.
Do not use steam jets, high-pressure water jets, aggressive
solvents or brushes with too rough bristles to prevent damaging
these O-rings.
Therefore, we recommend exclusive use of recommended prod-
ucts to clean the transmission chain.

21
Wipe the chain and lubricate it thoroughly using engine oil or
specific lubricant for chains with O-rings.
Do not use other kinds of lubricants on the transmission chain as
they might contain solvents that would damage the O-rings.

20
Apply:
• A thin and smooth layer of lubricant on the whole chain, be-
ing careful not to reach the surrounding parts, especially the
tyres.
S
R
G
Recommended lubricant
SINTOFLON
TO
O
M

CHAIN GUIDE CHECK

A

Visually check the chain guide slide (A) Fig. F.

G
D

Replace:
The chain guide if faulty or damaged.
BA

3 - 33
- Benelli TRK 502 - Page 68
 FRAME/TRANSMISSION CHAIN
CHECKING WEAR OF TRANSMISSION CHAIN

Check:
• The transmission chain
D
Rigidity. Clean and lubricate or replace.

Clean:
• The transmission chain

Clean the transmission chain with a clean rag.

Soak the transmission chain in kerosene and remove any re-
maining dirt.
Remove the transmission chain from the kerosene and leave it
to dry completely.

IMPORTANT NOTICE
This motorbike is fitted with a transmission chain complete

21
with small rubber O-rings (B) Fig. E, inserted between one
side plate and another.
To clean the transmission chain, do not use high-pressure
E

20
jets of water or air, do not use steam, petrol, aggressive sol-
vents (such as petroleum petrol), or brushes with overly stiff
B
bristles.
Using high-pressure items could force dirt into the cavities
inside the transmission chain, while solvents could cause
the O-rings to deteriorate.
The O-rings could also be damaged by the use of brushes of S D
R
overly stiff bristles.
Therefore, we recommend exclusive use of white oil to clean
TO

the transmission chain.

C
Check:
• The O-rings (B)
In the event of damage, replace the transmission chain.
O

• The transmission chain rollers (D)

In the event of damage/wear, replace the transmission chain. F
4
M

• The side plates of the transmission chain (C)

In the event of damage/wear, replace the transmission chain.
If there are any cracks, replace the transmission chain and
make sure that the bleeder pipe from the battery is correct and 2
A

sufficiently distant from the transmission chain and below the 1

swinging arm.
D

Lubricate:
• The transmission chain 3
BA

NOTE:__________________________________________
Use specific grease

Check:
• Driving gear
• Rear toothed sprocket
If more than 1/4 of each tooth (4) is worn Fig. F, replace the
transmission chain sprockets all together. NOTE:__________________________________________
If the teeth are bent, replace the transmission chain sprockets Never fit a new chain with worn sprockets.
all together. Both the chain and sprockets need to be in good condition or
the new chain will become quickly worn.
1. Correct
2. Transmission chain roller
3. Transmission chain sprockets

3 - 34
- Benelli TRK 502 - Page 69
 FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE
CHECK/ADJUSTMENT OF STEERING CLEARANCE

Park:
• The motorcycle on a level surface.
A
NOTE:__________________________________________
Place the motorcycle on a suitable support so that the front
wheel is raised.

Check:
• The steering sleeve
Gently oscillate the front fork, holding it by the ends of the tubes
Fig. A.
If there is any jamming/loosening, adjust the steering sleeve.

Remove:
• Movable windscreen, see chapter “Removal of movable
windscreen, Chapter 4”.

21
• Front fairing, see chapter “Removal of front fairing, Chap-
ter 4”.
• Instrumentation plate, see chapter “Removal of the instru- 2 B
mentation plate, Chapter 4”.

20
Loosen:
• The stop screws on the top steering plate “1” Fig. B.
Remove:
•
•
•
the upper u-clamps (2) Fig. B
The bolt cap of the steering head (3) Fig. B
Slide out the plate (4) Fig. C S 3
R
Adjust:
TO

• the steering sleeve

• Remove the steering pin ring nut (5) Fig. C 1
• Loosen the steering ring nut (6), then tighten at the speci-
fied value using the apposite wrench “7”.
O

. C
(**)Tool to tighten the steering sleeve lock nut
M

Code:...................... R180297129000 4
T. R .
A

Torque 15 N*m
D

• Tighten the ring nut “E” with the apposite wrench to the 5
BA

following torque:

T. R .

Torque 60 N*m

Check:
Should the steering be too hard or too soft, repeat the adjust-
D
ment.

WARNING
Do not overtighten the steering ring nut.

Remove:
• The cap (6) with the special tool (7) Fig. D 7

.
(**) Steering head wrench 6
Code: R180297129000
Remove:

3 - 35
- Benelli TRK 502 - Page 70
 FRAME/CHECK AND ADJUSTMENT OF STEERING SLEEVE
STEERING SLEEVE BEARING LUBRICATION

• the steering ring nut (1), then using the apposite wrench (2)
A
remove the steering ring nut (3). Fig. A-B.
2
.
Tool to tighten the steering sleeve lock nut
Code: R180297129000 1
Using a solvent with a high flash point,
wash the top/bottom ball bearings in the retainers, then wipe up
the upper and lower outer races that are installed for interfer-
ence on the frame pipe, remove the grease and dirt.
3
Check:
• Visually check the outer races and the balls. Replace if worn

21
or damaged Fig. C.
• Insert the balls with some grease, then apply a thin layer of B
grease on the outer top/bottom races.

20
Assemble:
Once assembled, tighten the steering ring nut to the following
torque:

S
R
Tool to tighten the steering sleeve lock nut
Code: R180297129000
TO

T. R .

Torque 60 N*m
O

Specific grease
M

G
A

Assemble:
• the steering ring nut support with the apposite tool to the
D

following torque:
BA

Tool to tighten the steering sleeve lock nut

Code: R180297129000

T. R .

Torque 15 N*m

3 - 36
- Benelli TRK 502 - Page 71
 FRAME/CHECK OF FRONT FORK
CHECK OF FRONT FORK

Park:
• The motorcycle on a level surface.
A

NOTE:__________________________________________
Prop the motorcycle on suitable supports so that it cannot
fall.

Check: A
• The fork stem “A” Fig. A
• The fork sleeve “B” Fig. A
If there is any damage/line, replace.
• The oil seal
If there is any leakage, replace. B

Keep:

21
• The motorcycle in a upright position.
Activate:
• The front brake

20
Check:
• The fork operation.

Push hard on the handlebar several times to check that the front
fork returns to the stationary position in a smooth way.
If the movement is not smooth, replace (see chapter FRAME/
CHECK AND ADJUSTMENT OF STEERING SLEEVE, section S
R
STEERING SLEEVE BEARING LUBRICATION).
TO
O
M
A
D
BA

3 - 37
- Benelli TRK 502 - Page 72
 FRAME/CHECK OF REAR SHOCK ABSORBER
SHOCK ABSORBER ADJUSTMENT

NOTE:__________________________________________
Prop the motorcycle on suitable supports so that it cannot A
fall.

Adjustment
• Adjust the spring preload Fig. A.
The rear shock absorber is equipped with an adjustment ring nut C
for the pre-load of spring “A" and a return ring nut "D”.
B

D
• To increase the spring pre-load, thus making the sus-
pension more rigid, turn the adjustment ring nut “A” to the A
direction (B).
• To reduce the spring pre-loading, thus making the suspen-

21
sion softer, turn the adjustment ring nut “A” to direction (C).
At the end of adjustment, tighten the return ring nut “D”.
B
IMPORTANT NOTICE

20
To avoid damaging the mechanism, do not try turning over
the maximum or minimum setting.
+
E
MIN
Position Gap
0 mm S
R
MAX 10 mm
-
TO

Adjustment
• Adjustment of the hydraulic braking device in extension Fig.
B.
It is possible to adjust the hydraulic braking device using the
adjustment ring “E” Fig. B.
O

• Turn it clockwise to increase the braking action. Turn it

counter-clockwise to reduce the braking action.
M

IMPORTANT NOTICE
To avoid damaging the mechanism, do not try turning over
A

the maximum or minimum setting.

D
BA

3 - 38
- Benelli TRK 502 - Page 73
 FRAME/CHECK OF FRONT/REAR TYRES
TYRE CHECK
The following procedure is applied to both tyres.
Check:
A
• The tyre pressure. If outside specifications, adjust Fig. A.

WARNING
The tyre pressure must be checked and adjusted only when
the wheel temperature corresponds to the ambient tempera-
ture.
3
The tyre pressure and the suspension must be adjusted ac-
0
cording to the total weight, including baggage, driver, pas- 2
senger and accessories, and considering the expected driv- 1

ing speed.
The use of the overloaded vehicle may cause damages to
tyres, with the risk of an accident or injuries for people.
NEVER OVERLOAD THE VEHICLE IN ANY CASE.

21
Position Wear limit (A)
Net weight B

20
(with oil and full fuel See general specifications
A
tank)
Max. load* See general specifications
COLD TYRE PRES-
SURE
FRONT REAR
S
R
Up to 90 kg load* C
2.20 bar 2.50 bar
B
TO

90 kg
2.20 bar 2.50 bar
~ max. load*

* Including baggage, driver, passenger, and accessories.

O

WARNING
It is dangerous to drive with the worn tread.
M

If the tread reaches the wear limit, replace the tyre immedi-
ately.
A

Check:
• The tyre surface Fig. B
D

If there is any damage or wear, replace.

BA

A. Depth of tread pattern

B. Side wall
C. Wearing warning device

WARNING
If tyres are new, the grip on the road is relatively weak until
they are slightly used. Therefore, it is advisable to drive at
normal speed for the first 100 km (62 mi) before driving at
higher speeds.

WARNING
Most countries have their own regulations that prescribe a
minimum depth of the tread. Always remain within the limits
set forth.
Check and balance the wheel when replacing the tyre.

3 - 39
- Benelli TRK 502 - Page 74
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

WARNING
The batteries produce a nitrogen-based explosive gas and
contain electrolyte, which is composed of sulfuric acid, a
poisonous substance and highly caustic.
The following precautions should be always observed:
Wear protective goggles when handling a battery or while
working nearby.
Recharge the batteries in a suitably ventilated area.
Battery must be far away from fire, sparks or open flames
(e.g., welding equipment, lighted cigarettes, etc.).
DO NOT SMOKE during recharging or handling of the bat-
tery.
PUT BATTERIES AND ELECTROLYTE BEYOND THE REACH
OF CHILDREN.

21
Do not allow electrolyte to come into contact with body parts
to prevent severe burns or permanent injury to eyes.

FIRST AID IN THE EVENT OF CONTACT:

20
EXTERNAL CONTACT
• Skin: wash with water.
• Eyes: Wash with water jets for 15 minutes and seek imme-
diate medical attention.
SWALLOWING
• Drink large quantities of water or milk, milk of magnesia, S
R
beaten egg or vegetal oil. Seek immediate medical atten-
tion.
TO

IMPORTANT NOTICE
This battery is sealed. Do not remove the sealing caps in any
case, to preserve the equilibrium between the cells and not
O

to affect the battery performance.

The time, the amperage, and the voltage for recharging the
battery differ from the standard ones. Recharge the battery
M

as shown in the figures. If the battery is overcharged, the

electrolyte level drops significantly. Therefore, during re-
charging, pay the utmost attention.
A

NOTE:_________________________________________
D

As the battery is sealed, the recharging state cannot be

checked by measuring the electrolyte density.
Therefore, check battery charging by measuring the voltage
BA

on the battery terminals.

Remove:
• Rider and passenger seats, see chapter “Removal of rider
and passenger seats, Chapter 4”.

Disconnect:

3 - 40
- Benelli TRK 502 - Page 75
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

• the battery cables from the terminals Fig. B

B
IMPORTANT NOTICE
Disconnect the negative cable of the battery “A” first, and A
then the positive cable “B” Fig. B.

Detach: D
• The battery
• Remove the battery rubber tip and slide out the battery “D”.
Check:
• The battery charge level
Connect a pocket tester to the battery terminals Fig. C.
B
Check the battery level as shown in the tables of the following
example Fig. D.

21
NOTE:__________________________________________
The charge status of a battery can be checked by measuring

20
its open-circuit voltage (that is the voltage when the positive C
terminal is disconnected).
If the open-circuit voltage is equal to/above 12.8 V, recharg-
ing is not necessary.

EXAMPLE:
- Open-circuit voltage = 12.0 V S
R
- Charging time = 6.5 hours
- Battery charge amount = 20 -30%
TO

-
Recharge:
• The battery (see the figure with the suitable charging man-
ner)
O

IMPORTANT NOTICE
Do not carry out a quick charging of the battery.
D
M
(V)

WARNING 13
(V)

Relation between the open

aperto

circuit voltage
tra la and the charge
circuit

• Never remove the caps that seal the battery. Relazione tensione a circuito
A

12.5
• Do not use fast battery charger as these devices transfer time at 20°C
aperto e il tempo di ricarica a 20°C
circuito

a high-amperage current to the battery at high speed, 12

ataopen
D

therefore the battery may overheat and its parts may be

damaged. 11.5
Tensione
Voltage
BA

If it is not possible to adjust the charging current of the bat-

tery charger, be careful to prevent the battery overcharge.
5 6.5
For charging, disconnect the battery from the vehicle. Charge time (hours)10
Tempo ricarica (ore)
(Should it be necessary to recharge with the battery mount-
These values
Questi valori change
variano col according
variare della to modifi
temperatura, della cations
condizione ofdella
delle piastre temperature,
batteria
ed on the vehicle, disconnect the negative cable from the e del livello di elettrolito.
battery plates conditions and electrolyte level
battery terminal).
To reduce the risk of sparks, connect the battery charger to
the power supply only after having connected the cables to
the battery. E
14
(V)

13
(V)
aperto
circuit

12
circuito
at aopen

11
Tensione

10 Room tempe-
Voltage

Temperatura
rature 20 20
°C°C
ambiente
100 75 50 30 25 0
20
Battery
Stato di charge status
ricarica della (%) (%)
batteria

3 - 41
- Benelli TRK 502 - Page 76
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

Before removing the battery charger cable clamps from the

terminals, turn the charger off. recharge
F
ricarica
Make sure the battery charger cable clamps are completely

(V)(V)
18
in contact with the battery terminals and are not short circuit-

aperto
17
ed.A corroded clamp may generate heat in the contact area

open circuit
and an ineffective clamp spring may cause sparks. 16
15

Tensioneata circuito
If the battery overheats during the charging process, dis-
connect the battery charger and allow it to cool down before 14
proceeding again. The batteries that overheat may explode!! 13
As shown in Fig. F, the open-circuit voltage of a battery sta- 12

Voltage
bilises 30 minutes after the charging end, before measuring 11
the open-circuit voltage. 10
0 10 20 30 40 50 60
Check voltage
Controllare at open
la tensione
circuit
a circuito aperto.

21
20
S
R
TO
O
M
A
D
BA

3 - 42
- Benelli TRK 502 - Page 77
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

CHARGING METHOD WITH A VARIABLE CURRENT (VOLTAGE) BATTERY CHARGER

NOTE:__________________________________________
• Measure the voltage after 30 minutes from switching off of the appliance.
• Set the charge voltage to 16 ~ 17 V. (Setting it on a lower value, the recharge would not be sufficient.
• By setting it at an overly high value, it would be overcharged).

Caricabatterie
Battery charger
Misurarethe
Measure la tensione
voltage at aopen
circuito aperto
circuit before
Ammeter
Amperometro
prima di procedere
chargingcon la ricarica.

21
A

Connect Collegare
a battery charger and anun
alla batteria ammeter

20
caricabatterie e unstart
to the battery and amperometro
charging
e iniziare la ricarica.

Check theche
Verificare current is highersia
la corrente than
piùthe stan-
elevata
YES
SI
dard
del value
valoreofstandard
the charge
ricarica riportato
della
S
onecorrente
indicated di
sulla batteria.
the battery
on
NO
R
TO

Ruotando la rotella di
By rotating a charge voltage
regolazione
setting roller, setdi
della tensione the charge
ricarica,
voltage to 20 ~ 24 V
impostare
la tensione di ricarica
su 20 ~ 24 V.
O
M

YES Tenere sotto controllo

Monitor the amps for 3 ~ 5
l’amperaggio
Set the
Regolare la tensione in modo
voltage
SI minutesper 3 ~ 5 ifminuti
to check the standard
tale che lasocorrente
that the sia
current is equal to
al livello chargeper verificare
current is reached
A

standard
di caricacharge level
standard. se la corrente di carica
standard viene raggiunta.
D

NO
BA

Impostare
Set il tempo
time according in base
to charge Se la corrente non supera
al tempo
time suitabledifor ricarica adatto
the voltage in la corrente
Should current di
not exceed the
anper
open la circuit.
tensione a circuito carica
standard standard
charge current after
aperto. una volta
5 minutes, trascorsi
replace the battery
Refer to instructions supplied 5 minuti, sostituire la
Vedere le istruzioni
with the battery
incluse alla batteria. batteria.

InSe
case
peritlatakes more
ricarica thannecessarie
sono 5 hours for più
charge,
di 5 itore,
is recommended
è consigliabileto controllare
check the charge currentdiafter
la corrente 5 hours.
carica dopo 5 ore.
InSe
the
si event of amps
verificano changes,dell’amperaggio,
variazioni set again the voltage to obtain
regolare the standard
nuovamente la charge
tensionecurrent
per ottenere la corrente di
carica standard.

Measure
Misurarethela battery
tensioneopen circuit voltage
a circuito apertoafter a downtime
della of 30 averla
batteria dopo minutes.
lasciata per più di 30 minuti inutilizzata.
12.8
12.8VVoro higher > Charge is complete
superiore La ricarica è completa
12.7VVoro lower
12.7 inferiore Ricarica necessaria.
>Charge necessary
Inferiore
Lower thana12.0V
12.0 V> ReplaceSostituire
the batteryla batteria.

3 - 43
- Benelli TRK 502 - Page 78
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

CHARGING METHOD WITH A CONSTANT VOLTAGE BATTERY CHARGER

NOTE:__________________________________________
• Measure the voltage after 30 minutes from switching off of the appliance.
• Set the maximum charging time to max. 20 hours.

NOTE:__________________________________________
• To ensure the highest performance and life of battery, it is advisable to use electronic battery chargers that can supply
correct charging voltages and currents, according to the specific requirements of the sealed battery technology.

21
20
Misurare
Measure la
thetensione a circuito
voltage in an openaperto
circuit
prima di procedere con la ricarica.
before charging

Connect a battery charger

caricabatterie
to the battery S
Collegare alla batteria un
and an ammeter
e un amperometro
e iniziare
andlastart
ricarica.
charging
R
TO

Check the che

Verificare current is highersia
la corrente than
piùthe stan-
elevata
dard
delvalue
valoreofstandard
the charge onecorrente
della indicateddion
YES
SI ricarica riportato sulla batteria.
the battery NO
O

This kindtipo
Questo of charger cannot
di caricabat-
be terie
usednon for può essere
charge these
utilizzato
batteries. per
It is ricaricare
recommended
M

queste
to use abatterie.
chargerSiwith
consiglia
varia-
l’uso di un caricabatterie a
ble voltage
tensione variabile.
A

Battery charger
D

Caricabatterie
Charge the battery
Caricare until charge
la batteria finchévoltage
la
reachesdi15
tensione V
carica
BA

non arriva a 15 V. Ammeter

Voltmeter Amperometro
Voltometro

A
V

Measure the la
Misurare open circuitavoltage
tensione circuitoafter
aperto
a battery dopo aver
downtime lasciato
of 30 la
minutes.
batteria per più di 30 minuti
inutilizzata.
12.8
12.8 V
Voorsuperiore
higher. Charge is La
complete.
ricarica è completa.
12.7 V or lower. Charge necessary.
12.7 V o inferiore Ricarica
necessaria.
Lower than 12.0V. C. Change the
battery
Inferiore a 12.0 V Sostituire
la batteria.

3 - 44
- Benelli TRK 502 - Page 79
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

Battery activation:
Filling Electrolyte
Make sure that the model [A] marked on the electrolyte bottle
matches with the model [B] of the battery. The denominations
must be the same.
Battery model name: YTX9-BS

WARNING
Every battery is supplied with a bottle of its own electrolyte.
The use of an unsuitable container may cause the leakage
with the wrong electrolyte, thus shortening the battery life
and jeopardizing performance.
Use the electrolyte bottle having the same battery model
name, as the volume and specific gravity of the electrolyte
change according to the type of battery.

21
WARNING
Tear the aluminium sealing film [A] of the filling port [B] only

20
immediately before use. Use the apposite container to be
sure to insert the correct amount of electrolyte.

IMPORTANT NOTICE
The sulfuric acid present in the battery electrolyte may cause
severe burns. To prevent burns from sulfuric acid, before S
R
handling the electrolyte wear protective clothing and safety
goggles.
TO

If the electrolyte comes into contact with eyes, wash the area
with plenty of water and contact a doctor in case of severe
burns.

• Place the battery on a flat surface.

O

• Make sure the sealing film is not frayed, broken or perforat-

ed.
M

• Remove the sealing film.

NOTE:__________________________________________
The battery is vacuum sealed. If air come into the battery
A

through the sealing film, the initial charging may require

more time.
D
BA

3 - 45
- Benelli TRK 502 - Page 80
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

• Take the electrolyte bottle away from vinyl bag.

• Detach the strip of caps [A] from the bottle and store it for
A
seal the battery subsequently, Fig. A.

NOTE:__________________________________________
Do not puncture or open the sealed cells [B] of the electro-
lyte bottle. Do not try to divide the single cells.

21
20
• Topple the electrolyte bottle by aligning the six sealed cells
to the filling ports of battery. By keeping the bottle in hori-
zontal position, push downwards to break the seals of the B
six cells. During filling, some air bubbles will go up to each
cells Fig. B.
NOTE:__________________________________________
Do not tilt the electrolyte bottle. S
R
TO
O
M

• Check the electrolyte flow.

A

• If there are no air bubbles [A](*) that go up through the filling

ports or the cells do not fill completely, tap the bottle [B] C
D

some times, Fig. C.

NOTE:__________________________________________
BA

Ba careful to prevent the battery from falling.

• Leave the bottle in its place. Do not remove the bottle from
the battery, since it is necessary that all electrolyte passes
into the battery for its proper operation.

WARNING
The removal of the bottle before it is completely empty may
reduce the technical life of the battery.
Do no remove the container until it is completely empty.

• After filling, leave the battery to rest with the electrolyte bot-
tle in its place for 20-60 minutes so that the electrolyte can
permeate deeply into the plates.
• Check the bottle cells are completely empty and remove the
bottle from the battery.

3 - 46
- Benelli TRK 502 - Page 81
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

• Place the strip of caps [A] on the filling ports and press
strongly with both hands to insert them into the battery Fig.
D
D (without tapping) Fig. E. If properly installed, the cap strip
will be aligned with the battery top.

WARNING
After installation of the cap strip, do not remove the caps and
do not add water/electrolyte into battery.

NOTE:__________________________________________
Charging immediately after filling may reduce the technical
life of the battery.

Initial Charge
The sealed battery just supplied require initial

21
charge.
Use a constant voltage battery charger.

20
Standard charge: 0.9 A × 5 – 10 hours
E
• After the initial charge, let the battery stand for 30 minutes,
and then check the voltage with a voltmeter. (The voltage
is temporarily high immediately after charge. For a precise
measurement, leave the battery to rest for the fixed period
of time). S
R
NOTE:__________________________________________
TO

• The charging values change according to the storage

duration, the temperature and the type of battery charger
used. If the voltage does not reach at least 12.6V, repeat
the charging cycle.
• In order to ensure the biggest battery life and the utmost
O

customer’s satisfaction, it is suggested to perform 15s

load testing under the three times of ampere hour rate.
M

Recheck the voltage and repeat the charging cycle and

load test if the voltage is less than 12.6V. If the voltage is
still below 12.6V, the battery is defective.
A
D
BA

3 - 47
- Benelli TRK 502 - Page 82
 ELECTRICAL SYSTEM
BATTERY CHECK AND CHARGING

IMPORTANT NOTICE G
Bring the start switch to the OFF position.
Install:
• The battery A
• Tighten 2 screws “A” fastening the battery bracket.
Connect:
• The battery cables to the terminals. D
IMPORTANT NOTICE
Connect the positive cable of the battery “B” first, and then
the negative cable “B” Fig. G.
B
Check:
• The battery terminals

21
If it is dirty, remove the dirt using a metal brush.
In case of loose connections, connect them properly.

20
S
R
TO
O
M
A
D
BA

3 - 48
- Benelli TRK 502 - Page 83
 ELECTRICAL SYSTEM
FUSES

The following procedure applies to all fuses.

IMPORTANT NOTICE
Bring the start switch to the OFF position.
Remove:
• Rider and passenger seats, see chapter “Removal of rider
and passenger seats, Chapter 4”.

Check:
• The fuse

Connect the pocket tester to the fuse and check the continuity.

NOTE:__________________________________________

21
Set the selector switch of the tester on “Ω x 1”

• If the pocket tester indicates “ ∞”, replace the fuse.

20
Replace:
• The blown fuse.

- Position the main selector switch at “OFF”.

-
-
Install a new fuse with the correct amperage.
Switch on the switches to check that the electrical circuit S
R
functions.
- If the fuse blows immediately, check the electrical circuit.
TO

WARNING
Never use fuses with aN amperage different from those
specified. The use of improvised techniques or fuses with
O

different amperages could cause irreversible damage to the

electrical system, or cause functioning defects of the light-
M

ing system and the ignition system and eventually cause a

fire.
A
D
BA

3 - 49
- Benelli TRK 502 - Page 84
 ELECTRICAL SYSTEM
FUSE CHECK

FUSE LEGEND
Refer to Fig. C
B

1. Petrol pump (15.00 A)

2. Fan (15.00 A)
3. ECU1 (15.00 A)
4. Services (10.00 A)
5. Lights (15.00 A)

21
20
C

S 15A

15A

15A

10A

15A
R
1 2 3 4 5
TO
O
M
A
D
BA

3 - 50
- Benelli TRK 502 - Page 85
 ELECTRICAL SYSTEM
REPLACEMENT OF THE FRONT LIGHTS

The following procedure applies only to the front lights.

A
IMPORTANT NOTICE
Seeing that the projector lamp reaches very high tempera-
tures, it is recommended to not touch it until it has cooled
down.

Remove:
• The two fixing screws “A” of the protection of the ignition
block Fig. A
• Lift the protection and gain access to the projector lamps’
covers and remove them “B” Fig. B
• Disconnect the lamp from the connectors “C” Fig. C
Install:
• Insert the new lamp

21
Connect: A
• Connect the new lamp to the connectors “C” Fig. C
• Replace the cover

20
• Position the protection of the ignition block and replace the B
two locking screws.

IMPORTANT NOTICE
Avoid touching the glass part of the projector lamp; keep it
clean and remove any traces of oil. If this is not done, the S
R
transparency of the glass will not be as it was before by the
duration of the lamp will be shortened and the projected light
beam. The lamp is dirty, clean it very carefully,
TO

using a cloth dampened with alcohol or diluent used for

enamel paint Fig. D

B
O
M

C
A
D
BA

3 - 51
- Benelli TRK 502 - Page 86
 ELECTRICAL SYSTEM
REMOVAL OF THE FRONT HEADLIGHT

Place the motorcycle on a flat, level floor.

C
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.
D D
The vehicles’ front headlight is a LED light. If it needs to be
replaced, carry out the following procedure: E
Remove:
• The mobile windscreen, refer to chapter “Removal of mo-
bile windscreen, Chapter 4”.
• Front fairing, see chapter “Removal of front fairing, Chap-
ter 4”.
• Instrumentation panel plate, refer to chapter “Removal of

21
the instrumentation panel plate, Chapter 4”.
• side locking screws “D”
• front locking screws “E” Fig. C.
Disconnect:

20
• the connector of the LED headlight “F” D
• the cables of the right and left front indicator lights “G”. Fig.
D.
G
F
S G
R
TO
O
M
A
D
BA

3 - 52
- Benelli TRK 502 - Page 87
 ELECTRICAL SYSTEM
INSTALLATION OF THE HEADLIGHT

Place the motorcycle on a flat, level floor.

A
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall. D
Install: D
Proceed using the opposite order to removal. E
Install:
• the side locking screws ”D” Fig. A.
• the front locking screws “E” Fig. A.
to the following torque:

T. R .

21
Torque 10 N*m

20
S
R
TO
O
M
A
D
BA

3 - 53
- Benelli TRK 502 - Page 88
 ELECTRICAL SYSTEM
ADJUSTMENT OF HEADLIGHT

To carry out the correct adjustment of the two headlights’ lumi-

nous beams:
A

• Position the vehicle approx. 10 metres distance from a verti-

cal wall on a perfectly flat piece of ground Fig. A
• Sit on the motorcycle in the riding position.
• Check that the upper limit of the luminous beams projected
onto the vertical wall is less than approx. 1/10 in respect of
horizontal axis of the headlights.
• If the luminous beam does not conform to this indication, h
carry out the adjustment until the luminous beams are in the 9/10
correct position.

10 m

21
20
Adjust: B
• The light beams of the two headlights by adjusting the reg-
ister screw “A” positioned down below on the right and left
side of the rear of the projector lamps Fig. B A
Rotating the screw in an anticlockwise direction, the luminous
beam is raised.
Rotating the screw in a clockwise direction, the luminous beam S
R
is lowered.
TO
O
M
A
D
BA

3 - 54
- Benelli TRK 502 - Page 89
 ELECTRICAL SYSTEM
SUBSTITUTION OF THE REAR LED LIGHT

Place the motorcycle on a flat, level floor.

IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot
fall.

To substitute the rear LED light, refer to “Chapter 4” Fair-

ings, paragraph “Removal of the rear light”.

21
20
S
R
TO
O
M
A
D
BA

3 - 55
- Benelli TRK 502 - Page 90
 ELECTRICAL SYSTEM
SUBSTITUTION OF THE REAR INDICATOR LIGHTS

Place the motorcycle on a flat, level floor.

D
IMPORTANT NOTICE
Prop the motorcycle on suitable supports so that it cannot D
fall.

NOTE:_________________________________
The following procedure is applicable to both rear indicators.
E
Remove:
• Rider and passenger seats, refer to chapter “Removal of
rider and passenger seats, Chapter 4”.
• Rear handles, refer to chapter “Removal of the rear han-
dles, Chapter 4”.

21
• Side fairings, refer to chapter “Removal of the side fair-
ings, Chapter 4”.

20
Disconnect:
• the indicator cables
• Remove the nuts of the rear indicator supports (E) Fig. D
• Remove the indicators and substitute them with the new
ones.

Install: S
R
Proceed in the reverse order of removal.
TO
O
M
A
D
BA

3 - 56
- Benelli TRK 502 - Page 91
 ELECTRICAL SYSTEM
SUBSTITUTION OF THE FRONT INDICATORS

Place the motorcycle on a flat, level floor. A

IMPORTANT NOTICE 1
Prop the motorcycle on suitable supports so that it cannot
fall. 1
Remove:
• Mobile windscreen, refer to chapter “Removal of mobile
windscreen, Chapter 4”.
• Front fairing, refer to chapter “Removal of front fairing,
Chapter 4”.
• Lighting unit, refer to chapter “Removal of the lighting
unit, Chapter 4”.

NOTE:_________________________________

21
The following procedure is applicable to both front indica-
tors

20
Remove:
• the support of the front indicators (1) Fig. A
• Remove the indicators.
Install:
• Proceed using the opposite order to removal.

S
R
TO
O
M
A
D
BA

3 - 57
- Benelli TRK 502 - Page 92
 ELECTRICAL SYSTEM
SUBSTITUTION OF THE IGNITION BLOCK

Remove: A
• Using a jointed hexagonal spanner, remove the ignition
block “A” positioned in front of the steering head Fig. A
• Remove the ignition block and disconnect the connector “B”
Fig. B
Install:
• Proceed using the opposite order to removal.

NOTE:_________________________________________
Each time a new ignition block is installed, it is necessary to
carry out the mapping of the new block.

21
20
S B
R
A
TO

B
O
M
A
D
BA

3 - 58
- Benelli TRK 502 - Page 93
 21
20
S
R
TO
4
O
M
A
D
BA

4-1
- Benelli TRK 502 - Page 94
 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

21
SPROCKET CHECK AND REPLACEMENT ............................................................................................................................18
INSTALLATION OF THE DISC BRAKE ....................................................................................................................................19
BACK TYRE INSTALLATION....................................................................................................................................................20

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

S
REAR BRAKE PUMP REMOVAL .............................................................................................................................................26
FRONT BRAKE PUMP INSTALLATION ...................................................................................................................................28
R
REAR BRAKE PUMP INSTALLATION .....................................................................................................................................29
ABS ANTI-LOCK BRAKING SYSTEM ........................................................................................................30
TO

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
O

REMOVAL OF THE ABS HYDRAULIC UNIT ...........................................................................................................................36

INSTALLATION OF THE ABS HYDRAULIC UNIT....................................................................................................................37
M

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
A

FRONT BRAKE CALLIPER INSTALLATION ............................................................................................................................42

REAR BRAKE CALLIPER INSTALLATION ..............................................................................................................................44
D

FRONT FORK ..............................................................................................................................................45

FRONT FORK STEM REMOVAL .............................................................................................................................................45
BA

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

4-2
- Benelli TRK 502 - Page 95
 CHAPTER 4
TRANSMISSION CHAIN AND SWINGING ARM ........................................................................................71
TRANSMISSION CHAIN REMOVAL ........................................................................................................................................71
REMOVAL OF THE SWINGING ARM ......................................................................................................................................73
FRAME .........................................................................................................................................................74
INSTALLATION/REMOVAL OF THE FRAME PARTS ..............................................................................................................74
LEFT/RIGHT ENGINE PROTECTION INSTALLATION............................................................................................................76
REMOVAL OF THE LEFT/RIGHT ENGINE PROTECTION .....................................................................................................77
REMOVAL OF THE FRONT FRAME/WINDSCREEN SUPPORT ............................................................................................78
INSTALLATION OF THE FRONT FRAME/WINDSCREEN SUPPORT ....................................................................................79
REMOVAL/INSTALLATION OF REAR FRAME PARTS ...........................................................................................................80
REMOVAL OF THE REAR FRAME ..........................................................................................................................................82
REAR FRAME FITTING ...........................................................................................................................................................83
REMOVAL OF SIDE BAG FRAME ...........................................................................................................................................84

21
INSTALLATION OF THE SIDE BAGS SUPPORT FRAME ......................................................................................................85
NUMBER PLATE HOLDER ......................................................................................................................................................86
REMOVAL OF THE NUMBER PLATE HOLDER ......................................................................................................................87
INSTALLATION OF THE NUMBER PLATE HOLDER ..............................................................................................................88

20
CYCLING .....................................................................................................................................................89
INSTALLATION OF THE STAND / FOOTRESTS .....................................................................................................................89
STAND/FOOTRESTS ...............................................................................................................................................................90
REMOVAL OF THE SIDE STAND ............................................................................................................................................91
S
INSTALLATION OF THE SIDE STAND ....................................................................................................................................92
R
REMOVAL OF THE REAR FOOTREST SUPPORT .................................................................................................................93
INSTALLATION OF THE REAR FOOTREST SUPPORT .........................................................................................................94
REMOVAL OF THE RIGHT/LEFT REAR FOOTREST .............................................................................................................95
TO

INSTALLATION OF THE LEFT/RIGHT REAR FOOTRESTS ...................................................................................................96

RIGHT FRONT FOOTREST REMOVAL...................................................................................................................................97
RIGHT FRONT FOOTREST FITTING ......................................................................................................................................98
LEFT FRONT FOOTREST REMOVAL .....................................................................................................................................99
O

LEFT FRONT FOOTREST INSTALLATION ...........................................................................................................................100

REMOVAL OF THE GEAR LEVER.........................................................................................................................................101
M

INSTALLATION OF THE GEARCHANGE LEVER .................................................................................................................102

EXHAUST SYSTEM...................................................................................................................................103
EXHAUST ASSEMBLY ...........................................................................................................................................................103
A

EXHAUST ASSEMBLY REMOVAL .........................................................................................................................................104

EXHAUST INSTALLATION .....................................................................................................................................................106
D

FRONT MUD GUARD ............................................................................................................................................................107

FRONT MUD GUARD REMOVAL ..........................................................................................................................................108
BA

REAR MUD GUARD REMOVAL............................................................................................................................................. 111

REAR MUD GUARD INSTALLATION .....................................................................................................................................112
REMOVAL OF THE RIDER SEAT AND PASSENGER SEAT .................................................................................................115
INSTALLATION OF THE RIDER SEAT AND PASSENGER SEAT .........................................................................................116
FRONT FAIRING ....................................................................................................................................................................117
REMOVAL OF THE FRONT FAIRING ....................................................................................................................................118
FRONT HEADLIGHT AND WINDSCREEN ............................................................................................................................120
REMOVAL OF MOVABLE WINDSCREEN .............................................................................................................................122
INSTALLATION OF THE MOBILE HEADLIGHT FAIRING .....................................................................................................123
REMOVAL OF THE HEADLIGHT UNIT ..................................................................................................................................126
INSTALLATION OF THE HEADLIGHT UNIT ..........................................................................................................................127
TANK COVER .........................................................................................................................................................................128
REMOVAL OF THE FUEL TANK COVER ..............................................................................................................................129
INSTALLATION OF THE FUEL TANK COVER.......................................................................................................................130
REMOVAL OF FUEL TANK ....................................................................................................................................................131
REMOVAL OF FUEL TANK ....................................................................................................................................................132
TANK FITTING........................................................................................................................................................................133

4-3
- Benelli TRK 502 - Page 96
 CHAPTER 4
TANK ..........................................................................................................................................................134
TANK PARTS ..........................................................................................................................................................................134
REMOVAL OF THE TANK CAP SUPPORT ............................................................................................................................135
INSTALLATION OF THE TANK CAP SUPPORT ....................................................................................................................136
REMOVAL OF THE TANK PUMP ...........................................................................................................................................137
INSTALLATION OF THE TANK PUMP ...................................................................................................................................138
REMOVAL OF THE TANK FUEL LEVEL SENSOR ................................................................................................................139
INSTALLATION OF THE TANK FUEL LEVEL SENSOR ........................................................................................................140
AIR FILTER ................................................................................................................................................141
AIR FILTER PARTS ................................................................................................................................................................141
REMOVAL OF THE AIR FILTER .............................................................................................................................................142
INSTALLATION OF THE AIR FILTER .....................................................................................................................................143
INSTALLATION OF THE AIR FILTER BOX ............................................................................................................................145
SIDE FAIRINGS ......................................................................................................................................................................146
REMOVAL OF THE SIDE FAIRINGS .....................................................................................................................................147
INSTALLATION OF THE SIDE FAIRINGS..............................................................................................................................148

21
UPPER TAIL FAIRING ............................................................................................................................................................149
TAILPIECE REMOVAL............................................................................................................................................................150
REMOVAL OF THE REAR PASSENGER HANDLES ............................................................................................................152

20
INSTALLATION OF THE REAR HANDLES ............................................................................................................................153
REMOVAL OF THE REAR LIGHT ..........................................................................................................................................154
INSTALLATION OF THE REAR LIGHTS ................................................................................................................................156
CHAIN PINION COVER..........................................................................................................................................................157

S
REMOVAL OF THE CHAIN PINION COVER .........................................................................................................................158
INSTALLATION OF THE CHAIN PINION COVER .................................................................................................................159
R
TO
O
M
A
D
BA

4-4
- Benelli TRK 502 - Page 97
 FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL REMOVAL

Park:
• The bike on a level surface
A

NOTE:_________________________________
Place the bike on a suitable support so that the front wheel
is raised.

