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1. 10 O a i 1 I i 1 ENGINE REGULATOR _ J r GENERATOR C N 7 A COPPER BRAID 1 STARTER N LI a JA 1 1 I gt i i J4 DTPO6 28 DTP04 2P Ir BIET Bd 1 a HO lt 2 A 3 2 1 1 4 t wp Jis Jie DTPO44P 07506 45 i 9 C3 1 lt i I O BATTERY i Y eo A 1 i I i Li i 55 i A i N i T X f 4 ewer 109 ee ma D 7 S c RELAY START ad i no i 1 i 15 2 2 1 4 3 A 1 4 4 EC DA 5 5 1 SS SWFPM SSS5WMPF i E 11 1 6 Sector F 4 4 J 5 SS5WFPM SS5W MPF H 1 1 SUL UNE PD REL ee ee SRL DONC USD L 1 1 L i L PAGE CHANGE 1 1 2 2 2 1 GND E GND 4 4 4 J i TACHO amp 5 1 6 6 6 N 1 2 7 LOCK UNLOCK 8 8 k RX 9 9 i A TX 10 10 ECONOSEAL 8W FPM LAMBDA 11 11 1 OTS SWITCH 12 12 1 STAND UP 1 L ECONOSEAL J SERIES ECONOSEAL J SERIES1 1 174
2. 185 s 186 111 General view SERIES S wiring diagram 187 uS EerevPet c EE a 188 11 1 2 COON e A paa maku aset 188 MEO E e 189 LR LEA Perle 189 11 1 59 SC COM nae ds 190 190 TE S E EEE M 191 11 71 80 De CON a 191 11 2 General view SERIES R wiring diagram 192 TT 2 1 SC JA mec M 11 2 2 CION B uestes A a E EIKA DIAS LLJLLILLI FA ES Fe ESEEl TESL L LCCCOFTT ver 2009 03 Page 4 215 72 Service Manual 2 8 E 194 LR S Se 194 12 5 C COTE aE E 195 RETE 195 196 eld e m 196 12 HSR BENELLI DIAGNOSTIC SYSTEM 197 12 1 HSR Benelli Utility Diagnostic System HUDS installation 198 12 2 HSR Diagnostic Tool settings 1 204 12
3. P1 I 2 OES 1 A2 CHECK 2 VREF Ael E m 64 INTAIR CT OM Tas PUMP INJ5 INJ1 g 7 7 INJ2 L 1 I IGNI T I i gi B1_ L I po 82 TACHO E B3 GND L a M INSMOT m B4 INTIPOVER P B Be B amp NIPSI M EE I GND 1 4 i t B8 IGN2 VBB2 i 1 1 T I 2 VBB1 i m C2 INTPS2 s i s INTENG i INSMOT M VENE E es INLAMBDA RS 3 7 CZ INCAM _ PEK eres EN 222 LI NDPOW 12 ce 28 GNDPO L 1 I 211 24951005 BROWN L L mI 4 vas ou P SE gt 1 ISHTI WORK ma 11 1 2 Sector B POW GNDPOw 12 4 I 1 211 24951005 BROWN 1 re ee ee eee ee ee M 2 i ai A1 lans L S i T 1 a2 INJ4 A2 A3 NE g FAN INJ6 i 1 A5 ECH z E A6 7 I AB B1 4 2 PRG 3 El B2 n3 INPTPS2 d BS INSPEED
4. ServiceHSR564 exe 7 The following window should appear LLILLILLI FPES BENE LLCO ver 2009 03 Page 200 215 SEIES SERIES Service Manual Console Parametri Configurazione e Stato F1 F2 Down Up Gruppi Freccette Down Up Grandezze Loading Messages Eg AJ Messages File Not Found 8 Click OK and choose language file English or Italian are currently available press Open button LLJLLILLJ FA ES BE TESL L LCCCOFTT ver 2009 03 Page 201 215 Service Manual Console Parametri Configurazione e Stato F1 F2 Down Up Gruppi Freccette Down Up Grandezze 283 Suchen in C3 Service HSR 564 v t e S DatiCons service E English WCL E Italianas WCL Datei Ge ndert 20 03 2007 16 29 Gr Be 24 3 KB Dateiname D ateityp File wel EI Abbrechen 9 Next window Select device will open Choose file B1HSR 07 US NEW dcn and click Open Console Parameters Status and Configuration F1 F2 Down Up Groups Arrows Down Up Corrections Select device Axi Suchen in Service HSA 564 DatiCons Service 91 CNS B1HSR 07 US MEW dcn Dateiname 5 B1HSR O7 US NEW dcn Dateityp Console Files 5 den Abbrechen A LLILLILLI F IST BES IE LLCO ver 2009 03 Page
5. 9 A M fu iTS HEN 4 Ft iG SER NICE us SENRIES SERIES Service Manual Table of Content 1 2 osassa n S nina S Em aa i mi 6 I MTO OOT ON 7 1 2 Service quidellri8S socio ndi assa am sta aavan sSey N Ossi S 9 JE Rue UT 9 C c G 10 1 2 3 Operating 12 1 24 1 RETI 13 1 2 5 Operating the engine on vehicle outside of water 13 9 S der MUI CAN OM MERE 14 1 3 14 HSR BENELLI Personal Watercraft Identification Numbers 14 1 23 2 VIN DUITIDOL 14 1 9 3 14 1 3 4 Three stars ultra low emission sues 15 1 39 59 Sale 15 14 General speciflCallOmNSvumssssusssaussuausvassaaasao eo ona uo so su Anas sn 16 1 4 1 General OA c 16 1 4 2 Standard Torque Specifications eese 17 9 OVI Cl OMG WALL 18 2 MAINTENANCE 19 2 1 Flushing system attachment 1 21 2 2 Periodic maintenance Chart 22 2 22 2 3 Periodic maintenance proc
6. 1 0 Kg m LOCTITE 2436 Tightening torque 10 N m 1 0 Kg m LLJLLJLLI FASES BE IELLICO YT ver 2009 03 Page 80 215 SERIES Service Manual Rotate the engine 180 to be placed on its bottom side Tighten the bolt under roll over valve in two phases shown in oval mark Tightening torque 1 phase 10 N m 1 0 Kg m 2 phase 25 N m 2 5 Kg m Tighten five screws shown in circle marks with specified torques Tightening torque 10 N m 1 0 Kg m Install Oil pump cover and tighten its screws with specified torque Tightening torque 10 N m 1 0 Kg m Install roll over valve assembly and tighten its fasteners with a specified torque Tightening torque 10 N m 1 0 Kg m LLJLLJLLI FPES BE IELLICOYT ver 2009 03 Page 81 215 1 RE SERIES Service Manual 3 2 4 Cooling system Thermostat and Water pump e Thermostat e Dismantling Thermostat A WARNING Always use new gaskets and oil seals Disconnect cooling system hose loosen and remove mounting screws and remove the thermostat cover Remove the thermostat 5 Verify that the by pass hole 6 is not obstructed e Check Thermostat The thermostat begins and opens at around 75 C and reaches 7mm minimum opening at 90 C as shown in the diagram on the figure OPENIMG TEMPERATURE LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 82 215 1 SEMIES Service Manual Check w
7. IE LLCO ver 2009 03 Page 71 215 72 Service Manual LLJILLSILLJ FA ES BE IE LLIN SELECTION SHEET CONNECTING ROD HEAD 40 395 40 401 40 401 40 407 0474041 3 3 Orange Internal Diameter Connecting Rod Foot Using a caliber for small holes measure the internal diameter of the connecting rod foot INTERNAL DIAMETER CONNECTING ROD FOOT SERVICE LIMIT 19 040 mm If the internal diameter of the connecting rod foot exceeds the specified limit change the connecting rod Connecting Rod Head Lateral Play Check the lateral play of the connecting rod with a feeler If the play exceeds the specified limit remove the connecting rod and check the width of the connecting rod head and pin If the width exceeds the specified limit change the connecting rod or the engine shaft CONNECTING ROD HEAD LATERAL PLAY SERVICE LIMIT 0 40 mm CONNECTING ROD HEAD WIDTH STANDARD 2 18 2 19 mm CONNECTING ROD PIN WIDTH STANDARD 22 0 22 05 mm ver 2009 03 Page 72 215 el Service Manual e Crankcase Assembling CONNECTING ROD SEMI BALL BEARING COLOUR SELECTION 1 680 1 684 Blue 1 684 1 688 There are 3 different sizes of connecting rod plain Mounting Crankshaft Yellow 1 688 1 692 bearings marked by colors mentioned in the chart 2 seat std A red 40 395 40 401 J seat std B blue 40 401 40 407 2 seat std C
8. Remove transmission gear box casing and place it beside Disassembling transmission cover Support the transmission cover and use special tools to open the coupler Loosen and remove the coupler NOTE The washer in between the bearing and the gear has a thickness of 4 5mm QYILIILL FPES BE IE LLC OST ver 2009 03 Page 96 215 SsErRIES Service Manual Remove circlip and bearing NOTE The washer in between the oil seal and the bearing has a thickness of 1 5mm LLJLLJLLI FAS BE IELLICO YT ver 2009 03 Page 97 215 SETIES R SErIES Service Manual Disassembling transmission housing Remove the oil seal and the O ring 4 2 Transmission Assembling Assembling the transmission cover Grease new oil seal on the seal lips and o the oil seal groove Press in the oil seal by hand QYILIILL ASTR BENE Le Ln l CCT ver 2009_03 Page 98 215 ee el Service Manual Press in the bearing and put in place the circlip to secure the bearing Subassembly of the PTO gear Press and glue the aluminum plug into the PTO gear with Loctite 648 as shown on the pictures below Put the washer 4 5 mm in place LLILLILLI F IST ET IE LLCO ver 2009 03 Page 99 215 SETIES PR SErIES Service Manual Assemble coupler into the PTO gear using grease and tighten the coupler with specified torque Tightening torque 80 N m Assembling transmissio
9. ver 2009 03 Page 3 215 72 Service Manual 8 COOLING SYSTEM v n eaa kanat 147 8 1 Closed circuit cooling system se 148 8 2 Opened Circuit cooling systems annan 150 8 2 1 Exhaust cooling e Sins Sia 153 0 2 2 156 9 STEERING SYSTEM 157 SERIES R STEERING SYSTEM 9 1 Steering Support Assembly 1 158 9 2 Assembly of the Steering Support on the PWC 160 9 3 Handle Bar assembly 1 1 1 161 SERIES S STEERING SYSTEM 9 4 Handle Pole Assembly eus 164 9 5 Handle Bar Assembly 3 170 9 6 Assembly of the Hanle Bar on the PWC 171 TO MULE 177 10 1 Dashboard COVEN 178 10 2 DraimageDOYX 180 10 3 Baggage Cover 181 10 4 Side Cover Assembling 184 10 5 Sponsons assembling 2 5
10. Unit Histor Overview y Logged in as Unit Search _ Testdealer Your registered Units Add Maintenance Entry for 508 Pro VIN HSRAD001C308 Active language English Maintenance Interv al TEE Logout gt gt Edit yaur prafile Comment ECU File ECU File amp dd maintenance entry gt gt VEE Le fEAT e Maintenance Interval Select performed maintenanace 10 hours 25 hours 50 hours 75 hours etc Hours Enter vehicle current Motor Hours value e Comment Add your comments if necessary e ECU File Ensure the filled in HUDS file screenshot is attached e ECU File Ensure the invoice for performed service scanned copy is attached Click Add maintenance entry button to save Maintenance Entry in Unit s history Maintenance Registration is complete LLILLILLI F IST ET IE LLCO ver 2009 03 Page 211 215 72 Service Manual FASES BES LLCO ver 2009 03 Page 212 215 72 Service Manual 13 Storage The decommissioning of the vehicle is necessary e atthe end of the season if the vehicle will be decommissioned during the winter months e if the vehicle will be used for more than 30 days In addition to the maintenance work described in the maintenance interval table under end of the season various other service work i
11. ver 2009 03 Page 15 215 SERIES SERIES Service Manual 1 4 General specifications 1 4 1 General data 2009 HSR BENELLI Series S Length 2 32 M 0 70 m RE 0 67 Dry Weight 168kg Category Stand up S 1 Fuel Capacity 18 litres 4 75 US Gal Series Length 3 23 Width 1 20m Height 1 03 Weight 263 Category Runabout 1 3 persons Fuel Capacity 70 litres 18 47 US Gal Emission Certification Three Star Ultra Low Emission ENGINE O EMISSION CONTROL SYSTEM FUEL CHAMPION RG4HC Tn SFI Sequential Fuel Injection Hecommended fuel Super petrol unleaded DIN 51607 Octane between 95 and 98 ROZ 85 MCZ US premium Unleaded gasoline 91 92 93 Octane or 95 98 ROZ ISO 5146 ENGINE DISPLACEMENT 1130 cc NUMBER OF CYLINDER CYLINDER LINING SURFACE Nicasil BORE x STROKE 88 x 62 mm COMPRESSION RATIO 12 13 1 SPARK PLUG GAP 0 75 0 8 mm 0 0028 0 032 in CYLINDER COMPRESSION 9 6 1 bar 140 14 5 psi MAXIMUM HORSEPOWER Series S Pro Edition 142 hp Series S Race Edition 162 hp Series R Naked Edition 142 hp Series H Pro Edition 172 hp COOLING SYSTEM closed loop with thermos
12. Take the fitting with smaller inner diameter apply green Loctite 278 on the thread and tighten the fitting as shown on the picture Take the fitting with the bigger inner diameter apply green Loctite 278 and tighten it Take the L fitting and apply green Loctite 278 and tighten it to the position like shown on the photo The view of the final assembly ver 2009 03 Page 142 215 sErRIES Service Manual Apply gasket seal Loctite 5699 on both sides of the exhaust gasket _ Put the applied gasket on the exhaust manifold as shown on the picture NOTE the cut edge of the gasket needs to be inline with the shape of the exhaust manifold Apply blue Loctite 243 on the thread of the screws and tighten them with specified torque M Pp Tightening torque 30 N m LLJLLJLLI FAS BE IELLICO YT ver 2009 03 Page 143 215 sErRIES Service Manual Final assembly of the exhaust manifold and the 3 to 1 exhaust hose view 7 3 Assembling the hoses on exhaust manifold There are two hoses of 135 mm length that need to be installed between the fittings of the exhaust manifold Clamps are tightening the hoses Install 2 x 80mm hoses like shown on the pictures Clamp in the same way as shown above wn N P LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 144 215 SETIES R SERIES Service Manual Assemble and clamp the big hose like shown on the picture 7 4 Leak te
13. Warranty period starts from date of registration A WARNING ECU could be registered only ONCE Do not attempt to register ECU for troubleshooting purposes Install HUDS software as described above NOTE Check that Diagnostic cable is attached to a proper connector of vehicle with its one end and to the COM port of your computer with other end see using USB to COM adapter if necessary Attachment of Diagnostic cable to Series R connector Placed at rear left side of vehicle engine compartment close to battery Corresponding connector of wire harness is to be disconnected during diagnostic process Ensure that safety lanyard is inserted to the STOP button of vehicle ignition is on LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 205 215 SEJIES SEMNIES Service Manual Starting Registration process Start program by ServiceHSR564 exe file Click End Of Line button on the upper panel The Line End Parameters window should appear E3 Line End Parameters TPS MIN 37 Set Line End Parameters TPS MAX 201 CO IDLE 0 1 000 CO IDLE 1 1 000 INJ ADJ 0 1 000 Read Line End Parameters TPS Value 35 INJ ADJ 1 E 000 CHASSIS NUMBER HSRJ 0008 80900000000 ENGINE NUMBER BH3300001 508080000 21610 This window should be used to complete vehicle warranty registration put VIN Chassis number 1 Engine number
14. 202 215 SENES SERIES Service Manual 10 Program start view Open Console COM Diagnostic End Of Line Hours Meter NOTE f your computer isn t equipped with a COM port see using USB to COM adapter chapter below Using USB to COM adapter If direct COM RS 232 connection is not possible for your computer USB to COM adapter should be used to complete Diagnostic or Registration process USB to COM adapters are after market available The general view of adapter is shown on the picture IE LLCO ver 2009 03 Page 203 215 1 RE SERIES Service Manual Adapter settings NOTE For a perfect operation the adapter should be configured in a range COM1 COM4 of your system Please contact your IT administrator if required to complete this setting 12 2 HSR Diagnostic Tool settings Start Diagnostic software as described above Press button of the upper panel The window will appear Select the COM port equal to your Adapter system settings see above and click Close button Now the HSR Diagnostic Tool should work correctly If there are any problems please contact your IT Administrator LLJILLSILLJ FA ES BENE LLIN ver 2009 03 Page 204 215 1 RE SERIES Service Manual 12 3 Vehicle registration process NOTE ECU of each new vehicle is limited to maximum 2500 rpm before registration process is completed
