Benelli TNT 300 Service Workshop Manual

Workshop Service Manual for the Benelli TNT 300 a must-have for any Benelli owner, This full workshop manual covers every component, service and repair procedure in full Benelli factory specification with clear step by step photographs and technical drawings for the TNT 300, with torque setting values throughout each chapter, this is the most comprehensive service manual available as used by service centres and independent garages the world over.

Contents
Preface
User Guide
Exhaust Emission Control Information
Symbols
Specific Symbols
Symbol Interpretation

Chapter I General Information
General Safety
Identification
Motorcycle Identification
Important Parts
Features
Instruments and Lights
Important Information
Preparation for Disassembly and Disassembling Operation
Gaskets, O-rings, Seals and Bearings
Lock Washer/locking plate, Bolt and Thread Sealant
Circlips
Cable-To-Cable Connector Check
Special Tools

Chapter 2 Specification
Basic Specifications
Technical Data of the engine
Technical Details of the Engine
Technical Data of the Motorcycle
Electrical Data
Technical data of Nut LockingTorque
Technical Data of Bolt and Screw Torque

Chapter 3 Check and Regular Adjustment
Regular Maintenance and Lubrication Interval
Regular Maintenance and Lubrication Interval Schedule
Air Filter
Fuel Hose
Control
Throttle Cable
Clutch Cable
Rearview Mirrors
Engine Oil
Engine Oil Filter
Coolant
Radiator Hoses
Spark Plugs
Valve Clearance
Brake Adjustment
Check of Brake Fluid
Check of Brake Pads
Check of Brake Hoses
Adjustment of the drive Chain
Check and Adjustment of the steering Stem Bearings
Check of Front Fork
Check of Rear shock absorber
Check of Front and Rear Tires
Check and Battery Charging
Check of Fuses
Replacement of the headlight Bulb
Adjustment oftheHeadlight
Replacement of the front Turn Signal Light Bulb
Replacement of the rear License Plate Light

Section 4 Motorcycle
Front Wheel and Front Brake Rotor
Rear Wheel and Rear Brake Rotor
Front and Rear Brakes
Front and Rear Brakes / Front Brake Pads
Front and Rear Brakes / Rear Brake Pads
Front and Rear Brakes / Front Brake
Front and Rear Brakes / Rear Brake
Front Suspension
Front Suspension/Front Fork
Front Suspension/Front Shock Absorber
Control
Control / Control
Control / Handlebar
Rear shock absorber
Drive Chain and Rear Swing Arm
Drive Chain and Rear Swing Arm
Drive Chain and Rear Swing Arm / Rear Swing Arm
Frame
Frame / Engine Assembly
Frame / Rear License Plate Support
Frame / Side Stand
Frame / Left Foot Pedal
Frame / Right Foot Pedal
Muffler
Fairing / Cowling Parts
Fairing / Cowling Parts / Front Fender
Fairing / Cowling Parts / Rear Fender
Assembly of Fairing / Cowling Parts / Rear Lower Fender and Chain Cover
Fairing / Cowling Parts / Fuel Tank Cowling and Lower Fairing
Fairing / Cowling Parts / Tailsection
Fairing / Cowling Parts / Headlight Fairing
Lights
Lights / Rear Taillight
Lights / Front Turn Signal Light
Lights / Rear Turn Signal Light

Chapter 5 Engine
Cylinder Head and Cylinder Head Cover
Exploded View
Technical Parameters
Special Tools and Sealants
Special Tools and Sealants
Cylinder Head Cover
Camshaft Timing Chain Tensioner
Camshaft and Camshaft Timing Chain
Cylinder Head
Valves
Intake Manifolds
Clutch
Breakdown Drawing
Technical Parameters
Special Tools and Fastening Adhesives
Right Engine Cover
Clutch
Engine Lubrication System
Breakdown Drawing
Engine Oil Flow Diagram
Technical Parameters
Special Tools and Fastening Adhesives
Engine Oil and Engine Oil Filter
Oil Pan
Engine Oil Pump
Engine Oil Pressure Relief Valve
Measurement of Engine Oil Pressure
Engine Oil Pressure Switch
Crankshaft / Transmission
Breakdown Drawing
Technical Parameters
Special Tools and Fastening Adhesives
Crankcase
Crankshaft and Connecting Rods
Pistons
Electric Starter
Gear Change Mechanism