Remove:
• The screw (E) B
• the ABS sensor “A”
• the screws “B” C E
• tube guide bracket (C) Fig. A

Detach:
A
• the left front calliper

21
NOTE:_________________________________
Repeat the above-mentioned procedure for the opposite B
front brake calliper.

20
NOTE:_________________________________
Do not pull the front brake lever while removing the callipers.

Loosen:
• the setscrews “B” Fig. B
S
R
Remove:
• the front wheel pin “C” Fig. C B
TO

• front wheel
• The left shim “D” Fig. C
• The spacer “E”, Fig. C
O

C
D
M

E
A
D
BA

4-5
- Benelli TRK 502 - Page 98
 FRONT WHEEL AND BRAKE DISCS
REMOVAL/INSTALLATION OF BRAKE DISCS

1
3

1 11

10 7

21
9
4 2
10

20
8
13
4
12
5

S 6
R
12
TO

12
O

CONTENTS
Pos. Description Sq. SYMBOLS REMARKS
DESCRIPTION
M

1 SCREW
2 FRONT BRAKE DISC
3 LEFT SHIM
A

4 BEARING
D

5 FRONT WHEEL RIM (GREY)

6 FRONT WHEEL AXLE
BA

7 VALVE
8 SHIM
9 INTERNAL SHIM
10 OIL SEAL
11 FRONT WHEEL ABS SENSOR
12 SCREW
13 FRONT TIRE

4-6
- Benelli TRK 502 - Page 99
 FRONT WHEEL AND BRAKE DISCS
REMOVAL/INSTALLATION OF BRAKE DISCS

Remove:
• front wheel, refer to chapter “Removal of the front wheel”
A
• brake callipers, refer to chapter “Removal of the front
brake callipers”
• screws (12*) 1
6
• brake disc (2*)
3
4
Install:
• left front brake disc (2*)
5
• and screws (12*) 2

NOTE:_________________________________
Repeat the above-mentioned procedure for the opposite

21
front disc brake.

AREXON SYSTEM 52A43

20
MEDIUM GRADE BRAKE
THREAD SEALANT

The procedure below applies to both brake discs.

NOTE:_________________________________ S
R
Tighten the bolts of the brake disc in successive passes, op-
erating in a criss-cross sequence - Fig. A.
TO

• Tighten the torque:

T. R .

Torque 22N*m
O

NOTE:_________________________________
M

The numbers marked (*) are a part of the table at the begin-
ning of the chapter.
A
D
BA

4-7
- Benelli TRK 502 - Page 100
 FRONT WHEEL AND BRAKE DISCS
CHECK OF BRAKE DISCS

The procedure below applies to all brake discs.

Check:
A
• the brake disc
If there is any damage/abrasion, replace.

Measure:
• The deformation of the brake disc.
Substitute the brake disc if it is outside the specification.

• Place the bike on a suitable support so that the wheel is

raised.
• Before measuring the bending of the front brake disc, turn
the handlebar right and then left to make sure that the front
wheel stops.

21
• To remove the disc brake, refer to chapter “Removal of the
disc brake”.
• Keep the gauge at a right angle to the surface of the brake B

20
disc.
• Measure the bending 1.5 mm (0.05 in) under the edge of
the brake disc Fig. A.

S
R
Brake disc Deformation limit
Front 0.1 mm
TO

Rear 0.15 mm
3
O

Measure:
• Brake disc thickness.
M

• Measure the thickness of the brake disc at various different

points - Fig. B.
• If outside specifications, replace.
A
D
BA

4-8
- Benelli TRK 502 - Page 101
 FRONT WHEEL AND BRAKE DISCS
WHEEL AXLE CHECK

Carry out a visual check of the front wheel and rear wheel axle
bolt to check for damage.
A
Substitute the wheel axle bolt if it is damaged or bent.

Check:
• Wheel axle.
• Position the wheel axle on two V-blocks approx. 100 mm
apart (A) and position a comparator (B) on the wheel axle at
a point halfway between the blocks – Fig. A.
• Rotate the wheel axle (C) to measure the lack of centring.

The difference between the upper and lower detections of the

comparator represents the measurement of the misalignment.
Substitute the wheel axle, if the misalignment exceeds the

21
service limit.

Wheel shaft runout /100 mm

20
STANDARD LIT 0.1 mm or less B
Service limit LIT 0.2 mm C

B
IMPORTANT NOTICE
Do not try to straighten the wheel axle if it is warped.
S
R
If there is any warping, replace.
TO

Check:
• Tyre
• Front wheel
If there is any warping, replace.
O

Measure:
• The radial eccentricity of the wheel “B” Fig. B.
M

• The side eccentricity of the wheel “C” Fig. B.

If the specified limit is exceeded, replace.
A
D

Eccentricity Limit
Radial(B) 0.05 mm
BA

Side(C) 0.05 mm

4-9
- Benelli TRK 502 - Page 102
 FRONT WHEEL AND BRAKE DISCS
CHECK/REPLACEMENT OF WHEEL BEARINGS

Check:
• Wheel bearings
A
If the front wheel turns irregularly or is loose, replace the wheel
bearings.

Replace:
• Wheel bearings
Remove the wheel bearings “A” using a general bearing ex-
tractor Fig. B.
Fit the new wheel bearing, following the removal steps in re-
verse order.

IMPORTANT NOTICE
When inserting the bearings do not touch the internal ring

21
(B) or the ball bearings of the wheel bearings. Contact must
be made only by the external ring.
B

20
NOTE:_________________________________
Use a wrench that adapts to the diameter of the external
edge of the wheel bearing.
A
S
R
TO
O
M
A
D
BA

4 - 10
- Benelli TRK 502 - Page 103
 FRONT WHEEL AND BRAKE DISCS
FRONT WHEEL INSTALLATION

Install:
• the wheel between the two tubes of the fork Fig. A
A
• the bush (8*) – left side Fig. A
• the bush (3*) – right side Fig. A

Tighten the torque:

• wheel axle (6*) 8*
3*

G
Recommended lubricant
MR2 TUTELA GREASE

6*
T. R .

21
Torque 60 N*m
B
• Set screws “B” Fig. B

20
T. R .

Torque 8 N*m

IMPORTANT NOTICE
Before tightening the front wheel axle bolt, push hard on the S
R
handlebars to check that the front fork returns to the station-
ary position in a smooth way.
B
TO

Install:
• right brake calliper Fig. C
• tube guide bracket Fig. C
O

• screw (E) Fig. C

• ABS sensor (A) Fig. C
• screws (B) Fig. C
C
M

Tighten the torque:

T. R .
A

Torque 50 N*m
D

NOTE:_________________________________ B
Repeat the above-mentioned procedure for the opposite
BA

brake calliper.
Ensure that there is enough space between the brake pads C E
before fitting the callipers on the relative brake discs.
Check that the travel of the flexible brake hose is correct. A
NOTE:_________________________________
The numbers marked (*) are a part of the table at the begin-
ning of the chapter.

4 - 11
- Benelli TRK 502 - Page 104
 REAR WHEEL AND BRAKE DISC
REAR WHEEL REMOVAL

8
11
20
19
9
21

12
18 22

18 15
15 10

21
13
17
23 16
15

20
10 10

7
13
14
4 whit ABS sensor
26

6
S 24
R
3
5
3
TO

1
3
2

25
O
M

CONTENTS
Pos. Description Sq. SYMBOLS REMARKS
DESCRIPTION
A

1 REAR WHEEL AXLE

2 BUSHING
D

3 SCREW
4 REAR BRAKE DISC
BA

5 VALVE
6 REAR WHEEL RIM (BLACK)
7 INTERNAL SHIM
8 DUST COVER
9 NUT
10 FLEXIBLE COUPLING
11 SHIM
12 O-RING
13 BEARING
14 OIL SEAL
15 SCREW
16 SPROCKET SUPPORT FLANGE
17 CROWN (Z42)
18 NUT M10
19 SHIM

4 - 12
- Benelli TRK 502 - Page 105
 REAR WHEEL AND BRAKE DISC
REAR WHEEL REMOVAL

CONTENTS
Pos. Description Sq. SYMBOLS REMARKS
DESCRIPTION
20 BEARING
21 ELASTIC RING
22 TRANSMISSION CHAIN
23 REAR TYRE (160/60-R17)
24 CALLIPER HOLDER PLATE
25 REAR WHEEL ABS SENSOR
26 SCREW

21
20
S
R
TO
O
M
A
D
BA

4 - 13
- Benelli TRK 502 - Page 106
 REAR WHEEL AND BRAKE DISC
REAR WHEEL REMOVAL

Park:
• The bike on a level surface
A

NOTE:_________________________________
Place the bike on a suitable support so that the rear wheel
is raised.

Remove:
• the fixing screws (A) of the brake calliper Fig. A
Detach: A
• the brake calliper.
Remove:
• the screws (C) Fig. B
• the phonic wheel sensor (B) Fig. B
• The nut (21*)

21
• the pin (1*)
• the register slide (D) Fig. C
B
NOTE:_________________________________ 9*

20
During this phase, be careful in separating the components
such as the chain tensioner register on the crown wheel side D
and the brake disc side and brake calliper support plate ”E”
Fig. C.

Remove:
S
R
• The bush (20*) Fig. D
• the spacer (2*) Fig. D
TO

NOTE:_________________________________ C B
The numbers marked (*) are a part of the “Rear wheel and
brake disc” table.
O

C
M

E
A

1*
D
BA

2*

20*

4 - 14
- Benelli TRK 502 - Page 107
 REAR WHEEL AND BRAKE DISC
REMOVAL OF THE REAR DISC BRAKE, CROWN WHEEL AND PHONIC WHEEL

Remove: A
• the screws (26*) Fig. A
• the brake disc (4*) Fig. A
Removal of the phonic wheel:
• the phonic wheel (25*) Fig. A
• loosen the screws (3*) Fig. A 26
• the nuts (18*)
• the crown wheel (17*) 3
• the flange (16*)
• the screws (15*) 3
• the flexible couplings (10*)
3
Check:
• the crown wheel holder flange (16*) 25
• If there is any cracking/damage, replace.

21
• The flexible couplings (10*)
• If there is any damage or wear, replace. 18 B
NOTE:_________________________________

20
The numbers marked (*) are a part of the “Rear wheel and
18 15
brake disc” table.
15 10
13
17
16

S 15
10 10
R
TO
O
M
A
D
BA

4 - 15
- Benelli TRK 502 - Page 108
 REAR WHEEL AND BRAKE DISC
WHEEL AXLE CHECK

Check:
• Wheel axle.
A
A
• Rotate the axle of wheel “A” on a flat surface Fig. A.
If there is any warping, replace.

WARNING
Do not try to straighten the wheel axle if it is warped.
Check:
• Tyre
• Front wheel
If there is any warping, replace.

Measure:
• The radial eccentricity of the wheel “B” Fig. B
• The lateral eccentricity of the wheel “C” Fig. B.

21
If the specified limit is exceeded, replace.
B
C

20
Eccentricity Limit B
Radial(B) 0.05 mm
Side(C) 0.05 mm
S
R
TO
O
M
A
D
BA

4 - 16
- Benelli TRK 502 - Page 109
 REAR WHEEL AND BRAKE DISC
CHECK/REPLACEMENT OF WHEEL BEARINGS

Check:
A
• Wheel bearings
If the front wheel turns irregularly or is loose, replace the wheel
bearings.

Replace:
• Wheel bearings
Remove the bearings from the wheel ”A” with a generic bearing
extractor Fig. B.
Fit the new wheel bearing, following the removal steps in re-
verse order.

IMPORTANT NOTICE
During the bearing insertion, do not touch the inner seat “B”

21
or the ball bearings of the wheel “C”. Contact must only oc-
cur with the outer seat of bearing “D” Fig. C.
B

20
NOTE:_________________________________
Use a wrench that is adapted to the diameter of the outer
edge “E” of the wheel bearing, Fig. C.

A
S
R
TO
O

C
M

E
A

D
D
BA

4 - 17
- Benelli TRK 502 - Page 110
 REAR WHEEL AND BRAKE DISC
SPROCKET CHECK AND REPLACEMENT

Check:
A
• The sprocket 1
If more than 1/4 of each tooth is worn, replace the sprocket.
If the teeth are bent, replace the sprocket.
3
1. 1/4 teeth 2
2. Correct
3. Transmission chain roller
4. Chain wheel 4

Replace:
• the crown wheel, refer to the “Removal of the rear brake
disc, crown wheel and phonic wheel” paragraph.
• Clean the crown wheel holder flange (16*) using a clean

21
cloth, especially surfaces that touch the crown wheel.
18 B
Recommended solvent

20
TUTELA MOTOR CLEAN 18 15
15 10
Install: 13
17
• the new crown wheel 16
• tighten the self-locking nuts (18*) to the following torque
pressure: S 15
10 10
R
T. R .
TO

Torque 45 N*m

NOTE:_________________________________
Tighten the self-locking nuts in several stages, proceeding
O

with a crossover sequence.

M

NOTE:_________________________________
The numbers marked (*) are a part of the “Rear wheel and
brake disc” table.
A
D
BA

4 - 18
- Benelli TRK 502 - Page 111
 REAR WHEEL AND BRAKE DISC
INSTALLATION OF THE DISC BRAKE

Install:
• brake disc (4*) Fig. A
A
• lubricate screws (26) Fig. A.

G MR2 TUTELA grease 26

3
• tighten to the following torque: 3

T. R . 3

Torque 10 N*m 25
Use Loctite thread locker to secure.

21
Loctite 243

20
NOTE:_________________________________
Tighten the self-locking nuts in several stages, proceeding
with a crossover sequence.

NOTE:_________________________________ S
R
The numbers marked (*) are a part of the “Rear wheel and
brake disc” table.
TO
O
M
A
D
BA

4 - 19
- Benelli TRK 502 - Page 112
 REAR WHEEL AND BRAKE DISC
BACK TYRE INSTALLATION

Install: A
• Position brake calliper support bracket (23*) Fig. A.
• Insert the bushes (2*) right side and (20*) left side Fig. B.
• Position the register slide (A) and (B) Fig. C. 23*
• position the rear wheel.
Lubricate and install:
• The axle (1*)
• the nut (24*)

G MR2 TUTELA grease

• tighten to the following torque pressure Fig. D:

21
T. R .

B
Torque 80 N*m

20
Install:
• the brake calliper. 2*
• screws
• tighten to the following torque pressure Fig. D:

T. R .
S
R
Torque 80 N*m
20*
TO

NOTE:_________________________________
Make sure that there is enough space between the brake
pads before fitting the calliper to the relevant brake discs.
O

IMPORTANT NOTICE C
Check that the travel of the flexible brake hose is correct. B
M

NOTE:_________________________________
The numbers marked (*) are a part of the “Rear wheel and A
brake disc” table.
A
D
BA

D
1

4 - 20
- Benelli TRK 502 - Page 113
 FRONT AND REAR BRAKES
REMOVAL AND INSTALLATION OF FRONT BRAKE PADS

The procedure that follows is applicable to both front brake

callipers.
A

NOTE:_________________________________
Substitute the brake pads always together to ensure a uni- A
form pressure.

Remove: B
• pin springs (B) Fig. A
• fixing pins (A) Fig. A
• Remove the brake pads (C) Fig. B.

Measure:
• The wear limit for the brake pads.
If outside specifications, replace the brake pads as a block.

21
B

20
Pads Wear limits
Front 1 mm

Clean:
• press the pistons of the calliper inside to permit the installa-
tion of the new brake pads. S C
R
Install:
• the brake pads in reverse order of disassembly.
TO

• the brake calliper.

Check:
O

The brake fluid level “B” Fig. C

If below the minimum notch, top up with the recommended C
brake fluid until it is at the correct level.
M

Refer to Chapter 3: Periodic maintenance, paragraph “Check-

ing and topping up the front brake fluid level”.
B
A

Check:
• Brake lever operation.
If the brake lever is soft or spongy to the touch, bleed the brake
D

circuit.
BA

4 - 21
- Benelli TRK 502 - Page 114
 FRONT AND REAR BRAKES
REMOVAL AND INSTALLATION OF REAR BRAKE PADS

Remove: A
• the screw “A” Fig. A.
• the calliper body “B” Fig. B.

Take out:
• The brake pads “C” Fig. B. A
Measure:
• The wear limit for the brake pads.
If outside specifications, replace the brake pads as a block.

Pads Wear limits

Rear 1 mm

21
Clean: B
• inside the calliper
• the pistons, then dry everything.
C

20
Press:
• the pistons of the calliper inside to permit the installation of
the new brake pads.

Install: S
R
• the brake pads in reverse order of disassembly.
• screws B
• the brake calliper.
TO

• tighten to the following torque:

T. R .
O

Torque 22 N*m C
D
M

Check:
• The brake fluid level “E” Fig. D.
A

Top up with brake fluid if the level is less that the minimum level
mark.
D

• Brake pedal operation.

BA

IMPORTANT NOTICE
Do not utilise the motorcycle if full efficiency of the brake
pedal cannot be obtained. Full efficiency is activated by op-
erating the brake pedal several times so as to bring the pads
into contact with the disc. If this operation is not carried out,
the brakes will not operate the first time when the pedal is D
activated.

4 - 22
- Benelli TRK 502 - Page 115
 FRONT AND REAR BRAKES
FRONT BRAKE PUMP REMOVAL

21
21
23
2
13 9 22
28
25
20 9
9 27 26
9

21
20

20
9 17 12 11
10 19
16 24
9 S 9 30 14
R
17 9
TO

9 31

18 15
O
M

CONTENTS
Pos. Description Sq. SYMBOLS REMARKS
A

DESCRIPTION
1 PIPE
D

2 BRACKET
BA

3 REAR BRAKE HOSE

4 REAR BRAKE CALLIPER HOSE – ABS CEN-

TRAL UNIT
5 FRONT BRAKE PUMP

6 REAR BRAKE CALLIPER

7 REAR BRAKE PADS (A PAIR)

8 REAR IDROSTOP

9 GASKET

10 FRONT BRAKE CALLIPER HOSE – ABS CEN-

TRAL UNIT
11 FRONT BRAKE HOSE

12 FRONT BRAKE HOSE

13 COMPLETE FRONT BRAKE PUMP

14 LEFT FRONT CALLIPER (RADIAL)

4 - 23
- Benelli TRK 502 - Page 116
 FRONT AND REAR BRAKES
FRONT BRAKE PUMP REMOVAL

CONTENTS
Pos. Description Sq. SYMBOLS REMARKS
DESCRIPTION
15 RIGHT BRAKE CALLIPER (RADIAL)

16 ABS CENTRAL UNIT

17 SCREW

18 FRONT BRAKE PADS (A PAIR)

19 SPECIAL SCREW

20 SPECIAL SCREW

21 SCREW

22 SPECIAL SCREW

21
23 SPECIAL SCREW

24 SPECIAL SCREW

25 FRONT BRAKE LEVER

20
26 SELF-LOCKING NUT

27 SCREW

28
29
MICROSWITCH
ELASTIC WASHER S
R
30 SPRING BAND
TO
O
M
A
D
BA

4 - 24
- Benelli TRK 502 - Page 117
 FRONT AND REAR BRAKES
FRONT BRAKE PUMP REMOVAL

NOTE:_________________________________
Drain out the brake fluid before proceeding with these oper-
A
ations.
Refer to Chapter 3: Periodic maintenance, paragraph “Check-
ing and topping up the front brake fluid level”.
1
IMPORTANT NOTICE
When removing the pump, avoid spilling onto the surfaces of
the motorcycle brake fluid that has remained in the system.

Remove:

• the special screws (22*)

• sealing washer (9*).
• Remove the front brake hose (10*).

21
• Detach the front brake hose (10*).
• disconnect the connector of the front brake switch (1) Fig. A.
• screw (27*)

20
• micro-switch (28*).
• nut (26*)
• screw (23*)
• front brake lever (25*)
• screws (21*)
•
•
clamp (2*).
remove the pump. S
R
IMPORTANT NOTICE
TO

during the disassembly stage, do not allow any brake fluid

remaining in the circuit to drip onto the vehicle.

NOTE:_________________________________
O

The numbers marked (*) are a part of the table at the begin-
ning of the chapter.
M
A
D
BA

4 - 25
- Benelli TRK 502 - Page 118
 FRONT AND REAR BRAKES
REAR BRAKE PUMP REMOVAL

8 9
9
5
1 3

21
30

20
20
7
21 29 20

6S 9
R
16
TO

9 17
9
20
O

4
M

NOTE:_________________________________
The above exploded view is part of the spare parts table of the chapter “Front and rear brakes”, paragraph “Removal of the
A

front brake pump”.

D
BA

4 - 26
- Benelli TRK 502 - Page 119
 FRONT AND REAR BRAKES
REAR BRAKE PUMP REMOVAL

NOTE:_________________________________
Drain out the brake fluid before proceeding with these oper-
A
ations.
Refer to Chapter 3: Periodic maintenance, paragraph “Check- A
ing and topping up the front brake fluid level”.

Remove:
• brake pump protection (A) Fig. A
• screws (2) Fig. A.
• idrostop (8) Fig. B. 2
• sealing washer (9*).
• Release the main brake hose (3*).
• Release the brake reservoir hose (1*).
• Remove the brake pump (5*).

21
IMPORTANT NOTICE B
During the disassembly stage, do not allow any brake fluid

20
remaining in the circuit to drip onto the vehicle surfaces.

NOTE:_________________________________ 8
The numbers marked (*) are a part of the table at the begin-
ning of the chapter. 1
S
R
TO
O
M
A
D
BA

4 - 27
- Benelli TRK 502 - Page 120
 FRONT AND REAR BRAKES
FRONT BRAKE PUMP INSTALLATION

WARNING A
Before installing, clean all of the internal parts of the brake,
and lubricate them with clean or new brake fluid. 1
Never use solvents on the internal parts of the brake.

Recommended brake fluid 27* 28*

TUTELA BRAKE FLUID TOP4
DOT4

23*
Install:
• position the pump body
25*
• clamp (2*) Fig. B
26*

21
• the screws (21*)
Tighten to the following torque:
B

20
T. R .

Torque 8 N*m
• micro-switch (28*)
• screw (27*)
Tighten to the following torque:
T. R . S 2*
R
21*
Torque 1.5 N*m
TO

• connect the connector of the front brake switch (1) Fig. A.

• Position the front brake hose to the brake pump (10*).
• sealing washer (9*).
• special screw (22*)
O

Tighten to the following torque:

M

T. R .

Torque 26 N*m
A

• Position the front brake lever (25*) Fig. A

• screw (23*) - tighten Fig. A
• nut (26*) Fig. A
D

Tighten to the following torque:

T. R .
BA

Torque 7 N*m

WARNING
To guarantee the safety of the bike, it is essential for the path
of the brake hose to be correct.

NOTE:_________________________________
Once topping up operations of the brake fluid has finished,
refer to Chapter 3: Periodic maintenance, paragraph “Check-
ing and topping up the front brake fluid level”.

NOTE:_________________________________
The numbers marked (*) are a part of the table at the begin-
ning of the chapter.

4 - 28
- Benelli TRK 502 - Page 121
 FRONT AND REAR BRAKES
REAR BRAKE PUMP INSTALLATION

Install:
A
• Connect the brake fluid reservoir hose (1*) to the brake
pump (5) Fig. B A
• Connect the main brake hose (3*).
• Position the Idrostop (8*) Fig. B and tighten to the following
torque pressure:
T. R .

10
Torque 12 N*m
• the sealing washers (9*) Fig. B.
• Position the protection and the brake pump (A) Fig. A.
• screws (10) Fig. A.
Tighten to the following torque:
T. R .

21
Torque 12 N*m B
9

20
IMPORTANT NOTICE
3
When assembling the pump, avoid spilling brake fluid that
has remained in the system onto the surfaces of the motor- 8
cycle.
9
1 5
NOTE:_________________________________
S
R
The numbers marked (*) are a part of the table at the begin-
ning of the chapter.
TO
O
M
A
D
BA

4 - 29
- Benelli TRK 502 - Page 122
 ABS ANTI-LOCK BRAKING SYSTEM
LOCATION OF THE COMPONENTS

The components that compose the anti-lock braking system are:

A
• phonic wheel sensor (A) – front wheel Fig. A
• phonic wheel (B) – front wheel Fig. A

21
B
• phonic wheel sensor (C) – rear wheel Fig. B
• phonic wheel (D) – rear wheel Fig. B C

20
S
R
D
TO
O

C
• ABS “yellow” warning light (E) Fig. C
M
A
D

E
BA

• ABS hydraulic unit (F) Fig. D D

4 - 30
- Benelli TRK 502 - Page 123
 ABS ANTI-LOCK BRAKING SYSTEM
POSITION OF THE COMPONENTS

• Fuse box “1” Fig. E E

21
1

20
S
R
TO

F
O

• Connector of the ABS diagnostic system “2” Fig. F

2
M
A
D
BA

4 - 31
- Benelli TRK 502 - Page 124
 ABS ANTI-LOCK BRAKING SYSTEM
ROTATION SENSOR CHECK

IMPORTANT NOTICE A
The wheel rotation sensor must be handled with caution,
must not receive knocks, e.g., with a hammer, or dropped on
a hard surface. It is a precision instrument.
Do not soak the rotation sensor in water or mud 2
Do not attempt to repair or remove the wheel rotation sensor.

Remove:
• screw (1) Fig. A
• phonic wheel sensor (2) of the front wheel Fig. A
Disconnect:
• the connector of the phonic wheel (5) Fig. C.
1
Carry out a visual check of the rotation sensor of the phonic

21
wheel. Substitute the wheel rotation sensor if it is cracked, bent
or damaged in anyway. If an electrical fault in the sensors is
suspected, check the electrical circuit. B

20
Remove:
• screw (3) Fig. B
• phonic wheel sensor (4) of the rear wheel Fig. A
Disconnect:
• the connector of the phonic wheel (6) Fig. D.

Carry out a visual check of the rotation sensor of the phonic S

R
wheel. Substitute the wheel rotation sensor if it is cracked, bent
or damaged in anyway. If an electrical fault in the sensors is
TO

suspected, check the electrical circuit.

4
3
NOTE:_________________________________
Place the motorcycle on a suitable support so that the front
wheel is raised.
O

C
Check:
M

Lift the front/rear wheels off the ground and measure the
distance at various points between the sensor and the phonic
wheel.
5
A
D

Air light
BA

Front Rear
0.1 – 1.5 mm 295 mm

NOTE:_________________________________
It is not possible to adjust the distance of the sensor.
D
• If the distance does not come within the prescribed values,
check the hub bearing (refer to paragraph Removal/Instal-
lation of the front/rear wheel), the sensor, the phonic wheel
and the assembly conditions of the sensor. 6

4 - 32
- Benelli TRK 502 - Page 125
 ABS ANTI-LOCK BRAKING SYSTEM
CHECK OF THE PHONIC WHEEL AND ABS OF THE FRONT AND REAR WHEEL

Check:
Carry out a visual check of the phonic wheel of the wheel.
E
Substitute the phonic wheel if it is deformed or damaged, such
as damaged teeth. Fig. E
Remove the deposits if there are deposits of metal or magnetic
material (B). If necessary, substitute the phonic wheel as follows:

SUBSTITUTION OF THE PHONIC WHEEL, ABS OF THE

21
FRONT AND REAR WHEEL
11 F
Remove:
• Front wheel - refer to the chapter “removal of the front

20
wheel”.
• screws (12*)
7
• the phonic wheel (11*) Fig. F
• Rear wheel - refer to the chapter “removal of the rear
wheel”.

NOTE:_________________________________ S 9
4
10
8
2
R
The numbers marked (*) are a part of the spare parts table, 4
chapter “Front wheel and brake discs”, paragraph Removal/ 12
TO

installation of the brake discs”.

6
12

12
O
M
A
D
BA

4 - 33
- Benelli TRK 502 - Page 126
 ABS ANTI-LOCK BRAKING SYSTEM
PRECAUTIONS

PRECAUTIONS DURING THE MAINTENANCE OF THE ABS

A series of important precautions must be adopted during the maintenance of the ABS system.
• The ABS system has been designed to be fed by a 12V sealed battery. Do not use any other type of battery, only sealed 12V.
• Do not invert cable connections of the battery. It would damage the ABS hydraulic unit.
• To avoid damage to the ABS components, do not disconnect the battery cables or other electrical connections when the start
switch is positioned at ON or when the engine is running.
• Be careful to not cause a short circuit between the cables directly connected to the positive terminal (+) of the battery and the
Earth of the frame.
• Do not position the start switch at ON whilst the ABS electrical connectors are disconnected. The hydraulic unit
• of the ABS memorises the maintenance codes.
• Do not spray water onto the electrical components, the components of the Abs, cables, connectors or the cabling.
• If there is a transmitter/receiver installed on the motorcycle, ensure that the functioning of the ABS system is not disturbed by
electromagnetic waves irradiated by the antenna.
• Position the antenna as far away as possible from the hydraulic unit of the ABS.

21
• Position the start switch at OFF before disconnecting the electrical connections of the ABS.
• The components of the ABS must never be hit, for example by a hammer or must not be dropped onto a hard surface. These
impacts could cause damage to the components.
• The ABS components cannot be disassembled. Even if there is a fault, substitute the ABS unit, do not try to disassemble and

20
repair the components.
• The ABS system is made up of numerous circuits, tubes and cables of the brakes.
• Furthermore, the ABS system is not capable of detecting problems of the conventional braking system (abnormal wear of the
brake discs,
•

•
S
brake pads and other mechanical faults). To avoid inconveniences, check that the brake circuits and tubes are arranged and
connected correctly, the cabling is opportunely laid out and the brakes are equipped with adequate braking power.
Check that there are no leaks of fluid and then accurately bleed the brake circuits.
R
IMPORTANT NOTICE
TO

Air in the brake tubes reduces the braking power that could cause a serious accident with severe injuries and even death. If
any union of the brake circuit, including the nuts of the ABS hydraulic unit joint, or the bleed valve are opened, the air entered
into the system must be completely bled from the brake circuit. If the brake lever is spongy when pressed, there could be air
in the tubes of the brake circuit, or the brake could be defective. In that case, do not use the vehicle and immediately repair
O

the brake system.

M

IMPORTANT NOTICE
Do not use the motorcycle if there is air in the brake circuit, otherwise the ABS system could function incorrectly.
A

IMPORTANT NOTICE
The use of tyres that are not recommended could cause malfunctioning of the ABS system and cause an increase in the
D

braking distance thereby causing a serious accident with severe injuries and even death. Always use the recommended
standard tyres for this motorcycle.
BA

4 - 34
- Benelli TRK 502 - Page 127
 ABS ANTI-LOCK BRAKING SYSTEM
PRECAUTIONS

IMPORTANT NOTICE A
The LED yellow warning light of the ABS “E” Fig. A could
come on if the tyre pressures are not correct, if tyre not rec-
ommended has been fitted, or if the wheel is deformed. If the
warning light comes on, solve the problem by cancelling the
maintenance code.

21
20
S
R
TO
O
M
A
D
BA

4 - 35
- Benelli TRK 502 - Page 128
 ABS ANTI-LOCK BRAKING SYSTEM
REMOVAL OF THE ABS HYDRAULIC UNIT

IMPORTANT NOTICE A
The ABS hydraulic unit “A” has been adjusted and set with
precision by the manufacturer. Therefore it must be handled A
very carefully, must never by hit for example by a hammer, or
dropped on a hard surface. Do not soak the ABS hydraulic
unit in water or mud.

• Bring the start switch to the OFF position.

Remove:
• Rider and passenger seats, see chapter “Removal of the
rider and passenger seat, Chapter 4”.
• Side fairings, see chapter “Removal of the side fairings,
Chapter 4”.

21
• For the fuel tank, refer to chapter “Removal of the fuel
tank, Chapter 4”.
• Discharge the brake fluid from the front and rear brake B
circuit utilising the bleed valve and pumping the brake lever

20
and the brake pedal.
• Do not forget to place a cloth underneath the ABS hydraulic
unit.
• The nuts of the rigid tubing (B). Fig. B
• the screws (D) Fig. C

Disconnect: SC
B
R
• The connector of the ABS hydraulic unit “C” Fig. B by rotat-
ing the lever as indicated in the figure.
TO

Remove:
• Remove the ABS hydraulic unit
NOTE:_________________________________
Be careful to not bend the brake hose when removing it.
ABS hydraulic unit
O

C
• Close the oil passage holes (A) of the ABS hydraulic unit (B)
M

with a cloth to avoid dirt from entering into the unit Fig. D.