15. HL IURE HNO THOS m 74562 2 FLUE ECONCSEAL J SERES SW K Boa 1 228 ammi 4 0 in ii 12 EAL 1 AL J SERES Ww L i IN a as a f s J E 2 LN Tug ji aac fai as i a t LUA k J 14 Soba 5 N Page 195 215 ver 2009 03 72 Service Manual 11 2 5 Sector G i ee 1 E ef FE __ be 3 L I J vies IT 1 02 14 PT las 11 2 5 Sector n dam EET a M N a n i cM E a i x KA Ex a a tan L nsa E i UA TM f gt ELST MWF i omm i f CYLIIJLL ASTR BENEL Ln l ver 2009_03 Page 196 215 72 Service Manual LLSILLSILLJ ASTR BES TESL L LCCCOFT ver 2009 03 Page 197 215 7 1 Service Manual 12 HSR Benelli diagnostic system 12 1 HSR Benelli Utility Diagnostic System HUDS installation Benelli engine version 1 Save provided file HUDS S
16. QYILIILL ASTR BENE Le Ln l CCT ver 2009_03 Page 40 215 1 RE SERIES Service Manual Adjust the acceleration wire until specified free play on throttle lever is given SPECIFIC VALUE N CLEARANCE A 2 3mm NOTE Insure that engine oil and coolant liguid are on proper level NOTE REMOVING THE ENGINE IS A REVERSE PROCEDURE TO DESCRIBED ABOVE 3 2 Engine Disassembly Assembly 3 2 1 CYLINDER HEAD e Head cover removal Loosen and remove self locking nuts 3 and coil support rods 2 Slip off ignition coils 4 Remove the spark plugs using 16mm spark plug wrench Unscrew 8 valve cover mounting screws 5 ATTENTION Take note of the position of the screws for correct reassembling LLILLILLI FPES BENE LLCO ver 2009 03 Page 41 215 el Service Manual NOTE Replace 8 screws rubber bushings 5 during reassembling e Removing Camshafts Remove the head cover Remove the chain pad 6 Unscrewing the two fixing screws 7 ATTENTION A Make sure that the distribution chain does not fall into the casing Remove the chain tensioner ATTENTION A Note the position of the elements for correct remounting Unscrew the fixing screws of the large caps 8 and remove them Remove the bridge 9 unscrewing the fixing screws Remove the camshafts and the chain e Camshafts Inspection Check that camshafts with a micrometer as shown on the picture If the value
17. WHE y 04 25 Qus 9 lt 4 n 200 0 d 80 m i I im i C 1 i HT ci 1 733 5 i i i H i 3 i n RTI ae i i E 11 2 1 Sector 11 2 2 Sector B N U 7 76 1 SENNIES Page 193 215 ver 2009_03 Service Manual 11 2 3 Sector C I7 1 1 I ES 1 co lE l L EE L 1 1 a 4 J i 1 L a bo L T ES L por N rh H i I D M L 1 1 H T P 1 E 1 Eb wed ka ESA MS N x 3 f 1 x LR o 1 ln Rs I C 1 d 1 7 T11 lt lt O0 7r 7 r 0r I l T i 1 1 I Fe CF E discit P 2 L md nr 1 p o0 ers Lm I ope T DC rrr 11 2 4 Sector D e l4 bf 1 I 1 l I 1 I I 1 I o I 122250224 11 lt p LLJLLILLJ FA ES BE TESL L LCCCOFTT ver 2009 03 Page 194 215 Service Manual SERIES SERIES 11 2 5 Sector E Tr 11 2 6 Sector F DAS HERORS
18. allowing the removal of the valve caps 1 LLILLILLI F IST ET IE LLCO ver 2009 03 Page 28 215 1 RE SERIES Service Manual Remove the cap 2 of the valve which requires adjustment using a magnet To change the valve clearance replace the shim with one of a different thickness Measure the thickness of the removed shim NOTE Mark and record the locations of the valve caps and shims so that they can be reinstalled in their original positions Valve clearance calculation In order to set a proper valve clearance please follow the points below 1 Measure the clearance of each individual valve and make note about this reading at cold engine 2 Check the present shim size 3 Calculate the thickness of the replacement shim Example your reading on the intake valve is 0 27mm spec 0 30 0 35mm Clearance is less than specified The shims are available in 0 025 mm steps of thickness Present shim gives 0 27mm clearance with its thickness 2 350 mm Shim size calculation Present clearance 0 27mm 0 30 0 35mm needs to be achieved by reducing shim size Using of 2 size thinner shim 2 300mm 22 350mm 2x0 025mm increases the valves clearance 0 27mm 2x0 025mm 0 32mm The result meets specified range The present 2 350mm shim is to be replaced by 2 300mm shim 4 Assemble the removed pats of cylinder head see Camshaft installation above tighten the fasteners according to given specification
19. does not enter within the specific measure change the element INTAKE SHAFT VALUE LIMIT Az 36 6 mm 27 85 mm EXHAUST SHAFT Az 36 6 mm Bz 27 85 mm LLILLILLI FPES BENE Le L l CCT ver 2009_03 Page 42 215 Service Manual Check the deformation of the camshaft with a comparator as shown on the picture If the value does not enter within the specific measure change the element N INTAKE AND EXHAUST SHAFT DIMENSIONS LIMIT MAX VALUE z 0 03 mm The maximum play between the distribution camshaft and seat is 0 1 mm If the value does enter within the specific value change the element VALUE LIMIT CAMSHAFT AND SEAT Max play 0 01 mm e Chain Sprocket Wheels and Camshaft Chain Guide Inspection Check the state of wear of the camshaft distribution chain Ru 1 If the element has blocked links is excessively worn change it LLJLLILLI FA ES TESL L LCCCOFTT ver 2009 03 Page 43 215 el Service Manual Visually check the timing chain guides 1 Fixed guide FRONT PART 2 Mobile guide REAR PART S78 3 Upper guide FIXED ON HEAD If one or more elements are worn change it them NOTE Always replace chain guides if timing chain is to be replaced e Chain Tensioner Inspection Check the free sliding of the chain stretcher rod Check the state of the chain stretcher spring Check the integrity of the chain stretcher If an
20. maintenance of eligible PWC ATTENTION The vehicle owner or user is responsible adhering to the maintenance intervals HSR assumes no liability for damage that arises due to maintenance not carried out ver 2009 03 Page 20 215 el Service Manual 2 1 Flushing system attachment For service purposes engine of vehicle could be started out of water using Flushing system to provide cooling by tap water A ATTENTION Engine could be operated only at idle rom even if flushing kit is attached Do not run engine when flushing kit is attached continuously for a period over 5 miutes to prevent overheating Flushing system hose Series R LEFT SIDE Flushing system fitting Flushing system hose Series S RIGHT SIDE QYILIILL ASTR BENE Le Lu l CCT ver 2009_03 Page 21 215 72 Service Manual 2 2 Periodic maintenance chart After the first 10 At25hof At50hof At 75h of hours of operation operation operation oi additional additional i operation 25 h 100 h operation Visual Check of all hoses pipes hose clips Visual Check of all nuts bolts and fixing elements Change oil and oil filter Lubricate throttle housing cable connection At 100 h Each Each Jobs to be performed La La Lac Lac dismantle x Dx a x a adjust in necessary EE lt lt lt lx x x lt x mount bolts X X x N X X X aape i e ventilati
21. not to damage dashboard gasket LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 178 215 7 Service Manual Apply BLUE Weicon Lock AN 302 43 on the screws like shown on the photo Sx NOTE It is very important to tighten the dashboard screws with the proper torgue of 2 Nm The other two screws need to be tightened with 5 Nm Assembly on the PWC Put in place the dashboard cover on the PWC Apply BLUE Weicon Lock AN 302 43 on thread of the screws 2 types of screws Top M6 x 12 below M6 x 20 Tighten the 6 screws with specified torgue Tightening torque 3 N m in X method LLILLILLI F IST ET IE LLCO ver 2009 03 Page 179 215 el Service Manual 10 2 Drainage box Those are the products you need to assemble a drainage box Note The Method of gluing requires 2 components The Primer and the glue Apply Primer on the surface that need to be glued Apply liquid Loctite on the surface that need to be glued Ensure you are putting primer and glue on the latches connecting both halfs of the drainage box Apply BLUE Weicon Lock AN 302 43 on the thread of the screw to put in place the drainage box in the hull LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 180 215 el Service Manual Tighten the screw for the drainage box Put in place the Hose sucking the water out of the hull into the Jet Pump tunnel to be released 10 3 Baggage Cover Those are the
22. system on the left hand side of the manifold and returns to the 3 to 1 hose on order to cool tt lt leaves the 3 in 1 hose through wards a fitting to exit the system via a hose to left rear part of the PWC QYILIILL FPES BE IE LLC OST ver 2009 03 Page 155 215 Series SERIES Service Manual 8 2 2 Oil cooling system The coolant for the oil cooler is supplied with hose from the Jet Pump at the rear of the PWC The coolant is split into the oil cooler through wards the coolant water manifold It passes the oil cooler and enters a second water manifold And goes through the hull to be released through wards a fitting in the jet pump tunnel BES IELLICOT ver 2009 03 Page 156 215 72 Service Manual LLSILLSILLJ ASTR BES TESL L LCCCOFT ver 2009 03 Page 157 215 Series SERIES Service Manual 9 Steering system SERIES R STEERING SYSTEM 9 1 Steering Support Assembly For Series R model only Take the steering support and press in the bearing inside the steering support by hand Put the steering tube in place LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 158 215 SsErRIES Service Manual Grease the oil seal and press it in by hand Oil seal needs to be in line with Steering support Put in place steering axle and put it in carefully with a soft hammer NOTE Ensure the parts are in li
23. ver 2009 03 Page 23 215 1 SEMIES Service Manual 2 3 2 Engine oil and filter replacement Remove the dipstick To suck the oil out with an oil removing pump put the suction hose as deep as possible into the engine into dipstick tube Suck the oil out of the engine completely Take out old oil filter Before installation of new oil filter grease filter O ring slightly with engine oil Install new oil filter and tighten with specified tightening torque Open oil filling cap on engine valve cover shown by arrow Refill the engine with new engine oil ATTENTION ALWAYS USE HSR BENELLI ENGINE OIL NOTE FOR SERIES S Volumes of oil in the engine min 1 7 litres without change of oil filter max 2 0 litres change of oil filter included In case of completely dry engine 2 3 litres lt Required torque for oil filter cover 24 Nm Required torque for ignition coils 10 Nm Required torque for spark plugs 12 Nm WARNING Never fill with more than 2 3 of oil into the engine oil filter included NOTE FOR SERIES R Volumes of oil in the engine min 2 1 litres without change of oil filter max 2 4 litres change of oil filter included In case of completely dry engine 2 7 litres Required torque for oil filter cover 24 Nm Required torque for ignition coils 10 Nm Required torque for spark plugs 12 Nm WARNING Never fill with more than 2 7 of oil into the engine oil filter inc
24. 011 2008 02 03 504 asdf asdf LLILLILLIFPASTI 6 ET TEL Lea 77 Scroll Unit History page to reach Maintenance field Example of Maintenance field Maintenance 2008 03 10 Hours 12 00 10 hours Dealer Testdealer Maintenance Document test den Document service without problems 2008 07 22 Hours 24 00 25 hours Dealer Testdealer Maintenance Document HUDS File jog Documents Changed Oil gap adjustment 008 08 22 Hours 22 00 Dealer Testdealer Document HSR BENELLI DEALERS FRANCE 2008 xls Documents Valve checkt and adjusted Changed Oil and Oilfilter Changed Oil seals and bearings on Jet Pump 008 08 22 Hours 49 00 Dealer Testdealer Document ECU File Original ipa Document Checked and adjusted Valve clearance changed oilfilter and ail changed jet pump changed bearing and oilseals 25 hours Maintenance 50 hours Maintenance 2008 09 18 Hours 50 00 50 hours Dealer Testdealer Maintenance Document HUDS File doc docx Documentz Periodical check tor the 58 Owner Manual sls Igewechselt und nach Serviceintervall gearbeitet Add maintenance entry gt gt LLILLILLJ FPES BE IE LLCO ver 2009 03 Page 210 215 SEPIES SERIES Service Manual Maintenance Entry window will open To register performed maintenance fill the following fields 4 BEEF TS m m EY E Mail Imprint Home Orders Warranty Registration Unit History Downloads
25. 1 i s lp INMAP 3 BS LIGHTRELAY PUMP f 8 B6 INSIDESTAND i B7 i B8 i N i C1 ex 2 INSPEED2 ca i C3 CA C4 os INPTPS1 FUEL LEVEL ce eS RS Td I LA ca e8 GNDPOW bz 211 24950005 BLACK bu m E E ME LE ucc i E s y i k 1 1 DWG LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 188 215 E i ME pe eme ee m N 4 s sg 1 Ts ammensi 31 7 Tm m O 5 eem E Bido ji A 0 N S Q 2 3 Q5 518 B PUMP s K 15 I3 9 E N EE J E J s s FE U 1 a 0 O C L li O O Ek Tnm cm O O E a 3 35 cB Ol D W lt I Y gt T J 3 189 215 ver 2009 03 Service Manual 01 21 SENIES 11 1 5 Sector E
26. 108 215 72 Service Manual FASES BES LLCO ver 2009 03 Page 109 215 el Service Manual 5 PUMP AND IMPELLER 5 1 Jet Pump overview Series R Pro pump shown LLILLILLI F IST ET IESL L LCCCOFT1 ver 2009 03 Page 110 215 SETIES PR SErIES Service Manual NOTE Series S and Series R engines have closed loop cooling system The radiator is integrated into jet pump housing which is connected to the cooling system lines A WARNING Each time JET PUMP STATOR or JET PUMP assembly were removed from the hull engine coolant could flow out After reassembling jet pump to the vehicle always perform engine coolant level check and refill to specified volume if necessary 5 2 JET PUMP DISASSEMBLING Remove the O rings from the jet pump and place it beside Remove 4 x Allen screws m5 locking the Nozzle Remove Jet Pump housing Impeller housing with the Stator Remove 3 x screws of the stator cone LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 111 215 SsErRIES Service Manual Remove cone NOTE Pay attention on the white O ring in order not to lose it Cleaning of the water sieve in the Jet Pump NOTE The water sieve protects the exhaust cooling system from sand and other particles to block the water supply A heat sensor will warn you and slow down your personal PWC into the limp home mode of 4000 rpm
