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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

29 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.

Open the source

53 items for a 2019 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

2019 Benelli Leoncino 500

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 310 mi

2 items

Check engine oil level

Pre-ride / on the road

Factory

Manual: Engine oil - check. Factory: Check every 500 km (310 mi)
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 500 mi

1 item

Check coolant level

Pre-ride / on the road

Guideline

On the road: every 600 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Guideline

Every 3,000 mi 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 3,728 mi or 12 months

9 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
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.
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.
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 3,728 mi

5 items

Replace oil filter

Engine

Factory

Manual: Oil filter - Replacement. Factory: Every service, or at any engine oil change
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
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
Check brake pads and discs

Brakes

Factory

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

Every 4,000 mi or 12 months

1 item

Inspect, clean and gap spark plugs

Engine

Guideline

Every 6,000 mi 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 8,078 mi 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 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 11,178 mi

2 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

Every 11,806 mi

2 items

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 12,000 mi 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 14,904 mi 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 14,904 mi

1 item

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 15,000 mi or 4 years

1 item

Check valve clearances (shim adjusted)

Engine

Guideline

Every 15,534 mi

2 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

Every 18,000 mi

1 item

Replace chain and sprockets (wear based)

Final drive

Guideline

Every 20,000 mi 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 24,900 mi

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 30,000 mi 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 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

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.