IMPORTANT NOTICE
A

Do not allow dirt to enter into the hydraulic system when the
D

tubes are disconnected. Brake fluid rapidly damages paint- D

ed plastic surfaces; completely wash the concerned zones
immediately.
BA

D
IMPORTANT NOTICE
The ABS hydraulic unit has been adjusted and set with preci-
sion by the manufacturer.
Do not attempt to repair or remove the ABS hydraulic unit.

Check:
• Carry out a visual check of the ABS hydraulic unit.
• Substitute the ABS hydraulic unit if any component is
cracked or damaged in any way.

4 - 36
- Benelli TRK 502 - Page 129
 ABS ANTI-LOCK BRAKING SYSTEM
INSTALLATION OF THE ABS HYDRAULIC UNIT
Install:
• Position the ABS hydraulic unit on the frame. A
• Install the rigid tubes of the brakes onto the ABS hydraulic
unit and manually screw in the flare nuts without tightening.

• front brake calliper hose (G) Fig. B

• front brake pump hose (D) Fig. B
• rear brake calliper hose (E) Fig. B
• rear brake pump hose (F) Fig. B
• the screws (1) Fig. A to the following torque: 1
T. R .

B
Torque 10 N*m
• Tighten the union nuts of the rigid tubing Fig. B to the fol-

21
lowing torque pressure:

T. R .

20
Torque 18 N*m E
C F
Connect:
• The connector of the ABS hydraulic unit (H) Fig. C

S D
G
R
Install:
To install, reverse the order of the removal operation.
• Bleed the air from the brake circuit, refer to chapter “Frame/
TO

brake fluid level check, Chapter 3”. C

O
M
A

H
D
BA

4 - 37
- Benelli TRK 502 - Page 130
 ABS ANTI-LOCK BRAKING SYSTEM
REMOVAL OF THE ABS ROTATION SENSORS – FRONT/REAR WHEEL

IMPORTANT NOTICE A
The wheel rotation sensor must be handled with caution,
must not receive knocks, e.g., with a hammer, or dropped on
a hard surface. It is a precision instrument.
Do not soak the wheel rotation sensor in water or mud Do not 5
attempt to repair or remove the wheel rotation sensor.

Remove:
• Rider and passenger seats, see chapter “Removal of the
rider and passenger seat, Chapter 4”.
• Side fairings, see chapter “Removal of the side fairings,
Chapter 4”.
• For the fuel tank, refer to chapter “Removal of the fuel
tank, Chapter 4”.

21
• For the front wheel rotation sensor refer to chapter “ABS
anti-lock braking system, paragraph rotation sensor
check”. B
• Disconnect the connector of the front wheel rotation sensor

20
(5) Fig. A
• Remove the cable (6) of the sensor from the fixing terminal
Fig. B. 6
Install:
For installation, reverse the order of the removal operation.
Replace the cable correctly. S
R
TO
O
M
A
D
BA

4 - 38
- Benelli TRK 502 - Page 131
 FRONT AND REAR BRAKES
FRONT BRAKE CALLIPER TIGHTNESS

The following procedure is applied to both brake callipers.

A
NOTE:_________________________________
20
9 17 12 11
Before disassembling the brake calliper, discharge the brake
fluid from the complete braking system: refer to “Frame/ 10 19
brake fluid level check, Chapter 3”. 16 24
9 9 30 14
Remove:
17 9
• the special screw (24*) and (19*) Fig. A
• the sealing washers (9*) Fig. A 9 31
• the front brake hose (12) Fig. A
• the screws (A) Fig. B
• Remove both callipers. 18 15

NOTE:_________________________________

21
Insert the end of the brake hose into a container and slowly
pump out and drain the brake fluid.
A B
IMPORTANT NOTICE A

20
Brake fluid rapidly damages painted plastic surfaces; com-
pletely wash the concerned zones immediately.

Detach:
•
•
the pistons (1) Fig. C
the seals (2) Fig. C S
R
Secure:
TO

• the pistons of the brake callipers with a block of wood Fig. D

• Blow compressed air into the attachment of the flexible
brake hose to push the left pistons outwards from the brake
calliper.
O

IMPORTANT NOTICE C
Never try to prise out the calliper pistons.
M

NOTE:_________________________________
Repeat the above-mentioned procedure to force the pistons
A

out from the opposite brake calliper.

D

Check:
The ring seal of the damaged brake calliper. 1
The ring seal (piston seal) (2) Fig. C that are found inside the
BA

piston to maintain the play between the pads and the disc.
If the seal is in bad condition, it can cause excessive wear of the
pads or sticking of the brake, with a consequent increase of the 2
temperature of the discs or the brake fluid.

Replace:
• the seals (2) Fig. C D
Substitute the seal if it shows signs of the following:
• Brake fluid leak around the brake pads.
• Brakes overheating.
• Notable difference of wear between the internal and exter-
nal brake pads.
• If the seal and piston are stuck to each other.
Substitute the seals when substituting the brake pads.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Front and rear brakes”, paragraph “Removal of the
front brake pump”.

4 - 39
- Benelli TRK 502 - Page 132
 FRONT AND REAR BRAKES
REAR BRAKE CALLIPER

NOTE:_________________________________
A
Before disassembling the brake calliper, discharge the brake
20
fluid from the complete braking system: refer to “Frame/ 7
brake fluid level check, Chapter 3”.
21 29 20
Remove: 9
•
•
the screw (20*) Fig. A
the sealing washers (9*) Fig. A
6
• the front brake hose (4) Fig. A
• the screws (A) Fig. B
Remove the calliper 9 1
9
NOTE:_________________________________ 20
Insert the end of the brake hose into a container and slowly
pump out and drain the brake fluid. 4

21
Detach: B
• the pistons (B) Fig. B
• the seals (C) Fig. B

20
• (first the oil seals – the smallest seals, then the O-rings –
the largest seals)
• Fix the pistons of the brake calliper with a block of wood B
Fig. C
C
•

•
Blow compressed air into the attachment of the flexible
brake hose to force the pistons from the brake calliper.
The sliding pins (3) and (4) Fig. E S D
R
• ear protectors against dust (1) and (2) Fig. D
TO

IMPORTANT NOTICE
Never try to prise out the calliper pistons. C
Replace:
O

• the seals (C) Fig. B

• Substitute the seal if it shows signs of the following:
M

- Brake fluid leak around the brake pads.

- Brakes overheating.
- Notable difference of wear between the internal and exter-
nal brake pads.
A

- If the seal and piston are stuck to each other.

D

Substitute the seals when substituting the brake pads. D

1
BA

IMPORTANT NOTICE
When the repair has finished, the brake lever and pedal must 2
pressed several times so that the pads come into contact
with the brake discs so that the braking distance is fore-
shortened and therefore avoiding an accident with serious
injuries or death. Do not utilise the motorcycle if full efficien-
cy of the brake pedal cannot be obtained. Full efficiency is
activated by operating the brake pedal several times so as to
bring the pads into contact with the disc.

E
3
NOTE:_________________________________
The numbers marked (*) are a part of the table at the begin-
ning of the chapter.
4

4 - 40
- Benelli TRK 502 - Page 133
 FRONT AND REAR BRAKES
CHECK THE FRONT AND REAR CALLIPERS

Check:
• the pistons (1) of the brake callipers Fig. A
A
Substitute the brake calliper pistons if there are signs of rust/
scoring/traces of wear.
• The cylinders of the brake callipers.
If there are any lines/signs of wear, replace the whole brake 1
calliper.
• The bodies of the brake calipers. 2
If there are any cracks/damage, replace the whole brake calliper. 3
• Brake fluid delivery passages (brake calliper body).
In the event of obstruction, clean with a jet of compressed air.
• The seals (2) and (3) Fig. A
If there is any rust/lines/signs of wear, replace the brake calliper
insulation.
• The sliding pins (4) and (5) the rear calliper Fig. B

21
If there are any lines/signs of wear, replace the whole brake
calliper. B
• The rear brake calliper bracket and the couplings on the 4
front fork.

20
If there are any rust spots/signs of wear, replace.
5
IMPORTANT NOTICE
Every time the brake calliper is removed, replace the piston
gaskets.
S
R
TO
O
M
A
D
BA

4 - 41
- Benelli TRK 502 - Page 134
 FRONT AND REAR BRAKES
FRONT BRAKE CALLIPER INSTALLATION

NOTE:_________________________________
The procedure mentioned below is applicable to both calli-
A
pers of the front brake.

IMPORTANT NOTICE
Before installing, clean all of the internal parts of the brake,
and lubricate them with clean or new brake fluid.
Never use solvents on internal components of the brake, in-
asmuch that the seals of the pistons would tend to swell and B
deform.
Every time the brake calliper is removed, replace the piston
gaskets.
E
Recommended brake fluid F
TUTELA BRAKE FLUID TOP4

21
DOT4
B
Install: 2

20
• the largest seals of the pistons (E) Fig. A
• the smallest seals of the pistons (F) Fig. A
• The pistons on the brake calliper (B) Fig. A

Install:
S
R
• The brake calliper (1) Fig. B
• the screws (2) Fig. B. 1
to the following torque:
TO

T. R .

Torque 50 N*m
O

C
Recommended lubricant 20
9 17 12 11
M

G MR2 TUTELA grease 10 19

16 24
9
A

9 30 14
17 9
D

Install:
• The brake hose (10) Fig. C
9 31
BA

• the sealing washers (9*) Fig. B.

• the special screws (20*) Fig. B 18 15
to the following torque:

T. R .

Torque 18 N*m

IMPORTANT NOTICE
To guarantee the safety of the bike, it is essential for the path
of the brake hose to be correct.

Check:
the level of the brake fluid and top up (refer to Chapter 3 Frame/
Brake fluid level check, paragraph Front brake fluid level
check/top up)

4 - 42
- Benelli TRK 502 - Page 135
 FRONT AND REAR BRAKES
REAR BRAKE CALLIPER INSTALLATION

IMPORTANT NOTICE A
Before installing, clean all of the internal parts of the brake,
and lubricate them with clean or new brake fluid. Never use
solvents on internal components of the brake, inasmuch that
the seals of the pistons would tend to swell and deform.
Every time the brake calliper is removed, replace the piston B
gaskets.
C
Recommended brake fluid
D
TUTELA BRAKE FLUID TOP4
DOT4

Install:

21
• the largest seals of the pistons (D) Fig. A
• the smallest seals of the pistons (C) Fig. A B
20
• The pistons on the brake calliper (B) Fig. A
Install: 7

20
• The brake calliper (6*) Fig. B
• the screws (21*) Fig. B 21 29 20
to the following torque: 9
6
T. R .

S
R
Torque 22 N*m

9
TO

Install: 9
• The sliding pins (3) and (4) Fig. D 20
• ear protectors against dust (1) and (2) Fig. C
O

C
1
M

2
A
D
BA

D
3

4 - 43
- Benelli TRK 502 - Page 136
 FRONT AND REAR BRAKES
REAR BRAKE CALLIPER INSTALLATION

Install: 20
E
7
• The brake hose (4) Fig. E
• the sealing washers (9*) Fig. E
21 29 20
• the special screw (20*) Fig. E
9
Tighten to the previous set torque pressure twice after having
been slackened:
6
T. R .

Torque 15 N*m 9
9
20
Check:

21
the level of the brake fluid (A) Fig. F and top up (refer to Chapter
3 Frame/check brake fluid level, paragraph Check rear brake
4
fluid level/top up)
F

20
IMPORTANT NOTICE
Only use the prescribed fluid. The use of other types of
brake fluid may cause damage to the rubber seals, leading
to leaks and to a drop in brake performance. Top up with the
same type of brake fluid in the system. The brake fluid must
never be mixed with fluids of other brands, since this could S
R
cause a dangerous chemical reaction, with a drop in brake A
performance as a result. MAX
TO

While topping up brake fluid, take care not to let any water
enter the container.
Water would considerably reduce the boiling point of the flu- MIN
id and may lead to the formation of vapour bubbles.
O
M

Check:
If below the minimum notch, top up with the recommended
A

brake fluid.
D

• Brake lever operation.

If the brake lever movement is spongy, bleed brake system.
BA

Refer to Chapter 3 Frame/Brake fluid level check, paragraph

Rear brake fluid level check/top up)

4 - 44
- Benelli TRK 502 - Page 137
 FRONT FORK
FRONT FORK STEM REMOVAL

21
20
S
R
TO
O
M

CONTENTS
A

Pos. Description Qty Sq. SYMBOLS REMARKS

DESCRIPTION
1
D

SCREW

2 UPPER U-CLAMP
BA

3 LOWER U-CLAMP
4 BUSHING
5 HANDLEBAR FIXING PIN
6 WASHER
7 NUT
8 SCREW
9 STEERING HEAD
10 SPECIAL SCREW
11 STEERING PIN RING NUT
12 STEERING RING NUT
13 DUST SEAL
14 BEARING
15 WASHER

4 - 45
- Benelli TRK 502 - Page 138
 FRONT FORK
FRONT FORK STEM REMOVAL

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
16 SCREW
17 SEEGER RING
18 STEERING BASE
19 SCREW
20 LEFT RADIAL STEM ASSEMBLY
21 RIGHT RADIAL STEM ASSEMBLY
22 SCREW
23 SCREW

21
24 SCREW
25 COVER
26 ABS SPEED SENSOR – REAR WHEEL

20
27 SCREW

S
R
TO
O
M
A
D
BA

4 - 46
- Benelli TRK 502 - Page 139
 FRONT FORK
FRONT FORK STEM REMOVAL

The following procedure is applied to both front fork stems.

A
Park:
• The bike on a level surface

NOTE:_________________________________
Place the bike on a suitable support so that the front wheel
is raised.

Remove:
• The front brake calliper (see procedure).
• Front wheel (see procedure)
• Front mudguard (see procedure)

21
Loosen:
• the screws (8*) Fig. A
• the screws (19*) Fig. B B

20
IMPORTANT NOTICE
Before loosening the setscrews on the top and bottom
brackets, fit a support for the front fork stem.

NOTE:_________________________________ S
R
The numbers marked (*) are a part of the spare parts table
of the chapter “Front fork”, paragraph “Removal of the front
TO

fork stems”.
O
M
A
D
BA

4 - 47
- Benelli TRK 502 - Page 140
 FRONT FORK
FRONT FORK STEM DISASSEMBLY

3
4

5
10
15

21
7

20
11

12

13 8
9

S 14
R
17
18
TO

Disassemble the pieces in the order listed.

A
O

NOTE:_________________________________ 1
The following procedure is applied to both front fork stems.
M

Secure:
• The fork sleeve (10) in a clamp Fig. A
A

• Completely unscrew the cap assembly (1) from the support

tube, using a 4 mm pin and hook wrench(B). A
D

• Lower the fork sleeve (10).

IMPORTANT NOTICE
BA

The fork spring is compressed.

B
Push down:
• The spring (5) Fig. B
• The preload shim so as to be able to insert a 17 mm wrench B
in the nut (4).
• Hold the cap assembly (1) in place with a 4 mm pin and
hook wrench and use a 17 mm wrench to loosen the nut 1
(4).
• Unscrew and remove the top cap assembly(1). 4
5

4 - 48
- Benelli TRK 502 - Page 141
 FRONT FORK
FRONT FORK STEM DISASSEMBLY

Slide out from inside the sleeve Fig. C: C

• The tip (2)
• The spring (5)
• The bush (6) 2
• Shim (7) 8
• The lower bush (8)
• The tip (9).
9 6 5
Release:
• The rod from the clamp 7
• Turn the rod towards a suitably sized container so as to
allow the oil it contains to flow out Fig. D.

NOTE:_________________________________
To help drain the rod, it is necessary to pump a few times by

21
pushing the pump rod forwards and backwards (15) Fig. D.
D
IMPORTANT NOTICE

20
This operation is only necessary after draining the oil from
inside the rod.

• Lock the wheel shoe (A) in a clamp Fig. E.

Remove:
• The screw (18) fastening the pump unit (15) S
R
• The washer (17)
• The pump unit (15)
TO

15
O

E
M

17
A
A

18
D
BA

15

4 - 49
- Benelli TRK 502 - Page 142
 FRONT FORK
FRONT FORK STEM DISASSEMBLY

F
IMPORTANT NOTICE
This operation is only necessary after completely draining
the oil from inside the sleeve.

Remove:
• The dust seal (14) from the seat using a small flat-blade
screwdriver Fig. F 14
Remove:
• The clip of the oil seal (13) using the small flat-blade screw-
driver Fig. G.
Slide out:
• The fork stem (B) from the fork sleeve (10), Fig. H.

21
NOTE:________________________________
To separate these two elements, it is necessary to pull them G
apart with a little force.

20
• Oil seal (12)
• Retaining ring (11)
• The bottom guide bushing (8)

Manually remove:
• The top guide bushing (6) S
R
NOTE:________________________________
TO

If this operation becomes difficult, it is possible to use a flat-

head screwdriver in the slot in the bushing, to make it easier.

• The bottom guide bushing (8)

• Retaining ring (11)
O

• Oil seal (12) H

• Dust seal clip (13)
M

• Dust seal (14)

8
NOTE:________________________________
11
Once the oil and dust seals have been removed, they may 12
A

not be re-used.
10
D

B
BA

I
6 8 11 12 13 14

4 - 50
- Benelli TRK 502 - Page 143
 FRONT FORK
FRONT FORK STEM INSPECTION

The following procedure is applied to both front fork stems. A

Check:
• Fork stem “A” Fig. A
• The fork sleeve (10).
If there is any deformation/damage/wear, replace.

WARNING A
Do not try to straighten the inner fork if bent, since it will be-
come weaker with time and could be dangerous.

Measure:
• The full length (B) of the spring (5). If outside specifications, 10
replace.

21
B

20
The full length of the
Detail
spring.
Spring 295 mm

B
Check:
• Damper shaft (15) Fig. C
If there is any damage or wear, replace. S
R
If there are any obstructions, free all oil passages with com-
pressed air. 5
TO

IMPORTANT NOTICE
The pump unit contains elements that are very sensitive to
O

foreign bodies.
C
While disassembling and refitting the front fork stem, never
M

let foreign bodies enter the front fork.

15
Check:
• O-Ring (3) of the cap (1) Fig. D
A

If there is any damage or wear, replace.

D
BA

4 - 51
- Benelli TRK 502 - Page 144
 FRONT FORK
FRONT FORK STEM ASSEMBLY

The following procedure is applied to both front fork stems.

A
IMPORTANT NOTICE
The oil and dust seals must not be reused after removal. Be-
fore refitting, check the condition of bushings and guides;
check the guide bushings; if they are lined or scratch, re-
place them. Check the Teflon coating on the guide bushes as
this must be integral.

Apply adhesive tape to the end of the supporting tube

• So as to cover the seat for the bushing.
• Slightly lubricate the oil and dust filters with grease.

Insert the dust seal Fig. B:

21
• Dust seal (14)
• Dust seal clip (13)
• Oil seal (12) B
• Retaining ring (11)

20
• The bottom guide bushing (8)

IMPORTANT NOTICE
Take note of the direction in which the oil filter is facing (12)
as it needs to be inserted with the hollow part facing the re-
taining ring (11). S
R
• Remove the adhesive tape applied at the end of the fork
TO

stem, together with any traces of adhesive remaining.

8 11 12 13 14
Insert:
• The upper guide bush (6) Fig. C using the appropriate tool
“X” Fig. C:
O

C
M

(**) Tool for stem guide bush insertion

A

NOTE:________________________________
If this operation becomes difficult, it is possible to use a flat-
head screwdriver in the slot in the bushing, to make it easier.
D

• Insert the fork stem into the sleeve, very gently to make sure 6
BA

it does not damage the top guide bushing.

Accompany: X
• The bottom guide bushing (8) as far as sleeve contact with
the fork Fig. D
• Retaining ring (11)
• Oil seal (12) D
Then place them in the seat.

4 - 52
- Benelli TRK 502 - Page 145
 FRONT FORK
FRONT FORK STEM ASSEMBLY

Assemble:
• The clip on the oil seal (13) using a small flathead screw-
E
driver, making sure that it is perfectly inserted into the
special raceway and taking care not to scratch the fork stem
Fig. E. 13
Then place the following in the seat:
• The dust seal (14) by pressing down manually Fig. F.

Insert:
• The assembled pump unit (15) into the fork sleeve (10) Fig.
G.
• Fit the fork in a clamp by the wheel foot Fig. H.
• Lower the fork sleeve over the stem.

21
Insert:
• The washer (17)
• The screw (18) fastening the pump unit.
F

20
Use an 8 mm Allen key to tighten to the following torque: 14
T. R .

Torque 50 N*m
S
R
TO
O

G
M

15
A

10
D
BA

17
18

4 - 53
- Benelli TRK 502 - Page 146
 FRONT FORK
FRONT FORK STEM ASSEMBLY

• Lift the fork sleeve completely Fig. I

• Using a graduated measuring container, prepare the correct
I
amount of oil to be poured into the stem Fig. I.

h
• Pour about 2/3 of the oil into the fork sleeve (A), then pump
the fork to eliminate any air.
• Continue pouring up to the required amount.
• Lower the fork sleeve over the stem as far as the dust seal
stop on the wheel foot.
• Wait a few minutes and check the air volume then top up if
necessary.
A

IMPORTANT NOTICE
A lower or higher air volume or a different type of oil to that

21
recommended may change the behaviour of the fork at every
stage. L

20
Insert the following into the fork sleeve:
• Spring tip (2) 2
• Fork spring (5) 8
• Top spring guide bushing (6)
• Shim (7)
•
•
Bottom spring guide bushing (8)
Spring tip (9)
9
S 7
6 5
R
IMPORTANT NOTICE
TO

In the same direction as spring insertion.

The narrowest section must be facing upwards.

Screw the following fully:

O

• Closing cap (1) Fig. M

M
1
M

Push down:
• The spring (5) Fig. N
• The preload shim
A

• Insert a 17 mm wrench in the nut (4).

• Hold the cap in place with a 4 mm pin and hook wrench and
D

use a 17 mm wrench to tighten the nut.

• Tighten to the following torque:
BA

T. R .

Torque 20 N*m
• Lift the fork sleeve over the stem.

Secure:
• The fork sleeve in a clamp M
• Hold the cap in place with a 4 mm pin and hook wrench and
tighten to the following torque:
4
T. R .

Torque 20 N*m 5

4 - 54
- Benelli TRK 502 - Page 147
 FRONT FORK
FRONT FORK STEM FITTING

The following procedure is applied to both front fork stems.

A
Install:
• The stems of the front fork (A) Fig. A.

tighten provisionally:

• The stop screws (19*) of the lower steering plate Fig. A.

NOTE:________________________________
Check the assembly quota “x” Fig. B that must be taken con-
A
sidering the lower part of the steering base (18*) and the final
part of the steering stem (with the exclusion of the thickness
of the dust seal)

21
B
Tighten:

20
• The stop screws of the lower steering plate (19*) to the fol- 18
lowing torque pressure:

T. R .

Torque 8 N*m S
R
NOTE:________________________________
Tighten in three steps.
TO

Tighten:
• The stop screws (8*) of the upper steering plate (9*) Fig. C to
the following torque pressure:
O

C
T. R .
M

Torque 22 N*m

recommended lubricant 9*
A
D

G MR2 TUTELA grease

BA

IMPORTANT NOTICE 8*
8*
Check that the path of the brake hoses is correct.

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Front fork”, paragraph “Removal of the front fork
stems”.

4 - 55
- Benelli TRK 502 - Page 148
 HANDLEBAR
HANDLEBAR REMOVAL

21
20
S ABS

37
R
TO
O
M
A

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
D

1 REAR VIEW MIRROR (LEFT)

2 REAR VIEW MIRROR (RIGHT)

BA

3 HANDLEBAR
4 SCREW
5 GRIP CAP
6 GRIP END
7 THREADED INSERT
8 LEFT HANDGRIP
9 THREADED INSERT
10 LEFT LIGHT COMMUTATOR SWITCH
11 RIGHT LIGHT COMMUTATOR SWITCH
12 ACCELERATOR CONTROL
13 ACCELERATOR CONTROL HOSE
14 FUEL OPEN CABLE
15 FUEL CLOSE CABLE

4 - 56
- Benelli TRK 502 - Page 149
 HANDLEBAR
HANDLEBAR REMOVAL

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
16 CLUTCH CABLE
17 CLUTCH CONTROL
18 RUBBER CLIP
19 SCREW
20 BUSHING
21 ELASTIC WASHER
22 BRAKE PEDAL
23 SCREW

21
24 NUT
25 SCREW
26 BRAKE PEDAL

20
27 NUT
28 BALL JOINT
29
30
NUT
REGISTER ROD S
R
31 SCREW
TO

32 RETURN SPRING
33 THREADED PIN
34 GEAR PEDAL
O

35 SCREW
36 TUBE GUIDE
M

37 ABS SWITCH
A
D
BA

4 - 57
- Benelli TRK 502 - Page 150
 HANDLEBAR
HANDLEBAR REMOVAL

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

NOTE:________________________________
Direct a jet of compressed air between the left of the handle-
bar and the relevant grip, so that it can be slid off the handle-
bar gradually.

Remove:
• right rear-view mirror (2*) and left rear-view mirror (1*)
• screws (4*) Fig. A
• cap (5*) Fig. A
• handgrip terminal (6*) Fig. A

21
• threaded insert (7*) Fig. A
• threaded insert (9*) Fig. A
• left handgrip (8*) Fig. A

20
• screws (B) left commutator switch (C) Fig. B B
• left commutator switch (10*) Fig. A
• screws (1) clutch control Fig. B 1
• U-clamp (2) clutch control (3) Fig. B
• clutch control (17*)
NOTE:________________________________
Disconnect the connector of the LEFT STOP light switch S 2
R
TO

3
O

C
M

Remove:
A

• right commutator switch screws

D

• Right commutator switch (11*)

• screws (1) Fig. D accelerator control (12*)
BA

• accelerator control (12*)

• Accelerator handgrip (13*)
• Fuel open cable (14*)
• Fuel close cable (15*)
• the screws (2) Fig. D brake pump
• U-clamp (3) brake pump (4) Fig. D.

D
4

1
2
3
Remove:

4 - 58
- Benelli TRK 502 - Page 151
 HANDLEBAR
HANDLEBAR REMOVAL

• screws (1) handlebar u-clamp (2) Fig. C

C
Detach: 2
• the handlebar (3*)
1
NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Handlebar”.

21
20
S
R
TO
O
M
A
D
BA

4 - 59
- Benelli TRK 502 - Page 152
 HANDLEBAR
HANDLEBAR INSPECTION

Check:
• Handlebar (3) Fig. D
D
]If there is any warping/cracking/damage, replace.

WARNING
Do not try to straighten the handlebar if bent, since it will
become weaker and could be dangerous.

21
20
S
R
TO
O
M
A
D
BA

4 - 60
- Benelli TRK 502 - Page 153
 HANDLEBAR
HANDLEBAR INSTALLATION

IMPORTANT NOTICE E
Prop the bike on suitable supports so that it cannot fall. A
Proceed to install, following the steps for removal in reverse
order, but taking care to observe the instructions below:

Install:
• Right commutator switch (11*) B
NOTE:________________________________
Align the projections (A) of the switch with the hole (B) on
the right side of the handlebar.

• Front brake pump; tighten to the following torque pressure:

21
T. R .

F
Torque 8 N*m
NOTE:________________________________

20
Install the brake pump clevis with “UP” facing upwards Fig.
F, tighten the upper screw first then the lower screw.
A
• Accelerator handgrip (13*)
•
•
accelerator control (12*)
fuel open cable (14*) S
R
• fuel close cable (15*)
• clutch control (17*), tighten to the following torque:
TO

T. R .
UP

Torque 8 N*m
• left selector switch (10*)
O

• left handgrip (8*)

• handgrip terminal (6*)
C
M

• right rear-view mirror (2*) and left rear-view mirror (1*) 2

Position the handlebar: 1
A

• handlebar (3*)
• U-clamp (2) of the handlebar (3*)
D

• screws (1), tighten to the following torque:

1
BA

T. R .

Torque 22 N*m

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Handlebar”.

4 - 61
- Benelli TRK 502 - Page 154
 STEERING HEAD
REMOVAL OF THE TOP AND BOTTOM STEERING BASE

21
20
S
R
TO
O
M

IMPORTANT NOTICE A
A

3
Prop the bike on suitable supports so that it cannot fall.
D

Remove the parts in the indicated order.

• Removal of the mobile and fixed head light fairing (Re-
BA

fer to paragraph)
• Removal of the front wheel (Refer to paragraph)
• Removal of the front fork stems (Refer to paragraph)
• Removal of the mudguard (Refer to paragraph)
• Removal of the handlebar (Refer to paragraph)

• The screws (8*) Fig. A

• the two upper u-clamps (3*) 8

4 - 62
- Benelli TRK 502 - Page 155
 STEERING HEAD
REMOVAL OF THE TOP AND BOTTOM STEERING BASE

Remove:
• The cap (10) using the special tool (A) Fig. B
B

(**) steering head wrench

Code:R300097146000

Pull out the upper steering base.

Loosen:
A

• the steering pin ring nut (B) 10

• the steering ring nut (C) using the steering lock nut spanner
(D)

21
C

20
(**) Tool to tighten the steering sleeve lock nut
Code: R180297129000
B
WARNING
Firmly support the bottom steering base, so that it cannot
fall.
S D
R
TO

C
O
M
A
D
BA

4 - 63
- Benelli TRK 502 - Page 156
 STEERING HEAD
TOP AND BOTTOM STEERING BASE INSPECTION

Wash: A
• The bearings
• The bearing tracks

RECOMMENDED SOLVENT
TUTELA MOTOR CLEAN

Check:
• The bearings (14) Fig. A
• Dust seal rings (13) Fig. A
]If there is any spotting/damage, replace.

Replace:

21
• The bearings
• The bearing tracks B
• Remove the outer races of the ball bearings (A) from the A

20
steering tube utilising a long rod and a hammer (B) Fig. B.
• Remove the outer race of the ball bearing (C) from the lower
bracket using a chisel (D) and a hammer Fig. B. B
• Fit a new rubber gasket and new bearing tracks.

IMPORTANT NOTICE S C D
R
If the bearing track is not correctly fitted, this could damage
the steering head tube.
TO

NOTE:________________________________
• The ball bearings and the relative races must always be
substituted together and greased as necessary Fig. C.
O

• Every time the steering sleeve is removed, a new rubber C

gasket must be fitted.
M

Check:
• The top steering base.
• The bottom steering base (along with the sleeve).
A

]If there is any warping/cracking/damage, replace.

D
BA

4 - 64
- Benelli TRK 502 - Page 157
 STEERING HEAD
TOP AND BOTTOM STEERING BASE FITTING

Lubricate: A
• The bearings Fig. A.
• The dust seal rings Fig. A.
• The races of the bearings Fig. A.

G
RECOMMENDED LUBRICANT
MR2 TUTELA GREASE

Install:
• The steering ring nut (2) Fig. C using the special tool
to the following torque:

21
T. R .

B
Torque 16 N*m 3*

20
4*

3*
(**) Tool to tighten the steering sleeve lock nut
Code: R180297129000
S
R
IMPORTANT NOTICE
Do not overtighten the steering ring nut. 9*
TO

• the steering ring nut (1) Fig. C

• Position the upper steering base (9*) Fig. B
• the cap (4*) Fig. B (using the special tool) and tighten to the
following torque pressure: C
O

T. R .
1
M

2
Torque 60 N*m
A

• the set screws (3*) Fig. B to the following torque pressure:

D

T. R .
BA

Torque 22 N*m

Check:

• The steering sleeve Fig. C.

Gently oscillate the front fork, holding it by the ends of the tubes. C
If there is any jamming/loosening, adjust the steering sleeve.

4 - 65
- Benelli TRK 502 - Page 158
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER REMOVAL

21
20
28
S
R
28
TO

CONTENTS
O

Pos. Description Qty Sq. SYMBOLS REMARKS

DESCRIPTION
1 SWINGING ARM PIN
M

2 BUSHING
3 OIL SEAL
A

4 SEEGER RING
D

5 BEARING
6 BEARING
BA

7 INTERNAL SHIM
8 NUT
9 SWINGING ARM
10 CHAIN SLIDE
11 SCREW
12 SHIM
13 VIBRATION DAMPING RUBBER
14 SCREW
15 GUIDE BUSHING
16 SCREW
17 SCREW
18 NUT
19 REAR SHOCK ABSORBER

4 - 66
- Benelli TRK 502 - Page 159
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER REMOVAL

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
20 SCREW
21 NUT
22 SCREW
23 CHAIN TENSIONER SLIDE
24 PLATE
25 ABS PHONIC WHEEL SENSOR – REAR WHEEL
26 SCREW
27 CHAIN COVER

21
28 WASHER

20
S
R
TO
O
M
A
D
BA

4 - 67
- Benelli TRK 502 - Page 160
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER REMOVAL

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall. B

Remove:
• Rider and passenger seats, see chapter “Removal of the
rider and passenger seat, Chapter 4”.
• Side fairings, see chapter “Removal of the side fairings,
Chapter 4”.
A
IMPORTANT NOTICE
This rear shock absorber and the gas cylinder contain a

21
highly compressed gas (nitrogen).
Before handling the rear shock absorber and the gas cylin-
der, carefully read the following information and ensure that B
you understand it.

20
The manufacturer cannot be held responsible for any dam-
age to property or personal injuries deriving from the im-
proper use of the rear shock absorber and the gas cylinder.
• Do not tamper with the rear shock absorber or the gas cyl- 20*
inder or try to open them.
• Do not expose the shock absorber or gas cylinder to open S17*
R
flames or other sources of extreme heat.
Elevated overheating could cause an explosion due to the
excessive pressure of the gas.
TO

• Do not deform or damage the rear shock absorber or the

gas cylinder in anyway. If the rear shock absorber, gas cylin-
der or both are damaged, the damping performance will be
prejudiced.
O

Remove:
• the screws (A) Fig. A
M

• The upper panels (B) on both sides, Fig. A

• the lower screw (17*) of the rear shock absorber unit Fig. B
• the relative nut (18*)
A

NOTE:________________________________
D

To remove the lower fixing screws of the rear shock absorber

unit, hold the swinging arm to stop it from falling.
BA

• the upper screw (20*) of the rear shock absorber unit Fig. B
• the relative nut (18*)

NOTE:________________________________
Lift the swinging arm, then remove the rear shock absorber
unit from the attachment point on the swinging arm.

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Rear swinging arm”, paragraph “Removal of the
rear shock absorber”.

4 - 68
- Benelli TRK 502 - Page 161
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER CHECK

Check:
• Rear shock absorber rod
C
]If there is any warping/damage, replace the rear shock absorber
assembly.
• Rear shock absorber
]If there is any gas/oil leak, replace the rear shock absorber as-
sembly.
• Spring
]If there is any damage/wear, replace the rear shock absorber
assembly.
• Bushing
If there is any damage or wear, replace.
• Dust seal
If there is any damage or wear, replace.
• Screws

21
If there is any warping/damage/signs of wear, replace.

20
S
R
TO
O
M
A
D
BA

4 - 69
- Benelli TRK 502 - Page 162
 REAR SHOCK ABSORBER
REAR SHOCK ABSORBER FITTING

Lubricate:
• the spacers of the shock absorber unit
D
• the xing screws

18*
18* 20*
G
RECOMMENDED LUBRICANT
MR2 TUTELA GREASE
17*
Clean:
• the nuts of the rear shock absorber unit
• the screws of the rear shock absorber unit

21
RECOMMENDED SOLVENT
TUTELA MOTOR CLEAN

20
Install:
• the rear shock absorber unit

NOTE:________________________________
Lift the swinging arm to install the rear shock absorber unit.
Insert the lower screw (17*) of the rear shock absorber unit.
S
R
Tighten:
• the lower nut (18*) of the rear shock absorber unit Fig. D to
TO

the following torque pressure

T. R .
O

Torque 80 N*m

Install:
M

• the upper screw (20*) of the rear shock absorber unit.

Tighten:
•
A

the upper nut (18) of the rear shock absorber unit to the
following torque:
D

T. R .
BA

Torque 80 N*m

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Rear fork”, paragraph “Removal of the rear shock
absorber”.