27. 2 To get the activation code for releasing ECU to full power mode please copy ECU code from field CODE 3 and insert this number during vehicle warranty registration procedure using on line B2B system see B2B 274 generation features below LLJLLILLI FA ES TESL L LCCCOFTT ver 2009 03 Page 206 215 SGrgas saGraias Service Manual Registration in B2B system Use the following link to access B2B system http hsrtest xpml at Fill in your Login and Password and click Login buton Username Password _ gt gt gt LLICLILLI FAGIT SP ESET Lk LET Fill in corresponding fields yva with unit s data VIN Serial Now Engine No e VIN number CHASSIS ECU No NUMBER to be Usage copied from field 1 of Line End Customer Information paraneters see First name above Last name Street e Engine number to be copied from Postal Code field 2 City e ECU number ECU CODE to ainda be copied from alt Choose Area field 3 e Select Usage Type File Durchsuchen e Enter Customer Information fields e Attach invoice scanned copy proving unit s sale Click Register button to complete Registration LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 207 215 1 RM SERIES Service Manual LLJILLSILLJ FA ES BENE LLIN Activation Code wi
28. 26 215 el Service Manual 5 4 Jet Pump Assembly into the PWC Grease the sealing lips of the jet pump Assemble the Flange bearing with it s 4 screws into the rear of jet pump tunnel Apply blue Loctite 243 on the threads of the screws or take new micro coated screws Support the Flange bearing during assembly with a hammer to pull it on the top position during tightening Tighten the screws with specified torque Tightening torque 30 N m in X method LLJLLJLLI ASTR BES IELLICOT ver 2009 03 Page 127 215 SS RS 2 Service Manual MAT v Apply blue Loctite 243 on the thread of the screws Tighten the screws with specified torgue Tightening torque 30 N m in X method Put in place the impeller housing with the impeller on the jet pump housing Apply blue Loctite 243 on the threads of the screws and tighten with Tighten the screws with specified torque Tightening torque 20 Nm ver 2009 03 Page 128 215 Service Manual 5 5 Assembly of the Reverse Gear For Series R Pro Model only Put in place the sleeves of the reverse shield Tightening torque 10 Nm NOTE Ensure the reverse shield moves easily BES IELLICOT ver 2009 03 Page 129 215 gt Service Manual 5 6 Assembling riding plate Apply blue Loctite 243 on the thread of the screws Put in place the Riding Plate and tighten 4 x
29. 3 Vehicle registration process e reuse 205 12 4 Periodic maintenance registration process 208 S PTORAGE e 212 14 APP EN DD 214 LLILLILLI F IST B5ET IELLICOYT ver 2009 03 Page 5 215 72 Service Manual LLSILLSILLJ ASTR BES TESL L LCCCOFT ver 2009 03 Page 6 215 72 Service Manual LLJLLILLI FA ES TESL L LCCCOFTT 1 General Information 1 1 Introduction This manual contains an introductory description of the HSR Benelli Series R and Series S Personal Water Craft PWC together with the procedures for control intervention and revision of the main components It is designed primarily for use by trained mechanics in a properly equipped workshop A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily All adjustments maintenance and repair should be carried out only by qualified mechanics in accordance with this service manual The present manual has been prepared on the basis of state of the art specifications valid at the date of publication In the case of modifications carried out after this date differences may exist between the contents of the manual and th
30. 661 2 PLUG 174663 2 CAP EP err er ECUB Hydrospace Wiring S08 Document Number ev ECUB HSR Wiring i Tuesday December 02 2008 Bheet 1 of 1 B a 1 1 A SHTI DWG WORK LLSILLJILLJ ASTR BENE La L l CCT ver 2009_03 Page 190 215 SENES SERIES Service Manual 11 1 7 Sector G I 1 e E 1 d TEMP smoT i amp 4 5 i ER 2W MINITIMER 2W E ja 78 a lt e 1 eT i mu 1 5 a S 1 5 l U 1 D i 1 i 1 J 1 1 i 1 i 1 i 1 J 1 I 1 1 L i 1 i I j 1 I 1 i 1 i 1 i 1 I 1 1 i 1 i 1 i 1 i 1 i 1 ana cte cio 1 kol i 5 ao J6 I SUMITOMO 6180 4181 SUMITOMO 6180 2181 1 ee eee en era 4 LI 1 1 1 SUMITOMO 200 000 o SUMITOMO 2000 2000 1 1 Ja d A 7 1 1 1 1 1 lv m gt gt ee ee gt AU A LT G i SHTI DWG WORK N 11 1 8 Sector H 1 I 3 L1 BOSCH 1926409966 BOSCH 1926403958 BOSCH 1928403066 c gt z 1 L
31. 72 Service Manual Series R c Pos Part description 4 COOLING HOSE HOTSHORT3Z 1 6 HosEctamP381 2 7 HOSECAMP2540 4 8 THREADEDTPIECE 1 9 PADS 30 131 SCREWCA SCREW CAP LLJLLILLI FA ES Fe ESEEl TESL L LCCCOFTT ver 2009 03 Page 149 215 1 RE SERIES Service Manual 8 2 Opened circuit systems m Series S as wot DE Ao El HEFTE dn beeches 11 C LLILLILLI F IST ET IE LLCO ver 2009 03 Page 150 215 72 Service Manual Series S cooling system components A OIL COOLER B WATER MANIFOLD 4 C T TYPE FITTING M8 THREAD Pos Part description O ty PLUG BLOT M8X10 EXHAUST MANIFOLD MAGNETIC VALVE IP67 T TYPE FITTING J INLINE FILTER INJECTOR EXHAUST L REDUCTION FITTINGSLEEVE 4 5 MM ZITTING DNO BLACK EF E37 77777 3 UR 6 EXITLINE EXHAUST COOLING HOSE INNER D 13MM 360M 7 INTAKE LINE EXHAUST COOLING HOSE INNER D 10MM 80CM 8 EXHAUST MANIFOLD COOLING HOSE INNER D 10MM 10 11 5 LLILLILLI F IST BET TESL L LCCCOFTT ver 2009 03 Page 151 215 72 Service Manual Series R Series R cooling system components Pos Part description QU OIL COOLER B WATER MANIFOLD C EXHAUST HO
32. ASES BES TESL L LCCCOFT ver 2009 03 Page 138 215 el Service Manual 7 Exhaust system 7 1 Muffler and Hoses Shown for Series R Pro Overview of the exhaust system in the Hull Inject 15 ml of engine oil into the exhaust muffler ensuring the temperature sensor will recognize the exhaust temperature in the exhaust system Put in place the copper gasket and the temperature sensor Apply green Loctite 278 and tighten the sensor with specified torque Tightening torque 20 N m LLILLILLI F IST ET IE LLCO ver 2009 03 Page 139 215 el Service Manual Apply Loctite on the thread of the screw tightening the exhaust mounting belt Tighten the exhaust end flange with 6 x screws and apply Blue Loctite 243 on the threads and tighten in with 5 Nm LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 140 215 el Service Manual 7 2 Exhaust Manifold In order to assemble the Exhaust Maifold following parts have to be assembled NOTE There are two different injectors with different Inner diameters Apply green Loctite 278 on the thread of the water injectors used on exhaust tubes of exhaust manifold Tighten the water injectors on its predefined position on the exhaust manifold to be in line QYILIILL ASTR BENE Le Lu l CCT ver 2009_03 Page 141 215 SERIES SERvi Ees s Service Manual There are three different fittings for the 3 in 1 exhaust hose
33. C Remove the roll over valve block unscrewing 6 mounting screws shown on the figure Remove the fixing bolt under roll over valve cover shown on the figure Remove 5 crankcase bolts shown by circle marks LLILLILLI ASTR BENE LLCO ver 2009 03 Page 66 215 SETIES R SERIES Service Manual Remove the oil pump cover Oil Pump and Oil Sump removal Rotate the engine 180 to access its bottom side Remove the oil hose attachment from the oil sump cover Remove the dipstick tube connection Untighten and remove oil sump cover mounting screws Remove the oil sump cover Dismantle Oil Pump intake tube and Oil Sump filter assy ATTENTION Note the position of the screws for correct remounting Remove the screws shown by circle marks on the figure Then remove 8 crankcase bolts shown by oval marks LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 67 215 SETIES R SERIES Service Manual Remove 2 balance shaft screws shown on the picture Remove the lower crankcase part pulling it up Use a soft hummer if necessary NOTE Pay attention to prevent crankshaft and balance shaft of falling down during casing removal QYILIILL ASTR BENE Le L l CT ver 2009_03 Page 68 215 el Service Manual Remove 2 large plastic lock nuts on both sides of balance shaft 14 Remove the ring 15 Remove the balance shaft Remove engine crankshaft ATTENTION Take note of cran
34. HAUST valves Cylinder 3 INTAKE valves Proceed the measurement for other valves rotating the engine using a wrench on a special nut of camshaft measure the clearance when the cams corresponding to eligible valves are in upwards position Cylinder 1 EXHAUST valves Cylinder 2 INTAKE valves and Cylinder 3 EXHAUST valves Cylinder 1 INTAKE valves LLILLILLI F IST ET IE LLCO ver 2009 03 Page 26 215 7 Service Manual SPECIFIC VALUE Intake 0 30 0 35 mm Exhaust 0 35 0 40 mm Note Engine must be cold If the valve clearance is out of specifications take note about your current reading for adjustment 2 3 5 Valve clearance adjustment ATTENTION To prevent falling of removed parts into crankcase please use proper sealing material at timing chain drive casing Remove the chain pad 6 unscrewing the two fixing Screws 7 LLILLILLI F IST ET IESL L LCCCOFT1 ver 2009 03 Page 27 215 7 Service Manual ATTENTION Make sure that the distribution chain does not fall into the casing Remove the chain tensioner ATTENTION Mark the removed elements for correct reassembling cylinder number camshaft IN EX etc Remove mounting screws of camshaft holders 8 and remove them Take care of removing metal bushings of each holder Remove the bridge 9 unscrewing the fixing screws Raise the camshaft paying attention to keep all teeth of the timing chain in place
35. L 1 EXHAUST WATER VALVE 3 2 1 SSgWwMr MINITIMER 2W MINITIMER 2W MINITIMER 2 TIPOVER OL PRESS SW FNG T TPS EXHAUST TEMP SNOT U i o en SUMITOMO 61872311 99 W MPF MNITMER 2W MINITIMER SW MINITMERZW MINIMER ow i 1 A vr 1 E om a a o ks as a eat p o a fjura a s s s bee n s ant eee be ee s n a a a ETETETT J N WORK LLILLILLI F IST BET IE LLCO ver 2009 03 Page 191 215 el Service Manual S 11 2 General view SERIES R wiring diagram Ly qH mi LLILLILLI FPES BENE LLCO ver 2009 03 Page 192 215 n HET L 1 N i I i i i i A i i T i i i T i 1 0 1 i al i i 4 i i i i T 1 L I gt Aj our i E 1 H k m i E 0 ea 2 ch E MN i i d E zm oe Se s i I zz LL dd c Gt Tt 5 E 1 i dn JA i i m i i kg il 1 A DE i i S if 2 1 1 i 4 1 a L LT 1 ven rne fs E E LN ra E a i 1 1 zd ar i lt lt 4 1 A3 d oy L LJ ee k L i E e
36. LIILL ASTR BENE Le Lu l CCT ver 2009_03 Page 118 215 SGrgas sSsGrias Service Manual Press in the first bearing smaller in diameter bearing with a tool A A Put in place the second smaller in diameter bearing with a tool Press in the second bearing smaller in diameter bearing with a tool LLILLILLI F IST ET IE LLCO ver 2009 03 Page 119 215 SGrgas sSsGrias Service Manual Put in place the distance sleeve Put in place the third bearing bigger diameter Press in the third bearing bigger diameter with a special tool Take a new oil seal and apply grease in the lips Place the oil seal on the sleeve RECOMMENDED LUBRICANT FUCHS URETHYN E M 2 LLSILLJILLJ ASTR BENE La L l CCT ver 2009_03 Page 120 215 SGrgas sSsGraias Service Manual Press in the new oil seal with a tool very carefully Apply grease on the remaining sleeve and put it in place RECOMMENDED LUBRICANT FUCHS URETHYN E M 2 Put in place the sieve in the housing Put in place the sieve housing and apply blue Loctite on the beginning of the thread QYILIILL ASTR BENE Le L l CT ver 2009_03 Page 121 215 7 Service Manual Tighten the screws for the sieve housing with specified torque Tightening torque 10 N m in X method Apply grease on the impeller shaft all the way around RECOMMENDED LUBRICANT FUCHS URETHYN E M 2 Press in the Impeller Shaft Assem
37. NESS STANDARD 1st 0 97 0 99 mm 2na 0 97 0 99 mm e Check Piston Pin The following procedure must be applied to all the piston pins Check that value a enters within the specific value NOMINAL VALUE 18 995 19 000 mm LLJLLILLI FA ES TESL L LCCCOFTT ver 2009 03 Page 62 215 SERIES SEI1R ES Service Manual Check the value of b 9 W NOMINAL VALUE W b 19 002 19 008 mm SALIT NOTE If the play between the piston pin and the pin is more than 0 03 mm change the piston e Mounting Piston Rings Install the piston rings in the order oil ring 2 piston ring 151 piston rings The first element to insert into the slot of the oil ring is the spacer 1 After having positioned the spacer insert its lateral rings 2 NOTE The spacer and the lateral rings do not possess a particular upper or lower side so they can be inserted in any way WARNING When installing the spacer pay attention so that its ends are not superimposed in the cable CORRECT KARAN N LLILLILLI F IST B5ET IELLICO YT ver 2009 03 Page 63 215 72 Service Manual Install the 2 a piston ring 3 and the 1st piston ring 4 NOTE The form and width of the 1st and 2nd piston ring are different W4 3 1 0 1 mm W3 3 7 0 1 mm The 1stand 2 piston ringhave the letter N on the upper side Make sure that the marked si
38. NS KC EE UE Transmission oil Lubricated by Engine oil see engine see engine system HSR Benelli engine oil oil volumes oil volumes 10w60 ACEA A3 B3 B4 SL Coolant Permanent type of antifreeze Total Total based on monoethylene glycol amount amount GREEN freezing point lt 38 C 2 5 litres 3 0 litres Trim system liquid Brake fluid DOT4 1 2 4 Engine Brake In WARNING HSR BENELLI recommends not to operate the engine over 6 000 r min RPM during first five hours of operation This protective braking in has a positive effect on the engine s lifespan 1 2 5 Operating the engine on vehicle outside of water WARNING If PWC is outside of water its engine may be operated at idle speed only for maximum of 30 seconds Never run the engine for more than 30 seconds without cooling water supply If itis necessary to operate the engine longer than 30 seconds on vehicle out of water the flushing equipment must be used Use flushing system to operate vehicle out of water An auxiliary cooling supply may be used if the watercraft cannot be operated in water during adjustments If possible always operate the watercraft in water rather than use an auxiliary cooling supply See chapter Maintenance Flushing system connection LLJLLILLI FA ES TESL L LCCCOFTT ver 2009 03 Page 13 215 1 RE SERIES Service Manual 1 3 Unit identification 1 3 1 HSR BENELLI Personal Watercra
39. RQUE SPECIFICATION STAINLESS STEEL FASTENERS METRIC LLJLLILLJ FA ES BE TESL L LCCCOFTT ver 2009 03 Page 17 215 72 Service Manual E 1 4 3 Convertion Chart oe o ja ja om X8448 US quarts US a Lier Pounds force per square inch x 6 895 Kilopascals kPa psi Kilopascals kPa 0 145 Pounds force per square inch psi Kilopascals kPa Kilograms force per square cm Kilograms force per square cm Kilopascals kPa C to F 9 40 5 40 F F to C 5 F 40 9 40 LLILLILLI FASES BES IE LL COST ver 2009 03 Page 18 215 72 Service Manual LLILLILLI FASES BES TESL L LCCCOFT ver 2009 03 Page 19 215 72 Service Manual LLSILLSILLJ FA ES BE TESL L LCCCOFTT 2 Maintenance The table in chapter Periodic maintenance table provides the manufacturer s recommended intervals for maintenance work Following the maintenance recommendations a long life span of the vehicle can be achieved and unnecessary environmental damage prevented The Maintenance intervals specified in the table should not be exceeded by more than 1096 All activities described in this manual must be carried out by trained service staff In case of warranty repairs HSR BENELLI reserves the right to request warranty approval documents for performed periodic