Chapter 6 Cooling system
Water Pump
Thermostat
Coolant Hose Connectors
Disassemble the Radiator
Dismantle the Radiator
Radiator
Fan
Radiator Cap
Water Temperature Sensor
Radiator Assembly
Cooling Liquid Filling

Chapter 7 Fuel System
Fuel System
Fuel Tank
Fuel Pump
Operating Principles of the Fuel Pump
Fuel Pump Appearance
Fuel Pump Composition
Tag and Identification Label of the Fuel Pump
Working Environment of the Fuel Pump
Fuel Pump Maintenance Procedure
Operation Precautions
Throttle Body
Operating Principles of the Throttle Body
Appearance of the Throttle Body
Technical Parameters
Working Environment of the Throttle Body
Disassembly of the Throttle Body
Negative Pressure Balance of the Throttle Body
Throttle Body Cleaning Method
Assembly of the Throttle Body
Installation Cautions for the Throttle Body
Operation Cautions for the Throttle Body
Fuel Injectors
Operating Principles of the Fuel Injectors
Appearance of the Fuel Injectors
Sealing O-ring of the Fuel Injectors
Overvoltage Effects of the Fuel Injectors
Temperature Range of the Fuel Injectors
Fuel Pollutants of the Fuel Injectors
Wiring Harness Layout of the Fuel Injectors
Operation Cautions for the Fuel Injectors
Installation Requirements for the Fuel Injectors
Fuel Injector Replacement Method
Fuel Injector Selection
Blockage of Fuel Injectors

Chapter 8 Electrical System
Charging System
Battery
Stator / Generator
Regulator / Rectifier
Ignition System
Ignition Coil
Crankshaft Position Sensor
ECU
Spark Plugs
Ignition System Troubleshooting
Starting System
Starter Motor
Starter Relay
Gauge Cluster
Gauge Cluster Disassembly
Gauge Cluster and Indicator Lights
Ignition Switch Disassembly
Ignition Switch Inspection
Horn
Disassembly
Inspection
Handlebar Switch (Chinese Market)
Handlebar Switch (US-STANDARD)
SpeedometerSensor
Disassembly of the Speedometer Sensor
Check of the Speedometer Sensor
Speedometer Sensor Assembly
Relay and Fuse-Block
Relays
Fuse-Block
Fuel Injection System
Fuel Injection System / ECU
Fuel Injection System / Water Temperature Sensor
Fuel Injection System / Intake Air Temperature Sensor
Fuel Injection System/Intake Manifold Pressure Sensor
Fuel Injection System / Oxygen Sensor
Fuel Injection System / Idle Speed Stepper Motor
Fuel Injection System / ECP

Chapter 9 Faults and Troubleshooting
Difficulty in Starting or Starting Failure
Poor Running(Especial at low speed)
Poor Running(High speed)
Charging Defect (Over Discharging or Over Charging of the battery Voltage)
No Spark Diagnosis
Diagnosis Breakdown Maintenance of the fuel Injection System
Directly Use The Fault Indicating Light Flashing Diagnosis (FI) on the Instrument
Using Diagnostic Apparatus for Fault Diagnosis
Check the Faults With Diagnostic Software PCHUD
Common Trouble Shooting Methods of the fuel Injection System
Repair Kit
Engine Working Data Flow Indicated on the Diagnostic Apparatus
Simple Troubleshooting Methods

Chapter 10 Appendices
Wire Wrapping Method of the cables, Wires and Hoses
TNT Circuit Diagram (Chinese Market)
TNTCircuit Diagram (EURO-STANDARD)