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Benelli · Shim-adjusted overhead-cam four-stroke, wet sump, gearbox shares engine oil, chain drive

Leoncino 500

Library entry covers 2017-2025

72 factory 24 guideline

Published source

Benelli Leoncino 500(T) E4 service manual, Periodic maintenance and lubrication intervals pp.3-5 to 3-8

Factory workshop manual. Covers Leoncino 500 (Trail) Euro 4 service manual.

96 items for a 2017 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, shim adjusted (incl. desmo)
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Fuel injection
Cooling: Liquid cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, single shock / cantilever
Front brake: Disc, hydraulic
Rear brake: Disc, hydraulic
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2017 Benelli Leoncino 500

On the road: every 500 km

4 items

Check engine oil level

Pre-ride / on the road

Factory

Manual: Engine oil - check. Factory: Check every 500 km (310 mi)
Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline
Lubricate drive chain

Pre-ride / on the road

Factory

Manual: Transmission chain - check tension, alignment, clean and grease. Factory: Every 500 km and after every wash or rain

On the road: every 800 km

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 1,000 km

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 5,000 km or 12 months

2 items

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline

Every 6,000 km or 12 months

23 items

Change engine oil

Engine

Factory

Manual: Engine oil - Check/Top up/Change. Factory: R every service + annual. Cols 1,000/7,000/13,000/19,000/25,000 km + annual; repeat fr
Chassis fasteners - Make sure all nuts, bolts and screws are correctly tightened.

Engine

Factory

Factory: As printed: T at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Cooling fluid - Check/Top up

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km services; R at 19,000 Km; I at 25,000 Km and Annual inspection
Cooling system - Check the level of the cooling fluid. make sure there are no leaks of fluid from the vehicle.

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Electric fans - Check/Operation

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Electrical System - Check/Operation

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Horn - Check/Operation

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Instrumentation - Check/Operation

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Instruments, lights, indicator lights, and switches - Check/Operation

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Parts and wires subject to movement - Check/Replacement

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection; Before every use of the vehicle.
Pinion/Retaining washer - Check/Replacement

Engine

Factory

Factory: As printed: I at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Throttle handgrip - check, adjust cable clearance, lubricate.
Clean battery terminals, check charge and strap

Ignition and electrics

Factory

Manual: Battery connections - Check/Operation.
Ignition switch - Check/Operation

Ignition and electrics

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch control - Check/Adjustment.
Inspect chain and sprockets for wear (measure stretch)

Final drive

Factory

Manual: Chain wheel / pinion - Check/Lubricate. Factory: Replace every time the chain is replaced
Check steering head bearing adjustment

Front end

Factory

Manual: Steering ring nut and sleeve - Check/Adjustment. Factory: T every service + annual
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front suspension - check function and leaks.
Grease and check center / side stand and springs

Rear suspension and frame

Factory

Manual: Side stand - Check/Operation.
Switch Side stand - Check/Operation

Rear suspension and frame

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Brake fluid * clutch - Check/Top up

Brakes

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Front brake/Rear brake - Check function and fluid level and make sure there are no leaks form the vehicle.

Brakes

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Tires - check tread depth, damage, pressure. Factory: Replace if worn to the limit

Every 6,000 km

17 items

Canister USA version - Check for faults and leaks.

Engine

Factory

Factory: As printed: I at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km; R at 25,000 Km
Catalytic converter - Check for faults and leaks.

Engine

Factory

Factory: As printed: I at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Headlamp - Check/Operation

Engine

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Oil intake filter - Check/Replacement

Engine

Factory

Factory: As printed: I at 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Oil sump screws - Replacement

Engine

Factory

Factory: As printed: T at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Replace oil filter

Engine

Factory

Manual: Oil filter - Replacement. Factory: Every service, or at any engine oil change
Throttled body - Check operation/Adjust clearance (row 18)

Engine

Factory

Factory: As printed: I at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Throttled body - Check/Adjustment (row 20)

Engine

Factory

Factory: As printed: I at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Replace air filter element

Fuel and air

Factory

Manual: Air filter - Check/Replacement. Factory: R at 7,000, 13,000, 19,000, 25,000 km
Clutch cover screws - Replacement

Primary and gearbox

Factory

Factory: As printed: T at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Swing arm chain guide slide - Check/Replacement

Final drive

Factory

Factory: As printed: I at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Swing arm chain slide - Check/Replacement

Final drive

Factory

Factory: As printed: I at 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Change fork oil

Front end

Factory

Manual: Front suspension oil - Replacement. Factory: R at 13,000 and 19,000 km columns
Inspect rear shocks for leaks and damping

Rear suspension and frame

Factory

Manual: Rear suspension - check/adjust, no leaks. Factory: 7,000 to 25,000 km columns
Swing arm - Check operation and make sure there is no excessive is no excessive clearance. Lubricate.