40. Remove the following parts Oil return line to the bottom of the engine Oil supply line Hear engine Support Coupler cover LLILLILLI FPES BENE LLCO ver 2009 03 Page 92 215 Series SERIES Service Manual Remove 2 x short and 10 x long 5mm mounting screws Take note of short screw position shown on figure Remove transmission cover with a suitable tool NOTE do not damage the gasket surface of the casting Remove the right hand thrust washer carefully and place beside LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 93 215 gt SERIES Service Manual Remove carefully the left hand transmission gear assy and place beside Remove carefully the second thrust washer and place beside Remove carefully the 3 x needle cage bearings and place beside Remove carefully the left had thrust bearing and place it beside LLJLLJLLI FAS BE IELLICO YT ver 2009 03 Page 94 215 2 SERIES Service Manual Remove Nut 41 mm with an impact tool Remove transmission gear with the gear wheel remover Tighten the screws of gear wheel remover in X method stopping the gear with a suitable tool Remove the gear and place it beside Remove 2 x transmission casing mounting screws and lower banjo bolt NOTE Remove the copper washer of lower banjo bolt LLILLILLI FP IST ET IELLICO YT ver 2009 03 Page 95 215 Series SERIES Service Manual
41. SE D EXHAUST MANIFOLD MAGNETIC VALVE IP67 F FITTING 5MM G L TYPE FITTING 5MM T TYPE FITTING 3MM INLINE FILTER 4 SPREDSERT M6 X 12 7 _ ELBOW SCREW IN NOZZLE SCREW IN HOSE NOZZLE IN HOSE NOZZLE BYPASS FITTING DNO BLACK s N REDUCTION FITTINGSLEEVE 4 5 MM ver 2009 03 Page 152 215 el Service Manual 4 EXIT LINE OIL COOLING HOSE INNER D 13MM 1050M _ 5 INTAKELINE EXHAUST COOLING HOSE INNER D 10MM 1150 6 FLUSHING SYSTEM HOSE INNER D 10MM 1 500M 7 INTAKELINE EXHAUST COOLING HOSE INNER D 10MM 250 8 MAGNETIC VALVEHOSE INNERD6MM 27M 9 INLINEFILTERHOSE INNERD 10MM 15 _ 8 2 1 Exhaust cooling system Overview of the exhaust cooling system Shown for Series R LLILLILLI FPES BENE LLCO ver 2009 03 Page 153 215 1 gt Service Manual The flow of the cooling liquid The water enters the system through wards the Jet Pump tunnel The T Fitting splits the water flow into the exhaust manifold and the Flushing system hose The hose for the exhaust manifold cooling system feeds first the end of the manifolds QYILIILL FPES BE IE LLC OST ver 2009 03 Page 154 215 1 gt Service Manual and goes through wards the tubes up to the end where the headed liquid is collected It leaves the
42. STIC SYSTEM Benelli engine version IMPELLER TOOL FLYWHEEL PULLER LLJLLILLI FA ES Fe ESEEl TESL L LCCCOFTT ver 2009 03 Page 10 215 gt Service Manual T D C MEASURER TRANSMISSION GEAR PULLER GEAR NUT REMOVAL TOOL COUPLER REMOVING TOOL VALVE OIL SEAL REMOVING TOOL OIL REMOVING TOOL LLILLILLI F IST ET IELLICOT ver 2009 03 Page 11 215 SEMIES F SEMNIES Service Manual 1 2 3 Operating materials WARNING Using of not recommended operating materials causes damage to the engine and voiding of the warranty e Fuel Super petrol unleaded DIN 51607 Octane between 95 and 98 ROZ 85 MOZ US premium Unleaded gasoline 91 92 93 Octane or 95 98 ROZ ISO 5146 In case of emergency unleaded fuel with 91 ROZ RON or 82 5 MOZ MON may be used for a short time ATTENTION Lower quality fuels could only be used in case of emergency If used regularly they cause decreases in performance and possibly damage to the engine e Recommended lubricants SRECIFCATONS KB AEN Engine Oil HSR Benelli engine oil 10w60 specification ACEA A3 B3 B4 API SL Engine Oil Initial filling completely dry system 2 3 litres 2 7 litres Filling volumes Oil change without changing filter 1 7 litres 2 1 litres Oil change with filter 2 0 litres 2 4 litres LLJLLILLI FA ES TESL L LCCCOFTT ver 2009 03 Page 12 215 Service Manual SPECIFICATIO
43. TE Take care to install the sealing rings Plug in the cooling water supply lines as shown on the picture into the oil cooler QYILIILL ASTR BENE Le L l CT ver 2009_03 Page 36 215 1 BRE sarias Service Manual Plug in the water relieve hoses from the oil cooler Plug in the water supply hose for the waterpump Plug in the coolant hose for the temperature thermostat QYILIILL ASTR BENE Le Lu l CCT ver 2009_03 Page 37 215 el Service Manual Plug in the Ignition wires for the ignition coils NOTE Ignition wires are marked with numbers of corresponding cylinders Plug in the wires for the injectors NOTE Injector wires are marked with numbers of corresponding cylinders Plug in the connector for the heat sensor Plug in the TPS sensor Plug in the pick up coil sensor LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 38 215 1 BRE sSsaGrias Service Manual Plug in the oil pressure sensor Plug in the SSSA connector Tighten the ground wire QYILIILL ASTR BENE Le Ln l CCT ver 2009_03 Page 39 215 1 BRE sSsaGrias Service Manual Connect the positive wire from the starter to the starter relays Connect the positive starter cable to the positive starter connector Connect the acceleration wire to the throttle bodies For adjustment of the acceleration wire insure the throttles are on open wide throttle position
44. This requires regular maintenance There is a second one in the water injection of the exhaust system Remove the sieve out of the housing with a tool QYILIILL ASTR BENE Le L l CT ver 2009_03 Page 112 215 1 gt Service Manual Removing of the Impeller Remove the impeller from the impeller shaft by loosen the impeller with a Special Tool Block the impeller shaft See Photo beside NOTE Remove the Impeller shaft with a soft tool in order to avoid damages on the thread Remove the impeller shaft Disassembly of the Stator Housing of the Jet Pump Remove the bearings out of the housing with a soft tool QYILIILL FPES BENE Lu L l CT ver 2009_03 Page 113 215 el Service Manual NOTE Take care of bearings place for correct assembling Disassembly of the Jet Pump Housing Disassembly of the Jet Pump Housing carrying the Liner for the engine Radiator NOTE The Jet Pump housing and the Liner cannot be taken apart and need to be replaced as one for repair Remove the cooling water supply hose Disassembly of the Jet Pump nozzles Open with an allen screw driver M 6mm the screws on the left and right hand side of the steering nozzle QYILIILL FPES BE IESL L LCCCOFT ver 2009 03 Page 114 215 el Service Manual Remove the spring located on the Nozzles Remove the Steering nozzle Remove plastic bushings from the steering n
45. ace Start Stop switch wire first Put in place the handle bar cover Apply BLUE Weicon Lock AN 302 43 on the threads of handlebar cover screws Tighten screws with specified torque QYILIILL FPES BE IE LLC OST ver 2009 03 Page 162 215 7 Service Manual 519 Tightening torque 25 N m X method Put throttle cable end in the throttle lever hole Assemble Trim oil line with the banjo bolt Tighten trim lever on the handlebar LLILLILLI FPES BENE LLCO ver 2009 03 Page 163 215 SERIES SERIES 5 Service Manual Tighten the Start Stop switch on the handle bar SERIES S STEERING SYSTEM 9 4 Handle Pole Assembly Parts for the Handle Pole assembly ver 2009_03 Page 164 215 SGrgas sSsaGraas Service Manual Assemble the red protection bar and tighten the screws for the extension 6 otick two aluminum profiles into the Handle Pole plate as shown in the picture Apply Loctite 243 on the thread of the 8 screws M5 x 35 as shown on the photo Tighten the screws into the handle bar and tighten them with specified torque Tightening torque 5 N m X method Apply Loctite 3425 A amp B on the top end of the handle bar and stick it together like shown on the photo 47 LLILLILLI F IST ET IE LLCO ver 2009 03 Page 165 215 5 2 SERIES Service Manual Apply Loctite 243 on the thread of the screws and tighten them with s
46. ally Miscellaneous Keep broken files C Display files in Explorer Save settings 5 Close WinRAR window Go to the location folder of RAR file Folder HUDS _ 39 23 5 See Ew D E his DVD RAM F 8 5 cds 192 168 207 102 wi network 132 158 207 102 H Se khabaravs 132 158 207 1 02 B acl H ic II Service manual 2 Series R and S should appear LLILLILLI ASTR BENE LLCO ver 2009 03 Page 199 215 1 RE SERIES Service Manual DIAGNOSTIC TOOL BE gt gt B Or re 3 ID C3 D HSR worki DIAGNOSTIC TOOL HUDS Series and 5 rar WinRAR archive 400 6 Open folder HUDS Series R and S and start the file ServiceHSR564 exe ES Service HSR 564 eJ d gt X i 0 1 HSR warkiDIAGMOSTIC TOOLIHUDS Series and SIHUDS Seri S DatiCons CNS_B1HSR_O7 US_NEW den English WL 4 Italiano
47. bly of the Impeller Screw carefully the Impeller on the Impeller Shaft and tighten it by hand QYILIILL FPES BE IE LLC OST ver 2009 03 Page 122 215 SGrgas SEVES Service Manual Use a special tool to tighten the impeller to the final torque Tighten the Impeller to the specified torque Tightening torque 100 N m Put in place the white plastic ring LLILLILLI FPES BENE LLCO ver 2009 03 Page 123 215 SETIES PR SErIES Service Manual Apply blue Loctite 243 on the screws of the cone and tighten it with a specified torque Tightening torque 7 Apply blue Loctite 243 in the thread of the water supply tube And tighten the tube on the housing Put in place the O Ring and apply slightly grease on the surface Apply grease on the sockets of the Impeller housing QYILIILL ASTR BENE Le L l CT ver 2009_03 Page 124 215 SGrgas sSsGrias Service Manual Put in place the Stator Housing on the Impeller Housing Put in place the Nozzle assembly Apply blue Loctite 243 on the beginning of the threads of the screws 5 Tighten the screws with specified torque Tightening torque 25 N m in X method LLILLILLI FPES BENE LLCO ver 2009 03 Page 125 215 1 gt Service Manual Put in place the O Rings and the rubber cone and the rubber seal Final assembly of the Jet Pump LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 1
48. de is turned upwards when being installed on the piston 2 segment e Piston Installation Position the two piston rings 1 and the oil ring 2 on the piston positioning the opening at 120 from each other LLJLLILLI FA ES Fe ESEEl TESL L LCCCOFTT ver 2009 03 Page 64 215 el Service Manual Position the piston 3 as shown in the figure with the arrow on the piston pointing towards the exhaust Insert the pin 4 ATTENTION Always use new elastic rings for mounting the pistons To avoid breaks that can take place with the rings bent Position the two elastic rings 5 one for each side pay attention not to deform them QYILIILL FPES BE IE LLC OST ver 2009 03 Page 65 215 7 Service Manual 3 2 3 Engine Bottom end e Crankcase Disassembling Remove the cylinder head see CYLINDER HEAD REMOVAL Remove the cylinder block see DISMANTLING CYLINDER BLOCK Remove the pistons see DISMANTLING PISTONS A ATTENTION Ensure that there is no oil left inside the engine before dismantling crankcase Remove engine oil using oil pump tool if necessary ATTENTION After reassembling ensure to rotate the engine with its electric starter without spark plugs but with transmission installed on it and filled with engine oil for 60 seconds before installing the engine into the PWC to ensure that all bearings are sufficiently lubricated with oil before the first test run in the PW
49. e 131 215 7 Service Manual Keep the Injector pressurized and pump the nozzle up and down until no air bubbles are released to Injector Put paper underneath the trim lever to collect remaining brake liquid Remove the Injector bleeding nipple put in place O Ring and screw the plug loosely into the Trim lever body Tilt the nozzle to the top position and ensure the excessive brake fluid will be released of the trim lever Tighten the plug screw Clean the trim leaver with a cleaner in order to avoid brake liquid contact with the paint of the hull QYILIILL FPES BE IE LLC OST ver 2009 03 Page 132 215 72 Service Manual FASES BES LLCO ver 2009 03 Page 133 215 1 SEMIES Service Manual 6 Fuel system 6 1 Fuel Tank and Fuel Pump Fuel tank disassembly out of the PWC Shown for Series R Pro Remove the 2 x screws of the fuel tank belts on the bottom of the hull Unscrew the clamp of the fuel filling hose and remove the hose NOTE Pump out any remaining fuel out of the tank if required Remove the fuel tank out of the hull Disassembly of the fuel pump out of the fuel tank Unscrew the 6 x screw from the fuel pump LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 134 215 1 BRE sSsaGrias Service Manual Pull out the fuel pump carefully out of the fuel tank Fuel pump filter and fuel
50. e 60 215 el Service Manual e Check Piston The following procedure must also be applied to all the other pistons Check eventual breaks on the piston Use a micrometer as shown in the figure to check that the value P enters within the specific value 87 950 87 960 87 961 87 971 87 972 87 982 ATTENTION In the case of changing one or more pistons The piston is distinguished by a letter that indicates the class it belongs to The cylinder piston coupling must be carried out among the same classes that they belong to NOTE The maximum play of the piston is of 0 1 mm Change the piston if necessary e Check Piston Rings The following procedure must be applied to all the piston rings Check the absence of scuffing and traces of shrinkage on every Piston ring Check that the edge of the section is well defined and free in the housings Whenever wear in the segments is found change the pistons as well QYILIILL ASTR BENE Le Lu l CCT ver 2009_03 Page 61 215 72 Service Manual e Piston Ring Play Measure the lateral play of the 1stand 2nasegment using feeler If one of the two plays exceeds the limit specified change both the piston and the segments PISTON RING PLAY SERVICE LIMIT 1st 0 20 mm 2na 0 18 mm PISTON RING WIDTH STANDARD 1s 1 02 1 04 mm 2na 1 01 1 03 mm OIL RING 2 01 2 03 PISTON RING THICK