4 - 70
- Benelli TRK 502 - Page 163
 TRANSMISSION CHAIN AND SWINGING ARM
TRANSMISSION CHAIN REMOVAL

NOTE:________________________________ A
Prop the bike on suitable supports so that it cannot fall.

Remove the parts in the indicated order.

• Chain pinion cover, refer to chapter “Removal of the chain
pinion cover, Chapter 4”.

Detach:
• The transmission chain A
(with a suitable tool for transmission chains (A) Fig. A, or with the
dedicated tool according to the transmission chain manufactur-
er’s specifications.

21
20
S
R
TO
O
M
A
D
BA

4 - 71
- Benelli TRK 502 - Page 164
 TRANSMISSION CHAIN AND SWINGING ARM
TRANSMISSION CHAIN REPLACEMENT

Loosen:
• The transmission chain
A
B
This chain uses a transmission chain with master link with safety
clip link.
• Use the special tool, according to the chain manufacturer’s
specifications and the type of use required.

NOTE:________________________________
Follow the instructions of the manufacturer when using the C
special tool.

IMPORTANT NOTICE
Never reutilise the old transmission chain, the master link,
the clip link of the master link and the O-rings. A

21
Insert:
• The master link (A) Fig. A

20
• The O-Rings (B) Fig. A
• The clip link (C) Fig. A

IMPORTANT NOTICE
Insert the master link from inside the transmission chain,
then fit the clip link with the ID mark facing out. S
R
• Mount and fix the set of tools for the transmission chain.
• Ensure that the pins of the master link are mounted correct-
TO

ly.
• Rivet the master link pins laterally.
• Ensure that the pins are tapped correctly.
O

Check:
• The surface affected by the clinched master link.
M

This must have no apertures.

If there are apertures, replace the master link, seal rings and clip
link.
A

IMPORTANT NOTICE
D

Never use a transmission chain with a clip master link.

BA

4 - 72
- Benelli TRK 502 - Page 165
 TRANSMISSION CHAIN AND SWINGING ARM
REMOVAL OF THE SWINGING ARM

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove the parts in the indicated order. 9*

• Rear mudguard, refer to chapter “Removal of the rear
mudguard, Chapter 4”. 1*
• Rear shock absorber, refer to chapter “Removal of the rear
shock absorber, Chapter 4”.
• Rear brake calliper, refer to chapter “Removal of the rear
brake calliper, Chapter 4”. B
• Rear wheel, refer to chapter “Removal of the rear wheel,
chapter 4”.

21
Remove: B
• The complete swinging arm (9*)
• The swinging arm pin (1*)

20
NOTE:________________________________ C
Position a stand (B) to support the rear swinging arm (9*)
Fig. A.

Remove:
• the rear brake tube ties (C) Fig. B S
R
• the rear brake support
• the screw (17*) Fig. B 17*
TO

• the swinging arm pivot (1*) Fig. C.

IMPORTANT NOTICE
During the removal stage, the swinging arm bushes (2*) and
O

the spacers (5*) could fall to the ground Fig. D.

C
Utilise the appropriate tool for the removal of the internal compo-
M

nents of the swinging arm:

1
A

(**) Tool for removing the rear swinging arm bearing

Refer to Chapter 1 “Special tools for the frame”
D

1
BA

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table
chapter “Rear fork”, paragraph “Removal of the rear shock
absorber”.

5
2

4 - 73
- Benelli TRK 502 - Page 166
 FRAME
INSTALLATION/REMOVAL OF THE FRAME PARTS

21
20
S
R
TO
O

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
M

1 FRAME

2 SCREW
A

3 NUT
4 SCREW
D

5 LEFT ENGINE PROTECTION

BA

6 SCREW
7 SCREW
8 SCREW
9 RUBBER BUSHING
10 SHIM
11 SHIM
12 SCREW
13 RIGHT ENGINE PROTECTION
14 SCREW
15 SCREW
16 PLATE
17 LEFT RADIATOR BRACKET
18 RIGHT RADIATOR BRACKET
19 HOMOLOGATION PLATE

4 - 74
- Benelli TRK 502 - Page 167
 FRAME
INSTALLATION/REMOVAL OF THE FRAME PARTS

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
20 RIVET
21 PAD
22 FRONT FRAME
23 METRIC RAPID FIXING CLIP
24 SCREW
25 BRACKET
26 SCREW
27 HEADLIGHT FAIRING SUPPORT

21
28 SCREW
29 ELASTIC WASHER
30 SCREW

20
31 SCREW
32 WASHER
33 SCREW
S
R
TO
O
M
A
D
BA

4 - 75
- Benelli TRK 502 - Page 168
 FRAME
LEFT/RIGHT ENGINE PROTECTION INSTALLATION

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Install:
• The left engine protection (5*) to the following torque pres-
sure:

T. R .

Torque (M10 screw) 45 N*m

21
• The screws (7*) and (6*) to the main frame Fig. A to the
following torque pressure:

T. R .

20
Torque (M6 screw) 10 N*m

• the right engine protection (13*)

• the screws (7*) and (6*) to the main frame Fig. A to the
following torque pressure: S
R
T. R .
TO

Torque (M8 screw) 22 N*m

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
O

chapter “Frame”, paragraph “Installation of frame parts”.

M
A
D
BA

4 - 76
- Benelli TRK 502 - Page 169
 FRAME
REMOVAL OF THE LEFT/RIGHT ENGINE PROTECTION

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Remove:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 77
- Benelli TRK 502 - Page 170
 FRAME
REMOVAL OF THE FRONT FRAME/WINDSCREEN SUPPORT

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• the screws (26*) Fig. A
• the front frame (22*) Fig. A

Remove:

21
• the screws (28*) B
• the screws (30*) Fig. B
• the windscreen support (27*) Fig. B.

20
NOTE:________________________________
The numbers marked (*) are a part of the spare parts table, B
chapter “Frame”, paragraph “Installation of frame parts”.

S
R
TO
O
M
A
D
BA

4 - 78
- Benelli TRK 502 - Page 171
 FRAME
INSTALLATION OF THE FRONT FRAME/WINDSCREEN SUPPORT

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 79
- Benelli TRK 502 - Page 172
 FRAME
REMOVAL/INSTALLATION OF REAR FRAME PARTS

16
23 23
16
26 22

22
28 24
21
19 19 21
12 11 9 18 29 27
10 14 29
20

21
14
8

20
13 9 10
9 15 9
7 11 12
6
25 97 8 1 9 13 9

3 4 S 5
98
87
R
4 7
3 25
16
TO

17
2
2 17 16
O

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
M

DESCRIPTION
1 REAR FRAME

2 SCREW
A

3 SCREW
D

4 NUT
5 LEFT BAG SUPPORT FRAME
BA

6 RIGHT BAG SUPPORT FRAME

7 SCREW
8 BUSHING
9 RUBBER TIP
10 SCREW
11 PLATE
12 CASE RELEASE
13 SCREW
14 SCREW
15 SCREW
16 SCREW
17 NUT
18 PLATE

4 - 80
- Benelli TRK 502 - Page 173
 FRAME
REMOVAL/INSTALLATION OF REAR FRAME PARTS

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
19 SCREW
20 ELASTIC CLIP
21 PIN
22 SCREW
23 SCREW
24 REAR TOP BOX RACK
25 TWO REAR SIDE BAGS
26 REAR TOP BOX

21
27 BRACKET
28 REAR TOP BOX SUPPORT PLATE
29 NUT

20
S
R
TO
O
M
A
D
BA

4 - 81
- Benelli TRK 502 - Page 174
 FRAME
REMOVAL OF THE REAR FRAME

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
3
• Rear footrests, refer to chapter “Removal of the rear foot-
4
rests’ support, chapter 4”.
• Rider and passenger seats, refer to chapter “Removal of
the rider and passenger seat, Chapter 4”. 3
• Rear handles, refer to chapter “Removal of the rear han-
dles, Chapter 4”. 2
• Side fairings, refer to chapter “Removal of the side fair- 2
ings, Chapter 4”.
• the screws (3*) Fig. A

21
• the nuts (4*) Fig. A.
• the screws (2*)
• the rear frame (1*) Fig. A

20
NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Frame”, paragraph “Installation of the rear frame”.

S
R
TO
O
M
A
D
BA

4 - 82
- Benelli TRK 502 - Page 175
 FRAME
REAR FRAME FITTING

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.
3
4
Install:
• the rear frame (1*) Fig. A.
• the screws (2*) Fig. A to the following torque: 3
T. R .

2
2
Torque 25 N*m
• the screws (3*) Fig. A to the following torque

21
T. R .

Torque 25 N*m

20
S
R
TO
O
M
A
D
BA

4 - 83
- Benelli TRK 502 - Page 176
 FRAME
REMOVAL OF SIDE BAG FRAME

Park the bike on a level surface.

B
IMPORTANT NOTICE 14*
Prop the bike on suitable supports so that it cannot fall.

Remove:
• the screws (14*) Fig. A
• the nut (17*) Fig. A
• the screw (15*) Fig. A
17*
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Frame”, paragraph “Installation of the rear frame”.
A.

21
C

20
15*

S
R
TO
O
M
A
D
BA

4 - 84
- Benelli TRK 502 - Page 177
 FRAME
INSTALLATION OF THE SIDE BAGS SUPPORT FRAME

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 85
- Benelli TRK 502 - Page 178
 FRAME
NUMBER PLATE HOLDER

21
20
S
R
TO
O

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
M

1 UPPER FAIRING

2 METRIC RAPID FIXING CLIP

A

3 SCREW
4 SNAP-ON CLIP
D

5 SCREW
BA

6 SCREW
7 PLATE
8 LICENCE PLATE HOLDER SUPPORT
9 VIBRATION DAMPING RUBBER
10 REFLECTOR
11 REFLECTOR BRACKET
12 NUMBER PLATE HOLDER
13 SCREW
14 NUT
15 REAR MUD GUARD
16 SCREW
17 SCREW
18 NUT
19 COVER

4 - 86
- Benelli TRK 502 - Page 179
 FRAME
REMOVAL OF THE NUMBER PLATE HOLDER

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
6*
Remove:

• the screws (6*) Fig. A

• The complete number plate holder support (8*) Fig. A

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Frame”, paragraph “Number plate holder”.

21
20
S
R
TO
O
M
A
D
BA

4 - 87
- Benelli TRK 502 - Page 180
 FRAME
INSTALLATION OF THE NUMBER PLATE HOLDER

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 88
- Benelli TRK 502 - Page 181
 CYCLING
INSTALLATION OF THE STAND / FOOTRESTS

21
407A

20
40 7A

S
R
40 7A
TO

40 7A
O
M

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
1 LEFT FRONT FOOTREST SUPPORT
A

2 PIN
D

2 PIN
3 PLATE
BA

4 LEFT FRONT FOOTREST

5 ANTI-SLIP RUBBER
6 NUT
7 ELASTIC RING
7A. COTTER PIN
8 SCREW
9 RIGHT FRONT FOOTREST SUPPORT
10 RIGHT FRONT FOOTREST
11 LEFT REAR FOOTREST SUPPORT
12 SCREW
13 PIN
14 PEDANA POSTERIORE SINISTRA
15 SPRING

4 - 89
- Benelli TRK 502 - Page 182
 CYCLING
STAND/FOOTRESTS

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
16 SPRING
17 BALL
18 PLATE
19 SCREW
20 LH FOOTREST RUBBER STOP
21 LEFT RUBBER FOOTREST COVER
22 RIGHT REAR FOOTREST SUPPORT
23 RIGHT REAR FOOTREST

21
24 RH FOOTREST RUBBER STOP
25 RIGHT RUBBER FOOTREST COVER
26 SPECIAL SCREW

20
27 WASHER
28 SIDE STAND
29
30
SCREW
SIDE STAND SUPPORT PLATE S
R
31 SCREW
TO

32 SIDE STAND SWITCH

33 BELLEVILLE WASHER
34 NUT
O

35 EXTERNAL SCREW
36 INTERNAL SPRING
M

37 SCREW
38 SCREW
A

39 WASHER
40 WASHER
D
BA

4 - 90
- Benelli TRK 502 - Page 183
 CYCLING
REMOVAL OF THE SIDE STAND

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Disconnect:
• the connector of the side stand sensor (32*) Fig. A
Remove: 32*
• the internal spring (36*) Fig. B
• the external spring (35*) Fig. B
• the screws (37*) Fig. B-C
• the screw (38*) Fig. B-C
• The stand support plate (30*) Fig. B-C

21
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
B
chapter “Cycling” paragraph “Stand/footrests”.

20
S
R
TO

C
O

37*
M
A

38*
D
BA

4 - 91
- Benelli TRK 502 - Page 184
 CYCLING
INSTALLATION OF THE SIDE STAND

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

Tighten:
• the screw (37*) Fig. B-C
• the screw (38*) Fig. B-C
to the following torque:

T. R .

21
Torque 45 N*m

Utilise Loctite

20
Loctite 243

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, S
R
chapter “Cycling” paragraph “Stand/footrests”.
TO
O
M
A
D
BA

4 - 92
- Benelli TRK 502 - Page 185
 CYCLING
REMOVAL OF THE REAR FOOTREST SUPPORT

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• the screws (12*) Fig. A
• The right rear footrest support (22*) Fig. A
• The left rear footrest support (11*) Fig. A
407A
NOTE:_________________________________
If the motorcycle is equipped with a side bag frame: 40 7A

Remove:

21
• the screw (1) Fig. B
B

20
NOTE:_________________________________ 12*
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” paragraph “Stand/footrests”.

S
R
1
TO
O
M
A
D
BA

4 - 93
- Benelli TRK 502 - Page 186
 CYCLING
INSTALLATION OF THE REAR FOOTREST SUPPORT

Park the bike on a level surface.

B
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall. 12*
Install:
Proceed using the opposite order to removal.

Tighten:
• the screws (12*) Fig. B
to the following torque: X
T. R .

21
Torque 25 N*m

Use Loctite thread locker to secure.

20
Loctite 243

NOTE:_________________________________
If the motorcycle is equipped with a side bag frame: S
R
TO

Tighten:
• the screw (X) Fig. B to the following torque pressure:

T. R .
O

Torque 25 N*m
Use Loctite thread locker to secure.
M

Loctite 243
A
D

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
BA

chapter “Cycling” paragraph “Stand/footrests”.

4 - 94
- Benelli TRK 502 - Page 187
 CYCLING
REMOVAL OF THE RIGHT/LEFT REAR FOOTREST

Park the bike on a level surface.

A
13*
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• the O-ring (7*) Fig. A
• the pin (13*) Fig. A
• the footrest (14*) Fig. B
• the plate (18*) Fig. B
• the ball (17*) Fig. B
• the spring (16*) Fig. B
7*
NOTE:_________________________________
Carry out the following operation for the left rear footrest

21
(23*).
B

20
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, 17*
chapter “Cycling” paragraph “Stand/footrests”.
18*

S 16*
R
TO

14*
O
M
A
D
BA

4 - 95
- Benelli TRK 502 - Page 188
 CYCLING
INSTALLATION OF THE LEFT/RIGHT REAR FOOTRESTS

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 96
- Benelli TRK 502 - Page 189
 CYCLING
RIGHT FRONT FOOTREST REMOVAL

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
3
Remove:
• The spring (1) Fig. A
• the screw (2) Fig. A
• the ball joint (3) Fig. A
• the special screw (4) Fig. B
• the brake pedal (5) Fig. B 2
1
NOTE:_________________________________
Substitute the rubber cover of the right footrest (5*) if it is
worn.

21
B
Remove: 5
• the two screws (8*)

20
• the right front footrest holder plate (9*) Fig. C

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” paragraph “Installation of the stand/foot-
rests”.
S
R
TO

C
O
M

9*
A

8*
D

5*
BA

4 - 97
- Benelli TRK 502 - Page 190
 CYCLING
RIGHT FRONT FOOTREST FITTING

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

Tighten:
• the screws (8*) Fig. A
to the following torque:
8*

T. R .

Torque 25 N*m

21
Use Loctite thread locker to secure.
B
Loctite 243

20
Tighten:
• the screws (4) Fig. B.
to the following torque:
S
R
T. R .
TO

Torque 25 N*m
Use Loctite thread locker to secure. 4

Loctite 243
O

C
M

Tighten:
• the screw (2) and the related fastening nut Fig. C
to the following torque:
A

T. R .
D

Torque 12 N*m
2
BA

Use Loctite thread locker to secure.

Loctite 243

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” paragraph “Installation of the stand/foot-
rests”.

4 - 98
- Benelli TRK 502 - Page 191
 CYCLING
LEFT FRONT FOOTREST REMOVAL

Park the bike on a level surface.

A
IMPORTANT NOTICE 8*
Prop the bike on suitable supports so that it cannot fall.

Remove:
• the screws (8*) Fig. A
• the left front footrest holder plate (1*) Fig. A

NOTE:_________________________________
Substitute the left anti-slip rubber cover (5*) if it is worn.
5*
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,

21
chapter “Cycling” paragraph “Installation of the stand/foot-
rests”.

20
S
R
TO
O
M
A
D
BA

4 - 99
- Benelli TRK 502 - Page 192
 CYCLING
LEFT FRONT FOOTREST INSTALLATION

Park the bike on a level surface.

A
IMPORTANT NOTICE 8*
Prop the bike on suitable supports so that it cannot fall.

Install:
Proceed using the opposite order to removal.

Tighten:
• the screws (8*) Fig. A
to the following torque:

T. R .

21
Torque 25 N*m
Use Loctite thread locker to secure.

20
Loctite 243

NOTE:_________________________________
Before installing the left front footrest, ensure that the
gearchange lever has been installed. S
R
NOTE:_________________________________
TO

The numbers marked (*) are a part of the spare parts table,
chapter “Cycling” paragraph “Installation of the stand/foot-
rests”.
O
M
A
D
BA

4 - 100
- Benelli TRK 502 - Page 193
 CYCLING
REMOVAL OF THE GEAR LEVER

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
2

Remove:
• The left front footrest, refer to chapter “Removal of the left
front footrest, Chapter 4”.
• the screw (1) Fig. A
• the lever (2) Fig. A 1

21
20
S
R
TO
O
M
A
D
BA

4 - 101
- Benelli TRK 502 - Page 194
 CYCLING
INSTALLATION OF THE GEARCHANGE LEVER

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.
Tighten:
• the screw (1) Fig. A
to the following torque:
1
T. R .

Torque 10 N*m
NOTE:_________________________________

21
Make use of grease during the assembly.

20
G
Recommended lubricant
MR2 TUTELA GREASE

S
R
TO
O
M
A
D
BA

4 - 102
- Benelli TRK 502 - Page 195
 EXHAUST SYSTEM
EXHAUST ASSEMBLY

21
20
S
R
TO

14
O

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
M

DESCRIPTION
1 EXHAUST GASKET

2
A

LAMBDA PROBE
3 NUT
D

4 EXHAUST MANIFOLD
BA

5 GRAPHITE GASKET
6 SILENCER
7 RUBBER TIP
8 SCREW
9 SCREW
10 BUSHING
11 RUBBER TIP
12 LEFT FLANGE
13 RIGHT FLANGE
14 SCREW CLIP

4 - 103
- Benelli TRK 502 - Page 196
 EXHAUST SYSTEM
EXHAUST ASSEMBLY REMOVAL

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Disconnect:
• the Lambda sensor (2*) Fig. A. 2*

Remove: 2*
• the screws (8*) Fig. B.
• the screws (9*) Fig. B
• the screw (9*) Fig. C
• the screw (6*) Fig. C
• the nuts (2*) of the corresponding studs Fig. D

21
B

20
S
R
TO

8* 9*
O

C
M
A
D
BA

8* 6*

2*
2*
2*

4 - 104
- Benelli TRK 502 - Page 197
 EXHAUST SYSTEM
EXHAUST ASSEMBLY REMOVAL

Disconnect:
• the exhaust system, removing it from inside to outside Fig.
E
E

NOTE:_________________________________
A
To make extraction easier, it is advisable to loosen the silenc-
er joint band (A) to the exhaust manifold Fig. E

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Exhaust system”, paragraph “exhaust system”.

21
20
S
R
TO
O
M
A
D
BA

4 - 105
- Benelli TRK 502 - Page 198
 EXHAUST SYSTEM
EXHAUST INSTALLATION

Park the bike on a level surface.

A
IMPORTANT NOTICE 2*
Prop the bike on suitable supports so that it cannot fall.
Install: 2*
Proceed using the opposite order to removal. 2*
Tighten:
• the nuts (2*) Fig. A
to the following torque:

T. R .

Torque 22 N*m
NOTE:_________________________________

21
Lubricate the nuts with copper grease during the assembly
phase. B

20
G TUTELA grease

• the screws (8*) Fig. B-C S

R
to the following torque:
TO

T. R .

8* 9*
Torque 12 N*m
• the screws (9*) Fig. B
to the following torque:
O

C
T. R .
M

• Torque 12 N*m
A

• the screw (6*) Fig. C

to the following torque:
D

T. R .
BA

8* 6*
• Torque 12 N*m
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Exhaust system”, paragraph “exhaust system”.

4 - 106
- Benelli TRK 502 - Page 199
 FAIRING
FRONT MUD GUARD

21
20
S
R
TO

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
O

DESCRIPTION
1 FRONT MUD GUARD
M

2 SCREW
3 NYLON WASHER
A

4 MUDGUARD SUPPORT PLATE

D

5 SCREW
6 SCREW
BA

7 ELASTIC WASHER
8 WASHER
9 SNAP-ON CLIP
10 LOWER MUD GUARD
11 SCREW
12 “T” BUSHING
13 NUT
14 REFLECTOR
15 LEFT RUBBER PROTECTION
16 RIGHT RUBBER PROTECTION
17 LEFT BRACKET
18 RIGHT BRACKET
19 INTERNAL SHIELD
20 ABS STICKER

4 - 107
- Benelli TRK 502 - Page 200
 FAIRING
FRONT MUD GUARD REMOVAL

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
6*

Remove: 2*
• the screw (6*) Fig. A
• the screw (2*) from both sides Fig. A
• the screw (11*) from both sides Fig. B
• the lower mud guard (10*) Fig. A 10*

21
B

20
11*
S
R
TO
O

Remove:
• the screws (2*) from both sides Fig. C
M

• The front mud guard (1*) Fig. D C

2*
A
D
BA

1*

4 - 108
- Benelli TRK 502 - Page 201
 FAIRING
FRONT MUD GUARD REMOVAL

Remove:
• the screws (11*) Fig. E
E
• the mud guard support plates (4*) Fig. E
4*
NOTE:_________________________________ 4*
The numbers marked (*) are a part of the spare parts table,
chapter “Fairing”, paragraph “Front mud guard”. 11*
11*

21
20
S
R
TO
O
M
A
D
BA

4 - 109
- Benelli TRK 502 - Page 202
 FAIRING
FRONT MUD GUARD INSTALLATION

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 110
- Benelli TRK 502 - Page 203
 FAIRING
REAR MUD GUARD REMOVAL

Park the bike on a level surface.

A
IMPORTANT NOTICE 2
Prop the bike on suitable supports so that it cannot fall.
1
Remove:
• the screws (1) Fig. A
• The flap guard (2) Fig. A
• the screws (16*) Fig. B-C
• The rear mudguard (27*) Fig. B

NOTE:_________________________________
The numbers marked (*) are shown in the replacement parts
table in the “Rear shock absorber” chapter, “Rear shock ab-
sorber removal” section.

21
B
27*

20
16*

S
R
TO
O

C
M
A

16*
D
BA

4 - 111
- Benelli TRK 502 - Page 204
 FAIRING
REAR MUD GUARD INSTALLATION

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install: 1
Proceed using the opposite order to removal.

Tighten:
• the screws (8*) Fig. A
to the following torque:

T. R .

Torque 10 N*m

21
20
S
R
TO
O
M
A
D
BA

4 - 112
- Benelli TRK 502 - Page 205
 FAIRING
REMOVAL OF THE UPPER CHAIN GUARD

Park the bike on a level surface.

A
11*
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• the screws (11*) Fig. A
• The chain guard (10*) Fig. A

NOTE:_________________________________
The numbers marked (*) are shown in the replacement parts
table in the “Rear shock absorber” chapter, “Rear shock ab-
sorber removal” section.
10*

21
20
11*

S
R
TO
O
M
A
D
BA

4 - 113
- Benelli TRK 502 - Page 206
 FAIRING
INSTALLATION OF THE UPPER CHAIN GUARD

Park the bike on a level surface.

A
11*
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

Tighten:
• the screws (11*) Fig. A
to the following torque:

T. R .

10*

21
Torque 10 N*m
Use Loctite thread locker to secure.

20
Loctite 243 11*

NOTE:_________________________________
The numbers marked (*) are shown in the replacement parts
table in the “Rear shock absorber” chapter, “Rear shock ab- S
R
sorber removal” section.
TO
O
M
A
D
BA

4 - 114
- Benelli TRK 502 - Page 207
 FAIRING
REMOVAL OF THE RIDER SEAT AND PASSENGER SEAT

Park the bike on a level surface.

A
1
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Remove:
• the passenger seat (1) using the supplied spanner (2) Fig.
A.
• the screws (3) Fig. A
• the rider seat (4) Fig. A 2

21
3

20
4
S
R
TO
O
M
A
D
BA

4 - 115
- Benelli TRK 502 - Page 208
 FAIRING
INSTALLATION OF THE RIDER SEAT AND PASSENGER SEAT
Park the bike on a level surface.
A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

Tighten:
• the screws (3) Fig. A
to the following torque:
3
T. R .

Torque 10 N*m

21
20
S
R
TO
O
M
A
D
BA

4 - 116
- Benelli TRK 502 - Page 209
 FAIRING
FRONT FAIRING

21
20
S
R
CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
TO

1 FRONT FAIRING

2 SCREW
3 TOP BUSHING
O

4 RUBBER TIP
5 SCREW
M

6 METRIC RAPID FIXING CLIP

7 LEFT AIR DUCT
A

8 RIGHT AIR DUCT

D

9 SCREW
10 LEFT RETINA
BA

11 RIGHT RETINA
12 LEFT SIDE (WHITE)
13 RIGHT SIDE (WHITE)
14 WASHER
15 DIRECTION INDICATOR (FRONT LEFT)
16 DIRECTION INDICATOR (FRONT RIGHT)
17 LEFT AIR INTAKE
18 RIGHT AIR INTAKE
19 SCREW

4 - 117
- Benelli TRK 502 - Page 210
 FAIRING
REMOVAL OF THE FRONT FAIRING

IMPORTANT NOTICE B
2
Prop the bike on suitable supports so that it cannot fall.

Remove: 1
• Rider and passenger seats, refer to chapter “Removal of
the rider and passenger seat, Chapter 4”.
• the screws (1) Fig. B.
• the left side (12*) Fig. B 2
• the screws (2) Fig. B 12* 7*
• the screws (3) - (4) Fig. C
• the screws (5) - (6) Fig. D
• the left air duct (7*) Fig. B
NOTE:_________________________________
Carry out the same procedure for the right side (13*) and the C

21
right air duct (8*).
• the screws (7) - (8) Fig. E
• the front fairing (1*) Fig. E

20
S 3
4
R
TO

D
O
M

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, 5
A

chapter “Fairings”, paragraph “Front fairing”. 6

D
BA

8
7

4 - 118
- Benelli TRK 502 - Page 211
 FAIRING
INSTALLATION OF THE FRONT FAIRING

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 119
- Benelli TRK 502 - Page 212
 FAIRING
FRONT HEADLIGHT AND WINDSCREEN

21
20
S
R
TO

25
25
O

CONTENTS
M

Pos. Description Qty Sq. SYMBOLS REMARKS

DESCRIPTION
1 HEADLIGHT FAIRING
A

2 SCREW
3 SHIM
D

4 VIBRATION DAMPING PAD

5 COMPLETE INSTRUMENT
BA

6 NUT
7 LEFT HEADLIGHT FAIRING
8 RIGHT HEADLIGHT FAIRING
9 SPECIAL SCREW
10 LEFT HAND GUARD
11 LEFT SUPPORT BRACKET
12 SCREW
13 BUSHING
14 METRIC RAPID FIXING CLIP
15 RIGHT HAND GUARD
16 RIGHT SUPPORT BRACKET
17 FIXED HEADLIGHT FAIRING
18 SCREW
19 WINDSCREEN
20 HEADLAMP

4 - 120
- Benelli TRK 502 - Page 213
 FAIRING
FRONT HEADLIGHT AND WINDSCREEN

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
DESCRIPTION
21 SCREW
22 TOP BUSHING
23 RUBBER TIP
24 INSTRUMENTATION PLATE
25 LAMP
26 ADHESIVE

21
20
S
R
TO
O
M
A
D
BA

4 - 121
- Benelli TRK 502 - Page 214
 FAIRING
REMOVAL OF MOVABLE WINDSCREEN

Park the bike on a level surface.

F
IMPORTANT NOTICE 2*
Prop the bike on suitable supports so that it cannot fall.
1*
Remove:
• the screws (9*)
• the screws (2*)
• The movable windscreen (1*) together with the left/right
headlight fairing 9*

21
20
S
R
TO
O
M
A
D
BA

4 - 122
- Benelli TRK 502 - Page 215
 FAIRING
INSTALLATION OF THE MOBILE HEADLIGHT FAIRING

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 123
- Benelli TRK 502 - Page 216
 FAIRING
REMOVAL OF THE INSTRUMENTATION PLATE

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• the screws (12*) Fig. A 12*
Disconnect:
• the instrument board wiring (B) Fig. B
Remove:
the instrument board (24*) Fig. B.

21
B

20
NOTE:_________________________________
24*
The numbers marked (*) are a part of the spare parts table,
chapter “Fairings”, paragraph “Front headlight and wind- S
B
R
screen”.
TO
O
M
A
D
BA

4 - 124
- Benelli TRK 502 - Page 217
 FAIRING
INSTALLATION OF THE INSTRUMENTATION PLATE

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 125
- Benelli TRK 502 - Page 218
 FAIRING
REMOVAL OF THE HEADLIGHT UNIT

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall. 1
Remove:
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• the screws (1) Fig. A
• the screw (2) underneath the small front frame (3) Fig. B

Disconnect:
• the cables of the left and right front indicators (4) Fig. C 1

21
• the connector (5), from the instrument panel as indicated in
Fig. C.

20
S
R
B
TO

3
O

2
M
A
D
BA

C
4

4 - 126
- Benelli TRK 502 - Page 219
 FAIRING
INSTALLATION OF THE HEADLIGHT UNIT

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 127
- Benelli TRK 502 - Page 220
 FAIRING
TANK COVER

21
20
S
R
TO

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
O

DESCRIPTION
1 FUEL TANK CAP
M

2 SCREW
3 TOP BUSHING
4 RUBBER TIP
A

5 SCREW
D

6 SCREW
7 METRIC RAPID FIXING CLIP
BA

8 LEFT FUEL TANK CAP

9 RIGHT FUEL TANK CAP
10 LEFT PANEL
11 RIGHT PANEL
12 SCREW
13 LEFT COVER
14 RIGHT COVER
15 SCREW
16 NYLON WASHER
17 STICKER (BENELLI BLACK)
18 STICKER (BENELLI WHITE)
19 WINDSCREEN
20 HEADLAMP

4 - 128
- Benelli TRK 502 - Page 221
 FAIRING
REMOVAL OF THE FUEL TANK COVER

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Rider and passenger seats, see chapter entitled “Removal 1
of rider and passenger seats, Chapter 4”.
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• the screws (1) Fig. A-B.
• the tank cap (2) Fig. C.

21
20
B

S
R
TO
O

1
M
A
D

C
BA

4 - 129
- Benelli TRK 502 - Page 222
 FAIRING
INSTALLATION OF THE FUEL TANK COVER

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 130
- Benelli TRK 502 - Page 223
 FAIRING
REMOVAL OF FUEL TANK

Park the bike on a level surface.

C
IMPORTANT NOTICE
1*
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Rider and passenger seats, see chapter entitled “Removal 10*
of rider and passenger seats, Chapter 4”.
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• Tank fairing, see chapter entitled “Removal of tank fairing,
Chapter 4”.

21
• The fixing screws of the tank (10*) and (1*) to the frame Fig.
C

20
S
R
TO
O
M
A
D
BA

4 - 131
- Benelli TRK 502 - Page 224
 FAIRING
REMOVAL OF FUEL TANK

Disconnect: D
• the tube of the non-return valve (10*) Fig. D.
• the connector of the level sensor (1) Fig. E.
10*

21
20
E
S
R
TO

1
O
M
A
D
BA

Disconnect:
• The tubing of the valve (12*) of the fuel pump. F

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, 12*
chapter “Tank”, paragraph “Tank parts”.

4 - 132
- Benelli TRK 502 - Page 225
 FAIRING
TANK FITTING

Park the bike on a level surface.

A
IMPORTANT NOTICE
1*
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.
Tighten: 10*
• the screws (10*) Fig. A
to the following torque:

T. R .

Torque 10 N*m

21
• the screws (1*) Fig. A
to the following torque:

T. R .

20
Torque 10 N*m

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, S
R
chapter “Tank”, paragraph “Tank parts”.
TO
O
M
A
D
BA

4 - 133
- Benelli TRK 502 - Page 226
 TANK
TANK PARTS

21
25
24

20
S
R
CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
TO

DESCRIPTION
1 SCREW
2 PLATE
O

3 BUSHING
4 BUSHING
M

5 VIBRATION DAMPING RUBBER

6 FUEL TANK
7 FUEL TUBE/HOSE
A

8 CENTRAL FAIRING CLOSURE

D

9 SCREW
10 SCREW
BA

11 PLATE
12 BUSHING
13 RUBBER TIP
14 WASHER
15 SCREW
16 FUEL TANK LEVEL PROBE
17 O-RING
18 SCREW
19 FUEL PUMP
20 SCREW
21 FUEL FILTER
22 FILTER SUPPORT
23 FUEL TUBE/HOSE
24 PIPE
25 SPRING

4 - 134
- Benelli TRK 502 - Page 227
 TANK
REMOVAL OF THE TANK CAP SUPPORT

Park the bike on a level surface.

A
IMPORTANT NOTICE 8*
Prop the bike on suitable supports so that it cannot fall.

Remove: 9*
• Rider and passenger seats, see chapter entitled “Removal
of rider and passenger seats, Chapter 4”.
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• Tank fairing, see chapter entitled “Removal of tank fairing,
Chapter 4”.
• the fixing screws (9*) Fig. A

21
• the central fairing closure (8*) Fig. A

NOTE:_________________________________

20
The numbers marked (*) are a part of the spare parts table,
chapter “Tank”, paragraph “Tank parts”.

S
R
TO
O
M
A
D
BA

4 - 135
- Benelli TRK 502 - Page 228
 TANK
INSTALLATION OF THE TANK CAP SUPPORT

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 136
- Benelli TRK 502 - Page 229
 TANK
REMOVAL OF THE TANK PUMP

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Rider and passenger seats, see chapter entitled “Removal
of rider and passenger seats, Chapter 4”.
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• Tank fairing, see chapter entitled “Removal of tank fairing,
Chapter 4”.
• Tank, see chapter entitled “Fuel tank removal, Chapter 4”.

21
• the screws (20*) Fig. A
• the petrol pump (19*) Fig. B 20*

20
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Tank”, paragraph “Tank parts”.
B

S
R
TO

19*
O
M
A
D
BA

4 - 137
- Benelli TRK 502 - Page 230
 TANK
INSTALLATION OF THE TANK PUMP

Park the bike on a level surface.

A
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

Tighten:
• the screws (20*) Fig. A
to the following torque:

T. R .

Torque 10 N*m

21
Use Loctite thread locker to secure.

20*
Loctite 243

20
NOTE:_________________________________
At the moment of reassembly of the pump, grease must be
smeared around the base of the pump housing (A) and the S B
R
pump must be inserted into the housing in reverse order of
removal Fig. B.
A
TO

G
Recommended lubricant
MR2 TUTELA GREASE
O
M

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Tank”, paragraph “Tank parts”.
A
D
BA

4 - 138
- Benelli TRK 502 - Page 231
 TANK
REMOVAL OF THE TANK FUEL LEVEL SENSOR

A
Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
18*
Remove:
• Rider and passenger seats, see chapter entitled “Removal
of rider and passenger seats, Chapter 4”.
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• Tank fairing, see chapter entitled “Removal of tank fairing,
Chapter 4”.