Rear suspension and frame

Factory

Factory: As printed: I at 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services
Brake/clutch hoses (I)

Brakes

Factory

Factory: Printed per the re-read doubt: row 51 Brake/clutch hoses has I at every service (columns 1000, 7,000, 13,000, 19,000, 25,000 Km on a 6,000 km / 3,726 mi step) plus 'Every 4 years'; the existing entry holds only the 4-year line. (From the re-read doubt notes: Benelli Leoncino 500, printed line or second operation stated in the DOUBT line.)
Check brake pads and discs

Brakes

Factory

Manual: Brake pads - Check/Replacement. Factory: Replace if worn up to limit

Every 6,500 km or 12 months

1 item

Inspect, clean and gap spark plugs

Engine

Guideline

Every 9,500 km or 12 months

6 items

Inspect coolant hoses and clamps

Engine

Guideline
Clean / inspect air filter

Fuel and air

Guideline

Mesh or oiled foam: clean and re-oil. Paper: blow out or replace. Some very early machines have no filter at all.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 12,000 km

1 item

Steering bearings - Check/Replacement

Front end

Factory

Factory: As printed: T at 13,000 Km and 25,000 Km

Every 13,000 km or 12 months

1 item

Fuel /CO* - Check

Fuel and air

Factory

Factory: As printed: I at 0 Km Pre-delivery, 1000 Km, 7,000 Km, 13,000 Km, 19,000 Km, 25,000 Km services and Annual inspection; Every 13,000 km (8,077 mi)

Every 13,000 km or 2 years

1 item

Replace coolant

Engine

Factory

Manual: Cooling fluid - Replace. Factory: Every 2 years or 13,000 km (8,078 mi)

Every 16,000 km or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 19,000 km

4 items

Replace spark plugs

Engine

Factory

Manual: Spark plugs - Check/Replacement. Factory: R at 19,000 km only; I at other services
Replace fuel filter

Fuel and air

Factory

Manual: Fuel filter - Check/Replacement. Factory: R marked at 19,000 km only; I at 7,000/13,000/25,000
Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings - lubricate with lithium-based grease. Factory: Every 19,000 km
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Wheels - check not off center or damaged. Factory: Every 19,000 Km (11,806 m)

Every 19,500 km or 2 years

3 items

Synchronize throttle bodies

Fuel and air

Guideline
Clean and grease rear suspension linkage

Rear suspension and frame

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 22,000 km

2 items

Distribution chain slides - Check/Replacement

Final drive

Factory

Factory: As printed: R at 25,000 Km; Each distribution chain replacement, every 22,000 km (13671 mi)
Distribution chain tensioner - Check/Replacement

Final drive

Factory

Factory: As printed: R at 25,000 Km; Each distribution chain replacement, every 22,000 km (13671 mi)

Every 24,000 km or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 25,000 km or 3 years

1 item

Replace fuel lines

Fuel and air

Factory

Manual: Fuel circuit hoses - Check for faults and leaks. Factory: R at 25,000 km; replace in any case every 3 years

Every 25,000 km

3 items

Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance - Check operation/Adjust. Factory: Check clearance every 25,000 km
Distribution chain - Check/Replacement

Final drive

Factory

Factory: Every 25,000 Km (15,534 m); slides/tensioner with chain
Replace swingarm bushes / bearings

Rear suspension and frame

Factory

Manual: Swing arm bearings - Check/Replacement. Factory: R at 25,000 km; every 25,000 km (14904 mi)

Every 29,000 km

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 32,000 km or 4 years

1 item

Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 40,000 km

1 item

Check wheel bearings for play

Wheels and tires

Factory

Manual: Front/rear wheel bearings - Check/Replacement. Factory: Every 40,000 km (24900 mi); I at 13,000 and 25,000

Every 48,500 km or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 2 years

4 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Factory

Manual: Parts inside the brake pump and callipers. Factory: Replace every two years (note)
Replace brake fluid

Brakes

Factory

Manual: Brake fluid / clutch - Replace. Factory: Replace every 2 years

Every 3 years

1 item

Fuel circuit hoses - Replace

Fuel and air

Factory

Factory: As printed: Replace in any case every 3 years. (R also in the 19,000 Km column)

Every 4 years

1 item

Inspect brake hoses; replace old rubber

Brakes

Factory

Manual: Brake/clutch hoses. Factory: Replace every 4 years or if cracked/damaged

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

12 items

Canister USA version - replace

Engine

Factory

Factory: As printed: No maintenance required. In case of malfunction, replace.
Catalytic converter - replace

Engine

Factory

Factory: As printed: No maintenance required. In case of malfunction replace.
Headlamp - Adjustment

Engine

Factory

Factory: As printed: At every change in vehicle set-up
Oil filter - Replacement (note)

Engine

Factory

Factory: As printed: Or at any engine oil change
Pinion/Retaining washer - Replace

Engine

Factory

Factory: As printed: Replace every time the chain is replaced.
Rear suspension (note)

Engine

Factory

Factory: As printed: Before every use of the vehicle.
Spark plugs (note)

Engine

Factory

Factory: As printed: Check the conditions, clean and restore the spark plug gap.
Air filter (NOTE)

Fuel and air

Factory

Factory: As printed: The air filter needs to be replaced more often when using the vehicle in particularly damp or dusty environments.
Chain wheel - Replace

Final drive

Factory

Factory: As printed: Replace every time the chain is replaced.
Swing arm chain guide slide - Replace

Final drive

Factory

Factory: As printed: Replace if worn up to limit.
Swing arm chain slide - Replace

Final drive

Factory

Factory: As printed: Replace if worn up to limit.
Tires - Replace

Wheels and tires

Factory

Factory: As printed: Replace if worn to the limit.

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.