51. e PWC under review The illustrations in this manual are used to highlight the fundamental principles and procedures of basic interventions They may not show exactly the PWC in your possession SYMBOLS Whenever you see these ATTENTION symbols heed their instructions Always follow safe operating and maintenance practices A ATTENTION aware that you will find death or serious injury in case the instructions are not observed WARNING Possibility of lesions in case the instructions are not observed NOTE of this message ts trying to avoid any damages to the vehicle things or environment ver 2009 03 Page 7 215 RR SERIES Service Manual OILING Indicates the type of oil to use TIGHTENING Indicates the correct tightness value to carry out SPECIFIC VALUE indicates the specific value using precision In struments SPECIFIC INSTRUMENTS indicates the specific instruments to use LLJLLILLI FA ES TESL L LCCCOFTT ver 2009 03 Page 8 215 SEMIES F SEMNIES Service Manual LLJLLILLI ASTR BENE Lu Ln l CCT 1 2 Service guidelines 1 2 1 Safety Warnings ATTENTION Clean inside and outside of watercraft prior to servicing Clean all parts before installing Always use a service apron to prevent damage to foot well and top deck fiberglass Watch for sharp edges which can cause personal injury Protect hands and arms when working wit
52. e perfectly sealed Remove the small bowls taking note of the position on each valve and coupling them to their pads Free the pusher spring plate 7 using the specified instrument to remove the two lock cones Remove the external spring 5 the internal spring 6 valve 4 the valve seal ring and the lower cup LLSILLJILLJ ASTR BENE La L l CCT ver 2009_03 Page 50 215 el Service Manual e Valves and Valve Guide Inspection The following procedure must be carried out on all valves and relative valve guides Check that values A and B are within the tolerance of the specific values If values A and are not within the value limits change the elements INTAKE VALVE DIAMETER LIMIT AS A max 5 05 mm w 4 965 mm EXHAUST DIMENSION LIMITS A max z 5 05 mm ai B min 4 955 mm Check condition of the surfaces of the valves Eliminate eventual carbon deposits If the surface is excessively ruined change the element Check thickness A indicated in the figure VALVE THICKNESS VALUE LIMIT 1 0 1 3 LLILLILLI F IST ET IE LLCO ver 2009 03 Page 51 215 7 1 Service Manual LLJLLILLI FA ES Fe ESEEl TESL L LCCCOFTT Check the deformation of the legs of the valve If the concentricity value does not enter within the margin change the element VALVE REFORMATION e Valve Seat Inspection The following procedure must be ap
53. ed on front left engine mounts to avoid damage from engine LLJLLILLI FA ES TESL L LCCCOFTT ver 2009 03 Page 33 215 el Service Manual Engine installation into the PWC shown for Series R Pro Lift the engine into the PWC using a lifting device Insure you hook on the exhaust hose and the and inline the Spider Couplers Position the Engine into the 4 x engine supports on the hull LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 34 215 el Service Manual Ensure the exhaust hose and the Spider Couplets are properly aligned Take a metal ruler like shown on the picture and check the alignment of the Spider coupler to see if the engine is positioned properly according to propulsion system If the engine position needs to be adjusted use special washer with 0 5 and 1 mm thickness to align the system NOTE If the engine needs to be heightened you have to use washers on all four engine supports Apply blue Loctite on the screws and tighten the screws of the engine support with specified torque Tightening torque 30 N m QYILIILL FPES BENE Le L l CT ver 2009_03 Page 35 215 SETIES PR SErIES Service Manual Tighten the exhaust hose with a screw driver Plug in the cooling hose for the 3 in 1 hose Plug in the water relieve hose for the 3 in 1 hose Y Plug in the water relieve hose for the exhaust manifold Tighten the fuel hose to the fuel rail NO
54. edures 23 AC MEO ET Peace NIETO 23 2 3 2 Engine oil and filter replacement 24 2 3 3 plugs TeplacelmieliLusu secuouseou ooa na esu a s coca ooa cu rex aora want 25 2 3 4 Valve clearance inspection ee 26 2 3 5 Valve clearance adjustment mm 27 2 3 6 Refilling of COC 2121 RETI 31 LLILLILLI F 1ST F9ET TELLICO ver 2009 03 Page 2 215 72 Service Manual 9 ENGINE 32 3 1 Engine Removal and Installation 33 3 2 Engine Disassembly Assembly 41 9 1 CYONDER HEAD via si avus ue dx Uer I duas 41 3 2 2 CYLINDER AND PISTONS 2 Peso rau va pav a oops nera stipe 58 9223 ENGINE BOTTOM END 66 3 2 4 Cooling system Thermostat and Water pump 82 4 Lxx 91 41 Transmission Dismantling esseeus 92 4 2 Transmission Assembling eee eere 98 4 3 Center flange bear
55. element or its components are damaged or ruined change it them e Camshafts installation Using a special tool set the piston of cylinder 1 to TDC position LLILLILLI FPES BENE LLCO ver 2009 03 Page 44 215 el Service Manual NOTE Ensure that during assembling engine crankshaft is not moved from 1 cylinder TDC position and camshafts marks are aligned as shown on the picture Position the exhaust shaft and the timing chain position the holders in their original direction written on the outside and tighten the fixing screws according to the diagram in the figure Tightening torque 1st phase 6 N m 2nd phase 13 N m Position the intake shaft and the timing chain position the holders in their original mark on the outside of holder should match the number engraved on inside of cylinder head and tighten the fixing screws according to the diagram in the figure Tightening torque 1st phase 6 N m 2nd phase 13 N m LLJLLJLLI ASTR BENE La Ln l CT ver 2009_03 Page 45 215 7 Service Manual Position the timing chain on the camshaft sprockets Position the bridge and the upper chain pad and tighten the fixing screws in two phases in shown sequence Tightening torque 1st phase 6 N m 2nd phase 13 N m NOTE Always oil the sliding parts with Teflon SINTOFLON paste Position the chain tensioner 1 complete with O ring 2 and tighten two screws 6 Tighte
56. en the dash board on the handle bar with 3 NM Assembly of the locking pin for the handle bar Put in place the location pin into the handle bar support Put in place the locking pin ball by hand Put in place the location pin holder and tighten it Clean the aluminum part of the handle bar and put the safety stickers on it Put in place the sticker for the load of the vehicle QYILIILL FPES BE IE LLC OST ver 2009 03 Page 169 215 SERIES SElJES Service Manual gt bly 9 5 Handle Bar Assem Apply Loctite 243 on the Screw for the steering control bushing Put the bearing in place and press it on the steering control bushing Put the steering control lever in place Put the subassembly of the steering control bushing in place Put in place the second ball bearing and press it in LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 170 215 SETIES R SErIES Service Manual Apply Loctite 243 on the thread of the second steering control bushing and put it in place Tighten the system with a torque meter MN Tightening torque 20 N m Take the ball joint screw and apply Loctite 243 on the thread of the screw Tighten the ball joint Put the Handle bar clamp and mounting screws in place Tighten the screws with a torque meter IN Tightening torgue 20 N m 9 6 Assembly of the Handle Bar on the PWC Place on the RIGHT SIDE of PWC Trim Dashboard and the S
57. eries and 5 to the hard disk of your computer 2 Open this file from location where you ve saved it WinRAR or analog software is required DIAGNOSTIC TOOL N e gt 3 Select folder HUDS Series R and S and press button Extract To on the upper bar LLJLLILLJ FA ES BE TESL L LCCCOFTT ver 2009 03 Page 198 215 1 1 7 6 1 Service Manual HUDS Series R and S rar WinRAR File Commands Tools Favorites Options Help 59 5 Ww 70 Add Extract To Test View Delete Find Wizard Info VirusScan Comment Protect SFX E SB Hups Extract files 5 rar RAR archive unpacked size 1 453 407 bytes Name 4 Size O HUDS Series R and 5 SERVICE Packed Folder Folder Modified 21 10 2008 20 30 O selected 1 Folder Total 1 Folder 4 Click OK to Extract folder to the directory were your RAR file was saved To change destination folder use right explorer panel to choose it then press Extraction path and options General Advanced Destination path will be created if does not exist Update mode Extract and replace files Extract and update files Fresh existing files only Overwrite mode Ask before overwrite CO Overwrite without prompt O Skip existing files Rename automatic
58. ft Identification Numbers The engine Serial number and VIN number are used to register the watercraft They are unique numbers that distinguish each watercraft from others of the same model If the watercraft is ever stolen these numbers will help identify it The owner should keep a record of these numbers in a place other than the watercraft 1 3 2 VIN number AT Manufacturing Country HSR HSR BENELLI A Model Code 1001 Sequential Serial Numbers Production Month C Month code Production Year 8 Model Year 08 Model year 8 2008 You will find the serial number at the right rear side of your PWC 1 3 3 Engine number Number is beside the starter motor Engine Number BH33 Engine Type 000001 Serial Number JJ808 Model and Year Code LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 14 215 1 RE SERIES Service Manual 1 3 4 Three stars ultra low emission The three star label identifies engines that meet the Air Resources Board s Personal Watercraft and Outboard marine engine 2008 exhaust emission standards Engines meeting these standards have 65 lower emissions than One Star Low Emission Engines 1 3 5 Safety instructions For Series S ONLY Safety Instructions sticker is placed under the handle pole on the Series S models For Series R ONLY Safety Instructions sticker is placed on the Luggage Cover on the Series R LLILLILLI F IST ET IESL L LCCCOFT
59. g Apply BLUE Weicon Lock AN 302 43 on the thread of the base stud Screw in the base stud by hand and let the Loctite dry out Put in place the side cover Put in place the rubber washers and tighten self locking nut carefully by hand LLILLILLI F IST ET IE LLCO ver 2009 03 Page 184 215 el Service Manual 10 5 Sponsons assembling Apply BLUE Weicon Lock AN 302 43 on the thread of the screws diak E Put in place the sponsons ground plate a Tighten it with specified torque JN Tightening torgue 15 N m Put in place the sponsons and tighten it withb Nm LLILLILLI FPES BENE LLCO ver 2009 03 Page 185 215 72 Service Manual LLSILLSILLJ ASTR BES TESL L LCCCOFT ver 2009 03 Page 186 215 el Service Manual 11 Electrical System 11 1 General view SERIES S wiring diagram m prem Y ere 1 m NLA I m qud T qe 4 4 hr a gm j EE W i e VP 4 E i a i 1 i li i oa I LLILLILLI FPES BE IE LLCO ver 2009 03 Page 187 215 1 oe oS Service Manual 11 1 1 Sector A I om c wee ee OO m o m L I I Lj I
60. g the right hand side gear tightening nut Tightening torque 160 N m Put in place transmission parts on the right hand side of the transmission Put in place the thrust washer Put in place the 15 cageless needle bearing Put in place the 1 thrust ring Put in place the 2 cageless needle bearing Put in place the 27 thrust ring Put in place the 3 cageless needle bearing Oil the bearing system LLILLILLI FPES BENE Lu Ln l CT ver 2009_03 Page 103 215 SERIES semIES 5 Service Manual Put in place the right hand gear assembly Put in place the thrust washer of the right hand transmission gear Put in place the thrust washer of the left hand transmission gear Put in place the 3 x cage needle bearing Oil the bearing system Ensure the 2 x location pins are in place Apply Loctite 5699 on the transmission housing sealing surface ver 2009_03 Page 104 215 7 Service Manual Put the Paper gasket for the transmission cover in place Apply Loctite 5699 on the sealing surface of the transmission cover NOTE The short screws are to be used on the left hand side of the transmission like shown on the figure Tighten using the other 10 screws Tighten all 12 screws according to the tightening procedure and with specified torque Tightening torque 10 N m Install the oil lines in the order your removed them Apply RED Weicon Lock AN 305 86 and tighten the banjo bolt with specified to
61. h sharp components Always use a soft faced hammer and extreme care when removing difficult or stuck components Some fasteners are installed with locking agents or lubricants Use of impact drivers will aid in fastener removal Always follow torques specifications located throughout manual Fasteners secured with either too little or too much torque may fail and cause severe property damage injury or death Always follow torque sequence patterns when founding this manual Tighten each fastener evenly and to the specified torque value and with specified locking agent Always use new gaskets o rings and seals clips cir clips and snap rings when assembling components Never reuse self locking nuts when assembling components Never reuse hose clamps when removed from fuel lines Replace with small gear clamps WARNING Always use HSR Benelli authorized lubricants greases and locking agents when assembling components Failure to do so may cause severe engine or vehicle damage Always disconnect the black negative cable first from the battery when removing the battery When installing the battery attach the red positive cable first then the black negative cable Wear appropriate clothing eye protection and rubber gloves when working with batteries Battery acid contains sulphuric acid and is extremely poisonous Serious burns can result when in contact with skin clothing eyes or internal body components If batter
62. hether the thermostat pad is cracked Pass a cord through the flange as indicated in the figure Check the above mentioned conditions by immerging the thermostat 1 in a container with water maintaining it in suspension Slowly heat the water and check the temperature with a thermometer 2 When a temperature of 75 C is reached the thermostat valve begins to open and arrives at a temperature of 90 C The thermostat valve reaches an opening of at least 7 mm Change thermostat if necessary Check that the thermostat cover and the tubes connected to it are not broken otherwise change the damaged element e Mounting the Thermostat n WARNING The thermostat must be mounted with the by pass hole 2 turned upwards as shown on the figure Position thermostat 1 as indicated on the figure Position the thermostat cover and tighten with the two mounting screws with specified torgue lt S 10 Nem 1 Kg m IE LLCO ver 2009 03 Page 83 215 el Service Manual e Dismantle Water Pump Loosen and remove the two screws 4 and the small plates 5 Remove the entry elbow 6 Loosen and remove the two screws 3 and remove the water pump from the engine Remove O Ring 7 Loosen and remove two screws 8 Remove the cover 9 LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 84 215 el Service Manual Loosen and remove the nut 10 and remo
