On the last legs of what began as a light service and ended up as a nearly full rebuild fixing up the PO:s cock-ups in almost every part of the engine I've sort of hit a wee roadbump.
Ive got almost everything sorted, in place and buttoned up when I suddenly noticed this stack of shims on the table under the bike. I've taken the engine apart again (clutch and gearbox) gone through the manual and all parts fiche pics with a lice-comb three times but to save the world I cannot figure out where these dang washers should go!!! To make it yet more interesting one of them has a smaller hole in the middle than the others. Completely stumped with these, any ideas greatly appreciated!
Benelli Tornado 900 LE No. 49
Benelli Tornado 900 LE No. 81
Benelli 1130 TNT Titainium
Benelli 1130 TRE-K
Benelli 750 SEI
Benelli 250 2c
My first thoughts as well BUT: A) the gear cassette was never opened B) the washers are way too small.
The larger one looks like the sump bung washer ,the other three look like blanking plug washers for the oil galleries if you had them apart.
I haven't, but having seen a whole plethora of idiocies the PO has done I'm going to test that theory. The big question lingers, if they indeed are those, WTF were they doing on the table under the bike glued together with motor oil?!?! The inside diameter of the three bigger holes match that of the tip of the clutch selector drum but there's not supposed to be any shims there if I'm not mistaken. Since I tested and as a result the gearbox shield refused to go all the way in because not enough room.
Just another thought could be the oil cooler pipe washers and maybe you have got one missing They fit either side of the banjo bolt on the cooler pipes .
Cheers mate I'll be sure to check on those tomorrow as well, can't today because paperwork night. My main concern is that the engine/gearbox won't go kablooey once I kick it into gear or sth, still cannot understand where the F they popped up from but as long as they're not from, or at least anymore IN the engine I'm good. Been a long winter fixing the PO:s jury rigs so it'd be a crying shame to blow at shakedown run!
Couldn't resist a quick peek into the shed, no they're not oil banjo seals, too big too hard and too precisely machined.
There are two that are 15.8mm inside, ~21mm outside and 0,8mm thick. One of the same in/out but only 0,3mm thick, and the one with the smaller hole is 12.7mm in 22mm out and 1.0mm thick so they're definitely shims of some sort.
Did you do any work on the suspension, or was it only the engine?