21
• Tank, see chapter entitled “Fuel tank removal, Chapter
4”.
• the fastening screws (18*) Fig. A

20
• the fuel level sensor (16*) Fig. B

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Tank”, paragraph “Tank parts”.
S B
R
TO
O
M

16*
A
D
BA

4 - 139
- Benelli TRK 502 - Page 232
 TANK
INSTALLATION OF THE TANK FUEL LEVEL SENSOR

Park the bike on a level surface.

B
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal. A 18*

Tighten:
• the screws (18*) Fig. A
to the following torque:

T. R .

Torque 10 N*m

21
Use Loctite thread locker to secure.

Loctite 243

20
NOTE:_________________________________
At the moment of reassembly, insert the sensor with the con-
necting lead (A) pointing upwards Fig. B
S
R
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
TO

chapter “Tank”, paragraph “Tank parts”.

O
M
A
D
BA

4 - 140
- Benelli TRK 502 - Page 233
 AIR FILTER
AIR FILTER PARTS

18

21
20
S
R
TO
O
M

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
A

DESCRIPTION
1 COMPLETE AIR FILTER BOX
D

2 SCREW
BA

3 AIR TEMPERATURE SENSOR

4 SCREW CLIP
5 SLEEVE
6 HOSE HOLDER CLIP
7 CARTRIDGE FILTER
8 SPRING BAND
9 PIPE
10 NON-RETURN VALVE
11 PIPE
12 VALVE
13 SPRING BAND
14 PIPE
15 PIPE
16 PLATE
17 SCREW
18 AIR FILTER

4 - 141
- Benelli TRK 502 - Page 234
 AIR FILTER
REMOVAL OF THE AIR FILTER

Park the bike on a level surface.

A
IMPORTANT NOTICE 2
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Rider and passenger seats, see chapter entitled “Removal
of rider and passenger seats, Chapter 4”. 1
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• Tank fairing, see chapter entitled “Removal of tank fairing,
Chapter 4”.
• Tank, see chapter entitled “Fuel tank removal, Chapter 4”.

21
• the screws (1) Fig. A
• the cover (2) Fig. A
3

20
Disconnect:
• the connector (3) from the cover Fig. A
Remove:
• the protection mesh (4) Fig. B
• the filter element (5) Fig. B

S
R
NOTE:_________________________________
Substitute the air filter element every 12,000 km. If the ve-
B
TO

hicle is used in particularly humid climates or in very dusty

areas, the air filter must be substituted more often.

Check:
Substitute the air filter element if it is damaged. If it is not dam-
O

aged wash it:

4
M

• Wash the filter element with specific solvents produced for

that use.
• Leave it to dry in the open air.
• Apply a specific oil over all surfaces of the filter element.
5
A

NOTE:_________________________________
D

Before installing the filter element into the air box, remove
any excess oil and making sure that there are no more drips
of oil.
BA

IMPORTANT NOTICE
Never switch on the engine if the ait filter is not installed.
The unfiltered air causes a quick wear of the engine parts
and might damage the engine. Furthermore, using the en-
gine without air filter, setting of the throttle bodies is affect-
ed, causing a worsening of engine performance, as well as
its overheating.
Therefore ensure that the air filter is always in a good con-
dition.
The long life durability of the engine greatly depends on this
component.

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Air filter”, paragraph “Air filter parts”.

4 - 142
- Benelli TRK 502 - Page 235
 AIR FILTER
INSTALLATION OF THE AIR FILTER

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 143
- Benelli TRK 502 - Page 236
 AIR FILTER
REMOVAL OF THE AIR FILTER BOX

Park the bike on a level surface.

D
IMPORTANT NOTICE 2
2
Prop the bike on suitable supports so that it cannot fall.
1
Remove:
• Rider and passenger seats, see chapter entitled “Removal 1
of rider and passenger seats, Chapter 4”.
• Movable windscreen, see chapter entitled “Removal of
movable windscreen, Chapter 4”.
• Front fairing, see chapter entitled “Removal of front fair-
ing, Chapter 4”.
• Tank fairing, see chapter entitled “Removal of tank fairing,
Chapter 4”.
• Tank, see chapter entitled “Fuel tank removal, Chapter 4”.

21
• the screws (1) Fig. D
• the two side covers - right and left - (2) Fig. D E

20
Loosen:
• the two screw clips (4*) Fig. E.

Disconnect:
• the manifold (5*) Fig. F
S
R
Remove:
• the filter box, Fig. F
4*
TO

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Air filter”, paragraph “Air filter parts”.
O

F
M
A

5*
D
BA

4 - 144
- Benelli TRK 502 - Page 237
 AIR FILTER
INSTALLATION OF THE AIR FILTER BOX

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 145
- Benelli TRK 502 - Page 238
 FAIRING
SIDE FAIRINGS

3 3
16
4 29
4 4 4
3
3 17
3
4 3
3
4 4
8 10 9 18
20
9
34 10 15 13
20 9 3 8
35 4 14 9
22
8 3 10
9 4
3 3 33
10 4 3 23
33 23 4 4
7 12

21
8
11 9
4 10 6
3
21 3

20
30 33 33 4 34
4
5
35
5 32
2 32 31 4 30
5
30 30
25
4 4 24
30
S 5
1
R
19 26
28 19
27
TO

19
19

CONTENTS
O

Pos. Description Qty Sq. SYMBOLS REMARKS

DESCRIPTION
1 LEFT PANEL
M

2 FAIRING CLOSURE
3 SCREW
A

4 METRIC RAPID FIXING CLIP

5 VIBRATION DAMPING RUBBER
D

6 LEFT TAIL FAIRING (WHITE)

7 RIGHT TAIL FAIRING (WHITE)
BA

9 TOP BUSHING
10 RUBBER TIP
11 LEFT LOWER SIDE
12 RIGHT LOWER SIDE
13 WASHER
14 LEFT REAR DIRECTION INDICATORS
15 RIGHT REAR DIRECTION INDICATORS
16 REAR CENTRAL FAIRING
17 CENTRAL COVER
18 REAR LIGHT
19 SCREW
20 NUT
21 SEAT
22 PASSENGER SEAT

4 - 146
- Benelli TRK 502 - Page 239
 FAIRING
REMOVAL OF THE SIDE FAIRINGS

Park the bike on a level surface.

3* A
IMPORTANT NOTICE 16*
Prop the bike on suitable supports so that it cannot fall.

Remove: 17*
• Rider and passenger seats, see chapter entitled “Removal
of rider and passenger seats, Chapter 4”.
• Rear handles, refer to chapter “Removal of the rear han-
dles, Chapter 4”. 3*
• the fastening screws (3*) Fig. A
• the rear central fairing (16*) Fig. A
• the central cover (17*) Fig. A
• the upper fixing screws (8*) Fig. B B
• the lower fixing screws (33*) Fig. B

21
• the left tail fairing (6*) Fig. B 8*
• the right tail fairing (7*) Fig. B

20
Disconnect: 7* 6*
• the left/right indicator leads of the tail fairing (1) Fig. D

NOTE:_________________________________
33*
The numbers marked (*) are a part of the spare parts table,
chapter “Fairings”, paragraph “Side fairings”.
S 8*
R
TO
O

D
M
A
D

1
BA

4 - 147
- Benelli TRK 502 - Page 240
 FAIRING
INSTALLATION OF THE SIDE FAIRINGS

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 148
- Benelli TRK 502 - Page 241
 FAIRING
UPPER TAIL FAIRING

21
20
S
R
TO

CONTENTS
O

Pos. Description Qty Sq. SYMBOLS REMARKS

DESCRIPTION
1 UPPER FAIRING
M

2 METRIC RAPID FIXING CLIP

3 SCREW
A

4 SNAP-ON CLIP
5 SCREW
D

6 SCREW
7 PLATE
BA

8 LICENCE PLATE HOLDER SUPPORT

9 VIBRATION DAMPING RUBBER
10 REFLECTOR
11 REFLECTOR BRACKET
12 NUMBER PLATE HOLDER
13 SCREW
14 NUT
15 REAR MUD GUARD
16 SCREW
17 SCREW
18 NUT
19 COVER

4 - 149
- Benelli TRK 502 - Page 242
 FAIRING
TAILPIECE REMOVAL

Park the bike on a level surface.

C
IMPORTANT NOTICE 1
3
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Rider and passenger seats, see chapter entitled “Removal
of rider and passenger seats, Chapter 4”.
• Rear handles, refer to chapter “Removal of the rear han-
dles, Chapter 4”. 2
• Side fairings, refer to chapter “Removal of the side fair-
ings, Chapter 4”.

Disconnect:

21
• the rear light connector (1) Fig. C D
Remove: 5
• the screws (2) Fig. C

20
• the headlight support bracket (3) Fig. C

Disconnect: S 4
R
• the central light unit (5) Fig. D.
• the injection central unit (4) Fig. D.
TO

E
O

Disconnect: 7
• the fuse box (6) Fig. E.
M

• the starter relays (7) Fig. E 6

• the relay box (8) Fig. F
A
D
BA

4 - 150
- Benelli TRK 502 - Page 243
 FAIRING
TAILPIECE REMOVAL

Remove:
G
• the fixing screws (3*) 3*
• the upper fairing (1*) Fig. G
1*

21
Remove:
• the fixing screws (17*) Fig. H H
• the upper fairing (1*) Fig. I

20
17*

NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, S
R
chapter “Fairings”, paragraph “Upper fairings / tail fairing”.
TO
O
M

I
A
D
BA

1*

4 - 151
- Benelli TRK 502 - Page 244
 FAIRING
REMOVAL OF THE REAR PASSENGER HANDLES

Park the bike on a level surface.

B
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.

Remove:
• Rider and passenger seats, see chapter entitled “Removal
of rider and passenger seats, Chapter 4”.
• the screws (1) Fig. A
• the rear handles (2) Fig. B

21
20
B
S 2
R
TO
O
M
A
D
BA

4 - 152
- Benelli TRK 502 - Page 245
 FAIRING
INSTALLATION OF THE REAR HANDLES

Park the bike on a level surface.

B
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

Tighten:
• the screws (1) Fig. A
to the following torque:

T. R .

1
Torque 10 N*m

21
20
S
R
TO
O
M
A
D
BA

4 - 153
- Benelli TRK 502 - Page 246
 FAIRING
REMOVAL OF THE REAR LIGHT

Park the bike on a level surface.

A
3*
IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall. 16*

Remove:
• Rider and passenger seats, see chapter entitled “Removal
of rider and passenger seats, Chapter 4”.
• Rear handles, refer to chapter “Removal of the rear han-
dles, Chapter 4”.
• the fixing screws (3*) Fig. A
• the rear central fairing (16*) Fig. A
• the central cover (17*) Fig. B

21
3*

20
B

S
R
17*
TO
O
M

C
A

1
D

Disconnect:
• the rear light connector (1) Fig. C
BA

4 - 154

Remove:
- Benelli TRK 502 - Page 247
 FAIRING
REMOVAL OF THE REAR LIGHT

• the screws (2) Fig. D

• the headlight support bracket (3) Fig. C
D

21
2

20
Remove:

• the rear light (18*) Fig. E. E

18*
NOTE:_________________________________
The numbers marked (*) are a part of the spare parts table, S
R
chapter “Fairings”, paragraph “Side fairings”.
TO
O
M
A
D
BA

4 - 155
- Benelli TRK 502 - Page 248
 FAIRING
INSTALLATION OF THE REAR LIGHTS

Park the bike on a level surface.

IMPORTANT NOTICE
Prop the bike on suitable supports so that it cannot fall.
Install:
Proceed using the opposite order to removal.

21
20
S
R
TO
O
M
A
D
BA

4 - 156
- Benelli TRK 502 - Page 249
 FAIRING
CHAIN PINION COVER

11 12
7
6 1
9 14

21
8

20
2 13
1
3

5
15
S
R
4
10
TO

8
O

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
M

DESCRIPTION
1 BUSHING
2 O-RING
A

3 THREADED CAP
D

4 MAGNETIC CAP
5 O-RING
BA

6 SCREW
7 PHASE SENSOR
8 SCREW
9 ALTERNATOR COVER
10 PINION COVER
11 PLATE
12 SCREW
13 FLY-WHEEL COVER GASKET
14 SCREW
15 SCREW

4 - 157
- Benelli TRK 502 - Page 250
 FAIRING
REMOVAL OF THE CHAIN PINION COVER

Remove: A
• the screws (15*) Fig. A.
• The pinion cover (10*) Fig. A

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Fairings”, paragraph “Removal of the chain pinion
cover”.

21
20
S
R
TO
O
M
A
D
BA

4 - 158
- Benelli TRK 502 - Page 251
 FAIRING
INSTALLATION OF THE CHAIN PINION COVER

Install:
• The pinion cover (10*) Fig. A.
• the screws (15*)
Tighten to the following torque:

T. R .

Torque 8 N*m

NOTE:________________________________
The numbers marked (*) are a part of the spare parts table,
chapter “Fairings”, paragraph “Removal of the chain pinion
cover”.

21
20
S
R
TO
O
M
A
D
BA

4 - 159
- Benelli TRK 502 - Page 252
 21
20
5 RS TO
O
M
A
D
BA

5- 1
- Benelli TRK 502 - Page 253
 CHAPTER 5

ENGINE
HEAD DISTRIBUTION ...................................................................................................................................4
COILS AND SPARK PLUGS REMOVAL ....................................................................................................................................5
COILS AND SPARK PLUGS ASSEMBLY ...................................................................................................................................6
TIMING GEAR COVER ASSEMBLY ..........................................................................................................................................8
DISTRIBUTION CHAIN TENSIONER REMOVAL ......................................................................................................................9
TIMING CHAIN TENSIONER ASSEMBLY ...............................................................................................................................10
INTAKE AND EXHAUST CAMSHAFT REMOVAL ....................................................................................................................11
CAMSHAFT CHECK.................................................................................................................................................................12
EXHAUST CAMSHAFT INSTALLATION ..................................................................................................................................13
INTAKE CAMSHAFT ASSEMBLY.............................................................................................................................................14
TIMING CHAIN SLIDE REMOVAL............................................................................................................................................15
TIMING CHAIN SLIDE ASSEMBLY ..........................................................................................................................................16

21
TIMING CHAIN REMOVAL .......................................................................................................................................................17
DISTRIBUTION CHAIN INSTALLATION ..................................................................................................................................18
VALVE CLEARANCE ADJUSTMENT .......................................................................................................................................19
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................20

20
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................21
CAMSHAFT AND VALVE PAD REMOVAL ...............................................................................................................................22
HEAD REMOVAL......................................................................................................................................................................23
VALVE FLAP AND SPRING REMOVAL....................................................................................................................................24

S
CHECK OF VALVES AND GUIDES ..........................................................................................................................................25
VALVE SEAT CHECK ...............................................................................................................................................................27
R
VALVE OIL SEAL REMOVAL- INSTALLATION ........................................................................................................................28
VALVE SPRING TEST ..............................................................................................................................................................29
TO

VALVE AND VALVE SPRING INSTALLATION..........................................................................................................................30

CYLINDER CHECK ..................................................................................................................................................................31
HEAD INSTALLATION ..............................................................................................................................................................32
PISTONS ......................................................................................................................................................33
O

PISTON REMOVAL ..................................................................................................................................................................35

PISTON PIN CHECK ................................................................................................................................................................36
M

PISTON RINGS CHECK...........................................................................................................................................................37

PISTON CHECK .......................................................................................................................................................................38
PISTON ASSEMBLY .................................................................................................................................................................39
A

PISTON INSTALLATION...........................................................................................................................................................40
REMOVAL OF CONNECTING RODS ......................................................................................................................................41
D

CRANKCASE...............................................................................................................................................41
CHECK OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS...................................................................43
BA

INSTALLATION OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS ......................................................44

MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION ................................................................................................46
DRIVE SHAFT CHECK.............................................................................................................................................................49
DRIVE SHAFT INSTALLATION ................................................................................................................................................50
CLUTCH .......................................................................................................................................................51
CLUTCH AND DISC REMOVAL ...............................................................................................................................................52
FRICTION DISC CHECK ..........................................................................................................................................................54
STEEL DISC CHECK ...............................................................................................................................................................55
DISC ASSEMBLY .....................................................................................................................................................................55
CLUTCH ASSEMBLY ...............................................................................................................................................................56
LUBRICATION SYSTEM .............................................................................................................................57
OIL SUMP AND INTAKE FILTER REMOVAL ...........................................................................................................................58
OIL SUMP AND INTAKE FILTER INSTALLATION....................................................................................................................59
PRESSURE-RELIEF VALVE INSTALLATION ..........................................................................................................................60
PRESSURE-RELIEF VALVE REMOVAL ..................................................................................................................................61
OIL PUMP REMOVAL...............................................................................................................................................................62
OIL PUMP ASSEMBLY .............................................................................................................................................................64
NEUTRAL POSITION/GEAR INDICATOR SENSOR REMOVAL .............................................................................................65

5- 2
- Benelli TRK 502 - Page 254
 CHAPTER 5

GEAR BOX ..................................................................................................................................................65

NEUTRAL POSITION/GEAR INDICATOR SENSOR ASSEMBLY ...........................................................................................66
GEAR BOX ASSEMBLY ...........................................................................................................................................................70
GEAR SHIFT CONTROL ..........................................................................................................................................................72
STARTER .................................................................................................................................................................................76
STARTING ...................................................................................................................................................76
STARTER REMOVAL ...............................................................................................................................................................77
STARTER INSTALLATION .......................................................................................................................................................78
FLYWHEEL REMOVAL.............................................................................................................................................................79
FLYWHEEL INSTALLATION .....................................................................................................................................................82
STARTER GEAR REMOVAL ....................................................................................................................................................83
STARTER GEAR ASSEMBLY ..................................................................................................................................................84
PHASE SENSOR......................................................................................................................................................................85
PHASE SENSOR REMOVAL ...................................................................................................................................................86

21
PHASE SENSOR INSTALLATION ...........................................................................................................................................87
POWER SYSTEM ........................................................................................................................................88
THROTTLE BODY ....................................................................................................................................................................88

20
THROTTLE VALVE REMOVAL.................................................................................................................................................90
THROTTLE VALVE INSTALLATION .........................................................................................................................................91

S
R
TO
O
M
A
D
BA

5- 3
- Benelli TRK 502 - Page 255
 HEAD DISTRIBUTION
DISTRIBUTION COVER REMOVAL

6
7
8

2
3
4
5

21
9

20
10

S
R
TO

1 COIL
O

2 RUBBER TIP
3 O-RING
M

4 SCREW
5 BUSHING
A

6 SCREW
7 SPECIAL WASHER
D

8 BRACKET
9 TIMING GEAR COVER
BA

10 TIMING GEAR COVER GASKET

5- 4
- Benelli TRK 502 - Page 256
 HEAD DISTRIBUTION
COILS AND SPARK PLUGS REMOVAL

Remove:
• the screw (6*) Fig. A
A
• washer (7*) Fig. A 6* 8*
• bracket (8*) Fig. A
• the coils (1*) Fig. B
• the spark plugs, using a special wrench. 7*

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Engine”, section entitled “Timing gear cover
removal ”. B
NOTE:_________________________________
To check the spark plugs, see the chapter entitled “Routine

21
maintenance, “spark plug removal” section.
1*

20
S
R
TO
O
M
A
D
BA

5- 5
- Benelli TRK 502 - Page 257
 HEAD DISTRIBUTION
COILS AND SPARK PLUGS ASSEMBLY

The procedure applies to all of the spark plugs Fig.C.

C
WARNING
Lubricate the spark plug threads with copper grease.

G Grease

D
NOTE:__________________________________________ 4
Before installing it, clean the spark plug and surface in
contact with the seal.

21
Install:
• the spark plug to the head, tightening it by hand until it
comes into contact with the base of the head. Tighten to

20
torque.
T. R .

Torque 12 N*m

Install: S
R
• The rubber tips (2*)
• the OR seals (3*) Fig. D
• the coils (1*) Fig.
TO

• the screws (6*)

• the washers (7*)
• the brackets (8*) Fig.
O

Tighten to torque.
T. R .
M

Torque 10 N*m
NOTE:_________________________________
Numbers marked (*) are part of the spare parts tables in
A

Chapter 5 “Engine”, section entitled “Timing gear cover

removal”.
D
BA

5- 6
- Benelli TRK 502 - Page 258
 HEAD DISTRIBUTION
TIMING GEAR COVER REMOVAL

Take care with the seal on the timing gear cover (10*) Fig. E.
during removal. 9* E

NOTE:_________________________________ 10*
In case of seal breakage on the timing gear cover (10),
replace.

During the assembly of the cover, install sealing paste on the

surface as shown in Fig. F

NOTE:_________________________________
Numbers marked (*) are part of the spare parts tables in
Chapter 5 “Engine”, section entitled “Timing gear cover
removal”.
F

21
20
S
R
TO
O
M
A
D
BA

5- 7
- Benelli TRK 502 - Page 259
 HEAD DISTRIBUTION
TIMING GEAR COVER ASSEMBLY

Assemble:
Proceed in the opposite direction to removal.
E

2
NOTE:_________________________________ 3
During the assembly stage of the timing gear cover, repla- 4
cement of the rubber tips (5*) is recommended. 5
Tighten: 9
Tighten the screws (4*) to the following torque:

T. R .

Torque 12 N*m

21
NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in

20
Chapter 5 “Engine”, section entitled “Timing gear cover
removal”.

S
R
TO
O
M
A
D
BA

5- 8
- Benelli TRK 502 - Page 260
 HEAD DISTRIBUTION
DISTRIBUTION CHAIN TENSIONER REMOVAL

Remove:
1. the screws (C) G
2. the screw (B) C B
3. the washer
4. the seal

NOTE:_________________________________
Operation to perform with the engine in TDC.
Using the special tool during the removal stage, keep the A
tensioner retracted, Fig. I., then remove the two screws “C”
Fig. G.

(*) Tool: Chain tensioner lock tool

Code: 0320097046001
I

21
20
S
R
TO
O
M
A
D
BA

5- 9
- Benelli TRK 502 - Page 261
 HEAD DISTRIBUTION
TIMING CHAIN TENSIONER ASSEMBLY

During the assembly stage, take care to ensure that the seal (D)
Fig. H is undamaged and unworn. Replace if necessary.
H

Move:
The tensioner to the retracted position and insert it into its hou-
sing using the special tool (*)

(*) Tool: Chain tensioner lock tool

Code: 0320097046001
D
Insert the tensioner into the seat and housing.
Tighten:
• The fastening screws (C) Fig. I to the following torque:
I

21
T. R .
C B
Torque 10 N*m

20
• The screws (B) to the following torque:
T. R .

A
Torque 8 N*m

S
R
TO
O
M
A
D
BA

5 - 10
- Benelli TRK 502 - Page 262
 HEAD DISTRIBUTION
INTAKE AND EXHAUST CAMSHAFT REMOVAL

Remove:
B
2 2
• Coils and Spark plugs, see the section entitled “Coil and 1
spark plug removal”. 1
• Head timing gear, see section entitled “Head timing gear
cover removal”.

NOTE:_________________________________
During the removal stage, use a marker pen to mark the
position of the holders since, when reinstalling, they need
to be in their original positions, Fig. E.
The “arrows” pressed into the holders show the direction in
which they need to be installed towards the timing gear.

21
Remove: C
• the fastening screws of the holders (1) Fig. B
• The holders (2)
• the intake camshaft Fig. C

20
• the exhaust camshaft (A) Fig. D

S
R
TO

D
O
M

A
A
D
BA

5 - 11
- Benelli TRK 502 - Page 263
 HEAD DISTRIBUTION
CAMSHAFT CHECK

Make a visual check of the camshaft lobes and if there is any

blue discolouration/pitting or lines, replace. A E

• Measure the size of the lobes.

If the measures taken (Fig. E) are not compliant with specifica-
tions, replace the shaft.
Specifications Table

Limit Limit B
Camshaft
(a) (b)
Camshaft exhaust side 31.9 mm 24.82 mm
Camshaft intake side 32.2 mm 24.85 mm

21
• Measure the eccentricity of the camshaft

20
F
If the measures taken (Fig. F) are not compliant with specifica-
tions, replace the shaft.
Specifications Table

Camshaft Eccentricity limit S

R
Camshaft exhaust side 0.05 mm
Camshaft intake side 0.05 mm
TO
O

• Measurement of clearance between camshaft main G

M

bearing bolts and holder

If the measures taken (Fig.G) are not compliant with specifica-

A

tions, replace the head gear and holder block.

Specifications Table
D

Clearance between bearing

Camshaft
journals and camshaft
BA

Camshaft outlet side 0.012 mm

Camshaft intake side 0.012 mm

• Measure the diameter of the camshaft support

H
If the measurements taken (Fig.H) are not within the specifica- C
tions, proceed with shaft replacement.
Specifications Table
Measurement of main bea-
Camshaft
rings (C)
Camshaft exhaust side
Camshaft intake side Ø 23 mm(-0.03/-0.043)

5 - 12
- Benelli TRK 502 - Page 264
 HEAD DISTRIBUTION
EXHAUST CAMSHAFT INSTALLATION

Insert:
Install the special tool (*) into the spark plug seat to check the
A
top dead centre Fig. A.
(*) Tool: Engine phasing tool
Code:R180197022000

Once the TDC has been identified, proceed to assemble the

camshaft, exhaust side.

NOTE:_________________________________
During this assembly, it is important for the lobes of the B

21
cylinder shaft 1 (Y) to be positioned outwards Fig. B. and
the two reference notches ”X” of the distribution gear are
aligned as in Fig. B.

20
Y

NOTE:_________________________________ S
R
When assembling the holders, it is necessary to lubricate
them with special grease to prevent the shafts from rotating
TO

dry during initial starting.

X

G Sintoflon Grease
O
M

When installing the holders, proceed in the opposite direction to

removal, tightening the screws to the following torque:
A

T. R .
D

Torque 13 N*m
BA

NOTE:_________________________________
lubricate the screws with copper grease.

G Copper grease

NOTE:_________________________________
Check the correct alignment of the exhaust camshaft using
the special tool (*).
(*) Tool: Engine phasing tool
Code:R180197022000

5 - 13
- Benelli TRK 502 - Page 265
 HEAD DISTRIBUTION
INTAKE CAMSHAFT ASSEMBLY

Install the relevant tool (*) into the spark plug seat to check the A
top dead centre Fig. A.
(*) Tool: Engine phasing tool
Code:R180197022000

Once the TDC has been identified, proceed to assemble the

camshaft, exhaust side.

NOTE:_________________________________
During installation, it is important for the lobes of cylinder
1 shaft are positioned outwards, and the two reference
notches”X” of the two timing gears are aligned as in Fig. B. B

21
NOTE:_________________________________
When assembling the holders, it is necessary to lubricate

20
them with special grease to prevent the shafts from rotating
dry during initial starting.
X

G Sintoflon Grease
S
R
C
TO

When assembling the holders, proceed in the opposite direction

to removal, tightening the screws to the following torque:

T. R .
O

Torque 10-13 N*m

M

NOTE:_________________________________
Lubricate the screws with copper grease.
A

G Copper grease D
D

2
BA

Turn the camshaft clockwise, using the fastening nut to the

1
flywheel, moving the TDC so it lines up with the reference mar-
kings “X” on the head surface Fig. B and the reference mark on
the magnet flywheel (2) Fig. D.

5 - 14
- Benelli TRK 502 - Page 266
 HEAD DISTRIBUTION
TIMING CHAIN SLIDE REMOVAL

Remove:
• Coils and Spark plugs, see the section entitled “Coil and
G
spark plug removal”.
1. Head timing gear, see section entitled “Head timing gear
cover removal”.
2. Chain tensioner, see chapter entitled “Chain tensioner
removal”.
3. Exhaust camshaft, see chapter entitled “Exhaust
camshaft removal”. 4
4. Intake camshaft, see chapter entitled “Intake camshaft
removal”.
5. Flywheel, see chapter entitled “Flywheel removal”.
6. Starter gear assembly, see chapter entitled “Starter gear
assembly removal”.

21
H

20
Remove:
• the fixed chain slide (4) sliding it towards the other 5
• the safety plate (5) Fig. H
• the mobile chain slide (6) Fig. I
• the fixing pin (7) Fig. I

S
R
CHECK OF THE TIMING CHAIN SLIDES
TO

Check:

• the contact surface of the fixed slide.

• The contact surface of the mobile slide.
O

If there is any damage or wear, replace the faulty parts. I

M

6
A

7
D
BA

5 - 15
- Benelli TRK 502 - Page 267
 HEAD DISTRIBUTION
TIMING CHAIN SLIDE ASSEMBLY

To assemble the chain slides, follow the removal process in the

opposite order.

NOTE:_________________________________
Operation to perform with the engine in TDC.

At the end of assembly, proceed to load the timing chain tensio-

ner. See chapter “Timing chain tensioner installing”.

21
20
S
R
TO
O
M
A
D
BA

5 - 16
- Benelli TRK 502 - Page 268
 HEAD DISTRIBUTION
TIMING CHAIN REMOVAL

Remove:
1. Coils and Spark plugs, see the section entitled “Coil and
I
spark plug removal”.
2. Head timing gear cover, see the chapter entitled “Head
timing gear cover removal”.
3. Chain tensioner, see chapter entitled “Chain tensioner
removal”.
4. Exhaust camshaft, see chapter entitled “Exhaust
camshaft removal”.
5. Intake camshaft, see chapter entitled “Intake camshaft
removal”.
6. Flywheel, see chapter entitled “Flywheel removal”.
7. Starter gear removal, see chapter entitled “Starter gear
assembly removal”.
8. Chain slides, see chapter entitled “Chain slide removal”.

21
• Once the parts listed above have been removed, proceed to
take out the same Fig. I

20
TIMING CHAIN CHECK C
The following process applies to all of the toothed wheels on the 2
camshafts and all of the timing chain guides.

Check:
S
R
• timing chain (2) Fig. C
In case of damage/lack of flexibility/locked links, replace the
TO

timing chain and camshaft gear block.

NOTE:_________________________________
In any case the timing chain needs to be replaced after
O

20,000 km.
M
A
D
BA

5 - 17
- Benelli TRK 502 - Page 269
 HEAD DISTRIBUTION
DISTRIBUTION CHAIN INSTALLATION

Insert: A
• the timing chain (1) in to the camshaft pinion, as in Fig. A

• Insert the fixed and mobile chain tensioner slides, see

chapter“Timing chain assembly”.
• The two camshafts, making sure that both are installed with
the phasing references “aligned” with the floor” as in Fig. B.

NOTE:_________________________________
Assembly of the timing chain must always take into account
the fact that the motor must be in the TDC condition Fig. B,
see chapter entitled “installation of intake camshaft.
1
(*) Engine tuning tool
Code: R180197022000

21
NOTE:_________________________________
During this operation, it is necessary to lubricate the chain

20
and timing gears with engine oil.
B
NOTE:_________________________________
Every time that the chain is replaced, it is also necessary to
replace the slides.
S
R
TO
O
M
A
D
BA

5 - 18
- Benelli TRK 502 - Page 270
 HEAD DISTRIBUTION
VALVE CLEARANCE ADJUSTMENT

Remove: A
1. Coils and Spark plugs, see the section entitled “Coil and
spark plug removal”.
2. Head timing gear cover, see chapter entitled “Head timing
gear cover removal”

NOTE:_________________________________
Valve clearance must be checked and adjusted when the
engine is cool (ambient temperature).

Check:
Use a feeler gauge to check the clearance between the cam and
the valve tappets, as shown in Fig. A.
If the measurement is outside specifications, replace the calibra-
ted pad.

21
NOTE:_________________________________
The measurement must be taken on all cams and tappets.

20
Camshaft Tappet-cam clearance
Camshaft exhaust side 0.19 ~ 0.25 mm
Camshaft intake side 0.13 ~ 0.19 mm

S
R
NOTE:_________________________________
In case of valve clearance correction, replace the calibrated
pads (see the following table).
TO
O
M
A
D
BA

5 - 19
- Benelli TRK 502 - Page 271
 HEAD DISTRIBUTION
CAMSHAFT AND VALVE PAD REMOVAL

1
20 22

19
21 22 4
23
25
26 25
18 3 27 26
5 27
28 28
33 29
6 30
17 30

32 31

21
7 2

16 15 7
14

20
11 8
10

13 S 9
24
R
12
TO

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
O

DESCRIPTION
1 BUSHING (M20)
M

2 SCREW
3 BUSHING
4 WASHER
A

5 VALVE RUBBER TIP

D

6 CYLINDER HEAD
7 STUD BOLT
BA

8 SCREW
9 THERMOSTAT CUP
10 THERMOSTAT
11 GRUB SCREW
12 HEAD GASKET
13 WATER TEMPERATURE SENSOR
14 COUPLING
15 RETAINING WASHER
16 SCREW
17 O-RING
18 SUCTION PIPE
19 WASHER
20 SCREW
21 SCREW CLIP
22 SCREW
23 CAP

5 - 20
- Benelli TRK 502 - Page 272
 HEAD DISTRIBUTION
CAMSHAFT AND VALVE PAD REMOVAL

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
24 PLUG
25 TAPPET VALVE
26 VALVE PAD
27 VALVE RUBBER TIP
28 TOP SHIELDED BULB
29 EXTERNAL VALVE SPRING
30 BOTTOM SHIELDED BULB
31 EXHAUST VALVE
32 INTAKE VALVE

21
33 INTERNAL VALVE SPRING

20
S
R
TO
O
M
A
D
BA

5 - 21
- Benelli TRK 502 - Page 273
 HEAD DISTRIBUTION
CAMSHAFT AND VALVE PAD REMOVAL

Remove:
A
1. Coils and Spark plugs, see the section entitled “Coil and
spark plug removal”.
2. Head timing gear cover, see the chapter entitled “Head
timing gear cover removal”.

To remove the intake and exhaust valve lifter, proceed as fol-

lows: 1
• Use a magnet to take out the tappet valve lifter (1) and then
the calibrated pad (5) Fig. A.
• Make a visual check of the tappet valve lifter, ensuring that 5
there is no damage or lines, and if not, replace.
• Check the outside diameter using a micrometer to exclude
any deformation Fig. B.

21
NOTE:_________________________________
During installation, lubricate the tappet valve lifter, using:
B

20
G Sintoflon Grease

NOTE:_________________________________
At the end of the check of the parts, check the valve clea-
rance , as in the chapter entitled “Valve clearance removal”. S
R
TO
O
M
A
D
BA

5 - 22
- Benelli TRK 502 - Page 274
 HEAD DISTRIBUTION
HEAD REMOVAL

Remove:
1. Coils and Spark plugs, see the section entitled “Coil and
C
spark plug removal”.
2. Head timing gear cover, see the chapter entitled “Head
timing gear cover removal”.
3. Chain tensioner, see chapter entitled “Chain tensioner
removal”.
4. Exhaust camshaft, see chapter entitled “Intake and
exhaust camshaft removal”. 6
5. Chain slides, see chapter entitled “Chain slide removal”.

Remove:
• the screws (6) Fig. C
• the fastening screws (7) Fig. D.

21
NOTE:_________________________________
Loosen each screw by 1/2 turn. D
then remove all screws.
7

20
• Head gasket.

S
R
TO
O
M
A
D
BA

5 - 23
- Benelli TRK 502 - Page 275
 HEAD DISTRIBUTION
VALVE FLAP AND SPRING REMOVAL

Remove:
1. Coils and Spark plugs, see the section entitled “Coil and
A
spark plug removal”.
2. Head timing gear cover, see the chapter entitled “Head
timing gear cover removal”.
3. Chain tensioner, see chapter entitled “Chain tensioner *
removal”.
4. Exhaust camshaft, see chapter entitled “Exhaust
camshaft removal”.
5. Intake camshaft, see chapter entitled “Intake camshaft
removal”.

Use the special tool to remove the valves Fig. A.

(**) Valve removal tool

21
Code:0320097050000
B
Remove:
• Tappet valve.

20
• Pad.
• Cotters.
• Top door.
• Spring.
•
•
Bottom plate.
Oil seal.
S 1
R
NOTE:_________________________________
During removal of the two cotters to lock the valve, use a
TO

magnet (1) to recover them Fig. B.