63. hree phases JN Tightening torgue 1 phase 15 1 5 Kg m 274 phase 25 2 5 Kg m 3 phase 50 NOTE An angle torque control wrench is required to carry out the third tightening phase Mounting Balance Shaft Position the ball bearing 1 and fix with the circlip 2 LLILLILLI F IST ET IE LLCO ver 2009 03 Page 75 215 el Service Manual o Position the bushing 4 Position the ring 5 Position the roller bearing 3 on the balance shaft BENCH SEMI BALL BEARING Mounting Casting STD COLOUR SELECTION NOTE A Red 1 918 1 922 B Blue 1 922 1 926 bearings marked by colors mentioned in the chart C Yellow 1 926 1 930 There 3 different sizes of crankshaft plain 2 seat std red 41 830 41 836 2 seat std B blue 41 836 41 843 4 seat std C yellow 41 843 41 849 4 single std shaft 37 960 37 970 LLILLILLI F IST ET IE LLCO ver 2009 03 Page 76 215 el Service Manual NOTE Reading the letters must always be carried out starting from timing chain side Position and center four semi bronze plain bearings 25 each slotted with the correct color according to its letter stamped on the exhaust side of the crankcase 24 Blue Yellow Position the crankshaft as shown on the figure Position the balance shaft BES IELLICOT ver 2009 03 Page 77 215 el Service Manual NOTE Make sure that s
64. ing Lees cesse eere e eene nnne nn 107 LIE PUMP E 109 5 1 Jet Pump overview nnn nn nhan nnn annus 110 5 2 JET PUMP DISASSEMBLING eee erre eee nnn 111 5 3 ASSEMBLING THE JET PUMP eere 116 5 4 Jet Pump Assembly into the PWC 127 5 5 Assembly of the Reverse Gear For Series R Pro Model only 129 5 6 Assembling riding plate suus 130 5 7 Steering cable setting 130 5 8 Trim system cec 131 FUEL SYSTEM 133 6 1 Fuel Tank and Fuel Pump 134 7 EXHAUST SYSTENLa S edrasesiu2ud22u0ccepRvsusE oT iNeuaak totsm keten 138 7 1 Muller and Hoses 139 722 qur 141 7 3 Assembling the hoses on exhaust manifold 144 7 4 Leak test of the Exhaust hose 145 7 5 Assembling the exhaust manifold on the engine 146 LLJLLILLI FA ES Fe ESEEl TESL L LCCCOFTT
65. kshaft plain bearings position for correct reassembling Remove the plain bearings BES IELLICOT ver 2009 03 Page 69 215 Series SERIES Service Manual Dismantling Balance Shaft Remove the circlip 1 Remove the ball bearing 2 and the toothed wheel 3 Remove the ball bearing 4 LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 70 215 1 RE SERIES Service Manual Dismantling Crankshaft A ATTENTION Take note of crankshaft parts position for correct reassemling The following procedure must be applied to all connecting rods mounted on the crankshaft shaft Unscrew and remove bolts 1 Remove connecting rod 2 from the crankshaft 3 Check Engine Shaft and Connecting Rod Check eventual breaks or excessive wear on the whole engine shaft 1 Change the piece if necessary Support the engine shaft with two V blocks and with the two ends resting upon the blocks install a comparator and turn the engine shaft slowly Check the deformation of the engine shaft at the points indicated in the figure If the deformation does not enter within the specific value change the piece DEFORMATION VALUE LIMIT z 0 040 mm Check eventual breaks or excessive play on the connecting rod 2 and on the two semi bronze bearings In case of replacement of the connecting rod verify the belonging class marked on the shank 1
66. linders gasket beneath Check that the walls do not present signs of seizure with the pistons Check the ovalisation of the cylinders as indicated in the figure ATTENTION In the case of changing the cylinder block also change the pistons and the elastic straps if necessary The cylinder is distinguished by a letter that indicates the class it belongs to The cylinder piston coupling must be carried out among the same classes that they belong to doine v The letters are on the external front part exhaust side of the LLILLILLI F IST ET IE LLCO ver 2009 03 Page 58 215 72 Service Manual e Dismantle Water Collector Unscrew and remove the three screws 1 and remove the collector 2 e Check Water collector Check eventual breaks on the collector and if necessary change the piece e Mount Water Collector ATTENTION Always use new gaskets Position the gasket 1 and the collector 2 and tighten the screws 3 LLJILLSILLJ FA ES BENE LLIN ver 2009 03 Page 59 215 Series SERIES Service Manual e Piston e Dismantle Piston Remove the cylinder see DISMANTLE CYLINDER BODY The following procedure must be applied to all 3 pistons Remove the elastic ring 1 ATTENTION Do not use hammers for the piston pin removal 2 Remove pin 2 and remove piston 3 QYILIILL FPES BE IELLICO YT ver 2009 03 Pag
67. ll appear in next window Copy the activation key and go back to Diagnostic system Le W egistration 508 508 Registration You now will find the unit details in the section Unit History Your registrations gt gt If you have questions related to your registration please contact us officeghsr benelli com or call 43 275748675 Finalizing Registration process Once received from B2B the Activation code should be copied and pasted to the field UNLOCK CODE 4 of End Line Parameters window To complete the ECU Unlocking procedure press Set Line End Parameters button 75 ECU is unlocked now vehicle could be operated in power mode LLILLILLI I ESTE BET L LCTCOPT7 12 4 Periodic maintenance registration process Periodic Maintenance registration NOTE In order to maintain Warranty during the warranty period it is absolutely necessary to record the maintenance based on periodic maintenance schedule in time in the B2B unit history The maintenance schedule is available in B2B download area ver 2009 03 Page 208 215 gt Service Manual To start Maintenance registration click Unit History button on the upper panel E Mail Imprint uem RTT Home Orders Warranty Registration Unit History Downloads Hello Testdealer Logged in as Orders _ Testdealer Warranty Registration Overview Active language English Unit Histo
68. luded LLILLILLI F IST ET IE LLCO ver 2009 03 Page 24 215 1 RE SERIES Service Manual 2 3 3 Spark plugs replacement ATTENTION A Replace spark plugs only when engine is COLD In other case there is a risk to damage cylinder head thread Use only spark plugs of recommended type in order to avoid engine damage NOTE RECOMMENDED SPARK PLUGS CHAMPION RG4HC Replace engine spark plugs every 100 hrs Check electrode gap and spark plug condition after the break in period 10 12hrs 1 Unscrew nut A 2 Remove ignition plate B 3 Remove ignition coil C 4 Unscrew spark plug To reinstall Follow the procedure exactly in the opposite way 2 WARNING Do not tighten spark plugs with torque over 12Nm not to damage cylinder head thread Electrode gap spark plug 0 75 0 80 mm LLILLILLI F IST ET IESL L LCCCOFT1 ver 2009 03 Page 25 215 7 Service Manual 2 3 4 Valve clearance inspection ATTENTION Valve clearance must be checked and adjusted when the engine is cold room temperature Remove cylinder head cover to access cylinder head See Head cover Removal Taking the engines cylinder 1 to the TDC verify that also the marks and of the Camshaft sprockets are aligned between them and with the head plain Measure the clearance between camshaft and valve cap by a thickness gauge making sure that the clearance is in the specific range Start from measuring clearance on Cylinder 2 EX
69. n the figure Position the rotor 12 making it meets clutch A Position the sealing washer 13 and fix it tight with the nut 14 SK 8 N m 0 8 Kg m Always use LOCTITE 243 LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 88 215 SGrgas sSsGrias Service Manual Position the cover and lock it tight with the two screws 15 Position the sealing washer 16 and tightly screw the purge screw 17 up VIT 10 N m 1 Kg m Always use LOCTITE 2436 Position the O Ring 18 on the pump body Position the entry elbow 19 and fix with the two small plates 20 and the two screws 21 tightly 10 N m 1 Kg m LLILLILLI F IST ET IE LLCO ver 2009 03 Page 89 215 1 gt Service Manual Position the pump 1 as in the figure and screw the two screws 2 up tightly 10 N m 1 Kg m Always use LOCTITE 243 Reposition the entry and exit tubes 3 of the pump tightening two hose clamps 4 LLILLILLI F IST ET IESL L LCCCOFT1 ver 2009 03 Page 90 215 72 Service Manual FASES BES LLCO ver 2009 03 Page 91 215 el Service Manual 4 Transmission 41 Transmission Dismantling Remove engine out of the PWC see Engine Removal chapter Remove the engine oil by opening the oil plug screw on the bottom of the engine 19 mm socket required Use suitable equipment to collect the engine oil
70. n housin Apply grease on the inside and sealing lips of the oil seal Press in the oil seal NOTE The greased side of the oil seal needs to be on the same side like the painted side of the oil seal cover gt gt 44 t N N 1 2 M bs 2 lt LLILLILLI F IST ET IE LLCO ver 2009 03 Page 100 215 SENVES SERIES Service Manual Apply Loctite 5699 on the surface of the transmission cover Assembling transmission on the engine Put in place the transmission housing and tighten 3 x bolts NOTE Pay attention not to damage the oil seal by thread of the crankshaft NOTE Insure that the oil delivery line will be placed in between the engine and the transmission housing Apply RED Weicon Lock AN 305 86 on the thread of all 3 screws Ensure the copper gasket is used on the bigger one LLSILLILLJ ASTR BENE Le L l CT ver 2009_03 Page 101 215 SGrgas SEVES Service Manual Tighten the 3 bolts with specified torque Tightening torque 45 N m Pressing in the transmission bolt During pressing in the transmission bolt ensure the lubrication holes are orientated to the right side 90 deg to the right Assembling the right hand side gear NOTE For correct Crankshaft gear installation apply Loctite 648 on the surface of the inner side of the cone LLJLLJLLI ASTR BES IELLICOT ver 2009 03 Page 102 215 sErRIES Service Manual Assemblin
71. ne and are sliding carefully Put in place the ring Put in place the steering lever Put in place the indicator disc Apply BLUE Weicon Lock AN 302 43 on the thread and tighten nut with specified torque XA c Tightening torque 25 N m LLILLILLI F IST ET IE LLCO ver 2009 03 Page 159 215 1 gt Service Manual Assemble and tighten SSSA sensor support with 2 x screws r Apply BLUE Weicon Lock AN 302 43 on screws thread NOTE SSSA sensor needs to be flattened to the support before tightening screws After final assembly please perform a check Steering shaft should move easily 9 2 Assembly of the Steering Support on the PWC For Series R model only Put in place steering support by tilting it Apply blue Loctite on thread of 6 mount screws LLILLILLI F IST ET IE LLCO ver 2009 03 Page 160 215 SGrgas SEVES Service Manual Tighten the screws with specified torque Tightening torque 20 N m in X method 9 3 Handle Bar assembly For Series R model only Assembly of the handelbar Assembling grips on the handle bar Apply Loctite 435 to insure the grips will not become loose Press by hand the grips on the handle bar after the Loctite has been applied LLILLILLI F IST ET IE LLCO ver 2009 03 Page 161 215 Service Manual Final assembly of the handle bar Assembly of the handlebar on the PWC Ensure you put in pl
72. ning torque 10 N m Position the rod pushing spring 3 and the washer 4 and tighten tensoiner cap nut 5 Tightening torque 7 8 N m ATTENTION Always check that chain tensioner is in position 0 before mounting it Align the marks on the camshaft sprockets as shown on the figure Count 30 chain pins from position 1 to position 30 as indicated on the figure LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 46 215 el Service Manual Check that cylinder 1 cams are turned towards each other as on the figure e Remove Cylinder Head Remove the chain tensioner chain pads camshafts see above Loosen and remove the eight nuts and washers 1 indicated in the figure according to the shown sequence and two screws on the right side of the engine timing chain side LLILLILLI F IST ET IELLICOT ver 2009 03 Page 47 215 7 Service Manual e Cylinder Head Inspection WARNING Do not use a pointed instrument to avoid damaging or scatching Spark plug hole threading Valve seats Check and eventually eliminate carbon deposits in the combustion chamber with a rounded off scraper If the surface is damaged or scratched change the element Check the distortion of the cylinder head as indicated in the figure If is is outside the specific value rectify the head VALUE LIMIT HEAD DISTORTION max distortion 0 2 mm e Mounting Cylinder Head NOTE Always use new gaske
73. ocedure must be applied to all the valves and relative components Oil the valve stem with the recommended oil RECOMMENED OIL Disulfide of molybdenum oil Mount the lower small cup 1 Check that the thickness of the small cap is 1 5 mm QYILIILL FPES BE IE LLC OST ver 2009 03 Page 55 215 SGrgas SEVES Service Manual A WARNING Always use new gaskets and oil seals Mount the rubber valve seal 2 with the appropriate pad 3 A ATTENTION Intake valves are larger than the exhaust valves Insert the valves 4 Position the internal 5 and external 6 springs as shown in the figure Insert the two lock cones 7 into the upper small cup 8 LLILLILLI F IST ET IELLICOT ver 2009 03 Page 56 215 el Service Manual Position the small cap as shown in the figure Use the dismantling valve instrument making sure that the valve is correct Position the calibrated pads 9 and valve caps 10 ATTENTION A Make sure that the individual valve lifters and the valve guide are re mounted in the original position NOTE Check that valve caps turn easily by rotating them with a finger QYILIILL ASTE BENE Le L l CCT ver 2009_03 Page 57 215 1 SEMIES Service Manual 3 2 2 Cylinder and Pistons e Dismantle Cylinder Body Remove the cylinder head see REMOVE CYLINDER HEAD Remove the gasket of the head the cylinder body 1 and the base of the cy