C
O
M
A
D
BA

5 - 24
- Benelli TRK 502 - Page 276
 HEAD DISTRIBUTION
CHECK OF VALVES AND GUIDES

The following process applies to all of the valves and valve

guides.
A

Check: 1
• the valve seals.
If there are leaks from the valve seats, check the contact surfa-
ce, the seat and the width of the valve seat.
See the section .............
• Pour clean solvent (1) into the intake doors.
• Make sure the valves have a suitable seal.
NOTE:_________________________________
There should not be any leaks from the valve seat (2) Fig. A.

21
Replace:
• the valve guide. B
NOTE:_________________________________

20
To make valve guide removal and installation operations
easier and to maintain correct assembly, heat the head in an
oven, taking it to 100° C (212° F).
3
•
•
Remove the valve guide with a special extractor (3) Fig. B.
Install the new valve guide with the special installer (4) and S
R
extractor (3) Fig. C.
• After installing the valve guide, bore it with a reamer (5) to
TO

create the correct clearance between the valve guide and

stem.

NOTE:_________________________________
O

C
After renstalling the valve guide, pass over the seat.
M

4
A
D
BA

5 - 25
- Benelli TRK 502 - Page 277
 HEAD DISTRIBUTION
CHECK OF VALVES AND GUIDES

Eliminate:
• The carbon deposits (5) (from the contact surface and valve
E
seat) Fig. E.

21
Check:
• the contact surface of the valve (7) Fig. F F
If there is any pitting/wear, grind the contact surface of the valve.

20
• end of the valve stem (6) Fig. F
If there is a shape or a diameter of the mushroom that is larger
than the body of the valve stem, replace the valve. 6

S
R
7
TO
O

Measure:
• the eccentricity of the valve stem Fig. G. G
M

If not compliant with specifications, replace the valve.

NOTE:_________________________________
If installing a new valve, always replace the relevant guide
A

If the valve is removed or installed, always replace the oil

seal.
D

Valve Valve stem eccentricity

BA

Intake
0.01 mm
Exhaust

5 - 26
- Benelli TRK 502 - Page 278
 HEAD DISTRIBUTION
VALVE SEAT CHECK

The following process is applied to all valves and valve seats

Fig. H H
Eliminate:
• carbon deposits
(from the contact surfaces and valve seat (A)
B
Check:
• the valve seat (A)
If there are marks/signs of wear, replace the head.
A A

Measure:
• the width of the valve seat (A)
If outside specifications, replace the head.

21
Valve Width of the valve seat (A)
Intake 1~ 1.1 mm
I
Exhaust 0.9 ~ 1.1 mm

20
1. Apply some blue colorant (Dykem) for mechanics to the
contact surface of the valve (B).
2. Install the valve in the head.
3. Push the valve into the guide and against its seat to leave a

4.
well-defined mark.
Measure the valve seat width S C
R
TO

NOTE:_________________________________
Where the valve seat and valve face are in contact with one
another, the Prussian blue liquid will have been removed.

Lap:
O

• the valve contact surfaces L

• the valve seat Fig. L
M

NOTE:_________________________________
After replacing the head or the valve and the relevant guide,
it is necessary to lap the seat and contact surfaces of the
A

valve.
D

• Apply a paste for rough lapping of the valve contact surfa-

ces (C) Fig. I
BA

IMPORTANT NOTICE
Do not allow the lapping paste to enter the area between the
valve stem and the guide.

• Apply molybdenum disulphide oil to the valve stem.

• Install the valve in the head.
• Turn the valve until the contact surface and the seat have
been polished evenly, then remove all the lapping paste.

NOTE:_________________________________
To get the best results from lapping, gently tap on the valve
seat while turning it forwards and back manually Fig. L

5 - 27
- Benelli TRK 502 - Page 279
 HEAD DISTRIBUTION
VALVE OIL SEAL REMOVAL- INSTALLATION

Remove:
Once the valve has been removed, using the special tool (*) to
B
take out the oil seal (AA) Fig. B.
(*) Tool for valve oil seal removal

AA

21
20
Install: C
Proceed to install the oil seal (AA) Fig. D using the special tool
** Fig. C.
**
(**) Valve oil seal insertion pad (**)
Code:R180197025000 S
R
TO
O
M

D
A
D
BA

5 - 28
- Benelli TRK 502 - Page 280
 HEAD DISTRIBUTION
VALVE SPRING TEST

The following process is applied to all valve springs.

A
Measure:
• the free length of the valve springs (A) Fig. A.
If not compliant with specifications, replace the valve spring.

Valve spring Dimension (A)

Intake 38.8 mm - 37.3 mm
Exhaust 41.6 mm - 40.1 mm

NOTE:________________________________
If outside specification, replace. A

21
20
S
R
TO
O
M
A
D
BA

5 - 29
- Benelli TRK 502 - Page 281
 HEAD DISTRIBUTION
VALVE AND VALVE SPRING INSTALLATION

Install the head:

A
NOTE:________________________________ 1
Lubricate the valve stem and oil seal.
2
E

A1
3 E

Engine oil
E

4
• Valve bottom spring plate (4),
• valve oil seal (3) Fig. A1 see section entitled “Valve oil seal
installation/removal”.
• valve (5)
• valve spring (2)

21
• Valve top spring plate (1), A2
• cotters.

20
E

NOTE:________________________________ E

Deburr the end of the valve stem with an oiling stone (A2).

NOTE:________________________________
Make sure that every valve has been reinstalled in its origi-
nal position. S 5
A3
R
NOTE:________________________________
TO

Reinstall the valve cotter pin, pressing the spring on each

valve with the special compression tool (*) Fig. B
B
(*) Valve spring compressor tool
Code: 0320097050000
O

Secure: *
• the cotters on the valve stems.
M

Gently tap on the valve tip with a soft hammer, Fig. C.

IMPORTANT NOTICE
A

Hitting the valve tip with too much force could damage the
D

valve.
C
BA

Install:
• the calibrated pad (1)
• the tappet valve (2)

NOTE:________________________________
Lubricate the tappet valve with copper grease (MOLYKOTE
HSC PLUS).
Manually turn the tappet valve, which must be able to slide
smoothly.
Reinstall each tappet valve and pad to its original position.
D
G Copper grease

2
The following process applies to all of the valves and relevant 1
components.

5 - 30
- Benelli TRK 502 - Page 282
 HEAD DISTRIBUTION
CYLINDER CHECK

Remove:
1. Coils and Spark plugs, see the section entitled “Coil and
A
spark plug removal”.
2. Head timing gear cover, see chapter entitled “Head timing
gear cover removal”
3. Head see chapter entitled “Head removal”

The following procedure applies the whole cylinder group.

Check:
• the cylinder walls with a special tool Fig. A.

If there are any vertical lines, replace the cylinder and the piston
all together and the relevant clips.

21
Measure:
B
• The cylinder bore Fig. B
Make different measurements at different distances of 10-43-90

20
mm from the head coupling surface.
The highest value is considered when calculating wear limits.
CYLINDER bore (C) = 69 (+0.01 , +0.02)
- 0.002
mm
C=Max D1 or D2 65- 0.003

Limit conicity: S
R
• Max D1= 0.5 mm
• Max D2= 0.5 mm
TO

• Max D3= 0.5 mm

• Max D4= 0.5 mm
• Max D5= 0.5 mm
Limit eccentricity:
• Max D1= 0.5 mm
O

• Max D2= 0.5 mm

• Max D3= 0.5 mm
M

• Max D4= 0.5 mm

• Max D5= 0.5 mm
A
D
BA

5 - 31
- Benelli TRK 502 - Page 283
 HEAD DISTRIBUTION
HEAD INSTALLATION

Before assembling the head, replace the seals (2).

Make sure that the alignment dowels (1) are in position Fig. C.
C
1
2

21
• Position the head and tighten the screws (3), following the
sequence stated in Fig. D. D
• Then the screws (4) Fig.
8
5 2 3

20
NOTE:_________________________________
During assembly of the head. lubricate the head screws
with copper grease.
8
8
G Copper grease S
R
4 1 6
TO

Tighten: 8
• the screws (8) Fig. D to torque in three steps:

T. R .
O

Step one: E
M

Torque 12.5 N*m

Step two:
Torque 25 N*m
Step three:
A

Torque 55 N*m
D

Tighten: 3
• the screws (4) Fig. E to torque. 4
BA

T. R .

Torque 12 N*m

To assemble the head, tighten the fastening screws (3) Fig. E,

after the screws (4) Fig.

NOTE:_________________________________
During assembly of the head. lubricate the head screws
with copper grease.

5 - 32
- Benelli TRK 502 - Page 284
 PISTONS

1
2

2 1
3
4
3
2

9 5

21
8
5 8
20

20
9
7
11 10
12 6
13 15
S 24
23
R
14 22
TO

21
O

16 25
17 18 19
M
A

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
D

1 PISTON SEGMENT SERIES

2 PIN RETAINING RING
BA

3 PISTON PIN
4 PISTON
5 COMPLETE CONNECTION ROD
6 PLUG
7 SCREW
8 GUIDE BUSHING
9 CONNECTING ROD MAIN BEARING SHELL
10 COUNTERSHAFT
11 NUT
12 WASHER
13 FULL DRIVE SHAFT
14 SPLINE
15 PLUG
16 GEAR
17 DRIVE SHAFT GEAR

5 - 33
- Benelli TRK 502 - Page 285
 PISTONS

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
18 WASHER
19 NUT
20 BEARING
21 NUT
22 COUNTERSHAFT GEAR
23 GUIDE BUSHING
24 BEARING
25 BEARING RETAINER

21
20
S
R
TO
O
M
A
D
BA

5 - 34
- Benelli TRK 502 - Page 286
 PISTONS
PISTON REMOVAL

The following removal process applies to all pistons.

A
Remove:
1. Coils and Spark plugs, see the section entitled “Coil and 1
spark plug removal”.
2. Head timing gear cover, see the chapter entitled “Head
2
timing gear cover removal”.
3. Head see chapter entitled “Head removal”. 2 1
4. Top base, see chapter entitled “Connecting rod remo-
3
val”. 4
Remove: 3
• the outer elastic ring (2) Fig. A 2
• the piston pin (3) Fig. A
• The piston (4) Fig. A

21
• the inner elastic ring (2) Fig. A

NOTE:_________________________________ B
To remove the piston pin, use a “pad*” Fig. B.

20
NOTE:_________________________________
Never use hammers to remove the pins.

S
R
TO
O
M
A
D
BA

5 - 35
- Benelli TRK 502 - Page 287
 PISTONS
PISTON PIN CHECK

The following procedure applies to all piston pins.

B
Check:
• piston pin

If there is blue discolouration or grooves, replace the piston pin

and check the lubrication system.

Measure:
• the outer diameter of the piston pin Fig. B.

If not compliant with specifications, replace the pin using the

measuring tool (A).

21
Measure:
• the inner diameter of the piston pin bore Fig. C.
C
If outside specifications, replace the piston.

20
Internal bore (A) Size
Pin bore Ø17 mm +0.0/+0.006

S
R
TO

A
O
M
A
D
BA

5 - 36
- Benelli TRK 502 - Page 288
 PISTONS
PISTON RINGS CHECK

The following procedure is applied to all elastic clips (1).

A
Check:
• the absence of lines and traces of forcing on each clip Fig.
1
A.

If outside specification, replace the relevant clips and pistons.

NOTE:_________________________________
Before measuring side clearance between the piston clips,
remove any carbon deposits from the piston clips and
grooves.

Measure:
• the side clearance between piston clips, using a thickness

21
gauge Fig. B.
B
If outside specifications, replace the piston and the relevant clips
all together.

20
Clip Piston clip side clearance.
Top clips 0.04-0.08 mm
Clips 0.05-0.09 mm
S
R
Measure:
TO

• The thickness of the top clip.

• The thickness of the second clip.
See Fig. C.
C
O

Clip Piston clip thickness

Top clips 0.8 -0.01/-0.03 mm
M

Clips 0.8 -0.02/-0.04 mm

A
D
BA

5 - 37
- Benelli TRK 502 - Page 289
 PISTONS
PISTON CHECK

The following procedure applies to both pistons.

D
Check:
• The sides of the piston (B) Fig. D.
If there are any vertical lines, replace the piston all together with
the relevant clips.

Measure:
• The diameter of the piston skirt (B) with a micrometer,
considering a distance from the bottom edge of around 10.5
mm Fig. E.
B

CLASS Piston skirt

A Ø69(-0.025/ -0.03) E

21
B Ø69(-0.02/ -0.025)

If outside specifications, replace the cylinder and the relevant

20
clips all together.

IMPORTANT NOTICE
The piston is marked by a letter stating its class. The
cylinder-piston coupling must be made between the same
classes. S
R
TO
O
M
A
D
BA

5 - 38
- Benelli TRK 502 - Page 290
 PISTONS
PISTON ASSEMBLY

The following procedure applies to all pistons.

A
3

D
Install:
in the following order:

PVD
1. oil scraper clip
2. second clip
3. top clip
2
See Fig. A
1
NOTE:_________________________________
The first and second ring are marked with the letter D on the
top side and PVD Fig. A.
Remember to install the piston clips so that the letters are
facing upwards.

21
Lubricate the clips with engine oil during the insertion
stage. B
The first element to insert in the oil scraper slot is the shim (D).

20
After positioning the shim, insert its side rings (E) Fig. B.

NOTE:_________________________________ E
The shim and side rings have no top or bottom side, mea-
D
ning they can be inserted in any way.

IMPORTANT NOTICE
S E
R
When installing the shim (D), make sure that its ends do not
TO

overlap the slot Fig. C.

C
O

Scorretto
M

Corretto
A
D
BA

5 - 39
- Benelli TRK 502 - Page 291
 PISTONS
PISTON INSTALLATION

NOTE:_________________________________
To install the pistons (1), first insert the inner rings (2), then C
the pins (4) and finally the outer rings (3) Fig. C
1
4
To insert the pistons inside the cylinders, it is necessary to use a 2
specific piston clamp to hold the clips.
General piston clamp.
3
NOTE:_________________________________
During this stage, lubricate parts with engine oil

IMPORTANT NOTICE

21
The pistons must be inserted in the sequence in which they
were removed. Do not change the assembly order and abo- D
ve all, make sure that the mark on the piston Fig. D is facing
the intake side.

20
S
R
TO
O
M
A
D
BA

5 - 40
- Benelli TRK 502 - Page 292
 CRANKCASE
REMOVAL OF CONNECTING RODS

Remove:
1. Coils and Spark plugs, see the section entitled “Coil and
E
spark plug removal”.
2. Head timing gear cover, see the chapter entitled “Head
timing gear cover removal”.
3. Chain tensioner, see chapter entitled “Chain tensioner
removal”.
4. Exhaust camshaft, see chapter entitled “Exhaust
camshaft removal”.
5. Intake camshaft, see chapter entitled “Intake camshaft
removal”.
6. Head see chapter entitled “Head removal”.
7. flywheel, see chapter entitled “Flywheel removal”.
8. Mobile chain slides, see chapter entitled “Mobile chain
slides removal”.

21
9. Clutch, see chapter entitled “Clutch removal”.
10. Oil sump, see chapter entitled “Oil sump removal”.
40 40 40 F
11. Oil pump, see chapter entitled “Oil pump removal”. 40

20
Remove: 40
• Base screws Fig. F
• raise the top base. 41

S 41
41
R
TO
O
M

40 40 40 42
A
D

G
Remove:
BA

• the gearbox output shaft (1) Fig. G

• the gearbox intake shaft
• the counter shaft (2) Fig. G 1
• the connecting rod screws (3) Fig. G
3

5 - 41
- Benelli TRK 502 - Page 293
 CRANKCASE
REMOVAL OF CONNECTING RODS

Remove:
• Take out the drive shaft, and slide out the connecting rod,
H
including the pistons, from the cylinder group.
• Remove the pistons, see the chapter entitled “PISTON
REMOVAL”.

21
20
S
R
TO
O
M
A
D
BA

5 - 42
- Benelli TRK 502 - Page 294
 CRANKCASE
CHECK OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS

Check:
• Any breakages or excessive clearance on the connecting
A
rod (5) and the big end bearing shells (8) Fig. A. 8
If replacing the connecting rod, check the class of origin marked 5
on the head.

Measure:
• It is also necessary to measure the inner dimensions of the
big end and check for any anomalies with the relevant tool,
commercially available Fig. B. Before measuring, assemble
the big end, tightening the fastening screws to the following
torque:
T. R .

21
Torque 25 N*m B

20
• It is also necessary to measure the dimensions of the small
end and check for any anomalies with the relevant tool,
commercially available Fig. B.

S
R
Item Reference size
Steering head Ø 32.6 mm (0.0/ 0.1)
TO

Small end Ø 16.6 mm (0.0/ 0.1)

Before installing the bushings (8) of the big end, measure them
with a specific micrometer, see Fig. C. C
O
M
A
D
BA

5 - 43
- Benelli TRK 502 - Page 295
 CRANKCASE
INSTALLATION OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS

Install:
• The connecting rod bearing shells:
D

Install the top and bottom bearing shells and bottom bearing of A
the big and and connecting rod cap.

NOTE:_________________________________
Align the projections “A” on the bearing shells of the big
end with the slots “B” in the connecting rod and cap. D.
B

21
20
S
R
TO
O
M
A
D
BA

5 - 44
- Benelli TRK 502 - Page 296
 CRANKCASE
INSTALLATION OF CONNECTING ROD AND CONNECTING ROD BEARING SHELLS

NOTE:_________________________________
Do not mix up the connecting rod bushings and the con-
E
necting rods. To achieve the correct clearance between the
connecting rod support and the big end main bearing shells
and to prevent engine damage, the big end bearing shells
must be installed in their original positions Fig. E
K4/
102600 A B C
According to the bushing type, make the envisaged couplings,
see table:

CONNECTING ROD MAIN BEARING SHELL

STD COLOUR THICKNESS
A Green 1.503~1.506 mm
B Blue 1.506~1.509 mm

21
C Yellow 1.500~1.503 mm
Ø std seat A green
F
Ø 33mm (+0.008/0)

20
Ø std seat B blue Ø 33 mm (+0.008/+0.016)
Ø std seat C yellow Ø 33 mm (-0.034/-0.041)
K4/
10K1
2600
According to the class, shown on the side of the connecting rod
Fig. F combine the different types according to the table below:
S
R
TO

SELECTION TABLE
Connecting rod internal Ø
1 2
33.000 ~ 33.008 ~
O

33.008 mm 33.016 mm G
-0.034 +0.003 -0.006
Crank pin A Ø 30 A (yellow)
-0.041 0 B (green) -0.003
M

external Ø
-0.041 -0.006 -0.009
B Ø 30 -0.048 B (green) -0.003 C (brown) -0.006
A

After all of these checks, install the fastening screws (6) Fig. G
and tighten to the following torque:
D

T. R .
BA

Torque 25 N*m
NOTE:_________________________________
Every time that the big end is installed, it is necessary to 6
6
replace the fastening screws.

5 - 45
- Benelli TRK 502 - Page 297
 CRANKCASE
MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION

34 39
18 39 38
38
14 17 36
21 37
19 22 23
10
11 20 37
18 24
9 37
37
45
26 44 27
12 13 45 26
8 4 25 5
3
2 15
16
28
35
7 43 46
31

21
40 40 40 40 30
29

40 6
26

20
40 13
41
41 12
41 42
40 29 1
38
39
38
36 40
32
40
41 S 40
33
R
41 41
41
34 41 37
TO

40 40 40 42
41
O

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
M

1 ENGINE CASING
2 O-RING
A

3 IDLE SENSOR
4 SCREW
D

5 CAP
6 OIL SEAL
BA

7 PLATE
8 SCREW
9 SCREW
10 PLATE
11 PLUG
12 SPECIAL SCREW
13 RETAINING WASHER
14 COUPLING
15 O-RING
16 SPECIAL SCREW
17 RUBBER TIP
18 CENTERING BUSHING
19 BUSHING
20 O-RING
21 WATER FITTING
22 SCREW

5 - 46
- Benelli TRK 502 - Page 298
 CRANKCASE
MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
23 OIL FILTER
24 JOINT
25 OIL PRESSURE SENSOR
26 WASHER
27 BEARING
27 BEARING
27 BEARING
27 BEARING
28 DISTRIBUTOR

21
29 SCREW
30 FLANGE
31 GASKET

20
32 OIL PRESSURE VALVE
33 SPECIAL SCREW
34 SCREW
35
36
JOINT
SCREW S
R
37 WASHER
38 SCREW
TO

39 SCREW
40 SCREW
41 SCREW
O

42 SCREW
43 GRUB SCREW
M

44 INSERT
45 CENTERING BUSHING
46 O-RING
A
D
BA

5 - 47
- Benelli TRK 502 - Page 299
 CRANKCASE
MAIN BEARING SHELL AND DRIVE SHAFT INSTALLATION

Install:
• clean the main bearing shells (6)
A
• connecting rod main bearing shells:
• install the connecting rod main bearing shells in the relevant
seats in the top and bottom base.
6

NOTE:_________________________________ A
Align the projections of the main bearing shells with the
slots in the top base Fig. A.
Use copper grease for assembly.

G Sintoflon Grease

21
B

20
IMPORTANT NOTICE
Do not get the main bearing shells mixed up.
To achieve the correct clearance between the connecting
rod support and the bearing shells and to prevent engine
damage, the bearing shells must be installed in their origi-
nal positions.
S
R
• The crankshaft bearing shells are in different sizes, marked
with different letters and colours, as shown in the table.
TO

MAIN BEARING SHELLS

STD COLOUR THICKNESS
A Green 1.5(0/0 + 0.003) mm
O

B Blue 1.5(0/0 + 0.006) mm C

M

C Yellow 1.5(0/0 + 0.009) mm

Ø std seat A green Ø 41(0.007+0.14)
Ø std seat B blue Ø 41(0+0.007)
A

Ø std seat C yellow Ø 41(0.014+0.021)

Ø std seat only A Ø 41(0/+0.007)
D

B Ø 41(0.007+0.014)
C Ø 41(0.014+0.021)
BA

• The support bearing layout is shown on the bottom casing,

as illustrated in Fig. C.

NOTE:_________________________________
In case of replacement of the drive shaft, it is necessary to
replace the connecting rod main bearing shells.

5 - 48
- Benelli TRK 502 - Page 300
 CRANKCASE
DRIVE SHAFT CHECK

Measure:
• the eccentricity of the camshaft
A
A
A
If outside specifications, replace the drive shaft.

Drive shaft eccentricity Size

Drive shaft A: Ø 30 (-0.005, -0.017) mm
B: Ø 32 (-0.028, -0.042) mm

Check:
• The surfaces of the shaft supports (A) Fig. A. B
• The surfaces of the connecting rod supports (A) Fig. A.
If there is any rust/lines/signs of wear, replace the drive shaft.

21
20
S
R
TO
O
M
A
D
BA

5 - 49
- Benelli TRK 502 - Page 301
 CRANKCASE
DRIVE SHAFT INSTALLATION

Once the drive shaft has been inserted, proceed to assemble

the big end Fig. B.
B
Tighten the nuts to the following torque:
T. R .

Torque 25 N*m

NOTE:_________________________________
Lubricate the big end pins with copper grease

Measure:
Once the big end has been assembled, use a thickness gauge
to measure the drive shaft-big end collar Fig. C.

21
Measuring Size
C
Drive shaft - steering head 0.1~0.25 mm

20
NOTE:_________________________________
Measure both big ends.

S
R
TO
O
M
A
D
BA

5 - 50
- Benelli TRK 502 - Page 302
 CLUTCH

10

8 7

9 5

21
14
4
13
3
16 6 2

20
15

S
R
TO

12
11
O

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
1 RING NUT
M

2 SCREW
3 FLANGE
A

4 SPRING
5 PUSHER DISC PLATE
D

6 CLUTCH DISCS
7 BELLEVILLE WASHER
BA

8 RING
9 CLUTCH DRUM
10 WASHER
11 BEARING
12 CLUTCH BELL
13 GUIDE BUSHING
14 ROLLER BEARING
15 PINION
16 SHIM

5 - 51
- Benelli TRK 502 - Page 303
 CLUTCH
CLUTCH AND DISC REMOVAL

Remove:
• the clutch cover screws Fig. A.
A
• clutch cover
• the gasket.

NOTE:_________________________________
In case of gasket anomalies, install a new gasket.

Remove:
• the guide bushing (1) Fig. B
• clutch control shaft (2) Fig. B

21
B

2 1

20
S
R
TO

• Remove the bearing (11*) Fig. C. C

• Remove the fastening nut (1*) and ring (10*) as shown in
the figure, Fig. D.
O
M

(*)Tool for clutch bell ring nut removal/assembly

Code:03200097052000
7*
A
D

(**)Toothed wrench for clutch bell lock

Code:03200097053000
BA

NOTE:_________________________________
Part numbers marked (*) are part of the spare parts table in
Chapter 5 “Clutch”.

10
(**)
(*)

5 - 52
- Benelli TRK 502 - Page 304
 CLUTCH
CLUTCH AND DISC REMOVAL

Take out the disc pack (6*), washer and clutch drum (9*) and the
guide shim (13*).
E

NOTE:_________________________________ 11*
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Clutch”.

6*

21
F

20
8*

S
R
3*
TO
O
M
A
D
BA

5 - 53
- Benelli TRK 502 - Page 305
 CLUTCH
FRICTION DISC CHECK

The following procedure applies to all friction discs.

Check:
A
• Friction disc
If there is any damage/wear, replace the friction discs.

Measure:
• The thickness of the friction disc Fig. A.
If not within specifications, replace the friction discs together.

Disc Size
Friction disc Thickness 2.7(±0.05) mm

NOTE:_________________________________

21
Measure the friction disc in four points.

20
S
R
TO
O
M
A
D
BA

5 - 54
- Benelli TRK 502 - Page 306
 CLUTCH
STEEL DISC CHECK

The following procedure applies to all steel discs.

Check:
B
• The steel disc.
If there is any damage/wear, replace the steel discs all together.

Measure:
• The warping of the steel discs Fig. B.
If not within specifications, replace the steel discs together.

Disc Twist limit

Disc 0.1 (0,-0.05) mm

NOTE:_________________________________

21
Carry out the check, placing the disc on a reference surface
and take the measurements using a thickness gauge.

20
DISC ASSEMBLY

Assemble the discs in the opposite order to their removal, star-

ting with the ring (8*) and then the belleville washer (7*) on the
clutch drum (9*) S C
R
NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
TO

Chapter 5 “Clutch”. 7*
O
M

9*
A
D
BA

5 - 55
- Benelli TRK 502 - Page 307
 CLUTCH
CLUTCH ASSEMBLY

Assemble:
• oil pump pinion (complete with chain) (A)
D
• guide shim (4*)
• clutch bell (8*)
• washer (6*)
• clutch drum complete with discs (8*)
• disc pusher plate (11*)
A
• using a specific tool (**) assemble the fastening ring nut (18)
and washer (6) as shown in the figure Fig. D.
• clutch spring (12*)
• flange (18*)
• fastening screws (13*) to the following torque:
T. R .

Torque 105 N*m

21
E

20
(**)Tool to remove/nstall the clutch bell ring nut
Code:03200097052000

(**)Toothed wrench to lock the clutch bell

Code:03200097053000
S
R
NOTE:_________________________________
Use a punch driver to rebate the fastening ring nut Fig. E.
TO

• insert the bearing (7*)

• renstall the guide bushing and the clutch control shaft (2) on
the cover
O

• insert the gasket

• place the clutch cover, inserting and tightening the cover F
fastening screws to the engine casing.
M

T. R .

Torque 12 N*m
A
D

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
BA

Chapter 5 “Clutch”.

5 - 56
- Benelli TRK 502 - Page 308
 LUBRICATION SYSTEM

14 14
19
20 19
18 20
13

12
8
21 7 1

21
11
10 6
15

5
9

20
16
2
9
4 3
17

S 9
R
TO

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
1 OIL PUMP CHAIN
2 COMPLETE OIL PUMP
O

3 SCREW
4 WASHER
M

5 OIL PUMP PINION

6 OIL PUMP COVER
A

7 OIL PUMP SHAFT

8 ROLLER
D

9 SCREW
10 OUTER ROTOR
BA

11 INNER ROTOR
12 WASHER
13 OIL PUMP
14 BUSHING
15 SCREW
16 INTAKE FILTER FITTING
17 INTAKE FILTER
18 THREADED CAP
19 PLUG
20 O-RING
21 SCREW

5 - 57
- Benelli TRK 502 - Page 309
 LUBRICATION SYSTEM
OIL SUMP AND INTAKE FILTER REMOVAL

Remove:
1. Coils and Spark plugs, see the section entitled “Coil and
A
spark plug removal”.
2. Head timing gear cover, see the chapter entitled “Head
timing gear cover removal”.
3. Chain tensioner, see chapter entitled “Chain tensioner
removal”.
4. Exhaust camshaft, see chapter entitled “Exhaust
camshaft removal”.
E
5. Intake camshaft, see chapter entitled “Intake camshaft
removal”.
6. Head see chapter entitled “Head removal”.
7. flywheel, see chapter entitled “Flywheel removal”.
8. Mobile chain slides, see chapter entitled “Mobile chain
slides removal”.

21
9. Clutch, see chapter entitled “Clutch removal”.

NOTE:_________________________________ B
C
Before removing the oil sump, first drain out any oil in the A

20
engine, removing the magnetic cap.
D
Remove:
• the oil sump fastening screws (E) Fig. A.

Check:
• the oil sump. S
R
If there is any damage replace.
Remove: B
TO

• The seal (A) Fig. B.

• The intake filter fitting (B) Fig. B.
• The intake filter (C) Fig. B.
• The pressure relief valve (D) Fig. B.
O

NOTE:_________________________________
If there is any damage to the above parts, replace.
M

NOTE:_________________________________
If there is any sediment or residue, clean the filtering area
carefully with solvent.
A
D
BA

5 - 58
- Benelli TRK 502 - Page 310
 LUBRICATION SYSTEM
OIL SUMP AND INTAKE FILTER INSTALLATION

Install: C
Proceed using the opposite order to removal.
• Tighten the screws fastening the oil sump (E) to the fol-
lowing torque:
T. R .

Torque 0.6 N*m

E
Tighten:
• the magnetic cap, complete with copper washer, to the
following torque:
T. R .

Torque 25 N*m

21
NOTE:_________________________________
Add engine oil once these steps have been completed.

20
S
R
TO
O
M
A
D
BA

5 - 59
- Benelli TRK 502 - Page 311
 LUBRICATION SYSTEM
PRESSURE-RELIEF VALVE INSTALLATION

Remove:
• Oil sump, see section entitled “Oil sump and intake filter
A
removal”.

Check:
Before installing the valve, make sure all the parts are free from
anomalies Fig. A.
If there is any damage or wear, replace the faulty parts.

Installation:
Install the pressure relief valve (A) with O-ring inside the bottom
casing, by slotting it in Fig. B

NOTE:_________________________________ B

21
Lubricate the pressure relief valve during insertion.

20
A

S
R
TO
O
M
A
D
BA

5 - 60
- Benelli TRK 502 - Page 312
 LUBRICATION SYSTEM
PRESSURE-RELIEF VALVE REMOVAL

Remove:
• Oil sump, see section entitled “Oil sump and intake filter
A
removal”.
• The pressure relief valve (A):

21
20
S
R
TO
O
M
A
D
BA

5 - 61
- Benelli TRK 502 - Page 313
 LUBRICATION SYSTEM
OIL PUMP REMOVAL

Remove:
1. Clutch, see chapter entitled “Clutch removal”.
A
• Use a wrench to block the pump control gear (5*)
• unscrew the screw (3*)
• take out the washer (4*) Fig. A.
• take out the pump pinion (5*)
2. Oil sump, see chapter entitled “Oil sump removal”.
4*
5* 3*

21
Remove:
• the screws (1) Fig. B. B
• slide out the pump body (13*) Fig. B.

20
1 13*

S
R
TO
O

Check: C
• the integrity of the two pins (19*) 19*
M

• the two O-rings (20*) Fig. C.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
A

Chapter 5 “Lubrication circuit”.

D

20*
BA

5 - 62
- Benelli TRK 502 - Page 314
 LUBRICATION SYSTEM
OIL PUMP REMOVAL

Remove:
• the screws (9*)
C
• the pump cover (6*)
C A
• outer rotor (10*)
• inner rotor (11*)
• roller (8*)
• oil pump shaft (7*)

Check:
• the pump body (13*) Fig. D
If there are any lines/damage/wear, replace.

• The pump pinion (5*)

If there is any damage or wear to the gears, replace.
B

21
Measure:
• the tolerance between the inner rotor (11*) and the outer
rotor (10*) ”C”. Fig. E and Fig. C (A)
• the tolerance between the outer rotor (11*) and the oil pump

20
housing (6*) ”E”. Fig. E and Fig. C (B)
• the flatness of both rotors compare to the oil pump housing
(6*) “C” Fig. C.

Clearance
between the inner rotor
Tolerance
S D
R
0.15 mm
and the outer rotor ”A”.
between the outer rotor
13*
TO

and the oil pump housing +0.06, +0.09 mm

“B”
O

Check:

• oil pump operation.

M

Turn the pump pinion (5*) as shown in Fig. F 5*

If the movement is not smooth, check the inner/outer rotor seat.
If there are any lines/damage, replace the
faulty part/s.
A

NOTE:_________________________________ D E
D

This check is carried out after securing the oil pump in the
engine body and inserting the pump pinion (5*) in its seat.
BA

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Lubrication circuit”.

5 - 63
- Benelli TRK 502 - Page 315
 LUBRICATION SYSTEM
OIL PUMP ASSEMBLY

Install:
Proceed using the opposite order to removal.
B
Tighten the assembly screws (1) to the following torque: 1
T. R .
1
Torque 12 N*m

Tighten the assembly screws (3*) with the pump pinion (5*) to
the following torque:
T. R . 1

Torque 7 N*m

NOTE:_________________________________ 1
Add engine oil once these steps have been completed.

21
NOTE:_________________________________

20
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Lubrication circuit”.

S
R
TO
O
M
A
D
BA

5 - 64
- Benelli TRK 502 - Page 316
 GEAR BOX
NEUTRAL POSITION/GEAR INDICATOR SENSOR REMOVAL

Remove:
• the screws (5)
A
Take out:
• the pin (3) Fig. A. 5
• the spring (2) Fig. A.
• the neutral position/gear indicator sensor (1) Fig. A.
• the gasket (4) Fig. B.
2

21
B
1 4

20
3
5 2

S
R
TO
O
M
A
D
BA

5 - 65
- Benelli TRK 502 - Page 317
 GEAR BOX
NEUTRAL POSITION/GEAR INDICATOR SENSOR ASSEMBLY

Assemble: A
• insert the spring (2) Fig. A
• the pin (3) Fig. A
• the gasket (4) Fig. B 5
• the neutral position/gear indicator sensor (1).