74. on Check throttle pe pe Check and clean jet pump including cooling system Eemi Check renew drive Check renew drive damper Lo 1 operation necessary x x x x x x _ necessary Series S only ox clamps E E Check torque 100 Replace Pump Seal check Pump Bearing replace if pousse NE change Sparkpiugs ll x Check free play of the hhh If necessary line banjo bolts for tightness 1 exhaust cooling water injection system LLILLILLI FASES BES IE LL COST ver 2009 03 Page 22 215 el Service Manual 2 3 Periodic maintenance procedures 2 3 1 Oil level check NOTE Use a clean lint free cloth PWC must be leveled to perform oil level verification Check the oil level when engine is cold by pulling the oil dipstick out of the engine The oil level must be within the minimum and maximum marks When engine is warm proceed the same way but insure your check is done five minutes after engine 1 stopped to enable the remaining oil to go back to the bottom of the engine Oil level may be higher than at cold engine since the oil volume increases in warm condition n WARNING PIN Engine oil may be hot Note Engine must be cold If the valve clearance is out of specifications take note about your current reading for adjustment max min LLJLLJLLI ASTR BES IELLICOT
75. othing paste from the face and the seat of the valve at the end of each operation Apply the tincture of bluing b on the face of the valve Install the valve in the cylinder head Press the valve through the valve guide and on the valve seat to leave a clear trace QYILIILL ASTR BENE Le Lu l CCT ver 2009_03 Page 53 215 7 1 Service Manual e Valve Spring Inspection The following procedure is valid for all valve springs Measure the length a of the free valve If the value does not enter within the envisaged limits change the spring N FREE VALVE SPRING LENGTH External valve spring Tollerance limit 37 mm Internal valve spring Tollerance limit 34 0 mm Bring the spring to a value length c and check the value of the load VALUE LIMIT External spring length 23 2 mm Load value limit 565 N Internal spring length 21 2 mm Load value limit 314 N Check the inclination a of the valve spring as illustrated in the figure If a does not enter within the specific value change it VALUE LIMIT INCLINATION SUCTION SPRING A 2 mm INCLINATION EXHAUST SPRING A 2 mm LLILLILLI F IST BET IELLICO YT ver 2009 03 Page 54 215 1 gt SERIES Service Manual e Valve Caps Inspection The following procedure must be applied to all valve caps Check that caps are not broken or scratched in other case replace them e Mount Valve The following pr
76. ozzle with a soft tool carefully Remove the allen screw M 6 mm from the trim nozzle LLILLILLI F IST ET IESL L LCCCOFT1 ver 2009 03 Page 115 215 SGrgas sSsGraias Service Manual Remove the Trim Nozzle Remove the plastic bushing with a soft tool carefully NOTE For Reverse Equipped PWC only Remove the reverse support from the jet pump with an allen screw Driver M 6mm 5 3 ASSEMBLING THE JET PUMP NOTE For Reverse Equipped PWC only Apply blue Loctite 243 on the threads of the screws QYILIILL ASTR BENE Le Ln l CCT ver 2009_03 Page 116 215 7 Service Manual Tighten the reverse support on the Jet Pump Housing Tightening torque 20 N m Reinstall the jet pump nozzles Press in the new plastic bushings into the trim nozzle IE MAS m Apply blue Loctite 243 on the threads of the screw tightening the Trim nozzle Tighten the screw with specified torque Tightening torque 20 N m LLJLLJLLI ASTR BES IELLICOT ver 2009 03 Page 117 215 SGrgas sSsGraias Service Manual Press in the new plastic bushings into the steering nozzle Apply blue Loctite 243 on the beginning of the threads of the screw and tighten the screws with specified torque Tightening torque 20 N m Proceed the same process on both sides of the pump Assembly of the Stator Housing of the Jet Pump Assembly of the Jet Pump Housing Put in place the first smaller in diameter bearing QYI
77. parts involved in the assembly of the Baggage Cover Assemble the axles with the springs and put it into the baggage cover on both sides p LLILLILLI FPES BENE LLCO ver 2009 03 Page 181 215 1 gt Service Manual Put in place the circlips with a suitable tool in order to lock the springs Insure the system is working easily and properly NEF Note For Series R Pro only Reverse Switch Put in place the reverse switch and wire Apply BLUE Weicon Lock AN 302 43 on the thread as shown on the picture Put in place the connectors for the electric reverse cable Assembly of the hood latch Install the axel into the latch through wards the spring Tighten the latch with 2 x screws QYILIILL ASTR BENE Le L l CT ver 2009_03 Page 182 215 72 1 RM SERIES Service Manual Final view of baggage hood Assembly of the luggage on the PWC deck Put in place the baggage cover on the PWC by hooking in the levers with the spring under plastic covers NOTE for Models with electric reverse only Put the electric cable through the hole of the dashboard Apply BLUE Weicon Lock AN 302 43 on the thread of the screws of the baggage latch cover LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 183 215 1 gt Service Manual Tighten the screws with a specified torque in x method JN Tightening torgue 5 Nm in X method 10 4 Side Cover Assemblin
78. pecified torque Tightening torque 5 N m g g torq Put the rubber protector of the lower handle plate in place and ensure the flatten side will be in position as shown on the photos Tighten the screws na LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 166 215 sErRIES Service Manual Put the rubber protector of the lower handling plate in place Ensure the flatten side will show to the upper side as shown on the photos Tighten the screws T uh Assemble the springs of the handle bar Warm the hose if needed and pull it on the spring with a knife Put in place the spring for the Handle bar and push carefully the bolt through the pushing LLJLLJLLI FASS BE IELLICO YT ver 2009 03 Page 167 215 SETIES PR SErIES Service Manual Press down the spring and screw in the bold with a tool NOTE Do not use hammer to install the bolt This will lead to destroy the thread on the handle bar support Tighten the bolt with a torque meter Tightening torque 25 N m Assembly of the dashboard in the handle bar Put in place the bracket for the dashboard And assemble it according to the pictures Assemble the dashboard like shown on the photos bellow Put 2 washers on the screws to insure the proper distance LLILLILLI FPES BENE LLCO ver 2009 03 Page 168 215 SGrgas sarias Service Manual Put in place the dashboard into the handle bar Tight
79. plied to all the valve seats Eliminate eventual carbon deposits Apply the tincture of bluing b on the face of the valve Install the valve into the appropriate seat Press it using the guide on the seat to leave an evident impression Measure the width of the seat of the valve NOTE It will be necessary to remove the bluing at the point at which the seat and the face of the valve touch NOTE If the trace is not partial or not uniform carry out a ver 2009 03 Page 52 215 1 RE SERIES Service Manual smoothing operation on the face and the seat of the valve Smooth the face of the valve the seat of the valve NOTE After having changed the cylinder head or the valve and the relative guide it will be necessary to smooth the seat and face of the valve Apply a coarse grained paste a for smoothing on the face of the valve ATTENTION A Do not allow the smoothing paste to enter into the space between the stem of the valve and the guide Apply disulfide of molybdenum to the stem of the valve Insert the valve into the cylinder head Rotate the valve until its face and seat shine uniformly Then remove the smoothing paste NOTE To obtain optimum smoothing results strike the seat of the valve lightly while turning it forwards and backwards in your hands Apply a fine grained paste to the face of the valve and repeat the above operations Completely eliminate the smo
80. pressure regulator are located on the fuel pump Assembly of the fuel pump into the fuel tank Put back in place the fuel pump for assembly NOTE It is EXTREMELY important to insure that THE FUEL FILTER IS NOT SQUECED INBETWEEN THE FUEL PUM AND THE TANK There is the risk of leaking fuel into the hull Apply blue Loctite 243 on the thread of the screws of the fuel tank LLSILLJILLJ ASTR B ENVEL L l CCT ver 2009_03 Page 135 215 7 Service Manual Screw in the screws and tighten them with specified torque Tightening torque 5 N m in X method Leak test of the subassembly of the Fuel Pump Fuel Tank Note Always perform a leak test during fuel tank disassembly fuel pump inspection Apply a pressure of 0 3 bar into the tank system and check for loss of pressure with the help a spray test See picture A HE WM Release the pressure carefully by opening the fuel cap as shown in the picture LLJLLJLLI FPES BENE Le L l CT ver 2009_03 Page 136 215 el Service Manual Assembly of the Fuel tank into the PWC Put back the fuel tank into the PWC as shownin the picture Reinstall the fuel tank hose with the clam on the fuel tank Apply blue Loctite 243 on the thread of the screw and tighten with specified torque Tightening torque 10 N m LLILLILLI F IST BET ELLICOT ver 2009 03 Page 137 215 72 Service Manual LLILLILLI F
81. procket wheels marks of the balance shaft and the crankshaft are aligned as shown on the figure Position balance shaft ring 28 Install 2 large plastic lock nuts on both sides of balance shaft 29 BES IELLICOT ver 2009 03 Page 78 215 7 Service Manual NOTE Apply proper amount of recommended sealant to the contact surfaces of both crankcase parts RECOMMENDED SEALANT LOCTITE 5699 FLANGE SEALANT Position the lower casing part on the upper A ATTENTION Follow the mounting phases correctly Position eight crankcase screws with washers apply recommended grease for their threads and tighten to specified torque in three phases according to the sequence marked on engine carter RECOMMENDED OIL MOLIKOTE BR2 PLUS GREASE JN Tightening torgue 1 phase 13 N m 1 3 Kg m 274 phase 25 N m 2 5 Kg m 3 phase 45 N m 4 5 Kg m LLILLILLI F IST ET IE LLCO ver 2009 03 Page 79 215 SEPIES Service Manual Tighten balance shaft M8 screws shown by arrows in two phases Tightening torque 1 phase 10 1 0 Kg m 2 phase 25 N m 2 5 Kg m Tighten screws shown by circle marks with specified torque Tightening torque 10 N m 1 0 Kg m ATTENTION Always use new gaskets Install Oil pump intake tube Oil sump filter and oil sump cover Tighten cover screws with a specified torque Oil sump filter mounting screws 10
82. re coolant can be added 4 Do a test run in the water to heat the engine Stop the engine couple of times and check the anti freeze coolant level Add coolant if necessary 5 Repeat this process couple of times until the thermostat has opened and the entire amount of coolant circulates in the cooling system WARNING If the engine is hot the Jet Pump is hot too and might be dangerous for your health NOTE Ensure the engine is fully filled with coolant after thermostat was opened WARNING Changing the battery ensure that engine is cold NOTE Use only high quality coolant See recommended lubricants QYILIILL ASTE BENE Le L l CCT ver 2009_03 Page 31 215 72 Service Manual LLILLILLI F IST BES TESL L LCCCOFT ver 2009 03 Page 32 215 72 Service Manual 3 Engine 3 1 Engine Removal and Installation The installation of the engine and engine subsystems is the reverse to their removal During engine installation several important notes must be made e Always verify the correct number of engine mounting strap shims are installed on each engine mounting post Remove the pump to check driveshaft alignment add shims to move the engine up or down to align properly e Always verify that the engine does not interfere with critical routings such as the steering cable cooling hoses and main wiring harness e Steering cable must be fix
83. rque Tightening torque 25 N m QYILIILL FPES BE IE LLC OST ver 2009 03 Page 105 215 7 Service Manual Apply RED Weicon Lock AN 305 86 and tighten both banjo bolts of oil suppling line with specified torque VAN Tightening torgue 20 N m WARNING Pay attention for amount of used Locking agent on the oil line banjo bolts thread There is a risk of blocking oil passages Tighten the oil plug screw with specified torgue JN Tightening torgue 30 N m Refill the proper oil volume in the engine ATTENTION Use only original HSR Benelli engine oil LLILLILLI F IST ET IE LLCO ver 2009 03 Page 106 215 el Service Manual 4 3 Center flange bearing Assembly of the flange bearing Grease the oil seal lips with water resistance grease on both sides Y RECOMMENDED LUBRICANT FUCHS URETHYN E M 2 Use new pre coated screws or apply blue Loctite 243 Put in place the flange bearing and tight 4 screws with specified torque Support the bearing with a hammer to put the bearing on the top position Tightening torque 30 N m LLJLLJLLI ASTR BES IELLICOT ver 2009 03 Page 107 215 SGrgas SEVES Service Manual Put in place the flange bearing cover apply blue Loctite 243 on the thread of the screws and tighten the screws with specified torque Tightening torque 10 N m in X method BES IELLICOT ver 2009 03 Page
84. ry Downloads Logout gt gt Y our profile Payment Edit your profile Language settings Item search Item list Orders Order list 0 Pending orders 1 Finished orders 1 Submit a claim Submit a PDI claim Authorisation requests 2 Pending claims 12 Finished claims 2 Rejected claims 0 Warran Next window view E Mail Imprint 2 noa Home Orders Warranty Registration Unit History Downloads Unit Histo Overview y Logged in as Unit Search _ Testdealer Your registered Units Overview Active language English Here you can search for all registerd units Unit search Logout gt gt Search for an unit gt gt Edit your profile Here you find all units which where Your registered units registerd in your shop Show units gt gt LLOICLILLIFPASITI 6S6S6ST ea a LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 209 215 gt SERIES Service Manual Registered Unit window example w 0 j 4 m E Mail Imprint Home Orders Warranty Registration Unit History Downloads Overview hi Logged in as Unit Search Testdealer Your registered Units Your registered Units Active language English Purchase ES HSR223498012 2008 05 05 Mathias Moser Edit your profile HSRA0001C808 2008 04 10 508 Pro Mathias Moser HSRO0810C708 2008 02 23 504 Erwin Lasslsberger O HSR223498
85. s o Remeasure the valve clearance and readjust if necessary LLILLILLI FPES BENE LLCO ver 2009 03 Page 29 215 SENES SERIES Service Manual Installing Cylinder Head cover ATTENTION Always use new gaskets Position the gaskets of the head cover 1 and 2 ATTENTION Make sure that gaskets 2 do not fall into the head during cover installation Apply THREEBOND paste as shown on the drawing Install the cylinder head cover and insert rubber bushings and the screws 3 and 4 as shown on the figure NOTE Replace the rubber bushings of the screws 3 and 4 during reassembly Tighten the head cover mounting screws to the specific torque take care not to cut or damage rubber bushings Tightening torque 10 N m 1 Kg m LLILLILLI F IST ET IESL L LCCCOFT1 ver 2009 03 Page 30 215 1 RE SERIES Service Manual 2 3 6 Refilling of coolant WARNING This process is a very sensitive and requires special attention The risk is that air bubbles remain in the cooling system so that the heat of the engine cannot be transferred into the radiator of the Jet Pump The total volume of coolant is for SERIES S 2 5 litres for SERIES R 3 0 litres 1 Fill the cooling system with cooling liquid of recommended type as much as possible 2 Press on the coolant hoses and ensure to get a maximum of air bubbles out of it Add more coolant 3 Repeat this process 2 3 times until no mo
86. s also required e Conserve the cylinders Check spark plugs See Chapter Checking the spark plugs Fill approx 10 ml 0 34 oz US of clean motor oil directly through the spark plug holes Before you replace the spark plugs crank up the motor briefly with the starter Replace the spark plugs ATTENTION Never fill more motor oil than specified into the spark plug holes Too much motor oil can cause engine damage e Fill the fuel tank all the way Full fuel tank prevents the formation of condensation inside the tank e Add fuel stabilizer After approx 30 days fuel begins to decompose You can use any common fuel stabilizer in order to maintain the fuel quality LLJLLILLI FA ES Fe ESEEl TESL L LCCCOFTT ver 2009 03 Page 213 215 SEJIES SERIES Service Manual LLILLILLI F IST BES IE LLCO ver 2009 03 Page 214 215 72 Service Manual 14 Appendix Address Wiener Stra e 71 3380 Pochlarn Austria Directives HSR Benelli thus confirms that the construction of the engine corresponds to the following pertinent conditions EU directive about sport boats 94 25 EG with addendum 2003 44 EG USA EPA Federal Register 40 CFR Part 91 USA CARB 13 California Code of Regulation Article 4 7 Spark Ignition Marine Engines LLJILLSILLJ FA ES BENE LLIN ver 2009 03 Page 215 215
87. screws with specified torque Tightening torque 12 Nm 5 7 Steering cable setting QYILIILL FPES BENE Le L l CT Hold the steering in straight forward position The distance of the jet nozzle to the jet drive outlet must be the same on the left and the right side Otherwise adjust the steering cable accordingly To disconnect the steering cable from the jet nozzle at the ball joint you must first pull the steering cable back Then pull up on the connection The cable will be free from the connection The distance should be the same on both sides x WARNING Pay special attention when assembling components of steering system Non proper assembling could result lost of contol during riding vehicle ver 2009 03 Page 130 215 SGrgas SsGraas Service Manual 5 8 Trim system bleeding NOTE Put protection on the hull to avoid brake liquid contact with the paint of the hull Fill an injector like shown in the picture with brake liquid half the way 10 cm and screw a bleeding nipple into the trim system Put covering material on the PWC in order to protect the paint of the deck Attach the Injector with a hose and tighten it with a plastic clamp Press the injector 10 times Put the nozzle in top position and repeat the injector pump process 10 times Put the nozzle in bottom position and repeat the injector pump process 10 times LLILLILLI ASS BE IESL L LCCCOFT ver 2009 03 Pag
88. st of the Exhaust hose The equipment of the leak test is shown bellow 1 Manometer 2 Long hose 3 Short hose Link the test equipment in between the outlet of the manifold and the outlet of the 3 in 1 exhaust hose fitting The circle of the water jacket should be closed by the mentioned equipment for the test Apply air pressure of 3 bar into the system QYILIILL ASTR BENE Le L l CT ver 2009_03 Page 145 215 el Service Manual Put the exhaust system into a water bath and check for air bubbles Apply blue Loctite 243 on the stainless steel nut and hand tight them on the stud screws of the cylinder head Tighten the screws in the X Method with a specified torque starting with the 274 cylinder continuing on 1 or 3 cylinder and finalizing respectively on the 3 or 1 cylinder Tightening torque 10 N m LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 146 215 72 Service Manual LLSILLSILLJ ASTR BES TESL L LCCCOFT ver 2009 03 Page 147 215 72 Service Manual 8 Cooling system 8 1 Closed circuit cooling system Series S Pos Part description 4 j coouNGHOSEHOT2 1 HOSE CLAMP 38 1 8 SCREWCAPLABAR 9 THREADEDT PIECE 2 lt TESL L LCCCOFTT ver 2009 03 Page 148 215
89. tart Stop switch wire Place on the LEFT SIDE of PWC Throttle and Steering cables Take left two cables for Throttle and Steering and put them through the handle bar E 4 LLILLILLI F IST ET IE LLCO ver 2009 03 Page 171 215 SS RS 2 Service Manual Take the other 3 cables for system Dashboard and from Start Stop switch two wires and put it through the handle bar Apply Loctite 243 on the 4 screws for the fixation of the handle bar Tighten screws with specified torque in x Method Tightening torque 30 Connect the dashboard wire and place it into the handle bar Put in place throttle cable on the throttle lever and put assemblies throttle lever and Start Stop switch on the steering system ver 2009 03 Page 172 215 SETIES R SErIES Service Manual Fix cable with a tie rap NOTE for initial adjustment of the steering cable install the fastener on steering cable thread steering plate side with 12 full turns Do the same for cable end on Jet pump side This should lead to a proper balanced adjustment of the steering system Connect steering cable with the Steering lever and Jet pump steering nozzle Do a control measurement as follows Take a ruler and aline it on the nozzle of the jet pump Take a measurement tool and measure the adjustment for the jet pump on both sides Adjust it accordingly LLSILLJILLJ ASTR BENE La L
90. tat auxiliary opened loop oil amp exhaust cooling systems THERMOSTAT EXHAUST OVERHEATING WARNING Exhaust Manifold Overheat switch engine limiter activation COOLANT OVERHEATING WARNING Cooling manifold Sensor 90 engine limiter activation ENGINE LUBRICATION SYSTEM Wet Sump ENGINE OIL SPECIFICATIONS HSR BENELLI Engine oil 10w60 ACEA A3 B3 BA API SL LLJLLJLLI FA ES BENE Lu Ln l CCT ver 2009_03 Page 16 215 72 Service Manual RPM LIMITER 9200 9300 1 min Determined by ECU EXHAUST SYSTEM Waterbox with water injector ENGINE MANAGEMENT SYSTEM 2242442 FUEL DELIVERY WALBRO Multi point fuel injection IDLE SPEED 1700 1 min 50 FUSES 30A Alternator 15A Fuel Pump 7 5A Stop switch STARTER Electric Motor 12V 850 W PROPULSION is JET PUMP TYPE SOLAS Axial Flow 12 Veins Steel stator IMPELLER Stainless steel 3 blade Series S Pro Edition 14 25 Series S Hace Edition 15 26 Series R Naked Edition 11 19 Series H Pro Edition 11 19 XL HULL BODY 2 Fiberglass RTM Process 1 4 2 Standard Torque Specifications The following torque specifications are to be used as a general guideline Use standard torque values for the appropriate size fastener when torque values are not specified Always consult the specific manual section for torque values of fasteners and use of locking agent RECOMMENDED TO
91. ts Clean and degrease the head surface and the cylinders LLILLILLI FPES BENE LLCO ver 2009 03 Page 48 215 1 RE SERIES Service Manual Position the head cylinder gasket Position the cylinder head Position the fixing washers and nuts lt Tighten to the specified torque following the shown sequence in following phases 1st phase 10 Nm 2nd phase 30 Nm 3rd phase 45 Nm 4th phase angle of 100 5th phase tighten 2 bolts on timing chain side with 10 8 Nm NOTE Apply grease to the fixing nuts to oil the threading MOLIKOTE BR2 PLUS grease e Valves and Valve Spring Remove Valves Remove the cylinder head see REMOVE CYLINDER HEAD Position the head on a slightly inclined surface to show the valves to remove perpendicular to the surface IE LLCO ver 2009 03 Page 49 215 SEMIES R SEMNIES Service Manual To remove the valves use a valve dismantling instrument 2 with correct attachment 3 press the valve down and take off the two semi cones Loosen the clamp and remove the valve and its components as shown on picture The following procedure is applied to the valves 4 the springs 5 and 6 and relative components 7 8 and 9 NOTE Make sure that valve 4 has a perfect seal by pouring petrol into the conduits and making sure that there are no losses through the valves Make sure that the valves ar
92. un l CCT ver 2009_03 Page 173 215 gt Service Manual Assembly of the Trim lever Put the O Ring in place Put banjo bolt into the fitting of trim system line put second O ring in place and Tighten the bolt Bleed the system See Trim system bleeding in PUMP chapter Assemble the hand grips Put Loctite 435 in the hand grips and distribute it internally Pull hand grips on the handle bar QYILIILL FPES BE IE LLC OST ver 2009 03 Page 174 215 SGrgas SsGraas Service Manual WARNING If throttle cable is not moving freely PWC could suddenly accelerate on its own while steering Put in place handle bar protector with two tie raps and cut the extending tie rap ends LLILLILLI F IST ET IESL L LCCCOFT ver 2009 03 Page 175 215 7 Service Manual Install the Throttle cable and insure there is free play of 2 3 mm on the throttle lever 4 LLILLILLI F IST BET IE LLCO ver 2009 03 Page 176 215 72 Service Manual FASES BES LLCO ver 2009 03 Page 177 215 Series SERIES Service Manual 10 Hull 10 1 Dashboard cover For Series R model only Disassembly of dashboard cover Remove the support plate screw from the dashboard and carefully remove the dashboard equipment by hand NOTE Take care not to damage the gasket Reassembly of the dashboard cover NOTE Take care
93. ve the rotor 11 P Remove the external circlip 12 the internal circlip 13 and the ball bearing beneath Remove the liner 14 the shaft 15 the ball bearing 16 and oil seal beneath Remove the mechanical seal 17 LLILLILLI FPES BE IE LLCO ver 2009 03 Page 85 215 el Service Manual Check the state of wear of the various components of the pump Check that the various elements are not broken Change worn or damaged elements if necessary e Water Pump Assembly Position the pump body 1 on a support ATTENTION The oil seal must be inserted downwards with the lip closed Position oil seal until it touches 2 Grease the shaft 4 at the points indicated on the figure QYILIILL FPES BE IE LLC OST ver 2009 03 Page 86 215 el Service Manual Position the shaft 4 inside the pump body 1 Position the first ball bearing 5 using a press to make it touch Position the liner 6 Position the second ball bearing 7 using a press to make it touch Fix the ball bearings with the external 8 and internal 9 circlips LLJLLJLLI FPES BE IELLICOYT ver 2009 03 Page 87 215 gt Service Manual ATTENTION While mounting the counter face and mechanical seal make sure that they are clean and bear no traces of grease Position the counter face as in the figure 10 Position the mechanical seal 11 until it touches as shown i
94. y acid is ingested drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physician immediately Flush eyes for 15 minutes with water and seek ver 2009 03 Page 9 215 7 1 Service Manual prompt medical attention if acid comes in contact with eyes Thoroughly wash affected external body parts that come in contact with battery acid with water Keep hands arms legs feet and hair away from rotating parts hot engine and exhaust components drive pump and impeller and engine induction when engine is running Never attempt engine or driveline inspections and or repairs without first removing lanyard and battery cables Gasoline is highly flammable and explosive under certain conditions Always exercise extreme care when handling gasoline Do not smoke or allow open flames in or near the area where refuelling is performed or where gasoline is stored Always refuel the watercraft outdoors and in a well ventilated area Do not fill the tank to the fuel cap If you get gasoline or oil on your skin or clothing wash it off immediately with soap and water and change clothing The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Only run engine outdoors or in a well ventilated area Never run the engine for more than 10 seconds without cooling water supply 1 2 2 Service Tools HSR BENELLI DIAGNO
95. yellow 40 407 40 413 5 single std shaft 36 976 36 986 Position each con rod plain bearings according to the marks on the rod flange see picture Take care the bearings are installed to relative slots A ATTENTION Two marks shown on the figure must couple for connection rod body 1 and big end cap 2 Assemble the connecting rod on the crankshaft so that the marks 1 and 2 are aligned as shown on picture LLILLILLI F IST ET IESL L LCCCOFT1 ver 2009 03 Page 73 215 1 RE SERIES Service Manual NOTE Apply MOLIKOTE grease on the inner halves of con rod plain bearings and ensure the outer halves and the con rod bodies are cleaned with fuel to increase the friction between both parts RECOMMENDED OIL MOLIKOTE amp BR2 PLUS GREASE ATTENTION Always change connecting rod bolts by new after each dismantling Oil the thread and the diameter under the flanging of the fixing bolts 3 with the recommended grease Tighten the fixing bolts 3 slightly RECOMMENDED OIL MOLIKOTE amp BR2 PLUS GREASE NOTE Apply MOLIKOTE grease on the inner halves of crankshaft plain bearings and ensure the outer halves and their crankcase seats are cleaned with fuel to increase the friction between both parts LLILLILLI FPES BENE LLCO ver 2009 03 Page 74 215 SGrgas SEVES Service Manual Position the crankshaft on the upper part of crankcase Tighten connecting rod bolts in t

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