NOTE:_________________________________ 2
Before assembly, check the continuity of the sensor (see
the chapter entitled “Electrical system”)
3
Tighten the two screws (5) of the sensor to the following torque:
T. R . 1

Torque 0.6 N*m

21
Use Loctite
B
Loctite 243 1 4 3

20
5 2

S
R
TO
O
M
A
D
BA

5 - 66
- Benelli TRK 502 - Page 318
 GEAR BOX

35
26 44
27 41
28
29 40
30
31
32 39
36
34 36
39

37
38
33 38
37 32

21
33 48
42 45
43
25

20
24
37
23 38
21 47 46
22

7
8
13 21
S
R
9
10
11 20
TO

6 12 19 35
5 13 18
4 14
3 17
2 15
16
O

1
M
A

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
D

1 SELECTOR SHAFT
2 STOP SPRING
BA

3 SHIM
4 BUSHING
5 SEEGER RING
6 SCRAPING
7 PLUG
8 SPRING
9 DESMODROMIC
10 PIN
11 BEARING
12 PLATE
13 SCREW
14 GEAR DRUM
15 WASHER
16 SCREW
17 SCREW
18 GEAR FIXING CLICK ASSEMBLY

5 - 67
- Benelli TRK 502 - Page 319
 GEAR BOX

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
19 WASHER
20 HAIRSPRING
21 SPRING
22 PIN
23 GEAR SELECTION FORK 5TH/6TH
24 GEAR SELECTION FORK 5TH/6TH
25 GEAR SELECTION FORK 1ST/4TH - 2ND/3RD
26 NUT (M18)
27 WASHER

21
28 PINION
29 OIL SEAL
30 BROACHED BUSHING

20
31 O-RING
32 BEARING
33 BEARING RETAINER
34
35
COMPLETE MAIN SHAFT
BEARING S
R
36 ELASTIC RING
37 SCRAPING
TO

38 ELASTIC RING
39 NOTCHED WASHER
40 NOTCHED WASHER
O

41 NOTCHED WASHER
42 NOTCHED WASHER
M

43 NOTCHED WASHER
44 GASKET
A

45 WASHER
46 SCRAPING
D

47 COMPLETE SECONDARY SHAFT

48 SLOTTED NUT (M20)
BA

5 - 68
- Benelli TRK 502 - Page 320
 GEAR BOX
GEAR BOX DISASSEMBLY

Remove:
1. Coils and Spark plugs, see the section entitled “Coil and
E
spark plug removal”.
2. Head timing gear cover, see the chapter entitled “Head
timing gear cover removal”.
3. Chain tensioner, see chapter entitled “Chain tensioner
removal”.
4. Exhaust camshaft, see chapter entitled “Exhaust
camshaft removal”.
5. Intake camshaft, see chapter entitled “Intake camshaft
removal”.
6. Head see chapter entitled “Head removal”.
7. flywheel, see chapter entitled “Flywheel removal”.
8. Mobile chain slides, see chapter entitled “Mobile chain
slides removal”.

21
9. Clutch, see chapter entitled “Clutch removal”.
10. Neutral position/gear indicator sensor, see chapter entitled F
“Neutral position/gear indicator sensor removal”.
11. Oil sump, see chapter entitled “Oil sump removal”.

20
12. Oil pump, see chapter entitled “Oil pump removal”. 2
Remove:
• Base screws Fig. E
• raise the lower base. F
Remove:
• the gearbox output shaft (1) Fig. F
S
R
1
• the gearbox intake shaft (2) Fig. F
TO
O
M
A
D
BA

5 - 69
- Benelli TRK 502 - Page 321
 GEAR BOX
GEAR BOX ASSEMBLY

Measure:
Use a specific gauge to check the size of the hole (1) in the top A
right casing Fig. A.

Housing port
size: Ø 47 (0,+0.022) mm
desmodronic

If outside specifications, replace the bottom casing. 1

Check:
• The grooving on the desmodromic shaft (9) Fig. B.

21
In the presence of damage/lines/signs of wear, replace the who-
le desmodromic shaft. B

20
Assemble:
• the desmodronic (9*) inside the casing
• nstall the bearing (11*) Fig. B

T. R .

Torque 12 N* S
R
NOTE:_________________________________ 9*
TO

Numbers marked (*) are part of the spare parts table in 11*
Chapter 5 “Gears”.

Assemble:
• the gear drum (14*)
O

using the special tool (**) Fig. C C

14*
M

(**) Gear selector drum assembly tool

Code:0320097051000
16*
A

• washer (15*)
• screw (16*) Fig. C to the following torque:
D

T. R .
BA

15*
Torque 12 N*m
(**)
Use Loctite

Loctite 243
D

NOTE:_________________________________
To tighten the screw (16*), use an aluminium pad (1) to keep
the desmodronic in place Fig. D.
1

5 - 70
- Benelli TRK 502 - Page 322
 GEAR BOX
GEAR BOX ASSEMBLY

Assemble:
• the plate (12*)
F
• the 2 screws (13*) Fig. F to the following torque:
12*
T. R .

Torque 12 N*m

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Gears”.
13*

21
20
S
R
TO
O
M
A
D
BA

5 - 71
- Benelli TRK 502 - Page 323
 GEAR BOX
GEAR SHIFT CONTROL

Measure:
The following procedure is applied to all gear shift control rods
G
(1). G.
Check:
• the follower of the gear shift control rod cam (A)
• The tooth of the gear shift control rod (B) B
If there is warping/damage/lines/traces of wear, replace the gear
A
shift control rod .

Measure:
• the thickness of the gear shift control rod, using a slide
gauge.

Part Size

21
Gear shift control rod 5.85 ± 0.05 mm

Check: H

20
• The guide pin of the gear shift control rod (23*)

Roll the guide pin of the gear shift control rod on a flat surface
Fig. H
If there is any warping, replace.

S
R
NOTE:________________________________
Do not try to straighten the control rod guide if it is warped. 23*
TO

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Gears”.
O
M
A
D
BA

5 - 72
- Benelli TRK 502 - Page 324
 GEAR BOX
GEAR BOX ASSEMBLY

Assemble: I
1. spring (21*).
2. gear selection fork 5th/6th (25*). 21*
3. gear selection fork 5th/6th (24*).
4. gear selection fork 1st/4th - 2nd/3rd (23*). 24*
5. spring
NOTE:_________________________________ 25*
see the sequence in Fig. I

Check: 23*
• the two bearing stops (33) Fig. L
If there is any warping/damage/lines/signs of wear, replace. 5

Check:

21
• The seats for the two bearing stops (33) Fig. L
If there is any warping/damage/lines/signs of wear, replace.
L
Assemble:

20
For the assembly sequence of the full input shaft (47), see the
exploded drawing at the start of the chapter.

For the assembly sequence of the full output shaft (34), see the 33* 33*
exploded drawing at the start of the chapter.
S
R
Position
• the full input shaft (47)
TO

• the full input shaft (34)

NOTE:_________________________________
Make sure the grooves on the two bearings (32) and (33)
match correctly.
O

NOTE:_________________________________
M
Before assembling the two half casings, top and bottom, it 47 32
M

is necessary to apply sealant paste along the whole profile

of the top casing, in order to achieve a good hold.
32
A

G PASTE THREEBOND
D
BA

34
Assemble:
Install the bottom casing over the top, taking care to insert
the follower (A) correctly in the segment corresponding to the
desmodronic shaft and the forks (23*-24*-25*) in their respective
seats Fig. N. N

NOTE:_________________________________ 23*
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Gears”.

B 24*

A 25*

5 - 73
- Benelli TRK 502 - Page 325
 GEAR BOX
GEAR BOX ASSEMBLY

Check:
that the end of the gear lock spring (2*) is in its seat on the
O
1*
selector (*1) plate.
Check:
that in the neutral position, the clearance between the two ends
of the spring and the strike pin is “0” Fig. O

Assemble:
• the gear shaft as in Fig. O
“0”

2*

21
Q
Position 1

20
• the gear (2)
• the drive shaft gear (1), locking it into place with the spline
(3) Fig. Q 2

S
R
TO

3
4
O

R
M

Install:
• the guide bushing (5)
• the counter shaft gear (6)
5
• the spline (7) Fig. R
A
D

6
7
BA

S
NOTE:________________________________
Bring the two shaft phasing points into line and check the
drive shaft Fig. S

5 - 74
- Benelli TRK 502 - Page 326
 GEAR BOX
GEAR BOX ASSEMBLY

Install:
• washer
S
• the counter shaft gear nut (6) 2
T. R .

6
Torque 90-100 N*m

Install:
• washer
• drive shaft gear nut (2)
T. R .

Torque 115-125 N*m (**)

21
NOTE:________________________________
To keep the two drive shafts still, it is necessary to use the

20
tool (**) in Fig. S
(**) Gear wrench
Code: 03200097053000

Assemble: S Q
R
41
40

41
after assembling the two half casings, tighten the screws Fig. Q
to the following torque:
TO

42
40

T. R .

40 40
Position screws (40): (M6)
40 40

Position screws (41): (M8)

O

Position screws (42): (M10)

41
M

Rotate the complete casing through 180° and tighten the screws
40

40
Fig. R to the following torque:
A

Position screws (38): (M8)

Position screws (36): (M8)
D

Position screws (34): (M10) R

36
38

Use Loctite while tightening

BA

34

Strong Loctite
39

Casing closure tightness torque

Sequence Size Phases

1°Phase 12 N.m
38

1 M10: 2°Phase 24 N.m

3°Phase 45 N.m
1°Phase 12 N.m
2 M8:
2°Phase 30 N.m
1°Phase 10 N.m
3 M6:
2°Phase 12 N.m

5 - 75
- Benelli TRK 502 - Page 327
 STARTING
STARTER

3 3

2
5
4

7
6

21
8
9

20
10

S
R
TO

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
O

1 STARTER MOTOR
2 O-RING
M

3 SCREW
4 IGNITION SHAFT
5 DOUBLE GEAR
A

6 START GEAR
D

7 FLYWHEEL ROTOR
8 SCREW
BA

9 MAGNET FLYWHEEL
10 COMPLETE FREEWHEEL

5 - 76
- Benelli TRK 502 - Page 328
 STARTING
STARTER REMOVAL

Remove:
1. the screws (3*) Fig. A
A
2. the starter motor (1*) from the clutch Fig. B.

Check:
• starter motor operation.
3*
NOTE:_________________________________
If the starter motor turns with force, replace the part.

• The O-ring gasket.

If there is any damage/spotting/traces of wear, replace the O-
ring gasket.

21
NOTE:_________________________________
Lubricate the O-ring and take care not to damage it.
B

20
S
R
TO
O
M
A
D
BA

5 - 77
- Benelli TRK 502 - Page 329
 STARTING
STARTER INSTALLATION

Install:
Proceed using the opposite order to removal.
A

Assemble:
• the screws (3*) Fig. A to the following torque:

T. R .

Torque 12 N*m
3*
Use Loctite thread sealant to secure.

Loctite 243

21
NOTE:_________________________________
Once the starter motor is assembled, proceed with the cur-

20
rent wire connection.

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Starting”.

S
R
TO
O
M
A
D
BA

5 - 78
- Benelli TRK 502 - Page 330
 STARTING
FLYWHEEL REMOVAL

Remove:
• the cap (1).
A
Use the tool (2*) for this operation Fig. A

(*) Tool to remove the magnetic cap from the alternator

cover
Code: 0320097043000.

2
1

21
Remove:
• the screws (3) Fig. B B
• take out the magnet flywheel cover Fig. B.

20
Use the tool (4*) for this operation Fig. B

(*) Flywheel cover extractor

Code: 0320097042000

S
R
3
TO

Remove: C
O

• the nut (5) Fig. C.

• the washer (6) Fig. C. 7
M

Use the tool (7) for this operation Fig. C

(*) Tool to Tighten/Loosen the flywheel
Code:0320097044000
A
D

6
BA

Remove:
• The flywheel rotor magnet (8). D
Use the tool* (8) for this operation Fig. D
(*) Flywheel cover extractor
Code:0320097045000

5 - 79
- Benelli TRK 502 - Page 331
 STARTING
FREEWHEEL REMOVAL

Remove: D
the assembled freewheel elements (6*) Fig. D.
• the 6 screws (8*). 6*
Check:
• the roller cage and support.
If there are any anomalies or signs of wear, replace the whole
freewheel (6*).

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in
Chapter 5 “Starting”.

21
20
S
R
TO
O
M
A
D
BA

5 - 80
- Benelli TRK 502 - Page 332
 STARTING
FREEWHEEL INSTALLATION

Installation:
7 A
Proceed in the opposite order to removal. 6
Assemble: 8
• the screws (8*) Fig. A to the following torque.

T. R .

Torque 35 N*m 10

Use Loctite thread sealant to secure.

Loctite 243

21
20
S
R
TO
O
M
A
D
BA

5 - 81
- Benelli TRK 502 - Page 333
 STARTING
FLYWHEEL INSTALLATION

Installation:
proceed in the opposite order to removal.
A

Assemble:
• the nut (5) Fig. A
• the washer (6) Fig. A.
Tighten the nut (5) to the following torque.

T. R .

Torque 90 N*m

21
Assemble:
• the flywheel magnet cover B

20
• gasket (7)

NOTE:_________________________________
When closing the magnet flywheel cover Fig. B pay atten-
tion to the gasket.
If the gasket is damaged, it must be replaced with a new
one. S
R
Assemble:
• the screws (3) Fig. C
TO

to the following torque:

T. R .
O

Torque 12 N*m C
M
A
D
BA

5 - 82
- Benelli TRK 502 - Page 334
 STARTING
STARTER GEAR REMOVAL

Remove: E
1. Flywheel, see chapter entitled “Flywheel removal”. 1

Remove:
• the satellite starter gear (1) Fig. E
• the freewheel starter gear (2) Fig. F
• the spline (3) Fig. F

21
F

20
S
R
TO

3
O
M
A
D
BA

5 - 83
- Benelli TRK 502 - Page 335
 STARTING
STARTER GEAR ASSEMBLY

To assemble the chain slides, follow the removal process in the opposite order.

21
20
S
R
TO
O
M
A
D
BA

5 - 84
- Benelli TRK 502 - Page 336
 STARTING
PHASE SENSOR

11 12
7
6 1
9 14

21
8

20
2 13
1
3

5
15
S
R
4
10
TO

8
O

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
M

DESCRIPTION
1 BUSHING
2 O-RING
A

3 THREADED CAP
D

4 MAGNETIC CAP
5 O-RING
BA

6 SCREW
7 PHASE SENSOR
8 SCREW
9 ALTERNATOR COVER
10 PINION COVER
11 PLATE
12 SCREW
13 THE FLYWHEEL COVER GASKET
14 SCREW
15 SCREW

5 - 85
- Benelli TRK 502 - Page 337
 STARTING
PHASE SENSOR REMOVAL

Disconnect:
• The connector for the phase sensor (7*):
A
Remove:
• the screw (6*) Fig. A 7*
• the phase sensor (7*) Fig. A
Check:
the integrity of the phase sensor.

6*

21
20
S
R
TO
O
M
A
D
BA

5 - 86
- Benelli TRK 502 - Page 338
 STARTING
PHASE SENSOR INSTALLATION

Assemble: B
• the phase sensor (7*) 7*
• the fastening screws (6*) to the following torque: B:
T. R .

Torque 12 N*m

Measure: 6*
• the distance (A) between the phase sensor (7*) and the
pick-up on the flywheel magnet Fig. B.

NOTE:_________________________________
A
Use a thickness gauge to take this measurement

21
20
S
R
TO
O
M
A
D
BA

5 - 87
- Benelli TRK 502 - Page 339
 POWER SYSTEM
THROTTLE BODY

21
35 29
5
28 8
31 9 51
34
33 27
32
9 26
31 30
20
38 15 7
48 19
39 40 18
25
17
45 36 23
15 22
16
48 47 24

21
50 49
23
41 11
35 45 40 50 49 10
38 15
37

20
14
52
38 6
42 12
5 3
46 13
4
43
14 S 12
2
1
R
44
14
TO

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
O

1 NUT
2 SCRAPING
M

3 FLANGE
4 WASHER
5 WASHER
A

6 OIL SEAL
D

7 SHAFT
8 THROTTLE VALVE FLANGE
BA

9 SCREW
10 BUSHING
11 SPRING
12 SCREW
13 BRACKET
14 STEERING RING NUT
15 SCREW
16 INSERT
17 CAP
18 INJECTOR
19 BRACKET
20 MAP SENSOR
21 SCREW
22 PIPE
23 PIPE GLAND CLIP
24 INSERT

5 - 88
- Benelli TRK 502 - Page 340
 POWER SYSTEM

INTERVENTION
Pos. Description Qty. SQ. SYMBOLS REMARKS
DESCRIPTION
25 SEALING RING
26 PLATE
27 SCREW
28 ROLLER BEARING
29 SEEGER
30 PLATE
31 SCREW
32 POTENTIOMETER
33 WASHER

21
34 SCREW
35 SCREW
36 THROTTLE VALVE

20
37 PIPE
38 CLIP
39 PIPE
40
41
PIPE
SPECIAL PLATE S
R
42 O-RING
43 STEPPER MOTOR
TO

44 SPECIAL WASHER
45 BUSHING
46 PIPE
O

47 DISTRIBUTOR
48 VIBRATION DAMPING RUBBER
M

49 SCREW
50 O-RING
51 SCREW
A

52 THROTTLE VALVE
D
BA

5 - 89
- Benelli TRK 502 - Page 341
 POWER SYSTEM
THROTTLE VALVE REMOVAL

Remove:
• Rider and passenger seats, see chapter entitled “Removal A
of rider and passenger seats, Chapter 4”. 3
• Fuel tank, see chapter entitled “Fuel tank removal , Chap-
ter 4”.
• Air filter, see chapter entitled “Air filter removal, Chapter 2
4”.

Remove:
• the 2 intake pipes (1) Fig. A.
• the gaskets 1
• the screws (2) Fig. A
• loosen the screw clips (3) Fig. A.

21
Disconnect: B
• the injector connections (3)

20
• the connections of the pressure sensor (4) from the electric
backbone to the throttle valve assembly, Fig. B

S 4
R
TO

3
O

C
• the connection (5) of the distributor, Fig. C
M

5
A
D
BA

Disconnect: D
• the bottom ends of the accelerator cable (6) before loose- 8
ning the cable nut supports (7) 6
• the bottom nuts (8) Fig. D
7
• take out the throttle valve.

5 - 90
- Benelli TRK 502 - Page 342
 POWER SYSTEM
THROTTLE VALVE INSTALLATION

Installation:
E
Proceed using the opposite order to removal.

IMPORTANT NOTICE 9
During assembly of the accelerator cables, take care to 10
insert the hood (9) on the control line (10) Fig. E.

21
20
S
R
TO
O
M
A
D
BA

5 - 91
- Benelli TRK 502 - Page 343
 21
20
6 RS TO
O
M
A
D
BA

6-1
- Benelli TRK 502 - Page 344
 CHAPTER 6

COOLING SYSTEM
WATER PUMP ...............................................................................................................................................3
WATER PUMP REMOVAL ..........................................................................................................................................................4
WATER PUMP INSTALLATION ..................................................................................................................................................5
THERMOSTAT ...............................................................................................................................................6
THERMOSTAT REMOVAL..........................................................................................................................................................6
THERMOSTAT INSTALLATION ..................................................................................................................................................7
WATER MANIFOLD .......................................................................................................................................8
WATER MANIFOLD REMOVAL..................................................................................................................................................8
WATER MANIFOLD INSTALLATION ..........................................................................................................................................9
HEAT EXCHANGER ....................................................................................................................................10
HEAT EXCHANGER REMOVAL...............................................................................................................................................10
HEAT EXCHANGER INSTALLATION .......................................................................................................................................11

21
RADIATOR ...................................................................................................................................................12
DISASSEMBLE THE RADIATOR .............................................................................................................................................13
RADIATOR INSTALLATION......................................................................................................................................................15

20
S
R
TO
O
M
A
D
BA

6-2
- Benelli TRK 502 - Page 345
 WATER PUMP

21

20

19 18
21
14
11 1
9 15
4

21
10 2

5 19

20
12 13 6 17
S 7
R
3 6
16
8
TO

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
O

DESCRIPTION
1 WATER PUMP IMPELLER
M

2 SEALING RING
3 OIL SEAL
4 WATER PUMP COVER
A

5 O-RING
6 BEARING
D

7 SEEGER RING
BA

8 WATER PUMP SHAFT

9 SCREW
10 COMPLETE WATER PUMP
11 L-SHAPED JOINT
12 SCREW
13 WASHER
14 WATER PUMP BODY
15 SCREW
16 BUSHING
17 SEEGER RING
18 SLEEVE
19 SCREW CLIP
20 PIPE
21 SPRING

6-3
- Benelli TRK 502 - Page 346
 WATER PUMP
WATER PUMP REMOVAL

Remove:
• Gear lever, see the section entitled “Gear lever installation”
A
in Chapter 4
• the bands (19*) Fig. A
• the water inlet manifold (2) Fig. A
• the water return manifold (3) Fig. A 19*
• the screws (9*) Fig. A
3
9*
NOTE:_________________________________
Drain out all coolant by taking out the screw (12*) before
proceeding with removal operations, as shown in Fig. A. 12*
2
• Take out all parts following the sequence shown in the ex-
ploded drawing, then check the entirety of each single part.
If any of the parts should show signs of wear, replace. B

21
IMPORTANT NOTICE
In case of faulty seals (2*), it is possible to notice leaks from the

20
howl shown in Fig. B

NOTE:_________________________________
Numbers marked (*) are part of the spare parts table in the
Chapter entitled “Cooling Circuit”, in the “radiator removal” S
R
section.
TO

C
Check:
• Water pump impeller (1*) Fig. C 1
• sealing ring (2*) Fig. C 2
• O-ring (5*) Fig. C
O

• oil seal (3*) Fig. C 5

• bearing (6*) Fig. C
• bushing (16*) Fig. C 6
M

• water pump shaft (8*) Fig. C

3 6
16
8
A
D
BA

6-4
- Benelli TRK 502 - Page 347
 WATER PUMP
WATER PUMP INSTALLATION

Install: A
Proceed to assemble the pump, lubricating it with engine oil:
• the pump shaft (8*)
• the bushing (16*)
• the bearings (6*)

NOTE:_________________________________
When inserting the pump, take care to ensure that the
groove on the water pump shaft (8*) is facing in the direc-
tion shown in Fig. A.

Install:

• the screws (9) and tighten to the following torque:

21
T. R .

Torque 12 N*m

20
Use Loctite thread locker to secure.

Loctite 242

S
R
TO
O
M
A
D
BA

6-5
- Benelli TRK 502 - Page 348
 THERMOSTAT
THERMOSTAT REMOVAL

Remove:
• Right-side bodywork, see the section in Chapter 4 entitled
A
“front bodywork”.
• screws (3) Fig. A
• thermostat (4) Fig. B
3
NOTE:_________________________________
Drain out the coolant before proceeding with these opera-
tions.
Check:
• The by-pass port (A)
If clogged, replace.
• Thermostat (4)
If this does not open at 75° ~ 90° C (167~ 194° F), replace, Fig.
B.
B

21
Thermostat check
1. Immerse the thermostat in a container filled with water Fig.
D.

20
2. Slowly heat the water.
3. Immerse a thermometer in the water. 4
4. Mix the water again, keeping an eye on the thermostat and
on the temperature shown on the thermometer.
5. When the water reaches a temperature of 75°C, the thermo-
stat valve will start to open, reaching a temperature of 90°C.
The thermostat valve reaches an opening of 7 mm. S
R
Key to Fig. D: C
TO

A
1. Thermometer
2. Container
3. Water
4. Thermostat
O

4
Thermostat opening/closure chart Fig. E
M

A. Fully closed
B. Fully open
A

IMPORTANT NOTICE
D
D

If there are any doubts about the precision of the thermostat, it 1

should be replaced. A faulty thermostat can cause notable over-
BA

heating or overcooling.

2
3
4

E
B
7
apertura(mm,
opening in)
(mm,in)

A
0
75°C (167°F) 90°C (194°F)
temperatura
temperature

6-6
- Benelli TRK 502 - Page 349
 THERMOSTAT
THERMOSTAT INSTALLATION

Install:
• Install the thermostat so that the bypass port (A) is facing
A
upwards. A
• the screws (3) and tighten to the following torque:

T. R .

5
Torque 12 N*m

Use Loctite thread locker to secure the screws.

Loctite 242

21
NOTE:_________________________________
Fill with coolant after completing these operations.

20
S
R
TO
O
M
A
D
BA

6-7
- Benelli TRK 502 - Page 350
 WATER MANIFOLD
WATER MANIFOLD REMOVAL

Remove:
• Coolant
A
• Manifolds drain, see the section entitled “Exhaust assem-
bly removal” in Chapter 4.
• the bands (1) Fig. A
• the screws (3) Fig. A
• the water manifold (2) Fig. A 2
• the seal (4) Fig. B

If there is any damage/breakage, replace the above parts.

3 1

21
B

20
4

S
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TO
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M
A
D
BA

6-8
- Benelli TRK 502 - Page 351
 WATER MANIFOLD
WATER MANIFOLD INSTALLATION

Install:
Carry out the removal steps in reverse order
A

• the screws (3) and tighten to the following torque:

T. R .

Torque 12 N*m

Use Loctite thread locker to secure the screws.

3
Loctite 242

21
NOTE:________________________________
Fill with coolant after completing these operations.

20
S
R
TO
O
M
A
D
BA

6-9
- Benelli TRK 502 - Page 352
 HEAT EXCHANGER
HEAT EXCHANGER REMOVAL

Remove:
• Coolant
A
• Manifolds drain, see the section entitled “Exhaust assem-
bly removal” in Chapter 4.
• the bands (1) Fig. A
• the hose (2) Fig. A
2
• the hose (3) Fig. A
• the distributor cap (4) Fig. A-B 1
• the seal (6) Fig. B

21
1 3

20
Check: B
• (visually) for any build up or breaks on the distributor cap
• the seal (6) Fig. B

NOTE:________________________________
If any of the parts should show signs of damage/breakage, S
R
replace.
TO

4 6
O
M

Remove:
• the special screw (7) Fig. C C
• the distributor (8) Fig. C
A

• the fitting (9) Fig. C 9

• the seal (10) Fig. C
D

8
NOTE:________________________________
7
BA

If any of the parts should show signs of damage/breakage,

replace.

10

6 - 10
- Benelli TRK 502 - Page 353
 HEAT EXCHANGER
HEAT EXCHANGER INSTALLATION

Install:
Proceed to install the distributor following the removal steps in
C
reverse order.
• the special screw (7) to the following torque:
T. R .

Torque 60 N*m

• the distributor cap to the following torque:

T. R .

Torque 25 N*m

21
NOTE:________________________________
If not worn, re-use the previously removed bands; other-
wise, fit new ones.

20
NOTE:________________________________
Fill with coolant after completing these operations.

S
R
TO

A
O
M
A
D
BA

6 - 11
- Benelli TRK 502 - Page 354
 RADIATOR

22 22

21
22

21
20
S
R
TO

CONTENTS
Pos. Description Qty Sq. SYMBOLS REMARKS
O

DESCRIPTION
1 SCREW
M

2 BUSHING
3 RUBBER TIP
4 WATER RADIATOR
A

5 BUSHING
D

6 INTAKE HOSE
7 WATER TANK CAP
BA

8 WATER TANK
9 SCREW
10 VIBRATION DAMPING RUBBER
11 PIPE
12 PIPE
13 CLIP
14 PIPE
15 SCREW CLIP
16 SLEEVE
17 SLEEVE
18 CLIP
19 PINION COVER
20 SCREW
21 ELECTRIC FAN

6 - 12
- Benelli TRK 502 - Page 355
 RADIATOR
DISASSEMBLE THE RADIATOR

Remove:
• Side bodywork, see the section in Chapter 4 entitled “front
A
bodywork”.
NOTE:_________________________________
Drain out all coolant by taking out the screw (12*) before
proceeding with removal operations, as shown in Fig. A. 19*
3
• the bands (19*) Fig. A 9*
• water inlet manifold (2) Fig. A
• water return manifold (3) Fig. A
• screws (9*) Fig. A 12*
2
NOTE:________________________________
To make it easier to drain out coolant, it is necessary to
open the radiator cap at the same time. B

21
Remove:
• the screws (3) fastening the radiator bracket to the frame.
Fig. B

20
• the fastening screws on the opposite side. 3

S
R
• the fastening bands (4) and (5) Fig. C. C
TO

4
O

5
M
A

Disconnect
• the recirculation hose of the expansion tank (6) from the D
D

coolant expansion tank Fig. D

BA

E
• The cooling fan connector (7) Fig. E

6 - 13
- Benelli TRK 502 - Page 356
 RADIATOR
DISASSEMBLE THE RADIATOR

Check:
• the radiator fins.
E
If clogged, clean.
Use a jet of compressed air on the back of the radiator.

NOTE:________________________________
Straighten any bent fins using a fine flathead screwdriver

Check:
• the radiator hoses.
• the radiator pipes.
If there is any cracking/damage, replace.
• the radiator fan
If there is any damage, replace.

21
In case of malfunction, check and repair.

20
S
R
TO
O
M
A
D
BA

6 - 14
- Benelli TRK 502 - Page 357
 RADIATOR
RADIATOR INSTALLATION

Install:
Once each individual part has been checked, proceed to install F
the radiator following the removal steps in reverse order.

• the screws to fasten the radiator to the bracket on the

frame, tightening to the following torque:

T. R .

Torque 10 N*m

• The bands must always be replaced once they have been

opened.

• Once the parts have been assembled, connect the wiring to

21
the radiator bulb and fan and proceed to fill the circuit, Fig. F

NOTE:________________________________

20
While filling, pinch the manifold close to the fluid inlet mani-
fold in order to eliminate any air bubbles, Fig. F.

S
R
TO
O
M
A
D
BA

6 - 15
- Benelli TRK 502 - Page 358
 21
20
S
R
TO
7
O
M
A
D
BA

ELE. - 16
- Benelli TRK 502 - Page 359
 ELECTRICAL SYSTEM
SENSORS.......................................................................................................................................................3
DESCRIPTION OF THE ENGINE MANAGEMENT SYSTEM.....................................................................................................3
COOLANT TEMPERATURE SENSOR........................................................................................................................................4
GEAR POSITION SENSOR........................................................................................................................................................5
PHASE SENSOR........................................................................................................................................................................6
AIR TEMPERATURE SENSOR...................................................................................................................................................7
SIDE STAND SWITCH................................................................................................................................................................8
LAMBDA PROBE.........................................................................................................................................................................9
OIL PRESSURE SENSOR........................................................................................................................................................10
FRONT BRAKE MICROSWITCH..............................................................................................................................................11
IDROSTOP................................................................................................................................................................................12
CLUTCH SWITCH.....................................................................................................................................................................13

21
MAP SENSOR (MANIFOLD ABSOLUTE PRESSURE)............................................................................................................14
POSITION SENSOR OF THE THROTTLE BODY UNIT (POTENTIOMETER).........................................................................15
DEVICES.......................................................................................................................................................16

20
DEVICES POSITION.................................................................................................................................................................16
RIGHT ELECTRIC DEVICE.......................................................................................................................................................17
STARTING RELAY (REMOTE CONTROL SWITCH)................................................................................................................18
HORN........................................................................................................................................................................................19
INSTRUMENTATION DASHBOARD.........................................................................................................................................20
S
MASTER SWITCH.....................................................................................................................................................................21
R
VOLTAGE REGULATOR...........................................................................................................................................................22
LEFT ELECTRIC DEVICE.........................................................................................................................................................23
CONVERTER OF CAN BUS SIGNALS . ..................................................................................................................................24
TO

INJECTION ECU.......................................................................................................................................................................25
INJECTION ECU CONNECTIONS............................................................................................................................................27
INDICATOR LIGHT INTERMITTENCE......................................................................................................................................28
ABS BUTTON............................................................................................................................................................................29
O

SERVICES RELAY....................................................................................................................................................................30
STATOR.....................................................................................................................................................................................31
M

ACTUATORS................................................................................................................................................32
POSITION OF ACTUATORS.....................................................................................................................................................32
IDLE AIR CONTROL SYSTEM (STEPPER)..............................................................................................................................33
A

INJECTORS...............................................................................................................................................................................34
IGNITION COILS.......................................................................................................................................................................35
D

COOLING FAN..........................................................................................................................................................................36
FUEL PUMP...............................................................................................................................................................................37
BA

FUEL LEVEL SENSOR..............................................................................................................................................................38

STARTER..................................................................................................................................................................................39
STARTER..................................................................................................................................................................................40
ABS ECU...................................................................................................................................................................................41
BATTERY......................................................................................................................................................44
VEHICLE BATTERY..................................................................................................................................................................44
BATTERY EFFICIENCY CONTROL..........................................................................................................................................45
DIAGNOSTICS..............................................................................................................................................46
VEHICLE DIAGNOSTICS..........................................................................................................................................................46
ELECTRICAL SYSTEM................................................................................................................................47
WIRING DIAGRAM OF TRK502 ELECTRICAL SYSTEM.........................................................................................................47
COLOUR KEY...........................................................................................................................................................................48

ELE. - 17
- Benelli TRK 502 - Page 360
 SENSORS
DESCRIPTION OF THE ENGINE MANAGEMENT SYSTEM

Each model is equipped with an electronic system of engine management featuring a control, which includes both starting and distri-
bution of fuel.
The electronic control module (ECM) gets information from the sensors around the engine, the cooling/intake systems and calculate
precisely the ignition advance and the need of fuel for all engine speeds/loads.
Furthermore, the system features hardware diagnostic functions in compliance with the provisions of the US State of California for
on-board diagnostics.
In the event of a system failure, this function ensures that the type of fault and the engine data at the time of fault are stored in the
ECM memory.
The stored data can be recovered by means of an apposite service equipment available at any Benelli’s Dealer (see Texa instruction
manual),
thus allowing a precise fault diagnostic and the immediate solving of the defect.

21
20
S
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TO
O
M
A
D
BA

ELE. - 18
- Benelli TRK 502 - Page 361
 SENSORS
COOLANT TEMPERATURE SENSOR

It is situated close to the cylinder head (A), Fig. A,

and calculates the information of temperature and coolant re-
A
ceived from the ECM that are used to optimize the supply to all
engine temperatures and to calculate the supply requirements in
the heat and cold setting off.

21
A

20
CHECKLIST

S
R
TO
O
M
A
D
BA

ELE. - 19
- Benelli TRK 502 - Page 362
 SENSORS
GEAR POSITION SENSOR

It is situated on the left side of the engine, close to the pinion,

and detects the position of the gear.

Disconnect:
• The electrical coupling.
Remove:
• The gear position sensor from the half casing.
Check:
• The continuity.

Ø 3: Neutral
Ø 3.5: Grey for Neutral
1. brown/yellow first gear
2. green/black second gear
3. green/blue third gear

21
4. yellow/blue fourth gear
5. brown/red fifth gear
6. yellow/red sixth gear

20
S
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A
D
BA

ELE. - 20
- Benelli TRK 502 - Page 363
 SENSORS
PHASE SENSOR

It is situated close to the left engine casing (1), Fig. A.

A
The position sensor of the crankshaft shows the movement of 1
a sprocket fixed to the right end of the drive shaft by reading a
particular wheel consisting of 28 equidistant teeth near to a triple
length space.
The interpretation of such reading is used by the ECM to fix the
position of the drive shaft in relation to the point in which fuel is
injected and to the requirements of fuel ignition.

Disconnect:
• The main wiring connector.
Measure:
• The resistance value at points A and B of engine (Fig. B).

21
B

20
Standard 550± 50 Ω (20°C)

NOTE:________________________________
If the measured resistance is lower than the stipulated val-
ue, the inner coil might be an open circuit or short-circuited, S
R
therefore it is necessary to replace it.
TO
O
M
A
D
BA

ELE. - 21
- Benelli TRK 502 - Page 364
 SENSORS
AIR TEMPERATURE SENSOR

Working principle of intake air temperature sensor

Within the sensor temperature range, the resistance varies
A
according to the various temperature. It is distinguished by the
negative temperature coefficient resistor. It is a part that can not
be maintained.
Appearance of intake air temperature sensor (see Fig. A):

Measured temperature Resistance value

(°C) (Ω)
0 9.399
5 7.263
10 5.658
15 4.441

21
20 3.511
25 2.795

20
30 2.240

S
R
TO
O
M
A
D
BA

ELE. - 22
- Benelli TRK 502 - Page 365
 SENSORS
SIDE STAND SWITCH

It is situated near the supporting plate of the side stand (A), Fig. G
G.

If the gear is engaged and the stand is open, and therefore the
circuit is open, the ECU prevents starting or shuts off the engine
(if rotating).

Check: A
• The continuity using the multitester.

STAND PIN 1 PIN 2

21
Raised
• •
Lowered
• •

20
NOTE:________________________________
When the above conditions are fulfilled, the sensor is work-
ing, otherwise replace the part.

S
R
TO
O
M
A
D
BA

ELE. - 23
- Benelli TRK 502 - Page 366
 SENSORS
LAMBDA PROBE

They are situated on the exhaust manifold (A), Fig. L. L

The lambda probe serves to detect the oxygen concentration in
the exhaust gases. More precisely, the lambda value indicates
the air/petrol ratio, in which:
• Value 1, when combustion is stoichiometric
• <1, in case of fuel excess
• <1, in case of air excess
The probe transmits the electric signal to the ECU, which con-
trols the insertion of fuel and air into the combustion chamber.
A
-- Threshold value of air-fuel ratio: >750 mVcc
-- Dilute threshold of air-fuel ratio: >120 mVcc
-- Heating power of lambda probe: 7.0 W
-- 450°C exhausted gas temperature, 70% duty ratio, 10Hz,

21
13.5V voltage.
-- Heating power: 9.6±1.5Ω (measured at 21°C)
-- Operating temperature range: 260-850°C

20
CHARACTERISTIC OPERATING CURVE

S
R
TO
O
M
A

COUPLER
D
BA

ELE. - 24
- Benelli TRK 502 - Page 367
 SENSORS
OIL PRESSURE SENSOR

It is situated on the lower half casing and measures oil pressure

in the bushing gallery (A), Fig. M.
M

It indicates the presence of sufficient oil pressure to the dash-

board.

Disconnect:
• The electrical coupling. A
Remove:
• The oil pressure sensor

from the half casing.

Check:
• The continuity between the PIN1 and the sensor ground

21
by means of an air pressure regulator with insertion on the
detection hole.
• Set the air pressure regulator at 2 bar.
• Reduce pressure gradually to reach 0.2 - 0.3 bar.

20
Continuity between PIN1 and
ground
0.2 - 0.3 bar
S
R
NOTE:________________________________
TO

If there is no continuity between PIN1 and engine ground,

replace the part.
O
M
A
D
BA

ELE. - 25
- Benelli TRK 502 - Page 368
 SENSORS
FRONT BRAKE MICROSWITCH

It is a switch in contact with the brake lever, situated on the front

brake pump, which serves to switch on the stop lights (A), Fig.
N
N.

A
Check:
• The continuity
by positioning the multitester on the symbol →|- (function diode/
continuity test) to check operation, as shown in the table.

SENSOR PIN 1 PIN 2

Brake lever Pulled
• •
• •

21
Brake lever Released

NOTE:________________________________

20
When the above conditions are fulfilled, the front brake sen-
sor is working properly, otherwise replace the part.

S
R
TO
O
M
A
D
BA

ELE. - 26
- Benelli TRK 502 - Page 369
 SENSORS
IDROSTOP
It is a switch situated on the rear brake pump, which reads the
O
oil pressure exerted on the pump. A
It serves to switch the stop lights on (A), Fig. O.

Check:
• The continuity
by positioning the multitester on PIN 1 and PIN 2 and checking
the table.

BRAKE PIN 1 PIN 2

Pulled
• •
Released
• •

21
NOTE:________________________________
When the above conditions are fulfilled, the front brake sen-

20
sor is working properly, otherwise replace the part.

S
R
TO
O
M
A
D
BA

ELE. - 27
- Benelli TRK 502 - Page 370
 SENSORS
CLUTCH SWITCH

It is situated on the clutch lever and serves to prevent the engine

from starting before the lever is completely pulled (A) Fig. P.
P
A
Disconnect:
• The clutch switch cables.
Use:
• The tester and check the clutch switch pins referring to the
table.

CLUTCH PIN 1 PIN 2

Pulled
• •
Released
• •

21
NOTE:________________________________
When the above conditions are fulfilled, the front brake sen-

20
sor is working properly, otherwise replace the part.

S
R
TO
O
M
A
D
BA

ELE. - 28
- Benelli TRK 502 - Page 371
 SENSORS
MAP SENSOR (MANIFOLD ABSOLUTE PRESSURE)

It is situated close to the throttle body and serves to detect the

absolute pressure on the intake manifold. It reflects the size
of inlet pressure, which can be converted to air intake volume
accessing the combustion chamber of the engine.

21
20
S
R
TO
O
M
A
D
BA

ELE. - 29
- Benelli TRK 502 - Page 372
 SENSORS
POSITION SENSOR OF THE THROTTLE BODY UNIT (POTENTIOMETER)

It is situated on the right end of the shaft of the throttle Q

body unit. A
The position sensor of the throttle body unit (potentiometer),
controlled and supplied directly by the ECM, gives out a signal,
which identifies the throttle opening position used by the ECM to
determine fuel dosage and ignition advance (A), Fig. Q.

Disconnect:
• The electrical coupling.
Check:
• The resistance using the multitester on symbol Ω between
pin 1 and pin 2.

TOTAL RESISTANCE 2K Ω ± 20%

21
20
S
R
TO
O
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A
D
BA

ELE. - 30
- Benelli TRK 502 - Page 373
 DEVICES
DEVICES POSITION

1 5

2 6

21
4
7

20
9
10

12 S
R
8
TO

11
O
M

Position Device
A

1 RIGHT ELECTRIC DEVICE

D

2 STARTING RELAY
3 HORN
BA

4 INSTRUMENTATION
5 IGNITION SWITCH
6 REGULATOR
7 LEFT ELECTRIC DEVICE
8 INJECTION ECU
9 LIGHT CONTROL RELAY
10 SERVICES RELAY
11 STATOR
12 CONVERTER OF CAN BUS SIGNALS

ELE. - 31
- Benelli TRK 502 - Page 374
 DEVICES
RIGHT ELECTRIC DEVICE

It is situated on the right side of the handlebar Fig. 1. The right

electric device consists of:
1
• RUN/OFF button (A)
A
it serves to break contact to the electric device in
case of emergency.
• Ignition button (C)
it serves to start the engine.
• Hazard lights switch (B)
B
it serves to activate the hazard lights in case of emer-
gency.

Check:
• The continuity C
by positioning the multitester on RUN/OFF button located on
ON.

21
Check:
• The continuity
by positioning the multitester on the ignition button pressed on

20
ON.

Check:
• The continuity
by positioning the multitester on the hazard lights switch located
on ON.
S
R
Refer to the table.
TO

AR/BL AR/GR N R MR/GR VE/GL

O
M
A
D
BA

ELE. - 32
- Benelli TRK 502 - Page 375
 DEVICES
STARTING RELAY (REMOTE CONTROL SWITCH)

It is situated close to the fuse block and breaks power contact

on the starter (1) Fig. A.
A
Apply:
• 12 volt to terminals (2) and (3) Fig. B 1
Check:
• The continuity between power terminals.
In presence of continuity, the starter relay works properly.

WARNING
Do not apply the battery voltage to the starter relay for more
than 5 seconds to prevent overheating and damages to
winding.

Check:
• If the winding Fig. B.

21
is “open” or “grounded” and if there is resistance.
The winding is in good working order if the resistance is:
B

20
Starting relay resistance 3-6Ω

S 2 3
R
TO
O
M

B
A
D
BA

ELE. - 33
- Benelli TRK 502 - Page 376
 DEVICES
HORN

It is situated on the left side of the frame close to the radiator (1) A
Fig. A.
The horn is an electromechanical device, which serves as
acoustic warning device.
1
Connect:
• PIN1 and PIN2 to the battery and check.
Check:
• After the external horn being connected to rechargeable
battery, if there is any sound, it refers to normal operation.

Resistance value: 3.2 Ω

21
20
S
R
TO
O
M
A
D
BA

ELE. - 34
- Benelli TRK 502 - Page 377
 DEVICES
INSTRUMENTATION DASHBOARD

It is situated on the headlight instrumentation support frame.

The instrumentation provides all information

concerning the motorcycle operation to the driver:

INDICATOR LIGHTS:
• high beam light
• left indicator light
• right indicator light
• neutral position indicator light
• injection fault indicator light
• ABS light
• oil pressure warning light

COOLANT TEMPERATURE GAUGE

21
• It indicates the coolant temperature.
TACHOMETER
• It indicates the number of revolutions per minute of the
engine.

20
SPEED
• It indicates the vehicle speed in km or miles.
TRIP
• It indicates the distance travelled from the reset.
TOTAL
• It indicates the total distance travelled.
S
R
Pin-out (see table)
TO
O
M
A
D
BA

ELE. - 35
- Benelli TRK 502 - Page 378
 DEVICES
MASTER SWITCH

The ignition switch (1), Fig. A, is positioned behind the steering A

sleeve and serves to:
• Provide the main contact to the electrical system 1

SH
• Close the steering block.
• Keep the parking lights on for all conditions required.

PU
Check:
• The continuity
using the multitester and referring to the table.

COLOUR V/G R/B

PIN PIN 1 PIN 2
Key ON
• •

21
Key OFF

Lock

20
When the above conditions are fulfilled, the ignition switch is
working properly, otherwise replace the part.

• Key in position “ON” S

R
All electric circuits are activated, the instrumentation and the
lights carry out the self-diagnostics. The engine can be started.
TO

The key cannot be removed.

• Key in position “OFF”

All electric circuits are deactivated, the key can be removed.
O

• Key in position “LOCK”

All electric circuits are deactivated and the steering is locked.
M

The key can be removed.

A
D
BA

ELE. - 36
- Benelli TRK 502 - Page 379
 DEVICES
VOLTAGE REGULATOR

It is situated on the left side of the vehicle close to the water

radiator and allows balancing of electrical consumption via the A
battery recharge (A), Fig. 6.

1. Multimeter selection: diode test.

2. Connect the black probe to the red line terminal of voltage
regulator. Connect the red probe to the white line terminal of
voltage regulator (white 1, white 2 and white 3). The pointer
shows a certain value (value range 0.1~0.5V) indicating the 3
need of replacing the regulator.
3. Connect the red probe to the red line terminal of voltage 2
regulator port. Connect the black probe to the white line
terminal of voltage regulator (white 1, white 2 and white 3).
The pointer shows a certain value (value range 0.3~0.8V)
1
indicating the need of replacing the regulator.

21
MULTIMETER
A

20
20 30
0 10

S - +
R
TO

- +
O
M
A
D
BA

ELE. - 37
- Benelli TRK 502 - Page 380
 DEVICES
LEFT ELECTRIC DEVICE

It is situated on the left side of the handlebar Fig. 7. The left

electric device consists of:
7
• Light switch control (A) D
for switching-over the high/low beam. A
• Indicator lights control (B)
by moving the control to the right or to the left, the relevant indi-
cator lights are activated.
The returns to the centre. Press to deactivate the indicator lights.

• Horn switch button (C)

press to activate the horn. B
• High beam flash button (D) C
It is used to signal the presence in conditions of poor visibility.

21
Check:
• The continuity using the multitester positioned on the rele-
vant terminals with the button pressed.

20
Check:
• The continuity
by positioning the multitester on the relevant terminals with the
button pressed.

Check: S
R
• The continuity
using the multitester positioned on the relevant terminals accord-
TO

ing to selection (left/right).

Check:
• The continuity
O

using the multitester positioned on the relevant terminals accord-

ing to selection (how/low beam).
M
A

Refer to the table.

D

Red/
WIRE COLOURING Red/Yel Light Blue Blue Red/Whi Gre/Bla Oran Gre/Whi Bro
Wh
BA

Right indicator light

• •
Left indicator light
• •
High beam
• •
Low
Beam • •
High beam flash
button • •
Horn
• •
When the above conditions are fulfilled, the horn, the light switching control, the high beam flash button are operat-
ing properly, otherwise replace the parts.

ELE. - 38
- Benelli TRK 502 - Page 381
 DEVICES
CONVERTER OF CAN BUS SIGNALS

It is situated on the left, front side of the vehicle and serves to

collect and convert the digital/analogue signals into CAM-BUS
A
for the instrument panel (Fig. A).

21
20
S
R
TO
O
M

C
A
D
BA

ELE. - 39
- Benelli TRK 502 - Page 382
 DEVICES
INJECTION ECU

Check the various utilities, situated close to the passenger’s

under-seat, according to the diagram below.
Hereunder is a table indicating the meaning corresponding to
the error code detected.

21
20
ERROR TABLE

Code error Error description

48
S
1st lambda heater cylinder - open/short circ.
R
49 1st lambda heater cylinder - ground open/short circ.
50 1st lambda heater cylinder - positive open/short circ.
TO

83 1st resistance lambda heater coil cylinder - abnormal value

54 2nd lambda heater cylinder - open/short circ.
55 2nd lambda heater cylinder - ground open/short circ.
O

56 2nd lambda heater cylinder - positive open/short circ.

89 2nd resistance lambda heater coil cylinder - abnormal value
M

261 MAP sensor - abnormal response (no variation)

262 MAP sensor - abnormal response (out of range values)
263 MAP sensor - abnormal circuit grounded
A

264 MAP sensor - abnormal circuit on positive

D

274 Air temperature sensor - output voltage too low

275 Air temperature sensor - output voltage too high
BA

278 ECT (Engine coolant temperature) - abnormal response (out of range)

279 ECT (Engine coolant temperature) - abnormal response (too low voltage)
280 ECT (Engine coolant temperature) - abnormal response (too high voltage)
290 TPS - abnormal response (too low voltage)
291 TPS - abnormal response (too high voltage)
304 1st lambda sensor cylinder - abnormal value (out of range)
305 1st lambda sensor cylinder - abnormal value (too low voltage)
306 1st lambda sensor cylinder - abnormal value (too high voltage)
308 1st lambda sensor cylinder - open circuit
310 2nd lambda sensor cylinder - abnormal value (out of range)
311 2nd lambda sensor cylinder - abnormal value (too low voltage)
312 2nd lambda sensor cylinder - abnormal value (too high voltage)
320 2nd lambda sensor cylinder - open circuit
513 1st injector - open circuit
609 1st injector - short circuit to ground
610 1st injector - positive short circuit

ELE. - 40
- Benelli TRK 502 - Page 383
 DEVICES
INJECTION ECU

ERROR TABLE

Code error Error description

514 2nd injector - open circuit

612 2nd injector - short circuit to ground
613 2nd injector - positive short circuit
801 Drive shaft position sensor - failure (out of range)
802 Drive shaft position sensor - failure (open circuit)
1092 Vapour exhaust checking valve - open circuit
1112 Vapour exhaust checking valve - too low circuit voltage
1113 Vapour exhaust checking valve - too high circuit voltage

21
1281 Speed sensor - failure (out of range)
1286 High minimum speed target compared to the limit of air control system

20
1287 Low minimum speed target compared to the limit of air control system
1288 IAC (idle air control) - short circuit to ground
1289 IAC (idle air control) - positive short circuit
1297 IAC (idle air control) - open circuit
1376
S
Abnormal system voltage response (out of range)
R
1378 Too low system voltage
1379 Too high system voltage
TO

1538 ECU map - coding error

1575 Fuel pump relay check - open circuit
1576 Fuel pump relay check - short circuit to ground
O

1577 Fuel pump relay check - positive short circuit

1616 Lamp circuit error - MIL indication
M

8567 Too high CLL value

8558 Too low CLL value
4375 Canister purge valve - positive short circuit
A

4374 Too high engine temperature

4375 Canister purge valve - short circuit to ground
D

4376 Canister purge valve - open circuit

BA

1393 Brake switch - failure

4406 K line - open circuit

ELE. - 41
- Benelli TRK 502 - Page 384
 DEVICES
INJECTION ECU CONNECTIONS

E_A_DKG
E_A_TMOT

B_D_CANL
36 E_S_DIAG1

B_D_CANH
E_A_TANS
10 M_R_SEN1

21 E_S_DIAG2
E_S_KL15

A.S.LSHVK2
A.S.LSHVK1
E_F_DGA
E_F_DGB

A_T_EV2

A_S_SAL
A_T_EV1
A_U_5V1

E.A.LSVK2
U_U_UBD
M_M_ZUE

E.A.LSVK1
U.U.UBR

A.P.ZUE1

A.P.ZUE2
12
30
13
42
43

11

48

47

16
32
33

15
9
8

20
1

4
5

19
2

21 R 68K
R 68K
36 21

10/5
10/4

82
线束内接 线束内接

20

81
80
19

20
1
2
68K电阻 68K电阻

82/1

82/2
21 34 21 34

7
1 2 2 1

10/1

10/6
10/2
30/1
t

30/2
13
t

83

88
92
10/3
42
43

11

48

47

4
12
9
A B A B 2 1+ 2 1+ 2 1+
1 2 3 1 2 A B C - - -

3 3

S
LAMBDA SENSOR LAMBDA SENSOR Zyl.1 GND TO GND TO Zyl.2
ENGINE ENGINE
IGNITION IGNITION

15
16
P
UPSTREAM 1 UPSTREAM 2
COIL 1 COIL 2
VDD

R
THROTTLE LSF LSF INTAKE TEMP. ZS-K1X1 ZS-K1X1
INTAKE
ENGINE COOLANT PRESSURE POSITION 氧传感器1 氧传感器2 SENSOR 点火线圈1 点火线圈2 INJECTOR 1 INJECTOR 2 SECOND AIR
TEMP. SENSOR SENSOR SENSOR TANS (CYL.1) SOLENOID
(CYL.2)
TMOT DS-S3 DKG 进气温度 EV14 EV14 SAL
CDI触发器 发动机冷却 进气压力 节气门位 传感器 CAN INTERFACE

TO
置传感器 喷油器1 喷油器2 二次补气 CAN

FUSE 5A
FUSE 5A
液温度传感 传感器 电磁阀
器 CAN总线接口
非UAES产品， 非UAES产品， 非UAES产品， 仅匹配使用
非UAES产品， 非UAES产品，
仅供参考 仅供参考 仅供参考
仅供参考 仅供参考

92

83
80

81

88
33
32

82
8

kl.87(HR)
5

UB kl.15
UB kl.30 SSW 熄火开关

O
GROUND P
A_P_DMTN

A.S.LAMP
E_S_KL15

B_D_DIAK

E.A.DUMP

A.S.FAN1

A_S_EKP
E_F_VFZ
M_M_ZUE

U_U_UBD
U_U_UBR

A_S_MIL

A.T.SMA

A.T.SMC
A.T.SMD

A.T.SMB

A.S.HR
M
O.S.CPV
38
29

44
32
33

34

14
41

40

46
27

28
17
18

45
5
8

6
A
D

94
46

96
95

95
120
119

30 85 86 87 1 2 3 4
45

112

114
113

115

116
137

44
14
30 85 86 87
6

30 85 86 87 30 85 86 87
BA

2- 1
+ M
27

28
17

18
41

A D C B
40

FAN 1
RELAY
FUSE

FUEL PUMP RELAY

38

ELECTRIC FUEL PUMP

29
34

VEHICLE FAN1 MAIN HEAD LIGHT

ENGINE CANISTER RELAY RELAY EKP-RELAY EKP
FUSE

FUSE
DUMP SPEED
MIL FUNCTION SENSOR SPEED PURGE 冷却风扇继电器 HR 油泵继电器 油泵
SIGNAL HLR
DIAK INDICATOR LAMP OUTPUT VALVE

FUSE 30A
VFZ 主继电器
诊断K线 倾倒 (TD/TN) TEV 头灯继电器
MIL
119

开关 车速信号 炭罐控 STEPPER MOTOR

故障灯 发动机
转速输出 制阀
（接仪表） STEPPER

96
137

112

113
114

115

116
120
33
32
8

kl.87(HR)
5

UB kl.15 步进电机

UB kl.30 SSW 熄火开关

GROUND P 非UAES产品
仅供参考

7 - 42
- Benelli TRK 502 - Page 385
 DEVICES
INDICATOR LIGHT INTERMITTENCE

It is situated inside the storage compartment, underneath the

vehicle seat, and allows to control the indicator flashers.

21
20
S
R
TO
O
M
A
D
BA

ELE. - 43
- Benelli TRK 502 - Page 386
 DEVICES
ABS BUTTON

It is situated on the left side of the control handlebar (3), Fig. A,

and allows to manage the insertion/release of ABS control.
A

3
Disconnect:
• The electrical coupling.
Check:
• The resistance using the multitester on symbol Ω between
pin 1 and pin 2.
1
Resistance:
• 0Ω

21
20
S
R
TO
O
M
A
D
BA

ELE. - 44
- Benelli TRK 502 - Page 387
 DEVICES
SERVICES RELAY

It is situated inside the storage compartment, underneath the ve-

hicle seat (Fig. A). The relay assembly is managed by the ECM
A
to control each load at best, such as:

• The lighting system

The ECM ensures that the lights turn on in certain conditions.
• The fuel pump
The fuel pump is activated only when the starter lets the engine
rotate.
• The electric fans
• The injection
The ECM controls the injection relay pull-in according to the
relevant conditions, as ignition, shutdown, and use of the vehi-
cle, thus allowing a stable supply to ECM, which can carry out
any correct procedure of storage and setting of the parameters

21
in the standstill phase, by continuing its self-powering for some
seconds after the instrument panel shutdown.
• Services B
All devices “with ignition on”, as dashboard, various safety devic- 30

20
es and lighting system, are connected to the services relay.
87
Check:
• The resistance using the multitester on symbol “Ω” between 86
85
pin 85 and pin 86 (Fig. B).

S 87
R
TO

Resistance 12 ± 2 Ω

Use:
• The tester and, referring to the table, check on relay pins,
O

by powering the PIN 85 and the PIN 86 to the battery.

M

RELAY PIN 87 PIN 30 PIN 87A

Powered on battery
• •
A

Not powered on
battery • •
D
BA

NOTE:________________________________
When the above conditions are fulfilled, the relays are oper-
ating properly, otherwise replace the parts.

ELE. - 45
- Benelli TRK 502 - Page 388
 DEVICES
STATOR

There are three types of failures of magnetoelectric generator

(stator): 1 2 3
• Short circuit A
• Line break (wire burnt)
• Rotor Magnetic Disappear.
Ω
Short circuit or open circuit of coil wires that cause low output or
even no output.
Disappearing of rotor magnetism will lead to low output, which
may be caused by AC electric generator or striving. Or it may be
because of aging.

Close the ignition switch

Disconnect:
• The connector of the 3-pole magnetoelectric generator.

21
Measure:
• The resistance value among the three black terminals of
the magnetoelectric generator with a multimeter.

20
Standard 0.18 Ω ± 0.01Ω to 25°C

• If the resistance is greater than the aforementioned values,

or it is not possible to measure (infinite value) one of the
two wires using the multimeter, it shall be replaced. When it
is far lower than the resistance, it refers to stator short-cir- S
R
cuit. It shall be replaced.

• Measure the resistance between every single black wire

TO

and frame grounding with a multimeter in the highest resis-

tance range.

• Use tester coil to check whether the engine is through.

O

If yes, it refers to short-circuit of coil and engine and the

charge coil shall be checked.
M

• If the resistance of stator coil is normal, but the voltage

check detects a failure of the magnetoelectric generator, the
rotor magnets might have become loose. At this moment,
A

replace the rotor.

D

Start up the engine:

• Run the revolutions per minute (rpm) according to Table 1.

BA

• Record the voltage readings (three measurement values in

total).

Table 1 Output voltage of magnetoelectric generator

Wiring Readings at
Range of tester
Tester (+) to Tester (-) to 5000 rpm

Another black 55 V or high-

750 V AC Black wire
wire er

NOTE:________________________________
If the output voltage indicated is within the value of the
table, the magnetoelectric generator works properly.
If the output voltage indicated is much lower than the value
within the value of the table, problems occur on the gener-
ator.

ELE. - 46
- Benelli TRK 502 - Page 389
 ACTUATORS
POSITION OF ACTUATORS

1
2

3
4

21
20
7
S 5
R
TO

6
O
M

Position
A

Device
1 STEPPER
D

2 INJECTORS
3 IGNITION COILS
BA

4 COOLING FAN
5 FUEL PUMP
6 STARTER
7 ABS ECU

ELE. - 47
- Benelli TRK 502 - Page 390
 ACTUATORS
IDLE AIR CONTROL SYSTEM (STEPPER)

The system is situated inside the air filter case, contains a valve
for checking air flow underneath the throttled body throttles and
is equipped with a stepper motor.
The system controls the following parameters:
• Idle speed
• Air supply in case of engine overspeed
• Adjustment of air/fuel ratio by working at idle speed at
altitudes above sea level.
• Adjustment of air/fuel ratio in cold/hot setting-off.
When the stepper motor is activated, it opens the valve that
controls the air flow and allows a certain air flow to run off along
a series of hoses in the throttled body unit.

Operating voltage 12V DC

21
Minimum /maximum operat- 14V DC/ 7.5V
ing voltage DC
Impedance per coil (27°C) 53±5.3Ω

20
Minimum impedance 35 Ω
Distance 0.04167 mm
8.5 mm (204
Maximum travel A
Resonant frequency range
steps)
70-120 pps S C
B
D
R
TO
O
M
A
D
BA

ELE. - 48
- Benelli TRK 502 - Page 391
 ACTUATORS
INJECTORS

They are positioned on the throttle body unit. A

The engine is equipped with three four-jet injectors (1), Fig. A.
The amount of jet of the injectors is constant, but the duration of
time during which each injector remains open is variable.
The duration of each injection is calculated via ECM according
to the data received from the various system sensors.

Disconnect:
• The electrical coupling.
1

Check:
• The resistance
using the multitester on symbol Ω between PIN1 and PIN2 (2),
Fig. B.

21
Resistance 12 ± 2 Ω B

20
MULTIMETER

20 30
0 10

- +

S 1 2
R
2
TO
O
M
A
D
BA

ELE. - 49
- Benelli TRK 502 - Page 392
 ACTUATORS
IGNITION COILS

The ignition coil is situated directly on the head of each spark

plug (1), Fig. A, and provides high voltage and ignition energy
A
necessary to produce high-voltage sparks between the elec-
trodes of the spark plug.

Check:
• The measurement of the coil terminal impedance. 1

Primary coil 0.65±0.07Ω

Secondary coil 4±0.5 kΩ

The optimal condition is achieved when the resistance value is

within the standard value.
Resistance value "∞" indicates coil wire disconnection”, therefore

21
it is necessary to replace the ignition coil.

20
S
R
TO
O
M
A
D
BA

ELE. - 50
- Benelli TRK 502 - Page 393
 ACTUATORS
COOLING FAN

It is situated on the radiator body (1) Fig. A. The ECM enables

and disables the cooling fan according to a signal received by
A
the coolant temperature sensor.
When the coolant temperature reaches the upper-tier tempera-
ture, the cooling fans are activated via command.
When the coolant temperature lowers enough (lower-tier tem-
perature), the coolant fans are activated via command by the
ECM.

Check:
• The load current of the fan motor by connecting an amme-
ter, as shown in Fig. B.
1

21
The voltmeter serves to check that the battery powers the 12
volt motor.
When the fan rotates at the highest speed, the ammeter must
show no more than 5 Amps. B
A

20
If the motor does not rotate, replace the motor unit of the fan.

NOTE:________________________________ Motorino Amperometro

Ventola
It is not necessary to remove the cooling fan from the radia-
tor to carry out the above test.
S
R
TO
O
M
A
D
BA

ELE. - 51
- Benelli TRK 502 - Page 394
 ACTUATORS
FUEL PUMP

The electric pump is situated in the fuel tank (1), Fig. A, and
provides fuel in the supply circuit via a pressure regulator at a
A
constant pressure of 3.5 bar.
The ECM controls the pump operation directly, by ensuring the
correct fuel pressure necessary for starting the engine from the
first activation of the instrument panel via a timed function, and a
continuous operation for the normal use of the vehicle.

Check:
• The fuel pump.

1. Put an outlet pipe into a container to let the fuel flow out
(Fig. A).
2. Connect the battery (12 V) to the fuel pump. 1
• RED/BLACK positive wire +

21
• BLACK negative wire -

20
S - +
R
TO
O
M
A
D
BA

ELE. - 52
- Benelli TRK 502 - Page 395
 ACTUATORS
FUEL LEVEL SENSOR

It is situated close to the fuel pump (1), Fig. A, and provides an A

outlet value of variable resistance according to the fuel level.

Check:
• The resistance depending on fuel level (Fig. B) by position-
ing the multitester on symbol Ω between the PIN1 - PIN2.

21
MULTIMETER
B

20
20 30
0 10

S - +
R
Marrone Rosso
Nero Blu
TO
O

Indicated level 6 5 4 3 2 1 0
M

Resistive value Ω 0-18 19-24 25-36 37-52 53-69 70-89 90-95

Tank fuel (Lt) 20 15.3 12.7 10 7.7 5.1 2.7
Extension (mm)
A

262 228±3 207±3 186±3 165±3 144±3 112±3

D
BA

ELE. - 53
- Benelli TRK 502 - Page 396
 ACTUATORS
STARTER

The starter (1), Fig. A, is a part that can be replaced totally. If the
starter is damaged, replace it.
A

Remove:
• Release the coiled spring of brushes.
• Remove the casing framework.
• Use an ohmmeter to measure the resistance between the
wire terminal and the insulated brush.

Reading should be max 0.3 ohm.

Measure the resistance between the wire terminal and the 1

brush holder.
• Make sure the brush does not come in contact with the
casing.

21
• Reading should be infinite (no reading).
•
Remove: B
• The brush holding plate and the brushes.

20
Measure:
• The brush length and replace in case of wearing exceeding
the allowed limit.

Brush wear limit (length) S

R
Standard 10 mm
Service Limit 5.0 mm
TO

Check:
O

• The switch surface for wearing or discoloration.

• The framework test. C
Make sure the insulating washer of the terminal bolt is inserted
M

properly into its housing and the tab on the brush holding plate
engages the housing notch of the plate.
• Remove the magnet housing by keeping the framework and
the brush holder united.
A
D

FRAMEWORK TEST
BA

Check:
• The switch surface.
Replace if overly worn or damaged.

Measure:
• The resistance between each segment of the switch (Fig.
C).
A digital multitester is used for measurement.

NOTE:________________________________
Reading should be max 3 ohm.

Continuity of lower framework

coil resistance 3 Ω at 20°C (68°F)

ELE. - 54
- Benelli TRK 502 - Page 397
 ACTUATORS
STARTER

Measure:
• The resistance between each segment of the switch and
D
the framework shaft (Fig. D). Reading should be infinite (no
continuity).

Insulation check
Ω infinite 20°C (68°F)

Check:
• The switch segments for discoloration.

NOTE:________________________________
The presence of discoloured segments in pairs refers to
short circuits of coils that require the replacement of the
starter.

21
• Position the framework in a short circuit detector.
• Switch on the detector and position longitudinally a saw

20
blade or a thickness gauge for 3 mm (1/8”) above the lami-
nates of the framework coil.
• Turn the framework by 360°.
NOTE:________________________________
If the saw blade is attracted towards a pole of the frame-
work, the latter has a short circuit and must be replaced.
S
R
Check:
• The permanent magnets in the starter housing.
TO

NOTE:________________________________
Make sure they are not cracked or far away from the hous-
ing.
O
M
A
D
BA

ELE. - 55
- Benelli TRK 502 - Page 398
 ACTUATORS
ABS ECU

It is situated underneath the fuel tank Fig. A.

A
Precautions

There are several precautions to follow concerning the ABS

system.
• The power supply of the ABS system must be equipped with
a 12 V sealed battery. Do not use other types of batteries.
• Do not reverse the battery connections to prevent damages
to the ABS hydraulic control.
• Do not disconnect the battery wire or other electric parts
when the main switch is on or the engine is operating to
prevent damages to the ABS parts.
• Do not short circuit the positive electrode of the battery (+)
on the frame.

21
• Do not activate the main switch when the ABS electric parts
are disconnected. The ABS control unit stores the diagnos-
tic fault code.
• Do not spray water on electric parts, ABS parts, connectors,

20
wires, and conductors.
• Make sure the motorcycle transceiver does not interfere
with the ABS system. Keep antennas as far away from ABS
ECU as possible.
•

•
Switch the master switch before disconnecting the ABS
electrical parts.
Never strike the ABS parts with a hammer or leave them fall S
R
on hard surfaces to prevent damages to the ABS parts.
• Do not disassemble or try to repair the ABS parts, even in
TO

case of malfunctioning of the ABS.

• The ABS system cannot detect malfunctioning of the
conventional braking system (burnt/worn discs, worn pads
or other mechanical failures). To avoid problems, keep
O

checked the hoses and the wiring for a correct layout. For
the standard braking performance, check for any brake fluid
leaks. Make sure the system is properly drained.
M

WARNING
If the linking parts of the brake hoses are removed, includ-
A

ing the connecting screws of the ABS hydraulic system or

the air bleed screws, bleed air in the circuit carefully.
D
BA

IMPORTANT NOTICE
Do not ride the vehicle if the system is not drained properly
as the presence of air may jeopardize the efficiency of the
ABS and the brakes.

ELE. - 56
- Benelli TRK 502 - Page 399
 ACTUATORS
ABS ECU

Please refer to the features on the Texa diagnostic device for

managing the diagnostics. Hereunder are the main fault codes
and the necessary corrective actions.

DTC (Hex) Fault codes Solutions

5055
5019
5017
Replace ABS unit
5013
5018
5014

21
5053
Check battery voltage
5052
5035 Replace ABS unit

20
5043
Check connection of the speed sensors using a new sensor
5045
5042
Check phonic wheel for deformation or faults
5044
5025 S
Check speed sensors, distance, phonic wheel, and tyre specifications
R
5122
Replace ABS unit
5223
TO
O
M
A
D
BA

ELE. - 57
- Benelli TRK 502 - Page 400
 ACTUATORS
ABS ECU

Diagram

21
20
S
R
TO
O
M
A

Position Code
1 GND_ECU
D

2 CAN1P
BA

3 WSS_F
4 WAU_IN1
5 DIAGK
6 BLS - input_PD -SW2H_NO
7 DIAGL
8 WSO_F
9 UB_VR
10 GND_MR
11 CAN1M
12 WSP_F
13 WSP_R
14 WSS_R
15 ABS_OFF -input_PU - SW2L_NO
16 WSO_R
17 NABS_SLAMP
18 UB_MR

ELE. - 58
- Benelli TRK 502 - Page 401
 BATTERY
VEHICLE BATTERY

IMPORTANT NOTICE 1
Do not use batteries other than the indicated ones (A), Fig. 1.

The MF battery (maintenance-free) mounted on this vehicle

does not require maintenance operations, as electrolyte level
control and topping up of distilled water.
Please note that the charging system of the MF battery differs
from the one of a standard one.
Therefore, do not replace the MF battery with a standard one.
The recommended battery is 12V-9Ah.

A
IMPORTANT NOTICE

21
Hydrogen is not produced during the normal recharge of the
battery, but it can be produced when the battery is recharged
excessively.

20
Please keep flames away from battery during recharge.

In case of corroded terminals, remove the battery, pour warm

water on it and clean using a metal brush.
At the end of connection, grease slightly.
Mount a cap on the positive terminal. S
R
TO
O
M
A
D
BA

ELE. - 59
- Benelli TRK 502 - Page 402
 BATTERY
BATTERY EFFICIENCY CONTROL

CHECKING BATTERY CURRENT LOSSES

2
Connect: mA
• The multitester between the negative terminal and the
negative wire of the battery as ammeter in direct current (B)
Fig. 2. +

IMPORTANT NOTICE
Since the current losses may be high in case of malfunctioning,
use a high range of the multitester first to prevent damages.
Do no position the ignition switch to ON whilst measuring the
current.
When the panel is off, the current losses must be >/- Ã 2~2.5
mA.
- +

21
• Otherwise, find out the source of such absorption by dis-
connecting the connectors of each utility powered by the
battery directly.

20
NOTE:________________________________
In the event an anti-theft device is installed, disconnect it
before carrying out the modifications.

S
R
TO
O
M
A
D
BA

ELE. - 60
- Benelli TRK 502 - Page 403
 DIAGNOSTICS
VEHICLE DIAGNOSTICS

Refer to the Texa diagnostic instructions.

21
20
S
R
TO
O
M
A
D
BA

ELE. - 61
- Benelli TRK 502 - Page 404
 ELECTRICAL SYSTEM
WIRING DIAGRAM OF TRK502 ELECTRICAL SYSTEM

21
20
S
R
TO
O
M
A
D
BA

7 - 62
- Benelli TRK 502 - Page 405
 ELECTRICAL SYSTEM
COLOUR KEY

CODE COLOUR
B Black
BL Blue
GR Green
W White
Y Yellow
O Orange
R Red
Dg Dark grey
P Purple
N Brown

21
G Grey
LR Pink

20
S
R
TO
O
M
A
D
BA

ELE. - 63
- Benelli TRK 502 - Page 406
 Pure Passion since 1911

21
20
S
R
TO
O
M
A
D
BA